Yamaha XF50W Service manual

©YAMAHA
XF50W
SERVICE MANUAL
LIT-11616-20-58
3B3-F8197-10
EAS00000
XF50W 2006
SERVICE MANUAL
©2006 by Yamaha Motor Taiwan Co., Ltd.
First edition, September 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Taiwan Co., Ltd.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-20-58
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha
dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Taiwan Company, Ltd. is continually striving to improve all of its models. Modifications
and significant changes in specifications or procedures will be forwarded to all authorized Yamaha
dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00005
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
Q
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
w
Failure to follow WARNING instructions could result in severe injury or death
to the scooter operator, a bystander or a person checking or repairing the
scooter.
cC
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.
NOTE:
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.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter. Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section
title(s) appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates
a disassembly step.
6 Symbols indicate parts to be lubricated or replaced.Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
6
2
CYLINDER AND PISTON ENG
W
REMOVING THE CYLINDER AND PISTON
1. Remove:
8piston pin clip 1
8piston pin 2
8piston 3
c
C
Do not use a hammer to drive the piston pin
out.
4
NOTE:
8 Before removing the piston pin clip, cover
the crankcase opening with a clean rag to
prevent the piston pin clip from falling into
the crankcase.
8 Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area. If both areas are deburred and
the piston pin is still difficult to remove, remove it with the piston pin puller set4.
5
Piston pin puller set
90890-01304(YU-01304)
7
3
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Removing the cylinder and piston
Cylinder head
Timing chain guide(exhaust side)
Cylinder
Dowel pin
Cylinder gasket
Piston pin clip
Piston pin
Piston
Piston ring set
2. Remove:
8top ring
82nd ring
8oil ring
Remarks
Remove the parts in the order listed.
Refer to”CYLINDER HEAD”.
1
1
2
1
2
1
1
1
When removing a piston ring, open the end gap
with your fingers and lift the other side of the
ring over the piston crown.
Refer to”REMOVING THE CYLINDER
AND PISTON” and “INSTALLING THE
PISTON AND CYLINDER”.
For installation, reverse the removal procedure.
5-31
5-32
8
EAS00008
1
2
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK i g l
ADJ I ^ < \
5
CHAS (3^3^)
6
ENG
COOL j K
m
%
7
8
FI
Ifl
9
1
2
3
4
5
6
7
8
9
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Fuel injection system
Electrical system
Troubleshooting
+i
ELEC
0
TRBL
SHTGl
f}
•
q
Symbols 0 to u indicate the following.
0 Serviceable with engine mounted
q Filling fluid
w Lubricant
e Special tool
r Tightening torque
t Wear limit, clearance
y Engine speed
u Electrical data
w
*Q
©
/•;
t
® H\
y
I
^4J
B
m
u
o I
^Gj
p I
^Mj
M
New
Symbols i to d in the exploded diagrams indicate the types of lubricants and lubrication
points.
i Engine oil
o Gear oil
p Molybdenum-disulfide oil
a Wheel-bearing grease
s Lithium-soap- based grease
d Molybdenum-disulfide grease
Symbols f to g in the exploded diagrams indicate the following.
f Apply locking agent (LOCTITE®)
g Replace the part
EAS00010
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
GEN
INFO
1
0»
SPEC
2
CHK
ADJ
3
#
%
CHAS
4
ENG
5
COOL
6
FI
5
+
ELECTRICAL SYSTEM
TROUBLESHOOTING
ELEC
BL
SHTG
8
GEN j y *
INFO \<^®
CHAPTER 1
GENERAL INFORMATION
SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
MODEL LABEL
FEATURES
OUTLINE OF THE FI SYSTEM
FI SYSTEM
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
REPLACEMENT PARTS
GASKETS, OIL SEALS AND O-RINGS
LOCK WASHERS/PLATES AND COTTER PINS
BEARINGS AND OIL SEALS
CIRCLIPS
EQUIPMENT PREPARATION
CHECKING THE CONNECTIONS
SPECIAL TOOLS
1-1
1-1
1-1
1-2
1-2
1-3
1-4
1-4
1-4
1-4
1-5
1-5
1-5
1-6
1-7
1-8
GEN
SCOOTER IDENTIFICATION INFO
#
^
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped
into the frame.
EAS00018
MODEL LABEL
The model label 1 is affixed to the frame trunk.
This information will be needed to order spare
parts.
1-1
FEATURES
EAS00896
FEATURES
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operation under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner.
To accommodate this need, this model has adopted an electronically controlled fuel injection(FI)
system, in place of the conventional carburetor system. This system can achieve an optimum airfuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions.
1
2
3
4
5
6
7
8
9
ECU
Engine trouble warning light
Lean angle cut-off switch
Fuel hose
Ignition coil
Fuel injector
Intake air pressure sensor
ISC(idle speed control) valve
Intake air temperature sensor
0
q
w
e
r
t
y
u
i
1-2
Battery
Air filter case
Catalytic converter
Crankshaft position sensor
Coolant temperature sensor
Spark plug
Fuel tank
Fuel pump
Throttle position sensor
FEATURES
EAS00897
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kg/cm2, 35.6 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater
the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is
energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the crankshaft position sensor, intake air pressure sensor, intake temperature sensor and engine
temperature sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is
required by the engine can be supplied at all times in accordance with the driving conditions.
1
2
3
4
5
6
7
8
9
0
Fuel pump
Fuel injector
Ignition coil
ECU
Catalytic converter
Coolant temperature sensor
Crankshaft position sensor
Intake air pressure sensor
Throttle body assembly
Intake air temperature sensor
q
w
e
A
B
C
1-3
Air filter case
ISC (idle speed control) valve
Throttle position sensor
Fuel system
Air system
Control system
IMPORTANT INFORMATION
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
1-
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands may
be similar in function and appearance, but inferior in quality.
"^N
^M
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.
1-4
IMPORTANT INFORMATION
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
1
Oil seal
cC
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1
Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use. When
installing a circlip 1 , make sure the sharp-edged
corner 2 is positioned opposite the thrust 3
that the circlip receives.
^
®-^>
//////K
/////©//
/ / / / / / / /
/ / / / / /
4
1-5
Shaft
GEN
IMPORTANT INFORMATION INFO
#
^
EAS00021
EQUIPMENT PREPARATION
Push Rivet (Push type)
Assembly status of the push rivet(push type).
Dissembling
1. Press center p i n 1 inward to release the
lock.
2. Remove the push rivet main body2.
<D
(^E
Assembling
1. Restore the center pin, replace the push
rivet main body.
Vo.
;
*
*
2. Push in the center pin until leveling off with
the surface position of the push rivet main
body.
1-6
CHECKING THE CONNECTIONS
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
8lead
8coupler
8connector
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:
8lead
8coupler
8connector
k
^Yv»
A
? ----.
^^1
^
V ff \°
1 +
?-V^ ^ ?
NOTE:
Make sure all connections are tight.
5. Check:
8continuity
(with the pocket tester)
p*
Pocket tester
90890-03112(YU-03112-C)
NOTE:
8 If there is no continuity, clean the terminals.
8 When checking the wire harness, perform
steps (1) to (3).
8 As a quick remedy, use a contact revitalizer
available at most part stores.
1-7
SPECIAL TOOLS
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.
NOTE:
8 For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
8 For others, use part number starting with “90890-”.
Tool NO.
90890-01052
90890-01085
YU-01083-2
90890-01084
YU-01083-3
90890-01235
YU-01235
90890-01268
YU-01268
90890-01304
YU-01304
90890-01337
YM-33285
YM-33285-6
90890-01325
YU-24460-01
90890-01352
YU-33984
90890-01367
YM-A9409-7
90890-01400
YM-A9409-3
Tool name / Function
Illustration
Meter gear bush tool
This tool is used when removing or installing the meter gear.
Slide hammer bolt(8mm)1
Weight2
^ 2
These tools are needed to remove the camshaft.
Rotor holding tool
This tool is used to hold the primary fixed
sheave and secondary sheave assembly.
Ring nut wrench
This tool is used to loosen and tighten the
exhaust and steering ring nut.
Piston pin puller set
This tool is used to remove the piston pin.
Clutch spring holder
These tool are used for removing the nut with
holding the compression spring.
Radiator cap tester1
Radiator cap tester adapter2
2
1
This tester and its adapter are needed for
checking the cooling system.
Fork seal driver weight1
Fork seal driver attachment2
This tool is used when installing the fork
seal.
1-8
1
2
SPECIAL TOOLS
Tool NO.
90890-01384
YM-33299
90890-01403
YU-A9472
90890-01444
YM-A9409-7
90890-01468
YU-33270-B
90890-01493
90890-01701
YS-01880-A
90890-03079
YM-34483
90890-03081
YU-33223
90890-03112
YU-03112-C
Tool name / Function
Oil seal guide
This tool is used for protecting the oil seal
lip when installing the secondary sliding
sheave.
Steering nut wrench
This tool is used to loosen and tighten the
steering ring nut.
Steering nut wrench(45mm)
This tool is used to loosen and tighten the
upper bearing inner race.
Flywheel puller set
This tool is used to remove the AC magneto
rotor.
Socket wrench(39mm)
This tool is used when removing or installing the secondary sheave nut.
Sheave holder
This tool is used for holding the secondary
sheave.
Thickness gauge
This tool is used to measure the valve
cleanance.
Compression gauge
This tool is used to measure the engine compression.
Pocket tester
90890-03174
This instrument is invaluable for checking
the electrical system.
Digital circuit tester
90890-03141
YU-03141
This instrument is invaluable for checking
the electrical system.
1-9
Illustration
SPECIAL TOOLS
Tool NO.
90890-03141
YU-03141
90890-03182
YU-03182
90890-04101
90890-04058
YM-04058
90890-04145
90890-04019
YM-04019
90890-04148
YM-04148
90890-06760
90890-06754
YM-34487
90890-04111
YM-04111
90890-04112
YM-04112
90890-04113
YM-04113
Tool name / Function
Illustration
Timing light
This tool is used to check the ignition timing.
FI diagnostic tool
Execute CO adjustment, confirm fault Code,
self diagnosis tool
Valve lapper
This tool is needed to remove and install the
valve lifters.
Middle driven shaft bearing driver1
Mechanical seal installer2
2
There tools are used to install the water pump
seal.
Valve spring compressor
Compressor adapter(Ø16.5mm)
These tools are used when removing or installing the valve and the valve spring.
Digital tachometer
This tool is needed for detecting engine rpm.
Ignition checker
This tool is used to check the ignition system components.
Valve guide remover(4.0mm)
This tool is used to remove or install the
valve guides.
Valve guide installer(4.0mm)
This tool is used to install the valve guides.
Valve guide remover(4.0mm)
This tool is used to rebore the new valve
guides.
1-10
SPECIAL TOOLS
Tool NO.
90890-01326
YM-01326
90890-01294
YM-01300-1
Tool name / Function
90890-03181
90890-85505
ACC-11001-05-01
#
Illustration
T-handle1
Damper rid holder2
These tools are used to hold the damper rod
when removing or installing the damper rod.
©
90890-03153
YU-03153
GEN
INFO
Pressure gauge
This tool is used to measure fuel pressure.
Fuel pressure adapter
This tool is used to measure fuel pressure.
Yamaha bond NO.1215
Sealant (Quick Gasket®)
This sealamt (bond) is used on crankcase
mating surfaces(e.g., crankcase mating surfaces).
1-11
(D
^
SPEC
0*
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS
2-1
ENGINE SPECIFICATIONS
2-2
CHASSIS SPECIFICATIONS
2-12
ELECTRICAL SPECIFICATIONS
2-15
CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS
2-18
TIGHTENING TORQUES
2-19
ENGINE
2-19
CHASSIS
2-21
LUBRICATION POINTS AND LUBRICANT TYPES
2-23
ENGINE
2-23
CHASSIS
2-25
COOLING SYSTEM DIAGRAMS
2-26
CABLE ROUTING
2-29
GENERAL SPECIFICATIONS SPEC
0 *
SPECIFICATIONS
GENERAL SPECIFICATIONS
Standard
Item
Limit
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet(without oil and a full fuel tank)
Dry(without oil and fuel)
Maximun load(total of cargo, rider,
passenger, and accessories)
3B32(USA)
3B33(CAN)
…
…
1905mm(75.00in)
685mm(26.97in)
1045mm(41.14in)
735mm(28.94in)
1280mm(50.39in)
115mm(4.53in)
2000mm(78.74in)
…
…
…
…
…
…
…
90kg(198lb)
85kg(187lb)
175kg(386lb)
…
…
…
2-1
ENGINE SPECIFICATIONS
SPEC
0*
ENGINE SPECIFICATIONS
Standard
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore×stroke
Compression ratio
Engine idle speed
Vacuum pressure at engine idle speed
Standard compression pressure(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total
Engine oil
Lubrication system
Recommended oil
Quantity
Periodic oil change
Total amount
Final gear oil
Recommended oil
Periodic oil change
Total amount
Oil filter
Oil filter type
Limit
Liquid-cooled, 4-stroke, SOHC
0.049L(49cm³, 2.99cu-in)
Forward inclined single cylinder
38.0×43.5mm(1.496×1.713in)
12:1
2000~2200r/min
34.7kPa(260mmHg,10.24inHg)
1450kPa(14.5kg/cm2)
at 700r/min
…
…
…
…
…
…
…
…
Unleaded gasoline only(USA)
Regular unleaded gasoline
only(CAN)
…
…
4.5L(0.98 Imp gal, 1.18 US gal) …
Wet sump
…
YAMALUBE4, SAE10W30
…
or SAE20W40
API service SG type or higher
JASO stand MA
0.73~0.83L(0.67~0.76 Imp qt,
0.80~0.90 US qt)
0.80~0.90L(0.74~0.83 Imp qt,
0.87~0.98 US qt)
…
SAE10W30 hypoid gear oil
0.09~0.11L(0.08~0.10 Imp qt,
0.10~0.12 US qt)
0.11~0.13L(0.10~0.12 Imp qt,
0.12~0.14 US qt)
…
…
Wire mesh
…
2-2
…
…
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Oil pump
Oil pump type
Inner rotor to outer rotor tip clearance
Trochoid
0.15mm(0.006in) or less
Outer rotor to pump housing clearance
0.13~0.18mm(0.005~0.007in)
Oil pump housing to inner rotor and
outer rotor clearance
0.07~0.12mm(0.003~0.005in)
Cooling system
Radiator capacity
Radiator cap opening pressure
Valve relief pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity(up to the maximum level mark)
<From low to full level>
Water pump
Water pump type
0*
Limit
…
0.23mm
(0.009in)
0.25mm
(0.010in)
0.19mm
(0.008in)
0.26L(0.23 Imp gal, 0.28 US gal) …
…
107.9~137.3kPa
2
(1.1~1.4kg/cm , 15.6~19.9psi)
1.1kPa(0.01kg/cm2, 0.16psi)
…
127.4mm(5.016in)
87mm(3.425in)
16mm(0.630in)
…
…
…
0.25L(0.22 Imp gal, 0.27 US gal) …
0.15L(0.13 Imp gal, 0.16 US gal) …
Single-suction centrifugal
pump
…
…
Starting system type
Electric and kick starter
…
Electric fuel injection
Type
Manufacturer
3B3
AISAN
…
…
Spark plug
Model(manufacturer)×quantity
Spark plug gap
CR7E(NGK)×1
0.7~0.8mm(0.028~0.031in)
…
…
Cylinder head
Volume
Maximum warpage
3.1~3.5cm³(0.19~0.21cu-in)
…
…
0.05mm
(0.0020in)
Max. impeller shaft tilt
,
i
i,
>
>
1
F
' •
2-3
0.15mm
(0.0059in)
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Camshaft
Drive system
Intake camshaft lobe dimensions
0*
Limit
Chain drive(left)
…
30.158~30.258mm
(1.1873~1.1913in)
25.082~25.182mm
(0.9875~0.9914in)
30.058mm
(1.1834in)
24.982mm
(0.9835in)
30.158~30.258mm
(1.1873~1.1913in)
25.020~25.120mm
(0.9850~0.9890in)
30.058mm
(1.1834in)
24.920mm
(0.9811in)
0.03mm
(0.0012in)
B
Measurement A
Measurement B
Exhaust camshaft lobe dimensions
6A
•^
Measurement A
Measurement B
Maximum camshaft runout
B
•
…
2-4
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Timing chain
Model/number of links
Tensioning system
Valve, valve seats, valve guides
Valve clearance(cold)
Intake
Exhaust
0*
Limit
Morse 92RH2005/82
Automatic
…
…
0.10~0.16mm
(0.0039~0.0063in)
0.18~0.24mm
(0.0071~0.0094in)
…
…
Valve dimensions
y
r
v
V
VB
\. \.C
Head Diameter
Face Width
Seat Width
Valve head diameter A
Intake
…
1.48~2.19mm
(0.0583~0.0862in)
1.48~2.19mm
(0.0583~0.0862in)
…
0.9~1.1mm
(0.0354~0.0433in)
0.9~1.1mm
(0.0354~0.0433in)
1.6mm
(0.0630in)
1.6mm
(0.0630in)
0.70mm(0.0276in)
0.70mm(0.0276in)
…
…
3.975~3.990mm
(0.1565~0.1571in)
3.975~3.990mm
(0.1565~0.1571in)
3.945mm
(0.1553in)
3.930mm
(0.1547in)
4.000~4.012mm
(0.1575~0.1580in)
4.000~4.012mm
(0.1575~0.1580in)
4.050mm
(0.1594in)
4.050mm
(0.1594in)
Valve face width B
Intake
Exhaust
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
2-5
D
Mar gin Thickness
15.4~15.6mm
(0.6063~0.6142in)
16.4~16.6mm
(0.6457~0.6535in)
Exhaust
Valve seat width C
Intake
J
T\
\
…
…
ENGINE SPECIFICATIONS
Standard
Item
Valve stem to valve guide clearance
Intake
0.010~0.037mm
(0.0004~0.0015in)
0.025~0.052mm
(0.0010~0.0020in)
^
0*
Limit
…
0.080mm
(0.0031in)
0.100mm
(0.0039in)
0.010mm
(0.0004in)
0.9~1.1mm
(0.0354~0.0433in)
0.9~1.1mm
(0.0354~0.0433in)
1.6mm
(0.0630in)
1.6mm
(0.0630in)
Exhaust
Valve stem runout
SPEC
%
/ / / / / / / / / / /w?.
//////////
Valve seat width
Intake
Exhaust
2-6
ENGINE SPECIFICATIONS
Exhaust
Limit
39.35mm(1.5492in)
37.38mm
(1.4717in)
39.49mm
(1.5547in)
41.57mm(1.6366in)
Installed length(valve closed)
Intake
Exhaust
Compressed spring force(installed)
Intake
Exhaust
0*
Standard
Item
Valve springs
Free length
Intake
SPEC
28.0mm(1.1024in)
30.0mm(1.1811in)
…
…
91.1~104.9N
(9.3~10.7kg, 20.48~23.58lb)
107.9~124.1N
(11.0~12.7kg, 24.26~27.90lb)
…
…
2.5°/1.7mm
(2.5°/0.0669in)
2.5°/1.8mm
(2.5°/0.0709in)
…
Spring tilt
— » •
Intake
V///////////A
Exhaust
…
Winding direction(top view)
Intake
Exhaust
Clockwise
Clockwise
…
…
Valve seat reformed
Yes
…
…
…
…
…
Maximum taper
Forward inclined single cylinder
38.0×43.5mm(1.496×1.713in)
12:1
38.000~38.010mm
(1.496~1.497in)
…
Maximum out-of-round
…
Cylinder
Cylinder arrangement
Bore×stroke
Compression ratio
Bore
2-7
0.05mm
(0.0020in)
0.05mm
(0.0020in)
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Piston
Piston-to-cylinder clearance
0*
Limit
0.010~0.035mm
(0.0004~0.0014in)
37.975~37.990mm
(1.4951~1.4957in)
0.150mm
(0.0059in)
…
5.0mm(0.1969in)
…
10.002~10.013mm
(0.3938~0.3942in)
0.35~0.65mm
(0.0138~0.0256in)
Intake side
10.043mm
(0.3954in)
…
9.996~10.000mm
(0.3935~0.3937in)
9.976mm
(0.3928in)
Barrel
0.8×1.65mm
(0.0315×0.0650in)
0.05~0.15mm
(0.0020~0.0059in)
0.03~0.07mm
(0.0012~0.0028in)
…
Taper
0.8×1.5mm
(0.0315×0.0591in)
0.05~0.17mm
(0.0020~0.0067in)
0.02~0.06mm
(0.0008~0.0024in)
…
…
Diameter D
_H
"X.
-D—
Height H
Piston pin bore(in the piston)
Diameter
Offset
Offset direction
Piston pin
Outside diameter
…
Piston rings
Top ring
Ring type
Dimensions(B×T)
B
End gap(installed)
T
Ring side clearance
…
0.40mm
(0.0157in)
0.12mm
(0.0047in)
2nd ring
T
Ring type
Dimensions(B×T)
End gap(installed)
Ring side clearance
\
I
IB
2-8
0.52mm
(0.0205in)
0.12mm
(0.0047in)
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Limit
Oil ring
i
1 i
1
i
B
T ,
Dimensions(B×T)
End gap(installed)
Ring side clearance
1.5×1.6mm
(0.0591×0.0630in)
0.2~0.7mm
(0.0079~0.0276in)
0.03~0.15mm
(0.0012~0.0059in)
2-9
0*
…
…
…
ENGINE SPECIFICATIONS
SPEC
Standard
Item
0*
Limit
Rocker arm/rocker arm shaft
Rocker arm inside diameter
Rocker arm shaft outside diameter
Arm-to-shaft clearance
Connecting rod
Connecting rod length
Small end inside diameter
10.000~10.015mm
(0.3937~0.3943in)
9.981~9.991mm
(0.3930~0.3933in)
0.009~0.034mm
(0.0004~0.0013in)
10.030mm
(0.3949in)
9.950mm
(0.3917in)
…
79.95~80.05mm
(3.1476~3.1516in)
10.015~10.028mm
(0.3943~0.3948in)
…
42.45~42.50mm
(1.671~1.673in)
…
…
…
Crankshaft
Width A
Maximum runout C
Big end side clearance D
Big end radial clearance E
1^
0.15~0.45mm
(0.006~0.018in)
0~0.010mm
(0~0.0004in)
2-10
0.03mm
(0.0012in)
1.00mm
(0.0394in)
…
ENGINE SPECIFICATIONS
Standard
Item
Clutch
Clutch type
Clutch shoe thickness
SPEC
Automatic centrifugal
3.7mm(0.146in)
Clutch shoe spring free length
Clutch housing inside diameter
30.1mm(1.185in)
107mm(4.213in)
Compression spring free length
Weight outside diameter
76.4mm(3.008in)
15.0mm(0.591in)
Clutch-in revolution
Clutch-stall revolution
3050~3450r/min
5000~6000r/min
0*
Limit
…
2.0mm
(0.079in)
…
107.5mm
(4.232in)
…
14.5mm
(0.571in)
…
…
V-belt
V-belt width
17.9mm(0.705in)
16.1mm
(0.634in)
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Single speed automatic
Maximum main axle runout
V-belt automatic
Helical gear
50/13(3.846)
Helical gear
43/12(3.583)
3.087~0.945:1
…
…
…
…
…
…
…
0.04mm
(0.002in)
0.04mm
(0.002in)
Maximum drive axle runout
…
Air filter type
Wet element
…
Fuel pump
Pump type
Model(manufacturer)
Output pressure
Electrical
3B3(AISAN)
250kPa(2.5kg/cm2, 35.6psi)
…
…
…
Throttle body
Throttle cable free play
(at the flange of the throttle grip)
ID mark
1.5~3.5mm(0.06~0.14in)
3B31 00
…
…
2-11
CHASSIS SPECIFICATIONS
SPEC
0*
CHASSIS SPECIFICATIONS
Standard
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Maximum radial wheel runout
Steel tube backbone
26°
84mm(3.31in)
…
…
…
Cast wheel
…
J10×MT3.00
Aluminum
58mm(2.28in)
…
…
…
…
1.0mm
(0.04in)
1.0mm
(0.04in)
0.25mm
(0.01in)
Maximum lateral wheel runout
…
Wheel axle bending limit
…
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Maximum radial wheel runout
Maximum lateral wheel runout
…
Front tire
Tire type
Size
Model(manufacturer)
Tire pressure(cold)
0~175kg(0~386lb)
Minimum tire tread depth
Limit
Cast wheel
…
J10×MT3.00
Aluminum
56mm(2.20in)
…
…
…
…
1.0mm
(0.04in)
1.0mm
(0.04in)
Tubeless
120/90-10 57J
C-6022(CHENG SHIN)
…
…
…
175kPa(1.75kgf/cm², 25psi)
…
…
0.8mm
(0.03in)
2-12
CHASSIS SPECIFICATIONS
Standard
Item
Rear tire
Tire type
Size
Model(manufacturer)
Tire pressure(cold)
0~175kg(0~386lb)
Minimum tire tread depth
Front brake
Brake type
Operation
Brake lever free play(at lever end)
Brake drum inside diameter
Lining thickness
Rear brake
Brake type
Operation
Brake lever free play(at lever end)
Brake drum inside diameter
Lining thickness
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Installed length
Spring rate(K1)
Spring stroke(K1)
Optional spring available
Fork oil
Recommended oil
Quantity(each front fork leg)
Inner tube outer diameter
Inner tube bending limit
SPEC
0*
Limit
Tubeless
120/90-10 57J
C-6022(CHENG SHIN)
…
…
…
175kPa(1.75kgf/cm², 25psi)
…
…
0.8mm
(0.03in)
Drum brake
Right-hand operation
10~20mm(0.39~0.79in)
110mm(4.33in)
…
…
…
110.5mm
(4.35in)
2.0mm
(0.08in)
4.0mm(0.16in)
Drum brake
Left-hand operation
10~20mm(0.39~0.79in)
110mm(4.33in)
4.0mm(0.16in)
…
…
…
110.5mm
(4.35in)
2.0mm
(0.08in)
Telescopic fork
Coil spring
65mm(2.56in)
…
…
…
202.2mm(7.96in)
198.2mm
(7.80in)
…
…
…
…
188.2mm(7.41in)
10.1N/mm(1.03kg/mm)
0~65mm(0~2.56in)
No
Fork oil 10W or equivalent
0.042L(0.038lmp qt,
0.046 US qt)
26mm(1.02in)
…
2-13
…
…
…
0.2mm
(0.01in)
CHASSIS SPECIFICATIONS
Standard
Item
Steering system
Steering bearing type
Lock-to-lock angle(left)
Lock-to-lock angle(right)
Rear suspension
Suspension type
Rear shock absorber assembly type
Rear shock absorber assembly travel
Spring
Free length
Installed length
Spring rate(K1)
Spring rate(K2)
Spring stroke(K1)
Spring stroke(K2)
Optional spring available
SPEC
Angular bearing
46°
46°
Limit
…
…
…
Unit swing
Coil spring
45mm(1.77in)
…
…
…
176.5mm(6.95in)
162.5mm(6.40in)
28.03N/mm
(2.85kg/mm, 159.59lb/in)
42.18N/mm
(4.30kg/mm, 240.79lb/in)
0~17mm(0~0.67in)
17~45mm(0.67~1.77in)
No
…
…
…
2-14
0*
…
…
…
…
ELECTRICAL SPECIFICATIONS
SPEC
0*
ELECTRICAL SPECIFICATIONS
Standard
Item
System voltage
Limit
12V
…
Transistorized coil ignition
5° BTDC at 2000~2200r/min
Digita
248~372 at 20°C(68°F)/
white/red-white/blue
…
…
…
…
Ignition coil
Model(manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
3B3 00(T-MORIC)
6mm(0.24in)
2.16~2.64Q at 20°C(68°F)
8.64~12.96k£2 at 20°C(68°F)
…
…
…
…
Spark plug cap
Material
Resistance
Resin
4~6k£2 at 20°C(68°F)
…
…
AC magneto
F3B3(T-MORIC)
14V 130W/5000r/min
0.28~0.42 at 20°C(68°F)/
white-white
…
…
…
…
Rectifier/regulator
Regulator type
Model(manufacturer)
No load regulated voltage
Rectifier capacity
Withstand voltage
Semiconductor, short circuit
SH745-AA(SHINDENGEN)
13.0~14.0V
24A
200V
…
…
…
…
…
Battery
Battery type(manufacturer)
Battery voltage/capacity
Specific gravity
Ten hour rate amperage
GTX5L-BS(GS)
12V/4AH
1.330
0.4A
…
…
…
…
Headlight type
Halogen bulb
…
Indicator light(voltage/wattage×quantity)
Turn signal indicator light
High beam indicator light
Engine trouble warning light
Water temperature indicator light
14V 3.0W×1
12V 1.7W×1
12V 1.7W×1
14V 1.7W×1
…
…
…
…
Ignition system
Ignition system type
Ignition timing
Advancer type
Crankshaft position sensor resistance/color
Charging system
System type
Model(manufacturer)
Nominal output
Stator coil resistance/color
2-15
ELECTRICAL SPECIFICATIONS
Standard
Item
Bulbs(voltage/wattage×quantity)
Headlight
Tail/brake light
Front turn signal light
Rear turn signal light
License plate light
Speedometer light
Electric starting system
System type
Starter motor
Model(manufacturer)
Suction voltage
Power output
Brushes
Overall length
Quantity
Spring force
Commutator diameter
Commutator resistance
Mica undercut(depth)
SPEC
0*
Limit
12V 35/35W×1
12V 5/21W×1
12V 10W×2
12V 10W×2
12V 5W×1
12V 1.7W×1
…
…
…
…
…
…
Constant mesh
…
3B3 00(T-MORIC)
12V
0.25kW
…
…
…
7.0mm(0.28in)
3.5mm
(0.14in)
…
…
2
3.92~5.88N
(400~600gf, 14.11~21.16oz)
17.6mm(0.69in)
16.6mm
(0.65in)
0.0378~0.0462 at 20°C(68°F) …
…
1.35mm(0.05in)
Starter relay
Model(manufacturer)
Amperage
Coil resistance
Suction voltage
5WC 00(OMRON)
50A
90-110
More than DC10V
…
…
…
…
Horn
Horn type
Model(manufacturer)
Maximum amperage
Performance
Coil resistance
Plane
GF-127(NIKKO)
1.0A
95~115dB/2m
3.96~4.10W at 20°C(68°F)
…
…
…
…
…
Turn signal relay
Relay type
Model(manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Condenser
FZ222SD(DENSO)
NO
75~95cycles/minute
10W×2+3.4W
…
…
…
…
…
2-16
ELECTRICAL SPECIFICATIONS
Standard
Item
Fuse(amperage×quantity)
Main fuse
SPEC
Limit
15A×1
…
3B3(AISAN)
4~10Q
90~100£2
…
…
…
Starting circuit cut-off relay
Model(manufacturer)
Coil resistance
Diode
4HC1(MATSU SHITA)
72~88
YES
…
…
…
Radiator fan
Model(manufacturer)
Running rpm
5ST1(LUNTAI)
10000r/min or less
…
…
Fuel gauge
Model(manufacturer)
Sender unit resistance-full
Sender unit resistance-empty
Thermostat
Type(manufacture)
Valve opening temperature
Valve full open temperature
Valve lift-full open
4BA1(NIPPON THERMOSTAT) …
83~87°C
…
…
100°C
…
3.5mm
Coolant temperature sensor
Model(manufacturer)
Coil resistance at 20°C(68°F)
Coil resistance at 80°C(176°F)
5YP1(DENSO)
2.32~2.59k£2
0.310~0.326k£2
…
…
…
Intake air pressure sensor
Output voltage
0.789~4.0V
…
5.7~6.3k at 20°C(68°F)/
brown-white/black-blue
…
Speed sensor
Output voltage
When sensor is on
When sensor is off
DC 4.8V or more
DC 0.6V or less
…
…
Throttle position sensor
Voltage/color
Output voltage(closed position)/color
5V/blue-black/blue
0.63~0.73V/yellow-black/blue
…
…
18~22 at 20°C(68°F)/
pink-green/yellow or
gray-sky blue
…
0.4~1.4V
3.7~4.4V
…
…
Intake air temperature sensor
Coil resistance/color
ISC(idle speed control) valve
Resistance/color
Lean angle cut-off switch
Voltage
Less than 65°
More than 65°
2-17
0*
CONVERTION TABLE / GENERAL TIGHTENING
TORQUE SPECIFICATIONS
SPEC
EAS00028
EAS00030
CONVERSION TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
Ex.
METRIC
MULTIPLIER
IMPERIAL
** mm
0.03937
** in
2 mm
0.03937
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
m·kg
Tightening torque m·kg
cm·kg
cm·kg
Multiplier
Imperial unit
7.233
86.794
0.0723
0.8679
ft·lb
in·lb
ft·lb
in·lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu-in
qt (IMP liq.)
gal (IMP liq.)
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit (°F)
Misc.
A: Width across flats
B: Thread diameter
A
(nut)
2-18
B
(bolt)
General tightening
torques
Nm
m#kg
fMb
10 mm
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE
Part to be tightened
Part name
Thread Q’ty
size
Tightening
torque
Remarks
Nm m»kg ft»lb
Exhaust pipe stud bolt
Oil check bolt
Cylinder head cover
Cylinder head and cylinder
Cylinder head(timing chain side)
Spark plug
Camshaft sprocket
Timing chain tensioner(body)
Guide stopper2
Timing chain tensioner(plug)
Water pump assembly
Thermostat cover air bleed bolt
Thermostat cover
Fan case
Fan
Radiator drain bolt
Radiator cover
Oil pump assembly
Engine oil drain plug
Intake manifold
Air filter assembly
Injector
Intake manifold side band
Air filter assembly side band
Protector
Exhaust pipe
Stay fender
Muffler
Reed valve and holder
AI filter case
Oil guide
Crankcase(left and right)
Cylinder stud bolt
Drain bolt(transmission oil fill bolt)
V-belt case cover
Drain bolt(transmission oil)
Transmission case
Transmission case
Cover1(starter clutch)
Hold lead plate bolt
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
plug
Bolt
Bolt
Bolt
Bolt
Screw
Screw
Bolt
Bolt
Bolt
Band
Band
Screw
Nut
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
-
2-19
M8
M6
M6
M6
M6
M10
M8
M6
M6
M8
M6
M6
M6
M6
M6
M10
6
M5
M35
M6
M6
M6
M4
M4
M6
M8
M8
M8
M6
M6
M6
M6
M6
M8
M6
M6
M6
M6
M6
M6
2
1
4
4
2
1
1
2
1
1
3
1
2
4
3
1
3
2
1
2
2
1
1
1
2
2
2
2
1
1
2
8
4
1
6
1
6
2
7
1
13
7
10
10
10
13
30
9
7
8
10
10
10
10
9
1
2
4
32
10
10
12
3
3
9
13
10
31
14
7
10
10
13
23
10
13
11
10
10
10
1.3
0.7
1.0
1.0
1.0
1.3
3.0
0.9
0.7
0.8
1.0
1.0
1.0
1.0
0.9
0.1
0.2
0.4
3.2
1.0
1.0
1.2
0.3
0.3
0.9
1.3
1.0
3.1
1.4
0.7
1.0
1.0
1.3
2.3
1.0
1.3
1.1
1.0
1.0
1.0
9.4
5.1
7.2
7.2 —4\\4jl
7.2
9.4
21.7
6.5
5.1
5.8
7.2
7.2
7.2
7.2
6.5
0.7
1.5
2.9
23.1
7.2
7.2
8.7
2.2
2.2
When fastened, apply
6.5 screw retaining com9.4 pound.
7.2
22.4
10.1
5.1
7.2
7.2
9.4
16.6
7.2
9.4
8.0
7.2
7.2
7.2
TIGHTENING TORQUES
Part to be tightened
Part name
Thread Q’ty
size
SPEC
Tightening
torque
0*
Remarks
Nm m»kg ft»lb
Drain bolt(engine oil)
Centerstand spring
Starter clutch
Kickstarter
Primary fixed sheave
Clutch housing
Stator coil
Pulser coil
AC magneto rotor
Starter motor assembly
Ignition coil
Coolant temperature sensor
Hook
Nut
Bolt
Nut
Nut
Bolt
Screw
Nut
Bolt
Bolt
-
Cylinder head tightening sequence
(1 -»2-»3-4-»2-»5-»6)
2-20
M8
M6
M22
M6
M10
M10
M5
M6
M12
M6
M6
M12
1
1
1
1
1
1
3
2
1
2
2
1
23
7
90
12
30
40
4
7
43
13
7
22
2.3
0.7
9.0
1.2
3.0
4.0
0.4
0.7
4.3
1.3
0.7
2.2
16.6
5.1
65.1
8.7
21.7
28.9
2.9
5.1
31.1
9.4
5.1
15.9
Left-hand thread
i
^ILT
TIGHTENING TORQUES
SPEC 0*"
CHASSIS
Thread
size
Part to be tightened
Tightening
torque
Nm
Frame and engine bracket3
Engine bracket3 and engine
Handlebar bracket and steering shaft
Rear shock absorber and frame
Rear shock absorber and engine
Steering shaft and upper bearing inner race
Steering shaft and ring nut
Front fork and lower bracket
Handlebar bracket and handlebar lower holder
Handlebar lower holder and handlebar upper holder
Throttle cable and holder lever2
Throttle cable and throttle body
Front reflector
Fuel tank
Fuel pump
Single seat lock assembly
Trunk
Bottom plate and single seat lock bracket
Bottom plate and frame(single seat)
Single seat and frame(single seat)
Single seat lock assembly and trunk
Resin part and resin cover
Footrest board
License bracket
Rear turn signal light
License light
Front wheel shaft
Front brake camshaft lever
Rear wheel shaft
Rear brake camshaft lever
Rear brake pin pivot
Speedometer cable
Main switch and headlight stay bracket
Headlight body and headlight unit
Headlight stay bracket and headlight body
Lower bracket and headlight stay bracket
Handlebar bracket and headlight stay bracket
ECU and trunk
Rear reflector and license bracket
Taillight underside
2-21
M10
M10
M10
M10
M8
BC1
BC1
M10
M10
M8
M5
M5
M5
M6
M5
M6
M6
M6
M6
M6
M6
About M5
M6
M6
M6
About M5
M10
M6
M14
M6
M8
M12
M6
M5
M6
M8
M8
M6
M5
M6
46
58
60
30
16
7
30
30
48
28
4
5
7
10
4
12
12
7
10
10
7
2
7
7
4
2
48
8
120
10
16
5
7
4
10
23
23
7
2
2
Remarks
m»kg ft»lb
4.6
5.8
6.0
3.0
1.6
0.7
3.0
3.0
4.8
2.8
0.4
0.5
0.7
1.0
0.4
1.2
1.2
0.7
1.0
1.0
0.7
0.2
0.7
0.7
0.4
0.2
4.8
0.8
12.0
1.0
1.6
0.5
0.7
0.4
1.0
2.3
2.3
0.7
0.2
0.2
33.1
42.0
43.4
21.7
11.6
5.1 See”NOTE”
21.7 See”NOTE”
21.7
34.7
20.3
2.9
3.6
5.1
7.2
2.9
8.7
8.7
5.1
7.2
7.2
5.1
1.5
5.1
5.1
2.9
1.5
34.7
5.8
86.8
7.2
11.6
3.6
5.1
2.9
7.2
16.6
16.6
5.1
1.5
1.5
TIGHTENING TORQUES
SPEC
0*
NOTE :
1. First,tighten the upper bearing inner race approximately 7Nm(0.7m»kg, 5.1ft»lb) by using the
torque wrench and check turn steering shaft smoothly.
2. Second,hold the upper bearing inner race and tighten the ring nut 30Nm(3.0m»kg, 21.7ft»lb) by
using the torque wrench.
3. Final,operate the steering shaft together with the steering stem nut now.
© Upper bearing inner race
(2) Ring nut
2-22
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
0*
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication Point
Lubricant
Oil seal lips
^^TLS^P^L
O-rings(except V-belt drive unit)
^^LS^^A
O-ring(fuel injector assembly)
~~^\4Jl
Cylinder head tightening nut mounting surface
~~^%4Jl
Cylinder head stud bolt thread
~^l4
Cylinder head gasket dowel pin
^HI4
Crankshaft pin outside surface
~~^\4Jl
Connecting rod
^HI4
Piston outside and ring groove
—H1C4J
Piston pin outside surface
~~^\4Jl
surface and bolt thread
^HI4
Crankshaft journal
^HI4
Piston(balancer) outside surface
~ ^ 4
Piston pin(balancer) outside surface
—^1^4^
Camshaft lobe
^HICM!
Camshaft profile journal
^HICM!
Valve stems(intake and exhaust)
^HICMI
Valve stem seals(intake and exhaust)
^HlM
Valve pads(intake and exhaust)
—HlMl
Valve stem ends(intake and exhaust)
^HlK4j
Oil pump assembly inside surface
^HI4
Oil pipe union bolt thread and surface
^Hlf4j
Starter clutch pin and weight
^HlM
Kick pinion gear and kick pinion gear clip thrust surface
^HlM
Idle gear 1 thrust surface
^Hlf4j
Idle gear2
~~^\4Jl
Main and drive axle serration(sprocket)
~HI^G]
2-23
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication Point
SPEC
0*
Lubricant
Drive axle taper rollor bearing
—HI^GJ
Transmission bearings
^HICGJ
Secondary fixed sheave inner surface
BEL-RAY asembly lube®
Secondary sliding sheave torque cam ditch
BEL-RAY asembly lube®
Crankcase mating surfaces
Sealant
2-24
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC 0*"
EAS00032
CHASSIS
Lubrication Point
Lubricant
Front wheel oil seal lips
^^LSp^L
Steering bearing and bearing races(upper and lower)
^^LSp^L
Frame head pipe dust seal lips(lower)
^^TLS^^^L
Tube guide(throttle grip) inner surface
^ L S ^ ^ A
Brake lever and lever holder bolt sliding surface
^^LSpn
Centerstand pivoting point and sliding surface
^^f LS^^^L
Single seat lock cable inner surface
^^TLS^^^L
Engine bracket and engine mound bolt sliding surface
2-25
^ L S ^ H
COOLING SYSTEM DIAGRAMS
EAS00033
A
COOLING SYSTEM DIAGRAMS
1
2
3
4
5
6
7
8
Raidator cap
Coolant reservoir hose
Radiator inlet hose
Air bleed bolt
Radiator outlet hose
Fan case
Damper
Raidator cover
B
C
D
E
F
G
2-26
SPEC
0*
Insert until contacting with the latch of radiator tank.
Install white paint marck of pipe 3 toward
the direction of radiator cover.
Install clip for the turning knob to face forward.
Hand and fix the claw of fan case 1 on the
radiator cover.
Insert to the bent part of radiator pipe.
Make sure that hose is inserted to the bottom.
Install clip for the turning knob to face downward.
COOLING SYSTEM DIAGRAMS
1
2
3
4
5
Radiator
Radiator inlet hose
Radiator outlet hose
Thermostat
Water pump outlet hose
A
2-27
SPEC
0*
Install clip for the turning knob to face downward.
COOLING SYSTEM DIAGRAMS
1
2
3
4
5
Thermostat assembly inlet breather hose
Breather hose
Water pump outlet hose
Radiator outlet hose
Water pump
A
B
C
D
E
2-28
SPEC
0*
Install the paint mark of hose facing up.
Install clip for the turning knob to face downward.
Make sure that hose is inserted to the bottom.
Align the paint mark of pipe 7 to the stopper
of water pump Ass’y.
Insert until contacting with the stopper.
CABLE ROUTING
EAS00035
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
q
w
e
Hose3
ECU
Ignition coil
Sidestand switch lead
Main switch
Hose
Coolant temperature sensor
Wiring harness
Throttle cable kit
Rear brake cable
AC magneto lead
Hose5
Starter motor lead
r
t
A
B
C
D
E
Battery positive lead
Wire lead cover
Assemble cramp on the Tstud at the right of back
stay.
Install the protruding part of
cable strap of electrical
wire harmess Ass’y on the
hole of box bracket 1 .
Install crap on the hols of
stay 1 .
Penetrate thermo unit lead
through the rear of hose 3.
Install the protruding part of
cable strap of electrical
wire harmess Ass’y on the
F
G
H
SPEC
hole of down tube 1 .
Fix connector cover on the
head light stay.
Install the protruding part of
cable strap of electrical
wire harmess Ass’y on the
hole of fuel tank bracket 2.
Connect AC magnet lead
on the cramp of fan case
1.
6
D-D
F-F
E-E
2-29
0*
G-G
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
q
w
Speedometer
Rectifier/Regulator
Turn signal relay
Throttle cable Ass’y
Holder
Cable holder
Rear brake cable
Speedometer cable
Front brake cable
Headlight
Horn
Starting circuit cut-off relay
A After wiring the cover,
cover the coupler.
B Enter tail/brake light.
C After fixing the rear brake
cable, fix crank case 1 .
When locking, make sure
that the stopper at the front
of holder touches the position of crank case 1 .
D After fixing the rear brake
cable, install the protruding
part of cramp on the hole
of under cover.
2-30
E
F
SPEC
0*
Install the horn of coupler
accotding to the direction
shown in the drawing, and
make sure that it is not
loosen easily.
Penetrate through the
speed meter cable.
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
Fuel pump
FI diagnostic tool connector
Fuse box
Battery negative lead
ECU lead
Battery positive lead
Starter relay
AC magneto lead
Tail/brake light lead
Starter motor lead
Holder
Cable holder
Lean angle cut-off switch
Ignition coil
Throttle cable Ass’y
Rear brake cable
Wiring harness
dx
©-
D
i
o
p
a
s
A
B
C
D
Rear fender
Fuel injector lead
Sub-wire harness lead
ISC(idle speed control)
valve lead
Crankcase2
Enter slant angle of sensor.
Enter tail/brake light.
Fix throttle cable Ass’y. Install the protruding part of
cramp on the hole of fuel
tank bracket.
Fix throttle cable Ass’y. Install the protruding part of
cramp on the hole of foot
rest bracket.
E
F
SPEC
Put the idle speed control
lead and wire sub lead in,
and then close the cramp.
Wire the starting device of
the rear fender of rear motor lead and crank case 2.
Do not clip the lead in.
©
C
©
®
©
©
©
©
y
B-B
A-A
C-C
t
u
s
p
o
5
F
a
E
D-D
E-E
F-F
2-31
0*
G-G
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
q
w
Speedometer
Rectifier/Regulator
Horn
Turn signal relay
Front brake cable
Rear brake cable
Throttle cable Ass’y
Speedometer cable
Rectifier/Regulator lead
Wiring harness
Main switch lead
Horn lead
A
B
C
Penetrate the rear brake
cable and throttle cable
through the left side of car
body.
Make sure to install the
cramp on the head light
stay.
Install the protruding part of
cable strap of electrical
wire harmess Ass’y on the
hole of head light stay.
D
E
F
SPEC
0*
Penetrate the main switch
Comp. Lead into the connector cover.
Penetrate horn cable
through the connector
cover without sticking out
horn cable.
Enter rectifier and regulator
Ass’y.
1
2
-©
C
GC
xi)
B
®-
-©
C
A
F
XD
0
-©
®
B-B
A-A
2-32
CABLE ROUTING
G
SPEC
0*
Let the left and right flasher
lights, meter, and right lead
wire of handle bar switch to
face upward, let the main
switch, front and rear brake
switchand left lead wire of
handle bar switch to face
downward, connect to the
coupler, and then store in
the connector cover.
1
2
-©
C-
mC
B
®C
F
0
B-B
A-A
2-33
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
q
Turn signal light lead(right)
Handlebar
switch
lead(right)
Front brake light switch
lead
Turn signal light lead(left)
Handlebar switch lead(left)
Rear brake light switch
Throttle cable Ass’y
Front brake cable
Rear brake cable
Backward screw
Forward screw
A
B
C
D
E
Penetrate the rear brake
cable and throttle cable
through the left side of car
body.
Make sure to install the
cramp on the head light
stay.
Install the protruding part of
cable strap of electrical
wire harmess Ass’y on the
hole of head light stay.
Penetrate the main switch
Comp. Lead into the connector cover.
Penetrate horn cable
through the connector
cover without sticking out
horn cable.
2-34
F
G
SPEC
0*
Enter rectifier and regulator
Ass’y.
First, tighting the backward
screw and tighting the forward screw.
CHK
ADJ
< &
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
3-1
PERIODIC MAINTENANCE AND MINOR REPAIR
3-2
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
3-2
GENERAL MAINTENANCE AND LUBRICATION CHART
3-3
COVER AND PANEL
3-5
SIDE COVERS AND TAIL/BRAKE LIGHT
3-5
SINGLE SEAT AND TRUNK
3-7
LEG SHIELD1,2
3-8
FOOTREST BOARD AND INNER FENDER
3-9
ENGINE
3-10
ADJUSTING THE VALVE CLEARANCE
3-10
CHECKING THE ENGINE IDLING SPEED
3-16
ADJUSTING THE THROTTLE CABLE FREE PLAY
3-17
CHECKING THE SPARK PLUG
3-18
CHECKING THE IGNITION TIMING
3-20
MEASURING THE COMPRESSION PRESSURE
3-22
CHECKING THE ENGINE OIL LEVEL
3-24
CHANGING THE ENGINE OIL
3-25
CHANGING THE TRANSMISSION OIL
3-27
MEASURING THE ENGINE OIL PRESSURE
3-28
REPLACING THE AIR FILTER ELEMENT
3-30
CHECKING THE THROTTLE BODY JOINT AND INTAKE
MANIFOLD
3-32
CHECKING THE FUEL HOSE
3-32
CHECKING THE BREATHER HOSES
3-33
CHECKING THE EXHAUST SYSTEM
3-34
CHECKING THE COOLANT LEVEL
3-35
CHECKING THE COOLING SYSTEM
3-36
CHANGING THE COOLANT
3-37
CHASSIS
3-40
ADJUSTING THE FRONT BRAKE
3-40
ADJUSTING THE REAR BRAKE
3-40
CHECKING THE FRONT AND REAR BRAKE SHOES
3-41
CHECKING AND ADJUSTING THE STEERING HEAD
3-42
CHECKING THE FRONT FORK
3-44
CHECKING THE TIRES
3-45
CHK
ADJ
CHECKING THE WHEELS
CHECKING AND LUBRICATING THE CABLES
LUBRICATING THE LEVERS AND PEDALS
LUBRICATING THE CENTERSTAND
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
CHECKING THE FUSE
REPLACING THE HEADLIGHT BULB
ADJUSTING THE HEADLIGHT BEAM
< &
3-48
3-48
3-49
3-49
3-50
3-50
3-56
3-58
3-59
CHK
INTRODUCTION ADJ
<
&
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
3-1
PERIODIC MAINTENANCE AND MINOR REPAIR
PERIODIC MAINTENANCE AND MINOR REPAIR
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
INITIAL
NO.
1
*
2
ITEM
ROUTINE
600 mi
(1,000 km)
or
1
month
ODOMETER READING
2,000 mi
(4,000 km)
or
6
months
4,000 mi
6,000 mi
8,000 mi
10,000 mi
(7,000 km) (10,000 km) (13,000 km) (16,000 km)
or
or
or
or
12
18
24
30
months
months
months
months
Fuel line
• Check fuel and vacuum hoses for
cracks or damage.
• Replace if necessary.
V
V
V
V
V
Spark plug
• Check condition.
• Adjust gap and clean.
• Replace at 4000 mi (7000 km) or
12 months and thereafter every
4000 mi (6000 km) or 12 months.
V
Replace.
V
Replace.
V
3
*
Valve clearance
• Check and adjust valve clearance
when engine is cold.
4
*
Crankcase breather
system
• Check breather hose for cracks or
damage.
• Replace if necessary.
5
*
Fuel injection
• Check engine idle speed.
6
*
Exhaust system
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
7
*
Air induction system
• Check the air cut-off valve, reed
valve, and hose for damage.
• Replace any damaged parts.
V
V
Every 6000 mi (10000 km)
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform
the service.
3-2
CHK
PERIODIC MAINTENANCE AND MINOR REPAIR ADJ
< &
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
NO.
1
*
ITEM
ROUTINE
Air filter element
• Replace.
600 mi
(1,000 km)
or
1
month
ODOMETER READING
2,000 mi
(4,000 km)
or
6
months
4,000 mi
6,000 mi
8,000 mi
10,000 mi
(7,000 km) (10,000 km) (13,000 km) (16,000 km)
or
or
or
or
12
18
24
30
months
months
months
months
v
v
v
v
v
V
V
V
V
V
V
V
V
V
V
V
V
2
*
Front brake
• Check operation.
• Adjust cable and replace brake
shoes if necessary.
3
*
Rear brake
• Check operation.
• Adjust cable and replace brake
shoes if necessary.
4
*
Wheels
• Check runout and for damage.
• Replace if necessary.
V
V
V
V
V
5
*
Tires
•
•
•
•
V
V
V
V
V
6
*
Wheel bearings
• Check bearings for smooth
operation.
• Replace if necessary.
V
V
V
V
V
Repack.
V
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
7
*
Steering bearings
• Check bearing assemblies for
looseness.
• Moderately repack with lithiumsoap-based grease every 8000 mi
(13000 km) or 24 months.
8
*
Chassis fasteners
• Check all chassis fitting and
fasteners.
• Correct if necessary.
Front and rear brake • Apply lithium-soap-based grease
lever pivot
(all-purpose grease) lightly.
9
12
15
V
V
V
V
V
V
V
V
V
V
Centerstand
• Check operation.
• Lubricate.
V
V
V
V
V
*
Front fork
• Check operation and for oil
leakage.
• Replace if necessary.
V
V
V
V
V
*
Shock absorber
assembly
• Check operation and for oil
leakage.
• Replace if necessary.
V
V
V
V
V
Engine oil
• Change (warm engine before
draining).
• Check oil level and vehicle for oil
leakage.
V
V
V
V
V
V
Engine oil strainer
• Clean.
V
Cooling system
• Check coolant level and vehicle for
coolant leakage.
*
V
V
• Change.
Final transmission
oil
• Check vehicle for oil leakage.
• Change.
*
V-belt
• Replace.
18
*
Front and rear brake
• Check operation.
switches
19
*
Control and meter
cables
20
*
• Check operation and free play.
• Adjust the throttle cable free play if
Throttle grip housing
necessary.
and cable
• Lubricate the throttle grip housing
and cable.
21
*
Lights, signals and
switches
16
17
• Apply Yamaha chain and cable
lube or engine oil 10W-30
thoroughly.
• Check operation.
• Adjust headlight beam.
V
V
V
V
V
Every 3 years
V
V
V
Every 6250 mi (10000 km)
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
3-3
CHK
PERIODIC MAINTENANCE AND MINOR REPAIR ADJ
<
*
&
Since these items require special tools, data and technical skills, have a Yamaha dealer perform
the service.
NOTE:
From 12000mi(19000km) or 36 months, repeat the maintenance intervals starting from
4000mi(7000km) or 12 months.
EAU17680
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
3-4
CHK
COVER AND PANEL ADJ
<
&
EAS00038
COVER AND PANEL
SIDE COVERS AND TAIL/BRAKE LIGHT
Order
1
2
3
4
5
6
7
8
Job/Part
Remarks
Q’ty
Removing the side covers and tail/
brake light
Front cover
Side cover(left)
Side cover(right)
Tail/brake and rear turn signal light(left
and right)
Battery cover
Battery negative lead
Battery positive lead
Battery
3-5
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
c
C
8First, disconnect the negative
battery lead, and then the positive
battery lead.
8After installing the battery be sure
to turn the main switch from “ON”
to “OFF” three times in 3 seconds
intervals to initialize the idle speed
CHK
COVER AND PANEL ADJ
Order
Job/Part
Q’ty
<
&
Remarks
control system.
For installation, reverse the removal procedure.
3-6
CHK
COVER AND PANEL ADJ
<
&
SINGLE SEAT AND TRUNK
\y10Nm(1.0m • kg, 7.2 ft • lb)
\ l 12Nm(1.2m« kg, 8.7 ft* lb)
[s& 7Nm(0.7m• kg, 5.1 ft• lb)
"10
/ \
/
'/* *£® /
/
/
Order
Job/Part
1
2
3
4
5
6
7
8
9
10
Single seat
Single seat upper cover
Bottom plate
Frame(single seat)
ECU
Starter relay
Main fuse
Single seat lock assembly
Helmet holder
Trunk
8
/
Remarks
Q’ty
Removing the single seat and trunk
Side cover(left and right)
\
/
Remove the parts in the order listed.
Refer to “SIDE COVERS AND TAIL/
BRAKE LIGHT”.
1
1
2
1
1
1
1
1
1
1
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
3-7
CHK
COVER AND PANEL ADJ
<
&
LEG SHIELD1,2
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Removing the leg shield1,2
Front fork upper cover
Reflector(left)
Front fork cover(left)
Reflector(right)
Front fork cover(right)
Leg shield1
Main switch cover
Leg shield2
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
Caution, do not damage the claw while
removing.
For installation, reverse the removal procedure.
3-8
CHK
COVER AND PANEL ADJ
<
&
FOOTREST BOARD AND INNER FENDER
Order
Job/Part
1
2
3
4
5
6
7
Removing the footrest board and inner fender
Single seat/trunk
Fuel tank cap cover
Fuel tank cap
Coolant reservoir cap cover
Panel
Footrest board
Coolant reservoir
Inner fender
Remarks
Q’ty
Remove the parts in the order listed.
Refer to “SINGLE SEAT AND TRUNK “.
1
1
1
1
1
1
1
When installing the fuel tank cap, align it
cap end and the mark on the car body.
Disconnect.
For installation, reverse the removal procedure.
3-9
ADJUSTING THE VALVE CLEARANCE
EAS00049
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
• front cover
• side cover(left and right)
• battery /battery cover
• single seat/trunk
• footrest board
• Refer to”COVER AND PANEL”.
2. Drain:
• coolant
(completely from the radiator)
3. Remove:
• radiator cover®
• radiator
• fan case®
Refer to”RADIATOR”in chapter 6.
4. Remove:
• spark plug cap
• spark plug
• ignition coil
• cylinder head cover
5. Remove:
• water pump
Refer to”WATER PUMP”in chapter 6.
6. Measure:
• valve clearance
Out of specification -» Adjust.
Valve clearance (cold)
Intake valve
0.10 ~ 0.16mm(0.0039 ~ 0.0063in)
Exhaust valve
0.18 ~ 0.24mm(0.0071 ~ 0.0094in)
3-10
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
<
&
•••••••••••••••••••••••
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compression stroke, align the punch mark a in the
camshaft sprocket with the stationary b on
the plate.
c. Align the TDC mark c on the AC magneto
rotor with the stationary pointer d on the
crankcase cover.
d. Measure the valve clearance with a thickness gauge ® .
Out of specification -» Adjust.
• • • • • • • • • • • • • • • • • • • • • • •
7.
Adjust:
valve clearance
• • • • • • • • • • • • • • • • • • • • • • •
a. Remove the timing chain tensioner and camshaft sprocket.
b. Remove the head nuts, bolts and plate.
c. Remove the rocker arm shaft, rocker arm
and collar.
d. Remove the valve p a d 2 with a magnetic
bar1.
NOTE:
8 Cover the timing chain opening with a rag
to prevent the valve pad from falling into the
crankcase.
8 Make a note of the position of each valve
pad so that they can be installed in the correct place.
e. Select the proper valve pad from the following table.
Valve pad thickness range
Nos.
120 ~ 240
Available
valve
pads
1.20 (0.0472in) 25 thicknesses in
~ 2.40 mm 0.05 mm (0.002 in)
(0.0945 in)
increments
f. Round off the original valve pad number according to the following table.
3-11
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
Last digit
0 or 2
5
8
<
&
Rounded value
0
5
10
EXAMPLE:
Original valve pad number =148(thickness
=1.48mm(0.0583in))
Rounded value =150
g. Locate the rounded number of the original
valve pad and the measured valve clearance in the valve pad selection table. The
point where the column and row intersect is
the new valve pad number.
NOTE:
The new valve pad number is only an approximation. The valve clearance must be measured
again and the above steps should be repeated if
the measurement is still incorrect.
h. Install the new valve pad .
NOTE:
• Lubricate the valve pad with molybdenum
disulfide oil.
• Install the valve pad in the correct place.
i. Install the rocker arm, collar and rocker arm
shaft.
j. Install the plate and cylinder head nuts
X | 10Nm(1.0m * kg, 7.2ft * lb)
k. Install the cylinder head bolts .
X | 10Nm(1.0m * kg, 7.2ft * lb)
l. Install the camshaft sprocket.
X | 30Nm(3.0m * kg, 21.7ft * lb)
m. Install the timing chain tensioner and gasket.
X | 9Nm(0.9m * kg, 6.5ft * lb)
3-12
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
<
&
n. Install the timing chain tensioner spring and
cap bolt .
X I 8Nm(0.8m * kg, 5.8ft * lb)
o. Measure the valve clearance again.
p. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance
is obtained.
• • • • • • • • • • • • • • • • • • • • • • •
3-13
ADJUSTING THE VALVE CLEARANCE
INTAKE
MEASURED
CLEARANCE
0.00~0.04
0.05~0.09
0.10~0.16
0.17~0.21
0.22~0.26
0.27~0.31
0.32~0.36
0.37~0.41
0.42~0.46
0.47~0.51
0.52~0.56
0.57~0.61
0.62~0.66
0.67~0.71
0.72~0.76
0.77~0.81
0.82~0.86
0.87~0.91
0.92~0.96
0.97~1.01
1.02~1.06
1.07~1.11
1.12~1.16
1.17~1.21
1.22~1.26
1.27~1.31
1.32~1.36
ORIGINAL VALVE PAD NUMBER
•
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
175
180
185
190
195
200
205
210
215
220
225
230
235
240
180
185
190
195
200
205
210
215
220
225
230
235
240
185
190
195
200
205
210
215
220
225
230
235
240
190
195
200
205
210
215
220
225
230
235
240
195
200
205
210
215
220
225
230
235
240
200
205
210
215
220
225
230
235
240
205
210
215
220
225
230
235
240
210
215
220
225
230
235
240
215
220
225
230
235
240
220
225
230
235
240
225 230 235 240
230 235 240
235 240
240
VALVE CLEARANCE(cold):
0.10~0.16mm(0.0039~0.0063in)
Example:175 pad is installed
Measured clearance is 0.24mm(0.0094in)
Replace pad 175 with pad 185
Pad number: (example)
Pad No.175=1.75mm(0.0689in)
Pad No.185=1.85mm(0.0728in)
EXHAUST
MEASURED
CLEARANCE
0.00~0.02
0.03~0.07
0.08~0.12
0.13~0.17
0.18~0.24
0.25~0.29
0.30~0.34
0.35~0.39
0.40~0.44
0.45~0.49
0.50~0.54
0.55~0.59
0.60~0.64
0.65~0.69
0.70~0.74
0.75~0.79
0.80~0.84
0.85~0.89
0.90~0.94
0.95~0.99
1.00~1.04
1.05~1.09
1.10~1.14
1.15~1.19
1.20~1.24
1.25~1.29
1.30~1.34
1.35~1.39
1.40~1.44
ORIGINAL VALVE PAD NUMBER
X
120 125 130 135 140
120
120 125
120 125 130
120 125 130 135
145
125
130
135
140
150
130
135
140
145
155
135
140
145
150
160
140
145
150
155
165
145
150
155
160
170
150
155
160
165
175
155
160
165
170
180
160
165
170
175
185
165
170
175
180
190
170
175
180
185
195
175
180
185
190
200
180
185
190
195
205
185
190
195
200
210
190
195
200
205
215
195
200
205
210
220
200
205
210
215
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
175
180
185
190
195
200
205
210
215
220
225
230
235
240
180
185
190
195
200
205
210
215
220
225
230
235
240
185
190
195
200
205
210
215
220
225
230
235
240
190
195
200
205
210
215
220
225
230
235
240
195
200
205
210
215
220
225
230
235
240
200
205
210
215
220
225
230
235
240
205
210
215
220
225
230
235
240
210
215
220
225
230
235
240
215
220
225
230
235
240
220
225
230
235
240
225 230 235 240
230 235 240
235 240
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
225
205
210
215
220
VALVE CLEARANCE(cold):
3-14
230
210
215
220
225
235
215
220
225
230
240
220
225
230
235
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
<
&
8. Install:
8all removed parts
NOTE:
For installation, reverse the removal procedure.
9. Fill:
8cooling system
(with the specified amount of the recommended coolant)
Refer to”CHANGING THE COOLANT”.
3-15
CHK
CHECKING THE ENGINE IDLING SPEED ADJ
<
&
EAS00054
CHECKING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed, the air
filter element should be clean, and the engine
should have adequate compression.
1. Start the engine and let it warm up for several minutes.
2. Remove:
8 panel
Refer to”FOOTREST BOARD AND INNER FENDER”.
3. Connect:
8 digital circuit tester
(onto the spark plug lead of cylinder)
Digital circuit tester
90890-06760
4. Check:
• engine idling speed
Out of specification -»Replace the throttle
body assembly.
A
Engine idling speed
2000~2200r/min
5. Install:
8 panel
Refer to”FOOTREST BOARD AND INNER FENDER”.
3-16
ADJUSTING THE THROTTLE CABLE FREE PLAY
EAS00056
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted properly.
1. Check:
• throttle cable free play a
Out of specification ^Adjust.
Throttle cable free play (at the flange
of the throttle grip)
1.5~3.5mm (0.06~0.14in)
2. Adjust:
8throttle cable free play
•••••••••••••••••••••••
Handlebar side
a. Loosen the locknut 1 .
b. Turn the adjusting nut 2 in direction a or
b until the specified throttle cable free play
is obtained.
Direction a
Direction b
Throttle cable free play is increased.
Throttle cable free play is decreased.
c. Tighten the locknut.
w
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
•••••••••••••••••••••••
3-17
CHECKING THE SPARK PLUG
EAS00060
CHECKING THE SPARK PLUG
1. Remove:
8 panel
Refer to”FOOTREST BOARD AND INNER FENDER”.
2. Disconnect:
8 spark plug cap
w
Remove the spark plug cap, the engine is
extremely hot.
3. Remove:
8 spark plug
cC
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
into the cylinder.
4. Check:
8 spark plug type
Incorrect -* Change.
Spark plug type (manufacturer)
CR7E(NGK)
5. Check:
8 electrode ©
Damage/wear -* Replace the spark plug.
8 insulator©
Abnormal color -* Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
8 spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
8 spark plug gap a
(with a wire Thickness gauge)
Out of specification -* Regap.
Spark plug gap
0.7 ~0.8mm(0.028 ~0.031in)
3-18
CHK
CHECKING THE SPARK PLUG ADJ
<
&
8. Install:
• spark plug
X I 13Nm(1.3m * kg, 9.4ft * lb)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
• spark plug cap
10. Install:
• panel
Refer to”FOOTREST BOARD AND INNER FENDER”.
3-19
CHK
CHECKING THE IGNITION TIMING ADJ
<
&
EAS00062
CHECKING THE IGNITION TIMING
NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure all connections are tight and free of
corrosion.
1. Remove:
8front cover
8side cover(left and right)
8battery /battery cover
8single seat/trunk
Refer to”COVER AND PANEL”.
2. Drain:
8coolant
(completely from the radiator)
3. Remove:
8radiator cover
8radiator
8fan case
Refer to”RADIATOR”in chapter 6.
4. Attach:
8timing light 1
8digital circuit tester2
(onto the spark plug lead of cylinder)
Timing light
90890-03141
YU-03141
Digital circuit tester
90890-06760
3-20
CHK
CHECKING THE IGNITION TIMING ADJ
<
&
5. Check:
8ignition timing
• • • • • • • • • • • • • • • • • • • • • • •
a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed.
A
Engine idling speed
2000 ~ 2200r/min
b. Check that the mark a on the AC magneto
rotor is within the firing range b on the right
crankcase cover.
Incorrect firing range -» Check the ignition
system.
• • • • • • • • • • • • • • • • • • • • • • •
NOTE:
The ignition timing is not adjustable.
6. Remove:
• timing light
• digital circuit tester
7. Install:
• fan case
• radiator
• radiator cover
Refer to”RADIATOR”in chapter 6.
8. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to”CHANGING THE COOLANT”.
9. Install:
• single seat/trunk
• battery /battery cover
• side cover(left and right)
• front cover
Refer to”COVER AND PANEL”.
3-21
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
<
&
EAS00067
MEASURING THE COMPRESSION PRESSURE
NOTE:
Insufficient compression pressure will result in
a loss of performance.
1. Measure:
8 valve clearance
Out of specification -» Adjust
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Remove:
8 panel
Refer to”FOOTREST BOARD AND INNER FENDER”.
4. Disconnect:
8 spark plug cap
w
Remove the spark plug cap, the engine is
extremely hot.
5. Remove:
8spark plug
cC
Before removing the spark plug, use
compressed air to blow away any dirt
accumulated in the spark plug well to
prevent it from falling into the cylinder.
6. Install:
8compression gauge 1
^
Compression gauge
90890-03081
YU-33223
7. Measure:
8 compression pressure
Out of specification -» Refer to steps (c)
and (d).
Compression pressure (at sea level)
Minimum
1262kPa(12.62kg/cm2, 179.7psi)
Standard
1450kPa(14.5kg/cm2, 206.5psi)
Maximum
1624kPa(16.24kg/cm2, 231.3psi)
3-22
MEASURING THE COMPRESSION PRESSURE
•••••••••••••••••••••••
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the engine until the reading on the compression
gauge stabilizes.
FflWUzWIgM
To prevent sparking, ground the spark plug
lead before cranking the engine.
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits -» Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
engine of oil into the spark plug bore and
measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than without oil
Piston ring(s) wear or
damage -»Repair.
Same as without oil
Piston ring(s), valves,
cylinder head gasket or
piston possibly defective -» Repair.
•••••••••••••••••••••••
8. Remove:
• compression gauge
9. Install:
• spark plug
X I 13Nm(1.3m * kg9.4ft* lb)
10. Connect:
• spark plug cap
11. Install:
• panel
Refer to”FOOTREST BOARD AND INNER FENDER”.
3-23
CHECKING THE ENGINE OIL LEVEL
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the scooter on a level surface.
NOTE:
8 Place the scooter on a suitable stand.
8 Make sure the scooter is upright.
-T-
V
~///^(S)
}yyf(M'
\
^
^ \
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Check:
8 engine oil level
The engine oil level should be between
the minimum level mark a and maximum
level mark b .
Below the minimum level mark -»Add the
recommended engine oil to the proper
level.
<\l.
^
*0
i b
! a
Recommended engine oil type
YAMALUBE 4, SAE10W30 or
SAE20W40
Recommended engine oil grade
API service SG type or higher
JASO standard MA
cC
Do not allow foreign materials to enter
the crankcase.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
3-24
CHK
CHANGING THE ENGINE OIL ADJ
<
&
EAS00076
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
8engine oil filler cap 1
8engine oil drain bolt 2
(along with the gasket)
4. Drain:
8engine oil
(completely from the crankcase)
5. If the oil filter element is also to be replaced
or cleaned, perform the following procedure.
•••••••••••••••••••••••
a. Remove the oil strainer cover 1,spring3
and oil filter element 4 .
b. Replace the O-ring New 2
c. Install the new or clean oil filter element and
the oil strainer cover.
Oil strainer cover
32Nm(3.2m • kg, 23.1ft • lb)
•••••••••••••••••••••••
6. Install:
• engine oil drain bolt
(along with the gasket)
X | 23Nm(2.3m * kg, 16.6ft * lb)
7. Fill:
• crankcase
(with the specified amount of the recommended engine oil)
«0
3-25
Quantity
Total amount
0.8~0.9L(0.74~0.83 Imp qt, 0.87~0.98
US qt)
Periodic oil change
0.73~0.83L(0.67~0.76 Imp qt,
0.80~0.90 US qt)
CHANGING THE ENGINE OIL
8. Install:
8engine oil filler cap
9. Start the engine, warm it up for several minutes, and then turn it off.
10.Check:
8engine
(for engine oil leaks)
11.Check:
8engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
12.Check:
engine oil pressure
• • • • • • • • • • • • • • • • • • • • • • •
a. Slightly loosen the oil gallery bolt <RN.1>.
b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.
c. Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
leakage. Refer to “OIL PUMP” in chapter 5.
d. Start the engine after solving the problem(s)
and check the engine oil pressure again.
e. Tighten the oil gallery bolt to specification.
V
%
Oil gallery bolt
7Nm (0.7m • kg, 5.1ft • lb)
•••••••••••••••••••••••
3-26
CHK
CHANGING THE TRANSMISSION OIL ADJ
<
&
CHANGING THE TRANSMISSION OIL
1. Stand the scooter on a level surface.
NOTE:
• Stand the scooter on a suitable stand.
• Make sure that the scooter upright.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Place a container under the transmission
oil drain bolt.
4 Remove:
• transmission oil fill bolt
(along with the gasket)
• transmission oil drain bolt©
5. Drain:
• transmission oil
(completely from the transmission case)
6. Install:
• transmission oil drain bolt
X I 13Nm(1.3m * kg, 9.4ft * lb)
7. Fill:
• transmission case
(with the specified amount of the recommended transmission oil)
K}
Recommended oil
SAE10W30 hypoid gear oil
Total amount
0.11~0.13L(0.10~0.12 Imp qt,
0.12~0.14 US qt)
Periodic oil change
0.09~0.11L(0.08~0.10 Imp qt,
0.10~0.12 US qt)
8. Install:
• transmission oil fill bolt©
(along with the gasket)
X I 23Nm(2.3m * kg, 16.6ft * lb)
3-27
9. Start the engine for several minutes to warm
it up and check for the oil leakage.
10.Check:
• transmission case
(for transmission oil leaks)
MEASURING THE ENGINE OIL PRESSURE
EAS00077
MEASURING THE ENGINE OIL PRESSURE
1. Check:
8 engine oil level
Below the minimum level mark -»Add the
recommended engine oil to the proper
level.
Refer to”CHECKING THE ENGINE OIL
LEVEL”.
2. Start the engine, warm it up for several minutes, and then turn it off.
C
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
3. Remove:
8 panel
Refer to”FOOTREST BOARD AND INNER FENDER”.
4. Lossen:
8oil gallery bolt 1
w
The engine, muffler and engine oil are
extremely hot.
5. Check:
8engine oil pressure
• • • • • • • • • • • • • • • • • • • • • • •
a. Start the engine and keep it idling until engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.
b. Check the engine oil passages, the oil filter
and oil pump for damage or leakage.Refer
to”OIL PUMP” in chapter 5.
c. Start the engine after solving the problem(s)
and check the engine oil pressure again.
•••••••••••••••••••••••
3-28
CHK
MEASURING THE ENGINE OIL PRESSURE ADJ
<
&
6. Install:
8oil gallery bolt
X I 7Nm(0.7m * kg, 5.1ft * lb)
7. Install:
• panel
Refer to”FOOTREST BOARD AND INNER FENDER”.
3-29
REPLACING THE AIR FILTER ELEMENT
EAS00086
REPLACING THE AIR FILTER ELEMENT
1. Remove:
8front cover
8side cover(left)
Refer to”SIDE COVERS AND TAIL/
BRAKE LIGHT”.
2. Remove:
8air filter case c o v e r 1
8air filter element
3. Check:
8 air filter element©
Damage/dirty^ Replace.
NOTE:
8 Replace the air filter element every
4000km(2000mi) .
8 The air filter needs more frequent service if
you are riding in unusually wet or dusty areas.
4. Install:
8 air filter element
8 air filter case cover
X I 10Nm(1.0m * kg, 7.2ft * lb)
C
Never operate the engine without the air
filter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the throttle body tuning, leading to poor
engine performance and possible
overheating.
NOTE:
When installing the air filter element into the air
filter case cover, make sure their sealing surfaces are aligned to prevent any air leaks.
3-30
CHK
REPLACING THE AIR FILTER ELEMENT ADJ
<
&
5. Install:
8side cover(left)
8front cover
Refer to”SIDE COVERS AND TAIL/
BRAKE LIGHT”.
3-31
CHECKING THE THROTTLE BODY JOINT AND
INTAKE MANIFOLD/CHECKING THE FUEL HOSE
EAS00094
CHECKING THE THROTTLE BODY JOINT
AND INTAKE MANIFOLD
1. Remove:
8front cover
8side cover(left and right)
8single seat/trunk
Refer to”COVER AND PANEL”.
2. Check:
• throttle body joint (T)
• intake manifold (2)
Cracks/damage -» Replace.
Refer to “FUEL INJECTION SYSTEM” in
chapter 7.
3. Install:
•single seat/trunk
•side cover(left and right)
•front cover
Refer to”COVER AND PANEL”.
EAS00096
CHECKING THE FUEL HOSE
The following procedure applies to all of the fuel
hose.
1. Remove:
•front cover
•side cover(left and right)
•single seat/trunk
•footrest board
Refer to”COVER AND PANEL”.
2. Check:
•fuel hose (T)
Cracks/damage -» Replace.
Loose connection -» Connect properly.
3. Install:
•footrest board
•single seat/trunk
•side cover(left and right)
•front cover
Refer to”COVER AND PANEL”.
3-32
CHK
CHECKING THE BREATHER HOSES ADJ
<
&
EAS00098
CHECKING THE BREATHER HOSES
1. Remove:
8front cover
8side cover(left and right)
8single seat/trunk
Refer to”COVER AND PANEL”.
2. Check:
8 breather hose (T)
8 transmission case breather hose (2)
Cracks/damage -» Replace.
Loose connection -» Connect properly.
C
Make sure the breather hoses are routed
correctly.
v^ fera
X
\
3. Install:
8single seat/trunk
8side cover(left and right)
8front cover
Refer to”COVER AND PANEL”.
\
\^V
\
i
iil^
tx 1>f Si M ^
tU>
i(f[i'@j)l ^
3-33
CHECKING THE EXHAUST SYSTEM
EAS00099
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
muffler assembly and gasket.
1. Remove:
8muffler assembly
Refer to”ENGINE REMOVAL”in chapter
5.
2. Check:
• muffler assembly (T)
Crack/damage -» Replace.
• gasket (2)
Exhaust gas leak -» Replace.
3. Check:
• tightening torque
Exhaust pipe nut (3)
13Nm(1.3m • kg, 9.4ft • lb)
Muffler and rear arm bolt (4)
31Nm(3.1m • kg, 22.4ft • lb)
4. Install:
8muffler assembly
Refer to”ENGINE REMOVAL”in chapter
5.
3-34
CHECKING THE COOLANT LEVEL
EAS00103
CHECKING THE COOLANT LEVEL
1. Stand the scooter on a level surface.
NOTE:
8 Place the scooter on a suitable stand.
8 Make sure the scooter is upright.
2. Check:
8 coolant level
The coolant level should be between the
maximum level mark a and minimum
level mark b .
Below the minimum level mark -»Add the
recommended coolant to the proper level.
C
8 Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
8 Use only distilled water. However, if distilled water is not available, soft water
may be used.
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Check:
8 coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
3-35
CHECKING THE COOLING SYSTEM
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:
8front cover
8side cover(left and right)
8battery /battery cover
8single seat/trunk
8footrest board
Refer to”COVER AND PANEL”.
8radiator cover
Refer to”RADIATOR”in chapter 6.
Jl "
<^Cl& ^ ^ v
\ / -/C-^y
iy,
^7
^
^^\^y^fe^^\^p—\
/
^~ ^
Vg
N^gf
/ ^ I\XMT^
'•'•':\
2. Check:
• radiator©
• radiator inlet hose (2)
• radiator outlet hose (3)
Cracks/damage -» Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:
• radiator cover
Refer to”RADIATOR”in chapter 6.
• footrest board
• single seat/trunk
• battery /battery cover
• side cover(left and right)
• front cover
Refer to”COVER AND PANEL”.
°V X3
1'
*so)
^^sr^/^js,
3-36
CHANGING THE COOLANT
EAS00105
CHANGING THE COOLANT
1. Remove:
8front cover
8side cover(right)
8coolant reservoir cap cover
Refer to”COVER AND PANEL”.
8radiator cover
Refer to”RADIATOR”in chapter 6.
2. Disconnect:
8coolant reservoir hose 1
3. Drain:
8coolant
(from the coolant reservoir)
8coolant
(from the radiator under drain bolt)
4. Remove:
8radiator cap
8coolant reservoir cap
w
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause
serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap
counterclockwise toward the detent to allow
any residual pressure to escape. When the
hissing sound has stopped, press down on
the radiator cap and turn it counterclockwise
to remove.
5. Connect:
8coolant reservoir hose
6. Install:
8radiator under drain bolt
X I 1Nm(0.1m * kg, 0.7ft * lb)
3-37
CHANGING THE COOLANT
7. Fill:
8cooling system
(with the specified amount of the recommended coolant)
«0
Recommended antifreeze
High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines
Mixing ratio
4:6(antifreeze:water)
Quantity
Total amount
0.50L(0.46 Imp qt, 0.53 US qt)
Coolant reservoir capacity
0.26L(0.23 Imp qt, 0.28 US qt)
Up to the maximum level mark
NOTE:
The specified amount of coolant is a standard
amount. Fill the cooling system with coolant until coolant comes out of the air bleed bolt hole.
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
w
If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
If coolant splashes on your clothes,
quickly wash it away with water and
then with soap and water.
If coolant is swallowed, induce vomiting
and get immediate medical attention.
cC
Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, if distilled water is not available, soft water
may be used.
If coolant comes into contact with
painted surfaces, immediately wash
them with water.
Do not mix different types of antifreeze.
8. Install:
8radiator cap
3-38
CHK
CHANGING THE COOLANT ADJ
<
&
9. Fill:
8coolant reservoir
(with the recommended coolant to the
maximum level mark 1 )
10.Install:
8coolant reservoir cap
11.Start the engine, warm it up for several minutes, and then stop it.
12.Check:
8coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
13.Install:
8radiator cover
Refer to”RADIATOR”in chapter 6.
8coolant reservoir cap cover
8side cover(right)
8front cover
Refer to”COVER AND PANEL”.
3-39
ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHK
ADJ
<
&
EAS00109
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
8 brake lever free play a
Out of specification -» Adjust.
Brake lever free play (at the end of
the brake lever)
10~20mm(0.39~0.79in)
2. Adjust:
8brake lever free play
• • • • • • • • • • • • • • • • • • • • • • •
a. Turn the adjusting nut 1 in direction a or
b until the specified brake lever free play
is obtained.
Direction a
Direction b
Brake lever free play is increased.
Brake lever free play is decreased.
cC
After adjusting the brake lever free play,
make sure there is no brake drag.
•••••••••••••••••••••••
EAS00114
ADJUSTING THE REAR BRAKE
1. Check:
8 brake lever free playa
Out of specification -» Adjust.
Brake lever free play
10~ 20mm(0.39~ 0.79in)
2. Adjust:
8brake lever free play
• • • • • • • • • • • • • • • • • • • • • • •
a. Turn the adjusting nut 1 in direction a or
b until the specified brake lever free play
is obtained.
Direction a
Direction b
Brake lever free play is increased.
Brake lever free play is decreased.
cC
After adjusting the brake lever free play,
make sure there is no brake drag.
•••••••••••••••••••••••
3-40
CHK
CHECKING THE FRONT AND REAR BRAKE SHOES ADJ
<
&
EAS00127
CHECKING THE FRONT AND REAR BRAKE
SHOES
1. Operate the brake.
2. Check:
• wear indicator (T)
Reaches the wear limit line (2) -» Replace
the brake shoes as a set.
Refer to “FRONT WHEEL AND BRAKE”
and “REAR WHEEL AND BRAKE” in
chapter 4.
A
B
3-41
Front brake
Rear brake
CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
<
&
EAS00148
CHECKING AND ADJUSTING THE STEERING HEAD
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness -» Adjust the steering
head.
3. Remove:
• front fork upper cover
• front fork cover(left, right)
• leg shield1,2
Refer to”LEG SHIELD1,2".
• headlight stay bracket
Refer to”HANDLE BRACKET AND
HEADLIGHT STAY BRACKET”in chapter 4.
4. Adjust:
8steering head
• • • • • • • • • • • • • • • • • • • • • • •
a. Loosen the steering nut 1 and then tighten
it to specification with the ring nut wrench.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
P*
Ring nut wrench
90890-01268
YU-01268
3-42
CHECKING AND ADJUSTING THE STEERING HEAD
b. Loosen the upper bearing inner race2 completely and then tighten it to specification
with a steering nut wrench3 .
Steering nut wrench
90890-01444
YM-A9409-7
^
w
Do not overtighten the upper bearing inner
race.
Upper bearing inner race(final tightening torque)
7Nm(0.7m • kg, 5.1ft • lb)
c. 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 bearing race .
Refer to “STEERING HEAD” in chapter 4.
d. Hold the upper bearing inner race with a
steering nut wrench and tighten the steering n u t 1 with a steering nut wrench2.
Steering nut wrench
90890-01403
YU-A9472
V
%
Steering nut
30Nm(3.0m • kg, 21.7ft • lb)
• • • • • • • • • • • • • • • • • • • • • • •
5. Install:
8headlight stay bracket
Refer to”HANDLE BRACKET AND
HEADLIGHT STAY BRACKET”in chapter 4.
8leg shield1,2
8front fork cover(left, right)
8front fork upper cover
Refer to”LEG SHIELD1,2".
3-43
CHK
CHECKING THE FRONT FORK ADJ
<
&
EAS00151
CHECKING THE FRONT FORK
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Check:
•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 4.
3-44
CHECKING THE TIRES
EAS00163
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• tire pressure
Out of specification -> Regulate.
rr\w«:»iwei
• 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.
Basic weight
(with oil
and a full
fuel tank)
90 kg (198 lb)
Maximum
load*
175 kg (386 lb)
Cold tire
pressure
Up to 55 kg
Front
Rear
175 kPa (1.75 175 kPa (1.75
kgf/cm2, 25 psi) kgf/cm2, 25 psi)
175 kPa (1.75 175 kPa (1.75
55 kg ~ 175 kg kgf/cm2, 25 psi) kgf/cm2, 25 psi)
* Total weight of rider, passenger, cargo and accessories
w
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-45
CHECKING THE TIRES
2. Check:
• tire surfaces
Damage/wear -» Replace the tire.
Minimum tire tread depth
0.8mm(0.03in)
1
2
3
Tire tread depth
Sidewall
Wear indicator
w
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.
A
B
Tire
Wheel
Tube wheel
Tubeless wheel
Tube tire only
Tube or tubeless tire
After extensive tests, the tires listed
below have been approved by Yamaha
Motor Taiwan Co., Ltd. for this model.
The front and rear tires should always
be by the same manufacturer and of
the same design. No guarantee concerning handling characteristics can
be given if a tire combination other
than one approved by Yamaha is used
on this scooter.
3-46
Front tire
Manufacturer
Model
CHENG SHIN C6022
Size
120/90-10 57J
Rear tire
Manufacturer
Model
CHENG SHIN C6022
Size
120/90-10 57J
CHK
CHECKING THE TIRES ADJ
w
<
&
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
NOTE:
For tires with a direction of rotation mark 1 :
8 Install the tire with the mark pointing in the
direction of wheel rotation.
8 Align the mark2 with the valve installation
point.
3-47
CHECKING THE WHEELS/
CHECKING AND LUBRICATING THE CABLES
CHK
ADJ
<
&
EAS00168
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
• wheel
Damage/out-of-round -»Replace.
FflWUzWIgM
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or replaced, always balance the wheel.
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the inner and outer cables.
FflWUzWIgM
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.
1. Check:
• outer cable
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.
3-48
LUBRICATING THE LEVERS AND PEDALS/
LUBRICATING THE CENTERSTAND
CHK
ADJ
<
&
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium-soap-based grease
EAS00173
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
Recommended lubricant
Lithium-soap-based grease
3-49
CHECKING AND CHARGING THE BATTERY
EAS00179
ELECTRICAL SYSTEM
BATTERY INSTRUCTION
This is a sealed lype 12 volt battery. No liquid level inspection is ever needed and no refilling water will be required.
CHECKING AND CHARGING THE BATTERY
IMPORTANT:
• Never interfere with the sealed state of the battery.
•Check the charging condition with a voltmeter (Normal charging voltage should be above 12.8V)
•This battery may be installed in an vehicle only If it replaces a similar sealed type battery.
=LAMMABLES
w
© ® A ® A
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
8 Wear protective eye gear when handling
or working near batteries.
8 Charge batteries in a well-ventilated
area.
8 Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
8 DO NOT SMOKE when charging or handling batteries.
8 KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
8 Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
eye injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
8 Skin — Wash with water.
8 Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
8 Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg or vegetable oil. Get immediate
medical attention.
SHIELD EVES
A
DANGER
• Do not use at the places near fire. Hydrogen gas generated from battery may cause fire and explosion.
•This 12V battery is only for starting engine. Do not apply for other uses.
• Keep out of the reach of children or the personnel who do not understand the manual. It may cause blindness or severe bum,
•When using the battery, wear safety glasses and rubber gloves. Sulfuric acid may cause blindness or severe bum,
cC
This is a sealed battery. Never remove
the sealing caps because the balance between cells will not be maintained and
battery performance will deteriorate.
Charging time, charging amperage and
charging voltage for an MF battery are
different from those of conventional batteries. The MF battery should be charged
as explained in the charging method illustrations. If the battery is overcharged,
the electrolyte level will drop considerably. Therefore, take special care when
charging the battery.
3-50
CHECKING AND CHARGING THE BATTERY
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery terminals.
1. Remove:
8battery cover
Refer to”SIDE COVERS AND TAIL/
BRAKE LIGHT”.
2. Disconnect:
8battery leads
(from the battery terminals)
cC
First, disconnect the negative battery lead
1 , and then the positive battery lead 2 .
3. Remove:
8battery
4. Check:
8battery charge
• • • • • • • • • • • • • • • • • • • • • • •
a. Connect a digital circuit tester to the battery
terminals.
Digital circuit tester
90890-03174
Positive tester probe -» positive battery terminal
Negative tester probe -» negative battery terminal
NOTE:
8 The charge state of an MF battery can be
checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected).
8 No charging is necessary when the opencircuit voltage equals or exceeds 12.8 V.
3-51
CHECKING AND CHARGING THE BATTERY
12.5
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
• • • • • • • • • • • • • • • • • • • • • • •
12.0
11.5 j -
5 6.5
10
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
14
13
< &
b. Check the charge of the battery, as shown
in the charts and the following example.
Relationship between the open-circuit voltage
and the charging time at 20 C
13.0
CHK
ADJ
Ambient
temperature
20 C
12
11
10
100
75
50
30 25 20
0
Charging condition of the battery (%)
5. Charge:
8battery
(refer to the appropriate charging method
illustration)
w
Do not quick charge a battery.
cC
Never remove the MF battery sealing
caps.
Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
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.
3-52
CHK
CHECKING AND CHARGING THE BATTERY ADJ
<
&
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!
As shown in the following illustration,
the open-circuit voltage of an MF battery
stabilizes about 30 minutes after charging has been completed. Therefore, wait
30 minutes after charging is completed
before measuring the open-circuit voltage.
3-53
CHECKING AND CHARGING THE BATTERY
Charging method using a variable-current (voltage) charger
Charger
Ammeter
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for more
than 30 minutes before measuring its
opencircuit voltage.
Set the charging voltage to 16-17 V.
(If the charging voltage is lower charging will be insufficient, if it is higher,
the battery will be over-charged.)
Set the timer to the charging
time determined by the
opencircuit voltage.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the amperage does not exceed the standard charging amperage after 5 minutes, replace
the battery.
If the required charging time exceeds 5 hours, it is advisable to check
the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring
its open-circuit voltage.
12.8 V ~ Charging is complete.
12.0 ~ 12.7 V ~ Recharging is required.
Under 12.0 V ~ Replace the battery.
3-54
CHECKING AND CHARGING THE BATTERY
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for more
than 30 minutes before measuring
its opencircuit voltage.
Connect a charger and ammeter to the battery and start
charging.
YES
Is the amperage higher than
the standard charging amperage written on the battery?
NO
i
This type of battery charger cannot
charge an MF battery. A
variablevoltage charger is recommended.
Charge the battery until the charging
voltage reaches 15 V.
NOTE:
Set the charging time to a maximum
of 20 hours.
i
Leave the battery unused for more
than 30 minutes before measuring its
open-circuit voltage.
12.8 V ~ Charging is complete.
12.0 ~ 12.7 V ~ Recharging is required.
Under 12.0 V ~ Replace the battery.
Charger
Ammeter
Voltmeter
NV
cC
Constant amperage chargers are not
suitable for charging MF batteries.
3-55
1
t
1
r
I
M
A
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSE
CHK
ADJ
<
&
6. Install:
8battery
7. Connect:
8battery leads
(to the battery terminals)
cC
First, connect the positive battery lead
1, and then the negative battery lead 2.
8 After installing the battery, be sure to
turn the main switch from “ON” to “OFF”
three times in 3 seconds intervals to initialize the idle speed control system.
8. Check:
8 battery terminals
Dirt -» Clean with a wire brush.
Loose connection -» Connect properly.
9. Lubricate:
8 battery terminals
Recommended lubricant
Dielectric grease
10.Install:
8battery cover
Refer to”SIDE COVERS AND TAIL/
BRAKE LIGHT”.
EAS00181
CHECKING THE FUSE
The following procedure applies to all of the fuse.
cC
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
8battery cover
Refer to”SIDE COVERS AND TAIL/
BRAKE LIGHT”.
3-56
CHECKING THE FUSE
2. Check:
8fuse
• • • • • • • • • • • • • • • • • • • • • • •
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “
^
× 1”.
Pocket tester
90890-03112(YU-03112-C)
b. If the pocket tester indicates “∞”, replace
the fuse.
• • • • • • • • • • • • • • • • • • • • • • •
3. Replace:
8blown fuse
• • • • • • • • • • • • • • • • • • • • • • •
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Fuse
Main
Amperage rating
15A
Q’ty
1
w
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage
rating may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
cC
After removing and installing the main fuse,
be sure to turn the main switch from “ON”
to “OFF” three times in 3 seconds intervals
to initialize the idle speed control system.
• • • • • • • • • • • • • • • • • • • • • • •
4. Install:
8battery cover
Refer to”SIDE COVERS AND TAIL/
BRAKE LIGHT”.
3-57
REPLACING THE HEADLIGHT BULB
EAS00182
REPLACING THE HEADLIGHT BULB
1. Remove:
8headlight unit
2. Disconnect:
8headlight lead coupler
3. Remove:
8dust b o o t 1
8headlight bulb holder2
8headlight bulb3
w
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
4. Install:
8headlight bulb New
Secure the new headlight bulb with the
headlight bulb holder.
cC
Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass, the
life of the bulb and the luminous flux will be
adversely affected. If the headlight bulb gets
soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
5. Install :
8headlight bulb holder
6. Install:
8dust boot
7. Connect:
8headlight lead coupler
8. Install:
8headlight unit
3-58
CHK
ADJUSTING THE HEADLIGHT BEAM ADJ
<
&
EAS00184
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
headlight beam (vertically)
• • • • • • • • • • • • • • • • • • • • • • •
a. Turn the adjusting screw 1 in direction a
or b .
Direction a
Direction b
Headlight beam is raised.
Headlight beam is lowered.
•••••••••••••••••••••••
2. Adjust:
headlight beam (horizontally)
• • • • • • • • • • • • • • • • • • • • • • •
a. Turn the adjusting screw2 in direction a
or b .
Direction a
Direction b
Headlight beam moves to the right.
Headlight beam moves to the left.
•••••••••••••••••••••••
3-59
CHAS (3^3^)
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE
FRONT WHEEL
FRONT BRAKE SHOE PLATE
REMOVING THE FRONT WHEEL
DISASSEMBLING THE BRAKE SHOE PLATE
CHECKING THE FRONT WHEEL
CHECKING THE SPEEDOMETER GEAR UNIT
CHECKING THE BRAKE
ASSEMBLING THE BRAKE SHOE PLATE
ASSEMBLING THE FRONT WHEEL
INSTALLING THE FRONT WHEEL
ADJUSTING THE FRONT WHEEL STATIC BALANCE
REAR WHEEL AND BRAKE
REMOVING THE REAR WHEEL
CHECKING THE REAR WHEEL
CHECKING THE REAR WHEEL DRIVE HUB
CHECKING THE BRAKE
ASSEMBLING THE BRAKE SHOE PLATE
INSTALLING THE REAR WHEEL
ADJUSTING THE REAR WHEEL STATIC BALANCE
FRONT FORK
REMOVING THE FRONT FORK LEGS
DISASSEMBLING THE FRONT FORK LEGS
CHECKING THE FRONT FORK LEGS
ASSEMBLING THE FRONT FORK LEGS
INSTALLING THE FRONT FORK LEGS
HANDLEBAR
REMOVING THE HANDLEBAR
CHECKING THE HANDLEBAR
INSTALLING THE HANDLEBAR
STEERING HEAD
HANDLEBAR BRACKET AND HEADLIGHT STAY BRACKET
LOWER BRACKET
REMOVING THE LOWER BRACKET
CHECKING THE STEERING HEAD
INSTALLING THE STEERING HEAD
4-1
4-2
4-3
4-4
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-13
4-14
4-14
4-15
4-15
4-16
4-18
4-18
4-19
4-21
4-21
4-23
4-24
4-26
4-27
4-29
4-29
4-30
4-32
4-32
4-33
4-34
4-35
4-36
CHAS (3^3^)
REAR SHOCK ABSORBER ASSEMBLY
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY
4-37
4-38
4-38
4-39
FRONT WHEEL AND BRAKE CHAS (3^3^)
EAS00517
CHASSIS
FRONT WHEEL AND BRAKE
Order
Job/Part
Removing the front wheel and brake
1
2
3
4
5
6
7
8
9
10
Stop ring
Speedometer cable
Brake adjuster
Front brake cable
Adjusting pin
Wheel axle nut
Wheel axle
Collar
Front brake shoe plate
Front wheel
Q’ty
1
1
1
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand so
that the front wheel is elevated.
Refer to”REMOVING THE FRONT
WHEEL and INSTALLING THE FRONT
WHEEL”.
For installation, reverse the removal procedure.
4-1
FRONT WHEEL AND BRAKE CHAS (3^3^)
EAS00518
FRONT WHEEL
Order
1
2
3
4
Job/Part
Q’ty
Disassembling the front wheel
Oil seal
Bearing
Spacer
Bearing
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-2
FRONT WHEEL AND BRAKE CHAS (3^3^)
FRONT BRAKE SHOE PLATE
Order
Job/Part
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
Disassembling the front brake shoe
plate
Brake shoe kit
Tension spring
Camshaft lever
Brake shoe wear indicator
Return spring
Brake camshaft/O-ring
Oil seal
Oil seal
Circlip
Plate washer
Speedometer clutch
Speedometer drive gear
Plate washer
Bushing
Oil seal
Speedometer driven gear
Plate washer
Q’ty
Remarks
Remove the parts in the order listed.
1
2
1
1
1
1/1
1
1
1
1
1
1
1
1
1
1
1
Refer to”DISASSEMBLING THE
BRAKE SHOE PLATE” and “ASSEMBLING THE BRAKE SHOE PLATE”.
For assembly, reverse the disassembly
procedure.
4-3
FRONT WHEEL AND BRAKE CHAS (3^3^)
EAS00520
REMOVING THE FRONT WHEEL
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
2. Remove:
8speedometer cable1
8front brake cable2
8front wheel axle n u t 3
8front wheel a x l e 4
8collar
8front wheel5
8front brake shoe plate6
EAS00524
DISASSEMBLING THE BRAKE SHOE PLATE
1. Remove:
8front brake shoe kit
8camshaft lever
8brake shoe wear indicator
8return spring
8brake camshaft
2. Remove:
8circlip
8plate washer
8speedometer clutch
8speedometer drive gear
8plate washer
3. Remove:
8bushing
(with the special tool)
8speedometer driven gear
8plate washer
Meter gear bush tool
90890-01052
NOTE:
Remove the bushing from the brake shoe plate
with the meter gear bush tool.
4-4
FRONT WHEEL AND BRAKE
EAS00525
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends -» Replace.
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 (T)
• lateral wheel runout @
Over the specified limits -» Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm(0.04 in)
4. Check:
• wheel bearings
Front wheel turns roughly or is loose -»
Replace the wheel bearings.
• oil seal
Damage/wear -» Replace.
5. Replace:
• wheel bearings New
• oil seal New
4-5
FRONT WHEEL AND BRAKE CHAS (3^3^)
•••••••••••••••••••••••
a. Clean the outside of the front wheel hub.
b. Remove the oil seal 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings 4 with a general bearing puller3.
d. Install the new wheel bearings and oil seal
in the reverse order of disassembly.
• • • • • • • • • • • • • • • • • • • • • • •
EAS00535
CHECKING THE SPEEDOMETER GEAR
UNIT
1. Check:
• speedometer clutch
Bends/damage/wear -» Replace.
2. Check:
• speedometer drive gear (T)
• speedometer driven gear®
Damage/wear -» Replace.
4-6
FRONT WHEEL AND BRAKE CHAS (3^3^)
EAS00536
(If
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.
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•—Q7\__
^
w
•B" '
••
12270603
2. Measure:
• brake shoe lining thickness a
Out of specification ^Replace.
Brake shoe lining thickness limit
(minimum)
2.0 mm (0.08 in)
w
Do not allow oil or grease to contact the
brake shoes.
NOTE:
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Measure:
• brake drum inside diameter b
Out of specification ^Replace the wheel.
Brake drum inside diameter limit
(maximum)
110.5 mm (4.35 in)
4-7
FRONT WHEEL AND BRAKE
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.
EAS00537
ASSEMBLING THE BRAKE SHOE PLATE
1. Lubricate:
8brake camshaft
Recommended lubricant
Lithium-soap-based grease
2. Install:
8brake camshaft 1
8spring
8brake shoe wear indicator 2
• • • • • • • • • • • • • • • • • • • • • • •
a. Install the brake camshaft so its punch mark
a is positioned as shown.
b. Align the projection b on the brake shoe
wear indicator with the notch in the brake
camshaft.
c. Check that the brake shoes are properly
positioned.
•••••••••••••••••••••••
4-8
FRONT WHEEL AND BRAKE CHAS (3^5^)
3. Install:
8 camshaft lever (T)
X I 8Nm(0.8m • kg, 5.8ft • lb)
•••••••••••••••••••••••
a. Align the camshaft punch mark a and camshaft lever punch mark b is positioned as
shown.
• • • • • • • • • • • • • • • • • • • • • • •
4. Install:
8 plate washer
8 speedometer driven gear
8 bushing
(with the special tool)
Meter gear bush tool
90890-01052
EAS00538
y
V \
) k V~
__JHQ)g
k P
ASSEMBLING THE FRONT WHEEL
1. Install:
*JiL
DBH1
8wheel bearing(right)1 New
8spacer
8wheel bearing(left) New
8oil seal New
• • • • • • • • • • • • • • • • • • • • • • •
a. Install the new wheel bearings and oil seal
in the reverse order of disassembly.
cC
Do not contact the wheel bearing inner race
1 or balls 2 . Contact should be made only
with the outer race 3 .
NOTE:
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
•••••••••••••••••••••••
2. Install:
8brake shoe plate
Align the tab on the speedometer clutch
with the slot in the wheel hub.
4-9
FRONT WHEEL AND BRAKE CHAS (3^3^)
EAS00540
INSTALLING THE FRONT WHEEL
1. Lubricate:
8wheel axle
8wheel bearings
8oil seal lips
8speedometer drive gear
8speedometer driven gear
Recommended lubricant
Lithium-soap-based grease
2. Install:
8front wheel1
NOTE:
Make sure the slot® in the brake shoe plate fits
over the stopper® on the outer tube.
3. Tighten:
8 wheel axle nut
X I 48 Nm (4.8 m * kg, 34.7 ft * lb)
Make sure the brake cable is routed properly.
cC
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
4-10
FRONT WHEEL AND BRAKE
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
8 After replacing the tire, wheel or both, the
front wheel static balance should be adjusted.
8 Adjust the front wheel static balance with
the brake disc installed.
1 . Remove:
8balancing weight(s)
2. Find:
8front 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 (d) through (f) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest
is the front wheel’s heavy spot “X”.
• • • • • • • • • • • • • • • • • • • • • • •
4-11
FRONT WHEEL AND BRAKE
CHAS (3^%
3. Adjust:
8front wheel static balance
• • • • • • • • • • • • • • • • • • • • • • •
a. Install a balancing weight 1 onto the rim
exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
• • • • • • • • • • • • • • • • • • • • • • •
4. Check:
8front wheel static balance
• • • • • • • • • • • • • • • • • • • • • • •
a. Turn the front wheel and make sure it stays
at each position shown.
b. If the front wheel does not remain stationary at all of the positions, rebalance it.
•••••••••••••••••••••••
4-12
REAR WHEEL AND BRAKE CHAS (3^3^)
EAS00555
REAR WHEEL AND BRAKE
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Remarks
Q’ty
Removing the rear wheel and brake
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand so
that the front wheel is elevated.
Muffler
Refer to”ENGINE REMOVAL”in chapter
5.
Self lock nut/Plate washer
Brake adjuster
Spring
Rear brake cable
Adjusting pin
Rear wheel
Brake shoe kit
Tension spring
Plate washer
Camshaft lever
Indicator plate
Brake camshaft/O-ring
1/1
1
1
1
1
1
1
2
1
1
1
1/2
Disconnect.
For installation, reverse the removal procedure.
4-13
REAR WHEEL AND BRAKE CHAS (3^3^)
EAS00564
REMOVING THE REAR WHEEL
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the rear wheel is elevated.
2. Remove:
8muffler
Refer to”ENGINE REMOVAL”in chapter
5.
3. Loosen:
8brake adjuster
4. Remove:
8wheel axle nut 1
8plate washer
8rear wheel2
EAS00565
CHECKING THE REAR WHEEL
1. Check:
•tire
• rear wheel
Damage/wear -» Replace.
Refer to”CHECKING THE TIRES ”and”
CHECKING THE WHEELS” in chapter 3.
2. Measure:
• radial wheel runout
•lateral wheel runout
Refer to”CHECKING THE FRONT
WHEEL”.
4-14
REAR WHEEL AND BRAKE CHAS (3^3^)
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• rear wheel drive hub
Cracks/damage -» Replace.
EAS00569
(If
^v-
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.
/)>
~~~G77\-__
3^
12270603
NOTE:
After sanding the glazed areas, clean the brake
shoe with a cloth.
2. Measure:
• brake shoe lining thickness a
Out of specification -» Replace.
Brake shoe lining thickness limit
(minimum)
2.0 mm(0.08 in)
w
Do not allow oil or grease to contact the
brake shoes.
NOTE:
Replace the brake shoes as a set, if either is
worn to the wear limit.
4-15
REAR WHEEL AND BRAKE CHAS (3^3^)
3. Measure:
• brake drum inside diameter b
Out of specification -» Replace the wheel.
Brake drum inside diameter limit
(maximum)
110.5 mm(4.35 in)
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.
EAS00570
ASSEMBLING THE BRAKE SHOE PLATE
1. Install:
8brake camshaft 1
8o-rings New
8brake shoe wear indicator 2
NOTE:
Lubricate the brake camshaft and o-rings with
lithium-soap-based grease.
w
After installing the brake camshaft and orings, remove any excess grease.
•••••••••••••••••••••••
a. Install the brake camshaft 1 so its punch
mark a is positioned as shown.
b. Align the projection b on the brake shoe
wear indicator with the notch in the brake
shoe camshaft.
c. Check that the brake shoes are properly
positioned.
•••••••••••••••••••••••
2. Tighten:
8brake camshaft bolt
10Nm(1.0m * kg, 7.2ft * lb)
4-16
REAR WHEEL AND BRAKE CHAS (3^3^)
3. Install:
8brake shoe k i t 1
8tension springs
cC
Do not put lubricating oil on the brake
lining.
Change the tension spring at the same
time of changing the brake shoe.
Refer to the direction in the illustration
when assembling the brake shoe and
spring.
Refer to the illustration with regards to
the assembly direction of tension spring,
and do not let the spring hook and coil
to be damaged by the pliers.
4-17
REAR WHEEL AND BRAKE CHAS (3^3^)
EAS00574
INSTALLING THE REAR WHEEL
1. Lubricate:
8wheel axle
Recommended lubricant
Lithium-soap-based grease
2. Install:
• rear wheel
3. Tighten:
• plate washer
• wheel axle nut©
X I 120Nm(12.0m * kg, 86.8ft* lb)
4. Install:
• muffler
Refer to”ENGINE REMOVAL”in chapter
5.
5. Adjust:
• brake lever free play
Refer to”ADJUSTING THE REAR
BRAKE” in chapter 3.
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
8 After replacing the tire, wheel or both, the
rear wheel static balance should be adjusted.
8 Adjust the rear wheel static balance with
the rear wheel drive hub installed.
1. Adjust:
8rear wheel static balance
Refer to “ADJUSTING THE FRONT
WHEEL STATIC BALANCE”.
4-18
FRONT FORK CHAS (3^3^)
EAS00646
FRONT FORK
S& 45Nm(4.5m • kg, 32.5 ft • lb)
gR 30Nm(3.0m • kg, 21.7 ft • lb)
Order
1
2
3
4
5
Job/Part
Q’ty
Removing the front fork legs
Front fork upper cover
Reflector
Front fork cover(left and right)
Front wheel
Cable guide
Cap bolt
O-ring
Lower bracket pinch bolt
Front fork leg
Remarks
Remove the parts in the order listed.
Refer to”LEG SHIELD1,2 “ in chapter 3.
Refer to”FRONT WHEEL AND BRAKE”.
1
1
1
1
1
Refer to”REMOVING THE FRONT
FORK LEGS” and “INSTALLING THE
FRONT FORK LEGS”
For installation, reverse the removal procedure.
4-19
FRONT FORK C H A S (3^3^)
EAS00648
(D
3R 23Nm(2.3m • kg, 16.6 ft < lb)
Order
1
2
3
4
5
6
7
8
9
Job/Part
Q’ty
Disassembling the front fork legs
Fork oil
Fork spring
Damper rod bolt/Copper washer
Damper rod
Rebound spring
Inner tube
Dust seal
Oil seal clip
Oil seal
Outer tube
Remarks
Remove the parts in the order listed.
Drain.
1
1/1
1
1
1
1
1
1
1
Refer to”DISASSEMBLING THE
FRONT FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”
For assembly, reverse the disassembly
procedure.
4-20
FRONT FORK CHAS (3^3^)
EAS00651
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
2. Remove:
8front fork upper cover
8front fork cover (left and right)
Refer to “LEG SHIELD1,2”in chapter 3.
8front wheel
Refer to “FRONT WHEEL AND BRAKE”.
3. Loosen:
8lower bracket pinch bolt 1
4. Remove:
8cap bolt 2
(with a 10 -mm hexagonal wrench3)
w
Before loosening the lower bracket pinch
bolt, support the front fork leg.
5. Remove:
8front fork leg
EAS00653
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
8fork spring1
4-21
FRONT FORK
2. Drain:
8fork oil
3. Remove:
8damper rod assembly b o l t 1
NOTE:
While holding the damper rod with the damper
rod holder 2 and T-handle3, loosen the damper
rod assembly bolt.
/
•
Damper rod holder
90890-01294(YM-01300-1)
T-handle
90890-01326(YM-01326)
4. Remove:
8damper r o d 1
8spring
8inner t u b e 2
5. Remove:
8dust seal
8oil seal clip 1
(with a flat-head screwdriver)
cC
Do not scratch the inner tube.
4-22
FRONT FORK CHAS (3^%
6. Remove:
8oil s e a l 1
cC
Never reuse the oil seal.
8Rag2
EAS00656
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
8 inner tube®
8 outer tube (2)
Bends/damage/scratches -* Replace.
w
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
8 spring free length a
Out of specification -* Replace.
Spring free length
202.2mm(7.96in)
<Limit> :198.2mm(7.80in)
3. Check:
8 damper r o d ®
Damage/wear -* Replace.
Obstruction -* Blow out all of the oil passages with compressed air.
4-23
FRONT FORK
EAS00658
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
NOTE:
8 When assembling the front fork leg, be sure
to replace the following parts:
- oil seal
- dust seal
8 Before assembling the front fork leg, make
sure all of the components are clean.
y
1. Install:
8damper rod assembly1
8rebound spring 2
® <?
\J$^
(gfm;^ ®
cC
Allow the damper rod assembly to slide
slowly down the inner t u b e 3 until it
protrudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
\ ^
2. Lubricate:
8inner tube’s outer surface
Recommended lubricant
Fork oil 10W or equivalent
3. Tighten:
8 Copper washer New
8 damper rod assembly bolt (T)
X I 23 Nm (2.3 m * kg, 16.6 ft * lb)
NOTE:
While holding the damper rod assembly with the
damper rod holder 2 and T-handle 3 , tighten
the damper rod assembly bolt.
Damper rod holder
90890-01294(YM-01300-1)
T-handle
90890-01326(YM-01326)
4-24
FRONT FORK CHAS (3^3^)
4. Install:
8oil seal 1New
(with the fork seal driver weight 2 and
adapter 3 )
^
Fork seal driver weight
90890-01367(YM-A9409-7)
Adapter
90890-01400(YM-A9409-3 )
cC
Make sure the numbered side of the oil seal
faces up.
NOTE:
8 Before installing the oil seal, lubricate its lips
with lithium soap base grease.
8 Lubricate the outer surface of the inner tube
with fork oil.
8 Before installing the oil seal, cover the top
of the front fork leg with a plastic bag 4 to
protect the oil seal during installation.
5. Install:
8oil seal c l i p 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
6. Fill:
8front fork leg
(with the specified amount of the recommended fork oil)
*®
V
Quantity (each front fork leg)
0.042 L (0.038 Imp qt, 0.046 US qt)
Recommended oil
Fork oil 10W or equivalent
•
4-25
FRONT FORK CHAS (3^3^)
NOTE:
8 While filling the front fork leg, keep it upright.
8 After filling, slowly pump the front fork leg
up and down to distribute the fork oil.
7. Install:
8fork spring 1
NOTE:
8 Install the spring with the smaller pitch facing down .
EAS00663
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
• front fork leg
• o-ring New
• cap bolt
NOTE:
Pull up the inner tube until it stops, then install
the cap bolt .
2. Tighten:
•cap bolt (T)
X | 45 Nm (4.5 m * kg, 32.5 ft * lb)
• lower bracket pinch bolt (2)
X | 30Nm(3.0m * kg, 21.7ft * lb)
4-26
HANDLEBAR CHAS (3^3^)
EAS00664
HANDLEBAR
-10^
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Part
Remarks
Q’ty
Removing the handlebar
Front fork upper cover
Front fork cover(left and right)
Leg shield1,2
Rear view mirror(left and right)
Band
Front brake cable
Brake lever(right)
Front brake switch
Front turn signal light(right)
Front turn signal light bracket(right)
Handlebar switch(right)
Throttle cable
Throttle grip assembly
Rear brake cable
Brake lever(left)
Rear brake switch
Remove the parts in the order listed.
Refer to”LEG SHIELD1,2"in chapter 3.
1/1
2
1
1
1
1
1
1
2
1
1
1
1
4-27
Disconnect.
Disconnect.
Disconnect.
HANDLEBAR CHAS (3^3^)
-10^
Order
14
15
16
17
18
19
20
Job/Part
Front turn signal light(left)
Front turn signal light bracket(left)
Handlebar switch(left)
Handlebar grip
Cap
Handlebar upper holder
Handlebar assembly
Q’ty
1
1
1
1
2
2
1
Remarks
For installation, reverse the removal procedure.
4-28
HANDLEBAR CHAS (3^3^)
EAS00666
REMOVING THE HANDLEBAR
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Remove:
8handlebar switch(right)1
8throttle grip assembly2
NOTE:
While removing the handlebar holder assembly
(right), pull back the rubber cover.
3. Remove:
8handlebar switch(left)
8handlebar grip 1
8handlebar upper holder
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.
Do not attempt to straighten a bent
handlebar as this may dangerously weaken
it.
4-29
HANDLEBAR
EAS00673
INSTALLING THE HANDLEBAR
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Install:
8 handlebar©
8 handlebar upper holders (2)
X I 28Nm(2.8m * kg, 20.3ft * lb)
C
First, tighten the bolts on the front side of
the handlebar holders, and then on the rear
side.
NOTE:
8 The upper handlebar holders should be installed with the arrow marks a facing forward A
8 Align the match marks b on the handlebar
with the upper surface of the handlebar
lower holder.
3. Install:
8 handlebar grip
NOTE:
Before installing the handlebar grip, apply the
bond.
4. Install:
8 left handlebar switch 1
NOTE:
Align the projection a on the left handlebar
switch with the hole b on the handlebar.
4-30
HANDLEBAR
5. Install:
8 throttle grip assembly1
8 right handlebar switch2
8 throttle cables 3
NOTE:
8 Align the projectiona on the right handlebar
switch with the hole b on the handlebar.
8 Lubricate the inside of the throttle grip with a
thin coat of lithium-soap-based grease and
install it onto the handlebar4.
w
Make sure the throttle grip operates
smoothly.
6. Adjust:
8 throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the flange
of the throttle grip)
1.5~3.5mm(0.06~0.14in)
4-31
STEERING HEAD CHAS (3^3^)
EAS00675
STEERING HEAD
HANDLEBAR BRACKET AND HEADLIGHT STAY BRACKET
®~.
S^>48Nm(4.8m • kg, 34.7 ft • lb)
S^60Nm(6.0m • kg, 43.4 ft • lb)
P^23Nm(2.3m kg, 16.6 ft lb)
al4Nm(0.4m • kg, 2.9 ft • lb)
Order
Job/Part
1
2
3
4
5
6
7
8
9
10
11
Removing the handlebar bracket and
headlight stay bracket
Front fork upper cover
Front fork cover(left and right)
Leg shield1,2
Handlebar assembly
Speedometer cable
Speedometer
Headlight unit/Headlight body
Main switch
Horn
Rectifier/regulator
Turn signal relay
Starting circuit cut-off relay
Headlight stay bracket
Handlebar lower holder
Handlebar bracket
Remarks
Q’ty
Remove the parts in the order listed.
Refer to”LEG SHIELD1,2"in chapter 3.
Refer to”HANDLEBAR”.
1
1
1/1
1
1
1
1
1
1
1
1
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
4-32
LOWER BRACKET
LOWER BRACKET
r V 30Nm(3.0m • kg, 21.7 ft • lb)f
Order
1
2
3
4
5
6
7
8
9
Job/Part
Q’ty
Removing the lower bracket
Front fork upper cover
Front fork cover(left and right)
Leg shield1,2
Front wheel
Front fork legs
Handlebar assembly
Headlight stay bracket
Handlebar bracket
Front fender
Ring nut
Upper bearing inner race
Upper bearing
Lower bracket
Lower bearing
Upper bearing outer race
Lower bearing outer race
Lower bearing inner race
Remarks
Remove the parts in the order listed.
Refer to”LEG SHIELD1,2"in chapter 3.
Refer to”FRONT WHEEL AND BRAKE”.
Refer to”FRONT FORK”
Refer to”HANDLEBAR”.
Refer to”HANDLEBAR BRACKET AND
HEADLIGHT STAY BRACKET”
1
1
1
1
1
1
1
1
1
Refer to”REMOVING THE LOWER
BRACKET” and “INSTALLING THE
STEERING HEAD”.
For installation, reverse the removal procedure.
4-33
STEERING HEAD CHAS (3^3^)
EAS00678
REMOVING THE LOWER BRACKET
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2 . Remove:
8handlebar bracket1
NOTE:
Remove the handlebar bracket by loosening the
ring n u t 2 gradually.
3. Remove:
8ring nut 1
(with the ring nut wrench 2 )
Ring nut wrench
90890-01268
YU-01268
4 . Remove:
8upper bearing inner r a c e 1
(with the steering nut wrench2)
Steering nut wrench
90890-01444
YM-A9409-7
w
Securely support the lower bracket3 so that
there is no danger of it falling.
4-34
STEERING HEAD CHAS (3^3^)
EAS00682
CHECKING THE STEERING HEAD
1. Wash:
8bearing balls
8bearing races
Recommended cleaning solvent
Kerosene
2. Check:
8bearing balls (T)
8bearing races (2)
Damage/pitting -» Replace.
3. Replace:
8bearing balls
8bearing races
• • • • • • • • • • • • • • • • • • • • • • •
a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer.
b. Remove the bearing race from the front fork
assembly with a floor chisel 2 and hammer.
c. Install a new bearing races.
cC
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the balls and bearing races as
a set.
• • • • • • • • • • • • • • • • • • • • • • •
4. Check:
8lower bracket
(along with the steering stem)
Bends/cracks/damage -» Replace.
4-35
STEERING HEAD CHAS (3^3^)
EAS00684
INSTALLING THE STEERING HEAD
1. Lubricate:
8bearing balls 1
8bearing races
Recommended lubricant
Lithium-soap-based grease
2. Install:
8lower bracket 1
8upper bearing inner r a c e 2
(with the steering nut wrench3)
Upper bearing inner race
7Nm(0.7m • kg, 5.1ft • lb)
f*
Steering nut wrench
90890-01444
YM-A9409-7
3. Install:
8ring nut 1
(with the steering nut wrench2)
V
%
Ring nut
30Nm(3.0m • kg, 21.7ft • lb)
Steering nut wrench
90890-01403
YU-A9472
4. Install:
8handlebar bracket1
NOTE:
Align the handlebar bracket across rod a on
the lower bracket concave b .
5. Tighten:
• handlebar bracket nut
\ | 60Nm(6.0m * kg, 43.4ft * lb)
4-36
REAR SHOCK ABSORBER ASSEMBLY CHAS (3^3^)
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Removing the rear shock absorber
assembly
Remove the parts in the order listed.
Front cover
Side cover(left)
Rear shock absorber assembly upper
nut
Rear shock absorber assembly upper
bolt
Rear shock absorber assembly lower
bolt
Rear shock absorber assembly
Refer to”SIDE COVERS AND TAIL/
BRAKE LIGHT”in chapter 3.
1
1
1
1
For installation, reverse the removal procedure.
4-37
REAR SHOCK ABSORBER ASSEMBLY
EAS00692
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the rear wheel is elevated.
2. Remove:
8front cover
8side cover(left)
Refer to”SIDE COVERS AND TAIL/
BRAKE LIGHT”in chapter 3.
3. Remove:
8rear shock absorber nut(upper)
8rear shock absorber bolt(upper)
8rear shock absorber bolt(lower)
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• rear shock absorber rod
Bend/damage -» Replace the rear shock
absorber assembly.
• rear shock absorber
Oil leak -» Replace the rear shock absorber assembly.
•spring
Damage/wear -» Replace the rear shock
absorber assembly.
•bushing
Damage/wear -» Replace.
•dust seal
Damage/wear -» Replace.
•bolts
Bends/damage/wear -» Replace.
4-38
REAR SHOCK ABSORBER ASSEMBLY CHAS (3^3^)
EAS00698
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY
1. Install:
• rear shock absorber assembly
2. Tighten:
• rear shock absorber assembly upper nut
X | 30Nm(3.0m * kg, 21.7ft * lb)
• rear shock absorber assembly lower bolt
X | 16Nm(1.6m * kg, 11.6ft * lb)
3. Install:
• side cover(left)
• front cover
Refer to”SIDE COVERS AND TAIL/
BRAKE LIGHT”in chapter 3.
4-39
ENG
m
%
CHAPTER 5
ENGINE
ENGINE REMOVAL
5-1
LEADS, HOSES AND MUFFLER
5-1
ENGINE
5-3
INSTALLING THE ENGINE
5-4
CYLINDER HEAD
5-5
REMOVING THE CYLINDER HEAD
5-7
CHECKING THE CYLINDER HEAD
5-9
INSTALLING THE CYLINDER HEAD
5-10
THE ROCKER ARMS AND CAMSHAFT
5-13
REMOVING THE ROCKER ARMS AND CAMSHAFT
5-14
CHECKING THE CAMSHAFT
5-15
CHECKING THE ROCKER ARMS AND ROCKER ARM
SHAFTS
5-16
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET, AND
TIMING CHAIN GUIDES
5-17
CHECKING THE TIMING CHAIN TENSIONER
5-18
INSTALLING THE CAMSHAFT AND ROCKER ARMS
5-19
VALVES AND VALVE SPRINGS
5-20
REMOVING THE VALVES
5-22
CHECKING THE VALVES AND VALVE GUIDES
5-24
CHECKING THE VALVE SEATS
5-26
CHECKING THE VALVE SPRINGS
5-28
INSTALLING THE VALVES
5-29
CYLINDER AND PISTON
5-31
REMOVING THE CYLINDER AND PISTON
5-32
CHECKING THE CYLINDER AND PISTON
5-33
CHECKING THE PISTON RINGS
5-35
CHECKING THE PISTON PIN
5-36
CHECKING THE TIMING CHAIN GUIDE
5-37
INSTALLING THE PISTON AND CYLINDER
5-37
BELT DRIVE
5-39
V-BELT CASE COVER
5-39
KICKSTARTER
5-40
INSTALLING THE KICKSTARTER
5-41
V-BELT AND PRIMARY/SECONDARY SHEAVE
5-42
SECONDARY SHEAVE
5-43
REMOVING THE PRIMARY SHEAVE
5-44
ENG
m
%
REMOVING THE SECONDARY SHEAVE AND V-BELT
5-44
DISASSEMBLING THE SECONDARY SHEAVE
5-45
CHECKING THE CLUTCH SHOES
5-45
CHECKING THE V-BELT
5-46
CHECKING THE PRIMARY SHEAVE
5-46
CHECKING THE PRIMARY SHEAVE WEIGHTS
5-47
CHECKING THE SLIDER
5-47
CHECKING THE SECONDARY SHEAVE
5-47
ASSEMBLING THE PRIMARY SHEAVE
5-48
ASSEMBLING THE SECONDARY SHEAVE
5-49
INSTALLING THE SECONDARY SHEAVE, V-BELT AND PRIMARY
SHEAVE
5-50
STARTER CLUTCH AND AC MAGNETO
5-53
STATOR COIL ASSEMBLY
5-53
STARTER CLUTCH
5-55
REMOVING THE AC MAGNETO
5-56
REMOVING THE STARTER CLUTCH
5-57
CHECKING THE STARTER CLUTCH
5-58
INSTALLING THE STARTER CLUTCH
5-59
INSTALLING THE AC MAGNETO
5-59
OIL PUMP
5-61
CHECKING THE OIL PUMP
5-62
ASSEMBLING THE OIL PUMP
5-63
INSTALLING THE OIL PUMP
5-63
TRANSMISSION
5-64
CHECKING THE TRANSMISSION
5-65
CRANKSHAFT
5-66
CRANKSHAFT ASSEMBLY
5-66
DISASSEMBLING THE CRANKCASE
5-68
REMOVING THE CRANKSHAFT ASSEMBLY
5-69
CHECKING THE CRANKSHAFT AND CONNECTING ROD
5-69
CHECKING THE CRANKCASE
5-70
CHECKING THE TIMING CHAIN AND TIMING CHAIN
GUIDE(INTAKE SIDE)
5-71
CHECKING THE BEARINGS AND OIL SEALS
5-71
CHECKING THE CIRCLIPS AND WASHERS
5-71
INSTALLING THE CRANKSHAFT
5-72
ASSEMBLING THE CRANKCASE
5-72
ENGINE REMOVAL
ENG
%m
EAS00188
ENGINE
ENGINE REMOVAL
LEADS, HOSES AND MUFFLER
r V 10Nm(1.0m • kg, 7.2 ft* lb)
r V 10Nm(1.0m • kg, 7.2 ft* lb)
Order
Job/Part
Q’ty
Removing the leads, hoses and muffler
Front cover/Single seat/Trunk
Battery cover/Battery
Side cover(left and right)
Footrest board
Coolant
Remove the parts in the order listed.
Refer to”COVER AND PANEL”in chapter 3.
Rear brake cable/Adjuster/Pin
Throttle body and fuel injector
Starter motor
1
2
Conduit hose
Coolant temperature sensor coupler
1
1
5-1
Remarks
Drain.
Refer to”CHANGING THE COOLANT”in
chapter 3.
Refer to”REAR WHEEL AND BRAKE”in
chapter 4.
Refer to”THROTTLE BODY AND FUEL
INJECTOR”in chapter 7.
Refer to”STARTER MOTOR”in chapter
8.
Disconnect.
Disconnect.
ENGINE REMOVAL
ENG
%m
r^10Nm(1.0m • kg, 7.2 ft* lb)
1 * 10Nm(1.0m • kg, 7.2 ft • lb)
Order
Job/Part
3
Crankshaft position sensor/Stator assembly coupler
Ignition primary coil coupler
Air filter assembly/Breather hose
Bracket
Muffler
Gasket
4
5
6
7
8
Q’ty
1/1
1
1/1
1
1
1
Remarks
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
5-2
ENGINE REMOVAL
ENG
%m
EAS00191
ENGINE
Order
Job/Part
Q’ty
Removing the engine
Remarks
Remove the parts in the order listed.
Place a suitable stand under the frame
and engine.
1
2
3
4
5
Rear shock absorber assembly lower
bolt
Engine mounting nut
Engine mounting bolt
Engine
Rear fender
1
1
1
1
1
Refer to”INSTALLING THE ENGINE”.
For installation, reverse the removal procedure.
5-3
ENGINE REMOVAL
ENG
m
%
EAS00192
INSTALLING THE ENGINE
1. Install:
8engine1
8engine mounting b o l t 2
8engine mounting n u t 3
NOTE:
8 Apply lithium-soap-based grease to the
unthreaded portion of the engine mounting
bolt shaft.
8 Do not fully tighten the engine mounting
bolt..
2. Install:
• rear shock absorber assembly lower
bolt®
NOTE:
Do not fully tighten the bolt.
3. Tighten:
• engine mounting bolt
X I 58Nm(5.8m * kg, 42.0ft * lb)
• rear shock absorber assembly lower bolt
\ | 16Nm(1.6m * kg, 11.6ft * lb)
5-4
CYLINDER HEAD
ENG
%m
EAS00221
CYLINDER HEAD
P^9Nm(0.9m • kg, 6.5 ft • lb)
P|^j8Nm(0.8m • kg, 5.8 ft • lb)
n^10Nm(1.0m« kg, 7.2 ft* lb)
I
4. i ^ \
[ \ 30Nm(3.0m • kg, 21.7 ft • lb)
«13Nm(1.3m • kg, 9.4 ft • lb)
Order
7
Job/Part
Q’ty
Removing the cylinder head
Radiator
Thermostat
1
2
3
4
5
6
7
8
9
Remarks
Remove the parts in the order listed.
Refer to”COOLING SYSTEM”in chapter
6.
Water pump
Muffler/Bracket
Intake manifold/O-ring
Joint/O-ring
Spark plug cap
Ignition coil
Spark plug
Coolant temperature sensor
Cylinder head cover
O-ring
Timing chain tensioner
Refer to”ENGINE REMOVAL”.
1/1
1/1
1
1
1
1
1
1
1
5-5
CYLINDER HEAD
ENG
m
%
P^9Nm(0.9m • kg, 6.5 ft • lb)
«13Nm(1.3m • kg, 9.4 ft • lb)
Order
10
11
12
13
14
15
16
17
Job/Part
Q’ty
1
1
2
4
1
1
1
2
Timing chain tensioner gasket
Camshaft sprocket
Bolt
Nut
Plate
Cylinder head
Cylinder head gasket
Dowel pin
Remarks
Refer to”REMOVING THE CYLINDER
HEAD” and “INSTALLING THE CYLINDER HEAD”.
For installation, reverse the removal procedure.
5-6
CYLINDER HEAD
ENG
%m
EAS00225
REMOVING THE CYLINDER HEAD
1. Remove :
8V-belt case cover
8Refer to “BELT DRIVE”.
8cylinder head cover
2. Align:
8“I” mark a on the AC magneto rotor
(with the stationary pointer b on the
crankcase cover)
• • • • • • • • • • • • • • • • • • • • • • •
a. Turn the primary fixed sheave counterclockwise.
b. When the piston is at TDC on the compression stroke, align the “I” mark c on the camshaft sprocket with the mark d on the plate.
•••••••••••••••••••••••
3. Loosen:
8timing chain tensioner cap bolt
8camshaft sprocket bolt 1
While holding the crank bolt with a
wrench2, remove the camshaft sprocket
bolt.
f,
5-7
Rotor holding tool
90890-01235
YU-01235
CYLINDER HEAD
ENG
%m
4. Remove:
8timing chain tensioner
(along with the gasket)
8camshaft sprocket 1
8timing chain 2
NOTE:
8 To prevent the timing chain from falling into
the crankcase, fasten it with a wire.
5. Remove:
8cylinder head
NOTE:
8 Loosen the nuts in the proper sequence as
shown.
8 Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove
them.
5-8
CYLINDER HEAD
ENG
%m
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:
8combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• spark plug bore thread
• valve seats
2. Check:
• cylinder head
Damage/scratches -» Replace.
3. Measure:
• cylinder head warpage
Out of specification -» Resurface the cylinder head.
Maximum cylinder head warpage
0.05 mm (0.0020 in)
•••••••••••••••••••••••
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
•••••••••••••••••••••••
5-9
CYLINDER HEAD
ENG
%m
EAS00231
INSTALLING THE CYLINDER HEAD
1. Install:
• gasket New
• dowel pins
2. Install:
• cylinder head
3. Tighten:
• cylinder head nuts
X | 10 Nm (1.0 m * kg, 7.2 ft * lb)
• cylinder head bolts
X | 10 Nm (1.0 m * kg, 7.2 ft * lb)
NOTE:
• Lubricate the cylinder head nuts with engine oil.
• Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages
• cylinder head tightening sequence
(1 -»2-»3-4-»2-»5-»6)
4. Install:
8camshaft sprocket
8timing chain
• • • • • • • • • • • • • • • • • • • • • • •
a. Turn the primary pulley counterclockwise.
b. Align the “I” mark a on the AC magneto
rotor with the stationary pointer b on the
crankcase cover.
c. Align the “I” mark c on the camshaft
sprocket with the stationary pointer d on
the plate.
d. Install the timing chain onto the camshaft
sprocket, and then install the camshaft
sprocket onto the camshaft.
NOTE:
8 When installing the camshaft sprocket, be
sure to keep the timing chain as tight as
possible on the exhaust side.
8 Align the slot on the camshaft with the tab
5-10
CYLINDER HEAD
ENG
%m
cC
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
e. While holding the camshaft, temporarily
tighten the camshaft sprocket bolt.
f. Remove the wire from the timing chain.
•••••••••••••••••••••••
5. Install
8camshaft sprocket bolt 1
6. Install:
8timing chain tensioner gasket New
8timing chain tensioner
• • • • • • • • • • • • • • • • • • • • • • •
a. Remove the cap bolt 1 and spring 2 .
b. Release the timing chain tensioner one-way
cam 3 and push the timing chain tensioner
rod 4 all the way into the timing chain
tensioner housing.
c. Install the timing chain tensioner and gasket 5 onto the cylinder.
V
%
Timing chain tensioner bolt
9 Nm (0.9 m • kg, 6.5 ft • lb)
d. Install the springs 2 and cap bolt 1 .
Cap bolt
8 Nm (0.8 m • kg, 5.8 ft • lb)
•••••••••••••••••••••••
5-11
CYLINDER HEAD
ENG
m
%
7. Turn:
8crankshaft
(several turns counterclockwise)
8. Check:
8“I” mark a
Align the “I” mark on the AC magneto rotor with the stationary pointer b on the
crankcase cover.
8“I” mark c
Align the “I” mark on the camshaft
sprocket with the stationary pointer d on
the plate.
Out of alignment -» Correct.
Refer to the installation steps above.
9. Tighten:
8camshaft sprocket bolt
X I 30 Nm (3.0 m * kg, 21.7 ft * lb)
C
Be sure to tighten the camshaft sprocket
bolt to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
10. Measure:
8valve clearance
Out of specification -» Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
5-12
THE ROCKER ARMS AND CAMSHAFT
ENG
m
%
THE ROCKER ARMS AND CAMSHAFT
Order
Job/Part
1
2
3
4
5
6
Removing the rocker arms and camshaft
Cylinder head
Camshaft
Rocker arm shaft(intake)
Rocker arm shaft(exhaust)
Rocker arm(intake)
Rocker arm(exhaust)
Collar
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
1
1
1
1
1
2
For installation, reverse the removal procedure.
5-13
THE ROCKER ARMS AND CAMSHAFT
ENG
m
%
EAS00202
REMOVING THE ROCKER ARMS AND CAMSHAFT
1. Remove:
8intake rocker arm shaft
8exhaust rocker arm shaft
8intake rocker arm
8exhaust rocker arm
8collar
NOTE:
Remove the rocker arm shafts with the clip plier.
2. Remove:
8camshaft 1
NOTE:
Remove the camshaft with the slide hammer bolt.
Slide hammer bolt
90890-01085
YU-01083-2
Weight
90890-01084
YU-01083-3
5-14
THE ROCKER ARMS AND CAMSHAFT
ENG
EAS00205
CHECKING THE CAMSHAFT
1. Check:
•camshaft bushings
Damage/wear -» Replace.
2. Check:
•camshaft lobes
Blue discoloration/pitting/scratches -*
Replace the camshaft.
®
m§>rgrxn^
X
3. Measure:
•camshaft lobe dimensions a and b
Out of specification -* Replace the camshaft.
\
Camshaft lobe dimension limit
Intake
a30.158~30.258mm
(1.1873~1.1913 in)
<Limit>:30.058mm (1.1834 in)
b25.082~25.182mm
(0.9875~0.9914 in)
<Limit>:24.982mm (0.9835 in)
Exhaust
a30.158~30.258mm
(1.1873~1.1913 in)
<Limit>:30.058mm (1.1834 in)
b25.020~25.120mm
(0.9850~0.9890 in)
<Limit>:24.920mm (0.9811 in)
11151001
4. Check:
•camshaft oil passage
Obstruction -* Blow out with compressed
air.
5-15
THE ROCKER ARMS AND CAMSHAFT
EAS00206
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
The following procedure applies to all of the
rocker arms and rocker arm shafts.
1. Check:
• rocker arm (camshaft touch surface©)
• rocker arm (valve touch surface®)
Damage/wear -» Replace.
2. Check:
• rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches -» Replace or check the lubrication system.
3. Check:
•camshaft lobe
Excessive wear -» Replace the camshaft.
4. Measure:
• rocker arm inside diameter a
Out of specification -» Replace.
Rocker arm inside diameter
10 ~ 10.015 mm (0.3937 ~ 0.3943
in)
<Limit>:10.030mm (0.3949 in)
5-16
THE ROCKER ARMS AND CAMSHAFT
5. Measure:
• rocker arm shaft outside diameter a
Out of specification -» Replace.
Rocker arm shaft outside diameter
9.981 ~ 9.991 mm (0.3930 ~ 0.3933
in)
<Limit>:9.950mm (0.3917 in)
6. Calculate:
•rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the rocker
arm shaft outside diameter from the rocker arm
inside diameter.
Above 0.034 mm (0.0013 in) -» Replace the defective part(s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.034 mm (0.0004 ~ 0.0013
in)
EAS00207
CHECKING THE TIMING CHAIN, CAMSHAFT
SPROCKET, AND TIMING CHAIN GUIDES
5-17
1. Check:
• timing chain
Damage/stiffness -» Replace the timing
chain and camshaft sprocket as a set.
2. Check:
• camshaft sprocket
More than 1/4 tooth wear a -» Replace
the camshaft sprocket and the timing
chain as a set.
a 1/4 tooth
b Correct
(T) Timing chain roller
(2) Camshaft sprocket
3. Check:
• timing chain guide (exhaust side)
• timing chain guide (intake side)
Damage/wear -» Replace the defective
part(s).
THE ROCKER ARMS AND CAMSHAFT
EAS00210
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage -» Replace.
2. Check:
• one-way cam operation
Rough movement -» Replace the timing
chain tensioner.
3. Check:
• cap bolt
• o-ring New
• spring
• one-way cam
• gasket New
• timing chain tensioner rod
Damage/wear -» Replace the defective
part(s).
•••••••••••••••••••••••
a. Removing the spring and cap bolt.
b. Return cam chain tensioner one way cam.
Press tensioner rod to the cam chain
tensioner housing.
c. Installing the spring and cap bolt.
d. Loosen the front end of cam chain tensioner
slowly.
e. Make sure to return to the front end of cam
chain tensioner.
• • • • • • • • • • • • • • • • • • • • • • •
Rough movement -» Replace the timing
chain tensioner.
5-18
THE ROCKER ARMS AND CAMSHAFT
ENG
%m
EAS00220
INSTALLING THE CAMSHAFT AND ROCKER
ARMS
1. Lubricate:
8camshaft 1
Recommended lubricant
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
2. Lubricate:
8rocker arm shafts
Recommended lubricant
Molybdenum disulfide oil
3. Install:
8exhaust rocker arm 1
8collar2
8exhaust rocker arm shaft
3
NOTE:
Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head.
4. Install:
8intake rocker arm 1
8collar2
8intake rocker arm shaft 3
NOTE:
Make sure the intake rocker arm shaft is completely pushed into the cylinder head.
5-19
VALVES AND VALVE SPRINGS
ENG
m
%
EAS00236
VALVES AND VALVE SPRINGS
Order
Job/Part
Q’ty
Removing the valves and valve
springs
Cylinder head
Rocker arms
Rocker arm shafts
Camshaft
1
2
3
4
5
6
7
8
9
Valve pad
Valve cotter
Valve spring retainer
Valve spring
Valve(intake)
Valve(exhaust)
Valve stem seal
Valve stem seat
Valve guide
Remove the parts in the order listed.
Refer to”CYLINDER HEAD”.
Refer to”REMOVING THE ROCKER
ARMS AND CAMSHAFT” and “INSTALLING THE CAMSHAFT AND ROCKER
ARMS”.
3
6
3
3
2
1
3
3
3
5-20
Remarks
Refer to”REMOVING THE VALVES” and
“INSTALLING THE VALVES”.
VALVES AND VALVE SPRINGS
Order
Job/Part
Q’ty
ENG
m
%
Remarks
For installation, reverse the removal procedure.
5-21
VALVES AND VALVE SPRINGS
ENG
%m
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Remove:
8valve pad 1
NOTE:
Make a note of the position of each valve pad
so that they can be reinstalled in their original
place.
2. Check:
• valve sealing
Leakage at the valve seat -» Check the
valve face, valve seat, and valve seat
width.
Refer to “CHECKING THE VALVE
SEATS”.
• • • • • • • • • • • • • • • • • • • • • • •
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat
©.
•••••••••••••••••••••••
3 . Remove:
valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment 2 .
5-22
VALVES AND VALVE SPRINGS
y-
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attachment
90890-04148
YM-04148
4 . Remove:
8valve spring retainer 1
8valve spring 2
8valve stem seal 3
8valve spring seat 4
8valve 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
5-23
VALVES AND VALVE SPRINGS
ENG
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1 . Measure:
8valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a Valve stem diameter b
Out of specification -* Replace the valve
guide.
Valve-stem-to-valve-guide clearance
Intake
0.010 ~ 0.037 mm(0.0004~0.0015 in)
<Limit>: 0.08 mm(0.0031 in)
Exhaust
0.025 ~ 0.052 mm(0.001~0.002 in)
<Limit>: 0.10 mm(0.0039 in)
2. Replace:
8valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100°C (212°F) in an oven.
•••••••••••••••••••••••
a. Remove the valve guide with the valve
guide remover 1 .
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3
to obtain the proper valve-stem-to-valveguide clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.
Valve guide remover (4.0 mm)
90890-04111(YM-04111)
Valve guide installer (4.0 mm)
90890-04112(YM-04112)
Valve guide reamer (4.0 mm)
90890-04113(YM-04113)
•••••••••••••••••••••••
5-24
VALVES AND VALVE SPRINGS
ENG
m
%
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear -* Grind the valve face.
• valve stem end
Mushroom shape or diameter larger than
the body of the valve stem -* Replace the
valve.
5. Measure:
• valve margin thickness a
Out of specification -* Replace the valve.
®-~
ODtE
Valve margin thickness
0.9~1.1mm(0.0354~0.0433in)
6. Measure:
• valve stem runout
Out of specification -* Replace the valve.
\J45°
NOTE:
• If the valve is removed or replaced, always
replace the oil seal.
Valve stem runout
0.01 mm(0.0004 in)
5-25
VALVES AND VALVE SPRINGS
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
• carbon deposits
(from the valve face and valve seat)
2. Check:
• valve seat
Pitting/wear -* Replace the cylinder head.
3. Measure:
• valve seat width a
Out of specification -* Replace the cylinder head.
Valve seat width
Intake: 0.9 ~ 1.1 mm (0.0354 ~
0.0433 in)
<Limit>: 1.6 mm(0.063 in)
Exhaust: 0.9 ~1.1 mm
(0.0354~0.0433 in)
<Limit>: 1.6 mm(0.063 in)
TTTTTTTTTTTTTTTTTTTTTTT
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been removed.
•••••••••••••••••••••••
4. Lap:
8valve face
8valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
5-26
VALVES AND VALVE SPRINGS
•••••••••••••••••••••••
a. Apply a coarse lapping compound a to the
valve face.
X"7
V
N\
cC
a
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
^
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j . Measure the valve seat width again. If the
valve seat width is out of specification,
reface and lap the valve seat.
• • • • • • • • • • • • • • • • • • • • • • •
5-27
VALVES AND VALVE SPRINGS
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the valve
springs.
1. Measure:
• valve spring free length a
Out of specification -» Replace the valve
spring.
Valve spring free length
Intake valve spring
39.35 mm (1.5492 in)
<Limit>: 37.38 mm (1.4717 in)
Exhaust valve spring
41.57 mm (1.6366 in)
<Limit>: 39.49 mm (1.5547 in)
2. Measure:
• compressed valve spring force a
Out of specification -» Replace the valve
spring.
b Installed length
Compressed valve spring force (installed)
Intake valve spring
91.1~104.9N(9.3~10.7kg,
20.48~23.58lb) at 28mm(1.1024in)
Exhaust valve spring
107.9~124.1N(11.0~12.7kg,
24.26~27.90lb) at 30mm(1.1811in)
3. Measure:
• valve spring tilt a
Out of specification -» Replace the valve
spring.
Spring tilt limit
Intake valve spring
1.7 mm (0.0669 in) ( 2.5° )
Exhaust valve spring
1.8 mm (0.0709 in)( 2.5° )
5-28
VALVES AND VALVE SPRINGS
ENG
m
%
EAS00245
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
8valve stem end
(with an oil stone)
2. Lubricate:
8valve stem 1
8valve stem seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:
8valve 1
8valve spring seat 2
8valve stem seal 3 N e w
8valve spring 4
8valve spring retainer 5
(into the cylinder head)
NOTE:
Install the valve spring with the larger pitch a
facing up.
b
Smaller pitch
4. Install:
8valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment 2 .
5-29
VALVES AND VALVE SPRINGS
ENG
m
%
Valve spring compressor
90890-04019(YM-04019)
Valve spring compressor attachment
90890-04148(YM-04148)
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a softface hammer.
cC
Hitting the valve tip with excessive force
could damage the valve.
6. Install:
valve pad 1
NOTE:
8 Lubricate the valve pad with engine oil.
8 Valve pad must be reinstalled in its original
position.
5-30
CYLINDER AND PISTON
ENG
m
%
EAS00251
CYLINDER AND PISTON
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Removing the cylinder and piston
Cylinder head
Timing chain guide(exhaust side)
Cylinder
Dowel pin
Cylinder gasket
Piston pin clip
Piston pin
Piston
Piston ring set
Remarks
Remove the parts in the order listed.
Refer to”CYLINDER HEAD”.
1
1
2
1
2
1
1
1
Refer to”REMOVING THE CYLINDER
AND PISTON” and “INSTALLING THE
PISTON AND CYLINDER”.
For installation, reverse the removal procedure.
5-31
CYLINDER AND PISTON
ENG
m
%
EAS00253
REMOVING THE CYLINDER AND PISTON
1. Remove:
8piston pin clip 1
8piston pin 2
8piston 3
cC
Do not use a hammer to drive the piston pin
out.
NOTE:
8 Before removing the piston pin clip, cover
the crankcase opening with a clean rag to
prevent the piston pin clip from falling into
the crankcase.
8 Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area. If both areas are deburred and
the piston pin is still difficult to remove, remove it with the piston pin puller s e t 4 .
Piston pin puller set
90890-01304(YU-01304)
2. Remove:
8top ring
82nd ring
8oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the
ring over the piston crown.
5-32
CYLINDER AND PISTON
ENG
EAS00255
CHECKING THE CYLINDER AND PISTON
1. Check:
• piston wall
• cylinder wall
Vertical scratches -* Rebore or replace
the cylinder, and replace the piston and
piston rings as a set.
2. Measure:
piston-to-cylinder clearance
• • • • • • • • • • • • • • • • • • • • • • •
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Cylinder bore “C”
38.000 ~ 38.010mm
(1.4961 ~ 1.4965in)
0.05mm (0.0020in)
Taper limit “T”
0.05mm (0.0020in)
Out-of-round “R”
~ D
“C” = maximum of D
“T” = maximum of D or D - maximum of D or D
“R” = maximum of D1, Dor
3 D5 - minimum of D2, D4
or D6
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a 5mm(0.1969in) from the bottom edge of the
piston
Standard
Piston size “P”
37.975 ~ 37.990mm
(1.4951 ~ 1.4957in)
d. If out of specification, replace the piston and
piston rings as a set.
5-33
CYLINDER AND PISTON
ENG
m
%
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” Piston skirt diameter “P”
Piston-to-cylinder clearance
0.010 ~ 0.035mm(0.0004 ~
0.0014in)
<Limit>:0.15mm(0.0059in)
f. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
• • • • • • • • • • • • • • • • • • • • • • •
5-34
CYLINDER AND PISTON
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
• piston ring side clearance
Out of specification -» Replace the piston and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
Piston ring side clearance
Top ring
0.03 ~ 0.07 mm(0.0012~0.0028 in)
<Limit>: 0.12mm(0.0047 in)
2nd ring
0.02 ~ 0.06 mm(0.0008~0.0024 in)
<Limit>:0.12 mm(0.0047 in)
2. Install:
8piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
a
10 mm (0.3937 in)
3. Measure:
• piston ring end gap
Out of specification -» Replace the piston ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
Piston ring end gap
Top ring
0.05 ~ 0.15 mm (0.0020 ~ 0.0059 in)
<Limit>: 0.40 mm (0.0157 in)
2nd ring
0.05 ~ 0.17 mm (0.0020 ~ 0.0067 in)
<Limit>: 0.52 mm (0.0205 in)
Oil ring
0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in)
5-35
CYLINDER AND PISTON
ENG
m
%
EAS00265
CHECKING THE PISTON PIN
1. Check:
• piston pin
Blue discoloration/grooves -* Replace the
piston pin and then check the lubrication
system.
2. Measure:
• piston pin outside diameter a
Out of specification -* Replace the piston pin.
Piston pin outside diameter
9.996 ~ 10.000 mm (0.3935 ~
0.3937 in)
<Limit>:9.976 mm (0.3928 in)
3. Measure:
• piston pin bore diameter b
Out of specification^ Replace the piston.
Piston pin bore diameter
10.002 ~ 10.013 mm (0.3938 ~
0.3942 in)
<Limit>:10.043 mm (0.3954 in)
4. Calculate:
• piston-pin-to-piston-pin-bore clearance
Out of specification -* Replace the piston pin and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter b Piston pin outside diameter a
Piston-pin-to-piston clearance
0.002 ~ 0.017 mm (0.0001 ~ 0.0007
in)
5-36
CYLINDER AND PISTON
ENG
m
%
CHECKING THE TIMING CHAIN GUIDE
1. Check:
8 timing chain guide (exhaust side)
Damage/wear -» Replace
EAS00267
INSTALLING THE PISTON AND CYLINDER
1. Install:
8oil ring expander 1
8oil ring rail 2
82nd ring 3
8top ring 4
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
2. Install:
8piston 1
8piston pin 2
8piston pin clip New 3
NOTE:
8 Apply engineoil the piston pin.
8 Make sure the arrow mark a on the piston
points towards the exhaust side of the cylinder.
8 Before installing the piston pin clip, cover
the crankcase opening with a clean rag to
prevent the clip from falling into the crankcase.
5-37
CYLINDER AND PISTON
ENG
m
%
3. Install:
8gasket N e w
8dowel pins
4. Lubricate:
8piston
8piston rings
8cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Offset:
8piston ring end gaps
a
b
c
d
A
Top ring
Lower oil ring rail
Upper oil ring rail
2nd ring
Exhaust side
6. Install:
8cylinder 1
8timing chain guide(exhaust side)
NOTE:
8 While compressing the piston rings with one
hand, install the cylinder with the other
hand.
8 Pass the timing chain and timing chain
guide (exhaust side) through the timing
chain cavity.
5-38
BELT DRIVE
ENG
%m
EAS00316
BELT DRIVE
V-BELT CASE COVER
%. 10Nm(1.0m • kg, 7.2 ft • lb)
P|« 12Nm(1.2m • kg, 8.7 ft* lb)
Order
1
2
3
4
5
Job/Part
Q’ty
Removing the V-belt case cover
Kickstarter
Cover
V-belt case cover
V-belt case cover gasket
Dowel pin
Remarks
Remove the parts in the order listed.
1
1
1
1
2
For installation, reverse the removal procedure.
5-39
BELT DRIVE
ENG
m
%
EAS00338
KICKSTARTER
Order
1
2
3
4
5
6
Job/Part
Q’ty
Disassembling the kickstarter
V-belt case cover
Kick pinion gear
Kick pinion gear clip
Circlip/Plate washer
Kickstarter shaft
Torsion spring
Solid bush
Remarks
Remove the parts in the order listed.
Refer to”V-BELT CASE COVER“.
1
1
1/1
1
1
1
Refer to”INSTALLING THE KICKSTARTER”.
For assembly, reverse the disassembly
procedure.
5-40
BELT DRIVE
ENG
%m
EAS00340
INSTALLING THE KICKSTARTER
1. Install:
8solid b u s h 1
8kick shaft assembly2
8torsion spring3
2. Hook:
8torsion spring
NOTE:
Hook the spring e n d a on the kickstarter shaft
b as shown, and hook the other end c on the
projectiond .
3. Install:
8plain washer
8circlip1 N e w
4. Install:
8kick pinion gear1
8kick pinion gear c l i p 2
NOTE:
8 Lubricate the kick pinion gear clip and shaft
with molybdenum disulfide oil.
8 Install the kick pinion gear clip at the position shown.
5-41
BELT DRIVE
ENG
%m
V-BELT AND PRIMARY/SECONDARY SHEAVE
40Nm (4.0 m«kg, 28.9 fHb)
30Nm (3.0 m«kg, 21.7 fHb)
Order
Job/Part
1
2
3
Removing the V-belt and primary/secondary sheave
Primary sheave nut/Plate washer
Oneway clutch
Primary fixed sheave
1/1
1
1
4
5
6
7
8
9
10
11
12
13
Secondary sheave nut
Clutch housing
Secondary sheave
V-belt
Plate washer
Collar
Primary sliding sheave
Cam/Weight
Slider
Plate washer
1
1
1
1
1
1
1
1/6
3
1
Q’ty
Remarks
Remove the parts in the order listed.
Refer to”REMOVING THE PRIMARY
SHEAVE” and “INSTALLING THE SECONDARY SHEAVE, V-BELT AND PRIMARY SHEAVE” .
Refer to”REMOVING THE SECONDARY SHEAVE AND V-BELT” and “INSTALLING THE
SECONDARY
SHEAVE, V-BELT AND PRIMARY
SHEAVE” .
For installation, reverse the removal procedure.
5-42
BELT DRIVE
ENG
%m
SECONDARY SHEAVE
Order
Job/Part
1
2
Disassembling
sheave
Clutch carrier nut
Clutch carrier
the
3
4
5
6
7
8
9
0
Clutch shoe spring
Compression spring
Secondary spring seat
Guide pin
Secondary sliding sheave
O-ring
Oil seal
Secondary fixed sheave
Q’ty
secondary
Remarks
Disassemble the parts in the order listed.
1
1
3
1
1
2
1
2
2
1
Refer to”DISASSEMBLING THE SECONDARY SHEAVE” and “ASSEMBLING
THE SECONDARY SHEAVE”.
Refer to”ASSEMBLING THE SECONDARY SHEAVE” .
For assembly, reverse the disassembly
procedure.
5-43
BELT DRIVE
ENG
%m
EAS00317
REMOVING THE PRIMARY SHEAVE
1. Remove:
8primary sheave nut 1
8plate washer
8oneway clutch
8primary fixed sheave 2
NOTE:
While holding the primary fixed sheave with the
rotor holding tool 3 , loosen the primary fixed
sheave nut.
Rotor holding tool
90890-01235 (YU-01235)
EAS00318
REMOVING THE SECONDARY SHEAVE AND
V-BELT
1. Remove:
8secondary sheave nut 1
8clutch housing 2
NOTE:
While holding the clutch housing with the sheave
holder 3 , loosen the secondary sheave nut.
-^— "\f ^^^^\\
Jf2/®
/J
®
ijy
/
y-
Sheave holder
90890-01701 (YS-01880-A)
2. Loosen:
8clutch carrier nut
cC
Do not remove the clutch carrier nut at this
stage.
-^z^r^^
NOTE:
While holding the clutch carrier with the rotor
holding tool 1 , loosen the clutch carrier nut one
full turn with the socket wrench 2 .
«S
f,
If M.
/
/
jS/Ki/
5-44
Rotor holding tool
90890-01235
YU-01235
Socket wrench(39mm)
90890-01493
BELT DRIVE
ENG
m
%
3. Remove:
8secondary sheave 1
8V-belt 2
NOTE:
Remove the V-belt and secondary sheave from
the primary sheave side.
EAS00319
%-©
DISASSEMBLING THE
SHEAVE
1. Remove:
8clutch carrier nut 1
1 // / /Py*—\ 1
SECONDARY
NOTE:
Install the clutch spring holder 2 and clutch
spring holder arm 3 onto the secondary sheave
as shown. Then, compress the spring, and remove the clutch carrier nut 1 .
Clutch spring holder
90890-01337
YM-33285
YM-33285-6
CHECKING THE CLUTCH SHOES
The following procedure applies to all of the clutch
shoes.
1. Check:
• clutch shoe
Damage/wear -» Replace the clutch
shoes and springs as a set.
Glazed areas -»Sand with coarse sandpaper.
NOTE:
After sanding the glazed areas, clean the clutch
with a cloth.
2. Measure:
• clutch shoe thickness
Out of specification -» Replace the clutch
shoes and springs as a set.
5-45
BELT DRIVE
Clutch shoe thickness
3.7mm(0.146in)
<Limit>:2.0mm(0.079in)
NOTE:
8 Inspect clutch shoesa.
8 After removing the clutch shoe spring, do
not use them again.
8 Replace the all three as a set.
EAS00320
j^ia
CHECKING THE V-BELT
1. Check:
• V-belt®
Cracks/damage/wear -» Replace.
Grease/oil -» Clean the primary and secondary sheave.
\1J
2. Measure:
• V-belt width a
Out of specification -» Replace.
V-belt width
17.9 mm (0.705 in)
<Limit>: 16.1 mm (0.634 in)
CHECKING THE PRIMARY SHEAVE
1. Check:
• primary sliding sheave©
• primary fixed sheave®
Cracks/damage/wear -» Replace the primary sliding sheave, primary fixed
sheave and V-belt.
2. Check:
•free movement
Stick or excessive play -» Replace the
primary sliding sheave or collar.
NOTE:
Insert the collar® into the primary sliding
sheave®, and check for free movement.
5-46
BELT DRIVE
ENG
EAS00321
CHECKING THE PRIMARY SHEAVE WEIGHTS
The following procedure applies to all of the primary sheave weights.
1. Check:
• primary sheave weight
Cracks/damage/wear -* Replace.
2. Measure:
• primary sheave weight outside diameter
a
Out of specification -* Replace.
Primary sheave weight outside diameter
15 mm (0.591 in)
<Limit>: 14.5 mm (0.571 in)
CHECKING THE SLIDER
1. Check:
• slider©
Damage/wear^ Replace
EAS00322
CHECKING THE SECONDARY SHEAVE
1. Check:
•secondary fixed sheave
•secondary sliding sheave
Cracks/damage/wear -* Replace the secondary fixed and sliding sheaves as a
set.
2. Check:
•torque cam groove ©
Damage/wear -* Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
•guide pin (2)
Damage/wear -* Replace the secondary
fixed and sliding sheaves as a set.
5-47
BELT DRIVE
ENG
%m
EAS00323
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
8primary fixed sheave 1
8primary sliding sheave 2
8collar 3
8primary sheave weights 4
NOTE:
Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5 .
2. Install:
8primary sliding sheave 1
8primary sheave weights 2
8collar 3
3. Install:
8sliders 1
8cam 2
5-48
BELT DRIVE
ENG
# 1
1&m\
EAS00324
ASSEMBLING THE SECONDARY SHEAVE
1. Lubricate:
8secondary fixed sheave’s inner surface
1
8secondary sliding sheave’s inner surface
2
8oil seals
8bearings
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube®
2. Install:
8secondary sliding sheave 1
NOTE:
Install the secondary sliding sheave onto the
secondary fixed sheave 2 with the oil seal guide
3.
m
Oil seal guide
90890-01384 (YM-33299)
3. Install:
8guide pin 1
4. Lubricate:
8guide pin groove 2
8o-ring New 3
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube®
5-49
BELT DRIVE
ENG
m
%
5. Install:
8secondary sheave 1
8spring
8clutch carrier 2
I f ' /
/F^r~\\
NOTE:
Attach the clutch spring holder 3 and clutch
spring holder arm 4 onto the secondary sheave
as shown. Then, compress the spring, and
tighten the clutch carrier nut 5 .
®
©
Clutch spring holder
90890-01337 (YM-33285)
( YM-33285-6)
EAS00325
INSTALLING THE SECONDARY SHEAVE, VBELT AND PRIMARY SHEAVE
1. Install:
8V-belt 1
8secondary sheave 2
cC
Do not allow grease to contact the V-belt,
secondary sheave assembly.
NOTE:
8 Install the V-belt onto the primary sheave
side.
8 Install the V-belt with printed arrow mark on
the V-belt facing in the direction shown in
the illustration.
2. Tighten:
8 clutch carrier nut
X I 55Nm(5.5m * kg, 39.8ft * lb)
NOTE:
While holding the clutch carrier with the rotor
holding tool © , tighten the clutch carrier nut with
the socket wrench®.
5-50
BELT DRIVE
ENG
%m
Rotor holding tool
90890-01235
YU-01235
Socket wrench(39mm)
90890-01493
3. Install:
• clutch housing (T)
• secondary sheave nut®
X I 40Nm(4.0m * kg, 28.9ft * lb)
NOTE:
Tighten the secondary sheave nut with the
sheave holder®.
^
Sheave holder
90890-01701
YS-01880-A
4. Install:
• primary fixed sheave©
• oneway clutch
• plate washer
• primary sheave nut®
X I 30Nm(3.0m * kg, 21.7ft * lb)
NOTE:
While holding the primary fixed sheave with the
rotor holding tool®, tighten the primary fixed
sheave nut.
5-51
BELT DRIVE
ENG
%m
5. Position:
8V-belt 1
NOTE:
Position the V-belt in the primary sheave 2
(when the pulley is at its widest position) and in
the secondary sheave 3 (when the pulley is at
its narrowest position), and make sure the Vbelt is tight.
5-52
STARTER CLUTCH AND AC MAGNETO
ENG
m
%
EAS00341
STARTER CLUTCH AND AC MAGNETO
STATOR COIL ASSEMBLY
Order
Job/Part
Q’ty
Removing the stator coil assembly
Coolant
1
2
3
4
5
Remarks
Remove the parts in the order listed.
Drain.
Refer to”CHANGING THE COOLANT”in
chapter 3.
Single seat/Trunk
Front cover
Side cover(left and right)
Battery cover/Battery
Footrest board
Radiator
Crankshaft position sensor coupler/Stator coil assembly coupler
Fan
Nut/Plate washer
AC magneto rotor
Woodruff key
5-53
Refer to”COVER AND PANEL”in chapter 3.
1/1
1
1/1
1
1
Refer to”RADIATOR”in chapter 6.
Disconnect.
STARTER CLUTCH AND AC MAGNETO
Order
6
7
8
Job/Part
Q’ty
1
1
1
Lock plate
Crankshaft position sensor
Stator coil assembly
ENG
m
%
Remarks
For installation, reverse the removal procedure.
5-54
STARTER CLUTCH AND AC MAGNETO
ENG
%m
EAS00342
STARTER CLUTCH
Order
Job/Part
Removing the starter clutch
Engine oil
1
2
3
4
5
6
7
8
Remarks
Q’ty
AC magneto rotor
Stator coil assembly
Crankcase cover(right)
Starter clutch nut
Washer
Starter wheel gear
Roller
Collar
Starter clutch
Idle gear
1
1
1
1
1
1
1
1
5-55
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE
OIL”in chapter 3.
Refer to”REMOVING THE AC MAGNETO” and “INSTALLING THE AC MAGNETO”.
cC
The starter clutch nut is left-hand
thread.
Refer to”REMOVING THE STARTER
CLUTCH” and “INSTALLING THE
STARTER CLUTCH” .
For installation, reverse the removal procedure.
STARTER CLUTCH AND AC MAGNETO
ENG
m
%
EAS00347
REMOVING THE AC MAGNETO
1. Remove:
8AC magneto rotor n u t 1
8washer
NOTE:
8 While holding the AC magneto rotor 2 with
the sheave holder 3 , loosen the AC magneto rotor nut.
8 Do not allow the sheave holder to touch the
projection on the AC magneto rotor.
Sheave holder
90890-01701
YS-01880-A
2. Remove:
8AC magneto rotor 1
(with the flywheel puller set 2 )
8woodruff key
cC
To protect the end of the crankshaft, place
an appropriate sized socket between the
flywheel puller set’s center bolt and the
crankshaft.
NOTE:
Make sure the flywheel puller is centered over
the AC magneto rotor.
Flywheel puller set
90890-01468
YU-33270-B
5-56
STARTER CLUTCH AND AC MAGNETO
ENG
m
%
EAS00344
REMOVING THE STARTER CLUTCH
1. Remove:
8crankcase cover (right)1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stages
and in a crisscross pattern. After all of the bolts
are fully loosened, remove them.
2. Remove:
8starter clutch n u t 1
8washer
8starter wheel gear
8roller
8collar
8starter clutch
8idle gear
NOTE:
The starter clutch nut is left-hand thread.
5-57
STARTER CLUTCH AND AC MAGNETO
ENG
%m
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
•starter clutch roller
Damage/wear -» Replace.
2. Check:
•starter clutch idle gear
•starter wheel gear
Burrs/chips/roughness/wear -» Replace
the defective part(s).
3. Check:
•starter wheel gear’s contacting surfaces
Damage/pitting/wear -» Replace the
starter clutch gear.
4. Check:
8starter clutch operation
•••••••••••••••••••••••
a. Install the starter wheel gear 1onto the
starter clutch 2 and hold the starter clutch.
b. When turning the starter wheel gear clockwise A , the starter clutch and the starter
wheel gear should engage, otherwise the
starter clutch is faulty and must be replaced.
c. When turning the starter wheel gear counterclockwise B , it should turn freely, otherwise the starter clutch is faulty and must be
replaced.
•••••••••••••••••••••••
5-58
STARTER CLUTCH AND AC MAGNETO
ENG
%m
EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:
• idle gear
• starter clutch
• collar
• roller
• starter wheel gear
• washer
• starter clutch nut®
\ | 90 Nm (9.0 m * kg, 65.1 ft * lb)
NOTE:
The starter clutch nut is left-hand thread.
2. Install:
• gasket New
• crankcase cover (right)©
X I 10 Nm (1.0 m * kg, 7.2 ft * lb)
EAS00354
INSTALLING THE AC MAGNETO
1. Install:
8stator coil assembly1
8crankshaft position sensor2
8woodruff k e y 3
8AC magneto rotor
8washer
8AC magneto rotor nut
NOTE:
8 Clean the tapered portion of the crankshaft
and the AC magneto rotor hub.
8 When installing the AC magneto rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
5-59
STARTER CLUTCH AND AC MAGNETO
ENG
m
%
2. Tighten:
•AC magneto rotor nut (T)
X I 43 Nm (4.3 m * kg, 31.1 ft * lb)
NOTE:
• While holding the AC magneto rotor (2)with
the sheave holder®, tighten the AC magneto rotor nut.
• Do not allow the sheave holder to touch the
projection on the AC magneto rotor.
f*
5-60
Sheave holder
90890-01701
YS-01880-A
OIL PUMP
ENG
%m
EAS00360
OIL PUMP
4Nm (0.4 m«kg, 2.9 fHb)
3
Order
1
2
3
4
5
Job/Part
Q’ty
Removing the oil pump
Radiator
AC magneto
Starter clutch
Drive gear
Circlip/Plate washer
Oil pump driven gear
Dowel pin
Oil pump
Remarks
Remove the parts in the order listed.
Refer to”RADIATOR”in chapter 6.
Refer to”STARTER CLUTCH AND AC
MAGNETO” .
1
1/1
1
2
1
For installation, reverse the removal procedure.
5-61
OIL PUMP
EAS00364
CHECKING THE OIL PUMP
1. Check:
• oil pump drive gear
• oil pump driven gear©
• oil pump housing
• oil pump housing cover
Cracks/damage/wear -»
defective part(s).
Replace the
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance A
• outer-rotor-to-oil-pump-housing clearance \B\
• oil-pump-housing-to-inner-rotor-andouter-rotor clearance \c\
Out of specification -» Replace the oil
pump.
© Inner rotor
(2) Outer rotor
(3) Oil pump housing
Inner-rotor-to-outer-rotor-tip clearance
0.15 mm (0.006 in) or less
<Limit>: 0.23 mm (0.009 in)
Outer-rotor-to-oil-pump-housing
clearance
0.13 ~ 0.18 mm (0.005 ~ 0.007 in)
<Limit>: 0.25mm (0.010 in)
Oil-pump-housing-to-inner-rotorand-outer-rotor clearance
0.07 ~ 0.12 mm (0.003 ~ 0.005 in)
<Limit>: 0.19 mm (0.008 in)
11710404
3. Check:
• oil pump operation
Rough movement -»Repeat steps (1) and
(2) or replace the defective part(s).
5-62
OIL PUMP
ENG
%m
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
8inner rotor
8outer rotor
8oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:
8 oil pump shaft (T)
(to the oil pump housing®)
8 pin (3)
8 inner rotor®
8 outer rotor©
8 oil pump housing cover®
8 oil pump housing screw
X I 4 Nm (0.4 m * kg, 2.9 ft * lb)
NOTE:
When installing the inner rotor, align the pin (3) in
the oil pump shaft with the groove a in the inner
rotor (4).
3. Check:
8 oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP
1. Install:
8oil pump drive gear 1
8gasket New
8oil p u m p 2
8oil pump bolt
\ | 4 Nm (0.4 m * kg, 2.9 ft * lb)
C
After tightening the bolts, make sure the oil
pump turns smoothly.
5-63
TRANSMISSION
ENG
m
%
EAS00419
TRANSMISSION
Order
Job/Part
Q’ty
Removing the transmission
Transmission oil
Remove the parts in the order listed.
Drain.
Refer to”CHANGING THE TRANSMISSION OIL” in chapter 3.
Refer to”ENGINE REMOVAL”.
Refer to”REAR WHEEL AND BRAKE”
in chapter 4.
Refer to”BELT DRIVE”.
Muffler/Bracket
Rear wheel
1
2
3
4
5
6
Remarks
V-belt case cover
Secondary sheave
Transmission cover
Transmission cover gasket
Dowel pin
Main axle
Drive axle
Primary drive gear
_
1
1
2
1
1
1
For installation, reverse the removal procedure.
5-64
TRANSMISSION
EAS00425
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial gauge )
Out of specification -» Replace the main
axle.
Main axle runout limit
0.04 mm (0.002 in)
2. Measure:
• drive axle runout
(with a centering device and dial gauge )
Out of specification -» Replace the drive
axle.
Primary drive gear shaft runout limit
0.04 mm (0.002 in)
3 . Check:
•transmission gears
Blue discoloration/pitting/wear -»Replace
the defective gear(s).
•transmission gear dogs
Cracks/damage/rounded edges -» Replace the defective gear(s).
4 . Check:
•transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect -»Reassemble the transmission
axle assemblies.
5 . Check:
•transmission gear movement
Rough movement -» Replace the defective part(s).
6 . Check:
•circlip
Bends/damage/looseness -» Replace.
5-65
CRANKSHAFT
ENG
%m
EAS00381
CRANKSHAFT
CRANKSHAFT ASSEMBLY
1 * 7Nm (0.7 m»kg, 5.1 fHb)
5
7Nm (0.7 m»kg, 5.1 fHb)
Order
Job/Part
Q’ty
Removing the crankshaft assembly
Engine
Cylinder head
Cylinder and piston
V-belt case cover
V-belt and primary/secondary sheave
Radiator
Water pump
Starter clutch
AC magneto
Oil pump
Transmission
Rear wheel
1
2
3
4
Tension spring
Circlip/Plate washer
Pin
Centerstand
Remove the parts in the order listed.
Refer to”ENGINE REMOVAL” .
Refer to”CYLINDER HEAD”.
Refer to”CYLINDER AND PISTON”.
Refer to”BELT DRIVE”.
Refer to”COOLING SYSTEM”in chapter
6.
Refer to”STARTER CLUTCH AND AC
MAGNETO”.
Refer to”OIL PUMP”.
Refer to”TRANSMISSION”.
Refer to”REAR WHEEL AND BRAKE”in
chapter 4.
1
1/1
1
1
5-66
Remarks
CRANKSHAFT
fV
ENG
%m
7Nm (0.7 m»kg, 5.1 fHb)
5
7Nm (0.7 m»kg, 5.1 fHb)
Order
Job/Part
5
6
7
8
9
10
Hook
Drain plug
Oil strainer
Compression spring
O-ring
Crankcase(right)
11
12
13
14
Spacer
Dowel pin
Guide
Crankshaft
15
16
17
18
19
Timing chain
Crankcase(left)
Oil seal
Bolt/O-ring
Timing chain guide (intake side)
Remarks
Q’ty
1
1
1
1
1
1
Refer to”DISASSEMBLING THE
CRANKCASE” and “ASSEMBLING THE
CRANKCASE”.
1
2
1
1
Refer to”REMOVING THE CRANKSHAFT ASSEMBLY” and “INSTALLING
THE CRANKSHAFT ASSEMBLY”.
1
1
1
1/1
1
For installation, reverse the removal procedure.
5-67
CRANKSHAFT
ENG
%m
EAS00385
DISASSEMBLING THE CRANKCASE
1. Remove:
8centerstand assembly
2. Remove:
8crankcase bolts1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stages
and in a crisscross pattern. After all of the bolts
are fully loosened, remove them.
3. Remove:
8right crankcase1
8spacer
cC
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly and
carefully and make sure the crankcase
halves separate evenly.
5-68
CRANKSHAFT
ENG
m
%
EAS00389
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:
8crankshaft assembly1
8timing chain2
8timing chain guide(intake side)
NOTE:
8 Before removing the crankshaft assembly,
remove the timing chain from the crankshaft
sprocket.
8 The crankshaft assembly cannot be removed if the timing chain is attached onto
the crankshaft sprocket.
EAS00394
CHECKING THE CRANKSHAFT AND CONNECTING ROD
1. Measure:
• crankshaft runout
Out of specification -» Replace the crankshaft, bearing or both.
NOTE:
Turn the crankshaft slowly.
Maximum crankshaft runout
0.03mm(0.0012in)
2. Measure:
• big end side clearance
Out of specification -»Replace the big end
bearing, crankshaft pin, or connecting rod.
Big end side clearance
0.15~0.45mm(0.006~0.018in)
5-69
CRANKSHAFT
ENG
m
%
3. Measure:
• crankshaft width
Out of specification -»Replace the crankshaft.
Crankshaft width
42.45~42.50mm(1.671~1.673in)
^^^
4. Check:
•crankshaft sprocket (T)
Damage/wear -»Replace the crankshaft.
•bearing (2)
Cracks/damage/wear -» Replace the
crankshaft.
•oil pump drive gear
Damage/wear -» Replace the crankshaft.
5. Check:
•crankshaft journal
Scratches/wear -» Replace the crankshaft.
•crankshaft journal oil passage
Obstruction -» Blow out with compressed
air.
//\
y>^ y&
my
y%
y/y
(if
\
^ ^ Lb
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in
a mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
•crankcase
Cracks/damage -» Replace.
•oil delivery passages
Obstruction -» Blow out with compressed
air.
5-70
CRANKSHAFT
ENG
EAS00207
CHECKING THE TIMING CHAIN AND TIMING
CHAIN GUIDE(INTAKE SIDE)
1. Check:
• timing chain
Damage/stiffness -> Replace the timing
chain and camshaft sprocket as a set.
2. Check:
• timing chain guide (intake side)
Damage/wear -> Replace.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
•bearings
Clean and lubricate the bearings, then rotate the inner race with your finger.
Rough movement -> Replace.
2. Check:
•oil seals
Damage/wear -» Replace.
EAS00402
CHECKING THE CIRCLIPS AND WASHERS
1. Check:
•circlips
Bends/damage/looseness -> Replace.
•washers
Bends/damage -> Replace.
5-71
CRANKSHAFT
EAS00408
INSTALLING THE CRANKSHAFT
1. Install:
8timing chain guide (intake side)
8timing chain1
8crankshaft assembly2
NOTE:
Install the timing chain so it is not visible through
the opening in the left crankcase 3 .
cC
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
NOTE:
Put the timing chain in parallel into the crankcase, then use hands to place the crankshaft
assembly into the crankcase. Manually rotate
the crankshaft to check whether it is tightly engaged with the timing chain. (if not, install again)
EAS00418
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.
2. Apply:
8sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
Sealant (Quick Gasket®)
ACC-11001-05-01
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
5-72
CRANKSHAFT
ENG
%m
3. Install:
8dowel pins
8spacer
8right crankcase1
NOTE:
Tap lightly on the right crankcase with a softface hammer.
4. Tighten:
•crankcase bolts
X I 10Nm(1.0m * kg, 7.2ft * lb)
NOTE:
Tighten the crankcase bolts in stages and in a
crisscross pattern.
5. Apply:
•engine oil
(onto the crankshaft pin, bearing and oil
delivery hole)
6. Check:
•crankshaft operation
Rough movement-*Repair.
5-73
COOL J C
CHAPTER 6
COOLING SYSTEM
RADIATOR
CHECKING THE RADIATOR
INSTALLING THE RADIATOR
THERMOSTAT
CHECKING THE THERMOSTAT
INSTALLING THE THERMOSTAT
WATER PUMP
DISASSEMBLING THE WATER PUMP
CHECKING THE WATER PUMP
ASSEMBLING THE WATER PUMP
INSTALLING THE WATER PUMP
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-9
6-9
6-10
6-11
RADIATOR
COOL J C
EAS00454
COOLING SYSTEM
RADIATOR
Order
Job/Part
Remove the parts in the order listed.
Removing the radiator
Front cover
Side cover(left and right)
Single seat/Trunk
Footrest board
Coolant
1
2
3
4
5
6
7
Remarks
Q’ty
Refer to”COVER AND PANEL”in chapter 3.
Drain.
Refer to”CHANGING THE COOLANT”in
chapter 3.
1
1
1
1
1
1
1
Radiator cover
Radiator cap
Conduit hose
Radiator inlet hose
Radiator outlet hose
Radiator
Fan case
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
6-1
RADIATOR
EAS00455
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction -» Clean.
Apply compressed air to the rear of the
radiator.
Damage -» Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flat-head
screwdriver.
2. Check:
• radiator inlet hose
• radiator outlet hose
• conduit hose
Cracks/damage -» Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure -» Replace
the radiator cap.
Radiator cap opening pressure
107.9 ~ 137.3kPa
(1.1 ~ 1.4kg/cm2, 15.6 ~ 19.9psi)
• • • • • • • • • • • • • • • • • • • • • • •
a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap
3.
Radiator cap tester
90890-01325
YU-24460-01
Radiator cap tester adapter
90890-01352
YU-33984
b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
• • • • • • • • • • • • • • • • • • • • • • •
4. Check:
• radiator fan
Damage -» Replace.
Malfunction -» Check and repair.
6-2
RADIATOR
EAS00456
INSTALLING THE RADIATOR
1. Fill:
8cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
2. Check:
• cooling system
Leaks -» Repair or replace any faulty part.
3 ©
^ ^ C
• • • • • • • • • • • • • • • • • • • • • • •
a. Attach the radiator cap tester 1 to the radiator.
y-
Radiator cap tester
90890-01325, YU-24460-01
Radiator cap tester adapter
90890-01352, YU-33984
b. Apply 100 kPa (1.0 kg/cm2, 14.22 psi) of
pressure.
c. Measure the indicated pressure with the
gauge.
• • • • • • • • • • • • • • • • • • • • • • A
3. Measure:
• radiator cap opening pressure
Below the specified pressure -» Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-3
THERMOSTAT
COOL J C
EAS00460
THERMOSTAT
10Nm (1.0 m«kg, 7.2 fHb)
10Nm (1.0 m«kg, 7.2 fHb)
4
Order
Job/Part
Removing the thermostat
Front cover
Side cover(left and right)
Single seat/Trunk
Footrest board
Coolant
1
2
3
4
5
6
Remarks
Q’ty
Remove the parts in the order listed.
Refer to”COVER AND PANEL”in chapter 3.
Drain.
Refer to”CHANGING THE COOLANT”in
chapter 3.
Clip
Thermostat inlet hose
Clip
Thermostat outlet hose
Thermostat cover
Thermostat
1
1
1
1
1
1
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
6-4
THERMOSTAT
EAS00462
CHECKING THE THERMOSTAT
1. Check:
• thermostat (T)
Does not open at 85 ~100°C (185 ~212°F)
-» Replace.
• • • • • • • • • • • • • • • • • • • • • • •
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
•••••••••••••••••••••••
©
(2)
(3)
(4)
A
B
Thermostat
Container
Thermometer
Water
Fully closed
Fully open
NOTE:
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.
m
'
^
2. Check:
• thermostat cover
Cracks/damage -» Replace.
3. Check:
• thermostat inlet hose
• thermostat outlet hose
Cracks/damage -» Replace.
i
3.5mm
(0.14 in)
m^^^^r
85±2 C
(185±3.6 F)
\
I
100 C
(212 F)
6-5
THERMOSTAT
COOL J C
EAS00466
INSTALLING THE THERMOSTAT
1. Install:
• thermostat©
• thermostat cover
X | 10Nm(1.0m * kg, 7.2ft * lb)
NOTE:
Align the breather a of thermostat to mark b of
thermosat before installation.
2. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
3. Check:
• cooling system
Leaks -»Repair or replace any faulty part.
4. Measure:
• radiator cap opening pressure
Below the specified pressure -» Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-6
WATER PUMP
COOL J C
EAS00468
WATER PUMP
lyJ2|10
10Nm(1.0m« kg, 7.2 ft* lb)
dr^ ®
Order
Job/Part
Q’ty
Removing the water pump
Front cover
Side cover(left and right)
Single seat/Trunk
Footrest board
Coolant
1
2
3
4
5
6
7
8
9
4i , /
Remarks
Remove the parts in the order listed.
Refer to”COVER AND PANEL”in chapter 3.
Breather hose
Thermostat inlet hose
Water pump outlet hose
Radiator outlet hose
Water pump housing cover
Gasket
Water pump housing
Plate
Impeller shaft
1
1
1
1
1
1
1
1
1
6-7
Drain.
Refer to”CHANGING THE COOLANT”in
chapter 3.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
WATER PUMP
COOL J C
6
10Nm(1.0m • kg, 7.2 ft* lb)
®^^ ®
Order
10
11
12
Job/Part
Q’ty
1
1
1
Oil seal
Bearing
Gasket
Remarks
For installation, reverse the removal procedure.
6-8
WATER PUMP
COOL J C
EAS00471
DISASSEMBLING THE WATER PUMP
1. Remove:
8water pump housing c o v e r 1
8dowel pin
8gasket
2. Remove:
8plate 2
8impeller shaft 3
8gasket
8oil seal
(with a thin, flat-head screwdriver)
8bearing
NOTE:
8 Remove the oil seal from the inside of the
water pump housing.
8 Remove the bearing from the inside of the
water pump housing.
EAS00474
CHECKING THE WATER PUMP
1. Check:
•water pump housing cover
•water pump housing
•impeller©
Cracks/damage/wear -» Replace.
2. Check:
•water pump seal (T)
Cracks/damage/wear -» Replace.
3. Check:
•bearing
Rough movement -» Replace.
4. Check:
• radiator outlet hose
Cracks/damage/wear -» Replace.
6-9
WATER PUMP
COOL J C
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
8bearing1
NOTE:
8 Before installing the oil seal, apply tap water or coolant onto its out surface.
8 Install the oil seal with a socket that
matches its outside diameter.
2. Install:
8water pump seal New 1
(into the water pump housing 2 )
cC
Never lubricate the water pump seal surface
with oil or grease.
NOTE:
8 Install the water pump seal with the special
tools.
8 Press in depth of water pump and oil seal
is 5.5~6.0mm a .
Mechanical seal installer
90890-04145 3
Middle driven shaft bearing driver
90890-04058 4
YM-04058
^
3. Measure:
8 impeller shaft tilt
Out of specification -»Replace the impeller
shaft .
1
Impeller shaft tilt limit
0.15mm(0.0059in)
^5
1 Straightedge
2 Impeller
4. Install:
8impeller shaft1
8plate2
cC
After installation, check that the impeller
shaft rotates smoothly.
6-10
WATER PUMP
COOL J C
5. Install:
8gasket New
8water pump housing c o v e r 1
Iae
M§
\ \Ji—-
b//
^
EAS00478
INSTALLING THE WATER PUMP
1. Install:
• water pump assembly (T)
X | 10Nm(1.0m * kg, 7.2ft * lb)
NOTE:
Align the slit a on the impeller shaft with
the projection b on the camshaft sprocket
bolt.
2. Install:
• breather hose
• thermostat inlet hose
• water pump outlet hose
• radiator outlet hose
3. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
4. Check:
• cooling system
Leaks -» Repair or replace the faulty part.
5. Measure:
• radiator cap opening pressure
Below the specified pressure -» Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-11
FI
ifl
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
7-1
WIRING DIAGRAM
7-2
ECU’S SELF-DIAGNOSTIC FUNCTION
7-4
CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING
LIGHT BULB
7-5
SELF-DIAGNOSTIC FANCTION TABLE
7-5
Self-diagnostic fanction table
7-5
TROUBLESHOOTING CHART
7-7
DIAGNOSTIC MODE
7-8
TROUBLESHOOTING DETAILS
7-12
THROTTLE BODY AND FUEL INJECTOR
7-26
THROTTLE BODY
7-26
FUEL INJECTOR AND FUEL HOSE
7-27
FUEL TANK
7-28
REMOVING THE FUEL HOSE
7-29
REMOVING THE FUEL PUMP
7-29
CHECKING THE THROTTLE BODY
7-30
INSTALLING THE FUEL PUMP
7-31
INSTALLING THE FUEL HOSE
7-31
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION
7-32
CHECKING THE THROTTLE POSITION SENSOR
7-32
CHECKING THE ISC (IDLE SPEED CONTROL) VALVE
7-34
AIR INDUCTION SYSTEM
7-35
AIR INJECTION
7-35
AIR CUT-OFF VALVE
7-35
AIR INDUCTION SYSTEM DIAGRAMS
7-36
AIR CUT-OFF VALVE AND AIR FILTER CASE
7-37
CHECKING THE AIR INDUCTION SYSTEM
7-38
FUEL INJECTION SYSTEM
FI
EAS00894
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
1
2
3
4
5
6
7
8
9
0
ECU
Engine trouble warning light
Lean angle cut-off switch
Fuel hose
Ignition coil
Fuel injector
Intake air pressure sensor
ISC(idle speed control) valve
Intake air temperature sensor
Battery
q
w
e
r
t
y
u
i
7-1
Air filter case
Catalytic converter
Crankshaft position sensor
Coolant temperature sensor
Spark plug
Fuel tank
Fuel pump
Throttle position sensor
ifl
FUEL INJECTION SYSTEM
FI
ifl
WIRING DIAGRAM
Br/W
L
x
B/L
©
Br/W
< P/W
Y
B/L
x
(BETWEEN MAIN 8 SUB
Y
< P/W
-Hi,®
5:
~
G/Y
Br
L/G
BSD
"O
W
W
7-2
mi
L H k J — © — t H i- B — 1
FUEL INJECTION SYSTEM
1
3
4
8
9
0
q
w
e
r
t
y
u
i
o
p
s
f
c
b
n
m
.
/
AC magneto
Main fuse
Battery
Engine stop switch
ECU
Main switch
Intake air pressure sensor
Intake air temperature sensor
Throttle position sensor
Lean angle cut-off switch
Coolant temperature sensor
Ignition coil
Spark plug
Fuel injector
Fuel pump
ISC (idle speed control) valve
Dimmer switch
Headlight
High beam indicator light
Engine trouble warning light
Coolant temperature indicator light
Speed sensor
FI diagnostic tool (optional)
Sidestand switch (optional)
7-3
FI
ifl
FI
FUEL INJECTION SYSTEM
ifl
ECU’S SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates
the engine under substitute characteristics and illuminates the engine trouble warning light to
alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected,
a fault code is stored in the memory of the ECU.
1
8 To inform the rider that the fuel injection system is not functioning correctly, the engine
trouble warning light flashes when the start
switch is being pushed to start the engine.
8 If a malfunction is detected in the system
by the self-diagnostic function, this mode
provides an appropriate substitute characteristic operation, and alerts the rider of the
detected malfunction by illuminating the engine trouble warning light.
8 After the engine has been stopped, the lowest fault code number appears on the engine trouble warning light (or displayed on
the Fl diagnostic tool). It remains stored in
the memory of the ECU until it is deleted.
Engine trouble warning light
Engine trouble warning light fault code indication
Digit of 10: Cycles of 1 see. ON and 1.5 sec. OFF.
Digit of 1: Cycles of 0.5 sec, ON and 0.5 sec. OFF.
<Example> 42
Light ON
Light OFF
1
1.5
1
1.5
1
1.5
1
1.5 0.5 0.5 0.5
3
EAS00900
Engine trouble warning light indication and Fl system operating condition
Engine condition
Operate
(cranking with electric
starter)
Stop
Warning light
indication
Flashing
Remains ON
Fl operation
Vehicle operation
Operation stopped
Unable
Operated with substitute char- Able
acteristics in accordance with
the description of the malfunction
Flashing
(indicate the fault code)
_
7-4
_
FUEL INJECTION SYSTEM
FI
ifl
EAS00901
CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB
The engine trouble warning light comes on for 2 seconds after the main switch has been turned “ON”
and when the start switch is being pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective.
Main switch
OFF
Engine trouble
warning light
Main switch
ON
Light
OFF
Light ON for
2 seconds
Light
OFF
Intialize
EAS00902
SELF-DIAGNOSTIC FANCTION TABLE
If the ECU detects an abnormal signal from a sensorwhile the vehicle is being driven, the ECU
illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that
are programmed for each sensor in order to provide the engine with alternate operating instructions
that enable the engine to continue to operate or stop operating, depending on the conditions.
Self-diagnostic fanction table
Fault
code No.
12
Crankshaft position sensor
13
14
Intake air pressure sensor
(open or short circuit) (pipe
system)
15
16
19
Symptom
Engine
startability
Vehicle
driveability
No normal signals are received from the
crankshaft position sensor.
Intake air pressure sensor-open or short
circuit detected.
Faulty intake air pressure sensor pipe system.
Throttle position sensor-open or short circuit detected.
A stuck throttle position sensor is detected.
Open circuit in the input line (blue/yellow
lead) of the ECU is detected.
Coolant temperature sensor-open or short
circuit is detected.
Intake temperature sensor-open or short
circuit is detected.
Open circuit detected in the primary lead
of the ignition coil.
Engine speed is high when the engine is
idling.
Unable
Unable
Able
Able
Able
Able
Unable
Unable
Able
Able
Able
Able
Unable
Unable
Able
Able
Item
Throttle position sensor
(open or short circuit)(stuck)
21
Broken or disconnected blue/
yellow lead of the ECU
Coolant temperature sensor
22
Intake temperature sensor
33
Faulty ignition
37
ISC (idle speed control) valve
(stuck fully open)
7-5
FUEL INJECTION SYSTEM
Fault
code No.
39
Fuel injector
30
41
Lean angle cut-off switch
(latch up detected) (open or
short circuit)
Speed sensor
42
43
44
46
50
61
_
Symptom
Engine
startability
Vehicle
driveability
Fuel injector open or short circuit is detected.
The vehicle has overturned.
Lean angle cut-off switch-open or short circuit is detected.
No normal signals are received from the
speed sensor.
Power supply to the fuel injector, fuel pump
and ignition coil are not normal.
An error is delected while reading from or
writing on E2PROM (CO adjustment
value).
Power supply to Fl system is not normal.
(red lead)
Faulty ECU memory. When this malfunction is detected, the code number might
not appear on the engine trouble warning
light or displayed on Fl diagnostic tool.
ISC (idle speed control) valve unit-open or
short circuit detected.
Relay is not activated even if the crank
signal is input while the start switch is
pushed.
Unable
Unable
Unable
Unable
Able
Able
Able
Able
Able
Able
Able
Able
Unable
Unable
Able
Able
Unable
Unable
Item
Fuel system voltage (monitoring voltage)
Error in reading from or writing on E2PROM
Vehicle system power supply (monitoring voltage)
ECU internal malfunction
(memory check error)
ISC (idle speed control) valve
unit (open or short circuit)
Start unable warning
Engine trouble warning light
flashes when the start
switch is turned ON.
7-6
FUEL INJECTION SYSTEM
FI
ifl
EAS00904
TROUBLESHOOTING CHART
Engine operation is not normal or the engine trouble warning light is on.
*Engine trouble warning light may not come on even if the engine operation is not normal.
I
I
I
The engine trouble warning light does not come on.
The engine trouble warning light comes on.
T
Check the operation of following sensors and actuators in the diagnostic mode. Refer to “Diagnostic mode table”.
33: Ignition coil
39: Fuel injector
Check the fault code number displayed on the Fl
diagnostic tool.
I
Identify the system with the malfunction. Refer to
“FAIL-SAFE ACTIONS TABLE”.
T
Identify the probable cause of malfunction. Refer
to “Fault code table”.
T
Check and repair the probable cause of malfunction.
Faultcode No.YES
Check and repair.
Refer to “TROUBLE
SHOOTING DETAILS”.
Monitor the operation
of the sensors and
actuators in the diagnostic mode. Refer to
“Diagnostic mode
table”.
Faultcode No. NO
Check and repair.
Refer to “FAIL-SAFE
ACTIONS TABLE”.
Parform ECU reinstatement action. Refer to “Reinstatement method” in ‘TROUBLESHOOTING DETAILS”.
Fault code number
displayed
Turn the main switch to “OFF”, turn the main switch
back to “ON”, and then check if the fault code number is still displayed.
X
Fault code number not displayed
Repairs completed
Erasing the malfunction history:*
The malfunction history is stored even if the main switch is turned OFF.
The malfunction history must be erased in the diagnostic mode. Referto “Diagnostic mode table (Diagnostic
code No.62)”.
* Operated when the engine trouble warning light is on.
7-7
FUEL INJECTION SYSTEM
FI
ifl
EAS00905
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators with connecting the Fl diagnostic tool to the normal mode
or the diagnostic monitoring mode.
<P
Fl diagnostic tool
90890-03182
YU-03182
Setting the normal mode
NOTE:
The engine speed, engine temperature, and fault
code, if detected, can be displayed on the LCD
of the Fl diagnostic tool when the tool is connected to the vhicle and is set to the normal
mode.
1. Turn the main switch to “OFF” and the engine stop switch to “RUN”.
2. Disconnect the self diag signal connector
1 , and then connect the Fl diagnostic tool
2 as shown.
3. Turn the main switch to “ON” and start the
engine.
NOTE:
8 Engine temperature and engine revolution
appears on the LCD of the Fl diagnostic tool.
8 ”POWER” LED (Green) comes on.
8 If a malfunction is detected in the system,
“WARNING” LED (Orange) comes on. How
ever the fault code is not appears on the
LCD of Fl diagnostic tool.
O POWER OWARNING
Fl Diagnostic Tool
©YAMAHA
2100rpm 60° C
oo
UP
MODE
DOWN
(
D
OPOWER OWARNING
Fl Diagnostic Tool
4. Stop the engine.
NOTE:
If a malfunction is detected in the system, the
fault code appears on the LCD of the Fl diagnostic tool. And also, “WARNING” LED(Orange)
comes on.
« YAM AHA'
Orpm 60 °C
S/D:
12
UP
MODE
DOWN
O O (D
5. Turn the main switch to “OFF” to cancel the
normal mode.
6. Disconnect the Fl diagnostic tool and connect the self diag signal connector.
7-8
FUEL INJECTION SYSTEM
FI
ifl
Setting the diagnostic mode
1. Turn the main switch to “OFF” and the engine stop switch to “RUN”..
2. Disconnect the self diag signal connector
1 , and then connect the Fl diagnostic-tool
2 as shown.
3. While press the “MODE” button, turn the
main switch to “ON”.
NOTE:
8 ”DIAG” appears on the LCD of the Fl diagnostic tool.
8 ”POWER” LED (Green) comes on.
4. Press the “UP” button to select the CO adjustment mode “CO” or the diagnostic mode
“DIAG”.
5. After selecting “DIAG”, press the “MODE”
button.
6. Select the diagnostic code number that applies to the item that was verified with the
fault code number by pressing the “UP” and
“DOWN” buttons.
NOTE:
8 The diagnostic code number appears on the
LCD (D01-D70).
8 To decrease the selected diagnostic code
number, press the “DOWN” button. Press
the “DOWN” button for 1 second or longer
to automatically decrease the diagnostic
code numbers.
8 To increase the selected diagnostic code
number, press the “UP” button. Press the
“UP” button for 1 second or longer to automatically increase the diagnostic code numbers.
OPOWER OWARNING
Fl Diagnostic Tool
D03:
©YAMAHA
101
o oo
JP
MODE
DOWN
7. Verify the operation of the sensor or actuator.
8Sensor operation
The data representing the operating conditions of the sensor appears on the LCD.
8Actuator operation
Press the “MODE” button to.operate the
actuator.
8. Turn the main switch to “OFF” to cancel the
diagnostic mode.
9. Disconnect the Fl diagnostic tool and connect the self diag signal connector.
7-9
FUEL INJECTION SYSTEM
FI
Fault code table
Fault
codeNo.
Symptom
No normal signals are received from
the crankshaft position sensor.
12
Intake air pressure sensor-open or
short circuit detected.
13
14
Faulty intake air pressure sensor
pipe system
Throttle position sensor-open or
short circuit detected.
15
16
19
21
A stuck throttle position sensor is
detected.
Open circuit in the input line (blue/
yellow lead) of ECU is detected
when the start switch is pressed.
Coolant temperature sensor-open
or short circuit detected.
Intake air temperature sensor-open
or short circuit detected.
22
30
33
The vehicle has overturned.
Open circuit is detected in the primary lead of the ignition coil.
37
The ISC (idle speed control) valve
is stuck fully open.
39
Fuel injector open or short circuit is
detected.
41
Lean angle cut-off switch-open or
short circuit detected.
42
43
44
46
50
61
No normal signals are received from
the speed sensor.
Power supply to the fuel injector, fuel
pump and ignition coil are not normal.
An error is detected while reading
or writing on E2PROM.
Power supply to Fl system is not
normal.(red lead)
Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the
meter.
ISC (idle speed control) valve open
or short circuit is detected.
Probable cause of malfunction
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Open or short circuit in wiring harness.
Defective crankshaft position sensor.
Malfunction in pickup rotor.
Improperly installed sensor lead connector in the
coupler.
Open or short circuit in wiring sub lead.
Open orshort circuit in wiring harness.
Defective intake air pressure sensor.
Improperly installed sendor lead connector in the
coupler.
Intake air pressure sensor is disconnected or
clogged.
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective throttle position sensor.
Improperly installed throttle’position sensor lead connector in the coupler.
Stuck throttle position sensor.
Defective throttle position sensor.
Open circuit in wiring harness (ECU coupler).
Diagnostic code
_
D03
D03
D01
D01
D20
• Open or short circuit in wiring harness.
• Defective coolant temperature sensor.
• Improperly installead sensor lead connector in the
coupler.
• Open or short circuit in wire sub lead.
• Open or short circuit in wiring harness.
• Defective intake temperature sensor.
• Improperly installed sensor lead connector in the
coupler.
• Overturned condition.
• Open circuit in wiring harness.
• Malfunction in ignition coil.
• Improperly installed primary lead connector in the
coupler.
• Malfunction in throttle body.
• Malfunction in throttle cables.
• ISC (idle speed control) valve is stuck fully open.
• Open or short circuit in wiring harness.
• Defective fuel injector.
• Improperly installed lead connector in the coupler.
• Open or short circuit in wiring harness.
• Defective lean angle cut-off switch.
• Improperly installed lead connector in the coupler.
• Open or short circuit in wiring harness.
• Defective speed sensor.
• Improperly installead lead connector in the coupler.
• Open or short circuit in wiring harness.
D06
D06
D08
D30
D54
D36
D08
D07
D09
• Malfunction in ECU. (The CO adjustment value, code
reregistering key code, and throttle valve fully closed
notification value are not properly written on or read
from the internal memory.)
• Malfunction in charging system.
• Malfunction in ECU. (The program and data are not
properly written on or read from the internal memory.)
• Open or short circuit in wiring harness.
• Improperly installed lead connector in the coupler.
7-10
D60
_
_
D54
FUEL INJECTION SYSTEM
FI
ifl
EAS00907
Diagnostic mode table
NOTE:
8 Check the intake air temperature and coolant temprature as close as possible to the intake air
temperature sensor and the coolant temperature sensor respectively.
8 If it is not possible to check the intake air temperature, use the ambient temperature as reference.
Diagnostic
code
Item
Description of action
Throttle angle
D01
D03
Intake air pressure
D05
Intake air temperature
D06
Coolant temperature
Vehicle speed pulse
D07
D08
D09
D20
Lean angle cut-off
switch
Fuel system voltage
(battery voltage)
Sidestand switch (Option)
Ignition coil
D30
Fuel injector
D36
Headlight
D52
ISC (idle speed control) valve
D54
E2PROM fault code
display.
D60
Malfunction
code display
history
D61
Malfunction history
code erasure
D62
D70
Control number
Displays the throttle angle.
• Check with throttle fully closed.
• Check with throttle fully open.
Displays the intake air pressure.
• Check the pressure in the intake manifold.
Displays the intake air temperature.
• Check the temperature in the intake manifold.
Displays the coolant temperature.
• Check the temperature of the coolant.
Displays the accumulation of the vehicle pulses
that are generated when the tire is spun.
Displays the lean angle cut-off switch values.
Displays the fuel system voltage (battery voltage).
Displays that the switch is ON or OFF.
When the “MODE” button is pressed, the ignition
coil is actuated five times per second and the
“WARNING” LED (orange) comes on.
• Connect an ignition checker.
When the “MODE”-button is pressed, the fuel
injector is actuated five times per second and the
“WARNING” LED (orange) comes on.
When the “MODE” button is pressed, the headlight is actuated five times every 5 seconds and
the engine trouble warning light comes on. (ON 2
seconds, OFF 3 seconds)
When the the “MODE” button is pressed, the ISC
(idle speed control) valve fully closes, and then it
opens until it is at the standby opening position
when the engine is started. This operation takes
approximately 3 seconds until it is completed.
• Transmits the abnormal portion of the data in
the E2PROM that has been detected as a fault
code 44.
• If multiple malfunctions have been detected,
different codes are displayed at 2-second intervals, and this process is repeated.
• Displays the codes of the history of the selfdiagnosis malfunctions (i.e., a code of a malfunction that occurred once and which has been
corrected).
• If multiple malfunctions have been detected,
different codes are displayed at 2-second intervals, and this process is repeated.
• Displays the total number of codes that are
being detected through self diagnosis and the
fault codes in the past history.
• Erases only the history codes when the
“MODE” button is pressed.
Displays the program control number.
7-11
Data displayed on FI diagnostic tool
(reference value)
0-125 degrees
• Fully closed position (14-20)
• Fully open position (97-107)
Compare it to the value displayed on the
Fl diagnostic tool.
Compare it to the value displayed on the
Fl diagnostic tool.
Compare it to the value displayed on the
FI diagnostic tool.
(0-999; resets to 0 after 999)
OK if the numbers appear on the FI diagnostic tool.
Upright: 0.4-1.4 V
Overturned: 3.7-4.4V
0-18.7 V
Normally, approximately 12.0 V
Stand retracted: ON
Stand extended: OFF
Check that spark is generated, 5 times
with the “MODE” button press.
Check the operating sound of the fuel injector five times with “MODE” button
press.
Check the headlight operating 5 times with
the “MODE” button is pressed.
The ISC (idle speed control) valve unit
vibrates when the ISC (idle speed control) valve operates.
01 CO adjustment value is detected.
(00) Displays when there is no malfunction.
12-61
(00) Displays when there is no malfunction.
00-18
(00) Dispiays when there is no malfunction.
00-254
FUEL INJECTION SYSTEM
Communication error with the FI diagnostic tool
LCD Display
Sympton
Waiting for connection...
No signals are received from the
ECU.
ERROR 4
Commands from the Fl diagnostic
tool are not accepted by the ECU.
Probable cause of malfunction
•
•
•
•
•
Improper installed lead connector in the coupler.
The main switch is OFF position.
Malfunction in Fl diagnostic tool.
Malfunction in ECU.
Turn the main switch to “OFF” once, and then turn it back to CO
adjustment mode or diagnostic mode.
• Vehicle battery is insufficiently charged.
• Malfunction in Fl diagnostic tool.
• Malfunction in ECU.
EAS00908
TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the Fl diagnostic
tool. Check and service the items or components that are the probable cause of the malfunction
following the order given.
After the check and service of the malfunctioned part has been completed, reset the Fl diagnostic
tool display according to the “Reinstatement method”.
Fault code No.:
Fault code number displayed on the Fl diagnostic tool when the engine failed to work normally.
Refer to “Fault code table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC MODE”.
7-12
FUEL INJECTION SYSTEM
Fault code No.
12
Symptom
FI
ifl
No normal signals are received from the crankshaft position sensor.
Used diagnostic code No. -Order
Inspection operation item and
probable cause
1
Installed condition of sensor.
2
Connected condition of connector.
Inspect the coupler for any
pins that may have pulled
out.
Check that the coupler is
connected securely.
NOTE:
Set the main switch to OFF
before connecting or disconnecting the connector.
3
Open or short circuit in wiring
harness.
4
Defective crankshaft position
sensor.
Operation item and countermeasure
Check the installed area for looseness or
pinching.
If there is a malfunction, repair it and connect
it securely.
Crankshaft position sensor coupler
Main wiring harness ECU coupler
Repair or replace if there is an open or short
circuit between the main wiring harnesses.
Between sensor coupler and ECU coupler.
white/red
black/blue
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
7-13
Reinstatement
method
Reinstated by cranking the engine.
FUEL INJECTION SYSTEM
Fault code No.
13
Symptom
FI
ifl
Intake air pressure sensor-open or short circuit detected.
Used diagnostic code No. D03 (intake air pressure sensor)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
1
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
NOTE:
Set the main switch to OFF
before connecting or disconnecting the connector.
If there is a malfunction, reper it and connect
it securely.
Intake air pressure sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in wiring
harnes and /or sub lead.
3
Defective intake air pressure
sensor.
Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler
black/blue - black/blue
pink/white - pink/whte
blue- blue
Execute the diagnostic mode (code No. D03)
Replace the throttle body.
NOTE:
Do not remove the sensor assembly (MAQS).
1. Connect the digital circuit tester to the intake air pressure sensor coupler as shown.
Positive tester probe -» pink/white 0
Negative tester prove -» black/blue (2)
^T^S,
Br/W P/W
B/L
Y
L
YZZZ^
^
^
© ©
n •
•
nn
•
•
2. Set the main switch to “ON”.
3. Measure the intake air pressure sensor output voltage.
n.
Intake air pressure sensor output
voltage
3.9~4.1V
4. Is the intake air pressure sensor OK?
7-14
Reinstatement
method
Reinstated by turning the main switch
ON.
FUEL INJECTION SYSTEM
FI
ifl
Intake air pressure sensor-hose system malfunction
(clogged or detached hose).
tached hose).
Used diagnostic code No. D03 (intake air pressure sensor)
Fault code No.
Order
1
2
14
Symptom
Inspection operation item and
probable cause
Connected state of connector
Intake air pressure sensor coupler
Main wirring harness ECU coupler
Sub-wire harness coupler
Defective intake air pressure
sensor.
Operation item and countermeasure
Check the coupler for any pins that may have
pulled out.
Check that the coupler is connected securely.
If there is a malfunction, repair it and connect
it securely.
Reinstatement
method
Reinstated by starting the engine and
operating it at idle.
Execute the diagnostic mode (code No. D03)
Replace the throttle body.
NOTE:
Do not remove the sensor assembly (MAQS).
Refer to “Fault code No. 13”.
Fault code No.
15
Symptom
Throttle position sensor-open or short circuit detected.
Used diagnostic code No. D01 (throttle position sensor)
Order
Inspection operation item and
probable cause
1
Installed condition of throttle
position sensor.
2
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Open or short circuit in wiring
harness and/or sub lead.
3
4
Defective throttle position sensor.
Operation item and countermeasure
Check the installed area for looseness or
pinching.
Check that it is installed in the specified position.
Refer to “THROTTLE BODY AND FUEL INJECTOR”.
If there is a malfunction, repair it and connect
it securely.
Throttle position sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler
black/blue - black/blue
yellow - yellow
blue -blue
Execute the diagnostic mode (code No. D01)
Replace the throttle body.
NOTE:
Do not remove the sensor assembly (MAQS).
Refer to “THROTTLE BODY AND FUEL INJECTOR ”.
7-15
Reinstatement
method
Reinstated by turning the main switch
ON.
FUEL INJECTION SYSTEM
Fault code No.
16
Symptom
FI
ifl
Stuck throttle position sensor detected.
Used diagnostic code No. D01 (throttle position sensor)
Order
Inspection operation item and
probable cause
1
Installed condition of throttle
position sensor.
2
Defective throttle position sensor
3
When fault code No.15 has
been detected
Fault code No.
19
Symptom
Operation item and countermeasure
Check the installed area for looseness or
pinching.
Check that it is installed in the specified position.
Refer to “THROTTLE BODY AND FUEL INJECTOR ”.
Execute the diagnostic mode (code No. 01)
Replace the throttle body.
NOTE:
Do not remove the sensor assembly (MAQS).
Refer to “THROTTLE BODY AND FUEL INJECTOR ”.
Refer to “Fault code No.15”.
Reinstatement
method
Reinstated by starting the engine, operating it at idle, and
then racing it.
Refer to “Fault code
No. 15”.
Open circuit in the input line of ECU (blue/yellow lead) detected.
Used diagnostic code No. D20 (sidestand switch :option)
Order
Inspection operation item and
probable cause
1
Connected state of connector
Main wiring harness ECU coupler
(blue/yellow connector)
2
Open or short circuit in wiring
harness and/or sub lead.
Operation item and countermeasure
Execute the diagnostic mode (code No. D20)
Check the coupler for any pins that may have
pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect
it securely.
Repair or replace if there is an open circuit.
Between main switch coupler and ECU coupler.
blue/yellow - blue/yellow
Sidestand switch signal input line of main
switch coupler.
blue/green - blue/green
7-16
Reinstatement
method
Reinstated by reconnecting the wiring
and retracting the
sidestand.
FUEL INJECTION SYSTEM
Fault code No.
21
Symptom
FI
ifl
Coolant temperature sensor open or short circuit is detected.
Used diagnostic code No. D06 (coolant temperature sensor)
Order
Inspection operation item and
probable cause
1
Installed condition of sensor
2
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Open or short circuit in wiring
harness.
3
4
Defective coolant temperature
sensor.
Operation item and countermeasure
Check the installed area for looseness or
pinching.
If there is a malfunction, repair it and connect
it securely.
Coolant temperature sensor coupler
Main wiring harness ECU coupler
Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler
black/blue-black/blue
green/red - green/red
Execute the diagnostic mode (code No.D06)
Replace if defective.
Refer to “COOLING SYSTEM” in chapter 8.
7-17
Reinstatement
method
Reinstated by turning the main switch
ON.
FUEL INJECTION SYSTEM
Fault code No.
22
Symptom
FI
ifl
Intake temperature sensor open or short circuit is detected.
Used diagnostic code No. D05 (intake air temperature sensor)
Order
Inspection operation item and
probable cause
1
Installed condition of sensor
2
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Open or short circuit in wireing
harness and/or sub lead.
3
4
Defective intake air temperature sensor.
Operation item and countermeasure
Check the installed area for looseness or
pinching.
If there is a malfunction, repair it and connect
it securely.
Intake air temperature sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler
black/blue - black/blue
brown/white - brown/white
Execute the diagnostic mode (code No. D05)
Replace the throttle body.
NOTE:
Do not remove the sensor assembly (MAQS).
1. Connect the digital circuit tester to the intake air temperature sensor terminal as
shown.
Positive tester probe -» brown/white 1
Negative tester probe -» black/blue 2
2. Measure the intake air temperature sensor
resistance.
n„
Intake air temperature sensor resistance
2.4~2.9k at 20°C (68°F)
w
8 Handle the intake air temperature sensor with special care.
8 Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace
it.
3. Is the intake air temperature sensor OK?
7-18
Reinstatement
method
Reinstated by turning the main switch
ON.
FUEL INJECTION SYSTEM
Fault code No.
30
FI
ifl
The vehicle has overturned.
Symptom
Used diagnostic code No. D08 (lean angle cut-off switch)
Order
1
2
3
4
Inspection operation item and
probable cause
The vehicle has overturned.
Installed condition of the lean
angle cut-off switch
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Defective lean angle cut-off
switch
Operation item and countermeasure
Reinstatement
method
Raise the vehicle upright.
Check the installed area for looseness or
pinching.
If there is a malfunction, repair it and connect
it securely.
Lean angle cut-off switch coupler
Main wiring harness ECU coupler
Reinstated by turning the main switch
ON (however, the
engine cannot be
restarted unless the
main switch is first
turned OFF).
Execute the diagnostic mode (code No. D08)
Replace if defective.
1. Remove the lean angle cut-off switch from
the vehicle.
2. Connect the lean angle cut-off switch coupler to the wire harness.
3. Connect the digital circuit tester to the lean
angle cut-off switch terminals as shown.
4. When turning the lean angle cut-off switch
approximately 65°, the voltage reading
change from 0.4 V to 4.4 V.
5. Is the lean angle cut-off switch OK?
7-19
FUEL INJECTION SYSTEM
Fault codeNo.
33
Symptom
FI
ifl
Open circuit detected in the primary lead of the ignition coil.
Used diagnostic code No. D30
Order
1
2
3
Inspection operation item and
probable cause
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Open or short circuit in lead.
Defective ignition coil (test the
primary and secondary coils for
continuity).
Fault code No.
37
Symptom
Operation item and countermeasure
If there is a malfunction, repair it and connect
it securely.
Ignition coil primary side coupler - orange
Main wiring harness ECU coupler
Reinstatement
method
Reinstated by starting the engine and
operating it at idle.
Repair or replace if there is an open or short
circuit.
Between ignition coil coupler and ECU coupler/main harness
orange - orange
Execute the diagnostic mode (code No. D30)
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Engine speed is high when the engine is idling.
Used diagnostic code No. D54 (ISC (idle speed control) valve)
Order
Inspection operation item and
probable cause
1
Incorrect speed sensor signal
2
Throttle valve does not fully
close
ISC (idle speed control) valve
stuck fully open
3
ISC (idle speed control) valve
not moving correctly
4
Operation item and countermeasure
Check the speed sensor.
Check the speed sensor leads.
Check the speed sensor coupler.
Check the throttle body.
Refer to “THROTTLE BODY ASSEMBLY AND
FUEL INJECTOR ASSEMBLY” .
Check the throttle cables.
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
The ISC (idle speed control) valve is stuck
fully open if it does not operate when the main
switch is set to OFF.
(Touch the ISC (idle speed control) valve unit
with your hand and check if it is vibrating to
confirm if the ISC (idle speed control) valve
is operating.)
NOTE:
Do not remove the ISC (idle speed control)
valve unit.
Execute the diagnostic mode (code No. D54)
After the ISC (idle speed control) valve is fully
closed, it opens until it is at the standby opening position when the engine is started. This
operation takes approximately 3 seconds until it is completed. Start the engine. If the error recurs, replace the throttle body assembly.
7-20
Reinstatement
method
Reinstated if the engine idle speed is
within specification
after starting the
engine.
FUEL INJECTION SYSTEM
Fault code No.
39
Symptom
FI
ifl
Fuel injector open or short circuit is detected.
Used diagnostic code No. D36 (fuel injector)
Order
1
2
3
Inspection operation item and
probable cause
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Open or short circuit in lead
wire.
Defective fuel injector
Fault code No.
41
Symptom
Operation item and countermeasure
If there is a malfunction, repair it and connect
it securely.
Fuel injector coupler - orange/black
Main wiring harness ECU coupler
Reinstatement
method
Reinstated by starting the engine.
Repair or replace if there is an open or short
circuit.
Between fuel injector coupler and ECU coupler/main harness
orange/black - orange/black
Execute the diagnostic mode (code No. D36)
Replace if defective.
Lean angle cut-off switch open or short circuit is detected.
Used diagnostic code No. D08 (lean angle cut-off switch)
Order
1
2
3
Inspection operation item and
probable cause
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Open or short circuit in wiring
harness.
Defective lean angle cut-off
switch
Operation item and countermeasure
If there is a malfunction, repair it and connect
it securely.
Lean angle cut-off switch coupler
Main wiring harness ECU coupler
Repair or replace if there is an open or short
circuit.
Between switch coupler and ECU coupler
black/blue - black/blue
yellow/green - yellow/green
blue- blue
Execute the diagnostic mode (code No. D08)
Replace if defective.
Refer to Fault code No. 30.
7-21
Reinstatement
method
Reinstated by turning the main switch
ON.
FUEL INJECTION SYSTEM
Fault code No.
42
Symptom
FI
ifl
No normal signals are received from the speed sensor.
Used diagnostic code No. D07 (speed sensor)
Order
1
2
Inspection operation item and
probable cause
Connected condition of speedometer connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Open or short circuit in speedometer lead.
3
Breakage speedometer cable or
speedometer gear unit.
4
Defective speed sensor.
Operation item and countermeasure
Reinstatement
method
If there is a malfunction, repair it and connect
it securely.
Speedometer coupler
Main wiring harness ECU coupler
Reinstated by inputting the vehicle speed
signals by turning the
front wheel.
Repair or replace if there is an open or short
circuit.
Between speedometer coupler and ECU coupler
white - white
black/blue - black/blue
Execute the diagnostic mode (code No.D07)
Checking the speedometer cable breakage
and loose connection.
Checking the movement of the speedometer
gear unit 1 .
Checking the breakage of the speedometer
clutch projections a and speedometer gear
unit slots b .
Execute the diagnostic mode (code No. D07)
Replace the meter assembly.
7-22
FUEL INJECTION SYSTEM
Fault code No.
43
Symptom
FI
ifl
Power supply to the fuel injector, fuel pump and ignistion coil are not
normal.
Used diagnostic code No. D09 (fuel system voltage)
Order
1
2
3
Inspection operation item and
probable cause
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Faulty battery
Open or short circuit in wiring
harness.
Operation item and countermeasure
Reinstatement
method
If there is a malfunction, repair it and connect Reinstated by startit securely.
ing the engine and
ECU coupler
operating it at idle.
Replace or charge the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Execute the diagnostic mode (code No. D09)
NOTE:
When the leads are disconnected, the voltage check by the code No. D09 is impossable.
Repair or replace if there is an open or short
circuit.
8 Between battery and main switch
red-red
8 Between main switch and handlebar switch
(engine stop switch)
brown-brown
8 Between handlebar switch (engine stop
switch) and ECU
red/white-red/black
Fault code No.
44
Symptom
Error is detected while reading from or writing on EEROM (code reregistering key code and throttle valve fully closed notification valve).
Used diagnostic code No. D60 (EEPROM improper cylinder indication)
Order
1
Inspection operation item and
probable cause
Malfunction in ECU
Operation item and countermeasure
Execute the diagnostic mode (code No. D60)
8 01 is displayed on meter.
Readjust the CO of the displayed cylinder.
Refer to “ADJUSTING THE EXHAUST
GAS VOLUME” in chapter 3.
Replace ECU if defective.
7-23
Reinstatement
method
Reinstated by turning the main switch
ON.
FUEL INJECTION SYSTEM
Fault code No.
46
Symptom
FI
ifl
Power supply to FI system is not normal. (red lead)
Used diagnostic code No. -Order
1
2
3
4
Inspection operation item and
probable cause
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Faulty battery
Malfunction in rectifier/ regulator
Open or short circuit in wiring
harness.
Fault code No.
50
Symptom
Operation item and countermeasure
Reinstatement
method
If there is a malfunction, repair it and connect
it securely.
ECU coupler
Reinstated by starting the engine and
operating it at idle.
Replace or charge the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Replace if defective.
Refer to “CHARGING SYSTEM” in chapter 8.
Repair or replace if there is an open or short
circuit.
Between battery and ECU
red-red
Faulty ECU memory. (when this malfunction is detected in the ECU, the
fault code number might not appear on the meter.)
Used diagnostic code No. -Order
1
Inspection operation item and
probable cause
Malfunction in ECU
Operation item and countermeasure
Replace the ECU.
7-24
Reinstatement
method
Reinstated by turning the main switch
ON.
FUEL INJECTION SYSTEM
Fault code No.
61
Symptom
FI
ifl
ISC (idle speed control) valve open or short circuit is detected.
Used diagnostic code No. -Order
1
2
3
Inspection operation item and
probable cause
Connected condition of connector
Inspect the coupler for any
pins that may have pulled
out.
Check the locking condition
of the coupler.
Open or short circuit in lead.
Detective ISC (idle speed control) valve
Operation item and countermeasure
If there is a malfunction, repair it and connect
it securely.
ISC (idle speed control) valve coupler
Main wiring harness ECU coupler
Repair or replace if there is an open or short
circuit.
Between ISC (idle speed control) valve and
ECU coupler/main harness
pink- pink
green/yellow-green/yellow
gray - gray
sky blue-sky blue
Execute diagnostic mode (code No.D54)
Replace the throttle body.
NOTE:
Do not remove the ISC (idle speed control)
valve.
Refer to “THROTTLE BODY AND FUEL INJECTOR ”.
7-25
Reinstatement
method
Reinstated by setting the main switch
to ON, The ISC (idle
speed control) valve
fully closes, and
then it opens until it
is at the standby
opening position
when the engine is
started.
THROTTLE BODY AND FUEL INJECTOR
FI
ifl
EAS00909
THROTTLE BODY AND FUEL INJECTOR
THROTTLE BODY
Order
Job/Part
Removing the throttle body
Side cover(left and right)
Single seat/Trunk
Air filter assembly
1
2
3
4
5
6
Remarks
Q’ty
Throttle body clamp screw
MAQS(modulated air quantity sensor)
coupler
ISC (idle speed control) valve coupler
Throttle cable
Throttle body
Sub-wire harness
1
1
1
2
1
1
Remove the parts in the order listed.
Refer to “COVER AND PANEL”in chapter 3.
Refer to"ENGINE REMOVAL" in chapter 5.
Lossen.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
7-26
THROTTLE BODYAND FUEL INJECTOR
FI
ifl
FUEL INJECTOR AND FUEL HOSE
Order
Job/Part
Removing the fuel injector and fuel
hose
Footrest board
1
2
3
4
5
6
7
8
Remarks
Q’ty
Fuel pump coupler
Fuel hose connector cover
Fuel hose connector
Fuel hose holder(to frame)
Fuel hose holder(to intake manifold)
Clamp
Fuel injector coupler
Fuel injector
Remove the parts in the order listed.
Refer to”COVER AND PANEL”in chap1
1
1
1
1
1
1
1
ter 3.
Disconnect.
Open lock.
Disconnect.
For installation, reverse the removal procedure.
7-27
THROTTLE BODYAND FUEL INJECTOR
FI
ifl
FUEL TANK
«& 4Nm(0.4m • kg, 2.9 ft • lb)
Order
Job/Part
Q’ty
Removing the fuel tank
Remarks
Remove the parts in the order listed.
Place the scooter on a suitable stand.
Fuel hose
1
Fuel tank
1
2
Fuel pump
1
7-28
Refer to “FUEL INJECTOR AND FUEL
HOSE”.
Refer to “REMOVING THE FUEL
HOSE”.
Refer to “REMOVING THE FUEL
PUMP”and “INSTALLING THE FUEL
PUMP”.
For installation, reverse the removal procedure.
THROTTLE BODY AND FUEL INJECTOR
FI
ifl
REMOVING THE FUEL HOSE
1. Extract the fuel in the fuel tank through the
fuel tank filler hole with a pump.
2. Remove:
8fuel hose connector cover 1
3. Disconnect:
8fuel hose 2
cC
8 Be sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the
hose with tools.
8 Although the fuel has been removed
from the fuel tank, be careful when removing the fuel hose, since there may
be fuel remaining in it.
8 Do not disconnect the fuel hose from the
fuel hose connector. Disconnect the connector from the fuel pump.
NOTE:
Before removing the hose, place a few rags in
the area under where it will be removed.
3. Remove:
8fuel tank
REMOVING THE FUEL PUMP
1. Disconnect:
8 fuel pump coupler
8 fuel hose
2. Remove:
8 fuel pump
cC
8 Do not drop the fuel pump or give it a
strong shock.
8 Do not touch the base section of the fuel
sender.
EAS00911
cC
The fuel pump should not be disassembled.
7-29
THROTTLE BODY AND FUEL INJECTOR
FI
ifl
EAS00912
CHECKING THE FUEL INJECTOR
1. Check:
8 fuel injector
Damage -» Replace.
EAS00913
CHECKING THE THROTTLE BODY
1. Check:
8 throttle body
Cracks/damage -» Replace the throttle
body.
2. Check:
8 butterfly valve
Damage/scratches/wear -» Replace.
C
Do not adjust the stop screw 1
Do not clean the throttle body using carburetor cleaner or compressed air.
When replace the throttle body, the main
switch is operated three times turn ON
and OFF position.
(ON position : 3 seconds more, OFF position : 3seconds more). And then, start
the engine and keep idling at 10 minutes
more.
7-30
THROTTLE BODY AND FUEL INJECTOR
FI
ifl
INSTALLING THE FUEL PUMP
1. Install:
8 fuel pump
X | 4Nm(0.4m»kg, 2.9ft*Ib)
NOTE:
8 Do not damage the installation surfaces of
the fuel tank when installing the fuel pump.
8 Always use a new fuel pump gasket.
8 Align the projection a on the fuel pump with
the alignment mark b on the fuel tank.
8 Tighten the fuel pump bolts in the proper
tightening sequence as shown and torque
them in two stages.
A
Forward
INSTALLING THE FUEL HOSE
1. Install:
8fuel hose
8fuel hose connector cover
cC
Be sure to connect the fuel hose securely
and install the fuel hose connector cover in
the correct position, otherwise the fuel hose
will not be properly installed.
NOTE:
8 Install the fuel hose connector securely onto
the fuel tank until a distinct “click” is heard,
and then make sure that it does not come
loose.
8 After installing the fuel hose connector
cover 1 , make sure that it is installed securely.
7-31
THROTTLE BODY AND FUEL INJECTOR
FI
ifl
EAS00915
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION
1. Check:
8 pressure regulator operation
• • • • • • • • • • • • • • • • • • • • • • •
a. Remove the footrest board.
Refer to “COVER AND PANEL” in chapter
3.
b. Remove the fuel hose connector cover (T)
and disconnect the fuel hose (2) from the
fuel pump.
C
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
NOTE:
Before removing the hose, place a few rags in
the area under where it will be removed.
c. Connect the pressure gauge (3) and adapter
(4) onto the fuel hose.
(tj//^ Pressure gauge
/f~"^
90890-03153
YU-03153
Adapter
90890-03181
d. Start the engine.
e. Measure the fuel pressure.
^
Fuel pressure
246 ~ 254 kPa
(2.46 ~ 2.54 kg/cm2, 35.0 ~ 36.1 psi)
Faulty -» Replace the fuel pump.
• • • • • • • • • • • • • • • • • • • • • • •
EAS0091 6
CHECKING THE THROTTLE POSITION SENSOR
1. Check:
8throttle position sensor
• • • • • • • • • • • • • • • • • • • • • • •
a. Connect the digital circuit tester to the terminals of the throttle position sensor.
7-32
THROTTLE BODY AND FUEL INJECTOR
FI
ifl
Positive tester probe -> blue terminal ®
Negative tester probe -» black/blue
terminal (2)
f*
Digital circuit tester
90890-03174
b. Measure the throttle position sensor voltage.
Out of specification -» Replace or repair the
wire harness.
U
Throttle position sensor voltage
5V
(blue-black/blue)
c. Connect the digital circuit tester to the terminals of the throttle position sensor.
Positive tester probed
yellow terminal
Negative tester probe
black/blue terminal
d. While slowly opening the throttle, check that
the throttle position sensor voltage is increased.
Voltage does not change or it changes
abruptly -» Replace the throttle body.
Out of specification (closed position) -» Replace the throttle body.
Bl
Throttle position sensor voltage
(closed position)
0.63 ~ 0.73 V
(yellow-black/blue)
•••••••••••••••••••••••
7-33
THROTTLE BODY AND FUEL INJECTOR
FI
ifl
EAS00916
CHECKING THE ISC (IDLE SPEED CONTROL) VALVE
NOTE:
Do not remove the ISC (idle speed control) valve
unit completely from the throttle body assembly.
1. Check:
8ISC (idle speed control) valve
• • • • • • • • • • • • • • • • • • • • • • •
a. Disconnect the ISC (idle speed control)
valve coupler from the ISC (idle speed control) valve.
b. Connect the digital circuit tester to the terminals of the ISC (idle speed control) valve.
Positive tester probe -> pink terminal ©
Negative tester probe -> green/yellow
terminal 2
Positive tester probe -> gray terminal ®
Negative tester probe -> sky blue terminal
©
Digital circuit tester
90890-03174
c. Measure the ISC (idle speed control) valve
resistance.
Out of specification -» Replace the throttle
body.
a
ISC (idle speed control) valve resistance
18 ~ 22 at 20°C(68°F)
•••••••••••••••••••••••
7-34
AIR INDUCTION SYSTEM
FI
ifl
EAS00507
AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned exhaust gases by injecting fresh air (secondary
air) into the exhaust pipe reducing the emission
of hydrocarbons.
When there is negative pressure at the exhaust
port, the reed valve opens, allowing secondary
air to flow into the exhaust port. The resuired
temperature for burning the unburned exhaust
gases is approximately 600 to 700 °C (1,112 to
1,292 °F)
EAS00917
E
0
r"
AIR CUT-OFF VALVE
The air cut-off valve prevents air backflow from
the exhaust pipe to the air filter.
A From the air filter
B To the exhaust pipe ass’y
)
w
M1"
//
hz
?
1
LJ
$
E
7-35
AIR INDUCTION SYSTEM
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1
2
3
4
5
Air induction system hose
Air filter case
Air induction system hose (air filter case to air cut-off valve)
Air cut-off valve
Air induction system hose (air cut-off valve to exhaust pipe)
7-36
FI
ifl
AIR INDUCTION SYSTEM
FI
ifl
AIR CUT-OFF VALVE AND AIR FILTER CASE
PV 7Nm(0.7m • kg, 5.1 ft • lb)
3R 7Nm(0.7m • kg, 5.1 ft • lb)
Order
1
2
3
4
5
Job/Part
Q’ty
Removing the air cut-off valve and
air filter case
Front cover
Side cover(right)
Hose(to air filter case)
Air filter case
Hose(air cut-off valve to air filter case)
Hose(air cut-off valve assembly to exhaust pipe)
Air cut-off valve
Remarks
Remove the parts in the order listed.
Refer to”COVER AND PANEL”in chapter 3.
1
1
1
1
1
For installation, reverse the removal procedure.
7-37
AIR INDUCTION SYSTEM
FI
ifl
EAS00918
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
• hoses
Loose connection -» Connect properly.
Cracks/damage -» Replace.
2. Check:
• reed valve
• reed valve stopper
• reed valve seat
Cracks/damage -» Replace the reed
valve.
3. Check:
• air cut-off valve
Cracks/damage -» Replace.
7-38
ELEC
- +
CHAPTER 8
ELECTORICAL
ELECTRICAL COMPONENTS
WIRING DIAGRAM
CHECKING SWITCH CONTINUITY
CHECKING THE SWITCHES
CHECKING THE BULBS AND BULB SOCKETS
TYPES OF BULBS
CHECKING THE CONDITION OF THE BULBS
CHECKING THE CONDITION OF THE BULB SOCKETS
IGNITION SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
TROUBLESHOOTING
STARTER MOTOR
CHECKING THE STARTER MOTOR
ASSEMBLING THE STARTER MOTOR
CHARGING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
LIGHTING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
CHECKING THE LIGHTING SYSTEM
SIGNALING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
CHECKING THE SIGNALING SYSTEM
COOLING SYSTEM
TROUBLESHOOTING
CHECKING THE COOLING SYSTEM
8-1
8-2
8-4
8-5
8-6
8-6
8-7
8-8
8-9
8-9
8-10
8-14
8-14
8-15
8-16
8-20
8-21
8-23
8-24
8-24
8-25
8-27
8-27
8-28
8-30
8-34
8-34
8-35
8-36
8-42
8-43
8-45
ELECTRICAL COMPONENTS
ELEC
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
9
Main switch
Front brake light switch
Rectifier/regulator
Rear brake light switch
Battery
Main fuse
ECU
Coolant temperature sensor
Ignition coil
0
q
w
e
r
t
y
u
8-1
Spark plug cap
Fuel pump
Starter relay
Horn
Turn signal relay
Starting circuit cut-off relay
Stator coil
Wire harness
+i
WIRING DIAGRAM
WIRING DIAGRAM
Y
L
Br/W
^x^
B/L
©
<—
Br/W
< P/W
rHi'
Y
T
go
P/W
Y
x
Br/W
R/B
x
B/L
Lg
x
B/W
W/R
' BrT
^
h
/R~f|
B/L
x
I
I NHM
@
((<p->)j—
4=
nrn
r-rrriTTT—rr
L/Y
B/R
WX
f\ B/Y
L/B
G/Y
Sb
P
B
B
x
^
gSj
8-2
ELEC
+i
WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
i
o
p
a
s
d
f
g
h
j
k
l
;
z
x
c
v
b
n
m
,
.
/
!
@
#
$
%
AC magneto
Rectifier/regulator
Main fuse
Battery
Starter relay
Starter motor
Start switch
Engine stop switch
ECU
Main switch
Intake air pressure sensor
Intake air temperature sensor
Throttle position sensor
Lean angle cut-off switch
Coolant temperature sensor
Ignition coil
Spark plug
Fuel injector
Fuel pump
ISC(idle speed control) valve
Horn switch
Dimmer switch
Turn signal switch
Headlight
Tail/brake light
Front brake light switch
Rear brake light switch
Horn
Turn signal relay
Front turn signal light(left)
Front turn signal light(right)
Fuel level meter
High beam indicator light
Speedometer light
Engine trouble warning light
Coolant temperature indicator light
Speed sensor
Turn signal indicator light
FI diagnostic tool(optional)
Sidestand switch (optional)
Rear turn signal light(left)
Rear turn signal light(right)
License plate light
Starting circuit cut-off relay
Connector
COLOR CODE
B
Black
Br
Brown
Ch
Chocolate
Dg
Dark green
G
Green
Gy
Gray
L
Blue
Lg
Light green
Or
Orange
P
Pink
R
Red
Sb
Sky blue
W
White
Y
Yellow
B/L
Black/Blue
B/G
Black/Green
B/R
Black/Red
B/W
Black/White
B/Y
Black/Yellow
G/R
Green/Red
G/Y
Green/Yellow
G/W
Green/White
L/B
Blue/Black
L/G
Blue/Green
L/W
Blue/White
L/Y
Blue/Yellow
Or/B
Orange/Black
P/W
Pink/White
R/B
Red/Black
R/L
Red/Blue
R/W
Red/White
W/L
White/Blue
W/R
White/Red
Y/G
Yellow/Green
Br/W .... Brown/White
Br/L
Brown/Blue
8-3
CHECKING SWITCH CONTINUITY
EAS00730
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace
the switch.
cC
Never insert the tester probes into the
coupler terminal slots. Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.
Pocket tester
90890-03132 (YU-03112-C)
NOTE:
8 Before checking for continuity, set the
pocket tester to “0” and to the “Q x 1” range.
8 When checking for continuity, switch back
and forth between the switch positions a
few times.
The terminal connections for switches (e.g., main
switch, engine stop switch) are shown in an illustration similar to the one on the left.
The switch positions a are shown in the far left
column and the switch lead colors b are shown
in the top row in the switch illustration.
NOTE:
“O-O” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at
the respective switch position).
The example illustration on the left shows
that:
There is continuity between black and black/
white when the switch is set to “OFF”.
There is continuity between red and brown when
the switch is set to “ON”.
8-4
CHECKING THE SWITCHES
+1
ELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the
terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear -» Repair or replace.
Improperly connected -» Properly connect.
Incorrect continuity reading -» Replace the switch.
1
9
t
(BLACK)
(BLACK)
©
/
R
L
/
B
B
LOCK
Y
G
R
Br
\
OFF
oo
oo
ON
OO
OO
R Br/L
R/B B
©
(RED)
PB
OFF
PUSH
OO
©
OFF
RUN
Ch
L
N
R
®
Br
OO
Dg
L/W
Br
B
R/W
B
oo
©
OFF
START
oo
oo
5
V
1
2
3
4
B B
Rear brake light switch
Dimmer switch
Horn switch
Turn signal switch
D
AD
U U
5
6
7
8
Main fuse
Start switch
Engine stop switch
Main switch
8-5
9
0
Front brake light switch
Sidestand switch (optional)
CHECKING THE BULBS AND BULB SOCKETS
EAS00733
CHECKING THE BULBS AND BULB
SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity between the terminals.
Damage/wear -» Repair or replace the
bulb, bulb socket or both.
Improperly connected -» Properly connect.
No continuity -»Repair or replace the bulb,
bulb socket or both.
TYPES OF BULBS
The bulbs used on this scooter are shown in the
illustration on the left.
8Bulbs A and B are used for the headlights and usually use a bulb holder that
must be detached before removing the
bulb. The majority of these types of bulbs
can be removed from their respective
socket by turning them counterclockwise.
8Bulbs C is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
8Bulbs D and E are used for meter and
indicator lights and can be removed from
their respective socket by carefully pulling them out.
8-6
CHECKING THE BULBS AND BULB SOCKETS
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
8bulb
w
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
cC
Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass,
the life of the bulb, and the luminous flux
will be adversely affected. If the headlight bulb gets soiled, thoroughly clean
it with a cloth moistened with alcohol or
lacquer thinner.
2.
^
Check:
8 bulb (for continuity)
(with the pocket tester)
No continuity -» Replace.
Pocket tester
90890-03112 (YU-03112-C)
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “ × 1” range.
•••••••••••••••••••••••
a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2 , and check the continuity.
b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3 , and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
• • • • • • • • • • • • • • • • • • • • • • •
8-7
CHECKING THE BULBS AND BULB SOCKETS
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity -» Replace.
Pocket tester
90890-03112 (YU-03112-C)
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
•••••••••••••••••••••••
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity, replace the bulb socket.
•••••••••••••••••••••••
8-8
IGNITION SYSTEM
EAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
-•- 1,®
8-9
ELEC
+i
IGNITION SYSTEM
EAS00736
EAS00738
TROUBLESHOOTING
1. Main Fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter 3.
* Is the fuse OK?
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. main fuse
2. battery
3. spark plug
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. crankshaft position sensor resistance
8. main switch
9. engine stop switch
10. sidestand switch(optional)
11. lean angle cut-off switch
12. wiring connections (of the entire ignition
system)
YES
V
4
NO
Replace the fuse.
EAS00739
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
a
Minimum open-circuit voltage
12.8 V or more at 20°C (68°F)
• Is the battery OK?
NOTE:
8 Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front cover
3. Side cover (right)
8 Troubleshoot with the following special
tool(s).
V
YES
I
NO
• Clean the battery terminals.
• Recharge or replace
the battery.
EAS00740
3. Spark plug
• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
in chapter 3.
Ignition checker
90890-06754
YM-34487
Pocket tester
90890-03112
YU-03112-C
Standard spark plug
CR7E (NGK)
Spark plug gap
0.7 ~ 0.8 mm(0.028 ~ 0.031 in)
• Is the spark plug in good condition, is it of
the correct type, and is its gap within specification?
-i
\7
YES
I
NO
Re-gap or replace the
spark plug.
8-10
IGNITION SYSTEM
EAS00742
EAS00744
4. Ignition spark gap
Disconnect the spark plug cap from the spark
plug.
Connect the ignition checker 1 as shown.
2Spark plug cap
Set the main switch to “ON”.
Measure the ignition spark gap a .
Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
5. Spark plug cap resistance
• Remove the spark plug cap from the spark
plug lead.
• Connect the pocket tester (“Q x1k” range)
to the spark plug cap as shown.
• Measure the spark plug cap resistance.
a
Spark plug cap resistance
4~6 k at 20°C(68°F)
• Is the spark plug cap OK?
Minimum ignition spark gap
6 mm(0.24 in)
YES
V
• Is there a spark and is the spark gap within
specification?
NO
*
ft
4
NO
Replace the spark plug
cap.
YES
EAS00746
6. Ignition coil resistance
• Disconnect the ignition coil connectors from
the ignition coil terminals.
• Connect the pocket tester (Q x1) to the ignition coil as shown.
The ignition system is
OK.
Positive tester probe -» orange ®
Negative tester probe -> red/black
8-11
IGNITION SYSTEM
EAS00748
7. Crankshaft position sensor resistance
• Disconnect the crankshaft position sensor
coupler from the wire harness.
• Connect the pocket tester (£2 x100) to the
crankshaft position sensor coupler as
shown.
Positive tester probe g white/red 1
Negative tester probe g white/blue2
• Measure the primary coil resistance.
a
Primary coil resistance
2.16 ~ 2.64 at 20°C(68°F)
• Connect the pocket tester (£1 x1k) to the ignition coil as shown.
Negative tester probe g orange 2
Positive tester probe g spark plug lead 1
• Measure the crankshaft position sensor resistance.
SI
Crankshaft position sensor resistance
248 ~ 372 at 20°C(68°F)
(between white/red and white/
blue)
• Is the crankshaft position sensor OK?
4
• Measure the secondary coil resistance.
m
Secondary coil resistance
8.64 ~ 12.96 k at 20°C(68°F)
YES
4
4
NO
Replace the crankshaft
position sensor/stator
assembly.
• Is the ignition coil OK?
YES
I
NO
EAS00749
8. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Replace the ignition coil.
YES
NO
Replace
switch.
8-12
the
main
IGNITION SYSTEM
ELEC
+i
EAS00750
9. Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
V
4
NO
Replace the right
handlebar switch.
YES
V
EAS00752
10. Sidestand switch(optional)
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
YES
*
Replace the lean angle
cut-off switch.
NO
EAS00754
12. Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly connected and without defects?
V
Replace the sidestand
switch.
11. Lean angle cut-off switch
• Remove the lean angle cut-off switch.
• Connect the pocket tester(£2 x1) to the lean
angle cut-off switch terminals as shown.
YES
V
Replace the ECU.
Positive tester probe -> blue ©
Negative tester probe -> yellow/green
/\
x
< • / / / / ,
X
m
NO
Lean angle cut-off switch voltage
Less than 65°®-» 0.4~1.4V
More than 65° © -»3.7~4.4V
8-13
I
NO
Properly connect or repair the ignition system’s
wiring.
ELECTRIC STARTING SYSTEM
ELEC
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
Main fuse
Battery
Starter relay
Starter motor
Start switch
Engine stop switch
Main switch
8-14
+i
ELECTRIC STARTING SYSTEM
EAS00756
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the engine stop switch is set to “ # ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
8 The brake lever(front or rear) is pulled to
the handlebar(the brake light switch is
closed) and the sidestand(optional) is
up(the sidestand switch(optional) is closed).
1
2
3
4
5
6
7
8
9
0
q
8-15
Battery
Main fuse
Main switch
Front brake light switch
Rear brake light switch
Engine stop switch
Starting circuit cut-off relay
Sidestand switch(optional)
Start switch
Starter relay
Starter motor
ELECTRIC STARTING SYSTEM
EAS00757
EAS00738
TROUBLESHOOTING
1. Main Fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter 3.
* Is the fuse OK?
The starter motor fails to turn.
Check:
1. main fuse
2. battery
3. starter motor
4. starting circuit cut-off relay
5. starter relay
6. main switch
7. brake light switch(front and rear)
8. engine stop switch
9. sidestand switch(optional)
10.start switch
11.wiring connections
(of the entire starting system)
YES
V
4
NO
Replace the fuse.
EAS00739
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
NOTE:
8 Before troubleshooting, remove the following part(s):
1. battery cover/front cover
2. side cover(left and right)
3. front fork upper cover
4. front fork cover(left and right)
5. leg shield1
6. air filter assembly
8 Troubleshoot with the following special
tool(s).
II
Minimum open-circuit voltage
12.8 V or more at 20°C (68°F)
• Is the battery OK?
YES
V
4
NO
• Clean the battery terminals.
• Recharge or replace
the battery.
Pocket tester
90890-03112 (YU-03112-C)
8-16
ELECTRIC STARTING SYSTEM
EAS00758
ELEC
+1 I
EAS00759
4. Starting circuit cut-off relay
• Remove the starting circuit cut-off relay.
• Connect the pocket tester (Q x1) and battery (12 V) to the starting circuit cut-off relay
coupler as shown.
Positive battery terminal -» red/white®
Negative battery terminal -> light green
Positive tester probe -» green/yellow®
Negative tester probe -> green/yellow®
1
3
2
4
w
8 A wire that is used as a jumper lead must
have at least the same capacity or more
as that of the battery
lead, otherwise
the jumper lead may burn.
8 This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
• Does the starting circuit cut-off relay have
continuity between green/yellow and green/
yellow?
• Does the starter motor turn?
0
YES
I
YES
NO
&
l
NO
Replace the starting circuit cut-off relay
Repair or replace the
starter motor.
8-17
ELECTRIC STARTING SYSTEM
EAS00761
ELEC
+i
EAS00751
5. Starter relay
• Remove the starter relay .
• Connect the pocket tester (Q x1) and battery (12 V) to the starter relay coupler as
shown.
7. Brake light switch(front and rear)
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is each brake light switch OK?
Positive battery terminal ^green/yellow©
Negative battery terminal -»blue/white(2)
Positive tester probe -» red (3)
Negative tester probe -»red (4)
YES
V
I
NO
Replace the brake light
switch(es).
EAS00750
8. Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
V
NO
*
Replace the right
handlebar switch.
YES
V
4
NO
Replace the starter relay.
EAS00752
9. Sidestand switch(optional)
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
EAS00749
6. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
V
4
Replace
switch.
YES
V
NO
the
I
NO
Replace the sidestand
switch.
main
EAS00764
10. Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES
NO
V
Replace the right
handlebar switch.
8-18
ELECTRIC STARTING SYSTEM
EAS00766
11. Wiring
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly connected and without defects?
YES
V
NO
*
The starting system Properly connect or recircuit is OK.
pair
the
starting
system’s wiring.
8-19
ELECTRIC STARTING SYSTEM
ELEC
+i
EAS00767
STARTER MOTOR
®
MM
®
Order
Job/Part
Q’ty
Removing the starter motor
Front cover
Single seat/Trunk
Air filter assembly
1
2
1
2
3
4
5
6
7
8
Starter motor lead coupler
Starter motor
1
1
Remarks
Remove the parts in the order listed.
Refer to “COVER AND PANEL”in chapter 3.
Refer to“ENGINE REMOVAL”in chapter
5.
Disconnect.
For installation, reverse the removal procedure.
Disassemble the parts in the order listed.
Disassembling the starter motor
O-ring
Gasket
Stator assembly
O-ring
Armature coil
Brush
Plate washer
Bracket
1
1
1
1
1
2
1
1
Refer to“ASSEMBLING THE STARTER
MOTOR”.
For assembly, reverse the disassembly
procedure.
8-20
ELECTRIC STARTING SYSTEM
ELEC
+1
EAS00769
CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt -» Clean with 600-grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification -» Replace the starter
motor.
Commutator wear limit
16.6 mm (0.65 in)
3.
Measure:
• mica undercut a
Out of specification -» Scrape the mica
to the proper measurement with a hacksaw blade that has been grounded to fit
the commutator.
Mica undercut
1.35 mm (0.05 in)
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
4. Measure:
• armature assembly resistances (commutator and insulation)
Out of specification -» Replace the starter
motor.
TTTTTTTTTTTTTTTTTTTTTTT
a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
90890-03112 (YU-03112-C)
a
8-21
Armature coil
Commutator resistance 1
0.0378 ~ 0.0462 at 20°C (68°F)
Insulation resistance 2
Above 1 M at 20°C(68°F)
ELECTRIC STARTING SYSTEM
ELEC
+i
b. If any resistance is out of specification, replace the starter motor.
• • • • • • • • • • • • • • • • • • • • • • •
5. Measure:
• brush length a
Out of specification -» Replace the
brushes as a set.
Brush length wear limit
3.5 mm (0.14 in)
6. Measure:
• brush spring force
Out of specification -» Replace the brush
springs as a set.
Brush spring force
3.92 ~ 5.88N(400 ~ 600gf, 14.11 ~
21.16oz)
7. Check:
• gear teeth
Damage/wear -» Replace the gear.
8. Check:
• bearing©
• oil seal©
• bush(3)
Damage/wear -» Replace.
8-22
ELECTRIC STARTING SYSTEM
ELEC
+i
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
8brush seat 1
2. Install:
8washer1
8armature coil 2
8o-ing New 3
8stator assembly4
3 . Install:
• bracket
• bolts (T)
X I 5 Nm (0.5 m * kg, 3.6 ft * lb)
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the bracket.
8-23
CHARGING SYSTEM
+i
ELEC
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
©
©
I
a
I
-vJHHL/-'
E
_ r
1
i«
£1
Br 1
^
h B
Y
/R —111
©
1 Cry J
AC magneto
Rectifier/regulator
Main fuse
Battery
Y
X
B/L
l-l
x
Lg
R
W
B/Y
G/Y
P
B
Or
it
-rfrffr-rr
nrn
R/B
x
L/Y
B/R
nrr
x
LB
Sb
—LIUL
U-l
Gy
B
x
X
— Dg 4
0 @ ©@©
JL
Li" j
ii
12V10W
LVlAr 1
Ch
B/L
G/R
12V10W
[J -=r
L
B/L
^
I P/W
EH
l(S)
Br
R/W .]
G/Y
LH KC1—©—r>|
W - (vfliL/1—I" Lg
• G/Y
(§)l
—
1
O
JO
h- B
@l
1— G/Y —
L/G
©I
Dg
m rr
1
Br—
-Dg
^
l-^H-B
12V10W
Ch
fa>
— Ch -L-
R/W
# G?
Br/L
i]M
12V10W
Br
BG
/
12V35/35W
L/W
^f
if
-i
-R 1
O-^O
I (CO) 15A
©in
h R -•
I
R ~(Q)
T
I I I
' ' '
JJ
(0)~
J
8-24
CHARGING SYSTEM
EAS00774
ELEC
+i
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
The battery is not being charged.
a
Check:
1 . main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections
(of the entire charging system)
Minimum open-circuit voltage
12.8 V or more at 20°C (68°F)
• Is the battery OK?
I
YES
V
NOTE:
8 Before troubleshooting, remove the following part(s):
1. battery cover/front cover
2. side cover(right)
3. front fork upper cover
4. front fork cover(left and right)
5. leg shield1
8 Troubleshoot with the following special
tool(s).
NO
• Clean the battery terminals.
• Recharge or replace
the battery.
EAS00775
3. Charging voltage
• Connect the digital tachometer to the spark
plug lead of cylinder.
• Connect the pocket tester (DC 20 V) to the
battery as shown.
Digital tachometer
90890-06760
Pocket tester
90890-03112
YU-03112-C
Positive tester probe
terminal
Negative tester probe
terminal
positive battery
negative battery
EAS00738
1. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter 3.
• Is the fuse OK?
YES
V
• Start the engine and let it run at approximately 5,000 r/min.
• Measure the charging voltage.
NO
*
a
Replace the fuse.
8-25
Charging voltage
14 V at 5000r/min
CHARGING SYSTEM
5. Wiring
• Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly connected and without defects?
• Is the charging voltage within specification?
YES
lz
*
YES
The charging circuit is
OK.
V
Replace the rectifier/regulator.
EAS00776
4. Stator coil resistance
• Disconnect the starter coil coupler from
wireharness.
• Connect the pocket tester (Q x 1) to the stator coil as shown.
Positive tester probe -»white 1
Negative tester probe -> white 2
• Measure the stator coil resistances.
SI
Stator coil resistance
0.28 ~ 0.42 at 20°C (68°F)
• Is the stator coil OK?
YES
V
4
+i
EAS00779
NOTE:
Make sure the battery is fully charged.
NO
ELEC
NO
Replace the crankshaft position sensor/
stator coil assembly.
8-26
4
NO
Properly connect or repair the charging
system’s wiring.
LIGHTING SYSTEM
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
Y
L
Br/W
xB/L
©
B/L
<v
x
I ! -H •
8-27
ELEC
+i
LIGHTING SYSTEM
EAS00781
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Any of the following fail to light: headlight,
high beam indicator light, taillight, license
plate light or meter light.
a
Check:
1. main fuse
2. battery
3. main switch
4. dimmer switch
5. wiring connections
(of the entire lighting system)
Minimum open-circuit voltage
12.8 V or more at 20°C (68°F)
• Is the battery OK?
`
YES
V
X
• Clean the battery terminals.
• Recharge or replace
the battery.
NOTE:
8 Before troubleshooting, remove the following part(s):
1. battery cover/front cover
2. side cover(right)
3. front fork upper cover
4. front fork cover(left and right)
5. leg shield1
8 Troubleshoot with the following special
tool(s).
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
y*
NO
V
Pocket tester
90890-03112
YU-03112-C
NO
\
Replace
switch.
the
main
EAS00784
4. Dimmer switch
• Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the dimmer switch OK?
EAS00738
1. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter 3.
• Is the fuse OK?
YES
V
X
r-i
V
NO
YES
X
NO
The dimmer switch is
faulty. Replace the left
handlebar switch.
Replace the fuse.
8-28
LIGHTING SYSTEM
EAS00787
5. Wiring
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly connected and without defects?
YES
V
Check the condition
of each of the lighting system’s circuits.
Refer to “CHECKING THE LIGHTING SYSTEM”.
NO
*
Properly connect or repair the lighting system’s
wiring.
8-29
LIGHTING SYSTEM
EAS00788
3. Voltage
• Connect the pocket tester (DC 20 V) to the
headlight and high beam indicator light couplers as shown.
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
1. Headlight bulb and socket
• Check the headlight bulb and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the headlight bulb and socket OK?
YES
AWhen the dimmer switch is set to “ % ”
BWhen the dimmer switch is set to “ & ”
Headlight
Positive tester probe
yellow 1 or green
2
Negative tester probe
NO
*
V
+i
ELEC
black/green 3
Headlight coupler
Replace the headlight
bulb, socket or both.
A
1
DC 20V
| G^L
-©+
®
2. High beam indicator light bulb and socket
• Check the high beam indicator light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the high beam indicator light bulb and
socket OK?
YES
V
4
High beam indicator light
Positive tester probe -> yellow (4)
Negative tester probe -» black/green
Meter assembly coupler
NO
DC20V
Replace the high beam
indicator light bulb ,
socket or both.
©
•
•
•
•
©
Fn
B G/W1 Br
B/G Lg G 1
n Ch
Dg
Y
1
Set the main switch to “ON”.
Start the engine.
Set the dimmer switch to %0” or %0”.
Measure the voltage (DC 12 V) of
yellow©(green (2)) on the headlight coupler
and yellow© on the meter assembly
coupler(wire harness side).
• Is the voltage within specification?
8-30
ELEC
LIGHTING SYSTEM
YES
V
This circuit is OK.
+i
EAS00789
NO
2. The meter light fails to come on.
1. Meter light bulb and socket
• Check the meter light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the meter light bulb and socket OK?
*
The wiring circuit from
the main switch to the
headlight coupler or
meter assembly coupler
is faulty and must be repaired.
Refer to “CIRCUIT DIAGRAM”.
YES
V
4
NO
Replace the meter light
bulb, socket or both.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as
shown.
Positive tester probe -» brown ©
Negative tester probe-* black (2)
®
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown (T)
on the meter light coupler (wire harness
side).
• Is the voltage within specification?
YES
V
This circuit is OK.
8-31
NO
*
The wiring circuit from
the main switch to the
meter light coupler is
faulty and must be repaired.
Refer to “CIRCUIT DIAGRAM”.
LIGHTING SYSTEM
EAS00790
3. Voltage
• Connect the pocket tester (DC 20 V) to the
ECU coupler (wire harness side) as shown.
3. The tail/brake light fails to come on.
1. Tail/brake light bulb and socket
• Check the tail/brake light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the tail/brake light bulb and socket OK?
Positive tester probe -> black/green ©
Negative tester probe -> black/white (§)
YES
V
©
V
This circuit is OK.
I
4
NO
Replace the tail/brake
light bulb, socket or both.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of black/
green© on the ECU coupler (wire harness
side).
• Is the voltage within specification?
YES
+i
ELEC
Positive tester probe -> blue ©
Negative tester probe -» black
NO
The wiring circuit from
the main switch to the
ECU coupler is faulty
and must be repaired.
Refer to “CIRCUIT DIAGRAM”.
©
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue © on
the tail/brake light coupler (tail/brake light
side).
• Is the voltage within specification?
YES
V
This circuit is OK.
8-32
4
NO
wiring circuit from the
main switch to the tail/
brake light coupler is
faulty and must be repaired.
Refer to “CIRCUIT DIAGRAM”.
LIGHTING SYSTEM
EAS00792
4. The license plate light fails to come on.
1. License plate light bulb and socket
• Check the license plate light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the license plate light bulb and socket
OK?
YES
V
NO
*
Replace the license
plate light bulb, socket
or both.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
license plate light coupler (license plate light
side) as shown.
Positive tester probe -> blue ©
Negative tester probe -> black
T
L
n<^^>n
B
®
©
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue © on
the license plate light coupler (license plate
light side).
• Is the voltage within specification?
YES
V
This circuit is OK.
4
NO
The wiring circuit from
the main switch to the license plate light coupler
is faulty and must be repaired.
Refer to “CIRCUIT DIAGRAM”.
8-33
SIGNALING SYSTEM
EAS00793
SIGNALING SYSTEM
(BETWEEN MAIN 8 SUB
CIRCUIT DIAGRAM
-H"
^<^
^ ^
W
B/R
L/B
Or/B
Main fuse
© Battery
(D ECU
Main switch
(3D Fuel pump
Horn switch
Turn signal switch
Tail/brake light
Front brake light switch
© Rear brake light switch
© Horn
© Turn signal relay
© Front turn signal light(left)
Front turn signal light(right)
© Fuel level meter
© Engine trouble warning
© Coolant temperatu
light
Speed
sensor
©
© Turn signal indicator light
© FI diagnostic tool(optional)
© Rear turn signal light(left)
© Rear turn signal light(right)
m
CD
-O
it
8-34
ELEC
+i
SIGNALING SYSTEM
EAS00794
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
II
Check:
1. main fuse
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
Minimum open-circuit voltage
12.8 V or more at 20°C (68°F)
• Is the battery OK?
YES
V
NOTE:
8 Before troubleshooting, remove the following part(s):
1. battery cover/front cover
2. side cover(left and right)
3. front fork upper cover
4. front fork cover(left and right)
5. leg shield1,2
6. footrest board
8 Troubleshoot with the following special
tool(s).
4
NO
• Clean the battery terminals.
• Recharge or replace
the battery.
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
V
P*
Pocket tester
90890-03112
YU-03112-C
4
Replace
switch.
EAS00738
NO
the
main
EAS00795
1. Main fuse
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter 3.
• Is the fuse OK?
YES
V
4. Wiring
• Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly connected and without defects?
NO
YES
V
*
Replace the fuse.
Check the condition of each of the
signaling system’s
circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
8-35
4
NO
Properly connect or repair the signaling
system’s wiring.
SIGNALING SYSTEM
EAS00796
The horn fails to sound.
1. Horn switch
• Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
•
Is the horn switch OK?
YES
T
NO
V
+i
3. Horn
• Disconnect the pink connector at the horn
terminal.
• Connect a jumper lead © to the horn terminal and ground the jumper lead.
• Set the main switch to “ON”.
• Push the horn switch.
• Does the horn sound?
CHECKING THE SIGNALING SYSTEM
1.
ELEC
Br
*
-©
Replace the left
handlebar switch.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
I
NO
YES
V
The horn is OK.
Positive tester probe -»brown ©
Negative tester probe -> ground
s.
Br
4. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the pink terminal as shown.
P
V L J.
Positive tester probe -» pink ©
Negative tester probe -> ground
X
€> w
rBr Pr
&
L
V
4
©
to)
• Set the main switch to “ON”.
• Push the horn switch.
• Measure the voltage (DC 12 V) of brown at
the horn terminal.
• Is the voltage within specification?
YES
J
X
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of pink © at
the horn terminal.
• Is the voltage within specification?
NO
The wiring circuit from
the main switch to the
horn connector is faulty
and must be repaired.
Refer to “CIRCUIT DIAGRAM”.
YES
V
Repair or replace
the horn.
8-36
4
NO
Replace the horn.
SIGNALING SYSTEM
EAS00798
2.
3. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
The tail/brake light fails to come on.
1. Tail/brake light bulb and socket
• Check the tail/brake light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the tail/brake light bulb and socket OK?
YES
V
I
Positive tester probe
Negative tester probe
green/ yellow 1
black 2
NO
J®
E
Replace the tail/brake
light bulb, socket or both.
V
G/Y
L
B
®
2. Brake light switches
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
YES
+i
ELEC
• Set the main switch to “ON”.
• Pull in the brake levers.
• Measure the voltage (DC 12 V) of green/
yellow © on the tail/brake light coupler (wire
harness side).
• Is the voltage within specification?
NO
YES
Replace the brake light
switch(es).
V
This circuit is OK.
8-37
4
NO
The wiring circuit from
the main switch to the
tail/brake light coupler is
faulty and must be repaired.
Refer to “CIRCUIT DIAGRAM”.
SIGNALING SYSTEM
EAS00799
3. The turn signal light, turn signal indicator light
or both fail to blink.
1. Turn signal indicator light bulb and socket
• Check the turn signal indicator light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the turn signal indicator light bulb and
socket OK?
YES
V
ELEC
+i
4. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
Positive tester probe -» brown ©
Negative tester probe -> ground
NO
*
Replace the turn signal
indicator light bulb,
socket or both.
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) on brown
©at the turn signal relay coupler (wire harness side).
• Is the voltage within specification?
2. Turn signal light bulb and socket
• Check the turn signal light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the turn signal light bulb and socket OK?
YES
V
4
YES
V
NO
The wiring circuit from
the main switch to the
turn signal relay coupler
is faulty and must be repaired.
Refer to “CIRCUIT DIAGRAM”.
Replace the turn signal
light bulb, socket or both.
3. Turn signal switch
• Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”
• Is the turn signal switch OK?
YES
V
I
NO
NO
*
Replace the left handlebar switch.
8-38
SIGNALING SYSTEM
5. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
6. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal light connector or meter assembly coupler (wire harness side) as shown.
Positive tester probe-* brown/white ©
Negative tester probe -> ground
ALeft turn signal light(front and rear)
BRight turn signal light(front and rear)
CTurn signal indicator light
Left turn signal light
Positive tester probe - chocolate 1
Negative tester probe ground
Right turn signal light
Positive tester probe - dark green 2
Negative tester probe ground
A
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) on brown/
white ® at the turn signal relay coupler (wire
harness side).
• Is the voltage within specification?
YES
V
I
B
JJ B Ch [L
E-
-*-
JJ B | Dg [L
—,
u
\ B | Dg
\ B | Ch \
©
NO
C
The turn signal relay is
faulty and must be replaced.
-JS)
Ch
Dg
Y
3
n
Ch
Dg
Y
wvw
(D
• Set the main switch to “ON”.
• Set the turn signal switch to “<^=i” or “i=£>”.
• Measure the voltage (DC 12 V) of the chocolate ® or dark green (2) at the turn signal
light connector (wire harness side).
• Is the voltage within specification?
YES
V
This circuit is OK.
8-39
NO
*
The wiring circuit from
the turn signal switch to
the turn signal light connector is faulty and must
be repaired.
SIGNALING SYSTEM
EAS00804
+i
ELEC
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as
shown.
4. The fuel level meter fails to operate.
1. Fuel sender
• Remove the fuel pump from the fuel tank.
• Connect the pocket tester (Q x1) to the fuel
sender coupler (wire harness side) as
shown.
Positive tester probe -> brown ©
Negative tester probe -> black
Positive tester probe -> green ©
Negative tester probe -> black
DC20V
CD^
g
1
©
n
Br
G
G
G/W
Lg-
Lg G/W
B
B/G
B/G B
Br
d)
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown (T)
on the meter light coupler (wire harness
side).
• Is the voltage within specification?
• Measure the fuel sender resistances.
if
Fuel sender resistance (up position
“F”)( × 1)
4~10 at 20°C (68°F)
Fuel sender resistance (down position “E”)( × 10)
90~100 at 20°C (68°F)
YES
V
• Is the fuel sender OK?
YES
V
4
NO
Replace the fuel pump.
8-40
4
NO
Check the wiring connections of the entire
signaling system.
Refer to “CIRCUIT DIAGRAM”.
SIGNALING SYSTEM
3. Fuel level meter
• Set the main switch to “ON”.
• Move the float u p ® or down (2).
• Check that the fuel level meter needle moves
to “F” or “E”.
NOTE:
Before reading the fuel level meter, leave the
float in one position (either up or down) for at
least three minutes.
• Does the fuel level meter needle move appropriately?
YES
V
This circuit is OK.
4
NO
Replace the speedo
meter.
8-41
ELEC
+i
COOLING SYSTEM
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
Y
L
X
Br/W
B/L
©
B/L
<
Y
x
I ! -H •
8-42
ELEC
+i
COOLING SYSTEM
EAS00808
+i
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
• The coolant temperature indicator light
fails to indicate.
• The coolant temperature indicator light
fails to indicate when the engine is warm.
II
Check:
1. main fuse
2. battery
3. main switch
4. coolant temperature sensor
5. wiring connections
(the entire cooling system)
YES
V
4
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
V
4
Replace
switch.
EAS00738
1. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter 3.
• Is the fuse OK?
4
NO
• Clean the battery terminals.
• Recharge or replace
the battery.
Pocket tester
90890-03112
YU-03112-C
YES
Minimum open-circuit voltage
12.8 V or more at 20°C (68°F)
• Is the battery OK?
NOTE:
8 Before troubleshooting, remove the following part(s):
1. battery cover/front cover
2. side cover(right)
3. front fork upper cover
4. front fork cover(left and right)
5. leg shield1,2
6. footrest board
8 Troubleshoot with the following special
tool(s).
V
ELEC
NO
Replace the fuse.
8-43
NO
the
main
COOLING SYSTEM ELEC
EAS00812
Coolant temperature sensor
22 Nm (2.2 m • kg, 15.9 ft • lb)
4. Coolant temperature sensor
Remove the coolant temperature sensor
from the cylinder head.
Connect the pocket tester ( × 1k ) to the
coolant temperature sensor1 as shown.
Immerse the coolant temperature sensor in
a container filled with coolant2.
NOTE:
Make sure the coolant temperature sensor terminals do not get wet.
• Does the coolant temperature sensor operate properly?
YES
NO
V
Replace the coolant
temperature sensor.
• Place a thermometer® in the coolant.
• Slowly heat the coolant, and then let it cool
to the specified temperature indicated in the
table.
• Check the thermo switch for continuity at the
temperatures indicated below.
EAS00813
5. Wiring
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly connected and without defects?
YES
V
Replace the ECU.
Bj
+1 I
Coolant temperature sensor resistance
20°C (68°F): 2.32 ~2.59k
80°C (176°F): 0.310 ~0.326k
r?ViW:WLVel
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
8-44
NO
#
Properly connect or repair the cooling system’s
wiring.
COOLING SYSTEM
CHECKING THE COOLING SYSTEM
3. Voltage
• Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as
shown.
1.
The coolant temperature indicator light fails
to come on.
1. Coolant temperature indicator light bulb and
socket
• Check the coolant temperature indicator light
bulb and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the coolant temperature indicator light
bulb and socket OK?
I
YES
V
Positive tester probe -> green/red ©
Negative tester probe-»ground
NO
Replace the coolant
temperature indicator
light bulb, socket or both.
• Set the main switch to “ON”.
• Measure the voltage (DC 12V) of green/
red© on the coolant temperature sensor
coupler (wire harness side).
• Is the voltage with in specification?
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as
shown.
YES
V
Positive tester probe -> brown ©
Negative tester probe-»green/white(D
©
KBr
,—t.G/W
rrrp_B
G
Lg
G
Br
Lg
G/W
B/ G
B/G
B
®
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown 1
on the meter light coupler (wire harness
side).
• Is the voltage within specification?
YES
V
I
NO
The wiring circuit from
the main switch to the
meter light coupler is
faulty and must be repaired.
8-45
4
NO
The wiring circuit from
the main switch to the
coolant temperature
sensor coupler is faulty
and must be repaired.
Refer to “CIRCUIT DIAGRAM”.
COOLING SYSTEM
4. Coolant temperature indicator light
• Disconnect the coolant temperature sensor
coupler at the coolant temperature sensor.
• Connect the green/red® and black/blue®
with a jumper lead®.
• Set the main switch to “ON”.
2
1
^
• Is the coolant temperature indicator light OK?
YES
V
This circuit is OK.
NO
*
Replace the coolant
temperature indicator
light.
8-46
ELEC
+i
TRBL Q
SHTGl •
CHAPTER 9
TROUBLE SHOOTING
STARTING FAILURE/HARD STARTING
9-1
ENGINE
9-1
FUEL SYSTEM
9-1
ELECTRICAL SYSTEMS
9-1
STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING
SPEED
9-2
ENGINE
9-2
FUEL SYSTEM
9-2
ELECTRICAL SYSTEMS
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY
CLUTCH
9-3
ENGINE
9-3
FUEL SYSTEM
9-3
FAULTY CLUTCH
9-3
ENGINE OPERATES BUT SCOOTER WILL NOT MOVE
9-3
CLUTCH SLIPS
9-3
POOR STARTING PERFORMANCE
9-3
POOR SPEED PERFORMANCE
9-4
OVERHEATING
9-4
ENGINE
9-4
COOLING SYSTEM
9-4
FUEL SYSTEM
9-4
CHASSIS
9-4
ELECTRICAL SYSTEMS
9-4
COOLING SYSTEM
9-4
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING
9-5
FAULTY FRONT FORK LEGS
9-5
LEAKING OIL
9-5
MALFUNCTION
9-5
UNSTABLE HANDLING
9-5
FAULTY LIGHTING OR SIGNALING SYSTEM
9-6
HEADLIGHT DOES NOT COME ON
9-6
HEADLIGHT BULB BURNT OUT
9-6
TAIL/BRAKE LIGHT DOES NOT COME ON
9-6
TAIL/BRAKE LIGHT BULB BURNT OUT
9-6
TRBL Q
SHTGl •
TURN SIGNAL DOES NOT COME ON
TURN SIGNAL BLINKS SLOWLY
TURN SIGNAL REMAINS LIT
TURN SIGNAL BLINKS QUICKLY
HORN DOES NOT SOUND
9-6
9-6
9-6
9-6
9-6
STARTING FAILURE/HARD STARTING
TRBL Q
SHTGl •
EAS00845
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual
for checks, adjustments, and replacement of parts.
STARTING
STARTING
FAILURE/HARD
Throttle body
8Deteriorated or contaminated fuel
8Sucked-in air
ENGINE
Cylinder and cylinder head
8Loose spark plug
8Loose cylinder head or cylinder
8Damaged cylinder head gasket
8Damaged cylinder gasket
8Worn or damaged cylinder
8Incorrect valve clearance
8Improperly sealed valve
8Incorrect valve-to-valve-seat contact
8Incorrect valve timing
8Faulty valve spring
8Seized valve
ELECTRICAL SYSTEMS
Battery
8Discharged battery
8Faulty battery
Fuse
8Blown, damaged or incorrect fuse
8Improperly installed fuse
Spark plug
8Incorrect spark plug gap
8Incorrect spark plug heat range
8Fouled spark plug
8Worn or damaged electrode
8Worn or damaged insulator
8Faulty spark plug cap
Piston and piston ring
8Improperly installed piston ring
8Damaged, worn or fatigued piston ring
8Seized piston ring
8Seized or damaged piston
Air filter
8Improperly installed air filter
8Clogged air filter element
Ignition coil
8Cracked or broken ignition coil body
8Broken or shorted primary or secondary
coil
8Faulty spark plug lead
Crankcase and crankshaft
8Improperly assembled crankcase
8Seized crankshaft
Ignition system
8Faulty ECU
8Faulty crankshaft position sensor
8Broken AC magneto rotor woodruff key
FUEL SYSTEM
Fuel tank
8Empty fuel tank
8Clogged fuel tank cap breather hole
8Deteriorated or contaminated fuel
8Clogged or damaged fuel hose
Switches and wiring
8Faulty main switch
8Faulty engine stop switch
8Broken or shorted wiring
8Faulty front, rear or both brake light
switches
8Faulty start switch
8Faulty sidestand switch(optional)
8Improperly grounded circuit
8Loose connections
Fuel pump
8Faulty fuel pump
8Improperly routed hose
9-1
STARTING FAILURES/HARD STARTING/
INCORRECT ENGINE IDLING SPEED
TRBL Q
SHTGl •
EAS00847
Starting system
8Faulty starter motor
8Faulty starter relay
8Faulty starting circuit cut-off relay
8Faulty starter clutch
INCORRECT
SPEED
ENGINE
IDLING
ENGINE
Cylinder and cylinder head
8Incorrect valve clearance
8Damaged valve train components
Air filter
8Clogged air filter element
FUEL SYSTEM
Throttle body
8Damaged or loose throttle body joint
8Improperly ISC(idle speed control) valve
8Improper throttle cable free play
8Flooded throttle body
8Faulty air induction system
ELECTRICAL SYSTEMS
Battery
8Discharged battery
8Faulty battery
Spark plug
8Incorrect spark plug gap
8Incorrect spark plug heat range
8Fouled spark plug
8Worn or damaged electrode
8Worn or damaged insulator
8Faulty spark plug cap
Ignition coil
8Faulty spark plug lead
Ignition system
8Faulty ECU
8Faulty crankshaft position sensor
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/
FAULTY CLUTCH
EAS00848
EAS00853
POOR
MEDIUM-AND-HIGHSPEED PERFORMANCE
FAULTY CLUTCH
TRBL Q
SHTGl •
ENGINE OPERATES BUT SCOOTER WILL
NOT MOVE
Refer to “STARTING FAILURE/HARD STARTING”.
ENGINE
Air filter
8Clogged air filter element
V-belt
8Bent, damaged or worn V-belt
8Slipping V-belt
FUEL SYSTEM
Throttle body
8Faulty diaphragm
Primary pulley cam and primary pulley slider
8Damaged or worn primary pulley cam
8Damaged or worn primary pulley slider
Fuel pump
8Faulty fuel pump
Clutch spring(s)
8Damaged clutch spring
Transmission gears
8Damaged transmission gear
CLUTCH SLIPS
Clutch shoe springs
8Damaged, loose or worn clutch shoe
spring
Clutch shoes
8Damaged or worn clutch shoe
Primary sliding sheave
8Seized primary sliding sheave
POOR STARTING PERFORMANCE
V-belt
8V-belt slips
8Oil or grease on the V-belt
Primary sliding sheave
8Faulty operation
8Worn pin groove
8Worn pin
Clutch shoes
8Bent, damaged or worn clutch shoe
9-3
FAULTY CLUTCH/OVERHEATING/OVERCOOLING
POOR SPEED PERFORMANCE
V-belt
8Worn V-belt
8Oil or grease on the V-belt
TRBL Q
SHTGl •
Hose(s) and pipe(s)
8Damaged hose
8Improperly connected hose
8Damaged pipe
8Improperly connected pipe
Primary pulley weight(s)
8Faulty operation
8Worn primary pulley weight
FUEL SYSTEM
Throttle body
8Damaged or loose throttle body joint
Primary fixed sheave
8Worn primary fixed sheave
Air filter
8Clogged air filter element
Primary sliding sheave
8Worn primary sliding sheave
CHASSIS
Brake(s)
8Dragging brake
Secondary fixed sheave
8Worn secondary fixed sheave
ELECTRICAL SYSTEMS
Spark plug
8Incorrect spark plug gap
8Incorrect spark plug heat range
Secondary sliding sheave
8Worn secondary sliding sheave
EAS00855
Ignition system
8Faulty coolant temperature sensor
8Faulty ECU
OVERHEATING
ENGINE
Clogged coolant passages
8Heavy carbon buildup
EAS00856
OVERCOOLING
Engine oil
8Incorrect oil level
8Incorrect oil viscosity
8Inferior oil quality
COOLING SYSTEM
Thermostat
8Thermostat stays open
COOLING SYSTEM
Coolant
8Low coolant level
Radiator
8Damaged or leaking radiator
8Faulty radiator cap
8Bent or damaged radiator fan
Water pump
8Damaged or faulty water pump
Thermostat
8Thermostat stays closed
Oil cooler
8Clogged or damaged oil cooler
9-4
POOR BRAKING PERFORMANCE/FAULTY FRONT
FORK LEGS/UNSTABLE HANDLING
TRBL Q
SHTGl •
EAS00859
EAS00862
POOR BRAKING PERFORMANCE
UNSTABLE HANDLING
Drum brake
8Worn brake shoe
8Worn or rusty brake drum
8Incorrect brake lever position
8Incorrect brake lever free play
8Incorrect brake camshaft lever position
8Incorrect brake shoe position
8Damaged or fatigued brake shoe spring
8Oil or grease on the brake shoe
8Oil or grease on the brake drum
Handlebar
8Bent or improperly installed handlebar
Steering head components
8Improperly installed handlebar bracket
8Improperly installed lower bracket
(improperly tightened ring nut)
8Bent steering stem
8Damaged ball bearing or bearing race
Front fork leg(s)
8Uneven oil levels (both front fork legs)
8Unevenly tensioned fork spring (both front
fork legs)
8Broken fork spring
8Bent or damaged inner tube
8Bent or damaged outer tube
EAS00861
FAULTY FRONT FORK LEGS
LEAKING OIL
8Bent, damaged or rusty inner tube
8Cracked or damaged outer tube
8Improperly installed oil seal
8Damaged oil seal lip
8Incorrect oil level (high)
8Loose damper rod assembly bolt
8Damaged damper rod assembly bolt copper washer
8Cracked or damaged cap bolt O-ring
Rear shock absorber assembly
8Faulty rear shock absorber spring
8Leaking oil
Tire(s)
8Uneven tire pressures (front and rear)
8Incorrect tire pressure
8Uneven tire wear
MALFUNCTION
8Bent or damaged inner tube
8Bent or damaged outer tube
8Damaged fork spring
8Worn or damaged outer tube bushing
8Bent or damaged damper rod
8Incorrect oil viscosity
8Incorrect oil level
Wheel(s)
8Incorrect wheel balance
8Deformed cast wheel
8Damaged wheel bearing
8Bent or loose wheel axle
8Excessive wheel runout
Frame
8Bent frame
8Damaged steering head pipe
8Improperly installed bearing race
9-5
FAULTY LIGHTING OR SIGNALING SYSTEM
EAS00866
TRBL Q
SHTGl •
TURN SIGNAL REMAINS LIT
FAULTY LIGHTING OR SIGNALING
SYSTEM
8 F a u l t y t u r n signal relay
8Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
8Incorrect turn signal bulb
8Faulty turn signal relay
8Burnt-out turn signal bulb
HEADLIGHT DOES NOT COME ON
8Wrong headlight bulb
8Too many electrical accessories
8Hard charging
8Incorrect connection
8Improperly grounded circuit
8Poor contacts (main or light switch)
8Burnt-out headlight bulb
HORN DOES NOT SOUND
8Improperly adjusted horn
8Damaged or faulty horne=
8Faulty main switch
8Faulty horn switch
8Faulty battery
8Blown, damaged or incorrect fuse
8Faulty wire harness
HEADLIGHT BULB BURNT OUT
8Wrong headlight bulb
8Faulty battery
8Faulty rectifier/regulator
8Improperly grounded circuit
8Faulty main switch
8Headlight bulb life expired
TAIL/BRAKE LIGHT DOES NOT COME ON
8Wrong tail/brake light bulb
8Too many electrical accessories
8Incorrect connection
8Burnt-out tail/brake light bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
8Wrong tail/brake light bulb
8Faulty battery
8Tail/brake light bulb life expired
TURN SIGNAL DOES NOT COME ON
8Faulty turn signal switch
8Faulty turn signal relay
8Burnt-out turn signal bulb
8Incorrect connection
8Damaged or faulty wire harness
8Improperly grounded circuit
8Faulty battery
8Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
8Faulty turn signal relay
8Faulty main switch
8Faulty turn signal switch
8Incorrect turn signal bulb
8Faulty battery
9-6
©YAMAHA
YAMAHA MOTOR TAIWAN CO., LTD
XF50W WIRING DIAGRAM
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MARK
EXPLANATION
R, Br, BrW... COLOR C O D E
4
CONNECTING WITH G R D . WIRE
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GRD.
CONNECTOR MARK
(BETWEEN MAIN & SUB HARNESS)
•
Black
Red
Green
Brown
Blue
Chocolate
O range
Pink
G ray
Light green
Brown/Blue
Red/Blue
Red/Black
Blue/White
Blue/Black
Black/Red
•
Black/Yellow
Black/Green
C
Green/Yellow
e
Green/White
Blue/ Green
9
White/Blue
•
•
Yellow/Green
Pink/White
o
White
Yellow
•
•
c
c
•
c
c
•
a
•
Dark green
Sky blue
Brown/White
Red/White
Blue/Yellow
Black/White
Black/Blue
Green/Red
White/Red
Orange/Black