Yamaha VINO XC50V Service manual

XC50V

SERVICE MANUAL

LIT-11616-19-49 3D1-F8197-10

EAS00000

XC50V 2005

SERVICE MANUAL

©2005 by Yamaha Motor Taiwan Co., Ltd.

First edition, July 2005

All rights reserved.

Any reproduction or unauthorized use without the written permission of

Yamaha Motor Taiwan Co., Ltd.

is expressly prohibited.

LIT-11616-19-49

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.

Yamaha Motor Taiwan Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00005

IMPORTANT MANUAL INFORMATION

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

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

c

Q w

C

NOTE:

The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOUR

SAFETY IS INVOLVED!

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

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

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

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter.

Refer to “SYMBOLS”.

2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) appears.

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

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

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

6 Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

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

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

EAS00251

CYLINDER AND PISTON

6 2 1


ENG

4

7

9

10

4

7

8

5

5

2

5

4

6

3

10Nm (1.0 m•kg, 7.2 ft•lb)

1

7

3

4

1

2

5

6

Order Job/Part

Removing the cylinder and piston

Cylinder head

Timing chain guide(exhaust side)

Cylinder

Case cap

Reed valve assembly

Dowel pin

Cylinder gasket

7

8

9

10

Piston pin clip

Piston pin

Piston

Piston ring set

Q’ty Remarks

Remove the parts in the order listed.

Refer to “CYLINDER HEAD”.

1

1

1

1

2

1 Refer to “ INSTALLING THE PISTON

AND CYLINDER”.

2

1 Refer to “ REMOVING THE CYLINDER

AND PISTON”.

1


AND CYLINDER”.

For installation, reverse the removal procedure.

5-27

3 2

4

2

1

3


ENG

EAS00253

REMOVING THE CYLINDER AND PISTON

1. Remove:

8piston pin clip 1

8piston pin 2

8piston 3 c C

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

NOTE:

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

8 Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller set 4.

Piston pin puller set

90890-01304(YU-01304)

3

8

5-28

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.

1

GEN

INFO

3

CHK

ADJ

5

ENG

7

CARB

9

TRBL

SHTG q

2

SPEC

4

CHAS

6

COOL

8

ELEC -

0

+

EAS00008

SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols 1 to 9 indicate the subject of each chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Chassis

5 Engine

6 Cooling system

7 Carburetor(s)

8 Electrical system

9 Troubleshooting w

Symbols 0 to u indicate the following.

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

.

T

R

.

i a f

B

4

LT o

G s

LS p d

M

M g

New

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

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

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

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

EAS00010

TABLE OF CONTENTS

GENERAL INFORMATION

GEN

INFO

1

SPECIFICATIONS

SPEC

2

PERIODIC CHECKS AND

ADJUSTMENTS

CHK

ADJ

3

CHASSIS

CHAS

4

ENGINE

ENG

5

COOLING

CARBURETOR

ELECTRICAL SYSTEM

COOL

CARB

6

5

7

+

ELEC

8

TROUBLESHOOTING

TRBL

SHTG

9

GEN

INFO

CHAPTER 1


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

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

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

IMPORTANT INFORMATION ................................................................... 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY ................... 1-2

REPLACEMENT PARTS ................................................................... 1-2

GASKETS, OIL SEALS AND O-RINGS ............................................ 1-2

LOCK WASHERS/PLATES AND COTTER PINS ............................. 1-3

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

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

Notes 3 on equipment preparation .................................................... 1-4

CHECKING THE CONNECTIONS ........................................................... 1-5

SPECIAL TOOLS ...................................................................................... 1-6

1-9

1

1

SCOOTER IDENTIFICATION

GEN

INFO

EAS00015


SCOOTER IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

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

EAS00018

MODEL LABEL

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

1-1

IMPORTANT INFORMATION

GEN

INFO

EAS00020


PREPARATION FOR REMOVAL AND DISAS-

SEMBLY

1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS”.

3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been

“mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

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

1-2

EAS00021

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by

Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.

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


GEN

INFO

EAS00023

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

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

EAS00024

BEARINGS AND OIL SEALS

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

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

1 Oil seal c C

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

1 Bearing

EAS00025

CIRCLIPS

Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.

4 Shaft

1-3

1


GEN

INFO

JAS00021

Notes 3 on equipment preparation

Push Rivet (Push type)

Assembly status of the Push Rivet (Push type)

2

Dissembling

1. Press Center Pin 1 inward to release the

Lock.

2. Remove the Push Rivet main body 2.

Assembling

1. Restore the Center Pin, replace the Push

Rivet main body.

2. Push in the Center Pin until leveling off with the surface position of the Push Rivet main body.

1-4

CHECKING THE CONNECTIONS

GEN

INFO

EAS00026

CHECKING THE CONNECTIONS

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

1. Disconnect:

8 lead

8 coupler

8 connector

2. Check:

8 lead

8 coupler

8 connector

Moisture J Dry with an air blower.

Rust/stains

J Connect and disconnect several times.

3. Check:

8 all connections

Loose connection J Connect properly.

NOTE:

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

1-5

4. Connect:

8 lead

8 coupler

8 connector

NOTE:

Make sure all connections are tight.

5. Check:

8 continuity

(with the pocket tester)

Pocket tester

90890-03132 (YU-03112-C)

NOTE:

8 If there is no continuity, clean the terminals.

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.

SPECIAL TOOLS

GEN

INFO

EAS00027

SPECIAL TOOLS

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

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

Tool NO.

90890-01085

YU-01083-2

90890-01084

YU-01083-3

Tool name / Function

Slide hammer bolt (8mm) 1

Weight 2

1

Illustration

2

90890-01235

YU-01235

These tools are needed to remove the camshaft.

Rotor holding tool

90890-01268

YU-01268

This tool is used to remove the flywheel magneto.

Ring nut wrench

90890-01304

YU-01304

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

Piston pin puller set

90890-01312

YM-01312-A

90890-01337

YM-33285

YM-33285-6

90890-01348

YM-01348

90890-01325

YU-24460-01

90890-01352

YU-33984

This tool is used to remove the piston pin.

Fuel level gauge

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

Clutch spring holder

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

Lock nut wrench

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

Radiator cap tester1

Radiator cap tester adapter2

This tester and its adapter are needed for checking the cooling system.

46

1 2

41

1-6

Tool NO.

90890-01367

YM-A9409-7

90890-01400

YM-A9409-3

90890-01384

YM-33299

90890-01403

YU-A9472

90890-01701

YS-01880-A

90890-03079

YM-34483

90890-03081

YU-33223

90890-03132

YU-03112-C

90890-03113

YU-08036-C


Fork seal driver weight1

SPECIAL TOOLS

GEN

INFO

Illustration

Fork seal driver attachment(Ø30mm)2

This tool is used when installing the fork seal.

Oil seal guide

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

Steering nut wrench

1 2

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

Sheave holder

This tool is used for holding the secondary sheave.

Thickness gauge

This tool is used to measure the valve cleanance.

Compression gauge

These tool are used to measure the engine compression.

Pocket tester

This instrument is invaluable for checking the electrical system.

Engine tachometer

90890-03141

YU-03141

This tool is needed for detecting engine rpm.

Timing light

This tool is needed for detecting ignition timing.

1-7

Tool NO.

90890-04109

YM-04109

90890-04148

YM-04148


Valve spring compressor

SPECIAL TOOLS

GEN

INFO

Illustration

Compressor adapter(Ø16.5mm)

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

Valve guide remover (4.0 mm) 90890-04111

YM-04111

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

Valve guide installer (4.0 mm) 90890-04112

YM-04112

This tool is used to install the valve guides.

Valve guide remover (4.0 mm) 90890-04113

YM-04113

This tool is used to rebore the new valve guides.

Ignition checker 90890-06754

YM-34487

90890-85505

ACC-11001-05-01

This instrument is necessary for checking the ignition system components.

Yamaha bond NO.1215

This sealant (bond) is used on crankcase mating surfaces, etc.

1-8

SPEC

CHAPTER 2

SPECIFICATIONS

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

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

CHASSIS SPECIFICATIONS ................................................................. 2-10

ELECTRICAL SPECIFICATIONS .......................................................... 2-12

CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICA-

TIONS ................................................................................................. 2-15

TIGHTENING TORQUES........................................................................ 2-16

ENGINE ............................................................................................ 2-16

CHASSIS .......................................................................................... 2-18

LUBRICATION POINTS AND LUBRICANT TYPES ............................. 2-19

ENGINE ............................................................................................ 2-19

CHASSIS .......................................................................................... 2-21

COOLING SYSTEM DIAGRAMS ........................................................... 2-22

OIL FLOW DIAGRAMS .......................................................................... 2-26

CABLE ROUTING .................................................................................. 2-28

2-34

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model code

Item Standard

3D11 (for USA)

3D12 (for CAN)

…

…

Limit

Dimensions

Overall length

Overall width

Overall height

Seat height

Wheelbase

Ground clearance

Minimum turning radius

Weight

Wet (without oil and a full fuel tank)

Dry (without oil and fuel)

Maximun load (total of cargo, rider, passenger, and accessories)

1665 mm( 65.6in )

630 mm( 24.8in )

1005 mm( 39.6in )

715 mm( 28.2in )

1160 mm( 45.7in )

85 mm( 3.4in )

1800mm( 70.9in )

81 kg( 179lb )

76kg( 168lb )

158kg( 348lb )

…

…

…

…

…

…

…

…

…

…

2-1

ENGINE SPECIFICATIONS

SPEC


Item Standard

Engine

Engine type

Displacement

Cylinder arrangement

Bore × stroke

Liquid-cooled, 4-stroke, SOHC …

0.049L(49cm 3 ) …

Forward inclined single cylinder …

38.0 × 43.5 mm …

Compression ratio

Engine idle speed

12:1

2000~2400 r/min

Vacuum pressure at engine idle speed(AI OFF) 34.7 kpa ( 260 mmHg )

Standard compression pressure (at sea level) 1450 kPa (14.5kgf/cm 2 ) at 700 r/min

…

…

…

…

Fuel

Recommended fuel

Fuel tank capacity

Total (including reserve)

Unleaded gasoline

4.5L ( 0.98 Imp gal,

1.18 US gal )

…

…

Engine oil

Lubrication system

Recommended oil

Wet sump …

-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚

SAE10W40

Yamaha 4-cycle oil

EFERO X,Z,BX

…

SAE 10W-30

SAE 10W-40

SAE 20W-40

SAE 20W-50

Limit

Quantity

Periodic oil change

Total amount

Final gear oil

Recommended oil

Periodic oil change

Total amount

0.73~0.83 L (0.67~0.76 Imp qt, …

0.80~0.90 US qt)

0.8~0.9L (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)

2-2


SPEC

Standard Item

Oil filter

Oil filter type

Oil pump

Oil pump type

Inner rotor to outer rotor tip clearance

Outer rotor to pump housing clearance

Oil pump housing to inner rotor and outer rotor clearance

Cooling system

Radiator capacity

Radiator cap opening pressure

Wire mesh

Trochoid

0.15 mm or less

0.13-0.18 mm

0.07-0.12 mm

…

0.26L

…

93.3~122.7 kpa

(0.95~1.25kgf/cm 2 ,

…

13.53~17.79 psi)

1.1kpa (0.01kgf/cm 2 , 0.16 psi) …

Limit

…

0.23mm

0.25mm

0.19mm

Valve relief pressure

Radiator core

Width

Height

Depth

Coolant reservoir

Capacity

<From low to full lever>

Water pump

Water pump type

Max. impeller shaft tilt

Starting system type

Spark plug

Model (manufacturer) × quantity

Spark plug gap

Cylinder head

Volume

Max. warpage

133.3mm

87mm

16mm

0.26L

0.15L

Single suction centrifugal pump …

… 0.15mm

Electric and kick starter …

CR7E (NGK) × 1

0.7~0.8mm

3.1~3.5cm³

…

…

…

…

…

…

…

…

…

0.03 mm

2-3

Item

Camshaft

Drive system

Intake camshaft lobe dimensions


SPEC

Standard Limit

Chain drive (left) …

C

A

B

Measurement A

Measurement B

Measurement C

Exhaust camshaft lobe dimensions

C

A

30.158~30.258 mm

25.082~25.182 mm

5.2077mm

B

Measurement A

Measurement B

Measurement C

Max. camshaft runout

30.158~30.258 mm

25.020~25.120 mm

5.2077mm

…

30.058 mm

24.982 mm

…

30.058 mm

24.920 mm

…

0.03 mm

2-4

Item

Timing chain

Model/number of links

Tensioning system

Valve, valve seats, valve guides

Valve clearance (cold)

Intake

Exhaust

Valve dimensions


SPEC

Standard Limit

Morse 92RH2005 / 82

Automatic

0.10~0.16 mm

0.18~0.24 mm

…

…

…

…

B

A

Head Diameter Face Width

Valve head diameter A

Intake

Exhaust

Valve face width B

Intake

Exhaust

Valve seat width C

Intake

Exhaust

Valve margin thickness D

Intake

Exhaust

Valve stem diameter

Intake

Exhaust

Valve guide inside diameter

Intake

Exhaust

Valve stem to valve guide clearance

Intake

Exhaust

Valve stem runout

Seat Width

C

15.4~15.6 mm

16.4~16.6 mm

1.48~2.19 mm

1.48~2.19 mm

0.9~1.1 mm

0.9~1.1 mm

0.7 mm

0.7 mm

3.975~3.990 mm

3.960~3.975 mm

4.000~4.012 mm

4.000~4.012 mm

0.010~0.037 mm

0.025~0.052 mm

…

D

Margin Thickness

…

…

…

…

1.6mm

1.6mm

…

…

3.945 mm

3.930 mm

4.050 mm

4.050 mm

0.080 mm

0.100 mm

0.010 mm

Valve seat width

Intake

Exhaust

2-5

0.9~1.1 mm

0.9~1.1 mm

1.6mm

1.6mm

Item

Valve springs

Free length

Intake

Exhaust

Installed length (valve closed)

Intake

Exhaust

Compressed spring force (installed)

Intake

Exhaust


SPEC

Standard Limit

39.35 mm

41.57 mm

28.0mm

30.0mm

91.1~104.9N(9.3~10.7kg)

107.9~124.1N

(11.0~12.7kg)

37.38 mm

39.49 mm

…

…

…

…

Spring tilt

Intake

Exhaust

Winding direction (top view)

Intake

Exhaust

Valve seat reformed

Cylinder

Cylinder arrangement

Bore × stroke

Compression ratio

Bore

Max. taper

Max. out-of-round

…

…

Clockwise

Clockwise

2.5 °/1.7 mm

2.5 °/1.8 mm

…

…

Yes

Forward inclined single cylinder

38.0 × 43.5 mm

12:1

38.000~38.010 mm

…

…

…

…

…

…

…

0.05 mm

0.010 mm

2-6

Item

Piston

Piston-to-cylinder clearance

Diameter D


SPEC

Standard Limit

0.010~0.035 mm

37.975~37.990 mm

0.150mm

…

H

D

Height H

Piston pin bore (in the piston)

Diameter

Offset

Offset direction

Piston pin

Outside diameter

Piston rings

Top ring

Ring type

Dimensions (B × T)

End gap (installed)

Ring side clearance

2nd ring

Ring type

Dimensions (B × T)

End gap (installed)

Ring side clearance

Oil ring

Dimensions (B × T)

End gap (installed)

Ring side clearance

5.0 mm

10.002~10.013 mm

0.35~0.65mm

Intake side

9.996~10.000 mm

T

T

T

B

B

Barrel

0.8 × 1.65mm

0.05~0.15 mm

0.02~0.08 mm

B

Taper

0.8 × 1.5mm

0.05~0.17 mm

0.02~0.06 mm

1.5 × 1.6 mm

0.2~0.7 mm

0.03~0.15 mm

…

…

…

…

10.043 mm

…

…

9.976 mm

…

…

0.40mm

0.13 mm

…

…

0.52mm

0.12mm

2-7

Item

Rocker arm/rocker arm shaft

Rocker arm inside diameter

Rocker arm shaft outside diameter

Arm-to-shaft clearance

Connecting rod

Connecting rod length

Small end inside diameter

Crankshaft


SPEC

Standard Limit

10.000~10.015mm

9.981~9.991 mm

0.009~0.034 mm

79.95~80.05 mm

10.015~10.028mm

…

…

…

…

…

Width A

Max. runout C

Big end side clearance D

Big end radial clearance E

42.45~42.50 mm

…

0.15~0.45 mm

0~0.010mm

…

0.03mm

1.00mm

…

2-8

Item

Clutch

Clutch type

Clutch shoe thickness

Clutch shoe spring free length

Clutch housing inside diameter

Compression spring free length

Weight outside diameter

Clutch-in revolution

Clutch-stall revolution

V-belt

V-belt width

Transmission

Transmission type

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Single speed automatic

Max. main axle runout

Max. drive axle runout

Air filter type

Carburetor

Model (manufacturer) × quantity

ID mark

Venturi tube bore(primary)

Venturi tube bore(secondary)

Main jet

Main air jet

Jet needle

Neddle jet

Slow air jet

Pilot outlet

Slow jet

Bypass 1

Bypass 2

Bypass 3

Valve seat size

Starter jet

Starter air jet

Throttle valve size

Fuel level ( using fuel level gauge )

Engine idle speed

CO% (air induction system ON)

CO% (air induction system OFF)

Oil temperature ( °C )


SPEC

Standard Limit

Automatic centrifugal

3.7 mm

30.1±0.4mm

107 mm

76.4 mm

15.0 mm

3450~3850 r/min

4350~5350 r/min

16.8 mm

V-belt automatic

Helical gear

48/13 (3.692)

Spur gear

43/12 (3.583)

2.805~0.863:1

…

…

Oil coated paper element

NCV18 (KEIHIN) × 1

3D11 00

Ø7.7

Ø16.6

#82

#80

N425-FBC00

N426-36628

#82

Ø0.9

#35/35

Ø0.7

Ø0.7

Ø0.7

Ø1.6

#38

Ø1.5

N503-69E00

6.6~7.6mm

2000~2400 r/min

Less than 3.5%

5.5~6.5 %

55~65 °C

15.8mm

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

2.0mm

…

…

…

14.5 mm

…

…

…

…

…

…

…

…

0.04 mm

0.04 mm

…

2-9

Item

Frame

Frame type

Caster angle

Trail

Front wheel

Wheel type

Rim

Size

Material

Wheel travel

Wheel runout

Max. radial wheel runout

Max. lateral wheel runout

Rear wheel

Wheel type

Rim

Size

Material

Wheel travel

Wheel runout

Max. radial wheel runout

Max. lateral wheel runout

Front tire

Tire type

Size

Model (manufacturer)

Tire pressure (cold)

0~55 kg

55~158 kg

Min. tire tread depth

Rear tire

Tire type

Size


Tire pressure (cold)

0~55 kg

55~158 kg

Min. tire tread depth

CHASSIS SPECIFICATIONS


SPEC

Standard Limit

Steel tube underbone

24 °

70 mm

Cast wheel

J10 × MT2.15

Aluminum

59mm

…

…

Cast wheel

J10 × MT2.15

Aluminum

54mm

…

…

…

…

…

…

1.0 mm

1.0 mm

Tubeless

90/90-10 50J

K348A (KENDA)

…

…

…

150kpa (1.5 kgf/cm², 22 psi) …

150kpa (1.5 kgf/cm², 22 psi) …

… 0.8mm

…

…

…

…

…

…

…

1.0 mm

1.0 mm

Tubeless

90/90-10 50J

K348A (KENDA)

…

…

…

175kpa (1.75 kgf/cm², 25 psi) …

175kpa (1.75 kgf/cm², 25 psi) …

… 0.8mm

2-10

Item

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

Inner tube outer diameter

Inner tube bending limit

Steering system

Steering bearing type

Lock to lock angle (left)

Lock to lock angle (Right)

Rear suspension

Suspension type

Rear shock absorber assembly type

Rear shock absorber assembly travel

Spring

Free length

Installed length

Spring rate (K1)

Spring rate (K2)

Spring rate (K3)

Spring stroke (K1)

Spring stroke (K2)

Spring stroke (K3)

Optional spring available


SPEC

Standard

Drum brake

Right-hand operation

10~20mm

110 mm

4.0mm

Drum brake

Left-hand operation

10~20mm

110 mm

4.0mm

Telescopic

Coil spring/grease damper

65 mm

120 mm

110mm

9.46N/mm (0.96 kgf/mm)

0~65mm

No

26 mm

…

Angular bearing

45°

45°

Unit swing

Coil spring/oil damper

55mm

192.5mm

182.5mm

24.82N/mm (2.53kgf/mm)

39.27N/mm (4.00kgf/mm)

60.50N/mm (6.17kgf/mm)

0~25mm

25~43mm

43~55mm

No

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

Limit

…

…

…

110.5mm

2.0mm

…

…

…

110.5mm

2.0mm

117.6mm

…

…

…

…

…

0.2 mm

2-11

ELECTRICAL SPECIFICATIONS

SPEC


System voltage

Ignition system

Ignition system type

Ignition timing

Item

Advancer type

Pickup coil resistance /color

C.D.I. unit model (manufacturer)

Ignition coil


Minimum ignition spark gap

Primary coil resistance

Secondary coil resistance

Spark plug cap

Material

Resistance

Charging system

System type


Nominal output

Stator coil resistance /color

Lighting coil resistance /color

Voltage regulator

Regulator type


No load regulated voltage(DC)

Rectifier


Rectifier capacity(DC)

Withstand voltage

Battery

Battery type (manufacturer)

Battery voltage capacity

Specific gravity

Ten hour rate amperage

Headlight type

Indicator light (voltage/wattage×quantity)

Turn signal indicator light

High beam indicator light

Water temperature indicator light

12V

Standard

C.D.I.

13 ° B.T.D.C. at

2000~2400 r/min

Digital

248~372

Ω / WR-WL

5ST (T-MORIC)

X7A (T-MORIC)

6mm

0.168~0.252

Ω at 20 ° C

2.4~3.6 k

Ω at 20 ° C

Resin

4~6 k

Ω

…

…

AC magneto

1P41 (T-MORIC)

14V 120W / 5000 r/min

0.288~0.432

Ω/Ground-W

0.256~0.384

Ω/Ground-Y/R

Semiconductor, short circuit …

SH656-12 (SHIN DEN GEN) …

14.1~14.9 V …

…

…

…

…

…

…

…

…

…

SH656-12 (SHIN DEN GEN) …

8A

200V

…

…

GTX5L-BS (GS)

12V 4AH

1.330

4AH

Halogen bulb

14 V 3.0 W × 2

12 V 1.7W × 1

14 V 3.0W × 1

…

…

…

…

…

…

…

…

…

…

…

…

…

…

Limit

2-12


SPEC

Standard Item

Bulbs (voltage/wattage × quantity)

Headlight

Tail/brake light

Front turn signal light

Rear turn signal light

Speedometer lighting

Electric starting system

System type

Starter motor


Suction voltage

Power output

Brushes

Overall length

Quantity

Spring force

Commutator diameter

Commutator resistance

Mica undercut (depth)

Starter relay


Amperage

Coil resistance

Suction voltage

Horn

Horn type


Max. amperage

Performance

Coil resistance

Turn signal relay

Relay type


Self-cancelling device built-in

Turn signal blinking frequency

Wattage

Fuel sender


Sender unit resistance-full

Sender unit resistance-empty

Head light relay


Coil resistance

Diode

12 V 35W/35W × 1

12 V 5W/21 W × 1

12 V 10 W × 2

12 V 10 W × 2

12 V 1.7 W × 2

Constant mesh

5STF (T-MORIC)

12V

0.25 kW

7.0 mm

2

3.92~5.88 N

17.6 mm

0.0378~0.0462

Ω at 20 ° C

1.35 mm

5WC 00 (OMRON)

50 A

90-110

Ω

More than DC10V

Plane

AH-368 (SAKURA)

1.5 A

98~108db/2m

4.05~4.55

Ω

Full transistor

5CA9 (TA YOUNG)

NO

75~95 cycles/min

10 W × 2 + 1.7 W+ AP

5ST1 (CHAO LONG)

6~8

Ω

93.5~96.5

Ω

5EB 10 (OMRON)

90~110 Ω

YES

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

…

Limit

3.5mm

…

…

16.6mm

…

…

2-13

Item

Throttle position sensor

Output voltage (throttle opens)

Output voltage (throttle closes)

Radiator fan


Running rpm

Thermostat switch


Thermo unit


Coil resistance at 80 °C

Coil resistance at 100 °C

Fuse (amperage × quantity)

Main fuse


SPEC

Standard

2.8~3.4V

0.625~0.775V

5ST-00 (LUNTAI)

10000 r/min

…

…

…

…

5ST (NIPPON THERMOSTAT) …

5JJ (NIPPON THERMOSTAT) …

3.413~4.007 k

Ω

1.645~1.855 k

Ω

…

…

7.5A×1 …

Limit

2-14

CONVERTION TABLE / GENERAL TIGHTENING

TORQUE SPECIFICATIONS

SPEC

EB201000

CONVERSION TABLE

All specification data in this manual are listed in SI and METRIC UNITS.

Use this table to convert METRIC unit data to

IMPERIAL unit data.

Ex.

METRIC

** mm

2 mm

MULTIPLIER IMPERIAL

0.03937

** in

0.03937

0.08 in

CONVERSION TABLE

Tightening torque

Weight

Speed

Distance

Volume/

Capacity

Misc.

METRIC TO IMPERIAL

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

7.233

86.794

0.0723

0.8679

2.205

0.03527

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

Centigrade

(°C)

0.6214

0.6214

3.281

1.094

0.3937

0.03937

0.03527

0.06102

0.8799

0.2199

55.997

14.2234

9/5+32 mph mi ft yd in in oz (IMP liq.) cu-in qt (IMP liq.) gal (IMP liq.) lb/in psi (lb/in 2 )

Fahrenheit (°F)

EAS00030

GENERAL TIGHTENING TORQUE

SPECIFICATIONS

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

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

A: Width across flats

B: Thread diameter

A

(nut)

B

(bolt)

10 mm

12 mm

6 mm

8 mm

14 mm 10 mm

17 mm 12 mm

19 mm 14 mm

22 mm 16 mm

General tightening torques

Nm m•kg ft•lb

6 0.6

4.3

15

30

55

85

1.5

3.0

5.5

8.5

130 13.0

11

22

40

61

94

2-15

TIGHTENING TORQUES

SPEC


ENGINE

Part to be tightened

Cylinder head and cylinder

Spark plug

Cylinder head(timing chain side)

Exhaust pipe stud bolt

Cylinder head cover

Oil check bolt

Water pump housing cover

Water pump assembly

Guide stopper2

Thermostat housing air bleed bolt

Camshaft sprocket

Timing chain tensioner (body)

Timing chain tensioner (plug)

Thermostat housing

Fan case

Fan

Oil pump assembly

Radiator drain bolt

Manifold

Air filter assembly

Engine oil drain plug

Air cut-off valve

Muffler

Oil guide

Muffler

Protector

Crankcase(left and right)

Transmission cover

Drain bolt(transmission oil)

Cover1(starter clutch)

Crankcase cover(left)

Hold lead plate bolt

Drain bolt(engine oil)

Rear wheel lock nut

Drain bolt(transmission oil fill bolt)

AI filter

Rear wheel lock cover

Plate

Kickstarter

Starter clutch

Part name

Thread size

Q ’ ty

Tightening torque

Nm m•kg ft•lb

Bolt

Bolt

Bolt

-

Bolt

Bolt

-

Bolt

Bolt

Nult

Nut

Screw

Bolt

Bolt

Bolt

-

Bolt

Bolt plug

Bolt

Nut

-

Bolt

-

Nut

-

Bolt

-

Bolt

Bolt

Bolt

Bolt

Nut

Bolt

Bolt

Bolt

Bolt

-

-

-

M6

M8

M6

M8

M6

M6

M6

M6

M5

M12

M6

M6

M35

M6

M6

M6

M8

M6

M8

M6

M6

M10

M6

M8

M6

M6

M6

M8

M6

M6

M6

M6

M22

M6

M6

M6

M6

M6

M8

M8

2

2

8

1

2

2

2

1

1

2

4

3

2

1

2

1

2

3

1

1

4

1

3

2

2

4

1

7

1

1

1

1

4

1

1

6

1

8

8

7

10

31

10

13

9

10

10

9

4

2

10

10

32

10

7

10

30

9

8

10

10

12.5

10

12.5

10

7

10

23

10

10

7

12

90

13

13

10

10

10

23

15

Remarks

7.2

22.4

7.2

9.4

6.5

7.2

7.2

6.5

2.9

1.5

7.2

7.2

23.1

7.2

5.1

7.2

21.7

6.5

5.8

7.2

7.2

9.0

7.2

9.0

7.2

5.1

7.2

4

9.4

9.4

7.2

7.2

7.2

16.6

10.9

Left-hand thread

16.6

7.2

7.2

5.1

8.7

65.1

Left-hand thread

1.0

3.1

1.0

1.3

0.9

1.0

1.0

0.9

0.4

0.2

1.0

1.0

3.2

1.0

0.7

1.0

3.0

0.9

0.8

1.0

1.0

1.25

1.0

1.25

1.0

0.7

1.0

1.5

2.3

1.0

1.0

0.7

1.2

9.0

1.3

1.3

1.0

1.0

1.0

2.3

2-16


Clutch housing

Ignition coil

Thermo unit

Primary fixed sheave

Starter motor assembly

AC magneto rotor

Stator coil

Pickup coil

Cylinder head tightening sequence

1


SPEC

Part name

Thread size

Q ’ ty

Tightening torque

Nm m•kg ft•lb

Nut

Bolt

-

Nut

Bolt

Nut

Bolt

Screw

M10

M5

PT1/8

M10

M6

M12

M5

M6

1

1

1

1

3

2

2

1

40

8

8

30

13

43

4

7

4.0

0.8

0.8

3.0

1.3

4.3

0.4

0.7

28.9

5.8

5.8

21.7

9.4

31.1

2.9

5.1

Remarks

LT

5

3

4

6

2

2-17


SPEC

CHASSIS


Frame and engine bracket 3

Engine bracket 3 and engine

Handlebar and steering shaft

Front fork and lower bracket

Seat lock assembly

Rear carrier(front)

Rear carrier(rear)

Steering shaft and upper bearing inner race

Steering shaft and ring nut

Trunk

Footrest board

Fuel sender

Resin part and resin cover

Seat lock adjuster

Main switch and frame

Front brake camshaft lever

Front wheel shaft

Rear wheel shaft

Rear brake camshaft lever

Rear brake pin pivot

Speedometer cable

Rear shock absorber and frame

Rear shock absorber and engine

Thread size

About M5

M6

M6

M6

M10

M14

M6

M8

M12

M10

M8

M10

M10

M10

M10

M6

M6

M8

BC

BC1

M6

M6

M5

Tightening torque

Nm m•kg ft•lb

104

7

16

3

30

16

3

1.5

2

7

8

48

12

10

23

7

30

12

4

46

58

60

30

10.4

0.7

1.6

0.3

3.0

1.6

0.3

0.15

0.2

0.7

0.8

4.8

1.2

1.0

2.3

0.7

3.0

1.2

0.4

4.6

5.8

6.0

3.0

75.2

5.1

11.6

2.2

21.7

11.6

2.2

1.1

1.5

5.1

5.8

34.7

33.1

42.0

43.4

21.7

8.7

7.2

16.6

5.1

21.7

8.7

2.9

Remarks

See”NOTE”

See”NOTE”

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, installing the ball race cover.

1 Upper bearing inner race

2 Ring nut

3 Ball race cover

2-18

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

EAS00031


ENGINE

Lubricant

LS

Lubrication Point

Oil seal lips

O-rings (Except V-belt drive unit)

Cylinder head tightening nut mounting surface

Cylinder head stud bolt thread

Cylinder head gasket dowel pin

Crankshaft pin outside surface

Connecting rod

Piston outside and ring groove

Piston pin outside surface surface and bolt thread

Crankshaft journal

Piston (balancer) outside surface

Piston pin (balancer) outside surface

Camshaft lobe

Camshaft profile journal

Valve stems (intake and exhaust)

Valve stem seals(intake and exhaust)

Valve pads(intake and exhaust)

Valve stem ends (intake and exhaust)

Oil pump assembly inside surface

Oil pipe union bolt thread and surface

Starter clutch pin and weight

Idle gear 1 thrust surface

Idle gear 2

Main and drive axle serration (sprocket)

Drive axle taper rollor bearing

Transmission bearing

LS

M

M

M

4

4

4

4

4

4

4

4

M

M

4

4

4

4

4

4

M

4

4

G

G

G

2-19


SPEC

Lubrication Point

Secondary fixed sheave inner surface

Secondary sliding sheave torque cam ditch

Crankcase mating surfaces

Lubricant

BEL-RAY asembly lube

®

BEL-RAY asembly lube

®

Sealant

2-20


SPEC

EAS00032

CHASSIS

Lubrication Point

Front wheel oil seal lips

Steering bearing and bearing races (upper and lower)

Frame head pipe dust seal lips ( lower)

Tube guide (throttle grip) inner surface

Brake lever and lever holder bolt sliding surface

Centerstand pivoting point and sliding surface

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

Seat lock cable and rear wheel lock cable inner surface

Engine bracket and engine mound bolt sliding surface

Lubricant

LS

LS

LS

LS

LS

LS

M

LS

LS

2-21

COOLING SYSTEM DIAGRAMS

SPEC

EAS00033


1 Raidator cap

2 Coolant reservoir

3 Radiator inlet hose

4 Radiator outlet hose

5 Thermo switch

6 Conduit hose

1

6

3

5

4

2

2-22

1 Outlet hose(to cylinder)

2 Radiator inlet hose


4 Thermostat

5 Thermostat housing


SPEC

1

2

5

4

3

2-23

1 Breather hose

2 Outlet hose(to cylinder)


4 Water pump


SPEC

4

3

2

1

2-24


SPEC

1 Thermostat housing

2 Thermostat assembly inlet breather hose

3 Water pump

4 Breather hose

2

1

4

3

2-25

OIL FLOW DIAGRAMS

1 Oil filter

2 Oil pump

3 To cylinder head

4 Oil strainer

5 Oil nozzle

6 Camshaft


SPEC

2-26

1 Crankshaft pin

2 Connecting rod big end bearing

3 Oil nozzle

4 Camshaft


SPEC

2-27

Cylinder wall

Connecting rod big end bearing

Rocker arm shaft and rocler arm

Camshaft

Crankshaft pin Oil nozzle

Centrifugal oil filter

Oil pump

Oil filter

Crankcase sump

EAS00035

CABLE ROUTING

1 Fuel sender lead

2 C.D.I. unit

3 AI filter

4 Starter motor lead

5 Main switch

6 Rectifier/Regulator

7 Overflow pipe

8 Thermo unit

9 Rear wheel lock cable

0 Rear brake cable q Throttle cable kit w Seat lock cable e Wire harness r Hose t Bend hose y Vacuum sensing hose u AC magneto lead

CABLE ROUTING

SPEC

A Insert the wire harness plate holder to the T-stud of down tube .

B Insert the seat lock cable into the frame, protector part to the hole position.

C Insert the L coupler to the ignition coil and installing direction of downward.

D Clamp the wire harness, thermo switch lead and conduit hose to the frame.

E Fasten the wire harness, AC magneto lead and starter motor lead to the frame with a plastic locking tie and end of plastic locking the upward.

F Route the AC magneto lead and bend hose through inside of the frame .

G Clamp the seat lock cable and wire harness to the frame of cover , install upward of the seat lock cable .

G

e

9

0

q

C-C

w

u

r

E-E

t

y

e

2 1 3

5

E

4

D

C

A

6

F 8

2-28

7 B

1 Turn signal relay

2 Horn

3 Head light relay

4 Speedometer cable

5 Front brake cable

6 Starter relay

7 Ignition coil

8 Throttle cable kit

9 Rear wheel lock cable

0 Air cut-off valve assembly q AI filter w Holder e Rectifier/Regulator r Clamp t Frame y Rear brake cable

CABLE ROUTING

SPEC

A Fasten the throttle cable kit and rear brake cable to the frame and cut the end to be shorter than 5mm, point the band tip to backward and reserve for a finger clearance.

B Route the rear brake cable through guide of the under cover.

C Route the seat lock cable through the guard mub rib.

D 30~40mm

E Clamp the rear brake cable stopper.

F Clamp the carburetor drain hose to the rear brake cable, pass the rear brake cable outside the carburetor drain hose.

G Clamp the rear brake cable to the under cover rib.

H Clamp the throttle cable kit and Rear wheel lock cable through upward of the frame.

I Route the rear brake cable through downward of the frame and upward of the under cover.

J Route the rear brake cable,

Rear wheel lock cable and throttle cable kit through side of the frame.

K Route the lever holder lead coupler(left and right), brake switch lead coupler(front and rear) and speedometer lead coupler into the connector cover. Position the connector cover on the rib of the leg shield 2.

L To the headlight and front turn signal light(left, right).

4

5

y

9

N-N

t

8

L

M

K e r

1

3

2

1

3

2

J

N

4

A

B

6

7 8

9

0 q

C

5

I H G F E

2-29

D w

M Assemble the horn lead to the best forward of connector cover, do not through back side of the other leads.

N Route the turn signal relay lead and front turn signal light lead(left) through backward of the steering head pipe.

CABLE ROUTING

SPEC

4

1

3

2

4

5

y

9

N-N

t

8

L

M

K e r

1

3

2

J

N

A

B

6

7 8

9

0 q

5

I H G F E D w

2-30

C

1 Battery negative - lead

2 Battery positive + lead

3 Fuse box

4 Starter motor lead

5 AC magneto lead

6 Fuel sender

A Insert the wire harness cable strap into the footrest bracket of hole.

B Route the wire harness through concave of the recovery tank and clamp it.

C Insert the ignition coil connector into the ignition coil terminal.

D Clamp the starter relay to the under cover of rib.

CABLE ROUTING

SPEC

E Route the starter motor lead through upward of the engine bracket and through left side of the wire harness.

F Route the breather pipe through downward of the spacer.

G Clamp the taillight lead to the side cover of hook.

H Install the C.D.I. unit to the fuel tank bracket of bracket

1.

I Clamp the seat lock cable protector of marking position to the fuel tank bracket.

J Route the drain pipe along the fuel tank bracket and through the clamp.

K Route the fuel hose and pipe

7 through downward of the breather pipe.

L Route the throttle cable kit through upward of the breather pipe.

M Clamp the auto choke lead and T.P.S. lead to the manifold of clamp.

N Install the ignition coil to the engine.

O Install the clamp to the under cover of hole.

P Install the clamp to the footrest bracket of hole.

A

B

D

C

1

2

3

4

5

E

F

G

H

6

P

O

N M

L

K

J

I

2-31

1 Front brake cable

2 Front brake switch lead

3 Speedometer assembly

4 Speedometer cable

5 Rear brake cable

6 Rear brake switch lead

7 Lever holder lead(left)

8 Handlebar

9 Lever holder lead(right)

0 Lever holder(left) q Grip(left) w Throttle cable kit e Speedometer assembly lead r Front fork t Frame

CABLE ROUTING

SPEC

A After locking the right side switch of control lever, confirm the driving status of holder. Turn the holder then release your hand and retrieve the holder quickly.

B Install the throttle cable to the lever holder (right), and tightening torque 4Nm (0.4m•kg,

2.9ft•lb).

C Route the lever holder lead(right) and front brake switch lead along backward of the front brake cable.

D Install the speedometer cable to the speedometer assembly, and tightening torque

3Nm(0.3m.kg,2.2ft.lb).

E Route the lever holder lead(left) and lever holder lead(right) through backward of the rear brake cable.

F First, tighten the upper screw, when assembling the lever holder(left), and tightening torque 4Nm(0.4m•kg,2.9ft•lb).

G When assembled, the projecting par t of the lever holder(left) should be in alignment with the handlebar

Comp. hold position.

1 C 2

D

F G H

A B

A 3 4

5 6

E

9

8 7 w

S

R Q P

U T

Right side

FWD.

Left side

C-C

1

4

5 e 2

6

7

9 w

B

A

O

K

C

N M

L

B

J

C r t

A-A

2-32 q

0

H After spread with adhesion agent on the inner side, push the grip into the handlebar assembly.

I Allow the gain position to arrive at this range.

J Install the handlebar cover to the handlebar bracket, and tightening torque

4Nm(0.4m•kg,2.9ft•lb).

K To the headlight.

L Insert the rear brake cable to the lever holder(left).

M When assembling the rear brake cable and speedometer cable, do not interfere.

CABLE ROUTING

SPEC

N Install the speedometer assembly to the handlebar bracket, and tightening torque

7Nm (0.7m•kg,5.1ft•lb).

O When assembling the leads and cables, clamp and do not interfere.

P Route the throttle cable through best backward of the cables and leads.

Q When assembling the front brake cable and speedometer cable, do not interfere.

R Route the throttle cable through upper of handlebar guide and handlebar upper cover.

S First, tighten the back screw, when assembling the lever holder(right).

T Install the handlebar to the steering shaft, and tightening torque 4Nm (0.4m•kg,2.9ft•lb).

U Route the bolt through bike of right side, and tightening the nut.

1 C 2

D

F G H

A B

A 3 4

5 6

E

9

8 7 w

S

R Q P

U T

Right side

FWD.

Left side

C-C

1

4

5 e 2

6

7

9 w

B

A

O

K

C

N M

L

B

J

C r t

A-A

2-33 q

0

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

CHK

ADJ

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

SEAT AND TRUNK ............................................................................ 3-5

SIDE COVER (LEFT AND RIGHT) ................................................... 3-6

FOOTREST BOARD AND FOOTREST BOARD SIDE COVER

MOLE .............................................................................................. 3-7

LEG SHIELD 1 , 2 .............................................................................. 3-8

ENGINE ..................................................................................................... 3-9

ADJUSTING THE VALVE CLEARANCE ........................................... 3-9

ADJUSTING THE ENGINE IDLING SPEED .................................. 3-14

CHECKING THE EXHAUST GAS AT IDLE .................................... 3-15

ADJUSTING THE THROTTLE CABLE FREE PLAY ...................... 3-17

CHECKING THE SPARK PLUG ...................................................... 3-18

CHECKING THE IGNITION TIMING ............................................... 3-19

MEASURING THE COMPRESSION PRESSURE ......................... 3-21

CHECKING THE ENGINE OIL LEVEL ........................................... 3-23

CHANGING THE ENGINE OIL ........................................................ 3-24

CHANGING THE TRANSMISSION OIL .......................................... 3-26

MEASURING THE ENGINE OIL PRESSURE ................................ 3-27

CHECKING THE AIR FILTER ELEMENT ....................................... 3-29

CHECKING THE CARBURETOR JOINT AND INTAKE

MANIFOLD ................................................................................... 3-30

CHECKING THE FUEL AND VACUUM HOSES ............................ 3-30

CHECKING THE FUEL HOSES AND FUEL FILTER ..................... 3-31

CHECKING THE CRANKCASE BREATHER HOSE ..................... 3-32

CHECKING THE EXHAUST SYSTEM ........................................... 3-33

CHECKING THE COOLANT LEVEL .............................................. 3-34

CHECKING THE COOLING SYSTEM ............................................ 3-35

CHANGING THE COOLANT ........................................................... 3-36

CHASSIS ................................................................................................. 3-39

ADJUSTING THE FRONT BRAKE ................................................. 3-39

ADJUSTING THE REAR BRAKE.................................................... 3-39

CHECKING THE FRONT AND REAR BRAKE SHOES ................ 3-40

CHECKING AND ADJUSTING THE STEERING HEAD ................ 3-41

CHECKING THE FRONT FORK ..................................................... 3-43

3-59

CHK

ADJ

CHECKING THE TIRES .................................................................. 3-44

CHECKING THE WHEELS.............................................................. 3-47

CHECKING AND LUBRICATING THE CABLES ............................ 3-47

LUBRICATING THE LEVERS AND PEDALS ................................. 3-48

LUBRICATING THE CENTERSTAND ............................................ 3-48

ELECTRICAL SYSTEM ......................................................................... 3-49

CHECKING AND CHARGING THE BATTERY............................... 3-49

CHECKING THE FUSE ................................................................... 3-55

REPLACING THE HEADLIGHT BULB ........................................... 3-57

ADJUSTING THE HEADLIGHT BEAM ........................................... 3-58

3-60

INTRODUCTION

CHK

ADJ

EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

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

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

NOTE:

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

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

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

3-1

PERIODIC MAINTENANCE AND MINOR REPAIR

CHK

ADJ

EAU17560*


Periodic maintenance chart for the emission control system

NO.

ITEM ROUTINE

INITIAL

600 mi

(1,000 km) or

1 month

2,000 mi

(4,000 km) or

6 months

ODOMETER READING

4,000 mi

(7,000 km) or

12 months

6,000 mi

(10,000 km) or

18 months

8,000 mi

(13,000 km) or

24 months

10,000 mi

(16,000 km) or

30 months

1

2

3

4

5

6

7

*

*

*

*

*

Fuel line

Spark plug

Valve clearance

Crankcase breather system

Idle speed

Exhaust system

* Air induction system

• Check fuel and vacuum hoses for cracks or damage.

• Replace if necessary.

• 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.

• Check and adjust valve clearance when engine is cold.

• Check breather hose for cracks or damage.


• Check and adjust engine idle speed.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

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

• Replace any damaged parts.

√

√

√

√

√

√

√

√

√

Replace.

√

√

√

√

√

√

Replace.

Every 6000 mi (10000 km)

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

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

3-2


CHK

ADJ

General maintenance and lubrication chart

Maintenance and lubrication, periodic

NO.

ITEM ROUTINE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

* Air filter element • Replace.

*

*

*

Front brake

Rear brake

Wheels

• Check operation.

• Adjust cable and replace brake shoes if necessary.


• Adjust cable and replace brake shoes if necessary.

• Check runout and for damage.


*

*

*

*

Tires

Wheel bearings

Steering bearings

Chassis fasteners

• Check tread depth and for damage.


• Check air pressure.

• Correct if necessary.

• Check bearings for smooth operation.


• Check bearing assemblies for looseness.

• Moderately repack with lithiumsoap-based grease every 8000 mi

(13000 km) or 24 months.

• Check all chassis fitting and fasteners.

• Correct if necessary.

Front and rear brake lever pivot

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

*

*

Centerstand

Front fork

Shock absorber assembly

Engine oil

Engine oil strainer


• Lubricate.

• Check operation and for oil leakage.


• Check operation and for oil leakage.


• Change (warm engine before draining).

• Check oil level and vehicle for oil leakage.

• Clean.

15

16

* Cooling system

Final transmission oil

• Check coolant level and vehicle for coolant leakage.

• Change.

• Check vehicle for oil leakage.

• Change.

17

18

* V-belt

*

Front and rear brake switches

• Replace.


19

20

21

*

*

*

Control and meter cables

• Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly.

Throttle grip housing and cable

• Check operation and free play.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.

Lights, signals and switches


• Adjust headlight beam.

INITIAL

600 mi

(1,000 km) or

1 month

2,000 mi

(4,000 km) or

6 months

√

ODOMETER READING

4,000 mi

(7,000 km) or

12 months

√

6,000 mi

(10,000 km) or

18 months

√

8,000 mi

(13,000 km) or

24 months

√

10,000 mi

(16,000 km) or

30 months

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Every 3 years

√

Every 6250 mi (10000 km)

√ √

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Repack.

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

3-3


CHK

ADJ

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

NOTE:

From 12000 mi ( 19000 km) or 36 months, repeat the maintenance intervals starting from 4000 mi

(7000 km) or 12 months.

EAU17680

NOTE:

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

3-4

COVER AND PANEL

SEAT AND TRUNK

1

12Nm (1.2 m•kg, 8.7 ft•lb)

2

COVER AND PANEL

CHK

ADJ

12Nm (1.2 m•kg, 8.7 ft•lb)

10Nm (1.0 m•kg, 7.2 ft•lb)

23Nm (2.3 m•kg, 16.6 ft•lb)

4

3

5

6

7

5

6

7

1

2

3

4

Order Job/Part

Removing the seat and trunk

Seat

Damper

Rubber cap

Trunk

Rear carrier

Mat

Battery cover

Q’ty Remarks


1

1

1

1

1

1

1


3-5

SIDE COVER (LEFT AND RIGHT)

4

6

COVER AND PANEL

CHK

ADJ

5

3

1

2

4

5

6

2

3

Order

1

Job/Part

Removing the side cover(left and right)

Seat/Trunk

Tail / brake and rear turn signal (left, right) light lead

Front cover

Side cover(left)

Side cover(right)

Tail/brake light

Rear cover

Q’ty

1

1

1

1

1

1

Remarks


Refer to “SEAT AND TRUNK”.

Disconnect.


3-6

COVER AND PANEL

CHK

ADJ

FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE

4Nm (0.4 m•kg, 2.9 ft•lb)

3

2

1

7

4

6

5

5

6

7

1

2

3

4

Order Job/Part

Removing the footrest board and footrest board side cover mole

Side cover(left and right)

Q’ty Remarks


Refer to “SIDE COVER(LEFT AND

RIGHT)”.

Battery holder

Battery negative - lead

Battery positive + lead

Battery

Footrest board side cover mole(left)

Footrest board side cover mole(right)

Footrest board

1

1

1

1

1

1

1

c C

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


3-7

LEG SHIELD 1 , 2

2

3

4

COVER AND PANEL

CHK

ADJ

8

7

9

5

6

10

11

12

1

8

9

10

11

12

6

7

4

5

Order

1

2

3

Removing the leg shield 1,2

Footrest board

Job/Part

Cap

Headlight cover

Head and front turn signal (left, right) light lead

Leg shield 1

Turn signal relay

Headlight relay

Rear wheel lock clip

Hook

Leg shield 2

Starter relay

Coolant reservoir

Under cover

Q’ty Remarks


Refer to “FOOTREST BOARD AND

FOOTREST BOARD SIDE COVER

MOLE”.

1

1

1 Disconnect.

1

1

1

1

1

1

1

1

1

Disconnect.

Disconnect.

Disconnect.

Disconnect.


3-8

b

2

ADJUSTING THE VALVE CLEARANCE

CHK

ADJ

EAS00049

ENGINE


The following procedure applies to all of the valves.

NOTE:

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

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

a

1

1. Remove:

8 seat/trunk

8 battery cover

8 battery holder

8 front cover

Refer to “COVER AND PANEL”.

2. Drain:

8 coolant

(completely from the radiator )

3. Remove:

8 radiator cover 1

8 radiator

8 fan case2

Refer to “RADIATOR”in chapter 6.

4. Remove:

8 spark plug cap

8 spark plug

8 ignition coil

8 cylinder head cover

5. Measure:

8 valve clearance

Out of specification J Adjust.

Valve clearance (cold)

Intake valve

0.10 ~ 0.16 mm (0.004 ~ 0.006 in)

Exhaust valve

0.18 ~ 0.24 mm (0.007 ~ 0.010 in)

***************************************************** 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.

3-9

d


CHK

ADJ d. Measure the valve clearance with a thickness gauge 1.

Out of specification

J Adjust.

***************************************************** c

1

1

2

6. Adjust:

8valve clearance

***************************************************** a. Remove the valve pad 2 with a magnetic bar 1.

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.

b. Select the proper valve pad from the following table.

Valve pad thickness range

Nos.

120 ~ 240

1.20 (0.047in)

~ 2.40 mm

(0.095 in)

Available valve pads

25 thicknesses in

0.05 mm (0.002 in) increments c. Round off the original valve pad number according to the following table.

3-10


CHK

ADJ

Last digit

0 or 2

5

8

Rounded value

0

5

10

EXAMPLE:

Original valve pad number = 148 (thickness

=1.48 mm (0.058 in))

Rounded value = 150 d. 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.

e. Install the new valve pad .

NOTE:

8 Lubricate the valve pad with molybdenum disulfide oil.

8 Install the valve pad in the correct place.

f. Measure the valve clearance again.

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

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

3-11


CHK

ADJ

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

120

125

125

130

130

135

135

140

210

215

220

225

230

235

240

185

190

195

200

205

125

130

135

140

145

150

155

160

165

170

175

180

130

135

135

140

140

145

150

155

145

150

155

160

160

165

165

170

170

175

175

180

180

185

185

190

190 195

195

200

205

210

200

205

210

215

215

220

220

225

225

230

230

235

235

240

240

140

145

145

150

150 155

155

160

160

165

165 170

170

175

180

185

175

180

185

190

190

195

195

200

200

205

205

210

210

215

215

220

220 225

225

230

235

240

230

235

240

185

190

195

200

205

210

215

220

225

150

155

160

165

170

175

180

230

235

240

195

200

205

210

215

220

225

230

235

240

160

165

170

175

180

185

190

190

195

200

205

210

215

220

225

230

235

240

155

160

165

170

175

180

185

200

205

210

215

220

225

230

235

240

165

170

175

180

185

190

195

140

145

145

150

150

155

155 160 165 170 175 180 185

160 165 170 175 180 185 190

STANDARD CLEARANCE

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

190

195

205

210

215

220

225

230

235

240

195

200

210

215

220

225

230

235

240

200

205

215

220

225

230

235

240

205

210

220

225

230

235

240

Valve Clearance (cold)

0.10

∼ 0.16 mm

Rounded value 175

210

215

225

230

235

240

215

220

230

235

240

220

225

225 230

230 235

235

240

240

Measured valve clearance is 0.24 mm

Replace pad 175 with pad 185

Pad No. 175 = 1.75 mm

Pad No. 185 = 1.85 mm

Always install the valve pad with the number facing down.

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

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

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

120

125

120

125

130

120 125

125

130

130

135

135 140

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

145

150

150

155

155 160

160

165

165

170

170

175

175

180

180

185

185

190

190

195

195

200

200

205

205

210

210 215

215

220

220

225

225

230

230

235

235

240

240

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

135

140

145

150

205

210

215

220

225

230

235

240

160

165

170

175

180

185

190

195

200

200

205

210

215

220

225

230

235

240

155

160

165

170

175

180

185

190

195

140

145

150

155 160 165 170 175 180 185 190

STANDARD CLEARANCE

165

170

175

210

215

220

225

145

150

155

170

175

180

180

185

185

190

190 195

195 200

200

205

205

210

215

220

225

230

230 235

235

240

240

150

155

160

175

180

185

190

195

200

205

210

215

220

225

230

235

240

155

160

165

180

185

190

195

200

205

210

215

220

225

230

235

240

160

165

170

185

190

195

200

205

210

215

220

225

230

235

240

165

170

175

190

195

200

205

210

215

220

225

230

235

240

170

175

180

195

200

205

210

215

220

225

230

235

240

175

180

185

200

205

210

215

220

225

230

235

240

0.18

∼

180

185

190

195

205

210

215

220

225

230

235

240

185

190

195

200

210

215

220

225

230

235

240

190

195

200

205

215

220

225

230

235

240

0.24 mm

Rounded value 175

195

200

205

210

220

225

230

235

240

Valve Clearance (cold)

200

205

210

215

225

230

235

240

205

210

215

220

230

235

240

Replace pad 175 with pad 185

Pad No. 175 = 1.75 mm

Pad No. 185 = 1.85 mm

210

215

220

225

215

220

225

230

235

240

240

Always install the valve pad with the number facing down.

220

225

230

235

Measured valve clearance is 0.32 mm

3-12


CHK

ADJ

7. Install:

8all removed parts

NOTE:


8. Fill:

8cooling system

(with the specified amount of the recommended coolant)

Refer to “CHANGING THE COOLANT”.

3-13

ADJUSTING THE ENGINE IDLING SPEED

CHK

ADJ

EAS00054

ADJUSTING THE ENGINE IDLING SPEED

NOTE:

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

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

2. Connect:

8 engine tachometer

(onto the spark plug lead of cylinder)

Engine tachometer

90890-03113

YU-08036-C

3. Check:

8 engine idling speed


J Adjust

Engine idling speed

2000 ~ 2400 r/min a b

1

3-14

4. Adjust:


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

Direction a Engine idling speed is increased.

Direction b Engine idling speed is decreased.

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

5 . Adjust:

8throttle cable free play

Refer to “ADJUSTING THE THROTTLE

CABLE FREE PLAY”.

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

1.5 ~ 3.5 mm (0.059 ~ 0.138 in)

1

CHECKING THE EXHAUST GAS AT IDLE

CHK

ADJ


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

1. Stand the scooter on a level surface.

NOTE:

8 Place the scooter on a suitable stand.

8 Make sure the scooter is upright.

1

2. Install:

8pocket tester1.

(onto the engine oil drain bolt)

8engine tachometer

(onto the spark plug lead )

Pocket tester

90890-03132

YU-03112-C


90890-03113

YU-08036-C

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

Oil temperature

50~70°C

4. Measure:



Refer to “ADJUSTING THE ENGINE

IDLING SPEED”


2000 ~ 2400 r/min

5. Install:

8 carbon monoxide and hydrocarbon tester1.

8 sampling probe2.

8 engine tachometer3.

2

3-15


CHK

ADJ

3

600 mm

NOTE:

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

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

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

6.

Measure:

8 carbon monoxide density

8 hydrocarbon density

Carbon monoxide density ( when air induction system is operating )

3.5% below

hydrocarbon density ( when air induction system is operating )

1000ppm below


J Check air induction system.

Refer to “AIR INDUCTION SYSTEM” in chapter 7.

3-16

ADJUSTING THE THROTTLE CABLE FREE PLAY

CHK

ADJ

EAS00057

ADJUSTING THE THROTTLE CABLE FREE

PLAY

NOTE:

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

b 1 a

2 a

1. Check:

8 throttle cable free play a



1.5 ~ 3.5 mm (0.059 ~ 0.138 in)

2. Adjust:

8 throttle 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 Throttle cable free play is increased.

Direction b Throttle cable free play is decreased.

c. Tighten the locknut.

w

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

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

3-17

CHECKING THE SPARK PLUG

CHK

ADJ

EAS00060

CHECKING THE SPARK PLUG

1. Remove:

8 battery cover

8 battery holder


2. Disconnect:

8 spark plug cap

3. Remove:

8 spark plug c C

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

4. Check:

8 spark plug type

Incorrect

J Change.

Spark plug type (manufacturer)

CR7E (NGK)

5. Check:

8 electrode 1

Damage/wear J Replace the spark plug.

8 insulator 2

Abnormal color

J Replace the spark plug.

Normal color is medium-to-light tan.

6. Clean:

8 spark plug

(with a spark plug cleaner or wire brush)

7. Measure:

8 spark plug gap a

(with a wire Thickness gauge)

Out of specification J Regap.

Spark plug gap

0.7 ~ 0.8 mm (0.028 ~ 0.032 in)

8. Install:

8 spark plug

T

R

12.5 Nm (1.25 m • kg, 9 ft • lb)

NOTE:

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

3-18

9. Connect:

8 spark plug cap

10.Install:

8 battery holder

8 battery cover


CHECKING THE IGNITION TIMING

CHK

ADJ

EAS00062


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. Drain:

8coolant

(completely from the radiator )

2. Remove:

8radiator cover

8radiator

8fan case


1 b a

2

3. Attach:

8timing light 1

8engine tachometer 2

(onto the spark plug lead of cylinder)

Timing light

90890-03141

YU-03141


90890-03113

YU-08036-C

4. Check:

8ignition timing

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


2000 ~ 2400 r/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 J Check the ignition system.

3-19


CHK

ADJ

NOTE:

The ignition timing is not adjustable.

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

5. Remove:

8timing light

8engine tachometer

6. Install:

8fan case

8radiator

8radiator cover


7. Fill:

8cooling system


Refer to “CHANGING THE COOLANT”.

3-20

MEASURING THE COMPRESSION PRESSURE

CHK

ADJ

EAS00067

MEASURING THE COMPRESSION PRES-

SURE

NOTE:

Insufficient compression pressure will result in a loss of performance.

1. Measure:

8valve clearance

Out of specification J Adjust

Refer to “ADJUSTING THE VALVE

CLEARANCE”.

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

3. Remove:

8battery cover

8battery holder


4. Disconnect:

8spark plug cap

5. Remove:

8spark plug c C

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

1

6.

Install:

8compression gauge 1

Compression gauge

90890-03081

YU-33223

7.

Measure:

8compression pressure

Out of specification J Refer to steps (c) and (d).

3-21

MEASURING THE COMPRESSION PRESSURE

CHK

ADJ

Compression pressure (at sea level)

Minimum

1262 kPa (12.6 kgf/cm 2 , 700r/min)

Standard

1450 kPa (14.5 kgf/cm 2 , 700r/min)

Maximum

1624 kPa (16.2 kgf/cm 2 , 700r/min)

3-22

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

Set the main switch to “ON”.

b.

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

w

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

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

Carbon deposits

J Eliminate.

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

Refer to the following table.

Compression pressure

(with oil applied into the cylinder)

Reading

Higher than without oil

Same as without oil

Diagnosis

Piston ring(s) wear or damage J Repair.

Piston ring(s), valves, cylinder head gasket or piston possibly defective J Repair.

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

8. Remove:

8 compression gauge

9. Install:

8 spark plug

T

R

12.5 Nm (1.25 m • kg 9.0 ft • lb)

10.Connect:

8spark plug cap

11.Install:

8battery holder

8battery cover


CHECKING THE ENGINE OIL LEVEL

CHK

ADJ

EAS00069

CHECKING THE ENGINE OIL LEVEL


-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚

SAE 10W-30

SAE 10W-40

SAE 20W-40

SAE 20W-50 b a

NOTE:




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

J Add the recommended engine oil to the proper level.

Recommended oil

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

API standard

SE or higher grade c C the crankcase.

NOTE:

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


5. Check the engine oil level again.

NOTE:

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

3-23

1

CHANGING THE ENGINE OIL

CHK

ADJ

EAS00076



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

3. Remove:

8 engine oil filler cap 1

8 engine oil drain bolt 2

(along with the gasket)

4. Drain:

8 engine oil

(completely from the crankcase)

2

1

4 3 2 1

3-24

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

***************************************************** a. Remove the oil strainer cover 1, spring3 and oil filter element 4.

b. Replace the o-ring 2.

c. Install the oil strainer cover.

T

.

R

.

Oil strainer cover

32 Nm (3.2 m • kg, 23.1 ft • lb)

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

6. Install:

8 engine oil drain bolt


T

R

23 Nm (2.3 m • kg, 16.6 ft • lb)

7. Fill:

8 crankcase

(with the specified amount of the recommended engine oil)

Quantity

Total amount

0.8~0.9L (0.74~0.83 Imp qt,

0.87~0.98 US qt)

Periodic oil change

0.73~0.83 L (0.67~0.76 Imp qt,

0.80~0.90 US qt)


CHK

ADJ

8. Install:

8engine oil filler cap


10. Check:

8engine

(for engine oil leaks)

11. Check:

8engine oil level

Refer to “CHECKING THE ENGINE OIL

LEVEL”.

12. Check:

8engine oil pressure


PRESSURE”.

3-25

1

CHANGING THE TRANSMISSION OIL

CHK

ADJ

CHANGING THE TRANSMISSION OIL


NOTE:

8 Stand the scooter on a suitable stand.

8 Make sure that the scooter up right.


3. Place a container under the transmission.

4 Remove:

8transmission oil drain bolt 1

8transmission oil fill bolt

Completely drain the transmission oil.

5 Install:

8transmission oil drain bolt

T

R

13 Nm (1.3 m • kg, 9.4 ft • lb)

6. Fill:

8transmission oil

( with the specified amount of the recommended transmission 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)

Recommended oil

SAE10W30

1

3-26

7.

Install:

8transmission oil fill bolt1


T

R

23 Nm (2.3 m • kg, 16.6 ft • lb)

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

1

MEASURING THE ENGINE OIL PRESSURE

CHK

ADJ

EAS00077


1. Check:

8 engine oil level

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


LEVEL”.


c C

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

3. Remove:

8 seat/trunk

8 battery cover

8 front cover


4. Lossen:

8 gallery bolt 1 w

The engine, muffler and engine oil are extremely hot.

3-27

5. Check:

8 engine oil pressure

***************************************************** a. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.

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

to”OIL PUMP” in chapter 5.

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

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


CHK

ADJ

6. Install:

8 gallery bolt

T

R

7 Nm (0.7 m • kg, 5.1 ft • lb)

7. Install:

8 front cover

8 battery cover

8 seat/trunk


3-28

1

CHECKING THE AIR FILTER ELEMENT

CHK

ADJ

EAS00086

CHECKING THE AIR FILTER ELEMENT

1. Remove:

8 air filter case cover 1

8 air filter element

2. Check:

8 air filter element

Damage/dirty J Replace.

3. Install:

8air filter element

8air filter case cover

T

R

10 Nm (1.0 m • kg, 7.2 ft • lb) c 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 carburetor 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.

3-29

2

CHECKING THE CARBURETOR JOINT AND INTAKE

MANIFOLD/CHECKING THE FUEL AND VACUUM HOSES

1

CHK

ADJ

EAS00094

CHECKING THE CARBURETOR JOINT AND

INTAKE MANIFOLD

1. Remove:

8 seat/trunk

8 rear carrier

8 battery cover

8 front cover

8 side cover (left and right)

8 rear cover


2. Check:

8 carburetor joint 1

8 intake manifold 2

Cracks/damage J Replace.

Refer to “CARBURETOR” in chapter 7.

3. Install:

8 rear cover

8 side cover (left and right)

8 front cover

8 battery cover

8 rear carrier

8 seat/trunk


2

1

3-30

EAS00096

CHECKING THE FUEL AND VACUUM

HOSES

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

1. Remove:

8 seat/trunk


2. Check:

8 vacuum hose 1

8 fuel hose 2

Cracks/damage

J Replace.

Loose connection

J Connect properly.

3. Install:

8 seat/trunk


CHECKING THE FUEL HOSES AND FUEL FILTER

CHK

ADJ

EAS00097

CHECKING THE FUEL HOSES AND FUEL

FILTER

The following procedure applies to all of the fuel hoses.

1. Remove:

8battery cover

8seat/trunk

8rear carrier

8front cover

8side cover (left and right)

8rear cover


2

1

2. Check:

8fuel hose 1

Cracks/damage

J Replace.

8fuel filter 2

Contaminants/damage J Replace.

NOTE:

8 Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident.

8 The arrow mark on the fuel filter must point towards the fuel cock as shown.

3.

Install:

8rear cover

8side cover (left and right)

8front cover

8rear carrier

8seat/trunk

8battery cover


3-31

CHECKING THE CRANKCASE BREATHER HOSE

CHK

ADJ

EAS00098

CHECKING THE CRANKCASE BREATHER

HOSE

1.

Remove:

8seat/trunk


1

2.

Check:

8crankcase breather hose 1


Loose connection

J Connect properly.

c C

Make sure the crankcase breather hose is routed correctly.

3.

Install:

8seat/trunk


3-32

CHECKING THE EXHAUST SYSTEM

CHK

ADJ

EAS00099

CHECKING THE EXHAUST SYSTEM

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

1. Remove:

8 muffler assembly

Refer to “MANIFOLD, AIR FILTER AND

MUFFLER ASSEMBLY” in chapter 5.

1

2

3

4

5

2 . Check:

8 muffler assembly 1


8 gasket 2

Exhaust gas leaks

J Replace.

3 . Check:

8 tightening torque

T

.

R

.

Muffler assembly nut 3

13 Nm (1.3 m • kg, 9.4 ft • lb)

Muffler and rear arm bolt 4

31 Nm (3.1 m • kg, 22.4 ft • lb)

Muffler and rear arm bolt 5

31 Nm (3.1 m • kg, 22.4 ft • lb)

4.

Install:

8muffler assembly


MUFFLER ASSEMBLY” in chapter 5.

3-33

a b

CHECKING THE COOLANT LEVEL

CHK

ADJ

EAS00103

CHECKING THE COOLANT LEVEL


NOTE:



2.

Remove:

8 mat

8 battery cover


3.

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

J Add the recommended coolant to the proper level.

c C the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.

tilled water is not available, soft water may be used.


5. Check:

8coolant level

NOTE:

Before checking the coolant level, wait a few minutes until it settles.

6. Install:

8 battery cover

8 mat


3-34

CHECKING THE COOLING SYSTEM

CHK

ADJ

EAS00104

CHECKING THE COOLING SYSTEM

1.

Remove:

8 seat/trunk

8 battery cover

8 front cover

8 battery holder/ battery

8 footrest board side cover mole( left and right)

8 mat/footrest board


8 radiator cover

Refer to “COOLING SYSTEM”in chapter 6.

1

2

3

2. Check:

8 radiator 1

8 radiator inlet hose 2

8 radiator outlet hose 3


Refer to “COOLING SYSTEM” in chapter 6.

3.

Install:

8 radiator cover


8 mat/footrest board

8 footrest board side cover mole( left and right)

8 battery holder/ battery

8 front cover

8 battery cover

8 seat/trunk


3-35

1

CHANGING THE COOLANT

CHK

ADJ

EAS00105


1. Remove:

8 mat

8 battery cover

8 footrest board side cover mole (right)


8 radiator cover


2. Disconnect:

8 coolant reservoir hose 1

3. Drain:

8 coolant

(from the coolant reservoir)

8 coolant

(from the radiator under drain bolt )

4. Remove:

8radiator 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.

The following procedure applies to all of the coolant drain bolts and copper washers.

5. Connect:

8coolant reservoir hose

6. Install:

8radiator under drain bolt

T

R

2 Nm (0.2 m • kg, 1.5 ft • lb)

3-36


CHK

ADJ

7. Fill:

8 cooling system


Recommended antifreeze

High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines

Mixing ratio

1:1 (antifreeze:water)

Quantity

Total amount

0.52 L (0.48 Imp qt, 0.57 US qt)

Coolant reservoir capacity

0.26 L (0.24 Imp qt, 0.28 US qt)

From minimum to maximum level mark

0.10~0.25 L (0.09~0.14 Imp qt,

0.11~0.16 US qt)

Handling notes for coolant

Coolant is potentially harmful and should be handled with special care.

w oughly wash them with water and consult a doctor.

quickly wash it away with water and then with soap and water.

and get immediate medical attention.

c C the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.

tilled water is not available, soft water may be used.

painted surfaces, immediately wash them with water.

8. Install:

8 radiator cap

3-37


CHK

ADJ

9. Fill:

8 coolant reservoir

(with the recommended coolant to the maximum level mark a)

10.Install:

8 coolant reservoir cap

11.Start the engine, warm it up for several minutes, and then stop it.

12.Check:

8 coolant level

Refer to “CHECKING THE COOLANT

LEVEL”.

NOTE:

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

13. Install:

8 radiator cover


8 footrest board side cover mole (right)

8 battery cover

8 mat


3-38

a a b

1

ADJUSTING THE FRONT BRAKE/

ADJUSTING THE REAR BRAKE a

CHK

ADJ

EAS00109

CHASSIS

ADJUSTING THE FRONT BRAKE

1. Check:

8 brake lever free play a


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

10 ~ 20 mm (0.394 ~ 0.787 in)

2.

Adjust:

8 brake 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 Brake lever free play is increased.

Direction b Brake lever free play is decreased.

c C

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

a b

1

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

EAS00114

ADJUSTING THE REAR BRAKE

1. Check:

8brake lever free playa


Brake lever free play

10 ~ 20 mm (0.394 ~ 0.787 in)

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 Brake lever free play is increased.

Direction b Brake lever free play is decreased.

c C

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

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

3-39

A

CHECKING THE FRONT AND REAR BRAKE SHOES

2

1

CHK

ADJ

EAS00127

CHECKING THE FRONT AND REAR BRAKE

SHOES

1. Operate the brake.

2. Check:

8 wear indicator 1

Reaches the wear limit line 2

J Replace the brake shoes as a set.

Refer to “FRONT WHEEL AND FRONT

BRAKE” and “REAR WHEEL AND

REAR BRAKE” in chapter 4.

B

A Front brake

B Rear brake

1

2

3-40

CHECKING AND ADJUSTING THE STEERING HEAD

CHK

ADJ

EAS00148

CHECKING AND ADJUSTING THE STEER-

ING HEAD


w

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

NOTE:

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

2. Check:

8 steering head

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

Binding/looseness

J Adjust the steering head.

3. Remove:

8 head light cover

8 leg shield 1


3

1

4.

Adjust:

8 steering head

***************************************************** a. Remove the upper cover .

b. Loosen the steering nut 1 and then tighten it to specification with the steering nut wrench.

NOTE:

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

2

3-41

Steering nut wrench

90890-01268

YU-01268 c. Loosen the upper bearing inner race2 completely and then tighten it to specification with a steering nut wrench3 .

CHECKING AND ADJUSTING THE STEERING HEAD

CHK

ADJ w

Do not overtighten the upper bearing inner race.

T

.

R

.

Upper bearing inner race(final tightening torque)

7 Nm (0.7 m • kg, 5.1 ft • lb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the upper cover and check the bearing race.

Refer to “STEERING HEAD” in chapter 4.

e. Hold the upper bearing inner race with a steering nut wrench and tighten the steering nut1 with a steering nut wrench2.

Steering nut wrench

90890-01403

YU-A9472

T

.

R

.

Steering nut

30 Nm (3.0 m • kg, 21.7 ft • lb)

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

5. Install:

8leg shield 1

8head light cover


3-42

CHECKING THE FRONT FORK

CHK

ADJ

EAS00151

CHECKING THE FRONT FORK


w


2. Check:

8inner tube

Damage/scratches J Replace.

8dust seal

Damage/scratches

J Replace.

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

4.

Check:

8front fork operation

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

Rough movement J Repair.

Refer to “FRONT FORK” in chapter 4.

3-43

CHECKING THE TIRES

CHK

ADJ

EAS00163


The following procedure applies to both of the tires.

1. Check:

8tire pressure


J Regulate.

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

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

could cause tire damage, an accident or an injury.

Basic weight

(with oil and a full fuel tank)

Maximum load*

Cold tire pressure

Up to 55 kg

81 kg (179 lb)

158 kg (348 lb)

Front Rear

150 kPa (1.5

kgf/cm 2 , 22 psi)

175 kPa (1.75

kgf/cm 2 , 25 psi)

55 kg ~ 158 kg

150 kPa (1.5

kgf/cm 2 , 22 psi)

175 kPa (1.75

kgf/cm 2 , 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.

3-44

A

3

2

B

1


CHK

ADJ

2. Check:

8tire surfaces

Damage/wear

J Replace the tire.

Minimum tire tread depth

0.8 mm (0.032 in)

1 Tire tread depth

2 Sidewall

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

the correct tube.

tube as a set.

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

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

A Tire

B Wheel

Tube wheel

Tubeless wheel

Tube tire only

Tube or tubeless tire

3-45 low have been approved by Yamaha

Motor Taiwan Co., Ltd. for this model.

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

Front tire

Manufacturer Model

KENDA K348A

Size

90/90-10 50J

Rear tire

Manufacturer Model Size

KENDA K348A 90/90-10 50J

2

1

V E

D R I


CHK

ADJ w

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

NOTE:

For tires with a direction of rotation mark 1:

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

8 Align the mark 2 with the valve installation point.

3-46

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:

8wheel

Damage/out-of-round

J Replace.

w

Never attempt to make any repairs to the wheel.

NOTE:

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

3-47

EAS00170

CHECKING AND LUBRICATING THE

CABLES

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

w

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

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

1. Check:

8 outer cable

Damage

J Replace.

2. Check:

8 cable operation

Rough movement J Lubricate.

Recommended lubricant

Engine oil or a suitable cable lubricant

NOTE:

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

LUBRICATING THE 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.


Lithium-soap-based grease

EAS00173

LUBRICATING THE CENTERSTAND

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



3-48

CHECKING AND CHARGING THE BATTERY

CHK

ADJ

EAS00179

ELECTRICAL SYSTEM

CHECKING AND CHARGING THE BATTERY w

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

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

area.

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

dling batteries.

OUT OF REACH OF CHILDREN.

it can cause severe burns or permanent eye injury.

FIRST AID IN CASE OF BODILY CONTACT:

EXTERNAL and get immediate medical attention.

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

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

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

3-49


CHK

ADJ

NOTE:

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

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

1. Remove:

8 mat

8 battery cover

8battery holder


-

+

2

1

2. Disconnect:

8 battery leads

(from the battery terminals) c C

First, disconnect the negative battery lead

3. Remove:

8 battery

4. Check:

8 battery charge

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

Pocket tester

90890-03132 (YU-03112-C)

3-50

Positive tester probe J positive battery terminal

Negative tester probe J negative battery terminal

NOTE:

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

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

13.0

12.5

12.0

11.5


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

CHK

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

5 6.5

10

Charging time (hours)

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

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

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

Ambient temperature

20 C

Charging condition of the battery (%)

3-51

5.

Charge:

8 battery

(refer to the appropriate charging method illustration) w

Do not quick charge a battery.

c C caps.

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

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

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

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


CHK

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

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

Hot batteries can explode!

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

3-52


CHK

ADJ

Charging method using a variable-current (voltage) charger

Charger

Ammeter

Measure the open-circuit voltage prior to charging.

NOTE:

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

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

NOTE:

Set the charging voltage to 16-17 V.

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

NO

YES

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

NO

Adjust the voltage to obtain the standard charging amperage.

YES

Adjust the char ging voltage to

20 ~ 25V.

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

NO

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

Refer to “CHECKING AND

CHARGING THE BATTERY”.

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

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

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

12.8 V ~ Charging is complete.

12.0 ~ 12.7 V ~ Recharging is required.

Under 12.0 V ~ Replace the battery.

3-53


CHK

ADJ

Charging method using a constant voltage charger

Measure the open-circuit voltage prior to charging.

NOTE:

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

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

YES

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

NO

Charge the battery until the charging voltage reaches 15 V.

NOTE:

Set the charging time to a maximum of 20 hours.

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

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

12.8 V ~ Charging is complete.

12.0 ~ 12.7 V ~ Recharging is required.

Under 12.0 V ~ Replace the battery.

c C

Constant amperage chargers are not suitable for charging MF batteries.

Voltmeter

Charger

Ammeter

3-54

CHECKING AND CHARGING THE BATTERY/

CHECKING THE FUSE

1

2

CHK

ADJ

6. Install:

8 battery

7. Connect:

8 battery leads

(to the battery terminals) c C

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

8. Check:

8 battery terminals

Dirt

J Clean with a wire brush.

Loose connection

J Connect properly.

9. Lubricate:

8 battery terminals


Dielectric grease

10. Install:

8 battery holder

8 battery cover

8 mat


EAS00181


The following procedure applies to all of the fuse.

c C

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

1. Remove:

8 mat

8 battery cover


3-55


CHK

ADJ

2. Check:

8 fuse

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

NOTE:

Set the pocket tester selector to “

Ω × 1”.

Pocket tester

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

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

3. Replace:

8 blown fuse

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

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

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

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

Fuse Amperage rating Q’ty

Main 7.5A

1 w

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

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

4. Install:

8 battery cover

8 mat


3-56

2

REPLACING THE HEADLIGHT BULB

CHK

ADJ

EAS00182

REPLACING THE HEADLIGHT BULB

1. Remove:

8 headlight cover

1

2. Disconnect:

8 headlight coupler

3. Remove:

8 headlight bulb holder rubber1

8 headlight bulb holder

8 headlight bulb 2 w

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

4. Install:

8 headlight bulb New

Secure the new headlight bulb with the headlight bulb holder.

c C

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

5. Install :

8 headlight bulb holder

6. Connect:

8 headlight bulb holder rubber

7. Install:

8 headlight lead coupler

8.

Install:

8headlight cover

3-57

1 b a

ADJUSTING THE HEADLIGHT BEAM

CHK

ADJ

EAS00184

ADJUSTING THE HEADLIGHT BEAM

1.

Adjust:

8headlight beam (vertically)

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

Turn the adjusting screw 1 in direction a or b .

Direction a Headlight beam is raised.

Direction b Headlight beam is lowered.

***************************************************** a b

2

2.

Adjust:

8 headlight beam (horizontally)

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

Turn the adjusting knob 2 in direction a or b.

Direction a Headlight beam moves to the right.

Direction b Headlight beam moves to the left.

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

3-58

CHAS

CHAPTER 4

CHASSIS

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

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

FRONT BRAKE SHOE PLATE ......................................................... 4-3

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

DISASSEMBLING THE BRAKE SHOE PLATE ................................ 4-4

CHECKING THE FRONT WHEEL .................................................... 4-5

CHECKING THE SPEEDOMETER GEAR UNIT ............................. 4-6

CHECKING THE BRAKE .................................................................. 4-7

ASSEMBLING THE BRAKE SHOE PLATE ...................................... 4-8

ASSEMBLING THE FRONT WHEEL ................................................ 4-9

INSTALLING THE FRONT WHEEL ................................................ 4-10

ADJUSTING THE FRONT WHEEL STATIC BALANCE ................. 4-11

REAR WHEEL AND BRAKE ................................................................. 4-13

REMOVING THE REAR WHEEL .................................................... 4-14

CHECKING THE REAR WHEEL ..................................................... 4-15

CHECKING THE REAR WHEEL DRIVE HUB ................................ 4-15

CHECKING THE BRAKE ................................................................ 4-16

ASSEMBLING THE BRAKE SHOE PLATE .................................... 4-17

INSTALLING THE REAR WHEEL ................................................... 4-18

ADJUSTING THE REAR WHEEL STATIC BALANCE ................... 4-18

FRONT FORK ......................................................................................... 4-19

REMOVING THE FRONT FORK LEGS.......................................... 4-21

DISASSEMBLING THE FRONT FORK LEGS ............................... 4-21

CHECKING THE FRONT FORK LEGS .......................................... 4-22

ASSEMBLING THE FRONT FORK LEGS ..................................... 4-23

INSTALLING THE FRONT FORK LEGS ........................................ 4-24

HANDLEBAR .......................................................................................... 4-25

REMOVING THE HANDLEBAR ...................................................... 4-27

CHECKING THE HANDLEBAR ...................................................... 4-27

INSTALLING THE HANDLEBAR..................................................... 4-28

STEERING HEAD ................................................................................... 4-30

REMOVING THE FRONT FORK ASSEMBLY ................................ 4-31

CHECKING THE STEERING HEAD ............................................... 4-32

INSTALLING THE STEERING HEAD ............................................. 4-33

REAR SHOCK ABSORBER ASSEMBLY............................................. 4-34

4-37

CHAS

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY .......... 4-35

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .......... 4-35

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ........ 4-36

4-38

FRONT WHEEL AND BRAKE

CHAS

EAS00517


CHASSIS

7

9

10

4

1

2

6

48Nm (4.8 m•kg, 34.7 ft•lb)

3

8

5

3

4

5

1

2

6

7

8

9

10

Order Job/Part

Removing the front wheel and brake

Stop ring

Speedometer cable

Adjuster

Front brake cable

Pin

Wheel axle nut

Wheel axle

Front brake shoe plate

Collar

Front wheel

4-1

1

1

1

1

1

1

1

1

1

1

Q’ty Remarks


NOTE:


Refer to”REMOVING THE FRONT

WHEEL and INSTALLING THE FRONT

WHEEL”.


EAS00518

FRONT WHEEL

1

2


CHAS

3

4

Order

1

2

3

4

Job/Part

Disassembling the front wheel

Oil seal

Bearing

Spacer

Bearing

Q’ty Remarks


1

1

1

1 Refer to”REMOVING THE FRONT

WHEEL” and “INSTALLING THE FRONT

WHEEL”

For assembly, reverse the disassembly procedure.

4-2

FRONT BRAKE SHOE PLATE


CHAS

2

LS t r y u

6

6

LS

1

9

0 q

LS w e

8

LS

7

8Nm (0.8 m•kg ,5.8 ft•lb)

5

4

LS

3

8

9

0 q w

1

2

3

4

5

6

7 e r t y u

Order Job/Part

Disassembling the front brake shoe plate

Brake shoe kit

Tension spring

Comshaft lever

Indicator plate

Return spring

Brake camshaft / O-ring

Oil seal

Oil seal

Circlip

Plate washer

Speedometer clutch

Drive gear

Plate washer

Bush

Oil seal

Speedometer gear

Plate washer

Q’ty

1

1

1

1

1

1

1

1

1

1/1

1

1

1

1

1

1

2

Remarks


Refer to”DISASSEMBLING THE

BRAKE SHOE PLATE” and “ASSEM-

BLING THE BRAKE SHOE PLATE”.


4-3

5

LS

1

2

6

LS

LS


CHAS

EAS00520

REMOVING THE FRONT WHEEL


w


4

LS

3

NOTE:


2. Remove:

8 speedometer cable 1

8 ront brake cable 2

8 front wheel axle nut 3

8 front wheel axle 4

8 front wheel 5

8 collar

8 front brake shoe plate 6

Refer to” FRONT WHEEL AND BRAKE”

.

EAS00524

DISASSEMBLING THE BRAKE SHOE PLATE

1. Remove:

8 front brake shoe

8 comshaft lever

8 indicator plate

8 return spring

8 brake camshaft

8 speedometer gear

NOTE:

Remove the bush from the brake shoe plate with the meter gear bush tool.

2.

Remove:

8circlip

8plate washer

8speedometer clutch

8drive gear

8plate washer

3.

Remove:

8bush

8speedometer gear

8plate washer

4-4


CHAS

EAS00525

CHECKING THE FRONT WHEEL

1. Check:

8 wheel axle

Roll the wheel axle on a flat surface.

Bends J Replace.

w

Do not attempt to straighten a bent wheel axle.

2. Check:

8 tire

8 front wheel

Damage/wear

J Replace.

Refer to “CHECKING THE TIRES” and

“CHECKING THE WHEELS” in chapter

3.

3. Measure:

8 radial wheel runout 1

8 lateral wheel runout 2

Over the specified limits J Replace.

Radial wheel runout limit

1.0 mm (0.04 in)

Lateral wheel runout limit

1.0 mm(0.04 in)

4-5

4. Check:

8 wheel bearings

Front wheel turns roughly or is loose J

Replace the wheel bearings.

8 oil seals

Damage/wear

J Replace.

5. Replace:

8 wheel bearings New

8 oil seal New

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

3

4

2

2

1


CHAS 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:

8 speedometer clutch

Bends/damage/wear J Replace.

2. Check:

8 speedometer drive gear 1

8 speedometer gear 2

Damage/wear J Replace.

1

4-6


CHAS

EAS00536

CHECKING THE BRAKE

The following procedure applies to all of the brake shoes.

1. Check:

8 brake shoe lining

Glazed areas

J Repair.

Sand the glazed areas with course sandpaper.

NOTE:

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

a a a a

2. Measure:

8 brake shoe lining thickness a


JReplace.

Brake shoe lining thickness limit

(minimum)

2.0 mm (0.079 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.

b

4-7

3. Measure:

8 brake drum inside diameter b

Out of specification JReplace the wheel.

Brake drum inside diameter limit

(maximum)

110.5 mm (4.35 in)


CHAS

4. Check:

8 brake drum inner surface

Oil deposits

J Clean.

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

Scratches

J Repair.

Lightly and evenly polish the scratches with an emery cloth.

5. Check:

8brake camshaft

Damage/wear

J Replace.

a b

2

1

EAS00537

ASSEMBLING THE BRAKE SHOE PLATE

1. 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.

***************************************************** a b

2. Install:

8comshaft lever

T

R

7 Nm (0.7 m • kg, 5.1 ft • lb)

4-8

Align the camshaft punch mark a and comshaft lever punch mark b is positioned as shown.

3. Install:

8speedometer gear

8bush (with the meter gear bush tool)

1


CHAS

EAS00538

ASSEMBLING THE FRONT WHEEL

1. Install:

8 wheel bearing(right)1 New

8 oil seal New

8 spacer

8 wheel bearing(left) New

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

c C

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

NOTE:

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

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

2. Install:

8 brake shoe plate

Align the tab on the speedometer clutch with the slot in the wheel hub.

4-9

1

2


CHAS

EAS00540

INSTALLING THE FRONT WHEEL

1.

Lubricate:

8 wheel axle

8 wheel bearings

8 oil seal lips

8 speedometer drive gear

8 speedometer gear



3

2.

Install:

8front wheel1

NOTE:

Make sure the slot2 in the brake shoe plate fits over the stopper3 on the outer tube.

3.

Tighten:

8 wheel axle nut

T

R

48 Nm (4.8 m • kg, 34.7 ft • lb) w

Make sure the brake cable is routed properly.

c C

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

4-10


CHAS

EAS00548

ADJUSTING THE FRONT WHEEL STATIC

BALANCE

NOTE:

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

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

1. Remove:

8 balancing weight(s)

X

1

X 2

2. Find:

8 front wheel’s heavy spot

NOTE:

Place the front wheel on a suitable balancing stand.

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

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

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

d. Release the front wheel.

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

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

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

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

4-11

X

1


CHAS

3. Adjust:

8 front wheel static balance

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

NOTE:

Start with the lightest weight.

b.

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

c.

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

d.

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

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

4. Check:

8 front wheel static balance

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

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

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

4-12

EAS00555

REAR WHEEL AND BRAKE


CHAS

5

7Nm (0.7 m•kg, 5.1 ft•lb)

9

4

10

11 6

2

7

12

12

3

7

8

Order Job/Part

Removing the rear wheel

5

6

7

8

9

10

11

12

3

4

1

2

Muffler assembly

Self lock nut/Plate washer

Brake adjuster

Rear brake cable

Pin

Rear wheel

Brake shoe kit

Tension spring

Plate washer

Camshaft lever

Indicator plate

Return spring

Brake camshaft/O-ring

1

104Nm (10.4 m•kg, 75.2 ft•lb)

4-13

1

1

2

1

1

1/1

1

1

1

1

1

1/2

Q’ty Remarks


NOTE:



MUFFLER ASSEMBLY “in chapter 5.



CHAS

EAS00564

REMOVING THE REAR WHEEL

1.

Stand the scooter on a level surface.

w


NOTE:

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

2.

Remove:

8brake adjuster

1

3.

Remove:

8muffler assembly

8wheel axle nut 1

1

4. Remove:

8rear wheel1

4-14


CHAS

EAS00565

CHECKING THE REAR WHEEL

1. Check:

8 tire

8 rear wheel


Refer to “CHECKING THE TIRES” and

“CHECKING THE WHEELS” in chapter

3.

2. Measure:

8 radial wheel runout

8 lateral wheel runout

Refer to “CHECKING THE FRONT

WHEEL”.

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB

1.

Check:

8rear wheel drive hub


4-15

a a a b a


CHAS

EAS00569

CHECKING THE BRAKE

The following procedure applies to all of the brake shoes.

1. Check:

8 brake shoe lining

Glazed areas

J Repair.

Sand the glazed areas with course sandpaper.

NOTE:

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

2. Measure:

8 brake shoe lining thickness a


J Replace.

Brake shoe lining thickness limit

(minimum)

2.0 mm(0.079 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.

4-16

3. Measure:

8 brake drum inside diameter b

Out of specification J Replace the wheel.

Brake drum inside diameter limit

(maximum)

110.5 mm(4.35 in)

4. Check:

8 brake drum inner surface

Oil deposits

J Clean.

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

Scratches J Repair.

Lightly and evenly polish the scratches with an emery cloth.

5. Check:

8 brake camshaft


1 2

3

1 a b


CHAS

EAS00570

ASSEMBLING THE BRAKE SHOE PLATE

1.

Install:

8 brake camshaft 1

T

R

7 Nm (0.7 m • kg, 5.1 ft • lb)

8 return spring 2

8 brake shoe wear indicator 3

***************************************************** 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.

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

1

2.

Install:

8 brake shoes1

8 tension springs c C lining.

time of changing the brake shoe.

when assembling the brake shoe and spring.

the assembly direction of tension spring, and do not let the spring hook and coil to be damaged by the pliers.

4-17

1


CHAS

EAS00574

INSTALLING THE REAR WHEEL

1. Lubricate:

8 wheel axle



2. Install:

8 rear wheel

3. Tighten:

8 wheel axle nut1

T

R

104 Nm (10.4 m • kg, 75.2 ft • lb)

4. Install:

8 muffler assembly

5. Adjust:

8 brake lever free play

Refer to “ADJUSTING THE REAR

BRAKE” in chapter 3.

4-18

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:

8 rear wheel static balance

Refer to “ADJUSTING THE FRONT

WHEEL STATIC BALANCE”.

FRONT FORK

CHAS

EAS00646

FRONT FORK

3

2

4

1

30Nm (3.0 m•kg, 21.7 ft•lb)

Order

1

2

3

4

Job/Part

Removing the front fork legs

Front wheel

Handlebar

Front fork assembly

Headlight cover

Leg shield 1

Lower bracket pinch bolt

Snap ring

Inner tube plug

Front fork leg

1

1

1

1

Q’ty Remarks


Refer to “FRONT WHEEL AND BRAKE”.

Refer to “HANDLE BAR”.

Refer to “STEERING HEAD”.

Refer to “COVER AND PANEL” in chapter 3.


4-19

FRONT FORK

CHAS

EAS00648

1g

3

4

4g

5

6

7

2

1

0

9

8

3g

7

8

9

0

1

2

3

4

5

6

Order Job/Part

Disassembling the front fork legs

Band

Boot

Dust seal

Circlip

Spring guide

Rebound spring

Inner tube

Damper rubber

Fork spring

Outer tube

Q’ty Remarks


1

1

1

1

1

1

1

1

1

1

Refer to “DISASSEMBLING AND IN-

STALLING THE FRONT FORK LEGS “


4-20

FRONT FORK

CHAS

EAS00651

REMOVING THE FRONT FORK LEGS

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

1.

Stand the scooter on a level surface.

w


NOTE:


2

1

3

2.

Loosen:

8lower bracket pinch bolt 1

3.

Remove:

8snap ring 2

8front fork leg3 w

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

EAS00653

DISASSEMBLING THE FRONT FORK LEGS


1.

Remove:

8band

8foot

8inner tube plug

5

4

3 2

1

4-21

2.

Remove:

8dust seal 1

8circlip2

8spring guide3

8rebound spring 4

8inner tube 5 c C

Do not scratch the inner tube.

3

2

1

FRONT FORK

CHAS

3.

Remove:

8 damper rubber 1

8 fork spring 2

8 outer tube 3

3

2

1

EAS00656

CHECKING THE FRONT FORK LEGS


1.

Check:

8 inner tube

8 outer tube

Bends/damage/scratches J Replace.

w

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

2.

Measure:

8 spring free length a


J Replace.

Spring free length

125 mm (4.921 in)

<Limit> : 122.5 mm (4.823 in)

3.

Check:

8 inner tube 1

8 spring guide2

8 rebound spring 3


3

2

1

4.

Check:

8 damper rubber 1

8 fork spring2

8 outer tube 3

Damage/wear

J Replace.

4-22

1

2

FRONT FORK

CHAS

EAS00658

ASSEMBLING THE FRONT FORK LEGS


NOTE:

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

- dust seal

- circlip

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

1.

Install:

8 fork spring 1

8 damper rubber2

NOTE:

8 Install the spring with the smaller pitch facing down .

2.

Lubricate:

8 inner tube’s outer surface

8 rebound spring

8 fork spring

8 circlip


Molybdenum-disulfide grease

1

2

3 4

5

3. Install:

8 inner tube1

8 rebound spring 2

8 spring guide3

8 circlip4

New

8 dust seal 5

New

4. Install:

8 boot

8 band

New

4-23

2

3

1

FRONT FORK

CHAS

EAS00663

INSTALLING THE FRONT FORK LEGS


1.

Install:

8front fork leg 1

8snap ring 2

New

8inner tube plug

8lower bracket pinch bolt 3

NOTE:

Pull up the inner tube until it stops, then install the snap ring to groove.

2.

Tighten:

8lower bracket pinch bolt

T

R

30 Nm (3.0 m • kg, 21.7 ft • lb)

4-24

HANDLEBAR

CHAS

EAS00664

HANDLEBAR

4

LS

17

8

3

LS

10 4

7

14

6

16

LS

9

5

12

11 15

LS

2

60Nm (6.0 m•kg, 43.4 ft•lb)

13

1

6

7

8

9

10

11

12

13

14

1

2

3

4

5

Order Job/Part

Removing the handlebar

Headlight cover

Leg shield 1

Clamp

Speedometer cable

Speedometer assembly

Rear view mirror(left and right)

Front brake cable

Front brake switch

Brake lever (right)

Handlebar holder assembly(right)

Throttle cable kit

Throttle grip assembly

Rear brake cable

Rear brake switch

Brake lever(left)

Handlebar holder assembly(left)

4-25

Q’ty Remarks



1

1

1

1

1

1

1

1

1

1

1

1

1/1

1

HANDLEBAR

CHAS

7

LS

10

LS

9

5

60Nm (6.0 m•kg, 43.4 ft•lb)

Order

15

16

17

Job/Part

Handlebar grip

Handlebar upper cover

Handlebar assembly

4

LS

17

8

6

3

4

14

16

12

11 15

LS

2

13

1

Q’ty

1

1

1

Remarks


4-26

HANDLEBAR

CHAS

EAS00666

REMOVING THE HANDLEBAR


w


1

2

2. Remove:

8handlebar holder assembly (right)1

8throttle grip assembly 2

NOTE:

While removing the handlebar holder assembly

(right), pull back the rubber cover.

3. Remove:

8handlebar grip

NOTE:

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

EAS00668

CHECKING THE HANDLEBAR


w


1

4-27

2. Check:

8handlebar 1

Bends/cracks/damage J Replace.

w

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

FORWARD

2

1

LEFT a

RIGHT b

HANDLEBAR

CHAS

EAS00673

INSTALLING THE HANDLEBAR


w


2. Install:

8handlebar 1

NOTE:

Align the slot a on the handlebar with the steering shaft 2 surface.

3. Tighten:

8handlebar

T

R

60 Nm (6.0 m • kg, 43.4 ft • lb) c C

There must be a space b

4. Install:

8handlebar upper cover

1 b

1

5. Install:

8handlebar holder assembly ( left )1

NOTE:

Align the projection a on the handlebar holder assembly ( left ) with the hole b on the handlebar.

a a b

2

6. Install:

8throttle grip assembly 1

8handlebar holder assembly (right)2

8throttle cable kit 3

4-28

4-29

HANDLEBAR

CHAS

NOTE:

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

8 Align the projectiona on the right handlebar holder assembly with the hole b on the handlebar.

w

Make sure the throttle grip operates smoothly.

7. Adjust:

8throttle cable free play


CABLE FREE PLAY” in chapter 3.


1.5 ~ 3.5 mm (0.059 ~ 0.138 in)

STEERING HEAD

CHAS

EAS00675

STEERING HEAD

1

2

7

9

12

11

3

7Nm (0.7 m•kg, 5.1 ft•lb)

30Nm (3.0 m•kg, 21.7 ft•lb)

8

10

6

5

4

7

8

9

5

6

1

2

3

4

10

11

12

Order Job/Part

Removing the front fork assembly

Front wheel

Leg shield 1

Handlebar assembly

Front fender

Inner fender

Cable holder

Ball race cover

Ring nut

Upper bearing inner race

Front fork assembly

Upper bearing

Lower bearing

Upper bearing outer race

Lower bearing outer race

Lower bearing inner race

4-30

1

1

1

1

1

1

1

1

1

1

1

1

Q’ty Remarks


Refer to “FRONT WHEEL AND BRAKE”.


Refer to “HANDLEBAR”.


1

2

STEERING HEAD

CHAS

EAS00678

REMOVING THE FRONT FORK ASSEMBLY


w


NOTE:


2 . Remove:

8ball race cover

8ring nut 1

(with the ring nut wrench 2)

Ring nut wrench

90890-01268

YU-01268

3 . Remove:

8upper bearing inner race1

(with the ring nut wrench 2) w

Securely support the front fork assembly so that there is no danger of it falling.

4-31

1 2

STEERING HEAD

CHAS

EAS00682

CHECKING THE STEERING HEAD

1. Wash:

8bearing balls

8bearing races

Recommended cleaning solvent

Kerosene

2. Check:

8bearing balls 1

8bearing races 2

Damage/pitting J 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 C

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:

8 front fork assembly

(along with the steering stem)

Bends/cracks/damage J Replace.

4-32

2

1

2

1

3

LS

1

STEERING HEAD

CHAS

EAS00684

INSTALLING THE STEERING HEAD

1.

Lubricate:

8 bearing balls 1

8 bearing races



2.

Install:

8 front fork assembly 1

8 upper bearing inner race 2

T

R

7 Nm (0.7 m • kg, 5.1 ft • lb)


3.

Install:

8 ring nut 1

T

R

30 Nm (3.0 m • kg, 21.7 ft • lb)


Ring nut wrench

90890-01403

YU-A9472

Refer to “CHECKING THE STEERING

HEAD” in chapter 3.

4-33

REAR SHOCK ABSORBER ASSEMBLY

CHAS

EAS00685


1

30Nm (3.0 m•kg, 21.7 ft•lb)

2

4

3

16Nm (1.6 m•kg, 11.6 ft•lb)

Order Job/Part

Removing the rear shock absorber assembly

Q’ty Remarks


1

2

3

4

Rear shock absorber assembly upper nut

Rear shock absorber assembly upper bolt

Rear shock absorber assembly lower bolt

Rear shock absorber assembly

1

1

1

1


4-34


CHAS

EAS00692

REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY


w


NOTE:

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

2. Remove:

8 rear shock absorber nut (upper)

8 rear shock absorber bolt (lower)

EAS00695

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY

1. Check:

8rear shock absorber rod

Bend/damage J Replace the rear shock absorber assembly.

8rear shock absorber

Oil leak

J Replace the rear shock absorber assembly.

8spring

Damage/wear J Replace the rear shock absorber assembly.

8bushing


8dust seal


8bolts

Bends/damage/wear

J Replace.

4-35


CHAS

EAS00698

INSTALLING THE REAR SHOCK ABSORBER

ASSEMBLY

1. Lubricate:

8 spacer

8 bush


Molybdenum disulfide grease

2. Install:

8 rear shock absorber assembly

3. Tighten:

8 rear shock absorber assembly upper nut

T

R

30 Nm (3.0 m • kg, 21.7 ft • lb)

8 rear shock absorber assembly lower bolt

T

R

16 Nm (1.6 m • kg, 11.6 ft • lb)

4-36

ENG

CHAPTER 5

ENGINE

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

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

MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY ................... 5-3

INSTALLING THE ENGINE ............................................................... 5-4

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

REMOVING THE CYLINDER HEAD................................................. 5-6

CHECKING THE CYLINDER HEAD ................................................. 5-8

INSTALLING THE CYLINDER HEAD ............................................... 5-9

THE ROCKER ARMS AND CAMSHAFT .............................................. 5-12

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

CHECKING THE CAMSHAFT......................................................... 5-13

CHECKING THE ROCKER ARMS AND ROCKER ARM

SHAFTS........................................................................................ 5-14

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND

TIMING CHAIN GUIDES .............................................................. 5-16

CHECKING THE TIMING CHAIN TENSIONER ............................. 5-16

INSTALLING THE CAMSHAFT AND ROCKER ARMS ................. 5-17

VALVES AND VALVE SPRINGS ............................................................ 5-18

REMOVING THE VALVES ............................................................... 5-19

CHECKING THE VALVES AND VALVE GUIDES ........................... 5-20

CHECKING THE VALVE SEATS ..................................................... 5-22

CHECKING THE VALVE SPRINGS ................................................ 5-24

INSTALLING THE VALVES .............................................................. 5-25

CYLINDER AND PISTON....................................................................... 5-27

REMOVING THE CYLINDER AND PISTON .................................. 5-28

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

CHECKING THE PISTON RINGS ................................................... 5-30

CHECKING THE PISTON PIN ........................................................ 5-31

CHECKING THE TIMING CHAIN GUIDE ....................................... 5-32

INSTALLING THE PISTON AND CYLINDER ................................. 5-32

BELT DRIVE............................................................................................ 5-34

CRANKCASE COVER (LEFT) ........................................................ 5-34

INSTALLING THE KICKSTARTER .................................................. 5-35

V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE ......... 5-36

REMOVING THE PRIMARY SHEAVE ............................................ 5-38

REMOVING THE SECONDARY SHEAVE AND V-BELT................ 5-38

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

CHECKING THE CLUTCH SHOE .................................................. 5-39

5-66

ENG

CHECKING THE V-BELT ................................................................. 5-40

CHECKING THE PRIMARY SHEAVE ............................................ 5-40

CHECKING THE PRIMARY SHEAVE WEIGHTS .......................... 5-41

CHECKING THE SLIDER ................................................................ 5-41

CHECKING THE SECONDARY SHEAVE ...................................... 5-41

ASSEMBLING THE PRIMARY SHEAVE ........................................ 5-42

ASSEMBLING THE SECONDARY SHEAVE ................................. 5-43

INSTALLING THE BELT DRIVE ...................................................... 5-44

STARTER CLUTCH AND AC MAGNETO ............................................. 5-46

STATOR COIL ASSEMBLY.............................................................. 5-46

STARTER CLUTCH ......................................................................... 5-48

REMOVING THE AC MAGNETO .................................................... 5-49

REMOVING THE STARTER CLUTCH ............................................ 5-50

CHECKING THE STARTER CLUTCH ............................................ 5-51

INSTALLING THE STARTER CLUTCH .......................................... 5-52

INSTALLING THE AC MAGNETO ................................................... 5-52

OIL PUMP ............................................................................................... 5-54

CHECKING THE OIL PUMP ........................................................... 5-55

ASSEMBLING THE OIL PUMP ....................................................... 5-56

INSTALLING THE OIL PUMP .......................................................... 5-56

TRANSMISSION ..................................................................................... 5-57

CHECKING THE TRANSMISSION ................................................. 5-58

CRANKSHAFT ....................................................................................... 5-59

CRANKSHAFT ASSEMBLY ............................................................ 5-59

DISASSEMBLING THE CRANKCASE ........................................... 5-61

CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE .... 5-62

CHECKING THE CRANKSHAFT AND CONNECTING ROD ........ 5-63

CHECKING THE CRANKCASE ...................................................... 5-64

CHECKING THE BEARINGS AND OIL SEALS ............................. 5-64

CHECKING THE CIRCLIPS AND WASHERS ................................ 5-64

INSTALLING THE CRANKSHAFT .................................................. 5-65

ASSEMBLING THE CRANKCASE ................................................. 5-65

5-67

ENGINE

ENG

EAS00188

ENGINE

LEADS, HOSES AND REAR BRAKE

46Nm (4.6 m•kg, 33.3 ft•lb)

12

5

D

C

B

A

4

2

6

1

E

3

B

ENGINE

A

C

D

E

13

10Nm (1.0 m•kg, 7.2 ft•lb)

12Nm (1.2 m•kg, 8.7 ft•lb)

16Nm (1.6 m•kg, 11.6 ft•lb)

10

Order

1

Job/Part

Removing the leads, hoses and rear brake

Seat/Trunk/Rear carrier

Battery cover/Battery holder

Battery/Front cover

Side cover(left and right)/Rear cover

Footrest board side cover mole (left and right)

Mat/Footrest board

Coolant

Q’ty

Radiator

Thermostat housing

Water pump assembly

Carburetor

Thermo unit lead 1

Remarks


Refer to “COVER AND PANEL”in chapter 3.

Drain.

Refer to “CHANGING THE COOLANT”in chapter 3.


Refer to “CARBURETOR”in chapter 7.

Disconnect.

5-1

11

9

7

7

8

ENGINE

ENG

46Nm (4.6 m•kg, 33.3 ft•lb)

12

5

D

C

B

A

4

2

1

E

3

C

D

E

6

B

A 13

10

10Nm (1.0 m•kg, 7.2 ft•lb)

12Nm (1.2 m•kg, 8.7 ft•lb)

16Nm (1.6 m•kg, 11.6 ft•lb)

11

9

7

7

8

7

8

9

10

11

2

3

4

5

6

Order

12

13

Job/Part

AC magneto lead

Starting motor lead/Earth lead

Ignition primary coil lead

Vacuum hose(to air cut-off valve)

Hose(to air cut-off valve)

Vacuum hose(to fuel cock)

Rear brake cable/Adjuster/Pin

Kickstarter

Rear wheel lock cable cover

Rear wheel lock cable

Rear shock absorber assembly lower bolt

Self lock nut

Engine mounting bolt

Q’ty

Disconnect.

Disconnect.

Remarks

Refer to “STARTER CLUTCH AND AC

MAGNETO”.

1/1/1

1

1

1

1

1

1

1

1

1

1

1

Refer to “ REAR SHOCK ABSORBER

ASSEMBLY “in chapter 4.

Refer to “ INSTALLING THE ENGINE “.


5-2

ENGINE

ENG

MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY

31Nm (3.1 m•kg, 22.4 ft•lb)

1

1

5

10Nm (1.0 m•kg, 7.2 ft•lb)

7

5

6

7

13Nm (1.3 m•kg, 9.4 ft•lb)

3

4

4

2 10Nm (1.0 m•kg, 7.2 ft•lb)

8Nm (0.8 m•kg, 5.8 ft•lb)

3

4

5

1

2

6

7

Order Job/Part

Removing the manifold, air filter and muffler assembly

Rear brake cable(adjuster/pin)


Hose(to air cut-off valve)

Vacuum hose(to air cut-off valve)

Vacuum hose(to fuel cock)

Throttle cable kit

Auto choke lead

Throttle position sensor lead

Muffler assembly/Gasket

Spark plug cap

Ignition coil

Air filter assembly/Breather hose

Starter motor assembly

Rear fender

Manifold/O-ring

Q’ty Remarks


1/1

1

1

1/1

1

1

1/1

Refer to “LEADS, HOSES AND REAR

BRAKE”.

Refer to “CARBURETOR”in chapter 7.


5-3

1

1

3

2

ENGINE

ENG

EAS00192

INSTALLING THE ENGINE

1. Install:

8engine 1

8engine mounting bolt 2

8self lock nut3

NOTE:

Do not fully tighten the bolts.

2. Tighten:

8self lock nut

T

R

46Nm(4.6 m • kg, 33.3 ft • lb)

3. Tighten:

8rear shock absorber assembly lower bolt1

T

R

16 Nm (1.6 m • kg, 11.6 ft • lb)

5-4

EAS00221

CYLINDER HEAD

10Nm (1.0 m•kg, 7.2 ft•lb)

10Nm (1.0 m•kg, 7.2 ft•lb)

5

10

CYLINDER HEAD

ENG

8Nm (0.8 m•kg, 5.8 ft•lb)

9Nm (0.9 m•kg, 6.5 ft•lb)

3

9

4

12.5Nm (1.25 m•kg, 9.0 ft•lb)

8Nm (0.8 m•kg, 5.8 ft•lb)

6

4

11

12

13

1

2

7

8

10Nm (1.0 m•kg, 7.2 ft•lb) 4 30Nm (3.0 m•kg, 21.7 ft•lb)

5

6

7

1

2

3

4

8

9

10

11

12

13

Order Job/Part

Removing the cylinder head

Muffler assembly

Air filter assembly/Breather hose

Manifold/O-ring

Thermostat unit

Spark plug

Cylinder head cover

O-ring

Timing chain tensioner assembly

Timing chain tensioner gasket

Camshaft sprocket

Bolt

Nut

Plate

Cylinder head

Cylinder head gasket

Dowel pin

5-5

1

1

1

1

1

1

1

1

1

1

2

2

4

Q’ty Remarks



MUFFLER ASSEMBLY”.

Refer to “ REMOVING THE CYLINDER

HEAD”.


2 b a

CYLINDER HEAD

ENG

EAS00225

REMOVING THE CYLINDER HEAD

1. Remove :

8 crankcase cover (left)

Refer to “ BELT DRIVE”.

8 cylinder head cover

2. Align:

8 “I” mark a on the 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.

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

1 d c

3. Loosen:

8timing chain tensioner bolt

8camshaft sprocket bolt 1

While holding the crank bolt with a wrench2, remove the camshaft sprocket bolt 1.

Rotor holding tool

90890-01235

YU-01235

5-6

1

2

4

6

5

3

2

1

CYLINDER HEAD

ENG

4. Remove:

8 timing chain tensioner


8 camshaft sprocket 1

8 timing chain 2

NOTE:

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

5. Remove:

8 cylinder 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.

5-7

5-8

CYLINDER HEAD

ENG

EAS00227

CHECKING THE CYLINDER HEAD

1. Eliminate:

8 combustion chamber carbon deposits

(with a rounded scraper)

NOTE:

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

8 spark plug bore thread

8 valve seats

2. Check:

8 cylinder head

Damage/scratches J Replace.

3. Measure:

8 cylinder head warpage


J Resurface the cylinder head.

Maximum cylinder head warpage

0.03 mm (0.001 in)

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

b. Measure the warpage.

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

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

NOTE:

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

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

4

2

4

3

1

5

6

4

CYLINDER HEAD

ENG

EAS00231

INSTALLING THE CYLINDER HEAD

1. Install:

8 gasket New

8 dowel pins

2. Install:

8 cylinder head

3. Tighten:

8 cylinder head nuts

T

R

10 Nm (1.0 m • kg, 7.2 ft • lb)

8 cylinder head bolts

T

R

10 Nm (1.0 m • kg, 7.2 ft • lb)

NOTE:

8 Lubricate the cylinder head nuts with engine oil.

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

b a d

2 c

1

4. Install:

8 camshaft sprocket 1

8 timing chain 2

***************************************************** 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.

5-9

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 in the camshaft sprocket.

CYLINDER HEAD

ENG c C

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

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

f. Remove the wire from the timing chain.

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

5. Install

8camshaft sprocket bolt 1

1

2

5

3 4

6. Install:

8timing chain tensioner gasket New

8timing chain tensioner

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

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

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

T

.

R

.

Timing chain tensioner bolt

9 Nm (0.9 m • kg, 6.5 ft • lb) d. Install the spring 2 and cap bolt 1.

T

.

R

.

Cap bolt

8 Nm (0.8 m • kg, 5.8 ft • lb)

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

5-10

b a d c

CYLINDER HEAD

ENG

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 J Correct.

Refer to the installation steps above.

5-11

9. Tighten:

8camshaft sprocket bolt

T

R

30 Nm (3.0 m • kg, 21.7 ft • lb) c C

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

10. Measure:

8valve clearance


Refer to “ADJUSTING THE VALVE

CLEARANCE” in chapter 3.

THE ROCKER ARMS AND CAMSHAFT

ENG


4

6

6

5

2

1

3

4

3

4

5

6

1

2

Order Job/Part

Removing the rocker arms and camshaft

Cylinder head

Camshaft

Rocker arm shaft(intake)

Rocker arm shaft(exhaust)

Rocker arm(intake)

Rocker arm(exhaust)

Spring

Q’ty

1

1

1

2

1

1

Remarks




5-12

a

1

1


ENG

EAS00202

REMOVING THE ROCKER ARMS AND CAM-

SHAFT

1. Remove:

8camshaft 1

2. Remove:

8intake rocker arm shaft

8exhaust rocker arm shaft

8intake rocker arm

8exhaust rocker arm

NOTE:

Remove the rocker arm shafts with the clip plier1 .

EAS00205

CHECKING THE CAMSHAFT

1. Check:

8camshaft bushings


2. Check:

8camshaft lobes

Blue discoloration/pitting/scratches J

Replace the camshaft.

3. Measure:

8camshaft lobe dimensions a and b


J Replace the camshaft.

b

5-13


ENG

Camshaft lobe dimension limit

Intake in)

<Limit>:30.058mm

in)

<Limit>:24.982mm

Exhaust in)

<Limit>:30.058mm

in)

<Limit>:24.920mm

4. Check:

8camshaft oil passage

Obstruction

J Blow out with compressed air.

2

1

1

2

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:

8rocker arm (camshaft touch surface1)

8rocker arm (valve touch surface2)


2. Check:

8rocker arm shaft

Blue discoloration/excessive wear/pitting/ scratches J Replace or check the lubrication system.

3. Check:

8camshaft lobe

Excessive wear

J Replace the camshaft.

5-14

a


ENG

4. Measure:

8rocker arm inside diameter a


J Replace.

Rocker arm inside diameter

10 ~ 10.015 mm (0.393 ~ 0.394 in) a

5. Measure:

8rocker arm shaft outside diameter a

Out of specification J Replace.

Rocker arm shaft outside diameter

9.981 ~ 9.991 mm (0.392 ~ 0.393

in)

6. Calculate:

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

NOTE:

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

Above 0.034 mm (0.001 in)

J Replace the defective part(s).

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

0.009 ~ 0.034 mm (0.0004 ~ 0.001

in)

5-15

a


ENG

EAS00208

CHECKING THE TIMING CHAIN, CAMSHAFT

SPROCKETS, AND TIMING CHAIN GUIDES

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

1. Check:

8 timing chain

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

1 b

2

2. Check:

8 camshaft sprocket

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

a 1/4 tooth b Correct

1 Timing chain roller

2 Camshaft sprocket

3. Check:

8 timing chain guide (exhaust side)

8 timing chain guide (intake side)

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

5-16

EAS00210

CHECKING THE TIMING CHAIN TENSIONER

1. Check:

8 timing chain tensioner

Cracks/damage

J Replace.

2. Check:

8 one-way cam operation

Rough movement J Replace the timing chain tensioner housing.

3. Check:

8 cap bolt

8 o-ring

New

8 spring

8 one-way cam

8 gasket

New

8 timing chain tensioner rod

Damage/wear


2

1


ENG

1

EAS00220

INSTALLING THE CAMSHAFT AND ROCKER

ARMS

1. Lubricate:

8 camshaft 1

4


Camshaft

Molybdenum disulfide oil

Camshaft bearing

Engine oil

2. Lubricate:

8 rocker arm shafts



3

1

2

3

3. Install:

8 exhaust rocker arm 1

8 spring 2

8 exhaust 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

8spring 2

8intake rocker arm shaft 3

NOTE:

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

5-17

VALVES AND VALVE SPRINGS

ENG

EAS00236


9

6

1 2

3

7

4

5

8

5

8

9

4

1

2

3

7

8

9

4

1

2

3

7

1

2

3

4

5

6

7

8

9

Order Job/Part

Removing the valves and valve springs

Cylinder head

Rocker arm and rocker arm shaft

Q’ty Remarks



Refer to “THE ROCKER ARMS AND

CANSHAFT”.

Valve pad

Valve cotter

Valve spring retainer

Valve spring

Valve(intake)

Valve(exhaust)

Valve stem seal

Valve stem seat

Valve guide

3

6

3

3

2

1

3

3

3

Refer to “ INSTALLING THE VALVES

AND VALVE SPRINGS “.


5-18

a

1 a


ENG

EAS00237

REMOVING THE VALVES

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

NOTE:

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

1. Check:

8 valve sealing

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

Refer to “CHECKING THE VALVE

SEATS”.

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

b. Check that the valves properly seal.

NOTE:

There should be no leakage at the valve seat

1.

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

1

2. Remove:

8valve pads1

2

1

5-19

3 . Remove:

8valve cotters 1

NOTE:

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

Valve spring compressor

90890-04109 (YM-04109)

Valve spring compressor attachment

90890-04148 (YM-04148)

5 a b

4

1

2


ENG

3

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.

EAS00239

CHECKING THE VALVES AND VALV E

GUIDES

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

1. Measure:

8 valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =

Valve guide inside diameter a -

Valve stem diameter b

Out of specification J Replace the valve guide.

Valve-stem-to-valve-guide clearance

Intake

0.010 ~ 0.037 mm(0.0004~0.0015 in)

<Limit>: 0.08 mm(0.003 in)

Exhaust

0.025 ~ 0.052 mm(0.001~0.002 in)

<Limit>: 0.10 mm(0.004 in)

2. Replace:

8 valve guide

NOTE:

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

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

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

1.

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

5-20


ENG

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)

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

3. Eliminate:

8 carbon deposits

(from the valve face and valve seat)

4. Check:

8 valve face

Pitting/wear J Grind the valve face.

8 valve stem end

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

J Replace the valve.

a

5-21

5. Measure:

8 valve margin thickness a

Out of specification J Replace the valve.

Valve margin thickness

0.70 mm (0.028 in)

6. Measure:

8 valve stem runout


J Replace the valve.

NOTE:

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

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

Valve stem runout

0.01 mm(0.0004 in)

a


ENG

EAS00240

CHECKING THE VALVE SEATS

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

1. Eliminate:

8 carbon deposits

(from the valve face and valve seat)

2. Check:

8 valve seat

Pitting/wear J Replace the cylinder head.

3. Measure:

8 valve seat width a

Out of specification J Replace the cylinder head.

b

Valve seat width

Intake: 0.9 ~ 1.1 mm(0.035 ~ 0.043

in)

<Limit>: 1.6 mm(0.063 in)

Exhaust: 0.9 ~1.1 mm(0.035~0.043

in)

<Limit>: 1.6 mm(0.063 in)

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

b. Install the valve into the cylinder head.

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

d. Measure the valve seat width.

NOTE:

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

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

4. Lap:

8 valve face

8 valve seat

NOTE:

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

5-22

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


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

c C

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

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

c. Install the valve into the cylinder head.

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

NOTE:

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

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

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

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

h. Install the valve into the cylinder head.

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

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

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

5-23

a


ENG

EAS00241

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the valve springs.

1. Measure:

8 valve spring free length a


J Replace the valve spring.

Valve spring free length

Intake valve spring

39.35 mm (1.549 in)

<Limit>: 37.38 mm (1.472 in)

Exhaust valve spring

41.57 mm (1.637 in)

<Limit>: 39.49 mm (1.555 in) b a

2. Measure:

8 compressed valve spring force a


J Replace the valve spring.

b Installed length

Compressed valve spring force (installed)


9.3~10.7 kg at 28 mm (20.5 ~ 23.6 lb at 1.102 in)


11.0 ~ 12.7 kg at 30 mm (24.3 ~ 28.0

lb at 1.181 in) a

5-24

3. Measure:

8 valve spring tilt a

Out of specification J Replace the valve spring.

Spring tilt limit


1.7 mm (0.067 in) ( 2.5° )


1.8 mm (0.071 in)( 2.5° )


ENG

EAS00245

INSTALLING THE VALVES

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

1. Deburr:

8valve stem end

(with an oil stone)

1

1

2 b a

2. Lubricate:

8valve stem 1

8valve stem seal 2

(with the recommended lubricant)



2

4

3

5

3.

Install:

8valve 1

8valve spring seat 2

8valve stem seal 3

New

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

1

2

5-25

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.

1


ENG

Valve spring compressor

90890-04109(YM-04109)

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.

c C

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

6.

Install: valve pad 1

NOTE:

8 Lubricate the valve pad with molybdenum disulfide oil.

8 Each valve pad must be reinstalled in its original position.

5-26

EAS00251



ENG

7

10

9

4

7

8

5

2

5

4

6

3

10Nm (1.0 m•kg, 7.2 ft•lb)

1

1

2

3

4

5

6

Order Job/Part

Removing the cylinder and piston

Cylinder head

Timing chain guide(exhaust side)

Cylinder

Case cap

Reed valve assembly

Dowel pin

Cylinder gasket

7

8

9

10

Piston pin clip

Piston pin

Piston

Piston ring set

5-27

Q’ty Remarks



1

1

1

1

2


AND CYLINDER”.

2

1 Refer to “ REMOVING THE CYLINDER

AND PISTON”.

1


AND CYLINDER”.


3 2

4

2

1

3


ENG

EAS00253

REMOVING THE CYLINDER AND PISTON

1. Remove:

8 piston pin clip 1

8 piston pin 2

8 piston 3 c C

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

NOTE:

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

8 Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller set4.

Piston pin puller set

90890-01304(YU-01304)

2. Remove:

8 top ring

8 2nd ring

8 oil ring

NOTE:

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

5-28

a

P


ENG

EAS00261

CHECKING THE CYLINDER AND PISTON

1.

Check:

8 piston wall

8 cylinder wall

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

2.

Measure:

8piston-to-cylinder clearance

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

8 cylinder

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

with a cylinder gauge.

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

When abrasion is beyond limit J Replace it

Standard

38.000 ~ 38.010 mm(1.4961 ~ 1.4965 in) b. If out of specification, replace the cylinder, and the piston and piston rings as a set.

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

a 5 mm (0.197 in) from the bottom edge of the piston

Piston size “P”

37.975 ~ 37.990 mm (1.495 ~ 1.496 in) d. If out of specification, replace the piston and piston rings as a set.

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

Piston-to-cylinder clearance =

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

Piston-to-cylinder clearance

0.010 ~ 0.035 mm (0.0004 ~ 0.0014

in)

<Limit>: 0.15 mm (0.006 in)

5-29 f. If out of specification, replace the cylinder, and the piston and piston rings as a set.

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

a


ENG

EAS00263

CHECKING THE PISTON RINGS

1. Measure:

8 piston ring side clearance

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

NOTE:

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

Piston ring side clearance

Top ring

0.02 ~ 0.08 mm(0.0008~0.0031 in)

<Limit>: 0.13mm(0.0051 in)

2nd ring

0.02 ~ 0.06 mm(0.0008~0.0024 in)

<Limit>:0.12 mm(0.0047 in)

5-30

2. Install:

8 piston ring

(into the cylinder)

NOTE:

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

a 10 mm (0.394 in)

3. Measure:

8 piston ring end gap

Out of specification J Replace the piston ring.

NOTE:

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

Piston ring end gap

Top ring

0.05 ~ 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)

b


ENG

EAS00265

CHECKING THE PISTON PIN

1. Check:

8 piston pin

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

a

2. Measure:

8 piston pin outside diameter a

Out of specification J Replace the piston pin.

Piston pin outside diameter

9.996 ~ 10.000 mm (0.3935 ~

0.3937 in)

<Limit>:9.976 mm (0.3928 in)

3. Measure:

8 piston pin bore diameter b

Out of specification J 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:

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

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

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

Piston pin bore diameter b -

Piston pin outside diameter a

Piston-pin-to-piston clearance

0.002 ~ 0.017 mm (0.0001 ~ 0.0007

in)

5-31


ENG

CHECKING THE TIMING CHAIN GUIDE

1.

Check:


Damage/wear J Replace

1

3 a

4

3

2

1

2

EAS00267

INSTALLING THE PISTON AND CYLINDER

1. Install:

8 oil ring expander 1

8 oil ring rail 2

8 2nd ring 3

8 top ring 4

NOTE:

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

2

2. Install:

8 piston 1

8 piston pin 2

8 piston pin clip

New

3

NOTE:

8 Apply engineoil the piston pin.

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

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

5-32


ENG

3. Install:

8 gasket New

8 dowel pins a b c A d

1

4. Lubricate:

8 piston

8 piston rings

8 cylinder



Engine oil

5. Offset:

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

A Exhaust side

6. Install:


8cylinder 1

NOTE:

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

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

5-33

BELT DRIVE

ENG

EAS00316

BELT DRIVE

CRANKCASE COVER (LEFT)

3

7

10Nm (1.0 m•kg, 7.2 ft•lb)

2

8

10

3

4

11

12

5

9

1

6

6

15Nm (1.5 m•kg, 10.9 ft•lb)

5

6

7

8

9

10

11

12

3

4

1

2

Order Job/Part

Removing the crankcase cover (left)

Kickstarter

Rear wheel lock cable cover



Crankcase cover gasket(left)

Dowel pin

Kick pinion gear

Kick pinion gear clip

Circlip/Plate washer

Kick shaft assembly

Torsion spring

Solid bush

Holder

Torsion spring

Stopper lever assembly

Q’ty

1

1/1

1

1

1

1

1

1

2

1

1

1

Remarks


Refer to “ LEADS, HOSES AND REAR

BRAKE “.

Refer to “ INSTALLING THE

KICKSTARTER “.


5-34

2

3

BELT DRIVE

ENG

EAS00340

INSTALLING THE KICKSTARTER

1. Install:

8 solid bush1

8 kick shaft assembly2

8 torsion spring3

1 b a d c

2. Hook:

8 kickstarter spring

NOTE:

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

3. Install:

8 plain washer

8 circlip1

New

1

4. Install:

8kick pinion gear1

8kick pinion gear clip2

NOTE:

Install the clip at the position shown.

2

1

5-35

V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE

BELT DRIVE

ENG

40Nm (4.0 m•kg, 28.9 ft•lb)

4

12

10

11

10

8

7

6

3

2

1

9

30Nm (3.0 m•kg, 21.7 ft•lb)

5

7

8

9

5

6

1

2

3

4

10

11

12

Order Job/Part

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

Primary sheave nut/Plate washer

Oneway clutch

Primary fixed sheave

Secondary sheave nut

Clutch housing

Secondary sheave assembly

V-belt

Collar

Primary sliding sheave

Cam/Weight

Slider

Plate washer

Q’ty

1

1

1

1

1

1/1

1

1

1

1/6

3

1

Remarks


Refer to “ REMOVING AND INSTALL-

ING THE SECONDARY SHEAVE “


ING THE PRIMARY SHEAVE “


5-36

BELT DRIVE

ENG

3

2

4

9

6

3

0

1

55Nm (5.5 m•kg, 39.8 ft•lb)

9

5

7

8

LS

LS

1

2

3

4

5

6

7

8

9

0

Order Job/Part

Disassembling the secondary sheave assembly

Clutch carrier nut

Clutch carrier

Clutch shoe spring

Compression spring

Secondary spring seat

Guide pin

Secondary sliding sheave

O-ring

Oil seal

Secondary fixed sheave

Q’ty

2

1

2

2

1

1

1

2

1

1

Remarks

Disassemble the parts in the order listed.


ING THE SECONDARY SHEAVE “ .


5-37

5

4

1

BELT DRIVE

ENG

EAS00317

REMOVING THE PRIMARY SHEAVE

1. Remove:

8primary sheave nut 1

8plate washer2

8oneway clutch3

8primary fixed sheave 4

NOTE:

While holding the primary fixed sheave with the rotor holding tool 5, loosen the primary fixed sheave nut.

Rotor holding tool:

90890-01235 (YU-01235)

3

4

2

1

3 1

1

3

2

2

5-38

EAS00318

REMOVING THE SECONDARY SHEAVE AND

V-BELT

1. Remove:

8 secondary sheave nut 1

8 clutch housing 2

NOTE:

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

Sheave holder:

90890-01701 (YS-01880-A)

2. Loosen:

8 clutch carrier nut 1 c C

Do not remove the clutch carrier nut at this stage.

NOTE:

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

Roter holding tool:

90890-01235 (YU-01235)

Locknut wrench:

90890-01348 (YM-01348)

1

BELT DRIVE

ENG

3. Remove:

8 secondary sheave assembly 1

8 V-belt 2

NOTE:

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

2

2

3

1

EAS00319

DISASSEMBLING THE SECONDARY SHEAVE

1. Remove:

8 clutch carrier nut 1

NOTE:

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

Clutch spring holder

90890-01337 (YM-33285)

(YM-33285-6) a

CHECKING THE CLUTCH SHOE

1. Measure:

8 clutch shoe

Scratches

J Glaze using coares sandpaper.


Clutch shoe thickness

3.7 mm (0.146 in)

<Limit>: 2.0 mm (0.079 in)

NOTE:

Inspect clutch shoes a.

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

Replace the all two as a set.

5-39

1

1

BELT DRIVE

ENG

EAS00320

CHECKING THE V-BELT

1. Check:

8 V-belt 1

Cracks/damage/wear J Replace.

Grease/oil J Clean the primary and secondary sheave.

a

2. Measure:

8 V-belt width a


V-belt width

16.8 mm (0.0661 in)

<Limit>: 15.8 mm (0.622 in)

2

CHECKING THE PRIMARY SHEAVE

1.

Check:

8 primary sliding sheave1

8 primary fixed sheave2

Cracks/damage/wear J Replace the primary sliding sheave, primary fixed sheave and V-belt.

2.

Check:

8 free movement

Insert the collar2 into the primary sliding sheave1, and check for free movement.

Stick or excessive play J Replace the primary sliding sheave or collar.

5-40

a

BELT DRIVE

ENG

EAS00321

CHECKING THE PRIMARY SHEAVE WEIGHTS

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

1. Check:

8 primary sheave weight

Cracks/damage/wear

J Replace.

2. Measure:

8 primary sheave weight outside diameter a


Primary sheave weight outside diameter

15 mm (0.591 in)

<Limit>: 14.5 mm (0.571 in)

CHECKING THE SLIDER

1.

Check:

8 slider 1


2

1

5-41

EAS00322

CHECKING THE SECONDARY SHEAVE

1. Check:

8secondary fixed sheave

8secondary sliding sheave

Cracks/damage/wear

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

2. Check:

8torque cam groove 1

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

3. Check:

8guide pin 2

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

1

2

5

1 3

2

3

2

1

4

BELT DRIVE

ENG

EAS00323

ASSEMBLING THE PRIMARY SHEAVE

1. Clean:


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:

8 slider 1

8 cam 2

5-42

BELT DRIVE

ENG

EAS00324

ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate:

8 secondary fixed sheave’s inner surface

1

8 secondary sliding sheave’s inner surface

2

8 oil seals

8 bearings



BEL-RAY assembly lube ®

3

1

2

2. Install:

8 secondary sliding sheave 1

NOTE:

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

3.

Oil seal guide

90890-01384 (YM-33299)

3

2

1

5-43

3. Install:

8 guide pin 1

4. Lubricate:

8 guide pin groove 2

8 o-ring

New

3



BEL-RAY assembly lube ®

3

1

4

2

5

BELT DRIVE

ENG

5. Install:

8 secondary sheave 1

8 spring

8 clutch carrier 2

NOTE:

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

Clutch spring holder

90890-01337 (YM-33285)

( YM-33285-6)

3 1

1

2

2

EAS00325

INSTALLING THE BELT DRIVE

1. Install:

8 V-belt 1

8 clutch assembly 2 c C

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

NOTE:

Install the V-belt onto the primary sheave side.

2. Install:

8 clutch carrier nut 1

T

R

55 Nm (5.5 m • kg, 39.8 ft • lb)

NOTE:

While holding the clutch carrier with the rotor holding tool 2, tighten the clutch carrier nut with the locknut wrench 3.

Rotor holding tool

90890-01235

Locknut wrench

90890-01348 (YM-01348)

5-44

3

2

1

BELT DRIVE

ENG

3. Install:

8 clutch housing 1

8 secondary sheave nut2

T

R

40 Nm (4.0 m • kg, 28.9 ft • lb)

NOTE:

Tighten the secondary sheave nut with the sheave holder 3.

Sheave holder

90890-01701 (YS-01880-A)

4. Install:


8primary sheave nut 2

T

R

30 Nm (3.0 m• kg, 21.7 ft• lb)

NOTE:

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

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.

5-45

STARTER CLUTCH AND AC MAGNETO

ENG

EAS00341


STATOR COIL ASSEMBLY

4Nm (0.4 m•kg, 2.9 ft•lb)

2

1

5

LT

9Nm (0.9 m•kg, 6.5 ft•lb)

6

7Nm (0.7 m•kg, 5.1 ft•lb)

4

8 7

7Nm (0.7 m•kg, 5.1 ft•lb)

3

43Nm (4.3 m•kg, 31.1 ft•lb)

3

4

5

1

2

Order

Removing the stator coil assembly

Coolant

Job/Part

Radiator

Seat/Trunk/Mat

Rear carrier/Front cover

Side cover(left and right)

Rear cover/Battery cover

Battery holder/Battery

Footrest board side cover mole(left and right)

Footrest board

AC magneto lead

Fan/O-ring

Nut/Plate washer

AC magneto rotor

Woodruff key

Q’ty Remarks


Drain.



1

1/1

1/1

1

1


Disconnect.

5-46


ENG

4Nm (0.4 m•kg, 2.9 ft•lb)

2

1

5

Order

6

7

8

Job/Part

Lock plate

Pick up coil

Stator coil assembly

LT

9Nm (0.9 m•kg, 6.5 ft•lb)

6

7Nm (0.7 m•kg, 5.1 ft•lb)

4

8 7

7Nm (0.7 m•kg, 5.1 ft•lb)

3

43Nm (4.3 m•kg, 31.1 ft•lb)

Q’ty

1

1

1

Remarks


5-47

EAS00342

STARTER CLUTCH


ENG

3

2

1

NEW image

9

10Nm (1.0 m•kg, 7.2 ft•lb)

7

90Nm (9.0 m•kg, 65.1 ft•lb)

6

3

10

8

11

Order Job/Part

Removing the starter clutch

Engine oil

7

8

9

5

6

10

11

1

2

3

4

AC magneto rotor

Stator coil assembly

Crankcase cover(right)

Gasket

Dowel pin

Starter clutch nut

Washer

Starter wheel gear

Roller

Collar

Starter clutch

Idle gear

Shaft

M

4

5

4

5-48

1

1

1

1

1

1

1

1

1

2

1

Q’ty Remarks


Drain.

Refer to “CHANGING THE ENGINE

OIL”in chapter 3.


ING THE AC MAGNETO “.

c C

The starter clutch nut is left-hand thread.


ING THE STARTER CLUTCH “.


2

3


ENG

1

EAS00347

REMOVING THE AC MAGNETO

1.

Remove:

8 AC magneto rotor nut1

8 washer

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

1

2

2.

Remove:

8AC magneto rotor 1

(with the flywheel puller 2)

8woodruff key c C

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.

5-49


ENG

1

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.

1

2.

Remove:

8starter clutch nut1

8washer

8starter wheel gear

8roller

8collar

8starter clutch

8idle gear

NOTE:

The starter clutch nut is left-hand thread.

5-50


ENG

EAS00351

CHECKING THE STARTER CLUTCH

1. Check:

8starter clutch roller 1


2. Check:

8starter clutch idle gear

8starter wheel gear

Burrs/chips/roughness/wear J Replace the defective part(s).

3. Check:

8starter wheel gear’s contacting surfaces

Damage/pitting/wear J Replace the starter clutch gear.

A

1

2

B

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.

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

5-51


ENG

1

EAS00355

INSTALLING THE STARTER CLUTCH

1. Install:

8 idle gear

8 starter clutch

8 collar

8 roller

8 starter wheel gear

8 washer

8 starter clutch nut1

T

R

90 Nm (9.0 m • kg, 65.1 ft • lb)

NOTE:

The starter clutch nut is left-hand thread.

1

2. Install:

8 gasket New

8 crankcase cover (right)1

T

R

10 Nm (1.0 m • kg, 7.2 ft • lb)

EAS00354

INSTALLING THE AC MAGNETO

1.

Install:

8stator coil assembly1

8pick up coil2

8woodruff key3

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.

5-52


ENG

2.

Tighten:

8AC magneto rotor nut 1

T

R

43 Nm (4.3 m • kg, 31.1 ft • lb)

NOTE:

8 While holding the AC magneto rotor 3with the sheave holder 2, tighten 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

5-53

OIL PUMP

ENG

EAS00360

OIL PUMP

1Nm (0.1 m•kg, 0.7 ft•lb)

4

5

6

7

8

9

10

1

2

3

4

Order Job/Part

Disassembling the oil pump

Radiator

AC magneto

Starter clutch

Drive gear


Oil pump driven gear

Dowel pin

Oil pump housing

Oil pump shaft

Inner rotor

Outer rotor

Oil pump housing cover

Gasket

1

4

10

9

8

7

6

5

4Nm (0.4 m•kg, 2.9 ft•lb)

3

4

2

2

1

1

1

1

1

1

1

1/1

1

2

Q’ty Remarks



Refer to “ STARTER CLUTCH AND AC

MAGNETO “ .


5-54

1

A

1

B

1

C

2

OIL PUMP

ENG

EAS00364

CHECKING THE OIL PUMP

1. Check:

8 oil pump drive gear

8 oil pump driven gear 1

8 oil pump housing

8 oil pump housing cover

Cracks/damage/wear


2. Measure:

8 inner-rotor-to-outer-rotor-tip clearance A

8 outer-rotor-to-oil-pump-housing clearance B

8 oil-pump-housing-to-inner-rotor-andouter-rotor clearance C


J Replace the oil pump.

1 Inner rotor

2 Outer rotor

3 Oil pump housing

Inner-rotor-to-outer-rotor-tip clearance

0.15 mm (0.006 in) 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)

5-55

3. Check:

8 oil pump operation

Rough movement J Repeat steps (1) and

(2) or replace the defective part(s).

6

3

5

4 a

1

2

2

1

OIL PUMP

ENG

EAS00375

ASSEMBLING THE OIL PUMP

1. Lubricate:

8 inner rotor

8 outer rotor

8 oil pump shaft



Engine oil

2. Install:

8 oil pump shaft 1

(to the oil pump housing2)

8 pin 3

8 inner rotor 4

8 outer rotor5

8 oil pump housing cover6

8 oil pump housing screw

T

R

1 Nm (0.1 m • kg, 0.7 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 pump assembly2

8oil pump bolt

T

R

4 Nm (0.4 m • kg, 2.9 ft • lb) c C

After tightening the bolts, make sure the oil pump turns smoothly.

5-56

TRANSMISSION

ENG

EAS00419

TRANSMISSION

LS

4

7

13Nm (1.3 m•kg, 9.34 ft•lb)

4

5

G 2

G

6

Order Job/Part

Removing the transmission

Transmission oil

3

4

5

1

2

6

7

Muffler assembly

Rear fender

Rear wheel


Belt drive

Secondary sheave

Circlip

Transmission cover

Transmission cover gasket

Dowel pin

Main axle

Drive axle

Primary drive gear shaft

3

1

LS

5-57

1

2

1

1

1

1

1

Q’ty Remarks


Drain.

Refer to “CHANGING THE TRANSMIS-

SION OIL “ in chapter 3.


MUFFLER ASSEMBLY “.

Refer to “REAR WHEEL AND BRAKE “ in chapter 4.

Refer to “BELT DRIVE “.


5-58

TRANSMISSION

ENG

EAS00425

CHECKING THE TRANSMISSION

1. Measure:

8 main axle runout

(with a centering device and dial gauge )

Out of specification J Replace the main axle.

Main axle runout limit

0.04 mm (0.0002 in)

2. Measure:

8 drive axle runout

(with a centering device and dial gauge )

Out of specification J Replace the drive axle.

Primary drive gear shaft runout limit

0.04 mm (0.0002 in)

3 . Check:

8transmission gears

Blue discoloration/pitting/wear J Replace the defective gear(s).

8transmission gear dogs

Cracks/damage/rounded edges

J Replace the defective gear(s).

4 . Check:

8transmission gear engagement

(each pinion gear to its respective wheel gear)

Incorrect J Reassemble the transmission axle assemblies.

5 . Check:

8transmission gear movement

Rough movement


6 . Check:

8circlip

Bends/damage/looseness

J Replace.

CRANKSHAFT

ENG

EAS00381

CRANKSHAFT

CRANKSHAFT ASSEMBLY

10Nm (1.0 m•kg, 7.2 ft•lb)

10 14

6

9

8

7

12

19

12

13

11

LS

17

2

15

32Nm (3.2 m•kg, 23.1 ft•lb)

4

3

2

LS

5

1

16

18

18

Order

1

2

3

4

Job/Part

Removing the crankshaft assembly

Engine

Cylinder head

Cylinder piston

V-belt, clutch, primary and secondary sheave

Radiator

Water pump

Starter clutch

AC magneto

Oil pump

Transmission

Rear wheel

Q’ty Remarks


Refer to “ ENGINE “ .

Refer to “CYLINDER HEAD “.

Refer to “CYLINDER AND PISTON “.

Refer to “V-BELT,CLUTCH ,PRIMARY

AND SECONDARY SHEAVE “.


Refer to “STARTER CLUTCH AND AC

MAGNETO “.

Refer to “OIL PUMP “.

Refer to “TRANSMISSION “.

Refer to “REAR WHEEL AND BRAKE “ in chapter 4.

Tension spring


Pin

Centerstand

1

1/1

1

1

5-59

CRANKSHAFT

ENG

10Nm (1.0 m•kg, 7.2 ft•lb)

10 14

6

9

8

7

12

19

12

13

11

LS

17

2

15

32Nm (3.2 m•kg, 23.1 ft•lb)

4

3

2

LS

5

1

16

18

18

15

16

17

18

19

Order

7

8

9

5

6

10

11

12

13

14

Job/Part

Hook

Drain plug

Oil strainer

Compression spring

O-ring

Crankcase (right )

Spacer

Dowel pin

Guide

Crankshaft

Timing chain

Crankcase ( left )

Oil seal

Bolt/O-ring

Timing chain guide

5-60

Q’ty

1

1

1

1

1

1

1

2

1

1

Remarks

Refer to “DISASSEMBLING THE

CRANKCASE “

1

1 Refer to “INSTALLING THE CRANK-

SHAFT “

1

1/1

1


CRANKSHAFT

ENG

EAS00385

DISASSEMBLING THE CRANKCASE

1. Remove:

8 centerstand assembly

1

2. Remove:

8 crankcase 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:

8 right crankcase1

8 spacer c C

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.

5-61

5-62

CRANKSHAFT

ENG

EAS00207

CHECKING THE TIMING CHAIN AND TIMING

CHAIN GUIDE

1.

Check:

8 timing chain

Damage/stiffness J Replace the timing chain.

2. Check:



CRANKSHAFT

ENG

EAS00394

CHECKING THE CRANKSHAFT AND CON-

NECTING ROD

1. Measure:

8 crankshaft runout

Out of specification J Replace the crankshaft, bearing or both.

NOTE:

Turn the crankshaft slowly.

Maximum crankshaft runout

0.03 mm ( 0.001 in )

2. Measure:

8 big end side clearance

Out of specification J Replace the big end bearing, crankshaft pin, or connecting rod.

Big end side clearance

0.15~0.45 mm (0.006~0.018 in)

3. Measure:

8 crankshaft width


J Replace the crankshaft.

Crankshaft width

42.45~42.50 mm (1.671~1.673 in)

2

1

5-63

4. Check:

8 crankshaft sprocket 1

Damage/wear


8 bearing 2

Cracks/damage/wear J Replace the crankshaft.

8 oil pump drive gear

Damage/wear


CRANKSHAFT

ENG

5. Check:

8 crankshaft journal

Scratches/wear


8 crankshaft journal oil passage

Obstruction


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:

8crankcase


8oil delivery passages

Obstruction


5-64

EAS00401

CHECKING THE BEARINGS AND OIL

SEALS

1. Check:

8bearings

Clean and lubricate the bearings, then rotate the inner race with your finger.

Rough movement J Replace.

2. Check:

8oil seals

Damage/wear

J Replace.

EAS00402

CHECKING THE CIRCLIPS AND WASHERS

1. Check:

8circlips

Bends/damage/looseness

J Replace.

8washers

Bends/damage J Replace.

1

3

2

1

CRANKSHAFT

ENG

EAS00408

INSTALLING THE CRANKSHAFT

1.

Install:


8 timing chain1

8 crankshaft assembly2

NOTE:

Install the timing chain so it is not visible through the opening in the left crankcase 3.

c C

To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.

NOTE:

Put the timing chain in parallel into the 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)

5-65

EAS00418

ASSEMBLING THE CRANKCASE

1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.

2. Apply:

8 sealant

(onto the crankcase mating surfaces)

Yamaha bond No. 1215

90890-85505

ACC-11001-05-01

NOTE:

Do not allow any sealant to come into contact with the oil gallery.

3. Install:

8 dowel pins

8 spacer

8 right crankcase1

4. Tighten:

8 crankcase

T

R

10 Nm (1.0 m • kg, 7.2 ft • lb)

COOL

CHAPTER 6

RADIATOR

RADIATOR ................................................................................................ 6-1

CHECKING THE RADIATOR ............................................................ 6-2

INSTALLING THE RADIATOR ........................................................... 6-3

THERMOSTAT ASSEMBLY ..................................................................... 6-4

CHECKING THE THERMOSTAT ...................................................... 6-6

INSTALLING THE THERMOSTAT ASSEMBLY ................................ 6-7

WATER PUMP .......................................................................................... 6-8

DISASSEMBLING THE WATER PUMP .......................................... 6-10

CHECKING THE WATER PUMP ..................................................... 6-10

ASSEMBLING THE WATER PUMP ................................................ 6-11

INSTALLING THE WATER PUMP ................................................... 6-12

6-13

EAS00454

RADIATOR

RADIATOR

COOL

COOLING SYSTEM

7

3

2

4

5

10Nm (1.0 m•kg, 7.2 ft•lb)

6

1

3

4

1

2

5

6

7

Order Job/Part

Removing the radiator

Seat/Trunk


Battery/Front cover

Footrest board side cover mole ( left and right )

Mat/Footrest board

Coolant

Q’ty Remarks



Drain.


Radiator cover

Radiator cap

Conduit hose

Radiator inlet hose

Radiator outlet hose

Radiator

Fan case

1

1

1

1

1

1

1


6-1

RADIATOR

COOL

EAS00455

CHECKING THE RADIATOR

1. Check:

8 radiator fins

Obstruction J Clean.

Apply compressed air to the rear of the radiator.

Damage

J Repair or replace.

NOTE:

Straighten any flattened fins with a thin, flat-head screwdriver.

2

3

1

2

1

6-2

2. Check:

8 radiator hoses Radiator inlet hose1

8 radiator pipes Radiator outlet hose2


3. Measure:

8 radiator cap opening pressure

Below the specified pressure

J Replace the radiator cap.

Radiator cap opening pressure

93.3 ~ 122.7 kPa

(0.95 ~ 1.25 kg/cm 2 , 13.53 ~ 17.79

psi)

***************************************************** 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.

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

6-3

RADIATOR

COOL

4. Check:

8 radiator fan

Damage

J Replace.

Malfunction J Check and repair.

EAS00456

INSTALLING THE RADIATOR

1. Fill:

8cooling system


Refer to “CHANGING THE COOLANT” in chapter 3.

2. Check:

8cooling system

Leaks

J Repair or replace any faulty part.

3. Measure:

8radiator cap opening pressure

Below the specified pressure J Replace the radiator cap.

Refer to “CHECKING THE RADIATOR”.

EAS00460

THERMOSTAT ASSEMBLY


COOL

10Nm (1.0 m•kg, 7.2 ft•lb)

A

4

1

4

5

3

A

6

2

10Nm (1.0 m•kg, 7.2 ft•lb)

Order Job/Part

Removing the thermostat assembly



Battery/Front cover

Side cover (left and right)/Rear cover


Mat/Footrest board

Coolant

Q’ty Remarks



1 1

Drain.


Refer to “RADIATOR”.

Disconnect.

2

3

4

5

Radiator inlet hose

Thermostat assembly inlet breather hose(to carburetor)

Thermostat assembly outlet breather hose(to water pump)

Thermo switch lead

Thermo switch/O-ring

Thermostat housing

1

1

1/1

1

Disconnect.

6-4

2

5

4

4

A


COOL

10Nm (1.0 m•kg, 7.2 ft•lb)

1

3

A

6

10Nm (1.0 m•kg, 7.2 ft•lb)

Order

6

Job/Part

Thermostat assembly

Q’ty

1

Remarks


6-5

1


COOL

EAS00462

CHECKING THE THERMOSTAT

1. Check:

8 thermostat 1

Does not open at 65 ~ 80°C J 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.

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

4

3

1

2

1 Thermostat

2 Container

3 Thermometer

4 Water

A Fully closed

B Fully open

NOTE:

If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.

2. Check:

8 thermostat housing


6-6

1


COOL

EAS00466

INSTALLING THE THERMOSTAT ASSEMBLY

1.

Install:

8thermostat1

8thermostat housing

8thermostat assembly inlet breather hose.

8thermostat assembly outlet breather hose.

2. Fill:

8cooling system



3. Check:

8cooling system

Leaks J Repair or replace any faulty part.

4. Measure:




6-7

WATER PUMP

COOL

EAS00468

WATER PUMP

1

7

10

5

11

7Nm (0.7 m•kg, 5.1 ft•lb)

6

10Nm (1.0 m•kg, 7.2 ft•lb)

4

9

8

3

10Nm (1.0 m•kg, 7.2 ft•lb)

2

Order Job/Part

Removing the water pump



Battery/Front cover

Side cover (left and right)/Rear cover


Mat/Footrest board

Coolant

Q’ty Remarks



Drain.


Refer to “THERMOSTAT ASSEMBLY”.

1

2

3

4

Thermostat assembly outlet breather hose

Radiator outlet hose

Breather hose

Outlet hose(to cylinder)

Water pump housing cover

Gasket

1

1

1

1

Refer to “RADIATOR”.

Disconnect.

6-8

WATER PUMP

COOL

1

7

10

5

11

7Nm (0.7 m•kg, 5.1 ft•lb)

6

10Nm (1.0 m•kg, 7.2 ft•lb)

10Nm (1.0 m•kg, 7.2 ft•lb)

4

9

8

3

2

Order

7

8

5

6

9

10

11

Job/Part

Water pump housing

Dowel pin

Plate

Impeller shaft

Oil seal

Bearing

Gasket

Q’ty

1

1

1

2

1

1

1

Remarks


6-9

3

2

1

WATER PUMP

COOL

EAS00471

DISASSEMBLING THE WATER PUMP

1. Remove:

8water pump housing cover1

8dowel pin

8gasket

2. Remove:

8plate 2

8impeller shaft 3

8gasket

8oil seal

(with a thin, flat-head screwdriver)

8bearing

NOTE:

Remove the oil seal from the inside of the water pump housing.

Remove the bearing from the inside of the water pump housing.

1

1

EAS00474

CHECKING THE WATER PUMP

1. Check:

8water pump housing cover

8water pump housing

8impeller 1

Cracks/damage/wear

J Replace.

6-10

2. Check:

8water pump seal 1


3. Check:

8bearing

Rough movement J Replace.

4. Check:

8radiator outlet hose

Cracks/damage/wear

J Replace.

2

1

3

1

1

2

2

1

WATER PUMP

COOL

EAS00475

ASSEMBLING THE WATER PUMP

1. Install:

8oil seal

New

1

(into the water pump housing 3)

8bearing 2

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.

c C

Never lubricate the water pump seal surface with oil or grease.

2. Measure:

8impeller shaft tilt


J Replace the impeller shaft.

Impeller shaft tilt limit

0.15 mm (0.006 in)

1 Straightedge

2 Impeller

3.

Install:

8impeller shaft1

8plate2 c C

After installation, check that the impeller shaft rotates smoothly.

4.

Install:

8gasket

New

8 water pump housing cover1

6-11

b a

1

WATER PUMP

COOL

EAS00478

INSTALLING THE WATER PUMP

1. Install:

8gasket New

8water pump assembly 1

T

R

10 Nm (1.0 m • kg, 7.2 ft • lb)

NOTE:

Align the slit a on the impeller shaft with the projection b on the camshaft sprocket bolt.

2. Fill:

8cooling system



3. Check:

8cooling system

Leaks J Repair or replace the faulty part.

4. Measure:




6-12

CARB

CHAPTER 7

CARBRETOR

CARBURETOR ......................................................................................... 7-1

CHECKING THE CARBURETOR ..................................................... 7-4

ASSEMBLING THE CARBURETOR................................................. 7-6

INSTALLING THE CARBURETOR ................................................... 7-7

MEASURING AND ADJUSTING THE FUEL LEVEL ....................... 7-8

CHECKING THE AUTOCHOKE UNIT .............................................. 7-9

CHECKING THE FUEL COCK ........................................................ 7-10

CHECKING THE THROTTLE POSITION SENSOR ...................... 7-11

AIR INDUCTION SYSTEM ..................................................................... 7-12

CHECKING THE AIR INDUCTION SYSTEM ................................. 7-13

7-14

EAS00480

CARBURETOR

CARBURETOR

CARB

CARBURETOR

A

7

10

8

5

A

6

F

B

2

C

F

E

D

B

9

E

C

4

D

1

3

Order

3

4

5

6

1

2

7

8

9

10

Job/Part

Removing the carburetor

Mat/Seat/Trunk

Battery cover/Front cover

Hose(to cylinder head)

Auto choke lead

Throttle position sensor lead

Fuel hose

Compensator hose

Thermostat assembly inlet breather hose

Throttle cable kit

Clamp(air filter assembly )

Manifold clamp screw

Carburetor assembly

1

1

1

1

1

1

1

1

1

1

1

Q’ty Remarks



Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Lossen.


7-1

CARBURETOR

CARB

EAS00483

5

6

8

1

7

2

9 w p q

0 o y i u t a e r

3

4

1

2

3

4

5

6

7 w e r t y

8

9

0 q

Order Job/Part

Disassembling the carburetor

Auto choke cap

Auto choke unit

Auto choke holder

Auto choke seat

Throttle stop screw kit

Bracket

Vacuum chamber cover/Piston valve spring

Piston valve

Jet needle kit

Float chamber

Float chamber rubber gasket

Accelerator pump assembly

Float pin

Float

Needle valve

Main jet

Q’ty Remarks


1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1/1

c C

Before leaving the factory, throttle position sensor should be measured and adjusted with a precision instrument. Any adjustment is strictly prohibited.

When changing, use carburetor for final assembly exchange. Supplier should not make any changes after dismounting the adjusting bolt.

Refer to “ASSEMBLING THE CARBU-

RETOR”.

7-2

CARBURETOR

CARB

5

6

8

1

7

2

9 w

Order u i o p a

Main nozzle

Nedle jet p q

0 o y i u t a e

Job/Part

Slow air jet

Slow jet

Throttle position sensor

3

4 r

Q’ty

1

1

1

1

1

Remarks


7-3

7-4

CARBURETOR

CARB

EAS00485

CHECKING THE CARBURETOR

1. Check:

8 carburetor body

8 float chamber


2. Check:

8 fuel passages


***************************************************** a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution.

b. Blow out all of the passages and jets with compressed air.

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

3. Check:

8 float chamber body

Dirt

J Clean.

4. Check:

8 float chamber rubber gasket


5. Check:

8 float

Damage J Replace.

1

2

1

CARBURETOR

CARB

6. Check:

8 needle valve

Damage/obstruction/wear

J Replace.

7. Check:

8 piston valve 1

Damage/scratches/wear

J Replace.

8 piston valve diaphragm 2

Cracks/tears

J Replace.

8. Check:

8 vacuum chamber cover 1

8 piston valve spring 2

Cracks/damage

J Replace.

2

1

4

6

3

2

5

9. Check:

8jet needle 1

8main jet 2

8main nozzle 3

8slow air jet 4

8slow jet 5

8needle jet 6

Bends/damage/wear

J Replace.


Blow out the jets with compressed air.

10. Check:

8 piston valve movement

Insert the piston valve into the carburetor body and move it up and down.

Tightness J Replace the piston valve.

11. Check:

8 vacuum hoses

8 fuel hoses



Blow out the hoses with compressed air.

7-5

1

CARBURETOR

CARB

EAS00487

ASSEMBLING THE CARBURETOR c C all of the parts in a petroleum-based solvent.

2

3

4

1. Install:

8 needle jet 1

8 main nozzle2

8 main jet 3

8 slow air jet 4

4

1

4

1

3

3

2

2. Install:

8 float 1

8 needle valve 2

8 float pin 3

8 screw 4

3. Install:

8 float chamber rubber gasket New

8 float chamber

4. Install:

8accelerator pump diaphragm 1

8accelerator pump spring 2

8boot3

8accelerator pump diaphragm gasket4

8float chamber body

2

1

2

3

5 . Install:

8coasting enricher diaphragm1

8compression spring2

8coasting enricher cover3

6. Install:

8jet needle kit

8piston valve

7-6

7-7

CARBURETOR

CARB

7. Install:

8piston valve spring

8vacuum chamber cover

8. Install:

8bracket

8auto choke unit

8throttle position sensor

EAS00492

INSTALLING THE CARBURETOR

1. Adjust:



2,000 ~ 2,400r/min

Refer to “ADJUSTING THE ENGINE

IDLING SPEED” in chapter 3.

2. Adjust:

8 throttle cable free play


1.5 ~ 3.5 mm (0.059 ~ 0.138 in)


CABLE FREE PLAY” in chapter 3.

3

1

1 a

2 a

CARBURETOR

CARB

EAS00498

MEASURING AND ADJUSTING THE FUEL

LEVEL

1. Measure:

8 fuel level a


Fuel level (below the float chamber mating surface)

6.6~7.6 mm (0.26~0.30 in)

***************************************************** a. Stand the motorcycle on a level surface.

b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up.

c. Install the fuel level gauge 1 onto the fuel drain pipe 2

Fuel level gauge

90890-01312 (YM-01312-A) d. Loosen the fuel drain screw e. Hold the fuel level gauge vertically next to the float chamber 3.

f. Measure the fuel level a.

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

2.

Adjust:

8 fuel level

***************************************************** a. Remove the carburetor.

b. Check the needle valve seat and needle valve.

c. If either is worn, replace them as a set.

d. If both are fine, adjust the float level by slightly bending the float tang 1.

e. Install the carburetor.

f. Measure the fuel level a again.

g. Repeat steps (a) to (f) until the fuel level is within specification.

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

7-8

1

2

1

2

Y G/B

4

3

CARBURETOR

CARB

EAS00503

CHECKING THE AUTOCHOKE UNIT

NOTE:

When checking the autochoke unit, the ambient temperature must be lower than 45°C.

1. Remove:

8carburetor

2. Check:

8autochoke unit

***************************************************** a. Connect a 3.3-mm hose 2 to the starter air passage 1 and blow into the hose.

NOTE:

When the starter plunger is open, air should come out of the other side of the starter air passage.

Starter plunger opens Perform step (3).

Starter plunger closes Replace the autochoke unit.

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

3. Check:

8 autochoke unit

***************************************************** a. Connect the autochoke unit leads to a 12.0-

V battery for five minutes.

Positive battery lead 1 J green/black

Negative battery lead 2 J yellow b. Connect a 3.3-mm hose 3 to the starter air passage 4 and blow into the hose.

Starter plunger opens.

Starter plunger closes.

Replace the autochoke unit.

Autochoke is OK.

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

7-9

7-10

CARBURETOR

CARB

EAS00504

CHECKING THE FUEL COCK

1. Remove:

8 seat/trunk

8 battery cover

8 front cover


2. Check:

8fuel cock1

***************************************************** a. Disconnect the fuel cock to carburetor fuel hose2from the carburetor .

b. Place a container under the end of the fuel hose.

c. Start the engine and check if fuel flows from the fuel hose 2.

Fuel flows.

Fuel does not flow.

Fuel cock is OK.

Replace the fuel cock.

d. Stop the engine and check if the fuel stops flowing from the fuel hose 2.

Fuel stops flowing.

Fuel flows.

Fuel cock is OK.

Replace the fuel cock.

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

3.

Install:

8front cover

8battery cover

8seat/trunk


L B/L Y/L

3 2 1

B/L

Y/L

L

CARBURETOR

CARB

CHECKING THE THROTTLE POSITION SEN-

SOR

NOTE:

Before checking the throttle position sensor, the engine idling speed should be properly adjusted.

1. Check:

8throttle position sensor

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

b. Connect the pocket tester (DC 20V) to the throttle position sensor.

Tester positive lead J yellow/blue 1

Tester negative lead Jblack/blue2 c. Check the throttle position sensor input voltage.

DC5V voltage positive lead Jblue 3

DC5V voltage negative lead Jblack/blue2 throttle opens.

throttle closes.

2.8~3.4V.

0.625~0.775V

Out of specification J Replace the carburetor .

c C

Please do not make any adjustment on throttle position sensor.

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

7-11

AIR INDUCTION SYSTEM


CARB

10Nm (1.0 m•kg, 7.2 ft•lb)

4

2

1

3

Order Job/Part

Removing the air induction system

Seat/Trunk

3

4

1

2

Hose(from AI air filter )

Vacuum hose(from mainfold )

Hose(to cylinder head )

Air cut-off valve assembly

1

1

1

1

Q’ty Remarks




7-12

1


CARB

EAS00510

CHECKING THE AIR INDUCTION SYSTEM

1. Check:

8 hoses

Loose connection J Connect properly.


8 pipe

Cracks/damage

J Replace.

2. Check:

8 air cut-off valve


NOTE:

When the negative pressure is applied to the part 1, check that the continuity in the direction of arrow mark is completely lost. If the negative pressure is not loaded, the continuity can be obtained.

7-13

ELEC +

CHAPTER 8

ELECTORICAL

ELECTRICAL COMPONENTS ................................................................ 8-1

WIRING DIAGRAM ................................................................................... 8-2

CHECKING SWITCH CONTINUITY ........................................................ 8-4

CHECKING THE SWITCHES ................................................................... 8-5

CHECKING THE BULBS AND BULB SOCKETS .................................. 8-6

TYPES OF BULBS ............................................................................ 8-6

CHECKING THE CONDITION OF THE BULBS ............................... 8-7

CHECKING THE CONDITION OF THE BULB SOCKETS .............. 8-8

IGNITION SYSTEM................................................................................... 8-9

CIRCUIT DIAGRAM ........................................................................... 8-9

TROUBLESHOOTING ..................................................................... 8-10

ELECTRIC STARTING SYSTEM ........................................................... 8-14

CIRCUIT DIAGRAM ......................................................................... 8-14

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ................ 8-15


STARTER MOTOR ........................................................................... 8-19

CHECKING THE STARTER MOTOR .............................................. 8-20

ASSEMBLING THE STARTER MOTOR ......................................... 8-22

CHARGING SYSTEM ............................................................................. 8-23

CIRCUIT DIAGRAM ......................................................................... 8-23


LIGHTING SYSTEM ............................................................................... 8-26

CIRCUIT DIAGRAM ......................................................................... 8-26


CHECKING THE LIGHTING SYSTEM ........................................... 8-29

SIGNALING SYSTEM ............................................................................ 8-32

CIRCUIT DIAGRAM ......................................................................... 8-32


CHECKING THE SIGNALING SYSTEM ......................................... 8-34

COOLING SYSTEM ................................................................................ 8-40

CIRCUIT DIAGRAM ......................................................................... 8-40


AUTO CHOKE SYSTEM ........................................................................ 8-45

CIRCUIT DIAGRAM ......................................................................... 8-45


8-49

ELECTRICAL COMPONENTS

ELEC

EAS00729

ELECTRICAL COMPONENTS

ELECTRICAL

1 Rear brake light switch

2 Front brake light switch

3 Main switch

4 Starter relay

5 Thermo unit

6 Fuel sender

7 C.D.I. unit

8 Ignition coil

9 Spark plug cap

0 Battery q Main fuse w Turn signal relay e Horn r Rectifier/Regulator t Thermo switch y Headlight relay u Wire harness

+

1

7

2

5 t

6

3 r e w y

9

8 u q

0

4

8-1

WIRING DIAGRAM

WIRING DIAGRAM

ELEC +

12V21W/5W

12V10W

12V10W

Connecting with GND

12V35W/35W

12V10W

12V10W

7.5A

8-2

TURN R

TURN L

HI BEAM

ILLUMI

ILLUMI

TEMP

1 Main switch

2 AC magneto

3 Rectifier/Regulator

4 Battery

5 Main fuse

6 Starter relay

7 Starter motor

8 C.D.I. unit

9 Ignition coil

0 Auto choke unit q Front brake light switch w Rear brake light switch e Start switch r Engine stop switch t Headlight relay y Horn u Horn switch i Turn signal switch o Turn signal relay p Tail/brake light a Dimmer switch s Water temperature indicator light d Speedometer light f High beam indicator light g Turn signal indicator light(left) h Turn signal indicator light(right) j Fuel sender k Headlight l Front turn signal light(left)

; Front turn signal light(right) z Rear turn signal light(left) x Rear turn signal light(right) c Thermo switch v Thermo unit b Throttle position sensor

WIRING DIAGRAM

ELEC +

Color Code

B Black

G Green

L

P

Blue

Pink

R Red

W White

Y Yellow

Br Brown

Ch Chocolate

Dg Dark green

Or Orange

B/L Black/Blue

G/B Green/Black

G/R Green/Red

G/Y Green/Yellow

G/W Green/White

L/W Blue/White

L/Y Blue/Yellow

W/L White/Blue

W/R White/Red

Y/B Yellow/Black

Y/L Yellow/Blue

Y/R Yellow/Red

Br/W Brown/White

8-3

a

OFF

ON

Br R b

Br R

+

CHECKING SWITCH CONTINUITY

ELEC

EAS00730

CHECKING SWITCH CONTINUITY

Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.

c C

Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

Pocket tester

90890-03132 (YU-03112-C)

NOTE:

8 Before checking for continuity, set the pocket tester to “0” and to the “

Ω × 1” range.

8 When checking for continuity, switch back and forth between the switch positions a few times.

The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left.

The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration.

NOTE:

“ c-c” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position).

The example illustration on the left shows that:

There is continuity between 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

ELEC

EAS00731

CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.

Damage/wear

J Repair or replace.

Improperly connected J Properly connect.

Incorrect continuity reading J Replace the switch.

Main switch

Br R

OFF

CHECK

ON

Br

-

-

R -

-

Rear barake light switch

B

B Front barake light switch

B

B

Dimmer switch

G L Y

HI

LO

Horn switch

P B

OFF

PUSH

Turn signal light switch

Ch

Br/

W

Dg

L

N

R

Y

G

L

P

B

Ch

Br/W

Dg

Start switch

OFF

START

L/

W

Engine stop switch

L/

Y

B

OFF

RUN

L/W

L/Y

B

Main fuse

8-5

+

CHECKING THE BULBS AND BULB SOCKETS

ELEC

EAS00733

CHECKING THE BULBS AND BULB

SOCKETS

Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals.

Damage/wear

J Repair or replace the bulb, bulb socket or both.

Improperly connected J Properly connect.

No continuity

J Repair or replace the bulb, bulb socket or both.

C

A B

D E

TYPES OF BULBS

The bulbs used on this scooter are shown in the illustration on the left.

8 Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb. The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise.

8 Bulbs C is used for turn signal and tail/ brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise.

8 Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out.

8-6

+


ELEC

CHECKING THE CONDITION OF THE

BULBS

The following procedure applies to all of the bulbs.

1. Remove:

8 bulb w

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

c C removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.

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

2.

Check:

8 bulb (for continuity)


No continuity

J Replace.

Pocket tester

90890-03132 (YU-03112-C)

NOTE:

Before checking for continuity, set the pocket tester to “0” and to the “ Ω × 1” range.

3

1

2

1

3

2

8-7

***************************************************** a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity.

b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity.

c.

If either of the readings indicate no continuity, replace the bulb.

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

+


ELEC

CHECKING THE CONDITION OF THE BULB

SOCKETS

The following procedure applies to all of the bulb sockets.

1.

Check:

8 bulb socket (for continuity)


No continuity

J Replace.

Pocket tester

90890-03132 (YU-03112-C)

NOTE:

Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following.

***************************************************** a. Install a good bulb into the bulb socket.

b. Connect the pocket tester probes to the respective leads of the bulb socket.

c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket.

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

8-8

EAS00734

IGNITION SYSTEM

CIRCUIT DIAGRAM

IGNITION SYSTEM

ELEC +

1 Main switch

2 Pickup coil

4 Battery

5 Main fuse

8 C.D.I. unit

9 Ignition coil r Engine stop switch

12V21W/5W 12V10W

Connecting with GND

12V10W

12V35W/35W

12V10W

12V10W

7.5A

8-9

TURN R

TURN L

HI BEAM

ILLUMI

ILLUMI

TEMP

EAS00736

TROUBLESHOOTING

The ignition system fails to operate (no spark or intermittent spark).

Check:

1. main fuse

2. battery

3. spark plug

4. ignition spark gap

5. spark plug cap resistance

6. ignition coil resistance

7. pickup coil resistance

8. main switch

9. engine stop switch

10.wiring connections (of the entire ignition system)

NOTE:

8 Before troubleshooting, remove the following part(s):

1. Battery cover/Battery holder

2. Head light cover

3. Leg shield 1

4. Seat/Trunk

8 Troubleshoot with the following special tool(s).

+

IGNITION SYSTEM

ELEC

EAS00738

1. Main Fuse

8 Check the fuse for continuity.

Refer to “CHECKING THE FUSE” in chapter 3.

8 Is the fuse OK?

YES NO

Replace the fuse.

EAS00739

2. Battery

8 Check the condition of the battery.

Refer to “CHECKING AND CHARGING

THE BATTERY” in chapter 3.

Minimum open-circuit voltage

12.8 V or more at 20°C

8 Is the battery OK?

YES NO

8 Clean the battery terminals.

8 Recharge or replace the battery.

Ignition checker

90890-06754

YM-34487

Pocket tester

90890-03132

YU-03112-C

EAS00740

3. Spark plug

8 Check the condition of the spark plug.

8 Check the spark plug type.

8 Measure the spark plug gap.

Refer to “CHECKING THE SPARK

PLUG” in chapter 3.

Standard spark plug

CR7E (NGK)

Spark plug gap

0.7 ~ 0.8 mm(0.028 ~ 0.032 in)

8 Is the spark plug in good condition, is it of the correct type, and is its gap within specification?

YES NO

Re-gap or replace the spark plug.

8-10

EAS00742

4. Ignition spark gap

8 Disconnect the spark plug cap from the spark plug.

8 Connect the ignition checker 1 as shown.

2 Spark plug cap

8 Set the main switch to “ON”.

8 Measure the ignition spark gap a.

8 Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.

+

IGNITION SYSTEM

ELEC

EAS00744

5. Spark plug cap resistance

8 Remove the spark plug cap from the spark plug lead.

8 Connect the pocket tester (“ Ω × 1k” range) to the spark plug cap as shown.

8 Measure the spark plug cap resistance.

1k

Spark plug cap resistance

4~6 k Ω

8Is the spark plug cap OK?

YES NO

Minimum ignition spark gap

6 mm(0.24 in)

8 Is there a spark and is the spark gap within specification?

NO YES

The ignition system is OK.

Replace the spark plug cap.

EAS00746

6. Ignition coil resistance

8 Disconnect the ignition coil connectors from the ignition coil terminals.

8 Connect the pocket tester ( Ω × 1) to the ignition coil as shown.

Positive tester probe J

Negative tester probe J

8-11

8 Measure the primary coil resistance.

Primary coil resistance

0.168 ~ 0.252 Ω

8 Connect the pocket tester ( Ω × 1k) to the ignition coil as shown.



+

IGNITION SYSTEM

ELEC

EAS00748

7. Pickup coil resistance

8 Disconnect the pickup coil coupler from the wire harness.

8 Connect the pocket tester ( Ω × 100) to the pickup coil terminal as shown.

Positive tester probe

J


1

W/R

W/L

2

2 k

1

8 Measure the secondary coil resistance.

Secondary coil resistance

2.4 ~ 3.6 k

Ω

8 Is the ignition coil OK?

YES NO

8 Measure the pickup coil resistance.

Pickup coil resistance

248 ~ 372 Ω

(between white/red and white/ blue)

8 Is the pickup coil OK?

YES NO

Replace the pickup coil.

EAS00749

8. Main switch

8 Check the main switch for continuity.

Refer to “CHECKING THE

SWITCHES”.

8 Is the main switch OK?

YES NO

Replace the main switch.

Replace the ignition coil.

8-12

EAS00750

9. Engine stop switch

8 Check the engine stop switch for continuity.

Refer to “CHECKING THE SWITCHES”.

8 Is the engine stop switch OK?

YES NO

Replace the right handlebar switch.

EAS00754

10.Wiring

8 Check the entire ignition system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

8 Is the ignition system’s wiring properly connected and without defects?

YES NO

Replace the C.D.I.

unit.

Properly connect or repair the ignition system’s wiring.

IGNITION SYSTEM

ELEC +

8-13

ELECTRIC STARTING SYSTEM

ELEC

EAS00755


CIRCUIT DIAGRAM

+

Connecting with GND

12V21W/5W

12V10W

12V10W

1 Main switch

4 Battery

5 Main fuse

6 Starter relay

7 Starter motor q Front brake light switch w Rear brake light switch e Start switch 12V10W r Engine stop switch

12V35W/35W

12V10W

TURN R

TURN L

HI BEAM

ILLUMI

ILLUMI

TEMP

7.5A

8-14

1

9

2

3

7

8

6

+


ELEC

EAS00756

STARTING CIRCUIT CUT-OFF SYSTEM OP-

ERATION

If the main switch is set to “ON” (switch is 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).

1 Battery

2 Main fuse

3 Main switch

4 Front brake light switch

5 Rear brake light switch

6 Engine stop switch

7 Start switch

8 Starter relay

9 Starter motor

5 4

8-15

EAS00757

TROUBLESHOOTING

The starter motor fails to turn.

Check:

1. mainfuse

2. battery

3. starter motor

4 starter relay

5 main switch

6 brake light switch (front, rear)

7 engine stop switch

8 start switch

9 wiring connections

(of the entire starting system)

YES NO

-

Replace the fuse.

+


ELEC

EAS00738

1. Main fuse

8 Check the fuse for continuity.


8 Is the fuse OK?

NOTE:


1. Seat/Trunk/Rear carrier

2. Mat/Front cover

3. Side cover(left and right)/Rear cover

4. Battery cover/Battery holder

5. Footrest board side cover mole(right,left )

6. Footrest board

7. Head light cover/Leg shield 1

8. Air filter assembly


EAS00739

2. Battery





12.8 V or more at 20°C


YES NO

Pocket tester

90890-03132 (YU-03112-C)

8 Clean the battery terminals.


8-16

+


ELEC

EAS00758

3. Starter motor

8 Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead3.

EAS00761

4. Starter relay

8 Disconnect the starter relay coupler from the coupler.

8 Connect the pocket tester ( Ω × 1) and battery (12 V) to the starter relay coupler as shown.

Positive battery terminal J

Negative battery terminal J



w have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn.

therefore make sure nothing flammable is in the vicinity.

8 Does the starter motor turn?

YES NO

Repair or replace the starter motor.

2

1

4

3

8 Does the starter relay have continuity between red3 and red 4?

YES NO

Replace the starter relay.

EAS00749

5. Main switch




YES NO


8-17


ELEC

EAS00751

6. Brake light switch(front and rear)

8 Check the brake light switch for continuity.


8 Is the brake light switch OK?

-

YES NO

Replace the brake light switch.

+

EAS00750

7. Engine stop switch

8 Check the engine stop switch for continuity.


8 Is the engine stop switch OK?

YES NO


EAS00764

8. Start switch

8 Check the start switch for continuity.


8 Is the start switch OK?

YES NO


EAS00766

9. Wiring

8 Check the entire starting system’s wiring.


8 Is the starting system’s wiring properly connected and without defects?

YES

The starting system circuit is OK.

NO

Properly connect or repair the star ting system’s wiring.

8-18

EAS00767

STARTER MOTOR


ELEC +

1

2

3

4

5

7

6

2

1

1

2

3

4

5

6

7

Order Job/Part

Removing the starter motor

Seat/Trunk

Front cover

1

2

Battery cover

Air filter assembly

Starter motor lead

Starter motor

Disassembling the starter motor

O-ring

Gasket

Stator assembly

O-ring

Armature coil

Brush

Plate washer

8-19

1

1

1

1

1

2

1

Q’ty Remarks



1

1

Refer to“MANIFOLD, AIR FILTER AND

MUFFLER ASSEMBLY”in chapter 5.

Disconnect.


Disassemble the parts in the order listed.


a

2

1

+


ELEC

EAS00769

CHECKING THE STARTER MOTOR

1. Check:

8 commutator

Dirt J Clean with 600-grit sandpaper.

2. Measure:

8 commutator diameter a


J Replace the starter motor.

Commutator wear limit

16.6 mm (0.654 in)

3.

Measure:

8 mica undercut a

Out of specification J Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

Mica undercut

1.35 mm (0.053 in)

NOTE:

The mica of the commutator must be undercut to ensure proper operation of the commutator.

4. Measure:

8 armature assembly resistances (commutator and insulation)


J Replace the starter motor.

***************************************************** a. Measure the armature assembly resistances with the pocket tester.

Pocket tester

90890-03132 (YU-03112-C)

Armature coil

Commutator resistance 1

0.0378 ~ 0.0462 Ω

Insulation resistance 2

Above 1 M

Ω b. If any resistance is out of specification, replace the starter motor.

8-20

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

2 1 a

+


ELEC

5. Measure:

8 brush length a


J Replace the brushes as a set.

Brush length wear limit

3.5 mm (0.14 in)

3

6. Measure:

8 brush spring force

Out of specification J Replace the brush springs as a set.

Brush spring force

3.92 ~ 5.88 N

7. Check:

8 gear teeth

Damage/wear

J Replace the gear.

8. Check:

8 bearing1

8 oil seal2

8 bush3

Damage/wear

J Replace.

8-21

1

-


ELEC

EAS00772

ASSEMBLING THE STARTER MOTOR

1. Install:

8 brush seat 1

+ b

4

3

2

1

2. Install:

8 washer1

8 armature coil 2

8 o-ing

New

3

8 stator assembly4 a

1

3 . Install:

8 bolts 1

T

R

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 front and starter motor rear covers.

8-22

EAS00773

CHARGING SYSTEM

CIRCUIT DIAGRAM

CHARGING SYSTEM

ELEC +

2 Stator coil

3 Rectifier/regulator

4 Battery

5 Main fuse

Connecting with GND

12V21W/5W

12V10W

12V10W

12V35W/35W

12V10W

12V10W

7.5A

8-23

TURN R

TURN L

HI BEAM

ILLUMI

ILLUMI

TEMP

EAS00774

TROUBLESHOOTING

The battery is not being charged.

Check:

1. main fuse

2. battery

3. charging voltage

4. stator coil resistance

5. wiring connections

(of the entire charging system)

NOTE:


1. Seat/Trunk

2. Battery cover

3. Head light cover

4. Leg shield 1



90890-03113 (YU-08036-C)

Pocket tester

90890-03132 (YU-03112-C)

+

CHARGING SYSTEM

ELEC

EAS00739

2. Battery

8Check the condition of the battery.




12.8 V or more at 20°C

8Is the battery OK?

YES NO

8Clean the battery terminals.

8Recharge or replace the battery.

EAS00775

3. Charging voltage

8Connect the engine tachometer to the spark plug lead of cylinder.

8Connect the pocket tester (DC 20 V) to the battery as shown.

Positive tester probe J terminal

Negative tester probe J terminal

EAS00738

1. Main fuse

8Check the fuse for continuity.


8Is the fuse OK?

YES NO

Replace the fuse.

-

+

8Start the engine and let it run at approximately 5,000 r/min.

8Measure the charging voltage.

Charging voltage

14 V at 5000r/min

8-24

NOTE:

Make sure the battery is fully charged.

8Is the charging voltage within specification?

NO YES

+

CHARGING SYSTEM

ELEC

EAS00754

5. Wiring

8Check the entire charging system’s wiring.


8Is the charging system’s wiring properly connected and without defects?

YES NO

The charging circuit is OK.

Replace the rectifier/regulator.

EAS00776

4. Stator coil resistance

8 Remove the starter coil couplers from wireharness.

8Connect the pocket tester ( Ω × 1) to the stator coils as shown.



Properly connect or repair the charging system’s wiring.

Y/R

W

1

8 Measure the stator coil resistances.

Stator coil resistance

0.288 ~ 0.432

Ω

(between white and ground)

8 Is the stator coil OK?

YES NO

Replace the stator coil assembly.

8-25

EAS00780

LIGHTING SYSTEM

CIRCUIT DIAGRAM

LIGHTING SYSTEM

ELEC +

1 Main switch

2 Lighting coil

4 Battery

5 Main fuse t Headlight relay a Dimmer switch d Speedometer light

Connecting with GND f High beam indicator light k Headlight

12V21W/5W

12V10W

12V10W

12V35W/35W

12V10W

12V10W

7.5A

8-26

TURN R

TURN L

HI BEAM

ILLUMI

ILLUMI

TEMP

EAS00781

TROUBLESHOOTING

Any of the following fail to light: headlight, high beam indicator light or meter light.

Check:

1. main fuse

2. battery

3. lighting coil resistance.

4. main switch

5. dimmer switch

6. headlight relay


(of the entire lighting system)

NOTE:

8Before troubleshooting, remove the following part(s):

1. Seat/Trunk

2. Battery cover

3. Head light cover

4. Leg shield 1

8Troubleshoot with the following special tool(s).

Pocket tester

90890-03132 (YU-03112-C)

+

LIGHTING SYSTEM

ELEC

EAS00739

2. Battery




`


12.8 V or more at 20°C

8Is the battery OK?

YES NO



EAS00748

3. Lighting coil resistance

8 Disconnect the lighting coil coupler from the wire harness.

8 Connect the pocket tester ( Ω × 1) to the lighting coil terminal as shown.


Negative tester probe

J

Y/R

W

1

EAS00738

1. Main fuse

8Check the fuses for continuity.

Refer to “CHECKING THE FUSES” in chapter 3.

8Is the fuse OK?

YES NO

Replace the fuse.

8 Measure the lighting coil resistance.

Lighting coil resistance

0.256 ~ 0.384

Ω

(between yellow/red and ground)

8 Is the lighting coil OK?

YES NO

Replace the lighting coil.

8-27

EAS00749

4. Main switch




YES NO

+

LIGHTING SYSTEM

ELEC

EAS00787

7. Wiring

8 Check the entire lighting system’s wiring.


8 Is the lighting system’s wiring properly connected and without defects?

YES NO


EAS00784

5. Dimmer switch

8 Check the dimmer switch for continuity.


8 Is the dimmer switch OK?

YES NO

The dimmer switch is faulty. Replace the left handlebar switch.

Check the condition of each of the lighting system’s circuits.

Refer to “CIRCUIT

DIAGRAM”.

Properly connect or repair the lighting system’s wiring.

6. Headlight relay

8 Disconnect the headlight relay coupler from the wire harness.

8 Connect the pocket tester ( Ω × 1) and battery (12 V) to the headlight relay coupler as shown.

Positive battery terminal J

Negative battery terminal

J



2

L/W L

G/Y Y/R

4

1 3

8 Does the starting headlight relay have continuity between blue and yellow/red?

YES NO

Replace the headlight relay.

8-28

EAS00788

CHECKING THE LIGHTING SYSTEM

1. The headlight and the high beam indicator light fail to come on.

1. Headlight bulb and socket

8 Check the headlight bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND

BULB SOCKETS”

8 Are the headlight bulb and socket OK?

YES NO

LIGHTING SYSTEM

ELEC +

3. Voltage

8 Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown.

When the dimmer switch is set to “%”

When the dimmer switch is set to “&”

Headlight coupler (wire harness side)

Headlight





Replace the headlight bulb, socket or both.

1

G

Y B

2 3

G

Y B

4

2. High beam indicator light bulb and socket

8 Check the high beam indicator light bulb and socket for continuity.


BULB SOCKETS”

8 Are the high beam indicator light bulb and socket OK?

YES NO

Replace the high beam indicator light bulb , socket or both.

High beam indicator light



J

Y

1

Br

G

G/W

B

2

G/W

Br

B G


8 Start the engine.

8 Set the dimmer switch to “%” or “&”.

8 Measure the voltage (DC 12 V) on the headlight coupler (wire harness side).

8 Measure the voltage (DC 12 V) on the dimmer switch coupler (wire harness side) when the dimmer switch is set to

“&”.

8 Is the voltage within specification?

8-29

YES NO

This circuit is OK.

The wiring circuit from the main switch to the headlight and hight beam indicator light coupler are faulty and must be repaired.

+

LIGHTING SYSTEM

ELEC

EAS00789

2. The meter light fails to come on.

1. Meter light bulb and socket

8 Check the meter light bulb and socket for continuity.


BULB SOCKETS”

8 Are the meter light bulb and socket OK?

YES NO

Replace the meter light bulb, socket or both.

2. Voltage

8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown.



1

Br G/W

2

G B

8Set the main switch to “ON”.

8Measure the voltage (DC 12 V) of brown

1 on the meter light coupler (wire harness side).

8Is the voltage within specification?

YES NO

This circuit is OK.

The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired.

Refer to “CIRCUIT

DIAGRAM”.

8-30

EAS00754

4. Wiring

8 Check the entire lighting system’s wiring.


8 Is the lighting system’s wiring properly connected and without defects?

YES NO

Check the condition of each of the lighting system’s circuits.

Refer to “CIRCUIT

DIAGRAM”.

Properly connect or repair the lighting system’s wiring.

LIGHTING SYSTEM

ELEC +

8-31

EAS00793

SIGNALING SYSTEM

CIRCUIT DIAGRAM

1 Main switch

4 Battery

5 Main fuse q Front brake light switch w Rear brake light switch y Horn u Horn switch i Turn signal switch o Turn signal relay p Tail/brake light g Left turn signal indicator light h Right turn signal indicator light j Fuel sender l Front turn signal light(left)

; Front turn signal light(right) z Rear turn signal light(left) x Rear turn signal light(right)


ELEC +

12V21W/5W 12V10W

12V10W

Connecting with GND

12V35W/35W

12V10W

12V10W

TURN R

TURN L

HI BEAM

ILLUMI

ILLUMI

TEMP

7.5A

8-32

EAS00794

TROUBLESHOOTING signal light, brake light or an indicator light.

+


ELEC

EAS00739

2. Battery





12.8 V or more at 20°C

Check:

1. main fuse

2. battery

3. main switch


(of the entire signaling system)


YES NO



NOTE:


1. Head light cover/Leg shield 1

2. Battery cover

3. Seat/Trunk

4. Rear carrier

5. Front cover

6. Side cover (left and right)/Rear cover


EAS00749

3. Main switch




YES NO


Pocket tester

90890-03132 (YU-03112-C)

EAS00738

1. Main fuse

8 Check the main fuse for continuity.


8 Is the fuse OK?

YES NO

Replace the fuse.

EAS00795

4. Wiring

8 Check the entire signal system’s wiring.


8 Is the signaling system’s wiring properly connected and without defects?

YES NO

Check the condition of each of the signaling system’s circuits.

Refer to “CHECKING

THE SIGNALING

SYSTEM”.

Properly connect or repair the signaling system’s wiring.

8-33

EAS00796

CHECKING THE SIGNALING SYSTEM

1.

The horn fails to sound.

1. Horn switch

8 Check the horn switch for continuity.


8 Is the horn switch OK?

YES NO


ELEC +

3. Horn

8 Disconnect the pink connector at the horn terminal.

8 Connect a jumper lead 1 to the horn terminal and ground the jumper lead.


8 Push the horn switch.

8 Does the horn sound?

P

Br

Replace the left handlebar switch.

1

2. Voltage

8 Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown.



J

1

Br P

NO YES

The horn is OK.

4. Voltage

8 Connect the pocket tester (DC 20 V) to the horn connector at the pink terminal as shown.



Br P

1


8 Push the horn switch.

8 Measure the voltage (DC 12 V) of brown at the horn terminal.


YES NO

The wiring circuit from the main switch to the horn connector is faulty and must be repaired.

Refer to “CIRCUIT DIA-

GRAM”.


8 Measure the voltage (DC 12 V) of pink

1 at the horn terminal.


YES NO

Repair or replace the horn.

Replace the horn.

8-34

EAS00798

2.

The tail/brake light fails to come on.

1. Tail/brake light bulb and socket

8 Check the tail/brake light bulb and socket for continuity.


BULB SOCKETS”

8 Are the tail/brake light bulb and socket

OK?


ELEC +

3. Voltage

8 Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.



1

YES NO

L

-

G/Y 2 G/Y L

B B -

Dg Ch Ch Dg

Replace the tail/brake light bulb, socket or both.

2. Brake light switches

8 Check the brake light switches for continuity.


8 Is the brake light switch OK?


8 Pull in the brake levers.

8 Measure the voltage (DC 12 V) of green/ yellow 1 on the tail/brake light coupler

(wire harness side).


YES NO

YES NO

The wiring circuit from the main switch to the tail/brake light bulb connector is faulty and must be repaired.

Refer to “CIRCUIT

DIAGRAM”.

Replace the brake light switch.

This circuit is OK.

The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.

Refer to “CIRCUIT

DIAGRAM”.

8-35

EAS00799

3. The turn signal light, turn signal indicator light or both fail to blink.

1. Turn signal light and turn signal indicator light bulbs and sockets

8 Check the turn signal light bulb and socket for continuity.


BULB SOCKETS”

8 Check the turn signal indicator light bulb and socket for continuity.


BULB SOCKETS”

8 Are the turn signal light bulb and socket

OK?


ELEC +

3. Voltage

8 Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.



B

Br/W

Br 1

YES NO

Replace the turn signal light and/or turn signal indicator light bulb, socket or both.


8 Measure the voltage (DC 12 V) on brown

1 at the turn signal relay coupler (wire harness side).


YES NO

2. Turn signal switch

8 Check the turn signal switch for continuity.


8 Is the turn signal switch OK?

The wiring circuit from the main switch to the turn signal relay coupler is faultyand must be repaired.


GRAM”.

YES NO

Replace the left handlebar switch.

8-36

4. Voltage

8Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.



J

B

Br/W

Br

1


ELEC +

5. Voltage

8Connect the pocket tester (DC 20 V) to the turn signal light connector or meter assembly coupler (wire harness side) as shown.

A Front turn signal light

B Rear turn signal light

C Turn signal indicator light

Left turn signal light

Positive tester probe

J


Right turn signal light



A B


8Set the turn signal switch to “4” or “6”.

8Measure the voltage (DC 12 V) on brown/ white 1 at the turn signal relay coupler

(wire harness side).


Ch Dg

Ch

Dg

B G/Y

L

Dg

Ch

L

B G/Y

YES NO

C

2

The turn signal relay is faulty and must be replaced.

Dg

Ch

L

Y

L

Y

Dg

Ch

1


8Set the turn signal switch to “4” or “6”.

8Measure the voltage (DC 12 V) of the chocolate 1 or dark green 2 at the turn signal light connector (wire harness side).


YES NO

This circuit is OK.

The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.

8-37

EAS00804

4. The fuel level meter fails to operate.

1. Fuel sender

8 Remove the fuel sender from the fuel tank.

8 Connect the pocket tester ( Ω × 1) to the fuel sender coupler (wire harness side) as shown.




ELEC +

2. Voltage




1

Br G/W

G B

2

(F)

1

G

B

(E)

2

8 Measure the fuel sender resistances.


8 Measure the voltage (DC 12 V) of brown

1 on the meter light coupler (wire harness side).


YES NO

Fuel sender resistance (up position

F)( Ω

6~8

Ω

Fuel sender resistance (down position E)(

Ω ××××× 10)

93.5~96.5 Ω

8Is the fuel sender OK?

Check the wiring connections of the entire signaling system.


GRAM”.

YES NO

Replace the fuel sender.

8-38

3. Fuel level meter


8 Move the float up 1 or down 2.

1

2


ELEC +

8 Check that the fuel level meter needle moves to “F” or “E”.

NOTE:

Before reading the fuel level meter, leave the float in one position (either up or down) for at

least three minutes.

8 Does the fuel level meter needle move appropriately?

YES NO

This circuit is OK.

Replace the speedo meter.

4.

Wiring

8 Check the entire signaling system’s wiring

8-39

EAS00807

COOLING SYSTEM

CIRCUIT DIAGRAM

COOLING SYSTEM

ELEC +

1 Main switch

4 Battery

5 Main fuse

8 C.D.I. unit light c Thermo switch v Thermo unit

12V10W

12V10W

Connecting with GND

12V35W/35W

12V10W

12V10W

TURN R

TURN L

HI BEAM

ILLUMI

ILLUMI

TEMP

7.5A

8-40

EAS00808

TROUBLESHOOTING

The cooling system fails to operate.

Check:

1. main fuse

2. battery

3. main switch

4. thermo switch

5. water temperature indicator light


(the entire cooling system)

NOTE:


1. Seat/Trunk

2. Battery cover

3. Front cover

4. Head light cover

5. Leg shield 1

6. Drain the coolant


Pocket tester

90890-03132(YU-03112-C)

+

COOLING SYSTEM

ELEC

EAS00739

2. Battery





12.8 V or more at 20°C


YES NO



EAS00749

3. Main switch




YES NO


EAS00738

1. Main fuse

8Check the fuse for continuity.


8Is the fuse OK?

YES NO

Replace the fuse.

8-41

EAS00811

4. Thermo switch

8 Remove the thermo switch from the thermostat housing.

8 Connect the pocket tester ( Ω × 1) to the thermo switch 1 as shown.

8 Immerse the thermo switch in a container filled with coolant2.

8 Place a thermometer3 in the coolant.

8 Slowly heat the coolant, then let it cool down to the specified temperature.

8 Check the thermo switch for continuity at the temperatures indicated below.

Test step

1

2

3*

4*

Coolant temperature

Thermo switch

0 ~56 °C

More than65 ± 2 °C

65± 2°C to 56°C

Less than56 °C

Continuity

NO

YES

YES

NO

Steps 1 & 2: Heating phase

Steps 3 & 4: Cooling phase

COOLING SYSTEM

ELEC -

A Cooling phase

B Heating phase

YES NO

+

8 Does the thermo switch operate properly as described above?

Replace the thermo switch.

3

1

2

w care.

strong shocks. If the thermo switch is dropped, replace it.

T

.

R

.

Thermo switch

23 Nm (2.3 m • kg, 16.6 ft • lb)

Three bond sealock ® 10

8-42

EAS00812

5. The water temperature indicator light fails to operate.

1. Thermo unit

8 Remove the thermo unit from the cylinder head.

8 Connect the pocket tester ( Ω × 1k) to the thermo unit as shown.



COOLING SYSTEM

ELEC +

2. Voltage




DC20V

G/R B/L

8 Measure the thermo unit resistance.

Thermo unit resistance

3.413~4.007k Ω

1.645~1.855k

Ω

8 Is the thermo unit OK?

YES NO

Replace the thermo unit.


8 Measure the voltage (DC 12 V) of green/ red 1 on the meter light coupler (wire harness side).


YES NO

The wiring circuit from the main switch to the thermo unit connector is faulty and must be repaired.

8-43

3. Water temperature indicator light

8 Remove the thermo unit coupler .


8 Connect the green/red1 and black/ blue2 with a jumper lead3.

COOLING SYSTEM

ELEC +

1

G/R B/L

3

2

8 Is the water temperature indicator light

OK?

YES NO

This circuit is OK.

Replace the water temperature indicator light

EAS00813

6. Wiring

8 Check the entire cooling system’s wiring.


8 Is the cooling system’s wiring properly connected and without defects?

YES NO

Replace the C.D.I.

unit.

Properly connect or repair the cooling system’s wiring.

8-44

AUTO CHOKE SYSTEM

CIRCUIT DIAGRAM


ELEC +

4 Battery

5 Main fuse

8 C.D.I. unit

0 Auto choke unit c Thermo switch

Connecting with GND

12V21W/5W

12V10W

12V10W

12V35W/35W

12V10W

12V10W

7.5A

8-45

TURN R

TURN L

HI BEAM

ILLUMI

ILLUMI

TEMP

EAS00821

TROUBLESHOOTING

The auto choke system fails to operate.

Check:

1. main fuse

2. battery

3. thermo switch

4. auto choke unit


(of the entire autochoke system)

NOTE:


1. Seat/Trunk

2. Battery cover

3. Front cover


+


ELEC

EAS00739

2. Battery





12.8 V or more at 20°C


YES NO



Pocket tester

90890-03132(YU-03112-C)

EAS00738

1. Main fuse

8 Check the main fuse for continuity.


8 Is the fuse OK?

YES NO

Replace the fuse.

8-46

EAS00811

3. Thermo switch

8 Remove the thermo switch from the thermostat housing.

8 Connect the pocket tester ( Ω × 1) to the thermo switch 1 as shown.

8 Immerse the thermo switch in a container filled with coolant2.

8 Place a thermometer3 in the coolant.

8 Slowly heat the coolant, then let it cool down to the specified temperature.

8 Check the thermo switch for continuity at the temperatures indicated below.

Test step

1

2

3*

4*

Coolant temperature

Thermo switch

0 ~56 °C

More than65 ± 2 °C

65± 2°C to 56°C

Less than56 °C

Continuity

NO

YES

YES

NO

Steps 1 & 2: Heating phase

Steps 3 & 4: Cooling phase


ELEC

A Cooling phase

B Heating phase

YES NO

+

8 Does the thermo switch operate properly as described above?

Replace the thermo switch.

3

1

2

w cial care.

strong shocks. If the thermo switch is dropped, replace it.

T

.

R

.

Thermo switch

23 Nm (2.3 m • kg, 16.6 ft • lb)

Three bond sealock ® 10

8-47

4. Auto choke unit

8 Disconnect the auto choke unit coupler from wire harness.

8 Connect the pocket tester( Ω × 1) to the

Auto choke unit coupler as shown.

Positive tester probe JJ



ELEC +

G/B

Y

1

2

8Measure the auto choke unit resistance.

Auto choke unit resistance

20

Ω

8 Is the auto choke unit OK?

YES NO

Replace the auto choke unit.

5. Wiring

8 Check the entire auto choke system’s wiring.


8 Is the auto choke system’s wiring properly connected and without defects?

YES NO

Replace the

C.D.I. unit

Properly connect or repair the auto choke system’s wiring.

8-48

TRBL

SHTG

CHAPTER 9

TROUBLE SHOOTING

STARTING FAILURE/HARD STARTING................................................. 9-1

ENGINE .............................................................................................. 9-1

FUEL SYSTEM .................................................................................. 9-1

ELECTRICAL SYSTEMS .................................................................. 9-1

INCORRECT ENGINE IDLING SPEED ................................................... 9-2

ENGINE .............................................................................................. 9-2

FUEL SYSTEM .................................................................................. 9-2


POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 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

OVERHEATING......................................................................................... 9-4

ENGINE .............................................................................................. 9-4

COOLING SYSTEM........................................................................... 9-4

FUEL SYSTEM .................................................................................. 9-4

CHASSIS ............................................................................................ 9-4


OVERCOOLING........................................................................................ 9-4

COOLING SYSTEM........................................................................... 9-4

POOR BRAKING PERFORMANCE ........................................................ 9-5

FAULTY FRONT FORK LEGS ................................................................. 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

TURN SIGNAL DOES NOT COME ON ............................................ 9-6

TURN SIGNAL BLINKS SLOWLY ..................................................... 9-6

TURN SIGNAL REMAINS LIT ........................................................... 9-6

TURN SIGNAL BLINKS QUICKLY .................................................... 9-6

HORN DOES NOT SOUND .............................................................. 9-6

9-7

STARTING FAILURE/HARD STARTING

TRBL

SHTG

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 FAILURE / HARD

STARTING

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

Piston and piston ring

8Improperly installed piston ring

8Damaged, worn or fatigued piston ring

8Seized piston ring

8Seized or damaged piston

Air filter

8Improperly installed air filter

8Clogged air filter element

Crankcase and crankshaft

8Improperly assembled crankcase

8Seized crankshaft

FUEL SYSTEM

Fuel tank

8Empty fuel tank

8Clogged fuel tank cap breather hole

8Deteriorated or contaminated fuel

8Clogged or damaged fuel hose

Fuel cock

8Faulty fuel cock

8Damaged vacuum hose

8Improperly routed hose

Carburetor

8Deteriorated or contaminated fuel

8Clogged slow jet

8Clogged pilot air passage

8Sucked-in air

8Damaged float

8Worn needle valve

8Improperly installed needle valve seat

8Incorrect fuel level

8Improperly installed slow jet

8Clogged starter jet

Autochoke unit

8Faulty starter plunger

8Faulty C.D.I.unit

8Faulty thermo switch

ELECTRICAL SYSTEMS

Battery

8Discharged battery

8Faulty battery

Fuse

8Blown, damaged or incorrect fuse

8Improperly installed fuse

Spark plug

8Incorrect spark plug gap

8Incorrect spark plug heat range

8Fouled spark plug

8Worn or damaged electrode

8Worn or damaged insulator

8Faulty spark plug cap

Ignition coil

8Cracked or broken ignition coil body

8Broken or shorted primary or secondary coils

8Faulty spark plug lead

9-1

STARTING FAILURES/HARD STARTING/

INCORRECT ENGINE IDLING SPEED

TRBL

SHTG

Ignition system

8Faulty C.D.I.unit

8Faulty pickup coil

8Broken AC magneto rotor woodruff key

EAS00847

INCORRECT ENGINE IDLING

SPEED

ENGINE

Cylinder and cylinder head

8Incorrect valve clearance

8Damaged valve train components Switches and wiring

8Faulty main switch

8Faulty engine stop switch

8Broken or shorted wiring

8Faulty front, rear or both brake light switches

8Faulty start switch

8Improperly grounded circuit

8Loose connections

Starting system

8Faulty starter motor

8Faulty starter relay

8Faulty starter clutch

Air filter


FUEL SYSTEM

Carburetor


8Loose or clogged slow jet

8Loose or clogged slow air jet

8Damaged or loose carburetor joint

8Improperly synchronized carburetor

8Improperly adjusted engine idling speed

(throttle stop screw)

8Improper throttle cable free play

8Flooded carburetor

Autochoke unit


8Faulty C.D.I. unit


Battery

8Discharged battery

8Faulty battery

Spark plug



8Fouled spark plug

8Worn or damaged electrode

8Worn or damaged insulator

8Faulty spark plug cap

Ignition coil

8Faulty spark plug lead

Ignition system

8Faulty C.D.I. unit

8Faulty pickup coil

9-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/

FAULTY CLUTCH

TRBL

SHTG

EAS00849

POOR MEDIUM-AND-HIGH-

SPEED PERFORMANCE

EAS00853

FAULTY CLUTCH

ENGINE OPERATES BUT SCOOTER WILL

NOT MOVE

Refer to “STARTING FAILURE/HARD START-

ING”.

ENGINE

Air filter


V-belt

8Bent, damaged or worn V-belt

8Slipping V-belt

Air intake system

8Bent, clogged or disconnected carburetor air vent hose

8Clogged or leaking air duct

Primary pulley cam and primary pulley slider

8Damaged or worn primary pulley cam

8Damaged or worn primary pulley slider

Clutch spring(s)

8Damaged clutch spring

FUEL SYSTEM

Carburetor

8Faulty diaphragm


8Loose or clogged main jet

8Faulty accelerating pump

Transmission gears

8Damaged transmission gear

Fuel cock

8Faulty fuel cock

CLUTCH SLIPS

Clutch shoe springs

8Damaged, loose or worn clutch shoe spring

Clutch shoes

8Damaged or worn clutch shoe

Primary sliding sheave

8Seized primary sliding sheave

POOR STARTING PERFORMANCE

V-belt

8V-belt slips

8Oil or grease on the V-belt


8Faulty operation

8Worn pin groove

8Worn pin

Clutch shoes

8Bent, damaged or worn clutch shoe

9-3

FAULTY CLUTCH/OVERHEATING/OVERCOOLING

TRBL

SHTG

POOR SPEED PERFORMANCE

V-belt

8Oil or grease on the V-belt

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

Primary fixed sheave

8Worn primary fixed sheave

FUEL SYSTEM

Carburetor

8Incorrect main jet setting


8Damaged or loose carburetor joint


8Worn primary sliding sheave Air filter


Secondary fixed sheave

8Worn secondary fixed sheave

Secondary sliding sheave

8Worn secondary sliding sheave

CHASSIS

Brake(s)

8Dragging brake

EAS00855

OVERHEATING


Spark plug



ENGINE

Clogged coolant passages

8Heavy carbon buildup

Ignition system

8Faulty C.D.I. unit

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

SHTG

EAS00859

POOR BRAKING PERFORMANCE

EAS00862

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

EAS00861

FAULTY FRONT FORK LEGS

MALFUNCTION

8Bent or damaged inner tube

8Bent or damaged outer tube

8Damaged fork spring

8Bent or damaged damper rod

Handlebar

8Bent or improperly installed handlebar

Steering head components

8Improperly installed lower bracket

(improperly tightened ring nut)

8Bent steering stem

8Damaged ball bearing or bearing race

Front fork leg(s)

8Unevenly tensioned fork spring (both front fork legs)

8Broken fork spring

8Bent or damaged inner tube

8Bent or damaged outer tube

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

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

TRBL

SHTG

EAS00866

FAULTY LIGHTING OR SIGNALING

SYSTEM

TURN SIGNAL REMAINS LIT

8Faulty turn signal relay

8Burnt-out turn signal bulb

HEADLIGHT DOES NOT COME ON

8Wrong headlight bulb

8Faulty headlight relay

8Too many electrical accessories

8Hard charging

8Incorrect connection


8Poor contacts (main or light switch)

8Burnt-out headlight bulb

TURN SIGNAL BLINKS QUICKLY

8Incorrect turn signal bulb



HORN DOES NOT SOUND

8Improperly adjusted horn

8Damaged or faulty horn

8Faulty main switch

8Faulty horn switch

8Faulty battery


8Faulty wire harness

HEADLIGHT BULB BURNT OUT

8Wrong headlight bulb

8Faulty battery

8Faulty rectifier/regulator


8Faulty main switch

8Faulty light switch

8Headlight bulb life expired

TAIL/BRAKE LIGHT DOES NOT COME ON

8Wrong tail/brake light bulb

8Too many electrical accessories


8Burnt-out tail/brake light bulb

TAIL/BRAKE LIGHT BULB BURNT OUT

8Wrong tail/brake light bulb

8Faulty battery

8Tail/brake light bulb life expired

TURN SIGNAL DOES NOT COME ON

8Faulty turn signal switch




8Damaged or faulty wire harness


8Faulty battery


TURN SIGNAL BLINKS SLOWLY


8Faulty main switch

8Faulty turn signal switch

8Incorrect turn signal bulb

8Faulty battery

9-6

YAMAHA MOTOR TAIWAN CO., LTD

Yamaha VINO XC50V Service manual

SERVICE MANUAL

NOTICE

HOW TO USE THIS MANUAL

TABLE OF CONTENTS

GENERAL INFORMATION

GEN

INFO

SPECIFICATIONS

SPEC

PERIODIC CHECKS AND

ADJUSTMENTS

CHK

ADJ

CHASSIS

CHAS

ENGINE

ENG

COOLING

CARBURETOR

ELECTRICAL SYSTEM

COOL

CARB

ELEC

TROUBLESHOOTING

TRBL

SHTG

GENERAL INFORMATION

SPECIFICATIONS

CONVERSION TABLE

GENERAL TIGHTENING TORQUE

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHECKING THE CARBURETOR JOINT AND INTAKE

MANIFOLD/CHECKING THE FUEL AND VACUUM HOSES

CHASSIS

ENGINE

COOLING SYSTEM

CARBURETOR

ELECTRICAL

TROUBLESHOOTING

Key Features

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Frequently Answers and Questions

What type of engine does the XC50V 2005 use?

What type of transmission does the XC50V 2005 have?

What type of brakes does the XC50V 2005 use?

How do I start the XC50V 2005?

Table of contents