Yamaha VINO XC50V Service manual

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!
Q
The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOUR
SAFETY IS INVOLVED!
w
Failure to follow WARNING instructions could result in severe injury or death
to the scooter operator, a bystander or a person inspecting or repairing the
scooter.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates
a disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
6
2
1
CYLINDER AND PISTON
ENG
CYLINDER AND PISTON
EAS00253
CYLINDER AND PISTON
REMOVING THE CYLINDER AND PISTON
1. Remove:
8 piston pin clip 1
8 piston pin 2
8 piston 3
2
1
Do not use a hammer to drive the piston pin
out.
7
4
9
3
8
10
4
5
7
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.
2
5
2
4
4
5
Piston pin puller set
90890-01304(YU-01304)
4
6
3
1
10Nm (1.0 m•kg, 7.2 ft•lb)
7
Order
3
cC
3
4
ENG
EAS00251
Job/Part
Q’ty
1
2
3
4
5
6
Removing the cylinder and piston
Cylinder head
Timing chain guide(exhaust side)
Cylinder
Case cap
Reed valve assembly
Dowel pin
Cylinder gasket
1
1
1
1
2
1
7
8
Piston pin clip
Piston pin
2
1
9
10
Piston
Piston ring set
1
1
2. Remove:
8 top ring
8 2nd ring
8 oil ring
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
5-27
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.
Refer to “ INSTALLING THE PISTON
AND CYLINDER”.
Refer to “ REMOVING THE CYLINDER
AND PISTON”.
Refer to “ INSTALLING THE PISTON
AND CYLINDER”.
For installation, reverse the removal procedure.
5-28
8
EAS00008
1
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1
2
3
4
5
6
7
8
9
CHAS
5
6
ENG
COOL
7
8
CARB
ELEC
9
0
-
w
e
r
+
Symbols 0 to u indicate the following.
0 Serviceable with engine mounted
q Filling fluid
w Lubricant
e Special tool
r Tightening torque
t Wear limit, clearance
y Engine speed
u Electrical data
TRBL
SHTG
q
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Carburetor(s)
Electrical system
Troubleshooting
T.
R.
t
y
i
u
o
4
a
p
G
s
B
d
M
LS
f
M
g
LT
New
Symbols i to d in the exploded diagrams indicate the types of lubricants and lubrication
points.
i Engine oil
o Gear oil
p Molybdenum-disulfide oil
a Wheel-bearing grease
s Lithium-soap- based grease
d Molybdenum-disulfide grease
Symbols f to g in the exploded diagrams indicate the following.
f Apply locking agent (LOCTITE®)
g Replace the part
EAS00010
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING
CARBURETOR
GEN
INFO
1
SPEC
2
CHK
ADJ
3
CHAS
4
ENG
5
COOL
6
5
7
CARB
-
ELECTRICAL SYSTEM
TROUBLESHOOTING
+
ELEC
8
TRBL
SHTG
9
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
SCOOTER IDENTIFICATION ................................................................... 1-1
VEHICLE IDENTIFICATION NUMBER ............................................. 1-1
MODEL LABEL .................................................................................. 1-1
IMPORTANT INFORMATION ................................................................... 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY ................... 1-2
REPLACEMENT PARTS ................................................................... 1-2
GASKETS, OIL SEALS AND O-RINGS ............................................ 1-2
LOCK WASHERS/PLATES AND COTTER PINS ............................. 1-3
BEARINGS AND OIL SEALS ............................................................ 1-3
CIRCLIPS ........................................................................................... 1-3
Notes 3 on equipment preparation .................................................... 1-4
CHECKING THE CONNECTIONS ........................................................... 1-5
SPECIAL TOOLS ...................................................................................... 1-6
1-9
SCOOTER IDENTIFICATION
GEN
INFO
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
1
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
1-1
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands may
be similar in function and appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1-2
IMPORTANT INFORMATION
GEN
INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
1 Oil seal
cC
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use. When
installing a circlip 1, make sure the sharp-edged
corner 2 is positioned opposite the thrust 3
that the circlip receives.
4 Shaft
1-3
IMPORTANT INFORMATION
GEN
INFO
JAS00021
Notes 3 on equipment preparation
Push Rivet (Push type)
Assembly status of the Push Rivet (Push type)
1
Dissembling
1. Press Center Pin 1 inward to release the
Lock.
2. Remove the Push Rivet main body 2.
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.
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.
1-5
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
90890-01235
YU-01235
90890-01268
YU-01268
90890-01304
YU-01304
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
Tool name / Function
Illustration
Slide hammer bolt (8mm) 1
1
Weight 2
2
These tools are needed to remove the camshaft.
Rotor holding tool
This tool is used to remove the flywheel
magneto.
Ring nut wrench
This tool is used to loosen and tighten the
exhaust and steering ring nut.
Piston pin puller set
This tool is used to remove the piston pin.
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.
1-6
41
46
1
2
SPECIAL TOOLS
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
90890-03141
YU-03141
Tool name / Function
GEN
INFO
Illustration
Fork seal driver weight1
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
This tool is used to loosen and tighten the
steering ring nut.
Sheave holder
This tool is used for holding the secondary
sheave.
Thickness gauge
This tool is used to measure the valve
cleanance.
Compression gauge
These tool are used to measure the engine
compression.
Pocket tester
This instrument is invaluable for checking
the electrical system.
Engine tachometer
This tool is needed for detecting engine rpm.
Timing light
This tool is needed for detecting ignition timing.
1-7
1
2
SPECIAL TOOLS
Tool NO.
90890-04109
YM-04109
90890-04148
YM-04148
90890-04111
YM-04111
90890-04112
YM-04112
Tool name / Function
Valve spring compressor
Compressor adapter(Ø16.5mm)
These tools are used when removing or installing the valve and the valve spring.
Valve guide remover (4.0 mm)
This tool is used to remove or install the
valve guides.
Valve guide installer (4.0 mm)
This tool is used to install the valve guides.
90890-04113
YM-04113
90890-06754
YM-34487
90890-85505
ACC-11001-05-01
Valve guide remover (4.0 mm)
This tool is used to rebore the new valve
guides.
Ignition checker
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
GEN
INFO
Illustration
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 SPECIFICATIONS ................................................................................................. 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
Standard
Item
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Ground clearance
Minimum turning radius
Weight
Wet (without oil and a full fuel tank)
Dry (without oil and fuel)
Maximun load (total of cargo, rider,
passenger, and accessories)
Limit
3D11 (for USA)
3D12 (for CAN)
…
…
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
ENGINE SPECIFICATIONS
Standard
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Engine idle speed
Vacuum pressure at engine idle speed(AI OFF)
Standard compression pressure (at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Engine oil
Lubrication system
Recommended oil
-20˚ -10˚
0˚
10˚
20˚ 30˚
40˚ 50˚
SAE 10W-30
Limit
Liquid-cooled, 4-stroke, SOHC
0.049L(49cm3)
Forward inclined single cylinder
38.0 × 43.5 mm
12:1
2000~2400 r/min
34.7 kpa ( 260 mmHg )
1450 kPa (14.5kgf/cm2 )
at 700 r/min
…
…
…
…
…
…
…
…
Unleaded gasoline
…
4.5L ( 0.98 Imp gal,
1.18 US gal )
…
Wet sump
…
SAE10W40
Yamaha 4-cycle oil
EFERO X,Z,BX
…
SAE 10W-40
SAE 20W-40
SAE 20W-50
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
ENGINE SPECIFICATIONS
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
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
SPEC
Limit
Wire mesh
…
Trochoid
0.15 mm or less
0.13-0.18 mm
0.07-0.12 mm
…
0.23mm
0.25mm
0.19mm
0.26L
…
93.3~122.7 kpa
…
(0.95~1.25kgf/cm2,
13.53~17.79 psi)
1.1kpa (0.01kgf/cm2, 0.16 psi) …
133.3mm
87mm
16mm
…
…
…
0.26L
0.15L
…
…
Single suction centrifugal pump …
…
0.15mm
Starting system type
Electric and kick starter
…
Spark plug
Model (manufacturer) × quantity
Spark plug gap
CR7E (NGK) × 1
0.7~0.8mm
…
…
Cylinder head
Volume
Max. warpage
3.1~3.5cm³
…
…
0.03 mm
2-3
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Camshaft
Drive system
Intake camshaft lobe dimensions
Limit
Chain drive (left)
…
30.158~30.258 mm
25.082~25.182 mm
5.2077mm
30.058 mm
24.982 mm
…
30.158~30.258 mm
25.020~25.120 mm
5.2077mm
…
30.058 mm
24.920 mm
…
0.03 mm
C
A
B
Measurement A
Measurement B
Measurement C
Exhaust camshaft lobe dimensions
C
A
B
Measurement A
Measurement B
Measurement C
Max. camshaft runout
2-4
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Timing chain
Model/number of links
Tensioning system
Valve, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Limit
Morse 92RH2005 / 82
Automatic
…
…
0.10~0.16 mm
0.18~0.24 mm
…
…
B
C
D
A
Head Diameter
Face Width
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve stem to valve guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
Seat Width
Margin Thickness
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
1.6mm
1.6mm
0.7 mm
0.7 mm
…
…
3.975~3.990 mm
3.960~3.975 mm
3.945 mm
3.930 mm
4.000~4.012 mm
4.000~4.012 mm
4.050 mm
4.050 mm
0.010~0.037 mm
0.025~0.052 mm
…
0.080 mm
0.100 mm
0.010 mm
0.9~1.1 mm
0.9~1.1 mm
1.6mm
1.6mm
2-5
ENGINE SPECIFICATIONS
Standard
Item
Valve springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force (installed)
Intake
Exhaust
SPEC
Limit
39.35 mm
41.57 mm
37.38 mm
39.49 mm
28.0mm
30.0mm
…
…
91.1~104.9N(9.3~10.7kg)
107.9~124.1N
(11.0~12.7kg)
…
…
Intake
Exhaust
Winding direction (top view)
Intake
Exhaust
…
…
2.5 °/1.7 mm
2.5 °/1.8 mm
Clockwise
Clockwise
…
…
Valve seat reformed
Yes
…
Forward inclined
single cylinder
38.0 × 43.5 mm
12:1
38.000~38.010 mm
…
…
…
Spring tilt
Cylinder
Cylinder arrangement
Bore × stroke
Compression ratio
Bore
Max. taper
Max. out-of-round
2-6
…
…
…
0.05 mm
0.010 mm
ENGINE SPECIFICATIONS
Standard
Limit
0.010~0.035 mm
37.975~37.990 mm
0.150mm
…
5.0 mm
…
10.002~10.013 mm
0.35~0.65mm
Intake side
10.043 mm
…
…
9.996~10.000 mm
9.976 mm
Barrel
0.8 × 1.65mm
0.05~0.15 mm
0.02~0.08 mm
…
…
0.40mm
0.13 mm
Taper
0.8 × 1.5mm
0.05~0.17 mm
0.02~0.06 mm
…
…
0.52mm
0.12mm
1.5 × 1.6 mm
0.2~0.7 mm
0.03~0.15 mm
…
…
…
Item
Piston
Piston-to-cylinder clearance
Diameter D
SPEC
H
D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pin
Outside diameter
Piston rings
Top ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
2nd ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
Ring side clearance
2-7
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Limit
Rocker arm/rocker arm shaft
Rocker arm inside diameter
Rocker arm shaft outside diameter
Arm-to-shaft clearance
10.000~10.015mm
9.981~9.991 mm
0.009~0.034 mm
…
…
…
Connecting rod
Connecting rod length
Small end inside diameter
79.95~80.05 mm
10.015~10.028mm
…
…
42.45~42.50 mm
…
0.15~0.45 mm
0~0.010mm
…
0.03mm
1.00mm
…
Crankshaft
Width A
Max. runout C
Big end side clearance D
Big end radial clearance E
2-8
ENGINE SPECIFICATIONS
SPEC
Standard
Item
Limit
Clutch
Clutch type
Clutch shoe thickness
Clutch shoe spring free length
Clutch housing inside diameter
Compression spring free length
Weight outside diameter
Clutch-in revolution
Clutch-stall revolution
Automatic centrifugal
3.7 mm
30.1±0.4mm
107 mm
76.4 mm
15.0 mm
3450~3850 r/min
4350~5350 r/min
…
2.0mm
…
…
…
14.5 mm
…
…
V-belt
V-belt width
16.8 mm
15.8mm
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
V-belt automatic
Helical gear
48/13 (3.692)
Spur gear
43/12 (3.583)
2.805~0.863:1
…
…
…
…
…
…
…
…
0.04 mm
0.04 mm
Air filter type
Oil coated paper element
…
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 )
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
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
2-9
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Standard
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0~55 kg
55~158 kg
Min. tire tread depth
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0~55 kg
55~158 kg
Min. tire tread depth
Limit
Steel tube underbone
24 °
70 mm
…
…
…
Cast wheel
…
J10 × MT2.15
Aluminum
59mm
…
…
…
…
…
1.0 mm
1.0 mm
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
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
CHASSIS SPECIFICATIONS
SPEC
Standard
Item
Limit
Front brake
Brake type
Operation
Brake lever free play (at lever end)
Brake drum inside diameter
Lining thickness
Drum brake
Right-hand operation
10~20mm
110 mm
4.0mm
…
…
…
110.5mm
2.0mm
Rear brake
Brake type
Operation
Brake lever free play (at lever end)
Brake drum inside diameter
Lining thickness
Drum brake
Left-hand operation
10~20mm
110 mm
4.0mm
…
…
…
110.5mm
2.0mm
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
Telescopic
Coil spring/grease damper
65 mm
…
…
…
120 mm
110mm
9.46N/mm (0.96 kgf/mm)
0~65mm
No
26 mm
…
117.6mm
…
…
…
…
…
0.2 mm
Steering system
Steering bearing type
Lock to lock angle (left)
Lock to lock angle (Right)
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
…
…
…
…
…
…
…
…
…
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
2-11
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Standard
Item
System voltage
Limit
12V
…
C.D.I.
13 ° B.T.D.C. at
2000~2400 r/min
Digital
248~372 Ω / WR-WL
5ST (T-MORIC)
…
…
…
…
…
Ignition coil
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
X7A (T-MORIC)
6mm
0.168~0.252 Ω at 20 ° C
2.4~3.6 kΩ at 20 ° C
…
…
…
…
Spark plug cap
Material
Resistance
Resin
4~6 kΩ
…
…
Charging system
System type
Model (manufacturer)
Nominal output
Stator coil resistance /color
Lighting coil resistance /color
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
…
…
…
…
…
Voltage regulator
Regulator type
Model (manufacturer)
No load regulated voltage(DC)
Semiconductor, short circuit
SH656-12 (SHIN DEN GEN)
14.1~14.9 V
…
…
…
Rectifier
Model (manufacturer)
Rectifier capacity(DC)
Withstand voltage
SH656-12 (SHIN DEN GEN)
8A
200V
…
…
…
Battery
Battery type (manufacturer)
Battery voltage capacity
Specific gravity
Ten hour rate amperage
GTX5L-BS (GS)
12V 4AH
1.330
4AH
…
…
…
…
Headlight type
Halogen bulb
…
Indicator light (voltage/wattage×quantity)
Turn signal indicator light
High beam indicator light
Water temperature indicator light
14 V 3.0 W × 2
12 V 1.7W × 1
14 V 3.0W × 1
…
…
…
Ignition system
Ignition system type
Ignition timing
Advancer type
Pickup coil resistance /color
C.D.I. unit model (manufacturer)
2-12
ELECTRICAL SPECIFICATIONS
Standard
Item
Bulbs (voltage/wattage × quantity)
Headlight
Tail/brake light
Front turn signal light
Rear turn signal light
Speedometer lighting
SPEC
Limit
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
…
Electric starting system
System type
Starter motor
Model (manufacturer)
Suction voltage
Power output
Brushes
Overall length
Quantity
Spring force
Commutator diameter
Commutator resistance
Mica undercut (depth)
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
3.5mm
…
…
16.6mm
…
…
Starter relay
Model (manufacturer)
Amperage
Coil resistance
Suction voltage
5WC 00 (OMRON)
50 A
90-110 Ω
More than DC10V
…
…
…
…
Horn
Horn type
Model (manufacturer)
Max. amperage
Performance
Coil resistance
Plane
AH-368 (SAKURA)
1.5 A
98~108db/2m
4.05~4.55Ω
…
…
…
…
…
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full transistor
5CA9 (TA YOUNG)
NO
75~95 cycles/min
10 W × 2 + 1.7 W+ AP
…
…
…
…
…
Fuel sender
Model (manufacturer)
Sender unit resistance-full
Sender unit resistance-empty
5ST1 (CHAO LONG)
6~8 Ω
93.5~96.5 Ω
…
…
…
Head light relay
Model (manufacturer)
Coil resistance
Diode
5EB 10 (OMRON)
90~110 Ω
YES
…
…
…
2-13
ELECTRICAL SPECIFICATIONS
SPEC
Standard
Item
Limit
Throttle position sensor
Output voltage (throttle opens)
Output voltage (throttle closes)
2.8~3.4V
0.625~0.775V
…
…
Radiator fan
Model (manufacturer)
Running rpm
5ST-00 (LUNTAI)
10000 r/min
…
…
Thermostat switch
Model (manufacturer)
5ST (NIPPON THERMOSTAT) …
Thermo unit
Model (manufacturer)
Coil resistance at 80 °C
Coil resistance at 100 °C
5JJ (NIPPON THERMOSTAT) …
3.413~4.007 kΩ
…
1.645~1.855 kΩ
…
Fuse (amperage × quantity)
Main fuse
7.5A×1
2-14
…
CONVERTION TABLE / GENERAL TIGHTENING
TORQUE SPECIFICATIONS
SPEC
EB201000
EAS00030
CONVERSION TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
Ex.
METRIC
MULTIPLIER
IMPERIAL
** mm
0.03937
** in
2 mm
0.03937
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
m·kg
Tightening torque m·kg
cm·kg
cm·kg
Multiplier
Imperial unit
7.233
86.794
0.0723
0.8679
ft·lb
in·lb
ft·lb
in·lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu-in
qt (IMP liq.)
gal (IMP liq.)
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit (°F)
Misc.
A: Width across flats
B: Thread diameter
A
(nut)
2-15
B
(bolt)
General tightening
torques
Nm
m•kg
ft•lb
10 mm
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE
Part to be tightened
Part name
Thread ’
Q ty
size
Tightening
torque
Remarks
Nm m•kg ft•lb
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
Nut
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
plug
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nult
Nut
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
2-16
M6
M10
M6
M8
M6
M6
M6
M6
M6
M6
M8
M6
M8
M6
M6
M6
M5
M12
M6
M6
M35
M6
M8
M6
M8
M6
M6
M6
M6
M6
M6
M6
M8
M8
M8
M6
M6
M6
M6
M22
4
1
2
2
4
1
3
3
1
1
1
2
1
2
4
3
2
1
2
2
1
1
2
2
2
2
8
8
8
7
6
1
1
1
1
1
4
7
1
1
10
12.5
10
12.5
10
7
10
10
7
10
30
9
8
10
10
9
4
2
10
10
32
10
31
10
13
9
10
13
13
10
10
10
23
15
23
10
10
7
12
90
1.0
1.25
1.0
1.25
1.0
0.7
1.0
1.0
0.7
1.0
3.0
0.9
0.8
1.0
1.0
0.9
0.4
0.2
1.0
1.0
3.2
1.0
3.1
1.0
1.3
0.9
1.0
1.3
1.3
1.0
1.0
1.0
2.3
1.5
2.3
1.0
1.0
0.7
1.2
9.0
7.2
9.0
7.2
9.0
7.2
5.1
7.2
7.2
5.1
7.2
21.7
6.5
5.8
7.2
7.2
6.5
2.9
1.5
7.2
7.2
23.1
7.2
22.4
7.2
9.4
6.5
7.2
9.4
9.4
7.2
7.2
7.2
16.6
10.9
16.6
7.2
7.2
5.1
8.7
65.1
4
Left-hand thread
Left-hand thread
TIGHTENING TORQUES
Part to be tightened
Part name
Thread ’
Q ty
size
SPEC
Tightening
torque
Remarks
Nm m•kg ft•lb
Clutch housing
Ignition coil
Thermo unit
Primary fixed sheave
Starter motor assembly
AC magneto rotor
Stator coil
Pickup coil
Nut
Bolt
Nut
Bolt
Nut
Bolt
Screw
Cylinder head tightening sequence
1
5
3
4
2
6
2-17
M10
M5
PT1/8
M10
M6
M12
M5
M6
1
1
1
1
2
1
3
2
40
8
8
30
13
43
4
7
4.0 28.9
0.8 5.8
0.8 5.8
3.0 21.7
1.3 9.4
4.3 31.1
0.4 2.9
0.7 5.1
LT
TIGHTENING TORQUES
SPEC
CHASSIS
Part to be tightened
Thread
size
Tightening
torque
Nm
M10
M10
M10
M10
M6
M6
M8
BC
BC1
M6
M6
M5
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
About M5
M6
M6
M6
M10
M14
M6
M8
M12
M10
M8
46
58
60
30
12
10
23
7
30
12
4
3
1.5
2
7
8
48
104
7
16
3
30
16
Remarks
m•kg ft•lb
4.6
5.8
6.0
3.0
1.2
1.0
2.3
0.7
3.0
1.2
0.4
0.3
0.15
0.2
0.7
0.8
4.8
10.4
0.7
1.6
0.3
3.0
1.6
33.1
42.0
43.4
21.7
8.7
7.2
16.6
5.1 See”NOTE”
21.7 See”NOTE”
8.7
2.9
2.2
1.1
1.5
5.1
5.8
34.7
75.2
5.1
11.6
2.2
21.7
11.6
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
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication Point
Lubricant
Oil seal lips
LS
O-rings (Except V-belt drive unit)
LS
Cylinder head tightening nut mounting surface
4
Cylinder head stud bolt thread
4
Cylinder head gasket dowel pin
4
Crankshaft pin outside surface
4
Connecting rod
4
Piston outside and ring groove
4
Piston pin outside surface
4
surface and bolt thread
4
Crankshaft journal
4
Piston (balancer) outside surface
4
Piston pin (balancer) outside surface
4
Camshaft lobe
M
Camshaft profile journal
M
Valve stems (intake and exhaust)
M
Valve stem seals(intake and exhaust)
M
Valve pads(intake and exhaust)
M
Valve stem ends (intake and exhaust)
4
Oil pump assembly inside surface
4
Oil pipe union bolt thread and surface
4
Starter clutch pin and weight
M
Idle gear 1 thrust surface
4
Idle gear 2
4
Main and drive axle serration (sprocket)
G
Drive axle taper rollor bearing
G
Transmission bearing
G
2-19
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication Point
SPEC
Lubricant
Secondary fixed sheave inner surface
BEL-RAY asembly lube®
Secondary sliding sheave torque cam ditch
BEL-RAY asembly lube®
Crankcase mating surfaces
Sealant
2-20
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00032
CHASSIS
Lubrication Point
Lubricant
Front wheel oil seal lips
LS
Steering bearing and bearing races (upper and lower)
LS
Frame head pipe dust seal lips ( lower)
LS
Tube guide (throttle grip) inner surface
LS
Brake lever and lever holder bolt sliding surface
LS
Centerstand pivoting point and sliding surface
LS
Rear shock absorber backward, bush inner surface and spacer sliding surface
M
Seat lock cable and rear wheel lock cable inner surface
LS
Engine bracket and engine mound bolt sliding surface
LS
2-21
COOLING SYSTEM DIAGRAMS
SPEC
EAS00033
COOLING SYSTEM DIAGRAMS
1
2
3
4
5
6
Raidator cap
Coolant reservoir
Radiator inlet hose
Radiator outlet hose
Thermo switch
Conduit hose
1
3
6
5
2
4
2-22
COOLING SYSTEM DIAGRAMS
1
2
3
4
5
SPEC
Outlet hose(to cylinder)
Radiator inlet hose
Radiator outlet hose
Thermostat
Thermostat housing
2
5
1
2-23
4
3
COOLING SYSTEM DIAGRAMS
1
2
3
4
Breather hose
Outlet hose(to cylinder)
Radiator outlet hose
Water pump
1
4
3
2
2-24
SPEC
COOLING SYSTEM DIAGRAMS
1
2
3
4
Thermostat housing
Thermostat assembly inlet breather hose
Water pump
Breather hose
1
2
4
3
2-25
SPEC
OIL FLOW DIAGRAMS
OIL FLOW DIAGRAMS
1
2
3
4
5
6
Oil filter
Oil pump
To cylinder head
Oil strainer
Oil nozzle
Camshaft
2-26
SPEC
OIL FLOW DIAGRAMS
1
2
3
4
SPEC
Crankshaft pin
Connecting rod big end bearing
Oil nozzle
Camshaft
Cylinder wall
Connecting rod
big end bearing
Crankshaft pin
Rocker arm shaft
and rocler arm
Camshaft
Oil nozzle
Centrifugal oil filter
Oil pump
Oil filter
Crankcase sump
2-27
CABLE ROUTING
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 .
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
9
SPEC
G Clamp the seat lock cable
and wire harness to the frame
of cover , install upward of the
seat lock cable .
0
q
G
e
u
e
w
t
r
y
E-E
C-C
2
1
3
5
E
6
A
4
D
C
F
8
7
2-28
B
CABLE ROUTING
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
4
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
t
y
9
L
8
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).
r
1
M
5
SPEC
2
N-N
3
K
e
1
N
J
3
2
q
C
0
A
4
9
7 8
B
5
I
H
6
G
2-29
F
E
D
w
CABLE ROUTING
SPEC
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.
4
t
r
1
M
5
L
y
9
8
2
3
K
N-N
e
1
N
J
3
2
q
C
0
A
4
9
7 8
B
5
I
H
6
G
2-30
F
E
D
w
CABLE ROUTING
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.
D
B
A
2
3
C
5
K
O
N
M
G
6
H
I
L
J
2-31
E
F
4
P
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.
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.
1
SPEC
CABLE ROUTING
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
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,
D
B
A
A
1C 2
34
SPEC
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.
F
E
G H
56
9
8 7
q
0
w
S
R
UT
Q P
A O
N M
L
Right side
FWD.
Left side
C-C
J
e2
1
6
4
K
B
C
7
5
9
C
w
r
t
B
2-32
A-A
CABLE ROUTING
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.
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.
D
B
A
A
1C 2
34
SPEC
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.
F
E
G H
56
9
8 7
q
0
w
S
R
UT
Q P
A O
N M
L
Right side
FWD.
Left side
C-C
J
e2
1
K
6
4
B
C
7
5
9
C
w
r
t
B
2-33
A-A
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION ....................................................................................... 3-1
PERIODIC MAINTENANCE AND MINOR REPAIR ................................ 3-2
Periodic maintenance chart for the emission control system ........... 3-2
General maintenance and lubrication chart...................................... 3-3
COVER AND PANEL ................................................................................ 3-5
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 AND MINOR REPAIR
Periodic maintenance chart for the emission control system
INITIAL
NO.
1
*
2
3
*
ITEM
ROUTINE
600 mi
(1,000 km)
or
1
month
ODOMETER READING
2,000 mi
(4,000 km)
or
6
months
4,000 mi
6,000 mi
8,000 mi
10,000 mi
(7,000 km) (10,000 km) (13,000 km) (16,000 km)
or
or
or
or
12
18
24
30
months
months
months
months
Fuel line
• Check fuel and vacuum hoses for
cracks or damage.
• Replace if necessary.
√
√
√
√
√
Spark plug
• Check condition.
• Adjust gap and clean.
• Replace at 4000 mi (7000 km) or
12 months and thereafter every
4000 mi (6000 km) or 12 months.
√
Replace.
√
Replace.
√
Valve clearance
• Check and adjust valve clearance
when engine is cold.
4
*
Crankcase breather
system
• Check breather hose for cracks or
damage.
• Replace if necessary.
5
*
Idle speed
• Check and adjust engine idle
speed.
6
*
Exhaust system
7
*
Air induction system
√
Every 6000 mi (10000 km)
√
√
√
√
√
√
√
√
√
√
• 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.
√
√
√
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform
the service.
3-2
PERIODIC MAINTENANCE AND MINOR REPAIR
CHK
ADJ
General maintenance and lubrication chart
Maintenance and lubrication, periodic
INITIAL
NO.
1
*
ITEM
ROUTINE
Air filter element
• Replace.
600 mi
(1,000 km)
or
1
month
ODOMETER READING
2,000 mi
(4,000 km)
or
6
months
4,000 mi
6,000 mi
8,000 mi
10,000 mi
(7,000 km) (10,000 km) (13,000 km) (16,000 km)
or
or
or
or
12
18
24
30
months
months
months
months
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
2
*
Front brake
• Check operation.
• Adjust cable and replace brake
shoes if necessary.
3
*
Rear brake
• Check operation.
• Adjust cable and replace brake
shoes if necessary.
4
*
Wheels
• Check runout and for damage.
• Replace if necessary.
√
√
√
√
√
5
*
Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
√
√
√
√
√
6
*
Wheel bearings
• Check bearings for smooth
operation.
• Replace if necessary.
√
√
√
√
√
√
√
√
Repack.
√
√
√
√
√
√
7
*
Steering bearings
• Check bearing assemblies for
looseness.
• Moderately repack with lithiumsoap-based grease every 8000 mi
(13000 km) or 24 months.
8
*
Chassis fasteners
• Check all chassis fitting and
fasteners.
• Correct if necessary.
√
Front and rear brake • Apply lithium-soap-based grease
lever pivot
(all-purpose grease) lightly.
9
10
√
√
√
√
√
Centerstand
• Check operation.
• Lubricate.
√
√
√
√
√
11
*
Front fork
• Check operation and for oil
leakage.
• Replace if necessary.
√
√
√
√
√
12
*
Shock absorber
assembly
• Check operation and for oil
leakage.
• Replace if necessary.
√
√
√
√
√
13
Engine oil
• Change (warm engine before
draining).
• Check oil level and vehicle for oil
leakage.
√
√
√
√
√
√
14
Engine oil strainer
• Clean.
√
Cooling system
• Check coolant level and vehicle for
coolant leakage.
15
*
√
√
• Change.
Final transmission
oil
• Check vehicle for oil leakage.
• Change.
*
V-belt
• Replace.
*
Front and rear brake
• Check operation.
switches
16
17
18
*
Control and meter
cables
• Apply Yamaha chain and cable
lube or engine oil 10W-30
thoroughly.
20
*
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.
21
*
Lights, signals and
switches
• Check operation.
• Adjust headlight beam.
19
√
√
√
√
√
Every 3 years
√
√
√
Every 6250 mi (10000 km)
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
3-3
PERIODIC MAINTENANCE AND MINOR REPAIR
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
CHK
ADJ
COVER AND PANEL
SEAT AND TRUNK
12Nm (1.2 m•kg, 8.7 ft•lb)
12Nm (1.2 m•kg, 8.7 ft•lb)
2
1
10Nm (1.0 m•kg, 7.2 ft•lb)
23Nm (2.3 m•kg, 16.6 ft•lb)
4
3
5
6
7
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the seat and trunk
Seat
Damper
Rubber cap
Trunk
Rear carrier
Mat
Battery cover
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
3-5
COVER AND PANEL
CHK
ADJ
SIDE COVER (LEFT AND RIGHT)
5
6
4
3
1
2
Order
1
2
3
4
5
6
Job/Part
Q’ty
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
Remarks
Remove the parts in the order listed.
1
Refer to “SEAT AND TRUNK”.
Disconnect.
1
1
1
1
1
For installation, reverse the removal procedure.
3-6
CHK
ADJ
COVER AND PANEL
FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE
4Nm (0.4 m•kg, 2.9 ft•lb)
1
3
2
7
4
6
5
Order
Job/Part
Q’ty
Removing the footrest board and
footrest board side cover mole
Side cover(left and right)
1
2
3
4
5
6
7
Battery holder
Battery negative - lead
Battery positive + lead
Battery
Footrest board side cover mole(left)
Footrest board side cover mole(right)
Footrest board
Remarks
Remove the parts in the order listed.
Refer to “SIDE COVER(LEFT AND
RIGHT)”.
1
1
1
1
1
1
1
cC
First, disconnect the negative battery
lead, and then the positive battery
lead.
For installation, reverse the removal procedure.
3-7
COVER AND PANEL
CHK
ADJ
LEG SHIELD 1 , 2
8
7
9
3
5
6
2
4
10
11
12
1
Order
Job/Part
Q’ty
Removing the leg shield 1,2
Footrest board
1
2
3
4
5
6
7
8
9
10
11
12
Remarks
Remove the parts in the order listed.
Refer to “FOOTREST BOARD AND
FOOTREST BOARD SIDE COVER
MOLE”.
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
1
1
1
1
1
1
1
1
1
1
1
1
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
3-8
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00049
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
8 Valve clearance adjustment should be made
on a cold engine, at room temperature.
8 When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
8 seat/trunk
8 battery cover
8 battery holder
8 front cover
Refer to “COVER AND PANEL”.
2. Drain:
8 coolant
(completely from the radiator )
2
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
1
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.
b
a
3-9
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
d. Measure the valve clearance with a thickness gauge 1.
Out of specification J Adjust.
*****************************************************
d
c
1
6. Adjust:
8valve clearance
2
*****************************************************
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.
1
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
ADJUSTING THE VALVE CLEARANCE
Last digit
0 or 2
5
8
CHK
ADJ
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
ADJUSTING THE VALVE CLEARANCE
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
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
STANDARD CLEARANCE
125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
175 180 185 190 195 200 205 210 215 220 225 230 235 240
180 185 190 195 200 205 210 215 220 225 230 235 240
185 190 195 200 205 210 215 220 225 230 235 240
Valve Clearance (cold)
190 195 200 205 210 215 220 225 230 235 240
0.10∼0.16 mm
195 200 205 210 215 220 225 230 235 240
Rounded
value 175
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
Measured valve clearance is 0.24 mm
210 215 220 225 230 235 240
Replace pad 175 with pad 185
215 220 225 230 235 240
Pad No. 175 = 1.75 mm
220 225 230 235 240
Pad No. 185 = 1.85 mm
225 230 235 240
Always install the valve pad with the
230 235 240
235 240
number facing down.
240
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
120 125 130 135 140
120
120 125
120 125 130
120 125 130 135
145
125
130
135
140
150
130
135
140
145
155
135
140
145
150
160
140
145
150
155
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
ORIGINAL VALVE PAD NUMBER
165 170 175 180 185 190 195 200 205 210 215
145 150 155 160 165 170 175 180 185 190 195
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
Valve Clearance (cold)
235 240
0.18∼0.24 mm
240
220
200
205
210
215
225
205
210
215
220
230
210
215
220
225
235 240
215 220
220 225
225 230
230 235
225 230 235 240
230 235 240
235 240
240
Rounded value 175
Measured valve clearance is 0.32 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.
3-12
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
7. Install:
8all removed parts
NOTE:
For installation, reverse the removal procedure.
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
Out of specification J Adjust
Engine idling speed
2000 ~ 2400 r/min
4. Adjust:
8 engine idling speed
*****************************************************
a . Turn the throttle stop screw 1 in direction
a or b until the specified engine idling
speed is obtained.
1
a
b
Direction a
Direction b
Engine idling speed is increased.
Engine idling speed is decreased.
*****************************************************
5 . Adjust:
8throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the flange
of the throttle grip)
1.5 ~ 3.5 mm (0.059 ~ 0.138 in)
3-14
CHECKING THE EXHAUST GAS AT IDLE
CHK
ADJ
CHECKING THE EXHAUST GAS AT IDLE
( Measuring the exhaust gas at idle(when air induction system is operation))
1. Stand the scooter on a level surface.
NOTE:
8 Place the scooter on a suitable stand.
8 Make sure the scooter is upright.
2. Install:
8pocket tester1.
(onto the engine oil drain bolt)
8engine tachometer
(onto the spark plug lead )
Pocket tester
90890-03132
YU-03112-C
Engine tachometer
90890-03113
YU-08036-C
1
3. Start the engine and warm it up until the specified oil temperature is reached.
Oil temperature
50~70°C
4. Measure:
8 engine idling speed
Out of specification J Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”
Engine idling speed
2000 ~ 2400 r/min
5. Install:
8 carbon monoxide and hydrocarbon
tester1.
8 sampling probe2.
8 engine tachometer3.
1
2
3-15
CHECKING THE EXHAUST GAS AT IDLE
CHK
ADJ
3
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.
600mm
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
Out of specification 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.
1. Check:
8 throttle cable free play a
Out of specification J Adjust.
Throttle cable free play (at the flange
of the throttle grip)
1.5 ~ 3.5 mm (0.059 ~ 0.138 in)
a
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.
b 1
a
Direction a
Direction b
2
Throttle cable free play is increased.
Throttle cable free play is decreased.
c. Tighten the locknut.
w
After adjusting the throttle cable free play,
start the engine and turn the 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
Refer to “COVER AND PANEL”.
2. Disconnect:
8 spark plug cap
3. Remove:
8 spark plug
cC
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
into the cylinder.
4. Check:
8 spark plug type
Incorrect J Change.
Spark plug type (manufacturer)
CR7E (NGK)
5. Check:
8 electrode 1
Damage/wear J Replace the spark plug.
8 insulator 2
Abnormal color J Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
8 spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
8 spark plug gap a
(with a wire Thickness gauge)
Out of specification J Regap.
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.032 in)
8. Install:
8 spark plug
T.
12.5 Nm (1.25 m • kg, 9 ft • lb)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
R.
9. Connect:
8 spark plug cap
10.Install:
8 battery holder
8 battery cover
Refer to “COVER AND PANEL”.
3-18
CHECKING THE IGNITION TIMING
CHK
ADJ
EAS00062
CHECKING THE IGNITION TIMING
NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure all connections are tight and free of
corrosion.
1. Drain:
8coolant
(completely from the radiator )
2. Remove:
8radiator cover
8radiator
8fan case
Refer to “RADIATOR”in chapter 6.
3. Attach:
8timing light 1
8engine tachometer 2
(onto the spark plug lead of cylinder)
1
Timing light
90890-03141
YU-03141
Engine tachometer
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.
2
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.
b
a
3-19
CHECKING THE IGNITION TIMING
CHK
ADJ
NOTE:
The ignition timing is not adjustable.
*****************************************************
5. Remove:
8timing light
8engine tachometer
6. Install:
8fan case
8radiator
8radiator cover
Refer to “RADIATOR”in chapter 6.
7. Fill:
8cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT”.
3-20
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
EAS00067
MEASURING THE COMPRESSION PRESSURE
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
Refer to “COVER AND PANEL”.
4. Disconnect:
8spark plug cap
5. Remove:
8spark plug
cC
Before removing the spark plug, use
compressed air to blow away any dirt
accumulated in the spark plug well to
prevent it from falling into the cylinder.
6.
1
Install:
8compression gauge 1
Compression gauge
90890-03081
YU-33223
7.
3-21
Measure:
8compression pressure
Out of specification J Refer to steps (c)
and (d).
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
Compression pressure (at sea level)
Minimum
1262 kPa (12.6 kgf/cm2, 700r/min)
Standard
1450 kPa (14.5 kgf/cm2, 700r/min)
Maximum
1624 kPa (16.2 kgf/cm2, 700r/min)
*****************************************************
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the engine until the reading on the compression
gauge stabilizes.
w
To prevent sparking, ground the spark plug
lead before cranking the engine.
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon 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
Diagnosis
Higher than without oil
Piston ring(s) wear or
damage J Repair.
Same as without oil
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
Refer to “COVER AND PANEL”.
3-22
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the scooter on a level surface.
NOTE:
8 Place the scooter on a suitable stand.
8 Make sure the scooter is upright.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Check:
8 engine oil level
The engine oil level should be between
the minimum level mark a and maximum
level mark b.
Below the minimum level mark J Add
the recommended engine oil to the proper
level.
b
a
-20˚ -10˚
0˚
10˚
20˚ 30˚
Recommended oil
Refer to the chart for the engine oil
grade which is best suited for
certain atmospheric temperatures.
API standard
SE or higher grade
40˚ 50˚
SAE 10W-30
SAE 10W-40
cC
SAE 20W-40
SAE 20W-50
8 Do not allow foreign materials to enter
the crankcase.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
3-23
CHANGING THE ENGINE OIL
CHK
ADJ
EAS00076
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
8 engine oil filler cap 1
8 engine oil drain bolt 2
(along with the gasket)
1
4. Drain:
8 engine oil
(completely from the crankcase)
2
4
3
5. If the oil filter element is also to be cleaned,
perform the following procedure.
2 1
*****************************************************
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.
1
T.
R.
Oil strainer cover
32 Nm (3.2 m • kg, 23.1 ft • lb)
*****************************************************
6. Install:
8 engine oil drain bolt
(along with the gasket)
T.
R.
23 Nm (2.3 m • kg, 16.6 ft • lb)
7. Fill:
8 crankcase
(with the specified amount of the recommended engine oil)
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)
3-24
CHANGING THE ENGINE OIL
CHK
ADJ
8. Install:
8engine oil filler cap
9. Start the engine, warm it up for several minutes, and then turn it off.
10. Check:
8engine
(for engine oil leaks)
11. Check:
8engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
12. Check:
8engine oil pressure
Refer to “CHECKING THE ENGINE OIL
PRESSURE”.
3-25
CHANGING THE TRANSMISSION OIL
CHK
ADJ
CHANGING THE TRANSMISSION OIL
1. Stand the scooter on a level surface.
NOTE:
8 Stand the scooter on a suitable stand.
8 Make sure that the scooter up right.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Place a container under the transmission.
4 Remove:
8transmission oil drain bolt 1
8transmission oil fill bolt
Completely drain the transmission oil.
5 Install:
8transmission oil drain bolt
1
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
7.
Install:
8transmission oil fill bolt1
(along with the gasket)
1
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.
3-26
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
EAS00077
MEASURING THE ENGINE OIL PRESSURE
1. Check:
8 engine oil level
Below the minimum level mark J Add the
recommended engine oil to the proper
level.
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
2. Start the engine, warm it up for several minutes, and then turn it off.
cC
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
3. Remove:
8 seat/trunk
8 battery cover
8 front cover
Refer to “COVER AND PANEL”.
4. Lossen:
8 gallery bolt 1
w
The engine, muffler and engine oil are
extremely hot.
1
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.
*****************************************************
3-27
MEASURING THE ENGINE OIL PRESSURE
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
Refer to “COVER AND PANEL”.
3-28
CHECKING THE AIR FILTER ELEMENT
CHK
ADJ
EAS00086
1
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)
cC
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
CHECKING THE CARBURETOR JOINT AND INTAKE
MANIFOLD/CHECKING THE FUEL AND VACUUM HOSES
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
Refer to “COVER AND PANEL”.
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
Refer to “COVER AND PANEL”.
1
2
EAS00096
CHECKING THE FUEL AND VACUUM
HOSES
The following procedure applies to all of the fuel
and vacuum hoses.
1. Remove:
8 seat/trunk
Refer to “COVER AND PANEL”.
2. Check:
8 vacuum hose 1
8 fuel hose 2
Cracks/damage J Replace.
Loose connection J Connect properly.
3. Install:
8 seat/trunk
Refer to “COVER AND PANEL”.
2
1
3-30
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
Refer to “COVER AND PANEL”.
2. Check:
8fuel hose 1
Cracks/damage J Replace.
8fuel filter 2
Contaminants/damage J Replace.
1
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.
2
3.
3-31
Install:
8rear cover
8side cover (left and right)
8front cover
8rear carrier
8seat/trunk
8battery cover
Refer to “COVER AND PANEL”.
CHECKING THE CRANKCASE BREATHER HOSE
CHK
ADJ
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
8seat/trunk
Refer to “COVER AND PANEL”.
2.
1
Check:
8crankcase breather hose 1
Cracks/damage J Replace.
Loose connection J Connect properly.
cC
Make sure the crankcase breather hose is
routed correctly.
3.
3-32
Install:
8seat/trunk
Refer to “COVER AND PANEL”.
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.
2 . Check:
8 muffler assembly 1
Cracks/damage J Replace.
8 gasket 2
Exhaust gas leaks J Replace.
3 . Check:
8 tightening torque
2
1
3
4
5
T.
R.
4.
3-33
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)
Install:
8muffler assembly
Refer to “MANIFOLD, AIR FILTER AND
MUFFLER ASSEMBLY” in chapter 5.
CHECKING THE COOLANT LEVEL
CHK
ADJ
EAS00103
CHECKING THE COOLANT LEVEL
1. Stand the scooter on a level surface.
NOTE:
8 Place the scooter on a suitable stand.
8 Make sure the scooter is upright.
2.
3.
a
b
Remove:
8 mat
8 battery cover
Refer to “COVER AND PANEL”.
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.
cC
8 Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
8 Use only distilled water. However, if distilled water is not available, soft water
may be used.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check:
8coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
6. Install:
8 battery cover
8 mat
Refer to “COVER AND PANEL”.
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
Refer to “COVER AND PANEL”.
8 radiator cover
Refer to “COOLING SYSTEM”in chapter 6.
2. Check:
8 radiator 1
8 radiator inlet hose 2
8 radiator outlet hose 3
Cracks/damage J Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:
8 radiator cover
Refer to “COOLING SYSTEM”in chapter 6.
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
Refer to “COVER AND PANEL”.
2
1
3
3-35
CHANGING THE COOLANT
CHK
ADJ
EAS00105
CHANGING THE COOLANT
1. Remove:
8 mat
8 battery cover
8 footrest board side cover mole (right)
Refer to “COVER AND PANEL”.
8 radiator cover
Refer to “COOLING SYSTEM”in chapter 6.
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
1
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.
3-36
2 Nm (0.2 m • kg, 1.5 ft • lb)
CHANGING THE COOLANT
CHK
ADJ
7. Fill:
8 cooling system
(with the specified amount of the recommended coolant)
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
8 If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
8 If coolant splashes on your clothes,
quickly wash it away with water and
then with soap and water.
8 If coolant is swallowed, induce vomiting
and get immediate medical attention.
cC
8 Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
8 Use only distilled water. However, if distilled water is not available, soft water
may be used.
8 If coolant comes into contact with
painted surfaces, immediately wash
them with water.
8 Do not mix different types of antifreeze.
8. Install:
8 radiator cap
3-37
CHANGING THE COOLANT
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
Refer to “COOLING SYSTEM”in chapter 6.
8 footrest board side cover mole (right)
8 battery cover
8 mat
Refer to “COVER AND PANEL”.
3-38
ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHK
ADJ
EAS00109
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
8 brake lever free play a
Out of specification J Adjust.
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.
b
a
Direction a
Direction b
1
Brake lever free play is increased.
Brake lever free play is decreased.
cC
After adjusting the brake lever free play,
make sure there is no brake drag.
*****************************************************
EAS00114
ADJUSTING THE REAR BRAKE
1. Check:
8brake lever free playa
Out of specification J Adjust.
a
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
Direction b
Brake lever free play is increased.
Brake lever free play is decreased.
cC
After adjusting the brake lever free play,
make sure there is no brake drag.
b
1
*****************************************************
a
3-39
CHECKING THE FRONT AND REAR BRAKE SHOES
CHK
ADJ
EAS00127
A
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.
2
1
B
A Front brake
B Rear brake
1
2
3-40
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
EAS00148
CHECKING AND ADJUSTING THE STEERING HEAD
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
2. Check:
8 steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness J Adjust the steering
head.
3. Remove:
8 head light cover
8 leg shield 1
Refer to “COVER AND PANEL”.
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.
1
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01268
YU-01268
2
c. Loosen the upper bearing inner race2 completely and then tighten it to specification
with a steering nut wrench3 .
3
3-41
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
Refer to “COVER AND PANEL”.
3-42
CHECKING THE FRONT FORK
CHK
ADJ
EAS00151
CHECKING THE FRONT FORK
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Check:
8inner tube
Damage/scratches J Replace.
8dust seal
Damage/scratches J Replace.
3. Hold the scooter upright and apply the front
brake.
4.
3-43
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.
CHECKING THE TIRES
CHK
ADJ
EAS00163
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
8tire pressure
Out of specification J Regulate.
w
8 The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air temperature.
8 The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger and accessories) and the anticipated
riding speed.
8 Operation of an overloaded scooter
could cause tire damage, an accident or
an injury.
8 NEVER OVERLOAD THE SCOOTER.
Basic weight
(with oil
and a full
fuel tank)
81 kg (179 lb)
Maximum
load*
158 kg (348 lb)
Cold tire
pressure
Up to 55 kg
Front
Rear
150 kPa (1.5 175 kPa (1.75
kgf/cm2, 22 psi) kgf/cm2, 25 psi)
150 kPa (1.5 175 kPa (1.75
55 kg ~ 158 kg kgf/cm2, 22 psi) kgf/cm2, 25 psi)
* Total weight of rider, passenger, cargo and accessories
w
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-44
CHECKING THE TIRES
CHK
ADJ
2. Check:
8tire surfaces
Damage/wear J Replace the tire.
1
Minimum tire tread depth
0.8 mm (0.032 in)
3
1 Tire tread depth
2 Sidewall
3 Wear indicator
2
w
A
8 Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
8 When using tube tires, be sure to install
the correct tube.
8 Always replace a new tube tire and a new
tube as a set.
8 To avoid pinching the tube, make sure
the wheel rim band and tube are centered in the wheel groove.
8 Patching a punctured tube is not recommended. If it is absolutely necessary to
do so, use great care and replace the
tube as soon as possible with a good
quality replacement.
B
A Tire
B Wheel
Tube wheel
Tubeless wheel
Tube tire only
Tube or tubeless tire
8 After extensive tests, the tires listed below have been approved by Yamaha
Motor Taiwan Co., Ltd. for this model.
The front and rear tires should always
be by the same manufacturer and of the
same design. No guarantee concerning
handling characteristics can be given if
a tire combination other than one approved by Yamaha is used on this
scooter.
Front tire
Manufacturer
KENDA
Model
K348A
Size
90/90-10 50J
Model
K348A
Size
90/90-10 50J
Rear tire
Manufacturer
KENDA
3-45
CHECKING THE TIRES
CHK
ADJ
w
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
NOTE:
For tires with a direction of rotation mark 1:
8 Install the tire with the mark pointing in the
direction of wheel rotation.
8 Align the mark 2 with the valve installation
point.
2
D
R
IV
E
1
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.
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the inner and outer cables.
w
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.
1. Check:
8 outer cable
Damage J Replace.
2. Check:
8 cable operation
Rough movement J Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suitable lubricating device.
3-47
LUBRICATING THE LEVERS AND PEDALS/
LUBRICATING THE CENTERSTAND
CHK
ADJ
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium-soap-based grease
EAS00173
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
Recommended lubricant
Lithium-soap-based grease
3-48
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:
8 Wear protective eye gear when handling
or working near batteries.
8 Charge batteries in a well-ventilated
area.
8 Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
8 DO NOT SMOKE when charging or handling batteries.
8 KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
8 Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
eye injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
8 Skin — Wash with water.
8 Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
8 Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg or vegetable oil. Get immediate
medical attention.
cC
8 This is a sealed battery. Never remove
the sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
8 Charging time, charging amperage and
charging voltage for an MF battery are
different from those of conventional batteries. The MF battery should be charged
as explained in the charging method illustrations. If the battery is overcharged,
the electrolyte level will drop considerably. Therefore, take special care when
charging the battery.
3-49
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery terminals.
1. Remove:
8 mat
8 battery cover
8battery holder
Refer to “COVER AND PANEL”.
2. Disconnect:
8 battery leads
(from the battery terminals)
cC
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
2
1
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)
+
Positive tester probe J positive battery terminal
Negative tester probe J negative battery terminal
NOTE:
8 The charge state of an MF battery can be
checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected).
8 No charging is necessary when the opencircuit voltage equals or exceeds 12.8 V.
3-50
Open-circuit voltage (V)
CHECKING AND CHARGING THE BATTERY
13.0
CHK
ADJ
b. Check the charge of the battery, as shown
in the charts and the following example.
Relationship between the open-circuit voltage
and the charging time at 20 C
12.5
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
*****************************************************
12.0
11.5
5 6.5
10
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
Open-circuit voltage (V)
Ambient
temperature
20 C
Charging condition of the battery (%)
5.
Charge:
8 battery
(refer to the appropriate charging method
illustration)
w
Do not quick charge a battery.
cC
8 Never remove the MF battery sealing
caps.
8 Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
8 If it is impossible to regulate the charging current on the battery charger, be
careful not to overcharge the battery.
8 When charging a battery, be sure to remove it from the scooter. (If charging has
to be done with the battery mounted on
the scooter, disconnect the negative battery lead from the battery terminal.)
8 To reduce the chance of sparks, do not
plug in the battery charger until the battery charger leads are connected to the
battery.
8 Before removing the battery charger
lead clips from the battery terminals, be
sure to turn off the battery charger.
3-51
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
8 Make sure the battery charger lead clips
are in full contact with the battery terminal and that they are not shorted. A
corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
8 If the battery becomes hot to the touch
at any time during the charging process,
disconnect the battery charger and let
the battery cool before reconnecting it.
Hot batteries can explode!
8 As shown in the following illustration,
the open-circuit voltage of an MF battery stabilizes about 30 minutes after
charging has been completed. Therefore,
wait 30 minutes after charging is completed before measuring the open-circuit
voltage.
3-52
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Charging method using a variable-current (voltage) charger
Charger
Ammeter
Measure the open-circuit
voltage prior to charging.
Connect a charger and ammeter to the battery and
start charging.
YES
Is the amperage higher than
the standard charging amperage written on the battery?
NOTE:
Leave the battery unused for more
than 30 minutes before measuring its
opencircuit voltage.
NOTE:
Set the charging voltage to 16-17 V.
(If the charging voltage is lower charging will be insufficient, if it is higher,
the battery will be over-charged.)
NO
Adjust the char ging voltage to
20 ~ 25V.
NO
Adjust the voltage to obtain the
standard charging amperage.
YES
Monitor the amperage for 3 ~ 5
minutes. Is the standard charging amperage exceeded?
NO
Set the timer to the charging
time determined by the
opencircuit voltage.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the amperage does not exceed the standard charging amperage after 5 minutes, replace
the battery.
If the required charging time exceeds 5 hours, it is advisable to check
the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring
its open-circuit voltage.
12.8 V ~ Charging is complete.
12.0 ~ 12.7 V ~ Recharging is required.
Under 12.0 V ~ Replace the battery.
3-53
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for more
than 30 minutes before measuring
its opencircuit voltage.
Connect a charger and ammeter to the battery and start
charging.
YES
Is the amperage higher than
the standard charging amperage written on the battery?
NO
This type of battery charger cannot
charge an MF battery. A
variablevoltage charger is recommended.
Charge the battery until the charging
voltage reaches 15 V.
NOTE:
Set the charging time to a maximum
of 20 hours.
Leave the battery unused for more
than 30 minutes before measuring its
open-circuit voltage.
12.8 V ~ Charging is complete.
12.0 ~ 12.7 V ~ Recharging is required.
Under 12.0 V ~ Replace the battery.
Charger
Ammeter
Voltmeter
cC
Constant amperage chargers are not
suitable for charging MF batteries.
3-54
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSE
CHK
ADJ
6. Install:
8 battery
7. Connect:
8 battery leads
(to the battery terminals)
1
cC
2
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
Recommended lubricant
Dielectric grease
10. Install:
8 battery holder
8 battery cover
8 mat
Refer to “COVER AND PANEL”.
EAS00181
CHECKING THE FUSE
The following procedure applies to all of the fuse.
cC
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
8 mat
8 battery cover
Refer to “COVER AND PANEL”.
3-55
CHECKING THE FUSE
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
Main
Amperage rating
7.5A
Q’ty
1
w
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rating
may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
*****************************************************
4. Install:
8 battery cover
8 mat
Refer to “COVER AND PANEL”.
3-56
REPLACING THE HEADLIGHT BULB
CHK
ADJ
EAS00182
REPLACING THE HEADLIGHT BULB
1. Remove:
8 headlight cover
2. Disconnect:
8 headlight coupler
3. Remove:
8 headlight bulb holder rubber1
8 headlight bulb holder
8 headlight bulb 2
1
w
2
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.
cC
Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass, the
life of the bulb and the luminous flux will be
adversely affected. If the headlight bulb gets
soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
5. Install :
8 headlight bulb holder
6. Connect:
8 headlight bulb holder rubber
7. Install:
8 headlight lead coupler
8. Install:
8headlight cover
3-57
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 .
1
b
a
Direction a
Direction b
Headlight beam is raised.
Headlight beam is lowered.
*****************************************************
2.
Adjust:
8 headlight beam (horizontally)
*****************************************************
a. Turn the adjusting knob 2 in direction a or
b.
b
2
Direction a
Direction b
Headlight beam moves to the right.
Headlight beam moves to the left.
a
*****************************************************
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
FRONT WHEEL AND BRAKE
7
10
6
1
9
2
48Nm (4.8 m•kg, 34.7 ft•lb)
4
3
8
Order
5
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand so
that the front wheel is elevated.
Removing the front wheel and brake
1
2
3
4
5
6
7
8
9
10
Remarks
1
1
1
1
1
1
1
1
1
1
Stop ring
Speedometer cable
Adjuster
Front brake cable
Pin
Wheel axle nut
Wheel axle
Front brake shoe plate
Collar
Front wheel
Refer to”REMOVING THE FRONT
WHEEL and INSTALLING THE FRONT
WHEEL”.
For installation, reverse the removal procedure.
4-1
FRONT WHEEL AND BRAKE
CHAS
EAS00518
FRONT WHEEL
1
2
3
4
Order
1
2
3
4
Job/Part
Q’ty
Disassembling the front wheel
Oil seal
Bearing
Spacer
Bearing
Remarks
Remove the parts in the order listed.
1
1
1
1
4-2
Refer to”REMOVING THE FRONT
WHEEL” and “INSTALLING THE FRONT
WHEEL”
For assembly, reverse the disassembly
procedure.
FRONT WHEEL AND BRAKE
CHAS
FRONT BRAKE SHOE PLATE
2
1
9
0
LS
q
w
LS
e
8
LS
6
LS
6
t
r
8Nm (0.8 m•kg ,5.8 ft•lb)
y
7
u
5
4
LS
3
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
Disassembling the front brake shoe
plate
Brake shoe kit
Tension spring
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
Remarks
Remove the parts in the order listed.
1
2
1
1
1
1/1
1
1
1
1
1
1
1
1
1
1
1
Refer to”DISASSEMBLING THE
BRAKE SHOE PLATE” and “ASSEMBLING THE BRAKE SHOE PLATE”.
For assembly, reverse the disassembly
procedure.
4-3
FRONT WHEEL AND BRAKE
CHAS
EAS00520
REMOVING THE FRONT WHEEL
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
5
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”
.
1
3
2
6
4
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
LS
LS
LS
NOTE:
Remove the bush from the brake shoe plate with
the meter gear bush tool.
2.
LS
3.
4-4
Remove:
8circlip
8plate washer
8speedometer clutch
8drive gear
8plate washer
Remove:
8bush
8speedometer gear
8plate washer
FRONT WHEEL AND BRAKE
CHAS
EAS00525
CHECKING THE FRONT WHEEL
1. Check:
8 wheel axle
Roll the wheel axle on a flat surface.
Bends J Replace.
w
Do not attempt to straighten a bent wheel
axle.
2. Check:
8 tire
8 front wheel
Damage/wear J Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter
3.
3. Measure:
8 radial wheel runout 1
8 lateral wheel runout 2
Over the specified limits J Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm(0.04 in)
4. Check:
8 wheel bearings
Front wheel turns roughly or is loose J
Replace the wheel bearings.
8 oil seals
Damage/wear J Replace.
5. Replace:
8 wheel bearings New
8 oil seal New
*****************************************************
4-5
FRONT WHEEL AND BRAKE
2
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.
1
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.
*****************************************************
3
4
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.
2
1
4-6
FRONT WHEEL AND BRAKE
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
2. Measure:
8 brake shoe lining thickness a
Out of specification JReplace.
a
Brake shoe lining thickness limit
(minimum)
2.0 mm (0.079 in)
a
w
Do not allow oil or grease to contact the
brake shoes.
NOTE:
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Measure:
8 brake drum inside diameter b
Out of specification JReplace the wheel.
b
Brake drum inside diameter limit
(maximum)
110.5 mm (4.35 in)
4-7
FRONT WHEEL AND BRAKE
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.
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.
*****************************************************
2
1
a
b
2. Install:
8comshaft lever
a
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • lb)
b
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)
4-8
FRONT WHEEL AND BRAKE
CHAS
EAS00538
ASSEMBLING THE FRONT WHEEL
1. Install:
8 wheel bearing(right)1 New
8 oil seal New
8 spacer
1
8 wheel bearing(left) New
*****************************************************
a. Install the new wheel bearings and oil seal
in the reverse order of disassembly.
cC
Do not contact the wheel bearing inner race
1 or balls 2. Contact should be made only
with the outer race 3.
NOTE:
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
*****************************************************
2. Install:
8 brake shoe plate
Align the tab on the speedometer clutch
with the slot in the wheel hub.
4-9
FRONT WHEEL AND BRAKE
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
Recommended lubricant
Lithium-soap-based grease
2.
2
1
Install:
8front wheel1
NOTE:
Make sure the slot2 in the brake shoe plate fits
over the stopper3 on the outer tube.
3
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.
cC
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
4-10
FRONT WHEEL AND BRAKE
CHAS
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
8 After replacing the tire, wheel or both, the
front wheel static balance should be adjusted.
8 Adjust the front wheel static balance with
the brake disc installed.
1. Remove:
8 balancing weight(s)
2. Find:
8 front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
X1
*****************************************************
a. Spin the front wheel.
b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
c. Turn the front wheel 90° so that the “X1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
f. Repeat steps (d) through (f) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest
is the front wheel’s heavy spot “X”.
*****************************************************
X2
4-11
FRONT WHEEL AND BRAKE
CHAS
3. Adjust:
8 front wheel static balance
*****************************************************
a. Install a balancing weight 1 onto the rim
exactly opposite the heavy spot “X”.
1
NOTE:
Start with the lightest weight.
X
b.
Turn the front wheel 90° so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
*****************************************************
4. Check:
8 front wheel static balance
*****************************************************
a. Turn the front wheel and make sure it stays
at each position shown.
b. If the front wheel does not remain stationary at all of the positions, rebalance it.
*****************************************************
4-12
REAR WHEEL AND BRAKE
CHAS
EAS00555
REAR WHEEL AND BRAKE
5
7
8
7Nm (0.7 m•kg, 5.1 ft•lb)
9
4
10
11
6
7
12
2
12
3
1
104Nm (10.4 m•kg, 75.2 ft•lb)
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Q’ty
Remarks
Removing the rear wheel
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand so
that the front wheel is elevated.
Muffler assembly
Refer to “MANIFOLD, AIR FILTER AND
MUFFLER ASSEMBLY “in chapter 5.
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
1/1
1
1
1
1
1
2
1
1
1
1
1/2
For installation, reverse the removal procedure.
4-13
REAR WHEEL AND BRAKE
CHAS
EAS00564
REMOVING THE REAR WHEEL
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the rear wheel is elevated.
1
2.
Remove:
8brake adjuster
3.
Remove:
8muffler assembly
8wheel axle nut 1
4. Remove:
8rear wheel1
1
4-14
REAR WHEEL AND BRAKE
CHAS
EAS00565
CHECKING THE REAR WHEEL
1. Check:
8 tire
8 rear wheel
Damage/wear J Replace.
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
Cracks/damage J Replace.
4-15
REAR WHEEL AND BRAKE
CHAS
EAS00569
CHECKING THE BRAKE
The following procedure applies to all of the
brake shoes.
1. Check:
8 brake shoe lining
Glazed areas J Repair.
Sand the glazed areas with course sandpaper.
a
a
NOTE:
After sanding the glazed areas, clean the brake
shoe with a cloth.
a
2. Measure:
8 brake shoe lining thickness a
Out of specification J Replace.
Brake shoe lining thickness limit
(minimum)
2.0 mm(0.079 in)
a
w
Do not allow oil or grease to contact the
brake shoes.
NOTE:
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Measure:
8 brake drum inside diameter b
Out of specification J Replace the wheel.
b
Brake drum inside diameter limit
(maximum)
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
Damage/wear J Replace.
4-16
REAR WHEEL AND BRAKE
CHAS
EAS00570
ASSEMBLING THE BRAKE SHOE PLATE
1. Install:
8 brake camshaft 1
T.
R.
1
2
7 Nm (0.7 m • kg, 5.1 ft • lb)
8 return spring 2
8 brake shoe wear indicator 3
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
a
b
2.
1
Install:
8 brake shoes1
8 tension springs
cC
8 Do not put lubricating oil on the brake
lining.
8 Change the tension spring at the same
time of changing the brake shoe.
8 Refer to the direction in the illustration
when assembling the brake shoe and
spring.
8 Refer to the illustration with regards to
the assembly direction of tension spring,
and do not let the spring hook and coil
to be damaged by the pliers.
4-17
REAR WHEEL AND BRAKE
CHAS
EAS00574
INSTALLING THE REAR WHEEL
1. Lubricate:
8 wheel axle
Recommended lubricant
Lithium-soap-based grease
2. Install:
8 rear wheel
3. Tighten:
8 wheel axle nut1
1
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.
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.
4-18
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
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE”.
Refer to “HANDLE BAR”.
Refer to “STEERING HEAD”.
Refer to “COVER AND PANEL” in chapter 3.
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
For installation, reverse the removal procedure.
4-19
FRONT FORK
CHAS
EAS00648
1
8
2
9
3
1g
4
3g
4g
5
6
0
7
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Disassembling the front fork legs
Band
Boot
Dust seal
Circlip
Spring guide
Rebound spring
Inner tube
Damper rubber
Fork spring
Outer tube
1
1
1
1
1
1
1
1
1
1
Refer to “DISASSEMBLING AND INSTALLING THE FRONT FORK LEGS “
For assembly, reverse the disassembly
procedure.
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
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.
2
3.
1
Loosen:
8lower bracket pinch bolt 1
Remove:
8snap ring 2
8front fork leg3
w
Before loosening the lower bracket pinch
bolts, support the front fork leg.
3
EAS00653
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
8band
8foot
8inner tube plug
2.
4
3
2
1
Remove:
8dust seal 1
8circlip2
8spring guide3
8rebound spring 4
8inner tube 5
cC
5
Do not scratch the inner tube.
4-21
FRONT FORK
3.
3
CHAS
Remove:
8 damper rubber 1
8 fork spring 2
8 outer tube 3
2
1
EAS00656
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
8 inner tube
8 outer tube
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
Out of specification J Replace.
Spring free length
125 mm (4.921 in)
<Limit> : 122.5 mm (4.823 in)
3
3.
Check:
8 inner tube 1
8 spring guide2
8 rebound spring 3
Damage/wear J Replace.
4.
Check:
8 damper rubber 1
8 fork spring2
8 outer tube 3
Damage/wear J Replace.
2
1
3
2
1
4-22
FRONT FORK
CHAS
EAS00658
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
NOTE:
8 When assembling the front fork leg, be sure
to replace the following parts:
- 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 .
1
2
2.
Lubricate:
8 inner tube’s outer surface
8 rebound spring
8 fork spring
8 circlip
Recommended lubricant
Molybdenum-disulfide grease
2
3
3. Install:
8 inner tube1
8 rebound spring 2
8 spring guide3
8 circlip4 New
8 dust seal 5 New
4
5
1
4. Install:
8 boot
8 band New
4-23
FRONT FORK
CHAS
EAS00663
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
8front fork leg 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
3
1
2.
Tighten:
8lower bracket pinch bolt
T.
R.
4-24
30 Nm (3.0 m • kg, 21.7 ft • lb)
HANDLEBAR
CHAS
EAS00664
HANDLEBAR
4
3
LS
17
10
4
8
LS
7
14
6
16
LS
5
12
9
11
15
LS
2
60Nm (6.0 m•kg, 43.4 ft•lb)
13
1
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Q’ty
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)
Remarks
Remove the parts in the order listed.
Refer to “COVER AND PANEL” in chapter 3.
1
1
1
1/1
1
1
1
1
1
1
1
1
1
1
4-25
HANDLEBAR
CHAS
4
3
LS
17
10
4
8
LS
7
14
6
16
LS
5
12
9
11
15
LS
2
60Nm (6.0 m•kg, 43.4 ft•lb)
13
1
Order
15
16
17
Job/Part
Handlebar grip
Handlebar upper cover
Handlebar assembly
Q’ty
1
1
1
Remarks
For installation, reverse the removal procedure.
4-26
HANDLEBAR
CHAS
EAS00666
REMOVING THE HANDLEBAR
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Remove:
8handlebar holder assembly (right)1
8throttle grip assembly 2
NOTE:
While removing the handlebar holder assembly
(right), pull back the rubber cover.
2
1
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
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
2. Check:
8handlebar 1
Bends/cracks/damage J Replace.
w
1
Do not attempt to straighten a bent
handlebar as this may dangerously weaken
it.
4-27
HANDLEBAR
CHAS
EAS00673
INSTALLING THE HANDLEBAR
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
FORWARD
2. Install:
8handlebar 1
NOTE:
Align the slot a on the handlebar with the steering shaft 2 surface.
RIGHT
2
b
1
LEFT
3. Tighten:
8handlebar
a
T.
R.
60 Nm (6.0 m • kg, 43.4 ft • lb)
cC
There must be a space b after tighting bolt.
4. Install:
8handlebar upper cover
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.
b
1
a
6. Install:
8throttle grip assembly 1
8handlebar holder assembly (right)2
8throttle cable kit 3
1
2
b
a
4-28
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
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the flange
of the throttle grip)
1.5 ~ 3.5 mm (0.059 ~ 0.138 in)
4-29
STEERING HEAD
CHAS
EAS00675
STEERING HEAD
2
4
5
6
11
8
9
12
10
7
7Nm (0.7 m•kg, 5.1 ft•lb)
1
3
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE”.
Refer to “COVER AND PANEL” in chapter 3.
Refer to “HANDLEBAR”.
Removing the front fork assembly
Front wheel
Leg shield 1
1
2
3
4
5
6
7
8
9
10
11
12
30Nm (3.0 m•kg, 21.7 ft•lb)
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
1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
4-30
STEERING HEAD
CHAS
EAS00678
REMOVING THE FRONT FORK ASSEMBLY
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
2 . Remove:
8ball race cover
8ring nut 1
(with the ring nut wrench 2)
1
Ring nut wrench
90890-01268
YU-01268
2
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
STEERING HEAD
CHAS
EAS00682
CHECKING THE STEERING HEAD
1. Wash:
8bearing balls
8bearing races
Recommended cleaning solvent
Kerosene
1
2. Check:
8bearing balls 1
8bearing races 2
Damage/pitting J Replace.
2
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.
cC
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the balls and bearing races as
a set.
*****************************************************
4. Check:
8 front fork assembly
(along with the steering stem)
Bends/cracks/damage J Replace.
4-32
STEERING HEAD
CHAS
EAS00684
INSTALLING THE STEERING HEAD
1. Lubricate:
8 bearing balls 1
8 bearing races
LS
1
Recommended lubricant
Lithium-soap-based grease
2.
1
Install:
8 front fork assembly 1
8 upper bearing inner race 2
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • lb)
(with the ring nut wrench 3)
2
3
3.
Install:
8 ring nut 1
1
T.
R.
30 Nm (3.0 m • kg, 21.7 ft • lb)
(with the ring nut wrench 2)
Ring nut wrench
90890-01403
YU-A9472
2
Refer to “CHECKING THE STEERING
HEAD” in chapter 3.
4-33
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
30Nm (3.0 m•kg, 21.7 ft•lb)
1
2
4
3
16Nm (1.6 m•kg, 11.6 ft•lb)
Order
Job/Part
Q’ty
Removing the rear shock absorber
assembly
1
2
3
4
Rear
nut
Rear
bolt
Rear
bolt
Rear
Remarks
Remove the parts in the order listed.
shock absorber assembly upper
1
shock absorber assembly upper
1
shock absorber assembly lower
1
shock absorber assembly
1
For installation, reverse the removal procedure.
4-34
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00692
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the scooter on a level surface.
w
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the rear wheel is elevated.
2. Remove:
8 rear 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
Damage/wear J Replace.
8dust seal
Damage/wear J Replace.
8bolts
Bends/damage/wear J Replace.
4-35
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00698
INSTALLING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Lubricate:
8 spacer
8 bush
Recommended lubricant
Molybdenum disulfide grease
2. Install:
8 rear shock absorber assembly
3. Tighten:
8 rear shock absorber assembly upper nut
T.
R.
30 Nm (3.0 m • kg, 21.7 ft • lb)
8 rear shock absorber assembly lower bolt
T.
R.
4-36
16 Nm (1.6 m • kg, 11.6 ft • lb)
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
ENGINE
LEADS, HOSES AND REAR BRAKE
46Nm (4.6 m•kg, 33.3 ft•lb)
10Nm (1.0 m•kg, 7.2 ft•lb)
12
12Nm (1.2 m•kg, 8.7 ft•lb)
2
A
5
16Nm (1.6 m•kg, 11.6 ft•lb)
4
B
C
1
13
A
D
6
3
11
E
B
E
9
D
C
8
7
10
Order
Job/Part
Q’ty
1
Refer to “COVER AND PANEL”in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT”in
chapter 3.
Refer to “COOLING SYSTEM”in chapter 6.
1
5-1
Remarks
Remove the parts in the order listed.
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
Radiator
Thermostat housing
Water pump assembly
Carburetor
Thermo unit lead
7
Refer to “CARBURETOR”in chapter 7.
Disconnect.
ENGINE
ENG
46Nm (4.6 m•kg, 33.3 ft•lb)
10Nm (1.0 m•kg, 7.2 ft•lb)
12
12Nm (1.2 m•kg, 8.7 ft•lb)
2
A
5
16Nm (1.6 m•kg, 11.6 ft•lb)
4
B
C
1
13
A
D
6
3
11
E
B
E
9
D
C
8
7
10
Order
Job/Part
Q’ty
AC magneto lead
2
3
4
5
6
7
8
9
10
11
12
13
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
5-2
7
Remarks
Refer to “STARTER CLUTCH AND AC
MAGNETO”.
Disconnect.
Disconnect.
1
1
1
1
1
1/1/1
1
1
1
Refer to “ REAR SHOCK ABSORBER
1
ASSEMBLY “in chapter 4.
Refer to “ INSTALLING THE ENGINE “.
1
1
For installation, reverse the removal procedure.
ENGINE
ENG
MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY
31Nm (3.1 m•kg, 22.4 ft•lb)
6
1
5
10Nm (1.0 m•kg, 7.2 ft•lb)
7
1
5
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)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
Removing the manifold, air filter and
muffler assembly
Rear brake cable(adjuster/pin)
Rear wheel lock cable
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
Remarks
Remove the parts in the order listed.
Refer to “LEADS, HOSES AND REAR
BRAKE”.
Refer to “CARBURETOR”in chapter 7.
1/1
1
1
1/1
1
1
1/1
For installation, reverse the removal procedure.
5-3
ENGINE
1
ENG
EAS00192
INSTALLING THE ENGINE
1. Install:
8engine 1
8engine mounting bolt 2
8self lock nut3
NOTE:
Do not fully tighten the bolts.
3
2
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.
1
5-4
16 Nm (1.6 m • kg, 11.6 ft • lb)
CYLINDER HEAD
ENG
EAS00221
CYLINDER HEAD
8Nm (0.8 m•kg, 5.8 ft•lb)
10Nm (1.0 m•kg, 7.2 ft•lb)
9Nm (0.9 m•kg, 6.5 ft•lb)
10Nm (1.0 m•kg, 7.2 ft•lb)
5
10
3
9
4
6
4
12.5Nm (1.25 m•kg, 9.0 ft•lb)
13
11
8Nm (0.8 m•kg, 5.8 ft•lb)
12
1
2
7
8
10Nm (1.0 m•kg, 7.2 ft•lb)
Order
4
30Nm (3.0 m•kg, 21.7 ft•lb)
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the cylinder head
Muffler assembly
Air filter assembly/Breather hose
Refer to “MANIFOLD, AIR FILTER AND
MUFFLER ASSEMBLY”.
1
2
3
4
5
6
7
Manifold/O-ring
Thermostat unit
Spark plug
Cylinder head cover
O-ring
Timing chain tensioner assembly
Timing chain tensioner gasket
Camshaft sprocket
1
1
1
1
1
1
1
8
9
10
11
12
13
Bolt
Nut
Plate
Cylinder head
Cylinder head gasket
Dowel pin
2
4
1
1
1
2
Refer to “ REMOVING THE CYLINDER
HEAD”.
For installation, reverse the removal procedure.
5-5
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)
b
*****************************************************
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.
*****************************************************
a
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.
1
Rotor holding tool
90890-01235
YU-01235
2
5-6
CYLINDER HEAD
4. Remove:
8 timing chain tensioner
(along with the gasket)
8 camshaft sprocket 1
8 timing chain 2
1
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
2
6
5
5. Remove:
8 cylinder head
1
3
4
ENG
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.
2
5-7
CYLINDER HEAD
ENG
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:
8 combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
8 spark plug bore thread
8 valve seats
2. Check:
8 cylinder head
Damage/scratches J Replace.
3. Measure:
8 cylinder head warpage
Out of specification J Resurface the cylinder head.
Maximum cylinder head warpage
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.
*****************************************************
5-8
CYLINDER HEAD
ENG
EAS00231
4
1
4
2
INSTALLING THE CYLINDER HEAD
1. Install:
8 gasket New
8 dowel pins
2. Install:
8 cylinder head
3. Tighten:
8 cylinder head nuts
10 Nm (1.0 m • kg, 7.2 ft • lb)
5
3
6
4
T.
R.
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.
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.
b
a
1
d
NOTE:
8 When installing the camshaft sprocket, be
sure to keep the timing chain as tight as
possible on the exhaust side.
8 Align the slot on the camshaft with the tab
in the camshaft sprocket.
c
2
5-9
CYLINDER HEAD
ENG
cC
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
e. While holding the camshaft, temporarily
tighten the camshaft sprocket bolt.
f. Remove the wire from the timing chain.
*****************************************************
5. Install
8camshaft sprocket bolt 1
1
6. Install:
8timing chain tensioner gasket New
8timing chain tensioner
*****************************************************
a. Remove the cap bolt 1 and spring 2.
b. Release the timing chain tensioner one-way
cam 3 and push the timing chain tensioner
rod 4 all the way into the timing chain
tensioner housing.
c. Install the timing chain tensioner and gasket 5 onto the cylinder.
2
3 4
5
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
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.
b
a
d
c
9. Tighten:
8camshaft sprocket bolt
T.
R.
30 Nm (3.0 m • kg, 21.7 ft • lb)
cC
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
10. Measure:
8valve clearance
Out of specification J Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
5-11
THE ROCKER ARMS AND CAMSHAFT
ENG
THE ROCKER ARMS AND CAMSHAFT
4
6
6
5
2
1
3
Order
Job/Part
Q’ty
1
2
3
4
5
6
Removing the rocker arms and camshaft
Cylinder head
Camshaft
Rocker arm shaft(intake)
Rocker arm shaft(exhaust)
Rocker arm(intake)
Rocker arm(exhaust)
Spring
4
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
1
1
1
1
1
2
For installation, reverse the removal procedure.
5-12
THE ROCKER ARMS AND CAMSHAFT
ENG
EAS00202
REMOVING THE ROCKER ARMS AND CAMSHAFT
1. Remove:
8camshaft 1
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 .
1
EAS00205
CHECKING THE CAMSHAFT
1. Check:
8camshaft bushings
Damage/wear J Replace.
2. Check:
8camshaft lobes
Blue discoloration/pitting/scratches J
Replace the camshaft.
3. Measure:
8camshaft lobe dimensions a and b
Out of specification J Replace the camshaft.
a
b
5-13
THE ROCKER ARMS AND CAMSHAFT
ENG
Camshaft lobe dimension limit
Intake
a 30.158~30.258 mm (1.187~1.191
in)
<Limit>:30.058mm
b 25.082~25.182 mm (0.987~0.991
in)
<Limit>:24.982mm
Exhaust
a 30.158~30.258 mm (1.187~1.191
in)
<Limit>:30.058mm
b 25.020~25.120 mm (0.985~0.989
in)
<Limit>:24.920mm
4. Check:
8camshaft oil passage
Obstruction J Blow out with compressed
air.
EAS00206
1
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)
Damage/wear J Replace.
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.
2
2
1
5-14
THE ROCKER ARMS AND CAMSHAFT
ENG
4. Measure:
8rocker arm inside diameter a
Out of specification J Replace.
a
Rocker arm inside diameter
10 ~ 10.015 mm (0.393 ~ 0.394 in)
5. Measure:
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)
a
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
THE ROCKER ARMS AND CAMSHAFT
ENG
EAS00208
CHECKING THE TIMING CHAIN, CAMSHAFT
SPROCKETS, AND TIMING CHAIN GUIDES
The following procedure applies to all of the camshaft sprockets and timing chain guides.
1. Check:
8 timing chain
Damage/stiffness J Replace the timing
chain and camshaft sprockets as a set.
a
1
2. Check:
8 camshaft sprocket
More than 1/4 tooth wear a J Replace
the camshaft sprockets and the timing
chain as a set.
a 1/4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
8 timing chain guide (exhaust side)
8 timing chain guide (intake side)
Damage/wear J Replace the defective
part(s).
b
2
EAS00210
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
8 timing chain tensioner
Cracks/damage J Replace.
2. Check:
8 one-way cam operation
Rough movement J Replace the timing
chain tensioner housing.
3. Check:
8 cap bolt
8 o-ring New
8 spring
8 one-way cam
8 gasket New
8 timing chain tensioner rod
Damage/wear J Replace the defective
part(s).
5-16
THE ROCKER ARMS AND CAMSHAFT
ENG
EAS00220
INSTALLING THE CAMSHAFT AND ROCKER
ARMS
1. Lubricate:
8 camshaft 1
1
Recommended lubricant
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
4
2. Lubricate:
8 rocker arm shafts
Recommended lubricant
Molybdenum disulfide oil
3. Install:
8 exhaust rocker arm 1
8 spring 2
8 exhaust rocker arm shaft 3
3
2
NOTE:
Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head.
1
4. Install:
8intake rocker arm 1
8spring 2
8intake rocker arm shaft 3
1
2
3
NOTE:
Make sure the intake rocker arm shaft is completely pushed into the cylinder head.
5-17
VALVES AND VALVE SPRINGS
ENG
EAS00236
VALVES AND VALVE SPRINGS
9
6
1 2
3
7
4
8
5
5
8
9
4
7
9
3
1
8
2
4
7
2
3
1
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the valves and valve
springs
Cylinder head
Rocker arm and rocker arm shaft
1
2
3
4
5
6
7
8
9
Refer to “CYLINDER HEAD”.
Refer to “THE ROCKER ARMS AND
CANSHAFT”.
3
6
3
3
2
1
3
3
3
Valve pad
Valve cotter
Valve spring retainer
Valve spring
Valve(intake)
Valve(exhaust)
Valve stem seal
Valve stem seat
Valve guide
Remarks
Refer to “ INSTALLING THE VALVES
AND VALVE SPRINGS “.
For installation, reverse the removal procedure.
5-18
VALVES AND VALVE SPRINGS
ENG
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Check:
8 valve sealing
Leakage at the valve seat J Check the
valve face, valve seat, and valve seat
width.
Refer to “CHECKING THE VALVE
SEATS”.
a
a
*****************************************************
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valves properly seal.
1
NOTE:
There should be no leakage at the valve seat
1.
*****************************************************
2. Remove:
8valve pads1
1
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.
1
2
5-19
Valve spring compressor
90890-04109 (YM-04109)
Valve spring compressor attachment
90890-04148 (YM-04148)
VALVES AND VALVE SPRINGS
4. Remove:
8valve spring retainer 1
8valve spring 2
8valve stem seal 3
8valve spring seat 4
8valve 5
4
2
3
5
ENG
1
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
8 valve-stem-to-valve-guide clearance
a
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a Valve stem diameter b
Out of specification J Replace the valve
guide.
b
Valve-stem-to-valve-guide clearance
Intake
0.010 ~ 0.037 mm(0.0004~0.0015 in)
<Limit>: 0.08 mm(0.003 in)
Exhaust
0.025 ~ 0.052 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
VALVES AND VALVE SPRINGS
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.
5. Measure:
8 valve margin thickness a
Out of specification J Replace the valve.
Valve margin thickness
0.70 mm (0.028 in)
a
6. Measure:
8 valve stem runout
Out of specification J Replace the valve.
NOTE:
8 When installing a new valve, always replace
the valve guide.
8 If the valve is removed or replaced, always
replace the oil seal.
Valve stem runout
0.01 mm(0.0004 in)
5-21
VALVES AND VALVE SPRINGS
ENG
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
8 carbon deposits
(from the valve face and valve seat)
2. Check:
8 valve seat
Pitting/wear J Replace the cylinder head.
3. Measure:
8 valve seat width a
Out of specification J Replace the cylinder head.
a
Valve seat width
Intake: 0.9 ~ 1.1 mm(0.035 ~ 0.043
in)
<Limit>: 1.6 mm(0.063 in)
Exhaust: 0.9 ~1.1 mm(0.035~0.043
in)
<Limit>: 1.6 mm(0.063 in)
*****************************************************
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
b
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been removed.
*****************************************************
4. Lap:
8 valve face
8 valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
*****************************************************
5-22
VALVES AND VALVE SPRINGS
ENG
a. Apply a coarse lapping compound a to the
valve face.
cC
a
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width c again. If
the valve seat width is out of specification,
reface and lap the valve seat.
*****************************************************
b
5-23
VALVES AND VALVE SPRINGS
ENG
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the valve
springs.
1. Measure:
8 valve spring free length a
Out of specification J Replace the valve
spring.
a
Valve spring free length
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)
2. Measure:
8 compressed valve spring force a
Out of specification J Replace the valve
spring.
b Installed length
b
a
Compressed valve spring force (installed)
Intake valve spring
9.3~10.7 kg at 28 mm (20.5 ~ 23.6 lb
at 1.102 in)
Exhaust valve spring
11.0 ~ 12.7 kg at 30 mm (24.3 ~ 28.0
lb at 1.181 in)
3. Measure:
8 valve spring tilt a
Out of specification J Replace the valve
spring.
a
Spring tilt limit
Intake valve spring
1.7 mm (0.067 in) ( 2.5° )
Exhaust valve spring
1.8 mm (0.071 in)( 2.5° )
5-24
VALVES AND VALVE SPRINGS
ENG
EAS00245
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
8valve stem end
(with an oil stone)
2. Lubricate:
8valve stem 1
8valve stem seal 2
(with the recommended lubricant)
2
1
Recommended lubricant
Molybdenum disulfide oil
3.
2
4
3
1
5
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.
a
b
Smaller pitch
b
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.
2
1
5-25
VALVES AND VALVE SPRINGS
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.
cC
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.
1
5-26
CYLINDER AND PISTON
ENG
EAS00251
CYLINDER AND PISTON
7
4
9
8
10
4
7
5
2
4
5
4
6
3
1
10Nm (1.0 m•kg, 7.2 ft•lb)
Order
Job/Part
Q’ty
1
2
3
4
5
6
Removing the cylinder and piston
Cylinder head
Timing chain guide(exhaust side)
Cylinder
Case cap
Reed valve assembly
Dowel pin
Cylinder gasket
1
1
1
1
2
1
7
8
Piston pin clip
Piston pin
2
1
9
10
Piston
Piston ring set
1
1
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
5-27
Refer to “ INSTALLING THE PISTON
AND CYLINDER”.
Refer to “ REMOVING THE CYLINDER
AND PISTON”.
Refer to “ INSTALLING THE PISTON
AND CYLINDER”.
For installation, reverse the removal procedure.
CYLINDER AND PISTON
ENG
EAS00253
REMOVING THE CYLINDER AND PISTON
1. Remove:
8 piston pin clip 1
8 piston pin 2
8 piston 3
2
1
cC
3
Do not use a hammer to drive the piston pin
out.
3
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.
2
4
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
CYLINDER AND PISTON
ENG
EAS00261
CHECKING THE CYLINDER AND PISTON
1. Check:
8 piston wall
8 cylinder wall
Vertical scratches J Replace the cylinder, and the piston and piston rings as a
set.
2.
Measure:
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 limitJ 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
P
a
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)
f. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
*****************************************************
5-29
CYLINDER AND PISTON
ENG
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
8 piston ring side clearance
Out of specification J Replace the piston and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
Piston ring side clearance
Top ring
0.02 ~ 0.08 mm(0.0008~0.0031 in)
<Limit>: 0.13mm(0.0051 in)
2nd ring
0.02 ~ 0.06 mm(0.0008~0.0024 in)
<Limit>:0.12 mm(0.0047 in)
2. Install:
8 piston ring
(into the cylinder)
a
NOTE:
Level the piston ring into the cylinder with the
piston crown.
a 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)
5-30
CYLINDER AND PISTON
ENG
EAS00265
CHECKING THE PISTON PIN
1. Check:
8 piston pin
Blue discoloration/grooves J Replace the
piston pin and then check the lubrication
system.
2. Measure:
8 piston pin outside diameter a
Out of specification J Replace the piston pin.
Piston pin outside diameter
9.996 ~ 10.000 mm (0.3935 ~
0.3937 in)
<Limit>:9.976 mm (0.3928 in)
a
3. Measure:
8 piston pin bore diameter b
Out of specificationJ Replace the piston.
b
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
CYLINDER AND PISTON
ENG
CHECKING THE TIMING CHAIN GUIDE
1. Check:
8 timing chain guide (exhaust side)
Damage/wear J Replace
EAS00267
INSTALLING THE PISTON AND CYLINDER
1. Install:
8 oil ring expander 1
8 oil ring rail 2
8 2nd ring 3
8 top ring 4
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
4
3
2
1
2
2. Install:
8 piston 1
8 piston pin 2
8 piston pin clip New 3
1
2
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.
a
3
5-32
CYLINDER AND PISTON
ENG
3. Install:
8 gasket New
8 dowel pins
4. Lubricate:
8 piston
8 piston rings
8 cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Offset:
8 piston ring end gaps
b
a
a
b
c
d
A
c
A
Top ring
Lower oil ring rail
Upper oil ring rail
2nd ring
Exhaust side
d
6. Install:
8 timing chain guide (exhaust side)
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.
1
5-33
BELT DRIVE
ENG
EAS00316
BELT DRIVE
CRANKCASE COVER (LEFT)
3
10Nm (1.0 m•kg, 7.2 ft•lb)
2
7
8
10
3
4
11
5
12
9
1
6
6
15Nm (1.5 m•kg, 10.9 ft•lb)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
11
12
Removing the crankcase cover (left)
Kickstarter
Rear wheel lock cable cover
Rear wheel lock cable
Crankcase cover(left)
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
Remarks
Remove the parts in the order listed.
Refer to “ LEADS, HOSES AND REAR
BRAKE “.
1
1
2
1
1
1/1
1
1
1
1
1
1
Refer to “ INSTALLING
KICKSTARTER “.
THE
For installation, reverse the removal procedure.
5-34
BELT DRIVE
ENG
EAS00340
2
INSTALLING THE KICKSTARTER
1. Install:
8 solid bush1
8 kick shaft assembly2
8 torsion spring3
3
1
d
2. Hook:
8 kickstarter spring
c
NOTE:
Hook the spring enda on the kickstarter shaft
b as shown, and hook the other end c on the
projectiond .
a
b
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
ENG
BELT DRIVE
V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE
5
40Nm (4.0 m•kg, 28.9 ft•lb)
4
7
8
6
3
12
2
10
1
10
11
9
30Nm (3.0 m•kg, 21.7 ft•lb)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
11
12
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
Remarks
Remove the parts in the order listed.
1/1
1
1
1
1
1
1
1
1
1/6
3
1
Refer to “ REMOVING AND INSTALLING THE SECONDARY SHEAVE “
Refer to “ REMOVING AND INSTALLING THE PRIMARY SHEAVE “
For installation, reverse the removal procedure.
5-36
BELT DRIVE
ENG
3
2
4
9
6
3
1
0
55Nm (5.5 m•kg, 39.8 ft•lb)
9
5
7
8
LS
LS
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
0
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
Remarks
Disassemble the parts in the order listed.
1
1
2
1
1
2
1
2
2
1
Refer to “ REMOVING AND INSTALLING THE SECONDARY SHEAVE “ .
For installation, reverse the removal procedure.
5-37
BELT DRIVE
ENG
EAS00317
REMOVING THE PRIMARY SHEAVE
1. Remove:
8primary sheave nut 1
8plate washer2
8oneway clutch3
8primary fixed sheave 4
4
5
1
NOTE:
While holding the primary fixed sheave with the
rotor holding tool 5, loosen the primary fixed
sheave nut.
4
Rotor holding tool:
90890-01235 (YU-01235)
3
2
1
EAS00318
1
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.
2
3
Sheave holder:
90890-01701 (YS-01880-A)
3
1
2. Loosen:
8 clutch carrier nut 1
cC
Do not remove the clutch carrier nut at this
stage.
2
NOTE:
While holding the clutch carrier with the rotor
holding tool 2, loosen the clutch carrier nut one
full turn with the locknut wrench 3.
Roter holding tool:
90890-01235 (YU-01235)
Locknut wrench:
90890-01348 (YM-01348)
5-38
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.
1
2
EAS00319
2
DISASSEMBLING THE SECONDARY SHEAVE
3
1. Remove:
8 clutch carrier nut 1
1
NOTE:
Install the clutch spring holder 2 and clutch
spring holder arm 3 onto the secondary sheave
as shown. Then, compress the spring, and remove the clutch carrier nut 1.
Clutch spring holder
90890-01337 (YM-33285)
(YM-33285-6)
CHECKING THE CLUTCH SHOE
1. Measure:
8 clutch shoe
Scratches J Glaze using coares sandpaper.
Damage/wear J Replace
a
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
BELT DRIVE
ENG
EAS00320
CHECKING THE V-BELT
1. Check:
8 V-belt 1
Cracks/damage/wear J Replace.
Grease/oil J Clean the primary and secondary sheave.
2. Measure:
8 V-belt width a
Out of specification J Replace.
1
V-belt width
16.8 mm (0.0661 in)
<Limit>: 15.8 mm (0.622 in)
a
CHECKING THE PRIMARY SHEAVE
1. Check:
8 primary sliding sheave1
8 primary fixed sheave2
Cracks/damage/wear J Replace the primary sliding sheave, primary fixed
sheave and V-belt.
1
2
2.
5-40
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.
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.
a
2. Measure:
8 primary sheave weight outside diameter
a
Out of specification J Replace.
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
Damage/wearJ Replace
EAS00322
CHECKING THE SECONDARY SHEAVE
1. Check:
8secondary fixed sheave
8secondary sliding sheave
Cracks/damage/wear J Replace the secondary fixed and sliding sheaves as a
set.
2. Check:
8torque cam groove 1
Damage/wear J Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
8guide pin 2
Damage/wear J Replace the secondary
fixed and sliding sheaves as a set.
2
1
5-41
BELT DRIVE
1
ENG
EAS00323
3
4
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
8primary fixed sheave 1
8primary sliding sheave 2
8collar 3
8primary sheave weights 4
2
5
NOTE:
Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5.
3
2. Install:
8primary sliding sheave 1
8primary sheave weights 2
8collar 3
2
1
3. Install:
8 slider 1
8 cam 2
1
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
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube®
2. Install:
8 secondary sliding sheave 1
3
1
NOTE:
Install the secondary sliding sheave onto the
secondary fixed sheave 2 with the oil seal guide
3.
2
Oil seal guide
90890-01384 (YM-33299)
3. Install:
8 guide pin 1
4. Lubricate:
8 guide pin groove 2
8 o-ring New 3
(with the recommended lubricant)
3
1
2
Recommended lubricant
BEL-RAY assembly lube®
5-43
BELT DRIVE
5. Install:
8 secondary sheave 1
8 spring
8 clutch carrier 2
4
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.
5
3
ENG
1
Clutch spring holder
90890-01337 (YM-33285)
( YM-33285-6)
EAS00325
INSTALLING THE BELT DRIVE
1. Install:
8 V-belt 1
8 clutch assembly 2
2
cC
Do not allow grease to contact the V-belt,
secondary sheave assembly.
1
NOTE:
Install the V-belt onto the primary sheave side.
2. Install:
8 clutch carrier nut 1
3
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.
2
Rotor holding tool
90890-01235
Locknut wrench
90890-01348 (YM-01348)
5-44
BELT DRIVE
ENG
3. Install:
8 clutch housing 1
8 secondary sheave nut2
T.
R.
2
1
40 Nm (4.0 m • kg, 28.9 ft • lb)
NOTE:
Tighten the secondary sheave nut with the
sheave holder 3.
3
Sheave holder
90890-01701 (YS-01880-A)
4. Install:
8primary fixed sheave 1
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
STARTER CLUTCH AND AC MAGNETO
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
7
8
7Nm (0.7 m•kg, 5.1 ft•lb)
3
43Nm (4.3 m•kg, 31.1 ft•lb)
Order
Job/Part
Q’ty
Removing the stator coil assembly
Coolant
1
2
3
4
5
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
5-46
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE COOLANT”in
chapter 3.
Refer to “RADIATOR”in chapter 6.
Refer to “COVER AND PANEL”in chapter 3.
1
1/1
1/1
1
1
Disconnect.
STARTER CLUTCH AND AC MAGNETO
ENG
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
7
8
7Nm (0.7 m•kg, 5.1 ft•lb)
3
43Nm (4.3 m•kg, 31.1 ft•lb)
Order
6
7
8
Job/Part
Lock plate
Pick up coil
Stator coil assembly
Q’ty
1
1
1
Remarks
For installation, reverse the removal procedure.
5-47
STARTER CLUTCH AND AC MAGNETO
ENG
EAS00342
STARTER CLUTCH
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
8
10
11
M
4
5
4
Order
Job/Part
Q’ty
Removing the starter clutch
Engine oil
1
2
3
4
5
6
7
8
9
10
11
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE
OIL”in chapter 3.
Refer to “ REMOVING AND INSTALLING THE AC MAGNETO “.
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
1
1
2
1
1
1
1
1
1
1
1
cC
The starter clutch nut is left-hand
thread.
Refer to “ REMOVING AND INSTALLING THE STARTER CLUTCH “.
For installation, reverse the removal procedure.
5-48
STARTER CLUTCH AND AC MAGNETO
ENG
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.
3
2
1
Sheave holder
90890-01701
YS-01880-A
2.
1
2
Remove:
8AC magneto rotor 1
(with the flywheel puller 2)
8woodruff key
cC
To protect the end of the crankshaft, place
an appropriate sized socket between the
flywheel puller set’s center bolt and the
crankshaft.
NOTE:
Make sure the flywheel puller is centered over
the AC magneto rotor.
5-49
STARTER CLUTCH AND AC MAGNETO
ENG
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.
1
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
STARTER CLUTCH AND AC MAGNETO
ENG
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
8starter clutch roller 1
Damage/wear J Replace.
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.
1
A
4. Check:
8starter clutch operation
2
*****************************************************
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.
*****************************************************
B
5-51
STARTER CLUTCH AND AC MAGNETO
ENG
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
90 Nm (9.0 m • kg, 65.1 ft • lb)
1
T.
R.
NOTE:
The starter clutch nut is left-hand thread.
2. Install:
8 gasket New
8 crankcase cover (right)1
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
STARTER CLUTCH AND AC MAGNETO
2.
ENG
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
1
10
9
8
4Nm (0.4 m•kg, 2.9 ft•lb)
7
6
5
1Nm (0.1 m•kg, 0.7 ft•lb)
4
3
4
4
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
2
2
Remarks
Remove the parts in the order listed.
Refer to “RADIATOR”in chapter 6.
Refer to “ STARTER CLUTCH AND AC
MAGNETO “ .
Disassembling the oil pump
Radiator
AC magneto
Starter clutch
Drive gear
Circlip/Plate washer
Oil pump driven gear
Dowel pin
Oil pump housing
Oil pump shaft
Inner rotor
Outer rotor
Oil pump housing cover
Gasket
1
1/1
1
2
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5-54
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 J Replace the
defective part(s).
1
2. Measure:
8 inner-rotor-to-outer-rotor-tip clearance A
8 outer-rotor-to-oil-pump-housing clearance B
8 oil-pump-housing-to-inner-rotor-andouter-rotor clearance C
Out of specification J Replace the oil
pump.
1
A
2
1
B
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)
C
3. Check:
8 oil pump operation
Rough movement J Repeat steps (1) and
(2) or replace the defective part(s).
5-55
OIL PUMP
ENG
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
8 inner rotor
8 outer rotor
8 oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
5
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
4a
1
2
6
3
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
1
2
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • lb)
cC
After tightening the bolts, make sure the oil
pump turns smoothly.
5-56
TRANSMISSION
ENG
EAS00419
TRANSMISSION
LS
4
13Nm (1.3 m•kg, 9.34 ft•lb)
7
4
5
G
G
2
6
G
3
1
LS
Order
Job/Part
Q’ty
Removing the transmission
Transmission oil
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE TRANSMISSION OIL “ in chapter 3.
Refer to “MANIFOLD, AIR FILTER AND
MUFFLER ASSEMBLY “.
Refer to “REAR WHEEL AND BRAKE “
in chapter 4.
Muffler assembly
Rear fender
Rear wheel
1
2
3
4
5
6
7
Remarks
Crankcase cover(left)
Belt drive
Secondary sheave
Circlip
Transmission cover
Transmission cover gasket
Dowel pin
Main axle
Drive axle
Primary drive gear shaft
Refer to “BELT DRIVE “.
1
1
1
2
1
1
1
For installation, reverse the removal procedure.
5-57
TRANSMISSION
ENG
EAS00425
CHECKING THE TRANSMISSION
1. Measure:
8 main axle runout
(with a centering device and dial gauge )
Out of specification J Replace the main
axle.
Main axle runout limit
0.04 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 J Replace the defective part(s).
6 . Check:
8circlip
Bends/damage/looseness J Replace.
5-58
CRANKSHAFT
ENG
EAS00381
CRANKSHAFT
CRANKSHAFT ASSEMBLY
10Nm (1.0 m•kg, 7.2 ft•lb)
14
10
4
12
11
16
LS
17
7
9
12
13
18
8
6
18
19
2
LS
2
15
3
32Nm (3.2 m•kg, 23.1 ft•lb)
5
4
1
Order
Job/Part
Q’ty
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
1
2
3
4
Tension spring
Circlip/Plate washer
Pin
Centerstand
Remove the parts in the order listed.
Refer to “ ENGINE “ .
Refer to “CYLINDER HEAD “.
Refer to “CYLINDER AND PISTON “.
Refer to “V-BELT,CLUTCH ,PRIMARY
AND SECONDARY SHEAVE “.
Refer to “COOLING SYSTEM”in chapter 6.
Refer to “STARTER CLUTCH AND AC
MAGNETO “.
Refer to “OIL PUMP “.
Refer to “TRANSMISSION “.
Refer to “REAR WHEEL AND BRAKE “
in chapter 4.
1
1/1
1
1
5-59
Remarks
CRANKSHAFT
ENG
10Nm (1.0 m•kg, 7.2 ft•lb)
14
10
4
12
11
16
LS
17
7
9
12
13
18
8
6
18
19
2
LS
2
15
3
32Nm (3.2 m•kg, 23.1 ft•lb)
5
4
1
Order
Job/Part
Q’ty
5
6
7
8
9
10
11
12
13
14
Hook
Drain plug
Oil strainer
Compression spring
O-ring
Crankcase (right )
Spacer
Dowel pin
Guide
Crankshaft
1
1
1
1
1
1
1
2
1
1
15
16
Timing chain
Crankcase ( left )
1
1
17
18
19
Oil seal
Bolt/O-ring
Timing chain guide
1
1/1
1
Remarks
Refer to “DISASSEMBLING THE
CRANKCASE “
Refer to “INSTALLING THE CRANKSHAFT “
For installation, reverse the removal procedure.
5-60
CRANKSHAFT
ENG
EAS00385
DISASSEMBLING THE CRANKCASE
1. Remove:
8 centerstand assembly
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.
1
3. Remove:
8 right crankcase1
8 spacer
cC
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly and
carefully and make sure the crankcase
halves separate evenly.
5-61
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:
8 timing chain guide (intake side)
Damage/wear J Replace.
5-62
CRANKSHAFT
ENG
EAS00394
CHECKING THE CRANKSHAFT AND CONNECTING ROD
1. Measure:
8 crankshaft runout
Out of specification J Replace the crankshaft, bearing or both.
NOTE:
Turn the crankshaft slowly.
Maximum crankshaft runout
0.03 mm ( 0.001 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
Out of specification J Replace the crankshaft.
Crankshaft width
42.45~42.50 mm (1.671~1.673 in)
4. Check:
8 crankshaft sprocket 1
Damage/wear J Replace the crankshaft.
8 bearing 2
Cracks/damage/wear J Replace the
crankshaft.
8 oil pump drive gear
Damage/wear J Replace the crankshaft.
2
1
5-63
CRANKSHAFT
ENG
5. Check:
8 crankshaft journal
Scratches/wear J Replace the crankshaft.
8 crankshaft journal oil passage
Obstruction J Blow out with compressed
air.
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
Cracks/damage J Replace.
8oil delivery passages
Obstruction J Blow out with compressed
air.
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.
5-64
CRANKSHAFT
ENG
EAS00408
INSTALLING THE CRANKSHAFT
1. Install:
8 timing chain guide (intake side)
8 timing chain1
8 crankshaft assembly2
2
NOTE:
Install the timing chain so it is not visible through
the opening in the left crankcase 3.
1
3
cC
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
NOTE:
Put the timing chain in parallel into the crankcase, then use hands to place the crankshaft
assembly into the crankcase. Manually rotate
the crankshaft to check whether it is tightly engaged with the timing chain. (if not, install again)
EAS00418
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.
2. Apply:
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.
1
3. Install:
8 dowel pins
8 spacer
8 right crankcase1
4. Tighten:
8 crankcase
T.
R.
5-65
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
COOL
RADIATOR
EAS00454
COOLING SYSTEM
RADIATOR
3
7
2
4
5
1
10Nm (1.0 m•kg, 7.2 ft•lb)
6
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the radiator
Seat/Trunk
Battery cover/Battery holder
Battery/Front cover
Footrest board side cover mole ( left
and right )
Mat/Footrest board
Coolant
1
2
3
4
5
6
7
Radiator cover
Radiator cap
Conduit hose
Radiator inlet hose
Radiator outlet hose
Radiator
Fan case
Remarks
Refer to “COVER AND PANEL”in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT”in
chapter 3.
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
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. Check:
8 radiator hoses Radiator inlet hose1
8 radiator pipes Radiator outlet hose2
Cracks/damage J Replace.
3. Measure:
8 radiator cap opening pressure
Below the specified pressure J Replace
the radiator cap.
1
2
Radiator cap opening pressure
93.3 ~ 122.7 kPa
(0.95 ~ 1.25 kg/cm2, 13.53 ~ 17.79
psi)
1
*****************************************************
a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap
3.
3
2
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.
*****************************************************
6-2
RADIATOR
COOL
4. Check:
8 radiator fan
Damage J Replace.
Malfunction J Check and repair.
EAS00456
INSTALLING THE RADIATOR
1. Fill:
8cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
2. Check:
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”.
6-3
THERMOSTAT ASSEMBLY
COOL
EAS00460
THERMOSTAT ASSEMBLY
10Nm (1.0 m•kg, 7.2 ft•lb)
A
4
1
4
5
A
6
3
2
10Nm (1.0 m•kg, 7.2 ft•lb)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the thermostat assembly
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
1
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
6-4
Remarks
Refer to “COVER AND PANEL”in chapter 3.
1
Drain.
Refer to “CHANGING THE COOLANT”in
chapter 3.
Refer to “RADIATOR”.
Disconnect.
1
1
1/1
1
Disconnect.
THERMOSTAT ASSEMBLY
COOL
10Nm (1.0 m•kg, 7.2 ft•lb)
A
4
1
4
5
A
6
3
2
10Nm (1.0 m•kg, 7.2 ft•lb)
Order
6
Job/Part
Q’ty
Thermostat assembly
Remarks
1
For installation, reverse the removal procedure.
6-5
THERMOSTAT ASSEMBLY
COOL
EAS00462
CHECKING THE THERMOSTAT
1. Check:
8 thermostat 1
Does not open at 65 ~ 80°C J Replace.
1
*****************************************************
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.
*****************************************************
1
2
3
4
A
B
3
4
1
2
Thermostat
Container
Thermometer
Water
Fully closed
Fully open
NOTE:
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.
2. Check:
8 thermostat housing
Cracks/damage J Replace.
6-6
THERMOSTAT ASSEMBLY
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
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
3. Check:
8cooling system
Leaks J Repair or replace any faulty part.
4. Measure:
8radiator cap opening pressure
Below the specified pressure J Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
1
6-7
WATER PUMP
COOL
EAS00468
WATER PUMP
1
7
5
10
10Nm (1.0 m•kg, 7.2 ft•lb)
4
3
11
9
6
8
7Nm (0.7 m•kg, 5.1 ft•lb)
10Nm (1.0 m•kg, 7.2 ft•lb)
2
Order
Job/Part
Q’ty
Removing the water pump
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
1
2
3
4
Thermostat assembly outlet breather
hose
Radiator outlet hose
Breather hose
Outlet hose(to cylinder)
Water pump housing cover
Gasket
6-8
Remarks
Remove the parts in the order listed.
Refer to “COVER AND PANEL”in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT”in
chapter 3.
Refer to “THERMOSTAT ASSEMBLY”.
1
1
1
1
Refer to “RADIATOR”.
Disconnect.
WATER PUMP
COOL
1
7
5
10
10Nm (1.0 m•kg, 7.2 ft•lb)
4
11
3
9
6
8
7Nm (0.7 m•kg, 5.1 ft•lb)
10Nm (1.0 m•kg, 7.2 ft•lb)
2
Order
5
6
7
8
9
10
11
Job/Part
Q’ty
Water pump housing
Dowel pin
Plate
Impeller shaft
Oil seal
Bearing
Gasket
Remarks
1
2
1
1
1
1
1
For installation, reverse the removal procedure.
6-9
WATER PUMP
COOL
EAS00471
1
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
3
2
NOTE:
Remove the oil seal from the inside of the water
pump housing.
Remove the bearing from the inside of the water
pump housing.
EAS00474
CHECKING THE WATER PUMP
1. Check:
8water pump housing cover
8water pump housing
8impeller 1
Cracks/damage/wear J Replace.
1
2. Check:
8water pump seal 1
Cracks/damage/wear J Replace.
3. Check:
8bearing
Rough movement J Replace.
4. Check:
8radiator outlet hose
Cracks/damage/wear J Replace.
1
6-10
WATER PUMP
COOL
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
8oil seal New 1
(into the water pump housing 3)
8bearing 2
2
1
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.
3
cC
Never lubricate the water pump seal surface
with oil or grease.
2. Measure:
8impeller shaft tilt
Out of specification J Replace the impeller
shaft.
1
Impeller shaft tilt limit
0.15 mm (0.006 in)
2
1 Straightedge
2 Impeller
3.
1
Install:
8impeller shaft1
8plate2
2
cC
After installation, check that the impeller
shaft rotates smoothly.
4.
1
6-11
Install:
8gasket New
8 water pump housing cover1
WATER PUMP
COOL
EAS00478
INSTALLING THE WATER PUMP
1. Install:
a
b
8gasket New
8water pump assembly 1
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
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
3. Check:
8cooling system
Leaks J Repair or replace the faulty part.
4. Measure:
8radiator cap opening pressure
Below the specified pressure J Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
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
CARBURETOR
CARB
EAS00480
CARBURETOR
CARBURETOR
7
A
10
8
5
A
6
B
2
F
F
C
E
B
D
9
C
E
4
D
3
1
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
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
Remarks
Remove the parts in the order listed.
Refer to “COVER AND PANEL”in chapter 3.
1
1
1
1
1
1
1
1
1
1
1
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Lossen.
For installation, reverse the removal procedure.
7-1
CARBURETOR
CARB
EAS00483
6
5
1
8
7
2
9
3
p
4
a
i
q
w
o
u
0
t
y
e
r
Order
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
Job/Part
Q’ty
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
7-2
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1/1
1
1
1
1
1
1
1
1
1
cC
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 CARBURETOR”.
CARBURETOR
CARB
6
5
1
8
7
2
9
3
p
4
a
i
q
w
o
u
0
t
y
e
r
Order
u
i
o
p
a
Job/Part
Q’ty
Main nozzle
Nedle jet
Slow air jet
Slow jet
Throttle position sensor
Remarks
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
7-3
CARBURETOR
CARB
EAS00485
CHECKING THE CARBURETOR
1. Check:
8 carburetor body
8 float chamber
Cracks/damage J Replace.
2. Check:
8 fuel passages
Obstruction J Clean.
*****************************************************
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
*****************************************************
3. Check:
8 float chamber body
Dirt J Clean.
4. Check:
8 float chamber rubber gasket
Cracks/damage/wear J Replace.
5. Check:
8 float
Damage J Replace.
7-4
CARBURETOR
CARB
6. Check:
8 needle valve
Damage/obstruction/wearJ Replace.
7. Check:
8 piston valve 1
Damage/scratches/wearJ Replace.
8 piston valve diaphragm 2
Cracks/tears J Replace.
2
1
8. Check:
8 vacuum chamber cover 1
8 piston valve spring 2
Cracks/damage J Replace.
1
2
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.
Obstruction J Clean.
Blow out the jets with compressed air.
6
1
4
3
5
2
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
Cracks/damage/wear J Replace.
Obstruction J Clean.
Blow out the hoses with compressed air.
7-5
CARBURETOR
CARB
EAS00487
ASSEMBLING THE CARBURETOR
cC
8 Before assembling the carburetor, wash
all of the parts in a petroleum-based solvent.
8 Always use a new gasket.
1. Install:
8 needle jet 1
8 main nozzle2
8 main jet 3
8 slow air jet 4
3
1
4
2
2. Install:
8 float 1
8 needle valve 2
8 float pin 3
8 screw 4
3. Install:
3
4
2
1
8 float chamber rubber gasket New
8 float chamber
4
4. Install:
8accelerator pump diaphragm 1
8accelerator pump spring 2
8boot3
8accelerator pump diaphragm gasket4
8float chamber body
1
3
2
2
5 . Install:
8coasting enricher diaphragm1
8compression spring2
8coasting enricher cover3
6. Install:
8jet needle kit
8piston valve
3
1
7-6
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:
8 engine idling speed
Engine idling speed
2,000 ~ 2,400r/min
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” in chapter 3.
2. Adjust:
8 throttle cable free play
Throttle cable free play (at the flange
of the throttle grip)
1.5 ~ 3.5 mm (0.059 ~ 0.138 in)
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
7-7
CARBURETOR
CARB
EAS00498
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
8 fuel level a
Out of specification J Adjust.
Fuel level (below the float chamber
mating surface)
6.6~7.6 mm (0.26~0.30 in)
a
*****************************************************
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
1
a
Fuel level gauge
90890-01312 (YM-01312-A)
2
3
d. Loosen the fuel drain screw
e. Hold the fuel level gauge vertically next to
the float chamber 3.
f. Measure the fuel level a.
*****************************************************
2.
Adjust:
8 fuel level
*****************************************************
a. Remove the carburetor.
b. Check the needle valve seat and needle
valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by
slightly bending the float tang 1.
e. Install the carburetor.
f. Measure the fuel level a again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
*****************************************************
1
7-8
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.
2
1
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 12.0V 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.
1
3
2
Y
G/B
Starter plunger opens.
4
Starter plunger closes.
Replace the autochoke
unit.
Autochoke is OK.
*****************************************************
7-9
CARBURETOR
CARB
EAS00504
CHECKING THE FUEL COCK
1. Remove:
8 seat/trunk
8 battery cover
8 front cover
Refer to “COVER AND PANEL”in chapter 3.
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.
7-10
Install:
8front cover
8battery cover
8seat/trunk
Refer to “COVER AND PANEL”in chapter 3.
CARBURETOR
CARB
CHECKING THE THROTTLE POSITION SENSOR
B/L
L
B/L Y/L
NOTE:
Before checking the throttle position sensor, the
engine idling speed should be properly adjusted.
Y/L
L
3
2
1
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 .
cC
Please do not make any adjustment on
throttle position sensor.
*****************************************************
7-11
AIR INDUCTION SYSTEM
CARB
AIR INDUCTION SYSTEM
10Nm (1.0 m•kg, 7.2 ft•lb)
4
2
1
3
Order
Job/Part
Q’ty
Removing the air induction system
Seat/Trunk
1
2
3
4
Hose(from AI air filter )
Vacuum hose(from mainfold )
Hose(to cylinder head )
Air cut-off valve assembly
Remarks
Remove the parts in the order listed.
Refer to “COVER AND PANEL”in chapter 3.
1
1
1
1
For installation, reverse the removal procedure.
7-12
AIR INDUCTION SYSTEM
CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
8 hoses
Loose connection J Connect properly.
Cracks/damage J Replace.
8 pipe
Cracks/damage J Replace.
2. Check:
8 air cut-off valve
Cracks/damage J Replace.
1
NOTE:
When the negative pressure is applied to the
part 1, check that the continuity in the direction
of arrow mark is completely lost. If the negative
pressure is not loaded, the continuity can be
obtained.
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
TROUBLESHOOTING ..................................................................... 8-16
STARTER MOTOR ........................................................................... 8-19
CHECKING THE STARTER MOTOR .............................................. 8-20
ASSEMBLING THE STARTER MOTOR ......................................... 8-22
CHARGING SYSTEM ............................................................................. 8-23
CIRCUIT DIAGRAM ......................................................................... 8-23
TROUBLESHOOTING ..................................................................... 8-24
LIGHTING SYSTEM ............................................................................... 8-26
CIRCUIT DIAGRAM ......................................................................... 8-26
TROUBLESHOOTING ..................................................................... 8-27
CHECKING THE LIGHTING SYSTEM ........................................... 8-29
SIGNALING SYSTEM ............................................................................ 8-32
CIRCUIT DIAGRAM ......................................................................... 8-32
TROUBLESHOOTING ..................................................................... 8-33
CHECKING THE SIGNALING SYSTEM......................................... 8-34
COOLING SYSTEM................................................................................ 8-40
CIRCUIT DIAGRAM ......................................................................... 8-40
TROUBLESHOOTING ..................................................................... 8-41
AUTO CHOKE SYSTEM ........................................................................ 8-45
CIRCUIT DIAGRAM ......................................................................... 8-45
TROUBLESHOOTING ..................................................................... 8-46
8-49
ELECTRICAL COMPONENTS
ELEC
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
Rear brake light switch
Front brake light switch
Main switch
Starter relay
Thermo unit
Fuel sender
C.D.I. unit
Ignition coil
Spark plug cap
Battery
Main fuse
Turn signal relay
Horn
Rectifier/Regulator
Thermo switch
Headlight relay
Wire harness
1
7
2
5
t
6
3
8
r
9
q
e
w
y
0
u
8-1
4
-
+
8-2
(BLACK)
(BLACK)
B
G
GW
B
g
Y
Ch
h
LW
LY
B
LY B
f
L
OFF
RUN
d
r
ENG.STOP SW.
OFF
START
R
LW
R
LW
s
B
LW
STARTER SW.
e
R
GY
R
TEMP
G
FUEL
Br
4
R
R
R
R
W B
R YR
(GREEN)
ILLUMI
j
Dg L
Ch Y
L Dg
Y Ch
5
R
Br
ILLUMI
TURN L
HI BEAM
G
B
GW Br
B G
Br
1
7.5A
Br GW
G B
OFF
CHECK
ON
MAIN SW.
Dg
B
3
LW
LY
B
6
W
R
GY
LW
GY
YR
B
LW L
GY YR
t
L
(RED)
(RED)
P
Br
Y Ch
B Dg
G
P
B
7
R
R
B
R
B
R
YB
Ch Y
Dg B
G
OFF
PUSH
u HORN
YR
R
c
(RED)
WR
WL
Ch
B
HI
LO
2
YR
W
B
B
k
GY
GY
L
(RED)
GB
Y
0
L BL YL
DIMMER
l
a
B
YR
y
YR
R
YR
W
YR
YR
W
;
Dg
i
L
N
R
Ch
Dg
BrW
FLASHER
(BLACK)
o
B
BL
L
BL
v
GR
YL
GW
8
L Ch
P BrW
B Dg
Br
GR
L GY
B
Dg Ch
Ch L
BrW P
Dg B
Y
Y
G
G
(RED) (RED)
(GRAY)
Br
GR BL
L
YL
BL
WL
YR
(RED)
B
BrW
Br
WL
WR
YR
B
b
WR
WL
(RED)
B
GY L
B
Ch Dg
LY
Ch
L
B
B
B
GY
GY
Br
12V21W/5W
p
BL B
WL Or
z
Or
GW L LY YR
YL GR
Br
Br
GY
x
Dg
(BLACK) (BLACK)
B
B
q
B
Or
w
Br
GY
TURN R
12V35W/35W
GND.
Connecting with
GND. Wire
Explanation
(BLACK) (BLACK)
B
B
MARK
GY
Br
9
WIRING DIAGRAM
ELEC
+
WIRING DIAGRAM
12V10W
12V10W
12V10W
12V10W
WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
i
o
p
a
s
d
f
g
h
j
k
l
;
z
x
c
v
b
Main switch
AC magneto
Rectifier/Regulator
Battery
Main fuse
Starter relay
Starter motor
C.D.I. unit
Ignition coil
Auto choke unit
Front brake light switch
Rear brake light switch
Start switch
Engine stop switch
Headlight relay
Horn
Horn switch
Turn signal switch
Turn signal relay
Tail/brake light
Dimmer switch
Water temperature indicator light
Speedometer light
High beam indicator light
Turn signal indicator light(left)
Turn signal indicator light(right)
Fuel sender
Headlight
Front turn signal light(left)
Front turn signal light(right)
Rear turn signal light(left)
Rear turn signal light(right)
Thermo switch
Thermo unit
Throttle position sensor
Color Code
B
Black
G
Green
L
Blue
P
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
ELEC
-
+
CHECKING SWITCH CONTINUITY
ELEC
-
+
EAS00730
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace
the switch.
cC
Never insert the tester probes into the
coupler terminal slots. Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.
Pocket tester
90890-03132 (YU-03112-C)
Br R
a
NOTE:
8 Before checking for continuity, set the
pocket tester to “0” and to the “Ω × 1” range.
8 When checking for continuity, switch back
and forth between the switch positions a
few times.
b
The terminal connections for switches (e.g., main
switch, engine stop switch) are shown in an illustration similar to the one on the left.
The switch positions a are shown in the far left
column and the switch lead colors b are shown
in the top row in the switch illustration.
OFF
ON
Br
R
NOTE:
“c-c” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at
the respective switch position).
The example illustration on the left shows
that:
There is continuity between 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
Rear barake light switch
B
B
Br - - R -
Front barake light switch
B
B
Dimmer switch
G L Y
HI
LO
Start switch
Horn switch
L/
W
Y
G
OFF
START
P B
OFF
PUSH
Turn signal light switch
Br/
Ch Dg
W
L
N
R
Engine stop switch
L/ B
Y
L Ch
P Br/W
B Dg
L/W
L/Y
B
OFF
RUN
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.
A
C
TYPES OF BULBS
The bulbs used on this scooter are shown in the
illustration on the left.
8 Bulbs A and B are used for the headlights and usually use a bulb holder that
must be detached before removing the
bulb. The majority of these types of bulbs
can be removed from their respective
socket by turning them counterclockwise.
B
D
8 Bulbs C is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
8 Bulbs D and E are used for meter and
indicator lights and can be removed from
their respective socket by carefully pulling them out.
E
8-6
CHECKING THE BULBS AND BULB SOCKETS
ELEC
-
+
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
8 bulb
w
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
cC
8 Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
8 Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass,
the life of the bulb, and the luminous flux
will be adversely affected. If the headlight bulb gets soiled, thoroughly clean
it with a cloth moistened with alcohol or
lacquer thinner.
2.
Check:
8 bulb (for continuity)
(with the pocket tester)
No continuity J Replace.
Pocket tester
90890-03132 (YU-03112-C)
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
1
*****************************************************
a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity.
b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
*****************************************************
1
2
3
3
2
8-7
CHECKING THE BULBS AND BULB SOCKETS
ELEC
-
+
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:
8 bulb socket (for continuity)
(with the pocket tester)
No continuity J Replace.
Pocket tester
90890-03132 (YU-03112-C)
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
*****************************************************
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity, replace the bulb socket.
*****************************************************
8-8
8-9
(BLACK)
(BLACK)
B
G
GW
B
g
Y
Ch
h
LW
LY
B
LY B
f
L
OFF
RUN
d
r
ENG.STOP SW.
OFF
START
R
LW
R
LW
s
B
LW
STARTER SW.
e
R
GY
R
TEMP
G
FUEL
Br
4
R
R
R
R
W B
R YR
(GREEN)
ILLUMI
j
Dg L
Ch Y
L Dg
Y Ch
5
R
Br
ILLUMI
TURN L
HI BEAM
Dg
B
3
LW
LY
B
6
W
R
GY
LW
GY
YR
B
LW L
GY YR
t
L
(RED)
(RED)
P
Br
Y Ch
B Dg
G
P
B
7
R
R
B
R
B
R
YB
Ch Y
Dg B
G
OFF
PUSH
u HORN
YR
R
c
(RED)
WR
WL
Ch
B
HI
LO
2
YR
W
B
B
k
GY
GY
L
(RED)
GB
Y
0
L BL YL
DIMMER
l
a
B
YR
y
YR
R
YR
W
YR
YR
W
;
Dg
i
L
N
R
Ch
Dg
BrW
FLASHER
(BLACK)
o
B
BL
L
BL
v
GR
YL
GW
8
L Ch
P BrW
B Dg
Br
GR
L GY
B
Dg Ch
Ch L
BrW P
Dg B
Y
Y
G
G
(RED) (RED)
(GRAY)
Br
GR BL
L
YL
BL
WL
YR
(RED)
B
BrW
Br
WL
WR
YR
B
b
WR
WL
(RED)
B
GY L
B
Ch Dg
LY
Ch
L
B
B
12V21W/5W
B
GY
GY
Br
Br
GY
(BLACK) (BLACK)
B
B
q
B
Or
GY
Br
9
w
x
Dg
Br
GY
(BLACK) (BLACK)
B
B
MARK
TURN R
Explanation
12V35W/35W
GND.
Connecting with
GND. Wire
Main switch
Pickup coil
Battery
Main fuse
C.D.I. unit
Ignition coil
Engine stop switch
p
BL B
WL Or
z
Or
GW L LY YR
YL GR
Br
1
2
4
5
8
9
r
G
B
GW Br
B G
Br
1
7.5A
Br GW
G B
OFF
CHECK
ON
MAIN SW.
IGNITION SYSTEM
ELEC
+
EAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
12V10W
12V10W
12V10W
12V10W
IGNITION SYSTEM
EAS00736
ELEC
-
+
EAS00738
TROUBLESHOOTING
1. Main Fuse
8 Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in
chapter 3.
8 Is the fuse OK?
The 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)
YES
NO
Replace the fuse.
EAS00739
2. Battery
8 Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20°C
NOTE:
8 Before troubleshooting, remove the following part(s):
1. Battery cover/Battery holder
2. Head light cover
3. Leg shield 1
4. Seat/Trunk
8 Troubleshoot with the following special
tool(s).
8 Is the battery OK?
YES
NO
8 Clean the battery terminals.
8 Recharge or replace
the battery.
EAS00740
Ignition checker
90890-06754
YM-34487
Pocket tester
90890-03132
YU-03112-C
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
IGNITION SYSTEM
EAS00742
ELEC
-
+
EAS00744
4. Ignition spark gap
8 Disconnect the spark plug cap from the
spark plug.
8 Connect the ignition checker 1 as
shown.
2 Spark plug cap
8 Set the main switch to “ON”.
8 Measure the ignition spark gap a.
8 Crank the engine by pushing the starter
switch and gradually increase the spark
gap until a misfire occurs.
5. Spark plug cap resistance
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
Ω at 20°C
4~6 kΩ
8Is the spark plug cap OK?
YES
NO
Minimum ignition spark gap
6 mm(0.24 in)
8 Is there a spark and is the spark gap
within specification?
NO
Replace the spark plug cap.
YES
EAS00746
The ignition system is OK.
6. Ignition coil resistance
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 orange
Negative tester probe J black
8-11
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 white/red 1
2
Negative tester probe J white/blue2
8 Measure the primary coil resistance.
1
W/R
Primary coil resistance
0.168 ~ 0.252 Ω at 20°C
W/L
8 Connect the pocket tester (Ω × 1k) to
the ignition coil as shown.
Negative tester probe J spark plug lead
2
Positive tester probe J spark plug lead
1
2
8 Measure the pickup coil resistance.
Pickup coil resistance
Ω at 20°C
248 ~ 372Ω
(between white/red and white/
blue)
2
k
8 Is the pickup coil OK?
YES
1
NO
Replace the pickup coil.
EAS00749
8 Measure the secondary coil resistance.
8. Main switch
8 Check the main switch for continuity.
Refer
to
“CHECKING
THE
SWITCHES”.
8 Is the main switch OK?
Secondary coil resistance
Ω at 20°C
2.4 ~ 3.6 kΩ
8 Is the ignition coil OK?
YES
YES
NO
NO
Replace the main switch.
Replace the ignition coil.
8-12
IGNITION SYSTEM
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
Replace the C.D.I.
unit.
NO
Properly connect or
repair the ignition
system’s wiring.
8-13
ELEC
-
+
8-14
(BLACK)
(BLACK)
B
B
TEMP
G
GW
g
Y
Ch
h
LW
LY
B
LY B
f
L
OFF
RUN
d
r
ENG.STOP SW.
OFF
START
R
LW
R
LW
s
B
LW
STARTER SW.
e
R
GY
R
W B
R YR
(GREEN)
ILLUMI
G
FUEL
Br
4
R
R
R
R
ILLUMI
TURN L
HI BEAM
j
Dg L
Ch Y
L Dg
Y Ch
5
R
Br
Dg
B
3
LW
LY
B
6
W
R
GY
LW
GY
YR
B
LW L
GY YR
t
L
(RED)
(RED)
P
Br
Y Ch
B Dg
G
P
B
7
R
R
B
R
B
R
YB
Ch Y
Dg B
G
OFF
PUSH
u HORN
YR
R
c
(RED)
WR
WL
Ch
2
YR
W
L
(RED)
GB
Y
0
L BL YL
DIMMER
l
a
B
YR
y
YR
R
YR
W
YR
YR
W
i
BrW
FLASHER
(BLACK)
o
B
BL
L
BL
v
GR
YL
HI
LO
L
N
R
L Ch
P BrW
B Dg
B
B
B
k
GY
;
Dg
Ch
Dg
Br
GR
L GY
B
Dg Ch
Ch L
BrW P
Dg B
Main switch
Battery
Main fuse
Starter relay
Starter motor
Front brake light switch
Rear brake light switch
Start switch
Engine stop switch
GY
GW
8
Y
Y
G
G
(RED) (RED)
(GRAY)
Br
GR BL
L
YL
BL
WL
YR
(RED)
B
BrW
Br
WL
WR
YR
B
b
WR
WL
(RED)
1
4
5
6
7
q
w
e
r
G
B
GW Br
B G
Br
1
7.5A
Br GW
G B
OFF
CHECK
ON
MAIN SW.
B
GY L
B
Ch Dg
LY
Ch
L
B
B
B
GY
GY
Br
12V21W/5W
p
BL B
WL Or
z
Or
GW L LY YR
YL GR
Br
Br
GY
x
Dg
(BLACK) (BLACK)
B
B
q
B
Or
w
Br
GY
TURN R
12V35W/35W
GND.
Connecting with
GND. Wire
Explanation
(BLACK) (BLACK)
B
B
MARK
GY
Br
9
ELECTRIC STARTING SYSTEM
ELEC
+
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
12V10W
12V10W
12V10W
12V10W
ELECTRIC STARTING SYSTEM
ELEC
-
+
EAS00756
9
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
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).
8
1
2
3
4
5
6
7
8
9
1
2
7
6
3
5
4
8-15
Battery
Main fuse
Main switch
Front brake light switch
Rear brake light switch
Engine stop switch
Start switch
Starter relay
Starter motor
ELECTRIC STARTING SYSTEM
EAS00757
ELEC
-
+
EAS00738
TROUBLESHOOTING
1. Main fuse
8 Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in
chapter 3.
8 Is the fuse OK?
The starter motor fails to turn.
Check:
1. 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.
NOTE:
8 Before troubleshooting, remove the following part(s):
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
8 Troubleshoot with the following special
tool(s).
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
Pocket tester
90890-03132 (YU-03112-C)
NO
8 Clean the battery terminals.
8 Recharge or replace the
battery.
8-16
ELECTRIC STARTING SYSTEM
EAS00758
ELEC
-
+
EAS00761
3. Starter motor
8 Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead3.
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 green/yellow 1
Negative battery terminal J blue/white 2
Positive tester probe J red 3
Negative tester probe Jred 4
w
2
8 A wire that is used as a jumper lead must
have at least the same capacity or more
as that of the battery
lead, otherwise
the jumper lead may burn.
8 This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
1
3
8 Does the starter relay have continuity
between red3 and red 4?
8 Does the starter motor turn?
YES
4
YES
NO
NO
Replace the starter
relay.
Repair or replace the
starter motor.
EAS00749
5. Main switch
8 Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the main switch OK?
YES
NO
Replace the main
switch.
8-17
ELECTRIC STARTING SYSTEM
EAS00751
6. Brake light switch(front and rear)
8 Check the brake light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the brake light switch OK?
YES
NO
Replace the brake light
switch.
EAS00750
7. 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.
EAS00764
8. Start switch
8 Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
EAS00766
9. Wiring
8 Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8 Is the starting system’s wiring properly
connected and without defects?
YES
The starting system
circuit is OK.
NO
Properly connect or
repair the star ting
system’s wiring.
8-18
ELEC
-
+
ELECTRIC STARTING SYSTEM
ELEC
-
+
EAS00767
STARTER MOTOR
1
2
3
4
5
6
2
7
Order
Job/Part
1
Q’ty
Remove the parts in the order listed.
Removing the starter motor
Seat/Trunk
Front cover
Refer to “COVER AND PANEL”in chapter 3.
Battery cover
Air filter assembly
1
2
1
2
3
4
5
6
7
Remarks
1
1
Starter motor lead
Starter motor
Refer to“MANIFOLD, AIR FILTER AND
MUFFLER ASSEMBLY”in chapter 5.
Disconnect.
For installation, reverse the removal procedure.
Disassemble the parts in the order listed.
Disassembling the starter motor
O-ring
Gasket
Stator assembly
O-ring
Armature coil
Brush
Plate washer
1
1
1
1
1
2
1
For assembly, reverse the disassembly
procedure.
8-19
ELECTRIC STARTING SYSTEM
ELEC
-
+
EAS00769
CHECKING THE STARTER MOTOR
1. Check:
8 commutator
Dirt J Clean with 600-grit sandpaper.
2. Measure:
8 commutator diameter a
Out of specification J Replace the starter
motor.
a
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.
2
1
4. Measure:
8 armature assembly resistances (commutator and insulation)
Out of specification J Replace the starter
motor.
*****************************************************
a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
90890-03132 (YU-03112-C)
Armature coil
Commutator resistance 1
0.0378 ~ 0.0462 Ω at 20°C
Insulation resistance 2
Ω at 20°C
Above 1 MΩ
b. If any resistance is out of specification, replace the starter motor.
8-20 *****************************************************
ELECTRIC STARTING SYSTEM
ELEC
-
+
5. Measure:
8 brush length a
Out of specification J Replace the
brushes as a set.
Brush length wear limit
3.5 mm (0.14 in)
a
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
2
1
7. Check:
8 gear teeth
Damage/wear J Replace the gear.
8. Check:
8 bearing1
8 oil seal2
8 bush3
Damage/wear J Replace.
3
8-21
ELECTRIC STARTING SYSTEM
ELEC
-
+
EAS00772
1
4
ASSEMBLING THE STARTER MOTOR
1. Install:
8 brush seat 1
2. Install:
8 washer1
8 armature coil 2
8 o-ing New 3
8 stator assembly4
3
2
1
3 . Install:
8 bolts 1
a
b
T.
R.
5 Nm (0.5 m • kg, 3.6 ft • lb)
1
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
8-23
(BLACK)
(BLACK)
B
GW
B
TEMP
G
g
Y
Ch
h
LW
LY
B
LY B
f
L
OFF
RUN
d
r
ENG.STOP SW.
OFF
START
R
LW
R
LW
s
B
LW
STARTER SW.
e
R
GY
R
W B
R YR
(GREEN)
ILLUMI
G
FUEL
Br
4
R
R
R
R
ILLUMI
TURN L
HI BEAM
j
Dg L
Ch Y
L Dg
Y Ch
5
R
Br
Dg
B
3
LW
LY
B
6
W
R
GY
LW
GY
YR
B
LW L
GY YR
t
L
(RED)
(RED)
P
Br
Y Ch
B Dg
G
P
B
7
R
R
B
R
B
R
YB
Ch Y
Dg B
G
OFF
PUSH
u HORN
YR
R
c
(RED)
WR
WL
Ch
B
HI
LO
2
YR
W
B
B
k
GY
GY
L
(RED)
GB
Y
0
L BL YL
DIMMER
l
a
B
YR
y
YR
R
YR
W
YR
YR
W
;
Dg
i
L
N
R
Ch
Dg
BrW
FLASHER
(BLACK)
o
B
BL
L
BL
v
GR
YL
GW
8
L Ch
P BrW
B Dg
Br
GR
L GY
B
Dg Ch
Ch L
BrW P
Dg B
Y
Y
G
G
(RED) (RED)
(GRAY)
Br
GR BL
L
YL
BL
WL
YR
(RED)
B
BrW
Br
WL
WR
YR
B
b
WR
WL
(RED)
B
GY L
B
Ch Dg
LY
Ch
L
B
B
B
GY
GY
Br
12V21W/5W
p
BL B
WL Or
z
Or
GW L LY YR
YL GR
Br
Br
GY
x
Dg
(BLACK) (BLACK)
B
B
q
B
Or
w
Br
GY
(BLACK) (BLACK)
B
B
MARK
GY
Br
9
Stator coil
Rectifier/regulator
Battery
Main fuse
TURN R
12V35W/35W
GND.
Connecting with
GND. Wire
Explanation
2
3
4
5
G
B
GW Br
B G
Br
1
7.5A
Br GW
G B
OFF
CHECK
ON
MAIN SW.
CHARGING SYSTEM
ELEC
+
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
12V10W
12V10W
12V10W
12V10W
CHARGING SYSTEM
EAS00774
ELEC
-
+
EAS00739
TROUBLESHOOTING
2. Battery
8Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
The battery is not being charged.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections
(of the entire charging system)
Minimum open-circuit voltage
12.8 V or more at 20°C
8Is the battery OK?
YES
NOTE:
8 Before troubleshooting, remove the following part(s):
1. Seat/Trunk
2. Battery cover
3. Head light cover
4. Leg shield 1
8 Troubleshoot with the following special
tool(s).
NO
8Clean the battery terminals.
8Recharge or replace the
battery.
EAS00775
3. Charging voltage
8Connect the engine tachometer to the
spark plug lead of cylinder.
8Connect the pocket tester (DC 20 V) to
the battery as shown.
Positive tester probe J positive battery
terminal
Negative tester probe J negative battery
terminal
Engine tachometer
90890-03113 (YU-08036-C)
Pocket tester
90890-03132 (YU-03112-C)
-
EAS00738
1. Main fuse
8Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in
chapter 3.
8Is the fuse OK?
YES
+
8Start the engine and let it run at approximately 5,000 r/min.
8Measure the charging voltage.
NO
Replace the fuse.
Charging voltage
14 V at 5000r/min
8-24
CHARGING SYSTEM
+
5. Wiring
8Check the entire charging system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8Is the charging system’s wiring properly
connected and without defects?
8Is the charging voltage within specification?
YES
YES
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.
Positive tester probe Jwhite 1
Negative tester probe J ground 2
Y/R
W
1
8 Measure the stator coil resistances.
Stator coil resistance
0.288 ~ 0.432 Ω at 20°C
(between white and ground)
8 Is the stator coil OK?
YES
-
EAS00754
NOTE:
Make sure the battery is fully charged.
NO
ELEC
NO
Replace the stator coil assembly.
8-25
NO
Properly connect or repair
the charging system’s wiring.
8-26
(BLACK)
(BLACK)
B
B
TEMP
G
GW
g
Y
Ch
h
LW
LY
B
LY B
f
L
OFF
RUN
d
r
ENG.STOP SW.
OFF
START
R
LW
R
LW
s
B
LW
STARTER SW.
e
R
GY
R
W B
R YR
(GREEN)
ILLUMI
G
FUEL
Br
4
R
R
R
R
ILLUMI
TURN L
HI BEAM
j
Dg L
Ch Y
L Dg
Y Ch
5
R
Br
Dg
B
3
LW
LY
B
6
W
R
GY
LW
GY
YR
B
LW L
GY YR
t
L
(RED)
(RED)
P
Br
Y Ch
B Dg
G
P
B
7
R
R
B
R
B
R
YB
Ch Y
Dg B
G
OFF
PUSH
u HORN
YR
R
c
(RED)
WR
WL
Ch
B
HI
LO
2
YR
W
B
B
k
GY
GY
L
(RED)
GB
Y
0
L BL YL
DIMMER
l
a
B
YR
y
YR
R
YR
W
YR
YR
W
;
Dg
i
L
N
R
Ch
Dg
BrW
FLASHER
(BLACK)
o
B
BL
L
BL
v
GR
YL
GW
8
L Ch
P BrW
B Dg
Br
GR
L GY
B
Dg Ch
Ch L
BrW P
Dg B
Y
Y
G
G
(RED) (RED)
(GRAY)
Br
GR BL
L
YL
BL
WL
YR
(RED)
B
BrW
Br
WL
WR
YR
B
b
WR
WL
(RED)
B
GY L
B
Ch Dg
LY
Ch
L
B
B
B
GY
GY
Br
12V21W/5W
p
BL B
WL Or
z
Or
GW L LY YR
YL GR
Br
Br
GY
x
Dg
(BLACK) (BLACK)
B
B
q
B
Or
GY
Br
9
w
Br
GY
(BLACK) (BLACK)
B
B
MARK
Main switch
Lighting coil
Battery
Main fuse
Headlight relay
Dimmer switch
Speedometer light
High beam indicator light
Headlight
TURN R
12V35W/35W
GND.
Connecting with
GND. Wire
Explanation
1
2
4
5
t
a
d
f
k
G
B
GW Br
B G
Br
1
7.5A
Br GW
G B
OFF
CHECK
ON
MAIN SW.
LIGHTING SYSTEM
ELEC
+
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
12V10W
12V10W
12V10W
12V10W
LIGHTING SYSTEM
EAS00781
ELEC
-
+
EAS00739
TROUBLESHOOTING
2. Battery
8 Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Any of the following fail to light: headlight,
high beam indicator light or meter light.
Check:
1. main fuse
2. battery
3. lighting coil resistance.
4. main switch
5. dimmer switch
6. headlight relay
7. wiring connections
(of the entire lighting system)
Minimum open-circuit voltage
12.8 V or more at 20°C
8Is the battery OK?
`
YES
NO
8Clean the battery terminals.
8Recharge or replace the
battery.
NOTE:
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).
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.
Positive tester probe J yellow/red 1
Negative tester probe J ground
Pocket tester
90890-03132 (YU-03112-C)
1
Y/R
EAS00738
W
1. Main fuse
8Check the fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
8Is the fuse OK?
YES
8 Measure the lighting coil resistance.
NO
Lighting coil resistance
Ω at 20°C
0.256 ~ 0.384Ω
(between yellow/red and ground)
Replace the fuse.
8 Is the lighting coil OK?
YES
NO
Replace the lighting coil.
8-27
LIGHTING SYSTEM
EAS00749
ELEC
-
+
EAS00787
4. Main switch
8 Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the main switch OK?
YES
7. Wiring
8 Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8 Is the lighting system’s wiring properly
connected and without defects?
NO
YES
Replace the main switch.
Check the condition
of each of the lighting system’s circuits.
Refer to “CIRCUIT
DIAGRAM”.
EAS00784
5. Dimmer switch
8 Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the dimmer switch OK?
YES
NO
The dimmer switch is
faulty. Replace the left
handlebar switch.
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 green/yellow 1
Negative battery terminal J blue/white 2
Positive tester probe J yellow/red 3
Negative tester probe J blue 4
2
4
L/W
G/Y
1
L
Y/R
3
8 Does the starting headlight relay have
continuity between blue and yellow/red?
YES
NO
Replace the headlight relay.
8-28
NO
Properly connect or
repair the lighting
system’s wiring.
LIGHTING SYSTEM
EAS00788
1. Headlight bulb and socket
8 Check the headlight bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Are the headlight bulb and socket OK?
NO
Replace the headlight bulb,
socket or both.
1
3
2
G
G
Y
2. High beam indicator light bulb and socket
8 Check the high beam indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Are the high beam indicator light bulb and
socket OK?
YES
+
3. Voltage
8 Connect the pocket tester (DC 20 V) to
the headlight and high beam indicator
light couplers as shown.
When the dimmer switch is set to “%”
When the dimmer switch is set to “&”
Headlight coupler (wire harness side)
Headlight
Positive tester probe J green 1
Negative tester probe J black 2
Positive tester probe J yellow 3
Negative tester probe J black 4
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
YES
-
ELEC
Y
B
4
B
High beam indicator light
Positive tester probe J yellow 1
Negative tester probe J black 2
NO
Br G/W
G B
Replace the high beam indicator light bulb , socket
or both.
G/W Br
Y
1
B G
2
8 Set the main switch to “ON”.
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
LIGHTING SYSTEM
YES
-
ELEC
+
EAS00789
NO
2. The meter light fails to come on.
1. Meter light bulb and socket
8 Check the meter light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Are the meter light bulb and socket OK?
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.
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.
Positive tester probe J brown 1
J black 2
Negative tester probeJ
1
Br G/W
G
2
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
This circuit is OK.
8-30
NO
The wiring circuit
from the main
switch to the meter
light coupler is faulty
and must be repaired.
Refer to “CIRCUIT
DIAGRAM”.
LIGHTING SYSTEM
EAS00754
4. Wiring
8 Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8 Is the lighting system’s wiring properly
connected and without defects?
YES
Check the condition of each of the
lighting system’s
circuits.
Refer to “CIRCUIT
DIAGRAM”.
NO
Properly connect or
repair the lighting
system’s wiring.
8-31
ELEC
-
+
8-32
B
G
G
GW
B
g
Y
Ch
h
LW
LY
B
LY B
f
L
OFF
RUN
d
r
ENG.STOP SW.
OFF
START
R
LW
R
LW
TEMP
j
(BLACK)
(BLACK)
LW
STARTER SW.
e
R
GY
R
W B
R YR
(GREEN)
ILLUMI
s
B
R
R
R
R
ILLUMI
TURN L
HI BEAM
G
B
Dg L
Ch Y
FUEL
Br
4
7.5A
L Dg
Y Ch
5
R
Br
Dg
B
3
LW
LY
B
6
W
R
GY
LW
GY
YR
B
LW L
GY YR
t
L
(RED)
(RED)
P
Br
Y Ch
B Dg
G
P
B
7
R
R
B
R
B
R
YB
Ch Y
Dg B
G
OFF
PUSH
u HORN
YR
R
c
(RED)
WR
WL
Ch
B
HI
LO
2
YR
W
B
B
k
GY
GY
L
(RED)
GB
Y
0
L BL YL
DIMMER
l
a
B
YR
y
YR
R
YR
W
YR
YR
W
;
Dg
i
L
N
R
Ch
Dg
BrW
FLASHER
(BLACK)
o
B
BL
L
BL
v
GR
YL
GW
8
L Ch
P BrW
B Dg
Br
GR
L GY
B
Dg Ch
Ch L
BrW P
Dg B
Y
Y
G
G
(RED) (RED)
(GRAY)
Br
GR BL
L
YL
BL
WL
YR
(RED)
B
BrW
Br
WL
WR
YR
B
b
WR
WL
(RED)
GW L LY YR
YL GR
Br
LY
B
Or
BL B
WL Or
Or
GY L
B
Ch Dg
Ch
z
L
B
B
B
12V21W/5W
p
GY
GY
Br
Br
GY
x
Dg
(BLACK) (BLACK)
B
B
q
B
9
w
Br
GY
TURN R
12V35W/35W
GND.
Connecting with
GND. Wire
Explanation
(BLACK) (BLACK)
B
B
MARK
GY
Br
Main switch
Battery
Main fuse
Front brake light switch
Rear brake light switch
Horn
Horn switch
Turn signal switch
Turn signal relay
Tail/brake light
Left turn signal indicator light
Right turn signal indicator light
Fuel sender
Front turn signal light(left)
Front turn signal light(right)
Rear turn signal light(left)
Rear turn signal light(right)
GW Br
B G
Br
1
1
4
5
q
w
y
u
i
o
p
g
h
j
l
;
z
x
Br GW
G B
OFF
CHECK
ON
MAIN SW.
SIGNALING SYSTEM
ELEC
+
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
12V10W
12V10W
12V10W
12V10W
SIGNALING SYSTEM
EAS00794
ELEC
-
+
EAS00739
TROUBLESHOOTING
2. Battery
8 Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
8 Any of the following fail to light: turn
signal light, brake light or an indicator light.
8 The horn fails to sound.
Minimum open-circuit voltage
12.8 V or more at 20°C
Check:
1. main fuse
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
8 Is the battery OK?
YES
NO
8Clean the battery
terminals.
8 Recharge or replace the battery.
NOTE:
8 Before troubleshooting, remove the following part(s):
1. Head light cover/Leg shield 1
2. Battery cover
3. Seat/Trunk
4. Rear carrier
5. Front cover
6. Side cover (left and right)/Rear cover
8 Troubleshoot with the following special
tool(s).
EAS00749
3. 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.
Pocket tester
90890-03132 (YU-03112-C)
EAS00738
EAS00795
1. Main fuse
8 Check the main fuse for continuity.
Refer to “CHECKING THE FUSE” in
chapter 3.
8 Is the fuse OK?
YES
4. Wiring
8 Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8 Is the signaling system’s wiring properly
connected and without defects?
NO
YES
Replace the fuse.
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING
THE SIGNALING
SYSTEM”.
8-33
NO
Properly connect or
repair the signaling
system’s wiring.
SIGNALING SYSTEM
EAS00796
The horn fails to sound.
1. Horn switch
8 Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the horn switch OK?
YES
Br
NO
1
2. Voltage
8 Connect the pocket tester (DC 20 V) to
the horn connector at the horn terminal
as shown.
Positive tester probe Jbrown 1
Negative tester probe J ground
Br
NO
YES
The horn is OK.
P
4. Voltage
8 Connect the pocket tester (DC 20 V) to
the horn connector at the pink terminal
as shown.
Positive tester probe J pink 1
Negative tester probe J ground
Br
8 Set the main switch to “ON”.
8 Push the horn switch.
8 Measure the voltage (DC 12 V) of brown
at the horn terminal.
8 Is the voltage within specification?
YES
+
P
Replace the left
handlebar switch.
1
-
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 Set the main switch to “ON”.
8 Push the horn switch.
8 Does the horn sound?
CHECKING THE SIGNALING SYSTEM
1.
ELEC
P
1
NO
8 Set the main switch to “ON”.
8 Measure the voltage (DC 12 V) of pink
1 at the horn terminal.
8 Is the voltage within specification?
The wiring circuit from the
main switch to the horn connector is faulty and must be
repaired.
Refer to “CIRCUIT DIAGRAM”.
YES
Repair or replace the
horn.
8-34
NO
Replace the horn.
SIGNALING SYSTEM
EAS00798
2.
+
3. Voltage
8 Connect the pocket tester (DC 20 V) to
the tail/brake light coupler (wire harness
side) as shown.
Positive tester probe J green/ yellow 1
Negative tester probe J black 2
The tail/brake light fails to come on.
1. Tail/brake light bulb and socket
8 Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Are the tail/brake light bulb and socket
OK?
YES
-
ELEC
1
L
NO
G/Y 2
G/Y L
-
B
B
-
Dg
Ch
Ch
Dg
Replace the tail/brake
light bulb, socket or
both.
8 Set the main switch to “ON”.
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).
8 Is the voltage within specification?
2. Brake light switches
8 Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the brake light switch OK?
YES
The wiring circuit from
the main switch to the
tail/brake light bulb
connector is faulty
and must be repaired.
Refer to “CIRCUIT
DIAGRAM”.
YES
NO
This circuit is OK.
Replace the brake
light switch.
8-35
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
Refer to “CIRCUIT
DIAGRAM”.
SIGNALING SYSTEM
EAS00799
1. Turn signal light and turn signal indicator
light bulbs and sockets
8 Check the turn signal light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Check the turn signal indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
8 Are the turn signal light bulb and socket
OK?
+
B
Br/W
Br
1
8 Set the main switch to “ON”.
8 Measure the voltage (DC 12 V) on brown
1 at the turn signal relay coupler (wire
harness side).
8 Is the voltage within specification?
NO
Replace the turn
signal light and/or
turn signal indicator
light bulb, socket or
both.
YES
NO
The wiring circuit from
the main switch to the
turn signal relay coupler
is faultyand must be repaired.
Refer to “CIRCUIT DIAGRAM”.
2. Turn signal switch
8 Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the turn signal switch OK?
YES
-
3. Voltage
8 Connect the pocket tester (DC 20 V) to
the turn signal relay coupler (wire harness side) as shown.
Positive tester probe J brown 1
Negative tester probe J ground
3. The turn signal light, turn signal indicator
light or both fail to blink.
YES
ELEC
NO
Replace the left
handlebar switch.
8-36
SIGNALING SYSTEM
4. Voltage
8Connect the pocket tester (DC 20 V) to
the turn signal relay coupler (wire harness side) as shown.
J brown/white 1
Positive tester probeJ
Negative tester probe J ground
B
Br/W
Br
-
+
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 chocolate 1
Negative tester probe J ground
Right turn signal light
Positive tester probe J dark green 2
Negative tester probe J ground
A
B
1
8Set the main switch to “ON”.
8Set the turn signal switch to “4” or “6”.
8Measure the voltage (DC 12 V) on brown/
white 1 at the turn signal relay coupler
(wire harness side).
8Is the voltage within specification?
YES
ELEC
Ch
Dg
Ch B
Dg
Dg
Ch B
NO
G/Y
L
L
G/Y
C
2
The turn signal relay is
faulty and must be replaced.
Dg
Ch
L
Y
L
Y
Dg
Ch
1
8Set the main switch to “ON”.
8Set the turn signal switch to “4” or “6”.
8Measure the voltage (DC 12 V) of the
chocolate 1 or dark green 2 at the turn
signal light connector (wire harness
side).
8Is the voltage within specification?
YES
This circuit is OK.
8-37
NO
The wiring circuit
from the turn signal
switch to the turn
signal light connector is faulty and must
be repaired.
SIGNALING SYSTEM
EAS00804
ELEC
-
+
2. Voltage
8 Connect the pocket tester (DC 20 V) to
the meter light coupler (wire harness
side) as shown.
Positive tester probe J brown 1
Negative tester probe J black 2
4. The fuel level meter fails to operate.
1. Fuel sender
8 Remove the fuel sender from the fuel
tank.
8 Connect the pocket tester (Ω × 1) to the
fuel sender coupler (wire harness side)
as shown.
Positive tester probe J green 1
Negative tester probe J black 2
1
Br
G/W
G
B
2
(F)
1
G
B
(E)
8 Set the main switch to “ON”.
8 Measure the voltage (DC 12 V) of brown
1 on the meter light coupler (wire harness side).
8 Is the voltage within specification?
2
8 Measure the fuel sender resistances.
YES
Fuel sender resistance (up position
Ω × 1)
F)(Ω
Ω at 20°C
6~8Ω
Fuel sender resistance (down poΩ × 10)
sition E)(Ω
93.5~96.5 Ω at 20°C
Check the wiring connections of the entire signaling system.
Refer to “CIRCUIT DIAGRAM”.
8Is the fuel sender OK?
YES
NO
NO
Replace the fuel sender.
8-38
SIGNALING SYSTEM
3. Fuel level meter
8 Set the main switch to “ON”.
8 Move the float up 1 or down 2.
1
2
8 Check that the fuel level meter needle
moves to “F” or “E”.
NOTE:
Before reading the fuel level meter, leave the
float in one position (either up or down) for at
least three minutes.
8 Does the fuel level meter needle move
appropriately?
YES
This circuit is OK.
4.
NO
Replace the speedo
meter.
Wiring
8 Check the entire signaling system’s
wiring
8-39
ELEC
-
+
8-40
(BLACK)
(BLACK)
B
B
TEMP
G
GW
g
Y
Ch
h
LW
LY
B
LY B
f
L
OFF
RUN
d
r
ENG.STOP SW.
OFF
START
R
LW
R
LW
s
B
LW
STARTER SW.
e
R
GY
R
W B
R YR
(GREEN)
ILLUMI
G
FUEL
Br
4
R
R
R
R
ILLUMI
TURN L
HI BEAM
j
Dg L
Ch Y
L Dg
Y Ch
5
R
Br
Dg
B
3
LW
LY
B
6
W
R
GY
LW
GY
YR
B
LW L
GY YR
t
L
(RED)
(RED)
P
Br
Y Ch
B Dg
G
P
B
7
R
R
B
R
B
R
YB
Ch Y
Dg B
G
OFF
PUSH
u HORN
YR
R
c
(RED)
WR
WL
Ch
B
HI
LO
2
YR
W
B
B
k
GY
GY
L
(RED)
GB
Y
0
L BL YL
DIMMER
l
a
B
YR
y
YR
R
YR
W
YR
YR
W
Br
;
Dg
i
L
N
R
Ch
Dg
BrW
FLASHER
(BLACK)
o
B
BL
L
BL
v
GR
YL
GW
8
L Ch
P BrW
B Dg
Br
GR
L GY
B
Dg Ch
Ch L
BrW P
Dg B
Y
Y
G
G
(RED) (RED)
(GRAY)
(RED)
L
YL
BL
WL
YR
GR BL
B
BrW
Br
WL
WR
YR
B
b
WR
WL
(RED)
B
GY L
B
Ch Dg
LY
Ch
L
BL B
WL Or
z
Or
B
GY
Br
GW L LY YR
YL GR
Br
Br
GY
(BLACK) (BLACK)
B
B
q
B
Or
12V21W/5W
B
p
B
x
Dg
Main switch
Battery
Main fuse
C.D.I. unit
Water temperature indicator
light
c Thermo switch
v Thermo unit
GY
1
4
5
8
s
G
B
GW Br
B G
Br
1
7.5A
Br GW
G B
OFF
CHECK
ON
MAIN SW.
w
Br
GY
TURN R
12V35W/35W
GND.
Connecting with
GND. Wire
Explanation
(BLACK) (BLACK)
B
B
MARK
GY
Br
9
COOLING SYSTEM
ELEC
+
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
12V10W
12V10W
12V10W
12V10W
COOLING SYSTEM
EAS00808
ELEC
-
+
EAS00739
TROUBLESHOOTING
2. Battery
8 Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
The cooling system fails to operate.
Check:
1. main fuse
2. battery
3. main switch
4. thermo switch
5. water temperature indicator light
6. wiring connections
(the entire cooling system)
Minimum open-circuit voltage
12.8 V or more at 20°C
8 Is the battery OK?
YES
NO
8Clean the battery terminals.
8Recharge or replace the
battery.
NOTE:
8 Before troubleshooting, remove the following part(s):
1. Seat/Trunk
2. Battery cover
3. Front cover
4. Head light cover
5. Leg shield 1
6. Drain the coolant
8 Troubleshoot with the following special
tool(s).
EAS00749
3. Main switch
8 Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
8 Is the main switch OK?
Pocket tester
90890-03132(YU-03112-C)
YES
NO
Replace the main switch.
EAS00738
1. Main fuse
8Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in
chapter 3.
8Is the fuse OK?
YES
NO
Replace the fuse.
8-41
COOLING SYSTEM
EAS00811
ELEC
-
+
A Cooling phase
B Heating phase
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.
8 Does the thermo switch operate properly as described above?
Test step Coolant temperature Continuity
Thermo switch
1
0 ~56 °C
NO
2
More than65 ± 2 °C
YES
3*
65± 2°C to 56°C
YES
4*
Less than56 °C
NO
YES
NO
Replace the thermo
switch.
Steps 1 & 2: Heating phase
Steps 3 & 4: Cooling phase
3
1
2
w
8 Handle the thermo switch with special
care.
8 Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
T.
R.
Thermo switch
23 Nm (2.3 m • kg, 16.6 ft • lb)
Three bond sealock®10
8-42
COOLING SYSTEM
EAS00812
ELEC
-
+
2. Voltage
8 Connect the pocket tester (DC 20 V) to
the meter light coupler (wire harness
side) as shown.
Positive tester probe J green/red 1
Negative tester probe J ground
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.
Positive tester probe J black/blue 1
2
Negative tester probe J green/red2
DC20V
G/R B/L
8 Set the main switch to “ON”.
8 Measure the voltage (DC 12 V) of green/
red 1 on the meter light coupler (wire
harness side).
8 Is the voltage within specification?
8 Measure the thermo unit resistance.
YES
Thermo unit resistance
3.413~4.007k Ω at 80 °C
1.645~1.855k Ω at 100 °C
The wiring circuit from the
main switch to the thermo unit
connector is faulty and must
be repaired.
8 Is the thermo unit OK?
YES
NO
NO
Replace the thermo unit.
8-43
COOLING SYSTEM
3. Water temperature indicator light
8 Remove the thermo unit coupler .
8 Set the main switch to “ON”.
8 Connect the green/red1 and black/
blue2 with a jumper lead3.
1
G/R B/L
2
3
8 Is the water temperature indicator light
OK?
YES
This circuit is OK.
NO
Replace the water
temperature indicator light
EAS00813
6. Wiring
8 Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8 Is the cooling system’s wiring properly
connected and without defects?
YES
Replace the C.D.I.
unit.
NO
Properly connect or
repair the cooling
system’s wiring.
8-44
ELEC
-
+
8-45
(BLACK)
(BLACK)
B
B
TEMP
G
GW
g
Y
Ch
h
LW
LY
B
LY B
f
L
OFF
RUN
d
r
ENG.STOP SW.
OFF
START
R
LW
R
LW
s
B
LW
STARTER SW.
e
R
GY
R
W B
R YR
(GREEN)
ILLUMI
G
FUEL
Br
4
R
R
R
R
ILLUMI
TURN L
HI BEAM
j
Dg L
Ch Y
L Dg
Y Ch
5
R
Br
Dg
B
3
LW
LY
B
6
W
R
GY
LW
GY
YR
B
LW L
GY YR
t
L
(RED)
(RED)
P
Br
Y Ch
B Dg
G
P
B
7
R
R
B
R
B
R
YB
Ch Y
Dg B
G
OFF
PUSH
u HORN
YR
R
c
(RED)
WR
WL
Ch
B
HI
LO
2
YR
W
B
B
k
GY
GY
L
(RED)
GB
Y
0
L BL YL
DIMMER
l
a
B
YR
y
YR
R
YR
W
YR
YR
W
;
Dg
i
L
N
R
Ch
Dg
BrW
FLASHER
(BLACK)
o
B
BL
L
BL
v
GR
YL
GW
8
L Ch
P BrW
B Dg
Br
GR
L GY
B
Dg Ch
Ch L
BrW P
Dg B
Y
Y
G
G
(RED) (RED)
(GRAY)
Br
GR BL
L
YL
BL
WL
YR
(RED)
B
BrW
Br
WL
WR
YR
B
b
WR
WL
(RED)
B
GY L
B
Ch Dg
LY
Ch
L
B
B
B
GY
GY
Br
12V21W/5W
p
BL B
WL Or
z
Or
GW L LY YR
YL GR
Br
Br
GY
x
Dg
(BLACK) (BLACK)
B
B
q
B
Or
w
Br
GY
(BLACK) (BLACK)
B
B
MARK
GY
Br
9
4
5
8
0
c
G
B
GW Br
B G
Br
1
7.5A
Br GW
G B
OFF
CHECK
ON
MAIN SW.
TURN R
Explanation
Battery
Main fuse
C.D.I. unit
Auto choke unit
Thermo switch
12V35W/35W
GND.
Connecting with
GND. Wire
AUTO CHOKE SYSTEM
ELEC
+
AUTO CHOKE SYSTEM
CIRCUIT DIAGRAM
12V10W
12V10W
12V10W
12V10W
AUTO CHOKE SYSTEM
EAS00821
ELEC
-
+
EAS00739
TROUBLESHOOTING
2. Battery
8 Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
The auto choke system fails to operate.
Check:
1. main fuse
2. battery
3. thermo switch
4. auto choke unit
5. wiring connections
(of the entire autochoke system)
NOTE:
8 Before troubleshooting, remove the following part(s):
1. Seat/Trunk
2. Battery cover
3. Front cover
8 Troubleshoot with the following special
tool(s).
Minimum open-circuit voltage
12.8 V or more at 20°C
8 Is the battery OK?
YES
8Clean the battery terminals.
8Recharge or replace
the battery.
Pocket tester
90890-03132(YU-03112-C)
EAS00738
1. Main fuse
8 Check the main fuse for continuity.
Refer to “CHECKING THE FUSE” in
chapter 3.
8 Is the fuse OK?
YES
NO
NO
Replace the fuse.
8-46
AUTO CHOKE SYSTEM
EAS00811
ELEC
-
+
A Cooling phase
B Heating phase
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.
8 Does the thermo switch operate properly as described above?
Test step Coolant temperature Continuity
Thermo switch
1
0 ~56 °C
NO
2
More than65 ± 2 °C
YES
3*
65± 2°C to 56°C
YES
4*
Less than56 °C
NO
YES
NO
Replace the thermo
switch.
Steps 1 & 2: Heating phase
Steps 3 & 4: Cooling phase
3
1
2
w
8 Handle the thermo switch with special care.
8 Never subject the thermo switch to
strong shocks. If the thermo switch
is dropped, replace it.
T.
R.
Thermo switch
23 Nm (2.3 m • kg, 16.6 ft • lb)
Three bond sealock®10
8-47
AUTO CHOKE SYSTEM
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
JJgreen/black 1
Negative tester probe Jyellow 2
1
2
G/B
Y
8Measure the auto choke unit resistance.
Auto choke unit resistance
20 Ω at 20°C
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.
Refer to “CIRCUIT DIAGRAM”.
8 Is the auto choke system’s wiring properly connected and without defects?
YES
Replace the
C.D.I. unit
NO
Properly connect or repair
the auto choke system’s
wiring.
8-48
ELEC
-
+
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
ELECTRICAL SYSTEMS .................................................................. 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
ELECTRICAL SYSTEMS .................................................................. 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
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
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
Autochoke unit
8Faulty starter plunger
8Faulty C.D.I.unit
8Faulty thermo switch
Piston and piston ring
8Improperly installed piston ring
8Damaged, worn or fatigued piston ring
8Seized piston ring
8Seized or damaged piston
ELECTRICAL SYSTEMS
Battery
8Discharged battery
8Faulty battery
Air filter
8Improperly installed air filter
8Clogged air filter element
Fuse
8Blown, damaged or incorrect fuse
8Improperly installed fuse
Crankcase and crankshaft
8Improperly assembled crankcase
8Seized crankshaft
Spark plug
8Incorrect spark plug gap
8Incorrect spark plug heat range
8Fouled spark plug
8Worn or damaged electrode
8Worn or damaged insulator
8Faulty spark plug cap
FUEL SYSTEM
Fuel tank
8Empty fuel tank
8Clogged fuel tank cap breather hole
8Deteriorated or contaminated fuel
8Clogged or damaged fuel hose
Ignition coil
8Cracked or broken ignition coil body
8Broken or shorted primary or secondary
coils
8Faulty spark plug lead
Fuel cock
8Faulty fuel cock
8Damaged vacuum hose
8Improperly routed hose
9-1
STARTING FAILURES/HARD STARTING/
INCORRECT ENGINE IDLING SPEED
TRBL
SHTG
EAS00847
Ignition system
8Faulty C.D.I.unit
8Faulty pickup coil
8Broken AC magneto rotor woodruff key
INCORRECT ENGINE IDLING
SPEED
ENGINE
Cylinder and cylinder head
8Incorrect valve clearance
8Damaged valve train components
Switches and wiring
8Faulty main switch
8Faulty engine stop switch
8Broken or shorted wiring
8Faulty front, rear or both brake light
switches
8Faulty start switch
8Improperly grounded circuit
8Loose connections
Air filter
8Clogged air filter element
FUEL SYSTEM
Carburetor
8Faulty starter plunger
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
Starting system
8Faulty starter motor
8Faulty starter relay
8Faulty starter clutch
Autochoke unit
8Faulty starter plunger
8Faulty C.D.I. unit
ELECTRICAL SYSTEMS
Battery
8Discharged battery
8Faulty battery
Spark plug
8Incorrect spark plug gap
8Incorrect spark plug heat range
8Fouled spark plug
8Worn or damaged electrode
8Worn or damaged insulator
8Faulty spark plug cap
Ignition coil
8Faulty spark plug lead
Ignition system
8Faulty C.D.I. unit
8Faulty pickup coil
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/
FAULTY CLUTCH
EAS00849
EAS00853
POOR
MEDIUM-AND-HIGHSPEED PERFORMANCE
FAULTY CLUTCH
TRBL
SHTG
ENGINE OPERATES BUT SCOOTER WILL
NOT MOVE
Refer to “STARTING FAILURE/HARD STARTING”.
ENGINE
Air filter
8Clogged air filter element
V-belt
8Bent, damaged or worn V-belt
8Slipping V-belt
Primary pulley cam and primary pulley slider
8Damaged or worn primary pulley cam
8Damaged or worn primary pulley slider
Air intake system
8Bent, clogged or disconnected carburetor air vent hose
8Clogged or leaking air duct
Clutch spring(s)
8Damaged clutch spring
FUEL SYSTEM
Carburetor
8Faulty diaphragm
8Incorrect fuel level
8Loose or clogged main jet
8Faulty accelerating pump
Transmission gears
8Damaged transmission gear
CLUTCH SLIPS
Clutch shoe springs
8Damaged, loose or worn clutch shoe
spring
Clutch shoes
8Damaged or worn clutch shoe
Fuel cock
8Faulty fuel cock
Primary sliding sheave
8Seized primary sliding sheave
POOR STARTING PERFORMANCE
V-belt
8V-belt slips
8Oil or grease on the V-belt
Primary sliding sheave
8Faulty operation
8Worn pin groove
8Worn pin
Clutch shoes
8Bent, damaged or worn clutch shoe
9-3
FAULTY CLUTCH/OVERHEATING/OVERCOOLING
TRBL
SHTG
Hose(s) and pipe(s)
8Damaged hose
8Improperly connected hose
8Damaged pipe
8Improperly connected pipe
POOR SPEED PERFORMANCE
V-belt
8Oil or grease on the V-belt
Primary pulley weight(s)
8Faulty operation
8Worn primary pulley weight
FUEL SYSTEM
Carburetor
8Incorrect main jet setting
8Incorrect fuel level
8Damaged or loose carburetor joint
Primary fixed sheave
8Worn primary fixed sheave
Primary sliding sheave
8Worn primary sliding sheave
Air filter
8Clogged air filter element
Secondary fixed sheave
8Worn secondary fixed sheave
CHASSIS
Brake(s)
8Dragging brake
Secondary sliding sheave
8Worn secondary sliding sheave
ELECTRICAL SYSTEMS
Spark plug
8Incorrect spark plug gap
8Incorrect spark plug heat range
EAS00855
OVERHEATING
Ignition system
8Faulty C.D.I. unit
ENGINE
Clogged coolant passages
8Heavy carbon buildup
EAS00856
OVERCOOLING
Engine oil
8Incorrect oil level
8Incorrect oil viscosity
8Inferior oil quality
COOLING SYSTEM
Thermostat
8Thermostat stays open
COOLING SYSTEM
Coolant
8Low coolant level
Radiator
8Damaged or leaking radiator
8Faulty radiator cap
8Bent or damaged radiator fan
Water pump
8Damaged or faulty water pump
Thermostat
8Thermostat stays closed
Oil cooler
8Clogged or damaged oil cooler
9-4
POOR BRAKING PERFORMANCE/FAULTY FRONT
FORK LEGS/UNSTABLE HANDLING
TRBL
SHTG
EAS00859
EAS00862
POOR BRAKING PERFORMANCE
UNSTABLE HANDLING
Drum brake
8Worn brake shoe
8Worn or rusty brake drum
8Incorrect brake lever position
8Incorrect brake lever free play
8Incorrect brake camshaft lever position
8Incorrect brake shoe position
8Damaged or fatigued brake shoe spring
8Oil or grease on the brake shoe
8Oil or grease on the brake drum
Handlebar
8Bent or improperly installed handlebar
Steering head components
8Improperly installed 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
EAS00861
FAULTY FRONT FORK LEGS
MALFUNCTION
8Bent or damaged inner tube
8Bent or damaged outer tube
8Damaged fork spring
8Bent or damaged damper rod
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
EAS00866
TRBL
SHTG
TURN SIGNAL REMAINS LIT
8Faulty turn signal relay
8Burnt-out turn signal bulb
FAULTY LIGHTING OR SIGNALING
SYSTEM
TURN SIGNAL BLINKS QUICKLY
8Incorrect turn signal bulb
8Faulty turn signal relay
8Burnt-out turn signal bulb
HEADLIGHT DOES NOT COME ON
8Wrong headlight bulb
8Faulty headlight relay
8Too many electrical accessories
8Hard charging
8Incorrect connection
8Improperly grounded circuit
8Poor contacts (main or light switch)
8Burnt-out headlight bulb
HORN DOES NOT SOUND
8Improperly adjusted horn
8Damaged or faulty horn
8Faulty main switch
8Faulty horn switch
8Faulty battery
8Blown, damaged or incorrect fuse
8Faulty wire harness
HEADLIGHT BULB BURNT OUT
8Wrong headlight bulb
8Faulty battery
8Faulty rectifier/regulator
8Improperly grounded circuit
8Faulty main switch
8Faulty light switch
8Headlight bulb life expired
TAIL/BRAKE LIGHT DOES NOT COME ON
8Wrong tail/brake light bulb
8Too many electrical accessories
8Incorrect connection
8Burnt-out tail/brake light bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
8Wrong tail/brake light bulb
8Faulty battery
8Tail/brake light bulb life expired
TURN SIGNAL DOES NOT COME ON
8Faulty turn signal switch
8Faulty turn signal relay
8Burnt-out turn signal bulb
8Incorrect connection
8Damaged or faulty wire harness
8Improperly grounded circuit
8Faulty battery
8Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
8Faulty turn signal relay
8Faulty main switch
8Faulty turn signal switch
8Incorrect turn signal bulb
8Faulty battery
9-6
YAMAHA MOTOR TAIWAN CO., LTD
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