Yamaha XF50W Service manual

©YAMAHA

XF50W

SERVICE MANUAL

LIT-11616-20-58 3B3-F8197-10

EAS00000

XF50W 2006

SERVICE MANUAL

©2006 by Yamaha Motor Taiwan Co., Ltd.

First edition, September 2006

All rights reserved.

Any reproduction or unauthorized use without the written permission of

Yamaha Motor Taiwan Co., Ltd. is expressly prohibited.

Printed in U.S.A.

LIT-11616-20-58

Q w c C

NOTE:

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!

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

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

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

EAS00007

HOW TO USE THIS MANUAL

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

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

4

5

7 Order

4

5

6

7

8

1

2

3

Job/Part

Removing the cylinder and piston

Cylinder head

Timing chain guide(exhaust side)

Cylinder

Dowel pin

Cylinder gasket

Piston pin clip

Piston pin

Piston

Piston ring set

Q’ty

Remarks

Remove the parts in the order listed.

Refer to”CYLINDER HEAD”.

1

2

1

1

1

1

1

2

Refer to”REMOVING THE CYLINDER

AND PISTON” and “INSTALLING THE

PISTON AND CYLINDER”.

For installation, reverse the removal procedure.

5-31

CYLINDER AND PISTON ENG W

REMOVING THE CYLINDER AND PISTON

1. Remove:

8piston pin clip 1

8piston pin 2

8piston 3 c C

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

NOTE:

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

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

Piston pin puller set

90890-01304(YU-01304)

3

8

2. Remove:

8top ring

82nd ring

8oil ring

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

5-32

1 2

SPEC

3

5

4

CHK i g l

ADJ I ^ < \

6

CHAS (3^3^)

7

ENG

% m

8

COOL j K

FI Ifl ELEC +i q

9 0

TRBL f}

SHTGl • w

*Q

© /•; ® H\

EAS00008

SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols 1 to 9 indicate the subject of each chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Chassis

5 Engine

6 Cooling system

7 Fuel injection system

8 Electrical system

9 Troubleshooting

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 t

B y u m

I o I p I

^4J ^Gj ^Mj

M

New

Symbols i to d in the exploded diagrams indicate the types of lubricants and lubrication points. i Engine oil o Gear oil p Molybdenum-disulfide oil a Wheel-bearing grease s Lithium-soap- based grease d Molybdenum-disulfide grease

Symbols f to g in the exploded diagrams indicate the following. f Apply locking agent (LOCTITE

®

) g Replace the part

EAS00010

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

GEN

INFO 1

0 »

SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS

CHK

ADJ 3

# %

CHAS 4

ENGINE

ENG 5

COOLING SYSTEM

COOL 6

FUEL INJECTION SYSTEM

ELECTRICAL SYSTEM

FI 5

+

ELEC 8

TROUBLESHOOTING

B L

SHTG

GEN j y *

INFO \<^®

CHAPTER 1


SCOOTER IDENTIFICATION 1-1

VEHICLE IDENTIFICATION NUMBER 1-1

MODEL LABEL 1-1

FEATURES 1-2

OUTLINE OF THE FI SYSTEM 1-2

FI SYSTEM 1-3

IMPORTANT INFORMATION 1-4

PREPARATION FOR REMOVAL AND DISASSEMBLY 1-4

REPLACEMENT PARTS 1-4

GASKETS, OIL SEALS AND O-RINGS 1-4

LOCK WASHERS/PLATES AND COTTER PINS 1-5

BEARINGS AND OIL SEALS 1-5

CIRCLIPS 1-5

EQUIPMENT PREPARATION 1-6

CHECKING THE CONNECTIONS 1-7

SPECIAL TOOLS 1-8

SCOOTER IDENTIFICATION

GEN

INFO # ^

EAS00015


SCOOTER IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the frame.

EAS00018

MODEL LABEL

The model label 1 is affixed to the frame trunk.

This information will be needed to order spare parts.

1-1

FEATURES

EAS00896

FEATURES

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions, such as acceleration, deceleration, or operation under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner.

To accommodate this need, this model has adopted an electronically controlled fuel injection(FI) system, in place of the conventional carburetor system. This system can achieve an optimum airfuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors.

The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions.

1 ECU

2 Engine trouble warning light

3 Lean angle cut-off switch

4 Fuel hose

5 Ignition coil

6 Fuel injector

7 Intake air pressure sensor

8 ISC(idle speed control) valve

9 Intake air temperature sensor

1-2

0 Battery q Air filter case w Catalytic converter e Crankshaft position sensor r Coolant temperature sensor t Spark plug y Fuel tank u Fuel pump i Throttle position sensor

FEATURES

EAS00897

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kg/cm

2

, 35.6 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU. Signals that are input from the crankshaft position sensor, intake air pressure sensor, intake temperature sensor and engine temperature sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.

1 Fuel pump

2 Fuel injector

3 Ignition coil

4 ECU

5 Catalytic converter

6 Coolant temperature sensor

7 Crankshaft position sensor


9 Throttle body assembly


1-3 q Air filter case w ISC (idle speed control) valve e Throttle position sensor

A Fuel system

B Air system

C Control system

IMPORTANT INFORMATION

EAS00020


PREPARATION FOR REMOVAL AND DISAS-

SEMBLY

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

2. Use only the proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS”.

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

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

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

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

1 "^N

^M

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.

1-4

^

®-^>

//////K

/////©//

/ / / / / / / / / / / / / /


EAS00023

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

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

EAS00024

BEARINGS AND OIL SEALS

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

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

1 Oil seal c C

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

1 Bearing

EAS00025

CIRCLIPS

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

4 Shaft

1-5


GEN

INFO # ^

EAS00021

EQUIPMENT PREPARATION

Push Rivet (Push type)

Assembly status of the push rivet(push type).

(Ê

<D

Dissembling

1. Press center p i n 1 inward to release the lock.

2. Remove the push rivet main b o d y 2 .

Vo.

; * *

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.

1-6

CHECKING THE CONNECTIONS

EAS00026

CHECKING THE CONNECTIONS

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

1. Disconnect:

8lead

8coupler

8connector

2. Check:

• lead

• coupler

• connector

Moisture -» Dry with an air blower.

Rust/stains -» Connect and disconnect several times.

3. Check:

• all connections

Loose connection -» Connect properly.

NOTE:

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

^ Y v »

^

V ff \°

-V 1 +

? ^ ^ ?

4. Connect:

8lead

8coupler

8connector

NOTE:

Make sure all connections are tight.

1-7

5. Check:

8continuity

(with the pocket tester) p* Pocket tester

90890-03112(YU-03112-C)

NOTE:

8 If there is no continuity, clean the terminals.

8 When checking the wire harness, perform steps (1) to (3).

8 As a quick remedy, use a contact revitalizer available at most part stores.

SPECIAL TOOLS

EAS00027

SPECIAL TOOLS

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

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

NOTE:

8 For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

8 For others, use part number starting with “90890-”.

Tool NO.

90890-01052

Tool name / Function

Meter gear bush tool

Illustration

90890-01085

YU-01083-2

90890-01084

YU-01083-3

90890-01235

YU-01235

90890-01268

YU-01268

90890-01304

YU-01304

This tool is used when removing or installing the meter gear.

Slide hammer bolt(8mm)1

Weight 2

These tools are needed to remove the camshaft.

Rotor holding tool

This tool is used to hold the primary fixed sheave and secondary sheave assembly.

Ring nut wrench

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

Piston pin puller set

^ 2

90890-01337

YM-33285

YM-33285-6

90890-01325

YU-24460-01

90890-01352

YU-33984

90890-01367

YM-A9409-7

90890-01400

YM-A9409-3

This tool is used to remove the piston pin.

Clutch spring holder

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

Radiator cap tester 1

Radiator cap tester adapter 2

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

Fork seal driver weight 1

Fork seal driver attachment 2

This tool is used when installing the fork seal.

1

1

2

2

1-8

Tool NO.

90890-01384

YM-33299

90890-01403

YU-A9472

90890-01444

YM-A9409-7

90890-01468

YU-33270-B

90890-01493

90890-01701

YS-01880-A

90890-03079

YM-34483

90890-03081

YU-33223

90890-03112

YU-03112-C

90890-03174

90890-03141

YU-03141

SPECIAL TOOLS

Illustration Tool name / Function

Oil seal guide

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

Steering nut wrench

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

Steering nut wrench(45mm)

This tool is used to loosen and tighten the upper bearing inner race.

Flywheel puller set

This tool is used to remove the AC magneto rotor.

Socket wrench(39mm)

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

Sheave holder

This tool is used for holding the secondary sheave.

Thickness gauge

This tool is used to measure the valve cleanance.

Compression gauge

This tool is used to measure the engine compression.

Pocket tester

This instrument is invaluable for checking the electrical system.

Digital circuit tester

This instrument is invaluable for checking the electrical system.

1-9

Tool NO.

90890-03141

YU-03141

90890-03182

YU-03182

90890-04101

90890-04058

YM-04058

90890-04145

90890-04019

YM-04019

90890-04148

YM-04148

90890-06760


Timing light

SPECIAL TOOLS

Illustration

This tool is used to check the ignition timing.

FI diagnostic tool

Execute CO adjustment, confirm fault Code, self diagnosis tool

Valve lapper

This tool is needed to remove and install the valve lifters.

Middle driven shaft bearing driver 1

Mechanical seal installer 2

There tools are used to install the water pump seal.

Valve spring compressor

Compressor adapter(Ø16.5mm)

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

Digital tachometer

2

90890-06754

YM-34487

90890-04111

YM-04111

90890-04112

YM-04112

90890-04113

YM-04113

This tool is needed for detecting engine rpm.

Ignition checker

This tool is used to check the ignition system components.

Valve guide remover(4.0mm)

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

Valve guide installer(4.0mm)

This tool is used to install the valve guides.

Valve guide remover(4.0mm)

This tool is used to rebore the new valve guides.

1-10

Tool NO.

90890-01326

YM-01326

90890-01294

YM-01300-1

90890-03153

YU-03153

SPECIAL TOOLS

GEN

INFO # ^


T-handle 1

Damper rid holder 2

These tools are used to hold the damper rod when removing or installing the damper rod.

Illustration

© (D

Pressure gauge

90890-03181

This tool is used to measure fuel pressure.

Fuel pressure adapter

90890-85505

ACC-11001-05-01

This tool is used to measure fuel pressure.

Yamaha bond NO.1215

Sealant (Quick Gasket

®

)

This sealamt (bond) is used on crankcase mating surfaces(e.g., crankcase mating surfaces).

1-11

SPEC 0 *

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1

ENGINE SPECIFICATIONS 2-2

CHASSIS SPECIFICATIONS 2-12

ELECTRICAL SPECIFICATIONS 2-15

CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICA-

TIONS 2-18

TIGHTENING TORQUES 2-19

ENGINE 2-19

CHASSIS 2-21

LUBRICATION POINTS AND LUBRICANT TYPES 2-23

ENGINE 2-23

CHASSIS 2-25

COOLING SYSTEM DIAGRAMS 2-26

CABLE ROUTING 2-29

GENERAL SPECIFICATIONS

SPEC 0 *

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code

3B32(USA)

3B33(CAN)

…

…

Dimensions

Overall length

Overall width

Overall height

Seat height

Wheelbase

Minimum ground clearance

Minimum turning radius

Weight

Wet(without oil and a full fuel tank)

Dry(without oil and fuel)

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

1905mm(75.00in)

685mm(26.97in)

1045mm(41.14in)

735mm(28.94in)

1280mm(50.39in)

115mm(4.53in)

2000mm(78.74in)

90kg(198lb)

85kg(187lb)

175kg(386lb)

…

…

…

…

…

…

…

…

…

…

2-1

ENGINE SPECIFICATIONS


SPEC 0 *

Item Standard

Engine

Engine type

Displacement

Cylinder arrangement

Bore×stroke

Compression ratio

Engine idle speed

Liquid-cooled, 4-stroke, SOHC …

0.049L(49cm³, 2.99cu-in)

Forward inclined single cylinder …

38.0×43.5mm(1.496×1.713in)

12:1

2000~2200r/min

…

…

…

…

Vacuum pressure at engine idle speed 34.7kPa(260mmHg,10.24inHg) …

Standard compression pressure(at sea level) 1450kPa(14.5kg/cm

2

) … at 700r/min

Fuel

Recommended fuel Unleaded gasoline only(USA) …

Regular unleaded gasoline … only(CAN)

Fuel tank capacity

Total 4.5L(0.98 Imp gal, 1.18 US gal) …

Engine oil

Lubrication system

Recommended oil

Wet sump

YAMALUBE4, SAE10W30 or SAE20W40

API service SG type or higher

JASO stand MA

…

…

Quantity

Periodic oil change …

Total amount

0.73~0.83L(0.67~0.76 Imp qt,

0.80~0.90 US qt)

0.80~0.90L(0.74~0.83 Imp qt,

0.87~0.98 US qt)

…

Final gear oil

Recommended oil

Periodic oil change

Total amount

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)

…

…

…

Oil filter

Oil filter type Wire mesh …

Limit

2-2

Item

Oil pump

Oil pump type

Inner rotor to outer rotor tip clearance


SPEC 0 *

Standard Limit

Outer rotor to pump housing clearance

Oil pump housing to inner rotor and outer rotor clearance

Cooling system

Radiator capacity

Radiator cap opening pressure

Trochoid

0.15mm(0.006in) or less

…

0.23mm

(0.009in)

0.13~0.18mm(0.005~0.007in) 0.25mm

(0.010in)

0.07~0.12mm(0.003~0.005in) 0.19mm

(0.008in)

0.26L(0.23 Imp gal, 0.28 US gal) …

107.9~137.3kPa …

(1.1~1.4kg/cm

2

, 15.6~19.9psi)

1.1kPa(0.01kg/cm

2

, 0.16psi) … Valve relief pressure

Radiator core

Width

Height

Depth

Coolant reservoir

Capacity(up to the maximum level mark)

<From low to full level>

Water pump

Water pump type

127.4mm(5.016in)

87mm(3.425in)

16mm(0.630in)

…

…

…

0.25L(0.22 Imp gal, 0.27 US gal) …

0.15L(0.13 Imp gal, 0.16 US gal) …

…

Max. impeller shaft tilt

Single-suction centrifugal pump

…

Electric and kick starter

0.15mm

(0.0059in)

… Starting system type

Electric fuel injection

Type

Manufacturer

Spark plug

Model(manufacturer)×quantity

Spark plug gap

Cylinder head

Volume

Maximum warpage

, i i ,

3B3

AISAN

CR7E(NGK)×1

0.7~0.8mm(0.028~0.031in)

…

…

…

…

3.1~3.5cm³(0.19~0.21cu-in) …

… 0.05mm

(0.0020in)

>

>

1

F

' •

2-3

Item

Camshaft

Drive system

Intake camshaft lobe dimensions


SPEC 0 *

Standard Limit

Chain drive(left) …

B

Measurement A

Measurement B

Exhaust camshaft lobe dimensions

Measurement A

Measurement B

•^

6 A

B •

Maximum camshaft runout

30.158~30.258mm

(1.1873~1.1913in)

25.082~25.182mm

(0.9875~0.9914in)

30.158~30.258mm

(1.1873~1.1913in)

25.020~25.120mm

(0.9850~0.9890in)

…

30.058mm

(1.1834in)

24.982mm

(0.9835in)

30.058mm

(1.1834in)

24.920mm

(0.9811in)

0.03mm

(0.0012in)

2-4

Item

Timing chain

Model/number of links

Tensioning system

Valve, valve seats, valve guides

Valve clearance(cold)

Intake

Exhaust


SPEC 0 *

Standard Limit

Morse 92RH2005/82

Automatic

0.10~0.16mm

(0.0039~0.0063in)

0.18~0.24mm

(0.0071~0.0094in)

…

…

…

…

Valve dimensions y v V V B r \

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

\ .

\ . C

T\

15.4~15.6mm

(0.6063~0.6142in)

16.4~16.6mm

(0.6457~0.6535in)

1.48~2.19mm

(0.0583~0.0862in)

1.48~2.19mm

(0.0583~0.0862in)

0.9~1.1mm

(0.0354~0.0433in)

0.9~1.1mm

(0.0354~0.0433in)

0.70mm(0.0276in)

0.70mm(0.0276in)

3.975~3.990mm

(0.1565~0.1571in)

3.975~3.990mm

(0.1565~0.1571in)

4.000~4.012mm

(0.1575~0.1580in)

4.000~4.012mm

(0.1575~0.1580in)

…

…

…

…

J D

1.6mm

(0.0630in)

1.6mm

(0.0630in)

…

…

3.945mm

(0.1553in)

3.930mm

(0.1547in)

4.050mm

(0.1594in)

4.050mm

(0.1594in)

2-5

Item

Valve stem to valve guide clearance

Intake


SPEC 0 *

Standard Limit

Exhaust

Valve stem runout

0.010~0.037mm

(0.0004~0.0015in)

0.025~0.052mm

(0.0010~0.0020in)

…

0.080mm

(0.0031in)

0.100mm

(0.0039in)

0.010mm

(0.0004in)

%

Valve seat width

Intake

Exhaust

^

0.9~1.1mm

(0.0354~0.0433in)

0.9~1.1mm

(0.0354~0.0433in)

1.6mm

(0.0630in)

1.6mm

(0.0630in)

2-6

Item

Valve springs

Free length

Intake

Exhaust

Installed length(valve closed)

Intake

Exhaust

Compressed spring force(installed)

Intake

Exhaust

Spring tilt


SPEC 0 *

Standard Limit

39.35mm(1.5492in)

41.57mm(1.6366in)

28.0mm(1.1024in)

30.0mm(1.1811in)

91.1~104.9N

(9.3~10.7kg, 20.48~23.58lb)

107.9~124.1N

(11.0~12.7kg, 24.26~27.90lb)

…

…

37.38mm

(1.4717in)

39.49mm

(1.5547in)

…

…

— » •

V///////////A

Intake

Exhaust

Winding direction(top view)

Intake

Exhaust

…

…

Clockwise

Clockwise

2.5°/1.7mm

(2.5°/0.0669in)

2.5°/1.8mm

(2.5°/0.0709in)

…

…

Valve seat reformed

Cylinder

Cylinder arrangement

Bore×stroke

Compression ratio

Bore

Maximum taper

Maximum out-of-round

2-7

Yes …

Forward inclined single cylinder …

38.0×43.5mm(1.496×1.713in) …

12:1

38.000~38.010mm

(1.496~1.497in)

…

…

…

…

0.05mm

(0.0020in)

0.05mm

(0.0020in)

Item

Piston

Piston-to-cylinder clearance

Diameter D


SPEC 0 *

Standard Limit

0.010~0.035mm

(0.0004~0.0014in)

37.975~37.990mm

(1.4951~1.4957in)

0.150mm

(0.0059in)

…

- D —

Height H

Piston pin bore(in the piston)

Diameter

"X.

Offset

Offset direction

Piston pin

Outside diameter

Piston rings

Top ring

_H

5.0mm(0.1969in)

10.002~10.013mm

(0.3938~0.3942in)

0.35~0.65mm

(0.0138~0.0256in)

Intake side

9.996~10.000mm

(0.3935~0.3937in)

Ring type

Dimensions(B×T)

End gap(installed)

Ring side clearance

2nd ring

Ring type

Dimensions(B×T)

End gap(installed)

Ring side clearance

T

B

\ I B

T I

Barrel

0.8×1.65mm

(0.0315×0.0650in)

0.05~0.15mm

(0.0020~0.0059in)

0.03~0.07mm

(0.0012~0.0028in)

Taper

0.8×1.5mm

(0.0315×0.0591in)

0.05~0.17mm

(0.0020~0.0067in)

0.02~0.06mm

(0.0008~0.0024in)

…

10.043mm

(0.3954in)

…

…

9.976mm

(0.3928in)

…

…

0.40mm

(0.0157in)

0.12mm

(0.0047in)

…

…

0.52mm

(0.0205in)

0.12mm

(0.0047in)

2-8


SPEC 0 *

Standard Limit Item

Oil ring

Dimensions(B×T)

End gap(installed)

Ring side clearance

i 1 B

1 i i

T ,

1.5×1.6mm

(0.0591×0.0630in)

0.2~0.7mm

(0.0079~0.0276in)

0.03~0.15mm

(0.0012~0.0059in)

…

…

…

2-9

Item

Rocker arm/rocker arm shaft

Rocker arm inside diameter

Rocker arm shaft outside diameter

Arm-to-shaft clearance

Connecting rod

Connecting rod length

Small end inside diameter


SPEC 0 *

Standard Limit

10.000~10.015mm

(0.3937~0.3943in)

9.981~9.991mm

(0.3930~0.3933in)

0.009~0.034mm

(0.0004~0.0013in)

79.95~80.05mm

(3.1476~3.1516in)

10.015~10.028mm

(0.3943~0.3948in)

10.030mm

(0.3949in)

9.950mm

(0.3917in)

…

…

…

Crankshaft

Width A

Maximum runout C

Big end side clearance D

Big end radial clearance E

1^

42.45~42.50mm

(1.671~1.673in)

…

0.15~0.45mm

(0.006~0.018in)

0~0.010mm

(0~0.0004in)

…

0.03mm

(0.0012in)

1.00mm

(0.0394in)

…

2-10

Item

Clutch

Clutch type

Clutch shoe thickness

Clutch shoe spring free length

Clutch housing inside diameter

Compression spring free length

Weight outside diameter

Clutch-in revolution

Clutch-stall revolution

V-belt

V-belt width

Transmission

Transmission type

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Single speed automatic

Maximum main axle runout

Maximum drive axle runout

Air filter type

Fuel pump

Pump type

Model(manufacturer)

Output pressure

Throttle body

Throttle cable free play

(at the flange of the throttle grip)

ID mark


SPEC 0 *

Standard Limit

Automatic centrifugal

3.7mm(0.146in)

30.1mm(1.185in)

107mm(4.213in)

76.4mm(3.008in)

15.0mm(0.591in)

3050~3450r/min

5000~6000r/min

17.9mm(0.705in)

V-belt automatic

Helical gear

50/13(3.846)

Helical gear

43/12(3.583)

3.087~0.945:1

…

…

Wet element

…

…

…

…

…

…

0.04mm

(0.002in)

0.04mm

(0.002in)

…

Electrical

3B3(AISAN)

250kPa(2.5kg/cm

2

, 35.6psi)

…

…

…

1.5~3.5mm(0.06~0.14in)

3B31 00

…

2.0mm

(0.079in)

…

107.5mm

(4.232in)

…

14.5mm

(0.571in)

…

…

16.1mm

(0.634in)

…

…

2-11

CHASSIS SPECIFICATIONS

SPEC 0 *


Standard Limit Item

Frame

Frame type

Caster angle

Trail

Front wheel

Wheel type

Rim

Size

Material

Wheel travel

Wheel runout

Maximum radial wheel runout

Maximum lateral wheel runout

Wheel axle bending limit

Rear wheel

Wheel type

Rim

Size

Material

Wheel travel

Wheel runout

Maximum radial wheel runout

Maximum lateral wheel runout

Front tire

Tire type

Size

Model(manufacturer)

Tire pressure(cold)

0~175kg(0~386lb)

Minimum tire tread depth

2-12

Item

Rear tire

Tire type

Size

Model(manufacturer)

Tire pressure(cold)

0~175kg(0~386lb)

Minimum tire tread depth

Front brake

Brake type

Operation

Brake lever free play(at lever end)

Brake drum inside diameter

Lining thickness

Rear brake

Brake type

Operation

Brake lever free play(at lever end)

Brake drum inside diameter

Lining thickness

Front suspension

Suspension type

Front fork type

Front fork travel

Spring

Free length

Installed length

Spring rate(K1)

Spring stroke(K1)

Optional spring available

Fork oil

Recommended oil

Quantity(each front fork leg)

Inner tube outer diameter

Inner tube bending limit


SPEC 0 *

Standard Limit

Tubeless

120/90-10 57J

C-6022(CHENG SHIN)

…

…

…

175kPa(1.75kgf/cm², 25psi)

…

…

0.8mm

(0.03in)

Drum brake

Right-hand operation

10~20mm(0.39~0.79in)

110mm(4.33in)

4.0mm(0.16in)

Drum brake

Left-hand operation

10~20mm(0.39~0.79in)

110mm(4.33in)

4.0mm(0.16in)

…

…

…

110.5mm

(4.35in)

2.0mm

(0.08in)

…

…

…

110.5mm

(4.35in)

2.0mm

(0.08in)

Telescopic fork

Coil spring

65mm(2.56in)

202.2mm(7.96in)

188.2mm(7.41in)

10.1N/mm(1.03kg/mm)

0~65mm(0~2.56in)

No

Fork oil 10W or equivalent

0.042L(0.038lmp qt,

0.046 US qt)

26mm(1.02in)

…

…

…

…

198.2mm

(7.80in)

…

…

…

…

…

…

…

0.2mm

(0.01in)

2-13

Spring rate(K2)

Spring stroke(K1)

Spring stroke(K2)

Optional spring available


SPEC 0 *

Standard Limit Item

Steering system

Steering bearing type

Lock-to-lock angle(left)

Lock-to-lock angle(right)

Rear suspension

Suspension type

Rear shock absorber assembly type

Rear shock absorber assembly travel

Spring

Free length

Installed length

Spring rate(K1)

Angular bearing

46°

46°

Unit swing

Coil spring

45mm(1.77in)

176.5mm(6.95in)

162.5mm(6.40in)

28.03N/mm

(2.85kg/mm, 159.59lb/in)

42.18N/mm

(4.30kg/mm, 240.79lb/in)

0~17mm(0~0.67in)

17~45mm(0.67~1.77in)

No

…

…

…

…

…

…

…

…

…

…

…

…

…

2-14

ELECTRICAL SPECIFICATIONS

SPEC 0 *


Item Standard

System voltage 12V …

Ignition system

Ignition system type

Ignition timing

Advancer type

Transistorized coil ignition

5° BTDC at 2000~2200r/min

Digita

Crankshaft position sensor resistance/color 248~372 at 20°C(68°F)/ white/red-white/blue

…

…

…

…

Ignition coil

Model(manufacturer)

Minimum ignition spark gap

Primary coil resistance

Secondary coil resistance

Spark plug cap

Material

Resistance

Charging system

System type

Model(manufacturer)

Nominal output

Stator coil resistance/color

3B3 00(T-MORIC)

6mm(0.24in)

2.16~2.64

Q at 20°C(68°F)

Resin

4~6k £2 at 20°C(68°F)

AC magneto

F3B3(T-MORIC)

14V 130W/5000r/min

0.28~0.42 at 20°C(68°F)/ white-white

…

…

…

8.64~12.96k

£2 at 20°C(68°F) …

…

…

…

…

…

…

Rectifier/regulator

Regulator type

Model(manufacturer)

No load regulated voltage

Rectifier capacity

Withstand voltage

Battery

Battery type(manufacturer)

Battery voltage/capacity

Specific gravity

Ten hour rate amperage

Headlight type

Indicator light(voltage/wattage×quantity)

Turn signal indicator light

High beam indicator light

Engine trouble warning light

Water temperature indicator light

Semiconductor, short circuit …

SH745-AA(SHINDENGEN) …

13.0~14.0V

24A

200V

GTX5L-BS(GS)

12V/4AH

1.330

0.4A

Halogen bulb

14V 3.0W×1

12V 1.7W×1

12V 1.7W×1

14V 1.7W×1

…

…

…

…

…

…

…

…

…

…

…

…

Limit

2-15


SPEC 0 *

Standard Limit Item

Bulbs(voltage/wattage×quantity)

Headlight

Tail/brake light

Front turn signal light

Rear turn signal light

License plate light

Speedometer light

Electric starting system

System type

Starter motor

Model(manufacturer)

Suction voltage

Power output

Brushes

Overall length

12V 35/35W×1

12V 5/21W×1

12V 10W×2

12V 10W×2

12V 5W×1

12V 1.7W×1

Constant mesh

3B3 00(T-MORIC)

12V

0.25kW

…

…

…

…

…

…

…

…

…

…

Quantity

Spring force

Commutator diameter

7.0mm(0.28in)

2

3.92~5.88N

(400~600gf, 14.11~21.16oz)

17.6mm(0.69in)

3.5mm

(0.14in)

…

…

0.0378~0.0462 at 20°C(68°F)

1.35mm(0.05in)

16.6mm

(0.65in)

…

…

Commutator resistance

Mica undercut(depth)

Starter relay

Model(manufacturer)

Amperage

Coil resistance

Suction voltage

Horn

Horn type

Model(manufacturer)

Maximum amperage

Performance

Coil resistance

Turn signal relay

Relay type

Model(manufacturer)

Self-cancelling device built-in

Turn signal blinking frequency

Wattage

5WC 00(OMRON)

50A

90-110

More than DC10V

Plane

GF-127(NIKKO)

1.0A

95~115dB/2m

3.96~4.10W at 20°C(68°F)

Condenser

FZ222SD(DENSO)

NO

75~95cycles/minute

10W×2+3.4W

…

…

…

…

…

…

…

…

…

…

…

…

…

…

2-16

Item

Fuse(amperage×quantity)

Main fuse

Fuel gauge

Model(manufacturer)

Sender unit resistance-full

Sender unit resistance-empty

Starting circuit cut-off relay

Model(manufacturer)

Coil resistance

Diode

Radiator fan

Model(manufacturer)

Running rpm

Thermostat

Type(manufacture)

Valve opening temperature

Valve full open temperature

Valve lift-full open

Coolant temperature sensor

Model(manufacturer)

Coil resistance at 20°C(68°F)

Coil resistance at 80°C(176°F)

Intake air pressure sensor

Output voltage

Intake air temperature sensor

Coil resistance/color


SPEC 0 *

Standard Limit

15A×1

3B3(AISAN)

4~10 Q

90~100 £2

4HC1(MATSU SHITA)

72~88

YES

5ST1(LUNTAI)

10000r/min or less

…

…

…

4BA1(NIPPON THERMOSTAT) …

83~87°C …

…

100°C

3.5mm

…

5YP1(DENSO)

2.32~2.59k

£2

0.310~0.326k

£2

0.789~4.0V

5.7~6.3k at 20°C(68°F)/ brown-white/black-blue

…

…

…

…

…

…

…

…

…

…

…

Speed sensor

Output voltage

When sensor is on

When sensor is off

Throttle position sensor

Voltage/color

Output voltage(closed position)/color

ISC(idle speed control) valve

Resistance/color

DC 4.8V or more

DC 0.6V or less

5V/blue-black/blue

0.63~0.73V/yellow-black/blue

…

…

18~22 at 20°C(68°F)/ pink-green/yellow or gray-sky blue

…

…

…

Lean angle cut-off switch

Voltage

Less than 65°

More than 65°

0.4~1.4V

3.7~4.4V

…

…

2-17

CONVERTION TABLE / GENERAL TIGHTENING

TORQUE SPECIFICATIONS

SPEC

EAS00028

CONVERSION TABLE

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

Use this table to convert METRIC unit data to

IMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMPERIAL

** mm

2 mm

0.03937

0.03937

** in

0.08 in

CONVERSION TABLE

Weight

Speed

Distance

Volume/

Capacity

Misc.

METRIC TO IMPERIAL

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

7.233

86.794

0.0723

0.8679 ft·lb in·lb ft·lb in·lb kg g km/hr km m m cm mm cc (cm

3

) cc (cm

3

) lt (liter) lt (liter)

2.205

0.03527

0.6214

0.6214

3.281

1.094

0.3937

0.03937

0.03527

0.06102

0.8799

0.2199 kg/mm kg/cm

(°C)

2

Centigrade

55.997

14.2234

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

2

)

Fahrenheit (°F)

EAS00030

GENERAL TIGHTENING TORQUE

SPECIFICATIONS

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

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

A: Width across flats

B: Thread diameter

General tightening torques

Nm m

# kg fMb

10 mm 6 mm

12 mm 8 mm

6

15

14 mm 10 mm 30

17 mm 12 mm 55

0.6

1.5

3.0

5.5

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13.0 94

4.3

11

22

40

2-18

TIGHTENING TORQUES

SPEC


ENGINE

Exhaust pipe stud bolt

Oil check bolt

Cylinder head cover

Cylinder head and cylinder

Cylinder head(timing chain side)

Spark plug

Camshaft sprocket

Timing chain tensioner(body)

Guide stopper2

Timing chain tensioner(plug)

Water pump assembly

Thermostat cover air bleed bolt

Thermostat cover

Fan case

Fan

Radiator drain bolt

Radiator cover

Oil pump assembly

Engine oil drain plug

Intake manifold

Air filter assembly

Injector

Intake manifold side band

Air filter assembly side band

Protector

Exhaust pipe

Stay fender

Muffler

Reed valve and holder

AI filter case

Oil guide

Crankcase(left and right)

Cylinder stud bolt

Drain bolt(transmission oil fill bolt)

V-belt case cover

Drain bolt(transmission oil)

Transmission case

Transmission case

Cover1(starter clutch)

Hold lead plate bolt

Bolt

-

Screw

Screw

-

Bolt

Bolt

Bolt

Band

Band

Screw

Nut

Bolt

Bolt

-

-

Bolt

Nut

Bolt

-

Bolt

Bolt

Bolt plug

Bolt

-

Bolt

Bolt

Bolt

Bolt

Nut

Bolt

-

-

Bolt

Bolt

Bolt

Bolt

Bolt

-

Q

’ ty

Tightening torque

Nm m » kg ft » lb

M8 2 13 1.3 9.4

M6 1 7 0.7 5.1

M6 4 10 1.0 7.2

M6 4 10 1.0 7.2

—4\\4jl

M6 2 10 1.0 7.2

M10 1 13 1.3 9.4

M8 1 30 3.0 21.7

M6 2 9 0.9 6.5

M6 1 7 0.7 5.1

M8 1 8 0.8 5.8

M6 3 10 1.0 7.2

M6 1 10 1.0 7.2

M6 2 10 1.0 7.2

M6 4 10 1.0 7.2

M6 3 9 0.9 6.5

M10 1 1 0.1 0.7

6 3 2 0.2 1.5

M5 2 4 0.4 2.9

M35 1 32 3.2 23.1

M6 2 10 1.0 7.2

M6 2 10 1.0 7.2

M6 1 12 1.2 8.7

M4 1 3 0.3 2.2

M4

M6

1

2

3

9

0.3

0.9

2.2

6.5

When fastened, apply screw retaining com-

M8 2 13 1.3 9.4 pound.

M8 2 10 1.0 7.2

M8 2 31 3.1 22.4

M6 1 14 1.4 10.1

M6 1 7 0.7 5.1

M6 2 10 1.0 7.2

M6 8 10 1.0 7.2

M6 4 13 1.3 9.4

M8 1 23 2.3 16.6

M6 6 10 1.0 7.2

M6 1 13 1.3 9.4

M6 6 11 1.1 8.0

M6 2 10 1.0 7.2

M6 7 10 1.0 7.2

M6 1 10 1.0 7.2

2-19

Drain bolt(engine oil)

Centerstand spring

Starter clutch

Kickstarter

Primary fixed sheave

Clutch housing

Stator coil

Pulser coil

AC magneto rotor

Starter motor assembly

Ignition coil

Coolant temperature sensor

Cylinder head tightening sequence

(1 -» 2 -» 3 4 -» 2 -» 5 -» 6)

-

Hook

Nut

Bolt

Nut

Nut

Bolt

Screw

Nut

Bolt

Bolt

-


SPEC 0 *

Q

’ ty

Tightening torque

Nm m » kg ft » lb

M8 1 23 2.3 16.6

M6 1 7 0.7 5.1

M22 1 90 9.0 65.1

Left-hand thread

M6 1 12 1.2 8.7

M10 1 30 3.0 21.7

M10 1 40 4.0 28.9

M5 3 4 0.4 2.9 i

ÎLT

M6 2 7 0.7 5.1

M12 1 43 4.3 31.1

M6 2 13 1.3 9.4

M6 2 7 0.7 5.1

M12 1 22 2.2 15.9

2-20


SPEC 0*"

CHASSIS

Frame and engine bracket3

Engine bracket3 and engine

Handlebar bracket and steering shaft

Rear shock absorber and frame

Rear shock absorber and engine

Steering shaft and upper bearing inner race

Steering shaft and ring nut

Front fork and lower bracket

Handlebar bracket and handlebar lower holder

Handlebar lower holder and handlebar upper holder

Throttle cable and holder lever2

Throttle cable and throttle body

Front reflector

Fuel tank

Fuel pump

Single seat lock assembly

Trunk

Bottom plate and single seat lock bracket

Bottom plate and frame(single seat)

Single seat and frame(single seat)

Single seat lock assembly and trunk

Resin part and resin cover

Footrest board

License bracket

Rear turn signal light

License light

Front wheel shaft

Front brake camshaft lever

Rear wheel shaft

Rear brake camshaft lever

Rear brake pin pivot

Speedometer cable

Main switch and headlight stay bracket

Headlight body and headlight unit

Headlight stay bracket and headlight body

Lower bracket and headlight stay bracket

Handlebar bracket and headlight stay bracket

ECU and trunk

Rear reflector and license bracket

Taillight underside

M10

M10

M10

M10

M8

BC1

BC1

M10

M10

M8

M5

M5

M5

M6

M5

M6

M6

M6

M6

M6

M6

About M5

M6

M6

M6

About M5

M10

M6

M14

M6

M8

M12

M6

M5

M6

M8

M8

M6

M5

M6

Tightening torque

Nm m » kg ft » lb

46 4.6 33.1

58 5.8 42.0

60 6.0 43.4

30 3.0 21.7

16 1.6 11.6

7 0.7 5.1 See”NOTE”

30 3.0 21.7 See”NOTE”

30 3.0 21.7

48 4.8 34.7

28 2.8 20.3

4 0.4 2.9

5 0.5 3.6

7 0.7 5.1

10 1.0 7.2

4 0.4 2.9

12 1.2 8.7

12 1.2 8.7

7 0.7 5.1

10 1.0 7.2

10 1.0 7.2

7 0.7 5.1

2 0.2 1.5

7 0.7 5.1

7 0.7 5.1

4 0.4 2.9

2 0.2 1.5

48 4.8 34.7

8 0.8 5.8

120 12.0 86.8

10 1.0 7.2

16 1.6 11.6

5 0.5 3.6

7 0.7 5.1

4 0.4 2.9

10 1.0 7.2

23 2.3 16.6

23 2.3 16.6

7 0.7 5.1

2 0.2 1.5

2 0.2 1.5

2-21


SPEC 0 *

NOTE :

1 . First,tighten the upper bearing inner race approximately 7Nm(0.7m

» kg, 5.1ft

» lb) by using the torque wrench and check turn steering shaft smoothly.

2. Second,hold the upper bearing inner race and tighten the ring nut 30Nm(3.0m

» kg, 21.7ft

» lb) by using the torque wrench.

3. Final,operate the steering shaft together with the steering stem nut now.

© Upper bearing inner race

(2) Ring nut

2-22

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC 0 *

EAS00031


ENGINE

Lubrication Point

Oil seal lips

O-rings(except V-belt drive unit)

O-ring(fuel injector assembly)

Cylinder head tightening nut mounting surface

Cylinder head stud bolt thread

Cylinder head gasket dowel pin

Crankshaft pin outside surface

Connecting rod

Piston outside and ring groove

Piston pin outside surface surface and bolt thread

Crankshaft journal

Piston(balancer) outside surface

Piston pin(balancer) outside surface

Camshaft lobe

Camshaft profile journal

Valve stems(intake and exhaust)

Valve stem seals(intake and exhaust)

Valve pads(intake and exhaust)

Valve stem ends(intake and exhaust)

Oil pump assembly inside surface

Oil pipe union bolt thread and surface

Starter clutch pin and weight

Kick pinion gear and kick pinion gear clip thrust surface

Idle gear 1 thrust surface

Idle gear2

Main and drive axle serration(sprocket)

Lubricant

^ ^ T L S ^ P ^ L

^ ^ L S ^ ^ A

~~^\4Jl

~~^%4Jl

~ ^ l 4

^ H I 4

~~^\4Jl

^ H I 4

—H1C4J

~~^\4Jl

^ H I 4

^ H I 4

~ ^ 4

—^1^4^

^ H I C M !

^ H I C M !

^ H I C M I

^ H l M

— H l M l

^ H l K 4 j

^ H I 4

^ H l f 4 j

^ H l M

^ H l M

^ H l f 4 j

~~^\4Jl

~HI^G]

2-23


SPEC 0 *

Lubrication Point

Drive axle taper rollor bearing

Transmission bearings

Secondary fixed sheave inner surface

Secondary sliding sheave torque cam ditch

Crankcase mating surfaces

Lubricant

—HI^GJ

^HICGJ

BEL-RAY asembly lube

®

BEL-RAY asembly lube

®

Sealant

2-24


SPEC 0*"

EAS00032

CHASSIS

Lubrication Point

Front wheel oil seal lips

Steering bearing and bearing races(upper and lower)

Frame head pipe dust seal lips(lower)

Tube guide(throttle grip) inner surface

Brake lever and lever holder bolt sliding surface

Centerstand pivoting point and sliding surface

Single seat lock cable inner surface

Engine bracket and engine mound bolt sliding surface

Lubricant

^^LSp^L

^^LSp^L

^ ^ T L S ^ ^ ^ L

^ L S ^ ^ A

^^LSpn

^^f LS^^^L

^ ^ T L S ^ ^ ^ L

^ L S ^ H

2-25

COOLING SYSTEM DIAGRAMS

SPEC 0 *

EAS00033


1 Raidator cap

2 Coolant reservoir hose

3 Radiator inlet hose

4 Air bleed bolt

5 Radiator outlet hose

6 Fan case

7 Damper

8 Raidator cover

A Insert until contacting with the latch of radiator tank.

B Install white paint marck of pipe 3 toward the direction of radiator cover.

C Install clip for the turning knob to face forward.

D Hand and fix the claw of fan case 1 on the radiator cover.

E Insert to the bent part of radiator pipe.

F Make sure that hose is inserted to the bottom.

G Install clip for the turning knob to face downward.

2-26

1 Radiator

2 Radiator inlet hose


4 Thermostat

5 Water pump outlet hose


SPEC 0 *

A Install clip for the turning knob to face downward.

2-27


SPEC 0 *

1 Thermostat assembly inlet breather hose

2 Breather hose

3 Water pump outlet hose


5 Water pump

A Install the paint mark of hose facing up.

B Install clip for the turning knob to face downward.

C Make sure that hose is inserted to the bottom.

D Align the paint mark of pipe 7 to the stopper of water pump Ass’y.

E Insert until contacting with the stopper.

2-28

EAS00035

CABLE ROUTING

1 Hose3

2 ECU

3 Ignition coil

4 Sidestand switch lead

5 Main switch

6 Hose


8 Wiring harness

9 Throttle cable kit

0 Rear brake cable q AC magneto lead w Hose5 e Starter motor lead

CABLE ROUTING

SPEC 0 * r t

A

B

C

D

E

Battery positive lead

Wire lead cover

Assemble cramp on the Tstud at the right of back stay.

Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of box bracket 1 .

Install crap on the hols of stay 1 .

Penetrate thermo unit lead through the rear of hose 3.

Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of down tube 1 .

F Fix connector cover on the head light stay.

G Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of fuel tank bracket 2.

H Connect AC magnet lead on the cramp of fan case

1.

D-D

6

E-E

2-29

F-F G-G

CABLE ROUTING

SPEC 0 *

1 Speedometer A

2 Rectifier/Regulator cover the coupler.

3 Turn signal relay B

4 Throttle cable Ass’y C

5 Holder

6 Cable holder

7 Rear brake cable

8 Speedometer cable cable, fix crank case 1 .

When locking, make sure that the stopper at the front of holder touches the posi-

9 Front brake cable tion of crank case 1 .

0 Headlight D q Horn cable, install the protruding w Starting circuit cut-off relay part of cramp on the hole of under cover.

E Install the horn of coupler accotding to the direction shown in the drawing, and make sure that it is not loosen easily.

F Penetrate through the speed meter cable.

2-30

CABLE ROUTING

SPEC 0 *

1 Fuel pump i Rear fender

2 FI diagnostic tool conneco Fuel injector lead tor

3 Fuse box

4 Battery negative lead

5 ECU lead

6 Battery positive lead

7 Starter relay p s

A

B

Sub-wire harness lead valve lead

Crankcase2

Enter slant angle of sensor.

Enter tail/brake light.

E Put the idle speed control lead and wire sub lead in, and then close the cramp. a ISC(idle speed control) F Wire the starting device of the rear fender of rear motor lead and crank case 2.

Do not clip the lead in.

8 AC magneto lead

9 Tail/brake light lead

0 Starter motor lead q Holder w Cable holder

C

D

Fix throttle cable Ass’y. Install the protruding part of cramp on the hole of fuel tank bracket.

Fix throttle cable Ass’y. Ine Lean angle cut-off switch r Ignition coil t Throttle cable Ass’y y Rear brake cable u Wiring harness stall the protruding part of cramp on the hole of foot rest bracket. dx

©©

D

©

C © ® © © ©

5

A-A u o t

D-D E-E

B-B p a

2-31

E

F-F

C-C s F y

G-G

1 Speedometer

2 Rectifier/Regulator

3 Horn

4 Turn signal relay

5 Front brake cable

6 Rear brake cable

7 Throttle cable Ass’y

8 Speedometer cable

9 Rectifier/Regulator lead

0 Wiring harness q Main switch lead w Horn lead

CABLE ROUTING

SPEC 0 *

A Penetrate the rear brake D Penetrate the main switch cable and throttle cable Comp. Lead into the conthrough the left side of car body.

B Make sure to install the cramp on the head light

E nector cover.

Penetrate horn cable through the connector cover without sticking out stay. horn cable.

C Install the protruding part of F Enter rectifier and regulator cable strap of electrical wire harmess Ass’y on the hole of head light stay.

Ass’y.

1

2

G-

®-

-©

C

B

C xi)

-©

C

A

F

XD

-©

®

0

A-A B-B

2-32

G Let the left and right flasher lights, meter, and right lead wire of handle bar switch to face upward, let the main switch, front and rear brake switchand left lead wire of handle bar switch to face downward, connect to the coupler, and then store in the connector cover.

CABLE ROUTING

SPEC 0 *

1

2 m-

®-

C

-©

C

B

C-

F

A-A B-B

0

2-33

CABLE ROUTING

SPEC 0 *

1 Turn signal light lead(right) A Penetrate the rear brake

2 Handlebar switch lead(right)

3 Front brake light switch lead

4 Turn signal light lead(left)

B through the left side of car body.

Make sure to install the cramp on the head light

5 Handlebar switch lead(left)

6 Rear brake light switch

7 Throttle cable Ass’y

8 Front brake cable

9 Rear brake cable

0 Backward screw q Forward screw

C

D stay.

Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of head light stay.

Penetrate the main switch

Comp. Lead into the connector cover.

E Penetrate horn cable through the connector cover without sticking out horn cable.

F Enter rectifier and regulator

Ass’y.

G First, tighting the backward screw and tighting the forward screw.

2-34

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

CHK

ADJ

< &

INTRODUCTION 3-1

PERIODIC MAINTENANCE AND MINOR REPAIR 3-2

PERIODIC MAINTENANCE CHART FOR THE EMISSION CON-

TROL SYSTEM 3-2

GENERAL MAINTENANCE AND LUBRICATION CHART 3-3

COVER AND PANEL 3-5

SIDE COVERS AND TAIL/BRAKE LIGHT 3-5

SINGLE SEAT AND TRUNK 3-7

LEG SHIELD1,2 3-8

FOOTREST BOARD AND INNER FENDER 3-9

ENGINE 3-10

ADJUSTING THE VALVE CLEARANCE 3-10

CHECKING THE ENGINE IDLING SPEED 3-16

ADJUSTING THE THROTTLE CABLE FREE PLAY 3-17

CHECKING THE SPARK PLUG 3-18

CHECKING THE IGNITION TIMING 3-20

MEASURING THE COMPRESSION PRESSURE 3-22

CHECKING THE ENGINE OIL LEVEL 3-24

CHANGING THE ENGINE OIL 3-25

CHANGING THE TRANSMISSION OIL 3-27

MEASURING THE ENGINE OIL PRESSURE 3-28

REPLACING THE AIR FILTER ELEMENT 3-30

CHECKING THE THROTTLE BODY JOINT AND INTAKE

MANIFOLD 3-32

CHECKING THE FUEL HOSE 3-32

CHECKING THE BREATHER HOSES 3-33

CHECKING THE EXHAUST SYSTEM 3-34

CHECKING THE COOLANT LEVEL 3-35

CHECKING THE COOLING SYSTEM 3-36

CHANGING THE COOLANT 3-37

CHASSIS 3-40

ADJUSTING THE FRONT BRAKE 3-40

ADJUSTING THE REAR BRAKE 3-40

CHECKING THE FRONT AND REAR BRAKE SHOES 3-41

CHECKING AND ADJUSTING THE STEERING HEAD 3-42

CHECKING THE FRONT FORK 3-44

CHECKING THE TIRES 3-45

CHK

ADJ

< &

CHECKING THE WHEELS 3-48

CHECKING AND LUBRICATING THE CABLES 3-48

LUBRICATING THE LEVERS AND PEDALS 3-49

LUBRICATING THE CENTERSTAND 3-49

ELECTRICAL SYSTEM 3-50

CHECKING AND CHARGING THE BATTERY 3-50

CHECKING THE FUSE 3-56

REPLACING THE HEADLIGHT BULB 3-58

ADJUSTING THE HEADLIGHT BEAM 3-59

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


PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

NO. ITEM ROUTINE

1

2

3

4

* Fuel line

Spark plug

* Valve clearance

*

Crankcase breather system

• Check fuel and vacuum hoses for cracks or damage.

• Replace if necessary.

• Check condition.

• Adjust gap and clean.

• Replace at 4000 mi (7000 km) or

12 months and thereafter every

4000 mi (6000 km) or 12 months.

• Check and adjust valve clearance when engine is cold.

• Check breather hose for cracks or damage.


5

6

7

* Fuel injection • Check engine idle speed.

* Exhaust system

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

* Air induction system

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

• Replace any damaged parts.

INITIAL

600 mi

(1,000 km) or

1 month

2,000 mi

(4,000 km) or

6 months

ODOMETER READING

4,000 mi

(7,000 km) or

12 months

6,000 mi 8,000 mi

(10,000 km) or

18 months

(13,000 km) or

24 months

10,000 mi

(16,000 km) or

30 months

V

V V V V V

V Replace. V Replace.

Every 6000 mi (10000 km)

V

V V V V V

V V V V V V

V V V V V

V V V V V

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

3-2


CHK

ADJ

GENERAL MAINTENANCE AND LUBRICATION CHART

< &

NO. ITEM ROUTINE

1

2

3

4

5

6

7

* Air filter element

* Front brake

* Rear brake

* Wheels

* Tires

* Wheel bearings

* Steering bearings

• Replace.

• Check operation.

• Adjust cable and replace brake shoes if necessary.


• Adjust cable and replace brake shoes if necessary.

• Check runout and for damage.


• Check tread depth and for damage.


• Check air pressure.

• Correct if necessary.

• Check bearings for smooth operation.


• Check bearing assemblies for looseness.

• Moderately repack with lithiumsoap-based grease every 8000 mi

(13000 km) or 24 months.

8

9

12

* Chassis fasteners

• Check all chassis fitting and fasteners.

• Correct if necessary.

Front and rear brake lever pivot

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

*

*

Centerstand

Front fork

Shock absorber assembly

Engine oil


• Lubricate.

• Check operation and for oil leakage.


• Check operation and for oil leakage.


• Change (warm engine before draining).

• Check oil level and vehicle for oil leakage.

15 *

Engine oil strainer

Cooling system

• Clean.

• Check coolant level and vehicle for coolant leakage.

• Change.

• Check vehicle for oil leakage.

• Change.

16

Final transmission oil

17 * V-belt • Replace.

18 *

Front and rear brake switches


19 *

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.

2 1 *

Lights, signals and switches


• Adjust headlight beam.

INITIAL

600 mi

(1,000 km) or

1 month

2,000 mi

(4,000 km) or

6 months

ODOMETER READING

4,000 mi

(7,000 km) or

12 months

6,000 mi

(10,000 km) or

18 months

8,000 mi

(13,000 km) or

24 months

10,000 mi

(16,000 km) or

30 months v v v v v

V V V V V V

V V V V V V

V V V V V

V V V V V

V V V V V

Repack. V

V V V V V

V V V V V

V V V V V

V V V V V

V V V V V

V V V V V V

V V V

V V V V V

Every 3 years

V V V

Every 6250 mi (10000 km)

V V V V V V

V V V V V V

V V V V V

V V V V V V

3-3


CHK

ADJ

< &

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

NOTE:

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

4000mi(7000km) or 12 months.

EAU17680

NOTE:

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

3-4

EAS00038

COVER AND PANEL

SIDE COVERS AND TAIL/BRAKE LIGHT

COVER AND PANEL

CHK

ADJ

< &

Order

5

6

7

8

1

2

3

4

Job/Part

Removing the side covers and tail/ brake light

Front cover

Side cover(left)

Side cover(right)

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

Battery cover

Battery negative lead

Battery positive lead

Battery

Q’ty

Remarks


1

1

1

1

1

1

1

1 c

C

8First, disconnect the negative battery lead, and then the positive battery lead.

8After installing the battery be sure to turn the main switch from “ON” to “OFF” three times in 3 seconds intervals to initialize the idle speed

3-5

COVER AND PANEL

CHK

ADJ

< &

Order Job/Part

Q’ty

Remarks control system.


3-6

SINGLE SEAT AND TRUNK

COVER AND PANEL

CHK

ADJ

< &

\y10Nm(1.0m • kg, 7.2 ft • lb)

\ l 12Nm(1.2m« kg, 8.7 ft* lb)

[s& 7Nm(0.7m• kg, 5.1 ft• lb)

" 10

/ \

/ \

/

'/* *£® /

/

/

/ 8

Order Job/Part

Removing the single seat and trunk

Side cover(left and right)

1

2

3

4

5

6

7

Single seat

Single seat upper cover

Bottom plate

Frame(single seat)

ECU

Starter relay

Main fuse

8 Single seat lock assembly

9 Helmet holder

10 Trunk

Remarks

Q’ty


Refer to “SIDE COVERS AND TAIL/

BRAKE LIGHT”.

1

1

2

1

1 Disconnect.

1 Disconnect.

1 Disconnect.

1

1

1


3-7

LEG SHIELD1,2

COVER AND PANEL

CHK

ADJ

< &

Order Job/Part

Q’ty

Remarks


Caution, do not damage the claw while removing.


3-8

FOOTREST BOARD AND INNER FENDER

COVER AND PANEL

CHK

ADJ

< &

Order Job/Part

Q’ty

Remarks


Refer to “SINGLE SEAT AND TRUNK “.

When installing the fuel tank cap, align it cap end and the mark on the car body.

Disconnect.


3-9

ADJUSTING THE VALVE CLEARANCE

EAS00049

ENGINE


The following procedure applies to all of the valves.

NOTE:

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

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

1. Remove:

• front cover

• side cover(left and right)

• battery /battery cover

• single seat/trunk

• footrest board

• Refer to”COVER AND PANEL”.

2. Drain:

• coolant

(completely from the radiator)

3. Remove:

• radiator cover ®

• radiator

• fan case ®

Refer to”RADIATOR”in chapter 6.

4. Remove:

• spark plug cap

• spark plug

• ignition coil

• cylinder head cover

5. Remove:

• water pump

Refer to”WATER PUMP”in chapter 6.

6. Measure:

• valve clearance

Out of specification -» Adjust.

Valve clearance (cold)

Intake valve

0.10 ~ 0.16mm(0.0039 ~ 0.0063in)

Exhaust valve

0.18 ~ 0.24mm(0.0071 ~ 0.0094in)

3-10


CHK

ADJ

< &

• • • • • • • • • • • • • • • • • • • • • • • a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compression stroke, align the punch mark a in the camshaft sprocket with the stationary b on the plate. c. Align the TDC mark c on the AC magneto rotor with the stationary pointer d on the crankcase cover. d. Measure the valve clearance with a thickness gauge ® .


• • • • • • • • • • • • • • • • • • • • • • •

3-11

7. Adjust: valve clearance

• • • • • • • • • • • • • • • • • • • • • • • a. Remove the timing chain tensioner and camshaft sprocket. b. Remove the head nuts, bolts and plate. c. Remove the rocker arm shaft, rocker arm and collar. d. Remove the valve p a d 2 with a magnetic b a r 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. e. Select the proper valve pad from the following table.

Valve pad thickness range Available valve pads

Nos.

120 ~ 240

1.20 (0.0472in)

~ 2.40 mm

(0.0945 in)

25 thicknesses in

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


CHK

ADJ

< &

Last digit

0 or 2

5

8

Rounded value

0

5

10

EXAMPLE:

Original valve pad number =148(thickness

=1.48mm(0.0583in))

Rounded value =150 g. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.

NOTE:

The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. h. Install the new valve pad .

NOTE:

• Lubricate the valve pad with molybdenum disulfide oil.

• Install the valve pad in the correct place. i. Install the rocker arm, collar and rocker arm shaft. j. Install the plate and cylinder head nuts

X | 10Nm(1.0m

* kg, 7.2ft

* lb) k. Install the cylinder head bolts .

X | 10Nm(1.0m

* kg, 7.2ft

* lb) l. Install the camshaft sprocket.

X | 30Nm(3.0m

* kg, 21.7ft

* lb) m. Install the timing chain tensioner and gasket.

X | 9Nm(0.9m

* kg, 6.5ft

* lb)

3-12


CHK

ADJ

< & n. Install the timing chain tensioner spring and cap bolt .

X I 8Nm(0.8m

* kg, 5.8ft

* lb) o. Measure the valve clearance again. p. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.

• • • • • • • • • • • • • • • • • • • • • • •

3-13


INTAKE

ORIGINAL VALVE PAD NUMBER •

0.00~0.04

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 0.05~0.09

0.10~0.16

0.17~0.21 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.22~0.26 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.27~0.31 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.32~0.36 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.37~0.41 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.42~0.46 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.47~0.51 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.52~0.56 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.57~0.61 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.62~0.66 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.67~0.71 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.72~0.76 180 185 190 195 200 205 210 215 220 225 230 235 240

0.77~0.81 185 190 195 200 205 210 215 220 225 230 235 240

0.82~0.86 190 195 200 205 210 215 220 225 230 235 240

0.87~0.91 195 200 205 210 215 220 225 230 235 240

0.92~0.96 200 205 210 215 220 225 230 235 240

0.97~1.01 205 210 215 220 225 230 235 240

1.02~1.06 210 215 220 225 230 235 240

1.07~1.11 215 220 225 230 235 240

1.12~1.16 220 225 230 235 240

1.17~1.21 225 230 235 240

1.22~1.26 230 235 240

1.27~1.31 235 240

1.32~1.36 240

VALVE CLEARANCE(cold):

0.10~0.16mm(0.0039~0.0063in)

Example:175 pad is installed

Measured clearance is 0.24mm(0.0094in)

Replace pad 175 with pad 185

Pad number: (example)

Pad No.175=1.75mm(0.0689in)

Pad No.185=1.85mm(0.0728in)

EXHAUST

ORIGINAL VALVE PAD NUMBER X

0.00~0.02

0.03~0.07

0.08~0.12

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

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225

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 0.13~0.17

0.18~0.24

0.25~0.29 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.30~0.34 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.35~0.39 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.40~0.44 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.45~0.49 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.50~0.54 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.55~0.59 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.60~0.64 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.65~0.69 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.70~0.74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.75~0.79 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.80~0.84 180 185 190 195 200 205 210 215 220 225 230 235 240

0.85~0.89 185 190 195 200 205 210 215 220 225 230 235 240

0.90~0.94 190 195 200 205 210 215 220 225 230 235 240

0.95~0.99 195 200 205 210 215 220 225 230 235 240

1.00~1.04 200 205 210 215 220 225 230 235 240

1.05~1.09 205 210 215 220 225 230 235 240

1.10~1.14 210 215 220 225 230 235 240

1.15~1.19 215 220 225 230 235 240

1.20~1.24 220 225 230 235 240

1.25~1.29 225 230 235 240

1.30~1.34 230 235 240

1.35~1.39 235 240

1.40~1.44 240

VALVE CLEARANCE(cold):

3-14


CHK

ADJ

< &

8. Install:

8all removed parts

NOTE:


9. Fill:

8cooling system

(with the specified amount of the recommended coolant)

Refer to”CHANGING THE COOLANT”.

3-15

CHECKING THE ENGINE IDLING SPEED

CHK

ADJ

< &

EAS00054

CHECKING THE ENGINE IDLING SPEED

NOTE:

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

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

2. Remove:

8 panel

Refer to”FOOTREST BOARD AND IN-

NER FENDER”.

3. Connect:

8 digital circuit tester

(onto the spark plug lead of cylinder)

Digital circuit tester

90890-06760

4. Check:

• engine idling speed

Out of specification -» Replace the throttle body assembly.

A Engine idling speed

2000~2200r/min

5. Install:

8 panel


NER FENDER”.

3-16

ADJUSTING THE THROTTLE CABLE FREE PLAY

EAS00056

ADJUSTING THE THROTTLE CABLE FREE

PLAY

NOTE:

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

1. Check:

• throttle cable free play a

Out of specification Âdjust.

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

1.5~3.5mm (0.06~0.14in)

2. Adjust:

8throttle cable free play

• • • • • • • • • • • • • • • • • • • • • • •

Handlebar side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained.

Direction a Throttle cable free play is increased.

Direction b Throttle cable free play is decreased. c. Tighten the locknut. w

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

• • • • • • • • • • • • • • • • • • • • • • •

3-17

CHECKING THE SPARK PLUG

EAS00060


1 . Remove:

8 panel


NER FENDER”.

2. Disconnect:

8 spark plug cap w

Remove the spark plug cap, the engine is extremely hot.

3. Remove:

8 spark plug c C

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

4. Check:

8 spark plug type

Incorrect -* Change.

Spark plug type (manufacturer)

CR7E(NGK)

3-18

5. Check:

8 electrode ©

Damage/wear -* Replace the spark plug.

8 insulator ©

Abnormal color -* Replace the spark plug.

Normal color is medium-to-light tan.

6. Clean:

8 spark plug

(with a spark plug cleaner or wire brush)

7. Measure:

8 spark plug gap a

(with a wire Thickness gauge)

Out of specification -* Regap.

Spark plug gap

0.7 ~0.8mm(0.028 ~0.031in)


CHK

ADJ

< &

8. Install:

• spark plug

X I 13Nm(1.3m

* kg, 9.4ft

* lb)

NOTE:

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

9. Connect:

• spark plug cap

10. Install:

• panel


NER FENDER”.

3-19

CHECKING THE IGNITION TIMING

CHK

ADJ

< &

EAS00062

CHECKING THE IGNITION TIMING wiring connections of the entire ignition system.

Make sure all connections are tight and free of corrosion.

1. Remove:

8front cover

8side cover(left and right)

8battery /battery cover

8single seat/trunk

Refer to”COVER AND PANEL”.

2. Drain:

8coolant

(completely from the radiator)

3. Remove:

8radiator cover

8radiator

8fan case


4. Attach:

8timing light 1

8digital circuit tester2

(onto the spark plug lead of cylinder)

Timing light

90890-03141

YU-03141


90890-06760

3-20

CHECKING THE IGNITION TIMING

CHK

ADJ

< &

5. Check:

8ignition timing

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

A Engine idling speed

2000 ~ 2200r/min b. Check that the mark a on the AC magneto rotor is within the firing range b on the right crankcase cover.

Incorrect firing range -» Check the ignition system.

• • • • • • • • • • • • • • • • • • • • • • •

NOTE:

The ignition timing is not adjustable.

6. Remove:

• timing light

• digital circuit tester

7. Install:

• fan case

• radiator

• radiator cover


8. Fill:

• cooling system


Refer to”CHANGING THE COOLANT”.

9. Install:




• front cover


3-21

MEASURING THE COMPRESSION PRESSURE

CHK

ADJ

< &

EAS00067

MEASURING THE COMPRESSION PRES-

SURE

NOTE:

Insufficient compression pressure will result in a loss of performance.

1. Measure:

8 valve clearance

Out of specification -» Adjust

Refer to “ADJUSTING THE VALVE

CLEARANCE”.

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

3. Remove:

8 panel


NER FENDER”.

4. Disconnect:

8 spark plug cap w

Remove the spark plug cap, the engine is extremely hot.

5. Remove:

8spark plug c C

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

6. Install:

8compression gauge 1

3-22

^

Compression gauge

90890-03081

YU-33223

7. Measure:

8 compression pressure

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

Compression pressure (at sea level)

Minimum

1262kPa(12.62kg/cm

2

, 179.7psi)

Standard

1450kPa(14.5kg/cm

2

, 206.5psi)

Maximum

1624kPa(16.24kg/cm

2

, 231.3psi)

MEASURING THE COMPRESSION PRESSURE

• • • • • • • • • • • • • • • • • • • • • • • a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

FflWUzWIgM

To prevent sparking, ground the spark plug lead before cranking the engine. c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits.

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

Refer to the following table.

Compression pressure

(with oil applied into the cylinder)

Reading Diagnosis

Higher than without oil Piston ring(s) wear or damage -» Repair.

Same as without oil Piston ring(s), valves, cylinder head gasket or piston possibly defective -» Repair.

• • • • • • • • • • • • • • • • • • • • • • •

8. Remove:

• compression gauge

9. Install:

• spark plug

X I 13Nm(1.3m

* kg9.4ft

* lb)

10. Connect:

• spark plug cap

11. Install:

• panel


NER FENDER”.

3-23

CHECKING THE ENGINE OIL LEVEL

EAS00069

CHECKING THE ENGINE OIL LEVEL

1. Stand the scooter on a level surface.

NOTE:

8 Place the scooter on a suitable stand.

8 Make sure the scooter is upright.

- T - V ~//

/

^(S) \ ^ ^ \

<\l.

}yyf(M' ^


3. Check:

8 engine oil level

The engine oil level should be between the minimum level mark a and maximum level mark b .

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

i b

!

a

*0

Recommended engine oil type

YAMALUBE 4, SAE10W30 or

SAE20W40

Recommended engine oil grade

API service SG type or higher

JASO standard MA c C

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.


5. Check the engine oil level again.

NOTE:

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

3-24

CHANGING THE ENGINE OIL

CHK

ADJ

< &

EAS00076



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

3. Remove:

8engine oil filler cap 1

8engine oil drain bolt 2

(along with the gasket)

4. Drain:

8engine oil

(completely from the crankcase)

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

• • • • • • • • • • • • • • • • • • • • • • • a. Remove the oil strainer cover 1,spring3 and oil filter element 4 . b. Replace the O-ring New 2 c. Install the new or clean oil filter element and the oil strainer cover.

Oil strainer cover

32Nm(3.2m

• kg, 23.1ft

• lb)

• • • • • • • • • • • • • • • • • • • • • • •

6. Install:

• engine oil drain bolt


3-25

X | 23Nm(2.3m

* kg, 16.6ft

* lb)

7. Fill:

• crankcase

(with the specified amount of the recommended engine oil)

«0

Quantity

Total amount

0.8~0.9L(0.74~0.83 Imp qt, 0.87~0.98

US qt)

Periodic oil change

0.73~0.83L(0.67~0.76 Imp qt,

0.80~0.90 US qt)


8. Install:

8engine oil filler cap


10.Check:

8engine

(for engine oil leaks)

11.Check:

8engine oil level

Refer to “CHECKING THE ENGINE OIL

LEVEL”.

12.Check: engine oil pressure

• • • • • • • • • • • • • • • • • • • • • • • a. Slightly loosen the oil gallery bolt <RN.1>. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to “OIL PUMP” in chapter 5. d. Start the engine after solving the problem(s) and check the engine oil pressure again. e. Tighten the oil gallery bolt to specification.

V

%

Oil gallery bolt

7Nm (0.7m

• kg, 5.1ft

• lb)

• • • • • • • • • • • • • • • • • • • • • • •

3-26

CHANGING THE TRANSMISSION OIL

CHK

ADJ

< &

CHANGING THE TRANSMISSION OIL


NOTE:

• Stand the scooter on a suitable stand.

• Make sure that the scooter upright.


3. Place a container under the transmission oil drain bolt.

4 Remove:

• transmission oil fill bolt


• transmission oil drain bolt ©

5. Drain:

• transmission oil

(completely from the transmission case)

6. Install:

• transmission oil drain bolt

X I 13Nm(1.3m

* kg, 9.4ft

* lb)

7. Fill:

• transmission case

(with the specified amount of the recommended transmission oil)

K} Recommended oil

SAE10W30 hypoid gear oil

Total amount

0.11~0.13L(0.10~0.12 Imp qt,

0.12~0.14 US qt)

Periodic oil change

0.09~0.11L(0.08~0.10 Imp qt,

0.10~0.12 US qt)

8. Install:

• transmission oil fill bolt ©


X I 23Nm(2.3m

* kg, 16.6ft

* lb)

3-27

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

10.Check:

• transmission case

(for transmission oil leaks)

MEASURING THE ENGINE OIL PRESSURE

EAS00077


1. Check:

8 engine oil level

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

Refer to”CHECKING THE ENGINE OIL

LEVEL”.


C

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

3. Remove:

8 panel


NER FENDER”.

4. Lossen:

8oil gallery bolt 1 w

The engine, muffler and engine oil are extremely hot.

5. Check:

8engine oil pressure

• • • • • • • • • • • • • • • • • • • • • • • a. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. b. Check the engine oil passages, the oil filter and oil pump for damage or leakage.Refer to”OIL PUMP” in chapter 5. c. Start the engine after solving the problem(s) and check the engine oil pressure again.

3-28

• • • • • • • • • • • • • • • • • • • • • • •


CHK

ADJ

< &

6. Install:

8oil gallery bolt

X I 7Nm(0.7m

* kg, 5.1ft

* lb)

7. Install:

• panel


NER FENDER”.

3-29

REPLACING THE AIR FILTER ELEMENT

EAS00086


1. Remove:

8front cover

8side cover(left)

Refer to”SIDE COVERS AND TAIL/

BRAKE LIGHT”.

2. Remove:

8air filter case c o v e r 1

8air filter element

3-30

3. Check:

8 air filter element ©

Damage/dirty^ Replace.

NOTE:

8 Replace the air filter element every

4000km(2000mi) .

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

4. Install:

8 air filter element

8 air filter case cover

X I 10Nm(1.0m

* kg, 7.2ft

* lb)

C

Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the throttle body tuning, leading to poor engine performance and possible overheating.

NOTE:

When installing the air filter element into the air filter case cover, make sure their sealing surfaces are aligned to prevent any air leaks.


CHK

ADJ

< &

5. Install:

8side cover(left)

8front cover


BRAKE LIGHT”.

3-31

CHECKING THE THROTTLE BODY JOINT AND

INTAKE MANIFOLD/CHECKING THE FUEL HOSE

EAS00094

CHECKING THE THROTTLE BODY JOINT

AND INTAKE MANIFOLD

1. Remove:

8front cover


8single seat/trunk


2. Check:

• throttle body joint (T)

• intake manifold (2)

Cracks/damage -» Replace.

Refer to “FUEL INJECTION SYSTEM” in chapter 7.

3. Install:



• front cover


EAS00096

CHECKING THE FUEL HOSE

The following procedure applies to all of the fuel hose.

1. Remove:

• front cover



• footrest board


3-32

2. Check:

• fuel hose (T)



3. Install:

• footrest board



• front cover


CHECKING THE BREATHER HOSES

CHK

ADJ

< &

EAS00098

CHECKING THE BREATHER HOSES

1. Remove:

8front cover


8single seat/trunk

Refer to”COVER AND PANEL”. fer

\ \

X

\ ^ V v^ tx tU

1>f a i i l ^

Si M ^

> i

2. Check:

8 breather hose (T)

8 transmission case breather hose (2)



C

Make sure the breather hoses are routed correctly.

3. Install:

8single seat/trunk


8front cover


3-33

CHECKING THE EXHAUST SYSTEM

EAS00099

CHECKING THE EXHAUST SYSTEM

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

1. Remove:

8muffler assembly

Refer to”ENGINE REMOVAL”in chapter

5.

2. Check:

• muffler assembly (T)

Crack/damage -» Replace.

• gasket (2)

Exhaust gas leak -» Replace.

3. Check:

• tightening torque

Exhaust pipe nut (3)

13Nm(1.3m

• kg, 9.4ft

• lb)

Muffler and rear arm bolt (4)

31Nm(3.1m

• kg, 22.4ft

• lb)

4. Install:

8muffler assembly


5.

3-34

CHECKING THE COOLANT LEVEL

EAS00103

CHECKING THE COOLANT LEVEL


NOTE:

8 Place the scooter on a suitable stand.

8 Make sure the scooter is upright.

2. Check:

8 coolant level

The coolant level should be between the maximum level mark a and minimum level mark b .

Below the minimum level mark -» Add the recommended coolant to the proper level.

C

8 Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.

8 Use only distilled water. However, if distilled water is not available, soft water may be used.


4. Check:

8 coolant level

NOTE:

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

3-35

CHECKING THE COOLING SYSTEM

EAS00104


1. Remove:

8front cover


8battery /battery cover

8single seat/trunk

8footrest board


8radiator cover


J l " iy,

\ / -/C-^y ^

<^Cl&

^^\^y^fe^^\^p—\

N^gf

/ ^ I \ X M T ^

^ ^ v

Vg

°V

X3

'•'•':\ 1 '

^7

/

*

s

o )

^~ ^ ^^sr^/^js,

2. Check:

• radiator ©

• radiator inlet hose (2)

• radiator outlet hose (3)


Refer to “COOLING SYSTEM” in chapter 6.

3. Install:

• radiator cover


• footrest board




• front cover


3-36

CHANGING THE COOLANT

EAS00105


1. Remove:

8front cover

8side cover(right)

8coolant reservoir cap cover


8radiator cover


2. Disconnect:

8coolant reservoir hose 1

3. Drain:

8coolant

(from the coolant reservoir)

8coolant

(from the radiator under drain bolt)

4. Remove:

8radiator cap

8coolant reservoir cap w

A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows:

Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.

5. Connect:

8coolant reservoir hose

6. Install:

8radiator under drain bolt

X I 1Nm(0.1m

* kg, 0.7ft

* l b )

3-37


7. Fill:

8cooling system


«0 Recommended antifreeze

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

Mixing ratio

4:6(antifreeze:water)

Quantity

Total amount

0.50L(0.46 Imp qt, 0.53 US qt)

Coolant reservoir capacity

0.26L(0.23 Imp qt, 0.28 US qt)

Up to the maximum level mark

3-38

NOTE:

The specified amount of coolant is a standard amount. Fill the cooling system with coolant until coolant comes out of the air bleed bolt hole.

Handling notes for coolant

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

If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.

If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.

If coolant is swallowed, induce vomiting and get immediate medical attention. c C

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

Use only distilled water. However, if distilled water is not available, soft water may be used.

If coolant comes into contact with painted surfaces, immediately wash them with water.

Do not mix different types of antifreeze.

8. Install:

8radiator cap


CHK

ADJ

< &

9. Fill:

8coolant reservoir

(with the recommended coolant to the maximum level mark 1 )

10.Install:

8coolant reservoir cap

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

12.Check:

8coolant level

Refer to “CHECKING THE COOLANT

LEVEL”.

NOTE:

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

13.Install:

8radiator cover


8coolant reservoir cap cover

8side cover(right)

8front cover


3-39

ADJUSTING THE FRONT BRAKE/

ADJUSTING THE REAR BRAKE

CHK

ADJ

< &

EAS00109

CHASSIS

ADJUSTING THE FRONT BRAKE

1. Check:

8 brake lever free play a


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

10~20mm(0.39~0.79in)

2. Adjust:

8brake lever free play

• • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.

Direction a Brake lever free play is increased.

Direction b Brake lever free play is decreased. c C

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

• • • • • • • • • • • • • • • • • • • • • • •

3-40

EAS00114

ADJUSTING THE REAR BRAKE

1. Check:

8 brake lever free playa


Brake lever free play

10~ 20mm(0.39~ 0.79in)

2. Adjust:

8brake lever free play

• • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.

Direction a Brake lever free play is increased.

Direction b Brake lever free play is decreased. c C

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

• • • • • • • • • • • • • • • • • • • • • • •

CHECKING THE FRONT AND REAR BRAKE SHOES

CHK

ADJ

< &

EAS00127

CHECKING THE FRONT AND REAR BRAKE

SHOES

1. Operate the brake.

2. Check:

• wear indicator (T)

Reaches the wear limit line (2) -» Replace the brake shoes as a set.

Refer to “FRONT WHEEL AND BRAKE” and “REAR WHEEL AND BRAKE” in chapter 4.

A Front brake

B Rear brake

3-41

CHECKING AND ADJUSTING THE STEERING HEAD

CHK

ADJ

< &

EAS00148

CHECKING AND ADJUSTING THE STEER-

ING HEAD

1. Stand the scooter on a level surface. w

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

NOTE:

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

2. Check:

• steering head

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

Binding/looseness -» Adjust the steering head.

3. Remove:

• front fork upper cover

• front fork cover(left, right)

• leg shield1,2

Refer to”LEG SHIELD1,2".

• headlight stay bracket

Refer to”HANDLE BRACKET AND

HEADLIGHT STAY BRACKET”in chapter 4.

4. Adjust:

8steering head

• • • • • • • • • • • • • • • • • • • • • • • a. Loosen the steering nut 1 and then tighten it to specification with the ring nut wrench.

NOTE:

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

P* Ring nut wrench

90890-01268

YU-01268

3-42

CHECKING AND ADJUSTING THE STEERING HEAD b. Loosen the upper bearing inner race2 completely and then tighten it to specification with a steering nut wrench3 .

^

Steering nut wrench

90890-01444

YM-A9409-7 w

Do not overtighten the upper bearing inner race.

Upper bearing inner race(final tightening torque)

7Nm(0.7m

• kg, 5.1ft

• lb) c. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the bearing race .

Refer to “STEERING HEAD” in chapter 4. d. Hold the upper bearing inner race with a steering nut wrench and tighten the steering n u t 1 with a steering nut wrench2.


90890-01403

YU-A9472

V

%

Steering nut

30Nm(3.0m

• kg, 21.7ft

• lb)

• • • • • • • • • • • • • • • • • • • • • • •

5. Install:

8headlight stay bracket

Refer to”HANDLE BRACKET AND

HEADLIGHT STAY BRACKET”in chapter 4.

8leg shield1,2

8front fork cover(left, right)

8front fork upper cover

Refer to”LEG SHIELD1,2".

3-43

CHECKING THE FRONT FORK

CHK

ADJ

< &

EAS00151

CHECKING THE FRONT FORK



2. Check:

• inner tube

Damage/scratches -» Replace.

• oil seal

Oil leakage -» Replace.

3. Hold the scooter upright and apply the front

• brake.

4. Check:

• front fork operation

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

Rough movement -» Repair.

Refer to “FRONT FORK” in chapter 4.

3-44

CHECKING THE TIRES

EAS00163


The following procedure applies to both of the tires.

1. Check:

• tire pressure

Out of specification -> Regulate. rr\w«:»iwei

• The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.

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

• Operation of an overloaded scooter could cause tire damage, an accident or an injury.

• NEVER OVERLOAD THE SCOOTER.

Basic weight

(with oil and a full fuel tank)

Maximum load*

Cold tire pressure

90 kg (198 lb)

175 kg (386 lb)

Front Rear

Up to 55 kg 175 kPa (1.75 175 kPa (1.75 kgf/cm

2

, 25 psi) kgf/cm

2

, 25 psi)

55 kg ~ 175 kg

175 kPa (1.75 kgf/cm

2

, 25 psi)

175 kPa (1.75 kgf/cm

2

, 25 psi)

* Total weight of rider, passenger, cargo and accessories w

It is dangerous to ride with a worn-out tire.

When the tire tread reaches the wear limit, replace the tire immediately.

3-45


2. Check:

• tire surfaces

Damage/wear -» Replace the tire.

Minimum tire tread depth

0.8mm(0.03in)

1 Tire tread depth

2 Sidewall

3 Wear indicator w

Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation.

When using tube tires, be sure to install the correct tube.

Always replace a new tube tire and a new tube as a set.

To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove.

Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement.

A

B

Tire

Wheel

Tube wheel

Tubeless wheel

Tube tire only

Tube or tubeless tire

After extensive tests, the tires listed below have been approved by Yamaha

Motor Taiwan Co., Ltd. for this model.

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

Front tire

Manufacturer Model

CHENG SHIN C6022

3-46

Rear tire

Manufacturer Model

CHENG SHIN C6022

Size

120/90-10 57J

Size

120/90-10 57J


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 m a r k 2 with the valve installation point.

3-47

CHECKING THE WHEELS/

CHECKING AND LUBRICATING THE CABLES

CHK

ADJ

< &

EAS00168

CHECKING THE WHEELS

The following procedure applies to both of the wheels.

1. Check:

• wheel

Damage/out-of-round -» Replace.

FflWUzWIgM

Never attempt to make any repairs to the wheel.

NOTE:

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

3-48

EAS00170

CHECKING AND LUBRICATING THE

CABLES

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

FflWUzWIgM

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

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

1. Check:

• outer cable

Damage -» Replace.

2. Check:

• cable operation

Rough movement -» Lubricate.

Recommended lubricant

Engine oil or a suitable cable lubricant

NOTE:

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

LUBRICATING THE LEVERS AND PEDALS/

LUBRICATING THE CENTERSTAND

CHK

ADJ

< &

EAS00171

LUBRICATING THE LEVERS AND PEDALS

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


Lithium-soap-based grease

EAS00173

LUBRICATING THE CENTERSTAND

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



3-49

CHECKING AND CHARGING THE BATTERY

BATTERY INSTRUCTION

This is a sealed lype 12 volt battery. No liquid level inspection is ever needed and no refilling water will be required.

IMPORTANT:

• Never interfere with the sealed state of the battery.

•Check the charging condition with a voltmeter (Normal charging voltage should be above 12.8V)

•This battery may be installed in an vehicle only If it replaces a similar sealed type battery.

© ® A ® A

=LAMMABLES SHIELD EVES

A DANGER

• Do not use at the places near fire. Hydrogen gas generated from battery may cause fire and explosion.

•This 12V battery is only for starting engine. Do not apply for other uses.

• Keep out of the reach of children or the personnel who do not understand the manual. It may cause blindness or severe bum,

•When using the battery, wear safety glasses and rubber gloves. Sulfuric acid may cause blindness or severe bum,

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. c C

This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate.

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

3-50


NOTE:

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

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

1. Remove:

8battery cover


BRAKE LIGHT”.

3-51

2. Disconnect:

8battery leads

(from the battery terminals) c C

First, disconnect the negative battery lead

1 , and then the positive battery lead 2 .

3. Remove:

8battery

4. Check:

8battery charge

• • • • • • • • • • • • • • • • • • • • • • • a. Connect a digital circuit tester to the battery terminals.


90890-03174

Positive tester probe -» positive battery terminal

Negative tester probe -» negative battery terminal

NOTE:

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

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

13.0

12.5

12.0

11.5 j -


CHK

ADJ

< &

Relationship between the open-circuit voltage and the charging time at 20 C b. Check the charge of the battery, as shown in the charts and the following example.

5 6.5 10

Charging time (hours)

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

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

• • • • • • • • • • • • • • • • • • • • • • •

14

13

Ambient temperature

20 C

11

10

100 75 50 30 25 20 0

Charging condition of the battery (%)

3-52

5. Charge:

8battery

(refer to the appropriate charging method illustration) w

Do not quick charge a battery. c C

Never remove the MF battery sealing caps.

Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.

If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery.

When charging a battery, be sure to remove it from the scooter. (If charging has to be done with the battery mounted on the scooter, disconnect the negative battery lead from the battery terminal.)

To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.

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


CHK

ADJ

< &

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

If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it.

Hot batteries can explode!

As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait

30 minutes after charging is completed before measuring the open-circuit voltage.

3-53


Charging method using a variable-current (voltage) charger

Charger

Ammeter

Measure the open-circuit voltage prior to charging.

NOTE:

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

Set the charging voltage to 16-17 V.

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

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

Refer to “CHECKING AND

CHARGING THE BATTERY”.

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

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

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

12.8 V ~ Charging is complete.

12.0 ~ 12.7 V ~ Recharging is required.

Under 12.0 V ~ Replace the battery.

3-54


Charging method using a constant voltage charger

Measure the open-circuit voltage prior to charging.

NOTE:

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

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

YES

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

NO

Charge the battery until the charging voltage reaches 15 V.

NOTE:

Set the charging time to a maximum of 20 hours. i

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

12.8 V ~ Charging is complete.

12.0 ~ 12.7 V ~ Recharging is required.

Under 12.0 V ~ Replace the battery.

Voltmeter

N -

V c C

Constant amperage chargers are not suitable for charging MF batteries. i

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

1

Charger

I

3-55

CHECKING AND CHARGING THE BATTERY/

CHECKING THE FUSE

CHK

ADJ

< &

6. Install:

7.

8battery

Connect:

8battery leads

(to the battery terminals) c C

First, connect the positive battery lead

1, and then the negative battery lead 2.

8 After installing the battery, be sure to turn the main switch from “ON” to “OFF” three times in 3 seconds intervals to initialize the idle speed control system.

8. Check:

8 battery terminals

Dirt -» Clean with a wire brush.


9. Lubricate:

8 battery terminals


Dielectric grease

10.Install:

8battery cover


BRAKE LIGHT”.

EAS00181


The following procedure applies to all of the fuse. c C

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

1. Remove:

8battery cover


BRAKE LIGHT”.

3-56


2. Check:

8fuse

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

NOTE:

Set the pocket tester selector to “ × 1”.

Pocket tester

90890-03112(YU-03112-C)

^ b. If the pocket tester indicates “∞”, replace the fuse.

• • • • • • • • • • • • • • • • • • • • • • •

3. Replace:

8blown fuse

• • • • • • • • • • • • • • • • • • • • • • • a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit.

Fuse

Main

Amperage rating

15A 1

Q’ty

3-57 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. c C

After removing and installing the main fuse, be sure to turn the main switch from “ON” to “OFF” three times in 3 seconds intervals to initialize the idle speed control system.

• • • • • • • • • • • • • • • • • • • • • • •

4. Install:

8battery cover


BRAKE LIGHT”.

REPLACING THE HEADLIGHT BULB

EAS00182

REPLACING THE HEADLIGHT BULB

1. Remove:

8headlight unit

2. Disconnect:

8headlight lead coupler

3. Remove:

8dust b o o t 1

8headlight bulb holder2

8headlight bulb3 w

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

4. Install:

8headlight bulb New

Secure the new headlight bulb with the headlight bulb holder. c C

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

5. Install :

8headlight bulb holder

6. Install:

8dust boot

7. Connect:

8headlight lead coupler

8. Install:

8headlight unit

3-58

ADJUSTING THE HEADLIGHT BEAM

CHK

ADJ

< &

EAS00184

ADJUSTING THE HEADLIGHT BEAM

1. Adjust: headlight beam (vertically)

• • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting screw 1 in direction a or b .

Direction a Headlight beam is raised.

Direction b Headlight beam is lowered.

• • • • • • • • • • • • • • • • • • • • • • •

2. Adjust: headlight beam (horizontally)

• • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting screw2 in direction a or b .

Direction a Headlight beam moves to the right.

Direction b Headlight beam moves to the left.

• • • • • • • • • • • • • • • • • • • • • • •

3-59

CHAS (3^3^)

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 4-14

CHECKING THE REAR WHEEL DRIVE HUB 4-15

CHECKING THE BRAKE 4-15

ASSEMBLING THE BRAKE SHOE PLATE 4-16

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 4-23

ASSEMBLING THE FRONT FORK LEGS 4-24

INSTALLING THE FRONT FORK LEGS 4-26

HANDLEBAR 4-27

REMOVING THE HANDLEBAR 4-29

CHECKING THE HANDLEBAR 4-29

INSTALLING THE HANDLEBAR 4-30

STEERING HEAD 4-32

HANDLEBAR BRACKET AND HEADLIGHT STAY BRACKET 4-32

LOWER BRACKET 4-33

REMOVING THE LOWER BRACKET 4-34

CHECKING THE STEERING HEAD 4-35

INSTALLING THE STEERING HEAD 4-36

CHAS (3^3^)

REAR SHOCK ABSORBER ASSEMBLY 4-37

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-38

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-38

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-39

FRONT WHEEL AND BRAKE

CHAS (3^3^)

EAS00517


CHASSIS

Order

1

2

3

4

5

6

7

Stop ring

Speedometer cable

Brake adjuster

Front brake cable

Adjusting pin

Wheel axle nut

Wheel axle

8 Collar

9 Front brake shoe plate

10 Front wheel

Job/Part

Removing the front wheel and brake

Remarks

Q’ty


NOTE:


1

1

1

1

1 Refer to”REMOVING THE FRONT

1 WHEEL and INSTALLING THE FRONT

1

1

1

1

WHEEL”.


4-1

EAS00518

FRONT WHEEL


CHAS (3^3^)

Order Job/Part

Disassembling the front wheel

1 Oil seal

2 Bearing

3 Spacer

4 Bearing

Q’ty

Remarks


1

1

1

1

For assembly, reverse the disassembly procedure.

4-2

FRONT BRAKE SHOE PLATE


CHAS (3^3^)

Order Job/Part

Disassembling the front brake shoe plate

1 Brake shoe kit

2 Tension spring

3 Camshaft lever

4 Brake shoe wear indicator

5 Return spring

6 Brake camshaft/O-ring

7 Oil seal

8 Oil seal

9 Circlip

0 Plate washer q Speedometer clutch w Speedometer drive gear e Plate washer r Bushing t Oil seal y Speedometer driven gear u Plate washer

Q’ty

Remarks


1

1

1

1

1

2

1

1

1

1/1

1 Refer to”DISASSEMBLING THE

1 BRAKE SHOE PLATE” and “ASSEM-

1 BLING THE BRAKE SHOE PLATE”.

1

1

1

1


4-3


CHAS (3^3^)

EAS00520

REMOVING THE FRONT WHEEL



NOTE:


2. Remove:

8speedometer cable 1

8front brake c a b l e 2

8front wheel axle n u t 3

8front wheel a x l e 4

8collar

8front w h e e l 5

8front brake shoe plate 6

EAS00524

DISASSEMBLING THE BRAKE SHOE PLATE

1. Remove:

8front brake shoe kit

8camshaft lever

8brake shoe wear indicator

8return spring

8brake camshaft

2. Remove:

8circlip

8plate washer

8speedometer clutch

8speedometer drive gear

8plate washer

3. Remove:

8bushing

(with the special tool)

8speedometer driven gear

8plate washer

Meter gear bush tool

90890-01052

NOTE:

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

4-4


EAS00525

CHECKING THE FRONT WHEEL

1. Check:

• wheel axle

Roll the wheel axle on a flat surface.

Bends -» Replace.

Do not attempt to straighten a bent wheel axle.

2. Check:

• tire

• front wheel

Damage/wear -» Replace.

Refer to “CHECKING THE TIRES” and

“CHECKING THE WHEELS” in chapter

3.

3. Measure:

• radial wheel runout (T)

• lateral wheel runout @

Over the specified limits -» Replace.

Radial wheel runout limit

1.0 mm (0.04 in)

Lateral wheel runout limit

1.0 mm(0.04 in)

4-5

4. Check:

• wheel bearings

Front wheel turns roughly or is loose -»

Replace the wheel bearings.

• oil seal


5. Replace:

• wheel bearings New

• oil seal New


CHAS (3^3^)

• • • • • • • • • • • • • • • • • • • • • • • a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver.

NOTE:

To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. c. Remove the wheel bearings 4 with a general bearing puller3. d. Install the new wheel bearings and oil seal in the reverse order of disassembly.

• • • • • • • • • • • • • • • • • • • • • • •

EAS00535

CHECKING THE SPEEDOMETER GEAR

UNIT

1. Check:

• speedometer clutch

Bends/damage/wear -» Replace.

2. Check:

• speedometer drive gear (T)

• speedometer driven gear ®


4-6

(If

^

• •

•

B

" ' w

•—Q7\__ y j

'


CHAS (3^3^)

12270603

EAS00536

CHECKING THE BRAKE

The following procedure applies to all of the brake shoes.

1. Check:

• brake shoe lining

Glazed areas -» Repair.

Sand the glazed areas with course sandpaper.

NOTE:

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

2. Measure:

• brake shoe lining thickness a

Out of specification ^Replace.

Brake shoe lining thickness limit

(minimum)

2.0 mm (0.08 in) w

Do not allow oil or grease to contact the brake shoes.

NOTE:

Replace the brake shoes as a set, if either is worn to the wear limit.

4-7

3. Measure:

• brake drum inside diameter b

Out of specification ^Replace the wheel.

Brake drum inside diameter limit

(maximum)

110.5 mm (4.35 in)


4. Check:

• brake drum inner surface

Oil deposits -» Clean.

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

Scratches -» Repair.

Lightly and evenly polish the scratches with an emery cloth.

5. Check:

• brake camshaft


4-8

EAS00537

ASSEMBLING THE BRAKE SHOE PLATE

1. Lubricate:

8brake camshaft



2. Install:

8brake camshaft 1

8spring

8brake shoe wear indicator 2

• • • • • • • • • • • • • • • • • • • • • • • a. Install the brake camshaft so its punch mark a is positioned as shown. b. Align the projection b on the brake shoe wear indicator with the notch in the brake camshaft. c. Check that the brake shoes are properly positioned.

• • • • • • • • • • • • • • • • • • • • • • •

V \

) k V~


CHAS (3^5^)

3. Install:

8 camshaft lever (T)

X I 8Nm(0.8m

• kg, 5.8ft

• lb)

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

• • • • • • • • • • • • • • • • • • • • • • •

4. Install:

8 plate washer

8 speedometer driven gear

8 bushing

(with the special tool)

Meter gear bush tool

90890-01052 y

*JiL k P DBH1

EAS00538

ASSEMBLING THE FRONT WHEEL

1. Install:

8wheel bearing(right)1 New

8spacer

8wheel bearing(left) New

8oil seal New

• • • • • • • • • • • • • • • • • • • • • • • a. Install the new wheel bearings and oil seal in the reverse order of disassembly. c C

Do not contact the wheel bearing inner race

1 or balls 2 . Contact should be made only with the outer race 3 .

NOTE:

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

• • • • • • • • • • • • • • • • • • • • • • •

2. Install:

8brake shoe plate

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

4-9


CHAS (3^3^)

EAS00540

INSTALLING THE FRONT WHEEL

1. Lubricate:

8wheel axle

8wheel bearings

8oil seal lips

8speedometer drive gear

8speedometer driven gear



2. Install:

8front w h e e l 1

NOTE:

Make sure the slot ® in the brake shoe plate fits over the stopper ® on the outer tube.

3. Tighten:

8 wheel axle nut

X I 48 Nm (4.8 m * kg, 34.7 ft * lb)

Make sure the brake cable is routed properly. c C

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

4-10


EAS00548

ADJUSTING THE FRONT WHEEL STATIC

BALANCE

NOTE:

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

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

1 . Remove:

8balancing weight(s)

4-11

2. Find:

8front wheel’s heavy spot

NOTE:

Place the front wheel on a suitable balancing stand.

• • • • • • • • • • • • • • • • • • • • • • • a. Spin the front wheel. b. When the front wheel stops, put an “X at the bottom of the wheel.

1

” mark c. Turn the front wheel 90° so that the “X

1

” mark d. is positioned as shown.

Release the front wheel. e. When the wheel stops, put an “X

2

” mark at f. the bottom of the wheel.

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

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

• • • • • • • • • • • • • • • • • • • • • • •


CHAS (3^%

3. Adjust:

8front wheel static balance

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

NOTE:

Start with the lightest weight. b. Turn the front wheel 90° so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that posid. tion, install a heavier weight.

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

• • • • • • • • • • • • • • • • • • • • • • •

4. Check:

8front wheel static balance

• • • • • • • • • • • • • • • • • • • • • • • a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it.

• • • • • • • • • • • • • • • • • • • • • • •

4-12

REAR WHEEL AND BRAKE

CHAS (3^3^)

EAS00555


Order Job/Part

Removing the rear wheel and brake

Q’ty

Remarks


NOTE:


Muffler

1 Self lock nut/Plate washer

2 Brake adjuster

3 Spring

4 Rear brake cable

5 Adjusting pin

6 Rear wheel

7 Brake shoe kit

8 Tension spring

9 Plate washer

10 Camshaft lever

11 Indicator plate

12 Brake camshaft/O-ring


5.

2

1

1

1

1/2

1/1

1

1

1

1

1

1

Disconnect.


4-13


CHAS (3^3^)

EAS00564

REMOVING THE REAR WHEEL



NOTE:

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

2. Remove:

8muffler


5.

3. Loosen:

8brake adjuster

4. Remove:

8wheel axle nut 1

8plate washer

8rear w h e e l 2

EAS00565

CHECKING THE REAR WHEEL

1. Check:

• tire

• rear wheel


Refer to”CHECKING THE TIRES ”and”

CHECKING THE WHEELS” in chapter 3.

2. Measure:

• radial wheel runout

• lateral wheel runout

Refer to”CHECKING THE FRONT

WHEEL”.

4-14


CHAS (3^3^)

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB

1. Check:

• rear wheel drive hub


(If

^v-

/)>

~~~G77\-__

3^

12270603

EAS00569

CHECKING THE BRAKE

The following procedure applies to all of the brake shoes.

1. Check:

• brake shoe lining

Glazed areas -» Repair.

Sand the glazed areas with course sandpaper.

NOTE:

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

4-15

2. Measure:

• brake shoe lining thickness a

Out of specification -» Replace.

Brake shoe lining thickness limit

(minimum)

2.0 mm(0.08 in) w

Do not allow oil or grease to contact the brake shoes.

NOTE:

Replace the brake shoes as a set, if either is worn to the wear limit.


CHAS (3^3^)

3. Measure:

• brake drum inside diameter b

Out of specification -» Replace the wheel.

Brake drum inside diameter limit

(maximum)

110.5 mm(4.35 in)

4. Check:

• brake drum inner surface

Oil deposits -» Clean.

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

Scratches -» Repair.

Lightly and evenly polish the scratches with an emery cloth.

5. Check:

• brake camshaft


EAS00570

ASSEMBLING THE BRAKE SHOE PLATE

1. Install:

8brake camshaft 1

8o-rings New

8brake shoe wear indicator 2

NOTE:

Lubricate the brake camshaft and o-rings with lithium-soap-based grease. w

After installing the brake camshaft and orings, remove any excess grease.

• • • • • • • • • • • • • • • • • • • • • • • a. Install the brake camshaft 1 so its punch mark a is positioned as shown. b. Align the projection b on the brake shoe wear indicator with the notch in the brake shoe camshaft. c. Check that the brake shoes are properly positioned.

• • • • • • • • • • • • • • • • • • • • • • •

2. Tighten:

8brake camshaft bolt

10Nm(1.0m

* kg, 7.2ft

* lb)

4-16


CHAS (3^3^)

3. Install:

8brake shoe k i t 1

8tension springs c C

Do not put lubricating oil on the brake lining.

Change the tension spring at the same time of changing the brake shoe.

Refer to the direction in the illustration when assembling the brake shoe and spring.

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

4-17


CHAS (3^3^)

EAS00574

INSTALLING THE REAR WHEEL

1. Lubricate:

8wheel axle



2. Install:

• rear wheel

3. Tighten:

• plate washer

• wheel axle nut ©

X I 120Nm(12.0m

* kg, 86.8ft

* lb)

4. Install:

• muffler


5.

5. Adjust:

• brake lever free play

Refer to”ADJUSTING THE REAR

BRAKE” in chapter 3.

4-18

EAS00575

ADJUSTING THE REAR WHEEL STATIC

BALANCE

NOTE:

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

8 Adjust the rear wheel static balance with the rear wheel drive hub installed.

1. Adjust:

8rear wheel static balance

Refer to “ADJUSTING THE FRONT

WHEEL STATIC BALANCE”.

EAS00646

FRONT FORK

FRONT FORK

CHAS (3^3^)

S& 45Nm(4.5m • kg, 32.5 ft • lb)

gR 30Nm(3.0m • kg, 21.7 ft • lb)

Order

1

2

3

4

5

Job/Part

Removing the front fork legs

Front fork upper cover

Reflector

Front fork cover(left and right)

Front wheel

Cable guide

Cap bolt

O-ring

Lower bracket pinch bolt

Front fork leg

Q’ty

Remarks


Refer to”LEG SHIELD1,2 “ in chapter 3.

Refer to”FRONT WHEEL AND BRAKE”.

1

1

1

1

1

Refer to”REMOVING THE FRONT

FORK LEGS” and “INSTALLING THE

FRONT FORK LEGS”


4-19

EAS00648

FRONT FORK C H A S (3^3^)

(D

3R 23Nm(2.3m • kg, 16.6 ft < lb)

Order Job/Part

Disassembling the front fork legs

Fork oil

1 Fork spring

2 Damper rod bolt/Copper washer

3 Damper rod

4 Rebound spring

5 Inner tube

6 Dust seal

7 Oil seal clip

8 Oil seal

9 Outer tube

Remarks

Q’ty


Drain.

1

1/1

1

1


1 FRONT FORK LEGS” and “ASSEM-

1 BLING THE FRONT FORK LEGS”

1

1


4-20

FRONT FORK

CHAS (3^3^)

EAS00651

REMOVING THE FRONT FORK LEGS

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



NOTE:


2. Remove:

8front fork upper cover

8front fork cover (left and right)

Refer to “LEG SHIELD1,2”in chapter 3.

8front wheel

Refer to “FRONT WHEEL AND BRAKE”.

3. Loosen:

8lower bracket pinch bolt 1

4. Remove:

8cap bolt 2

(with a 10 -mm hexagonal wrench3) w

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

5. Remove:

8front fork leg

4-21

EAS00653

DISASSEMBLING THE FRONT FORK LEGS


1. Remove:

8fork spring 1

FRONT FORK

2. Drain:

8fork oil

3. Remove:

8damper rod assembly b o l t 1

NOTE:

While holding the damper rod with the damper rod holder 2 and T-handle3, loosen the damper rod assembly bolt.

/ •

Damper rod holder

90890-01294(YM-01300-1)

T-handle

90890-01326(YM-01326)

4. Remove:

8damper r o d 1

8spring

8inner t u b e 2

4-22

5. Remove:

8dust seal

8oil seal clip 1

(with a flat-head screwdriver) c C

Do not scratch the inner tube.

FRONT FORK

CHAS (3^%

6. Remove:

8oil s e a l 1 c C

Never reuse the oil seal.

8 R a g 2

EAS00656

CHECKING THE FRONT FORK LEGS


1. Check:

8 inner t u b e ®

8 outer tube (2)

Bends/damage/scratches -* Replace. w

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

4-23

2. Measure:

8 spring free length a

Out of specification -* Replace.

Spring free length

202.2mm(7.96in)

<Limit> :198.2mm(7.80in)

3. Check:

8 damper r o d ®

Damage/wear -* Replace.

Obstruction -* Blow out all of the oil passages with compressed air.

y

® <?

\J$^

(gfm;

\ ^

FRONT FORK

EAS00658

ASSEMBLING THE FRONT FORK LEGS


NOTE:

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

- oil seal

- dust seal

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

1. Install:

8damper rod assembly 1

8rebound spring 2 c C

Allow the damper rod assembly to slide slowly down the inner t u b e 3 until it protrudes from the bottom of the inner tube.

Be careful not to damage the inner tube.

2. Lubricate:

8inner tube’s outer surface


Fork oil 10W or equivalent

3. Tighten:

8 Copper washer New

8 damper rod assembly bolt (T)

X I 23 Nm (2.3 m * kg, 16.6 ft * lb)

NOTE:

While holding the damper rod assembly with the damper rod holder 2 and T-handle 3 , tighten the damper rod assembly bolt.

Damper rod holder

90890-01294(YM-01300-1)

T-handle

90890-01326(YM-01326)

4-24

V •

FRONT FORK

CHAS (3^3^)

4. Install:

8oil seal 1 New

(with the fork seal driver weight 2 and adapter 3 )

^

Fork seal driver weight

90890-01367(YM-A9409-7)

Adapter

90890-01400(YM-A9409-3 ) c C

Make sure the numbered side of the oil seal faces up.

NOTE:

8 Before installing the oil seal, lubricate its lips with lithium soap base grease.

8 Lubricate the outer surface of the inner tube with fork oil.

8 Before installing the oil seal, cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation.

5. Install:

8oil seal c l i p 1

NOTE:

Adjust the oil seal clip so that it fits into the outer tube’s groove.

4-25

6. Fill:

8front fork leg

(with the specified amount of the recommended fork oil)

*® Quantity (each front fork leg)

0.042 L (0.038 Imp qt, 0.046 US qt)

Recommended oil

Fork oil 10W or equivalent

4-26

FRONT FORK

CHAS (3^3^)

NOTE:

8 While filling the front fork leg, keep it upright.

8 After filling, slowly pump the front fork leg up and down to distribute the fork oil.

7. Install:

8fork spring 1

NOTE:

8 Install the spring with the smaller pitch facing down .

EAS00663

INSTALLING THE FRONT FORK LEGS


1. Install:

• front fork leg

• o-ring New

• cap bolt

NOTE:

Pull up the inner tube until it stops, then install the cap bolt .

2. Tighten:

• cap bolt (T)

X | 45 Nm (4.5 m * kg, 32.5 ft * lb)

• lower bracket pinch bolt (2)

X | 30Nm(3.0m

* kg, 21.7ft

* lb)

EAS00664

HANDLEBAR

10 ^

HANDLEBAR

CHAS (3^3^)

Order Job/Part

Removing the handlebar



Leg shield1,2

1 Rear view mirror(left and right)

2 Band

3 Front brake cable

4 Brake lever(right)

5 Front brake switch

6 Front turn signal light(right)

7 Front turn signal light bracket(right)

8 Handlebar switch(right)

9 Throttle cable

10 Throttle grip assembly

11 Rear brake cable

12 Brake lever(left)

13 Rear brake switch

4-27

Q’ty

Remarks


Refer to”LEG SHIELD1,2"in chapter 3.

1/1

2

1 Disconnect.

1

1

1

1

1

2 Disconnect.

1

1 Disconnect.

1

1

10 ^

HANDLEBAR

CHAS (3^3^)

Order

14

15

16

17

18

19

20

Job/Part

Front turn signal light(left)

Front turn signal light bracket(left)

Handlebar switch(left)

Handlebar grip

Cap

Handlebar upper holder

Handlebar assembly

Remarks

Q’ty

1

1

1

1

2

2

1


4-28

4-29

HANDLEBAR

CHAS (3^3^)

EAS00666

REMOVING THE HANDLEBAR

1 . Stand the scooter on a level surface. w


2. Remove:

8handlebar switch(right)1

8throttle grip assembly 2

NOTE:

While removing the handlebar holder assembly

(right), pull back the rubber cover.

3. Remove:

8handlebar switch(left)

8handlebar grip 1

8handlebar upper holder

NOTE:

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

EAS00668

CHECKING THE HANDLEBAR

1. Check:

• handlebar ©

Bends/cracks/damage -» Replace.

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

HANDLEBAR

EAS00673

INSTALLING THE HANDLEBAR



2. Install:

8 handlebar ©

8 handlebar upper holders (2)

X I 28Nm(2.8m

* kg, 20.3ft

* lb)

C

First, tighten the bolts on the front side of the handlebar holders, and then on the rear side.

NOTE:

8 The upper handlebar holders should be installed with the arrow marks a facing forward A

8 Align the match marks b on the handlebar with the upper surface of the handlebar lower holder.

3. Install:

8 handlebar grip

NOTE:

Before installing the handlebar grip, apply the bond.

4-30

4. Install:

8 left handlebar switch 1

NOTE:

Align the projection a on the left handlebar switch with the hole b on the handlebar.

4-31

HANDLEBAR

5. Install:

8 throttle grip assembly 1

8 right handlebar switch 2

8 throttle cables 3

NOTE:

8 Align the projectiona on the right handlebar switch with the hole b on the handlebar.

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

Make sure the throttle grip operates smoothly.

6. Adjust:

8 throttle cable free play

Refer to “ADJUSTING THE THROTTLE

CABLE FREE PLAY” in chapter 3.

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

1.5~3.5mm(0.06~0.14in)

STEERING HEAD

CHAS (3^3^)

EAS00675

STEERING HEAD

HANDLEBAR BRACKET AND HEADLIGHT STAY BRACKET

®~.

P^23Nm(2.3m kg, 16.6 ft lb)

S^

>

48Nm(4.8m • kg, 34.7 ft • lb)

S^60Nm(6.0m • kg, 43.4 ft • lb) al4Nm(0.4m • kg, 2.9 ft • lb)

1

2

3

4

5

6

7

8

9

10

11

Order Job/Part

Removing the handlebar bracket and headlight stay bracket



Leg shield1,2

Handlebar assembly

Speedometer cable

Speedometer

Headlight unit/Headlight body

Main switch

Horn

Rectifier/regulator

Turn signal relay

Starting circuit cut-off relay

Headlight stay bracket

Handlebar lower holder

Handlebar bracket

Q’ty

1

1

1/1

1

1

1

1

1

1

1

1

Remarks



Refer to”HANDLEBAR”.

Disconnect.

Disconnect.


4-32

LOWER BRACKET

LOWER BRACKET

r V 30Nm(3.0m • kg, 21.7 ft • lb)f

5

6

7

8

9

1

2

3

4

Order Job/Part

Removing the lower bracket



Leg shield1,2

Front wheel

Front fork legs

Handlebar assembly

Headlight stay bracket

Handlebar bracket

Front fender

Ring nut

Upper bearing inner race

Upper bearing

Lower bracket

Lower bearing

Upper bearing outer race

Lower bearing outer race

Lower bearing inner race

4-33

Q’ty

Remarks



Refer to”FRONT WHEEL AND BRAKE”.

Refer to”FRONT FORK”

Refer to”HANDLEBAR”.

Refer to”HANDLEBAR BRACKET AND

HEADLIGHT STAY BRACKET”

1

1

1

1

1

1

1

1

1 Refer to”REMOVING THE LOWER

BRACKET” and “INSTALLING THE

STEERING HEAD”.


4-34

STEERING HEAD

CHAS (3^3^)

EAS00678

REMOVING THE LOWER BRACKET



2 . Remove:

8handlebar bracket 1

NOTE:

Remove the handlebar bracket by loosening the ring n u t 2 gradually.

3. Remove:

8ring nut 1

(with the ring nut wrench 2 )

Ring nut wrench

90890-01268

YU-01268

4 . Remove:

8upper bearing inner r a c e 1

(with the steering nut wrench2)


90890-01444

YM-A9409-7 w

Securely support the lower bracket 3 so that there is no danger of it falling.

STEERING HEAD

CHAS (3^3^)

EAS00682

CHECKING THE STEERING HEAD

1. Wash:

8bearing balls

8bearing races

Recommended cleaning solvent

Kerosene

2. Check:

8bearing balls (T)

8bearing races (2)

Damage/pitting -» Replace.

4-35

3. Replace:

8bearing balls

8bearing races

• • • • • • • • • • • • • • • • • • • • • • • a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the front fork assembly with a floor chisel 2 and hammer. c. Install a new bearing races. c C

If the bearing race is not installed properly, the steering head pipe could be damaged.

NOTE:

Always replace the balls and bearing races as a set.

• • • • • • • • • • • • • • • • • • • • • • •

4. Check:

8lower bracket

(along with the steering stem)

Bends/cracks/damage -» Replace.

STEERING HEAD

CHAS (3^3^)

EAS00684

INSTALLING THE STEERING HEAD

1. Lubricate:

8bearing balls 1

8bearing races



2. Install:

8lower bracket 1

8upper bearing inner r a c e 2


Upper bearing inner race

7Nm(0.7m • kg, 5.1ft

• lb) f*


90890-01444

YM-A9409-7

3. Install:

8ring nut 1


V

%

Ring nut

30Nm(3.0m

• kg, 21.7ft

• lb)


90890-01403

YU-A9472

4. Install:

8handlebar bracket 1

NOTE:

Align the handlebar bracket across rod a on the lower bracket concave b .

5. Tighten:

• handlebar bracket nut

4-36

\ | 60Nm(6.0m

* kg, 43.4ft

* lb)

REAR SHOCK ABSORBER ASSEMBLY

CHAS (3^3^)

EAS00685


Order Job/Part

Removing the rear shock absorber assembly

Q’ty

Remarks


1

2

3

4

Front cover

Side cover(left)

Rear shock absorber assembly upper nut

Rear shock absorber assembly upper bolt

Rear shock absorber assembly lower bolt

Rear shock absorber assembly

1

1

1

1


BRAKE LIGHT”in chapter 3.


4-37


EAS00692

REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY

1 . Stand the scooter on a level surface. w


NOTE:

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

2. Remove:

8front cover

8side cover(left)



3. Remove:

8rear shock absorber nut(upper)

8rear shock absorber bolt(upper)

8rear shock absorber bolt(lower)

4-38

EAS00695

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY

1. Check:

• rear shock absorber rod

Bend/damage -» Replace the rear shock absorber assembly.

• rear shock absorber

Oil leak -» Replace the rear shock absorber assembly.

• spring

Damage/wear -» Replace the rear shock absorber assembly.

• bushing


• dust seal


• bolts

Bends/damage/wear -» Replace.


CHAS (3^3^)

EAS00698

INSTALLING THE REAR SHOCK AB-

SORBER ASSEMBLY

1. Install:

• rear shock absorber assembly

2. Tighten:

• rear shock absorber assembly upper nut

X | 30Nm(3.0m

* kg, 21.7ft

* lb)

• rear shock absorber assembly lower bolt

X | 16Nm(1.6m

* kg, 11.6ft

* lb)

3. Install:

• side cover(left)

• front cover



4-39

ENG

% m

CHAPTER 5

ENGINE

ENGINE REMOVAL 5-1

LEADS, HOSES AND MUFFLER 5-1

ENGINE 5-3

INSTALLING THE ENGINE 5-4

CYLINDER HEAD 5-5

REMOVING THE CYLINDER HEAD 5-7

CHECKING THE CYLINDER HEAD 5-9

INSTALLING THE CYLINDER HEAD 5-10

THE ROCKER ARMS AND CAMSHAFT 5-13

REMOVING THE ROCKER ARMS AND CAMSHAFT 5-14

CHECKING THE CAMSHAFT 5-15

CHECKING THE ROCKER ARMS AND ROCKER ARM

SHAFTS 5-16

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET, AND

TIMING CHAIN GUIDES 5-17

CHECKING THE TIMING CHAIN TENSIONER 5-18

INSTALLING THE CAMSHAFT AND ROCKER ARMS 5-19

VALVES AND VALVE SPRINGS 5-20

REMOVING THE VALVES 5-22

CHECKING THE VALVES AND VALVE GUIDES 5-24

CHECKING THE VALVE SEATS 5-26

CHECKING THE VALVE SPRINGS 5-28

INSTALLING THE VALVES 5-29

CYLINDER AND PISTON 5-31

REMOVING THE CYLINDER AND PISTON 5-32

CHECKING THE CYLINDER AND PISTON 5-33

CHECKING THE PISTON RINGS 5-35

CHECKING THE PISTON PIN 5-36

CHECKING THE TIMING CHAIN GUIDE 5-37

INSTALLING THE PISTON AND CYLINDER 5-37

BELT DRIVE 5-39

V-BELT CASE COVER 5-39

KICKSTARTER 5-40

INSTALLING THE KICKSTARTER 5-41

V-BELT AND PRIMARY/SECONDARY SHEAVE 5-42

SECONDARY SHEAVE 5-43

REMOVING THE PRIMARY SHEAVE 5-44

ENG

% m

REMOVING THE SECONDARY SHEAVE AND V-BELT 5-44

DISASSEMBLING THE SECONDARY SHEAVE 5-45

CHECKING THE CLUTCH SHOES 5-45

CHECKING THE V-BELT 5-46

CHECKING THE PRIMARY SHEAVE 5-46

CHECKING THE PRIMARY SHEAVE WEIGHTS 5-47

CHECKING THE SLIDER 5-47

CHECKING THE SECONDARY SHEAVE 5-47

ASSEMBLING THE PRIMARY SHEAVE 5-48

ASSEMBLING THE SECONDARY SHEAVE 5-49

INSTALLING THE SECONDARY SHEAVE, V-BELT AND PRIMARY

SHEAVE 5-50

STARTER CLUTCH AND AC MAGNETO 5-53

STATOR COIL ASSEMBLY 5-53

STARTER CLUTCH 5-55

REMOVING THE AC MAGNETO 5-56

REMOVING THE STARTER CLUTCH 5-57

CHECKING THE STARTER CLUTCH 5-58

INSTALLING THE STARTER CLUTCH 5-59

INSTALLING THE AC MAGNETO 5-59

OIL PUMP 5-61

CHECKING THE OIL PUMP 5-62

ASSEMBLING THE OIL PUMP 5-63

INSTALLING THE OIL PUMP 5-63

TRANSMISSION 5-64

CHECKING THE TRANSMISSION 5-65

CRANKSHAFT 5-66

CRANKSHAFT ASSEMBLY 5-66

DISASSEMBLING THE CRANKCASE 5-68

REMOVING THE CRANKSHAFT ASSEMBLY 5-69

CHECKING THE CRANKSHAFT AND CONNECTING ROD 5-69

CHECKING THE CRANKCASE 5-70

CHECKING THE TIMING CHAIN AND TIMING CHAIN

GUIDE(INTAKE SIDE) 5-71

CHECKING THE BEARINGS AND OIL SEALS 5-71

CHECKING THE CIRCLIPS AND WASHERS 5-71

INSTALLING THE CRANKSHAFT 5-72

ASSEMBLING THE CRANKCASE 5-72

EAS00188

ENGINE REMOVAL

LEADS, HOSES AND MUFFLER

ENGINE REMOVAL

ENG %m

ENGINE

r V 10Nm(1.0m • kg, 7.2 ft* lb)

r V 10Nm(1.0m • kg, 7.2 ft* lb)

Order Job/Part

Removing the leads, hoses and muffler

Front cover/Single seat/Trunk

Battery cover/Battery


Footrest board

Coolant

Q’ty

Remarks


Refer to”COVER AND PANEL”in chapter 3.

1

2

Rear brake cable/Adjuster/Pin

Throttle body and fuel injector

Starter motor

Conduit hose

Coolant temperature sensor coupler

1

1

Drain.

Refer to”CHANGING THE COOLANT”in chapter 3.

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

Refer to”THROTTLE BODY AND FUEL

INJECTOR”in chapter 7.

Refer to”STARTER MOTOR”in chapter

8.

Disconnect.

Disconnect.

5-1

ENGINE REMOVAL

ENG %m r^10Nm(1.0m • kg, 7.2 ft* lb)

1 * 10Nm(1.0m • kg, 7.2 ft • lb)

Order

3

4

5

6

7

8

Job/Part

Crankshaft position sensor/Stator assembly coupler

Ignition primary coil coupler

Air filter assembly/Breather hose

Bracket

Muffler

Gasket

Q’ty

1/1 Disconnect.

Remarks

1

1/1

1

1

1

Disconnect.


5-2

EAS00191

ENGINE

ENGINE REMOVAL

ENG %m

Order Job/Part

5-3

Q’ty

Remarks


Place a suitable stand under the frame and engine.

Refer to”INSTALLING THE ENGINE”.


5-4

ENGINE REMOVAL

ENG

% m

EAS00192

INSTALLING THE ENGINE

1. Install:

8engine 1

8engine mounting b o l t 2

8engine mounting n u t 3

NOTE:

8 Apply lithium-soap-based grease to the unthreaded portion of the engine mounting bolt shaft.

8 Do not fully tighten the engine mounting bolt..

2. Install:

• rear shock absorber assembly lower bolt ®

NOTE:

Do not fully tighten the bolt.

3. Tighten:

• engine mounting bolt

X I 58Nm(5.8m

* kg, 42.0ft

* lb)

• rear shock absorber assembly lower bolt

\ | 16Nm(1.6m

* kg, 11.6ft

* lb)

EAS00221

CYLINDER HEAD n^10Nm(1.0m« kg, 7.2 ft* lb)

I

4 .

i ^ \ 7

CYLINDER HEAD

ENG %m

P^9Nm(0.9m • kg, 6.5 ft • lb)

P|^j8Nm(0.8m • kg, 5.8 ft • lb)

«13Nm(1.3m • kg, 9.4 ft • lb)

[ \ 30Nm(3.0m • kg, 21.7 ft • lb)

7

8

9

1

2

3

4

5

6

Order Job/Part

Removing the cylinder head

Radiator

Thermostat

Water pump

Muffler/Bracket

Intake manifold/O-ring

Joint/O-ring

Spark plug cap

Ignition coil

Spark plug

Coolant temperature sensor

Cylinder head cover

O-ring

Timing chain tensioner

Q’ty

Remarks


Refer to”COOLING SYSTEM”in chapter

6.

5-5

1/1

1/1

1

1

1

1

1

1

1

Refer to”ENGINE REMOVAL”.

CYLINDER HEAD

ENG

% m

P^9Nm(0.9m • kg, 6.5 ft • lb)

«13Nm(1.3m • kg, 9.4 ft • lb)

Order Job/Part

10 Timing chain tensioner gasket

11 Camshaft sprocket

12 Bolt

13 Nut

14 Plate

15 Cylinder head

16 Cylinder head gasket

17 Dowel pin

Remarks

Q’ty

1

1 Refer to”REMOVING THE CYLINDER

2 HEAD” and “INSTALLING THE CYLIN-

4 DER HEAD”.

1

1

1

2


5-6

5-7

CYLINDER HEAD

ENG %m

EAS00225

REMOVING THE CYLINDER HEAD

1. Remove :

8V-belt case cover

8Refer to “BELT DRIVE”.

8cylinder head cover

2. Align:

8“I” mark a on the AC magneto rotor

(with the stationary pointer b on the crankcase cover)

• • • • • • • • • • • • • • • • • • • • • • • a. Turn the primary fixed sheave counterclockwise. b. When the piston is at TDC on the compression stroke, align the “I” mark c on the camshaft sprocket with the mark d on the plate.

• • • • • • • • • • • • • • • • • • • • • • •

3. Loosen:

8timing chain tensioner cap bolt

8camshaft sprocket bolt 1

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

Rotor holding tool

90890-01235

YU-01235

5-8

CYLINDER HEAD

ENG %m

4. Remove:

8timing chain tensioner


8camshaft sprocket 1

8timing chain 2

NOTE:

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

5. Remove:

8cylinder head

NOTE:

8 Loosen the nuts in the proper sequence as shown.

8 Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

5-9

CYLINDER HEAD

ENG %m

EAS00227

CHECKING THE CYLINDER HEAD

1. Eliminate:

8combustion chamber carbon deposits

(with a rounded scraper)

NOTE:

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

• spark plug bore thread

• valve seats

2. Check:

• cylinder head

Damage/scratches -» Replace.

3. Measure:

• cylinder head warpage

Out of specification -» Resurface the cylinder head.

Maximum cylinder head warpage

0.05 mm (0.0020 in)

• • • • • • • • • • • • • • • • • • • • • • • a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows. d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern.

NOTE:

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

• • • • • • • • • • • • • • • • • • • • • • •

CYLINDER HEAD

ENG %m

EAS00231

INSTALLING THE CYLINDER HEAD

1. Install:

• gasket New

• dowel pins

2. Install:

• cylinder head

3. Tighten:

• cylinder head nuts

X | 10 Nm (1.0 m * kg, 7.2 ft * lb)

• cylinder head bolts

X | 10 Nm (1.0 m * kg, 7.2 ft * lb)

NOTE:

• Lubricate the cylinder head nuts with engine oil.

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

• cylinder head tightening sequence

(1 -» 2 -» 3 4 -» 2 -» 5 -» 6)

5-10

4. Install:

8camshaft sprocket

8timing chain

• • • • • • • • • • • • • • • • • • • • • • • a. Turn the primary pulley counterclockwise. b. Align the “I” mark a on the AC magneto c. rotor with the stationary pointer b on the crankcase cover.

Align the “I” mark c on the camshaft sprocket with the stationary pointer d on the plate. d. Install the timing chain onto the camshaft sprocket, and then install the camshaft sprocket onto the camshaft.

NOTE:

8 When installing the camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side.

8 Align the slot on the camshaft with the tab

5-11

CYLINDER HEAD

ENG %m c C

Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. e. While holding the camshaft, temporarily tighten the camshaft sprocket bolt. f. Remove the wire from the timing chain.

• • • • • • • • • • • • • • • • • • • • • • •

5. Install

8camshaft sprocket bolt 1

6. Install:

8timing chain tensioner gasket New

8timing chain tensioner

• • • • • • • • • • • • • • • • • • • • • • • a. Remove the cap bolt 1 and spring 2 . b. Release the timing chain tensioner one-way cam 3 and push the timing chain tensioner rod 4 all the way into the timing chain tensioner housing. c. Install the timing chain tensioner and gasket 5 onto the cylinder.

V

%

Timing chain tensioner bolt

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

Cap bolt

8 Nm (0.8 m • kg, 5.8 ft • lb)

• • • • • • • • • • • • • • • • • • • • • • •

CYLINDER HEAD

ENG

% m

7. Turn:

8crankshaft

(several turns counterclockwise)

8. Check:

8“I” mark a

Align the “I” mark on the AC magneto rotor with the stationary pointer b on the crankcase cover.

8“I” mark c

Align the “I” mark on the camshaft sprocket with the stationary pointer d on the plate.

Out of alignment -» Correct.

Refer to the installation steps above.

5-12

9. Tighten:

8camshaft sprocket bolt

X I 30 Nm (3.0 m * kg, 21.7 ft * lb)

C

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

10. Measure:

8valve clearance


Refer to “ADJUSTING THE VALVE

CLEARANCE” in chapter 3.

THE ROCKER ARMS AND CAMSHAFT

ENG

% m


1

2

3

4

5

6

Order Job/Part

Removing the rocker arms and camshaft

Cylinder head

Camshaft

Rocker arm shaft(intake)

Rocker arm shaft(exhaust)

Rocker arm(intake)

Rocker arm(exhaust)

Collar

Q’ty

Remarks


1

1

1

1

1

2

Refer to “CYLINDER HEAD”.


5-13


ENG

% m

EAS00202

REMOVING THE ROCKER ARMS AND CAM-

SHAFT

1. Remove:

8intake rocker arm shaft

8exhaust rocker arm shaft

8intake rocker arm

8exhaust rocker arm

8collar

NOTE:

Remove the rocker arm shafts with the clip plier.

2. Remove:

8camshaft 1

NOTE:

Remove the camshaft with the slide hammer bolt.

Slide hammer bolt

90890-01085

YU-01083-2

Weight

90890-01084

YU-01083-3

5-14


ENG

EAS00205

CHECKING THE CAMSHAFT

1. Check:

• camshaft bushings


2. Check:

• camshaft lobes

Blue discoloration/pitting/scratches -*

Replace the camshaft.

® m§> rgrxn^

X \

11151001

3. Measure:

• camshaft lobe dimensions a and b

Out of specification -* Replace the camshaft.

Camshaft lobe dimension limit

Intake a30.158~30.258mm

(1.1873~1.1913 in)

<Limit>:30.058mm (1.1834 in) b25.082~25.182mm

(0.9875~0.9914 in)

<Limit>:24.982mm (0.9835 in)

Exhaust a30.158~30.258mm

(1.1873~1.1913 in)

<Limit>:30.058mm (1.1834 in) b25.020~25.120mm

(0.9850~0.9890 in)

<Limit>:24.920mm (0.9811 in)

4. Check:

• camshaft oil passage

Obstruction -* Blow out with compressed air.

5-15


EAS00206

CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS

The following procedure applies to all of the rocker arms and rocker arm shafts.

1. Check:

• rocker arm (camshaft touch surface © )

• rocker arm (valve touch surface ® )


2. Check:

• rocker arm shaft

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

3. Check:

• camshaft lobe

Excessive wear -» Replace the camshaft.

4. Measure:

• rocker arm inside diameter a


Rocker arm inside diameter

10 ~ 10.015 mm (0.3937 ~ 0.3943 in)

<Limit>:10.030mm (0.3949 in)

5-16


5. Measure:

• rocker arm shaft outside diameter a


Rocker arm shaft outside diameter

9.981 ~ 9.991 mm (0.3930 ~ 0.3933 in)

<Limit>:9.950mm (0.3917 in)

6. Calculate:

• rocker-arm-to-rocker-arm-shaft clearance

NOTE:

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

Above 0.034 mm (0.0013 in) -» Replace the defective part(s).

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

0.009 ~ 0.034 mm (0.0004 ~ 0.0013 in)

EAS00207

CHECKING THE TIMING CHAIN, CAMSHAFT

SPROCKET, AND TIMING CHAIN GUIDES

5-17

1. Check:

• timing chain

Damage/stiffness -» Replace the timing chain and camshaft sprocket as a set.

2. Check:

• camshaft sprocket

More than 1/4 tooth wear a -» Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth

b Correct

(T) Timing chain roller

(2) Camshaft sprocket

3. Check:

• timing chain guide (exhaust side)

• timing chain guide (intake side)

Damage/wear -» Replace the defective part(s).


EAS00210

CHECKING THE TIMING CHAIN TENSIONER

1. Check:

• timing chain tensioner


2. Check:

• one-way cam operation

Rough movement -» Replace the timing chain tensioner.

3. Check:

• cap bolt

• o-ring New

• spring

• one-way cam

• gasket New

• timing chain tensioner rod

Damage/wear -» Replace the defective part(s).

• • • • • • • • • • • • • • • • • • • • • • • a. Removing the spring and cap bolt. b. c. d.

Return cam chain tensioner one way cam.

Press tensioner rod to the cam chain tensioner housing.

Installing the spring and cap bolt.

Loosen the front end of cam chain tensioner slowly. e. Make sure to return to the front end of cam chain tensioner.

• • • • • • • • • • • • • • • • • • • • • • •

Rough movement -» Replace the timing chain tensioner.

5-18


ENG %m

EAS00220

INSTALLING THE CAMSHAFT AND ROCKER

ARMS

1 . Lubricate:

8camshaft 1


Camshaft

Molybdenum disulfide oil

Camshaft bearing

Engine oil

2. Lubricate:

8rocker arm shafts



3. Install:

8exhaust rocker arm 1

8collar 2

8exhaust rocker arm shaft 3

NOTE:

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

4. Install:

8intake rocker arm 1

8collar 2

8intake rocker arm shaft 3

NOTE:

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

5-19

VALVES AND VALVE SPRINGS

ENG

% m

EAS00236


Order

1

2

3

7

8

9

Valve pad

Valve cotter

Valve spring retainer

4 Valve spring

5 Valve(intake)

6 Valve(exhaust)

Valve stem seal

Valve stem seat

Valve guide

Job/Part

Removing the valves and valve springs

Cylinder head

Rocker arms

Rocker arm shafts

Camshaft

Q’ty

Remarks



Refer to”REMOVING THE ROCKER

ARMS AND CAMSHAFT” and “INSTALL-

ING THE CAMSHAFT AND ROCKER

ARMS”.

3

6

3

3

2 Refer to”REMOVING THE VALVES” and

1 “INSTALLING THE VALVES”.

3

3

3

5-20


ENG

% m

Order Job/Part

Q’ty

Remarks


5-21


ENG %m

EAS00237

REMOVING THE VALVES

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

NOTE:

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

1. Remove:

8valve pad 1

NOTE:

Make a note of the position of each valve pad so that they can be reinstalled in their original place.

2. Check:

• valve sealing

Leakage at the valve seat -» Check the valve face, valve seat, and valve seat width.

Refer to “CHECKING THE VALVE

SEATS”.

• • • • • • • • • • • • • • • • • • • • • • • a. Pour a clean solvent a into the intake and exhaust ports. b. Check that the valves properly seal.

NOTE:

There should be no leakage at the valve seat

© .

• • • • • • • • • • • • • • • • • • • • • • •

5-22

3 . Remove: valve cotters 1

NOTE:

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

VALVES AND VALVE SPRINGS yValve spring compressor

90890-04019

YM-04019

Valve spring compressor attachment

90890-04148

YM-04148

4 . Remove:

8valve spring retainer 1

8valve spring 2

8valve stem seal 3

8valve spring seat 4

8valve 5

NOTE:

Identify the position of each part very carefully so that it can be reinstalled in its original place.

5-23


ENG

EAS00239

CHECKING THE VALVES AND VALVE

GUIDES

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

1 . Measure:

8valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =

Valve guide inside diameter a -

Valve stem diameter b

Out of specification -* Replace the valve guide.

Valve-stem-to-valve-guide clearance

Intake

0.010 ~ 0.037 mm(0.0004~0.0015 in)

<Limit>: 0.08 mm(0.0031 in)

Exhaust

0.025 ~ 0.052 mm(0.001~0.002 in)

<Limit>: 0.10 mm(0.0039 in)

2. Replace:

8valve guide

NOTE:

To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100°C (212°F) in an oven.

• • • • • • • • • • • • • • • • • • • • • • • a. Remove the valve guide with the valve guide remover 1 . b. Install the new valve guide with the valve guide installer 2 and valve guide remover

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

NOTE:

After replacing the valve guide, reface the valve seat.

Valve guide remover (4.0 mm)

90890-04111(YM-04111)

Valve guide installer (4.0 mm)

90890-04112(YM-04112)

Valve guide reamer (4.0 mm)

90890-04113(YM-04113)

5-24

• • • • • • • • • • • • • • • • • • • • • • •


ENG

% m

3. Eliminate:

• carbon deposits

(from the valve face and valve seat)

4. Check:

• valve face

Pitting/wear -* Grind the valve face.

• valve stem end

Mushroom shape or diameter larger than the body of the valve stem -* Replace the valve.

O D t E

5. Measure:

• valve margin thickness a

Out of specification -* Replace the valve.

Valve margin thickness

0.9~1.1mm(0.0354~0.0433in)

6. Measure:

• valve stem runout

Out of specification -* Replace the valve.

NOTE:

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

Valve stem runout

0.01 mm(0.0004 in)

5-25


EAS00240

CHECKING THE VALVE SEATS

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

1. Eliminate:

• carbon deposits

(from the valve face and valve seat)

2. Check:

• valve seat

Pitting/wear -* Replace the cylinder head.

3. Measure:

• valve seat width a

Out of specification -* Replace the cylinder head.

Valve seat width

Intake: 0.9 ~ 1.1 mm (0.0354 ~

0.0433 in)

<Limit>: 1.6 mm(0.063 in)

Exhaust: 0.9 ~1.1 mm

(0.0354~0.0433 in)

<Limit>: 1.6 mm(0.063 in)

T T T T T T T T T T T T T T T T T T T T T T T a. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. b. c.

Install the valve into the cylinder head.

Press the valve through the valve guide and onto the valve seat to make a clear impresd. sion.

Measure the valve seat width.

NOTE:

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

• • • • • • • • • • • • • • • • • • • • • • •

5-26

4. Lap:

8valve face

8valve seat

NOTE:

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


X"7

V N\ a

• • • • • • • • • • • • • • • • • • • • • • • a. Apply a coarse lapping compound a to the valve face. c C

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

^ b. 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 g. the valve face and valve seat.

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

Install the valve into the cylinder head.

Press the valve through the valve guide and onto the valve seat to make a clear impression. j . Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat.

• • • • • • • • • • • • • • • • • • • • • • •

5-27


EAS00241

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the valve springs.

1. Measure:

• valve spring free length a

Out of specification -» Replace the valve spring.

Valve spring free length

Intake valve spring

39.35 mm (1.5492 in)

<Limit>: 37.38 mm (1.4717 in)

Exhaust valve spring

41.57 mm (1.6366 in)

<Limit>: 39.49 mm (1.5547 in)

2. Measure:

• compressed valve spring force a

Out of specification -» Replace the valve spring. b Installed length

Compressed valve spring force (installed)


9 1 . 1 ~ 1 0 4 . 9 N ( 9 . 3 ~ 1 0 . 7 k g ,

20.48~23.58lb) at 28mm(1.1024in)


1 0 7 . 9 ~ 1 2 4 . 1 N ( 1 1 . 0 ~ 1 2 . 7 k g ,

24.26~27.90lb) at 30mm(1.1811in)

5-28

3. Measure:

• valve spring tilt a

Out of specification -» Replace the valve spring.

Spring tilt limit


1.7 mm (0.0669 in) ( 2.5° )


1.8 mm (0.0709 in)( 2.5° )


ENG

% m

EAS00245

INSTALLING THE VALVES

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

1 . Deburr:

8valve stem end

(with an oil stone)

2. Lubricate:

8valve stem 1

8valve stem seal 2

(with the recommended lubricant)



3. Install:

8valve 1

8valve spring seat 2

8valve stem seal 3 N e w

8valve spring 4

8valve spring retainer 5

(into the cylinder head)

NOTE:

Install the valve spring with the larger pitch a facing up. b Smaller pitch

5-29

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 .


ENG

% m

Valve spring compressor

90890-04019(YM-04019)

Valve spring compressor attachment

90890-04148(YM-04148)

5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer. c C

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

6. Install: valve pad 1

NOTE:

8 Lubricate the valve pad with engine oil.

8 Valve pad must be reinstalled in its original position.

5-30

EAS00251

CYLINDER AND PISTON


ENG

% m

1

2

3

4

5

6

7

8

Order Job/Part

Removing the cylinder and piston

Cylinder head

Timing chain guide(exhaust side)

Cylinder

Dowel pin

Cylinder gasket

Piston pin clip

Piston pin

Piston

Piston ring set

Q’ty

Remarks



1

1

2

1

2

1

1

1

Refer to”REMOVING THE CYLINDER

AND PISTON” and “INSTALLING THE

PISTON AND CYLINDER”.


5-31


ENG

% m

EAS00253

REMOVING THE CYLINDER AND PISTON

1 . Remove:

8piston pin clip 1

8piston pin 2

8piston 3 c C

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

NOTE:

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

8 Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller s e t 4 .

Piston pin puller set

90890-01304(YU-01304)

2. Remove:

8top ring

82nd ring

8oil ring

NOTE:

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

5-32


ENG

EAS00255

CHECKING THE CYLINDER AND PISTON

1. Check:

• piston wall

• cylinder wall

Vertical scratches -* Rebore or replace the cylinder, and replace the piston and piston rings as a set.

2. Measure: piston-to-cylinder clearance

• • • • • • • • • • • • • • • • • • • • • • • a. Measure cylinder bore “C” with the cylinder bore gauge.

NOTE:

Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder.

Then, find the average of the measurements.

Cylinder bore “C” 38.000 ~ 38.010mm

(1.4961 ~ 1.4965in)

0.05mm (0.0020in)

Taper limit “T”

Out-of-round “R”

0.05mm (0.0020in)

~ D

- maximum of D or D

“R” = maximum of D

1

, D

3 5

- minimum of D

2

, D

4 or D

6 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer.

5-33 a 5mm(0.1969in) from the bottom edge of the piston

Standard

Piston size “P”

37.975 ~ 37.990mm

(1.4951 ~ 1.4957in) d. If out of specification, replace the piston and piston rings as a set.


ENG

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

Piston-to-cylinder clearance =

Cylinder bore “C” -

Piston skirt diameter “P”

Piston-to-cylinder clearance

0.010 ~ 0.035mm(0.0004 ~

0.0014in)

<Limit>:0.15mm(0.0059in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

• • • • • • • • • • • • • • • • • • • • • • •

5-34


EAS00263

CHECKING THE PISTON RINGS

1. Measure:

• piston ring side clearance

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

NOTE:

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

5-35

Piston ring side clearance

Top ring

0.03 ~ 0.07 mm(0.0012~0.0028 in)

<Limit>: 0.12mm(0.0047 in)

2nd ring

0.02 ~ 0.06 mm(0.0008~0.0024 in)

<Limit>:0.12 mm(0.0047 in)

2. Install:

8piston ring

(into the cylinder)

NOTE:

Level the piston ring into the cylinder with the piston crown. a 10 mm (0.3937 in)

3. Measure:

• piston ring end gap

Out of specification -» Replace the piston ring.

NOTE:

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

Piston ring end gap

Top ring

0.05 ~ 0.15 mm (0.0020 ~ 0.0059 in)

<Limit>: 0.40 mm (0.0157 in)

2nd ring

0.05 ~ 0.17 mm (0.0020 ~ 0.0067 in)

<Limit>: 0.52 mm (0.0205 in)

Oil ring

0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in)


ENG

% m

EAS00265

CHECKING THE PISTON PIN

1. Check:

• piston pin

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

2. Measure:

• piston pin outside diameter a

Out of specification -* Replace the piston pin.

Piston pin outside diameter

9.996 ~ 10.000 mm (0.3935 ~

0.3937 in)

<Limit>:9.976 mm (0.3928 in)

3. Measure:

• piston pin bore diameter b

Out of specification^ Replace the piston.

Piston pin bore diameter

10.002 ~ 10.013 mm (0.3938 ~

0.3942 in)

<Limit>:10.043 mm (0.3954 in)

4. Calculate:

• piston-pin-to-piston-pin-bore clearance

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

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

Piston pin bore diameter b -

Piston pin outside diameter a

Piston-pin-to-piston clearance

0.002 ~ 0.017 mm (0.0001 ~ 0.0007 in)

5-36


ENG

% m

CHECKING THE TIMING CHAIN GUIDE

1. Check:

8 timing chain guide (exhaust side)

Damage/wear -» Replace

EAS00267

INSTALLING THE PISTON AND CYLINDER

1 . Install:

8oil ring expander 1

8oil ring rail 2

82nd ring 3

8top ring 4

NOTE:

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

5-37

2. Install:

8piston 1

8piston pin 2

8piston pin clip New 3

NOTE:

8

8

Apply engineoil the piston pin.

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.


ENG

% m

3. Install:

8gasket

N e w

8dowel pins

4. Lubricate:

8piston

8piston rings

8cylinder



Engine oil

5. Offset:

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

A Exhaust side

6. Install:

8cylinder 1

8timing chain guide(exhaust side)

NOTE:

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

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

5-38

EAS00316

BELT DRIVE

V-BELT CASE COVER

BELT DRIVE

ENG %m

%. 10Nm(1.0m • kg, 7.2 ft • lb)

Order

1

2

3

4

5

Job/Part

Removing the V-belt case cover

Kickstarter

Cover

V-belt case cover

V-belt case cover gasket

Dowel pin

P|« 12Nm(1.2m • kg, 8.7 ft* lb)

Q’ty

Remarks


1

1

1

1

2


5-39

EAS00338

KICKSTARTER

BELT DRIVE

ENG

% m

Order Job/Part

Disassembling the kickstarter

V-belt case cover

1 Kick pinion gear

2 Kick pinion gear clip

3 Circlip/Plate washer

4 Kickstarter shaft

5 Torsion spring

6 Solid bush

Remarks

Q’ty


Refer to”V-BELT CASE COVER“.

1

1

1/1 Refer to”INSTALLING THE KICKSTARTER”.

1

1

1


5-40

5-41

BELT DRIVE

ENG %m

EAS00340

INSTALLING THE KICKSTARTER

1. Install:

8solid b u s h 1

8kick shaft assembly 2

8torsion spring 3

2. Hook:

8torsion spring

NOTE:

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

3. Install:

8plain washer

8circlip 1 N e w

4. Install:

8kick pinion g e a r 1

8kick pinion gear c l i p 2

NOTE:

8 Lubricate the kick pinion gear clip and shaft with molybdenum disulfide oil.

8 Install the kick pinion gear clip at the position shown.

V-BELT AND PRIMARY/SECONDARY SHEAVE

BELT DRIVE

ENG %m

40Nm (4.0 m « kg, 28.9 f H b)

30Nm (3.0 m « kg, 21.7 f H b)

8

9

10

11

12

13

4

5

6

7

Order

1

2

3

Job/Part

Removing the V-belt and primary/secondary sheave

Primary sheave nut/Plate washer

Oneway clutch

Primary fixed sheave

Secondary sheave nut

Clutch housing

Secondary sheave

V-belt

Plate washer

Collar

Primary sliding sheave

Cam/Weight

Slider

Plate washer

Q’ty

Remarks


1/1

1

1

1

1

1

1/6

3

1

1

1

1

1

Refer to”REMOVING THE PRIMARY

SHEAVE” and “INSTALLING THE SEC-

ONDARY SHEAVE, V-BELT AND PRI-

MARY SHEAVE” .

Refer to”REMOVING THE SECOND-

ARY SHEAVE AND V-BELT” and “IN-

STALLING THE SECONDARY

SHEAVE, V-BELT AND PRIMARY

SHEAVE” .


5-42

SECONDARY SHEAVE

BELT DRIVE

ENG %m

Order Job/Part

Disassembling the secondary

Q’ty sheave

1 Clutch carrier nut

2 Clutch carrier

Remarks

Disassemble the parts in the order listed.

Refer to”DISASSEMBLING THE SEC-

1 ONDARY SHEAVE” and “ASSEMBLING

THE SECONDARY SHEAVE”.

3 Clutch shoe spring

4 Compression spring

5 Secondary spring seat

6 Guide pin

7 Secondary sliding sheave

8 O-ring

9 Oil seal

0 Secondary fixed sheave

3

1

1

2

1

2

2

1

Refer to”ASSEMBLING THE SECOND-

ARY SHEAVE” .


5-43

BELT DRIVE

ENG %m

EAS00317

REMOVING THE PRIMARY SHEAVE

1. Remove:

8primary sheave nut 1

8plate washer

8oneway clutch

8primary fixed sheave 2

NOTE:

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


90890-01235 (YU-01235)

-^— "\f ^^^^\\

Jf2/®

-^z^r^^

«S

If M.

/ / jS/Ki/

EAS00318

REMOVING THE SECONDARY SHEAVE AND

V-BELT

1 . Remove:

8secondary sheave nut 1

8clutch housing 2

NOTE:

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

Sheave holder

90890-01701 (YS-01880-A)

2. Loosen:

8clutch carrier nut c C

Do not remove the clutch carrier nut at this stage.

NOTE:

While holding the clutch carrier with the rotor holding tool 1 , loosen the clutch carrier nut one full turn with the socket wrench 2 .

5-44 f,


90890-01235

YU-01235

Socket wrench(39mm)

90890-01493

%-©

1 // / /Py*—\ 1

BELT DRIVE

ENG

% m

3. Remove:

8secondary sheave 1

8V-belt 2

NOTE:

Remove the V-belt and secondary sheave from the primary sheave side.

EAS00319

DISASSEMBLING THE SECONDARY

SHEAVE

1. Remove:

8clutch carrier nut 1

NOTE:

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

Clutch spring holder

90890-01337

YM-33285

YM-33285-6

5-45

CHECKING THE CLUTCH SHOES

The following procedure applies to all of the clutch shoes.

1. Check:

• clutch shoe

Damage/wear -» Replace the clutch shoes and springs as a set.

Glazed areas -» Sand with coarse sandpaper.

NOTE:

After sanding the glazed areas, clean the clutch with a cloth.

2. Measure:

• clutch shoe thickness

Out of specification -» Replace the clutch shoes and springs as a set.

jîa

\1J

BELT DRIVE

Clutch shoe thickness

3.7mm(0.146in)

<Limit>:2.0mm(0.079in)

NOTE:

8 Inspect clutch shoesa.

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

8 Replace the all three as a set.

EAS00320

CHECKING THE V-BELT

1. Check:

• V-belt ®

Cracks/damage/wear -» Replace.

Grease/oil -» Clean the primary and secondary sheave.

2. Measure:

• V-belt width a


V-belt width

17.9 mm (0.705 in)

<Limit>: 16.1 mm (0.634 in)

CHECKING THE PRIMARY SHEAVE

1. Check:

• primary sliding sheave ©

• primary fixed sheave ®

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

5-46

2. Check:

• free movement

Stick or excessive play -» Replace the primary sliding sheave or collar.

NOTE:

Insert the collar ® into the primary sliding sheave ® , and check for free movement.

BELT DRIVE

ENG

EAS00321

CHECKING THE PRIMARY SHEAVE WEIGHTS

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

1. Check:

• primary sheave weight

Cracks/damage/wear -* Replace.

2. Measure:

• primary sheave weight outside diameter a

Out of specification -* Replace.

Primary sheave weight outside diameter

15 mm (0.591 in)

<Limit>: 14.5 mm (0.571 in)

CHECKING THE SLIDER

1. Check:

• slider ©

Damage/wear^ Replace

EAS00322

CHECKING THE SECONDARY SHEAVE

1. Check:

• secondary fixed sheave

• secondary sliding sheave

Cracks/damage/wear -* Replace the secondary fixed and sliding sheaves as a set.

5-47

2. Check:

• torque cam groove ©

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

3. Check:

• guide pin (2)

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

5-48

BELT DRIVE

ENG %m

EAS00323

ASSEMBLING THE PRIMARY SHEAVE

1 . Clean:

8primary fixed sheave 1

8primary sliding sheave 2

8collar 3

8primary sheave weights 4

NOTE:

Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5 .

2. Install:

8primary sliding sheave 1

8primary sheave weights 2

8collar 3

3. Install:

8sliders 1

8cam 2

BELT DRIVE

ENG

# 1

1&m\

EAS00324

ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate:

8secondary fixed sheave’s inner surface

1

8secondary sliding sheave’s inner surface

2

8oil seals

8bearings



BEL-RAY assembly lube

®

2. Install:

8secondary sliding sheave 1

NOTE:

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

3 . m

Oil seal guide

90890-01384 (YM-33299)

5-49

3. Install:

8guide pin 1

4. Lubricate:

8guide pin groove 2

8o-ring New 3



BEL-RAY assembly lube

®

®

©

I f ' / /F^r~\\

BELT DRIVE

ENG

% m

5. Install:

8secondary sheave 1

8spring

8clutch carrier 2

NOTE:

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

Clutch spring holder

90890-01337 (YM-33285)

( YM-33285-6)

EAS00325

INSTALLING THE SECONDARY SHEAVE, V-

BELT AND PRIMARY SHEAVE

1. Install:

8V-belt 1

8secondary sheave 2 c C

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

NOTE:

8 Install the V-belt onto the primary sheave side.

8 Install the V-belt with printed arrow mark on the V-belt facing in the direction shown in the illustration.

5-50

2. Tighten:

8 clutch carrier nut

X I 55Nm(5.5m

* kg, 39.8ft

* lb)

NOTE:

While holding the clutch carrier with the rotor holding tool © , tighten the clutch carrier nut with the socket wrench ® .

5-51

BELT DRIVE

ENG %m


90890-01235

YU-01235

Socket wrench(39mm)

90890-01493

3. Install:

• clutch housing (T)

• secondary sheave nut ®

X I 40Nm(4.0m

* kg, 28.9ft

* lb)

NOTE:

Tighten the secondary sheave nut with the sheave holder ® .

^

Sheave holder

90890-01701

YS-01880-A

4. Install:

• primary fixed sheave ©

• oneway clutch

• plate washer

• primary sheave nut ®

X I 30Nm(3.0m

* kg, 21.7ft

* lb)

NOTE:

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

5-52

BELT DRIVE

ENG %m

5. Position:

8V-belt 1

NOTE:

Position the V-belt in the primary sheave 2

(when the pulley is at its widest position) and in the secondary sheave 3 (when the pulley is at its narrowest position), and make sure the Vbelt is tight.

STARTER CLUTCH AND AC MAGNETO

ENG

% m

EAS00341


STATOR COIL ASSEMBLY

Order

1

2

3

4

5

Removing the stator coil assembly

Coolant

Job/Part

Q’ty

Remarks


Drain.


Single seat/Trunk

Front cover


Battery cover/Battery

Footrest board

Radiator

Crankshaft position sensor coupler/Stator coil assembly coupler

Fan

Nut/Plate washer

AC magneto rotor

Woodruff key

1/1

1

1/1

1

1



Disconnect.

5-53


ENG

% m

Order

6

7

8

Job/Part

Lock plate

Crankshaft position sensor

Stator coil assembly

Remarks

Q’ty

1

1

1


5-54

EAS00342

STARTER CLUTCH


ENG %m

Order Job/Part

Removing the starter clutch

Engine oil

1

2

3

4

5

6

7

8

AC magneto rotor

Stator coil assembly

Crankcase cover(right)

Starter clutch nut

Washer

Starter wheel gear

Roller

Collar

Starter clutch

Idle gear

1

1

1

1

1

1

1

1

Q’ty

Remarks


Drain.

Refer to “CHANGING THE ENGINE

OIL”in chapter 3.

Refer to”REMOVING THE AC MAG-

NETO” and “INSTALLING THE AC MAG-

NETO”. c C

The starter clutch nut is left-hand thread.

Refer to”REMOVING THE STARTER

CLUTCH” and “INSTALLING THE

STARTER CLUTCH” .


5-55


ENG

% m

EAS00347

REMOVING THE AC MAGNETO

1. Remove:

8AC magneto rotor n u t 1

8washer

NOTE:

8 While holding the AC magneto rotor 2 with the sheave holder 3 , loosen the AC magneto rotor nut.

8 Do not allow the sheave holder to touch the projection on the AC magneto rotor.

Sheave holder

90890-01701

YS-01880-A

2. Remove:

8AC magneto rotor 1

(with the flywheel puller set 2 )

8woodruff key c C

To protect the end of the crankshaft, place an appropriate sized socket between the flywheel puller set’s center bolt and the crankshaft.

NOTE:

Make sure the flywheel puller is centered over the AC magneto rotor.

Flywheel puller set

90890-01468

YU-33270-B

5-56


ENG

% m

EAS00344

REMOVING THE STARTER CLUTCH

1. Remove:

8crankcase cover (right)1

NOTE:

Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

2. Remove:

8starter clutch n u t 1

8washer

8starter wheel gear

8roller

8collar

8starter clutch

8idle gear

NOTE:

The starter clutch nut is left-hand thread.

5-57


ENG %m

EAS00351

CHECKING THE STARTER CLUTCH

1. Check:

• starter clutch roller


2. Check:

• starter clutch idle gear

• starter wheel gear

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

3. Check:

• starter wheel gear’s contacting surfaces

Damage/pitting/wear -» Replace the starter clutch gear.

4. Check:

8starter clutch operation

• • • • • • • • • • • • • • • • • • • • • • • a. Install the starter wheel gear 1 o n t o the starter clutch 2 and hold the starter clutch. b. When turning the starter wheel gear clockwise A , the starter clutch and the starter wheel gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter wheel gear counterclockwise B , it should turn freely, otherwise the starter clutch is faulty and must be replaced.

• • • • • • • • • • • • • • • • • • • • • • •

5-58


ENG %m

EAS00355

INSTALLING THE STARTER CLUTCH

1. Install:

• idle gear

• starter clutch

• collar

• roller

• starter wheel gear

• washer

• starter clutch nut ®

\ | 90 Nm (9.0 m * kg, 65.1 ft * lb)

NOTE:

The starter clutch nut is left-hand thread.

2. Install:

• gasket New

• crankcase cover (right) ©

X I 10 Nm (1.0 m * kg, 7.2 ft * lb)

5-59

EAS00354

INSTALLING THE AC MAGNETO

1. Install:

8stator coil assembly 1

8crankshaft position sensor 2

8woodruff k e y 3

8AC magneto rotor

8washer

8AC magneto rotor nut

NOTE:

8 Clean the tapered portion of the crankshaft and the AC magneto rotor hub.

8 When installing the AC magneto rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft.


ENG

% m

2. Tighten:

• AC magneto rotor nut (T)

X I 43 Nm (4.3 m * kg, 31.1 ft * lb)

NOTE:

• While holding the AC magneto rotor (2) with the sheave holder ® , tighten the AC magneto rotor nut.

• Do not allow the sheave holder to touch the projection on the AC magneto rotor. f*

Sheave holder

90890-01701

YS-01880-A

5-60

OIL PUMP

ENG %m

EAS00360

OIL PUMP

4Nm (0.4 m « kg, 2.9 f H b)

Order

1

2

3

4

5

Job/Part

Removing the oil pump

Radiator

AC magneto

Starter clutch

Drive gear

Circlip/Plate washer

Oil pump driven gear

Dowel pin

Oil pump

3

Q’ty

Remarks



1

1/1

1

2

1


5-61

11710404

OIL PUMP

EAS00364

CHECKING THE OIL PUMP

1. Check:

• oil pump drive gear

• oil pump driven gear ©

• oil pump housing

• oil pump housing cover

Cracks/damage/wear -» Replace the defective part(s).

2. Measure:

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

• outer-rotor-to-oil-pump-housing clearance \B\

• oil-pump-housing-to-inner-rotor-andouter-rotor clearance \c\

Out of specification -» Replace the oil pump.

© Inner rotor

(2) Outer rotor

(3) Oil pump housing

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

0.15 mm (0.006 in) or less

<Limit>: 0.23 mm (0.009 in)

Outer-rotor-to-oil-pump-housing clearance

0.13 ~ 0.18 mm (0.005 ~ 0.007 in)

<Limit>: 0.25mm (0.010 in)

Oil-pump-housing-to-inner-rotorand-outer-rotor clearance

0.07 ~ 0.12 mm (0.003 ~ 0.005 in)

<Limit>: 0.19 mm (0.008 in)

5-62

3. Check:

• oil pump operation

Rough movement -» Repeat steps (1) and

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

5-63

OIL PUMP

ENG %m

EAS00375

ASSEMBLING THE OIL PUMP

1. Lubricate:

8inner rotor

8outer rotor

8oil pump shaft



Engine oil

2. Install:

8 oil pump shaft (T)

(to the oil pump housing ® )

8 pin (3)

8 inner rotor ®

8 outer rotor ©

8 oil pump housing cover ®

8 oil pump housing screw

X I 4 Nm (0.4 m * kg, 2.9 ft * lb)

NOTE:

When installing the inner rotor, align the pin (3) in the oil pump shaft with the groove a in the inner rotor (4) .

3. Check:

8 oil pump operation

Refer to “CHECKING THE OIL PUMP”.

EAS00376

INSTALLING THE OIL PUMP

1. Install:

8oil pump drive gear 1

8gasket New

8oil p u m p 2

8oil pump bolt

\ | 4 Nm (0.4 m * kg, 2.9 ft * lb)

C

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

EAS00419

TRANSMISSION

TRANSMISSION

ENG

% m

Order Job/Part

Removing the transmission

Transmission oil

Muffler/Bracket

Rear wheel

V-belt case cover

Secondary sheave

1 Transmission cover

2 Transmission cover gasket

3 Dowel pin

4 Main axle

5 Drive axle

6 Primary drive gear

1

1

2

1

1

1

Q’ty

Remarks


Drain.

Refer to”CHANGING THE TRANSMIS-

SION OIL” in chapter 3.

Refer to”ENGINE REMOVAL”.

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

Refer to”BELT DRIVE”.


5-64

5-65

TRANSMISSION

EAS00425

CHECKING THE TRANSMISSION

1. Measure:

• main axle runout

(with a centering device and dial gauge )

Out of specification -» Replace the main axle.

Main axle runout limit

0.04 mm (0.002 in)

2. Measure:

• drive axle runout

(with a centering device and dial gauge )

Out of specification -» Replace the drive axle.

Primary drive gear shaft runout limit

0.04 mm (0.002 in)

3 . Check:

• transmission gears

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

• transmission gear dogs

Cracks/damage/rounded edges -» Replace the defective gear(s).

4 . Check:

• transmission gear engagement

(each pinion gear to its respective wheel gear)

Incorrect -» Reassemble the transmission axle assemblies.

5 . Check:

• transmission gear movement

Rough movement -» Replace the defective part(s).

6 . Check:

• circlip

Bends/damage/looseness -» Replace.

EAS00381

CRANKSHAFT

CRANKSHAFT ASSEMBLY

CRANKSHAFT

ENG %m

1 * 7Nm (0.7 m » kg, 5.1 f H b)

5

7Nm (0.7 m » kg, 5.1 f H b)

Order

1

2

3

4

Job/Part

Removing the crankshaft assembly

Engine

Cylinder head

Cylinder and piston

V-belt case cover

V-belt and primary/secondary sheave

Radiator

Water pump

Starter clutch

AC magneto

Oil pump

Transmission

Rear wheel

Q’ty

Remarks


Refer to”ENGINE REMOVAL” .


Refer to”CYLINDER AND PISTON”.

Refer to”OIL PUMP”.

Refer to”TRANSMISSION”.

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

Tension spring

Circlip/Plate washer

Pin

Centerstand

1

1/1

1

1

5-66

CRANKSHAFT

ENG %m f V 7Nm (0.7 m » kg, 5.1 f H b)

5

7Nm (0.7 m » kg, 5.1 f H b)

Order

5 Hook

6 Drain plug

Job/Part

7 Oil strainer

8 Compression spring

9 O-ring

10 Crankcase(right)

11

12

13

14

Spacer

Dowel pin

Guide

Crankshaft

15 Timing chain

16 Crankcase(left)

17 Oil seal

18 Bolt/O-ring

19 Timing chain guide (intake side)

5-67

Remarks

Q’ty

1

1

1

1

1


CRANKCASE” and “ASSEMBLING THE

CRANKCASE”.

1

1

1

1/1

1

1

2

1

1 Refer to”REMOVING THE CRANK-

SHAFT ASSEMBLY” and “INSTALLING

THE CRANKSHAFT ASSEMBLY”.


5-68

CRANKSHAFT

ENG %m

EAS00385

DISASSEMBLING THE CRANKCASE

1. Remove:

8centerstand assembly

2. Remove:

8crankcase b o l t s 1

NOTE:

Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

3. Remove:

8right crankcase 1

8spacer c C

Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly.

CRANKSHAFT

ENG

% m

EAS00389

REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:

8crankshaft assembly 1

8timing c h a i n 2

8timing chain guide(intake side)

NOTE:

8 Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket.

8 The crankshaft assembly cannot be removed if the timing chain is attached onto the crankshaft sprocket.

EAS00394

CHECKING THE CRANKSHAFT AND CON-

NECTING ROD

1. Measure:

• crankshaft runout

Out of specification -» Replace the crankshaft, bearing or both.

NOTE:

Turn the crankshaft slowly.

Maximum crankshaft runout

0.03mm(0.0012in)

5-69

2. Measure:

• big end side clearance

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

Big end side clearance

0.15~0.45mm(0.006~0.018in)

^ ^ ^ //\ y>^ y& y% y/y

(if my

CRANKSHAFT

ENG

% m

3. Measure:

• crankshaft width

Out of specification -» Replace the crankshaft.

Crankshaft width

42.45~42.50mm(1.671~1.673in)

4. Check:

• crankshaft sprocket (T)

Damage/wear -» Replace the crankshaft.

• bearing (2)

Cracks/damage/wear -» Replace the crankshaft.

• oil pump drive gear

Damage/wear -» Replace the crankshaft.

5. Check:

• crankshaft journal

Scratches/wear -» Replace the crankshaft.

• crankshaft journal oil passage

Obstruction -» Blow out with compressed air.

EAS00399

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a mild solvent.

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

3. Check:

• crankcase


• oil delivery passages

Obstruction -» Blow out with compressed air.

5-70

CRANKSHAFT

ENG

EAS00207

CHECKING THE TIMING CHAIN AND TIMING

CHAIN GUIDE(INTAKE SIDE)

1. Check:

• timing chain

Damage/stiffness -> Replace the timing chain and camshaft sprocket as a set.

2. Check:

• timing chain guide (intake side)

Damage/wear -> Replace.

EAS00401

CHECKING THE BEARINGS AND OIL

SEALS

1. Check:

• bearings

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

Rough movement -> Replace.

2. Check:

• oil seals


5-71

EAS00402

CHECKING THE CIRCLIPS AND WASHERS

1. Check:

• circlips

Bends/damage/looseness -> Replace.

• washers

Bends/damage -> Replace.

5-72

CRANKSHAFT

EAS00408

INSTALLING THE CRANKSHAFT

1. Install:

8timing chain guide (intake side)

8timing c h a i n 1

8crankshaft assembly 2

NOTE:

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

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

NOTE:

Put the timing chain in parallel into the crankcase, then use hands to place the crankshaft assembly into the crankcase. Manually rotate the crankshaft to check whether it is tightly engaged with the timing chain. (if not, install again)

EAS00418

ASSEMBLING THE CRANKCASE

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

2. Apply:

8sealant

(onto the crankcase mating surfaces)

Yamaha bond No. 1215

90890-85505

Sealant (Quick Gasket

®

)

ACC-11001-05-01

NOTE:

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

5-73

CRANKSHAFT

ENG %m

3. Install:

8dowel pins

8spacer

8right crankcase 1

NOTE:

Tap lightly on the right crankcase with a softface hammer.

4. Tighten:

• crankcase bolts

X I 10Nm(1.0m

* kg, 7.2ft

* lb)

NOTE:

Tighten the crankcase bolts in stages and in a crisscross pattern.

5. Apply:

• engine oil

(onto the crankshaft pin, bearing and oil delivery hole)

6. Check:

• crankshaft operation

Rough movement -* Repair.

COOL J C

CHAPTER 6

COOLING SYSTEM

RADIATOR 6-1

CHECKING THE RADIATOR 6-2

INSTALLING THE RADIATOR 6-3

THERMOSTAT 6-4

CHECKING THE THERMOSTAT 6-5

INSTALLING THE THERMOSTAT 6-6

WATER PUMP 6-7

DISASSEMBLING THE WATER PUMP 6-9

CHECKING THE WATER PUMP 6-9

ASSEMBLING THE WATER PUMP 6-10

INSTALLING THE WATER PUMP 6-11

EAS00454

RADIATOR

RADIATOR

COOL J C

COOLING SYSTEM

Order Job/Part

Removing the radiator

Front cover


Single seat/Trunk

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

6-1

Q’ty

Remarks



Drain.


1

1

1

1

1

1

1

Disconnect.

Disconnect.

Disconnect.


RADIATOR

EAS00455

CHECKING THE RADIATOR

1. Check:

• radiator fins

Obstruction -» Clean.

Apply compressed air to the rear of the radiator.

Damage -» Repair or replace.

NOTE:

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

2. Check:

• radiator inlet hose

• radiator outlet hose

• conduit hose


6-2

3. Measure:

• radiator cap opening pressure

Below the specified pressure -» Replace the radiator cap.

Radiator cap opening pressure

107.9 ~ 137.3kPa

(1.1 ~ 1.4kg/cm

2

, 15.6 ~ 19.9psi)

• • • • • • • • • • • • • • • • • • • • • • • a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap

3 .

Radiator cap tester

90890-01325

YU-24460-01

Radiator cap tester adapter

90890-01352

YU-33984 b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

• • • • • • • • • • • • • • • • • • • • • • •

4. Check:

• radiator fan

Damage -» Replace.

Malfunction -» Check and repair.

RADIATOR

EAS00456

INSTALLING THE RADIATOR

1. Fill:

8cooling system


Refer to “CHANGING THE COOLANT” in chapter 3.

2. Check:

• cooling system

Leaks -» Repair or replace any faulty part.

3 © ^ ^ C

• • • • • • • • • • • • • • • • • • • • • • • a. Attach the radiator cap tester 1 to the radiator. y-

Radiator cap tester

90890-01325, YU-24460-01

Radiator cap tester adapter

90890-01352, YU-33984 b. Apply 100 kPa (1.0 kg/cm

2

, 14.22 psi) of pressure. c. Measure the indicated pressure with the gauge.

• • • • • • • • • • • • • • • • • • • • • • A

3. Measure:



Refer to “CHECKING THE RADIATOR”.

6-3

EAS00460

THERMOSTAT

THERMOSTAT

COOL J C

10Nm (1.0 m « kg, 7.2 f H b)

10Nm (1.0 m « kg, 7.2 f H b)

4

Order Job/Part

Removing the thermostat

Front cover


Single seat/Trunk

Footrest board

Coolant

1

2

3

4

5

6

Clip

Thermostat inlet hose

Clip

Thermostat outlet hose

Thermostat cover

Thermostat

6-4

Q’ty

Remarks



Drain.


1

1

1

1

1

1

Disconnect.

Disconnect.


THERMOSTAT

EAS00462

CHECKING THE THERMOSTAT

1. Check:

• thermostat (T)

Does not open at 85 ~100°C (185 ~212°F)

-» Replace.

• • • • • • • • • • • • • • • • • • • • • • • a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.

• • • • • • • • • • • • • • • • • • • • • • • m

^ m^^^^r

85±2 C

(185±3.6 F)

100 C

(212 F)

' i

3.5mm

(0.14 in)

\

I

© Thermostat

(2) Container

(3) Thermometer

(4) Water

A Fully closed

B Fully open

NOTE:

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

2. Check:

• thermostat cover


3. Check:

• thermostat inlet hose

• thermostat outlet hose


6-5

6-6

THERMOSTAT

COOL J C

EAS00466

INSTALLING THE THERMOSTAT

1. Install:

• thermostat ©

• thermostat cover

X | 10Nm(1.0m

* kg, 7.2ft

* lb)

NOTE:

Align the breather a of thermostat to mark b of thermosat before installation.

2. Fill:

• cooling system



3. Check:

• cooling system

Leaks -» Repair or replace any faulty part.

4. Measure:




EAS00468

WATER PUMP

WATER PUMP

COOL J C lyJ2| 10 4i , /

10Nm(1.0m« kg, 7.2 ft* lb) d r ^ ®

Order Job/Part

Removing the water pump

Front cover


Single seat/Trunk

Footrest board

Coolant

5

6

7

8

9

1

2

3

4

Breather hose

Thermostat inlet hose

Water pump outlet hose

Radiator outlet hose

Water pump housing cover

Gasket

Water pump housing

Plate

Impeller shaft

6-7

Q’ty

Remarks



1

1

1

1

1

1

1

1

1

Drain.


Disconnect.

Disconnect.

Disconnect.

Disconnect.

WATER PUMP

COOL J C

6

Order

10

11

12

Oil seal

Bearing

Gasket

Job/Part

® ^ ^ ®

10Nm(1.0m • kg, 7.2 ft* lb)

Remarks

Q’ty

1

1

1


6-8

WATER PUMP

COOL J C

EAS00471

DISASSEMBLING THE WATER PUMP

1. Remove:

8water pump housing c o v e r 1

8dowel pin

8gasket

2. Remove:

8plate 2

8impeller shaft 3

8gasket

8oil seal

(with a thin, flat-head screwdriver)

8bearing

NOTE:

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

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

EAS00474

CHECKING THE WATER PUMP

1. Check:

• water pump housing cover

• water pump housing

• impeller ©


6-9

2. Check:

• water pump seal (T)


3. Check:

• bearing

Rough movement -» Replace.

4. Check:



1

6-10

WATER PUMP

COOL J C

EAS00475

ASSEMBLING THE WATER PUMP

1. Install:

8bearing1

NOTE:

8 Before installing the oil seal, apply tap water or coolant onto its out surface.

8 Install the oil seal with a socket that matches its outside diameter.

2. Install:

8water pump seal New 1

(into the water pump housing 2 ) c C

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

NOTE:

8 Install the water pump seal with the special tools.

8 Press in depth of water pump and oil seal is 5.5~6.0mm a .

^

Mechanical seal installer

90890-04145 3

Middle driven shaft bearing driver

90890-04058 4

YM-04058

3. Measure:

8 impeller shaft tilt

Out of specification -» Replace the impeller shaft .

Impeller shaft tilt limit

0.15mm(0.0059in)

1 Straightedge

2 Impeller

4. Install:

8impeller s h a f t 1

8 p l a t e 2 c C

After installation, check that the impeller shaft rotates smoothly.

WATER PUMP

COOL J C

5. Install:

8gasket New

8water pump housing c o v e r 1

• water pump assembly (T)

M§

Iae EAS00478

INSTALLING THE WATER PUMP

1. Install:

X | 10Nm(1.0m

* kg, 7.2ft

* lb)

NOTE: b//

Align the slit a on the impeller shaft with

^ bolt.

2. Install:

• breather hose

• thermostat inlet hose

• water pump outlet hose


3. Fill:

• cooling system



4. Check:

• cooling system

Leaks -» Repair or replace the faulty part.

5. Measure:




6-11

FI ifl

CHAPTER 7


FUEL INJECTION SYSTEM 7-1

WIRING DIAGRAM 7-2

ECU’S SELF-DIAGNOSTIC FUNCTION 7-4

CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING

LIGHT BULB 7-5

SELF-DIAGNOSTIC FANCTION TABLE 7-5

Self-diagnostic fanction table 7-5

TROUBLESHOOTING CHART 7-7

DIAGNOSTIC MODE 7-8

TROUBLESHOOTING DETAILS 7-12

THROTTLE BODY AND FUEL INJECTOR 7-26

THROTTLE BODY 7-26

FUEL INJECTOR AND FUEL HOSE 7-27

FUEL TANK 7-28

REMOVING THE FUEL HOSE 7-29

REMOVING THE FUEL PUMP 7-29

CHECKING THE THROTTLE BODY 7-30

INSTALLING THE FUEL PUMP 7-31

INSTALLING THE FUEL HOSE 7-31

CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OP-

ERATION 7-32

CHECKING THE THROTTLE POSITION SENSOR 7-32

CHECKING THE ISC (IDLE SPEED CONTROL) VALVE 7-34

AIR INDUCTION SYSTEM 7-35

AIR INJECTION 7-35

AIR CUT-OFF VALVE 7-35

AIR INDUCTION SYSTEM DIAGRAMS 7-36

AIR CUT-OFF VALVE AND AIR FILTER CASE 7-37

CHECKING THE AIR INDUCTION SYSTEM 7-38


EAS00894



1 ECU


3 Lean angle cut-off switch

4 Fuel hose

5 Ignition coil

6 Fuel injector


8 ISC(idle speed control) valve


0 Battery q Air filter case w Catalytic converter e Crankshaft position sensor r Coolant temperature sensor t Spark plug y Fuel tank u Fuel pump i Throttle position sensor

FI ifl

7-1

WIRING DIAGRAM


FI ifl

Y L

< P/W

Br/W x

B/L

Br/W B/L

< P/W x

Y

-Hi,®

5:

G/Y

~

L / G

Br mi

L H k J — © — t H i B — 1

BSD

" O

W

W

7-2

1 AC magneto

3 Main fuse

4 Battery

8 Engine stop switch

9 ECU

0 Main switch q Intake air pressure sensor w Intake air temperature sensor e Throttle position sensor r Lean angle cut-off switch t Coolant temperature sensor y Ignition coil u Spark plug i Fuel injector o Fuel pump p ISC (idle speed control) valve s Dimmer switch f Headlight c High beam indicator light b Engine trouble warning light n Coolant temperature indicator light m Speed sensor

.

FI diagnostic tool (optional)

/ Sidestand switch (optional)


FI ifl

7-3


FI ifl

ECU’S SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU.


8 To inform the rider that the fuel injection system is not functioning correctly, the engine trouble warning light flashes when the start switch is being pushed to start the engine.

8 If a malfunction is detected in the system by the self-diagnostic function, this mode provides an appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminating the engine trouble warning light.

8 After the engine has been stopped, the lowest fault code number appears on the engine trouble warning light (or displayed on the Fl diagnostic tool). It remains stored in the memory of the ECU until it is deleted.

Engine trouble warning light fault code indication

Digit of 10: Cycles of 1 see. ON and 1.5 sec. OFF.

Digit of 1 : Cycles of 0.5 sec, ON and 0.5 sec. OFF.

<Example> 42

Light ON

Light OFF

1 1.5 1 1.5 1 1.5 1 0.5 0.5 0.5 3

EAS00900

Engine trouble warning light indication and Fl system operating condition

Engine condition

Stop

Warning light indication

Flashing

Remains ON

Flashing

(indicate the fault code)

Fl operation Vehicle operation

Operation stopped

Operated with substitute characteristics in accordance with the description of the malfunction

Unable

Able

_ _

7-4


FI ifl

EAS00901

CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB

The engine trouble warning light comes on for 2 seconds after the main switch has been turned “ON” and when the start switch is being pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective.

Engine trouble warning light

Main switch Main switch

OFF ON

Light

OFF

Light ON for

2 seconds

Intialize

Light

OFF

EAS00902

SELF-DIAGNOSTIC FANCTION TABLE

If the ECU detects an abnormal signal from a sensorwhile the vehicle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.

When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions.

Self-diagnostic fanction table

Fault code No.

Item Symptom

12 Crankshaft position sensor No normal signals are received from the crankshaft position sensor.

13

14

Intake air pressure sensor

(open or short circuit) (pipe system)

Intake air pressure sensor-open or short circuit detected.

Faulty intake air pressure sensor pipe system.

15

16

Throttle position sensor

(open or short circuit)(stuck)

Throttle position sensor-open or short circuit detected.

A stuck throttle position sensor is detected.

19 Broken or disconnected blue/ yellow lead of the ECU

Open circuit in the input line (blue/yellow lead) of the ECU is detected.

21 Coolant temperature sensor Coolant temperature sensor-open or short circuit is detected.

22 Intake temperature sensor Intake temperature sensor-open or short circuit is detected.

33 Faulty ignition Open circuit detected in the primary lead of the ignition coil.

37 ISC (idle speed control) valve

(stuck fully open)

Engine speed is high when the engine is idling.

Engine startability

Vehicle driveability

Unable

Able

Able

Unable

Able

Able

Unable

Able

Unable

Able

Able

Unable

Able

Able

Unable

Able

7-5


Fault code No.

Item Symptom

39

30

41

Fuel injector

Lean angle cut-off switch

(latch up detected) (open or short circuit)

The vehicle has overturned.

Lean angle cut-off switch-open or short circuit is detected.

42 Speed sensor

Fuel injector open or short circuit is detected.

No normal signals are received from the speed sensor.

43 Fuel system voltage (monitoring voltage)

44

Error in reading from or writing on E2PROM

46 Vehicle system power supply (monitoring voltage)

Power supply to the fuel injector, fuel pump and ignition coil are not normal.

An error is delected while reading from or writing on E2PROM (CO adjustment value).

Power supply to Fl system is not normal.

(red lead)

50

61

ECU internal malfunction

(memory check error)

ISC (idle speed control) valve unit (open or short circuit)

Faulty ECU memory. When this malfunction is detected, the code number might not appear on the engine trouble warning light or displayed on Fl diagnostic tool.

ISC (idle speed control) valve unit-open or short circuit detected.

_

Start unable warning

Engine trouble warning light flashes when the start switch is turned ON.

Relay is not activated even if the crank signal is input while the start switch is pushed.

Engine startability

Vehicle driveability

Unable

Unable

Able

Able

Able

Able

Unable

Able

Unable

Unable

Unable

Able

Able

Able

Able

Unable

Able

Unable

7-6

FI ifl


EAS00904

TROUBLESHOOTING CHART

Engine operation is not normal or the engine trouble warning light is on.

*Engine trouble warning light may not come on even if the engine operation is not normal.

I

The engine trouble warning light comes on.

I

The engine trouble warning light does not come on.

T

Check the fault code number displayed on the Fl diagnostic tool.

I

Identify the system with the malfunction. Refer to

“FAIL-SAFE ACTIONS TABLE”.

T

Identify the probable cause of malfunction. Refer to “Fault code table”.

T

Check and repair the probable cause of malfunction.

Faultcode No.YES Faultcode No. NO

Check and repair.

Refer to “TROUBLE

SHOOTING DE-

TAILS”.

Monitor the operation of the sensors and actuators in the diagnostic mode. Refer to

“Diagnostic mode table”.

Check and repair.

Refer to “FAIL-SAFE

ACTIONS TABLE”.

I

Check the operation of following sensors and actuators in the diagnostic mode. Refer to “Diagnostic mode table”.

33: Ignition coil

39: Fuel injector

Parform ECU reinstatement action. Refer to “Reinstatement method” in ‘TROUBLESHOOTING DE-

TAILS”.

Fault code number displayed

Turn the main switch to “OFF”, turn the main switch back to “ON”, and then check if the fault code number is still displayed.

X Fault code number not displayed

Repairs completed

Erasing the malfunction history:*

The malfunction history is stored even if the main switch is turned OFF.

The malfunction history must be erased in the diagnostic mode. Referto “Diagnostic mode table (Diagnostic code No.62)”.

* Operated when the engine trouble warning light is on.

7-7

O POWER OWARNING

Fl Diagnostic Tool ©YAMAHA

2100 rpm 60 ° o o

(

D

OPOWER OWARNING

Fl Diagnostic Tool « YAM AHA'

Orpm 60 °C

S/D: 12


FI ifl

EAS00905

DIAGNOSTIC MODE

It is possible to monitor the sensor output data or check the activation of actuators with connecting the Fl diagnostic tool to the normal mode or the diagnostic monitoring mode.

<P Fl diagnostic tool

90890-03182

YU-03182

Setting the normal mode

NOTE:

The engine speed, engine temperature, and fault code, if detected, can be displayed on the LCD of the Fl diagnostic tool when the tool is connected to the vhicle and is set to the normal mode.

1. Turn the main switch to “OFF” and the engine stop switch to “RUN”.

2. Disconnect the self diag signal connector

1 , and then connect the Fl diagnostic tool

2 as shown.

3. Turn the main switch to “ON” and start the engine.

NOTE:

8 Engine temperature and engine revolution appears on the LCD of the Fl diagnostic tool.

8 ”POWER” LED (Green) comes on.

8 If a malfunction is detected in the system,

“WARNING” LED (Orange) comes on. How ever the fault code is not appears on the

LCD of Fl diagnostic tool.

4. Stop the engine.

NOTE:

If a malfunction is detected in the system, the fault code appears on the LCD of the Fl diagnostic tool. And also, “WARNING” LED(Orange) comes on.

5. Turn the main switch to “OFF” to cancel the normal mode.

6. Disconnect the Fl diagnostic tool and connect the self diag signal connector.

7-8

OPOWER OWARNING

Fl Diagnostic Tool ©YAMAHA

D03: 101

JP MODE DOWN o o o


FI ifl

Setting the diagnostic mode

1. Turn the main switch to “OFF” and the engine stop switch to “RUN”..

2. Disconnect the self diag signal connector

1 , and then connect the Fl diagnostic-tool

2 as shown.

3. While press the “MODE” button, turn the main switch to “ON”.

NOTE:

8 ”DIAG” appears on the LCD of the Fl diagnostic tool.

8 ”POWER” LED (Green) comes on.

4. Press the “UP” button to select the CO adjustment mode “CO” or the diagnostic mode

“DIAG”.

5. After selecting “DIAG”, press the “MODE” button.

6. Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the “UP” and

“DOWN” buttons.

NOTE:

8 The diagnostic code number appears on the

LCD (D01-D70).

8 To decrease the selected diagnostic code number, press the “DOWN” button. Press the “DOWN” button for 1 second or longer to automatically decrease the diagnostic code numbers.

8 To increase the selected diagnostic code number, press the “UP” button. Press the

“UP” button for 1 second or longer to automatically increase the diagnostic code numbers.

7. Verify the operation of the sensor or actuator.

8Sensor operation

The data representing the operating conditions of the sensor appears on the LCD.

8Actuator operation

Press the “MODE” button to.operate the actuator.

8. Turn the main switch to “OFF” to cancel the diagnostic mode.

9. Disconnect the Fl diagnostic tool and connect the self diag signal connector.

7-9


Fault code table

Fault codeNo.

12

13

14

15

16

19

21

22

30

33

37

39

41

42

43

44

46

50

61

Symptom Probable cause of malfunction

No normal signals are received from the crankshaft position sensor.

Intake air pressure sensor-open or short circuit detected.

Faulty intake air pressure sensor pipe system

Throttle position sensor-open or short circuit detected.

A stuck throttle position sensor is detected.

Open circuit in the input line (blue/ yellow lead) of ECU is detected when the start switch is pressed.

Coolant temperature sensor-open or short circuit detected.

• Open or short circuit in wiring harness.

• Defective crankshaft position sensor.

• Malfunction in pickup rotor.

• Improperly installed sensor lead connector in the coupler.

• Open or short circuit in wiring sub lead.

• Open orshort circuit in wiring harness.

• Defective intake air pressure sensor.

• Improperly installed sendor lead connector in the coupler.

• Intake air pressure sensor is disconnected or clogged.

• Open or short circuit in wiring sub lead.


• Defective throttle position sensor.

• Improperly installed throttle’position sensor lead connector in the coupler.

• Stuck throttle position sensor.

• Defective throttle position sensor.

• Open circuit in wiring harness (ECU coupler).

Intake air temperature sensor-open or short circuit detected.

The vehicle has overturned.

Open circuit is detected in the primary lead of the ignition coil.

The ISC (idle speed control) valve is stuck fully open.

Fuel injector open or short circuit is detected.

Lean angle cut-off switch-open or short circuit detected.

No normal signals are received from the speed sensor.


• Defective coolant temperature sensor.

• Improperly installead sensor lead connector in the coupler.

• Open or short circuit in wire sub lead.


• Defective intake temperature sensor.

• Improperly installed sensor lead connector in the coupler.

• Overturned condition.

• Open circuit in wiring harness.

• Malfunction in ignition coil.

• Improperly installed primary lead connector in the coupler.

• Malfunction in throttle body.

• Malfunction in throttle cables.

• ISC (idle speed control) valve is stuck fully open.


• Defective fuel injector.

• Improperly installed lead connector in the coupler.


• Defective lean angle cut-off switch.

• Improperly installed lead connector in the coupler.


• Defective speed sensor.

• Improperly installead lead connector in the coupler.

• Open or short circuit in wiring harness. Power supply to the fuel injector, fuel pump and ignition coil are not normal.

An error is detected while reading or writing on E2PROM.

• Malfunction in ECU. (The CO adjustment value, code reregistering key code, and throttle valve fully closed notification value are not properly written on or read from the internal memory.)

• Malfunction in charging system. Power supply to Fl system is not normal.(red lead)

Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter.

ISC (idle speed control) valve open or short circuit is detected. •

•

• Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.)

Open or short circuit in wiring harness.

Improperly installed lead connector in the coupler.

FI

Diagnostic code

_

D03

D03

D01

D01

D20

D06

D06

D08

D30

D54

D36

D08

D07

D09

D60

_

_

D54

7-10


FI ifl

EAS00907

Diagnostic mode table

NOTE:

8 Check the intake air temperature and coolant temprature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively.

8 If it is not possible to check the intake air temperature, use the ambient temperature as reference.

Diagnostic code

D01

D03

D05

D06

D07

D08

D09

D20

D30

D36

D52

D54

D60

D61

D62

D70

Item Description of action

Data displayed on FI diagnostic tool

(reference value)

Throttle angle

Intake air pressure

Displays the throttle angle.

• Check with throttle fully closed.

• Check with throttle fully open.

Displays the intake air pressure.

• Check the pressure in the intake manifold.

Intake air temperature Displays the intake air temperature.

• Check the temperature in the intake manifold.

Coolant temperature

Vehicle speed pulse

Displays the coolant temperature.

• Check the temperature of the coolant.

Displays the accumulation of the vehicle pulses that are generated when the tire is spun.

Lean angle cut-off switch

Fuel system voltage

(battery voltage)

Sidestand switch (Option)

Ignition coil

Displays the lean angle cut-off switch values.

Displays the fuel system voltage (battery voltage).

Displays that the switch is ON or OFF.

Fuel injector

Headlight

ISC (idle speed control) valve

E2PROM fault code display.

When the “MODE” button is pressed, the ignition coil is actuated five times per second and the

“WARNING” LED (orange) comes on.

• Connect an ignition checker.

When the “MODE”-button is pressed, the fuel injector is actuated five times per second and the

“WARNING” LED (orange) comes on.

When the “MODE” button is pressed, the headlight is actuated five times every 5 seconds and the engine trouble warning light comes on. (ON 2 seconds, OFF 3 seconds)

When the the “MODE” button is pressed, the ISC

(idle speed control) valve fully closes, and then it opens until it is at the standby opening position when the engine is started. This operation takes approximately 3 seconds until it is completed.

• Transmits the abnormal portion of the data in the E2PROM that has been detected as a fault code 44.

• If multiple malfunctions have been detected, different codes are displayed at 2-second intervals, and this process is repeated.

Malfunction history code display

• Displays the codes of the history of the selfdiagnosis malfunctions (i.e., a code of a malfunction that occurred once and which has been corrected).

• If multiple malfunctions have been detected, different codes are displayed at 2-second intervals, and this process is repeated.

Malfunction history code erasure

• Displays the total number of codes that are being detected through self diagnosis and the fault codes in the past history.

Control number

• Erases only the history codes when the

“MODE” button is pressed.

Displays the program control number.

0-125 degrees

• Fully closed position (14-20)

• Fully open position (97-107)

Compare it to the value displayed on the

Fl diagnostic tool.


Fl diagnostic tool.


FI diagnostic tool.

(0-999; resets to 0 after 999)

OK if the numbers appear on the FI diagnostic tool.

Upright: 0.4-1.4 V

Overturned: 3.7-4.4V

0-18.7 V

Normally, approximately 12.0 V

Stand retracted: ON

Stand extended: OFF

Check that spark is generated, 5 times with the “MODE” button press.

Check the operating sound of the fuel injector five times with “MODE” button press.

Check the headlight operating 5 times with the “MODE” button is pressed.

The ISC (idle speed control) valve unit vibrates when the ISC (idle speed control) valve operates.

01 CO adjustment value is detected.

(00) Displays when there is no malfunction.

12-61

(00) Displays when there is no malfunction.

00-18

(00) Dispiays when there is no malfunction.

00-254

7-11


Communication error with the FI diagnostic tool

LCD Display Sympton Probable cause of malfunction

Waiting for connection...

ERROR 4

No signals are received from the

ECU.

Commands from the Fl diagnostic tool are not accepted by the ECU.

• Improper installed lead connector in the coupler.

• The main switch is OFF position.

• Malfunction in Fl diagnostic tool.

• Malfunction in ECU.

• Turn the main switch to “OFF” once, and then turn it back to CO adjustment mode or diagnostic mode.

• Vehicle battery is insufficiently charged.

• Malfunction in Fl diagnostic tool.

• Malfunction in ECU.

EAS00908

TROUBLESHOOTING DETAILS

This section describes the countermeasures per fault code number displayed on the Fl diagnostic tool. Check and service the items or components that are the probable cause of the malfunction following the order given.

After the check and service of the malfunctioned part has been completed, reset the Fl diagnostic tool display according to the “Reinstatement method”.

Fault code No.:

Fault code number displayed on the Fl diagnostic tool when the engine failed to work normally.

Refer to “Fault code table”.

Diagnostic code No.:

Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAG-

NOSTIC MODE”.

7-12


FI ifl

Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor.

Used diagnostic code No. --

Order

Inspection operation item and probable cause

Operation item and countermeasure

Installed condition of sensor. Check the installed area for looseness or pinching.

Connected condition of connector.

Inspect the coupler for any pins that may have pulled out.

Check that the coupler is connected securely.

NOTE:

Set the main switch to OFF before connecting or disconnecting the connector.

If there is a malfunction, repair it and connect it securely.

Crankshaft position sensor coupler

Main wiring harness ECU coupler

Reinstatement method


4 Defective crankshaft position sensor.

Repair or replace if there is an open or short circuit between the main wiring harnesses.

Between sensor coupler and ECU coupler. white/red black/blue

Replace if defective.

Refer to “IGNITION SYSTEM” in chapter 8.

7-13


FI ifl

Fault code No. 13 Symptom Intake air pressure sensor-open or short circuit detected.

Used diagnostic code No. D03 (intake air pressure sensor)

Order

1




Connected condition of connector


Check the locking condition of the coupler.

NOTE:

Set the main switch to OFF before connecting or disconnecting the connector.

If there is a malfunction, reper it and connect it securely.

Intake air pressure sensor coupler


Sub-wire harness coupler

Reinstated by turning the main switch

ON.

2

3

Open or short circuit in wiring harnes and /or sub lead.

Defective intake air pressure sensor.

Repair or replace if there is an open or short circuit.

Between sensor coupler and ECU coupler black/blue - black/blue pink/white - pink/whte blue- blue

Execute the diagnostic mode (code No. D03)

Replace the throttle body.

NOTE:

Do not remove the sensor assembly (MAQS).

1. Connect the digital circuit tester to the intake air pressure sensor coupler as shown.

Positive tester probe -» pink/white 0

Negative tester prove -» black/blue (2)

^T^S,

Br/W P/W B/L Y L

YZZZ^

^

© ©

n n

^ n • • • •

2. Set the main switch to “ON”.

3. Measure the intake air pressure sensor output voltage. n. Intake air pressure sensor output voltage

3.9~4.1V

4. Is the intake air pressure sensor OK?

7-14


FI ifl

Intake air pressure sensor-hose system malfunction

Fault code No. 14 Symptom

(clogged or detached hose). tached hose).

Used diagnostic code No. D03 (intake air pressure sensor)

Order




Connected state of connector

Intake air pressure sensor coupler

Main wirring harness ECU coupler


2 Defective intake air pressure sensor.

Check the coupler for any pins that may have pulled out.

Check that the coupler is connected securely.




NOTE:


Refer to “Fault code No. 13”.

Fault code No. 15 Symptom Throttle position sensor-open or short circuit detected.

Used diagnostic code No. D01 (throttle position sensor)

Order



4

Installed condition of throttle position sensor.




Open or short circuit in wiring harness and/or sub lead.

Check the installed area for looseness or pinching.

Check that it is installed in the specified position.

Refer to “THROTTLE BODY AND FUEL IN-

JECTOR”.


Throttle position sensor coupler



Defective throttle position sensor.


Between sensor coupler and ECU coupler black/blue - black/blue yellow - yellow blue -blue



NOTE:




JECTOR ”.

7-15


FI ifl

Fault code No. 16 Symptom Stuck throttle position sensor detected.

Used diagnostic code No. D01 (throttle position sensor)

Order



Installed condition of throttle position sensor.

Defective throttle position sensor


Check that it is installed in the specified position.


JECTOR ”.

Execute the diagnostic mode (code No. 01)


NOTE:



3 When fault code No.15 has been detected


JECTOR ”.

Refer to “Fault code No.15”. Refer to “Fault code

No. 15”.

Fault code No. 19 Symptom Open circuit in the input line of ECU (blue/yellow lead) detected.

Used diagnostic code No. D20 (sidestand switch :option)

Order



Connected state of connector


(blue/yellow connector)

2 Open or short circuit in wiring harness and/or sub lead.


Check the coupler for any pins that may have pulled out.



Repair or replace if there is an open circuit.

Between main switch coupler and ECU coupler. blue/yellow - blue/yellow

Sidestand switch signal input line of main switch coupler. blue/green - blue/green


7-16


FI ifl

Fault code No. 21 Symptom Coolant temperature sensor open or short circuit is detected.

Used diagnostic code No. D06 (coolant temperature sensor)

Order



Installed condition of sensor Check the installed area for looseness or pinching.

4






Coolant temperature sensor coupler


Defective coolant temperature sensor.


Between sensor coupler and ECU coupler black/blue-black/blue green/red - green/red

Execute the diagnostic mode (code No.D06)


Refer to “COOLING SYSTEM” in chapter 8.


7-17


FI ifl

Fault code No. 22 Symptom Intake temperature sensor open or short circuit is detected.

Used diagnostic code No. D05 (intake air temperature sensor)

Order

1

2

3

4




Installed condition of sensor Check the installed area for looseness or pinching.




Open or short circuit in wireing harness and/or sub lead.


Intake air temperature sensor coupler



Defective intake air temperature sensor.


Between sensor coupler and ECU coupler black/blue - black/blue brown/white - brown/white



NOTE:



ON.

1 . Connect the digital circuit tester to the intake air temperature sensor terminal as shown.

Positive tester probe -» brown/white 1

Negative tester probe -» black/blue 2

2. Measure the intake air temperature sensor resistance. n„

Intake air temperature sensor resistance

2.4~2.9k at 20°C (68°F)

w

8 Handle the intake air temperature sensor with special care.

8 Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it.

3. Is the intake air temperature sensor OK?

7-18


FI ifl

Fault code No. 30 Symptom The vehicle has overturned.

Used diagnostic code No. D08 (lean angle cut-off switch)

Order

1

2

3

4




The vehicle has overturned. Raise the vehicle upright.

Installed condition of the lean angle cut-off switch




Defective lean angle cut-off switch



Lean angle cut-off switch coupler




1 . Remove the lean angle cut-off switch from the vehicle.

2. Connect the lean angle cut-off switch coupler to the wire harness.

3. Connect the digital circuit tester to the lean angle cut-off switch terminals as shown.


ON (however, the engine cannot be restarted unless the main switch is first turned OFF).

4. When turning the lean angle cut-off switch approximately 65°, the voltage reading change from 0.4 V to 4.4 V.

5. Is the lean angle cut-off switch OK?

7-19


FI ifl

Fault codeNo. 33 Symptom Open circuit detected in the primary lead of the ignition coil.

Used diagnostic code No. D30

Order







Ignition coil primary side coupler - orange


Open or short circuit in lead. Repair or replace if there is an open or short circuit.

Between ignition coil coupler and ECU coupler/main harness orange - orange

3 Defective ignition coil (test the primary and secondary coils for continuity).



Refer to “IGNITION SYSTEM” in chapter 8.


Reinstated by starting the engine and operating it at idle.

Fault code No. 37 Symptom Engine speed is high when the engine is idling.

Used diagnostic code No. D54 (ISC (idle speed control) valve)

Order



Incorrect speed sensor signal Check the speed sensor.

Check the speed sensor leads.

Check the speed sensor coupler.

Throttle valve does not fully close

Check the throttle body.

Refer to “THROTTLE BODY ASSEMBLY AND

FUEL INJECTOR ASSEMBLY” .

Check the throttle cables.

Refer to “ADJUSTING THE THROTTLE

CABLE FREE PLAY” in chapter 3.

ISC (idle speed control) valve stuck fully open

The ISC (idle speed control) valve is stuck fully open if it does not operate when the main switch is set to OFF.

(Touch the ISC (idle speed control) valve unit with your hand and check if it is vibrating to confirm if the ISC (idle speed control) valve is operating.)

NOTE:

Do not remove the ISC (idle speed control) valve unit.


ISC (idle speed control) valve not moving correctly


After the ISC (idle speed control) valve is fully closed, it opens until it is at the standby opening position when the engine is started. This operation takes approximately 3 seconds until it is completed. Start the engine. If the error recurs, replace the throttle body assembly.

7-20


FI ifl

Fault code No. 39 Symptom Fuel injector open or short circuit is detected.

Used diagnostic code No. D36 (fuel injector)

Order



3





Fuel injector coupler - orange/black


Open or short circuit in lead wire.

Defective fuel injector


Between fuel injector coupler and ECU coupler/main harness orange/black - orange/black




Reinstated by starting the engine.

Fault code No. 41 Symptom Lean angle cut-off switch open or short circuit is detected.

Used diagnostic code No. D08 (lean angle cut-off switch)

Order








Lean angle cut-off switch coupler



Between switch coupler and ECU coupler black/blue - black/blue yellow/green - yellow/green blue- blue

3 Defective lean angle cut-off switch



Refer to Fault code No. 30.



ON.

7-21


FI ifl

Fault code No. 42 Symptom No normal signals are received from the speed sensor.

Used diagnostic code No. D07 (speed sensor)

Order

1

2

3




Connected condition of speedometer connector




Speedometer coupler


Open or short circuit in speedometer lead.

Breakage speedometer cable or speedometer gear unit.


Between speedometer coupler and ECU coupler white - white black/blue - black/blue

Execute the diagnostic mode (code No.D07)

Checking the speedometer cable breakage and loose connection.

Checking the movement of the speedometer gear unit 1 .

Checking the breakage of the speedometer clutch projections a and speedometer gear unit slots b .

Reinstated by inputting the vehicle speed signals by turning the front wheel.

4 Defective speed sensor. Execute the diagnostic mode (code No. D07)

Replace the meter assembly.

7-22


FI ifl


Power supply to the fuel injector, fuel pump and ignistion coil are not normal.

Used diagnostic code No. D09 (fuel system voltage)

Order




3




Faulty battery


ECU coupler


Replace or charge the battery.

Refer to “CHECKING AND CHARGING THE

BATTERY” in chapter 3.


NOTE:

When the leads are disconnected, the voltage check by the code No. D09 is impossable.

Reinstated by starting the engine and operating it at idle.


8 Between battery and main switch red-red

8 Between main switch and handlebar switch

(engine stop switch) brown-brown

8 Between handlebar switch (engine stop switch) and ECU red/white-red/black

Error is detected while reading from or writing on EEROM (code re-

Fault code No. 44 Symptom registering key code and throttle valve fully closed notification valve).

Used diagnostic code No. D60 (EEPROM improper cylinder indication)

Order




1 Malfunction in ECU Execute the diagnostic mode (code No. D60)

8 01 is displayed on meter.

Readjust the CO of the displayed cylinder.

Refer to “ADJUSTING THE EXHAUST

GAS VOLUME” in chapter 3.

Replace ECU if defective.


ON.

7-23


FI ifl

Fault code No. 46 Symptom Power supply to FI system is not normal. (red lead)


Order



4





ECU coupler

Faulty battery

Malfunction in rectifier/ regulator


Replace or charge the battery.

Refer to “CHECKING AND CHARGING THE

BATTERY” in chapter 3.


Refer to “CHARGING SYSTEM” in chapter 8.


Between battery and ECU red-red



Faulty ECU memory. (when this malfunction is detected in the ECU, the fault code number might not appear on the meter.)


Order


1 Malfunction in ECU


Replace the ECU.



ON.

7-24


FI ifl

Fault code No. 61 Symptom ISC (idle speed control) valve open or short circuit is detected.


Order







ISC (idle speed control) valve coupler


Open or short circuit in lead. Repair or replace if there is an open or short circuit.

Between ISC (idle speed control) valve and

ECU coupler/main harness pink- pink green/yellow-green/yellow gray - gray sky blue-sky blue

3 Detective ISC (idle speed control) valve

Execute diagnostic mode (code No.D54)


NOTE:

Do not remove the ISC (idle speed control) valve.


Reinstated by setting the main switch to ON, The ISC (idle speed control) valve fully closes, and then it opens until it is at the standby opening position when the engine is started.


JECTOR ”.

7-25

THROTTLE BODY AND FUEL INJECTOR

EAS00909


THROTTLE BODY

FI ifl

Order

1

2

3

4

5

6

Job/Part

Removing the throttle body


Single seat/Trunk

Air filter assembly

Throttle body clamp screw

MAQS(modulated air quantity sensor) coupler

ISC (idle speed control) valve coupler

Throttle cable

Throttle body

Sub-wire harness

Q’ty

1

1

Remarks


Refer to “COVER AND PANEL”in chapter 3.

Refer to"ENGINE REMOVAL" in chapter 5.

Lossen.

Disconnect.

1

2

1

1

Disconnect.

Disconnect.


7-26

THROTTLE BODYAND FUEL INJECTOR

FUEL INJECTOR AND FUEL HOSE

FI ifl

1

2

3

4

5

6

7

8

Order Job/Part

Removing the fuel injector and fuel hose

Footrest board

Q’ty

Remarks



Disconnect.

Fuel pump coupler

Fuel hose connector cover

Fuel hose connector

Fuel hose holder(to frame)

Fuel hose holder(to intake manifold)

Clamp

Fuel injector coupler

Fuel injector

1

1

1

1

1

1

1

1

Open lock.

Disconnect.


7-27

FUEL TANK

THROTTLE BODYAND FUEL INJECTOR

FI ifl

«& 4Nm(0.4m • kg, 2.9 ft • lb)

Order Job/Part

Removing the fuel tank

Fuel hose

1 Fuel tank

2 Fuel pump

7-28

Q’ty

Remarks


Place the scooter on a suitable stand.

Refer to “FUEL INJECTOR AND FUEL

HOSE”.

1 Refer to “REMOVING THE FUEL

HOSE”.

1 Refer to “REMOVING THE FUEL

PUMP”and “INSTALLING THE FUEL

PUMP”.



FI ifl

REMOVING THE FUEL HOSE

1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump.

2. Remove:

8fuel hose connector cover 1

3. Disconnect:

8fuel hose 2 c C

8 Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools.

8 Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose, since there may be fuel remaining in it.

8 Do not disconnect the fuel hose from the fuel hose connector. Disconnect the connector from the fuel pump.

NOTE:

Before removing the hose, place a few rags in the area under where it will be removed.

3. Remove:

8fuel tank

REMOVING THE FUEL PUMP

1. Disconnect:

8 fuel pump coupler

8 fuel hose

2. Remove:

8 fuel pump c C

8 Do not drop the fuel pump or give it a strong shock.

8 Do not touch the base section of the fuel sender.

EAS00911 c C

The fuel pump should not be disassembled.

7-29


FI ifl

EAS00912

CHECKING THE FUEL INJECTOR

1. Check:

8 fuel injector

Damage -» Replace.

EAS00913

CHECKING THE THROTTLE BODY

1. Check:

8 throttle body

Cracks/damage -» Replace the throttle body.

2. Check:

8 butterfly valve

Damage/scratches/wear -» Replace.

C

Do not adjust the stop screw 1

Do not clean the throttle body using carburetor cleaner or compressed air.

When replace the throttle body, the main switch is operated three times turn ON and OFF position.

(ON position : 3 seconds more, OFF position : 3seconds more). And then, start the engine and keep idling at 10 minutes more.

7-30


FI

INSTALLING THE FUEL PUMP

1. Install:

8 fuel pump

X | 4Nm(0.4m

» kg, 2.9ft

* Ib)

ifl

NOTE:

8 Do not damage the installation surfaces of the fuel tank when installing the fuel pump.

8 Always use a new fuel pump gasket.

8 Align the projection a on the fuel pump with the alignment mark b on the fuel tank.

8 Tighten the fuel pump bolts in the proper tightening sequence as shown and torque them in two stages.

A Forward

INSTALLING THE FUEL HOSE

1. Install:

8fuel hose

8fuel hose connector cover c C

Be sure to connect the fuel hose securely and install the fuel hose connector cover in the correct position, otherwise the fuel hose will not be properly installed.

NOTE:

8 Install the fuel hose connector securely onto the fuel tank until a distinct “click” is heard, and then make sure that it does not come loose.

8 After installing the fuel hose connector cover 1 , make sure that it is installed securely.

7-31


FI ifl

EAS00915

CHECKING THE FUEL PUMP AND PRES-

SURE REGULATOR OPERATION

1. Check:

8 pressure regulator operation

• • • • • • • • • • • • • • • • • • • • • • • a. Remove the footrest board.

Refer to “COVER AND PANEL” in chapter

3. b. Remove the fuel hose connector cover (T) and disconnect the fuel hose (2) from the fuel pump.

C

Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose, since there may be fuel remaining in it.

NOTE:

Before removing the hose, place a few rags in the area under where it will be removed. c. Connect the pressure gauge (3) and adapter

(4) onto the fuel hose.

(tj//^ Pressure gauge

/f~"^ 90890-03153

YU-03153

Adapter

90890-03181 d. Start the engine. e. Measure the fuel pressure.

^

Fuel pressure

246 ~ 254 kPa

(2.46 ~ 2.54 kg/cm

2

, 35.0 ~ 36.1 psi)

Faulty -» Replace the fuel pump.

• • • • • • • • • • • • • • • • • • • • • • •

7-32

EAS0091 6

CHECKING THE THROTTLE POSITION SEN-

SOR

1 . Check:

8throttle position sensor

• • • • • • • • • • • • • • • • • • • • • • • a. Connect the digital circuit tester to the terminals of the throttle position sensor.

FI ifl


Positive tester probe -> blue terminal ®

Negative tester probe -» black/blue terminal (2) f*


90890-03174 b. Measure the throttle position sensor voltage.

Out of specification -» Replace or repair the wire harness.

U Throttle position sensor voltage

5V

(blue-black/blue) c. Connect the digital circuit tester to the terminals of the throttle position sensor.

Positive tester probed yellow terminal

Negative tester probe black/blue terminal d. While slowly opening the throttle, check that the throttle position sensor voltage is increased.

Voltage does not change or it changes abruptly -» Replace the throttle body.

Out of specification (closed position) -» Replace the throttle body.

Bl Throttle position sensor voltage

(closed position)

0.63 ~ 0.73 V

(yellow-black/blue)

• • • • • • • • • • • • • • • • • • • • • • •

7-33


FI ifl

EAS00916

CHECKING THE ISC (IDLE SPEED CON-

TROL) VALVE

NOTE:

Do not remove the ISC (idle speed control) valve unit completely from the throttle body assembly.

1 . Check:

8ISC (idle speed control) valve

• • • • • • • • • • • • • • • • • • • • • • • a. Disconnect the ISC (idle speed control) valve coupler from the ISC (idle speed control) valve. b. Connect the digital circuit tester to the terminals of the ISC (idle speed control) valve.

Positive tester probe -> pink terminal ©

Negative tester probe -> green/yellow terminal 2

Positive tester probe -> gray terminal ®

Negative tester probe -> sky blue terminal

©


90890-03174 c. Measure the ISC (idle speed control) valve resistance.

Out of specification -» Replace the throttle body. a

ISC (idle speed control) valve resistance

18 ~ 22 at 20°C(68°F)

• • • • • • • • • • • • • • • • • • • • • • •

7-34

AIR INDUCTION SYSTEM

FI ifl

EAS00507


AIR INJECTION

The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust pipe reducing the emission of hydrocarbons.

When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The resuired temperature for burning the unburned exhaust gases is approximately 600 to 700 °C (1,112 to

1,292 °F)

E

0 r

" ) w

$

E

1

L J

// h z

M

1

"

?

EAS00917

AIR CUT-OFF VALVE

The air cut-off valve prevents air backflow from the exhaust pipe to the air filter.

A From the air filter

B To the exhaust pipe ass’y

7-35


EAS00509

AIR INDUCTION SYSTEM DIAGRAMS

1 Air induction system hose

2 Air filter case

3 Air induction system hose (air filter case to air cut-off valve)

4 Air cut-off valve

5 Air induction system hose (air cut-off valve to exhaust pipe)

FI ifl

7-36


AIR CUT-OFF VALVE AND AIR FILTER CASE

FI ifl

PV 7Nm(0.7m • kg, 5.1 ft • lb)

3R 7Nm(0.7m • kg, 5.1 ft • lb)

Order Job/Part

Q’ty

1

2

Removing the air cut-off valve and air filter case

Front cover

Side cover(right)

Hose(to air filter case)

Air filter case

1

1

3 Hose(air cut-off valve to air filter case) 1

4 Hose(air cut-off valve assembly to ex1 haust pipe)

5 Air cut-off valve 1

Remarks



7-37


FI ifl

EAS00918

CHECKING THE AIR INDUCTION SYSTEM

1. Check:

• hoses



2. Check:

• reed valve

• reed valve stopper

• reed valve seat

Cracks/damage -» Replace the reed valve.

3. Check:

• air cut-off valve


7-38

ELEC

- +

CHAPTER 8

ELECTORICAL

ELECTRICAL COMPONENTS 8-1

WIRING DIAGRAM 8-2

CHECKING SWITCH CONTINUITY 8-4

CHECKING THE SWITCHES 8-5

CHECKING THE BULBS AND BULB SOCKETS 8-6

TYPES OF BULBS 8-6

CHECKING THE CONDITION OF THE BULBS 8-7

CHECKING THE CONDITION OF THE BULB SOCKETS 8-8

IGNITION SYSTEM 8-9

CIRCUIT DIAGRAM 8-9

TROUBLESHOOTING 8-10

ELECTRIC STARTING SYSTEM 8-14

CIRCUIT DIAGRAM 8-14

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-15


STARTER MOTOR 8-20

CHECKING THE STARTER MOTOR 8-21

ASSEMBLING THE STARTER MOTOR 8-23

CHARGING SYSTEM 8-24



LIGHTING SYSTEM 8-27



CHECKING THE LIGHTING SYSTEM 8-30

SIGNALING SYSTEM 8-34



CHECKING THE SIGNALING SYSTEM 8-36

COOLING SYSTEM 8-42


CHECKING THE COOLING SYSTEM 8-45

ELECTRICAL COMPONENTS

ELEC

EAS00729

ELECTRICAL

ELECTRICAL COMPONENTS

1 Main switch

2 Front brake light switch

3 Rectifier/regulator


5 Battery

6 Main fuse

7 ECU


9 Ignition coil

0 Spark plug cap q Fuel pump w Starter relay e Horn r Turn signal relay t Starting circuit cut-off relay y Stator coil u Wire harness

+i

8-1

WIRING DIAGRAM

ELEC +i

WIRING DIAGRAM

Lg

P/W

Y x Br/W

R/B x x

B/L B/W

W/R

L/Y

W B/R

X f\ B/Y L / B

G/Y Sb

P

B B x

^

4= rHi'

<— go nrn

T ^ h

' Br T ( (

< p -

>

) j —

/R ~f| I

@

Y L

Br/W

^x^

B/L

Br/W B/L

< P/W x

Y

r-rrriTTT—rr

8-2 gSj

1 AC magneto

2 Rectifier/regulator

3 Main fuse

4 Battery

5 Starter relay

6 Starter motor

7 Start switch


9 ECU

0 Main switch q Intake air pressure sensor w Intake air temperature sensor e Throttle position sensor r Lean angle cut-off switch t Coolant temperature sensor y Ignition coil u Spark plug i Fuel injector o Fuel pump p ISC(idle speed control) valve a Horn switch s Dimmer switch d Turn signal switch f Headlight g Tail/brake light h Front brake light switch j Rear brake light switch k Horn l Turn signal relay

; Front turn signal light(left) z Front turn signal light(right) x Fuel level meter c High beam indicator light v Speedometer light b Engine trouble warning light n Coolant temperature indicator light m Speed sensor

, Turn signal indicator light

.

FI diagnostic tool(optional)

/ Sidestand switch (optional)

!

Rear turn signal light(left)

@ Rear turn signal light(right)

# License plate light

$ Starting circuit cut-off relay

% Connector

WIRING DIAGRAM

COLOR CODE

B Black

Br Brown

Ch Chocolate

Dg Dark green

G Green

Gy Gray

L Blue

Lg Light green

Or Orange

P Pink

R Red

Sb Sky blue

W White

Y Yellow

B/L Black/Blue

B/G Black/Green

B/R Black/Red

B/W Black/White

B/Y Black/Yellow

G/R Green/Red

G/Y Green/Yellow

G/W Green/White

L/B Blue/Black

L/G Blue/Green

L/W Blue/White

L/Y Blue/Yellow

Or/B Orange/Black

P/W Pink/White

R/B Red/Black

R/L Red/Blue

R/W Red/White

W/L White/Blue

W/R White/Red

Y/G Yellow/Green

Br/W .... Brown/White

Br/L Brown/Blue

8-3

CHECKING SWITCH CONTINUITY

EAS00730

CHECKING SWITCH CONTINUITY

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

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

Pocket tester

90890-03132 (YU-03112-C)

NOTE:

8 Before checking for continuity, set the pocket tester to “0” and to the “ Q x 1” range.

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

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

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

NOTE:

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

The example illustration on the left shows that:

There is continuity between black and black/ white when the switch is set to “OFF”.

There is continuity between red and brown when the switch is set to “ON”.

8-4

CHECKING THE SWITCHES

ELEC + 1

EAS00731

CHECKING THE SWITCHES

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

Damage/wear -» Repair or replace.

Improperly connected -» Properly connect.

Incorrect continuity reading -» Replace the switch.

1

9 t

(BLACK)

(BLACK)

©

G Y o o

O O

©

P B

OFF

PUSH O O

©

Ch Dg

L

N

R o o o o

\

Br

/

L

R

R

/

B

B

LOCK

OFF

ON oo O O

R Br/L

R/B B

(RED)

Br

OFF

RUN O O

B

OFF

START o o

®

L/W Br

B R/W

©

V B B

5

D

A

D

U U

1 Rear brake light switch 5

2 Dimmer switch 6

3 Horn switch 7

4 Turn signal switch 8


0 Sidestand switch (optional)

8-5

CHECKING THE BULBS AND BULB SOCKETS

EAS00733

CHECKING THE BULBS AND BULB

SOCKETS

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

Damage/wear -» Repair or replace the bulb, bulb socket or both.

Improperly connected -» Properly connect.

No continuity -» Repair or replace the bulb, bulb socket or both.

TYPES OF BULBS

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

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

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

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

8-6


CHECKING THE CONDITION OF THE

BULBS

The following procedure applies to all of the bulbs.

1 . Remove:

8bulb w

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

Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.

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

2. Check:

8 bulb (for continuity)

(with the pocket tester)

No continuity -» Replace.

^

Pocket tester

90890-03112 (YU-03112-C)

NOTE:

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

8-7

• • • • • • • • • • • • • • • • • • • • • • • a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2 , and check the continuity. b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3 , and check the continuity. c. If either of the readings indicate no continuity, replace the bulb.

• • • • • • • • • • • • • • • • • • • • • • •


CHECKING THE CONDITION OF THE BULB

SOCKETS

The following procedure applies to all of the bulb sockets.

1. Check:

• bulb socket (for continuity)

(with the pocket tester)

No continuity -» Replace.

Pocket tester

90890-03112 (YU-03112-C)

NOTE:

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

• • • • • • • • • • • • • • • • • • • • • • • a. Install a good bulb into the bulb socket. b. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket.

• • • • • • • • • • • • • • • • • • • • • • •

8-8

EAS00734

IGNITION SYSTEM

CIRCUIT DIAGRAM

IGNITION SYSTEM

ELEC +i

-•-

1,®

8-9

EAS00736

TROUBLESHOOTING

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

Check:

1 . main fuse

2. battery

3. spark plug

4. ignition spark gap

5. spark plug cap resistance

6. ignition coil resistance

7. crankshaft position sensor resistance

8. main switch

9. engine stop switch

10. sidestand switch(optional)

11. lean angle cut-off switch

12. wiring connections (of the entire ignition system)

NOTE:

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

1 . Battery cover

2. Front cover

3. Side cover (right)

8 Troubleshoot with the following special tool(s).

Ignition checker

90890-06754

YM-34487

Pocket tester

90890-03112

YU-03112-C

IGNITION SYSTEM

EAS00738

1. Main Fuse

• Check the fuse for continuity.

Refer to “CHECKING THE FUSE” in chapter 3.

* Is the fuse OK?

V

YES

4

NO

Replace the fuse.

EAS00739

2. Battery

• Check the condition of the battery.

Refer to “CHECKING AND CHARGING

THE BATTERY” in chapter 3. a

Minimum open-circuit voltage

12.8 V or more at 20°C (68°F)

• Is the battery OK?

V

YES

I

NO

• Clean the battery terminals.

• Recharge or replace the battery.

EAS00740

3. Spark plug

• Check the condition of the spark plug.

• Check the spark plug type.

• Measure the spark plug gap.

Refer to “CHECKING THE SPARK PLUG” in chapter 3.

Standard spark plug

CR7E (NGK)

Spark plug gap

0.7 ~ 0.8 mm(0.028 ~ 0.031 in)

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

-i YES

\7

NO

I

Re-gap or replace the spark plug.

8-10

EAS00742

4. Ignition spark gap

Disconnect the spark plug cap from the spark plug.

Connect the ignition checker 1 as shown.

2 Spark plug cap

Set the main switch to “ON”.

Measure the ignition spark gap a .

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

IGNITION SYSTEM

EAS00744

5. Spark plug cap resistance

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

• Connect the pocket tester (“ Q x 1k” range) to the spark plug cap as shown.

• Measure the spark plug cap resistance.

Minimum ignition spark gap

6 mm(0.24 in)

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

NO

* ft YES

The ignition system is

OK. a

Spark plug cap resistance

4~6 k at 20°C(68°F)

• Is the spark plug cap OK?

V

YES 4 NO

Replace the spark plug cap.

EAS00746

6. Ignition coil resistance

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

• Connect the pocket tester ( Q x 1) to the ignition coil as shown.

Positive tester probe -» orange ®

Negative tester probe -> red/black

8-11

IGNITION SYSTEM

EAS00748

7. Crankshaft position sensor resistance

• Disconnect the crankshaft position sensor coupler from the wire harness.

• Connect the pocket tester ( £2 x 100) to the crankshaft position sensor coupler as shown.

Positive tester probe g white/red 1

Negative tester probe g white/blue 2

• Measure the primary coil resistance. a

Primary coil resistance

2.16 ~ 2.64 at 20°C(68°F)

• Connect the pocket tester ( £1 x 1k) to the ignition coil as shown.

Negative tester probe g orange 2

Positive tester probe g spark plug lead 1

• Measure the secondary coil resistance. m

Secondary coil resistance

8.64 ~ 12.96 k at 20°C(68°F)

• Is the ignition coil OK?

4 YES NO 4

Replace the ignition coil.

• Measure the crankshaft position sensor resistance.

SI

Crankshaft position sensor resistance

248 ~ 372 at 20°C(68°F)

(between white/red and white/ blue)

• Is the crankshaft position sensor OK?

4

YES

I

NO

Replace the crankshaft position sensor/stator assembly.

EAS00749

8. Main switch

• Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the main switch OK?

YES NO

Replace the main switch.

8-12

EAS00750

9. Engine stop switch

• Check the engine stop switch for continuity.


• Is the engine stop switch OK?

V

YES NO 4

Replace the right handlebar switch.

IGNITION SYSTEM

ELEC +i

EAS00752

10. Sidestand switch(optional)

• Check the sidestand switch for continuity.


• Is the sidestand switch OK?

NO

V

YES

Replace the sidestand switch.

11. Lean angle cut-off switch

• Remove the lean angle cut-off switch.

• Connect the pocket tester( £2 x 1) to the lean angle cut-off switch terminals as shown.

Positive tester probe -> blue ©

Negative tester probe -> yellow/green

/ \ x

< • / / / / ,

X

V

YES NO

*

Replace the lean angle cut-off switch.

EAS00754

12. Wiring

• Check the entire ignition system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

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

YES NO

V

I

Replace the ECU. Properly connect or repair the ignition system’s wiring. m

Lean angle cut-off switch voltage

Less than 65° ®-» 0.4~1.4V

More than 65° © -» 3.7~4.4V

8-13

ELECTRIC STARTING SYSTEM

ELEC +i

EAS00755


CIRCUIT DIAGRAM

Main fuse

Battery

Starter relay

Starter motor

Start switch

Engine stop switch

Main switch

8-14


EAS00756

STARTING CIRCUIT CUT-OFF SYSTEM OP-

ERATION

If the engine stop switch is set to “ # ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met:

8 The brake lever(front or rear) is pulled to the handlebar(the brake light switch is closed) and the sidestand(optional) is up(the sidestand switch(optional) is closed).

1 Battery

2 Main fuse

3 Main switch




7 Starting circuit cut-off relay

8 Sidestand switch(optional)

9 Start switch

0 Starter relay q Starter motor

8-15

EAS00757

TROUBLESHOOTING

The starter motor fails to turn.

Check:

1 . main fuse

2. battery

3. starter motor

4. starting circuit cut-off relay

5. starter relay

6. main switch

7. brake light switch(front and rear)

8. engine stop switch

9. sidestand switch(optional)

10.start switch

11.wiring connections

(of the entire starting system)


EAS00738

1. Main Fuse



* Is the fuse OK?

V

YES

4

NO

Replace the fuse.

EAS00739

2. Battery



THE BATTERY” in chapter 3. NOTE:


1 . battery cover/front cover

2. side cover(left and right)

3. front fork upper cover

4. front fork cover(left and right)

5. leg shield1

6. air filter assembly


Pocket tester

90890-03112 (YU-03112-C)

II Minimum open-circuit voltage

12.8 V or more at 20°C (68°F)


V

YES

4

NO



8-16

EAS00758


ELEC +1 I

EAS00759

4. Starting circuit cut-off relay

• Remove the starting circuit cut-off relay.

• Connect the pocket tester ( Q x 1) and battery (12 V) to the starting circuit cut-off relay coupler as shown.

Positive battery terminal -» red/white ®

Negative battery terminal -> light green

Positive tester probe -» green/yellow ®

Negative tester probe -> green/yellow ®

1 3 w

8 A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn.

8 This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity.

• Does the starter motor turn?

0 YES NO I

Repair or replace the starter motor.

2 4

• Does the starting circuit cut-off relay have continuity between green/yellow and green/ yellow?

&

YES NO l

Replace the starting circuit cut-off relay

8-17


ELEC +i

EAS00761

5. Starter relay

• Remove the starter relay .

• Connect the pocket tester ( Q x 1) and battery (12 V) to the starter relay coupler as shown.

EAS00751

7. Brake light switch(front and rear)

• Check the brake light switches for continuity.


• Is each brake light switch OK?

Positive battery terminal ^green/yellow ©

Negative battery terminal -» blue/white (2)

Positive tester probe -» red (3)

Negative tester probe -» red (4)

V

YES NO I

Replace the brake light switch(es).

EAS00750

8. Engine stop switch

• Check the engine stop switch for continuity.


• Is the engine stop switch OK?

V

YES NO

*


V

YES NO 4

Replace the starter relay.

EAS00749

6. Main switch




V

YES

EAS00752

9. Sidestand switch(optional)

• Check the sidestand switch for continuity.


• Is the sidestand switch OK?

V

YES

NO 4


I NO

Replace the sidestand switch.

EAS00764

10. Start switch

• Check the start switch for continuity.


• Is the start switch OK?

V

YES NO


8-18


EAS00766

11. Wiring

• Check the entire starting system’s wiring.


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

YES

V

The starting system circuit is OK.

*

NO

Properly connect or repair the starting system’s wiring.

8-19

EAS00767

STARTER MOTOR


ELEC +i

® MM

®

Order Job/Part

Removing the starter motor

Front cover

Single seat/Trunk

Air filter assembly

1

2

Starter motor lead coupler

Starter motor

5

6

7

8

1

2

3

4

Disassembling the starter motor

O-ring

Gasket

Stator assembly

O-ring

Armature coil

Brush

Plate washer

Bracket

8-20

Q’ty

1

1

Remarks


Refer to “COVER AND PANEL”in chapter 3.

Refer to“ENGINE REMOVAL”in chapter

5.

Disconnect.


Disassemble the parts in the order listed.

1

1

1

1

1

2

1

1

Refer to“ASSEMBLING THE STARTER

MOTOR”.



ELEC + 1

EAS00769

CHECKING THE STARTER MOTOR

1. Check:

• commutator

Dirt -» Clean with 600-grit sandpaper.

2. Measure:

• commutator diameter a

Out of specification -» Replace the starter motor.

Commutator wear limit

16.6 mm (0.65 in)

3. Measure:

• mica undercut a

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

Mica undercut

1.35 mm (0.05 in)

NOTE:

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

8-21

4. Measure:

• armature assembly resistances (commutator and insulation)

Out of specification -» Replace the starter motor.

T T T T T T T T T T T T T T T T T T T T T T T a. Measure the armature assembly resistances with the pocket tester.

Pocket tester

90890-03112 (YU-03112-C) a

Armature coil

Commutator resistance 1

0.0378 ~ 0.0462 at 20°C (68°F)

Insulation resistance 2

Above 1 M at 20°C(68°F)


ELEC +i b. If any resistance is out of specification, replace the starter motor.

• • • • • • • • • • • • • • • • • • • • • • •

5. Measure:

• brush length a

Out of specification -» Replace the brushes as a set.

Brush length wear limit

3.5 mm (0.14 in)

6. Measure:

• brush spring force

Out of specification -» Replace the brush springs as a set.

Brush spring force

3.92 ~ 5.88N(400 ~ 600gf, 14.11 ~

21.16oz)

7. Check:

• gear teeth

Damage/wear -» Replace the gear.

8. Check:

• bearing ©

• oil seal ©

• bush (3)


8-22


ELEC +i

EAS00772

ASSEMBLING THE STARTER MOTOR

1. Install:

8brush seat 1

2. Install:

8 w a s h e r 1

8armature coil 2

8o-ing New 3

8stator assembly 4

3 . Install:

• bracket

• bolts (T)

X I 5 Nm (0.5 m * kg, 3.6 ft * lb)

NOTE:

Align the match marks a on the starter motor yoke with the match marks b on the bracket.

8-23

CHARGING SYSTEM

ELEC +i

EAS00773

CHARGING SYSTEM

CIRCUIT DIAGRAM

X

Y

R/B x x

B/L l-l Lg

R L/Y

W B/R

B/Y

G/Y x

LB

Sb

Gy

P

B

Or

B x

X

-vJHHL/-'

E _ r i«

£1

1 ^ h B

Br 1 1 C r y J

/R —111

© a

I

I Y

©

©

AC magneto

Rectifier/regulator

Main fuse

Battery nrn

—LIUL U - l

-rfrffr-rr

it nrr

0 @ ©@©

JL

L i " j

LVlAr

1

B/L

G/R [J -=r L

B/L

^ I P/W

Br l(S)

— Dg 4

12V10W ii

Ch

12V10W

G/Y

EH

R/W .] W (vfliL/1—I" Lg

• G/Y

L / G

(§)l

1 m rr

# G?

L/W

R/W

Br

— 1 O

J O

1— G/Y —

Br — l - ^ H B

Br/L

^ f if

L H K C 1 — © — r > | h B

@ l

Dg

Ch

©I

D g ^

12V10W fa>

— Ch -L-

12V10W i]M

12V35/35W

-i © i n

J J

R 1 O-Ô h R - • R ~(Q) I I I (0)~

I (CO) 15A I T ' ' ' J

8-24

EAS00774

TROUBLESHOOTING

The battery is not being charged.

Check:

1 . main fuse

2. battery

3. charging voltage

4. stator coil resistance

5. wiring connections

(of the entire charging system)

NOTE:



2. side cover(right)



5. leg shield1


CHARGING SYSTEM

ELEC +i

EAS00739

2. Battery





12.8 V or more at 20°C (68°F)


V

YES

I

NO



EAS00775

3. Charging voltage

• Connect the digital tachometer to the spark plug lead of cylinder.

• Connect the pocket tester (DC 20 V) to the battery as shown.

Digital tachometer

90890-06760

Pocket tester

90890-03112

YU-03112-C

Positive tester probe terminal

Negative tester probe terminal positive battery negative battery

EAS00738

1 . Main fuse



• Is the fuse OK?

YES

V

NO

*

Replace the fuse.

• Start the engine and let it run at approximately 5,000 r/min.

• Measure the charging voltage. a

Charging voltage

14 V at 5000r/min

8-25

NOTE:

Make sure the battery is fully charged.

• Is the charging voltage within specification?

*

NO YES l z

The charging circuit is

OK.

EAS00776

4. Stator coil resistance

• Disconnect the starter coil coupler from wireharness.

• Connect the pocket tester ( Q x 1) to the stator coil as shown.

CHARGING SYSTEM

ELEC +i

EAS00779

5. Wiring

• Check the wiring connections of the entire charging system.


• Is the charging system’s wiring properly connected and without defects?

YES

V

Replace the rectifier/regulator.

4

NO

Properly connect or repair the charging system’s wiring.

Positive tester probe -» white 1

Negative tester probe -> white 2

• Measure the stator coil resistances.

SI Stator coil resistance

0.28 ~ 0.42 at 20°C (68°F)

• Is the stator coil OK?

V

YES NO 4

Replace the crankshaft position sensor/ stator coil assembly.

8-26

EAS00780

LIGHTING SYSTEM

CIRCUIT DIAGRAM

LIGHTING SYSTEM

ELEC +i

Y

Br/W

L x

B/L

< v

B/L x

I ! -H •

8-27

EAS00781

TROUBLESHOOTING

Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light or meter light.

Check:

1 . main fuse

2. battery

3. main switch

4. dimmer switch


(of the entire lighting system)

`

LIGHTING SYSTEM

EAS00739

2. Battery





12.8 V or more at 20°C (68°F)


YES

V

NO X



NOTE:



2. side cover(right)



5. leg shield1


EAS00749

3. Main switch



• Is the main switch OK? y*

Pocket tester

90890-03112

YU-03112-C

V

YES NO

\


EAS00738

1 . Main fuse



• Is the fuse OK?

YES

V

NO X

Replace the fuse.

EAS00784

4. Dimmer switch

• Check the dimmer switch for continuity.


• Is the dimmer switch OK? r-i YES

V

NO

X

The dimmer switch is faulty. Replace the left handlebar switch.

8-28

EAS00787

5. Wiring

• Check the entire lighting system’s wiring.


• Is the lighting system’s wiring properly connected and without defects?

YES NO

V *

Check the condition of each of the lighting system’s circuits.

Refer to “CHECK-

ING THE LIGHT-

ING SYSTEM”.

Properly connect or repair the lighting system’s wiring.

LIGHTING SYSTEM

8-29

EAS00788

CHECKING THE LIGHTING SYSTEM

1 . The headlight and the high beam indicator light fail to come on.

LIGHTING SYSTEM

ELEC +i

3. Voltage

• Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown.

1 . Headlight bulb and socket

• Check the headlight bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND

BULB SOCKETS”

• Are the headlight bulb and socket OK?

AWhen the dimmer switch is set to “ % ”

BWhen the dimmer switch is set to “ & ”

Headlight

Positive tester probe

2

Negative tester probe yellow 1 or green black/green 3

V

YES NO

*

Replace the headlight bulb, socket or both.

Headlight coupler

A

DC 20V

- © +

®

2. High beam indicator light bulb and socket

• Check the high beam indicator light bulb and socket for continuity.


BULB SOCKETS”

• Are the high beam indicator light bulb and socket OK?

V

YES NO 4

Replace the high beam indicator light bulb , socket or both.

High beam indicator light

Positive tester probe -> yellow (4)

Negative tester probe -» black/green

Meter assembly coupler

DC20V Fn

B G/W 1 Br

©

B/G Lg G 1

1

n Ch Dg Y

©

• Set the main switch to “ON”.

• Start the engine.

• Set the dimmer switch to %0 ” or %0 ”.

• Measure the voltage (DC 12 V) of yellow © (green (2) ) on the headlight coupler and y e l l o w © on the meter assembly coupler(wire harness side).

• Is the voltage within specification?

8-30

YES

V

This circuit is OK.

NO

*

The wiring circuit from the main switch to the headlight coupler or meter assembly coupler is faulty and must be repaired.

Refer to “CIRCUIT DIA-

GRAM”.

LIGHTING SYSTEM

ELEC +i

EAS00789

2. The meter light fails to come on.

1. Meter light bulb and socket

• Check the meter light bulb and socket for continuity.


BULB SOCKETS”

• Are the meter light bulb and socket OK?

V

YES NO 4

Replace the meter light bulb, socket or both.

2. Voltage

• Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown.

Positive tester probe -» brown ©

Negative tester probe -* black (2)

8-31

®


• Measure the voltage (DC 12 V) of brown (T) on the meter light coupler (wire harness side).


YES

V

This circuit is OK.

NO

*

The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired.


GRAM”.

3. Voltage

• Connect the pocket tester (DC 20 V) to the

ECU coupler (wire harness side) as shown.

Positive tester probe -> black/green ©

Negative tester probe -> black/white (§)

LIGHTING SYSTEM

ELEC +i

EAS00790

3. The tail/brake light fails to come on.

1. Tail/brake light bulb and socket

• Check the tail/brake light bulb and socket for continuity.


BULB SOCKETS”

• Are the tail/brake light bulb and socket OK?

©

V

YES NO 4

Replace the tail/brake light bulb, socket or both.


• Measure the voltage (DC 12 V) of black/ green © on the ECU coupler (wire harness side).


YES

V

This circuit is OK.

NO I

The wiring circuit from the main switch to the

ECU coupler is faulty and must be repaired.


GRAM”.

2. Voltage

• Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.

Positive tester probe -> blue ©

Negative tester probe -» black

©

8-32


• Measure the voltage (DC 12 V) of blue © on the tail/brake light coupler (tail/brake light side).


YES

V

This circuit is OK.

NO 4 wiring circuit from the main switch to the tail/ brake light coupler is faulty and must be repaired.


GRAM”.

EAS00792

4. The license plate light fails to come on.

1 . License plate light bulb and socket

• Check the license plate light bulb and socket for continuity.


BULB SOCKETS”

• Are the license plate light bulb and socket

OK?

V

YES NO

*

Replace the license plate light bulb, socket or both.

2. Voltage

• Connect the pocket tester (DC 20 V) to the license plate light coupler (license plate light side) as shown.

Positive tester probe -> blue ©

Negative tester probe -> black

LIGHTING SYSTEM

L

© n<^^>n

®

T

B


• Measure the voltage (DC 12 V) of blue © on the license plate light coupler (license plate light side).


YES NO

V

4

This circuit is OK. The wiring circuit from the main switch to the license plate light coupler is faulty and must be repaired.


GRAM”.

8-33

EAS00793

SIGNALING SYSTEM

CIRCUIT DIAGRAM


ELEC +i

- H "

^<^

^ ^

W

B/R

L/B

Or/B

©

©

©

©

©

©

©

©

©

©

©

©

©

(D

(3D

Main fuse

Battery

ECU

Main switch

Fuel pump

Horn switch

Turn signal switch

Tail/brake light

Front brake light switch

Rear brake light switch

Horn

Turn signal relay

Front turn signal light(left)

Front turn signal light(right)

Fuel level meter

Engine trouble warning

Coolant temperatu light

Speed sensor

Turn signal indicator light

FI diagnostic tool(optional)

Rear turn signal light(left)

Rear turn signal light(right) m

C D

- O it

8-34

EAS00794

TROUBLESHOOTING

• Any of the following fail to light: turn signal light, brake light or an indicator light.

• The horn fails to sound.


EAS00739

2. Battery



THE BATTERY” in chapter 3.

Check:

1 . main fuse

2. battery

3. main switch


(of the entire signaling system)


12.8 V or more at 20°C (68°F)


NOTE:



2. side cover(left and right)



5. leg shield1,2

6. footrest board


V

YES

4

NO



EAS00749

3. Main switch




P* Pocket tester

90890-03112

YU-03112-C

V

YES NO 4


EAS00738

1 . Main fuse

• Check the main fuse for continuity.


• Is the fuse OK?

YES

V

NO

*

Replace the fuse.

EAS00795

4. Wiring

• Check the entire signal system’s wiring.


• Is the signaling system’s wiring properly connected and without defects?

YES

V

Check the condition of each of the signaling system’s circuits.

Refer to “CHECK-

ING THE SIG-

NALING SYS-

TEM”.

NO 4

Properly connect or repair the signaling system’s wiring.

8-35

EAS00796

CHECKING THE SIGNALING SYSTEM

1. The horn fails to sound.

1 . Horn switch

• Check the horn switch for continuity.


• Is the horn switch OK?

V

YES NO

*

Replace the left handlebar switch.


ELEC +i

3. Horn

• Disconnect the pink connector at the horn terminal.

• Connect a jumper lead © to the horn terminal and ground the jumper lead.


• Push the horn switch.

• Does the horn sound?

T

Br

-©

2. Voltage

• Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown.


Negative tester probe -> ground

X €>

w

& s.

Br P

V L J.


• Push the horn switch.

• Measure the voltage (DC 12 V) of brown at the horn terminal.


V

YES NO 4

The wiring circuit from the main switch to the horn connector is faulty and must be repaired.


GRAM”.

I NO YES

V

The horn is OK.

4. Voltage

• Connect the pocket tester (DC 20 V) to the horn connector at the pink terminal as shown.

Positive tester probe -» pink ©

Negative tester probe -> ground r r

Br P

L J

© to)

X


• Measure the voltage (DC 12 V) of pink © at the horn terminal.


YES

V

4 NO

Repair or replace the horn.

Replace the horn.

8-36

EAS00798

2. The tail/brake light fails to come on.

1 . Tail/brake light bulb and socket

• Check the tail/brake light bulb and socket for continuity.


BULB SOCKETS”

• Are the tail/brake light bulb and socket OK?


ELEC +i

3. Voltage

• Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.

Positive tester probe

Negative tester probe green/ yellow 1 black 2

V

YES NO I

Replace the tail/brake light bulb, socket or both.

J®

E

G/Y

L

B

®

2. Brake light switches

• Check the brake light switches for continuity.


• Is the brake light switch OK?

NO

V

YES

Replace the brake light switch(es).


• Pull in the brake levers.

• Measure the voltage (DC 12 V) of green/ yellow © on the tail/brake light coupler (wire harness side).


YES NO

V

4

This circuit is OK. The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.


GRAM”.

8-37

EAS00799

3. The turn signal light, turn signal indicator light or both fail to blink.


ELEC +i

4. Voltage

• Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.

1 . Turn signal indicator light bulb and socket

• Check the turn signal indicator light bulb and socket for continuity.


BULB SOCKETS”

• Are the turn signal indicator light bulb and socket OK?



V

YES NO

*

Replace the turn signal indicator light bulb, socket or both.

2. Turn signal light bulb and socket

• Check the turn signal light bulb and socket for continuity.


BULB SOCKETS”

• Are the turn signal light bulb and socket OK?

V

YES NO 4

Replace the turn signal light bulb, socket or both.


• Measure the voltage (DC 12 V) on brown

© at the turn signal relay coupler (wire harness side).


V

YES NO I

The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be repaired.


GRAM”.

3. Turn signal switch

• Check the turn signal switch for continuity.

Refer to “CHECKING THE SWITCHES”

• Is the turn signal switch OK?

V

YES NO

*

Replace the left handlebar switch.

8-38

5. Voltage

• Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.


6. Voltage

• Connect the pocket tester (DC 20 V) to the turn signal light connector or meter assembly coupler (wire harness side) as shown.

Positive tester probe -* brown/white ©


ALeft turn signal light(front and rear)

BRight turn signal light(front and rear)

CTurn signal indicator light

A

Left turn signal light

Positive tester probe -

Negative tester probe

Right turn signal light

Positive tester probe -

Negative tester probe

B chocolate 1 ground dark green 2 ground


• Measure the voltage (DC 12 V) on brown/ white ® at the turn signal relay coupler (wire harness side).


V

YES NO I

The turn signal relay is faulty and must be replaced.

C

JJ B Ch [L

E -

-*- —,

\ B | Ch \

Ch

Dg

Y

JJ B | Dg [L

\ u

©

Ch

-JS)

Y w v w

(D

8-39


• Set the turn signal switch to “ <^=i ” or “ i=£> ”.

• Measure the voltage (DC 12 V) of the chocolate ® or dark green (2) at the turn signal light connector (wire harness side).


YES NO

V *

This circuit is OK. The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.

EAS00804

4. The fuel level meter fails to operate.

1 . Fuel sender

• Remove the fuel pump from the fuel tank.

• Connect the pocket tester ( Q x 1) to the fuel sender coupler (wire harness side) as shown.


ELEC +i

2. Voltage


Positive tester probe -> brown ©


Positive tester probe -> green ©


DC20V

1

©

CD

^ n

Br G g

G/W Lg -

B B/G d)

G Br

Lg G/W

B/G B

• Measure the fuel sender resistances. if

Fuel sender resistance (up position

“F”)( × 1)

4~10 at 20°C (68°F)

Fuel sender resistance (down position “E”)( × 10)

90~100 at 20°C (68°F)

• Is the fuel sender OK?

YES

V

NO 4

Replace the fuel pump.


• Measure the voltage (DC 12 V) of brown (T) on the meter light coupler (wire harness side).


V

YES NO 4

Check the wiring connections of the entire signaling system.


GRAM”.

8-40

3. Fuel level meter


• Move the float u p ® or down (2) .


ELEC +i

• Check that the fuel level meter needle moves to “F” or “E”.

NOTE:

Before reading the fuel level meter, leave the float in one position (either up or down) for at least three minutes.

• Does the fuel level meter needle move appropriately?

YES

V

This circuit is OK.

4 NO

Replace the speedo meter.

8-41

EAS00807

COOLING SYSTEM

CIRCUIT DIAGRAM

COOLING SYSTEM

ELEC +i

Y

Br/W

L

X

B/L

<

Y

B/L x

I ! -H •

8-42

EAS00808

TROUBLESHOOTING

• The coolant temperature indicator light fails to indicate.

• The coolant temperature indicator light fails to indicate when the engine is warm.

COOLING SYSTEM

ELEC +i

EAS00739

2. Battery



THE BATTERY” in chapter 3.


12.8 V or more at 20°C (68°F)


Check:

1 . main fuse

2. battery

3. main switch

4. coolant temperature sensor


(the entire cooling system)

NOTE:

8 Before troubleshooting, remove the follow-

1.

2.

3. ing part(s): battery cover/front cover side cover(right) front fork upper cover

4.

5. front fork cover(left and right) leg shield1,2

6. footrest board


V

YES

4

NO



EAS00749

3. Main switch




V

YES NO 4


Pocket tester

90890-03112

YU-03112-C

EAS00738

1 . Main fuse



• Is the fuse OK?

V

YES NO 4

Replace the fuse.

8-43

EAS00812

4. Coolant temperature sensor

Remove the coolant temperature sensor from the cylinder head.

Connect the pocket tester ( × 1k ) to the coolant temperature sensor 1 as shown.

Immerse the coolant temperature sensor in a container filled with coolant2.

NOTE:

Make sure the coolant temperature sensor terminals do not get wet.

COOLING SYSTEM

ELEC +1 I

Coolant temperature sensor

22 Nm (2.2 m • kg, 15.9 ft • lb)

• Does the coolant temperature sensor operate properly?

V

YES NO

Replace the coolant temperature sensor.

• Place a thermometer ® in the coolant.

• Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table.

• Check the thermo switch for continuity at the temperatures indicated below.

EAS00813

5. Wiring

• Check the entire cooling system’s wiring.


• Is the cooling system’s wiring properly connected and without defects?

YES NO

V #

Replace the ECU. Properly connect or repair the cooling system’s wiring.

Bj Coolant temperature sensor resistance

20°C (68°F): 2.32 ~2.59k

80°C (176°F): 0.310 ~0.326k r?ViW:WLVel

• Handle the coolant temperature sensor with special care.

• Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it.

8-44


1. The coolant temperature indicator light fails to come on.

1. Coolant temperature indicator light bulb and socket

• Check the coolant temperature indicator light bulb and socket for continuity.


BULB SOCKETS”

• Are the coolant temperature indicator light bulb and socket OK?

COOLING SYSTEM

3. Voltage


Positive tester probe -> green/red ©

Negative tester probe -» ground

V

YES NO I

Replace the coolant temperature indicator light bulb, socket or both.

2. Voltage


Positive tester probe -> brown ©

Negative tester probe -» green/white (D

©

K

Br

,—t.G/W

G

Lg

B/ G

®

G Br

Lg G/W

B/ G B


• Measure the voltage (DC 12V) of green/ red © on the coolant temperature sensor coupler (wire harness side).

• Is the voltage with in specification?

V

YES NO 4

The wiring circuit from the main switch to the coolant temperature sensor coupler is faulty and must be repaired.


GRAM”.


• Measure the voltage (DC 12 V) of brown 1 on the meter light coupler (wire harness side).


V

YES NO I

The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired.

8-45

4. Coolant temperature indicator light

• Disconnect the coolant temperature sensor coupler at the coolant temperature sensor.

• Connect the green/red ® and black/blue ® with a jumper lead ® .


COOLING SYSTEM

ELEC +i

1 2

^

• Is the coolant temperature indicator light OK?

YES

V

This circuit is OK.

NO

*

Replace the coolant temperature indicator light.

8-46

TRBL Q

SHTGl •

CHAPTER 9

TROUBLE SHOOTING

STARTING FAILURE/HARD STARTING 9-1

ENGINE 9-1

FUEL SYSTEM 9-1

ELECTRICAL SYSTEMS 9-1

STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING

SPEED 9-2

ENGINE 9-2

FUEL SYSTEM 9-2


POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY

CLUTCH 9-3

ENGINE 9-3

FUEL SYSTEM 9-3

FAULTY CLUTCH 9-3

ENGINE OPERATES BUT SCOOTER WILL NOT MOVE 9-3

CLUTCH SLIPS 9-3

POOR STARTING PERFORMANCE 9-3

POOR SPEED PERFORMANCE 9-4

OVERHEATING 9-4

ENGINE 9-4

COOLING SYSTEM 9-4

FUEL SYSTEM 9-4

CHASSIS 9-4


COOLING SYSTEM 9-4

POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UN-

STABLE HANDLING 9-5

FAULTY FRONT FORK LEGS 9-5

LEAKING OIL 9-5

MALFUNCTION 9-5

UNSTABLE HANDLING 9-5

FAULTY LIGHTING OR SIGNALING SYSTEM 9-6

HEADLIGHT DOES NOT COME ON 9-6

HEADLIGHT BULB BURNT OUT 9-6

TAIL/BRAKE LIGHT DOES NOT COME ON 9-6

TAIL/BRAKE LIGHT BULB BURNT OUT 9-6

TRBL Q

SHTGl •

TURN SIGNAL DOES NOT COME ON 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

STARTING FAILURE/HARD STARTING

TRBL Q

SHTGl •

EAS00845

TROUBLESHOOTING

NOTE:

The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.

STARTING FAILURE/HARD

STARTING

ENGINE

Cylinder and cylinder head

8Loose spark plug

8Loose cylinder head or cylinder

8Damaged cylinder head gasket

8Damaged cylinder gasket

8Worn or damaged cylinder

8Incorrect valve clearance

8Improperly sealed valve

8Incorrect valve-to-valve-seat contact

8Incorrect valve timing

8Faulty valve spring

8Seized valve

Throttle body

8Deteriorated or contaminated fuel

8Sucked-in air

ELECTRICAL SYSTEMS

Battery

8Discharged battery

8Faulty battery

Fuse

8Blown, damaged or incorrect fuse

8Improperly installed fuse

Piston and piston ring

8Improperly installed piston ring

8Damaged, worn or fatigued piston ring

8Seized piston ring

8Seized or damaged piston

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

Air filter

8Improperly installed air filter

8Clogged air filter element

Crankcase and crankshaft

8Improperly assembled crankcase

8Seized crankshaft

Ignition coil

8Cracked or broken ignition coil body

8Broken or shorted primary or secondary coil

8Faulty spark plug lead

FUEL SYSTEM

Fuel tank

8Empty fuel tank

8Clogged fuel tank cap breather hole

8Deteriorated or contaminated fuel

8Clogged or damaged fuel hose

Ignition system

8Faulty ECU

8Faulty crankshaft position sensor

8Broken AC magneto rotor woodruff key

Fuel pump

8Faulty fuel pump

8Improperly routed hose

Switches and wiring

8Faulty main switch

8Faulty engine stop switch

8Broken or shorted wiring

8Faulty front, rear or both brake light switches

8Faulty start switch

8Faulty sidestand switch(optional)

8Improperly grounded circuit

8Loose connections

9-1

STARTING FAILURES/HARD STARTING/

INCORRECT ENGINE IDLING SPEED

TRBL Q

SHTGl •

Starting system

8Faulty starter motor

8Faulty starter relay

8Faulty starting circuit cut-off relay

8Faulty starter clutch

EAS00847

INCORRECT ENGINE IDLING

SPEED

ENGINE

Cylinder and cylinder head

8Incorrect valve clearance

8Damaged valve train components

Air filter


FUEL SYSTEM

Throttle body

8Damaged or loose throttle body joint

8Improperly ISC(idle speed control) valve

8Improper throttle cable free play

8Flooded throttle body

8Faulty air induction system


Battery

8Discharged battery

8Faulty battery

Spark plug



8Fouled spark plug

8Worn or damaged electrode

8Worn or damaged insulator

8Faulty spark plug cap

Ignition coil

8Faulty spark plug lead

Ignition system

8Faulty ECU

8Faulty crankshaft position sensor

9-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL Q

FAULTY CLUTCH SHTGl •

EAS00848

POOR MEDIUM-AND-HIGH-

SPEED PERFORMANCE

EAS00853

FAULTY CLUTCH

ENGINE OPERATES BUT SCOOTER WILL

NOT MOVE

Refer to “STARTING FAILURE/HARD START-

ING”.

ENGINE

Air filter


V-belt

8Bent, damaged or worn V-belt

8Slipping V-belt

FUEL SYSTEM

Throttle body

8Faulty diaphragm

Primary pulley cam and primary pulley slider

8Damaged or worn primary pulley cam

8Damaged or worn primary pulley slider

Fuel pump

8Faulty fuel pump

Clutch spring(s)

8Damaged clutch spring

Transmission gears

8Damaged transmission gear

CLUTCH SLIPS

Clutch shoe springs

8Damaged, loose or worn clutch shoe spring

Clutch shoes

8Damaged or worn clutch shoe

Primary sliding sheave

8Seized primary sliding sheave

POOR STARTING PERFORMANCE

V-belt

8V-belt slips

8Oil or grease on the V-belt


8Faulty operation

8Worn pin groove

8Worn pin

Clutch shoes

8Bent, damaged or worn clutch shoe

9-3

FAULTY CLUTCH/OVERHEATING/OVERCOOLING

TRBL Q

SHTGl •

POOR SPEED PERFORMANCE

V-belt

8Worn V-belt

8Oil or grease on the V-belt

Hose(s) and pipe(s)

8Damaged hose

8Improperly connected hose

8Damaged pipe

8Improperly connected pipe

Primary pulley weight(s)

8Faulty operation

8Worn primary pulley weight

FUEL SYSTEM

Throttle body

8Damaged or loose throttle body joint

Primary fixed sheave

8Worn primary fixed sheave Air filter



8Worn primary sliding sheave

Secondary fixed sheave

8Worn secondary fixed sheave

CHASSIS

Brake(s)

8Dragging brake

Secondary sliding sheave

8Worn secondary sliding sheave


Spark plug



EAS00855

OVERHEATING Ignition system

8Faulty coolant temperature sensor

8Faulty ECU

ENGINE

Clogged coolant passages

8Heavy carbon buildup

EAS00856

OVERCOOLING

Engine oil

8Incorrect oil level

8Incorrect oil viscosity

8Inferior oil quality

COOLING SYSTEM

Thermostat

8Thermostat stays open

COOLING SYSTEM

Coolant

8Low coolant level

Radiator

8Damaged or leaking radiator

8Faulty radiator cap

8Bent or damaged radiator fan

Water pump

8Damaged or faulty water pump

Thermostat

8Thermostat stays closed

Oil cooler

8Clogged or damaged oil cooler

9-4

POOR BRAKING PERFORMANCE/FAULTY FRONT

FORK LEGS/UNSTABLE HANDLING

TRBL Q

SHTGl •

EAS00859

POOR BRAKING PERFORMANCE

EAS00862

UNSTABLE HANDLING

Drum brake

8Worn brake shoe

8Worn or rusty brake drum

8Incorrect brake lever position

8Incorrect brake lever free play

8Incorrect brake camshaft lever position

8Incorrect brake shoe position

8Damaged or fatigued brake shoe spring

8Oil or grease on the brake shoe

8Oil or grease on the brake drum

EAS00861

FAULTY FRONT FORK LEGS

LEAKING OIL

8Bent, damaged or rusty inner tube

8Cracked or damaged outer tube

8Improperly installed oil seal

8Damaged oil seal lip

8Incorrect oil level (high)

8Loose damper rod assembly bolt

8Damaged damper rod assembly bolt copper washer

8Cracked or damaged cap bolt O-ring

MALFUNCTION

8Bent or damaged inner tube

8Bent or damaged outer tube

8Damaged fork spring

8Worn or damaged outer tube bushing

8Bent or damaged damper rod

8Incorrect oil viscosity

8Incorrect oil level

Handlebar

8Bent or improperly installed handlebar

Steering head components

8Improperly installed handlebar bracket

8Improperly installed lower bracket

(improperly tightened ring nut)

8Bent steering stem

8Damaged ball bearing or bearing race

Front fork leg(s)

8Uneven oil levels (both front fork legs)

8Unevenly tensioned fork spring (both front fork legs)

8Broken fork spring

8Bent or damaged inner tube

8Bent or damaged outer tube

Rear shock absorber assembly

8Faulty rear shock absorber spring

8Leaking oil

Tire(s)

8Uneven tire pressures (front and rear)

8Incorrect tire pressure

8Uneven tire wear

Wheel(s)

8Incorrect wheel balance

8Deformed cast wheel

8Damaged wheel bearing

8Bent or loose wheel axle

8Excessive wheel runout

Frame

8Bent frame

8Damaged steering head pipe

8Improperly installed bearing race

9-5

FAULTY LIGHTING OR SIGNALING SYSTEM

TRBL Q

SHTGl •

EAS00866

TURN SIGNAL REMAINS LIT

FAULTY LIGHTING OR SIGNALING

8 F a u l t y t u r n s i g n a l relay

SYSTEM 8Burnt-out turn signal bulb

HEADLIGHT DOES NOT COME ON

8Wrong headlight bulb

8Too many electrical accessories

8Hard charging

8Incorrect connection


8Poor contacts (main or light switch)

8Burnt-out headlight bulb

HEADLIGHT BULB BURNT OUT

8Wrong headlight bulb

8Faulty battery

8Faulty rectifier/regulator


8Faulty main switch

8Headlight bulb life expired

TURN SIGNAL BLINKS QUICKLY

8Incorrect turn signal bulb

8Faulty turn signal relay

8Burnt-out turn signal bulb

HORN DOES NOT SOUND

8Improperly adjusted horn

8Damaged or faulty horne=

8Faulty main switch

8Faulty horn switch

8Faulty battery


8Faulty wire harness

TAIL/BRAKE LIGHT DOES NOT COME ON

8Wrong tail/brake light bulb

8Too many electrical accessories


8Burnt-out tail/brake light bulb

TAIL/BRAKE LIGHT BULB BURNT OUT

8Wrong tail/brake light bulb

8Faulty battery

8Tail/brake light bulb life expired

TURN SIGNAL DOES NOT COME ON

8Faulty turn signal switch


8Burnt-out turn signal bulb


8Damaged or faulty wire harness


8Faulty battery


TURN SIGNAL BLINKS SLOWLY


8Faulty main switch

8Faulty turn signal switch

8Incorrect turn signal bulb

8Faulty battery

9-6

©YAMAHA

YAMAHA MOTOR TAIWAN CO., LTD

XF50W WIRING DIAGRAM

•q=

» • r 0 r o ,

© X

XK • c • X e 4, Oft • »

MARK EXPLANATION

R, Br, BrW... COLOR C O D E

4

CONNECTING WITH G R D . W I R E

^ L

GRD.

• CONNECTOR MARK

(BETWEEN MAIN & SUB HARNESS)

Black Red o

White

Brown Green Yellow

Blue

O range

G ray

Brown/Blue

Red/Black

Blue/Black

Chocolate

Pink

Light green

Red/Blue

Blue/White

Black/Red

•

Dark green

•

Sky blue c

Brown/White c

Red/White

•

Blue/Yellow c

Black/White

•

Black/Yellow

C

Green/Yellow

Black/Green c

Black/Blue e

Green/White

•

Green/Red

•

Blue/ Green

9

White/Blue a

White/Red

•

Yellow/Green Pink/White

•

Orange/Black