YP400(S) - IIS Floriani

YP400(S) - IIS Floriani
2004
YP400(S)
5RU1-AE1
SERVICE MANUAL
EAS00000
YP400(S) 2004
SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
First edition, December 2003
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
NOTICE
This manual was produced by the Yamaha Motor 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 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!
WARNING
CAUTION:
NOTE:
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.
1
EAS00008
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1 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
CHAS
5
6
ENG
COOL
7
8
FI
–
ELEC
9
Symbols 0 to G indicate the following.
0
0 Serviceable with engine mounted
A Filling fluid
B Lubricant
C Special tool
D Tightening torque
E Wear limit, clearance
F Engine speed
G Electrical data
TRBL
SHTG
A
B
C
D
+
T.
R.
E
F
G
H
I
J
G
E
K
M
L
B
M
M
LS
N
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Symbols N to O in the exploded diagrams
indicate the following.
O
LT
H Engine oil
I Gear oil
J Molybdenum-disulfide oil
K Wheel-bearing grease
L Lithium-soap- based grease
M Molybdenum-disulfide grease
New
N Apply locking agent (LOCTITE®)
O Replace the part
EAS00010
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
GEN
INFO
1
SPEC
2
CHK
ADJ
3
CHAS
4
ENG
5
COOL
6
FI
7
–
ELECTRICAL SYSTEM
TROUBLESHOOTING
+
ELEC
8
TRBL
SHTG
9
GEN
INFO
1
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
SCOOTER IDENTIFICATION..........................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
OUTLINE OF FI SYSTEM ......................................................................... 1-2
FI SYSTEM................................................................................................1-3
INSTRUMENT FUNCTION ....................................................................... 1-4
IMPORTANT INFORMATION ....................................................................... 1-10
PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-10
REPLACEMENT PARTS.........................................................................1-10
GASKETS, OIL SEALS AND O-RINGS .................................................. 1-10
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-11
BEARINGS AND OIL SEALS .................................................................. 1-11
CIRCLIPS ................................................................................................1-11
CHECKING THE CONNECTIONS ................................................................1-12
SPECIAL TOOLS .......................................................................................... 1-13
GEN
INFO
SCOOTER IDENTIFICATION
GEN
INFO
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1
stamped into the frame.
1
is
EAS00018
MODEL LABEL
The model label 1 is affixed inside the storage
box. Record the information on this label in the
space provided. This information will be
needed when ordering spare parts.
1
1-1
FEATURES
GEN
INFO
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 operating 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
air-fuel 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.
3
7
2
9
8
A
B
0
6
4
1
I
1 ECU
2 Fuel injection system
relay
3 Engine trouble warning light
4 Lean angle cut-off
switch
5
H
F
G
5 Fuel hose
6 Ignition coil
7 Fuel injector
8 Intake air pressure
sensor
9 Throttle position sensor
E
D
0 ISC (idle speed control) valve
A Intake air temperature
sensor
B Battery
C Air filter case
D Catalytic converter
1-2
C
E Crankshaft position
sensor
F Coolant temperature
sensor
G Spark plug
H Fuel tank
I Fuel pump
GEN
INFO
FEATURES
EAS00897
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains
the fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kg/cm2, 35.6 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens,
causing the fuel to be injected into the intake manifold only during the time the passage remains
open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the
greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector
is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake temperature sensor and coolant 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.
C
B
Ê
4
2
È
3
1
A
5
É
0
9
8
6
7
Illustration is for reference only.
1 Fuel pump
2 Fuel injector
3 Ignition coil
4 ECU
5 Catalytic converter
6 Coolant temperature
sensor
7 Crankshaft position
sensor
8 Intake air pressure
sensor
9 Throttle body
0 Intake air temperature
sensor
A Air filter case
B Throttle position sensor
C ISC (idle speed control) valve
1-3
È Fuel system
É Air system
Ê Control system
FEATURES
INSTRUMENT FUNCTIONS
Multifunction display
1
2
3
WARNING
Be sure to stop the vehicle before making
any setting changes to the multifunction
display.
4
5
6
1
2
GEN
INFO
1 Clock/ambient temperature display
2 Coolant temperature meter
3 Fuel meter
4 Odometer/tripmeters
5 “SELECT” button
6 “RESET” button
3
1 V-belt replacement indicator “V-BELT”
2 Fuel level warning symbol “ ”
3 Coolant temperature symbol “
”
4 Oil change indicator “OIL”
4
The multifunction display is equipped with the
following:
• a fuel meter
• a coolant temperature meter
• an odometer (which shows the total distance traveled)
• two tripmeters (which show the distance
traveled since they were last set to zero)
• a fuel reserve tripmeter (which shows the
distance traveled since the bottom segment
of the fuel meter and fuel level warning
symbol started flashing)
• a self-diagnosis device
• a clock
• an ambient temperature display
• an oil change indicator
• a V-belt replacement indicator
NOTE:
• Be sure to turn the key to “ON” before using
the “SELECT” and “RESET” buttons.
• When the key is turned to “ON”, all of the display segments of the multifunction display
will appear one after the other and then disappear, in order to test the electrical circuit.
1-4
FEATURES
GEN
INFO
Odometer and tripmeter modes
Pushing the “SELECT” button switches the
display between the odometer mode “ODO”
and the tripmeter modes “TRIP” in the following order:
ODO → TRIP (top) → TRIP (bottom) → ODO
When approximately 2.8 L (0.62 Imp gal,
0.74 US gal) of fuel remains in the fuel tank,
the bottom segment of the fuel meter and fuel
level warning symbol will start flashing, and the
display will automatically change to the fuel
reserve tripmeter mode “TRIP F” and start
counting the distance traveled from that point.
In that case, pushing the “SELECT” button
switches the display between the various tripmeter and odometer modes in the following
order:
TRIP F → TRIP (top) → TRIP (bottom) →
ODO → TRIP F
1 Fuel reserve tripmeter
To reset a tripmeter, select it by pushing the
“SELECT” button, and then push the “RESET”
button for at least one second. If you do not
reset the fuel reserve tripmeter manually, it will
reset itself automatically and the display will
return to the prior mode after refueling and
traveling 5 km (3 mi).
1
Fuel meter
With the key in the “ON” position, the fuel
meter indicates the amount of fuel in the fuel
tank. The display segments of the fuel meter
disappear towards “E” (Empty) as the fuel level
decreases. When the fuel level reaches the
bottom segment near “E”, the fuel level warning symbol and the bottom segment will flash.
Refuel as soon as possible.
1-5
FEATURES
GEN
INFO
Coolant temperature meter
With the key in the “ON” position, the coolant
temperature meter indicates the temperature
of the coolant. The coolant temperature varies
with changes in the weather and engine load.
If the top segment and coolant temperature
symbol flash, stop the vehicle and let the
engine cool.
CAUTION:
Do not operate the engine if it is overheated.
Oil change indicator “OIL”
This indicator flashes at the initial 1,000 km
(600 mi), then at 5,000 km (3,000 mi) and
every 5,000 km (3,000 mi) thereafter to indicate that the engine oil should be changed.
After changing the engine oil, reset the oil
change indicator. Refer to “To reset the oil
change indicator”. If the engine oil is changed
before the oil change indicator comes on (i.e.
before the periodic oil change interval has
been reached), the indicator must be reset
after the oil change for the next periodic oil
change to be indicated at the correct time.
The electrical circuit of the indicator can be
checked according to the following procedure.
1. Set the engine stop switch to “ ” and turn
the key to “ON”.
2. Check that the indicator comes on for a few
seconds and then goes off.
3. If the indicator does not come on, check the
electrical circuit. Refer to “SIGNALING
SYSTEM” in chapter 8.
NOTE:
The oil change indicator may flash when the
engine is revved with the scooter on the centerstand, but this does not indicate a malfunction.
1-6
FEATURES
GEN
INFO
To reset the oil change indicator
1. Turn the key to “ON”.
2. Hold the reset button pushed for two to
eight seconds.
1 Reset button “OIL CHANGE”
3. Release the reset button, and the oil
change indicator will go off.
NOTE:
If the engine oil is changed before the oil
change indicator comes on (i.e. before the
periodic oil change interval has been reached),
the indicator must be reset after the oil change
for the next periodic oil change to be indicated
at the correct time. To reset the oil change
indicator before the periodic oil change interval
has been reached, follow the above procedure, but note that the indicator will come on
for 1.4 seconds after releasing the reset button, otherwise repeat the procedure.
1
V-belt replacement indicator “V-BELT”
This indicator flashes every 20,000 km
(12,000 mi) when the V-belt needs to be
replaced.
The electrical circuit of the indicator can be
checked according to the following procedure.
1. Turn the key to “ON” and make sure that the
engine stop switch is set to “ ”.
2. If the indicator does not come on, check the
electrical circuit. Refer to “SIGNALING
SYSTEM” in chapter 8.
1-7
FEATURES
GEN
INFO
Self-diagnosis device
This model is equipped with a self-diagnosis
device for various electrical circuits.
If any of those circuits are defective, the multifunction display will indicate a two-digit error
code (e.g., 12, 13, 14).
If the multifunction display indicates an error
code, note the code number, and then check
the vehicle. Refer to “FUEL INJECTION SYSTEM” in chapter 7.
CAUTION:
If the multifunction display indicates an
error code, the vehicle should be checked
as soon as possible in order to avoid
engine damage.
This model is also equipped with a self-diagnosis device for the immobilizer system.
If any of the immobilizer system circuits are
defective, the immobilizer system indicator
light will flash, and then the multifunction display will indicate a two-digit error code (e.g.,
51, 52, 53) when the key is turned to “ON”.
NOTE:
If the multifunction display indicates error code
52, this could be caused by transponder interference. If this error appears, try the following.
1. Use the code re-registering key to start the
engine.
NOTE:
Make sure there are no other immobilizer keys
close to the main switch, and do not keep
more than one immobilizer key on the same
key ring! Immobilizer system keys may cause
signal interference, which may prevent the
engine from starting.
2. If the engine starts, turn it off, and try starting the engine with the standard keys.
3. If one or both of the standard keys do not
start the engine, re-register the standard
keys.
If the multifunction display indicates an error
code, note the code number, and then check
the vehicle. Refer to “IMMOBILIZER SYSTEM”
in chapter 8.
1-8
FEATURES
GEN
INFO
Clock mode
To set the clock:
1. Push the “SELECT” button and “RESET”
button together for at least two seconds.
2. When the hour digits start flashing, push
the “RESET” button to set the hours.
3. Push the “SELECT” button, and the minute
digits will start flashing.
4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then
release it to start the clock. Pushing the
“RESET” button for at least two seconds
switches the clock display to the ambient
temperature display.
Ambient temperature display
This display shows the ambient temperature
from –10 °C to 50 °C in 1 °C increments. The
temperature displayed may vary from the
ambient temperature. Pushing the “RESET”
button for at least two seconds switches the
ambient temperature display to the clock display.
• When the ambient temperature falls below
–10.0 °C, “–10.0 °C” is displayed.
• When the ambient temperature climbs
above 50.0 °C, “50.0” is displayed.
NOTE:
• If “– – °C” is displayed or “50.0” flashes while
the ambient temperature is between –10.0 °C
and 50.0 °C, there is a problem with the electrical circuit. Check or repair the electric circuit or replace the thermistor.
• The accuracy of the temperature reading
may be affected when riding slowly (approximately under 20 km/h) or when stopped at
traffic signals, railroad crossings, etc.
1-9
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1 - 10
IMPORTANT INFORMATION
GEN
INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropriate.
1 Oil seal
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
2 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 - 11
CHECKING THE CONNECTIONS
GEN
INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
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 1 on the terminal is flattened, bend it
up.
_
4.
•
•
•
Connect:
lead
coupler
connector
NOTE:
Make sure all connections are tight.
_
5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112, YU-03112-C
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
_
1 - 12
SPECIAL TOOLS
GEN
INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Tool No.
Tool name/Function
Rotor holding tool
90890-01235
YU-01235
This tool is used to hold the primary fixed
sheave and clutch shoe assembly.
Ring nut wrench
90890-01268
YU-01268
This tool is used to loosen or tighten the
steering ring nuts.
Piston pin puller set
90890-01304
YU-01304
This tool is used to remove the piston
pins.
Radiator cap tester
90890-01325
YU-24460-01
Radiator cap tester
adapter
90890-01352
YU-33984
T-handle
90890-01326
Damper rod holder
90890-01460
Radiator cap tester
Radiator cap tester adapter
These tools are used to check the cooling
system.
T-handle
Damper rod holder
These tools are used to hold the damper
rod when removing or installing the
damper rod.
Locknut wrench
90890-01348
YM-01348
This tool is used to remove or install the
clutch shoe assembly nut.
1 - 13
Illustration
SPECIAL TOOLS
Tool No.
Flywheel puller
90890-01362
Flywheel puller
attachment
90890-04089
YM-33282
Fork seal driver weight
90890-01367
YM-A9409-7
Fork seal driver
attachment
90890-01381
YM-A5142-2
Tool name/Function
Flywheel puller
Flywheel puller attachment
This tool is used to remove the generator
rotor.
Fork seal driver weight
Fork seal driver attachment (41 mm)
These tools are used to install the oil
seal, dust seal, and the outer tube bushing of a front fork leg.
Oil seal guide
90890-01396
This tool is used for protecting the oil seal
lip when installing the secondary sliding
sheave.
Steering nut wrench
90890-01403
YU-A9472
This tool is used to loosen or tighten the
steering ring nuts.
Pivot shaft wrench
90890-01471
YM-01471
Pivot shaft wrench
adapter
90890-01476
Pivot shaft wrench
Pivot shaft wrench adapter
These tools are used to tighten the subframe adjusting bolt.
Sheave holder
90890-01701
YS-01880-A
This tool is used to hold the generator
rotor and clutch housing.
Compression gauge Compression gauge
Adapter (compression gauge)
90890-03081
YU-33223
Adapter (compression gauge)
These tools are used to measure engine
90890-04082
compression.
Pocket tester
90890-03112
YU-03112-C
This tool is used to check the electrical
system.
1 - 14
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Timing light
90890-03141
YU-03141
This tool is used to check the ignition timing.
Pressure gauge
90890-03153
YU-03153
This tool is used to measure fuel pressure.
Adapter
90890-03181
This tool is used to measure fuel pressure.
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attachment
90890-01243
YM-01253-1
Middle driven shaft
bearing driver
90890-04058
YM-04058
Mechanical seal
installer
90890-04145
Valve spring compressor
Valve spring compressor attachment
These tools are used to remove or install
the valve assemblies.
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water
pump seal.
Valve guide remover (5 mm)
90890-04097
YM-04097
This tool is used to remove or install the
valve guides.
Valve guide installer (5 mm)
90890-04098
YM-04098
This tool is used to install the valve
guides.
Valve guide reamer (5 mm)
90890-04099
YM-04099
This tool is used to rebore the new valve
guides.
1 - 15
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Valve lapper
90890-04101
This tool is needed to remove and install
the valve lifters.
Sheave spring compressor
90890-04134
YM-04134
Sheave fixed block
90890-04135
YM-04135
Sheave spring compressor
Sheave fixed block
This tool is used to hold the compression
spring when removing or installing the
clutch shoe assembly nut.
Plane bearing installer/remover
90890-04146
This tool is used to install or remove the
crankshaft journal bearings.
Ignition checker
90890-06754
YM-34487
This tool is used to check the ignition system components.
Bond
90890-85505
Sealant
ACC-11001-05-01
Yamaha bond No. 1215
Sealant (Quick Gasket®)
This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
1 - 16
GEN
INFO
Illustration
SPEC
2
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ...........................................................................2-2
CHASSIS SPECIFICATIONS ........................................................................2-10
ELECTRICAL SPECIFICATIONS .................................................................2-14
CONVERSION TABLE .................................................................................. 2-17
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-17
TIGHTENING TORQUES .............................................................................. 2-18
ENGINE TIGHTENING TORQUES......................................................... 2-18
CHASSIS TIGHTENING TORQUES.......................................................2-21
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-23
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ................ 2-23
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ............. 2-25
COOLING SYSTEM DIAGRAMS .................................................................. 2-26
CABLE ROUTING ......................................................................................... 2-28
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Maximum load (total of cargo, rider,
passenger, and accessories)
Standard
Limit
5RU1 (EUR)
5RU3 (AUS)
-------
2,230 mm (87.8 in)
780 mm (30.7 in)
1,380 mm (54.3 in)
750 mm (29.5 in)
1,565 mm (61.6 in)
120 mm (4.72 in)
2,600 mm (102.4 in)
----------------------
210 kg (463 lb)
198 kg (437 lb)
-------
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total
Engine oil
Lubrication system
Recommended oil
-20 -10 0 10 20 30 40 50 ˚C
Standard
Limit
Liquid-cooled, 4-stroke, DOHC
394.9 cm3 (24.10 cu.in)
Forward-inclined single cylinder
83.0 × 73.0 mm (3.27 × 2.87 in)
10.6 : 1
1,300 ~ 1,500 r/min
36.0 ~ 42.0 kPa
(270 ~ 315 mmHg, 10.6 ~ 12.4 inHg)
1,400 kPa (14.00 kg/cm2, 199.1 psi) at
500 r/min
----------------------
Regular unleaded gasoline only (EUR)
Unleaded gasoline only (AUS)
-------
14 L (3.08 Imp gal, 3.70 US gal)
----
Wet sump
----
Refer to the chart for the engine oil grade.
----
API service SE, SF, SG type or higher
----
1.7 L (1.50 Imp qt, 1.80 US qt)
1.5 L (1.32 Imp qt, 1.59 US qt)
-------
1.7 L (1.50 Imp qt, 1.80 US qt)
80 °C (176 °F)
-------
SAE10W-30 type SE motor oil
0.25 L (0.22 Imp qt, 0.26 US qt)
-------
----
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40
SAE 20W-50
Recommended engine oil grade
Quantity
Total amount
Without oil filter element replacement
With oil filter element replacement
Engine oil temperature
Final transmission oil
Type
Quantity
2-2
ENGINE SPECIFICATIONS
Item
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Outer-rotor-to-oil-pump-housing
clearance
Oil-pump-housing-to-inner-and-outer
rotor clearance
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
Coolant temperature
Starting system type
Electric fuel injection
Type
Manufacturer
Spark plug
Model (manufacturer) × quantity
Spark plug gap
Cylinder head
Volume
Maximum warpage
Standard
Trochoid
0.07 mm
(0.0028 in)
0.013 ~ 0.036 mm
(0.0005 ~ 0.0014 in)
0.040 ~ 0.096 mm
(0.0016 ~ 0.0038 in)
SPEC
Limit
---0.15 mm
(0.0059 in)
0.106 mm
(0.0042 in)
0.166 mm
(0.0065 in)
1.57 L (1.38 Imp qt, 1.66 US qt)
110.0 ~ 140.0 kPa
(1.10 ~ 1.40 kg/cm2, 15.6 ~ 19.9 psi)
-------
260 mm (10.24 in)
148 mm (5.83 in)
24 mm (0.94 in)
----------
0.32 L (0.28 Imp qt, 0.34 US qt)
----
Single-suction centrifugal pump
37/22 × 25/37 (1.136)
90 ~ 100 °C (194 ~ 212 °F)
Electric starter
-------------
1100-87C00-A
AISAN
-------
CR7E (NGK) × 1
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
-------
30.3 ~ 31.1 cm3 (1.85 ~ 1.90 cu.in)
----
2-3
---0.05 mm
(0.002 in)
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-cap
clearance
Intake camshaft lobe dimensions
Limit
Chain drive (right)
---24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in)
---24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in)
---0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in)
0.08 mm
(0.0031 in)
A
B
Measurement A
34.350 ~ 34.450 mm (1.352 ~ 1.356 in)
Measurement B
24.950 ~ 25.050 mm (0.982 ~ 0.986 in)
34.250 mm
(1.3484 in)
24.850 mm
(0.9783 in)
Exhaust camshaft lobe dimensions
A
B
Measurement A
33.450 ~ 33.550 mm (1.317 ~ 1.321 in)
Measurement B
24.956 ~ 25.056 mm (0.982 ~ 0.986 in)
Maximum camshaft runout
----
2-4
33.350 mm
(1.3130 in)
24.856 mm
(0.9786 in)
0.03 mm
(0.0012 in)
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Limit
SCR-0409 SDH/136
Automatic
-------
0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in)
0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in)
-------
B
C
D
A
Head Diameter
Face Width
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Seat Width
Margin Thickness
30.9 ~ 31.1 mm (1.2165 ~ 1.2244 in)
27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in)
-------
1.838 ~ 2.687 mm (0.0724 ~ 0.1058 in)
1.697 ~ 2.828 mm (0.0668 ~ 0.1113 in)
-------
1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)
1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)
0.85 ~ 1.15 mm (0.0335 ~ 0.0453 in)
0.85 ~ 1.15 mm (0.0335 ~ 0.0453 in)
4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in)
4.960 ~ 4.975 mm (0.1953 ~ 0.1959 in)
5.000 ~ 5.015 mm (0.1969 ~ 0.1974 in)
5.000 ~ 5.015 mm (0.1969 ~ 0.1974 in)
0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)
0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)
2-5
1.6 mm
(0.06 in)
1.6 mm
(0.06 in)
------4.945 mm
(0.1947 in)
4.930 mm
(0.1941 in)
5.053 mm
(0.1989 in)
5.053 mm
(0.1989 in)
0.080 mm
(0.0032 in)
0.100 mm
(0.0039 in)
ENGINE SPECIFICATIONS
Item
Standard
SPEC
Limit
Valve stem runout
----
0.01 mm
(0.0004 in)
Valve seat width
Intake
1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)
1.6 mm
(0.06 in)
1.6 mm
(0.06 in)
Exhaust
1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in)
Valve springs
Free length
Intake
46.45 mm (1.83 in)
Exhaust
46.45 mm (1.83 in)
Installed length (valve closed)
Intake
Exhaust
Compressed spring force (installed)
Intake
Exhaust
44.13 mm
(1.74 in)
44.13 mm
(1.74 in)
35.10 mm (1.38 in)
35.10 mm (1.38 in)
-------
160.5 ~ 184.7 N at 35.10 mm
(16.37 ~ 18.83 kg at 35.10 mm,
36.08 ~ 41.52 lb at 1.38 in)
160.5 ~ 184.7 N at 35.10 mm
(16.37 ~ 18.83 kg at 35.10 mm,
36.08 ~ 41.52 lb at 1.38 in)
----
----
Spring tilt
Intake
----
Exhaust
----
Winding direction (top view)
Intake
Exhaust
2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
Clockwise
Clockwise
2-6
-------
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Cylinder
Cylinder arrangement
Bore × stroke
Compression ratio
Bore
Maximum taper
Limit
Forward-inclined single cylinder
---83.0 × 73.0 mm (3.27 × 2.87 in)
---10.6 : 1
---83.000 ~ 83.010 mm (3.2677 ~ 3.2681 in)
------0.05 mm
(0.002 in)
Piston
Piston-to-cylinder clearance
0.060 ~ 0.075 mm (0.0024 ~ 0.0030 in)
0.15 mm
(0.0060 in)
82.930 ~ 82.945 mm (3.2650 ~ 3.2656 in)
----
Diameter D
H
D
Height H
Piston pin bore (in the piston)
Diameter
5.0 mm (0.20 in)
----
20.004 ~ 20.015 mm
(0.7876 ~ 0.7880 in)
1.0 mm (0.0394 in)
Intake side
20.045 mm
(0.7892 in)
-------
19.991 ~ 20.000 mm
(0.7870 ~ 0.7874 in)
0.004 ~ 0.024 mm (0.0002 ~ 0.0010 in)
19.971 mm
(0.7863 in)
0.074 mm
(0.0029 in)
Ring type
Dimensions (B × T)
End gap (installed)
Barrel
1.00 × 2.70 mm (0.04 × 0.11 in)
0.20 ~ 0.35 mm (0.0079 ~ 0.0138 in)
Ring side clearance
0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in)
------0.50 mm
(0.0197 in)
0.100 mm
(0.0039 in)
Offset
Offset direction
Piston pin
Outside diameter
Piston-pin-to-piston-pin-bore clearance
Piston rings
Top ring
B
T
2-7
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
2nd ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Taper
1.00 × 3.10 mm (0.04 × 0.12 in)
0.40 ~ 0.55 mm (0.0157 ~ 0.0217 in)
Ring side clearance
0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in)
------0.80 mm
(0.0315 in)
0.100 mm
(0.0039 in)
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
Ring side clearance
Crankshaft
C
2.00 × 2.25 mm (0.08 × 0.09 in)
0.10 ~ 0.40 mm (0.0039 ~ 0.0157 in)
0.040 ~ 0.140 mm (0.0016 ~ 0.0055 in)
----------
C
E
D
A
Width A
Maximum runout C
63.95 ~ 64.00 mm (2.518 ~ 2.520 in)
----
Big end side clearance D
Big end radial clearance E
Crankshaft-journal-to-crankshaftjournal-bearing clearance
Bearing color code
0.350 ~ 0.850 mm (0.0138 ~ 0.0335 in)
0.010 ~ 0.024 mm (0.0004 ~ 0.0009 in)
0.030 ~ 0.077 mm (0.0012 ~ 0.0030 in)
0 = White 1 = Blue 2 = Black 3 = Brown
4 = Green
2-8
---0.030 mm
(0.0012 in)
------0.09 mm
(0.0035 in)
----
ENGINE SPECIFICATIONS
Item
Automatic centrifugal clutch
Clutch shoe thickness
Standard
4.0 mm (0.16 in)
Clutch shoe spring free length
Clutch housing inside diameter
34.7 mm (1.37 in)
160 mm (6.30 in)
Compression spring free length
103.5 mm (4.075 in)
Weight outside diameter
25 mm (0.98 in)
Clutch-in revolution
Clutch-stall revolution
V-belt
V-belt width
Transmission
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Clutch type
Transmission type
Operation
Single speed automatic
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
2,100 ~ 2,700 r/min
4,000 ~ 5,000 r/min
30 mm (1.18 in)
SPEC
Limit
2.5 mm
(0.10 in)
---160.5 mm
(6.30 in)
91 mm
(3.58 in)
24.5 mm
(0.96 in)
------27 mm
(1.06 in)
Helical gear
31/14 (2.214)
Helical gear
42/16 (2.625)
Dry, centrifugal automatic
V-belt automatic
Centrifugal automatic type
2.380 ~ 0.892:1
Wet element
----------------------------
Electrical
5RU (AISAN)
250 kPa (2.5 kg/cm2, 35.6 psi)
----------
3 ~ 5 mm (0.12 ~ 0.20 in)
----
5RU 00
----
2-9
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Maximum radial wheel runout
Standard
Aluminum die-cast and steel tube backbone
27°
100.0 mm (3.94 in)
----
Cast wheel
----
14 M/C × MT3.00
Aluminum
107 mm (4.21 in)
----------
----
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 ~ 90 kg (0 ~ 198 lb)
90 ~ 198 kg (198 ~ 437 lb)
High-speed riding
Minimum tire tread depth
Limit
-------
1 mm
(0.04 in)
0.5 mm
(0.02 in)
0.25 mm
(0.01 in)
Cast wheel
----
13 M/C × MT4.00
Aluminum
104 mm (4.09 in)
----------
----
1 mm
(0.04 in)
0.5 mm
(0.02 in)
----
Tubeless
120/80-14M/C 58S
MB 67 (IRC)
D305FL (DUNLOP)
200 kPa (2.00 kgf/cm2, 29 psi)
200 kPa (2.00 kgf/cm2, 29 psi)
200 kPa (2.00 kgf/cm2, 29 psi)
----
2 - 10
---------------------1.6 mm
(0.06 in)
CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb)
90 ~ 198 kg (198 ~ 437 lb)
High-speed riding
Minimum tire tread depth
Front brakes
Brake type
Operation
Recommended fluid
Brake discs
Diameter × thickness
Minimum thickness
Standard
Tubeless
150/70-13M/C 64S
MB 67 (IRC)
D305L (DUNLOP)
250 kPa (2.50 kgf/cm2, 36 psi)
250 kPa (2.50 kgf/cm2, 36 psi)
250 kPa (2.50 kgf/cm2, 36 psi)
----
Single-disc brake
Right-hand operation
DOT 4
267 × 5 mm (10.51 × 0.20 in)
----
Maximum deflection
----
Brake pad lining thickness
6.0 mm (0.24 in)
Master cylinder inside diameter
Caliper cylinder inside diameter
14.0 mm (0.55 in)
30.16 mm and 33.34 mm
(1.19 in and 1.31 in)
2 - 11
SPEC
Limit
---------------------1.6 mm
(0.06 in)
------------4.5 mm
(0.18 in)
0.15 mm
(0.006 in)
0.8 mm
(0.03 in)
-------
CHASSIS SPECIFICATIONS
Item
Rear brake
Brake type
Operation
Recommended fluid
Brake discs
Diameter × thickness
Minimum thickness
Standard
Single-disc brake
Left-hand operation
DOT 4
267 × 5 mm (10.51 × 0.20 in)
----
Maximum deflection
----
Brake pad lining thickness
8.3 mm (0.33 in)
Master cylinder inside diameter
Caliper cylinder inside diameter
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
SPEC
Limit
------------4.5 mm
(0.18 in)
0.15 mm
(0.006 in)
0.8 mm
(0.03 in)
14.0 mm (0.55 in)
38.1 mm (1.50 in)
-------
Telescopic fork
Coil spring/oil damper
120 mm (4.72 in)
----------
316.7 mm (12.47 in)
Installed length
Spring rate (K1)
Spring rate (K2)
Spring stroke (K1)
Spring stroke (K2)
Inner tube outer diameter
Inner tube bending limit
296.7 mm (11.68 in)
14.09 N/mm (1.44 kg/mm, 80.45 lb/in)
26.67 N/mm (2.72 kg/mm, 152.28 lb/in)
0 ~ 90 mm (0 ~ 3.5433 in)
90 ~ 120 mm (3.5433 ~ 4.7244 in)
41 mm (1.61 in)
----
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully compressed, and without the fork
spring)
No
Fork oil 10 W or equivalent
0.298 L (0.262 Imp qt, 0.315 US qt)
88 mm (3.46 in)
2 - 12
310.4 mm
(12.22 in)
------------------0.2 mm
(0.01 in)
-------------
CHASSIS SPECIFICATIONS
Item
Steering
Steering bearing type
Lock-to-lock angle (left)
Lock-to-lock angle (right)
Rear suspension
Suspension type
Rear shock absorber assembly type
Rear shock absorber assembly travel
Spring
Free length
Installed length
Spring rate (K1)
Spring rate (K2)
Spring rate (K3)
Spring stroke (K1)
Spring stroke (K2)
Spring stroke (K3)
Optional spring available
Swingarm
Free play (at the end of the swingarm)
Radial
Axial
SPEC
Standard
Limit
Angular and taper roller bearings
40°
40°
----------
Unit swing
Coil spring/oil damper
130 mm (5.12 in)
----------
306.6 mm (12.07 in)
290.6 mm (11.44 in)
6.22 N/mm (0.63 kg/mm, 35.52 lb/in)
11.80 N/mm (1.20 kg/mm, 67.38 lb/in)
22.50 N/mm (2.29 kg/mm, 128.47 lb/in)
0 ~ 29 mm (0 ~ 1.14 in)
29 ~ 90 mm (1.14 ~ 3.54 in)
90 ~ 130 mm (3.54 ~ 5.12 in)
Yes
----
300.0 mm
(11.81 in)
-------------------------
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
----
2 - 13
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
System voltage
Ignition system
Ignition system type
Ignition timing
Advancer type
Crankshaft position sensor resistance/color
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
Rectifier/regulator
Regulator type
Model (manufacturer)
No-load regulated voltage
Rectifier capacity
Withstand voltage
Battery
Battery type
Battery voltage/capacity
Specific gravity
Manufacturer
Ten hour rate amperage
Minimum open-circuit voltage
Headlight
Headlight type
Bulbs (voltage/wattage × quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
Licence plate light
Meter light
Standard
Limit
12 V
----
Transistorized coil ignition (digital)
5° BTDC at 1,400 r/min
Digital
248 ~ 372 Ω at 20 °C (68 °F)/red–white
-------------
2JN (MORIC)
6 mm (0.24 in)
2.16 ~ 2.64 Ω at 20 °C (68 °F)
8.64 ~ 12.96 kΩ at 20 °C (68 °F)
-------------
Resin
10.0 kΩ at 20 °C (68 °F)
-------
A.C. magneto
F5RU (MORIC)
14 V/27.5 A at 5,000 r/min
0.184 ~ 0.276 Ω at 20 °C (68 °F)/
white–white
-------------
Semiconductor, short-circuit type
SH678-11 (SHINDENGEN)
14.1 ~ 14.9 V
22 A
200 V
----------------
GT9B-4
12 V/8 Ah
1.320
GS
0.8 A
12.8 V or more at 20 °C (68 °F)
-------------------
Halogen bulb
----
12 V 60/55 W × 2
12 V 5 W × 2
LED × 1
12 V 21 W × 4
12 V 5 W × 1
12 V 2.0 W × 3
-------------------
2 - 14
ELECTRICAL SPECIFICATIONS
Item
Indicator light
(voltage/wattage × quantity)
High beam indicator light
Turn signal indicator light
Engine trouble warning light
Immobilizer system indicator light
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Armature coil resistance
Insulation resistance
Commutator diameter
Mica undercut
Starter relay
Model (manufacturer)
Amperage
Horn
Horn type
Model (manufacturer) × quantity
Maximum amperage
Performance
Coil resistance
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Standard
SPEC
Limit
12 V 1.4 W × 1
12 V 1.4 W × 2
12 V 1.4 W × 1
LED × 1
-------------
Constant mesh
----
SM-13 (MITSUBA)
0.65 kW
-------
12 mm (0.47 in)
7.65 ~ 10.01 N
(780 ~ 1,021 gf, 27.54 ~ 36.03 oz)
0.0012 ~ 0.0022 Ω at 20 °C (68 °F)
Above 1 MΩ at 20 °C (68 °F)
28 mm (1.1 in)
0.7 mm (0.028 in)
4.0 mm
(0.16 in)
---------27 mm
(1.06 in)
----
2768098-A (JIDECO)
180 A
-------
Plane
HF-12 (NIKKO) × 1
3A
108 ~ 116 dB/2 m
1.01 ~ 1.11 Ω at 20 °C (68 °F)
----------------
Full transistor
FE246BH (DENSO)
No
75 ~ 95 cycles/minute
21 W × 2 + 3.4 W
----------------
2 - 15
ELECTRICAL SPECIFICATIONS
Item
Fuses (amperage × quantity)
Main fuse
Fuel injection system fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan motor fuse
Backup fuse (storage box light,
immobilizer unit and meter assembly)
Turn signal/hazard fuse
Spare 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 motor
Model (manufacturer)
Running rpm
Coolant temperature sensor
Model (manufacturer)
Resistance at 20 °C (68 °F)
Resistance at 80 °C (176 °F)
Resistance at 110 °C (230 °F)
Intake air pressure sensor
Output voltage
Intake air temperature sensor
Resistance
Speed sensor
Output voltage
When sensor is on
When sensor is off
Throttle position sensor
Voltage/color
Voltage (closed position)/color
ISC (idle speed control) valve
Resistance/color
Lean angle cut-off switch
Voltage
Less than 45°
More than 45°
Standard
SPEC
Limit
40 A × 1
10 A × 1
25 A × 1
10 A × 1
10 A × 1
10 A × 1
10 A × 1
----------------------
10 A × 1
40 A, 25 A, 10 A × 1
-------
5RU (AISAN)
19 ~ 21 Ω
137 ~ 143 Ω
----------
ACA12115-4 (MATSUSHITA)
72 ~ 88 Ω
Yes
----------
5RU (MITSUBA)
4,500 r/min
-------
5PS (DENSO)
2.32 ∼ 2.59 kΩ
0.310 ∼ 0.326 kΩ
0.140 ∼ 0.144 kΩ
-------------
3.4 ~ 3.8 V
----
2.3 ~ 2.6 kΩ at 20 °C (68 °F)
----
DC 4.8 V or more
DC 0.6 V or less
-------
5V/blue–black/blue
0.4 ~ 0.9 V/yellow/blue–black/blue
-------
27 ~ 33 Ω at 20 °C (68 °F)/
pink–light green or gray–sky blue
----
Approximately 1 V
Approximately 4 V
-------
2 - 16
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EAS00028
EAS00029
CONVERSION TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
Ex.
METRIC
MULTIPLIER
IMPERIAL
** mm
×
0.03937
=
** in
2 mm
×
0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
m·kg
Tightenm·kg
ing torque
cm·kg
cm·kg
Weight
kg
g
Multiplier
Imperial unit
7.233
86.794
0.0723
0.8679
ft·lb
in·lb
ft·lb
in·lb
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP lip.)
cu.in
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit (°F)
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
A: Width across flats
B: Thread diameter
A
(nut)
2 - 17
B
(bolt)
General tightening
torques
Nm
m•kg
10 mm
6 mm
6
0.6
12 mm
8 mm
15
1.5
14 mm
10 mm
30
3.0
17 mm
12 mm
55
5.5
19 mm
14 mm
85
8.5
22 mm
16 mm
130
13.0
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Thread
Q’ty
size
Tightening torque
Item
Fastener
Camshaft cap
Exhaust pipe stud bolt
Spark plug
Cylinder head and cylinder
Cylinder head and cylinder
Cylinder head and cylinder
Cylinder head cover and cylinder
head
Cylinder head cover and camshaft
cap
Oil gallery bolt
Cylinder and crankcase
Generator rotor
Camshaft sprocket (intake and
exhaust)
Timing chain guide (intake side)
Timing chain tensioner assembly
Timing chain tensioner cap bolt
Water pump cover
Oil cooler outlet hose joint
Thermostat cover
Radiator filler hose and bracket
Radiator pipe assembly
Oil cooler pipe
Oil cooler cover
Coolant drain bolt
Air bleed bolt (coolant)
Oil pump assembly
Oil strainer cover
Oil filter element cover
Cylinder head and intake manifold
Intake manifold and throttle body joint
Fuel injector assembly
Fuel hose stay
Intake air pressure sensor and stay
Air filter case (left and right)
Muffler joint
Muffler protector
Muffler end cover
Muffler end cover stay
Exhaust pipe protector
Bolt
—
—
Bolt
Nut
Cap nut
M6
M8
M10
M6
M10
M10
8
2
1
2
2
2
10
13
13
10
40
52
1.0
1.3
1.3
1.0
4.0
5.2
7.2
9.4
9.4
7.2
29
37
Bolt
M6
9
10
1.0
7.2
Bolt
M6
1
10
1.0
7.2
—
Bolt
Nut
M6
M6
M18
1
1
1
10
10
130
1.0
1.0
13.0
7.2
7.2
94
Bolt
M7
4
20
2.0
14
Bolt
Bolt
—
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
—
—
Bolt
—
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M6
M6
M6
M6
M6
M6
M5
M6
M6
M6
M6
M5
M6
M35
M6
M6
M6
M6
M5
M6
M6
M8
M6
M6
M6
M6
2
2
1
3
1
2
1
3
2
3
1
1
2
1
3
2
2
1
1
3
4
1
2
5
3
2
10
10
7
10
10
10
9
7
10
10
10
6
7
32
10
10
10
12
7
10
7
14
10
10
10
10
1.0
1.0
0.7
1.0
1.0
1.0
0.9
0.7
1.0
1.0
1.0
0.6
0.7
3.2
1.0
1.0
1.0
1.2
0.7
1.0
0.7
1.4
1.0
1.0
1.0
1.0
7.2
7.2
5.1
7.2
7.2
7.2
6.5
5.1
7.2
7.2
7.2
4.3
5.1
23
7.2
7.2
7.2
8.7
5.1
7.2
5.1
10
7.2
7.2
7.2
7.2
2 - 18
Nm m · kg ft · lb
Remarks
LT
LT
LT
LT
LT
LT
TIGHTENING TORQUES
Item
Exhaust pipe
Air induction system pipe
Air induction system pipe stay
Air cut-off valve
Muffler mount
V-belt case air duct 1 and 2
Crankcase
Crankcase
Crankcase
Cylinder head stud bolt
Transmission oil drain bolt
Bearing retainer
Transmission case cover
V-belt case
V-belt case
V-belt case cover
Generator rotor cover inner bracket
Generator rotor cover
Primary sheave
Timing plug
Engine oil drain bolt
Secondary sheave
Starter clutch
Clutch shoe assembly
Stator coil
Crankshaft position sensor
Starter motor
Coolant temperature sensor
Fastener
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
—
—
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
—
—
Nut
Bolt
Nut
Bolt
Bolt
Bolt
—
Thread
Q’ty
size
M8
M6
M6
M6
M10
M6
M6
M8
M8
M10
M8
M6
M8
M8
M6
M6
M6
M6
M18
M16
M12
M14
M8
M36
M6
M6
M6
M12
2 - 19
2
2
1
2
3
4
7
5
1
4
1
1
7
1
9
6
2
11
1
1
1
1
6
1
3
2
2
1
SPEC
Tightening torque
Nm m · kg ft · lb
20
12
7
10
53
7
10
16
30
13
20
10
16
22
10
7
7
10
83
8
20
60
30
90
10
10
12
18
2.0
1.2
0.7
1.0
5.3
0.7
1.0
1.6
3.0
1.3
2.0
1.0
1.6
2.2
1.0
0.7
0.7
1.0
8.3
0.8
2.0
6.0
3.0
9.0
1.0
1.0
1.2
1.8
14
8.7
5.1
7.2
38
5.1
7.2
11
22
9.4
14
7.2
11
16
7.2
5.1
5.1
7.2
60
5.8
14
43
22
65
7.2
7.2
8.7
13
Remarks
LT
LT
LT
LT
LT
TIGHTENING TORQUES
Camshaft cap tightening sequence:
Cylinder head tightening sequence:
2 - 20
SPEC
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Tightening torque
Item
Thread size
Bottom cover and sub-frame
Radiator cover and frame
Front cowling and front cowling stay
Footrest board and footrest board stay
Footrest board and sub-frame
Reflector and reflector bracket
Storage compartment and frame
Rear fender and frame
Sub-frame adjusting bolt
Sub-frame front upper mounting nut
Sub-frame front lower mounting bolt
Sub-frame rear mounting bolt
Radiator and sub-frame
Coolant reservoir and sub-frame
Footrest board plate and sub-frame
Fuel tank and sub-frame (bolt)
Fuel tank and sub-frame (nut)
Fuel hose holder and sub-frame
Ignition coil and ignition coil bracket
Ignition coil bracket and sub-frame
Engine bracket upper mounting nut
Engine bracket lower mounting bolt
Engine mounting nut
Engine bracket bolt
Front cowling stay and frame
Steering stem nut
Upper steering ring nut
Lower steering ring nut
Rear axle nut
Rear shock absorber assembly upper nut
Rear shock absorber assembly lower bolt
Rear brake caliper bracket and swingarm
Rear brake hose holder and swingarm
Swingarm and engine
Brake hose union bolt (front and rear brake hose)
Rear brake caliper and rear brake caliper bracket
Bleed screw (front and rear brake caliper)
Upper handlebar holder and lower handlebar
holder
Front brake master cylinder and front brake master cylinder holder
M6
M6
M6
M6
M6
M6
M6
M6
M18
M10
M10
M10
M6
M6
M6
M6
M6
M6
M6
M8
M12
M10
M12
M10
M10
M20
M30
M30
M14
M10
M8
M10
M6
M10
M10
M10
M7
7
7
7
7
7
7
7
10
4
54
54
54
7
7
7
10
7
7
7
16
59
45
65
56
32
140
90
24
135
34
29
40
10
46
30
27
6
0.7
0.7
0.7
0.7
0.7
0.7
0.7
1.0
0.4
5.4
5.4
5.4
0.7
0.7
0.7
1.0
0.7
0.7
0.7
1.6
5.9
4.5
6.5
5.6
3.2
14.0
9.0
2.4
13.5
3.4
2.9
4.0
1.0
4.6
3.0
2.7
0.6
5.1
5.1
5.1
5.1
5.1
5.1
5.1
7.2
2.9
39
LT
39
LT
39
5.1
5.1
5.1
7.2
5.1
5.1
5.1
11
43
LT
32
47
LT
40
23
100
65 See “NOTE”.
17 See “NOTE”.
98
24
21
29
7.2
33
22
19
4.3
M8
23
2.3
17
M6
10
1.0
7.2
2 - 21
Nm m · kg ft · lb
Remarks
TIGHTENING TORQUES
Item
Thread size
Rear brake master cylinder and rear brake master cylinder holder
Grip end
Right handlebar switch
Rear brake lock lever and left handlebar switch
Storage box and frame
Rider seat and bottom plate
Seat lock assembly and frame
Grab bar bracket and frame
Grab bar and grab bar bracket
Grab bar and frame
Passenger seat and grab bar
Seat bracket and frame
Gas spring assembly bracket and frame
Front brake hose holder and lower bracket
Front brake hose holder and outer tube
Sidestand and sub-frame
ECU bracket and front cowling stay
ECU and ECU bracket
Front cowling stay and horn
Front wheel axle pinch bolt
Damper rod bolt
Lower bracket pinch bolt
Cap bolt
Front wheel axle
Front wheel and brake disc
Front brake caliper bracket and outer tube
Front brake caliper and front brake caliper
bracket
Rear wheel and brake disc
SPEC
Tightening torque
Nm m · kg ft · lb
M6
10
1.0
7.2
M16
M5
M5
M6
M6
M6
M8
M8
M8
M6
M8
M8
M6
M6
M10
M6
M6
M6
M8
M10
M10
M38
M14
M8
M10
26
4
6
11
7
10
30
23
23
7
30
30
7
7
39
7
7
10
20
30
30
70
55
23
40
2.6
0.4
0.6
1.1
0.7
1.0
3.0
2.3
2.3
0.7
3.0
3.0
0.7
0.7
3.9
0.7
0.7
1.0
2.0
3.0
3.0
7.0
5.5
2.3
4.0
19
2.9
4.3
8.0
5.1
7.2
22
17
17
5.1
22
22
5.1
5.1
28
5.1
5.1
7.2
14
22
22
50
40
17
29
M10
27
2.7
19
M8
23
2.3
17
Remarks
LT
LT
LT
NOTE:
1. Tighten the lower steering ring nut 36 Nm (3.6 m · kg, 25 ft · lb) with a torque wrench and the
steering nut wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower steering ring nut 24 Nm (2.4 m · kg, 17 ft · lb) with a torque wrench and the
steering nut wrench.
3. Install the rubber washer and the center steering ring nut.
4. Finger tighten the center steering ring nut, align the slots of both steering ring nuts, and then
install the lock washer.
5. Hold the lower and center steering ring nuts, and then tighten the upper steering ring nut 90 Nm
(9.0 m · kg, 65 ft · lb) with a torque wrench and the steering nut wrench.
2 - 22
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Oil seal lips
Lubricant
LS
Bearings
E
O-rings
LS
Cylinder head nut
E
Camshaft cap and camshaft cap bolts
E
Crankshaft pin
E
Connecting rod big end thrust surface
E
Balancer drive gear inner surface
E
Crankshaft thrust surface
E
Crankshaft journals
E
Crankshaft end (generator rotor side)
E
Generator rotor nut and washer
E
Piston and piston rings
E
Piston pin and connecting rod small end
E
Balancer driven gear assembly
E
Impeller shaft end
E
Camshaft lobes
M
Camshaft journals
M
Valve stems (intake and exhaust)
M
Valve stem ends (intake and exhaust)
E
Decompressor (lever, pin and spring)
E
Oil pump shafts
E
O-ring (fuel injector assembly)
Silicone oil
Primary sheave collar and O-ring
Shell BT grease 3®
Secondary sheave collar and O-ring
Shell BT grease 3®
Engine mounting bolt collars
LS
Crankshaft journal bearings
E
Starter clutch idle gear and shaft
E
Starter clutch gear
E
Main axle thrust surface
E
Main and drive axle serration
E
Drive axle spline
LS
Drive axle bearing
LS
Primary sheave
BEL-RAY
assembly lube®
Secondary sheave
BEL-RAY
assembly lube®
2 - 23
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Water pump seal lip
SPEC
Lubricant
LS
Crankcase breather pipe
LT
Transmission case breather pipe
LT
Cylinder head cover (guide stopper mating surface)
Yamaha bond
No. 1215
Crankcase mating surface
Yamaha bond
No. 1215
Generator rotor cover (grommet mating surface)
Yamaha bond
No. 1215
2 - 24
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00032
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication Point
Symbol
Engine mounting bolt
LS
Swingarm, oil seal
LS
Steering bearings and oil seal
LS
Throttle grip inner surface and throttle cables
LS
Brake lever pivoting point and metal-to-metal moving parts (left and right)
LS
Rear brake lock lever cable and rear brake lock lever (cable connection
area)
LS
Front wheel oil seal
LS
Speed sensor oil seal
LS
Rear axle
LS
Sidestand pivoting point, metal-to-metal moving parts and collar outer surface
LS
Centerstand shaft pivoting point and metal-to-metal moving parts
LS
Centerstand stopper pivoting point
LS
Centerstand and sidestand spring hook metal-to-metal moving parts
LS
Sidestand switch contact point
LS
Fuel tank lid hinge and stopper
LS
2 - 25
COOLING SYSTEM DIAGRAMS
SPEC
EAS00033
COOLING SYSTEM DIAGRAMS
1 Radiator outlet hose
2 Radiator
3 Radiator cap
4 Coolant reservoir hose
5 Radiator filler hose
6 Radiator inlet hose
7 Radiator pipe assembly
1
2
3
7
6
7
6
5
4
2
1
2 - 26
COOLING SYSTEM DIAGRAMS
1 Radiator pipe assembly
2 Oil cooler outlet hose
3 Oil cooler cover
4 Water pump outlet hose
5 Water pump cover
6 Water pump inlet hose
7 Thermostat inlet hose
8 Cooling system air bleed hose
9 Thermostat outlet hose
0 Thermostat
A Thermostat cover
SPEC
B Water jacket inlet pipe
C Oil cooler pipe
A
6 7 8
9
A
A-A
0
1
A
5
C
B
C
4 3 2
3
C
2
B
C-C
B
2 - 27
CABLE ROUTING
SPEC
EAS00035
CABLE ROUTING
1 Rear brake lock lever cable
2 Rear brake hose
3 Cable guide (lower handlebar holder)
4 Throttle cable (accelerator cable)
5 Throttle cable (decelerator cable)
6 Front brake hose
7 Handlebar switch leads
È Route the handlebar switch leads to the left of
the cable guide (lower handlebar holder).
É Route the throttle cables in front of the handlebar.
Ê Fasten the right handlebar switch lead to the
handlebar with a plastic locking tie.
Ð 1
È
3
4 5
2
1
4
5
6
A
Ñ
B
B
A
Ë
Ê
Ì
É
2
Ï
Î
7
C
1
4
C
6
5
Ï
C-C
6
Í
2 - 28
CABLE ROUTING
Ë Fasten the left handlebar switch lead to the handlebar with a plastic locking tie.
Ì Route the rear brake lock lever cable in front of
the handlebar.
Í Route the throttle cables under the rear brake
hose, rear brake lock lever cable, and front
brake hose, and then to the right side of the
scooter.
Î Pass the throttle cables, rear brake hose, and
rear brake lock lever cable through the cable
guide (lower handlebar holder).
SPEC
Ï Install the grommet on the front brake hose in
the hole in the lower handlebar cover before
connecting the hose.
Ð Pass the rear brake lock lever cable through the
hole in the lower handlebar cover.
Ñ Pass the throttle cables through the hole in the
lower handlebar cover.
Ð 1
È
3
4 5
2
1
4
5
6
A
Ñ
B
B
A
Ë
Ê
Ì
É
2
Ï
Î
7
C
1
4
C
6
5
Ï
C-C
6
Í
2 - 29
SPEC
CABLE ROUTING
1 Meter assembly
2 Handlebar switch leads
3 Throttle cable (accelerator cable)
4 Throttle cable (decelerator cable)
5 Front brake hose
6 Rear brake lock lever cable
7 Rear brake hose
8 Wire harness
9 Fuel overflow hose
0 Radiator fan motor lead
A Radiator
8
D
B Rectifier/regulator
C Speed sensor lead
D Front turn signal light lead (right)
E Front turn signal light lead (left)
F Front turn signal light lead coupler (right)
G Headlight lead
H Front turn signal light lead coupler (left)
I Starting circuit cut-off relay
J Headlight relay 2
K Turn signal relay
L Radiator fan motor relay
E
2
È 1
D
I
I
B
A
C
A F
HG
JKLM
I J
K
J
K
N
C
O
G
E
3
4
5
6
7
É
Ê
Ë
É
Ì 8
E
F
D
H
F
P
H
G
R
Î
Q
B
S
4
3
7
6
T
5
Ð
Ï
Í
B
A
0 9
Ó
B
0
Ñ
8
Ö
G
C
5
34
E
Ô
H-H
F-F
S
U
7
0
T
6 D
J-J
8
G
E
8
×
Õ
Ò
F-F
I-I
2 - 30
D
K-K
SPEC
CABLE ROUTING
M Fuel injection system relay
N Headlight relay 1
O Meter assembly lead
P Lean angle cut-off switch
Q Horn
R ECU
S Right handlebar switch lead
T Left handlebar switch lead
U Rectifier/regulator lead
È After connecting the meter assembly coupler,
install the cover to the meter assembly.
É Fasten the wire harness to the frame with a plastic locking tie. Face the end of the plastic locking
tie down.
Ê The paint marks on the rear brake lock lever
cable and the rear brake hose should be within
20 mm (0.79 in) above or below the upper edge
of the hole in the frame.
8
D
E
2
È 1
D
I
I
B
A
C
A F
HG
JKLM
I J
K
J
K
N
C
O
G
E
3
4
5
6
7
É
Ê
Ë
É
Ì 8
E
F
D
H
F
P
H
G
R
Î
Q
B
S
4
3
7
6
T
5
Ð
Ï
Í
B
A
0 9
Ó
B
0
Ñ
8
Ö
G
C
5
34
E
Ô
H-H
F-F
S
U
7
0
T
6 D
J-J
8
G
E
8
×
Õ
Ò
F-F
I-I
2 - 31
D
K-K
SPEC
CABLE ROUTING
Ë Pass the rear brake lock lever cable and rear
brake hose through the hole in the frame so that
the rear brake lock lever cable is to the outside
of the rear brake hose.
Ì Route the throttle cable (decelerator cable)
above the throttle cable (accelerator cable).
Í Connect the wire harness to the rectifier/regulator.
Î Fasten the wire harness with a cable holder.
Ï Route the front brake hose in front of the throttle
cables.
8
D
Ð Route the handlebar switch leads in front of the
front brake hose.
Ñ Route the rear brake hose and rear brake lock
lever cable in front of the front brake hose and
throttle cables.
Ò Fasten the rectifier/regulator lead and radiator
fan motor lead to the sub-frame with a plastic
band. Face the end of the plastic band towards
the rear of the scooter.
E
2
È 1
D
I
I
B
A
C
A F
HG
JKLM
I J
K
J
K
N
C
O
G
E
3
4
5
6
7
É
Ê
Ë
É
Ì 8
E
F
D
H
F
P
H
G
R
Î
Q
B
S
4
3
7
6
T
5
Ð
Ï
Í
B
A
0 9
Ó
B
0
Ñ
8
Ö
G
C
5
34
E
Ô
H-H
F-F
S
U
7
0
T
6 D
J-J
8
G
E
8
×
Õ
Ò
F-F
I-I
2 - 32
D
K-K
SPEC
CABLE ROUTING
Ó Pass the radiator fan motor lead through the cutout in the left side of the bottom cover.
Ô Face the end of the plastic locking tie away from
the scooter.
Õ Fasten the headlight lead, front turn signal light
lead (left), and front turn signal light lead (right)
to the front cowling with a plastic band. The end
of the plastic band should be towards the rear of
the scooter facing down.
8
D
Ö Fasten the wire harness to the front cowling stay
with a plastic band. The end of the plastic band
should be towards the rear of the scooter facing
down.
× Fasten the wire harness at the white tape to the
front cowling stay with a plastic band. The end of
the plastic band should be towards the rear of
the scooter facing down.
E
2
È 1
D
I
I
B
A
C
A F
HG
JKLM
I J
K
J
K
N
C
O
G
E
3
4
5
6
7
É
Ê
Ë
É
Ì 8
E
F
D
H
F
P
H
G
R
Î
Q
B
S
4
3
7
6
T
5
Ð
Ï
Í
B
A
0 9
Ó
B
0
Ñ
8
Ö
G
C
5
34
E
Ô
H-H
F-F
S
U
7
0
T
6 D
J-J
8
G
E
8
×
Õ
Ò
F-F
I-I
2 - 33
D
K-K
SPEC
CABLE ROUTING
1 Sidestand switch lead
2 Crankshaft position sensor lead coupler
3 Sub-wire harness
4 Crankshaft position sensor/stator coil lead
5 Storage box light switch lead
6 Storage box light
7 Negative battery lead
8 Starter motor lead
9 Fuse box
0 Tail/brake light lead
A Rear turn signal light/license plate light lead
1
B Starter motor
C Fuel hose
D Spark plug lead
E Sidestand switch
F Stator coil lead
G Wire harness
H Throttle cable (accelerator cable)
I Throttle cable (decelerator cable)
J Stator coil lead coupler
K Storage box light lead
L Turn signal/hazard fuse
6
F
8
7
Ê
9
G
É
F
G
I
H
Ï
G
A-A
4
5
E
3
E
D
B
È 2
1
C
Ì
C
A
Ë
Í
B
B
7
0
8
7
L
Ù
A
A
J
Ø
×
Ö
J Û
M
Ô
Ú
G
7
B
G
8
Ü
3
J
Î
E
D
C
E-E
Ð
G
G
Ó
5
H
3
B-B
Ñ
H
B
4
3
4
Õ
6
I
78
Þ
5
Ò
K
D
F
C-C
2 - 34
I
M
8
O
Ý G
N
7
J-J
SPEC
CABLE ROUTING
M Battery band
N Positive battery lead
O V-belt replacement indicator reset coupler lead
Ë Route the tail/brake light lead and rear turn signal light/license plate light lead below the
bracket on the frame.
Ì Fasten the wire harness, starter motor lead, and
negative battery lead to the frame with plastic
locking ties. Face the end of each plastic locking
tie away from the scooter.
Í Pass the sub-wire harness, crankshaft position
sensor/stator coil lead, and fuel injector lead
between the starter motor and the throttle body.
È After connecting the stator coil lead coupler,
slide the cover over the coupler.
É Route the storage box light lead through the two
guides in the storage box.
Ê Route the wire harness, starter motor lead, and
negative battery lead on the outside of the grab
bar bracket.
1
6
F
8
7
Ê
9
G
É
F
G
I
H
Ï
G
A-A
4
5
E
3
E
D
B
È 2
1
C
Ì
C
A
Ë
Í
B
B
7
0
8
7
L
Ù
A
A
J
Ø
×
Ö
J Û
M
Ô
Ú
G
7
B
G
8
Ü
3
J
Î
E
D
C
E-E
Ð
G
G
Ó
5
H
3
B-B
Ñ
H
B
4
3
4
Õ
6
I
78
Þ
5
Ò
K
D
F
C-C
2 - 35
I
M
8
O
Ý G
N
7
J-J
SPEC
CABLE ROUTING
Î Connect the orange lead to the upper terminal of
the ignition coil and connect the red/black lead to
the lower terminal.
Ï Fasten the throttle cables, sidestand switch lead,
and wire harness with a plastic holder as shown.
³ Fasten the sub-wire harness, stator coil lead
coupler, and wire harness with a plastic locking
tie. Face the end of the plastic locking tie down.
Ñ Install the plastic locking tie in the hole above
the footrest bracket.
1
Ò Fasten the sub-wire harness at the white tape
and the crankshaft position sensor/stator coil
lead to the engine bracket with a plastic locking
tie. Face the end of the plastic locking tie away
from the scooter.
Ó Route the rear brake hose and rear brake lock
lever cable through the two engine bracket
guides so that the rear brake lock lever cable is
towards the outside of the scooter.
6
F
8
7
Ê
9
G
É
F
G
I
H
Ï
G
A-A
4
5
E
3
E
D
B
È 2
1
C
Ì
C
A
Ë
Í
B
B
7
0
8
7
L
Ù
A
A
J
Ø
×
Ö
J Û
M
Ô
Ú
G
7
B
G
8
Ü
3
J
Î
E
D
C
E-E
Ð
G
G
Ó
5
H
3
B-B
Ñ
H
B
4
3
4
Õ
6
I
78
Þ
5
Ò
K
D
F
C-C
2 - 36
I
M
8
O
Ý G
N
7
J-J
SPEC
CABLE ROUTING
Ô Fasten the wire harness, starter motor lead, and
negative battery lead to the frame with a plastic
locking tie. Face the end of the plastic locking tie
away from the scooter.
Õ Connect the storage box light lead coupler
securely.
Ö Route the negative battery lead below the
bracket on the frame.
× Route the starter motor lead and wire harness
over the boss of the upper rear cover.
1
Ø Route the positive battery lead between the
leads and the battery.
Ù Install the cover over the positive battery terminal.
Ú Route the negative battery lead between the
leads and the battery.
Û Fasten the V-belt replacement indicator reset
coupler with the battery band.
Ü Install the negative battery lead terminal to the
starter motor bolt hole that is closest to the cylinder.
6
F
8
7
Ê
9
G
É
F
G
I
H
Ï
G
A-A
4
5
E
3
E
D
B
È 2
1
C
Ì
C
A
Ë
Í
B
B
7
0
8
7
L
Ù
A
A
J
Ø
×
Ö
J Û
M
Ô
Ú
G
7
B
G
8
Ü
3
J
Î
E
D
C
E-E
Ð
G
G
Ó
5
H
3
B-B
Ñ
H
B
4
3
4
Õ
6
I
78
Þ
5
Ò
K
D
F
C-C
2 - 37
I
M
8
O
Ý G
N
7
J-J
SPEC
CABLE ROUTING
Ý Route the starter motor lead and negative battery lead below the boss on the left engine
bracket as shown.
Þ Install the battery band with its projection in the
recess in the top of the battery case.
1
6
F
8
7
Ê
9
G
É
F
G
I
H
Ï
G
A-A
4
5
E
3
E
D
B
È 2
1
C
Ì
C
A
Ë
Í
B
B
7
0
8
7
L
Ù
A
A
J
Ø
×
Ö
J Û
M
Ô
Ú
G
7
B
G
8
Ü
3
J
Î
E
D
C
E-E
Ð
G
G
Ó
5
H
3
B-B
Ñ
H
B
4
3
4
Õ
6
I
78
Þ
5
Ò
K
D
F
C-C
2 - 38
I
M
8
O
Ý G
N
7
J-J
SPEC
CABLE ROUTING
1 Rear brake lock lever cable
2 Rear brake hose
3 Throttle cable (accelerator cable)
4 Throttle cable (decelerator cable)
5 Seat lock cable
6 Main switch/immobilizer unit
7 Thermistor lead coupler
8 Front brake hose
9 Speed sensor lead
0 Coolant reservoir
A Front cowling stay
È Route the seat lock cable through the cable
cover.
É Pass the throttle cables through the hole in the
frame.
Ê The paint marks on the throttle cables should be
within 20 mm (0.79 in) above or below the upper
edge of the hole in the frame.
Ë Route the speed sensor lead over the lower tube
of the front cowling stay.
Ë
Î
5
6
A-A
5
5
F
Ì
4
Ï
F
3
B-B
7
8
Ê
É
A
5
È
2
C-C
1
A
Í
B
9
B
D
E
E
C
D
C
Ð
E-E
Ñ
0
2 - 39
A
F-F
SPEC
CABLE ROUTING
Ì After connecting the main switch lead, immobilizer unit lead, and speed sensor lead, put the
cover on the couplers.
Í Route the front brake hose and speed sensor
lead through the guide on the front cowling stay
so that the speed sensor lead is towards the outside of the scooter.
Î Hook the end of the cable cover in the hole in
the frame.
Ï Attach the cable cover by installing the quick fastener in the hole in the frame.
Ð Hook the end of the cable cover in the hole in
the frame.
Ñ Fasten a plastic band around the middle of the
coupler cover, and then face the end of the plastic band down.
Ë
Î
5
6
A-A
5
5
F
Ì
4
Ï
F
3
B-B
7
8
Ê
É
A
5
È
2
C-C
1
A
Í
B
9
B
D
E
E
C
D
C
Ð
E-E
Ñ
0
2 - 40
A
F-F
SPEC
CABLE ROUTING
1 Seat lock cable
2 Rear brake lock lever cable
3 Rear brake hose
4 Fuel overflow hose
5 Coolant reservoir breather hose
È Fasten the rear brake hose with the brake hose
holder and route the rear brake lock lever cable
through the guide.
É Fasten the rear brake hose with the plastic
holder.
Ê Route the seat lock cable above the rear brake
lock lever cable.
Ë Align the white paint mark on the fuel overflow
hose with the holder on the bottom cover.
Ë
2
Ì
4
É
3
A-A
1
Ê
2
Ï
3
C
É
Î
B-B
Í
5
1
2
3
A
A
B
B
C
È
2 - 41
SPEC
CABLE ROUTING
Ì Route the fuel overflow hose to the outside of
the hose guide.
Í Fasten the coolant reservoir breather hose with
the two holders on the bottom cover.
Î Route the coolant reservoir breather hose to the
outside of the hose guide.
Ï The end of the coolant reservoir breather hose
should extend 15 ± 10 mm (0.59 ± 0.39 in) past
the end of the bottom cover.
Ë
2
Ì
4
É
3
A-A
1
Ê
2
Ï
3
C
É
Î
B-B
Í
5
1
2
3
A
A
B
B
C
È
2 - 42
CABLE ROUTING
1 Seat lock cable
2 Throttle cable (decelerator cable)
3 Throttle cable (accelerator cable)
4 Rear brake lock lever cable
5 Rear brake hose
6 Wire harness
7 Thermistor
8 Thermistor lead
2 3
È Route the throttle cables above the seat lock
cable guide.
É Route the section of the wire harness shown and
the throttle cables through the cutout in the rubber sheet and then below the frame cross member.
Ê Fasten the wire harness with a plastic locking
tie.
Ë 20 mm (0.79 in)
Ì Route the throttle cables below the gas spring
assembly.
1
Î
5
SPEC
8
1
Ï
7
4
C
A
B
C
Ð
B
È
6
5
1
4
3
Í
Ì
A
2
Ë
Ê
É
2 - 43
CABLE ROUTING
SPEC
Í Route the throttle cable (decelerator cable)
above the throttle cable (accelerator cable).
Î Route the throttle cables above the rear brake
hose and rear brake lock lever cable.
Ï Pass the seat lock cable through the space
between the storage compartment and seat lock
cable guide.
Ð Route the seat lock cable through the lower section of the seat lock cable guide.
2 3
1
Î
5
8
1
Ï
7
4
C
A
B
C
Ð
B
È
6
5
1
4
3
Í
Ì
A
2
Ë
Ê
É
2 - 44
CABLE ROUTING
1 Spark plug cap
2 Seat lock cable
3 Seat lock assembly
4 ISC (idle speed control) valve lead
5 Rear brake lock lever cable
6 Rear brake hose
7 Wire harness
8 Starter motor lead
9 Positive battery lead
0 Negative battery leads
A Intake air temperature sensor
SPEC
B Fuel injector lead
C Storage box light switch lead
D Storage box light switch
E Sub-wire harness
F Crankshaft position sensor/stator coil lead
G Crankshaft position sensor lead coupler
H Throttle cable (decelerator cable)
I Stator coil lead coupler
7
1
I
H
2
Í
G
3
F
E
4
Ì
5
D
6
C
B
Ë
A
0
È
8
É
7
8
9
0
7
8
Ê
2 - 45
CABLE ROUTING
È Do not pinch any hoses, leads, etc., when
installing the storage box.
É After connecting the positive battery lead, starter
motor lead, and wire harness, install the starter
relay cover.
Ê 30°
Connect the positive battery lead to the starter
relay within the angle shown. Route the starter
motor lead parallel to the positive battery lead.
SPEC
Ë Route the starter motor lead and negative battery lead between the two projections on the
frame.
Ì Pass the fuel hose through the hose guide on
the sub-frame.
Í After installing the spark plug cap, fasten the
spark plug lead to the cylinder head with the
lead holder.
7
1
I
H
2
Í
G
3
F
E
4
Ì
5
D
6
C
B
Ë
A
0
È
8
É
7
8
9
0
7
8
Ê
2 - 46
CHK
ADJ
3
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
PERIODIC MAINTENANCE AND LUBRICATION CHART ............................ 3-1
COWLING AND COVERS............................................................................... 3-3
PASSENGER SEAT AND SIDE COVERS................................................ 3-3
RIDER SEAT AND STORAGE BOX .........................................................3-4
SIDE COVER MOULDINGS AND FOOTREST BOARDS ........................3-6
FRONT COWLING .................................................................................... 3-7
AIR FILTER CASES ........................................................................................3-9
ENGINE .........................................................................................................3-10
ADJUSTING THE VALVE CLEARANCE ................................................ 3-10
ADJUSTING THE EXHAUST GAS VOLUME .........................................3-15
CHECKING THE ENGINE IDLING SPEED ............................................3-16
ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-17
CHECKING THE SPARK PLUG ............................................................. 3-17
CHECKING THE IGNITION TIMING.......................................................3-19
MEASURING THE COMPRESSION PRESSURE..................................3-20
CHECKING THE ENGINE OIL LEVEL....................................................3-22
CHANGING THE ENGINE OIL ...............................................................3-23
CHANGING THE TRANSMISSION OIL.................................................. 3-26
REPLACING THE AIR FILTER ELEMENTS...........................................3-27
CLEANING THE V-BELT CASE AIR FILTER ELEMENT .......................3-28
CHECKING THE THROTTLE BODY JOINT AND
INTAKE MANIFOLD ............................................................................... 3-29
CHECKING THE FUEL HOSE ................................................................3-29
CHECKING THE BREATHER HOSES ...................................................3-30
CHECKING THE EXHAUST SYSTEM....................................................3-31
CHECKING THE COOLANT LEVEL.......................................................3-31
CHECKING THE COOLING SYSTEM ....................................................3-32
CHANGING THE COOLANT................................................................... 3-33
CHK
ADJ
CHASSIS ....................................................................................................... 3-36
ADJUSTING THE REAR BRAKE LOCK LEVER CABLE .......................3-36
CHECKING THE BRAKE FLUID LEVEL................................................. 3-37
CHECKING THE FRONT AND REAR BRAKE PADS ............................ 3-38
CHECKING THE FRONT AND REAR BRAKE HOSES.......................... 3-38
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-39
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-40
CHECKING THE FRONT FORK ............................................................. 3-42
CHECKING THE TIRES..........................................................................3-43
CHECKING THE WHEELS ..................................................................... 3-46
CHECKING AND LUBRICATING THE CABLES .................................... 3-46
LUBRICATING THE LEVERS .................................................................3-47
LUBRICATING THE SIDESTAND........................................................... 3-47
LUBRICATING THE CENTERSTAND ....................................................3-47
ELECTRICAL SYSTEM................................................................................. 3-48
CHECKING AND CHARGING THE BATTERY....................................... 3-48
CHECKING THE FUSES ........................................................................3-53
REPLACING THE HEADLIGHT BULBS ................................................. 3-55
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-57
INTRODUCTION/
PERIODIC MAINTENANCE AND LUBRICATION CHART
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.
PERIODIC MAINTENANCE AND LUBRICATION CHART
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
No.
1 *
Fuel line
(See page 3-29.)
2
Spark plug
(See page 3-17.)
Valves
3 *
(See page 3-10.)
20
30
40
ANNUAL
CHECK
• Check fuel hoses for cracks or damage.
√
√
√
√
√
• Check condition.
• Clean and regap.
√
CHECK OR MAINTENANCE JOB
• Replace.
5
V-belt case air filter element
(See page 3-28.)
• Clean.
√
√
• Check valve clearance.
• Adjust.
Air filter element
(See page 3-27.)
Rear brake
7 * (See pages 3-37,
38, 39.)
1
• Replace.
4
Front brake
6 * (See pages 3-37,
38, 39.)
ODOMETER READING (× 1,000 km)
10
ITEM
√
Every 40,000 km
√
• Check operation, fluid level and vehicle for fluid
leakage.
√
• Replace brake pads.
√
√
√
√
√
√
√
√
√
√
Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid
leakage.
√
• Replace brake pads.
√
√
√
√
√
Whenever worn to the limit
8
Rear brake lock
(See page 3-36.)
• Check operation.
• Adjust.
9 *
Brake hoses
(See page 3-38.)
• Replace.
10 *
Wheels
(See page 3-46.)
• Check runout and for damage.
√
√
√
√
11 *
Tires
(See page 3-43.)
•
•
•
•
√
√
√
√
12 *
Wheel bearings
(See page 4-4.)
• Check bearing for looseness or damage.
√
√
√
√
13 *
Steering bearings
(See page 3-40.)
√
√
√
• Lubricate with lithium-soap-based grease.
14 *
Chassis fasteners
(See page 2-21.)
• Make sure that all nuts, bolts and screws are
properly tightened.
√
√
√
• Check for cracks or damage.
√
√
√
√
√
√
√
√
Every 4 years
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
• Check bearing play and steering for roughness.
3-1
√
√
√
Every 20,000 km
√
√
√
√
√
PERIODIC MAINTENANCE AND LUBRICATION CHART
No.
ITEM
CHECK OR MAINTENANCE JOB
CHK
ADJ
ODOMETER READING (× 1,000 km)
1
10
20
30
40
ANNUAL
CHECK
√
√
√
√
√
√
√
√
√
√
15
Sidestand, center• Check operation.
stand
• Lubricate.
(See page 3-47.)
16 *
Sidestand switch
(See page 8-4.)
• Check operation.
17 *
Front fork
(See page 3-42.)
• Check operation and for oil leakage.
√
√
√
√
Shock absorber
18 * assemblies
(See page 4-67.)
• Check operation and shock absorbers for oil leakage.
√
√
√
√
Electronic fuel
19 * injection
(See page 3-16.)
• Adjust engine idling speed.
√
√
√
√
√
• Change. (See pages 1-6, 7.)
√
When the oil change indicator flashes
(every 5,000 km)
20
21
Engine oil
(See pages 3-22,
23.)
Engine oil filter
element
(See page 3-23.)
Cooling system
22 * (See pages 3-31,
32, 33.)
• Check oil level and vehicle for oil leakage.
• Check coolant level and vehicle for coolant leakage.
• Change.
Final transmission • Check vehicle for oil leakage.
oil
• Change.
(See page 3-26.)
24 *
V-belt
(See page 5-37.)
26
Moving parts and
cables
(See page 3-46.)
√
√
√
√
√
Every 5,000 km
√
• Replace.
23
Front and rear
25 * brake switches
(See page 8-4.)
√
√
√
√
√
Every 3 years
√
√
√
√
√
• Replace.
√
Every 20,000 km
√
• Check operation.
• Lubricate.
Throttle grip hous- • Check operation and free play.
• Adjust the throttle cable free play if necessary.
27 * ing and cable
• Lubricate the throttle grip housing and cable.
(See page 3-17.)
Lights, signals and
• Check operation.
28 * switches
• Adjust headlight beam.
(See page 3-57.)
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
CHK
ADJ
COWLING AND COVERS
COWLING AND COVERS
PASSENGER SEAT AND SIDE COVERS
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
4
3
5
7
6
6
1
2
7
Order
1
2
3
4
5
6
7
Job/Part
Removing the passenger seat and
side covers
Upper rear cover
Lower rear cover
Grab bar cover
Passenger seat
Grab bar
Cap
Side cover (left and right)
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
2
2
For installation, reverse the removal procedure.
3-3
COWLING AND COVERS
CHK
ADJ
RIDER SEAT AND STORAGE BOX
R.
7
T.
4
7 Nm (0.7 m • kg, 5.1 ft • Ib)
13
12
3
T.
11 Nm (1.1 m • kg, 8.0 ft • Ib)
R.
5
6
14
1
(4)
2
T.
R.
15
30 Nm (3.0 m • kg, 22 ft • Ib)
11
8
10
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
9
8
Order
1
2
3
4
5
6
Job/Part
Removing the rider seat and storage
box
Side cover (left and right)
Fuel tank cap
Cover
Rider seat
Upper cover
Clip
Gas spring assembly
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “PASSENGER SEAT AND SIDE
COVERS”.
1
1
1
1
1
1
3-4
NOTE:
Install the gas spring assembly to the
frame and bottom plate with its rod side
backward and labels upward.
COWLING AND COVERS
R.
7
T.
4
CHK
ADJ
7 Nm (0.7 m • kg, 5.1 ft • Ib)
13
12
3
T.
11 Nm (1.1 m • kg, 8.0 ft • Ib)
R.
5
6
14
1
(4)
2
T.
15
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
11
8
10
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
9
8
Order
7
8
9
10
Job/Part
Bottom plate
Grab bar bracket
Fuse box
Starter relay
Q’ty
1
2
1
1
Remarks
CAUTION:
First, disconnect the negative battery
lead, and then the positive battery
lead.
11
12
13
14
15
Storage box light connector
Storage box mat
Storage box lower plate
Storage box
Rubber sheet
2
1
1
1
1
Disconnect.
For installation, reverse the removal procedure.
3-5
COWLING AND COVERS
CHK
ADJ
EAS00040
SIDE COVER MOULDINGS AND FOOTREST BOARDS
1
4
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
3
5
5
1
3
2
Order
1
2
3
4
5
Job/Part
Removing the side cover mouldings
and footrest boards
Storage box
Footrest board mat 1 (left and right)
Footrest board mat 2 (left and right)
Side cover moulding (left and right)
Coolant reservoir cover
Footrest board (left and right)
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “RIDER SEAT AND STORAGE
BOX”.
2
2
2
1
2
For installation, reverse the removal procedure.
3-6
COWLING AND COVERS
CHK
ADJ
EAS00042
FRONT COWLING
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
11
12
6
2
5
3
7
1
8
5
4
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
13
9
1
2
3
4
5
6
7
8
9
10
R.
R.
Order
T.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
10
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Removing the front cowling
Footrest board (left and right)
Q’ty
Upper cover
Windshield
Inner panel
Front turn signal light assembly coupler
Front turn signal light assembly (left
and right)
Meter assembly
Meter assembly coupler
Headlight coupler
Plastic clamp
Front cowling
1
1
1
2
2
1
1
1
1
1
3-7
Remarks
Remove the parts in the order listed.
Refer to “SIDE COVER MOULDINGS
AND FOOTREST BOARDS”.
Disconnect.
Disconnect.
Disconnect.
COWLING AND COVERS
CHK
ADJ
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
11
12
6
2
5
3
7
1
8
5
4
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
13
9
Job/Part
Main switch cover
Storage compartment
Radiator cover
R.
R.
Order
11
12
13
T.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
10
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Q’ty
1
1
1
Remarks
For installation, reverse the removal procedure.
3-8
AIR FILTER CASES
CHK
ADJ
AIR FILTER CASES
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
6
5
4
2
5
1
3
7
T.
R.
Order
1
2
3
4
5
6
7
Job/Part
Removing the air filter cases
Storage box
Q’ty
Crankcase breather hose
Air filter case to throttle body hose
Air induction system hose (air filter
case to air cut-off valve)
Intake air temperature sensor coupler
Air filter case clamp screw
Air filter case (left)
Air filter case (right)
1
1
1
1
2
1
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “RIDER SEAT AND STORAGE
BOX”.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Loosen.
For installation, reverse the removal procedure.
3-9
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00048
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
_
1. Remove:
• storage box
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Remove:
• V-belt case air filter cover 1
• V-belt case air filter element
1
2
1
3.
•
•
•
•
•
Remove:
timing plug
spark plug
rubber sheet 1
cylinder head cover 2
cylinder head cover gasket
4. Measure:
• valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake valve
0.15 ~ 0.20 mm
(0.0059 ~ 0.0079 in)
Exhaust valve
0.25 ~ 0.30 mm
(0.0098 ~ 0.0118 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the primary sheave nut on the left side
of the crankshaft counterclockwise to turn
the crankshaft.
b. Align the “I” mark a on the generator rotor
with the stationary pointer b on the generator rotor cover to position the piston at TDC
on the compression stroke.
3 - 10
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
• TDC on the compression stroke can be
found when the camshaft lobes are turned
away from each other.
• In order to be sure that the piston is at TDC,
the punch marks c on the intake camshaft
sprocket and the punch mark d on the
exhaust camshaft sprocket must align with
the cylinder head mating surface as shown in
the illustration.
_
c
d
c. Measure the valve clearance with a thickness gauge 1.
NOTE:
If the valve clearance is incorrect, record the
measured reading.
_
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Remove:
• intake camshaft
• exhaust camshaft
NOTE:
• Refer to “CAMSHAFTS” in chapter 5.
• When removing the timing chain and camshafts, fasten a wire to the timing chain to
retrieve it if it falls into the crankcase.
_
6. Adjust:
• valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve lifter 1 and the valve pad
2 with the valve lapper 3.
Valve lapper
90890-04101
NOTE:
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
• Make a note of the position of each valve
lifter 1 and valve pad 2 so that they can be
installed in the correct place.
_
3 - 11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
b. Select the proper valve pad from the following table.
Valve pad thickness range
Available valve
pads
1.20 ~
Nos.
2.40 mm
120 ~ 240 (0.0472 ~
0.0945 in)
25 thicknesses in
0.05 mm (0.002 in)
increments
NOTE:
• The thickness a of each valve pad is
marked in hundredths of millimeters on the
side that touches the valve lifter.
• Since valve pads of various sizes are originally installed, the valve pad number must be
rounded in order to reach the closest equivalent to the original.
_
c. Round off the original valve pad number
according to the following table.
Last digit
Rounded value
0 or 2
0
5
5
8
10
EXAMPLE:
Original valve pad number = 148 (thickness =
1.48 mm (0.058 in))
Rounded value = 150
d. Locate the rounded number of the original
valve pad and the measured valve clearance in the valve pad selection table. The
point where the column and row intersect is
the new valve pad number.
NOTE:
The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be
repeated if the measurement is still incorrect.
_
e. Install the new valve pad 1 and the valve
lifter 2.
2
1
3 - 12
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
• Lubricate the valve pad with molybdenum
disulfide grease.
• Lubricate the valve lifter with molybdenum
disulfide oil.
• The valve lifter must turn smoothly when
rotated by hand.
• Install the valve lifter and the valve pad in the
correct place.
_
f. Install the exhaust and intake camshafts,
timing chain and the camshaft caps.
T.
Camshaft cap bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
NOTE:
• Refer to “CAMSHAFTS” in chapter 5.
• Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.
• First, install the exhaust camshaft.
• Align the camshaft sprocket marks with the
edge of the cylinder head.
• Turn the crankshaft counterclockwise several full turns to seat the parts.
_
g. Measure the valve clearance again.
h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 13
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
INTAKE
MEASURED
CLEARANCE
0.00 ~ 0.04
0.05 ~ 0.09
0.10 ~ 0.14
0.15 ~ 0.20
0.21 ~ 0.25
0.26 ~ 0.30
0.31 ~ 0.35
0.36 ~ 0.40
0.41 ~ 0.45
0.46 ~ 0.50
0.51 ~ 0.55
0.56 ~ 0.60
0.61 ~ 0.65
0.66 ~ 0.70
0.71 ~ 0.75
0.76 ~ 0.80
0.81 ~ 0.85
0.86 ~ 0.90
0.91 ~ 0.95
0.96 ~ 1.00
1.01 ~ 1.05
1.06 ~ 1.10
1.11 ~ 1.15
1.16 ~ 1.20
1.21 ~ 1.25
1.26 ~ 1.30
1.31 ~ 1.35
1.36 ~ 1.40
120 125 130 135
120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
160
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135 140 145
120
120 125
120 125 130
120 125 130 135
120 125 130 135 140
150
125
130
135
140
145
155
130
135
140
145
150
160
135
140
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
INSTALLED PAD NUMBER
165 170 175 180 185 190 195
150 155 160 165 170 175 180
155 160 165 170 175 180 185
160 165 170 175 180 185 190
STANDARD CLEARANCE
170 175 180 185 190 195 200
175 180 185 190 195 200 205
180 185 190 195 200 205 210
185 190 195 200 205 210 215
190 195 200 205 210 215 220
195 200 205 210 215 220 225
200 205 210 215 220 225 230
205 210 215 220 225 230 235
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
235 240
VALVE
240
0.15
200
185
190
195
205
190
195
200
210
195
200
205
215
200
205
210
220
205
210
215
225
210
215
220
230
215
220
225
235
220
225
230
205
210
215
220
225
230
235
240
210
215
220
225
230
235
240
215
220
225
230
235
240
220
225
230
235
240
225 230 235 240
230 235 240
235 240
240
240
225
230
235
CLEARANCE (cold):
~ 0.20 mm (0.0059 ~ 0.0079 in)
Example: 175 pad is installed
Measured clearance is 0.27 mm
(0.0106 in)
Replace pad 175 with pad 185
Pad number: (example)
Pad No. 175 = 1.75 mm (0.0689 in)
Pad No. 185 = 1.85 mm (0.0728 in)
EXHAUST
MEASURED
CLEARANCE
0.00 ~ 0.04
0.05 ~ 0.09
0.10 ~ 0.14
0.15 ~ 0.19
0.20 ~ 0.24
0.25 ~ 0.30
0.31 ~ 0.35
0.36 ~ 0.40
0.41 ~ 0.45
0.46 ~ 0.50
0.51 ~ 0.55
0.56 ~ 0.60
0.61 ~ 0.65
0.66 ~ 0.70
0.71 ~ 0.75
0.76 ~ 0.80
0.81 ~ 0.85
0.86 ~ 0.90
0.91 ~ 0.95
0.96 ~ 1.00
1.01 ~ 1.05
1.06 ~ 1.10
1.11 ~ 1.15
1.16 ~ 1.20
1.21 ~ 1.25
1.26 ~ 1.30
1.31 ~ 1.35
1.36 ~ 1.40
1.41 ~ 1.45
1.46 ~ 1.50
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
INSTALLED PAD NUMBER
165 170 175 180 185 190 195
140 145 150 155 160 165 170
145 150 155 160 165 170 175
150 155 160 165 170 175 180
155 160 165 170 175 180 185
160 165 170 175 180 185 190
STANDARD CLEARANCE
170 175 180 185 190 195 200
175 180 185 190 195 200 205
180 185 190 195 200 205 210
185 190 195 200 205 210 215
190 195 200 205 210 215 220
195 200 205 210 215 220 225
200 205 210 215 220 225 230
205 210 215 220 225 230 235
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
235 240
VALVE
240
0.25
200
175
180
185
190
195
205
180
185
190
195
200
210
185
190
195
200
205
215
190
195
200
205
210
220
195
200
205
210
215
225
200
205
210
215
220
230
205
210
215
220
225
235
210
215
220
225
230
205
210
215
220
225
230
235
240
210
215
220
225
230
235
240
215
220
225
230
235
240
220
225
230
235
240
225 230 235 240
230 235 240
235 240
240
240
215
220
225
230
235
CLEARANCE (cold):
~ 0.30 mm (0.0098 ~ 0.0118 in)
Example: 175 pad is installed
Measured clearance is 0.37 mm
(0.0146 in)
Replace pad 175 with pad 185
Pad number: (example)
Pad No. 175 = 1.75 mm (0.0689 in)
Pad No. 185 = 1.85 mm (0.0728 in)
3 - 14
ADJUSTING THE VALVE CLEARANCE/
ADJUSTING THE EXHAUST GAS VOLUME
CHK
ADJ
7. Install:
• all removed parts
Refer to “CYLINDER HEAD” in chapter 5.
NOTE:
For installation, reverse the removal procedure. Note the following points.
_
EAS00869
ADJUSTING THE EXHAUST GAS VOLUME
NOTE:
Be sure to set the CO density level to standard, and then adjust the exhaust gas volume.
_
1. Turn the main switch to “OFF” and set the
engine stop switch to “ON”.
2. Simultaneously press and hold the
“SELECT” and “RESET” buttons, turn the
main switch to “ON”, and continue to press
the buttons for 8 seconds or more.
NOTE:
• All displays on the meter disappear except
the odometer displays.
• “dIAG” appears on the odometer LCD.
_
3. Press the “SELECT” button to select the CO
adjustment mode “CO” or the diagnostic
mode “dIAG”.
4. After selecting “CO”, simultaneously press
the “SELECT” and “RESET” buttons for 2
seconds or more to execute the selection.
3 - 15
ADJUSTING THE EXHAUST GAS VOLUME/
CHECKING THE ENGINE IDLING SPEED
CHK
ADJ
5. Check that “C1” appears on the odometer
LCD, and then simultaneously press the
“SELECT” and “RESET” buttons for 2 seconds or more.
6. Change the CO adjustment volume by
pressing the “SELECT” and “RESET” buttons.
NOTE:
The CO adjustment volume appears on the
odometer LCD.
• To decrease the CO adjustment volume,
press the “RESET” button.
• To increase the CO adjustment volume,
press the “SELECT” button.
_
7. Release the “RESET” and “SELECT” buttons to execute the selection.
8. Turn the main switch to “OFF” to cancel the
mode.
EAS00054
CHECKING THE ENGINE IDLING SPEED
NOTE:
Prior to checking 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:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
3. Check:
• engine idling speed
Out of specification → Replace the throttle
body.
Engine idling speed
1,300 ~ 1,500 r/min
4. Install:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
3 - 16
ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUG
CHK
ADJ
EAS00056
ADJUSTING THE THROTTLE CABLE FREE
PLAY
1. Check:
• throttle cable free play a
Out of specification → Adjust.
a
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
• throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
a
1b
2
Direction a
Throttle cable free play
is increased.
Direction b
Throttle cable free play
is decreased.
c. Tighten the locknut.
WARNING
_
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00060
CHECKING THE SPARK PLUG
1. Remove:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Disconnect:
• spark plug cap
3 - 17
CHECKING THE SPARK PLUG
CHK
ADJ
3. Remove:
• spark plug
CAUTION:
_
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling into the cylinder.
4. Check:
• spark plug type
Incorrect → Change.
Spark plug type (manufacturer)
CR7E (NGK)
5. Check:
• electrode 1
Damage/wear → Replace the spark plug.
• insulator 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• spark plug gap a
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
T.
R.
8. Install:
• spark plug
13 Nm (1.3 m · kg, 9.4 ft · lb)
NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
_
9. Connect:
• spark plug cap
10.Install:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
3 - 18
CHECKING THE IGNITION TIMING
CHK
ADJ
EAS00064
CHECKING THE IGNITION TIMING
NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system. Make sure all connections are tight and
free of corrosion.
_
1
1. Remove:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Remove:
• timing plug
3. Connect:
• timing light 1
Timing light
90890-03141, YU-03141
4. Check:
• ignition timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine, warm it up for several minutes, and then let it run at the specified
engine idling speed.
Engine idling speed
1,300 ~ 1,500 r/min
b. Check that the stationary pointer a is within
the firing range b on the generator rotor.
Incorrect firing range → Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
R.
3 - 19
Install:
8 Nm (0.8 m · kg, 5.8 ft · lb)
timing plug
Install:
storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
T.
5.
•
6.
•
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
EAS00067
MEASURING THE COMPRESSION
PRESSURE
NOTE:
Insufficient compression pressure will result in
a loss of performance.
_
1. Remove:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Disconnect:
• spark plug cap
5. Remove:
• spark plug
CAUTION:
_
Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it
from falling into the cylinder.
1
6. Install:
• compression gauge 1
Compression gauge
90890-03081, YU-33223
Adapter (compression gauge)
90890-04082
3 - 20
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
7. Measure:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (at sea
level)
Minimum
1,218 kPa
(12.18 kg/cm2, 173.2 psi)
Standard
1,400 kPa
(14.00 kg/cm2, 199.1 psi)
Maximum
1,568 kPa
(15.68 kg/cm2, 223.0 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the compression
gauge stabilizes.
WARNING
_
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 wear or
damage → Repair.
Same as without
oil
Piston rings,
valves, cylinder
head gasket or piston possibly defective → Repair.
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3 - 21
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
T.
8. Install:
13 Nm (1.3 m · kg, 9.4 ft · lb)
• spark plug
9. Connect:
• spark plug cap
10.Install:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
R.
EAS00070
CHECKING THE ENGINE OIL LEVEL
1. Stand the scooter on a level surface.
NOTE:
• Place the scooter on a suitable stand.
• Make sure the scooter is upright.
_
1
1
b
a
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Check:
• engine oil level
Wipe the dipstick 1 clean, insert it into the
oil filler hole (without screwing it in), and
then remove it to check the 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.
Recommended oil
Refer to the chart for the engine
oil grade which is best suited
for certain atmospheric temperatures.
API standard
SE or higher grade
ACEA standard
G4 or G5
-20 -10 0 10 20 30 40 50 ˚C
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40
SAE 20W-50
CAUTION:
_
Do not allow foreign materials to enter the
crankcase.
3 - 22
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHK
ADJ
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
_
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
_
EAS00076
1
2
CHANGING THE ENGINE OIL
1. Remove:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Place a container under the engine oil drain
bolt.
4. Remove:
• engine oil filler cap 1
• engine oil drain bolt 2
(along with the gasket)
5. Drain:
• engine oil
(completely from the crankcase)
3 - 23
CHANGING THE ENGINE OIL
CHK
ADJ
6. If the oil filter element is also to be replaced,
perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Remove the oil filter element cover 1 and
oil filter element 2.
b. Install new O-rings 3.
c. Install the new oil filter element and the oil
filter element cover.
T.
Oil filter element cover bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
3
2
3
7. If the oil strainer is also to be cleaned, perform the following procedure.
2
3
New
1
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil strainer cover 1 and oil
strainer 2.
b. Install new O-ring 3.
c. Install the oil strainer cover.
T.
Oil strainer cover
32 Nm (3.2 m · kg, 23 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Check:
• engine oil drain bolt gasket
Damage → Replace.
9. Install:
• engine oil drain bolt
(along with the gasket)
T.
R.
3 - 24
20 Nm (2.0 m · kg, 14 ft · lb)
CHANGING THE ENGINE OIL
CHK
ADJ
10.Fill:
• crankcase
(with the specified amount of the recommended engine oil)
Quantity
Total amount
1.7 L (1.50 Imp qt, 1.80 US qt)
Without oil filter element
replacement
1.5 L (1.32 Imp qt, 1.59 US qt)
With oil filter element replacement
1.7 L (1.50 Imp qt, 1.80 US qt)
11.Install:
• engine oil filler cap
12.Start the engine, warm it up for several minutes, and then turn it off.
13.Check:
• engine
(for engine oil leaks)
14.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
15.Check:
• engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Slightly loosen the oil gallery bolt 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
element 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.
T.
Oil gallery bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
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3 - 25
CHANGING THE ENGINE OIL/
CHANGING THE TRANSMISSION OIL
CHK
ADJ
16.Reset:
• engine oil change indicator
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Turn the key to “ON”.
b. Hold the reset button 1 pushed for two to
eight seconds.
c. Release the reset button and the engine oil
change indicator will go off.
NOTE:
If the engine oil is changed before the engine
oil change indicator comes on (i.e. before the
periodic engine oil change interval has been
reached), the indicator must be reset after the
engine oil change for the next periodic engine
oil change to be indicated at the correct time.
To reset the engine oil change indicator before
the periodic engine oil change interval has
been reached, follow the above procedure, but
note that the indicator will come on for 1.4 seconds after releasing the reset button, otherwise repeat the procedure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
17.Install:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
CHANGING THE TRANSMISSION OIL
1. Stand the scooter on a level surface.
NOTE:
• Place the scooter on a suitable stand.
• Make sure that the scooter is upright.
1
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Place a container under the transmission oil
drain bolt.
4. Remove:
• transmission oil filler plug
• transmission oil drain bolt 1
5. Drain:
• transmission oil
(completely from the transmission case)
6. Install:
• transmission oil drain bolt
T.
R.
3 - 26
20 Nm (2.0 m · kg, 14 ft · lb)
CHANGING THE TRANSMISSION OIL/
REPLACING THE AIR FILTER ELEMENTS
CHK
ADJ
7. Fill:
• transmission case
(with the specified amount of the recommended transmission oil)
Recommended oil
SAE 10W30 type SE motor oil
Quantity
0.25 L (0.22 Imp qt, 0.26 US qt)
1
1
2
8.
•
•
9.
Install:
transmission oil filler plug 1
O-ring 2
Start the engine, warm it up for several minutes, and then turn it off.
10.Check:
• transmission case
(for transmission oil leaks)
EAS00088
È
REPLACING THE AIR FILTER ELEMENTS
The following procedure applies to both air filter elements.
1. Remove:
• air filter case cover 1
• air filter element
1
È Left air filter case cover
É Right air filter case cover
É
1
1
2. Check:
• air filter element
Damage → Replace.
NOTE:
Replace the air filter element every 20,000 km.
The air filter needs more frequent service if
you are riding in unusually wet or dusty areas.
3 - 27
REPLACING THE AIR FILTER ELEMENTS/
CLEANING THE V-BELT CASE AIR FILTER ELEMENT
CHK
ADJ
3. Install:
• air filter element
• air filter case cover
(along with the gasket)
CAUTION:
_
Never operate the engine without the air filter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible overheating.
NOTE:
When installing the air filter element into the air
filter case cover, be sure their sealing surfaces
are aligned to prevent any air leaks.
_
EAS00091
1
1
CLEANING THE V-BELT CASE AIR FILTER
ELEMENT
1. Remove:
• footrest board (left)
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Remove:
• V-belt case air filter cover 1
• V-belt case air filter cover seal
• V-belt case air filter element
3. Clean:
• V-belt case air filter element 1
Blow the compressed air to the outer surface of the V-belt case air filter element.
4. Check:
• V-belt case air filter element
Damage → Replace.
CAUTION:
_
Since the V-belt case air filter element is a
dry type, do not let grease or water contact
it.
5.
•
•
•
•
3 - 28
Install:
V-belt case air filter element
V-belt case air filter cover seal
V-belt case air filter cover
V-belt case air filter cover screw
CLEANING THE V-BELT CASE AIR FILTER ELEMENT/
CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD/
CHECKING THE FUEL HOSE
CHK
ADJ
6. Install:
• footrest board (left)
Refer to “RIDER SEAT AND STORAGE
BOX”.
EAS00094
1
2
CHECKING THE THROTTLE BODY JOINT
AND INTAKE MANIFOLD
1. Remove:
• storage box
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Check:
• throttle body joint 1
• intake manifold 2
Cracks/damage → Replace.
Refer to “CYLINDER HEAD” in chapter 5.
3. Install:
• storage box
Refer to “RIDER SEAT AND STORAGE
BOX”.
EAS00096
1
CHECKING THE FUEL HOSE
1. Remove:
• storage box
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Check:
• fuel hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.
3. Install:
• storage box
Refer to “RIDER SEAT AND STORAGE
BOX”.
3 - 29
CHECKING THE BREATHER HOSES
CHK
ADJ
EAS00098
CHECKING THE BREATHER HOSES
1. Remove:
• storage box
Refer to “RIDER SEAT AND STORAGE
BOX”.
3
2. Check:
• crankcase breather hose 1
• transmission case breather hose 2
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
1
_
Make sure the breather hoses are routed
correctly.
2
3.
•
4.
•
Remove:
catch tank 3
Clean:
catch tank
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Thoroughly flush out the catch tank with
clean water.
b. Hold the catch tank upside down to allow
the water to drain out.
c. Repeat the flushing steps until the excess
water is clear and free of debris.
d. Place the catch tank in an upright position
to allow any remaining water to drain out of
the lower drain tube.
e. Keep the catch tank upright to allow it to dry
sufficiently.
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5.
•
6.
•
3 - 30
Install:
catch tank
Install:
storage box
Refer to “RIDER SEAT AND STORAGE
BOX”.
CHECKING THE EXHAUST SYSTEM/
CHECKING THE COOLANT LEVEL
CHK
ADJ
EAS00099
3
1
5
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
exhaust pipes and gaskets.
1. Remove:
• footrest board (right)
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
2. Check:
• exhaust pipe 1
• muffler 2
Cracks/damage → Replace.
• gasket
Exhaust gas leaks → Replace.
3. Check:
• tightening torque
5
4
R.
5
T.
2
Exhaust pipe nut 3
20 Nm (2.0 m · kg, 14 ft · lb)
Muffler joint bolt 4
14 Nm (1.4 m · kg, 10 ft · lb)
Muffler mounting bolt 5
53 Nm (5.3 m · kg, 38 ft · lb)
4. Install:
• footrest board (right)
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
EAS00103
CHECKING THE COOLANT LEVEL
1. Stand the scooter on a level surface.
NOTE:
• Place the scooter on a suitable stand.
• Make sure the scooter is upright.
_
a
b
2. Remove:
• coolant reservoir cover
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
3. Check:
• coolant level
The coolant level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.
3 - 31
CHECKING THE COOLANT LEVEL/
CHECKING THE COOLING SYSTEM
CHK
ADJ
CAUTION:
_
• 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.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check:
• coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
_
6. Install:
• coolant reservoir cover
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
EAS00104
4
1
6
3
2
7
CHECKING THE COOLING SYSTEM
1. Remove:
• footrest boards (left and right)
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
2. Check:
• radiator 1
• radiator inlet hose 2
• radiator outlet hose 3
• radiator filler hose 4
• oil cooler outlet hose
• water pump inlet hose 5
• water pump outlet hose 6
• thermostat outlet hose 7
• thermostat inlet hose
Cracks/damage → Replace.
Refer to “COOLING SYSTEM” in chapter 6.
5
3 - 32
CHECKING THE COOLING SYSTEM/
CHANGING THE COOLANT
CHK
ADJ
3. Install:
• footrest boards (left and right)
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
EAS00105
CHANGING THE COOLANT
1. Remove:
• storage box
• footrest board (right)
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
2. Disconnect:
• coolant reservoir hose 1
3. Drain:
• coolant
(from the coolant reservoir)
4. Remove:
• radiator cap cover
• radiator cap 1
1
WARNING
_
1
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.
1
5. Remove:
• coolant drain bolt 1
(along with the copper washer)
6. Drain:
• coolant
(from the engine and radiator)
3 - 33
CHANGING THE COOLANT
CHK
ADJ
7. Install:
• copper washer New
• coolant drain bolt
T.
R.
1
10 Nm (1.0 m · kg, 7.2 ft · lb)
8. Connect:
• coolant reservoir hose
9. Remove:
• air bleed bolt (coolant) 1
10.Fill:
• cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
1.57 L (1.38 Imp qt, 1.66 US qt)
Coolant reservoir capacity
0.32 L (0.28 Imp qt, 0.34 US qt)
Up to the maximum level mark
NOTE:
The specified amount of coolant is a standard
amount. Fill the cooling system with coolant
until coolant comes out of the air bleed bolt
hole.
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
_
• 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.
3 - 34
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
_
• 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.
11.Install:
• air bleed bolt (coolant)
T.
R.
a
6 Nm (0.6 m · kg, 4.3 ft · lb)
12.Install:
• radiator cap
13.Fill:
• coolant reservoir
(with the recommended coolant to the maximum level mark a)
14.Install:
• coolant reservoir cap
15.Start the engine, warm it up for several minutes, and then stop it.
16.Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
_
17.Install:
• storage box
• footrest board (right)
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
3 - 35
ADJUSTING THE REAR BRAKE LOCK LEVER CABLE
CHK
ADJ
EAS00116
CHASSIS
ADJUSTING THE REAR BRAKE LOCK
LEVER CABLE
NOTE:
• Place the scooter on a suitable stand.
• Before adjusting the rear brake lock lever,
check the rear brake fluid level.
a
1. Measure:
• rear brake lock lever cable length a
Out of specification → Adjust.
1
Rear brake lock lever cable length
45 ~ 47 mm (1.77 ~ 1.85 in)
b
c
2. Adjust:
• rear brake lock lever cable length
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting nut 1 in direction b or
c until the rear brake lock lever cable
length a is 42 ~ 44 mm (1.65 ~ 1.73 in)
when the rear brake lock lever is released.
b. Slowly apply the rear brake several times.
c. Set the rear brake lock lever and wait more
than 5 minutes.
d. Release the rear brake lock lever.
e. Turn the adjusting nut 1 in direction b or
c until the rear brake lock lever cable
length a is 45 ~ 47 mm (1.77 ~ 1.85 in).
Direction b
Rear brake lock lever
cable length is
increased.
Direction c
Rear brake lock lever
cable length is
decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 36
CHECKING THE BRAKE FLUID LEVEL
È
CHK
ADJ
CHECKING THE BRAKE FLUID LEVEL
1. Stand the scooter on a level surface.
a
NOTE:
• Place the scooter on a suitable stand.
• Make sure the scooter is upright.
_
2. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
É
a
Recommended brake fluid
DOT 4
È Front brake
É Rear brake
WARNING
_
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake master cylinder reservoir is horizontal.
_
3 - 37
CHECKING THE FRONT AND REAR BRAKE PADS/
CHECKING THE FRONT AND REAR BRAKE HOSES
CHK
ADJ
EAS00118
È
CHECKING THE FRONT AND REAR BRAKE
PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• front brake pad
Wear indicator groove a almost disappeared → Replace the brake pads as a set.
Refer to “REPLACING THE FRONT
BRAKE PADS” in chapter 4.
• rear brake pad
Wear indicator a almost touch the brake
disc → Replace the brake pads as a set.
Refer to “REPLACING THE REAR BRAKE
PADS” in chapter 4.
É
È Front brake
É Rear brake
EAS00132
È
1
CHECKING THE FRONT AND REAR BRAKE
HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
• brake hose 1
Cracks/damage/wear → Replace.
È Front brake
É Rear brake
É
1
2. Check:
• brake hose clamp
Loose → Tighten the clamp bolt.
3. Hold the scooter upright and apply the
brake several times.
4. Check:
• brake hose
Brake fluid leakage → Replace the damaged hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
3 - 38
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EAS00134
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
_
Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected
or replaced.
• the brake fluid level is very low.
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably lengthening the bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
_
1. Bleed:
• hydraulic brake system
È
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
1
a. Fill the brake master cylinder reservoir to
the proper level with the recommended
brake fluid.
b. Install the brake master cylinder reservoir
diaphragm.
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2.
È Front
É Rear
É
2
1
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever and do not
release it.
3 - 39
BLEEDING THE HYDRAULIC BRAKE SYSTEM/
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake levers to contact
the handlebar.
_
h. Tighten the bleed screw and then release
the brake lever.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
T.
Bleed screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
R.
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
_
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00148
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
_
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3 - 40
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
3. Remove:
• lower handlebar holder
Refer to “STEERING HEAD” in chapter 4.
4. Adjust:
• steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the upper steering ring nut 1, the
lock washer 2, the center steering ring nut
3 and the rubber washer.
b. Loosen the lower steering ring nut 4 and
then tighten it to specification with the steering nut wrench 5.
NOTE:
Set a torque wrench at a right angle to the
steering nut wrench.
_
Steering nut wrench
90890-01403, YU-A9472
T.
R.
Lower steering ring nut (initial
tightening torque)
36 Nm (3.6 m · kg, 25 ft · lb)
c. Loosen the lower steering ring nut 4 1/4
turn, and then tighten it to the specified
torque with a torque wrench and the steering nut wrench.
WARNING
_
Do not overtighten the lower steering ring
nut.
T.
R.
Lower steering ring nut (final
tightening torque)
24 Nm (2.4 m · kg, 17 ft · lb)
d. Check the steering head for looseness or
binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” in chapter 4.
e. Install the rubber washer.
f. Install the center steering ring nut.
3 - 41
CHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
CHK
ADJ
g. Finger tighten the center steering ring nut,
and then align the slots of both ring nuts. If
necessary, hold the lower steering ring nut
and tighten the center steering ring nut until
their slots are aligned.
h. Install the lock washer 1.
NOTE:
Make sure the lock washer tabs a sit correctly
in the steering ring nut slots b.
_
i. Install the upper steering ring nut.
j. Hold the lower and center steering ring nuts
with a steering nut wrench and tighten the
upper steering ring nut with a steering nut
wrench.
Steering nut wrench
90890-01403, YU-A9472
T.
Upper steering ring nut
90 Nm (9.0 m · kg, 65 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• lower handlebar holder
Refer to “STEERING HEAD” in chapter 4.
EAS00151
CHECKING THE FRONT FORK
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
2. Check:
• inner tube
Damage/scratches → Replace.
• oil seal
Oil leakage → Replace.
3. Hold the scooter upright and apply the front
brake.
3 - 42
CHECKING THE FRONT FORK/
CHECKING THE TIRES
CHK
ADJ
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.
EAS00165
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• tire pressure
Out of specification → Regulate.
WARNING
_
• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.
• Operation of an overloaded scooter could
cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE SCOOTER.
Basic weight
(with oil and a 210 kg (463 lb)
full fuel tank)
Maximum
load*
Cold tire pressure
198 kg (437 lb)
Front
Rear
Up to 90 kg
load*
200 kPa
(2.00 kgf/cm2,
29 psi)
250 kPa
(2.50 kgf/cm2,
36 psi)
90 kg ~ maximum load*
200 kPa
(2.00 kgf/cm2,
29 psi)
250 kPa
(2.50 kgf/cm2,
36 psi)
High-speed
riding
200 kPa
(2.00 kgf/cm2,
29 psi)
250 kPa
(2.50 kgf/cm2,
36 psi)
* Total weight of rider, passenger, cargo and
accessories
3 - 43
CHECKING THE TIRES
CHK
ADJ
WARNING
_
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
2. Check:
• tire surfaces
Damage/wear → Replace the tire.
Minimum tire tread depth
1.6 mm (0.06 in)
1 Tire tread depth
2 Sidewall
3 Wear indicator
WARNING
_
È
É
• 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.
È Tire
É Wheel
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless
tire
• After extensive tests, the tires listed
below have been approved by Yamaha
Motor Co., Ltd. for this model. The front
and rear tires should always be by the
same manufacturer and of the same
design. No guarantee concerning handling characteristics can be given if a tire
combination other than one approved by
Yamaha is used on this scooter.
3 - 44
CHECKING THE TIRES
CHK
ADJ
Front tire
Manufacturer
Size
Model
DUNLOP
120/8014M/C
58S
D305FL
IRC
120/8014M/C
58S
MB 67
Manufacturer
Size
Model
DUNLOP
150/7013M/C
64S
D305L
IRC
150/7013M/C
64S
MB 67
Rear tire
WARNING
_
1
2
• 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.
• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
nut 1 and locknut 2 to specification.
(rear tire only)
NOTE:
For tires with a direction of rotation mark 3,
install the tire with the mark pointing in the
direction of wheel rotation.
_
T.
R.
3 - 45
Tire air valve stem (rear tire only)
Valve stem nut
1.5 Nm (0.15 m · kg, 1.1 ft · lb)
Valve stem locknut
3 Nm (0.3 m · kg, 2.2 ft · lb)
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.
WARNING
_
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or
replaced, always balance the wheel.
_
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the
inner and outer cables.
WARNING
_
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.
1. Check:
• outer cable
Damage → Replace.
2. Check:
• cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
_
3 - 46
LUBRICATING THE LEVERS/LUBRICATING THE
SIDESTAND/LUBRICATING THE CENTERSTAND
CHK
ADJ
EAS00171
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Recommended lubricant
Lithium-soap-based grease
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium-soap-based grease
EAS00173
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
Recommended lubricant
Lithium-soap-based grease
3 - 47
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
EAS00179
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
_
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
_
• 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 - 48
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible to check the charge state of the battery by
measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to
be checked by measuring the voltage at the
battery terminals.
_
2
1
1. Remove:
• upper rear cover
Refer to “PASSENGER SEAT AND SIDE
COVERS”.
2. Disconnect:
• battery leads
(from the battery terminals)
CAUTION:
_
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3.
•
4.
•
Remove:
battery
Check:
battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Open-circuit voltage (V)
a. Connect a pocket tester to the battery terminals.
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
NOTE:
• 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).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
_
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
b. Check the charge of the battery, as shown
in the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 49
CHECKING AND CHARGING THE BATTERY
Ambient temperature 20 °C (68 °F)
Open-circuit voltage (V)
Charging
CHK
ADJ
5. Charge:
• battery
(refer to the appropriate charging method
illustration)
WARNING
_
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage.
CAUTION:
_
Open-circuit voltage (V)
Ambient temperature
20 °C (68 °F)
Charging condition of the battery (%)
• 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.
• 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 - 50
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a variable-current (voltage) charger
Charger
Ammeter
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
NOTE:
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?
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 overcharged.)
NO
Adjust the charging voltage to
20 ~ 25 V.
Adjust the voltage to obtain the
standard charging amperage.
Monitor the amperage for 3 ~ 5
minutes. Is the standard charging amperage exceeded?
YES
NO
If the amperage does not
exceed the standard charging
amperage after 5 minutes,
replace the battery.
Set the timer to the charging
time determined by the opencircuit voltage.
Refer to “CHECKING AND
CHARGING 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 - 51
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit 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?
Charge the battery until the charging
voltage reaches 15 V.
NO
This type of battery charger cannot
charge an MF battery. A variable
voltage charger is recommended.
NOTE:
Set the charging time to a maximum of 20 hours.
Charger
Ammeter
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
CAUTION:
Constant amperage chargers are
not suitable for charging MF batteries.
3 - 52
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
1
2
6.
•
7.
•
CHK
ADJ
Install:
battery
Connect:
battery leads
(to the battery terminals)
CAUTION:
_
First, connect the positive battery lead 1,
and then the negative battery lead 2.
8. Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
• battery terminals
Recommended lubricant
Dielectric grease
10.Install:
• upper rear cover
Refer to “PASSENGER SEAT AND SIDE
COVERS”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
CAUTION:
_
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
• side covers (left and right)
Refer to “PASSENGER SEAT AND SIDE
COVERS”.
3 - 53
CHECKING THE FUSES
CHK
ADJ
2. Check:
• fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
_
Pocket tester
90890-03112, YU-03112-C
b. If the pocket tester indicates “∞”, replace
the fuse.
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3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
3 - 54
Fuses
Amperage
rating
Q’ty
Main
40 A
1
Headlight
25 A
1
Signaling system
10 A
1
Ignition
10 A
1
Radiator fan motor
10 A
1
Turn signal/hazard
10 A
1
Fuel injection system
10 A
1
Backup (storage
box light, immobilizer unit, and meter
assembly)
10 A
1
Spare
40 A
25 A
10 A
1
1
1
CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
WARNING
_
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rating may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• side covers (left and right)
Refer to “PASSENGER SEAT AND SIDE
COVERS”.
EAS00183
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Remove:
• front cowling
Refer to “FRONT COWLING”.
2.
•
3.
•
2
Disconnect:
headlight coupler 1
Remove:
headlight bulb holder cover 2
1
4. Detach:
• headlight bulb holder 1
1
3 - 55
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
5. Remove:
• headlight bulb 1
1
WARNING
_
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
6. Install:
• headlight bulb New
Secure the new headlight bulb with the
headlight bulb holder.
CAUTION:
_
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
7. Attach:
• headlight bulb holder
8. Install:
• headlight bulb holder cover
9. Connect:
• headlight coupler
10.Install:
• front cowling
Refer to “FRONT COWLING”.
3 - 56
ADJUSTING THE HEADLIGHT BEAMS
CHK
ADJ
EAS00185
1
a
1
a
b
b
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
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)
1
1
b b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
a a
Direction a
Headlight beam moves
to the right.
Direction b
Headlight beam moves
to the left.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 57
CHAS
4
CHAS
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISC............................................................... 4-1
REMOVING THE FRONT WHEEL............................................................ 4-3
CHECKING THE FRONT WHEEL ............................................................ 4-3
CHECKING THE BRAKE DISCS .............................................................. 4-4
INSTALLING THE FRONT WHEEL .......................................................... 4-6
ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-7
REAR WHEEL AND BRAKE DISC.................................................................4-9
REMOVING THE REAR WHEEL ............................................................ 4-10
CHECKING THE REAR WHEEL............................................................. 4-10
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-10
FRONT AND REAR BRAKES....................................................................... 4-11
FRONT BRAKE PADS ............................................................................4-11
REAR BRAKE PADS............................................................................... 4-12
REPLACING THE FRONT BRAKE PADS .............................................. 4-13
REPLACING THE REAR BRAKE PADS................................................. 4-15
FRONT BRAKE MASTER CYLINDER....................................................4-18
REAR BRAKE MASTER CYLINDER ......................................................4-21
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............. 4-24
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER................ 4-24
CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS...4-25
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER ............................................................................. 4-26
ASSEMBLING AND INSTALLING THE REAR BRAKE
MASTER CYLINDER ............................................................................. 4-28
FRONT BRAKE CALIPER....................................................................... 4-31
REAR BRAKE CALIPER .........................................................................4-33
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-36
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-36
CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................4-37
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER ....... 4-39
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER..........4-41
FRONT FORK................................................................................................4-44
REMOVING THE FRONT FORK LEGS.................................................. 4-48
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-48
CHECKING THE FRONT FORK LEGS .................................................. 4-50
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-50
INSTALLING THE FRONT FORK LEGS ................................................ 4-53
HANDLEBAR ................................................................................................4-54
REMOVING THE HANDLEBAR..............................................................4-56
CHECKING THE HANDLEBAR ..............................................................4-56
INSTALLING THE HANDLEBAR ............................................................ 4-56
CHAS
STEERING HEAD.......................................................................................... 4-60
LOWER BRACKET ................................................................................. 4-60
REMOVING THE LOWER BRACKET.....................................................4-62
CHECKING THE STEERING HEAD .......................................................4-63
INSTALLING THE STEERING HEAD .....................................................4-64
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM................... 4-65
REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ............... 4-67
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 4-67
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES.............. 4-67
REMOVING THE SWINGARM................................................................4-68
CHECKING THE SWINGARM ................................................................4-68
INSTALLING THE SWINGARM ..............................................................4-69
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00513
CHASSIS
FRONT WHEEL AND BRAKE DISC
T.
R.
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
20 Nm (2.0 m • kg, 14 ft • Ib)
1
3
2
6
7
LT
4
5
Job/Part
Removing the front wheel and brake
disc
R.
Order
T.
LT
Q’ty
23 Nm (2.3 m • kg, 17 ft • Ib)
Remarks
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand so
that the front wheel is elevated.
_
1
2
3
4
5
6
7
Front wheel axle end plug
Front wheel axle pinch bolt
Front wheel axle
Front wheel assembly
Speed sensor
Spacer
Front brake disc
1
1
1
1
1
1
1
Loosen.
Refer to “REMOVING
THE FRONT WHEEL” and
“INSTALLING THE
FRONT WHEEL”.
For installation, reverse the removal procedure.
4-1
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00518
LS
1
2
3
2
Order
1
2
3
Job/Part
Disassembling the front wheel
Oil seal
Bearing
Collar
Q’ty
Remarks
Remove the parts in the order listed.
1
2
1
For assembly, reverse the disassembly
procedure.
4-2
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00520
REMOVING THE FRONT WHEEL
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
2. Elevate:
• front wheel
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
_
EAS00525
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent wheel
axle.
2. Check:
• tire
• front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:
• radial wheel runout 1
• lateral wheel runout 2
Over the specified limits → Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4-3
FRONT WHEEL AND BRAKE DISC
CHAS
4. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
Damage/wear → Replace.
5. Replace:
• wheel bearings New
• oil seal New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 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 3 with a general bearing puller.
d. Install the new wheel bearings and new oil
seal in the reverse order of disassembly.
CAUTION:
_
Do not contact the wheel bearing inner race
4 or balls 5. Contact should be made only
with the outer race 6.
NOTE:
Use a socket 7 that matches the diameter of
the wheel bearing outer race and oil seal.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00532
CHECKING THE BRAKE DISCS
The following procedure applies to each brake
disc.
1. Check:
• brake disc
Damage/galling → Replace.
4-4
FRONT WHEEL AND BRAKE DISC
CHAS
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Brake disc deflection limit (maximum)
Front: 0.15 mm (0.006 in)
Rear: 0.15 mm (0.006 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the scooter on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in)
below the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
Brake disc thickness limit (minimum)
Front: 4.5 mm (0.18 in)
Rear: 4.5 mm (0.18 in)
4-5
FRONT WHEEL AND BRAKE DISC
CHAS
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
_
T.
R.
Brake disc bolt
23 Nm (2.3 m · kg, 17 ft · lb)
LOCTITE®
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00542
INSTALLING THE FRONT WHEEL
1. Lubricate:
• wheel axle
• wheel bearings
• oil seal lips
• speed sensor
Recommended lubricant
Lithium-soap-based grease
4-6
FRONT WHEEL AND BRAKE DISC
2.
•
•
•
CHAS
Install:
spacer
speed sensor
front wheel
NOTE:
• Make sure that the projections on the speed
sensor are installed in the slots on the wheel
hub.
• Make sure that the slot a in the speed sensor fits over the stopper b on the outer tube.
_
3. Tighten:
• front wheel axle
a
T.
R.
55 Nm (5.5 m · kg, 40 ft · lb)
• front wheel axle pinch bolt
b
T.
R.
20 Nm (2.0 m · kg, 14 ft · lb)
WARNING
_
Make sure the brake hose is routed properly.
CAUTION:
_
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the
front wheel static balance should be
adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
_
1. Remove:
• balancing weight(s)
4-7
FRONT WHEEL AND BRAKE DISC
CHAS
2. Find:
• front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
b. When the front wheel stops, put an “X1”
mark at the bottom of the wheel.
c. Turn the front wheel 90° so that the “X1”
mark is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
f. Repeat steps (d) through (f) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest
is the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight 1 onto the rim
exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
_
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays
at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-8
REAR WHEEL AND BRAKE DISC
CHAS
EAS00552
REAR WHEEL AND BRAKE DISC
LS
LT
2
1
LT
T.
R.
Order
Job/Part
Removing the rear wheel and brake
disc
Q’ty
23 Nm (2.3 m • kg, 17 ft • Ib)
Remarks
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand so
that the rear wheel is elevated.
_
Muffler
Swingarm
1
Rear wheel
1
2
Rear brake disc
1
Refer to “ENGINE REMOVAL” in chapter
5.
Refer to “REAR SHOCK ABSORBER
ASSEMBLIES AND SWINGARM”.
Refer to “REMOVING THE REAR
WHEEL”.
For installation, reverse the removal procedure.
4-9
REAR WHEEL AND BRAKE DISC
CHAS
EAS00561
REMOVING THE REAR WHEEL
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the rear wheel is elevated.
_
EAS00565
CHECKING THE REAR WHEEL
1. Check:
• tire
• rear wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
2. Measure:
• radial wheel runout
• lateral wheel runout
Refer to “CHECKING THE FRONT
WHEEL”.
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the
rear wheel static balance should be adjusted.
• Adjust the rear wheel static balance with the
brake disc installed.
_
1. Adjust:
• rear wheel static balance
Refer to “ADJUSTING THE
WHEEL STATIC BALANCE”.
4 - 10
FRONT
FRONT AND REAR BRAKES
CHAS
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS
T.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
1
6
2
4
6
5
3
Order
1
2
3
4
5
6
Job/Part
Removing the front brake pads
Front brake caliper retaining bolt
Front brake caliper
Brake pad
Brake pad spring
Brake pad spring
Brake pad shim
Q’ty
2
1
2
1
2
2
Remarks
Remove the parts in the order listed.
Refer to “REPLACING THE FRONT
BRAKE PADS”.
For installation, reverse the removal procedure.
4 - 11
FRONT AND REAR BRAKES
CHAS
REAR BRAKE PADS
LS
4
2
1
LS
4
T.
R.
3
27 Nm (2.7 m • kg, 19 ft • Ib)
Order
Job/Part
Removing the rear brake pads
Air filter case (right)
Q’ty
1
2
3
4
Rear brake caliper retaining bolt
Rear brake caliper
Brake pad
Brake pad spring
2
1
2
2
Remarks
Remove the parts in the order listed.
Refer to “AIR FILTER CASES” in chapter
3.
Refer to “REPLACING THE REAR
BRAKE PADS”.
For installation, reverse the removal procedure.
4 - 12
FRONT AND REAR BRAKES
CHAS
EAS00579
CAUTION:
_
Disc brake components rarely require disassembly.
Therefore, always follow these preventive
measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS00581
REPLACING THE FRONT BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
_
1
2
1
2
1. Remove:
• front brake caliper retaining bolts 1
• front brake caliper 2
• brake pad spring
2. Remove:
• brake pads 1
• brake pad springs 2
• brake pad shims 3
3
4 - 13
FRONT AND REAR BRAKES
CHAS
3. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit
0.8 mm (0.03 in)
3
1
4.
•
•
•
Install:
brake pad shims 1
brake pads 2
brake pad springs 3
NOTE:
Always install new brake pads, new brake pad
shims, and a new brake pad springs as a set.
2
_
3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 4 tightly to the
bleed screw 5. Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
T.
Bleed screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
R.
d. Install new brake pad shims, new brake
pads and new brake pad springs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Lubricate:
• front brake caliper retaining bolts
Recommended lubricant
Lithium-soap-based grease
CAUTION:
_
• Do not allow grease to contact the brake
pads.
• Remove any excess grease.
4 - 14
FRONT AND REAR BRAKES
CHAS
6. Install:
• front brake caliper 1
• front brake caliper retaining bolts 2
T.
R.
27 Nm (2.7 m · kg, 19 ft · lb)
2
1
7. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
a
2
EAS00583
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
_
1
1. Remove:
• rear brake caliper retaining bolts 1
• rear brake caliper 2
2. Remove:
• brake pads 1
• brake pad springs 2
4 - 15
FRONT AND REAR BRAKES
CHAS
3. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit
0.8 mm (0.03 in)
4.
•
•
•
1
Install:
brake pad springs 1
brake pads 2
rear brake caliper
NOTE:
Always install new brake pads, and new brake
pad springs as a set.
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
b. Loosen the brake caliper bleed screw, and
then turn the brake caliper piston 3 clockwise until section a of the brake caliper piston is level with the surface of the brake
caliper body.
1
2
NOTE:
Align the recesses b in the brake caliper piston with the brake caliper body as shown in the
illustration.
c. Tighten the brake caliper bleed screw.
3
T.
R.
3
a
b
4 - 16
Brake caliper bleed screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
FRONT AND REAR BRAKES
CHAS
d. Install new brake pads, new pad springs,
and the rear brake caliper.
NOTE:
Align the projection c on the piston side of the
brake pad with the lower recess in the brake
caliper piston.
È
É
c
È Up
É Down
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Lubricate:
• rear brake caliper retaining bolts
Recommended lubricant
Lithium-soap-based grease
CAUTION:
• Do not allow grease to contact the brake
pads.
• Remove any excess grease.
6. Install:
• rear brake caliper retaining bolts
T.
R.
a
27 Nm (2.7 m · kg, 19 ft · lb)
7. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 17
FRONT AND REAR BRAKES
CHAS
EAS00584
FRONT BRAKE MASTER CYLINDER
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the front brake master
cylinder
Upper handlebar cover
Brake fluid
Brake master cylinder reservoir cap
Brake master cylinder reservoir diaphragm holder
Brake master cylinder reservoir diaphragm
Brake lever
Front brake light switch connector
Union bolt
Brake hose
Copper washer
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “HANDLEBAR”.
Drain.
1
1
1
1
2
1
1
2
4 - 18
Disconnect.
Refer to “DISASSEMBLING THE
FRONT BRAKE MASTER CYLINDER”
and “ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYLINDER”.
FRONT AND REAR BRAKES
Order
9
10
11
Job/Part
Brake master cylinder holder
Brake master cylinder
Front brake light switch
Q’ty
1
1
CHAS
Remarks
Refer to “ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER”.
1
For installation, reverse the removal procedure.
4 - 19
FRONT AND REAR BRAKES
CHAS
EAS00585
Order
1
2
3
4
Job/Part
Disassembling the front brake master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder body
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 20
FRONT AND REAR BRAKES
CHAS
EAS00586
REAR BRAKE MASTER CYLINDER
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Remarks
Removing the rear brake master cylRemove the parts in the order listed.
inder
Upper handlebar cover
Refer to “HANDLEBAR”.
Brake fluid
Drain.
Brake master cylinder reservoir cap
1
Brake master cylinder reservoir dia1
phragm holder
Brake master cylinder reservoir dia1
phragm
Brake lever
1
Rear brake light switch connector
2
Disconnect.
Union bolt
1
Refer to “DISASSEMBLING THE REAR
BRAKE
MASTER CYLINDER” and
Brake hose
1
“ASSEMBLING AND INSTALLING THE
Copper washer
2
REAR BRAKE MASTER CYLINDER”.
4 - 21
FRONT AND REAR BRAKES
Order
9
10
11
Job/Part
Brake master cylinder holder
Brake master cylinder
Rear brake light switch
Q’ty
1
1
CHAS
Remarks
Refer to “ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER”.
1
For installation, reverse the removal procedure.
4 - 22
FRONT AND REAR BRAKES
CHAS
EAS00587
Order
1
2
3
4
Job/Part
Disassembling the rear brake master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder body
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 23
FRONT AND REAR BRAKES
CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
_
1.
•
•
•
2
Remove:
union bolt 1
copper washers 2
brake hoses 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
_
1
3
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the rear brake master
cylinder, drain the brake fluid from the entire
brake system.
_
1.
•
•
•
2
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
_
1
3
Remove:
union bolt 1
copper washers 2
brake hose 3
4 - 24
FRONT AND REAR BRAKES
CHAS
EAS00592
È
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
• brake master cylinder 1
Damage/scratches/wear → Replace.
• brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed
air.
É
È Front
É Rear
2. Check:
• brake master cylinder kit 1
Damage/scratches/wear → Replace.
1
2
3
3. Check:
• brake master cylinder reservoir cap 1
Cracks/damage → Replace.
• brake master cylinder reservoir diaphragm
holder 2
• brake master cylinder diaphragm 3
Damage/wear → Replace.
4. Check:
• brake hoses
Cracks/damage/wear → Replace.
4 - 25
FRONT AND REAR BRAKES
CHAS
EAS00596
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
_
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components.
Recommended brake fluid
DOT 4
1.
•
•
•
1
Install:
brake master cylinder kit 1
circlip 2 New
dust boot 3
2. Install:
• brake master cylinder 1
• brake master cylinder holder 2
T.
R.
a
2
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
• Make sure to install the brake master cylinder holder that has the “R” mark.
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Align the end of the brake master cylinder
holder with the punch mark a in the handlebar.
• First, tighten the upper bolt, then the lower
bolt.
Install:
copper washers New
brake hose
30 Nm (3.0 m · kg, 22 ft · lb)
union bolt
T.
R.
3.
•
•
•
WARNING
_
Proper brake hose routing is essential to
insure safe scooter operation. Refer to
“CABLE ROUTING” in chapter 2.
4 - 26
FRONT AND REAR BRAKES
CHAS
NOTE:
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
other parts (e.g., wire harness, cables,
leads). Correct if necessary.
_
a
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a on the brake
master cylinder.
4. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
_
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 27
FRONT AND REAR BRAKES
a
CHAS
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00596
ASSEMBLING AND INSTALLING THE
REAR BRAKE MASTER CYLINDER
WARNING
_
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components.
Recommended brake fluid
DOT 4
1.
•
•
•
4 - 28
Install:
brake master cylinder kit 1
circlip 2 New
dust boot 3
FRONT AND REAR BRAKES
CHAS
2. Install:
• brake master cylinder 1
• brake master cylinder holder 2
1
2
T.
R.
a
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
• Make sure to install the brake master cylinder holder that has the “L” mark.
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Align the end of the brake master cylinder
holder with the punch mark a on the handlebar.
• First, tighten the upper bolt, then the lower
bolt.
Install:
copper washers New
brake hose
30 Nm (3.0 m · kg, 22 ft · lb)
union bolt
T.
R.
3.
•
•
•
WARNING
_
Proper brake hose routing is essential to
insure safe scooter operation. Refer to
“CABLE ROUTING” in chapter 2.
NOTE:
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
other parts (e.g., wire harness, cables,
leads). Correct if necessary.
_
CAUTION:
a
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projections a on the
brake master cylinder.
4 - 29
FRONT AND REAR BRAKES
CHAS
4. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
_
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
a
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 30
FRONT AND REAR BRAKES
CHAS
EAS00612
FRONT BRAKE CALIPER
Order
1
2
3
Job/Part
Removing the front brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
4
5
6
Brake caliper bracket bolt
Speed sensor lead holder
Front brake caliper
Q’ty
1
2
1
2
1
1
Remarks
Remove the parts in the order listed.
Drain.
Refer to “DISASSEMBLING THE
FRONT BRAKE CALIPER” and
“ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPER”.
Refer to “ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER”.
For installation, reverse the removal procedure.
4 - 31
FRONT AND REAR BRAKES
CHAS
EAS00614
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the front brake caliper
Brake caliper retaining bolt
Brake caliper bracket
Bleed screw
Brake pad
Brake pad shim
Brake pad spring
Brake pad spring
Brake caliper piston
Dust seal
Brake caliper piston seal
A
Brake caliper body
Q’ty
2
1
1
2
2
1
2
2
2
2
Remarks
Remove the parts in the order listed.
Refer to “DISASSEMBLING THE
FRONT BRAKE CALIPER” and
“ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPER”.
1
For assembly, reverse the disassembly
procedure.
4 - 32
FRONT AND REAR BRAKES
CHAS
EAS00616
REAR BRAKE CALIPER
11
T.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
5
7
6
New
9
10
T.
R.
12
8
1
3
4
40 Nm (4.0 m • kg, 29 ft • Ib)
2
13
13
8
LS
Order
Job/Part
Removing the rear brake caliper
Air filter case (right)
Q’ty
Muffler
1
2
3
4
5
6
7
Brake fluid
Rear brake lock lever adjusting nut
Rear brake lock lever cable
Rear brake lock lever adjusting pin
Rear brake lock lever spring
Union bolt
Copper washer
Rear brake hose
1
1
1
1
1
2
1
4 - 33
Remarks
Remove the parts in the order listed.
Refer to “AIR FILTER CASES” in chapter
3.
Refer to “ENGINE REMOVAL” in chapter
5.
Drain.
Disconnect.
Refer to “DISASSEMBLING THE REAR
BRAKE CALIPER” and “ASSEMBLING
AND INSTALLING THE REAR BRAKE
CALIPER”.
FRONT AND REAR BRAKES
CHAS
11
T.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
5
7
6
New
9
10
T.
R.
12
8
1
3
4
40 Nm (4.0 m • kg, 29 ft • Ib)
2
13
13
8
LS
Order
8
9
10
11
12
13
Job/Part
Rear brake caliper retaining bolt
Rear brake caliper
Brake caliper bracket bolt
Brake caliper bracket
Brake pad
Brake pad spring
Q’ty
2
1
2
1
2
2
Remarks
Refer to “ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER”.
For installation, reverse the removal procedure.
4 - 34
FRONT AND REAR BRAKES
CHAS
EAS00617
2 New
4
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
1
5
3 New
6
T.
R.
Order
22 Nm (2.2 m • kg, 16 ft • Ib)
1
2
3
Job/Part
Disassembling the rear brake caliper
Brake caliper piston
Dust seal
Brake caliper piston seal
4
5
6
Bleed screw
Rear brake lock lever cable holder
Brake caliper body
Q’ty
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “DISASSEMBLING THE REAR
BRAKE CALIPER” and “ASSEMBLING
AND INSTALLING THE REAR BRAKE
CALIPER”.
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 35
FRONT AND REAR BRAKES
CHAS
EAS00619
DISASSEMBLING THE FRONT BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
_
1.
•
•
•
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
_
2.
•
•
•
Remove:
brake caliper pistons 1
dust seals 2
brake caliper piston seals 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening a to force out the pistons
from the brake caliper.
WARNING
_
• Cover the brake caliper pistons with a
rag. Be careful not to get injured when the
pistons are expelled from the brake caliper.
• Never try to pry out the brake caliper pistons.
b. Remove the brake caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00626
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
_
4 - 36
FRONT AND REAR BRAKES
1
1.
•
•
•
3
CHAS
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
_
2
2.
•
•
•
3
1
2
Remove:
brake caliper piston 1
dust seal 2
brake caliper piston seal 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Operate the rear brake lock lever 4 continuously in the direction shown by the arrow
until the piston comes out.
b. Remove the dust seal and brake caliper piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
4 - 37
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years
and whenever the
brake is disassembled
FRONT AND REAR BRAKES
È
É
2
3
1
CHAS
1. Check:
• brake caliper pistons 1
Rust/scratches/wear → Replace the brake
caliper pistons.
• brake caliper cylinders 2
Scratches/wear → Replace the brake caliper assembly.
• brake caliper body 3
Cracks/damage → Replace the brake caliper assembly.
• brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed
air.
WARNING
_
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
È Front
É Rear
2. Check:
• brake caliper brackets 1
Cracks/damage → Replace.
È
È Front
É Rear
É
1
4 - 38
FRONT AND REAR BRAKES
CHAS
EAS00635
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPER
WARNING
_
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
1.
•
•
•
2.
•
Install:
brake caliper piston seals 1 New
dust seals 2 New
brake caliper piston 3
Install:
brake caliper bracket
T.
R.
Install:
brake caliper (temporarily)
copper washers 1 New
brake hose 2
30 Nm (3.0 m · kg, 22 ft · lb)
union bolt 3
T.
R.
3.
•
•
•
•
40 Nm (4.0 m · kg, 2.9 ft · lb)
WARNING
_
Proper brake hose routing is essential to
insure safe scooter operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
_
When installing the brake hose onto the
brake caliper 1, make sure the brake pipe
touches the projection a on the brake caliper.
4 - 39
FRONT AND REAR BRAKES
4.
•
5.
•
•
•
CHAS
Remove:
brake caliper
Install:
brake pad springs
brake pads
brake caliper retaining bolts
T.
R.
27 Nm (2.7 m · kg, 19 ft · lb)
Refer to “REPLACING THE FRONT
BRAKE PADS”.
6. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
_
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
7. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 40
FRONT AND REAR BRAKES
CHAS
8. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
9. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
a
ASSEMBLING AND INSTALLING THE
REAR BRAKE CALIPER
WARNING
_
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
1. Install:
• brake caliper piston seal 1 New
• dust seal 2 New
2 New
1 New
4 - 41
FRONT AND REAR BRAKES
CHAS
2. Install:
• brake caliper piston 1
Turn the brake caliper piston clockwise until
section a of the brake caliper piston is level
with the surface of the brake caliper body.
NOTE:
Align the recesses b in the brake caliper piston with the brake caliper body as shown in the
illustration.
1
3. Install:
• brake caliper bracket
1
T.
a
R.
40 Nm (4.0 m · kg, 29 ft · lb)
b
3
2
1
Install:
brake caliper (temporarily)
brake hose 1
copper washers New
30 Nm (3.0 m · kg, 22 ft · lb)
union bolt 2
T.
R.
4.
•
•
•
•
WARNING
_
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
When installing the brake hose onto the
brake caliper 3, make sure the brake pipe
touches the projection a on the brake caliper.
3
a
5.
•
6.
•
•
•
Remove:
brake caliper
Install:
brake pad springs
brake pads
brake caliper retaining bolts
T.
R.
27 Nm (2.7 m · kg, 19 ft · lb)
Refer to “REPLACING THE REAR BRAKE
PADS”.
7. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
4 - 42
FRONT AND REAR BRAKES
CHAS
Recommended brake fluid
DOT 4
WARNING
_
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
a
8. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
9. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
10.Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
11.Adjust:
• rear brake lock lever cable length
Refer to “ADJUSTING THE REAR BRAKE
LOCK LEVER CABLE” in chapter 3.
4 - 43
FRONT FORK
CHAS
EAS00646
FRONT FORK
T.
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
R.
5
6 New
T.
R.
7
70 Nm (7.0 m • kg, 50 ft • lb)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
8
4
3
2
T.
R.
Order
Job/Part
Removing the front fork legs
Q’ty
Storage compartment
Front wheel
1
2
3
4
Brake hose holder
Front brake caliper
Speed sensor lead holder
Front fender
1
1
1
1
4 - 44
40 Nm (4.0 m • kg, 29 ft • Ib)
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to “COWLING AND COVERS” in
chapter 3.
Refer to “FRONT WHEEL AND BRAKE
DISC”.
FRONT FORK
T.
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
R.
70 Nm (7.0 m • kg, 50 ft • lb)
5
6 New
T.
R.
7
CHAS
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
8
4
3
2
T.
R.
Order
5
6
7
8
Job/Part
Cap bolt
O-ring
Lower bracket pinch bolt
Front fork leg
Q’ty
1
1
2
Loosen.
1
40 Nm (4.0 m • kg, 29 ft • Ib)
Remarks
Refer to “REMOVING
THE FRONT FORK
LEGS” and “INSTALLING
THE FRONT FORK
LEGS”.
For installation, reverse the removal procedure.
4 - 45
FRONT FORK
CHAS
EAS00648
8
0
A New
3
4
B New
C
D New
9
1
2
E
7
New 6
LT
5
T.
R.
Order
1
2
3
4
5
6
7
8
9
0
A
B
Job/Part
Disassembling the front fork legs
Fork spring seat
Fork spring
Dust seal
Oil seal clip
Damper rod bolt
Copper washer
Damper rod
Rebound spring
Oil flow stopper
Inner tube
Inner tube bushing
Oil seal
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
4 - 46
30 Nm (3.0 m • kg, 22 ft • Ib)
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to “DISASSEMBLING THE
FRONT FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”.
FRONT FORK
CHAS
8
0
A New
3
4
B New
C
D New
9
1
2
E
7
New 6
LT
5
T.
R.
Order
C
D
E
Job/Part
Washer
Outer tube bushing
Outer tube
Q’ty
1
1
1
4 - 47
30 Nm (3.0 m • kg, 22 ft • Ib)
Remarks
Refer to “DISASSEMBLING THE
FRONT FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”.
For assembly, reverse the disassembly
procedure.
FRONT FORK
CHAS
EAS00651
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the front wheel is elevated.
_
2
1
2. Remove:
• cap bolt 1
(with a 17-mm hexagonal wrench)
3. Loosen:
• lower bracket pinch bolt 2
WARNING
_
Before loosening the lower bracket pinch
bolts, support the front fork leg.
4. Remove:
• front fork leg
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
• fork spring seat
• fork spring
2. Drain:
• fork oil
NOTE:
Stroke the outer tube several times while
draining the fork oil.
4 - 48
FRONT FORK
CHAS
3. Remove:
• dust seal 1
• oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
_
Do not scratch the inner tube.
4. Remove:
• damper rod bolt 1
NOTE:
While holding the damper rod with the damper
rod holder 2 and T-handle 3, loosen the
damper rod bolt.
_
Damper rod holder
90890-01460
T-handle
90890-01326
5. Remove:
• inner tube
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in
a vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but carefully.
CAUTION:
_
• Excessive force will damage the oil seal
and bushing. A damaged oil seal or bushing must be replaced.
• Avoid bottoming the inner tube into the
outer tube during the above procedure,
as the oil flow stopper will be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 49
FRONT FORK
CHAS
EAS00656
1
2
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
WARNING
_
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• spring free length a
Out of specification → Replace.
Spring free length
316.7 mm (12.47 in)
<Limit>: 310.4 mm (12.22 in)
1
2
3. Check:
• damper rod 1
Damage/wear → Replace.
Obstruction → Blow out all of the oil passages with compressed air.
• oil flow stopper 2
Damage → Replace.
EAS00659
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
_
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor handling and a loss of stability.
4 - 50
FRONT FORK
CHAS
NOTE:
• When assembling the front fork leg, be sure
to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
- cap bolt O-ring
• Before assembling the front fork leg, make
sure all of the components are clean.
_
1
3
1. Install:
• damper rod 1
• rebound spring 2
CAUTION:
_
2
Allow the damper rod to slide slowly down
the inner tube 3 until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
2. Lubricate:
• inner tube’s outer surface
Recommended lubricant
Fork oil 10 W or equivalent
3. Tighten:
• copper washer New
• damper rod bolt 1
T.
R.
Damper rod bolt
30 Nm (3.0 m · kg, 22 ft · lb)
LOCTITE®
NOTE:
While holding the damper rod assembly with
the damper rod holder 2 and T-handle 3,
tighten the damper rod bolt.
_
Damper rod holder
90890-01460
T-handle
90890-01326
4 - 51
FRONT FORK
CHAS
4. Install:
• outer tube bushing 1 New
• washer 2
(with the fork seal driver weight 3 and fork
seal driver attachment 4)
Fork seal driver weight
90890-01367, YM-A9409-7
Fork seal driver attachment
(41 mm)
90890-01381, YM-A5142-2
5. Install:
• oil seal 1 New
(with the fork seal driver weight 2 and fork
seal driver attachment 3)
CAUTION:
_
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 4 to protect the oil seal during installation.
_
6. Install:
• oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the
outer tube’s groove.
_
7. Install:
• dust seal 1
(with the fork seal driver weight 2)
Fork seal driver weight
90890-01367, YM-A9409-7
4 - 52
FRONT FORK
CHAS
8. Fill:
• front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
0.298 L
(0.262 Imp qt, 0.315 US qt)
Recommended oil
Yamaha fork and shock oil 10 W
or equivalent
Front fork leg oil level a (from
the top of the inner tube, with the
inner tube fully compressed and
without the fork spring)
88 mm (3.46 in)
NOTE:
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
_
9. Install:
• fork spring 1
• fork spring seat
NOTE:
Install the fork spring with the smaller pitch facing up.
_
EAS00663
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
• front fork leg
NOTE:
• Before installing the cap bolt, lubricate its Oring with grease.
• Pull up the inner tube until it stops.
_
2. Tighten:
• lower bracket pinch bolt 1
T.
R.
4 - 53
R.
• cap bolt 2
2
T.
1
30 Nm (3.0 m · kg, 22 ft · lb)
70 Nm (7.0 m · kg, 50 ft · lb)
CHAS
HANDLEBAR
EAS00664
HANDLEBAR
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
2
1
5
10
2
18
11
17
9
6
19
7
8
15
3
4
14
5
12
16
11
T.
R.
3
13
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
T.
R.
T.
R.
26 Nm (2.6 m • kg, 19 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the handlebar
Windshield
Upper handlebar cover
Rearview mirror (left and right)
Grip end
Plastic locking tie
Right handlebar switch
Throttle cable
Throttle grip
Front brake light switch connector
Front brake master cylinder holder
Front brake master cylinder
Left handlebar switch
Q’ty
1
2
2
2
1
2
1
2
1
1
1
4 - 54
26 Nm (2.6 m • kg, 19 ft • Ib)
6 Nm (0.6 m • kg, 4.3 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVERS” in
chapter 3.
Disconnect.
Disconnect.
Refer to “INSTALLING
THE HANDLEBAR”.
CHAS
HANDLEBAR
T.
23 Nm (2.3 m • kg, 17 ft • Ib)
R.
2
1
5
10
2
18
11
17
9
6
19
7
8
15
3
4
14
5
12
16
11
T.
R.
3
13
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
T.
R.
T.
R.
26 Nm (2.6 m • kg, 19 ft • Ib)
Order
12
13
14
15
16
17
18
19
Job/Part
Rear brake light switch connector
Rear brake lock lever cable
Rear brake master cylinder holder
Rear brake master cylinder
Handlebar grip
Upper handlebar holder
Handlebar
Lower handlebar cover
26 Nm (2.6 m • kg, 19 ft • Ib)
6 Nm (0.6 m • kg, 4.3 ft • Ib)
Q’ty
Remarks
2
Disconnect.
1
Disconnect. Refer to “INSTALLING
THE HANDLEBAR”.
1
1
1
Refer to “REMOVING THE HANDLEBAR” and “INSTALLING THE HANDLEBAR”.
2
Refer to “INSTALLING THE HANDLEBAR”.
1
1
For installation, reverse the removal procedure.
4 - 55
HANDLEBAR
CHAS
EAS00666
REMOVING THE HANDLEBAR
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
2. Remove:
• handlebar grip 1
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 1
Bends/cracks/damage → Replace.
WARNING
_
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
EAS00671
INSTALLING THE HANDLEBAR
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
4 - 56
HANDLEBAR
CHAS
2. Install:
• handlebar 1
• upper handlebar holders 2
1
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
CAUTION:
_
b
2
First, tighten the bolts on the front side of
the handlebar holders, and then on the rear
side.
NOTE:
• The upper handlebar holders should be
installed with the arrow marks a facing forward È.
• Align the match marks b on the handlebar
with the upper surface of the lower handlebar
holder.
_
3. Install:
• handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
@
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• rear brake master cylinder 1
• rear brake master cylinder holder 2
T.
R.
1
2
a
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
• Make sure to install the brake master cylinder holder that has the “L” mark.
• Install the rear brake master cylinder holder
with the “UP” mark facing up.
• Align the end of the rear brake master cylinder holder with the punch mark a in the handlebar.
• First, tighten the upper bolt, then the lower
bolt.
4 - 57
HANDLEBAR
CHAS
5. Install:
• rear brake lock lever cable 1
NOTE:
Lubricate the inside of the rear brake lock lever
cable and rear brake lock lever with a thin coat
of lithium-soap-based grease.
LS
1
6. Install:
• left handlebar switch 1
a
T.
b
R.
6 Nm (0.6 m · kg, 4.3 ft · lb)
NOTE:
Align the projection a on the left handlebar
switch with the hole b in the handlebar.
1
7. Install:
• front brake master cylinder 1
• front brake master cylinder holder 2
1
2
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
• Make sure to install the brake master cylinder holder that has the “R” mark.
• Install the front brake master cylinder holder
with the “UP” mark facing up.
• Align the end of the front brake master cylinder holder with the punch mark a in the handlebar.
• First, tighten the upper bolt, then the lower
bolt.
a
LS
8. Install:
• throttle grip
• throttle cables 1
NOTE:
Lubricate the inside of the throttle grip with a
thin coat of lithium-soap-based grease and
install it onto the handlebar.
_
1
4 - 58
HANDLEBAR
b
CHAS
9. Install:
• right handlebar switch 1
WARNING
_
a
Make sure
smoothly.
the
throttle
grip
operates
1
NOTE:
Align the projection a on the right handlebar
switch with the hole b in the handlebar.
_
10.Install:
• grip end (left)
NOTE:
There should be 1 ~ 3 mm (0.04 ~ 0.12 in) of
clearance a between the throttle grip and the
grip end.
11.Install:
• grip end (right)
NOTE:
There should be 2.4 ~ 4.4 mm (0.09 ~ 0.17 in)
of clearance a between the throttle grip and
the grip end.
12.Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
4 - 59
STEERING HEAD
CHAS
EAS00675
STEERING HEAD
LOWER BRACKET
T.
R.
140 Nm (14.0 m • kg, 100 ft • lb)
2
3
T.
R.
90 Nm (9.0 m • kg, 65 ft • Ib)
4
T.
R.
1st 36 Nm (3.6 m • kg, 25 ft • lb)
2nd 24 Nm (2.4 m • kg, 17 ft • lb)
LS
15
16
LS
18
6
7
8
9
10
12
13
14
17
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
5
11
1
Order
Job/Part
Removing the lower bracket
Front wheel
Q’ty
Front fork legs
Storage compartment
1
2
3
4
5
6
7
8
Handlebar
Brake hose holder
Steering stem nut
Washer
Lower handlebar holder
Woodruff key
Upper steering ring nut
Lock washer
Center steering ring nut
1
1
1
1
1
1
1
1
4 - 60
Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISC”.
Refer to “FRONT FORK”.
Refer to “COWLING AND COVERS” in
chapter 3.
Refer to “HANDLEBAR”.
Refer to “REMOVING THE LOWER
BRACKET” and “INSTALLING THE
STEERING HEAD”.
STEERING HEAD
CHAS
T.
R.
140 Nm (14.0 m • kg, 100 ft • lb)
2
3
T.
R.
90 Nm (9.0 m • kg, 65 ft • Ib)
4
T.
R.
1st 36 Nm (3.6 m • kg, 25 ft • lb)
2nd 24 Nm (2.4 m • kg, 17 ft • lb)
LS
15
16
LS
18
6
7
8
9
10
12
13
14
17
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
5
11
1
Order
9
10
11
12
13
14
15
16
17
18
Job/Part
Rubber washer
Lower steering ring nut
Lower bracket
Bearing cover
Upper bearing inner race
Upper bearing
Lower bearing outer race
Lower bearing
Upper bearing outer race
Dust seal
Q’ty
1
1
1
1
1
1
1
1
1
1
Remarks
Refer to “REMOVING THE LOWER
BRACKET” and “INSTALLING THE
STEERING HEAD”.
Refer to “INSTALLING THE STEERING
HEAD”.
For installation, reverse the removal procedure.
4 - 61
STEERING HEAD
CHAS
EAS00680
REMOVING THE LOWER BRACKET
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
2. Remove:
• handlebar lower holder 1
• woodruff key 2
NOTE:
Remove the handlebar lower holder by loosening the upper steering ring nut 3 gradually.
3. Remove:
• upper steering ring nut 1
(with the ring nut wrench)
• lock washer 2
• center steering ring nut 3
• rubber washer
Ring nut wrench
90890-01268, YU-01268
4. Remove:
• lower steering ring nut 1
(with the ring nut wrench 2)
Ring nut wrench
90890-01268, YU-01268
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
4 - 62
STEERING HEAD
CHAS
EAS00681
CHECKING THE STEERING HEAD
1. Wash:
• bearings
• bearing races
Recommended cleaning solvent
Kerosene
2. Check:
• bearings 1
• bearing races 2
Damage/pitting → Replace.
3. Replace:
• bearings
• bearing 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 lower
bracket with a floor chisel 2 and hammer.
c. Install a new rubber seal and new bearing
races.
CAUTION:
_
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
• Always replace the bearings and bearing
races as a set.
• Whenever the steering head is disassembled, replace the rubber seal.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
4 - 63
STEERING HEAD
CHAS
EAS00684
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
Recommended lubricant
Lithium-soap-based grease
a
2.
•
•
•
Clean:
lower bracket
steering ring nuts
lower handlebar holder
NOTE:
Clean the area a of the lower bracket indicated in the illustration and the inner surfaces
of the lower handlebar holder and steering ring
nuts.
3.
•
•
•
•
•
Install:
lower steering ring nut 1
rubber washer
center steering ring nut 2
lock washer 3
upper steering ring nut 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
4. Install:
• woodruff key 1
• lower handlebar holder 2
T.
R.
140 Nm (14.0 m · kg, 100 ft · lb)
NOTE:
Align the alignment mark a on the lower handlebar holder with the woodruff key.
_
4 - 64
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM
CHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
2
5
11
4
LS
7
10
9
8
LS
4
6
1
LS
T.
R.
135 Nm (13.5 m • kg, 98 ft • lb)
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
T.
T.
R.
R.
Order
29 Nm (2.9 m • kg, 21 ft • Ib)
Job/Part
Removing the rear shock absorber
assemblies and swingarm
Storage box
46 Nm (4.6 m • kg, 33 ft • Ib)
34 Nm (3.4 m • kg, 24 ft • Ib)
Q’ty
Air filter case (right)
Muffler
1
2
3
4
Rear axle nut
Rear brake caliper
Brake hose holder
Rear shock absorber (left and right)
1
1
1
2
5
Swingarm
1
4 - 65
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVERS” in
chapter 3.
Refer to “AIR FILTER CASES” in chapter
3.
Refer to “ENGINE REMOVAL” in chapter
5.
Refer to “REMOVING THE SWINGARM” and “INSTALLING THE SWINGARM”.
Refer to “REMOVING THE REAR
SHOCK ABSORBER ASSEMBLIES” and
“INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLIES”.
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM
CHAS
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
2
5
11
4
LS
7
10
9
8
LS
4
6
1
LS
T.
R.
135 Nm (13.5 m • kg, 98 ft • lb)
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
Collar
Oil seal
Bearing
Oil seal
Dust seal
R.
R.
7
8
9
10
11
Job/Part
Spacer
T.
T.
Order
6
29 Nm (2.9 m • kg, 21 ft • Ib)
46 Nm (4.6 m • kg, 33 ft • Ib)
34 Nm (3.4 m • kg, 24 ft • Ib)
Q’ty
Remarks
1
Refer to “REMOVING THE SWINGARM”
and “INSTALLING THE SWINGARM”.
1
1
1
1
1
For installation, reverse the removal procedure.
4 - 66
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM
CHAS
EAS00693
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLIES
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the rear wheel is elevated.
_
2. Remove:
• rear shock absorber assemblies 1
1
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES
The following procedure applies both of the
rear shock absorber assemblies.
1. Check:
• rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• rear shock absorber
Oil leaks → Replace the rear shock
absorber assembly.
• spring
Damage/wear → Replace the rear shock
absorber assembly.
• bolts
Bends/damage/wear → Replace.
EAS00699
1
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLIES
1. Install:
• rear shock absorber assembly upper nuts 1
T.
R.
34 Nm (3.4 m · kg, 24 ft · lb)
• rear shock absorber assembly lower bolts 2
T.
R.
2
4 - 67
29 Nm (2.9 m · kg, 21 ft · lb)
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM
CHAS
EAS00702
REMOVING THE SWINGARM
1. Stand the scooter on a level surface.
WARNING
_
Securely support the scooter so that there
is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that
the rear wheel is elevated.
_
2
3
2.
•
•
•
•
4
Remove:
rear axle nut 1
rear brake caliper 2
brake hose holder 3
rear shock absorber assembly lower bolt
(right) 4
NOTE:
Do not squeeze the brake lever when removing the brake caliper.
1
3. Remove:
• swingarm
EAS00708
2
3
43
1
CHECKING THE SWINGARM
1. Check:
• swingarm
Bends/cracks/damage → Replace.
2. Check:
• spacer 1
• collar 2
• oil seals 3
• bearing 4
• bushing
Damage/wear → Replace.
• dust seal
Damage/wear → Replace.
4 - 68
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM
CHAS
EAS00711
INSTALLING THE SWINGARM
1. Lubricate:
• bearing
• oil seal lips
• drive axle splines
Recommended lubricant
Lithium-soap-based grease
4
3
T.
2. Install:
46 Nm (4.6 m · kg, 33 ft · lb)
• swingarm 1
• rear shock absorber assembly lower bolt
29 Nm (2.9 m · kg, 21 ft · lb)
(right) 2
• brake hose holder 3
R.
T.
R.
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• rear brake caliper 4
T.
2
R.
5
40 Nm (4.0 m · kg, 29 ft · lb)
• rear axle nut 5
1
T.
R.
4 - 69
135 Nm (13.5 m · kg, 98 ft · lb)
ENG
5
ENG
CHAPTER 5
ENGINE
ENGINE REMOVAL ........................................................................................5-1
LEADS, HOSES, EXHAUST PIPE AND MUFFLER .................................5-1
ENGINE..................................................................................................... 5-3
INSTALLING THE ENGINE....................................................................... 5-5
CAMSHAFTS...................................................................................................5-6
CYLINDER HEAD COVER........................................................................ 5-6
CAMSHAFTS ............................................................................................ 5-7
REMOVING THE CAMSHAFTS................................................................5-9
CHECKING THE CAMSHAFTS ..............................................................5-10
CHECKING THE CAMSHAFT SPROCKETS .........................................5-12
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-12
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-13
INSTALLING THE CAMSHAFTS ............................................................ 5-13
CYLINDER HEAD.......................................................................................... 5-17
REMOVING THE CYLINDER HEAD.......................................................5-19
CHECKING THE CYLINDER HEAD .......................................................5-19
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ................. 5-20
INSTALLING THE CYLINDER HEAD .....................................................5-20
VALVES AND VALVE SPRINGS.................................................................. 5-21
REMOVING THE VALVES...................................................................... 5-22
CHECKING THE VALVES AND VALVE GUIDES ..................................5-23
CHECKING THE VALVE SEATS ............................................................ 5-25
CHECKING THE VALVE SPRINGS........................................................ 5-27
CHECKING THE VALVE LIFTERS ......................................................... 5-28
INSTALLING THE VALVES .................................................................... 5-28
CYLINDER AND PISTON.............................................................................. 5-30
REMOVING THE PISTON ...................................................................... 5-31
CHECKING THE CYLINDER AND PISTON ...........................................5-31
CHECKING THE PISTON RINGS........................................................... 5-33
CHECKING THE PISTON PIN ................................................................5-34
INSTALLING THE PISTON AND CYLINDER .........................................5-34
ENG
BELT DRIVE.................................................................................................. 5-37
V-BELT CASE COVER ...........................................................................5-37
V-BELT AND PRIMARY/SECONDARY SHEAVE................................... 5-38
SECONDARY SHEAVE ..........................................................................5-40
REMOVING THE PRIMARY SHEAVE....................................................5-42
REMOVING THE SECONDARY SHEAVE AND V-BELT .......................5-42
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-43
CHECKING THE V-BELT........................................................................5-44
CHECKING THE V-BELT CASE AIR DUCTS.........................................5-44
CHECKING THE PRIMARY SHEAVE ....................................................5-44
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-44
CHECKING THE SECONDARY SHEAVE .............................................. 5-45
CHECKING THE CLUTCH SHOES ........................................................ 5-45
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-46
ASSEMBLING THE SECONDARY SHEAVE..........................................5-46
INSTALLING THE SECONDARY SHEAVE, V-BELT AND
PRIMARY SHEAVE................................................................................ 5-47
STARTER CLUTCH AND GENERATOR......................................................5-49
GENERATOR ROTOR COVER AND STATOR COIL ............................ 5-49
STARTER CLUTCH AND GENERATOR................................................ 5-51
REMOVING THE GENERATOR ............................................................. 5-52
CHECKING THE STARTER CLUTCH ....................................................5-53
INSTALLING THE STARTER CLUTCH .................................................. 5-54
INSTALLING THE GENERATOR............................................................ 5-54
OIL PUMP...................................................................................................... 5-56
CHECKING THE OIL PUMP ................................................................... 5-57
CHECKING THE OIL PUMP DRIVE CHAIN ...........................................5-57
ASSEMBLING THE OIL PUMP...............................................................5-58
INSTALLING THE OIL PUMP .................................................................5-58
CRANKSHAFT ..............................................................................................5-59
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ASSEMBLY...... 5-59
CRANKCASE BEARINGS....................................................................... 5-61
DISASSEMBLING THE CRANKCASE....................................................5-62
REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......................5-62
CHECKING THE CRANKSHAFT AND CONNECTING ROD ................. 5-63
CHECKING THE BALANCER SHAFT ASSEMBLY................................5-66
CHECKING THE CRANKCASE ..............................................................5-66
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE
(INTAKE SIDE) ....................................................................................... 5-66
CHECKING THE OIL PUMP GEARS AND SHAFTS..............................5-67
CHECKING THE RELIEF VALVE ........................................................... 5-67
CHECKING THE BEARINGS AND OIL SEALS...................................... 5-67
CHECKING THE CIRCLIPS AND WASHERS ........................................ 5-67
INSTALLING THE CRANKSHAFT JOURNAL BEARINGS.....................5-68
INSTALLING THE CRANKSHAFT ASSEMBLY AND BALANCER
SHAFT ASSEMBLY ............................................................................... 5-68
ASSEMBLING THE CRANKCASE.......................................................... 5-69
TRANSMISSION............................................................................................ 5-70
CHECKING THE TRANSMISSION ......................................................... 5-72
INSTALLING THE PRIMARY DRIVE GEAR OIL SEAL.......................... 5-72
ENG
ENGINE REMOVAL
EAS00188
ENGINE
ENGINE REMOVAL
LEADS, HOSES, EXHAUST PIPE AND MUFFLER
3
2
5
1
4
7 New
6
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
R.
Order
20 Nm (2.0 m • kg, 14 ft • Ib)
14 Nm (1.4 m • kg, 10 ft • Ib)
Job/Part
Removing the leads, hoses, exhaust
pipe and muffler
Negative battery lead
Positive battery lead
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
CAUTION:
_
• First, disconnect the negative battery lead, and then the positive battery lead.
• For connecting, reverse the disconnection procedure.
Air filter case (left and right)
Refer to “AIR FILTER CASES” in chapter
3.
Refer to “THROTTLE BODY AND FUEL
INJECTOR” in chapter 7.
Throttle body and fuel injector
5-1
ENG
ENGINE REMOVAL
3
2
5
1
4
7 New
6
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
R.
Order
Job/Part
Q’ty
Starter motor
Thermostat cover and thermostat
Rear brake caliper
1
2
3
4
5
6
7
20 Nm (2.0 m • kg, 14 ft • Ib)
14 Nm (1.4 m • kg, 10 ft • Ib)
Spark plug cap
Coolant temperature sensor coupler
Crankshaft position sensor/stator
assembly coupler
Water pump inlet hose
Muffler
Exhaust pipe
Gasket
1
1
2
1
1
1
1
Remarks
Refer to “STARTER MOTOR” in chapter
8.
Refer to “THERMOSTAT” in chapter 6.
Refer to “FRONT AND REAR BRAKES”
in chapter 4.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
5-2
ENGINE REMOVAL
ENG
EAS00191
ENGINE
LS
T.
T.
R.
R.
56 Nm (5.6 m • kg, 40 ft • Ib)
LT
LT
LS
6
7
65 Nm (6.5 m • kg, 47 ft • Ib)
5
5
LS
9
4
T.
8
59 Nm (5.9 m • kg, 43 ft • Ib)
R.
T.
29 Nm (2.9 m • kg, 21 ft • Ib)
R.
6
LT
4
1
4
3
2
1
10
4
3
2
LT
T.
R.
Order
45 Nm (4.5 m • kg, 32 ft • Ib)
Job/Part
Removing the engine
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
_
1
2
3
4
5
6
7
8
Rear shock absorber assembly lower
bolt
Engine bracket lower mounting bolt
Washer
Engine bracket upper mounting nut/
bolt
Engine bracket bolt
Engine mounting nut/bolt
Left engine bracket
Center engine bracket
2
2
2
2/2
4
1/1
1
1
5-3
Refer to “INSTALLING THE ENGINE”.
ENGINE REMOVAL
LS
T.
T.
R.
R.
56 Nm (5.6 m • kg, 40 ft • Ib)
LT
LT
LS
6
7
ENG
65 Nm (6.5 m • kg, 47 ft • Ib)
5
5
LS
9
4
T.
8
R.
T.
R.
6
59 Nm (5.9 m • kg, 43 ft • Ib)
29 Nm (2.9 m • kg, 21 ft • Ib)
LT
4
1
4
3
2
1
10
4
3
2
LT
T.
R.
Order
9
10
Job/Part
Right engine bracket
Engine
45 Nm (4.5 m • kg, 32 ft • Ib)
Q’ty
1
1
Remarks
Refer to “INSTALLING THE ENGINE”.
For installation, reverse the removal procedure.
5-4
ENGINE REMOVAL
5
4
2
5
3
ENG
EAS00192
4
INSTALLING THE ENGINE
1. Install:
• right engine bracket 1
• center engine bracket 2
• left engine bracket 3
• engine mounting bolt/nut 4
• engine bracket bolts 5
1
6
6
LT
NOTE:
• Apply lithium-soap-based grease to the
unthreaded portion of the engine mounting
bolt shaft.
• Do not fully tighten the engine mounting bolt
and engine bracket bolts.
_
9
6
78
9
2. Tighten:
• engine mounting nut 4
6
T.
R.
65 Nm (6.5 m · kg, 47 ft · lb)
• engine bracket bolts 5
8 7
T.
R.
56 Nm (5.6 m · kg, 40 ft · lb)
3. Install:
• engine bracket upper mounting bolts/nuts
6
• washers 7
• engine bracket lower mounting bolts 8
LT
NOTE:
Do not fully tighten the bolts.
_
4. Tighten:
• engine bracket upper mounting nuts 6
T.
R.
59 Nm (5.9 m · kg, 43 ft · lb)
• engine bracket lower mounting bolts 8
T.
R.
45 Nm (4.5 m · kg, 32 ft · lb)
• rear shock absorber assembly lower bolts 9
T.
R.
5-5
29 Nm (2.9 m · kg, 21 ft · lb)
CAMSHAFTS
ENG
EAS00194
CAMSHAFTS
CYLINDER HEAD COVER
5
New 4
3
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5
(9)
1
2
T.
R.
Order
13 Nm (1.3 m • kg, 9.4 ft • Ib)
Job/Part
Removing the cylinder head cover
Storage box and rubber sheet
Q’ty
Throttle body and fuel injector
1
2
3
4
5
Spark plug cap
Spark plug
Cylinder head cover
Cylinder head cover gasket
Semicircular plug
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVERS” in
chapter 3.
Refer to “THROTTLE BODY AND FUEL
INJECTOR” in chapter 7.
1
1
1
1
2
For installation, reverse the removal procedure.
5-6
CAMSHAFTS
ENG
EAS00196
CAMSHAFTS
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
LS
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
5
E
4
4
12
M
6 New
9
13
8
11
(8)
14
10
E
8
M
7
3
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(4)
Order
1
2
3
4
5
6
7
8
9
10
11
12
2
Job/Part
Removing the camshafts
Timing plug
V-belt case air filter cover
V-belt case air filter element
Camshaft sprocket bolt
Timing chain tensioner assembly
Gasket
Camshaft cap
Dowel pin
Intake camshaft
Exhaust camshaft
Intake camshaft sprocket
Exhaust camshaft sprocket
Q’ty
1
1
1
4
1
1
1
2
1
1
1
1
5-7
(4)
Remarks
Remove the parts in the order listed.
Loosen.
Refer to “REMOVING
THE CAMSHAFTS” and
“INSTALLING THE CAMSHAFTS”.
CAMSHAFTS
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
ENG
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
LS
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
5
E
4
4
12
M
6 New
9
13
8
11
(8)
14
10
E
8
M
7
3
2
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(4)
Order
13
14
Job/Part
Decompressor lever
Decompressor lever pin
Q’ty
1
1
5-8
(4)
Remarks
Refer to “INSTALLING THE CAMSHAFTS”.
For installation, reverse the removal procedure.
CAMSHAFTS
ENG
EAS00198
REMOVING THE CAMSHAFTS
1. Remove:
• timing plug
• V-belt case air filter cover 1
• V-belt case air filter element
2. Align:
• TDC mark on the generator rotor
(with the stationary pointer on the generator
rotor cover)
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the primary sheave nut on the left side
of the crankshaft counterclockwise to turn
the crankshaft.
b. Align the “I” mark a on the generator rotor
with the stationary pointer b on the generator rotor cover to position the piston at TDC
on the compression stroke.
NOTE:
• TDC on the compression stroke can be
found when the camshaft lobes are turned
away from each other.
• In order to be sure that the piston is at TDC,
the punch marks c on the intake camshaft
sprocket and the punch mark d on the
exhaust camshaft sprocket must align with
the cylinder head mating surface as shown in
the illustration.
_
c
d
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Loosen:
• camshaft sprocket bolts 1
1
1
4.
•
5.
•
•
1
2
5-9
Loosen:
timing chain tensioner cap bolt 1
Remove:
timing chain tensioner 2
gasket
CAMSHAFTS
8
5
2
3
1
ENG
6. Remove:
• camshaft cap 1
• dowel pins
NOTE:
• Loosen the camshaft cap bolts in the
descending order of the embossed numbers
on the camshaft cap.
• Loosen each camshaft cap bolt 1/2 of a turn
at a time. After all of the camshaft cap bolts
are fully loosened, remove them.
_
4
1
6
7
3
1
7. Remove:
• intake camshaft 1
• exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 3.
_
2
8. Remove:
• camshaft sprockets
EAS00204
CHECKING THE CAMSHAFTS
1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• camshaft lobe dimensions a and b
Out of specification → Replace the camshaft.
Camshaft lobe dimension limit
Intake camshaft
a 34.250 mm (1.3484 in)
b 24.850 mm (0.9783 in)
Exhaust camshaft
a 33.350 mm (1.3130 in)
b 24.856 mm (0.9786 in)
5 - 10
CAMSHAFTS
ENG
3. Measure:
• camshaft runout
Out of specification → Replace.
Camshaft runout limit
0.03 mm (0.0012 in)
1
4. Measure:
• camshaft-journal-to-camshaft-cap clearance
Out of specification → Measure the camshaft journal diameter.
Camshaft-journal-to-camshaftcap clearance limit
0.08 mm (0.0031 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
8
5
2
3
1
4
7
6
1
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft cap).
b. Position a strip of Plastigauge® 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft cap.
NOTE:
• Tighten the camshaft cap bolts in the order of
the embossed numbers on the camshaft cap.
• Do not turn the camshaft when measuring
the camshaft journal-to-camshaft cap clearance with the Plastigauge® 1.
_
T.
Camshaft cap bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
d. Remove the camshaft cap and then measure the width of the Plastigauge®.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 11
CAMSHAFTS
ENG
5. Measure:
• camshaft journal diameter a
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and the camshaft cap as a set.
Camshaft journal diameter
24.459 ~ 24.472 mm
(0.9630 ~ 0.9635 in)
CHECKING THE CAMSHAFT SPROCKETS
1. Check:
• camshaft sprockets
Wear/damage → Replace the camshaft
sprockets and timing chain as a set.
a 1/4 of a tooth
b Correct
1 Roller
2 Sprocket
1
2
CHECKING THE DECOMPRESSION
SYSTEM
1. Check:
• decompression system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the decompressor lever pin 1
projects from the camshaft.
b. Check that the decompressor cam 2
moves smoothly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 12
CAMSHAFTS
ENG
EAS00210
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage/rough movement →
Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
housing smoothly. If there is rough movement, replace the timing chain tensioner.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00217
3
1
2
INSTALLING THE CAMSHAFTS
1. Install:
• decompressor lever pin 1
• decompressor lever 2
• exhaust camshaft 3
NOTE:
Install the decompressor lever pin 1 and
decompressor lever 2 in the exhaust camshaft 3 as shown in the illustration.
_
2
a
1
a
2. Install:
• exhaust camshaft sprocket 1
• intake camshaft sprocket 2
NOTE:
• Make sure that the punch marks a on the
camshaft sprockets are in the position shown
in the illustration.
• Temporarily tighten the camshaft sprocket
bolts.
5 - 13
CAMSHAFTS
3
1
2
ENG
3. Install:
• intake camshaft 1
• exhaust camshaft 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the primary sheave nut on the left side
of the crankshaft counterclockwise to turn
the crankshaft.
b. When piston is at TDC on the compression
stroke, align the “I” mark a on the generator rotor with the stationary pointer b on the
generator rotor cover.
c. Install the timing chain 3 onto both camshaft sprockets, and then install the camshafts onto the cylinder head.
NOTE:
The camshafts should be installed onto the
cylinder head so that the punch marks c on
the intake camshaft sprocket and the punch
mark d on the exhaust camshaft sprocket
align with the cylinder head mating surface, as
shown in the illustration.
CAUTION:
_
c
d
Do not turn the crankshaft when installing
the camshafts to avoid damage or improper
valve timing.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8
5
2
3
4.
•
•
•
Install:
dowel pins
camshaft cap
camshaft cap bolts
4
1
6
7
NOTE:
• Lubricate the camshaft cap bolt threads with
engine oil.
• Finger tighten the camshaft cap bolts.
5. Tighten:
• camshaft cap bolts
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Tighten the camshaft cap bolts in the order of
the embossed numbers on the camshaft cap.
_
5 - 14
CAMSHAFTS
ENG
CAUTION:
_
The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft cap, and camshafts will result.
6. Install:
• timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
b. With the timing chain tensioner rod turned
all the way into the timing chain tensioner
housing (with the thin screwdriver still
installed), install the gasket and the timing
chain tensioner 2 onto the cylinder block.
3
WARNING
_
1
3
Always use a new gasket.
c. Tighten the timing chain tensioner bolts 3
to the specified torque.
2
T.
Timing chain tensioner bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
d. Remove the screwdriver, make sure the timing chain tensioner rod releases, and then
tighten the cap bolt to the specified torque.
T.
Cap bolt
7 Nm (0.7 m · kg, 5.1 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Tighten:
• camshaft sprocket bolts 1
T.
R.
1
1
5 - 15
20 Nm (2.0 m · kg, 14 ft · lb)
CAMSHAFTS
ENG
8. Turn:
• crankshaft
(turn the primary sheave nut on the left side
of the crankshaft several turns counterclockwise)
9. Check:
• “I” mark
Make sure the “I” mark on the generator
rotor is aligned with the stationary pointer
on the generator rotor cover.
• camshaft sprocket punch marks
Make sure the punch marks on the camshaft sprockets are aligned with the cylinder
head mating surface.
Out of alignment → Adjust.
Refer to the installation steps above.
10.Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
5 - 16
CYLINDER HEAD
ENG
EAS00221
CYLINDER HEAD
T.
R.
R.
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
5
4
6
10
1
New
7
9
3
8 New
2
9
E
T.
E
R.
T.
R.
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
Order
1
2
3
4
5
6
12 Nm (1.2 m • kg, 8.7 ft • Ib)
52 Nm (5.2 m • kg, 37 ft • Ib)
Job/Part
Removing the cylinder head
Exhaust pipe and muffler
Coolant
Thermostat
Camshafts
Coolant temperature sensor
Air induction system pipe
Gasket
Throttle body joint
Intake manifold
Gasket
Q’ty
1
1
1
1
1
1
5 - 17
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “THERMOSTAT” in chapter 6.
Refer to “CAMSHAFTS”.
CYLINDER HEAD
T.
R.
R.
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
ENG
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
5
4
6
10
1
New
7
9
3
8 New
2
9
E
T.
E
R.
T.
R.
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
Order
7
8
9
10
12 Nm (1.2 m • kg, 8.7 ft • Ib)
52 Nm (5.2 m • kg, 37 ft • Ib)
Job/Part
Cylinder head
Cylinder head gasket
Dowel pin
Timing chain guide (exhaust side)
Q’ty
Remarks
1
Refer to “REMOVING THE CYLINDER
HEAD” and “INSTALLING THE CYLINDER HEAD”.
1
Refer to “INSTALLING THE CYLINDER
2
HEAD”.
1
For installation, reverse the removal procedure.
5 - 18
CYLINDER HEAD
ENG
EAS00222
4
2
REMOVING THE CYLINDER HEAD
1. Remove:
• cylinder head nuts
NOTE:
• Loosen the cylinder head nuts in the proper
sequence as shown.
• Loosen each cylinder head nut 1/2 of a turn
at a time. After all of the cylinder head nuts
are fully loosened, remove them.
_
1
3
EAS00229
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• spark plug bore threads
• valve seats
_
2. Check:
• cylinder head
Damage/scratches → Replace.
• cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylinder head.
1
Maximum cylinder head warpage
0.05 mm (0.002 in)
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 19
CYLINDER HEAD
ENG
CHECKING THE TIMING CHAIN GUIDE
(EXHAUST SIDE)
1. Check:
• timing chain guide (exhaust side)
Damage/wear → Replace.
EAS00232
INSTALLING THE CYLINDER HEAD
1. Install:
• timing chain guide (exhaust side)
• cylinder head gasket New
• dowel pins
2. Install:
• cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
_
1
3. Tighten:
• cylinder head nuts 1
3
T.
R.
1
• cylinder head nuts 2
2
2
T.
R.
4
40 Nm (4.0 m · kg, 29 ft · lb)
52 Nm (5.2 m · kg, 37 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.
_
5 - 20
VALVES AND VALVE SPRINGS
ENG
EAS00236
VALVES AND VALVE SPRINGS
E
3
1
2
3
4
1
2
3
M
4
5
6
7
M
E
3
5
6
M
7
New
10
New
M
10
M
8
9
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the valves and valve
springs
Cylinder head
Valve lifter
Adjusting pad
Valve cotter
Upper valve spring seat
Valve spring
Stem seal
Lower valve spring seat
Exhaust valve
Intake valve
Valve guide
M
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
4
4
8
4
4
4
4
2
2
4
Refer to “REMOVING THE VALVES”
and “INSTALLING THE VALVES”.
For installation, reverse the removal procedure.
5 - 21
VALVES AND VALVE SPRINGS
ENG
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
_
1. Remove:
• valve lifter 1
• valve pad 2
NOTE:
Make a note of the position of each valve lifter
and 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”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat
1.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
3
3. Remove:
• valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment 3.
_
1
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor attachment
90890-01243, YM-01253-1
5 - 22
VALVES AND VALVE SPRINGS
4.
•
•
•
•
•
ENG
Remove:
upper spring seat 1
valve spring 2
valve stem seal 3
lower spring seat 4
valve 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
_
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
• valve-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>: 0.080 mm (0.0032 in)
Exhaust
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
<Limit>: 0.100 mm (0.0039 in)
5 - 23
VALVES AND VALVE SPRINGS
ENG
2. Replace:
• valve 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 (5 mm)
90890-04097, YM-04097
Valve guide installer (5 mm)
90890-04098, YM-04098
Valve guide reamer (5 mm)
90890-04099, YM-04099
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear → Grind the valve face.
• valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace the
valve.
5. Measure:
• valve margin thickness a
Out of specification → Replace the valve.
Valve margin thickness
0.85 ~ 1.15 mm
(0.0394 ~ 0.0472 in)
5 - 24
VALVES AND VALVE SPRINGS
ENG
6. Measure:
• valve stem runout
Out of specification → Replace the valve.
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always
replace the oil seal.
_
Valve stem runout
0.01 mm (0.0004 in)
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 limit
1.6 mm (0.06 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
5 - 25
VALVES AND VALVE SPRINGS
ENG
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• valve face
• valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound a to the
valve face.
CAUTION:
_
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
NOTE:
For the best lapping results, lightly tap the
valve seat while rotating the valve back and
forth between your hands.
_
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
5 - 26
VALVES AND VALVE SPRINGS
ENG
j. Measure the valve seat width again. If the
valve seat width is out of specification,
reface and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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
46.45 mm (1.83 in)
<Limit>: 44.13 mm (1.74 in)
2. Measure:
• compressed valve spring force a
Out of specification → Replace the valve
spring.
b Installed length
Compressed valve spring force
(installed)
160.5 ~ 184.7 N at 35.10 mm
(16.37 ~ 18.83 kg at 35.10 mm,
36.08 ~ 41.52 lb at 1.38 in)
5 - 27
VALVES AND VALVE SPRINGS
ENG
3. Measure:
• valve spring tilt a
Out of specification → Replace the valve
spring.
Spring tilt limit
2.0 mm (0.08 in)
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:
• valve lifter
Damage/scratches → Replace the valve lifters and cylinder head.
EAS00245
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)
2. Lubricate:
• valve stem 1
• valve stem seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
5
2
4
1
3.
•
•
•
•
•
3
5 - 28
Install:
valve 1
lower spring seat 2
valve stem seal 3
valve spring 4
upper spring seat 5
(into the cylinder head)
VALVES AND VALVE SPRINGS
ENG
NOTE:
Install the valve spring with the larger pitch a
facing up.
_
b Smaller pitch
4. Install:
• valve cotters 1
2
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment 3.
3
_
1
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor attachment
90890-01243, YM-01253-1
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
_
Hitting the valve tip with excessive force
could damage the valve.
6. Install:
• valve pad 1
• valve lifter 2
NOTE:
• Lubricate the valve lifter and valve pad with
molybdenum disulfide oil.
• The valve lifter must move smoothly when
rotated with a finger.
• Each valve lifter and valve pad must be reinstalled in its original position.
_
2
1
5 - 29
CYLINDER AND PISTON
ENG
EAS00251
CYLINDER AND PISTON
7 New
9
10
8
New 7
E
6
E
4
6
LS
New
T.
R.
T.
•
3
•
T.
R.
R.
1
2
3
4
5
6
7
8
9
10
2
7 Nm (0.7 m kg, 5.1 ft Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
5 New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the cylinder and piston
Cylinder head
Water jacket inlet pipe
O-ring
Air induction system pipe stay bolt
Cylinder
Cylinder gasket
Dowel pin
Piston pin clip
Piston pin
Piston
Piston ring set
Q’ty
1
1
1
1
1
2
2
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “INSTALLING THE PISTON
AND CYLINDER”.
Refer to “REMOVING THE PISTON”
and “INSTALLING THE PISTON AND
CYLINDER”.
For installation, reverse the removal procedure.
5 - 30
CYLINDER AND PISTON
ENG
EAS00253
2
1
REMOVING THE PISTON
1. Remove:
• piston pin clip 1
• piston pin 2
• piston 3
CAUTION:
_
3
Do not use a hammer to drive the piston
pin out.
NOTE:
• 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.
• Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area. If both areas are deburred and the
piston pin is still difficult to remove, remove it
with the piston pin puller set 4.
_
Piston pin puller set
90890-01304, YU-01304
2.
•
•
•
Remove:
top ring
2nd ring
oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
_
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.
5 - 31
CYLINDER AND PISTON
ENG
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the measurements.
_
Cylinder bore “C”
83.000 ~ 83.010 mm
(3.2677 ~ 3.2681 in)
Taper limit “T”
0.05 mm (0.002 in)
“C” = maximum of D1 ~ D2
“T” = maximum of D1 or D2 – maximum of
D5 or D6
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a 5 mm (0.20 in) from the bottom edge of the piston
Piston size “P”
Standard
82.930 ~ 82.945 mm
(3.2650 ~ 3.2656 in)
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.060 ~ 0.075 mm
(0.0024 ~ 0.0030 in)
<Limit>: 0.15 mm (0.0059 in)
f. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 32
CYLINDER AND PISTON
ENG
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
• piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
_
Piston ring side clearance
Top ring
0.030 ~ 0.070 mm
(0.0012 ~ 0.0028 in)
<Limit>: 0.100 mm (0.0039 in)
2nd ring
0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)
<Limit>: 0.100 mm (0.0039 in)
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
_
a 40 mm (1.6 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
0.20 ~ 0.35 mm
(0.0079 ~ 0.0138 in)
<Limit>: 0.50 mm (0.0197 in)
2nd ring
0.40 ~ 0.55 mm
(0.0157 ~ 0.0217 in)
<Limit>: 0.80 mm (0.0315 in)
Oil ring
0.10 ~ 0.40 mm
(0.0039 ~ 0.0157 in)
5 - 33
CYLINDER AND PISTON
ENG
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
19.991 ~ 20.000 mm
(0.7870 ~ 0.7874 in)
<Limit>: 19.971 mm (0.7863 in)
3. Measure:
• piston pin bore diameter b (in the piston)
Out of specification → Replace the piston.
Piston pin bore diameter
20.004 ~ 20.015 mm
(0.7876 ~ 0.7880 in)
<Limit>: 20.045 mm (0.7892 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-pin-bore
clearance
0.004 ~ 0.024 mm
(0.0002 ~ 0.0009 in)
<Limit>: 0.074 mm (0.0029 in)
EAS00267
INSTALLING THE PISTON AND CYLINDER
1. Install:
• top ring
• 2nd ring
• lower oil ring rail
• upper oil ring rail
• oil ring expander
5 - 34
CYLINDER AND PISTON
ENG
NOTE:
Be sure to install the top and 2nd rings so that
the manufacturer’s marks or numbers face up.
_
2
3
New
a
1
2.
•
•
•
Install:
piston 1
piston pin 2
piston pin clips 3
New
NOTE:
• Apply engine oil onto the piston pin.
• Make sure the arrow mark a on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent the clip from falling into the crankcase.
_
3.
•
•
4.
•
•
•
Install:
cylinder gasket New
dowel pins
Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5.
•
•
•
Position:
top ring
2nd ring
oil ring
Offset the piston ring end gaps as shown.
a Top ring end
b Upper oil ring rail end
c Oil ring expander end
d Lower oil ring rail end
e 2nd ring end
f 20 mm (0.79 in)
5 - 35
CYLINDER AND PISTON
Install:
dowel pins
cylinder gasket New
cylinder
10 Nm (1.0 m · kg, 7.2 ft · lb)
cylinder bolt
T.
R.
6.
•
•
•
•
ENG
NOTE:
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
_
5 - 36
BELT DRIVE
ENG
EAS00316
BELT DRIVE
V-BELT CASE COVER
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
LT
7
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(9)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
6
(6)
5
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
T.
R.
22 Nm (2.2 m • kg, 16 ft • Ib)
3
(4)
1
2
(4)
Order
Job/Part
Removing the V-belt case cover
Side cover (left)
Q’ty
Air filter case (left)
1
2
3
4
5
6
7
V-belt case air filter cover
V-belt case air filter element
V-belt case cover
V-belt case gasket
V-belt case
V-belt case air duct 1
V-belt case air duct 2
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVERS” in
chapter 3.
Refer to “AIR FILTER CASES” in chapter
3.
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5 - 37
BELT DRIVE
ENG
V-BELT AND PRIMARY/SECONDARY SHEAVE
* Apply Shell BT grease 3®
(YAMAHA grease G 90890-40010)
** Apply BEL-RAY assembly lube®
Order
1
2
Job/Part
Removing the V-belt and primary/
secondary sheave
Primary sheave nut/collar
Primary fixed sheave
3
4
5
6
7
8
9
10
Secondary sheave nut
Collar
Clutch housing
Secondary sheave assembly
V-belt
Primary sliding sheave
Spacer
Cam
Q’ty
1/1
1
1
1
1
1
1
1
1
1
5 - 38
Remarks
Remove the parts in the order listed.
Refer to “REMOVING THE PRIMARY
SHEAVE” and “INSTALLING THE SECONDARY SHEAVE, V-BELT AND PRIMARY SHEAVE”.
Refer to “REMOVING THE SECONDARY SHEAVE AND V-BELT” and
“INSTALLING THE SECONDARY
SHEAVE, V-BELT AND PRIMARY
SHEAVE”.
BELT DRIVE
ENG
* Apply Shell BT grease 3®
(YAMAHA grease G 90890-40010)
** Apply BEL-RAY assembly lube®
Order
11
12
13
14
Job/Part
Weight
Slider
Spacer
O-ring
Q’ty
8
4
1
1
Remarks
For installation, reverse the removal
procedure.
5 - 39
BELT DRIVE
ENG
SECONDARY SHEAVE
** Apply BEL-RAY assembly lube®
Order
1
2
Job/Part
Disassembling the secondary
sheave
Clutch shoe assembly nut
Clutch shoe assembly
3
4
5
6
7
8
9
0
A
Clutch shoe spring
Compression spring
Spring seat
Guide pin
Secondary sliding sheave
O-ring
Oil seal
Secondary fixed sheave
Bearing
Q’ty
1
1
3
1
1
4
1
2
2
1
1
5 - 40
Remarks
Remove the parts in the order listed.
Refer to “DISASSEMBLING THE SECONDARY SHEAVE” and “ASSEMBLING
THE SECONDARY SHEAVE”.
Refer to “ASSEMBLING THE SECONDARY SHEAVE”.
BELT DRIVE
ENG
** Apply BEL-RAY assembly lube®
Order
B
C
Job/Part
Circlip
Bearing
Q’ty
1
1
Remarks
For assembly, reverse the disassembly
procedure.
5 - 41
BELT DRIVE
ENG
EAS00317
REMOVING THE PRIMARY SHEAVE
1. Remove:
• primary sheave nut 1
• collar
• primary fixed sheave 2
3
NOTE:
While holding the primary fixed sheave with
the rotor holding tool 3, loosen the primary
sheave nut.
_
2 1
Rotor holding tool
90890-01235, YU-01235
EAS00318
REMOVING THE SECONDARY SHEAVE
AND V-BELT
1. Remove:
• secondary sheave nut 1
• collar
• clutch housing 2
2
1
3
NOTE:
While holding the clutch housing with the
sheave holder 3, loosen the secondary
sheave nut.
_
Sheave holder
90890-01701, YS-01880-A
5 - 42
BELT DRIVE
2
ENG
2. Loosen:
• clutch shoe assembly nut 1
CAUTION:
_
Do not remove the clutch shoe assembly
nut at this stage.
3
NOTE:
While holding the clutch shoe assembly with
the rotor holding tool 2, loosen the clutch
shoe assembly nut one full turn with the locknut wrench 3.
_
1
Rotor holding tool
90890-01235, YU-01235
Locknut wrench
90890-01348, YM-01348
3. Remove:
• secondary sheave assembly 1
• V-belt 2
NOTE:
Remove the V-belt and secondary sheave
assembly from the primary sheave side.
_
2
1
EAS00319
2
1
DISASSEMBLING THE SECONDARY
SHEAVE
1. Remove:
• clutch shoe assembly nut 1
NOTE:
Install the sheave spring compressor 2 and
sheave fixed block 3 onto the secondary
sheave assembly as shown. Then, compress
the spring, and remove the clutch shoe assembly nut.
_
3
Sheave spring compressor
90890-04134, YM-04134
Sheave fixed block
90890-04135, YM-04135
5 - 43
BELT DRIVE
ENG
EAS00320
CHECKING THE V-BELT
1. Check:
• V-belt 1
Cracks/damage/wear → Replace.
Grease/oil → Clean the primary and secondary sheaves.
2. Measure:
• V-belt width 2
Out of specification → Replace.
V-belt width
30 mm (1.18 in)
<Limit>: 27 mm (1.06 in)
CHECKING THE V-BELT CASE AIR DUCTS
1. Check:
• V-belt case air ducts
Cracks/damage → Replace.
CHECKING THE PRIMARY SHEAVE
1. Check:
• primary fixed sheave
• primary sliding sheave
• spacer
Cracks/damage/wear → Replace.
NOTE:
Replace the primary sliding sheave and spacer
as a set.
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
Out of specification → Replace.
Primary sheave weight outside
diameter
25.0 mm (0.98 in)
<Limit>: 24.5 mm (0.96 in)
5 - 44
BELT DRIVE
ENG
EAS00322
CHECKING THE SECONDARY SHEAVE
1. Check:
• secondary fixed sheave
• secondary sliding sheave
Cracks/damage/wear → Replace the secondary fixed and sliding sheaves as a set.
2. Check:
• torque cam groove 1
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.
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.
Clutch shoe thickness
4.0 mm (0.16 in)
<Limit>: 2.5 mm (0.10 in)
NOTE:
After sanding the glazed areas, clean the
clutch with a cloth.
2. Measure:
• clutch shoe thickness
Out of specification → Replace the clutch
shoes and springs as a set.
5 - 45
BELT DRIVE
ENG
EAS00323
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
• primary fixed sheave 1
• primary sliding sheave 2
• collar 3
• primary sheave weights 4
• cam
2. Lubricate:
• collar’s inner and outer surface
Recommended lubricant
BEL-RAY assembly lube
3.
•
•
4.
•
•
Install:
primary sheave weights
collar
Install:
sliders
cam
EAS00324
ASSEMBLING THE SECONDARY SHEAVE
1. Lubricate:
• secondary fixed sheave’s inner surface 1
• secondary sliding sheave’s inner surface 2
• oil seals
• bearings
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube
3
1
2
2. Install:
• secondary sliding sheave 1
NOTE:
Install the secondary sliding sheave onto the
secondary fixed sheave 2 with the oil seal
guide 3.
_
Oil seal guide
90890-01396
5 - 46
BELT DRIVE
3.
•
4.
•
•
ENG
Install:
guide pin 1
Lubricate:
guide pin groove 2
O-ring 3 New
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube
5.
•
•
•
•
2
1
Install:
spring seat
compression spring
clutch shoe assembly
clutch shoe assembly nut 1
NOTE:
Attach the sheave spring compressor 2 and
sheave fixed block 3 onto the secondary
sheave assembly as shown. Then, compress
the spring, and tighten the clutch shoe assembly nut.
_
3
Sheave spring compressor
90890-04134, YM-04134
Sheave fixed block
90890-04135, YM-04135
EAS00325
INSTALLING THE SECONDARY SHEAVE,
V-BELT AND PRIMARY SHEAVE
1. Install:
• V-belt 1
• secondary sheave assembly 2
CAUTION:
_
1
2
Do not allow grease to contact the V-belt
and the secondary sheave assembly.
NOTE:
• Install the V-belt onto the primary sheave
side.
• Install the V-belt with the printed arrow mark
on the V-belt facing in the direction shown in
the illustration.
_
5 - 47
BELT DRIVE
ENG
2. Tighten:
• clutch shoe assembly nut 1
2
T.
R.
90 Nm (9.0 m · kg, 65 ft · lb)
NOTE:
While holding the clutch shoe assembly with
the rotor holding tool 2, tighten the clutch
shoe assembly nut with the locknut wrench 3.
_
3
1
Rotor holding tool
90890-01235, YU-01235
Locknut wrench
90890-01348, YM-01348
1
3.
•
•
•
2
Install:
clutch housing 1
collar
secondary sheave nut 2
T.
R.
3
60 Nm (6.0 m · kg, 43 ft · lb)
NOTE:
While holding the clutch housing with the
sheave holder 3, tighten the secondary
sheave nut.
Sheave holder
90890-01701, YS-01880-A
4.
•
•
•
•
Install:
V-belt
primary fixed sheave
collar
primary sheave nut
T.
R.
1
2
83 Nm (8.3 m · kg, 60 ft · lb)
NOTE:
• Install the V-belt onto the primary sheave 1
(when the pulley is at its widest position) and
onto the secondary sheave assembly 2
(when the pulley is at its narrowest position),
and make sure the V-belt is tight.
• While holding the primary fixed sheave with
the rotor holding tool, tighten the primary
sheave nut.
Rotor holding tool
90890-01235, YU-01235
5 - 48
STARTER CLUTCH AND GENERATOR
ENG
EAS00341
STARTER CLUTCH AND GENERATOR
GENERATOR ROTOR COVER AND STATOR COIL
Order
Job/Part
Removing the generator rotor cover
and stator coil
Side cover (right)
Q’ty
Engine oil
Coolant
Exhaust pipe and muffler
Air cut-off valve
1
2
Crankcase breather hose
Thermostat inlet hose
1
1
5 - 49
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “ENGINE REMOVAL”.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Disconnect.
Disconnect.
STARTER CLUTCH AND GENERATOR
Order
3
4
5
6
Job/Part
Water pump inlet hose
Oil cooler outlet hose
Crankshaft position sensor/stator
assembly coupler
Generator rotor cover
7
8
9
10
Gasket
Dowel pin
Stator coil
Crankshaft position sensor
Q’ty
1
Disconnect.
1
Disconnect.
2
Disconnect.
1
1
2
1
1
5 - 50
ENG
Remarks
Refer to “INSTALLING THE GENERATOR”.
Refer to “INSTALLING THE GENERATOR”.
For installation, reverse the removal procedure.
STARTER CLUTCH AND GENERATOR
ENG
EAS00343
STARTER CLUTCH AND GENERATOR
Order
1
2
3
4
5
6
Job/Part
Removing the starter clutch and
generator
Generator rotor
Starter clutch
Woodruff key
Starter clutch gear
Starter clutch idle gear shaft
Starter clutch idle gear
Q’ty
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “REMOVING THE GENERATOR”, “INSTALLING THE STARTER
CLUTCH” and “INSTALLING THE GENERATOR”.
For installation, reverse the removal procedure.
5 - 51
STARTER CLUTCH AND GENERATOR
ENG
EAS00347
REMOVING THE GENERATOR
1. Remove:
• generator rotor cover bolts
• generator rotor cover
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
2.
•
•
•
1
4
3
2
Remove:
generator rotor nut 1
washer
starter clutch bolts 2
NOTE:
• While holding the generator rotor 3 with the
sheave holder 4, loosen the generator rotor
nut and all starter clutch bolts.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
• Remove every other starter clutch bolt (3
bolts only) to install the flywheel puller.
_
Sheave holder
90890-01701, YS-01880-A
2
1
3. Remove:
• generator rotor 1
(with the starter clutch 2)
• woodruff key
• starter clutch gear
CAUTION:
_
To protect the end of the crankshaft, place
an appropriate sized socket between the
flywheel puller set’s center bolt and the
crankshaft.
NOTE:
• Install the flywheel puller bolts to the
threaded holes of the starter clutch.
• Make sure the flywheel puller is centered
over the generator rotor.
_
5 - 52
STARTER CLUTCH AND GENERATOR
ENG
Flywheel puller
90890-01362
Flywheel puller attachment
90890-04089, YM-33282
4. Remove:
• starter clutch bolts
• starter clutch
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch rollers 1
Damage/wear → Replace.
2. Check:
• starter clutch idle gear
• starter clutch gear
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• starter clutch gear’s contacting surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch drive gear 1 onto
the starter clutch 2 and hold the starter
clutch.
b. When turning the starter clutch drive gear
clockwise È, the starter clutch and the
starter clutch drive gear should engage,
otherwise the starter clutch is faulty and
must be replaced.
c. When turning the starter clutch drive gear
counterclockwise É, it should turn freely,
otherwise the starter clutch is faulty and
must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 53
STARTER CLUTCH AND GENERATOR
ENG
EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:
• starter clutch bolts 1
LT
T.
R.
30 Nm (3.0 m · kg, 22 ft · lb)
NOTE:
• While holding the generator rotor 2 with the
sheave holder 3, tighten the starter clutch
bolts.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
_
Sheave holder
90890-01701, YS-01880-A
EAS00354
INSTALLING THE GENERATOR
1. Install:
• starter clutch gear 1
• woodruff key 2
• generator rotor
• washer
• generator rotor nut
1
2
NOTE:
• Clean the tapered portion of the crankshaft
and the generator rotor hub.
• When installing the generator rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
_
1
2. Tighten:
• generator rotor nut 1
3
T.
2
R.
130 Nm (13.0 m · kg, 94 ft · lb)
NOTE:
• While holding the generator rotor 2 with the
sheave holder 3, tighten the generator rotor
nut.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
_
Sheave holder
90890-01701, YS-01880-A
5 - 54
STARTER CLUTCH AND GENERATOR
ENG
3. Apply:
• sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)
Yamaha bond No. 1215
90890-85505
Sealant (Quick Gasket®)
ACC-11001-05-01
4. Install:
• generator rotor cover
• generator rotor cover bolts
T.
R.
a
b
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
• Align the projection a on the impeller shaft
with the slit b on the balancer shaft.
• Tighten the generator rotor cover bolts in
stages and in a crisscross pattern.
5 - 55
OIL PUMP
ENG
EAS00356
OIL PUMP
Order
Job/Part
Removing the oil pump
Generator rotor
Q’ty
1
Oil pump assembly
1
2
3
4
5
Oil pump gasket
Oil pump driven sprocket
Oil pump drive chain
Oil pump drive sprocket
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “STARTER CLUTCH AND GENERATOR”.
Refer to “ASSEMBLING THE OIL PUMP”
and “INSTALLING THE OIL PUMP”.
Refer to “INSTALLING THE OIL PUMP”.
For installation, reverse the removal procedure.
5 - 56
OIL PUMP
ENG
EAS00364
CHECKING THE OIL PUMP
1. Check:
• oil pump drive sprocket
• oil pump driven sprocket
• 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-and-outerrotor clearance c
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.07 mm (0.0028 in)
<Limit>: 0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-housing
clearance
0.013 ~ 0.036 mm
(0.0005 ~ 0.0014 in)
<Limit>: 0.106 mm (0.0042 in)
Oil-pump-housing-to-inner-rotorand-outer-rotor clearance
0.040 ~ 0.096 mm
(0.0016 ~ 0.0038 in)
<Limit>: 0.166 mm (0.0065 in)
3. Check:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
CHECKING THE OIL PUMP DRIVE CHAIN
1. Check:
• oil pump drive chain
Cracks/stiffness → Replace the oil pump
chain, oil pump drive and driven sprocket as
a set.
5 - 57
OIL PUMP
ENG
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:
• oil pump shaft 1
(to the oil pump cover 2)
• pin 3
• inner rotor 4
• outer rotor 5
• oil pump housing 6
• screw
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:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
a
INSTALLING THE OIL PUMP
1. Install:
• oil pump gasket New
• oil pump assembly
T.
R.
b
7 Nm (0.7 m · kg, 5.1 ft · lb)
CAUTION:
_
After tightening the bolts, make sure the oil
pump turns smoothly.
NOTE:
Align the projection a on the oil pump shaft
with the slot in the oil pump driven gear shaft.
_
5 - 58
ENG
CRANKSHAFT
EAS00381
CRANKSHAFT
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ASSEMBLY
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
8
LT
2
E
5
E
LT
9
4
3
12
1
New
6
8
7
New
11
E
10
(3)
(7)
E
13
R.
T.
New
T.
14
30 Nm (3.0 m • kg, 22 ft • Ib)
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
Order
1
2
3
Job/Part
Removing the crankshaft assembly
and balancer shaft assembly
Engine
Cylinder and piston
Belt drive
Oil pump
Transmission
Timing chain
Timing chain guide (intake side)
Right crankcase
4
5
Crankshaft assembly
Balancer shaft assembly
Q’ty
16 Nm (1.6 m • kg, 11 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER AND PISTON”.
Refer to “BELT DRIVE”.
Refer to “OIL PUMP”.
Refer to “TRANSMISSION”.
1
1
1
1
1
5 - 59
Refer to “DISASSEMBLING THE
CRANKCASE” and “ASSEMBLING THE
CRANKCASE”.
Refer to “INSTALLING THE CRANKSHAFT ASSEMBLY AND BALANCER
SHAFT ASSEMBLY”.
ENG
CRANKSHAFT
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
8
LT
2
E
5
E
LT
9
4
3
12
1
New
6
8
7
New
11
E
10
(3)
(7)
E
13
R.
T.
New
T.
14
30 Nm (3.0 m • kg, 22 ft • Ib)
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
Order
6
7
8
9
10
11
12
13
14
Job/Part
Dowel pin
O-ring
Dowel pin
Left crankcase
Relief valve assembly
Oil pump drive gear
Oil pump drive gear shaft
Oil pump driven gear
Oil pump driven gear shaft
Q’ty
1
1
2
1
1
1
1
1
1
16 Nm (1.6 m • kg, 11 ft • Ib)
Remarks
For installation, reverse the removal procedure.
5 - 60
CRANKSHAFT
ENG
CRANKCASE BEARINGS
2
2
E
1
1
E
LS
3 New
Order
1
Job/Part
Removing the crankcase bearings
Crankshaft journal bearing
2
3
Bearing
Oil seal
Q’ty
2
Remarks
Remove the parts in the order listed.
Refer to “REMOVING THE CRANKSHAFT JOURNAL BEARINGS” and
“INSTALLING THE CRANKSHAFT
JOURNAL BEARINGS”.
2
1
For installation, reverse the removal procedure.
5 - 61
CRANKSHAFT
ENG
EAS00385
DISASSEMBLING THE CRANKCASE
1. Remove:
• crankcase bolts
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:
• right crankcase
CAUTION:
_
Tap on one side of the crankcase with a
soft-face 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.
EAS00387
2
1
REMOVING THE CRANKSHAFT JOURNAL
BEARINGS
1. Remove:
• crankshaft journal bearings 1
NOTE:
Remove the journal bearings with the plane
bearing installer/remover 2.
Plane bearing installer/remover
90890-04146
2
NOTE:
Identify the position of each crankshaft journal
bearing so that they can be reinstalled in their
original places.
1
5 - 62
CRANKSHAFT
ENG
EAS00394
CHECKING THE CRANKSHAFT AND
CONNECTING ROD
1. Measure:
• crankshaft runout
Out of specification → Replace the crankshaft, bearing or both.
NOTE:
Turn the crankshaft slowly.
_
Maximum crankshaft runout
0.030 mm (0.0012 in)
2. Check:
• crankshaft journal surfaces
Scratches/wear → Replace the crankshaft.
3. Measure:
• big end side clearance
Out of specification → Replace the big end
bearing, crankshaft pin, or connecting rod.
Big end side clearance
0.350 ~ 0.850 mm
(0.0138 ~ 0.0335 in)
4. Measure:
• crankshaft-journal-to-crankshaft-journalbearing clearance
Out of specification → Replace the crankshaft journal bearings as a set.
Crankshaft-journal-to-crankshaftjournal-bearing clearance
0.030 ~ 0.077 mm
(0.0012 ~ 0.0030 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The following procedure applies to each
crankshaft journal and its corresponding
journal bearing.
a. Clean the surface of the journal and the
journal bearing.
b. Check the bearing surface. If the bearing
surface is worn or scratched, replace the
bearings as a set.
5 - 63
CRANKSHAFT
ENG
NOTE:
If either the left or right journal bearing is worn
or scratched, replace both bearings as a set.
a
c. Measure the crankshaft journal outside
diameter a in two places. If it is out of specification, replace the crankshaft.
d. Measure the journal bearing inside diameter b in two places.
CAUTION:
When calculating the journal oil clearance,
use the larger of the two values from the
crankshaft journal and use the smaller of
the two values from the journal bearing.
b
e. If the journal bearing inside diameter is
“35.064” and the crankshaft journal outside
diameter is “35.014”, then the journal oil
clearance is:
Journal oil clearance:
Journal bearing inside diameter –
Crankshaft journal outside diameter =
35.064 – 35.014 = 0.050 mm
If the oil clearance is out of specification,
select replacement bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
È
1
5. Select:
• crankshaft journal bearings
NOTE:
The numbers 1 on the crankcase are used to
determine the replacement crankshaft journal
bearing size.
È Left crankcase
É Right crankcase
É
1
5 - 64
CRANKSHAFT
ENG
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Select the crankshaft journal bearings from the
following table according to the number
stamped on the inside of the crankcase.
BEARING COLOR
CODE
0
white
1
blue
2
black
3
brown
4
green
BEARING
THICKNESS
1.981 ~ 1.991 mm
(0.0780 ~ 0.0784 in)
1.977 ~ 1.987 mm
(0.0778 ~ 0.0782 in)
1.973 ~ 1.983 mm
(0.0777 ~ 0.0781 in)
1.969 ~ 1.979 mm
(0.0775 ~ 0.0779 in)
1.965 ~ 1.975 mm
(0.0774 ~ 0.0778 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Measure:
• crankshaft width
Out of specification → Replace the crankshaft.
Crankshaft width
63.95 ~ 64.00 mm
(2.518 ~ 2.520 in)
7. Check:
• crankshaft sprocket 1
Damage/wear → Replace the crankshaft.
• balancer drive gear 2
Damage/wear → Replace the crankshaft.
2
1
8. Check:
• crankshaft journal
Scratches/wear → Replace the crankshaft.
• crankshaft journal oil passage
Obstruction → Blow out with compressed
air.
5 - 65
CRANKSHAFT
ENG
CHECKING THE BALANCER SHAFT
ASSEMBLY
1. Check:
• balancer shaft assembly
Cracks/damage → Replace.
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• crankcase
Cracks/damage → Replace.
• oil delivery passages
Obstruction → Blow out with compressed
air.
EAS00207
CHECKING THE TIMING CHAIN AND
TIMING CHAIN GUIDE (INTAKE SIDE)
1. Check:
• timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprockets as a set.
2. Check:
• timing chain guide (intake side)
Damage/wear → Replace.
5 - 66
CRANKSHAFT
ENG
CHECKING THE OIL PUMP GEARS AND
SHAFTS
1. Check:
• oil pump drive gear
• oil pump driven gear
• oil pump drive gear shaft
• oil pump driven gear shaft
Cracks/damage/wear → Replace the defective part(s).
EAS00365
3
2
1
CHECKING THE RELIEF VALVE
1. Check:
• relief valve body 1
• relief valve 2
• spring 3
Damage/wear → Replace the defective
part(s).
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
2. Check:
• oil seals
Damage/wear → Replace.
EAS00402
CHECKING THE CIRCLIPS AND WASHERS
1. Check:
• circlips
Bends/damage/looseness → Replace.
• washers
Bends/damage → Replace.
5 - 67
CRANKSHAFT
ENG
INSTALLING THE CRANKSHAFT JOURNAL
BEARINGS
1. Attach:
• crankshaft journal bearings 1
a
NOTE:
Attach the crankshaft journal bearing to the
installer 2.
Plane bearing installer/remover
90890-04146
2. Install:
• crankshaft journal bearings
2
NOTE:
• Install each crankshaft journal bearing from
the inside of the crankcase with the notch a
facing inward.
• To install the crankshaft journal bearings,
press each bearing into the crankcase as
shown in the illustration.
1
b 1.9 ~ 2.7 mm (0.075 ~ 0.106 in)
3 Left crankcase
4 Right crankcase
b
b
3
4
EAS00410
b
a
INSTALLING THE CRANKSHAFT
ASSEMBLY AND BALANCER SHAFT
ASSEMBLY
1. Install:
• crankshaft assembly
• balancer shaft assembly
NOTE:
Align the punch mark a in the balancer drive
gear with the punch mark b in the balancer
driven gear.
_
5 - 68
CRANKSHAFT
ENG
EAS00418
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.
2. Apply:
• sealant
(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.
_
2 3
5
4
1
5
3. Tighten:
• crankcase bolts
NOTE:
Tighten the crankcase bolts in stages and in a
crisscross pattern.
•
•
•
•
•
5
M8 × 100 mm (3.94 in) bolt: 1
M8 × 90 mm (3.54 in) bolt: 2
M8 × 80 mm (3.15 in) bolt: 3
M8 × 60 mm (2.36 in) bolts: 4
M6 × 70 mm (2.76 in) bolts: 5
T.
R.
5 - 69
Crankcase bolt
Bolt 1
30 Nm (3.0 m · kg, 22 ft · lb)
Bolt 2 ~ 4
16 Nm (1.6 m · kg, 11 ft · lb)
Bolt 5
10 Nm (1.0 m · kg, 7.2 ft · lb)
TRANSMISSION
ENG
EAS00419
TRANSMISSION
Order
Job/Part
Removing the transmission
Rear wheel
Q’ty
Transmission oil
1
2
3
4
5
6
7
Secondary sheave assembly
Transmission case cover
Transmission case cover gasket
Dowel pin
Primary drive gear
Washer
Washer
1st wheel gear
1
1
2
1
1
1
1
5 - 70
Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL AND BRAKE
DISC” in chapter 4.
Drain.
Refer to “CHANGING THE TRANSMISSION OIL” in chapter 3.
Refer to “BELT DRIVE”.
TRANSMISSION
Order
8
9
10
11
12
Job/Part
Drive axle
Main axle
Washer
Primary driven gear
Washer
Q’ty
1
1
1
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
5 - 71
TRANSMISSION
ENG
EAS00425
CHECKING THE TRANSMISSION
1. Check:
• transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
2. Check:
• transmission gear movement
Rough movement → Replace the defective
part(s).
3. Check:
• circlips
Bends/damage/looseness → Replace.
INSTALLING THE PRIMARY DRIVE GEAR
OIL SEAL
1. Install:
• primary drive gear oil seal 1
a
1
NOTE:
Press the primary drive gear oil seal into the
transmission case cover as shown in the illustration.
a 1.5 ~ 2.0 mm (0.059 ~ 0.079 in)
5 - 72
COOL
6
COOL
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 AND OIL COOLER ................................................................6-7
CHECKING THE WATER PUMP .............................................................. 6-9
CHECKING THE OIL COOLER ................................................................6-9
ASSEMBLING THE WATER PUMP........................................................ 6-10
COOL
RADIATOR
COOL
EAS00454
COOLING SYSTEM
RADIATOR
5
7
4
1
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3
T.
R.
Order
8
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Removing the radiator
Radiator cover
Q’ty
Coolant
1
2
3
4
5
6
7
8
Radiator filler hose
Coolant reservoir hose
Coolant reservoir
Radiator inlet hose
Radiator outlet hose
Radiator fan motor coupler
Radiator
Radiator fan
6
1
1
1
1
1
1
1
1
2
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
6-1
RADIATOR
COOL
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, flathead screwdriver.
_
2.
•
•
•
•
•
Check:
radiator inlet hose
radiator outlet hose
radiator filler hose
coolant reservoir hose
radiator pipe assembly
Cracks/damage → Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Radiator cap opening pressure
110.0 ~ 140.0 kPa
(1.10 ~ 1.40 kg/cm2,
15.6 ~ 19.9 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester 1 and radiator
cap tester adapter 2 to the radiator cap 3.
Radiator cap tester
90890-01325, YU-24460-01
Radiator cap tester adapter
90890-01352, YU-33984
b. Apply the specified pressure for ten seconds and make sure there is no drop in
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• radiator fan motor
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
6-2
RADIATOR
COOL
EAS00456
INSTALLING THE RADIATOR
1. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
• cooling system
Leaks → Repair or replace any faulty part.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the radiator cap tester 1 to the radiator.
1
Radiator cap tester
90890-01325, YU-24460-01
Radiator cap tester adapter
90890-01352, YU-33984
b. Apply 100 kPa (1.0 kg/cm2, 14.22 psi) of
pressure.
c. Measure the indicated pressure with the
gauge.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-3
THERMOSTAT
COOL
EAS00460
THERMOSTAT
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
4
5
2
3
1
Order
1
2
3
4
5
Job/Part
Removing the thermostat
Storage box
Rubber sheet
Coolant
Thermostat outlet hose
Cooling system air bleed hose
Thermostat inlet hose
Thermostat cover
Thermostat
Q’ty
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
6-4
THERMOSTAT
COOL
EAS00462
CHECKING THE THERMOSTAT
1. Check:
• thermostat 1
Does not open at 70.5 ~ 73.5 °C (158.9 ~
164.3 °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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 Thermostat
2 Container
3 Thermometer
4 Water
È Fully closed
É 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
Cracks/damage → Replace.
3. Check:
• thermostat inlet hose
• thermostat outlet hose
Cracks/damage → Replace.
6-5
THERMOSTAT
COOL
EAS00467
INSTALLING THE THERMOSTAT
1. Install:
• thermostat 1
• thermostat cover
1
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
2. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
3. Check:
• cooling system
Leaks → Repair or replace any faulty part.
4. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-6
WATER PUMP AND OIL COOLER
COOL
EAS00469
WATER PUMP AND OIL COOLER
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9 New
New 5
4
LS
LT
6
12
New
New 13
1
10
11
New
LT
E
New 8
7
2 New
LT
T.
R.
1
2
3
4
5
6
7
8
9
10
R.
T.
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the water pump and oil
cooler
Generator rotor cover
Q’ty
Oil cooler pipe
O-ring
Water pump outlet hose
Oil cooler cover
Oil cooler cover gasket
Generator rotor cover inner bracket
Water pump cover
O-ring
Circlip
Impeller shaft
1
2
1
1
1
1
1
1
1
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “STARTER CLUTCH AND GENERATOR” in chapter 5.
6-7
WATER PUMP AND OIL COOLER
COOL
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9 New
New 5
4
LS
LT
6
12
New
New 13
1
11
New
LT
10
E
New 8
7
2 New
LT
T.
R.
T.
R.
Order
11
12
13
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Water pump seal
Circlip
Bearing
Q’ty
1
1
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
For installation, reverse the removal procedure.
6-8
WATER PUMP AND OIL COOLER
COOL
EAS00473
CHECKING THE WATER PUMP
1. Check:
• water pump cover
• impeller shaft
• water pump seal
Cracks/damage/wear → Replace.
2. Check:
• bearing
Rough movement → Replace.
3. Check:
• water pump inlet hose
• water pump outlet hose
• thermostat inlet hose
Cracks/damage → Replace.
CHECKING THE OIL COOLER
1. Check:
• oil cooler pipe 1
Cracks/damage → Replace.
1
2. Check:
• oil cooler cover 1
Cracks/damage → Replace.
3. Check:
• oil cooler outlet hose
Cracks/damage → Replace.
1
6-9
WATER PUMP AND OIL COOLER
COOL
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
• bearing New
• circlip New
• water pump seal 1 New
(into the generator rotor cover 2)
NOTE:
Install the water pump seal with the special
tools.
_
Mechanical seal installer
90890-04145 3
Middle driven shaft bearing driver
90890-04058, YM-04058 4
È Push down.
2. Lubricate:
• water pump seal
Recommended lubricant
Lithium-soap-based grease
6 - 10
FI
7
FI
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM............................................................................7-1
WIRING DIAGRAM ................................................................................... 7-2
ECU’S SELF-DIAGNOSTIC FUNCTION................................................... 7-3
ALTERNATE INSTRUCTIONS OPERATION CONTROL
(FAIL-SAFE ACTION) ..............................................................................7-4
FAIL-SAFE ACTIONS TABLE ...................................................................7-4
TROUBLESHOOTING CHART .................................................................7-6
DIAGNOSTIC MODE ................................................................................ 7-7
TROUBLESHOOTING DETAILS ............................................................ 7-12
THROTTLE BODY AND FUEL INJECTOR .................................................. 7-25
THROTTLE BODY AND FUEL INJECTOR............................................. 7-25
FUEL HOSE ............................................................................................ 7-27
FUEL TANK............................................................................................. 7-28
REMOVING THE FUEL HOSE ...............................................................7-30
REMOVING THE FUEL PUMP ...............................................................7-30
CHECKING THE FUEL INJECTOR ........................................................ 7-31
CHECKING THE THROTTLE BODY ......................................................7-31
INSTALLING THE FUEL PUMP..............................................................7-32
INSTALLING THE SUB-FRAME ............................................................. 7-32
INSTALLING THE FUEL HOSE ..............................................................7-33
CHECKING THE FUEL PUMP AND PRESSURE
REGULATOR OPERATION ................................................................... 7-34
CHECKING THE THROTTLE POSITION SENSOR ...............................7-34
CHECKING THE ISC (IDLE SPEED CONTROL) VALVE.......................7-36
AIR INDUCTION SYSTEM ............................................................................7-37
AIR INJECTION....................................................................................... 7-37
AIR CUT-OFF VALVE ............................................................................. 7-37
AIR INDUCTION SYSTEM DIAGRAMS.................................................. 7-38
AIR CUT-OFF VALVE AND AIR INDUCTION SYSTEM HOSES ...........7-39
CHECKING THE AIR INDUCTION SYSTEM..........................................7-40
FI
FUEL INJECTION SYSTEM
FI
EAS00894
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
1 ECU
2 Fuel injection system relay
3 Engine trouble warning light
4 Lean angle cut-off switch
5 Fuel hose
6 Ignition coil
7 Fuel injector
8 Intake air pressure sensor
9 Throttle position sensor
0 ISC (idle speed control) valve
A Intake air temperature sensor
B Battery
C Air filter case
D Catalytic converter
E Crankshaft position sensor
F Coolant temperature sensor
G Spark plug
H Fuel tank
I Fuel pump
J Pressure regulator
3
7
2
9
8
A
B
0
6
4
1
J
I
5
H
F
G
7-1
E
D
C
7-2
§
B
Gy
B
B
B
7
L/G
R/G
B
(GRAY)
B
x
B B/L
BB4 BB1
B
(GRAY)
BB3 BB2
B
B
£
B
z
B
Br/L
G
©
®
Gy
Br
Br
Br
R/Y
R/W
Y
R/W R/G
Y/L B/L Gy
| } ~ å
Br
Br/L
ß
¶
8
R
Br
Br/L
Ch Dg
G/L L
{
y
R
W
R
R
Br
W
(BLACK)
B
W
R
Br/L
Br/R
R
Br/L
B/L
Br/L
R/W
R/G Y/L
R
B
3
BB2
BB1
w G/L
ON
OFF
OPEN
LOCK
P
4
W
W
W
9
BB3
BB4
B2
B1
B1 B2
B
B2 B1
W
W
W
W/R
W/L
R/G R/W Y/L
G/L B2
B
W
1
W
R/W Lg Y/L
5
W
Y/L G/L R/W
W
R/G B2 B
W
W
(BLACK)
R
B B2 R/G
6
B Gy
•
R L/G
L/G R/G
W
(BLACK)
W/L W/R
2
R/G
0
B
B
R
G
B
Y
Dg
B
B
B
B
D
B
B
B
R/W
R/B
B
Ch
R/Y
G/L
R/Y
Y
G/L
Y
Y
B
G
B
(BLACK)
B
d
G/B G
W/B
R
R
J
B
Y G
e
G/LW/B
v
L/W
G/Y
E
L/W
G/Y
PASS
g
R/Y
Br
v
G
G/B
B
A
B
B
Y G
Y G
A A
Y G
Y
G
B
(BLACK)
Dg G/B W/Y Br/W R/Y
Ch G/Y B Br P
(BLACK)
R/Y Br/W W/Y G/B Dg
P Br B G/Y Ch
f
Ch
Dg
Br/W
(BLACK)
R/YR/Y
G/W
L/W
G/Y
L/W G/Y
L/B
B
R
C
I
R
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
G
H
B
A
ç † ¢
L
G/W R/W
Br Dg
G/Y Ch Br/W L/B R/B
B
R
P
B Ch L
L Ch B
G/B
L
P
P
c
Br
L
Br
Br/W
OFF
j
Br
B
B
L Dg B
Br
k
B Dg L
(BLACK)
(BLACK)
Dg
Br/W
Br/W
b
Ch
(BLUE)
B L/Y
B B
(BLUE)
(BLACK)
Ch
B
B
L/Y
G/Y L/Y
F
q L Dg
r u r s
i
(BLACK)
Br
t
W/Y
h
G/Y
K
R/B G/Y
L/Y G/W
G/W
R/B
G/Y
(GRAY)
(BLACK)
B/L P/W L
L Y/G B/L
(GREEN)
Br/W B/L
L
Y/L
B/L
B Ch
Br Dg
Ch B
Dg L/R
B
l Ch Dg Br
mn o
M
L B/L Y/L
B
Br
P
B
G/Y Br
L Y
B
G/Y
L Y/G B/L
O
N
p
B/L
Br/W
L
P/W
B/L
B/L
Q
B/L B B/L
Br/W B Br/W
B
R/W
Y/L
L/B
L/Y
G/Y
R/W
W/B
Y/G
B/L
Br/W
Y
L
P/W
G/R
W/R
W/L
R
Br
G/Y
B/W
R
B
Br
Br
W
G/B
O/B
R/L
R/Y
P
Lg
Gy
Sb
O
SUB-WIRE HARNESS 1
Y
WIRE HARNESS
B
G/B
OFF
ON
W
L
B/L
B
B
B
B
B
O
R/B
(GRAY)
W
B
L
L G/Y
L
(BLACK)
L
(BLACK)
B
B
L
L
L
B
C
B
B
L
L
L
L
L G/B
Br Br
Br
C
Br
B
W R
X
O/B
P
Lg
Gy
Sb
Y
G/B
C
L
L
L
B
(BLUE)
L
(BLUE)
L
L
L
(BLUE)
L
B
R/L
Y
B
G
V
Br
B
R/Y R/L
R/B R
R/B
R
R/L
R/Y
SUB-WIRE HARNESS 3
B
WIRE HARNESS
G/B
Br
C
G/B
P Lean angle cut-off
switch
Q Coolant temperature sensor
R ECU
S Ignition coil
T Spark plug
U ISC (idle speed
control) valve
V Fuel injection system relay
W Fuel injector
X Speed sensor
Y Fuel pump
y Multifunction meter
~ Engine trouble
warning light
R/L B
(RED)
G/B
B R/L
G B
R/L
O/B R/L
(BLACK)
(BLACK)
P Gy
Lg Sb
T
(BLUE)
L
(RED)
L
Br
L W
B/L
L
(BLACK)
U
S
SUB-WIRE HARNESS 2
(GRAY)
WIRE HARNESS
Y/L R/L O/B P
G/R Lg Gy Sb
P/W B/L L Br/W
B
P O/B R/L Y
Sb Gy Lg G/R
Br/W L B/L P/W
2 Crankshaft position
sensor
4 Main switchZ
_
8 Ignition fuse
0 Fuel injection
sys[
tem fuse
A
a Battery
B Main fuse \
F Starting circuit cutoff relay
H Engine stop ]switch
L Sidestand switch
M Throttle position
sensor
N Intake air pressure
sensor
O Intake air temperature sensor
Br R/W
(GREEN)
G/R B/L
Y/L B Y
L B L
P/W B P/W
G/R
W/L L/B Y/L B/W B G/Y R/Y
G/R Y W/R
L/Y B/L W/B G/B
R/L Br/W
R/W W Lg P O/B
P/W Y/G
L
R Sb Gy O
A
G
B
G
Y
FUEL INJECTION SYSTEM
FI
WIRING DIAGRAM
FI
FUEL INJECTION SYSTEM
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.
• 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.
• 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.
• After the engine has been stopped, the lowest fault code number appears on the LCD meter.
Once a fault code has been displayed, it remains stored in the memory of the ECU until it is
deleted.
EAS00900
Engine trouble warning light indication and FI system operating condition
Warning light
indication
ECU’s operation
FI operation
Vehicle operation
Flashing*
Warning provided
when unable to start
engine
Operation stopped
Unable
Remains ON
Malfunction detected
Operated with substitute characteristics in
accordance with the
description of the malfunction
Able/Unable depending on the self-diagnostic fault code
* The warning light flashes when any one of the conditions listed below is present and the start
switch is pushed.
12: Crankshaft position sensor
19: Broken or disconnected blue/yellow lead of
the ECU
30: Lean angle cut-off switch
(latch up detected)
33: Faulty ignition
39: Fuel injector
(open or short circuit)
41: Lean angle cut-off switch
(open or short circuit)
50: ECU internal malfunction
(memory check error)
7-3
FI
FUEL INJECTION SYSTEM
EAS00901
Checking for a defective engine trouble warning light bulb
The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned
“ON” and when the start switch is being pushed. If the warning light does not come on under these
conditions, the warning light bulb may be defective.
Main switch Main switch
OFF
ON
Engine trouble
warning light
Light
OFF
Light ON for
1.4 seconds
Light
OFF
Initialize
EAS00902
ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while 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.
The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed
value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions
are given in the table below.
FAIL-SAFE ACTIONS TABLE
Fault
code No.
Item
Symptom
Fail-safe action
Engine startability
Vehicle driveability
Unable
Unable
Able
Able
Able
Able
Unable
Unable
12
Crankshaft position
sensor
No normal signals are
received from the crankshaft
position sensor.
• Stops the engine (by stopping the injection and ignition).
13
14
Intake air pressure
sensor (open or short
circuit) (pipe system)
Intake air pressure sensoropen or short circuit detected.
Faulty intake air pressure sensor pipe system.
• Fixes the intake air pressure to 101.3 kPa
(1.01 kgf/cm2, 14.4 psi).
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.
• Fixes the throttle position
sensor to middle open.
Broken or disconnected blue/yellow lead
of the ECU
Open circuit in the input line
(blue/yellow lead) of the ECU
is detected.
-- (No start)
21
Coolant temperature
sensor
Coolant temperature sensoropen or short circuit is
detected.
• Fixes the coolant temperature to 80 °C.
Able
Able
22
Intake temperature
sensor
Intake temperature sensoropen or short circuit is
detected.
• Fixes the intake temperature to 20 °C.
Able
Able
Faulty ignition
Open circuit detected in the
primary lead of the ignition
coil.
-Unable
Unable
19
33
7-4
FI
FUEL INJECTION SYSTEM
Fault
code No.
37
39
30
41
Item
Engine speed is high when the
engine is idling.
--
Fuel injector
Fuel injector open or short circuit is detected.
--
Lean angle cut-off
switch (latch up
detected) (open or
short circuit)
The scooter has overturned.
Lean angle cut-off switch-open
or short circuit is detected.
--
Speed sensor
No normal signals are
received from the speed sensor.
--
Fuel system voltage
(monitoring voltage)
Supply power to the fuel injector and fuel pump is not normal.
• Fixes the battery voltage
to 12 V.
Error in reading from or
writing on EEPROM
An error is detected while
reading from or writing on
EEPROM (CO adjustment
value, code re-registering key
code, and throttle valve fully
closed notification value).
--
Vehicle system power
supply (monitoring voltage)
Power supply to the FI system
not normal
--
ECU internal malfunction (memory check
error)
Faulty ECU memory. When
this malfunction is detected,
the code number might not
appear on the meter.
--
ISC (idle speed control) valve unit (open or
short circuit)
ISC (idle speed control) valve
unit-open or short circuit
detected.
--
Start unable warning
Relay is not activated even if
the crank signal is input while
the start switch is pushed. The
start switch is pushed when
fault code No.12, 19, 30, 33,
39, 41, or 50 is displayed to
indicate an error.
Engine trouble warning light
flashes when the start
switch is turned ON.
44
46
50
61
Fail-safe action
ISC (idle speed control) valve (stuck fully
open)
42
43
Symptom
—
Engine startability
Vehicle driveability
Able
Able
Unable
Unable
Unable
Unable
Able
Able
Able
Able
Able
Able
Able
Able
Unable
Unable
Able
Able
Unable
Unable
Engine startability
Vehicle driveability
Unable
Unable
Unable
Unable
Unable
Unable
Unable
Unable
Communication error with the meter
Fault
code No.
Item
ECU internal malfunction (output signal
error)
No signals are received from
the ECU.
–
Er-1
ECU internal malfunction (output signal
error)
No signals are received from
the ECU within the specified
duration.
–
Er-2
ECU internal malfunction (output signal
error)
Data from the ECU cannot be
received correctly.
–
Er-3
Er-4
ECU internal malfunction (input signal error)
Non-registered data has been
received from the meter.
–
Symptom
Fail-safe action
7-5
FI
FUEL INJECTION SYSTEM
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.
The engine trouble warning light comes on.
The engine trouble warning light does not come on.
Check the fault code number displayed on the meter.
Check the operation of following sensors and actuators in the diagnostic mode. Refer to “Diagnostic
mode table”.
01: Throttle position sensor (throttle angle)
30: Ignition coil
36: Fuel injector
Identify the system with the malfunction. Refer to
“FAIL-SAFE ACTIONS TABLE”.
Identify the probable cause of malfunction. Refer to
“Fault code table”.
OK
Check and repair the probable cause of malfunction.
Fault code No. YES
Check and repair.
Refer to “TROUBLESHOOTING DETAILS”.
Monitor the operation of
the sensors and actuators in the diagnostic
mode. Refer to “Diagnostic mode table”.
NG
Engine malfunction
Defective sensor or
actuator
Check and repair the
inner parts of engine.
Refer to Chapter 5.
Check and repair the
corresponding sensor or actuator.
Fault code No. NO
Check and repair.
Refer to “FAIL-SAFE
ACTIONS TABLE”.
OK
NG
OK
Check the engine condition.
Perform ECU reinstatement action. Refer to “Reinstatement method” in “TROUBLESHOOTING
DETAILS”.
Fault code number
displayed
OK
Turn the main switch to “OFF”, turn the main switch
back to “ON”, and then check if the fault code number
is still displayed.
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. Refer to “Diagnostic mode table (Diagnostic code
No.62)”.
*
Operated when the engine trouble warning light is on.
7-6
FUEL INJECTION SYSTEM
FI
EAS00905
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators without
connecting the measurement equipment by
simply switching the meter indication from the
normal mode to the diagnostic monitoring
mode.
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the
engine stop switch to “OFF”.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Simultaneously press and hold the
“SELECT” and “RESET” buttons, turn the
main switch to “ON”, and continue to press
the buttons for 8 seconds or more.
NOTE:
• All displays on the meter disappear except
the clock and tripmeter displays.
• “dIAG” appears on the LCD meter.
4. Press the “SELECT” button to select the CO
adjustment mode “Co” or the diagnostic
mode “dIAG”.
5. After selecting “dIAG”, simultaneously press
the “SELECT” and “RESET” buttons for 2
seconds or more to execute the selection.
6. Select the diagnostic code number that
applies to the item that was verified with the
fault code number by pressing the
“SELECT” and “RESET” buttons.
01
70
70
NOTE:
• The diagnostic code number appears on the
LCD meter (01-70).
• To decrease the selected diagnostic code
number, press the “RESET” button. Press
the “RESET” button for 1 second or longer to
automatically decrease the diagnostic code
numbers.
• To increase the selected diagnostic code
number, press the “SELECT” button. Press
the “SELECT” button for 1 second or longer
to automatically increase the diagnostic code
numbers.
01
7-7
FUEL INJECTION SYSTEM
FI
7. Verify the operation of the sensor or actuator.
• Sensor operation
The data representing the operating conditions of the sensor appears on the trip LCD.
• Actuator operation
Set the engine stop switch to “ON” to operate the actuator.
* If the engine stop switch is set to “ON”, set it
to “OFF”, and then set it to “ON” again.
8. Turn the main switch to “OFF” to cancel the
the diagnostic mode.
NOTE:
To perform a reliable diagnosis, make sure to
turn “OFF” the power supply before every
check and then start right from the beginning.
7-8
FUEL INJECTION SYSTEM
FI
Fault code table
Fault
Code No.
Symptom
No normal signals are received from
the crankshaft position sensor.
14
Diagnostic code
•
•
•
•
•
Open or short circuit in wiring harness.
Defective crankshaft position sensor.
Malfunction in pickup rotor.
Malfunction in ECU.
Improperly installed sensor.
—
Intake air pressure sensor-open or
short circuit detected.
•
•
•
•
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective intake air pressure sensor.
Malfunction in ECU.
03
Faulty intake air pressure sensor pipe
system
• disconnected hose
• clogged hose
• Intake air pressure sensor hose is disconnected,
clogged, kinked, or pinched.
• Malfunction in ECU.
Throttle position sensor-open or short
circuit detected.
•
•
•
•
•
12
13
Probable cause of malfunction
15
Open or short circuit in wiring sub lead.
Open or short circuit in wiring harness.
Defective throttle position sensor.
Malfunction in ECU.
Improperly installed throttle position sensor.
03
01
16
A stuck throttle position sensor is
detected.
• Stuck throttle position sensor.
• Malfunction in ECU.
19
Open circuit in the input line (blue/yellow lead) of ECU is detected when
the start switch is pressed.
• Open circuit in wiring harness (ECU coupler).
• Malfunction in ECU.
Coolant temperature sensor-open or
short circuit detected.
•
•
•
•
Open or short circuit in wiring harness.
Defective coolant temperature sensor.
Malfunction in ECU.
Improperly installed sensor.
06
Intake air temperature sensor-open or
short circuit detected.
•
•
•
•
Open or short circuit in wiring harness.
Defective intake temperature sensor.
Malfunction in ECU.
Improperly installed sensor.
05
The scooter has overturned.
• Overturned.
• Malfunction in ECU.
Open circuit is detected in the primary
lead of the ignition coil.
•
•
•
•
Open circuit in wiring harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cut-off circuit system.
30
•
•
•
•
•
Defective speed sensor.
Malfunction in throttle body.
Malfunction in throttle cables.
ISC (idle speed control) valve is stuck fully open.
Malfunction in ECU.
54
21
22
30
33
The ISC (idle speed control) valve is
stuck fully open.
37
01
20
08
39
Fuel injector open or short circuit is
detected.
• Open or short circuit in wiring harness.
• Defective fuel injector.
• Malfunction in ECU.
36
41
Lean angle cut-off switch-open or
short circuit detected.
• Open or short circuit in wiring harness.
• Defective lean angle cut-off switch.
• Malfunction in ECU.
08
No normal signals are received from
the speed sensor.
•
•
•
•
Open or short circuit in wiring harness.
Defective speed sensor.
Malfunction in vehicle speed sensor detected unit.
Malfunction in ECU.
07
Supply power to the fuel injector and
fuel pump is not normal.
• Open circuit in wiring harness. (red or red/blue lead)
• Malfunction in ECU.
09
42
43
7-9
FUEL INJECTION SYSTEM
Fault
Code No.
Probable cause of malfunction
Diagnostic code
An error is detected while reading or
writing on EEPROM.
• 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.)
60
46
Power supply to the FI system is not
normal.
• Malfunction in charging system.
50
Faulty ECU memory. When this malfunction is detected, the code number
might not appear on the meter.
• Malfunction in ECU. (The program and data are not
properly written on or read from the internal memory.)
ISC (idle speed control) valve open or
short circuit is detected.
• Open or short circuit in wiring harness.
• Defective ISC (idle speed control) valve.
• Malfunction in ECU.
54
Er-1
No signals are received from the
ECU.
• Open or short circuit in wiring sub lead.
• Malfunction in meter.
• Malfunction in ECU.
—
Er-2
No signals are received from the ECU
within the specified duration.
• Improper connection in wiring sub lead.
• Malfunction in meter.
• Malfunction in ECU.
—
Er-3
Data from the ECU cannot be
received correctly.
• Improper connection in wiring sub lead.
• Malfunction in meter.
• Malfunction in ECU.
—
Er-4
Non-registered data has been
received from the meter.
• Improper connection in wiring sub lead.
• Malfunction in meter.
• Malfunction in ECU.
—
44
61
Symptom
FI
—
—
EAS00907
Diagnostic mode table
Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer
to “DIAGNOSTIC MODE”.
NOTE:
• Check the intake air temperature and coolant temperature as close as possible to the intake air
temperature sensor and the coolant temperature sensor respectively.
• If it is not possible to check the intake air temperature, use the ambient temperature as reference.
_
Diagnostic
code
Item
05
06
Displays the throttle angle.
• Check with throttle fully closed.
• Check with throttle fully open.
0 ~ 125 degrees
• Fully closed position (15 ~ 16)
• Fully open position (97 ~ 102)
Pressure difference
(atmospheric pressureintake air pressure)
Displays the pressure difference (atmospheric pressure-intake air pressure).
Engine stop switch is on.
• Generate the pressure difference by cranking the
engine with the starter, without actually starting the
engine.
When engine is stopped:
Atmospheric pressure 101.3 kPa
(760 mmHg, 30 inHg) when cranking
the engine with the start switch.
0 ~ 126 kPa (1.26 kgf/cm2, 17.9 psi)
Intake air temperature
Displays the intake air temperature.
• Check the temperature in the air cleaner case.
Compare it to the value displayed on
the meter.
Coolant temperature
Displays the coolant temperature.
• Check the temperature of the coolant.
Compare it to the value displayed on
the meter.
Vehicle speed pulse
Displays the accumulation of the vehicle pulses that
are generated when the tire is spun.
(0 ~ 999; resets to 0 after 999)
OK if the numbers appear on the
meter.
Lean angle cut-off switch
Displays the lean angle cut-off switch values.
Upright: 0.4 ~ 1.4 V
Overturned: 3.8 ~ 4.2 V
07
08
Data displayed on meter
(reference value)
Throttle angle
01
03
Description of action
7 - 10
FUEL INJECTION SYSTEM
Diagnostic
code
09
20
Item
Data displayed on meter
(reference value)
Fuel system voltage
(battery voltage)
Displays the fuel system voltage (battery voltage).
Engine stop switch is on.
0 ~ 18.7 V
Normally, approximately 12.0 V
Sidestand switch
Displays that the switch is ON or OFF.
Stand retracted: ON
Stand extended: OFF
Ignition coil
When the engine stop switch is turned from OFF to
ON, the ignition coil is actuated five times per second and the engine trouble warning light comes on.
• Connect an ignition checker.
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
Check that spark is generated,
5 times with the engine stop switch
ON.
Fuel injector
When the engine stop switch is turned from OFF to
ON, the fuel injector is actuated five times per second and the engine trouble warning light comes on.
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
Check the operating sound of the fuel
injector five times with engine stop
switch ON.
Fuel injection system
relay
When the engine stop switch is turned from OFF to
ON, the fuel injection system relay is actuated five
times per second and the engine trouble warning
light comes on (the light is OFF when the relay is
ON, and the light is ON when the relay is OFF).
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
Check the fuel injection system relay
operating sound 5 times with the
engine stop switch ON.
Radiator fan motor relay
When the engine stop switch is turned from OFF to
ON, the radiator fan motor relay is actuated five
times every 5 seconds and the engine trouble warning light comes on. (ON 2 seconds, OFF 3 seconds)
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
Check the radiator fan motor relay
operating sound 5 times with the
engine stop switch ON.
(At that time, the fan motor rotates.)
Headlight relay 1
When the engine stop switch is turned from OFF to
ON, the headlight relay is actuated five times every
5 seconds and the engine trouble warning light
comes on. (ON 2 seconds, OFF 3 seconds)
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
Check the headlight relay operating
sound 5 times with the engine stop
switch ON.
(At that time, the headlight turns ON.)
ISC (idle speed control)
valve
When the engine stop switch is turned from OFF 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. This operation
takes approximately 12 seconds until it is completed.
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
The ISC (idle speed control) valve
unit vibrates when the ISC (idle speed
control) valve operates.
Grip warmer relay
When the engine stop switch is turned from OFF to
ON, the grip warmer relay is actuated and the
engine trouble warning light comes on. (the light is
OFF when the relay is OFF, and the light is ON
when the relay is ON).
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
Check the grip warmer relay operating sound 1 time with the engine stop
switch ON.
30
36
50
51
52
54
57
EEPROM fault code display
60
Description of action
FI
• Transmits the abnormal portion of the data in the
EEPROM 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.
7 - 11
01 CO adjustment value is detected.
03 Code re-registering key (immobilizer) is detected.
04 Throttle valve fully closed notification value is detected.
(00) Displays when there is no malfunction.
FUEL INJECTION SYSTEM
Diagnostic
code
Item
Data displayed on meter
(reference value)
Malfunction history code
display
• Displays the codes of the history of the self-diagnosis 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.
12 ~ 61
(00) Displays when there is no malfunction.
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.
• Erases only the history codes when the engine
stop switch is turned from OFF to ON. If the engine
stop switch is ON, turn it OFF once, and then turn
it back ON.
00 ~ 19
(00) Displays when there is no malfunction.
Control number
• Displays the program control number.
00 ~ 255
61
62
70
Description of action
FI
EAS00908
TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the meter. 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 meter display
according to the “Reinstatement method”.
Fault code No.:
Fault code number displayed on the meter when the engine failed to work normally. Refer to “Fault
code table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC MODE”.
7 - 12
FUEL INJECTION SYSTEM
Fault code No.
12
Symptom
FI
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
Reinstatement
method
1
Installed condition of sensor.
Check the installed area for looseness or pinching.
2
Connected condition of connector.
Inspect the coupler for any pins
that may have pulled out.
Check that the coupler is connected securely.
If there is a malfunction, repair it and connect it
securely.
Crankshaft position sensor coupler
Main wiring harness ECU coupler
Reinstated by
cranking the
engine.
NOTE:
Set the main switch to OFF before
connecting or disconnecting the
connector.
3
Open or short circuit in wiring harness.
Repair or replace if there is an open or short circuit
between the main wiring harnesses.
Between sensor coupler and ECU coupler.
white/blue – white/blue
white/red – white/red
4
Defective crankshaft position sensor.
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
7 - 13
FUEL INJECTION SYSTEM
Fault code No.
13
Symptom
FI
Intake air pressure sensor - open or short circuit detected.
Used diagnostic code No. 03 (intake air pressure sensor)
Order
1
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Intake air pressure sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
Reinstated by turning the main switch
ON.
NOTE:
Set the main switch to OFF before
connecting or disconnecting the
connector.
2
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit.
Between sensor coupler and ECU coupler
black/blue – black/blue
pink/white – pink/white
blue – blue
3
Defective intake air pressure sensor
Execute the diagnostic mode (code No. 03)
Replace if defective.
1. Connect the pocket tester (DC 20 V) to the intake
air pressure sensor coupler as shown.
Positive tester probe → pink/white 1
Negative tester probe → black/blue 2
2. Set the main switch to “ON”.
3. Measure the intake air pressure sensor output
voltage.
Intake air pressure sensor output
voltage
3.4 ~ 3.8 V
4. Is the intake air pressure sensor OK?
7 - 14
FUEL INJECTION SYSTEM
Fault code No.
14
Symptom
FI
Intake air pressure sensor - hose system malfunction (clogged or detached
hose).
Used diagnostic code No. 03 (intake air pressure sensor)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Intake air pressure sensor hose
detached, clogged, kinked, or
pinched.
Intake air pressure sensor malfunction at intermediate electrical
potential.
Repair or replace the sensor hose.
Inspect and repair the connection.
Reinstated by
starting the engine
and operating it at
idle.
2
Connected state of connector
Intake air pressure sensor coupler
Main wiring harness ECU coupler
Check the coupler for any pins that may have pulled
out.
Check that the coupler is connected securely.
If there is a malfunction, repair it and connect it
securely.
3
Defective intake air pressure sensor.
Execute the diagnostic mode (code No. 03)
Replace if defective.
Refer to “Fault code No. 13”.
Fault code No.
15
Symptom
Throttle position sensor - open or short circuit detected.
Used diagnostic code No. 01 (throttle position sensor)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Installed condition of throttle position sensor.
Check the installed area for looseness or pinching.
Check that it is installed in the specified position.
Refer to “THROTTLE BODY AND FUEL INJECTOR”.
Reinstated by turning the main switch
ON.
2
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Throttle position sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
3
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit.
Between sensor coupler and ECU coupler
black/blue – black/blue
yellow – yellow, yellow/blue – yellow/blue
blue – blue
4
Throttle position sensor lead wire
open circuit output voltage check.
Check for open circuit and replace the throttle position sensor.
black/blue – yellow/blue
5
Defective throttle position sensor.
Execute the diagnostic mode (code No. 01)
Replace if defective.
Refer to “THROTTLE BODY AND FUEL INJECTOR”.
7 - 15
FUEL INJECTION SYSTEM
Fault code No.
16
Symptom
FI
Stuck throttle position sensor detected.
Used diagnostic code No. 01 (throttle position sensor)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Installed condition of throttle position sensor.
Check the installed area for looseness or pinching.
Check that it is installed in the specified position.
Refer to “THROTTLE BODY AND FUEL INJECTOR”.
Reinstated by
starting the engine,
operating it at idle,
and then racing it.
2
Defective throttle position sensor
Execute the diagnostic mode (code No. 01)
Replace if defective.
Refer to “THROTTLE BODY AND FUEL INJECTOR”.
3
When fault code No. 15 has been
detected.
Refer to “Fault code No. 15”.
Fault code No.
19
Symptom
Refer to “Fault
code No. 15”.
Open circuit in the input line of ECU (blue/yellow lead) detected.
Used diagnostic code No. 20 (sidestand switch)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected state of connector
Main wiring harness ECU coupler
(blue/yellow connector)
Execute the diagnostic mode (code No. 20)
Check the coupler for any pins that may have pulled
out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connect it
securely.
Reinstated by
reconnecting the
wiring and retracting the sidestand.
2
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open circuit.
Sidestand switch signal input line of ECU coupler
blue/yellow
Fault code No.
21
Symptom
Coolant temperature sensor open or short circuit is detected.
Used diagnostic code No. 06 (coolant temperature sensor)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Installed condition of sensor
Check the installed area for looseness or pinching.
2
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Coolant temperature sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
Reinstated by turning the main switch
ON.
3
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit.
Between sensor coupler and ECU coupler
black/blue – black/blue
green/red – green/red
4
Defective coolant temperature sen- Execute the diagnostic mode (code No. 06)
sor.
Replace if defective.
Refer to “COOLING SYSTEM” in chapter 8.
7 - 16
FUEL INJECTION SYSTEM
Fault code No.
22
Symptom
FI
Intake temperature sensor open or short circuit is detected.
Used diagnostic code No. 05 (intake air temperature sensor)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Installed condition of sensor
Check the installed area for looseness or pinching.
2
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Intake air temperature sensor coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
Reinstated by turning the main switch
ON.
3
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit.
Between sensor coupler and ECU coupler
black/blue – black/blue
brown/white – brown/white
4
Defective intake air temperature
sensor.
Execute the diagnostic mode (code No. 05)
Replace if defective.
1. Remove the intake air temperature sensor from
the air filter case.
2. Connect the pocket tester (Ω × 100) to the intake
air temperature sensor terminal as shown.
Positive tester probe → brown/white 1
Negative tester probe → black/blue 2
Br/W B/L
2
1
3. Measure the intake air temperature sensor resistance.
Intake air temperature sensor
resistance
2.3 ~ 2.6 kΩ at 20 °C (68 °F)
WARNING
• Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it.
4. Is the intake air temperature sensor OK?
7 - 17
FUEL INJECTION SYSTEM
Fault code No.
30
Symptom
FI
The scooter has overturned.
Used diagnostic code No. 08 (lean angle cut-off switch)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
The scooter has overturned.
Raise the scooter upright.
2
Installed condition of the lean
angle cut-off switch
Check the installed area for looseness or pinching.
3
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Lean angle cut-off switch coupler
Main wiring harness ECU coupler
Reinstated by turning the main switch
ON (however, the
engine cannot be
restarted unless
the main switch is
first turned OFF).
4
Defective lean angle cut-off switch
Execute the diagnostic mode (code No. 08)
Replace if defective.
1. Remove the lean angle cut-off switch from the
scooter.
2. Connect the lean angle cut-off switch coupler to
the wire harness.
3. Connect the pocket tester (DC 20 V) to the lean
angle cut-off switch terminals as shown.
Positive tester probe → blue 1
Negative tester probe → yellow/green 2
4. When turning the lean angle cut-off switch
approximately 45 °, the voltage reading change
from 0.9 V to 4.1 V.
5. Is the lean angle cut-off switch OK?
Fault code No.
33
Symptom
Open circuit detected in the primary lead of the ignition coil.
Used diagnostic code No. 30
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler – orange
Main wiring harness ECU coupler
Sub-wire harness coupler
Reinstated by
starting the engine
and operating it at
idle.
2
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 pri- Execute the diagnostic mode (code No. 30)
mary and secondary coils for conti- Replace if defective.
nuity).
Refer to “IGNITION SYSTEM” in chapter 8.
7 - 18
FUEL INJECTION SYSTEM
Fault code No.
37
Symptom
FI
Engine speed is high when the engine is idling.
Used diagnostic code No. 54 (ISC (idle speed control) valve)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Incorrect speed sensor signal
Check the speed sensor.
Check the speed sensor leads.
Check the speed sensor coupler.
2
Throttle valve does not fully close
Check the throttle body.
Refer to “THROTTLE BODY AND FUEL INJECTOR”.
Check the throttle cables.
Refer to “ADJUSTING THE THROTTLE CABLE
FREE PLAY” in chapter 3.
Reinstated if the
engine idle speed
is within specification after starting
the engine.
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.
4
ISC (idle speed control) valve not
moving correctly
Fault code No.
39
Symptom
Execute the diagnostic mode (code No. 54)
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 12 seconds until it is completed. Start the engine. If the error recurs, replace
the throttle body assembly.
Fuel injector open or short circuit is detected.
Used diagnostic code No. 36 (fuel injector)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Fuel injector coupler – orange/black
Main wiring harness ECU coupler
Sub-wire harness coupler
Reinstated by
starting the engine.
2
Open or short circuit in lead wire.
Repair or replace if there is an open or short circuit.
Between fuel injector coupler and ECU coupler/main
harness
orange/black – orange/black
3
Defective fuel injector
Execute the diagnostic mode (code No. 36)
Replace if defective.
7 - 19
FUEL INJECTION SYSTEM
Fault code No.
41
Symptom
FI
Lean angle cut-off switch open or short circuit is detected.
Used diagnostic code No. 08 (lean angle cut-off switch)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Lean angle cut-off switch coupler
Main wiring harness ECU coupler
Reinstated by turning the main switch
ON.
2
Open or short circuit in wiring harness.
Repair or replace if there is an open or short circuit.
Between switch coupler and ECU coupler
black/blue – black/blue
yellow/green – yellow/green
blue – blue
3
Defective lean angle cut-off switch
Execute the diagnostic mode (code No. 08)
Replace if defective.
Refer to Fault code No. 30.
Fault code No.
42
Symptom
No normal signals are received from the speed sensor.
Used diagnostic code No. 07 (speed sensor)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
1
Connected condition of speed sen- If there is a malfunction, repair it and connect it
sor connector
securely.
Inspect the coupler for any pins
Speed sensor coupler
that may have pulled out.
Main wiring harness ECU coupler
Check the locking condition of the
coupler.
2
Open or short circuit in speed sensor lead.
Repair or replace if there is an open or short circuit.
Between sensor coupler and ECU coupler
blue – blue
white – white
black/blue – black/blue
3
Defective speed sensor
Execute the diagnostic mode (code No. 07)
Replace if defective.
Refer to “SIGNALING SYSTEM” in chapter 8.
7 - 20
Reinstatement
method
Reinstated by
starting the engine,
and inputting the
vehicle speed signals by operating
the scooter at a low
speed of 20 to
30 km/h.
FUEL INJECTION SYSTEM
Fault code No.
43
Symptom
FI
Supply power to the fuel injector and fuel pump is not normal.
Used diagnostic code No. 09 (fuel system voltage)
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Fuel injection system relay coupler
Fuel pump coupler
Fuel injector coupler
ECU coupler
Reinstated by
starting the engine
and operating it at
idle.
2
Malfunction in ECU
Fuel injection system relay is on.
3
Open or short circuit in the wiring
harness.
Repair or replace if there is an open or short circuit.
Between battery and ECU coupler
red – red
red/blue – red/blue
4
Malfunction or open circuit in fuel
injection system relay
Execute the diagnostic mode (code No. 09)
NOTE:
When the leads are disconnected, the voltage check
by the code No. 09 is impossible.
Replace if defective.
1. Remove the fuel injection system relay.
2. Connect the pocket tester (Ω × 1) and battery
(12 V) to the starting circuit cut-off relay terminals
as shown.
Positive battery terminal → red/black 1
Negative battery terminal → red/yellow 2
Positive tester probe → red 3
Negative tester probe → red/blue 4
3
4
1
2
R/Y
R/B
R/L
R
3. Does the fuel injection system relay have continuity between red and red/blue?
7 - 21
FUEL INJECTION SYSTEM
Fault code No.
44
Symptom
FI
Error is detected while reading from or writing on EEPROM
(code re-registering key code and throttle valve fully closed notification value).
Used diagnostic No. 60 (EEPROM improper cylinder indication)
Order
1
Inspection operation item and
probable cause
Operation item and countermeasure
Malfunction in ECU
Execute diagnostic mode (code No. 60)
Reinstated by turn• 01 is displayed on meter.
ing the main switch
Readjust the CO of the displayed cylinder.
ON.
Refer to “ADJUSTING THE EXHAUST GAS
VOLUME” in chapter 3.
Replace ECU if defective.
• 03 is displayed on meter.
Replace the ECU.
• 04 is displayed on meter.
Turn the main switch to ON, and turn the throttle grip to full open and then to full close position.
Replace ECU if defective.
Fault code No.
46
Symptom
Reinstatement
method
Power supply to the FI system relay is not normal.
Used diagnostic code No. – –
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
ECU coupler
Reinstated by
starting the engine
and operating it at
idle.
2
Faulty battery
Replace or charge the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3.
3
Open or short circuit in wiring harness.
Repair or replace if there is an open or short circuit.
• Between battery and main switch
red – red
• Between main switch and fuse (ignition)
brown/blue – brown/blue
• Between fuse (ignition) and engine stop switch
red/white – red/white
• Between engine stop switch and fuel injection
system relay
red/black – red/black
• Between fuel injection system relay and ECU
red/yellow – red/yellow
7 - 22
FUEL INJECTION SYSTEM
Fault code No.
50
Symptom
FI
Faulty ECU memory. (When this malfunction is detected in the ECU, the fault
code number might not appear on the meter.)
Used diagnostic code No. – –
Order
1
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
Malfunction in ECU
Replace the ECU.
Reinstated by turning the main switch
ON.
Fault code No.
61
Symptom
ISC (idle speed control) valve open or short circuit is detected.
Used diagnostic code No. – –
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
ISC (idle speed control) valve coupler
Main wiring harness ECU coupler
Sub-wire harness coupler
2
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
light green – light green
gray – gray
sky blue – sky blue
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.
3
Detective ISC (idle speed control)
valve
Execute diagnostic mode (code No. 54)
Replace if defective.
Refer to “THROTTLE BODY AND FUEL INJECTOR”.
Fault code No.
Er-1
Symptom
No signals are received from the ECU.
Used diagnostic code No. – –
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit.
Between meter coupler and ECU coupler
yellow/blue – yellow/blue
Reinstated if normal signal is
received from the
ECU when the
main switch is set
to ON.
3
Malfunction in meter
Replace the meter.
4
Malfunction in ECU
Replace the ECU.
7 - 23
FUEL INJECTION SYSTEM
Fault code No.
Er-2
Symptom
FI
No signals are received from the ECU within the specified duration.
Used diagnostic code No. – –
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit.
Between meter coupler and ECU coupler
yellow/blue – yellow/blue
Reinstated if normal signal is
received from the
ECU when the
main switch is set
to ON.
3
Malfunction in meter
Replace the meter.
4
Malfunction in ECU
Replace the ECU.
Fault code No.
Er-3
Symptom
Data from the ECU cannot be received correctly.
Used diagnostic code No. – –
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit.
Between meter coupler and ECU coupler
yellow/blue – yellow/blue
Reinstated if normal signal is
received from the
ECU when the
main switch is set
to ON.
3
Malfunction in meter
Replace the meter.
4
Malfunction in ECU
Replace the ECU.
Fault code No.
Er-4
Symptom
Non-registered data has been received from the meter.
Used diagnostic code No. – –
Order
Inspection operation item and
probable cause
Operation item and countermeasure
Reinstatement
method
1
Connected condition of connector
Inspect the coupler for any pins
that may have pulled out.
Check the locking condition of the
coupler.
If there is a malfunction, repair it and connect it
securely.
Main wiring harness ECU coupler
Sub-wire harness coupler
2
Open or short circuit in wiring harness and/or sub lead.
Repair or replace if there is an open or short circuit.
Between meter coupler and ECU coupler
yellow/blue – yellow/blue
Reinstated if normal signal is
received from the
ECU when the
main switch is set
to ON.
3
Malfunction in meter
Replace the meter.
4
Malfunction in ECU
Replace the ECU.
7 - 24
FI
THROTTLE BODY AND FUEL INJECTOR
EAS00909
THROTTLE BODY AND FUEL INJECTOR
THROTTLE BODY AND FUEL INJECTOR
T.
R.
R.
T.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
6
3
13
12
1
7
8
New
11
4
5
9
10
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the throttle body and fuel
injector
Air filter case (left and right)
Q’ty
ISC (idle speed control) valve coupler
Throttle position sensor coupler
Intake air pressure sensor
Throttle body clamp screw
Throttle body
Vacuum chamber cover
Piston valve spring
Piston valve
Throttle cable
Air filter case to throttle body hose
1
1
1
1
1
1
1
1
2
1
7 - 25
Remarks
Remove the parts in the order listed.
Refer to “AIR FILTER CASES” in chapter
3.
Disconnect.
Disconnect.
Loosen.
Disconnect.
Disconnect.
FI
THROTTLE BODY AND FUEL INJECTOR
T.
R.
R.
T.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
6
3
13
12
1
7
8
New
11
4
5
9
10
Order
11
12
13
Job/Part
Throttle position sensor
Fuel injector coupler
Fuel injector assembly
Q’ty
Remarks
1
1
Disconnect.
1
For installation, reverse the removal procedure.
7 - 26
FI
THROTTLE BODY AND FUEL INJECTOR
FUEL HOSE
3
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
10
7
6
8
3
9
2
5
1
11
4
T.
R.
Order
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
2
3
4
5
6
7
8
Job/Part
Removing the fuel hose
Radiator
Plastic band
Cover
Footrest board plate (left and right)
Bottom cover
Sidestand switch coupler
Fuel pump coupler
Fuel hose connector cover
Fuel hose
9
10
11
Fuel hose holder
Ignition coil bracket
Radiator pipe assembly
Q’ty
1
1
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “RADIATOR” in chapter 6.
Disconnect.
Disconnect.
Refer to “REMOVING THE FUEL
HOSE” and “INSTALLING THE FUEL
HOSE”.
1
1
1
For installation, reverse the removal procedure.
7 - 27
THROTTLE BODY AND FUEL INJECTOR
FI
FUEL TANK
T.
5
R.
6
54 Nm (5.4 m • kg, 39 ft • Ib)
5
LT
(6)
LT
10
6
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
1
New
7
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
3
1
2
LT
4
8
4
LT
7
3
2
Job/Part
Removing the fuel tank
R.
Order
T.
1
Q’ty
54 Nm (5.4 m • kg, 39 ft • Ib)
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
1
2
3
4
5
6
Fuel hose
Sub-frame front upper mounting bolt/
nut (left and right)
Washer
Sub-frame front lower mounting bolt
(left and right)
Washer
Sub-frame rear mounting bolt (left and
right)
Washer
Refer to “FUEL HOSE”.
2/2
2
2
2
4
4
7 - 28
Refer to “INSTALLING THE SUBFRAME”.
THROTTLE BODY AND FUEL INJECTOR
T.
5
R.
6
FI
54 Nm (5.4 m • kg, 39 ft • Ib)
5
LT
(6)
LT
10
6
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
1
New
7
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
3
1
2
LT
4
8
4
LT
7
3
2
R.
Order
7
8
9
10
T.
1
54 Nm (5.4 m • kg, 39 ft • Ib)
Job/Part
Q’ty
Remarks
Sub-frame adjusting bolt (left and right)
2
Refer to “INSTALLING THE SUBFRAME”.
Sub-frame (with centerstand)
1
Fuel tank
1
Refer to “REMOVING THE FUEL HOSE”.
Fuel pump
1
Refer to “REMOVING THE FUEL PUMP”
and “INSTALLING THE FUEL PUMP”.
For installation, reverse the removal procedure.
7 - 29
THROTTLE BODY AND FUEL INJECTOR
1
2
FI
REMOVING THE FUEL HOSE
1. Extract the fuel in the fuel tank through the
fuel tank filler hole with a pump.
2. Remove:
• fuel hose connector cover 1
3. Disconnect:
• fuel hose 2
CAUTION:
• 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.
• 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:
• fuel tank
REMOVING THE FUEL PUMP
1. Remove:
• fuel pump
CAUTION:
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
EAS00911
CAUTION:
_
The throttle body should not be disassembled.
7 - 30
THROTTLE BODY AND FUEL INJECTOR
FI
EAS00912
CHECKING THE FUEL INJECTOR
1. Check:
• fuel injector
Damage → Replace.
EAS00913
2
1
CHECKING THE THROTTLE BODY
1. Check:
• throttle body
Cracks/damage → Replace the throttle
body.
2. Check:
• piston valve 1
Damage/scratches/wear → Replace.
• piston valve diaphragm 2
Cracks/tears → Replace.
3. Check:
• vacuum chamber cover 1
• piston valve spring 2
Cracks/damage → Replace.
4. Check:
• piston valve movement
Insert the piston valve into the throttle body
and move it up and down.
Tightness → Replace the piston valve.
7 - 31
THROTTLE BODY AND FUEL INJECTOR
4
FI
INSTALLING THE FUEL PUMP
1. Install:
4 Nm (0.4 m · kg, 2.9 ft · lb)
• fuel pump
2
T.
R.
5
6
È
1
3
a
b
NOTE:
• Do not damage the installation surfaces of
the fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Align the projection a on the fuel pump with
the alignment mark b on the fuel tank.
• Tighten the fuel pump bolts in the proper
tightening sequence as shown and torque
them in two stages.
È Forward
2
INSTALLING THE SUB-FRAME
1. Install:
• sub-frame adjusting bolts 1
• sub-frame rear mounting bolts 2
• sub-frame front lower mounting bolts 3
• sub-frame front upper mounting bolts 4
2
NOTE:
Do not fully tighten the bolts.
2. Tighten:
• sub-frame rear mounting bolts
4
T.
R.
3 1
54 Nm (5.4 m · kg, 39 ft · lb)
NOTE:
Tighten the bolts on the left side of the scooter
first.
3
1
3. Tighten:
• sub-frame front lower mounting bolts
T.
R.
54 Nm (5.4 m · kg, 39 ft · lb)
NOTE:
Tighten the bolt on the left side of the scooter
first.
7 - 32
THROTTLE BODY AND FUEL INJECTOR
FI
4. Tighten:
• sub-frame adjusting bolts
T.
R.
1
a
2
4 Nm (0.4 m · kg, 2.9 ft · lb)
NOTE:
• Tighten the bolt on the left side of the scooter
first.
• Use the pivot shaft wrench 1 and pivot shaft
wrench adapter 2 to tighten the sub-frame
adjusting bolts.
• When tightening the sub-frame adjusting
bolts, make sure that the gap a shown
between the frame and the sub-frame is the
same on both sides of the scooter.
Pivot shaft wrench
90890-01471, YM-01471
Pivot shaft wrench adapter
90890-01476
5. Tighten:
• sub-frame front upper mounting nuts
T.
R.
54 Nm (5.4 m · kg, 39 ft · lb)
NOTE:
Tighten the nut on the left side of the scooter
first.
INSTALLING THE FUEL HOSE
1. Install:
• fuel hose
• fuel hose connector cover
CAUTION:
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.
7 - 33
THROTTLE BODY AND FUEL INJECTOR
FI
EAS00915
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION
1. Check:
• pressure regulator operation
1
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the storage box.
Refer to “COWLING AND COVERS” in
chapter 3.
b. Remove the fuel hose connector cover 1
and disconnect the fuel hose 2 from the
fuel pump.
CAUTION:
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.
4
3
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.
Pressure gauge
90890-03153, YU-03153
Adapter
90890-03181
d. Start the engine.
e. Measure the fuel pressure.
Fuel pressure
246 ~ 254 kPa
(2.46 ~ 2.54 kg/cm2,
35.0 ~ 36.1 psi)
Faulty → Replace the fuel pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00916
CHECKING THE THROTTLE POSITION
SENSOR
1. Check:
• throttle position sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
terminals of the throttle position sensor.
7 - 34
THROTTLE BODY AND FUEL INJECTOR
FI
Positive tester probe → blue terminal 1
Negative tester probe →
black/blue terminal 2
Y/L B/L L
Pocket tester
90890-03112, YU-03112-C
3
2
1
b. Measure the throttle position sensor voltage.
Out of specification → Replace or repair the
wire harness.
Throttle position sensor voltage
5V
(blue–black/blue)
c. Connect the pocket tester (DC 20 V) to the
terminals of the throttle position sensor.
Positive tester probe →
yellow/blue terminal 3
Negative tester probe →
black/blue terminal 2
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 position
sensor.
Out of specification (closed position) →
Replace the throttle position sensor.
Throttle position sensor voltage
(closed position)
0.4 ~ 0.9 V
(yellow/blue–black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 35
THROTTLE BODY AND FUEL INJECTOR
FI
EAS00916
CHECKING THE ISC (IDLE SPEED
CONTROL) VALVE
NOTE:
Do not remove the ISC (idle speed control)
valve unit completely from the throttle body
assembly.
1. Check:
• ISC (idle speed control) valve
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ISC (idle speed control)
valve coupler from the ISC (idle speed control) valve.
b. Connect the pocket tester (Ω × 10) to the
terminals of the ISC (idle speed control)
valve.
Positive tester probe → pink terminal 1
Negative tester probe →
light green terminal 2
Lg
P
1
Positive tester probe → gray terminal 3
Negative tester probe →
sky blue terminal 4
Sb
Gy
3
Pocket tester
90890-03112, YU-03112-C
2
4
c. Measure the ISC (idle speed control) valve
resistance.
Out of specification → Replace the throttle
body.
ISC (idle speed control) valve
resistance
27 ~ 33 Ω at 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 36
AIR INDUCTION SYSTEM
FI
EAS00507
AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned
exhaust gases by injecting fresh air (secondary air) into the exhaust port, 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
required temperature for burning the unburned
exhaust gases is approximately 600 to 700 °C
(1,112 to 1,292 °F).
EAS00917
È
AIR CUT-OFF VALVE
The air cut-off valve prevents air backflow from
the exhaust port of the cylinder head to the air
filter.
È From the air filter
É To the cylinder head
É
7 - 37
FI
AIR INDUCTION SYSTEM
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1 Air induction system hose (air filter case to air cut-off valve)
2 Air cut-off valve
3 Air induction system hose (air cut-off valve to cylinder head)
4 Air induction system pipe
5 Air filter case cover (right)
1
1
B
2
B
3
A
2
5
4
A
7 - 38
AIR INDUCTION SYSTEM
FI
AIR CUT-OFF VALVE AND AIR INDUCTION SYSTEM HOSES
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
3
2
Order
1
2
3
Job/Part
Removing the air cut-off valve and
air induction system hoses
Air induction system hose (air filter
case to air cut-off valve)
Air induction system hose (air cut-off
valve to air filter case)
Air cut-off valve
Q’ty
Remarks
Remove the parts in the order listed.
1
Disconnect.
1
Disconnect.
1
For installation, reverse the removal procedure.
7 - 39
AIR INDUCTION SYSTEM
FI
EAS00918
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
• hoses
Loose connections → Connect properly.
Cracks/damage → Replace.
• pipes
Cracks/damage → Replace.
2. Check:
• reed valve
• reed valve stopper
• reed valve seat
Cracks/damage → Replace the reed valve.
3. Check:
• air cut-off valve
Cracks/damage → Replace.
7 - 40
–
ELEC
+
8
ELEC
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS........................................................................ 8-1
CHECKING SWITCH CONTINUITY................................................................8-3
CHECKING THE SWITCHES..........................................................................8-4
CHECKING THE BULBS AND BULB SOCKETS .......................................... 8-5
TYPES OF BULBS .................................................................................... 8-5
CHECKING THE CONDITION OF THE BULBS ....................................... 8-6
CHECKING THE CONDITION OF THE BULB SOCKETS .......................8-7
CHECKING THE LEDs..............................................................................8-7
IGNITION SYSTEM ......................................................................................... 8-8
CIRCUIT DIAGRAM .................................................................................. 8-8
TROUBLESHOOTING ..............................................................................8-9
ELECTRIC STARTING SYSTEM .................................................................. 8-14
CIRCUIT DIAGRAM ................................................................................ 8-14
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 8-15
TROUBLESHOOTING ............................................................................8-16
STARTER MOTOR........................................................................................ 8-19
CHECKING THE STARTER MOTOR .....................................................8-21
ASSEMBLING THE STARTER MOTOR................................................. 8-22
CHARGING SYSTEM....................................................................................8-23
CIRCUIT DIAGRAM ................................................................................ 8-23
TROUBLESHOOTING ............................................................................8-24
LIGHTING SYSTEM ......................................................................................8-26
CIRCUIT DIAGRAM ................................................................................ 8-26
TROUBLESHOOTING ............................................................................8-27
CHECKING THE LIGHTING SYSTEM....................................................8-30
SIGNALING SYSTEM ...................................................................................8-35
CIRCUIT DIAGRAM ................................................................................ 8-35
TROUBLESHOOTING ............................................................................8-37
CHECKING THE SIGNALING SYSTEM ................................................. 8-38
COOLING SYSTEM....................................................................................... 8-45
CIRCUIT DIAGRAM ................................................................................ 8-45
TROUBLESHOOTING ............................................................................8-46
–
+
ELEC
IMMOBILIZER SYSTEM................................................................................ 8-49
SYSTEM DIAGRAM ................................................................................ 8-49
CIRCUIT DIAGRAM ................................................................................ 8-50
GENERAL INFORMATION ..................................................................... 8-51
KEY CODE REGISTRATION .................................................................. 8-52
SELF-DIAGNOSIS MALFUNCTION CODES..........................................8-54
TROUBLESHOOTING ............................................................................8-56
CHECKING THE IMMOBILIZER SYSTEM ............................................. 8-57
PART REPLACEMENT KEY REGISTRATION REQUIREMENTS.........8-59
–
+
ELECTRICAL COMPONENTS
–
ELEC
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1 Starting circuit cut-off relay
2 Headlight relay 1
3 Turn signal relay
4 Radiator fan motor relay
5 Headlight relay 2
6 Main switch/immobilizer unit
7 Front brake light switch
1
2
3
8 Rear brake light switch
9 Storage box light switch
0 Starter relay
A Main fuse
B Battery
C Fuse box
D Diode
4
5
6
9
A
L
8
7
0
B
K
M
C
D
J
I
E
H
F
G
8-1
+
ELECTRICAL COMPONENTS
–
ELEC
E Stator coil
F Sidestand switch
G Ignition coil
H Radiator fan motor
I Rectifier/regulator
J Horn
K Thermistor
L ECU
M Wire harness
1
2
3
4
5
6
9
A
L
8
7
0
B
K
M
C
D
J
I
E
H
F
G
8-2
+
CHECKING SWITCH CONTINUITY
ELEC
–
+
EAS00730
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the
pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.
CAUTION:
_
Never insert the tester probes into the coupler terminal slots a. Always insert the
probes from the opposite end of the coupler, taking care not to loosen or damage
the leads.
Pocket tester
90890-03112, YU-03112-C
NOTE:
• Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back
and forth between the switch positions a few
times.
_
b
R
a
Br/L Br/R
ON
OFF
OPEN
LOCK
P
R
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.
Br/R
Br/L
NOTE:
“
” 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 red, brown/blue,
and brown/red when the switch is set to “ON”.
There is continuity between red and brown/red
when the switch is set to “ ”.
8-3
ELEC
CHECKING THE SWITCHES
–
+
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
4
R/W R/B
2
L/W B
5
Br
G/Y
R Br/L Br/R
3
ON
OFF
OPEN
LOCK
P
Ch Br/W Dg
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
B
R/Y W/Y
0
R
Br/L
6
B
B
7
8
9
Br/R
R L/G
G/B R/Y
PASS
G/Y
C
A
Br
Ch Br/W Dg
P B
OFF
1 Engine stop switch
2 Start switch
3 Hazard switch
4 Front brake light switch
5 Main switch
R/Y Br/W W/Y G/B Dg
P Br B G/Y Ch
6 Sidestand switch
7 Fuse
8 Storage box light switch
9 Rear brake light switch
0 Dimmer switch
8-4
A Turn signal switch
B Pass switch
C Horn switch
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
EAS00733
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage
or wear, proper connections, and also for continuity between the terminals.
Damage/wear → 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.
• Bulbs a and b are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulb c is used for turn signal and tail/brake
lights and can be removed from the socket
by pushing and turning the bulb counterclockwise.
• Bulbs d and e are used for meter and indicator lights and can be removed from their
respective socket by carefully pulling them
out.
8-5
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
WARNING
_
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
_
• 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:
• 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 “Ω × 1” range.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity.
b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-6
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
• 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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE LEDs
The following procedure applies to all of the
LEDs.
1. Check:
• LED (for proper operation)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Ch Dg
G/L
1
L
Y
a. Connect the pocket tester (DC 20 V) to the
meter coupler as shown.
R/W R/G G
Y/L B/L Gy
B
Positive tester probe → green/blue 1
Negative tester probe → black 2
2
b. Turn the main switch to “ON”.
c. Measure the immobilizer indicator light voltage.
Immobilizer indicator light voltage
2.6 V
Out of specification → Replace the meter
assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-7
8-8
Gy
B
B
B
BB3 BB2
BB4 BB1
B
B
B
B
B
B
(GRAY)
B B/L
(GRAY)
B
z
B
Br/L
G
©
®
Gy
Br
Br
Br
R/Y
R/W
Y
R/W R/G
Y/L B/L Gy
| } ~ å
Br
Br/L
ß
¶
8
R
Br
Br/L
Ch Dg
G/L L
{
y
R
W
R
R
Br
W
(BLACK)
B
W
R
Br/L
Br/R
R
BB2
BB1
B/L
Br/L
R/W
R/G Y/L
ON
OFF
OPEN
LOCK
P
R
B
3
Br/L
G/L
W
W
W
4
R/G R/W Y/L
G/L B2
B
W
W
W
W
W/R
W/L
9
BB3
BB4
B2
B1
B1 B2
R/W Lg Y/L
B2 B1
2
1
W
Y/L G/L R/W
5
W
R/G B2 B
W
B B2 R/G
6
B Gy
•
L/G
R/G
W
W
(BLACK)
R
2 Crankshaft position
sensor
4 Main switch
8 Ignition fuse
A Battery
w
B Main fuse
F Starting circuit cutx
off relay
H Engine
stop switch
§
L Sidestand switch
P Lean angle cut-off£
switch
R ECU
S Ignition coil
T Spark plug
B
7
R L/G
L/G R/G
W
(BLACK)
W/L W/R
R/G
0
B
B
R
G
B
Y
Dg
B
B
B
B
D
B
B
B
R/W
R/B
B
Ch
R/Y
G/L
R/Y
Y
G/L
Y
Y
B
G
B
(BLACK)
B
d
G/B G
W/B
R
R
J
B
Y G
e
G/LW/B
v
L/W
G/Y
E
L/W
G/Y
PASS
g
Br
v
G
G/B
A
G
B
B Ch L
L Ch B
G/B
L
B L/Y
Br
Br/W
OFF
j
Br
B
B
L Dg B
Br
k
B Dg L
(BLACK)
(BLACK)
Dg
Br/W
Br/W
b
Ch
(BLUE)
(BLACK)
Ch
B
B
B B
(BLUE)
q L Dg
r u r s
i
P
P
c
Br
L
L/Y
G/Y L/Y
F
(BLACK)
B/L P/W L
L Y/G B/L
(GREEN)
Br/W B/L
L
Y/L
B/L
B Ch
Br Dg
Ch B
Dg L/R
B
l Ch Dg Br
mn o
G/Y
(GRAY)
B
Br
P
B
G/Y Br
L Y
B
G/Y
L Y/G B/L
O
N
p
B/L
Br/W
L
P/W
B/L
B/L
B/L B B/L
Br/W B Br/W
Q
B
L
L G/Y
B
a
_
Br R/W
(GREEN)
G/R B/L
Y/L B Y
L B L
P/W B P/W
G/R
(BLACK)
L
(BLACK)
B
G/Y
L
L
Br
B/W
R
B
R/W
Y/L
L/B
L/Y
G/Y
R/W
W/B
Y/G
B/L
Br/W
Y
L
P/W
G/R
W/R
W/L
R
B
Br
L
Br
W
G/B
O/B
R/L
R/Y
P
Lg
Gy
Sb
O
OFF
ON
W
]
\
L
B
C
B
B
L
L
L
L
L G/B
Br Br
Br
C
Br
B
W R
X
O/B
P
Lg
Gy
Sb
Z
[
G/B
W
L
B/L
B
B
B
B
B
O
R/B
Y
L
B
(BLUE)
L
(BLUE)
L
L
L
(BLUE)
L
(BLUE)
L
L
L
(RED)
R/L B
L
G/B
C
G/B
B R/L
G B
R/L
O/B R/L
(BLACK)
(BLACK)
P Gy
Lg Sb
T
(RED)
Br
L W
B/L
L
(BLACK)
U
S
B
R/L
Y
B
G
V
Br
B
R/Y R/L
R/B R
R/B
R
R/L
R/Y
SUB-WIRE HARNESS 3
B
WIRE HARNESS
G/B
Br
C
G/B
–
B
Y
P
(BLACK)
Br
t
W/Y
h
G/Y
K
R/B G/Y
L/Y G/W
G/W
R/B
M
L B/L Y/L
W/L L/B Y/L B/W B G/Y R/Y
G/R Y W/R
L/Y B/L W/B G/B
R/L Br/W
R/W W Lg P O/B
P/W Y/G
L
R Sb Gy O
(GRAY)
SUB-WIRE HARNESS 2
(GRAY)
WIRE HARNESS
Y/L R/L O/B P
G/R Lg Gy Sb
P/W B/L L Br/W
B
P O/B R/L Y
Sb Gy Lg G/R
Br/W L B/L P/W
ELEC
B
B
Y G
Y G
A A
Y G
(BLACK)
Dg G/B W/Y Br/W R/Y
Ch G/Y B Br P
(BLACK)
R/Y Br/W W/Y G/B Dg
P Br B G/Y Ch
f
R/Y
Ch
Dg
Br/W
(BLACK)
R/YR/Y
G/W
L/W
G/Y
L/W G/Y
L/B
B
R
C
I
R
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
G
H
B
A
ç † ¢
L
G/W R/W
Br Dg
G/Y Ch Br/W L/B R/B
B
R
SUB-WIRE HARNESS 1
Y
WIRE HARNESS
B
G
B
G
Y
IGNITION SYSTEM
+
EAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
EAS00736
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
The ignition system fails to operate (no
spark or intermittent spark).
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main and ignition fuses
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
11.starting circuit cut-off relay
12.lean angle cut-off switch
13.wiring connections (of the entire ignition
system)
Minimum open-circuit voltage
12.8 V or more at 20°C (68°F)
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00740
3. Spark plug
NOTE:
• Before troubleshooting, remove the following
part(s):
1. storage box
2. front cowling
• Troubleshoot with the following special
tool(s).
• 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)
Ignition checker
90890-06754, YM-34487
Pocket tester
90890-03112, YU-03112-C
• Is the spark plug in good condition, is it of
the correct type, and is its gap within specification?
EAS00738
YES
1. Main and ignition fuses
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
NO
Re-gap or replace
the spark plug.
NO
Replace the fuse(s).
8-9
IGNITION SYSTEM
EAS00742
ELEC
–
+
EAS00744
4. Ignition spark gap
5. Spark plug cap resistance
• 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 start
switch and gradually increase the spark
gap until a misfire occurs.
• Remove the spark plug cap from the spark
plug lead.
• Connect the pocket tester (“Ω × 1k” range)
to the spark plug cap as shown.
• Measure the spark plug cap resistance.
Spark plug cap resistance
10 kΩ at 20 °C (68 °F)
• Is the spark plug cap OK?
Minimum ignition spark gap
6 mm (0.24 in)
• Is there a spark and is the spark gap within
specification?
YES
NO
YES
NO
The ignition system
is OK.
8 - 10
Replace the
plug cap.
spark
ELEC
IGNITION SYSTEM
EAS00746
–
+
EAS00748
7. Crankshaft position sensor resistance
6. Ignition coil resistance
• Disconnect the crankshaft position sensor
coupler from the wire harness.
• Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as
shown.
• Disconnect the ignition coil connectors
from the ignition coil terminals.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Positive tester probe → red/black
Negative tester probe → orange
Positive tester probe → red 1
Negative tester probe → white 2
1
2
R
W
• Measure the primary coil resistance.
• Measure the crankshaft position sensor
resistance.
Primary coil resistance
2.16 ~ 2.64 Ω at 20 °C (68 °F)
Crankshaft position sensor resistance
248 ~ 372 Ω at 20 °C (68 °F)
(between red and white)
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
Negative tester probe → spark plug lead 1
Positive tester probe → red/black 2
• Is the crankshaft position sensor OK?
• Measure the secondary coil resistance.
YES
NO
Replace 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?
Secondary coil resistance
8.64 ~ 12.96 kΩ at 20 °C (68 °F)
• Is the ignition coil OK?
YES
YES
NO
NO
Replace the ignition
coil.
8 - 11
Replace the main
switch/immobilizer
unit.
IGNITION SYSTEM
EAS00750
ELEC
–
+
EAS00753
9. Engine stop switch
11.Starting circuit cut-off relay
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
• Remove the starting circuit cut-off relay.
• Connect the pocket tester (Ω × 1) to the
starting circuit cut-off relay terminals as
shown.
• Check the starting circuit cut-off relay for
continuity.
NO
Replace the right
handlebar switch.
EAS00752
Positive tester probe →
blue/yellow 1
Continuity
Negative tester probe →
red/black 2
Positive tester probe →
red/black 2 No
Negative tester probe →
continuity
blue/yellow 1
10.Sidestand switch
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
2
YES
NO
Replace the
stand switch.
side-
1
L/Y G/W
R/B G/Y
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
_
• Are the tester readings correct?
YES
NO
Replace the starting
circuit cut-off relay.
8 - 12
IGNITION SYSTEM
• Remove the lean angle cut-off switch.
• Connect the pocket tester (Ω × 1) to the
lean angle cut-off switch terminals as
shown.
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly
connected and without defects?
YES
Replace the ECU.
Lean angle cut-off switch voltage
Less than 45° a →
Approximately 1 V
More than 45° b →
Approximately 4 V
a
ON
b
• Is the lean angle cut-off switch OK?
YES
+
13.Wiring
Positive tester probe → blue 1
Negative tester probe → yellow/green 2
a
–
EAS00754
12.Lean angle cut-off switch
ON
ELEC
NO
Replace the lean
angle cut-off switch.
8 - 13
NO
Properly connect or
repair the ignition
system’s wiring.
8 - 14
§
B
Gy
B
B
B
7
L/G
R/G
W
Br/L
B
(GRAY)
B
x
B B/L
BB4 BB1
B
£
B
z
B
G
©
®
Gy
Br
Br
Br
R/Y
R/W
Y
R/W R/G
Y/L B/L Gy
| } ~ å
Ch Dg
G/L L
{
y
Br
Br/L
ß
¶
8
R
Br/L
Br
0
B
B
R
G
B
Y
Dg
B
B
B
B
D
B
B
B
R/W
R/B
B
Ch
R/Y
G/L
R/Y
Y
G/L
Y
B
(BLACK)
B
d
G/B G
W/B
R
R
J
Y G
e
G/LW/B
v
L/W
G/Y
E
L/W
G/Y
PASS
g
R/Y
Br
v
G
G/B
P
G/B
L
P
P
c
Br
L
Br
Br/W
OFF
j
Br
Dg
Br/W
Br/W
b
Ch
(BLUE)
B L/Y
B B
(BLUE)
(BLACK)
Ch
B
B
L/Y
G/Y L/Y
F
q L Dg
r u r s
i
(BLACK)
Br
t
W/Y
h
G/Y
K
R/B G/Y
L/Y G/W
G/W
R/B
k
Br
G/Y
(BLACK)
B/L P/W L
L Y/G B/L
(GREEN)
Br/W B/L
L
Y/L
B/L
l Ch Dg Br
mn o
M
(GRAY)
L B/L Y/L
Br
P
G/Y
L Y/G B/L
O
N
B/L
Br/W
L
P/W
B/L
B/L B B/L
Br/W B Br/W
B/L
Q
B
R/W
Y/L
L/B
L/Y
G/Y
R/W
W/B
Y/G
B/L
Br/W
Y
L
P/W
G/R
W/R
W/L
R
Br
G/Y
B/W
R
B
Br
Br
W
G/B
O/B
R/L
R/Y
P
Lg
Gy
Sb
O
G/B
OFF
ON
W
L
B/L
B
B
B
B
B
O
R/B
W
Br
C
Br
B
W R
X
O/B
P
Lg
Gy
Sb
Y
Br
L W
B/L
L
C
G/B
L
B
B R/L
R/L B
G
R/L
O/B R/L
(BLACK)
(BLACK)
P Gy
Lg Sb
T
G/B
(BLACK)
U
S
B
R/L
Y
B
L
L G/Y
L
(BLACK)
L
(BLACK)
B
B
L
L
L
B
C
B
B
L
L
L
L
L G/B
Br Br
L
B
(BLUE)
L
(BLUE)
L
L
L
(BLUE)
L
(BLUE)
L
L
(RED)
L
(RED)
B
G
V
4 Main switch
Z
8 Ignition fuse
_
A Battery
B Main fuse
[
C Starter relay
D Starter motor
a
E Diode
\ cut-off relay
F Starting circuit
H Engine stop switch
I Start switch
]
K Front brake light
switch
L Sidestand switch
k Rear brake light switch
® Signaling system fuse
Br R/W
(GREEN)
G/R B/L
Y/L B Y
L B L
P/W B P/W
G/R
W/L L/B Y/L B/W B G/Y R/Y
G/R Y W/R
L/Y B/L W/B G/B
R/L Br/W
R/W W Lg P O/B
P/W Y/G
L
R Sb Gy O
(GRAY)
SUB-WIRE HARNESS 2
(GRAY)
WIRE HARNESS
Y/L R/L O/B P
G/R Lg Gy Sb
P/W B/L L Br/W
B
P O/B R/L Y
Sb Gy Lg G/R
Br/W L B/L P/W
R/Y R/L
R/B R
WI
–
Y G
Y G
A A
Y G
(BLACK)
Dg G/B W/Y Br/W R/Y
Ch G/Y B Br P
(BLACK)
R/Y Br/W W/Y G/B Dg
P Br B G/Y Ch
f
Ch
Dg
Br/W
(BLACK)
R/YR/Y
G/W
L/W
G/Y
L/W G/Y
L/B
B
R
C
I
R
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
G
H
B
A
ç † ¢
L
G/W R/W
Br Dg
G/Y Ch Br/W L/B R/B
B
R
SUB-WIRE HARNESS 1
Y
WIRE HARNESS
B
ELEC
(GRAY)
BB3 BB2
B
B
R
W
R
R
Br
W
(BLACK)
B
W
R
Br/L
Br/R
R
Br/L
B/L
Br/L
R/W
R/G Y/L
ON
OFF
OPEN
LOCK
P
R
B
3
BB2
BB1
w G/L
W
W
W
4
R/G R/W Y/L
G/L B2
B
W
W
W
W
W/R
W/L
9
BB3
BB4
B2
B1
B1 B2
B
B2 B1
R/W Lg Y/L
5
W
2
1
Y/L G/L R/W
W
W
R/G B2 B
W
R
(BLACK)
B B2 R/G
6
B Gy
•
R L/G
L/G R/G
W
(BLACK)
W/L W/R
R/G
A
G
B
G
Y
ELECTRIC STARTING SYSTEM
+
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
–
+
EAS00756
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the engine stop switch is set to “ ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if
the following conditions are met:
• A brake lever is pulled to the handlebar (the
brake light switch is closed) and the sidestand is up (the sidestand switch is closed).
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cut-off relay
7 Sidestand switch
8 Signaling system fuse
9 Front brake light switch
0 Rear brake light switch
A Start switch
B Starter relay
C Starter motor
8 - 15
ELECTRIC STARTING SYSTEM
EAS00757
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
The starter motor fails to turn.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, ignition, and signaling system fuses
2. battery
3. starter motor
4. starting circuit cut-off relay
5. starter relay
6. main switch
7. engine stop switch
8. brake light switch (front and rear)
9. sidestand switch
10.start switch
11.wiring connections
(of the entire starting system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
NOTE:
• Before troubleshooting, remove the following
part(s):
1. storage box
2. front cowling
• Troubleshoot with the following special
tool(s).
_
EAS00758
3. Starter motor
• Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
Pocket tester
90890-03112, YU-03112-C
EAS00738
1. Main, ignition, and signaling system fuses
• Check the main, ignition, and signaling
system fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition, and signaling system fuses OK?
YES
NO
Replace the fuse(s).
WARNING
_
• 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.
• This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
• Does the starter motor turn?
YES
NO
Repair or replace the
starter motor.
8 - 16
ELECTRIC STARTING SYSTEM
EAS00759
ELEC
–
+
EAS00761
4. Starting circuit cut-off relay
5. Starter relay
• Remove the starting circuit cut-off relay.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cut-off
relay terminals as shown.
Positive battery terminal → red/black 1
Negative battery terminal → blue/yellow 2
Positive battery terminal →
green/yellow 1
Negative battery terminal → blue/white 2
Positive tester probe → green/yellow 3
Negative tester probe → green/white 4
1
3
2
4
• Remove the starter relay.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay terminal as
shown.
Positive tester probe → black 3
Negative tester probe → red 4
L/Y G/W
R/B G/Y
• Does the starting circuit cut-off relay have
continuity between green/yellow and
green/yellow?
YES
• Does the starter relay have continuity
between black and black?
NO
YES
NO
Replace the starter
relay.
Replace the starting
circuit cut-off relay.
EAS00749
6. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
Replace the main
switch/immobilizer
unit.
8 - 17
ELECTRIC STARTING SYSTEM
EAS00750
ELEC
–
+
EAS00766
7. Engine stop switch
11.Wiring
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly
connected and without defects?
NO
YES
YES
Replace the right
handlebar switch.
The starting system
circuit is OK.
EAS00751
8. Brake light switch (front and rear)
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is each brake light switch OK?
YES
NO
Replace the brake
light switch(s).
EAS00752
9. Sidestand switch
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
YES
NO
Replace the
stand switch.
side-
EAS00764
10.Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
8 - 18
NO
Properly connect or
repair the starting
system’s wiring.
STARTER MOTOR
ELEC
–
+
EAS00767
STARTER MOTOR
Order
1
2
Job/Part
Removing the starter motor
Throttle body
Starter motor lead
Starter motor
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “THROTTLE BODY AND FUEL
INJECTOR” in chapter 7.
1
1
For installation, reverse the removal procedure.
8 - 19
STARTER MOTOR
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the starter motor
Front bracket
O-ring
Shim
Lock washer
Rear bracket
O-ring
Shim
Brush holder set
Armature assembly
Starter motor yoke
Q’ty
1
1
1
1
1
1
1
1
1
1
ELEC
–
+
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE STARTER
MOTOR”.
For assembly, reverse the disassembly
procedure.
8 - 20
STARTER MOTOR
ELEC
–
+
EAS00770
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
27 mm (1.06 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
0.7 mm (0.028 in)
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
_
4. Measure:
• armature assembly resistances (commutator and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
90890-03112, YU-03112-C
Armature coil
Commutator resistance 1
0.0012 ~ 0.0022 Ω at 20 °C
(68 °F)
Insulation resistance 2
Above 1 MΩ at 20 °C (68 °F)
b. If any resistance is out of specification,
replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 21
STARTER MOTOR
ELEC
–
+
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
Brush length wear limit
4.0 mm (0.16 in)
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force
7.65 ~ 10.01 N
(780 ~ 1,021 gf, 27.54 ~ 36.03 oz)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8.
•
•
•
Check:
bearing 1
oil seal 2
bushing 3
Damage/wear → Replace the defective
part(s).
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
• starter motor yoke 1
• front bracket 2
• rear bracket 3
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
rear brackets.
_
8 - 22
8 - 23
L/G
R/G
•
1 A.C. magneto
3 Rectifier/regulator
A Battery
B Main fuse
B
7
R L/G
L/G R/G
W
W
W
W
Br
Br/L
BB3 BB2
BB4 BB1
B
B
B
Br
Br/L
©
®
ß
¶
8
R
Br/L
Br
R
R
Br/L
W
R
W
(BLACK)
B
W
R
Br/L
Br/R
R
BB2
BB1
R
B
3
Br/L
ON
OFF
OPEN
LOCK
P
4
R/G R/W Y/L
G/L B2
B
W
W
W
W
W/R
W/L
9
BB3
BB4
B2
B1
B1 B2
B
B2 B1
R/W Lg Y/L
5
W
1
Y/L G/L R/W
W
W
R/G B2 B
W
R
(BLACK)
B B2 R/G
6
W
W/L W/R
(BLACK)
2
R/G
Br
Br
Br
R/Y
R/W
0
B
B
R
G/W R/W
Br Dg
G/Y Ch Br/W L/B R/B
B
R
B
B
B
B
R/W
R/B
D
B
B
B
R/Y
W/B
d
R
L/W
G/Y
J
E
L/W
G/Y
Ch
Dg
Br/W
(BLACK)
R/YR/Y
G/W
L/W
G/Y
Br
G/Y
K
P
(BLACK)
Br
R/B G/Y
L/Y G/W
P
c
Br
L
B
Br
Br/W
(BLUE)
B L/Y
B B
(BLUE)
F
Br/W
b
Br
(BLACK)
B/L P/W L
L Y/G B/L
(GREEN)
Br/W B/L
L
Y/L
B/L
P
L Y/G B/L
O
N
B/L
Br/W
L
P/W
B/L
–
(BLACK)
L/Y
G/Y L/Y
G/W
R/B
M
(GRAY)
ELEC
G/L
R/Y
R
L/W G/Y
L/B
B
R
C
I
R
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
G
H
B
A
B
L B/L Y/L
W
G/R
R/L
P/W Y
CHARGING SYSTEM
+
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
CHARGING SYSTEM
EAS00774
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
The battery is not being charged.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections
(of the entire charging system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. footrest board (left)
• Troubleshoot with the following special
tool(s).
NO
_
Pocket tester
90890-03112, YU-03112-C
EAS00738
1. Main fuse
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Is the main fuse OK?
YES
NO
Replace the fuse.
8 - 24
• Clean the battery
terminals.
• Recharge or
replace the battery.
ELEC
CHARGING SYSTEM
EAS00775
–
+
EAS00776
3. Charging voltage
4. Stator coil resistance
• Connect the pocket tester (DC 20 V) to the
battery as shown.
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
• Disconnect the stator coil coupler from the
wire harness.
• Connect the pocket tester (Ω × 1) to the
stator coil as shown.
Positive tester probe → white 1
Negative tester probe → white 2
Positive tester probe → white 1
Negative tester probe → white 3
23
W W W
• Start the engine and let it run at approximately 5,000 r/min.
• Measure the charging voltage.
1
• Measure the stator coil resistances.
Charging voltage
14 V at 5,000 r/min
Stator coil resistance
0.184 ~ 0.276 Ω at 20 °C (68 °F)
NOTE:
Make sure the battery is fully charged.
• Is the stator coil OK?
_
YES
• Is the charging voltage within specification?
NO
Replace the crankshaft position sensor/
stator assembly.
YES
The charging circuit
is OK.
NO
EAS00779
5. Wiring
• Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly
connected and without defects?
YES
Replace the rectifier/
regulator.
8 - 25
NO
Properly connect or
repair the charging
system’s wiring.
8 - 26
§
B
Gy
B
B
B
7
L/G
R/G
W
Br/L
B
(GRAY)
B
x
B B/L
BB4 BB1
B
(GRAY)
BB3 BB2
B
B
£
B
z
B
G
©
®
Gy
Br
Br
Br
R/Y
R/W
Y
R/W R/G
Y/L B/L Gy
| } ~ å
Ch Dg
G/L L
{
y
Br
Br/L
ß
¶
8
R
Br/L
Br
R
R
Br
R
W
R
Br/L
Br/R
W
(BLACK)
B
W
BB2
BB1
B/L
Br/L
R/W
R/G Y/L
ON
OFF
OPEN
LOCK
P
R
B
3
R
Br/L
w G/L
W
W
W
4
R/G R/W Y/L
G/L B2
B
W
W
W
W
W/R
W/L
9
BB3
BB4
B2
B1
B1 B2
B
B2 B1
R/W Lg Y/L
5
W
Y/L G/L R/W
W
1
R/G B2 B
W
W
(BLACK)
R
B B2 R/G
6
B Gy
•
R L/G
L/G R/G
W
(BLACK)
W/L W/R
2
R/G
0
B
B
R
G
B
Y
Dg
B
B
B
B
D
B
B
B
R/W
R/B
B
Ch
R/Y
G/L
R/Y
Y
G/L
B
Y
Y
B
G
B
(BLACK)
G/B G
W/B
d
R
R
J
B
Y G
e
G/LW/B
v
L/W
G/Y
E
L/W
G/Y
PASS
g
R/Y
Br
v
G
G/B
A
G
B
B Ch L
L Ch B
G/B
L
P
B L/Y
Br
Br/W
OFF
j
Br
B
B
L Dg B
Br
k
B Dg L
(BLACK)
(BLACK)
Dg
Br/W
Br/W
b
Ch
(BLUE)
(BLACK)
Ch
B
B
B B
(BLUE)
q L Dg
r u r s
i
P
c
Br
L
L/Y
G/Y L/Y
F
L Y/G B/L
(GREEN)
B Ch
Br Dg
Ch B
Dg L/R
B
l Ch Dg Br
mn o
G/Y
(BLACK)
B/L P/W L
Br/W B/L
L
Y/L
B/L
B
Br
P
B
G/Y Br
L Y
B
G/Y
L Y/G B/L
O
N
p
B/L
Br/W
L
P/W
B/L
B/L
B/L B B/L
Br/W B Br/W
Q
B
L
L G/Y
B
a
_
Br R/W
(GREEN)
G/R B/L
Y/L B Y
L B L
P/W B P/W
G/R
(BLACK)
L
(BLACK)
L
G/Y
B
L
Br
B/W
R
B
R/W
Y/L
L/B
L/Y
G/Y
R/W
W/B
Y/G
B/L
Br/W
Y
L
P/W
G/R
W/R
W/L
R
B
Br
L
Br
W
G/B
O/B
R/L
R/Y
P
Lg
Gy
Sb
O
G/B
W
W R
O/B
P
Lg
Gy
Sb
Y
L W
B/L
L
L
B R/L
G B
R/L
O/B R/L
(BLACK)
(BLACK)
P Gy
Lg Sb
T
G/B
(BLACK)
U
S
B
R/L
Y
B
G
V
B
R/Y R/L
R/B R
R/B
R
R/L
R/Y
SUB-WIRE HARNESS 3
Br
B
WIRE HARNESS
G/B
Br
C
G/B
OFF
ON
L
B
C
B
B
L
L
L
L
L G/B
Br Br
Br
C
Br
B
L
Br
L
L
B
(BLUE)
L
(BLUE)
L
L
(BLUE)
L
L
(RED)
(BLUE)
L
(RED)
C
G/B
R/L B
4 Main switch
6 Storage box light switch
X
7 Storage box light
9 Backup fuse (storage
box light, immobilizer
unit, and meter assembly)
A Battery
Z
B Main fuse
R ECU
d Headlight relay 1
[
e Headlight relay 2
g Pass switch
h Dimmer switch
\
o License plate light
p Tail/brake light
]
r Auxiliary light
v Headlight
å Meter light
ç High beam indicator
light
¶ Headlight fuse
® Signaling system fuse
© Turn signal/hazard fuse
W
L
B/L
B
B
B
B
B
O
R/B
SUB-WIRE HARNESS 2
(GRAY)
(GRAY)
WIRE HARNESS
Y/L R/L O/B P
G/R Lg Gy Sb
P/W B/L L Br/W
B
P O/B R/L Y
Sb Gy Lg G/R
Br/W L B/L P/W
–
B
Y
P
(BLACK)
Br
t
W/Y
h
G/Y
K
R/B G/Y
L/Y G/W
G/W
R/B
M
(GRAY)
L B/L Y/L
W/L L/B Y/L B/W B G/Y R/Y
G/R Y W/R
L/Y B/L W/B G/B
R/L Br/W
R/W W Lg P O/B
P/W Y/G
L
R Sb Gy O
SUB-WIRE HARNESS 1
Y
WIRE HARNESS
B
ELEC
B
B
Y G
Y G
A A
Y G
(BLACK)
Dg G/B W/Y Br/W R/Y
Ch G/Y B Br P
(BLACK)
R/Y Br/W W/Y G/B Dg
P Br B G/Y Ch
f
Ch
Dg
Br/W
(BLACK)
R/YR/Y
G/W
L/W
G/Y
L/W G/Y
L/B
B
R
C
I
R
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
G
H
B
A
ç † ¢
L
G/W R/W
Br Dg
G/Y Ch Br/W L/B R/B
B
R
A
G
B
G
Y
LIGHTING SYSTEM
+
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
EAS00781
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
Any of the following fail to light: headlights, high beam indicator light, taillight,
license plate light, storage box light, auxiliary lights or meter light.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, headlights, signaling system, turn signal/hazard, and backup fuses
2. battery
3. main switch
4. dimmer switch
5. pass switch
6. storage box light switch
7. headlight relay 1
8. headlight relay 2
9. wiring connections
(of the entire lighting system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1. storage box
2. front cowling
3. meter assembly
• Troubleshoot with the following special
tool(s).
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00749
3. Main switch
_
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
Replace the main
switch/immobilizer
unit.
Pocket tester
90890-03112, YU-03112-C
EAS00784
EAS00738
4. Dimmer switch
1. Main, headlight, signaling system, turn signal/hazard, and backup fuses
• Check the main, headlight, signaling system, turn signal/hazard, and backup fuses
for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, headlight, signaling system,
turn signal/hazard, and backup fuses OK?
YES
NO
Replace the fuse(s).
8 - 27
• Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the dimmer switch OK?
YES
NO
The dimmer switch is
faulty. Replace the
left handlebar switch.
LIGHTING SYSTEM
ELEC
–
+
EAS00786
7. Headlight relay 1
5. Pass switch
• Remove the headlight relay 1.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay 1 terminals
as shown.
• Check the headlight relay 1 for continuity.
• Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the pass switch OK?
NO
YES
The pass switch is
faulty. Replace the
left handlebar switch.
Positive battery terminal → red/yellow 1
Negative battery terminal → white/black 2
Positive tester probe → red/yellow 3
Negative tester probe → green/blue 4
3
6. Storage box light switch
4
• Check the storage box light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the storage box light switch OK?
+
2
1
W/B
R/Y
G/L
YES
NO
R/Y
The storage box light
switch
is
faulty.
Replace the storage
box light switch.
• Does the headlight relay 1 have continuity
between red/yellow and green/blue?
YES
NO
Replace the headlight relay 1.
8 - 28
LIGHTING SYSTEM
ELEC
–
+
EAS00787
8. Headlight relay 2
9. Wiring
• Remove the headlight relay 2.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay 2 terminal
as shown.
• Check the headlight relay 2 for continuity.
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly
connected and without defects?
Positive tester probe → green/blue 1
Negative tester probe → green 2
YES
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
1
2
B
G G/B
Y
G/L
Positive battery terminal → green/black 3
Negative battery terminal → black 4
Positive tester probe → green/blue 5
Negative tester probe → yellow 6
5
6
+
4
3
B
G G/B
Y
G/L
• Does the headlight relay 2 have continuity
between green/blue and green or yellow?
YES
NO
Replace the headlight relay 2.
8 - 29
NO
Properly connect or
repair the lighting
system’s wiring.
EAS00788
CHECKING THE LIGHTING SYSTEM
1. The headlights and the high beam indicator
light fail to come on.
1. Headlight bulb and socket
• Check the headlight bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the headlight bulb and socket OK?
È When the dimmer switch is set to “
É When the dimmer switch is set to “
È
2
• Check the high beam indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the high beam indicator light bulb and
socket OK?
É
1
Y
B
3
High beam indicator light
Positive tester probe → yellow 4
Negative tester probe → black 5
Meter assembly coupler
Ch Dg
G/L
YES
G
+
2. High beam indicator light bulb and socket
”
”
Headlight coupler
NO
Replace the headlight bulb, socket or
both.
+
Headlight
Positive tester probe →
yellow 1 or green 2
Negative tester probe → black 3
DC 20V
YES
–
ELEC
LIGHTING SYSTEM
Y
L
R/W R/G G
Y/L B/L Gy
B
NO
4
5
•
•
•
•
Set the main switch to “ON”.
Start the engine.
Set the dimmer switch to “
” or “
”.
Measure the voltage (DC 12 V) of yellow
1 (green 2) on the headlight coupler and
yellow 4 on the meter assembly coupler
(wire harness side).
• Is the voltage within specification?
Replace the high
beam indicator light
bulb, socket or both.
3. Voltage
• Connect the pocket tester (DC 20 V) to the
headlight and meter assembly couplers as
shown.
YES
This circuit is OK.
8 - 30
NO
The wiring circuit
from the main switch
to the headlight coupler or meter assembly coupler is faulty
and
must
be
repaired.
ELEC
LIGHTING SYSTEM
EAS00789
EAS00790
2. The meter light fails to come on.
3. The tail/brake light fails to come on.
1. Meter light bulb and socket
1. Tail/brake light LEDs
+
• Check the tail/brake light LEDs.
• Are the tail/brake light LEDs OK?
• Check the meter light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the meter light bulb and socket OK?
NO
YES
Replace the tail/
brake light assembly.
NO
YES
–
Replace the meter
light bulb, socket or
both.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness
side) as shown.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
Positive tester probe → brown 1
Negative tester probe → black 2
1
Positive tester probe → blue 1
Negative tester probe → black 2
L
Y
B
G/Y Br
B
2
Ch Dg
G/L
Y
L
1
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown
1 on the tail/brake light coupler (wire harness side).
• Is the voltage within specification?
R/W R/G G
Y/L B/L Gy
B
2
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue 1
on the meter assembly coupler (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and
must
be
repaired.
8 - 31
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
LIGHTING SYSTEM
–
ELEC
EAS00791
EAS00792
4. The auxiliary lights fail to come on.
5. The license plate light fails to come on.
1. Auxiliary light bulb and socket
1. License plate light bulb and socket
• Check the license plate light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the license plate light bulb and socket
OK?
• Check the auxiliary light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the auxiliary light bulb and socket OK?
NO
YES
+
NO
YES
Replace the auxiliary
light bulb, socket or
both.
Replace the license
plate
light
bulb,
socket or both.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
front turn signal light assembly coupler
(wire harness side) as shown.
È Front turn signal light assembly (left)
É Front turn signal light assembly (right)
B Dg L
B Ch L
2
• Connect the pocket tester (DC 20 V) to the
taillight assembly coupler (wire harness
side) as shown.
Positive tester probe → brown 1
Negative tester probe → black 2
Positive tester probe → blue 1
Negative tester probe → black 2
È
É
B Ch L
2. Voltage
Ch Dg
Dg Ch
B L/R
Br B
1
2
B Dg L
1
2
1
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown
1 on the taillight assembly coupler (wire
harness side).
• Is the voltage within specification?
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue 1
on the front turn signal light assembly coupler (wire harness side).
• Is the voltage within specification?
YES
YES
NO
This circuit is OK.
This circuit is OK.
NO
The wiring circuit
from the main switch
to the front turn signal light assembly
coupler is faulty and
must be repaired.
8 - 32
The wiring circuit
from the main switch
to the taillight assembly coupler is faulty
and
must
be
repaired.
LIGHTING SYSTEM
EAS00792
6. The storage box light fails to come on.
1. Storage box light bulb and socket
• Check the storage box light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the storage box light bulb and socket
OK?
YES
NO
Replace the storage
box light bulb, socket
or both.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
storage box light connectors (wire harness
side) as shown.
Positive tester probe → blue/green 1
Negative tester probe → black 2
L/G
B
1
2
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue/
green 1 on the storage box light connector (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the storage box
light connector is
faulty and must be
repaired.
8 - 33
ELEC
–
+
LIGHTING SYSTEM
8 - 34
ELEC
–
+
8 - 35
§
B
Gy
B
B
B
7
L/G
R/G
B
(GRAY)
B
x
B B/L
BB4 BB1
B
B
(GRAY)
BB3 BB2
B
£
B
z
B
Br/L
G
©
®
Gy
Br
Br
Br
R/Y
R/W
Y
R/W R/G
Y/L B/L Gy
| } ~ å
Br
Br/L
ß
¶
8
R
Br
Br/L
Ch Dg
G/L L
{
y
R
W
R
R
Br
W
(BLACK)
B
W
R
Br/L
Br/R
R
BB2
BB1
B/L
Br/L
R/W
R/G Y/L
R
B
3
Br/L
w G/L
ON
OFF
OPEN
LOCK
P
4
W
W
W
9
BB3
BB4
B2
B1
B1 B2
B
B2 B1
W
W
W
W/R
W/L
R/G R/W Y/L
G/L B2
B
W
1
W
R/W Lg Y/L
5
W
Y/L G/L R/W
W
R/G B2 B
W
W
(BLACK)
R
B B2 R/G
6
B Gy
•
R L/G
L/G R/G
W
(BLACK)
W/L W/R
2
R/G
0
B
B
R
G
B
Y
Dg
B
B
B
B
D
B
B
B
R/W
R/B
B
Ch
R/Y
G/L
R/Y
Y
G/L
Y
Y
B
G
B
(BLACK)
B
d
G/B G
W/B
R
R
J
B
Y G
e
G/LW/B
v
L/W
G/Y
E
L/W
G/Y
PASS
g
R/Y
Br
v
G
G/B
A
G
B
B Ch L
L Ch B
G/B
L
P
B L/Y
Br
Br/W
OFF
j
Br
B
B
L Dg B
Br
k
B Dg L
(BLACK)
(BLACK)
Dg
Br/W
Br/W
b
Ch
(BLUE)
(BLACK)
Ch
B
B
B B
(BLUE)
q L Dg
r u r s
i
P
c
Br
L
L/Y
G/Y L/Y
F
(BLACK)
B/L P/W L
L Y/G B/L
(GREEN)
Br/W B/L
L
Y/L
B/L
B Ch
Br Dg
Ch B
Dg L/R
B
l Ch Dg Br
mn o
G/Y
(GRAY)
B
Br
P
B
G/Y Br
L Y
B
G/Y
L Y/G B/L
O
N
p
B/L
Br/W
L
P/W
B/L
B/L
Q
B/L B B/L
Br/W B Br/W
B
L
L G/Y
B
a
_
Br R/W
(GREEN)
G/R B/L
Y/L B Y
L B L
P/W B P/W
G/R
(BLACK)
L
(BLACK)
L
G/Y
B
L
Br
B/W
R
B
R/W
Y/L
L/B
L/Y
G/Y
R/W
W/B
Y/G
B/L
Br/W
Y
L
P/W
G/R
W/R
W/L
R
B
Br
L
Br
W
G/B
O/B
R/L
R/Y
P
Lg
Gy
Sb
O
OFF
ON
W
]
\
L
B
C
B
B
L
L
L
L
L G/B
Br Br
Br
C
Br
B
W R
X
O/B
P
Lg
Gy
Sb
Z
[
G/B
W
L
B/L
B
B
B
B
B
O
R/B
Y
L
L
R/L B
L
B
(BLUE)
L
(BLUE)
L
L
(BLUE)
L
L
(RED)
G/B
C
G/B
B R/L
G B
R/L
O/B R/L
(BLACK)
(BLACK)
P Gy
Lg Sb
T
(BLUE)
L
(RED)
L
Br
L W
B/L
L
(BLACK)
U
S
B
R/L
Y
B
G
V
Br
B
B
R/Y R/L
R/B R
R/B
R
R/L
R/Y
SUB-WIRE HARNESS 3
Br
WIRE HARNESS
G/B
G/B
–
B
Y
P
(BLACK)
Br
t
W/Y
h
G/Y
K
R/B G/Y
L/Y G/W
G/W
R/B
M
L B/L Y/L
W/L L/B Y/L B/W B G/Y R/Y
G/R Y W/R
L/Y B/L W/B G/B
R/L Br/W
R/W W Lg P O/B
P/W Y/G
L
R Sb Gy O
SUB-WIRE HARNESS 2
(GRAY)
(GRAY)
WIRE HARNESS
Y/L R/L O/B P
G/R Lg Gy Sb
P/W B/L L Br/W
P O/B R/L Y
Sb Gy Lg G/R
Br/W L B/L P/W
ELEC
B
B
Y G
Y G
A A
Y G
(BLACK)
Dg G/B W/Y Br/W R/Y
Ch G/Y B Br P
(BLACK)
R/Y Br/W W/Y G/B Dg
P Br B G/Y Ch
f
Ch
Dg
Br/W
(BLACK)
R/YR/Y
G/W
L/W
G/Y
L/W G/Y
L/B
B
R
C
I
R
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
G
H
B
A
ç † ¢
L
G/W R/W
Br Dg
G/Y Ch Br/W L/B R/B
B
R
SUB-WIRE HARNESS 1
Y
WIRE HARNESS
B
G
B
G
Y
SIGNALING SYSTEM
+
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
SIGNALING SYSTEM
4 Main switch
8 Ignition fuse
9 Backup fuse (storage box light, immobilizer unit, and meter assembly)
A Battery
B Main fuse
J Hazard switch
K Front brake light switch
R ECU
X Speed sensor
b Turn signal relay
c Horn
i Horn switch
j Turn signal switch
k Rear brake light switch
m Rear turn signal light (left)
n Rear turn signal light (right)
p Tail/brake light
s Front turn signal light (right)
u Front turn signal light (left)
y Multifunction meter
z Speedometer
| Engine oil change indicator
} V-belt replacement indicator
~ Engine trouble warning light
† Right turn signal indicator light
¢ Left turn signal indicator light
§ V-belt replacement indicator reset coupler
® Signaling system fuse
© Turn signal/hazard fuse
8 - 36
ELEC
–
+
SIGNALING SYSTEM
EAS00794
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Any of the following fail to light: turn
signal light, brake light or an indicator
light.
• The horn fails to sound.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
Check:
1. main, ignition, signaling system, turn signal/
hazard, and backup fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1. storage box
2. front cowling
3. meter assembly
• Troubleshoot with the following special
tool(s).
• Is the battery OK?
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112, YU-03112-C
YES
EAS00738
YES
EAS00795
4. Wiring
• Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
connected and without defects?
YES
NO
Replace the fuse(s).
NO
Replace the main
switch/immobilizer
unit.
1. Main, ignition, signaling system, turn signal/hazard, and backup fuses
• Check the main, ignition, signaling system,
turn signal/hazard, and backup fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition, signaling system,
turn signal/hazard, and backup fuses OK?
NO
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
8 - 37
NO
Properly connect or
repair the signaling
system’s wiring.
SIGNALING SYSTEM
EAS00796
–
+
3. Horn
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
• Disconnect the horn coupler at the horn.
• Connect a jumper lead 1 to the brown terminal in the horn coupler and the horn terminal.
• Connect a jumper lead 2 to the horn terminal and ground.
• Set the main switch to “ON”.
• Does the horn sound?
1. Horn switch
• Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the horn switch OK?
NO
YES
ELEC
1
Replace the left handlebar switch.
Br
2. Voltage
P
• Connect the pocket tester (DC 20 V) to the
horn coupler as shown.
2
Positive tester probe → brown 1
Negative tester probe → ground
NO
YES
1
The wiring circuit
from the horn coupler
to the horn switch
coupler and/or horn
switch to ground are
faulty and must be
repaired.
Br
P
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown at
the horn coupler.
• Is the voltage within specification?
YES
The horn is OK.
EAS00798
2. The tail/brake light fails to come on.
1. Tail/brake light LEDs
• Check the tail/brake light LEDs.
• Are the tail/brake light LEDs OK?
NO
The wiring circuit
from the main switch
to the horn coupler is
faulty and must be
repaired.
8 - 38
YES
NO
Replace the tail/
brake light assembly.
SIGNALING SYSTEM
ELEC
–
+
EAS00799
2. Brake light switches
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
3. The turn signal light, turn signal indicator
light or both fail to blink.
1. Turn signal light bulb and socket
• Check the turn signal light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the turn signal light bulb and socket
OK?
NO
YES
Replace the brake
light switch(s).
YES
NO
3. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
Positive tester probe → green/yellow 1
Negative tester probe → black 2
Replace the turn signal light bulb, socket
or both.
2. Turn signal indicator light bulb and socket
• Check the turn signal indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the turn signal indicator light bulb and
socket OK?
1
L
Y
B
G/Y Br
B
2
YES
• Set the main switch to “ON”.
• Pull in the brake levers.
• Measure the voltage (DC 12 V) of green/
yellow 1 on the tail/brake light coupler
(wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
NO
Replace the turn signal indicator light
bulb, socket or both.
3. Turn signal switch
• Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the turn signal switch OK?
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
8 - 39
YES
NO
Replace the left handlebar switch.
ELEC
SIGNALING SYSTEM
–
+
6. Voltage
4. Hazard switch
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness
side) as shown.
• Check the hazard switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the hazard switch OK?
Positive tester probe → brown/white 1
Negative tester probe → ground
NO
YES
Replace the right
handlebar switch.
5. Voltage
Br/W
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness
side) as shown.
Positive tester probe → brown 1
Negative tester probe → ground
Br
1
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) on brown/
white 1 at the turn signal relay coupler
(wire harness side).
• Is the voltage within specification?
Br/W
YES
NO
Br
1
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) on brown
1 at the turn signal relay coupler (wire
harness side).
• Is the voltage within specification?
YES
NO
The wiring circuit
from the main switch
to the turn signal
relay coupler is faulty
and
must
be
repaired.
8 - 40
The turn signal relay
is faulty and must be
replaced.
SIGNALING SYSTEM
–
+
• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (DC 12 V) of the
chocolate 1 or dark green 2 at the turn
signal light coupler or meter assembly
coupler (wire harness side).
• Is the voltage within specification?
7. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal light coupler or meter assembly
coupler (wire harness side) as shown.
È Front turn signal light assembly (left)
É Front turn signal light assembly (right)
Ê Tail/brake light assembly
Ë Meter assembly
YES
Left turn signal light
Positive tester probe → chocolate 1
Negative tester probe → ground
ELEC
This circuit is OK.
Right turn signal light
Positive tester probe → dark green 2
Negative tester probe → ground
È
É
NO
The wiring circuit
from the turn signal
switch to the turn signal light coupler or
meter assembly coupler is faulty and
must be repaired.
4. The V-belt replacement indicator fails to
come on.
B Ch L
B Dg L
B Ch L
1. V-belt replacement indicator bulb and
socket
B Dg L
1
2
• Check the V-belt replacement indicator
bulb and socket for continuity.
• Are the V-belt replacement indicator bulb
and socket OK?
Ê
2
1
Ch Dg
Dg Ch
B L/R
Br B
YES
NO
Replace the V-belt
replacement indicator bulb, socket or
both.
Ë
1
Ch Dg
G/L
Y
L
R/W R/G G
Y/L B/L Gy
B
2
8 - 41
SIGNALING SYSTEM
2. V-belt replacement indicator reset coupler
–
+
3. Voltage
• Connect the pocket tester (Ω × 1) to the Vbelt replacement indicator reset coupler as
shown.
• Check the V-belt replacement indicator
reset coupler for continuity.
Positive tester probe → black 1
Negative tester probe → black 2
1
ELEC
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness
side) as shown.
Positive tester probe → gray 1
Negative tester probe → ground
2
Ch Dg
B
B
G/L
Y
L
R/W R/G G
Y/L B/L Gy
B
1
• Set the main switch to “ON”.
• Measure the voltage (12 V) of gray 1 at
the meter assembly coupler.
• Is the voltage within specification?
• Is the V-belt replacement indicator reset
coupler OK?
YES
NO
YES
Replace the V-belt
replacement indicator reset coupler.
Replace the meter
assembly.
8 - 42
NO
The wiring circuit
from
the
V-belt
replacement indicator reset coupler to
the meter assembly
coupler (wire harness
side) is faulty and
must be repaired.
SIGNALING SYSTEM
ELEC
EAS00803
EAS00806
5. The engine oil change indicator fails to
come on.
6. The speedometer fails to operate.
YES
Replace the meter
assembly.
+
1. Speed sensor
1. Engine oil change indicator bulb and
socket
• Check the engine oil change indicator bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the engine oil change indicator bulb
and socket OK?
–
• Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side)
as shown.
Positive tester probe → white 1
Negative tester probe → blue 2
NO
Replace the engine
oil change indicator
bulb, socket or both.
• Set the main switch to “ON”.
• Elevate the front wheel and slowly rotate
it.
• Measure the voltage (DC 5 V) of white and
blue. With each full rotation of the front
wheel, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
• Does the voltage reading cycle correctly?
YES
NO
Replace the speed
sensor.
8 - 43
SIGNALING SYSTEM
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness
side) as shown.
Positive tester probe → yellow/blue 1
Negative tester probe → black 2
Ch Dg
G/L
Y
L
R/W R/G G
Y/L B/L Gy
1
B
2
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of yellow/
blue 1 on the meter assembly coupler
(wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
NO
Replace the meter
assembly.
8 - 44
ELEC
–
+
R
W
W
8 - 45
Br/L
G
©
Gy
Br
Br
B
B
R
L
Y
Dg
G/W R/W
Br Dg
G/Y Ch Br/W L/B R/B
0
B
B
£
Ch Dg
G/L L
Y
R/W R/G
Y/L B/L Gy
G
B
R/W
R/B
D
B
B
B
Ch
R/Y
G/L
R/Y
Y
G/L
B
Y
B
(BLACK)
G/B G
W/B
d
R
R
L/W
G/Y
J
e
G/LW/B
E
L/W
G/Y
PASS
g
R/Y
Br
G
G/B
A A
Y G
(BLACK)
Dg G/B W/Y Br/W R/Y
Ch G/Y B Br P
(BLACK)
R/Y Br/W W/Y G/B Dg
P Br B G/Y Ch
f
Ch
Dg
Br/W
(BLACK)
R/YR/Y
G/W
L/W
G/Y
L/W G/Y
L/B
B
R
C
I
R
W/Y
h
G/Y
K
P
G/B
i
(BLACK)
Br
L/Y G/W
R/B G/Y
P
P
c
Br
L
B
B
Br
Br/W
OFF
j
Br
Dg
Br/W
Br/W
b
Ch
(BLUE)
B L/Y
B B
(BLUE)
F
(BLACK)
L/Y
G/Y L/Y
G/W
R/B
k
Br
M
G/Y
(GRAY)
L B/L Y/L
(BLACK)
B/L P/W L
L Y/G B/L
(GREEN)
Br/W B/L
L
Y/L
B/L
P
L Y/G B/L
O
N
B/L
Br/W
L
P/W
B/L
B/L
Q
B/L B B/L
Br/W B Br/W
B
L
L G/Y
B
a
_
Br R/W
(GREEN)
G/R B/L
Y/L B Y
L B L
P/W B P/W
G/R
R
(BLACK)
L
(BLACK)
L
G/Y
B
L
Br
B/W
R
B
R/W
Y/L
L/B
L/Y
G/Y
R/W
W/B
Y/G
B/L
Br/W
Y
L
P/W
G/R
W/R
W/L
W/L L/B Y/L B/W B G/Y R/Y
G/R Y W/R
L/Y B/L W/B G/B
R/L Br/W
R/W W Lg P O/B
P/W Y/G
L
R Sb Gy O
B
Br
L
Br
W
G/B
O/B
R/L
R/Y
P
Lg
Gy
Sb
O
OFF
ON
[
G/B
W
]
\
L
B
C
B
B
L
L
L
L
L G/B
Br Br
Br
C
Br
B
W R
X
O/B
P
Lg
Gy
Sb
Z
W
L
B/L
B
B
B
B
B
O
R/B
Y
L
B
(BLUE)
L
(BLUE)
L
L
L
(BLUE)
L
(BLUE)
L
L
L
(RED)
L
G/B
C
G/B
B
B R/L
R/L B
G
R/L
O/B R/L
(BLACK)
(BLACK)
P Gy
Lg Sb
T
(RED)
Br
L W
B/L
L
(BLACK)
U
S
B
R/L
Y
B
G
V
SUB-WIRE HARNESS 2
(GRAY)
(GRAY)
WIRE HARNESS
Y/L R/L O/B P
G/R Lg Gy Sb
P/W B/L L Br/W
B
P O/B R/L Y
Sb Gy Lg G/R
Br/W L B/L P/W
B
R/Y R/L
R/B R
R/B
R
R/L
R/Y
SUB-WIRE HARNESS 3
Br
B
WIRE HARNESS
G/B
Br
C
G/B
–
B
B
B
B
B
B
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
G
H
B
A
4 Main switch
8 Ignition fuse
A Battery
B Main fuse
w
Q
Coolant temperature sensor
R ECU y
x
| }
~ å relay
ç † ¢
_ Radiator fan
motor
z
{
a Radiator fan motor
ß Radiator fan motor fuse
Br
Br/L
Br
R/Y
R/W
B
R
SUB-WIRE HARNESS 1
Y
WIRE HARNESS
B
ELEC
B/L
B4 BB1
B3 BB2
®
ß
¶
8
R
Br/L
Br
R
R
Br
W
R
W
(BLACK)
B
W
R
Br/L
Br/R
R
Br/L
B/L
Br/L
R/W
R/G Y/L
ON
OFF
OPEN
LOCK
P
R
B
3
B2
B1
G/L
W
W
W
4
R/G R/W Y/L
G/L B2
B
W
W
W
W
W/R
W/L
9
B3
B4
2
B1 B2
R/W Lg Y/L
R/G B2 B
5
W
1
(BLACK)
2
R/G
A
G
B
G
Y
COOLING SYSTEM
+
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
COOLING SYSTEM
EAS00808
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• The radiator fan motor fails to turn.
• The coolant temperature meter (meter
assembly) fails to indicate.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, ignition, and radiator fan motor fuses
2. battery
3. main switch
4. radiator fan motor
5. radiator fan motor relay
6. coolant temperature sensor
7. wiring connections
(the entire cooling system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the following part(s):
1. storage box
2. front cowling
3. radiator cover
• Troubleshoot with the following special
tool(s).
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
Pocket tester
90890-03112, YU-03112-C
Replace the main
switch/immobilizer
unit.
EAS00738
1. Main, ignition, and radiator fan motor fuses
• Check the main, ignition, and radiator fan
motor fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition, and radiator fan
motor fuses OK?
YES
NO
Replace the fuse(s).
8 - 46
COOLING SYSTEM
ELEC
–
+
EAS00809
5. Radiator fan motor relay
4. Radiator fan motor
• Disconnect the radiator fan motor coupler
from the wire harness.
• Connect the battery (DC 12 V) as shown.
• Remove the radiator fan motor relay.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the radiator fan motor terminal
as shown.
• Check the radiator fan motor relay of continuity.
Positive battery terminal → red/white 1
Negative battery terminal →
green/yellow 2
Positive tester probe → brown 3
Negative tester probe → blue 4
Positive battery lead → blue 1
Negative battery lead → black 2
• Does the radiator fan motor turn?
YES
NO
The
radiator
fan
motor is faulty and
must be replaced.
• Does the radiator fan motor relay have continuity between brown and blue?
YES
NO
Replace the radiator
fan motor relay.
8 - 47
COOLING SYSTEM
ELEC
–
+
EAS00812
6. Coolant temperature sensor
• Remove the coolant temperature sensor.
• Connect the pocket tester (Ω × 1k) to the
coolant temperature sensor 1 as shown.
• Immerse the coolant temperature sensor
in a container filled with coolant 2.
NOTE:
Make sure the coolant temperature sensor
terminals do not get wet.
_
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, and then let it cool
to the specified temperature indicated in
the table.
• Check the coolant temperature sensor for
continuity at the temperatures indicated
below.
Coolant temperature sensor
resistance
20 °C (68 °F): 2.32 ~ 2.59 kΩ
80 °C (176 °F): 0.310 ~ 0.326 kΩ
110 °C (230 °F): 0.140 ~ 0.144 kΩ
WARNING
_
• 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.
• Does the coolant temperature sensor
operate properly?
YES
T.
Coolant temperature sensor
18 Nm (1.8 m · kg, 13 ft · lb)
NO
R.
Replace the coolant
temperature sensor.
EAS00813
7. Wiring
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly
connected and without defects?
YES
This circuit is OK.
8 - 48
NO
Properly connect or
repair the cooling
system’s wiring.
IMMOBILIZER SYSTEM
ELEC
–
IMMOBILIZER SYSTEM
SYSTEM DIAGRAM
2
1
3
1 ECU
2 Immobilizer system indicator light
3 Main switch and immobilizer unit
Main switch
Fuel injection system fuse
R
Br/L
Ignition
fuse
R/W
R
R/G
Immobilizer
unit
Backup
fuse
G/L
CYCLELOCK
(optional)
R.....
Br/L . . .
G/L . . .
R/G . . .
R/W . . .
Y/L. . . .
Main
fuse
Meter
assembly
Immobilizer
system indicator light
R/W
R/W
Y/L
Battery
ECU
8 - 49
Red
Brown/Blue
Green/Blue
Red/Green
Red/White
Yellow/Blue
+
8 - 50
§
B
Gy
B
B
B
7
L/G
R/G
B
(GRAY)
B
x
B B/L
BB4 BB1
B
(GRAY)
BB3 BB2
B
B
£
B
z
B
Br/L
G
©
®
Gy
Br
Br
Br
R/Y
R/W
Y
R/W R/G
Y/L B/L Gy
| } ~ å
Br
Br/L
ß
¶
8
R
Br
Br/L
Ch Dg
G/L L
{
y
R
W
R
R
Br
W
(BLACK)
B
W
R
Br/L
Br/R
R
BB2
BB1
B/L
Br/L
R/W
R/G Y/L
ON
OFF
OPEN
LOCK
P
R
B
3
Br/L
w G/L
W
W
W
4
R/G R/W Y/L
G/L B2
B
W
W
W
W
W/R
W/L
9
BB3
BB4
B2
B1
B1 B2
B
B2 B1
2
1
W
R/W Lg Y/L
5
W
Y/L G/L R/W
W
R/G B2 B
W
W
(BLACK)
R
B B2 R/G
6
B Gy
•
R L/G
L/G R/G
W
(BLACK)
W/L W/R
R/G
0
B
B
R
G
B
Y
Dg
B
B
B
B
D
B
B
B
R/W
R/B
B
Ch
R/Y
G/L
R/Y
Y
G/L
Y
Y
B
G
B
(BLACK)
B
d
G/B G
W/B
R
R
J
B
Y G
e
G/LW/B
v
L/W
G/Y
E
L/W
G/Y
PASS
g
Br
v
G
G/B
A
G
B
B Ch L
L Ch B
G/B
L
B L/Y
Br
Br/W
OFF
j
Br
B
B
L Dg B
Br
k
B Dg L
(BLACK)
(BLACK)
Dg
Br/W
Br/W
b
Ch
(BLUE)
(BLACK)
Ch
B
B
B B
(BLUE)
q L Dg
r u r s
i
P
P
c
Br
L
L/Y
G/Y L/Y
F
(BLACK)
B/L P/W L
L Y/G B/L
(GREEN)
Br/W B/L
L
Y/L
B/L
B Ch
Br Dg
Ch B
Dg L/R
B
l Ch Dg Br
mn o
G/Y
(GRAY)
B
Br
P
B
G/Y Br
L Y
B
G/Y
L Y/G B/L
O
N
p
B/L
Br/W
L
P/W
B/L
B/L
B/L B B/L
Br/W B Br/W
Q
B
L
L G/Y
B
a
_
Br R/W
(GREEN)
G/R B/L
Y/L B Y
L B L
P/W B P/W
G/R
(BLACK)
L
(BLACK)
B
G/Y
L
L
Br
B/W
R
B
R/W
Y/L
L/B
L/Y
G/Y
R/W
W/B
Y/G
B/L
Br/W
Y
L
P/W
G/R
W/R
W/L
R
B
Br
W
L
L
L G/B
Br Br
Br
C
Br
B
W R
X
O/B
P
Lg
Gy
Sb
Z
[
G/B
W
L
B/L
B
B
B
B
B
O
R/B
Y
Br
L W
B/L
L
C
G/B
L
B R/L
R/L B
G B
R/L
O/B R/L
(BLACK)
(BLACK)
P Gy
Lg Sb
T
G/B
(BLACK)
U
S
B
R/L
Y
B
G
V
B
R/Y R/L
R/B R
R/B
R
R/L
R/Y
OFF
ON
B
C
B
B
L
L
L
L
B
(BLUE)
L
(BLUE)
L
L
L
(BLUE)
L
(BLUE)
L
L
(RED)
L
(RED)
4 Main switch
5 Immobilizer unit
8 Ignition fuse
\
9 Backup
fuse (storage box
light, immobilizer unit, and
meter
assembly)
]
0 Fuel injection system fuse
A Battery
B Main fuse
R ECU
x Immobilizer system indicator light
y Multifunction meter
L
Br
W
G/B
O/B
R/L
R/Y
P
Lg
Gy
Sb
O
Br
SUB-WIRE HARNESS 3
B
WIRE HARNESS
G/B
Br
C
G/B
–
B
Y
P
(BLACK)
Br
t
W/Y
h
G/Y
K
R/B G/Y
L/Y G/W
G/W
R/B
M
L B/L Y/L
W/L L/B Y/L B/W B G/Y R/Y
G/R Y W/R
L/Y B/L W/B G/B
R/L Br/W
R/W W Lg P O/B
P/W Y/G
L
R Sb Gy O
(GRAY)
SUB-WIRE HARNESS 2
(GRAY)
WIRE HARNESS
Y/L R/L O/B P
G/R Lg Gy Sb
P/W B/L L Br/W
B
P O/B R/L Y
Sb Gy Lg G/R
Br/W L B/L P/W
ELEC
B
B
Y G
Y G
A A
Y G
(BLACK)
Dg G/B W/Y Br/W R/Y
Ch G/Y B Br P
(BLACK)
R/Y Br/W W/Y G/B Dg
P Br B G/Y Ch
f
R/Y
Ch
Dg
Br/W
(BLACK)
R/YR/Y
G/W
L/W
G/Y
L/W G/Y
L/B
B
R
C
I
R
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
G
H
B
A
ç † ¢
L
G/W R/W
Br Dg
G/Y Ch Br/W L/B R/B
B
R
SUB-WIRE HARNESS 1
Y
WIRE HARNESS
B
G
B
G
Y
IMMOBILIZER SYSTEM
+
CIRCUIT DIAGRAM
IMMOBILIZER SYSTEM
ELEC
–
+
GENERAL INFORMATION
This scooter is equipped with an immobilizer system to help prevent theft by registering codes in
standard keys. This system consists of the following:
• a code re-registering key (with a red bow)
• two standard keys (with black bows) that can be re-registered with new codes
• transponders (one installed in each key bow)
• an immobilizer unit
• an ECU
• an immobilizer system indicator light
The key with the red bow is used to register codes in each standard key. Do not use the key with the
red bow for driving. It should only be used for registering new codes in the standard keys. The
immobilizer system cannot be operated with a new standard key until a code is registered in the
key. If you lose the code re-registering key, the ECU, main switch, and immobilizer unit must be
replaced. Therefore, always use a standard key for driving.
NOTE:
Each standard key is registered during production, therefore, registering the keys at purchase is not
necessary.
1 Code re-registering key (red bow)
2 Standard keys (black bow)
CAUTION:
• DO NOT LOSE THE CODE RE-REGISTERING KEY! If the code re-registering key is lost, registering new codes in the standard keys is impossible. The standard keys can still be used
to start the scooter, however, if code re-registering is required (i.e., if a new standard key is
made or all keys are lost) the entire immobilizer system must be replaced. Therefore, it is
highly recommended to use either standard key and keep the code re-registering key in a
safe place.
• Do not submerse the keys in water.
• Do not expose the keys to excessively high temperatures.
• Do not place the keys close to magnets (this includes, but not limited to, products such as
speakers, etc.).
• Do not place heavy items on the keys.
• Do not grind the keys or alter their shape.
• Do not disassemble the key bows.
• Do not put two keys of any immobilizer system on the same key ring.
• Keep the standard keys as well as other immobilizer system keys away from the code reregistering key.
• Keep other immobilizer system keys away from the main switch as they may cause signal
interference.
8 - 51
IMMOBILIZER SYSTEM
ELEC
–
+
KEY CODE REGISTRATION
Code registration of the code re-registering key or standard keys may be required when parts are
replaced or a standard key is lost.
NOTE:
Each standard key is registered during production, therefore, registering the keys at purchase is not
necessary.
Code re-registering key registration:
When the immobilizer unit or ECU is replaced, the code re-registering key must be re-registered.
To register a code re-registering key:
1. Turn the main switch to “ON” with the code re-registering key.
NOTE:
Check that the immobilizer system indicator light comes on for 1 second, then goes off. When the
indicator light goes off, the code re-registering key has been registered.
2. Check that the engine can be started.
3. Register the standard keys. Refer to “Standard key registration:”.
Standard key registration:
A standard key should be registered or the other standard key should be re-registered when a registered standard key has been lost. The standard keys must be re-registered when the immobilizer
unit or ECU has been replaced and the code re-registering key has been re-registered.
NOTE:
Do not start the engine with a standard key that has not been registered.
If the main switch is turned to “ON” with a standard key that has not been registered, the immobilizer
system indicator light flashes to indicate malfunction code 52. (Refer to “SELF-DIAGNOSIS MALFUNCTION CODES”.)
1. Check that the immobilizer system indicator light flashes to indicate the standby mode. To activate the standby mode, turn the main switch to “OFF”. The standby mode will be activated after
30 seconds. The indicator light stops flashing after 24 hours and the standby mode is deactivated.
30 s
Main
switch
Standby mode
24 h
ON
OFF
On
LED
Off
0.05 s
2.45 s
2. Using the code re-registering key, turn the main switch to “ON”, then to “OFF”, and then remove
the key within 5 seconds.
8 - 52
IMMOBILIZER SYSTEM
ELEC
–
+
3. Insert the standard key to be registered into the main switch, and then turn the main switch to
“ON” within 5 seconds to activate the key registration mode.
NOTE:
All existing standard key codes will be erased from the memory when the key registration mode is
activated. When the key registration mode is activated, the immobilizer system indicator light
flashes rapidly (i.e., off for 0.5 second and on for 0.5 second).
4. While the indicator light is flashing, turn the main switch to “OFF”, remove the key, and then insert
the second standard key to be registered into the main switch within 5 seconds.
NOTE:
If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered, the registration mode is deactivated. If this occurs, the second standard key cannot be registered, therefore, repeat steps 2 to 4 to register both standard keys.
5. Turn the main switch to “ON”.
NOTE:
When the indicator light goes off, registration is complete.
6. Check that the engine can be started with the two registered standard keys.
less than 5.0 s
Standard key
registration
Main ON
switch
OFF
On
LED
Off
less than 5.0 s
less than 5.0 s
less than 5.0 s
First standard
key
Registration mode
Code re-registering key
0.5 s
0.5 s
Registration of the
second standard key
is complete.
Second standard key
Immobilizer system indicator light stops flashing when the registration of the second standard key is complete.
Voiding a standard key code:
If a registered standard key has been lost and you want to disable its use, register a new standard
key or re-register the other standard key. For registration of a standard key, refer to “Standard key
registration:”.
Standard key registration erases the stored standard key codes from memory, therefore, the lost
standard key is disabled.
less than 5.0 s
Main
switch
Standard key
code voiding
method
LED
ON
OFF
On
less than 5.0 s
less than 5.0 s
5.0 s
Remaining
standard key
Registration mode
Code re-registering key
Off
0.5 s
8 - 53
0.5 s
If the immobilizer system indicator light
stops flashing 5 seconds after the first
standard key is registered, the second
standard key cannot be registered.
IMMOBILIZER SYSTEM
ELEC
–
+
SELF-DIAGNOSIS MALFUNCTION CODES
When a system malfunction occurs, the malfunction code number is displayed on the LCD display
of the meter assembly and is indicated by the immobilizer system indicator light flash patterns.
Malfunction
code
Part
Symptom
Cause
Action
Immobilizer unit
Code cannot be transmitted
between the key and immobilizer unit.
1) Radio wave interference
caused by objects around the
keys and antennas.
2) Immobilizer unit malfunction
3) Key malfunction
1) Keep magnets, metal
objects, and other
immobilizer system
keys away from the
keys and antennas.
2) Replace the main
switch/immobilizer unit.
3) Replace the key.
Immobilizer unit
Codes transmitted between
the key and immobilizer unit
do not match.
1) Signal received from other
transponder (failed to recognize code after ten consecutive attempts).
2) Signal received from unregistered standard key.
1) Place the immobilizer
unit at least 50 mm
away from the transponder of other scooters.
2) Register the standard
key.
Immobilizer unit
Code cannot be transmitted
between the ECU and
immobilizer unit.
Noise interference or disconnected lead/cable.
1) Interference due to radio wave
noise.
2) Disconnected communication
harness.
3) Immobilizer unit malfunction
4) ECU malfunction
1) Check the wire harness
and connector.
2) Replace the main
switch/immobilizer unit.
3) Replace the ECU.
Immobilizer unit
Codes transmitted between
ECU and immobilizer unit
do not match.
Noise interference or disconnected lead/cable.
1) Interference due to radio wave
noise.
2) Disconnected communication
harness.
3) Immobilizer unit malfunction
4) ECU malfunction
(The ECU or immobilizer unit
has been replaced with a used
unit from another scooter.)
1) Register the code reregistering key.
2) Check the wire harness
and connector.
3) Replace the main
switch/immobilizer unit.
4) Replace the ECU.
Immobilizer unit
Key code registration malfunction
Same standard key was
attempted to be registered two
consecutive times.
Register a new standard
key.
ECU
Unidentified code is
received.
Noise interference or disconnected lead/cable.
1) Interference due to radio wave
noise.
2) Disconnected communication
harness.
3) Immobilizer unit malfunction
4) ECU malfunction
1) Check the wire harness
and connector.
2) Replace the main
switch/immobilizer unit.
3) Replace the ECU.
51
52
53
54
55
56
8 - 54
IMMOBILIZER SYSTEM
Immobilizer system indicator light malfunction code indication
Units of 10: on for 1 second and off for 1.5 seconds.
Units of 1: on for 0.5 second and off for 0.5 second.
<Example> malfunction code 52
Light on
Light off
8 - 55
ELEC
–
+
IMMOBILIZER SYSTEM
EAS00794
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
When the main switch is turned “ON”,
the immobilizer system indicator light
does not come on or flash.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, ignition, and backup fuses
2. battery
3. main switch
4. wiring connections
(of the entire immobilizer system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. front cowling
2. upper rear cover
• Troubleshoot with the following special
tool(s).
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112, YU-03112-C
EAS00738
YES
NO
1. Main, ignition and backup fuses
• Check the main, ignition and backup fuses
for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition and backup fuses
OK?
YES
Replace the main
switch/immobilizer
unit.
EAS00787
4. Wiring
NO
• Check the entire immobilizer system wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the immobilizer system wiring properly
connected and without defects?
Replace the fuse(s).
YES
Check the condition
of each of the immobilizer system circuits.
Refer to “CHECKING THE IMMOBILIZER SYSTEM”.
8 - 56
NO
Properly connect or
repair the immobilizer
system wiring.
IMMOBILIZER SYSTEM
EAS00788
CHECKING THE IMMOBILIZER SYSTEM
1. The immobilizer system indicator light does
not come on.
–
ELEC
+
3. Wiring
• Disconnect the meter coupler and immobilizer unit coupler.
• Check the immobilizer system indicator
light lead (green/blue) continuity.
(meter coupler – immobilizer unit coupler).
• Is the immobilizer system indicator light
lead OK?
1. Immobilizer system indicator light (LED)
• Check the immobilizer system indicator
light for continuity.
Refer to “CHECKING THE LEDs”.
• Is the immobilizer system indicator light
OK?
NO
YES
NO
YES
Replace the meter
assembly.
Replace the main
switch/immobilizer
unit.
The wiring circuit
from
the
meter
assembly to immobilizer unit is faulty and
must be repaired.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
immobilizer unit coupler as shown.
2. No malfunction code is displayed on the
LCD display of the meter assembly.
1. Voltage
3
• Connect the pocket tester (DC 20 V) to the
meter coupler as shown.
2
B B R/G
Y/L G/L R/W
R/G B B
R/W Lg Y/L
1
1 2
Ch Dg
Positive tester probe →
red/white 1 or red/green 2
Negative tester probe → black 3
• Turn the main switch to “ON”.
• Measure the voltage (DC 12 V) on the
immobilizer unit coupler (wire harness
side).
• Is the voltage within specification?
YES
G/L
R/W R/G G
Y/L B/L Gy
B
3
LCD display
Positive tester probe →
red/white 1 or red/green 2
Negative tester probe → black 3
• Turn the main switch to “ON”.
• Measure the voltage (DC 12 V) at the
meter coupler (wire harness side).
• Is the voltage within specification?
NO
The wiring circuit
from the main switch
to the immobilizer
unit coupler is faulty
and
must
be
repaired.
Y
L
YES
Replace the meter
assembly.
8 - 57
NO
The wiring circuit
from the main switch
to the meter coupler
is faulty and must be
repaired.
IMMOBILIZER SYSTEM
ELEC
–
+
3. When the main switch is turned to “ON”, the immobilizer system indicator light flashes.
• Check if a metal object or other immobilizer system keys are placed near the immobilizer unit. If
so, remove the object or keys, and then check the condition again.
Turn the main switch to “ON” with
another registered standard key and
check the immobilizer system indicator
light. The indicator light goes on for
about 1 second, then goes off.
Correct
First standard key (transponder) is
defective.
Correct
Second standard
key
(transponder) is defective.
Malfunction
Turn the main switch to “ON” with the
code re-registering key and check the
immobilizer system indicator light.
Malfunction
Re-register
the
standard key.
Malfunction
Replace the
standard
key.
Check if a malfunction code is displayed.
Displayed
Read the malfunction code and check
the corresponding part.
Refer to “SELF-DIAGNOSIS MALFUNCTION CODES”.
Malfunction
Yellow/blue lead is disconnected or
short-circuited. Repair or replace the
circuit.
Not displayed
Immobilizer unit or ECU malfunction
Check the signal lead (yellow/blue)
between the immobilizer unit and ECU
connector.
Correct
Replace the immobilizer unit.
8 - 58
IMMOBILIZER SYSTEM
ELEC
–
+
PART REPLACEMENT KEY REGISTRATION REQUIREMENTS
Parts to be replaced
Main
switch
Immobilizer
unit
Standard
key
Standard key is lost
All keys have been lost
(including code re-registering key)
ECU
Required key
registration
Accessory
lock*2 and
key
New standard key
Code re-registering
key and standard keys
*1
ECU is defective
Code re-registering
key and standard keys
Immobilizer unit is
defective
Code re-registering
key and standard keys
Main switch is defective
Code re-registering
key and standard keys
*1
Accessory lock*2 is
defective
*1
*2
Not required
Replace as a set with the main switch.
Accessory locks include the fuel tank cap lock and storage compartment lock.
NOTE:
If the ECU or the immobilizer unit is replaced, both the code re-registering key and the standard
keys need to be registered with the new unit(s).
8 - 59
TRBL
SHTG
9
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING .......................................................9-1
ENGINE..................................................................................................... 9-1
FUEL SYSTEM.......................................................................................... 9-1
ELECTRICAL SYSTEMS ..........................................................................9-2
INCORRECT ENGINE IDLING SPEED........................................................... 9-2
ENGINE..................................................................................................... 9-2
FUEL SYSTEM.......................................................................................... 9-2
ELECTRICAL SYSTEMS ..........................................................................9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .................................9-3
ENGINE..................................................................................................... 9-3
FUEL SYSTEM.......................................................................................... 9-3
FAULTY CLUTCH ........................................................................................... 9-3
ENGINE OPERATES BUT SCOOTER WILL NOT MOVE........................9-3
CLUTCH SLIPS......................................................................................... 9-3
POOR STARTING PERFORMANCE........................................................9-3
POOR SPEED PERFORMANCE.............................................................. 9-3
OVERHEATING............................................................................................... 9-4
ENGINE..................................................................................................... 9-4
COOLING SYSTEM .................................................................................. 9-4
FUEL SYSTEM.......................................................................................... 9-4
CHASSIS...................................................................................................9-4
ELECTRICAL SYSTEMS ..........................................................................9-4
OVERCOOLING .............................................................................................. 9-4
COOLING SYSTEM .................................................................................. 9-4
POOR BRAKING PERFORMANCE................................................................9-5
FAULTY FRONT FORK LEGS........................................................................ 9-5
LEAKING OIL ............................................................................................ 9-5
MALFUNCTION......................................................................................... 9-5
UNSTABLE HANDLING.................................................................................. 9-5
TRBL
SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM..............................................9-6
HEADLIGHT DOES NOT COME ON ........................................................9-6
HEADLIGHT BULB BURNT OUT.............................................................. 9-6
TAIL/BRAKE LIGHT DOES NOT COME ON ............................................9-6
TAIL/BRAKE LIGHT BULB BURNT OUT.................................................. 9-6
TURN SIGNAL DOES NOT COME ON .................................................... 9-6
TURN SIGNAL BLINKS SLOWLY............................................................. 9-6
TURN SIGNAL REMAINS LIT...................................................................9-6
TURN SIGNAL BLINKS QUICKLY............................................................ 9-6
HORN DOES NOT SOUND ...................................................................... 9-6
STARTING FAILURE/HARD STARTING
TRBL
SHTG
EAS00845
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
_
STARTING FAILURE/HARD STARTING
ENGINE
Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
Piston and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
Air filter
• Improperly installed air filter
• Clogged air filter element
Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
FUEL SYSTEM
Fuel tank
• Empty fuel tank
• Clogged fuel tank cap breather hole
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose
Fuel pump
• Faulty fuel pump
• Faulty fuel injection system relay
• Improperly routed hose
Throttle body
• Deteriorated or contaminated fuel
• Sucked-in air
9-1
STARTING FAILURE/HARD STARTING/
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
• Discharged battery
• Faulty battery
Fuse(s)
• Blown, damaged or incorrect fuse
• Improperly installed fuse
Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coil
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
TRBL
SHTG
Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
Switches and wiring
• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty front, rear or both brake light
switches
• Faulty start switch
• Faulty sidestand switch
• Improperly grounded circuit
• Loose connections
Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch
EAS00847
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
• Discharged battery
• Faulty battery
Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coil
• Faulty spark plug lead
Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
ENGINE
Cylinder and cylinder head
• Incorrect valve clearance
• Damaged valve train components
Air filter
• Clogged air filter element
FUEL SYSTEM
Throttle body
• Damaged or loose throttle body joint
• Improper throttle cable free play
• Flooded throttle body
• Faulty air induction system
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/
FAULTY CLUTCH
TRBL
SHTG
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING”.
ENGINE
FUEL SYSTEM
Air filter
Throttle body
• Clogged air filter element
• Faulty diaphragm
Fuel pump
• Faulty fuel pump
EAS00853
FAULTY CLUTCH
ENGINE OPERATES BUT SCOOTER WILL
NOT MOVE
V-belt
• Bent, damaged or worn V-belt
• Slipping V-belt
Primary pulley cam and primary pulley
slider(s)
• Damaged or worn primary pulley cam
• Damaged or worn primary pulley slider
Transmission gear(s)
• Damaged transmission gear
CLUTCH SLIPS
Clutch shoe spring(s)
• Damaged, loose or worn clutch shoe spring
Clutch shoe
• Damaged or worn clutch shoe
Primary sliding sheave
• Seized primary sliding sheave
POOR STARTING PERFORMANCE
V-belt
• V-belt slips
• Oil or grease on the V-belt
Primary sliding sheave
• Worn primary sliding sheave
Clutch shoe
• Bent, damaged or worn clutch shoe
POOR SPEED PERFORMANCE
V-belt
• Oil or grease on the V-belt
Primary pulley weight(s)
• Faulty operation
• Worn primary pulley weight
Primary fixed sheave
• Worn primary fixed sheave
Primary sliding sheave
• Worn primary sliding sheave
Secondary fixed sheave
• Worn secondary fixed sheave
Secondary sliding sheave
• Worn secondary sliding sheave
9-3
OVERHEATING/
OVERCOOLING
TRBL
SHTG
EAS00855
OVERHEATING
ENGINE
Clogged coolant passages
• Cylinder head and piston
• Heavy carbon buildup
Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
COOLING SYSTEM
Coolant
• Low coolant level
Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
Water pump
• Damaged or faulty water pump
• Thermostat
• Thermostat stays closed
• Oil cooler
• Hose(s) and pipe(s)
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
FUEL SYSTEM
Throttle body
• Damaged or loose throttle body joint
Air filter
• Clogged air filter element
CHASSIS
Brake(s)
• Dragging brake
ELECTRICAL SYSTEMS
Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
Ignition system
• Faulty radiator fan motor relay
• Faulty coolant temperature sensor
• Faulty ECU
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
• Thermostat stays open
9-4
POOR BRAKING PERFORMANCE/
FAULTY FRONT FORK LEGS/UNSTABLE HANDLING
TRBL
SHTG
EAS00857
POOR BRAKING PERFORMANCE
•
•
•
•
•
•
•
•
•
•
•
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper kit
Faulty brake caliper seal
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
EAS00861
FAULTY FRONT FORK LEGS
MALFUNCTION
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
LEAKING OIL
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
EAS00862
UNSTABLE HANDLING
Handlebar
• Bent or improperly installed handlebar
Steering head components
• Improperly installed lower handlebar holder
• Improperly installed lower bracket
(improperly tightened steering ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
Front fork leg(s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
Rear shock absorber assembly(-ies)
• Faulty rear shock absorber spring
• Leaking oil
Tire(s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
Wheel(s)
• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
9-5
FAULTY LIGHTING OR SIGNALING SYSTEM
TRBL
SHTG
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT COME ON
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main switch)
• Burnt-out headlight bulb
• Faulty headlight relay (on/off)
HEADLIGHT BULB BURNT OUT
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Headlight bulb life expired
TAIL/BRAKE LIGHT DOES NOT COME ON
• Too many electrical accessories
• Incorrect connection
TAIL/BRAKE LIGHT BULB BURNT OUT
• Faulty battery
• Incorrectly adjusted brake light switch(s)
TURN SIGNAL DOES NOT COME ON
• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
• Faulty turn signal relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
• Faulty turn signal relay
• Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
• Incorrect turn signal bulb
• Faulty turn signal relay
• Burnt-out turn signal bulb
HORN DOES NOT SOUND
• Improperly adjusted horn
• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness
9-6
YP400(S) 2004 WIRING DIAGRAM
1 A.C. magneto
2 Crankshaft position sensor
3 Rectifier/regulator
4 Main switch
5 Immobilizer unit
6 Storage box light switch
7 Storage box light
8 Ignition fuse
9 Backup fuse (storage box light,
immobilizer unit, and meter
assembly)
0 Fuel injection system fuse
A Battery
B Main fuse
C Starter relay
D Starter motor
E Diode
F Starting circuit cut-off relay
G Right handlebar switch
H Engine stop switch
I Start switch
J Hazard switch
K Front brake light switch
L Sidestand switch
M Throttle position sensor
N Intake air pressure sensor
O Intake air temperature sensor
P Lean angle cut-off switch
Q Coolant temperature sensor
R ECU
S Ignition coil
T Spark plug
U ISC (idle speed control) valve
V Fuel injection system relay
W Fuel injector
X Speed sensor
Y Fuel pump
Z Grip warmer relay (optional)
[ Grip warmer switch (optional)
\ Left grip warmer-heater
(optional)
] Right grip warmer-heater
(optional)
_ Radiator fan motor relay
a Radiator fan motor
b Turn signal relay
c Horn
d Headlight relay 1
e Headlight relay 2
f Left handlebar switch
g Pass switch
h Dimmer switch
i Horn switch
j Turn signal switch
k Rear brake light switch
l Tail/brake light assembly
m Rear turn signal light (left)
n Rear turn signal light (right)
o License plate light
p Tail/brake light
q Front turn signal light assembly
(right)
r Auxiliary light
s Front turn signal light (right)
t Front turn signal light assembly
(left)
u Front turn signal light (left)
v Headlight
w Meter assembly
x Immobilizer system indicator
light
y Multifunction meter
z Speedometer
{ Tachometer
| Engine oil change indicator
} V-belt replacement indicator
~ Engine trouble warning light
å Meter light
ç High beam indicator light
† Right turn signal indicator light
¢ Left turn signal indicator light
£ Thermistor
§ V-belt replacement indicator
reset coupler
• CYCLELOCK (optional)
¶ Headlight fuse
ß Radiator fan motor fuse
® Signaling system fuse
© Turn signal/hazard fuse
COLOR CODE
B............ Black
Br .......... Brown
Ch ......... Chocolate
Dg ......... Dark green
G ........... Green
Gy ......... Gray
L ............ Blue
Lg .......... Light green
O ........... Orange
P............ Pink
R ........... Red
Sb.......... Sky blue
W........... White
Y............ Yellow
B/L......... Black/Blue
B/W ....... Black/White
Br/L ....... Brown/Blue
Br/R ....... Brown/Red
Br/W ...... Brown/White
G/B ........ Green/Black
G/L ........ Green/Blue
G/R........ Green/Red
G/W ....... Green/White
G/Y ........ Green/Yellow
L/B......... Blue/Black
L/G ........ Blue/Green
L/R ........ Blue/Red
L/W........ Blue/White
L/Y......... Blue/Yellow
O/B ........ Orange/Black
P/W ....... Pink/White
R/B ........ Red/Black
R/G........ Red/Green
R/L ........ Red/Blue
R/W ....... Red/White
R/Y ........ Red/Yellow
W/B ....... White/Black
W/L........ White/Blue
W/R ....... White/Red
W/Y ....... White/Yellow
Y/G ........ Yellow/Green
Y/L......... Yellow/Blue
Y/R ........ Yellow/Red
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
YP400(S) 2004 WIRING DIAGRAM
A
Y
C
B
B
B
G
Y
G
P O/B R/L Y
Sb Gy Lg G/R
Br/W L B/L P/W
Y/L R/L O/B P
G/R Lg Gy Sb
P/W B/L L Br/W
(GRAY)
(GRAY)
WIRE HARNESS
SUB-WIRE HARNESS 2
G/B
G/B
Br
Br
B
WIRE HARNESS
9
W/L W/R
R
(BLACK)
W
W
R
R
W/L L/B Y/L B/W B G/Y R/Y
G/R Y W/R
L/Y B/L W/B G/B
R/L Br/W
R/W W Lg P O/B
P/W Y/G
L
R Sb Gy O
W
(BLACK)
W
W
W
W
W
W
W
W
W
R
R
W
R
W
W
R
A
(BLACK)
B
Br/R
ON
OFF
OPEN
LOCK
P
L/G
Br
B
R
Br/L
Br/L
G/W
R/B
G/Y
C
G/Y
E
L/W
D
B B2 R/G
R/G B2 B
R/W Lg Y/L
G/W R/W
Br Dg
G/Y Ch Br/W L/B R/B
B1 B2
G/R B/L
R/Y R/L
R/Y
Br/W
Br/W B Br/W
R/L
(BLACK)
W
B/L
G/Y L/Y
R
Y/G
O/B
R/L
BB2
BB1
R
R/L
G B
G/W
I
L
B B
(BLUE)
R/W L/W
Dg Br
R/B B Br/W Ch G/Y
R/L B
L/Y
G/Y
R/W
L/Y
J
B
Y/L
L/B
W
W
L
B/L
B
Ch
Dg
Br/W
Br
G/Y
B/W
X
B
(BLUE)
W R
Br
Br
Br
©
Br
Br
Br R/W
R/YR/Y
Br
R/Y
Br/W
W/B
R/Y
P
h
g
L
L G/Y
Br/W
i
Br
a
R/W
R/G Y/L
G
Gy
L
Y
Dg
Ch
k
(BLACK)
B
x
e
| } ~ å
Gy
z
ç † ¢
B
Y
B
G/B
B
Ch
L
(BLACK)
(BLACK)
\
]
B B/L
B
B
£
B
R/W R/G
Y/L B/L Gy
C
Y G
G
B
B
A A
Y G
(GRAY)
Y G
B
v
G
Y
t
q L Dg
r u r s
L
Y G
v
G
B
Y
B
Br
L Dg B
p
B
B Dg L
(BLACK)
Dg L/R
L Y
B
Ch B
B
A
B
G/Y
(BLACK)
B
B
l Ch Dg Br
mn o
Ch
L Ch B
B Ch L
B
L
(BLUE)
(BLUE)
L
B
Y
L
L
(BLACK)
{
Ch Dg
G/L L
L
L
B
B/L
(RED)
L
Dg
B Gy
B
L
(RED)
L
Dg G/B W/Y Br/W R/Y
Ch G/Y B Br P
G
G/B
L
L
B
L
(BLACK)
W/Y
y
Br
OFF
ON
OFF
R/Y Br/W W/Y G/B Dg
P Br B G/Y Ch
B
[
L
G/Y
j
PASS
Y
G/B G
G/B
L G/B
Br/W
G/LW/B
G/L
L
Br
(BLACK)
P
f
G/B
Z
Br
G/Y
_
b
C
Br
Br
(BLACK)
d
G/L
c
P
R/W
G/B
C
Br Br
L
Br
(GRAY)
L W
B/L
R/Y
R/Y
B
G
Y
®
w G/L
B R/L
G/B
W/B
Br
B
O/B R/L
ß
Br
B
(BLACK)
Y
O/B
B
B
Br/L
§
L
¶
Br/L
V
(BLACK)
B L/Y
BB3
BB4
BB4 BB1
R/B
P Gy
P
R/W
R/B
L/B
BB3 BB2
R/L
(GREEN)
B/L B B/L
K
B
R
U
B/L
(GREEN)
R/W
G
H
B2
B1
P
Lg
Gy
Sb
B
B
B
B
L Y/G B/L
Br/L
B
Q
L Y/G B/L
R/G R/W Y/L
G/L B2
B
B
P
Lg
Gy
Sb
O
Br/W B/L
L/Y G/W
R/B G/Y
(BLACK)
8
B
B
Br/W
Br
Y/L G/L R/W
B2 B1
(BLACK)
Br/L
5
•
B
R/B R
Y
L
P/W
G/R
Lg Sb
B/L
L/W
7
N
F
B
B
Y/L B Y
L B L
P/W B P/W
G/R
L
P/W
B/L
G/Y
L/W
B
B
R
T
B/L P/W L
B
B
B
L
Y/L
B/L
M
O
W/R
W/L
B
R
B
(GRAY)
R
B
4
R
L/W G/Y
B
B
W
6
R/B
O
3
R/G
R L/G
S
R
L B/L Y/L
B
L/G R/G
R
W/R
W/L
1
B
WIRE HARNESS
0
R/G
2
SUB-WIRE HARNESS 1
B
Br Dg
G/Y Br
B Ch
B
L
L
L
B
(BLUE)
(BLUE)
B
R/Y
SUB-WIRE HARNESS 3
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