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ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHK
ADJ
< &
EAS00109
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
8 brake lever free play a
Out of specification -» Adjust.
Brake lever free play (at the end of the brake lever)
10~20mm(0.39~0.79in)
2. Adjust:
8brake lever free play
• • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.
Direction a Brake lever free play is increased.
Direction b Brake lever free play is decreased. c C
After adjusting the brake lever free play, make sure there is no brake drag.
• • • • • • • • • • • • • • • • • • • • • • •
3-40
EAS00114
ADJUSTING THE REAR BRAKE
1. Check:
8 brake lever free playa
Out of specification -» Adjust.
Brake lever free play
10~ 20mm(0.39~ 0.79in)
2. Adjust:
8brake lever free play
• • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.
Direction a Brake lever free play is increased.
Direction b Brake lever free play is decreased. c C
After adjusting the brake lever free play, make sure there is no brake drag.
• • • • • • • • • • • • • • • • • • • • • • •
CHECKING THE FRONT AND REAR BRAKE SHOES
CHK
ADJ
< &
EAS00127
CHECKING THE FRONT AND REAR BRAKE
SHOES
1. Operate the brake.
2. Check:
• wear indicator (T)
Reaches the wear limit line (2) -» Replace the brake shoes as a set.
Refer to “FRONT WHEEL AND BRAKE” and “REAR WHEEL AND BRAKE” in chapter 4.
A Front brake
B Rear brake
3-41
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
< &
EAS00148
CHECKING AND ADJUSTING THE STEER-
ING HEAD
1. Stand the scooter on a level surface. w
Securely support the scooter so that there is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that the front wheel is elevated.
2. Check:
• steering head
Grasp the bottom of the front fork legs and gently rock the front fork.
Binding/looseness -» Adjust the steering head.
3. Remove:
• front fork upper cover
• front fork cover(left, right)
• leg shield1,2
Refer to”LEG SHIELD1,2".
• headlight stay bracket
Refer to”HANDLE BRACKET AND
HEADLIGHT STAY BRACKET”in chapter 4.
4. Adjust:
8steering head
• • • • • • • • • • • • • • • • • • • • • • • a. Loosen the steering nut 1 and then tighten it to specification with the ring nut wrench.
NOTE:
Set the torque wrench at a right angle to the steering nut wrench.
P* Ring nut wrench
90890-01268
YU-01268
3-42
CHECKING AND ADJUSTING THE STEERING HEAD b. Loosen the upper bearing inner race2 completely and then tighten it to specification with a steering nut wrench3 .
^
Steering nut wrench
90890-01444
YM-A9409-7 w
Do not overtighten the upper bearing inner race.
Upper bearing inner race(final tightening torque)
7Nm(0.7m
• kg, 5.1ft
• lb) c. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the bearing race .
Refer to “STEERING HEAD” in chapter 4. d. Hold the upper bearing inner race with a steering nut wrench and tighten the steering n u t 1 with a steering nut wrench2.
Steering nut wrench
90890-01403
YU-A9472
V
%
Steering nut
30Nm(3.0m
• kg, 21.7ft
• lb)
• • • • • • • • • • • • • • • • • • • • • • •
5. Install:
8headlight stay bracket
Refer to”HANDLE BRACKET AND
HEADLIGHT STAY BRACKET”in chapter 4.
8leg shield1,2
8front fork cover(left, right)
8front fork upper cover
Refer to”LEG SHIELD1,2".
3-43
CHECKING THE FRONT FORK
CHK
ADJ
< &
EAS00151
CHECKING THE FRONT FORK
1. Stand the scooter on a level surface. w
Securely support the scooter so that there is no danger of it falling over.
2. Check:
• inner tube
Damage/scratches -» Replace.
• oil seal
Oil leakage -» Replace.
3. Hold the scooter upright and apply the front
• brake.
4. Check:
• front fork operation
Push down hard on the handlebar several times and check if the front fork rebounds smoothly.
Rough movement -» Repair.
Refer to “FRONT FORK” in chapter 4.
3-44
CHECKING THE TIRES
EAS00163
CHECKING THE TIRES
The following procedure applies to both of the tires.
1. Check:
• tire pressure
Out of specification -> Regulate. rr\w«:»iwei
• The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
• The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
• Operation of an overloaded scooter could cause tire damage, an accident or an injury.
• NEVER OVERLOAD THE SCOOTER.
Basic weight
(with oil and a full fuel tank)
Maximum load*
Cold tire pressure
90 kg (198 lb)
175 kg (386 lb)
Front Rear
Up to 55 kg 175 kPa (1.75 175 kPa (1.75 kgf/cm
2
, 25 psi) kgf/cm
2
, 25 psi)
55 kg ~ 175 kg
175 kPa (1.75 kgf/cm
2
, 25 psi)
175 kPa (1.75 kgf/cm
2
, 25 psi)
* Total weight of rider, passenger, cargo and accessories w
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, replace the tire immediately.
3-45
CHECKING THE TIRES
2. Check:
• tire surfaces
Damage/wear -» Replace the tire.
Minimum tire tread depth
0.8mm(0.03in)
1 Tire tread depth
2 Sidewall
3 Wear indicator w
Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation.
When using tube tires, be sure to install the correct tube.
Always replace a new tube tire and a new tube as a set.
To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove.
Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement.
A
B
Tire
Wheel
Tube wheel
Tubeless wheel
Tube tire only
Tube or tubeless tire
After extensive tests, the tires listed below have been approved by Yamaha
Motor Taiwan Co., Ltd. for this model.
The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this scooter.
Front tire
Manufacturer Model
CHENG SHIN C6022
3-46
Rear tire
Manufacturer Model
CHENG SHIN C6022
Size
120/90-10 57J
Size
120/90-10 57J
CHECKING THE TIRES
CHK
ADJ
< & w
New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.
NOTE:
For tires with a direction of rotation mark 1 :
8 Install the tire with the mark pointing in the direction of wheel rotation.
8 Align the m a r k 2 with the valve installation point.
3-47
CHECKING THE WHEELS/
CHECKING AND LUBRICATING THE CABLES
CHK
ADJ
< &
EAS00168
CHECKING THE WHEELS
The following procedure applies to both of the wheels.
1. Check:
• wheel
Damage/out-of-round -» Replace.
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Never attempt to make any repairs to the wheel.
NOTE:
After a tire or wheel has been changed or replaced, always balance the wheel.
3-48
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the inner and outer cables.
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Damaged outer cable may cause the cable to corrode and interfere with its movement.
Replace damaged outer cable and inner cables as soon as possible.
1. Check:
• outer cable
Damage -» Replace.
2. Check:
• cable operation
Rough movement -» Lubricate.
Recommended lubricant
Engine oil or a suitable cable lubricant
NOTE:
Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device.
LUBRICATING THE LEVERS AND PEDALS/
LUBRICATING THE CENTERSTAND
CHK
ADJ
< &
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals.
Recommended lubricant
Lithium-soap-based grease
EAS00173
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.
Recommended lubricant
Lithium-soap-based grease
3-49
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