XC50V

SERVICE MANUAL

LIT-11616-19-49

3D1-F8197-10

EAS00000

XC50V 2005 SERVICE MANUAL 2005 by Yamaha Motor Taiwan Co., Ltd. First edition, July 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd. is expressly prohibited. LIT-11616-19-49

EAS00002

NOTICE
This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Yamaha Motor Taiwan Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice.
EAS00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Q w cC
NOTE:

The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander or a person inspecting or repairing the scooter. A CAUTION indicates special precautions that must be taken to avoid damage to the scooter. A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to SYMBOLS. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (PERIODIC CHECKS AND ADJUSTMENTS), where the sub-section title(s) appears. 3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced. Refer to SYMBOLS. 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially. 6
EAS00251

1
ENG
CYLINDER AND PISTON
EAS00253

CYLINDER AND PISTON CYLINDER AND PISTON

ENG

1 3

REMOVING THE CYLINDER AND PISTON 1. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 3

cC

7 9 8
4

Do not use a hammer to drive the piston pin out. NOTE: 8 Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. 8 Before removing the piston pin, deburr the piston pin clips groove and the pistons pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller set4.

10 4

5
4

4
5

4 6

Piston pin puller set 90890-01304(YU-01304)

3 1
10Nm (1.0 mkg, 7.2 ftlb)

Order

Job/Part Removing the cylinder and piston Cylinder head Timing chain guide(exhaust side) Cylinder Case cap Reed valve assembly Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set

Qty

Remarks Remove the parts in the order listed. Refer to CYLINDER HEAD.

2. Remove: 8 top ring 8 2nd ring 8 oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.

1 2 3 4 5 6 7 8 9 10

1 1 1 1 2 1 2 1 1 1

Refer to INSTALLING THE PISTON AND CYLINDER. Refer to REMOVING THE CYLINDER AND PISTON. Refer to INSTALLING THE PISTON AND CYLINDER. For installation, reverse the removal procedure.
5-28

5-27

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SYMBOLS
The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 2 3 4 5 6 7 8 9
+

GEN INFO
3

SPEC
4

CHK ADJ
5

CHAS
6

ENG
7

COOL
8

General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Carburetor(s) Electrical system Troubleshooting

CARB
9

ELEC
0

TRBL SHTG
q w

r
T.

Symbols 0 to u indicate the following. 0 Serviceable with engine mounted q Filling fluid w Lubricant e Special tool r Tightening torque t Wear limit, clearance y Engine speed u Electrical data
R.

i
4

o
G

p
M

a
B

s
LS

d
M

Symbols i to d in the exploded diagrams indicate the types of lubricants and lubrication points. i Engine oil o Gear oil p Molybdenum-disulfide oil a Wheel-bearing grease s Lithium-soap- based grease d Molybdenum-disulfide grease Symbols f to g in the exploded diagrams indicate the following. f Apply locking agent (LOCTITE) g Replace the part

f
LT

New

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TABLE OF CONTENTS
GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING CARBURETOR ELECTRICAL SYSTEM TROUBLESHOOTING
GEN INFO

1 2 3 4 5 6 5 7
+

SPEC

CHK ADJ

CHAS

ENG

COOL

CARB
-

ELEC

8 9

TRBL SHTG

GEN INFO
CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ............................................. 1-1 MODEL LABEL .................................................................................. 1-1 IMPORTANT INFORMATION ................................................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ................... 1-2 REPLACEMENT PARTS ................................................................... 1-2 GASKETS, OIL SEALS AND O-RINGS ............................................ 1-2 LOCK WASHERS/PLATES AND COTTER PINS ............................. 1-3 BEARINGS AND OIL SEALS ............................................................ 1-3 CIRCLIPS ........................................................................................... 1-3 Notes 3 on equipment preparation .................................................... 1-4 CHECKING THE CONNECTIONS ........................................................... 1-5 SPECIAL TOOLS ...................................................................................... 1-6

1-9

SCOOTER IDENTIFICATION
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GEN INFO

GENERAL INFORMATION
1

SCOOTER IDENTIFICATION
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VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the steering head pipe.

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

1-1

IMPORTANT INFORMATION
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GEN INFO

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning equipment. Refer to the SPECIAL TOOLS. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been mated through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire.

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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.
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GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.

1-2

IMPORTANT INFORMATION
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GEN INFO

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.

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BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturers marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. 1 Oil seal

cC
Do not spin the bearing with compressed air because this will damage the bearing surfaces. 1 Bearing

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CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives. 4 Shaft

1-3

IMPORTANT INFORMATION
JAS00021

GEN INFO

Notes 3 on equipment preparation Push Rivet (Push type) Assembly status of the Push Rivet (Push type)

Dissembling 1. Press Center Pin 1 inward to release the Lock. 2. Remove the Push Rivet main body 2.

Assembling 1. Restore the Center Pin, replace the Push Rivet main body.

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

1-4

CHECKING THE CONNECTIONS

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GEN INFO

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector 2. Check: 8 lead 8 coupler 8 connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times.

3. Check: 8 all connections Loose connection

Connect properly.

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

4. Connect: 8 lead 8 coupler 8 connector NOTE: Make sure all connections are tight. 5. Check: 8 continuity (with the pocket tester) Pocket tester 90890-03132 (YU-03112-C) NOTE: 8 If there is no continuity, clean the terminals. 8 When checking the wire harness, perform steps (1) to (3). 8 As a quick remedy, use a contact revitalizer available at most part stores.
1-5

SPECIAL TOOLS
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GEN INFO

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. Tool NO.
90890-01085 YU-01083-2 90890-01084 YU-01083-3

Tool name / Function

Slide hammer bolt (8mm) 1 Weight 2 These tools are needed to remove the camshaft. Rotor holding tool

Illustration 1 2

90890-01235 YU-01235

90890-01268 YU-01268

This tool is used to remove the flywheel magneto. Ring nut wrench

90890-01304 YU-01304

This tool is used to loosen and tighten the exhaust and steering ring nut. Piston pin puller set

90890-01312 YM-01312-A

This tool is used to remove the piston pin. Fuel level gauge

90890-01337 YM-33285 YM-33285-6

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

90890-01348 YM-01348

These tool are used for removing the nut with holding the compression spring. Lock nut wrench
46

41

90890-01325 YU-24460-01 90890-01352 YU-33984

This tool is used when removing or installing the secondary sheave nut. Radiator cap tester1 Radiator cap tester adapter2 This tester and its adapter are needed for checking the cooling system.

1-6

SPECIAL TOOLS
Tool NO.
90890-01367 YM-A9409-7 90890-01400 YM-A9409-3

GEN INFO

Tool name / Function

Fork seal driver weight1 Fork seal driver attachment(30mm)2 This tool is used when installing the fork seal. Oil seal guide This tool is used for protecting the oil seal lip when installing the secondary sliding sheave. Steering nut wrench

Illustration

90890-01384 YM-33299

90890-01403 YU-A9472

90890-01701 YS-01880-A

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

90890-03079 YM-34483

This tool is used for holding the secondary sheave. Thickness gauge

90890-03081 YU-33223

This tool is used to measure the valve cleanance. Compression gauge

90890-03132 YU-03112-C

These tool are used to measure the engine compression. Pocket tester

90890-03113 YU-08036-C

This instrument is invaluable for checking the electrical system. Engine tachometer

90890-03141 YU-03141

This tool is needed for detecting engine rpm. Timing light

This tool is needed for detecting ignition timing.

1-7

SPECIAL TOOLS
Tool NO.
90890-04109 YM-04109 90890-04148 YM-04148

GEN INFO

Tool name / Function

Valve spring compressor Compressor adapter(16.5mm) These tools are used when removing or installing the valve and the valve spring. Valve guide remover (4.0 mm)

Illustration

90890-04111 YM-04111

90890-04112 YM-04112

This tool is used to remove or install the valve guides. Valve guide installer (4.0 mm)

This tool is used to install the valve guides. 90890-04113 YM-04113 Valve guide remover (4.0 mm)

90890-06754 YM-34487

This tool is used to rebore the new valve guides. Ignition checker

90890-85505 ACC-11001-05-01

This instrument is necessary for checking the ignition system components. Yamaha bond NO.1215

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

1-8

SPEC
CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................................................................. 2-1 ENGINE SPECIFICATIONS ..................................................................... 2-2 CHASSIS SPECIFICATIONS ................................................................. 2-10 ELECTRICAL SPECIFICATIONS .......................................................... 2-12 CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS ................................................................................................. 2-15 TIGHTENING TORQUES........................................................................ 2-16 ENGINE ............................................................................................ 2-16 CHASSIS .......................................................................................... 2-18 LUBRICATION POINTS AND LUBRICANT TYPES ............................. 2-19 ENGINE ............................................................................................ 2-19 CHASSIS .......................................................................................... 2-21 COOLING SYSTEM DIAGRAMS ........................................................... 2-22 OIL FLOW DIAGRAMS .......................................................................... 2-26 CABLE ROUTING .................................................................................. 2-28

2-34

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Weight Wet (without oil and a full fuel tank) Dry (without oil and fuel) Maximun load (total of cargo, rider, passenger, and accessories) Standard 3D11 (for USA) 3D12 (for CAN) 1665 mm( 65.6in ) 630 mm( 24.8in ) 1005 mm( 39.6in ) 715 mm( 28.2in ) 1160 mm( 45.7in ) 85 mm( 3.4in ) 1800mm( 70.9in ) 81 kg( 179lb ) 76kg( 168lb ) 158kg( 348lb ) Limit

2-1

ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS

Item Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Engine idle speed Vacuum pressure at engine idle speed(AI OFF) Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Engine oil Lubrication system Recommended oil
-20 -10 0 10 20 30 40 50

SPEC

Standard Liquid-cooled, 4-stroke, SOHC 0.049L(49cm3) Forward inclined single cylinder 38.0 43.5 mm 12:1 2000~2400 r/min 34.7 kpa ( 260 mmHg ) 1450 kPa (14.5kgf/cm2 ) at 700 r/min Unleaded gasoline 4.5L ( 0.98 Imp gal, 1.18 US gal ) Wet sump SAE10W40 Yamaha 4-cycle oil EFERO X,Z,BX

Limit

SAE 10W-30 SAE 10W-40 SAE 20W-40 SAE 20W-50

Quantity Periodic oil change Total amount Final gear oil Recommended oil Periodic oil change Total amount

0.73~0.83 L (0.67~0.76 Imp qt, 0.80~0.90 US qt) 0.8~0.9L (0.74~0.83 Imp qt, 0.87~0.98 US qt) SAE10W30 hypoid gear oil 0.09~0.11L (0.08~0.10 Imp qt, 0.10~0.12 US qt) 0.11~0.13L (0.10~0.12 Imp qt, 0.12~0.14 US qt)

2-2

ENGINE SPECIFICATIONS
Item Oil filter Oil filter type Oil pump Oil pump type Inner rotor to outer rotor tip clearance Outer rotor to pump housing clearance Oil pump housing to inner rotor and outer rotor clearance Cooling system Radiator capacity Radiator cap opening pressure Standard Wire mesh Trochoid 0.15 mm or less 0.13-0.18 mm 0.07-0.12 mm

SPEC
Limit 0.23mm 0.25mm 0.19mm

Valve relief pressure Radiator core Width Height Depth Coolant reservoir Capacity <From low to full lever> Water pump Water pump type Max. impeller shaft tilt Starting system type Spark plug Model (manufacturer) quantity Spark plug gap Cylinder head Volume Max. warpage

0.26L 93.3~122.7 kpa (0.95~1.25kgf/cm2, 13.53~17.79 psi) 1.1kpa (0.01kgf/cm2, 0.16 psi) 133.3mm 87mm 16mm 0.26L 0.15L

Single suction centrifugal pump 0.15mm Electric and kick starter CR7E (NGK) 1 0.7~0.8mm 3.1~3.5cm 0.03 mm

2-3

ENGINE SPECIFICATIONS
Item Camshaft Drive system Intake camshaft lobe dimensions Standard Chain drive (left)

SPEC
Limit

C A

Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions

C A

30.158~30.258 mm 25.082~25.182 mm 5.2077mm

30.058 mm 24.982 mm

Measurement A Measurement B Measurement C Max. camshaft runout

30.158~30.258 mm 25.020~25.120 mm 5.2077mm

30.058 mm 24.920 mm 0.03 mm

2-4

ENGINE SPECIFICATIONS
Item Timing chain Model/number of links Tensioning system Valve, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions
B A

SPEC
Limit

Standard Morse 92RH2005 / 82 Automatic

0.10~0.16 mm 0.18~0.24 mm

C D

Head Diameter

Face Width

Seat Width

Margin Thickness

Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve stem to valve guide clearance Intake Exhaust Valve stem runout

15.4~15.6 mm 16.4~16.6 mm 1.48~2.19 mm 1.48~2.19 mm 0.9~1.1 mm 0.9~1.1 mm 0.7 mm 0.7 mm 3.975~3.990 mm 3.960~3.975 mm 4.000~4.012 mm 4.000~4.012 mm 0.010~0.037 mm 0.025~0.052 mm

1.6mm 1.6mm 3.945 mm 3.930 mm 4.050 mm 4.050 mm 0.080 mm 0.100 mm 0.010 mm

Valve seat width Intake Exhaust

0.9~1.1 mm 0.9~1.1 mm

1.6mm 1.6mm

2-5

ENGINE SPECIFICATIONS
Item Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt Standard

SPEC
Limit

39.35 mm 41.57 mm 28.0mm 30.0mm 91.1~104.9N(9.3~10.7kg) 107.9~124.1N (11.0~12.7kg)

37.38 mm 39.49 mm

Intake Exhaust Winding direction (top view) Intake Exhaust

Clockwise Clockwise

2.5 /1.7 mm 2.5 /1.8 mm

Valve seat reformed Cylinder Cylinder arrangement Bore stroke Compression ratio Bore Max. taper Max. out-of-round

Yes Forward inclined single cylinder 38.0 43.5 mm 12:1 38.000~38.010 mm

0.05 mm 0.010 mm

2-6

ENGINE SPECIFICATIONS
Item Piston Piston-to-cylinder clearance Diameter D Standard 0.010~0.035 mm 37.975~37.990 mm

SPEC
Limit 0.150mm

H D

Height H Piston pin bore (in the piston) Diameter Offset Offset direction Piston pin Outside diameter Piston rings Top ring
B T

5.0 mm 10.002~10.013 mm 0.35~0.65mm Intake side 9.996~10.000 mm

10.043 mm 9.976 mm

Ring type Dimensions (B T) End gap (installed) Ring side clearance 2nd ring
B T

Barrel 0.8 1.65mm 0.05~0.15 mm 0.02~0.08 mm

0.40mm 0.13 mm

Ring type Dimensions (B T) End gap (installed) Ring side clearance Oil ring
B T

Taper 0.8 1.5mm 0.05~0.17 mm 0.02~0.06 mm

0.52mm 0.12mm

Dimensions (B T) End gap (installed) Ring side clearance

1.5 1.6 mm 0.2~0.7 mm 0.03~0.15 mm

2-7

ENGINE SPECIFICATIONS
Item Rocker arm/rocker arm shaft Rocker arm inside diameter Rocker arm shaft outside diameter Arm-to-shaft clearance Connecting rod Connecting rod length Small end inside diameter Crankshaft Standard 10.000~10.015mm 9.981~9.991 mm 0.009~0.034 mm 79.95~80.05 mm 10.015~10.028mm

SPEC
Limit

Width A Max. runout C Big end side clearance D Big end radial clearance E

42.45~42.50 mm 0.15~0.45 mm 0~0.010mm

0.03mm 1.00mm

2-8

ENGINE SPECIFICATIONS
Item Clutch Clutch type Clutch shoe thickness Clutch shoe spring free length Clutch housing inside diameter Compression spring free length Weight outside diameter Clutch-in revolution Clutch-stall revolution V-belt V-belt width Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Single speed automatic Max. main axle runout Max. drive axle runout Air filter type Carburetor Model (manufacturer) quantity ID mark Venturi tube bore(primary) Venturi tube bore(secondary) Main jet Main air jet Jet needle Neddle jet Slow air jet Pilot outlet Slow jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter air jet Throttle valve size Fuel level ( using fuel level gauge ) Engine idle speed CO% (air induction system ON) CO% (air induction system OFF) Oil temperature ( C ) Standard Automatic centrifugal 3.7 mm 30.10.4mm 107 mm 76.4 mm 15.0 mm 3450~3850 r/min 4350~5350 r/min 16.8 mm V-belt automatic Helical gear 48/13 (3.692) Spur gear 43/12 (3.583) 2.805~0.863:1 Oil coated paper element NCV18 (KEIHIN) 1 3D11 00 7.7 16.6 #82 #80 N425-FBC00 N426-36628 #82 0.9 #35/35 0.7 0.7 0.7 1.6 #38 1.5 N503-69E00 6.6~7.6mm 2000~2400 r/min Less than 3.5% 5.5~6.5 % 55~65 C

SPEC
Limit 2.0mm 14.5 mm 15.8mm 0.04 mm 0.04 mm

2-9

CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS

Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0~55 kg 55~158 kg Min. tire tread depth Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0~55 kg 55~158 kg Min. tire tread depth Standard Steel tube underbone 24 70 mm Cast wheel J10 MT2.15 Aluminum 59mm Cast wheel J10 MT2.15 Aluminum 54mm Tubeless 90/90-10 50J K348A (KENDA)

SPEC

Limit 1.0 mm 1.0 mm 1.0 mm 1.0 mm 0.8mm

150kpa (1.5 kgf/cm, 22 psi) 150kpa (1.5 kgf/cm, 22 psi) Tubeless 90/90-10 50J K348A (KENDA)

175kpa (1.75 kgf/cm, 25 psi) 175kpa (1.75 kgf/cm, 25 psi) 0.8mm

2-10

CHASSIS SPECIFICATIONS
Item Front brake Brake type Operation Brake lever free play (at lever end) Brake drum inside diameter Lining thickness Rear brake Brake type Operation Brake lever free play (at lever end) Brake drum inside diameter Lining thickness Front suspension Suspension type Front fork type Front fork travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Inner tube outer diameter Inner tube bending limit Steering system Steering bearing type Lock to lock angle (left) Lock to lock angle (Right) Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring rate (K2) Spring rate (K3) Spring stroke (K1) Spring stroke (K2) Spring stroke (K3) Optional spring available Standard Drum brake Right-hand operation 10~20mm 110 mm 4.0mm Drum brake Left-hand operation 10~20mm 110 mm 4.0mm Telescopic Coil spring/grease damper 65 mm 120 mm 110mm 9.46N/mm (0.96 kgf/mm) 0~65mm No 26 mm Angular bearing 45 45 Unit swing Coil spring/oil damper 55mm 192.5mm 182.5mm 24.82N/mm (2.53kgf/mm) 39.27N/mm (4.00kgf/mm) 60.50N/mm (6.17kgf/mm) 0~25mm 25~43mm 43~55mm No

SPEC
Limit 110.5mm 2.0mm 110.5mm 2.0mm 117.6mm 0.2 mm

2-11

ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS

Item System voltage Ignition system Ignition system type Ignition timing Advancer type Pickup coil resistance /color C.D.I. unit model (manufacturer) 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 Lighting coil resistance /color Voltage regulator Regulator type Model (manufacturer) No load regulated voltage(DC) Rectifier Model (manufacturer) Rectifier capacity(DC) Withstand voltage Battery Battery type (manufacturer) Battery voltage capacity Specific gravity Ten hour rate amperage Headlight type Indicator light (voltage/wattagequantity) Turn signal indicator light High beam indicator light Water temperature indicator light 12V C.D.I. 13 B.T.D.C. at 2000~2400 r/min Digital 248~372 / WR-WL 5ST (T-MORIC) X7A (T-MORIC) 6mm 0.168~0.252 at 20 C 2.4~3.6 k at 20 C Resin 4~6 k Standard

SPEC

Limit

AC magneto 1P41 (T-MORIC) 14V 120W / 5000 r/min 0.288~0.432 /Ground-W 0.256~0.384 /Ground-Y/R Semiconductor, short circuit SH656-12 (SHIN DEN GEN) 14.1~14.9 V SH656-12 (SHIN DEN GEN) 8A 200V GTX5L-BS (GS) 12V 4AH 1.330 4AH Halogen bulb 14 V 3.0 W 2 12 V 1.7W 1 14 V 3.0W 1

2-12

ELECTRICAL SPECIFICATIONS
Item Bulbs (voltage/wattage quantity) Headlight Tail/brake light Front turn signal light Rear turn signal light Speedometer lighting Electric starting system System type Starter motor Model (manufacturer) Suction voltage Power output Brushes Overall length Quantity Spring force Commutator diameter Commutator resistance Mica undercut (depth) Starter relay Model (manufacturer) Amperage Coil resistance Suction voltage Horn Horn type Model (manufacturer) Max. amperage Performance Coil resistance Turn signal relay Relay type Model (manufacturer) Self-cancelling device built-in Turn signal blinking frequency Wattage Fuel sender Model (manufacturer) Sender unit resistance-full Sender unit resistance-empty Head light relay Model (manufacturer) Coil resistance Diode Standard

SPEC
Limit

12 V 35W/35W 1 12 V 5W/21 W 1 12 V 10 W 2 12 V 10 W 2 12 V 1.7 W 2 Constant mesh 5STF (T-MORIC) 12V 0.25 kW 7.0 mm 2 3.92~5.88 N 17.6 mm 0.0378~0.0462 at 20 C 1.35 mm 5WC 00 (OMRON) 50 A 90-110 More than DC10V Plane AH-368 (SAKURA) 1.5 A 98~108db/2m 4.05~4.55 Full transistor 5CA9 (TA YOUNG) NO 75~95 cycles/min 10 W 2 + 1.7 W+ AP 5ST1 (CHAO LONG) 6~8 93.5~96.5 5EB 10 (OMRON) 90~110 YES

3.5mm 16.6mm

2-13

ELECTRICAL SPECIFICATIONS
Item Throttle position sensor Output voltage (throttle opens) Output voltage (throttle closes) Radiator fan Model (manufacturer) Running rpm Thermostat switch Model (manufacturer) Thermo unit Model (manufacturer) Coil resistance at 80 C Coil resistance at 100 C Fuse (amperage quantity) Main fuse Standard 2.8~3.4V 0.625~0.775V 5ST-00 (LUNTAI) 10000 r/min

SPEC
Limit

5ST (NIPPON THERMOSTAT) 5JJ (NIPPON THERMOSTAT) 3.413~4.007 k 1.645~1.855 k 7.5A1

2-14

CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS

EB201000 EAS00030

SPEC

CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC ** mm 2 mm MULTIPLIER 0.03937 0.03937 IMPERIAL ** in 0.08 in

GENERAL TIGHTENING TORQUE SPECIFICATIONS

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.

CONVERSION TABLE
METRIC TO IMPERIAL Metric unit mkg Tightening torque mkg cmkg cmkg Weight Speed kg g km/hr km m m cm mm cc (cm3) cc (cm3) lt (liter) lt (liter) kg/mm kg/cm2 Centigrade (C) Multiplier 7.233 86.794 0.0723 0.8679 2.205 0.03527 0.6214 0.6214 3.281 1.094 0.3937 0.03937 0.03527 0.06102 0.8799 0.2199 55.997 14.2234 9/5+32 Imperial unit ftlb inlb ftlb inlb lb oz mph mi ft yd in in oz (IMP liq.) cu-in qt (IMP liq.) gal (IMP liq.) lb/in psi (lb/in2) Fahrenheit (F)

Distance

A: Width across flats B: Thread diameter A (nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B (bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General tightening torques Nm 6 15 30 55 85 130 mkg 0.6 1.5 3.0 5.5 8.5 13.0 ftlb 4.3 11 22 40 61 94

Volume/ Capacity

Misc.

2-15

TIGHTENING TORQUES TIGHTENING TORQUES

ENGINE Part to be tightened Part name Thread Q ty size M6 M10 M6 M8 M6 M6 M6 M6 M6 M6 M8 M6 M8 M6 M6 M6 M5 M12 M6 M6 M35 M6 M8 M6 M8 M6 M6 M6 M6 M6 M6 M6 M8 M8 M8 M6 M6 M6 M6 M22 4 1 2 2 4 1 3 3 1 1 1 2 1 2 4 3 2 1 2 2 1 1 2 2 2 2 8 8 8 7 6 1 1 1 1 1 4 7 1 1

SPEC

Tightening torque Nm mkg ftlb

Remarks

Cylinder head and cylinder Spark plug Cylinder head(timing chain side) Exhaust pipe stud bolt Cylinder head cover Oil check bolt Water pump housing cover Water pump assembly Guide stopper2 Thermostat housing air bleed bolt Camshaft sprocket Timing chain tensioner (body) Timing chain tensioner (plug) Thermostat housing Fan case Fan Oil pump assembly Radiator drain bolt Manifold Air filter assembly Engine oil drain plug Air cut-off valve Muffler Oil guide Muffler Protector Crankcase(left and right) Transmission cover Drain bolt(transmission oil) Cover1(starter clutch) Crankcase cover(left) Hold lead plate bolt Drain bolt(engine oil) Rear wheel lock nut Drain bolt(transmission oil fill bolt) AI filter Rear wheel lock cover Plate Kickstarter Starter clutch

Nut Bolt Nut Bolt Bolt Bolt Bolt Bolt plug Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nult Nut Screw Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut

10 12.5 10 12.5 10 7 10 10 7 10 30 9 8 10 10 9 4 2 10 10 32 10 31 10 13 9 10 13 13 10 10 10 23 15 23 10 10 7 12 90

1.0 1.25 1.0 1.25 1.0 0.7 1.0 1.0 0.7 1.0 3.0 0.9 0.8 1.0 1.0 0.9 0.4 0.2 1.0 1.0 3.2 1.0 3.1 1.0 1.3 0.9 1.0 1.3 1.3 1.0 1.0 1.0 2.3 1.5 2.3 1.0 1.0 0.7 1.2 9.0

7.2 9.0 7.2 9.0 7.2 5.1 7.2 7.2 5.1 7.2 21.7 6.5 5.8 7.2 7.2 6.5 2.9 1.5 7.2 7.2 23.1 7.2 22.4 7.2 9.4 6.5 7.2 9.4 9.4 7.2 7.2 7.2 16.6 10.9 16.6 7.2 7.2 5.1 8.7 65.1

Left-hand thread

Left-hand thread

2-16

TIGHTENING TORQUES
Part to be tightened Part name Thread Q ty size M10 M5 PT1/8 M10 M6 M12 M5 M6 1 1 1 1 2 1 3 2

SPEC
Remarks

Tightening torque Nm mkg ftlb 40 8 8 30 13 43 4 7 4.0 28.9 0.8 5.8 0.8 5.8 3.0 21.7 1.3 9.4 4.3 31.1 0.4 2.9 0.7 5.1

Clutch housing Ignition coil Thermo unit Primary fixed sheave Starter motor assembly AC magneto rotor Stator coil Pickup coil Cylinder head tightening sequence
1

Nut Bolt Nut Bolt Nut Bolt Screw

LT

3 4 2 6

2-17

TIGHTENING TORQUES
CHASSIS Part to be tightened Thread size M10 M10 M10 M10 M6 M6 M8 BC BC1 M6 M6 M5
About M5

SPEC

Tightening torque Nm mkg ftlb 4.6 5.8 6.0 3.0 1.2 1.0 2.3 0.7 3.0 1.2 0.4 0.3 0.15 0.2 0.7 0.8 4.8 10.4 0.7 1.6 0.3 3.0 1.6 46 58 60 30 12 10 23 7 30 12 4 3 1.5 2 7 8 48 104 7 16 3 30 16

Remarks 33.1 42.0 43.4 21.7 8.7 7.2 16.6 5.1 SeeNOTE 21.7 SeeNOTE 8.7 2.9 2.2 1.1 1.5 5.1 5.8 34.7 75.2 5.1 11.6 2.2 21.7 11.6

Frame and engine bracket 3 Engine bracket 3 and engine Handlebar and steering shaft Front fork and lower bracket Seat lock assembly Rear carrier(front) Rear carrier(rear) Steering shaft and upper bearing inner race Steering shaft and ring nut Trunk Footrest board Fuel sender Resin part and resin cover Seat lock adjuster Main switch and frame Front brake camshaft lever Front wheel shaft Rear wheel shaft Rear brake camshaft lever Rear brake pin pivot Speedometer cable Rear shock absorber and frame Rear shock absorber and engine

M6 M6 M6 M10 M14 M6 M8 M12 M10 M8

NOTE : 1. First, tighten the upper bearing inner race approximately 7Nm(0.7mkg, 5.1ftlb) by using the torque wrench and check turn steering shaft smoothly. 2. Second, hold the upper bearing inner race and tighten the ring nut 30Nm(3.0mkg, 21.7ftlb) by using the torque wrench. 3. Final, installing the ball race cover. 1 Upper bearing inner race 2 Ring nut 3 Ball race cover

2-18

LUBRICATION POINTS AND LUBRICANT TYPES

EAS00031

SPEC

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE Lubrication Point Oil seal lips O-rings (Except V-belt drive unit) Cylinder head tightening nut mounting surface Cylinder head stud bolt thread Cylinder head gasket dowel pin Crankshaft pin outside surface Connecting rod Piston outside and ring groove Piston pin outside surface surface and bolt thread Crankshaft journal Piston (balancer) outside surface Piston pin (balancer) outside surface Camshaft lobe Camshaft profile journal Valve stems (intake and exhaust) Valve stem seals(intake and exhaust) Valve pads(intake and exhaust) Valve stem ends (intake and exhaust) Oil pump assembly inside surface Oil pipe union bolt thread and surface Starter clutch pin and weight Idle gear 1 thrust surface Idle gear 2 Main and drive axle serration (sprocket) Drive axle taper rollor bearing Transmission bearing Lubricant
LS

LS

4 4 4 4 4 4 4 4 4 4 4 M M M M M 4 4 4 M 4 4 G G G

2-19

LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication Point Secondary fixed sheave inner surface Secondary sliding sheave torque cam ditch Crankcase mating surfaces

SPEC
Lubricant
BEL-RAY asembly lube BEL-RAY asembly lube

Sealant

2-20

LUBRICATION POINTS AND LUBRICANT TYPES

EAS00032

SPEC

CHASSIS Lubrication Point Front wheel oil seal lips Steering bearing and bearing races (upper and lower) Frame head pipe dust seal lips ( lower) Tube guide (throttle grip) inner surface Brake lever and lever holder bolt sliding surface Centerstand pivoting point and sliding surface Rear shock absorber backward, bush inner surface and spacer sliding surface Seat lock cable and rear wheel lock cable inner surface Engine bracket and engine mound bolt sliding surface Lubricant
LS LS

LS

LS

LS LS

M
LS

LS

2-21

COOLING SYSTEM DIAGRAMS

EAS00033

SPEC

COOLING SYSTEM DIAGRAMS

1 2 3 4 5 6 Raidator cap Coolant reservoir Radiator inlet hose Radiator outlet hose Thermo switch Conduit hose

1 6

3 5

2-22

COOLING SYSTEM DIAGRAMS

1 2 3 4 5 Outlet hose(to cylinder) Radiator inlet hose Radiator outlet hose Thermostat Thermostat housing

SPEC

2-23

COOLING SYSTEM DIAGRAMS

1 2 3 4 Breather hose Outlet hose(to cylinder) Radiator outlet hose Water pump

SPEC

2-24

COOLING SYSTEM DIAGRAMS

1 2 3 4 Thermostat housing Thermostat assembly inlet breather hose Water pump Breather hose

SPEC

2-25

OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS

1 2 3 4 5 6 Oil filter Oil pump To cylinder head Oil strainer Oil nozzle Camshaft

SPEC

2-26

OIL FLOW DIAGRAMS

1 2 3 4 Crankshaft pin Connecting rod big end bearing Oil nozzle Camshaft

SPEC

Cylinder wall

Rocker arm shaft and rocler arm Camshaft

Connecting rod big end bearing

Crankshaft pin

Oil nozzle

Centrifugal oil filter

Oil pump Oil filter

Crankcase sump

2-27

CABLE ROUTING
EAS00035

SPEC

CABLE ROUTING
1 Fuel sender lead 2 C.D.I. unit 3 AI filter 4 Starter motor lead 5 Main switch 6 Rectifier/Regulator 7 Overflow pipe 8 Thermo unit 9 Rear wheel lock cable 0 Rear brake cable q Throttle cable kit w Seat lock cable e Wire harness r Hose t Bend hose y Vacuum sensing hose u AC magneto lead

A Insert the wire harness plate holder to the T-stud of down tube . B Insert the seat lock cable into the frame, protector part to the hole position. C Insert the L coupler to the ignition coil and installing direction of downward. D Clamp the wire harness, thermo switch lead and conduit hose to the frame. E Fasten the wire harness, AC magneto lead and starter motor lead to the frame with a plastic locking tie and end of plastic locking the upward. F Route the AC magneto lead and bend hose through inside of the frame .

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

9 G e

0 q u y e r t

C-C
2

E-E
1 3 5 E 4 D C 6

8
2-28

CABLE ROUTING
1 Turn signal relay 2 Horn 3 Head light relay 4 Speedometer cable 5 Front brake cable 6 Starter relay 7 Ignition coil 8 Throttle cable kit 9 Rear wheel lock cable 0 Air cut-off valve assembly q AI filter w Holder e Rectifier/Regulator r Clamp t Frame y Rear brake cable A Fasten the throttle cable kit and rear brake cable to the frame and cut the end to be shorter than 5mm, point the band tip to backward and reserve for a finger clearance. B Route the rear brake cable through guide of the under cover. C Route the seat lock cable through the guard mub rib. D 30~40mm E Clamp the rear brake cable stopper. F Clamp the carburetor drain hose to the rear brake cable, pass the rear brake cable outside the carburetor drain hose. G Clamp the rear brake cable to the under cover rib. H Clamp the throttle cable kit

SPEC

and Rear wheel lock cable through upward of the frame. I Route the rear brake cable through downward of the frame and upward of the under cover. J Route the rear brake cable, Rear wheel lock cable and throttle cable kit through side of the frame. K Route the lever holder lead coupler(left and right), brake switch lead coupler(front and rear) and speedometer lead coupler into the connector cover. Position the connector cover on the rib of the leg shield 2. L To the headlight and front turn signal light(left, right).

t 5 y 9 8

M L K e

r 1 2

N-N
1 3 2

N J

q 0 4 A 7 8 B 6 9

G
2-29

CABLE ROUTING
M Assemble the horn lead to the best forward of connector cover, do not through back side of the other leads. N Route the turn signal relay lead and front turn signal light lead(left) through backward of the steering head pipe.

SPEC

t 5 y 9 8

M L K e

r 1 2 3

N-N
1 3 2

N J

q 0 4 A 7 8 B 6 9

G
2-30

CABLE ROUTING
1 Battery negative - lead 2 Battery positive + lead 3 Fuse box 4 Starter motor lead 5 AC magneto lead 6 Fuel sender A Insert the wire harness cable strap into the footrest bracket of hole. B Route the wire harness through concave of the recovery tank and clamp it. C Insert the ignition coil connector into the ignition coil terminal. D Clamp the starter relay to the under cover of rib. E Route the starter motor lead through upward of the engine bracket and through left side of the wire harness. F Route the breather pipe through downward of the spacer. G Clamp the taillight lead to the side cover of hook. H Install the C.D.I. unit to the fuel tank bracket of bracket 1. I Clamp the seat lock cable protector of marking position to the fuel tank bracket. J Route the drain pipe along the fuel tank bracket and through the clamp. K Route the fuel hose and pipe 7 through downward of the breather pipe.

SPEC

L Route the throttle cable kit through upward of the breather pipe. M Clamp the auto choke lead and T.P.S. lead to the manifold of clamp. N Install the ignition coil to the engine. O Install the clamp to the under cover of hole. P Install the clamp to the footrest bracket of hole.

D B A C

1 2

3 5 4 E F G 6 H

P O

K N M L J

2-31

CABLE ROUTING
1 Front brake cable 2 Front brake switch lead 3 Speedometer assembly 4 Speedometer cable 5 Rear brake cable 6 Rear brake switch lead 7 Lever holder lead(left) 8 Handlebar 9 Lever holder lead(right) 0 Lever holder(left) q Grip(left) w Throttle cable kit e Speedometer assembly lead r Front fork t Frame A After locking the right side switch of control lever, confirm the driving status of holder. Turn the holder then release your hand and retrieve the holder quickly. B Install the throttle cable to the lever holder (right), and tightening torque 4Nm (0.4mkg, 2.9ftlb). C Route the lever holder lead(right) and front brake switch lead along backward of the front brake cable. D Install the speedometer cable to the speedometer assembly,
D A B 1C 2
A

SPEC

and tightening torque 3Nm([Link],[Link]). E Route the lever holder lead(left) and lever holder lead(right) through backward of the rear brake cable. F First, tighten the upper screw, when assembling the lever holder(left), and tightening torque 4Nm(0.4mkg,2.9ftlb). G When assembled, the projecting par t of the lever holder(left) should be in alignment with the handlebar Comp. hold position.

34 56

G H

9 w S

8 7

q 0

Q P

A O

N M L

UT
FWD.

Right side

Left side

C-C e2 1 4 5 6 7 9 w B
2-32

J
B C

r t

A-A

CABLE ROUTING
H After spread with adhesion agent on the inner side, push the grip into the handlebar assembly. I Allow the gain position to arrive at this range. J Install the handlebar cover to the handlebar bracket, and tightening torque 4Nm(0.4mkg,2.9ftlb). K To the headlight. L Insert the rear brake cable to the lever holder(left). M When assembling the rear brake cable and speedometer cable, do not interfere. N Install the speedometer assembly to the handlebar bracket, and tightening torque 7Nm (0.7mkg,5.1ftlb). O When assembling the leads and cables, clamp and do not interfere. P Route the throttle cable through best backward of the cables and leads. Q When assembling the front brake cable and speedometer cable, do not interfere.

SPEC

R Route the throttle cable through upper of handlebar guide and handlebar upper cover. S First, tighten the back screw, when assembling the lever holder(right). T Install the handlebar to the steering shaft, and tightening torque 4Nm (0.4mkg,2.9ftlb). U Route the bolt through bike of right side, and tightening the nut.

D A B 1C 2

34 56

G H

9 w S

8 7

q 0

Q P

A O

N M L

UT
FWD.

Right side

Left side

C-C e2 1 4 5 6 7 9 w B
2-33

J
B C

r t

A-A

CHK ADJ
CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ....................................................................................... 3-1 PERIODIC MAINTENANCE AND MINOR REPAIR ................................ 3-2 Periodic maintenance chart for the emission control system ........... 3-2 General maintenance and lubrication chart...................................... 3-3 COVER AND PANEL ................................................................................ 3-5 SEAT AND TRUNK ............................................................................ 3-5 SIDE COVER (LEFT AND RIGHT) ................................................... 3-6 FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE .............................................................................................. 3-7 LEG SHIELD 1 , 2 .............................................................................. 3-8 ENGINE ..................................................................................................... 3-9 ADJUSTING THE VALVE CLEARANCE........................................... 3-9 ADJUSTING THE ENGINE IDLING SPEED .................................. 3-14 CHECKING THE EXHAUST GAS AT IDLE .................................... 3-15 ADJUSTING THE THROTTLE CABLE FREE PLAY ...................... 3-17 CHECKING THE SPARK PLUG ...................................................... 3-18 CHECKING THE IGNITION TIMING ............................................... 3-19 MEASURING THE COMPRESSION PRESSURE ......................... 3-21 CHECKING THE ENGINE OIL LEVEL ........................................... 3-23 CHANGING THE ENGINE OIL ........................................................ 3-24 CHANGING THE TRANSMISSION OIL .......................................... 3-26 MEASURING THE ENGINE OIL PRESSURE................................ 3-27 CHECKING THE AIR FILTER ELEMENT ....................................... 3-29 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD ................................................................................... 3-30 CHECKING THE FUEL AND VACUUM HOSES ............................ 3-30 CHECKING THE FUEL HOSES AND FUEL FILTER..................... 3-31 CHECKING THE CRANKCASE BREATHER HOSE ..................... 3-32 CHECKING THE EXHAUST SYSTEM ........................................... 3-33 CHECKING THE COOLANT LEVEL .............................................. 3-34 CHECKING THE COOLING SYSTEM ............................................ 3-35 CHANGING THE COOLANT ........................................................... 3-36 CHASSIS ................................................................................................. 3-39 ADJUSTING THE FRONT BRAKE ................................................. 3-39 ADJUSTING THE REAR BRAKE.................................................... 3-39 CHECKING THE FRONT AND REAR BRAKE SHOES ................ 3-40 CHECKING AND ADJUSTING THE STEERING HEAD ................ 3-41 CHECKING THE FRONT FORK ..................................................... 3-43
3-59

CHK ADJ
CHECKING THE TIRES .................................................................. 3-44 CHECKING THE WHEELS.............................................................. 3-47 CHECKING AND LUBRICATING THE CABLES ............................ 3-47 LUBRICATING THE LEVERS AND PEDALS ................................. 3-48 LUBRICATING THE CENTERSTAND ............................................ 3-48 ELECTRICAL SYSTEM ......................................................................... 3-49 CHECKING AND CHARGING THE BATTERY............................... 3-49 CHECKING THE FUSE ................................................................... 3-55 REPLACING THE HEADLIGHT BULB ........................................... 3-57 ADJUSTING THE HEADLIGHT BEAM ........................................... 3-58

3-60

INTRODUCTION
EAS00036

CHK ADJ

PERIODIC CHECKS AND ADJUSTMENTS

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

NOTE: The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 30,000 km, repeat the maintenance intervals starting from 6,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

3-1

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17560*

CHK ADJ

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance chart for the emission control system
INITIAL NO. ITEM ROUTINE 600 mi (1,000 km) or 1 month 2,000 mi (4,000 km) or 6 months ODOMETER READING 4,000 mi 6,000 mi 8,000 mi 10,000 mi (7,000 km) (10,000 km) (13,000 km) (16,000 km) or or or or 12 18 24 30 months months months months

Fuel line

Check fuel and vacuum hoses for cracks or damage. Replace if necessary. Check condition. Adjust gap and clean. Replace at 4000 mi (7000 km) or 12 months and thereafter every 4000 mi (6000 km) or 12 months. Check and adjust valve clearance when engine is cold. Check breather hose for cracks or damage. Replace if necessary. Check and adjust engine idle speed. Check for leakage. Tighten if necessary. Replace gasket(s) if necessary. Check the air cut-off valve, reed valve, and hose for damage. Replace any damaged parts.

Spark plug

Replace.

Replace.

3 4 5 6

* * * * *

Valve clearance Crankcase breather system Idle speed Exhaust system

Every 6000 mi (10000 km)

Air induction system

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

3-2

PERIODIC MAINTENANCE AND MINOR REPAIR

General maintenance and lubrication chart Maintenance and lubrication, periodic
INITIAL NO. ITEM ROUTINE 600 mi (1,000 km) or 1 month 2,000 mi (4,000 km) or 6 months

CHK ADJ

ODOMETER READING 4,000 mi 6,000 mi 8,000 mi 10,000 mi (7,000 km) (10,000 km) (13,000 km) (16,000 km) or or or or 12 18 24 30 months months months months

1 2

* * * * *

Air filter element Front brake

Replace. Check operation. Adjust cable and replace brake shoes if necessary. Check operation. Adjust cable and replace brake shoes if necessary. Check runout and for damage. Replace if necessary. Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. Check bearings for smooth operation. Replace if necessary. Check bearing assemblies for looseness. Moderately repack with lithiumsoap-based grease every 8000 mi (13000 km) or 24 months. Check all chassis fitting and fasteners. Correct if necessary.

3 4

Rear brake Wheels

Tires

Wheel bearings

Steering bearings

Repack.

8 9 10 11

Chassis fasteners

Front and rear brake Apply lithium-soap-based grease lever pivot (all-purpose grease) lightly. Centerstand Check operation. Lubricate. Check operation and for oil leakage. Replace if necessary. Check operation and for oil leakage. Replace if necessary. Change (warm engine before draining). Check oil level and vehicle for oil leakage. Clean. Check coolant level and vehicle for coolant leakage. Change. Check vehicle for oil leakage. Change. Replace.

* *

Front fork Shock absorber assembly

12

13 14 15 16 17 18 19

Engine oil Engine oil strainer

Cooling system Final transmission oil

Every 3 years Every 6250 mi (10000 km)

* * *

V-belt

Front and rear brake Check operation. switches Control and meter cables Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly. Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. Check operation. Adjust headlight beam.

20

Throttle grip housing and cable Lights, signals and switches

21

3-3

PERIODIC MAINTENANCE AND MINOR REPAIR

*

CHK ADJ

Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 12000 mi ( 19000 km) or 36 months, repeat the maintenance intervals starting from 4000 mi (7000 km) or 12 months.
EAU17680

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

3-4

COVER AND PANEL COVER AND PANEL

SEAT AND TRUNK

CHK ADJ

12Nm (1.2 mkg, 8.7 ftlb)

12Nm (1.2 mkg, 8.7 ftlb) 10Nm (1.0 mkg, 7.2 ftlb) 23Nm (2.3 mkg, 16.6 ftlb)

4 3 5

Order 1 2 3 4 5 6 7

Job/Part Removing the seat and trunk Seat Damper Rubber cap Trunk Rear carrier Mat Battery cover

Qty 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed.

For installation, reverse the removal procedure.

3-5

COVER AND PANEL

SIDE COVER (LEFT AND RIGHT)

CHK ADJ

5 4 6

1 2

Order

Job/Part Removing the side cover(left and right) Seat/Trunk Tail / brake and rear turn signal (left, right) light lead Front cover Side cover(left) Side cover(right) Tail/brake light Rear cover

Qty

Remarks Remove the parts in the order listed. Refer to SEAT AND TRUNK. Disconnect.

1 2 3 4 5 6

1 1 1 1 1 1

For installation, reverse the removal procedure.

3-6

COVER AND PANEL

FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE
4Nm (0.4 mkg, 2.9 ftlb)

CHK ADJ

1 3 2 7

Order

Job/Part Removing the footrest board and footrest board side cover mole Side cover(left and right)

Qty

Remarks Remove the parts in the order listed. Refer to SIDE COVER(LEFT AND RIGHT).

1 2 3 4 5 6 7

Battery holder Battery negative - lead Battery positive + lead Battery Footrest board side cover mole(left) Footrest board side cover mole(right) Footrest board

1 1 1 1 1 1 1

cC
First, disconnect the negative battery lead, and then the positive battery lead. For installation, reverse the removal procedure.

3-7

COVER AND PANEL

LEG SHIELD 1 , 2
7

CHK ADJ
8

9 3 5 2 6

4 10 11

12

Order

Job/Part Removing the leg shield 1,2 Footrest board

Qty

Remarks Remove the parts in the order listed. Refer to FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE.

1 2 3 4 5 6 7 8 9 10 11 12

Cap Headlight cover Head and front turn signal (left, right) light lead Leg shield 1 Turn signal relay Headlight relay Rear wheel lock clip Hook Leg shield 2 Starter relay Coolant reservoir Under cover

1 1 1 1 1 1 1 1 1 1 1 1

Disconnect.

Disconnect. Disconnect.

Disconnect. Disconnect. For installation, reverse the removal procedure.

3-8

ADJUSTING THE VALVE CLEARANCE

EAS00049

CHK ADJ

ENGINE
ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: 8 Valve clearance adjustment should be made on a cold engine, at room temperature. 8 When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: 8 seat/trunk 8 battery cover 8 battery holder 8 front cover Refer to COVER AND PANEL. 2. Drain: 8 coolant (completely from the radiator ) 3. Remove: 8 radiator cover 1 8 radiator 8 fan case2 Refer to RADIATORin chapter 6. 4. Remove: 8 spark plug cap 8 spark plug 8 ignition coil 8 cylinder head cover 5. Measure: 8 valve clearance Out of specification

Adjust.

Valve clearance (cold) Intake valve 0.10 ~ 0.16 mm (0.004 ~ 0.006 in) Exhaust valve 0.18 ~ 0.24 mm (0.007 ~ 0.010 in) ***************************************************** a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compression stroke, align the punch mark a in the camshaft sprocket with the stationary b on the plate. c. Align the TDC mark c on the AC magneto rotor with the stationary pointer d on the crankcase cover.

b a

3-9

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

d. Measure the valve clearance with a thickness gauge 1. Out of specification Adjust. *****************************************************
d c

6. Adjust: 8valve clearance ***************************************************** a. Remove the valve pad 2 with a magnetic bar 1. NOTE: 8 Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. 8 Make a note of the position of each valve pad so that they can be installed in the correct place. b. Select the proper valve pad from the following table.
Valve pad thickness range Nos. 120 ~ 240 1.20 (0.047in) ~ 2.40 mm (0.095 in) Available valve pads 25 thicknesses in 0.05 mm (0.002 in) increments

c. Round off the original valve pad number according to the following table.

3-10

ADJUSTING THE VALVE CLEARANCE

Last digit 0 or 2 5 8

CHK ADJ
Rounded value 0 5 10

EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. e. Install the new valve pad . NOTE: 8 Lubricate the valve pad with molybdenum disulfide oil. 8 Install the valve pad in the correct place. f. Measure the valve clearance again. g. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. *****************************************************

3-11

ADJUSTING THE VALVE CLEARANCE

INTAKE
MEASURED CLEARANCE

CHK ADJ

0.000.04 0.050.09 0.100.16 0.170.21 0.220.26 0.270.31 0.320.36 0.370.41 0.420.46 0.470.51 0.520.56 0.570.61 0.620.66 0.670.71 0.720.76 0.770.81 0.820.86 0.870.91 0.920.96 0.971.01 1.021.06 1.071.11 1.121.16 1.171.21 1.221.26 1.271.31 1.321.36

ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 STANDARD CLEARANCE 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 175 180 185 190 195 200 205 210 215 220 225 230 235 240 180 185 190 195 200 205 210 215 220 225 230 235 240 185 190 195 200 205 210 215 220 225 230 235 240 Valve Clearance (cold) 190 195 200 205 210 215 220 225 230 235 240 0.100.16 mm 195 200 205 210 215 220 225 230 235 240 Rounded value 175 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 Measured valve clearance is 0.24 mm 210 215 220 225 230 235 240 Replace pad 175 with pad 185 215 220 225 230 235 240 Pad No. 175 = 1.75 mm 220 225 230 235 240 Pad No. 185 = 1.85 mm 225 230 235 240 Always install the valve pad with the 230 235 240 235 240 number facing down. 240

EXHAUST
MEASURED CLEARANCE

0.000.02 0.030.07 0.080.12 0.130.17 0.180.24 0.250.29 0.300.34 0.350.39 0.400.44 0.450.49 0.500.54 0.550.59 0.600.64 0.650.69 0.700.74 0.750.79 0.800.84 0.850.89 0.900.94 0.950.99 1.001.04 1.051.09 1.101.14 1.151.19 1.201.24 1.251.29 1.301.34 1.351.39 1.401.44

120 125 130 135 140 120 120 125 120 125 130 120 125 130 135 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

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

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

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

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

ORIGINAL VALVE PAD NUMBER 165 170 175 180 185 190 195 200 205 210 215 145 150 155 160 165 170 175 180 185 190 195 150 155 160 165 170 175 180 185 190 195 200 155 160 165 170 175 180 185 190 195 200 205 160 165 170 175 180 185 190 195 200 205 210 STANDARD CLEARANCE 170 175 180 185 190 195 200 205 210 215 220 175 180 185 190 195 200 205 210 215 220 225 180 185 190 195 200 205 210 215 220 225 230 185 190 195 200 205 210 215 220 225 230 235 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 Valve Clearance (cold) 235 240 0.180.24 mm 240

220 200 205 210 215

225 205 210 215 220

230 210 215 220 225

235 240 215 220 220 225 225 230 230 235

225 230 235 240 230 235 240 235 240 240

Rounded value 175 Measured valve clearance is 0.32 mm Replace pad 175 with pad 185 Pad No. 175 = 1.75 mm Pad No. 185 = 1.85 mm Always install the valve pad with the number facing down.

3-12

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

7. Install: 8all removed parts NOTE: For installation, reverse the removal procedure. 8. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT.

3-13

ADJUSTING THE ENGINE IDLING SPEED

EAS00054

CHK ADJ

ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression.

1. Start the engine and let it warm up for several minutes. 2. Connect: 8 engine tachometer (onto the spark plug lead of cylinder) Engine tachometer 90890-03113 YU-08036-C 3. Check: 8 engine idling speed Out of specification Engine idling speed 2000 ~ 2400 r/min

Adjust

1 a b

4. Adjust: 8 engine idling speed ***************************************************** a . Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained.
Direction a Direction b Engine idling speed is increased. Engine idling speed is decreased.

***************************************************** 5 . Adjust: 8throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.5 mm (0.059 ~ 0.138 in)

3-14

CHECKING THE EXHAUST GAS AT IDLE

CHK ADJ

CHECKING THE EXHAUST GAS AT IDLE ( Measuring the exhaust gas at idle(when air induction system is operation)) 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Install: 8pocket tester1. (onto the engine oil drain bolt) 8engine tachometer (onto the spark plug lead ) Pocket tester 90890-03132 YU-03112-C Engine tachometer 90890-03113 YU-08036-C 3. Start the engine and warm it up until the specified oil temperature is reached. Oil temperature 50~70C 4. Measure: 8 engine idling speed Out of specification Adjust. Refer to ADJUSTING THE ENGINE IDLING SPEED Engine idling speed 2000 ~ 2400 r/min

5. Install: 8 carbon monoxide and hydrocarbon tester1. 8 sampling probe2. 8 engine tachometer3.
2

3-15

CHECKING THE EXHAUST GAS AT IDLE

CHK ADJ

600mm

NOTE: 8 Since it is necessary to insert the sampling probe 600mm into the exhaust pipe, be sure to use a heat-resisant rubber tube as shown in the illustration. 8 Be sure to set the heat-resistant rubber tube so that exhaust gas does not leak out. 8 Before using the carbon monoxide and hydrocarbon tester, be sure to read the user,s manual. 6. Measure: 8 carbon monoxide density 8 hydrocarbon density Carbon monoxide density ( when air induction system is operating ) 3.5% below hydrocarbon density ( when air induction system is operating ) 1000ppm below

Out of specification Check air induction system. Refer to AIR INDUCTION SYSTEM in chapter 7.

3-16

ADJUSTING THE THROTTLE CABLE FREE PLAY

EAS00057

CHK ADJ

ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly.

1. Check: 8 throttle cable free play a Out of specification Adjust. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.5 mm (0.059 ~ 0.138 in) 2. Adjust: 8 throttle cable free play ***************************************************** Handlebar side a. Loosen the locknut 1. b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained.
2
Direction a Direction b Throttle cable free play is increased. Throttle cable free play is decreased.

b 1 a

c. Tighten the locknut.

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

3-17

CHECKING THE SPARK PLUG

EAS00060

CHK ADJ

CHECKING THE SPARK PLUG 1. Remove: 8 battery cover 8 battery holder Refer to COVER AND PANEL. 2. Disconnect: 8 spark plug cap 3. Remove: 8 spark plug

cC
Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 4. Check: 8 spark plug type Incorrect Change. Spark plug type (manufacturer) CR7E (NGK) 5. Check: 8 electrode 1 Damage/wear Replace the spark plug. 8 insulator 2 Abnormal color Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: 8 spark plug (with a spark plug cleaner or wire brush) 7. Measure: 8 spark plug gap a (with a wire Thickness gauge) Out of specification Regap. Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.032 in) 8. Install: 8 spark plug 12.5 Nm (1.25 m kg, 9 ft lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: 8 spark plug cap [Link]: 8 battery holder 8 battery cover Refer to COVER AND PANEL. 3-18
T.

R.

CHECKING THE IGNITION TIMING

EAS00062

CHK ADJ

CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Drain: 8coolant (completely from the radiator ) 2. Remove: 8radiator cover 8radiator 8fan case Refer to RADIATORin chapter 6.

3. Attach: 8timing light 1 8engine tachometer 2 (onto the spark plug lead of cylinder) Timing light 90890-03141 YU-03141 Engine tachometer 90890-03113 YU-08036-C
2

4. Check: 8ignition timing ***************************************************** a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 2000 ~ 2400 r/min b. Check that the mark a on the AC magneto rotor is within the firing range b on the right crankcase cover. Incorrect firing range Check the ignition system.

b a

3-19

CHECKING THE IGNITION TIMING

CHK ADJ

NOTE: The ignition timing is not adjustable. ***************************************************** 5. Remove: 8timing light 8engine tachometer 6. Install: 8fan case 8radiator 8radiator cover Refer to RADIATORin chapter 6. 7. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT.

3-20

MEASURING THE COMPRESSION PRESSURE

EAS00067

CHK ADJ

MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: 8valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Remove: 8battery cover 8battery holder Refer to COVER AND PANEL. 4. Disconnect: 8spark plug cap 5. Remove: 8spark plug

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

6.

Install: 8compression gauge 1 Compression gauge 90890-03081 YU-33223

7.

Measure: 8compression pressure Out of specification Refer to steps (c) and (d).

3-21

MEASURING THE COMPRESSION PRESSURE

CHK ADJ

Compression pressure (at sea level) Minimum 1262 kPa (12.6 kgf/cm2, 700r/min) Standard 1450 kPa (14.5 kgf/cm2, 700r/min) Maximum 1624 kPa (16.2 kgf/cm2, 700r/min)

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

w
To prevent sparking, ground the spark plug lead before cranking the engine. c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits. Carbon deposits Eliminate. d. If the compression pressure is below the minimum specification, pour a teaspoonful engine of oil into the spark plug bore and measure again. Refer to the following table.
Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oil Piston ring(s) wear or damage Repair. Same as without oil Piston ring(s), valves, cylinder head gasket or piston possibly defective Repair.

***************************************************** 8. Remove: 8 compression gauge 9. Install: 8 spark plug 12.5 Nm (1.25 m kg 9.0 ft lb)
T.

[Link]: 8spark plug cap [Link]: 8battery holder 8battery cover Refer to COVER AND PANEL.
3-22

R.

CHECKING THE ENGINE OIL LEVEL

EAS00069

CHK ADJ

CHECKING THE ENGINE OIL LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Check: 8 engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark 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

b a

-20 -10

10

20 30

40 50

SAE 10W-30 SAE 10W-40 SAE 20W-40 SAE 20W-50

cC
8 Do not allow foreign materials to enter the crankcase. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.

3-23

CHANGING THE ENGINE OIL

EAS00076

CHK ADJ

CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: 8 engine oil filler cap 1 8 engine oil drain bolt 2 (along with the gasket) 4. Drain: 8 engine oil (completely from the crankcase)

2 1

5. If the oil filter element is also to be cleaned, perform the following procedure. ***************************************************** a. Remove the oil strainer cover 1, spring3 and oil filter element 4. b. Replace the o-ring 2. c. Install the oil strainer cover. Oil strainer cover 32 Nm (3.2 m kg, 23.1 ft lb)

***************************************************** 6. Install: 8 engine oil drain bolt (along with the gasket) 23 Nm (2.3 m kg, 16.6 ft lb)
T.

T.

R.

7. Fill: 8 crankcase (with the specified amount of the recommended engine oil) Quantity Total amount 0.8~0.9L (0.74~0.83 Imp qt, 0.87~0.98 US qt) Periodic oil change 0.73~0.83 L (0.67~0.76 Imp qt, 0.80~0.90 US qt)
3-24

R.

CHANGING THE ENGINE OIL

CHK ADJ

8. Install: 8engine oil filler cap 9. Start the engine, warm it up for several minutes, and then turn it off. 10. Check: 8engine (for engine oil leaks) 11. Check: 8engine oil level Refer to CHECKING THE ENGINE OIL LEVEL. 12. Check: 8engine oil pressure Refer to CHECKING THE ENGINE OIL PRESSURE.

3-25

CHANGING THE TRANSMISSION OIL

CHK ADJ

CHANGING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. NOTE: 8 Stand the scooter on a suitable stand. 8 Make sure that the scooter up right. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place a container under the transmission. 4 Remove: 8transmission oil drain bolt 1 8transmission oil fill bolt Completely drain the transmission oil. 5 Install: 8transmission oil drain bolt 13 Nm (1.3 m kg, 9.4 ft lb)
T.

6. Fill: 8transmission oil ( with the specified amount of the recommended transmission oil ) Total amount 0.11~0.13L (0.10~0.12 Imp qt, 0.12~0.14 US qt) Periodic oil change 0.09~0.11L (0.08~0.10 Imp qt, 0.10~0.12 US qt) Recommended oil SAE10W30

R.

7.
1
T.

Install: 8transmission oil fill bolt1 (along with the gasket) 23 Nm (2.3 m kg, 16.6 ft lb)
R.

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

3-26

MEASURING THE ENGINE OIL PRESSURE

EAS00077

CHK ADJ

MEASURING THE ENGINE OIL PRESSURE 1. Check: 8 engine oil level Below the minimum level mark Add the recommended engine oil to the proper level. Refer to CHECKING THE ENGINE OIL LEVEL. 2. Start the engine, warm it up for several minutes, and then turn it off.

cC
When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine. 3. Remove: 8 seat/trunk 8 battery cover 8 front cover Refer to COVER AND PANEL.

4. Lossen: 8 gallery bolt 1

w
The engine, muffler and engine oil are extremely hot.
1

5. Check: 8 engine oil pressure ***************************************************** a. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. b. Check the engine oil passages, the oil filter and oil pump for damage or [Link] toOIL PUMP in chapter 5. c. Start the engine after solving the problem(s) and check the engine oil pressure again. *****************************************************
3-27

MEASURING THE ENGINE OIL PRESSURE

6. Install: 8 gallery bolt

CHK ADJ

7 Nm (0.7 m kg, 5.1 ft lb)

7. Install: 8 front cover 8 battery cover 8 seat/trunk Refer to COVER AND PANEL.

T.

R.

3-28

CHECKING THE AIR FILTER ELEMENT

EAS00086

CHK ADJ

CHECKING THE AIR FILTER ELEMENT 1. Remove: 8 air filter case cover 1 8 air filter element 2. Check: 8 air filter element Damage/dirty Replace. 3. Install: 8air filter element 8air filter case cover 10 Nm (1.0 m kg, 7.2 ft lb)
T.

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

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

R.

3-29

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/CHECKING THE FUEL AND VACUUM HOSES
EAS00094

CHK ADJ

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Remove: 8 seat/trunk 8 rear carrier 8 battery cover 8 front cover 8 side cover (left and right) 8 rear cover Refer to COVER AND PANEL. 2. Check: 8 carburetor joint 1 8 intake manifold 2 Cracks/damage Replace. Refer to CARBURETOR in chapter 7. 3. Install: 8 rear cover 8 side cover (left and right) 8 front cover 8 battery cover 8 rear carrier 8 seat/trunk Refer to COVER AND PANEL.

EAS00096

CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses. 1. Remove: 8 seat/trunk Refer to COVER AND PANEL.

2 1

2. Check: 8 vacuum hose 1 8 fuel hose 2 Cracks/damage Replace. Loose connection Connect properly. 3. Install: 8 seat/trunk Refer to COVER AND PANEL.

3-30

CHECKING THE FUEL HOSES AND FUEL FILTER

EAS00097

CHK ADJ

CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. 1. Remove: 8battery cover 8seat/trunk 8rear carrier 8front cover 8side cover (left and right) 8rear cover Refer to COVER AND PANEL.

2. Check: 8fuel hose 1 Cracks/damage Replace. 8fuel filter 2 Contaminants/damage Replace. NOTE: 8 Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident. 8 The arrow mark on the fuel filter must point towards the fuel cock as shown. 3. Install: 8rear cover 8side cover (left and right) 8front cover 8rear carrier 8seat/trunk 8battery cover Refer to COVER AND PANEL.

3-31

CHECKING THE CRANKCASE BREATHER HOSE

EAS00098

CHK ADJ

CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: 8seat/trunk Refer to COVER AND PANEL.

2.
1

Check: 8crankcase breather hose 1 Cracks/damage Replace. Loose connection Connect properly.

cC
Make sure the crankcase breather hose is routed correctly. 3. Install: 8seat/trunk Refer to COVER AND PANEL.

3-32

CHECKING THE EXHAUST SYSTEM

EAS00099

CHK ADJ

CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler assembly and gaskets. 1. Remove: 8 muffler assembly Refer to MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY in chapter 5.

2 1 3 4

2 . Check: 8 muffler assembly 1 Cracks/damage Replace. 8 gasket 2 Exhaust gas leaks Replace. 3 . Check: 8 tightening torque Muffler assembly nut 3 13 Nm (1.3 m kg, 9.4 ft lb) Muffler and rear arm bolt 4 31 Nm (3.1 m kg, 22.4 ft lb) Muffler and rear arm bolt 5 31 Nm (3.1 m kg, 22.4 ft lb)

T.

R.

4.

Install: 8muffler assembly Refer to MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY in chapter 5.

3-33

CHECKING THE COOLANT LEVEL

EAS00103

CHK ADJ

CHECKING THE COOLANT LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Remove: 8 mat 8 battery cover Refer to COVER AND PANEL. Check: 8 coolant level The coolant level should be between the maximum level mark a and minimum level mark b. Below the minimum level mark Add the recommended coolant to the proper level.

3.
a b

cC
8 Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. 8 Use only distilled water. However, if distilled water is not available, soft water may be used. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check: 8coolant level NOTE: Before checking the coolant level, wait a few minutes until it settles.

6. Install: 8 battery cover 8 mat Refer to COVER AND PANEL.

3-34

CHECKING THE COOLING SYSTEM

EAS00104

CHK ADJ

CHECKING THE COOLING SYSTEM 1. Remove: 8 seat/trunk 8 battery cover 8 front cover 8 battery holder/ battery 8 footrest board side cover mole( left and right) 8 mat/footrest board Refer to COVER AND PANEL. 8 radiator cover Refer to COOLING SYSTEMin chapter 6.

2 1

2. Check: 8 radiator 1 8 radiator inlet hose 2 8 radiator outlet hose 3 Cracks/damage Replace. Refer to COOLING SYSTEM in chapter 6. 3. Install: 8 radiator cover Refer to COOLING SYSTEMin chapter 6. 8 mat/footrest board 8 footrest board side cover mole( left and right) 8 battery holder/ battery 8 front cover 8 battery cover 8 seat/trunk Refer to COVER AND PANEL.

3-35

CHANGING THE COOLANT

EAS00105

CHK ADJ

CHANGING THE COOLANT 1. Remove: 8 mat 8 battery cover 8 footrest board side cover mole (right) Refer to COVER AND PANEL. 8 radiator cover Refer to COOLING SYSTEMin chapter 6.

2. Disconnect: 8 coolant reservoir hose 1 3. Drain: 8 coolant (from the coolant reservoir) 8 coolant (from the radiator under drain bolt ) 4. Remove: 8radiator cap

w
A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove. The following procedure applies to all of the coolant drain bolts and copper washers. 5. Connect: 8coolant reservoir hose 6. Install: 8radiator under drain bolt 2 Nm (0.2 m kg, 1.5 ft lb)
T.

R.

3-36

CHANGING THE COOLANT

CHK ADJ

7. Fill: 8 cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 0.52 L (0.48 Imp qt, 0.57 US qt) Coolant reservoir capacity 0.26 L (0.24 Imp qt, 0.28 US qt) From minimum to maximum level mark 0.10~0.25 L (0.09~0.14 Imp qt, 0.11~0.16 US qt) Handling notes for coolant Coolant is potentially harmful and should be handled with special care.

w
8 If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. 8 If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. 8 If coolant is swallowed, induce vomiting and get immediate medical attention.

cC
8 Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. 8 Use only distilled water. However, if distilled water is not available, soft water may be used. 8 If coolant comes into contact with painted surfaces, immediately wash them with water. 8 Do not mix different types of antifreeze. 8. Install: 8 radiator cap

3-37

CHANGING THE COOLANT

CHK ADJ

9. Fill: 8 coolant reservoir (with the recommended coolant to the maximum level mark a) [Link]: 8 coolant reservoir cap [Link] the engine, warm it up for several minutes, and then stop it. [Link]: 8 coolant level Refer to CHECKING THE COOLANT LEVEL. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. 13. Install: 8 radiator cover Refer to COOLING SYSTEMin chapter 6. 8 footrest board side cover mole (right) 8 battery cover 8 mat Refer to COVER AND PANEL.

3-38

ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE

EAS00109

CHK ADJ

CHASSIS
a

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 ~ 20 mm (0.394 ~ 0.787 in) 2. Adjust: 8 brake lever free play

b a 1

***************************************************** a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.
Direction a Direction b Brake lever free play is increased. Brake lever free play is decreased.

cC
After adjusting the brake lever free play, make sure there is no brake drag. *****************************************************
EAS00114

ADJUSTING THE REAR BRAKE 1. Check: 8brake lever free playa Out of specification Adjust.
a

Brake lever free play 10 ~ 20 mm (0.394 ~ 0.787 in) Adjust: 8brake lever free play ***************************************************** a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.
Direction a Direction b Brake lever free play is increased. Brake lever free play is decreased.

2.

cC
b 1 a

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

3-39

CHECKING THE FRONT AND REAR BRAKE SHOES

A 2
EAS00127

CHK ADJ

CHECKING THE FRONT AND REAR BRAKE SHOES 1. Operate the brake. 2. Check: 8 wear indicator 1 Reaches the wear limit line 2 Replace the brake shoes as a set. Refer to FRONT WHEEL AND FRONT BRAKE and REAR WHEEL AND REAR BRAKE in chapter 4. A Front brake B Rear brake

3-40

CHECKING AND ADJUSTING THE STEERING HEAD

EAS00148

CHK ADJ

CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the scooter on a level surface.

w
Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Check: 8 steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness Adjust the steering head. 3. Remove: 8 head light cover 8 leg shield 1 Refer to COVER AND PANEL.

Adjust: 8 steering head ***************************************************** a. Remove the upper cover . b. Loosen the steering nut 1 and then tighten it to specification with the steering nut wrench. NOTE: Set the torque wrench at a right angle to the steering nut wrench.

4.

Steering nut wrench 90890-01268 YU-01268

2 3

c. Loosen the upper bearing inner race2 completely and then tighten it to specification with a steering nut wrench3 .
3-41

CHECKING AND ADJUSTING THE STEERING HEAD

CHK ADJ

w
Do not overtighten the upper bearing inner race.

Upper bearing inner race(final tightening torque) 7 Nm (0.7 m kg, 5.1 ft lb)

d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the upper cover and check the bearing race. Refer to STEERING HEAD in chapter 4. e. Hold the upper bearing inner race with a steering nut wrench and tighten the steering nut1 with a steering nut wrench2.

***************************************************** 5. Install: 8leg shield 1 8head light cover Refer to COVER AND PANEL.

T.

R.
T.

Steering nut wrench 90890-01403 YU-A9472

Steering nut 30 Nm (3.0 m kg, 21.7 ft lb)

R.

3-42

CHECKING THE FRONT FORK

EAS00151

CHK ADJ

CHECKING THE FRONT FORK 1. Stand the scooter on a level surface.

w
Securely support the scooter so that there is no danger of it falling over. 2. Check: 8inner tube Damage/scratches Replace. 8dust seal Damage/scratches Replace. 3. Hold the scooter upright and apply the front brake.

4.

Check: 8front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement Repair. Refer to FRONT FORK in chapter 4.

3-43

CHECKING THE TIRES

EAS00163

CHK ADJ

CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 8tire pressure Out of specification Regulate.

w
8 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. 8 The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. 8 Operation of an overloaded scooter could cause tire damage, an accident or an injury. 8 NEVER OVERLOAD THE SCOOTER.
Basic weight (with oil and a full fuel tank) Maximum load* Cold tire pressure Up to 55 kg

81 kg (179 lb)

158 kg (348 lb)

Front

Rear

150 kPa (1.5 175 kPa (1.75 kgf/cm2, 22 psi) kgf/cm2, 25 psi)

150 kPa (1.5 175 kPa (1.75 55 kg ~ 158 kg kgf/cm2, 22 psi) kgf/cm2, 25 psi)

* Total weight of rider, passenger, cargo and accessories

w
It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately.

3-44

CHECKING THE TIRES

1

CHK ADJ

2. Check: 8tire surfaces Damage/wear

Replace the tire.

3 2

Minimum tire tread depth 0.8 mm (0.032 in) 1 Tire tread depth 2 Sidewall 3 Wear indicator

w
8 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. 8 When using tube tires, be sure to install the correct tube. 8 Always replace a new tube tire and a new tube as a set. 8 To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. 8 Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. A Tire B Wheel
Tube wheel Tubeless wheel Tube tire only Tube or tubeless tire

8 After extensive tests, the tires listed below have been approved by Yamaha Motor Taiwan Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this scooter. Front tire
Manufacturer KENDA Model K348A Size 90/90-10 50J

Rear tire
Manufacturer KENDA
3-45

Model K348A

Size 90/90-10 50J

CHECKING THE TIRES

CHK ADJ

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

NOTE: For tires with a direction of rotation mark 1: 8 Install the tire with the mark pointing in the direction of wheel rotation. 8 Align the mark 2 with the valve installation point.
2

IV

3-46

CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES

EAS00168

CHK ADJ

CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: 8wheel Damage/out-of-round Replace.

w
Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.

EAS00170

CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables.

w
Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: 8 outer cable Damage Replace. 2. Check: 8 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.

3-47

LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE CENTERSTAND

EAS00171

CHK ADJ

LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease

EAS00173

LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant Lithium-soap-based grease

3-48

CHECKING AND CHARGING THE BATTERY

EAS00179

CHK ADJ

ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY

w
Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 8 Wear protective eye gear when handling or working near batteries. 8 Charge batteries in a well-ventilated area. 8 Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). 8 DO NOT SMOKE when charging or handling batteries. 8 KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. 8 Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL 8 Skin Wash with water. 8 Eyes Flush with water for 15 minutes and get immediate medical attention. INTERNAL 8 Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.

cC
8 This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. 8 Charging time, charging amperage and charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.

3-49

CHECKING AND CHARGING THE BATTERY

CHK ADJ

NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: 8 mat 8 battery cover 8battery holder Refer to COVER AND PANEL.

2. Disconnect: 8 battery leads (from the battery terminals)

cC
2 1

First, disconnect the negative battery lead 1, and then the positive battery lead 2. 3. Remove: 8 battery 4. Check: 8 battery charge ***************************************************** a. Connect a digital pocket tester to the battery terminals.

Pocket tester 90890-03132 (YU-03112-C)

Positive tester probe positive battery terminal Negative tester probe negative battery terminal

NOTE: 8 The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). 8 No charging is necessary when the opencircuit voltage equals or exceeds 12.8 V.
3-50

CHECKING AND CHARGING THE BATTERY

Open-circuit voltage (V)
13.0 12.5 12.0 11.5 Relationship between the open-circuit voltage and the charging time at 20 C

CHK ADJ

b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% *****************************************************

5 6.5 10 Charging time (hours) These values vary with the temperature, the condition of the battery plates, and the electrolyte level.

Open-circuit voltage (V)

Ambient temperature 20 C

Charging condition of the battery (%)

5.

Charge: 8 battery (refer to the appropriate charging method illustration)

w
Do not quick charge a battery.

cC
8 Never remove the MF battery sealing caps. 8 Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. 8 If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. 8 When charging a battery, be sure to remove it from the scooter. (If charging has to be done with the battery mounted on the scooter, disconnect the negative battery lead from the battery terminal.) 8 To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. 8 Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
3-51

CHECKING AND CHARGING THE BATTERY

CHK ADJ

8 Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. 8 If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! 8 As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.

3-52

CHECKING AND CHARGING THE BATTERY

Charging method using a variable-current (voltage) charger
Charger

CHK ADJ

Ammeter

Measure the open-circuit voltage prior to charging.

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

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

NOTE: Set the charging voltage to 16-17 V. (If the charging voltage is lower charging will be insufficient, if it is higher, the battery will be over-charged.)

YES

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

NO

NO

Adjust the char ging voltage to 20 ~ 25V.

Adjust the voltage to obtain the standard charging amperage.

YES

Monitor the amperage for 3 ~ 5 minutes. Is the standard charging amperage exceeded? NO

Set the timer to the charging time determined by the opencircuit voltage. Refer to CHECKING AND CHARGING THE BATTERY.

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

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

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. 12.8 V ~ Charging is complete. 12.0 ~ 12.7 V ~ Recharging is required. Under 12.0 V ~ Replace the battery.

3-53

CHECKING AND CHARGING THE BATTERY

Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging.

CHK ADJ

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

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

YES

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

NO

Charge the battery until the charging voltage reaches 15 V.

NOTE: Set the charging time to a maximum of 20 hours.

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

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. 12.8 V ~ Charging is complete. 12.0 ~ 12.7 V ~ Recharging is required. Under 12.0 V ~ Replace the battery.

Charger Ammeter Voltmeter

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

3-54

CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSE

CHK ADJ

1 2

6. Install: 8 battery 7. Connect: 8 battery leads (to the battery terminals)

cC
First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: 8 battery terminals Dirt Clean with a wire brush. Loose connection Connect properly. 9. Lubricate: 8 battery terminals Recommended lubricant Dielectric grease 10. Install: 8 battery holder 8 battery cover 8 mat Refer to COVER AND PANEL.

EAS00181

CHECKING THE FUSE The following procedure applies to all of the fuse.

cC
To avoid a short circuit, always set the main switch to OFF when checking or replacing a fuse. 1. Remove: 8 mat 8 battery cover Refer to COVER AND PANEL.

3-55

CHECKING THE FUSE

CHK ADJ

2. Check: 8 fuse ***************************************************** a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to 1.

Pocket tester 90890-03132 (YU-03112-C) b. If the pocket tester indicates , replace the fuse. ***************************************************** 3. Replace: 8 blown fuse ***************************************************** a. Set the main switch to OFF. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit.
Fuse Main Amperage rating 7.5A Qty 1

w
Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ***************************************************** 4. Install: 8 battery cover 8 mat Refer to COVER AND PANEL.

3-56

REPLACING THE HEADLIGHT BULB

EAS00182

CHK ADJ

REPLACING THE HEADLIGHT BULB 1. Remove: 8 headlight cover

2. Disconnect: 8 headlight coupler 3. Remove: 8 headlight bulb holder rubber1 8 headlight bulb holder 8 headlight bulb 2

w
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: 8 headlight bulb New Secure the new headlight bulb with the headlight bulb holder.

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

5. Install : 8 headlight bulb holder 6. Connect: 8 headlight bulb holder rubber 7. Install: 8 headlight lead coupler 8. Install: 8headlight cover

3-57

ADJUSTING THE HEADLIGHT BEAM

EAS00184

CHK ADJ

1 b a

ADJUSTING THE HEADLIGHT BEAM 1. Adjust: 8headlight beam (vertically) ***************************************************** a. Turn the adjusting screw 1 in direction a or b .
Direction a Direction b Headlight beam is raised. Headlight beam is lowered.

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

Adjust: 8 headlight beam (horizontally) ***************************************************** a. Turn the adjusting knob 2 in direction a or b.
b a 2
Direction a Direction b Headlight beam moves to the right. Headlight beam moves to the left.

2.

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

3-58

CHAS
CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE ................................................................. 4-1 FRONT WHEEL ................................................................................. 4-2 FRONT BRAKE SHOE PLATE ......................................................... 4-3 REMOVING THE FRONT WHEEL .................................................... 4-4 DISASSEMBLING THE BRAKE SHOE PLATE ................................ 4-4 CHECKING THE FRONT WHEEL .................................................... 4-5 CHECKING THE SPEEDOMETER GEAR UNIT ............................. 4-6 CHECKING THE BRAKE .................................................................. 4-7 ASSEMBLING THE BRAKE SHOE PLATE ...................................... 4-8 ASSEMBLING THE FRONT WHEEL ................................................ 4-9 INSTALLING THE FRONT WHEEL ................................................ 4-10 ADJUSTING THE FRONT WHEEL STATIC BALANCE ................. 4-11 REAR WHEEL AND BRAKE ................................................................. 4-13 REMOVING THE REAR WHEEL .................................................... 4-14 CHECKING THE REAR WHEEL ..................................................... 4-15 CHECKING THE REAR WHEEL DRIVE HUB................................ 4-15 CHECKING THE BRAKE ................................................................ 4-16 ASSEMBLING THE BRAKE SHOE PLATE .................................... 4-17 INSTALLING THE REAR WHEEL ................................................... 4-18 ADJUSTING THE REAR WHEEL STATIC BALANCE ................... 4-18 FRONT FORK ......................................................................................... 4-19 REMOVING THE FRONT FORK LEGS.......................................... 4-21 DISASSEMBLING THE FRONT FORK LEGS ............................... 4-21 CHECKING THE FRONT FORK LEGS .......................................... 4-22 ASSEMBLING THE FRONT FORK LEGS ..................................... 4-23 INSTALLING THE FRONT FORK LEGS ........................................ 4-24 HANDLEBAR .......................................................................................... 4-25 REMOVING THE HANDLEBAR ...................................................... 4-27 CHECKING THE HANDLEBAR ...................................................... 4-27 INSTALLING THE HANDLEBAR..................................................... 4-28 STEERING HEAD ................................................................................... 4-30 REMOVING THE FRONT FORK ASSEMBLY ................................ 4-31 CHECKING THE STEERING HEAD ............................................... 4-32 INSTALLING THE STEERING HEAD ............................................. 4-33 REAR SHOCK ABSORBER ASSEMBLY............................................. 4-34

4-37

CHAS
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY .......... 4-35 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .......... 4-35 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ........ 4-36

4-38

FRONT WHEEL AND BRAKE

EAS00517

CHAS

CHASSIS
FRONT WHEEL AND BRAKE
7

10 6 1 9 2
48Nm (4.8 mkg, 34.7 ftlb)

Order

Job/Part Removing the front wheel and brake

Qty

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 8 9 10

Stop ring Speedometer cable Adjuster Front brake cable Pin Wheel axle nut Wheel axle Front brake shoe plate Collar Front wheel

1 1 1 1 1 1 1 1 1 1

Refer toREMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL.

For installation, reverse the removal procedure.

4-1

FRONT WHEEL AND BRAKE

EAS00518

CHAS

FRONT WHEEL

1 2

3 4

Order 1 2 3 4

Job/Part Disassembling the front wheel Oil seal Bearing Spacer Bearing

Qty 1 1 1 1

Remarks Remove the parts in the order listed.

Refer toREMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL For assembly, reverse the disassembly procedure.

4-2

FRONT WHEEL AND BRAKE

FRONT BRAKE SHOE PLATE

CHAS

2 1 9

0 q

LS

LS

e 8
LS

LS

6 t r y u
8Nm (0.8 mkg ,5.8 ftlb)

LS

Order

Job/Part Disassembling the front brake shoe plate Brake shoe kit Tension spring Comshaft lever Indicator plate Return spring Brake camshaft / O-ring Oil seal Oil seal Circlip Plate washer Speedometer clutch Drive gear Plate washer Bush Oil seal Speedometer gear Plate washer

Qty

Remarks Remove the parts in the order listed.

1 2 3 4 5 6 7 8 9 0 q w e r t y u

1 2 1 1 1 1/1 1 1 1 1 1 1 1 1 1 1 1

Refer toDISASSEMBLING THE BRAKE SHOE PLATE and ASSEMBLING THE BRAKE SHOE PLATE.

For assembly, reverse the disassembly procedure.

4-3

FRONT WHEEL AND BRAKE

EAS00520

CHAS

REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface.

w
Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Remove: 8 speedometer cable 1 8 ront brake cable 2 8 front wheel axle nut 3 8 front wheel axle 4 8 front wheel 5 8 collar 8 front brake shoe plate 6 Refer to FRONT WHEEL AND BRAKE .
EAS00524

1 3 2 6 4

LS

DISASSEMBLING THE BRAKE SHOE PLATE 1. Remove: 8 front brake shoe 8 comshaft lever 8 indicator plate 8 return spring 8 brake camshaft 8 speedometer gear NOTE: Remove the bush from the brake shoe plate with the meter gear bush tool. 2. Remove: 8circlip 8plate washer 8speedometer clutch 8drive gear 8plate washer Remove: 8bush 8speedometer gear 8plate washer

LS LS

LS

3.

4-4

FRONT WHEEL AND BRAKE

EAS00525

CHAS

CHECKING THE FRONT WHEEL 1. Check: 8 wheel axle Roll the wheel axle on a flat surface. Bends Replace.

w
Do not attempt to straighten a bent wheel axle. 2. Check: 8 tire 8 front wheel Damage/wear Replace. Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3.

3. Measure: 8 radial wheel runout 1 8 lateral wheel runout 2 Over the specified limits

Replace.

Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm(0.04 in)

4. Check: 8 wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings. 8 oil seals Damage/wear Replace. 5. Replace: 8 wheel bearings New 8 oil seal New *****************************************************
4-5

FRONT WHEEL AND BRAKE

CHAS

a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface.

c. Remove the wheel bearings 4 with a general bearing puller3. d. Install the new wheel bearings and oil seal in the reverse order of disassembly. *****************************************************
3 4
EAS00535

CHECKING THE SPEEDOMETER GEAR UNIT 1. Check: 8 speedometer clutch Bends/damage/wear Replace.

2. Check: 8 speedometer drive gear 1 8 speedometer gear 2 Damage/wear Replace.

4-6

FRONT WHEEL AND BRAKE

EAS00536

CHAS

CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: 8 brake shoe lining Glazed areas Repair. Sand the glazed areas with course sandpaper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth.

2. Measure: 8 brake shoe lining thickness a Out of specification Replace. Brake shoe lining thickness limit (minimum) 2.0 mm (0.079 in)
a

w
Do not allow oil or grease to contact the brake shoes. NOTE: Replace the brake shoes as a set, if either is worn to the wear limit.

3. Measure: 8 brake drum inside diameter b Out of specification Replace the wheel. Brake drum inside diameter limit (maximum) 110.5 mm (4.35 in)

4-7

FRONT WHEEL AND BRAKE

CHAS

4. Check: 8 brake drum inner surface Oil deposits Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches Repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: 8brake camshaft Damage/wear Replace.

EAS00537

2 1

ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 8brake camshaft 1 8spring 8brake shoe wear indicator 2 ***************************************************** a. Install the brake camshaft so its punch mark a is positioned as shown. b. Align the projection b on the brake shoe wear indicator with the notch in the brake camshaft. c. Check that the brake shoes are properly positioned. *****************************************************

a b

2. Install: 8comshaft lever 7 Nm (0.7 m kg, 5.1 ft lb)

T.

Align the camshaft punch mark a and comshaft lever punch mark b is positioned as shown. 3. Install: 8speedometer gear 8bush (with the meter gear bush tool)
4-8

R.

FRONT WHEEL AND BRAKE

EAS00538

CHAS

ASSEMBLING THE FRONT WHEEL 1. Install: 8 wheel bearing(right)1 New

1

8 oil seal New 8 spacer 8 wheel bearing(left) New ***************************************************** a. Install the new wheel bearings and oil seal in the reverse order of disassembly.

cC
Do not contact the wheel bearing inner race 1 or balls 2. Contact should be made only with the outer race 3. NOTE: Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal. ***************************************************** 2. Install: 8 brake shoe plate Align the tab on the speedometer clutch with the slot in the wheel hub.

4-9

FRONT WHEEL AND BRAKE

EAS00540

CHAS

INSTALLING THE FRONT WHEEL 1. Lubricate: 8 wheel axle 8 wheel bearings 8 oil seal lips 8 speedometer drive gear 8 speedometer gear Recommended lubricant Lithium-soap-based grease 2.
2 1 3

Install: 8front wheel1

NOTE: Make sure the slot2 in the brake shoe plate fits over the stopper3 on the outer tube. 3. Tighten: 8 wheel axle nut 48 Nm (4.8 m kg, 34.7 ft lb)
T.

w
Make sure the brake cable is routed properly.

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

R.

4-10

FRONT WHEEL AND BRAKE

EAS00548

CHAS

ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: 8 After replacing the tire, wheel or both, the front wheel static balance should be adjusted. 8 Adjust the front wheel static balance with the brake disc installed. 1. Remove: 8 balancing weight(s)

2. Find: 8 front wheels 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 wheels heavy spot X. *****************************************************

X1

X2

4-11

FRONT WHEEL AND BRAKE

1

CHAS

3. Adjust: 8 front wheel static balance ***************************************************** a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot X. NOTE: Start with the lightest weight.

b.

Turn the front wheel 90 so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. *****************************************************

4. Check: 8 front wheel static balance ***************************************************** a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it. *****************************************************

4-12

REAR WHEEL AND BRAKE

EAS00555

CHAS

REAR WHEEL AND BRAKE

5 7

7Nm (0.7 mkg, 5.1 ftlb)

9 4 10 11 6 7 12 2 3 12

1
104Nm (10.4 mkg, 75.2 ftlb)

Order

Job/Part Removing the rear wheel

Qty

Remarks Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. Refer to MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY in chapter 5.

Muffler assembly 1 2 3 4 5 6 7 8 9 10 11 12 Self lock nut/Plate washer Brake adjuster Rear brake cable Pin Rear wheel Brake shoe kit Tension spring Plate washer Camshaft lever Indicator plate Return spring Brake camshaft/O-ring 1/1 1 1 1 1 1 2 1 1 1 1 1/2

For installation, reverse the removal procedure.

4-13

REAR WHEEL AND BRAKE

EAS00564

CHAS

REMOVING THE REAR WHEEL 1. Stand the scooter on a level surface.

w
Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated. 2. Remove: 8brake adjuster

3.
1

Remove: 8muffler assembly 8wheel axle nut 1

4. Remove: 8rear wheel1

4-14

REAR WHEEL AND BRAKE

EAS00565

CHAS

CHECKING THE REAR WHEEL 1. Check: 8 tire 8 rear wheel Damage/wear Replace. Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3. 2. Measure: 8 radial wheel runout 8 lateral wheel runout Refer to CHECKING THE FRONT WHEEL.

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB 1. Check: 8rear wheel drive hub Cracks/damage Replace.

4-15

REAR WHEEL AND BRAKE

EAS00569

CHAS

CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: 8 brake shoe lining Glazed areas Repair. Sand the glazed areas with course sandpaper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. 2. Measure: 8 brake shoe lining thickness a Out of specification Replace.
a

Brake shoe lining thickness limit (minimum) 2.0 mm(0.079 in)

w
Do not allow oil or grease to contact the brake shoes. NOTE: Replace the brake shoes as a set, if either is worn to the wear limit.

3. Measure: 8 brake drum inside diameter b Out of specification Replace the wheel. Brake drum inside diameter limit (maximum) 110.5 mm(4.35 in) 4. Check: 8 brake drum inner surface Oil deposits Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches Repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: 8 brake camshaft Damage/wear Replace.

4-16

REAR WHEEL AND BRAKE

EAS00570

CHAS

ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 8 brake camshaft 1 7 Nm (0.7 m kg, 5.1 ft lb) 8 return spring 2 8 brake shoe wear indicator 3 ***************************************************** a. Install the brake camshaft 1 so its punch mark a is positioned as shown. b. Align the projection b on the brake shoe wear indicator with the notch in the brake shoe camshaft. c. Check that the brake shoes are properly positioned. *****************************************************
T.

R.

1 a b

2.
1

Install: 8 brake shoes1 8 tension springs

cC
8 Do not put lubricating oil on the brake lining. 8 Change the tension spring at the same time of changing the brake shoe. 8 Refer to the direction in the illustration when assembling the brake shoe and spring. 8 Refer to the illustration with regards to the assembly direction of tension spring, and do not let the spring hook and coil to be damaged by the pliers.

4-17

REAR WHEEL AND BRAKE

EAS00574

CHAS

INSTALLING THE REAR WHEEL 1. Lubricate: 8 wheel axle Recommended lubricant Lithium-soap-based grease 2. Install: 8 rear wheel 3. Tighten: 8 wheel axle nut1
1
T.

104 Nm (10.4 m kg, 75.2 ft lb)

4. Install: 8 muffler assembly 5. Adjust: 8 brake lever free play Refer to ADJUSTING THE REAR BRAKE in chapter 3.

EAS00575

ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: 8 After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. 8 Adjust the rear wheel static balance with the rear wheel drive hub installed. 1. Adjust: 8 rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE.

R.

4-18

FRONT FORK
EAS00646

CHAS

FRONT FORK

3 2

4 1

30Nm (3.0 mkg, 21.7 ftlb)

Order

Job/Part Removing the front fork legs Front wheel Handlebar Front fork assembly Headlight cover Leg shield 1 Lower bracket pinch bolt Snap ring Inner tube plug Front fork leg

Qty

Remarks Remove the parts in the order listed. Refer to FRONT WHEEL AND BRAKE. Refer to HANDLE BAR. Refer to STEERING HEAD. Refer to COVER AND PANEL in chapter 3.

1 2 3 4

1 1 1 1 For installation, reverse the removal procedure.

4-19

FRONT FORK
EAS00648

CHAS

1 8 2

9
1g

3 4
3g

4g

5 6

0 7

Order 1 2 3 4 5 6 7 8 9 0

Job/Part Disassembling the front fork legs Band Boot Dust seal Circlip Spring guide Rebound spring Inner tube Damper rubber Fork spring Outer tube

Qty 1 1 1 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed.

Refer to DISASSEMBLING AND INSTALLING THE FRONT FORK LEGS

For assembly, reverse the disassembly procedure.

4-20

FRONT FORK
EAS00651

CHAS

REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface.

w
Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.

2.
2 1

3.

Loosen: 8lower bracket pinch bolt 1 Remove: 8snap ring 2 8front fork leg3

w
3

Before loosening the lower bracket pinch bolts, support the front fork leg.
EAS00653

DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: 8band 8foot 8inner tube plug

2.
4

Remove: 8dust seal 1 8circlip2 8spring guide3 8rebound spring 4 8inner tube 5

cC
Do not scratch the inner tube.
4-21

FRONT FORK
3.
3 2 1

CHAS

Remove: 8 damper rubber 1 8 fork spring 2 8 outer tube 3

EAS00656

CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 8 inner tube 8 outer tube Bends/damage/scratches Replace.

w
Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: 8 spring free length a Out of specification

Replace.

Spring free length 125 mm (4.921 in) <Limit> : 122.5 mm (4.823 in) 3.
3

2 1

Check: 8 inner tube 1 8 spring guide2 8 rebound spring 3 Damage/wear Replace.

4.
3 2 1

Check: 8 damper rubber 1 8 fork spring2 8 outer tube 3 Damage/wear Replace.

4-22

FRONT FORK
EAS00658

CHAS

ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: 8 When assembling the front fork leg, be sure to replace the following parts: - dust seal - circlip 8 Before assembling the front fork leg, make sure all of the components are clean. 1.
1 2

Install: 8 fork spring 1 8 damper rubber2 NOTE: 8 Install the spring with the smaller pitch facing down . 2. Lubricate: 8 inner tubes outer surface 8 rebound spring 8 fork spring 8 circlip Recommended lubricant Molybdenum-disulfide grease

4 5

3. Install: 8 inner tube1 8 rebound spring 2 8 spring guide3 8 circlip4 New 8 dust seal 5 New

4. Install: 8 boot 8 band New

4-23

FRONT FORK
EAS00663

CHAS

2 3

INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: 8front fork leg 1 8snap ring 2 New 8inner tube plug 8lower bracket pinch bolt 3 NOTE: Pull up the inner tube until it stops, then install the snap ring to groove. 2. Tighten: 8lower bracket pinch bolt 30 Nm (3.0 m kg, 21.7 ft lb)
T.

R.

4-24

HANDLEBAR
EAS00664

CHAS

HANDLEBAR

4 3
LS

10
LS

17 8

7 6 16
LS

14

5 9 12

11 2
60Nm (6.0 mkg, 43.4 ftlb)

15
LS

13 1

Order

Job/Part Removing the handlebar Headlight cover Leg shield 1 Clamp Speedometer cable Speedometer assembly Rear view mirror(left and right) Front brake cable Front brake switch Brake lever (right) Handlebar holder assembly(right) Throttle cable kit Throttle grip assembly Rear brake cable Rear brake switch Brake lever(left) Handlebar holder assembly(left)

Qty

Remarks Remove the parts in the order listed. Refer to COVER AND PANEL in chapter 3.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 1 1 1/1 1 1 1 1 1 1 1 1 1 1
4-25

HANDLEBAR

CHAS

4 3
LS

10
LS

17 8

7 6 16
LS

14

5 9 12

11 2
60Nm (6.0 mkg, 43.4 ftlb)

15
LS

13 1

Order 15 16 17

Job/Part Handlebar grip Handlebar upper cover Handlebar assembly

Qty 1 1 1

Remarks

For installation, reverse the removal procedure.

4-26

HANDLEBAR
EAS00666

CHAS

REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface.

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

2. Remove: 8handlebar holder assembly (right)1 8throttle grip assembly 2 NOTE: While removing the handlebar holder assembly (right), pull back the rubber cover.

3. Remove: 8handlebar grip NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

EAS00668

CHECKING THE HANDLEBAR 1. Stand the scooter on a level surface.

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

2. Check: 8handlebar 1 Bends/cracks/damage

1

Replace.

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

4-27

HANDLEBAR
EAS00673

CHAS

INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface.

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

FORWARD

RIGHT b

2. Install: 8handlebar 1 NOTE: Align the slot a on the handlebar with the steering shaft 2 surface. 3. Tighten: 8handlebar

1 LEFT a

60 Nm (6.0 m kg, 43.4 ft lb)

cC
There must be a space b after tighting bolt. 4. Install: 8handlebar upper cover

b 1 a

5. Install: 8handlebar holder assembly ( left )1 NOTE: Align the projection a on the handlebar holder assembly ( left ) with the hole b on the handlebar.

1 2 b a
4-28

6. Install: 8throttle grip assembly 1 8handlebar holder assembly (right)2 8throttle cable kit 3

T.

R.

HANDLEBAR

CHAS

NOTE: 8 Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar4. 8 Align the projectiona on the right handlebar holder assembly with the hole b on the handlebar.

w
Make sure the throttle grip operates smoothly. 7. Adjust: 8throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.5 mm (0.059 ~ 0.138 in)

4-29

STEERING HEAD
EAS00675

CHAS

STEERING HEAD

4 5 6 11 9 12 7 1 3
7Nm (0.7 mkg, 5.1 ftlb)

8 10

30Nm (3.0 mkg, 21.7 ftlb)

Order

Job/Part Removing the front fork assembly Front wheel Leg shield 1 Handlebar assembly Front fender Inner fender Cable holder Ball race cover Ring nut Upper bearing inner race Front fork assembly Upper bearing Lower bearing Upper bearing outer race Lower bearing outer race Lower bearing inner race

Qty

Remarks Remove the parts in the order listed. Refer to FRONT WHEEL AND BRAKE. Refer to COVER AND PANEL in chapter 3. Refer to HANDLEBAR.

1 2 3 4 5 6 7 8 9 10 11 12

1 1 1 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.

4-30

STEERING HEAD
EAS00678

CHAS

REMOVING THE FRONT FORK ASSEMBLY 1. Stand the scooter on a level surface.

w
Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2 . Remove: 8ball race cover 8ring nut 1 (with the ring nut wrench 2)
1

Ring nut wrench 90890-01268 YU-01268

3 . Remove: 8upper bearing inner race1 (with the ring nut wrench 2)

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

4-31

STEERING HEAD
EAS00682

CHAS

CHECKING THE STEERING HEAD 1. Wash: 8bearing balls 8bearing races Recommended cleaning solvent Kerosene

2. Check: 8bearing balls 1 8bearing races 2 Damage/pitting Replace.

3. Replace: 8bearing balls 8bearing races ***************************************************** a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the front fork assembly with a floor chisel 2 and hammer.

cC
If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Always replace the balls and bearing races as a set. ***************************************************** 4. Check: 8 front fork assembly (along with the steering stem) Bends/cracks/damage Replace.

4-32

STEERING HEAD
EAS00684

CHAS

LS

INSTALLING THE STEERING HEAD 1. Lubricate: 8 bearing balls 1 8 bearing races Recommended lubricant Lithium-soap-based grease

2.

Install: 8 front fork assembly 1 8 upper bearing inner race 2 7 Nm (0.7 m kg, 5.1 ft lb) (with the ring nut wrench 3)
T.

R.

2 3

3.
1
T.

Install: 8 ring nut 1 30 Nm (3.0 m kg, 21.7 ft lb) (with the ring nut wrench 2)
R.

Ring nut wrench 90890-01403 YU-A9472 Refer to CHECKING THE STEERING HEAD in chapter 3.

4-33

REAR SHOCK ABSORBER ASSEMBLY

EAS00685

CHAS

REAR SHOCK ABSORBER ASSEMBLY

30Nm (3.0 mkg, 21.7 ftlb)

1 2

3
16Nm (1.6 mkg, 11.6 ftlb)

Order

Job/Part Removing the rear shock absorber assembly

Qty

Remarks Remove the parts in the order listed.

1 2 3 4

Rear nut Rear bolt Rear bolt Rear

shock absorber assembly upper shock absorber assembly upper shock absorber assembly lower shock absorber assembly

1 1 1 1 For installation, reverse the removal procedure.

4-34

REAR SHOCK ABSORBER ASSEMBLY

EAS00692

CHAS

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the scooter on a level surface.

w
Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated. 2. Remove: 8 rear shock absorber nut (upper) 8 rear shock absorber bolt (lower)

EAS00695

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: 8rear shock absorber rod Bend/damage Replace the rear shock absorber assembly. 8rear shock absorber Oil leak Replace the rear shock absorber assembly. 8spring Damage/wear Replace the rear shock absorber assembly. 8bushing Damage/wear Replace. 8dust seal Damage/wear Replace. 8bolts Bends/damage/wear Replace.

4-35

REAR SHOCK ABSORBER ASSEMBLY

EAS00698

CHAS

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: 8 spacer 8 bush Recommended lubricant Molybdenum disulfide grease 2. Install: 8 rear shock absorber assembly

3. Tighten: 8 rear shock absorber assembly upper nut

30 Nm (3.0 m kg, 21.7 ft lb)

8 rear shock absorber assembly lower bolt

T.

R.
T.

16 Nm (1.6 m kg, 11.6 ft lb)

R.

4-36

ENG
CHAPTER 5 ENGINE ENGINE ..................................................................................................... 5-1 LEADS, HOSES AND REAR BRAKE ............................................... 5-1 MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY ................... 5-3 INSTALLING THE ENGINE ............................................................... 5-4 CYLINDER HEAD ..................................................................................... 5-5 REMOVING THE CYLINDER HEAD................................................. 5-6 CHECKING THE CYLINDER HEAD ................................................. 5-8 INSTALLING THE CYLINDER HEAD ............................................... 5-9 THE ROCKER ARMS AND CAMSHAFT .............................................. 5-12 REMOVING THE ROCKER ARMS AND CAMSHAFT ................... 5-13 CHECKING THE CAMSHAFT......................................................... 5-13 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS........................................................................................ 5-14 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES .............................................................. 5-16 CHECKING THE TIMING CHAIN TENSIONER ............................. 5-16 INSTALLING THE CAMSHAFT AND ROCKER ARMS ................. 5-17 VALVES AND VALVE SPRINGS ............................................................ 5-18 REMOVING THE VALVES ............................................................... 5-19 CHECKING THE VALVES AND VALVE GUIDES ........................... 5-20 CHECKING THE VALVE SEATS ..................................................... 5-22 CHECKING THE VALVE SPRINGS ................................................ 5-24 INSTALLING THE VALVES .............................................................. 5-25 CYLINDER AND PISTON....................................................................... 5-27 REMOVING THE CYLINDER AND PISTON .................................. 5-28 CHECKING THE CYLINDER AND PISTON ................................... 5-29 CHECKING THE PISTON RINGS ................................................... 5-30 CHECKING THE PISTON PIN ........................................................ 5-31 CHECKING THE TIMING CHAIN GUIDE ....................................... 5-32 INSTALLING THE PISTON AND CYLINDER ................................. 5-32 BELT DRIVE............................................................................................ 5-34 CRANKCASE COVER (LEFT) ........................................................ 5-34 INSTALLING THE KICKSTARTER .................................................. 5-35 V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE ......... 5-36 REMOVING THE PRIMARY SHEAVE ............................................ 5-38 REMOVING THE SECONDARY SHEAVE AND V-BELT................ 5-38 DISASSEMBLING THE SECONDARY SHEAVE ........................... 5-39 CHECKING THE CLUTCH SHOE .................................................. 5-39
5-66

ENG
CHECKING THE V-BELT ................................................................. 5-40 CHECKING THE PRIMARY SHEAVE ............................................ 5-40 CHECKING THE PRIMARY SHEAVE WEIGHTS .......................... 5-41 CHECKING THE SLIDER ................................................................ 5-41 CHECKING THE SECONDARY SHEAVE ...................................... 5-41 ASSEMBLING THE PRIMARY SHEAVE ........................................ 5-42 ASSEMBLING THE SECONDARY SHEAVE ................................. 5-43 INSTALLING THE BELT DRIVE ...................................................... 5-44 STARTER CLUTCH AND AC MAGNETO ............................................. 5-46 STATOR COIL ASSEMBLY.............................................................. 5-46 STARTER CLUTCH ......................................................................... 5-48 REMOVING THE AC MAGNETO .................................................... 5-49 REMOVING THE STARTER CLUTCH ............................................ 5-50 CHECKING THE STARTER CLUTCH ............................................ 5-51 INSTALLING THE STARTER CLUTCH .......................................... 5-52 INSTALLING THE AC MAGNETO ................................................... 5-52 OIL PUMP ............................................................................................... 5-54 CHECKING THE OIL PUMP ........................................................... 5-55 ASSEMBLING THE OIL PUMP ....................................................... 5-56 INSTALLING THE OIL PUMP .......................................................... 5-56 TRANSMISSION ..................................................................................... 5-57 CHECKING THE TRANSMISSION ................................................. 5-58 CRANKSHAFT ....................................................................................... 5-59 CRANKSHAFT ASSEMBLY ............................................................ 5-59 DISASSEMBLING THE CRANKCASE ........................................... 5-61 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE .... 5-62 CHECKING THE CRANKSHAFT AND CONNECTING ROD ........ 5-63 CHECKING THE CRANKCASE ...................................................... 5-64 CHECKING THE BEARINGS AND OIL SEALS ............................. 5-64 CHECKING THE CIRCLIPS AND WASHERS ................................ 5-64 INSTALLING THE CRANKSHAFT .................................................. 5-65 ASSEMBLING THE CRANKCASE ................................................. 5-65

5-67

ENGINE
EAS00188

ENG

ENGINE
ENGINE
LEADS, HOSES AND REAR BRAKE
46Nm (4.6 mkg, 33.3 ftlb) 10Nm (1.0 mkg, 7.2 ftlb)

12 2
A

12Nm (1.2 mkg, 8.7 ftlb) 16Nm (1.6 mkg, 11.6 ftlb)

5
C D

13

3
E

6 11
B

E D C

8 7 10 7

Order

Job/Part Removing the leads, hoses and rear brake Seat/Trunk/Rear carrier Battery cover/Battery holder Battery/Front cover Side cover(left and right)/Rear cover Footrest board side cover mole (left and right) Mat/Footrest board Coolant

Qty

Remarks Remove the parts in the order listed.

Refer to COVER AND PANELin chapter 3.

Radiator Thermostat housing Water pump assembly Carburetor Thermo unit lead
5-1

Drain. Refer to CHANGING THE COOLANTin chapter 3. Refer to COOLING SYSTEMin chapter 6. Refer to CARBURETORin chapter 7. Disconnect.

ENGINE
46Nm (4.6 mkg, 33.3 ftlb)

ENG

10Nm (1.0 mkg, 7.2 ftlb)

12 2
A

12Nm (1.2 mkg, 8.7 ftlb) 16Nm (1.6 mkg, 11.6 ftlb)

5
C D

13

3
E

6 11
B

E D C

8 7 10 7

Order

Job/Part AC magneto lead

Qty

Remarks Refer to STARTER CLUTCH AND AC MAGNETO. Disconnect. Disconnect.

2 3 4 5 6 7 8 9 10 11 12 13

Starting motor lead/Earth lead Ignition primary coil lead Vacuum hose(to air cut-off valve) Hose(to air cut-off valve) Vacuum hose(to fuel cock) Rear brake cable/Adjuster/Pin Kickstarter Rear wheel lock cable cover Rear wheel lock cable Rear shock absorber assembly lower bolt Self lock nut Engine mounting bolt

1 1 1 1 1 1/1/1 1 1 1 Refer to REAR SHOCK ABSORBER 1 ASSEMBLY in chapter 4. Refer to INSTALLING THE ENGINE . 1 1 For installation, reverse the removal procedure.

5-2

ENGINE
MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY

ENG

31Nm (3.1 mkg, 22.4 ftlb)

10Nm (1.0 mkg, 7.2 ftlb)

7 1 5

7
13Nm (1.3 mkg, 9.4 ftlb)

3 4 2

8Nm (0.8 mkg, 5.8 ftlb)

10Nm (1.0 mkg, 7.2 ftlb)

Order

Job/Part Removing the manifold, air filter and muffler assembly Rear brake cable(adjuster/pin) Rear wheel lock cable Hose(to air cut-off valve) Vacuum hose(to air cut-off valve) Vacuum hose(to fuel cock) Throttle cable kit Auto choke lead Throttle position sensor lead Muffler assembly/Gasket Spark plug cap Ignition coil Air filter assembly/Breather hose Starter motor assembly Rear fender Manifold/O-ring

Qty

Remarks Remove the parts in the order listed.

Refer to LEADS, HOSES AND REAR BRAKE.

Refer to CARBURETORin chapter 7. 1/1 1 1 1/1 1 1 1/1 For installation, reverse the removal procedure.

1 2 3 4 5 6 7

5-3

ENGINE
1
EAS00192

ENG

INSTALLING THE ENGINE 1. Install: 8engine 1 8engine mounting bolt 2 8self lock nut3 NOTE: Do not fully tighten the bolts.

2. Tighten: 8self lock nut 46Nm(4.6 m kg, 33.3 ft lb)

T.

3. Tighten: 8rear shock absorber assembly lower bolt1 16 Nm (1.6 m kg, 11.6 ft lb)
T.

R. R.

5-4

CYLINDER HEAD
EAS00221

ENG

CYLINDER HEAD
10Nm (1.0 mkg, 7.2 ftlb) 10Nm (1.0 mkg, 7.2 ftlb) 8Nm (0.8 mkg, 5.8 ftlb) 9Nm (0.9 mkg, 6.5 ftlb)

5 10

9 4 4 11

12.5Nm (1.25 mkg, 9.0 ftlb) 8Nm (0.8 mkg, 5.8 ftlb)

13 12

1 2 7

8
10Nm (1.0 mkg, 7.2 ftlb)

30Nm (3.0 mkg, 21.7 ftlb)

Order

Job/Part Removing the cylinder head Muffler assembly Air filter assembly/Breather hose Manifold/O-ring Thermostat unit Spark plug Cylinder head cover O-ring Timing chain tensioner assembly Timing chain tensioner gasket Camshaft sprocket Bolt Nut Plate Cylinder head Cylinder head gasket Dowel pin

Qty

Remarks Remove the parts in the order listed. Refer to MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY.

1 2 3 4 5 6 7 8 9 10 11 12 13

1 1 1 1 1 1 1 2 4 1 1 1 2

Refer to REMOVING THE CYLINDER HEAD.

For installation, reverse the removal procedure.

5-5

CYLINDER HEAD
EAS00225

ENG

REMOVING THE CYLINDER HEAD 1. Remove : 8 crankcase cover (left) Refer to BELT DRIVE. 8 cylinder head cover

b a

2. Align: 8 I mark a on the magneto rotor (with the stationary pointer b on the crankcase cover) ***************************************************** a. Turn the primary fixed sheave counterclockwise. b. When the piston is at TDC on the compression stroke, align the I mark c on the camshaft sprocket with the mark d on the plate. *****************************************************

3. Loosen: 8timing chain tensioner bolt 8camshaft sprocket bolt 1 While holding the crank bolt with a wrench2, remove the camshaft sprocket bolt 1.
1

Rotor holding tool 90890-01235 YU-01235

5-6

CYLINDER HEAD
1

ENG

4. Remove: 8 timing chain tensioner (along with the gasket) 8 camshaft sprocket 1 8 timing chain 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire. 5. Remove: 8 cylinder head NOTE: 8 Loosen the nuts in the proper sequence as shown. 8 Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

6 3 4 5 2

5-7

CYLINDER HEAD
EAS00227

ENG

CHECKING THE CYLINDER HEAD 1. Eliminate: 8 combustion chamber carbon deposits (with a rounded scraper)

NOTE: Do not use a sharp instrument to avoid damaging or scratching: 8 spark plug bore thread 8 valve seats 2. Check: 8 cylinder head Damage/scratches

Replace.

3. Measure: 8 cylinder head warpage Out of specification Resurface the cylinder head. Maximum cylinder head warpage 0.03 mm (0.001 in) ***************************************************** a. Place a straightedge and a thickness gauge across the cylinder head. b. Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows. d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. *****************************************************

5-8

CYLINDER HEAD
EAS00231

ENG

4 1 4 2 3 6

INSTALLING THE CYLINDER HEAD 1. Install: 8 gasket New 8 dowel pins 2. Install: 8 cylinder head 3. Tighten: 8 cylinder head nuts 10 Nm (1.0 m kg, 7.2 ft lb) 8 cylinder head bolts 10 Nm (1.0 m kg, 7.2 ft lb)
T. T.

NOTE: 8 Lubricate the cylinder head nuts with engine oil. 8 Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages.

b a

4. Install: 8 camshaft sprocket 1 8 timing chain 2 ***************************************************** a. Turn the primary pulley counterclockwise. b. Align the I mark a on the AC magneto rotor with the stationary pointer b on the crankcase cover. c. Align the I mark c on the camshaft sprocket with the stationary pointer d on the plate. d. Install the timing chain onto the camshaft sprocket, and then install the camshaft sprocket onto the camshaft. NOTE: 8 When installing the camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side. 8 Align the slot on the camshaft with the tab in the camshaft sprocket.
5-9

R.

R.

d 2

CYLINDER HEAD

ENG

cC
Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. e. While holding the camshaft, temporarily tighten the camshaft sprocket bolt. f. Remove the wire from the timing chain. ***************************************************** 5. Install 8camshaft sprocket bolt 1

3 4 5

6. Install: 8timing chain tensioner gasket New 8timing chain tensioner ***************************************************** a. Remove the cap bolt 1 and spring 2. b. Release the timing chain tensioner one-way cam 3 and push the timing chain tensioner rod 4 all the way into the timing chain tensioner housing. c. Install the timing chain tensioner and gasket 5 onto the cylinder. Timing chain tensioner bolt 9 Nm (0.9 m kg, 6.5 ft lb)

d. Install the spring 2 and cap bolt 1. Cap bolt 8 Nm (0.8 m kg, 5.8 ft lb)

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

T.

R.
T.

R.

5-10

CYLINDER HEAD

ENG

7. Turn: 8crankshaft (several turns counterclockwise)

b a

8. Check: 8I mark a Align the I mark on the AC magneto rotor with the stationary pointer b on the crankcase cover. 8I mark c Align the I mark on the camshaft sprocket with the stationary pointer d on the plate. Out of alignment Correct. Refer to the installation steps above.

9. Tighten: 8camshaft sprocket bolt 30 Nm (3.0 m kg, 21.7 ft lb)

T.

cC
Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. 10. Measure: 8valve clearance Out of specification Adjust. Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3.

R.

5-11

THE ROCKER ARMS AND CAMSHAFT THE ROCKER ARMS AND CAMSHAFT
4 6 6

ENG

Order

Job/Part Removing the rocker arms and camshaft Cylinder head Camshaft Rocker arm shaft(intake) Rocker arm shaft(exhaust) Rocker arm(intake) Rocker arm(exhaust) Spring

Qty

Remarks Remove the parts in the order listed. Refer to CYLINDER HEAD.

1 2 3 4 5 6

1 1 1 1 1 2 For installation, reverse the removal procedure.

5-12

THE ROCKER ARMS AND CAMSHAFT

EAS00202

ENG

REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Remove: 8camshaft 1

2. Remove: 8intake rocker arm shaft 8exhaust rocker arm shaft 8intake rocker arm 8exhaust rocker arm NOTE: Remove the rocker arm shafts with the clip plier1 .
1
EAS00205

CHECKING THE CAMSHAFT 1. Check: 8camshaft bushings Damage/wear Replace.

2. Check: 8camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft.

3. Measure: 8camshaft lobe dimensions a and b Out of specification Replace the camshaft.

5-13

THE ROCKER ARMS AND CAMSHAFT

ENG

Camshaft lobe dimension limit Intake a 30.158~30.258 mm (1.187~1.191 in) <Limit>:30.058mm b 25.082~25.182 mm (0.987~0.991 in) <Limit>:24.982mm Exhaust a 30.158~30.258 mm (1.187~1.191 in) <Limit>:30.058mm b 25.020~25.120 mm (0.985~0.989 in) <Limit>:24.920mm

4. Check: 8camshaft oil passage Obstruction Blow out with compressed air.

EAS00206

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: 8rocker arm (camshaft touch surface1) 8rocker arm (valve touch surface2) Damage/wear Replace. 2. Check: 8rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches Replace or check the lubrication system. 3. Check: 8camshaft lobe Excessive wear Replace the camshaft.

5-14

THE ROCKER ARMS AND CAMSHAFT

ENG

4. Measure: 8rocker arm inside diameter a Out of specification Replace.

a

Rocker arm inside diameter 10 ~ 10.015 mm (0.393 ~ 0.394 in)

5. Measure: 8rocker arm shaft outside diameter a Out of specification Replace. Rocker arm shaft outside diameter 9.981 ~ 9.991 mm (0.392 ~ 0.393 in) 6. Calculate: 8rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Above 0.034 mm (0.001 in) fective part(s). Replace the de-

Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.034 mm (0.0004 ~ 0.001 in)

5-15

THE ROCKER ARMS AND CAMSHAFT

EAS00208

ENG

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: 8 timing chain Damage/stiffness Replace the timing chain and camshaft sprockets as a set. 2. Check: 8 camshaft sprocket More than 1/4 tooth wear a Replace the camshaft sprockets and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3. Check: 8 timing chain guide (exhaust side) 8 timing chain guide (intake side) Damage/wear Replace the defective part(s).

b 2

EAS00210

CHECKING THE TIMING CHAIN TENSIONER 1. Check: 8 timing chain tensioner Cracks/damage Replace. 2. Check: 8 one-way cam operation Rough movement Replace the timing chain tensioner housing. 3. Check: 8 cap bolt 8 o-ring New 8 spring 8 one-way cam 8 gasket New 8 timing chain tensioner rod Damage/wear Replace the defective part(s).

5-16

THE ROCKER ARMS AND CAMSHAFT

EAS00220

ENG

INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 8 camshaft 1 Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2. Lubricate: 8 rocker arm shafts Recommended lubricant Molybdenum disulfide oil

3. Install: 8 exhaust rocker arm 1 8 spring 2 8 exhaust rocker arm shaft 3

2 1 3

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

1 2 3

4. Install: 8intake rocker arm 1 8spring 2 8intake rocker arm shaft 3 NOTE: Make sure the intake rocker arm shaft is completely pushed into the cylinder head.

5-17

VALVES AND VALVE SPRINGS

EAS00236

ENG

VALVES AND VALVE SPRINGS

9 1 2 6 3 7 4 8 5

5 8 4 7 3 1 2 4 7 2 1 3 8 9 9

Order

Job/Part Removing the valves and valve springs Cylinder head Rocker arm and rocker arm shaft

Qty

Remarks Remove the parts in the order listed. Refer to CYLINDER HEAD. Refer to THE ROCKER ARMS AND CANSHAFT.

1 2 3 4 5 6 7 8 9

Valve pad Valve cotter Valve spring retainer Valve spring Valve(intake) Valve(exhaust) Valve stem seal Valve stem seat Valve guide

3 6 3 3 2 1 3 3 3

Refer to INSTALLING THE VALVES AND VALVE SPRINGS .

For installation, reverse the removal procedure.

5-18

VALVES AND VALVE SPRINGS

EAS00237

ENG

REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.

1. Check: 8 valve sealing Leakage at the valve seat Check the valve face, valve seat, and valve seat width. Refer to CHECKING THE VALVE SEATS. ***************************************************** a. Pour a clean solvent a into the intake and exhaust ports. b. Check that the valves properly seal. NOTE: There should be no leakage at the valve seat 1. *****************************************************

2. Remove: 8valve pads1

1 2

3 . Remove: 8valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2.

5-19

Valve spring compressor 90890-04109 (YM-04109) Valve spring compressor attachment 90890-04148 (YM-04148)

VALVES AND VALVE SPRINGS

4 2 5 1 3

ENG

4. Remove: 8valve spring retainer 1 8valve spring 2 8valve stem seal 3 8valve spring seat 4 8valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
EAS00239

CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: 8 valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance = Valve guide inside diameter a Valve stem diameter b

Out of specification guide.

Replace the valve

Valve-stem-to-valve-guide clearance Intake 0.010 ~ 0.037 mm(0.0004~0.0015 in) <Limit>: 0.08 mm(0.003 in) Exhaust 0.025 ~ 0.052 mm(0.001~0.002 in) <Limit>: 0.10 mm(0.004 in) 2. Replace: 8 valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100C in an oven.

***************************************************** a. Remove the valve guide with the valve guide remover 1. b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. c. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valveguide clearance.

5-20

VALVES AND VALVE SPRINGS

ENG

NOTE: After replacing the valve guide, reface the valve seat.

Valve guide remover (4.0 mm) 90890-04111(YM-04111) Valve guide installer (4.0 mm) 90890-04112(YM-04112) Valve guide reamer (4.0 mm) 90890-04113(YM-04113) ***************************************************** 3. Eliminate: 8 carbon deposits (from the valve face and valve seat) 4. Check: 8 valve face Pitting/wear Grind the valve face. 8 valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve.

5. Measure: 8 valve margin thickness a Out of specification Replace the valve.

Valve margin thickness 0.70 mm (0.028 in)

a
6. Measure: 8 valve stem runout Out of specification

Replace the valve.

NOTE: 8 When installing a new valve, always replace the valve guide. 8 If the valve is removed or replaced, always replace the oil seal.

Valve stem runout 0.01 mm(0.0004 in)

5-21

VALVES AND VALVE SPRINGS

EAS00240

ENG

CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: 8 carbon deposits (from the valve face and valve seat) 2. Check: 8 valve seat Pitting/wear Replace the cylinder head. 3. Measure: 8 valve seat width a Out of specification der head.

Replace the cylin-

Valve seat width Intake: 0.9 ~ 1.1 mm(0.035 ~ 0.043 in) <Limit>: 1.6 mm(0.063 in) Exhaust: 0.9 ~1.1 mm(0.035~0.043 in) <Limit>: 1.6 mm(0.063 in) ***************************************************** a. Apply Mechanics blueing dye (Dykem) b onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impression. d. Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. *****************************************************

4. Lap: 8 valve face 8 valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. *****************************************************
5-22

VALVES AND VALVE SPRINGS

ENG

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

cC
a

Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g. Apply Mechanics blueing dye (Dykem) b onto the valve face. h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impression. j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. *****************************************************

5-23

VALVES AND VALVE SPRINGS

EAS00241

ENG

CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: 8 valve spring free length a Out of specification Replace the valve spring.
a

Valve spring free length Intake valve spring 39.35 mm (1.549 in) <Limit>: 37.38 mm (1.472 in) Exhaust valve spring 41.57 mm (1.637 in) <Limit>: 39.49 mm (1.555 in)

b a

2. Measure: 8 compressed valve spring force a Out of specification Replace the valve spring. b Installed length Compressed valve spring force (installed) Intake valve spring 9.3~10.7 kg at 28 mm (20.5 ~ 23.6 lb at 1.102 in) Exhaust valve spring 11.0 ~ 12.7 kg at 30 mm (24.3 ~ 28.0 lb at 1.181 in)

3. Measure: 8 valve spring tilt a Out of specification spring.

Replace the valve

Spring tilt limit Intake valve spring 1.7 mm (0.067 in) ( 2.5 ) Exhaust valve spring 1.8 mm (0.071 in)( 2.5 )
5-24

VALVES AND VALVE SPRINGS

EAS00245

ENG

INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 8valve stem end (with an oil stone)

2 1

2. Lubricate: 8valve stem 1 8valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil

2 4 1 5 3

3.

Install: 8valve 1 8valve spring seat 2 8valve stem seal 3 New 8valve spring 4 8valve spring retainer 5 (into the cylinder head)

NOTE: Install the valve spring with the larger pitch a facing up.
a

Smaller pitch

4. Install: 8valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2.

5-25

VALVES AND VALVE SPRINGS

ENG

Valve spring compressor 90890-04109(YM-04109) Valve spring compressor attachment 90890-04148(YM-04148)

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

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

6.
1

Install: valve pad 1 NOTE: 8 Lubricate the valve pad with molybdenum disulfide oil. 8 Each valve pad must be reinstalled in its original position.

5-26

CYLINDER AND PISTON

EAS00251

ENG

CYLINDER AND PISTON

7 9 8

Order

9 10

4
10 2

4
4 6 3 1
10Nm (1.0 mkg, 7.2 ftlb)

Job/Part Removing the cylinder and piston Cylinder head Timing chain guide(exhaust side) Cylinder Case cap Reed valve assembly Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set

Qty

Remarks Remove the parts in the order listed. Refer to CYLINDER HEAD.

1 2 3 4 5 6 7 8

1 1 1 1 2 1 2 1 1 1

Refer to INSTALLING THE PISTON AND CYLINDER. Refer to REMOVING THE CYLINDER AND PISTON. Refer to INSTALLING THE PISTON AND CYLINDER. For installation, reverse the removal procedure.

5-27

CYLINDER AND PISTON

EAS00253

ENG

2 1 3

REMOVING THE CYLINDER AND PISTON 1. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 3

cC
Do not use a hammer to drive the piston pin out. NOTE: 8 Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. 8 Before removing the piston pin, deburr the piston pin clips groove and the pistons pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller set4.

Piston pin puller set 90890-01304(YU-01304)

2. Remove: 8 top ring 8 2nd ring 8 oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.

5-28

CYLINDER AND PISTON

EAS00261

ENG

CHECKING THE CYLINDER AND PISTON 1. Check: 8 piston wall 8 cylinder wall Vertical scratches Replace the cylinder, and the piston and piston rings as a set.

Measure: 8piston-to-cylinder clearance ***************************************************** a. Please carry out the following inspections: 8 cylinder Measure the piston pin in both of its horizontal axis direction a and its right angle direction b at six positions of A, B, etc. with a cylinder gauge. Abrasion=Nax. value - min. value as measured at those six positions. When abrasion is beyond limit Replace it
Standard 38.000 ~ 38.010 mm(1.4961 ~ 1.4965 in)

2.

b. If out of specification, replace the cylinder, and the piston and piston rings as a set. c. Measure piston skirt diameter P with the micrometer. a 5 mm (0.197 in) from the bottom edge of the piston
Piston size P 37.975 ~ 37.990 mm (1.495 ~ 1.496 in)

d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula.
Piston-to-cylinder clearance = Cylinder bore C - Piston skirt diameter P

Piston-to-cylinder clearance 0.010 ~ 0.035 mm (0.0004 ~ 0.0014 in) <Limit>: 0.15 mm (0.006 in) f. If out of specification, replace the cylinder, and the piston and piston rings as a set. *****************************************************
5-29

CYLINDER AND PISTON

EAS00263

ENG

CHECKING THE PISTON RINGS 1. Measure: 8 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 0.02 ~ 0.08 mm(0.0008~0.0031 in) <Limit>: 0.13mm(0.0051 in) 2nd ring 0.02 ~ 0.06 mm(0.0008~0.0024 in) <Limit>:0.12 mm(0.0047 in)

2. Install: 8 piston ring (into the cylinder)

a

NOTE: Level the piston ring into the cylinder with the piston crown. a 10 mm (0.394 in) 3. Measure: 8 piston ring end gap Out of specification ton ring.

Replace the pis-

NOTE: The oil ring expander spacers end gap cannot be measured. If the oil ring rails gap is excessive, replace all three piston rings.

Piston ring end gap Top ring 0.05 ~ 0.15 mm (0.0020 ~ 0.0059 in) <Limit>: 0.40 mm (0.0157 in) 2nd ring 0.05 ~ 0.17 mm (0.0020 ~ 0.0067 in) <Limit>: 0.52 mm (0.0205 in) Oil ring 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in)

5-30

CYLINDER AND PISTON

EAS00265

ENG

CHECKING THE PISTON PIN 1. Check: 8 piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system.

2. Measure: 8 piston pin outside diameter a Out of specification Replace the piston pin. Piston pin outside diameter 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in) <Limit>:9.976 mm (0.3928 in) 3. Measure: 8 piston pin bore diameter b Out of specification Replace the piston.
b

Piston pin bore diameter 10.002 ~ 10.013 mm (0.3938 ~ 0.3942 in) <Limit>:10.043 mm (0.3954 in) 4. Calculate: 8 piston-pin-to-piston-pin-bore clearance Out of specification Replace the piston pin and piston as a set.
Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter b Piston pin outside diameter a

Piston-pin-to-piston clearance 0.002 ~ 0.017 mm (0.0001 ~ 0.0007 in)

5-31

CYLINDER AND PISTON

ENG

CHECKING THE TIMING CHAIN GUIDE 1. Check: 8 timing chain guide (exhaust side) Damage/wear Replace

EAS00267

INSTALLING THE PISTON AND CYLINDER 1. Install: 8 oil ring expander 1 8 oil ring rail 2 8 2nd ring 3 8 top ring 4 NOTE: Be sure to install the piston rings so that the manufacturers marks or numbers face up.

4 3 2 1 2

1 2 a 3

2. Install: 8 piston 1 8 piston pin 2 8 piston pin clip New 3 NOTE: 8 Apply engineoil the piston pin. 8 Make sure the arrow mark a on the piston points towards the exhaust side of the cylinder. 8 Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase.

5-32

CYLINDER AND PISTON

3. Install: 8 gasket New 8 dowel pins

ENG

4. Lubricate: 8 piston 8 piston rings 8 cylinder (with the recommended lubricant) Recommended lubricant Engine oil
a b

5. Offset: 8 piston ring end gaps a b c d A Top ring Lower oil ring rail Upper oil ring rail 2nd ring Exhaust side

6. Install: 8 timing chain guide (exhaust side) 8cylinder 1 NOTE: 8 While compressing the piston rings with one hand, install the cylinder with the other hand. 8 Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.

5-33

BELT DRIVE
EAS00316

ENG

BELT DRIVE
CRANKCASE COVER (LEFT)
3

10Nm (1.0 mkg, 7.2 ftlb)

7 8 10 4

11 5 9 1 6

12

6
15Nm (1.5 mkg, 10.9 ftlb)

Order

Job/Part Removing the crankcase cover (left) Kickstarter Rear wheel lock cable cover Rear wheel lock cable Crankcase cover(left) Crankcase cover gasket(left) Dowel pin Kick pinion gear Kick pinion gear clip Circlip/Plate washer Kick shaft assembly Torsion spring Solid bush Holder Torsion spring Stopper lever assembly

Qty

Remarks Remove the parts in the order listed. Refer to LEADS, HOSES AND REAR BRAKE .

1 2 3 4 5 6 7 8 9 10 11 12

1 1 2 1 1 1/1 1 1 1 1 1 1

Refer to INSTALLING KICKSTARTER .

THE

For installation, reverse the removal procedure.

5-34

BELT DRIVE
2 3
EAS00340

ENG

INSTALLING THE KICKSTARTER 1. Install: 8 solid bush1 8 kick shaft assembly2 8 torsion spring3

2. Hook: 8 kickstarter spring NOTE: Hook the spring enda on the kickstarter shaft b as shown, and hook the other end c on the projectiond .

a b

3. Install: 8 plain washer 8 circlip1 New

1

4. Install: 8kick pinion gear1 8kick pinion gear clip2 NOTE: Install the clip at the position shown.
2 1

5-35

BELT DRIVE
V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE

ENG

40Nm (4.0 mkg, 28.9 ftlb)

7 8 3

12 10 10 11 9

2 1

30Nm (3.0 mkg, 21.7 ftlb)

Order

Job/Part Removing the V-belt, clutch, primary and secondary sheave Primary sheave nut/Plate washer Oneway clutch Primary fixed sheave Secondary sheave nut Clutch housing Secondary sheave assembly V-belt Collar Primary sliding sheave Cam/Weight Slider Plate washer

Qty

Remarks Remove the parts in the order listed.

1 2 3 4 5 6 7 8 9 10 11 12

1/1 1 1 1 1 1 1 1 1 1/6 3 1

Refer to REMOVING AND INSTALLING THE SECONDARY SHEAVE

Refer to REMOVING AND INSTALLING THE PRIMARY SHEAVE

For installation, reverse the removal procedure.

5-36

BELT DRIVE

ENG

3 2 4

6 3 1

0
55Nm (5.5 mkg, 39.8 ftlb)

9 7 8
LS

LS

Order

Job/Part Disassembling the secondary sheave assembly Clutch carrier nut Clutch carrier Clutch shoe spring Compression spring Secondary spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave

Qty

Remarks Disassemble the parts in the order listed.

1 2 3 4 5 6 7 8 9 0

1 1 2 1 1 2 1 2 2 1

Refer to REMOVING AND INSTALLING THE SECONDARY SHEAVE .

For installation, reverse the removal procedure.

5-37

BELT DRIVE
EAS00317

ENG

5 1

REMOVING THE PRIMARY SHEAVE 1. Remove: 8primary sheave nut 1 8plate washer2 8oneway clutch3 8primary fixed sheave 4 NOTE: While holding the primary fixed sheave with the rotor holding tool 5, loosen the primary fixed sheave nut. Rotor holding tool: 90890-01235 (YU-01235)

3 2 1

EAS00318

1 3

REMOVING THE SECONDARY SHEAVE AND V-BELT 1. Remove: 8 secondary sheave nut 1 8 clutch housing 2 NOTE: While holding the clutch housing with the sheave holder 3, loosen the secondary sheave nut.

Sheave holder: 90890-01701 (YS-01880-A)

3 1

2. Loosen: 8 clutch carrier nut 1

cC
2

Do not remove the clutch carrier nut at this stage. NOTE: While holding the clutch carrier with the rotor holding tool 2, loosen the clutch carrier nut one full turn with the locknut wrench 3.

Roter holding tool: 90890-01235 (YU-01235) Locknut wrench: 90890-01348 (YM-01348)

5-38

BELT DRIVE
1

ENG

3. Remove: 8 secondary sheave assembly 1 8 V-belt 2 NOTE: Remove the V-belt and clutch assembly from the primary sheave side.

2
EAS00319

DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: 8 clutch carrier nut 1

1

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

Clutch spring holder 90890-01337 (YM-33285) (YM-33285-6)

CHECKING THE CLUTCH SHOE 1. Measure: 8 clutch shoe Scratches Glaze using coares sandpaper. Damage/wear Replace Clutch shoe thickness 3.7 mm (0.146 in) <Limit>: 2.0 mm (0.079 in) NOTE: Inspect clutch shoes a. After removing the clutch weight spring, do not use them again. Replace the all two as a set.

5-39

BELT DRIVE
EAS00320

ENG

CHECKING THE V-BELT 1. Check: 8 V-belt 1 Cracks/damage/wear Replace. Grease/oil Clean the primary and secondary sheave.

2. Measure: 8 V-belt width a Out of specification

Replace.

V-belt width 16.8 mm (0.0661 in) <Limit>: 15.8 mm (0.622 in)

CHECKING THE PRIMARY SHEAVE 1. Check: 8 primary sliding sheave1 8 primary fixed sheave2 Cracks/damage/wear Replace the primary sliding sheave, primary fixed sheave and V-belt.
1 2

2.

Check: 8 free movement Insert the collar2 into the primary sliding sheave1, and check for free movement. Stick or excessive play Replace the primary sliding sheave or collar.

5-40

BELT DRIVE
EAS00321

ENG

CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the primary sheave weights. 1. Check: 8 primary sheave weight Cracks/damage/wear Replace.
a

2. Measure: 8 primary sheave weight outside diameter a Out of specification Replace. Primary sheave weight outside diameter 15 mm (0.591 in) <Limit>: 14.5 mm (0.571 in)

CHECKING THE SLIDER 1. Check: 8 slider 1 Damage/wear Replace

EAS00322

CHECKING THE SECONDARY SHEAVE 1. Check: 8secondary fixed sheave 8secondary sliding sheave Cracks/damage/wear Replace the secondary fixed and sliding sheaves as a set.

2. Check: 8torque cam groove 1 Damage/wear Replace the secondary fixed and sliding sheaves as a set. 3. Check: 8guide pin 2 Damage/wear Replace the secondary fixed and sliding sheaves as a set.

5-41

BELT DRIVE
1
EAS00323

ENG

2 5

ASSEMBLING THE PRIMARY SHEAVE 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 NOTE: Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5.

3 2 1

2. Install: 8primary sliding sheave 1 8primary sheave weights 2 8collar 3

3. Install: 8 slider 1 8 cam 2

1 2

5-42

BELT DRIVE
EAS00324

ENG

ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: 8 secondary fixed sheaves inner surface 1 8 secondary sliding sheaves inner surface 2 8 oil seals 8 bearings (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube

3 1

2. Install: 8 secondary sliding sheave 1 NOTE: Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3.

Oil seal guide 90890-01384 (YM-33299)

1 2

3. Install: 8 guide pin 1 4. Lubricate: 8 guide pin groove 2 8 o-ring New 3 (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube
5-43

BELT DRIVE
4 2 3 1 5

ENG

5. Install: 8 secondary sheave 1 8 spring 8 clutch carrier 2 NOTE: Attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch carrier nut 5.

Clutch spring holder 90890-01337 (YM-33285) ( YM-33285-6)

EAS00325

INSTALLING THE BELT DRIVE 1. Install: 8 V-belt 1 8 clutch assembly 2

cC
Do not allow grease to contact the V-belt, secondary sheave assembly.
1

NOTE: Install the V-belt onto the primary sheave side. 2. Install: 8 clutch carrier nut 1
3 1

55 Nm (5.5 m kg, 39.8 ft lb)

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

T.

R.

Rotor holding tool 90890-01235 Locknut wrench 90890-01348 (YM-01348)

5-44

BELT DRIVE

ENG

3. Install: 8 clutch housing 1 8 secondary sheave nut2 40 Nm (4.0 m kg, 28.9 ft lb)
T.

R.

2 3

NOTE: Tighten the secondary sheave nut with the sheave holder 3.

Sheave holder 90890-01701 (YS-01880-A)

4. Install: 8primary fixed sheave 1 8primary sheave nut 2 30 Nm (3.0 m kg, 21.7 ft lb)
T.

NOTE: While holding the primary fixed sheave with the rotor holding tool 3, tighten the primary fixed sheave nut. 5. Position: 8V-belt 1 NOTE: Position the V-belt in the primary sheave 2 (when the pulley is at its widest position) and in the secondary sheave 3 (when the pulley is at its narrowest position), and make sure the Vbelt is tight.

R.

5-45

STARTER CLUTCH AND AC MAGNETO

EAS00341

ENG

STARTER CLUTCH AND AC MAGNETO

STATOR COIL ASSEMBLY

4Nm (0.4 mkg, 2.9 ftlb)

2 5 1

7
7Nm (0.7 mkg, 5.1 ftlb)

43Nm (4.3 mkg, 31.1 ftlb)

Order

Job/Part Removing the stator coil assembly Coolant

Qty

1 2 3 4 5

Radiator Seat/Trunk/Mat Rear carrier/Front cover Side cover(left and right) Rear cover/Battery cover Battery holder/Battery Footrest board side cover mole(left and right) Footrest board AC magneto lead Fan/O-ring Nut/Plate washer AC magneto rotor Woodruff key
5-46

Remove the parts in the order listed. Drain. Refer to CHANGING THE COOLANTin chapter 3. Refer to RADIATORin chapter 6.

Refer to COVER AND PANELin chapter 3.

1 1/1 1/1 1 1

Disconnect.

LT

9Nm (0.9 mkg, 6.5 ftlb)

7Nm (0.7 mkg, 5.1 ftlb)

Remarks

STARTER CLUTCH AND AC MAGNETO

ENG

4Nm (0.4 mkg, 2.9 ftlb)

2 5 1

7
7Nm (0.7 mkg, 5.1 ftlb)

43Nm (4.3 mkg, 31.1 ftlb)

Order 6 7 8

Job/Part Lock plate Pick up coil Stator coil assembly

Qty 1 1 1

For installation, reverse the removal procedure.

5-47

LT

9Nm (0.9 mkg, 6.5 ftlb)

7Nm (0.7 mkg, 5.1 ftlb)

Remarks

STARTER CLUTCH AND AC MAGNETO

EAS00342

ENG

STARTER CLUTCH
3 2 1

NEW image
9

10Nm (1.0 mkg, 7.2 ftlb)

7 3 10 11
M 4

90Nm (9.0 mkg, 65.1 ftlb)

6 8

5 4

Order

Job/Part Removing the starter clutch Engine oil

Qty

Remarks Remove the parts in the order listed. Drain. Refer to CHANGING THE ENGINE OILin chapter 3. Refer to REMOVING AND INSTALLING THE AC MAGNETO .

1 2 3 4 5 6 7 8 9 10 11

AC magneto rotor Stator coil assembly Crankcase cover(right) Gasket Dowel pin Starter clutch nut Washer Starter wheel gear Roller Collar Starter clutch Idle gear Shaft

1 1 2 1 1 1 1 1 1 1 1

cC
The starter clutch nut is left-hand thread.

Refer to REMOVING AND INSTALLING THE STARTER CLUTCH .

For installation, reverse the removal procedure.

5-48

STARTER CLUTCH AND AC MAGNETO

EAS00347

ENG

3 2 1

REMOVING THE AC MAGNETO 1. Remove: 8 AC magneto rotor nut1 8 washer NOTE: 8 While holding the AC magneto rotor 2 with the sheave holder 3, loosen the AC magneto rotor nut. 8 Do not allow the sheave holder to touch the projection on the AC magneto rotor.

Sheave holder 90890-01701 YS-01880-A

2.

Remove: 8AC magneto rotor 1 (with the flywheel puller 2) 8woodruff key

cC
To protect the end of the crankshaft, place an appropriate sized socket between the flywheel puller sets center bolt and the crankshaft. NOTE: Make sure the flywheel puller is centered over the AC magneto rotor.

5-49

STARTER CLUTCH AND AC MAGNETO

EAS00344

ENG

REMOVING THE STARTER CLUTCH 1. Remove: 8crankcase cover (right)1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

2.

Remove: 8starter clutch nut1 8washer 8starter wheel gear 8roller 8collar 8starter clutch 8idle gear

NOTE: The starter clutch nut is left-hand thread.

5-50

STARTER CLUTCH AND AC MAGNETO

EAS00351

ENG

CHECKING THE STARTER CLUTCH 1. Check: 8starter clutch roller 1 Damage/wear Replace. 2. Check: 8starter clutch idle gear 8starter wheel gear Burrs/chips/roughness/wear Replace the defective part(s). 3. Check: 8starter wheel gears contacting surfaces Damage/pitting/wear Replace the starter clutch gear.

1 A

4. Check: 8starter clutch operation ***************************************************** a. Install the starter wheel gear 1onto the starter clutch 2 and hold the starter clutch. b. When turning the starter wheel gear clockwise A, the starter clutch and the starter wheel gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter wheel gear counterclockwise B, it should turn freely, otherwise the starter clutch is faulty and must be replaced. *****************************************************

5-51

STARTER CLUTCH AND AC MAGNETO

EAS00355

ENG

INSTALLING THE STARTER CLUTCH 1. Install: 8 idle gear 8 starter clutch 8 collar 8 roller 8 starter wheel gear 8 washer 8 starter clutch nut1 90 Nm (9.0 m kg, 65.1 ft lb) NOTE: The starter clutch nut is left-hand thread.
T.

2. Install: 8 gasket New 8 crankcase cover (right)1

1

EAS00354

INSTALLING THE AC MAGNETO 1. Install: 8stator coil assembly1 8pick up coil2 8woodruff key3 8AC magneto rotor 8washer 8AC magneto rotor nut NOTE: 8 Clean the tapered portion of the crankshaft and the AC magneto rotor hub. 8 When installing the AC magneto rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft.

R.

10 Nm (1.0 m kg, 7.2 ft lb)

T.

R.

5-52

STARTER CLUTCH AND AC MAGNETO

2.

ENG

Tighten: 8AC magneto rotor nut 1 43 Nm (4.3 m kg, 31.1 ft lb)

T.

NOTE: 8 While holding the AC magneto rotor 3with the sheave holder 2, tighten the AC magneto rotor nut. 8 Do not allow the sheave holder to touch the projection on the AC magneto rotor.

R.

Sheave holder 90890-01701 YS-01880-A

5-53

OIL PUMP
EAS00360

ENG

OIL PUMP

10 9 8 7 6
1Nm (0.1 mkg, 0.7 ftlb) 4Nm (0.4 mkg, 2.9 ftlb)

5 3

4
4

Order

Job/Part Disassembling the oil pump Radiator AC magneto Starter clutch Drive gear Circlip/Plate washer Oil pump driven gear Dowel pin Oil pump housing Oil pump shaft Inner rotor Outer rotor Oil pump housing cover Gasket

Qty

Remarks Remove the parts in the order listed. Refer to RADIATORin chapter 6. Refer to STARTER CLUTCH AND AC MAGNETO .

1 2 3 4 5 6 7 8 9 10

1 1/1 1 2 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.

5-54

OIL PUMP
EAS00364

ENG

CHECKING THE OIL PUMP 1. Check: 8 oil pump drive gear 8 oil pump driven gear 1 8 oil pump housing 8 oil pump housing cover Cracks/damage/wear defective part(s).

Replace the

1 A

2. Measure: 8 inner-rotor-to-outer-rotor-tip clearance A 8 outer-rotor-to-oil-pump-housing clearance B 8 oil-pump-housing-to-inner-rotor-andouter-rotor clearance C Out of specification Replace the oil pump.
2

1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0.15 mm (0.006 in) or less <Limit>: 0.23 mm (0.009 in) Outer-rotor-to-oil-pump-housing clearance 0.13 ~ 0.18 mm (0.005 ~ 0.007 in) <Limit>: 0.25mm (0.010 in) Oil-pump-housing-to-inner-rotorand-outer-rotor clearance 0.07 ~ 0.12 mm (0.003 ~ 0.005 in) <Limit>: 0.19 mm (0.008 in)

3. Check: 8 oil pump operation Rough movement Repeat steps (1) and (2) or replace the defective part(s).

5-55

OIL PUMP
EAS00375

ENG

ASSEMBLING THE OIL PUMP 1. Lubricate: 8 inner rotor 8 outer rotor 8 oil pump shaft (with the recommended lubricant)

Recommended lubricant Engine oil

5 4a 1 2 6 3

2. Install: 8 oil pump shaft 1 (to the oil pump housing2) 8 pin 3 8 inner rotor 4 8 outer rotor5 8 oil pump housing cover6 8 oil pump housing screw 1 Nm (0.1 m kg, 0.7 ft lb)
T.

NOTE: When installing the inner rotor, align the pin 3 in the oil pump shaft with the groove a in the inner rotor 4. 3. Check: 8 oil pump operation Refer to CHECKING THE OIL PUMP.
EAS00376

INSTALLING THE OIL PUMP 1. Install: 8oil pump drive gear 1 8gasket New 8oil pump assembly2 8oil pump bolt

R.

4 Nm (0.4 m kg, 2.9 ft lb)

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

T.

R.

5-56

TRANSMISSION
EAS00419

ENG

TRANSMISSION

LS

13Nm (1.3 mkg, 9.34 ftlb)

4 5
G
G

6
G

3 1

LS

Order

Job/Part Removing the transmission Transmission oil

Qty

Remarks Remove the parts in the order listed. Drain. Refer to CHANGING THE TRANSMISSION OIL in chapter 3. Refer to MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY . Refer to REAR WHEEL AND BRAKE in chapter 4. Refer to BELT DRIVE .

Muffler assembly Rear fender Rear wheel Crankcase cover(left) Belt drive Secondary sheave Circlip Transmission cover Transmission cover gasket Dowel pin Main axle Drive axle Primary drive gear shaft

1 2 3 4 5 6 7

1 1 1 2 1 1 1 For installation, reverse the removal procedure.

5-57

TRANSMISSION
EAS00425

ENG

CHECKING THE TRANSMISSION 1. Measure: 8 main axle runout (with a centering device and dial gauge ) Out of specification Replace the main axle. Main axle runout limit 0.04 mm (0.0002 in) 2. Measure: 8 drive axle runout (with a centering device and dial gauge ) Out of specification Replace the drive axle. Primary drive gear shaft runout limit 0.04 mm (0.0002 in)

3 . Check: 8transmission gears Blue discoloration/pitting/wear Replace the defective gear(s). 8transmission gear dogs Cracks/damage/rounded edges Replace the defective gear(s). 4 . Check: 8transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect Reassemble the transmission axle assemblies. 5 . Check: 8transmission gear movement Rough movement Replace the defective part(s). 6 . Check: 8circlip Bends/damage/looseness Replace.

5-58

CRANKSHAFT
EAS00381

ENG

CRANKSHAFT
CRANKSHAFT ASSEMBLY

10Nm (1.0 mkg, 7.2 ftlb)

10

14

12
4

11
LS

16

17 7 9 6 8 19 2 2 15
32Nm (3.2 mkg, 23.1 ftlb)
LS

12

13 18 18

3 4 1

Order

Job/Part Removing the crankshaft assembly Engine Cylinder head Cylinder piston V-belt, clutch, primary and secondary sheave Radiator Water pump Starter clutch AC magneto Oil pump Transmission Rear wheel

Qty

Remarks Remove the parts in the order listed. Refer to ENGINE . Refer to CYLINDER HEAD . Refer to CYLINDER AND PISTON . Refer to V-BELT,CLUTCH ,PRIMARY AND SECONDARY SHEAVE . Refer to COOLING SYSTEMin chapter 6. Refer to STARTER CLUTCH AND AC MAGNETO . Refer to OIL PUMP . Refer to TRANSMISSION . Refer to REAR WHEEL AND BRAKE in chapter 4.

1 2 3 4

Tension spring Circlip/Plate washer Pin Centerstand

5-59

1 1/1 1 1

CRANKSHAFT

ENG

10Nm (1.0 mkg, 7.2 ftlb)

10

14

12
4

11
LS

16

17 7 9 6 8 19 2 2 15
32Nm (3.2 mkg, 23.1 ftlb)
LS

12

13 18 18

3 4 1

Order 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Job/Part Hook Drain plug Oil strainer Compression spring O-ring Crankcase (right ) Spacer Dowel pin Guide Crankshaft Timing chain Crankcase ( left ) Oil seal Bolt/O-ring Timing chain guide

Qty 1 1 1 1 1 1 1 2 1 1 1 1 1 1/1 1

Remarks

Refer to DISASSEMBLING THE CRANKCASE Refer to INSTALLING THE CRANKSHAFT

For installation, reverse the removal procedure.

5-60

CRANKSHAFT
EAS00385

ENG

DISASSEMBLING THE CRANKCASE 1. Remove: 8 centerstand assembly

2. Remove: 8 crankcase bolts1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
1

3. Remove: 8 right crankcase1 8 spacer

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

5-61

CRANKSHAFT
EAS00207

ENG

CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1. Check: 8 timing chain Damage/stiffness Replace the timing chain.

2. Check: 8 timing chain guide (intake side) Damage/wear Replace.

5-62

CRANKSHAFT
EAS00394

ENG

CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: 8 crankshaft runout Out of specification Replace the crankshaft, bearing or both. NOTE: Turn the crankshaft slowly.

Maximum crankshaft runout 0.03 mm ( 0.001 in )

2. Measure: 8 big end side clearance Out of specification Replace the big end bearing, crankshaft pin, or connecting rod.

Big end side clearance 0.15~0.45 mm (0.006~0.018 in)

3. Measure: 8 crankshaft width Out of specification shaft.

Replace the crank-

Crankshaft width 42.45~42.50 mm (1.671~1.673 in)

2 1

4. Check: 8 crankshaft sprocket 1 Damage/wear Replace the crankshaft. 8 bearing 2 Cracks/damage/wear Replace the crankshaft. 8 oil pump drive gear Damage/wear Replace the crankshaft.

5-63

CRANKSHAFT

ENG

5. Check: 8 crankshaft journal Scratches/wear Replace the crankshaft. 8 crankshaft journal oil passage Obstruction Blow out with compressed air.

EAS00399

CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: 8crankcase Cracks/damage Replace. 8oil delivery passages Obstruction Blow out with compressed air.

EAS00401

CHECKING THE BEARINGS AND OIL SEALS 1. Check: 8bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement Replace. 2. Check: 8oil seals Damage/wear Replace.
EAS00402

CHECKING THE CIRCLIPS AND WASHERS 1. Check: 8circlips Bends/damage/looseness Replace. 8washers Bends/damage Replace.

5-64

CRANKSHAFT
EAS00408

ENG

INSTALLING THE CRANKSHAFT 1. Install: 8 timing chain guide (intake side) 8 timing chain1 8 crankshaft assembly2
1

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

cC
To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. NOTE: Put the timing chain in parallel into the crankcase, then use hands to place the crankshaft assembly into the crankcase. Manually rotate the crankshaft to check whether it is tightly engaged with the timing chain. (if not, install again)

EAS00418

ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces. 2. Apply: 8 sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery.
1

3. Install: 8 dowel pins 8 spacer 8 right crankcase1 4. Tighten: 8 crankcase 10 Nm (1.0 m kg, 7.2 ft lb)
T.

R.

5-65

COOL
CHAPTER 6 RADIATOR RADIATOR ................................................................................................ 6-1 CHECKING THE RADIATOR ............................................................ 6-2 INSTALLING THE RADIATOR ........................................................... 6-3 THERMOSTAT ASSEMBLY ..................................................................... 6-4 CHECKING THE THERMOSTAT ...................................................... 6-6 INSTALLING THE THERMOSTAT ASSEMBLY ................................ 6-7 WATER PUMP .......................................................................................... 6-8 DISASSEMBLING THE WATER PUMP .......................................... 6-10 CHECKING THE WATER PUMP ..................................................... 6-10 ASSEMBLING THE WATER PUMP ................................................ 6-11 INSTALLING THE WATER PUMP ................................................... 6-12

6-13

RADIATOR
EAS00454

COOL

COOLING SYSTEM
RADIATOR

2 4

1
10Nm (1.0 mkg, 7.2 ftlb)

Order

Job/Part Removing the radiator Seat/Trunk Battery cover/Battery holder Battery/Front cover Footrest board side cover mole ( left and right ) Mat/Footrest board Coolant

Qty

Remarks Remove the parts in the order listed.

Refer to COVER AND PANELin chapter 3.

Drain. Refer to CHANGING THE COOLANTin chapter 3. 1 1 1 1 1 1 1 For installation, reverse the removal procedure.

1 2 3 4 5 6 7

Radiator cover Radiator cap Conduit hose Radiator inlet hose Radiator outlet hose Radiator Fan case

6-1

RADIATOR
EAS00455

COOL

CHECKING THE RADIATOR 1. Check: 8 radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator. Damage Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver.

1 2

2. Check: 8 radiator hoses Radiator inlet hose1 8 radiator pipes Radiator outlet hose2 Cracks/damage Replace. 3. Measure: 8 radiator cap opening pressure Below the specified pressure Replace the radiator cap. Radiator cap opening pressure 93.3 ~ 122.7 kPa (0.95 ~ 1.25 kg/cm2, 13.53 ~ 17.79 psi) ***************************************************** a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3.

Radiator cap tester 90890-01325 YU-24460-01 Radiator cap tester adapter 90890-01352 YU-33984 b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. *****************************************************

6-2

RADIATOR

COOL

4. Check: 8 radiator fan Damage Replace. Malfunction Check and repair.

EAS00456

INSTALLING THE RADIATOR 1. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT in chapter 3. 2. Check: 8cooling system Leaks Repair or replace any faulty part. 3. Measure: 8radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to CHECKING THE RADIATOR.

6-3

THERMOSTAT ASSEMBLY
EAS00460

COOL

THERMOSTAT ASSEMBLY
10Nm (1.0 mkg, 7.2 ftlb)

4 1

6 2

10Nm (1.0 mkg, 7.2 ftlb)

Order

Job/Part Removing the thermostat assembly Seat/Trunk/Rear carrier Battery cover/Battery holder Battery/Front cover Side cover (left and right)/Rear cover Footrest board side cover mole ( left and right ) Mat/Footrest board Coolant

Qty

Remarks Remove the parts in the order listed.

Refer to COVER AND PANELin chapter 3.

1 2 3 4 5

Radiator inlet hose Thermostat assembly inlet breather hose(to carburetor) Thermostat assembly outlet breather hose(to water pump) Thermo switch lead Thermo switch/O-ring Thermostat housing
6-4

1 1 1 1/1 1

Drain. Refer to CHANGING THE COOLANTin chapter 3. Refer to RADIATOR. Disconnect.

Disconnect.

THERMOSTAT ASSEMBLY
10Nm (1.0 mkg, 7.2 ftlb)

COOL

4 1

6 2

10Nm (1.0 mkg, 7.2 ftlb)

Order 6

Job/Part Thermostat assembly

Qty 1

Remarks For installation, reverse the removal procedure.

6-5

THERMOSTAT ASSEMBLY
EAS00462

COOL

CHECKING THE THERMOSTAT 1. Check: 8 thermostat 1 Does not open at 65 ~ 80C

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 thermometers indicated temperature. *****************************************************

1 2 3 4 A B

Thermostat Container Thermometer Water Fully closed Fully open

NOTE: If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling. 2. Check: 8 thermostat housing Cracks/damage Replace.

6-6

THERMOSTAT ASSEMBLY
EAS00466

COOL

INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: 8thermostat1 8thermostat housing 8thermostat assembly inlet breather hose. 8thermostat assembly outlet breather hose. 2. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT in chapter 3. 3. Check: 8cooling system Leaks Repair or replace any faulty part. 4. Measure: 8radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to CHECKING THE RADIATOR.

6-7

WATER PUMP
EAS00468

COOL

WATER PUMP

7 10

10Nm (1.0 mkg, 7.2 ftlb)

4 11
7Nm (0.7 mkg, 5.1 ftlb) 10Nm (1.0 mkg, 7.2 ftlb)

3 6 9 8

Order

Job/Part Removing the water pump Seat/Trunk/Rear carrier Battery cover/Battery holder Battery/Front cover Side cover (left and right)/Rear cover Footrest board side cover mole ( left and right ) Mat/Footrest board Coolant

Qty

Remarks Remove the parts in the order listed. Refer to COVER AND PANELin chapter 3.

1 2 3 4

Thermostat assembly outlet breather hose Radiator outlet hose Breather hose Outlet hose(to cylinder) Water pump housing cover Gasket
6-8

Drain. Refer to CHANGING THE COOLANTin chapter 3. Refer to THERMOSTAT ASSEMBLY. Refer to RADIATOR. Disconnect.

1 1 1 1

WATER PUMP

COOL

7 10

10Nm (1.0 mkg, 7.2 ftlb)

4 11
7Nm (0.7 mkg, 5.1 ftlb) 10Nm (1.0 mkg, 7.2 ftlb)

3 6 9 8

Order 5 6 7 8 9 10 11

Job/Part Water pump housing Dowel pin Plate Impeller shaft Oil seal Bearing Gasket

Qty 1 2 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

6-9

WATER PUMP
1
EAS00471

COOL

DISASSEMBLING THE WATER PUMP 1. Remove: 8water pump housing cover1 8dowel pin 8gasket

2. Remove: 8plate 2 8impeller shaft 3 8gasket 8oil seal (with a thin, flat-head screwdriver) 8bearing NOTE: Remove the oil seal from the inside of the water pump housing. Remove the bearing from the inside of the water pump housing.

EAS00474

CHECKING THE WATER PUMP 1. Check: 8water pump housing cover 8water pump housing 8impeller 1 Cracks/damage/wear Replace.

2. Check: 8water pump seal 1 Cracks/damage/wear Replace. 3. Check: 8bearing Rough movement Replace. 4. Check: 8radiator outlet hose Cracks/damage/wear Replace.
6-10

WATER PUMP
EAS00475

COOL

2 1 3

ASSEMBLING THE WATER PUMP 1. Install: 8oil seal New 1 (into the water pump housing 3) 8bearing 2 NOTE: 8 Before installing the oil seal, apply tap water or coolant onto its out surface. 8 Install the oil seal with a socket that matches its outside diameter.

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

2. Measure: 8impeller shaft tilt Out of specification shaft.

Replace the impeller

Impeller shaft tilt limit 0.15 mm (0.006 in)

2

1 Straightedge 2 Impeller
1

3.

Install: 8impeller shaft1 8plate2

cC
After installation, check that the impeller shaft rotates smoothly.

4.

Install: 8gasket New 8 water pump housing cover1

6-11

WATER PUMP
EAS00478

COOL

a b 1

INSTALLING THE WATER PUMP 1. Install: 8gasket New 8water pump assembly 1 10 Nm (1.0 m kg, 7.2 ft lb)
T.

NOTE: Align the slit a on the impeller shaft with the projection b on the camshaft sprocket bolt. 2. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT in chapter 3. 3. Check: 8cooling system Leaks Repair or replace the faulty part. 4. Measure: 8radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to CHECKING THE RADIATOR.

R.

6-12

CARB
CHAPTER 7 CARBRETOR CARBURETOR ......................................................................................... 7-1 CHECKING THE CARBURETOR ..................................................... 7-4 ASSEMBLING THE CARBURETOR................................................. 7-6 INSTALLING THE CARBURETOR ................................................... 7-7 MEASURING AND ADJUSTING THE FUEL LEVEL ....................... 7-8 CHECKING THE AUTOCHOKE UNIT .............................................. 7-9 CHECKING THE FUEL COCK ........................................................ 7-10 CHECKING THE THROTTLE POSITION SENSOR ...................... 7-11 AIR INDUCTION SYSTEM ..................................................................... 7-12 CHECKING THE AIR INDUCTION SYSTEM ................................. 7-13

7-14

CARBURETOR
EAS00480

CARB

CARBURETOR
CARBURETOR

7
A

10 8
A B F E D B

6 2
C F

9
C E

4
D

3 1

Order

Job/Part Removing the carburetor Mat/Seat/Trunk Battery cover/Front cover Hose(to cylinder head) Auto choke lead Throttle position sensor lead Fuel hose Compensator hose Thermostat assembly inlet breather hose Throttle cable kit Clamp(air filter assembly ) Manifold clamp screw Carburetor assembly

Qty

Remarks Remove the parts in the order listed. Refer to COVER AND PANELin chapter 3.

1 2 3 4 5 6 7 8 9 10

1 1 1 1 1 1 1 1 1 1 1

Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.

Lossen. For installation, reverse the removal procedure.

7-1

CARBURETOR
EAS00483

CARB

6 1 8 7 2

9 3 p i w q 0 y o u t a 4

e r

Order 1 2 3 4 5 6 7 8 9 0 q w e r t y

Job/Part Disassembling the carburetor Auto choke cap Auto choke unit Auto choke holder Auto choke seat Throttle stop screw kit Bracket Vacuum chamber cover/Piston valve spring Piston valve Jet needle kit Float chamber Float chamber rubber gasket Accelerator pump assembly Float pin Float Needle valve Main jet
7-2

Qty 1 1 1 1 1 1 1/1 1 1 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed.

cC
Before leaving the factory, throttle position sensor should be measured and adjusted with a precision instrument. Any adjustment is strictly prohibited. When changing, use carburetor for final assembly exchange. Supplier should not make any changes after dismounting the adjusting bolt.

Refer to ASSEMBLING THE CARBURETOR.

CARBURETOR

CARB

6 1 8 7 2

9 3 p i w q 0 y o u t a 4

e r

Order u i o p a

Job/Part Main nozzle Nedle jet Slow air jet Slow jet Throttle position sensor

Qty 1 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

7-3

CARBURETOR
EAS00485

CARB

CHECKING THE CARBURETOR 1. Check: 8 carburetor body 8 float chamber Cracks/damage Replace.

2. Check: 8 fuel passages Obstruction Clean. ***************************************************** a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air. ***************************************************** 3. Check: 8 float chamber body Dirt Clean.

4. Check: 8 float chamber rubber gasket Cracks/damage/wear Replace.

5. Check: 8 float Damage

Replace.

7-4

CARBURETOR

CARB

2 1

6. Check: 8 needle valve Damage/obstruction/wear Replace. 7. Check: 8 piston valve 1 Damage/scratches/wear Replace. 8 piston valve diaphragm 2 Cracks/tears Replace.

8. Check: 8 vacuum chamber cover 1 8 piston valve spring 2 Cracks/damage Replace.

6 1 4 3 5

9. Check: 8jet needle 1 8main jet 2 8main nozzle 3 8slow air jet 4 8slow jet 5 8needle jet 6 Bends/damage/wear Replace. Obstruction Clean. Blow out the jets with compressed air. 10. Check: 8 piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness Replace the piston valve. 11. Check: 8 vacuum hoses 8 fuel hoses Cracks/damage/wear Replace. Obstruction Clean. Blow out the hoses with compressed air.

7-5

CARBURETOR
EAS00487

CARB

ASSEMBLING THE CARBURETOR

cC
8 Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. 8 Always use a new gasket.

3 1 4 2

1. Install: 8 needle jet 1 8 main nozzle2 8 main jet 3 8 slow air jet 4

2 1

2. Install: 8 float 1 8 needle valve 2 8 float pin 3 8 screw 4 3. Install: 8 float chamber rubber gasket New 8 float chamber

1 3

4. Install: 8accelerator pump diaphragm 1 8accelerator pump spring 2 8boot3 8accelerator pump diaphragm gasket4 8float chamber body
2

5 . Install: 8coasting enricher diaphragm1 8compression spring2 8coasting enricher cover3 6. Install: 8jet needle kit 8piston valve

7-6

CARBURETOR

CARB

7. Install: 8piston valve spring 8vacuum chamber cover 8. Install: 8bracket 8auto choke unit 8throttle position sensor

EAS00492

INSTALLING THE CARBURETOR 1. Adjust: 8 engine idling speed Engine idling speed 2,000 ~ 2,400r/min Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3. 2. Adjust: 8 throttle cable free play Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.5 mm (0.059 ~ 0.138 in) Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3.

7-7

CARBURETOR
EAS00498

CARB

MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: 8 fuel level a Out of specification Adjust.
a

Fuel level (below the float chamber mating surface) 6.6~7.6 mm (0.26~0.30 in) ***************************************************** a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. c. Install the fuel level gauge 1 onto the fuel drain pipe 2 Fuel level gauge 90890-01312 (YM-01312-A) d. Loosen the fuel drain screw e. Hold the fuel level gauge vertically next to the float chamber 3. f. Measure the fuel level a. *****************************************************

1 a 3 2

Adjust: 8 fuel level ***************************************************** a. Remove the carburetor. b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slightly bending the float tang 1. e. Install the carburetor. f. Measure the fuel level a again. g. Repeat steps (a) to (f) until the fuel level is within specification. *****************************************************

2.

7-8

CARBURETOR
EAS00503

CARB

CHECKING THE AUTOCHOKE UNIT NOTE: When checking the autochoke unit, the ambient temperature must be lower than 45C. 1. Remove: 8carburetor 2. Check: 8autochoke unit ***************************************************** a. Connect a 3.3-mm hose 2 to the starter air passage 1 and blow into the hose.
2 1

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

Starter plunger opens Starter plunger closes

Perform step (3). Replace the autochoke unit.

***************************************************** 3. Check: 8 autochoke unit ***************************************************** a. Connect the autochoke unit leads to a 12.0V battery for five minutes.
Positive battery lead 1 green/black Negative battery lead 2 yellow

1 3 2
Y
G/B

b. Connect a 3.3-mm hose 3 to the starter air passage 4 and blow into the hose.
Starter plunger opens. Starter plunger closes. Replace the autochoke unit. Autochoke is OK.

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

7-9

CARBURETOR
EAS00504

CARB

CHECKING THE FUEL COCK 1. Remove: 8 seat/trunk 8 battery cover 8 front cover Refer to COVER AND PANELin chapter 3. 2. Check: 8fuel cock1 ***************************************************** a. Disconnect the fuel cock to carburetor fuel hose2from the carburetor . b. Place a container under the end of the fuel hose. c. Start the engine and check if fuel flows from the fuel hose 2.
Fuel flows. Fuel does not flow. Fuel cock is OK. Replace the fuel cock.

d. Stop the engine and check if the fuel stops flowing from the fuel hose 2.
Fuel stops flowing. Fuel flows. Fuel cock is OK. Replace the fuel cock.

***************************************************** 3. Install: 8front cover 8battery cover 8seat/trunk Refer to COVER AND PANELin chapter 3.

7-10

CARBURETOR

CARB

CHECKING THE THROTTLE POSITION SENSOR

B/L

B/L Y/L

Y/L L

NOTE: Before checking the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: 8throttle position sensor ***************************************************** a. Turn the main switch to ON. b. Connect the pocket tester (DC 20V) to the throttle position sensor.
Tester positive lead Tester negative lead yellow/blue 1 black/blue2

c. Check the throttle position sensor input voltage.

DC5V voltage positive lead blue 3 DC5V voltage negative lead black/blue2 throttle opens. throttle closes. 2.8~3.4V. 0.625~0.775V

Out of specification buretor .

Replace the car-

cC
Please do not make any adjustment on throttle position sensor. *****************************************************

7-11

AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM

CARB

10Nm (1.0 mkg, 7.2 ftlb)

Order

Job/Part Removing the air induction system Seat/Trunk

Qty

Remarks Remove the parts in the order listed. Refer to COVER AND PANELin chapter 3.

1 2 3 4

Hose(from AI air filter ) Vacuum hose(from mainfold ) Hose(to cylinder head ) Air cut-off valve assembly

1 1 1 1 For installation, reverse the removal procedure.

7-12

AIR INDUCTION SYSTEM

EAS00510

CARB

CHECKING THE AIR INDUCTION SYSTEM 1. Check: 8 hoses Loose connection Connect properly. Cracks/damage Replace. 8 pipe Cracks/damage Replace.

2. Check: 8 air cut-off valve Cracks/damage

Replace.

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

7-13

ELEC
CHAPTER 8 ELECTORICAL

ELECTRICAL COMPONENTS ................................................................ 8-1 WIRING DIAGRAM ................................................................................... 8-2 CHECKING SWITCH CONTINUITY ........................................................ 8-4 CHECKING THE SWITCHES ................................................................... 8-5 CHECKING THE BULBS AND BULB SOCKETS .................................. 8-6 TYPES OF BULBS ............................................................................ 8-6 CHECKING THE CONDITION OF THE BULBS ............................... 8-7 CHECKING THE CONDITION OF THE BULB SOCKETS .............. 8-8 IGNITION SYSTEM................................................................................... 8-9 CIRCUIT DIAGRAM ........................................................................... 8-9 TROUBLESHOOTING ..................................................................... 8-10 ELECTRIC STARTING SYSTEM ........................................................... 8-14 CIRCUIT DIAGRAM ......................................................................... 8-14 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ................ 8-15 TROUBLESHOOTING ..................................................................... 8-16 STARTER MOTOR ........................................................................... 8-19 CHECKING THE STARTER MOTOR .............................................. 8-20 ASSEMBLING THE STARTER MOTOR ......................................... 8-22 CHARGING SYSTEM ............................................................................. 8-23 CIRCUIT DIAGRAM ......................................................................... 8-23 TROUBLESHOOTING ..................................................................... 8-24 LIGHTING SYSTEM ............................................................................... 8-26 CIRCUIT DIAGRAM ......................................................................... 8-26 TROUBLESHOOTING ..................................................................... 8-27 CHECKING THE LIGHTING SYSTEM ........................................... 8-29 SIGNALING SYSTEM ............................................................................ 8-32 CIRCUIT DIAGRAM ......................................................................... 8-32 TROUBLESHOOTING ..................................................................... 8-33 CHECKING THE SIGNALING SYSTEM......................................... 8-34 COOLING SYSTEM................................................................................ 8-40 CIRCUIT DIAGRAM ......................................................................... 8-40 TROUBLESHOOTING ..................................................................... 8-41 AUTO CHOKE SYSTEM ........................................................................ 8-45 CIRCUIT DIAGRAM ......................................................................... 8-45 TROUBLESHOOTING ..................................................................... 8-46

8-49

ELECTRICAL COMPONENTS
EAS00729

ELEC

ELECTRICAL
ELECTRICAL COMPONENTS
1 2 3 4 5 6 7 8 9 Rear brake light switch Front brake light switch Main switch Starter relay Thermo unit Fuel sender C.D.I. unit Ignition coil Spark plug cap 0 q w e r t y u Battery Main fuse Turn signal relay Horn Rectifier/Regulator Thermo switch Headlight relay Wire harness

1 2 5 t 7

6 3

r 9

q e w y 0

8-1

MAIN SW. WR WL YR W
Or WL WR WL YR

1 YR W WR WL (RED) 8 BL B WL Or
Or B

GW L LY YR YL GR Br

Br (RED)
W YR

OFF CHECK ON

R 2

W B R YR (GREEN)

YR

Br

c
BL LY GR B YL GW L Br

R YB R YR 9
YR BL

b L BL YL
YL L

WIRING DIAGRAM

R GY

R LW

R LW YR

R GY

4 7 B R (RED) (GRAY)
BL B

7.5A
R YR GR

GY

LW

t 0
L

v YR B GR BL (RED)

LW

STARTER SW. e

OFF START

LW LY B
B

LW LY B B R

LW L GY YR GB Y

[Link] SW.

OFF RUN

8-2
Br Br Br

LY B Br

q o
B BrW

y
P

Br

B BrW Br (BLACK)
L

Y P

Ch

Dg

B B

Br GY (BLACK) (BLACK)

B B

Br GY (BLACK) (BLACK)
GY GY

s u HORN DIMMER FLASHER Y Y G G (RED) (RED) L Ch P BrW B Dg

Ch Dg

d a i

Br GW G B

GW Br B G

HI BEAM

ILLUMI

TURN R

TEMP
OFF PUSH HI LO L N R

TURN L

ILLUMI

FUEL

L Dg Y Ch
B GY

Dg L Ch Y

Ch L BrW P Dg B

(BLACK)

(BLACK)

GW

Ch

GY

Dg

G Ch GY Dg

WIRING DIAGRAM

12V21W/5W

G B k

L GY B Dg Ch

GY L B Ch Dg

12V35W/35W

Ch Y Dg B G Y Ch B Dg G (RED)
B B

(RED)

B B

ELEC

z ;
12V10W

x
12V10W 12V10W

l
12V10W

MARK

Explanation

Connecting with GND. Wire GND.

WIRING DIAGRAM
1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g h j k l ; z x c v b Main switch AC magneto Rectifier/Regulator Battery Main fuse Starter relay Starter motor C.D.I. unit Ignition coil Auto choke unit Front brake light switch Rear brake light switch Start switch Engine stop switch Headlight relay Horn Horn switch Turn signal switch Turn signal relay Tail/brake light Dimmer switch Water temperature indicator light Speedometer light High beam indicator light Turn signal indicator light(left) Turn signal indicator light(right) Fuel sender Headlight Front turn signal light(left) Front turn signal light(right) Rear turn signal light(left) Rear turn signal light(right) Thermo switch Thermo unit Throttle position sensor Color Code B Black G Green L Blue P Pink R Red W White Y Yellow Br Brown Ch Chocolate Dg Dark green Or Orange B/L Black/Blue G/B Green/Black G/R Green/Red G/Y Green/Yellow G/W Green/White L/W Blue/White L/Y Blue/Yellow W/L White/Blue W/R White/Red Y/B Yellow/Black Y/L Yellow/Blue Y/R Yellow/Red Br/W Brown/White

ELEC

8-3

CHECKING SWITCH CONTINUITY

EAS00730

ELEC

CHECKING SWITCH CONTINUITY

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

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

Pocket tester 90890-03132 (YU-03112-C) NOTE: 8 Before checking for continuity, set the pocket tester to 0 and to the 1 range. 8 When checking for continuity, switch back and forth between the switch positions a few times. The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration. NOTE: - indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position). The example illustration on the left shows that: There is continuity between black and black/ white when the switch is set to OFF. There is continuity between red and brown when the switch is set to ON.

Br R OFF ON

Br

8-4

CHECKING THE SWITCHES

EAS00731

ELEC

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.

Main switch Br R OFF CHECK ON Br - - R -

Rear barake light switch

B B

Front barake light switch

Dimmer switch

B B

G L Y HI LO Horn switch P B OFF PUSH Turn signal light switch Br/ Ch Dg W L N R Y G OFF START Engine stop switch L/ B Y OFF RUN Start switch L/ W L/W L/Y B

L Ch P Br/W B Dg

Main fuse

8-5

CHECKING THE BULBS AND BULB SOCKETS

EAS00733

ELEC

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. 8 Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb. The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise. 8 Bulbs C is used for turn signal and tail/ brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. 8 Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out.

8-6

CHECKING THE BULBS AND BULB SOCKETS

ELEC

CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 8 bulb

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

cC
8 Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler. 8 Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 2. Check: 8 bulb (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03132 (YU-03112-C) NOTE: Before checking for continuity, set the pocket tester to 0 and to the 1 range.

1 2 3

***************************************************** 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. *****************************************************
8-7

CHECKING THE BULBS AND BULB SOCKETS

ELEC

CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: 8 bulb socket (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03132 (YU-03112-C) NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ***************************************************** a. Install a good bulb into the bulb socket. b. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket. *****************************************************

8-8

EAS00734

MAIN SW. WR WL YR W
Or WL WR WL YR

1 YR W WR WL (RED) 8 BL B WL Or
Or B

GW L LY YR YL GR Br

Br (RED)
W YR

OFF CHECK ON

R 2

W B R YR (GREEN)

YR

Br

c
BL LY GR B YL GW L Br

R YB R YR 9
YR BL

CIRCUIT DIAGRAM

b L BL YL
YL L

R GY

R LW

IGNITION SYSTEM

R LW YR

R GY

4 7 B R (RED) (GRAY)
BL B

7.5A
R YR GR

GY

LW

t 0
L

v YR B GR BL (RED)

LW

STARTER SW. e

OFF START

LW LY B
B

LW LY B B R

LW L GY YR GB Y

[Link] SW.

OFF RUN

8-9
Br Br Br

LY B Br

q o
B BrW

y
P

Br

B BrW Br (BLACK)
L

Y P

Ch

Dg

B B

Br GY (BLACK) (BLACK)

B B

Br GY (BLACK) (BLACK)
GY GY

s u HORN DIMMER FLASHER Y Y G G (RED) (RED) L Ch P BrW B Dg

Ch Dg

d a i

Br GW G B

GW Br B G

HI BEAM

ILLUMI

TURN R

TEMP
OFF PUSH HI LO L N R

TURN L

ILLUMI

FUEL

1 2 4 5 8 9 r

L Dg Y Ch
B GY

Dg L Ch Y

Ch L BrW P Dg B

(BLACK)

(BLACK)

GW

Ch

GY

Dg

G Ch GY Dg

IGNITION SYSTEM

12V21W/5W

G B k

L GY B Dg Ch

GY L B Ch Dg

12V35W/35W

Ch Y Dg B G Y Ch B Dg G (RED)
B B

(RED)

B B

ELEC

z ;
12V10W

x
12V10W

Main switch Pickup coil Battery Main fuse C.D.I. unit Ignition coil Engine stop switch
MARK

12V10W

l
12V10W

Explanation

Connecting with GND. Wire GND.

IGNITION SYSTEM
EAS00736 EAS00738

ELEC

TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Check: 1. main fuse 2. battery 3. spark plug 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. pickup coil resistance 8. main switch 9. engine stop switch [Link] connections (of the entire ignition system) NOTE: 8 Before troubleshooting, remove the following part(s): 1. Battery cover/Battery holder 2. Head light cover 3. Leg shield 1 4. Seat/Trunk 8 Troubleshoot with the following special tool(s).

1. Main Fuse 8 Check the fuse for continuity. Refer to CHECKING THE FUSE in chapter 3. 8 Is the fuse OK? YES NO

Replace the fuse.

EAS00739

2. Battery 8 Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C 8 Is the battery OK? YES NO 8 Clean the battery terminals. 8 Recharge or replace the battery.
EAS00740

Ignition checker 90890-06754 YM-34487 Pocket tester 90890-03132 YU-03112-C

3. Spark plug 8 Check the condition of the spark plug. 8 Check the spark plug type. 8 Measure the spark plug gap. Refer to CHECKING THE SPARK PLUG in chapter 3. Standard spark plug CR7E (NGK) Spark plug gap 0.7 ~ 0.8 mm(0.028 ~ 0.032 in) 8 Is the spark plug in good condition, is it of the correct type, and is its gap within specification? YES NO Re-gap or replace the spark plug.

8-10

IGNITION SYSTEM
EAS00742 EAS00744

ELEC

4. Ignition spark gap 8 Disconnect the spark plug cap from the spark plug. 8 Connect the ignition checker 1 as shown. 2 Spark plug cap 8 Set the main switch to ON. 8 Measure the ignition spark gap a. 8 Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.

5. Spark plug cap resistance 8 Remove the spark plug cap from the spark plug lead. 8 Connect the pocket tester ( 1k range) to the spark plug cap as shown. 8 Measure the spark plug cap resistance.

1k

Spark plug cap resistance 4~6 k at 20C 8Is the spark plug cap OK? YES Minimum ignition spark gap 6 mm(0.24 in) 8 Is there a spark and is the spark gap within specification? NO YES
EAS00746

NO

Replace the spark plug cap.

The ignition system is OK.

6. Ignition coil resistance 8 Disconnect the ignition coil connectors from the ignition coil terminals. 8 Connect the pocket tester ( 1) to the ignition coil as shown. Positive tester probe orange Negative tester probe black

8-11

IGNITION SYSTEM
EAS00748

ELEC

7. Pickup coil resistance 8 Disconnect the pickup coil coupler from the wire harness. 8 Connect the pocket tester ( 100) to the pickup coil terminal as shown. Positive tester probe Negative tester probe 8 Measure the primary coil resistance. Primary coil resistance 0.168 ~ 0.252 at 20C 8 Connect the pocket tester ( 1k) to the ignition coil as shown. Negative tester probe 2 Positive tester probe 1
2
W/R W/L

white/red 1 white/blue2 2
1

spark plug lead spark plug lead

8 Measure the pickup coil resistance. Pickup coil resistance 248 ~ 372 at 20C (between white/red and white/ blue) 8 Is the pickup coil OK? YES NO Replace the pickup coil.
EAS00749

8 Measure the secondary coil resistance. Secondary coil resistance 2.4 ~ 3.6 k at 20C 8 Is the ignition coil OK?

8. Main switch 8 Check the main switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the main switch OK? YES NO

YES

NO Replace the main switch.

Replace the ignition coil.

8-12

IGNITION SYSTEM
EAS00750

ELEC

9. Engine stop switch 8 Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the engine stop switch OK? YES NO

Replace the right handlebar switch.

EAS00754

[Link] 8 Check the entire ignition systems wiring. Refer to CIRCUIT DIAGRAM. 8 Is the ignition systems wiring properly connected and without defects? YES Replace the C.D.I. unit. NO Properly connect or repair the ignition systems wiring.

8-13

EAS00755

MAIN SW. WR WL YR W
Or WL WR WL YR

1 YR W WR WL (RED) 8 BL B WL Or
Or B

GW L LY YR YL GR Br

Br (RED)
W YR

OFF CHECK ON

R 2

W B R YR (GREEN)

YR

Br

c
BL LY GR B YL GW L Br

R YB R YR 9
YR BL

CIRCUIT DIAGRAM

b L BL YL
YL L

R GY

R LW

R LW YR

R GY

4 7 B R (RED) (GRAY)
BL B

ELECTRIC STARTING SYSTEM

7.5A
R YR GR

GY

LW

t 0
L

v YR B GR BL (RED)

LW

STARTER SW. e

OFF START

LW LY B
B

LW LY B B R

LW L GY YR GB Y

[Link] SW.

OFF RUN

LY B Br Br Br Br

ELECTRIC STARTING SYSTEM

8-14
y o
B BrW P

Br

B BrW Br (BLACK)
L

q B B B B Br GY (BLACK) (BLACK) Y Y G G (RED) (RED)

GY GY

w Br GY (BLACK) (BLACK)

Y P

Ch

Dg

s u HORN DIMMER FLASHER a i

Br GW G B

GW Br B G

HI BEAM

ILLUMI

TURN R

TEMP

TURN L

ILLUMI

1 4 5 6 7 q w e r

FUEL
OFF PUSH HI LO L N R

L Dg Y Ch
B GY Ch Dg

Dg L Ch Y

L Ch P BrW B Dg

Ch L BrW P Dg B

(BLACK)

(BLACK)

GW

Ch

GY

Dg

G Ch GY Dg

12V21W/5W

G B k

L GY B Dg Ch

GY L B Ch Dg

12V35W/35W

Ch Y Dg B G Y Ch B Dg G (RED)
B B

(RED)

ELEC

z ;

x
12V10W 12V10W

Main switch Battery Main fuse Starter relay Starter motor Front brake light switch Rear brake light switch Start switch Engine stop switch
12V10W 12V10W

MARK

Explanation

Connecting with GND. Wire GND.

ELECTRIC STARTING SYSTEM

EAS00756

ELEC

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to ON (switch is closed), the starter motor can only operate if at least one of the following conditions is met: 8 The brake lever ( front or rear) is pulled to the handlebar (the brake light switch is closed).

8 1 2 7 3 6

1 2 3 4 5 6 7 8 9

Battery Main fuse Main switch Front brake light switch Rear brake light switch Engine stop switch Start switch Starter relay Starter motor

8-15

ELECTRIC STARTING SYSTEM

EAS00757 EAS00738

ELEC

TROUBLESHOOTING The starter motor fails to turn. Check: 1. mainfuse 2. battery 3. starter motor 4 starter relay 5 main switch 6 brake light switch (front, rear) 7 engine stop switch 8 start switch 9 wiring connections (of the entire starting system) NOTE: 8 Before troubleshooting, remove the following part(s): 1. Seat/Trunk/Rear carrier 2. Mat/Front cover 3. Side cover(left and right)/Rear cover 4. Battery cover/Battery holder 5. Footrest board side cover mole(right,left ) 6. Footrest board 7. Head light cover/Leg shield 1 8. Air filter assembly 8 Troubleshoot with the following special tool(s).

1. Main fuse 8 Check the fuse for continuity. Refer to CHECKING THE FUSE in chapter 3. 8 Is the fuse OK? YES NO

Replace the fuse.

EAS00739

2. Battery 8 Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C 8 Is the battery OK? YES NO

Pocket tester 90890-03132 (YU-03112-C)

8 Clean the battery terminals. 8 Recharge or replace the battery.

8-16

ELECTRIC STARTING SYSTEM

EAS00758 EAS00761

ELEC

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

4. Starter relay 8 Disconnect the starter relay coupler from the coupler. 8 Connect the pocket tester ( 1) and battery (12 V) to the starter relay coupler as shown. Positive battery terminal green/yellow 1 Negative battery terminal blue/white 2 Positive tester probe red 3 Negative tester probe red 4

w
8 A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn. 8 This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity. 8 Does the starter motor turn? YES NO Repair or replace the starter motor.
EAS00749

2 1

8 Does the starter relay have continuity between red3 and red 4? YES NO Replace the starter relay.

5. Main switch 8 Check the main switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the main switch OK? YES NO Replace the main switch.

8-17

ELECTRIC STARTING SYSTEM

EAS00751

ELEC

6. Brake light switch(front and rear) 8 Check the brake light switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the brake light switch OK? YES NO Replace the brake light switch.
EAS00750

7. Engine stop switch 8 Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the engine stop switch OK? YES NO Replace the right handlebar switch.
EAS00764

8. Start switch 8 Check the start switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the start switch OK? YES NO

Replace the right handlebar switch.

EAS00766

9. Wiring 8 Check the entire starting systems wiring. Refer to CIRCUIT DIAGRAM. 8 Is the starting systems wiring properly connected and without defects?

YES The starting system circuit is OK.

NO Properly connect or repair the star ting systems wiring.

8-18

ELECTRIC STARTING SYSTEM

EAS00767

ELEC

STARTER MOTOR
1 2

3 4 5 6

2 1

Order

Job/Part Removing the starter motor Seat/Trunk Front cover Battery cover Air filter assembly

Qty

Remarks Remove the parts in the order listed. Refer to COVER AND PANELin chapter 3. Refer toMANIFOLD, AIR FILTER AND MUFFLER ASSEMBLYin chapter 5. Disconnect. For installation, reverse the removal procedure. Disassemble the parts in the order listed.

1 2

Starter motor lead Starter motor

1 1

1 2 3 4 5 6 7

Disassembling the starter motor O-ring Gasket Stator assembly O-ring Armature coil Brush Plate washer

1 1 1 1 1 2 1 For assembly, reverse the disassembly procedure.

8-19

ELECTRIC STARTING SYSTEM

EAS00769

ELEC

CHECKING THE STARTER MOTOR 1. Check: 8 commutator Dirt Clean with 600-grit sandpaper. 2. Measure: 8 commutator diameter a Out of specification Replace the starter motor. Commutator wear limit 16.6 mm (0.654 in) 3. Measure: 8 mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 1.35 mm (0.053 in) NOTE: The mica of the commutator must be undercut to ensure proper operation of the commutator.

4. Measure: 8 armature assembly resistances (commutator and insulation) Out of specification Replace the starter motor. ***************************************************** a. Measure the armature assembly resistances with the pocket tester. Pocket tester 90890-03132 (YU-03112-C)

Armature coil Commutator resistance 1 0.0378 ~ 0.0462 at 20C Insulation resistance 2 Above 1 M at 20C b. If any resistance is out of specification, replace the starter motor. 8-20 *****************************************************

ELECTRIC STARTING SYSTEM

ELEC

5. Measure: 8 brush length a Out of specification brushes as a set.

Replace the

Brush length wear limit 3.5 mm (0.14 in)

a

6. Measure: 8 brush spring force Out of specification springs as a set.

Replace the brush

Brush spring force 3.92 ~ 5.88 N 7. Check: 8 gear teeth Damage/wear 8. Check: 8 bearing1 8 oil seal2 8 bush3 Damage/wear

Replace the gear.

Replace.

8-21

ELECTRIC STARTING SYSTEM

EAS00772

ELEC

ASSEMBLING THE STARTER MOTOR 1. Install: 8 brush seat 1

3 2 1

2. Install: 8 washer1 8 armature coil 2 8 o-ing New 3 8 stator assembly4

a b

3 . Install: 8 bolts 1 5 Nm (0.5 m kg, 3.6 ft lb)

T.

R.

NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers.

8-22

EAS00773

MAIN SW. WR WL YR W
Or WL WR WL YR

1 YR W WR WL (RED) 8 BL B WL Or
Or B

GW L LY YR YL GR Br

Br (RED)
W YR

OFF CHECK ON

R 2

W B R YR (GREEN)

YR

Br

c
BL LY GR B YL GW L Br

R YB R YR 9
YR BL

CIRCUIT DIAGRAM

b L BL YL
YL L

R GY

R LW

CHARGING SYSTEM

R LW YR

R GY

4 7 B R (RED) (GRAY)
BL B

7.5A
R YR GR

GY

LW

t 0
L

v YR B GR BL (RED)

LW

STARTER SW. e

OFF START

LW LY B
B

LW LY B B R

LW L GY YR GB Y

[Link] SW.

OFF RUN

8-23
Br Br Br

LY B Br

q o
B BrW

y
P

Br

B BrW Br (BLACK)
L

Y P

Ch

Dg

B B

Br GY (BLACK) (BLACK)

B B

Br GY (BLACK) (BLACK)
GY GY

s u HORN DIMMER FLASHER Y Y G G (RED) (RED) L Ch P BrW B Dg

Ch Dg

d a i

Br GW G B

GW Br B G

HI BEAM

ILLUMI

TURN R

TEMP
OFF PUSH HI LO L N R

TURN L

ILLUMI

FUEL

L Dg Y Ch
B GY

Dg L Ch Y

Ch L BrW P Dg B

2 3 4 5

(BLACK)

(BLACK)

GW

Ch

GY

Dg

G Ch GY Dg

CHARGING SYSTEM

12V21W/5W

G B k

L GY B Dg Ch

GY L B Ch Dg

12V35W/35W

Ch Y Dg B G Y Ch B Dg G (RED)
B B

(RED)

B B

ELEC

Stator coil Rectifier/regulator Battery Main fuse

z ;
12V10W

x
12V10W 12V10W

l
12V10W

MARK

Explanation

Connecting with GND. Wire GND.

CHARGING SYSTEM
EAS00774 EAS00739

ELEC

TROUBLESHOOTING The battery is not being charged. Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil resistance 5. wiring connections (of the entire charging system) NOTE: 8 Before troubleshooting, remove the following part(s): 1. Seat/Trunk 2. Battery cover 3. Head light cover 4. Leg shield 1 8 Troubleshoot with the following special tool(s).

2. Battery 8Check 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 20C 8Is the battery OK? YES NO 8Clean the battery terminals. 8Recharge or replace the battery.
EAS00775

Engine tachometer 90890-03113 (YU-08036-C) Pocket tester 90890-03132 (YU-03112-C)

3. Charging voltage 8Connect the engine tachometer to the spark plug lead of cylinder. 8Connect the pocket tester (DC 20 V) to the battery as shown. Positive tester probe positive battery terminal Negative tester probe negative battery terminal

EAS00738

1. Main fuse 8Check the fuse for continuity. Refer to CHECKING THE FUSE in chapter 3. 8Is the fuse OK? YES NO Replace the fuse.

8Start the engine and let it run at approximately 5,000 r/min. 8Measure the charging voltage. Charging voltage 14 V at 5000r/min

8-24

CHARGING SYSTEM
NOTE: Make sure the battery is fully charged. 8Is the charging voltage within specification? NO YES The charging circuit is OK.
EAS00776 EAS00754

ELEC

5. Wiring 8Check the entire charging systems wiring. Refer to CIRCUIT DIAGRAM. 8Is the charging systems wiring properly connected and without defects? YES Replace the rectifier/regulator. NO Properly connect or repair the charging systems wiring.

4. Stator coil resistance 8 Remove the starter coil couplers from wireharness. 8Connect the pocket tester ( 1) to the stator coils as shown. Positive tester probe white 1 Negative tester probe ground 2

Y/R W 1

8 Measure the stator coil resistances. Stator coil resistance 0.288 ~ 0.432 at 20C (between white and ground) 8 Is the stator coil OK? YES NO Replace the stator coil assembly.

8-25

EAS00780

MAIN SW. WR WL YR W
Or WL WR WL YR

1 YR W WR WL (RED) 8 BL B WL Or
Or B

GW L LY YR YL GR Br

Br (RED)
W YR

OFF CHECK ON

R 2

W B R YR (GREEN)

YR

Br

c
BL LY GR B YL GW L Br

R YB R YR 9
YR BL

CIRCUIT DIAGRAM

b L BL YL
YL L

R GY

R LW

LIGHTING SYSTEM

R LW YR

R GY

4 7 B R (RED) (GRAY)
BL B

7.5A
R YR GR

GY

LW

t 0
L

v YR B GR BL (RED)

LW

STARTER SW. e

OFF START

LW LY B
B

LW LY B B R

LW L GY YR GB Y

[Link] SW.

OFF RUN

LY B Br Br Br Br

8-26
y o
B BrW P

Br

B BrW Br (BLACK)
L

q B B B B Br GY (BLACK) (BLACK) Y Y G G (RED) (RED) L Ch P BrW B Dg

Ch Dg Ch L GY Dg GY GY

w Br GY (BLACK) (BLACK)

Y P

Ch

Dg

s u HORN DIMMER FLASHER a i

Br GW G B

GW Br B G

HI BEAM

ILLUMI

TURN R

TEMP
OFF PUSH HI LO L N R

TURN L

ILLUMI

FUEL

1 2 4 5 t a d f k

L Dg Y Ch
B GY

Dg L Ch Y

Ch L BrW P Dg B

(BLACK)

(BLACK)

GW

G Ch GY Dg

LIGHTING SYSTEM

12V21W/5W

G B k

L GY B Dg Ch

GY L B Ch Dg

12V35W/35W

Ch Y Dg B G Y Ch B Dg G (RED)
B B

(RED)

B B

ELEC

z ;
12V10W

x
12V10W 12V10W

l
12V10W

MARK

Explanation

Connecting with GND. Wire

Main switch Lighting coil Battery Main fuse Headlight relay Dimmer switch Speedometer light High beam indicator light Headlight
GND.

LIGHTING SYSTEM
EAS00781 EAS00739

ELEC

TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light or meter light. Check: 1. main fuse 2. battery 3. lighting coil resistance. 4. main switch 5. dimmer switch 6. headlight relay 7. wiring connections (of the entire lighting system) NOTE: 8Before troubleshooting, remove the following part(s): 1. Seat/Trunk 2. Battery cover 3. Head light cover 4. Leg shield 1 8Troubleshoot with the following special tool(s).

2. Battery 8 Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C 8Is the battery OK? ` YES NO 8Clean the battery terminals. 8Recharge or replace the battery.

EAS00748

Pocket tester 90890-03132 (YU-03112-C)

3. Lighting coil resistance 8 Disconnect the lighting coil coupler from the wire harness. 8 Connect the pocket tester ( 1) to the lighting coil terminal as shown. Positive tester probe yellow/red 1 Negative tester probe ground
1 Y/R

EAS00738

1. Main fuse 8Check the fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. 8Is the fuse OK? YES NO Replace the fuse.

8 Measure the lighting coil resistance. Lighting coil resistance 0.256 ~ 0.384 at 20C (between yellow/red and ground) 8 Is the lighting coil OK? YES NO Replace the lighting coil.

8-27

LIGHTING SYSTEM
EAS00749 EAS00787

ELEC

4. Main switch 8 Check the main switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the main switch OK? YES NO Replace the main switch.
EAS00784

7. Wiring 8 Check the entire lighting systems wiring. Refer to CIRCUIT DIAGRAM. 8 Is the lighting systems wiring properly connected and without defects? YES Check the condition of each of the lighting systems circuits. Refer to CIRCUIT DIAGRAM. NO Properly connect or repair the lighting systems wiring.

5. Dimmer switch 8 Check the dimmer switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the dimmer switch OK? YES NO The dimmer switch is faulty. Replace the left handlebar switch.

6. Headlight relay 8 Disconnect the headlight relay coupler from the wire harness. 8 Connect the pocket tester ( 1) and battery (12 V) to the headlight relay coupler as shown. Positive battery terminal green/yellow 1 Negative battery terminal blue/white 2 Positive tester probe yellow/red 3 Negative tester probe blue 4

2
L/W G/Y L Y/R

8 Does the starting headlight relay have continuity between blue and yellow/red? YES NO Replace the headlight relay.

8-28

LIGHTING SYSTEM
EAS00788

ELEC

CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb and socket 8 Check the headlight bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Are the headlight bulb and socket OK? YES NO Replace the headlight bulb, socket or both.

3. Voltage 8 Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown. When the dimmer switch is set to % When the dimmer switch is set to & Headlight coupler (wire harness side) Headlight Positive tester probe green 1 Negative tester probe black 2 Positive tester probe yellow 3 Negative tester probe black 4

1 G Y B

3 Y

4 B

2. High beam indicator light bulb and socket 8 Check the high beam indicator light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Are the high beam indicator light bulb and socket OK? YES NO Replace the high beam indicator light bulb , socket or both.

High beam indicator light Positive tester probe yellow 1 Negative tester probe black 2

Br G/W G B 2

G/W Br

B G

8 Set the main switch to ON. 8 Start the engine. 8 Set the dimmer switch to % or &. 8 Measure the voltage (DC 12 V) on the headlight coupler (wire harness side). 8 Measure the voltage (DC 12 V) on the dimmer switch coupler (wire harness side) when the dimmer switch is set to &. 8 Is the voltage within specification?

8-29

LIGHTING SYSTEM
YES NO
EAS00789

ELEC

This circuit is OK. The wiring circuit from the main switch to the headlight and hight beam indicator light coupler are faulty and must be repaired.

2. The meter light fails to come on. 1. Meter light bulb and socket 8 Check the meter light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Are the meter light bulb and socket OK? YES NO Replace the meter light bulb, socket or both. 2. Voltage 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. Positive tester probe brown 1 Negative tester probe black 2

1 Br G/W G B 2

8Set the main switch to ON. 8Measure the voltage (DC 12 V) of brown 1 on the meter light coupler (wire harness side). 8Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired. Refer to CIRCUIT DIAGRAM.

8-30

LIGHTING SYSTEM
EAS00754

ELEC

4. Wiring 8 Check the entire lighting systems wiring. Refer to CIRCUIT DIAGRAM. 8 Is the lighting systems wiring properly connected and without defects? YES Check the condition of each of the lighting systems circuits. Refer to CIRCUIT DIAGRAM. NO Properly connect or repair the lighting systems wiring.

8-31

EAS00793

MAIN SW.

GW L LY YR YL GR Br

1 4 5 q w y u i o p g h j l ; z x

Br (RED)
W YR Or WL WR WL YR

OFF CHECK ON

R 2 BL B WL Or
Or

W B R YR (GREEN) 8

WR WL YR W WR WL (RED)

YR W

YR

Br B

c
BL LY YL GW GR B L Br

R YB R YR 9
YR BL

CIRCUIT DIAGRAM

b L BL YL
YL L

R GY

R LW

SIGNALING SYSTEM

R LW YR

R GY

Main switch Battery Main fuse Front brake light switch Rear brake light switch Horn Horn switch Turn signal switch Turn signal relay Tail/brake light Left turn signal indicator light Right turn signal indicator light Fuel sender Front turn signal light(left) Front turn signal light(right) Rear turn signal light(left) Rear turn signal light(right)

4 7 B R (RED) (GRAY)
BL B

7.5A
R YR GR

GY

LW

t 0
L

v YR B GR BL (RED)

LW

STARTER SW. e

OFF START

LW LY B
B

LW LY B B R

LW L GY YR GB Y

[Link] SW.

OFF RUN

8-32
Br Br Br

LY B Br

q o
B BrW

y
P

Br

B BrW Br (BLACK)
L

Y P

Ch

Dg

B B

Br GY (BLACK) (BLACK)

B B

Br GY (BLACK) (BLACK)
GY GY

s u HORN DIMMER FLASHER Y Y G G (RED) (RED) L Ch P BrW B Dg

Ch Dg

d a i

Br GW G B

GW Br B G

HI BEAM

ILLUMI

TURN R

TEMP
OFF PUSH HI LO L N R

TURN L

ILLUMI

FUEL

L Dg Y Ch
B GY

Dg L Ch Y

Ch L BrW P Dg B

(BLACK)

(BLACK)

GW

Ch

GY

Dg

G Ch GY Dg

SIGNALING SYSTEM

12V21W/5W

G B k

L GY B Dg Ch

GY L B Ch Dg

12V35W/35W

Ch Y Dg B G Y Ch B Dg G (RED)
B B

(RED)

B B

ELEC

z ;
12V10W

x
12V10W 12V10W

l
12V10W

MARK

Explanation

Connecting with GND. Wire GND.

SIGNALING SYSTEM
EAS00794 EAS00739

ELEC

TROUBLESHOOTING 8 Any of the following fail to light: turn signal light, brake light or an indicator light. 8 The horn fails to sound. Check: 1. main fuse 2. battery 3. main switch 4. wiring connections (of the entire signaling system) NOTE: 8 Before troubleshooting, remove the following part(s): 1. Head light cover/Leg shield 1 2. Battery cover 3. Seat/Trunk 4. Rear carrier 5. Front cover 6. Side cover (left and right)/Rear cover 8 Troubleshoot with the following special tool(s).

2. Battery 8 Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C 8 Is the battery OK? YES NO 8Clean the battery terminals. 8 Recharge or replace the battery.
EAS00749

3. Main switch 8 Check the main switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the main switch OK? YES NO Replace the main switch.

Pocket tester 90890-03132 (YU-03112-C)

EAS00738

EAS00795

1. Main fuse 8 Check the main fuse for continuity. Refer to CHECKING THE FUSE in chapter 3. 8 Is the fuse OK? YES NO Replace the fuse.

4. Wiring 8 Check the entire signal systems wiring. Refer to CIRCUIT DIAGRAM. 8 Is the signaling systems wiring properly connected and without defects? YES Check the condition of each of the signaling systems circuits. Refer to CHECKING THE SIGNALING SYSTEM. NO Properly connect or repair the signaling systems wiring.

8-33

SIGNALING SYSTEM
EAS00796

ELEC

CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound.

1. Horn switch 8 Check the horn switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the horn switch OK? YES NO Replace the left handlebar switch.

3. Horn 8 Disconnect the pink connector at the horn terminal. 8 Connect a jumper lead 1 to the horn terminal and ground the jumper lead. 8 Set the main switch to ON. 8 Push the horn switch. 8 Does the horn sound?
Br P

2. Voltage 8 Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown. Positive tester probe brown 1 Negative tester probe ground
1
Br P

NO

YES The horn is OK.

4. Voltage 8 Connect the pocket tester (DC 20 V) to the horn connector at the pink terminal as shown. Positive tester probe pink 1 Negative tester probe ground
Br P

8 Set the main switch to ON. 8 Push the horn switch. 8 Measure the voltage (DC 12 V) of brown at the horn terminal. 8 Is the voltage within specification? YES NO The wiring circuit from the main switch to the horn connector is faulty and must be repaired. Refer to CIRCUIT DIAGRAM.

8 Set the main switch to ON. 8 Measure the voltage (DC 12 V) of pink 1 at the horn terminal. 8 Is the voltage within specification? YES Repair or replace the horn. NO Replace the horn.

8-34

SIGNALING SYSTEM
EAS00798

ELEC

2.

The tail/brake light fails to come on.

1. Tail/brake light bulb and socket 8 Check the tail/brake light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Are the tail/brake light bulb and socket OK? YES NO Replace the tail/brake light bulb, socket or both. 2. Brake light switches 8 Check the brake light switches for continuity. Refer to CHECKING THE SWITCHES. 8 Is the brake light switch OK? YES The wiring circuit from the main switch to the tail/brake light bulb connector is faulty and must be repaired. Refer to CIRCUIT DIAGRAM. NO Replace the brake light switch.

3. Voltage 8 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
1
L Dg G/Y 2 B Ch G/Y L B Ch Dg

8 Set the main switch to ON. 8 Pull in the brake levers. 8 Measure the voltage (DC 12 V) of green/ yellow 1 on the tail/brake light coupler (wire harness side). 8 Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired. Refer to CIRCUIT DIAGRAM.

8-35

SIGNALING SYSTEM
EAS00799

ELEC

3. The turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal light and turn signal indicator light bulbs and sockets 8 Check the turn signal light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Check the turn signal indicator light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Are the turn signal light bulb and socket OK? YES NO Replace the turn signal light and/or turn signal indicator light bulb, socket or both. 2. Turn signal switch 8 Check the turn signal switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the turn signal switch OK? YES NO Replace the left handlebar switch.

3. Voltage 8 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

B Br/W Br

8 Set the main switch to ON. 8 Measure the voltage (DC 12 V) on brown 1 at the turn signal relay coupler (wire harness side). 8 Is the voltage within specification? YES NO The wiring circuit from the main switch to the turn signal relay coupler is faultyand must be repaired. Refer to CIRCUIT DIAGRAM.

8-36

SIGNALING SYSTEM
4. Voltage 8Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe brown/white 1 Negative tester probe ground

ELEC

B Br/W Br

5. Voltage 8Connect the pocket tester (DC 20 V) to the turn signal light connector or meter assembly coupler (wire harness side) as shown. A Front turn signal light B Rear turn signal light C Turn signal indicator light Left turn signal light Positive tester probe chocolate 1 Negative tester probe ground Right turn signal light Positive tester probe dark green 2 Negative tester probe ground A B
Ch Dg Ch B Dg Dg Ch B
G/Y

8Set the main switch to ON. 8Set the turn signal switch to 4 or 6. 8Measure the voltage (DC 12 V) on brown/ white 1 at the turn signal relay coupler (wire harness side). 8Is the voltage within specification? YES NO The turn signal relay is faulty and must be replaced. C

L L
G/Y

2
Dg Ch L Y L Y Dg Ch

8Set the main switch to ON. 8Set the turn signal switch to 4 or 6. 8Measure the voltage (DC 12 V) of the chocolate 1 or dark green 2 at the turn signal light connector (wire harness side). 8Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.

8-37

SIGNALING SYSTEM
EAS00804

ELEC

4. The fuel level meter fails to operate. 1. Fuel sender 8 Remove the fuel sender from the fuel tank. 8 Connect the pocket tester ( 1) to the fuel sender coupler (wire harness side) as shown. Positive tester probe green 1 Negative tester probe black 2

2. Voltage 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. Positive tester probe brown 1 Negative tester probe black 2
1
Br G G/W B

(F) G B

(E)

8 Measure the fuel sender resistances. Fuel sender resistance (up position F)( 1) 6~8 at 20C Fuel sender resistance (down position E)( 10) 93.5~96.5 at 20C 8Is the fuel sender OK? YES NO Replace the fuel sender.

8 Set the main switch to ON. 8 Measure the voltage (DC 12 V) of brown 1 on the meter light coupler (wire harness side). 8 Is the voltage within specification? YES NO Check the wiring connections of the entire signaling system. Refer to CIRCUIT DIAGRAM.

8-38

SIGNALING SYSTEM
3. Fuel level meter 8 Set the main switch to ON. 8 Move the float up 1 or down 2.

ELEC

8 Check that the fuel level meter needle moves to F or E. NOTE: Before reading the fuel level meter, leave the float in one position (either up or down) for at least three minutes. 8 Does the fuel level meter needle move appropriately? YES NO

This circuit is OK.

Replace the speedo meter.

4.

Wiring 8 Check the entire signaling systems wiring

8-39

EAS00807

MAIN SW. WR WL YR W
Or WL WR WL YR

1 YR W WR WL (RED) 8 BL B WL Or
Or B

GW L LY YR YL GR Br

Br (RED)
W YR

OFF CHECK ON

R 2

W B R YR (GREEN)

YR

Br

c
BL LY GR B YL GW L Br

R YB R YR 9
YR BL

CIRCUIT DIAGRAM

b L BL YL
YL L

R GY

R LW

COOLING SYSTEM

R LW YR

R GY

4 7 B R (RED) (GRAY)
BL B

7.5A
R YR GR

GY

LW

t 0
L

v YR B GR BL (RED)

LW

STARTER SW. e

OFF START

LW LY B
B

LW LY B B R

LW L GY YR GB Y

[Link] SW.

OFF RUN

LY B Br Br Br Br

8-40
y o
B BrW P

Br

B BrW Br (BLACK)
L

q B B B B Br GY (BLACK) (BLACK)

w Br GY (BLACK) (BLACK)

Y P

Ch

Dg

s u HORN DIMMER FLASHER Y Y G G (RED) (RED) L Ch P BrW B Dg

Ch Dg

d a i

Br GW G B

GW Br B G

1 4 5 8 s
GY

GY

HI BEAM

ILLUMI

TURN R

TEMP
OFF PUSH HI LO L N R

TURN L

ILLUMI

FUEL

L Dg Y Ch
B GY

Dg L Ch Y

Ch L BrW P Dg B

(BLACK)

(BLACK)

GW

Ch

GY

Dg

G Ch GY Dg

COOLING SYSTEM

12V21W/5W

G B k

L GY B Dg Ch

GY L B Ch Dg

12V35W/35W

Ch Y Dg B G Y Ch B Dg G (RED)
B B

(RED)

ELEC

z ;
12V10W

Main switch Battery Main fuse C.D.I. unit Water temperature indicator light c Thermo switch v Thermo unit

12V10W

12V10W

l
12V10W

MARK

Explanation Connecting with GND. Wire GND.

COOLING SYSTEM
EAS00808 EAS00739

ELEC

TROUBLESHOOTING The cooling system fails to operate. Check: 1. main fuse 2. battery 3. main switch 4. thermo switch 5. water temperature indicator light 6. wiring connections (the entire cooling system) NOTE: 8 Before troubleshooting, remove the following part(s): 1. Seat/Trunk 2. Battery cover 3. Front cover 4. Head light cover 5. Leg shield 1 6. Drain the coolant 8 Troubleshoot with the following special tool(s).

2. Battery 8 Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C 8 Is the battery OK? YES NO 8Clean the battery terminals. 8Recharge or replace the battery.

EAS00749

3. Main switch 8 Check the main switch for continuity. Refer to CHECKING THE SWITCHES. 8 Is the main switch OK? YES NO Replace the main switch.

Pocket tester 90890-03132(YU-03112-C)

EAS00738

1. Main fuse 8Check the fuse for continuity. Refer to CHECKING THE FUSE in chapter 3. 8Is the fuse OK? YES NO Replace the fuse.

8-41

COOLING SYSTEM
EAS00811

ELEC

4. Thermo switch 8 Remove the thermo switch from the thermostat housing. 8 Connect the pocket tester ( 1) to the thermo switch 1 as shown. 8 Immerse the thermo switch in a container filled with coolant2. 8 Place a thermometer3 in the coolant. 8 Slowly heat the coolant, then let it cool down to the specified temperature. 8 Check the thermo switch for continuity at the temperatures indicated below. Test step Coolant temperature Continuity Thermo switch 1 0 ~56 C NO 2 More than65 2 C YES 3* 65 2C to 56C YES 4* Less than56 C NO Steps 1 & 2: Heating phase Steps 3 & 4: Cooling phase

A Cooling phase B Heating phase

8 Does the thermo switch operate properly as described above? YES NO

Replace the thermo switch.

3 1

w
8 Handle the thermo switch with special care. 8 Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it.

Thermo switch 23 Nm (2.3 m kg, 16.6 ft lb) Three bond sealock10

T.

R.

8-42

COOLING SYSTEM
EAS00812

ELEC

5. The water temperature indicator light fails to operate. 1. Thermo unit 8 Remove the thermo unit from the cylinder head. 8 Connect the pocket tester ( 1k) to the thermo unit as shown. Positive tester probe black/blue 1 Negative tester probe green/red2 2

2. Voltage 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. Positive tester probe green/red 1 Negative tester probe ground

DC20V

G/R B/L

8 Measure the thermo unit resistance. Thermo unit resistance 3.413~4.007k at 80 C 1.645~1.855k at 100 C 8 Is the thermo unit OK? YES NO

8 Set the main switch to ON. 8 Measure the voltage (DC 12 V) of green/ red 1 on the meter light coupler (wire harness side). 8 Is the voltage within specification? YES NO The wiring circuit from the main switch to the thermo unit connector is faulty and must be repaired.

Replace the thermo unit.

8-43

COOLING SYSTEM
3. Water temperature indicator light 8 Remove the thermo unit coupler . 8 Set the main switch to ON. 8 Connect the green/red1 and black/ blue2 with a jumper lead3.

ELEC

G/R B/L

2 3

8 Is the water temperature indicator light OK? YES This circuit is OK. NO Replace the water temperature indicator light

EAS00813

6. Wiring 8 Check the entire cooling systems wiring. Refer to CIRCUIT DIAGRAM. 8 Is the cooling systems wiring properly connected and without defects? YES NO

Replace the C.D.I. unit.

Properly connect or repair the cooling systems wiring.

8-44

MAIN SW. WR WL YR W
Or WL WR WL YR

1 YR W WR WL (RED) 8 BL B WL Or
Or B

GW L LY YR YL GR Br

Br (RED)
W YR

OFF CHECK ON

R 2

W B R YR (GREEN)

YR

Br

c
BL LY GR B YL GW L Br

R YB R YR 9
YR BL

CIRCUIT DIAGRAM

b L BL YL
YL L

R GY

R LW

R LW YR

R GY

AUTO CHOKE SYSTEM

4 7 B R (RED) (GRAY)
BL B

7.5A
R YR GR

GY

LW

t 0
L

v YR B GR BL (RED)

LW

STARTER SW. e

OFF START

LW LY B
B

LW LY B B R

LW L GY YR GB Y

[Link] SW.

OFF RUN

AUTO CHOKE SYSTEM

8-45
Br Br Br

LY B Br

q o
B BrW

y
P

Br

B BrW Br (BLACK)
L

Y P

Ch

Dg

B B

Br GY (BLACK) (BLACK)

B B

Br GY (BLACK) (BLACK)
GY GY

s u HORN DIMMER FLASHER Y Y G G (RED) (RED) L Ch P BrW B Dg

Ch Dg

d a i

Br GW G B

GW Br B G

HI BEAM

ILLUMI

TURN R

TEMP
OFF PUSH HI LO L N R

TURN L

ILLUMI

FUEL

4 5 8 0 c

L Dg Y Ch
B GY

Dg L Ch Y

Ch L BrW P Dg B

(BLACK)

(BLACK)

GW

Ch

GY

Dg

G Ch GY Dg

12V21W/5W

G B k

L GY B Dg Ch

GY L B Ch Dg

12V35W/35W

Ch Y Dg B G Y Ch B Dg G (RED)
B B

(RED)

Battery Main fuse C.D.I. unit Auto choke unit Thermo switch

B B

ELEC

z ;
12V10W

x
12V10W 12V10W

l
12V10W

MARK

Explanation

Connecting with GND. Wire GND.

AUTO CHOKE SYSTEM

EAS00821 EAS00739

ELEC

TROUBLESHOOTING The auto choke system fails to operate. Check: 1. main fuse 2. battery 3. thermo switch 4. auto choke unit 5. wiring connections (of the entire autochoke system) NOTE: 8 Before troubleshooting, remove the following part(s): 1. Seat/Trunk 2. Battery cover 3. Front cover 8 Troubleshoot with the following special tool(s).

2. Battery 8 Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C 8 Is the battery OK? YES NO

8Clean the battery terminals. 8Recharge or replace the battery.

Pocket tester 90890-03132(YU-03112-C)

EAS00738

1. Main fuse 8 Check the main fuse for continuity. Refer to CHECKING THE FUSE in chapter 3. 8 Is the fuse OK? YES NO

Replace the fuse.

8-46

AUTO CHOKE SYSTEM

EAS00811

ELEC

3. Thermo switch 8 Remove the thermo switch from the thermostat housing. 8 Connect the pocket tester ( 1) to the thermo switch 1 as shown. 8 Immerse the thermo switch in a container filled with coolant2. 8 Place a thermometer3 in the coolant. 8 Slowly heat the coolant, then let it cool down to the specified temperature. 8 Check the thermo switch for continuity at the temperatures indicated below. Test step Coolant temperature Continuity Thermo switch 1 0 ~56 C NO 2 More than65 2 C YES 3* 65 2C to 56C YES 4* Less than56 C NO Steps 1 & 2: Heating phase Steps 3 & 4: Cooling phase

A Cooling phase B Heating phase

8 Does the thermo switch operate properly as described above? YES NO

Replace the thermo switch.

3 1

w
8 Handle the thermo switch with special care. 8 Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it.

Thermo switch 23 Nm (2.3 m kg, 16.6 ft lb) Three bond sealock10

T.

R.

8-47

AUTO CHOKE SYSTEM

4. Auto choke unit 8 Disconnect the auto choke unit coupler from wire harness. 8 Connect the pocket tester( 1) to the Auto choke unit coupler as shown. Positive tester probe green/black 1 Negative tester probe yellow 2

ELEC

G/B Y

1 2

8Measure the auto choke unit resistance. Auto choke unit resistance 20 at 20C 8 Is the auto choke unit OK? YES NO Replace the auto choke unit.

5. Wiring 8 Check the entire auto choke systems wiring. Refer to CIRCUIT DIAGRAM. 8 Is the auto choke systems wiring properly connected and without defects? YES Replace the C.D.I. unit NO Properly connect or repair the auto choke systems wiring.

8-48

TRBL SHTG
CHAPTER 9 TROUBLE SHOOTING STARTING FAILURE/HARD STARTING................................................. 9-1 ENGINE .............................................................................................. 9-1 FUEL SYSTEM .................................................................................. 9-1 ELECTRICAL SYSTEMS .................................................................. 9-1 INCORRECT ENGINE IDLING SPEED ................................................... 9-2 ENGINE .............................................................................................. 9-2 FUEL SYSTEM .................................................................................. 9-2 ELECTRICAL SYSTEMS .................................................................. 9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 9-3 ENGINE .............................................................................................. 9-3 FUEL SYSTEM .................................................................................. 9-3 FAULTY CLUTCH ..................................................................................... 9-3 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE ............... 9-3 CLUTCH SLIPS ................................................................................. 9-3 POOR STARTING PERFORMANCE ................................................ 9-3 OVERHEATING......................................................................................... 9-4 ENGINE .............................................................................................. 9-4 COOLING SYSTEM........................................................................... 9-4 FUEL SYSTEM .................................................................................. 9-4 CHASSIS ............................................................................................ 9-4 ELECTRICAL SYSTEMS .................................................................. 9-4 OVERCOOLING........................................................................................ 9-4 COOLING SYSTEM........................................................................... 9-4 POOR BRAKING PERFORMANCE ........................................................ 9-5 FAULTY FRONT FORK LEGS ................................................................. 9-5 MALFUNCTION ................................................................................. 9-5 UNSTABLE HANDLING ........................................................................... 9-5 FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 9-6 HEADLIGHT DOES NOT COME ON ................................................ 9-6 HEADLIGHT BULB BURNT OUT ..................................................... 9-6 TAIL/BRAKE LIGHT DOES NOT COME ON .................................... 9-6 TAIL/BRAKE LIGHT BULB BURNT OUT ......................................... 9-6 TURN SIGNAL DOES NOT COME ON ............................................ 9-6 TURN SIGNAL BLINKS SLOWLY ..................................................... 9-6 TURN SIGNAL REMAINS LIT ........................................................... 9-6 TURN SIGNAL BLINKS QUICKLY .................................................... 9-6 HORN DOES NOT SOUND .............................................................. 9-6

9-7

STARTING FAILURE/HARD STARTING

EAS00845

TRBL SHTG

TROUBLESHOOTING
NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.

STARTING FAILURE / HARD STARTING

ENGINE Cylinder and cylinder head 8Loose spark plug 8Loose cylinder head or cylinder 8Damaged cylinder head gasket 8Damaged cylinder gasket 8Worn or damaged cylinder 8Incorrect valve clearance 8Improperly sealed valve 8Incorrect valve-to-valve-seat contact 8Incorrect valve timing 8Faulty valve spring 8Seized valve Piston and piston ring 8Improperly installed piston ring 8Damaged, worn or fatigued piston ring 8Seized piston ring 8Seized or damaged piston Air filter 8Improperly installed air filter 8Clogged air filter element Crankcase and crankshaft 8Improperly assembled crankcase 8Seized crankshaft FUEL SYSTEM Fuel tank 8Empty fuel tank 8Clogged fuel tank cap breather hole 8Deteriorated or contaminated fuel 8Clogged or damaged fuel hose Fuel cock 8Faulty fuel cock 8Damaged vacuum hose 8Improperly routed hose Carburetor 8Deteriorated or contaminated fuel 8Clogged slow jet 8Clogged pilot air passage 8Sucked-in air 8Damaged float 8Worn needle valve 8Improperly installed needle valve seat 8Incorrect fuel level 8Improperly installed slow jet 8Clogged starter jet Autochoke unit 8Faulty starter plunger 8Faulty [Link] 8Faulty thermo switch ELECTRICAL SYSTEMS Battery 8Discharged battery 8Faulty battery Fuse 8Blown, damaged or incorrect fuse 8Improperly installed fuse Spark plug 8Incorrect spark plug gap 8Incorrect spark plug heat range 8Fouled spark plug 8Worn or damaged electrode 8Worn or damaged insulator 8Faulty spark plug cap Ignition coil 8Cracked or broken ignition coil body 8Broken or shorted primary or secondary coils 8Faulty spark plug lead

9-1

STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING SPEED

Ignition system 8Faulty [Link] 8Faulty pickup coil 8Broken AC magneto rotor woodruff key
EAS00847

TRBL SHTG

INCORRECT ENGINE IDLING SPEED

ENGINE Cylinder and cylinder head 8Incorrect valve clearance 8Damaged valve train components Air filter 8Clogged air filter element FUEL SYSTEM Carburetor 8Faulty starter plunger 8Loose or clogged slow jet 8Loose or clogged slow air jet 8Damaged or loose carburetor joint 8Improperly synchronized carburetor 8Improperly adjusted engine idling speed (throttle stop screw) 8Improper throttle cable free play 8Flooded carburetor Autochoke unit 8Faulty starter plunger 8Faulty C.D.I. unit ELECTRICAL SYSTEMS Battery 8Discharged battery 8Faulty battery Spark plug 8Incorrect spark plug gap 8Incorrect spark plug heat range 8Fouled spark plug 8Worn or damaged electrode 8Worn or damaged insulator 8Faulty spark plug cap Ignition coil 8Faulty spark plug lead Ignition system 8Faulty C.D.I. unit 8Faulty pickup coil

Switches and wiring 8Faulty main switch 8Faulty engine stop switch 8Broken or shorted wiring 8Faulty front, rear or both brake light switches 8Faulty start switch 8Improperly grounded circuit 8Loose connections Starting system 8Faulty starter motor 8Faulty starter relay 8Faulty starter clutch

9-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY CLUTCH

EAS00849 EAS00853

TRBL SHTG

POOR MEDIUM-AND-HIGHSPEED PERFORMANCE

Refer to STARTING FAILURE/HARD STARTING. ENGINE Air filter 8Clogged air filter element Air intake system 8Bent, clogged or disconnected carburetor air vent hose 8Clogged or leaking air duct FUEL SYSTEM Carburetor 8Faulty diaphragm 8Incorrect fuel level 8Loose or clogged main jet 8Faulty accelerating pump Fuel cock 8Faulty fuel cock

FAULTY CLUTCH
ENGINE OPERATES BUT SCOOTER WILL NOT MOVE V-belt 8Bent, damaged or worn V-belt 8Slipping V-belt Primary pulley cam and primary pulley slider 8Damaged or worn primary pulley cam 8Damaged or worn primary pulley slider Clutch spring(s) 8Damaged clutch spring Transmission gears 8Damaged transmission gear CLUTCH SLIPS Clutch shoe springs 8Damaged, loose or worn clutch shoe spring Clutch shoes 8Damaged or worn clutch shoe Primary sliding sheave 8Seized primary sliding sheave POOR STARTING PERFORMANCE V-belt 8V-belt slips 8Oil or grease on the V-belt Primary sliding sheave 8Faulty operation 8Worn pin groove 8Worn pin Clutch shoes 8Bent, damaged or worn clutch shoe

9-3

FAULTY CLUTCH/OVERHEATING/OVERCOOLING
POOR SPEED PERFORMANCE V-belt 8Oil or grease on the V-belt Primary pulley weight(s) 8Faulty operation 8Worn primary pulley weight Primary fixed sheave 8Worn primary fixed sheave Primary sliding sheave 8Worn primary sliding sheave Secondary fixed sheave 8Worn secondary fixed sheave Secondary sliding sheave 8Worn secondary sliding sheave

TRBL SHTG

Hose(s) and pipe(s) 8Damaged hose 8Improperly connected hose 8Damaged pipe 8Improperly connected pipe FUEL SYSTEM Carburetor 8Incorrect main jet setting 8Incorrect fuel level 8Damaged or loose carburetor joint Air filter 8Clogged air filter element CHASSIS Brake(s) 8Dragging brake ELECTRICAL SYSTEMS Spark plug 8Incorrect spark plug gap 8Incorrect spark plug heat range Ignition system 8Faulty C.D.I. unit

EAS00855

OVERHEATING
ENGINE Clogged coolant passages 8Heavy carbon buildup Engine oil 8Incorrect oil level 8Incorrect oil viscosity 8Inferior oil quality COOLING SYSTEM Coolant 8Low coolant level Radiator 8Damaged or leaking radiator 8Faulty radiator cap 8Bent or damaged radiator fan Water pump 8Damaged or faulty water pump Thermostat 8Thermostat stays closed Oil cooler 8Clogged or damaged oil cooler

EAS00856

OVERCOOLING
COOLING SYSTEM Thermostat 8Thermostat stays open

9-4

POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING

EAS00859 EAS00862

TRBL SHTG

POOR BRAKING PERFORMANCE

Drum brake 8Worn brake shoe 8Worn or rusty brake drum 8Incorrect brake lever position 8Incorrect brake lever free play 8Incorrect brake camshaft lever position 8Incorrect brake shoe position 8Damaged or fatigued brake shoe spring 8Oil or grease on the brake shoe 8Oil or grease on the brake drum

UNSTABLE HANDLING
Handlebar 8Bent or improperly installed handlebar Steering head components 8Improperly installed lower bracket (improperly tightened ring nut) 8Bent steering stem 8Damaged ball bearing or bearing race Front fork leg(s) 8Unevenly tensioned fork spring (both front fork legs) 8Broken fork spring 8Bent or damaged inner tube 8Bent or damaged outer tube Rear shock absorber assembly 8Faulty rear shock absorber spring 8Leaking oil Tire(s) 8Uneven tire pressures (front and rear) 8Incorrect tire pressure 8Uneven tire wear Wheel(s) 8Incorrect wheel balance 8Deformed cast wheel 8Damaged wheel bearing 8Bent or loose wheel axle 8Excessive wheel runout Frame 8Bent frame 8Damaged steering head pipe 8Improperly installed bearing race

EAS00861

FAULTY FRONT FORK LEGS

MALFUNCTION 8Bent or damaged inner tube 8Bent or damaged outer tube 8Damaged fork spring 8Bent or damaged damper rod

9-5

FAULTY LIGHTING OR SIGNALING SYSTEM

EAS00866

TRBL SHTG

FAULTY LIGHTING OR SIGNALING SYSTEM

HEADLIGHT DOES NOT COME ON 8Wrong headlight bulb 8Faulty headlight relay 8Too many electrical accessories 8Hard charging 8Incorrect connection 8Improperly grounded circuit 8Poor contacts (main or light switch) 8Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT 8Wrong headlight bulb 8Faulty battery 8Faulty rectifier/regulator 8Improperly grounded circuit 8Faulty main switch 8Faulty light switch 8Headlight bulb life expired TAIL/BRAKE LIGHT DOES NOT COME ON 8Wrong tail/brake light bulb 8Too many electrical accessories 8Incorrect connection 8Burnt-out tail/brake light bulb TAIL/BRAKE LIGHT BULB BURNT OUT 8Wrong tail/brake light bulb 8Faulty battery 8Tail/brake light bulb life expired TURN SIGNAL DOES NOT COME ON 8Faulty turn signal switch 8Faulty turn signal relay 8Burnt-out turn signal bulb 8Incorrect connection 8Damaged or faulty wire harness 8Improperly grounded circuit 8Faulty battery 8Blown, damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY 8Faulty turn signal relay 8Faulty main switch 8Faulty turn signal switch 8Incorrect turn signal bulb 8Faulty battery

TURN SIGNAL REMAINS LIT 8Faulty turn signal relay 8Burnt-out turn signal bulb TURN SIGNAL BLINKS QUICKLY 8Incorrect turn signal bulb 8Faulty turn signal relay 8Burnt-out turn signal bulb HORN DOES NOT SOUND 8Improperly adjusted horn 8Damaged or faulty horn 8Faulty main switch 8Faulty horn switch 8Faulty battery 8Blown, damaged or incorrect fuse 8Faulty wire harness

9-6

YAMAHA MOTOR TAIWAN CO., LTD