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Honda Metropolitan CHF50 Service Manual Download Page 33

GENERAL INFORMATION

1-29

ALTERNATOR/STARTER WIRE

MAIN WIRE HARNESS

LOWER COVER

WHITE TAPE

SEAT LOCK CABLE

FUEL PUMP WIRE

FUEL PUMP

IGNITION COIL 

WIRE

FUEL HOSE

MAIN STAND LOCK 

CABLE

 

20

°

 

±

 8

°

FUEL FILTER

FUEL LINE 

CHECK VALVE

FUEL PUMP/IGNITION 

COIL WIRE

WIRE BAND

AFTER ’07 MODEL:

1.0 – 3.0 mm 

(0.04 – 0.12 in)

FUEL HOSE

Summary of Contents for Metropolitan CHF50

Page 1: ......

Page 2: ...ral service safety precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures Only you can decide whether or not you...

Page 3: ...he vehicle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAU TION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow i...

Page 4: ...bdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil J...

Page 5: ...LUTCH SPECIFICATIONS 1 7 FINAL REDUCTION SPECIFICATIONS 1 7 CRANKSHAFT PISTON CYLINDER SPECIFICATIONS 1 8 FRONT WHEEL BRAKE SUSPENSION STEERING SPECIFICATIONS 1 8 REAR WHEEL BRAKE SUSPENSION SPECIFICA...

Page 6: ...rchangeable with English fasteners 4 Install new gaskets O rings cotter pins and lock plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner bolt first Then t...

Page 7: ...UMBER The engine serial number is stamped on the left side of the belt case ENGINE SERIAL NUMBER The carburetor identification numbers are stamped on the left side of the carburetor body CARBURETOR ID...

Page 8: ...ormation Label After 05 model is attached on the left side of the luggage box inside The Emission Control Information Label Canada type only After 05 model is attached on the right side of the luggage...

Page 9: ...eduction P type 02 05 model Gear ratio P type 02 05 model Ignition system Starting system Charging system Lighting system SPECIFICATION 1 685 mm 66 3 in 630 mm 24 8 in 1 005 mm 39 6 in 1 190 mm 46 9 i...

Page 10: ...Main jet 72 Slow jet 35 X 35 Pilot screw initial opening 2 3 4 turns out P type 2 1 8 turns out Float level 13 mm 0 5 in Idle speed 2 000 100 rpm Starting enrichment SE valve resistance 20 C 68 F 2 8...

Page 11: ...9 29 2907 29 3707 1 15318 1 15633 27 8909 27 9709 1 09806 1 10121 27 9503 28 0303 1 10040 1 10355 SERVICE LIMIT 0 05 0 002 4 465 0 1758 4 455 0 1754 4 54 0 179 0 075 0 0030 0 085 0 0033 1 5 0 06 32 2...

Page 12: ...0 60 0 004 0 024 0 005 0 035 0 0002 0 0014 10 013 10 028 0 3942 0 3948 0 013 0 034 0 0005 0 0013 SERVICE LIMIT 0 60 0 024 0 05 0 002 0 10 0 004 37 76 1 487 0 05 0 002 0 05 0 002 0 05 0 002 37 72 1 485...

Page 13: ...osition sensor Resistance 20 C 68 F Input voltage SPECIFICATIONS CR8EH 9 NGK U24FER9 DENSO CR7EH 9 NGK U22FER9 DENSO CR9EH 9 NGK U27FER9 DENSO 0 80 0 90 mm 0 031 0 035 in 80 V minimum 0 7 V minimum 10...

Page 14: ...d seating surface 2 Apply sealant to the threads 3 Apply a locking agent to the threads 4 ALOC bolt replace with a new one 5 U nut ENGINE MAINTENANCE ITEM Spark plug Engine oil drain bolt QTY 1 1 THRE...

Page 15: ...6 12 6 TORQUE N m kgf m Ibfft 12 1 2 9 44 4 5 33 7 8 0 8 5 8 REMARKS CRANKSHAFT PISTON CYLINDER ITEM Crankcase bolt QTY 9 THREAD DIA mm 6 TORQUE N m kgf m Ibfft 12 1 2 9 REMARKS NOTE 1 LIGHTS METERS S...

Page 16: ...ter surface Driven face bearing Oil pump drive driven gear teeth Camshaft bearing Rocker arm shaft sliding surface Cylinder head bolt threads and seating surfaces 6X119mm Piston and cylinder sliding s...

Page 17: ...Fill up 1 5 2g Throttle grip pipe flange cable groove Apply grease 0 1 0 2g Brake lever pivots Steering stem bearings and race sliding surface Apply 1 5 2g per each bearing Seat catch hook sliding are...

Page 18: ...BLE FRONT WIRE HARNESS LEFT BRAKE CABLE RIGHT BRAKE LIGHT SWITCH WIRE LEFT BRAKE LIGHT SWITCH WIRE LEFT BRAKE CABLE RIGHT HANDLEBAR SWITCH WIRE LEFT BRAKE LIGHT SWITCH WIRE RIGHT BRAKE LIGHT SWITCH WI...

Page 19: ...GENERAL INFORMATION RIGHT BRAKE CABLE SPEEDOMETER CABLE FRONT BRAKE CABLE 1 15...

Page 20: ...N METER INDICATOR 6P R CONNECTOR INDICATOR BLAKE LIGHT SWITCH 6P W CONNECTOR RIGHT HANDLEBAR 4P BI CONNECTOR LEFT HANDLEBAR SWITCH 9P CONNECTOR FUEL LEVEL SENSOR MAIN WIRE HARNESS FUEL LEVEL SENSOR 3P...

Page 21: ...BRAKE CABLE THROTTLE CABLE MAIN WIRE HARNESS SEAT LOCK CABLE FUEL LEVEL SENSOR 3P Bu CONNECTOR MAIN WIRE HARNESS SEAT LOCK CABLE LOWER COVER IGNITION COIL SPARK PLUG WIRE THROTTLE CABLE REAR BRAKE CAB...

Page 22: ...MAIN WIRE HARNESS FUEL PUMP IGNITION COIL WIRE LOWER COVER WIRE BAND WHITE TAPE SEAT LOCK CABLE FUEL LINE CHECK VALVE ALTERNATOR STARTER WIRE MAIN STAND LOCK CABLE IGNITION COIL WIRE 20 8 FUEL PUMP WI...

Page 23: ...ROTTLE POSITION SENSOR PAIR CONTROL VALVE VACUUM HOSE AIR SUPPLY HOSE CARBURETOR VACUUM HOSE GROUND WIRE ECT SENSOR THROTTLE POSITION SENSOR STARTING ENRICHMENT SE VALVE WIRE CARBURETOR VACUUM PISTON...

Page 24: ...OX BATTERY WIRE MAIN STAND LOCK CABLE ENGINE CONTROL MODULE ECM CONNECTOR MAIN HARNESS 6P W 9P W CONNECTORS SEAT LOCK CABLE ALTERNATOR STARTER 3P BI 6P W CONNECTORS CARBURETORVACUUM PISTON HOSE THROTT...

Page 25: ...GENERAL INFORMATION RADIATOR RESERVE TANK BATTERY CARBURETOR VACUUM PISTON HOSE THROTTLE CABLE ENGINE BREATHER HOSE MAIN STAND LOCK CABLE WATER HOSE IGNITION COIL WIRE LOWER COVER AIR SUPPLY HOSE 1 21...

Page 26: ...AL INFORMATION SIPHON HOSE GROUND POINT WIRE BAND SIPHON HOSE ECT SENSOR THROTTLE POSITION SENSOR SE VALVE WIRE SEAT LOCK CABLE WATER HOSES RADIATOR AIR SUPPLY HOSE WATER PUMP ALTERNATOR STARTER WIRE...

Page 27: ...GENERAL INFORMATION THROTTLE CABLE GROUND WIRE REAR BRAKE CABLE AIR CLEANER HOUSING CRANKCASE BREATHER DRAIN HOSE AIR SUPPLY HOSE 1 23...

Page 28: ...STAND LOCK CABLE SIPHON HOSE MAIN STAND MAIN WIRE HARNESS LOCK CABLE LEFT REAR TURN SIGNAL WIRE BRAKE TAIL LIGHT WIRE LICENSE LIGHT WIRE BODY COVER BODY COVER RIGHTREARTURN SIGNAL WIRE SEAT LOCK CABLE...

Page 29: ...CABLE FRONT WIRE HARNESS LEFT BRAKE CABLE RIGHT BRAKE LIGHT SWITCH WIRE LEFT BRAKE LIGHT SWITCH WIRE LEFT BRAKE CABLE RIGHT HANDLEBAR SWITCH WIRE LEFT BRAKE LIGHT SWITCH WIRE RIGHT BRAKE LIGHT SWITCH...

Page 30: ...GENERAL INFORMATION RIGHT BRAKE CABLE SPEEDOMETER CABLE FRONT BRAKE CABLE 1 26...

Page 31: ...N METER INDICATOR 6P R CONNECTOR INDICATOR BLAKE LIGHT SWITCH 6P W CONNECTOR RIGHT HANDLEBAR 4P Bl CONNECTOR LEFT HANDLEBAR SWITCH 9P CONNECTOR FUEL LEVEL SENSOR MAIN WIRE HARNESS FUEL LEVEL SENSOR 3P...

Page 32: ...RAKE CABLE THROTTLE CABLE FUEL LEVEL SENSOR 3P Bu CONNECTOR SEAT LOCK CABLE REAR BRAKE CABLE SPARK PLUG WIRE THROTTLE CABLE REAR BRAKE CABLE LOWER COVER IGNITION COIL MAIN WIRE HARNESS SEAT LOCK CABLE...

Page 33: ...WIRE HARNESS LOWER COVER WHITE TAPE SEAT LOCK CABLE FUEL PUMP WIRE FUEL PUMP IGNITION COIL WIRE FUEL HOSE MAIN STAND LOCK CABLE 20 8 FUEL FILTER FUEL LINE CHECK VALVE FUEL PUMP IGNITION COIL WIRE WIRE...

Page 34: ...ECT SENSOR REED V A L V E THROTTLE POSITION SENSOR AIR SUCTION HOSE AIR SUPPLY HOSE CARBURETOR VACUUM HOSE GROUND WIRE ECT SENSOR THROTTLE POSITION SENSOR STARTING ENRICHMENT SE VALVE WIRE CARBURETOR...

Page 35: ...AIN STAND LOCK CABLE ENGINE CONTROL MODULE ECM CONNECTOR MAIN HARNESS 6P W 9P W CONNECTORS SEAT LOCK CABLE ALTERNATOR STARTER 3P BI 6P W CONNECTORS CARBURETORVACUUM PISTON HOSE AIR SUCTION HOSE AIR SU...

Page 36: ...TANK IGNITION COIL FRAME AIR SUPPLY HOSE LOWER COVER AIR SUPPLY HOSE IGNITION COIL WIRE WATER HOSE SIPHON HOSE MAINSTAND LOCK CABLE CARBURETORVACUUM PISTON HOSE BATTERY ENGINE BREATHER HOSE AIR SUCTI...

Page 37: ...L INFORMATION SIPHON HOSE GROUND POINT WIRE BAND SIPHON HOSE ECT SENSOR THROTTLE POSITION SENSOR SE VALVE WIRE SEAT LOCK CABLE WATER HOSES 7 RADIATOR AIR SUPPLY HOSE WATER PUMP ALTERNATOR STARTER WIRE...

Page 38: ...ENERAL INFORMATION THROTTLE CABLE GROUND WIRE REAR BRAKE CABLE CARBURETOR VACUUM PISTON HOSE AIR CLEANER HOUSING ENGINE BREATHER HOSE AIR SUCTION HOSE AIR SUPPLY HOSE CRANKCASEBREATHER DRAIN HOSE 1 34...

Page 39: ...STAND LOCK CABLE MAIN STAND LOCK CABLE BODY COVER MAIN WIRE HARNESS LEFT REAR TURN SIGNAL WIRE BODY COVER RIGHTREARTURN SIGNAL WIRE SEAT LOCK CABLE BRAKE TAIL LIGHT WIRE LICENSE LIGHT WIRE BRAKE TAIL...

Page 40: ...n the same way but it is toxic Honda Motor Co Ltd utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons CRANKCASE EMISSION CONTROL SYSTEM The engine is...

Page 41: ...ocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has the pulse secondary air injection PAIR control valve it consists of check valves built into the PAIR...

Page 42: ...her tan for purposes of maintenance repair or replacement of any device or element of design incorporated into any vehicle for the purpose of noise control prior to its sale or delivery to the ultimat...

Page 43: ...2 7 BODY PANEL REMOVAL CHART 2 2 SIDE COVER 2 8 SERVICE INFORMATION 2 3 STEP FLOOR 2 9 TROUBLESHOOTING 2 3 LEG SHIELD 2 9 TRIM CLIPS 2 4 LOWER COVER 2 10 FRONT COVER 2 4 REAR FENDER 2 11 FRONT FENDER...

Page 44: ...r page 2 8 7 Step Floor page 2 9 8 Leg shield page 2 9 8 9 Lower Cover page 2 10 10 Rear Fender page 2 11 11 Front Meter Cover page 2 12 BODY PANEL REMOVAL CHART This chart shows removal order of fram...

Page 45: ...the exhaust system loosely install all of the exhaust pipe fasteners Always tighten the exhaust joints first then tighten the mounting fasteners If you tighten the mounting fasteners first the exhaus...

Page 46: ...e center pin until the pin flush with the outer casing FRONT COVER REMOVAL Remove the four screws and front cover from the leg shield Disconnect the headlight connector and remove the front cover INST...

Page 47: ...om fender A Remove fender A bolt and fender A INSTALLATION Installation is in the reverse order of removal BOLT FENDER A FENDER B CABLE GUIDE SEAT REMOVAL Open the seat Remove the nuts and the seat IN...

Page 48: ...e screw and main stand lock lever Remove the maintenance cover Remove the four bolts and luggage box INSTALLATION Atinstallation be Installation is in the reverse order of removal careful not to damag...

Page 49: ...seat lock cable from the clamp Remove the four trim clips Remove the screws and body cover INSTALLATION At installation be Installation is in the reverse order the removal careful notto Route t n e w...

Page 50: ...CLAMP REAR BODY COVER REAR COMBINATION LIGHT UNIT SIDE COVER REMOVAL INSTALLATION Remove the two screws Remove the side cover as follows 1 Pull out the rear side tabs on the outside of the floor panel...

Page 51: ...to damage the wire harness After installation make sure the tabs on the step floor are attached on the leg shield BOLT SCREW LEG SHIELD REMOVAL Remove the following Front cover page 2 4 Step floor see...

Page 52: ...y i s j n t h e r e v e r se order of disassembly the key cylinder cover KEY CYLINDER COVER SCREW LOWER COVER REMOVAL Remove the following Side cover page 2 8 Step floor page 2 9 Leg shield page 2 9 R...

Page 53: ...te the wire Installation is in the reverse order of removal harness and cables correctly page 1 14 LOWER CM BOLT 1 GUIDE r COVER 1 If1 CLAMP TAB III I X BOLT REAR FENDER REMOVAL Remove the battery pag...

Page 54: ...ctly page 1 14 FRONT METER COVER REMOVAL Remove the screws Remove two tabs from the rear meter cover while pulling the bottom of the front meter cover out Becareful notto Remove the top of the front m...

Page 55: ...is in the reverse order of removal by loosely tightening all fasteners Tighten the joint nut first then tighten the mount bolts After installation inspect the exhaust system for leaks GASKET MUFFLER...

Page 56: ...MEMO...

Page 57: ...NE OIL 3 10 ENGINE OIL STRAINER SCREEN 3 11 ENGINE IDLE SPEED 3 12 RADIATOR COOLANT 3 13 COOLING SYSTEM 3 13 SECONDARY AIR SUPPLY SYSTEM 02 05 model 3 14 SECONDARY AIR SUPPLY SYSTEM After 05 model 3 1...

Page 58: ...CR7EH 9 CR9EH 9 DENSO U24FER9 U22FER9 U27FER9 0 80 0 90 mm 0 031 0 035 in 0 10 0 03 mm 0 004 0 001 in 0 19 0 03 mm 0 007 0 001 in 0 6 liter 0 6 US qt 0 5 Imp qt 0 7 liter 0 7 US qt 0 6 Imp qt Pro Hon...

Page 59: ...ES STEERING HEAD BEARINGS WHICHEVER COMES FIRST NOTE 2 NOTE 3 02 05 model After 05 model NOTE 4 V ODOMETER READING NOTE 1 X1 000mi X1 000km 0 6 1 2 5 4 I C 5 8 I C R 7 5 12 I I R C EVERY 15 000 mi 24...

Page 60: ...ot return properly lubricate the throttle cable and overhaul and lubricate the throttle grip housing For cable lubrication Disconnect the throttle cable at their pivot points with a commercially avail...

Page 61: ...us paper element type air cleaner can not be cleaned because the element contains a dust adhesive If the scooter is used in unusually wet or dusty areas more frequent inspections are required Remove t...

Page 62: ...ug from the hose end and drain deposits into a suitable container then install the crankcase breather drain hose plug securely DRAIN HOSE HOSE PLUG SPARK PLUG Open the fuel tank cap lid and remove the...

Page 63: ...ow 5 C 41 F CR7EH 9 NGK U22FER9 DENSO For extended high speed riding CR9EH 9 NGK U27FER9 DENSO Measure the spark plug gap between the center and side electrodes with a wire type feeler gauge If necess...

Page 64: ...eel with the index mark Make sure the index line on the cam sprocket aligns with the index mark on the stopper plate and the lobe of the camshaft faces the cylinder side TDC on the compression stroke...

Page 65: ...00 mm SHIM Calculate the new shim thickness using the equa tion below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct...

Page 66: ...oil level is below or near the lower level line on the dipstick add the recommended oil to the upper level RECOMMENDED ENGINE OIL Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil or equi...

Page 67: ...ine and remove the oil filler cap dip stick Remove the drain bolt and washer and drain the oil DRAIN BOLT WASHER Remove the oil strainer cap spring and strainer screen Clean the oil strainer Install t...

Page 68: ...are no oil leaks DRAIN BOLT WASHER ENGINE IDLE SPEED NOTE Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications The engine must b...

Page 69: ...coolant with silicate inhibitors may cause pre mature wear of water pump seals or blockage of radiator passages Using tap water may cause engine damage Check to see if there are any coolant leaks whe...

Page 70: ...x page 2 6 SECONDARY AIRSUPPLY SYSTEM 02 05 model Remove the luggage box page 2 6 Check the air supply hoses between the air cleaner case and PAIR control valve and PAIR check valves for damage or loo...

Page 71: ...of heat damage inspect the PAIR check valves page 5 23 Install the luggage box page 2 6 INTAKE MANIFOLD AIR SUPPLY HOSE PAIR CHECK VALVE BRAKE SHOES WEAR Check the brake shoes and brake drum if the a...

Page 72: ...urethe Adjust the right brake lever free play by turning the cutouton the front brake arm adjusting nut adjusting nut is seated on the joint pin Measure the left brake lever free play at the end of th...

Page 73: ...adjust nut all the way in 3 Remove the front cover page 2 4 Loosen the lock nut of the right brake cable turn the adjust bolt until there is no brake lever free play Tighten the lock nut TORQUE 6 8 N...

Page 74: ...the left brake lever is 10 20 mm 3 8 13 16 in 7 Install the front cover page 2 4 10 20 mm 3 8 13 16 in BRAKE LOCK OPERATION Check the brake lock operation The brake lock will not function if the left...

Page 75: ...e repaired Tighten all nuts and bolts Refer to page 13 13 for fork service REAR Check the action of the shock absorber by com pressing it several times Check the entire shock absorber assembly for dam...

Page 76: ...embedded nails or other damage Check the front wheel page 13 6 and rear wheel page 14 4 for trueness Measure the tread depth at the center of the tires Replace the tires when the tread depth reaches...

Page 77: ...4 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 2 TROUBLESHOOTING 4 3 SERVICE INFORMATION 4 3 OIL PUMP 4 4 4 1...

Page 78: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CRANKSHAFT ROCKER ARM SHAFT ROCKER ARM OIL STRAINER 4 2...

Page 79: ...p has been installed check that there are no oil leaks SPECIFICATIONS Unit mm in ITEM Engine oil capacity At draining At disassembly Recommended engine oil Oil pump rotor Tip clearance Body clearance...

Page 80: ...ternator starter assembly page 11 4 pump do notallow R e m o v e t h e f o u r b o t s a n d s t a t e r b a s e dust or dirt to enter the engine Remove the dowel pins O ring and oil seal O RING 02 05...

Page 81: ...rew and oil pump cover SCREW COVER DOWEL PIN Remove the oil pump outer rotor and inner rotor OUTER ROTOR INNER ROTOR INSPECTION NOTE Measure at several points and use the largest reading to compare th...

Page 82: ...mm 0 009 in BODY CLEARANCE Measure the side clearance using a straight edge c i n c and feeler gauge biut SERVICE LIMIT 0 12 mm 0 005 in ASSEMBLY Dip all parts in clean engine oil before assembly OIL...

Page 83: ...oil pump body DOWEL PIN Install the oil pump cover onto the oil pump body Install and tighten the oil pump cover screw to the specified torque TORQUE 2 0 N m 0 2 kgfrn 1 4 Ibf ft SCREW COVER INSTALLAT...

Page 84: ...ar sliding surface Install the oil pump shaft with driven gear while aligning the cut out in the shaft and oil pump NOTE Check the proper alignment of the oil pump shaft and oil pump driven gear at th...

Page 85: ...ce before tighten ing the bolts If the stator base is un seated check the oil pump driven shaft and oil pump driven gear alignment again Tighten the four bolts securely Install the alternator starter...

Page 86: ...MEMO...

Page 87: ...05 model 5 7 CARBURETOR REMOVAL 5 8 CARBURETOR DISASSEMBLY 5 10 CARBURETOR ASSEMBLY 5 13 CARBURETOR INSTALLATION 5 16 PILOT SCREW ADJUSTMENT 02 05 model 5 18 PILOT SCREW ADJUSTMENT After 05 model 5 19...

Page 88: ...FUEL SYSTEM COMPONENT LOCATION 02 05 model 5 2...

Page 89: ...FUEL SYSTEM COMPONENT LOCATION After 05 model 5 3...

Page 90: ...LS ITEM SPECIFICATIONS Carburetor identification number NVK00E P type NVK00F Main jet 72 Slow jet 35 X 35 Pilot screw 2 3 4 turns out P type 2 1 8 turns out Float level 13 mm 0 51 in Idle speed 2 000...

Page 91: ...sted Pilot screw misadjusted Fuel tank breather hole clogged Air cleaner clogged Slow circuit clogged Faulty starting enrichment SE valve Fuel pump faulty page 4 4 ECT sensor faultypipage 18 16 Igniti...

Page 92: ...her hose and vac uum hose from the air cleaner housing Remove the rear fender bolt and air cleaner housing mounting bolts Loosen the connecting hose band screw and remove the connecting hose from the...

Page 93: ...el REMOVAL INSTALLATION Refer topage 3 5 Remove the luggage box page 2 6 for aircleaner element replacement Remove the rear fender bolt and air cleaner housing mounting bolts Loosen the connecting hos...

Page 94: ...ose fuel hose and water hose from the carburetor Disconnect the throttle position sensor 3P connector and starting enrichment SE valve 2P connector Loosen the throttle cable lock nut Remove the thrott...

Page 95: ...cting hose Loosen the insulator band screw and remove the insulator from the intake manifold Remove the bolts intake manifold and O ring Seal the cylinder head intake port with a shop towel or cover i...

Page 96: ...the sensor is removed be sure to reset the data page 16 8 Remove the followings from the carburetor Water hose Throttle position sensor page 16 9 THROTTLE POSITION SENSOR WATER HOSE STARTING ENRICHME...

Page 97: ...arburetor body SPRING DIAPHRAGM VACUUM PISTON Becareful not to Turn the needle holder counterclockwise while damage thedia pressing it in and remove the holder flanges from phragm the piston grooves R...

Page 98: ...loat valve seat for scores scratches clogs and damage Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination Replace the valve if the tip is worn or contam...

Page 99: ...spring washer O ring Cleaning theairand Blow open all air and fuel passages in the carbure fuelpassages with tor body with compressed air a piece of wire will damage the carburetor body CARBURETOR ASS...

Page 100: ...T PILOT SCREW Install the float and float valve in the carburetor body then install the float pin through the body and float FLOAT VALVE FLOAT PIN FLOAT LEVEL INSPECTION NOTE Check the float level aft...

Page 101: ...body aligning the diaphragm tab with the needle groove in the carburetor body Hold the vacuum piston almost full open so the dia phragm is not pinched by the chamber cover Be careful not to pinchthe...

Page 102: ...roove Install the SE valve into the carburetor body as shown Install and tighten the screw securely TORQUE 2 1 N m 0 21 kgf m 1 5 Ibf ft Install the throttle position sensor page 16 9 Connect the wate...

Page 103: ...ke manifold and adjust the level position of the carburetor 02 03 model Tighten the band screws securely as shown 5 1 mm 0 2 0 04 in After 03 V I NAfter Tighten the band screws to the specified torque...

Page 104: ...hometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change Damage tothe pilot 1 Turn the pilot screw clockwise until it seats lightly and then back it out to the speci...

Page 105: ...rpm change Damage to thepilot 1 Turn the pilot screw clockwise until it seats screw seat will occur if the pilot screw is tightened against the seat lightly and then back it out to the specification...

Page 106: ...r high altitude operation When the vehicle is to be operated continuously above 2 000 m 6 500 feet the carburetor must be readjusted as described below to improve driveability and decrease exhaust emi...

Page 107: ...llows Warm up the engine to operating temperature Ride the scooter for approximately 10 minutes Turn the pilot screw out 1 4 turn from the high alti tude setting Replace the high altitude main jet wit...

Page 108: ...ng temperature Remove the air cleaner housing cover page 3 5 Remove the secondary air cleaner element Check that the secondary air intake ports are clean and free of carbon deposits If the ports are c...

Page 109: ...FIED VACUUM 450 mm Hg If air is drawn in or if the specified vacuum is not maintained install a new PAIR control valve VACUUM PUMP VACUUM HOSE PLUG PAIR CONTROL VALVE AIR SUPPLY HOSE AIR SUPPLY HOSE P...

Page 110: ...ce between the reed and seat Install the PAIR check valve in the reverse order of the removal Install the plug maintenance lid page 3 6 PAIR CHECK VALVE REED VALVE R U B B ER SEAT PCV CONTROL SOLENOID...

Page 111: ...e solenoid valve O RING Remove the bolts and cover from the case Remove the PCV reed valve from the case Install the PCV reed valve to the case securely PCV CONTROL SOLENOID VALVE BOLTS CASE COVER PCV...

Page 112: ...alve Tighten the solenoid valve bolts securely PCV CONTROL SOLENOID VALVE PCV CONTROL SOLENOID VALVE BOLTS Install and tighten the bolts securely Connect the air suction hoses and the PCV control sole...

Page 113: ...minals of the PCV control solenoid valve STANDARD 22 26 Q at 20 C 68 F If the resistance is out of specification replace the PCV control valve SOLENOID VALVE BATTERY B SOLENOID VALVE PCV REED VALVE Ch...

Page 114: ...der cover and disconnect the fuel level sensor 3P Bu connector Lift the fuel tank and attach the clamp to the fuel hose Disconnect the fuel hose from the fuel filter and remove the fuel tank 3P BLUE C...

Page 115: ...OOLING SYSTEM SYSTEM FLOW PATTERN 6 2 COOLANT REPLACEMENT 6 6 SERVICE INFORMATION 6 3 WATER PUMP THERMOSTAT 6 9 TROUBLESHOOTING 6 4 RADIATOR 6 13 COOLANT SYSTEM TESTING 6 5 RADIATOR RESERVE TANK 6 15...

Page 116: ...COOLING SYSTEM SYSTEM FLOW PATTERN RESERVE TANK WATER PUMP RADIATOR THERMOSTAT 6 2...

Page 117: ...stem tester When the coolant temperature exceeds 120 C 248 F the coolant temperature indicator will blink The ECM will then control the ignition and reduce engine speed to 9 mph 15 km h At this time c...

Page 118: ...tor hoses or water jacket Air in system Faulty water pump Faulty temperature gauge or ECT sensor Engine temperature too low Faulty temperature gauge or ECT sensor Thermostat stuck open Coolant leak De...

Page 119: ...86 1 095 1 100 5 41 1 009 1 017 1 027 1 035 1 044 1 052 1 062 1 070 1 078 1 084 1 093 1 098 10 50 1 008 1 017 1 026 1 034 1 043 1 051 1 060 1 068 1 076 1 082 1 091 1 095 15 59 1 008 1 016 1 025 1 033...

Page 120: ...components Do not exceed 137 kPa 1 4kgf cm2 20 psi RADIATOR CAP TESTER RADIATOR CAP TESTER COOLANT REPLACEMENT PREPARATION NOTICE Using coolant with silicate corrosion inhibitors may cause premature...

Page 121: ...emoving the drain bolt and O ring Remove the cylinder drain bolt and drain the cool ant from the cylinder Unlock and open the seat using the ignition key Remove the maintenance cover Remove the reserv...

Page 122: ...for 2 3 minutes 2 Snap the throttle three or four times to bleed air from the system 3 Stop the engine and add coolant to the proper level if necessary Reinstall the radiator cap Check the level of co...

Page 123: ...page 2 9 Lower cover page 2 10 Ignition coil page 16 7 Remove the ignition coil wire from the wire band Remove the clamp and disconnect the water hoses Remove the wire band from the water pump stay Re...

Page 124: ...the thermostat hous ing cover Remove the thermostat COVER RUBBER SEAL SEAL THERMOSTAT INSPECTION Visually inspect the thermostat for damage Heat a pan of water with an electric heating element to oper...

Page 125: ...COVER THERMOSTAT Coat a new seal ring with coolant and install it into the groove in the thermostat Install the thermostat into the water pump align the tab of the thermostat with the groove in the wa...

Page 126: ...mp magnet and check that no nuts or bolts are magnetically attached to the magnet Coat a new O ring with engine oil and install it into the groove into the water pump WATER PUMP MAGNET Install the wat...

Page 127: ...em with the recommended coolant and bleed any air page 6 7 RADIATOR REMOVAL Drain the coolant page 6 7 Remove the right side cover page 2 8 Remove the radiator cover Remove the radiator joint bolt Dis...

Page 128: ...tor Remove the water pipe and O rings INSTALLATION WATER HOSE SIPHON HOSE O RING WATER HOSE RADIATOR Coat a new O rings with coolant and install them into the grooves in the water pipe Install the wat...

Page 129: ...ed any air page 6 7 WATER PIPE SIPHON HOSE RADIATOR RESERVE TANK REMOVAL Remove the body cover page 2 7 Remove the ECM page 15 11 Disconnect the siphon hose from the radiator reserve tank Remove the s...

Page 130: ...MEMO...

Page 131: ...7 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION SERVICE INFORMATION 7 4 02 05 model 7 2 ENGINE REMOVAL 7 5 COMPONENT LOCATION After 05 model 7 3 ENGINE INSTALLATION 7 8 7 1...

Page 132: ...ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 02 05 model 39 N m 4 0 kgf m 29 Ibf ft 26 N m 2 7 kgf m 20 Ibf ft 39 N m 4 0 kgf m 29 Ibf ft 49 N m 5 0 kgf m 36 Ibf ft 7 2...

Page 133: ...ENGINE REMOVAL INSTALLATION COMPONENT LOCATION After 05 model 39 N m 4 0 kgf m 29 Ibf ft 39 N m 4 0 kgfm 29 Ibf ft 26 N m 2 7 kgf m 20 Ibf ft 49 N m 5 0 kgf m 36 Ibf ft 7 3...

Page 134: ...tarter drive pulley driven pulley clutch page 9 6 Final reduction page 10 5 Alternator starter page 11 4 Cylinder head valve page 8 7 Water pump page 6 9 Carburetor page 5 8 Oil pump page 4 4 SPECIFIC...

Page 135: ...arm adjusting nut joint pin and spring Remove the brake cable from the belt case groove Disconnect the ECT sensor connector throttle posi tion sensor 3P G connector and SE valve 2P Bl connector Remov...

Page 136: ...nnect the siphon hose from the radiator Disconnect the fuel hose from the carburetor Disconnect the throttle cable form the throttle drum FUEL HOSE THROTTLE CABLE SIPHON HOSE Disconnect the main stand...

Page 137: ...n remove the engine from the frame Move the joint tubes inside and remove the mount ing collar from the engine Check the bushings for wear deterioration or dam age Remove the two bolts and engine hang...

Page 138: ...he engine hanger link aligning the rubber stopper with the frame BUSHING RUBBER STOPPER Install and tighten the engine hanger link bolts to the specified torque TORQUE 39 N m 4 0 kgf m 29 Ibf ft Insta...

Page 139: ...UE 26 Nm 2 7 kgf m 20 Ibfft Install the removed parts in the reverse order of removal After installing the engine check for the following Left brake lever free play page 3 16 Throttle grip free play p...

Page 140: ...MEMO...

Page 141: ...INDER HEAD COVER REMOVAL 8 6 CAMSHAFT ROCKER ARM REMOVAL 8 7 CYLINDER HEAD REMOVAL 8 10 CYLINDER HEAD DISASSEMBLY 8 11 VALVE GUIDE REPLACEMENT 8 13 VALVE SEAT INSPECTION REFACING 8 14 CYLINDER HEAD AS...

Page 142: ...CYLINDER HEAD VALVES COMPONENT LOCATION 12Nm 1 2kgfm 9 Ibfft 10N m 1 0kgfm 7lbfft After 05 model 8 2...

Page 143: ...I D Rocker arm shaft O D IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX Side spring free length Cam lobe height P type IN EX IN EX STANDARD 1 393 kPa 14 2 kgf cm2 202 psi at 1 500 rpm 0 1010 0...

Page 144: ...equivalent commercially avail able in U S A or equivalent commercially avail able in U S A or equivalent commercially avail able in U S A Interior cutter 17 mm 60 EX 07780 0014600 Cutter holder 4 5 mm...

Page 145: ...ve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Loose spring plug Worn cylinder piston or piston rings page 12 8 Compres...

Page 146: ...til the gauge reading stops rising The maximum reading is usually reached within 4 7 seconds COMPRESSION PRESSURE 1 393 kPa 14 2 kg cm2 202 psi at 1 500 rpm Low compression can be caused by Blown cyli...

Page 147: ...cylinder side Shift the rocker arms to the spring side and remove the shims NOTE Do not allow the shims to fall into the crankcase Mark all shims to ensure correct reassembly in their original locatio...

Page 148: ...sprocket from the camshaft and cam chain off the cam sprocket Attach a piece of wire to the cam chain to prevent it from falling into the crankcase Remove the bolts and stopper plate Remove the camsh...

Page 149: ...sure the height of each cam lobe SERVICE LIMITS IN 29 2065 mm 1 14986 in EX 29 2607 mm 1 15199 in P type IN 27 8623 mm 1 09694 in EX 27 9217 mm 1 09928 in ROCKER ARM SHAFT Check the rocker arm shafts...

Page 150: ...ioner shaft should be pulled into the body The shaft should spring out of the body as soon as the screwdriver is released TENSIONER SHAFT TENSIONER LIFTER CYLINDER HEAD REMOVAL Remove the following Mu...

Page 151: ...the valve tension do not spring compressor compress the valve springs more than TOOL necessary to Valve spring compressor 07757 0010000 remove the cotters Valve spring compressor attachment 07GME KT7...

Page 152: ...ylinder head for warpage with a straight edge and feeler gauge SERVICE LIMIT 0 05 mm 0 002 in VALVE SPRINGS Measure the free length of the valve springs SERVICE LIMIT IN EX 32 2 mm 1 27in VALVE VALVE...

Page 153: ...ervice limit with new guide also replace the valve CAM CHAIN TENSIONER GUIDE Check the tensioner and guide for excessive wear or damage If necessary replacement in the following proce dure Remove the...

Page 154: ...ML0010A U S A only Clean the cylinder head thoroughly to remove any metal particles after reaming and reface the valve seat as described below VALVE SEAT INSPECTION REFACING Clean the intake and exha...

Page 155: ...LOW TOO HIGH VALVE SEAT REFACING NOTE Follow the refacing manufacturer s operating instructions Be careful not to grind the seat more than neces sary If the contact area is too high on the valve the s...

Page 156: ...S Flat cutter 22 mm 32 IN Flat cutter 20 mm 32 EX Cutter holder 4 5mm 07780 0012601 07780 0013200 07781 0010600 or equivalent commercially available in U S A Use a 60 interior cutter remove 1 4 of the...

Page 157: ...the cylinder head and valve and recheck the seat con tact LAPPING TOOL CYLINDER HEAD ASSEMBLY SPARK PLUG THERMOSENSOR COTTER SHIM 1 RETAINER SPRING EXHAUST VALVE SPRING SEAT STEM SEAL VALVE GUIDE Blo...

Page 158: ...sor attachment 07757 0010000 07GME KT70200 Support the cylinder head so the valve heads will not contact anything that cause damage Tap the valve stems gently with two plastic ham mers as shown to sea...

Page 159: ...gf m 9 Ibfft Install the following thermosensor page 18 16 muffler page 2 13 camshaft rocker arm see below CAMSHAFT ROCKER ARM INSTALLATION ROCKER ARM HOLDER ASSEMBLY Apply molybdenum oil solution to...

Page 160: ...hten the outside bolts of the cylinder head Remove the radiator cover Turn the drive pulley crankshaft counterclockwise and align the T mark on the flywheel with the index mark while holding the cam c...

Page 161: ...the cam chain tensioner onto the cylinder and tighten the bolts securely 02 05 model Remove the special tool to cancel the lock of the tensioner lifter Coat a new O ring with engine oil Install and ti...

Page 162: ...the crankcase Install the following Water pump page 6 9 Belt case cover page 9 5 CYLINDER HEAD COVER INSTALLATION Clean the gasket groove of the cylinder head cover Coat a new O rings with engine oil...

Page 163: ...9 KICKSTARTER DRIVE PULLEY DRIVEN PULLEY CLUTCH COMPONENT LOCATION 9 2 KICKSTARTER 9 6 SERVICE INFORMATION 9 3 DRIVE PULLEY 9 9 TROUBLESHOOTING 9 4 CLUTCH DRIVEN PULLEY 9 12 BELT CASE COVER 9 5 9 1...

Page 164: ...KICKSTARTER DRIVE PULLEY DRIVEN PULLEY CLUTCH COMPONENT LOCATION 32 N m 3 3 kgf m 24 Ibf ft 39 N m 4 0 kgf m 29 Ibf ft 9 2...

Page 165: ...er O D Face spring face length Driven face O D Movable driven face I D STANDARD 107 0 107 2 4 21 4 22 18 15 0 715 20 035 20 085 0 7888 0 7907 20 010 20 025 0 7878 0 7884 15 92 16 08 0 627 0 633 79 6 3...

Page 166: ...0 Puller attachment 07YMC GCS0100 or 07960 KM1000A U S A only TROUBLESHOOTING Engine starts but scooter won t move Worn drive belt Damaged ramp plate Worn or damaged clutch shoe Broken driven face spr...

Page 167: ...NSTALLATION Check the rubber seal and replace it if it is nesec carly Clean the rubber seal groove in the belt case cover Install the dowel pins and the rubber seal onto the belt case cover RUBBER SEA...

Page 168: ...he original location Remove the bolt and kickstarter pedal MARK Release the hook end of the return spring from the belt case cover Remove the snap ring and washer TOOL Snap ring pliers 07914 SA50001 R...

Page 169: ...LEY DRIVEN PULLEY CLUTCH Check the kickstarter driven gear and ratchet plate for wear or damage DRIVEN GEAR Check the friction spring for fatigue or damage Check the journals of the belt case cover fo...

Page 170: ...e cover Install the return spring as shown Apply molybdenum solution to the kickstarter spin dle sliding surface Install the kickstarter spindle to the belt case cover and hook the return spring end o...

Page 171: ...belt case cover and kickstarter gear with driven gear Install the belt case cover page 9 5 DRIVE PULLEY REMOVAL Remove the belt case cover page 9 5 Hold the drive pulley face with special tool and loo...

Page 172: ...nor mal or excessive wear Measure the drive belt width SERVICE LIMIT 17 15 mm 0 68 in WEIGHT ROLLER Check each roller for wear or damage Measure the weight roller O D SERVICE LIMIT 15 4 mm 0 61 in 9 M...

Page 173: ...le drive face assembly onto the crankshaft while holding the ramp plate Install the drive belt onto the drive face boss WEIGHT ROLLER RAMP PLATE MOVABLE DRIVE FACE Install the drive pulley face ratche...

Page 174: ...Universal holder 07725 0030000 Remove the nut and clutch outer Remove the clutch driven pulley assembly Remove the drive belt from the driven pulley CLUTCH DRIVEN PULLEY DISASSEMBLY Set the clutch spr...

Page 175: ...r or equivalent tool and special tool as shown TOOL Puller attachment 07YMC GCS0100 Loosen the clutch spring compressor gradually and tighten the gear puller gradually Repeat this procedure and remove...

Page 176: ...BEARING REMOVER special tools TOOL Bearing remover 17 mm 07936 3710300 Remover handle 07936 3710100 Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Remove the snap ring then...

Page 177: ...en face with the marked side facing up TOOLS Driver 07749 0010000 Attachment 22 X 24 mm 07746 0010800 Pilot 17 mm 07746 0040400 Install the snap ring to the groove in the driven face securely TOOL Sna...

Page 178: ...iven face boss O D SERVICE LIMIT 33 70 mm 1 327 in Check the movable driven face for scratches scor ing or damage Check the guide grooves for stepped wear or dam age Measure the movable driven face I...

Page 179: ...PERS Install the shoe springs into the clutch shoes as shown SHORT SPRING LONG Install the clutch shoes assembly into the drive plate Install the washers and E clips SHOES E CLIPS WASHERS Assemble the...

Page 180: ...iven pulley assembly and compress the driven face spring TOOL Clutch spring compressor 07LME GZ40200 or 07960 KM1000A U S A only Align the spline of the driven face with the spline of the drive plate...

Page 181: ...ll the clutch outer and clutch outer nut Hold the clutch outer with the special tool and tighten the clutch outer nut to the specified torque TOOL Universal holder 07725 0030000 TORQUE 39 N m 4 0 kgf...

Page 182: ...MEMO...

Page 183: ...FINAL REDUCTION COMPONENT LOCATION 10 2 FINAL REDUCTION DISASSEMBLY 10 5 SERVICE INFORMATION 10 3 BEARING REPLACEMENT 10 8 TROUBLESHOOTING 10 4 FINAL REDUCTION ASSEMBLY 10 9 FINAL REDUCTION OIL 10 5 1...

Page 184: ...FINAL REDUCTION 10 4 COMPONENT LOCATION 26 N m 2 7 kgf m 20 lbf ft 2002 only...

Page 185: ...SPECIFICATIONS ITEM Final reduction oil capacity at disassembly Recommended final reduction oil SPECIFICATIONS 0 1 liter 0 11 US qt 0 09 Imp qt Hypoid gear oil 90 TORQUE VALUES Final drive oil check b...

Page 186: ...0 not available in U S A Bearing remover shaft 07936 1660120 Assembly collar 07965 GM00100 Assembly shaft 07965 GM00300 not available in U S A Case puller 07SMC 0010001 TROUBLESHOOTING Engine does sta...

Page 187: ...ve oil check bolt with a new seal ing washer and tighten it TORQUE 13 N m 1 3 kgf m 9 Ibfft FINAL REDUCTION DISASSEMBLY TRANSMISSION DISASSEMBLY Remove the following Clutch driven pulley page 9 12 Rea...

Page 188: ...the driveshaft using the special tools Remove the driveshaft oil seal and bearing If the bearing is left on the driveshaft remove it with the special tool DOWEL PINS COUNTERSHAFT FINAL GEAR SHAFT COU...

Page 189: ...ace fits tightly in the case Remove and discard the bearing if the races do not turn smoothly and quietly or if they fit loosely in the case FINAL GEAR SHAFT BEARING FINAL GEAR SHAFT SL DING SURFACE C...

Page 190: ...AL Becareful not to Remove the final gear shaft oil seal and bearing damage the transmission case mating surface Remove the driveshaft bearing using the special tools TOOLS Bearing remover set 12 mm 0...

Page 191: ...9 0010000 Attachment 32 X 35 mm 07746 0010100 Pilot 12 mm 07746 0040200 Final gear shaft bearing Driver 07749 0010000 Attachment 37 X 40 mm 07746 0010200 Pilot 17 mm 07746 0040400 Apply oil to a new f...

Page 192: ...t and draw the driveshaft into the bearing inner race by turning the nut TOOLS Assembly shaft 07965 GM00300 Assembly collar 07965 GM00100 ASSEMBLY SHAFT Apply oil to a new driveshaft oil seal lip and...

Page 193: ...countershaft and final gear shaft Apply sealant to the transmission case mating sur face Install the dowel pins Apply molybdenum oil solution to the countershaft and final gear shaft sliding surface I...

Page 194: ...he transmission case holder REAR SHOCK ABSORBER LOWER MOUNTING BOLT CASE BOLT r CLAMP Install the air cleaner housing and tighten the bolts securely Install the crankcase breather drain hose into the...

Page 195: ...11 ALTERNATOR STARTER COMPONENT LOCATION 11 2 ALTERNATOR STARTER 11 4 SERVICE INFORMATION 11 3 11 1...

Page 196: ...ALTERNATOR STARTER COMPONENT LOCATION 12 N m 1 2 kgf m 9 Ibf ft 44 N m 4 5 kgf m 33 Ibf ft 7 8 N m 0 8 kgf m 5 8 Ibf ft 11 2...

Page 197: ...val and installation of the flywheel alternator starter and ignition pulse generator These service can be done with the engine installed in the frame Refer to page 15 8 for alternator starter inspecti...

Page 198: ...an Hold the flywheel with the special tool and loosen the flywheel nut TOOL Universal holder 07725 0030000 Remove the flywheel nut and washer Remove the flywheel using the special tools TOOL Flywheel...

Page 199: ...groove Install the stator and tighten the bolts to the speci fied torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft Apply sealant to the grommet seating surface and install it to the crankcase groove properly I...

Page 200: ...ll the washer and flywheel nut Hold the flywheel with the special tool and tighten the flywheel nut to the specified torque TOOL Universal holder 07725 0030000 TORQUE 44 N m 4 5 kgf m 33 Ibf ft Instal...

Page 201: ...12 CRANKSHAFT PISTON CYLINDER COMPONENT LOCATION 12 2 CRANKCASE SEPARATION 12 5 SERVICE INFORMATION 12 3 CRANKSHAFT PISTON 12 5 TROUBLESHOOTING 12 4 CRANKCASE ASSEMBLY 12 11 12 1...

Page 202: ...CRANKSHAFT PISTON CYLINDER COMPONENT LOCATION 25 N m 2 5 kgf m 18 Ibf ft 12N m 1 2kgf m 9 Ibf ft 12 2...

Page 203: ...n pin bore I D Piston pin O D Piston to piston pin clearance Piston ring to ring groove clearance Piston ring end gap Top Second Top Second Oil side rail Cylinder to piston clearance Connecting rod sm...

Page 204: ...rheating or knocking Excessive carbon build up on piston head or on combustion chamber Excessive smoke Worn cylinder piston or piston ring Improper installation of piston rings Scored or scratched pis...

Page 205: ...and sealing washer Loosen the crankcase bolts in a crisscross pattern in two or three steps Remove the crankcase bolts Becareful notto Place the upper crankcase facing down and sepa damage thecrank ra...

Page 206: ...spreading theends too far Spread each piston ring and remove it by lifting up at a point opposite the gap Never usea wire brush it will scratch the groove Clean carbon deposits from the ring grooves w...

Page 207: ...ring with your finger The bearing should turn smoothly and quietly Also check that the bearing inner race fits tightly on the crankshaft Replace the crankshaft assembly if the bearings do not turn smo...

Page 208: ...o the bottom of the cylin der squarely using the piston Measure the ring end gap SERVICE LIMIT Top Second 0 40 mm 0 016 in Oil side rail 0 80 mm 0 031 in Measure the piston pin hole Take the maximum r...

Page 209: ...e Measure the cylinder I D in the X and Y axes at three levels Take the maximum reading to determine the cylin der wear SERVICE LIMIT 37 76 mm 1 487 in Calculate the taper and out of round at three le...

Page 210: ...pply molybdenum disulfide oil to the piston pin Apply engine oil to the connecting rod small end and piston pin hole Install the piston with the IN mark facing the intake side Install the piston pin a...

Page 211: ...chain side while compressing the piston rings with rings andcylinder your fingers walls Align the crankshaft bearing groove with the set ring CRANKCASE ASSEMBLY Apply oil to a new crankshaft oil seal...

Page 212: ...ten the bolt to the specified torque TORQUE 25 Nm 2 5 kgf m 18 Ibf ft CRANKCASE BOLTS Clean the belt case mating surface of the crankcase Install a new rubber seal onto the crankcase Install the belt...

Page 213: ...NT WHEEL BRAKE SUSPENSION STEERING COMPONENT LOCATION 13 2 FORK 13 13 SERVICE INFORMATION 13 3 HANDLEBAR 13 17 TROUBLESHOOTING 13 5 EQUALIZER 13 20 FRONT WHEEL 13 6 STEERING STEM 13 21 FRONT BRAKE 13...

Page 214: ...FRONT WHEEL BRAKE SUSPENSION STEERING COMPONENT LOCATION 42 N m 4 3 kgf m 31 Ibfft 69 N m 7 0 kgf m 51 Ibf ft 44 N m 4 5 kgf m 33 Ibf ft 13 2...

Page 215: ...ECIFICATIONS Unit mm in ITEM Minimum tire tread depth Cold tire pressure Axle runout Wheel rim runout Brake Radial Axial Right brake lever free play Brake drum I D Brake lining thickness Fork spring f...

Page 216: ...nstaller 29 x 50 mm 07XMF GEE0200 two required Stem race installer 26 x 47 mm 07XMF GEE0100 Attachment 28 x 30 mm 07946 1870100 not available in U S A not available in U S A Fork seal driver 27 mm 079...

Page 217: ...ht Bent fork Bent front axle Wheel installed incorrectly Bent frame Worn wheel bearings Worn or damaged engine mounting bushings page 7 5 Front wheel wobbles Bent rim Worn or damaged front wheel beari...

Page 218: ...Loosen the front axle nut Support the scooter securely using a hoist or equiv alent and raise the front wheel off the ground Remove the front axle nut Remove the front axle out and remove the front wh...

Page 219: ...er race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if the races do no...

Page 220: ...e facing up until it is fully seated Install the distance collar Drive the new right bearing squarely with the sealed side facing up until it is fully seated using the same tools DRIVER TOOLS Driver A...

Page 221: ...ut and tighten it to the specified torque TORQUE 44 N m 4 5 kgf m 33 Ibf ft Apply oil to a new O ring and install it on the speed ometer cable Connect the speedometer cable into the brake panel j BRAK...

Page 222: ...n DISASSEMBLY NOTE Always replace the brake shoes as a set Mark all parts during disassembly so they can be placed back in the original locations Pull the brake shoes away from the anchors and remove...

Page 223: ...EERING Remove the nut bolt and brake arm NUT Remove the wear indicator felt seal and return spring Remove the brake cam from the brake panel INDICATOR PLATE BRAKE CAM RETURN SPRING ASSEMBLY NUT FELT S...

Page 224: ...shown Install the wear indicator onto the brake cam by aligning its wide tooth with the wide groove in the brake cam Install the brake arm by aligning the punch marks on the arm and brake cam Install...

Page 225: ...as shown Wipe any excess grease off the brake cam and anchor pin INSTALLATION Install the front wheel page 13 9 SHOE SPRINGS BRAKE SHOES REMOVAL Remove the front fender page 2 5 Remove the front whee...

Page 226: ...ube Remove the guide bushing and rebound from the fork tube spring FORK TUBE GUIDE BUSHING REBOUND SPRING Remove the fork spring and rubber stopper right side only from the bottom case BOTTOM CASE FOR...

Page 227: ...fork spring free length SERVICE LIMIT 125 9 mm 4 96 in ASSEMBLY RUBBER STOPPER RIGHT SIDE ONLY FORK SPRING BOTTOM CASE FORK CAP GUIDE BUSHING REBOUND SPRING FORK TUBE Apply 6 5 8g of grease to the fo...

Page 228: ...ing and guide bushing into the fork tube Install the fork tube into the bottom case GUIDE BUSHING Press the fork tube into the bottom case until the snap ring groove is visible Install the snap ring i...

Page 229: ...the front fender page 2 5 UPPER FORK PINCH BOLTS FORK LOWER FORK PINCH BOLTS HANDLEBAR REMOVAL Remove the front cover page 2 4 Remove the speedometer page 18 9 Remove the wire band from the handlebar...

Page 230: ...ove the stem cover only After 05 model only INSTALLATION Install the stem cover Install the handlebar post into the steering stem while aligning the tab of the handlebar post with the groove in the st...

Page 231: ...ip for even application of the adhesive before using Install the left handlebar switch housing aligning its locating pin with the hole in the handlebar Install the screws and tighten the forward screw...

Page 232: ...crew Install the rearview mirrors Install the wire bands Install the front cover page 2 4 Install the following Speedometer page 18 10 Front cover page 2 4 EQUALIZER REMOVAL INSTALLATION Remove the le...

Page 233: ...the reverse order of removal NOTE Apply silicone grease to the sliding surface of the equalizer Connect the left and right brake cables into the equalizer with the paint marks facing the cover Set th...

Page 234: ...ing puller 25 40 mm Slide hammer 3 8 X 16 07JAC PH80100 07JAC PH80200 07741 0010201 07736 A01000B or 07736 A01000A Commercially available Install a new lower bearing outer race and the spe cial tools...

Page 235: ...r attachment A aligns with the upper end of the steering head This will allow you to install the upper bearing outer race Install the steering stem lock nut onto the steering stem to prevent the threa...

Page 236: ...o each new bearing and inner race Install the lower bearing onto the stem STEERING STEM Insert the steering stem into the steering head pipe Install the upper bearing and top cone race Tighten the ste...

Page 237: ...cone race fully by hand after loos ening the top cone race 45 degrees Install the lock washer and lock nut Tighten the steering stem lock nut to the specified torque TOOL Socket wrench 32 mm 07916 KM...

Page 238: ...MEMO...

Page 239: ...14 REAR WHEEL BRAKE SUSPENSION COMPONENT LOCATION 14 2 REAR WHEEL 14 4 SERVICE INFORMATION 14 3 REAR BRAKE 14 5 TROUBLESHOOTING 14 3 REAR SHOCK ABSORBER 14 8 14 1...

Page 240: ...REAR WHEEL BRAKE SUSPENSION COMPONENT LOCATION 26 N m 2 7 kgfm 20 Ibf ft 26 N m 2 7 kgf m 20 Ibf ft 118 N m 12 0 kgf m 87 Ibf ft 14 2...

Page 241: ...0 0 04 TORQUE VALUES Rear axle nut Rear brake arm bolt Rear shock absorber mounting bolt 118 N m 12 0 kgfm 87 Ibfft 4 9 N m 0 5 kgf m 3 8 Ibfft 26 N m 2 7 kgf m 20 Ibf ft Apply oil to the threads U nu...

Page 242: ...Remove the two bolts and rear inner fender Remove the rear axle nut washer and rear wheel REAR INNER FENDER 1 INSTALLATION Install the rear wheel onto the final gear shaft align ing the spline Instal...

Page 243: ...Measure the brake lining thickness SERVICE LIMIT 1 0 mm 0 04 in DISASSEMBLY NOTE Always replace the brake shoes as a set Mark all parts during disassembly so they can be placed back in the original lo...

Page 244: ...n and return spring RETURN SPRING 3 BRAKE CABLE m JOINT v ADJUSTING 1 II w rzFyy j 1 PIN s ijr NUT Remove the brake arm bolt Remove the brake arm while pulling the brake cam out BRAKE CAM Remove the w...

Page 245: ...the brake cam into the brake panel Apply oil to the felt seal and install it into the brake panel Install the wear indicator plate onto the brake cam by aligning its wide tooth with the wide groove on...

Page 246: ...ING NUT BRAKE CABLE JOINT PIN Install the brake shoes and shoe springs onto the brake panel as shown Install the rear wheel page 14 4 Adjust the left brake lever free play page 3 16 SPRINGS BRAKE SHOE...

Page 247: ...sembly if necessary INSTALLATION Install the rear shock absorber and tighten the upper and lower mounting bolts to the specified torque TORQUE 26 N m 2 7 kgf m 20 Ibfft Install the air cleaner housing...

Page 248: ...MEMO...

Page 249: ...CHARGING SYSTEM SYSTEM DIAGRAM 15 2 CHARGING SYSTEM INSPECTION 15 7 SERVICE INFORMATION 15 3 ALTERNATOR CHARGING COIL 15 8 TROUBLESHOOTING 15 5 ENGINE CONTROL MODULE ECM 15 9 BATTERY 15 6 MAIN RELAY...

Page 250: ...DIAGRAM STARTER RELAY E C M MAIN FUSE MAIN RELAY IGNITION SWITCH ALTERNATOR STARTER MAIN FUSE MAIN RELAY 20A START RELAY ENGINE CONTROL MODULE ECM ALTERNATOR STARTER B l Y B u G R w B r BLACK YELLOW B...

Page 251: ...battery itself which may appear to be an overcharging symptom If one of the battery cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the batte...

Page 252: ...ly charged Needs charging Normal Quick Capacity Charging coil resistance 20 C 68 F SPECIFICATION 12V 6 Ah 0 1 mA max 13 0 13 2 V Below 12 3 V 0 6 A 5 10 h 3A 1h 190W 5 000 rpm 0 05 0 5 Q TOOLS Battery...

Page 253: ...tch YES Faulty ECM 4 CHARGING VOLTAGE INSPECTION Measure and record the battery voltage using a digital multimeter page 15 7 Start the engine Measure the charging voltage page 15 8 Compare the measure...

Page 254: ...n nect the negative cable Remove the positive terminal bolt and discon nect the fuse box positive cable Remove the battery band and battery Install the battery in the reverse order of removal NOTE Con...

Page 255: ...HARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST Turn the ignition switch to OFF and disconnect the negative cable from the battery Connect the ammeter probe to the negative cable and the ammeter probe...

Page 256: ...ith the headlight on high beam restart the engine Measure the voltage on the multimeter when the engine runs at 5 000 rpm Standard Measured BV Measured CV 15 5 V BV Battery Voltage page 15 7 CV Chargi...

Page 257: ...tery voltage at all times If there is no voltage check for a blown main fuse 15A and an open or short circuit in the wire har ness GROUND LINE Check the continuity between the Green wire termi nal and...

Page 258: ...e is no continuity check for an open or short circuit in the wire harness CHARGING COIL LINE Measure the resistance between the Red yellow Red White and Red blue wire terminals STANDARD 0 05 0 5 Q 20...

Page 259: ...26P s CONNECTOR MAIN RELAY Remove the body cover page 2 7 Remove the ECM see above 6P CONNECTOR WIRE CLAMP Disconnect the main relay 3P connector then remove the main relay SYSTEM INSPECTION NOTE Mak...

Page 260: ...the voltage between the Red green and Green white wire terminals Is there battery voltage NO Check for an open or short circuit in wire harness If there is normal replace the ECM YES GO TO STEP 4 FVG...

Page 261: ...CTION Check for continuity between the A and Bterminals There is usually no continuity there should be con tinuity when the battery is connected to C and D terminals INSTALLATION Install the main rela...

Page 262: ...MEMO...

Page 263: ...16 IGNITION SYSTEM SYSTEM DIAGRAM 16 2 IGNITION COIL 16 7 SERVICE INFORMATION 16 3 IGNITION TIMING 16 8 TROUBLESHOOTING 16 4 THROTTLE POSITION SENSOR 16 8 IGNITION SYSTEM INSPECTION 16 5 16 1...

Page 264: ...ATTERY IGNITION SWITCH IGNITION COIL ECTSENSOR SPARK PLUG IGNITION PULSE GENERATOR IGNITION SWITCH TJ ECT SENSOR IGNITION COIL THROTTLE POSITION SENSOR SPARK PLUG ENGINE STOP SWITCH ENGINE CONTROL MOD...

Page 265: ...ngine speed fundamentally ignition timing is assisted also with the signal from the throttle position sensor and ECT sensor Use a spark plug of the correct heat range Using a spark plug with an incorr...

Page 266: ...ce Does not apply to Imrie tester 5 Poorly connected connectors or an open circuit in igni tion system 6 Faulty ignition coil 7 Faulty ECM in case when above No 1 6 are normal 1 Incorrect peak voltage...

Page 267: ...h commercially available digital multimeter impedance 10 MU DCV minimum or IgnitionMate peak voltage tester MTP 08 0193 U S A only DIGITAL MULTIMETER PEAK VOLTAGE ADAPTOR IGNITION COIL PRIMARY PEAK VO...

Page 268: ...ed value fol low the checks described in the troubleshooting chart page 16 4 Install the removed parts in the reverse order of removal IGNITION PULSE GENERATOR PEAK VOLTAGE NOTE Check cylinder compres...

Page 269: ...oltage measured at the ECM is abnormal and the one measured at the alterna tor starter is normal the wire harness has an open or short circuit or loose connection If the peak voltage is lower than sta...

Page 270: ...aligns with the index mark at idle Install the removed parts in the reverse order of removal THROTTLE POSITION SENSOR SYSTEM INSPECTION Disconnect the ECM 26P connector Measure the resistance between...

Page 271: ...ion sensor 3P connec tor Turn the ignition switch to ON and engine stop switch to Measure the input voltage between the Yellow red and Blue green wire terminals of the wire har ness side connector If...

Page 272: ...and rotate the throttle grip while resetting the throttle position sensor Remove the fuse box cover 1 Turn the ignition switch to OFF 2 Short the Blue Yellow wire terminal of the ser vice check 2P con...

Page 273: ...17 ELECTRIC STARTER SYSTEM DIAGRAM 17 2 STARTER RELAY 17 6 SERVICE INFORMATION 17 3 ENGINE CONTROL MODULE ECM 17 7 TROUBLESHOOTING 17 4 17 1...

Page 274: ...AIN RELAY RIGHT BRAKE LIGHT SWITCH STARTER SWITCH IGNITION SWITCH THROTTLE POSITION SENSOR BATTERY ALTERNATOR STARTER SUB FUSE 10A RIGHT BRAKE LIGHT SWITCH ENGINE CONTROL MODULE ECM STARTER SWITCH THR...

Page 275: ...equence on page 17 4 This scooter has adopted an alternator starter that functions like both an alternator and starter motor A weak battery may be unable to turn the starter quickly enough or supply a...

Page 276: ...he Green wire terminal of the wire harness and body ground Does continuity exist YES GO TO STEP 5 NO Open circuit in the Green wire between the 6P connector of the ECM and battery 5 Stator Coil Inspec...

Page 277: ...witch circuit normal YES GO TO STEP7 NO Open circuit in the Green yellow wire between the brake light switch and starter switch Faulty starter switch Open circuit in Yellow green wire between starter...

Page 278: ...nuity when the battery is con nected to E andC terminals of the starter relay RELAY CIRCUIT INSPECTION NOTE Make sure the main relay and relative circuit is normal before performing this inspection Re...

Page 279: ...9PCONNECTOR ANGLE SENSOR CIRCUIT INSPECTION Remove the luggage box page 2 6 Disconnect the alternator starter 6P W connector and check the connector for loose contacts of cor roded terminals Check fo...

Page 280: ...MEMO...

Page 281: ...N SIGNAL LIGHT 18 5 BRAKE TAIL LIGHT 18 7 LICENSE LIGHT 18 8 TURN SIGNAL INDICATOR 18 9 SPEEDOMETER 18 9 FUEL GAUGE FUEL LEVEL SENSOR 18 12 COOLANT TEMPERATURE INDICATOR ECT SENSOR 18 14 FUEL PUMP 18...

Page 282: ...TEM LOCATION ENGINE STOP SWITCH LEFT BRAKE LIGHT SWITCH METER DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH STARTER SWITCH RIGHT BRAKE LIGHT SWITCH u IGNITION SWITCH TURN SIGNAL RELAY FUEL LEVEL SENSOR...

Page 283: ...s and cables properly after servicing each component page 1 14 The following color codes used are indicated through out this section Bu Bl Br Blue Black Brown G Green Gr Gray Lb Light Blue Lg 0 R Ligh...

Page 284: ...nt its early failure Install the bulb into the headlight and hook the bulb retainer properly Install the dust cover properly on to the headlight with the TOP mark facing up Install the front cover pag...

Page 285: ...ll the headlight unit in the reverse order of removal Adjust the headlight beam vertically and horizon tally page 3 18 TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw and turn signal light lens Wh...

Page 286: ...nuity exist NO Faulty turn signal switch YES Open circuit in Black gray wire of the turn signal relay Open circuit in the Green black wire between the turn signal light and ECM Faulty ECM REMOVAL INST...

Page 287: ...t but will go on or be ready for operation after starting the engine Brake tail light does not operate 1 Operation of The Lights Inspection Check if the tail light and brake light do not oper ate Whic...

Page 288: ...n relay page 15 11 Blown sub fuse 10A Faulty ignition switch page 18 19 Faulty ECM YES Open circuit in the Green yellow wire between the brake light switch and brake light REMOVAL INSTALLATION Remove...

Page 289: ...replace with a new one Install the turn signal indicator lends SPEEDOMETER BULB REPLACEMENT Remove the front meter cover page 2 12 Remove the bulb socket Remove the bulb from the bulb socket and repla...

Page 290: ...ct the connectors and speedometer cable CONNECTORS Disconnect the meter 6P and 3P connectors Remove the screws and speedometer Route thecables Installation is in the reverse order of removal and wire...

Page 291: ...e screw and clamp Disconnect the connectors SCREW Remove the screws and wires from the speedome ter Remove the screws meter lens and meter SOCKET SCREW SCREWS CLAMP Remove the cap Remove the indicator...

Page 292: ...as shown Install the speedometer page 18 10 YELLOW WHITE BLACK BLUE WHITE FUEL GAUGE FUEL LEVEL SENSOR SYSTEM INSPECTION Remove the front meter cover page 2 12 Measure the voltage between the Black w...

Page 293: ...or 3P Bu connector from the back side of the lower cover Disconnect the fuel level sensor 3P Bu connector Remove the wire harness from the clamp Turn the sensor retainer counterclockwise remove it Rem...

Page 294: ...he arrows are aligned Install the wire to the clamp Install the step floor page 2 9 COOLANT TEMPERATURE INDICATOR ECT SENSOR NOTE When the coolant temperature exceeds 120 C 248 F the coolant temperatu...

Page 295: ...oes the indicator light NO Faulty indicator wire harness YES Open circuit of White wire between the ECM and ECT sensor Open circuit of Light green red wire between the speedometer and ECM Faulty ECM W...

Page 296: ...den change of temperature will result in incorrect reading Do not let the thermometer or ECT sensor touch the pan Measure the resistance between the ECT sensor terminal and its threads Temperature Res...

Page 297: ...ry voltage with the ignition switch turned to ON and the engine stop switch turned to Q Is there battery voltage NO Open circuit in Red black wire between the fuel pump and main relay Inspect the main...

Page 298: ...Multiply the amount in the beaker by 12 to deter mine the fuel pump flow capacity per minute FUEL PUMP FLOW CAPACITY 100 cm3 3 4 US oz 3 5 Imp oz minimum minute If the flow capacity is out of specific...

Page 299: ...switch 3P connector Open the cover of the ignition switch Remove the seat lock cable from the ignition switch and disconnect the cable from the arm Remove the wire band from the stay Remove the two sc...

Page 300: ...OLOR CDI C Y G ST o G Y ENGINE STOP SWITCH o COLOR BAT 0 Bl R CONV 0 Bl W BRAKE LIGHT SWITCH DIMMER SWITCH HORN SWITCH TURN SIGNAL SWITCH ENGINE STOP SWITCH STARTER SWITCH Remove the front meter cover...

Page 301: ...N Remove the front cover page 2 4 Disconnect the horn connectors from the horn Connect a 12V battery to the horn terminals The horn is normal if it sounds when the 12V battery is connected across the...

Page 302: ...MEMO...

Page 303: ...19 WIRING DIAGRAMS STANDARD 02 05 model 19 3 After 05 model 19 5 P type 02 05 model 19 4 19 1...

Page 304: ...V a I 1 TTTLL_ I 1 T T I 1 I 111 1 ill F 1 1 COOLANTTEMPERATURE i L E V m J n H O R N I J l L j fj J f I MAIN RELAY SPEEDOM ETER iii EMBiy rl p f f l L 1 I SPARKPLUG E C T R N j fX _ S s r 4 J J J J...

Page 305: ...L U r j Ln fTlM P i t t 1U Y THLE S k i I M A I N R E W Y SPEEDOMETERASSEMBLY A S S f l l I I SPARKPLUG ECTSOR PosmORN j _W f I L Ur i T F U E L LEVELS E N S O R UNIT j t SH U f TURNSIGNAL 1 2 V Z F...

Page 306: ...1 juluL b d I t r 1 IGNITION p cr pgi n r L JI T fe fc I Wjs l W T J5 T ffi P U E L P U M P I co r f j Afl m TTT J I V T L e Ll l Bu 1 i LEFT REAR B R A K E I I V I i 3 V l i oS S5 i S I C O O L T T E...

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Page 308: ...20 TECHNICAL FEATURES MAGNETIC COUPLING WATER PUMP 20 2 BRUSHLESS ALTERNATOR STARTER 20 3 20 1...

Page 309: ...e which separates the coolant from the engine oil A plastic collar acts as a bearing Compared to a conventional type water pump this pump eliminates the mechanical seal oil seal and ball bearing allow...

Page 310: ...r coil to turn the flywheel when starting and to increase charging current under 3 500 rpm to enhance charging capability ROTOR CORE MAGNET CRANKSHAFT FLYWHEEL STATOR SENSOR MAGNET ANGLE SENSOR The fl...

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Page 312: ...21 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO POOR PERFORMANCE START 21 2 AT HIGH SPEED 21 6 ENGINE LACKS POWER 21 3 POOR HANDLING 21 7 POOR PERFORMANCE AT LOW AND IDLE SPEED 21 5 21 1...

Page 313: ...3 Cylinder Compression Inspection Test the cylinder compression Is the compression within specification IMO Valve stuck open Worn cylinder and piston rings Seized valve Improper valve timing YES GO T...

Page 314: ...ace spring Additive in engine oil Weight roller stuck YES GO TO STEP 4 4 Engine Performance Inspection Accelerate lightly Does the engine speedincrease NO Faulty starting enrichment SE valve Clogged a...

Page 315: ...enough NO G O TO STEP 10 10 lubrication Inspection Remove the cylinder head cover and inspect for sings of proper lubrication Is the valve train lubricated properly NO Clogged oil passage YES G O TO S...

Page 316: ...osition NO page 5 18 YES GO TO STEP 4 4 Starting enrichment SE valve Inspection Check the starting enrichment SE valve te the starting enrichment SE valveOK NO Faulty starting enrichment SE valve YES...

Page 317: ...ets Are the jets clogged YES Clean the jets NO GO TO STEP 4 4 Spark Plug Inspection Remove and inspect the spark plug Is the spark plug in good condition NO Plug not serviced frequently enough Incorre...

Page 318: ...oo tight Damaged steering head bearings Either wheel wobbles Excessive wheel bearing play Bent rim Excessively worn engine mounting bushing Bent frame The scooter pulls to one side Front and rear whee...

Page 319: ...MEMO...

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