Yamaha 2005 YP400T Service Manual Download Page 184

Page: 184 / 390

4 - 51

CHAS

FRONT FORK

NOTE:

•

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

- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
- cap bolt O-ring

•

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

1. Install:

•

damper rod

•

rebound spring

CAUTION:

Allow the damper rod to slide slowly down
the inner tube

until it protrudes from the

bottom of the inner tube. Be careful not to
damage the inner tube.

2. Lubricate:

•

inner tube

’

s outer surface

Recommended lubricant

Yamaha fork oil 10 WT

3. Tighten:

•

copper washer

•

damper rod bolt

NOTE:

While holding the damper rod assembly with
the damper rod holder

and T-handle

tighten the damper rod bolt.

Damper rod bolt

30 Nm (3.0 m

kg, 22 ft

lb)

LOCTITE

Damper rod holder

90890-01460

T-handle

90890-01326

New

Downloaded

from www.ScooterTime.net

Summary of Contents for 2005 YP400T

Page 1: ...2005 2007 MOTORCYCLE SERVICE MANUAL Model YP400T YP400V YP400W 5RU281972000 5RU281972000 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 2: ...Yamaha Motor Co Ltd First edition June 2004 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 3: ...ficant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers 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 B...

Page 4: ...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 i...

Page 5: ...ool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Engine oil I Gear oil J Molybdenum disulfide oil K Wheel bearing grease L Lithium soap based grease M Molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate the following N Apply locking agent LOCTITE...

Page 6: ...I SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 10 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 10 REPLACEMENT PARTS 1 10 GASKETS OIL SEALS AND O RINGS 1 10 LOCK WASHERS PLATES AND COTTER PINS 1 11 BEARINGS AND OIL SEALS 1 11 CIRCLIPS 1 11 CHECKING THE CONNECTIONS 1 12 SPECIAL TOOLS 1 13 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 7: ...ification number 1 is stamped into the frame 1 EAS00018 MODEL LABEL The model label 1 is affixed inside the storage box Record the information on this label in the space provided This information will be needed when ordering spare parts 1 SCOOTER IDENTIFICATION D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 8: ...rmance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor tha...

Page 9: ...he injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake tempera ture sensor and coolant temperature sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that is requ...

Page 10: ...led since they were last set to zero a fuel reserve tripmeter which shows the distance traveled since the bottom segment of the fuel meter and fuel level warning symbol started flashing a self diagnosis device a clock an ambient temperature display an oil change indicator a V belt replacement indicator NOTE Be sure to turn the key to ON before using the SELECT and RESET buttons When the key is tur...

Page 11: ...or TRIP F will only flash for five seconds While TRIP or TRIP F is flashing push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automati cally and the display will return to the prior mode after refueling and traveling 5 km 3 mi NOTE The display cannot be changed back to TRIP F after pushing the RESET button Fuel meter With the...

Page 12: ...icator Refer to To reset the oil change indicator If the engine oil is changed before the oil change indicator comes on i e before the periodic oil change interval has been reached the indicator must be reset after the oil change for the next periodic oil change to be indicated at the correct time The electrical circuit of the indicator can be checked according to the following procedure 1 Set the...

Page 13: ... when the V belt needs to be replaced The electrical circuit of the indicator can be checked according to the following procedure 1 Turn the key to ON and make sure that the engine stop switch is set to 2 If the indicator does not come on check the electrical circuit Refer to SIGNALING SYSTEM in chapter 8 To reset the V belt replacement indicator 1 Turn the key to ON and make sure that the engine ...

Page 14: ...icates an error code the vehicle should be checked as soon as possible in order to avoid engine damage Clock mode To set the clock 1 Push the SELECT button and RESET button together for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the min utes 5 Pus...

Page 15: ...alls below 10 0 C 10 0 C is displayed When the ambient temperature climbs above 50 0 C 50 0 is displayed NOTE If C is displayed or 50 0 flashes while the ambient temperature is between 10 0 C and 50 0 C there is a problem with the elec trical circuit Check or repair the electric cir cuit or replace the thermistor The accuracy of the temperature reading may be affected when riding slowly approxi ma...

Page 16: ...em in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS00022 ...

Page 17: ...al lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 2 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing ...

Page 18: ...l connections Loose connection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all connections are tight 5 Check continuity with the pocket tester NOTE _ If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part st...

Page 19: ...5 Rotor holding tool This tool is used to hold the primary fixed sheave and clutch shoe assembly 90890 01268 YU 01268 Ring nut wrench This tool is used to loosen or tighten the steering ring nuts 90890 01304 YU 01304 Piston pin puller set This tool is used to remove the piston pins Radiator cap tester 90890 01325 YU 24460 01 Radiator cap tester adapter 90890 01352 YU 33984 Radiator cap tester Radi...

Page 20: ...iding sheave 90890 01403 YU A9472 Steering nut wrench This tool is used to loosen or tighten the steering ring nuts Pivot shaft wrench 90890 01471 YM 01471 Pivot shaft wrench adapter 90890 01476 Pivot shaft wrench Pivot shaft wrench adapter These tools are used to tighten the sub frame adjusting bolt 90890 01701 YS 01880 A Sheave holder This tool is used to hold the generator rotor and clutch hous...

Page 21: ...to remove or install the valve assemblies Middle driven shaft bearing driver 90890 04058 YM 04058 Mechanical seal installer 90890 04145 YM 04145 Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal 90890 04097 YM 04097 Valve guide remover 5 mm This tool is used to remove or install the valve guides 90890 04098 YM 04098 Valve guide install...

Page 22: ...lling the clutch shoe assembly nut 90890 04146 YM 04146 Plane bearing installer remover This tool is used to install or remove the crankshaft journal bearings 90890 06754 YM 34487 Ignition checker This tool is used to check the ignition sys tem components Bond 90890 85505 Sealant ACC 11001 05 01 Yamaha bond No 1215 Sealant Quick Gasket This bond is used to seal two mating sur faces e g crankcase m...

Page 23: ...TENING TORQUE SPECIFICATIONS 2 17 TIGHTENING TORQUES 2 18 ENGINE TIGHTENING TORQUES 2 18 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2 23 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES 2 25 COOLING SYSTEM DIAGRAMS 2 26 CABLE ROUTING 2 28 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 24: ...th 780 mm 30 7 in Overall height 1 380 mm 54 3 in Seat height 750 mm 29 5 in Wheelbase 1 565 mm 61 6 in Minimum ground clearance 120 mm 4 72 in Minimum turning radius 2 600 mm 102 4 in Weight Wet with oil and a full fuel tank 212 kg 467 lb Maximum load total of cargo rider passenger and accessories 196 kg 432 lb D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 25: ... Unleaded gasoline only USA Regular unleaded gasoline only CDN Fuel tank capacity Total 14 0 L 3 08 Imp gal 3 70 US gal Engine oil Lubrication system Wet sump Recommended oil Refer to the chart for the engine oil grade Recommended engine oil grade API service SE SF SG type or higher Quantity Total amount 1 70 L 1 50 Imp qt 1 80 US qt Without oil filter element replace ment 1 50 L 1 32 Imp qt 1 59 ...

Page 26: ...10 1 40 kg cm2 15 6 19 9 psi Radiator core Width 260 mm 10 24 in Height 148 mm 5 83 in Depth 24 mm 0 94 in Coolant reservoir Capacity 0 32 L 0 28 Imp qt 0 34 US qt Water pump Water pump type Single suction centrifugal pump Reduction ratio 37 22 25 37 1 136 Coolant temperature 80 90 C 176 194 F Starting system type Electric starter Electric fuel injection Type 1100 87C00 A Manufacturer AISAN Spark ...

Page 27: ...8 mm 0 0031 in Intake camshaft lobe dimensions Measurement A 34 350 34 450 mm 1 352 1 356 in 34 250 mm 1 3484 in Measurement B 24 950 25 050 mm 0 982 0 986 in 24 850 mm 0 9783 in Exhaust camshaft lobe dimensions Measurement A 33 450 33 550 mm 1 317 1 321 in 33 350 mm 1 3130 in Measurement B 24 956 25 056 mm 0 983 0 986 in 24 856 mm 0 9786 in Maximum camshaft runout 0 03 mm 0 0012 in Item Standard ...

Page 28: ...xhaust 1 0 1 2 mm 0 0394 0 0472 in 1 6 mm 0 06 in Valve margin thickness D Intake 0 85 1 15 mm 0 0335 0 0453 in Exhaust 0 85 1 15 mm 0 0335 0 0453 in Valve stem diameter Intake 4 975 4 990 mm 0 1959 0 1965 in 4 945 mm 0 1947 in Exhaust 4 960 4 975 mm 0 1953 0 1959 in 4 930 mm 0 1941 in Valve guide inside diameter Intake 5 000 5 012 mm 0 1969 0 1973 in 5 050 mm 0 1988 in Exhaust 5 000 5 012 mm 0 19...

Page 29: ...5 10 mm 1 38 in Spring rate K1 Intake 15 21 N mm 1 55 kg mm 86 77 lb in Exhaust 15 21 N mm 1 55 kg mm 86 77 lb in Spring rate K2 Intake 19 84 N mm 2 02 kg mm 113 28 lb in Exhaust 19 84 N mm 2 02 kg mm 113 28 lb in Compressed spring force installed Intake 160 5 184 7 N at 35 10 mm 16 37 18 83 kg at 35 10 mm 36 08 41 52 lb at 1 38 in Exhaust 160 5 184 7 N at 35 10 mm 16 37 18 83 kg at 35 10 mm 36 08...

Page 30: ...m 0 20 in Piston pin bore in the piston Diameter 20 004 20 015 mm 0 7876 0 7880 in 20 045 mm 0 7892 in Offset 1 0 mm 0 0394 in Offset direction Intake side Piston pin Outside diameter 19 991 20 000 mm 0 7870 0 7874 in 19 971 mm 0 7863 in Piston pin to piston pin bore clear ance 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dimensions B T 1 00 2 70 mm 0 0...

Page 31: ...157 in Ring side clearance 0 040 0 140 mm 0 0016 0 0055 in Crankshaft Width A 63 95 64 00 mm 2 518 2 520 in Maximum runout C 0 030 mm 0 0012 in Big end side clearance D 0 350 0 850 mm 0 0138 0 0335 in Big end radial clearance E 0 010 0 024 mm 0 0004 0 0009 in Crankshaft journal to crankshaft journal bearing clearance 0 030 0 077 mm 0 0012 0 0030 in 0 09 mm 0 0035 in Bearing color code 0 White 1 Bl...

Page 32: ...stem Helical gear Primary reduction ratio 31 14 2 214 Secondary reduction system Helical gear Secondary reduction ratio 42 16 2 625 Clutch type Dry centrifugal automatic Transmission type V belt automatic Operation Centrifugal automatic type Single speed automatic 2 380 0 892 1 Air filter Air filter element Oil coated paper element Air filter oil grade Foam air filter oil or SAE10W30SE Fuel pump P...

Page 33: ...e bending limit 0 25 mm 0 01 in Rear wheel Wheel type Cast wheel Rim Size 13 M C MT4 00 Material Aluminum Wheel travel 104 mm 4 09 in Wheel runout Maximum radial wheel runout 1 0 mm 0 04 in Maximum lateral wheel runout 0 5 mm 0 02 in Front tire Tire type Tubeless Size 120 80 14M C 58S Model manufacturer MB 67 IRC D305FL DUNLOP Tire pressure cold 0 90 kg 0 198 lb 200 kPa 2 00 kgf cm2 29 psi 90 196 ...

Page 34: ...d depth 1 0 mm 0 04 in Front brake Brake type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Brake discs Diameter thickness 267 5 mm 10 51 0 20 in Minimum thickness 4 5 mm 0 18 in Maximum deflection 0 15 mm 0 006 in Brake pad lining thickness 6 0 mm 0 24 in 0 8 mm 0 03 in Master cylinder inside diameter 14 0 mm 0 55 in Caliper cylinder inside diameter 30 16 mm and 33 34 m...

Page 35: ... travel 120 mm 4 72 in Spring Free length 316 7 mm 12 47 in 310 4 mm 12 22 in Installed length 296 7 mm 11 68 in Spring rate K1 14 09 N mm 1 44 kg mm 80 45 lb in Spring rate K2 26 67 N mm 2 72 kg mm 152 28 lb in Spring stroke K1 0 90 mm 0 3 54 in Spring stroke K2 90 120 mm 3 54 4 72 in Inner tube outer diameter 41 mm 1 61 in Inner tube bending limit 0 2 mm 0 01 in Optional spring available No Fork...

Page 36: ...6 mm 12 07 in 300 0 mm 11 81 in Installed length 290 6 mm 11 44 in Spring rate K1 6 22 N mm 0 63 kg mm 35 52 lb in Spring rate K2 11 80 N mm 1 20 kg mm 67 38 lb in Spring rate K3 22 50 N mm 2 29 kg mm 128 47 lb in Spring stroke K1 0 29 mm 0 1 14 in Spring stroke K2 29 90 mm 1 14 3 54 in Spring stroke K3 90 130 mm 3 54 5 12 in Optional spring available No Swingarm Free play at the end of the swing ...

Page 37: ...C 68 F Spark plug cap Material Resin Resistance 10 0 kΩ at 20 C 68 F Charging system System type A C magneto Model manufacturer F5RU MORIC Nominal output 14 V 27 5 A at 5 000 r min Stator coil resistance color 0 184 0 276 Ω at 20 C 68 F white white Rectifier regulator Regulator type Semiconductor short circuit type Model manufacturer SH678 11 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectif...

Page 38: ...l length 12 mm 0 47 in 4 0 mm 0 16 in Spring force 7 65 10 01 N 780 1 021 gf 27 54 36 03 oz Armature coil resistance 0 0012 0 0022 Ω at 20 C 68 F Insulation resistance Above 1 MΩ at 20 C 68 F Commutator diameter 28 mm 1 1 in 27 mm 1 06 in Mica undercut 0 7 mm 0 028 in Starter relay Model manufacturer 2768098 A JIDECO Amperage 180 A Horn Horn type Plane Model manufacturer quantity HF 12 NIKKO 1 Max...

Page 39: ...Running rpm 4 500 r min Coolant temperature sensor Model manufacturer 5PS DENSO Resistance at 20 C 68 F 2 32 2 59 kΩ Resistance at 80 C 176 F 0 310 0 326 kΩ Resistance at 110 C 230 F 0 140 0 144 kΩ Intake air pressure sensor Output voltage 3 4 3 8 V Intake air temperature sensor Resistance 2 3 2 6 kΩ at 20 C 68 F Speed sensor Output voltage When sensor is on DC 4 8 V or more When sensor is off DC ...

Page 40: ...ations require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Tighten ing torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph Distan...

Page 41: ...Bolt M6 3 10 1 0 7 2 Oil cooler outlet hose joint Bolt M6 1 10 1 0 7 2 Thermostat cover Bolt M6 2 10 1 0 7 2 Radiator filler hose and bracket Bolt M5 1 9 0 9 6 5 Radiator pipe assembly Bolt M6 3 7 0 7 5 1 Oil cooler pipe Bolt M6 2 10 1 0 7 2 LT Oil cooler cover Bolt M6 3 10 1 0 7 2 Coolant drain bolt M6 1 10 1 0 7 2 Air bleed bolt coolant M5 1 6 0 6 4 3 Oil pump assembly Bolt M6 2 7 0 7 5 1 Oil st...

Page 42: ...7 16 1 6 11 V belt case Bolt M8 1 22 2 2 16 V belt case Bolt M6 9 10 1 0 7 2 V belt case cover Bolt M6 6 7 0 7 5 1 Generator rotor cover inner bracket Bolt M6 2 7 0 7 5 1 LT Generator rotor cover Bolt M6 11 10 1 0 7 2 Primary sheave Nut M18 1 83 8 3 60 Timing plug M16 1 8 0 8 5 8 Engine oil drain bolt M12 1 20 2 0 14 Secondary sheave Nut M14 1 60 6 0 43 Starter clutch Bolt M8 6 30 3 0 22 LT Clutch...

Page 43: ...2 20 SPEC Camshaft cap tightening sequence Cylinder head tightening sequence TIGHTENING TORQUES D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 44: ... 0 7 5 1 Fuel hose holder and sub frame M6 7 0 7 5 1 Ignition coil and ignition coil bracket M6 7 0 7 5 1 Ignition coil bracket and sub frame M8 16 1 6 11 Engine bracket upper mounting nut M12 59 5 9 43 Engine bracket lower mounting bolt M10 45 4 5 32 LT Engine mounting nut M12 65 6 5 47 Engine bracket bolt M10 56 5 6 40 LT Front cowling stay and frame M10 32 3 2 23 Steering stem nut M20 140 14 0 ...

Page 45: ... and frame M6 10 1 0 7 2 Grab bar bracket and frame M8 30 3 0 22 Grab bar and grab bar bracket M8 23 2 3 17 Grab bar and frame M8 23 2 3 17 Passenger seat and grab bar M6 7 0 7 5 1 Seat bracket and frame M8 30 3 0 22 Gas spring assembly bracket and frame M8 30 3 0 22 Front brake hose holder and lower bracket M6 7 0 7 5 1 Front brake hose holder and outer tube M6 7 0 7 5 1 Sidestand and sub frame M...

Page 46: ...od small end E Balancer driven gear assembly E Impeller shaft end E Camshaft lobes M Camshaft journals M Valve stems intake and exhaust M Valve stem ends intake and exhaust E Decompressor lever pin and spring E Oil pump shafts E O ring fuel injector assembly Silicone oil Primary sheave collar and O ring Shell BT grease 3 Secondary sheave collar and O ring Shell BT grease 3 Engine mounting bolt col...

Page 47: ...ransmission case breather pipe LT Cylinder head cover guide stopper mating surface Yamaha bond No 1215 Crankcase mating surface Yamaha bond No 1215 Generator rotor cover grommet mating surface Yamaha bond No 1215 Lubrication point Lubricant D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 48: ...t LS Rear brake lock lever cable and rear brake lock lever cable connection area LS Front wheel oil seal LS Speed sensor oil seal LS Rear axle LS Sidestand pivoting point metal to metal moving parts and collar outer sur face LS Centerstand shaft pivoting point and metal to metal moving parts LS Centerstand stopper pivoting point LS Centerstand and sidestand spring hook metal to metal moving parts ...

Page 49: ...LING SYSTEM DIAGRAMS 1 Radiator outlet hose 2 Radiator 3 Radiator cap 4 Coolant reservoir hose 5 Radiator filler hose 6 Radiator inlet hose 7 Radiator pipe assembly 1 2 3 5 6 7 6 2 1 7 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 50: ...let hose 5 Water pump cover 6 Water pump inlet hose 7 Thermostat inlet hose 8 Cooling system air bleed hose 9 Thermostat outlet hose 0 Thermostat A Thermostat cover B Water jacket inlet pipe C Oil cooler pipe A A C C B C C B A C 2 0 3 B 5 4 3 2 6 7 8 9 1 A A D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 51: ... Front brake hose 7 Handlebar switch leads È Route the handlebar switch leads to the left of the cable guide lower handlebar holder É Route the throttle cables in front of the handle bar Ê Fasten the right handlebar switch lead to the handlebar with a plastic locking tie 6 Ï A B C C Ñ A B C C 6 Í 7 Î Ï 2 4 5 1 3 4 6 5 4 5 Ñ È 1 1 2 Ð Ë Ì Ê É D o w n l o a d e d f r o m w w w S c o o t e r T i m e ...

Page 52: ...ass the throttle cables rear brake hose and rear brake lock lever cable through the cable guide lower handlebar holder Ï Install the grommet on the front brake hose in the hole in the lower handlebar cover before connecting the hose Ð Pass the rear brake lock lever cable through the hole in the lower handlebar cover Ñ Pass the throttle cables through the hole in the lower handlebar cover 6 Ï A B C...

Page 53: ... position light lead right E Front turn signal position light lead left F Front turn signal position light lead coupler right G Headlight lead H Front turn signal position light lead coupler left I Starting circuit cut off relay J Headlight relay 2 K Turn signal relay D A B C D 4 3 5 6 È H H E F F G E B F F H H Ó F F G 0 U 0 8 Ò Ô J J K K I I G D E 8 Ö 8 Õ D E 8 JKLM F Q R N O D P I Ï C 4 3 S 6 7 ...

Page 54: ...ire harness to the frame with a plas tic locking tie Face the end of the plastic locking tie down Ê The paint marks on the rear brake lock lever cable and the rear brake hose should be within 20 mm 0 79 in above or below the upper edge of the hole in the frame D A B C D 4 3 5 6 È H H E F F G E B F F H H Ó F F G 0 U 0 8 Ò Ô J J K K I I G D E 8 Ö 8 Õ D E 8 JKLM F Q R N O D P I Ï C 4 3 S 6 7 T 5 S 5 ...

Page 55: ...rottle cables Ð Route the handlebar switch leads in front of the front brake hose Ñ Route the rear brake hose and rear brake lock lever cable in front of the front brake hose and throttle cables Ò Fasten the rectifier regulator lead and radiator fan motor lead to the sub frame with a plastic band Face the end of the plastic band towards the rear of the scooter D A B C D 4 3 5 6 È H H E F F G E B F...

Page 56: ...ter facing down Ö Fasten the wire harness to the front cowling stay with a plastic band The end of the plastic band should be towards the rear of the scooter facing down Fasten the wire harness at the white tape to the front cowling stay with a plastic band The end of the plastic band should be towards the rear of the scooter facing down D A B C D 4 3 5 6 È H H E F F G E B F F H H Ó F F G 0 U 0 8 ...

Page 57: ... C Fuel hose D Spark plug lead E Sidestand switch F Stator coil lead G Wire harness H Throttle cable accelerator cable I Throttle cable decelerator cable J Stator coil lead coupler K Storage box light lead L Turn signal position light fuse I J E E Ô 8 7 È 1 I H Ï F G G Ñ C C D D A A 3 4 5 B B 3 J G Ð C C A A B B B 6 É 9 F F D D K L L K 8 7 L M B Ø Ú Û Þ Ý Ü ß 7 8 G Ö G K 6 Õ 8 O G N G N 7 8 Á K K ...

Page 58: ...ead below the bracket on the frame Ì Fasten the wire harness starter motor lead and negative battery lead to the frame with plastic locking ties Face the end of each plastic locking tie away from the scooter Í Pass the sub wire harness crankshaft position sensor stator coil lead and fuel injector lead between the starter motor and the throttle body I J E E Ô 8 7 È 1 I H Ï F G G Ñ C C D D A A 3 4 5...

Page 59: ...r stator coil lead and storage box light switch lead with a plastic locking tie Place the end of the plastic locking tie between the frame and the leads negative battery lead and starter motor lead Ó Fasten the sub wire harness at the white tape and the crankshaft position sensor stator coil lead to the engine bracket with a plastic locking tie Face the end of the plastic locking tie away from the...

Page 60: ...m the scooter Connect the storage box light lead coupler securely Ø Route the negative battery lead below the bracket on the frame Ù Route the starter motor lead and wire harness over the boss of the upper rear cover Ú Route the positive battery lead between the leads and the battery Û Install the cover over the positive battery termi nal I J E E Ô 8 7 È 1 I H Ï F G G Ñ C C D D A A 3 4 5 B B 3 J G...

Page 61: ...ive bat tery lead below the boss on the left engine bracket as shown Á Install the battery band with its projection in the recess in the top of the battery case Fasten the starter motor lead wire harness and positive battery lead with a plastic band Face the end of the plastic band towards the front of the scooter A A I J E E Ô 8 7 È 1 I H Ï F G G Ñ C C D D A A 3 4 5 B B 3 J G Ð C C A A B B B 6 É ...

Page 62: ...g stay È Route the seat lock cable through the cable cover É Pass the throttle cables through the hole in the frame Ê The paint marks on the throttle cables should be within 20 mm 0 79 in above or below the upper edge of the hole in the frame Ë Route the speed sensor lead over the lower tube of the front cowling stay B A A C C B B D E E F F 9 Í Î 7 8 Ð Ñ Ò 6 5 3 4 É È 2 0 A 1 Ë 5 5 Ï Ê 5 C B A A C...

Page 63: ...h the cable cover by installing the quick fas tener in the hole in the frame Ð Hook the end of the cable cover in the hole in the frame Ñ Fasten a plastic band around the middle of the coupler cover and then face the end of the plas tic band down Ò After connecting the main switch lead and speed sensor lead put the cover on the couplers B A A C C B B D E E F F 9 Í Î 7 8 Ð Ñ Ò 6 5 3 4 É È 2 0 A 1 Ë...

Page 64: ...holder and route the rear brake lock lever cable through the guide É Fasten the rear brake hose with the plastic holder Ê Route the seat lock cable above the rear brake lock lever cable Ë Align the white paint mark on the fuel overflow hose with the holder on the bottom cover A A B B C 2 1 2 3 3 É Ê É Ë Î È Ï 5 1 2 3 Í 4 Ì A A B B C D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 65: ...wo holders on the bottom cover Î Route the coolant reservoir breather hose to the outside of the hose guide Ï The end of the coolant reservoir breather hose should extend 15 10 mm 0 59 0 39 in past the end of the bottom cover A A B B C 2 1 2 3 3 É Ê É Ë Î È Ï 5 1 2 3 Í 4 Ì A A B B C D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 66: ...the throttle cables above the seat lock cable guide É Route the seat lock cable rear brake lock lever cable rear brake hose throttle cables and wire harness so that they do not cause the rubber sheet to be folded or turned over Ê Fasten the wire harness with a plastic locking tie Ë 20 mm 0 79 in Î Ë Ê 2 5 4 3 6 5 4 Í Ì 2 É C B A B C 1 1 8 1 Ï Ð È 7 3 A D o w n l o a d e d f r o m w w w S c o o t e...

Page 67: ...e throttle cables above the rear brake hose and rear brake lock lever cable Ï Pass the seat lock cable through the space between the storage compartment and seat lock cable guide Ð Route the seat lock cable through the lower sec tion of the seat lock cable guide Î Ë Ê 2 5 4 3 6 5 4 Í Ì 2 É C B A B C 1 1 8 1 Ï Ð È 7 3 A D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 68: ... Negative battery leads A Intake air temperature sensor B Fuel injector lead C Storage box light switch lead D Storage box light switch E Sub wire harness F Crankshaft position sensor stator coil lead G Crankshaft position sensor lead coupler H Throttle cable decelerator cable I Stator coil lead coupler 1 2 3 4 5 6 É È 7 8 9 0 8 0 A Ë B C D Ì E F Í G H I 7 7 8 Ê D o w n l o a d e d f r o m w w w S...

Page 69: ... the angle shown Route the starter motor lead parallel to the positive battery lead Ë Route the starter motor lead and negative bat tery lead between the two projections on the frame Ì Pass the fuel hose through the hose guide on the sub frame Í After installing the spark plug cap fasten the spark plug lead to the cylinder head with the lead holder 1 2 3 4 5 6 É È 7 8 9 0 8 0 A Ë B C D Ì E F Í G H...

Page 70: ...se 3 Rollover valve to canister hose 4 Rollover valve 5 Fuel tank to rollover valve hose 6 Fuel tank 7 Throttle body 8 Canister to throttle body hose 9 Plastic holder 0 Fuel hose A Plastic clip B Guide D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 71: ... body hose with the plastic holder between the stoppers on the hose Ë Align the plastic clips with the paint marks on the canister to throttle body hose Ì Route the canister to throttle body hose through the guide Í Install the canister to throttle body hose and the rollover valve to canister hose onto the canister making sure they contact the canister body D o w n l o a d e d f r o m w w w S c o ...

Page 72: ...IDLING SPEED 3 17 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 18 CHECKING THE SPARK PLUG 3 18 CHECKING THE IGNITION TIMING 3 20 MEASURING THE COMPRESSION PRESSURE 3 21 CHECKING THE ENGINE OIL LEVEL 3 23 CHANGING THE ENGINE OIL 3 24 CHANGING THE TRANSMISSION OIL 3 27 REPLACING THE AIR FILTER ELEMENTS 3 28 CLEANING THE V BELT CASE AIR FILTER ELEMENT 3 29 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANI...

Page 73: ...ING THE STEERING HEAD 3 41 CHECKING THE FRONT FORK 3 43 CHECKING THE TIRES 3 44 CHECKING THE WHEELS 3 47 CHECKING AND LUBRICATING THE CABLES 3 47 LUBRICATING THE LEVERS 3 48 LUBRICATING THE SIDESTAND 3 48 LUBRICATING THE CENTERSTAND 3 48 ELECTRICAL SYSTEM 3 49 CHECKING AND CHARGING THE BATTERY 3 49 CHECKING THE FUSES 3 54 REPLACING THE HEADLIGHT BULBS 3 56 ADJUSTING THE HEADLIGHT BEAMS 3 58 D o w ...

Page 74: ...s 13000 km 8000 mi or 12 months 19000 km 12000 mi or 18 months 25000 km 16000 mi or 24 months 31000 km 20000 mi or 30 months 1 Fuel line See page 3 30 Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug See page 3 18 Check condition Adjust gap and clean Replace every 19000 km 12000 mi or 18 months Replace 3 Valve clearance See page 3 11 Check and adjust valve clearance when eng...

Page 75: ...ngs See page 4 4 Check bearings for smooth operation Replace if necessary 10 Steering bearings See page 3 41 Check bearing assemblies for looseness Moderately repack with lithium soap based grease Every 19000 km 12000 mi 11 Chassis fasteners See page 2 21 Check all chassis fitting and fasteners Correct if necessary 12 Front and rear brake lever pivot See page 3 48 Apply lithium soap based grease a...

Page 76: ...ster cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 20 Final transmission oil See page 3 27 Check vehicle for oil leakage Change 21 V belt See page 5 37 Replace Every 20000 km 12500 mi 22 Front and rear brake switches See page 8 4 Check operation 23 Throttle grip hous ing and cable See pages 3 18 47 Check operation and free play...

Page 77: ... Ib Order Job Part Q ty Remarks Removing the passenger seat and side covers Remove the parts in the order listed 1 Upper rear cover 1 2 Lower rear cover 1 3 Grab bar cover 1 4 Passenger seat 1 5 Grab bar 1 6 Cap 2 7 Side cover left and right 2 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 78: ...rt Q ty Remarks Removing the rider seat and storage box Remove the parts in the order listed Side cover left and right Refer to PASSENGER SEAT AND SIDE COVERS 1 Fuel tank cap 1 2 Cover 1 3 Rider seat 1 4 Upper cover 1 5 Clip 1 6 Gas spring assembly 1 NOTE Install the gas spring assembly to the frame and bottom plate with its rod side backward and labels upward D o w n l o a d e d f r o m w w w S c...

Page 79: ...y Remarks 7 Bottom plate 1 8 Grab bar bracket 2 9 Fuse box 1 10 Starter relay 1 CAUTION First disconnect the negative battery lead and then the positive battery lead 11 Storage box light connector 2 Disconnect 12 Storage box mat 1 13 Storage box lower plate 1 14 Storage box 1 15 Rubber sheet 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n...

Page 80: ...d footrest boards Remove the parts in the order listed Storage box Refer to RIDER SEAT AND STORAGE BOX 1 Footrest board mat 1 left and right 2 2 Footrest board mat 2 left and right 2 3 Side cover moulding left and right 2 4 Coolant reservoir cover 1 5 Footrest board left and right 2 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 81: ...ove the parts in the order listed Footrest board left and right Refer to SIDE COVER MOULDINGS AND FOOTREST BOARDS 1 Upper cover 1 2 Windshield 1 3 Inner panel 1 4 Front turn signal position light coupler 2 Disconnect 5 Front turn signal position light left and right 2 6 Meter assembly 1 7 Meter assembly coupler 1 Disconnect 8 Headlight coupler 1 Disconnect 9 Plastic clamp 1 10 Front cowling 1 D o ...

Page 82: ...b T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 11 Main switch cover 1 12 Storage compartment 1 13 Radiator cover 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 83: ...SEAT AND STORAGE BOX 1 Crankcase breather hose 1 Disconnect 2 Air filter case to throttle body hose 1 Disconnect 3 Air induction system hose air filter case to air cut off valve 1 Disconnect 4 Intake air temperature sensor coupler 1 Disconnect 5 Air filter case clamp screw 2 Loosen 6 Air filter case left 1 7 Air filter case right 1 For installation reverse the removal pro cedure D o w n l o a d e ...

Page 84: ...ilter cover 1 V belt case air filter element 1 3 Remove timing plug spark plug rubber sheet 1 cylinder head cover 2 cylinder head cover gasket 1 2 4 Measure valve clearance Out of specification Adjust a Turn the primary sheave nut on the left side of the crankshaft counterclockwise to turn the crankshaft b Align the I mark a on the generator rotor with the stationary pointer b on the genera tor ro...

Page 85: ...e is incorrect record the measured reading 5 Remove intake camshaft exhaust camshaft NOTE _ Refer to CAMSHAFTS in chapter 5 When removing the timing chain and cam shafts fasten a wire to the timing chain to retrieve it if it falls into the crankcase c d 1 6 Adjust valve clearance a Remove the valve lifter 1 and the valve pad 2 with the valve lapper 3 NOTE _ Cover the timing chain opening with a ra...

Page 86: ...48 mm 0 058 in Rounded value 150 d Locate the rounded number of the original valve pad and the measured valve clear ance 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 approxi mation The valve clearance must be mea sured again and the above steps should be repeated if the measurement is still inco...

Page 87: ...efer to CAMSHAFTS in chapter 5 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft sprocket marks with the edge of the cylinder head Turn the crankshaft counterclockwise sev eral full turns to seat the parts g Measure the valve clearance again h If the valve clearance is still out of specifica tion repeat all of the valve clear...

Page 88: ...40 240 MEASURED CLEARANCE INSTALLED 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 0 00 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0 05 0 09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 10 0 14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190...

Page 89: ...in switch to OFF and set the engine stop switch to ON 2 Simultaneously press and hold the SELECT and RESET buttons turn the main switch to ON and continue to press the buttons for 8 seconds or more NOTE _ All displays on the meter disappear except the odometer displays dIAG appears on the odometer LCD 3 Press the SELECT button to select the CO adjustment mode CO or the diagnostic mode dIAG 4 After...

Page 90: ...7 Release the RESET and SELECT but tons to execute the selection 8 Turn the main switch to OFF to cancel the mode EAS00054 CHECKING THE ENGINE IDLING SPEED NOTE _ Prior to checking the engine idling speed the air filter element should be clean and the engine should have adequate compression 1 Start the engine and let it warm up for sev eral minutes 2 Remove storage box lower plate Refer to RIDER S...

Page 91: ...RNING _ After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in Direction a Throttle cable free play is increased Direction b Throttle cable free play is decreased a a b 1 2 EAS00060 CHECKING ...

Page 92: ...spark plug Normal color is medium to light tan 6 Clean spark plug with a spark plug cleaner or wire brush 7 Measure spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install spark plug NOTE _ Before installing the spark plug clean the spark plug and gasket surface 9 Connect spark plug cap 10 Install storage box lower plate Refer to RIDER SEAT AND STORAGE BOX Spark plug type...

Page 93: ...k ignition timing a Start the engine warm it up for several min utes and then let it run at the specified engine idling speed b Check that the stationary pointer a is within the firing range b on the generator rotor Incorrect firing range Check the ignition system NOTE _ The ignition timing is not adjustable 5 Install timing plug 6 Install storage box lower plate Refer to RIDER SEAT AND STORAGE BO...

Page 94: ... Refer to ADJUSTING THE VALVE CLEARANCE 3 Start the engine warm it up for several min utes and then turn it off 4 Disconnect spark plug cap 5 Remove spark plug CAUTION _ Before removing the spark plug use com pressed air to blow away any dirt accumu lated in the spark plug well to prevent it from falling into the cylinder 6 Install compression gauge 1 Compression gauge 90890 03081 YU 33223 Adapter...

Page 95: ...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 at sea level Minimum 1 100 kPa 11 0 kg cm2 156 5 psi Standard 1 400 kPa 14 0 kg cm2 199 1 psi Maximum 1 650 kPa 16 5 kg cm2 234 7 psi Compression pressure with oil...

Page 96: ...dipstick 1 clean insert it into the oil filler hole without screwing it in and then remove it to check the oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level CAUTION _ Do not allow foreign materials to enter the crankcase Recommended oil At 5 C 40 F or higher Yamalube 4 2...

Page 97: ...l level again NOTE _ Before checking the engine oil level wait a few minutes until the oil has settled EAS00076 CHANGING THE ENGINE OIL 1 Remove storage box lower plate Refer to RIDER SEAT AND STORAGE BOX 2 Start the engine warm it up for several min utes and then turn it off 3 Place a container under the engine oil drain bolt 4 Remove engine oil filler cap 1 engine oil drain bolt 2 along with the...

Page 98: ... element cover bolt 10 Nm 1 0 m kg 7 2 ft lb 1 1 3 2 3 7 If the oil strainer is also to be cleaned per form the following procedure a Remove the oil strainer cover 1 and oil strainer 2 b Install new O ring 3 c Install the oil strainer cover 8 Check engine oil drain bolt gasket Damage Replace 9 Install engine oil drain bolt along with the gasket T R Oil strainer cover 32 Nm 3 2 m kg 23 ft lb 1 2 3 ...

Page 99: ...he oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter element and the oil pump for damage or leakage Refer to OIL PUMP in chapter 5 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification Quantity Total amount 1 70 L 1...

Page 100: ...gine oil change interval has been reached follow the above procedure but note that the indicator will come on for 1 4 sec onds after releasing the reset button other wise repeat the procedure 17 Install storage box lower plate Refer to RIDER SEAT AND STORAGE BOX 1 CHANGING THE TRANSMISSION OIL 1 Stand the scooter on a level surface NOTE Place the scooter on a suitable stand Make sure that the scoo...

Page 101: ... oil SAE 10W30 type SE motor oil Quantity 0 25 L 0 22 Imp qt 0 26 US qt 1 1 2 EAS00088 REPLACING THE AIR FILTER ELEMENTS The following procedure applies to both air fil ter elements 1 Remove air filter case cover 1 air filter element È Left air filter case cover É Right air filter case cover 1 È 1 É 2 Check air filter element 1 Damage Replace NOTE Replace the air filter element every 20 000 km The...

Page 102: ... sealing surfaces are aligned to prevent any air leaks EAS00091 CLEANING THE V BELT CASE AIR FILTER ELEMENT 1 Remove footrest board left Refer to RIDER SEAT AND STORAGE BOX 2 Remove V belt case air filter cover 1 V belt case air filter cover seal V belt case air filter element 3 Clean V belt case air filter element 1 Blow the compressed air to the outer sur face of the V belt case air filter eleme...

Page 103: ...er to RIDER SEAT AND STORAGE BOX 2 Check throttle body joint 1 intake manifold 2 Cracks damage Replace Refer to CYLINDER HEAD in chapter 5 3 Install storage box Refer to RIDER SEAT AND STORAGE BOX 1 2 EAS00096 CHECKING THE FUEL HOSE 1 Remove storage box Refer to RIDER SEAT AND STORAGE BOX 2 Check fuel hose 1 Cracks damage Replace Loose connection Connect properly 3 Install storage box Refer to RID...

Page 104: ...3 4 Clean catch tank a Thoroughly flush out the catch tank with clean water b Hold the catch tank upside down to allow the water to drain out c Repeat the flushing steps until the excess water is clear and free of debris d Place the catch tank in an upright position to allow any remaining water to drain out of the lower drain tube e Keep the catch tank upright to allow it to dry sufficiently 5 Ins...

Page 105: ...BOARDS T R Exhaust pipe nut 3 20 Nm 2 0 m kg 14 ft lb Muffler joint bolt 4 14 Nm 1 4 m kg 10 ft lb Muffler mounting bolt 5 53 Nm 5 3 m kg 38 ft lb 3 1 2 5 5 4 5 EAS00103 CHECKING THE COOLANT LEVEL 1 Stand the scooter on a level surface NOTE _ Place the scooter on a suitable stand Make sure the scooter is upright 2 Remove coolant reservoir cover Refer to SIDE COVER MOULDINGS AND FOOTREST BOARDS 3 C...

Page 106: ...oolant level NOTE _ Before checking the coolant level wait a few minutes until it settles 6 Install coolant reservoir cover Refer to SIDE COVER MOULDINGS AND FOOTREST BOARDS EAS00104 CHECKING THE COOLING SYSTEM 1 Remove footrest boards left and right Refer to SIDE COVER MOULDINGS AND FOOTREST BOARDS 2 Check radiator 1 radiator inlet hose 2 radiator outlet hose 3 radiator filler hose 4 oil cooler o...

Page 107: ... Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped...

Page 108: ...rs for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Total amount 1 57 L 1 38 Imp qt 1 66 US qt Coolant reservoir capacity 0 32 L 0 28 Imp qt 0 34 US qt Up to the maximum level mark New T R 10 Nm 1 0 m kg 7 2 ft lb 1 Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING _ If coolant splashes in your eyes thor oughly wash them with w...

Page 109: ...ot mix different types of antifreeze 11 Install air bleed bolt coolant 12 Install radiator cap 13 Fill coolant reservoir with the recommended coolant to the maxi mum level mark a 14 Install coolant reservoir cap 15 Start the engine warm it up for several min utes and then stop it 16 Check coolant level Refer to CHECKING THE COOLANT LEVEL NOTE _ Before checking the coolant level wait a few minutes ...

Page 110: ...rear brake lock lever cable length a is 42 44 mm 1 65 1 73 in when the rear brake lock lever is released b Slowly apply the rear brake several times c Set the rear brake lock lever and wait more than 5 minutes d Release the rear brake lock lever e Turn the adjusting nut 1 in direction b or c until the rear brake lock lever cable length a is 45 47 mm 1 77 1 85 in Rear brake lock lever cable length ...

Page 111: ...e type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts ...

Page 112: ...rake disc Replace the brake pads as a set Refer to REPLACING THE REAR BRAKE PADS in chapter 4 È Front brake É Rear brake È É EAS00132 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check brake hose 1 Cracks damage wear Replace È Front brake É Rear brake 2 Check brake hose clamp Loose Tighten the clamp bolt 3 Hold the scoote...

Page 113: ...air to enter the hydraulic brake system considerably length ening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed hydraulic brake system a Fill the brake master cylinder reservoir to the proper level with the recommended brake fluid b Install th...

Page 114: ...oir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING _ After bleeding the hydraulic brake system check the brake operation T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb EAS00148 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the scooter on a level surface WARNING _ Securely support the scooter so that there is no danger of it falling over NOTE _ Plac...

Page 115: ...ghten it to the specified torque with a torque wrench and the steer ing nut wrench WARNING _ Do not overtighten the lower steering ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD in chapter 4 e Install the rubber washer f...

Page 116: ...ld the lower and center steering ring nuts with a steering nut wrench and tighten the upper steering ring nut with a steering nut wrench 5 Install lower handlebar holder Refer to STEERING HEAD in chapter 4 Steering nut wrench 90890 01403 YU A9472 T R Upper steering ring nut 90 Nm 9 0 m kg 65 ft lb EAS00151 CHECKING THE FRONT FORK 1 Stand the scooter on a level surface WARNING _ Securely support th...

Page 117: ...and the suspension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded scooter could cause tire damage an accident or an injury NEVER OVERLOAD THE SCOOTER Total weight of rider passenger cargo and accessories Basic weight with oil and a full fuel tank 212 kg 467 lb Maximum load 196 kg 432 lb Cold...

Page 118: ...he wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement È Tire É Wheel After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the s...

Page 119: ...tely 100 km should be traveled at normal speed before any high speed riding is done After a tire has been repaired or replaced be sure to tighten the tire air valve stem nut 1 and locknut 2 to specification rear tire only NOTE _ For tires with a direction of rotation mark 3 install the tire with the mark pointing in the direction of wheel rotation T R Tire air valve stem rear tire only Valve stem ...

Page 120: ...E CABLES The following procedure applies to all of the inner and outer cables WARNING _ Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check outer cable Damage Replace 2 Check cable operation Rough movement Lubricate NOTE _ Hold the cable end upright and pour a few drops of lubricant into the cab...

Page 121: ...ant Lithium soap based grease EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Recommended lubricant Lithium soap based grease EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Lithium soap based grease D o w n l o a d e d f r o m w w w S c o o t ...

Page 122: ...s or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing caps because the balance between c...

Page 123: ...nals NOTE _ The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive termi nal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V 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 ...

Page 124: ...moving the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during th...

Page 125: ...eded NO YES 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 circu...

Page 126: ...sed 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 This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage NOTE Set the charging time to a maxi mum o...

Page 127: ...nection Connect properly 9 Lubricate battery terminals 10 Install upper rear cover Refer to PASSENGER SEAT AND SIDE COVERS Recommended lubricant Dielectric grease 1 2 EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION _ To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove side covers left and right Refer to PASSE...

Page 128: ...g c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Pocket tester 90890 03112 YU 03112 C Fuses Amperage rating Q ty Main 40 A 1 Headlight 20 A 1 Signaling system 10 A 1 Ignition 10 A 1 Radiator fan motor 10 A 1 Turn signal posi tion light 10 A 1 Fuel injection sys tem 10 A 1 Backup storage box light and meter...

Page 129: ...ng and ignition systems to malfunction and could possibly cause a fire 4 Install side covers left and right Refer to PASSENGER SEAT AND SIDE COVERS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Remove front cowling Refer to FRONT COWLING 2 Disconnect headlight coupler 1 3 Remove headlight bulb holder cover 2 1 2 4 Detach headlight bulb hold...

Page 130: ...id touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Attach headlight bulb holder 8 Install headlight bulb holder cover 9 Connect headlight coupler 10 Instal...

Page 131: ...n the adjusting screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is low ered 1 1 a b b a 2 Adjust headlight beam horizontally a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left 1 1 a b a b D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 132: ... CYLINDER 4 24 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 25 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 26 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 4 28 FRONT BRAKE CALIPER 4 31 REAR BRAKE CALIPER 4 33 DISASSEMBLING THE FRONT BRAKE CALIPER 4 36 DISASSEMBLING THE REAR BRAKE CALIPER 4 36 CHECKING THE FRONT AND REAR BRAKE CALIPERS 4 37 ASSEMBLING AND INSTALL...

Page 133: ...REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 65 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 4 67 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 4 67 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES 4 67 REMOVING THE SWINGARM 4 68 CHECKING THE SWINGARM 4 68 INSTALLING THE SWINGARM 4 69 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 134: ...r listed NOTE _ Place the scooter on a suitable stand so that the front wheel is elevated 1 Front wheel axle end plug 1 2 Front wheel axle pinch bolt 1 Loosen Refer to REMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL 3 Front wheel axle 1 4 Front wheel assembly 1 5 Speed sensor 1 6 Spacer 1 7 Front brake disc 1 For installation reverse the removal pro cedure FRONT WHEEL AND BRAKE DISC D o w ...

Page 135: ...2 1 2 LS Order Job Part Q ty Remarks Disassembling the front wheel Remove the parts in the order listed 1 Oil seal 1 2 Bearing 2 3 Collar 1 For assembly reverse the disassembly procedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 136: ...00525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent wheel axle 2 Check tire front wheel Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure radial wheel runout 1 lateral wheel runout 2 Over the specified limits Replace Radial wheel runout limit 1 0 mm 0 04 in L...

Page 137: ... wheel sur face c Remove the wheel bearings 3 with a gen eral bearing puller d Install the new wheel bearings and new oil seal in the reverse order of disassembly CAUTION _ Do not contact the wheel bearing inner race 4 or balls 5 Contact should be made only with the outer race 6 NOTE _ Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal New New EAS00532 CHECKING T...

Page 138: ...t wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm 0 06 in below the edge of the brake disc Brake disc deflection limit maxi mum Front 0 15 mm 0 006 in Rear 0 15 mm 0 006 in 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Bra...

Page 139: ...n e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc T R Brake disc bolt 23 Nm 2 3 m kg 17 ft lb LOCTITE EAS00542 INSTALLING THE FRONT WHEEL 1 Lubricate wheel axle wheel bearings oil seal lips speed sensor Recommended lubricant Lithium soap based g...

Page 140: ...ure the brake hose is routed prop erly CAUTION _ Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly b a T R 55 Nm 5 5 m kg 40 ft lb T R 20 Nm 2 0 m kg 14 ft lb EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE _ After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front...

Page 141: ...spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust front wheel static balance a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X NOTE _ Start with the lightest weight b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c unti...

Page 142: ...parts in the order listed NOTE _ Place the scooter on a suitable stand so that the rear wheel is elevated Muffler Refer to ENGINE REMOVAL in chapter 5 Swingarm Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1 Rear wheel 1 Refer to REMOVING THE REAR WHEEL 2 Rear brake disc 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 143: ...l Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 2 Measure radial wheel runout lateral wheel runout Refer to CHECKING THE FRONT WHEEL EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE _ After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc installed 1 Adjust rear whe...

Page 144: ...emoving the front brake pads Remove the parts in the order listed 1 Front brake caliper retaining bolt 2 Refer to REPLACING THE FRONT BRAKE PADS 2 Front brake caliper 1 3 Brake pad 2 4 Brake pad spring 1 5 Brake pad spring 2 6 Brake pad shim 2 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 145: ...n the order listed Air filter case right Refer to AIR FILTER CASES in chapter 3 1 Rear brake caliper retaining bolt 2 Refer to REPLACING THE REAR BRAKE PADS 2 Rear brake caliper 1 3 Brake pad 2 4 Brake pad spring 2 For installation reverse the removal pro cedure FRONT AND REAR BRAKES D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 146: ...s Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get immediate medical attention EAS00581 REPLACING THE FRONT BRAKE PADS NOTE _ When replacing the brake pads it is no...

Page 147: ...the bleed screw 5 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pad shims new brake pads and new brake pad springs 5 Lubricate front brake caliper retaining bolts CAUTION _ Do not allow grease to contact the brake pads Remove any excess grease T R...

Page 148: ... in chapter 3 8 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 a EAS00583 REPLACING THE REAR BRAKE PADS NOTE _ When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove rear brake caliper retaining bolts 1 rear brake caliper 2 2 Remove brake pads 1 b...

Page 149: ...aliper bleed screw 2 Put the other end of this hose into an open container b Loosen the brake caliper bleed screw and then turn the brake caliper piston 3 clock wise until section a of the brake caliper pis ton is level with the surface of the brake caliper body NOTE Align the recesses b in the brake caliper pis ton with the brake caliper body as shown in the illustration c Tighten the brake calip...

Page 150: ...cess grease 6 Install rear brake caliper retaining bolts Recommended lubricant Lithium soap based grease È É c T R 27 Nm 2 7 m kg 19 ft lb 7 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE H...

Page 151: ... 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia phragm holder 1 3 Brake master cylinder reservoir dia phragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Union bolt 1 Refer to DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER and ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLIN DER 7 Brake hose 1 8 Copper washer 2 D o w n l o a d e d f r o ...

Page 152: ...older 1 Refer to ASSEMBLING AND INSTALL ING THE FRONT BRAKE MASTER CYLINDER 10 Brake master cylinder 1 11 Front brake light switch 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 153: ...ssembling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly procedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 154: ...n 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia phragm holder 1 3 Brake master cylinder reservoir dia phragm 1 4 Brake lever 1 5 Rear brake light switch connector 2 Disconnect 6 Union bolt 1 Refer to DISASSEMBLING THE REAR BRAKE MASTER CYLINDER and ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 7 Brake hose 1 8 Copper washer 2 D o w n l o a d e d f r o m w...

Page 155: ...holder 1 Refer to ASSEMBLING AND INSTALL ING THE REAR BRAKE MASTER CYL INDER 10 Brake master cylinder 1 11 Rear brake light switch 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 156: ...ssembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly procedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 157: ...e fluid place a container under the master cylinder and the end of the brake hose 2 1 3 EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER NOTE _ Before disassembling the rear brake master cylinder drain the brake fluid from the entire brake system 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE _ To collect any remaining brake fluid place a container under the master cylinder and the ...

Page 158: ... passages brake master cylinder body Obstruction Blow out with compressed air È Front É Rear È É 2 Check brake master cylinder kit 1 Damage scratches wear Replace 3 Check brake master cylinder reservoir cap 1 Cracks damage Replace brake master cylinder reservoir diaphragm holder 2 brake master cylinder diaphragm 3 Damage wear Replace 4 Check brake hoses Cracks damage wear Replace 1 2 3 D o w n l o...

Page 159: ... master cylinder holder 2 NOTE Make sure to install the brake master cylin der holder that has the R mark Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder holder with the punch mark a in the handle bar First tighten the upper bolt then the lower bolt 3 Install copper washers brake hose union bolt WARNING _ Proper brake hose routing is e...

Page 160: ...rake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling poin...

Page 161: ...e system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 a EAS00596 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER WARNING _ Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components 1 Install brake master cylinder kit 1 circlip 2 dust boot 3 Recommended brake fluid DOT 4 New...

Page 162: ...nion bolt WARNING _ Proper brake hose routing is essential to insure safe scooter operation Refer to CABLE ROUTING in chapter 2 NOTE _ While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary CAUTION When installing the brake hose onto the brake mas...

Page 163: ...er cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the minimum level mark a Add the recommende...

Page 164: ... 1 Refer to DISASSEMBLING THE FRONT BRAKE CALIPER and ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 2 Copper washer 2 3 Brake hose 1 4 Brake caliper bracket bolt 2 Refer to ASSEMBLING AND INSTALL ING THE FRONT BRAKE CALIPER 5 Speed sensor lead holder 1 6 Front brake caliper 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 165: ... 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad spring 1 7 Brake pad spring 2 8 Brake caliper piston 2 Refer to DISASSEMBLING THE FRONT BRAKE CALIPER and ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 9 Dust seal 2 0 Brake caliper piston seal 2 A Brake caliper body 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 166: ...filter case right Refer to AIR FILTER CASES in chapter 3 Muffler Refer to ENGINE REMOVAL in chapter 5 Brake fluid Drain 1 Rear brake lock lever adjusting nut 1 2 Rear brake lock lever cable 1 Disconnect 3 Rear brake lock lever adjusting pin 1 4 Rear brake lock lever spring 1 5 Union bolt 1 Refer to DISASSEMBLING THE REAR BRAKE CALIPER and ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 6 Copper w...

Page 167: ...LS Order Job Part Q ty Remarks 8 Rear brake caliper retaining bolt 2 Refer to ASSEMBLING AND INSTALL ING THE REAR BRAKE CALIPER 9 Rear brake caliper 1 10 Brake caliper bracket bolt 2 11 Brake caliper bracket 1 12 Brake pad 2 13 Brake pad spring 2 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 168: ...ove the parts in the order listed 1 Brake caliper piston 1 Refer to DISASSEMBLING THE REAR BRAKE CALIPER and ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 2 Dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Rear brake lock lever cable holder 1 6 Brake caliper body 1 For assembly reverse the disassembly procedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 169: ...2 brake caliper piston seals 3 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper WARNING _ Cover the brake caliper pistons with a rag Be careful not to get injured when the pistons are expelled from the brake cali per Never try to pry out the brake caliper pis tons b Remove the brake caliper piston seals EAS00626 DISASSEMBLING THE REAR BRAKE ...

Page 170: ...ar brake lock lever 4 contin uously in the direction shown by the arrow until the piston comes out b Remove the dust seal and brake caliper pis ton seal 1 2 3 4 EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is di...

Page 171: ...liper body 3 Cracks damage Replace the brake cali per assembly brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING _ Whenever a brake caliper is disassembled replace the brake caliper piston seals È Front É Rear È 3 1 2 É 2 Check brake caliper brackets 1 Cracks damage Replace È Front É Rear È 1 É D o w n l o a d e d f r o m w w w S c o o t e r T i m e ...

Page 172: ...Recommended brake fluid DOT 4 1 Install brake caliper piston seals 1 dust seals 2 brake caliper piston 3 2 Install brake caliper bracket New New T R 40 Nm 4 0 m kg 2 9 ft lb 3 Install brake caliper temporarily copper washers 1 brake hose 2 union bolt 3 WARNING _ Proper brake hose routing is essential to insure safe scooter operation Refer to CABLE ROUTING in chapter 2 CAUTION _ When installing the...

Page 173: ...ke fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore alw...

Page 174: ...r 3 a ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING _ Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Ins...

Page 175: ...r washers union bolt 2 WARNING _ Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 CAUTION When installing the brake hose onto the brake caliper 3 make sure the brake pipe touches the projection a on the brake cali per 5 Remove brake caliper 6 Install brake pad springs brake pads brake caliper retaining bolts Refer to REPLACING THE REAR BRA...

Page 176: ...se vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 8 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 9 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 10 Check brake le...

Page 177: ...Removing the front fork legs Remove the parts in the order listed The following procedure applies to both of the front fork legs Storage compartment Refer to COWLING AND COVERS in chapter 3 Front wheel Refer to FRONT WHEEL AND BRAKE DISC 1 Brake hose holder 1 2 Front brake caliper 1 3 Speed sensor lead holder 1 4 Front reflector 2 5 Front fender 1 6 Front reflector bracket 2 D o w n l o a d e d f ...

Page 178: ...g 50 ft lb 7 8 5 6 4 6 4 9 10 2 1 3 New Order Job Part Q ty Remarks 7 Cap bolt 1 Refer to REMOVING THE FRONT FORK LEGS and INSTALLING THE FRONT FORK LEGS 8 O ring 1 9 Lower bracket pinch bolt 2 Loosen 10 Front fork leg 1 For installation reverse the removal pro cedure FRONT FORK D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 179: ...following procedure applies to both of the front fork legs 1 Fork spring seat 1 Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEM BLING THE FRONT FORK LEGS 2 Fork spring 1 3 Dust seal 1 4 Oil seal clip 1 5 Damper rod bolt 1 6 Copper washer 1 7 Damper rod 1 8 Rebound spring 1 9 Oil flow stopper 1 0 Inner tube 1 A Inner tube bushing 1 B Oil seal 1 D o w n l o a d e d f r o m w w w S c o o t e r T...

Page 180: ...New LT Order Job Part Q ty Remarks C Washer 1 Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEM BLING THE FRONT FORK LEGS D Outer tube bushing 1 E Outer tube 1 For assembly reverse the disassembly procedure FRONT FORK D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 181: ...t wheel is elevated 2 Remove cap bolt 1 with a 17 mm hexagonal wrench 3 Loosen lower bracket pinch bolt 2 WARNING _ Before loosening the lower bracket pinch bolts support the front fork leg 4 Remove front fork leg 2 1 EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove fork spring seat fork spring 2 Drain fork oil NOTE Stroke the outer...

Page 182: ... Remove inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but care fully CAUTION _ Excessive force will damage the oil seal and bushing A damaged oil seal or bush ing must be replaced Avoid bottoming the inner tube into the outer tube during the abo...

Page 183: ...tion Replace Spring free length 316 7 mm 12 47 in Limit 310 4 mm 12 22 in 1 2 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil flow stopper 2 Damage Replace 1 2 EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING _ Make sure the oil levels in both front fork legs are equal Uneve...

Page 184: ...lowly down the inner tube 3 until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate inner tube s outer surface Recommended lubricant Yamaha fork oil 10 WT 2 1 3 3 Tighten copper washer damper rod bolt 1 NOTE _ While holding the damper rod assembly with the damper rod holder 2 and T handle 3 tighten the damper rod bolt T R Damper rod bolt 30 Nm 3 0 m...

Page 185: ...Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag 4 to pro tect the oil seal during installation Fork seal driver weight 90890 01367 YM A9409 7 Fork seal driver attachment 41 mm 90890 01381 YM A5142 2 New New 6 Install oil seal clip 1 NOTE _ Adjust the oil seal clip so that it fits into the outer tube s...

Page 186: ... 0 315 US qt Recommended oil Yamaha fork oil 10 WT Front fork leg oil level a from the top of the inner tube with the inner tube fully compressed and without the fork spring 88 mm 3 46 in EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install front fork leg NOTE _ Before installing the cap bolt lubricate its O ring with grease Pull up the i...

Page 187: ...lebar Remove the parts in the order listed Windshield Refer to COWLING AND COVERS in chapter 3 1 Upper handlebar cover 1 2 Rearview mirror left and right 2 3 Grip end 2 Refer to INSTALLING THE HANDLEBAR 4 Plastic locking tie 2 5 Right handlebar switch 1 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Front brake light switch connector 2 Disconnect 9 Front brake master cylinder holder 1 10 Front ...

Page 188: ...switch connector 2 Disconnect Refer to INSTALLING THE HANDLEBAR 13 Rear brake lock lever cable 1 Disconnect 14 Rear brake master cylinder holder 1 15 Rear brake master cylinder 1 16 Handlebar grip 1 Refer to REMOVING THE HANDLE BAR and INSTALLING THE HANDLE BAR 17 Upper handlebar holder 2 Refer to INSTALLING THE HANDLE BAR 18 Handlebar 1 19 Lower handlebar cover 1 For installation reverse the remo...

Page 189: ... the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECKING THE HANDLEBAR 1 Check handlebar 1 Bends cracks damage Replace WARNING _ Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS00671 INSTALLING THE HANDLEBAR 1 Stand the scooter on a level surface WARNING _ Securely support the scooter so that there is no danger of it falling over D o w...

Page 190: ...the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried 4 Install rear brake master cylinder 1 rear brake master cylinder holder 2 NOTE Make sure to install the brake master cylin der holder that has the L mark Install the rear brake master cy...

Page 191: ...brake master cylinder holder 2 NOTE Make sure to install the brake master cylin der holder that has the R mark Install the front brake master cylinder holder with the UP mark facing up Align the end of the front brake master cylin der holder with the punch mark a in the han dlebar First tighten the upper bolt then the lower bolt a 1 2 T R 10 Nm 1 0 m kg 7 2 ft lb 8 Install throttle grip throttle c...

Page 192: ... mm 0 04 0 12 in of clearance a between the throttle grip and the grip end 11 Install grip end right NOTE There should be 2 4 4 4 mm 0 09 0 17 in of clearance a between the throttle grip and the grip end 12 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in HANDLEBAR D o w n l ...

Page 193: ... Remove the parts in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISC Front fork legs Refer to FRONT FORK Storage compartment Refer to COWLING AND COVERS in chapter 3 Handlebar Refer to HANDLEBAR 1 Brake hose holder 1 2 Steering stem nut 1 3 Washer 1 4 Lower handlebar holder 1 Refer to REMOVING THE LOWER BRACKET and INSTALLING THE STEERING HEAD 5 Woodruff key 1 6 Upper steering rin...

Page 194: ...rks 9 Rubber washer 1 Refer to REMOVING THE LOWER BRACKET and INSTALLING THE STEERING HEAD 10 Lower steering ring nut 1 11 Lower bracket 1 12 Bearing cover 1 13 Upper bearing inner race 1 Refer to INSTALLING THE STEERING HEAD 14 Upper bearing 1 15 Lower bearing outer race 1 16 Lower bearing 1 17 Upper bearing outer race 1 18 Dust seal 1 For installation reverse the removal pro cedure D o w n l o a...

Page 195: ...ower holder by loosen ing the upper steering ring nut 3 gradually 3 Remove upper steering ring nut 1 with the ring nut wrench lock washer 2 center steering ring nut 3 rubber washer Ring nut wrench 90890 01268 YU 01268 4 Remove lower steering ring nut 1 with the ring nut wrench 2 WARNING Securely support the lower bracket so that there is no danger of it falling Ring nut wrench 90890 01268 YU 01268...

Page 196: ...move the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new rubber seal and new bearing races CAUTION _ If the bearing race is not installed properly the steering head pipe could be damaged NOTE _ Always replace the bearings and bearing races as a set Whenever the steering head is disassem bled replace the rubber seal 4 Check upper bracket lower bracket along with...

Page 197: ...ustration and the inner surfaces of the lower handlebar holder 3 Install lower steering ring nut 1 rubber washer center steering ring nut 2 lock washer 3 upper steering ring nut 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD in chapter 3 a 4 Install woodruff key 1 lower handlebar holder 2 NOTE _ Align the alignment mark a on the lower han dlebar holder with the woodruff key T R 140 Nm 14 0 m ...

Page 198: ...bsorber assemblies and swingarm Remove the parts in the order listed Storage box Refer to COWLING AND COVERS in chapter 3 Air filter case right Refer to AIR FILTER CASES in chapter 3 Muffler Refer to ENGINE REMOVAL in chapter 5 1 Rear axle nut 1 Refer to REMOVING THE SWING ARM and INSTALLING THE SWING ARM 2 Rear brake caliper 1 3 Brake hose holder 1 4 Rear shock absorber left and right 2 Refer to ...

Page 199: ...T R 46 Nm 4 6 m kg 33 ft Ib LS LS 3 T R 34 Nm 3 4 m kg 24 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib LS Order Job Part Q ty Remarks 6 Spacer 1 Refer to REMOVING THE SWINGARM and INSTALLING THE SWINGARM 7 Collar 1 8 Oil seal 1 9 Bearing 1 10 Oil seal 1 11 Dust seal 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 200: ...MBLIES The following procedure applies both of the rear shock absorber assemblies 1 Check rear shock absorber rod Bends damage Replace the rear shock absorber assembly rear shock absorber Oil leaks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock absorber assembly bolts Bends damage wear Replace EAS00699 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES 1 Install rear...

Page 201: ...l is elevated 2 Remove rear axle nut 1 rear brake caliper 2 brake hose holder 3 rear shock absorber assembly lower bolt right 4 NOTE Do not squeeze the brake lever when remov ing the brake caliper 3 Remove swingarm 4 1 2 3 EAS00708 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check spacer 1 collar 2 oil seals 3 bearing 4 bushing Damage wear Replace dust seal Damage wear Rep...

Page 202: ...ithium soap based grease 2 Install swingarm 1 rear shock absorber assembly lower bolt right 2 brake hose holder 3 rear brake caliper 4 rear axle nut 5 2 5 1 4 3 T R 46 Nm 4 6 m kg 33 ft lb T R 29 Nm 2 9 m kg 21 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 135 Nm 13 5 m kg 98 ft lb D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 203: ...E CYLINDER HEAD 5 19 CHECKING THE CYLINDER HEAD 5 19 CHECKING THE TIMING CHAIN GUIDE EXHAUST SIDE 5 20 INSTALLING THE CYLINDER HEAD 5 20 VALVES AND VALVE SPRINGS 5 21 REMOVING THE VALVES 5 22 CHECKING THE VALVES AND VALVE GUIDES 5 23 CHECKING THE VALVE SEATS 5 25 CHECKING THE VALVE SPRINGS 5 27 CHECKING THE VALVE LIFTERS 5 28 INSTALLING THE VALVES 5 28 CYLINDER AND PISTON 5 30 REMOVING THE PISTON ...

Page 204: ...LLING THE GENERATOR 5 54 OIL PUMP 5 56 CHECKING THE OIL PUMP 5 57 CHECKING THE OIL PUMP DRIVE CHAIN 5 57 ASSEMBLING THE OIL PUMP 5 58 INSTALLING THE OIL PUMP 5 58 CRANKSHAFT 5 59 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ASSEMBLY 5 59 CRANKCASE BEARINGS 5 61 DISASSEMBLING THE CRANKCASE 5 62 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 5 62 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 63 CHECKING THE BALA...

Page 205: ...er listed Negative battery lead Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Positive battery lead CAUTION _ First disconnect the negative bat tery lead and then the positive bat tery lead For connecting reverse the discon nection procedure Air filter case left and right Refer to AIR FILTER CASES in chapter 3 Throttle body and fuel injector Refer to THROTTLE BODY AND FUEL INJECTOR in ch...

Page 206: ...ERMOSTAT in chapter 6 Rear brake caliper Refer to FRONT AND REAR BRAKES in chapter 4 1 Spark plug cap 1 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Crankshaft position sensor stator assembly coupler 2 Disconnect 4 Water pump inlet hose 1 Disconnect 5 Muffler 1 6 Exhaust pipe 1 7 Gasket 1 For installation reverse the removal pro cedure ENGINE REMOVAL D o w n l o a d e d f r o m w...

Page 207: ...he engine Remove the parts in the order listed NOTE _ Place a suitable stand under the frame and engine 1 Plug 1 2 Rear shock absorber assembly lower bolt 2 Refer to INSTALLING THE ENGINE 3 Engine bracket lower mounting bolt 2 4 Washer 2 5 Engine bracket upper mounting nut bolt 2 2 6 Engine bracket bolt 4 7 Engine mounting nut bolt 1 1 8 Left engine bracket 1 9 Center engine bracket 1 ENGINE REMOV...

Page 208: ...ft Ib T R 56 Nm 5 6 m kg 40 ft Ib LS 2 2 5 3 4 5 9 8 7 11 10 6 6 5 1 5 LS LT LT 4 3 LT LT LS 7 Order Job Part Q ty Remarks 10 Right engine bracket 1 Refer to INSTALLING THE ENGINE 11 Engine 1 For installation reverse the removal pro cedure ENGINE REMOVAL D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 209: ...ghten engine mounting nut 4 engine bracket bolts 5 3 Install engine bracket upper mounting bolts nuts 6 washers 7 engine bracket lower mounting bolts 8 NOTE _ Do not fully tighten the bolts 4 Tighten engine bracket upper mounting nuts 6 engine bracket lower mounting bolts 8 rear shock absorber assembly lower bolts 9 4 1 5 2 5 3 4 6 6 7 6 6 8 7 9 9 8 LT T R 65 Nm 6 5 m kg 47 ft lb T R 56 Nm 5 6 m k...

Page 210: ... the order listed Storage box and rubber sheet Refer to COWLING AND COVERS in chapter 3 Throttle body and fuel injector Refer to THROTTLE BODY AND FUEL INJECTOR in chapter 7 1 Spark plug cap 1 2 Spark plug 1 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Semicircular plug 2 For installation reverse the removal pro cedure CAMSHAFTS D o w n l o a d e d f r o m w w w S c o o t e r T i m e n...

Page 211: ... the camshafts Remove the parts in the order listed 1 Timing plug 1 Refer to REMOVING THE CAMSHAFTS and INSTALLING THE CAM SHAFTS 2 V belt case air filter cover 1 3 V belt case air filter element 1 4 Camshaft sprocket bolt 4 Loosen 5 Timing chain tensioner assembly 1 6 Gasket 1 7 Camshaft cap 1 8 Dowel pin 2 9 Intake camshaft 1 10 Exhaust camshaft 1 11 Intake camshaft sprocket 1 12 Exhaust camshaf...

Page 212: ...b T R 8 Nm 0 8 m kg 5 8 ft Ib 1 New LS 8 E M E M 5 6 4 12 13 10 14 7 8 8 3 2 4 4 4 11 9 Order Job Part Q ty Remarks 13 Decompressor lever 1 Refer to INSTALLING THE CAM SHAFTS 14 Decompressor lever pin 1 For installation reverse the removal pro cedure CAMSHAFTS D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 213: ... the genera tor rotor cover to position the piston at TDC on the compression stroke NOTE _ TDC on the compression stroke can be found when the camshaft lobes are turned away from each other In order to be sure that the piston is at TDC the punch marks c on the intake camshaft sprocket and the punch mark d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in...

Page 214: ...vent the timing chain from falling into the crankcase fasten it with a wire 3 8 Remove camshaft sprockets 1 8 2 4 6 5 3 1 7 1 2 3 EAS00204 CHECKING THE CAMSHAFTS 1 Check camshaft lobes Blue discoloration pitting scratches Replace the camshaft 2 Measure camshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake camshaft a 34 250 mm 1 3484 in b 2...

Page 215: ...amshaft journal as shown c Install the dowel pins and camshaft cap NOTE _ Tighten the camshaft cap bolts in the order of the embossed numbers on the camshaft cap Do not turn the camshaft when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge 1 d Remove the camshaft cap and then mea sure the width of the Plastigauge Camshaft journal to camshaft cap clearance limit 0 08 ...

Page 216: ...9635 in CHECKING THE CAMSHAFT SPROCKETS 1 Check camshaft sprockets Wear damage Replace the camshaft sprockets and timing chain as a set a 1 4 of a tooth b Correct 1 Roller 2 Sprocket CHECKING THE DECOMPRESSION SYSTEM 1 Check decompression system a Check that the decompressor lever pin 1 projects from the camshaft b Check that the decompressor cam 2 moves smoothly 2 1 D o w n l o a d e d f r o m w ...

Page 217: ...sioner housing smoothly If there is rough move ment replace the timing chain tensioner EAS00217 INSTALLING THE CAMSHAFTS 1 Install decompressor lever pin 1 decompressor lever 2 exhaust camshaft 3 NOTE _ Install the decompressor lever pin 1 and decompressor lever 2 in the exhaust cam shaft 3 as shown in the illustration 2 Install exhaust camshaft sprocket 1 intake camshaft sprocket 2 NOTE Make sure...

Page 218: ...er head so that the punch marks c on the intake camshaft sprocket and the punch mark d on the exhaust camshaft sprocket align with the cylinder head mating surface as shown in the illustration CAUTION _ Do not turn the crankshaft when installing the camshafts to avoid damage or improper valve timing 1 2 3 c d 4 Install dowel pins camshaft cap camshaft cap bolts NOTE Lubricate the camshaft cap bolt...

Page 219: ...oner housing with the thin screwdriver still installed install the gasket and the timing chain tensioner 2 onto the cylinder block WARNING _ Always use a new gasket c Tighten the timing chain tensioner bolts 3 to the specified torque d Remove the screwdriver make sure the tim ing chain tensioner rod releases and then tighten the cap bolt to the specified torque T R Timing chain tensioner bolt 10 N...

Page 220: ... stationary pointer on the generator rotor cover camshaft sprocket punch marks Make sure the punch marks on the cam shaft sprockets are aligned with the cylinder head mating surface Out of alignment Adjust Refer to the installation steps above 10 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 D o w n l o a d e d f r o m w w w S c o o t e r T...

Page 221: ...ty Remarks Removing the cylinder head Remove the parts in the order listed Exhaust pipe and muffler Refer to ENGINE REMOVAL Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Thermostat Refer to THERMOSTAT in chapter 6 Camshafts Refer to CAMSHAFTS 1 Coolant temperature sensor 1 2 Air induction system pipe 1 3 Gasket 1 4 Throttle body joint 1 5 Intake manifold 1 6 Gasket 1 CYLINDER HEAD D o w...

Page 222: ... 9 7 6 5 4 1 10 3 2 E E New New Order Job Part Q ty Remarks 7 Cylinder head 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD 8 Cylinder head gasket 1 Refer to INSTALLING THE CYLINDER HEAD 9 Dowel pin 2 10 Timing chain guide exhaust side 1 For installation reverse the removal pro cedure CYLINDER HEAD D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 223: ...lve seats 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on...

Page 224: ... pins 2 Install cylinder head NOTE _ Pass the timing chain through the timing chain cavity 3 Tighten cylinder head nuts 1 cylinder head nuts 2 NOTE _ Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages New 3 2 1 4 2 1 T R 40 Nm 4 0 m kg 29 ft lb T R 52 Nm 5 2 m kg 37 ft lb D o w n l o a d e d f r o...

Page 225: ...ts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Valve lifter 4 Refer to REMOVING THE VALVES and INSTALLING THE VALVES 2 Adjusting pad 4 3 Valve cotter 8 4 Upper valve spring seat 4 5 Valve spring 4 6 Stem seal 4 7 Lower valve spring seat 4 8 Exhaust valve 2 9 Intake valve 2 10 Valve guide 4 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e ...

Page 226: ...ace 2 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE _ There should be no leakage at the valve seat 1 3 Remove valve cotters 1 NOTE _ Remove the valve cotters by compressing the valve spring with the valve spring...

Page 227: ...S The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 ...

Page 228: ...r valve stem to valve guide clearance NOTE _ After replacing the valve guide reface the valve seat 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valve face Pitting wear Grind the valve face valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve Valve guide remover 5 mm 90890 04097 YM 04097 Valve guide installer 5 mm 90890 04098 Y...

Page 229: ... valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wear Replace the cylinder head 3 Measure valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a c...

Page 230: ...ve 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...

Page 231: ...rings 1 Measure valve spring free length a Out of specification Replace the valve spring Valve spring free length 46 45 mm 1 83 in Limit 44 13 mm 1 74 in 2 Measure compressed valve spring force a Out of specification Replace the valve spring b Installed length Compressed valve spring force installed 160 5 184 7 N at 35 10 mm 16 37 18 83 kg at 35 10 mm 36 08 41 52 lb at 1 38 in D o w n l o a d e d ...

Page 232: ...der head EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr valve stem end with an oil stone 2 Lubricate valve stem 1 valve stem seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install valve 1 lower spring seat 2 valve stem seal 3 valve spring 4 upper spring seat 5 into the cylinder head 1 2 4 3...

Page 233: ...ompressor attach ment 90890 01243 YM 01253 1 2 3 1 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION _ Hitting the valve tip with excessive force could damage the valve 6 Install valve pad 1 valve lifter 2 NOTE _ Lubricate the valve lifter and valve pad with molybdenum disulfide oil The valve lifter must move smoothly when rotated with a fi...

Page 234: ...in the order listed Cylinder head Refer to CYLINDER HEAD 1 Water jacket inlet pipe 1 2 O ring 1 3 Air induction system pipe stay bolt 1 4 Cylinder 1 Refer to INSTALLING THE PISTON AND CYLINDER 5 Cylinder gasket 1 6 Dowel pin 2 7 Piston pin clip 2 Refer to REMOVING THE PISTON and INSTALLING THE PISTON AND CYLINDER 8 Piston pin 1 9 Piston 1 10 Piston ring set 1 For installation reverse the removal p...

Page 235: ...e piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Piston pin puller set 90890 01304 YU 01304 1 2 3 2 Remove top ring 2nd ring oil ring NOTE _ When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS00255 CHECKING THE CYLINDER AND PISTON 1 ...

Page 236: ...pis ton 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 f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set Cylinder bore C 83 000 83 010 mm 3 2677 3 2681 in Taper limit T 0 05 mm 0 002 in C maximum of D1 D2 T maximum of D1 or D2 maximum of D5 or D6 P...

Page 237: ...008 0 0022 in Limit 0 100 mm 0 0039 in 2 Install piston ring into the cylinder NOTE _ Level the piston ring into the cylinder with the piston crown a 40 mm 1 6 in 3 Measure piston ring end gap Out of specification Replace the piston ring NOTE _ The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top r...

Page 238: ...fication Replace the piston pin and piston as a set Piston pin outside diameter 19 991 20 000 mm 0 7870 0 7874 in Limit 19 971 mm 0 7863 in Piston pin bore diameter 20 004 20 015 mm 0 7876 0 7880 in Limit 20 045 mm 0 7892 in Piston pin to piston pin bore clearance Piston pin bore diameter b Piston pin outside diameter a Piston pin to piston pin bore clearance 0 004 0 024 mm 0 0002 0 0009 in Limit ...

Page 239: ...r the crankcase opening with a clean rag to pre vent the clip from falling into the crankcase 3 Install cylinder gasket dowel pins 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil 2 3 1 a New New New 5 Position top ring 2nd ring oil ring Offset the piston ring end gaps as shown a Top ring end b Upper oil ring rail end c Oil ring expander end ...

Page 240: ...olt NOTE _ While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cav ity New T R 10 Nm 1 0 m kg 7 2 ft lb D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 241: ...arks Removing the V belt case cover Remove the parts in the order listed Side cover left Refer to COWLING AND COVERS in chapter 3 Air filter case left Refer to AIR FILTER CASES in chapter 3 1 V belt case air filter cover 1 2 V belt case air filter element 1 3 V belt case cover 1 4 V belt case gasket 1 5 V belt case 1 6 V belt case air duct 1 1 7 V belt case air duct 2 1 For installation reverse th...

Page 242: ...llar 1 1 Refer to REMOVING THE PRIMARY SHEAVE and INSTALLING THE SEC ONDARY SHEAVE V BELT AND PRI MARY SHEAVE 2 Primary fixed sheave 1 3 Secondary sheave nut 1 Refer to REMOVING THE SECOND ARY SHEAVE AND V BELT and INSTALLING THE SECONDARY SHEAVE V BELT AND PRIMARY SHEAVE 4 Collar 1 5 Clutch housing 1 6 Secondary sheave assembly 1 7 V belt 1 8 Primary sliding sheave 1 9 Spacer 1 10 Cam 1 BELT DRIV...

Page 243: ...rease G 90890 40010 Apply BEL RAY assembly lube Order Job Part Q ty Remarks 11 Weight 8 12 Slider 4 13 Spacer 1 14 O ring 1 For installation reverse the removal procedure BELT DRIVE D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 244: ...fer to DISASSEMBLING THE SEC ONDARY SHEAVE and ASSEMBLING THE SECONDARY SHEAVE 2 Clutch shoe assembly 1 3 Clutch shoe spring 3 4 Compression spring 1 Refer to ASSEMBLING THE SECOND ARY SHEAVE 5 Spring seat 1 6 Guide pin 4 7 Secondary sliding sheave 1 8 O ring 2 9 Oil seal 2 0 Secondary fixed sheave 1 A Bearing 1 BELT DRIVE D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 245: ...1 ENG Apply BEL RAY assembly lube Order Job Part Q ty Remarks B Circlip 1 C Bearing 1 For assembly reverse the disassembly procedure BELT DRIVE D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 246: ...ool 3 loosen the primary sheave nut Rotor holding tool 90890 01235 YU 01235 1 3 2 EAS00318 REMOVING THE SECONDARY SHEAVE AND V BELT 1 Remove secondary sheave nut 1 collar 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 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 247: ...1 2 3 3 Remove secondary sheave assembly 1 V belt 2 NOTE _ Remove the V belt and secondary sheave assembly from the primary sheave side 2 1 EAS00319 DISASSEMBLING THE SECONDARY SHEAVE 1 Remove clutch shoe assembly nut 1 NOTE _ Install the sheave spring compressor 2 and sheave fixed block 3 onto the secondary sheave assembly as shown Then compress the spring and remove the clutch shoe assem bly nut...

Page 248: ...mary sliding sheave spacer Cracks damage wear Replace NOTE Replace the primary sliding sheave and spacer as a set V belt width 30 mm 1 18 in Limit 27 mm 1 06 in EAS00321 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the primary sheave weights 1 Check primary sheave weight Cracks damage wear Replace 2 Measure primary sheave weight outside diameter Out of specificatio...

Page 249: ... secondary fixed and sliding sheaves as a set CHECKING THE CLUTCH SHOES The following procedure applies to all of the clutch shoes 1 Check clutch shoe Damage wear Replace the clutch shoes and springs as a set Glazed areas Sand with coarse sandpa per NOTE After sanding the glazed areas clean the clutch with a cloth 2 Measure clutch shoe thickness Out of specification Replace the clutch shoes and sp...

Page 250: ...L RAY assembly lube EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1 Lubricate secondary fixed sheave s inner surface 1 secondary sliding sheave s inner surface 2 oil seals bearings with the recommended lubricant 2 Install secondary sliding sheave 1 NOTE _ Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 Recommended lubricant BEL RAY assembly lube Oil seal...

Page 251: ...ly nut Recommended lubricant BEL RAY assembly lube Sheave spring compressor 90890 04134 YM 04134 Sheave fixed block 90890 04135 YM 04135 New 2 1 3 EAS00325 INSTALLING THE SECONDARY SHEAVE V BELT AND PRIMARY SHEAVE 1 Install V belt 1 secondary sheave assembly 2 CAUTION _ Do not allow grease to contact the V belt and the secondary sheave assembly NOTE _ Install the V belt onto the primary sheave sid...

Page 252: ... 01348 Sheave holder 90890 01701 YS 01880 A 1 2 3 T R 90 Nm 9 0 m kg 65 ft lb 3 2 1 T R 60 Nm 6 0 m kg 43 ft lb 4 Install V belt primary fixed sheave collar primary sheave nut NOTE Install the V belt onto the primary sheave 1 when the pulley is at its widest position and onto the secondary sheave assembly 2 when the pulley is at its narrowest position and make sure the V belt is tight While holdin...

Page 253: ...ed Side cover right Refer to COWLING AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Exhaust pipe and muffler Refer to ENGINE REMOVAL Air cut off valve Refer to AIR INDUCTION SYSTEM in chapter 7 1 Crankcase breather hose 1 Disconnect 2 Thermostat inlet hose 1 Disconnect D o w n l o a d e d f r o m w w w...

Page 254: ... Crankshaft position sensor stator assembly coupler 2 Disconnect 6 Generator rotor cover 1 Refer to INSTALLING THE GENERA TOR 7 Gasket 1 8 Dowel pin 2 9 Stator coil 1 Refer to INSTALLING THE GENERA TOR 10 Crankshaft position sensor 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 255: ...n the order listed 1 Generator rotor 1 Refer to REMOVING THE GENERA TOR INSTALLING THE STARTER CLUTCH and INSTALLING THE GEN ERATOR 2 Starter clutch 1 3 Woodruff key 1 4 Starter clutch gear 1 5 Starter clutch idle gear shaft 1 6 Starter clutch idle gear 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 256: ...Do not allow the sheave holder to touch the projection on the generator rotor Remove every other starter clutch bolt 3 bolts only to install the flywheel puller Sheave holder 90890 01701 YS 01880 A 3 1 2 4 2 3 Remove generator rotor 1 with the starter clutch 2 woodruff key starter clutch gear CAUTION _ To protect the end of the crankshaft place an appropriate sized socket between the flywheel pull...

Page 257: ...ontacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear clockwise È the starter clutch and the starter clutch drive gear should engage otherwise the starter clutch is faulty and must be replaced c When turning t...

Page 258: ...lutch gear 1 woodruff key 2 generator rotor washer generator rotor nut NOTE _ Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 2 Tighten generator rotor nut 1 NOTE _ While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor nut Do n...

Page 259: ...nerator rotor cover bolts NOTE Align the projection a on the impeller shaft with the slit b on the balancer shaft Tighten the generator rotor cover bolts in stages and in a crisscross pattern Yamaha bond No 1215 90890 85505 Sealant Quick Gasket ACC 11001 05 01 T R 10 Nm 1 0 m kg 7 2 ft lb a b D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 260: ...TER CLUTCH AND GEN ERATOR 1 Oil pump assembly 1 Refer to ASSEMBLING THE OIL PUMP and INSTALLING THE OIL PUMP 2 Oil pump gasket 1 Refer to INSTALLING THE OIL PUMP 3 Oil pump driven sprocket 1 4 Oil pump drive chain 1 5 Oil pump drive sprocket 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 261: ...3 Oil pump housing 3 Check oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s Inner rotor to outer rotor tip clearance 0 07 mm 0 0028 in Limit 0 15 mm 0 0059 in Outer rotor to oil pump housing clearance 0 013 0 036 mm 0 0005 0 0014 in Limit 0 106 mm 0 0042 in Oil pump housing to inner rotor and outer rotor clearance 0 040 0 096 mm 0 0016 0 0038 in Limit 0 166 mm...

Page 262: ... the oil pump shaft with the groove a in the inner rotor 4 3 Check oil pump operation Refer to CHECKING THE OIL PUMP Recommended lubricant Engine oil EAS00376 INSTALLING THE OIL PUMP 1 Install oil pump gasket oil pump assembly CAUTION _ After tightening the bolts make sure the oil pump turns smoothly NOTE _ Align the projection a on the oil pump shaft with the slot b in the oil pump driven gear sh...

Page 263: ...haft assembly Remove the parts in the order listed Engine Refer to ENGINE REMOVAL Cylinder and piston Refer to CYLINDER AND PISTON Belt drive Refer to BELT DRIVE Oil pump Refer to OIL PUMP Transmission Refer to TRANSMISSION 1 Timing chain 1 2 Timing chain guide intake side 1 3 Right crankcase 1 Refer to DISASSEMBLING THE CRANKCASE and ASSEMBLING THE CRANKCASE 4 Crankshaft assembly 1 Refer to INSTA...

Page 264: ...2 1 3 9 11 12 14 13 E E E LT LT E Order Job Part Q ty Remarks 6 Dowel pin 1 7 O ring 1 8 Dowel pin 2 9 Left crankcase 1 10 Relief valve assembly 1 11 Oil pump drive gear 1 12 Oil pump drive gear shaft 1 13 Oil pump driven gear 1 14 Oil pump driven gear shaft 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 265: ... parts in the order listed 1 Left crankshaft journal bearing 1 Refer to REMOVING THE CRANK SHAFT JOURNAL BEARINGS and INSTALLING THE CRANKSHAFT JOURNAL BEARINGS 2 Right crankshaft journal bearing 1 3 Bearing 2 4 Oil seal 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 266: ...ions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly EAS00387 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 1 Remove crankshaft journal bearings 1 NOTE Remove the journal bearings with the plane bearing installer remover 2 NOTE Identify the position of each crankshaft journal bearing so that they can be reinstalled in th...

Page 267: ...nnecting rod 4 Measure crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings as a set The following procedure applies to each crankshaft journal and its corresponding journal bearing a Clean the surface of the journal and the journal bearing b Check the bearing surface If the bearing surface is worn or scratched replace the bearing...

Page 268: ... smaller of the two values from the journal bearing e If the journal bearing inside diameter is 35 064 and the crankshaft journal outside diameter is 35 014 then the journal oil clearance is If the oil clearance is out of specification select replacement bearings Journal oil clearance Journal bearing inside diameter Crankshaft journal outside diameter 35 064 35 014 0 050 mm a b 5 Select crankshaft...

Page 269: ...in 1 blue 1 977 1 987 mm 0 0778 0 0782 in 2 black 1 973 1 983 mm 0 0777 0 0781 in 3 brown 1 969 1 979 mm 0 0775 0 0779 in 4 green 1 965 1 975 mm 0 0774 0 0778 in BEARING COLOR CODE BEARING THICKNESS 0 white 1 985 1 995 mm 0 0781 0 0785 in 1 blue 1 981 1 991 mm 0 0780 0 0784 in 2 black 1 977 1 987 mm 0 0778 0 0782 in 3 brown 1 973 1 983 mm 0 0777 0 0781 in 4 green 1 969 1 979 mm 0 0775 0 0779 in 6 ...

Page 270: ...tion Blow out with compressed air CHECKING THE BALANCER SHAFT ASSEMBLY 1 Check balancer shaft assembly Cracks damage Replace EAS00399 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check crankcase Cracks damage Replace oil delivery passages Obstruction Blow out with compressed air D o w n l ...

Page 271: ... pump driven gear oil pump drive gear shaft oil pump driven gear shaft Cracks damage wear Replace the defec tive part s EAS00365 CHECKING THE RELIEF VALVE 1 Check relief valve body 1 relief valve 2 spring 3 Damage wear Replace the defective part s 3 2 1 EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough m...

Page 272: ...to the installer 2 2 Install crankshaft journal bearings NOTE Install each crankshaft journal bearing from the inside of the crankcase with the notch a facing inward To install the crankshaft journal bearings press each bearing into the crankcase as shown in the illustration b 1 9 2 7 mm 0 075 0 106 in 3 Left crankcase 4 Right crankcase Plane bearing installer remover 90890 04146 YM 04146 a 2 1 4 ...

Page 273: ...unch mark b in the balancer driven gear a b EAS00418 ASSEMBLING THE CRANKCASE 1 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 2 Apply sealant onto the crankcase mating surfaces NOTE _ Do not allow any sealant to come into contact with the oil gallery Yamaha bond No 1215 90890 85505 Sealant Quick Gasket ACC 11001 05 01 D o w n l o a d e d f r o m w w w S c o o t e r...

Page 274: ...m 3 94 in bolt 1 M8 90 mm 3 54 in bolt 2 M8 80 mm 3 15 in bolt 3 M8 60 mm 2 36 in bolts 4 M6 70 mm 2 76 in bolts 5 T R Crankcase bolt Bolt 1 30 Nm 3 0 m kg 22 ft lb Bolt 2 4 16 Nm 1 6 m kg 11 ft lb Bolt 5 10 Nm 1 0 m kg 7 2 ft lb 5 5 3 2 4 1 5 CRANKSHAFT D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 275: ...R WHEEL AND BRAKE DISC in chapter 4 Transmission oil Drain Refer to CHANGING THE TRANSMIS SION OIL in chapter 3 Secondary sheave assembly Refer to BELT DRIVE 1 Transmission case cover 1 2 Transmission case cover gasket 1 3 Dowel pin 2 4 Primary drive gear 1 5 Washer 1 6 Washer 1 7 1st wheel gear 1 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 276: ...b Part Q ty Remarks 8 Drive axle 1 9 Main axle 1 10 Washer 1 11 Primary driven gear 1 12 Washer 1 For installation reverse the removal procedure TRANSMISSION D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 277: ...e gear s 2 Check transmission gear movement Rough movement Replace the defective part s 3 Check circlips Bends damage looseness Replace INSTALLING THE PRIMARY DRIVE GEAR OIL SEAL 1 Install primary drive gear oil seal 1 NOTE Press the primary drive gear oil seal into the transmission case cover as shown in the illus tration a 1 5 2 0 mm 0 059 0 079 in 1 a D o w n l o a d e d f r o m w w w S c o o t...

Page 278: ...ALLING THE RADIATOR 6 3 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT 6 6 WATER PUMP AND OIL COOLER 6 7 CHECKING THE WATER PUMP 6 9 CHECKING THE OIL COOLER 6 9 ASSEMBLING THE WATER PUMP 6 10 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 279: ... COWLING AND COVERS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator filler hose 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Radiator inlet hose 1 Disconnect 5 Radiator outlet hose 1 Disconnect 6 Radiator fan motor coupler 1 Disconnect 7 Radiator 1 8 Radiator fan 1 For installation reverse the removal pro cedure RADIATOR D o w n l o a d e d f r o m w w w S ...

Page 280: ...p opening pressure Below the specified pressure Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check radiator fan motor Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 110 0 ...

Page 281: ...t a Attach the radiator cap tester 1 to the radi ator b Apply 100 kPa 1 0 kg cm2 14 22 psi of pressure c Measure the indicated pressure with the gauge 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR Radiator cap tester 90890 01325 YU 24460 01 Radiator cap tester adapter 90890 01352 YU 33984 1 D o w n l o a d e d f r o m w...

Page 282: ...sted Storage box Refer to COWLING AND COVERS in chapter 3 Rubber sheet Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Thermostat outlet hose 1 Disconnect 2 Cooling system air bleed hose 1 Disconnect 3 Thermostat inlet hose 1 Disconnect 4 Thermostat cover 1 5 Thermostat 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 283: ...e water observe the ther mostat and thermometer s indicated tem perature 1 Thermostat 2 Container 3 Thermometer 4 Water È Fully closed É Fully open NOTE _ If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check thermostat cover Cracks damage Replace 3 Check thermostat inlet hose thermostat outlet hose Cracks damage Replac...

Page 284: ...the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 3 Check cooling system Leaks Repair or replace any faulty part 4 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR 1 T R 10 Nm 1 0 m kg 7 2 ft lb D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 285: ...T E Order Job Part Q ty Remarks Removing the water pump and oil cooler Remove the parts in the order listed Generator rotor cover Refer to STARTER CLUTCH AND GEN ERATOR in chapter 5 1 Oil cooler pipe 1 2 O ring 2 3 Water pump outlet hose 1 4 Oil cooler cover 1 5 Oil cooler cover gasket 1 6 Generator rotor cover inner bracket 1 7 Water pump cover 1 8 O ring 1 9 Circlip 1 10 Impeller shaft 1 D o w n...

Page 286: ... 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LS LT LT LT E Order Job Part Q ty Remarks 11 Water pump seal 1 12 Circlip 1 13 Bearing 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 287: ...ring Rough movement Replace 3 Check water pump inlet hose water pump outlet hose thermostat inlet hose Cracks damage Replace CHECKING THE OIL COOLER 1 Check oil cooler pipe 1 Cracks damage Replace 1 2 Check oil cooler cover 1 Cracks damage Replace 3 Check oil cooler outlet hose Cracks damage Replace 1 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 288: ...tor cover 2 NOTE _ Install the water pump seal with the special tools È Push down Mechanical seal installer 90890 04145 YM 04145 3 Middle driven shaft bearing driver 90890 04058 YM 04058 4 New New New 2 Lubricate water pump seal Recommended lubricant Lithium soap based grease D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 289: ...7 30 REMOVING THE FUEL PUMP 7 30 CHECKING THE FUEL INJECTOR 7 31 CHECKING THE THROTTLE BODY 7 31 INSTALLING THE FUEL PUMP 7 32 INSTALLING THE SUB FRAME 7 32 INSTALLING THE FUEL HOSE 7 33 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 7 34 CHECKING THE THROTTLE POSITION SENSOR 7 34 CHECKING THE ISC IDLE SPEED CONTROL VALVE 7 36 AIR INDUCTION SYSTEM 7 37 AIR INJECTION 7 37 AIR CUT OFF VALVE...

Page 290: ...l 7 Fuel injector 8 Intake air pressure sensor 9 Throttle position sensor 0 ISC idle speed control valve A Intake air temperature sensor B Battery C Air filter case D Catalytic converter E Crankshaft position sensor F Coolant temperature sensor G Spark plug H Fuel tank I Fuel pump J Pressure regulator 3 C 2 1 D E F G H I J 5 6 7 8 0 A 9 B 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n...

Page 291: ...K 0 7 å ç V E D N d g f e v w x o n i j k l m p p z y u t r s 8 2 1 5 6 3 C G H I J K L M O P Q R S T U X Y Z a b h c q W F 4 A B 9 R R R B B B B R B B B R R G R R R R Y Br Br Br Br L Br L R Br W R W L W W W W R W W B L L W G B O B O B R L R L W Y B G G B Br L R W G Y L W B R G B L G L Y G B L B W B R R Y R L R Y Sb Gy Lg P O G R P W B L W B G Y L Y B R B R B R R W Y L L B Y G L B L B L Br W Br W ...

Page 292: ... engine trouble warning light After the engine has been stopped the lowest fault code number appears on the LCD meter Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted EAS00900 Engine trouble warning light indication and FI system operating condition The warning light flashes when any one of the conditions listed below is present and the start swit...

Page 293: ... Item Symptom Fail safe action Engine start ability Vehicle drive ability 12 Crankshaft position sensor No normal signals are received from the crankshaft position sensor Stops the engine by stop ping the injection and igni tion Unable Unable 13 14 Intake air pressure sensor open or short circuit pipe system Intake air pressure sensor open or short circuit detected Faulty intake air pressure sen s...

Page 294: ...emory When this malfunction is detected the code number might not appear on the meter Unable Unable 61 ISC idle speed con trol valve unit open or short circuit ISC idle speed control valve unit open or short circuit detected Able Able Start unable warning Relay is not activated even if the crank signal is input while the start switch is pushed The start switch is pushed when fault code No 12 19 30...

Page 295: ...NG DETAILS Turn the main switch to OFF turn the main switch back to ON and then check if the fault code number is still displayed Repairs completed Fault code number not displayed Erasing the malfunction history The malfunction history is stored even if the main switch is turned OFF The malfunction history must be erased in the diagnostic mode Refer to Diagnostic mode table Diagnostic code No 62 O...

Page 296: ...G appears on the LCD meter 4 Press the SELECT button to select the CO adjustment mode Co or the diagnostic mode dIAG 5 After selecting dIAG simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection 6 Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the SELECT and RESET buttons NOTE The diagnos...

Page 297: ...n Set the engine stop switch to ON to oper ate the actuator If the engine stop switch is set to ON set it to OFF and then set it to ON again 8 Turn the main switch to OFF to cancel the the diagnostic mode NOTE To perform a reliable diagnosis make sure to turn OFF the power supply before every check and then start right from the beginning D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e ...

Page 298: ...pen or short circuit in wiring harness Defective coolant temperature sensor Malfunction in ECU Improperly installed sensor 06 22 Intake air temperature sensor open or short circuit detected Open or short circuit in wiring harness Defective intake temperature sensor Malfunction in ECU Improperly installed sensor 05 30 The scooter has overturned Overturned Malfunction in ECU 08 33 Open circuit is de...

Page 299: ... correctly Improper connection in wiring sub lead Malfunction in meter Malfunction in ECU Er 4 Non registered data has been received from the meter Improper connection in wiring sub lead Malfunction in meter Malfunction in ECU Diagnostic code Item Description of action Data displayed on meter reference value 01 Throttle angle Displays the throttle angle Check with throttle fully closed Check with ...

Page 300: ...iator fan motor relay operating sound 5 times with the engine stop switch ON At that time the fan motor rotates 52 Headlight relay 1 When the engine stop switch is turned from OFF to ON the headlight relay is actuated five times every 5 seconds and the engine trouble warning light comes on ON 2 seconds OFF 3 seconds If the engine stop switch is ON turn it OFF and then turn it back ON Check the hea...

Page 301: ...ys the codes of the history of the self diag nosis malfunctions i e a code of a malfunction that occurred once and which has been corrected If multiple malfunctions have been detected differ ent codes are displayed at 2 second intervals and this process is repeated 12 61 00 Displays when there is no mal function 62 Malfunction history code erasure Displays the total number of codes that are being ...

Page 302: ...y have pulled out Check that the coupler is con nected securely NOTE Set the main switch to OFF before connecting or disconnecting the connector If there is a malfunction repair it and connect it securely Crankshaft position sensor coupler Main wiring harness ECU coupler 3 Open or short circuit in wiring har ness Repair or replace if there is an open or short circuit between the main wiring harnes...

Page 303: ...iring harness ECU coupler Sub wire harness coupler Reinstated by turn ing the main switch ON 2 Open or short circuit in wiring har ness and or sub lead Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler black blue black blue pink white pink white blue blue 3 Defective intake air pressure sen sor Execute the diagnostic mode code No 03 Replace if defective ...

Page 304: ...ode No 01 throttle position sensor Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Installed condition of throttle posi tion sensor Check the installed area for looseness or pinching Check that it is installed in the specified position Refer to THROTTLE BODY AND FUEL INJEC TOR Reinstated by turn ing the main switch ON 2 Connected conditio...

Page 305: ...the locking condition of the coupler If there is a malfunction repair it and connect it securely Reinstated by reconnecting the wiring and retract ing the sidestand 2 Open or short circuit in wiring har ness and or sub lead Repair or replace if there is an open circuit Sidestand switch signal input line of ECU coupler blue yellow Fault code No 21 Symptom Coolant temperature sensor open or short ci...

Page 306: ...g har ness and or sub lead Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler black blue black blue brown white brown white 4 Defective intake air temperature sensor Execute the diagnostic mode code No 05 Replace if defective 1 Remove the intake air temperature sensor from the air filter case 2 Connect the pocket tester Ω 100 to the intake air temperature...

Page 307: ...0 V to the lean angle cut off switch terminals as shown 4 When turning the lean angle cut off switch approximately 45 the voltage reading change from 0 9 V to 4 1 V 5 Is the lean angle cut off switch OK Fault code No 33 Symptom Open circuit detected in the primary lead of the ignition coil Used diagnostic code No 30 Order Inspection operation item and probable cause Operation item and countermeasu...

Page 308: ... idle speed control valve not moving correctly Execute the diagnostic mode code No 54 After the ISC idle speed control valve is fully closed it opens until it is at the standby opening position when the engine is started This operation takes approximately 12 seconds until it is com pleted Start the engine If the error recurs replace the throttle body assembly Fault code No 39 Symptom Fuel injector...

Page 309: ...e No 08 Replace if defective Refer to Fault code No 30 Fault code No 42 Symptom No normal signals are received from the speed sensor Used diagnostic code No 07 speed sensor Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Connected condition of speed sen sor connector Inspect the coupler for any pins that may have pulled out Check the lock...

Page 310: ...jection system relay is on 3 Open or short circuit in the wiring harness Repair or replace if there is an open or short circuit Between battery and ECU coupler red red red blue red blue 4 Malfunction or open circuit in fuel injection system relay Execute the diagnostic mode code No 09 NOTE When the leads are disconnected the voltage check by the code No 09 is impossible Replace if defective 1 Remo...

Page 311: ...Power supply to the FI system relay is not normal Used diagnostic code No Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely ECU coupler Reinstated b...

Page 312: ...ition when the engine is started 2 Open or short circuit in lead Repair or replace if there is an open or short circuit Between ISC idle speed control valve and ECU coupler main harness pink pink light green light green gray gray sky blue sky blue 3 Detective ISC idle speed control valve Execute diagnostic mode code No 54 Replace if defective Refer to THROTTLE BODY AND FUEL INJEC TOR Fault code No...

Page 313: ...locking condition of the coupler If there is a malfunction repair it and connect it securely Main wiring harness ECU coupler Sub wire harness coupler Reinstated if nor mal signal is received from the ECU when the main switch is set to ON 2 Open or short circuit in wiring har ness and or sub lead Repair or replace if there is an open or short circuit Between meter coupler and ECU coupler yellow blu...

Page 314: ...e parts in the order listed Air filter case left and right Refer to AIR FILTER CASES in chapter 3 1 ISC idle speed control valve coupler 1 Disconnect 2 Throttle position sensor coupler 1 Disconnect 3 Intake air pressure sensor 1 4 Throttle body clamp screw 1 Loosen 5 Throttle body 1 6 Vacuum chamber cover 1 7 Piston valve spring 1 8 Piston valve 1 9 Throttle cable 2 Disconnect 10 Air filter case t...

Page 315: ...2 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 11 Throttle position sensor 1 12 Fuel injector coupler 1 Disconnect 13 Fuel injector assembly 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 316: ...and 1 2 Cover 1 3 Footrest board plate left and right 2 4 Bottom cover 1 5 Sidestand switch coupler 1 Disconnect 6 Fuel pump coupler 1 Disconnect 7 Fuel hose connector cover 1 Refer to REMOVING THE FUEL HOSE and INSTALLING THE FUEL HOSE 8 Fuel hose 1 9 Fuel hose holder 1 10 Ignition coil bracket 1 11 Radiator pipe assembly 1 For installation reverse the removal pro cedure THROTTLE BODY AND FUEL IN...

Page 317: ... fuel tank Remove the parts in the order listed NOTE Place a suitable stand under the frame and engine Fuel hose Refer to FUEL HOSE 1 Sub frame front upper mounting bolt nut left and right 2 2 Refer to INSTALLING THE SUB FRAME 2 Washer 2 3 Sub frame front lower mounting bolt left and right 2 4 Washer 2 5 Sub frame rear mounting bolt left and right 4 6 Washer 4 THROTTLE BODY AND FUEL INJECTOR D o w...

Page 318: ...ew Order Job Part Q ty Remarks 7 Sub frame adjusting bolt left and right 2 Refer to INSTALLING THE SUB FRAME 8 Sub frame with centerstand 1 9 Fuel tank 1 Refer to REMOVING THE FUEL HOSE 10 Fuel pump 1 Refer to REMOVING THE FUEL PUMP and INSTALLING THE FUEL PUMP For installation reverse the removal pro cedure THROTTLE BODY AND FUEL INJECTOR D o w n l o a d e d f r o m w w w S c o o t e r T i m e n ...

Page 319: ...eful when removing the fuel hose since there may be fuel remaining in it Do not disconnect the fuel hose from the fuel hose connector Disconnect the con nector from the fuel pump NOTE Before removing the hose place a few rags in the area under where it will be removed 3 Remove fuel tank 1 2 REMOVING THE FUEL PUMP 1 Remove fuel pump CAUTION Do not drop the fuel pump or give it a strong shock Do not...

Page 320: ... the throttle body 2 Check piston valve 1 Damage scratches wear Replace piston valve diaphragm 2 Cracks tears Replace 1 2 3 Check vacuum chamber cover 1 piston valve spring 2 Cracks damage Replace 4 Check piston valve movement Insert the piston valve into the throttle body and move it up and down Tightness Replace the piston valve D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 321: ...rward T R 4 Nm 0 4 m kg 2 9 ft lb a b È 1 6 4 2 5 3 INSTALLING THE SUB FRAME 1 Install sub frame adjusting bolts 1 sub frame rear mounting bolts 2 sub frame front lower mounting bolts 3 sub frame front upper mounting bolts 4 NOTE Do not fully tighten the bolts 2 Tighten sub frame rear mounting bolts NOTE Tighten the bolts on the left side of the scooter first 3 Tighten sub frame front lower mounti...

Page 322: ...ter first Pivot shaft wrench 90890 01471 YM 01471 Pivot shaft wrench adapter 90890 01476 T R 4 Nm 0 4 m kg 2 9 ft lb a 2 1 T R 54 Nm 5 4 m kg 39 ft lb INSTALLING THE FUEL HOSE 1 Install fuel hose fuel hose connector cover CAUTION Be sure to connect the fuel hose securely and install the fuel hose connector cover in the correct position otherwise the fuel hose will not be properly installed NOTE In...

Page 323: ...ay be fuel remain ing in it NOTE Before removing the hose place a few rags in the area under where it will be removed c Connect the pressure gauge 3 and adapter 4 onto the fuel hose d Start the engine e Measure the fuel pressure Faulty Replace the fuel pump Pressure gauge 90890 03153 YU 03153 Adapter 90890 03181 YM 03181 Fuel pressure 246 254 kPa 2 46 2 54 kg cm2 35 0 36 1 psi 1 2 3 4 EAS00916 CHE...

Page 324: ...r it changes abruptly Replace the throttle position sensor Out of specification closed position Replace the throttle position sensor Positive tester probe blue terminal 1 Negative tester probe black blue terminal 2 Pocket tester 90890 03112 YU 03112 C Throttle position sensor voltage 5 V blue black blue Positive tester probe yellow blue terminal 3 Negative tester probe black blue terminal 2 Thrott...

Page 325: ...onnect the pocket tester Ω 10 to the terminals of the ISC idle speed control valve c Measure the ISC idle speed control valve resistance Out of specification Replace the throttle body Positive tester probe pink terminal 1 Negative tester probe light green terminal 2 Positive tester probe gray terminal 3 Negative tester probe sky blue terminal 4 Pocket tester 90890 03112 YU 03112 C ISC idle speed c...

Page 326: ...ssure at the exhaust port the reed valve opens allowing secondary air to flow into the exhaust port The required temperature for burning the unburned exhaust gases is approximately 600 to 700 C 1 112 to 1 292 F EAS00917 AIR CUT OFF VALVE The air cut off valve prevents air backflow from the exhaust port of the cylinder head to the air filter È From the air filter É To the cylinder head È É D o w n ...

Page 327: ...ction system hose air filter case to air cut off valve 2 Air cut off valve 3 Air induction system hose air cut off valve to cylinder head 4 Air induction system pipe 5 Air filter case cover right B B A 1 A 1 3 2 2 4 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 328: ...ff valve and air induction system hoses Remove the parts in the order listed 1 Air induction system hose air filter case to air cut off valve 1 Disconnect 2 Air induction system hose air cut off valve to air filter case 1 Disconnect 3 Air cut off valve 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 329: ... Loose connections Connect properly Cracks damage Replace pipes Cracks damage Replace 2 Check reed valve reed valve stopper reed valve seat Cracks damage Replace the reed valve 3 Check air cut off valve Cracks damage Replace D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 330: ...ister Remove the parts in the order listed 1 Canister 1 2 Rollover valve 1 3 Fuel tank to rollover valve hose 1 4 Rollover valve to canister hose 1 5 Canister to throttle body hose 1 For installation reverse the removal pro cedure CANISTER D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 331: ...IRCUIT DIAGRAM 8 14 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 15 TROUBLESHOOTING 8 16 STARTER MOTOR 8 19 CHECKING THE STARTER MOTOR 8 21 ASSEMBLING THE STARTER MOTOR 8 22 CHARGING SYSTEM 8 23 CIRCUIT DIAGRAM 8 23 TROUBLESHOOTING 8 24 LIGHTING SYSTEM 8 26 CIRCUIT DIAGRAM 8 26 TROUBLESHOOTING 8 27 CHECKING THE LIGHTING SYSTEM 8 29 SIGNALING SYSTEM 8 35 CIRCUIT DIAGRAM 8 35 TROUBLESHOOTING 8 37 CHE...

Page 332: ...ay 4 Radiator fan motor relay 5 Headlight relay 2 6 Main switch 7 Front brake light switch 8 Rear brake light switch 9 Storage box light switch 0 Starter relay A Main fuse B Battery C Fuse box D Diode 1 2 3 4 5 7 8 0 A 6 B C D E F G H I J K L 9 M ELECTRICAL COMPONENTS D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 333: ...ator coil F Sidestand switch G Ignition coil H Radiator fan motor I Rectifier regulator J Horn K Thermistor L ECU M Wire harness 1 2 3 4 5 7 8 0 A 6 B C D E F G H I J K L 9 M D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 334: ... 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...

Page 335: ...ty reading Replace the switch P B R Y G B Br W Ch Dg 9 A 0 4 1 3 2 7 6 B BLUE BLACK B R R Y G Y P Br W Br B G B Dg Ch 5 8 G Y Br L G R B R W B L W OFF G Y Br Br R W L W G Y R B B Br L R R Br L L Y L B OFF ON L B L Y RED 1 Engine stop switch 2 Start switch 3 Front brake light switch 4 Main switch 5 Sidestand switch 6 Fuse 7 Storage box light switch 8 Rear brake light switch 9 Dimmer switch 0 Turn s...

Page 336: ...er are shown in the illustration on the left Bulbs a and b are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulb c is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb co...

Page 337: ...ass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE _ Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to termi nal 1 and the...

Page 338: ... 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 Pocket tester 90890 03112 YU 03112 C D o w n l o a d e d f...

Page 339: ... L G R R Y G Y B B W Y L L B W L O BLACK BLACK BLACK BLACK OFF GRAY GRAY B B L Y L Y L B L Y Br BLACK P R W Br G W R B G Y L B Br R W L W G Y R B B RED RED BLACK 0 7 å ç V E D N d g f e v w x o n i j k l m p p z y u t r s 8 2 1 5 6 3 C G H I J K L M O P Q R S T U X Y Z a b h c q W F 4 A B 9 R R R B B B B R B B B R R G R R R R Y Br Br Br Br L Br L R Br W R W L W W W W R W W B L L W G B O B O B R L ...

Page 340: ...54 YM 34487 Pocket tester 90890 03112 YU 03112 C 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clea...

Page 341: ...ncrease the spark gap until a misfire occurs Minimum ignition spark gap 6 mm 0 24 in Is there a spark and is the spark gap within specification The ignition system is OK 5 Spark plug cap resistance Remove the spark plug cap from the spark plug lead Connect the pocket tester Ω 1k to the spark plug cap as shown Measure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20 C 68 F Is the...

Page 342: ...coil resistance 8 64 12 96 kΩ at 20 C 68 F Is the ignition coil OK Replace the ignition coil 7 Crankshaft position sensor resistance Disconnect the crankshaft position sensor coupler from the wire harness Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown Positive tester probe red 1 Negative tester probe white 2 Measure the crankshaft position sensor resistance Cran...

Page 343: ... Remove the starting circuit cut off relay Connect the pocket tester Ω 1 to the starting circuit cut off relay terminals as shown Check the starting circuit cut off relay for continuity Positive tester probe blue yellow 1 Negative tester probe red black 2 Continuity Positive tester probe red black 2 Negative tester probe blue yellow 1 No continuity NOTE _ When you switch the positive and negative ...

Page 344: ...ean angle cut off switch voltage Less than 45 a Approximately 1 V More than 45 b Approximately 4 V Is the lean angle cut off switch OK Replace the lean angle cut off switch a a b ON ON 13 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly connected and without defects Replace the ECU Properly connect or repair the ignition system s wi...

Page 345: ...R B B RED RED BLACK 0 7 å ç V E D N d g f e v w x z y u t r s 8 2 1 5 6 3 C G H I J K L M O P Q R S U X Y Z a b h c q F 4 A B 9 R R R B B B B R B B B R R G R R R R Y Br Br Br Br L Br L R Br W R W L W W W W R W W B L L W G B O B O B W Y B G G B Br L R W G Y L W B R G B L G L Y G B L B W B R R Y Sb Gy Lg P O G R P W B L W B G Y L Y R W Y L L B Y G L B L B L Br W Br W B L B L Br W B L P W P W L L Y L...

Page 346: ...e met A brake lever is pulled to the handlebar the brake light switch is closed and the side stand is up the sidestand switch is closed 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 7 Sidestand switch 8 Signaling system fuse 9 Front brake light switch 0 Rear brake light switch A Start switch B Starter relay C Starter motor D o w n l o a d...

Page 347: ...signaling system fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and signaling sys tem fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Starter mot...

Page 348: ... continuity between green yellow and green white Replace the starting circuit cut off relay 2 1 4 3 G W R B L Y G Y 5 Starter relay Remove the starter relay Connect the pocket tester Ω 1 and bat tery 12 V to the starter relay terminal as shown Positive battery terminal green yellow 1 Negative battery terminal blue white 2 Positive tester probe black 3 Negative tester probe red 4 Does the starter r...

Page 349: ...eplace the brake light switch s 9 Sidestand switch Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK Replace the side stand switch 10 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK Replace the right handlebar switch 11 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM...

Page 350: ...oving the starter motor Remove the parts in the order listed Throttle body Refer to THROTTLE BODY AND FUEL INJECTOR in chapter 7 1 Starter motor lead 1 2 Starter motor 1 For installation reverse the removal pro cedure D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 351: ...ont bracket 1 Refer to ASSEMBLING THE STARTER MOTOR 2 O ring 1 3 Shim 1 4 Lock washer 1 5 Rear bracket 1 6 O ring 1 7 Shim 1 8 Brush holder set 1 9 Armature assembly 1 0 Starter motor yoke 1 For assembly reverse the disassembly procedure STARTER MOTOR D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 352: ...be undercut to ensure proper operation of the commutator 4 Measure armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter motor Commutator wear limit 27 mm 1 06 in Mica undercut 0 7 mm 0 028 in Pocket tester 90890 03112...

Page 353: ...gth wear limit 4 0 mm 0 16 in Brush spring force 7 65 10 01 N 780 1 021 gf 27 54 36 03 oz 8 Check bearing 1 oil seal 2 bushing 3 Damage wear Replace the defective part s EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install starter motor yoke 1 front bracket 2 rear bracket 3 NOTE _ Align the match marks a on the starter motor yoke with the match marks b on the front and rear brackets D o w n l o a d e d...

Page 354: ...LACK BLACK L Y L Y L B L Y Br BLACK P R W Br G W R B G Y L B Br R W L W G Y R B B RED RED BLACK 0 7 å ç E D N 8 2 1 5 6 3 C G H I J K L M a b F 4 A B 9 R R R B B B B R B B B R R G R R R R Y Br Br Br Br L Br L R Br W R W L W W W W R W W Br L R W G Y L W B R G B L G L Y G B L B L B L Br W Br W B L B L B P L Y P W L B L Y L L Br Br P R YR Y G LW B R L Y L Y G W G Y L W R B L Y G Y L B G W R B R W Br ...

Page 355: ...S NO EAS00739 YES NO The battery is not being charged Pocket tester 90890 03112 YU 03112 C 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in chapter 3 Is the main fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean th...

Page 356: ...sconnect the stator coil coupler from the wire harness Connect the pocket tester Ω 1 to the stator coil as shown Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Measure the stator coil resistances Stator coil resistance 0 184 0 276 Ω at 20 C 68 F Is the stator coil OK Replace the crank shaft position sensor stator assembly 5 W...

Page 357: ...LACK P R W Br G W R B G Y L B Br R W L W G Y R B B RED RED BLACK 0 7 å ç V E D N d g f e v w x o n i j k l m p p z y u t r s 8 2 1 5 6 3 C G H I J K L M O P Q R S T U X Y Z a b h c q W F 4 A B 9 R R R B B B B R B B B R R G R R R R Y Br Br Br Br L Br L R Br W R W L W W W W R W W B L L W G B O B O B R L R L W Y B G G B Br L R W G Y L W B R G B L G L Y G B L B W B R R Y R L R Y Sb Gy Lg P O G R P W B...

Page 358: ...1 Main headlight signaling system turn sig nal position light and backup fuses Check the main headlight signaling sys tem turn signal position light and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main headlight signaling system turn signal position light and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARG...

Page 359: ...egative tester probe green blue 4 Does the headlight relay 1 have continuity between red yellow and green blue Replace the head light relay 1 R Y G L R Y W B 1 2 4 3 7 Headlight relay 2 Remove the headlight relay 2 Connect the pocket tester Ω 1 and bat tery 12 V to the headlight relay 2 terminal as shown Check the headlight relay 2 for continuity Positive tester probe green blue 1 Negative tester ...

Page 360: ...TING SYSTEM Properly connect or repair the lighting system s wiring 1 Headlight bulb and socket Check the headlight bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK Replace the head light bulb socket or both 2 High beam indicator light bulb and socket Check the high beam indicator light bulb and socket for continuity Refer to CHECKING...

Page 361: ... L B L Gy B Ch Dg Y R G R W G 5 4 Set the main switch to ON Start the engine Set the dimmer switch to or Measure the voltage DC 12 V of yellow 1 green 2 on the headlight coupler and yellow 4 on the meter assembly coupler wire harness side Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the headlight cou pler or meter assem bly coupler is faulty and...

Page 362: ... Replace the tail brake light assembly L Ch Dg Y 2 1 Y L B L Gy B R G R W G 2 Voltage Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Positive tester probe brown 1 Negative tester probe black 2 Set the main switch to ON Measure the voltage DC 12 V of brown 1 on the tail brake light coupler wire har ness side Is the voltage within specification This circ...

Page 363: ... L Ch B L Ch B L Dg B L Dg 1 2 1 2 È É 1 License plate light bulb and socket Check the license plate light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the license plate light bulb and socket OK Replace the license plate light bulb socket or both 2 Voltage Connect the pocket tester DC 20 V to the rear turn signal license plate light coupler wire harness side as s...

Page 364: ... the pocket tester DC 20 V to the storage box light connectors wire harness side as shown Positive tester probe blue green 1 Negative tester probe black 2 Set the main switch to ON Measure the voltage DC 12 V of blue green 1 on the storage box light connec tor wire harness side Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the storage box light c...

Page 365: ...8 34 ELEC LIGHTING SYSTEM D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 366: ... W L B L P W GRAY Y L R L O B P G R Lg Gy Sb P W B L L GRAY Br W Gy Sb R L Y G P W O B P Lg W G B W B B L L Y R W Br W W R Y R L G R R Y G Y B B W Y L L B W L O BLACK BLACK BLACK BLACK OFF GRAY GRAY B B L Y L Y L B L Y Br BLACK P R W Br G W R B G Y L B Br R W L W G Y R B B RED RED BLACK 0 7 å ç V E D N d g f e v w x o n i j k l m p p z y u t r s 8 2 1 5 6 3 C G H I J K L M O P Q R S T U X Y Z a b ...

Page 367: ...left k Rear turn signal light right m Tail brake light n Front turn signal position light right o Front turn signal position light left r Multifunction meter s Speedometer u Engine oil change indicator v V belt replacement indicator w Engine trouble warning light z Right turn signal indicator light Left turn signal indicator light V belt replacement indicator reset coupler ç Signaling system fuse ...

Page 368: ...light and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition signaling system turn signal position light and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or ...

Page 369: ...pler Is the voltage within specification The wiring circuit from the main switch to the horn coupler is faulty and must be repaired Br P 1 3 Horn Disconnect the horn coupler at the horn Connect a jumper lead 1 to the brown ter minal in the horn coupler and the horn ter minal Connect a jumper lead 2 to the horn ter minal and ground Set the main switch to ON Does the horn sound The wiring circuit fr...

Page 370: ...ircuit is OK The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired L Y B G Y Br B 1 2 1 Turn signal light bulb and socket Check the turn signal light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the turn signal light bulb and socket OK Replace the turn sig nal light bulb socket or both 2 Turn signal indicator light...

Page 371: ...wiring circuit from the main switch to the turn signal relay coupler is faulty and must be repaired Br Br W 1 5 Voltage Connect 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 Set the main switch to ON Measure the voltage DC 12 V on brown white 1 at the turn signal relay coupler wire harness side...

Page 372: ... 2 1 Ê L Y L B L Gy B Ch Dg Y R W R G G 2 1 Ë Set the main switch to ON Set the turn signal switch to or Measure the voltage DC 12 V of the chocolate 1 or dark green 2 at the front turn signal position light coupler rear turn signal license plate light coupler or meter assembly coupler wire harness side Is the voltage within specification This circuit is OK The wiring circuit from the turn signal ...

Page 373: ...dica tor reset coupler 1 2 B B 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Positive tester probe gray 1 Negative tester probe ground Set the main switch to ON Measure the voltage 12 V of gray 1 at the meter assembly coupler Is the voltage within specification Replace the meter assembly The wiring circuit from the V belt replacement indica to...

Page 374: ...bly Replace the engine oil change indicator bulb socket or both 1 Speed sensor Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Positive tester probe white 1 Negative tester probe blue 2 Set the main switch to ON Elevate the front wheel and slowly rotate it Measure the voltage DC 5 V of white and blue With each full rotation of the front wheel the voltage re...

Page 375: ...r probe yellow blue 1 Negative tester probe black 2 Set the main switch to ON Measure the voltage DC 12 V of yellow blue 1 on the meter assembly coupler wire harness side Is the voltage within specification This circuit is OK Replace the meter assembly L Y L B L Gy B Ch Dg Y R W R G G 2 1 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 376: ... B P Lg W G B W B B L L Y R W Br W W R Y R L G R R Y G Y B B W Y L L B W L O BLACK BLACK BLACK BLACK OFF GRAY GRAY B B L Y L Y L B L Y Br BLACK P R W Br G W R B G Y L B Br R W L W G Y R B B RED RED BLACK 0 7 å ç V E D N d g f e v w x o n i j k l m p p z y u t r s 8 2 1 5 6 3 C G H I J K L M O P Q R S T U X Y Z a b h c q W F 4 A B 9 R R R B B B B R B B B R R G R R R R Y Br Br Br Br L Br L R Br W R ...

Page 377: ...ter assembly fails to indicate Pocket tester 90890 03112 YU 03112 C 1 Main ignition and radiator fan motor fuses Check the main ignition and radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and radiator fan motor fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Mini...

Page 378: ... 5 Radiator fan motor relay Remove the radiator fan motor relay Connect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor terminal as shown Check the radiator fan motor relay of conti nuity Positive battery terminal red white 1 Negative battery terminal green yellow 2 Positive tester probe brown 3 Negative tester probe blue 4 Does the radiator fan motor relay have con tinuity betwe...

Page 379: ...ratures indicated below Coolant temperature sensor resistance 20 C 68 F 2 32 2 59 kΩ 80 C 176 F 0 310 0 326 kΩ 110 C 230 F 0 140 0 144 kΩ WARNING _ Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it T R Coolant temperature sensor 18 Nm 1 8 m kg 13 ft lb Does the coolant temper...

Page 380: ...3 FUEL SYSTEM 9 3 FAULTY CLUTCH 9 3 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE 9 3 CLUTCH SLIPS 9 3 POOR STARTING PERFORMANCE 9 3 POOR SPEED PERFORMANCE 9 3 OVERHEATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 OVERCOOLING 9 4 COOLING SYSTEM 9 4 POOR BRAKING PERFORMANCE 9 5 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 5 D ...

Page 381: ... 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 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 382: ...ect valve to valve seat contact Incorrect valve timing Faulty valve spring Seized valve Piston and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft FUEL SYSTEM Fuel tank Empty f...

Page 383: ...tches Faulty start switch Faulty sidestand switch Improperly grounded circuit Loose connections Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch EAS00847 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder and cylinder head Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Thrott...

Page 384: ...ission gear CLUTCH SLIPS Clutch shoe spring s Damaged loose or worn clutch shoe spring Clutch shoe Damaged or worn clutch shoe Primary sliding sheave Seized primary sliding sheave POOR STARTING PERFORMANCE V belt V belt slips Oil or grease on the V belt Primary sliding sheave Worn primary sliding sheave Clutch shoe Bent damaged or worn clutch shoe POOR SPEED PERFORMANCE V belt Oil or grease on the...

Page 385: ...hermostat Thermostat stays closed Oil cooler Hose s and pipe s Damaged hose Improperly connected hose Damaged pipe Improperly connected pipe FUEL SYSTEM Throttle body Damaged or loose throttle body joint Air filter Clogged air filter element CHASSIS Brake s Dragging brake ELECTRICAL SYSTEMS Spark plug Incorrect spark plug gap Incorrect spark plug heat range Ignition system Faulty radiator fan moto...

Page 386: ... outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS00862 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed lower handlebar holder Improperly installed lower bracket improperly tightened steering ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels...

Page 387: ... Incorrectly adjusted brake light switch s TURN SIGNAL DOES NOT COME ON Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb ...

Page 388: ...switch i Tail brake light assembly j Rear turn signal light left k Rear turn signal light right l License plate light m Tail brake light n Front turn signal position light right o Front turn signal position light left p Headlight q Meter assembly r Multifunction meter s Speedometer t Tachometer u Engine oil change indicator v V belt replacement indicator w Engine trouble warning light x Meter ligh...

Page 389: ...g Gy Sb P W B L L GRAY Br W Gy Sb R L Y G P W O B P Lg W G B W B B L L Y R W Br W W R B R Y R L G R R Y G Y B B W Y L L B W L O BLACK BLACK BLACK BLACK OFF GRAY GRAY B B L YL Y L B L Y Br BLACK P R W Br G W R B G Y L B Br R WL W G Y R B B RED RED BLACK 0 7 å ç V E D N d g f e v w x o n i j k l m p p z y u t r s 8 2 1 5 6 3 C G H I J K L M O P Q R S T U X Y Z a b h c q W F 4 A B 9 R R R B B B B R B...

Page 390: ...Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto ON M2H 3B4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Search results

Summary of Contents for 2005 YP400T

Reviews:

Related manuals for 2005 YP400T

Brands by name

Popular brands

Yamaha 2005 YP400T, Service Manual

Search results

Summary of Contents for 2005 YP400T

Reviews:

Related manuals for 2005 YP400T

Brands by name

Popular brands