Yamaha 2009 YW125Y Service Manual Download Page 15

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1-8

GEN

INFO

CHECKING THE CONNECTIONS

EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.

1. Disconnect:

lead

coupler

connector

2. Check:

lead

coupler

connector
Moisture

Dry with an air blower.

Rust/stains

Connect and disconnect

several times.

3. Check:

all connections
Loose connection

Connect properly.

TIP

If the pin

on the terminal is flattened, bend it

up.

4. Connect:

lead

coupler

connector

TIP

Make sure all connections are tight.

5. Check:

continuity
(with the pocket tester)

Pocket tester

90890-03112 (YU-03112-C)

TIP

If there is no continuity, clean the terminals.

When checking the wire harness, perform
steps (1) to (3).

As a quick remedy, use a contact revitalizer
available at most part stores.

Summary of Contents for 2009 YW125Y

Page 1: ...2009 MOTORCYCLE SERVICE MANUAL Model YW125Y_ 32SF819770E0 32SF819770E0 ...

Page 2: ...rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co Ltd is expressly prohibited 0 10 0 14mm 0 004 0 006in 0 16 0 20mm 0 006 0 008in Valve Clearance cold Intake Exhuast Spark plug gap 0 7 0 8 mm 0 028 0 031in Spark Plug U22ESR N DENSO CR7E NGK ...

Page 3: ...h the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Taiwan Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP This Service Manual con...

Page 4: ...mation such as special tools and technical data are described se quentially 5 32 ENG Remarks Order Job Part Q ty 1 2 3 4 5 6 7 8 EAS00251 CYLINDER AND PISTON Removing the cylinder and piston Cylinder head Timing chain guide exhaust side Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set Remove the parts in the order listed Refer to CYLINDER HEAD Refer to REMOVING ...

Page 5: ...g Symbols 0 to u indicate the following 0 Serviceable with engine mounted q Filling fluid w Lubricant e Special tool r Tightening torque t Wear limit clearance y Engine speed u Electrical data Symbols i to g in the exploded diagrams indi cate the types of lubricants and lubrication points i Engine oil o Gear oil p Molybdenum disulfide oil a Brake fluid s Wheel bearing grease d Lithium soap based g...

Page 6: ... OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL INJECTION SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO SPEC CHK ADJ CHAS ENG FI ELEC TRBL SHTG 1 2 3 4 5 6 7 8 ...

Page 7: ...OUTLINE OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 O2 sensor 1 4 IMPORTANT INFORMATION 1 5 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 5 REPLACEMENT PARTS 1 5 GASKETS OIL SEALS AND O RINGS 1 5 LOCK WASHERS PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 6 CIRCLIPS 1 6 EQUIPMENT PREPARATION 1 7 CHECKING THE CONNECTIONS 1 8 SPECIAL TOOLS 1 9 ...

Page 8: ...ION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EAS00018 MODEL LABEL The model label 1 is affixed to the frame under the seat This information will be needed to or der spare parts 1 1 ...

Page 9: ...the engine to deliver more performance and cleaner exhaust gases in crease it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all tim...

Page 10: ...The injection duration and the injection timing are controlled by the ECU Signals that are input from the crankshaft position sensor intake air pressure sensor intake temperature sensor and engine temperature sensor enable the ECU to determine the injection duration The injection timing is deter mined through the signals from the crankshaft position sensor As a result the volume of fuel that is re...

Page 11: ...n level is known When a difference in the oxygen concentration level is created between the outside and the inside of the zirconia tube the oxygen ion passes through the zirconia element and generates an electromotive force The electro motive force increases when the oxygen concentration level is low rich air fuel ratio and the elec tromotive force decreases when the oxygen concentration level is ...

Page 12: ...an all of the parts and place them 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 replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance b...

Page 13: ...isible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appropriate 1 Oil seal NOTICE Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways repla...

Page 14: ... status of the turn rivet turn type Dissembling 1 Press center pin1 inward to release the lock 2 Remove the push rivet main body2 Assembling 1 Restore the center pin replace the turn rivet main body 2 Turn in the center pin until leveling off with the surface position of the turn rivet main body ...

Page 15: ...sconnect several times 3 Check 8all connections Loose connection J Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect 8lead 8coupler 8connector TIP Make sure all connections are tight 5 Check 8continuity with the pocket tester Pocket tester 90890 03112 YU 03112 C TIP 8 If there is no continuity clean the terminals 8 When checking the wire harness perform steps 1 to...

Page 16: ...e nut with holding the compression spring Valve adjusting tool This tool is necessary for adjusting valve clearance T handle 1 Damper rod holder 2 These tools are used to hold the damper rod when removing or installing the damper rod Lock nut wrench This tool is used when removing or install ing the secondary sheave nut SPECIAL TOOLS 1 2 1 2 EAS00027 SPECIAL TOOLS The following special tools are n...

Page 17: ...stalling the fork seal Oil seal guide This tool is used for protecting the oil seal lip when installing the secondary sliding sheave Steering nut wrench This tool is used to loosen and tighten the steering ring nut Sheave holder This tool is used for holding the secondary sheave Thickness gauge This tool is used to measure the valve cleanance Compression gauge This tool is used to measure the engi...

Page 18: ...g compressor Compressor adapter Ø19mm These tools are used when removing or in stalling the valve and the valve spring Valve guide remover 4 5mm This tool is used to remove or install the valve guides Valve guide installer 4 5mm This tool is used to install the valve guides Valve guide reamer 4 5mm This tool is used to rebore the new valve guides Ignition checker This tool is used to check the ign...

Page 19: ...1 12 GEN INFO SPECIAL TOOLS Tool NO Tool name Function Illustration 90890 85505 ACC 11001 05 01 Yamaha bond NO 1215 Sealant Quick Gasket This sealant bond is used to apply on crankcase mating surfaces ...

Page 20: ...GINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 12 ELECTRICAL SPECIFICATIONS 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 18 TIGHTENING TORQUES 2 19 ENGINE 2 19 CHASSIS 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE 2 23 CHASSIS 2 25 CABLE ROUTING 2 26 ...

Page 21: ...mm 75 2in Overall width 765mm 30 1in Overall height 1110mm 43 7in Seat height 780mm 30 7in Wheelbase 1290mm 50 8in Minimum ground clearance 125mm 4 9in Minimum turning radius 1900mm 74 8in Weight Wet with oil and a full fuel tank 122kg 269lb Dry without oil and fuel 116kg 256lb Maximum load total of cargo rider 155kg 342lb passenger and accessories ...

Page 22: ...ion pressure 1350kPa at sea level 13 5kgf cm2 192psi at 1800r min Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity Total 6 0L 1 59 US gal 1 32 Imp gal Engine oil Lubrication system Wet sump Recommended oil SAE20W 40 or SAE10W 30 API service SG type or higher JASO standard MA Quantity Periodic oil change 0 80 0 90L 0 87 0 98 US qt 0 74 0 83 Imp qt Total amount 0 85 0 95L 0 9 ...

Page 23: ...or tip clearance 0 15mm 0 006in or less 0 23mm 0 009in Outer rotor to pump housing clearance 0 07 0 12mm 0 19mm 0 003 0 005in 0 008in Starting system type Electric starter Spark plug Model manufacturer quantity U22ESR N DENSO 1 Spark plug gap 0 7 0 8mm 0 028 0 031in Cylinder head Volume 11 4 12 0cm 0 70 0 73cu in Maximum warpage 0 05mm 0 002in ...

Page 24: ...ensions Measurement A 25 267 25 367mm 25 167mm 0 995 0 999in 0 991in Measurement B 21 069 21 169mm 20 969mm 0 829 0 833in 0 826in Exhaust camshaft lobe dimensions Measurement A 25 275 25 375mm 25 175mm 0 995 0 999in 0 991in Measurement B 21 069 21 169mm 20 969mm 0 829 0 833in 0 826in Maximum camshaft runout 0 03mm 0 0012in ...

Page 25: ...8 9 19 1mm 0 744 0 752in Exhaust 16 9 17 1mm 0 665 0 673in Valve face width B Intake 1 48 2 18mm 0 058 0 086in Exhaust 1 91 2 61mm 0 075 0 103in Valve seat width C Intake 0 9 1 1mm 0 035 0 043in Exhaust 0 9 1 1mm 0 035 0 043in Valve margin thickness D Intake 0 7mm 0 028in Exhaust 1 0mm 0 039in Valve stem diameter Intake 4 970 4 985mm 4 940mm 0 1956 0 1963in 0 1945in Exhaust 4 955 4 970mm 4 925mm 0...

Page 26: ...lve guide clearance Intake 0 015 0 042mm 0 08mm 0 0006 0 0017in 0 0031in Exhaust 0 030 0 057mm 0 1mm 0 0012 0 0022in 0 0039in Valve stem runout 0 01mm 0 0004 in Valve seat width Intake 0 9 1 1mm 0 035 0 043in 1 6mm 0 063in Exhaust 0 9 1 1mm 0 035 0 043in 1 6mm 0 063in ...

Page 27: ...57N mm 13 97 16 01kgf mm 30 83 35 33lbf in Exhaust 137 157N mm 13 97 16 01kgf mm 30 83 35 33lbf in Spring tilt Intake 2 5 1 8mm 2 5 0 07in Exhaust 2 5 1 8mm 2 5 0 07in Winding direction top view Intake Clockwise Exhaust Clockwise Valve seat reformed Yes Cylinder Cylinder arrangement Forward inclined single cylinder Bore stroke 52 4 57 9mm 2 06 2 28in Compression ratio 10 1 Bore 52 40 52 41mm 2 063...

Page 28: ...0 0138 0 0256in Offset direction Intake side Piston pin Outside diameter 14 995 15 000mm 14 975mm 0 5904 0 5906in 0 5896in Piston rings Top ring Ring type Barrel Dimensions B T 1 0 2 1mm 0 0394 0 0827in End gap installed 0 10 0 25mm 0 50mm 0 0039 0 0098in 0 0197in Ring side clearance 0 02 0 08mm 0 13mm 0 0008 0 0031in 0 0051in 2nd ring Ring type Taper Dimensions B T 1 0 2 1mm 0 0394 0 0827in End g...

Page 29: ...2 9 SPEC ENGINE SPECIFICATIONS Item Standard Limit B T Oil ring Dimensions B T 2 0 2 5mm 0 0787 0 0984in End gap installed 0 2 0 7mm 0 0079 0 0276in Ring side clearance 0 04 0 12mm 0 0016 0 0047in ...

Page 30: ...ft Width A 45 45 45 50mm 1 789 1 791in Maximum runout C 0 03mm 0 0012in Big end side clearance D 0 15 0 45mm 0 006 0 018in Big end radial clearance E 0 0 01mm 0 0 0014in Clutch Clutch type Automatic centrifugal Clutch shoe thickness 3 2mm 3 5mm 0 13 0 14in 2 0mm 0 079in Clutch shoe spring free length 28 5mm 1 12in Clutch housing inside diameter 120mm 4 72in 120 5mm 4 74in Compression spring free l...

Page 31: ...in Maximum drive axle runout 0 04mm 0 002in Air filter Type Wet element Fuel pump Pump type Electrical Model manufacturer 5S9 AISAN Maximum consumption amperage 1 9A Output pressure 250kPa 2 5kgf cm2 35 6psi Throttle body Model manufacturer quantity AC24 7 AISAN 1 Throttle cable free play 3 5mm 0 12 0 20in at the flange of the throttle grip ID mark 5S91 00 Engine idling speed 1700 1900r min Carbon...

Page 32: ...in Maximum lateral wheel runout 1 0mm 0 04in Wheel axle bending limit 0 25mm 0 01in Rear wheel Wheel type Cast wheel Rim Size J12 MT3 00 Material Aluminum Wheel travel 71mm 2 80in Wheel runout Maximum radial wheel runout 1 0mm 0 04in Maximum lateral wheel runout 1 0mm 0 04in Front tire Tire type Tubeless Size 120 70 12 51L Model manufacturer K761 KENDA Tire pressure cold 0 90kg 0 198lb 175kPa 1 75...

Page 33: ...6in 220 3 5mm 8 66 0 14in Minimum thickness 3 5mm 0 14in Maximum deflection 0 15mm 0 006in Brake pad lining thickness inner 5 8mm 0 23in 0 8mm 0 03in Brake pad lining thickness outer 5 8mm 0 23in 0 8mm 0 03in Master cylinder inside diameter 11mm 0 43in Caliper cylinder inside diameter 35mm 1 38in Rear brake Brake type Drum brake Operation Left hand operation Brake lever free play at lever end 10 2...

Page 34: ...nded oil Fork oil 10W or equivalent Quantity each front fork leg 0 104L 0 11 US qt 0 09 Imp qt Inner tube outer diameter 33mm 1 30in Inner tube bending limit 0 2mm 0 008in Rear suspension Suspension type Unit swing Rear shock absorber assembly type Coil spring oil damper Rear shock absorber assembly travel 70mm 2 76in Spring Free length 235mm 9 25in Installed length 224mm 8 82in Spring rate K1 9 3...

Page 35: ... type AC magneto Model manufacturer 5S9 T MORIC Nominal output 14V 170W 5000r min Stator coil resistance color 0 56 0 84Ω at 20 C 68 F white white Rectifier regulator Model manufacturer SH640E 11 TAIGENE No load regulated voltage 14 1 14 9V Rectifier capacity 25A Battery Battery type manufacturer YT7B BS YUASA Battery voltage capacity 12V 6 5AH Specific gravity 1 340 Ten hour rate amperage 6 5AH H...

Page 36: ...68 F Mica undercut depth 1 5mm 0 06in Starter relay Model manufacturer 5S9 00 SHIHLIN Amperage 100A Coil resistance 3 6 4 4Ω Suction voltage DC8V Horn Horn type Plane Model manufacturer YF 12 NIKKO Maximum amperage 3A Performance 105 120dB 2m Coil resistance 1 15 1 25Ω Turn signal relay Relay type Condenser Model manufacturer 5XN4 OMRON Self cancelling device built in NO Turn signal blinking frequ...

Page 37: ... temperature sensor Model manufacturer 4P91 PANASONIC Coil resistance at 100 C 212 F 0 210 0 221kΩ Intake air pressure sensor Output voltage 0 789 4 0V Intake air temperature sensor Coil resistance color 6kΩ at 0 C 32 F brown white black blue Throttle position sensor Voltage color 5V blue black blue Output voltage closed position color 0 63 0 73V yellow black blue ISC idle speed control valve Resi...

Page 38: ...stener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Width across flats B Thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 1...

Page 39: ...base Cover 1 magneto base V belt case cover V belt case cover Cylinder stud bolt Drain bolt transmission oil Drain bolt engine oil Guide element ft lbf Nm m kgf Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Plug Screw Screw Screw Bolt Screw Screw Bolt Screw Bolt Band Band Bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Bolt Screw M8 M10 M6 M8 M6 M6 M6 M6 M5 M8 M6 M8 6 0 6 0 M6 M6 6 0 M5 M30 M6 M6 ...

Page 40: ...Engine temperature sensor Clamp holder Bolt Bolt Bolt Nut Nut Bolt Nut Screw Screw Screw Bolt Part to be tightened Part name Thread size Q ty Tightening torque Remarks ft lbf Nm m kgf LT M6 M6 M6 M14 M12 M6 M12 M6 M6 M6 M18 M10 M6 4 2 1 1 1 2 1 3 2 2 1 1 2 10 10 10 60 45 7 70 7 7 7 44 18 10 1 0 1 0 1 0 6 0 4 5 0 7 7 0 0 7 0 7 0 7 4 4 1 8 1 0 7 2 7 2 7 2 43 4 32 5 5 1 50 6 5 1 5 1 5 1 31 8 13 0 7 2...

Page 41: ...eat lock assembly Fuel pump bracket Resin part and resin cover Front fender Leg shield assembly Footrest board Front wheel shaft Rear wheel shaft Rear brake camshaft lever Rear brake pin pivot Front brake caliper Front brake disc rotor Brake hose and front brake caliper Front brake caliper and bleed screw M10 M10 M10 M10 M10 M8 M8 M10 M8 M25 M10 M10 M12 M12 M10 M8 M10 M6 M6 M6 M6 M6 M5 About M5 M6...

Page 42: ...ut and touch rubber washer Align the slots both ring nut and install the lock washer 5 Final hold the ring nuts lower and center and tighten the ring nut upper 75Nm 7 5m kgf 54 2ft lbf by using the torque wrench 6 Confirm adjust the direction handlebar to the right direction front wheel suspend Push direction handlebar lightly with the finger approxomately 0 15Nm 0 015m kgf 0 11ft lbf direction ha...

Page 43: ... surface Crankshaft journals Connecting rod big end thrust surface Piston and piston rings Piston pin and connecting rod small end surface and bolt thread Piston balancer outside surface Piston pin balancer outside surface Rocker arm shaft outside surface intake and exhaust Rocker arm shaft and rockor arm Camshaft lobes Camshaft journals Valve stems intake and exhaust Valve stem seals intake and e...

Page 44: ...5 Lubrication Point Lubricant LUBRICATION POINTS AND LUBRICANT TYPES G G Main and drive axle serration sprocket Drive axle taper rollor bearing Transmission bearing Secondary fixed sheave inner surface Secondary sliding sheave torque cam ditch Crankcase mating surfaces G ...

Page 45: ... oil seal Front wheel axle Speedometer gear unit Rear wheel axle Sidestand pivoting point and sliding surface metal to metal moving parts and bolt outer surface Centerstand shaft pivoting point and metal to metal moving parts Centerstand stopper pivoting point Centerstand and sidestand spring hook metal to metal moving parts Caliper piston seal Rubber parts inside the master cylinder Caliper pisto...

Page 46: ...lead i Engine temperature sensor lead o Positive wire lead p Starter relay lead a Clamp 90464 25803 s Air shroud cylinder 2 d Rectifier regulator f Body earth lead g ECU h Speedometer lead j Left lever holder lead A After connect the headlight coupler lead do not touch horn B Speedometer cable passes through the right hole of inner fender C Five couplers of speedometer lead and le ver holder D ECU...

Page 47: ... Fuse box passes under the wire harness O Speedometer cable passes through the wire holder P Rectifier regulator lead passes by the back of the head pipe Q ECU lead passes under of the front bracket R Turn signal relay lead passes under of the front bracket S After connecting put the front signal light coupler left and right brake light switch coupler front and rear and right handlebar switch lead...

Page 48: ... cable passes through the wire guide of front bracket B Brake hose passes through the left hole of inner fender C Locate the end of gasoline overflow pipe at between frame and air duct D Rear brake holder 2 holds the rear brake cable and covers the ultrasonic weld mark at the PVC protector E Locate at between compression rod and air duct F Rear brake cable passes through the wire guide G Tightenin...

Page 49: ...i Ignition coil o Battery p Battery band a Clamp 90464 12812 A Fasten the sidestand switch lead to the frame with a plastic locking tie point the band tip to down of car body B Seat lock cable inserts into the right hole of frame and the protector must be at the hole C Fuse box lead passes under the wire har ness D Pass the positive and negative battery leads through the slot in the footrest board...

Page 50: ...at license bracket and combine with tail brake light lead N After combining the couplers insert them into the sockets at tail brake light O Yellow mark to up of pipe 11 P Assembly range of starter motor negative lead terminal Q Torque 7Nm 0 7m kgf 5 1ft lbf R The terminal of battery negative pole black lead shall tough the left surface of battery box at least S Battery band buckles the rear side a...

Page 51: ...meter lead u Rear brake light switch lead i Left lever holder lead o Turn signal light lead left p Brake hose A Fasten the right handlebar switch lead front brake light switch lead and right turn signal light lead to the handlebar B Upper screw tighten first C Torque 4Nm 0 4m kgf 2 9ft lbf D Band holds the wires and hoses with finger clearance and cut off the surplus until 5mm left Band is above t...

Page 52: ...SION PRESSURE 3 19 CHECKING THE ENGINE OIL LEVEL 3 22 CHANGING THE ENGINE OIL 3 23 CHANGING THE TRANSMISSION OIL 3 25 MEASURING THE ENGINE OIL PRESSURE 3 26 CLEANING THE AIR FILTER ELEMENT 3 28 CLEANING THE V BELT CASE AIR FILTER ELEMENT 3 29 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 3 30 CHECKING THE FUEL HOSE 3 30 CHECKING THE BREATHER HOSES 3 31 CHECKING THE EXHAUST SYSTEM 3 32 CHECK...

Page 53: ...BLES 3 46 LUBRICATING THE LEVERS 3 47 LUBRICATING THE SIDESTAND 3 47 LUBRICATING THE CENTERSTAND 3 47 LUBRICATING THE REAR SUSPENSION 3 47 ELECTRICAL SYSTEM 3 48 CHECKING AND CHARGING THE BATTERY 3 48 CHECKING THE FUSES 3 55 REPLACING THE HEADLIGHT BULBS 3 57 ADJUSTING THE HEADLIGHT BEAMS 3 58 ...

Page 54: ... or 18 months 13000 km 8000 mi or 24 months 16000 km 10000 mi or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean Replace at 7000 km 4000 mi or 12 months and thereafter every 6000 km 4000 mi or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold 4 Crankcase breather system...

Page 55: ...ssis fasteners Check all chassis fitting and fasteners Correct if necessary 11 Front brake lever pivot shaft Apply silicone grease lightly 12 Rear brake lever pivot shaft Apply lithium soap based grease lightly 13 Centerstand and sidestand pivots Check operation Apply lithium soap based grease lightly 14 Sidestand switch Check operation and replace if necessary 15 Front fork Check operation and fo...

Page 56: ...ssembling the brake master cylinder and caliper always change the fluid Regularly check the brake fluid level and fill the reservoir as required Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hose every four years and if cracked or damaged PERIODIC MAINTENANCE AND ADJUSTMENT Since these items require special too...

Page 57: ... 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal pro cedure COVER AND PANEL Removing the seat and trunk Seat Fuel tank cap cover Seat hinge Upper cover Trunk Side cover left Side cover right 7 2 7Nm 0 7 m kgf 5 1 ft lbf 5 1 3 6 4 7Nm 0 7 m kgf 5 1 ft lbf ...

Page 58: ...tive battery lead and then the positive battery lead After installing the battery be sure to turn the main switch from ON to OFF three times in 3 seconds intervals to initialize the idle speed control system Removing the footrest board Battery box cover Front cover Band Battery negative lead Battery positive lead Battery Cap 1 5 4 6 3 7 2 8 7Nm 0 7 m kgf 5 1 ft lbf ...

Page 59: ...D PANEL Remarks Order Job Part Q ty TIP While installing the fuse box should be installed to the correct position For installation reverse the removal pro cedure 8 Footrest board 1 1 5 4 6 3 7 2 8 7Nm 0 7 m kgf 5 1 ft lbf ...

Page 60: ...D 1 ASSEMBLY AND LEG SHIELD 2 Remarks Order Job Part Q ty COVER AND PANEL Removing the leg shield 1 assembly and leg shield 2 Footrest board Safeguard Headlight coupler Leg shield 1 assembly Main switch cover Leg shield 2 1 2 3 4 5 1 1 1 1 1 Remove the parts in the order listed Refer to FOOTREST BOARD Disconnect For installation reverse the removal pro cedure ...

Page 61: ...ty Disassembling the leg shield 1 as sembly Panel Headlight cover Headlight assembly Panel leg shield 1 Leg shield 1 1 2 3 4 5 1 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 5 4 7Nm 0 7 m kgf 5 1 ft lbf 1 2 3 ...

Page 62: ...on the compression stroke 1 Remove 8battery box cover 8front cover Refer to COVER AND PANEL 2 Remove 8spark plug cap 8spark plug 8ignition coil 8valve cover intake and exhaust 8breather 3 Measure 8valve clearance Out of specification J Adjust Valve clearance cold Intake valve 0 10 0 14mm 0 004 0 006in Exhaust valve 0 16 0 20mm 0 006 0 008in a Turn the crankshaft counterclockwise b When the piston ...

Page 63: ...oosen the locknut 1 b Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip c Turn the adjusting screw 3 in direction a or b until the specified valve clearance is obtained Direction a Valve clearance is increased Direction b Valve clearance is decreased Valve adjusting tool 90890 01311 YM 08035 A d Hold the adjusting screw to prevent it from moving and tighten the lo...

Page 64: ... all of the valve clearance ad justment steps until the specified clearance is obtained 5 Install 8breather 7Nm 0 7m kgf 5 1ft lbf 8valve cover intake and exhaust 7Nm 0 7m kgf 5 1ft lbf 8ignition coil 7Nm 0 7m kgf 5 1ft lbf 8spark plug 13Nm 1 3m kgf 9 4ft lbf 6 Install 8front cover 8battery box cover Refer to COVER AND PANEL T R T R T R T R ...

Page 65: ...mpression 1 Start the engine and let it warm up for sev eral minutes 2 Remove 8battery box cover 8front cover Refer to COVER AND PANEL 3 Connect 8digital tachometer 1 onto the spark plug lead of cylinder Digital tachometer 90890 06760 4 Check 8engine idling speed Out of specification J Replace the throttle body Engine idling speed 1700 1900r min 5 Install 8front cover 8battery box cover Refer to C...

Page 66: ...e of the throttle grip 3 5mm 0 12 0 20in 2 Adjust 8throttle cable free play a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction a Throttle cable free play is increased Direction b Throttle cable free play is de creased c Tighten the locknut WARNING After adjusting the throttle cable free play start the engine and ...

Page 67: ...G THE SEAT SPRING FORCE TIP When open the seat and seat will not fold up automatically adjust the spring force 1 Remove 8seat 8upper cover 2 Adjust 8screw 1 Direction a Spring force is increased Direction b Spring force is decreased 3 Install 8upper cover 8seat ...

Page 68: ...ated in the spark plug well with compressed air to prevent it from falling into the cylinder 4 Check 8spark plug type Incorrect J Change Spark plug type manufacturer U22ESR N DENSO 5 Check 8electrode 1 Damage wear J Replace the spark plug 8insulator 2 Abnormal color JReplace the spark plug Normal color is medium to light tan 6 Clean 8spark plug with a spark plug cleaner or wire brush 7 Measure 8sp...

Page 69: ...ARK PLUG 8 Install 8spark plug 13Nm 1 3m kgf 9 4ft lbf TIP Before installing the spark plug clean the spark plug and gasket surface 9 Connect 8spark plug cap 10 Install 8front cover 8battery box cover Refer to COVER AND PANEL T R ...

Page 70: ...all connections are tight and free of corrosion 1 Remove 8battery box cover 8front cover Refer to COVER AND PANEL 2 Attach 8digital tachometer 1 onto the spark plug lead of cylinder 8timing light 2 Timing light 90890 03141 YU 03141 Digital tachometer 90890 06760 3 Check 8ignition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed ...

Page 71: ...hat the mark a on the AC magneto rotor is within the firing range b on the crankcase Incorrect firing range J Check the ignition system TIP The ignition timing is not adjustable 4 Remove 8timing light 8digital tachometer 5 Install 8front cover 8battery box cover Refer to COVER AND PANEL ...

Page 72: ...rt the engine warm it up for several min utes and then turn it off 3 Remove 8battery box cover 8front cover Refer to COVER AND PANEL 4 Disconnect 8spark plug cap WARNING Remove the spark plug cap the engine is extremely hot 5 Remove 8spark plug NOTICE Before removing the spark plug use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylin...

Page 73: ...dard 1350kPa 13 5kgf cm2 192psi at 1800r min Maximum 1512kPa 15 1kgf cm2 215psi at 1800r min a Set the main switch to ON b With the throttle wide open crank the en gine until the reading on the compression gauge stabilizes WARNING To prevent sparking ground the spark plug lead before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head valve ...

Page 74: ...ADJ MEASURING THE COMPRESSION PRESSURE T R 8 Remove 8compression gauge 9 Install 8spark plug 13Nm 1 3m kgf 9 4ft lbf 10 Connect 8spark plug cap 11 Install 8front cover 8battery box cover Refer to COVER AND PANEL ...

Page 75: ...terials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has settled CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1 Stand the scooter o...

Page 76: ...n 8engine oil completely from the crankcase 5 If the oil filter element is also to be replaced or cleaned perform the following procedure a Remove the oil strainer cover 1 spring 3 and oil filter element 4 b Replace the new O ring 2 c Install the new or clean oil filter element and the oil strainer cover Oil strainer cover 20Nm 2 0m kgf 14 5ft lbf 6 Install 8engine oil drain bolt along with the ga...

Page 77: ...erature sensor coupler b Slightly loosen the engine temperature sen sor 1 c Start the engine and keep it idling until en gine oil starts to seep from the engine tem perature sensor If no engine oil comes out after one minute turn the engine off so that it will not seize d Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP in chapter 5 e ...

Page 78: ...oil drain bolt 1 5 Drain 8transmission oil completely from the transmission case 6 Install 8transmission oil drain bolt 23Nm 2 3m kgf 16 6ft lbf 7 Fill 8transmission case with the specified amount of the recom mended transmission oil Recommended oil SAE10W 30 type SE motor oil Total amount 0 14 0 16L 0 15 0 17 US qt 0 12 0 14 Imp qt Periodic oil change 0 12 0 14L 0 13 0 15 US qt 0 11 0 12 Imp qt 8...

Page 79: ...erefore be sure to measure the engine oil pressure after warming up the engine 3 Remove 8battery box cover 8front cover Refer to COVER AND PANEL 4 Disconnect 8engine temperature sensor coupler 1 5 Lossen 8engine temperature sensor 1 WARNING The engine muffler and engine oil are extremely hot 6 Check 8engine oil pressure a Start the engine and keep it idling until en gine oil starts to seep from th...

Page 80: ...art the engine after solving the problem s and check the engine oil pressure again 7 Tighten 8engine temperature sensor 18Nm 1 8m kgf 13 0ft lbf 8 Connect 8engine temperature sensor coupler 9 Install 8front cover 8battery box cover Refer to COVER AND PANEL ...

Page 81: ...more frequent service if you are riding in unusually wet or dusty ar eas 4 Install 8air filter element 8air filter case cover NOTICE Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning leading to poor engine performa...

Page 82: ...nt 3 Check 8V belt case air filter element Damage J Replace CLEANING THE V BELT CASE AIR FILTER ELEMENT 4 Apply the recommended oil to the entire surface of the V belt case air filter element and then carefully pat the V belt case air fil ter element on a clean cloth to remove the excess oil The V belt case air filter element should be wet but not dripping Recommended oil Engine oil 5 Install 8V b...

Page 83: ...E FUEL TANK in chapter 6 EAS00096 CHECKING THE FUEL HOSE The following procedure applies to all of the fuel and impulse hoses 1 Remove 8seat 8trunk 8battery box cover 8front cover Refer to COVER AND PANEL 3 Check 8throttle body joint 1 8intake manifold 2 Cracks damage J Replace Refer to CYLINDER HEAD in chapter 5 4 Install 8fuel tank Refer to INSTALLING THE FUEL TANK AND FUEL HOSE in chapter 6 5 I...

Page 84: ...racks damage J Replace Loose connection J Connect properly NOTICE Make sure the breather hoses are routed correctly CHECKING THE FUEL HOSE CHECKING THE BREATHER HOSES 3 Install 8front cover 8battery box cover 8trunk 8seat Refer to COVER AND PANEL 2 Check 8fuel hose 1 Cracks damage J Replace Loose connection J Connect properly 3 Install 8front cover 8battery box cover 8trunk 8seat Refer to COVER AN...

Page 85: ...SSEMBLIES AND SWINGARM in chapter 4 2 Check 8muffler 1 Crack damage J Replace 8gasket 2 Exhaust gas leak J Replace 3 Check 8tightening torque Exhaust pipe nut 3 3 3 3 3 13Nm 1 3m kgf 9 4ft lbf Muffler and swingarm bolt 4 4 4 4 4 31Nm 3 1m kgf 22 4ft lbf Muffler and swingarm bolt 5 5 5 5 5 53Nm 5 3m kgf 38 3ft lbf 4 Install 8muffler 8O2 sensor coupler Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWI...

Page 86: ... Remove 8seat 8trunk Refer to COVER AND PANEL 2 Check 8hose to throttle body 1 8hose to roll over valve 2 Cracks damage J Replace Loose connection J Connect properly 3 Remove 8canister 1 4 Check 8canister Cracks damage J Replace Obstruction J Blow out with compressed air 5 Install 8canister TIP While installing make sure the canister is routed correctly 6 Remove 8roll over valve 1 ...

Page 87: ...uction J Replace d Put roll over valve with the horizontal angle e Connect the hose to direction a and blow air in the hose Unobstructed J Replace Obstruction J Normal 8 Install 8roll over valve TIP Roll over valve should be installed on the frame with the vertical angle If roll over valve to slope or the horizontal more than about 45 degrees installation will make the scooter unable to start 9 In...

Page 88: ...ake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if necessary bleed the brake system 2 Adjust 8brake lever free play a Turn the adjusting nut 1 in direction a or b until the specified brake lever free pla...

Page 89: ...te causing leakage and poor brake performance 8 8 8 8 8 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 8 8 8 8 8 When refilling be careful that water does not enter the brake fluid reservoir Wa ter will significantly lower the boiling point of the brake fluid and could cause vapo...

Page 90: ...FRONT BRAKE PADS in chapter 4 EAS00130 CHECKING THE FRONT BRAKE HOSE 1 Check 8brake hose 1 Cracks damage wear J Replace 2 Check 8brake hose holder Loose connection J Tighten the holder bolt 3 Hold the scooter upright and apply the front brake several times 4 Check 8brake hose Brake fluid leakage J Replace the dam aged hose Refer to FRONT BRAKE in chapter 4 EAS00126 CHECKING THE REAR BRAKE SHOES 1 ...

Page 91: ...brake Ignoring this precaution could allow air to enter the hy draulic brake system considerably length ening the bleeding procedure 8 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 2 Bleed 8hydraulic brake system a Fill the brake fluid reservoir to the proper level with the...

Page 92: ...til all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification Bleed screw 6Nm 0 6m kgf 4 3ft lbf k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING After bleeding the hydraulic brake system check the brake operation 3 Install 8brake master cylinder re...

Page 93: ...vated 2 Check 8steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness J Adjust the steering head 3 Remove 8leg shield 1 Refer to COVER AND PANEL 4 Adjust 8steering head a Remove the upper ring nut 1 lock washer 2 the center ring nut 3 and the rubber washer 4 b Loosen the lower ring nut 5 and then tighten it to specification with the ring nut wrench 6...

Page 94: ...heck the up per and lower bearings Refer to STEERING HEAD in chapter 4 e Install the rubber washer f Install the center ring nut 7 g Finger tighten the center ring nut then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the center ring nut until their slots are aligned h Install the lock washer 8 TIP Make sure the lock washer tabs a sit correctly in the ring nut...

Page 95: ...at there is no danger of it falling over 2 Check 8inner tube Damage scratches J Replace 8oil seal Oil leakage J Replace 3 Hold the scooter upright and apply the front brake 4 Check 8front fork operation Push down hard on the handlebar sev eral times and check if the front fork re bounds smoothly Rough movement J Repair Refer to FRONT FORK in chapter 4 ...

Page 96: ... ger and accessories and the anticipated riding speed 8 8 8 8 8 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 ac cessories WARNING It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately Basic weight with oil and a full fuel tank Ma...

Page 97: ...be make sure the wheel rim band and tube are cen tered in the wheel groove 8 8 8 8 8 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 A Tire B Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire 8 8 8 8 8 After extensive tests the tires listed be low have bee...

Page 98: ...es have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done TIP For tires with a direction of rotation mark 1 8 Install the tire with the mark pointing in the direction of wheel rotation 8 Align the mark 2 with the valve installation point ...

Page 99: ...ration Rough movement J Lubricate Recommended lubricant Engine oil or a suitable cable lubricant TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device CHECKING THE WHEELS CHECKING AND LUBRICATING THE CABLES EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check 8wheel Damage out of round J Re...

Page 100: ...UBRICATING 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 EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to m...

Page 101: ...ectrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL 8 8 8 8 8 Skin Wash with water 8 8 8 8 8 Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL 8 8 8 8 8 Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention NOTICE 8 8 8 8 8 This is a s...

Page 102: ...s NOTICE First disconnect the negative battery lead 1 1 1 1 1 and then the positive battery lead 2 2 2 2 2 3 Remove 8band 8battery 4 Check 8battery charge a Connect a digital circuit tester 1 to the bat tery terminals Digital circuit tester 90890 03174 Positive tester probe J positive battery terminal Negative tester probe J negative battery terminal TIP 8 The charge state of an MF battery can be ...

Page 103: ...nd battery plate damage 8 8 8 8 8 If it is impossible to regulate the charg ing current on the battery charger be careful not to overcharge the battery 8 8 8 8 8 When charging a battery be sure to re move it from the scooter If charging has to be done with the battery mounted on the scooter disconnect the negative bat tery lead from the battery terminal 8 8 8 8 8 To reduce the chance of sparks do ...

Page 104: ...d clip may gen erate heat in the contact area and a weak clip spring may cause sparks 8 8 8 8 8 If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode 8 8 8 8 8 As shown in the following illustration the open circuit voltage of an MF battery stabilizes about 30 minutes ...

Page 105: ...age Set the timer to the charging time determined by the opencircuit voltage Refer to CHECKING AND CHARGING THE BATTERY Adjust the char ging voltage to 20 25V Monitor the amperage for 3 5 minutes Is the standard charg ing amperage exceeded If the amperage does not ex ceed the standard charging am perage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisab...

Page 106: ... on the bat tery TIP Set the charging time to a maximum of 20 hours TIP Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage Charge the battery until the charging voltage reaches 15 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V J Charging is complete 12 0 12 7 V J Recharging is re quired Under 12 0 V J Rep...

Page 107: ...ls NOTICE First connect the positive battery lead 1 1 1 1 1 and then the negative battery lead 2 2 2 2 2 8 Check 8battery terminals Dirt J Clean with a wire brush Loose connection J Connect properly 9 Lubricate 8battery terminals Recommended lubricant Dielectric grease 10 Install 8battery box cover Refer to COVER AND PANEL ...

Page 108: ...E FUSES 2 Check 8fuse a Connect the pocket tester to the fuse and check the continuity TIP Set the pocket tester selector to Ω 1 Pocket tester 90890 03112 YU 03112 C b If the pocket tester indicates replace the fuse 3 Replace 8blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the...

Page 109: ...0A 15A 10A 10A 20A 15A 10A WARNING Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install 8battery box cover Refer to COVER AND PANEL ...

Page 110: ...d your hands away from the bulb until it has cooled down 4 Install 8headlight bulb New Secure the new headlight bulb with the headlight bulb holder NOTICE Avoid touching the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with...

Page 111: ...Headlight beam is lowered b Turn the high beam light adjusting screw 2 in direction c or d Direction c Headlight beam is raised Direction d Headlight beam is lowered 2 Adjust 8headlight beam horizontally a Turn the low beam light adjusting screw 1 in direction a or b Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left b Turn the high beam light adjusting scre...

Page 112: ...TALLING THE REAR WHEEL 4 17 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 18 FRONT BRAKE 4 19 FRONT BRAKE PADS 4 19 REPLACING THE FRONT BRAKE PADS 4 21 FRONT BRAKE MASTER CYLINDER 4 23 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 25 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 26 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 27 FRONT BRAKE CALIPER 4 30 DISASSEMBLING THE FRONT BRAKE CALI...

Page 113: ...ET 4 56 REMOVING THE LOWER BRACKET 4 58 CHECKING THE STEERING HEAD 4 59 INSTALLING THE STEERING HEAD 4 60 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 61 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 4 62 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES 4 63 REMOVING THE SWINGARM 4 63 CHECKING THE SWINGARM 4 64 INSTALLING THE SWINGARM 4 64 ...

Page 114: ...c 1 2 3 4 5 6 7 1 1 1 1 1 1 1 Remove the parts in the order listed TIP Place the scooter on a suitable stand so that the front wheel is elevated Disconnect For installation reverse the removal pro cedure EAS00513 CHASSIS FRONT WHEEL AND BRAKE DISC Refer to REMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL 1 6 4 5 2 3 7 70Nm 7 0 m kgf 50 6 ft lbf 23Nm 2 3 m kgf 16 6 ft lbf 4Nm 0 4 m kgf 2 9 f...

Page 115: ... Part Q ty 1 1 1 1 EAS00518 FRONT WHEEL FRONT WHEEL AND BRAKE DISK Disassembling the front wheel Oil seal Bearing Spacer Bearing 1 2 3 4 Remove the parts in the order listed For assembly reverse the disassembly procedure 2 1 4 3 ...

Page 116: ...rely support the scooter so that there is no danger of it falling over TIP Place the scooter on a suitable stand so that the front wheel is elevated 2 Remove 8speedometer cable 8front wheel axle nut 8front wheel axle 8front wheel 8collar 8speedometer gear unit TIP Do not apply the brake lever when removing the front wheel ...

Page 117: ...le on a flat surface Bends Replace Wheel axle bending limit 0 25mm 0 01in WARNING Do not attempt to straighten a bent wheel axle 2 1 3 Measure 8radial wheel runout 1 8lateral wheel runout 2 Over the specified limits Replace Radial wheel runout limit 1 0mm 0 04in Lateral wheel runout limit 1 0mm 0 04in 4 Check 8wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings 8oil sea...

Page 118: ...ve the oil seal 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gen eral bearing puller 4 d Install the new wheel bearings and oil seal in the reverse order of disassembly FRONT WHEEL AND BRAKE DISK ...

Page 119: ...nt brake disc de flection turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 2 3mm 0 08 0 12in below the edge of the brake disc 3 Measure 8brake disc thickness b Measure the brake disc thickness at a few different locations Out of specification...

Page 120: ...ake disc EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1 Check 8speedometer clutch Bends damage wear Replace 2 Check 8speedometer drive gear 1 8speedometer driven gear 2 Damage wear Replace EAS00539 ASSEMBLING THE FRONT WHEEL 1 Install 8wheel bearing 8spacer 8oil seal New a Install the new wheel bearings and oil seal in the reverse order of disassembly NOTICE Do not contact the wheel bearing inner r...

Page 121: ...r unit and the wheel hub are installed with the two projections 2 meshed into the speedmeter clutch 3 re spectively 3 Install 8front wheel TIP Make sure the slot 1 in the speedometer gear unit fits over the stopper 2 on the outer tube 4 Tighten 8wheel axle 70Nm 7 0m kgf 50 6ft lbf NOTICE Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork ...

Page 122: ...wheel s heavy spot TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps d through f several times until all the marks come to re...

Page 123: ...rn 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 until the front wheel is balanced 4 Check 8front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain station ary at all of the positions rebalance it ...

Page 124: ...djuster Brake cable Compression spring Pin Rear wheel Brake shoe kit Tension spring Plate washer Camshaft lever Brake shoe wear indicator Brake camshaft O ring REAR WHEEL AND REAR BRAKE Remove the parts in the order listed TIP Place the scooter on a suitable stand so that the front wheel is elevated Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Refer to ASSEMBLING THE BRAKE SHOES EAS00555 R...

Page 125: ...CHAS 4 12 Remarks Order Job Part Q ty For installation reverse the removal pro cedure REAR WHEEL AND REAR BRAKE 2 3 1 9 10 4 6 5 8 12 12 11 7 10Nm 1 0 m kgf 7 2 ft lbf 12 Collar 1 ...

Page 126: ...r of it falling over TIP Place the scooter on a suitable stand so that the rear wheel is elevated 2 Disconnect 8O2 sensor coupler 3 Remove 8muffler 8wheel axle nut 1 8swingarm Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM REAR WHEEL AND REAR BRAKE 4 Loosen 8brake adjuster 5 Remove 8rear wheel 6 Remove 8brake shoe kit 8brake camshaft lever ...

Page 127: ...l of the brake shoes 1 Check 8brake shoe lining Glazed areas Repair Sand the glazed areas with course sand paper TIP After sanding the glazed areas clean the brake shoe with a cloth EAS00565 CHECKING THE REAR WHEEL 1 Check 8tire 8rear wheel Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 2 Measure 8radial wheel runout 8lateral wheel runout Refer to CHECKING THE...

Page 128: ...L AND REAR BRAKE 3 Measure 8brake drum inside diameter b Out of specification Replace the wheel Brake drum inside diameter limit maximum 151mm 5 94in 4 Check 8brake drum inner surface Oil deposits Clean Remove the oil with a rag soaked in lac quer thinner or solvent Scratches Repair Lightly and evenly polish the scratches with an emery cloth 5 Check 8brake camshaft Damage wear Replace EAS00570 ASS...

Page 129: ...amshaft c Check that the brake shoes are properly positioned 2 Tighten 8brake camshaft lever 10Nm 1 0m kgf 7 2ft lbf 3 Install 8brake shoe kit 1 8tension springs NOTICE 8 8 8 8 8 Do not put lubricating oil on the brake lining 8 8 8 8 8 Change the tension spring at the same time of changing the brake shoe 8 8 8 8 8 Refer to the direction in the illustration when assembling the brake shoe and spring...

Page 130: ...eel axle Recommended lubricant Lithium soap based grease 2 Install 8rear wheel 3 Install 8swingarm 8wheel axle nut 1 8muffler Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1 4 Connect 8O2 sensor coupler 5 Adjust 8brake lever free play Refer to ADJUSTING THE REAR BRAKE in chapter 3 ...

Page 131: ...replacing the tire wheel or both the rear wheel static balance should be ad justed 8 Adjust the rear wheel static balance with the rear wheel drive hub installed 1 Adjust 8rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE REAR WHEEL AND REAR BRAKE ...

Page 132: ...lip Brake pad retaining bolt Brake pad Brake pad spring Remove the parts in the order listed Disconnect For installation reverse the removal pro cedure FRONT BRAKE EAS00576 FRONT BRAKE FRONT BRAKE PADS Refer to REPLACING THE FRONT BRAKE PADS 1 2 3 5 4 5 4 13Nm 1 3 m kgf 9 4 ft lbf 49Nm 4 9 m kgf 35 4 ft lbf ...

Page 133: ...ined cleaned properly filled and bled after reassembly 8 8 8 8 8 Never use solvents on internal brake components 8 8 8 8 8 Use only clean or new brake fluid for cleaning brake components 8 8 8 8 8 Brake fluid may damage painted sur faces and plastic parts Therefore al ways clean up any spilt brake fluid im mediately 8 8 8 8 8 Avoid brake fluid coming into contact with the eyes as it can cause seri...

Page 134: ...ing bolt 1 2 Remove 8brake caliper 2 3 Remove 8circlip 8brake pad retaining bolt 8brake pads 8brake pad springs 4 Measure 8brake pad wear limit a Out of specification Replace the brake pads as a set Brake pad wear limit 0 8mm 0 03in 5 Install 8brake pad springs 8brake pads TIP Always install new brake pads and a new brake pad springs as a set TIP Make sure the brake pad springs is installed correc...

Page 135: ...tall 8brake pad retaining bolt 13Nm 1 3m kgf 9 4ft lbf 8circlip 8brake caliper 49Nm 4 9m kgf 35 4ft lbf T R T R 8 Check 8brake fluid level Below the level mark a Add the rec ommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 9 Check 8brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter...

Page 136: ... right Brake fluid Brake master reservoir cap Brake master reservoir holder Brake master reservoir diaphragm Brake lever compress spring Front brake light switch Union bolt Copper washer Brake hose Brake master cylinder holder Brake master cylinder Remove the parts in the order listed Refer to HANDLEBAR Drain Disconnect For installation reverse the removal pro cedure Refer to DISASSEM BLING THE FR...

Page 137: ...y 1 2 3 4 5 1 1 1 1 1 Disassembling the front brake mas ter cylinder Dust boot Circlip Washer Brake master cylinder kit Brake master cylinder body Remove the parts in the order listed For assembly reverse the disassembly procedure EAS00585 1 2 3 4 5 ...

Page 138: ...emove 8brush guard right Refer to HANDLEBAR 2 Remove 8brake lever compress spring 8front brake light switch 8union bolt 1 8copper washers 2 8brake hose 3 TIP To collect any remaining brake fluid place a con tainer under the master cylinder and the end of the brake hose 3 Remove 8brake master cylinder holder 8brake master cylinder 4 Remove 8dust boot 8circlip 8washer 8brake master cylinder kit ...

Page 139: ...8brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check 8brake master cylinder kit 1 Damage scratches wear Replace 3 Check 8brake master cylinder reservoir Cracks damage Replace brake master cylinder reservoir dia phragm 1 Damage wear Replace 4 Check brake hose 1 Cracks damage wear Replace 1 ...

Page 140: ...s on internal brake components Recommended brake fluid DOT 4 1 Install 8brake master cylinder kit 1 8washer 2 8circlip 3 New 8dust boot 4 2 Install 8brake master cylinder 1 8brake master cylinder holder 2 9Nm 0 9m kgf 6 5ft lbf TIP 8 Install the brake master cylinder holder with the UP mark facing up 8 Align the end of the brake master cylinder holder with the punch mark a in the handle bar 8 Firs...

Page 141: ...e does not touch other parts e g wire harness cables leads Correct if necessary 4 Fill 8brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended brake fluid DOT 4 WARNING 8 8 8 8 8 Use only the designated brake fluid Other brake fluids may cause the rub ber seals to deteriorate causing leakage and poor brake performance 8 8 8 8 8 Refill with the same type of brak...

Page 142: ...G THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check 8brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check 8brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 8 Install 8brush guard right Refer to HANDLEBAR ...

Page 143: ... Brake hose holder 1 Union bolt Copper washer Brake hose Brake caliper Remove the parts in the order listed Drain Disconnect For installation reverse the removal pro cedure EAS00612 FRONT BRAKE CALIPER FRONT BRAKE 1 2 3 3 4 5 26Nm 2 6 m kgf 18 8 ft lbf 7Nm 0 7 m kgf 5 1 ft lbf 49Nm 4 9 m kgf 35 4 ft lbf ...

Page 144: ...rake caliper piston Brake caliper dust seal Brake caliper piston seal Spring Spring seat Bleed screw cap Brake caliper body Remove the parts in the order listed Refer to REPLACING THE FRONT BRAKE PADS Refer to DISASSEMBLING THE FRONT BRAKE CALIPER and AS SEMBLING AND INSTALLING THE FRONT BRAKE CALIPER For assembly reverse the disassembly procedure EAS00614 2 3 4 5 6 8 7 1 ...

Page 145: ...t the brake fluid carefully 2 Remove 8brake caliper piston 8brake caliper dust seal 8brake caliper piston seal 8spring 8spring seat a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper WARNING 8 8 8 8 8 Cover the brake caliper piston with a rag Be careful not to get injured when the piston are expelled from the brake cali per 8 8 8 8 8 Never try...

Page 146: ...ed 1 Check 8brake caliper piston 1 Rust scratches wear Replace the brake caliper piston 8brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly 8brake caliper body 3 Cracks damage Replace the brake caliper assembly 8brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING Whenever a brake caliper is disassembled replace the piston seal a...

Page 147: ...ell and distort 8 8 8 8 8 Whenever a brake caliper is disas sembled replace the brake caliper pis ton seal and dust seal Recommended brake fluid DOT 4 1 Install 8brake caliper piston seal 1 New 8brake caliper dust seal 2 New 8brake caliper piston 3 2 Lubricate 8brake caliper piston seal 8brake caliper dust seal Recommended lubricant Brake caliper piston seal Brake fluid Brake caliper dust seal Sil...

Page 148: ...e safe scooter operation Refer to CABLE ROUTING in chapter 2 T R T R NOTICE When installing the brake hose onto the brake caliper 1 1 1 1 1 make sure the brake pipe touch the projection a a a a a on the brake caliper 6 Remove 8brake caliper 7 Install 8spring seat 8spring 8brake pads 8brake pad springs 8brake caliper retaining bolt 13Nm 1 3m kgf 9 4ft lbf 8circlip 8brake caliper 49Nm 4 9m kgf 35 4f...

Page 149: ... in a harmful chemical reaction leading to poor brake performance 8 8 8 8 8 When refilling be careful that water does not enter the brake fluid reservoir Wa ter will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 9 Bleed 8brake system Ref...

Page 150: ...CHAS 4 37 FRONT BRAKE 11 Check 8brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 151: ...fork leg Remove the parts in the order listed The following procedure applies to both of the front fork legs Refer to COVER AND PANEL in chap ter 3 Refer to FRONT WHEEL AND BRAKE DISC Refer to FRONT BRAKE Loosen For installation reverse the removal pro cedure EAS00646 FRONT FORK Refer to REMOVING THE FRONT FORK LEGS and INSTALLING THE FRONT FORK LEGS 3 2 4 1 5Nm 0 5 m kgf 3 6 ft lbf 26Nm 2 6 m kgf...

Page 152: ...ollar O ring Fork spring Damper rod bolt copper washer Damper rod Rebound spring Inner tube Oil seal clip Oil seal Outer tube Remove the parts in the order listed The following procedure applies to both of the front fork legs Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEM BLING THE FRONT FORK LEGS EAS00648 2 3 4 5 7 8 9 1 6 6 q 0 4 w 20Nm 2 0 m kgf 14 5 ft lbf ...

Page 153: ...CHAS 4 40 FRONT FORK Remarks Order Job Part Q ty For assembly reverse the disassembly procedure 2 3 4 5 7 8 9 1 6 6 q 0 4 w 20Nm 2 0 m kgf 14 5 ft lbf ...

Page 154: ...f it falling over TIP Place the scooter on a suitable stand so that the front wheel is elevated 2 Remove 8leg shield 1 Refer to COVER AND PANEL in chap ter 3 8brake hose holder 1 8brake caliper Refer to FRONT BRAKE 8front wheel Refer to FRONT WHEEL AND BRAKE DISC 3 Loosen 8lower bracket pinch bolt 1 4 Remove 8stopper ring 2 WARNING Before loosening the lower bracket pinch bolts support the front f...

Page 155: ...r ring 8collar O ring 8fork spring 1 NOTICE The collar O ring and fork spring jump out after removing stopper ring 3 Drain 8fork oil TIP Stoke the outer tube several times while drain ing the fork oil 4 Remove 8damper rod assembly bolt 1 8copper washer TIP While holding the damper rod with the damper rod holder 2 andT handle3 loosen the damper rod assembly bolt 3 1 2 1 ...

Page 156: ... spring 8inner tube 2 6 Remove 8oil seal clip 1 with a flat head screwdriver NOTICE Do not scratch the inner tube 7 Remove 8oil seal 1 NOTICE Never reuse the oil seal 8Rag 2 1 2 1 1 2 Damper rod holder 90890 01294 YM 01300 1 T handle 90890 01326 YM 01326 ...

Page 157: ...es Replace WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure 8spring free length a Out of specification Replace Spring free length 252 1mm 9 93in Limit 247mm 9 72in 3 Check 8damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air 4 Check 8collar 1 8O ring 2 Damage wear Replace 1 2 1 2 1 ...

Page 158: ...ure to replace the following parts oil seal 8 Before assembling the front fork leg make sure all of the components are clean 1 Install 8damper rod assembly 1 8rebound spring 2 NOTICE Allow the damper rod assembly to slide slowly down the inner tube 3 3 3 3 3 until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate 8inner tube s outer surface Recommen...

Page 159: ...seal driver weight 2 and adapter 3 Fork seal driver weight 90890 01367 YM A9409 7 Adapter 90890 01368 YM A9409 4 NOTICE Make sure the numbered side of the oil seal faces up TIP 8 Before installing the oil seal lubricate its lips with lithium soap base grease 8 Lubricate the outer surface of the inner tube with fork oil 8 Before installing the oil seal cover the top of the front fork leg with a pla...

Page 160: ...specified amount of the recom mended fork oil Quantity each front fork leg 0 104L 0 11 US qt 0 09 Imp qt Recommended oil Fork oil 10W or equivalent TIP 8 While filling the front fork leg keep it up right 8 After filling slowly pump the front fork leg up and down to distribute the fork oil 7 Install 8fork spring 1 8collar 8O ring New 8stopper ring 8cap 1 ...

Page 161: ...ll 8clamp boot EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install 8front fork leg 8stopper ring 1 TIP Pull up the inner tube until it stops then install the stopper ring 2 Tighten 8lower bracket pinch bolt 2 26Nm 2 6m kgf 18 8ft lbf 3 Install 8front wheel Refer to FRONT WHEEL AND BRAKE DISC 8brake caliper 8brake hose holder 1 Refer to F...

Page 162: ... 6 7 8 9 10 11 12 1 1 1 1 2 1 1 1 1 1 1 1 1 1 EAS00664 HANDLEBAR Removing the handlebar Leg shield 1 Leg shield 2 Brake master cylinder Rear view mirror left and right Brush guard left and right Band Front turn signal light right Right handlebar switch Throttle cable assembly Throttle grip assembly Handlebar grip Brake light switch rear Front turn signal light left Rear brake cable Left lever hold...

Page 163: ... 2 8 m kgf 20 3 ft lbf 1 8 12 10 2 11 9 3 14 3 13 5 7 1 4 2 6 5Nm 0 5 m kgf 3 6 ft lbf HANDLEBAR Remarks Order Job Part Q ty 13 14 Upper handlebar holder Handlebar 2 1 For installation reverse the removal pro cedure ...

Page 164: ...band 3 Disconnect 8brake master cylinder Refer to FRONT BRAKE 4 Remove 8front turn signal light right 8right handlebar switch 1 8throttle cable assembly 2 8throttle grip assembly 3 TIP While removing the right handlebar switch pull back the rubber cover 5 Remove 8rear brake cable 8brake light switch rear 8front turn signal light left 8left lever holder 8handlebar grip 1 8upper handlebar holder 8ha...

Page 165: ...CHAS 4 52 EAS00668 CHECKING THE HANDLEBAR 1 Check 8handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken it HANDLEBAR 1 ...

Page 166: ...hten the bolts on the front side of the handlebar holders and then on the rear side TIP 8 The upper handlebar holders should be in stalled with the arrow marks a facing for ward A 8 Align the match marks b on the handlebar with the upper surface of the handlebar lower holder 3 Install 8 left lever holder 1 TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 4 I...

Page 167: ...t handle bar switch with the hole b in the handle bar WARNING Make sure the throttle grip operates smoothly 6 Install 8brake master cylinder Refer to FRONT BRAKE 7 Install 8band New 8brush guard left and right 8rear view mirror left and right 8 Install 8leg shield 2 8leg shield 1 Refer to COVER AND PANEL in chap ter 3 9 Adjust 8throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PL...

Page 168: ...RACKET AND FRONT BRACKET Removing the handlebar bracket and front bracket Handlebar Handlebar cover Lower handlebar holder Speedometer cable Speedometer Turn signal relay Rectifier regulator ECU Horn Headlight relay Starting circuit cut off relay Front bracket Band Handlebar bracket 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to HANDLEBAR Disc...

Page 169: ...inner race Lower bracket Upper bearing 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 Refer to FRONT WHEEL AND BRAKE DISC Refer to FRONT BRAKE Refer to FRONT FORK Refer to HANDLEBAR Refer to HANDLEBAR BRACKET AND FRONT BRACKET Refer to REMOVING THE LOWER BRACKET and INSTALLING THE STEERING HEAD 7Nm 0 7 m kgf 5 1 ft lbf 2 9 3 4 5...

Page 170: ... bearing outer race Lower bearing outer race Lower bearing inner race Dust seal 1 1 1 1 1 For installation reverse the removal pro cedure 7Nm 0 7 m kgf 5 1 ft lbf 2 9 3 4 5 6 10 12 7 8 13 11 14 15 1 75Nm 7 5 m kgf 54 2 ft lbf 1st 38Nm 3 8 m kgf 27 5 ft lbf 2nd 14Nm 1 4 m kgf 10 1 ft lbf ...

Page 171: ...se holder 2 8handlebar bracket 1 TIP Remove the handlebar bracket by loosening the ring nut 2 gradually 3 Remove 8upper ring nut 1 with the ring nut wrench 2 8lock washer 8center ring nut 8rubber washer Ring nut wrench 90890 01268 YU 01268 4 Remove 8lower ring nut 1 with the ring nut wrench 2 Ring nut wrench 90890 01268 YU 01268 WARNING Securely support the lower bracket so that there is no danger...

Page 172: ...e with a long rod 1 and ham mer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal bearings and bear ing races NOTICE If the bearing race is not installed properly the steering head pipe could be damaged TIP 8 Always replace the bearings and bearing races as a set 8 Whenever the steering head is disas sembled replace the dust seal 4 Check 8h...

Page 173: ...r ring nut 1 8rubber washer 2 8center ring nut 3 8lock washer 4 8upper ring nut 5 Refer to CHECKING THE STEERING HEAD in chapter 3 1 LS T R 3 Install 8handlebar bracket 1 60Nm 6 0m kgf 43 4ft lbf TIP Align the handlebar bracket across rod 2 on the lower bracket concave 3 T R 4 Tighten 8brake hose holder 2 7Nm 0 7m kgf 5 1ft lbf 8lower handlebar holder 48Nm 4 8m kgf 34 7ft lbf T R ...

Page 174: ...marks Order Job Part Q ty REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS00685 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Removing the rear shock absorber assemblies and swingarm O2 sensor coupler Muffler gasket O2 sensor Rear shock absorber assembly left and right Rear wheel axle nut Spacer Oil seal Swingarm Oil seal Bearing Collar 1 2 3 4 5 6 7 8 9 10 11 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the par...

Page 175: ...ABSORBER ASSEMBLY The following procedure applies to both of the rear shock absorber assemblies 1 Check 8rear shock absorber rod Bends damage Replace the rear shock absorber assembly 8rear shock absorber Oil leaks Replace the rear shock ab sorber assembly 8spring Damage wear Replace the rear shock absorber assembly 8bushings Damage wear Replace 8dust seals Damage wear Replace 8bolts Bends damage w...

Page 176: ...lbf REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS00702 REMOVING THE SWINGARM 1 Stand the scooter on a level surface WARNING Securely support the scooter so that there is no danger of it falling over TIP Place the scooter on a suitable stand so that the rear wheel is elevated 2 Disconnect 8O2 sensor coupler 3 Remove 8muffler 4 Remove 8rear wheel axle nut 1 8rear shock absorber assembly lower bolt...

Page 177: ...SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS00711 INSTALLING THE SWINGARM 1 Lubricate 8bearing 8oil seal lips 8rear wheel axle splines Recommended lubricant Lithium soap based grease T R T R 2 Install 8swingarm 31Nm 3 1m kgf 22 4ft lbf 8rear wheel axle nut 1 105Nm 10 5m kgf 75 9ft lbf 8rear shock absorber assembly lower bolt right 2 18Nm 1 8m kgf 13 0ft lbf 3 Install 8muffler T R ...

Page 178: ...ORBER ASSEMBLIES AND SWINGARM 4 Tighten 8exhaust pipe nut 13Nm 1 3m kgf 9 4ft lbf 8muffler and swingarm bolt 31Nm 3 1m kgf 22 4ft lbf 8muffler and swingarm bolt 53Nm 5 3m kgf 38 3ft lbf 5 Connect 8O2 sensor coupler T R T R T R ...

Page 179: ...AFT AND ROCKER ARMS 5 19 VALVES AND VALVE SPRINGS 5 21 REMOVING THE VALVES 5 23 CHECKING THE VALVES AND VALVE GUIDES 5 24 CHECKING THE VALVE SEATS 5 27 CHECKING THE VALVE SPRINGS 5 29 INSTALLING THE VALVES 5 30 CYLINDER AND PISTON 5 32 REMOVING THE CYLINDER AND PISTON 5 33 CHECKING THE CYLINDER AND PISTON 5 34 CHECKING THE PISTON RINGS 5 36 CHECKING THE PISTON PIN 5 37 CHECKING THE TIMING CHAIN GU...

Page 180: ...HE AC MAGNETO 5 55 CHECKING THE STARTER CLUTCH 5 56 INSTALLING THE AC MAGNETO 5 57 OIL PUMP 5 58 CHECKING THE OIL PUMP 5 59 ASSEMBLING THE OIL PUMP 5 60 INSTALLING THE OIL PUMP 5 60 TRANSMISSION 5 61 CHECKING THE TRANSMISSION 5 62 CRANKSHAFT 5 63 CRANKSHAFT ASSEMBLY 5 63 DISASSEMBLING THE CRANKCASE 5 65 REMOVING THE CRANKSHAFT ASSEMBLY 5 66 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 66 CHECKING ...

Page 181: ...le adjuster spring pin O2 sensor coupler Muffler Air duct Crankshaft position sensor stator coil assembly coupler Throttle body and fuel injector Starter motor Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 Refer to REAR WHEEL AND REAR BRAKE in chapter 4 Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM in chapter 4 Refer to BELT DRIVE Refer to STARTER CLUTCH AND AC...

Page 182: ... 2 2 ft lbf ENGINE REMOVAL Remarks Order Job Part Q ty 1 2 3 4 Rear brake cable holder Spark plug cap Engine temperature sensor coupler Air filter breather hose 1 1 1 1 1 TEM in chapter 7 Disconnect Disconnect For installation reverse the removal pro cedure ...

Page 183: ...emoving the engine Rear fender Rear shock absorber assembly lower bolt Engine mounting nut washer Engine mounting bolt Engine Washer Collar 1 2 3 4 5 6 7 1 2 1 1 1 1 1 2 Remove the parts in the order listed TIP Place a suitable stand under the frame and engine Refer to INSTALLING THE ENGINE For installation reverse the removal pro cedure ...

Page 184: ...m soap based grease to the unthreaded portion of the engine mounting bolt shaft 8 Do not fully tighten the engine mounting bolt 2 Install 8rear shock absorber assembly lower bolts 1 TIP Do not fully tighten the bolts 3 Tighten 8engine mounting bolt 32Nm 3 2m kgf 23 1ft lbf 8rear shock absorber assembly lower bolts 18Nm 1 8m kgf 13 0ft lbf 1 1 2 3 ...

Page 185: ...DER HEAD EAS00221 CYLINDER HEAD Removing the cylinder head Air guide Air shroud cylinder 3 V belt case Muffler Engine temperature sensor Intake manifold O ring Joint O ring Spark plug Breather O ring Valve cover intake O ring Valve cover exhaust O ring Air shroud cylinder 2 1 2 3 4 5 6 7 8 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to STARTER CLUTCH AND AC MAGNETO Refer t...

Page 186: ... 1 8 m kgf 13 0 ft lbf 22Nm 2 2 m kgf 15 9 ft lbf 12Nm 1 2 m kgf 8 7 ft lbf 30Nm 3 0 m kgf 21 7 ft lbf 7Nm 0 7 m kgf 5 1 ft lbf 7 CYLINDER HEAD Remarks Order Job Part Q ty 9 10 11 12 13 14 15 Air shroud cylinder 1 Timing chain tensioner Camshaft sprocket plate Camshaft sprocket Cylinder head Cylinder head gasket Dowel pin 1 1 1 1 1 1 2 For installation reverse the removal pro cedure ...

Page 187: ...n 8 I mark a on the AC magneto rotor with the stationary pointer b on the crankcase a Turn the primary fixed sheave counterclock wise b When the piston is at TDC on the compres sion stroke align the I mark c on the cam shaft sprocket with the mark d on the cyl inder head 4 Remove 8air shroud cylinder 2 8air shroud cylinder 1 5 Loosen 8timing chain tensioner cap bolt 8camshaft sprocket bolt 1 While...

Page 188: ...aft sprocket plate 2 8camshaft sprocket 3 8timing chain 4 TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 7 Remove 8cylinder head TIP 8 Loosen the nuts in the proper sequence as shown 8 Loosen each nut 1 2 of a turn at a time Af ter all of the nuts are fully loosened remove them 2 1 2 3 4 ...

Page 189: ...sure 8cylinder head warpage Out of specification J Resurface the cyl inder head Maximum cylinder head warpage Less than 0 05mm 0 002in 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 the surface plate and resurface the cylin der head using a fig...

Page 190: ...nuts and bolts in the proper tightening sequence as shown and torque them in two stages CYLINDER HEAD T R T R 4 Install 8camshaft sprocket 1 8timing chain 2 a Turn the primary fixed sheave counterclock wise b Align the I mark a on the AC magneto rotor with the stationary pointer b on the crankcase c Align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head d In...

Page 191: ...mshaft sprocket plate 1 8camshaft sprocket bolt 2 TIP While holding the camshaft and install the cam shaft sprocket plate temporarily tighten the cam shaft sprocket bolt 6 Install 8timing chain tensioner gasket New 8timing chain tensioner a Remove the cap bolt 1 and spring 2 b Release the timing chain tensioner one way cam 3 and push the timing chain tensioner rod 4 all the way into the timing cha...

Page 192: ...the installation steps above 9 Tighten 8camshaft sprocket bolt 30 Nm 3 0 m kgf 21 7 ft lbf NOTICE Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 10 Measure 8valve clearance Out of specification J Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 Cap bolt 8 Nm 0 8 m kgf 5 8 ft lbf 7 Turn 8cran...

Page 193: ...the order listed Refer to CYLINDER HEAD Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALL ING THE CAMSHAFT AND ROCKER ARMS For installation reverse the removal pro cedure THE ROCKER ARMS AND CAMSHAFT Removing the rocker arms and cam shaft Cylinder head Stopper plate Locknut Adjusting screw Rocker arm shaft intake Rocker arm intake Rocker arm shaft exhaust Rocker arm exhaust Camshaft ...

Page 194: ... arm shaft 8intake rocker arm 8exhaust rocker arm TIP Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2 Slide hammer bolt 90890 01085 YU 01083 2 Weight 90890 01084 YU 01083 3 3 Remove 8 camshaft 1 TIP Slide hammer bolt 2 into the threaded end of the camshaft and then pull out the camshaft Slide hammer bolt 90890 01085 YU 01083 2 Weight 90890 01084 YU 01083 3 ...

Page 195: ... specification J Replace the cam shaft Camshaft lobe dimension limit Intake a a a a a25 267 25 367mm 0 995 0 999in Limit 25 167mm 0 991in b b b b b21 069 21 169mm 0 829 0 833in Limit 20 969mm 0 826in Exhaust a a a a a25 275 25 375mm 0 995 0 999in Limit 25 175mm 0 991in b b b b b21 069 21 169mm 0 829 0 833in Limit 20 969mm 0 826in 3 Check 8camshaft oil passage Obstruction J Blow out with compressed...

Page 196: ...Replace or check the lubri cation system 3 Check 8camshaft lobe Excessive wear J Replace the camshaft 4 Measure 8rocker arm inside diameter a Out of specification J Replace Rocker arm inside diameter 10 000 10 015mm 0 3937 0 3943in 5 Measure 8rocker arm shaft outside diameter a Out of specification J Replace Rocker arm shaft outside diameter 9 981 9 991mm 0 3930 0 3933in a a 6 Calculate 8rocker ar...

Page 197: ...applies to all of the cam shaft sprocket and timing chain guides 1 Check 8timing chain Damage stiffness J Replace the timing chain and camshaft sprocket as a set 2 Check 8camshaft sprocket More than 1 4 tooth wear a J Replace the camshaft sprocket and the timing chain as a set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check 8timing chain guide exhaust side 8timing chain gui...

Page 198: ...ner 3 Check 8cap bolt 8O ring New 8spring 8one way cam 8gasket New 8timing chain tensioner rod Damage wear J Replace the defective part s a Removing the spring and cap bolt b Return cam chain tensioner one way cam Press tensioner rod to the cam chain tensioner housing c Installing the spring and cap bolt d Loosen the front end of cam chain tensioner slowly e Make sure to return to the front end of...

Page 199: ...ricant Molybdenum disulfide oil THE ROCKER ARMS AND CAMSHAFT 3 Install 8exhaust rocker arm 1 8exhaust rocker arm shaft 2 TIP Make sure the exhaust rocker arm shaft is com pletely pushed into the cylinder head 4 Install 8intake rocker arm 1 8intake rocker arm shaft 2 TIP Make sure the intake rocker arm shaft is com pletely pushed into the cylinder head NOTICE Make sure the threaded part of the rock...

Page 200: ...ENG 5 20 THE ROCKER ARMS AND CAMSHAFT 5 Install 8stopper plate 1 8locknut 2 12Nm 1 2m kgf 8 7ft lbf T R ...

Page 201: ...ft Valve cotter Valve spring retainer Valve spring Valve intake Valve exhaust Valve stem seal Valve stem seat valve guide O ring Remove the parts in the order listed Refer to CYLINDER HEAD Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALL ING THE CAMSHAFT AND ROCKER ARMS Refer to REMOVING THE VALVES and INSTALLING THE VALVES VALVES AND VALVE SPRINGS 1 2 3 6 8 7 8 1 2 8 3 6 8 7 4 5 ...

Page 202: ...5 22 ENG VALVES AND VALVE SPRINGS Remarks Order Job Part Q ty For installation reverse the removal pro cedure 1 2 3 6 8 7 8 1 2 8 3 6 8 7 4 5 ...

Page 203: ...e valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 04108 YM 04108 1 a 1 Check 8valve sealing Leakage at the valve seat J Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a int...

Page 204: ...E VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure 8valve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Out of specification J Replace the valve guide Valve stem to valve guide clearance Intake 0 015 0 042mm 0 0006 0 0017in Limit 0 08mm 0 0031in Exhaust 0 030 0 057mm 0 001...

Page 205: ...ing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve guide remover 4 5mm 90890 04116 YM 04116 Valve guide installer 4 5mm 90890 04117 YM 04117 Valve guide reamer 4 5mm 90890 04118 YM 04118 3 Eliminate 8carbon deposits from the valve face and valve seat 4 Check ...

Page 206: ...0 7mm 0 028in Valve margin thickness exhaust 1 0mm 0 039in VALVES AND VALVE SPRINGS 6 Measure 8valve stem runout Out of specification J Replace the valve TIP 8 When installing a new valve always replace the valve guide 8 If the valve is removed or replaced always replace the oil seal Valve stem runout 0 01mm 0 0004in ...

Page 207: ...t 1 6mm 0 063in Exhaust 0 9 1 1mm 0 035 0 043in Limit 1 6mm 0 063in a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blueing will have been removed VALVES A...

Page 208: ...y tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve throug...

Page 209: ...e length 41 88mm 1 649in Limit 39 786mm 1 566in VALVES AND VALVE SPRINGS 2 Measure 8compressed valve spring force a Out of specification J Replace the valve spring b Installed length Compressed valve spring force in stalled 137 157N mm 13 97 16 01kgf mm 30 83 35 33lbf in at 30mm 1 18in 3 Measure 8valve spring tilt a Out of specification J Replace the valve spring Spring tilt limit 2 5 1 8mm 2 5 0 ...

Page 210: ... Recommended lubricant Molybdenum disulfide oil VALVES AND VALVE SPRINGS b a 1 2 3 Install 8valve 1 8valve stem seal 2 New 8valve spring 3 8valve spring retainer 4 into the cylinder head TIP Install the valve spring with the larger pitch a facing up b Smaller pitch 4 Install 8valve cotters 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the va...

Page 211: ... Valve spring compressor attach ment 90890 04108 YM 04108 VALVES AND VALVE SPRINGS 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE Hitting the valve tip with excessive force could damage the valve ...

Page 212: ...ide exhaust side Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set Remove the parts in the order listed Refer to CYLINDER HEAD Refer to REMOVING THE CYLINDER AND PISTON and INSTALLING THE PISTON AND CYLINDER For installation reverse the removal pro cedure 1 1 2 1 2 1 1 1 CYLINDER AND PISTON 5 8 6 5 3 3 4 2 1 7 ...

Page 213: ...from falling into the crankcase 8 Before removing the piston pin deburr the piston pin clip s groove and the piston s pin bore area 8 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 CYLINDER AND PISTON 2 Remove 8top ring 82nd ring 8oil ring TIP When removing a piston ring open the end g...

Page 214: ...nder Then find the average of the measurements b If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer a 7mm 0 28in from the bottom edge of the piston d If out of specification replace the piston and piston rings as a set a P 52 40 52 41mm 2 0630 2 0634in 0 05mm 0 002in 0 05mm 0 002in Taper limi...

Page 215: ...ula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 010 0 035mm 0 0004 0 0014in Limit 0 15mm 0 0059in f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set CYLINDER AND PISTON ...

Page 216: ...02 0 06mm 0 0008 0 0024in Limit 0 12mm 0 0047in CYLINDER AND PISTON a 2 Install 8piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown a 20mm 0 79in 3 Measure 8piston ring end gap Out of specification J Replace the pis ton ring TIP 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 ri...

Page 217: ...Measure 8piston pin bore diameter b Out of specificationJ Replace the piston Piston pin bore diameter 15 002 15 013mm 0 5906 0 5911in Limit 15 043mm 0 5922in 2 Measure 8piston pin outside diameter a Out of specification J Replace the pis ton pin Piston pin outside diameter 14 995 15 000mm 0 5904 0 5906in Limit 14 975mm 0 5896in EAS00265 CHECKING THE PISTON PIN 1 Check 8piston pin Blue discoloratio...

Page 218: ... CHECKING THE TIMING CHAIN GUIDE EX HAUST SIDE 1 Check 8timing chain guide exhaust side Damage wear J Replace 2 Install 8piston 1 8piston pin 2 8piston pin clip 3 New TIP 8 Apply engine oil the piston pin 8 Make sure the arrow mark a on the piston points towards the exhaust side of the cyl inder 8 Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the cli...

Page 219: ...ecommended lubricant Engine oil 5 Offset 8piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Exhaust side 6 Install 8cylinder 1 TIP 8 While compressing the piston rings with one hand install the cylinder with the other hand 8 Pass the timing chain and timing chain guide exhaust side through the timing chain cavity ...

Page 220: ...er V belt case filter guide V belt case filter element O ring Gasket V belt case Plate Gasket plate V belt case Remove the parts in the order listed For installation reverse the removal pro cedure BELT DRIVE x8 6 9 7 8 5 4 1 2 3 11Nm 1 1 m kgf 8 0 ft lbf 7Nm 0 7 m kgf 5 1 ft lbf 10Nm 1 0 m kgf 7 2 ft lbf 7Nm 0 7 m kgf 5 1 ft lbf 7Nm 0 7 m kgf 5 1 ft lbf ...

Page 221: ... and IN STALLING THE SECONDARY SHEAVE V BELT AND PRIMARY SHEAVE For installation reverse the removal pro cedure Removing theV belt and primary sec ondary sheave V belt case Primary fixed sheave nut plate washer Oneway clutch Primary fixed sheave Clutch housing Secondary sheave V belt Plate washer Collar Cam slider Primary sheave weight Oil seal Primary sliding sheave V BELT AND PRIMARY SECONDARY S...

Page 222: ...2 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure Disassembling the secondary sheave Clutch carrier nut Clip Plate Clutch shoe spring Clutch shoe Damper Clutch carrier Compression spring Spring seat Guide pin Secondary sliding sheave O ring Oil seal Secondary fixed sheave BELT DRIVE SECONDARY SHEAVE ...

Page 223: ... holder 90890 01701 YS 01880 A EAS00317 REMOVING THE PRIMARY SHEAVE 1 Remove 8V belt case 8Refer to V BELT CASE 2 Remove 8primary fixed sheave nut 1 8plate washer 8oneway clutch 8primary fixed sheave 2 TIP While holding the primary fixed sheave with the rotor holding tool 3 loosen the primary fixed sheave nut Rotor holding tool 90890 01235 YU 01235 2 Loosen 8clutch carrier nut 1 NOTICE Do not remo...

Page 224: ... from the primary sheave side CHECKING THE CLUTCH SHOES The following procedure applies to all of the clutch shoes 1 Check 8clutch shoe Damage wear J Replace the clutch shoes and springs as a set Glazed areas JSand with coarse sand paper EAS00319 DISASSEMBLING THE SECONDARY SHEAVE 1 Remove 8clutch carrier nut 1 TIP Install the clutch spring holder 2 and clutch spring holder arm 3 onto the secondar...

Page 225: ...fter removing the clutch shoe spring do not use them again 8 Replace the all three as a set TIP After sanding the glazed areas clean the clutch with a cloth BELT DRIVE EAS00320 CHECKING THE V BELT 1 Check 8V belt 1 Cracks damage wear J Replace Grease oil J Clean the primary and sec ondary sheave 2 Measure 8V belt width a Out of specification J Replace V belt width 22mm 0 87in Limit 19 8mm 0 78in a...

Page 226: ...the primary sliding sheave collar or both TIP Insert the collar 2 into the primary sliding sheave 1 and check for free movement EAS00321 CHECKINGTHE PRIMARY SHEAVEWEIGHTS The following procedure applies to all of the pri mary sheave weights 1 Check 8primary sheave weight Cracks damage wear J Replace 2 Measure 8primary sheave weight outside diameter a Out of specification J Replace Primary sheave w...

Page 227: ...k 8secondary fixed sheave 8secondary sliding sheave Cracks damage wear J Replace the sec ondary fixed and sliding sheaves as a set 2 Check 8torque cam groove 1 Damage wear J Replace the secondary fixed and sliding sheaves as a set 3 Check 8guide pin 2 Damage wear J Replace the secondary fixed and sliding sheaves as a set 1 2 ...

Page 228: ... SHEAVE 1 Clean 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 TIP Use thinner to clean up grease dirt on the pri mary sliding sheave cam side 5 2 Install 8primary sheave weights 1 8collar 2 3 Install 8sliders 1 8cam 2 1 2 1 2 ...

Page 229: ...d lubricant Recommended lubricant BEL RAY assembly lube 2 Install 8secondary sliding sheave 1 TIP Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 Oil seal guide 90890 01384 YM 33299 BELT DRIVE 3 1 2 1 2 3 Install 8guide pin 1 4 Lubricate 8guide pin groove 2 8O ring 3 New with the recommended lubricant Recommended lubricant BEL RAY assembly lube ...

Page 230: ...LING THE SECONDARY SHEAVE V BELT AND PRIMARY SHEAVE 1 Install 8V belt 1 8secondary sheave 2 NOTICE Do not allow grease to contact theV belt and secondary sheave TIP 8 Install the V belt onto the primary sheave side 8 Install the V belt with printed arrow mark on the V belt facing in the direction shown in the illustration 2 Install 8clutch carrier nut 1 90Nm 9 0m kgf 65 1ft lbf TIP While holding t...

Page 231: ...ft lbf TIP Tighten the secondary sheave nut with the sheave holder 3 Sheave holder 90890 01701 YS 01880 A T R T R 4 Install 8primary fixed sheave 1 8oneway clutch 8plate washer 8primary fixed sheave nut 2 45Nm 4 5m kgf 32 5ft lbf TIP While holding the primary fixed sheave with the rotor holding tool 3 tighten the primary fixed sheave nut Rotor holding tool 90890 01235 YU 01235 ...

Page 232: ... 1 TIP Position the V belt in the primary sheave 2 when the pulley is at its widest position and in the secondary sheave 3 when the pulley is at its narrowest position and make sure the V belt is tight 6 Install 8V belt case Refer to V BELT CASE ...

Page 233: ...7 8 9 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Disconnect For installation reverse the removal pro cedure Removing the stator coil assembly Air guide Air shroud cylinder 3 Pickup coil stator coil assembly coupler Fan AC magneto rotor Woodruff key Lock plate Pickup coil Stator coil assembly STARTER CLUTCH AND AC MAGNETO EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY ...

Page 234: ...ng the starter clutch V belt case Primary fixed sheave Primary sliding sheave Idle gear plate Plate washer Idle gear Starter clutch Starter wheel gear holder Starter wheel gear Roller Remove the parts in the order listed Refer to V BELT CASE Refer to V BELT AND PRIMARY SEC ONDARY SHEAVE For installation reverse the removal pro cedure STARTER CLUTCH AND AC MAGNETO ...

Page 235: ...eto ro tor nut Rotor holding tool 90890 01235 YU 01235 3 Remove 8AC magneto rotor 1 with the flywheel puller 2 8woodruff key 8stator coil assembly NOTICE To protect the end of the crankshaft place an appropriate sized socket between the flywheel puller set s center bolt and the crankshaft TIP Make sure the flywheel puller set is centered over the AC magneto rotor Flywheel puller 90890 01189 YM 011...

Page 236: ...ce the starter wheel gear 4 Check 8starter clutch operation a Install the starter wheel gear 1onto the starter clutch 2 and hold the starter clutch b When turning the starter wheel gear clock wise A the starter clutch and the starter wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear coun terclockwise B it should turn freely o...

Page 237: ...shaft and the AC magneto rotor hub 8 When installing the AC magneto rotor make sure the woodruff key is properly seated in the keyway of the crankshaft T R T R 2 Tighten 8AC magneto rotor nut 2 70 Nm 7 0 m kgf 50 6 ft lbf TIP While holding the AC magneto rotor 1 with the rotor holding tool 3 tighten the AC magneto rotor nut Rotor holding tool 90890 01235 YU 01235 3 Install 8fan 9Nm 0 9m kgf 6 5ft ...

Page 238: ...t Q ty 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1 1 Removing the oil pump AC magneto rotor Stator coil assembly Cover O ring Gasket Oil seal Dowel pin Circlip plate washer Oil pump driven gear Dowel pin Oil pump Gasket Remove the parts in the order listed Refer to STARTER CLUTCH AND AC MAGNETO For installation reverse the removal pro cedure OIL PUMP ...

Page 239: ...learance a 8outer rotor to oil pump housing clearance b Out of specification J Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clear ance 0 15mm 0 006in or less Limit 0 23mm 0 009in Outer rotor to oil pump housing clearance 0 07 0 12mm 0 003 0 005in Limit 0 19mm 0 008in OIL PUMP 3 Check 8oil pump operation Rough movement J Repeat steps 1 and 2 or ...

Page 240: ...kgf 2 9 ft lbf NOTICE After tightening the bolts make sure the oil pump turns smoothly 2 Install 8O ring New 8cover 13 Nm 1 3 m kgf 9 4 ft lbf 2 Install 8oil pump shaft 1 to the oil pump housing 2 8pin 3 8inner rotor 4 8outer rotor 5 8oil pump housing cover 6 8oil pump housing screw TIP When installing the inner rotor align the pin 3 in the oil pump shaft with the groove a in the inner rotor 4 3 C...

Page 241: ...Right crankcase cover gasket Dowel pin Primary drive gear shaft Main axle Drive axle Remove the parts in the order listed Drain Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM in chapter 4 Refer to REAR WHEEL AND REAR BRAKE in chapter 4 Refer to BELT DRIVE For installation reverse the removal pro cedure TRANSMISSION EAS00419 TRANSMISSION G G G G 5 4 3 3 2 1 6 10Nm 1 0 m kgf 7 2 ft lbf ...

Page 242: ...ce the drive axle Drive axle runout limit 0 04mm 0 002in 3 Check 8transmission gears Blue discoloration pitting wear J Replace the defective gear s 8transmission gear dogs Cracks damage rounded edges J Re place the defective gear s 4 Check 8transmission gear engagement each pinion gear to its respective wheel gear Incorrect J Reassemble the transmission axle assemblies 5 Check 8transmission gear m...

Page 243: ...Refer to CYLINDER AND PISTON Refer to BELT DRIVE Refer to STARTER CLUTCH AND AC MAGNETO Refer to OIL PUMP Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM in chapter 4 Refer to Refer to REAR WHEEL AND REAR BRAKE in chapter 4 Removing the crankshaft assembly Engine Cylinder head Cylinder and piston V belt case V belt and primary secondary sheave Starter clutch AC magneto Oil pump Muffler Swinga...

Page 244: ...kgf 5 1 ft lbf 7Nm 0 7 m kgf 5 1 ft lbf 13Nm 1 3 m kgf 9 4 ft lbf CRANKSHAFT Remarks Order Job Part Q ty 5 6 7 8 9 10 11 12 13 Timing chain guide intake side Crankcase right Oil seal Crankshaft assembly Timing chain Oil seal Shaft Bearing Crankcase left 1 1 1 1 1 1 1 2 1 For installation reverse the removal pro cedure ...

Page 245: ... and in a crisscross pattern After all of the bolts are fully loosened remove them 3 Remove 8right crankcase 1 NOTICE Tap on one side of the crankcase with a soft face hammer 2 2 2 2 2 Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly CRANKSHAFT ...

Page 246: ... moved if the timing chain is attached onto the crankshaft sprocket EAS00394 CHECKING THE CRANKSHAFT AND CON NECTING ROD 1 Measure 8crankshaft runout Out of specification J Replace the crank shaft bearing or both TIP Turn the crankshaft slowly Maximum crankshaft runout 0 03mm 0 0012in 2 Measure 8big end side clearance Out of specification J Replace the big end bearing crankshaft pin or connecting ...

Page 247: ...3 Damage wear J Replace the crankshaft EAS00399 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check 8crankcase Cracks damage J Replace 8oil delivery passages Obstruction J Blow out with compressed air CRANKSHAFT 5 Check 8crankshaft journal Scratches wear J Replace the crank shaft 8crankshaf...

Page 248: ... the timing chain and camshaft sprocket as a set 2 Check 8timing chain guide intake side Damage wear J Replace EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1 Check 8bearings Clean and lubricate the bearings then ro tate the inner race with your finger Rough movement J Replace 2 Check 8oil seals Damage wear J Replace CRANKSHAFT ...

Page 249: ...LY 1 Install 8timing chain 1 8crankshaft assembly 2 TIP Install the timing chain so it is not visible through the opening in the left crankcase NOTICE To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil TIP Put the timing chain in parallel into the crank case then use hands to place th...

Page 250: ...ight crankcase with a soft face hammer T R 4 Tighten 8crankcase bolts 13Nm 1 3m kgf 9 4ft lbf TIP Tighten the crankcase bolts in stages and in a crisscross pattern 5 Apply 8engine oil onto the crankshaft pin bearing and oil delivery hole 6 Check 8crankshaft operation Rough movementJRepair ...

Page 251: ...ESHOOTING DETAILS 6 12 THROTTLE BODY AND FUEL INJECTOR 6 26 FUEL TANK 6 26 FUEL INJECTOR AND FUEL HOSE 6 28 THROTTLE BODY 6 29 REMOVING THE FUEL TANK 6 30 REMOVING THE FUEL PUMP 6 31 CHECKING THE FUEL INJECTOR 6 32 CHECKING THE THROTTLE BODY 6 32 INSTALLING THE FUEL PUMP 6 33 INSTALLING THE FUEL TANK AND FUEL HOSE 6 33 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 6 34 CHECKING THE THROT...

Page 252: ...l 6 Fuel injector 7 Intake air pressure sensor 8 ISC idle speed control valve 9 Intake air temperature sensor 0 Battery q Air filter case w Catalytic converter e Crankshaft position sensor r Engine temperature sensor t Spark plug y Fuel tank u Fuel pump i Throttle position sensor o O2 sensor FUEL INJECTION SYSTEM q 4 7 9 i u y 8 6 1 2 3 0 t e w o 5 r ...

Page 253: ...W L B P B Ch Br W Dg Ch Br W Dg L B P B Y G Y G Br Br BLACK BLACK Br G Y Br G Y BLACK BLACK B B B B G Y G Y L Y Y G G R P W Br W B L Y L L G R B L P W Br W B L Y L BLACK G R B L L Y G B L B L Y G B L Y L P W Br W B L R B BLACK BLACK Gy G Gy G B G B G B G Gy G R B B L B W B L Lg Sb Gy G Y P P G Y Sb Gy Or Or B P G Y R W W R Lg B L L Gy G Y G R B G Gy Sb L B L Y W R B W Br W Y G P W R L Y Br L B B W...

Page 254: ...gine stop switch y Ignition fuse u Signaling system fuse s Engine trouble warning light d Speed sensor Ignition coil Spark plug Fuel injector Fuel pump ECU Lean angle cut off switch Engine temperature sensor Intake air pressure sensor Intake air temperature sensor Throttle position sensor O2 sensor ISC idle speed control valve FI diagnostic tool ...

Page 255: ...stic function this mode provides an appropriate substitute charac teristic operation and alerts the rider of the detected malfunction by illuminating the en gine trouble warning light 8 After the engine has been stopped the low est fault code number appears on the en gine trouble warning light or displayed on the Fl diagnostic tool It remains stored in the memory of the ECU until it is deleted Eng...

Page 256: ...ions the warning light bulb may be defective Crankshaft position sensor Intake air pressure sensor open or short circuit system Throttle position sensor open or short circuit stuck Broken or disconnected sidestand lead of the ECU Intake air temperature sensor O2 sensor Engine temperature sensor Faulty ignition ISC idle speed control valve stuck fully open Fault code No Item Symptom Engine startabi...

Page 257: ... switch open or short cir cuit is detected No normal signals are received from the speed sensor Power supply to fuel injector fuel pump and ignition coil are not normal An error is delected while reading from or writing on EEPROM CO adjustment value code re registering key code and throttle valve fully closed notification value Power supply to Fl system is not normal red lead Faulty ECU memory Whe...

Page 258: ...robable cause of malfunc tion Faultcode No NO Check and repair Refer to FAIL SAFE ACTIONS TABLE Faultcode No YES Check and repair Refer to TROUBLE SHOOTING DE TAILS Monitor the operation of the sensors and actuators in the diag nostic mode Refer to Diagnostic mode table Parform ECU reinstatement action Refer to Rein statement method in TROUBLESHOOTING DE TAILS Turn the main switch to OFF turn the ...

Page 259: ...ag signal connector 1 and then connect the Fl diagnostic tool 2 as shown 3 Turn the main switch to ON and start the engine TIP 8 Engine temperature and engine revolution appears on the LCD of the Fl diagnostic tool 8 POWER LED Green comes on 8 If a malfunction is detected in the system WARNING LED Orange comes on How ever the fault code is not appears on the LCD of Fl diagnostic tool 4 Stop the en...

Page 260: ...TIP 8 The diagnostic code number appears on the LCD D01 D70 8 To decrease the selected diagnostic code number press the DOWN button Press the DOWN button for 1 second or longer to automatically decrease the diagnostic code numbers 8 To increase the selected diagnostic code number press the UP button Press the UP button for 1 second or longer to auto matically increase the diagnostic code num bers ...

Page 261: ... is disconnected or clogged Open or short circuit in wiring sub lead Open or short circuit in wiring harness Defective throttle position sensor Improperly installed throttle position sensor lead con nector in the coupler Stuck throttle position sensor Defective throttle position sensor Open circuit in wiring harness ECU coupler Open or short circuit in wire sub lead Open or short circuit in wiring...

Page 262: ...s been detected as a fault code 44 If multiple malfunctions have been detected different codes are displayed at 2 second in tervals and this process is repeated Displays the codes of the history of the self diagnosis malfunctions i e a code of a mal function that occurred once and which has been corrected If multiple malfunctions have been detected different codes are displayed at 2 second in terv...

Page 263: ...t method Fault code No Fault code number displayed on the Fl diagnostic tool when the engine failed to work normally Refer to Fault code table Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to DIAG NOSTIC MODE Improper installed lead connector in the coupler The main switch is OFF position Malfunction in Fl diagnostic tool Malfunction in ECU Turn th...

Page 264: ...ankshaft position sensor Check the installed area for looseness or pinching If there is a malfunction repair it and connect it securely Crankshaft position sensor coupler Main wiring harness ECU coupler Repair or replace if there is an open or short circuit between the main wiring harnesses Between sensor coupler and ECU coupler white red black blue Replace if defective Reinstated by crank ing the...

Page 265: ...and ECU coupler black blue black blue pink white pink whte blue blue Execute the diagnostic mode code No D03 Replace the throttle body TIP Do not remove the sensor module 1 Connect the digital circuit tester to the in take air pressure sensor coupler as shown Positive tester probe J J J J J pink white 1 1 1 1 1 Negative tester prove J J J J J black blue 2 2 2 2 2 2 Set the main switch to ON 3 Meas...

Page 266: ...ted condition of con nector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler Open or short circuit in wiring harness Defective throttle position sen sor Check the installed area for looseness or pinching Check that it is installed in the specified po sition Refer to THROTTLE BODY AND FUEL IN JECTOR If there is a malfunction repair it and connect ...

Page 267: ...e throttle body TIP Do not remove the sensor module Refer to THROTTLE BODY AND FUEL IN JECTOR Refer to Fault code No 15 Open circuit in the input line of ECU sidestand lead detected 1 2 Fault code No 19 Symptom Used diagnostic code No D20 sidestand switch Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstatedbyrecon necting the wiring a...

Page 268: ...ect it securely Intake air temperature sensor coupler Main wiring harness ECU coupler 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 Execute the diagnostic mode code No D05 Replace the throttle body TIP Do not remove the sensor module 1 Connect the digital circuit tester to the in take air temperature sens...

Page 269: ...k blue green red green red Execute the diagnostic mode code No D11 Replace if defective No normal signal is received from the O2 sensor 1 2 3 4 5 Fault code No 24 Symptom Used diagnostic code No Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by start ing the engine oper ating it at idle and then racing it after it has warmed up ...

Page 270: ...pler Defective lean angle cut off switch Raise the vehicle upright Check the installed area for looseness or pinching If there is a malfunction repair it and connect it securely Lean angle cut off switch coupler Main wiring harness ECU coupler Execute the diagnostic mode code No D08 Replace if defective 1 Remove the lean angle cut off switch from the vehicle 2 Connect the lean angle cut off switch...

Page 271: ... 37 Symptom Used diagnostic code No D54 ISC idle speed control valve Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated if the en gine idle speed is within specification after starting the engine Throttle valve does not fully close ISC idle speed control valve stuck fully open ISC idle speed control valve not moving correctly Check ...

Page 272: ...orange black Execute the diagnostic mode code No D36 Replace if defective Lean angle cut off switch open or short circuit is detected 1 2 3 Fault code No 41 Symptom Used diagnostic code No D08 lean angle cut off switch Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by turn ing the main switch ON Connected condition of con nector...

Page 273: ...of the coupler Open or short circuit in speed ometer lead Breakagespeedometercableor speedometer gear unit Defective speed sensor If there is a malfunction repair it and connect it securely Speedometer coupler Main wiring harness ECU coupler Repair or replace if there is an open or short circuit Between speedometer coupler and ECU cou pler white white black blue black blue Execute the diagnostic m...

Page 274: ...09 fuel system voltage Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by start ing the engine and operating it at idle Connected condition of con nector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler Faulty battery Open or short circuit in wiring harness If there is a malfunc...

Page 275: ...r Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by start ing the engine and operating it at idle Connected condition of con nector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler Faulty battery Malfunction in rectifier regula tor Open or short circuit in wiring harness If there is ...

Page 276: ...on nector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler Open or short circuit in lead Detective ISC idle speed con trol valve If there is a malfunction repair it and connect it securely ISC idle speed control valve coupler Main wiring harness ECU coupler Repair or replace if there is an open or short circuit Between ISC idle speed control valv...

Page 277: ...LE BODY AND FUEL INJECTOR Removing the fuel tank Seat trunk Battery box cover front cover Side cover left and right Fuel Fuel pump coupler Fuel hose Fuel return hose Fuel tank cap Filler cover overflow pipe 1 2 3 4 5 1 1 1 1 1 1 Remove the parts in the order listed TIP Place the scooter on a suitable stand Refer to COVER AND PANEL in chap ter 3 Drain Disconnect Disconnect Disconnect ...

Page 278: ...gf 5 1 ft lbf Remarks Order Job Part Q ty THROTTLE BODY AND FUEL INJECTOR 6 7 Fuel pump Fuel tank 1 1 Refer to REMOVING THE FUEL PUMP and INSTALLING THE FUEL PUMP Refer to REMOVING THE FUEL TANK and INSTALLING THE FUEL TANK AND FUEL HOSE For installation reverse the removal pro cedure ...

Page 279: ...uel hose holder to frame Fuel hose holder to intake manifold Clamp Fuel injector coupler Fuel injector and fuel hose 1 2 3 4 5 Remove the parts in the order listed Refer to REMOVING THE FUEL TANK Disconnect For installation reverse the removal pro cedure 1 1 1 1 1 3 2 1 5 4 10Nm 1 0 m kgf 7 2 ft lbf 12Nm 1 2 m kgf 8 7 ft lbf 7Nm 0 7m kgf 5 1 ft lbf ...

Page 280: ...clamp screw Sensor module coupler ISC idle speed control valve coupler Throttle cable assembly Throttle body 1 2 3 4 5 6 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE REMOVAL in chap ter 5 Refer to FUEL TANK Disconnect Lossen Disconnect Disconnect Disconnect For installation reverse the removal pro cedure 6 1 5 3 4 2 5Nm 0 5 m kgf 3 6 ft lbf 3Nm 0 3 m kgf 2 2 ft lbf ...

Page 281: ...ince there may be fuel remaining in it 8 8 8 8 8 Do not disconnect the fuel hose from the fuel hose connector Disconnect the con nector from the fuel pump TIP 8 Before removing the hose place a few rags in the area under where it will be removed 8 Hold fuel hose connector 1 draw down press tenon 2 draw backward and then can remove the fuel hose A Draw down B Draw backward 3 Disconnect 8fuel pump c...

Page 282: ...UMP 1 Remove 8fuel tank Refer to REMOVING THE FUEL TANK 2 Remove 8fuel pump NOTICE 8 8 8 8 8 Do not drop the fuel pump or give it a strong shock 8 8 8 8 8 Do not touch the base section of the fuel sender EAS00911 NOTICE The fuel pump should not be disassembled ...

Page 283: ...tches wear J Replace NOTICE 8 8 8 8 8 Do not adjust the stop screw 1 1 1 1 1 8 8 8 8 8 Do not clean the throttle body ass y us ing carburetor cleaner or compressed air 8 8 8 8 8 When replace the throttle body the main switch is operated three times turn ON and OFF position ON position 3 seconds more OFF po sition 3seconds more And then start the engine and keep idling at 10 minutes more THROTTLE B...

Page 284: ...rward INSTALLING THE FUEL TANK AND FUEL HOSE 1 Install 8fuel tank 10Nm 1 0m kgf 7 2ft lbf 2 Connect 8fuel pump coupler T R T R 3 Install 8fuel hose 1 8fuel return hose NOTICE When installing the fuel hose make sure that it is securely connected and that the fuel hose holders are in the correct position otherwise the fuel hose will not be properly installed TIP 8 Install the fuel hose connector sec...

Page 285: ...has been removed from the fuel tank be careful when removing the fuel hose since there may be fuel remaining in it TIP Before removing the hose place a few rags in the area under where it will be removed c Connect the pressure gauge 2 and adapter 3 onto the fuel hose Pressure gauge 90890 03153 YU 03153 Adapter 90890 03186 d Start the engine e Measure the fuel pressure Fuel pressure 250kPa 2 5kgf c...

Page 286: ...Out of specification J Replace or repair the wire harness Throttle position sensor voltage 5V blue black blue c Connect the digital circuit tester to the ter minals of the throttle position sensor Positive tester probed J J J J J yellow terminal 3 3 3 3 3 Negative tester probe J J J J J black blue terminal 2 2 2 2 2 d While slowly opening the throttle check that the throttle position sensor voltag...

Page 287: ...r minals of the ISC idle speed control valve Positive tester probe J J J J J pink terminal 1 1 1 1 1 Negative tester probe J J J J J green yellow terminal 2 2 2 2 2 Positive tester probe J J J J J gray terminal 3 3 3 3 3 Negative tester probe J J J J J sky blue terminal 4 4 4 4 4 Digital circuit tester 90890 03174 c Measure the ISC idle speed control valve resistance Out of specification J Replace...

Page 288: ...9 CIRCUIT DIAGRAM 7 9 TROUBLESHOOTING 7 10 ELECTRIC STARTING SYSTEM 7 15 CIRCUIT DIAGRAM 7 15 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 7 16 TROUBLESHOOTING 7 17 STARTER MOTOR 7 21 CHECKING THE STARTER MOTOR 7 23 ASSEMBLING THE STARTER MOTOR 7 25 CHARGING SYSTEM 7 26 CIRCUIT DIAGRAM 7 26 TROUBLESHOOTING 7 27 LIGHTING SYSTEM 7 29 CIRCUIT DIAGRAM 7 29 TROUBLESHOOTING 7 30 CHECKING THE LIGHTING SYSTE...

Page 289: ...lator 4 Rear brake light switch 5 Sidestand switch 6 Battery 7 Main fuse 8 ECU 9 Fuse box 0 Ignition coil q Spark plug cap w Fuel pump e Starter relay r Horn t Turn signal relay y Starting circuit cut off relay u Headlight relay i Stator coil o Wire harness ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o ...

Page 290: ... B P B Ch Br W Dg Ch Br W Dg L B P B Y G Y G Br Br BLACK BLACK Br G Y Br G Y BLACK BLACK B B B B G Y G Y L Y Y G G R P W Br W B L Y L L G R B L P W Br W B L Y L BLACK G R B L L Y G B L B L Y G B L Y L P W Br W B L R B BLACK BLACK Gy G Gy G B G B G B G Gy G R B B L B W B L Lg Sb Gy G Y P P G Y Sb Gy Or Or B P G Y R W W R Lg B L L Gy G Y G R B G Gy Sb L B L Y W R B W Br W Y G P W R L Y Br L B B W Br...

Page 291: ...signal light left v Front turn signal light right b Rear turn signal light left n Rear turn signal light right m Tail brake light Ignition coil Spark plug Fuel injector Fuel pump ECU Lean angle cut off switch Engine temperature sensor Intake air pressure sensor Intake air temperature sensor Throttle position sensor O2 sensor ISC idle speed control valve FI diagnostic tool Color Code B Black Br Bro...

Page 292: ...er to 0 and to the Ω 1 range 8 When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an il lustration 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 TIP c ...

Page 293: ...ect continuity reading J Replace the switch CHECKING THE SWITCHES 1 Rear brake light switch 2 Dimmer switch 3 Horn switch 4 Turn signal switch 5 Main fuse 6 Start switch 7 Engine stop switch 8 Main switch 9 Front brake light switch 0 Sidestand switch OFF ON OFF PUSH L N R HI LO OFF LOCK ON B L Y R Br L L Y B G L B Y P B Ch Br W Dg L B P B Ch Br W Dg Y G B L Y B B 1 7 5 8 2 3 4 6 B B 9 BLACK RED BL...

Page 294: ... be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise 8Bulbs C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise 8Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by car...

Page 295: ...h the pocket tester No continuity J Replace Pocket tester 90890 03112 YU 03112 C TIP 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 negative tester probe to ter minal 2 and check the continuity b Connect the positive tester probe to termi nal 1 and the negative tester probe to ter minal 3 and check the conti...

Page 296: ...bed 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 re spective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity re place the bulb socket CHECKING THE BULBS AND BULB SOCKETS ...

Page 297: ...Y BLACK BLACK B B B B G Y G Y L Y Y G G R P W Br W B L Y L L G R B L P W Br W B L Y L BLACK G R B L L Y G B L B L Y G B L Y L P W Br W B L R B BLACK BLACK Gy G Gy G B G B G B G Gy G R B B L B W B L Lg Sb Gy G Y P P G Y Sb Gy Or Or B P G Y R W W R Lg B L L Gy G Y G R B G Gy Sb L B L Y W R B W Br W Y G P W R L Y Br L B B W Br R L Y 1 2 R 4 6 7 8 9 q r t y u i j k h g l z p a s d f x c v m 12V 1 7W 1...

Page 298: ...12 C EAS00738 1 Main and ignition fuses 8 Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 8 Are the main and ignition fuses OK YES NO EAS00739 2 Battery 8 Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F 8 Is the battery OK YES NO 8 Clean the battery termin...

Page 299: ...The ignition system is OK EAS00744 5 Spark plug cap resistance 8 Remove the spark plug cap from the spark plug lead 8 Connect the pocket tester Ω 1k range to the spark plug cap as shown 8 Measure the spark plug cap resistance Spark plug cap resistance 8 12 kΩ Ω Ω Ω Ω at 20 C 68 F 8 Is the spark plug cap OK YES NO Replace the spark plug cap EAS00746 6 Ignition coil resistance 8 Disconnect the ignit...

Page 300: ...the ignition coil IGNITION SYSTEM EAS00748 7 Crankshaft position sensor resistance 8 Disconnect the crankshaft position sensor coupler from the wire harness 8 Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown Positive tester probe J J J J J white red 1 1 1 1 1 Negative tester probe J J J J J white blue 2 2 2 2 2 8 Measure the crankshaft position sensor re sistance ...

Page 301: ...he sidestand switch for continuity Refer to CHECKING THE SWITCHES 8 Is the sidestand switch OK YES NO Replace the sidestand switch 11 Lean angle cut off switch 8 Remove the lean angle cut off switch 8 Connect the pocket tester Ω 1 to the lean angle cut off switch terminals as shown Positive tester probe J J J J J blue 1 1 1 1 1 Negative tester probe J J J J J yellow green 2 2 2 2 2 Lean angle cut ...

Page 302: ...54 12 Wiring 8 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM 8 Is the ignition system s wiring properly con nected and without defects YES NO Properly connect or repair the ignition system s wiring Replace the ECU ...

Page 303: ...Y Y G G R P W Br W B L Y L L G R B L P W Br W B L Y L BLACK G R B L L Y G B L B L Y G B L Y L P W Br W B L R B BLACK BLACK Gy G Gy G B G B G B G Gy G R B B L B W B L Lg Sb Gy G Y P P G Y Sb Gy Or Or B P G Y R W W R Lg B L L Gy G Y G R B G Gy Sb L B L Y W R B W Br W Y G P W R L Y Br L B B W Br R L Y 1 2 R 4 6 7 8 9 q r t y u i j k h g l z p a s d f x c v m 12V 1 7W 12V 1 7W 12V 1 7W 12V 1 7W 12V 1 ...

Page 304: ...ke lever front or rear is pulled to the handlebar the brake light switch is closed and the sidestand is up the sidestand switch is closed 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Signaling system fuse 6 Front brake light switch 7 Rear brake light switch 8 Engine stop switch 9 Starting circuit cut off relay 0 Sidestand switch q Start switch w Wire lead e Starter relay r Starter motor E...

Page 305: ...2 seat trunk 3 side cover right 4 leg shield 1 8Troubleshoot with the following special tool s Pocket tester 90890 03112 YU 03112 C ELECTRIC STARTING SYSTEM EAS00738 1 Main signal and ignition fuses 8 Check the main signal and ignition fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 8 Are the main signal and ignition fuses OK YES NO EAS00739 2 Battery 8 Check the condition of the ba...

Page 306: ...e starter motor ELECTRIC STARTING SYSTEM EAS00759 4 Starting circuit cut off relay 8 Disconnect the starting circuit cut off relay coupler from the wire harness 8 Connect the pocket tester Ω 1 and bat tery 12 V to the starting circuit cut off relay coupler as shown Positive battery terminal J J J J J red blcak 1 1 1 1 1 Negative battery terminal J J J J J black white 2 2 2 2 2 Positive tester prob...

Page 307: ...2 L W R W Starter relay EAS00749 6 Main switch 8 Check the main switch for continuity Refer to CHECKING THE SWITCHES 8 Is the main switch OK YES NO Replace the main switch EAS00750 7 Engine stop switch 8 Check the engine stop switch for continuity Refer to CHECKING THE SWITCHES 8 Is the engine stop switch OK YES NO Replace the right handlebar switch EAS00751 8 Brake light switch front and rear 8 C...

Page 308: ... OK YES NO Replace the right handlebar switch EAS00766 11 Wiring 8 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM 8 Is the starting system s wiring properly con nected and without defects YES NO Properly connect or repair the starting system s wiring The starting system circuit is ok ELECTRIC STARTING SYSTEM ...

Page 309: ...rush Spring Circlip Armature Stator O ring Starter motor rear cover 1 2 1 2 3 4 5 6 7 8 9 0 1 1 1 1 1 1 2 2 1 1 1 1 1 Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 Refer to ENGINE REMOVEL in chap ter 5 Disconnect For installation reverse the removal pro cedure Disassemble the parts in the order listed Refer to ASSEMBLING THE STARTER MOTOR ELECTRIC STARTING SYSTEM 1 2 ...

Page 310: ...7 22 ELEC ELECTRIC STARTING SYSTEM Remarks Order Job Part Q ty For assembly reverse the disassembly procedure 1 2 7Nm 0 7 m kgf 5 1 ft lbf 4Nm 0 4 m kgf 2 9 ft lbf ...

Page 311: ...Mica undercut 1 5 mm 0 06in TIP The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure 8armature assembly resistances commu tator and insulation Out of specification J Replace the starter motor a Measure the armature assembly resis tances with the pocket tester Pocket tester 90890 03112 YU 03112 C Armature coil Commutator resistance 1 1 1 1 1 0 0252 0 03...

Page 312: ...mit 3 5 mm 0 14in 6 Measure 8brush spring force Out of specification J Replace the brush springs as a set Brush spring force 5 52 8 28 N mm 0 56 0 84kgf mm 1 24 1 86lbf in 7 Check 8gear teeth Damage wear J Replace the gear a ELECTRIC STARTING SYSTEM 8 Check 8bearing 1 8oil seal 2 8bush 3 Damage wear J Replace ...

Page 313: ... the match marks a on the stator with the match marks b on the front and starter motor rear covers EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install 8brush spring 8brush 1 2 Install 8armature 8starter motor front cover 1 8O ing 2 New 8stator 3 8O ing 4 New 8starter motor rear cover 5 T R 1 2 1 4 5 3 1 ...

Page 314: ...Br W Dg L B P B Y G Y G Br Br BLACK BLACK Br G Y Br G Y BLACK BLACK B B B B G Y G Y L Y Y G G R P W Br W B L Y L L G R B L P W Br W B L Y L BLACK G R B L L Y G B L B L Y G B L Y L P W Br W B L R B BLACK BLACK Gy G Gy G B G B G B G Gy G R B B L B W B L Lg Sb Gy G Y P P G Y Sb Gy Or Or B P G Y R W W R Lg B L L Gy G Y G R B G Gy Sb L B L Y W R B W Br W Y G P W R L Y Br L B B W Br R L Y 1 2 R 4 6 7 8 ...

Page 315: ...t the pocket tester DC 20 V to the battery as shown Positive tester probe J J J J J positive battery terminal Negative tester probe J J J J J negative battery terminal 8 Start the engine and let it run at approxi mately 5 000 r min 8 Measure the charging voltage Charging voltage 14 V at 5000r min CHARGING SYSTEM EAS00738 1 Main fuse 8 Check the main fuse for continuity Refer to CHECKING THE FUSES ...

Page 316: ...2 Negative tester probe J J J J J white 3 3 3 3 3 8 Measure the stator coil resistances Stator coil resistance 0 28 0 42 Ω Ω Ω Ω Ω at 20 C 68 F 8 Is the stator coil OK YES NO Replace the crank shaft position sensor stator coil assembly CHARGING SYSTEM TIP Make sure the battery is fully charged 8Is the charging voltage within specification YES NO EAS00779 5 Wiring 8 Check the wiring connections of ...

Page 317: ... Br G Y Br G Y BLACK BLACK B B B B G Y G Y L Y Y G G R P W Br W B L Y L L G R B L P W Br W B L Y L BLACK G R B L L Y G B L B L Y G B L Y L P W Br W B L R B BLACK BLACK Gy G Gy G B G B G B G Gy G R B B L B W B L Lg Sb Gy G Y P P G Y Sb Gy Or Or B P G Y R W W R Lg B L L Gy G Y G R B G Gy Sb L B L Y W R B W Br W Y G P W R L Y Br L B B W Br R L Y 1 2 R 4 6 7 8 9 q r t y u i j k h g l z p a s d f x c v...

Page 318: ...ight fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 8 Are the fuses OK YES NO Replace the fuse s LIGHTING SYSTEM EAS00739 2 Battery 8 Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F 8 Is the battery OK YES NO 8 Clean the battery terminals 8 Recharge or re place the battery EAS00749 3...

Page 319: ...t bulb and socket 8 Check the high beam indicator light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Are the high beam indicator light bulb and socket OK YES NO Replace the headlight bulb socket or both Replace the high beam indicator light bulb socket or both LIGHTING SYSTEM Replace the headlight relay 5 Headlight relay 8 Disconnect the headlight relay coupler fro...

Page 320: ...er probe J J J J J black 2 2 2 2 2 Positive tester probe J J J J J green 3 3 3 3 3 Negative tester probe J J J J J black 4 4 4 4 4 Headlight coupler High beam indicator light Positive tester probe J J J J J yellow 5 5 5 5 5 Negative tester probe J J J J J black 6 6 6 6 6 Meter assembly coupler 8 Set the main switch to ON 8 Set the engine stop switch to 8 Start the engine 8 Set the dimmer switch to...

Page 321: ... coupler wire harness side 8 Is the voltage within specification YES NO The wiring circuit from the main switch to the meter light coupler is faulty and must be re paired Refer to CIRCUIT DIAGRAM This circuit is OK EAS00789 2 The meter light fails to come on 1 Meter light bulb and socket 8 Check the meter light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Are the m...

Page 322: ...Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Positive tester probe J J J J J blue 1 1 1 1 1 Negative tester probe J J J J J black 2 2 2 2 2 8 Set the main switch to ON 8 Measure the voltage DC 12 V of blue 1 on the meter light coupler wire harness side 8 Is the voltage within specification YES NO The wiring circuit from the main switch to the tail br...

Page 323: ...K G R B L L Y G B L B L Y G B L Y L P W Br W B L R B BLACK BLACK Gy G Gy G B G B G B G Gy G R B B L B W B L Lg Sb Gy G Y P P G Y Sb Gy Or Or B P G Y R W W R Lg B L L Gy G Y G R B G Gy Sb L B L Y W R B W Br W Y G P W R L Y Br L B B W Br R L Y 1 2 R 4 6 7 8 9 q r t y u i j k h g l z p a s d f x c v m 12V 1 7W 12V 1 7W 12V 1 7W 12V 1 7W 12V 1 7W 12V 60W HI 12V 55W LO 12V 10W 12V 10W 12V 21 5W R W G B...

Page 324: ... and without defects YES NO Properly connect or repair the signaling system s wiring Check the condition of each of the signaling system s circuits Refer to CHECKING THE SIGNALING SYSTEM SIGNALING SYSTEM EAS00738 1 Main and signaling fuses 8 Check the main and signaling fuses for con tinuity Refer to CHECKING THE FUSES in chap ter 3 8 Are the main and signaling fuses OK YES NO EAS00739 2 Battery 8...

Page 325: ...nnect the pocket tester DC 20 V to the horn connector at the horn terminal as shown Positive tester probe J J J J J brown 1 1 1 1 1 Negative tester probe J J J J J ground 8 Set the main switch to ON 8 Push the horn switch 8 Measure the voltage DC 12 V of brown at the horn terminal 8 Is the voltage within specification YES NO The wiring circuit from the main switch to the horn connector is faulty a...

Page 326: ... Replace the tail brake light bulb socket or both 3 Voltage 8 Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Positive tester probe J J J J J green yellow 1 1 1 1 1 Negative tester probe J J J J J black 2 2 2 2 2 8 Set the main switch to ON 8 Pull in the brake levers 8 Measure the voltage DC 12 V of green yel low 1 on the tail brake light coupler wire h...

Page 327: ... socket OK YES NO Replace the turn sig nal light bulb socket or both SIGNALING SYSTEM 3 Turn signal switch 8 Check the turn signal switch for continuity Refer to CHECKING THE SWITCHES 8 Is the turn signal switch OK YES NO Replace the left handlebar switch 4 Voltage 8 Connect the pocket tester DC 20 V to the turn signal relay coupler wire harness side as shown Positive tester probe J J J J J brown ...

Page 328: ... as shown A Left turn signal light front and rear B Right turn signal light front and rear C Turn signal indicator light Left turn signal light Positive tester probe J J J J J chocolate 1 1 1 1 1 Negative tester probe J J J J J ground Right turn signal light Positive tester probe J J J J J dark green 2 2 2 2 2 Negative tester probe J J J J J ground 8 Set the main switch to ON 8 Set the turn signal...

Page 329: ...nder resistance down posi tion E Ω Ω Ω Ω Ω 10 90 100 Ω Ω Ω Ω Ω at 20 C 68 F 8 Is the fuel sender OK YES NO Replace the fuel pump 2 Voltage 8 Connect the pocket tester DC 20 V to the meter light coupler wire harness side as shown Positive tester probe J J J J J brown 1 1 1 1 1 Negative tester probe J J J J J black 2 2 2 2 2 8 Set the main switch to ON 8 Measure the voltage DC 12 V of brown 1 on the...

Page 330: ...ge needle moves to F or E TIP Before reading the fuel level gauge leave the float in one position either up or down for at least three minutes 8 Does the fuel level gauge needle move ap propriately YES NO Replace the speed ometer 4 Wiring Check the entire signaling system s wiring SIGNALING SYSTEM This circuit is OK 2 1 ...

Page 331: ...OOR STARTING PERFORMANCE 8 3 POOR SPEED PERFORMANCE 8 3 OVERHEATING 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 CHASSIS 8 3 ELECTRICAL SYSTEMS 8 3 POOR BRAKING PERFORMANCE 8 4 FAULTY FRONT FORK LEGS 8 4 LEAKING OIL 8 4 MALFUNCTION 8 4 UNSTABLE HANDLING 8 4 FAULTY LIGHTING OR SIGNALING SYSTEM 8 5 HEADLIGHT DOES NOT COME ON 8 5 HEADLIGHT BULB BURNT OUT 8 5 TAIL BRAKE LIGHT DOES NOT COME ON 8 5 TAIL BRAKE LIGHT B...

Page 332: ...zed crankshaft FUEL SYSTEM Fuel tank 8Empty fuel tank 8Clogged fuel tank cap breather hole 8Deteriorated or contaminated fuel 8Clogged or damaged fuel hose Fuel pump 8Faulty fuel pump 8Improperly routed hose Throttle body 8Deteriorated or contaminated fuel 8Sucked in air ELECTRICAL SYSTEMS Battery 8Discharged battery 8Faulty battery Fuse s 8Blown damaged or incorrect fuse 8Improperly installed fus...

Page 333: ...e cable free play 8Flooded throttle body ELECTRICAL SYSTEMS Battery 8Discharged battery 8Faulty battery Spark plug 8Incorrect spark plug gap 8Incorrect spark plug heat range 8Fouled spark plug 8Worn or damaged electrode 8Worn or damaged insulator 8Faulty spark plug cap Ignition coil 8Faulty spark plug lead Ignition system 8Faulty ECU 8Faulty crankshaft position sensor EAS00848 POOR MEDIUM AND HIGH...

Page 334: ...tch shoes 8Bent damaged or worn clutch shoe POOR SPEED PERFORMANCE V belt 8Worn V belt 8Oil or grease on the V belt Primary pulley weight s 8Faulty operation 8Worn primary pulley weight Primary fixed sheave 8Worn primary fixed sheave Primary sliding sheave 8Worn primary sliding sheave Secondary fixed sheave 8Worn secondary fixed sheave Secondary sliding sheave 8Worn secondary sliding sheave EAS008...

Page 335: ...bolt cop per washer 8Cracked or damaged cap bolt O ring MALFUNCTION 8Bent or damaged inner tube 8Bent or damaged outer tube 8Damaged fork spring 8Worn or damaged outer tube bushing 8Bent or damaged damper rod 8Incorrect oil viscosity 8Incorrect oil level EAS00862 UNSTABLE HANDLING Handlebar 8Bent or improperly installed handlebar Steering head components 8Improperly installed handlebar bracket 8Im...

Page 336: ...B BURNT OUT 8Wrong tail brake light bulb 8Faulty battery 8Faulty front or rear brake light switch 8Tail brake light bulb life expired TURN SIGNAL DOES NOT COME ON 8Faulty turn signal switch 8Faulty turn signal relay 8Burnt out turn signal bulb 8Incorrect connection 8Damaged or faulty wire harness 8Improperly grounded circuit 8Faulty battery 8Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWL...

Page 337: ...ng system fuse i Headlight fuse o Fuel level gauge p Speedometer light a High beam indicator light s Engine trouble warning light d Speed sensor f Turn signal indicator light g Horn h Turn signal relay j Front brake light switch k Rear brake light switch l Horn switch Dimmer switch z Turn signal switch x Headlight c Front turn signal light left v Front turn signal light right b Rear turn signal li...

Page 338: ...Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto ON M2H 3B4 ...

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