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COOL

CHAPTER 5.

COOLING SYSTEM

RADIATOR ..................................................................................................... 5-1

REMOVAL ................................................................................................ 5-2
INSPECTION ........................................................................................... 5-2
INSTALLATION ........................................................................................ 5-2

WATER PUMP ............................................................................................... 5-3

REMOVAL ................................................................................................ 5-4
INSPECTION ........................................................................................... 5-4
INSTALLATION ........................................................................................ 5-4

THERMOSTATIC VALVE .............................................................................. 5-5

REMOVAL ................................................................................................ 5-6
INSPECTION ........................................................................................... 5-6
INSTALLATION ........................................................................................ 5-6

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Summary of Contents for AEROX YQ50

Page 1: ...SERVICE MANUAL YQ50 5BS AE2 97 ...

Page 2: ...YQ50 SERVICE MANUAL 1997 by MBK INDUSTRIE 2st Edition November 1997 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited ...

Page 3: ...riving to improve all models manufactured Modifications and significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and MBK dealers and will where applicable appear in future editions of this manual DOCUMENTATION TECHNIQUE MBK INDUSTRIE PARTICULARY IMPORTANT INFORMATION This material is distinguished by the following notation The safety Alert Symbol means ATT...

Page 4: ... with an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particulary important procedure 4 is placed between a line of asterisks with each step preceded by IMPORTANT FEATURES Data and a special tools are framed in a box preceded by a relevant symbol 5 An encircled numeral 6 indicates a part name and an encircled alph...

Page 5: ...s appearing in the text O Filling fluid P Lubricant Special tool Tightening q Wear limit clearance w Engine speed e Ω V A Illustrated symbols r to in the exploded diagram indicate grade of lubricant and location of lubrication point r Apply engine oil t Apply gear oil y Apply molybdenum disulfide oil u Apply wheel bearing grease i Apply lightweight lithium soap base grease o Apply molybdenum disul...

Page 6: ...8 9 INDEX SPECIFICATIONS ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GENERALINFORMATION PERIODIC INSPECTION AND ADJUSTMENT SPEC ENG CARB CHAS ELEC TRBL SHTG GEN INFO INSP ADJ 5 COOLING SYSTEM ENG ...

Page 7: ...1 GEN INFO ...

Page 8: ...FICATION 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 ENGINE SERIAL NUMBER 1 1 IMPORTANT INFORMATION 1 2 ALL REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 2 CIRCLIPS 1 3 SPECIAL TOOLS 1 4 ...

Page 9: ...identify your scooter and may be used to register your scooter with the licensing authority in your state ENGINE SERIAL NUMBER The engine serial number Q is stamped into the crankcase NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number NOTE Designsandspecificationsaresubjecttochange without notice SCOOTER IDENTIFICATION 햲 햲...

Page 10: ... reassembly Apply grease to the oil seal lips LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates Q and cotter pins must be replaced when they are removed Locktab s shouldbebentalongtheboltornut flat s after the bolt or nut has been properly tightened BEARINGS AND OIL SEALS 1 Install the bearing s Q and oil seal s W with their manufacturer s marks or numbers facing outward In other words...

Page 11: ...ldbeinspectedcarefullybefore reassembly Always replace piston pin clips once they have been removed Replace bent circlips When installing a circlip Q make sure that the sharp edge W is positioned opposite to the thrust E it receives See the sectional view R Shaft ...

Page 12: ...el puller This tool is used to remove the flywheel magneto Rotor holding tool This tool is used to remove the flywheel magneto Crankcase separating tool This tool is used to separate the crank case and remove the crankshaft 90890 01135 90890 01189 90890 01235 90890 01274 90890 01275 90890 01277 90890 01411 SPECIAL TOOLS 90890 01337 90890 01701 90890 01348 Clutch spring holder This tool is used for...

Page 13: ...ed for detecting the en gine rpm 90890 01326 90890 1294 90890 01184 90890 01186 9079Q 02218 90890 03112 90890 03113 90890 06754 T handle Damper rod holder These tools are used for holding the damper rod holder when removing or in stalling the damper rod holder Fork seal driver weight Fork seal driver attachment ø27 These tools are used wheninstalling the fork seals Ignition checker This instrument...

Page 14: ...2 SPEC ...

Page 15: ...SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 6 ELECTRICAL 2 7 CABLE ROUTING 2 8 ...

Page 16: ...ntal Displacement 49 cm3 Bore x stroke 40 x 39 2 mm Compression ratio 7 9 1 F B P E I 8 1 D NL CHE Starting system Electric and kick starter Lubrication system Separate lubrication Yamaha Autolube Oil type or grade Engine oil Semi synthetic in accordance with the API TC TSC 3 Standard Transmission oil SAE 10W30 type SE motor oil Oil capacity Transmission oil Periodic oil change 0 11 L Total amount...

Page 17: ...hassis Frame type Steel tube underbone Caster angle 27 Trail 90 mm Tire Type Tubeless Size Front 130 60 13 Rear 140 60 13 Manufacturer type Front PIRELLI SL36 MICHELIN BOPPER Rear PIRELLI SL36 MICHELIN BOPPER Tire pressure cold tire Front 150 kPa 1 50 kg cm2 Rear 150 kPa 1 50 kg cm2 Brake Front brake type Disc brake Operation Right hand operation Rear brake type Disk brake Operation Left hand oper...

Page 18: ...ty 12V 4AH Headlight type Bulb Bulb wattage quantity Headlight 12V 35W 35W x 1 Auxiliary light 12V 5W x 1 Taillight brake light 12V 5W 21W x 1 Flasher light Front 12V 21W x 2 Rear 12V 10W x 2 Meter light 12V 1 2W x 3 Warning lights wattage quantity OIL 12V 1 2W x 1 HIGH BEAM 12V 1 2W x 1 TURN 12V 1 2W x 1 Cooling warning light 12V 1 2W x 1 Model YQ50 ...

Page 19: ... Piston pin Outside diameter 9 996 10 000 mm Piston ring Sectional sketch BxT Type Top ring 1 5 1 8 mm 2nd ring 1 5 1 8 mm End gap installed Top ring 0 15 0 35 mm 2nd ring 0 15 0 35 mm Side clearance installed Top ring 0 03 0 05 mm 2nd ring 0 03 0 05 mm Crankshaft Crank width A 37 90 37 95 mm Runout limit C 0 03 mm Connecting rod big end side clearance D 0 2 0 5 mm Big end radial clearance E 0 004...

Page 20: ...e Kick clip tension 0 15 0 25 kg Carburetor I D mark DELLORTO PHBN 12 HS Main jet M J 86 F B P I E 85 CHE 74 NL Main air jet M A J ø1 5 Jet needle J N A21 2 5 F B P I E A12 3 5 D CHE A20 3 5 NL Needle jet N J 210 GA F B P I E D 209 GA CHE 208 GA NL Cutaway C A 3 0 4 0 CHE Pilot jet P J 36 34 CHE Bypass 1 B P 1 0 8 Air screw A S 1 3 8 1 8 F B P I E 1 3 4 1 8 D 1 5 8 1 8 NL 2 1 8 CHE Valve seat size...

Page 21: ...Rear wheel type Cast wheel Front wheel size Material MT 3 00 x13 Aluminium Front wheel size Material MT 3 50 x13 Aluminium Rim runout limit Front 1 0 mm Rear 1 0 mm Front disc brake Type Single disc Diameter and thickness 190 x 3 5 mm Pad thickness 4 5 mm Wear limit 2 0 mm Master cylinder inside diameter 11 mm Caliper cylinder inside diameter 30 mm Brake fluid type DOT 3 or DOT 4 Rear disk brake T...

Page 22: ... 48 0 72 Ω at 20 C 68 F White Black Voltage regulator Rectifier Type Semi conductor short circuit type No load regulated voltage 13 14 V Capacity 8 A Withstand voltage 600 V Battery Specific gravity 1 280 Starter motor Out put 0 14 kW Armature coil resistance 0 06 0 08 Ω at 20 C 68 F Brush overall lenght 3 9 mm Wear limit 0 9 mm Brush spring pressure 563 844 g Commutator diameter 15 8 mm Wear limi...

Page 23: ...front flasher harness E Install the right handlebar grip in regard to the right handlebar switch F Group the connexions here G Attach the wiring harness cord on the handlebar bracket H Pass the starter choke through the handle cover I Glue the left handlebar grip J Cut the band at 5 mm of his end K Clip the front handlebar cover on the speedometer case L Front steering assembly Tighten the ring nu...

Page 24: ...el sender so that the cable points toward C Pass the fuel lines above the rear brake hose D Pass the fuel overflow pipe in the trunk slot E Push the fuel cock without turning it completly in the tank and screw the collar F Install the hoses facing to the inside of the frame G Pass the fuel tank pipe overflow and carburetor drain pipes in the bracket H Attach the fuel and suction pipes in the bands...

Page 25: ...p betwween 8 9 mm at the seat lock aperture B Install the starter relay on the footrest board C Group the connections here D Turn the connectors towards E Puch the wiring inside F Pass the wiring harness through the footrest board G Turn the ground lead one turn around the starter motor leads H The water temperature sender lead must go straight to the wiring harness I Put one drop of Loctite 542 o...

Page 26: ...r tank I Clamps P Frame CABLE ROUTING 햲 햳 햴 햵 햶 햷 햸 햹 E 햸 햷 햷 햸 햷 햺 A Install the wiring harness in the middle of the frame B Set the resistor at 45 0 30 on the frame bracket C Clip the front brake hose on the front fork bracket D Install the 8 clamps just beside the marks at the end side of the hoses ...

Page 27: ...rburetor P Water hoses CABLE ROUTING A Install the rear brake hose in the clip B Install the oil delivery hose from oil pump to carburator under the water hose C Pass the rear brake hose under the frame reinforcement tube D Alignthemarkonthewaterhoseinfrontofthemarkinthewaterpump housing E Pass the speedometer cable through the slot of the front fender F Install the 8 clamps just beside the marks ...

Page 28: ...3 CHK ADJ ...

Page 29: ...R CLEANER ELEMENT CLEANING 3 19 EXHAUST PIPE ASSEMBLY AND ADJUSTMENT 3 20 CHASSIS 3 21 FRONT BRAKE LEVER FREE PLAY ADJUSTMENT 3 21 REAR BRAKE LEVER FREE PLAY ADJUSTMENT 3 21 BRAKE PAD INSPECTION 3 21 BRAKE FLUID LEVEL INSPECTION 3 22 AIR BLEEDING HYDRAULIC BRAKE SYSTEM 3 23 STEERING HEAD ADJUSTMENT 3 23 TIRE INSPECTION 3 24 WHEEL INSPECTION 3 25 CABLE INSPECTION AND LUBRICATION 3 25 LEVER LUBRICAT...

Page 30: ...nd vacuum pipe for cracks or damage Replace if necessary Check for oil leakage Correct if necessary Replace every 12 000 8 000 or 24 months Warm engine before draining Check operation Correct if necessary Bleed the air Check operation fluid leakage See NOTE Correct if necessary Check hoose condition Replace if necessary Replace coolant every 12 000 8 000 or 24 months Check damage runout Tightening...

Page 31: ...ng the master cylinder or caliper cylinder replace the brake fluid Normally check the brake fluid level and add fluid as required 2 On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 Replace the brake hoses every four years or when cracked or damaged ...

Page 32: ... Mark Name of the intervention of the part Qty Observation COVERS REMOVAL 1 Seat 1 2 Fuel tank cap 1 3 Rear seat screws and strap 2 4 Side cover left and right 2 5 Rear seat 1 For installation reverse the REMOVAL procedure When removing the cover be careful not to damage the mounting clips CAUTION ...

Page 33: ... kg Mark Name of the intervention of the part Qty Observation COVERS REMOVAL 1 Glove compartment cover 1 2 Oil cover 1 3 Side cover left and right 2 4 Box 1 5 Rear mudguard 1 For installation reverse the REMOVAL procedure When removing the cover be careful not to damage the mounting clips CAUTION ...

Page 34: ... kg T R 6 5 Nm 0 65 m kg Mark Name of the intervention of the part Qty Observation COVERS REMOVAL 1 Frame reinforcement 1 2 Fuel tank 1 3 Rear lower cover 1 4 Rear light 1 For installation reverse the REMOVAL procedure When removing the cover be careful not to damage the mounting clips CAUTION ...

Page 35: ... 2 Nm 0 2 m kg T R 3 Nm 0 3 m kg T R 3 Nm 0 3 m kg T R 3 Nm 0 3 m kg T R 3 Nm 0 3 m kg 1 Front cover and headlight 1 2 Front inner cover 1 3 Front fender 1 4 Front inner panel 1 For installation reverse the REMOVAL procedure When removing the cover be careful not to damage the mounting clips CAUTION ...

Page 36: ...HANDLEBAR COVERS 1 Handlebar cover front 1 2 Handlebar cover rear 1 3 Meter 1 4 Flasher light 1 For installation reverse the REMOVAL procedure When removing the cover be careful not to damage the mounting clips CAUTION T R 3 Nm 0 3 m kg T R 3 Nm 0 3m kg T R 3 Nm 0 3 m kg 2 4 1 3 ...

Page 37: ...on of the part Qty Observation COVERS REMOVAL T R 3 Nm 0 3 m kg T R 3 Nm 0 3 m kg 1 2 1 Battery cover 1 2 Lower cover 1 When removing the cover be careful not to damage the mounting clips CAUTION For installation reverse the REMOVAL procedure ...

Page 38: ... COVERS REMOVAL 1 Inner panel 1 Main switch ring Turn the ring anticlockwise to remove it 2 Footrest board 1 For installation reverse the REMOVAL procedure When removing the cover be careful not to damage the mounting clips CAUTION T R 4 Nm 0 4 m kg T R 4 Nm 0 4 m kg 1 2 ...

Page 39: ... and wires is essential for a safe operation of this scooter Refer to the section CABLE ROUTING in Chapter 2 NOTE Be careful not to pinch any wires with the covers NOTE When installing the covers be careful not to damage the mounting clips COVERS ...

Page 40: ...osition DELL ORTO 1 3 8 turns out 1 8 F B P I E 1 3 4 turns out 1 8 D 1 5 8 turns out 1 8 NL 2 1 8 turns out CHE 4 Attach Inductive tachometer to the spark plug lead Inductive tachometer Ref 90890 03113 WARNING 3 Start the engine and let it warm up for several minutes For safety reasons place the scooter on the center stand before starting the engine 5 Check Engine idle speed Out of specification ...

Page 41: ... throttle cable free play the engine idle speed should be adjusted First step Loosen the locknut on the throttle cable Turn the adjuster in or out until the specified free play is obtained Tighten the locknuts After adjusting turn the handlebar to the right and left making sure that the engine idling speed does not change Turning left Idling speed increased Turning right Idling speed decreased Tur...

Page 42: ...al color Replace Standard spark plug BR8HS NGK 3 Measure Plug gap Out of specification Adjust Use a wire gauge or feeler gauge Spark plug gap 0 5 0 7 mm 0 019 0 027 in 4 Tighten Spark plug Before installing the spark plug clean the gasket surface and plug surface NOTE Firsttightenbyhand thentorquetospecification Spark plug 20 Nm 2 0 m kg ...

Page 43: ...he pump Remove the bleed screw Let oil run until there are no more air bubbles in it When there are no more bubbles tighten the bleed screw NOTE Check the condition of the bleed screw gasket If it is damaged replace it with a new one Start the engine Let the engine run two or three minutes at 2000 rpm This will force out any air in the hose ...

Page 44: ...c Engine oil level and electric circuit are OK OIL indicator goes OIL indicator stays on Add oil OIL indicator stays on Turn main switch to ON OIL indicator light Recommended oil Semi synthetic oil in accordance with APITC TSC3 STANDARD Capacity Total 1 3 L 1 14 Imp qt 1 37 US qt NOTE Install the oil tank filler cap Q and push it fully into the filler Always use the same type of engine oil mixing ...

Page 45: ... Damaged Replace 3 Install Gasket Drain plug Drain plug 18 Nm 1 8 m kg 4 Fill Transmission case Transmission oil SAE 10W30 type SE motor oil Capacity Periodic replacement 0 11 L 0 10 Imp qt 0 12 US qt Total amount 0 13 L 0 11 Imp qt 0 13 US qt NOTE Wipe off any oil spilt on the crankcase tire or wheel 5 Install Oil filler plug TRANSMISSIONOILREPLACEMENT T R ...

Page 46: ... to proper level Hard water or salt water is harmful to the engine parts use boiled or distilled water if you can t get soft water 4 Install Front cover Refer to the section COVER CAUTION COOLANT REPLACEMENT 1 Remove Front cover Refer to the section COVER Radiator cap Do not remove the radiator cap when the engine and radiator are hot Scalping hot fluid and steam may be blown out under pressure wh...

Page 47: ...E Place the scooter on its centerstand if 3 Remove Water pump fixing bold Drain the radiator and engine of its coolant 4 Install Gasket Water pump fixing bold Water pump fixing bold 7 Nm 0 7 m kg 5 Fill Cooling system radiator engine and hoses to specified level Recommended coolant High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Radiator capacity includ...

Page 48: ...3 Inspect Element Q Damage replace 4 Clean Air filter element Cleaning steps Wash the element gently but thoroughly in solvent Never use low flashpoint solvents such as gasoline to clean the element Such solvents may lead to fire or explosion Squeezeexcesssolventoutoftheelementand let dry Do not twist the element Apply foam air filter oil or SAE 10W30 typ SE oil on the element Sqeeze out the exces...

Page 49: ...INSP ADJ 3 20 EXHAUST PIPE ASSEMBLY AND ADJUSTMENT 29 Nm 2 9 m kg 7 Nm 0 7 m kg 4 5 Nm 0 45 m kg MUFFLER Q Exhaust pipe W Cylinder E Crankcase R Bolt T Bolt Y Gasket ...

Page 50: ...e system Thisairmustberemovedbybleeding the brake system before the scooter is operated Air in the system will reduce brake performance and can result in loss of control andanaccident Inspectandbleedthesystem if necessary BRAKE PADS INSPECTION 1 Measure Brake pads Out of specification Replace NOTE Replace the brake pad and spring as a set when replacing the brake pads Wear limit 2 0 mm 0 08 in WAR...

Page 51: ...e fluid DOT 3 or DOT 4 Thebrakefluidmaycorrodepaintedsurfaces or plastic parts Always clean up spilled fluid immediately Use only the designated quality fluid Otherwise therubbersealsmaydeteriorate causing leakage and poor brake performance Refill with the same type of fluid Mixing fluids may result in a harmful chemical reaction leading to poor brake perfor mance Be careful that water does no ent...

Page 52: ...id Air bleeding steps a Add proper brake fluid into the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect a clear plastic tube Q tightly to the caliper bleed screw d Placetheotherendofthetubeintoacontainer e Slowly apply the brake lever several times f Pull the lever as far as possible and hold it there g Loosen the bleed screw and pul...

Page 53: ...rider passenger accessories and luggage TIRE INSPECTION 1 Measure Air pressure Out of specification Adjust Proper loading of your scooter is important for the handling braking and other perfor mance and safety characteristics of your scooter Do not carry loosely packed items that can shift Securely pack your heaviest items close to the center of the scooter and distribute the weight evenly from si...

Page 54: ...ing the rim When installing the tire make sure the arrow points to the front 3 Measure Tire tread depth Out of specification Replace Minimum tire tread depth front and rear 0 8 mm 0 03 in Q Tread depth W Side wall E Wear indicator WHEEL INSPECTION 1 Inspect Wheels Damage Bends Replace Neverattemptevensmallrepairstothewheel CABLE INSPECTION AND LUBRICATION A damaged cable sheath will rapidly corrod...

Page 55: ...parts of the levers Recommended lubricant Engine oil SAE 10W30 CENTERSTAND LUBRICATION 1 Lubricate rotating parts Recommended lubricant Engine oil SAE 10W30 REAR SHOCK ABSORBER 1 Check Rear shock absorber Oil leaks Damage Replace 2 Check Tightening torque Upper bolt 31 Nm 3 1 m kg Lower bolt 18 Nm 1 8 m kg CABLE INSPECTION AND LUBRICATION FRONT FORK INSPECTION REAR SHOCK ABSORBER FRONT FORK INSPEC...

Page 56: ...ove 3 Inspect Battery Replace the battery if Battery voltage will not rise to a specific value or bubbles fail to rise during charging Sulfation of one or more cells occurs As indicated by the plates turning white or an accumulation of material in the bottom of the sell Specific gravity readings after a long slow charge indicate that one cell is lower than the rest Warpage or buckling of plates or...

Page 57: ...er for 15 minutes and get immediate medical attention Antidote INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive measures Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment ...

Page 58: ...witches to verify the operation of the electric circuit If the fuse immediately blows again check the electric circuit Never use a fuse with a rating higher than specified An improper fuse may cause damage to the electrical circuit and possibly cause a fire Fuse Main circuit 7 5 A HEADLIGHT BEAM ADJUSTMENT 1 Adjust Headlight beam Higher Turn out screw Q Lower Turn in screw W WARNING ...

Page 59: ... out the pins 3 Remove Gasket 4 Install Reverse the REMOVAL procedure HEADLIGHT BULB REPLACEMENT 1 Remove Front cover 2 Remove Headlight bulb socket Q Turn one quart of a turn 3 Remove Headlight bulb 4 Install Reverse the REMOVAL procedure HEADLIGHT LENS REPLACEMENT HEADLIGHT BULB REPLACEMENT ...

Page 60: ...4 ENG ...

Page 61: ...ND CRANKSHAFT 4 9 INSPECTION AND REPAIR 4 11 CYLINDER HEAD 4 11 CYLINDER AND PISTON 4 11 PISTON RINGS 4 13 PISTON PIN AND PISTON PIN BEARING 4 14 KICK STARTER 4 15 TRANSMISSION 4 15 AUTOLUBE PUMP 4 16 CRANKSHAFT 4 16 PRIMARY SHEAVE 4 16 SECONDARY SHEAVE 4 17 V BELT 4 18 STARTER CLUTCH AND GEARS 4 19 ENGINE ASSEMBLY AND ADJUSTMENT 4 20 CRANKSHAFT AND CRANKCASE 4 21 AUTOLUBE PUMP 4 23 CDI MAGNETO 4 ...

Page 62: ...RS AND FOOTREST BOARD HANDLEBAR COVER ENGINE REMOVAL CARBURETOR 1 Remove Air cleaner case assembly Q 2 Disconnect Carburetor cover Hoses Carburetor top Coolant hose on the cylinder head Thermostat on the cylinder head 3 Remove Carburetor 4 Remove Muffler assembly COOLING SYSTEM 1 Drain Coolant ...

Page 63: ...se to prevent oil spillage 2 Disconnect CDI unit lead pump side Spark plug cap Starter motor lead Temperature sender lead on the cylinder head ENGINE REMOVAL 5 Loosen Rear wheel fixing bolts 6 Remove Rear wheel 7 Loosen Rear wheel axle nut 8 Remove Rear caliper Rear wheel collar assembly ...

Page 64: ...AL 1 Place a suitable stand under the frame 2 Remove Rear shock absorber bolt lower Q Engine mounting bolt W 3 Remove Engine NOTE Lift up the frame and remove the engine 4 Place the frame on a suitable stand ENGINE REMOVAL ...

Page 65: ...e Cylinder head Cylinder head gasket NOTE Beforelooseningthecylinderheadnuts loosen the spark plug Loosen the cylinder head nuts crosswise 1 4 of a turn each before removing them 2 Remove Cylinder Cylinder gasket PISTON PIN AND PISTON 1 Remove Piston pin clip Q NOTE Before removing the piston pin clip cover the crankcase with a clean rag so that the clip cannot accidentally fall into the crankcase...

Page 66: ...ammer to drive out the piston pin KICKSTARTER 1 Remove Kick crank Transmission cover Q left 2 Remove Kick pinion gear Q NOTE To remove the kick pinion gear push down the kick crank 3 Unhook Kick return spring W 4 Remove Circlips Q Plate washer W Kick shaft E 307002 313001 317001 317002 CAUTION ...

Page 67: ...heel holder W Flywheel holder 90890 01235 ENGINE DISASSEMBLY 3 Remove Washer Q Ratchet W Special washer E Fixed primary sheave R Washer T V belt 4 Remove Spacer Q Primary sliding sheave W SECONDARY SHEAVE 1 Remove Nut Q secondary sheave NOTE Holdthesecondarysheavewithasheaveholder W to loosen the nut Sheave holder 90890 01701 319001 319002 319003 ...

Page 68: ...Attach Clutch spring holder Q NOTE Compressthesecondarysheaveusingtheclutch spring holder Q Clutch spring holder 90890 01337 6 Remove Clutch securing nut 7 Remove Clutch assembly Q Clutch spring W Spring seat E Guide pin R Secondary sliding sheave T Secondary fixed sheave Y STARTER SYSTEM 1 Remove Starter clutch assembly Q Plate W idle gear Idle gear E Starter wheel gear R Spacer T Bearing Y Washe...

Page 69: ...Remove Transmission case Q Gasket Dowel pins 2 Remove Main shaft Q Drive shaft W Plate washer E Conical spring washer R 3 Remove Oil seal Q Secondary sheave axle W CDI MAGNETO 1 Remove Nut Q rotor Plate washer NOTE Hold the rotor using a flywheel holder W to loosen the nut Flywheel holder 90890 01235 319032 321004 ...

Page 70: ...Pump drive gear W Pin E Circlip R CRANKCASE AND CRANKSHAFT 1 Remove Oil seal stopper Screws crankcase NOTE Loosen each screw one quart of a turn before beginning to remove them 2 Attach Crankcase separating tool Q Crankcase separating tool 90890 01135 NOTE Fully tighten the tool holding bolts Insure that thetoolbodyisparallelwiththecase Ifnecessary ENGINE DISASSEMBLY 313002 314001 314002 ...

Page 71: ...reinforced spots of the case Never tap on the gasket mating surfaces Work slowly and carefully Make sure the cases separate evenly If one end hangs up take the pressure off the push screw realign the cases and the tool and start again If the cases do not separate at all check for a remaining case screw or fitting Do not force 4 Attach Crankcase separating tool Q Crankcase separating tool 90890 011...

Page 72: ... Q and a thickness gauge W to the cylinder head Measure the warpage limit Warpage limit 0 02 mm 0 0078 in Ifthewarpageisoutofspecification re surface the cylinder head NOTE Rotate the head several times to avoid removing too much material from one side CYLINDER AND PISTON 1 Eliminate Carbon deposits Use a rounded scraper Q 2 Inspect Cylinder wall Wear Scratches Replace 3 Eliminate Carbon deposits ...

Page 73: ...t angles to the crankshaft Then calculate the average of the measurements Standard Wear limit Cylinder 39 99 40 01mm 40 10 mm Bore C 1 574 1 575 in 1 579 in Taper _ 0 05mm T 0 0019 in C Maximum D T Maximum D1 D3 or D5 Maximum D2 D4 or D6 2nd step Measure the piston skirt diameter P with a micrometer 5 mm 0 20 in from the piston bottom edge Piston Size Standard 39 957 39 977 mm 1 5731 1 5738 in If ...

Page 74: ...ston to cylinder clearance 0 029 0 042 mm 0 0011 0 0016 in Wear limit 0 1 mm 0 004 in INSPECTION AND REPAIR PISTON RINGS 1 Measure Side clearance Out of specification Replace piston and or rings Use a Feeler Gauge Q Standard Limit Top 0 03 0 05 mm 0 10 mm ring 0 0012 0 0020 in 0 004 in 2nd 0 03 0 05 mm 0 10 mm ring 0 0012 0 0020 in 0 004 in 2 Install Piston ring Into the cylinder Push the ring wit...

Page 75: ...en inspect lubrication system 2 Measure Outside diameter piston pin Out of specification Replace Outside diameter piston pin 9 996 10 000 mm 0 3935 0 3937 in 3 Measure Piston pin to piston clearance Out of specification Replace piston Piston pin to piston clearance Bore piston pin b Outside diameter piston pin a Piston pin to piston clearance 0 004 0 019 mm 0 0002 0 0008 in Limit 0 07 mm 0 028 in ...

Page 76: ...easure Clip tension kick pinion gear Q Out of specification Replace Use a spring balance W Standard tension 150 250 g 5 3 8 8 oz TRANSMISSION 1 Inspect Drive axle Q Main axle W Secondary sheave axle E Burrs Chips Roughness Wear Replace 2 Inspect Secondary sheave axle bearing Q Main axle bearing W Drive axle bearing E Spin the bearing inner race Excessive play Roughness Replace Pitting Damage Repla...

Page 77: ... gear teeth Q Autolube pump driven gear teeth W Pitting Wear Damage Replace INSPECTION AND REPAIR CRANKSHAFT 1 Measure Crankshaft width A Runout limit C Connecting rod big end side clearance D Use V blocks dial gauge and thickness gauge Crankshaft width A 37 90 37 95 mm 1 492 1 494 in Runout limit C 0 03 mm 0 0012 in Connecting rod big end side clearance D 0 2 0 5 mm 0 008 0 02 in PRIMARY SHEAVE 1...

Page 78: ... 15 0 mm 0 59 in Limit 14 5 mm 0 57 in SECONDARY SHEAVE 1 Inspect Secondary fixed sheave Q Secondary sliding sheave W Scratch Crack Damage Replace as a set Oil seal E Damage Replace INSPECTION AND REPAIR 2 Inspect Torque cam groove Q Guide pin W Wear Damage Replace as a set O rings E Damage Replace 3 Measure Clutch spring free length Out of specification Replace Clutch spring free length 121 7 mm ...

Page 79: ...Clutch housing inside diameter 107 0 mm 4 21 in Wear Limit 107 4 mm 4 22 in 6 Inspect Clutch shoes Glazed parts Sand with coarse sandpaper NOTE Afterusingthesandpaper cleanoffthepolished particles with a cloth Oil Scratches 7 Measure Clutch shoe thickness Out of specification Replace Clutch shoe thickness 2 0 mm 0 07 in Wear Limit 1 mm 0 03 in V BELT 1 Inspect V belt Crack Wear Replace NOTE Replac...

Page 80: ...mit 15 7 mm 0 62 in STARTER CLUTCH AND GEARS 1 Inspect Starter clutch Push the dowel pin in arrow direction Unsmooth operation Replace starter clutch assembly 2 Inspect Starter wheel gear teeth Q Idle gear teeth W Burrs Chips Roughness Wear Replace Bearing E starter wheel gear Pitting Damage Replace 317008 317009 312001 ...

Page 81: ... W Oil seal holder E Crankcase right R Dowel pin T Bearing Y Crankshaft right U Bearing I Crankshaft pin O Connecting rod P Crankshaft left Bearing Engine mount shaft q Crankcase left w Oil seal ENGINE ASSEMBLY AND ADJUSTMENT E A D C C A CRANKSHAFT A 37 90 37 95 mm C 0 03 mm D 0 2 0 5 mm E 0 004 0 017 mm ...

Page 82: ...n tool with the other Tighten the installation tool until the crankshaft bottoms against the bearing CRANKSHAFT AND CRANKCASE To protect the crankshaft against scratches and to facilitate the engine assembly and installation apply grease to oil seal lips and engine oil to bearings ENGINE ASSEMBLY AND ADJUSTMENT 3 Install Dowel pins Spacer 4 Apply HEATPROOF or Yamaha Bond No 1215 To the mating surf...

Page 83: ...crew oil seal stopper plate 8 Nm 0 8 m kg 5 Attach Crankshaft installation tool Q W E R Crankshaft installation tool Q 90890 01274 W 90890 01275 E 90890 01277 R 90890 01411 NOTE Hold the connecting rod at top dead center with one hand while tightening the nut of the installation tool with the other Tighten the installation tool until the crankcase halves close with one another 6 Install Right cran...

Page 84: ...assembly R Lighting coil T Charge coil Y Pick up coil U Stator assembly I Oil seal O Gasket P Oil hose Oil delivery hose Clip q Autolube pump w O ring e Circlip r Oil pump drive gear ENGINE ASSEMBLY AND ADJUSTMENT L S LS 37 5 Nm 3 75 m kg 8 5 Nm 0 85 m kg 4 Nm 0 4 m kg ...

Page 85: ...mp 4 Nm 0 4 m kg ENGINE ASSEMBLY AND ADJUSTMENT 4 Apply Lithium soap base grease to autolube pump gear Lithium soap base grease 15 cc 0 92 cu in CDI MAGNETO 1 Install Gasket 2 Apply Lithium soap base grease to oil seal Q 3 Pass the CDI magneto lead through the crankcase hole 4 Install Stator assembly Screw stator assembly 8 5 Nm 0 85 m kg 321001 T R T R 314005 314006 ...

Page 86: ...key is properly seated in the key way of the crankshaft Apply a light coating of lithium soap base grease to the tapered portion of the crankshaft end ENGINE ASSEMBLY AND ADJUSTMENT 6 Tighten Nut Q magneto rotor Use the flywheel holding tool W Flywheel holding tool 90890 01235 Nut Flywheel magneto 37 5 Nm 3 75 m kg 321002 321004 T R ...

Page 87: ... Oil seal R Drive axle T Bearing Y Main axle U Conical spring washer I Plain washer O Secondary sheave axle P Bearing Dowel pin Gasket q Transmission case cover w Circlips e Oil seal ENGINE ASSEMBLY AND ADJUSTMENT LT LS LS E E G G 10 Nm 1 0 m kg ...

Page 88: ...ondary sheave axle operation Unsmooth operation Repair 5 Apply 10W30 type SE Motor oil to main axle bearing and drive axle bearing 6 Install Drive axle Q Main axle W Conical spring washer E Plain washer R NOTE Applylithiumsoapbasegreaseontotheoilseal lips Always use a new gasket 7 Install Gasket Q Dowel pins W Transmission case cover E Screw case cover 10 Nm 1 0 m kg ENGINE ASSEMBLY AND ADJUSTMENT...

Page 89: ... 28 STARTER SYSTEM Q Collar W Starter wheel gear E Bearing R Starter clutch T Plate Y Shaft U Washer I Idle gear O O Ring P Starter motor ENGINE ASSEMBLY AND ADJUSTMENT LS E 13 Nm 1 3 m kg 8 Nm 0 8 m kg M LS ...

Page 90: ...ide oil to the shaft starter clutch ENGINE ASSEMBLY AND ADJUSTEMENT 2 Install Plain washer Q Idle gear W Plain washer E Plate R idle gear Screw idle gear plate 8 Nm 0 8 m kg NOTE Apply engine oil to the idle gear W 3 Install Starter motor Q Screw starter motor 13 Nm 1 3 m kg NOTE Apply lithium soap base grease to the O ring of the starter motor 317011 317012 317013 T R T R ...

Page 91: ...ide pin A Clutch shoe spring free lenght 29 9 mm B Clutch housing wear limit 107 4 mm C Clutch shoes wear limit 1 0 mm D V belt wear limit 15 7 mm E Weight outside diameter wear limit 14 5 mm Secondary fixed sheave q Conical washer w One way clutch e Special washer r Primary fixed sheave t Washer y Spacer u Primary sliding sheave i Clutch weights o Slider p Came Apply BEL RAY Assembly Lube ENGINE ...

Page 92: ... KICK STARTER Q Kick shaft W Return spring E Collar R Gasket T Transmission case Y Washer U Circlips I Kick crank O Kick clip P Rachet ENGINE ASSEMBLY AND ADJUSTMENT G 12 Nm 1 2 m kg 150 250 g 10 Nm 1 0 m kg LS ...

Page 93: ...il seal lips when installing the sheave ENGINE ASSEMBLY AND ADJUSTEMENT 3 Install Pin Q 4 Apply BEL RAY Assembly Lube to the torque cam grooves and O rings 5 Check Sliding sheave Unsmooth operation Repair Remove excessive grease 6 Install Clutch securing nut Use the clutch spring holder Q Clutch spring holder 90890 01337 7 Tighten Clutch securing nut Use sheave holder Q 41mm Sheave holder 90890 01...

Page 94: ... Nut secondary sheave 30 Nm 3 0 m kg PRIMARY SHEAVE 1 Clean Primary sliding sheave face Q Primary fixed sheave face W Collar E Weight R Primary sliding sheave cam surface T 2 Install Weight Q Cam W Slider E Collar R 3 Check Cam operation Unsmooth operation Repair 4 Install Primary sheave assembly Q Collar W ENGINE ASSEMBLY AND ADJUSTEMENT 319022 319023 319024 319025 T R ...

Page 95: ... the V belt is not stained with oil or grease 6 Install Shim Q Primary fixed sheave W Washer E One way clutch R Washer T Nut Y ENGINE ASSEMBLY AND ADJUSTEMENT 7 Tighten Nut primary sheave Nut primary sheave 33 Nm 3 3 m kg NOTE When tightening the nut primary sheave hold the magneto rotor using the flywheel holding tool Flywheel holding tool 90890 01235 8 Adjust V belt Tense the V belt by turning t...

Page 96: ... Bolt kick crank 10 Nm 1 0 m kg 9 Install Fan Screw fan 7 Nm 0 7 m kg ENGINE ASSEMBLY AND ADJUSTEMENT KICK STARTER 1 Install Return spring Q Kick shaft W Collar E Washer R Circlip T 2 Hook Return spring to the kick gear and boss 3 Install Kick pinion gear Q NOTE Install the clamp as shown 317016 319029 T R T R T R ...

Page 97: ...nt W Reed valve E Gasket R Cylinder head T Cylinder head gasket Y Cylinder U Cylinder gasket I Piston ring O Piston P Piston pin Piston pin clip Bearing A Piston clearance 0 029 0 042 mm B Piston rings end gap 0 15 0 35 mm C Piston rings side clearance 0 03 0 05 mm D Spark plug Type BR8HS Manufacturer NGK ENGINE ASSEMBLY AND ADJUSTMENT ...

Page 98: ...piston pin clip cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material into the crankcase The ends of the piston pin clip must not come together at the slot in the piston groove Always use new piston pin clip CYLINDER AND CYLINDER HEAD 1 Install Cylinder gasket new gasket 2 Check Piston rings NOTE Make sure the ring ends Q are properly fitted arou...

Page 99: ... to chapter 8 REAR WHEEL 4 Install Cylinder head gaskets new gaskets 5 Install Cylinder head Spark plug Thermostat NOTE Tightenthecylinderheadholdingnutsinstages and crisscross sequence The arrow on the cylinder head must point to the front Nut cylinder head 14 Nm 1 4 m kg Spark plug 20 Nm 2 0 m kg Thermostat 16 Nm 1 6 m kg 6 Install Center stand Axle Plate washer Clip Spring T R ...

Page 100: ...Rear shock absorber bolt lower 16 Nm 1 6 m kg 3 Install Carburetor top together with throttle valve Q Fuel hose W Vacuum hose E Brake cable plug cap 4 Connect Water hoses NOTE When installing the throttle valve into the carburetor align the groove of the throttle valve with the projection of the carburetor 5 Connect Starter motor CDI magneto lead Earth 7 Tighten Rear wheel axle nut Q NOTE When tig...

Page 101: ...efer to CHAPTER 3 TRANSMISSION OIL REPLACEMENT section 12 Fill Radiator Refer to CHAPTER 5 COOLING SYSTEM section 13 Adjust Brake lever free play Refer to CHAPTER 3 FRONT REAR BRAKE LEVER FREE PLAY ADJUSTMENT section Engine idle speed Throttle cable free play Refer to THROTTLE CABLE FREE PLAY ADJUSTMENT and ENGINE IDLE SPEED ADJUSTMENT CAUTION 8 Install Rear wheel 9 Tighten Rear wheel fixing bolt ...

Page 102: ...5 COOL ...

Page 103: ...CHAPTER 5 COOLING SYSTEM RADIATOR 5 1 REMOVAL 5 2 INSPECTION 5 2 INSTALLATION 5 2 WATER PUMP 5 3 REMOVAL 5 4 INSPECTION 5 4 INSTALLATION 5 4 THERMOSTATIC VALVE 5 5 REMOVAL 5 6 INSPECTION 5 6 INSTALLATION 5 6 ...

Page 104: ...g 햲 햳 햴 햵 햵 햶 햷 햸 햹 햺 햻 햽 LT LT 7 Nm 0 7 m kg RADIATOR Q Coolant tank cap W Coolant tank E Radiator R Hose T Water pump Y O Ring U Impeller O Ring I Cylinder Head O Cylinder P Thermostatic valve Thermo switch COOLING SYSTEM ...

Page 105: ... COOLANTREPLACEMENT 3 Remove Hose Radiator assembly INSPECTION 1 Inspect Radiator core Obstruction Blow out with compressed air through rear of the radiator Flattened fin Repair Remplace 2 Inspect Radiator hoses Cracks Damage Replace 3 Inspect Coolant tank Cracks Damage Replace INSTALLATION Reverse the REMOVAL procedure Refer to the chapter 2 CABLE ROUTING ...

Page 106: ...M 햲 햳 햴 햵 햶 햷 햸 햹 햺 햻 햽 햾 햿 7 Nm 0 7 m kg 6 5 Nm 0 65 m kg 6 5 Nm 0 65 m kg L S WATER PUMP Q Water pump housing W O Ring E Impeller R Seal T Cover Y Bearing U Spacer I Bearing O Rotor P Circlips Rubber Driving plug q Washer ...

Page 107: ...sit Clean 2 Inspect Rotor Used Damaged Replace INSTALLATION Reverse the REMOVAL procedure Note the following points NOTE It is no necessary to remove and inspect the water pump if the coolant is not unsually low or if it has no engine oil mixed in it Always replace the entire water pump as a set 1 Apply Lithium soap base grease to the seal 2 Install Water pump assembly Side cover Align the mark on...

Page 108: ...COOL 5 5 COOLING SYSTEM THERMOSTATIC VALVE Q Thermostatic switch W Cylinder head E Thermostatic valve R Cylinder 16 Nm 1 6 m kg 햳 햵 햴 햲 LT LT ...

Page 109: ... INSPECTION 1 Inspect Thermostatic valve Valve does not open Replace Inspection steps Suspend thermostatic valve in a vessel Place reliable thermometer in a water Observe thermometer while stirring water continually 햲 Thermostatic valve 햳 Vessel 햴 Thermometer 햵 Water INSTALLATION Reverse the REMOVAL procedure Thermostat valve screws 5Nm 0 5 m kg 햲 햳 햴 햵 햲 ...

Page 110: ...6 CARB ...

Page 111: ...6 CARBURETION CARBURETOR 6 1 DELL ORTO CARBURETOR 6 1 REMOVAL 6 2 DISASSEMBLY 6 2 INSPECTION 6 3 ASSEMBLY 6 5 INSTALLATION 6 6 FUEL COCK 6 7 INSPECTION 6 7 REED VALVE 6 7 REMOVAL 6 7 INSPECTION 6 8 INSTALLATION 6 9 ...

Page 112: ...ETOR Q Carburetor top W Gasket E Throttle valve spring R Needle set T Throttle valve Y Starter plunger spring U Starter plunger I Air screw O Throttle stop screw P Pilot jet Needle jet Needle valve q Main jet w Float pin e Float r Float chamber gasket t Float chamber y Drain screw ...

Page 113: ...n Chapter 3 Air filter case assembly 2 Drain Coolant Refertochapter3 COOLANTREPLACEMENT 3 Disconnect Fuel hose Oil hose Coolant hoses 4 Remove Carburetor top Throttle valve Starter plunger top Starter plunger Carburetor DISASSEMBLY 1 Remove Float chamber Q 2 Remove Float pin Q Float W Needle valve E 햲 322007 322026 햲 햳 햴 ...

Page 114: ...screw Air screw W Spring air screw 5 Remove Needle clip Q Jet needle W Throttle valve E INSPECTION 1 Check Carburetor body Q Dirt Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with compressed air 2 Inspect Main jet Q Main nozzle W Pilot jet E Starter jet Contamination Clean 햲 햳 햴 햵 322027 햲 햳 햴 322029 322012 햲 햳 햴 ...

Page 115: ...movement Unsmooth stickiness Replace Insert the throttle valve Q into the carburetor body W and check for smooth movement 6 Check Throttle stop screw Q Air screw W Needle E Starter plunger R Wear Damage Replace 7 Measure Float height Out of specification Inspect needle valve float and valve seat Float height 15 0 17 0 mm 0 59 0 67 in 햲 햳 322013 322014 햲 햲 햳 322015 322016 햲 햳 햴 햵 322017 a ...

Page 116: ...the float height is not within specification inspect the needle valve float and valve seat If one of these parts is worn replace the whole set If both parts are in good condition replace the float Check the float height again NOTE The float height is factory adjusted Never try to adjust it yourself ASSEMBLY Reversethe DISASSEMBLY procedures Note the following points Before reassembling the carbure...

Page 117: ...jection Q with projection W INSTALLATION To install the carburetor reverse the REM OVAL procedures Note the following points 1 Install Carburetor cover 2 Connect Coolant hose 3 Adjust Throttle cable free play Refer to the section THROTTLE CABLE FREE PLAY ADJUSTMENT in Chapter 3 4 Install Air filter case 햲 5 Fill Coolant Refer to the chapter 3 COOLANT REPLACEMENT 햲 햳 322019 햴 햲 햳 322020 햲 ...

Page 118: ...in the fuel cock If fuel flows out of the fuel hose when vacuum is applied and stops flowing when vacuum stops the fuel cock is in good condition If not clean or replace the vacuum hose the fuel hose and the fuel cock FUEL COCK FUEL FILTER CLEANING REED VALVE FUEL FILTER CLEANING The fuel filter is fitted inside the fuel tank It is accessible when the fuel hose between the fuel tank and the fuel c...

Page 119: ... good condition should be completely or at least nearly flush with the valve seat If in doubt apply suction to the carburetor side of the assembly Leakage should be minimal to moderate 2 Measure Valve stopper height Q Out of specification Replace valve stopper Valve stopper height 6 0 6 4 mm 0 23 0 25 in 3 Measure Reed valve clearance Q Out of specification Replace reed valve Reed valve clearance ...

Page 120: ...VAL procedure Note the following points 1 Install Gasket new 2 Tighten Reed valve assembly bolts Reed valve assembly bolts 9 Nm 0 9 m kg NOTE Tighten the screws crosswise in several steps to preventwarpageofthereadvalveassemblyand the carburetor joint REED VALVE T R ...

Page 121: ...7 CHAS ...

Page 122: ...BLY 7 8 INSPECTION AND REPAIR 7 9 CALIPER ASSEMBLY 7 10 MASTER CYLINDER ASSEMBLY 7 11 REAR WHEEL 7 13 REAR MASTER CYLINDER 7 14 REMOVAL 7 15 INSPECTION 7 15 ASSEMBLY 7 16 INSTALLATION 7 16 FRONT FORK 7 17 REMOVAL 7 18 DISASSEMBLY 7 19 INSPECTION 7 20 ASSEMBLY 7 20 INSTALLATION 7 21 STEERING HEAD AND HANDLEBAR 7 22 REMOVAL 7 23 INSPECTION 7 24 ASSEMBLY AND INSTALLATION 7 25 ...

Page 123: ...WHEEL Q Axle W Speedometer gear E Bearing R Collar T Front rim CHASSIS Y Tire U Valve I Collar O Spacer P Nut TIRE SIZE 130 60 13 RIM RUNOUT LIMIT VERTICAL 1 0 mm LATERAL 1 0 mm B A 35 Nm 3 5 m kg LS 햲 햳 햴 햵 햶 햷 햸 햴 햹 햺 햻 B L S B ...

Page 124: ...nspect Front axle runout Out of specification Replace Axle runout limit 0 25 mm 0 01 in Do not attempt to straighten a bent axle 2 Measure Wheel runout Out of specification Replace Rim runout limit Radial 1 0 mm 0 04 in Lateral 1 0 mm 0 01 in 3 Inspect Tire Wear Cracks Warpage Replace 4 Inspect Wheel bearings Bearings allow play in the wheel hub or wheel turns roughly Replace 5 Check Speedometer g...

Page 125: ... Q NOTE Be sure that the two projections at the gear unit mesh with the two slots on the wheel hub 3 Install Front wheel Q Front caliper W NOTE Be sure that the slot torque stopper of the gear unit housing is positioned correctly 4 Tighten Front wheel axle Front caliper mounting bolts Apply Loctite LOCTITE Front wheel axle 35 Nm 3 5 m kg Front caliper mounting bolts 23 Nm 2 3 m kg Make sure that t...

Page 126: ...r bleed screw NOTE Be sure to install the pads correctly U Pad spring I Pad retainer O Brake pads P O Ring Bolt Mounting bolt 햲 햳 햴 햵 햵 햶 햶 햷 햸 햹 햺 햻 햽 햾 햾 23 Nm 2 3 m kg 23 Nm 2 3 m kg 21 Nm 2 1 m kg 6 Nm 0 6 m kg LT LT A Front brake pad wear limit 2mm B Front disk wear limit 3 2 mm LT ...

Page 127: ...Q Master cylinder W Master cylinder piston ass y E Diaphragm R Master cylinder cap T Master cylinder bracket Y Copper washer 23 Nm 2 3 m kg 23 Nm 2 3 m kg 1 5 Nm 0 15 m kg 14 Nm 1 4 m kg 11 Nm 1 1 m kg 햲 햳 햴 햵 햶 햷 햷 햸 햹 햺 햻 햽 U Union bolt I Brake hose O Union bolt P Front brake switch Front brake lever ...

Page 128: ... clean brake fluid for cleaning Use care with brake fluid Never allow brake fluid to come in contact with the eyes Brake fluid can damage painted surfaces and plastic parts BRAKE PAD REPLACEMENT It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Remove Pin Q Axle W 2 Remove Pad spring E Brake pads R NOTE Replace the brake pads as a set when either one i...

Page 129: ...pply LOCTITE LOCTITE Wheel axle 35 Nm 3 5 m kg Mounting bolt 21 Nm 2 1 m kg CALIPER DISASSEMBLY NOTE Before disassembling the front brake caliper drain all brake fluid from the brake hose master cylinder brake caliper and tank 1 Remove Union bolt Q Copper washers W NOTE Place the open end of the drain hose into a container and pump out the remaining brake fluid carefully 2 Remove Caliper body Cali...

Page 130: ...ston does not cause injury as it is expelled from the cylinder Remove the piston seals MASTER CYLINDER DISASSEMBLY NOTE Before disassembling the front brake master cylinder drain all brake fluid from the brake hose master cylinder brake caliper and tank 1 Remove Upper handlebar cover 2 Remove Brake switch Brake lever Union bolt Copper washer 3 Remove Master cylinder holder Master cylinder 346004 W...

Page 131: ...place only when brakesaredisassembled Brake pads Piston seal Dust seal Brake hoses Brake fluid 1 Inspect Caliper piston Q Scratches Rust Wear Replace caliper assembly Caliper body W Wear Scratches Cracks Damage Replace caliper assembly Replacethepistonsealswheneverthecaliper is disassembled 2 Inspect Master cylinder Wear Scratches Replace the master cylinder assembly Master cylinder body Diaphragm...

Page 132: ... Out of specification Replace Minimum thickness 3 2 mm 0 125 in Bolt brake disc 23 Nm 2 3 m kg LOCTITE CALIPER ASSEMBLY All internal parts should be cleaned in new brake fluid only Internal parts should be lubricated with clean brake fluid when installed Recommended brake fluid DOT 3 or DOT 4 Replacethepistonsealswheneveracaliper is disassembled 1 Install Piston seals Q Caliper piston W Always use...

Page 133: ... brake hose to the caliper turn the brake pipe against the projection on the caliper Proper hose routing is essential to insure safe operation Refer to CABLE ROUTING Always use new copper washers MASTER CYLINDER ASSEMBLY All internal parts should be cleaned in new brake fluid only Internal parts should be lubricated with clean brake fluid when installed Recommended brake fluid DOT 3 or DOT 4 T R T...

Page 134: ... base grease to the brake lever pivot 3 Install Brake hose Copper washers Union bolts Brake switch Union bolt 23 Nm 2 3 m kg Proper hose routing is essential to insure safe operation Refer to CABLE ROUTING in CHAPTER 2 Always use new copper washers FRONT BRAKE 4 Check that the brake hose does not touch other parts throttle cable wire harness etc when the handlebar is turned to the left or right Re...

Page 135: ... plug W Nut E Washer R Bolt T Rear wheel tire Y Valve U Rear rim I Distance collar O Rear brake disk 23 Nm 2 3 m kg 120 Nm 12 0 m kg 47 Nm 4 7 m kg LT 햲 햳 햴 햵 햶 햷 햸 햹 햺 TIRE SIZE 140 60 13 RIM RUNOUT LIMIT VERTICAL 1 0 mm LATERAL 1 0 mm B A ...

Page 136: ... 햺 햻 햽 11 Nm 1 1 m kg REAR MASTER CYLINDER Q Master cylinder W Master cylinder piston ass y E Diaphragm R Master cylinder cap T Master cylinder bracket Y Copper washer U Union bolt I Brake hose O Union bolt P Rear brake switch Rear brake lever NOTE Drain completely before removing the master cylinder ...

Page 137: ...ire disassembly Do not disassemble components unless absolutely necessary If any hydraulic connection is disconnected the entire system must be disassembled drained cleaned and then properly filled and bled after reassembly Do not use solvents on internal brake component Solvents will cause seals to swell and distort Use only clean brake fluid for cleaning Use care with brake fluid Never allow bra...

Page 138: ...BRAKE 햲 INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Install Rear wheel 2 Tighten Rear wheel fixing bolts Rear wheel fixing bolt 47 Nm 4 7 m kg T R T R 3 Install Muffler Bolt exhaust pipe 7 Nm 0 7 m kg Bolt muffler 29 Nm 2 9 m kg 4 Adjust Rear brake lever free play Refer to the section REAR BRAKE LEVER FREE PLAY ADJUSTMENT in CHAPTER 3 ...

Page 139: ... Spring seat U O Ring I Spring O Piston P Spring Spacer Plunger q Dust boot w Retainer e Oil seal r Outer fork tube t Washer y Screw 23 Nm 2 3 m kg 30 Nm 3 0 m kg 22 5 Nm 22 5 m kg 햲 햳 햴 햵 햶 햷 햸 햹 햺 햻 햽 햾 햿 헀 헁 헂 헃 헄 A Oil capacity of each fork leg 75 cc B Oil grade ISO 6743 4 LHV 46 or SAE10 ...

Page 140: ...r Refer to section COVERS REMOVAL AND INSTALLATION in Chapter 3 5 Remove Steering head Refer to section STEERING HEAD AND HANDLEBAR in Chapter 7 6 Remove Nut Q Washer W Ring nut E NOTE Loosen the ring nut with the ring nut wrench R Ring nut wrench 9079Q 02218 Support the steering shaft to prevent it from falling 7 Remove Front fork assembly Bearing balls 8 Remove Circlip Q 9 Loosen Pinch bolt W 10...

Page 141: ...olt Q Copper washer NOTE To remove the drain bolt Q use the T handle W and the holder E T handle for front fork 90890 01326 Holder 90890 01294 3 Remove Inner fork tube Q Piston W Spring E Spring seat R 4 Remove Dust boot Q Retainer W Oil seal E 342014 햲 햳 햴 햵 햲 햳 햴 342010 햲 햳 햴 햵 342015 342016 햲 햳 햴 ...

Page 142: ... Q Used bends Damage Replace ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points NOTE When reassembling the front fork make sure you use following new parts Oil seals Circlips and retainers Makesurethatallcomponentsarecleanbefore reassembling 1 Install Oil seal Retainer Dust boot NOTE Before installing the oil seal apply lithium soap grease onto the oil seal lips 2 Install Inner f...

Page 143: ...1326 Holder 90890 01294 4 Fill Fork oil Fork oil type ISO 6743 4 LHV 46 or SAE 10 Amount per fork tube 75 cc 5 Install Spring Spring seat Circlip Rubber plug INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Install Left and right fork tube into the steering crown 2 Install Circlips Q 3 Install Pinch bolts W Pinch bolt 30 Nm 3 0 m kg 햲 햳 햴 342010 T R 햲 햳 ...

Page 144: ...CHAS 7 22 STEERING HEAD AND HANDLEBAR STEERING HEAD AND HANDLEBAR Q Handlebar W Nut E Bolt R Trottle grip T Throttle cable Y Starter cable Choke 60 Nm 6 0 m kg E 햲 햳 햴 햵 햶 햷 ...

Page 145: ...D INSTALLATI ON OF COVERS in Chapter 3 3 Drain Front and rear brakes system Refer to section FRONT BRAKE in Chapter 6 4 Remove Front and rear brakes master cylinder Refer to section FRONT BRAKE in Chapter 6 5 Remove Front and rear brakes calipers mounting bolts 6 Remove Front wheel Refer to section FRONT BRAKE in Chapter 6 7 Remove Throttle grip 8 Disconnect Ground wire All couplers Wire harness b...

Page 146: ...ng balls Pitting Damage Replace NOTE Always replace the bearing balls and the upper and lower bearing races as a set Bearing race replacement steps Drive out the bearing race from the steering tube by hitting on it in several places Remove the bearing race on the steering shaft with a hammer and a chisel Q as shown Drive in the new bearing races evenly by hitting on them in several places STEERING...

Page 147: ...nt steering shaft ASSEMBLY AND INSTALLATION Reversethe REMOVAL and DISASSEMBLY procedure Note the following points Proper cable and hose routing is essential to insure safe scooter operation Refer to section CABLE ROUTING in Chapter 3 1 Install Bearing balls 2 Apply Bearing grease onto upper and lower bearing balls 3 Install Steering shaft Bearing race upper Q Ring nut wrench 9079Q 02218 354009 35...

Page 148: ...ing shaft ring nut 22 5 Nm 2 25 m kg 5 Install Handlebar Q Bolt W new Nut E new NOTE Install the handlebar onto the steering shaft notch Install the wire harness the throttle cable the speedometer cable and the rear brake cable 6 Install Throttle grip complete Master cylinder Brake hose into the clip Before installing the handlebar wipe off any trace of oil from the inserted section of the shaft w...

Page 149: ...8 ELEC ...

Page 150: ...IAGRAM 8 5 IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM 8 6 TROUBLESHOOTING 8 7 CHARGING SYSTEM 8 13 CIRCUIT DIAGRAM 8 13 TROUBLESHOOTING 8 14 LIGHTING SYSTEM 8 16 CIRCUIT DIAGRAM 8 16 TROUBLESHOOTING 8 17 SIGNAL SYSTEM 8 21 WIRING DIAGRAM 8 21 TROUBLESHOOTING 8 22 COOLING SYSTEM 8 30 CIRCUIT DIAGRAM 8 30 TROUBLESHOOTING 8 31 ...

Page 151: ...ELEC 8 1 ELECTRICAL SYSTEM 햲 햳 햵 햴 햸 햶 햷 햹 ELECTRICAL COMPONENTS Q Wire harness W Fuel sender E Starter relay R Ignition coil T CDI unit Y Oil sender U Battery I Resistance ELECTRICAL SYSTEM ...

Page 152: ...ELEC 8 2 ELECTRICALSYSTEM 햲 햳 햴 햵 ELECTRICAL COMPONENTS Q Main switch W Flasher relay E Horn R Rectifier Regulator ...

Page 153: ...W Br W Dg N R B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B M O O W R B R B W L W G Y R R R R W Br Gy Gy Gy LR LR LR LR L Y R Y R Y R Y B R Y R G Br Br Br Br W Br Br Br Br G Y P G Y Ch Ch Dg Dg GB Y Q W E R T U I O P q s a e r r r B B LR LR L L t y u i o p A S F D G H J K Y w B B B B H C 40 70 110 F E CIRCUIT DIAGRAM ...

Page 154: ...tifier regulator Y Dimmer switch U Starter motor I Starter relay O Fuse P Battery Starter switch Main switch q Lighting switch w HIGH BEAM indicator e Head light r Meter light t Tail Stop light y Front stop switch u Rear stop switch i Flasher relay o Flasher switch p Flasher indicator Rear flasher light Left Front flasher light Left A Front flasher light Right S Rear flasher light Right D Horn F H...

Page 155: ... Y R R R R W Br Gy Gy Gy LR LR LR LR L Y R Y R Y R Y B R Y R G Br Br Br Br W Br Br Br Br G Y P G Y Ch Ch Dg Dg GB Y Q W E R T U I O P q s a e r r r B B LR LR L L t y u i o p A S F D G H J K Y w B B B B H C 40 70 110 F E IGNITION AND STARTING SYSTEM IGNITION AND STARTING SYSTEM Q Spark plug W Ignition coil E CDI magneto R CDI unit U Starter motor I Starter relay O Fuse P Battery Starter switch Main...

Page 156: ...g W Ignition coil R CDI unit U Starter Motor I Starter relay O Fuse P Battery Starter switch Main switch t Front brake switch y Rear brake switch Source coil Pickup coil Wave shape shaping circuit Condenser Diode SCR To oil level switch a b c d e f g R B BW LOCK ON CHECK OFF Br Gy B B O B B B B B B M L W G Y R B B B B B W R B W B R Br R 햲 햳 햵 햸 햹 햺 햻 햽 햾 헃 헄 c d d f e e e e a b g ...

Page 157: ...it or adjust the spark plug gap MEETS SPECIFICATION Ignition system in good condition IGNITION AND STARTING SYSTEM 1 Spark plug Check the spark plug type Check the condition of the spark plug Check the spark plug gap Refer to SPARK PLUG INSPECTION in Chapter 3 Standard spark plug BR8HS NGK Spark plug gap 0 5 0 7 mm 0 019 0 028 in CORRECT 2 Spark check Remove the spark plug cap Connect the ignition...

Page 158: ... ignition coil Ignition coil Pocket tester lead Orange Pocket tester lead Ground Check the primary coil resistance Primary coil resistance 0 32 0 48 Ω at 20 C 68 F Connect the pocket tester Ω x 1k to the ignition coil Pocket tester lead Ground Pocket tester lead Spark plug lead Check the secondary coil resistance Secondary coil resistance 5 68 8 52kΩ at 20 C 68 F MEETS SPECIFICATION DOES NOT MEET ...

Page 159: ...ness Connect the pocket tester Ω x 100 to the source coil Pocket tester lead Q Black Red Pocket tester lead W Ground Check the source coil resistance Source coil resistance 640 960 Ω at 20 C 68 F MEETS SPECIFICATION 7 Connections Check all connections in the ignition system Refer to WIRING DIAGRAM GOOD CONNECTIONS Replace the CDI unit IGNITION AND STARTING SYSTEM DOES NOT MEET SPECIFICATION Pickup...

Page 160: ... MOTOR DOES NOT WORK NOTE Remove the following parts before proceeding with the troubleshooting 1 Side covers left and right 2 Footrest boards 3 Front panel 4 Handlebar cover For accurate troubleshooting use the following special tools Pocket tester 90890 03112 IGNITIONAND STARTING SYSTEM WORKS NO CONTINUITY Defect Replace fuse DOES NOT MEET SPECIFICATION Clean battery terminals Charge or replace ...

Page 161: ... wire harness Check for continuity between Red Q and Brown W MEETS SPECIFICATION 6 Starter switch Disconnect the right handlebar switch cou pler from the wire harness Check for continuity between Blue White Q and Black W IGNITION AND STARTING SYSTEM DOES NOT WORK Starter relay defect Replace DOES NOT MEET SPECIFICATION Main switch defect Replace R B BW LOCK LOCK ON ON CHECK CHECK OFF OFF Br Gy BW ...

Page 162: ... MEETS SPECIFICATION 7 Connections Check all connections in the starter system Referto WIRINGDIAGRAM DOES NOT MEET SPECIFICATION Starter switch defect Replace right handle bar switch POOR CONNECTIONS Repair OFF ON LW B B LR YR LW YB L 햳 햲 ...

Page 163: ... B B B B B B B B B B B M O O W R B R B W L W G Y R R R R W Br Gy Gy Gy LR LR LR LR L Y R Y R Y R Y B R Y R G Br Br Br Br W Br Br Br Br G Y P G Y Ch Ch Dg Dg GB Y Q W E R T U I O P q s a e r r r B B LR LR L L t y u i o p A S F D G H J K Y w B B B B H C 40 70 110 F E CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM E CDI magneto T Rectifier regulator O Fuse P Battery ...

Page 164: ...e battery Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F 3 Charging voltage Connecttheenginetachometertothespark plug lead Connect the pocket tester DC20V to the battery terminals Pocket tester lead Battery terminal Pocket tester lead Battery terminal Start the engine and accelerate to about 5000 rpm Check the charging voltage Charging voltage 14 15 V at ...

Page 165: ...sistance Tester lead White Q Tester lead Ground W Charging coil resistance 0 48 0 72 Ω at 20 C 68 F MEETS SPECIFICATION 5 Connections Check all connections in the charging system Refer to WIRING DIAGRAM MEETS SPECIFICATION Replace the rectifier regulator CHARGING SYSTEM OUT OF SPECIFICATION Charging coil defect Replace POOR CONNECTIONS Repair Y R w W R B R CDI MAGNETO 햲 햳 ...

Page 166: ...R R R R W Br Gy Gy Gy LR LR LR LR L Y R Y R Y R Y B R Y R G Br Br Br Br W Br Br Br Br G Y P G Y Ch Ch Dg Dg GB Y Q W E R T U I O P q s a e r r r B B LR LR L L t y u i o p A S F D G H J K Y w B B B B H C 40 70 110 F E LIGHTINGSYSTEM CIRCUITDIAGRAM LIGHTINGSYSTEM E CDI magneto Y Dimmer switch q Lighting switch w HIGH BEAM indicator e Head light r Meter light t Tail Stop light L Position light Resist...

Page 167: ...itch to LO Check for continuity between Blue Q and Green Black W Set the switch to HI Check for continuity between Blue Q and Yellow E CONTINUITY 1 LIGHTS switch Disconnect the right handlebar switch cou pler from the wire harness Set the switch to PO auxiliary light Check for continuity between Yellow Red Q and Blue Red W Set the switch to ON Check for continuity between Yellow Red Q and Blue Red...

Page 168: ...ck the lighting coil resistance Tester lead Yellow Red Q Tester lead Ground W Lighting coil resistance 0 4 0 6 Ω at 20 C 68 F Lighting coil defect Replace POOR CONNECTIONS Repair Circuit is in good condition LIGHTINGSYSTEM MEETS SPECIFICATION 4 Connections Check all connections in the lighting system Referto WIRINGDIAGRAM OUT OF SPECIFICATION Y R w W R B R CDI MAGNETO 햲 햳 ...

Page 169: ...er lead Yellow W Pocket tester lead Black E Headlight indicator Pocket tester lead Yellow R Pocket tester lead Black T Set the main switch to ON Start the engine Switch from HI to LO and back Check the voltage 12V between the head light coupler leads NO CONTINUITY Replace bulb or socket 1 Bulb and socket Check the bulb and socket for continuity CONTINUITY OUT OF SPECIFICATION There is a defect in ...

Page 170: ...o the taillight coupler Pocket tester lead Blue Black Q Pocket tester lead Black W Set the main switch to ON Start the engine Check the voltage 12V between the head light coupler leads Blue Red and Black OUT OF SPECIFICATION There is a defect in the wire harness between the main switch and the meter light coupler Repair NO CONTINUITY Replace bulb or socket OUT OF SPECIFICATION There is a defect in...

Page 171: ... Br Br Br Br G Y P G Y Ch Ch Dg Dg GB Y Q W E R T U I O P q s a e r r r B B LR LR L L t y u i o p A S F D G H J K Y w B B B B H C 40 70 110 F E SIGNAL SYSTEM WIRING DIAGRAM SIGNAL SYSTEM O Fuse P Battery Main switch t Tail Stop light i Flasher relay o Flasher switch p Flasher indicator Rear flasher light Left Front flasher light Left A Front flasher light Right S Rear flasher light Right D Horn F ...

Page 172: ...rd Handlebar cover For accurate troubleshooting use the following special tools 1 Fuse Remove the fuse Connect the pocket tester Ω x 1 to the fuse Check the fuse for continuity Refer to FUSE INSPECTION in Chapter 3 CONTINUITY 3 Main switch Disconnect the main switch from the wire harness Turn the main switch to Check for continuity between Red Q and Gray E Turn the main switch to ON Check for cont...

Page 173: ...ions in the signal system Refer to WIRING DIAGRAM Check the condition of each circuit of the signal system Refer to the section SIGNAL SYSTEM CHECK SIGNAL SYSTEM CHECK 1 Horn does not sound 1 HORN switch Disconnect the handlebar switch left from the wire harness Check for continuity between Black Q and Pink W NO CONTINUITY Horn switch is defect Replace POOR CONNECTIONS Repair GOOD CONNECTIONS CONT...

Page 174: ...erminal Q with a jumper lead Set the main switch to ON 4 Voltage Connect the pocket tester DC20V to the Pink lead Pocket tester lead Pink Q Pocket tester lead Ground Turn the main switch to ON Press the HORN switch Check the voltage 12V between Pink and ground MEETS SPECIFICATION Horn is defect Replace DOES NOT MEET SPECIFICATION SIGNALSYSTEM HORN SOUNDS Horn in good condition Adjust the horn 햲 Br...

Page 175: ...ket Pocket tester lead Green Yellow Q Pocket tester lead Black W Turn the main switch to ON Pull the brake lever Check the voltage 12V between Green Yellow Q and Black W There is a defect in the wire harness between the main switch and the tail light socket Repair OUT OF SPECIFICATION CONTINUITY CONTINUITY Circuit is in good condition MEETS SPECIFICATION NO CONTINUITY Replace bulb or socket Brake ...

Page 176: ...ightside Brown WhiteQ andDarkgreenE 3 Voltage Connect the pocket tester DC20V to the flasher relay Pocket tester lead Brown Q Pocket tester lead Ground Turn the main switch to ON Checkthevoltage 12V betweenthe Brown lead and the ground SIGNALSYSTEM NO CONTINUITY NO CONTINUITY DOES NOT MEET SPECIFICATION Left handlebar switch is defect Replace CONTINUITY CONTINUITY MEETS SPECIFICATION Replace bulb ...

Page 177: ...cket tester lead Ground Right flasher bulb Pocket tester lead Dark green W Pocket tester lead Ground Turn the main switch to ON Set the TURN switch to L then to R Check the voltage 12V between Choco late and the ground then Dark green and the ground DOES NOT MEET SPECIFICATION DOES NOT MEET SPECIFICATION SIGNAL SYSTEM MEETS SPECIFICATION Flasher relay defect Replace Defect in the wire harness betw...

Page 178: ...minal Q Pocket tester lead Terminal Q Check the switch for continuity Float Good Bad position condition condition HIGH X O X O LOW O X X O O Continuity X No continuity NO CONTINUITY DOES NOT MEET SPECIFICATION Replace oil level switch is defect Replace bulb or socket 4 The OIL indicator light does not work 1 Bulb and socket Check the bulb and socket for continuity CONTINUITY MEETS SPECIFICATION 햲 ...

Page 179: ...n the signal system Refer to WIRING DIAGRAM Y Dg Dg Ch Ch Gy Gy Br Br YR YR Y Dg Dg Ch Ch Gy Gy 햲 5 The fuel meter does not work 1 Fuel sender unit Disconnect the fuel sender leads Connect the pocket tester Ω x 100 then Ω x 10 to the fuel sender Drain the fuel tank Measure the resistance Sender unit resistance empty tank 90 100 Ω at 20 C 68 F Fill the tank Measure the resistance Sender unit resist...

Page 180: ... N R B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B M O O W R B R B W L W G Y R R R R W Br Gy Gy Gy LR LR LR LR L Y R Y R Y R Y B R Y R G Br Br Br Br W Br Br Br Br G Y P G Y Ch Ch Dg Dg GB Y Q W E R T U I O P q s a e r r r B B LR LR L L t y u i o p A S F D G H J K Y w B B B B H C 40 70 110 F E O Fuse P Battery Main switch a Water temperature indicator s Water sender ...

Page 181: ...accurate troubleshooting use the following special tools 1 Fuse Remove the fuse Connect the pocket tester Ω x 1 to the fuse Check the fuse for continuity Refer to FUSE INSPECTION in Chapter 3 3 Main switch Disconnect the main switch from the wire harness Turn the main switch to Check for continuity between Red Q and Gray E Turn the main switch to ON Check for continuity between Red Q and Brown W D...

Page 182: ...nit resistance 25 C 504 614 Ω 100 C 37 8 41 6 Ω Handle the thermo unit with special care Never subject it to strong shock or allow it to be dropped Should it be dropped it must be replaced MEETS SPECIFICATION DOES NOT MEET SPECIFICATION WARNING 7 Wiring connection Check the entire cooling system for connec tions Refer to CIRCUIT DIAGRAM Replace the thermo unit Replace the meter unit complete Corre...

Page 183: ...9 TRBL SHTG ...

Page 184: ...N SYSTEM 9 3 FAULTY AUTOMATIC V BELT TYPE 9 3 SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING 9 3 CLUTCH OUT FAILURE 9 3 POOR STANDING START LOW CLIMBING ABILITY 9 4 POOR ACCELERATION POOR HIGH SPEED 9 4 OVER HEATING OR OVER COOLING 9 4 OVER HEATING 9 4 OVER COOLING 9 4 IMPROPER KICKING 9 5 SLIPPING 9 5 HARD KICKING 9 5 KICK CRANK NOT RETURNING 9 5 FAULTY BRAKE 9 5 POOR BRAKING EFFECT 9 5 INSTABLE...

Page 185: ...ilot jet foreign material Clogged pilot air passage Clogged fuel tank cap Sucked in air Fuel cock Deformed float Clogged fuel hose Groove worm needle valve Air cleaner Improperly sealed valve seat Clogged air filter Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Starter plunger malfunction Improperly adjusted pilot air screw ELECTRICAL SYSTEM Spark plug CDI unit system...

Page 186: ...rn damaged or seized cylinder Reed valve Piston and piston rings Deformed reed valve stopper Improperly installed piston ring Improperly seated reed valve Worn fatigued or broken piston ring Loose intake manifold Seized piston ring Broken gasket Seized or damaged piston Broken reed valve POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Clogged ...

Page 187: ...ug cap COMPRESSION SYSTEM Cylinder and cylinder head Crankcase and crankshaft Loose spark plug Improperly seated crankcase Loose cylinder head or cylinder Improperly sealed crankcase Broken cylinder head gasket damaged oil seal Broken cylinder gasket Seized crankshaft Worn damaged or seized cylinder Piston and piston rings Reed valve Improperly installed piston ring Deformed reed valve stopper Wor...

Page 188: ...lity high viscosity Low engine oil quality Brakes Dragging brake Cooling system Faulty thermostat Faulty thermo switch Incorrect coolant level low coolant level Faulty radiator Clogged Damage Impeller shaft gear malfunction bent dowel pin gear Damaged impeller shaft POOR STANDING START LOW CLIMBING ABILITY V belt Secondary sheave Worn damaged or slipped v belt Fatigued compression spring Primary s...

Page 189: ...properly seated crankshaft Damaged or seized crankshaft Cylinder piston and piston ring Damaged or seized crankshaft bearing Damaged or seized cylinder Damaged or seized piston Damaged or seized piston ring KICK CRANK NOT RETURNING Kick axle assembly Damaged kick return spring Kick return spring coming off Kick clip coming off Damaged kick return spring stopper FAULTY BRAKE POOR BRAKING EFFECT Dis...

Page 190: ...ngine bracket Broken spring Bent or damaged Bended front forks Tires Rear shock absorber Uneven tire pressures on both sides Fatigued spring Incorrect tire pressure Oil leakage Unevenly worn tires FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE MALFUNCTION Bent damaged or rusty inner tube Bent deformed or damaged inner tube Damaged or cracked outer tube Bent or deformed outer tube Da...

Page 191: ...NAL AND LIGHTING SYSTEM Headlight dark Flasher does not light Improper bulb Improperly grounded Too many electric accessories Discharged battery Hard charging broken charging coil Faulty flasher switch Incorrect connection Faulty flasher relay Improperly grounded Broken wireharness Poor contacts main or light switch Loosely connected coupler Bulb life expires Bulb burnt out Faulty fuse Bulb burnt ...

Page 192: ...B B B B B Br B Br B G RY LR F E Meter with tachometer Q W E R T Y U I O P q w e r t y u i o p A S D F G H J K L a s d f K L g a h s COLOR CODE B Black O Orange B R Black Red Br Y Brown Yellow L Blue Br Brown B W Black White Br W Brown White G Green Gy Grey L W Blue White W R White Red Y Yellow Ch Chocolate G Y Green Yellow R Y Red Yellow R Red Dg Dark green Y B Yellow Black P Pink W White Y R Yell...

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