Yamaha CYGNUS.X XC125 Service Manual Download Page 36

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Page 1: ...Model 1WA281972000 1F1281977000 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 2: ... Motor Co Ltd 1stEdition August1985 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 3: ... IMPORTANT INFORMATION This material is distinguished by the following notation NOTE A NOTE provides key information to make procedures easier or clearer _ A CAUTION indicates special procedures that must be followed to avoid damage to the scooter IltJ_F_lTi_ll_r_jm A WARNING indicates special procedures that must be followed to avoid injury to a scooter operator or person inspecting or repairing ...

Page 4: ...ify the _ specifications appearing in the text _ _ Filling fluid __ __ _ Lubricant _ Tightening _ Wear limit clearance _ _ _ _ Engine speed a V A __ Symbols _ to _ in the exploded diagram l _ _ _ _ indicate grade of lubricant and location of lubrication point _ _ _ Apply engine oil _ Apply gear oil _ _ _ Apply molybdenum disulfide oil Apply wheel bearing grease _ _ _ Apply lightweight lithium soap...

Page 5: ...ERAL iNFORMATiON _E_R j PERIODIC INSPECTIONS AND ADJUSTMENTS _Nsp t ___ ADJ ENGINE OVERHAUL ENG _ CHASSIS CHAS_ ELECTRICAL ELECr_ APPENDICES APpx _ J D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 6: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 7: ...NFORMATION 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 3 FOR TUNE UP 1 3 FOR ENGINE SERVICE 1 4 FOR CHASSIS SERVICE 1 7 FOR ELECTRICAL COMPONENTS 1 7 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 8: ... used to register your scooter with the licensing authority in your state ENGINE SERIAL NUMBER The engine serial number _ is stamped into the elevated part of the left rear section of the transmission case NOTF The first three digits of these numbers are for model identifications the remaining digits are the unit production number i Starting Serial Number 1WA 000101 NOTE Designs and specifications...

Page 9: ... PINS 1 All lock washers plates _ and cotter pins must be replaced when they are removed __ Lock tab s should be bent along the bolt _ or nut flat s after the bolt or nut has been properly tightened BEARINGS AND OIL SEALS 1 Install the bearing s _ and oil seal s _ with their manufacturer s marks or numbers facing ou_tward In other words the stamped letters must be on the sideexposed to view When i...

Page 10: ...onal view _ Shaft SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune up and assembly Using the correct special tool will help pre vent damage caused by the use of improper tools or improvised techniques FOR TUNE UP 1 Inductive Tachometer P N YU 8036 This tool is needed for detecting engine rpm 2 Timing Light P N YU 08037 This tool is necessary for checking timing 3...

Page 11: ...he valveclearance FOR ENGINE SERVICE 1 Rotor Holder P N YU 01235 This tool is used to hold the flywheel magneto when removing or installing the flywheel magneto securing nut 2 Flywheel Magneto Puller P N YM 01189 This tool is usedto removethe flywheel 3 Primary Sheave Holder P N YU 01701 This tool is usedwhen holding the clutch hub 1 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 12: ...ese tools are used to remove and install the valve assemblies 6 Valve Seat Cutter _r __ _ _ P N YM 91043 _ 5 mm Pilot P N YM 91043 50 _ T J JL J_ _ Thesetools areusedto resurfacethe valveseat o 7 Valve Guide Remover P N YM 4097 This tool is neededto installthe valveguidesproperly 8 Valve Guide Installer P N YM 4098 This tool is neededto install the valveguidesproperly 1 5 D o w n l o a d e d f r o...

Page 13: ...s tool is used to disassembly and assembly the secondarysheave 11 Cylinder Gauge P N 90890 03016 This tool is usedto measures cylinder bore 12 Slide Hammer Set M6 P N YU 01083 These tools are used to remove and install the rocker arm shafts 13 Dial Gauge P N YU 03097 1 6 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 14: ...d tighten the steering ring nut FOR ELECTRICAL COMPONENTS 1 Pocket Tester P N YU 03112 This instrument is invaluable for electrical system inspection and adjustment 2 Electro Tester P N YU 33260 This instrument is necessary for ignition system in spection 1 7 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 15: ...CTION 2 8 ENGINE OIL LEVEL INSPECTION 2 8 ENGINE OIL REPLACEMENT 2 8 FINAL GEAR OIL SUB TRANSMISSION OIL REPLACEMENT 2 9 AIR FILTER AND CRANKCASE FILTER CLEANING 2 10 V BELT INSPECTION 2 11 COMPRESSION PRESSURE MEASUREMENT 2 11 SPARK PLUG INSPECTION 2 12 CHASSIS 2 13 BRAKE LINING INSPECTION 2 13 FRONT BRAKE ADJUSTMENT 2 13 REAR BRAKE ADJUSTMENT 2 14 TIRES AND CAST WHEELS CHECK 2 14 STEERING HEAD I...

Page 16: ...fore draining o o o Check oil level oil leakage REPLACE o o Final gear oil Replace every 24 000 16 000 or 24 months Brake Check operation Adjust if necessary o Clutch Check operation Adjust if necessary o Front brake tensionbar pivots and bottom Apply until new greaseshows o o link pivots li Front axle Apply grease gnuy o Wheels Check balance damage runout o o Repair if necessary Check bearings as...

Page 17: ...the cover s make sure that all hooks are free After installing the cover s make sure that all hooks are securely fitted SIDE COVER Right Left 1 Remove o Screws Side cover _ 2 Unhook o Hooks _ 3 Remove Side cover _ I __ FRONT COVER 1 Open the seat 2 Remove e Screws Front cover _ o Bolts Front cover 3 Close the seat 4 Remove Front cover _ 2 2 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n...

Page 18: ...move _J_ ___ Screws Leg shield Bolts Footrest board Front leg shield Rear LegShield 1 Remove Footrest board Front legshield Screws Rear legshield Nut Rear legshield Main switchcap _ Turn counterclockwiseand pull off 2 Loosen Rearbrake adjuster 3 Apply the rear brake fully move the leg _ shieldthen removethe leg shield 4 Remove e Rearleg shield 2 3 D o w n l o a d e d f r o m w w w S c o o t e r T ...

Page 19: ...NCE ADJUSTMENT NOTE Valve clearance must be measured when the engine is cool to the touch 1 Remove Side cover Right Front cover Valve covers _ Intake Exhaust e Spark plug Timing check window plug _ _ 2 Measure Valve clearance _i _ _ i _i_ By the following measurement steps _ Valve clearance measurement steps o Align the T mark _ on the flywheel with the stationary pointer _ on the crankcase When t...

Page 20: ...r clockwise with the Valve Adjusting Tool _ YM 08035 until proper clearance is attained Intake Valve Cold 0 08 0 12 mrn 0 003 0 005 in Exhaust Valve Cold 0 10 0 14 mm 0 004 _ 0 006 in Hold the adjuster to prevent it from moving and thoroughly tighten the lock nut Valve Clearance Adjusting Locknut 7 Nm 0 7 m kg 5 1 ft lb Measure the valve clearance If the clearance is incorrect repeat above steps u...

Page 21: ...ee play If the free play is incorrect repeat above stepsuntil the properfree play isobtained NOTE After adjusting turn the handlebarsto right and left and make surethat the engine idling doesnot run faster i iDLE SPEED ADJUSTMENT 1 Remove Side covers Right Left 2 Start the engine and warm it up before settingidle speed NOTE A warn engine is difined asone which hadbeen operated for about 3 minutes ...

Page 22: ...onnect the timing light YU 08037 _ to spark plug lead Warm up the engine and allow it to idle at the specified engine speed Use the tachometer Engine Speed 1 400 r rain Visually check the stationary pointer _ on the crankcase to verify it is within the required firing range indicated on the flywheel Incorrect firing range Check flywheel and or pickup assembly tightness damage Refer to CHAPTER 6 EL...

Page 23: ...ve the oil level through the level window D located at the lower part of left side crankcase cover If the level is lower add the oil up to the proper level NOTE Position scooter straight up when checking oil level a slight tilt to the side can produce false readings Wait a few minutes until level settles before checking Oil level should be between maximum _ and minimum _ marks ENGINE OIL REPLACEME...

Page 24: ...C 10 C 15 C NOTE Recommended engine oil classification API Service SE SF type or equivalent e g SF SE SF SE CC SF SE SD etc Do not allow foreign material to enter the crankcase 7 Observe Oil level 8 Install Oil filler cap FINAL GEAR OIL SUB TRANSMISSION OIL REPLACEMENT 1 Place the scooter on a level place 2 Warm up engine for several minutes and stop it 3 Place an oil pan under the final gear case...

Page 25: ...Crankcase filter element __ _ __ I_ _ _ 2 Clean Airfilter element _ _ __1 Crankcase filter element Wash the filter gently but thoroughly in solvent Squeeze the solvent out of the filter and allow the filter to dry Pouraa o rc stroke engine oil on the filter and work it thoroughly into the foam Wrap it with a clean cloth and squeeze it lightly NOTE Don t squeeze the filter in the manner as shown Re...

Page 26: ...n _ Adjust 3 Warm up the engine for a few minutes and stop it 4 Remove Spark plug 5 Measure Compression pressure By the following measurement steps Compression pressure measurement steps Install the Compression Gauge YU 33223 Q using an adapter Crank over the engine with the electric starter be sure the battery is fully charged with the throttle wide open until the com pression reading on the gaug...

Page 27: ...s Defective ring s valves Same as without oil cylinder head gasket or piston is possible Above maximum Inspect cylinder head valve surfaces or piston level crown for carbon deposits SPARK PLUG INSPECTION 1 Inspect Electrode _ Wear Damage _ Replace Insulator color _ _ Normal condition is a medium to light tan color _ Distinctly different color Check the engine condition _ Spark plug gap 2 Clean Spa...

Page 28: ... spark plug a good estimate of the correct torque is 1 4 to 1 2 turns part finger tight Have the spark plug torqued to the correct value as soon as possible with a torque wrench _ _ CHASSIS e _ _ BRAKE LINING INSPECTION __ 1 Activate the brake lever or brake pedal 2 Inspect Wear indicator _ _ _ __ _ _ _ i _ _ k _ Indicator reaches the wear limit line _ _ _ _ _ _ _ _ Replace brake shoes FRONT REAR ...

Page 29: ...brake light TIRES AND CAST WHEELS CHECK This scooter is equipped with cast wheels designed for tubelesstires only Tubeless tires are installed as standard equip ments 1 Measure Air pressure Usean air gauge Out of specification _ Adjust pressure Maximum load 168 kg 370 Ib Cold tire pressure Front Rear 147 kPa 196 kPa Up to 75 kg 165 Ib load 1 5 kg cm 2 2 0 kg cm 2 21 psi 28 psi 147 kPa 294 kPa 75 k...

Page 30: ...model does not exceed the maximum load of the scooter Operation of an overloaded scooter could cause tire damage an accident or even injury q 2 Inspect _ _ ___ Tire surface ____ Wear Damage Cracks Road hazards __ _ __ Replace _ _ c_ __ Aluminum wheels I___ Damage Bends _ Replace i Never attempt even small repairs to the wheel Install the rear wheel air valve on the right of the scooter on the muff...

Page 31: ...33975 3 Tighten Ring Nuts Lower and upper By the following tightening steps R ing nuts tightening steps e Tighten the ring nut lower _ using the Ring Nut Wrench YU 33975 NOTE Set the Torque Wrench to the Ring Nut Wrench so that they form a right angle Do not over tightening Ring Nut Lower 30 Nm 3 0 m kg 22 ft Ib Loosen the ring nut _ 1 4 turn Hold the ring nut lower and tighten the ring nut upper ...

Page 32: ...eck e Fluid level Incorrect Refill Fluid level should be between upper _ and lower _ level marks Refill with distilled water only tap water con A I tains minerals harmful to a battery ___ _ _ _ _ _ 2 Connect e Breather hose _ _ _ _ Be sure the hose is properly attached and __ routed 3 Inspect Breather hose Obstruction _ Remove Damage Replace HOWTO LAYOUT BATTERY BREATHER HOSE _ Battery _ Clamp Alw...

Page 33: ...ediate medical attention Antidote INTERNAL Drink large quantities of water or milk follow with milk of magnesia beaten egg or vege table oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these pre ventive measures Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment l...

Page 34: ...ls clean it with a cloth moistened thoroughly with alcohol or lacquer thinner 4 Connect Headlight lead connnecters 5 Install Handlebar cover Front HEADLIGHT BEAM ADJUSTMENT 1 Adjust Headlight beam Horizontally Horizontal Adjustment Turn adjusting screw _ _ _ i_ i_ iiiii _iz_ il _ _ _ _ Right clockwise _ Left Turn adjusting screw counterclockwise 2 Adjust Headlight beam Vertically Vertical Adjustme...

Page 35: ...the circuit Install a new fuse of proper amperage _ _ Turn on switches to verify operation of electrical device If fuse blows immediately again check circuit in question Do not use fuses of higher amperage rating than recommended Extensive electrical system damage and fire could result from substitution of a fuse of improper amperage 2 20 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e...

Page 36: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 37: ...D SECONDARY SHEAVE 3 4 STARTER SYSTEM 3 5 _ CDI MAGNETO 3 6 _ IlPJ OIL PUMP 3 6 TRANSMISSION 3 6 CRANKCASE AND CRANKSHAFT 3 7 INSPECTION AND REPAIR 3 8 CYLINDER HEAD 3 8 VALVE VALVE GUIDE AND VALVE SEAT 3 9 ROCKER ARM AND ROCKER ARM SHAFTS 3 16 CAMSHAFT 3 17 CAM CHAIN 3 17 CYLINDER 3 18 PISTON PISTON RING AND PISTON PIN 3 19 STARTER DRIVES 3 21 OIL PUMP 3 22 OIL GALLERY PIPE 3 22 CRANKSHAFT AND CO...

Page 38: ... TRANSMISSION 3 30 OIL PUMP GEARS 3 31 CDI MAGNETO 3 31 STARTER SYSTEM 3 32 PRIMARY SHEAVE SECONDARY SHEAVE V BELT 3 33 CRANKCASE COVER 3 36 CYLINDER AND PISTON 3 37 CYLINDER HEAD 3 40 ENGINE MOUNTING 3 43 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 39: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 40: ...g equipment _11_ Referto CHAPTER 1 SPECIALTOOL NOTE When disassembling the engine keep mated _F k_ _ parts together This includes gears cylinders I_istons and other parts that have been mated _____ _j through normal wear Mated parts must be __ reused as an assembly or replaced 3 During the engine disassembly clean all parts and place them in trays in the order of disassembly This will speed up ass...

Page 41: ...e Bridge plate _ Cover _ 2 Disconnect Battery negative lead _ i D AIR FILTER ELEMENT CASE AND THROT TLE CABLE 1 Remove e Air filter element case _ e Throttle cable _ CARBURETOR HOSES _ _ 1 Remove o Fuel hose _ Vacuum hose _ Fuel cock _ REAR WHEEL 1 Remove Cotter pin 2 Loosen Axle nut _ by applying the rear brake _ 3 Remove Brake cable support Brake cable 3 2 D o w n l o a d e d f r o m w w w S c o...

Page 42: ...2 Place the frame on a suitable stand COMPON ENTS 1 Remove i Rear fender _ e Shock absorber Left _ o Carburetor _ o Ventilation hose _ Air shroud 1 _ Air shroud 2 _ 2 Remove Muffler _ o Air shroud 3 _ Shock absorber Right _ 3 Loosen o Spark plug ENGINE DISASSEMBLY CAM CHAIN TENSIONER AND CYLINDER HEAD 1 Loosen Bolt Cam chain tensioner _ 2 Remove Cam chain tensioner assembly _ Cam sprocket cover _ ...

Page 43: ... loose Cyinder head CYLINDER AND PISTON _ _ 1 Remove e Cylinder head gasket _ Cam chain guide Front Cylinder _i _ _ _ i i _ _ vl 2 Remove Piston pin clips NOTE Before removing the piston pin clip cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase Piston pin _ Piston _ PRIMARY AND SECONDARY SHEAVE 1 Remove Screws Crankcase cover Crankcase cover 1 _ 3 ...

Page 44: ...Remove _ _ _ Nut Secondary sheave Use the Rotor Holder YU 01235 _ Clutch housing _ Secondary sheave assembly _ STARTE R SYSTEM 1 Remove Crankcase cover _ 2 Remove Starter idle gear _ o Oil gallery pipe _ pull out o Starter driven gear _ together with starter clutch _ 3 Remove o Starter motor assembly _ 3 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 45: ... Washer 2 Remove Magneto rotor _ Use the Flywheel Magneto Puller YM _ _i 01189 3 Remove Generator assembly _ Woodruff key _ OIL PUMP 1 Remove Oil pump idler gear _ TRANSMISSION 1 Remove Nut Rear wheel axle _ Rear arm _ _ Rear wheel _ Main stand assembly 3 6 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 46: ...ve Bolts Crankcase _ _ 2 Remove o Crankcase Right _ Usea soft hammer 3 Remove Oil pump driven gearshaft assembly _ Crank shaft Balancer _ Engine mount spacer _ Cam chain 4 Remove o Oil pump assembly _ i _ Cam chain casecover Cam chain guide Rear _ i 3 7 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 47: ...ter YM 4108 _ o Valve Spring Compressor YM 04019 ___ 4 Remove Valve retainers _ Use Magneto or Tweezers _ Valve spring seat Upper _ I _______ __ Valve spring Valve spring seat Lower _ Oil seal o Valve NOTE Deburr _ any deformed valve stem end Use an oil stone to smooth the stem end 5 Eliminate Carbon deposit _ Use rouded scraper NOTE Do not a sharp instrument and avoid damaging or scratching Spark...

Page 48: ...0 012 in Exhaust 0 7 mm 0 027 in Beveled _ 0 25 mm 0 010 in Minimum Length Service limit _ 4 5 mm 0 177 in 2 Measure Valve stem clearance Cold Use Micrometer _ and Bore Gauge _ _____ I ValveValveOUt of specification Replace either IStemand orClearanceguide rB _L_ _ Valve Stem Clearance Maximum _ _ 0 010 0 037 mm 0 08 mm Intake 0 0004 0 0015 in 0 0031 in 0 025 0 052 mm 0 10 mm Exhaust 0 0010 0 0020...

Page 49: ...y e Mechanics bluing dye Dykem _ to valve face 3 Insert Valves to cylinder head Lap the valve to the seat by rotating the lapping stick _ in both directions 4 Remove Valves 5 Measure Valve face Valve seat contact surface Wherever valve seat and valve face made contact bluing will have been removed Out of specification Pitting Variation of valve seat width Cut valve seat further Seat Width 1 Standa...

Page 50: ...tter Set Desiredresult l _ i i_ i _ i _ 30 cutter Use To centar the seat or i either 45 cutter to reduceitswidth 60 cutter Valve face indicates that valve seat is centered on valve face but is too wide I I _ see diagram i ValveSeatCutter Set Desiredresult _ Use 30 cutter To reduce valve seat _ width to 1 0 mm lightly 60 cutter 0 039 in Valve seat is in the middle of the valve face but too narrow S...

Page 51: ...eve its width of 45 cutter 1 0 mm 0 039 in Valve Valve Seat Assembly Lapping _ _ 1 Apply e Coarse lapping compound _ Small amount _ to valve face o Molybdenum disulfide oil _ to valve stem Be sure no compound enters into the gap between the valve stem and guide 2 Insert Valves to cylinder head 3 Rotate Valve Turn until valve and valve seat are evenly polished then clean off all compound NOTE To ob...

Page 52: ...e below 10 Clean Intake Exhaust port and valve assembly spray solvent with compre ssed air NOTE After the lapping has been completed and the valve assemblies have been reinstalled the valve seal should be tested Pour solvent _ into intake and exhaust ports There should be no leakage past the seat _ 11 Check Valve seal Leakage past valve seat _ Relap q See procedure below Relapping steps Disassembl...

Page 53: ...tain correct interference fit 1 Remove Valve guide Use the Valve Guide Remover YM _ll_J 04097 _ Valve Guide Installation 1 Install O ring New _ _ o Valve guide Oversize Use the Valve Guide Remover YM 04097 _ with Valve Guide Installer YM 04098 NOTE After installing valve guide e Use 5 mm Valve Guide Reamer 90890 04099 _ to obtain proper valve guide _ valve stem clearance Valve guide reamer must be...

Page 54: ...re o Spring force Installed length Out of specification Replace V__ Force _ _ _ _ 9 8 kg 21 5 Ib _ 24 9 mm 0 98 in Valve Installation _ _ 1 Lubricate LJ _ Valve stem e Oil seal _l_ _ High Quality Molybdenum Disulfide Motor Oil or Molybdenum Disulfide Grease 2 Install Valve _ l_ _ Oil seal _ _ Valve spring seat Lower _ Valve spring _ Valve spring seat Upper _ Valve retainers _ C 3 15 D o w n l o a ...

Page 55: ...Inspect Rocker arm shaft Groove can be felt bearing surface Blue _ _ discoloration rocker arm shaft _ Re place then inspect lubrication system 3 Measure Rocker arm inside diameter Use a Bore Gage _ Out of specification _ Replace Rocker Arm Inside Diameter 10 00 10 015 mm 0 3937 0 3943 in 4 Measure Rocker arm shaft outside diameter Use a Micrometer _ Out of specification _ Replace _rm Shaft Outside...

Page 56: ...T 1 Inspect Cam lobes Pitting Scratches Blue discoloration _ Replace 2 Measure o Cam lobes Use a Micrometer Out of specification _ Replace B _ Cam Lobe Cam Lobe A B Intake 26 169 _ 26 269 mm 21 061 _ 21 161 mm 1 030 _ 1 034 in 0 829 _ 0 833 in Exhaust 26 169 _ 26 269 mm 21 061 _ 21 161 mm 1 030 _ 1 034 in 0 829 _ 0 833 in CAM CHAIN 1 Inspect Cam chain Chain stretch Cracks Damaged Re place 3 17 D o...

Page 57: ... Endplug _ Tensionerbody _ Spring _ Tensionerrod _ O ring CYLINDER 1 Inspect Cylinder wall _ ___ Wear Scratches Rebore or replace 2 Measure __ Cylinderbere C Use a Cylinder Bore Gauge _ Measure the cylinder bore C horizon tally and laterally at 19 0 mm 0 75 in from the cylinder top Then find the coverage of the measure ii o ents X Y Out of specificaiton Rebore Standard Wear limit Cylinder 49 00 49...

Page 58: ... 2 49 50 1 949 in mm Oversize 4 50 00 mm 1 969 in 3 Measure Piston clearance Out of specification Rebore cylinder or replace piston _ 0 0016 in nee C P 1 040 mm C Cylinder bore P Piston outside diameter O _ _ Piston Ring _____ _ 1 Measure Side clearance Use a Feeler Gauge _ Out of specification Replace piston j and or rings 0 03 0 07 rnm _ Side Top 0 0012 0 0028 in _ _ G_ _ Clearance 2nd 0 02 _ 0 ...

Page 59: ...set Standard Limit 0 15 0 30 mm 0 40 mm Top Ring 0 006 0 012 in 0 16 in 0 15 _ 0 30 mm 0 40 mm 2rid Ring 0 006 0 012 in 0 16 in Oil Control 0 30 0 90 mm 0 40 mm Rails 0 012 0 035 in 0 16 in Oversize Piston Rings The oversize top and middle ring sizes are stamped on top of the ring Oversize 2 0 50 mm 0 0197 in Oversize 4 1 00 mm 0 0394 in 3 20 D o w n l o a d e d f r o m w w w S c o o t e r T i m e...

Page 60: ...ce in piston _ _____ Free play Replace piston pin and or piston 7 _ _ _ STARTER DRIVES _ _ Electric Starter Clutch o Roller operation i _ Spring cap _ operation Spring _ operation _i i_ii Unsmooth operation _ Replace one way _ clutch 2 Apply e Molybdenum disulfide oil with the hole in which the spring is installed Starter Gear 1 Inspect e Idle gear teeth _ Contacting surfaces with the clutch _ Pit...

Page 61: ...0 0024 0 0039 in Limit 0 15 mm 0 006 in 2 Measure o Outer rotor _ Inner rotor _ clearance Use a Feeler Gauge Out of specification _ Replace oil pump assembly Tip Clearance B 0 15 mm 0 0059 in Limit 0 2 mm 0 008 in OIL GALLERY PIPE 1 Inspect O rings CD _ Wear Cracks Damage _ Replace Gallery pipe C_ Cracks Damage Clog Replace 3 22 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 62: ... 0 0177 in _ Limit 0 5 mm 0 0197 in Small end free play Out of specification Replace connect ing rod Small End Free Play Standard 0 8 _ 1 0 mm 0 031 0 039 in Limit 1 5 mm 0 059 in Crank width _ Out of specification _ Replace crank shaft _ Crank Width 44 95 45 00 mm 1 770 1 772 in Crankshaft Bearings 1 Inspect Bearing races Pitting Rust Scoring _ Replace _ z NOTE _ Clean and dry bearing before chec...

Page 63: ...ring _ Main axle bearing _ Pitting Damage Replace PRIMARY SHEAVE 1 Inspect Primary sliding sheave _ e Primary fixed sheave _ e Collar _ Wear Cracks Scratches Damage Re place 2 Position e Collar _ into primary sliding sheave 3 Check e Freely Free play Replace 4 Remove i _ Primary sheave cap _ _ Cam _ Slider bushings _ _ i Weights _ 3 24 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 64: ...ave assembly Replace primary SECONDARY SHEAVE 1 Attach e Primary Sheave Holder YU 01701 _ Nut Wrench YM 04045A _ 2 Loosen Nut Clutch Do not remove the clutch securing nut yet 3 Using a proper bolt _ washers nuts _ and spacers _ with Crankcase Separator YU 01135 _ compress the clutch spring 4 Remove Nut Clutch _ 5 Remove Clutch assembly Spring _ t e Spring seat _ _ 3 25 D o w n l o a d e d f r o m ...

Page 65: ...ide pin Collar _ _ Wear Damage Replaceasa set e Oil seal _ O rings _ _ Damage Wear Replace 9 Measure Slidingspringfree length Out of specification Replace SlidingSpring Free Length Standard 76 8 mm 3 02 in Limit 71 0 mm 2 80 in 10 Inspect Clutch housing Inner surfaces Scratches Damage Replace _ _ Oil Grease Check oil sealsand O rings of the secondary fixed sheave and sliding sheave Clutch HousingW...

Page 66: ...ness Standard 3 5 mm 0 138 in Limit 2 0 mm 0 079 in V BELT 1 Inspect o V belt Cracks Wear Scaling Chipping Replace Oil Grease _ Check primary sheave and secondary sheave 2 Measure _ V belt width _ Out of specification Replace Standard 19 5 mm 0 77 in Limit 17 5 _ram 0 69 in Replace at 18 000 km 11 400 mi irrespective at limit 3 27 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 67: ... cover B 0 03 mm 0 0012 in _ Big end bearing _ O ring _ Connecting rod _ Engine mount damper C SIDE CLEARANCE 0 05 _ 0 45 mm 0 0020 _ 0 0177 in _ Crank Left _ Engine mount spacer SMALL END FREE PLAY _ Balancer bearing _ Crankcase Right D 0 8 _ 1 0 mm 0 031 _ 0 039 in _ Balancer _ Ventilation hose E BALANCER GEAR ALIGN MARKS _ Filler cap 10 Nm 1 0 m kg 7 2 ft lb _ I 16 Nm 1 6 m kg 11 ft lb 7 Nm 0 7...

Page 68: ...ft _ Spring pin _ Driven gear _ _ _ _ _ Spacer __ _ Oil pump body plate _ Oil pump idler gear _ Idle gearshaft 3 Apply e Quick Gasket_ ACC 11001 05 01 _ to the mating surfaces _ 4 Install Dowel pins _ 5 Install _ __ Crankcase Right Tap the crankcase on lightly using a Soft Hammer 6 Tighten Bolts Crankcase Bolts Crankcase 10 Nm 1 0 m kg 7 2 ft lb NOTE Tighten the bolt using crisscrosspattern 3 29 D...

Page 69: ... ft ib kl TRANSMISSION 1 Install Drive axle _ NOTE Be careful so that the oil seal lip is not turned over by edge of the drive axle when installing the drive axle e Main axle _ Conical spring washer _ Plate washer _ 2 Install Gasket New Transmission cover 3 Tighten e Bolts Transmission cover in two steps j_J Bolts Transmission Cover I 10 Nm 1 0 m kg 7 2 ft lb 3 30 D o w n l o a d e d f r o m w w w...

Page 70: ...ghten e Rear wheel axle nut _ __ Tighten temporarily _ e Final gear drain plug _ 1_ Final Gear Drain Plug _ _ 16 Nm 1 6 m kg 11 ft lb _ OIL PUMP GEARS Oil pump idle gear CD MAGNETO 1 Install Woodruff key _ Gasket New 2 Tighten Generator assembly _ N 7 Bolt Generator 7 Nm 0 7 m kg 5 1 ft Ib 3 31 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 71: ...to rotor 6 Tighten Screws Cooling fan _ STARTER SYSTEM 1 Install Starter motor assembly Starter driven gear Plate washer _ Starter clutch assembly _ Starter idle gear _ 2 Install Oil gallery pipe 3_ Apply grease to the O rings New e Dowel pins _ Oil filter screen _ Crankcase cover nkcase Cover _ 10Nm 1 0 rn kg 7 2 ftolb 3 32 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 72: ...r bushing _ Guide collar _ Cam Secondary sliding sheave _ Weight _ Oil seal _ Primary sliding sheave _ Spring seat V belt _ Spring _ Collar _ Clutch assembly _ Primary fixed sheave I i SLIDING SPRING FREE J CLUTCH SHOE WEAR LIMIT B LENGTH LIMIT A 2 0 mm 0 079 in 71 0 mm 2 80 in 90 Nm 9 0 m kg 65 ft lb 60 Nm 6 0 m kg 43 ft lb I J I V BELT WEAR _e e_ C LIMIT 17 5 mm 0 69 in _ 55 Nm 5 5 mokg 40 ft lb...

Page 73: ...to the collar e Be careful so that the oil seal lips are not turned overwhen installingthe collar Claw washer _ Weight _ O ring _ Oil seal _ Slider bushing _ Primary sliding sheave _ Cam _ Oil seal 4 Install Primaryslidingsheave_ _ Collar _ e Primary fixed sheave __ Rockwasher New _ o Nut Primary sheave _ 5 Tighten e Nut Primary sheave Usethe Rotor Holder YU 01235 I_ Nut PrimarySheave I 55 Nm 5 5 ...

Page 74: ...e cam grooves on the sliding _ _ sheave _ 5 Install Spring seat _ Spring _ e Clutch assembly 0 6 Attach e Primary Sheave Holder YU 1701 _ o Nut Wrench YM 04045 A _ 7 Tighten Nut Clutch _ 1 90 Nm 19 0 m kg 65 ft lb 8 Install Secondary sheave assembly _ Clutch housing o Nut Secondary sheave _ NOTE Before installation remove the any oil and or grease from the clutch clutch housing and sheaves with a ...

Page 75: ...imary sheave NOTE The V belt must be installed with the arrow marks _ facing the direction of travel _ Be sure to remove the any oil and or grease CRAN KCASE COVER __ i 1 Install e Dowel pins O rings _ Crankcase cover _ _ 2 Tighten Screws Crankcase cover NOTE Do not install the screw _ as it is tighten with rear fender _ Screw Crankcase C ver I 10 Nm 1 0 m kg 7 2 ft Ib 3 36 D o w n l o a d e d f r...

Page 76: ...ylinder gasket _ Piston pin clip _ Cam chain tensioner Cam chain guide Front t_ END GAP LIMIT f___ x T_ 0 4 mm 0 016 in _ _ _ _ y _ s o_ c ARA c _ y _ O 1 mrn O OO n r_ C 0 020 _ 0 040 mm 10 0008 _ 0 0016 in 10 Nm 11 0 m kg 7 2 ft lb 1 D I CYLINDER BORE C IMEASUREMENT 19 0 mm 0 75 in E Always usea new one 3 37 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 77: ...Cover crankcase with clean rag before installing _llD _ piston pin clips to prevent clips from falling _1___ into crankcase cavity J _ _ _ i _ Gasket _ New o Dowel pins _ 3 Lubricate o Piston o Piston rings Use the engine oil 4 Align __25o_25_o Top ring _ EX Oil ring Lower rail _ Oil ring Upper rail _ o 2nd ring _ __ Align the above components as shown NOTE Manufacturer s marks or numbers stamped ...

Page 78: ...tall Cylinder Route the cam chain and the cam chain guide through the cam chain journal 7 Install Cam chain guide Front The lower end and the upper end of the guide must rest in slot in the crankcase and the cylinder 3 39 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 79: ...uide __j___ _D_ _ A Intake 0 18 _ 0 12 mm 0 003 _ 0 001 in _ Exhaust 0 10 _ 0 14 mm 0 004 _ 0 006 in 22 Nm 2 2 m kg 16 ftolb Always use a new one I v _ B I CYLINDER HEAD WARP LIMIT STANDARD SPARK PLUG _ SPARK PLUG GAP _ 0 05 mm 0 6 _ 0 7 mm 0 024 _ 0 028 in _ 0 002 in I 10 Nm 1 0 m kg 7 2 ft lb I i_i i I 7 Nm 0 7 m kg 5 1 ft lb J 28 Nm 2 8 mokgo 20 ftolb 7 Nm 10 7 m kg 5 1 ft lb J 10 Nm 1 0 m kg 7...

Page 80: ...cylinder head Stopper plate _ Bolt Stopper Plate 7 Nm 0 7 m kg 5 1 ft lb 3 Install Cylinder head gasket New o Dowel pins _ 4 Install Cylinder head Route the cam chain through the cam chain journal in the cylinder head Washers Bolts Cylinder head 5 Tighten Bolts Cylinder head Tighten the bolts in numerical order Bolt Cylinder Head M8 22 Nm 2 2 m kg 16 ft lb M6 10 Nm 1 0 m kg 7 2 ft lb 6 Align Flywh...

Page 81: ...tall Cam sprocket cover NOTE Left lower screw is fasten together with the air shroud 1 Valve covers Intake Exhaust Screw Cam Sprocket Cover 12 Nm 1 2 m kg 8 7 ft lb Valve Cover 7 Nm 0 7 mokg 5 1 ft lb 11 Release the cam chain tensioner oneway cam _ and insert the tension rod _ into _ the tensioner body _ 12 Install Gasket Tensioner body Copper washer _ 10 Nm 1 0 m kg 7 2 ftolb Tension spring _ e O...

Page 82: ...e Frame on the engine assembly 2 Tighten Engine mounting bolt Engine Mounting Bolt 74 Nm 7 4 m kg 53 ft lb e Rear shock absorber pivot bolts I_ Rear Shock Absorber Pivot Bolt 16 Nm 1 6 m kg 11 ft lb 3 Install Rear brake cable 4 Tighten Rear wheel axle nut _ Bolt Rear arm _ This tightening sequence is important So follow this steps Axle Nut J 105 Nm 10 5 m kg 75 ft lb Bolt Rear Arm 23 Nm 2 3 m kg 1...

Page 83: ...e play 8 Install e Air cleaner box _ 9 Connect Battery negative lead _ 10 Install Cover _ Bridge plate Bolt Bridge Plate 8 Nm 0 8 m kg 58 ft lb 11 Fill e Engine oil Final gear oil _ Engine Oil SAE 10W30 type SE motor oil 1 1 L 1 0 Imp qt 1 2 US qt Final Gear Oil SAE 10W30 type SE motor oil 0 15 L 0 13 Imp qt 0 16 US qt 12 Install Footrest board _ e Front cover e Side covers Left Right _ O 3 44 D o...

Page 84: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 85: ...RETOR 4 1 SECTION VIEW 4 2 AUTO CHOKE SYSTEM 4 3 REMOVAL 4 6 DISASSEMBLY 4 6 INSPECTION 4 7 FLOAT HEIGHT ADJUSTMENT 4 8 ASSEMBLY AND INSTALLATION 4 8 FUEL LEVEL ADJUSTMENT 4 9 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 86: ...needle holder _ O ring Pilot jet P J 34 _ Spring seat _ Needle jet Pilot air jet P A J 140 _ Circrip _ Blind plug _ Jet needle _ Starter plunger assembly Fuel level F L 4 5 _ 5 5 mm _ Vacuum piston _ Pilot screw 0 18_0 22 in _ Needle valve _ Starter choke unit Float height F H 26 5 _ 27 5 mm 1 04 _ 1 08 in _ Pilot jet Pilot screw P S 1 3 4 Valve seat V S 2 0 Engine idle speed 1 350 _ 1 450 r min P...

Page 87: ... _ Air Vacuum piston spring Main air jet _ Jet needle B _ _ Fuel _ Needle jet C _ Mixture _ Main jet _ Throttle valve _ Pilot jet _ Pilot air jet _ Bypass holes o s ow M_TE OSV TEM I EMA M_T_ OSYSTEM I D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 88: ...dstarterjet _ Coldstarterairjet _ _ _ II II Ii II II II II II II II nI I I I t l Ii _ Lk Construction 1 Choke unit The choke unit which is composed of wax and thermostat controls the plunger assembly after the engine is started Heat generated in the thermostat due to an electric current flow causes the wax to expand and push the cam which controls the plunger assembly D o w n l o a d e d f r o m w...

Page 89: ... engine When the starter plunger is fully open due to unexpanded wax in the choke unit a __ _ rich mixture is provided for starting the engine _ Chokeunit _ Cam _ _ Starterplunger Starteroutlet _ 2 With a slightly warm engine The wa _contracts slowly since it is covered with a heat insulating material thus a leaner mixture than that produced for a cold engine is provided _ Choke unit Cam Starter p...

Page 90: ...thermostat However fuel will not be supplied unless the engine is accelerated When the engine warms up sufficiently the plunger will close due to the warmed wax in the thermostat _ Starter plunger _ CSNplunger _ CSnozzle _ CSJet _ CS Air jet IAIOPE I 1 ok _PERATING DIAGRAMS IB Ics I __ I D Fuelis supplied J IA IOPE l _ IE ISTI l f I F I IGHI I D I Fuel issuPpliedl t 3 IGIE G TEMPI _ i I I lE G STA...

Page 91: ...emove _ i_ _k_ e Over flow hose 7_ Starter choke unit assembly _ _ __ i i_ e Starter plunger assembly _ 2 Remove _ _ _ _ _ii_ _ o Vacuum chamber cover _ _ _ _ o Spring _ _ _ Vacuum piston _ Jet needle _ _ the needle be sure not to When removing jet loose the small spring _ that may fall out This spring holds the jet needle 3 Remove Float chamber _ _ Float pin _ ii_2 _ _ Float _ _ _ _ _ Float valve...

Page 92: ...i Damage Torn _ Replace iiii i_ Needle valve and valve seat _ Wear Replace as a set ii_ 4 Inspect Vacuum piston _ _ _ Scratches _ Replace asa set _ _ _ _ _ _ t e Rubber diaphragm _ _i i ii _ __ _ Damage Torn _ Replace as a set 5 Inspect e Starter plunger _ Damage Wear _ Replace 6 Install the starter pluger into the carburetor body and check for smooth movement with finger Not smooth _ Replace plun...

Page 93: ...at chamber gasket removed to the top of the float NOTE The float should be just resting on but not depressing the spring loaded inlet needle Float Height 26 5 27 5 mm 1 04 1 08 in If the fuel height is incorrect adjust the fuel height 2 Adjust e Float height By the following steps Float height adjustment step _ Remove the float o Adjust float height by bending the float tang _ slightly _j o Rechec...

Page 94: ...Connect the Fuel Level Gauge _ YM 01312 to the drain nozzle _ Loosen the drain screw _ and start the engine Measure the fuel level Fuel Level Below the carburetor body 4 5_ 5 5 mm 0 18 _ 0 22 in ll_l e If the fuel level is incorrect adjust the fuel level _ Float chamber Carburetorbody 2 Adjust _ _ Fuel level By the following steps Adjustment steps f _ Remove the carburetor Adjust float level by be...

Page 95: ...NSPECTION 5 2 INSTALLATION 5 4 REAR WHEEL 5 5 REMOVAL 5 6 BRAKE DISASSEMBLY 5 6 INSPECTION 5 6 INSTALLATION 5 7 FRONT FORKS AND STEERING HEAD 5 8 REMOVAL 5 9 INSPECTION 5 9 ASSEMBLY 5 10 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 96: ...rclip _ Collar _ Washer _ Washer _ Rubber cap I A TIRESlZE 3 50 10 4PR RIM RUNOUT LIMIT I i6201Z C3J B I Radial 2 0mm 0 0Bin Lateral 2 0 mm 0 08 in BRAKE DRUM WEAR LIMIT cI 131 mm 5 16 in I B6301ZI BRAKE SHOE WEAR LIMIT l 2 0 mm 0 08 in j _ 1 s _ _ lr_ __ 40 Nm 4 0 m kg 29 ft lb J _2C _ _ _ _ _O___ 49 Nm 4 9m kg 35 ft lb 70 Nm 7 0 m kg 50 ft lb J _ _ 10 Nm 1 0 m kg 7 2 ft lb J 5 1 D o w n l o a d ...

Page 97: ...spect Front axle D u Roll the axle on a Flat Surface _1 _ _ _ _ _ _ r_ _ Bends oo0 Replace Do not attempt to straighten a bent axle _ ___ _ 2 inspect Wheel Cracks Bends Warpage _ Replace 1 3 Measure _ _ _ e Wheelrunout Out of specification _ Replace Rim Runout Limits Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in u nTll 4 Inspect _ _ Wheelbearings Bearings allow play in the wheel hub or wheel turns ...

Page 98: ...e 5 Inspect Brake shoes Glazed parts _ Sand with coarse sand paper _ 6 Measure Brake shoe Thickness _ Out of specification _ Replace _ Brake Shoe Thickness Standard 4 0 mm 0 16 in Limit 2 0 mm 0 08 in 7 Inspect Brake drum Inner surface Oil _ Wipe off brake drum with rag soaked in lacquer thinner or solvent Scratches _ Polish brake drum lightly and evenly with emery cloth 8 Measure Brake drum insid...

Page 99: ...following parts Oil seals _ lips Camshaft _ shaft and cam Speedometer drive gear _ o Pivot shaft _ _ Lightweight Lithium soap Base Grease O ring _ o Collars _ insides and outside Seal covers _ inside _ Collar _ inside and outside Molybdenum Disulfide Grease 2 Tighten Nut Tension bar _ Bolt Tension bar Axle nut Nut Tension Bar _ 49 Nm 4 9 m kg 35 ft Ib Bolt Tension Bar _ 40 Nm 4 0 m kg 29 ft Ib Axl...

Page 100: ...9 Nm 1 9 mokg 13 ftolb RIM RUNOUT LIMIT B I Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in I BRAKE DRUM WEAR LIMIT I 105Nm 10 5m kg 75ft lb l _ C I 131mm 5 16 in AIR VALVE ___ _ Install the air valve on the right of the scooter 23 m 23 m kg 17 ft b l i o B ESOEWE LMT 2 0 mm 0 08 in __I _ lT6Nm 19m kg 13_t Ib li0 Nm 1 0 m kg 7 2 ft lb I 5 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e ...

Page 101: ...AKE DISASSEMBLY 1 Disconnect o Rear brake cable _ 2 Remove Brake shoes _ Brake shoe plate _ INSPECTION 1 Inspect o Front axle Wheel Wheel bearings e Brake shoes Brake drum Inner surface Camshaft Refer to FRONT WHEEL INSPEC TION section 2 Measure Wheel runout Brake shoe Thickness Brake druminside diameter Refer to FRONT WHEEL INSPEC TI ON section 5 6 D o w n l o a d e d f r o m w w w S c o o t e r ...

Page 102: ... arm _ Shock abosrber pivot nut _ This tightening sequence is important So follow this steps _ Axle Nut 105 Nm 10 5 m kg 75 ft lb Rear Arm 23 Nrn 2 3 m kg 17 ft lb Shock Absorber 16 Nm 1 6 m kg 11 ftolb I 4 Install Cotter pin New _ 5 Install Muffler _ Exhaust 10 Nm 1 0 m kg 7 2 ft lb Body 16 Nm 1 6 m kg 11 ft Ib Front cover Side cover Right 5 7 D o w n l o a d e d f r o m w w w S c o o t e r T i m...

Page 103: ...over _ Arm _ Upper bearing _ Bushing _ Lower bearing _ Collar _ Fork cover _ Grease nipple _ Shock absorber _ Arm cover _ Thrust cover 30 Nrn 3 0 m kg 22 ft lb 19 Nm 1 9 m kg 13 ft lb _ 40 Nm 4 0 m kg 29 ft lb I 19 Nm 1 9 m kg 13 ft lb I 5 8 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 104: ...ndlebar assembly _ 4 Remove Ring nuts Upper and lower _ Use the Ring Nut Wrench YU 33975 NOTE Support the forks not to drop the ball bearings Front fork cover Front fender Front Front fender Rear 5 Remove __ o Tension bar _ Bolts Arm _ Arms Bolts Shock absorber _ Shock absorbers _ iNSPECTION 1 Inspect e Shock absorber assembly _ _ _ _ Leakage Damage _ Replace _ _v _fV_ _ _ _ 5 9 D o w n l o a d e ...

Page 105: ...ace NOTE Always replace bearing and race as a set 5 When removing the race drive out by strik ing it in steps And fit the race squarely in the head pipe _ _ _ __ _ _ _ _ If the bearing race is fitted not squarely the head pipe could be damaged ASSEMBLY 1 Apply _ _ Arm pivot _ Shock absorber lower mount _ r_ Lightweight Lithium soap 1 Base Grease Tension bar and front wheel Refer to FRONT WHEEL WHE...

Page 106: ...alls in it NOTE Make sure the balls are of the same size and the quantity is correct Upper 22 pcs 3 16 in Lower 19 pcs 1 4 in 5 Install e Bearing Race Upper o Bearing cover o Front fork cover o Ring nuts Lower and upper NOTE The tapered side of ring nut must face down ward 6 Tighten o Ring nuts Lower and upper By the following tightening steps Ring nuts tightening steps Tighten the ring nut lower ...

Page 107: ...as required z _ _ _ 7 Install _ e Handlebar assembly 8 Tighten Bolt Handlebar mounting _ _Mounting kg 24 ft Ib I NOTE Take care for handlebar front wheel alignment 9 Continue Assemble Reverse the dis assembly procedures and note the follow ing points Check for smooth throttle operation and quick spring return Make certain that the housing does not rotate on the handlebar Before installing the leg ...

Page 108: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 109: ...NITION SYSTEM 6 21 CIRCUIT DIAGRAM 6 21 TROUBLESHOOTING 6 23 IGNITION SPARK GAP TEST 6 25 IGNITION COIL RESISTANCE TEST 6 25 PICKUP COl L RESISTANCE TEST 6 26 SPARK PLUG INSPECTION 6 26 LIGHTING SYSTEM 6 27 CIRCUIT DIAGRAM 6 27 LIGHTING TESTS AND CHECKS 6 29 SIGNAL SYSTEM 6 33 CIRCUIT DIAGRAM 6 33 W_ TROUBLESHOOTING 6 35 HORN TEST 6 36 BRAKE LIGHT TEST 6 36 FUEL METER SYSTEM TEST 6 37 SWITCHES TES...

Page 110: ...M A L B _ _N l_ ____ I _ Ill L IL T _ I _dTt 4 _ _ Jr 1 4 _ I II r p _ J I I l qi _ i _ Br T Br iBr 8r _r _ G Y O Br R Br Y _G Y O Oid_ B r _ _ J _ q _ _ _i _ O Br W Br W Br 4 B 6 1 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 111: ...t Pickup coil _ HIGH BEAM indicator light _ Fuel meter _ LIGHTS Dimmer switch _ Fuel sender _ START switch _ HORN switch _ Starting circuit cut off relay _ Flasher relay _ Starter relay _ TURN switch _ Starter motor _ TURN indicator light COLOR CODE B Black Br Brown L W Blue White L Blue Ch Chocolate L B Blue Black O Orange Dg Dark green G W Green White G Green W B White Black G R Green Red R Red ...

Page 112: ...g circuit cut off relay Blue White Green Yellow _ Fuse Starting Circuit Cut off Relay _ Battery B Coil Resistance _ Horn 68 _ 83 _ at 20 C 68 F _ Rectifire Regulater Blue White Red White _ Main switch Battery _ Audio pilot C Capacity 12V 7AH Specific gravity 1 280 Rectifire Regulated Voltage D 14_ 15V 6 3 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 113: ...ition _ Rear brake switch A 4 10_ at 20 C 68 F _ Ignition coil Empty position 90 _ 100_ at 20 C 68 F Ignition Coil Primary winding resistance B 2 43 _ 2 97_ at 20 C 68_F Secondary winding resistance 10 6 _ 15 8k_ at 20 C 68 F 6 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 114: ...ARTING SYSTEM CIRCUIT DIAGRAM Belowcircuitdiagram shows startercircuit Br R _ _ L W Y L 0 0 I 0 0 J 0 F NC F B K 1 R OR _ar Br _ Br Br _G L O _ G Y O _q Br R G Y O 0_ Br fl I0 _ _ 6 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 115: ...h _ ENGINE STOP switch _ STAND indicator light _ Rear brake switch _ Front brake switch Battery _ START switch _ Starting circuit cut off relay _ Starter relay _ Starter motor 6 6 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 116: ... i C nnectthe2 pinc upler R GandG Y J r Thestarterm t rd es_ t perate _tothestarterrelay _ If the starter relay does not click Connect the L W lead into the 2 pin replace the relay coupler to the battery negative termi nal use a jumper lead _ If the starter relay clicks check the starter motor operation using the heavy duty jumper lead _ tar er motor o0era e I e tar er motor 0oe not 1 _ _ operate ...

Page 117: ...nd is up Check the battery voltage 12V on the _11 Check for an open or poor connection R W lead into the 4 pin coupler between the battery and starting circuit cut off relay Connect the 4 pin coupler N G R W B and L W to the starting circuit cut off relay g Connect ea intot e n I I es ar n c c I to ground on the frame use a jumper click replace the relay lead If the starting circuit cut off relay ...

Page 118: ...ARTING SYSTEM STARTER MOTOR TEST _ O ring _ Armature _ Brush holder _ Spring _ Brush COMMUTATOR WEAR B LIMIT 21 0 mm 0 83 in ARMATURE COIL C 0 05 _ 0 06 _ 6 9 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 119: ..._ _ 3 Measure I _W_I_ Mica undercut Out of specification Scrape the mica to proper value use a hacksaw blade can be ground to fit Mica Undercut _ 1 5 mm 0 06 in NOTE The mica insulation of the commutator must be undercut to ensure proper operation of commu tator 4 Inspect 1 5M_ or more Armature coil insulation continuity _ _0_ Defect s Replace starter motor _ i_ I _ J_xl o By the following inspect...

Page 120: ...o Oil seal _ Wear Damage Replace i ii _ii_ ii ii_ i i 6 Measure __ _ Brush length Each _ Out of specification Replace Minimum Brush Length _ 3 5 mm 0 14 in J _ 7 Inspect Brush springs Compare with new spring Wear Damage Replace Installation 1 Apply grease to the starter motor O ring and install the starter motor assembly 2 Tighten e Bolts _ Starter Motor 1 7 Nm 0 7 m kg 5 1 ft lb 6 11 D o w n l o ...

Page 121: ..._ I_2 7_ _ 3 3__ pedal h ld the brake lever or step down the brake Push the START switch and check to see if the starter relay clicks _1_ Starter relay clicking Starter relay OK 9 x 1 o Starter relay not clicking _ Measure coil resistance Connect the Pocket Tester YU 03112 I leads to the starter relay _ Blue White _ Green Yellow Measure the coil resistance Starter Relay Resistance 2 7 3 39 at 20 C...

Page 122: ...idestandisup 68 83_ e Push the START switch and check to see if the starting circuit cut off relay clicks Starting circuit cut off relay clicking _ Starting circuit cut off relay OK Starting circuit cut off relay not clicking Measure coil resistance _ e Connect the Pocket Tester YU 03112 leads to the starter relay _ Red White _ Blue White o Measure the coil resistance Starter Relay Resistance 68 8...

Page 123: ...ELEOT OSTA T O S STEM iE EOi i 6 14 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 124: ...EL_i_ I _ CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM Belowcircuitdiagram shows charging circuit 6 15 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 125: ...C A O O S ST M IELEOI I _ AC generator _ Rectifier Regulator _ Fuse Battery 6 16 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 126: ...to measure the charging voltage Startle en ne a ac e e eto out C aro n Vo ta e I 2 000 r m or more More than 15V I I Charging Voltage Less than 14V Measure the charging coil resistance and Replace the rectifire regulator cheek the rectifier regulator Charging coil resistance White White __ 0 64 _ 0 96_ at 20 C 68 F I Replace the defective part s I 6 17 D o w n l o a d e d f r o m w w w S c o o t e...

Page 127: ...isconnect the leads from the battery while the generator is operating otherwise the voltage across the generator terminals will increase and damage the semiconductors CHARGING COIL RESISTANCE TEST 1 Remove Front cover 2 Disconnect Stator leads connector 3 Connect Pocket Tester YU 03112 4 Measure Charging coil resistance Out of specification Replace the charging coil assembly o 1 _ 0 64 o 96aat20c ...

Page 128: ... replaced NOTE 1 Never disconnect wires from the battery while the generator is in operation If the battery is disconnected the voltage across the generator terminals will increase damaging the semiconductors 2 When checking the regulator being in stalled on a machine the battery should not be removed and it should be fully charged 3 Never use a high voltage insulation ohm meter such as a megaohmm...

Page 129: ...y x Discontinuity NOTE The results O or X should be reversed according to the pocket tester polarity Even if one of elements is broken replace assembly The silicon rectifier can be damaged if subject to overcharging Special care should be taken to avoid a short circuit and or incorrect connection of the positive and negative leads at the battery Never connect the rectifier directly to the battery ...

Page 130: ...L__ iGNITiON SYSTEM P IGNiTiON SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows ignition circuit D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 131: ...STE 1 _ Main switch _ Fuse _ Sidestand switch _ ENGINE STOP switch _ STAND indicator light _ Ignitor unit _ Ignition coil _ Pickup coil Battery 6 22 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 132: ...rk gap 0_ _1 __ Start the engine and increase the spark gap until misfire occurs Test at various r min between idle and red line Faulty ignition system operation at the minimum spark gap or smaller _ Follow the troubleshooting chart until the source of the problem is located _ Spark plug lead _ Spark plug Do not run the engine in neutral above 6 000 r rain for more than 1 or 2 seconds i Minimum Sp...

Page 133: ...e fuse j OK _ Faulty Check sidestand and engine stop switches p Repair or replace Check the ignition coil for resistance primary and secondary Primary 2 43_ 2 97a at 20 C 6B F Secondary 10 6 _ 15 8k_2 at 20 C 6B F D xl _ _xlk O_ 0 O_ _0 l T o_ 5 _o Measure the pickup coil for resistance Replace the ignition coil I Pickup coil 90 135_at 20 C 68 F No I White Red White Black Replace the pickup coil a...

Page 134: ...ease the gap to the maximum limit unless misfire occurs first _ Minimum Spark Gap I 6 mm 0 24 in IGNITION COIL RESISTANCE TEST 2 43 2 97_ I_ _ 1 Connect Pocket Tester YU 03112 2 Measure e Primary coil resistance Secondary coil resistance Out of specification Reptace _ Primary Coil Resis ance 2 43 2 97_ at 20 C 68 F Secondary Coil Resistance 10 6 15 8k_q at 20 C 68 F _ li 6_ 15 8k_ 1k o_ O r r 6 25...

Page 135: ...oil connector 3 Measure Pickupcoil resistance Usea PocketTester YU 03112 Out of specification _ Replace J_l PickupCoil Res stance 90 135_ at 20 C 68 F White Red White Black SPARK PLUG INSPECTION Refer to CHAPTER 2 SPARK PLUG IN SPECTION section 6 26 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 136: ...HTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows lighting circuit L H B 0 I 4 0 0 0 _ B G W W W _ I I I L B I B L J o K 6 27 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 137: ...r _ Rectifier Regulator _ Main switch _ Fuse _ Tail Brake light _ Battery _ Meter lights _ Headlight _ HIGH BEAM indicator light _ LIGHTS Dimmer switch _ START switch 6 28 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 138: ...further Low battery voltage indicates either a faulty battery low battery fluid level or a defective charging system Also check fuse condition Replace any open fuses There are individual fuses for various circuits see complete Circuit Diagram NOTE Check each bulb first before performing the following check 6 29 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 139: ...essary _ No voltage I Measure voltage at LIGHTS Dimmer I_____J Check LIGHTS Dimmer switch I switch terminal replace if necessary I No voltage An open or poor connection Measure voltage at headlight high beam or l_ P l low beam terminal between headlight and LIGHTS Dimmer switch terminal I Poor ground or poor connection of head light wiring I 6 30 D o w n l o a d e d f r o m w w w S c o o t e r T i...

Page 140: ...surev ltage nBr wnleadfr mmain 1_1 Check main switch replace if I switch ON position necessary No voltage i A open or poor connection 1 Measure voltage at taillight terminal I__V I between taillight and LIGHTS I Dimmer switch terminal J v I oor ground or poor connection of I wiring 6 31 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 141: ...L OHT NOS STE IELEOI I 6 32 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 142: ... ELEC _ _ j SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM Belowcircuit diagramshowssignal circuit D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 143: ...lay _ TURN switch _ TURN indicator light _ Audio pilot _ Rear flasher light Right _ Front flasher light Right Rear flasher light Left _ Front flasher light Left _ Tail Brake light _ Rear brake switch _ Front brake switch _ Battery 6 34 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 144: ...main switch Connect as er re a connector an0 j J check for the battery voltage 12V on Replace theflasher relay the Br W lead at the connector I Connect the Br lead and Br W lead I use a jumper lead I Turn the TURN switch to L and or r _l If any flasher light does not come on R and check to see if the lights come _ _1 replace the bulb on g I If all flasher lights come on replace the I I TURN switch...

Page 145: ...n lead Pink lead _ _ 1 05_ 10 R x 1 3 Adjust L 1 vome Turn the adjuster _ in and out so that _ lU ul _ the volume is maximum at the maximum amperage _ Battery 12V Tester s lead Maximum Red lead Black lead Amperage Tester s range Horn lead Battery and lead Battery 1 5A DC5A lead BRAKE LIGHT TEST Brake light inoperative Defective bulb Check for 12V on yellow lead to brake light 12V on brown lead to ...

Page 146: ...nder resistance full position Sender resistance empty position Out of specification Replace In specification _ Go to next test Fuel Sender Resistance Full Position 4 10_ at 20 C 68 F Empty position 90 100Q at 20 C 68 F 6 Connect Connections 7 Check Fuel meter operation Move the sender float up and down Not operating Replace the fuel meter 6 37 D o w n l o a d e d f r o m w w w S c o o t e r T i m ...

Page 147: ...Position R Br LOCK OFF ON 0 D ENGINE STOP Switch Lead Color Switch Position Br R R W OFF RUN 0 START Switch Lead Color Switch Position L W B Br L B OFF 0 0 PUSH C_ O LIGHTS Dimmer Switch Lead Color Switch Position Y L B G LO 0 _ H I O 0 HORN Switch Lead Color Switch Position P B PUSH 0 OFF 6 38 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 148: ...Switch Position Ch Br W Dg R N L 0 BRAKE Switches Front and Rear Lead Color Switch Position Br G Y FREE DEPRESS Sidestand Switch Lead Color Switch Position Br R Br G L FREE _ PUSH 0 6 39 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 149: ...S GNAL SYSTEM IELEC_ 6 40 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 150: ... ELEC _ _1 AUTO CHOKE SYSTEM AUTO CHOKE SYSTEM CIRCUIT DIAGRAM Belowcircuitdiagram shows autochokecircuit D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 151: ...AUTO CHOKE SYSTEM _ AC generator Rectifier Regulator _ Choke relay _ Choke unit _ Main switch Battery 6 42 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 152: ... be a trouble or hard to start when the engine is warmed up Check the engine asfollows i The engine shows a trouble after i warmed up I Connect battery to the choke unit NO _ I Replace the ch ke unit assembly i directly The cam in the unit must be activated directly C nnect Check for voltage of the i FI Replace the chOke relay _ l_ I batteries to the relay unit I NO relay NO i Check the stator coi...

Page 153: ...oke unit _ 4 Measure o Choke unit resistance IS _ __2 _ 4_ Out of specification Replace _xl_ o I r 5 Connect 12V Battery 6 Check Cam movement Incorrect movement _ Replace BATTERY IS NOT CONNECTED WAX IS COLD BATTERY ISCONNECTED WAX IS WARM 6 44 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 154: ...s DC20V o _ _ NOTE The relay unit needs at least 13 5V to be activated Set the tester selector to DC20V posi tion Measurement of the voltage between the Green Red _ and the Black _ terminals is l should be 12V _ Brown terminal _ Battery 6V _ Battery 12V STATOR COIL RESISTANCE TEST 1 Measure e Stator coil resistance Refer to Charge Coil Resistance Measurement 6 45 D o w n l o a d e d f r o m w w w ...

Page 155: ...7 1 GENERAL SPECIFICATIONS 7 1 MAINTENANCE SPECIFICATIONS 7 4 GENERAL TORQUE SPECIFICATIONS 7 13 DEFINITION OF UNITS 7 13 LUBRICATION DIAGRAM 7 14 CABLE ROUTING 7 15 COLOR WIRING DIAGRAM D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 156: ... mm 1 929 x 2 598 in Compression Ratio 10 0 1 Compression Pressure 90 kPa 9 0 kg cm 2 128 psi Starting System Electric starter Lubrication System Wet sump Pressure lubricated Oil Type or Grade Engine Oil 30 40 50 60 F Yamalube 4 cycle or SAE 20W40 type SE motor oil _I If temperature does not go below 5 C 40 F I v I SAE 10W30 type SE motor oil 0 5 10 15 C If temperature does not go above 15 C 60 F ...

Page 157: ...to 75 kg 165 Ib load _ 147 kPa 196 kPa 1 5 kg cm 2 21 psi 2 0 kg cm 2 28 psi 90 kg 198 Ib _ Maximum load _ 147 kPa 294 kPa 1 5 kg cm 2 21 psi 3 0 kg cm 2 43 psi Brake Front Brake Type Durm Brake Operation Right Hand Operation Rear Brake Type Drum Brake Operation Right Foot Operation Suspension Front Bottom Link Fork Rear Unit Swing Shock Absorber Front Coil Spring Oil Damper Rear Coil Spring Gas O...

Page 158: ...light 12V 45W 40W Tail Brake Light 12V 8W 27W Flasher Light 12V 27W x 4 Licence Light 12V 8W Meter Light 12V 3 4W x 2 Indicator Light Wattage x Quantity HIGH BEAM 12V 3 4W TURN 12V 3 4W STAND 12V 3 4W 7 3 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 159: ...0134 in Limit 0 08 mm 0 0032 in Valve Valve Seat Valve Guide Valve Clearance Colde IN 0 08 _ 0 12 mm 0 003 _ 0 005 in EX 0 10 _ 0 14 mm 0 004 _ 0 006 in Valve Dimensions Head Dia Face Width Seat Width Margin Thickness A Head Diameter IN 25 9 _ 26 1 mm 11 020 _ 1 028 in EX 21 9 _ 22 1 mm 0 862 _ 0 870 in B Face Width IN 1 4 _ 3 0 mm 0 055 _ 0 118 in EX 1 7 _2 8 mm 0 067 _ 0 110 in C Seat Width Limi...

Page 160: ...m 1 127 in 25 4 mm 1 00 in EX 28 63 mm 1 127 in 25 4 mm 1 00 in Compressed Length Valve Closed IN 24 9 mm 0 98 in EX 24 9 mm 0 98 in Spring Rate IN 25 8 N mm 2 62 kg mm 147 Ib in X EX 25 8 N mm 2 62 kg mm 147 Ib in Tilt Limit X IN EX 2 5 or 1 2 mm 0 047 in z Y l Direction of Winding Top view IN EX Piston Piston Size D _ 48 945 _ 48 985 mm 1 927 _ 1 929 in Measuring Point H _ 5 mm 0 2 in H From bot...

Page 161: ...0 0024 in 0 12 mm 0 0047 in Crankshaft Crank Width A 44 95 45 00 mm 1 770 _ 1 772 in Runout Limit B Left 0 01 mm 0 0004 in Right 0 03 mm 0 0012 in Big End Side Clearance C Limit 0 05 _ 0 45 mm 0 0020 _ 0 0177 in 0 5 mm 0 0197 in Big End Radial Clearance D 0 004 _ 0 019 mm 0 00016 _ 0 00075 in D Small End Free Play E Limit I 0 8 _ 1 0 mm 0 031 _ 0 039 in E 1 5 mm 0 059 in A Balancer Drive Method Ge...

Page 162: ...evel F L 4 5 _ 5 5 mm 0 18 _ 0 22 in Float Height F H 26 5 _ 27 5 mm 1 04 _ 1 08 in Engine Idling Speed 1 350 _ 1 450 r min Vacuum Pressure at Idling Speed Above 170 mmHg 6 69 inHg Oil Temperature 35 _ 45 C 95 _ 113 F Lubrication System Oil Filter Type Wire Mesh Oil Pump Type Trochoid Pump Tip Clearance Limit 0 15 mm 0 0059 in 0 2 mm 0 008 in Side Clearance Limit 0 06 _ 0 10 mm 0 0024 _ 0 0039 in ...

Page 163: ... 1 16 1 6 11 Crankcase M 6 x 1 0 9 12 1 2 8 7 Crankcase Cover 1 M 6 x 1 0 9 10 1 0 7 2 Crankcase Cover 2 M 6 x 1 0 8 12 1 2 8 7 Cam Chain Case Cover M 6 x 1 0 2 7 0 7 5 1 Oil Pump M 6 1 0 3 7 0 7 5 1 Drain Plug Engine M12 x 1 5 1 20 2 0 14 Transnission M 8 x 1 25 1 16 1 6 11 Primary Sheave M12 x 1 0 1 55 5 5 40 Secondary Sheave Clutch M36 x 1 5 1 90 9 0 65 Clutch Housing M14 x 1 25 1 60 6 0 43 Cra...

Page 164: ...e Stroke K1 9 92 N mm 1 011 kg mm 56 60 Ib in 0 _ 47 5 mm 0 _ 1 87 in K2 18 31 N mm 1 867 kg mm 104 51 Ib in 47 5 _ 70 mm 1 87 2 76 in K3 42 49 N mm 4 333 kg mm 242 56 Ib in 70 _ 85 mm 2 76 _ 3 35 in Optional Spring No Wheel Front Wheel Type Cast Wheel Rear Wheel Type Cast Wheel Front Rim Size Material MT2 50 x 10 Aluminum Rear Rim Size Material MT2 50 x 10 Aluminum Rim Runout Limit Vertical 2 0 m...

Page 165: ...1 0 3 11 1 1 8 Fuel Cock M 6 x 1 0 2 7 0 7 5 1 Fuel Sensor M 5 x 0 8 4 2 0 2 1o4 Seat Hinge M 6 x 1 0 1 7 0 7 5 1 Seat Lock M 6 x 1 0 2 7 0 7 5 1 Carrier Stay M 6 x 1 6 4 8 0 8 5 8 Carrier Front M 6 x 1 0 2 8 0 8 5 8 Rear M 8 x 1 25 2 16 1 6 11 Front Axle Shaft M12 x 1 25 1 70 7 0 50 Front Brake Cam Lever M 6 x 1 0 1 10 1 0 7 2 Tension Bar Brake plate M10 x 1 25 1 49 4 9 35 Fork M10 x 1 25 1 40 4 ...

Page 166: ... _ 135_ at 20 C 68 F White Black White Red TCI Unit Model Manufacture TI D 11 07 HITACH I Ignition Coil Model Manufacturer CM 11 61 H ITACH I Primary Winding Resistance 2 43 _ 2 97 at 20 C 68 F Secondary Winding Resistance 10 6 _ 15 8 k_ at 20 C 68 F Charging System Type A C Magneto AC Generator Model Manufacturer FL 112 10 HITACHI Normal Output 12V 12A at 5 000 r min 15 10 J f O __ O 0 1 2 3 4 5 ...

Page 167: ...urer 50W TATEISHI OMRON Amperage Rating 80A Coil Winding Resistance Color 2 7 _ 3 3_ at 20 C 60 F Blue White Green Yellow Horn Type Quantity Plain type Model Manufacturer MF 12 NIKKO Maximum Amperage 1 5A Flasher Relay Type Condenser type Model Manufacturer FZ26TSD NIPPON DENSO Self Cancelling Device No Flasher Frequency 75 _ 95 cycle min Wattage 27W x 2 3 4W Audio Pilot Fuel Gauge Model Manufactu...

Page 168: ...full torque is reached 14 mm 10 mm 30 3 0 22 Unless otherwise specified torque specifications 17 mm 12 mm 55 5 5 40 call for clean dry threads Components should 19 mm 14 mm 85 8 5 61 be at room temperature 22 mm 16 mm 130 13 0 94 A DEFINITION OF UNITS Unit Read Definition Measure mm millimeter 10 3 meter Length cm centi meter 10 2 meter Length kg kilogram 103 gram Weight N Newton 1 kg x m sec 2 Fo...

Page 169: ...LUBR CATION O AORAM L PPX I LUBRICATION DIAGRAM 7 14 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 170: ... of the speedometer cable _ Flasher relay Insert the flasher lead coupler into the Front flasher light lead holder cover socket _ Throttle cable Pass the brake switch lead outside the _ Front brake switch lead brake cable Hook the loop of the wireharness here 7 15 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 171: ...ttery breather pipe Clamp the starter motor lead ground lead _ Band and flywheel magneto lead _ Main switch The head of the screw is right side _ Rectifier Regulator Clamp the breather hose Horn Flywheel magneto lead _ Carburetor clamp _ Choke unit air filter hose _ Fuel hose Breather hose 7 16 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 172: ... Taillight lead _ Passthe speedometer cable and front brake _ White tape _ Rear brake cable cable through the front fender hole _ Tape _ Throttle cable _ Clamp the wireharness and fuel sendor lead _ Cable holder _ Wireharness _ Clamp the wireharness only _ Speedometer cable _ Clamp the wireharness and throttle cable A B B I L 7 17 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 173: ...switch lead _ Battery breather pipe Blue coupler _ Relay on blue mark _ Throttle cable White coupler _ Relay on 25G mark _ Rear brake cable _ Sidestand switch _ Clamp _ Starter switch _ Battery negative lead O0 O0 0 _ _ O0 7 18 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 174: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 175: ...Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto ON M2H 3B4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

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