Yamaha MAJESTY YP250 Service Manual Download

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CHAPTER 4.

ENGINE

ENGINE OVERHAUL

4-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIREHARNESS AND CABLE

4-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT
AND ENGINE

4-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE REMOUNTING

4-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD

4-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD REMOVAL

4-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD INSPECTION

4-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD INSTALLATION

4-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT AND ROCKER ARMS

4-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT AND ROCKER ARM SHAFT REMOVAL

4-12

. . . . . . . . . . . .

CAMSHAFT INSPECTION

4-12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT AND ROCKER ARM SHAFT INSPECTION

4-13

. . . . . . . . .

CAMSHAFT AND ROCKER ARM INSTALLATION

4-13

. . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS

4-15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS REMOVAL

4-16

. . . . . . . . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS INSPECTION

4-16

. . . . . . . . . . . . . . . . .

VALVE SEAT INSPECTION

4-17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS INSTALLATION

4-19

. . . . . . . . . . . . . . . .

CYLINDER AND PISTON

4-21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PISTON AND PISTONRINGS REMOVAL

4-22

. . . . . . . . . . . . . . . . . . . . . .

CYLINDER INSPECTION

4-22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PISTON AND PISTON PIN INSPECTION

4-23

. . . . . . . . . . . . . . . . . . . . . .

PISTON RINGS INSPECTION

4-24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PISTON RINGS, PISTON AND CYLINDER INSTALLATION

4-25

. . . . . .

V BELT, CLUTCH AND SECONDARY/ PRIMARY SHEAVE

4-27

. . . . . . . . .

CRANKCASE FILTER COVER AND CRANKCASE

COVER (LEFT)

4-27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V BELT, CLUTCH AND SECONDARY/ PRIMARY SHEAVE

4-28

. . . . . . .

SECONDARY SHEAVE

4-30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMARY SHEAVE REMOVAL

4-31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY SHEAVE AND V BELT REMOVAL

4-31

. . . . . . . . . . . . . . .

SECONDARY SHEAVE DISASSEMBLY

4-32

. . . . . . . . . . . . . . . . . . . . . . .

CLUTCH INSPECTION

4-32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V BELT INSPECTION

4-33

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEIGHT INSPECTION

4-33

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY SHEAVE INSPECTION

4-33

. . . . . . . . . . . . . . . . . . . . . . . . .

PRIMARY SHEAVE ASSEMBLY

4-34

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY SHEAVE INSTALLATION

4-34

. . . . . . . . . . . . . . . . . . . . . . .

A.C. MAGNETO AND STARTER CLUTCH

4-37

. . . . . . . . . . . . . . . . . . . . . . . .

MAGNETO COVER AND STATOR COIL

4-37

. . . . . . . . . . . . . . . . . . . . . . .

A.C. MAGNETO AND STARTER CLUTCH

4-38

. . . . . . . . . . . . . . . . . . . . .

A.C. MAGNETO AND ROTER REMOVAL

4-39

. . . . . . . . . . . . . . . . . . . . . .

STARTER DRIVE GEAR INSPECTION

4-40

. . . . . . . . . . . . . . . . . . . . . . . .

A.C. MAGNETO AND ROTER INSTALLATION

4-40

. . . . . . . . . . . . . . . . .

Summary of Contents for MAJESTY YP250

Page 1: ......

Page 2: ......

Page 3: ...0 YP250 SERVICE MANUAL 1996 by Yamaha Motor Co Ltd 1st Edition January 1996 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...l its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert S...

Page 5: ... To heps identify parts and clarify procedure steps there are exploded diagrams at start of each remov al and disassembly section 1 An easy to see exploded diagram 4 is provided for disassembly and assembly jobs 2 Numbers 5 are given in the order of jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an ...

Page 6: ...he text 10 Possible to maintain with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening 15 Wear limit clearance 16 Engine speed 17 Ω V A Illustrated symbols 18 to 23 in the exploded dia grams indicate the types of lubricants and lu brication points 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing grease 22 Apply lightweight lith...

Page 7: ...MATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 INDEX ...

Page 8: ......

Page 9: ...S 1 2 OIL INDICATOR LIGHT 1 2 AUTO CHOKE SYSTEM 1 3 IGNITION CIRCUIT CUT OFF SYSTEM 1 3 IMPORTANT INFORMATION 1 4 PREPARATION FOR REMOVAL PROCEDURES 1 4 REPLACEMENT PARTS 1 4 GASKETS OIL SEALS AND O RINGS 1 4 LOCK WASHERS PLATES AND COTTER PINS 1 5 BEARINGS AND OIL SEALS 1 5 CIRCLIPS 1 5 CHECKING OF CONNECTIONS 1 6 HOW TO USE THE CONVERSION TABLE 1 7 SPECIAL TOOLS 1 8 ...

Page 10: ......

Page 11: ...ify your scooter and may be used to regis ter your scooter with the licensing authority in your country YP100020 FRAME SERIAL NUMBER except for E The frame serial number 1 is stamped into the right side of the frame EB100030 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase Designs and specifications are subject to change without notice MODEL LABEL The model label 1 is ...

Page 12: ...e the oil light is off the oil indicator light comes on for 1 4 seconds for resetting confirmation Failure diagnosis 1 Checking oil indicator light for breakage This oil indicator light is kept on for 1 4 seconds immediately after the main switch is turned on thereby checking the bulb for breakage 2 In case of meter pulse failure If travel distance signals are not detected during running the oil i...

Page 13: ...Start with the cold engine Crank with the cold engine Crank with the warm engine Restart with the warm engine Thermo switch OFF OFF ON ON Ignitor unit circuit OFF ON ON OFF Auto choke Activates Activates Not activate Not activate IGNITION CIRCUIT CUT OFF SYSTEM A sidestand circuit is added to the existing electric starting circuit thereby controlling the starter motor operation and the ignition sy...

Page 14: ...e disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly and allow for the correct installation of all parts 6 Keep all parts away from any source of fire EB101010 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all re placements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and ...

Page 15: ... are visible When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liberally when installing if appropri ate 1 Oil seal Do not use compressed air to spin the bearings dry This will damage the bearing surfaces 1 Bearing EB101050 CIRCLIPS 1 Check all circlips carefully before reas sembly Always replace piston pin clips af ter one use Replace...

Page 16: ...ad to check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect SConnector The two connectors click together 7 Check for continuity with a tester D If there is no continuity clean the terminals D Be sure to perform the steps 1 to 7 listed above when checking the wireharness D For a field remedy use a contact revitalizer ava...

Page 17: ...0 08 in CONVERSION TABLE METRIC TO IMP Known Multiplier Result Torque mSkg mSkg cmSkg cmSkg 7 233 86 794 0 0723 0 8679 ftSlb inSlb ftSlb inSlb Weight kg g 2 205 0 03527 lb oz Distance km hr km m m cm mm 0 6214 0 6214 3 281 1 094 0 3937 0 03937 mph mi ft yd in in Volume Capacity cc cm3 cc cm3 lit liter lit liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cuSin qt IMP liq gal IMP liq Miscella neous kg...

Page 18: ...eel magneto 90890 01268 Ringnut wrench This tool is used to loosen and tighten the exhaust and steering ringnut 90890 01311 Valve adjusting tool This tool is necessary for adjusting valve clearance 90890 01312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber 90890 01325 01352 Radiator cap tester Adaptor These tools are used for checking the cooling system 90890 01...

Page 19: ...t wrench This tool is used to loosen and tighten the steering ring nut 90890 01701 Sheave holder This tool is used for holding the secondary sheave 90890 01996 Cylinder cup installer set This tool is used for installing the cylinder cup to the master cylinder piston 90890 03079 Thickness gauge This tool is used to measure the valve clearance 90890 03081 Compression gauge These tools are used to me...

Page 20: ...90890 04019 04108 Valve spring compressor Attachment These tools are used when removing or installing the valve and the valve spring 90890 04058 04078 Middle shaft bearing driver Mechanical seal installer These tools are used for installing mechanical seal 90890 06754 Ignition checker This instrument is necessary for checking the ignition system components 90890 85505 Yamaha bond No 1215 This seal...

Page 21: ...S GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 10 ELECTRICAL 2 14 GENERAL TORQUE SPECIFICATIONS 2 16 LUBRICATION POINTS AND GRADE OF LUBRICANT 2 17 ENGINE 2 17 CHASSIS 2 18 CABLE ROUTING 2 19 ...

Page 22: ......

Page 23: ... Displacement Bore stroke Compression ratio Compression pressure STD Starting system Lubrication system Liquid cooled 4 stroke SOHC Forward inclined single cylinder 0 249L 249 cm3 69 0 66 8 mm 10 1 1 400 kPa 14 kg cm2 14 bar at 500 r min Electric starter Wet sump Oil type or grade Engine oil API STANDERD SE or higher grade Periodic oil change Total amount Transmission oil Total amount 1 2 L 1 4 L ...

Page 24: ...gal automatic type 2 20 X 0 88 1 Chassis Frame type Caster angle Trail Steel tube underbone 28 103 mm Tire Type Size front rear Manufacturer front rear Type front rear Tubeless 110 90 12 64J 130 70 12 62L IRC CHENG SHIN IRC CHENG SHIN MB61 C922 MB61 C940 Tire pressure cold tire Maximum load except motorcycle Loading condition A front rear Loading condition B front rear High speed riding front rear...

Page 25: ...amper Coil spring Oil damper Wheel travel Front wheel travel Rear wheel travel 85 mm 90 mm Electrical Ignition system Generator system Battery type Battery capacity T C I Digital A C magneto GT7B 5 12 V 6 AH Headlight type Quartz bulb Halogen Bulb wattage quantity Headlight Marker light Tail brake light Flasher light Meter light High beam indicator light Oil indicator light Turn indicator light Li...

Page 26: ...4A SDH 104 SSS Rocker arm rocker armshaft Rocker arm inside diameter Rocker shaft outside diameter Rocker arm to rocker armshaft clearance 12 000 X 12 018 mm 11 981 X 11 991 mm 0 009 X 0 012 mm 12 03 mm 11 995 mm SSS Valve valve seat valve guide Valve clearance cold IN EX 0 08 X 0 12 mm 0 16 X 0 20 mm SSS SSS Valve dimensions A head diameter IN EX B face width IN EX C seat width IN EX D margin thi...

Page 27: ...X 42 83 kg SSS SSS 36 1 mm 35 0 mm SSS SSS SSS SSS 2 5_ 1 7 mm 2 5_ 1 7 mm Piston Piston to cylinder clearance Piston size D Measuring point H Piston pin bore inside diameter Piston pin outside diameter 0 02 X 0 04 mm 68 965 X 68 980 mm 5 mm 17 004 X 17 015 mm 16 991 X 17 000 mm 0 15 mm SSS SSS 17 045 mm 16 975 mm Piston rings Top ring Type End gap installed Side clearance installed 2nd ring Type ...

Page 28: ...lot air jet P A J 1 Needle jet N J Pilot outlet P O Pilot jet P J Bypass B P Pilot screw P S Valve seat size V S Starter jet 1 G S 1 Starter jet 2 G S 2 Float height F H Engine idle speed Intake vacuum Oil temperature Cooling water temperature Y28V 1B 1 4UC 00 4UD 00 CH A ø28 130 ø0 9 5D32 3 5 11_ ø1 2 ø2 585 ø0 8 44 0 7 4 17 8 1 4 ø0 45 ø0 5 27 mm 1 450 X 1 550 r min 220 X 260 mmHg 65 X 75_C 80_C...

Page 29: ...OSTAT 80 5 X 83 5_C 95_C 3 mm Item Size Bearings and oil seals Big end bearing Crankshaft bearing left Crankshaft bearing right Crankshaft oil seal left Crankshaft oil seal right Water pump bearing Water pump oil seal Main axle bearing left Main axle bearing right Drive axle bearing left Drive axle bearing right Drive axle oil seal Camshaft bearing left Camshaft bearing right Primary drive gear be...

Page 30: ...y Muffler Muffler and exhaust pipe Protector Muffler Protector Exhaust pipe Crankcase left and right Drain bolt Oil filler Transmission case cover Crankcase cover left Crankcase filter cover Crankcase cover protector Magnet cover Bolt Nut Bolt Bolt Nut Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Bolt Bolt Bolt Nut Bolt Screw Nut Bolt Bolt Screw Screw Bolt Bolt Bolt Bolt Bolt Bolt M6 M8 M12 M...

Page 31: ...ing check plug One way clutch Clutch housing Grease stopper Primary sheave Primary fixed sheave Clutch carrier assembly Stator Pick up coil Starter motor Thermo switch Thermo unit Bolt Plug Bolt Bolt M6 M16 M8 M14 M4 M14 M36 M5 M5 M6 M16 Pt 1 8 2 1 3 1 4 1 1 3 2 2 2 1 12 8 30 60 3 60 90 7 7 10 23 8 1 2 0 8 3 0 6 0 0 3 6 0 9 0 0 7 0 7 1 0 2 3 0 8 ...

Page 32: ... Stroke K1 K2 K3 106 mm 265 mm 317 mm 7 7 N mm 0 77 kg mm 10 9 N mm 1 09 kg mm 17 6 N mm 1 76 kg mm 0 X 40 mm 40 X 75 mm 75 X 106 mm SSS 260 mm SSS SSS SSS SSS SSS SSS SSS Front wheel Type Rim size Rim material Rim runout limit radial Rim runout limit lateral Cast wheel MT2 75 12 Aluminum SSS SSS SSS SSS SSS 2 mm 2 mm Rear wheel Type Rim size Rim material Rim runout limit radial Rim runout limit l...

Page 33: ... front at lever side Brake lever free play rear Throttle cable free play 2 X 5 mm 10 X 20 mm 3 X 5 mm SSS SSS SSS Item Size Bearings and oil seals Front wheel bearing left Front wheel bearing right Front wheel oil seal left Meter gear oil seal right Rear wheel bearing left Rear wheel oil seal inner Rear wheel oil seal outer 6302RS 6302RS SD 22 42 7 1 SDD 47 58 7 6302RS SDO 28 35 4 DD 26 42 8 ...

Page 34: ...y Footrest board Headlight assembly Tail light assembly Front wheel axle and nut Rear wheel axle and nut Rear brake cam lever Rear pivot pin Front brake caliper and front fork Brake disc and hub Brake hose and caliper Brake caliper and bleed screw Windscreen M12 1 25 M10 1 25 M10 1 25 M10 1 25 M10 1 25 M 6 1 0 M 8 1 25 M10 1 25 M 8 1 25 M25 1 0 M20 1 5 M 8 1 25 M10 1 25 M 6 1 0 M 6 1 0 M 6 1 0 M 5...

Page 35: ...n loosen the ring nut 1 4 turn 2 Second tighten the ring nut lower approximately 22 Nm 2 2 mSkg by using the torque wrench then finger tighten the ring nut center Align the slots both ring nut and install the lock washer 3 Final hold the ring nuts lower and center and tighten the ring nut upper 75 Nm 7 5 mSkg by using the torque wrench ...

Page 36: ...esin type 5 kΩ SSS SSS Charging system Type Model manufacturer Normal output Stator coil resistance color A C magneto 4HC MITSUBISHI 14 V 16 A at 5 000 r min 0 8 X 1 0 Ω at 20_C White White SSS SSS SSS SSS Rectifire regulator Model manufacturer No load regulated voltage Capacity Withstand voltage SH640D 12 SHINDENGEN 14 7 V 20 A 200 V SSS SSS SSS SSS Battery Specific gravity 1 310 SSS Electric sta...

Page 37: ... Model manufacturer Sender unit resistance full Sender unit resistance empty 4HC NIPPON SEIKI 4 X 10 Ω 90 X 100 Ω SSS SSS SSS Starting circuit cut off relay Model manufacturer Coil winding resistance 4HC MATSUSHITA 72 X 88 Ω SSS SSS Electric fan motor Model manufacturer 4HC MITSUBA SSS Thermo switch electric fan Model manufacturer 3LN NIHON THERMOSTAT SSS Thermo switch auto choke Model manufacture...

Page 38: ...k To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specified torque specifica tions call for clean dry threads Components should be at room temperature A Distance across flats B Outside thread diameter A Nut B Bolt General torque specifications Nut Bolt Nm mSkg 10 mm 6 mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 ...

Page 39: ...Drive gear inner surface Cam chain outside sprocket inner surface Piston pin Piston outside and ring groove Camshaft cam profile Valve stem IN EX Valve stem end lN EX Rocker shaft Valve rocker arm inner surface Shaft Shaft Oil pump assembly Gasket Oil pump assembly Holder Idle gear 1 thrust surfaces Shaft 1 Idle gear 2 thrust surfaces Idle gear 2 inner surface Main axle thrust surfaces Crankcase m...

Page 40: ...ft right Steering head pipe bearing upper lower Steering head pipe dust seal lips upper lower Tube guide throttle grip inner surface Brake cable brake lever Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft Brake cam pivot shaft and cam surface ...

Page 41: ...lead 15 Battery negative lead 16 Flasher relay 17 Reservoir tank 18 Breather hose 19 Air filter 20 Mainharness 21 Link engine bracket 22 A C magneto lead 23 Starter motor lead 24 Engine earth lead 25 Mudguard A Clamp the fuel sender lead and auto choke lead to the frame B Pass the seat lock cable through the protection pipe C Clamp the mainharness and radiator over flow hose together to the frame ...

Page 42: ... connecting to the taillight assembly to the frame I Connect the taillight assembly lead to the mainharness over the mudguard CABLE ROUTING SPEC J Keep the clamping clearance over 5 mm Bend the metal clamp to keep the clearance between the metal clamp and link over 5 mm K Install the meter cable with its sheaved side facing to the meter gear L Separate the thermo switch lead and ather lead forward...

Page 43: ...d C Install the positive lead between the battery and the starter relay to the starter relay along the chassis D Clamp the seat lock cable to the the frame E Clamp the thermo switch lead and fan motor lead the frame F Clamp the overflow hose to the metal clamp on the frame G Put the coupler of the A C magneto lead and the auto choke lead along the frame pipe after connection H Clamp the mainharnes...

Page 44: ... lead the stay 1 B Pass the speedometer cable and the brake hose through the clamps on the frame Front Speedometer cable Rear Brake hose C Pass the handlebar switch right lead and front brake switch lead through the plastic U clamp D Do not interfere each other after installing the handlebar upper cover E Pass the handlebar switch left lead and rear brake switch lead on the left of the speedometer...

Page 45: ...E ROUTING SPEC G Pass the brake hose through the hose holder and clamp H Clamp the headlight lead and horn lead from mainharness to the stay 1 I Install the brake hose with its marking facing to the stopper side ...

Page 46: ...e crankcase B Pass the air vent hose coolant drain hose and fuel drain hose through the U clamp on the holder C Put the lock of the band to the center from the line a D Pass the drain hose through the clamp spring hook E Pass the overflow hoses from the filler neck and the fuel tank through the clamp F Pass the brake cable 2 through the guide ring G Pass the overflow hose from the tank through the...

Page 47: ...view B D Band the brake cable 2 to the frame at the upper part of the radiator noting the band direction view C E Band the brake cable 2 at the left front of the steering head pipe and set the rest of the band to the left F Set the lock of the band in this range G Clamp the brake cable in front of the pipe H Put the rest of the band end to the side I Pass the brake cable through the guide ring J P...

Page 48: ...SPEC ...

Page 49: ... 16 ENGINE OIL PRESSURE INSPECTION 3 17 TRANSMISSION OIL REPLACEMENT 3 18 EXHAUST SYSTEM INSPECTION 3 19 AIR FILTER CLEANING 3 19 CRANKCASE FILTER CLEANING 3 20 COOLANT LEVEL INSPECTION 3 21 COOLANT REPLACEMENT 3 21 COOLING SYSTEM INSPECTION 3 25 CHASSIS 3 26 FRONT BRAKE ADJUSTMENT 3 26 BRAKE FLUID LEVEL INSPECTION 3 27 BRAKE PAD INSPECTION 3 28 AIR BLEEDING HYDRAULIC BRAKE SYSTEM 3 28 REAR BRAKE ...

Page 50: ......

Page 51: ... Check condition Adjust gap and clean Refer to SPARK PLUG INSPECTION 3 Fuel line Check fuel hose and vacuum pipe for cracks or damage 4 Idle speed Check and adjust engine idle speed Adjust throttle cable free play 5 Engine oil Replace Refer to ENGINE OIL INSPECTION Replace Replace every 3 000 km 6 Oil strainer Clean with solvent Clean Clean every 3 000 km 7 Transmission oil Replace Same as engine ...

Page 52: ... looseness 19 Wheel bearings Check bearing for smooth rotation Items marked with an asterisk require special tools data and technical skills for servicing Take the scooter to a Yamaha dealer The air filter needs more frequent service if you are riding in unusually wet or dusty areas Brake fluid replacement 1 Replace the brake fluid after disassembling the master cylinder or caliper cylinder Check ...

Page 53: ...l left Side panel right Rivet Front panel Clip Damper assembly Seat 1 1 1 2 1 2 1 1 Remove the parts in order Install the damper assembly to the body with its rod side backward and labels up ward Reverse the removal procedure for installation NOTE COVER AND PANEL INSP ADJ COVER AND PANEL SIDE PANEL AND SEAT ...

Page 54: ...acket Screw Tail cover Fuel tank cap Fuel overflow hose Cover Fuel tank cover Coupler fuel sender lead Fuel overflow hose Fuel hose 1 1 2 1 1 1 1 1 1 1 1 Remove the parts in order Tail cover Fuel tank Disconnect the couplers NOTE 10 Nm 1 0 m kg 7 Nm 0 7 m kg 7 Nm 0 7 m kg COVER AND PANEL INSP ADJ TAIL COVER AND FUEL TANK ...

Page 55: ...OVER AND PANEL INSP ADJ Order Job name Part name Q ty Remarks 12 13 14 Vacuum hose Bracket Fuel tank 1 1 1 Reverse the removal procedure for installation Fuel tank 10 Nm 1 0 m kg 7 Nm 0 7 m kg 7 Nm 0 7 m kg ...

Page 56: ...d left right Cover 2 Battery negative lead Battery positive lead Battery Flasher relay Starter relay Reservoir tank Footrest Lid Box Lower cover Footrest board 1 1 1 1 1 1 1 1 1 2 1 1 1 1 Remove the parts in order Reverse the removal procedure for installation 7 Nm 0 7 m kg COVER AND PANEL INSP ADJ FOOTREST BOARD AND LOWER COVER ...

Page 57: ...nner panel Cowling body Coupler headlight lead Coupler front flasher light lead left Coupler front flasher light lead right 1 1 1 1 1 1 Remove the parts in order Reverse the removal procedure for installation Disconnect the couplers NOTE 7 Nm 0 7 m kg 7 Nm 0 7 m kg COVER AND PANEL INSP ADJ COWLING ...

Page 58: ...gshield removal Handle cover Coupler meter lead Meter cable Meter assembly Main switch cover Cover Legshield 1 1 1 2 1 2 1 Remove the parts in order Disconnect the couplers Reverse the removal procedure for installation NOTE COVER AND PANEL INSP ADJ HANDLE COVER METER ASSEMBLY AND LEGSHIELD ...

Page 59: ...rankcase filter cover 1 Crankcase filter cover seal Crankcase filter element 2 3 Remove Spark plug Valve cover intake side Valve cover exhaust side 4 Remove Timing check plug 5 Measure Valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 08 0 12 mm Exhaust valve 0 16 0 20 mm Measurement steps Rotate the primary fixed sheave counter clockwise to align the slit a on the ro...

Page 60: ...g tool 90890 01311 D Hold the adjuster to prevent it from moving and tighten the locknut D Measure the valve clearance D If the clearance is incorrect repeat above steps until specified clearance is obtained 7 Install D Valve cover intake side 1 D O ring 2 8 Install D Valve cover exhaust side D O ring D Spark plug D Timing check window screw D Crankcase filter element D Crankcase filter cover seal...

Page 61: ...crew 2 in or out until the specified idling speed is obtained Turning in Idling speed is increased Turning out Idling speed is decreased 5 Adjust Throttle cable free play Refer to THROTTLE CABLE FREE PLAY ADJUSTMENT section YP303032 THROTTLE CABLE ADJUSTMENT Prior to adjusting the throttle cable free play the engine idling speed should be adjusted 1 Check Throttle cable free play a Out of specific...

Page 62: ...gine idling speed to change EB303040 SPARK PLUG INSPECTION 1 Remove Spark plug cap Spark plug Before removing the spark plug use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinder 1 Check Spark plug type Incorrect Replace Standard spark plug DR8EA NGK 2 Inspect Electrode 1 Wear damage Replace Insulator 2 Abnormal color Replace No...

Page 63: ...tight and free of corrosion and that all ground connec tions are tight 1 Remove D Timing check plug 2 Attach D Timing light 1 Engine tachometer 2 to the spark plug lead Timing light 90890 03141 Engine tachometer 90890 03113 3 Check D Ignition timing Checking steps D Start the engine and let it warm up for several minutes Let the engine run at the specified speed Engine idling speed 1 450 1 550 r m...

Page 64: ...ction 3 Start the engine and let it warm up for sev eral minutes 4 Turn off the engine 5 Remove Spark plug Before removing the spark plug use com pressed air to blow away any dirt accumu lated in the spark plug well to prevent it from falling into the cylinder 6 Attach Compression gauge 1 Compression gauge 90890 03081 7 Measure Compression pressure If it exceeds the maximum pressure al lowed Inspe...

Page 65: ...ps D Crank the engine with the throttle wideopen until the reading on the compression gauge stabilizes Before cranking the engine ground all spark plug leads to prevent sparking 8 Install D Spark plug 9 Install D Side panels Refer to COVER AND PANEL section YP303070 ENGINE OIL LEVEL INSPECTION 1 Stand the scooter on a level surface Make sure the scooter is upright when inspect ing the oil level 2 ...

Page 66: ...use clutch slippage D Be sure no foreign material enters the crankcase 5 Start the engine and let it warm up for a few minutes 6 Turn off the engine Wait a few minutes until the oil settles before in specting the oil level YP ENGINE OIL REPLACEMENT 1 Start the engine and let it warm up for sev eral minutes 2 Turn off the engine and place an oil pan un der the engine 3 Remove D Oil filler plug D Dr...

Page 67: ... reached be sure to reset the oil indi cator light after changing the oil so that it will come on at the correct time to indicate the next 3 000 km oil replacement To reset the oil indicator light before it comes on Release the reset button and the oil indicator light will come on for 1 4 seconds YP ENGINE OIL PRESSURE INSPECTION 1 Remove Side panels Refer to the COVER AND PANEL sec tion 2 Inspect...

Page 68: ...ot apply at high speeds more than specified when checking the pressure Wipe any spilled oil off the engine YP TRANSMISSION OIL REPLACEMENT Make sure the scooter is upright when replacing the oil 1 Stand the scooter on a level surface 2 Start the engine for several minutes to warm it up and then stop 3 Place an oil pan under the crankcase 4 Remove D Oil filler cap D Drain bolt 1 Drain the oil 5 Tig...

Page 69: ...ge Tighten replace D Gasket exhaust pipe Exhaust gas leaks Tighten replace 3 Inspect D Bolt 2 muffler D Connecting bolt 3 muffler Loose Damage Tighten replace YP303123 AIR FILTER CLEANING 1 Remove D Side panels D Air filter case cover Refer to COVER AND PANEL section 2 Remove D Air filter element 1 Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid w...

Page 70: ...The element should be wet but not dripping Recommended oil Engine oil Never use low flash point solvents such as gasoline to clean the air filter element Such solvents may cause a fire or an explosion 6 Install D Air filter element D Air filter case cover D Side panels Refer to ENGINE REMOVAL section in chapter 4 YP CRANKCASE FILTER CLEANING 1 Remove D Crankcase filter cover 1 D Crankcase filter c...

Page 71: ...when inspect ing the coolant level 1 Stand the scooter on a level surface 2 Stand the scooter on its centerstand 3 Inspect D Coolant level Coolant level should be between the maximum a and minimum b marks Coolant level is below the LOWER level line Add soft water tap water up to the proper level Hard water or salt water is harmful to engine parts Use only distilled water if soft water is not avail...

Page 72: ...ing hot fluid and steam may be blown out under pres sure which could cause serious injury When the engine has cooled open the radia tor cap as follows Place a thick rag or a towel over the radiator cap Slowly rotate the cap counterclockwise toward the detent This allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remov...

Page 73: ...owly until the coolant comes out from the carburetor drain pipe D Reservoir tank to maximum level a Recommended coolant High quality ethylene glycol anti freeze containing corrosion inhibitors for aluminium engine Coolant 2 and water 3 soft water Mixed ratio 50 50 Total amount 1 4 L Reservoir tank capacity 0 35 L Handling notes for coolant Coolant is potentially harmful and should be handled with ...

Page 74: ... sure it is soft water Do not use water containing impurities or oil Take care that no coolant splashes onto painted surfaces If it does wash them straightaway with water Do not mix different types of ethylene gly col antifreeze containing corrosion inhib itors for aluminum engines 9 Tighten Screw carburetor bleed Fill the coolant slowly to the specified lev el 10 Install Radiator cap 11 Start the...

Page 75: ...EM INSPECTION INSP ADJ YP303190 COOLING SYSTEM INSPECTION 1 Inspect Radiator 1 Filler hose radiator 2 Outlet hose radiator 3 Pipe Outlet hose radiator 4 Cracks Damage Replace Refer to COOLING SYSTEM section in chapter 5 ...

Page 76: ...urning in Free play is decreased Turning out Free play is increased Tighten the locknut Make sure that there is no brake drag after adjusting the front brake lever free play A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system This air must be removed by bleed ing the brake system before the motorcycle is operated Air in the brake system will con siderab...

Page 77: ...sure the top of the handlebar brake fluid reservoir is horizontal If DOT 4 is not available DOT 3 can be used Brake fluid may corrode painted surfaces or plastic parts Always clean up any split fluid im mediately Use only the designated brake fluid Other fluids may deteriorate the rubber seals causing leakage and poor brake perfor mance Refill with the same type of fluid Mixing fluids may result i...

Page 78: ...ormance may occur if the brake system is not properly bled 1 Bleed Brake system Air bleeding steps a Fill the reservoir with the proper brake fluid b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect a clear plastic hose 1 tightly to the caliper bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake lever severa...

Page 79: ...essary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the brake system have disappeared k Fill the brake fluid reservoir to the proper level Refer to BRAKE FLUID LEVEL IN SPECTION Check brake operation after bleeding the brake system YP REAR BRAKE ADJUSTMENT 1 Check D Brake lever free play 1 rear Out of specification Adjust Free play 10 20 mm 2...

Page 80: ...dicator 1 reaches the wear limit line 2 Replace the brake shoes as a set Refer to REAR WHEEL in CHAPTER 6 YP304130 STEERING HEAD INSPECTION Securely support the scooter so that there is no danger of it falling over 1 Stand the scooter on a level surface Stand the scooter on its centerstand 2 Elevate the front wheel by placing a suit able stand under the engine 3 Check Steering assembly bearings Gr...

Page 81: ...ght angles to the ring nut wrench Ring nut wrench 90890 01403 D Loosen the ring nut lower 4 completely then tighten it to specification Do not overtighten D Check the steering head for looseness or binding by turning it all the way in both direc tions If it binds remove the steering stem as sembly and inspect the steering bearings Refer to STEERING HEAD in CHAPTER 7 D Install the rubber washer D I...

Page 82: ...lebar lower holder Refer to STEERING section in CHAP TER 7 D Handlebar Refer to HANDLEBER section in CHAPTER 7 9 Install D Handlebar cover Refer to COVER AND PANEL section YP304140 FRONT FORK INSPECTION Securely support the scooter so that there is no danger of it falling over 1 Stand the scooter on a level surface 2 Check D Inner tube Scratches damage Replace D Oil seal Excessive oil leakage Repl...

Page 83: ... 7 YP REAR SHOCK ABSORBER INSPECTION 1 Remove D Side panel D Fuel tank D Box Refer to COVER AND PANEL section 2 Check D Rear shock absorber mount Looseness Tighten Bolt upper 1 Bolt lower 2 Refer to REAR SHOCK ABSORBER AND SWINGARM section in chapter 7 YP304160 REAR SHOCK ABSORBER ADJUSTMENT D Always adjust each rear shock absorber preload to the same setting Uneven ad justment can cause poor hand...

Page 84: ...g EB304171 TIRE INSPECTION 1 Measure Tire inflation pressure Out of specification Adjust Tire inflation pressure should only be checked and adjusted when the tire tem perature equals the ambient air tempera ture Tire inflation pressure and suspen sion must be adjusted according to the total weight of the cargo rider passenger and accessories fairing saddlebags etc if approved for this model and ac...

Page 85: ...cator It is dangerous to ride with a worn out tire When the tire tread begins to show signs of wear replace the tire immediately Do not use tubeless tires on a wheel de signed for tube type tires only Tire failure and personal injury may result from sud den deflation Tube type wheel Tube type tire only Tubeless type wheel Tube type or tubeless tire Be sure to install the correct tube when using tu...

Page 86: ... for a while to give the tire time to seat itself properly in the rim Failure to do so could lead to an accident with possible injury to the rider or damage to the scooter 2 After a tire repair or replacement besure to tighten the valve stem locknut 1 to specifi cation EB304180 WHEEL INSPECTION 1 Inspect Wheels Damage Bends Replace Always balance the wheel when a tire or wheel has been changed or ...

Page 87: ...battery are different from those of batterie of general type The MF battery should be charged as ex plained in CHARGING METHOD if the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the bat tery Battery electrolyte is dangerous it contains sulfuric acid which is poisonous and highly caustic Always follow these preventive mea sures Avoid...

Page 88: ... etc D DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 1 Remove D Mat right D Cover battery case Refer to COVER AND PANEL section 2 Disconnect D Battery leads Disconnect the negative lead 1 first and then disconnect the positive lead 2 3 Remove D Battery 4 Check D Battery condition Battery condition checking steps D Connect a digital voltme...

Page 89: ...to be done with the battery mounted on the motorcycle be sure to disconnect the wire at the negative terminal D Never remove the sealing caps of an MF battery D Make sure that the charging clips are in full contact with the terminal and that they are not shorted together A corroded clip on the charger may cause the battery to generate heat in the contact area A weak clip spring may cause sparks D ...

Page 90: ...rd charging current after 5 minutes re place the battery In case that charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after having left the battery unused for more than 30 minutes 12 8 V or more Charg...

Page 91: ...type of battery charger cannot charge the MF battery A variable volt age charger is recommended Check the open circuit voltage after having left the battery for 30 minutes after charging 12 8 V or more Charging is com plete 12 7 V or less Recharging is neces sary Under 12 V Replace the battery NOTE Set the charging time at 20 hours maxi mum YES NO Charging method using a constant current type char...

Page 92: ...ct the negative lead 9 Install Cover battery case Mat right Refer to COVER AND PANEL section YP305010 FUSE INSPECTION Always turn off the main switch when checking or replacing the fuse Otherwise a short circuit may occur 1 Remove Mat right Cover battery case Refer to COVER AND PANEL section 2 Inspect Fuse Inspection steps Connect the Pocket tester to the fuse and check it for continuity Set the t...

Page 93: ...r use other materials in place of a fuse An improper fuse may cause ex tensive damage to the electrical system malfunction of lighting and ignition systems and could possibly cause a fire 4 Install Side panel Panels Refer to COVER AND PANEL section EB305022 HEADLIGHT BEAM ADJUSTMENT 1 Adjust Headlight beam vertical Turn the adjuster 1 in or out Turning in Headlight beam moves lower Turning out Hea...

Page 94: ...INSP ADJ ...

Page 95: ...1 PISTON AND PISTONRINGS REMOVAL 4 22 CYLINDER INSPECTION 4 22 PISTON AND PISTON PIN INSPECTION 4 23 PISTON RINGS INSPECTION 4 24 PISTON RINGS PISTON AND CYLINDER INSTALLATION 4 25 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE 4 27 CRANKCASE FILTER COVER AND CRANKCASE COVER LEFT 4 27 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE 4 28 SECONDARY SHEAVE 4 30 PRIMARY SHEAVE REMOVAL 4 31 SECONDARY SHEAVE AND...

Page 96: ...OIL PUMP 4 42 OIL PUMP INSPECTION 4 43 TRANSMISSION 4 44 CRANKCASE AND CRANKSHAFT 4 46 CRANKSHAFT REMOVAL 4 48 CRANKSHAFT INSPECTION 4 48 CRANKSHAFT INSTALLATION 4 49 ...

Page 97: ...k plug cap Thermo unit lead Startor coil Pick up coil lead Starting motor lead Earth lead Adjuster Brake cable 1 1 1 1 1 1 1 1 Remove the parts in order Refer to COVER AND PANEL section in CHAPTER 3 Refer to COOLANT REPLACEMENT section in CHAPTER 3 Refer to CARBURETOR section in CHAPTER 6 7 Nm 0 7 m kg 10 Nm 1 0 m kg EB400000 ENGINE OVERHAUL ENGINE REMOVAL WIREHARNESS CABLE ...

Page 98: ... 2 ENGINE REMOVAL ENG Order Job name Part name Q ty Remarks 8 9 10 11 Pin Compression spring Cable holder Cable holder 1 1 1 1 Reverse the removal procedure for installation 7 Nm 0 7 m kg 10 Nm 1 0 m kg ...

Page 99: ... Outlet hose cylinder head Air filter case assembly Bolt Self locknut Plane washer Bolt Bolt Plane washer Rod assembly Engine 1 1 1 1 1 2 1 1 1 1 2 1 1 Remove the parts in order Rear shock absorber lower Refer to ENGINE REMOUNTING section Reverse the removal procedure for installation 32 Nm 3 2 m kg 19 Nm 1 9 m kg 7 Nm 0 7 m kg 64 Nm 6 4 m kg HOSES AIR FILTER CASE ENGINE MOUNTING BOLT AND ENGINE ...

Page 100: ...emounting the engine reverse the re moval procedure in job instruction chart Note the following points 1 Install Engine 1 Plane washer 2 Rod 3 Temporarily install the rod and engine and then tighten the bolts and nuts to specifications 2 Tighten Bolt 1 Self locknut engine and swingarm 2 ...

Page 101: ...it lead Plug cap Crankcase breather hose Outlet hose cylinder head Vacuum hose Breather hose crankcase Carburetor joint Joint O ring 1 1 2 1 1 1 1 1 2 Remove the parts in the order Refer to CARBURETOR section in CHAPTER 6 Refer to the COVER AND PANELS section in CHAPTER 3 10 Nm 1 0 m kg 22 Nm 2 2 m kg 60 Nm 6 0 m kg 8 Nm 0 8 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg CYLINDER HEAD ...

Page 102: ...ide O ring Timing chain tensioner assembly Timing chain tensioner gasket Breather plate Cam sprocket Timing chain Cylinder head Cylinder head gasket Dowel pin 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Reverse the removal procedure for installation Refer to CYLINDER HEAD REMOVAL AND INSTALLATION section 22 Nm 2 2 m kg 10 Nm 1 0 m kg 60 Nm 6 0 m kg 10 Nm 1 0 m kg 8 Nm 0 8 m kg 10 Nm 1 0 m kg CYLINDER HE...

Page 103: ...g chain tensioner gasket 4 Remove SBreather plate 2 SCam sprocket 3 STiming chain 4 D Fasten a safety wire to the timing chain to prevent it from falling into the crankcase D Remove the bolt 1 while holding the rotor mounting bolt with a wrench 5 Remove SCylinder head D Loosen the nuts in their proper loosening se quence D Start by loosening each nut 1 2 turn until all are loose YP402000 CYLINDER ...

Page 104: ...ylinder head D Measure the warpage If the warpage is out of specification resur face the cylinder head D Place a 400 600 grit wet abrasive paper on the surface plate and resurface the head us ing a figure eight sanding pattern Rotate the cylinder head several times for an even resurfacement YP404190 CYLINDER HEAD INSTALLATION 1 Install SGasket cylinder head SDowel pins SCylinder head D Apply engin...

Page 105: ... sprocket on the camshaft D When installing the cam sprocket keep the timing chain as tense as possible on the ex haust side D Align the match mark c on the cam sprocket with the stationary pointer d on the cylinder head D Align the pin on the camshaft with the slot in the cam sprocket Do not turn the crankshaft during installa tion of the camshaft Damage or improper valve timing will result D Whi...

Page 106: ...d 4 all the way in D Install the tensioner with a new gasket 5 onto the cylinder D Install the springs 2 and cap bolt 1 D Tighten the bolt with gasket to the specified torque Bolt chain tensioner Cap bolt timing chain tensioner 6 Tighten SBolt cam sprocket 7 Check SValve timing Out of alignment Adjust Refer to the above steps 3 5 8 Check SValve clearance Out of specification Adjust Refer to the VA...

Page 107: ...ntake Rocker arm shaft exhaust Rocker arm Camshaft Locknut Adjuster O ring 1 1 1 1 2 1 2 2 1 Remove the parts in order Refer to CYLINDER HEAD section Refer to ROCKER ARM AND ROCKER SHAFT REMOVAL AND INSTALLATION section Refer to CAMSHAFT INSTALLATION section Reverse the removal procedure for installation 14 Nm 1 4 m kg 14 Nm 1 4 m kg 8 Nm 0 8 m kg CAMSHAFT AND ROCKER ARMS ...

Page 108: ...ft puller bolt 90890 01085 Weight 90890 01084 YP402052 CAMSHAFT INSPECTION 1 Inspect Cam lobes Pitting Scratches Blue discoloration Replace 2 Measure Cam lobes length a and b Out of specification Replace Cam lobes length Intake a 36 545 36 645 mm Limit 36 45 mm b 30 021 30 121 mm Limit 29 92 mm Exhaust a 36 547 36 647 mm Limit 36 45 mm b 30 067 30 167 mm Limit 29 17 mm 3 Inspect Camshaft oil passa...

Page 109: ... Replace D Inspect the surface condition of the rocker arm shafts Pitting scratches blue discoloration Re place or check lubrication D Measure the inside diameter a of the rocker arm holes Out of specification Replace Inside diameter rocker arm 12 000 12 018 mm Limit 12 030 mm D Measure the outside diameter b of the rocker arm shafts Out of specification Replace Outside diameter rocker arm shaft 1...

Page 110: ...rm shaft Molybdenum disulfide oil 4 Install Rocker arm 1 Rocker arm shaft 2 exhaust Exhaust Install the rocker arm shaft exhaust complete ly pushed in 5 Install Rocker arm 1 Rocker arm shaft 2 intake Intake Insert the guide shaft 8 mm 3 into the stud bolt hole on the cylinder head to the rocker arm shaft intake Do not confuse the installation direction of rocker arm shaft Be sure to install the th...

Page 111: ...ve spring inner Valve spring outer Valve intake Valve exhaust Valve guide Spring seat 4 2 2 2 1 1 2 2 Remove the parts in order Refer to CYLINDER HEAD section Refer to ROCKER ARM SHAFT AND ROCKER ARMS section Refer to VALVES AND VALVE SPRINGS REMOVAL INSTALLATION section Refer to VALVES AND VALVE SPRINGS INSTALLATION section Reverse the removal procedure for installation VALVES AND VALVE SPRINGS ...

Page 112: ...ng Valve spring compressor 90890 04019 Attachment 90890 04108 YP VALVES AND VALVE SPRINGS INSPECTION 1 Measure Valve stem diameter Out of specification Replace Valve stem diameter Intake 5 975 5 990 mm Limit 5 94 mm Exhaust 5 960 5 975 mm Limit 5 92 mm YP402010 2 Measure Runout valve stem Out of specification Replace Runout limit 0 01 mm YP402030 3 Measure Free length valve spring Out of specifica...

Page 113: ...ce Valve guide inside diameter Intake 6 000 6 012 mm Limit 6 05 mm Exhaust 6 000 6 012 mm Limit 6 05 mm YP402010 7 Measure Stem to guide clearance Valve guide inside diameter Valve stem diameter Out of specification Replace the valve guide Stem to guide clearance limit Intake 0 08 mm Exhaust 0 10 mm EB402020 VALVE SEATS INSPECTION 1 Eliminate SCarbon deposits from the valve face and valve seat 2 I...

Page 114: ...ear pattern D Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed D If the valve seat is too wide too narrow or the seat is not centered the valve seat must be replaced EB402020 4 Lap SValve face SValve seat After replacing the valve seat valve and valve guide the valve seat and valve face should be lapped Lapping steps D Apply a coarse lapp...

Page 115: ...chanic s blueing dye Dykem b to the valve face D Install the valve into the cylinder head D Press the valve through the valve guide and onto the valve seat to make a clear pattern D Measure the valve seat width c again EB404032 VALVES AND VALVE SPRINGS INSTALLATION 1 Deburr SValve stem end Use an oil stone to smooth the stem end 2 Apply SMolybdenum disulfide oil onto the valve stem 3 and oil seal ...

Page 116: ... valve cotters while compressing the valve spring with a valve spring compressor and attachment 2 Valve spring compressor 90890 04019 Attachment 90890 04108 5 Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood Do not hit so much as to damage the valve ...

Page 117: ...iston pin Piston Piston ring top Piston ring 2nd Side rail Spacer 1 2 1 1 2 1 2 1 1 1 1 2 1 Remove the parts in order Refer to CYLINDER HEAD section Refer to PISTON RINGS PISTON AND CYLINDER INSTALLATION section Refer to PISTON AND PISTON RINGS REMOVAL section Reverse the removal procedure for installation Refer to PISTON RINGS PISTON AND CYLINDER INSTALLATION section CYLINDER AND PISTON ENG CYLIN...

Page 118: ...oving the piston ring open the end gap of the ring by fingers and push up the other side of the ring YP402100 CYLINDER INSPECTION 1 Measure SCylinder bore Out of specification Rebore or replace D Measure the cylinder bore with a cylinder bore gauge D Measure the cylinder bore in parallel to and at right angles to the crankshaft Then find the average of the measurements Cylinder bore 69 000 69 005 ...

Page 119: ...linder bore Piston skirt diameter Refer to CYLINDER section for cylinder bore measurement Out of specification Replace the piston and piston rings as a set Piston to cylinder clearance 0 02 X 0 04 mm 3 Measure Piston pin bore diameter Out of specification Replace Piston pin bore diameter 17 004 17 015 mm Limit 17 045 mm 4 Measure Piston pin outside diameter Out of specification Replace Piston pin ...

Page 120: ...Top ring 0 04 0 08 mm Limit 0 12 mm 2nd ring 0 03 0 07 mm Limit 0 12 mm 2 Position Piston ring into the cylinder Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore a 5 0 mm 3 Measure End gap Out of specification Replace You cannot measure the end gap on the expan der spacer of the oil ring If the oil ring rails show excessive gap replace all three ri...

Page 121: ...de of the rings D Lubricate pistons and piston rings liberally with engine oil 2 Install SPiston 1 SPiston pin 2 SPiston pin clip 3 D Apply engine oil onto the piston pins D The mark a on the piston must face the exhaust side of the cylinder D Before installing the piston pin clip cover the crankcase opening with a clean rag to pre vent the piston pin clip from falling into the crankcase D Make su...

Page 122: ...end lower c Oil ring end upper d 2nd ring end 5 Lubricate SPiston outer surface SPiston ring SCylinder inner surface Engine oil 6 Install SCylinder D Install the cylinder with one hand while com pressing the piston rings with the other hand D Pass the timing chain and timing chain guide exhaust side through the timing chain cav ity ...

Page 123: ... element Crankcase cover protector Crankcase cover left Crankcase cover gasket 1 1 1 1 1 1 Remove the parts in order Refer to COVER AND PANEL section in CHAPTER 3 Reverse the removal procedure for installation 7 Nm 0 7 m kg 7 Nm 0 7 m kg 10 Nm 1 0 m kg V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ENG V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE CRANKCASE FILTER COVER AND CRANKCASE COVER LEFT ...

Page 124: ...Clutch assembly V belt Primary sliding sheave Collar Primary sheave cap 1 1 1 1 1 1 1 1 1 1 Remove the parts in order Refer to PRIMARY SHEAVE REMOVAL section Refer to SECONDARY SHEAVE AND V BELT REMOVAL section Refer to SECONDARY SHEAVE INSTALLATION section Refer to PRIMARY SHEAVE ASSEMBLY section 60 Nm 6 0 m kg 60 Nm 6 0 m kg 3 Nm 0 3 m kg V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE Shell BT greas...

Page 125: ...4 Cam Weight Slider Spacer Oil seal 1 8 4 4 1 Refer to PRIMARY SHEAVE ASSEMBLY section Reverse the removal procedure for installation 60 Nm 6 0 m kg 60 Nm 6 0 m kg 3 Nm 0 3 m kg V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ENG Shell BT grease No 3 90890 69927 ...

Page 126: ... spring Spring seat Guide pin Secondary sliding sheave O ring Oil seal Secondary fixed sheave 1 1 3 1 1 4 1 2 2 1 Disassemble the parts in order Refer to SECONDARY SHEAVE DISASSEMBLY section Refer to SECONDARY SHEAVE INSTALLATION section Refer to SECONDARY SHEAVE INSTALLATION section Reverse the disassembly procedure for assembly 90 Nm 9 0 m kg SECONDARY SHEAVE Apply BEL RAY assembly lube ...

Page 127: ...r holder 90890 01235 YP SECONDARY SHEAVE AND V BELT REMOVAL 1 Remove Nut 1 secondary sheave Clutch housing 2 Loosen the nut secondary sheave while hold ing the clutch housing with the sheave holder 3 Sheave holder 90890 01701 2 Remove Nut 1 clutch carrier Do not remove the nut clutch carrier yet Loosen the nut clutch carrier one turn using the locknut wrench 3 while holding the clutch carrier with...

Page 128: ... compressor 2 and clutch spring holder arm 3 and release the compressed spring after removing the nut Use the spacer 4 ø 30 mm thickness 2 3 mm Clutch spring holder 90890 01337 Clutch spring holder arm 90890 01464 YP CLUTCH INSPECTION 1 Measure SClutch shoe thickness Scratches Glaze using coarse sandpa per Wear Damage Replace Clutch shoe thickness 3 0 mm Limit 2 0 mm D After using the sandpaper cl...

Page 129: ...th 22 6 mm Limit 21 0 mm YP WEIGHT INSPECTION 1 Inspect Weight minimum outside diameter Cracks Wear Scaling Chipping Re place Out of specification Replace Weight out side diameter 20 0 mm Limit 19 5 mm SECONDARY SHEAVE INSPECTION 1 Inspect Secondary fixed sheave smooth opera tion Secondary sliding sheave smooth opera tion Scratches Damage Replace as a set 2 Inspect Torque cam groove 1 Wear Damage ...

Page 130: ... weight and install D Apply Shell BT grease No 3 90890 69927 to the inside of the collar 3 Install SSpacer 1 SSlider 2 SCam 3 SPrimary sliding sheave cap SECONDARY SHEAVE INSTALLATION 1 Apply SBEL RAY assembly lube to the secondary sliding sheave 1 inner surface grease nipple groove and oil seals SBEL RAY assembly lube to the bearings oil seals and inner sur face of the secondary fixed sheave 2 2 ...

Page 131: ... spring Clutch carrier 2 Temporarily tighten the nut 5 while attaching the clutch spring holder 3 and clutch spring holder arm 4 and compress the spring Use the spacer 6 ø 30 mm thickness 2 3 mm Clutch spring holder 90890 01337 Clutch spring holder arm 90890 01464 6 Install V belt 1 Clutch assembly 2 Install the V belt with the clutch assembly to the primary sheave side Never smear grease to the V...

Page 132: ...holding the clutch carrier with the rotor holder 2 Rotor holder 90890 01235 Locknut wrench 90890 01348 8 Install Clutch housing 1 Nut 2 clutch housing Tighten the nut clutch housing using the sheave holder 3 Sheave holder 90890 01701 9 Set V belt 1 Move the V belt to minimum diameter of the pri mary sheave 1 maximum diameter of the sec ondary sheave 2 and make the V belt tense ...

Page 133: ...to cover Dowel pins Startor coil Pick up coil 2 1 1 2 1 2 1 1 Remove the parts in order NOTE Refer to ENGINE OIL REPLACEMENT section in CHAPTER 3 Refer to COVER AND PANEL section in CHAPTER 3 Disconnect the couplers Reverse the removal procedure for installation 7 Nm 0 7 m kg 20 Nm 2 0 m kg 7 Nm 0 7 m kg 10 Nm 1 0 m kg A C MAGNETO AND STARTER CLUTCH ENG A C MAGNETO AND STARTER CLUTCH MAGNETO COVER...

Page 134: ...tor Shaft idle gear Idler gear Starter one way clutch assembly Woodruff key Starter wheel gear 1 1 1 1 1 1 Remove the parts in order Refer to A C MAGNETO ROTOR REMOVAL INSTALLATION section Refer to ROTOR INSTALLATION section Reverse the removal procedure for installation 10 Nm 1 0 m kg 80 Nm 8 0 m kg A C MAGNETO AND STARTER CLUTCH ...

Page 135: ...rotor Sheave holder 90890 01701 2 Remove SRotor 1 SWoodruff key D Remove the rotor 2 using the flywheel pull er D Center the flywheel puller over the rotor Make sure after installing the holding bolts that the clearance between the flywheel pull er and the rotor is the same everywhere If necessary one holding bolt maybe turned out slightly to adjust the flywheel puller s position Cover the cranksh...

Page 136: ...A the starter clutch and the starter wheel gear should be engaged D If not the starter clutch is faulty Replace it D When turning the starter wheel gear counter clockwise B it should turn freely D If not the starter clutch is faulty Replace it YP404131 A C MAGNETO ROTOR INSTALLATION 1 Install SStarter wheel gear 1 SWoodruff key 2 Install the starter wheel gear 1 then install the woodruff key 2 2 I...

Page 137: ...4 41 A C MAGNETO AND STARTER CLUTCH ENG 80 Nm 8 0 m kg NOTE 3 Tighten Nut rotor 1 Tighten the nut rotor 1 while holding the mag neto rotor 2 with a sheave holder 3 Sheave holder 90890 01701 ...

Page 138: ...al A C magneto Cover Pump driven gear Dowel pin Oil pump assembly Gasket Impeller shaft gear Dowel pin Shaft 1 1 1 1 1 1 1 1 Remove the parts in order Refer to the A C MAGNETO AND STARTER CLUTCH section Reverse the removal procedure for installation 7 Nm 0 7 m kg 12 Nm 1 2 m kg OIL PUMP ...

Page 139: ...and the outer rotor 2 Side clearance B between the outer rotor 2 and the pump housing 3 Out of specification Replace the oil pump assembly Housing and rotor clearance C between the pump housing 3 and the ro tors 1 2 Out of specification Replace the oil pump assembly Tip clearance A 0 10 0 34 mm Limit 0 40 mm Side clearance B 0 013 0 036 mm Limit 0 15 mm Housing and rotor clearance C 0 04 0 09 mm L...

Page 140: ...ansmission case cover Gasket transmission case cover Dowel pin Primary drive gear Plain washer Plain washer 1st wheel gear 1 1 2 1 1 1 1 Remove the parts in order Refer to REAR WHEEL REAR BRAKE section in CHAPTER 7 Refer to V BELT CLUTCH SECONDARY PRIMARY SHEAVE section Refer to TRANSMISSION OIL REPLACEMENT section in CHAPTER 3 16 Nm 1 6 m kg TRANSMISSION ...

Page 141: ...4 45 Order Job name Part name Q ty Remarks 8 9 10 11 Drive axle Main axle Primary driven gear Plain washer 1 1 1 1 Reverse the removal procedure for installation 16 Nm 1 6 m kg TRANSMISSION ENG ...

Page 142: ...ear wheel Bolt O ring 1 1 Remove the parts in the order Refer to ENGINE REMOVAL section Refer to CYLINDER HEAD section Refer to CYLINDER AND PISTON sec tion Refer to V BELT CLUTCH AND SEC ONDARY PRIMARY SHEAVE section Refer to A C MAGNETO AND STARTER CLUTCH section Refer to OIL PUMP section Refer to WATER PUMP section in CHAPTER 5 Refer to REAR WHEEL AND REAR BRAKE section in CHAPTER 7 10 Nm 1 0 m...

Page 143: ...kcase right Dowel pin Crankshaft assembly Timing chain Crankcase left Oil seal 1 1 2 1 1 1 1 Refer to CRANKSHAFT INSTALLATION section Refer to CRANKSHAFT REMOVAL INSTALLATION section Reverse the removal procedure for installation 10 Nm 1 0 m kg 10 Nm 1 0 m kg CRANKCASE AND CRANKSHAFT ENG ...

Page 144: ...nkshaft cannot be removed YP CRANKSHAFT INSPECTION 1 Measure Crankshaft runout Out of specification Replace crankshaft and or bearing Measure the crankshaft runout with the crank shaft assembly turning slowly Runout limit 0 03 mm 2 Measure Big end side clearance Out of specification Replace big end bearing crank pin and or connecting rod Big end side clearance 0 35 0 85 mm 3 Measure Crank width Ou...

Page 145: ...l Clogged Blow out the journal with com pressed air YP404073 CRANKCASE INSTALLATION 1 Clean all the gasket mating surface and crankcase mating surface thoroughly 2 Apply Sealant onto the crankcase mating surfaces Yamaha bond No 1215 DO NOT ALLOW any sealant to come in con tact with the oil gallery 3 Install Dowel pins Timing chain 1 Install the timing chain not to be seen through the the crankshaf...

Page 146: ...ENG ...

Page 147: ...CHAPTER 5 COOLING SYSTEM RADIATOR 5 1 INSPECTION 5 2 WATER PUMP 5 3 INSPECTION 5 5 WATER PUMP INSTALLATION 5 5 THERMOSTAT 5 7 INSPECTION 5 8 INSTALLATION 5 8 ...

Page 148: ......

Page 149: ... Fan motor leads Thermo switch leads Filler hose radiator Outlet hose radiator Inlet hose radiator Radiator 1 2 1 1 1 1 Remove the parts in order Refer to COOLANT REPLACEMENT section in CHAPTER 3 Refer to COVER AND PANEL section in CHAPTER 3 Reverse the removal procedure for installation 23 Nm 2 3 m kg RADIATOR COOL YP500000 COOLING SYSTEM RADIATOR ...

Page 150: ...ace 3 Measure D Radiator cap opening pressure D Radiator cap opens at a pressure below the specified pressure Replace Radiator cap opening pressure 110 140 kPa 1 1 1 4 kg cm2 1 1 1 4 bar Measurement steps D Attach the radiator cap tester 1 and adapter 2 to the radiator cap 3 Radiator cap tester 90890 01325 Adapter 90890 01352 D Apply the specified pressure for 10 seconds and make sure there is no ...

Page 151: ...r pump Holder Housing cover Housing cover gasket Water pump housing 1 1 1 1 1 1 1 1 1 Remove the parts in order Refer to COOLANT REPLACEMENT section in CHAPTER 3 Refer to A C MAGNETO AND STARTER CLUTCH section in CHAPTER 4 Refer to WATER PUMP INSTALLATION section A C magneto 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg Oil pump side WATER PUMP COOL WATER PUMP ...

Page 152: ... name Q ty Remarks 9 10 11 Impeller shaft O ring O ring 1 1 1 Refer to WATER PUMP INSTALLATION section Reverse the removal procedure for installation 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg Oil pump side WATER PUMP COOL ...

Page 153: ...pect D Impeller shaft Wear damage Replace Fur deposits Clean 2 Inspect D Impeller shaft gear Wear damage Replace 3 Inspect D Mechanical seal 1 Damage worn wear Replace YP WATER PUMP INSTALLATION 1 Install D Mechanical seal 1 Installation steps D Apply the Yamaha bond 1215 to the outside of the mechanical seal D Install the mechanical seal by using the me chanical seal installer 2 and middle shaft ...

Page 154: ...l installation Incorrect level Reinstall 4 Install D Impeller shaft 1 D Circlip 2 Installation steps D Apply a small amount of grease to the impel ler shaft tip D Install the impeller shaft while turning it Use care so that the oil seal lip is not dam aged or the spring does not slip off its posi tion After installing the impeller shaft check it for smooth rotation 5 Install D O ring 1 6 Install D...

Page 155: ...or Hose clamp Outlet hose thermostat Thermostatic cover Thermostatic valve 1 1 1 1 1 1 Remove the parts in order Refer to COOLANT REPLACEMENT section in CHAPTER 3 Refer to COVER AND PANEL section in CHAPTER 3 10 Nm 1 0 m kg Reverse the removal procedure for installation Refer to THERMOSTAT INSTALLATION section THERMOSTAT COOL THERMOSTAT ...

Page 156: ...water D Observe the thermometer while continually stirring the water 1 Thermostatic valve 2 Vessel 3 Thermometer 4 Water A CLOSE B OPEN The thermostatic valve is sealed and its setting requires specialized work If its accuracy is in doubt replace it A faulty unit could cause seri ous overheating or over cooling 2 Inspect D Thermostatic cover Cracks damage Replace YP INSTALLATION 1 Install D Thermo...

Page 157: ...CHAPTER 6 CARBURETION CARBURETION 6 1 CARBURETOR DISASSEMBLY 6 2 ASSEMBLY 6 4 FUEL LEVEL ADJUSTMENT 6 5 AUTO CHOKE INSPECTION 6 6 FUEL PUMP INSPECTION 6 7 ...

Page 158: ......

Page 159: ...oolant Auto choke lead coupler Inlet Outlet hose carburetor Fuel hose Throttle cable Air filter joint Nut Carburetor ass y 1 1 1 1 2 1 2 1 Remove the parts in order Reverse the removal procedure for installation Refer to COOLANT REPLACEMENT section in CHAPTER 3 Refer to COVER AND PANEL section in CHAPTER 3 CAUTION 10 Nm 1 0 m kg CARBURETOR CARB EB600000 CARBURETION CARBURETOR ...

Page 160: ...emarks Carburetor disassembly Auto choke unit Throttle stop screw set Pilot screw set Cover Diaphragm spring Piston valve Jet needle ass y Coasting enricher Accererating pump Float chamber Float pin 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in order 1 2 3 4 5 6 7 8 9 10 CARBURETOR CARB CARBURETOR DISASSEMBLY ...

Page 161: ...er Job name Part name Q ty Remarks Float Needle valve Main jet Pilot jet Main nozzle 1 1 1 1 1 Refer to CARBURETOR ASSEMBLY section Reverse the disassembly procedure for assembly 11 12 13 14 15 CARBURETOR CARB ...

Page 162: ...spect D Float height a Inspection and adjustment steps D Hold the carburetor in an upside down posi tion D Measure the distance from the mating sur face of the float chamber gasket removed to the top of the float D If the float height is not within specification inspect the valve seat and valve needle D If either is worn replace them both D If both are fine adjust the float height by bending the f...

Page 163: ...Install D Compression spring 1 D Cover 2 YP600060 FUEL LEVEL ADJUSTMENT Gasoline fuel and its vapors are highly flammable and explosive Keep away from sparks cigarettes flames or other sources of ignition 1 Measure D Fuel level a Out of specification Adjust Fuel level 5 6 mm below the float chamber line Measurement and adjustment steps D Place the scooter on a level surface ...

Page 164: ...oth are fine adjust float level by bending the float tang 4 slightly D Install the carburetor D Recheck the fuel level YP AUTO CHOKE INSPECTION Ambient temperature lower than 45_C 1 Remove D Carburetor 2 Inspect D Autochoke unit Connect ø 3 3 mm pipe 2 to the starter 1 and blow it with the mouth etc Possible Good condition Impossible Replace auto choke unit 3 Inspect D Auto choke unit with battery...

Page 165: ...and inspect gasoline to flow out from fuel pipe 1 Engine is running Gasoline flows out Good Engine is stopping Gasoline does not flow out Good D Gasoline fuel and its vapors are highly flammable and explosive Keep away from sparks cigarettes flames or other sources of ignition D Failure to check for fuel leakage may re sult in fire or explosion 3 Install D Side panels Refer to COVER AND PANEL sect...

Page 166: ...CARB ...

Page 167: ...STER CYLINDER DISASSEMBLY 7 15 MASTER CYLINDER INSPECTION 7 16 MASTER CYLINDER ASSEMBLY 7 16 MASTER CYLINDER INSTALLATION 7 17 CALIPER 7 19 CALIPER DISASSEMBLY 7 20 BRAKE CALIPER DISASSEMBLY 7 21 CALIPER INSPECTION 7 21 BRAKE CALIPER ASSEMBLY 7 22 CALIPER INSTALLATION 7 22 FRONT FORK 7 23 FRONT FORK 7 23 FRONT FORK DISASSEMBLY 7 24 FRONT FORK REMOVAL 7 25 FRONT FORK DISASSEMBLY 7 25 FRONT FORK INS...

Page 168: ......

Page 169: ...ar Brake disc 1 1 1 1 1 1 1 Remove the parts in order Securely support the scooter so there is no danger of it falling over Refer to FRONT WHEEL ASSEMBLY section Reverse the removal procedure for installation Refer to FRONT WHEEL INSTALLATION section 70 Nm 7 0 m kg 23 Nm 2 3 m kg FRONT WHEEL AND BRAKE DISC CHAS CHASSIS FRONT WHEEL AND BRAKE DISC FRONT WHEEL AND BRAKE DISC ...

Page 170: ...arks Front wheel disassembly Oil seal Bearing Spacer Bearing 1 1 1 1 Remove the parts in order Reverse the removal procedure for installation Refer to FRONT WHEEL DISASSEMBLY ASSEMBLY section FRONT WHEEL AND BRAKE DISC CHAS FRONT WHEEL DISASSEMBLY ...

Page 171: ...ng it on a flat surface Bends Replace Do not attempt to straighten a bent axle Wheel axle bending limit 0 25 mm 2 Inspect Front tire Wear damage Replace Refer to TIRE INSPECTION in CHAP TER 3 Front wheel Refer to WHEEL INSPECTION in CHAPTER 3 3 Measure Front wheel runout Over the specified limits Replace Front wheel runout limits Radial 1 2 0 mm Lateral 2 2 0 mm 4 Inspect Front wheel bearings Bear...

Page 172: ...Minimum thickness 3 5 mm Out of specification Replace YP FRONT WHEEL ASSEMBLY 1 Install SBearing 1 SSpacer 2 SBearing 3 SOil seal 4 D Apply the lithium soap base grease on the bearing and oil seal lip when installing D Use a socket that matches the outside diam eter of the race of the bearing D Always use a new oil seal D Install the oil seal with its manufacturer s marks or numbers facing outward...

Page 173: ...mmended lubricant Lithium soap base grease 2 Install Speedometer gear unit 1 Make sure that the wheel hub and the speedometer gear unit are installed with the three projections 2 meshed into the three slots 3 3 Install Front wheel Make sure that the slot in the speedometer gear unit fits over the stopper on the front fork outer tube 4 Tighten Front wheel axle Axle nut front wheel axle 1 Before tig...

Page 174: ...on the wheel s bottom spot c Turn the wheel so that the X1 mark is 90_ up d Release the wheel and wait for it to rest Put an X2 mark on the wheel s bottom spot e Repeat the above b c and d several times until all marks come to the same spot f This spot is the wheel s heavy spot X 4 Adjust SWheel static balance Adjusting steps D Install a balancing weight 1 on the rim exact ly opposite to the heavy...

Page 175: ... AND BRAKE DISC CHAS 5 Check SWheel static balance Checking steps D Turn the wheel so that it comes to each point as shown D Check that the wheel is at rest at each point If not readjust the front wheel static balance ...

Page 176: ...ompression spring Pin Rear wheel assembly Brake lining Tension spring Plate washer Camshaft lever Indicator plate Camshaft 1 1 1 1 1 2 2 1 1 1 1 Remove the part in order Refer to REAR SHOCK ABSORBER AND SWINGARM section Refer to REAR BRAKE INSTALLATION section 10 Nm 1 0 m kg REAR WHEEL AND REAR BRAKE CHAS REAR WHEEL AND REAR BRAKE ...

Page 177: ...7 9 REAR WHEEL AND REAR BRAKE CHAS Order Job name Part name Q ty Remarks 12 13 Camshaft shim Camshaft seal 1 1 Reverse the removal procedure for installation 10 Nm 1 0 m kg ...

Page 178: ...pect Brake lining surface Glazed areas Polish Use coarse sand paper After polishing wipe the polished particles with a cloth 2 Measure Brake lining thickness Brake lining thickness a Standard 4 mm Limit 2 mm Out of specification Replace Measuring points Replace the brake shoes as a set if either is worn to the limit 3 Measure Brake drum inside diameter a Out of specification Replace the wheel Brak...

Page 179: ...brake lining do not spill oil or grease on the brake lining YP REAR BRAKE INSTALLATION 1 Install SCamshaft 1 SIndicator plate 2 Installation steps D Set the camshaft with its punched mark a facing the direction as shown D Align the projection b on the indicator plate with th camshaft notch and install D Check the proper position of the brake shoe 2 Install SCamshaft lever 1 Install the camshaft le...

Page 180: ...t name Q ty Remarks 1 2 3 Brake pad removal Caliper support bolt Brake pad Pad support 1 2 1 Remove the parts in order Refer to BRAKE PAD REPLACEMENT section Reverse the removal procedure for installation 23 Nm 2 3 m kg FRONT BRAKE BRAKE PAD ...

Page 181: ...s as a set if either is found to be worn to the wear limit 3 Push the caliper piston into the brake cali per by finger When pushing the caliper piston into the brake caliper brake fluid level in reservoir tank is increasing higher 4 Install SBrake pad 1 Install the brake pad and move the brake caliper to the allow mark direction 5 Install SBolt caliper support bolt 6 Inspect SBrake fluid level Ref...

Page 182: ...g Brake switch Union bolt Plain washer Brake hose Master cylinder bracket Master cylinder 1 1 1 1 1 2 1 1 1 Remove the parts in order Refer to BRAKE FLUID REPLACE MENT section in CHAPTER 3 Refer to MASTER CYLINDER INSTALLATION section Reverse the removal procedure for installation 10 Nm 1 0 m kg 10 Nm 1 0 m kg 26 Nm 2 6 m kg FRONT BRAKE CHAS MASTER CYLINDER ...

Page 183: ...ster cylinder disassembly Master cylinder boot Circlip Master cylinder assembly Spring 1 1 1 1 Remove the parts in order Refer to MASTER CYLINDER ASSEMBLY section Reverse the disassembly procedure for assembly FRONT BRAKE CHAS MASTER CYLINDER DISASSEMBLY ...

Page 184: ...inder assembly 3 Inspect SDiaphragm Wear damage Replace YP MASTER CYLINDER ASSEMBLY D All internal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid DOT 4 D Replace the piston seals and dust seals whenever a master cylinder is disas sembled 1 Install SCylinder cup 1 SMaster cylinder piston 2 Install cylinder cup 1 by using cylin...

Page 185: ...rely into the master cylinder groove Master cylinder boot 2 YP MASTER CYLINDER INSTALLATION 1 Install Master cylinder 1 Master cylinder bracket 2 Align the end of the master cylinder with the punch mark on the handlebar then install the master cylinder bracket 2 with the UP mark facing upward 2 Install Plain washer 1 Brake hose 2 Plain washer 3 Union bolt 4 Align the plain washer notch and master ...

Page 186: ...rubber seals may deterio rate causing leakage and poor brake per formance D Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance D Be careful that water does not enter the significantly lower the boiling point of the fluid may result in vapor lock 4 Inspect SBrake operation ...

Page 187: ...der Union bolt Plain washer Brake hose Caliper support bolt Caliper assembly 1 1 2 1 1 1 Remove the parts in order Refer to BRAKE FLUID REPLACE MENT section in CHAPTER 3 Refer to CALIPER INSTALLATION section Reverse the removal procedure for installation 26 Nm 2 6 m kg 23 Nm 2 3 m kg FRONT BRAKE CHAS CALIPER ...

Page 188: ...embly Brake pad Pad support Caliper piston Dust seal Piston seal Bleed screw Cap 2 1 2 2 2 1 1 Remove the parts in order Refer to BRAKE CALIPER DIS ASSEMBLY ASSEMBLY section Reverse the disassembly procedure for assembly 6 Nm 0 6 m kg FRONT BRAKE CHAS CALIPER DISASSEMBLY ...

Page 189: ...iston from the brake caliper body D Never try to pry out the caliper piston D Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the master cylinder Carefully remove the caliper piston to pre vent damage 2 Remove SDust seal 1 SPiston seal 2 When removing push the seals by your finger D Do not use a sharp instrument Remove seals by your finger D Do no...

Page 190: ...per piston seals whenev er a brake caliper is disassembled 1 Install SPiston seals 1 SDust seal 2 2 Install SCaliper piston 1 Apply brake fluid to the outer surface and install D Do not force D Use care to prevent damage on caliper piston YP CALIPER INSTALLATION 1 Install SCaliper 1 SCaliper support bolt 2 SBrake hose 3 SPlain washer 4 SUnion bolt 5 When installing the brake hose to the cali per l...

Page 191: ...bracket upper Cap bolt O ring Bolt under bracket lower Front fork left right 1 1 1 2 2 2 2 1 1 Remove the parts in order Refer to FRONT WHEEL section Refer to FRONT FORK REMOVAL INSTALLATION section Reverse the removal procedure for installation 45 Nm 4 5 m kg 23 Nm 2 3 m kg 23 Nm 2 3 m kg 49 Nm 4 9 m kg FRONT FORK CHAS FRONT FORK FRONT FORK ...

Page 192: ...d Gasket Inner tube Oil lock piece Damper rod Rebound spring 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in order Refer to FRONT FORK REMOVAL INSTALLATION section Refer to FRONT FORK ASSEMBLY section Refer to FRONT FORK DISASSEM BLY ASSEMBLY section Refer to FRONT FORK ASSEMBLY section Reverse the disassembly procedure for assembly 45 Nm 4 5 m kg 23 Nm 2 3 m kg FRONT FORK DISASSEMBLY ...

Page 193: ...acket upper 1 Loosen only the upper bolt 2 Remove SCap bolt 1 Use 17 mm width hexagonal wrench for remov ing 3 Loosen the bolt under bracket lower to re move the front forks Support the front fork before loosening the pinch bolts YP703020 FRONT FORK DISASSEMBLY 1 Remove SBolt damper rod 1 Loosen the bolt damper rod 1 while holding the damper rod with T handle 2 and holder 3 Damper rod holder 90890...

Page 194: ...imit 0 2 mm Scratches bends damage Replace Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube 2 Measure Fork spring a Front fork spring free length 268 5 mm Wear limit 263 5 mm Over the specified limit Replace YP FRONT FORK ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points 1 Install Damper rod 1 Rebound spring Oil lock piece 2 Inner tube 3 ...

Page 195: ... damper rod holder 3 Damper rod holder 90890 04084 T handle 90890 01326 6 Install SOil seal 1 SRetaining clip SDust seal Use the fork seal driver weight 3 and the attachment 2 D Before installing the oil seal 1 apply lithium soap base grease onto the oil seal lips D Adjust the retaining clip so that it fits into the outer tube groove Make sure that the oil seal numbered side faces upward Fork seal...

Page 196: ...pump the fork up and down to distribute the fork oil 10 Measure SOil level a Out of specification Adjust Oil level 80 mm from the top of the inner tube fully compressed and without the fork spring Hold the fork in an upright position 11 Install SFront fork spring 1 D Install the fork spring with its smaller pitch up ward D Before installing the cap bolt apply grease to the O ring D Temporarily tig...

Page 197: ... the REMOVAL procedure Note the following points 1 Install Front fork 1 Temporary tighten the pinch bolts Pull up the inner tube until its end flushes the top of the under bracket 2 then temporarily tighten the bolt under bracket lower 3 2 Tighten Cap bolts 1 Pinch bolts under bracket upper lower ...

Page 198: ...Master cylinder bracket Master cylinder Grip end right Handlebar switch right Throttle cable Grip assembly Brake cable Lever holder left 1 1 1 1 1 1 2 1 1 1 Remove the parts in order Refer to COVER AND PANEL section in CHAPTER 3 Left thread screw Refer to HANDLEBAR INSTALLATION section Refer to HANDLEBAR INSTALLATION section 10 Nm 1 0 m kg 23 Nm 2 3 m kg HANDLEBAR ...

Page 199: ...Handlebar switch left Grip end left Grip Upper handlebar holder Handlebar 1 1 1 2 1 Refer to HANDLEBAR INSTALLATION section Refer to HANDLEBAR REMOVAL section Refer to HANDLEBAR INSTALLATION section Reverse the removal procedure for installation 10 Nm 1 0 m kg 23 Nm 2 3 m kg ...

Page 200: ...ghten a bent handle bar as this may dangerously weaken the handlebar YP HANDLEBAR INSTALLATION 1 Install SHandlebar 1 D Apply a light coat of lithium soap base grease onto the handlebar right end D Align the match marks a on the handlebar with the lower handlebar holder upper sur face 2 Install SUpper handlebar holder 1 The upper handlebar holders should be installed with the arrow marks a facing ...

Page 201: ...ll SThrottle cable 1 SGrip assembly 2 Apply a light coat of lithium soap base grease onto the inside of the grip assembly and install it to the handlebar 7 Install SGrip end right 1 SHandlebar switch right 2 Installation steps D Align the handlebar switch right mating sur face and punched mark a on the handlebar D Provide a clearance b of 2 5 mm between the grip assembly 3 and handlebar grip Other...

Page 202: ...nter Rubber washer Ring nut lower Ball race cover Ball race 1 Lower bracket 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in order Refer to FRONT WHEEL BRAKE DISC section Refer to FRONT FORK section Refer to HANDLEBAR section Refer to STEERING REMOVAL INSTALLATION section 139 Nm 13 9 m kg 75 Nm 7 5 m kg 1st step 38 Nm 3 8 m kg 2nd step Loosen the ring nut 1 4 turn 3rd step 22 Nm 2 2 m kg STEERING CHAS ST...

Page 203: ... 15 Ball bearing Ball bearing Ball race 1 Ball race 2 22 19 1 1 Refer to STEERING INSTALLATION section Reverse the removal procedure for installation 139 Nm 13 9 m kg 75 Nm 7 5 m kg 1st step 38 Nm 3 8 m kg 2nd step Loosen the ring nut 1 4 turn 3rd step 22 Nm 2 2 m kg ...

Page 204: ...he ring nut upper 3 gradually 2 Remove SRing nut upper SLock washer 1 SRing nut center 2 SRubber washer 3 Remove SRing nut lower 1 Hold the lower bracket by hand then remove by using the exhaust ring and steering nut wrench 2 Exhaust and steering nut wrench 90890 01268 Securely support the steering shaft so that there is no danger of it falling down INSPECTION 1 Wash the bearing and bearing races ...

Page 205: ...eal whenever a steering head disassembled If the bearing race is fitted not squarely the head pipe could be damaged EB704030 STEERING INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Lubricate SBearings upper and lower SBearing races Recommended lubricant Lithium soap base grease 2 Install SRing nut lower SRubber washer SRing nut center SLock washer SRing nut upper Refer to S...

Page 206: ...al Bearing 1 2 1 1 1 1 1 1 1 Remove the parts in order Refer to COVER AND PANEL section in CHAPTER 3 Loosen Remove with the rear brake applied Reverse the removal procedure for installation NOTE NOTE 40 Nm 4 0 m kg 19 Nm 1 9 m kg 135 Nm 13 5 m kg 7 Nm 0 7 m kg 20 Nm 2 0 m kg 23 Nm 2 3 m kg 20 Nm 2 0 m kg 53 Nm 5 3 m kg REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM ...

Page 207: ...ESHOOTING 8 7 CHARGING SYSTEM 8 11 CIRCUIT DIAGRAM 8 11 TROUBLE SHOOTING 8 12 ELECTRIC STARTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLE SHOOTING 8 16 STARTER MOTOR 8 19 LIGHTING SYSTEM 8 22 CIRCUIT DIAGRAM 8 22 TROUBLESHOOTING 8 23 SIGNAL SYSTEM 8 28 CIRCUIT DIAGRAM 8 28 TROUBLESHOOTING 8 29 SIGNAL SYSTEM CHECK 8 31 COOLING SYSTEM 8 37 CIRCUIT DIAGRAM 8 37 TROUBLESHOOTING 8 38 AUTO CHOKE SYSTEM 8...

Page 208: ......

Page 209: ...tion coil 3 Spark plug cap 4 Fuel sender 5 Rectifier Regulator 6 Starting circuit cut off relay 7 Wireharness 8 Thermo unit 9 Ignitor unit 10 Sidestand switch 11 Battery 12 Starter relay 13 Flasher relay 14 Horn EB800000 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 210: ...8 2 CIRCUIT DIAGRAM ELEC CIRCUIT DIAGRAM ...

Page 211: ... light 34 Rear flasher lights 35 Front flasher lights 36 Head light 37 Auxiliary light 38 Turn indicator lights 39 High beam indicator light 40 Meter lights 41 Oil indicator light 42 Reset switch 43 Fuel gauge 44 Read switch 45 Clock 46 Thermometer 47 Speedometer 48 Meter assembly 49 Fuel sender 50 Thermo unit NOTE Starter switch is closed while the button switch is pushed Sidestand switch is clos...

Page 212: ... checking switches Set the pocket tester selector to 1 Ω SWITCH CONNECTION AS SHOWN IN THIS MANUAL This manual contains connection charts like the one shown on the left showing the terminal connections of switches e g the main switch handlebar switch brake switch lighting switch etc The column on the extreme left indicates the dif ferent switch positions the top line indicates the colors of the le...

Page 213: ...n in the left page and check for the correct terminal connections closed circuit according to the color combinations shown in the chart Poor connection fault Repair or replace Indicates coupler positions CHECKING SWITCHES ELEC YP SWITCH POSITION AND TERMINAL CONNECTION ...

Page 214: ...6 IGNITION SYSTEM ELEC 3 Main switch 4 Battery 5 Main fuse 10 Ignitor unit 11 Ignition coil 12 Spark plug 13 Pickup coil 14 Sidestand switch 18 Engine stop switch EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 215: ...Repair or replace the spark plug OUT OF SPECIFICATION Standard spark plug DR8EA NGK Spark plug gap 0 6 X 0 7 mm YP802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE NO SPARK OR INTERMITTENT SPARK Procedure Check 1 Fuse Main 2 Battery 3 Spark plug 4 Ignition spark gap 5 Spark plug cap resistance 6 Ignition coil D Remove the following parts before trouble shooting 1 Footrest board 2 Cowl...

Page 216: ...pocket tester Ω 1 k to the spark plug cap SWhen removing the spark plug cap do not pull the spark plug cap from high tension cord SRemove Turning counterclockwise SConnect Turning clockwise SCheck the high tension cord when connect ing the spark plug cap S When connecting the spark plug cap cut the high tension cord about 5 mm CORRECT Replace the spark plug cap OUT OF SPECIFICATION Tester lead Spa...

Page 217: ...cified re sistance SConnect the pocket tester Ω 1 k to the ignition coil SCheck the secondary has the specified re sistance BOTH MEET SPECIFICATION Replace the ignition coil OUT OF SPECIFICATION Tester lead Red White Terminal Tester lead Orange Terminal Secondary coil resistance 10 7 X 14 5 kΩ 20_C 1 2 Primary coil resistance 3 6 X 4 8 Ω 20_C Tester lead Spark plug lead Tester lead Red White Termi...

Page 218: ... Tester lead Blue Terminal 1 2 SCheck the pickup coil has the specified re sistance MEETS SPECIFICATION Replace the pickup coil OUT OF SPECIFICATION CONTINUITY YP 9 Engine stop switch Refer to CHECKING SWITCHES section NO CONTINUITY Replace the right handlebar switch CONTINUITY YP 10 Sidestand switch Refer to CHECKING SWITCHES section NO CONTINUITY Replace the sidestand switch CORRECT YP 11 Wiring...

Page 219: ...8 11 CHARGING SYSTEM ELEC 1 A C magneto 2 Rectifier regulator 4 Battery 5 Main fuse YP804000 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 220: ...als SRecharge or replace the battery INCORRECT CORRECT YP804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED Procedure Check 1 Fuse Main 2 Battery 3 Charging voltage D Remove the following parts before trouble shooting 1 Side panels 2 Tail cover D Use the special tools specified in the trouble shooting section Engine tachometer 90890 03113 Pocket tester 90890 03112 4 Stator coil resistance 5 Wiri...

Page 221: ...age SStart the engine and accelerate to about 5 000 r min SCheck the terminal voltage OUT OF SPECIFICATION The charging circuit is not faulty Replace the battery MEETS SPECIFICATION Tester lead Battery terminal Tester lead Battery terminal NOTE Charging voltage measured voltage terminal voltage 0 2 X 2 5 V up 1 1 2 Use a fully charged battery CHARGING SYSTEM ELEC ...

Page 222: ...sure the stator coil resistance Replace the stator coil OUT OF SPECIFICATION Tester lead white terminal Tester lead White terminal Stator coil resistance 0 8 X 1 0 Ω 20_C MEETS SPECIFICATION YP 5 Wiring connection Check the entire charging system for connec tions Refer to CIRCUIT DIAGRAM section POOR CONNECTION CORRECT Correct Replace the rectifier regulator ...

Page 223: ...witch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 14 Sidestand switch 15 Starting circuit cut off relay 17 Starter switch 18 Engine stop switch 23 Rear brake switch 24 Front brake switch EB80300 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 224: ...RECT CORRECT YP803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE Procedure Check 1 Fuse Main 2 Battery 3 Starter motor 4 Starter relay 5 Starting circuit cut off relay 6 Main switch D Remove the following parts before trouble shooting 1 Side panels 2 Tail cover 3 Box D Use the special tools specified in the trouble shooting section Pocket tester 90890 03112 7 Engine stop switch 8 Sidest...

Page 225: ...apacity as that of the battery lead or more otherwise it may burn This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity SCheck the starter relay for continuity Tester lead terminal Tester lead terminal 3 4 Replace the starter relay NO CONTINUITY CONTINUITY YP 5 Starting circuit cut off relay SDisconnect the starting circuit cut off relay coupler from t...

Page 226: ...G SWITCHES section NO CONTINUITY Replace the sidestand switch CORRECT YP 9 Front Rear brake switch Refer to CHECKING SWITCHES section in CHAPTER 8 NO CONTINUITY Replace the brake switch CORRECT YP 10 Starter switch Refer to CHECKING SWITCHES section NO CONTINUITY Replace the right handlebar switch CORRECT YP 11 Wiring connection SCheck the connections of the entire starting system Refer to CIRCUIT...

Page 227: ...ction in CHAPTER 4 Reverse the removal procedure for instal lation 7 Nm 0 7 mSkg 7 Nm 0 7 mSkg 10 Nm 1 0 mSkg 5 Nm 0 5 mSkg 1 2 3 4 5 6 7 8 9 Starter motor disassembly Front bracket Ring Shims Rear bracket Ring Shims Brush holder set Armature ass y Stator ass y 1 1 1 1 1 1 1 1 1 Disassembly the parts in order Refer to Starter motor assembly Reverse the disassembly procedure for assembly STARTER MO...

Page 228: ... specification Scrape the mica to the proper value a hacksaw blade can be ground to fit The mica insulation of the commutator must be undercut to ensure proper operation of commu tator 4 Inspect SArmature coil resistances installation continuity Defects Replace the starter motor If commutator is dirty clean it with sandpa per f Continuity No continuity Bad condition Replace 5 Measure SBrush length...

Page 229: ...rocedure Note the following points 1 Install SBrush holder 1 Align the projection a on the brush seat with the slot b on the housing 2 Install SShims 1 SArmature coil 2 3 Install SRing 1 SStator ass y 2 SShims 3 SFront bracket 4 D Apply molybdenum grease lightly on to the bearings of the starter motor D Align the match marks on the yoke with the match marks on the brackets ...

Page 230: ... 4 Battery 5 Main fuse 16 Lights switch 29 Dimmer switch 30 Pass switch 32 Tail Brake light 33 Licence light 36 Head light 39 Auxiliary light 40 Meter lights LIGHTING SYSTEM ELEC EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 231: ...TY CONTINUITY YP 4 Lights switch Refer to CHECKING SWITCHES section Replace the right handlebar switch NO CONTINUITY CONTINUITY YP805010 TROUBLESHOOTING IF THE HEADLIGHT HIGH BEAM INDICATOR LIGHT TAILLIGHT MARKER LIGHT AND OR METER LIGHT FAIL TO COME ON Procedure Check 1 Fuse Main 2 Battery 3 Main switch D Remove the following parts before trouble shooting 1 Tail cover 2 Cowling body D Use the spe...

Page 232: ...ulb socket Refer to CHECKING SWITCHES section Replace the bulb and or bulb socket NO CONTINUITY 2 Voltage SConnect the pocket tester DC20 V to the headlight and high beam indicator light cou plers When the dimmer switch is on low beam When dimmer switch is on high beam or the Pass switch is pushed Headlight Tester lead Green or Yellow lead Tester negative lead Black lead High beam indicator light ...

Page 233: ... leads on the bulb socket connector CONTINUITY 1 STurn the main switch to on STurn the light switch to on position STurn the dimmer switch to low beam or high beam SPass switch to push in SCheck for voltage 12 V on the lead at bulb socket connectors This circuit is not faulty MEETS SPECIFICATION The wiring circuit from the main switch to bulb socket connector is faulty Repair OUT OF SPECIFICATION ...

Page 234: ...ocket connector Tester lead Blue terminal Tester lead Black terminal STurn the main switch to on STurn the lights switch to on or pilot position SCheck the voltage 12 V on the bulb socket connector CONTINUITY 1 2 MEETS SPECIFICATION This circuit is not faulty The wiring circuit from main switch to bulb connector is faulty Repair OUT OF SPECIFICATION YP805022 3 The taillight fails to come on ...

Page 235: ... connector Tester lead Blue terminal Tester lead Black terminal STurn the main switch to on STurn the lights switch to on or pilot position SCheck the voltage 12 V on the bulb socket connector CONTINUITY 1 2 MEETS SPECIFICATION This circuit is not faulty The wiring circuit from main switch to bulb connector is faulty Repair OUT OF SPECIFICATION YP805023 4 If the auxiliary light fails to come on ...

Page 236: ...e 23 Rear brake switch 24 Front brake switch 25 Flasher relay 26 Horn 27 Turn switch 28 Horn switch 33 Tail Brake light 34 Rear flasher lights 35 Front flasher lights 38 Turn indicator lights 43 Fuel gauge 49 Fuel sender EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 237: ...YP 3 Main switch Refer to CHECKING SWITCHES section Replace the main switch NO CONTINUITY CONTINUITY YP806010 TROUBLESHOOTING IF THE FLASHER LIGHT BRAKE LIGHT AND OR INDICATOR LIGHT FAIL TO COME ON IF THE HORN FAILS TO SOUND Procedure Check 1 Fuse Main 2 Battery D Remove the following parts before trouble shooting 1 Cowling body 2 Side panels D Use the special tools in the troubleshooting section ...

Page 238: ...harness SCheck the connections of the entire signal system Refer to CIRCUIT SYSTEM WIRING DIA GRAM section Correct POOR CONNECTION Check condition of each of the signal sys tem s circuits Refer to SIGNAL SYSTEM CHECK section CONTINUITY ...

Page 239: ... to on SCheck for voltage 12 V on the Brown lead at the horn terminal The wiring circuit from the main switch to the horn is faulty Repair OUT OF SPECIFICATION 3 Horn SConnect the pocket tester DC20 V to the horn at the Pink terminal Tester lead Pink terminal Tester lead Frame ground 1 STurn the main switch to on SCheck for voltage on the Pink lead to frame ground Replace the horn NO CONTINUITY CO...

Page 240: ...r is pulled in SCheck for voltage 12 V of the Yellow lead on the bulb socket connector CONTINUITY 1 2 MEETS SPECIFICATION This circuit is not faulty OUT OF SPECIFICATION 2 Brake switch Front Rear Refer to CHECKING SWITCHES section Replace brake switch NO CONTINUITY CONTINUITY 4 Wiring connection SWiring circuit from the main switch to the bulb socket connector is faulty Repair Refer to SIGNAL SYST...

Page 241: ...uit from main switch to flasher relay connector is faulty Repair OUT OF SPECIFICATION 4 Voltage SConnect the pocket tester DC20 V to the flasher relay coupler Tester lead Brown White terminal Tester lead Frame ground 1 STurn the main switch to on SCheck for voltage 12 V on the Brown White lead at the flasher relay terminal The flasher relay is faulty Replace OUT OF SPECIFICATION CONTINUITY 2 Turn ...

Page 242: ... flasher light left Tester lead Chocolate lead Tester lead Black terminal STurn the main switch to on STurn the turn switch to left or right SCheck for voltage 12 V on the Chocolate lead and Dark green at the flasher light ter minal 1 3 MEETS SPECIFICATION This circuit is not faulty OUT OF SPECIFICATION At flasher light right Tester lead Dark green lead Tester lead Black terminal 2 3 SIGNAL SYSTEM...

Page 243: ...coupler Tester lead Green terminal Tester lead Black terminal 1 3 SCheck the fuel sender for specificated resis tance Replace the fuel sender OUT OF SPECIFICATION STurn the main switch to ON SCheck for voltage 12 V of the Brown lead on the fuel sender lead OUT OF SPECIFICATION Check the connection of the entire signal system Refer to CHECKING OF CONNECTIONS Refer to CIRCUIT DIAGRAM MEETS SPECIFICA...

Page 244: ...or DOWN 1 STurn the main switch to ON SCheck the fuel gauge needle moves F or E Replace the fuel gauge DOES NOT MOVE 2 MOVES Float position Needle moves This circuit is not faulty NOTE Before reading the meter stay put the float for more than three minutes respectively at UP or DOWN 1 2 SIGNAL SYSTEM ELEC ...

Page 245: ...8 37 3 Main switch 4 Battery 5 Main fuse 20 Fuse fan 21 Thermo switch 22 Fan motor 46 Thermo meter 50 Thermo unit COOLING SYSTEM ELEC YP80700 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 246: ...efer to CHECKING SWITCHES section Replace the main switch NO CONTINUITY CONTINUITY YP TROUBLESHOOTING IF THE FAN MOTOR FAILS TO TURN Procedure Check 1 Fuse Main Fan 2 Battery 3 Fan motor inspection 1 D Remove the following parts before trouble shooting 1 Side panels 2 Footrest board 3 Under cover 4 Drain the cooling water D Use the special tools specified in the trouble shooting section Pocket tes...

Page 247: ...Remove the thermo switch lead from thermo switch Connect jumper lead to thermo switch leads Turn the main switch to on The wiring circuit from battery to fan motor is faulty Repair DOES NOT MOVE YP YP 2 1 6 Thermo switch Remove the thermo switch from the radiator Connect the pocket tester Ω 1 to the thermo switch Immerse the thermo switch in the water Check the thermo switch for continuity Measure...

Page 248: ...e dropped it must be replaced SDo not touch the thermo switch to the bottom of the heated vessel 7 Wiring connection SCheck the connection of the entire cooling system Refer to CIRCUIT DIAGRAM section Replace the thermo switch OUT OF SPECIFICATION Thermo switch ON Thermo switch OFF A B CORRECT Correct POOR CONNECTION More than 98_C 105 3_C ...

Page 249: ... 3 Main switch Refer to CHECKING SWITCHES section Replace the main switch NO CONTINUITY CONTINUITY YP807010 TROUBLESHOOTING IF THE WATER TEMPERATURE METER FAILS TO MOVE WHEN ENGINE IS WARM Procedure Check 1 Fuse Main Fan 2 Battery 3 Main switch D Remove the following parts before trouble shooting 1 Fuel tank 2 Cowling body D Use the special tools specified in the trouble shooting section Pocket te...

Page 250: ...rom the radiator SImmerse the thermo unit in the cool ant Thermometer Replace the thermo unit OUT OF SPECIFICATION MEETS SPECIFICATION Coolant temperature Resistance YP CORRECT 5 Voltage SConnect the pocket tester DC20 V to the temperature gauge coupler YP Tester lead Green Red terminal Tester lead Frame ground 1 1 2 3 STurn the main switch to on SCheck for voltage 12 V on the temperature gauge le...

Page 251: ...8 43 YP 6 Wiring connection SCheck the connections of the entire cooling system Refer to CIRCUIT DIAGRAM section Correct POOR CONNECTION Replace the temperature gauge CORRECT COOLING SYSTEM ELEC ...

Page 252: ...8 44 3 Main switch 4 Battery 5 Main fuse 8 Thermo switch auto choke 9 Auto choke 10 Ignitor unit 18 Engine stop switch AUTO CHOKE SYSTEM ELEC YP AUTO CHOKE SYSTEM CIRCUIT DIAGRAM ...

Page 253: ... NO CONTINUITY CONTINUITY YP 4 Engine stop switch Refer to CHECKING SWITCHES section Replace the right handlebar switch NO CONTINUITY CONTINUITY YP TROUBLESHOOTING IF THE AUTO CHOKE FAILS TO OPERATE Procedure Check 1 Fuse Main 2 Battery 3 Main switch 4 Engine stop switch D Remove the following parts before trouble shooting 1 Fuel tank 2 Footrest board 3 Cowling body D Use the special tools specifi...

Page 254: ...temperatures while heating the water with the temperature gauge SHandle the thermo switch with special care Never subject it to strong shocks or allow it to be dropped Should it be dropped it must be replaced SDo not touch the thermo switch to bot tom of the heated vessel Replace the thermo switch OUT OF SPECIFICATION Thermo switch on Thermo switch off A B CORRECT 5 Thermo switch NOTE 2 1 3 More t...

Page 255: ... 8 Wiring connection SCheck the connection of the entire auto choke system Refer to CIRCUIT DIAGRAM section POOR CONNECTION Correct YP 7 Voltage temperature under 68_C SConnect the pocket teser DC20 V to the ig nitor unit Tester lead Yellow Red terminal 1 terminal Tester lead Frame ground 1 Replace the ignitor unit OUT OF SPECIFICATION STurn the main switch to on and start the en gine SCheck for v...

Page 256: ...ELEC ...

Page 257: ... DOES NOT RUN 9 4 POOR SPEED PERFORMANCE 9 4 POOR STARTING PERFORMANCE 9 4 OVERHEATING OR OVER COOLING 9 5 OVERHEATING 9 5 OVER COOLING 9 5 FAULTY BRAKE 9 6 POOR BRAKING EFFECT 9 6 FRONT FORK MALFUNCTION 9 6 OIL LEAKAGE 9 6 MALFUNCTION 9 6 INSTABLE HANDLING 9 7 INSTABLE HANDLING 9 7 STARTER MOTOR DOES NOT OPERATE 9 7 STARTER MOTOR DOES NOT OPERATE 9 7 FAULTY SIGNAL AND LIGHTING SYSTEM 9 8 HEADLIGH...

Page 258: ......

Page 259: ... Clogged air passage Improperly set pilot air screw Clogged pilot air passage Improperly sealed valve seat Improperly adjusted fuel level Clogged starter jet Clogged emulsion heated water tube Sucked in air Auto choke Starter plunger malfunction Wax malfunction P T C thermister malfunction Ignitor unit malfunction Thermo switch malfunction Air cleaner Clogged air cleaner element Improper air clean...

Page 260: ... brake switch Faulty sidestand switch Wiring Loose battery terminal Loose coupler connection Improperly grounded Broken wireharness YP901000 POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Loose or clogged pilot jet Damaged carburetor joint Improperly tightened carburetor joint clamp hose Improperly adjusted idle speed Pilot screw Throttle stop screw CO test Improperly adjusted ...

Page 261: ...spark plug Improper heat range Faulty ignitor unit Faulty pick up coil Fuel system Clogged fuel tank cap breather hole Clogged air cleaner element Clooged jet Improperly adjusted fuel level Improper carburetor air vent hose setting Compression system Worn cylinder Worn or seized piston ring Cylinder head gasket broken Cylinder gasket broken Carbon deposit build up Improperly adjusted valve clearan...

Page 262: ... Worn loose Clutch shoe Worn damaged Primary sliding sheave Seized YP POOR STARTING PERFORMANCE V belt Slipping oily V belt Primary sliding sheave Improper operation Damage Compression spring Worn loose Secondary sliding sheave Improper operation Worn guide pin groove Worn guide pin Clutch shoe Worn bent POOR SPEED PERFORMANCE V belt Worn Oily V belt Roller weight Worn improper operation Primary s...

Page 263: ...justed valve timing Improperly adjusted valve clearance Engine oil Incorrect engine oil level Improper engine oil quality High viscosity Low engine oil quality Brakes Dragging brake Cooling system Inoperative fan motor Faulty thermostat Faulty thermo switch Incorrect coolant level low coolant level Faulty radiator Clogged damage Faulty radiator cap Impeller shaft gear malfunction bent dowel pin ge...

Page 264: ...adjustment Worn brake shoe Improper brake shoe contact Worn camshaft Worn brake drum Mud or water into brake drum inside Oily or greasy brake lining Faulty brake cable Broken or fatigued tension spring Faulty camshaft cam lever YP907000 FRONT FORK MALFUNCTION OIL LEAKAGE Bent damaged or rusty inner tube Damaged or cracked outer tube Damaged oil seal lip Loose hexagon bolt Damage cap bolt O ring MA...

Page 265: ...Twisted Damaged head pipe bearings Rear arm Faulty bearings Bent rear arm Rear shock absorber Fatigued spring Improperly adjusted spring preload Oil leakage Cowling Damage Improper mounting YP STARTER MOTOR DOES NOT OPERATE STARTER MOTOR DOES NOT OPERATE Battery Insufficient battery capacity Faulty battery Fuse Burnt out improper connection Switch Faulty main switch Faulty sidestand switch Faulty ...

Page 266: ...xpired FLASHER DOES NOT BLILNK Improperly grounded Insufficient battery capacity Faulty fuse Faulty turn switch Faulty flasher relay Broken wireharness incorrect coupler con nection Bulb burnt out FLASHER KEEPS ON Faulty flasher relay Insufficient battery capacity nearly discharged Bulb burnt out front or rear FLASHER BLINKS SLOWER Faulty flasher relay Insufficient battery capacity nearly discharg...

Page 267: ...witch 31 Handlebar switches left 32 Tail Brake light 33 Licence light 34 Rear flasher lights 35 Front flasher lights 36 Head light 37 Auxiliary light 38 Turn indicator lights 39 High beam indicator light 40 Meter lights 41 Cil indicator light 42 Reset switch 43 Fuel gauge 44 Read switch 45 Clock 46 Thermometer 47 Speedometer 48 Meter assembly 49 Fuel sender 50 Thermo unit COLOR CODE B Black Br Bro...

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