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Yamaha MBK YQ100, Service Manual

The Yamaha MBK YQ100 Service Manual is a comprehensive guide for maintaining and repairing your motorcycle. This detailed manual covers everything you need to know, from troubleshooting to step-by-step instructions. Available for free download at manualshive.com, ensuring you have the necessary resources to keep your bike in top condition.

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CHAS

6-20

FRONT BRAKE

EAS00585

Order

Disassembling the master cylinder

I

Remove:

Q

Master cylinder cap

1

W

Diaphragm

1

II

Remove:

E

Dust boot

1

R

Actuator

1

T

Actuator spring

1

Y

Master cylinder piston

1

U

Piston return spring

1

Remove the parts in the order listed.

NOTE:

Drain completely before removing the
master cylinder.

For installation, reverse the removal proce-
dure.

Q'ty

Job/Part

Remarks

T.R

1.2 Nm (0.12 m.kg)

 

Summary of Contents for MBK YQ100

Page 1: ...YQ100 5ME1 AE1 00 SERVICE MANUAL ...

Page 2: ...YQ100 SERVICE MANUAL 2000 by MBK INDUSTRIE 1st Edition February 2000 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited ...

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

Page 4: ...USE THIS MANUAL This manual is intended as a handy easy to read reference book for the mechanic Comprehensive explanations of all installation removal disassembly assembly repair and check procedures are laid out with the individual steps in sequential order The manual is divided into chapters An abbreviation and symbol in the upper right corner of each page indicate the current chapter Refer to S...

Page 5: ...al system I Troubleshooting Symbols O to r indicate the following O Serviceable with engine mounted P Filling fluid Lubricant Special tool q Tightening torque w Wear limit clearance e Engine speed r Electrical data Symbols t to p in the exploded diagrams indicate the types of lubricants and lubrication points t Engine oil y Gear oil u Molybdenum disulfide oil i Wheel bearing grease o Lithium soap ...

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

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

Page 8: ...GINE NUMBER 1 1 IMPORTANT INFORMATION 1 3 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 3 REPLACEMENT PARTS 1 3 GASKETS OIL SEALS AND O RINGS 1 3 LOCK WASHERS PLATES AND COTTER PINS 1 4 BEARINGS AND OIL SEALS 1 4 CIRCLIPS 1 4 CHECKING THE CONNECTIONS 1 5 HOW TO USE THE CONVERSION TABLE 1 6 SPECIAL TOOLS 1 7 ...

Page 9: ...ion number is stamped on the bottom of the frame as shown ENGINE NUMBER The engine serial number is stamped on the crankcase as shown NOTE The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your state NOTE Designsandspecificationsaresubjecttochange without notice ...

Page 10: ...ll of the parts and placethemintraysintheorderofdisassembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS 1 Use only genuine Yamaha MBK parts for all replacements Use oil and grease recommended by Yamaha MBK for all lubrication jobs Other brands may be similar in function and appearance but i...

Page 11: ...r numbers are visible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appropriate Bearing Do not spin the bearing with compressed air because this will damage the bearing surfaces Oil seal EAS00025 CIRCLIPS 1 Before reassembly check all circlips carefully and replace damaged or distorted circlips Always r...

Page 12: ...isconnectseveral times 3 Check all connections Loose connection Connect properly NOTE If the pin on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE Make sure all connections are tight 5 Check continuity with the pocket tester Pocket tester 90890 03112 NOTE If there is no continuity clean the terminals NOTE When checking the wire harness perform steps 1 to 3 NOTE As a qui...

Page 13: ...VERSION TABLE Metric unit Multiplier Imperial unit Torque m kg 7 233 ft lb m kg 86 794 in lb cm kg 0 0723 ft lb cm kg 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km h 0 6214 mph Distance km 0 6214 mi m 3 281 ft m 1 094 yd cm 0 3937 in mm 0 03937 in Volume cc cm3 0 03527 oz IMP liq Capacity cc cm3 0 061102 cu in lit litre 0 8799 qt IMP liq lit litre 0 2199 gal IMP liq Miscella kg mm 55 997 l...

Page 14: ...ve when removing or installing the nut Locknut wrench This tool is used when removing or installing the secondary sheave nut Tool N Tool name usage Illustration EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune up and assembly Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised ...

Page 15: ... 90890 03113 90890 06754 Fork seal driver weight Fork seal driver attachment ø30 These tools are used when installing the fork seals Ignition checker This instrument is necessary for checking the ignition system components 90890 01337 Clutch spring holder This tool is used for compressing the spring of the secondary sheave when removing the nut 90890 01409 90890 01410 Oil seal guide Oil seal insta...

Page 16: ...2 SPEC ...

Page 17: ...1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 TIGHTENING TORQUES ENGINE 2 7 CHASSIS 2 9 TIGHTENING TORQUES CHASSIS 2 11 ELECTRICAL 2 13 GENERAL TORQUE SPECIFICATIONS 2 15 LUBRICATION POINTS AND LUBRICANT TYPES 2 16 ENGINE 2 16 CHASSIS 2 17 CABLE ROUTING 2 18 ...

Page 18: ...e cylinder Displacement 101 cm3 Bore x stroke 52 0 x 47 6 mm Compression ratio 12 1 0 5 Starting system Electrical and Kick starter Lubrication system Separate lubrification Oil type or grade Engine oil Yamalube 2 or 2 stroke engine oil JASO FC grade or ISO EG C ISO EG D grade Transmission oil SAE 85W140 type SE Oil capacity Engine oil 1 3 L Transmission oil Periodic oil change 0 11 L Total amount...

Page 19: ...es Type Tubeless Size Front 130 60 13 Rear 140 60 13 Manufacturer Type MICHELIN BOPPER PIRELLI SL 36 Wear limit Front Rear 0 8 mm Tires pressure Cold tire Front single riding 150 kPa 1 50 Kg cm2 1 50 bar Rear single riding 150 kPa 1 50 Kg cm2 1 50 bar Front dual riding 150 kPa 1 50 Kg cm2 1 50 bar Rear dual riding 150 kPa 1 50 Kg cm2 1 50 bar Brakes Front brake type Disk brake Operation Right hand...

Page 20: ...AH Headlight type Bulb Bulb wattage x quantity Headlight 12V 35W 35W x 1 Position light 12V 5W x 1 License light 12V 5W x 1 Taillight brake light 12V 5W 21W x 1 Flasher light Front 12V 10W x 2 Rear 12V 10W x 2 Meter light 12V 1 2W x 2 Warning lights wattage quantity OIL 12V 1 2W x 1 TURN 12V 1 2W x 1 HIGH BEAM 12V 1 2W x 1 GENERAL SPECIFICATIONS Model YQ100 ...

Page 21: ... mm 2nd 52 50 mm Piston rings Sectional sketch BxT Type Top ring 1 2 x 2 05 mm keystone 2nd ring 1 2 x 2 05 mm keystone End gap Installed Top ring 0 15 0 35 mm 2nd ring 0 15 0 35 mm Side clearance Installed Top ring 0 03 0 05 mm 2nd ring 0 03 0 05 mm Piston pin Outside diameter 13 996 14 000 mm 13 975 mm Piston pin to piston clearance 14 004 14 015 mm 14 045 mm MAINTENANCE SPECIFICATIONS ENGINE MA...

Page 22: ...m Clutch in revolution 2800 3400 r min Clutch stall revolution 4500 5500 r min V belt Width 17 7 mm 16 0 mm Transmission Main axle runout limit 0 08 mm Drive axle runout limit 0 08 mm Kick starter Type Ratchet type Kick clip tension force 0 15 0 25 kg Carburetor TEIKEI I D mark TK ø16 Main jet M J 76 Main air jet M A J Jet needle J N 3SOF 3 5 Needle jet N J ø2 090 Cutaway C A 3 0 Pilot jet P J 44 ...

Page 23: ... Reed valve Valve stopper height 6 0 6 4 mm Reed Valve Clearance Less than 0 2 mm Lubrication System Autolub Pump Plunger diameter 2 5 mm Autolub pump stroke Manufacturer PLB D39 Dell orto Minimum output at 3000rpm 4 5 cc h Maximum output at 3000rpm 16 cc h ...

Page 24: ... pipe engine Screw M8 2 29 2 9 Exhaust pipe Cylinder Bolt M6 2 8 5 0 85 Muffler protector Bolt M6 3 9 0 9 Cap and pipe Bolt M6 3 11 1 1 Exhaust Cover Bolt M6 3 13 1 3 Crankcase 1x2 Bolt M6 6 12 1 2 Holder Bolt M6 1 7 0 7 Crankcase cover right cover Bolt M6 6 12 1 2 Crankcase cover left cover Bolt M6 12 12 1 2 Drain bolt Bolt M8 1 18 1 8 Plug oil Plug oil M14 1 3 0 3 Idle gear plate Screw M6 2 8 0 ...

Page 25: ... mm Stroke K1 0 80 mm Rear suspension Shock absorber travel 60 mm Spring free length 234 mm Spring fitting length 199 5 mm Spring rate K1 28 N mm K2 35 N mm Stroke K1 0 92 mm K2 92 115 mm Optional spring No Wheels Front wheel type Cast wheel Rear wheel type Cast wheel Front wheel size Material MT 3 00 x13 Aluminium Rear wheel size Material MT 3 50 x 13 Aluminium Rim runout limit Front Radial 1 mm ...

Page 26: ...s 4 5 mm 2 mm Master cylinder inside diameter 11 mm Caliper cylinder inside diameter 30 mm Brake fluid type DOT 3 or DOT 4 Rear drum brake Type Leading trailing Drum inside diameter 130 mm 130 5 mm Lining thickness 4 mm 2 mm Spring free length 54 mm Brake lever freeplay Front brake lever free play 10 20 mm Rear brake lever free play 10 20 mm ...

Page 27: ... shaft M10 60 6 0 Steering nut securing nut Upper 75 7 5 Center Lower 38 3 8 1st tightening 22 2 2 2nd tightening Fuel tank M6 6 5 0 65 Seat lock assy M6 9 5 0 95 Box M6 8 0 8 Cover tail Reinforcement tail M6 6 0 6 Fuel tank Fuel cock 2 5 0 25 Handle seat Reinforcement tail M6 3 5 0 35 Front disk brake M10 23 2 3 Front caliper M10 23 2 3 Lever camshaft M6 13 5 1 35 Front wheel shaft M10 35 3 5 Rea...

Page 28: ...SPEC 2 11 MAINTENANCE SPECIFICATIONS Tightening Part to be tightened Thread torque Remarks size Nm m kg Screws tapping in plastic Ø5 3 2 0 32 Screws tapping in clip Ø5 2 2 0 22 ...

Page 29: ...RYAMA Minimum spark length Primary coil resistance 0 32 0 48 Ω at 20 C Secondary coil resistance 5 68 8 52 kΩ at 20 C Spark plug cap Type Resin Resistance 5 kΩ at 20 C Charging system Type Flywheel magneto CDI Magneto Model Manufacturer 4VP YAMAHA Charging coil resistance color 0 48 0 72 Ω at 20 C White Black Lighting coil resistance color 0 40 0 60 Ω at 20 C Yellow Red Black Voltage Regulator Rec...

Page 30: ...Manufacturer G8MS OMRON Amperage rating 20 A Coil resistance 54 66 Ω at 20 C Horn Type Quantity Plane type 1pc Model Manufacturer GF 12 NIKKO or TR9 TRANSVAL Maximum amperage 2 5 A Flasher relay Type Condenser type Self cancelling device No Flasher frequency 80 160 cycles min Wattage 10W x 2 Circuit breaker Type Fuse Amperage for individual circuit x Quantity 7 5 A x 1 Fuel sender unit Model Manuf...

Page 31: ...torques for stan dard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean...

Page 32: ...gs Secondary sheave axle bearing Piston rings piston pin and piston Kick pinion gear Kick shaft Starter idle gear Starter clutch pin Oil pump driven gear and drive gear Secondary sliding sheave cam groove BEL RAY assembly lube Secondary fixed sheave inside diameter BEL RAY assembly lube Crankcase surface Yamaha N 1215 LS LS LS LS LS LS EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE ...

Page 33: ...ype Front wheel oil seal right left Rear wheel oil seal Steering bearing and bearing race upper lower Throttle grip inner surface Lever pivots and cable end Oil seal lips front wheel Bearing front wheel Speedometer gear Center stand pivot LS LS LS LS LS LS LS LS LS EAS00032 CHASSIS ...

Page 34: ...nd switch 햶 Clip 햷 Starter relay 햸 Fuse 햹 Battery assy 햺 Ignition coil assy 햻 Starter motor 햽 Rear right flasher light 햾 Oil pump wire 햿 Wire harness 헀 Seat lock cable 헁 Fuel and sunction pipe EAS00035 CABLE ROUTING G B A H F E D C 15 10 mm A A q R Y R U I R O R P Q W E R T w A A w e ...

Page 35: ...the footrest board C Pass the wire harness through the footrest board D Push the wire harness to the inside E Place leads backwards F Group connections all together G Place the wire harness in the middle of the engine bracket H Tight hook end with pliers to avoid the cable way out G B A H F E D C 15 10 mm A A q R Y R U I R O R P Q W E R T w A A w e ...

Page 36: ...h R Oil level sender T Wire cylinder assy Y Rectifier Regulator U Band switch cordon I Main switch A A A A A B C D E F Q W E E R E T Y U I O P q w e r O Resistor P Headlight Engine assy Starter wire q Throttle cable w Oil pump wire e Wire harness r Rear brake cable ...

Page 37: ... together B Fix the wire harness C Pass the wire harness between the regulator and the steering head pipe D Secure the right position of the headlight protection E Adjust the oil pump F Turn one round the ground wire around the starter wire A A A A A B C D E F Q W E E R E T Y U I O P q w e r ...

Page 38: ...nd switch 햵 Frame 햶 Front brake hose 햷 Speedometer cable 햸 Gear unit assy 햹 Front mudguard 햺 Front fork assy U I O Q W E R T Y A B A Install the front brake hose on the front fork assy clip B Pass the speedometer cable through the front mudguard bracket ...

Page 39: ...ter cylinder 햴 Speedometer assy 햵 Left hand grip 햶 Rear brake lever 햷 Rear brake cable 햲 햳 햵 햶 햵 햶 햷 햸 햹 햺 햻 햽 햾 햾 햲 햳 햴 햴 F G H E D C B A I 햸 Starter wire 햹 Stop switch wire 햺 Front brake hose 햻 Wire harness 햽 Speedometer cable 햾 Front brake lever ...

Page 40: ...r cable through the hole D Tight this bolt first E Tight this bolt first F Stop the cap on the handlebar end Tight at 7 Nm 0 7 m kg G Stop the grip on the handlebar projection H Pass the flasher light wire through the hole I Position the grip in regards of this switch 햲 햳 햵 햶 햵 햶 햷 햸 햹 햺 햻 햽 햾 햾 햲 햳 햴 햴 F G H E D C B A I ...

Page 41: ...Speedometer cover 햸 Speedometer 햹 Rear handlebar cover 햺 Handlebar switch wire 햻 Starter wire 햽 Master cylinder 햾 Throttle grip A Secure the installation of the clip B Group all connections in this area 5 mm A A B B A B A B 10 1 5 3 0 mm FRONT RIGHT LEFT A B 햲 햳 햳 햴 햴 햵 햵 햶 햶 햷 햸 햹 햹 햺 햺 햻 햻 햽 햾 CABLE ROUTING ...

Page 42: ...3 CHK ADJ ...

Page 43: ...ISSION OIL 3 16 AUTOLUBE PUMP AIR BLEEDING 3 16 CLEANING THE AIR FILTER ELEMENT 3 17 CHECKING THE EXHAUST SYSTEM 3 18 CHASSIS 3 19 ADJUSTING THE FRONT BRAKE 3 19 ADJUSTING THE REAR BRAKE 3 19 CHECKING THE BRAKE FLUID LEVEL 3 20 CHECKING THE FRONT BRAKE PADS 3 21 CHECKING THE BRAKE SHOES 3 21 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 21 CHECKING AND ADJUSTING THE STEERING HEAD 3 22 CHECKING THE FRONT F...

Page 44: ...ecessary Clean or replace if necessary Check electrolyte level and specific gravity Correct or recharge if necessary Check operation fluid level and vehicule for fluid leakage see NOTE on page 3 2 Correct accordingly Replace brake pads if necessary Check operation Adjust brake lever freeplay and replace brake shoes if necessary Check for cracks and damage Replace if necessary Check balance runout ...

Page 45: ... or when cracked or damaged Items maked with an asterisk require special tools data and technical skills for servicing Take the scooter to a Yamaha or MBK dealer when servicing these items INITIAL 1 000 km N ITEM 19 V belt 20 Front and rear bake switches 21 Moving parts and cables 22 Lights signals and switches CHECKS AND MAINTENANCE JOBS Check for wear and damage Replace Check operation Correct a...

Page 46: ...0 8 m kg T R 8 Nm 0 8 m kg Removing the seat and side covers Remove the parts in the order listed I Remove 1 Seat 1 2 Fuel tank cap 1 3 Rear seat screws and strap 2 4 Side covers left and right 2 5 Rear seat 1 For installation reverse the removal procedure Whenremovingthecover becarefulto not damage the mounting clips CAUTION ...

Page 47: ...Removing the box lower side covers Remove the parts in the order listed and mudguard I Remove 1 Glove compartment cover 1 2 Oil cover 1 3 Lower side covers left and right 2 4 Box 1 5 Rear mudguard 1 Whenremovingthecover becarefulto not damage the mounting clips CAUTION Order Job Part Q ty Remarks For installation reverse the removal procedure ...

Page 48: ...SEAT AND SIDE COVERS section For installation reverse the removal procedure Q ty Job Part Remarks FRAME REINFORCEMENT FUEL TANK AND REAR UNDER COVER I Remove 1 Frame reinforcement 1 2 Fuel tank 1 3 Rear under cover 1 4 Rear light 1 2 1 4 3 T R 6 5 Nm 0 65 m kg T R 13 Nm 1 3 m kg T R 3 Nm 0 3 m kg T R 2 Nm 0 2 m kg T R 6 5 Nm 0 65 m kg Whenremovingthecover becarefulto not damage the mounting clips ...

Page 49: ...light 1 2 Front fender 1 3 Front inner panel 1 Remove the parts in the order listed For installation reverse the removal procedure Q ty Job Part Remarks FRONT COVERS 3 T R 2 Nm 0 2 m kg T R 3 Nm 0 3 m kg T R 3 Nm 0 3 m kg T R 3 Nm 0 3 m kg 1 2 3 Whenremovingthecover becarefulto not damage the mounting clips CAUTION ...

Page 50: ...andlebar cover front 1 2 Handlebar cover rear 1 3 Speedometer assy 1 4 Flasher light 1 Remove the parts in the order listed For installation reverse the removal procedure Q ty Job Part Remarks COVERS HANDLEBAR COVERS T R 3 Nm 0 3 m kg T R 3 Nm 0 3m kg T R 3 Nm 0 3 m kg 2 4 1 3 햲 Whenremovingthecover becarefulto not damage the mounting clips CAUTION ...

Page 51: ...arts in the order listed Refer to SEAT AND SIDE COVERS section Refer to BOX SIDE COVERS AND MUD GUARD section Refer to FRONT COVERS section For installation reverse the removal procedure Q ty Job Part Remarks BATTERY COVER AND LOWER COVER COVERS T R 3 Nm 0 3 m kg T R 3 Nm 0 3 m kg 1 2 Whenremovingthecover becarefulto not damage the mounting clips CAUTION ...

Page 52: ...d 1 Remove the parts in the order listed NOTE To remove the main switch ring turn it counterclockwise For installation reverse the removal procedure Q ty Job Part Remarks INNER PANEL AND FOOTREST BOARD Whenremovingthecover becarefulto not damage the mounting clips CAUTION T R 4 Nm 0 4 m kg T R 4 Nm 0 4 m kg 1 2 ...

Page 53: ... cables and wires is essential for a safe operation of this scooter Refer to the section CABLE ROUTING in Chapter 2 NOTE Be careful not to pinch any wires with the covers NOTE When installing the covers be careful to not damage the mounting clips ...

Page 54: ...ed Out of specification Adjust Engine idling speed 2000 200 r mn 4 Adjust engine idling speed a Turnthepilotscrew 햲inuntilitislightlyseated b Turn the pilot screw out the specified number of turns Pilot screw setting TEIKEI TK ø 16 1 5 8 c Turn the throttle stop screw 햳 in direction left or right until the specified engine idling speed is obtained Direction left Engine idling speed is increased Di...

Page 55: ...n the throttle is opened the accelerator cable is pulled Carburetor side a Loosen the locknut on the accelerator cable b Turn the adjusting nut in direction left or right until the specified throttle cable free play is obtained Direction left Throttle cable free play is increased Direction right Throttle cable free play is decreased c Tighten the locknut NOTE If the specified throttle cable free p...

Page 56: ...to ensure that this does not cause the engine idling speed to change ADJUSTING THE THROTTLE CABLE FREE PLAY CHECKING THE SPARK PLUG WARNING EAS00060 CHECKING THE SPARK PLUG 1 Disconnect spark plug cap 햲 2 Remove spark plug 햳 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder 3 Check spark plug type I...

Page 57: ...e spark plug gap 햲 with a wire gauge or feeler gauge Out of specification Adjust Spark plug gap 0 5 0 7 mm 7 Install spark plug Spark plug 20 Nm 2 m kg NOTE Before installing the spark plug clean the spark plug and gasket surface First tighten by hand then torque to specification 8 Connect spark plug cap T R ...

Page 58: ...t Light bulb etc Engine oil level and electric circuit are OK OIL indicator goes OIL indicator stays on Add oil OIL indicator stays on Turn main switch to ON OIL indicator light Recommended oil Yamalube 2 or 2 stroke engine oil JASO FC or EG C EG D grade Capacity Total 1 3 L NOTE Install the oil tank filler cap 햲 and push it fully into the filler Always use the same type of engine oil mixing oils ...

Page 59: ...2 Check gasket drain plug O ring oil filler plug Damage Replace 3 Install gasket drain plug Drain plug 18 Nm 1 8 m kg 4 Fill transmision case Transmission oil SAE 85W 140 type SE Capacity 0 11 L Total amount 0 13 L NOTE Wipe off any oil spilt on the crankcase tire or wheel 5 Install O ring 햲 oil filler plug 햳 AUTOLUBE PUMP AIR BLEEDING 1 Remove fan cover 햲 T R 햲 햳 햲 햳 ...

Page 60: ...lvent a Wash the element gently but thoroughly in a solvent Never use low flash point solvents such as gasoline to clean the air filter element Such solvents may cause a fire or an explosion CAUTION 2 Bleed Pump housing and oil hose a Place a rag under the pump b Remove the bleed screw 햲 c Let oil run until there are no more air bubbles in it d When there are no more bubbles tighten the bleed scre...

Page 61: ... THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes mufflers and gaskets 1 Remove exhaust pipe bolt cylinder exhaust pipe bolt engine 2 Check exhaust pipe 햲 muffler 햳 Cracks damage Replace gasket 햴 Exhaust gas leaks Replace 3 Install exhaust pipe bolt engine exhaust pipe bolt cylinder 4 Tighten exhaust pipe bolt cylinder 햶 exhaust pipe bolt engine 햵 Exhaust pipe bolt en...

Page 62: ...perated Air in the system will reduce brake performance and can result in lost of control andanaccident Inspectandbleedthesystem if necessary EAS00114 ADJUSTING THE REAR BRAKE 1 Check brake lever free play Out of specification Adjust Brake lever free play 10 20 mm 2 Adjust brake lever free play Rear wheel side a Turntheadjustingnut햲indirection햳or햴until the specified brake lever free play is obtain...

Page 63: ...mended brake fluid DOT 3 or DOT 4 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causingleakageandpoorbrake performance Refill with the same type of brake fluid that isalreadyinthesystem Mixingbrakefluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the reservoir Wat...

Page 64: ...ace the brake pad and spring as a set when replacing the brake pads Wear limit 햲 0 5 mm Refer to FRONT BRAKE in chapter 6 EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM 1 Bleed brake fluid a Add proper brake fluid into the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir overflow c Connect a clear plastic tube 햲 tightly to the caliper bleed screw d Placetheo...

Page 65: ...f it falling over NOTE Place the scooter on a suitable stand so that the front wheel is elevated 2 Check steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjustthesteeringhead 3 Remove front cover Refer to FRONT COVER handlebar Refer to REMOVING THE HANDLEBAR in chapter 6 4 Adjust steering head a Remove the upper ring nut 햲 the lock washer 햳 th...

Page 66: ...er and lower bearings Refer to STEERING HEAD in chapter 6 e Install the rubber washer f Install the center ring nut g Finger tighten the center ring nut 햴 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the center ring nut until their slots are aligned h Install the lock washer 햲 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots i Hol...

Page 67: ... FORK 1 Stand the scooter on a level surface Securely support the scooter so that there is no danger of it falling over 2 Check inner tube Damage scratches Replace oil seal Oil leakage Replace 3 Hold the scooter upright and apply the front brake 4 Check front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FR...

Page 68: ...eanticipatedridingspeed Operation of an overloaded scooter could cause tire damage an accident or an injury NEVER OVERLOAD THE SCOOTER Basic weight with oil and a full fuel tank 95 kg Maximum load 280 kg WARNING Cold tire pressure Up to 90 kg load Front Rear 150 kPa 1 50 kg cm2 150 kPa 1 50 kg cm2 90 kg maximum load 150 kPa 1 50kg cm2 150 kPa 1 50 kg cm2 total of cargo rider passenger and accessor...

Page 69: ...y necessary to do so use great care and replace the tube as soon as possible with a good quality replacement Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire After extensive tests the tires listed below have been approved by MBK industrie for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee concerning handling character...

Page 70: ...AS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables Damaged cable sheaths may cause the cable to corrode and interfere with its movement Replace damaged cable sheaths and cables as soon as possible 1 Check cable sheath Damage Replace 2 Check cable operation Rough movement Lubricate Recommended lubricant Engine oil or a suitable cable l...

Page 71: ... CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Engine oil EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Molybdenum disulfide grease ...

Page 72: ...ttes DONOTSMOKEwhenchargingorhandling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL SKIN Wash with water EYES Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk followed with mil...

Page 73: ...ore using it Do not use a high rate battery charger They force a high amperage current into the battery quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery Whenchargingabattery besuretoremove it from the scooter If charging has to be done with the battery mounted on t...

Page 74: ...t rise to specification or bubbles fail to rise during charging sulphation of one or more battery cells occurs as indicated by the battery plates turning white or material accumulating in the bottom of the battery cell specific gravity readings after a long slow charge indicate that one battery cell s charge is lower than the rest warpage or buckling of the battery plates or insulators is evident ...

Page 75: ...se 1 Remove battery cover Refer to BATTERY COVER AND LOWER COVER 2 Check continuity a Connect the pocket tester to the fuse 햲 and check the continuity NOTE Set the pocket tester selector to Ω x 1 Pocket tester 90890 03112 b If the pocket tester indicates replace the fuse CAUTION sm3245 햳 10 Lubricate battery terminals Recommended lubricant Dielectric grease 11 Install battery cover Refer to BATTER...

Page 76: ...the wrong amperage rating may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install battery cover Refer to BATTERY COVER AND LOWER COVER CHECKING THE FUSE REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1 Disconnect front cover 햲 Refer to FRONT COVERS 2 Detach headlight bulb holder 햲 3 Rem...

Page 77: ...ency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 5 Attach headlight bulb holder 6 Connect headlight bulb 7 Install front cover Refer to FRONT COVERS EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam a Turn the adjusting screw 햲 in higher or...

Page 78: ...4 ENG ...

Page 79: ...MARY SHEAVE 4 14 CRANKCASE COVER LEFT 4 14 KICK STARTER 4 15 KICK STARTER INSTALLATION 4 16 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE 4 17 SECONDARY SHEAVE 4 18 PRIMARY SHEAVE REMOVAL 4 19 SECONDARY SHEAVE REMOVAL 4 19 CLUTCH INSPECTION 4 20 V BELT INSPECTION 4 21 PRIMARY SHEAVE INSPECTION 4 22 SECONDARY SHEAVE INSPECTION 4 23 SECONDARY SHEAVE INSTALLATION 4 24 PRIMARY SHEAVE INSTALLATION 4 25 ST...

Page 80: ...ENG CRANKCASE AND REED VALVE 4 37 CRANKCASE RIGHT REMOVAL 4 39 CRANKCASE RIGHT INSTALLATION 4 40 CRANKSHAFT 4 42 CRANKSHAFT REMOVAL 4 43 CRANKSHAFT INSPECTION 4 43 CRANKSHAFT INSTALLATION 4 44 ...

Page 81: ...rder listed Seat Refer to SEAT AND SIDE COVERS Upper side covers in chapter 3 Glove compartment cover Oil cover Refer to BOX SIDE COVERS AND Lower side covers MUDGUARD in chapter 3 Rear mudguard I Remove 1 Air shroud 1 II Remove 2 Autolube delivery hose 1 3 Autolube pump cable 1 4 Spark plug cap 1 5 Battery lead 1 6 CDI magneto leads coupler 2 1 2 3 4 5 6 7 8 9 11 10 ...

Page 82: ...t Q ty Remarks 7 Starter motor lead coupler 1 III Untighten 8 Rear wheel nut 1 Note Loosen the rear wheel nut IV Remove 9 Rear brake adjuster 1 10 Rear brake cable 1 11 Pin 1 For installation reverse the removal procedure 1 2 3 4 5 6 7 8 9 11 10 ...

Page 83: ...in the order listed Lower cover Refer to BATTERY COVER AND LOWER COVER in chapter 3 I Untighten Bolt from cylinder 2 II Remove 1 Gasket 1 2 Bolt 2 3 Spacer damper 1 1 III Remove 4 Bolt from cylinder 2 5 Exhaust pipe 1 For installation reverse the removal procedure LT T R 8 5 Nm 0 85 m kg T R 29 Nm 2 9 m kg 1 2 3 4 5 ...

Page 84: ...rts in the order listed Leads and hoses NOTE Exhaust pipe Place a suitable stand under the frame and engine I Remove 1 Rear shock absorber bolt lower 1 2 Engine mounting bolt 1 II Remove 3 Engine 1 Refer to INSTALLING THE ENGINE Forinstallation reversetheremovalprocedure EAS00192 ENGINE 1 3 2 ...

Page 85: ...y tighten the bolts II Tighten the bolts in the following order 1 Rear shock absorber bolt 1 17 5 Nm 1 75 m kg 2 Engine mounting bolt 1 50 Nm 5 0 m kg III Install 3 Rear brake cable 4 Leads and hoses Referto ENGINE LEADSANDHOSES EAS00192 INSTALLING THE ENGINE 1 4 4 4 4 4 4 4 8 3 T R 17 5 Nm 1 75 m kg T R 50 Nm 5 0 m kg ...

Page 86: ... Refer to BATTERY COVER AND LOWER COVER in chapter 3 Exhaust pipe Refer to EXHAUST PIPE I Remove 1 Air shroud cylinder head 1 2 Spark plug 1 3 Cylinder head Cylinder head gasket 1 1 4 Cylinder 1 5 Cylinder gasket 1 6 Piston pin clip 2 7 Piston pin Piston bearing 1 1 8 Piston 1 9 Piston rings 2 For installation reverse the removal procedure E 2 1 3 4 5 6 9 8 7 T R 14 Nm 1 4 m kg ...

Page 87: ...on pin out CYLINDER HEAD INSPECTION 1 Eliminate Carbon deposits Use a rounded scrapper 2 Inspect Cylinder head warpage Out of specification Re surface Warpage measurement and resurfacement steps Attach a straight edge and a thickness gauge on the cylinder head Measure the warpage limit Warpage limit 0 05 mm If the warpage is out of specification reface the cylinder head NOTE Rotatetheheadseveralti...

Page 88: ...core markes and lacquer deposits From the sides of piston 5 Inspect Piston wall Wear Scratches Damage Replace 6 Measure Piston to cylinder clearance Piston to cylinder clearance measurement steps First step Measure the cylinder bore C with a cylinder bore gauge NOTE Measure the cylinder bore C in parallel to and at right angles to the crankshaft Then find the average of the measurements CYLINDER H...

Page 89: ... a set 3rd step Calculate the piston to cylinder clearance with following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter p If out of specification rebore or replace cylinder and replace piston and piston rings as a set Piston to cylinder clearance 0 044 0 045mm Limit 0 1 mm Standard Wear limit C Maximum D T Maximum D1 or D2 Maximum D5 or D6 R Maximum D1 D3 or D5 Maximum...

Page 90: ... 2 Install Piston ring Into the cylinder Push the ring with the piston crown 3 Measure End gap Out of specification Replace rings as a set Use a feeler gauge Top ring 0 15 0 35 mm 0 60 mm 2nd ring 0 15 0 35 mm 0 60 mm Standard Limit Standard Limit a CYLINDER HEAD CYLINDER PISTON PISTON PIN AND PISTON PIN BEARING INSPECTION 1 Inspect Piston pin Bluediscoloration GrooveÆReplace then inspect lubricat...

Page 91: ...e size piston pin Outside diameter piston pin Piston pin to piston clearance 0 004 0 019 mm 4 Inspect Bearing piston pin Pitting Damage Replace PISTON PIN AND PISTON INSTALLATION 1 Apply Engine oil to the crankshaft bearing connecting rod big end bearing small end bearing piston pin piston ring grooves and piston skirt areas 2 Install Reed valve gasket Reed valve Carburetor joint 11Nm 1 1 m kg T R...

Page 92: ...lly drop the pin clip material into the crankcase Always use a new piston pin clip CYLINDER AND CYLINDER HEAD 1 Install Cylinder gasket new gasket 2 Check Piston rings 1st ring 2nd ring NOTE Make sure the ring ends are properly fitted around the ring locating pins in the piston grooves 3 Install Cylinder NOTE Install the cylinder with one hand while compressing the piston rings with the other hand...

Page 93: ...Cylinder head gasket new gasket 5 Install Cylinder head 14Nm 1 4m kg Spark plug 20Nm 2 0m kg Air shroud NOTE Tighten the cylinder head holding nuts in stage using a crisscross pattern T R T R CYLINDER HEAD CYLINDER PISTON ...

Page 94: ... 1 1 1 2 Job name Part name Crankcase cover left removal Air cleaner assembly mounting screw Screw Bind Kick starter Crankcase left Gasket Pin V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE CRANKCASE COVER LEFT 1 12Nm 1 2kg m T R 2 3 4 5 6 9 Nm 0 9kg m T R 13 Nm 1 3kg m T R ...

Page 95: ...rt name Kick starter removal Kickstarter pinion gear Kickstarter pinion gear clip Circlip Plain washer Kick shaft Return spring Collar Remarks Remove the parts in order Reverse the removal procedure for installation B V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ...

Page 96: ... Plain washer Circlip Installation steps a Install return spring and kick shaft as shown V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE b Install collar plain washer and clip c Hook the spring onto the crankcase projection d Install the kick starter pinion gear and the kick starter ...

Page 97: ... Refer to PRIMARY SHEAVE REMOVAL INSTALLATION section Reverse the removal procedure for installation Job name Part name V belt clutch and secondary primary sheave removal Lower rear cover Air shroud 3 Crankcase left Clutch housing Secondary sheave assembly V belt Conical washer One way clutch Crow washer Primary fixed sheave Collar Washer Primary sliding sheave Cam Slider Weight 1 2 3 4 5 6 7 8 10...

Page 98: ...E INSTALLATION section Refer to SECONDARY SHEAVE INSTALLATION section Reverse the disassembly procedure for assembly Job name Part name Secondary sheave disassembly Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O ring Oil seal Secondary fixed sheave V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE LS LS ...

Page 99: ... tool 90890 01235 3 Remove Conical spring washer One way clutch Crow washer Primary fixed sheave Shim V Belt 4 Remove Collar Primary sheave assembly V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE SECONDARY SHEAVE REMOVAL 1 Remove Nut secondary sheave NOTE Hold the secondary sheave using sheave hol der Sheave holder 90890 01701 2 Remove Clutch housing Secondary sheave assembly Dowel pins ...

Page 100: ... shoes Glazed parts Sand with coarse sandpaper NOTE After using the sand paper clean of the polished particles with cloth 3 Loosen Nut Clutch carrier NOTE Install the secondary sheave to primary drive shaft as shown and hold the secondary sheave by Universal Roter Holder to loosen the nut Flywheel holding tool 90890 01235 Do not remove the clutch securing nut yet If the nut is removed without comp...

Page 101: ...oe thickness 4 mm Wear limit 2 5 mm V BELT INSPECTION 1 Inspect V belt Crack Replace NOTE Replace the V belt smeared with a lot of oil or grease 2 Measure V belt width a Out of specification Replace V belt width 17 7 mm Wear limit 16 0 mm a V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ...

Page 102: ...imary fixed sheave Wear Cracks Scratch Damage Replace 2 Check Free movement Insert the collar into the primary sliding sheave and check for free movement Stick or excessive play Replace the sheave or collar 3 Measure Outside diameter weight Out of specification Replace Outside diameter weight 15 0 mm Limit 14 5 mm ...

Page 103: ...asure Clutch spring free length Out of specification Replace Clutch spring free length 81 mm Limit 73 mm 4 Inspect Clutch housing inner surface Oil Scratches Remove 5 Measure Clutch housing inside diameter a Out of specification Replace Clutch housing inside diameter 112 0 mm Wear limit 112 5 mm Use a rag soaked in lacquer thinner or solvent Use an emery cloth lightly and evenly polishing Oil Scra...

Page 104: ...2 Install Sliding sheave NOTE Be careful so that the oil seal lips are not turned over when installing the sheave 3 Apply BEL RAY assembly lube to the torque cam grooves and O rings 4 Install Guide pin 1 5 Check Sliding sheave Unsmooth operation Repair 6 Install Clutch securing nut Use clutch spring holder Clutch spring holder 90890 01337 7 Tighten Clutch securing nut 50 Nm 5 0 m kg Use Flywheel h...

Page 105: ...mary sliding sheave face Primary fixed sheave face Collar Weight Primary sliding sheave cam surface 2 Install Weight Cam Slider Collar 3 Check Cam operation Not smooth Repair 4 Install Primary sheave assembly Collar 5 Install V belt 8 Install Secondary sheave assembly Clutch housing V belt NOTE The V belt must be installed with the arrow frontward T R 40 Nm 4 0 m kg ...

Page 106: ...lutch Conical spring washer Nut 7 Tighten Nut primary sheave 45 Nm 4 5 kg m NOTE When tightening the nut primary sheave hold the C D I magneto using Flywheel Holding Tool Flywheel holding tool 90890 01235 8 Adjust V belt TensetheV beltbyturningtheprimarysheave several times 9 Install Fan 7 Nm 0 7 kg m T R T R ...

Page 107: ...n Refer to CRANKCASE COVER LEFT section Refer to V BELT PRIMARY SHEAVE section Job name Part name Starter clutch and starter motor removal Left Right lower side cover Left right upper side cover Oil cover Air shroud 3 Cooling fan Crankcase cover left Primary sheave Plate Plain washer Idle gear Plain washer 10 9 8 7 6 5 4 3 2 1 13Nm 1 3kg m T R 8Nm 0 8kg m T R STARTER CLUTCH AND STARTER MOTOR B ...

Page 108: ...tarter clutch Plain washer Starter wheel gear Collar Starter motor Starter motor connector Q ty 1 2 1 1 2 1 Remarks Reverse the removal procedure for instalation 10 9 8 7 6 5 4 3 2 1 13Nm 1 3kg m T R 8Nm 0 8kg m T R STARTER CLUTCH AND STARTER MOTOR B ...

Page 109: ...3 Inspect Starter clutch operation Clutch operation checking steps Install the starter wheel gear to the starter clutch and hold the starter clutch When turning the wheel gear counter clockwise A the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it When turning the wheel gear clockwise B the wheelgearshouldturnfreely Ifnot thestarter clutch is faul...

Page 110: ...R AND LOWER COVER section in chapter 3 Reverse the removal procedure for installation Job name Part name C D I magneto removal Lower cover Oil cover Air shroud 3 Fan O ring Magneto rotor Bind Couplers magneto leads Stator coil Woodruff key Gasket Magneto cover 1 2 3 4 5 6 7 8 43Nm 4 3kg m T R 8Nm 0 8kg m T R C D I MAGNETO 7Nm 0 7kg m T R ...

Page 111: ...ff key Use the flywheel magneto puller Flywheel magneto puller 90890 01189 Stator assembly Gasket ENGINE DISASSEMBLY C D I MAGNETO INSTALLATION 1 Install Gasket 2 Apply Lithium soap base grease to oil seal 3 Pass the C D I magneto lead through the crankcase hole 4 Install Stator assembly 8 Nm 0 8 kg m 5 Install Woodruff key C D I magneto Rotor Plain washer Nut 43Nm 4 3 kg m T R T R B ...

Page 112: ... C D I MAGNETO section Refer to AUTOLUBE PUMP INSTALLA TION section Reverse the removal procedure for ins tallation Job name Part name Autolube pump removal C D I magneto Air shroud 2 Circlip Pump drive gear Pin Oil hose Oil delivery hose Autolube pump cable Autolube pump ass y 1 2 3 4 5 6 7 8 4Nm 0 4kg m T R AUTOLUBE PUMP ...

Page 113: ...er installing autolube pump it must be bleeded 1 Install Pin Pump drive gear Circlip 2 Apply Lithium soap base grease to O ring 3 Install Autolube pump 4 Nm 0 4m kg 4 Apply Lithium soap base grease to autolube pump gear 15 cc 0 92 cu in LS T R CAUTION LS ...

Page 114: ...ECONDARY PRIMARY SHEAVE section Refer to CHANGING THE TRANSMIS SION OIL section in chapter 3 Job name Part name Transmission removal Rear wheel Secondary sheave Drain the transmission oil Transmission case cover Gasket transmission case cover Dowel pin Secondary sheave axle Plain washer Conical spring washer Drive gear 18Nm 1 8kg m T R 12Nm 1 2kg m T R 1 2 3 4 5 6 7 8 9 10 TRANSMISSION B ...

Page 115: ...ISSION TRANSMISSION 18Nm 1 8kg m T R 12Nm 1 2kg m T R 1 2 3 4 5 6 7 8 9 10 TRANSMISSION B Order 8 9 10 Job name Part name Circlip Main axle Drive axle Q ty 1 1 1 Remarks Reverse the removal procedure for installation ...

Page 116: ...ction limit 0 08 mm 2 Measure drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle Drive axle deflection limit 0 08 mm T R T R 319005 a 319005 b 3 Check secondary sheaveaxle bearing main axle bearing drive axle bearing Spin the bearing inner race Excessive play Roughness Replace Pitting Damage Replace 319038 TRANSMISSION ...

Page 117: ...ction Refer to V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE sec tion Refer to C D I MAGNETO section Refer to STARTER CLUTCH AND STAR TER MOTOR section Refer to AUTOLUBE PUMP section Refer to REAR WHEEL AND BRAKE section in chapter 6 Refer to TRANSMISSION section Job name Part name Crankcase and Reed valve removal Engine removal Cylinder head cylinder piston Crankcase cover left V belt clutch seconda...

Page 118: ...SE AND REED VALVE B Order 1 2 3 4 5 6 7 8 9 10 Job name Part name Intake manifold Reed valve Valve seat gasket Stopper Crankcase 2 Dowel pin Engine mount spacer Circlip Bearing Oil seal Q ty 1 1 1 1 1 2 1 1 1 1 Remarks Refer to CRANCKCASE REMOVEL and CRANCKCASE INSTALLATION Reverse the removal procedure for installation ...

Page 119: ...mmer to tap on the case Tap only on reinforced spots of the case Never tap on the gasket mating surfaces Work slowly and carefully Make sure the cases separate evently If one end hand up take the pressure off the push screw realign the cases and the tool and start again If the cases do not separate at all check for remaining case screw or fitting Do not force CRANKCASE AND REED VALVE CRANKCASE RIG...

Page 120: ... tools Crankshaft installing tool 90890 01274 90890 01275 90890 01277 90890 01288 CRANKCASE AND REED VALVE 4 Tighten Crankcase holding screws 12 Nm 1 2 kg m NOTE Tighten the crankcase holding screws in stage using a crisscross pattern 5 Check Crankshaft operation Unsmnoth operation Repair 6 Install Oil seal right crank case Apply grease onto oil seal lip 7 Install Oil seal stopper plate 9 Nm 0 9 k...

Page 121: ...ENG 4 41 CRANKCASE AND REED VALVE 8 Install Gasket Reed valve 11 Nm 1 1 kg m T R ...

Page 122: ...ove the parts in order Refer to CRANKCASE AND REED VALVE section Reverse the removal procedure for installation Job name Part name Crankshaft removal Right crankcase removal Crankshaft Bearing Oil seal Crankcase cover left CRANKSHAFT 1 2 3 4 2 3 CRANKSHAFT B B ...

Page 123: ...limit C Connectingrodbigendsideclearance D Small end free play limit F Out of specification Replace Use V blocks dial gauge and thickness gauge Runout limit C 0 03 mm Connecting rod big end side clearance D 0 2 0 5 mm Small end free play F 0 4 0 8 mm 2 Inspect Bearings crankshaft Spin the bearing inner race Excessive play Roughness Replace Pitting Damage Replace D F C C ...

Page 124: ...ing tool 90890 01274 90890 01275 90890 01277 90890 01288 2 Install Crankshaft to the crankcase CRANKSHAFT 3 Install Oil seal Apply lithium soap base grease onto the oil seal lip Use the guide and seal driver to install the oil seal Oil seal installer 90890 01410 Oil seal guide 90890 01409 ...

Page 125: ...5 CARB ...

Page 126: ...EI CARBURETOR DISASSEMBLY 5 2 CHECKING THE CARBURETOR 5 4 ASSEMBLING THE CARBURETOR 5 5 INSTALLING THE CARBURETOR 5 6 FUEL COCK 5 7 INSPECTING THE FUEL COCK 5 7 CLEANING THE FUEL FILTER 5 7 REED VALVE 5 8 CHECKING THE REED VALVE 5 9 INSTALLING THE REED VALVE 5 9 ...

Page 127: ... Fuel hose 1 2 Vacuum hose 1 3 Oil delivery hose 1 4 Choke cable 1 5 Air filter joint 1 6 Throttle cable 1 7 Carburetor 1 EAS00480 CARBURETOR CARBURETOR Remove the parts in the order listed For installation reverse the removal procedure Remarks Unhook T R 9Nm 0 9kg m 5 7 4 1 2 3 6 ...

Page 128: ...alve 1 Y Starter retaining plate 1 U Starter top cover 1 I Starter plunger O ring 1 O Starter plunger spring 1 P Starter plunger 1 Air screw set 1 Throttle stop screw 1 q Drain screw 1 EAS000483 TEIKEI CARBURETOR DISASSEMBLY Order Job Part Q ty Remarks Remove the parts in the order listed Q U I O P q w e r t y u o i Y W E R T ...

Page 129: ... 1 t Float Needle valve 1 1 y Main jet 1 u Main nozzle 1 i Pilot jet 1 o Carburetor body 1 Order Job name Part name Q ty Remarks CARBURETOR For installation reverse the removal procedure EAS000483 TEIKEI CARBURETOR DISASSEMBLY Q U I O P q w e r t y u o i Y W E R T ...

Page 130: ... not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 2 Check float chamber rubber gasket Cracks damage wear Replace 3 Check main jet 햲 needle jet 햳 pilot jet 햴 Contamination Clean 4 Check float 햳 Damage Replace needle valve 햲 Wear Contamination Replace gasket Damage Replace 5 Check Throttle valve 햲 Damage Wear Replace 322006 햲 햲 햳 322013 322...

Page 131: ... screw 햲 air screw 햳 needle 햴 starter plunger 햵 Damage Wear Replace NOTE The float height is factory adjusted Never try to adjust it yourself EAS00487 ASSEMBLING THE CARBURETOR Before assembling the carburetor wash all of the parts in a petroleum based solvent Always use a new gasket 1 Install needle 햳 clip 햴 throttle valve 햲 spring seat 햵 spring Jet needle clip position 3 5 CAUTION 햲 햳 322015 322...

Page 132: ...gn projection 햲 with projection 햳 햲 햳 322019 햴 햲 햳 322020 EAS00492 INSTALLING THE CARBURETOR 1 Adjust engine idling speed Engine idling speed 1800 2200 r min Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3 2 Adjust throttle cable free play Throttle cable free play at the flange of the throttle grip 1 5 3 0 mm Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 ...

Page 133: ...econds the fuel cock is in good condition If not clean or replace the fuel cock Disconnect the vaccum hose and breathe in through the vaccum hose for vaccum If fuel flows out of the fuel hose under vaccum and stops under non vaccum the fuel cock is in good condition If not clean or replace the vaccum hose fuel hose and fuel cock CLEANING THE FUEL FILTER The fuel filter 햲 is fitted inside the fuel ...

Page 134: ...buretor 1 Carburetor joint 1 2 Reed valve assembly 1 Order Job Part Q ty Remarks REED VALVE REED VALVE For installation reverse the removal procedure Remove the parts in the order listed Refer to CARBURETOR section 2 1 11 Nm 1 1 m kg T R ...

Page 135: ... to carburetor side of assembly Leakage should be slight to moderate INSTALLING THE REED VALVE Reserve the removal procedure Note the following points 1 Install Gasket 2 Tighten Reed valve securing bolts NOTE Tighten the bolts gradually to avoid warping 322023 햲 햲 322024 3 Measure Reed valve clearance 햲 Out of specification Replace reed valve Reed valve clearance 햲 Less than 0 2 mm 2 Measure Valve...

Page 136: ...6 CHAS ...

Page 137: ...ALANCE 6 9 REAR WHEEL AND BRAKE 6 11 CHECKING THE REAR WHEEL 6 13 CHECKING THE BRAKE 6 13 INSTALLING THE REAR BRAKE 6 14 INSTALLING THE REAR WHEEL 6 15 FRONT BRAKE 6 16 FRONT BRAKE PADS 6 16 BRAKE PADS REPLACEMENT 6 18 FRONT BRAKE MASTER CYLINDER 6 19 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 6 21 CHECKING THE FRONT BRAKE MASTER CYLINDER 6 21 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CY...

Page 138: ...SEMBLING THE FRONT FORK LEGS 6 34 HANDLEBAR 6 37 REMOVING THE HANDLEBAR 6 39 CHECKING THE HANDLEBAR 6 39 INSTALLING THE HANDLEBAR 6 40 STEERING HEAD 6 42 REMOVING THE LOWER BRACKET 6 44 CHECKING THE STEERING HEAD 6 44 INSTALLING THE STEERING HEAD 6 45 REAR SHOCK ABSORBER ASSEMBLY 6 46 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 6 47 ...

Page 139: ... Brake disc 1 Remove the parts in the order listed Securely support the scooter so there is no danger of it falling over NOTE Place the scooter on a suitable stand so that the front wheel is elevated Refer to INSTALLINGTHE FRONTWHEEL For installation reverse the removal procedure Q ty Job Part Remarks WARNING EAS00513 CHASSIS FRONT WHEEL AND BRAKE DISC FRONT WHEEL AND BRAKE DISC FWD 1 2 3 7 4 5 7 ...

Page 140: ...the front wheel I Remove 1 Oil seal 1 2 Bearing 2 3 Collar 1 Remove the parts in the order listed Refer to DISASSEMBLING ASSEM BLING THE FRONT WHEEL section For assembly reverse the disassembly procedure Q ty Job Part Remarks EAS00518 FRONT WHEEL FWD 1 3 2 2 ...

Page 141: ...connect Speedometer cable 3 Remove Front brake caliper 4 Loosen Axle nut 5 Remove Axle nut Front wheel axle Front wheel assembly Speedometer gear Collar Front wheel Brake disc NOTE Never depress the brake lever when the wheel is off the scooter Otherwise the brake pads will be forced out Handle the wheel with care not to damage the brake disc If the brake disc is damaged replace it EAS00523 DISASS...

Page 142: ... Check Wheel axle Roll the wheel axle on a flat surface Bends Replace Do not attempt to straighten a bent wheel axle 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure Radial wheel runout Lateral wheel runout Over the specified limits Replace Radial wheel runout limit 1 0 mm Lateral wheel runout limit 1 0 mm WARNING c Remove the ...

Page 143: ...prevent damaging the wheel place a rag between the screwdriver and the wheel surface c Remove the wheel bearings with a general bearing puller CAUTION d Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing inner race or balls Contact should be made only with the outer race NOTE Use a socket that matches the diameter of the wheel bearing ...

Page 144: ...e disc deflection turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 2 3 mm below the edge of the brake disc 347002 347001 3 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace...

Page 145: ...AR UNIT 1 Check Speedometer clutch Bends damage wear Replace 2 Check Speedometer drive gear Speedometer driven gear Damage wear Replace the speedometer gear unit 340004 a EAS00539 ASSEMBLING THE FRONT WHEEL 1 Install Wheel bearings Oil seals a Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing inner race or balls Contact should be made...

Page 146: ... disc bolt 23 Nm 2 3 m kg NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 3 Install Speedometer gear unit NOTE Make sure the speedometer gear unit and the wheel hub are installed with the two projections meshed into the two slots respectively 4 Install Front wheel Besuretoassemblethefrontwheelasshown Difference between A and B 3 mm FRONT WHEEL AND BRAKE DISC WARNING A B T R...

Page 147: ...el c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through f several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X FRONT WHEEL AND BRAKE DISC 5 Tighten Wheel axle Brake caliper bolts ...

Page 148: ...e heavy spot is positioned as shown c If the heavy spot does not stay in that position install a heavier weight d Repeat steps b and c until the front wheel is balanced FRONT WHEEL AND BRAKE DISC 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it X X X X X X ...

Page 149: ...ing 2 2 4 Plate washer 1 5 Adjuster 1 6 Brake cable 1 7 Compression spring 1 Remove the parts in the order listed Refer to BATTERY COVER AND LOWER COVER in chapter 3 Refer to EXHAUST PIPE in Chapter 4 NOTE Place the scooter on a suitable stand so that the rear wheel is elevated Q ty Job Part Remarks Refer to INSTALLING THE REAR WHEEL section FWD 1 3 4 5 8 7 9 10 11 6 2 T R 125 Nm 12 5 m kg T R 9 7...

Page 150: ...ob Part Remarks 8 Pin 1 9 Camshaft lever 1 10 Wear indicator 1 11 Brake camshaft 1 For installation reverse the removal pro cedure Refer to INSTALLING THE REAR BRAKE section FWD 1 3 4 5 8 7 9 10 11 6 2 T R 125 Nm 12 5 m kg T R 9 75 Nm 0 98 m kg ...

Page 151: ... 1 0 mm Lateral wheel runout limit 1 0 mm WARNING EAS00569 CHECKING THE BRAKE The following procedure applies to all of the brake shoes 1 Check Brake shoe lining Glazed areas Repair Sand the glazed areas with course sandpaper NOTE After sanding the glazed areas clean the brake shoe with a cloth 2 Measure Brake shoe lining thickness Out of specification Replace Brake shoe lining thickness limit min...

Page 152: ...installing the springs and the brake shoes take care not to damage the springs CAUTION CAUTION 346009 LS 346010 3 Measure Brake drum inside diameter a Out of specification Replace the wheel Brake drum inside diameter limit maximum 130 5 mm 4 Check Brake drum inner surface Oil deposits Clean Remove the oil with a rag soaked in lacquer thin ner or solvent Scratches Repair Lightly and evenly polish t...

Page 153: ...uffler Bolt exhaust pipe 8 5 Nm 0 85 m kg Bolt muffler 29 Nm 2 9 m kg 4 Adjust Rear brake lever free play Refer to REAR BRAKE LEVER FREE PLAY ADJUSTMENT in Chapter 3 T R 3 Install Wear indicator Camshaft lever a Align the projection on the wear indicator with the camshaft notch and install b Align the punch marks c Check the proper position of the brake shoe 4 Install Plain washer Pin Compression ...

Page 154: ...Remove 1 Plastic cap 1 2 Retaining clip 1 3 Retaining pin 1 4 Pad spring 1 5 Brake pad 2 6 Bleed screw 1 Remove the parts in the order listed Refer to BRAKE PAD REPLACE MENT section For installation reverse the removal proce dure Q ty Job Part Remarks 5 4 2 3 6 Nm 0 6 m kg T R 31 Nm 3 1 m kg T R 6 1 ...

Page 155: ...mble brake components unless absolutely necessary If any connection on the hydraulic brake system is disconnected the entire brake system must be disassembled drained cleaned properly filled and bled after reassembly Never use solvents on internal brake components Use only clean or new brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore alw...

Page 156: ...place the pads as a set if either is found to be worn to the wear limit Wear limit 0 5 mm 2 Push the caliper piston into the brake caliper by finger When pushing the caliper piston into the brake caliper brake fluid level in reservoir tank is increasing higher 3 Install Brake pads Pad spring 4 Inspect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section in Chapter 3 5 Check Brake leve...

Page 157: ... 4 Copper washer Brake hose 2 1 5 Master cylinder bracket 1 II Remove 6 Master cylinder 1 Remove the parts in the order listed Refer to HANDLEBAR COVERS in chapter 3 For installation reverse the removal proce dure Q ty Job Part Remarks FRONT BRAKE EAS00584 FRONT BRAKE MASTER CYLINDER 3 4 2 1 6 5 T R 23 Nm 2 3 m kg T R 6 Nm 0 6 m kg T R 8 5 Nm 0 85 m kg ...

Page 158: ... Diaphragm 1 II Remove E Dust boot 1 R Actuator 1 T Actuator spring 1 Y Master cylinder piston 1 U Piston return spring 1 Remove the parts in the order listed NOTE Drain completely before removing the master cylinder For installation reverse the removal proce dure Q ty Job Part Remarks T R 1 2 Nm 0 12 m kg ...

Page 159: ...ke hose EAS00590 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check brake master cylinder Damage scratches wear Replace brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check brake master cylinder kit Damage scratches wear Replace 347006 346014 a 3 Check brake master cylinder reservoir Cracks damage Replace brake master cylinder reservoir diaphragm ...

Page 160: ...r kit In the master cylinder 2 Install brake master cylinder brake master cylinder bracket 3 Install copper washers brake hose union bolt Union bolt 23 Nm 2 3 m kg Proper brake hose routing is essential to insure safe scooter operation Refer to CABLE ROUTING in Chapter 2 NOTE While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and to the right to make sure t...

Page 161: ...reful that water does not enter the brake master cylinder reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the mini...

Page 162: ...1 Union bolt 1 2 Copper washer 1 3 Brake hose 1 4 Copper washer 1 II Remove 5 Brake caliper 1 Remove the parts in the order listed For installation reverse the removal proce dure Q ty Job name Part name Remarks EAS00612 FRONT BRAKE CALIPER 23 Nm 2 3 m kg T R 1 2 4 5 3 LT LT 31 Nm 3 1 m kg T R ...

Page 163: ...E PADS Refer to DISASSEMBLING THE FRONT BRAKE CALIPER For installation reverse the removal proce dure Q ty Job Part Remarks Caliper disassembly Brake pads I Remove Q Caliper 1 W O ring 1 E Caliper piston 2 R Dust seal 2 T Piston seal 2 Y Bleed screw 1 6 Nm 0 6 m kg T R 23 Nm 2 3 m kg T R 23 Nm 2 3 m kg T R ...

Page 164: ...iston seals and a Secure the right side brake caliper piston with a piece of wood b Blow compressed air into the brake hose joint opening to force out the left side piston from the brake caliper Never try to pry out the brake caliper pistons Do not loosen the bolts Carefullyremovethecaliperpistontoprevent damage c Remove the brake caliper piston seals Do not use a sharp instrument Remove seals by ...

Page 165: ...sas sembled 1 Check brake caliper pistons Rust scratches wear Replace the brake caliper brake caliper cylinders Scratches wear Replace the brake caliper Dust piston seals Damaged Replace the brake caliper brake caliper body Cracks damaged Replacethebrakecaliper brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air 2 Check brake caliper bracket Cracks damage Repl...

Page 166: ...stall brake caliper temporarily copper washers brake hose union bolt Union bolt 23 Nm 2 3 m kg Proper brake hose routing is essential to insure safe scooter operation Refer to CABLE ROUTING 2 Remove brake caliper 3 Install brake pads brake pads springs brake pads retaining pin brake pads retaining clip Brake pads cap brake caliper Refer to REPLACING THE BRAKE PADS Brake caliper bolt 31 Nm 3 1 m kg...

Page 167: ...ater does not enter the brake master cylinder reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the minimum level ma...

Page 168: ...efer to REMOVING THE FRONT FORK LEGS For installation reverse the removal procedure Q ty Job Part Remarks Removing the front fork Front wheel I Remove 1 Caliper assembly 1 2 Front fender 1 II Remove 3 Clip 2 4 Pinch bolt 2 5 Front fork leg 2 FRONT FORK FWD T R 3 Nm 0 3 m kg T R 31 Nm 3 1 m kg T R 30 Nm 3 0 m kg 1 2 4 5 3 ...

Page 169: ...the removal procedure Q ty Job Part Remarks Disassembling the front fork I Remove Q Spring seat clip 2 W Spring seat 2 E O ring 2 R Fork spring 2 II Remove T Dust seal 2 Y Retaining clip 2 U Damper rod bolt gasket 2 2 I Oil seal 2 O Inner tube 2 P Damper rod damper rod spring 2 2 Oil flow stopper 1 EAS00648 LS T R 23 Nm 2 3 m kg ...

Page 170: ...following procedure applies to both of the front fork legs 1 Remove spring seat clip spring seat o ring fork spring a Hold the inner tube vertically b Securely clamp the inner tube in a vise with soft jaws Do not scratch the inner tube c Press down on the spring seat with a suitable bar d While pressing down on the spring seat remove the spring seat clip with a thin flat head screwdriver e Remove ...

Page 171: ...with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully Avoid bottoming the inner tube into the outer tube during the above procedure as the oil flow stopper will be damaged CAUTION 342010 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check inner tube outer tube Bends damage scratches R...

Page 172: ...e assembling the front fork leg make sure all of the components are clean 1 Install damper rod assembly Allowthedamperrodassemblytoslideslowly down the inner tube until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate inner tube s outer surface Recommended lubricant Fork oil ISO 6743 4 LHV 46 or SAE 10 3 Tighten damper rod assembly bolt Damper rod ...

Page 173: ...ap base grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install oil seal clip NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 6 Install dust seal with the fork seal driver weight Fork seal driver weight 90890 01367 7 Fill ...

Page 174: ...e front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 8 Install spring o ring spring seat spring seat clip NOTE Before installing the spring seat lubricate its O ring with grease LS ...

Page 175: ...efer to INSTALLING THE HANDLE BAR Q ty Job Part Remarks Removing the handlebar Handlebar covers I Disconnect Stop switch 2 Handlebar switch 2 II Remove 1 Rear view mirror 1 2 Stop switch 2 Front master cylinder 1 3 Handlebar switch right 1 4 Throttle cable 1 5 Throttle grip assembly 1 1 2 3 3 4 6 9 10 6 7 8 5 T R 60 Nm 6 0 m kg ...

Page 176: ...o INSTALLING THE HANDLE BAR For installation reverse the removal pro cedure Q ty Job Part Remarks 6 Handlebar switch left 1 7 Rear brake cable 1 8 Starter cable 1 9 Left grip 1 10 Handlebar 1 1 2 3 3 4 6 9 10 6 7 8 5 T R 60 Nm 6 0 m kg ...

Page 177: ...e handlebar WARNING EAS00668 CHECKING THE HANDLEBAR 1 Check handlebar Bends cracks damage Replace Donotattempttostraightenabenthandlebar as this may dangerously weaken it 2 Install handlebar grip a Apply a thin coat of rubber adhesive onto the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag Do not touch ...

Page 178: ...from the left as shown 3 Tighten handlebar holder Handlebar holder bolt 60 Nm 6 0 m kg 4 Fasten wire harness to the handlebar bracket Refer to CABLE ROUTING in chapter 2 5 Install left handlebar switch NOTE Align the projection on the left handlebar switch with the hole in the handlebar 6 Install throttle cable throttle grip NOTE Lubricate the inside of the throttle grip with a thin coat of lithiu...

Page 179: ... Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 1 5 3 0 mm 9 Install master cylinder master cylinder bracket 10 Install stop switches 11 Connect stop switches connectors Handlebar switches connectors 12 Fasten cables and wires Refer to CABLE ROUTING in chapter 2 WARNING ...

Page 180: ... to HANDLEBAR Refer to REMOVING THE LOWER BRACKET Q ty Job Part Remarks Removing the lower bracket Front fork Handlebar I Remove 1 Ring nut upper 1 2 Lock washer 1 3 Ring nut center 1 4 Rubber washer 1 5 Ring nut lower 1 6 Ball race cover 1 WARNING 1 2 3 4 5 6 7 8 9 10 12 11 T R 75 Nm 7 5 m kg T R Fisrt step 38 Nm 3 8 m kg 2nd step Loosen the ring nut 1 4 turn 3rd step 22 Nm 2 2 m kg LS LS ...

Page 181: ...l proce dure Q ty Job Part Remarks STEERING HEAD 7 Ball race upper 1 8 Lower bracket 1 9 Ball 22 10 Bearing 1 11 Ball race 2 12 Ball race lower 1 1 2 3 4 5 6 7 8 9 10 12 11 T R 75 Nm 7 5 m kg T R Fisrt step 38 Nm 3 8 m kg 2nd step Loosen the ring nut 1 4 turn 3rd step 22 Nm 2 2 m kg LS LS ...

Page 182: ...washer lower ring nut NOTE Hold the lower ring nut with the steering nut wrench and then remove the center ring nut with the ring nut wrench Ring nut wrench 90890 01268 Steering nut wrench 90890 01403 Securely support the lower bracket so that there is no danger of it falling WARNING EAS00682 CHECKING THE STEERING HEAD 1 Wash bearing balls bearing races Recommended cleaning solvent Kerosene 2 Chec...

Page 183: ...races a Remove the bearing races from the steering head pipe with a long rod and hammer b Remove the bearing race from the lower bracket with a floor chisel and hammer c Install a new dust seal and new bearing races If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearing balls and bearing races as a set Whenever the steering head is dis...

Page 184: ...VERS in chapter 3 For installation reverse the removal procedure Q ty Job Part Remarks Removing the rear shock absorber assembly Rear covers I Remove 1 Rear under cover 1 II Remove 2 Rear shock absorber 1 EAS00685 REAR SHOCK ABSORBER ASSEMBLY FWD 1 2 T R 31 5 Nm 3 15 m kg T R 17 5 Nm 1 75 m kg ...

Page 185: ... damage Replace the rear shock absorber assembly rear shock absorber Oil leaks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock absorber assembly bushings Damage wear Replace dust seals Damage wear Replace bolts Bends damage wear Replace REAR SHOCK ABSORBER ASSEMBLY ...

Page 186: ...7 ELEC ...

Page 187: ...5 IGNITION AND STARTING SYSTEM 7 7 CIRCUIT DIAGRAM 7 7 TROUBLESHOOTING 7 8 STARTER MOTOR 7 14 INSPECTION 7 15 CHARGING SYSTEM 7 17 CIRCUIT DIAGRAM 7 17 TROUBLESHOOTING 7 18 LIGHTING SYSTEM 7 21 CIRCUIT DIAGRAM 7 21 TROUBLESHOOTING 7 22 LIGHTING SYSTEM CHECK 7 24 SIGNAL SYSTEM 7 28 CIRCUIT DIAGRAM 7 28 TROUBLESHOOTING 7 29 SIGNAL SYSTEM CHECK 7 31 ...

Page 188: ... Ch P P BrW BrW L L Dg Dg B B LR LR LR GB LR GY G G B G B B B G Br Br B B Br LR Gy R B A MAIN HARNESS STARTER MOTOR T Q W E R Y U I O P S t y B B Y B q u i o p A Dg Dg B 12V10W 12V 21W 5W 12V 35W 35W B YB L L LR OFF LW B ON L L B B B LW YR LW YR YB YB LR LR OFF B P P ON HI LOW L GB Y Y YR L N R BrW BrW Ch Ch Dg Dg OFF PO ON YR LR B r Ch Ch B 12V10W B B e Dg Dg B 12V10W B B w Ch Ch B 12V10W 12V 1 2...

Page 189: ... t Rear flasher light right y Tail STOP light u Horn i Flasher relay o Front brake switch p Rear brake switch Oil level gauge Fuel sender A Meter assembly H Meter light I Oil indicator light J Flasher indicator light K High beam indicator light L Fuel meter M Tachometer S Resistor D License light CIRCUIT DIAGRAM B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Grey L Blue Or Orange P Pink R ...

Page 190: ...ELEC 7 3 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS Q Wire harness W Fuel sender E Starter relay R Ignition coil T CDI unit Y Oil sender U Battery I Resistance 햲 햳 햵 햴 햸 햶 햷 햹 ...

Page 191: ...ELEC 7 4 햲 햳 햴 햵 Q Main switch W Flasher relay E Horn R Rectifier Regulator ELECTRICAL COMPONENTS ...

Page 192: ... it SWITCH CONTINUITY INSPECTION The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indicates the terminals with continuity The example chart shows that 햲 There is continuity be...

Page 193: ...ing to color combinations shown in the chart Poor connection fault Repair or replace SWITCH INSPECTION Main switch Dimmer switch Horn switch Flasher switch Rear brake switch GY Br Front brake switch GY Br Fuse Start switch Light switch YB L OFF LW B ON L B LW YR YB LR OFF PO ON YR LR OFF B P ON HI LOW L GB Y L N R BrW Ch Dg Y B GB Ch P BrW L Dg LOCK OFF CHECK ON Br Gy B R BW BW Br Gy B R ...

Page 194: ...o p A Dg Dg B 12V10W 12V 21W 5W 12V 35W 35W B YB L L LR OFF LW B ON L L B B B LW YR LW YR YB YB LR LR OFF B P P ON HI LOW L GB Y Y YR L N R BrW BrW Ch Ch Dg Dg OFF PO ON YR LR B r Ch Ch B 12V10W B B e Dg Dg B 12V10W B B w Ch Ch B 12V10W 12V 1 2W 12V 1 2W 12V 1 2W 12V 1 2W B C A B D E G F K M L H I J R B BR GW WR WL GW BR WR WL 12V 5W B D 12V 5W G B Br Ch Dg Y YR Gy LR LR LR IGNITION AND STARTING S...

Page 195: ...ccurate troubleshooting use the following special tools Ignition tester 90890 06754 Pocket tester 90890 03112 1 Fuse Refer to SWITCH INSPECTION section 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Clean battery terminals Charge or replace the battery NO CONTINUITY DOES NOT MEET SPECIFICATION 3 Spark plug Check the spark plug type Check the condition of th...

Page 196: ...se the spark length until the engine begins to misfire Minimum spark gap 6 mm MEETS SPECIFICATION 5 Spark plug cap resistance Disconnect the spark plug cap Connect the pocket tester Ωx1k to the ignition coil Check the resistance of the spark plug cap DOES NOT MEET SPECIFICATION OUT OF SPECIFICATION OR NO SPARK CORRECT Spark plug cap resistance 5kΩ 20 C 햲 햳 a Ignition system in good condition Repla...

Page 197: ...cket tester lead Spark plug lead Check the secondary coil resistance Secondary coil resistance 5 68 8 52 kΩ 20 C DOES NOT MEET SPECIFICATION 7 Pickup coil resistance Disconnect the pickup coil coupler Connect the pocket tester Ωx100 to the pickup coil Pocket tester lead White Red 햲 Pocket tester lead White Blue 햳 Check the pickup coil resistance DOES NOT MEET SPECIFICATION Replace the pickup coil ...

Page 198: ...the CDI unit Repair CONTINUITY NO CONTINUITY POOR CONNECTIONS GOOD CONNECTIONS 8 Source coil resistance Disconnect the source coil coupler from the wire harness Connect the pocket tester Ωx100 to the source coil Pocket tester lead Black Red 햲 Pocket tester lead Green white 햳 Check the source coil resistance Source coil resistance 640 960 Ω at 20 C Replace the source coil MEETS SPECIFICATION 햲 햳 BR...

Page 199: ...ion CONTINUITY NO CONTINUITY 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in the Chapter 3 MEETS SPECIFICATIONS DOES NOT MEET SPECIFICATION Clean battery terminals Charge or replace the battery 3 Starter motor Use a jumper lead 햴 to connect the 햲 terminal of the battery to the starter motor terminal 햳 햳 햲 햴 If the gauge of the jumper lead is smaller than that of the b...

Page 200: ...epair or replace Replace the main switch 5 Main switch Refer to SWITCH INSPECTION section MEETS SPECIFICATION 6 Starter motor switch Refer to SWITCH INSPECTION section MEETS SPECIFICATION Replace the right handlebar switch DOES NOT WORK DOES NOT WORK DOES NOT MEET SPECIFICATION DOES NOT MEET SPECIFICATION 7 Connections Check all connections in the starter system Refer to WIRING DIAGRAM section Rep...

Page 201: ...assembly 햲 O ring 1 햳 Front bracket 1 햴 Rubber seal 1 햵 Brush holder assembly 1 햶 Armature 1 햷 Rubber seal 1 Refer to STARTER CLUTCH AND GENERATOR in Chapter 4 Disassemble the parts in the order below For the assembly reverse the disassembling procedure STARTER MOTOR 햲 햳 햴 햵 햶 햷 T R 13 Nm 1 3 m kg LS ...

Page 202: ...e can be ground to fit Mica undercut 1 15 mm N B The mica insulation of the commutator must be undercut to ensure proper operation of commutator 4 Inspect Armature coil insulation continuity Defects Replace starter motor Inspecting steps Connect the pocket tester for continuity check 햲 and insulation check 햳 Measure the armature resistances Armature coil resistance Continuity check 햲 0 06 0 08 Ω a...

Page 203: ...EC 7 16 STARTER MOTOR 6 Measure Brush spring force Fatigue Out of specification Replace as a set Brush spring force 563 844 g 5 Measure Brush length Out of specification Replace Brush length limit 0 9 mm ...

Page 204: ...B Br LR Gy R B A MAIN HARNESS STARTER MOTOR T Q W E R Y U I O P S t y B B Y B q u i o p A Dg Dg B 12V10W 12V 21W 5W 12V 35W 35W B YB L L LR OFF LW B ON L L B B B LW YR LW YR YB YB LR LR OFF B P P ON HI LOW L GB Y Y YR L N R BrW BrW Ch Ch Dg Dg OFF PO ON YR LR B r Ch Ch B 12V10W B B e Dg Dg B 12V10W B B w Ch Ch B 12V10W 12V 1 2W 12V 1 2W 12V 1 2W 12V 1 2W B C A B D E G F K M L H I J R B BR GW WR WL...

Page 205: ...hooting 1 Battery cover 2 Side covers right and left For accurate troubleshooting special tools Inductive tachometer 90890 03113 Pocket tester 90890 03112 1 Fuse Refer to SWITCH INSPECTION section CONTINUITY NO CONTINUITY 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in the Chapter 3 MEETS SPECIFICATION DOES NOT MEET SPECIFICATION Clean battery terminals Charge or repl...

Page 206: ... DC20V to the battery terminals Pocket tester lead Battery terminals Pocket tester lead Battery terminals Start the engine and accelerate to about 5 000 rpm Check the charging voltage Charging voltage 14 15V at 5 000 r min NOTE Use a fully charged battery OUT OF SPECIFICATION MEETS SPECIFICATION Charging circuit is OK ...

Page 207: ...ad White 햲 Pocket tester lead Ground 햳 5 Connections Check all connections in the charging sys tem Refer to WIRING DIAGRAM MEETS SPECIFICATION Replace the rectifier regulator POOR CONNECTIONS Repair MEETS SPECIFICATION OUT OF SPECIFICATION Charging coil defect Replace Charging coil resistance 0 48 0 72 Ω at 20 C Check the charging coil resistance 햲 햳 BR GW WR WL YR W BR GW WR WL ...

Page 208: ... Dg Dg B 12V10W 12V 21W 5W 12V 35W 35W B YB L L LR OFF LW B ON L L B B B LW YR LW YR YB YB LR LR OFF B P P ON HI LOW L GB Y Y YR L N R BrW BrW Ch Ch Dg Dg OFF PO ON YR LR B r Ch Ch B 12V10W B B e Dg Dg B 12V10W B B w Ch Ch B 12V10W 12V 1 2W 12V 1 2W 12V 1 2W 12V 1 2W B C A B D E G F K M L H I J R B BR GW WR WL GW BR WR WL 12V 5W B D 12V 5W G B Br Ch Dg Y YR Gy LR LR LR LIGHTING SYSTEM LIGHTING SYS...

Page 209: ...D OR TAILLIGHT DO NOT WORK Procedure Check 1 LIGHTS switch 2 Lighting coil resistance 3 HI LO switch 4 Connections NOTE Removethefollowingpartsbeforeproceed ing with the troubleshooting 1 Side covers 2 Handlebar covers 3 Front panel For accurate troubleshooting use the fol lowing special tools Pocket tester 90890 03112 ...

Page 210: ...ster lead Ground 햳 MEETS SPECIFICATION OUT OF SPECIFICATION Lighting coil defect Replace CONTINUITY 3 HI LO switch Refer to SWITCH INSPECTION 4 Connections Check all connections in the lighting sys tem Refer to WIRING DIAGRAM CONTINUITY NO CONTINUITY CORRECT Circuit is in good condition Replace the HI LO switch POOR CONNECTIONS Repair Replace the right handlebar switch Check the lighting coil resi...

Page 211: ...ester lead Green Black 햲 Pocket tester lead Black 햴 HI Pocket tester lead Yellow 햳 Pocket tester lead Black 햴 High beam indicator light Pocket tester lead Yellow 햵 Pocket tester lead Black 햶 Set the main switch to ON Start the engine Set the light switch to Switch from to and back Check for voltage 12 V to the bulb socket connector NO CONTINUITY Replace the bulb or socket 3 The front position ligh...

Page 212: ...ir 3 The meter light does not work 1 Bulb and socket Refer to SWITCH INSPECTION section CONTINUITY NO CONTINUITY Replace bulb or socket 2 Voltage Connect the pocket tester AC 20 V to the meter light coupler Pocket tester lead Blue Red 햲 Pocket tester lead Black 햳 Set the main switch to ON Start the engine Set the light switch to or Check for voltage 12 V to the meter light coupler MEETS SPECIFICAT...

Page 213: ...e engine Set the light switch to or Check for voltage 12 V to the taillight coupler There is a defect in the wire harness between the main switch and the taillight connectors Repair CONTINUITY Replace bulb or socket NO CONTINUITY OUT OF SPECIFICATION MEETS SPECIFICATION Circuit is in good condition 4 The license light does not work 1 Bulb and socket Refer to SWITCH INSPECTION section CONTINUITY Re...

Page 214: ...d Black 햳 Set the main switch to ON Start the engine Set the light switch to or Check for voltage 12 V to the license light coupler There is a defect in the wire harness between the main switch and the bulb socket connector Repair OUT OF SPECIFICATION MEETS SPECIFICATION Circuit is in good condition LIGHTING SYSTEM 햲 햳 B 12V 5W LR ...

Page 215: ...N L L B B B LW YR LW YR YB YB LR LR OFF B P P ON HI LOW L GB Y Y YR L N R BrW BrW Ch Ch Dg Dg OFF PO ON YR LR B r Ch Ch B 12V10W B B e Dg Dg B 12V10W B B w Ch Ch B 12V10W 12V 1 2W 12V 1 2W 12V 1 2W 12V 1 2W B C A B D E G F K M L H I J R B BR GW WR WL GW BR WR WL 12V 5W B D 12V 5W G B Br Ch Dg Y YR Gy LR LR LR SIGNAL SYSTEM CIRCUIT DIAGRAM T Main switch Y Fuse U Battery Left handle switch C Horn sw...

Page 216: ...bar covers 3 Front panel Foraccuratetroubleshootingusethefollowing special tools Pocket tester 90890 03112 1 Fuse Refer to SWITCH INSPECTION section CONTINUITY NO CONTINUITY 2 Battery Check the condition of the battery Refer CHECKING THE BATTERY in the Chapter 3 MEETS SPECIFICATION DOES NOT MEET SPECIFICATION Clean battery terminals Charge or replace the battery 3 Main switch Refer to SWITCH INSPE...

Page 217: ...IGNAL SYSTEM 4 Connections Check all connections in the signal system Refer to WIRE DIAGRAM CONTINUITY Check the condition of each circuit of the signal system Refer to SIGNAL SYSTEM CHECK POOR CONNECTIONS Repair ...

Page 218: ...ster DC20 V to the horn lead Pocket tester lead Pink 햲 Pocket tester lead Ground Turn the main switch to ON Press the HORN switch Check the voltage 12V between Pink and ground MEETS SPECIFICATON Adjust Horn NO CONTINUITY Replace the horn switch OUT OF SPECIFICATION Defect in the wire harness between the main switch and the horn Repair NO CONTINUITY 햲 햳 Br P 햲 Br P Replace Horn 3 Horn Disconnect th...

Page 219: ...t tester lead Black 햳 MEETS SPECIFICATION Circuit is in good condition NO CONTINUITY Replace bulb or socket NO CONTINUITY Brake switch is defect Replace OUT OF SPECIFICATION 4 Connections There is a defect in the wire harness be tween the main switch and the taillight bulb socket connector Repair Referto CIRCUITDIAGRAMOFTHESIG NAL SYSTEM Turn the main switch to ON Pull the brake lever Check the vo...

Page 220: ...the Brown lead and the Ground MEETS SPECIFICATION 4 Voltage Connect the pocket tester DC20 V to the flasher connector Pocket tester lead Brown White 햲 Pocket tester lead Ground 햳 Turn the main switch to ON Check the voltage 12 V between Brown White and the ground MEETS SPECIFICATION NO CONTINUITY Replace buld and or socket NO CONTINUITY Replace the left handlebar switch OUT OF SPECIFICATION Defect...

Page 221: ...nd the ground then Dark green and the ground MEETS SPECIFICATION This circuit is in good condition OUT OF SPECIFICATION 6 Connections Defect in the wire harness between the main switch and the flasher bulb socket Repair Refer to WIRING DIAGRAM 4 The Oil indicator light does not work 1 Bulb and socket Refer to SWITCH INSPECTION CONTINUITY NO CONTINUITY 2 Oil level switch Refer to SWITCH INSPECTION ...

Page 222: ...ystem Refer to WIRING DIAGRAM 1 Voltage Disconnect the fuel sender leads Connect the pocket tester Ω x 100 then Ωx10 to the fuel sender Drain the fuel tank Measure the resistance Sender unit resistance empty tank 90 100 Ω at 20 C Fill the tank Measure the resistance Sender unit resistance fuel tank 1 5 7 5 Ω at 20 C MEETS SPECIFICATION DOES NOT MEET SPECIFICATION This circuit is in good condition ...

Page 223: ...8 TRBL SHTG ...

Page 224: ...AUTOMATIC V BELT TYPE 8 3 MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING 8 3 CLUTCH OUT FAILURE 8 4 POOR STANDING START LOW CLIMBING ABILITY 8 4 POOR ACCELERATION POOR HIGH SPEED 8 4 OVER HEATING 8 4 OVER HEATING 8 4 IMPROPER KICKING 8 5 SLIPPING 8 5 HARD KICKING 8 5 KICK CRANK NOT RETURNING 8 5 FAULTY BRAKE 8 5 POOR BRAKING EFFECT 8 5 FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION 8 6 OIL ...

Page 225: ...l tank cap Sucked in air Fuel cock Deformed float Clogged fuel hose Groove worn needle valve Clogged vacuum Improperly sealed valve seat Faulty diaphragm Improperly adjusted fuel level Air filter Improperly set pilot jet Clogged air filter Clogged starter jet Starter plunger malfunction Improperly adjusted pilot air screw ELECTRICAL SYSTEM Spark plug CDI unit system Improper plug gap Faulty CDI un...

Page 226: ...rn damaged or seized cylinder Reed valve Piston and piston rings Deformed reed valve stopper Improperly installed piston ring Improperly seated reed valve Worn fatigued or broken piston ring Loose intake manifold Seized piston ring Broken gasket Seized or damaged piston Broken reed valve POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Clogged ...

Page 227: ...minals broken Faulty pick up coil Improper heat range Faulty spark plug cap COMPRESSION SYSTEM Cylinder and cylinder head Crankcase and crankshaft Loose spark plug Improperly seated crankcase Loose cylinder head or cylinder Improperly sealed crankcase Broken cylinder head gasket damaged oil seal Broken cylinder gasket Seized crankshaft Worn damaged or seized cylinder Piston and piston rings Reed v...

Page 228: ...e Air in the autolube pump Damaged air shrouds Compression system Heavy carbon deposit build up CLUTCH OUT FAILURE Primary pulley Secondary pulley Seized primary sliding pulley and collar Broken or fatigued clutch shoe spring POOR STANDING START LOW CLIMBING ABILITY V belt Secondary pulley Worn damaged or slippery v belt Fatigued compression spring Primary pulley Improper operation of secondary sl...

Page 229: ... Damaged or seized piston Damaged or seized piston ring KICK CRANK NOT RETURNING Kick axle assembly Damaged kick return spring Kick return spring coming off Kick clip coming off Damaged kick return spring stopper FAULTY BRAKE POOR BRAKING EFFECT Front disc brake Rear drum brake Worn brake pads Worn brake shoe Worn disc Worn or rusty brake drum Air in brake fluid Improperly adjuster brake play Leak...

Page 230: ...maged Bent or deformed suspension arm and pivots Oil level Tires Rear shock absorber Incorrect tire pressure Uneven tire pressures on both sides Fatigued spring Unevenly worn tires Oil leakage FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE MALFUNCTION Bent damaged or rusty inner tube Bent deformed or damaged inner tube Damaged or cracked outer tube Bent or deformed outer tube Damage...

Page 231: ...ND LIGHTING SYSTEM Headlight dark Flasher does not light Improper bulb Improperly grounded Too many electric accessories Discharged battery Hard charging broken charging coil Faulty flasher switch Incorrect connection Faulty flasher relay Improperly grounded Broken wire harness Poor contacts main or light switch Loosely connected coupler Bulb life expired high internal resistance Bulb burnt out Fa...

Page 232: ...ow B R Black Red B W Black White Br W Brown White G B Green Black G W Green White G Y Green Yellow L R Blue Red L W Blue White W L White Blue W R White Red Y B Yellow Black Y R Yellow Red M LOCK OFF CHECK ON RED RED Br Br Br LR Gy Gy Gy GY B B Gy B B LR GY B R R Br R BW BW BW Gy Br R B BW BW Or Or B B Or B B BR BR GW GW WR WR WL WL W W YR YR W YR W YR YR R W B YR R B R R LW B GY LW GY LW GY R A R ...

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