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Yamaha VINO XC50V Service Manual Download Page 215

6-13

COOL

CHAPTER 6

RADIATOR

RADIATOR ................................................................................................ 6-1

CHECKING THE RADIATOR ............................................................ 6-2
INSTALLING THE RADIATOR ........................................................... 6-3

THERMOSTAT ASSEMBLY ..................................................................... 6-4

CHECKING THE THERMOSTAT ...................................................... 6-6
INSTALLING THE THERMOSTAT ASSEMBLY ................................ 6-7

WATER PUMP .......................................................................................... 6-8

DISASSEMBLING THE WATER PUMP .......................................... 6-10
CHECKING THE WATER PUMP ..................................................... 6-10
ASSEMBLING THE WATER PUMP ................................................ 6-11
INSTALLING THE WATER PUMP ................................................... 6-12

Summary of Contents for VINO XC50V

Page 1: ...XC50V SERVICE MANUAL LIT 11616 19 49 3D1 F8197 10 ...

Page 2: ...CE MANUAL 2005 by Yamaha Motor Taiwan Co Ltd First edition July 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co Ltd is expressly prohibited LIT 11616 19 49 ...

Page 3: ...gnificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EAS00005 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert Symbol means ATTENTION B...

Page 4: ...e quentially 5 27 ENG Remarks Order Job Part Q ty 1 2 3 4 5 6 7 8 9 10 EAS00251 CYLINDER AND PISTON Removing the cylinder and piston Cylinder head Timing chain guide exhaust side Cylinder Case cap Reed valve assembly Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set Remove the parts in the order listed Refer to CYLINDER HEAD Refer to INSTALLING THE PISTON AND CYLINDER Ref...

Page 5: ...ical system 9 Troubleshooting Symbols 0 to u indicate the following 0 Serviceable with engine mounted q Filling fluid w Lubricant e Special tool r Tightening torque t Wear limit clearance y Engine speed u Electrical data Symbols i to d in the exploded diagrams indi cate the types of lubricants and lubrication points i Engine oil o Gear oil p Molybdenum disulfide oil a Wheel bearing grease s Lithiu...

Page 6: ...CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING CARBURETOR ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO SPEC CHK ADJ CHAS ENG CARB ELEC TRBL SHTG COOL 1 2 3 4 5 6 5 7 8 9 ...

Page 7: ...MODEL LABEL 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 Notes 3 on equipment preparation 1 4 CHECKING THE CONNECTIONS 1 5 SPECIAL TOOLS 1 6 ...

Page 8: ...TION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the steering head pipe EAS00018 MODEL LABEL The model label 1 is affixed to the trunk This information will be needed to order spare parts SCOOTER IDENTIFICATION 1 1 ...

Page 9: ...d place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but infe rior in qualit...

Page 10: ...ng oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appropriate 1 Oil seal cC Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips afte...

Page 11: ... Rivet Push type Dissembling 1 Press Center Pin 1 inward to release the Lock 2 Remove the Push Rivet main body 2 Assembling 1 Restore the Center Pin replace the Push Rivet main body 2 Push in the Center Pin until leveling off with the surface position of the Push Rivet main body 1 2 IMPORTANT INFORMATION ...

Page 12: ...eck 8all connections Loose connection J Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect 8lead 8coupler 8connector NOTE Make sure all connections are tight 5 Check 8continuity with the pocket tester Pocket tester 90890 03132 YU 03112 C NOTE 8 If there is no continuity clean the terminals 8 When checking the wire harness perform steps 1 to 3 8 As a quick remedy u...

Page 13: ...2 A 90890 01337 YM 33285 YM 33285 6 90890 01348 YM 01348 90890 01325 YU 24460 01 90890 01352 YU 33984 Slide hammer bolt 8mm 1 Weight 2 These tools are needed to remove the cam shaft Rotor holding tool This tool is used to remove the flywheel magneto Ring nut wrench This tool is used to loosen and tighten the exhaust and steering ring nut Piston pin puller set This tool is used to remove the piston...

Page 14: ... seal guide This tool is used for protecting the oil seal lip when installing the secondary sliding sheave Steering nut wrench This tool is used to loosen and tighten the steering ring nut Sheave holder This tool is used for holding the secondary sheave Thickness gauge This tool is used to measure the valve cleanance Compression gauge These tool are used to measure the engine compression Pocket te...

Page 15: ... tools are used when removing or in stalling the valve and the valve spring Valve guide remover 4 0 mm This tool is used to remove or install the valve guides Valve guide installer 4 0 mm This tool is used to install the valve guides Valve guide remover 4 0 mm This tool is used to rebore the new valve guides Ignition checker This instrument is necessary for checking the ignition system components ...

Page 16: ...CIFICATIONS 2 10 ELECTRICAL SPECIFICATIONS 2 12 CONVERTION TABLE GENERAL TIGHTENING TORQUE SPECIFICA TIONS 2 15 TIGHTENING TORQUES 2 16 ENGINE 2 16 CHASSIS 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 ENGINE 2 19 CHASSIS 2 21 COOLING SYSTEM DIAGRAMS 2 22 OIL FLOW DIAGRAMS 2 26 CABLE ROUTING 2 28 ...

Page 17: ... 1665 mm 65 6in Overall width 630 mm 24 8in Overall height 1005 mm 39 6in Seat height 715 mm 28 2in Wheelbase 1160 mm 45 7in Ground clearance 85 mm 3 4in Minimum turning radius 1800mm 70 9in Weight Wet without oil and a full fuel tank 81 kg 179lb Dry without oil and fuel 76kg 168lb Maximun load total of cargo rider 158kg 348lb passenger and accessories ...

Page 18: ...a 260 mmHg Standard compression pressure at sea level 1450 kPa 14 5kgf cm2 at 700 r min Fuel Recommended fuel Unleaded gasoline Fuel tank capacity Total including reserve 4 5L 0 98 Imp gal 1 18 US gal Engine oil Lubrication system Wet sump Recommended oil SAE10W40 Yamaha 4 cycle oil EFERO X Z BX Quantity Periodic oil change 0 73 0 83 L 0 67 0 76 Imp qt 0 80 0 90 US qt Total amount 0 8 0 9L 0 74 0 ...

Page 19: ...stem Radiator capacity 0 26L Radiator cap opening pressure 93 3 122 7 kpa 0 95 1 25kgf cm2 13 53 17 79 psi Valve relief pressure 1 1kpa 0 01kgf cm2 0 16 psi Radiator core Width 133 3mm Height 87mm Depth 16mm Coolant reservoir Capacity 0 26L From low to full lever 0 15L Water pump Water pump type Single suction centrifugal pump Max impeller shaft tilt 0 15mm Starting system type Electric and kick s...

Page 20: ... Intake camshaft lobe dimensions Measurement A 30 158 30 258 mm 30 058 mm Measurement B 25 082 25 182 mm 24 982 mm Measurement C 5 2077mm Exhaust camshaft lobe dimensions Measurement A 30 158 30 258 mm 30 058 mm Measurement B 25 020 25 120 mm 24 920 mm Measurement C 5 2077mm Max camshaft runout 0 03 mm ...

Page 21: ...4 16 6 mm Valve face width B Intake 1 48 2 19 mm Exhaust 1 48 2 19 mm Valve seat width C Intake 0 9 1 1 mm 1 6mm Exhaust 0 9 1 1 mm 1 6mm Valve margin thickness D Intake 0 7 mm Exhaust 0 7 mm Valve stem diameter Intake 3 975 3 990 mm 3 945 mm Exhaust 3 960 3 975 mm 3 930 mm Valve guide inside diameter Intake 4 000 4 012 mm 4 050 mm Exhaust 4 000 4 012 mm 4 050 mm Valve stem to valve guide clearanc...

Page 22: ... spring force installed Intake 91 1 104 9N 9 3 10 7kg Exhaust 107 9 124 1N 11 0 12 7kg Spring tilt Intake 2 5 1 7 mm Exhaust 2 5 1 8 mm Winding direction top view Intake Clockwise Exhaust Clockwise Valve seat reformed Yes Cylinder Cylinder arrangement Forward inclined single cylinder Bore stroke 38 0 43 5 mm Compression ratio 12 1 Bore 38 000 38 010 mm Max taper 0 05 mm Max out of round 0 010 mm ...

Page 23: ...mm Offset direction Intake side Piston pin Outside diameter 9 996 10 000 mm 9 976 mm Piston rings Top ring Ring type Barrel Dimensions B T 0 8 1 65mm End gap installed 0 05 0 15 mm 0 40mm Ring side clearance 0 02 0 08 mm 0 13 mm 2nd ring Ring type Taper Dimensions B T 0 8 1 5mm End gap installed 0 05 0 17 mm 0 52mm Ring side clearance 0 02 0 06 mm 0 12mm Oil ring Dimensions B T 1 5 1 6 mm End gap ...

Page 24: ...5mm Rocker arm shaft outside diameter 9 981 9 991 mm Arm to shaft clearance 0 009 0 034 mm Connecting rod Connecting rod length 79 95 80 05 mm Small end inside diameter 10 015 10 028mm Crankshaft Width A 42 45 42 50 mm Max runout C 0 03mm Big end side clearance D 0 15 0 45 mm 1 00mm Big end radial clearance E 0 0 010mm ...

Page 25: ...pur gear Secondary reduction ratio 43 12 3 583 Single speed automatic 2 805 0 863 1 Max main axle runout 0 04 mm Max drive axle runout 0 04 mm Air filter type Oil coated paper element Carburetor Model manufacturer quantity NCV18 KEIHIN 1 ID mark 3D11 00 Venturi tube bore primary Ø7 7 Venturi tube bore secondary Ø16 6 Main jet 82 Main air jet 80 Jet needle N425 FBC00 Neddle jet N426 36628 Slow air ...

Page 26: ... Cast wheel Rim Size J10 MT2 15 Material Aluminum Wheel travel 54mm Wheel runout Max radial wheel runout 1 0 mm Max lateral wheel runout 1 0 mm Front tire Tire type Tubeless Size 90 90 10 50J Model manufacturer K348A KENDA Tire pressure cold 0 55 kg 150kpa 1 5 kgf cm 22 psi 55 158 kg 150kpa 1 5 kgf cm 22 psi Min tire tread depth 0 8mm Rear tire Tire type Tubeless Size 90 90 10 50J Model manufactur...

Page 27: ...pring Free length 120 mm 117 6mm Installed length 110mm Spring rate K1 9 46N mm 0 96 kgf mm Spring stroke K1 0 65mm Optional spring available No Inner tube outer diameter 26 mm Inner tube bending limit 0 2 mm Steering system Steering bearing type Angular bearing Lock to lock angle left 45 Lock to lock angle Right 45 Rear suspension Suspension type Unit swing Rear shock absorber assembly type Coil ...

Page 28: ...magneto Model manufacturer 1P41 T MORIC Nominal output 14V 120W 5000 r min Stator coil resistance color 0 288 0 432 Ω Ground W Lighting coil resistance color 0 256 0 384 Ω Ground Y R Voltage regulator Regulator type Semiconductor short circuit Model manufacturer SH656 12 SHIN DEN GEN No load regulated voltage DC 14 1 14 9 V Rectifier Model manufacturer SH656 12 SHIN DEN GEN Rectifier capacity DC 8...

Page 29: ...utator resistance 0 0378 0 0462 Ω at 20 C Mica undercut depth 1 35 mm Starter relay Model manufacturer 5WC 00 OMRON Amperage 50 A Coil resistance 90 110 Ω Suction voltage More than DC10V Horn Horn type Plane Model manufacturer AH 368 SAKURA Max amperage 1 5 A Performance 98 108db 2m Coil resistance 4 05 4 55Ω Turn signal relay Relay type Full transistor Model manufacturer 5CA9 TA YOUNG Self cancel...

Page 30: ...age throttle closes 0 625 0 775V Radiator fan Model manufacturer 5ST 00 LUNTAI Running rpm 10000 r min Thermostat switch Model manufacturer 5ST NIPPON THERMOSTAT Thermo unit Model manufacturer 5JJ NIPPON THERMOSTAT Coil resistance at 80 C 3 413 4 007 kΩ Coil resistance at 100 C 1 645 1 855 kΩ Fuse amperage quantity Main fuse 7 5A 1 ...

Page 31: ...dry threads Com ponents should be at room temperature A Width across flats B Thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Tighten ing torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 281 1 09...

Page 32: ...Left handthread 7 2 9 0 7 2 9 0 7 2 5 1 7 2 7 2 5 1 7 2 21 7 6 5 5 8 7 2 7 2 6 5 2 9 1 5 7 2 7 2 23 1 7 2 22 4 7 2 9 4 6 5 7 2 9 4 9 4 7 2 7 2 7 2 16 6 10 9 16 6 7 2 7 2 5 1 8 7 65 1 4 TIGHTENING TORQUES ENGINE Cylinder head and cylinder Spark plug Cylinder head timing chain side Exhaust pipe stud bolt Cylinder head cover Oil check bolt Water pump housing cover Water pump assembly Guide stopper2 T...

Page 33: ... Nm m kg ft lb Remarks Clutch housing Ignition coil Thermo unit Primary fixed sheave Starter motor assembly AC magneto rotor Stator coil Pickup coil Nut Bolt Nut Bolt Nut Bolt Screw M10 M5 PT1 8 M10 M6 M12 M5 M6 1 1 1 1 2 1 3 2 40 8 8 30 13 43 4 7 4 0 0 8 0 8 3 0 1 3 4 3 0 4 0 7 28 9 5 8 5 8 21 7 9 4 31 1 2 9 5 1 LT 1 2 3 4 5 6 ...

Page 34: ...et Seat lock assembly Rear carrier front Rear carrier rear Steering shaft and upper bearing inner race Steering shaft and ring nut Trunk Footrest board Fuel sender Resin part and resin cover Seat lock adjuster Main switch and frame Front brake camshaft lever Front wheel shaft Rear wheel shaft Rear brake camshaft lever Rear brake pin pivot Speedometer cable Rear shock absorber and frame Rear shock ...

Page 35: ...ace and bolt thread Crankshaft journal Piston balancer outside surface Piston pin balancer outside surface Camshaft lobe Camshaft profile journal Valve stems intake and exhaust Valve stem seals intake and exhaust Valve pads intake and exhaust Valve stem ends intake and exhaust Oil pump assembly inside surface Oil pipe union bolt thread and surface Starter clutch pin and weight Idle gear 1 thrust s...

Page 36: ...AY asembly lube BEL RAY asembly lube Sealant Lubrication Point Lubricant LUBRICATION POINTS AND LUBRICANT TYPES Secondary fixed sheave inner surface Secondary sliding sheave torque cam ditch Crankcase mating surfaces ...

Page 37: ...s upper and lower Frame head pipe dust seal lips lower Tube guide throttle grip inner surface Brake lever and lever holder bolt sliding surface Centerstand pivoting point and sliding surface Rear shock absorber backward bush inner surface and spacer sliding surface Seat lock cable and rear wheel lock cable inner surface Engine bracket and engine mound bolt sliding surface LS ...

Page 38: ...2 22 SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Raidator cap 2 Coolant reservoir 3 Radiator inlet hose 4 Radiator outlet hose 5 Thermo switch 6 Conduit hose 2 5 3 6 1 4 ...

Page 39: ...2 23 SPEC 1 Outlet hose to cylinder 2 Radiator inlet hose 3 Radiator outlet hose 4 Thermostat 5 Thermostat housing COOLING SYSTEM DIAGRAMS 2 5 4 3 1 ...

Page 40: ...2 24 SPEC COOLING SYSTEM DIAGRAMS 1 Breather hose 2 Outlet hose to cylinder 3 Radiator outlet hose 4 Water pump 1 4 3 2 ...

Page 41: ...2 25 SPEC COOLING SYSTEM DIAGRAMS 1 Thermostat housing 2 Thermostat assembly inlet breather hose 3 Water pump 4 Breather hose 1 2 3 4 ...

Page 42: ...2 26 SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Oil filter 2 Oil pump 3 To cylinder head 4 Oil strainer 5 Oil nozzle 6 Camshaft ...

Page 43: ...ting rod big end bearing 3 Oil nozzle 4 Camshaft Cylinder wall Connecting rod big end bearing Crankshaft pin Crankcase sump Oil filter Oil pump Oil nozzle Camshaft Rocker arm shaft and rocler arm Centrifugal oil filter OIL FLOW DIAGRAMS ...

Page 44: ...ert the seat lock cable into the frame protector part to the hole position C Insert the L coupler to the ignition coil and installing di rection of downward D Clamp the wire harness thermo switch lead and con duit hose to the frame E Fasten the wire harness AC magneto lead and starter motor lead to the frame with a plastic locking tie and end of plastic locking the upward F Route the AC magneto le...

Page 45: ... brake cable stopper F Clamp the carburetor drain hose to the rear brake cable pass the rear brake cable outside the carburetor drain hose G Clamp the rear brake cable to the under cover rib H Clamp the throttle cable kit and Rear wheel lock cable through upward of the frame I Route the rear brake cable through downward of the frame and upward of the un der cover J Route the rear brake cable Rear ...

Page 46: ...orward of connec tor cover do not through back side of the other leads N Route the turn signal relay lead and front turn signal light lead left through backward of the steering head pipe 1 3 2 4 5 6 7 8 w 9 0 q A B I H G F E D C 2 r J 1 3 N K e M L N N 9 y 5 4 8 t ...

Page 47: ... Route the breather pipe through downward of the spacer G Clamp the taillight lead to the side cover of hook H Install the C D I unit to the fuel tank bracket of bracket 1 I Clamp the seat lock cable protector of marking position to the fuel tank bracket J Route the drain pipe along the fuel tank bracket and through the clamp K Route the fuel hose and pipe 7 through downward of the breather pipe L...

Page 48: ...lder right and tight ening torque 4Nm 0 4m kg 2 9ft lb C Route the lever holder lead right and front brake switch lead along backward of the front brake cable D Install the speedometer cable to the speedometer assembly and tightening torque 3Nm 0 3m kg 2 2ft lb E Route the lever holder lead left and lever holder lead right through backward of the rear brake cable F First tighten the upper screw wh...

Page 49: ...ning torque 7Nm 0 7m kg 5 1ft lb O When assembling the leads and cables clamp and do not interfere P Route the throttle cable through best backward of the cables and leads Q When assembling the front brake cable and speedom eter cable do not interfere R Route the throttle cable through upper of handlebar guide and handlebar upper cover S First tighten the back screw when assembling the lever holde...

Page 50: ...G 3 18 CHECKING THE IGNITION TIMING 3 19 MEASURING THE COMPRESSION PRESSURE 3 21 CHECKING THE ENGINE OIL LEVEL 3 23 CHANGING THE ENGINE OIL 3 24 CHANGING THE TRANSMISSION OIL 3 26 MEASURING THE ENGINE OIL PRESSURE 3 27 CHECKING THE AIR FILTER ELEMENT 3 29 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 3 30 CHECKING THE FUEL AND VACUUM HOSES 3 30 CHECKING THE FUEL HOSES AND FUEL FILTER 3 31 CHEC...

Page 51: ...HECKING AND LUBRICATING THE CABLES 3 47 LUBRICATING THE LEVERS AND PEDALS 3 48 LUBRICATING THE CENTERSTAND 3 48 ELECTRICAL SYSTEM 3 49 CHECKING AND CHARGING THE BATTERY 3 49 CHECKING THE FUSE 3 55 REPLACING THE HEADLIGHT BULB 3 57 ADJUSTING THE HEADLIGHT BEAM 3 58 ...

Page 52: ...haul work This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter NOTE The annual checks must be performed every year except if a kilometer based maintenance is performed instead From 30 000 km repeat the maintenance intervals starting from 6 000 km Items marked with an a...

Page 53: ...or 30 months 1 Fuel line Check fuel and vacuum hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean Replace at 4000 mi 7000 km or 12 months and thereafter every 4000 mi 6000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold Every 6000 mi 10000 km 4 Crankcase breather system Check breather hose for cra...

Page 54: ...00 mi 13000 km or 24 months Repack 8 Chassis fasteners Check all chassis fitting and fasteners Correct if necessary 9 Front and rear brake lever pivot Apply lithium soap based grease all purpose grease lightly 10 Centerstand Check operation Lubricate 11 Front fork Check operation and for oil leakage Replace if necessary 12 Shock absorber assembly Check operation and for oil leakage Replace if nece...

Page 55: ... data and technical skills have aYamaha dealer perform the service NOTE From 12000 mi 19000 km or 36 months repeat the maintenance intervals starting from 4000 mi 7000 km or 12 months EAU17680 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas ...

Page 56: ... Remove the parts in the order listed For installation reverse the removal pro cedure COVER AND PANEL Removing the seat and trunk Seat Damper Rubber cap Trunk Rear carrier Mat Battery cover 23Nm 2 3 m kg 16 6 ft lb 12Nm 1 2 m kg 8 7 ft lb 10Nm 1 0 m kg 7 2 ft lb 12Nm 1 2 m kg 8 7 ft lb 6 7 4 2 1 5 3 ...

Page 57: ...e cover left and right Seat Trunk Tail brake and rear turn signal left right light lead Front cover Side cover left Side cover right Tail brake light Rear cover Remove the parts in the order listed Refer to SEAT AND TRUNK Disconnect For installation reverse the removal pro cedure COVER AND PANEL 5 6 4 2 1 3 ...

Page 58: ...Battery holder Battery negative lead Battery positive lead Battery Footrest board side cover mole left Footrest board side cover mole right Footrest board COVER AND PANEL Remove the parts in the order listed Refer to SIDE COVER LEFT AND RIGHT cC First disconnect the negative battery lead and then the positive battery lead For installation reverse the removal pro cedure 4Nm 0 4 m kg 2 9 ft lb 1 7 2...

Page 59: ...l left right light lead Leg shield 1 Turn signal relay Headlight relay Rear wheel lock clip Hook Leg shield 2 Starter relay Coolant reservoir Under cover Remove the parts in the order listed Refer to FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE Disconnect Disconnect Disconnect Disconnect Disconnect For installation reverse the removal pro cedure COVER AND PANEL 8 9 6 5 10 11 12 3 4 2 1 7 ...

Page 60: ...2 Drain 8coolant completely from the radiator 3 Remove 8radiator cover 1 8radiator 8fan case2 Refer to RADIATOR in chapter 6 4 Remove 8spark plug cap 8spark plug 8ignition coil 8cylinder head cover 5 Measure 8valve clearance Out of specification J Adjust Valve clearance cold Intake valve 0 10 0 16 mm 0 004 0 006 in Exhaust valve 0 18 0 24 mm 0 007 0 010 in a Turn the crankshaft counterclockwise b ...

Page 61: ...ith a rag to prevent the valve pad from falling into the crankcase 8 Make a note of the position of each valve pad so that they can be installed in the cor rect place b Select the proper valve pad from the follow ing table c d 1 2 1 c Round off the original valve pad number according to the following table 1 20 0 047in 2 40 mm 0 095 in Available valve pads 25 thicknesses in 0 05 mm 0 002 in increm...

Page 62: ... new valve pad number is only an approxi mation The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect e Install the new valve pad NOTE 8 Lubricate the valve pad with molybdenum disulfide oil 8 Install the valve pad in the correct place f Measure the valve clearance again g If the valve clearance is still out of specifi cation repeat...

Page 63: ... 230 235 240 205 210 220 225 230 235 240 210 215 225 230 235 240 215 220 230 235 240 220 225 235 240 225 230 240 230 235 0 00 0 04 0 05 0 09 0 10 0 16 0 17 0 21 0 22 0 26 0 27 0 31 0 32 0 36 0 37 0 41 0 42 0 46 0 47 0 51 0 52 0 56 0 57 0 61 0 62 0 66 0 67 0 71 0 72 0 76 0 77 0 81 0 82 0 86 0 87 0 91 0 92 0 96 0 97 1 01 1 02 1 06 1 07 1 11 1 12 1 16 1 17 1 21 1 22 1 26 1 27 1 31 1 32 1 36 0 00 0 02...

Page 64: ...DJUSTING THE VALVE CLEARANCE 7 Install 8all removed parts NOTE For installation reverse the removal procedure 8 Fill 8cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT ...

Page 65: ...ylinder Engine tachometer 90890 03113 YU 08036 C 3 Check 8engine idling speed Out of specification J Adjust Engine idling speed 2000 2400 r min 4 Adjust 8engine idling speed a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained Direction a Engine idling speed is increased Direction b Engine idling speed is decreased 5 Adjust 8throttle cable free p...

Page 66: ...er1 onto the engine oil drain bolt 8engine tachometer onto the spark plug lead Pocket tester 90890 03132 YU 03112 C Engine tachometer 90890 03113 YU 08036 C 3 Start the engine and warm it up until the speci fied oil temperature is reached Oil temperature 50 70 C 4 Measure 8engine idling speed Out of specification J Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED Engine idling speed 2000 2400 r m...

Page 67: ...er tube so that exhaust gas does not leak out 8 Before using the carbon monoxide and hy drocarbon tester be sure to read the user s manual 6 Measure 8 carbon monoxide density 8 hydrocarbon density Carbon monoxide density when air induction system is operating 3 5 below hydrocarbon density when air in duction system is operating 1000ppm below Out of specification J Check air induc tion system Refer...

Page 68: ... grip 1 5 3 5 mm 0 059 0 138 in 2 Adjust 8throttle cable free play Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction a Throttle cable free play is increased Direction b Throttle cable free play is de creased c Tighten the locknut w After adjusting the throttle cable free play start the engine and ...

Page 69: ...park plug type manufacturer CR7E NGK 5 Check 8electrode 1 Damage wear J Replace the spark plug 8insulator 2 Abnormal color J Replace the spark plug Normal color is medium to light tan 6 Clean 8spark plug with a spark plug cleaner or wire brush 7 Measure 8spark plug gap a with a wire Thickness gauge Out of specification J Regap Spark plug gap 0 7 0 8 mm 0 028 0 032 in 8 Install 8spark plug 12 5 Nm ...

Page 70: ...ase Refer to RADIATOR in chapter 6 3 Attach 8timing light 1 8engine tachometer 2 onto the spark plug lead of cylinder Timing light 90890 03141 YU 03141 Engine tachometer 90890 03113 YU 08036 C 4 Check 8ignition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed Engine idling speed 2000 2400 r min b Check that the mark a on the AC mag...

Page 71: ...ition timing is not adjustable 5 Remove 8timing light 8engine tachometer 6 Install 8fan case 8radiator 8radiator cover Refer to RADIATOR in chapter 6 7 Fill 8cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT ...

Page 72: ...engine warm it up for several min utes and then turn it off 3 Remove 8battery cover 8battery holder Refer to COVER AND PANEL 4 Disconnect 8spark plug cap 5 Remove 8spark plug cC Before removing the spark plug use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder 6 Install 8compression gauge 1 Compression gauge 90890 03081 YU 33223 ...

Page 73: ...ck the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits J Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful engine of oil into the spark plug bore and measure again Refer to the following table 8 Remove 8compression gauge 9 Install 8spark plug 12 5 Nm 1 25 m kg 9 0 ft lb 10 Connect 8spark plug cap 11 Install 8battery hold...

Page 74: ... Add the recommended engine oil to the proper level Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures API standard SE or higher grade cC 8 8 8 8 8 Do not allow foreign materials to enter the crankcase NOTE Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several mi...

Page 75: ...lter element is also to be cleaned perform the following procedure a Remove the oil strainer cover 1 spring3 and oil filter element 4 b Replace the o ring 2 c Install the oil strainer cover Oil strainer cover 32 Nm 3 2 m kg 23 1 ft lb 6 Install 8engine oil drain bolt along with the gasket 23 Nm 2 3 m kg 16 6 ft lb 7 Fill 8crankcase with the specified amount of the recom mended engine oil Quantity ...

Page 76: ... filler cap 9 Start the engine warm it up for several min utes and then turn it off 10 Check 8engine for engine oil leaks 11 Check 8engine oil level Refer to CHECKING THE ENGINE OIL LEVEL 12 Check 8engine oil pressure Refer to CHECKING THE ENGINE OIL PRESSURE ...

Page 77: ... 1 8transmission oil fill bolt Completely drain the transmission oil 5 Install 8transmission oil drain bolt 13 Nm 1 3 m kg 9 4 ft lb 6 Fill 8transmission oil with the specified amount of the recom mended transmission oil Total amount 0 11 0 13L 0 10 0 12 Imp qt 0 12 0 14 US qt Periodic oil change 0 09 0 11L 0 08 0 10 Imp qt 0 10 0 12 US qt Recommended oil SAE10W30 1 1 T R T R 7 Install 8transmissi...

Page 78: ...sure to measure the engine oil pressure after warming up the engine 3 Remove 8seat trunk 8battery cover 8front cover Refer to COVER AND PANEL 4 Lossen 8gallery bolt 1 w The engine muffler and engine oil are extremely hot 5 Check 8engine oil pressure a Start the engine and keep it idling until en gine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the ...

Page 79: ...3 28 CHK ADJ MEASURING THE ENGINE OIL PRESSURE 6 Install 8gallery bolt 7 Nm 0 7 m kg 5 1 ft lb 7 Install 8front cover 8 battery cover 8seat trunk Refer to COVER AND PANEL T R ...

Page 80: ...7 2 ft lb cC Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning leading to poor engine performance and possible overheating NOTE When installing the air filter element into the air filter case cover make sure their ...

Page 81: ...ll 8rear cover 8side cover left and right 8front cover 8battery cover 8rear carrier 8seat trunk Refer to COVER AND PANEL EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses 1 Remove 8seat trunk Refer to COVER AND PANEL 2 Check 8vacuum hose 1 8fuel hose 2 Cracks damage J Replace Loose connection J Connect properly 3 Install 8seat trunk Ref...

Page 82: ...right 8rear cover Refer to COVER AND PANEL 2 Check 8fuel hose 1 Cracks damage J Replace 8fuel filter 2 Contaminants damage J Replace NOTE 8 Drain and flush the fuel tank if abrasive dam age to any components of the fuel line is evident 8 The arrow mark on the fuel filter must point towards the fuel cock as shown 3 Install 8rear cover 8side cover left and right 8front cover 8rear carrier 8seat trun...

Page 83: ...t trunk Refer to COVER AND PANEL CHECKING THE CRANKCASE BREATHER HOSE 2 Check 8crankcase breather hose 1 Cracks damage J Replace Loose connection J Connect properly cC Make sure the crankcase breather hose is routed correctly 3 Install 8seat trunk Refer to COVER AND PANEL 1 ...

Page 84: ...LER ASSEMBLY in chapter 5 2 Check 8muffler assembly 1 Cracks damage J Replace 8gasket 2 Exhaust gas leaks J Replace 3 Check 8tightening torque Muffler assembly nut 3 3 3 3 3 13 Nm 1 3 m kg 9 4 ft lb Muffler and rear arm bolt 4 4 4 4 4 31 Nm 3 1 m kg 22 4 ft lb Muffler and rear arm bolt 5 5 5 5 5 31 Nm 3 1 m kg 22 4 ft lb 4 Install 8muffler assembly Refer to MANIFOLD AIR FILTER AND MUFFLER ASSEMBLY...

Page 85: ...lant to the proper level cC 8 8 8 8 8 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant 8 8 8 8 8 Use only distilled water However if dis tilled water is not available soft water may be used 4 Start the engine warm it up for several min utes and then turn it off...

Page 86: ...cover Refer to COOLING SYSTEM in chap ter 6 CHECKING THE COOLING SYSTEM 2 Check 8radiator 1 8radiator inlet hose 2 8radiator outlet hose 3 Cracks damage J Replace Refer to COOLING SYSTEM in chap ter 6 3 Install 8radiator cover Refer to COOLING SYSTEM in chap ter 6 8mat footrest board 8footrest board side cover mole left and right 8 battery holder battery 8front cover 8 battery cover 8seat trunk Re...

Page 87: ...engine is hot Scalding hot fluid and steam may be blown out which could cause serious injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it countercl...

Page 88: ... 8 8 If coolant splashes in your eyes thor oughly wash them with water and con sult a doctor 8 8 8 8 8 If coolant splashes on your clothes quickly wash it away with water and then with soap and water 8 8 8 8 8 If coolant is swallowed induce vomiting and get immediate medical attention cC 8 8 8 8 8 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead...

Page 89: ... up for several min utes and then stop it 12 Check 8coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Before checking the coolant level wait a few minutes until the coolant has settled 13 Install 8radiator cover Refer to COOLING SYSTEM in chap ter 6 8footrest board side cover mole right 8battery cover 8mat Refer to COVER AND PANEL CHANGING THE COOLANT ...

Page 90: ...e play is increased Direction b Brake lever free play is decreased cC After adjusting the brake lever free play make sure there is no brake drag EAS00114 ADJUSTING THE REAR BRAKE 1 Check 8brake lever free playa Out of specification J Adjust Brake lever free play 10 20 mm 0 394 0 787 in 2 Adjust 8brake lever free play a Turn the adjusting nut 1 in direction a or b until the specified brake lever fr...

Page 91: ...perate the brake 2 Check 8wear indicator 1 Reaches the wear limit line 2 J Replace the brake shoes as a set Refer to FRONT WHEEL AND FRONT BRAKE and REAR WHEEL AND REAR BRAKE in chapter 4 A Front brake B Rear brake CHECKING THE FRONT AND REAR BRAKE SHOES A 2 1 1 B 2 ...

Page 92: ...of the front fork legs and gently rock the front fork Binding looseness J Adjust the steering head 3 Remove 8head light cover 8leg shield 1 Refer to COVER AND PANEL 4 Adjust 8steering head a Remove the upper cover b Loosen the steering nut 1 and then tighten it to specification with the steering nut wrench NOTE Set the torque wrench at a right angle to the steering nut wrench Steering nut wrench 9...

Page 93: ... by turning the front fork all the way in both directions If any binding is felt re move the upper cover and check the bear ing race Refer to STEERING HEAD in chapter 4 e Hold the upper bearing inner race with a steering nut wrench and tighten the steer ing nut1 with a steering nut wrench2 Steering nut wrench 90890 01403 YU A9472 Steering nut 30 Nm 3 0 m kg 21 7 ft lb 5 Install 8leg shield 1 8head...

Page 94: ...re is no danger of it falling over 2 Check 8inner tube Damage scratches J Replace 8dust seal Damage scratches J Replace 3 Hold the scooter upright and apply the front brake 4 Check 8front fork operation Push down hard on the handlebar sev eral times and check if the front fork re bounds smoothly Rough movement J Repair Refer to FRONT FORK in chapter 4 ...

Page 95: ...ate w 8 8 8 8 8 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air tem perature 8 8 8 8 8 The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passen ger and accessories and the anticipated riding speed 8 8 8 8 8 Operation of an overloaded scooter could cause tire damage an accident or an inju...

Page 96: ...l groove 8 8 8 8 8 Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement A Tire B Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire 8 8 8 8 8 After extensive tests the tires listed be low have been approved by Yamaha Motor Taiwan Co Ltd for this model The front ...

Page 97: ... slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 8 Install the tire with the mark pointing in the direction of wheel rotation 8 Align the mark 2 with the valve installation point D R I V E 2 1 ...

Page 98: ...0 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables w Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check 8outer cable Damage J Replace 2 Check 8cable operation Rough movement J Lubricate Recommended lubricant Engine oil or a suitable cable...

Page 99: ...ing parts of the levers and pedals Recommended lubricant Lithium soap based grease LUBRICATING THE LEVERS AND PEDALS LUBRICATING THE CENTERSTAND EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Lithium soap based grease ...

Page 100: ...ctrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL 8 8 8 8 8 Skin Wash with water 8 8 8 8 8 Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL 8 8 8 8 8 Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention cC 8 8 8 8 8 This is a sealed...

Page 101: ...isconnect the negative battery lead 1 1 1 1 1 and then the positive battery lead 2 2 2 2 2 3 Remove 8battery 4 Check 8battery charge a Connect a digital pocket tester to the bat tery terminals Pocket tester 90890 03132 YU 03112 C Positive tester probe J positive battery terminal Negative tester probe J negative battery terminal NOTE 8 The charge state of an MF battery can be checked by measuring i...

Page 102: ...e battery 8 8 8 8 8 When charging a battery be sure to re move it from the scooter If charging has to be done with the battery mounted on the scooter disconnect the negative bat tery lead from the battery terminal 8 8 8 8 8 To reduce the chance of sparks do not plug in the battery charger until the bat tery charger leads are connected to the battery 8 8 8 8 8 Before removing the battery charger le...

Page 103: ...f the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode 8 8 8 8 8 As shown in the following illustration the open circuit voltage of an MF bat tery stabilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is com pleted before ...

Page 104: ...perage Set the timer to the charging time determined by the opencircuit voltage Refer to CHECKING AND CHARGING THE BATTERY Adjust the char ging voltage to 20 25V Monitor the amperage for 3 5 minutes Is the standard charg ing amperage exceeded If the amperage does not ex ceed the standard charging am perage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advi...

Page 105: ...tten on the bat tery NOTE Set the charging time to a maximum of 20 hours NOTE Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage Charge the battery until the charging voltage reaches 15 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is re quired Under 12 0 V Rep...

Page 106: ...ction J Connect properly 9 Lubricate 8battery terminals Recommended lubricant Dielectric grease 10 Install 8battery holder 8battery cover 8mat Refer to COVER AND PANEL CHECKING AND CHARGING THE BATTERY CHECKING THE FUSE EAS00181 CHECKING THE FUSE The following procedure applies to all of the fuse cC To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remo...

Page 107: ...orrect amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit w Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction an...

Page 108: ...ooled down 4 Install 8headlight bulb New Secure the new headlight bulb with the headlight bulb holder cC Avoid touching the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner...

Page 109: ...ly a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered 2 Adjust 8headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left 1 b a 2 b a ...

Page 110: ...CHECKING THE REAR WHEEL 4 15 CHECKING THE REAR WHEEL DRIVE HUB 4 15 CHECKING THE BRAKE 4 16 ASSEMBLING THE BRAKE SHOE PLATE 4 17 INSTALLING THE REAR WHEEL 4 18 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 18 FRONT FORK 4 19 REMOVING THE FRONT FORK LEGS 4 21 DISASSEMBLING THE FRONT FORK LEGS 4 21 CHECKING THE FRONT FORK LEGS 4 22 ASSEMBLING THE FRONT FORK LEGS 4 23 INSTALLING THE FRONT FORK LEGS 4 24 ...

Page 111: ...CHAS 4 38 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 35 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 35 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 36 ...

Page 112: ...ake shoe plate Collar Front wheel 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed NOTE Place the scooter on a suitable stand so that the front wheel is elevated Refer to REMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL For installation reverse the removal pro cedure EAS00517 CHASSIS FRONT WHEEL AND BRAKE 6 48Nm 4 8 m kg 34 7 ft lb 1 2 4 3 5 8 10 9 7 ...

Page 113: ...ONT WHEEL FRONT WHEEL AND BRAKE Disassembling the front wheel Oil seal Bearing Spacer Bearing 1 2 3 4 Remove the parts in the order listed Refer to REMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL For assembly reverse the disassembly procedure 1 2 3 4 ...

Page 114: ... spring Brake camshaft O ring Oil seal Oil seal Circlip Plate washer Speedometer clutch Drive gear Plate washer Bush Oil seal Speedometer gear Plate washer 1 2 3 4 5 6 7 8 9 0 q w e r t y u Remove the parts in the order listed Refer to DISASSEMBLING THE BRAKE SHOE PLATE and ASSEM BLING THE BRAKE SHOE PLATE For assembly reverse the disassembly procedure 2 9 0 q w e 8 4 5 7 6 6 u y r t 1 8Nm 0 8 m k...

Page 115: ...le 2 8front wheel axle nut 3 8front wheel axle 4 8front wheel 5 8collar 8front brake shoe plate 6 Refer to FRONT WHEEL AND BRAKE EAS00524 DISASSEMBLINGTHE BRAKE SHOE PLATE 1 Remove 8front brake shoe 8comshaft lever 8indicator plate 8return spring 8brake camshaft 8speedometer gear NOTE Remove the bush from the brake shoe plate with the meter gear bush tool 2 Remove 8circlip 8plate washer 8speedomet...

Page 116: ...wear J Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure 8radial wheel runout 1 8lateral wheel runout 2 Over the specified limits J Replace Radial wheel runout limit 1 0 mm 0 04 in Lateral wheel runout limit 1 0 mm 0 04 in 4 Check 8wheel bearings Front wheel turns roughly or is loose J Replace the wheel bearings 8oil seals Damage wear J Replace 5 Replace 8wheel bea...

Page 117: ...r and the wheel surface c Remove the wheel bearings 4 with a gen eral bearing puller3 d Install the new wheel bearings and oil seal in the reverse order of disassembly EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1 Check 8speedometer clutch Bends damage wear J Replace 2 Check 8speedometer drive gear 1 8speedometer gear 2 Damage wear J Replace 2 1 3 4 2 1 FRONT WHEEL AND BRAKE ...

Page 118: ...oe with a cloth 2 Measure 8brake shoe lining thickness a Out of specification JReplace Brake shoe lining thickness limit minimum 2 0 mm 0 079 in w Do not allow oil or grease to contact the brake shoes NOTE Replace the brake shoes as a set if either is worn to the wear limit 3 Measure 8brake drum inside diameter b Out of specification JReplace the wheel Brake drum inside diameter limit maximum 110 ...

Page 119: ...ke camshaft 1 8spring 8brake shoe wear indicator 2 a Install the brake camshaft so its punch mark a is positioned as shown b Align the projection b on the brake shoe wear indicator with the notch in the brake camshaft c Check that the brake shoes are properly positioned 2 Install 8comshaft lever 7 Nm 0 7 m kg 5 1 ft lb Align the camshaft punch mark a and comshaft lever punch mark b is positioned a...

Page 120: ...ings and oil seal in the reverse order of disassembly cC Do not contact the wheel bearing inner race 1 1 1 1 1 or balls 2 2 2 2 2 Contact should be made only with the outer race 3 3 3 3 3 NOTE Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal 2 Install 8brake shoe plate Align the tab on the speedometer clutch with the slot in the wheel hub 1 ...

Page 121: ...bricant Lithium soap based grease 2 Install 8front wheel1 NOTE Make sure the slot2 in the brake shoe plate fits over the stopper3 on the outer tube 3 Tighten 8wheel axle nut 48 Nm 4 8 m kg 34 7 ft lb w Make sure the brake cable is routed properly cC Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly 2 3 1 ...

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

Page 123: ...he front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check 8front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain station ary at all of the positions rebalance it X 1 ...

Page 124: ...Plate washer Camshaft lever Indicator plate Return spring Brake camshaft O ring REAR WHEEL AND BRAKE Remove the parts in the order listed NOTE Place the scooter on a suitable stand so that the front wheel is elevated Refer to MANIFOLD AIR FILTER AND MUFFLER ASSEMBLY in chapter 5 For installation reverse the removal pro cedure EAS00555 REAR WHEEL AND BRAKE 5 7Nm 0 7 m kg 5 1 ft lb 7 8 7 12 12 3 11 ...

Page 125: ...rface w Securely support the scooter so that there is no danger of it falling over NOTE Place the scooter on a suitable stand so that the rear wheel is elevated 2 Remove 8brake adjuster 3 Remove 8muffler assembly 8wheel axle nut 1 4 Remove 8rear wheel1 REAR WHEEL AND BRAKE 1 1 ...

Page 126: ...rear wheel Damage wear J Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 2 Measure 8radial wheel runout 8lateral wheel runout Refer to CHECKING THE FRONT WHEEL EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check 8rear wheel drive hub Cracks damage J Replace ...

Page 127: ...ning thickness limit minimum 2 0 mm 0 079 in w Do not allow oil or grease to contact the brake shoes NOTE Replace the brake shoes as a set if either is worn to the wear limit 3 Measure 8brake drum inside diameter b Out of specification J Replace the wheel Brake drum inside diameter limit maximum 110 5 mm 4 35 in 4 Check 8brake drum inner surface Oil deposits J Clean Remove the oil with a rag soake...

Page 128: ...rake shoe camshaft c Check that the brake shoes are properly positioned 2 Install 8brake shoes1 8tension springs cC 8 8 8 8 8 Do not put lubricating oil on the brake lining 8 8 8 8 8 Change the tension spring at the same time of changing the brake shoe 8 8 8 8 8 Refer to the direction in the illustration when assembling the brake shoe and spring 8 8 8 8 8 Refer to the illustration with regards to ...

Page 129: ...ter replacing the tire wheel or both the rear wheel static balance should be ad justed 8 Adjust the rear wheel static balance with the rear wheel drive hub installed 1 Adjust 8rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE 3 Tighten 8wheel axle nut1 104 Nm 10 4 m kg 75 2 ft lb 4 Install 8muffler assembly 5 Adjust 8brake lever free play Refer to ADJUSTING THE REAR BRAKE...

Page 130: ... Leg shield 1 Lower bracket pinch bolt Snap ring Inner tube plug Front fork leg Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE Refer to HANDLE BAR Refer to STEERING HEAD Refer to COVER AND PANEL in chap ter 3 For installation reverse the removal pro cedure FRONT FORK EAS00646 FRONT FORK 3 2 4 1 30Nm 3 0 m kg 21 7 ft lb ...

Page 131: ...ork legs Band Boot Dust seal Circlip Spring guide Rebound spring Inner tube Damper rubber Fork spring Outer tube Remove the parts in the order listed Refer to DISASSEMBLING AND IN STALLING THE FRONT FORK LEGS For assembly reverse the disassembly procedure FRONT FORK EAS00648 0 8 1 2 3 4 5 6 7 9 3g 1g 4g ...

Page 132: ...table stand so that the front wheel is elevated EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove 8band 8foot 8inner tube plug 2 Loosen 8lower bracket pinch bolt 1 3 Remove 8snap ring 2 8front fork leg3 w Before loosening the lower bracket pinch bolts support the front fork leg 2 Remove 8dust seal 1 8circlip2 8spring guide3 8rebound ...

Page 133: ...e Bends damage scratches J Replace w Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure 8spring free length a Out of specification J Replace Spring free length 125 mm 4 921 in Limit 122 5 mm 4 823 in 3 Check 8inner tube 1 8spring guide2 8rebound spring 3 Damage wear J Replace 4 Check 8damper rubber 1 8fork spring2 8outer tube 3 Damage wear J Replace 1 2 3 1 ...

Page 134: ...ore assembling the front fork leg make sure all of the components are clean 1 Install 8fork spring 1 8damper rubber2 NOTE 8 Install the spring with the smaller pitch fac ing down 2 Lubricate 8inner tube s outer surface 8rebound spring 8fork spring 8circlip Recommended lubricant Molybdenum disulfide grease 2 1 5 4 3 2 1 3 Install 8inner tube1 8rebound spring 2 8spring guide3 8circlip4New 8dust seal...

Page 135: ...ocedure applies to both of the front fork legs 1 Install 8front fork leg 1 8snap ring 2New 8inner tube plug 8lower bracket pinch bolt 3 NOTE Pull up the inner tube until it stops then install the snap ring to groove 2 Tighten 8lower bracket pinch bolt 30 Nm 3 0 m kg 21 7 ft lb 3 2 1 ...

Page 136: ...bly Rear view mirror left and right Front brake cable Front brake switch Brake lever right Handlebar holder assembly right Throttle cable kit Throttle grip assembly Rear brake cable Rear brake switch Brake lever left Handlebar holder assembly left Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 HANDLEBAR 2 9 5 6 7 10 17 4 12 11 13 15 14 4 16 3 8 1 60Nm 6 0 m kg 43 4 ft ...

Page 137: ... installation reverse the removal pro cedure Remarks Order Job Part Q ty 2 9 5 6 7 10 17 4 12 11 13 15 14 4 16 3 8 1 60Nm 6 0 m kg 43 4 ft lb LS LS LS LS 1 1 1 Handlebar grip Handlebar upper cover Handlebar assembly 15 16 17 ...

Page 138: ...older assembly right pull back the rubber cover 3 Remove 8handlebar grip NOTE Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECKINGTHE HANDLEBAR 1 Stand the scooter on a level surface w Securely support the scooter so that there is no danger of it falling over 2 Check 8handlebar 1 Bends cracks damage J Replace w Do not atte...

Page 139: ...the steer ing shaft 2 surface 3 Tighten 8handlebar 60 Nm 6 0 m kg 43 4 ft lb cC There must be a space b b b b b after tighting bolt 4 Install 8handlebar upper cover 5 Install 8handlebar holder assembly left 1 NOTE Align the projection a on the handlebar holder assembly left with the hole b on the handle bar 6 Install 8throttle grip assembly 1 8handlebar holder assembly right 2 8throttle cable kit ...

Page 140: ...e handlebar4 8 Align the projectiona on the right handle bar holder assembly with the hole b on the handlebar w Make sure the throttle grip operates smoothly 7 Adjust 8throttle 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 5 mm 0 059 0 138 in ...

Page 141: ...Front fork assembly Upper bearing Lower bearing Upper bearing outer race Lower bearing outer race Lower bearing inner race 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE Refer to COVER AND PANEL in chap ter 3 Refer to HANDLEBAR For installation reverse the removal pro cedure STEERING HEAD EAS00675 STEERING HEAD 7Nm 0 7 m kg 5 1 ft lb 4 5 6 10 11 9 12 8 ...

Page 142: ...danger of it falling over NOTE Place the scooter on a suitable stand so that the front wheel is elevated 2 Remove 8ball race cover 8ring nut 1 with the ring nut wrench 2 Ring nut wrench 90890 01268 YU 01268 3 Remove 8upper bearing inner race1 with the ring nut wrench 2 w Securely support the front fork assembly so that there is no danger of it falling 1 2 ...

Page 143: ... 8bearing races a Remove the bearing races from the steer ing head pipe with a long rod 1 and ham mer b Remove the bearing race from the front fork assembly with a floor chisel 2 and ham mer cC If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the balls and bearing races as a set 4 Check 8front fork assembly along with the steering stem Bends...

Page 144: ...ant Lithium soap based grease 2 Install 8front fork assembly 1 8upper bearing inner race 2 7 Nm 0 7 m kg 5 1 ft lb with the ring nut wrench 3 T R 3 Install 8ring nut 1 30 Nm 3 0 m kg 21 7 ft lb with the ring nut wrench 2 Ring nut wrench 90890 01403 YU A9472 Refer to CHECKING THE STEERING HEAD in chapter 3 T R 1 2 3 1 2 1 LS ...

Page 145: ...ssembly Rear shock absorber assembly upper nut Rear shock absorber assembly upper bolt Rear shock absorber assembly lower bolt Rear shock absorber assembly Remove the parts in the order listed For installation reverse the removal pro cedure REAR SHOCK ABSORBER ASSEMBLY 16Nm 1 6 m kg 11 6 ft lb 3 4 1 2 30Nm 3 0 m kg 21 7 ft lb ...

Page 146: ...8rear shock absorber nut upper 8rear shock absorber bolt lower EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check 8rear shock absorber rod Bend damage J Replace the rear shock absorber assembly 8rear shock absorber Oil leak J Replace the rear shock ab sorber assembly 8spring Damage wear J Replace the rear shock absorber assembly 8bushing Damage wear J Replace 8dust seal Damage wear J Repla...

Page 147: ...cer 8bush Recommended lubricant Molybdenum disulfide grease 2 Install 8rear shock absorber assembly 3 Tighten 8rear shock absorber assembly upper nut 30 Nm 3 0 m kg 21 7 ft lb 8rear shock absorber assembly lower bolt 16 Nm 1 6 m kg 11 6 ft lb T R T R REAR SHOCK ABSORBER ASSEMBLY ...

Page 148: ...ING THE CAMSHAFT AND ROCKER ARMS 5 17 VALVES AND VALVE SPRINGS 5 18 REMOVING THE VALVES 5 19 CHECKING THE VALVES AND VALVE GUIDES 5 20 CHECKING THE VALVE SEATS 5 22 CHECKING THE VALVE SPRINGS 5 24 INSTALLING THE VALVES 5 25 CYLINDER AND PISTON 5 27 REMOVING THE CYLINDER AND PISTON 5 28 CHECKING THE CYLINDER AND PISTON 5 29 CHECKING THE PISTON RINGS 5 30 CHECKING THE PISTON PIN 5 31 CHECKING THE TI...

Page 149: ...CLUTCH 5 50 CHECKING THE STARTER CLUTCH 5 51 INSTALLING THE STARTER CLUTCH 5 52 INSTALLING THE AC MAGNETO 5 52 OIL PUMP 5 54 CHECKING THE OIL PUMP 5 55 ASSEMBLING THE OIL PUMP 5 56 INSTALLING THE OIL PUMP 5 56 TRANSMISSION 5 57 CHECKING THE TRANSMISSION 5 58 CRANKSHAFT 5 59 CRANKSHAFT ASSEMBLY 5 59 DISASSEMBLING THE CRANKCASE 5 61 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 5 62 CHECKING THE ...

Page 150: ...bly Carburetor Thermo unit lead Remarks Order Job Part Q ty 1 1 Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 Drain Refer to CHANGINGTHE COOLANT in chapter 3 Refer to COOLING SYSTEM in chap ter 6 Refer to CARBURETOR in chapter 7 Disconnect EAS00188 ENGINE ENGINE LEADS HOSES AND REAR BRAKE ENGINE A A B B C C D D E E 12Nm 1 2 m kg 8 7 ft lb 12 2 4 5 3 1 6 13 11 9 8 7 7 ...

Page 151: ... lock cable Rear shock absorber assembly lower bolt Self lock nut Engine mounting bolt 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Refer to STARTER CLUTCH AND AC MAGNETO Disconnect Disconnect Refer to REAR SHOCK ABSORBER ASSEMBLY in chapter 4 Refer to INSTALLING THE ENGINE For installation reverse the removal pro cedure A A B B C C D D E E 12Nm 1 2 m kg 8 7 ft lb 12 2 4 5 3 1 6 13 11 9...

Page 152: ...hrottle cable kit Auto choke lead Throttle position sensor lead Muffler assembly Gasket Spark plug cap Ignition coil Air filter assembly Breather hose Starter motor assembly Rear fender Manifold O ring ENGINE Remove the parts in the order listed Refer to LEADS HOSES AND REAR BRAKE Refer to CARBURETOR in chapter 7 For installation reverse the removal pro cedure 10Nm 1 0 m kg 7 2 ft lb 8Nm 0 8 m kg ...

Page 153: ... ENGINE 1 Install 8engine 1 8engine mounting bolt 2 8self lock nut3 NOTE Do not fully tighten the bolts 2 Tighten 8self lock nut 46Nm 4 6 m kg 33 3 ft lb 1 2 3 1 T R 3 Tighten 8rear shock absorber assembly lower bolt1 16 Nm 1 6 m kg 11 6 ft lb ...

Page 154: ...haft sprocket Bolt Nut Plate Cylinder head Cylinder head gasket Dowel pin Remove the parts in the order listed Refer to MANIFOLD AIR FILTER AND MUFFLER ASSEMBLY Refer to REMOVING THE CYLINDER HEAD For installation reverse the removal pro cedure CYLINDER HEAD EAS00221 CYLINDER HEAD 5 8Nm 0 8 m kg 5 8 ft lb 9Nm 0 9 m kg 6 5 ft lb 6 4 3 9 10 10Nm 1 0 m kg 7 2 ft lb 10Nm 1 0 m kg 7 2 ft lb 30Nm 3 0 m ...

Page 155: ...b on the crankcase cover a Turn the primary fixed sheave counterclock wise b When the piston is at TDC on the compres sion stroke align the I mark c on the cam shaft sprocket with the mark d on the plate 3 Loosen 8timing chain tensioner bolt 8camshaft sprocket bolt 1 While holding the crank bolt with a wrench2 remove the camshaft sprocket bolt 1 Rotor holding tool 90890 01235 YU 01235 a b c d 1 2 ...

Page 156: ... 1 8timing chain 2 NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire 5 Remove 8cylinder head NOTE 8 Loosen the nuts in the proper sequence as shown 8 Loosen each nut 1 2 of a turn at a time Af ter all of the nuts are fully loosened remove them 2 1 5 3 6 4 1 2 ...

Page 157: ... Measure 8cylinder head warpage Out of specification J Resurface the cyl inder head Maximum cylinder head warpage 0 03 mm 0 001 in a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylin der head using a figure eigh...

Page 158: ... 1 8timing chain 2 a Turn the primary pulley counterclockwise b Align the I mark a on the AC magneto rotor with the stationary pointer b on the crankcase cover c Align the I mark c on the camshaft sprocket with the stationary pointer d on the plate d Install the timing chain onto the camshaft sprocket and then install the camshaft sprocket onto the camshaft NOTE 8 When installing the camshaft spro...

Page 159: ...all 8timing chain tensioner gasket New 8timing chain tensioner a Remove the cap bolt 1 and spring 2 b Release the timing chain tensioner one way cam 3 and push the timing chain tensioner rod 4 all the way into the timing chain tensioner housing c Install the timing chain tensioner and gas ket 5 onto the cylinder Timing chain tensioner bolt 9 Nm 0 9 m kg 6 5 ft lb d Install the spring 2 and cap bol...

Page 160: ...tionary pointer d on the plate Out of alignment J Correct Refer to the installation steps above CYLINDER HEAD T R a b c d 9 Tighten 8camshaft sprocket bolt 30 Nm 3 0 m kg 21 7 ft lb cC Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 10 Measure 8valve clearance Out of specification J Adjust Refer to AD...

Page 161: ...arms and cam shaft Cylinder head Camshaft Rocker arm shaft intake Rocker arm shaft exhaust Rocker arm intake Rocker arm exhaust Spring 1 1 1 1 1 2 Remove the parts in the order listed Refer to CYLINDER HEAD For installation reverse the removal pro cedure THE ROCKER ARMS AND CAMSHAFT 4 6 4 6 5 3 2 1 ...

Page 162: ... shaft 8intake rocker arm 8exhaust rocker arm NOTE Remove the rocker arm shafts with the clip plier1 EAS00205 CHECKING THE CAMSHAFT 1 Check 8camshaft bushings Damage wear J Replace 2 Check 8camshaft lobes Blue discoloration pitting scratches J Replace the camshaft 1 1 a b 3 Measure 8camshaft lobe dimensions a and b Out of specification J Replace the cam shaft ...

Page 163: ...4 920mm 4 Check 8camshaft oil passage Obstruction J Blow out with compressed air EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check 8rocker arm camshaft touch surface1 8rocker arm valve touch surface2 Damage wear J Replace 2 Check 8rocker arm shaft Blue discoloration excessive wear pitting scratches J Repl...

Page 164: ...eter a Out of specification J Replace Rocker arm shaft outside diameter 9 981 9 991 mm 0 392 0 393 in 6 Calculate 8rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Above 0 034 mm 0 001 in J Replace the de fective part s Rocker arm to rocker arm shaft clearance 0 009 0 034 mm 0 0004 0 001 i...

Page 165: ...the timing chain as a set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check 8timing chain guide exhaust side 8timing chain guide intake side Damage wear J Replace the defective part s THE ROCKER ARMS AND CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1 Check 8timing chain tensioner Cracks damage J Replace 2 Check 8one way cam operation Rough movement J Replace the timi...

Page 166: ...mmended lubricant Molybdenum disulfide oil 3 Install 8exhaust rocker arm 1 8spring 2 8exhaust rocker arm shaft 3 NOTE Make sure the exhaust rocker arm shaft is com pletely pushed into the cylinder head THE ROCKER ARMS AND CAMSHAFT 4 Install 8intake rocker arm 1 8spring 2 8intake rocker arm shaft 3 NOTE Make sure the intake rocker arm shaft is com pletely pushed into the cylinder head 1 4 3 2 1 3 2...

Page 167: ...lve pad Valve cotter Valve spring retainer Valve spring Valve intake Valve exhaust Valve stem seal Valve stem seat Valve guide Remove the parts in the order listed Refer to CYLINDER HEAD Refer to THE ROCKER ARMS AND CANSHAFT Refer to INSTALLING THE VALVES AND VALVE SPRINGS For installation reverse the removal pro cedure VALVES AND VALVE SPRINGS 5 6 9 8 4 7 3 9 5 9 1 2 2 1 3 4 8 7 1 2 3 4 7 8 ...

Page 168: ... and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 2 Remove 8valve pads1 VALVES AND VALVE SPRINGS 3 Remove 8valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compre...

Page 169: ...ve stem diameter b Out of specification J Replace the valve guide Valve stem to valve guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 003 in Exhaust 0 025 0 052 mm 0 001 0 002 in Limit 0 10 mm 0 004 in 2 Replace 8valve guide NOTE To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100 C in an oven a Remove the valve guide wi...

Page 170: ...ck 8valve face Pitting wear J Grind the valve face 8valve stem end Mushroom shape or diameter larger than the body of the valve stem J Replace the valve 5 Measure 8valve margin thickness a Out of specification J Replace the valve Valve margin thickness 0 70 mm 0 028 in 6 Measure 8valve stem runout Out of specification J Replace the valve NOTE 8 When installing a new valve always replace the valve ...

Page 171: ... mm 0 063 in Exhaust 0 9 1 1 mm 0 035 0 043 in Limit 1 6 mm 0 063 in a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width NOTE Where the valve seat and valve face contacted one another the blueing will have been removed 4 Lap ...

Page 172: ...ap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through t...

Page 173: ...Limit 39 49 mm 1 555 in VALVES AND VALVE SPRINGS 2 Measure 8compressed valve spring force a Out of specification J Replace the valve spring b Installed length Compressed valve spring force in stalled Intake valve spring 9 3 10 7 kg at 28 mm 20 5 23 6 lb at 1 102 in Exhaust valve spring 11 0 12 7 kg at 30 mm 24 3 28 0 lb at 1 181 in 3 Measure 8valve spring tilt a Out of specification J Replace the ...

Page 174: ...ricant Molybdenum disulfide oil 3 Install 8valve 1 8valve spring seat 2 8valve stem seal 3New 8valve spring 4 8valve spring retainer 5 into the cylinder head NOTE Install the valve spring with the larger pitch a facing up b Smaller pitch 4 Install 8valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachm...

Page 175: ...e valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer cC Hitting the valve tip with excessive force could damage the valve VALVES AND VALVE SPRINGS 6 Install valve pad 1 NOTE 8 Lubricate the valve pad with molybdenum disulfide oil 8 Each valve pad must be reinstalled in its original position 1 ...

Page 176: ...owel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set Remove the parts in the order listed Refer to CYLINDER HEAD Refer to INSTALLING THE PISTON AND CYLINDER Refer to REMOVING THE CYLINDER AND PISTON Refer to INSTALLING THE PISTON AND CYLINDER For installation reverse the removal pro cedure 1 1 1 1 2 1 2 1 1 1 CYLINDER AND PISTON 10Nm 1 0 m kg 7 2 ft lb 5 6 1 3 4 2 5 7 8 7 4 1...

Page 177: ...lling into the crankcase 8 Before removing the piston pin deburr the piston pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove re move it with the piston pin puller set4 Piston pin puller set 90890 01304 YU 01304 CYLINDER AND PISTON 2 Remove 8top ring 82nd ring 8oil ring NOTE When removing a piston ring open the end gap with ...

Page 178: ...abrasion is beyond limitJ Replace it Standard 38 000 38 010 mm 1 4961 1 4965 in b If out of specification replace the cylinder and the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer a 5 mm 0 197 in from the bottom edge of the piston Piston size P 37 975 37 990 mm 1 495 1 496 in d If out of specification replace the piston and piston rings as a set e Calculat...

Page 179: ...mm 0 0008 0 0024 in Limit 0 12 mm 0 0047 in 2 Install 8piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown a 10 mm 0 394 in 3 Measure 8piston ring end gap Out of specification J Replace the pis ton ring NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end g...

Page 180: ...7 in Limit 9 976 mm 0 3928 in 3 Measure 8piston pin bore diameter b Out of specificationJ Replace the piston Piston pin bore diameter 10 002 10 013 mm 0 3938 0 3942 in Limit 10 043 mm 0 3954 in 4 Calculate 8piston pin to piston pin bore clearance Out of specification J Replace the pis ton pin and piston as a set Piston pin to piston pin bore clearance Piston pin bore diameter b Piston pin outside ...

Page 181: ... 2 Install 8piston 1 8piston pin 2 8piston pin clip New 3 NOTE 8 Apply engineoil the piston pin 8 Make sure the arrow mark a on the piston points towards the exhaust side of the cyl inder 8 Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the clip from falling into the crank case CHECKING THE TIMING CHAIN GUIDE 1 Check 8 timing chain guide exhaust side ...

Page 182: ...il 5 Offset 8piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Exhaust side 6 Install 8timing chain guide exhaust side 8cylinder 1 NOTE 8 While compressing the piston rings with one hand install the cylinder with the other hand 8 Pass the timing chain and timing chain guide exhaust side through the timing chain cavity a c d A b 1 ...

Page 183: ...r left Crankcase cover gasket left Dowel pin Kick pinion gear Kick pinion gear clip Circlip Plate washer Kick shaft assembly Torsion spring Solid bush Holder Torsion spring Stopper lever assembly Remove the parts in the order listed Refer to LEADS HOSES AND REAR BRAKE Refer to INSTALLING THE KICKSTARTER For installation reverse the removal pro cedure BELT DRIVE 10Nm 1 0 m kg 7 2 ft lb 2 9 6 6 11 1...

Page 184: ...torsion spring3 2 Hook 8kickstarter spring NOTE Hook the spring enda on the kickstarter shaft b as shown and hook the other end c on the projectiond 3 Install 8plain washer 8circlip1 New 4 Install 8kick pinion gear1 8kick pinion gear clip2 NOTE Install the clip at the position shown 1 3 1 2 d c a b 1 2 ...

Page 185: ...VE For installation reverse the removal pro cedure Removing theV belt clutch primary and secondary sheave Primary sheave nut Plate washer Oneway clutch Primary fixed sheave Secondary sheave nut Clutch housing Secondary sheave assembly V belt Collar Primary sliding sheave Cam Weight Slider Plate washer V BELT CLUTCH PRIMARY AND SECONDARY SHEAVE BELT DRIVE 1 30Nm 3 0 m kg 21 7 ft lb 2 3 8 9 11 10 10...

Page 186: ...ING THE SECONDARY SHEAVE For installation reverse the removal pro cedure Disassembling the secondary sheave assembly Clutch carrier nut Clutch carrier Clutch shoe spring Compression spring Secondary spring seat Guide pin Secondary sliding sheave O ring Oil seal Secondary fixed sheave BELT DRIVE 3 2 1 5 9 8 7 9 0 6 4 55Nm 5 5 m kg 39 8 ft lb LS LS 3 ...

Page 187: ...t this stage NOTE While holding the clutch carrier with the rotor holding tool 2 loosen the clutch carrier nut one full turn with the locknut wrench 3 Roter holding tool 90890 01235 YU 01235 Locknut wrench 90890 01348 YM 01348 EAS00317 REMOVING THE PRIMARY SHEAVE 1 Remove 8primary sheave nut 1 8plate washer2 8oneway clutch3 8primary fixed sheave 4 NOTE While holding the primary fixed sheave with t...

Page 188: ...h spring holder 90890 01337 YM 33285 YM 33285 6 CHECKING THE CLUTCH SHOE 1 Measure 8clutch shoe Scratches J Glaze using coares sand paper Damage wear J Replace Clutch shoe thickness 3 7 mm 0 146 in Limit 2 0 mm 0 079 in NOTE Inspect clutch shoes a After removing the clutch weight spring do not use them again Replace the all two as a set 3 Remove 8secondary sheave assembly 1 8V belt 2 NOTE Remove t...

Page 189: ...V belt width 16 8 mm 0 0661 in Limit 15 8 mm 0 622 in CHECKING THE PRIMARY SHEAVE 1 Check 8primary sliding sheave1 8primary fixed sheave2 Cracks damage wear J Replace the pri mary sliding sheave primary fixed sheave and V belt 2 Check 8free movement Insert the collar2 into the primary sliding sheave1 and check for free movement Stick or excessive play J Replace the primary sliding sheave or collar...

Page 190: ...de di ameter 15 mm 0 591 in Limit 14 5 mm 0 571 in BELT DRIVE CHECKING THE SLIDER 1 Check 8slider 1 Damage wearJ Replace EAS00322 CHECKING THE SECONDARY SHEAVE 1 Check 8secondary fixed sheave 8secondary sliding sheave Cracks damage wear J Replace the sec ondary fixed and sliding sheaves as a set 1 2 a 2 Check 8torque cam groove 1 Damage wear J Replace the secondary fixed and sliding sheaves as a s...

Page 191: ...fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 NOTE Use thinner to clean up grease dirt on the pri mary sliding sheave cam side 5 2 Install 8primary sliding sheave 1 8primary sheave weights 2 8collar 3 3 Install 8slider 1 8cam 2 1 2 3 5 4 2 3 1 1 2 ...

Page 192: ...bricant Recommended lubricant BEL RAY assembly lube 2 Install 8secondary sliding sheave 1 NOTE Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 Oil seal guide 90890 01384 YM 33299 3 Install 8guide pin 1 4 Lubricate 8guide pin groove 2 8o ring New 3 with the recommended lubricant Recommended lubricant BEL RAY assembly lube BELT DRIVE 3 1 2 2 3 1 ...

Page 193: ...6 BELT DRIVE EAS00325 INSTALLING THE BELT DRIVE 1 Install 8V belt 1 8clutch assembly 2 cC Do not allow grease to contact the V belt secondary sheave assembly NOTE Install the V belt onto the primary sheave side 2 Install 8clutch carrier nut 1 55 Nm 5 5 m kg 39 8 ft lb NOTE While holding the clutch carrier with the rotor holding tool 2 tighten the clutch carrier nut with the locknut wrench 3 Rotor ...

Page 194: ...8primary fixed sheave 1 8primary sheave nut 2 30 Nm 3 0 m kg 21 7 ft lb NOTE While holding the primary fixed sheave with the rotor holding tool 3 tighten the primary fixed sheave nut 5 Position 8V belt 1 NOTE Position the V belt in the primary sheave 2 when the pulley is at its widest position and in the secondary sheave 3 when the pulley is at its narrowest position and make sure the V belt is ti...

Page 195: ...r Seat Trunk Mat Rear carrier Front cover Side cover left and right Rear cover Battery cover Battery holder Battery Footrest board side cover mole left and right Footrest board AC magneto lead Fan O ring Nut Plate washer AC magneto rotor Woodruff key STARTER CLUTCH AND AC MAGNETO EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY 43Nm 4 3 m kg 31 1 ft lb 3 4 6 8 7 1 5 7Nm 0 7 m kg 5 1 ft ...

Page 196: ... reverse the removal pro cedure STARTER CLUTCH AND AC MAGNETO 43Nm 4 3 m kg 31 1 ft lb 3 4 6 8 7 1 5 7Nm 0 7 m kg 5 1 ft lb 7Nm 0 7 m kg 5 1 ft lb 9Nm 0 9 m kg 6 5 ft lb 4Nm 0 4 m kg 2 9 ft lb L T 2 6 7 8 Lock plate Pick up coil Stator coil assembly 1 1 1 ...

Page 197: ...r Starter wheel gear Roller Collar Starter clutch Idle gear Shaft Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to REMOVING AND INSTALL ING THE AC MAGNETO cC The starter clutch nut is left hand thread Refer to REMOVING AND INSTALL ING THE STARTER CLUTCH For installation reverse the removal pro cedure STARTER CLUTCH AND AC MAGNETO 90Nm 9 0 m kg 65 1 ...

Page 198: ...older to touch the projection on the AC magneto rotor Sheave holder 90890 01701 YS 01880 A 2 Remove 8AC magneto rotor 1 with the flywheel puller 2 8woodruff key cC To protect the end of the crankshaft place an appropriate sized socket between the flywheel puller set s center bolt and the crankshaft NOTE Make sure the flywheel puller is centered over the AC magneto rotor 2 1 1 2 3 STARTER CLUTCH AN...

Page 199: ...lt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them 2 Remove 8starter clutch nut1 8washer 8starter wheel gear 8roller 8collar 8starter clutch 8idle gear NOTE The starter clutch nut is left hand thread 1 STARTER CLUTCH AND AC MAGNETO 1 ...

Page 200: ...the starter clutch gear 4 Check 8starter clutch operation a Install the starter wheel gear 1onto the starter clutch 2 and hold the starter clutch b When turning the starter wheel gear clock wise A the starter clutch and the starter wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear coun terclockwise B it should turn freely oth...

Page 201: ...her 8AC magneto rotor nut NOTE 8 Clean the tapered portion of the crankshaft and the AC magneto rotor hub 8 When installing the AC magneto rotor make sure the woodruff key is properly seated in the keyway of the crankshaft EAS00355 INSTALLING THE STARTER CLUTCH 1 Install 8idle gear 8starter clutch 8collar 8roller 8starter wheel gear 8washer 8starter clutch nut1 90 Nm 9 0 m kg 65 1 ft lb NOTE The s...

Page 202: ... 1 ft lb NOTE 8 While holding the AC magneto rotor 3with the sheave holder 2 tighten the AC mag neto rotor nut 8 Do not allow the sheave holder to touch the projection on the AC magneto rotor Sheave holder 90890 01701 YS 01880 A T R STARTER CLUTCH AND AC MAGNETO ...

Page 203: ...Circlip Plate washer Oil pump driven gear Dowel pin Oil pump housing Oil pump shaft Inner rotor Outer rotor Oil pump housing cover Gasket Remove the parts in the order listed Refer to RADIATOR in chapter 6 Refer to STARTER CLUTCH AND AC MAGNETO For assembly reverse the disassembly procedure OIL PUMP 4 1Nm 0 1 m kg 0 7 ft lb 9 8 7 6 5 4 3 2 2 10 1 4 4Nm 0 4 m kg 2 9 ft lb ...

Page 204: ...uter rotor clearance C Out of specification J Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clear ance 0 15 mm 0 006 in or less Limit 0 23 mm 0 009 in Outer rotor to oil pump housing clearance 0 13 0 18 mm 0 005 0 007 in Limit 0 25mm 0 010 in Oil pump housing to inner rotor and outer rotor clearance 0 07 0 12 mm 0 003 0 005 in Limit 0 19 mm 0 00...

Page 205: ... pump housing cover6 8oil pump housing screw 1 Nm 0 1 m kg 0 7 ft lb NOTE When installing the inner rotor align the pin 3 in the oil pump shaft with the groove a in the inner rotor 4 3 Check 8oil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install 8oil pump drive gear 1 8gasket New 8oil pump assembly2 8oil pump bolt 4 Nm 0 4 m kg 2 9 ft lb cC After tightening t...

Page 206: ...Transmission cover gasket Dowel pin Main axle Drive axle Primary drive gear shaft Remove the parts in the order listed Drain Refer to CHANGING THE TRANSMIS SION OIL in chapter 3 Refer to MANIFOLD AIR FILTER AND MUFFLER ASSEMBLY Refer to REAR WHEEL AND BRAKE in chapter 4 Refer to BELT DRIVE For installation reverse the removal pro cedure TRANSMISSION EAS00419 TRANSMISSION 2 13Nm 1 3 m kg 9 34 ft lb...

Page 207: ...imary drive gear shaft runout limit 0 04 mm 0 0002 in 3 Check 8transmission gears Blue discoloration pitting wear J Replace the defective gear s 8transmission gear dogs Cracks damage rounded edges J Re place the defective gear s 4 Check 8transmission gear engagement each pinion gear to its respective wheel gear Incorrect J Reassemble the transmission axle assemblies 5 Check 8transmission gear move...

Page 208: ...Refer to OIL PUMP Refer to TRANSMISSION Refer to REAR WHEEL AND BRAKE in chapter 4 Removing the crankshaft assembly Engine Cylinder head Cylinder piston V belt clutch primary and secondary sheave Radiator Water pump Starter clutch AC magneto Oil pump Transmission Rear wheel Tension spring Circlip Plate washer Pin Centerstand EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY CRANKSHAFT 32Nm 3 2 m kg 23 1 ft ...

Page 209: ...in Guide Crankshaft Timing chain Crankcase left Oil seal Bolt O ring Timing chain guide 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Refer to DISASSEMBLING THE CRANKCASE Refer to INSTALLING THE CRANK SHAFT For installation reverse the removal pro cedure CRANKSHAFT 32Nm 3 2 m kg 23 1 ft lb 18 18 2 5 1 3 4 2 15 19 16 14 17 13 11 12 7 8 9 6 12 10Nm 1 0 m kg 7 2 ft lb 10 4 LS LS ...

Page 210: ...ages and in a crisscross pattern After all of the bolts are fully loosened remove them 3 Remove 8right crankcase1 8spacer cC Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly 1 CRANKSHAFT ...

Page 211: ...NG 5 62 EAS00207 CHECKINGTHE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check 8timing chain Damage stiffness J Replace the timing chain 2 Check 8timing chain guide intake side Damage wear J Replace CRANKSHAFT ...

Page 212: ...rance Out of specification J Replace the big end bearing crankshaft pin or connecting rod Big end side clearance 0 15 0 45 mm 0 006 0 018 in 3 Measure 8crankshaft width Out of specification J Replace the crank shaft Crankshaft width 42 45 42 50 mm 1 671 1 673 in 4 Check 8crankshaft sprocket 1 Damage wear J Replace the crankshaft 8bearing 2 Cracks damage wear J Replace the crankshaft 8oil pump driv...

Page 213: ...s and crankcase mating surfaces 3 Check 8crankcase Cracks damage J Replace 8oil delivery passages Obstruction J Blow out with compressed air EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1 Check 8bearings Clean and lubricate the bearings then ro tate the inner race with your finger Rough movement J Replace 2 Check 8oil seals Damage wear J Replace EAS00402 CHECKING THE CIRCLIPS AND WASHERS 1 Check 8...

Page 214: ...n parallel into the crank case then use hands to place the crankshaft assembly into the crankcase Manually rotate the crankshaft to check whether it is tightly en gaged with the timing chain if not install again EAS00418 ASSEMBLING THE CRANKCASE 1 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 2 Apply 8sealant onto the crankcase mating surfaces Yamaha bond No 1215 9...

Page 215: ...R 6 2 INSTALLING THE RADIATOR 6 3 THERMOSTAT ASSEMBLY 6 4 CHECKING THE THERMOSTAT 6 6 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE WATER PUMP 6 12 ...

Page 216: ...d right Mat Footrest board Coolant Radiator cover Radiator cap Conduit hose Radiator inlet hose Radiator outlet hose Radiator Fan case Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 For installation reverse the removal pro cedure EAS00454 COOLING SYSTEM RADIATOR RADIATOR 10Nm 1 0 m kg 7 2 ft lb 2 4 5 1 7 3 6 ...

Page 217: ...ator outlet hose2 Cracks damage J Replace 3 Measure 8radiator cap opening pressure Below the specified pressure J Replace the radiator cap Radiator cap opening pressure 93 3 122 7 kPa 0 95 1 25 kg cm2 13 53 17 79 psi a Install the radiator cap tester 1 and radia tor cap tester adapter 2 to the radiator cap 3 Radiator cap tester 90890 01325 YU 24460 01 Radiator cap tester adapter 90890 01352 YU 339...

Page 218: ...nt Refer to CHANGING THE COOLANT in chapter 3 2 Check 8cooling system Leaks J Repair or replace any faulty part 3 Measure 8radiator cap opening pressure Below the specified pressure J Replace the radiator cap Refer to CHECKING THE RADIATOR RADIATOR 4 Check 8radiator fan Damage J Replace Malfunction J Check and repair ...

Page 219: ...lant Radiator inlet hose Thermostat assembly inlet breather hose to carburetor Thermostat assembly outlet breather hose to water pump Thermo switch lead Thermo switch O ring Thermostat housing Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to RADIATOR Disconnect Disconnect EAS00460 THERMOSTAT ASSEMBLY A A 10Nm 1 0 ...

Page 220: ...6 5 COOL Remarks Order Job Part Q ty For installation reverse the removal pro cedure A A 10Nm 1 0 m kg 7 2 ft lb 6 3 2 5 4 1 10Nm 1 0 m kg 7 2 ft lb 4 THERMOSTAT ASSEMBLY 6 Thermostat assembly 1 ...

Page 221: ...meter in the water d While stirring the water observe the ther mostat and thermometer s indicated tem perature 1 Thermostat 2 Container 3 Thermometer 4 Water A Fully closed B Fully open NOTE If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause seri ous overheating or overcooling 2 Check 8thermostat housing Cracks damage J Replace 1 1 3 4 2 THERMOSTAT ASSEMBLY ...

Page 222: ... outlet breather hose 2 Fill 8cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 3 Check 8cooling system Leaks J Repair or replace any faulty part 4 Measure 8radiator cap opening pressure Below the specified pressure J Replace the radiator cap Refer to CHECKING THE RADIATOR 1 THERMOSTAT ASSEMBLY ...

Page 223: ...ght Mat Footrest board Coolant Thermostat assembly outlet breather hose Radiator outlet hose Breather hose Outlet hose to cylinder Water pump housing cover Gasket Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to THERMOSTAT ASSEMBLY Refer to RADIATOR Disconnect WATER PUMP 10Nm 1 0 m kg 7 2 ft lb 1 7 5 4 9 8 11 10 6...

Page 224: ... 10 11 Water pump housing Dowel pin Plate Impeller shaft Oil seal Bearing Gasket 1 2 1 1 1 1 1 For installation reverse the removal pro cedure WATER PUMP 10Nm 1 0 m kg 7 2 ft lb 1 7 5 4 9 8 11 10 6 3 10Nm 1 0 m kg 7 2 ft lb 7Nm 0 7 m kg 5 1 ft lb 2 ...

Page 225: ...wear J Replace 2 Remove 8plate 2 8impeller shaft 3 8gasket 8oil seal with a thin flat head screwdriver 8bearing NOTE Remove the oil seal from the inside of the water pump housing Remove the bearing from the inside of the water pump housing 2 Check 8water pump seal 1 Cracks damage wear J Replace 3 Check 8bearing Rough movement J Replace 4 Check 8radiator outlet hose Cracks damage wear J Replace 1 3...

Page 226: ...cket that matches its outside diameter cC Never lubricate the water pump seal surface with oil or grease 2 Measure 8impeller shaft tilt Out of specification JReplace the impeller shaft Impeller shaft tilt limit 0 15 mm 0 006 in 1 Straightedge 2 Impeller 3 Install 8impeller shaft1 8plate2 cC After installation check that the impeller shaft rotates smoothly 4 Install 8gasketNew 8 water pump housing ...

Page 227: ...ection b on the camshaft sprocket bolt 2 Fill 8cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 3 Check 8cooling system Leaks J Repair or replace the faulty part 4 Measure 8radiator cap opening pressure Below the specified pressure J Replace the radiator cap Refer to CHECKING THE RADIATOR T R 1 a b WATER PUMP ...

Page 228: ...4 ASSEMBLING THE CARBURETOR 7 6 INSTALLING THE CARBURETOR 7 7 MEASURING AND ADJUSTING THE FUEL LEVEL 7 8 CHECKING THE AUTOCHOKE UNIT 7 9 CHECKING THE FUEL COCK 7 10 CHECKING THE THROTTLE POSITION SENSOR 7 11 AIR INDUCTION SYSTEM 7 12 CHECKING THE AIR INDUCTION SYSTEM 7 13 ...

Page 229: ...hose Compensator hose Thermostat assembly inlet breather hose Throttle cable kit Clamp air filter assembly Manifold clamp screw Carburetor assembly CARBURETOR Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 Disconnect Disconnect Disconnect Disconnect Disconnect Lossen For installation reverse the removal pro cedure EAS00480 CARBURETOR CARBURETOR A A B D C F B E D F C E ...

Page 230: ... Float pin Float Needle valve Main jet 1 2 3 4 5 6 7 8 9 0 q w e r t y 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed cC Before leaving the factory throttle position sensor should be measured and adjusted with a precision instrument Any adjustment is strictly prohibited When changing use carburetor for final assembly exchange Supplier should not make any changes after dismo...

Page 231: ...arks Order Job Part Q ty u i o p a Main nozzle Nedle jet Slow air jet Slow jet Throttle position sensor 1 1 1 1 1 For assembly reverse the disassembly procedure CARBURETOR 8 7 9 1 2 3 4 t e u r y o 0 q w 6 5 p i a ...

Page 232: ... passages Obstruction J Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check 8float chamber body Dirt J Clean 5 Check 8float Damage J Replace 4 Check 8float chamber rubber gasket Cracks damage wear J Replace ...

Page 233: ... and move it up and down Tightness J Replace the piston valve 11 Check 8vacuum hoses 8fuel hoses Cracks damage wear J Replace Obstruction J Clean Blow out the hoses with compressed air 1 2 1 2 8 Check 8vacuum chamber cover 1 8piston valve spring 2 Cracks damage J Replace 9 Check 8jet needle 1 8main jet 2 8main nozzle 3 8slow air jet 4 8slow jet 5 8needle jet 6 Bends damage wear J Replace Obstructi...

Page 234: ...8slow air jet 4 2 Install 8float 1 8needle valve 2 8float pin 3 8 screw 4 3 Install 8float chamber rubber gasketNew 8float chamber CARBURETOR 5 Install 8coasting enricher diaphragm1 8compression spring2 8coasting enricher cover3 6 Install 8jet needle kit 8piston valve 4 Install 8accelerator pump diaphragm 1 8accelerator pump spring 2 8boot3 8accelerator pump diaphragm gasket4 8float chamber body 2...

Page 235: ...GINE IDLING SPEED in chapter 3 2 Adjust 8throttle cable free play Throttle cable free play at the flange of the throttle grip 1 5 3 5 mm 0 059 0 138 in Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 7 Install 8piston valve spring 8vacuum chamber cover 8 Install 8bracket 8auto choke unit 8throttle position sensor CARBURETOR ...

Page 236: ...e 1 onto the fuel drain pipe 2 Fuel level gauge 90890 01312 YM 01312 A d Loosen the fuel drain screw e Hold the fuel level gauge vertically next to the float chamber 3 f Measure the fuel level a 2 Adjust 8fuel level a Remove the carburetor b Check the needle valve seat and needle valve c If either is worn replace them as a set d If both are fine adjust the float level by slightly bending the float...

Page 237: ... air should come out of the other side of the starter air pas sage 3 Check 8autochoke unit a Connect the autochoke unit leads to a 12 0 V battery for five minutes Positive battery lead 1 J green black Negative battery lead 2 J yellow b Connect a 3 3 mm hose 3 to the starter air passage 4 and blow into the hose Starter plunger opens Starter plunger closes Perform step 3 Replace the autochoke unit S...

Page 238: ...arburetor b Place a container under the end of the fuel hose c Start the engine and check if fuel flows from the fuel hose 2 d Stop the engine and check if the fuel stops flowing from the fuel hose 2 3 Install 8front cover 8battery cover 8seat trunk Refer to COVER AND PANEL in chap ter 3 Fuel flows Fuel does not flow Fuel cock is OK Replace the fuel cock Fuel cock is OK Replace the fuel cock Fuel ...

Page 239: ...er DC 20V to the throttle position sensor Tester positive lead J yellow blue 1 Tester negative lead Jblack blue2 c Check the throttle position sensor input volt age DC5V voltage positive lead Jblue 3 DC5V voltage negative lead Jblack blue2 Out of specification J Replace the car buretor cC Please do not make any adjustment on throttle position sensor CARBURETOR 3 1 2 B L Y L L L B L Y L 2 8 3 4V 0 ...

Page 240: ... Trunk Hose from AI air filter Vacuum hose from mainfold Hose to cylinder head Air cut off valve assembly 1 2 3 4 1 1 1 1 Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 For installation reverse the removal pro cedure AIR INDUCTION SYSTEM 10Nm 1 0 m kg 7 2 ft lb 2 1 3 4 ...

Page 241: ...e J Replace 8pipe Cracks damage J Replace 2 Check 8air cut off valve Cracks damage J Replace NOTE When the negative pressure is applied to the part 1 check that the continuity in the direction of arrow mark is completely lost If the negative pressure is not loaded the continuity can be obtained AIR INDUCTION SYSTEM 1 ...

Page 242: ...M 8 14 CIRCUIT DIAGRAM 8 14 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 15 TROUBLESHOOTING 8 16 STARTER MOTOR 8 19 CHECKING THE STARTER MOTOR 8 20 ASSEMBLING THE STARTER MOTOR 8 22 CHARGING SYSTEM 8 23 CIRCUIT DIAGRAM 8 23 TROUBLESHOOTING 8 24 LIGHTING SYSTEM 8 26 CIRCUIT DIAGRAM 8 26 TROUBLESHOOTING 8 27 CHECKING THE LIGHTING SYSTEM 8 29 SIGNALING SYSTEM 8 32 CIRCUIT DIAGRAM 8 32 TROUBLESHOOTING ...

Page 243: ... switch 2 Front brake light switch 3 Main switch 4 Starter relay 5 Thermo unit 6 Fuel sender 7 C D I unit 8 Ignition coil 9 Spark plug cap 0 Battery q Main fuse w Turn signal relay e Horn r Rectifier Regulator t Thermo switch y Headlight relay u Wire harness 6 7 1 5 9 4 8 q 0 y w e r 3 2 t u ...

Page 244: ...D BLACK BLACK BLACK BLACK RED RED BLACK Y B G Ch Dg Ch Dg Y B G RED RED HORN DIMMER FLASHER ENG STOP SW STARTER SW MAIN SW 6 7 e u k p y o q w c j 0 b t 2 8 9 v 1 5 4 3 Connecting with GND Wire MARK Explanation GND r s d f g h a i z x B Or Or B WL YR WL WR YR W YR R BL YL L W YR R R Br R R LW R GY GY LW LW R R B B LY B B B R YR Br G G B GW L Y Ch Dg L P P Br Ch Dg G Y Y G BL GR Br B BrW B GY GY Br...

Page 245: ...7 Starter motor 8 C D I unit 9 Ignition coil 0 Auto choke unit q Front brake light switch w Rear brake light switch e Start switch r Engine stop switch t Headlight relay y Horn u Horn switch i Turn signal switch o Turn signal relay p Tail brake light a Dimmer switch s Water temperature indicator light d Speedometer light f High beam indicator light g Turn signal indicator light left h Turn signal ...

Page 246: ...r continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an il lustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE c c indicates a continuity of electricity be twe...

Page 247: ...place Improperly connected J Properly connect Incorrect continuity reading J Replace the switch CHECKING THE SWITCHES Rear barake light switch Dimmer switch Horn switch Turn signal light switch Main switch Front barake light switch Start switch Engine stop switch B B HI LO G L Y OFF PUSH P B Y G L P B Ch Br W Dg L N R Ch Br W Dg OFF CHECK ON Br R B B OFF START OFF RUN L W L W L Y B L Y B Main fuse...

Page 248: ...e bulbs used on this scooter are shown in the illustration on the left 8Bulbs A and B are used for the head lights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise 8Bulbs C is used for turn signal and tail brake lights and can be removed from the socket by p...

Page 249: ...fe of the bulb and the luminous flux will be adversely affected If the head light bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check 8bulb for continuity with the pocket tester No continuity J Replace Pocket tester 90890 03132 YU 03112 C NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester...

Page 250: ...0890 03132 YU 03112 C NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the re spective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity re place the bulb socket CHECKING THE BULBS AND B...

Page 251: ...G STOP SW STARTER SW MAIN SW 6 7 e u k p y o q w c j 0 b t 2 8 9 v 1 5 4 3 Connecting with GND Wire MARK Explanation GND r s d f g h a i z x B Or Or B WL YR WL WR YR W YR R BL YL L W YR R R Br R R LW R GY GY LW LW R R B B LY B B B R YR Br G G B GW L Y Ch Dg L P P Br Ch Dg G Y Y G BL GR Br B BrW B GY GY Br Br GY L BL YL B LY GR Br GW L B 7 5A FUEL TEMP ILLUMI HI BEAM TURN L TURN R ILLUMI 12V21W 5W ...

Page 252: ...NGK Spark plug gap 0 7 0 8 mm 0 028 0 032 in 8Is the spark plug in good condition is it of the correct type and is its gap within specification YES NO Re gap or replace the spark plug IGNITION SYSTEM EAS00736 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 main fuse 2 battery 3 spark plug 4 ignition spark gap 5 spark plug cap resistance 6 ignition coil r...

Page 253: ...cation NO YES The ignition system is OK EAS00744 5 Spark plug cap resistance 8Remove the spark plug cap from the spark plug lead 8Connect the pocket tester Ω 1k range to the spark plug cap as shown 8Measure the spark plug cap resistance Spark plug cap resistance 4 6 kΩ Ω Ω Ω Ω at 20 C 8Is the spark plug cap OK YES NO Replace the spark plug cap EAS00746 6 Ignition coil resistance 8Disconnect the ig...

Page 254: ...n coil IGNITION SYSTEM EAS00748 7 Pickup coil resistance 8Disconnect the pickup coil coupler from the wire harness 8Connect the pocket tester Ω 100 to the pickup coil terminal as shown Positive tester probe J J J J J white red 1 1 1 1 1 Negative tester probe J J J J J white blue2 2 2 2 2 8Measure the pickup coil resistance Pickup coil resistance 248 372Ω Ω Ω Ω Ω at 20 C between white red and white...

Page 255: ...SWITCHES 8Is the engine stop switch OK YES NO Replace the right handlebar switch EAS00754 10 Wiring 8Check the entire ignition system s wir ing Refer to CIRCUIT DIAGRAM 8Is the ignition system s wiring properly connected and without defects YES NO Replace the C D I unit Properly connect or repair the ignition system s wiring ...

Page 256: ... k p y o q w c j 0 b t 2 8 9 v 1 5 4 3 Connecting with GND Wire MARK Explanation GND r s d f g h a i z x B Or Or B WL YR WL WR YR W YR R BL YL L W YR R R Br R R LW R GY GY LW LW R R B B LY B B B R YR Br G G B GW L Y Ch Dg L P P Br Ch Dg G Y Y G BL GR Br B BrW B GY GY Br Br GY L BL YL B LY GR Br GW L B 7 5A FUEL TEMP ILLUMI HI BEAM TURN L TURN R ILLUMI 12V21W 5W YR L 12V35W 35W Ch 12V10W 12V10W GY ...

Page 257: ...rter motor can only operate if at least one of the following conditions is met 8The brake lever front or rear is pulled to the handlebar the brake light switch is closed 1 Battery 2 Main fuse 3 Main switch 4 Front brake light switch 5 Rear brake light switch 6 Engine stop switch 7 Start switch 8 Starter relay 9 Starter motor 9 8 2 3 6 4 5 1 7 ...

Page 258: ...tery holder 5 Footrest board side cover mole right left 6 Footrest board 7 Head light cover Leg shield 1 8 Air filter assembly 8Troubleshoot with the following special tool s Pocket tester 90890 03132 YU 03112 C EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO...

Page 259: ...otor EAS00761 4 Starter relay 8Disconnect the starter relay coupler from the coupler 8Connect the pocket tester Ω 1 and battery 12 V to the starter relay cou pler as shown Positive battery terminal J J J J J green yellow 1 1 1 1 1 Negative battery terminal J J J J J blue white 2 2 2 2 2 Positive tester probe J J J J J red 3 3 3 3 3 Negative tester probe J J J J Jred 4 4 4 4 4 8Does the starter rel...

Page 260: ... CHECKINGTHE SWITCHES 8Is the engine stop switch OK YES NO Replace the right handlebar switch EAS00764 8 Start switch 8Check the start switch for continuity Refer to CHECKING THE SWITCHES 8Is the start switch OK YES NO EAS00766 9 Wiring 8Check the entire starting system s wir ing Refer to CIRCUIT DIAGRAM 8Is the starting system s wiring properly connected and without defects YES NO Replace the rig...

Page 261: ...g Armature coil Brush Plate washer 1 2 1 2 3 4 5 6 7 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 Refer to MANIFOLD AIR FILTER AND MUFFLER ASSEMBLY in chapter 5 Disconnect For installation reverse the removal pro cedure Disassemble the parts in the order listed For assembly reverse the disassembly procedure ELECTRIC STARTING SYSTEM EAS00767 STARTER ...

Page 262: ...Mica undercut 1 35 mm 0 053 in NOTE The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure 8armature assembly resistances commu tator and insulation Out of specification J Replace the starter motor a Measure the armature assembly resis tances with the pocket tester Pocket tester 90890 03132 YU 03112 C Armature coil Commutator resistance 1 1 1 1 1 0 0378 ...

Page 263: ... length wear limit 3 5 mm 0 14 in 6 Measure 8brush spring force Out of specification J Replace the brush springs as a set Brush spring force 3 92 5 88 N 7 Check 8gear teeth Damage wear J Replace the gear 8 Check 8bearing1 8oil seal2 8bush3 Damage wear J Replace ELECTRIC STARTING SYSTEM a 1 3 2 ...

Page 264: ...TOR 1 Install 8brush seat 1 2 Install 8washer1 8armature coil 2 8o ing New 3 8stator assembly4 3 Install 8bolts 1 5 Nm 0 5 m kg 3 6 ft lb NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers 1 1 3 4 2 1 a b ...

Page 265: ... HORN DIMMER FLASHER ENG STOP SW STARTER SW MAIN SW 6 7 e u k p y o q w c j 0 b t 2 8 9 v 1 5 4 3 Connecting with GND Wire MARK Explanation GND r s d f g h a i z x B Or Or B WL YR WL WR YR W YR R BL YL L W YR R R Br R R LW R GY GY LW LW R R B B LY B B B R YR Br G G B GW L Y Ch Dg L P P Br Ch Dg G Y Y G BL GR Br B BrW B GY GY Br Br GY L BL YL B LY GR Br GW L B 7 5A FUEL TEMP ILLUMI HI BEAM TURN L T...

Page 266: ... in chapter 3 8Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO 8Clean the battery termi nals 8Recharge or replace the battery EAS00775 3 Charging voltage 8Connect the engine tachometer to the spark plug lead of cylinder ...

Page 267: ... 1 1 1 1 1 Negative tester probe J J J J J ground 2 2 2 2 2 8Measure the stator coil resistances Stator coil resistance 0 288 0 432 Ω Ω Ω Ω Ω at 20 C between white and ground 8Is the stator coil OK YES NO Replace the stator coil as sembly EAS00754 5 Wiring 8Check the entire charging system s wir ing Refer to CIRCUIT DIAGRAM 8Is the charging system s wiring properly connected and without defects YE...

Page 268: ...MAIN SW 6 7 e u k p y o q w c j 0 b t 2 8 9 v 1 5 4 3 Connecting with GND Wire MARK Explanation GND r s d f g h a i z x B Or Or B WL YR WL WR YR W YR R BL YL L W YR R R Br R R LW R GY GY LW LW R R B B LY B B B R YR Br G G B GW L Y Ch Dg L P P Br Ch Dg G Y Y G BL GR Br B BrW B GY GY Br Br GY L BL YL B LY GR Br GW L B 7 5A FUEL TEMP ILLUMI HI BEAM TURN L TURN R ILLUMI 12V21W 5W YR L 12V35W 35W Ch 12...

Page 269: ...n chapter 3 8Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO 8Clean the battery termi nals 8Recharge or replace the battery LIGHTING SYSTEM EAS00748 3 Lighting coil resistance 8Disconnect the lighting coil coupler from t...

Page 270: ... headlight relay cou pler as shown Positive battery terminal J J J J J green yellow 1 1 1 1 1 Negative battery terminal J J J J J blue white 2 2 2 2 2 Positive tester probe J J J J J yellow red 3 3 3 3 3 Negative tester probe J J J J J blue 4 4 4 4 4 8Does the starting headlight relay have continuity between blue and yellow red YES NO Replace the headlight re lay EAS00787 7 Wiring 8Check the entir...

Page 271: ...e 8Connect the pocket tester DC 20 V to the headlight and high beam indicator light couplers as shown When the dimmer switch is set to When the dimmer switch is set to Headlight coupler wire harness side Headlight Positive tester probe J J J J J green 1 1 1 1 1 Negative tester probe J J J J J black 2 2 2 2 2 Positive tester probe J J J J J yellow 3 3 3 3 3 Negative tester probe J J J J J black 4 4...

Page 272: ...Set the main switch to ON 8Measure the voltage DC 12 V of brown 1 on the meter light coupler wire har ness side 8Is the voltage within specification YES NO EAS00789 2 The meter light fails to come on 1 Meter light bulb and socket 8Check the meter light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS 8Are the meter light bulb and socket OK YES NO Replace the meter light ...

Page 273: ...ing system s wir ing Refer to CIRCUIT DIAGRAM 8Is the lighting system s wiring properly connected and without defects YES NO Properly connect or repair the lighting system s wiring Check the condi tion of each of the lighting system s circuits Refer to CIRCUIT DIAGRAM ...

Page 274: ... x B Or Or B WL YR WL WR YR W YR R BL YL L W YR R R Br R R LW R GY GY LW LW R R B B LY B B B R YR Br G G B GW L Y Ch Dg L P P Br Ch Dg G Y Y G BL GR Br B BrW B GY GY Br Br GY L BL YL B LY GR Br GW L B 7 5A FUEL TEMP ILLUMI HI BEAM TURN L TURN R ILLUMI 12V21W 5W YR L 12V35W 35W Ch 12V10W 12V10W GY B Ch L Dg L Dg GY B Ch l 12V10W 12V10W B B Dg Dg Ch B B B B SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM...

Page 275: ...ING THE FUSE in chapter 3 8Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO 8Clean the battery terminals 8Recharge or re place the battery EAS00749 3 Main switch 8Check the main switch for continuity Refer to CHECKING THE...

Page 276: ...onnect the pocket tester DC 20 V to the horn connector at the horn terminal as shown Positive tester probe J J J J Jbrown 1 1 1 1 1 Negative tester probe J J J J J ground 8Set the main switch to ON 8Push the horn switch 8Measure the voltage DC 12 V of brown at the horn terminal 8Is the voltage within specification YES NO The wiring circuit from the main switch to the horn con nector is faulty and ...

Page 277: ...2 2 2 2 8Set the main switch to ON 8Pull in the brake levers 8Measure the voltage DC 12V of green yellow 1 on the tail brake light coupler wire harness side 8Is the voltage within specification YES NO 2 Brake light switches 8Check the brake light switches for conti nuity Refer to CHECKINGTHE SWITCHES 8Is the brake light switch OK YES NO Replace the brake light switch The wiring circuit from the ma...

Page 278: ... bulb socket or both 2 Turn signal switch 8Check the turn signal switch for conti nuity Refer to CHECKING THE SWITCHES 8Is the turn signal switch OK YES NO 3 Voltage 8Connect the pocket tester DC 20 V to the turn signal relay coupler wire har ness side as shown Positive tester probe J J J J J brown 1 1 1 1 1 Negative tester probe J J J J J ground 8Set the main switch to ON 8Measure the voltage DC ...

Page 279: ...rness side as shown A Front turn signal light B Rear turn signal light C Turn signal indicator light Left turn signal light Positive tester probe J J J J J chocolate 1 1 1 1 1 Negative tester probe J J J J J ground Right turn signal light Positive tester probe J J J J J dark green 2 2 2 2 2 Negative tester probe J J J J J ground 8Set the main switch to ON 8Set the turn signal switch to 4 or 6 8Mea...

Page 280: ...ender resistance down po sition E Ω Ω Ω Ω Ω 10 93 5 96 5 Ω Ω Ω Ω Ω at 20 C 8Is the fuel sender OK YES NO Replace the fuel sender 2 Voltage 8Connect the pocket tester DC 20 V to the meter light coupler wire harness side as shown Positive tester probe J J J J J brown 1 1 1 1 1 Negative tester probe J J J J J black 2 2 2 2 2 8Set the main switch to ON 8Measure the voltage DC 12 V of brown 1 on the me...

Page 281: ...r needle moves to F or E NOTE Before reading the fuel level meter leave the float in one position either up or down for at least three minutes 8Does the fuel level meter needle move appropriately YES NO Replace the speedo meter SIGNALING SYSTEM This circuit is OK 4 Wiring 8Check the entire signaling system s wiring 1 2 ...

Page 282: ...P SW STARTER SW MAIN SW 6 7 e u k p y o q w c j 0 b t 2 8 9 v 1 5 4 3 Connecting with GND Wire MARK Explanation GND r s d f g h a i z x B Or Or B WL YR WL WR YR W YR R BL YL L W YR R R Br R R LW R GY GY LW LW R R B B LY B B B R YR Br G G B GW L Y Ch Dg L P P Br Ch Dg G Y Y G BL GR Br B BrW B GY GY Br Br GY L BL YL B LY GR Br GW L B 7 5A FUEL TEMP ILLUMI HI BEAM TURN L TURN R ILLUMI 12V21W 5W YR L ...

Page 283: ...with the following special tool s Pocket tester 90890 03132 YU 03112 C EAS00738 1 Main fuse 8Check the fuse for continuity Refer to CHECKING THE FUSE in chapter 3 8Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO 8Clean t...

Page 284: ... temperatures indicated below Steps 1 2 Heating phase Steps 3 4 Cooling phase w 8 8 8 8 8 Handle the thermo switch with special care 8 8 8 8 8 Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it Thermo switch 23 Nm 2 3 m kg 16 6 ft lb Three bond sealock 10 Continuity NO YES YES NO Test step 1 2 3 4 Coolant temperature Thermo switch 0 56 C More than65 2 C 65 ...

Page 285: ... Ω Ω Ω at 80 C 1 645 1 855k Ω Ω Ω Ω Ω at 100 C 8Is the thermo unit OK YES NO Replace the thermo unit 2 Voltage 8Connect the pocket tester DC 20 V to the meter light coupler wire harness side as shown Positive tester probe J J J J J green red 1 1 1 1 1 Negative tester probe J J J J J ground 8Set the main switch to ON 8Measure the voltage DC 12V of green red 1 on the meter light coupler wire harness...

Page 286: ...Water temperature indicator light 8Remove the thermo unit coupler 8Set the main switch to ON 8Connect the green red1 and black blue2 with a jumper lead3 8Is the water temperature indicator light OK YES NO This circuit is OK Replace the water temperature indica tor light Replace the C D I unit Properly connect or repair the cooling system s wiring G R B L 2 1 3 COOLING SYSTEM ...

Page 287: ...RN DIMMER FLASHER ENG STOP SW STARTER SW MAIN SW 6 7 e u k p y o q w c j 0 b t 2 8 9 v 1 5 4 3 Connecting with GND Wire MARK Explanation GND r s d f g h a i z x B Or Or B WL YR WL WR YR W YR R BL YL L W YR R R Br R R LW R GY GY LW LW R R B B LY B B B R YR Br G G B GW L Y Ch Dg L P P Br Ch Dg G Y Y G BL GR Br B BrW B GY GY Br Br GY L BL YL B LY GR Br GW L B 7 5A FUEL TEMP ILLUMI HI BEAM TURN L TURN...

Page 288: ...8 Troubleshoot with the following special tool s Pocket tester 90890 03132 YU 03112 C AUTO CHOKE SYSTEM EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO EAS00738 1 Main fuse 8Check the main fuse for continuity Refer to CHECKING THE FUSE in chapter 3 8Is the fu...

Page 289: ...emperatures indicated below Steps 1 2 Heating phase Steps 3 4 Cooling phase w 8 8 8 8 8 Handle the thermo switch with spe cial care 8 8 8 8 8 Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it Thermo switch 23 Nm 2 3 m kg 16 6 ft lb Three bond sealock 10 A Cooling phase B Heating phase 8Does the thermo switch operate prop erly as described above YES NO Repl...

Page 290: ... J J Jyellow 2 2 2 2 2 8Measure the auto choke unit resistance Auto choke unit resistance 20 Ω Ω Ω Ω Ω at 20 C 8Is the auto choke unit OK YES NO 5 Wiring 8Check the entire auto choke system s wiring Refer to CIRCUIT DIAGRAM 8Is the auto choke system s wiring prop erly connected and without defects YES NO Replace the auto choke unit Properly connect or repair the auto choke system s wiring AUTO CHO...

Page 291: ...TARTING PERFORMANCE 9 3 OVERHEATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 OVERCOOLING 9 4 COOLING SYSTEM 9 4 POOR BRAKING PERFORMANCE 9 5 FAULTY FRONT FORK LEGS 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 5 FAULTY LIGHTING OR SIGNALING SYSTEM 9 6 HEADLIGHT DOES NOT COME ON 9 6 HEADLIGHT BULB BURNT OUT 9 6 TAIL BRAKE LIGHT DOES NOT COME ON 9 6 TAIL BRAKE L...

Page 292: ...se and crankshaft 8Improperly assembled crankcase 8Seized crankshaft FUEL SYSTEM Fuel tank 8Empty fuel tank 8Clogged fuel tank cap breather hole 8Deteriorated or contaminated fuel 8Clogged or damaged fuel hose Fuel cock 8Faulty fuel cock 8Damaged vacuum hose 8Improperly routed hose Carburetor 8Deteriorated or contaminated fuel 8Clogged slow jet 8Clogged pilot air passage 8Sucked in air 8Damaged fl...

Page 293: ... clearance 8Damaged valve train components Air filter 8Clogged air filter element FUEL SYSTEM Carburetor 8Faulty starter plunger 8Loose or clogged slow jet 8Loose or clogged slow air jet 8Damaged or loose carburetor joint 8Improperly synchronized carburetor 8Improperly adjusted engine idling speed throttle stop screw 8Improper throttle cable free play 8Flooded carburetor Autochoke unit 8Faulty sta...

Page 294: ...LUTCH ENGINE OPERATES BUT SCOOTER WILL NOT MOVE V belt 8Bent damaged or worn V belt 8Slipping V belt Primary pulley cam and primary pulley slider 8Damaged or worn primary pulley cam 8Damaged or worn primary pulley slider Clutch spring s 8Damaged clutch spring Transmission gears 8Damaged transmission gear CLUTCH SLIPS Clutch shoe springs 8Damaged loose or worn clutch shoe spring Clutch shoes 8Damag...

Page 295: ... coolant level Radiator 8Damaged or leaking radiator 8Faulty radiator cap 8Bent or damaged radiator fan Water pump 8Damaged or faulty water pump Thermostat 8Thermostat stays closed Oil cooler 8Clogged or damaged oil cooler Hose s and pipe s 8Damaged hose 8Improperly connected hose 8Damaged pipe 8Improperly connected pipe FUEL SYSTEM Carburetor 8Incorrect main jet setting 8Incorrect fuel level 8Dam...

Page 296: ...per rod EAS00862 UNSTABLE HANDLING Handlebar 8Bent or improperly installed handlebar Steering head components 8Improperly installed lower bracket improperly tightened ring nut 8Bent steering stem 8Damaged ball bearing or bearing race Front fork leg s 8Unevenly tensioned fork spring both front fork legs 8Broken fork spring 8Bent or damaged inner tube 8Bent or damaged outer tube Rear shock absorber ...

Page 297: ...ulb TAIL BRAKE LIGHT BULB BURNT OUT 8Wrong tail brake light bulb 8Faulty battery 8Tail brake light bulb life expired TURN SIGNAL DOES NOT COME ON 8Faulty turn signal switch 8Faulty turn signal relay 8Burnt out turn signal bulb 8Incorrect connection 8Damaged or faulty wire harness 8Improperly grounded circuit 8Faulty battery 8Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY 8Faulty turn si...

Page 298: ...YAMAHA MOTOR TAIWAN CO LTD ...

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