Yamaha XC200T Service Manual Download Page 70

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Summary of Contents for XC200T

Page 1: ...1987 MOTORCYCLE SERVICE MANUAL Model XC200T 1YA281972000 1YA281972000 ...

Page 3: ...VUCE MANUAL 1986 by Yamaha Motor Co Ltd 1st Edition June 1986 ARI rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is e pressBy prohibited Printed in Japan ...

Page 4: ...O USE TH IS MAN UAL PARTICULARLY iMPORTANT INFORMATmON This material is distinguished by the following notation NOTE A NOTE provides key information to make procedures easier or clearer ii i_i_i_ii_iii i_i i_ i A CAUTION indicates special procedures that must be foltowed to avoid damage to the scooter A WARNING indicates special procedures that must be followed to avoid injury to a scooter operato...

Page 5: ...lustrated symbols _ to _ are used to identify 6_ _ the specifications appearing in the text _ Filling fluid _ Lubricant _ Tightening Wear limit clearance Engine speed _ _ Illustrated symbols _ to _ in the exploded _ _ _ diagram indicate grade of lubricant and location of lubrication point _ _ _ Apply engine oil _ Apply gear oil _ _ _ Apply molybdenum disulfide oil Apply wheel bearing grease _ Appl...

Page 6: ..._ii_ iii_ i _i_ iiiiii i_i_ i_i_ i_ _ _ __ _ i_i i_i ii_ _i_iii _ _ _i ...

Page 7: ... mNDEX GENERAL NFORMA r oN IJ PERmODmC INSPE ONS AND ADJUSTMENTS UNSP ADJ ENGmNEOVERHAUL _ ENG CARSUREYION CAR8 CHASSMS CHAS_ ELECTRICAL ELEC APPENDmCES APPX ...

Page 8: ...iill iii_i _i _iiii _i __ i_i _iiii_ ...

Page 9: ...NE SERIAL NUMBER 1 1 INPORTANT iNFORMATiON 1 2 I_ ALL REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 2 CIRCLIPS 1 3 SPECIAL TOOLS 1 3 FOR TUNE UP 1 3 FOR ENGINE SERVICE 1 4 FOR CHASSIS SERVICE 1 8 FOR ELECTRICAL COMPONENTS 1 8 ...

Page 10: ... register your scooter with the licensing authority in your state Starting Seriam Number JYA1YA00_ HA000101 ENGINE SERIAL NUMBER The engine sedaf number 1_ is stamped into the elevated part of the left rear section of the trans mission case NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number Starting SeriaJ Number 1YA 00010...

Page 11: ...PLATES AND COT TERPaNS 1 All lock washers plates _ and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been properly tightened 300 000 BEARINGS AND OiL SEALS C3 1 Install the bearing s _ and oil seal s _ with their manufacturer s marks or numbers _ _ _ facing outward In other words the stamped letters must be on th...

Page 12: ...the sec U tional view 30000 _4_ Shaft SPECIAL TOOLS The proper special tools are necessary for com plete and accurate tuneoup and assembly Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques FOR TUNE UP 1 Inductive Tachometer P N YU_08036 This tool is needed for detecting engine rpm 2 Inductive Timing Light P N YUo33277 This tool is ...

Page 13: ...235 This tool is used to hold the flywheel magneto when removing or installing the flywheel magneto securing nut 2 Flywheel Magneto Puller P N YM 01080 This tool is used for removing the flywheel magneto 3 Primary Sheave Holder P N YS 01880 This tool is used when holding the clutch hub 4 Clutch Spring Holder P N YS 28891 This tool is used to dis re assemble the secon dary sheave 1 4 ...

Page 14: ...is tool is used to loosen or tighten the clutch assembly securing nut 7 40 Torx Driver P N YU_29843o7 This tool is used to loosen or tighten the starter wheel securing screw 8 Valve Spring Compressor P N YM 04019 This tool is needed to remove and install the valve assemblies 9 Slide Hammer Set P N YU 01083 These tools are used to remove the rocker arm and rocker arm shaft 1 5 ...

Page 15: ... 91043 This tool is needed to resurface the valve seat 12 Valve Guide Remover 7 0 mm P N YM 01225 This tool is used to remove the valve guides 13 Valve Guide Reamer 7 0 mm P N YM 01227 This tool is used to rebore the new valve guide 14 Valve Guide Installer P N YM 04017 This tool is needed to install the valve guides properly 1 6 ...

Page 16: ... _ Plain Bearing Installer Remover P N YM 33297 LI_II These tools are used for removing and installing the crankshaft plain bearing 17 Plastigage Set Green P N YU 33210 This gauge is needed to measure the clearance for the connecting rod bearing 18 Sealant Quick Gasket P N ACCo11001 05_01 This sealant bond is used for crankcase mating surfaces etc IW ...

Page 17: ...ls are used to loosen and tighten the steering ring nut FOR ELECTRICAL COMPONENTS 1 Electro Tester P N YU 33260 _ This instrument is necessaryfor checking the ig nition system components 2 Pocket Tester P N YU 33263 _ or YU 03112 _ Thisinstrumentis invaluablefor checkingthe elec trical system 1 8 ...

Page 18: ..._ _ _ _i_ ii_i i _ _ llLm q I ...

Page 19: ...OVING THE COVERS AND PANELS 2 12 AIR FILTER ELEMENT CLEANING 2 14 FUEL COCK CLEANING 2 15 FRONT AND REAR BRAKE INSPECTION 2 16 TIRE AND CAST WHEEL INSPECTION 2 17 FRONT WHEEL BEARING CHECK 2 20 STEERING HEAD ADJUSTMENT 2 20 REAR SHOK ABSORBER ADJUSTMENT 2 21 CONTROL AND METER CABLES LUBRICATION 2 22 BRAKE LEVER AND BRAKE PEDAL SHAFT LUBRICATION 2 22 CENTERSTAND AND SIDESTAND LUBRICATION 2 22 FRONT...

Page 20: ..._ Check idle speed starter operation O O O Adjust if necessary Fuel line Check fuel hose and vacuum pipe for L_ O cracks or damage Replace if necessary Engine oil Replace Warm engine before draining O O _ Engine oil filter _ Replace O O Final gear oil Sub Check oil level oil leakage REPLACE O O transmission oil Replace every 24 000 16 000 or 24 months Brake Check operation Adjust if necessary O V ...

Page 21: ...s Correct if necessary 0 0 0 Center and sidestand Check operation Repair if necessary 0 0 0 Sidestand switch Check operation Clean or replace if necessary 0 0 0 Check specific gravity Check breather Battery pipe for proper operation 0 0 Correct if necessary It is recommended that these items be serviced by a Yamaha dealer Medium weight wheel bearing grease E4 Lithium soap base grease 2 2 ...

Page 22: ...se _ _ oVacuum hose _ Cracks Damage Replace INTAKE MANRFOLD iNSPECTiON 1 Inspect olntake manifold _1_ _ _ _Carburetor joint _2 f _Gasket htake manifold _ _ _ 2 Tighten Screw Carburetor clamp _ oBolts Intake manifold _5 _ _ Boit ntakeMan fold _ 1 10 Nm 1 0 m okg 7 2 ftoib EXHAUST SYSTEM _NSPECTmON 1 Inspect _Gasket Exhaust pipe _i_ oMuffler assembly _ Damage _ _ Replace 2 Tighten 6Socket bolt Exhau...

Page 23: ..._0 28 inl NOTE Before adjusting the throttle cable free play the engine idling speed should be adjusted 1 Check oThrottle cable free play _ Out of specification _Adjust _ Throttle Cable Free Play 3 7 rnrn 0 12 0 28 in 2 Adjust oThrottle cable free play Throttle cable adjustment steps eLoosen the adjuster lock nut _ oTurn the adjuster _ clockwise or counter clockwise until proper free play is attai...

Page 24: ... checking Pull up the dipstick and inspect the oil level whether or not it is between maximum 50 40 50 60 F and minimum level _3 __ If the level is lower add the oil up to the 1 m proper level _ _ _ _ Recommended oil _ At 5 C 40 F or Higher 0 5 IO 15 C SAE 20W40 Type SE Motor Oil At 15 C 60 F or Lower _6_ SAE 10W30 Type SE Motor Oil ENGINE OIL REPLACEMENT Engine Oil RepJacement Without OiJ Filter ...

Page 25: ...rial to enter the __ crankcase 6 Install Dipstick 7 Inspect oOil leaks Oil level oOil pressure Refer to OIL PRESSURE INSPECTION section Engine Oil Replacement With Oil Filter 1 Warm up the engine for several minutes then place a receptacle under the engine 2 Remove Side cover Left Refer to REMOVING THE COVERS AND PANELS page 2 13 oDipstick _ oDrain bolt _ Drain the engine oil completely 3 Remove o...

Page 26: ...6 Tighten Drain bolt oBolt Oil filter cover Drain Bolt 43 Nm 4 3 m kg 31 ft lb Bolt Oit Fiffer Cover 10 Nm 1 0 m kg 7 2 ft _b 7 Fill oCrankcase Recommended OiJ 30 40 50 60 F At 5 C 40 F or Higher SAE 20W40 Type SE Motor Oil _ w _ _ At 15 C 60 F or Lower _ _2 _ 2_ _ _ _ SAE 10W30 Type SE Motor Oil With OH Filter Replacement 0 5 IO 15 C 1 1 L 0 97 imp qt 1 16 US qt Do not allow foreign material to e...

Page 27: ... pressure is good No oil comes out Oil pressure is bad If no oil comes out after a lapse of one minute turn off the engine immediately so it will not seize 4 Tighten Air bleed bolt _ Air Bleed Bolt 20 Nm 2 0 m okg 14 ftolb V BELT INSPECTION 1 Remove oCheck plug V belt _ 2 Inspect oV belt _ Crack Wear Chipping _ Replace Oil or grease adhered to the V belt _Check the primary and secondary sheaves Re...

Page 28: ...dd the oil up to theproper level I _ _ _ Recom m ended OiH O 5 JO t5 C _ At 5 C 40 F or Higher ilb SAE 20W40 Type SE Motor OiN At 15 C 60 F or Lower _2_9 SAE 10W30 Type SE Motor Oi_ TotaW Amount 0 2 L 0 18 Wrapqt 0 21 US qt Do not allow foreign materia_ to enter the transmission case TRANSMiSSiON OIL REPLACEMENT 1 Remove Rear wheet assembly Refer to CHAPTER 5 REAR WHEEL_ REMOVAL section 2 Replace ...

Page 29: ...OIL LEVEL IN SPECTION section CONIPRESSION PRESSURE MEASUREMENT NOTE Insufficient compression pressure will result in performance loss 1 Warm up the engine and stop it 2 Remove Front cover Refer to REMOVING THE COVERS AND PANELS section Spark plug 3 Measure eCompression pressure Compression pressure measurement st eps elnstall the Compression Gauge _ YU 33223 oCrank over the engine with the electr...

Page 30: ...re fails below the minimum level 1 Squirt a few drops of oil into the affected cylinder 2 Measure the compression again Compression Pressure with oh introduced into cylinder Reading Diagnosis Higher than without Worn or damaged Oil pistonrings Defective ring s Same as without Oil valves cylinder head gasket or piston is possible Inspect cyRinder Above Maximum head valve surfaces Level or piston cr...

Page 31: ...panel _ Fronttrunk _ Frontcover _ Uppercover _ Side cover _ Footrestboard iil _ii_iiiiiiiii eBefore removing the cover s make sure that aft hooks are free After installing the cover s make sure that all hooks are securely fitted Front Cover _S __ O0eot oso t 2 Remove o oec a scre Front cover _ 2 12 ...

Page 32: ... then unhook the lobs z _3 _ on the side cover from the receptacles _4_in the upper cover _ Footrest Board t Remove Bolt Rear brake pedal Brake pedal 2 Remove Caps Lower _ Upper _ 3 Remove eBolts Footrest board 9 Footrest board Pull up the footrest board end and then pull out the footrest board to the backward i _i_ 2 13 ...

Page 33: ... 1 Disconnect Flasherlead couplers _ 2 Remove Bolts Scooter panel _ Screws Scooter panel _ oScooter panel assembly AiR FILTER ELEMENT CLEANING 1 Remove Front cover Side cover Left Refer to REMOVING THE COVERS AND PANELS section oCover Air filter case _ Remove the cleaner joint hose _ from the sheave case _ at the same time 2 Remove oElement The engine should never be run without the air filter ele...

Page 34: ...stalling the element make sure i_ it is positioned correctly in place 3 Lightly grease the element sealing side for an air t ght seal between the element and case 4o Install _Element Rear _ Element Front _ eOomponents in above list Step 1 NOTE _ Install the rear element first FUEL COCK CLEANING 1 Remove oFront cover Side cover Left and right Refer to REMOVING THE COVERS AND PANELS section 2oTurn t...

Page 35: ...reen oFilter cup Clean it with solvent 9 Install oFuel cock component parts NOTE Be careful not to clamp the fuel cock too tightly as this may unseat the rubber gaskets and lead to a fuel leak FRONT AND REAR BRAKE INSPECTION Lining Inspecton Front Rear 1 Activate the brake lever or brake pedal 2 Inspect _Wear indicator _ Indicator at wear limit line _Replace brake shoes Refer to CHAPTER 5 FRONT WH...

Page 36: ...ter until the free play is wi thin the specified range NOTE After adjusting check the operation of the brake light TIRE AND CAST WHEEL _NSPECTION This scooter is equipped with cast wheels designed for tubeless tires only Tubeless tires are installed as standard equipments 1 Proper loading of your scooter is impor tant for the handling braking and other performance and safety characteristics of you...

Page 37: ...ily turn over Always perform the following steps to ensure safe operation maximum tire performance and long service 1 Measure oTire pressure Use an air gauge Out of specification _Adjust Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Tire in flation pressure must be adjusted according to total weight of cargo rider passeng...

Page 38: ... view replace the tire immediately 3 Inspect _Alumh_um wheels Damage Bends NOTE Always balance the wheel when a tire or wheel has been changed or replaced Never attempt even small repairs to the wheel 4_ Tighten _Valve stem Iocknuts J_ Front wheel only _ VaNve Stem Locknut q 1 5 Nm 0 15 mokg 1 1 ft Jb elnsta J the rear whee_ air valve on the right of the scooter on the muffler side eRide conservat...

Page 39: ...forth Looseness _Adjust Steering head adjustment steps eRemove the steering nut cover _ oLoosen the upper ring nut _ completely us ing the Ring Nut Wrench YU 01268 NOTE Set the Torque Wrench to the Ring Nut Wrench so that they form a right angle oTighten the lower ring nut _ using the Ring Nut Wrench YU 33975 _ Ring Nut _ Initial Tightening 30 Nm 3 0 mokg 22 ftolb oLoosen the lower ring nut _ comp...

Page 40: ... The spring pr oad of the rear shock absorber can be adjusted to suit dder s preferance weight and the course conditions Spring pre_oad adjustment steps oAdjust the sprinq prebad with the spring sea_ Stiffer _ _ncrease the spring reload h A _ r J _ Turn the _pr n_ sea C ookw se A _ Softer _b_Decrease the spring preload Turn the spring seat counter c_ockwise Standard Position B Softest Position Min...

Page 41: ...rts of the brake leverand pedal shaft _ YamahaChainandCabieLubeor _ SAE 10W30 Motor Oil CENTERSTAND AND SiDESTAND LUBRICATION Lubricate the centerstand and sidestandat their pivot points Yamaha Chain and Cable Lube or SAE 10W30 Motor Oil FRONT SHOCK ABSORBER LOWER PIVOT LUBRICATION Apply the grease from nipple on the compresion arm until new grease comes out _ Lithium Soap Base Grease COMPRESSION ...

Page 42: ...G THE COVERS AND i PANELS section 2 Remove aPassenger footrest Right _ 3 Remove oSocket bolts Exhaust pipe oF_ange bolts Muffler _21 eMuffler assembly 4 Remove Screws lAir shroud I _ Screws Fancase cover _Air shroud 1 _ with fancase cover 5 Install Muffler assembly When check rig the ignition timing the muf fief must be installed in placeo 2 23 ...

Page 43: ...U 08036 to check the engine speed oVisually check the stationary pointer _ on the crankcaseto verify it is within the required firing range _ indicated on the flywheel Incorrect firing range Check flywheel and or pickup assembly tightness and or damage Refer to CHAPTER 6 ELECTRICAL for fur ther information 7 Remove eMuffler assembly 8 Install oComponents in above list step 4 1 9 Tighten oComponent...

Page 44: ... injury Wear protective eye gear when handling or working near batteries Antidote EXTERNAL SKmN Nush with water EYES Flush with water for 15 minutes and get immeditate medical attention Antidote iNTERNAL eDrink large quantities of water or mimk foF tow with milk of magnesia beaten egg or vegetabJe oil Get immediate medicaJ at o tention Batteries also generate explosive hydrogen gas therefore you s...

Page 45: ...fic Gravity 1 280 at 20 C 68 F 4 Install eBattery NOTE Connect the positive lead farst 5 Inspect oBreather hose Obstruction _ Remove Damage Replace 6 Connect eBreather hose Be sure the hose is properly attached and __ routed When inspecting the battery be sure the breather hose touches the frame or exits in such a way as to cause battery electroRyte or gas to exit onto the frame structural and cos...

Page 46: ...ith a spark plug clean er or wire brush 4 Measure _Spark pkJg gap a Out of specification _Regap Use a wffe gauge E_ spark P ug Gap ka_ 1 0 8 0o9 mm 0 031 _ 0 035 in 5 Tighten eSpark Plug NOTE Before installing a spark plug clean the gasket surface and plug surface Spark P_ug 17 5 Nm 1 75 mokg 12 5 fto_b NOTE If a torque wrench is not available when you are installing a spark plug a good estimate o...

Page 47: ...urn the adjuster _ until the operating timing is correct HEADLIGHT BULB REPLACEMENT 1 Remove Bolts Headlight unit _ 2 Remove Headlight unit _ 3 Disconnect Connecter Headlight lead _ 4 Remove oRubber cover Headlight bulb oBulb holder _ While pushing the bulb holder _ turn it counterclockwise 5 Remove oBulb _ Do not touch headlight bulb when it is on as the bulb generates enormous heat keep flammabl...

Page 48: ... 1 Adjust o Headlight beam Refer to following section HEADLIGHT BEAM ADJUSTMENT 1o Adjust Headlight beam Horizontally HorizontaJ Adjustment Ii Right I Turn screw _ c iockwise e 2 Adjust oHeadlight beam Vertically Vertica_ Adjustment igher 7urn o osting sc ew clookwise Lower _un_ercBocKwlse FUSE INSPECTRON 1 Open the seat 2 Remove o Battery cover 3 Inspect eFuse i_ Defective _ Rep ace Blow fuse new...

Page 49: ...in 20A 1 Reserve 20A 1 Blown fuse replacement steps eTurn off ignition and the circuit olnstall a new fuse of proper amperage Turnon the switches and seeif the electrical device operates Fuse interrupts the circuit again Check elec trical system Refer to CHAPTER 6 ELECTRICAL for fur ther information 2 30 ...

Page 50: ...i_i_i_ _ _i _i_ _i_ii 2_31 ...

Page 51: ...EAVE 3 9 FLYWHEEL MAGNETO AND STARTER MOTOR 3 10 REAR WHEEL AND MAINSTAND 3 10 STARTER CLUTCH AND CAMSHAFT 3 11 TRANSMISSION 3 12 OIL PUMP 3 12 CRANKCASE AND CRANKSHAFT 3 13 INSPECTION AND REPAIR 3 14 CYLINDER HEAD COVER ROCKER ARMS AND ROCKER ARM SHAFTS 3 14 PUSH RODS 3 17 CYLINDER HEAD 3 17 VALVE VALVE GUIDE AND VALVE SEAT 3 18 CYLINDER 3 26 PISTON PISTON RING AND PISTON PIN 3 26 HYDRAULIC VALVE...

Page 52: ...CASE 3 50 TRANSMISSION 3 51 i CAMSHAFT AND STARTER CLUTCH 3 55 MAINSTAND AND REAR WHEEL 3 57 STARTER MOTOR AND FLYWHEEL MAGNETO 3458 SECONDARY AND PRIMARY SHEAVES 3 59 CYLINDER AND PISTON 3 62 CYLINDER HEAD AND CYLINDER HEAD COVER 3 63 ENGINE MOUNTING 3 67 _i iii ...

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Page 54: ...n matedat before removal and disassembly 2 Use proper tools and cleaning equipment Refer to CHAPTER 1 SPECIALTOOL NOTE When disassembling the engine keep mated parts together This includes gears cylinders pistons and other parts that have been mated through normal wear Mated parts must be reused as an r_ _ assembly or replaced o 3 During the engine disassembly clean all parts and place them in tra...

Page 55: ...y Refer to CHAPTER 2 ENGINE OIL REPLACEMENT section H 6 Remove eDipstick Transmission case _ oDrain bolt Transmission case _ Drain the transmission oil completely Refer to CHAPTER 2 TRANSMISSION OIL REPLACEMENT section BATTERY LEAD 1 Remove oBridge plate _ eCover _ 2 Disconnect eBattely leads NOTE Disconnect the negative lead _ first AiR CLEANER CASE 1 Remove Screws Air cleaner case _ oBreather ho...

Page 56: ... fuel cock side CONNECTORS 1 Remove Starter motor lead Positive Starter motor lead Negative 2 o Band 3 2o Disconnect _AC magneto lead connecter _Pickup coil lead connecter _ Choke unit lead coupler 3 Oil level switch lead couple_ _4_ CONTROL CABLES 1 Loosen Looknut f Throttle cable adjuster 0_ 2 Remove Throttle came _ From carburetor side Spark plug cap 3 3_3 ...

Page 57: ...ter Rear brake _ oPivot pin _ oBolt Rear brake cable clamp _ 6 Loosen Bolt Rear brake cable clamp _ 7 Remove oBolt Rear brake cable guide _ Rear brake cable _ with guide _ ENGINE 1 Remove oBolt Shock absorber lower _ Pivot shaft Engine _ 2 Remove Frame assembly _ From the engine assembly 3 Place the frame assembly _ on a suitable stand _ 3 4 ...

Page 58: ...or assemby _ 3 Remove Clamp plate Heat protecter _ Heat protecter 2 4 Remove _lntake manifold _i_ with O ring _ MUFFLER 1 Remove Socket boJts Exhaust pipe _ Flange bolts Muffler Muffler assembly _ with gasket FANCASE COVER AND AmR SHROUD 1 Remove Fancase cover _1_ Air shroud 1 F2 Air shroud 2 _3 _ 3_5 ...

Page 59: ... _ on the crankcasesothat the pistonisat TDC on the compression stroke 2 Remove oBolts Cylinder head cover oCylinder head cover NOTE Follow numerical ordershown in photo Start by looseningeach bolt 1 2 turn until all are loose 3 Remove ePush rods _ oDowel pins _ oNozzle _ with O ring _ J 4 Remove oSocket bolt Cylinder head _ oBolts Cylinder head _ oStay Air shroud _ NOTE Loosen the bolts in stage ...

Page 60: ...e _ screw driver atthe reinforced points _ shown Remove _Gasket Cylinder head Dowei pins 0_ _NoZZle _ with oil seal CYUNDER AND P_STON I RemOve Socket bolts Cy inder _ 19_ Cy in_er _ with O_r _g _ Tap ightly the cylinder Solid points with a soft head hammer tO remove the cylinder 2 Remove ePiston pin clip _ _ NOTE Before removing the piston pin clip cover the crankcase with as Cleanrag Soyou will ...

Page 61: ...Piston Pin Puller YU 01304 Do not use a hammer to drive the piston pin out 4 Remove oDowel pins _ oNozzle _ with O ring _ eGasket Cylinder _ 5 Remove oValve lifter Intake _ and Exhaust _ NOTE Put marks on them so that they can be identified as intake and exhaust PRIMARY SHEAVE AND V BELT 1 Remove oSheave case cover _ NOTE Working in a crisscross pattern loosen screw 1 4 turn each Remove them after...

Page 62: ...t Primary sheave assembly _2 Use the Roter Holder YU 1235 _ Lock washer _ Primary fixed sheave _ V belt 5_ Remove Primary slidhlg sheave _ 1 with collar _2_ CLUTCH HOUSING AND SECONDARY SHEAVE 1 RemoVe _Nut Secondary sheave _ Use the Sheave Holder YS 01880 oCnteh ho_sing 2 Remove Secondary sheave assembly _ 3 9 ...

Page 63: ...move eFlywheel magneto _ Use the Rotor Holder YU 01235 _ and Flywheel Magneto Puller YU 01080 _ 3 Remove oStator assembly _ oWoodruff key _ eStarter motor _ REAR WHEEL AND IV AINSTAND 1 Unhook eSpring Mainstand _ 2 Loosen Bolts Mainstand _ NOTE Do not remove the bolts Mainstand yet 3 Remove eNut Rear wheel axle oRear wheel _ oThrust washer _ 3 10 ...

Page 64: ... _Starter gear case cover NOTE _ _ Working in a crisscross pattern loosen screw 1 4 turn each Remove them after all are ioosened_ _ oDowet pins _ _ _Gasket 3 2 Remove eStarter clutch assembly i idler gea r Starter motor _ eShaft Idler gear 3 3 Remove Camshaft assembly _ NOTE o When removing the camshaft assembly fit the knock pin _2 to the camshaft driven gear 3 11 ...

Page 65: ...case cover _ with primary drive axle _ oDowel pins oGasket NOTE Working in a crisscross pattern loosen screw 1 4 turn each Remove them after all are loosened 2 Remove oThrust washer _ Main axle _ eThrust washer _ 3 Remove oDrive axle _ NOTE Take care not to damage the oil seal OIL PUMP 1 Remove Oil pump assembly _ O rings _ 3 12 ...

Page 66: ...e Botts Oit filier case _ Guard Oit revel switch lead 0 t filler case 3 2 Remove Oit level switch 1_ 3 Remove OiLfilter C0ver _ oil 4 Remove Screws Crankcase _ _ NOTE RemoVethe screws staging with the highest num _ bered one in two steps _ _ R GHT F_ LEFT 3 13 ...

Page 67: ... eDowel pins _ _ oNozzle _ with O ring _ E i 9 Remove Oil strainer _ oRelief valve _ INSPECTHON AND REPAUR CYLINDER HEAD COVER ROCKER ARMS AND ROCKER ARM SHAFTS 1 Remove eRocker arm shafts _ Use the Slide Hammer Set YU 01083 _ and _ _ ii cRocker arms eWave washers _ ePlate washers _ NOTE Identify each rocker arm and rocker arm shaft po sition very carefully so that it can be reinstalled in its ori...

Page 68: ...hole i _ 2 Camqobe_contact surface 2 _ Excessive wear_e Replace Inspect the surface condition of the rocker arm shaft Pitting Scratches Blue discoBoration Re_ _ _ pJace Check lubrication Inspect the oil passages of the rocker arm shaft Ctogged Damage Clean or replace NOTE Always use a new O_ring If rocker arm shaft is removed oMeasure the inside diameter _ _of the rock_ er arm holeo Use the Bore G...

Page 69: ...urfaces oWave wahsers Plate washers 5 Install _ _ ___ _ Rocker arms __ Wave washers ePlate washers _ eRocker arm shafts _ NOTE The rocker arms are consist of intake _ and ex haust _ parts Make sure they are installed to correct positions _iii NOTE oThe rocker arm shaft should be installed so that the threaded portion faces outward eThe hole in the rocker arm shaft should be aligned with the hole _...

Page 70: ...pring Compressor YU 04019 k l rW_ Depress the valve springs 2 Remove J _ _ Valve retainers i _ _ VaLve spring seat Upper 2_ _ VaLve spring Outer 3_ _ _ _ Valve spring Inner _ 0ii seal _ 7_0 Valve spring seat Lower Valve _ NOTE If any deformation is occurred on the valve stem end deburr before pulting out the valve from the valve guide on the cylinder head Use an oil stone to srnooth the stem end D...

Page 71: ...Head Warp Limit Less than 0 025 rnm 0 001 in VALVE VALVE GUIDE AND VALVE SEAT __ I_ Valve Inspection _ 1 Eliminate Carbon deposit T_ _ _j r Use a 400 600 grit wet sandpaper 2 Check _ I _ Valve face _ _ oStem end _ 45 Wear Pitting Out of specification Replace Margin Thickness Service limit _ intake 0 7 mrn 0 028 in Exhaust 0 7 mm 0 028 in Beveled _ 0 50 mm 0 020 in Minimum Length Service lirnit 4 0...

Page 72: ...75 m m 5 920 m m xnaust 0 2348 o_0 2352 in 0 233 in 6_ Measher _Valve guide inside diameter _ Use the Bore Gauge _ Out of specification _Reptace the valve guide and valve as a seL _VaDve Guide _nside Diameter _ Limit Intake 000 _ 012 mm i 05 mm Exhaust 0 2362_ _ 0 2387 in i 0 238 in _ Valve 4_ Valve guide Valve Guide Inspection Inspect eValve guides Wear Oil leakage into cylinder _Reptace NOTE Alw...

Page 73: ...eplaced oAfter installing the valve guide in the cylinder head cut the valve guide with the Valve Guide Reamer YM 01227 to the specified clearance limit After replacing the valve guide relap the valve 2 Measure oValve stem to valve guide clearance Y Subtracting the valve stem outside diameter from the valve guide inside diameter _ __ Refer to Valve Inspection section Less than Limit _Cut Valve gui...

Page 74: ...hanics bluing dye Dykem _ Ob To contact surface of valve face 3 Position oVatves Intake and exhaust Into cyfinder head Spin the vatve quickly back and forth with a Lapping Stick _i then putl out the valves 4 Measure _Valve seat width The valve seat and vatve face will have re moved bluing wherever they contacted each other Out of specification Pitting Variation of valve seat width Cut vatve seat f...

Page 75: ... To reduce valve seat width to 1 0 mm It t lightly 60 cutter 0 039 in oValve seat is in the middle of the valve face bu too narrow See _ diagram I To achieve a uniform I Use 45 cutter valve seat width of 1 0 mm 0 039 in oValve seat is too narrow and right near I valve margin see _ diagram i i Valve Seat Cutter Set Desired Result 30 cutter first To center the seat an Use to achieve its width o_ 45o...

Page 76: ... lapping results lightly tap the valve seat while rotating the valve back and forth between your hands 4 Apply Fine lapping compound SrnaJl amount To vaive face 5o Repeat steps 2 and 3 NOTE Be sure to dean off all compound from valve face after every lapping operation 6 lnspect Valve face Not yet uniformly smooth Repeat proce_ dure from step 1 7 Apply _Mechanics bluing dye Dykem To valve face and ...

Page 77: ...ast valve seat_Relap See procedure below Relapping steps oDisassemble head parts eRepeat lapping steps using fine lapping compound Clean all parts thoroughly Reassemble and check for leakage again us ing solvent oRepeat steps as often as necessaryto achieve a satisfactory seal _ Valve Spring 1 Measure Spring free length i Out of specification _Replace _ Minimum Free Length Inner Spring in 35 5 mm ...

Page 78: ... F_ High Quality MoJybdenum Disulfide _ _ Motor Oil or Molybdenum Disumfide Grease _f _ _ f _ _ 2 lnstatk a Valve d Valve spring seat Lower 2 Valve stem seat New _ _ Valve spring Inner 4 _ Valve spring Outer _ _ Valve spring seat Upper _6 Valve retainers _ NOTE All valve springs must be installed with larger pitch upword as shown Larger pitch Smaller pitch NOTE After installing the valve assembt y...

Page 79: ...5 mm Taper T 0 002 in C Maximum D D2D4D6 T Maximum D or D2 Minimum Ds or D6 Dl D2 D3 D4_ Ds D6 4ram PISTON PISTON RiNG AND PISTON PiN 0 16 in Piston i 1 Inspect ePiston wall Wear Scratches Damage_ Replace 2 Measure oPiston outside diameter P Use Micrometer Out of specification _ Replace NOTE Measurement should be made at a point 4 0 mm 0 16 in below the bottom edge of the piston Size 67 95 68 00 m...

Page 80: ...ize 2 0 _ rnm 0 0197 in Oversize 4 1 00 mm 0 0394 in The expander spacer of the bottom ring ot con I_l trot dng is color coded to identify sizes The color mark is painted on the expander spacer Size Color Oversize 2 Blue Oversize 4 Yellow 1 Measure Side clearance Use a Feeler Gauge 1_ Out of specification _ Reptace piston and or rings Side Clearance i Standard _ i_ t i 0 03 0 07 mm 0 12 mm Ring 0 ...

Page 81: ...0 80 mm 2rid Ring 0 0118 0 0177 in 0 0315in Oil Control 0 20 0 70 mm Rails 0 0079 0 0276 in Piston Pin 1 Lubricate oPiston pin lightly 2 Install ePiston pin Into small end of connecting rod _ 3 Check oFree play Free play Inspect connecting rod and piston pin for wear 4 Position Piston pin Into piston 5 Check Free play When pin is in place in piston Freeplay Replace piston pin and or piston HYDRAUL...

Page 82: ...Damage Wear Scratches _ Replace valve lifter assemMyo H 2_ Inspect oVatve lifter body Contact surface of the plunger with the camshaft Damage wear scratches_ Replace vatve lifter assembly and camshaft as a set Assembly _ _ Circlip _ Push rod seat 9 Plunger _4_ Retainer _ Return spring _ Valve Hfter body High pressure chamber Check bali spring _ Check ball Oil reservoir _1 Oil inlet hole 3 29 ...

Page 83: ...he high pressure chamber is filled with oil Service Points for Hydraulic Valve Lifter 1 This engine may create some valve noise when started After few seconds the noise will be eliminated when the valve lifter assem bly is lubricated 2 As the valve lifter is composed of high preci sion parts oil and oil filter mast be kept clean at all the time Replace the oil and oil filter periodically as descri...

Page 84: ...xcesive noise _ Block of oil gallery Lack of oil supply to hydraulic valve Repiaoe engh e oiJ and oil lifter causes excessive movement of filter Check and clean oil plunger in hydraulic valve tifter passages NOTE Oil is supplied to valve lifter throu h Small orifice 2 mm 0 08 in in oil filter chamber Therefore if oil filter is damaged this orifice can be easily blocked by foreign particles _nsuffi...

Page 85: ...oPrimary fixed sheave _ oCollar _ Wear Cracks Scratches_ Replace _vJ 2 Position eCollar _ Into primary sliding sheave _ 3 Check oFree play Excessivefree play or stiff _ Inspect collar or sliding sheave inner bushing if necessary replaced 4 Inspect oWeight _ Ramps Sliding sheave _ Damage Scratch Wear _ Replace 5 Inspect _ _ eCam plate _ ePrimary sheave cap _ oSlider bushings _ oHolding plate _ Dama...

Page 86: ...aJ should be installed with the rnak er s mark and size No facing outward 2 Apply eOit seat tip lightly 3 Apptv Weights 1 _Ramps Sliding sheave _2 olnner bushing Sliding sheave _ Stide_ bushings Cam plate __4 T Uthium Soap Base Grease 1 t 4 Install oO_ring New 1 NOTE Always use a new Oo ring_ 5 Apply oO ring Lightly _ Molybdenum Disulfide Grease Be sure to remove the anv oH and or grease from the ...

Page 87: ...ch YM 04045 A _ and Primary Sheave Holder YS 01880 _ Do not remove the clutch Uocknut at this stage yet 3 Remove Clutch compressor Holder YM 33285 1 Hexagon Wrench YM 01307 _ or suitable collar and plate washer 4 Attach oSecondary Sheave Compressor YS 28891 5 Remove oLocknut Clutch assembly _ 6 Loosen oNut Secondary Sheave Compressor _ Until the sliding spring gets free 7 Remove oSecondary Sheave ...

Page 88: ...r _ _Secondary sliding sheave _ anspection 2_ 1 l _spect _Secondarv fixed sheave _i oSecondary sliding sheave _2 Scratch Damage_ Replace 2 Inspect oTorque cars grooves Sliding sheave _1 oGuide pin _ oGuide collar _ Wear Damage _ RepEace 3 inspect eBall bearing _ Needb bearing _ Roughness Damage wear _Replace 3 35 ...

Page 89: ...ces Scratch Damage Replace I_ Clutch Housing Wear Limit I 136 mm 5 35 in 6 Inspect oClutch body _ Clutch spring _ oClutch shoe _ __ Damage Replace as set 7 Measure oClutch shoe thickness _ Out of specification Replace _ Clutch Shoe Thickness _ New 4 0 mm 0 157 in Limit 2 0 mm 0 079 in Assembly When reassembling the secondary sheave reverse the disassembly procedure Note the following points 3 36 ...

Page 90: ... Wh_d o oAdhesive tape Around the shaft end of the secondary fixed sheave _ 5 Install oStidinq sheave _ 3_ NOTE Be carefult so that the oil seal lips are not turned over when installing the sliding sheave 6 Install Guide collar _ Guide pin 2_ eO_rings New _3 _ NOTE _ _ Always use a new O ring 7_ Apply Groove Secondary sliding sheave _i_ cO rings _ _ Lithiumosoap Base Grease Sufficientmy Coat 8 Ins...

Page 91: ...ar Scaling Chipping _ Replace Oil or grease adhered to the V belt_Check the primary and secondary sheaves 2 Measure _ oV belt width _ Out of specification Replace V belt STD Limit Width 20 0 22 6 mm mm 0 787 0 890 in in Replace at 11 000 km 6 900 mi irrespective at limit STARTER CLUTCH AND iDLE GEAR Starter Clutch Disassembly 1 Remove oStarter clutch gear NOTE While pulling the starter clutch gear...

Page 92: ...oSprings _ _nspeetion 1 Inspect _ _ o Roller i _ Spring cap 2_ Spring _ Cfutch housing _ Deform Wear Damage RepJace 2 inspect oBushing Roller contact surfaces Starter _ clutch gear _ L1 Bushing contact surfaces Starter wheel _ Scratches Heat damage Wear _ Replace Starter cJutch gear _ Idle gears _ Idle gear shaft Scratches Wear Damage o_ RepLace 3_39 ...

Page 93: ... screw _ Screw Starter Wheel 30 Nrn 3 0 m kg 22 ft lb _ _ 1 LOCTiTE 3 Clinch eScrew head Starter wheel Use a center punch Screw head flattens in the recess in the start er wheel 4 After installing the rollers check the smooth movement 5 Install oStarter clutch gear NOTE While pushing the starter clutch gear turn it counterclockwise CAMSHAFT 1 Inspect oCamshaft zero rash gear spring damper Loosenes...

Page 94: ...ting Scratches Blue d scolorat on _ R place 4 Measure Cam lobes Use a Micrometer Out of specification Reptace Cam Lobe Cam Lobe A B 32o37 32 49 mm 25 9g _26 01 mm intake 1 2744 1 2791 in 1 0232 1o0240 in 32 37_32 4g mm 25 99 _ 26 01 mm Exhaust 1o2744 _1o2791 in 1 0232 _ 1 0240 in TRANSMISSION Gear _ i 1 Inspect Gear teeth Pitting Galling Wea r _eReplace eThrust washers _ i Damage Wear _ place _ i ...

Page 95: ...or _ clearance Use Feeler Gauge Out of specification Replace oil pump as sembly p Side CUearane _ 0 03 0 08 mm 0 0012 0 0031 in Limit 0 15 mm 0 006 in 3 Measure eOuter rotor _ Inner rotor _ clearance Use a Feeler Gauge Out of specification Replace oil pump as sembly _ Tip Clearance 0 12 mm 0 0 _7 in Limit 0 2 mm 0 008 in 4 Measure oRotor _ Q Housing _ clearance Use a Feeler Gauge and Straight Edge...

Page 96: ...U 3 Install Dowel pins eSprings _8_ _h x To the buffer boss 8 NOTE Place the pins as iJtustrated position 4 Install oBuffer boss assembly _i To the weight gear _2 NOTE Align tile match mark _on the weight gear with the match mark _ on the buffer boss_ 5 Install _ Holding plate _1_ _Weight gear assembly _2 _ To the balancer weight NOTE Align the hole 3 on the holding plate and buffer boss with the ...

Page 97: ...ar teeth Balancer _ Pitting Galling Wear _ Replace crankshaft assembly oCrankshaft splines _ Wear Damage _ Replace _ oCrankshaft journals Pitting Scratches Replace NI 3 Measure I _ _ _ oRounout Use the V Blocks _ and Dial Gauge _ Out of specification _Replace I _ RounoutLirnit I 0 02 rnm 0 0_8 in Crankshaft Main Bearing Clearance Measurement 1 Measher oMain bearing clearance 3 44 ...

Page 98: ...earing inside diameter Journal Oil Clearance 0 02 0 0008 0 0020 in On the journal the larger measurement is used as a basis for calculation of the oim clearance and on the main bearing the smaller value is used _ 4 _ Main Bearing Remova_ and Selection 1 Remove oMain bearing i_ Use a Plain Bearing Handle YU 04058 3 Plain Bearing Installer Remover YU 04095 i _ _ _ and Haydraulic Press 4 TTx _ Crankc...

Page 99: ...The new crankcase is already fitted with main bear ___ ings and their inside diameters are normally 30 000 to 30 020 mm 1 1811 1 1818 in Main Bearing Installation 1 Position _Main bearing Oversize _ _ To the Plain Bearing Installer Remover _ YM 33297 _ _ _ NOTE i _i As shown in the photo fit the key _ vertically _ to the bearing _ and align the straight cutaway t I of the plate special tool with t...

Page 100: ...m perfect character 5 Apply 3 Bolt threads Connecting rod _ oNuts surfaces Connecting rod cap _ 9F_ Molybdenum Disulfide Grease 1 6 Tighten eNuts Connecting rod cap NOTE Do not turn connecting rod until clearance meas urement has been completed Tighten to fun torque specification without pausing Apply continuous torque between 1 0 and 1 8 m kg Once you reach 1 0 m kg DO NOT STOP TIGHTENING until f...

Page 101: ... rod size numbers are indi cated by 3 or 4 and are marked in ink on the connecting rods and caps oThe rod bearing journal size numbers is in dicated by 0 1 or 2 and are stamped on the left end of the crank web Example selection of the connecting rod bearing olf the connecting rod sizeis No 4 and crank shaft size is No 2 respectively the bearing size No is Bearing Size No Connecting rod No Cranksha...

Page 102: ... Y mark _2 _ on the connecting rod should face towards the primary sheave side Left side of the crankshaft 4 Install oConnecting rod cap _ Bolts Connecting rod cap _2_ NOTE _ Be sure the letters on both components align to form a perfect character oApply Molybdenum disulfide grease to the rod cap bolt threads and nut surfaces 5 Tighten Nuts Connecting rod capl I_ Nut IConnectinq Rod Capk 18 Nm 1 8...

Page 103: ...0020 in weight Drain bolt Crankshaft _ Dipstick _ Plain bearing _ Oil filler case CONNECTING ROD BEARING CLEARANCE _ Connecting rod _ Oil level switch guard 0 021 0 045 turn 0 0008 0 0018 in Connecting rod cap _ Oil strainer ENGINE OiL _ Oil pump _ Relief valve TOTAL AMOUNT _ Crankcase 2 _ Oil filter 1 3 L 1 2 Imp qt 1 4 US qt _ Collar _ Oil filter cover _ Breather hose _ Air bleed bolt AUGN PUNCH...

Page 104: ...in axle _ Roller _ _ Woodruff key _ Primary drive axle _ Spring cap _ Camshaft drive gear _ Gasket _ Spring _ Camshaft Transmission case cover _1_Cluch housing _ Bearing _ Dowel pin Starter clutch gear Oil seat 1_ _Starter gear case cover Starter Idle gear _8_Drive axle _ Gasket _ Idle gear shaft _USE A NEW ONE ii i 3 51 ...

Page 105: ... _ oOil strainer _ NOTE Before installing the oil strainer thorough wash the oil strainer in a solvent H Crankshaft and Balancer Weight 1 Apply oCrankshaft jounals oMain bearings oBalancer shaft jounals oBalancer shaft jounal bearings Disulfide Grease Molybdenum 2 Install oCrankshaft _ Balancer weight _ To the crankcase 1 _ _Be careful not to damage the main bearing when installing the crankshaft ...

Page 106: ...all Nozzle _ oO_ ing New o Dowel pins _3 _ Spacer collar _z_ To the crankcase 1 4 Fit the crankcase 2 onto the crankcase 1 Tap lightly the crankcase 2 with a soft head hammer 5 Check _Crankshaft smooth movement Not smooth _ Reset 6o Tighten _Screws Crankcase _ _ _ NOTE _ __ Tighten the screws starting with the lowest num i bered one in two or three steps Screw Cran i_ RIGHT LEFT 3 53 ...

Page 107: ... on the filter cover 8 Tighten Oil filter cover _ 1_ Oil Filter Cover I 10 Nm 1 0 mokg 7 2 1b 9 Install oOil level switch _ 10 Install _ O ring New _ To the oil filler case _ Oil filler case _ oGuard Oil level switch lead _ _ OilFiilerCase _ I 10 Nm 1 0 m kg 7 2 ft lb NOTE oApply the engine oil to the O ring on the filler case oBefore installing the guard _ through the oil level switch lead betwee...

Page 108: ...drive axle bearing and shaft Grease the oil seal lip Be careful not to damage the oil seal rip when installing the drive axle 2 Install Thrust washer _ Main axle Thrust washer NOTE Oil the main axle bearing shaft and thrust washers 3 Install Dowel pins Gasket New Transmission case cover _ with primary drive axle _ 4 Tighten Screws Transmission case cover NOTE Tighten the screws in two stage using ...

Page 109: ...Grease the O ring 4 Install Shaft Idler gear Idler gear Starter motor _ Starter clutch assembly _ NOTE Before installing the Idler gear shaft grease the Idler gear shaft bearing 5 Install eDowel pins _ eGasket New _ oStarter gear case cover _ NOTE eBefore installing the starter gear case cover grease the oil seal rip eBe careful not to damage the oil seal rip when _ installing the case cover 6 Tig...

Page 110: ...ainstandl 30 Nm 13i0 m kg _ ft lbl I 4 Instatl eBrake shoe plate _ 3 oBolts Brake shoe plate _2 Brake shoes 4 NOTE Grease the cam and pivot pin on the brake shoe plate 5 Tighten Boks Brake shoe plate _ Bolt Brake Shoe Plate _ 18 Nm 1 8 kg 13 ftomb LOCTITE 6 Install oThrust washer _ Rear wheel j_ oNut Rear wheel axle NOTE eGrease the thrust washer QDo not thighten the wheel axle nut at this point 3...

Page 111: ...sembly 7 Nm 0 7 m ekg 5 0 ftolb 3 Install _1_ Flywheel magento _ oFlange bolt _ NOTE oWhen installingthe flywheel magneto make sure the woodruff key is properly seated in the key way of the flywheel magneto Lightly grease the tapered portion of the crankshaft 4 Tighten eFlange bolt Flywheel magneto _ Use the Rotor Holder YU 01235 _ Flange Bolt Flywheel Magneto 35 Nm 3 5 rn kg 25 ft lb 5 Install eC...

Page 112: ...ock washer Clutch houshng 1_ Primary sheave cap _ Dowel pin Secondary fixed sheave _i_ Slider bushing _z_ Gasket V_ bett _ O ring Sheave case cover Secondary sliding sheave Camplate _ O ring _ Weight 1 _ CLUTCH HOUSING WEAR LiMiT 90 Nm 9 0 m kg 65 fto_b 136 mm 5 35 in CLUTCH SHOE THICKNESS B_i LiMiT 2 0 mm 0 079 in UMIT 2 0 mm 0 787 in SUD_NG SPRING FREE LENGTH UM_T 93 7 mm 3 69 in _ USE A NEW ONE...

Page 113: ...er eBe careful not to damage the oil seal lip on the secondary sheave when installing the secondary sheave 2 Install oClutch housing 3 Tighten oNut Secondary sheave _ Use the Sheave Holder YS 01880 i 50 Nm 15 0 m kg 36 ftolb Primary Sheave and V belt 1 Install eHolding plate eCollar _ To the primary sliding sheave _ oPrimary sliding sheave _ Remove the any oil and grease from the con tact surfaces...

Page 114: ...fixed sheave _ _i 3 Tighten Nut Primary sheave assembly _ Use the Rotor Holder YU 01235 _ 4 Bend the lock washer tab 5 Install V_belt 1_ Place the V belt around he secondary sheave and compress the secondary sheave spring hard so that the V_belt moves toward the clutch hub And hook onto the primary sheave NOTE __ The V bek must be installed with the arrow marks _2_facing tl_e direction of travel _...

Page 115: ...ver _ Bolts Sheave Case Cover 10 Nm 1 0 m kg 7 2 ft lb NOTE Thighten the boltsin two stage usingacrisscross pattern CYLINDER AND PISTON 1 Install Valve lifters Intake _ and Exhaust _ NOTE Liberally coat the valve lifters with a engine oil 2 Install Dowel pins _ Nozzle _ cO ring New _ eGasket New 3 62 ...

Page 116: ...her 2nd ring 2ND RING 0 12 mm 0i0047 in _ _Air bleed bolt Oil dng Cylinder head cover Circlip END GAP L_MIT _7 O ring Piston pin TOP RING 0 80 mm 0i0315 in Nozzle Piston 2ND RING 0 80 mm 0_0315 in _ Cylinder head Valve lifter ARM_TOoSHAFT CLEARANCE _ Gasket Push rod STANDARD Dowel pin Oil ring lower rail 0 009 0 042 mm 0 0004 0 0017 in Cylinder Oit ring Upper rail PUSH ROD RUNOUT LIMIT 0 3 mm 0 01...

Page 117: ...rag so you will not accidentally drop the pin clip and material into the crankcase eAIways use a new piston pin clip 4 Install oPiston rings NOTE _ _ __ Be sure to install rings so that Manufacturer s marks or numbers are located on the top side of the rings 5 Oil liberally oPistons oRings eCylinders 6 Set oPiston ring ends iVlake sure the ends of the oil ring expanders do not overlap ___ _ OIL RI...

Page 118: ...socket boks _ at this point Finger tighten the bolts _ ki k x _ cf k CYUNDER HEAD AND CYLINDER HEAD COVER 1 Install _Nozzie _ _0 t seal _Oowel pins 2_ _Gasket New _ 2_ ff_stalk Cylinder head assembly 5_ oStay Air shrond _ _Bolts Cylinder head _p eSocket bolt Cylinder head 0 4 With washer 3_Tighten eBotts Cylinder head _ 2 _Socket bolts Cylinder _ _ _Socket bolt CyJ nder head i This tightening sque...

Page 119: ... T wark _ on the flywheel magneto _ with the stationary pointer _ on the crankcase so that the piston is at TDC on the compression stroke 5 Install oNozzle eO ring New oDowel pins _ oPush rods _ NOTE Oil the push rod ends i 6 Apply eQuick Gasket ACC 11001 05 01 To the cylinder head cover mating surface i _ i _ _ i _i_i __i ii_ _ii_ _i_ _i 7 Install oCylinder head cover NOTE Make sure the push rod ...

Page 120: ...lowing points 1 Instafl _Maffler assembly _ with new gasket _4 eFJange bolts Muffler _2_ eSocket bolts Exhaust pipe _ _ F angeBo t Muff er _2_ 25 Nm 2 5 mokg 18 ftoJb Socket Bolt Exhaust pipe _1_ 30Nm 3 0 mokg _ ftolb 2 Instatl olntake manifold _1_ with new O_ring _2_ Moo o 1 2 ft orob 3 tnstalk eEngine assembly _0_ To the frame assembly _ ePivot shaft Engine _3 _ Grease the pivot shaft surfaceo e...

Page 121: ...ew 6 Adjust oThrottle cable free plays Refer to CHAPTER 2 THROTTLE CABLE ADJUSTMENT section oRear brake pedal free play Refer to CHAPTER 2 FRONT AND REAR BRAKE INSPECTION section 7 Add oEngine oil Refer to CHAPTER 2 ENGINE OIL AND OIL FILTER REPLACEMENT section 8 Add Transmission oil Refer to CHAPTER 2 TRANSMISSION OIL REPLACEMENT section 3 68 ...

Page 122: ..._i_ i _i_il_ 3 69 ...

Page 123: ...IoAooI CHAPTER 4 CAP BURETmON CARBURETOR 4 1 SECTION VIEW 4 2 FUEL FLOW DIAGRAMS 4 3 AUTO CHOKE SYSTEM 4 4 REMOVAL 4 7 DISASSEMBLY 4 8 INSPECTION 4 9 ASSEMBLY 4 11 INSTALLATION 4 12 ADJUSTMENT 4 12 E ...

Page 124: ...p screw BYPASS 1 B P t 0 8 _9_Spring _ Main jet BYPASS 2 B P_2 0 8 Needle valve _ Gasket FUEL LEVEL 4 5_5 5 mm _1 Float pin _ Needle jet 0 177_0 217 in Pilot jet _ _ Rubber cap FLOAT HEIGHT 26 _28 mm Float Cable homer 1 024_ 1 102 in 1_ Float chamber _ Spring PILOT SCREW 2 0 turns out _ Drain screw _ Starter ptunger assembly FLOAT VALVE SEAT 2 0 _ O ring Pilot screw STARTER JET G S I 48 Gasket _ S...

Page 125: ...W _ Starter plunger assembly _ Needle jet _ Cold starter nozzle _ Float _ Cold starter jet _ Main jet _ Vacuum piston _ Rubber cap _ Spring _ Rubber gasket _ Jet needle _ Throttle valve _ Valve seat _ Pilot jet _ Needle valve 4 2 ...

Page 126: ...rottel vaJve Bypass holes ___Vacuum piston _ 33_ Pilot air jet _ Main air jet Air jet Coasting enricher 1_ _ Needle jet _ Diaphram Coasting enricher Main jet _ Pilot jet I_ Jet needle Fuel M ixtu re SLOW METE G SYSTEM I D _ MAIN METER3NG SYSTEM 4 3 ...

Page 127: ...rter jet _ Cold starter outlet _ Cold starter air jet _ Starter nozzle A _ Air B _ Fuel C _ Mixture E Construction 1 Choke unit The choke unit which is composed of wax and heater controls the plunger assembly after _i the engine is started Heat generated in the heater due to an elec _ tric current flow causes the wax to expand and push the cam which controls the plun ger assembly 4 4 ...

Page 128: ...old engine _ _ _ When the starter plunger is fully open due to unexpanded wax in the choke unit a rich mix _ _ ture is provided for starting the engine 17 Choke unit _ _ _ Cam _ _Starter plunger _b Starter outlet 2 With a slightly warm engine _ The wax contracts slowly since it is covered _ _ with a heat insulating material thus a leaner mixture than that produced for a cold engine is provided _s ...

Page 129: ... open due to the cold wax in the choke unit However fuel will not be supplied unless the engine is ac celerated When the engine warms up suffi ciently the plunger will close due to the warmed wax in the choke unit _ Starter plunger Cold starter nozzle plunger _ Cold starter nozzle _ Cold starter jet _ Cold starter air jet starter plunger H IBIcLOSE 4 L_ Fuel is supplied i _ JStarter plunger I L_ A...

Page 130: ... 2 13 2 Remove Air cleaner case _1_ Refer to ENGINE REMOVAL AIR CLEAN ER CASE page 3 2 3 Disconnect Fuel feed hose Vacuum hose From carburetor side Choke unit lead coupler 4 Remove Throttle cable _ From carburetor side Refer to ENGINE REMOVAL CONTROL CABLES page 3 3 5 Loosen Screw Carburetor clamp _ 6 Remove Carburetor assembly 4 7 ...

Page 131: ...Remove oVacuum chamber cover _ oSpring _ _ Vacuum piston _ eScrew Jet needle holder oJet needle holder _ _ oJet needle _ J_ NOTE When removing the jet needlebe sure not ot loose the small spring that may fall out This spring holds the jet needle 3 Remove oFloat chamber oFIoat pin _ Float _ oFloat valve 4 Remove oMain jet oNeedle jet Pilot jet _ Rubber cap 4 8 ...

Page 132: ...Ciean o NOTE oUse a petroleum based solvent for cleaning Blow out all passages and jets with compressed air 2 inspect Damage _ Replace oGasket O rings Damage Replace 3 Inspect oNeedle valve _ _ eVaIve seat _ _ Wear Contamination Replace Carburetor Assembly 4 Inspect Vacuum piston 1 Scratches Cracks Damage Replace Diaphragm _2 Damge Torn _ Replace 4_9 ...

Page 133: ... Check oVlave free movement Stick Replace carburetor assembly 8 Inspect Jet needle Bends Wear Replace 9 Inspect oNeedle jet _ Pilot jet _ Damage Contamination Replace 10 Inspect Starter plunger Damage Wear _ Replace 11 Install the starter pluger into the carburetor body and check for smooth movement with finger Not smooth Replace plunger assembly and carburetor body as a set 4 10 ...

Page 134: ...embling wash aimparts in cmean gasoBineo eA_ways use a new gasket 1 Measure Float height Out of specification Adjust FJoat Height 26 _28 mm 1 024_ 1 102 in Float height measurement and adjustment steps Hotd the carburetor in an upside down po __ sit on oMeasure the distance between the mating sur face of the float chamber and top of the float using a guage _ Float height NOTE The float arm should ...

Page 135: ...uum piston _ NOTE There is a tab on the rubber diaphragm and a matching recess in the carburetor body to accept the diaphragm tab 3 Install oChoke unit _ Apply LOCTITE to the choke unit secur ing screws CII iNSTALLATiON 1 Install oCarburetor assembly Reverse the removal steps ADJ USTM ENT NOTE Before adjusting the fuel level the float height should be adjusted 1 Measure oFuel level Out of specific...

Page 136: ...lly eAttach the Fuel Level Gauge G YM 01312 A to the float chamber nozzle to the float chamber nozzle Loosen the drain screw _ and start the engine _Measure the fuet level _ vvkh gauge If the fueElevel is incorrect adjust the fue level 2 Adjust 3 _ _7 mm Throttle cable free play Refer to CHAPTER 2_THROTTLE CABLE ADJUSTMENT section D __i ii il ii_ _ii i_ i_ _ _ _ 13 ...

Page 137: ...NSPECTION 5 3 INSTALLATION 5 6 REAR WHEEL 5 8 REMOVAL 5 9 BRAKE DISASSEMBLY 5 9 INSPECTION 5 10 INSTALLATION 5 11 HANDLEBAR AND FRONT FORK 5 13 REMOVAL 5 14 INSPECTION 5 17 ASSEMBLY 5 18 REAR SHOCK ABSORBER 5 21 REMOVAL 5 21 INSPECTION 5 22 INSTALLATION 5 22 ...

Page 138: ... 2 O ring WITH OIL AND 128 kg 282 Ib Meter clutch _ Dust cover FULL FUEL TANK _ Speedometer drive gear_ Return spring _ Brake shoe Wear indicator plate MAXIMUM LOAD 156 kg 343 lb I1 Brake cam shaft Cam lever _ Brake shoe plate _Load is the total weight of cargo rider passenger and accessories TmRE SNZE A _ 4 00 10 4PR mMRuNOuT uMm B Radial 1 0 mm 0 04 in Lateral 1 0 mm 0 04 in BRAKE DRUM WEAR L_MI...

Page 139: ...edometer cable 3 Remove Cotter pin oNut Tension bar _ Plain washer _ oBolt Tension bar 4 Remove Cotter pin _ Nut Front wheel axle _ oFront wheel axle eFront wheel Brake Shoe Plate Disassembly 1 Remove It oBrake shoes _ olnner collar _ 2 Remove oCirclip _ oWasher _ oMeter clutch _ oDrive gear Speedometer cable eWasher 5 2 ...

Page 140: ...position J 4 Remove Bushing _ Washer _ Driven gear Speedometer cable 3_ Use the Meter Gear Bush Driver INSPECTION AxRe Shaft 1 tnspect __ Front axle shaft _i_ Bends _R tl the Replace aXle on a Flat Surface Do not attempt to straighten a bent axme Wheel Bearing and OimSeal 1 Inspect Wheel bearing i_ Bearings aIIow play in the wheel hub or wheel turns roughly_Replace Oil seal_2_ j_ Wear Damage_ Repl...

Page 141: ...meter of the race of the bearing and oil seal Do not strike the center race _ or balls of the bearing Contact should be made only with the outer race _ _ _ _ Wheel Runout and Wheel Balance _r_ 1 Inspect oWheel 17 Cracks Bends flarpage Replace _ 2 Measure iii iiiiiiiii iiiiiiiiiiii iil j_i_ i t_ _i _Out Rim f specification Replace Runout Limits Radial 1 0 rnrn 0 04 in Lateral 1 0 rnrn 0 04 in 3 Che...

Page 142: ...ecification _Reptace _ Brake Shoe Thickness STD 4 0 mm 0o16 in Limit 2 0 mm 0 08 in 3 Inspect Shoe springs Wear Damage Replace 4o Measure oShoe spring free tength Out of specification _4Replace Shoe Spring Free Length Limit 3 5 mm 1 44 in Brake Drum I Inspect Brake drum inner surface Oi brake drum with rag soaked in lacquer thinner or solvent Scracthes _ Polish brake drum tightly and evenly with e...

Page 143: ...oMeter gear _ oDrive gear _ oMeter clutch _ Wear Damage Replace INSTALLATION When installing the front wheel reverse the removal procedure Note the following points 1 When installingthe wear indicator _ to the camshaft _ align the projection _ on the wear indicator with the slot _ on the camshaft 2 Apply eSpeedometer drive and meter gears _ Lightweight Lithium Soap 1 Base Grease 3 Install eBrake s...

Page 144: ... seat _ Lips eAxte shaft LK_ Collar _8_ Inside and outside _ MoJybdenumD suff deGrease l 5 Tighten Brake cam lever _ eNut Axle shaft _ _Nut Tension bar Brake Cam Lever _9 10 Nm 1 0 mokg 7 2 ftolb Nut Axte Shaft Q _ 70 N m 7 0 m kg 50 ft oJb Nut Tension Bar 45 Nrn 4 5 m kg 32 ftolb NOTE _Thoroughly wipe off the excess grease ___ oAIways use a new O_ring and cotter pin 5_7 ...

Page 145: ...turn spring _ Brake shoe _ Wear indicator plate _ Return spring _ Cam lever TIRE SIZE A USE NEW ONE 4 00 10 4PR RIM RUNOUT LiMiT _ _ B Radial 1 0 mm 0 04 in Lateral 1 0 mm 0 04 in BRAKE DRUM WEAR LIMIT C 151 rnrn 5 94 in AiR VALVE install the air valve on the right of the scooter y 2 0 mm 0 08 in _ _ i18 Nm 1 8 m kg 13 fto b I x 5 8 ...

Page 146: ...ove Socket bolts Exhaust pipe Flange bolts Muffler Muffler assembly _ 4 Remove eCotter pin 5 Loosen Nut Rear wheet axle _ NOTE While applying the rear brake fully to sen the axle nut 6 Remove eNut Rear wheel axle _ Plate washer _ Rear wheel assembly _ 3 Thrust washer BRAKE DISASSEMBLY 1 Remove Rear brake cable _ _1 _ _ eBrake shoes _8 eBrake shoe ptate _ 5_9 ...

Page 147: ...t can be reinstalled in the original position _2 _ 3 Remove oCamshaft _ oPiate washer _ INSPECTION 1 Inspect _1_ oCamshaft _ Camshaft hole _ Scratches Excessive wear Replace 2 Inspect oSplines Rear wheel _ oSplines Drive axle _ Wear Damage Replace 3 Inspect Brake shoes oShoe springs eBrake drum Inner surface Refer to FRONT WHEEL INSPECTION section 5 10 ...

Page 148: ...e the following points 1 When installing the wear indicator _ to the camshaft _ align the projection _ on the wear indicator with the stot _4 on the camshaft li Jj__ 2 AppJy Camshaft 1_ _ Shaft and cam ePivot pin _ Brake shoe eThrust washer _ Lithium_soap 3_ Tighten oBrake cam lever __ oBotts Brake shoe plate oNut Rear wheel axle 5 _ _ _ Brake Cam Lever _4_ 10 BJm 1o0 mokg 7 2 ftomb _4_ Bo_ts Brak...

Page 149: ... EA W EEL NOTE oThoroughly wipe off the excess grease oAIways use a new cotter pin 4 Adjust oRear brake pedal free play Refer to CHAPTER 2 REAR BRAKE IN SEPCTION section 5 12 ...

Page 150: ...AND FRONT FORK S Ring nut Upper _ Compression arm Ring nut Lower _ _ Collar Ball race cover _ Bushing Bearing Upper Dust seat _ Bearing Lower _ Dust cover __ Front fork _ Side caps _ Shock absorber _ Side cap stay _8 Nipple _ _ Cable clamp 5 13 ...

Page 151: ...n eBolts Handlebar cover upper _ 5 Remove eSpeedometer cable eAudio pilot From upper handlebar cover _ 6 Disconnect Speedometer lead connecters 7 Remove oUpper handlebar cover _ _ _ 8 Remove _ Diode _ oFlasher relay unit _ 9 Disconnect Front brake cable _ From brake lever eHandlebar switch connecters _ __ _ Brake switch connecter Front _ 10 Remove oThrottle cable _ From throttle cable holder _ 5 1...

Page 152: ...nt Cover _ oSide cover Left and right _2 _ _ Footrest board _ Front trunk Scooter panel Refer to REMOVING THE COVERS AND PANELS section 2 Remove oFront wheel _1_ oBrake cable _ _ eSpeedometer cable 3 Remove oCable damp _ _ with cables 4 Remove oS de caps _ _goks Shock absorber Upper _ Bolts Shock absorber Lower 3_ _Shock absorbers 5q5 ...

Page 153: ... position Left Right 5 Remove _2___ _ Cotter pin _ oBolt _ _1_ _ Washer _ omension arm _ _ oWasher _ 1 I 6 Remove Ring nuts Upper and Lower Use the Ring Nut Wrench YU 012681 or YU 33975 _ oFront fork assembly _ NOTE Support the front fork not to drop the ball bearings 7 Remove Ball race cover _ oBall race Upper _ oBall bearings Upper 22 pcs _ 8 Remove _ oBall bearings Lower 19 pcs J 5 16 ...

Page 154: ... Bend Damage RepLace olnner collar _ Wear Pitting Damage RepLace eLnner busMng _ Wear Pitting Damage RepLace U _ _2_ 3_ Inspect eTension arm _ _2 Crack Bend Damage RepLace _ _5_ _ oLnner collar bushing _ _ Pitting Damage Replace Rubber bushing _ Damage BaH Race and BaH 1 Wash the ball bearings and baLLraces in a s vent_ 2 Inspect oBall bearings _1_ 9 ge _ pl Pittin Dama Re ace Bearin9 races _ Pitt...

Page 155: ...embling the front fork assembly reverse the removal procedure Note the following poits ifl _ Front Fork _ _ _ _ 1 Grease the races and put the balls in it _ Wheel Bearing Grease NOTE Make suretheballs areofthesame size and the quantity iscorrect Upper 22 pcs 3 16 in Lower 19 pcs I 4 in Upper Lower 2 Install oFront fork NOTE Hold the front fork until it is secured Ballrace Upper oBall race cover _ ...

Page 156: ...wer dng nut 1_ completeiy and retighten it to specification Do not over tightening ot ioo 0 too n0 kg 2 2 ftolb oCheck the front fork by turning it lock to lock Jfthere is any binding remove the front fork assembly and inspect the steering boll bear ings and boll races Hold the lower ring nut t _ i and tighten the upper ring nut _ _ using the Ring Nut Wrench YU 33975 _2_o _g 22 ft_lb Shock Absorbe...

Page 157: ... 0 m kg 29 ft lb Nut Compresion arm Front fork 45 Nm 4 5 mokg 32 ftoUb Nut Shock absorber Lower Front fork _ 20 Nm 2 0 mokg 14 ft lb Bolt Shock absorber Upper Front fork 35 Nm 3 5 mokg 25 ftolb NOTE Always use a new cotter pin _ 3 Tighten H oNut Front wheel axle _ _ Nut Front Wheel A le _ 70 Nm 7 0 m okg 50 ftolb 4 Install oCotter pin New _ 5 After assembling the front fork apply the grease from n...

Page 158: ...rake lever free play Refer to CHAPTER 2o FRONT AND REAR BRAKE INSPECTION section REAR SHOCK ABSORBER _ REMOVAL I 1 Remove Front cover Side cover Left 2 Refer to CHAPTER 2 REMOVING THE COVERS AND PANELS section 2 Remove Air cleaner case _1_ Refer to CHAPTER 3 AIR CLEANER CASE section 3 Remove eBok Shock absorberoUpper _ oBolt Shock absorber Lower _ Rear shock absorber _ _ 5 21 ...

Page 159: ...bly Move the spring up and down INSTALLATION When installing the rear shock absorber reverse the removalprocedure Note the following points 1 Apply eLithium base grease To the pivot points ___ 2 Tighten eBolt Shock absorber Upper _ eBolt Shock absorber Lower _ _ 50 Nm 5 0 rn kg 36 ft lb Bolt Shock Absorber Lower _ 50 Nrn 5 0 mokg 36 ft lb 3 Adjust oSpring preload Refer to CHAPTER 2 REAR SHOCK AB S...

Page 160: ...CHAS _1 5 23 ...

Page 161: ...ESISTANCE TEST 6 22 RECTIFIER TEST 6 23 IGNITaON SYSTEM 6 25 TROUBLESHOOTING 6 27 IGNITION SPARK GAP TEST 6 29 IGNITION COIL RESISTANCE TEST 6 29 PICKUP COIL RESISTANCE TEST 6 30 SPARK PLUG INSPECTION 6 30 LIGHTHNG SYSTEM 6 31 LIGHTING TESTS AND CHECKS 6 33 SIGNAL SYSTEM 6 37 TROUBLESHOOTING 6 39 AUDIO PILOT TEST 6 41 SWITCH ES TEST 6 41 ACCESSORY SYSTEM 6 43 MAIN SWITCH ILLUMINATION 6 45 TROUBLES...

Page 162: ...ELEC_ _ CIRCUIT DIAGFIAM ELECTRNCAL C RCUIT DiAG RAM 64 ...

Page 163: ...or light _ Choke unit _ TURN indicator light Right _ Starter relay _ Headlight _ Starter motor _ START switch _ Battery _ Horn _ Oil level switch _ Rectifier Regulator _ Main fuse _ AC magneto generator _ Starting circuit cut off relay _ HORN switch _ Diode unit _ Choke relay _ ront flasher light Right Rear flasher light Right COLOR CODE B Black Br Brown L W Blue White L Blue Ch Chocolate L B Blue...

Page 164: ...at 20 C 68 F _ Main fuse 20Ax 1 Empty position I Secondary winding resistance Battery 236_ 10 at 20 C 68 F 13 2k_ 20 at 20 C 68 F Fuel sender _ Rectifier Regulator Ignitor unit _ idestand switch Rear brake switch _1_Oil level switch Starter Relay Coil Resistance A I 4 10 at 20 C 68 F Red Green Red White Battery B I Capacity 12V 10AH Specific gravity t 280 VoJtage Regulator C l ReguRated Voltage 14...

Page 165: ...ilot _ Flasher relay _ Handlebar switch Left _ Horn _ Choke relay Starting circuit cut off relay _T Starting Circuit Cut off Relay Main swtich Coil Resistance _Main switch illumination 75_ 10 at 20 C 68 F O_ Handlebar switch Right Blue White Red Green Front brake switch 6 4 ...

Page 166: ... 6_5 ...

Page 167: ...ring diagram NOTE For the encirclednumbers and colorcodes see page 6 2 _ Front brake switch _ Main fuse _ Tail Brake light _ Starting circuit cut off relay _ Rear brake switch _ Diode unit _ Main switch _ START switch _ ENGINE STOP switch _ Sidestand switch _ Starter relay _ Starter motor _ Battery 6 6 ...

Page 168: ... o ENGtNE STOP switch eBrake switch e START switch Refer to SW_TCHES TEST page 6q6 Connect the battery positive lead and starter motor lead _ use the heavy duty ium per lead _3 __ o _f the starter motor does not run in spect and repair the starter motor NOTE Make sure that the battery should be fully charged This test shouW be performed within a few seconds to prevent further damage Also there sho...

Page 169: ...the body earth _ use a jumper lead i _ __ If the starter motor does not run Ireplace the starter relay _l l _ __ Connect the Red White lead to the Yellow lead _ on the starting circuit cut off relay coupler _ use a jumper lead If the starter motor does not run replace the starting circuit cut off relay I i f the sta er motor runs re0 acethed o0eun t U Ni 6 8 ...

Page 170: ...ngine Fold sidestand in sidestand switch is ON U Apply either front or rear brake 1 Brake switch is ON NOTE The starting circuit cut off repay prevents the starter from operating when neither of t_ above conditions has been met _ Battery _2_Fuse _ Main switch _ Front brake switch _ Rear brake switch _6_Sidestand switch 8_ ENGINE STOP switch Starter relay _ tarting c_rcuit cut off relay Diode _ STA...

Page 171: ...TER MOTOR _ Bracket _ Brush holder assembly _ Brush _ Brush spring _ O ring _ Housing _ Armature ALIGN MATCH iViARK A MiNiMUM BRUSH LENGTH 5 0 mrn 0 20 in B COMMUTATOR WEAR LliVlIT 22 0 mm 0 87 in MICA UNDERCUT C 0 8 mm 0 031 in 6 10 ...

Page 172: ...ANELS section 2o Remove _Passenger footrest Right _ 3 Remove eSocket bolts Exhaust pipe 11 Flange bolts Muffler eMuffler assembly 3_i 4 Remove Screws Air shroud 1 _ eScrews Faro_case cover _Fancase cover _3_ with air shroud _ 5 Remove eCooling fan 1 _Starter motor lead Positive _ eStarter motor lead Negative _ eStarter motor assembly _4_ t 6 11 ...

Page 173: ... Replace _ Commutator Wear Limit _ 1 _ 22 0 mm 0 87 in 3 Measure oMica undercut I between commutator segments Out of specification _Scrape mica to proper value Use a hacksaw blade that is ground to fit _ Mica Undercut _ 0 8 mm 0 031 in NOTE The mica insulation of the commutator must be undercut to ensure proper operation of the com mutator 4 Measure eArmature coil resistance insulation continuity ...

Page 174: ...or brushes Damage _ Replace 7 Measure Brush length KL_ Out of specification _ Replace Brush Length _ 5 0 mm 0 20 in 8 Inspect eBrush springs Compare with new spring Wear Damage _ Replace Installation 1_ Install eStarter motor NOTE Align the match marks _ on the brackets with the match marks _ on the housing 643 ...

Page 175: ... rear brake and sidestand to up ePush the starter switch and check to see if the starter relay clicks Starter relay clicking Starter relay OK Starter relay not clicking_Measure coil resistance 2 Measure L W R G 1 oStarter relay resistance Out of specification Replace Starter relay resistance measurement steps oDisconnect the 2 pin connector _ from starter relay _ oConnect the Pocket Tester YU 0311...

Page 176: ...Use the Pocket Tester _ YU o03112 Out of specification _Rep ace I O _ Starti_ Resistance at20o 68OF J Red White _ Yei ow 4 Check eStarting circuit cut off relay contacts Use 12V battery _i_ and the Pocket Tester i 2 YU 3112 Out of specification Replace Battery Connected _ 0__ 1 Battery Disconnected _ co _5 Black _ Red Green Yellow _ Red White DIODE UNiT TEST I_ Remove o Headlight unit Refer to CHA...

Page 177: ... IK x Discontinuity co ScaJe 9 x 1 NOTE The results or should be reversed ac cording to the pocket tester polarity SWITCHES TEST Sidestand Switch 1 Remove eScooter panel Refer to CHAPTER 2 REMOVING THE COVERS AND PANELS section 2 Disconnect o3 pin connector Brown Brown Red and Green Blue 3 Check oSidestand switch contacts Out of specification _Replace switch Sidestand Pocket tester Good position c...

Page 178: ...ke Switch 1 Remove oScooter panel Refer to CHAPTER 2 REMOVING THE COVERS AND PANELS section 2 Disconnect e2 in connector _ Green Yellow Brown 3 Check oRear brake switch contact Out of specification _ Replace switch Brake Tester pedal Depress 0B T_ Free oo 1 _ Brown _ Green Yellow ENGINE STOP switch and START switch 1o RemoVe _Headlight unit _ 2 Refer to CHAPTER HEADUGHT BULB REPLACE MENT section 2...

Page 179: ...connecting point oN Push _ _ x OFF o Free _ X Continuity 0n _ Discontinuity oo _ Blue White Black _ Brown Blue Black Main Switch 1 Remove oScooter panel Refer to CHAPTER 2 REMOVING THE COVERS AND PANELS section 2 Disconnect o6 pin connector _ Green Brown Blue Green Black and Red 3 Check oIVlain switch contacts Out of specification _Replace switch Main switch Pocket tester Good position connecting ...

Page 180: ...ELEC _ CHARGING SYSTEM CHAnGiNG SYSTEM u o 6 19 ...

Page 181: ......

Page 182: ... battery Battery vokage More than 12V Specific gravity 1 280 _Y ES _Start the engine and accelerate to about 2 000 tot Vottage More than 15V g I Replace rectifier with regulatoro Generator Vo tage Less than 14V g check the stator coil resistance_ Stator coil resistance White _White 0 44 _ 15 at 20 C 68 F I 1 Replace the stator coil 6 21 ...

Page 183: ...re oGenerator voltage Out of specification _ Check battery stator coil and rectifier regulator 1 Generator Voltage 14 15V _ iiii z i ii i ii i i i i Never disconnect the wires from the battery while the generator is operating otherwise the voltage across the generator terminals will increase and damage the semicon ductors STATOR COnL RESISTANCE TEST 1 Open the seat and remove the front cover 2 Dis...

Page 184: ...Side cover Left Refer to CHAPTER 2o REMOVING THE COVERS AND PANELS section 2 Disconnect o6 pin connector 1_ White White White Red Brown and Black _ Rectifier Regulator 3 Check r B_ Defective element _ Replace rectifier o _ C2 _ White B Brown _ _ White C Rectifier D D_ID 3 White o _ i Bl_0k tester J D4 D5 D6 point f L _ O Continuity OI x Discontinuity _ NOTE The results o 0r should beieversed ac co...

Page 185: ...CHARGING SYSTEM ELEC _ Do not overcharge rectifier or damage may result Avoid eA short circuit olnverting and battery Ueads oDirect connection of rectifier to battery 6 24 ...

Page 186: ...ELECI _ mGN_TION SYSTEM IGNIT_ON SYSTEM _ii_ i_ 6_25 ...

Page 187: ...diagram shows ignition circuit in wiring diagram NOTE For the encircled numbers and color codes see page 6 2 _ Main switch _ ENGINE STOP switch _ Sidestand switch _ Ignition coil _ Spark plug _ Ignitor unit _ Pickup coil _ Battery _ Main fuse 6 26 ...

Page 188: ...ctro Tester YU 33260 _ 3 Start the engine and increase the spark gap until misfire occurs Test at various r min be O G tween idle and red line _ Spark p_ug lead Spark p_ug Do not run the engine in neutral above 6 000 r min for more than 1 or 2 seconds _ Minimum Spark Gap 6 mm 0 24 in Faulty ignition system operation at the minimum spark gap or smaller _ Follow the troubleshoot ing chart until the ...

Page 189: ...up Check for vol __ 1Check the main fuse and wiring circuit tage 12V on the Red White lead at the ig _ nitor unit and ignition coil Measure the pickup coil for resistance NO 4 Replace the pickup coil assembly Pickup coil 114 5f_4 15 at 20 C 68 F l WhiteRed WhiteBlack Check the ignition coil for resistance primary and secondary Primary 2 7f_ 10 at 20 C 68 F Secondary 13 2 kf_ 20 at 20 C 68 F 2 7_ 1...

Page 190: ...fully charged 12V battery _i 4_Turn the spark plug gap adiuster and increase the gap to the maximum limit unless misfire occurs first _ Minimum Spark Gap 1 A_ mGNiTION COiL RESISTANCE TEST 1 Connect _ Pocket Tester YU 03112 2 7_ _ 2 Measure __ Primary coil resistance _ Secondary coil resistance _ x _2 Out of specification ReplaCe o o tance I 13 2 k _ 20 at 20 C 68 F 13 2 k_2 x 1 k_ o_ o C_ 6_29 ...

Page 191: ...VERS AND PANELS section 2 Disconnect 2 pin connecter White Red White Black 3 Measure oPickup coil resistance Use a Pocket Tester YU 03112 Out of specification_ Replace _ Pickup Coil Resistance 114 5_3 15 at 20 C 68 F White Red White B0ack SPARK PLUG iNSPECTiON Refer to CHAPTER 2 SPARK PLUG INSPEC TION section 6 30 ...

Page 192: ......

Page 193: ...hows lighting circuit in wiring diagram NOTE For the encircled numbers and color codes see page 6 2 _ LIGHTS Dimmer switch _ Tail Brake light _ Main switch _ Battery _ Main fuse _ Meter illumination _ HIGH BEAM indicator light Headlight _ START switch C 6 32 ...

Page 194: ...f the above fail to operate proceed further Low battery voltage indicates either a faulty battery low battery fluid level or a defective charging system Also check fuse condition Replace any open fuses There are individual fuses for various cir cuits see complete Circuit Diagram NOTE Check each bulb first before performing the fol lowing check 6 33 ...

Page 195: ... n Br wn lead fr m _i Check main switch and batterY switch ON position i q NO VOLTAGE Measurevoltage 12V on Blue Black lead j_l_ Check START switch from START switch Free OFF position _OK NO Measurevoltage 12V on Yellow Hi po _1 1 sition and Green Lo position leads from Check LIGHTS Dimmer switch LIGHTS Dimmer switch _OK Poor ground or poor connection of headlight wiring 6 34 ...

Page 196: ...shooting COME ON Check main fuse Replace Check taillight bulbs Replace _OK NO t Measure voltage 12V on Brown lead from Check main switch and battery main switch ON position Poor ground or poor connection of taillight wiring 6 35 i ...

Page 197: ...LJGHTINGSYSTEM EL_ _ 1 MEMO 6 36 ...

Page 198: ...I ELEC _ I SIGNAL SYSTEM SIGNAL SYSTEM 6 37 ...

Page 199: ...nd colorcodes see page 6 2 _ Front brake switch Tail Brake light Rear brake switch Main switch _ Battery Main fuse Front flasher light Right Rear flasher light Right _ Front flasher light Left _ Rear flasher light Left _ TURN switch _ Audio pilot _ Flasher relay _ TURN indicator light Left _ TURN indicator light Right 8 6 38 ...

Page 200: ..._OK N0 Measure voltage 12V on Brown lead from Check main switch and battery main switch ON position _OK NO VOLTAGE Measure voltage 12V on Brown Whke lead _ Replace flasher relay from flasher relay v _0 K DOES NOT toTUrn TURN switcht L r R andcheCksee if the flasher lights come on _ Replace TURN switch I COMES ON Poor ground or poor connection of flasher light wiring I11 6 39 ...

Page 201: ... J_OK NO 1 Measure voltage 12V on Brown lead from Check main switch and battery main switch ON position Apply the front and or rear brake Brake switch is ON J_ NO Measure voltage 112V on GreenYellow _1 Replace front and or rear brake leads from front and or rear brake switches _1 switches Poor ground or poor connection of brake light wiring 6 40 ...

Page 202: ...io pilot resistance Use the Pocket Tester YU 03112 Out of specification _Reptace o0 o oo tooo PHot 40ft 10 at 20 C 68 F SWITCHES TEST TURN Switch Switches may be checked for continuity with a Pocket Tester YU 03112 on the Ohm x 1 po sition Lead color Switch position D_ g B_r W Ch N k _ Front and Rear Brake Switch Refer to SWITCHES TEST page 6_16 6 41 ...

Page 203: ......

Page 204: ... ELEC _ I ACCESSORY SYSTEM ACCESSORY SYSTEM 643 ...

Page 205: ...ssory circuit in wiring diagram NOTE For the encircled numbers and color codes see page 6 2 _ Main switch illumination _ Main switch _ Battery _ Oil level switch _ Main fuse _ Diode unit _ Fuel sender _ Fuel meter _ OIL LEVEL indicator light _ Horn _ HORN switch 6 44 ...

Page 206: ... ILLUM_NATmON DOES NOT COME ON _ FAULTY Check main fuse Replace _K Turn main switch to OFF and or LOCK I VOLTAGE Measure voltage 12V on BlueGreen lead Check main switch and battery from main switch _OK Measure voltage 12V on Blue Green lead from HORN switch while pushing the HORN switch Switch is ON NO VOLTAGE Replace HORN switch NO OK VOLTAGE coo o om _ Green White Check condition of GreenWhite l...

Page 207: ...Check main switch and battery _OK Disconnect fuel sender connector and meas IVOLTAGE _Check for an open or poor connection ure voltage 12V on Green lead from wire _lil_lbetween the main switch and fuel harness sender Connect Green lead from wire harness to Ground on frame use a jumper lead _ _ue _eternee0e_ s_n0 r _ _ _ _ _1 _e0ace ue _e_er i _Y_S Replace fuel sender I 6 46 ...

Page 208: ...OME ON FAUkTY _ _OK NO main switch ON position Check main switch and battery Disconnect oil level switch coupler and corn nect Black Red lead _ from diode unit _ to Ground on frame use a jumper lead _ LIGHT DOES NOT COME ON B R LtGHT COMES ON IReptace oil level switch 1 x 6 47 ...

Page 209: ...oupler _ and con nect horn terminal _ at Pink lead side to Ground on frame use a jumper lead _ NOT _ Check condition of Brown lead be tween main switch and horn I IIOK _ I Replace horn SOUNDS Disconnect 4 pin connector at HORN switch and connect Pink lead _ from horn to Ground on frame use a jumper lead NOT SOUND Check condition of Pink lead be tween horn and HORN switch SOUNDS i Replace HORN swit...

Page 210: ...Tester YU 03112 Out of specification _Replace Fuel Sender Resistance FulmPosition _ 20_ 10 at 20 C 68 F Empty Position _ 236_ 10 at 20 C 68 F Black Green OIL LEVEL SW_TCH TEST 1o Drain Engine oil 2 Remove oOit level switch 3 Measure Oil level switch resistance Use the Pocket Tester YU_03t12 Out of specifiCation _ Replace Leve loat_s ao__0a C ___J Black Red Ground Lj 6 49 ...

Page 211: ...esistance range Brown lead Pink lead terminal terminal 1 05_ 10 Rx 1 __o 2 Adjust eVolume Turn the adjuster _ in and out so that the __ volumeismaximumatthemaximumam perage _ _ Horn2 sAMaximumAmperage Battery 12V SWITCHES TEST Switches may be checked for continuity with a Pocket Tester YU 03112 on the Ohm x 1 po sition Main Switch Lead color Switch position L G R Br LOCK O _ O OFF O ON O O HORN Sw...

Page 212: ...LELEC I _ AUTO CHOKE SYSTEM AUTO CHOKE SYSTEM _ i_ _i _ _ _ x 6 51 ...

Page 213: ...ementioned circuit diagram shows auto choke circuit in wiring diagram NOTE For the encircled numbers and color codes see page 6 2 _ Main switch _ Choke unit Battery Main fuse Rectifier Regulator AC magneto generator _ Choke relay 6 52 ...

Page 214: ...ne is warmed up Check the engine asfollows The engine shows a trouble after warmed up Connect batteries to the choke unit directlyq NO The cam in the unit must be activated Refer _ Replace the choke unit assembly to CHOKE UNG TEST section_ NO Connect batteries to the relay unit directly I 1 Check for voltage of the re_ay Refer to _ Replace the choke relay CHOKE UNIT TEST section Check the stator c...

Page 215: ... the Pocket Tester YU 03112 Out of specification_ Replace Choke Unit Resistance 3 0 1 0_ at 25 C 77 F 3 Connect e12V Battery _ 4 Check oCam movement Incorrect movement_ Replace BATTERY IS NOT CONNECTED __ _ WAX IS COLD BATTERY IS CONNECTED WAX IS WARM CHOKE RELAY TEST 1 Remove eScooter panel Refer to REMOVING THE COVERS AND PANELS section 2 Remove eChoke relay unit _ 6 54 ...

Page 216: ...o be ac tivated oSet the tester selector to DC2OV position Measurement of the voltage between the 6VBattery 12VBattery Green Red 3 and the Black _ terminals is should be S2V olf less than 12V replace the choke unit Brown terminaJ STATOR COiL RESISTANCE TEST 1 Measure oStator coil resistance Out of specification Replace E Stator Coil Resistance WhiteoWhite 0 44 _ 15 at 20 C 68 F Refer to STATOR COI...

Page 217: ...PPENDmCE SPECIFICATIONS 7 1 GENERAL SPECIFICATIONS 7 1 MAINTENANCE SPECIFICATIONS 7 4 GENERAL TORQUE SPECIFICATIONS 7 17 DEFINITnON OF UNITS 7 17 LUBRICATION DIAGRAMS 7 18 CABLE ROUTING 7 19 XC2OOT WIRING DHAGRAM ...

Page 218: ...rangement Single Forward Inclined Displacement 200 cm 3 Bore x Stroke 68 0 x 55 0 mm 2 677 x 2 165 in Compression Ratio 9 5 1 Compression Pressure 1 177 kPa 12 0 kg cm z 171 psi Starting System Electric starter Lubrication System Wet Sump Pressure Lubricated Oil Type or Grade Engine Oil Transmission oil 30 40 60 60 F I I i SAE 20W40 type SE motor oil If temperature does not go below 5 C 40 F SAE 1...

Page 219: ......

Page 220: ...ber Coil Spring Oil Damper Wheel Travel Front Wheel Travel 76 mm 2 99 in Rear Wheel Travel 70 mm 2 76 in Electrical Ignition System T C M Generator System A C Magneto Generator Battery Type or Model YB10L Battery Capacity 12V 10AH Headlight Type Bulb Bulb Wattage Quantity Headlight 45W 40W Tail Brake Light 8W 27W Flasher Light 27W x 4 License Light 8W x 2 Meter Light 3o4Wx 3 Indicator Light Wattag...

Page 221: ...der Clearance L 0 025 0 066 mm 0 001 0 003 in R 0 020 0 051 mm 0 0008 0 0020 in Cam Dimensions _ l Intake A 32 37 32 49 mm 1 274 1 279 in Limit 32 33 mm 1 273 in Intake B _ 1 A 25 99 26 01 mm 1 023 1 024 in Intake C 6 38 6 48 mm 0 2512 0 2551 in Exhaust A _ 32 37 32 49 mm 1 274 1 279 in Limit B J_ 32 33 mm 1 273 in Exhaust B 25 99 26 01 mm 1 023 1 024 in Exhaust C 6 38 6 48 mm 0 2512 0 2551 in Roc...

Page 222: ...8 0 2352 in Limit IN 5 945 mm 0 234 in EX 5 920 mm 0 233 in Guide Inside Dia IN 6 000 6 012 mm 0 2362_0 2367 in EX 6 000 _ 6 012 mm 0 2362 0 2367 in Limit IN 6 05 mm 0 238 in EX 6 05 mm 0 238 in Stem to Guide Clearance IN 0 010 _ 0 034 mm 0 0004_0 0013 in EX 0 025 _ 0 049 mm 0 0010 0 0019 in Limit IN 0 08 mm 0 0031 in EX 0 10 mm 0 0039 in Stem Runout Limit 0 01 mm 0 0004 in Valve Seat Width IN 0 9...

Page 223: ...2 0 mm 1 260 in Compression Force Valve Closed IN 16 6 20 4 kg 36 6 45 0 Ib EX 16 6 20 4 kg 36 6 45 0 Ib Tilt Limit IN 2 5 1 6 mm 0 063 in _ EX 2 5 1 6 mm 0 063 in Direction of Winding IN Counterclockwise EX Counterclockwise Piston Piston Size D _ 67 95 68 00 mm 2 675 2 677 in Measuring Point H _l _ _j____ 4 0 mm 0 157 in From bottom line of piston skirt H Piston Clearance 0 02 0 04 mm 0 0008 0 00...

Page 224: ..._ 0_02 0 06 mm 0 0008 0 0024 in Limit _ __ 0 12 mm 0 0047 in Oil Ring Dimensions B x T 2 0 x 2 5 mm 0 0787 x 0 0984 in End Gap installed 0 2_ 0 7 mm 0 0079 0 0276 in Connecting Rod Oil Clearance 0o021 0 045 mm 0 0008_0o0018 in Bearing Color Code 1 Blue 2 Black 3 Brown 4 Green Crankshaft Crank Width A 60 95 _ 61 00 mm 2A00_2 402 in Runout Limit B 0 02 mm 0 0008 in Big End Side Clearance C 0 160_0 2...

Page 225: ...14 3 5 Needle Jet N J 95 Pilot Jet P J 36 Pilot Air Jet P A J _0 8 Pilot Outlet P O q_0 8 Bypass 1 B P 1 _0 8 Bypass 2 B P 2 q_0 8 Bypass 3 B P 3 _0 8 Pilot Screw P S 2 0 turns out Valve Seat V S 02 0 Starter Jet G S G S I 48 G S 2 _0 8 Float Height F H 26 28 mm 1 024 1 103 in Engine Idling Speed 1 250 1 350 r min Vacuum Pressure at Idling Speed Above 170 mm Hg 6 69 in Hg Oil Temperature 55 65 C 9...

Page 226: ...del _ XC200T Lubrication chart Feed Left Journal Scavenge Connecting big end L _ Balancer shaft _ Right Jooinoi I _L_ r L ifter hole Crankshaft Rocker shaft Rocke arm ill Oil pan Oil strainer Crankcase Tightening Sequence 7 9 ...

Page 227: ... M 8 30 3 0 22 Muffler M 8 25 2 5 18 Mission Cover M 5 3 0 3 2 2 Oil Drain Bolt Engine M14 43 4 3 31 Oil Drain Bolt Transmission M 8 18 1 8 13 Crankcase 1 M 6 12 1 2 8 7 Oil Filter Cover M 6 10 1 0 7 2 Oil Filler Case M 6 10 1 0 7 2 Transmission Cover M 6 10 1 0 7 2 Crankcase Cover 2 M 6 10 1 0 7 2 Starter Motor Assembly M 6 7 0 7 5 0 Cooling Fan M 6 7 0 7 5 0 Oil Pump Assembly M 6 7 0 7 5 0 Start...

Page 228: ... 772 2 165 in Optional Spring No Oil Capacity 24 cm3 0 85 Imp oz 0 81 US oz Rear Suspension Shock Absorber Travel 70 mm 2 76 in Spring Free Length 225 5 mm 8 88 in 224 mm 8 82 in Limit 2t5 5 mm 8 48 in Fitting Length 215 5 mm 8 48 in Spring Rate K1 26 16 N mm 2 67 kg mm 149 Ib in K2 43 11 N mm 4A0 kg mm 246 Ib in Stroke KI 0 35 mm 0 1 378 in K2 35 70 mm 1 378 2 756 in Optional Spring No Rear Arm S...

Page 229: ...mm 5 91 in 151 mm 5 94 in Lining Thickness Front Rear 4 mm 0 16 in Limit 2 mm 0 08 in Shoe Spring Free Length Limit Front 36 5 mm 1 44 in Rear 68 0 mm 2 68 in Brake Lever 8 Brake Pedal Brake Lever Free Play Position 10 20 mm 0 4 0 8 in at lever end Brake Pedal Position 57 mm 2 24 in Vertical height below footrest top Brake Pedal Free Play 5 15 mm 0 20 0 60 in 7 12 ...

Page 230: ... Rear Brake Cam Lever M 6 10 Rear Shock Upper M10 50 Rear Shock Lower M12 50 Wheel Hub M 8 30 Side Stand M10 30 Main Stand MI0 30 Rear Stay Front M 8 25 Rear Stay Upper M 8 20 Rear Stay Lower M 8 20 Steering Shaft Ring Nut Lower M25 30 Refer to NOTE 3 Steering Shaft Ring Nut Upper M25 Fuel tank Front Rear NOTE Ring nut lower 1 First tighten the ring nut approximately 50 Nm 5 0 mokg 36 ftolb by usi...

Page 231: ... Coil resistance Color 114 59 15 at 20 C 68 F White Black White Red T C I Unit Model Manufacturer TID11 06 HITACHI Ignition Coil Model Manufacturer CMll 61 HITACHI Primary Winding Resistance 2 79 10 at 20 C 68 F Secondary Winding Resistance 13 2K9 20 at 20 C 68 F Charging System Type A C Magneto Generator A C Generator Model Manufactu rer FL118 05 H ITAC HI Normal Output 14V 15A at 5 000 r min 4O ...

Page 232: ...ength 10 5 mm 0 41 in Limit 5 0 mm 0 20 in Spring Pressure 540 660 g t9 0 23 3 oz Commutator Dia 23 0 mm 0 91 in Wear Limit 22 0 mm 0 87 in Mica Undercut 0 8x 1 8 mm 0 03x0 07 in Starer Switch Model Manufacturer HON DALOCK Amperage Rating 150A Coil Winding Resistance 3 4 _ 10 at 20 C 60 F Horn Type Quantity Plain Type 1 Model M anufactu rer YF12 NIKKO Maximum Amperage 2 5A Flasher Relay Type Conde...

Page 233: ...XC200T Starting Circuit Cut off Relay Model Manufacturer 25G TATEISHI OMRON Coil Winding Resistance 75_ 10 at 20 C 68 F Diode No Circuit Breaker Type Fuse Amperage for Individual Circuit Quantity Main 20A x 1 Reserve 20A 1 7 16 ...

Page 234: ...in a crisscross fashion in progressive stages 19 mm 14 mm 85 8 5 61 until full torque is reached Unless otherwise 22 mm 16 mm 130 13 0 specified torque specifications call for clean dry threads Components should be at room tem_ perature A A Distance across flats B Outside thread diameter DEFmN T ON OF UNmTS Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10z meter Length...

Page 235: ...m shaft Bearing _ Balancer shaft Crankcase 2 _ Nozzle _ Crankshaft Crankcase 1 _ Cylinder head cover _ Oil filter Cylinder head _ Rocker arm shaft _ Bypass valve _ Rocker arm _ Relief valve _ Camshaft _ Oil pump _ Plug _ Oil strainer E _ SCAVENGE 7 18 ...

Page 236: ...APPx 1 cAoLE ooT oo CABLE ROUTING f i i m _ LI __ i i _ _i_ ill _jJ _ 7 19 ...

Page 237: ...k Handlebar switch Right lead _ Audio pilot lead Place the wire harness front brake switch lead _ Speedometer cable and sidestand switch lead through the cut out _ Handlebar switch Left lead section of the inner fender _ Diode unit _ Main switch illumination lead _ Main switch _ Headlight lead _ Front brake cable _ Front flasher light Left lead _ Wire harness _ Front flasher light Right lead _ Sta...

Page 238: ...IAPPX _L__ _ CABLE ROUTING 7_21 ...

Page 239: ...ay lead ignition coil lead _ Starter relay and starter motor positive lead _ Fuse _ Battery positive lead Install the starter motor positive lead with the _ Battery breather hose terminal facing out _ Wire harness _ Rear brake cable Clamp five wires the starter motor positive _ Clamp lead auto choke unit lead AC magneto gener _ Starter motor positive lead ator lead starter motor negative lead and ...

Page 240: ...1c E ooT o _il i_i _ 7 I t 7 23 ...

Page 241: ...or lead Pass the fuel sender lead inside of the seat _ Starter motor positive lead bracket _ Starter motor negative lead Do not pinch the lead _ Fuel sender lead _ Clamp Clamp the wire harness starter relay negative _ Battery negative lead lead and battery negative lead _ Battery _ Ignition coil Fasten the battery negative lead so as to hang _ Spark plug lead downward Fasten the ignition coil nega...

Page 242: ...w I_ i 8 0 B r 0 C Z t I i i i i J s i Y F i _ _ _ _y _ i_ii _i _L_ i y i_ i ii_ii_i _ iiii_ i_i_ii_i _i_ ii _ii_ii_ iiill _i_i_ i_ii_i_il _ i_i_i _i_ii_i i_ i_ _I__ _ _ _ _i_i_ _ _i ...

Page 243: ...d the harness _ Rectifier Regulator _ Ignitor unit Clamp the throttle cable _ Battery breather hose _ Carburetor breather hose Double tape the wire harness brake switch _ Sidestand switch lead and sidestand switch _ Sidestand switch lead _ Front brake switch lead Pass the wire harness inside of the rear brake cable Clamp the wire harness at where the white ta pe is Clamp the battery positive lead ...

Page 244: ...IAPPxl l CABLE ROOT NO 7 27 ...

Page 245: ... lead inside of the engine pro _ Rear brake switch tector without them getting pinched by a rib _ Spark plug _ Ignition coil Pass the right flasher light lead under the _ Battery negative terminal frame bracket _ Battery _ To fuel sender Pass the wire harness under the pin _ Rear brake cable _ Band Clamp _ Fuse _ Battery positive terminal _ Starter relay _ Throttle cable 7 28 ...

Page 246: ...APPX _i_ _ i_ _i __i i_i_ _iii_ _ii 7 29 ...

Page 247: ...RIGHT START SWITCH _ TURN INDICATOR LIGHT RIGHT HIGH BEAM iNDICATOR LIGHT SIDESTAND INDICATOR LIGHT OIL LEVEL INDICATOR LIGHT _ _ TU RN IN DICATO R LIGHT LEFT METER LIGHT CLOCK Fii I FUEL LEVEL F GAUGE E I_ HEADLIGHT m _ ilii _ii ii TURN SWITCH ...

Page 248: ...FRONT BRAKE REAR BRAKE SWITCH SWITCH MAIN SWITCH FUEL SENDER p_ I I I I SID SW m m m i n rn _ F _i _ ___ UNIT AUDIO FLASHER HORN OiL LEVEL RECTIFIER A C MAGNETO PILOT RELAY SWITCH REGULATOR GENERATOR ...

Page 249: ...k ...

Page 250: ...FRONT BRAKE REAR BRAKE SWITCH SWITCH MAIN SWITCH FUEL SENDER p_ I I I I SID SW m m m i ...

Page 251: ...m m m i n rn _ F _i _ ___ UNIT AUDIO FLASHER HORN OiL LEVEL RECTIFIER A C MAGNETO PILOT RELAY SWITCH REGULATOR GENERATOR ...

Page 252: ...G STARTER CIRCUIT RELAY CUT OFF RELAY COLOR CODE 0 Black 0 Black Red _ Chocolate _ Brown _ Brown Red _ Brown White Darkgreen O Green _ Green Blue Green Red _ Green White _ Green Yellow Blue O Sky blue 0 Blue Black Blue Green _ Blue White C White _ White Black _ White Green _ White Red Red _ Pink Yellow Red Green _ Red White _ Orange ...

Page 253: ...k ...

Page 254: ...ESTAND IGNITOR IGNITION iTCH UNIT COIL REAR FLASHER LIGHT RIGHT REAR FLASHER LIGHT LEFT G ...

Page 255: ...LAY CUT OFF RELAY COLOR CODE 0 Black 0 Black Red _ Chocolate _ Brown _ Brown Red _ Brown White Darkgreen O Green _ Green Blue Green Red _ Green White _ Green Yellow Blue O Sky blue 0 Blue Black Blue Green _ Blue White C White _ White Black _ White Green _ White Red Red _ Pink Yellow Red Green _ Red White _ Orange ...

Page 256: ... I I i 1111 i i i i i ii i i i iii iiiii i ii iiiii iiii i i i iiiii i ii iiiii i i iii iiiii iiii iiii i ii ii ii iii iii iiiii ii iiii iii ...

Page 257: ...Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto ON M2H 3B4 ...

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