Yamaha XN125 2000 Service Manual Download

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ENG

4-47

CRANKCASE AND CRANKSHAFT

EAS00416

ASSEMBLING THE CRANKCASE
1. Apply:

• sealant

(onto the crankcase mating surfaces)

Yamaha bond No. 1215

90890-85505

NOTE:
Do not allow any sealant to come into contact
with the oil gallery.

2. Install:

• dowel pins

3. Install:

• crankshaft

4. Install:

• timing chain

5. Install:

• left crankcase

(onto the right crankcase)

NOTE:
Tap lightly on the left crankcase with a soft-face
hammer.

6. Install:

• crankcase bolts

7. Apply:

• engine oil

(onto the crankshaft bearings, conrod and
crank pin)

8. Check:

• crankshaft operation

Rough movement

→

Repair.

• timing chain position

T.R

9 Nm (0.9m•kg)

Summary of Contents for XN125 2000

Page 1: ...XN125 2000 XN150 5MF1 AE2 SERVICE MANUAL ...

Page 2: ...0000 XN125 XN150 SERVICE MANUAL 2000 by MBK Industrie 2nd edition April 2001 All rights reserved Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited ...

Page 3: ...maha and MBK dealers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one manual Therefore anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles Repair and maintenance work attempted by anyone without this knowledge is l...

Page 4: ...tially ENG ENG EASM0025 CYLINDER AND PISTON Removing the cylinder and piston Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD section 1 Cylinder bolt 2 2 Timing chain guide exhaust side 1 3 Cylinder 1 4 Dowel pin 2 5 Cylinder gasket 1 6 Piston pin clip 2 7 Piston pin 1 8 Piston 1 9 Piston ring top 1 10 Piston ring 2nd 1 11 Oil ring 1 For installation reverse the removal pr...

Page 5: ...ls 햻 to 헃 indicate the following 햻 Serviceable with engine mounted 햽 Filling fluid 햾 Lubricant 햿 Special tool 헀 Tightening torque 헁 Wear limit clearance 헂 Engine speed 헃 Electrical data Symbols 헄to쎻 23 intheexplodeddiagramsindicate the types of lubricants and lubrication points 헄 Engine oil 헅 Gear oil 헆 Molybdenum disulfide oil 쎻 21 Wheel bearing grease 쎻 22 Lithium soap base grease 쎻 23 Molybdenu...

Page 6: ...FICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM CARBURETOR CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING 1 2 3 4 6 7 8 9 TRBL SHTG GEN INFO SPEC CHK ADJ ENG CARB ELEC CHAS 5 COOL EAS00010 TABLE OF CONTENTS ...

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

Page 8: ...TRIPMETER READING MODE 1 2 BATTERY VOLTAGE FUEL GAUGE 1 2 THE CLOCK 1 3 AUTO CHOKE SYSTEM 1 3 IMPORTANT INFORMATION 1 4 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 4 REPLACEMENT PARTS 1 4 GASKETS OIL SEALS AND O RINGS 1 4 LOCK WASHERS PLATES AND COTTER PINS 1 5 BEARINGS AND OIL SEALS 1 5 CIRCLIPS 1 5 CHECKING THE CONNECTIONS 1 6 SPECIAL TOOLS 1 7 GEN INFO ...

Page 9: ...OOTER IDENTIFICATION EASM0002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 햲 is stamped into the frame EASM0003 MODEL LABEL The model label 햲 is affixed under the seat This information will be needed to order spare parts 1 1 ZAUM0071 햲 ZAUM0072 햲 ...

Page 10: ...to the following procedure 1 Turn the key to ON 2 Press the TRIP button until the current mode appears in the dispaly CONT continental for kilometer mode and EnGL English for the mile mode 3 Press the TRIP button to switch mode 4 Press the TRIP button for two seconds to confirm the setting NOTE The odometer tripmeter reading mode can be changed any number of times while the odometer reading is bel...

Page 11: ... the second minute digit 8 Press the TRIP button for two seconds to set the clock AUTO CHOKE SYSTEM This system is the parallel connection of the ignitor unit circuit and the thermo switch as shown detecting the engine temperature and facilitates the restarting with the warm engine Circuit diagram Auto choke operation FEATURES Main switch Fuse Battery Thermo switch Auto choke Ignitor unit C P U Ig...

Page 12: ...in trays in the order of disassem bly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS 1 Use only genuine Yamaha and MBK parts for all replacements Use oil and grease recom mended by Yamaha or MBK for all lubrication jobs Other brands may be similar in function and appearance but inferior in qua...

Page 13: ...are visible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appro priate 햳 Oil seal EAS00025 CIRCLIPS 1 Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 햲 make sure the sharp edged corner 햳 is p...

Page 14: ...d disconnect sev eral times 3 Check all connections Loose connection Connect properly NOTE If the pin 햲 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE Make sure all connections are tight 5 Check continuity with the pocket tester Pocket tester 90890 03112 NOTE If there is no continuity clean the terminals Whencheckingthewireharness performsteps 1 to 3 As a quick remed...

Page 15: ...afts Rotor holding tool This tool is used to remove the flywheel magneto Ring nut wrench 햲 Steering nut wrench 햳 These tools are used to loosen and tighten the steering ring nuts Damper rod holder T handle These tools are used for disassembling or assembling the front fork Piston pin puller This tool is used to remove the piston pins Fuel level gauge This tool is used to measure the fuel level in ...

Page 16: ...able for checking the electrical system Engine tachometer This tool is needed for detecting the engine rpm Timing light This tool is needed for detecting ignition timing Valve spring compressor Attachment These tools are used when removing or installing the valve and the valve spring Valve guide remover This tool is used to remove the valve guide 90890 01367 90890 01368 90890 01701 90890 03111 908...

Page 17: ...nition checker This instrument is necessary for checking the ignition system components Yamaha bond No 1215 This sealant bond is used for crankcase mating surface etc Compression gauge This gauge is used to measure the engine compression 90890 04117 90890 04118 90890 06754 90890 85505 90890 03081 Tool No Tool name usage Illustration SPECIAL TOOLS 1 9 ...

Page 18: ...2 SPEC ...

Page 19: ...RICAL 2 10 CONVERSION TABLE 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 13 TIGHTENING TORQUES 2 14 TIGHTENING TORQUES ENGINE 2 14 TIGHTENING TORQUES CHASSIS 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 17 ENGINE 2 17 CHASSIS 2 18 COOLING SYSTEM DIAGRAMS 2 19 LUBRICATION DIAGRAMS 2 21 CABLE ROUTING 2 23 SPEC ...

Page 20: ...eriodic oil change Total amount Final gear case oil Total amount Coolant system Radiator capacity including all routes Coolant reservoir capacity from low to full level Air filter type Fuel Recommended fuel Fuel tank capacity 1 868 mm 740 mm 1 096 mm 777 mm 1 315 mm 105 mm 1 800 mm 123 kg 116 kg Liquid cooled 4 stroke SOHC Forward inclined single cylinder 124 cm3 152 cm3 53 7 x 54 8 mm 59 5 x 54 8...

Page 21: ...e rear Tyre pressure cold Maximum load except motorcycle Loading condition A Front Rear Loading condition B Front Rear Front wheel Wheel type Rim size Rear wheel Wheel type Rim size TK 5DS 1 TK 5KD 1 TEIKEI CR8E NGK 0 5 0 7 mm Dry centrifugal automatic Helical gear 40 15 2 666 Spur gear 44 12 3 666 42 14 3 V belt automatic Centrifugal automatic type Steel tube backbone 26 80 mm Tubeless 120 70 12 ...

Page 22: ...light Position light Brake tail light Front flasher light Rear flasher light Meter light High beam indicator light Turn indicator light Coolant temperature warning light Amperage for fuses Main fuse Radiator fan fuse Single disc brake Right hand operation Drum brake Left hand operation Telescopic fork Unit swing Coil spring oil damper Coil spring oil damper 90 mm 80 mm C D I Flywheel magneto CB7L ...

Page 23: ...to guide clearence IN EX Stem runout limit Valve seat width IN EX A C B A B C Face width Seat width Item Standard Limit MAINTENANCE SPECIFICATIONS XN150 0 03 mm 53 700 53 705 mm 59 500 59 505mm 0 05 mm Chain drive left 30 811 30 911 mm 30 711 mm 25 145 25 245 mm 25 045 mm 5 666 m 30 811 30 911 mm 30 711 mm 25 152 25 252 mm 25 052 mm 5 659 m 0 03 mm 82 RH2005 94 12 000 12 018 mm 12 030mm 11 981 11 ...

Page 24: ...D Automatic centrifugal clutch Clutch shoe thickness Clutch housing inside diameter Weight outside diameter Clutch in revolution Clutch stall revolution V Belt V belt width 41 94 mm 39 84 mm 37 5 mm 45 1 50 9 N 2 5 1 9 mm 0 025 0 035 mm 0 15 mm 53 670 53 687 mm 59 470 59 487 mm 4 5 mm 15 002 15 013 mm 15 045 mm 14 991 15 000 mm 14 975 mm Barrel 0 15 0 25 mm 0 50 mm 0 03 0 07 mm 0 12 mm Taper 0 15 ...

Page 25: ... rotor clearence Radiator Type Width height thickness Radiator cap opening pressure Reservoir tank capacity Thermostatic valve Manufacturer Valve opening temperature Valve full open temperature TK 5DS TK 5KD 116 114 ø1 0 ø1 4 4E31 3 5 4E32 3 5 ø1 30 2 590 38 36 2 1 4 2 3 4 2 4 ø2 00 0 45 5 6 mm 1 600 1 800 rpm Trochoid 0 15 mm 0 15 mm 0 17 mm Cooling fin with electric fan 170 282 29 mm 90 110 kPa ...

Page 26: ...Primary drive gear oil seal Main axle bearing left Main axle bearing right Drive axle bearing left Drive axle bearing right Drive axle oil seal 22 x 32 x 7 19 x 30 x 8 Reinforced 19 x 30 x 8 Double lips 20 x 42 x 12 15 x 32 x 9 17 x 35 x 10 25 x 52 x 15 17 x 40 x 12 25 x 42 x 6 Double lips 15 x 25 x 12 Needle bearing 12 x 37 x 12 17 x 47 x 14 Sphere 22 x 50 x 14 Sphere 32 x 52 x 7 Item Size MAINTE...

Page 27: ...brake Type Disc outside diameter x thickness Pad thickness Master cylinder inside diameter Caliper cylinder outside diameter Brake fluid type Rear drum brake Type Drum inside diameter Shoe thickness Shoe spring free length MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit MAINTENANCE SPECIFICATIONS Ball bearing 15 pcs 4 75 mm 15 pcs 4 75 mm 90 mm 11 N mm 0 90 mm 125 cm3 SAE20 33 mm No 80 mm 2...

Page 28: ...2 9 SPEC Brake lever Brake lever free play front Brake lever free play rear Throttle cable free play Item Standard Limit MAINTENANCE SPECIFICATIONS 10 20 mm 10 20 mm 1 5 3 0 mm ...

Page 29: ...oltage Output Armature coil resistance Brush overall length Brush quantity Spring force Commutator diameter Mica undercut depth Starter relay Model manufacturer Amperage rating Coil winding resistance MAINTENANCE SPECIFICATIONS ELECTRICAL MAINTENANCE SPECIFICATIONS Item Standard Limit 10 at 1 700 rpm 32 at 5 000 rpm Digital 248 372 Ω at 20 C white red white blue 720 1080 Ω at 20 C green white brow...

Page 30: ...ay Flasher frequency Fuel gauge Model manufacturer Sender unit resistance full empty Circuit breaker Main Radiagtor fan fuse YF 12 NIKKO 3 A 80 160 cycle min 25 33 06 MAXIMA 4 10 Ω 90 100 Ω 20 A x 1 pcs 7 5 A x 1 pcs MAINTENANCE SPECIFICATIONS Item Standard Limit ...

Page 31: ... in cc cm3 0 03527 oz IMP liq Volume Capacity cc cm3 0 06102 cu in L liter 0 8799 qt IMP liq L liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb in2 Centigrade C 9 5 32 Fahrenheit F CONVERSION TABLE AS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLI...

Page 32: ...n multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature A Width across flats B Thread diameter B A A B General tightening nut bolt torques Nm m kg 10 mm 6 mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 mm 30 3 0 17 m...

Page 33: ...e drain plug M35 1 32 3 2 Inlet manifold on cylinder head Bolt M6 2 10 1 0 Air filter cover Bolt M6 8 6 5 0 65 Exhaust pipe stud bolt on cylinder Nut M6 2 11 1 1 Muffler on bracket Bolt M8 2 27 2 7 Muffler bracket on crankcase Bolt M8 2 27 2 7 Muffler protector Bolt M6 2 4 5 0 45 Crankcase left Bolt M6 8 9 0 9 Cover crankcase 1 Bolt M6 11 10 1 0 Cover crankcase 2 Bolt M6 6 10 1 0 Cover oil pump Bo...

Page 34: ...mo unit Pt 1 8 1 75 7 5 Coolant drain bolt on cylinder Bolt M6 1 8 0 8 Starter motor Bolt M6 2 65 6 5 Rotor Nut M12 1 70 7 0 M16 1 225 22 5 M16 1 225 22 5 Stator Bolt M6 3 70 7 0 Item Fastener Thread size Q ty Tightening torque Nm m kg Remarks TIGHTENING TORQUES ...

Page 35: ...6 2 8 0 8 Carrier with frame Bolt M8 1 19 1 9 Carrier with reinforcement tail Bolt M8 2 19 1 9 Footrest board with frame Bolt M6 4 4 0 4 Mud guard with frame Bolt M6 2 7 0 7 Fender on front fork Bolt M6 3 4 0 4 Cover handle with handle Bolt M5 2 4 5 0 45 Mainstand Nut M10 2 42 4 2 Rear footrest Nut M8 2 14 1 4 Front wheel axle Nut M12 1 70 7 0 Rear wheel axle Nut M14 1 104 10 4 Rear brake cam leve...

Page 36: ... and ring groove Camshaft cam profile Valve stem IN EX Valve stem end IN EX Rocker shaft Valve rocker arm inner surface Shaft Shaft Oil pump assembly Gasket Oil pump assembly Holder Idle gear 1 thrust surfaces Shaft 1 Idle gear 2 thrust surfaces Idle gear 2 inner surface Main axle thrust surfaces Crankcase mating surfaces Yamaha bond No 1215 Crankcase breather plug Stator grommet Yamaha bond No 12...

Page 37: ...l lips left right Steering head pipe bearing upper lower Tube guide throttle grip inner surface Brake cable brake lever Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft Brake cam pivot shaft and cam surface ...

Page 38: ...2 19 SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS Radiator cap Radiator Radiator fan Thermo switch Coolant tank Water pump Cylinder Inlet manifold A A Pass the hose under inlet manifold ...

Page 39: ...2 20 SPEC COOLING SYSTEM DIAGRAMS EAS00033 bis COOLING SYSTEM DIAGRAMS Radiator Radiator fan Radiator cap Coolant tank Water pump Thermostat A A Pass the hose between radiator and radiator filler hose ...

Page 40: ...2 21 SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1Lubrication of the cylinder head Cylinder head Cylinder Crankcase 2Lubrication of the crankshaft Crankshaft 2 1 ...

Page 41: ...ION DIAGRAMS 1Oil flow Cylinder head Cylinder Oil pump 2Lubrication table A Oil pressure flow B Oil return flow LUBRICATION DIAGRAMS Rocker arm Camshaft Cylinder head Oil pump Oil strainer Crankcase Crankshaft Connecting rod A B 1 2 ...

Page 42: ... adjuster Radiator Fan Headlight and front flasher connector Front fork assembly Wire harness Horn Horn wire Rear brake cable Throttle cable Band switch AMake the wire harness getting out here BPlace the speedometer wire as shown CPass the thermo switch lead between the hoses CABLE ROUTING FA FA A A A A A B 5 10 mm C ...

Page 43: ...embly Footrest board Starter relay Battery ground Wire harness Seat lock assembly Fuel tank Wire lead Mud guard Fuel cock APlace the wire as shown BPlace the sidestand wire as shown option C Apply grease on stater motor connector terminal 1 6 A A A B B C C A B D D D D C C B B A 110 mm 5 10 mm 5 10 mm C ...

Page 44: ...t Seat lock cable Throttle cable Battery Starter relay Frame Fuses box Relay Sender Fuel pipe 21Engine air breather 22 Fuel cock 23 Seat lock assembly AConnection for anti thelf option BPlace the Starter motor ground as shown CPass the carburetor breather hose between air duct and air filter case A B C 10 19 23 22 20 21 20 13 18 8 7 6 5 17 16 13 12 14 15 11 9 3 1 2 3 4 CABLE ROUTING ...

Page 45: ... D view D 1 5 3 mm 30 2 3 mm A A A B Right handlebar switches Inner handlebar cover Left handlebar switches Rear brake lever Front handlebar cover Master cylinder Front brake lever AGlue the handlebar grip BInstall the handlebar switch as shown ...

Page 46: ... cylinder Inner handlebar cover Speedometer assembly Rear brake cable Throttle cable Front brake hose Wire harness Handlebar Speedometer coupler Front handlebar cover APasswiresbehindtheturnsignalrelaybracket BClip all wires and cables all together CInstall the wire harness behind the turn signal relay bracket ...

Page 47: ...3 CHK ADJ ...

Page 48: ...E OIL PRESSURE 3 17 CLEANING THE AIR FILTER ELEMENT 3 18 CLEANING THE V BELT CASE AIR FILTER ELEMENT 3 18 CHECKING THE FUEL AND VACUUM HOSES 3 19 EXHAUST SYSTEM INSPECTION 3 19 CHECKING THE COOLANT LEVEL 3 20 CHANGING THE COOLANT 3 21 INSPECTING THE COOLANT SYSTEM 3 24 CHASSIS 3 25 CHECKING THE FRONT BRAKE LEVER FREE PLAY 3 25 ADJUSTING THE REAR BRAKE 3 25 CHECKING THE BRAKE FLUID LEVEL 3 26 CHECK...

Page 49: ...NG THE FUSES 3 40 REPLACING THE HEADLIGHT BULBS AND THE FRONT TURN SIGNAL LIGHT BULBS 3 41 REPLACING THE REAR TURN SIGNAL LIGHT BULBS 3 42 REPLACING THE TAIL BRAKE LIGHT BULBS 3 43 ADJUSTING THE HEADLIGHT BEAMS 3 44 ADJUSTING THE DIGITAL CLOCK 3 44 CHK ADJ ...

Page 50: ...ke disc 8 Rear brake drum 9 Brake hose 10 Wheels 11 Tires 12 Wheel bearings 13 Steering bearings 14 Chassis fasteners 15 Centerstand CHECK MAINTENANCE AND LUBRICATION Check fuel hoses and vacuum hose for cracks or damage Check condition Clean regap Replace Check valve clearance Adjust Clean Replace Clean Check electrolyte level and specific gravity Make sure that the breather hose is properly rout...

Page 51: ...lt 24 Moving parts and cables 25 Light signals and switches Check operation and for oil leakage Check operation and shock absorber for oil leakage Check engine idling speed and starter operation Change Clean Check vehicle for oil leakage Change Check coolant level and vehicle for coolant leakage Change Check wear and damage Replace Lubricate Check operation Adjust headlight beam 앀 앀 앀 앀 앀 앀 앀 앀 앀 ...

Page 52: ...t axle 1 Seat 1 Gasket 1 II Unplug 3 Fuel tank overflow pipe 1 III Remove 4 Rear carrier 1 IV Disconnect 5 Taillight coupler 1 6 Rear flasher light left and right 1 NOTE Open the seat to remove it EASM0005 COVER AND PANEL SIDE COVERS AND SEAT Order Job Part Q ty Remarks FWD 1 2 3 6 6 7 8 5 4 T R 7 Nm 0 7 m kg T R 7 Nm 0 7 m kg T R 18 5 Nm 1 85 m kg T R 8 Nm 0 8 m kg ...

Page 53: ...NEL V Remove 7 Side cover right 1 8 Side cover left 1 For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 1 2 3 6 6 7 8 5 4 T R 7 Nm 0 7 m kg T R 7 Nm 0 7 m kg T R 18 5 Nm 1 85 m kg T R 8 Nm 0 8 m kg ...

Page 54: ... cover Remove 1 Coolant tank cover 1 2 Main switch cap 1 3 Helmet holder 1 II Untight 4 Front cover 1 III Disconnect 5 Headlight lead 1 IV Remove 6 Front cover Radiator panel 1 1 7 Inner panel 1 For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 1 2 3 4 5 6 7 T R 7 Nm 0 7 m kg T R 7 Nm 0 7 m kg T R T R 7 Nm 0 7 m kg T R 7 Nm 0 7 m kg 7 Nm 0 7 m kg ...

Page 55: ...n Inner panel 1 Refer to FRONT COVER INNER PANEL AND INNER FRONT COVER section II Remove 1 Footrest 2 1 washer 1 spring washer 1 washer 2 Battery 1 3 Fuses box 4 Starter relay 1 5 Under cover 1 6 Side under cover footrest board 1 1 assembly For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 1 1 2 3 4 5 6 T R 13 5 Nm 1 35 m kg T R 7 Nm 0 7 m kg T R 4 Nm 0 4 m kg T R 7 Nm...

Page 56: ...ove the parts in the order listed I Remove 1 Front handlebar cover 1 II Disconnect 2 Speedometer assy lead III Remove 3 Inner handlebar cover 1 For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 1 2 3 T R T R 4 5 Nm 0 45 m kg 4 5 Nm 0 45 m kg T R 7 Nm 0 7 m kg ...

Page 57: ...IDE COVERS AND SEAT sec tion Spark plug Plug on magneto cover Valve cover inlet Valve cover exhaust 2 Measure valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 10 0 14 mm Exhaust valve 0 16 0 20 mm 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sionstroke alignthemark a ontheg...

Page 58: ... the adjusting screw and the valve tip c Turn the adjusting screw in or out until the specified valve clearance is obtained Turning in Valve clearance is decreased Turning out Valve clearance is increased Valve adjusting tool 90890 01311 Hold the adjusting screw to prevent it from moving and tighten the locknut to specification Locknut 6 5 Nm 0 65 m kg d Measure the valve clearance again e Iftheva...

Page 59: ... 2 1 4 2 3 4 XN 150 2 4 c Turn the throttle stop screw in or out until the specified engine idling speed is obtained 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 Turning in Engine idling speed is increased Turning out Engine idling speed is decreased 5 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY Throttle cable free play at the flange of the throttl...

Page 60: ...free play is decreased WARNING After adjusting the throttle cable free play start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 ADJUSTING THE THROTTLE CABLE FREE PLAY CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1 Disconnect spark plug cap 2 Re...

Page 61: ...ING THE IGNITION TIMING 4 Check electrodes Damage wear Replace the spark plug insulator Abnormal color Replace the spark plug Normal color is medium to light tan ZAUM0037 EAS00061 CHECKING THE IGNITION TIMING NOTE Prior to checking the ignition timing check the wiring connections of the entire ignition system Make sure all connections are tight and free of corrosion 1 Attach timing light engine ta...

Page 62: ... 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 CHECKING THE IGNITION TIMING TRANSMISSION OIL REPLACEMENT TRANSMISSION OIL REPLACEMENT NOTE Make sure the scooter is upright when replacing the oil 1 Stand the scooter on a level surface 2 Start the engine for several minutes to warm it up and then stop 3 Place an oil pan under the crankcase 4 Remove oil filler cap drain bolt Drain the oil 5 Tighten drain bolt 6 Fill crankcase...

Page 63: ... plug use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder 5 Install compression gauge Compression gauge 90890 03081 6 Measure compression pressure Out of specification Refer to steps c and d Compression pressure at sea level Minimum 1 120 kPa 11 20 kg cm2 Standard 1 400 kPa 14 00 kg cm2 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔...

Page 64: ...gasket or without oil piston possibly defective Repair 7 Install spark plug 8 Connect spark plug cap EAS00070 CHECKING THE ENGINE OIL LEVEL 1 Stand the scooter on a level surface NOTE Place the scooter on a suitable stand Make sure the scooter is upright 2 Start the engine warm it up for several minu tes and then turn it off NOTE Before checking the engine oil level wait a few minutes until the oi...

Page 65: ... LEVEL CHANGING THE ENGINE OIL ZAUM0040 ZAUM0040 T R 32 Nm 3 2m kg T R 32 Nm 3 2m kg 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 Non friction modified CAUTION Do not allow foreign materials to enter the crankcase NOTE Before checking the engine oil level wait a few minutes until the oil has se...

Page 66: ...ply at high speeds more than specified when checking the pressure NOTE Wipe any spilled oil off the engine 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 CHECKING THE ENGINE OIL MEASURING THE ENGINE OIL PRESSURE 7 Reset engine oil warning circuit 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Press the TRIP button while turning the key to ON b Release the TRIP button and oi...

Page 67: ...R ELEMENT ZAUM0048 ZAUM0050 EAS00086 CLEANING THE AIR FILTER ELEMENT 1 Remove air filter case cover 2 Clean air filter element Apply compressed air to the outer surface of the air filter element 3 Check air filter element Damage Replace 4 Install air filter element air filter case cover CAUTION Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear o...

Page 68: ...er Loose Damage Tighten Replace CHECKING THE FUEL AND VACUUM HOSES EXHAUST SYSTEM INSPECTION EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses 1 Remove Seat Box Referto SIDECOVERSANDSEAT section 2 Check vacuum hose fuel hose Cracks damage Replace Loose connection Connect properly 3 Install Box Seat Referto SIDECOVERSANDSEAT section T R ...

Page 69: ...olant to the proper level CAUTION 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 concen tration of the coolant Use only distilled water However if distilled water is not available soft water may be used 4 Start the engine warm it up for several minu tes and then turn it off 5 Check coola...

Page 70: ...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 counterclockwise to remove The following procedure a...

Page 71: ...ining corrosion inhibitors for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Total amount 1 1 L Coolant reservoir capacity 0 35 L Handling notes for coolant Coolant is potentially harmful and should be handled with special care CHANGING THE COOLANT T R 10 Nm 1 0m kg T R 10 Nm 1 0m kg WARNING If coolant splashes in your eyes thoroughly wash them with water and consult a doctor If cool...

Page 72: ...them with water Do not mix different types of antifreeze 11 Install radiator cap 12 Fill coolant reservoir with the recommended coolant to the maxi mum level mark 13 Install coolant reservoir cap 14 Start the engine warm it up for several minutes and then stop it 15 Check coolant level Referto CHECKINGTHECOOLANTLEVEL section NOTE Before checking the coolant level wait a few minutes until the coola...

Page 73: ...0015 INSPECTING THE COOLANT SYSTEM 1 Inspect Radiator Filler hose radiator Outlet hose radiator Pipe Outlet hose radiator Cracks Damage Replace Refer to COOLING SYSTEM section in chapter 5 INSPECTING THE COOLANT SYSTEM ...

Page 74: ...ly reduce braking performance and could result in loss of control and possibly an accident Therefore check and if necessary bleed the brake system EAS00114 ADJUSTING THE REAR BRAKE 1 Check brake lever free play a Out of specification Adjust Brake lever free play 10 20 mm 2 Adjust brake lever free play Handlebar side Rear wheel side 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Turn t...

Page 75: ...ont brake WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the reservoir Water wil...

Page 76: ...he brake shoes as a set Referto REARWHEELANDBRAKE section in chapter 7 CHECKING THE BRAKE PADS CHECKING THE BRAKE SHOES CHECKING THE BRAKE HOSES ZAUM0058 ZAUM0059 A EAS00131 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check brake hose Cracks damage wear Replace 2 Check brake hose clamp Loose Tighten the clamp bolt 3 Hold the motorcycle...

Page 77: ...be necessary to let thebrakefluidsettleforafewhours Repeatthe bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed hydraulic brake system 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the brake master cylinder reservoir diaphragm c Connect a clear plastic hose tightl...

Page 78: ... 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 BLEEDING THE HYDRAULIC BRAKE SYSTEM CHECKING AND ADJUSTING THE STEERING HEAD EAS00148 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the scooter on a level surface WARNING 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 front wheel is elevated 2 Check steering head Grasp the bottom of...

Page 79: ... lower ring nut Lower ring nut final tightening torque 22 Nm 2 2 m kg d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD section in chapter 7 e Install the rubber washer f Install the centre ring nut g Finger tighten the centre ring ...

Page 80: ...ter on a level surface WARNING Securely support the scooter so that there is no danger of it falling over 2 Check inner tube Damage scratches Replace oil seal Oil leakage Replace 3 Hold the scooter upright and apply the front brake 4 Check front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK secti...

Page 81: ...re The tyre pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded scooter could cause tyre damage an accident or an injury NEVER OVERLOAD THE SCOOTER INSPECTING THE REAR SHOCK ABSORBER CHECKING THE TYRES Basic weight with oil and 123 kg a full fuel tank Maximum load 187 ...

Page 82: ... as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recommended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement Tube wheel Tube tyre only Tubeless wheel Tube or tubeless tyre After extensive tests the tyres listed below have been ap...

Page 83: ...een slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done After a tyre has been repaired or replaced be sure to tighten the tyre air valve stem locknut to specification NOTE For tyres with a direction of rotation mark Install the tyre with the mark pointing in the direction of wheel rotation Align the mark with the valve installation p...

Page 84: ... procedure applies to all of the cable sheaths and cables WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its movement Replace damaged cable sheaths and cables as soon as possible 1 Check cable sheath Damage Replace 2 Check cable operation Rough movement Lubricate Recommended lubricant Engine oil or a suitable cable lubricant NOTE Hold the cable end upright and pour...

Page 85: ...al moving parts of the levers and pedals Recommended lubricant Engine oil EAS00172 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Engine oil LUBRICATING THE LEVERS AND PEDALS LUBRICATING THE CENTERSTAND ZAUM0061 ZAUM0062 ...

Page 86: ...ies KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Ge...

Page 87: ...lways charge a new battery before using it Do not use a high rate battery charger They force a high amperage current into the battery quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the scooter If charging has to b...

Page 88: ...cells occurs as indicated by the battery plates turning white or material accumulating in the bottom of the battery cell specific gravity readings after a long slow charge indicate that one battery cell s charge is lower than the rest warpage or buckling of the battery plates or insulators is evident 7 Check battery breather hose and battery vent Obstruction Clean Damage Replace 8 Install battery ...

Page 89: ...e pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω x 1 Pocket tester 90890 03112 b If the pocket tester indicates replace the fuse 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 11 Connect battery leads to the battery terminals CAUTION First connect the positive battery lead and then the negative battery lead 12 Lubricate battery terminals Reco...

Page 90: ...y cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Battery cover Refer to SIDE COVERS AND SEAT sec tion EAS00183 REPLACING THE HEADLIGHT BULBS AND THE FRONT TURN SIGNAL LIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Remove Front cover Refer to FRONT COVER INNER PANEL AND FR...

Page 91: ...EAR TURN SIGNAL LIGHT BULBS EAS00183 REPLACING THE REAR TURN SIGNAL LIGHT BULBS The following procedure applies to both of the turn signal light bulbs 1 Remove Turn signal light lens 2 Remove Turn signal bulb push and turn it counterclockwise WARNING Since the turn signal light bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 3 Install Turn...

Page 92: ... products and your hands away from the bulb until it has cooled down 3 Install Tail brake light bulb push and turn it clockwise until it stops CAUTION Avoid touching the glass part of the tail brake 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 ...

Page 93: ... 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Turn the adjusting screw in or out Turning in Headlight beam is raised Turning out Headlight beam is lowered 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 EASM0019 ADJUSTING THE DIGITAL CLOCK To adjuste the digital clock refer to FEATURES section in chapter 1 ADJUSTING THE HEADLIGHT BEAMS ADJUSTING THE DIGITAL CLOCK ...

Page 94: ...4 ENG ...

Page 95: ... COVERS AND CAMSHAFT SPROCKET COVER 4 8 INSTALLING THE CAMSHAFT AND ROCKER ARMS 4 8 CYLINDER HEAD 4 10 REMOVING THE CYLINDER HEAD 4 12 CHECKING THE CYLINDER HEAD 4 12 INSTALLING THE CYLINDER HEAD 4 13 VALVES AND VALVE SPRINGS 4 14 REMOVING THE VALVES 4 15 CHECKING THE VALVES AND VALVE GUIDES 4 16 CHECKING THE VALVE SEATS 4 17 CHECKING THE VALVE SPRINGS 4 19 INSTALLING THE VALVES 4 20 CYLINDER AND ...

Page 96: ...SSEMBLING THE PRIMARY SHEAVE 4 34 INSTALLING THE SECONDARY SHEAVE 4 35 STARTER CLUTCH AND GENERATOR 4 37 MAGNETO COVER AND STATOR COIL 4 37 STARTER CLUTH 4 38 CHECKING THE STARTER CLUTCH 4 39 INSTALLING THE GENERATOR 4 39 OIL PUMP 4 40 CHECKING THE OIL PUMP 4 41 CRANKCASE AND CRANKSHAFT 4 42 DISASSEMBLING THE CRANKCASE 4 44 REMOVING THE CRANKSHAFT ASSEMBLY 4 44 CHECKING THE CRANKSHAFT AND CONNECTI...

Page 97: ... Under cover UNDER COVER section in chapter 3 Carburetor Refer to CARBURETOR section in chapter 6 Drain coolant Refer to CHANGING THE COOLANT section in chapter 3 I Remove 1 Spark plug cap 1 2 Thermo unit lead 1 3 Startor coil Pick up coil lead 1 1 4 Starting motor lead 1 EASM0020 bis OVERHAULING THE ENGINE ENGINE WIRING HARNESS CABLE Order Job Part Q ty Remarks FWD 1 2 3 4 5 6 7 8 9 10 Nm 1 0 m k...

Page 98: ...6 Adjuster 1 7 Rear brake cable 1 8 Rear brake cable pin 1 9 Rear brake cable compression spring 1 10 Cable holder 1 For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 1 2 3 4 5 6 7 8 9 10 Nm 1 0 m kg T R ...

Page 99: ...1 2 Pump inlet hose 1 3 Cylinder head outlet hose 1 4 Air filter case assembly 1 5 Rear shock absorber bolt lower 1 6 Self locknut Plane washer 1 1 7 Engine mounting bolt 1 8 Engine 1 For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 2 3 4 8 5 6 7 1 T R 43 Nm 4 3 m kg T R 17 5 Nm 1 75 m kg Place the scooter on a suitable stand so that teh rear wheel is elevated CAUTION...

Page 100: ...take 1 Slide hammer bolt 90890 01083 4 Rocker arm shaft exhaust 1 Weight 90890 01084 5 Camshaft retaining plate 1 6 Camshaft 1 7 Rocker arms intake and exhaust 2 8 Locknut 2 9 Adjuster 2 For installation reverse the removal procedure Order Job Part Q ty Remarks 8 9 7 5 6 LS E E M M 3 4 2 8 9 7 M 10 Nm 1 0 m kg T R 6 5 Nm 0 65 m kg T R 6 5 Nm 0 65 m kg T R 12 Nm 1 2 m kg T R LS LS 1 1 ...

Page 101: ...re turned away from each other 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 2 Loosen locknuts adjusting screws 3 Remove timing chain tensioner assembly NOTE Remove the timing chain tensioner adjusting screw and spring to release the spring tension and then remove the timing chain tensioner body 4 Remove bolt camshaft sprocket Rocker arms shaft 5 Remove camshaft retaining plate and bol...

Page 102: ...ve wear Replace the camshaft 4 Measure rocker arm inside diameter Out of specification Replace Rocker arm inside diameter 12 000 12 018 mm Limit 12 030mm 5 Measure rocker arm shaft outside diameter Out of specification Replace Rocker arm shaft outside diameter 11 981 11 991 mm Limit 11 950 mm 3 Measure camshaft lobe dimensions a and b Out of specification Replace the camshaft Camshaft lobe dimensi...

Page 103: ...et 2 Check camshaft sprocket More than 1 4 tooth a wear Replace the camshaft sprocket and the timing chain as a set a 1 4 tooth b Correct Timing chain roller Camshaft sprocket 3 Check timing chain guide exhaust side timing chain guide intake side Damage wear Replace the defective part s EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage Replace 2 Check one wa...

Page 104: ...t Molybdenum disulfide oil Camshaft bearing Engine oil 4 Align T mark on the generator rotor with the mark on the generator rotor cover 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align the T mark a on the generator rotor with the mark b ont the generator rotor cover NOTE Be sure to keep the...

Page 105: ...ign the camshaft mark c with the edge of the cylinder head d as shown CAUTION Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing 8 Install camshaft sprocket bolt 9 Adjust valves clearance Refer to ADJUSTING THE VALVES CLEA RANCE section in chapter 3 10 Lubricate cylinder head components Recommended lubricant Engine oil 11 Turn crankshaft NOTE Turn the ...

Page 106: ...EAR SHOCKS ABSORBER AND EXHAUST PIPE section in chapter 7 Drain coolant Refer to CHANGING THE COOLANT section in chapter 3 I Remove 1 Spark plug cap 1 2 Thermo switch connector 1 3 Pump inlet hose 1 4 Pump outlet hose 1 5 Cylinder head outlet hose 1 EASM0020 CYLINDER HEAD Order Job Part Q ty Remarks FWD 1 2 3 4 5 8 7 9 10 13 15 T R 22 Nm 2 2 m kg T R 10 Nm 1 0 m kg T R 8 Nm 0 8 m kg T R 12 Nm 1 2 ...

Page 107: ... 1 14 Dowel pin 2 15 Cylinder head gasket 1 For installation reverse the removal procedure CYLINDER HEAD Order Job Part Q ty Remarks FWD 1 2 3 4 5 8 7 9 10 13 15 T R 22 Nm 2 2 m kg T R 10 Nm 1 0 m kg T R 8 Nm 0 8 m kg T R 12 Nm 1 2 m kg T R 30 Nm 3 0 m kg 6 11 12 14 Follow the arrows WARNING NOTE Lock the flywheel with the special tool NOTE Avoid the dowel pin falling in the cylinder ...

Page 108: ...YLINDER HEAD 1 Remove combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damaging or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Remove 3 Measure cylinder head warpage Out of specification Resurface the cylinder head Maximum cylinder head warpage 0 0...

Page 109: ...the proper tighteningsequenceasshownandtorquethem in two stages 3 Install camshaft rocker arms Refer to INSTALLING THE CAMSHAFTS AND ROCKER ARMS section d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 ...

Page 110: ...ker arm shaft Refer to CAMSHAFT section 1 Valve cotters 4 2 Spring retainer 2 3 Valve spring 2 Valve spring compressor 90890 04019 4 Valve intake 1 Attachement 90890 04108 5 valve exhaust 1 6 Valve guide oil seals 2 7 Spring seat 2 For installation reverse the removal procedure Order Job Part Q ty Remarks 5 4 1 1 2 3 6 7 2 3 6 7 M M NOTE After installation refer to Adjusting valve section in chapt...

Page 111: ...왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 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 b 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 2 Remove valve cotters NOTE Remove the valve cotters by compressing the valve springs with the valve spring compressor and attachment Valve spring compressor 90890 0...

Page 112: ...2 mm Exhaust 4 500 4 512 mm limit 4 542 mm Valve stem diameter Intake 4 475 4 490 mm limit 4 445 mm Exhaust 4 460 4 475 mm limit 4 430 mm Valve stem to valve guide clearance Intake 0 01 0 037mm Limit 0 08 mm Exhaust 0 025 0 052 mm Limit 0 10mm 2 Replace valve 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 왔 왔 왔 왔 왔...

Page 113: ...ing wear Grind the valve face valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure valve margin thickness a Out of specification Replace the valve 6 Measure valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the valve guide If the valve is removed or replaced always replace the oil seal Va...

Page 114: ...make a clear impres sion d Measure the valve seat width NOTE Where the valve seat and valve face contacted oneanother theblueingwillhavebeenremoved 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 4 Lap valve face valve seat NOTE After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔...

Page 115: ...nto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies t...

Page 116: ...ubricant Recommended lubricant Molybdenum disulfide oil 3 Install valve spring seat valve stem seal valve valve spring spring retainer into the cylinder head NOTE Install the valve spring with the larger pitch a facing up b Smaller pitch Spring compressed pressure intake and exhaust 45 1 50 9 N 3 Measure valve spring tilt a Out of specification Replace the valve spring Spring tilt limit Intake and...

Page 117: ... the valve spring compressor and attachment Valve spring compressor 90890 04019 Attachment 90890 04108 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION Hitting the valve tip with excessive force could damage the valve VALVES AND VALVE SPRINGS ...

Page 118: ...er to CYLINDER HEAD section 1 Cylinder bolts 2 2 Timing chain guide lower 1 3 Cylinder 1 4 Dowel pin 2 5 Cylinder gasket 1 6 Piston pin clip 2 7 Piston pin 1 8 Piston 1 9 Piston ring top 1 10 Piston ring 2nd 1 11 Oil ring 1 For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 1 2 3 4 5 6 7 8 9 10 11 T R 12 Nm 1 2 m kg E ...

Page 119: ... clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller Piston pin puller 90890 01304 2 Remove top ring 2nd ring oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS00255 CHECKING THE CYLINDER AND PISTON 1 Check ...

Page 120: ... or D6 b If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer Piston size P Standard XN 125 53 670 53 687 mm XN 150 59 470 59 487 mm Oversize 2 XN 125 53 92 mm XN 150 59 72 mm Oversize 4 XN 125 54 17 mm XN 150 59 97 mm d If out of specification replace the piston and piston rings as a set e Cal...

Page 121: ... 07 mm Limit 0 12 mm 2nd ring 0 02 0 06 Limit 0 12 mm 2 Install piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown a 0 5 mm 3 Measure piston ring end gap Out of specification Replace the piston ring NOTE The oil ring expander spacer s end gap cannot bemeasured Iftheoilringrail sgapisexcessive replace all three piston rings Piston ring end gap Top ring ...

Page 122: ...er 14 991 15 000 mm 3 Calculate piston pin to piston clearance Out of specification Replace the piston pin and piston as a set Piston pin to piston clearance Piston pin bore size b Piston pin outside diameter a Piston pin to piston clearance 0 002 0 022 mm EAS00267 INSTALLING THE PISTON AND CYLINDER 1 Install top ring 2nd ring lower oil ring rail upper oil ring rail oil ring expander NOTE Be sure ...

Page 123: ...he clip from falling into the crankcase 3 Install gasket dowel pins 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil 5 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring 6 Install cylinder NOTE While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing c...

Page 124: ...T section in chapter 3 1 Air filter crankcase cover 1 2 Air filter crankcase cover gasket 1 3 Air filter crankcase element 1 4 Crankcase cover protector 1 5 Crankcase cover left 1 6 Crankcase cover gasket 1 For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 1 2 3 4 5 6 T R 10 Nm 1 0 m kg T R 9 Nm 0 9 m kg T R 10 Nm 1 0 m kg ...

Page 125: ...VING THE SECONDARY 4 Clutch housing 1 SHEAVE AND V BELT section 5 Clutch assembly 1 Refer to INSTALLING THE 6 V belt 1 SECONDARY SHEAVE section 7 Washer 1 8 Primary sliding sheave 1 9 Collar 1 Refer to ASSEMBLING THE PRIMARY 10 Cam 1 SHEAVE section 11 Weight 6 12 Slider 3 13 Oil seal 2 For installation reverse the removal procedure V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE Order Job Part Q ty Rem...

Page 126: ...rrier 1 SECONDARY SHEAVE section Clutch shoe spring 3 Refer to INSTALLING THE Compression spring 1 SECONDARY SHEAVE section Spring seat 1 Guide pin 3 Secondary sliding sheave 1 Refer to INSTALLING THE O ring 2 SECONDARY SHEAVE section Oil seal 2 Secondary fixed sheave 1 For assembly reverse the disassembly procedure Order Job Part Q ty Remarks FWD T R 90 Nm 9 0 m kg LS Apply BEL RAY assembly lube ...

Page 127: ...DARY SHEAVE AND V BELT 1 Remove nut secondary sheave clutch housing NOTE Loosenthenut secondarysheave whileholding the clutch housing with the sheave holder Sheave holder 90890 01701 2 Remove nut clutch carrier CAUTION Do not remove the nut clutch carrier yet NOTE Loosen the nut clutch carrier one turn using the locknutwrench whileholdingtheclutchcarrier with the rotor holder Rotor holder 90890 01...

Page 128: ...pressor and clutch spring holder arm and release the compressed spring after removing the nut CAUTION Use the spacer ø 40 mm thickness 2 3 mm Clutch spring holder 90890 01337 Clutch spring holder arm 90809 01464 CHECKING THE CLUTCH 1 Measure clutch shoe thickness Scratches Glazeusingcoarsesandpaper Wear damage Replace Clutch shoe thickness 2 0 mm Limit 1 0 mm NOTE Afterusingthesandpaper cleanoffth...

Page 129: ...0 130 5 mm EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check clutch spring Damage Replace the clutch springs as a set 2 Measure clutch spring free length Out of specification Replace the clutch springs as a set Clutch spring free length XN125 28 mm XN150 31 3 mm CHECKING THE V BELT 1 Check V belt Cracks wear scaling chipping Replace Oil greas...

Page 130: ... mm CHECKING THE SECONDARY SHEAVE 1 Check secondary fixed sheave smooth operation secondary sliding sheave smooth operation Scratches damage Replace as a set 2 Check Torque cam groove Wear damage Replace 3 Check Guide pin Wear damage Replace ASSEMBLING THE PRIMARY SHEAVE 1 Clean primary sliding sheave face primary fixed sheave face collar weight primary sliding sheave cam face 2 Install weight col...

Page 131: ...older arm and compress the spring CAUTION Usethespacer ø40mm thickness 2 3mm Clutch spring holder 90890 01337 Clutch spring holder arm 90890 01464 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE E E INSTALLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sliding sheave inner sur face grease nipple groove and oil seals BEL RAY assembly lube to the bearings oil seals and inner surf...

Page 132: ...sheave and clutch 7 Install nut clutch carrier NOTE Tighten the nut clutch carrier using the locknut wrench whlie holding the clutch carrier with the rotor holder Rotor holder 90890 01235 8 Install clutch housing nut clutch housing NOTE Tightenthenut clutchhousing usingthesheave holder Sheave holder 90890 01701 9 Set V belt NOTE Move the V belt to minimum diameter of the primary sheave maximum dia...

Page 133: ...VERS AND SEAT section in chapter 3 1 Flywheel lead coupler 2 2 Flywheel cover 1 3 Nut 1 4 Washer 2 5 Rotor 1 6 Stator fixing screws 3 7 Woodruf key 1 8 Stator 1 9 Pick up coil screw 2 10 Pick up coil 1 For installation reverse the removal procedure STARTER CLUTCH AND GENERATOR Order Job Part Q ty Remarks FWD 1 2 3 4 5 6 8 10 7 9 T R 70 Nm 7 0 m kg T R 7 Nm 0 7 m kg T R 7 Nm 0 7 m kg ...

Page 134: ...h Remove the parts in the order listed 1 Gear retainer plane 1 2 Washer 1 3 Idle gear 1 4 Washer 1 5 Starter one way cluth 1 6 Collar 1 7 Starter wheel gear 1 For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 1 2 5 7 6 4 3 T R 7 Nm 0 7 m kg T R 65 Nm 6 5 m kg ...

Page 135: ...tch is faulty and must be replaced c When turning the starter clutch drive gear clockwise it should turn freely otherwise the starter clutch is faulty and must be replaced 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 STARTER CLUTCH AND GENERATOR EAS00354 INSTALLING THE GENERATOR 1 Install woodruff key generator rotor washers generator rotor nut NOTE Clean the tapered portion of the cr...

Page 136: ... 3 Flywheel Refer to STARTER CLUTCH AND GENERATOR section 1 Oil pump cover fixing screws 3 2 Oil pump cover 1 3 Oil pump clip 1 4 Washer 1 5 Oil pump gear 1 6 Oil pump gear dowel pin 1 7 Oil pump fixing screws 2 8 Oil pump assembly 1 For installation reverse the removal procedure Order Job Part Q ty Remarks FWD 2 1 3 4 5 6 8 7 T R 65 Nm 6 5 m kg T R 7 Nm 0 7 m kg ...

Page 137: ...rotor tip clearance A outer rotor to oil pump housing clearance B Pump housing to rotors clearance C Out of specification Replace the oil pump Inner rotor Outer rotor Oil pump housing Inner rotor to outer rotor tip clearance limit 0 15 mm Outer rotor to oil pump housing clearance limit 0 15 mm Pump housing to rotors clearance limit 0 17 mm 3 Check oil pump operation Rough movement Replace the defe...

Page 138: ...iston Refer to CYLINDER AND PISTON section V belt cluth secondary primary sheave Refer to V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE section CDI magneto Refer to STARTER CLUTCH AND GENERATOR section Oil pump Refer to OIL PUMP section Water pump Refer to WATER PUMP section in chapter 5 Rear wheel Refer to REAR WHEEL AND BRAKE section in chapter 7 Order Job Part Q ty Remarks FWD 3 4 5 6 8 1 T R 9 Nm...

Page 139: ...STALLING THE CRANK SHAFT AND STARTER CLUTCH section 5 Dowel pin 2 6 Crankshaft assembly 1 7 Timing chain 1 8 Crankcase left 1 For installation reverse the removal procedure CRANKCASE AND CRANKSHAFT Order Job Part Q ty Remarks FWD 3 4 5 6 8 1 T R 9 Nm 0 9 m kg T R 9 Nm 0 9 m kg E E 2 7 ...

Page 140: ...de of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly 3 Remove timing chain from crankshaft sprocket EAS00388 REMOVING THE CRANKSHAFT ASSEMBLY 1 Remove crankshaft assembly CAUTION Tap on one side of the crankshaft with a soft face hammer Work slo...

Page 141: ...crankshaft Big end side clearance 0 15 0 45 mm 3 Measure crankshaft width Outofspecification Replacethecrankshaft Crankshaft width 47 95 48 00 mm 4 Check crankshaft sprocket Damage wear Replace the crankshaft bearing Cracks damage wear Replace the crankshaft oil pump drive gear Damage wear Replace the crankshaft 5 Check crankshaft journal Scratches wear Replace the crankshaft crankshaft journal oi...

Page 142: ...BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace EAS00402 CHECKING THE CIRCLIPS AND WASHERS 1 Check circlips Bends damage looseness Replace washers Bends damage Replace EAS00408 INSTALLING THE CRANKSHAFT 1 Install crankshaft assembly timing chain CAUTION To avoid scratch...

Page 143: ...o contact with the oil gallery 2 Install dowel pins 3 Install crankshaft 4 Install timing chain 5 Install left crankcase onto the right crankcase NOTE Tap lightly on the left crankcase with a soft face hammer 6 Install crankcase bolts 7 Apply engine oil onto the crankshaft bearings conrod and crank pin 8 Check crankshaft operation Rough movement Repair timing chain position T R 9 Nm 0 9m kg ...

Page 144: ...RY SHEAVE section Drain the transmission oil Refer to TRANSMISSON OIL REPLACEMENT section in chapter 3 1 Transmission cover screws 6 2 Transmission case cover 1 3 Gasket 1 4 Dowel pin 2 Refer to INSTALLING THE CRANK SHAFT AND STARTER CLUTCH section 5 Primary drive gear 1 6 Plain washer 1 7 Secondary drive gear axle 1 TRANSMISSION Order Job Part Q ty Remarks FWD 2 1 3 4 6 7 9 5 T R 6 5 Nm 0 65 m kg...

Page 145: ...ENG 4 49 8 Idle gear 1 9 Main axle 1 For installation reverse the removal procedure TRANSMISSION Order Job Part Q ty Remarks FWD 2 1 3 4 6 7 9 5 T R 6 5 Nm 0 65 m kg E E E E E G G L S 8 ...

Page 146: ...5 COOL ...

Page 147: ...STEM RADIATOR 5 1 CHECKING THE RADIATOR 5 3 INSTALLING THE RADIATOR 5 3 THERMOSTAT 5 4 CHECKING THE THERMOSTAT 5 5 INSTALLING THE THERMOSTAT 5 5 WATER PUMP 5 6 CHECKING THE WATER PUMP 5 7 INSTALLING THE WATER PUMP 5 7 COOL ...

Page 148: ...PANEL AND INNER FRONT COVER section in chapter 3 Footrest board Refer to FOOTREST BOARD AND UNDER COVER section in chapter 3 I Disconnet 1 Fan motor coupler 1 2 Thermo switch connectors 4 II Unplug 3 Radiator outlet hose 1 4 Radiator inlet hose 1 5 Radiator filler hose 1 III Untight 6 Radiator bracket frame 1 Order Job Part Q ty Remarks 1 2 3 4 2 8 7 6 5 ...

Page 149: ...COOL 5 2 RADIATOR IV Remove 7 Radiator 1 8 Radiator fan 1 For installation reverse the removal procedure Order Job Part Q ty Remarks 1 2 3 4 2 8 7 6 5 NOTE Avoid the radiator of falling ...

Page 150: ...2 Check radiator hoses radiator pipes Crack damage Replace 3 Check radiator cap Cracks damage Replace 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM section in chapter 8 EAS00456 INSTALLING THE RADIATOR 1 Fill cooling system with the specified amount of the recommended coolant Refer to CHANGING THE COOLANT sec tion in chapter 3 2 Check cooling system Leaks...

Page 151: ... Refer to CHANGING COOLANT section in chapter 3 Box Refer to SIDE COVERS AND SEAT section in chapter 3 1 Hose 1 2 Cylinder head outlet hose 1 3 Thermostat cover fixing screws 2 4 Thermostat cover 1 5 Thermostat 1 For installation reverse the removal procedure Order Job Part Q ty Remarks 1 2 3 4 5 T R 9 Nm 0 9 m kg ...

Page 152: ...the water observe the ther mostat and thermometer s indicated temperature 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 햲 Thermometer 햳 Water 햴 Thermostat 햵 Container A Fully closed B Fully open NOTE If the accuracy of the thermostat is in doubt replaceit Afaultythermostatcouldcauseserious overheating or overcooling 2 Check thermostat housing cover 햲 thermostat housing Cracks damage Re...

Page 153: ...rain coolant Refer to CHANGING THE COOLANT section in chapter 3 1 Pump inlet hose 1 2 Pump outlet hose 1 3 Water pump fixing screws 3 4 Water pump assembly 1 Disassembling water pump 햲 Water pump mounting screws 4 햳 Bleed screw with copper washer 1 1 햴 Water pump inner cover 1 햵 O ring 1 햶 Water pump cover gasket 1 1 햷 Impeller shaft 1 햸 Dowel pin 1 For installation reverse the removal procedure N...

Page 154: ...racks damage wear Replace the water pump housing assembly water pump housing Cracks damage Replace the water pump housing assembly EAS00477 INSTALLING THE WATER PUMP NOTE Alwaysreplacetheentirewaterpumpassembly 1 Install impeller water pump inner cover screw NOTE After installation check that the impeller shaft rotates smoothly 2 Install O ring NOTE Lubricate the O ring with a thin coat of lithium...

Page 155: ... 8 WATER PUMP 3 Install dowel pin gasket water pump housing cover screws copper washer 햲 bleed screw 햳 NOTE Do not forget to install the copper washer on the bleed screw T R 7 Nm 0 7m kg T R 7 Nm 0 7m kg 햲 햳 ...

Page 156: ...6 CARB ...

Page 157: ...BURETOR 6 1 CARBURETOR REMOVAL 6 1 CARBURETOR DISASSEMBLY 6 2 CHECKING THE CARBURETOR 6 3 ASSEMBLING THE CARBURETOR 6 5 MEASURING AND ADJUSTING THE FUEL LEVEL 6 6 CHECKING THE AUTOCHOKE UNIT 6 6 CHECKING THE FUEL COOK 6 7 CARB ...

Page 158: ... chapter section 3 Box I Disconnect 1 Auto choke coupler 1 2 Carburetor heater connectors 2 II Unplug 3 Fuel hose 1 III Remove 4 Throttle cable 1 5 Fixing clip 2 6 Air duct 1 7 Carburetor assembly 1 For installation reverse the removal procedure CAUTION Do not bend the air filter joint clamp when installing the carburetor Order Job Part Q ty Remarks 4 6 5 5 7 3 1 2 ...

Page 159: ...cover spring 1 1 햶 Throttle valve 1 햷 Needle set 1 햸 Accelerating pump lever 1 햹 Float chamber gasket 1 1 햺 Float axle 1 1 햻 Float 1 햽 Needle jet 1 햾 Main jet 1 햿 Pilot jet 1 헀 Main nozzle 1 헁 Heater assembly 1 Forassembly reversethedisassemblyprocedure Order Job Part Q ty Remarks Y Q U I R T e q w P O Y E W NOTE Remove the float pin from the side of the arrow ...

Page 160: ...ts with compressed air 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 CARBURETOR 1 2 3 Check float chamber body 햲 Dirt Clean 4 Check float chamber rubber gasket Cracks damage wear Replace 5 Check float 햳 Damage Replace 6 Check needle valve 햲 needle valve seat 햳 Damage obstruction wear Replace the needlevalve needlevalveseatandO ringas a set 7 Check o ring 햲 Damage wear Replace the needl...

Page 161: ...eplace Obstruction Replace 햲 322015 11 Check piston valve movement Insert the piston valve 햲 into the carburetor body and move it up and down Tightness Replace the throttle valve 12 Check starter plunger starter plunger spring Bends cracks damage Replace 13 Check hose joints Cracks damage Replace 14 Check vacuum hoses fuel hoses Cracks damage wear Replace Obstruction Clean Blow out the hoses with ...

Page 162: ...lve float axle 햳 NOTE Install the float pin from the side opposite the arrow 4 Install float chamber 햲 gasket 햳 pilot screw 5 Install O ring accelerator pump diaphragm accelerator pump spring accelerator pump cover 6 Install starter plunger kit 7 Install piston valve jet needle holder jet needle 8 Install throttle cable lever arm 9 Install vacuum chamber cover 10 Install Carburetor on engine Refer...

Page 163: ...straight up c Install the fuel level gauge 햲 onto the fuel drain pipe 햳 Fuel level gauge 90890 01312 d Loosen the fuel drain screw 햴 e Hold the fuel level gauge vertically next to the float chamber f Measure the fuel level a 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 2 Adjust fuel level 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Remove the carburetor b Check the nee...

Page 164: ...왖 왖 왖 왖 왖 왖 왖 3 Check autochoke unit 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Connect the autochoke unit leads to a 12 0V battery for five minutes Positive battery lead black Negative battery lead black b Connect ø 3 3 mm hose to the starter air passage and blow into the hose Starter plunger opens Replace the autochoke unit Starter plunger closes Autochoke unit is OK 왖 왖 왖 왖 왖 왖...

Page 165: ...7 CHAS ...

Page 166: ...CE 7 11 FRONT BRAKE 7 12 FRONT BRAKE PADS 7 12 REPLACING THE FRONT BRAKE PADS 7 13 FRONT BRAKE MASTER CYLINDER 7 15 MASTER CYLINDER 7 16 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 7 17 CHECKING THE FRONT BRAKE MASTER CYLINDER 7 17 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING 7 18 DISASSEMBLING THE FRONT BRAKE CALIPER 7 19 CHECKING THE FRONT BRAKE CALIPER 7 20 ASSEMBLING AND...

Page 167: ...2 INSTALLING THE HANDLEBAR 7 32 STEERING HEAD 7 34 REMOVING THE LOWER BRACKET 7 35 CHECKING THE STEERING HEAD 7 35 INSTALLING THE STEERING HEAD 7 36 REAR SHOCK ABSORBER AND EXHAUST PIPE 7 37 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 7 38 CHAS ...

Page 168: ... sensor 1 7 Front wheel 1 8 Front brake disc mounting screws 4 9 Front brake disc 1 For installation reverse the removal procedure FRONT WHEEL AND BRAKE DISC NOTE Place the scooter on a suitable stand so that the front wheel is elevated EASM0040 CHASSIS FRONT WHEEL AND BRAKE DISC FRONT WHEEL AND BRAKE DISC Order Job Part Q ty Remarks L S 23 Nm 2 3 m kg T R 23 Nm 2 3 m kg T R LT 7 6 9 5 4 2 70 Nm 7...

Page 169: ...ort the scooter so that there is no danger of it falling over NOTE Place the scooter on a suitable stand so that the front wheel is elevated 2 Remove brake caliper NOTE Do not squeeze the brake lever when removing the brake caliper 3 Elevate front wheel NOTE Place the scooter on a suitable stand so that the front wheel is elevated ...

Page 170: ... runout lateral wheel runout Over the specified limits Replace Radial wheel runout limit 1 0 mm Lateral wheel runout limit 0 5 mm 4 Check wheel bearings Front wheel turns roughly or is loose Re place the wheel bearings oil seals Damage wear Replace 5 Replace wheel bearings oil seals 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Clean the outside of the front wheel hub b Remove the oi...

Page 171: ...old the dial gauge at a right angle against the brake disc surface e Measure the deflection 2 3 mm below the edge of the brake disc 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Brake disc thickness limit minimum 4 mm c Remove the wheel bearings with a general beari...

Page 172: ...on repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 FRONT WHEEL AND BRAKE DISC EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1 Check speedometer gear unit Bends damage wear Replace EAS00539 ASSEMBLING THE FRONT WHEEL...

Page 173: ...l collar front wheel front wheel axle WARNING Be sure to assemble the front wheel as shown on page 7 1 4 Tighten wheel axle nut WARNING Make sure the brake hose is routed properly Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE After replacing the tyre wheel or bo...

Page 174: ... 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 3 Adjust front wheel static balance 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Install a balancing weight onto the rim exactly opposite the heavy spot X NOTE Start with the lightest weight b Turn the 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 wei...

Page 175: ...washer 1 5 Rear wheel 1 6 Brake shoes lining 2 7 Tension spring 2 8 Plate washer 1 9 Brake cam lever 1 10 Indicator plate 1 11 Brake cam 1 For installation reverse the removal procedure REAR WHEEL AND BRAKE EASM0041 REAR WHEEL AND BRAKE NOTE Place the scooter on a suitable stand so that the rear wheel is elevated Order Job Part Q ty Remarks FWD T R 103 5 Nm 10 35 m kg T R 13 5 Nm 1 35 m kg LS LS 3...

Page 176: ...RONTWHEELANDBRAKEDISC section Radial wheel runout limit 1 0 mm Lateral wheel runout limit 0 5 mm EAS00569 CHECKING THE REAR BRAKE The following procedure applies to all of the brake shoes 1 Check brake shoe lining Glazed areas Repair Sandtheglazedareaswithcoursesandpaper NOTE After sanding the glazed areas clean the brake shoe with a cloth 346007 a 2 Measure brake shoe lining thickness a Out of sp...

Page 177: ...emery cloth 5 Check brake camshaft Damage wear Replace EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1 Install brake camshaft spring brake shoe wear indicator 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Install the brake camshaft so its punch mark is positioned as shown b Align the projection on the brake shoe wear indicator with the notch in the brake shoe camshaft c Check that the bra...

Page 178: ... plain washer Recommended lubricant Lithium soap base grease 4 Tighten plain washer wheel axle nut 5 Adjust brake lever free play Refer to ADJUSTING THE REAR BRAKE section in chapter 3 REAR WHEEL AND BRAKE EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake ...

Page 179: ...the parts in the order listed Front caliper Refer to REMOVING THE FRONT WHEEL section 1 Caliper fixing bolt 2 2 Retaining clip 1 3 Retaining pin 1 4 Pad spring 1 5 Brake pads 2 6 Bleed screw 1 For installation reverse the removal procedure Order Job Part Q ty Remarks 6 2 1 4 3 5 22Nm 2 2 m kg LS LT ...

Page 180: ...brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get immediate medical attention EAS00581 REPLACING THE FRONT BRAKE PADS NOTE ...

Page 181: ...aliper piston into the brakecaliper brakefluidlevelinthereservoir tank is increasing higher 7 Install retaining pin retaining clip Donotallowgreasetocontactthebrakepads 8 Install brake caliper brake caliper fixing bolt 9 Check brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL section in chapter 3 10 Check brak...

Page 182: ...IC BRAKE SYSTEM section in chapter 3 Handlebar covers Refer to HANDLEBAR COVERS section in chapter 3 1 Front brake lever 1 2 Front brake switch 1 3 Hose union bolt 1 4 Plain washer hose 2 1 5 Master cylinder bracket 1 6 Master cylinder 1 For installation reverse the removal procedure Order Job Part Q ty Remarks LS T R 8 5 Nm 0 85 m kg T R 10 Nm 1 0 m kg T R 23 Nm 2 3 m kg 2 1 4 6 5 3 ...

Page 183: ...ing the master cylinder Disassemble the parts in the order listed Master cylinder Refer to FRONT BRAKE MASTER CYLINDER section Master cylinder kit 1 Master cylinder spring seat 1 Spring 1 For assembly reverse the removal procedure Order Job Part Q ty Remarks ...

Page 184: ...er reservoir Cracks damage Replace brakemastercylinderreservoirdiaphragm Damage wear Replace 4 Check brake hoses Cracks damage wear Replace EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE Before disassembling the front brake master cylinder drain the brake fluid from the entire brake system 1 Disconnect brake switch coupler from the brake switch 2 Remove union bolt copper washers brake...

Page 185: ... essential to insure safe scooter operation Refer to CA BLE ROUTING NOTE While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and to the right to make sure the brake hose does not touch other parts e g wireharness cables leads Correct if necessary 3 Fill brake master cylinder reservoir with the specified amount of the recommended brake fluid Recommended brake...

Page 186: ...tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00618 DISASSEMBLING THE FRONT BRAKE CALIP...

Page 187: ... 왖 EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Brake fluid Every two years and whenever the brake is disassembled 1 Check brake caliper pistons Rust scratches wear Replace the brake caliper brake caliper cylinders Scratches wear Replacethebrakecaliper brake caliper body C...

Page 188: ...n seals Recommended brake fluid DOT 3 or DOT 4 1 Install brake caliper temporarily copper washers brake hose union bolt WARNING Proper brake hose routing is essential to insure safe scooter operation Refer to CA BLE ROUTING When installing the brake hose onto the brake caliper make sure the brake pipe touches the projection on the brake caliper 2 Remove brake caliper 3 Install brake pads brake pad...

Page 189: ...illing be careful that water does not enter the brake master cylinder reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Be...

Page 190: ...section 1 Front mudguard 1 2 Cap bolt O ring 1 1 3 Bolt under bracket upper and lower 2 4 Front fork leg right and left 2 For installation reverse the removal procedure FRONT FORK Order Job Part Q ty Remarks 2 2 4 3 1 LT T R 23 Nm 2 3 m kg T R 45 Nm 4 5 m kg T R 33 Nm 3 3m kg NOTE Disconnectthespeedometersensorcoupler to remove the front mudguard ...

Page 191: ...der listed Cap bolt 1 O ring 1 Fork spring 1 Dust seal 1 Retaining clip 1 Oil seal 1 Bolt damper rod Gasket 1 1 Inner tube 1 Oil lock piece 1 Damper rod 1 Rebound spring 1 For assembly reverse the disassembly procedure Order Job Part Q ty Remarks 2 2 4 3 1 LT T R 23 Nm 2 3 m kg T R 45 Nm 4 5 m kg T R 33 Nm 3 3m kg ...

Page 192: ...EMOVING THE FRONT WHEEL section 3 Loosen upper bracket pinch bolt cap bolt lower bracket pinch bolt WARNING Before loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove front fork leg EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove cap bolt from the damper adjusting rod 2 Remove O ring 3 Drain fork o...

Page 193: ...왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vice with soft jaws c Separate the inner tube from the outer tube bypullingtheinnertubeforcefullybutcarefully Excessive force will damage the oil seal and bushing A damaged oil seal or bushing must be replaced Avoid bottoming the inner tube into the outer tube during the...

Page 194: ...cedure applies to both of the front fork legs WARNING Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor handling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following parts oil seal dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install piston WARNING Always use new ...

Page 195: ...ng with the fork seal driver weight and adap ter Fork seal driver weight 90890 01367 Fork seal driver attachment 90890 01368 5 Install washer oil seal with the fork seal driver weight and adapter Make sure the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap base grease Lubricate the outer surface of the inner tube with fork oil Before...

Page 196: ...en disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork 10 After filling the front fork leg slowly stroke the damper rod up and down at least ten times to distribute the fork oil NOTE Be sure to stroke the damper rod slowly because the fork oil may spurt out 11 Slowly stroke the inner tube up and down to distribute the fork oil once more 1 strok...

Page 197: ...ressed and without the spring 80 mm 14 Install spring NOTE Install the spring with its denser of pitch to upper side O ring EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install front fork leg cap bolt under bracket bracket bolt NOTE Pull up the inner tube until it stops then install the cap bolt 2 Tighten cap bolt lower bracket pinch bolt...

Page 198: ... 3 Master cylinder 1 4 Handlebar switch right 1 5 Throttle cable 1 6 Grip assembly 1 7 Rear brake cable 1 8 Brake lever holder left 1 9 Brake lever holder right 1 10 Handlebar switch left 1 11 Handlebar 1 12 Bolt nut 1 1 For installation reverse the removal procedure Order Job Part Q ty Remarks LS 12 6 4 7 11 9 8 1 1 10 2 3 5 T R 10 Nm 1 0 m kg T R 10 Nm 1 0 m kg T R 60 Nm 6 0 m kg T R 10 Nm 1 0 m...

Page 199: ...the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 T R 60 Nm 6 0 m kg EAS00673 INSTALLING THE HANDLEBAR 1 Stand the scooter on a level surface WARNING Securely supp...

Page 200: ...p with a thin coat of lithium soap base grease and install it onto the handlebar 8 Install right handlebar switch WARNING Make sure the throttle grip operates smoothly NOTE Align the projection on the right handlebar switch with the hole a in the handlebar There should be 2 5 mm of clearance between the throttle grip and the right grip end 9 Adjust throttle cable free play Refer to ADJUSTING THE T...

Page 201: ...R section 1 Ring nut 1 2 Lock washer 1 3 Ring nut middle 1 4 Rubber washer 1 5 Ring nut lower 1 6 Ball race cover 7 Ball race upper 1 8 Lower bracket 1 9 Ball bearing 22 10 Bearing 1 11 Ball races in lower bracket 2 12 Ball race lower 1 13 Steering oil seal 1 For installation reverse the removal procedure Order Job Part Q ty Remarks 1 2 3 4 5 6 7 8 9 10 12 13 11 T R 75 Nm 7 5 m kg T R Fisrt step 3...

Page 202: ... wrench Ring nut wrench 90890 01268 WARNING Securely support the steering shaft so that there is no danger of it falling down EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Recommended cleaning solvent Kerosene 2 Check bearings bearing races Damage pitting Replace 3 Replace bearings bearing races a Remove the bearing races from the steering head pipe with a long rod and hammer b...

Page 203: ... nut Referto CHECKINGANDADJUSTINGTHE STEERING HEAD section in chapter 3 3 Install handlebar bolt nut If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set Whenever the steering head is disassembled replace the rubber seal 4 Check lower bracket along with the steering stem Bends cracks damage Replace 354009 ...

Page 204: ...in chapter 3 Box 1 1 Exhaust pipe bolt bracket 2 2 Exhaust pipe nut engine 2 3 Rear shock absorber bolt engine 1 4 Rear shock absorber bolt frame 1 For installation reverse the removal procedure Order Job Part Q ty Remarks T R 27 Nm 2 7m kg 17 5 Nm 1 75m kg T R T R 31 5 Nm 3 15m kg T R 11 Nm 1 1m kg T R 31 5 Nm 3 15 m kg T R 17 5 Nm 1 75 m kg T R 4 5 Nm 0 45 m kg T R 27 Nm 2 7 m kg T R 27 Nm 2 7 m...

Page 205: ...eck rear shock absorber rod Bends damage Replace the rear shock absorber assembly rear shock absorber Oil leaks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock absorber assembly bushings Damage wear Replace dust seals Damage wear Replace bolts Bends damage wear Replace ...

Page 206: ...8 ELEC ...

Page 207: ...NG SYSTEM 8 11 CIRCUIT DIAGRAM 8 11 TROUBLESHOOTING 8 12 STARTER MOTOR 8 14 CHECKING THE STARTER MOTOR 8 16 ASSEMBLING THE STARTER MOTOR 8 17 CHARGING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 20 LIGHTING SYSTEM 8 22 CIRCUIT DIAGRAM 8 22 TROUBLESHOOTING 8 23 CHECKING THE LIGHTING SYSTEM 8 24 SIGNALING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 CHECKING THE SIGNALING SYSTEM 8 30...

Page 208: ...PONENTS Wire harness Battery Ignition unit CDI Main switch Ignition coil Spark plug cap Rectifier Regulator Fuel sender Starter relay Starter motor Thermo switch Flasher relay Horn Fuses Relays Coolant thermo switch Carburator heater thermo switch ...

Page 209: ...nge When checking for 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 illustration 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 indicatesacontinuityofelectri...

Page 210: ...nnected Properly connect Incorrect continuity reading Replace the switch Horn switch Dimmer switch Turn signal switch Main switch Front brake light switch Light switch Start switch Fuses Rear brake light switch B Br B R BW CHECK GR OPEN OFF ON Br GyR R LOCK GY Br GY Br B B B LY B BLUE BLUE LY OPTION B B BLUE B B Ch P G BrW B Y Dg LB R N L Ch LO HI PUSH OFF G Y LB BrW Dg ON GY L Br LB POS OFF START...

Page 211: ...andturningthebulbcounterclockwise Bulbs D and E are used for meter and indi cator lights and can be removed from their respective socket by pushing and turning the bulb conterclockwise for D and carefully pulling them out for E EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear proper connections and also for continuity between the terminals Damage wear...

Page 212: ...ted If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 NOTE Before checking for continuity set the pocket tester to 0 and to the x 1 Ω range 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Connect the positive tester probe to termi...

Page 213: ...in the same manner as described in the bulb section however note the following 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 a Install a good bulb into the bulb socket b Connect the pocket tester probes to the res pective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 ...

Page 214: ... B B Or WL WR GW B Y G BR BLACK BLACK Dg Ch Ch LW LW LW LW Dg Ch Br Br G Ch Ch LW R B LW LW Dg BR NO CONNECTION Br Ch GW WR WL NO CONNECTION B NO CONNECTION RED NO CONNECTION B NO CONNECTION METER ASSY Br R ANTI THEFT ALARM OPTION B Dg LW LW L R L Br R W W HEAD LIGHT ASSY Sb Dg B NO CONNECTION LW LW RED L Ch G B Dg Y LW L Ch G B Dg Y B L Y Br Y GY GY Br Br YB YB Br L L L Y Ch G Dg Ch BW B LW B Dg ...

Page 215: ...use Check the main fuse for continuity Referto CHECKINGTHEFUSES inchapter 3 Is the main fuse OK Replace the fuse Clean the battery terminals Recharge or re place the battery YES NO EAS00739 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is the battery OK YES NO EAS00740 3 Spark plug Check the condition of ...

Page 216: ... Measure the spark plug cap resistance Spark plug cap resistance 10 x kΩ at 20 C Is the spark plug cap OK Replace the spark plug cap EAS00746 6 Ignition coil resistance Disconnect the ignition coil connectors from the ignition coil terminals Connect the pocket tester Ω X 1 to the ignition coil as shown Measure primary coil resistance Positive tester probe black Negative tester probe orange Measure...

Page 217: ...coil resistance Disconnect the pickup coil coupler from the wire harness Connect the pocket tester Ω X 100 to the pickup coil terminal as shown Positive tester probe red black Negative tester probe green white Measure the pickup coil resistance Pickup coil resistance 248 372 Ω at 20 C between white red and white green Is the pickup coil OK EAS00754 10 Wiring Check the entire ignition system s wiri...

Page 218: ...GY LB L Dg Br LR B B B B B Or WL WR GW B Y G BR BLACK BLACK Dg Ch Ch LW LW LW LW Dg Ch Br Br G Ch Ch LW R B LW LW Dg BR NO CONNECTION Br Ch GW WR WL NO CONNECTION B NO CONNECTION RED NO CONNECTION B NO CONNECTION METER ASSY Br R ANTI THEFT ALARM OPTION B Dg LW LW L R L Br R W W HEAD LIGHT ASSY Sb Dg B NO CONNECTION LW LW RED L Ch G B Dg Y LW L Ch G B Dg Y B L Y Br Y GY GY Br Br YB YB Br L L L Y Ch...

Page 219: ...wing special tool s Pocket tester 90890 03112 EAS00738 1 Main fuse Check the main fuse for continuity Referto CHECKINGTHEFUSES inchapter 3 Is the main fuse OK Replace the fuse Clean the battery terminals Rechargeorreplace the battery YES NO YES NO EAS00758 3 Starter motor Connect the positive battery terminal and starter motor lead with a jumper lead WARNING A wire that is used as a jumper lead mu...

Page 220: ...ront and rear switches OK EAS00764 7 Starter switch Check the starter switch for continuity Refer to CHECKING THE SWITCHES Is the starter switch OK EAS00766 8 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly con nected and without defects Replace the starter relay Replace the front or rear brake switch The starting system circuit is...

Page 221: ...seat section in chapter 3 1 Starter connector and coupler 1 1 2 Starter motor fixing bolts washer 2 2 3 Starter motor 1 Disassembling the starter motor Starter motor mounting bolts 2 Washers o rings 2 2 Starter motor rear cover 1 O ring 1 Stator assembly 1 Armature assembly 1 STARTER MOTOR Order Job Part Q ty Remarks 1 2 3 T R 65 Nm 6 5 m kg T R 5 Nm 0 5 m kg ...

Page 222: ... 2 2 Brush holder washer 1 1 O ring 1 Starter motor front cover O ring 1 1 For installation assembly reverse the removal disassembly procedure STARTER MOTOR Order Job Part Q ty Remarks 1 2 3 T R 65 Nm 6 5 m kg T R 5 Nm 0 5 m kg ...

Page 223: ...out of specification re place the starter motor 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 왖 EAS00770 CHECKING THE STARTER MOTOR 1 Check commutator Dirt Clean with 600 grit sandpaper 2 Measure commutator diameter a Out of specification Replace the starter motor Commutator diameter 22 mm Limit 21 mm 3 Measure mica undercut a Out of specification Scrape the mica to the proper measuremen...

Page 224: ... cover 2 Install Armature assembly Stator assembly starter motor front cover starter motor rear cover NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers 6 Measure brush spring force Out of specification Replace the brush springs as a set Brush spring force 5 6 8 3 N 7 Check gear teeth Damage wear Replace the gear 8 Check bearing...

Page 225: ...ELEC 8 18 3 Install O rings washers starter motor mounting bolts stater motor fixing bolts STARTER MOTOR T R 5 Nm 0 5m kg T R 65 Nm 6 5m kg ...

Page 226: ...Ch Ch LW LW LW LW Dg Ch Br Br G Ch Ch LW R B LW LW Dg BR NO CONNECTION Br Ch GW WR WL NO CONNECTION B NO CONNECTION RED NO CONNECTION B NO CONNECTION METER ASSY Br R ANTI THEFT ALARM OPTION B Dg LW LW L R L Br R W W HEAD LIGHT ASSY Sb Dg B NO CONNECTION LW LW RED L Ch G B Dg Y LW L Ch G B Dg Y B L Y Br Y GY GY Br Br YB YB Br L L L Y Ch G Dg Ch BW B LW B Dg Ch ILLUMI Y R WIRE LEAD sur ANTI THEFT 1 ...

Page 227: ...ester 90890 03112 YES NO Clean the battery terminals Recharge or re place the battery EAS00739 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is the battery OK YES NO EAS00775 3 Charging voltage Connect the engine tachometer to the spark plug lead of the cylinder Connect the pocket tester DC V 20 to the ba...

Page 228: ...or coil resistance 0 6 0 9 Ω at 20 C Is the stator coil OK EAS00779 5 Wiring connections Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring properly con nected and without defects Replacethestatorcoil assembly Properly connect or repair the charging system s wiring Replace the rectifier regulator NOTE Make sure the battery is fully c...

Page 229: ...R GW B Y G BR BLACK BLACK Dg Ch Ch LW LW LW LW Dg Ch Br Br G Ch Ch LW R B LW LW Dg BR NO CONNECTION Br Ch GW WR WL NO CONNECTION B NO CONNECTION RED NO CONNECTION B NO CONNECTION METER ASSY Br R ANTI THEFT ALARM OPTION B Dg LW LW L R L Br R W W HEAD LIGHT ASSY Sb Dg B NO CONNECTION LW LW RED L Ch G B Dg Y LW L Ch G B Dg Y B L Y Br Y GY GY Br Br YB YB Br L L L Y Ch G Dg Ch BW B LW B Dg Ch ILLUMI Y ...

Page 230: ...fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 Is the main fuse OK Replace the fuse YES NO Clean the battery terminals Recharge or re place the battery EAS00739 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is the battery OK YES NO EAS00749 3 Main switch Check the main switch for continuity...

Page 231: ...he headlight bulb and socket OK YES NO The Hi Lo beam switch is faulty Replace the left handlebar switch YES NO Check the condition of each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYSTEM Properly connect or repair the lighting system s wiring YES NO 2 Voltage Connect the pocket tester DC V 20 to the headlight and high beam indicator light cou plers as shown A When the dimm...

Page 232: ...circuitfrom the main switch to the headlight coupler is faulty and must be repaired 2 Voltage Connect the pocket tester 20 V to the meter light coupler wire harness side as shown Positive tester probe blue Negative tester probe black Set the main switch to ON Set the light switch to or Measure the voltage 12 V of blue on the meter light coupler wire harness side Is the voltage within specification...

Page 233: ...circuitfrom the main switch to the tail brakelightcoupler is faulty and must be repaired B L B Y EAS00791 4 The front postion light fails to come on 1 Auxiliary light bulb and socket Check the auxiliary light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKET Are the auxiliary light bulb and socket OK YES NO Replace the auxiliary light bulb socket or both 2 Voltage Connect ...

Page 234: ...Br Br G Ch Ch LW R B LW LW Dg BR NO CONNECTION Br Ch GW WR WL NO CONNECTION B NO CONNECTION RED NO CONNECTION B NO CONNECTION METER ASSY Br R ANTI THEFT ALARM OPTION B Dg LW LW L R L Br R W W HEAD LIGHT ASSY Sb Dg B NO CONNECTION LW LW RED L Ch G B Dg Y LW L Ch G B Dg Y B L Y Br Y GY GY Br Br YB YB Br L L L Y Ch G Dg Ch BW B LW B Dg Ch ILLUMI Y R WIRE LEAD sur ANTI THEFT 1 et 4 WIRE LEAD sur SIDE ...

Page 235: ...urn signal switch H Left front flasher J Right front flasher Left rear flasher Right rear flasher Tail stop light Horn Flasher relay 22 P Coolant thermo indicator light N Fuel sender indicator R Clock and odometer L Flasher light indicator M Flasher light indicator 23 Sender ...

Page 236: ...use Clean the battery terminals Recharge or re place the battery YES NO EAS00739 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is the battery OK YES NO EAS00749 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK YES NO Replace the main switch SIGNALING ...

Page 237: ...sitive tester probe pink Negative tester probe ground Set the main switch to ON Push the horn switch Measure the voltage 12 V of brown at the horn terminal Is the voltage within specification Replace the left handlebar switch YES NO Thewiringcircuitfrom the main switch to the horn connector is faulty and must be repaired YES NO The horn is OK 4 Voltage Connect the pocket tester DC V 20 to the horn...

Page 238: ... to CHECKING THE SWITCHES Is the brake light switch OK YES NO Replace the brake light switch 3 Voltage Connect the pocket tester DC V 20 to the tail brake light coupler wire harness side as shown Positive tester probe yellow Negative tester probe black Set the main switch to ON Pull in the brake levers Measure the voltage 12 V of yellow on thetail brakelightcoupler wireharnessside Is the voltage w...

Page 239: ...easure the voltage 12 V on brown white at the turn signal relay coupler wire har ness side Is the voltage within specification YES NO The turn signal relay is faulty and must be replaced 5 Voltage Connect the pocket tester DC V 20 to the turn signal light connector as shown A Turn signal light B Turn signal indicator light Left turn signal light Positive tester probe chocolate Negative tester prob...

Page 240: ...vel gauge fails to operate 1 Fuel sender Remove the fuel sender from the fuel tank Connect the pocket tester to the fuel sender coupler wire harness side as shown Positive tester probe green Negative tester probe black Measure the fuel sender resistances Fuel sender resistance up position Ω x 1 1 5 7 5 Ω at 20 C Fuel sender resistance down position Ω x 10 90 100 Ω at 20 C Is the fuel sender OK YES...

Page 241: ...witch to ON Move the float up or down Checkthatthefuellevelgaugeneedlemoves to up or down NOTE Before reading the fuel level gauge leave the float in one position either up or down for at least three minutes Does the fuel level gauge needle move ap propriately YES NO Replace the speedo meter unit 4 Wiring Check the entire signal system s wiring Refer to CIRCUIT DIAGRAM Is the signalling system s w...

Page 242: ...ltage 12 V Is the voltage within specification YES NO Thewiringcircuitfrom the main switch to the clock coupler is faulty andmustberepaired 2 Clock Check that the clock is operating properly When setting the clock after its power source has been disconnected e g when the bat teryisremoved firstsettheclockto1 00AM and then to the correct time Is the clock operating properly YES NO This circuit is O...

Page 243: ...Y G BR BLACK BLACK Dg Ch Ch LW LW LW LW Dg Ch Br Br G Ch Ch LW R B LW LW Dg BR NO CONNECTION Br Ch GW WR WL NO CONNECTION B NO CONNECTION RED NO CONNECTION B NO CONNECTION METER ASSY Br R ANTI THEFT ALARM OPTION B Dg LW LW L R L Br R W W HEAD LIGHT ASSY Sb Dg B NO CONNECTION LW LW RED L Ch G B Dg Y LW L Ch G B Dg Y B L Y Br Y GY GY Br Br YB YB Br L L L Y Ch G Dg Ch BW B LW B Dg Ch ILLUMI Y R WIRE ...

Page 244: ... motor fails to turn 1 Main and radiator fan motor fuses Check the fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the fuses OK Clean the battery terminals Recharge or re place the battery EAS00739 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is the battery OK YES NO EAS00749 3 Main swi...

Page 245: ... Does the radiator fan motor turn YES NO Theradiatorfanmotor is faulty and must be replaced WARNING Handle the thermo switch with special care Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it YES NO Replace the thermo switch B A EAS00813 7 Wiring Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM Is the cooling system s wiring properly con ...

Page 246: ...ant Slowly heat the coolant and then let it cool to the specified temperature indicated in the table Check the thermo switch for continuity at the temperatures indicated in the table Temperature sender resistance 80 C 47 5 56 8 Ω 100 C 26 2 29 3 Ω WARNING Handle the temperature sender with special care Never subject the temperature sender to strong shocks If the temperature sender is dropped repla...

Page 247: ... B Y G BR BLACK BLACK Dg Ch Ch LW LW LW LW Dg Ch Br Br G Ch Ch LW R B LW LW Dg BR NO CONNECTION Br Ch GW WR WL NO CONNECTION B NO CONNECTION RED NO CONNECTION B NO CONNECTION METER ASSY Br R ANTI THEFT ALARM OPTION B Dg LW LW L R L Br R W W HEAD LIGHT ASSY Sb Dg B NO CONNECTION LW LW RED L Ch G B Dg Y LW L Ch G B Dg Y B L Y Br Y GY GY Br Br YB YB Br L L L Y Ch G Dg Ch BW B LW B Dg Ch ILLUMI Y R WI...

Page 248: ...g special tool s Pocket tester 90890 03112 EAS00738 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 Is the main fuse OK Replace the fuse YES NO Clean the battery terminals Recharge or re place the battery EAS00739 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is th...

Page 249: ...S00826 6 Wiring oftheentirecarburetorheatingsystem Check the entire carburetor heating sys tem s wiring Refer to CIRCUIT DIAGRAM Is the carburetor heating system properly connected and without defects YES NO Replace the thermo switch YES NO Replace the carbu retorheatingelement YES NO This circuit is OK Properly connect or repair the carburetor heating system s wir ing Check the thermo switch for ...

Page 250: ...9 TRBL SHTG ...

Page 251: ... HIGH SPEED PERFORMANCE 9 2 ENGINE 9 2 FUEL SYSTEM 9 2 FAULTY CLUTCH 9 3 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE 9 3 CLUTCH SLIPS 9 3 POOR STARTING PERFORMANCE 9 3 POOR SPEED PERFORMANCE 9 3 OVER HEATING 9 3 ENGINE 9 3 COOLING SYSTEM 9 3 FUEL SYSTEM 9 3 CHASSIS 9 3 ELECTRICAL SYSTEMS 9 3 OVERCOOLING 9 4 COOLING SYSTEM 9 4 POOR BRAKING 9 4 FAULTY FRONT FORK LEGS 9 4 LEAKING OIL 9 4 MALFUNCTION 9 ...

Page 252: ...DOES NOT LIGHT 9 5 HEADLIGHT BULB BURNT OUT 9 5 TAIL BRAKE LIGHT DOES NOT LIGHT 9 5 TAIL BRAKE LIGHT BULB BURNT OUT 9 5 TURN SIGNAL DOES NOT LIGHT 9 5 TURN SIGNAL BLINKS SLOWLY 9 5 TURN SIGNAL REMAINS LIT 9 6 TURN SIGNAL BLINKS QUICKLY 9 6 HORN DOES NOT SOUND 9 6 TRBL SHTG ...

Page 253: ...e Piston and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft STARTING FAILURE HARD STARTING FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel tank cap breather hole Deteriorat...

Page 254: ...tarter relay Faulty starter clutch EAS00847 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder and cylinder head Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Carburetor Faulty starter plunger Loose or clogged pilot jet Loose or clogged pilot air jet Damaged or loose carburetor joint Improperly adjusted engine idling speed throttle stop screw...

Page 255: ...ystem Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin Water pump Damaged or faulty water pump Thermostat Thermostat stays closed FUEL SYSTEM Carburetor Incorrect main jet setting Incorrect fuel level Damaged or loose carburetor joint Air filter Clogged air filter element CHASSIS Brake s Dragging brake ELECTRICAL SYSTEMS Spark plug Incorrect spark plug gap Incorrect spa...

Page 256: ...on Incorrect brake shoe position Damaged or fatigued brake shoe spring Oil or grease on the brake shoe Oil or grease on the brake drum Broken brake torque rod Improper brake lever adjustement EAS00860 FAULTY FRONT FORK LEGS LEAKING OIL Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly...

Page 257: ...GHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts main or light switch Burnt out headlight bulb HEADLIGHT BULB BURNT OUT Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired TAIL BRAKE LIGHT DOES ...

Page 258: ... BLINKS QUICKLY Incorrect turn signal bulb Faulty turn signal relay Burnt out turn signal bulb HORN DOES NOT SOUND Improperly adjusted horn Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness FAULTY LIGHTING OR SIGNALING SYSTEM ...

Page 259: ...B Y G BR BLACK BLACK Dg Ch Ch LW LW LW LW Dg Ch Br Br G Ch Ch LW R B LW LW Dg BR NO CONNECTION Br Ch GW WR WL NO CONNECTION B NO CONNECTION RED NO CONNECTION B NO CONNECTION METER ASSY Br R ANTI THEFT ALARM OPTION B Dg LW LW L R L Br R W W HEAD LIGHT ASSY Sb Dg B NO CONNECTION LW LW RED L Ch G B Dg Y LW L Ch G B Dg Y B L Y Br Y GY GY Br Br YB YB Br L L L Y Ch G Dg Ch BW B LW B Dg Ch ILLUMI Y R WIR...

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Yamaha XN125 2000, Service Manual

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