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Yamaha YJ125S Service Manual Download Page 12

1-5

GEN

INFO

EAS00027

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.

Tool NO.

Tool name / Function

Illustration

90890-01083(M6)
YU-01083-1
90890-01085(M8)
YU-01083-2
90890-01084
YU-01083-3

90890-01235
YU-01235

90890-01268
YU-01268

90890-01311
YM-08035-A

90890-01312
YM-01312-A

90890-01326
YM-01326
90890-01294
YM-01300-1

90890-01337
YM-33285
YM-33285-6

90890-01348
YM-01348

90890-01189
YM-01189

Rocker arm shaft puller bolt

1

Weight

2

These tools are used when removing or in-
stalling the rocker arm shafts.

Rotor holding tool

This tool is used to remove the flywheel
magneto.

Ringnut wrench

This tool is used to loosen and tighten the
exhaust and steering ring nut.

Valve adjusting tool

This tool is necessary for adjusting valve
clearance.

Fuel level gauge

This gauge is used to measure the fuel level
in the float chamber.

T-handle

1

Damper rod holder

2

These tool are used for holding the Damper
rod holder when removing or installing the
damper rod holder.

Clutch spring holder

These tool are used for removing the nut
with holding the compression spring.

Lock nut wrench

This tool is used when removing or install-
ing the secondary sheave nut.

Flywheel puller

This tool is used for removing the
A.C. magneto rotor.

1

2

1

2

41

46

SPECIAL TOOLS

Summary of Contents for YJ125S

Page 1: ...YJ125S SERVICE MANUAL LIT 11616 17 43 5YR 28197 10 ...

Page 2: ...2003 by Yamaha Motor Taiwan Co Ltd First edition November 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co Ltd is expressly prohibited Printed in U S A LIT 11616 17 43 ...

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

Page 4: ...mation such as special tools and technical data are described se quentially 5 28 ENG Remarks Order Job Part Q ty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EAS00251 CYLINDER AND PISTON Removing the cylinder and piston Cylinder head Clamp Pipe Timing chain guide exhaust side Cylinder O ring Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring Expander Remove the parts in the...

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

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

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

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

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

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

Page 11: ...heck 8all connections Loose connection J Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect 8lead 8coupler 8connector NOTE Make sure all connections are tight 5 Check 8continuity with the pocket tester Pocket tester 90890 03132 YU 03112 C NOTE 8 If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 8 As a quick remedy us...

Page 12: ...285 6 90890 01348 YM 01348 90890 01189 YM 01189 Rocker arm shaft puller bolt1 Weight2 These tools are used when removing or in stalling the rocker arm shafts Rotor holding tool This tool is used to remove the flywheel magneto Ringnut wrench This tool is used to loosen and tighten the exhaust and steering ring nut Valve adjusting tool This tool is necessary for adjusting valve clearance Fuel level ...

Page 13: ...l seal lip when installing the secondary sliding sheave Ring nut wrench This tool is used to loosen and tighten the steering ring nut Sheave holder This tool is used for holding the secondary sheave Thickness gauge This tool is used to measure the valve cleanance Compression gauge These tool are used to measure the engine compression Pocket tester This instrument is invaluable for checking the ele...

Page 14: ...strument is necessary for checking the ignition system components Yamaha bond NO 1215 This sealant bond is used for crankcase mating surface etc Valve guide remover 4 5 mm This tool is used to remove or install the valve guides Valve guide installer 4 5 mm This tool is used to install the valve guides Valve guide reamer 5 0 mm This tool is used to rebore the new valve guides SPECIAL TOOLS ...

Page 15: ... 14 CONVERTION TABLE GENERAL TIGHTENING TORQUE SPECIFICA TIONS 2 18 TIGHTENING TORQUES 2 19 ENGINE TIGHTENING TORQUES 2 19 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2 22 CHASSIS LUBRICATION POINTS AND LUBRICATION TYPES 2 24 OIL FLOW DIAGRAMS 2 25 CABLE ROUTING 2 27 ...

Page 16: ...th 699 mm 27 5 in Overall height 1063 mm 41 8 in Seat height 759 mm 29 8 in Wheelbase 1230 mm 48 4 in Ground clearance 95 mm 3 8 in Minimum turning radius 1800mm 72 in Weight Wet without oil and a full fuel tank 109 kg 240 lb Dry without oil and fuel 104kg 229 lb Maximun load total of cargo rider 253kg 558 lb passenger and accessories GENERAL SPECIFICATIONS ...

Page 17: ...l Recommended fuel Regular unleaded gasoline Fuel tank capacity Total including reserve 4 5L 0 98lmp gal 1 18 USgal Engine oil Lubrication system Wet sump Recommended oil SAE20W40SE Yamaha 4 cycle oil EFERO X Z BX Quantity Periodic oil change 1 0L 0 92 lmp qt 1 09 US qt With oil filter replacement 1 2L 1 10 lmp qt 1 31 US qt Total amount 1 2L 1 10 lmp qt 1 31 US qt Final gear oil Recommended oil S...

Page 18: ...mm 0 23mm Outer rotor to pump housing clearance 0 013 0 036 mm 0 106mm Oil pump housing to inner rotor and outer 0 06 0 10 mm 0 17mm rotor clearance Starting system type Electric and kick starter Spark plug Model manufacturer quantity CR7E NGK 1 Spark plug gap 0 7 0 8mm Cylinder head Volume 12 3 12 7cm Max warpage 0 03 mm ENGINE SPECIFICATIONS ...

Page 19: ...easurement A 26 153 26 253 mm 26 053 mm Measurement B 21 015 21 115 mm 20 915 mm Measurement C 5 203mm Exhaust camshaft lobe dimensions Measurement A 26 153 26 253 mm 26 053 mm Measurement B 21 056 21 156 mm 20 956 mm Measurement C 5 203 mm Max camshaft runout 0 03 mm C A B C A B ENGINE SPECIFICATIONS ...

Page 20: ...Intake 0 9 1 1 mm 1 6mm Exhaust 0 9 1 1 mm 1 6mm Valve margin thickness D Intake 0 85 1 15 mm Exhaust 0 85 1 15 mm Valve stem diameter Intake 4 475 4 490 mm 4 445 mm Exhaust 4 460 4 475 mm 4 430 mm Valve guide inside diameter Intake 4 500 4 512 mm 4 550 mm Exhaust 4 500 4 512 mm 4 550 mm Valve stem to valve guide clearance Intake 0 010 0 037 mm 0 080 mm Exhaust 0 025 0 057 mm 0 100 mm Valve stem r...

Page 21: ...led Intake 147 11N 15 0 1 1 kgf mm Exhaust 147 11N 15 0 1 1 kgf mm Spring tilt Intake 2 5 1 6 mm Exhaust 2 5 1 6 mm Winding direction top view Intake Clockwise Exhaust Clockwise Valve seat reformed Yes Cylinder Cylinder arrangement Forward inclined single cylinder Bore stroke 51 5 60mm Compression ratio 9 8 0 4 1 Bore 51 49 51 53 mm Max taper 0 05 mm Max out of round 0 05 mm ENGINE SPECIFICATIONS ...

Page 22: ... pin Outside diameter 12 996 13 000 mm 12 976 mm Piston rings Top ring Ring type Barrel Dimensions B T 1 0 2 1mm End gap installed 0 10 0 20 mm 0 45mm Ring side clearance 0 02 0 08 mm 0 13 mm 2nd ring Ring type Plain Dimensions B T 1 0 2 1mm End gap installed 0 20 0 30 mm 0 65mm Ring side clearance 0 02 0 06 mm 0 12mm Oil ring Dimensions B T 2 0 2 2 mm End gap installed 0 2 0 7 mm Ring side cleara...

Page 23: ...side diameter 9 981 9 991 mm Arm to shaft clearance 0 009 0 034 mm Connecting rod Connecting rod length 97 95 98 05 mm Small end inside diameter 13 015 13 028mm Crankshaft Width A 45 15 45 20 mm Max runout C 0 03mm Big end side clearance D 0 10 0 40 mm 1 00mm Big end radial clearance E 0 0 010mm ENGINE SPECIFICATIONS ...

Page 24: ...ction ratio 40 15 2 667 Secondary reduction system Spur gear Secondary reduction ratio 38 13 2 923 Max main axle runout 0 02 mm Max drive axle runout 0 02 mm Carburetor Model manufacturer quantity BS26 MIKUNI 1 ID mark 5YR 00 Venturi tube bore Ø22 3 Main jet 97 5 Main air jet 0 5 Jet needle 4D 16 1 Needle jet 0 4M Pilot air jet 1 160 Pilot outlet 0 81 Pilot jet 22 5 Bypass 1 Ø0 8 Bypass 2 Ø1 0 Byp...

Page 25: ...ard Limit Throttle bodys Model manufacturer quantity 5YR SAFETY CONTROL CABLE 2 Intake vacuum pressure 30 0kpa 238 6mmHg Throttle cable free play at the flange of the 3 5mm throttle grip ID mark 5YR1 ENGINE SPECIFICATIONS ...

Page 26: ...ast wheel Rim Size 10 MT2 15 Material Aluminum Wheel travel 54mm Wheel runout Max radial wheel runout 1 0 mm Max lateral wheel runout 1 0 mm Front tire Tire type Tubeless Size 3 50 10 51J Model manufacturer C 922L CHENG SHIN Tire pressure cold 0 90 kg 150kpa 1 5 kg cm 22 psi 90 197 kg 150kpa 1 5 kg cm 22 psi Min tire tread depth 0 8mm Rear tire Tire type Tubeless Size 3 50 10 51J Model manufacture...

Page 27: ...lever end 3 5mm Recommended fluid DOT 4 Brake disc Diameter x thickness 180 0 4 0 mm 180 0 3 5 mm Min thickness 3 5mm Max deflection 0 10 mm Brake pad lining thickness inner 6 0 mm 0 8mm Brake pad lining thickness outer 6 0 mm 0 8mm Master cylinder inside diameter 11mm Caliper cylinder inside diameter 34 93mm CHASSIS SPECIFICATIONS ...

Page 28: ... rate K2 19 6N mm 1 96kg mm Spring stroke K2 50 80mm Optional spring available No Fork oil Recommended oil Fork oil G10 or equivalent Quantity each front fork leg 126 2 5cc Inner tube outer diameter 33 mm Inner tube bending limit 0 2 mm Steering system Steering bearing type Angular bearing Lock to lock angle left 47 5 Lock to lock angle Right 47 5 Rear suspension Suspension type Swingarm Rear shoc...

Page 29: ...rging system System type C D I magneto Model manufacturer 5NW 01 T MORIC Nominal output 14V 120W 5000 r min Lighting coil resistance color 0 28 0 42 Ω B YR Lighting coil resistance color 0 32 0 48 Ω B W Voltage regulator Regulator type Semiconductor short circult Model manufacturer SH671 12 XIN DIAN YUAN No load regulated voltage DC 14 15 V Rectifier Model manufacturer SH671 12 XIN DIAN YUAN Recti...

Page 30: ...m Standard Limit Bulbs voltage wattage quantity Headlight 12 V 60 W 55 W 1 Tail brake light 12 V 8W 27 W 1 Front turn signal light 12 V 10 W 2 Rear turn signal light 12 V 10 W 2 Speedometer light 14 V 3 W 1 Fuel lever meter light 14 V 3 W 1 ...

Page 31: ...ction voltage Below DC8V Horn Horn type Plane Model manufacturer AH 368 ASIA TRAFFIC Max amperage 1 5 A Performance 95 105db 2m Coil resistance 4 05 4 55 Ω Turn signal relay Relay type Semi transistor Model manufacturer 5CA9 TA YOUNG Self cancelling device built in NO Turn signal blinking frequency 75 95 cycles min Wattage 10 W 2 1 7 W AP Fuel sender Model manufacturer 5YR1 CHAO LONG Sender unit r...

Page 32: ...2 17 SPEC Item Standard Limit ELECTRICAL SPECIFICATIONS Fuel lever meter Type manufacturer Moving magneto CHAO LONG Fuse amperage quantity Main fuse 10A 1 Reserve fuse 10A 1 ...

Page 33: ...dry threads Com ponents should be at room temperature A Width across flats B Thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Tighten ing torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 281 1 09...

Page 34: ...mp AI filter Crankcase 1and 2 Crankcase cover1 Crankcase cover2 Cover1 magneto Drain bolt transmission oil Nut _ Bolt _ _ Bolt Bolt Bolt _ Bolt Bolt plug Screw Screw Bolt Screw Screw Bolt _ Union bolt Bolt plug Nut Screw Screw Screw plug Nut Bolt Screw Screw Screw Bolt Hose clamp Bolt Bolt Bolt Bolt Screw Bolt M8 M10 M6 M6 M6 M6 M6 M6 M5 M8 M6 M8 M6 M6 M6 M6 M6 M6 M8 M6 M35 M6 M6 M6 M6 M6 M6 M8 M6...

Page 35: ... Crankcase cover3 Plate V belt guide Idle gear plate Kick crank assembly Clutch housing Clutch carrier assembly Primary fixed sheave Starter motor assembly C D I rotor _ Screw Bolt _ _ Screw Screw Screw Bolt Nut Nut Nut Bolt Nut M8 M6 M6 M8 M8 M6 M6 M6 M8 M14 M36 M12 M6 M12 1 1 1 2 2 3 3 2 1 1 1 1 2 1 23 7 10 12 5 12 5 7 9 7 23 60 90 55 7 70 2 3 0 7 1 0 1 25 1 25 0 7 0 9 0 7 2 3 6 0 9 0 5 5 0 7 7 ...

Page 36: ...d screw M10 M10 M10 M10 M8 M8 M8 M8 M25 M10 M10 M8 M6 M10 M5 M8 M6 M12 M14 M6 M10 M10 M8 M10 M7 42 55 32 30 18 28 1 19 75 60 47 5 30 9 26 7 23 10 70 105 10 22 35 20 23 6 4 2 5 5 3 2 3 0 1 8 2 8 0 1 1 9 7 5 6 0 4 75 3 0 0 9 2 6 0 7 2 3 1 0 7 0 10 5 1 0 2 2 3 5 2 0 2 3 0 6 See NOTE NOTE 1 First tighten the ring nut lower approximately 28 Nm 2 8m kg 20 3ft lb by using the torque wrench then loosen th...

Page 37: ...de surface Connecting rod Piston outside and ring groove Piston pin outside surface surface and bolt thread Crankshaft journal Piston balancer outside surface Piston pin balancer outside surface Camshaft profile journal Valve stem IN EX Valve stem seal Valve stem end IN EX Valve lifter Oil pump assembly inside Oil pipe union bolt thread and surface Gasket Oil pump assembly Idle gear 1 thrust surfa...

Page 38: ...ubrication Point Lubricant LUBRICATION POINTS AND LUBRICANT TYPES LS Primary sheave inside Collar Solid bush Secondary fixed inner surface Secondary sheave torque cam ditch Gasket Cylinder head cover Stopper guide Cylinder head cover Crankcase mating surfaces Oil pipe C D I magneto lead grommet ...

Page 39: ...d lower Frame head pipe dust seal lips lower Tube guide throttle grip inner surface Brake lever and lever holder bolt sliding surface Sidestand and frame sliding surface Centerstand sliding surface and mounting bolt Rear footrest pin outside surface Rear shock absorber backward bush inner surface and spacer sliding surface Seat lock cable and cylinder inner surface Engine bracket and engine mound ...

Page 40: ...2 25 SPEC OIL FLOW DIAGRAMS 1 Oil strainer 2 Oil pump 3 Oil filter 4 Oil delivery pipe 5 Oil delivery pipe union bolt OIL FLOW DIAGRAMS ...

Page 41: ...2 26 SPEC OIL FLOW DIAGRAMS 1 Connecting rod big end bearing ...

Page 42: ...ght side hole C Route the front brake hose through the front brake hose holder D Colar white mark to the out side E The seat lock cable pass the frame right side hole into frame inside protector part to the hole position F Clamp the wire harness wire positive lead and wire nega tive lead to the frame clamp position to the white mark and press to tighten G Fasten the wire harness wire positive lead...

Page 43: ...ter than 5mm L Pass the seat lock cable along the outside of the reinf tail M Installing the bend hose 5 to the AI Filter assembly into the frame inside N Route the trail light lead and rear turn signal light lead through the rear cover hole O The tail light through the base hole F 4 5 A F 1 2 3 B C D E t F G B B 6 7 8 9 H I 0 J q K L M N O w e r T t o u a p i P u t 7 6 y 8 7 d s Q FORWARD BACKWAR...

Page 44: ...ble holder D Pass the rear brake cable over the engine bracket cross tube bar E Route the vacuum sensing hose between throttle cable 1 and throttle cable 2 F Clamp the canister pipe breather hose and fuel cock vacuum hose the end of down G Clamp the canister pipe fuel hose and fuel cock vacuum hose H The filler cover and fuel over flow hose into the spacer I Pass the fuel overflow hose outside the...

Page 45: ... the footrest board F Fasten the autochoke lead and heater lead to the cross tube and cut the end to be shorter than 5mm G Fasten the vacuum sensing hose starter motor positive lead C D I magneto lead and high tension cord and the vacuum sensing hose to the over position and cut the end H Clamp the starter motor lead and C D I magneto lead I Pass the fuel overflow hose along the left side of the f...

Page 46: ...DLING SPEED 3 10 CHECKING THE EXHAUST GAS AT IDLE 3 11 CHECKING THE EXHAUST GAS AT IDLE 3 11 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 13 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 13 CHECKING THE SPARK PLUG 3 15 CHECKING THE SPARK PLUG 3 15 CHECKING THE IGNITION TIMING 3 16 CHECKING THE IGNITION TIMING 3 16 MEASURING THE COMPRESSION PRESSURE 3 17 MEASURING THE COMPRESSION PRESSURE 3 17 CHECKING THE ...

Page 47: ...DJUSTING THE FRONT BRAKE 3 31 ADJUSTING THE REAR BRAKE 3 31 CHECKING THE BRAKE FLUID LEVEL 3 32 CHECKING THE BRAKE FLUID LEVEL 3 32 CHECKING THE FRONT BRAKE PADS CHECKING THE REAR BRAKE SHOES CHECKING THE FRONT BRAKE HOSE 3 33 CHECKING THE FRONT BRAKE PADS 3 33 CHECKING THE REAR BRAKE SHOES 3 33 CHECKING THE FRONT BRAKE HOSE 3 33 BRAKE FLUID CHANGE 3 34 BRAKE FLUID CHANGE 3 34 BLEEDING THE HYDRAUL...

Page 48: ...AND 3 45 CHECKING AND CHARGING THE BATTERY 3 46 ELECTRICAL SYSTEM 3 46 CHECKING AND CHARGING THE BATTERY 3 46 CHECKING AND CHARGING THE BATTERY CHECKING THE FUSES 3 52 CHECKING THE FUSES 3 52 REPLACING THE HEADLIGHT BULB 3 54 REPLACING THE HEADLIGHT BULB 3 54 ADJUSTING THE HEADLIGHT BEAMS 3 55 ADJUSTING THE HEADLIGHT BEAMS 3 55 ...

Page 49: ...haul work This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter NOTE The annual checks must be performed every year except if a kilometer based maintenance is performed instead From 30 000 km repeat the maintenance intervals starting from 6 000 km Items marked with an a...

Page 50: ...ths 6 000 mi 10 000 km or 18 months 8 000 mi 13 000 km or 24 months 1 Fuel line Check fuel hoses and vacuum hose for cracks or damage 2 Valves Check valve clearance Adjust if necessary 3 Spark plug Check condition Clean and regap Replace 4 Air filter element Clean Replace 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Carburetor Adjust engine idling spe...

Page 51: ...Rear brake Check operation and adjust brake lever free play Replace brake shoes Whenever worn to the limit 4 Brake hose Check for cracks or damage Replace See NOTE Every 4 years 5 Wheels Check runout and for damage 6 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 7 Wheel bearings Check bearing for looseness or damage 8 Steering bearings Check be...

Page 52: ...oving the seat and side covers Seat Rear carrier Side cover left Side cover right Hook left Hook right Cover Front cover Fuel tank cap Rear cover Tail brake light License plate Trunk Remove the parts in the order listed For installation reverse the removal pro cedure COVER AND PANEL 13 4 6 5 7 1 8 3 12 10 11 9 2 23Nm 2 3m kg 16 6 ft lb ...

Page 53: ...eft and right Mat Battery cover Battery negative lead Battery positive lead Battery Footrest board side cover mole left Footrest board side cover mole right Footrest board Remove the parts in the order listed Refer to SEAT AND SIDE COVERS cC First disconnect the negative battery lead and then the positive battery lead For installation reverse the removal pro cedure COVER AND PANEL 1 7 4 3 5 2 8 6 ...

Page 54: ...otrest board Headlight cover Headlight assembly Front turn signal light bracket Leg shield 1 Main switch cover Fuel lever meter Leg shield 2 Remove the parts in the order listed Refer to FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE For installation reverse the removal pro cedure COVER AND PANEL 6 5 7 3 2 4 1 ...

Page 55: ... clearance is to be mea sured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove 8cover 8rear carrier 8side cover right left 8hook 8front cover 8spark plug cap Refer to COVER AND PANEL 2 Remove 8spark plug 8engine oil cap 8valve cover exhaust 8cap1 3 Measure 8valve clearance Out of specification J Adjust Valve clearance cold Intake valve 0 08 0 12 mm 0 003 0 0...

Page 56: ...t 1 b Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip c Turn the adjusting screw 3 in direction a or b until the specified valve clearance is obtained Direction a Valve clearance is increased Direction b Valve clearance is decreased Tappet adjusting tool 90890 01311 YM 08035 A d Hold the adjusting screw to prevent it from moving and tighten the locknut to specif...

Page 57: ...E VALVE CLEARANCE 5 Install 8cap 8spark plug 12 5 Nm 1 25 m kg 9 ft lb 8valve cover exhaust 8engine oil cap 6 Install 8spark plug cap 8front cover 8hook 8side cover right left 8rear carrier 8cover Refer to COVER AND PANEL T R ...

Page 58: ...of cylinder Engine tachometer 90890 03113 YU 08036 C 3 Check 8engine idling speed Out of specification J Adjust Engine idling speed 1600 1700 r min 4 Adjust 8engine idling speed a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained Direction a Engine idling speed is increased Direction b Engine idling speed is decreased 5 Adjust 8throttle cable fr...

Page 59: ...r1 onto the engine oil drain bolt 8engine tachometer onto the spark plug lead Pocket tester 90890 03132 YU 03112 C Engine tachometer 90890 03113 YU 08036 C 3 Start the engine and warm it up until the specified oil temperature is reached Oil temperature 70 80 C 4 Measure 8engine idling speed Out of specification J Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED Engine idling speed 1600 1700 r min...

Page 60: ...t rubber tube so that exhaust gas does not leak out 8 Before using the carbon monoxide and hy drocarbon tester be sure to read the user s manual 6 Measure 8carbon monoxide density 8 hydrocarbon density Carbon monoxide density when air induction system is operating 0 2 1 4 hydrocarbon density when air in duction system is operating 1000ppm below Out of specification J Check air induc tion system Re...

Page 61: ...er 8side cover right Refer to COVER AND PANEL 3 Adjust 8throttle cable free play Carburetor side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction a Throttle cable free play is increased Direction b Throttle cable free play is de creased c Tighten the locknuts NOTE If the specified throttle cable free play canno...

Page 62: ... is increased Direction b Throttle cable free play is de creased c Tighten the locknut w After adjusting the throttle cable free play start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change 4 Install 8side cover right 8rear carrier 8cover Refer to COVER AND PANEL ADJUSTING THE THROTTLE CABLE FREE PLAY 1 2 b a ...

Page 63: ...7E NGK 5 Check 8electrode 1 Damage wear J Replace the spark plug 8insulator 2 Abnormal color J Replace the spark plug Normal color is medium to light tan 6 Clean 8spark plug with a spark plug cleaner or wire brush 7 Measure 8spark plug gap a with a wire Thickness gauge Out of specification J Regap Spark plug gap 0 7 0 8 mm 0 028 0 032 in 8 Install 8spark plug 12 5 Nm 1 25 m kg 9 ft lb NOTE Before ...

Page 64: ...ad of cylinder Timing light 90890 03141 YU 03141 Engine tachometer 90890 03113 YU 08036 C 3 Check ignition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed Oil temperture 70 80 C Engine idling speed 1600 1700 r min b Check that the mark 1 on the magneto ro tor is within the firing range 2 on the crank case Incorrect firing rangeJ C...

Page 65: ...VE CLEARANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Remove 8cover 8rear carrier 8side cover right left 8hook 8front cover Refer to COVER AND PANEL 4 Disconnect 8spark plug cap 5 Remove 8spark plug cC Before removing the spark plug use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder 6 Install 8co...

Page 66: ...gine c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposit J Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful engine of oil into the spark plug bore and measure again Refer to the following table Compression pressure with oil applied into the cylinder R...

Page 67: ...3 19 CHK ADJ 11 Install 8front cover 8hook 8side cover right left 8rear carrier 8cover Refer to COVER AND PANEL MEASURING THE COMPRESSION PRESSURE ...

Page 68: ...mark J Add the recommended engine oil to the proper level Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures API standard SE or higher grade cC 8 8 8 8 8 Do not allow foreign materials to enter the crankcase NOTE Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for seve...

Page 69: ...e cleaned 8 perform the following procedure a Remove the oil strainer cover 1 and oil fil ter element 2 b Replace the O ring 3 c Install the oil strainer cover Oil strainer cover 32 Nm 3 2 m kg 23 1 ft lb 6 Install 8engine oil drain bolt along with the gasket 23 Nm 2 3 m kg 16 6 ft lb 7 Fill 8crankcase with the specified amount of the recom mended engine oil Periodic oil change 1 0 L 0 92 lmp qt 1...

Page 70: ...rain 8engine oil 2 Remove 8oil delivery pipe bolt 1 8copper washers 3 Remove 8oil filter element cover1 8o ring2 8oil filter element 3 4 Install cC Be careful because it causes an engine trouble when the attachment direction of the oil filter element is mistaken 8oil filter element 1 8o ring2New 8oil filter element cover3 8 Nm 0 8 m kg 5 8 ft lb 8copper washers 8oil delivery pipe bolt 10 Nm 1 0 m ...

Page 71: ... a check bolt is removed and an engine is started 5 Fill 8crankcase Refer to CHECKING THE ENGINE OIL Quantity Total amount 1 2L 1 10 Imp qt 1 31 US qt Without oil filter element replace ment 1 2L 1 10 Imp qt 1 31 US qt Periodic oil change 1 0 L 0 92 Imp qt 1 09 US qt CHANGING THE ENGINE OIL FILTER ELEMENT ...

Page 72: ...p 8Transmission oil drain bolt 1 8Completely drain the transmission oil 5 Install 8transmission oil drain bolt 23 Nm 2 3 m kg 16 6 ft lb 6 Fill 8transmission oil with the specified amount of the recom mended transmission oil Total amount 0 15L 0 14 Imp qt 0 16 US qt Periodic oil change 0 13L 0 12 Imp qt 0 14 US qt Recommended oil SAE85W140SE 7 Install 8o ring1 8oil filler cap2 8 Start the engine f...

Page 73: ...ore be sure to measure the engine oil pressure after warming up the engine 3 Remove 8cover Refer to COVER AND PANEL 4 Lossen 8gallery bolt 1 w The engine muffler and engine oil are extremely hot 5 Check 8engine oil pressure a Start the engine and keep it idling until en gine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will...

Page 74: ... belt case air filter element 2 NOTE When assembling the element the yellow side the coarser side must face the case cover side of the air cleaner Wrong side assembling will result in failure of filtering Moreover the ele ment should be tightly sealed with the case cover of the crank to prevent from air leakage 3 Check 8V belt case air filter element 1 Damage J Replace 4 Clean 8V belt case air fil...

Page 75: ...ase air filter element when squeezing it 5 Apply the recommended oil to the entire surface of the air filter element and squeeze out the excess oil The air filter element should be wet but not dripping Recommanded oil Engine oil 6 Install 8element 1 7 Install 8element holder1 7 Nm 0 7 m kg 5 1 ft lb 8 Install 8damper cover 1 8kick starter 2 23 Nm 2 3 m kg 16 6 ft lb T R T R 1 1 2 1 ...

Page 76: ... 8side cover right left 8seat 8hook 8front cover 8fuel tank cap 8rear cover 8trunk Refer to COVER AND PANEL 2 Check 8carburetor joint 1 8intake manifold 2 Cracks damage J Replace Refer to CARBURETOR in chapter 6 3 Install 8trunk 8rear cover 8fuel tank cap 8front cover 8hook 8seat 8side cover right left 8rear carrier 8cover Refer to COVER AND PANEL 1 2 ...

Page 77: ...PANEL 2 Check 8vacuum hose 1 8fuel hose 2 Cracks damage J Replace Loose connection J Connect properly 3 Install 8side cover left 8rear carrier 8cover Refer to COVER AND PANEL EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove 8cover Refer to COVER AND PANEL 2 Check 8crankcase breather hose 1 Cracks damage J Replace Loose connection J Connect properly cC Make sure the crankcase breather hose is...

Page 78: ...INDUCTION SYSTEM in chapter 6 2 Check 8muffler assembly 1 Cracks damage J Replace 8gasket Exhaust gas leaks J Replace 3 Check 8tightening torque Muffler assembly nut2 2 2 2 2 10 Nm 1 0 m kg 7 2 ft lb Muffler and rear arm bolt 3 3 3 3 3 31 Nm 3 1 m kg 22 4 ft lb Protector screw 4 4 4 4 4 7 Nm 0 7 m kg 5 1 ft lb 4 Install 8air cut off valve assembly 8hose to cylinder head 8vacuum hose 8hose from air...

Page 79: ...considerably 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 8brake lever free playa Out of specification J Adjust Brake lever free play 10 20 mm 0 4 0 8 in 2 Adjust 8brake lever free play Rear wheel side a Turn the adjusting nut 1 in direction a or b until the ...

Page 80: ... causing leak age and poor brake performance 8 8 8 8 8 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 8 8 8 8 8 When refilling be careful that water does not enter the brake fluid reservoir Wa ter will significantly lower the boiling point of the brake fluid and could cause vapor...

Page 81: ...BRAKE PADS in chapter 4 EAS00126 CHECKING THE REAR BRAKE SHOES 1 Operate the brake 2 Check 8wear indicator 1 Reaches the wear limit line 2 J Replace the brake shoes as a set Refer to REAR WHEEL AND REAR BRAKE in chapter 4 EAS00130 CHECKING THE FRONT BRAKE HOSE 1 Check 8brake hose 1 Cracks damage wear J Replace 2 Check 8brake hose clamp Loose connection J Tighten the clamp bolt 3 Hold the scooter u...

Page 82: ... place the scooter in upright position 8 During change be sure the scooter is standing vertically 2 Remove 8reservoir cap 1 Remove the reservoir cap of the master cylinder at horizontal condition 3 Bleed 8hydraulic brake system a Securely connect the transparent vinyl hose 1 to the fluid screw 2 b Place the other end of the hose in the oil pan receiving pan c Slowing operate the brake lever for se...

Page 83: ...ke lever slowly for several times Repeat the procedures until the small amount of air air bubbles in the reservoir tank disappears and the brake lever feels heavy h Bleed Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM w Following air expelling for the hydraulic brake please verify the actuating condition of the brake 4 Install 8reservoir cap 1 6Nm 0 16m kg 1 2 ft lb BRAKE FLUID CHANGE T R ...

Page 84: ...llow air to enter the hy draulic brake system considerably length ening the bleeding procedure 8 If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 2 Bleed 8hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the...

Page 85: ...d from the brake fluid in the plastic hose j Tighten the bleed screw to specification Bleed screw 6 Nm 0 6 m kg 4 3 ft lb k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKINGTHE BRAKE FLUID LEVEL w After bleeding the hydraulic brake system check the brake operation 3 Install reservoir cap 1 6 Nm 0 16 m kg 1 2 ft lb T R T R ...

Page 86: ...Adjust the steering head 3 Remove 8head light cover 8front turn signal light bracket 8leg shield 1 Refer to COVER AND PANEL 4 Adjust 8steering head a Remove the upper ring nut 1 the lock washer 2 the center ring nut 3 and the rubber washer 4 b Loosen the lower ring nut 5 and then tighten it to specification with the steering nut wrench 6 NOTE Set the torque wrench at a right angle to the steering ...

Page 87: ...NG HEAD in chapter 4 e Install the rubber washer f Install the center ring nut g Finger tighten the center ring nut 7 then align the slots of both ring nuts If neces sary hold the lower ring nut and tighten the center ring nut until their slots are aligned h Install the lock washer 8 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b i Hold the lower and center ring nuts w...

Page 88: ... falling over 2 Check 8inner tube Damage scratches J Replace 8oil seal Oil leakage J Replace 3 Hold the scooter upright and apply the front brake 4 Check 8front fork operation Push down hard on the handlebar sev eral times and check if the front fork re bounds smoothly Rough movement J Repair Refer to FRONT FORK in chapter 4 CHECKING THE FRONT FORK ...

Page 89: ...re pressure and the suspension must be adjusted according to the total weight including cargo rider passen ger and accessories and the anticipated riding speed 8 8 8 8 8 Operation of an overloaded scooter could cause tire damage an accident or an injury 8 8 8 8 8 NEVER OVERLOAD THE SCOOTER Total weight of rider passenger cargo and accessories w It is dangerous to ride with a worn out tire When the...

Page 90: ...roove 8 8 8 8 8 Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement A Tire B Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire 8 8 8 8 8 After extensive tests the tires listed be low have been approved by Yamaha MotorTaiwan Co Ltd for this model The front and ...

Page 91: ... Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 8 Install the tire with the mark pointing in the direction of wheel rotation 8 Align the mark 2 with the valve installation point CHECKING THE TIRES 2 1 ...

Page 92: ...edure applies to all of the in ner and outer cables w Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check 8outer cable Damage J Replace 2 Check 8cable operation Rough movement J Lubricate Recommended lubricant Engine oil or a suitable cable lubricant NOTE Hold the cable end upright and pour a fe...

Page 93: ... moving parts of the sidestand Recommended lubricant Lithium soap based grease EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Lithium soap based grease LUBRICATING THE SIDESTAND LUBRICATING THE CENTERSTAND ...

Page 94: ...ctrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL 8 8 8 8 8 Skin Wash with water 8 8 8 8 8 Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL 8 8 8 8 8 Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention cC 8 8 8 8 8 This is a sealed...

Page 95: ...the negative battery lead 1 1 1 1 1 and then the positive battery lead 2 2 2 2 2 3 Remove 8battery 4 Check 8battery charge a Connect a digital pocket tester 1 to the battery terminals Pocket tester 90890 03132 YU 03112 C Positive tester probe J positive battery terminal Negative tester probe J negative battery terminal NOTE 8 The charge state of an MF battery can be checked by measuring its open c...

Page 96: ...e battery 8 8 8 8 8 When charging a battery be sure to re move it from the scooter If charging has to be done with the battery mounted on the scooter disconnect the negative bat tery lead from the battery terminal 8 8 8 8 8 To reduce the chance of sparks do not plug in the battery charger until the bat tery charger leads are connected to the battery 8 8 8 8 8 Before removing the battery charger le...

Page 97: ...f the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode 8 8 8 8 8 As shown in the following illustration the open circuit voltage of an MF bat tery stabilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is com pleted before ...

Page 98: ...perage Set the timer to the charging time determined by the opencircuit voltage Refer to CHECKING AND CHARGING THE BATTERY Adjust the char ging voltage to 20 25V Monitor the amperage for 3 5 minutes Is the standard charg ing amperage exceeded If the amperage does not ex ceed the standard charging am perage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advi...

Page 99: ...n on the bat tery NOTE Set the charging time to a maximum of 20 hours NOTE Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage Charge the battery until the charging voltage reaches 15 V Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is re quired Under 12 0 V Replac...

Page 100: ... connection J Connect properly 9 Lubricate 8battery terminals Recommended lubricant Dielectric grease 10 Install 8battery cover 8mat Refer to COVER AND PANEL CHECKING AND CHARGING THE BATTERY CHECKING THE FUSES EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses cC To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove 8mat...

Page 101: ...amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit w Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could...

Page 102: ...til it has cooled down 5 Install 8headlight bulb New Secure the new headlight bulb with the headlight bulb holder cC Avoid touching the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lac...

Page 103: ... the adjusting screw 1and press headlight in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered 2 Adjust 8headlight beam horizontally a Turn the adjusting knob 1 in direction a or b Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left ADJUSTING THE HEADLIGHT BEAMS 1 a b b a 1 ...

Page 104: ...BRAKE PADS 4 16 FRONT BRAKE MASTER CYLINDER 4 19 DISASSEMBING THE FRONT BRAKE MASTER CYLINDER 4 20 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 21 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 21 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 23 FRONT BRAKE CALIPER 4 26 DISASSEMBING THE FRONT BRAKE CALIPER 4 27 DISASSEMBLING THE FRONT BRAKE CALIPER 4 28 CHECKING THE FRONT BRAKE CALIPE...

Page 105: ...WER FENDER COVER AND HANDLEBAR LOWER HOLDER 4 47 LOWER BRACKET 4 48 REMOVING THE LOWER BRACKET 4 50 CHECKING THE STEERING HEAD 4 51 INSTALLING THE STEERING HEAD 4 52 REAR SHOCK ABSORBER 4 53 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 53 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 53 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 54 ...

Page 106: ...t Wheel axle Front wheel Speedometer gear unit assembly Spacer Front brake disc 1 2 3 4 5 6 7 8 1 1 1 1 1 1 1 1 Remove the parts in the order listed NOTE Place the scooter on a suitable stand so that the front wheel is elevated Refer to REMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL For installation reverse the removal pro cedure 1 4 2 3 7 8 5 6 70Nm 7 0m kg 50 6 ft lb 20Nm 2 0m kg 14 5 f...

Page 107: ...HEEL FRONT WHEEL AND BRAKE DISC Disassembling the front wheel Oil seal Bearing Collar Bearing 1 2 3 4 Remove the parts in the order listed Refer to REMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL For assembly reverse the disassembly procedure 4 3 2 1 B B ...

Page 108: ... on a suitable stand so that the front wheel is elevated 2 Remove 8speedometer cable 8brake hose holder Refer to REMOVING THE FRONT WHEEL AND BRAKE DISC 3 Remove 8brake caliper1 8front wheel axle 8front wheel 8speedometer gear unit assembly NOTE Do not apply the brake lever when removing the brake caliper 4 Elevate 8front wheel NOTE Place the scooter on a suitable stand so that the front wheel is ...

Page 109: ...ge wear J Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure 8radial wheel runout 1 8lateral wheel runout 2 Over the specified limits J Replace Radial wheel runout limit 1 0 mm 0 04 in Lateral wheel runout limit 1 0 mm 0 04 in 4 Check 8wheel bearings Front wheel turns roughly or is loose J Replace the wheel bearings 8oil seals Damage wear J Replace 5 Replace 8wheel ...

Page 110: ...E DISC 1 Check 8brake disc Damage galling J Replace 2 Measure 8brake disc deflection a Out of specification J Correct the brake disc deflection or replace the brake disc Brake disc deflection limit maxi mum 0 10 mm 0 04 in a Place the scooter on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc de flection turn the handlebar to the left or right to ensure...

Page 111: ...ve the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern Brake disc bolt 20 Nm 2 0 m kg 14 5 ft lb LOCTITE d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought...

Page 112: ...New a Install the new wheel bearings and oil seals in the reverse order of disassembly cC Do not contact the wheel bearing inner race 1 1 1 1 1 or balls 2 2 2 2 2 Contact should be made only with the outer race 3 3 3 3 3 NOTE Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal ...

Page 113: ...e two slots3 respectively 3 Install 8front wheel 1 NOTE Make sure the slot2 in the speedometer gear unit fits over the stopper 3on the outer tube 4 Tighten 8wheel axle 70 Nm 7 0 m kg 50 6 ft lb cC Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly 5 Install 8brake caliper 1 8brake caliper bolts 2 35 Nm 3 5 m kg 25 3 ft l...

Page 114: ...nt wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps d through f several times until all the marks come t...

Page 115: ...n 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 weight d Repeat steps b and c until the front wheel is balanced 4 Check 8front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain station ary at all of the positions rebalance it X 1 ...

Page 116: ...e shoe Tension spring Plate washer Camshaft lever Indicator plate Brake camshaft REAR WHEEL AND REAR BRAKE REAR WHEEL AND REAR BRAKE Remove the parts in the order listed NOTE Place the scooter on a suitable stand so that the front wheel is elevated Refer to MAINFOLD AIR FILTER AND MUFFLER ASSEMBLY in chapter 5 For installation reverse the removal pro cedure 11 4 3 2 1 9 10 6 8 7 5 LS LS 105Nm 10 5...

Page 117: ...EL 1 Check 8wheel axle 8rear wheel Refer to CHECKING THE FRONT WHEEL 2 Check 8tire 8rear wheel Damage wear J Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure 8radial wheel runout 8lateral wheel runout Refer to CHECKING THE FRONT WHEEL ...

Page 118: ...e shoe lining thickness limit minimum 2 0 mm 0 08 in w Do not allow oil or grease to contact the brake shoes NOTE Replace the brake shoes as a set if either is worn to the wear limit 3 Measure 8brake drum inside diameter b Out of specification J Replace the wheel Brake drum inside diameter limit maximum 111 mm 4 37 in 4 Check 8brake drum inner surface Oil deposits J Clean Remove the oil with a rag...

Page 119: ... ADJUSTING THE FRONT WHEEL STATIC BALANCE REAR WHEEL AND REAR BRAKE EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1 Install 8brake camshaft 1 8brake shoe wear indicator 2 a Install the brake camshaft so its punch mark a is positioned as shown b Align the projection b on the brake shoe wear indicator with the notch in the brake shoe camshaft c Check that the brake shoes are properly positioned 2 Check 8...

Page 120: ... pad bolt Brake pad Brake pad plate Brake pad spring Caliper brake bracket Caliper assembly Remove the parts in the order listed Refer to REPLACING THE FRONT BRAKE PADS For installation reverse the removal pro cedure EAS00576 FRONT BRAKE FRONT BRAKE PADS FRONT BRAKE 2 1 1 6 5 5 3 3 4 7 LS 35Nm 3 5m kg 25 3 ft lb 22Nm 2 2m kg 15 9 ft lb ...

Page 121: ...nents 8 8 8 8 8 Use only clean or new brake fluid for cleaning brake components 8 8 8 8 8 Brake fluid may damage painted sur faces and plastic parts Therefore al ways clean up any spilt brake fluid im mediately 8 8 8 8 8 Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES 8 8 8 8 8 Flush with water for 15 minutes and get im...

Page 122: ... 3 NOTE Always install new brake pads and a new brake pad spring as a set a Connect a clear plastic hose 2 tightly to the bleed screw 1 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg 4 3 ft lb d Install new brake pads3 and new brake pad sprin...

Page 123: ...ke pad bolt 22 Nm 2 2 m kg 15 9 ft lb 8brake caliper bolt 35 Nm 3 5 m kg 23 5 ft lb 8 Check 8brake fluid level Below the MIN level mark a J Add the recommended brake fluid to the proper level Refer to CHECKINGTHE BRAKE FLUID LEVEL in chapter 3 9 Check 8brake lever operation Soft or spongy feeling J Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 FRONT BRAKE T R T R...

Page 124: ...e light switch Union bolt Copper washer Brake hose Master cylinder bracket Master cylinder assembly 1 1 1 1 2 1 1 1 Remove the parts in the order listed Drain For installation reverse the removal pro cedure EAS00584 FRONT BRAKE MASTER CYLINDER FRONT BRAKE 7 4 5 3 2 6 26Nm 2 6m kg 18 8 ft lb 4 1 6Nm 0 16m kg 1 2 ft lb 9Nm 0 9m kg 6 5 ft lb LS 1 ...

Page 125: ... DISASSEMBING THE FRONT BRAKE MASTER CYLINDER Disassembling the front brake mas ter cylinder Reservoir diaphragm Dust boot Circlip Washer Master cylinder kit Spring Remove the parts in the order listed For assembly reverse the disassembly procedure FRONT BRAKE 5 1 3 4 2 ...

Page 126: ...copper washer 2 8brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose FRONT BRAKE EAS00590 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check 8brake master cylinder 1 8Damage scratches wear J Replace 8brake fluid delivery passages 2 brake master cylinder body Obstruction J Blow out with compressed air 2 Check 8brake master c...

Page 127: ...S 4 22 FRONT BRAKE 3 Check 8brake master cylinder reservoir Cracks damage J Replace brake master cylinder reservoir diaphragm 1 Damage wear J Replace 4 Check brake hoses 1 Cracks damage wear J Replace 1 1 ...

Page 128: ...spring with its smaller diameter to the master cylinder kit 8master cylinder kit 2 2 Install 8circlip1 New 8dust boot2 3 Install 8brake switch 8brake lever 4 Install 8master cylinder1 8master cylinder bracket2 9 Nm 0 9 m kg 6 5 ft lb cC 8 8 8 8 8 Install the brake master cylinder holder with the UP mark a a a a a facing up 8 8 8 8 8 Align the end of the brake master cylin der holder with the punch...

Page 129: ...om mended brake fluid Recommended brake fluid DOT 4 w 8 8 8 8 8 Use only the designated brake fluid Other brake fluids may cause the rub ber seals to deteriorate causing leak age and poor brake performance 8 8 8 8 8 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 8 8 8 8 8 When re...

Page 130: ... 3 8 Check 8brake fluid level Below the MIN level mark a J Add the recommended brake fluid to the proper level Refer to CHECKINGTHE BRAKE FLUID LEVEL in chapter 3 9 Check 8brake lever operation Soft or spongy feeling J Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 a ...

Page 131: ...g the front brake caliper Brake fluid Union bolt Copper washer Brake hose Front brake caliper bracket bolt Front brake caliper assembly Remove the parts in the order listed Drain For installation reverse the removal pro cedure FRONT BRAKE 3 1 2 4 5 23Nm 2 3m kg 16 6 ft lb 35Nm 3 5m kg 25 3 ft lb ...

Page 132: ...PER Disassembling the front brake cali per Cap Caliper bracket Brake pad Brake pad plate Brake spring Dust seal Piston seal Caliper piston Bleed screw Cap Remove the parts in the order listed For assembly reverse the disassembly procedure FRONT BRAKE 3 1 3 9 4 7 6 8 5 2 6Nm 0 6m kg 4 3 ft lb 22Nm 2 2m kg 15 9 ft lb LS ...

Page 133: ...f the brake hose into a container and pump out the brake fluid carefully 2 Remove 8brake caliper piston 1 8brake caliper piston seal 2 8brake caliper dust seal 3 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper w 8 8 8 8 8 Cover the brake caliper pistons with a rag Be careful not to get injured when the piston are expelled from the brake cal...

Page 134: ...3 Cracks damage J Replace the brake caliper assembly 8brake fluid delivery passages brake caliper body Obstruction J Blow out with compressed air w Whenever a brake caliper is disassembled replace the piston seal 2 Check 8brake caliper bracket Cracks damage J Replace FRONT BRAKE Brake pads Piston seal Brake fluid Recommended brake component replacement schedule If necessary Every 2 years Every 2 y...

Page 135: ...eals to swell and distort 8 8 8 8 8 Whenever a brake caliper is disas sembled replace the brake caliper pis ton seals Recommended brake fluid DOT 4 1 Install 8brake caliper piston seal 1 New 8brake caliper dust seal 2 New 2 Install 8brake caliper piston1 cC 8 8 8 8 8 Do not force 8 8 8 8 8 Use care to prevent damage on caliper piston 3 Install 8brake pads 8brake springs 8brake caliper assembly1 8b...

Page 136: ... b b on the brake caliper 4 Fill 8brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended brake fluid DOT 4 w 8 8 8 8 8 Use only the designated brake fluid Other brake fluids may cause the rub ber seals to deteriorate causing leak age and poor brake performance 8 8 8 8 8 Refill with the same type of brake fluid that is already in the system Mixing brake fluids m...

Page 137: ...spilt brake fluid immediately a 5 Bleed 8brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check 8brake fluid level Below the MIN level mark a J Add the recommended brake fluid to the proper level Refer to CHECKINGTHE BRAKE FLUID LEVEL in chapter 3 7 Check 8brake lever operation Soft or spongy feeling J Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in c...

Page 138: ...ect cover Brake hose holder 1 Speedometer cable guide Front brake caliper assembly Cap bolt O ring Pinch bolt Front fork leg Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISC Refer to COVER AND PANEL in chap ter 3 For installation reverse the removal pro cedure FRONT FORK 5 3 1 7 6 4 2 45Nm 4 5m kg 32 5 ft lb 23Nm 2 3m kg 16 6 ft lb ...

Page 139: ...egs Fork oil Fork spring Clamp Boot Damper rod bolt Gasket Inner tube Damper rod Rebound spring Oil flow stopper Oil seal clip Oil seal Outer tube Remove the parts in the order listed Drain Refer to DISASSEMBLING AND IN STALLING THE FRONT FORK LEGS For assembly reverse the disassembly procedure FRONT FORK 1 5 6 4 7 8 9 0 3 2 30Nm 3 0m kg 21 7 ft lb 3 LT ...

Page 140: ...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 Loosen 8pinch bolt 1 3 Remove 8cap bolt 2 with a 10 mm hexagonal wrench3 w 8 8 8 8 8Fork spring will jump out after removing cap bolt w Before loosening the upper and lower bracket pinch bolts support the front fork leg 5 Remove 8front fork leg 2 3 1 ...

Page 141: ...Remove 8fork spring 1 2 Drain 8fork oil 3 Remove 8damper rod assembly bolt 1 8damper rod assembly NOTE While holding the damper rod with the damper rod holder 2 and T handle3 loosen the damper rod assembly bolt Damper rod holder 90890 01294 YM 01300 1 T handle 90890 01326 YM 01326 4 Remove 8damper rod 1 8spring 8inner tube 2 3 1 2 1 ...

Page 142: ...CHAS 4 37 FRONT FORK 5 Remove 8oil seal clip 1 with a flat head screwdriver cC Do not scratch the inner tube 6 Remove 8oil seal 1 cC Never reuse the oil seal 8Rag 2 1 1 2 ...

Page 143: ...t to straighten a bent inner tube as this may dangerously weaken it 1 2 a 1 2 1 2 2 Measure 8spring free length a Out of specification J Replace Spring free length 257 5 mm 10 14 in Limit 252 4 mm 9 94 in 3 Check 8damper rod 1 Damage wear J Replace Obstruction J Blow out all of the oil pas sages with compressed air 8oil flow stopper 2 Damage J Replace 4 Check 8cap bolt 1 Damage wear J Replace 8O r...

Page 144: ...assembling the front fork leg make sure all of the components are clean 1 Install 8damper rod assembly 1 8 rebound spring 2 cC Allow the damper rod assembly to slide slowly down the inner tube 3 3 3 3 3 until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate 8inner tube s outer surface Recommended lubricant Fork oil 10W or equivalent 3 Tighten 8damp...

Page 145: ... numbered side of the oil seal faces up NOTE 8 Before installing the oil seal lubricate its lips with lithium soap base grease 8 Lubricate the outer surface of the inner tube with fork oil 8 Before installing the oil seal cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation 5 Install 8oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into...

Page 146: ... qt Recommended oil Fork oil 10W or equivalent NOTE 8 While filling the front fork leg keep it up right 8 After filling slowly pump the front fork leg up and down to distribute the fork oil 8 Install 8fork spring 1 NOTE 8 Install the spring with the smaller pitch fac ing up 8 Before installing the cap bolt lubricate its O ring with grease 8 Temporarily tighten the cap bolt 1 1 ...

Page 147: ...owing procedure applies to both of the front fork legs 1 Install 8front fork leg NOTE Pull up the inner tube until it stops then install the cap bolt 2 Tighten 8cap bolt 1 45 Nm 4 5 m kg 32 5 ft lb 8pinch bolt 2 23 Nm 2 3 m kg 16 6 ft lb FRONT FORK T R T R 1 2 ...

Page 148: ...e master cylinder assembly Handlebar switch assembly right Throttle cable Throttle grip assembly Band Rear brake cable Handlebar switch assembly left Handlebar grip Cap Handlebar upper holder Handlebar assembly Remove the parts in the order listed For installation reverse the removal pro cedure HANDLEBAR 1 9 13 10 8 12 12 7 7 2 3 5 5 6 1 4 11 11 9Nm 0 89m kg 6 5 ft lb LS 30Nm 3 0m kg 21 7 ft lb LS...

Page 149: ...g the handlebar switch assembly right pull back the rubber cover 3 Remove 8handlebar grip 1 NOTE Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECKINGTHE HANDLEBAR 1 Stand the scooter on a level surface w Securely support the scooter so that there is no danger of it falling over 2 Check 8handlebar 1 Bends cracks damage J Re...

Page 150: ... 0 m kg 21 7 ft lb cC 8 8 8 8 8 First tighten the bolts on the front side of the handlebar holder and then on the rear side NOTE 8The upper handlebar holders should be in stalled with the arrow marks a facing for ward A 8Align the match marks b on the handlebar with the upper surface of the lower handle bar holders 3 Install 8handlebar grip NOTE Before installing the handlebar grip apply the bond ...

Page 151: ...t onto the handlebar4 8 Align the projection a on the right handle bar switch with the hole b in the handle bar w Make sure the throttle grip operates smoothly 6 Install 8 front brake master cylinder 1 NOTE 8 Align the mating surfaces of the front brake master cylinder with the punch mark a on the handlebar 7 Adjust 8 throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chap...

Page 152: ...r front Lower fender cover inner Handlebar cover Speedometer cable Speedometer assembly Handlebar lower holder 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISC Refer to COVER AND PANEL in chap ter 3 Refer to FRONT FORK Refer to HANDLEBAR For installation reverse the removal pro cedure STEERING HEAD EAS00675 STEERING HEAD LOWER FENDER COVER AND HANDLEBAR LO...

Page 153: ...inner race Lower bracket Upper bearing Lower bearing Upper bearing outer race Lower bearing outer race Lower bearing inner race 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISC Refer to LOWER FENDER COVER AND HANDLEBAR LOWER HOLDER EAS00675 LOWER BRACKET STEERING HEAD 12 10 8 7 6 5 4 3 2 1 13 11 14 15 9 60Nm 6 0m kg 43 4 ft lb LS LS 75Nm 7 5m kg ...

Page 154: ...rt Q ty 15 Rubber washer 1 For installation reverse the removal pro cedure STEERING HEAD 12 10 8 7 6 5 4 3 2 1 13 11 14 15 9 60Nm 6 0m kg 43 4 ft lb LS LS 75Nm 7 5m kg 54 2 ft lb 28Nm 2 8m kg 20 3 ft lb 1st 2nd 9Nm 0 9m kg 6 5 ft lb ...

Page 155: ...hat there is no danger of it falling over 2 Remove 8handlebar holder bracket 1 NOTE 8 Remove the handlebar holder bracket by loosening the upper ring nut2 gradually 3 Remove 8ring nut 1 with the ring nut wrench 2 Ring nut wrench 90890 01268 YU 01268 w Securely support the lower bracket so that there is no danger of it falling 1 2 1 2 ...

Page 156: ...with a long rod 1 and ham mer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new rubber washer and new bear ing races cC If the bearing race is not installed properly the steering head pipe could be damaged NOTE 8Always replace the bearings and bearing races as a set 8Whenever the steering head is disassembled replace the rubber washer 4 Check 8handle...

Page 157: ...p based grease 2 Install 8lower ring nut 1 8rubber washer 2 8center ring nut 3 8lock washer 4 8upper ring nut 5 Refer to CHECKING THE STEERING HEAD in chapter 3 3 Install 8handlebar holder bracket 1 60 Nm 6 0 m kg 43 4 ft lb NOTE Align the handlebar holder bracket across rod 2 on the lower bracket concave3 STEERING HEAD 3 4 1 2 T R 1 2 3 ...

Page 158: ...over left Refer to COVER AND PANEL in chap ter 3 3 Remove 8rear shock absorber nut upper 1 8rear shock absorber bolt lower 2 EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check 8rear shock absorber rod Bends damage J Replace the rear shock absorber assembly 8rear shock absorber Oil leaks J Replace the rear shock ab sorber assembly 8spring Damage wear J Replace the rear shock absorber assemb...

Page 159: ...enum disulfide grease 2 Install 8rear shock absorber assembly 3 Tighten 8rear shock absorber assembly upper nut1 30 Nm 3 0 m kg 21 7 ft lb 8rear shock absorber assembly lower bolt2 18 Nm 1 8 m kg 13 0 ft lb 4 Install 8side cover left 8rear carrier Refer to COVER AND PANEL in chap ter 3 REAR SHOCK ABSORBER T R T R 1 2 ...

Page 160: ...MSHAFT 5 16 CHECKING THE TIMING CHAIN CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES 5 17 CHECKING THE TIMING CHAIN TENSIONER 5 17 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 18 VALVES AND VALVE SPRINGS 5 19 VALVES AND VALVE SPRINGS 5 19 REMOVING THE VALVES 5 20 CHECKING THE VALVES AND VALVE GUIDES 5 21 CHECKING THE VALVE SEATS 5 23 CHECKING THE VALVE SPRINGS 5 25 INSTALLING THE VALVES 5 26 CYLINDER AND...

Page 161: ...SSEMBLING THE SECONDARY SHEAVE 5 45 INSTALLING THE BELT DRIVE 5 46 STARTER CLUTCH AND STARTER MOTOR 5 48 STARTER CLUTCH AND STARTER MOTOR 5 48 CHECKING THE STARTER WHEEL GEAR 5 49 C D I MAGNETO 5 50 C D I MAGNETO 5 50 REMOVING THE C D I MAGNETO 5 51 INSTALLING THE C D I MAGNETO 5 52 OIL PUMP 5 53 OIL PUMP 5 53 CHECKING THE OIL PUMP 5 54 INSTALLING THE OIL PUMP 5 55 TRANSMISSION 5 56 TRANSMISSION 5...

Page 162: ...pin Air inlet hose Fuel hose Carburetor inlet hose Fuel cock vacuum pipe Rear shock absorber bolt Self lock nut Engine mounting bolt Remarks Order Job Part Q ty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to COVER AND PANEL in chap ter 3 cC First disconnect the negative lead and then the positive lead Refer to INSTALLING THE ENGI...

Page 163: ...5 2 ENG Remarks Order Job Part Q ty For installation reverse the removal pro cedure ENGINE 2 6 5 10 11 12 3 4 7 8 14 13 9 1 15 42Nm 4 2m kg 30 4 ft lb LS 18Nm 1 8m kg 13 0 ft lb ...

Page 164: ...set the oil change indicator when the oil is changed ENGINE T R 1 EAS00192 INSTALLING THE ENGINE 1 Install 8engine bracket bolt 1 NOTE Do not fully tighten the bolts 2 Tighten 8engine bracket bolt1 55Nm 5 5 m kg 39 8 ft lb 8engine ...

Page 165: ...adjuster pin Hose from AI air filter Vacuum hose from mainfold Hose to cylinder head Muffler assembly AI pipe Air filter Breather hose Carburetor Mainfold O ring Joint Gasket 1 2 3 4 5 6 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to LEADS HOSES AND REAR BRAKE Refer to AIR INDUCTION SYSTEM in chapter 6 For installation reverse the removal pro cedure 4 5 6 1 2 3 7Nm 0 7m kg 5 1 ft ...

Page 166: ...gine oil cap O ring Valve cover O ring Timing chain tensioner assembly Camshaft sprocket plate Camshaft sprocket Nut Washer Plate Cylinder head Cylinder head gasket Remove the parts in the order listed Refer to MAINFOLD AIR FILTER AND MUFFLER ASSEMBLY Refer to REMOVING THE CYLINDER HEAD CYLINDER HEAD 8Nm 0 8m kg 5 8 ft lb 10Nm 1 0m kg 7 2 ft lb 10 5 3 17 17 11 12 15 7 7 9 13 14 8 6 16 2 1 4 30Nm 3...

Page 167: ...pin 2 For installation reverse the removal pro cedure 8Nm 0 8m kg 5 8 ft lb 10Nm 1 0m kg 7 2 ft lb 10 5 3 17 17 11 12 15 7 7 9 13 14 8 6 16 2 1 4 30Nm 3 0m kg 21 7 ft lb 12Nm 1 2m kg 8 7 ft lb 22Nm 2 2m kg 15 9 ft lb 10Nm 1 0m kg 7 2 ft lb 8Nm 0 8m kg 5 8 ft lb ...

Page 168: ...mary sheave counterclockwise b When the piston is at TDC on the compres sion stroke align the I mark c on the cam shaft sprocket with the mark d on the cyl inder head 3 Loosen 8timing chain tensioner bolt 8camshaft sprocket plate bolt 1 While holding the crank bolt with a wrench remove the camshaft sprocket plate bolt 1 4 Remove 8timing chain tensioner along with the gasket 8camshaft sprocket plat...

Page 169: ... it with a wire 8 While holding the C D I magneto bolt with a wrench remove the camshaft sprocket plate bolt 1 3 4 5 6 1 2 5 Remove 8cylinder head NOTE 8 Loosen the nuts in the proper sequence as shown 8 Loosen each nut 1 2 of a turn at a time After all of the nuts are fully loosened re move them ...

Page 170: ... head warpage Out of specification J Resurface the cyl inder head Maximum cylinder head warpage Less than0 05 mm 0 002 in a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylin der head using a figure eight sanding...

Page 171: ...iming chain 2 a Turn the primary pulley counterclockwise b Align the I mark a on the C D I magneto rotor with the stationary pointer b on the crankcase cover c Align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head d Install the timing chain onto the camshaft sprocket and then install the camshaft sprocket onto the camshaft NOTE 8 When installing the camshaf...

Page 172: ... bolt 2 6 Install 8timing chain tensioner gasket New 8timing chain tensioner a Remove the cap bolt 1 and spring 2 b Release the timing chain tensioner one way cam 3 and push the timing chain tensioner rod 4 all the way into the timing chain tensioner housing c Install the timing chain tensioner and gas ket 5 onto the cylinder Timing chain tensioner bolt 10 Nm 1 0 m kg 7 2 ft lb d Install the sprin...

Page 173: ...nary pointer d on the cylinder head Out of alignment J Correct Refer to the installation steps above 9 Tighten 8camshaft sprocket bolt 30 Nm 3 0 m kg 21 7 ft lb cC Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 10 Measure 8valve clearance Out of specification J Adjust Refer to ADJUSTING THE VALVE CLE...

Page 174: ... Rocker arm Camshaft 1 2 2 2 2 2 1 Remove the parts in the order listed Refer to CYLINDER HEAD Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALL ING THE ROCKER ARMS AND CAM SHAFT Refer to INSTALLING THE CAMSHAFT AND ROCKER ARMS For installation reverse the removal pro cedure THE ROCKER ARMS AND CAMSHAFT 7Nm 0 7m kg 5 1 ft lb 7 1 2 3 M M 4 5 6 4 4 5 6 7Nm 0 7m kg 5 1 ft lb 3 2 M M 4 LS ...

Page 175: ...rm NOTE Remove the rocker arm shafts with the slide hammer bolt 1 and weight2 Slide hammer bolt 90890 01083 YU 01083 1 90890 01085 YU 01083 2 Weight 90890 01084 YU 01083 3 3 Remove 8 camshaft1 Screw 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft Slide hammer bolt 90890 01085 YU 01083 2 Weight 90890 01084 YU 01083 3 THE ROCKER ARMS AND CAMSHAFT 1 2 2 1 2 1 ...

Page 176: ...Replace the camshaft 4 Measure 8rocker arm inside diameter a Out of specification J Replace Rocker arm inside diameter 10 10 015 mm 0 393 0 394 in 5 Measure 8rocker arm shaft outside diameter a Out of specification J Replace Rocker arm shaft outside diameter 9 981 9 991 mm 0 392 0 393 in 6 Calculate 8rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rocker ar...

Page 177: ...place the camshaft 3 Measure 8camshaft lobe dimensions a and b Out of specification J Replace the cam shaft Camshaft lobe dimension limit Intake a a a a a 26 153 26 253 mm 1 030 1 034 in Limit 26 053mm b b b b b 21 015 21 115 mm 0 827 0 831 in Limit 20 915mm Exhaust a a a a a 26 153 26 253 mm 1 030 1 034 in Limit 26 053mm b b b b b 21 056 21 156 mm 0 829 0 833 in Limit 20 956mm 4 Check 8camshaft o...

Page 178: ...set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check 8timing chain guide exhaust side 8timing chain guide intake side 8timing chain guide top side Damage wear J Replace the defective part s EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1 Check 8timing chain tensioner Cracks damage J Replace 2 Check 8one way cam operation Rough movement J Replace the timing chain tensioner hou...

Page 179: ...ust rocker arm 1 8exhaust rocker arm shaft 2 NOTE Make sure the exhaust rocker arm shaft is com pletely pushed into the cylinder head 4 Install 8intake rocker arm 1 8intake rocker arm shaft 2 NOTE Make sure the intake rocker arm shaft is com pletely pushed into the cylinder head cC Make sure the threaded part of the rocker arm shaft faces out 5 Install 8stopper plate 1 8locknut 2 7 Nm 0 7 m kg 5 1...

Page 180: ...arm shaft Valve cotter Valve spring retainer Valve spring Valve intake Valve exhaust Valve stem seal Valve stem seat Remove the parts in the order listed Refer to CYLINDER HEAD Refer to ROCKER ARMS AND ROCKER ARMS SHAFTS Refer to INSTALLING THE VALVES AND VALVE SPRINGS For installation reverse the removal pro cedure VALVES AND VALVE SPRINGS 1 2 6 M 3 7 7 3 6 2 1 M 4 5 M M ...

Page 181: ...lve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 2 Remove 8valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 Valve sp...

Page 182: ... Valve stem diameter b Out of specification J Replace the valve guide Valve stem to valve guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 003 in Exhaust 0 025 0 057 mm 0 001 0 002 in Limit 0 10 mm 0 004 in a b 2 Replace 8valve guide NOTE To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven a Remove the ...

Page 183: ... the valve face 8valve stem end Mushroom shape or diameter larger than the body of the valve stem J Replace the valve 5 Measure 8valve margin thickness a Out of specification J Replace the valve Valve margin thickness 0 85 1 15 mm 0 033 0 045 in 6 Measure 8valve stem runout Out of specification J Replace the valve NOTE 8 When installing a new valve always replace the valve guide 8 If the valve is ...

Page 184: ...6 mm 0 063 in Exhaust 0 9 1 1 mm 0 035 0 043 in Limit 1 6 mm 0 063 in a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width NOTE Where the valve seat and valve face contacted one another the blueing will have been removed 4 Lap...

Page 185: ...ap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through t...

Page 186: ... length 37 30 mm 1 469 in Limit 35 40 mm 1 394 in 2 Measure 8compressed valve spring force a Out of specification J Replace the valve spring b Installed length Compressed valve spring force in stalled 147 11N 15 0 1 1 kg at 25 77 mm 33 075 2 426 lb at 1 015 in a a b a VALVES AND VALVE SPRINGS 3 Measure 8valve spring tilt a Out of specification J Replace the valve spring Spring tilt limit 1 6 mm 2 ...

Page 187: ...num disulfide oil 3 Install 8valve 1 8valve spring seat 2 8valve stem seal 3New 8valve spring 4 8valve spring retainer 5 8 valve cotter 6 into the cylinder head NOTE Install the valve spring with the larger pitch a facing up b Smaller pitch 4 Install 8valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor at...

Page 188: ...09 Valve spring compressor attach ment 90890 04108 YM 04108 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer cC Hitting the valve tip with excessive force could damage the valve VALVES AND VALVE SPRINGS ...

Page 189: ...sket Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring Expander Remove the parts in the order listed Refer to CYLINDER HEAD Refer to INSTALLING THE PISTON AND CYLINDER Refer to REMOVING THE CYLINDER AND PISTON Refer to INSTALLING THE PISTON AND CYLINDER For installation reverse the removal pro cedure 1 1 1 1 1 2 1 2 1 1 1 1 2 1 CYLINDER AND PISTON 1 2 10 9 8 8 13 14 13 12 11 7 5 12Nm 1 ...

Page 190: ...cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase 8 Before removing the piston pin deburr the piston pin clip s groove and the piston s pin bore area 2 Remove 8top ring 82nd ring 8oil 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 CYLINDER AND PISTON 3 2 1 ...

Page 191: ...r inner di ameter 52 40 52 41mm 2 063 2 064 in Service limit of cylinder inner diam eter 52 5mm 2 067 in b If out of specification replace the cylinder and the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer a 3 5 mm 0 138 in from the bottom edge of the piston Piston size P 51 470 51 510 mm 2 026 2 028 in d If out of specification replace the piston and pisto...

Page 192: ...0 06 mm 0 0008 0 0024 in Limit 0 12 mm 0 0047 in 2 Install 8piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown a 20 mm 0 79 in 3 Measure 8piston ring end gap Out of specification J Replace the pis ton ring NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring e...

Page 193: ... 5118 in Limit 12 976 mm 0 5109 in 3 Measure 8piston pin bore diameter b Out of specificationJ Replace the piston Piston pin bore diameter 13 002 13 013 mm 0 5119 0 5123 in Limit 13 043 mm 0 5135 in 4 Calculate 8piston pin to piston pin bore clearance Out of specification J Replace the pis ton pin and piston as a set Piston pin to piston pin bore clearance Piston pin bore diameter b Piston pin out...

Page 194: ... 4 NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers face up 2 Install 8piston 1 8piston pin 2 8piston pin clip New 3 NOTE 8 Apply engineoil the piston pin 8 Make sure the arrow mark a on the piston points towards the exhaust side of the cyl inder 8 Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the clip from falling...

Page 195: ...mmended lubricant Engine oil 5 Offset 8piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Exhaust side 6 Install 8cylinder 1 NOTE 8 While compressing the piston rings with one hand install the cylinder with the other hand 8 Pass the timing chain and timing chain guide exhaust side through the timing chain cavity 2 1 1 ...

Page 196: ...e Kickstarter Crankcase cover 3 V belt case air filter element holder V belt case filter element Crankcase cover 1 Dowel pin O ring Dowel pin O ring Remove the parts in the order listed For installation reverse the removal pro cedure BELT DRIVE 6 5 2 1 3 4 8 6 7 9 7Nm 0 7m kg 5 1 ft lb 23Nm 2 3m kg 16 6 ft lb 10Nm 1 0m kg 7 2 ft lb ...

Page 197: ...COVER Referto INSTALLINGTHEKICKSTARTER For installation reverse the removal pro cedure EAS00338 KICKSTARTER Removing the kickstarter Crankcase cover Plate V belt guide Gasket Kick pinion gear Kick pinion gear clip Circlip Plate washer Kick shaft assembly Torsion spring Solid bush BELT DRIVE 8 5 3 4 2 1 6 7 9Nm 0 9m kg 6 5 ft lb ...

Page 198: ... Hook 8kickstarter spring NOTE Hook the spring enda on the kickstarter shaft b as shown and hook the other end c on the projectiond 3 Install 8plain washer1 8circlip2 New 4 Install 8kick pinion gear1 8kick pinion gear clip 2 NOTE Install the clip at the position shown 5 Install 8gasket1 New 8plate2 2 3 1 d c a b 1 2 2 1 1 2 ...

Page 199: ... installation reverse the removal pro cedure Removing the V belt clutch primary and secondary sheave Primary sheave nut Plate washer Oneway clutch Primary fixed sheave Secondary sheave nut Clutch housing Secondary sheave assembly V belt Washer Collar Primary sliding sheave Cam Weight Slider Oil seal Gasket V BELT CLUTCH PRIMARY AND SECONDARY SHEAVE BELT DRIVE 5 4 6 8 3 2 1 12 9 12 10 11 13 60Nm 6 ...

Page 200: ...SECONDARY SHEAVE For assembly reverse the disassembly procedure Disassembling the secondary sheave Clutch carrier nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O ring Oil seal Secondary fixed sheave DISASSEMBLING THE SECONDARY SHEAVE BELT DRIVE 5 4 3 2 1 0 6 9 7 8 9 90Nm 9 0m kg 65 1 ft lb LS LS LS ...

Page 201: ... BELT 1 Remove 8secondary sheave nut 1 8clutch housing 2 NOTE While holding the clutch housing with the sheave holder 3 loosen the secondary sheave nut Sheave holder 90890 01701 YS 01880 A 2 Loosen 8clutch carrier nut 1 cC Do not remove the clutch carrier nut at this stage NOTE While holding the clutch carrier with the rotor holding tool 2 loosen the clutch carrier nut one full turn with the lockn...

Page 202: ...spring holder 90890 01337 YM 33285 YM 33285 6 CHECKING THE CLUTCH SHOE 1 Measure 8Clutch shoe Scratches J Glaze using coares sand paper Damage wear J Replace Clutch shoe thickness 3 5 mm 0 138 in Limit 2 0 mm 0 079 in NOTE 8 Inspect clutch shoes a 8 After removing the clutch weight spring do not use them again 8 Replace the all three as a set 1 2 3 a a a 3 Remove 8secondary sheave assembly 1 8V be...

Page 203: ...ck 8Primary sliding sheave1 8Primary fixed sheave2 Cracks damage wear J Replace the pri mary sliding sheave primary fixed sheave and V belt EAS00321 CHECKINGTHE PRIMARY SHEAVEWEIGHTS The following procedure applies to all of the pri mary sheave weights 1 Check 8primary sheave weight Cracks damage wear J Replace 2 Measure 8primary sheave weight outside diameter a Out of specification J Replace Prim...

Page 204: ... groove 1 Damage wear J Replace the secondary fixed and sliding sheaves as a set 3 Check 8guide pin 2 Damage wear J Replace the secondary fixed and sliding sheaves as a set EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1 Clean 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 NOTE Use thinner to clean up grease dirt on the pri mary sliding sheave cam side 5 2 Install 8...

Page 205: ...ENG 5 44 3 Install 8slider 1 8primary sliding sheave 2 8cam 3 3 2 1 BELT DRIVE ...

Page 206: ...nded lubricant Recommended lubricant BEL RAY assembly lube 2 Install 8secondary sliding sheave 1 NOTE Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 Oil seal guide 90890 01384 YM 33299 3 Install 8guide pin 1 4 Lubricate 8guide pin groove 2 8o ring New 3 with the recommended lubricant Recommended lubricant BEL RAY assembly lube 1 2 3 1 2 2 3 1 BELT ...

Page 207: ... sheave as shown Then compress the spring and tighten the clutch carrier nut 5 Clutch spring holder 90890 01337 YM 33285 YM 33285 6 2 4 1 3 5 BELT DRIVE EAS00325 INSTALLING THE BELT DRIVE 1 Install 8V belt 1 8clutch assembly 2 cC Do not allow grease to contact the V belt secondary sheave assembly NOTE Install the V belt onto the primary sheave side 2 1 ...

Page 208: ...348 YM 01348 3 Install 8clutch housing 1 8secondary sheave nut2 60 Nm 6 0 m kg 43 4 ft lb NOTE Tighten the secondary sheave nut with the sheave holder 3 Sheave holder 90890 01701 YS 01880 A 4 Position 8V belt 1 NOTE Position the V belt in the primary sheave 2 when the pulley is at its widest position and in the secondary sheave 3 when the pulley is at its narrowest position and make sure the V bel...

Page 209: ... REMOVING THE PRIMARY SHEAVE For installation reverse the removal pro cedure Removing the starter clutch and starter motor Primary sheave Idle gear plate Plate washer Idle gear Starter clutch Washer Circlip Bearing Starter wheel gear Starter motor O ring Shaft STARTER CLUTCH AND STARTER MOTOR 2 3 2 11 1 6 7 5 4 8 10 9 7Nm 0 7m kg 5 1 ft lb LS B 7Nm 0 7m kg 5 1 ft lb ...

Page 210: ...e starter clutch2 and hold the starter clutch b When turning the starter wheel gear clock wise A the starter clutch and the starter wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear coun terclockwise B it should turn freely other wise the starter clutch is faulty and must be replaced STARTER CLUTCH AND STARTER MOTOR 2 1 A B ...

Page 211: ...to CYLINDER HEAD in chapter 3 cC Disconnect the C D I magneto lead coupler For installation reverse the removal pro cedure Removing the C D I magneto Air shroud 1 Fan C D I magneto rotor Woodruff key Stator coil assembly C D I MAGNETO C D I MAGNETO 3 2 4 1 70Nm 7 0m kg 50 6 ft lb 7Nm 0 7m kg 5 1 ft lb ...

Page 212: ...the C D I magneto rotor with the holding tool 2 loosen the C D I mag neto nut1 8 Do not allow the sheave holder to touch the projection on the C D I magneto rotor Rotor holding tool 90890 01235 YU 01235 2 Remove 8C D I magneto rotor1 8 with flywheel puller 2 Flywheel puller 90890 01189 YM 01189 1 2 1 2 ...

Page 213: ...o rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 2 Tighten 8nut 2 70 Nm 7 0 m kg 50 6 ft lb NOTE 8 While holding the C D I magneto with the holding tool 3 tighten the C D I magneto rotor nut 2 8 Do not allow the sheave holder to touch the projection on the C D I magneto rotor Rotor holding tool 90890 01235 YU 01235 C D I MAGNETO T R 2 3 1 ...

Page 214: ...r O ring Gasket Oil seal Dowel pin Circlip Plate washer Oil pump driven gear Dowel pin Oil pump body Outer rotor Inner rotor Oil pump shaft Oil pump housing cover Gasket Remove the parts in the order listed Refer to C D I MAGNETO For assembly reverse the disassembly procedure OIL PUMP 4 3 2 1 7 9 10 11 12 8 13 14 5 7Nm 0 7m kg 5 1 ft lb 7Nm 0 7m kg 5 1 ft lb LS 6 ...

Page 215: ... inner rotor and outer rotor clearance c Out of specification J Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clear ance 0 15 mm 0 006 in Limit 0 23 mm 0 009 in Outer rotor to oil pump housing clearance 0 013 0 036 mm 0 0005 0 0014 in Limit 0 106 mm 0 0042 in Oil pump housing to inner rotor and outer rotor clearance 0 06 0 10 mm 0 002 0 004 in L...

Page 216: ...gasket 1 New 8oil pump assembly2 8oil pump bolt 7 Nm 0 7 m kg 5 1 ft lb cC After tightening the bolts make sure the oil pump turns smoothly 3 Check 8oil pump operation Rough movement J Repeat steps 1 and 2 or replace the defective part s OIL PUMP T R 2 1 ...

Page 217: ...e Secondary sheave Crankcase cover 2 Crankcase cover gasket 2 Dowel pin Primary drive gear shaft Plate washer Main axle Drive axle Remove the parts in the order listed Drain Refer to REAR WHEEL AND REAR BRAKE in chapter 4 Refer to BELT DRIVE Refer to V BELT CLUTCH PRIMARY AND SECONDARY SHEAVE For installation reverse the removal pro cedure TRANSMISSION 3 6 5 6 2 1 7 4 12Nm 1 2m kg 8 7 ft lb B G B ...

Page 218: ...0008 in 3 Measure 8drive axle runout with a centering device and dial gauge Out of specification J Replace the drive axle Drive axle runout limit 0 02 mm 0 0008 in 4 Check 8transmission gears Blue discoloration pitting wear J Replace the defective gear s 8transmission gear dogs Cracks damage rounded edges J Re place the defective gear s 5 Check 8transmission gear engagement each pinion gear to its...

Page 219: ...Refer to C D I MAGNETO Refer to OIL PUMP Refer to REAR WHEEL Removing the crankshaft assembly Engine Cylinder head Cylinder piston V belt clutch primary Secondary sheave Starter clutch C D I magneto Oil pump Rear wheel Bolt Collar Plate washer Spring Centerstand Engine bracket Oil elemet cover O ring Oil elemet Crankcase right CRANKCASE AND CRANKSHAFT 11 10 9 8 7 1 2 3 6 5 4 1 2 3 18 11 19 17 13 1...

Page 220: ...Bolt O ring Timing chain guide Oil pipe O ring 2 1 1 1 1 1 1 1 1 Refer to DISASSEMBLING THE CRANKCASE Refer to INSTALLING THE CRANK SHAFT For installation reverse the removal pro cedure 11 10 9 8 7 1 2 3 6 5 4 1 2 3 18 11 19 17 13 14 32Nm 3 2m kg 23 1 ft lb LS 16 32Nm 3 2m kg 23 1 ft lb 12Nm 1 2m kg 8 7 ft lb 4 8Nm 0 8m kg 5 8 ft lb 12 15 ...

Page 221: ...t a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them 3 Remove 8right crankcase1 NOTE Tap on one side of the crankcase with a soft face hammer2 Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly 1 1 2 ...

Page 222: ...chain from the crankshaft sprocket 8 The crankshaft assembly cannot be re moved if the timing chain is attached onto the crankshaft sprocket EAS00207 CHECKINGTHE TIMING CHAIN AND TIMING CHAIN GUIDES 1 Check 8timing chain Damage stiffness J Replace the timing chain 2 Check 8timing chain guide Damage wear J Replace the timing chain guide CRANKCASE AND CRANKSHAFT 1 2 ...

Page 223: ... of specification J Replace the big end bearing crankshaft pin or connecting rod Big end side clearance 0 10 0 40 mm 0 004 0 016 in 3 Measure 8crankshaft width Out of specification J Replace the crank shaft Crankshaft width 45 15 45 20 mm 1 778 1 780 in 4 Check 8crankshaft sprocket 1 Damage wear J Replace the crankshaft 8bearing 2 Cracks damage wear J Replace the crankshaft 8oil pump drive gear 3 ...

Page 224: ...y 1 8crankcase2 8timing chain3 cC To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil NOTE Put the timing chain in parallel into the crank case then use hands to place the crank shaft Ass y into the crank case Manually rotate the crank shaft to check whether it is tightly engaged with ...

Page 225: ...amaha bond No 1215 90890 85505 ACC 11001 05 01 NOTE Do not allow any sealant to come into contact with the oil gallery 3 Install 8dowel pins 8timing chain 1 NOTE Install the timing chain so it is not visible through the opening a in the left crankcase 2 4 Install 8crankshaft 1 8crankcase right 5 Tighten 8crankcase 12 Nm 1 2 m kg 8 7 ft lb CRANKCASE AND CRANKSHAFT T R 1 2 a 1 ...

Page 226: ...KING THE CARBURETOR 6 3 ASSEMBLING THE CARBURETOR 6 5 INSTALLING THE CARBURETOR 6 6 MEASURING AND ADJUSTING THE FUEL LEVEL 6 7 CHECKING THE FUEL COCK 6 8 CHECKING THE AUTOCHOKE UNIT 6 8 AIR INDUCTION SYSTEM 6 10 CHECKING THE AIR INDUCTION SYSTEM 6 11 ...

Page 227: ...holder Throttle stop screw Spring Bracket Clamp Vacuum chamber cover Piston valve spring Piston valve Jet needle kit Float chamber Gasket Accelerator pump assembly Float pin Float Needle valve Needle valve seat Main jet Main nozzle Main air jet Pilot jet CARBURETOR CARBURETOR EAS00483 CARBURETOR Remove the parts in the order listed 5 6 8 7 9 r t y u 0 e w o q 2 a p 1 4 3 i ...

Page 228: ...6 2 CARB Remarks Order Job Part Q ty p a Carburetor heater Ground terminal 1 1 For assembly reverse the disassembly procedure CARBURETOR 5 6 8 7 9 r t y u 0 e w o q 2 a p 1 4 3 i ...

Page 229: ...uction J Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check 8float chamber body 1 Dirt J Clean 4 Check 8float chamber rubber gasket 2 Cracks damage wear J Replace 5 Check 8float Damage J Replace CARBURETOR 2 1 ...

Page 230: ...ce 9 Check 8vacuum chamber cover 1 8piston valve spring 2 Cracks damage J Replace 10 Check 8jet needle1 8main jet2 8main nozzle3 8pilot jet4 8main air jet5 Bends damage wear J Replace Obstruction J Clean Blow out the jets with compressed air 11 Check 8piston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness J Replace the piston valve 12 Check 8vacuum...

Page 231: ...eum based sol vent 8 8 8 8 8 Always use a new gasket 1 Install 8main nozzle 1 8main jet 2 8pilot jet 3 2 Install 8needle valve seat 1 8float 2 8needle valve 3 8float pin 4 8 screw 5 3 Install 8accelerator pump assembly CARBURETOR 4 Install 8piston valve 8jet needle 8piston valve spring 8vacuum chamber cover 2 1 3 5 4 1 2 3 ...

Page 232: ...gine idling speed 1 600 1 700r min Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3 2 Adjust 8throttle cable free play Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 CARBURETOR ...

Page 233: ...e 1 onto the fuel drain pipe 2 Fuel level gauge 90890 01312 YM 01312 A d Loosen the fuel drain screw e Hold the fuel level gauge vertically next to the float chamber 3 f Measure the fuel level a 2 Adjust 8fuel level a Remove the carburetor b Check the needle valve seat and needle valve c If either is worn replace them as a set d If both are fine adjust the float level by slightly bending the float...

Page 234: ... AUTOCHOKE UNIT NOTE When checking the autochoke unit the ambient temperature must be lower than 45 C 113 F 1 Remove 8carburetor 1 1 2 2 Check 8autochoke unit a Connect a 3 3 mm hose 1 to the starter air passage 2 and blow into the hose NOTE When the starter plunger is open air should come out of the other side of the starter air pas sage Starter plunger opens Perform step 3 Starter plunger closes...

Page 235: ...V battery for five minutes Positive battery lead 1 J black Negative battery lead 2 J black b Connect a 3 3 mm hose 3 to the starter air passage 4 and blow into the hose Starter plunger opens Replace the autochoke unit Starter plunger closes Autochoke is OK CARBURETOR 1 2 3 4 B B ...

Page 236: ...Vacuum hose from mainfold Hose to cylinder head Muffler assembly Gasket Air cut off valve bracket Air cut off valve assembly 1 2 3 4 5 6 7 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal pro cedure AIR INDUCTION SYSTEM 4 3 7 6 5 1 2 4Nm 0 4m kg 2 9 ft lb 31Nm 3 1m kg 22 4 ft lb ...

Page 237: ...e J Replace 8pipe Cracks damage J Replace 2 Check 8air cut off valve Cracks damage J Replace NOTE When the negative pressure is applied to the part 1 check that the continuity in the direction of arrow mark is completely lost If the negative pressure is not loaded the continuity can be obtained AIR INDUCTION SYSTEM 1 ...

Page 238: ... CIRCUIT DIAGRAM 7 14 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 7 15 TROUBLESHOOTING 7 16 STARTER MOTOR 7 20 CHECKING THE STARTER MOTOR 7 21 ASSEMBLING THE STARTER MOTOR 7 23 CHARGING SYSTEM 7 24 CIRCUIT DIAGRAM 7 24 TROUBLESHOOTING 7 25 LIGHTING SYSTEM 7 27 CIRCUIT DIAGRAM 7 27 TROUBLESHOOTING 7 28 CHECKING THE LIGHTING SYSTEM 7 29 SIGNALING SYSTEM 7 33 CIRCUIT DIAGRAM 7 33 TROUBLESHOOTING 7 34 C...

Page 239: ...uretor heater 5 Sidestand switch 6 Horn 7 Rectifier Regulator 8 Ignition coil 9 Rear brake light switch 0 Main switch q Thermo switch w Fuel sender e Starter relay r Turn signal relay t Front brake light switch y Starting circuit cut off relay ELECTRICAL COMPONENTS 0 t r 9 w 3 e 4 1 5 8 2 y q 7 6 ...

Page 240: ...EEN RED RED BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLUE LOCK OFF ON OFF START OFF RUN OFF PUSH HI LO L N R MAIN START E G STOP HORN SW DIMMER SW TURN SIGNAL SW ILLUM 12V3W HI BEAM 12V3W TURN 12V3W 12V 10W 12V 10W 12V 10W 12V 10W 12V 27 8W 12V 60W 55W 10A Br R B BW R R R R R B R RW B B B B B L L Br 14V3W G G B B B B Ch Dg Ch Dg B B B B Y Y G G Y Y L P BW BW Br LW B R BR BR GW GW WR WR W W ...

Page 241: ...al relay f Speedometer light g Tail brake light h Dimmer switch j High beam indicator light k Turn signal indicator light l Fuel lever meter Fuel sender z Headlight x Front turn signal light left c Front turn signal light right v Rear turn signal light left b Rear turn signal light right n Thermo switch m Carburetor heater Color Cod B Black Br Brown Ch Chocolate Dg Dark green G Green L Blue Or Ora...

Page 242: ... and to the Ω 1 range 8 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 il lustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE c c indi...

Page 243: ... Properly connect Incorrect continuity reading J Replace the switch CHECKING THE SWITCHES Rear barake light switch Dimmer switch Horn switch Turn signal light switch Main switch Front barake light switch Start switch Engine stop switch B B HI LO Y L G OFF PUSH P B Dg Ch L B L P B Ch Br W Dg L N R Ch Br W Dg LOCK OFF ON Br R B B W R B Br Br G Y OFF START OFF RUN L W B W L W B W Br L W B W B W L W B...

Page 244: ...F BULBS The bulbs used on this scooter are shown in the illustration on the left 8Bulbs A and B are used for the head lights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise 8Bulbs C is used for turn signal and tail brake lights and can be removed from the s...

Page 245: ...fe of the bulb and the luminous flux will be adversely affected If the head light bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check 8bulb for continuity with the pocket tester No continuity J Replace Pocket tester 90890 03132 YU 03112 C NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester...

Page 246: ...0890 03132 YU 03112 C NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the re spective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity re place the bulb socket CHECKING THE BULBS AND B...

Page 247: ...FF ON OFF START OFF RUN OFF PUSH HI LO L N R MAIN START E G STOP HORN SW DIMMER SW TURN SIGNAL SW ILLUM 12V3W HI BEAM 12V3W TURN 12V3W 12V 10W 12V 10W 12V 10W 12V 10W 12V 27 8W 12V 60W 55W 10A Br R B BW R R R R R B R RW B B B B B L L Br 14V3W G G B B B B Ch Dg Ch Dg B B B B Y Y G G Y Y L P BW BW Br LW B R BR BR GW GW WR WR W W YR YR YR LW RW B GY Sb P Br BrW Br B BrW Dg Ch Ch Dg B B B GY L GY GY B...

Page 248: ...M 34487 Pocket tester 90890 03132 YU 03112 C EAS00738 1 Main Fuse 8 Check the fuse for continuity Refer to CHECKING THE FUSE in chap ter 3 8 Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO 8Clean the battery ter minals 8...

Page 249: ...ication NO YES The ignition system is OK EAS00744 5 Spark plug cap resistance 8Remove the spark plug cap from the spark plug lead 8Connect the pocket tester Ω 1k range to the spark plug cap as shown 8Measure the spark plug cap resistance Spark plug cap resistance 8 12 kΩ Ω Ω Ω Ω at 20 C 8Is the spark plug cap OK YES NO Replace the spark plug cap EAS00746 6 Ignition coil resistance 8Disconnect the ...

Page 250: ...0 C 8Is the ignition coil OK YES NO Replace the ignition coil EAS00749 7 Main switch 8Check the main switch for continuity Refer to CHECKINGTHE SWITCHES 8Is the main switch OK YES NO EAS00750 8 Engine stop switch 8Check the engine stopswitch for continu ity Refer to CHECKING THE SWITCHES 8Is the engine stop switch OK YES NO Replace the main switch Replace the right handlebar switch IGNITION SYSTEM...

Page 251: ...obe J J J J J white blue 2 2 2 2 2 8Measure the pickup coil resistance Pickup coil resistance 304 456Ω Ω Ω Ω Ω at 20 C 8Is the pickup coil OK YES NO Replace the pickup coil EAS00754 11 Wiring 8Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM 8Is the ignition system s wiring properly connected and without defects YES NO Properly connect or repair the ignition system s wiring Repla...

Page 252: ... R MAIN START E G STOP HORN SW DIMMER SW TURN SIGNAL SW ILLUM 12V3W HI BEAM 12V3W TURN 12V3W 12V 10W 12V 10W 12V 10W 12V 10W 12V 27 8W 12V 60W 55W 10A Br R B BW R R R R R B R RW B B B B B L L Br 14V3W G G B B B B Ch Dg Ch Dg B B B B Y Y G G Y Y L P BW BW Br LW B R BR BR GW GW WR WR W W YR YR YR LW RW B GY Sb P Br BrW Br B BrW Dg Ch Ch Dg B B B GY L GY GY Br Br B LY LY Sb BW B B Or Or Br Y Y B 2 o ...

Page 253: ...d switch is up the side stand switch is closed and the brake lever front or rear is pulled to the handlebar the brake light switch is closed 1 Battery 2 Main fuse 3 Main switch 4 Front brake light switch 5 Rear brake light switch 6 Engine stop switch 7 Starting circuit cut off relay 8 Sidestand switch 9 Start switch 0 Starter relay q Starter motor w C D I unit ELECTRIC STARTING SYSTEM q 0 2 3 9 w ...

Page 254: ...ont turn signal light bracket 3 Leg shield 1 4 Rear carrier 5 Side cover right 6 Cover 7 Battery cover 8Troubleshoot with the following special tool s Pocket tester 90890 03132 YU 03112 C EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO EAS00738 1 Main fuse 8C...

Page 255: ...he starter motor EAS00759 4 Starting circuit cut off relay 8Disconnect the starting circuit cut off re lay coupler from the wire harness 8Connect the pocket tester Ω 1 and battery 12 V to the starting circuit cut off relay coupler as shown Positive battery terminal J J J J J red white 1 1 1 1 1 Negative battery terminal J J J J J blue white 2 2 2 2 2 Positive tester probe J J J J J green yellow 3 ...

Page 256: ... starter relay Replace the main switch EAS00751 7 Brake light switch front and rear 8Check the brake light switch for continu ity Refer to CHECKINGTHE SWITCHES 8Is the brake light switch OK YES NO Replace the brake light switch 1 3 4 2 L W R W Starter relay ELECTRIC STARTING SYSTEM EAS00750 8 Engine stop switch 8Check the engine stop switch for conti nuity Refer to CHECKINGTHE SWITCHES 8Is the eng...

Page 257: ... wiring or replace the C D I unit The starting sys tem circuit is OK EAS00766 11 Wiring 8Check the entire starting system s wir ing Refer to CIRCUIT DIAGRAM 8Is the starting system s wiring properly connected and without defects YES NO ELECTRIC STARTING SYSTEM ...

Page 258: ...p Brush Brush spring Brush seat Plate washer Front bracket 1 2 1 2 3 4 5 6 7 8 9 0 q 1 1 1 1 2 1 1 1 2 2 1 1 1 Remove the parts in the order listed Refer to LEADS HOSES AND REAR BRAKE in chapter 5 For installation reverse the removal pro cedure Remove the parts in the order listed For assembly reverse the disassembly procedure ELECTRIC STARTING SYSTEM 5 6 0 3 2 7 8 9 7 8 4 q 1 1 2 3 5Nm 0 35m kg 2...

Page 259: ...r Mica undercut 1 5 mm 0 06 in NOTE The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure 8armature assembly resistances commu tator and insulation Out of specification J Replace the starter motor a Measure the armature assembly resis tances with the pocket tester Pocket tester 90890 03132 YU 03112 C Armature coil Commutator resistance 1 1 1 1 1 0 0306 ...

Page 260: ...eplace the brushes as a set Brush length wear limit 3 5 mm 0 14 in 6 Measure 8brush spring force Out of specification J Replace the brush springs as a set Brush spring force 5 52 8 28 N 7 Check 8gear teeth Damage wear J Replace the gear ELECTRIC STARTING SYSTEM ...

Page 261: ...gasket 1 8starter motor front bracket 2 8starter motor rear bracket 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear brackets ELECTRIC STARTING SYSTEM 2 2 1 T R 3 1 1 2 1 2 3 Install 8O ring New 1 8washer 8bolts 2 3 5 Nm 0 35 m kg 2 5 ft lb a b ...

Page 262: ...LACK BLACK BLACK BLACK BLACK BLUE LOCK OFF ON OFF START OFF RUN OFF PUSH HI LO L N R MAIN START E G STOP HORN SW DIMMER SW TURN SIGNAL SW ILLUM 12V3W HI BEAM 12V3W TURN 12V3W 12V 10W 12V 10W 12V 10W 12V 10W 12V 27 8W 12V 60W 55W 10A Br R B BW R R R R R B R RW B B B B B L L Br 14V3W G G B B B B Ch Dg Ch Dg B B B B Y Y G G Y Y L P BW BW Br LW B R BR BR GW GW WR WR W W YR YR YR LW RW B GY Sb P Br BrW...

Page 263: ...hapter 3 8Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO 8Clean the battery termi nals 8Recharge or replace the battery EAS00775 3 Charging voltage 8Connect the engine tachometer to the spark plug lead of cylinder 8Conn...

Page 264: ...1 1 1 1 1 Negative tester probe J J J J J black red 2 2 2 2 2 8Measure the stator coil resistances Stator coil resistance 688 1032 Ω Ω Ω Ω Ω at 20 C 8Is the stator coil OK YES NO Replace the stator coil as sembly EAS00754 5 Wiring 8Check the entire charging system s wir ing Refer to CIRCUIT DIAGRAM 8Is the charging system s wiring properly connected and without defects YES NO Properly connect or r...

Page 265: ...ACK BLACK BLACK BLUE LOCK OFF ON OFF START OFF RUN OFF PUSH HI LO L N R MAIN START E G STOP HORN SW DIMMER SW TURN SIGNAL SW ILLUM 12V3W HI BEAM 12V3W TURN 12V3W 12V 10W 12V 10W 12V 10W 12V 10W 12V 27 8W 12V 60W 55W 10A Br R B BW R R R R R B R RW B B B B B L L Br 14V3W G G B B B B Ch Dg Ch Dg B B B B Y Y G G Y Y L P BW BW Br LW B R BR BR GW GW WR WR W W YR YR YR LW RW B GY Sb P Br BrW Br B BrW Dg ...

Page 266: ...38 1 Main fuse 8Check the fuses for continuity Refer to CHECKING THE FUSES in chapter 3 8Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO 8Clean the battery termi nals 8Recharge or replace the battery EAS00749 3 Main swit...

Page 267: ... headlight and the high beam indicator light fail to come on 1 Headlight bulb and socket 8Check the headlight bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS 8Are the headlight bulb and socket OK YES NO 2 High beam indicator light bulb and socket 8Check the high beam indicator light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS 8Are the hig...

Page 268: ... 4 4 4 4 4 High beam indicator light Positive tester probe J J J J J yellow 1 1 1 1 1 Negative tester probe J J J J J black 2 2 2 2 2 8Set the main switch to ON 8Start the engine 8Set the dimmer switch to or 8Measure the voltage DC 12 V on the headlight coupler wire harness side 8Measure the voltage DC 12 V on the dimmer switch coupler wire harness side when the dimmer switch is set to 8Is the vol...

Page 269: ...o come on 1 Meter light bulb and socket 8Check the meter light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS 8Are the meter light bulb and socket OK YES NO Replace the meter light bulb socket or both This circuit is OK The wiring circuit from the main switch to the meter light coupler is faulty and must be re paired Refer to CIRCUIT DIAGRAM EAS00841 3 Fuel level meter...

Page 270: ...e the lighting coil resistance Lighting coil resistance 0 28 0 42 Ω Ω Ω Ω Ω at 20 C between yellow red and ground 8Connect the pocket tester Ω 1 to the lighting coil terminal as shown Positive tester probe J J J J J white 1 1 1 1 1 Negative tester probe J J J J J ground 8Measure the lighting coil resistance Lighting coil resistance 0 32 0 48 Ω Ω Ω Ω Ω at 20 C between white and ground 8Is the light...

Page 271: ... BEAM 12V3W TURN 12V3W 12V 10W 12V 10W 12V 10W 12V 10W 12V 27 8W 12V 60W 55W 10A Br R B BW R R R R R B R RW B B B B B L L Br 14V3W G G B B B B Ch Dg Ch Dg B B B B Y Y G G Y Y L P BW BW Br LW B R BR BR GW GW WR WR W W YR YR YR LW RW B GY Sb P Br BrW Br B BrW Dg Ch Ch Dg B B B GY L GY GY Br Br B LY LY Sb BW B B Or Or Br Y Y B 2 o 4 i w 5 0 8 l c x e d p y f z r t m n 9 b v 1 3 q g MOTOR 6 7 j k u a ...

Page 272: ...G THE FUSES in chapter 3 8Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO 8Clean the battery terminals 8Recharge or re place the battery EAS00749 3 Main switch 8Check the main switch for continuity Refer to CHECKINGTHE S...

Page 273: ...tage 8Connect the pocket tester DC 20 V to the horn connector at the horn terminal as shown Positive tester probe J J J J Jbrown 1 1 1 1 1 Negative tester probe J J J J J ground 8Set the main switch to ON 8Push the horn switch 8Measure the voltage DC 12 V of brown at the horn terminal 8Is the voltage within specification YES NO The wiring circuit from the main switch to the horn con nector is faul...

Page 274: ...2 2 2 2 2 8Set the main switch to ON 8Pull in the brake levers 8Measure the voltage DC 12 V of yel low green yellow 1 on the tail brake light coupler wire harness side 8Is the voltage within specification YES NO 2 Brake light switches 8Check the brake light switches for conti nuity Refer to CHECKINGTHE SWITCHES 8Is the brake light switch OK YES NO Replace the brake light switch The wiring circuit ...

Page 275: ... bulb socket or both 2 Turn signal switch 8Check the turn signal switch for continu ity Refer to CHECKINGTHE SWITCHES 8Is the turn signal switch OK YES NO 3 Voltage 8Connect the pocket tester DC 20 V to the turn signal relay coupler wire har ness side as shown Positive tester probe J J J J J brown 1 1 1 1 1 Negative tester probe J J J J J ground 8Set the main switch to ON 8Measure the voltage DC 1...

Page 276: ...tor or meter assembly coupler wire harness side as shown Turn signal light Turn signal indicator light Left turn signal light Positive tester probe J J J J J chocolate 1 1 1 1 1 Negative tester probe J J J J J ground Right turn signal light Positive tester probe J J J J J dark green 2 2 2 2 2 Negative tester probe J J J J J ground 8Set the main switch to ON 8Set the turn signal switch to 4 or 6 8M...

Page 277: ...der resistance down po sition E Ω Ω Ω Ω Ω 10 90 100 Ω Ω Ω Ω Ω at 20 C 8Is the fuel sender OK YES NO Replace the fuel sender 2 Voltage 8Connect the pocket tester DC 20 V to the meter light coupler wire harness side as shown Positive tester probe J J J J J brown 1 1 1 1 1 Negative tester probe J J J J J black 2 2 2 2 2 8Set the main switch to ON 8Measure the voltage DC 12 V of brown 1 on the meter l...

Page 278: ...needle moves to F or E NOTE Before reading the fuel level meter leave the float in one position either up or down for at least three minutes 8Does the fuel level meter needle move appropriately YES NO Replace the fuel level meter 1 2 SIGNALING SYSTEM This circuit is OK 4 Wiring 8Check the entire signaling system s wiring ...

Page 279: ...CK BLACK BLACK BLACK BLACK BLUE LOCK OFF ON OFF START OFF RUN OFF PUSH HI LO L N R MAIN START E G STOP HORN SW DIMMER SW TURN SIGNAL SW ILLUM 12V3W HI BEAM 12V3W TURN 12V3W 12V 10W 12V 10W 12V 10W 12V 10W 12V 27 8W 12V 60W 55W 10A Br R B BW R R R R R B R RW B B B B B L L Br 14V3W G G B B B B Ch Dg Ch Dg B B B B Y Y G G Y Y L P BW BW Br LW B R BR BR GW GW WR WR W W YR YR YR LW RW B GY Sb P Br BrW B...

Page 280: ...with the following special tool s Pocket tester 90890 03132 YU 03112 C EAS00738 1 Main fuse 8Check the fuse for continuity Refer to CHECKING THE FUSES in chapter 3 8Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 8Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 8Is the battery OK YES NO 8Clean ...

Page 281: ...hermo switch is dropped replace it Continuity YES NO NO YES Test step 1 2 3 4 C o o l a n t temperature 0 11 3 C More than16 3 C 16 3 11 3 C Less than11 3 C A The coolant temperature sensor circuit is closed B The coolant temperature sensor circuit is open 8Does the thermo switch operate prop erly YES NO Replace the thermo switch EAS00824 5 Carburetor heater 8Remove the carburetor heating element ...

Page 282: ...ire carburetor heating system s wiring Refer to CIRCUIT DIAGRAM 8Is the carburetor heating system s wir ing properly connected and without de fects NO Properly connect or re pair the carburetor heat ing system s wiring CRABURETOR HEATING SYSTEM ...

Page 283: ...ED RED BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLUE LOCK OFF ON OFF START OFF RUN OFF PUSH HI LO L N R MAIN START E G STOP HORN SW DIMMER SW TURN SIGNAL SW ILLUM 12V3W HI BEAM 12V3W TURN 12V3W 12V 10W 12V 10W 12V 10W 12V 10W 12V 27 8W 12V 60W 55W 10A Br R B BW R R R R R B R RW B B B B B L L Br 14V3W G G B B B B Ch Dg Ch Dg B B B B Y Y G G Y Y L P BW BW Br LW B R BR BR GW GW WR WR W W YR YR...

Page 284: ...ler from the wire harness 8Connect the pocket tester Ω 1 to the lighting coil terminal as shown Positive tester probe J J J J J yellow red 1 1 1 1 1 Negative tester probe J J J J J ground 8Measure the lighting coil resistance Lighting coil resistance 0 28 0 42 Ω Ω Ω Ω Ω at 20 C between yellow red and ground 8Connect the pocket tester Ω 1 to the lighting coil terminal as shown Positive tester probe...

Page 285: ... probe J J J J Jblack 2 2 2 2 2 8Measure the auto choke unit resistance Auto choke unit resistance 30 Ω Ω Ω Ω Ω at 20 C 8Is the auto choke unit OK YES NO EAS00826 3 Wiring 8Check the entire auto choke system s wir ing Refer to CIRCUIT DIAGRAM 8Is the auto choke system s wiring prop erly connected and without defects YES NO Replace the auto choke unit Properly connect or repair the auto choke syste...

Page 286: ...PEED PERFORMANCE FAULTY CLUTCH 8 3 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 FAULTY CLUTCH 8 3 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE 8 3 CLUTCH SLIPS 8 3 POOR STARTING PERFORMANCE 8 3 OVERHEATING POOR BRAKING PERFORMANCE FAULTY FRONT FORK LEGS 8 4 POOR SPEED PERFORMANCE 8 4 OVERHEATING 8 4 ENGINE 8 4 FUEL SYSTEM 8 4 CHASSIS 8 4 ELECTRICAL SYSTEMS 8 4 POOR BRAKING PE...

Page 287: ...ING OR SIGNALING SYSTEM 8 5 HEADLIGHT DOES NOT COME ON 8 5 HEADLIGHT BULB BURNT OUT 8 5 TAIL BRAKE LIGHT DOES NOT COME ON 8 5 TAIL BRAKE LIGHT BULB BURNT OUT 8 5 TURN SIGNAL DOES NOT COME ON 8 5 TURN SIGNAL BLINKS SLOWLY 8 5 TURN SIGNAL REMAINS LIT 8 6 TURN SIGNAL BLINKS QUICKLY 8 6 HORN DOES NOT SOUND 8 6 ...

Page 288: ...nkcase and crankshaft 8Improperly assembled crankcase 8Seized crankshaft FUEL SYSTEM Fuel tank 8Empty fuel tank 8Clogged fuel filter 8Clogged fuel tank cap breather hole 8Clogged or damaged fuel hose 8Deteriorated or contaminated fuel Fuel cock 8Clogged or damaged fuel hose Carburetor 8Deteriorated or contaminated fuel 8Clogged pilot jet 8Clogged pilot air passage 8Sucked in air 8Damaged float 8Wo...

Page 289: ...ect valve clearance 8Damaged valve train components Air filter 8Clogged air filter element FUEL SYSTEM Carburetor 8Faulty starter plunger 8Loose or clogged pilot jet 8Loose or clogged pilot air jet 8Damaged or loose carburetor joint 8Improperly adjusted engine idling speed throttle stop screw 8Improper throttle cable free play 8Flooded carburetor ELECTRICAL SYSTEMS Battery 8Discharged battery 8Fau...

Page 290: ...NGINE OPERATES BUT SCOOTER WILL NOT MOVE V belt 8Bent damaged or worn V belt 8Slipping V belt Primary pulley cam and primary pulley slider 8Damaged or worn primary pulley cam 8Damaged or worn primary pulley slider Clutch spring s 8Damaged clutch spring Transmission gears 8Damaged transmission gear CLUTCH SLIPS Clutch shoe springs 8Damaged loose or worn clutch shoe spring Clutch shoes 8Damaged or w...

Page 291: ...lty C D I unit EAS00859 POOR BRAKING PERFORMANCE Disc brake 8Worn brake pad 8Worn brake disc 8Air in hydraulic brake system 8Leaking brake fluid 8Faulty brake caliper kit 8Faulty brake caliper seal 8Loose union bolt 8Damaged brake hose 8Oil or grease on the brake disc 8Oil or grease on the brake pad 8Incorrect brake fluid level Drum brake 8Worn brake shoe 8Worn or rusty brake drum 8Incorrect brake...

Page 292: ...ing race EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON 8Wrong headlight bulb 8Too many electrical accessories 8Hard charging 8Incorrect connection 8Improperly grounded circuit 8Poor contacts main or light switch 8Burnt out headlight bulb HEADLIGHT BULB BURNT OUT 8Wrong headlight bulb 8Faulty battery 8Faulty rectifier regulator 8Improperly grounded circuit 8Faulty main swi...

Page 293: ...out turn signal bulb TURN SIGNAL BLINKS QUICKLY 8Incorrect turn signal bulb 8Faulty turn signal relay 8Burnt out turn signal bulb HORN DOES NOT SOUND 8Improperly adjusted horn 8Damaged or faulty horn 8Faulty main switch 8Faulty horn switch 8Faulty battery 8Blown damaged or incorrect fuse 8Faulty wire harness ...

Page 294: ...YAMAHA MOTOR TAIWAN CO LTD ...

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