2008 MOTORCYCLE SERVICE MANUAL Model : YW50X_ 5PNF81972100 *5PNF81972100*
FORWORD This supplementary service manual has been prepared to introduce new service and data for YW50BP 2001. For complete service manual procedures it is necessary to use this supplementary service manual together with the following manual. YW50BP 2001 SERVICE MANUAL : 5PN1-ME1 EAS00000 YW50X 2007 SUPPLEMENTARY SERVICE MANUAL ©2007 by Yamaha Motor Taiwan Co., Ltd. First edition, June 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co.
EAS00002 NOTICE This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
EAS00008 1 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 2 3 4 5 6 7 8 9 CHAS 5 6 ENG COOL 7 8 CARB ELEC 9 0 - + Symbols 0 to u indicate the following.
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CARBURETOR GEN INFO 1 SPEC 2 CHK ADJ 3 CARB 4 5 6 5 7 8 9
GEN INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ............................................. 1-1 MODEL LABEL .................................................................................. 1-1 IMPORTANT INFORMATION ................................................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ................... 1-2 REPLACEMENT PARTS .......................
SCOOTER IDENTIFICATION GEN INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION 1 EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL LABEL The model label 1 is affixed to the seat. This information will be needed to order spare parts.
IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector 2. Check: 8 lead 8 coupler 8 connector Moisture i Dry with an air blower. Rust/stains i Connect and disconnect several times. 3. Check: 8 all connections Loose connection i Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. 4.
SPECIAL TOOLS 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 inappropriate 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. NOTE: 8 For U.S.A.
SPECIAL TOOLS Tool NO. 90890-06760 90890-03112 YU-03112-C 90890-01409 YM-01409 90890-01410 YM-01410 90890-06754 YM-34487 90890-85505 ACC-11001-05-01 90890-01348 YM-01348 90890-01268 YU-01268 90890-01367 YM-A9409-7 90890-01400 YM-A9409-3 90890-01326 YM-01326 90890-01294 YM-01300-1 Tool name / Function GEN INFO Illustration Digital tachometer This tool is needed for detecting engine rpm. Pocket tester This instrument is invaluable for checking the electrical system.
SPECIAL TOOLS Tool NO. 90890-01312 YM-01312-A Tool name / Function Fuel level gauge This gauge is used to measure the fuel lever in the float chamber.
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................................................................. 2-1 ENGINE SPECIFICATIONS ..................................................................... 2-2 CHASSIS SPECIFICATIONS ................................................................... 2-6 ELECTRICAL SPECIFICATIONS ............................................................ 2-9 CONVERTION TABLE ............................................................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Standard Item Model Code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (without oil and a full fuel tank) Dry (without oil and fuel) Maximun load (total of cargo, rider, passenger, and accessories) Limit 5PJ5 (USA) 5PN6 (CAN) … … 1890mm (74.41in) 705mm (27.76in) 1110mm (43.70in) 765mm (30.12in) 1275mm (50.20in) 120mm (4.72in) 1800mm (70.
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Standard Item Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Engine idle speed Fuel Recommended fuel Fuel tank capacity Total Engine oil Lubrication system Recommended oil Quantity Oil tank Air-cooled 2-stroke reed valve 0.049L (49cm³, 2.99cu-in) Forward inclined single cylinder 40.0 × 39.2mm (1.57 × 1.54in) 7.
ENGINE SPECIFICATIONS Standard Item Cylinder Bore Maximum taper 40.000 ~ 40.014mm (1.5748 ~ 1.5754in) … Maximum out-of-round … Piston Piston-to-cylinder clearance Diameter D H Height H Piston pin bore (in the piston) Diameter Piston pin Outside diameter Piston rings Section sketch (B × T)/type Top ring 2nd ring End gap (installed) Top ring 2nd ring Side clearance (installed) Top ring 2nd ring Connecting rod Connecting rod length Small end inside diameter SPEC D Limit … 0.05mm (0.0020in) 0.05mm (0.
ENGINE SPECIFICATIONS SPEC Standard Item Limit Crankshaft Width “A” Maximum runout “C” Big end side clearance “D” Big end radial clearance Small end free play “F” Clutch Clutch type Clutch shoe thickness 37.90 ~ 37.95mm (1.4921 ~ 1.4941in) … 0.20 ~ 0.50mm (0.0079 ~ 0.0197in) 0.004 ~ 0.017mm (0.0002 ~ 0.0007in) 0.40 ~ 0.80mm (0.0157 ~ 0.0315in) Automatic centrifugal 2.5mm (0.10in) Clutch shoe spring free length Clutch housing inside diameter 26.2mm (1.03in) 105mm (4.
ENGINE SPECIFICATIONS Standard Item Carburetor ID mark Main jet (M.J.) Needle jet (N.J.) Jet needle-clip position (J.N.) Main air jet (M.A.J.) Cutaway (C.A.) Pilot jet (P.J.) Bypass Valve seat size (V.S.) Starter jet (St.J.) Float height Fuel level height Engine idle speed Reed valve Thickness Valve stopper height Valve bending limit SPEC 5PJ5 00 # 80 2.085 3N24-1/1 2.0 3.0 # 44 0.8 1.8 0.45 15 ~ 17mm (0.59 ~ 0.67in) 3.0 ~ 4.0mm (0.12 ~ 0.16in) 1800 ~ 1900r/min 0.132 ~ 0.172mm (0.0052 ~ 0.0068in) 5.
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Standard Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Maximum lateral wheel runout Wheel axle bending limit Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Maximum lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) Up to 90kg (198lb) load 90kg (198lb) load ~ Maximum load* Minimum ti
CHASSIS SPECIFICATIONS Standard Item Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) Up to 90kg (198lb) load 90kg (198lb) load ~ Maximum load* Minimum tire tread depth SPEC Limit Tubeless 130/90-10 59J C-924 (CHENG SHIN) … … … 200kPa (2.00kgf/cm², 29psi) 200kPa (2.00kgf/cm², 29psi) … … … 0.8mm (0.03in) Pad thickness Single disk brake Right-hand operation 180 × 4.0mm (7.09 × 0.16in) 4.0mm (0.
CHASSIS SPECIFICATIONS Standard Item Front suspension Suspension type Front fork type Front fork travel Spring Free length Installed length Spring rate (K1) Spring rate (K2) Spring stroke (K1) Spring stroke (K2) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Inner tube outer diameter Inner tube bending limit Steering system Steering bearing type Lock-to-lock angle (left) Lock-to-lock angle (right) Rear suspension Suspension type Rear shock absorber assembly type Rear shoc
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Standard Item System voltage Limit 12V … C.D.I. 14° BTDC at 5000r/min Fixed 400 ~ 600Ωat 20°C (68°F)/ black - white/red 5PJ (T-MORIC) … … … … … Ignition coil Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance 2JN (T-MORIC) 6mm (0.24in) 0.184 ~ 0.276Ω at 20°C (68°F) 6.32 ~ 9.
ELECTRICAL SPECIFICATIONS SPEC Standard Item Limit Headlight type Halogen bulb … Indicator light (voltage/wattage × quantity) Turn signal indicator light High beam indicator light Oil level indicator light 12V 1.7W × 1 12V 1.7W × 1 12V 1.7W × 1 … … … Bulbs (voltage/wattage × quantity) Headlight Tail/brake light Front turn signal light Rear turn signal light License plate light Speedometer light 12V 35/35W × 1 12V 5/21W × 1 12V 10W × 2 12V 10W × 2 12V 5W × 1 12V 3.4W × 1, 1.
ELECTRICAL SPECIFICATIONS SPEC Standard Item Limit Fuse (amperage × quantity) Main fuse 7A × 1 … Fuel sender Model (manufacturer) Sender unit resistance - full Sender unit resistance - empty 4VP (TATUNG) 4 ~ 10Ω 90 ~ 100Ω … … … Oil lever gauge Model (manufacturer) 4VP (LUN PING) … 2-11
CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE Part to be tightened Part name Thread ’ Q ty size Tightening torque Remarks Nm m•kg ft•lb Spark plug Cylinder head and cylinder Cylinder Air shroud 1 Air shroud 1× 2 Fan Autolube pump Reed valve Air filter Carburetor cap Exhaust pipe Muffler Exhaust protector Protector Crankcase 1× 2 Transmission case cover Crankcase cover 1(left) Bolt(case2) Crankcase cover2(left) Drain bolt Oil plug Idle gear plate Kick crank Starter motor Clutch housing Clutch weig
TIGHTENING TORQUES SPEC CHASSIS Part to be tightened Thread size Tightening torque Nm M 12 M 10 M6 M 10 M8 M 25 M 10 M8 M6 M6 M5 M6 M6 M5 M6 M 10 M 14 M6 M8 M10 M8 M5 Frame and engine bracket Engine bracket, compression rod and engine Rear carrier Rear shock absorber and frame Rear shock absorber and engine Steering ring nut Handle holder and steering shaft Brake hose and master cylinder Fuel tank Fuel cock Fuel sender Box Seat lock assembly Plastic parts & cover Footrest board Front wheel axle and nu
TIGHTENING TORQUES SPEC NOTE : 1. First, tighten the ring nut(lower) approximately 38Nm(3.8m•kg, 27.5ft•lb) by using the torque wrench, then loosen the ring nut 1/4 turn. 2. Second, tighten the ring nut(lower) approximately 12Nm(1.2m•kg, 8.7ft•lb) by using the torque wrench. 3. Installing the rubber washer. 4. Then finger tighten the center ring nut and touch rubber washer. Align the slots both ring nut and install the lock washer. 5.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant Oil seal lips LS O-rings LS Bearings E Piston surface E Piston pin E Cylinder E Transmission case (bearing) G Autolube pump LS Starter wheel gear LS Idle gear plate M Secondary drive gear G Kickstarter pinion gear LS Drive axle M Pump drive gear LS Main axle G Main axle (bearing) G 2-16
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS Lubrication Point Lubricant Oil seal lips LS O-rings LS Bearings LS Speedometer drive gear LS Front brake lever pivot shaft S Rear brake lever pivot shaft LS Front brake camshaft LS Front brake cable LS Throttle cable LS Tube guide (throttle grip) inner surface LS Upper steering stem ring nut LS Upper bearing outer race LS Lower bearing outer race LS Rear brake camshaft LS Centerstand LS 2-17
CABLE ROUTING t Wire harness A Pass the speedometer cable through the right hole of front fender, then through the guide. B Pass the wire harness through the inside of ignition coil. C Secure the ground lead and the ignition coil base to the ignition coil stay. D Pass the wire harness through the inside of oil tank. E Pass the seat cable through the inside of frame.
CABLE ROUTING 1 Brake cable 2 Speedometer cable 3 Fuel tank overflow hose 4 Brake cable holder 5 Brake hose 6 Brake hose holder 7 License bracket 8 Flasher relay 9 Fuel tank breather hose 0 Fuel hose q Breather hose A Pass the brake hose through the holder. B Insert the fuel overflowhose bottom. C Pass the fuel overflowhose through the rear fender hole. D Pass the fuel overflowhose through the holder. E Hold the fuel overflowhose with a clamp. F Pass the brake cable through the holder.
CABLE ROUTING 1 Brake hose 2 Front fender 3 Front fork assembly 4 Nut 5 Plate washer 6 Brake hose holder 1 7 Flange bolt 8 Brake hose holder 2 9 Bolt 0 Grommet q Flange bolt w Brake hose holder e Brake hose holder 3 SPEC A Tighting torque:3.5 ~ 5.5Nm. B Assemble the brake hose holder 3 hang hook must certainty hook the brake hose holder. C Tighting torque:8.5 ~ 14Nm. D Tighting torque:3.5 ~ 5Nm. E Tighting torque:3.5 ~ 5.5Nm. F Pass the brake hose through the brake hose holder.
CABLE ROUTING 1 Ignition coil 2 Spark plug lead 3 Starter relay leads 4 Auto choke leads 5 Starter relay 6 Band 7 C.D.I. unit 8 Autolube hose 9 Seat lock cable 0 Bracket q Fuel tank breather hose w Band 2 e Battery - lead r Battery + lead A Pass battery leads through the slot of footrestboard. B Cover them after securing starter relay leads. C Pass the seat lock cable through the hole of bracket. D Pass the fuel tank breath hose over seat lock cable.
CABLE ROUTING 1 Grip assembly 2 Handlebar switch(right) 3 Front brake light switch 4 Speedometer 5 Rear brake cable 6 Handlebar switch(left) 7 Grip 8 Handlebar assembly 9 Wire harness 0 Throttle cable 1 q Throttle cable 3 w Speedometer cable e Brake hose A Route the front brake light switch lead through between the handlebar pipe and the brake hose. B Route the front brake light switch lead, left handlebar switch lead and front turn signal light lead through the backward of speedometer cable .
CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ....................................................................................... 3-1 PERIODIC MAINTENANCE AND MINOR REPAIR ................................ 3-1 Periodic maintenance chart for the emission control system ........... 3-1 General maintenance and lubrication chart...................................... 3-2 COVER AND PANEL ................................................................................ 3-4 SEAT AND SIDE COVERS..
INTRODUCTION/PERIODIC MAINTENANCE AND MINOR REPAIR CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE AND MINOR REPAIR CHK ADJ EAU32115 General maintenance and lubrication chart INITIAL NO. ITEM ROUTINE 1,000 km (600 mi) or 1 month ODOMETER READING 4,000 km (2,000 mi) or 6 months 7,000 km (4,000 mi) or 12 months 10,000km (6,000 mi) or 18 months 13,000 km 16,000 km (8,000 mi) (10,000 mi)) or or 24 30 months months * Air filter element • Clean with solvent. • Replace if necessary. 2 * Front brake • Check operation, fluid level, and for fluid leakage.
PERIODIC MAINTENANCE AND MINOR REPAIR CHK ADJ EAU17620 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake system • When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. • Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. • Replace the brake hoses every four years or if cracked or damaged.
COVER AND PANEL CHK ADJ EAS00038 COVER AND PANEL SEAT AND SIDE COVERS 13Nm (1.3 m•kg, 9.4 ft•lb) 4 2 5 3 7 8 1 6 Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Removing the seat and side covers Battery box cover Seat Seat hanger Rear carrier Rear cover Side cover(left) Side cover(right) Center cover 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. NOTE: Insert the (-) screwdriver into the slot of battery box cover and pickup then remove. For installation, reverse the removal procedure.
COVER AND PANEL CHK ADJ LOWER COWLING, UPPER COVER AND LEG SHIELD 1 4 3 2 5 1 Order Job/Part Q’ty 1 2 3 4 5 Removing the lower cowling, upper cover, and leg shield 1 Lower cowling Head light lead coupler(low) Head light lead coupler(high) Upper cover Leg shield 1 Remarks Remove the parts in the order listed. 1 1 1 1 1 Disconnect. Disconnect. For installation, reverse the removal procedure.
COVER AND PANEL CHK ADJ LEG SHIELD 2 AND FOOTREST BOARD 1 7Nm (0.7 m•kg, 5.1 ft•lb) 5 2 6 7 4 3 8 Order Job/Part Q’ty Removing the leg shield 2 and footrest board Leg shield 1 1 2 3 4 5 6 7 8 Remove the parts in the order listed. Refer to “LOWER COWLING, UPPER COVER AND LEG SHIELD 1”.
COVER AND PANEL CHK ADJ HANDLEBAR COVER(FRONT AND REAR) 3 2 1 Order Job/Part Q’ty 1 2 3 Removing the handlebar cover(front and rear) Handlebar cover(front) Speedometer cable Handlebar cover(rear) Remarks Remove the parts in the order listed. 1 1 1 Disconnect. For installation, reverse the removal procedure.
ADJUSTING THE ENGINE IDLING SPEED CHK ADJ EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. w Before starting the engine, be sure to use the centerstand for safety. 2. Remove: 8 battery box cover 1 Refer to “SEAT AND SIDE COVERS”. 1 3.
ADJUSTING THE ENGINE IDLING SPEED b CHK ADJ 5. Adjust: 8engine idling speed a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. 1 Direction a Direction b Engine idling speed is increased. Engine idling speed is decreased. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6 . Install: 8 battery box cover Refer to “SEAT AND SIDE COVERS”.
CARB CHAPTER 4 CARBURETOR AIR INDUCTION SYSTEM ....................................................................... 4-1 AIR FILTER CASE ASSEMBLY ......................................................... 4-1 CHECKING THE AIR INDUCTION SYSTEM ...................................
AIR INDUCTION SYSTEM CARB AIR INDUCTION SYSTEM AIR FILTER CASE ASSEMBLY 2 1 3 Order Job/Part Q’ty 1 2 3 Removing the air filter case assembly Hose(to air filter) Pipe(to exhaust pipe) Air filter case assembly Remarks Remove the parts in the order listed. 1 1 1 Disconnect. Disconnect. For installation, reverse the removal procedure.
AIR INDUCTION SYSTEM CARB 8 1 9 2 0 q 3 w 4 5 7 6 Order Job/Part Q’ty 1 2 3 4 5 6 7 8 9 0 q w Disassembling the air filter case assembly Cap Damper Air filter case cap Reed valve Reed valve stopper Reed valve seat Reed valve assembly Element Plate O-ring Air filter case body Damper 4-2 Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
AIR INDUCTION SYSTEM CARB EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: 8 hoses Loose connection i Connect properly. Cracks/damage i Replace. 8 pipes Cracks/damage i Replace. 2. Check: 8 reed valve 1 8 reed valve stopper 8 reed valve seat Cracks/damage i Replace the reed valve assembly. 3. Measure: 8 reed valve bending limit a Out of specification i Replace the reed valve assembly. Reed valve bending limit 0.2 mm (0.0078 in) 1 Surface plate 4.
YW50X WIRING DIAGRAM 1 LOCK OPEN OFF CHECK ON 0 (GREEN) 6 8 9 7 2 q 12V 7A 4 5 (BLACK)(BLACK) 3 n m , 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g h j k l ; z x c v b n m , Main switch Main fuse Battery Starter relay Starter motor Rectifier/regulator Auto choke C.D.I. magneto C.D.I.
EBO00000 YW50BP SERVICE M A N U A L ©2001 by Yamaha M o t o r Taiwan Co,.Ltd. First edition, November 2001 All rights reserved. A n y reprinting or unauthorized use w i t h o u t the w r i t t e n permission of Yamaha M o t o r Taiwan Co,.Ltd. is expressly prohibited.
EB001000 NOTICE T h i s m a n u a l w a s p r o d u c e d b y t h e Y a m a h a M o t o r C o m p a n y , Ltd. p r i m a r i l y for use b y Y a m a h a dealers and t h e i r q u a l i f i e d m e c h a n i c s . It is not p o s s i b l e to i n c l u d e all t h e k n o w l e d g e o f a m e c h a n i c in one m a n u a l .
HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. C o m p r e h e n s i v e explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. (~ The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to " S Y M B O L S " . (~ Each chapter is divided into sections.
Q ® EAS00009 SYMBOLS GEN INFO SPEC ® ® INSP ENG ® ~)~ ® CHAS ( ~ ® CARB ® ELEC ~=] TRBL SHTG ® @ w.~ • Symbols (~ to (~) indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data © ® @ @ @ @ @ @ @ @ ® -n~ @ @ @ ® ® @ i i 1 ® The following symbols are not relevant to every vehicle. Symbols (~to (~ are designed as thumb tabs to indicate the chapter's number and content.
CHAPTER GENERAL SCOOTER INDENTIFICATION VEHICLE MODEL ........................................................................................................... 1-1 ........................................................................................... 1-1 ................................................................................................................................ 1-1 IMPORTANT INFORMATION PREPARATION ...........................................................................
C H A P T E R 2. SPECIFICATIONS GENERAL SPECIFICATION MAINTENANCE ENGINE TORQUES CHASSIS SPECIFICATION ..................................................................................................... ........................................................................................................................................ TIGHTENING CHASSIS TORQUES ............................................................................................................... ......................
CHAPTER 3. PERIODIC I N S P E C T I O N A N D A D J U S T M E N T S INTRODUCTION PERIODIC COVER ................................................................................................................................ MAINTENANCE/LUBRICATION AND PANEL SIDECOVER LOWER ENGINE AND SEAT 3-1 3-1 ................................................................................................................ 3-3 UPPER COVER, COVER(FRONT LEG SHIELD AND 1, 2 A N D FOOTREST BOARD ............
C H A P T E R 4. ENGINE E N G I N E O V E R H A U L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 WlREHARNESS AND CABLES ...................................................................................................... 4-1 C Y L I N D E R HEAD, C Y L I N D E R A N D P I S T O N . . . . . . . . . . . .
CHAPTER 5 CARBURETION CARBURETION .................................................................................................................................. CARBURETOR ................................................................................................................................ CABURETOR DISASSEMBLY CABURETOR 5-1 5-1 ....................................................................................................... 5-2 INSPECTION ....................................
CHAPTER 6 CHASSIS F R O N T W H E E L A N D B R A K E D I S C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 FRONT WHEEL AND FRONT WHEEL DISASSEMBLY BRAKE FRONT WHEEL DISASSEMBLY FRONT WHEEL INSPECTION BRAKE DISC INSPECTION D I S C ............................................................................................... 6-1 ........
CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS ............................................................................................................ 7-1 ........................................................................................................ 7-1 ........................................................................................................................ 7-2 CHECKING SWITCHES .................................................................................................
CHAPTER 8 TROUBLESHOOTING STARTING FAILURE/HARD FUEL SYSTEM IGNITION S T A R T I N G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 ............................................................................................................................... SYSTEM COMPRESSION .........................................................................................
SCOOTER INDENTIFICATION f I GEN EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE I D E N T I F I C A T I O N N U M B E R The vehicle identification number (~) is stamped into the frame. f EAS00018 M O D E L CODE The model code label ~) is affixed to the location s h o w n in the figure. Record the information on this label in the space provided. This information will be needed to order spare parts.
IMPORTANT INFORMATION I GEN EAS00020 IMPORTANT INFORMATION P R E P A R A T I O N FOR R E M O V A L A N D D I S A S SEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use o n l y the proper tools and cleaning equipment. Refer to "SPECIAL TOOLS". 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been " m a t e d " t h r o u g h normal wear.
IMPORTANT INFORMATION I ,NFOI GEN I EAS00024 ~\\\\\\\\~1 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu facturer's marks or n u m b e r s are visible. W h e n installing oil seals, lubricate the oil seal l i p s w i t h a light coat of lithium soap base grease. Oil bearings liberally w h e n installing, if appro priate. ~) Oil seal CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces.
IMPORTANT INFORMATION I GEN EB801000 CHECKING OF C O N N E C T I O N S D e a l i n g w i t h stains, rust, m o i s t u r e , etc. on t h e connector. 1. D i s c o n n e c t : • Connector 2. D r y each t e r m i n a l w i t h an air b l o w e r . 3. 4. 5. 6. C o n n e c t and d i s c o n n e c t t h e c o n n e c t o r t w o or t h r e e . Pull t h e read to c h e c k t h a t it w i l l not c o m e off.
H O W TO USE THE C O N V E R S I O N TABLE I GEN EB201000 H O W TO USE THE C O N V E R S I O N TABLE All s p e c i f i c a t i o n data in t h i s m a n u a l are listed in SI and M E T R I C U N I T S . Use t h i s t a b l e to c o n v e r t M E T R I C u n i t data t o I M P E R I A L u n i t data. Ex. METRIC MULTIPLIER IMP ** mm x 0.03937 = * * in 2 mm x 0.03937 = 0.083 in CONVERSION TABLE METRIC TO IMP Known Multiplier Result m.kg m.kg cm.kg cm.kg 7.233 86.794 0.0723 0.8679 ft.lb in.lb ft.
SPECIAL TOOLS I GEN EEl02000 SPECIAL TOOLS T h e f o l l o w i n g s p e c i a l t o o l s are n e c e s s a r y f o r c o m p l e t e and a c c u r a t e t u n e - u p and a s s e m b l y . Use o n l y t h e a p p r o p r i a t e s p e c i a l t o o l s ; t h i s Will h e l p p r e v e n t d a m a g e c a u s e d b y t h e use o f i n a p p r o p r i ate t o o l s or i m p r o v i s e d t e c h n i q u e s .
,.,o1 1 SPECIAL TOOLS I GEN Tool No. YU-03112 Tool name / Function I llustratio n Pocket tester This tool is used to c h e c k t h e electrical system. YM-1409 Oil seal guide This tool is used to install the left side crankcase oil seal. YM-1410 Oil seal d r i v e r This tool is used to install the left side crankcase oil seal. YM-34487 D y n a m i c spark tester This i n s t r u m e n t is necessary for checking the ignition s y s t e m c o m p o n e n t s .
G E N E R A L SPECIFICATION SPECIFICATION IsPEcl.-I GENERAL SPECIFICATION Model YW50AP Model code: 5P J1 Dimensions: Overall length Overall w i d t h Overall height Seat height Wheelbase M i n i m u m ground clearance M i n i m u m turning radius 1,890 mm(74.4 in) 705 mm(27.8 in) 1,110 mm(43.7 in) 765 mm(30.1 in) 1,275 mm(50.2 in) 120 mm(4.7 in) 2,000 mm(78.
G E N E R A L SPECIFICATION Model YW50A Spark Plug: Type/Manufacturer Gap BPRTHS/NGK 0.6 ~ 0.7 mm(0.02 ~ 0.03 in) Clutch Type Dry, Centrifugal automatic Transmission: Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type Operation Helical gear 4.000 Supur gear 3.666 V-belt Automatic Chassis: Frame type Caster angle Trail Steel tube underbone 26.5 ° 93mm(3.
G E N E R A L SPECIFICATION Model Headlight type: Bulb wattage x quantity: Headlight Tail/brake light Flasher light Licence plate light Meter light High beam indicator light Oil indicator light Turn indicator light YW50A Bulb 12V 35W/35Wx2 12 5W/21Wx1 V 10Wx4 5Wx 1 3.4Wxl/1.7Wxl 1.7Wx 1 1.7Wx 1 1.7Wx 1 2-3 IsPEcl.
MA...E°A.OE SPEO.F.OA-.O° ISPEcl M A I N T E N A N C E SPECIFICATION ENGINE Item C y l i n d e r head: Warp l i m i t Sta nda rd "~ Limit 0.03 m m (0.0012 in) *Lines indicate s t r a i g h t e d g e m e a s u r e m e n t Cylinder: Bore size 40.000~40.014mm (1.5748~1.5754 in) 40.10 m m (1.5787 in) 0.05 m m (0.0020 in) 0.03 rnm (0.0012 in) 0.035~0.040 m m (0.0014~0.0016 in) 39.958~39.972 m m (1.5731~1.5737 in) 5 mm(O.2 in) 10.004~10.015 m m (0.3939~0.3943 in) 9.996~10.000 rnrn (0.3935~0.3937 in) 0.
MA..TE°A°OESPEO.F.OAT.O°ISPEcl " Item Standard Crankshaft: F Crank Width " A " Run Out Limit " C " Connecting Rod Big End Side Clearance " D " - 37.90~37.95 mm(1.49~1.49 in) 0.03 mm(0.0012 in) "--D .q- .
M..°TE°..OE SPEO.F.C.T.O. ISPEcl "" I TIGHTENING TORQUES ENGINE Part to be tightened Spark plug Cylinder head and cylinder Cylinder Air shroud 1 Air shroud l x 2 Fan Autolube pump Reed valve Air filter Carburetor cap Exhaust pipe Muffler Exhaust protector Protector Crankcase l x 2 T r a n s m i s s i o n case cover Crankcase cover 1(left) Bolt(case2) Crankcase cover2(left) Drain bolt Oil plug Idle gear plate Kick crank Starter m o t o r Clutch housing Clutch w e i g h t Magnet base C.D.I.
MA. A.OE SPEO.F.OAT.O. ISPEcl " CHASSIS Item Steering system: Steering bearing type No/size of steel balls: Standard Ball and race bearing 22 pcs 19 pcs Upper Lower Front suspension: Front fork travel Fork spring free length Fork length (Installed) Spring rate (K1) (K2) Inner tube vend limit 70 rnrn(2.8 in) 236.6 mm(9.31 in) 212.1 mm(8.35 in) 15.68 Nm/mm(1.6 kg/mm,901b/in) 23.5 Nm/mm(2.43 kg/mm,1361b/in) Rear wheel: Type Rim size Rim material Rim runout limit ... ... ... 233.6 mm 0.2 mm (0.
MA. A.OE SPEO.F.OAT.O.
MA. A.OE SPEO.F.OAT.O. ISPEcl " ELECTRICAL Item Standard Ignition t i m i n g : Ignition t i m i n g (B.T.D.C.) Advanced type 14 °at 5,000 r/min Fixed C.D.I.: Pickup coil resistance/color limit ... ... C.D.I.
MA. A.OE SPEO.F.OAT.O. ISPEcl " Item Standard Horn: M o d e l / m a n ufacturer Maximum amperage 4KP/Asian 1.5A Flasher relay: Type Flasher f r e q u e n c y Capacitor 60~ 120 C y c l e / m i n Fuel gage: M o d e l / m a n ufacturer S e n d e r unit resistance full - empty - limit 4VP/Sa n Chu 4~10 ~ 90~100 ~ Oil level g a u g e : M o d e l / m a n ufacturer 4VP/Lun Ping Circuit breaker: Type MAIN Fuse 7 A x l pc . 2-10 ... ... . . .
OEOERA"TOROOESPEC,F,CAT,ONS ISPEcl " GENERAL TORQUE SPECIFICATIONS A (Nut) This chart specifies torque for standard fasteners w i t h standard I.S.O. pitch threads. Torque specifications for special c o m p o n e n t s or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, t o r q u e specifications call for clean, dry threads.
LUB..OAT.O° PO.°TS A.O LUB..OAT.O° T'.
• OB"'OAT'O" PO'°TS A"O'OB"'OAT'O° T PE ISPEcl " CHASSIS Lubrication Point Lubricant Type Oil seal lips O-rings Bearings Speedometer drive gear Front brake camshaft Front brake cable Throttle cable Tube guide (throttle grip) inner surface Upper steering stem ring nut Upper bearing outer race Lower bearing outer race Rear brake camshaft Centersta nd 2-13 I
CAB'E.OOT,.O ISPEcl " CABLE R O U T I N G (~ Horn (~ Rectifier regulator (~ Main switch (~ Headlight leads (~) Speedometer cable (~ Ignition coil (~ Throttle cable 1 (~ Throttle cable 3 (~ Battery negative(-) @ Wire brake (~) Fuel sender lead (~) Seat lock cable (~) Oil tank hose @ C.D.I. unit (~) Wire harness [ ] Pass the speedometer cable through the right hole of front fender, then t h r o u g h the guide. [ ] Pass the wire harness through the inside of ignition coil.
OAB'E.OOT,°O (~ (~) (~ (~ (~ (~ (~ (~ (~ @ @ Brake cable Speedometer cable Fuel tank overflow hose Brake cable holder Brake hose Brake hose holder License bracket Flasher relay Fuel tank breather hose Fuel hose Breather hose [ ] Pass the brake hose through the holder. [ ] Insert the fuel overflowhose bottom. [ ] Pass the fuel overflowhose through the rear fender hole. [ ] Pass the fuel o v e r f l o w h o s e t h r o u g h the holder. [ ] Hold the fuel overflowhose with a clamp.
CAB'E.OOT,°O IS"Eel " (~ (~) (~ (~ (~ (~ (~ (~ (~ @ [ ] Pass the brake hose through the holder. Brake hose Front fender Front fork assembly Nut Plate washer Brake holder hose Flange bolt Bolt Brake holder hose Flange bolt Q .
C,B'E.OOT,°O IS"Eel " and autolube hose on to carburetor throttle cable. [ ] Pass the battery leads over frame member. [ ] Put fuse box on to footrest board holder. [ ] Pass throttle cable1,3 wireharness, autolube pump cable, brake cable through the outside of battery box. @ Battery(+)lead (~ Ignition coil [ ] Pass battery leads through (~) Spark plug lead the slot of footrestboard. (~ Starter relay leads [ ] Cover them after securing (~ Auto choke leads starter relay leads.
CAB'E ROOT,OO ISPEcl " (~ Handlebar switch(right) (~) Speedometer (~ Wire brake (~ Handlebar switch(left) (~ Wire harness (~ Brake hose (~ Speedometer cable (~ Throttle cable1 (~ Throttle cable 3 @ Front flasher leads [ ] Pass brake cable through the slot of bracket. [ ] Avoid clamping front flasher leads when installing handlebar covers. [ ] P a s s throttle cable1,3 t h r o u g h between handlebar and wireharness. [ ] Hang the wireharness bind on to the bracket. f I " :'7. . . . . . . . . . . . . . .
INTRODUCTION/ PERIODICIVIAINTENANCE/LUBLICATION INTERVALS I INSP EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION T h i s c h a p t e r i n c l u d e s all i n f o r m a t i o n ments. These preventive operation necessary'to perform maintenance procedures, recommended if f o l l o w e d , inspections and adjust- will ensure more reliable vehicle a n d a l o n g e r s e r v i c e life. T h e n e e d f o r costly" o v e r h a u l w o r k w i l l be g r e a t l y " r e d u c e d .
PERIODICINSPECTION AND ADJUSTMENTSI INSPDI EVERY BREAK-IN NO. ITEM TYPE ROUTINE 11 Centerstand • Check operation. • Lubricate with lithium soap base greese (all purpose grease). 12" Front fork - Check operation and for oil leakage. 13" Rear s h o c k absorberassembly - C h e c k o p e r a t i o n and shock absorber for oil leakage. - Replace shock absorber assembly if necessary. 14 *Carburetor 15" A u t o l u b e pump • Check operation. - Correct if necessary. • Bleed if necessary.
COVER AND PANEL COVER AND PANEL I INSP SIDECOVER A N D SEAT ' i ~,~/~ ~ m . k g , 9.4ft.lb) 8 y---// j j @ Order . J o b name/Part n a m e Q'ty Remarks Remove the parts in order. NOTF" Sidecover and seat removal Battery box cover Insert the (-) s c r e w d r i v e r into the slot of battery cover and pickup then remove. . 3. 4. 5. 6. 7. 8. Seat Seat hange Rear carrier Rear cover Left side cover Right side cover Center cover Reverse the removal procedure for installation.
I COVER AND PANEL INSP LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 A N D FOOTREST BOARD 4 5 [~1 7Nm(0.7m.kg, 5.1ft.lb) 6 .. o ~ "" ~ I / // Order . 2. 3. 4. 5. 6. Job n a m e / p a r t name L o w e r c o w l i n g , u p p e r cover, leg shield 1,2 and f o o t r e s t board removal Lower c o w l i n g Upper cover Leg shield 1 Main switch c o v e r / l e g shield 2 Battery Footrest board Q'ty Remarks Remove the parts in order. 1 1 1 1/1 1 1 Reverse the removal procedure for installation.
COVER AND PANEL I INSP H A N D L E B A R C O V E R ( F R O N T A N D REAR) 1 Order 1. 2. 3. 4. Job name/Part name H a n d l e b a r c o v e r ( F r o n t and Rear) removal. Mirrors Front h a n d l e b a r c o v e r Rear h a n d l e b a r c o v e r Flasher light(Left/Right) Q'ty Remarks R e m o v e t h e part in order. 2 1 1 1/1 Reverse the r e m o v a l p r o c e d u r e for installation.
ENGINE IDLE SPEED ADJUSTMENT I INSP ENGINE IDLE SPEED A D J U S T M E N T 1. Remove • Battery box cover (~ 2. Tighten: • Pilot air screw (~) Turn the pilot air screw in until lightly seated. 3. Loosen: • Pilot air screw Back it out from its lightly seated position. I Pilot air screw turn out: load 1-1/4 \ I 2. Start the engine and let it warm up. r!~VAVL,W--']~ I [¢-! I ~ Before starting t h e engine, be sure to use t h e c e n t e r s t a n d for safety. .
THROTTLE CABLE FREE A D J U S T M E N T I INSP T H R O T T L E CABLE FREE A D J U S T M E N T 1. Check: • Throttle cable free play (~ Out of specification-->Adjust. ree3 o~ mm(0.12 5 ~ 0.20 in) I Throttle cable free play a d j u s t m e n t steps; NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. • Remove the adjuster cover (~ • Loosen the Iocknut @~)on the throttle cable. • Turn the adjuster (~ in or out until the specified free play is obtained.
I INSP A U T O L U B E P U M P AIR BLEEDING A U T O L U B E P U M P AIR BLEEDING 1. Remove • Lower cowling • A i r shroud 1 (~ 2. Air bleeding: • Pump case and / or oil hose. * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ Air bleeding steps: • Place a rag under the autolube p u m p t o catch the oil. • Remove the bleed screw (~. • Keepthe oil running out until air bubbles disappear. • When air bubbles are expelled completely, tighten the bleed screw.
SPARK PLUG INSPECTION INSP I SPARK PLUG I N S P E C T I O N 1. 2. I Remove: • Battery box cover Inspect: • Spark plug type I nco rrect-->Replace. Standard spark plug: BPR7HS/NGK 3. 4. 5. Inspect: • Electrode (~ Wea r/Da m ag e-->Re place. • Insulator (~) A b n o r m a l color->Replace. Normal color is a medium-to-light tan color. Clean the spark plug w i t h a spark plug cleaner or wire brush. Measure: • Plug gap (~ Use a wire gauge or feeler gauge. Out of specification-->Regap. I l'0ar'0u00ao 0.
I E N G I N E OIL LEVEL I N S P E C T I O N INSP E N G I N E OIL LEVEL I N S P E C T I O N 1. Inspect: • Engine oil level Oil level Iow--~Add sufficient oil by the f o l l o w i n g inspection steps. (~ "OIL" indicator light Engine oil level visual inspection steps: Turn main switch to " * " position. t | "OIL" indicator comes on. "OIL" indicator light does I not comes on. I light Turn main switch " O N " position. t / "OIL" indicator light does I _ not come on.
T R A N S M I S S I O N OIL R E P L A C E M E N T TRANSMISSION I INSP OIL R E P L A C E M E N T 1. Warm up the engine for several minutes, then stop the engine. 2. Place a container under the drain hole. 3. Remove: • Oil filler plug (~ • Drain bolt (with gasket) ~) NOTE: Drain the t r a n s m i s s i o n oil completely. While draining, slightly tilt the scooter to the right and to the left. 4. Inspect: • Gasket (drain bolt) (~ • O-ring (oil filler plug) (~ Damage--~Replace. 5. 6.
AIR FILTER E L E M E N T C L E A N I N G I INSP AIR FILTER E L E M E N T C L E A N I N G 1. Remove: • Battery b o x c o v e r 2. Remove: • Caburetor jont clamp ~) 3. Remove: • Screw • A i r filter ( ~ 4. Remove: • A i r filter case (~) • A i r filter e l e m e n t CAUTION: N e v e r o p e r a t e t h e e n g i n e w i t h t h e air f i l t e r ele m e n t r e m o v e d . T h i s w i l l a l l o w u n f i l t e r e d air t o enter, c a u s i n g r a p i d w e a r and p o s s i b l e engine damage.
AIR FILTER E L E M E N T C L E A N I N G AWARNING I INSP N e v e r use l o w flash p o i n t s o l v e n t s such as gasoline t o clean t h e e l e m e n t . Such s o l v e n t m a y lead to a fire or explosion. • S q u e e z e t h e e x c e s s s o l v e n t o u t of t h e elem e n t a n d let dry. CAUTION: Do not t w i s t t h e e l e m e n t w h e n s q u e e z i n g t h e element. • A p p l y t h e f o a m -air f i l t e r oil or e n g i n e o i l . • S q u e e z e o u t t h e e x c e s s oil.
V-BELT I N S P E C T I O N I INSP V-BELT INSPECTION 1. Remove: • Kick crank ( ~ • Screws (~ • Crankcase c o v e r 2(left) (~) • S c r e w s ( A i r c l e a n e r and left crankcase cover (~ • Crankcase c o v e r 1(left) ( ~ . Inspect • V-belt ( ~ Cracks/Wea r/Da mage-->Replace. Oil or grease a d h e r e to t h e V-belt-->Check the p r i m a r y and s e c o n d ary sheaves. Refer to "ENGINE OVERHAUL -INSPECTION A N D REPAIR" section in the CHAPTER 4. .
F"O"T B"A"E'EVE" F"EE P'AY C"EC"'"EA" B"A"E I,.Sp I LEVER FREE PLAY CHECK/BRAKE PAD INSPECTION A D J I CHASSIS F R O N T BRAKE LEVER FREE PLAY CHECK 1. Check: • Front brake lever free play I ~ 1 2~5 mm(0.08~0.20 in) I xkWARNING A soft or s p o n g y feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated.
B"AKES"OE'"SPECT'O°'I'"SP I BRAKE FLUID LEVEL INSPECTION \ BRAKE SHOE I N S P E C T I O N 1. 2. Activate the brake lever. Inspect: • W e a r indicator (~ Indicator at w e a r limit line (~)-->Replace brake shoes. BRAKE FLUID LEVEL I N S P E C T I O N NOTE: Position the scooter straight up w h e n inspecting the fluid level. G-L m . Ii~l Inspect: • Fluid level is under " L O W E R " level line (~-->Fill to proper level.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEIVI)I INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1. Bleed: • Brake f l u i d Air bleeding steps: a. A d d p r o p e r brake f l u i d to the reservoir. b. Install the d i a p h r a g m . Be careful not to spill a n y f l u i d or a l l o w t h e r e s e r v o i r to overflow. c. C o n n e c t t h e clear plastic tu be ( ~ t i g h t l y to the caliper bleed screw. d. Place the o t h e r end o f t h e t u b e into a container. e.
I INSP STEERING ADJUSTMENT STEERING ADJUSTMENT 1. Check: • Steering assembly bearings Gap the bottom of the forks and gently rock the fork assembly back and forth. Loosen-->Adjust. * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ A d j u s t m e n t steps: • Remove u p p e r cover, l o w e r c o w l i n g , leg shield 1,2. refer to "COVER AND PANEL" section. • Remove all ringnuts using ringnut wrench.
TIRE I N S P E C T I O N FRONT Manufacturec CHENG SHIN TIRE I N S P E C T I O N Size 120/90-10 WARNING Type 56J • The tire pressure should only be checked and r e g u l a t e d w h e n t h e tire t e m p e r a t u r e equals t h e a m b i e n t air t e m p e r a t u r e , • T h e tire pressure m u s t be adjusted according to t h e total w e i g h t (including cargo, rider passenger and accessories) and t h e anticip a t e d riding speed, • O p e r a t i o n of an o v e r l o a d e d scooter could caus
CHECKING THE TmESl INSP I I •WARNING a__l • Do not use a tubeless tire on a w h e e l designed only for t u b e tires t o avoid tire failure and personal injury f r o m sudden deflation. • When using t u b e tires, be sure t o install t h e correct tube. • A l w a y s replace a n e w t u b e tire and a n e w t u b e as a set. • To avoid pinching the tube, make sure t h e w h e e l rim band and t u b e are centered in t h e w h e e l groove.
CHECKING THE T I R E S / C H E C K I N G THE WHEELSI INSP N e w tires have a relatively l o w grip on the road surface until t h e y have been s l i g h t l y w o r n . Therefore, a p p r o x i m a t e l y 100 km should be t r a v e l e d at n o r m a l speed b e f o r e any highspeed riding is done. NOTE: For tires w i t h a direction of rotation mark (~: • Install the tire w i t h the mark pointing in the direction of wheel rotation. • Align the mark (~)with the valve installation point.
WHEEL INSPECTION/FRONT FORK INSPECTION REAR SHOCK ABSORBER INSPECTION/SEAT LOCK C A B L E A D J U S T M E N T I INSP WHEEL INSPECTION 1. Inspect: • wheels Da mage/Bends-->Replace. Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel. FRONT FORK INSPECTION 1. Inspect: • Front f o r k ~ Bends/Damage-->Replace inner t u b e comp, fork ass'y. Grease leakage--~Replace inner t u b e comp. fork ass'y.
CABLE C°EOK.°O A ° O " U B . . O A T . ° O . "EVE.S "UB..OAT.°O "'"SP''"' I C E N T E R S T A N D LUBRICATING ADJ ' I~1 EAS00170 CABLE C H E C K I N G A N D L U B R I C A T I N G The f o l l o w i n g procedure applies to all of the cable sheaths and cables. r!~VAVL, W --'t~ [¢-!I I ~ D a m a g e d cable sheaths m a y cause the cable to corrode and interfere w i t h its m o v e m e n t . Replace d a m a g e d cable sheaths and cables as soon as possible. . .
BATTERY I N S P E C T I O N I INSP ELECTRICAL BATTERY INSPECTION NOTE: Since the MF battery is of a sealed-type construction, it is impossible to measure the specific g r a v i t y of the electrolyte in order to check the state of charge in the battery. Therefore, to check the state of charge in the battery, voltage must be measured at the batteryterminals. CAUTION: CHARGING METHOD • This b a t t e r y is sealed type. Never r e m o v e sealing caps even w h e n charging.
BATTERY I N S P E C T I O N I INSP Batteries g e n e r a t e e x p l o s i v e h y d r o g e n gas and c o n t a i n e l e c t r o l y t e w h i c h is m a d e of p o i s o n o u s a n d h i g h l y c a u s t i c s u l f u r i c acid. Therefore, always follow these preventive measures: • W e a r p r o t e c t i v e eye gear w h e n h a n d l i n g or w o r k i n g near b a t t e r i e s . • C h a r g e b a t t e r i e s in a w e l l - v e n t i l a t e d area.
BATTERYINSPECTION I INSP ~1(~1 14 Open circuit voltage Charging time Ambient temperature 20°C .~ 11 | I B 100 75 50 | 12.8 or vmore No charging is necessary. • Check the b a t t e r y c o n d i t i o n u s i n g f i g u r e s . EXAMPLE: Open circuit v o l t a g e = 12.0v C h a r g i n g t i m e = 6.5 h o u r s C o n d i t i o n of c h a r g e in b a t t e r y = 20 ~ 30% | I B 30 25 20 Condition of charge in battel~J(%) 2.
I INSP BATTERY INSPECTION C h a r g i n g m e t h o d u s i n g a v a r i a b l e - c u r r e n t (voltage) t y p e c h a r g e r Charger AMP meter Measure the open-circuit voltage prier to c h a r g i n g . t C o n n e c t a c h a r g e r and A M P m e t e r to the b a t t e r y and start charging. + NOTE: Voltage should be measured 30 minutes after the machine is stopped. NOTE: Set the c h a n g i n g v o l t a g e at 16 V. 17 (Ifthe setting is lower, charging Will be insufficient.
BATTERY I N S P E C T I O N I INSP Charging method using a constant-voltage type charger Charger Volt meter Measure the open-circuit voltage prier to charging. NOTE: V o l t a g e s h o u l d be m e a s u r e d 30 minutes after the m a c h i n e is s t o p p e d . AMP meter II ~ I YES 1 Connect a c h a r g e r and A M P meter to the battery, and start charging. Make sure the current is higher than the standard charging current w r i t t e n on the battery.
FUSE INSPECTION I INSP 4. Inspect: • Battery terminal D i r t y terminal-->Clean w i t h w i r e brush. Poor co n nection-->Co rrect. NOTE: A f t e r cleaning t e r m i n a l s , a p p l y terminals. . l i g h t l y to the Install • Battery • Battery box cover FUSE I N S P E C T I O N 1. R e m o v e : • Battery box cover Refer to " C O V E R A N D P A N E L " section. 2. R e m o v e : • Fuse ( ~ 3.
HEADLIGHT BEAM A D J U S T M E N T I INSP /HEADLIGHT BULB REPLACEIVIENT I I HEAD LIGHT BEAM A D J U S T M E N T 1. \ j) Adjust: • Head l i g h t (vertically) T u r n t h e a d j u s t i n g s c r e w ( ~ in or o u t to a d j u s t h e a d l i g h t beam. • Head l i g h t (Horizontal) T u r n t h e a d j u s t i n g s c r e w ( ~ in or o u t to a d j u s t h e a d l i g h t beam. HEADLIGHT BULB REPLACEMENT 1. Remove: • Upper cover Refer to "COVER A N D P A N E L " section. 2.
HEADLIGHT BULB / TURN SIGNAL BULB REPLACEMENT 6. i,.S.l l ADJ Install: • Bulb(new) CAUTION: A v o i d t o u c h i n g t h e glass p a r t of t h e h e a d - l i g h t b u l b t o keep it free f r o m oil, o t h e r w i s e t h e t r a n s p a r e n c y of t h e glass, t h e life of t h e b u l b a n d t h e l u m i n o u s f l u x w i l l be a d v e r s e l y affected.
TAILLIGHT BULB / LICENCE LIGHT BULB REPLACEMENT i,.s l l ADJ CAUTION: A v o i d t o u c h i n g the glass part of t h e head-light bulb t o keep it free f r o m oil, o t h e r w i s e t h e t r a n s p a r e n c y of t h e glass, t h e life of t h e bulb and t h e l u m i n o u s f l u x w i l l be a d v e r s e l y affected. If t h e h e a d l i g h t bulb gets soiled, t h o r o u g h l y clean it w i t h a cloth m o i s t e n e d w i t h alcohol or lacquer thinner.
E.O..E.EMOVA" I E"O I o '1 EB400000 ENGINE OVERHAUL ENGINE R E M O V A L W l R E H A R N E S S A N D CABLES ~ 1 2 0 N m ( 1 2 . 0 m.kg, 87 ft.lb) 7 12 Order 1~145Nm(4-5 m.kg, 31ft.lb) I Job name/Part name Q'ty Remove the parts in order. W i r e h a r n e s s and cables r e m o v a l Rear carrier Tail cover Left side panel Right side panel Battery b o x cover Center c o w l i n g Air filter case Carburetor 1 2 Remarks Refer to "COVER A N D PANEL" section in CHAPTER 3.
ENGINE R E M O V A L mENG m~)~,mm [~m120Nm(12.0 m.kg, 87 ft.lb) 12 [~q45Nm(4.5m.kg, 31ft.lb) \ I ~ 7 // Order J o b name/Part name Q'ty Spark plug cap Battery (-) lead C.D.I magneto leads coupler Starter m o t o r leads coupler Rear wheel nut 8 9 10 11 12 13 1 1 1 1 1 Remarks NOTF" Loosen the rear wheel nut. Rear brake adjuster Rear brake cable Pin Bolt Engine m o u n t bolt Engine Reverse the removal procesure for installation.
CYLINDER HEAD, CYLINDER A N D PISTON I ENG I~>]DI CYLINDER HEAD, CYLINDER A N D PISTON C Y L I N D E R HEAD, C Y L I N D E R A N D P I S T O N ~126Nm(2.6 m.kg, 10[]~ ~ ~ H1,Nm(1. ' 1 ..~ ~ 9N m(0.9 m m.kg, 10 ft.'bll 2 Order 1 2 3 4 5 6 7 8 9 10 9 Job name/Part name .
CV'..OE..EAO. OV'..OE.. P.STO. E"O IoI .1 P I S T O N PIN A N D P I S T O N R E M O V A L 1. Remove: • Piston pin clip ( ~ NOTE: Before r e m o v i n g the p i s t o n pin clip, c o v e r the crankcase w i t h a clean rag so y o u w i l l not accid e n t a l l y d r o p t h e clip into the crankcase. 2. Remove: • Piston pin ( ~ • Piston ~ ) • Piston pin b e a r i n g ( ~ CAUTION: Do not use a h a m m e r t o d r i v e t h e p i s t o n pin out. CYLINDER HEAD INSPECTION 1.
CYLINDER AND PISTON INSPECTION I ENG I TDI CYLINDER AND PISTON INSPECTION 1. E l i m i n a t e : • Carbon deposits Use a r o u n d e d scraper (~. 2. Inspect: • Cylinder wall Wear/Scratches-->Rebore or replace. Q . 4. 5. 6. Eliminate: • Carbon d e p o s i t s ( ~ From the piston grooves. crown and ring Remove: • Score markes and lacquer d e p o s i t s From the sides of piston. Inspect: • Piston w a l l Wea r/Scratches/Da m age-->Re place.
CYLINDER HEAD, CYLINDER A N D PISTON I ENG I Standard C y l i n d e r bore IJCF, 40.000~40.014mm (1.5748~ 1.5754 in) - Taper "T" O u t of r o u n d " R" C =M a x i m u m T=( M a x i m u m D6 ) R=( M a x i m u m D4 or D6 ) - Wear limit 40.10 m m (1.5787 in) 0.05 mm (0.0020 in) 0.03mm (0.
OV'.°OE..EAO. OV'..OE. A°O P.STO. E"O IIo =1 PISTON R I N G S I N S P E C T I O N 1. Measure: • Side clearance O u t of s p e c i f i c a t i o n - - > R e p l a c e a n d / o r rings. Use a feeler g a u g e ( ~ Standard T o p ring 2nd ring 2. . L piston Li m i t 0.03~0.05mm 0.1 m m (0.0012 ~ 0.002 in) (0.0039 in) 0.03-0.05mm 0.1 m m (0.0012 ~ 0.002 in) (0.0039 in) Install: • Piston ring Into the c y l i n d e r Push t h e ring w i t h the piston c r o w n .
CV'..OE..EAO CV'..OE. A.O P.STO. E"O IIo '1 . f "2 Measure: • Outside d i a m e t e r (~ (piston pin) Out of specification-->Replace. ootsdedameter,0ston on' ' 9.996~ 10.000 m m(0.3935~0.3937in t . Measure: • Piston pin-to-piston clearance Out of specification-->Replace piston. Piston pin-to-piston clearance = Bore size (piston pin) Outside d i a m e t e r (piston pin) Piston pin-to-piston clearance" I 0.004-0.019 mm(0.0016-0.00075 in (0.003 in) 1 4.
OV',.OE..EAO. CV',°OE. A.O ,,StO. I E"O I0 '1 3. Q~ °-, J Install: • Small end bearing • Piston (~ • Piston pin (~) • Piston pin clip ~) NOTE: • The a r r o w (~ on the piston to the e x h a u s t side. • Before installing the piston pin clip, cover the crankcase w i t h a clean towel or rag so you will not accidentally drop the pin clip material into the crankcase. • A l w a y s use a n e w piston pin clip. CYLINDER AND CYLINDER HEAD 1. Install: • Cylinder gasket (new gasket) 2.
O*'.°OE..EAO. C*'.°OE. A°O P.S*O. I' "0 I0 .1 4. Install: • Cylinder head gasket (new gasket) 5. Install: • Cylinder head (~ ~114Nm(1.4m.kg,10ft.lb) • Spark plug (~) r~120Nm(2.0m.kg,14ft.lb) • Air shroud NOTE: Tighten the cylinder head holding nuts in stage, using a crisscross pattern.
V-BELT, CLUTCH A N D V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE KICK STARTER AND CRANKCASE COVER (LEFT) 12Nm(1.2m.kg, 8.4 ft.lb)~ 4 ~ 3 I ~ l 7Nm(0.Tm.kg, 5.1 ft.lb // I~190Nm(0.9m.kg, 6.5 ft.lb) I Order 1 2 3 4 5 Job name/Part name Q'ty Kick starter and crankcase cover (left) removal Kick starter Crankcase cover 2 (left) Crankcase cover 1 (left) Gasket Pin Remarks Remove the parts in order. Reverse the removal procedure for installation.
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE I ENG V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE KICK STARTER ® Order (# ® ® ® ® ® J o b name/Part n a m e Q'ty Remarks R e m o v e the parts in order.
V-BELT, CLUTCH AND SECONDARY/PRIIVIARY SHEAVEI ENG I ~>= I KICK S T A R T E R I N S T A L L A T I O N 1. Install: Return spring • Kickstarter segment gear (~ • Collar (~ • Plain w a s h e r (~ • Circlip (~ Installation steps: a. Install return spring (~ and s e g m e n t gear (~ as s h o w n . b. Install clip (~. c. Hook the spring onto the crankcase projection (~. d. Install the kick starter pinion gear (~ and the kick starter.
V-BELT" CLUTCH AND I I~)~1 ENG SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 3 2 t/~~ / 7
V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE I I ENG SECONDARY SHEAVE / [~150Nm(5.0m.kg, ""-4 Order (# ® ® ® ® ® @ ® ® ® Job name/Part name Q'ty Secondary sheave d i s a s s e m b l y Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave Remarks Disassemble the parts in order. 1 1 2 1 1 2 1 2 2 1 Refer to "SECONDARY SHEAVE DISASS E M B L Y " section.
V-BE'T" O'UTC" A"O I ENG Io =1 S E C O N D A R Y / P R I M A R Y SHEAVE / i PRIMARY SHEAVE REMOVAL 1. Remove: • Fan 2. Remove: • Nut (~ (primary sheave) NOTE: When loosening the nut (primary sheave), hold the C.D.I. magneto using flywheel holding tool ® ®. I ~ I Rotor holdiyu_01235ngtool: I 3. Remove: • Conical spring washer (~ • One-way clutch ® • Washer (~ • Primary fixed sheave (~ • Shim (~ • V-Belt 4. Remove: • Collar (~ • Primary sheave assembly® SECONDARY SHEAVE REMOVAL 1.
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE 3. I ENG I{ =l Loosen: • Nut(Clutch carrier)(~ NOTE: Install the secondary sheave to primary drive shaft as shown, and hold the secondary sheave by Universal Roter Holder(~to loosen the nut (#. ~ Roter holding tool" YU-01235 ] CAUTION: Do not r e m o v e the clutch securing nut yet. If the nut is r e m o v e d w i t h o u t c o m p r e s s i o n g the secondary sheave. It j u m p s and causes injury. 4.
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE . I ENG Measure: • Clutch shoe thickness (~ Out of specification-->Replace. Clutch shoe thickness: 4 mm (0.16 in) < Wear limit>: 2.5 mm (0.1 in) V-BELT I N S P E C T I O N 1. Inspect: • V-belt(~ Crack->Replace. NOTE: Replace the V-belt smeared w i t h a lot of oil or grease. . ~ 1 4-18 Measure: • V-belt w i d t h (~ Out of specification-->Replace. V-belt width" 16.6 mm(0.65 in) : 14.6 mm(0.
V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE I i ENG PRIMARY SHEAVE INSPECTION 1. Inspect: • Primary sliding sheave (~ • Primary fixed sheave (~) Wea r/Cracks/Scratch/Da mage -->Replace. . Check: • Free m o v e m e n t Insert the collar (~into the p r i m a r y sliding sheave(~, and check for free movement. Stick or excessive p l a y - > R e p l a c e the sheave or collar. . Measure: • Out side d i a m e t e r (~) (weight) Out of specification-->Replace.
V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE SECONDARY 1. I I ENG SHEAVE Inspect: • S e c o n d a r y fixed s h e a v e ( ~ • Secondary sliding sheave (~ Scratch/Crack/Damage-->Replace as a set. • Oil seal ( ~ Da mage-->Replace . Inspect: • T o r q u e cam g r o v e ( ~ • G u i d e pin (~) Wear/Damage-->Replace as a set. • O - r i n g s (~) Damage-->Replace. . Measure: • Clutch s p r i n g free l e n g t h Out of specification-->Replace. Clutch s p r i n g free length: 94 m m ( 3 .
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE SECONDARY SHEAVE I ENG I~=1 INSTALLATION When assembling the secondary sheave, reverse the d i s a s s e m b l y procedure. Note the following points. . Apply: • Lithium soap base grease (to the inside of the sliding/fixed sheave) 2. Install: • Sliding sheave (~ NOTE: Be careful so that the oil seal (~ lips are not turned over w h e n installing the sheave. 3. Apply: • Lithium soap base grease (to the torque cam grooves and O-rings) 4.
V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE 8. I I ENG Install: • Secondary sheave assembly • Clutch h o u s i n g ( ~ • V-belt (~) NOTE: The V-belt m u s t be i n s t a l l e d w i t h t h e a r r o w fro ntwa rd. . Tighten: • Nut ( ~ (secondary sheave) 1~140 Nm(4.0 m.kg, 29 ft.,b)I Use s h e a v e h o l d e r ( ~ Sheaveho'der: YU-01701 PRIMARY 1. . Install: • Weight (~ • Cam@ • Slider (~ • Collar ( ~ . Check: • Cam o p e r a t i o n Not s m o o t h . R e p a i r . @ 4. .
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE . / I ENG I%=I Install: • Shim (~ • Primary fixed sheave ~) • Washer (~ • One-way clutch (~ • Conical spring washer (~) • Nut(~ . Tighten: • Nut (~ (primary sheave) [%l 45 Nm(4.5 m.kg, 31ft.lb) J i N O T E : When tightening the nut (primary sheave), hold the C.D.I. magneto using Flywheel Holding Tool ®. ~l . 9. 4-23 ~°t°r t°°':¥~-01 h°'~d'n° I Adjust: • V-belt O Tense the V-belt by turning the primary sheave several times.
S T A R T E R CLUTCH A N D STARTER M O T O R I ENG I~ll S T A R T E R CLUTCH A N D STARTER M O T O R ~TARTER C L U T C H A N D S T A R T E R M O T O R 11 ~, ,10 9.4 ft.lb 4 9 J 3 Ns,ml0 8mk0.58,t,b 6 8 Order Job name/Part name S t a r t e r clutch and s t a r t e r m o t o r removal Left/Right side cover Center cover Lower cowling Air shroud 3 Cooling fan Rear wheel Crankcase cover (left)l,2 Primary sheave 1 2 3 4 5 Remarks Q'ty Remove the parts in order.
STARTERCLUTCH AND STARTERMOTOR I ENG I ~TDI 11 ~. .10 9.4 ft.lb 4 3 Ns.ml0.sm.k0.5.8 ft.
STARTERCLUTCHAND STARTERIVIOTORI ENG I {~ I STARTER CLUTCH AND GEARS INSPECTION 1. Inspect: • Starter c l u t c h Push t h e d o w e l pin to a r r o w d i r e c t i o n . U n s m o o t h operation-->Replace starter clutch a s s e m b l y . 2. Inspect: • Starter w h e e l gear teeth ( ~ • Idle gear teeth (~) B rrs/C u h ps/Ro i u g ess/Wea h n r-->Re la ce. p 3.
C.O.'."'°"ETO ENO I O '1 I C.D.I. M A G N E T O .'.D.I. M A G N E T O 5 . 4 7 ,0i80 m(3.8 m.kg, 27 ft.lb) I [ ~ 1 7 N m ( 0 . 7 m . k g " 5.1ft.lb) i 17Nm(0.7m.kg, 5.1 ft.I ) I 1 Order 1 2 3 4 5 6 7 8 Q'ty Job name/Part name R e mks a r R e m o v e t h e parts in o r d e r . C.D.I.
co, MAo.ETol E"° I o --I C.D.I. M A G N E T O 1. REMOVAL Remove: Nut (~(roto r) • Plain washer • NOTE: Hold the rotor to loosen the nut bythe flywheel holding tool (~. I<~l 2. Rotor holdiyu_01235ng tool: I Remove: • Rotor O • Wood ruff key Use the flywheel magneto puller (~. I<~l Flywheel puller: YU-01189 I • Stator assembly • Gasket C.D.I. M A G N E T O 1. 2. 3. 4. 5. INSTALLATION Install: • Gasket (~ Apply: • Lithium soap base grease (to oil seal) Pass the C.D.I.
AOTO'OBEPUMP I E"O I O '1 AUTOLUBEPUMPF ~ AUTOLUBE PUMP 5 JZ // \ 2 ,~314Nm(0.4m.kg, 2.8ft.l~b)i /\ ' ~ '~ 1 ~ 7 Order 1 2 3 4 5 6 7 Job name/Part name Q'ty Remarks Remove the parts in order. Refer to "C.D.I. magneto" section. Autolube pump removal C.D.I. magneto Air shroud 2. Circlip Pump drive gear Pin Oil hose Oil delivery hose Autolube pump ass'y 1 1 1 1 1 1 1 Refer to "Autolube pump installation" section Reverse the removal procedure for installation.
AUTOLUBE PUMP I ENG I{~]DI AUTOLUBE PUMP INSTALLATION CAUTION: A f t e r installing a u t o l u b e p u m p , it m u s t be bleeded. 1. 2. 3. 4. Install • Pin O • P u m p d r i v e gear (~) • Circlip ~ Apply: • L i t h i u m soap base (to O-ring) Install: • Autolube pump (~ Apply: • L i t h i u m soap base (to a u t o l u b e p u m p grease [~J4 Nm(0.4m.kg, 2.8ft.lb~ grease gear (~,(~) 15 cc (0.
T.A.SM.SS.O. I E"O I o '1 TRANSMISSION TRANSMISSION I / 4 [~418Nm(1.8 Order / ~ O m.kg, 13ft.lb Job name/Part name I Q'ty 6 7 a r ks " Drain the transmission oil. 4 R e m Remove the parts in order. Refer to "REAR WHEEL/REAR BRAKE section in chapter 7. Refer to "V-BELT, CLUTCH, SECONDARY/ PRIMARY SHEAVE" section Refer to " T R A N S M I S S I O N OIL REPLACEMENT " section in chapter 3. Secondary sheave 5 2 I~112N m(1.2 m.kg, 8.4ft.
TRANSMISSIONI ENGI~>]DI - 3 5 / 4/ I.~..~ ~ [~112Nm(1"2m'kg• 8"4ft'lb: [~'~11 8Nm(1.8 m.kg, 13ft.lb I Order 8 J o b name/Part name Q'ty Drive axle Remarks 1 Reverse the r e m o v a l p r o c e d u r e for installation.
C R A N K C A S E A N D REED V A L V E I ENG I TDI C R A N K C A S E A N D REED V A L V E C R A N K C A S E A N D REED V A L V E ~19Nm(0.9m.kg,6.5ft.lb)l ~112Nm(1.2m.kg,8.4ft.lb) I 4 1 1 N m ( 1 1 m kg,8ft Ib) I ~ Order j 3 j, ~ ~ j - J J" J o b name/Part n a m e Q'ty R e mks a r Crankcase a n d Reed valve r e m o v a l R e m o v e the parts in order. Engine removal C y l i n d e r head, c y l i n d e r , p i s t o n Refer to " E N G I N E R E M O V A L " section.
CRANKCASE AND REEDVALVE ~19Nm(0.9m.kg,6.5ft.lb)l I ENG I >]DI ~ 1 1 2 N m ( 1 . 2 m . k g , 8.4ft.lb) I 4 11Nm(1 l m kg,8ft Ib) I ~ Order 1 2 3 4 5 6 7 8 9 10 j 3 j. ~ ~ j-J J" Job name/Part name Q'ty Intake manifold Reed valve Valve seat gasket Stopper Crankcase 2 Dowel pin Engine m o u n t spacer Circlip Bearing Oil seal Remarks 1 1 1 1 1 2 1 1 1 1 Reverse the removal procedure for installation.
O.A°KOASEA°O.EEOVA'VE I E"O Io =1 CRANKCASE(RIGHT) REMOVAL 1. Remove: • Oil seal s t o p p e r (~ • Screws ( c r a n k c a s e ~ 19Nm(0.9 m.kg,6.5ft.lb ! NOTE: Loosen each s c r e w 1/4turn, and remove t h e m after all are loosened. =~r~ri 2. Attach: • Crankcase separating tool (~ I<~l CrankcaSeyu_01135se pa rating tool: I NOTE: Fully tighten the tool holding bolts, but make sure the tool b o d y is parallel w i t h the case.
C R A N K C A S E A N D REED V A L V E I ENG I TDI REED V A L V E I N S P E C T I O N 1. Measure: • Valve stopper height (~ Out of specification-->Adjust stopper/Replace valve stopper. I ~ l Valve stopper height (~ 6.0~6.4 mm(0.24~0.25 in) . Measure: • Reed valve clearance @) Out of specification-->Replace va lye. reed lReedvavecearance I I Less than 0.2 mm(0.0079 in) C R A N K C A S E (RIGHT) I N S T A L L A T I O N 1. Install: • Dowel pins (~ • Engine mount spacer (~ 2.
.OASE A.O.EEO VA'VE I E"O Io .1 4. Tighten: • Crankcase holding screws [ ~ l 12 Nm(1.2 m.kg,8.4 ft.lb) I NOTE: T i g h t e n t h e c r a n k c a s e h o l d i n g s c r e w s in stage, using a crisscross pattern. ,4 5. 6. Check: • Crankshaft operation Unsmnothoperation Install: Repair. • Oil seal ( r i g h t c r a n k case) ( ~ A p p l y g r e a s e on to oil seal lip. . Install: • Oil seal s t o p p e r plate ( ~ H . 4-37 .ml09 9 m.kg, 6.
KS.AFT I ENO I O ,,I CRANKSHAFT CRANKSHAFT ~ 4 2 Order Job name/Part name Q'ty Crankshaft removal Right crankcase r e m o v a l 1 2 3 4 R e mks a r R e m o v e the parts in order. Refer to " C R A N K C A S E A N D V A L V E " section. Crankshaft Bearing Oil seal Crankcase c o v e r (left) REED 1 2 2 1 Reverse the r e m o v a l p r o c e d u r e for instal lation.
KS.AFT I E"O I o '1 CRANKSHAFT REMOVAL 1. Attach: • Crankcase s e p a r a t i n g tool ( ~ ~ l Crankcase s e p a r a t i n g t o o l : YU-01135-A 2. Remove: • Crankshaft (~ NOTE: Make sure the crankcase s e p a r a t i n g tool is centered o v e r t h e c r a n k s h a f t a s s e m b l y . CRANKSHAFT INSPECTION 1. Measure: • Runout limit " C" • C o n n e c t i n g rod big end side clearance F iJ g rr • Small end free play l i m i t " F " Out of specification-->Replace.
CRANKSHAFTI ENGI{ ll CRANKSHAFT INSTALLATION 1. Attach: • Crankshaft Installing Tool Crankshaft installation set (~ YU-90050 Crankshaft installer adapter (M10) ~) YU-90062 Q 2. Install: • Crankshaft ® (to the crankcase (~) CAUTION: To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips w i t h grease and each bear-ing w i t h engine oil.
CARBURETION CARBURETOR 4 / / 2 1 Order 1 2 3 4 5 6 Q'ty Job name/Part name k l 9 N m l 0 . 9 m.kg, 6.5 ft.lb) I R e m ks a r Remove the parts in order. Carbu retor removal Battery b o x cover Grip End cover Left/Right cover Center cover Air cleaner case a s s e m b l y A u t o choke lead coupler Fuel hose/vacuum hose Oil delivery pipe a s s e m b l y Carburetor Throttle cable Refer to "COVER A N D PANEL" section in CHAPTER 3. Reverse the removal procedure for installation.
• CABURETOR DISASSEMBLY ' ~,_ .~'~ Order O ® ® ® ® ® @ ® ® ® ® @ @ Job name/Part name Q'ty Carburetor d i s a s s e m b l y Throttle cable Throttle valve Needle set Carburetor top cover/o-ring Throttle stop screw A u t o choke unit assembly Float chamber/Seal ring Float pin Float/Needle valve Main jet Pilot jet Main nozzle Carburetor b o d y Remarks Disassemble the parts in order. 1 1 1 1 1 1 1/1 1 1 1 1 1 1 Reverse the removal procedure for installation.
O'"'O"'TO" Ic""'l V CABURETOR INSPECTION 1. Check: • Carburetor b o d y • Float c h a m b e r • Jet housing Cracks/damage --> Replace. 2. Check: • Fuel passages Obstruction --~ 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 w i t h compressed air. 3. Q 4. 5. 5-3 Check: • Float c h a m b e r b o d y Dirt --> Clean. Check: • Float c h a m b e r rubber gasket Cracks/damage/wear --> Replace.
OA"BO"ETO" ICA"BI V Check: • Jet n e e d l e kit ( ~ • M a i n nozzle ~ ) • M a i n jet ( ~ • Pilot jet ( ~ B e n d s / d a m a g e / w e a r --> Replace. O b s t r u c t i o n --> Clean. B l o w o u t the jets w i t h c o m p r e s s e d air. . 9. Check: • Throttle valve movement Insert the t h r o t t l e v a l v e into t h e c a r b u retor B o d y and m o v e it up and d o w n . T i g h t n e s s --> Replace the p i s t o n valve. 10.
CARBURETOR Ic..,I • NOTE: The float arm should be resting on the needle valve, but not compressing the needle valve. • If the float height is not w i t h i n specification, inspect the needle valve, float and valve seat. • If it is w o r n , replace it. NOTE: The float height is properly adjusted at the Yama ha factory. Never attempt to adjust it. CARBURETOR ASSEMBLY To assemble the carburetor, reverse the disass e m b l y procedures. Note the f o l l o w i n g points.
OA"BU"ETO"IOA"BI V 1. I Install: • T h r o t t l e cable ( ~ 2. Install: • Carburetor assembly NOTE: A l i g n the p r o j e c t i o n ( ~ w i t h t h e p r o j e c t i o n s @ . FUEL LEVEL A D J U S T M E N T 1. Measure: • Fuel level ( ~ Out of specifications-->Adjust. Fuel level (~: 3.0~4.0 m m ( 0 . 1 2 ~ 0 . 1 6 in) ( B e l o w the float c h a m b e r line) M e a s u r e m e n t steps: • Place the s c o o t e r on a level surface.
• Install the c a r b u r e t o r . • Recheck the fuel level. * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ AUTO CHOKE INSPECTION (Ambient temperature lower than 45°C) 1. Remove: • Carburetor 2. Inspect: • Autochoke unit C o n n e c t a s u i t a b l e hose ( ~ to t h e starter (~, a n d b l o w it w i t h t h e m o u t h etc. Possible--~Good c o n d i t i o n . Impossible-->Replace auto choke unit. 3.
CA"BO"ETO"IOA"BI V I FUEL COCK INSPECTION 1. 2. Stop the engine. Remove: • Rear c a r r i e r • Tail c o v e r • Left s i d e c o v e r • Battery box cover R e f e r to " C O V E R A N D P A N E L " s e c t i o n in c h a p t e r 3. Inspect: • Fuel c o c k 3. Fuel cock inspection steps: • D i s c o n n e c t t h e fuel h o s e (~. • Place t h e r e c e p t a c l e u n d e r t h e fuel h o s e e n d .
F.O°T W.EEL A.O B.AKE O.SC IC"ASI oI CHASSIS F R O N T W H E E L A N D BRAKE DISC 4 _ _ ~--/~ : /1 ,/ m (0.7 m.kg, 5. lft.i b) ' ~ " ' - ~ %~ZJ70 Nm(7 m.kg, ~1-O" Order -'~'I~.~.~I7~N ( .0 g,. .5ft.lb) I Q'ty Job name/Part name b)l5 lft.I ~ R e mks a r Remove the parts in order. Front wheel and brake disc removal ~WARNIN( S e c u r e l y s u p p o r t t h e s c o o t e r so t h e r e is no d a n g e r of it falling over.
FROOT W.EEL AO0 BRAKE O,SC IC"ASI oI FRONT WHEEL DISASSEMBLY Order (# ® ® ® ® Job name/Part name Remarks Q'ty Front wheel disassembly Oil seal Bearing Collar Spacer Bearing 1 m 1 Remove the parts in order. Refer to "FRONT WHEEL DISASSEMBLY/ASSEMBLY" section. 1 1 1 - Reverse the removal procedure for installation.
F.OOT W.EE. AO0 B.A.E O.SC IC'ASI f f f oI YP ...... - f FRONT W H E E L D I S A S S E M B L Y 1. Remove: • Bearing ( ~ • Spacer Remove the bearing using a general bearing p u l l e r (~). CAUTION: Handle the wheel w i t h care not to d a m a g e the brake disc. If the brake disc is d a m a g e d , replace. YP700020 FRONT W H E E L INSPECTION 1. Inspect: • Front w h e e l axle (by r o l l i n g it on a flat surface) Bends-->Replace.
F.O°T W.EE. A°O B.A.E O.SO IC"ASI 4. Ye oI Inspect: • Collar Grooved wear-->Replace the collar and the oil seal as a set. ..... BRAKE DISC I N S P E C T I O N 1. Measure: • Brake disc deflection(~ I ~ 1 M a x i m u m deflection: 0.15 mm (0.0059 in) Out of specification-->Replace. 2. Measure: • Brake disc thickness(~ Brake disc thickness: 4.0 mm (0.16 in) M i n i m u m thickness: 3.5 mm(0.14 in) Out of specification-->Replace. Ye ..... FRONT WHEEL ASSEMBLY 1.
F.O°T W . E E . . ° O 2. i B . . . E O.SO IC"ASI Install: • Brake disc O H 20 Nm~20 ~k~, oI 14 ft.lb) I NOTE: T i g h t e n the bolts (brake disc) in stage u s i n g a c r i s s c r o s s pattern. EB700030 FRONT WHEEL INSTALLATION Reverse the " R E M O V A L " p r o c e d u r e . Note t h e f o l l o w i n g points. 1. Lubricate: • Front w h e e l axle • Bearings • Oil seal (lips) • D r i v e / d r i v e n gear ( s p e e d o m e t e r ) Recommended lubricant: L i t h i u m soap base grease @ 2.
F.OOT W . E E . . O 0 B . . . E O.SO IONASI oI YP700040 WHEEL STATIC BALANCE ADJUSTMENT NOTE: • After replacing the tire and/or rim, the wheel static balance should be adjusted. • A d j u s t the front wheel static balance with the brake disc installed. 1. 2. 3. Remove: • Balancing w e i g h t Set: • Wheel (on a suitable stand) Find: • Heavy spot Procedure: a. Spin the wheel and w a i t for it to rest. b. Put an "X~" mark on the w h e e l ' s b o t t o m spot. c.
F.OOT W.EE. AOO B.A.E O.SC IC"ASI 5. X * X * oI Check: • W h e e l static balance * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ Checking steps: • T u r n the w h e e l so t h a t it c o m e s to each p o i n t as s h o w n . • C h e c k t h a t the w h e e l is at rest at each point. If not, readjust the f r o n t w h e e l static balance.
F.O°T B.AKE IC"ASI oI F R O N T BRAKE BRAKE PAD ~ H23Nm(23. m.kg, 16.6 ft.lb) I ~ Order 1 2 3 4 ~ ~ J o b name/Part n a m e [~423NmI2.3m.kg,16.6ft.lb)I Q'ty Brake pad r e m o v a l Caliper s u p p o r t bolt Caliper Brake pad Pad s p r i n g R e mks a r R e m o v e the parts in order. BRAKE PAD R E P L A C E M E N T 1 --I Refer to 1 J section . 2 2 Reverse the r e m o v a l p r o c e d u r e for installation.
F.ONT B.A.E IC"ASI oI CAUTION: Disc b r a k e c o m p o n e n t s r a r e l y r e q u i r e disass e m b l y . DO NOT: • Disassembly components unless absolutely necessary. • Use s o l v e n t s in i n t e r n a l brake c o m p o n e n t . • Use c o n t a m i n a t e d b r a k e f l u i d for c l e a n i n g . • Use o n l y clean fluid. • A l l o w brake f l u i d t o c o m e in c o n t a c t w i t h t h e eyes o t h e r w i s e eye i n j u r y m a y occur.
,.o°T B.AKE Ic"AsI 4. ol Install: • Pad springs • Brake pads (new) Installation steps: • Connect a suitable hose (~ t i g h t l y to the caliper bleed screw (~. Then, place the other end of this hose into an open container. • Loosen the caliper bleed screw and push the piston (~ into the caliper by y o u r finger. • Tighten the capliper bleed screw. / H ~~ (0.~ ~.k~, 4.3 ~.'~ i • Install the pad spring (new) and brake pad (new) (~ • Tighten retaining bolt (~ ~ 1 2 3 Nm (2.3 m.kg, 16.6 ft.
F.O.T B.A.E IC"ASI . Check: • Brake lever o p e r a t i o n A s o f t y or s p o n g y feeling Bleed-->brake system. AIR BLEEDING " section in Refer to the CHAPTER 3.
F.O°T B.AKE IC"ASI oI MASTER CYLINDER 6 ] 6 3 l~120Nm(2.0m.kg, 14 ft.lb) Order J o b name/Part n a m e Q'ty R e m o v e the parts in order. R e f e r t o " B R A K E F L U I D REPLACEM E N T " section in CHAPTER 3.
F.O°T B.AKE IC"ASI oI M A S T E R CYLINDER D I S A S S E M B L Y Order O ® ® ® Job name/Part name Q'ty Master cylinder disassembly Master cylinder boot Circlip M a s t e r c y l i n d e r kit Spring R e mks a r R e m o v e the parts in order. 1 1 1 1 Refer to " M A S T E R CYLINDER A S S E M B L Y " section. Reverse the d i s a s s e m b l y p r o c e d u r e for assembly.
F.ONT B.A.E IC"ASI oI YP702040 MASTER CYLINDER INSPECTION 1. Inspect: • Master cylinder kit O Wear/scratches-->Replace the master cylinder assembly. • Master cylinder boot Cracks/da m age-->Re pla ce. . Inspect: • Master cylinder O • Scratches/wear/damage-->Replace the master cylinder assembly. . Inspect: • Diaphragm (~ Wea r/da mag e-->Re place. Y P .....
F.O.T B.A.E IC"ASI Ye oI . Install: • Spring (~ Install the s p r i n g w i t h its s m a l l e r d i a m eter to the m a s t e r c y l i n d e r piston. • M a s t e r c y l i n d e r kit ( ~ . Install: • Circlip (~) Install the circlip s e c u r e l y into the master c y l i n d e r g r o o v e . • M a s t e r c y l i n d e r boot ( ~ ..... MASTER CYLINDER INSTALLATION 1. Install: • Master cylinder (~ • M a s t e r c y l i n d e r bracket ( ~ ~ l 9 Nm (0.9 m.kg, 6.5 ft.
F.O.T B.A.E IC"ASI 2. oI Air bleed: • Brake s y s t e m Refer to " A I R B L E E D I N G " s e c t i o n in CHAPTER 3. r!~vAvg_,W --']~ I [¢-] I ~ • Use o n l y d e s i g n a t e d q u a l i t y brake fluid: O t h e r w i s e , t h e r u b b e r seals m a y d e t e r i o r a t e , causing leakage and poor brake perforrmance.
F.O.T..AKE IC"ASI oI CALIPER lh%123Nm(2.3 m.k,g, 16.6 ........ Order Job name/Part name i ....... Q'ty 3 Remarks Caliper removal Drain the brake fluid 1 2 3 4 5 ft.lb)l Remove the parts in order. Refer t o " B R A K E F L U I D REPLACEM E N T " section in CHAPTER 3. Union bolt Copper w a s h e r Brake hose Caliper s u p p o r t bolt Caliper assembly 1 2 1 1 1 Refer to "CALl PER INSTALLATION" section. Reverse the removal procedure for installation.
F.O°T B.AKE IC"ASI oI CALIPER D I S A S S E M B L Y ~ ~ ~ j~J'~ Order (# ® ® ® ® ® @ ~ Job name/Part name ~ ~ [~0"6m~ Q'ty "4"3ft'lb) l R e m ks a r Remove the parts in order. Caliper disassembly Caliper bracket Brake pad Pad spring Caliper piston Dust seal Piston seal Bleed screw 1 2 2 1 1 1 1 Refer to "BRAKE CALIPER --I BLY/ASSEMBLY" section. J Reverse the disassembly procedure for assembly.
F.ONT B.A.E IC"ASI oI YP702020 BRAKE CALIPER D I S A S S E M B L Y NOTE: Before disassembling either brake caliper, drain the brake fluid from the brake hose, master cylinder, brake caliper and reservoir tank. 1. Remove: • Brake caliper piston Removal steps: • B l o w c o m p r e s s e d air into the hose joint opening to force out the caliper piston from the brake caliper body. ~!~LVAV/_'I-"] ~ I [¢'] I ~ • N e v e r try to pry out the caliper piston. • Cover the caliper piston w i t h a rag.
F.O.T B.A.E IC"ASI oI EB702050 BRAKE CALIPER ASSEMBLY r!~vAvg_,1--'t~ I [¢-! I ~ • All i n t e r n a l brake c o m p o n e n t s s h o u l d be cleaned and lubricated w i t h n e w brake fluid o n l y before installation. DOT #4(or DOT #3) • Replace the caliper piston seals w h e n e v e r a brake caliper is disassembled. 1. Install: • Piston seal (~ • Dust seal (~ 2. Install: • Caliper piston (~ A p p l y brake fluid to the outer surface and install. ) O( ) CAUTION: • Do n o t force.
, E , , w.EE, A ° 0 , E , , =,,KE IC"A=I oI REAR WHEEL AND REAR BRAKE REAR W H E E L < 2 [;;l~i~]((;16~i:18:8f.?liilb)~" Order 1 J o b name/Part name Q'ty Remarks Remove the parts in order. NOTE" Rear w h e e l and rear brake removal Place the scooter on a suitable atand so that the rear wheel is elevated. 1 2 3 4 Muffler assem bly/Gasket Nut/Plain w a s h e r Rear w h e e l a s s e m b l y Plain w a s h e r 1/1 1 1 1 Reverse the d i s a s s e m b l y procedure for installation.
,E,, w,EE,,.o,EA, B,AKE IC"Asl REAR BRAKE kllONm(1.0 m.kg, 7.2 ft.lb) I . / J 8 \ Order 1 2 3 4 5 6 7 8 t3 ./ - Job name/Part name Q'ty Adjuster Brake cable Pin Return s p r i n g Brake shoe C a m s h a f t lever Wear indicator Brake c a m s h a f t Remarks 1 1 1 1 1 1 1 1 Reverse the r e m o v a l p r o c e d u r e for installation.
.EA. W.EE" A.O .EA. B.A.E I C"Asl EB701020 REAR W H E E L I N S P E C T I O N 1 Inspect: • Rear w h e e l axle • Rear w h e e l • Rear w h e e l b e a r i n g s • Oil seals Refer to " F R O N T WHEEL". 2. Measure: • Rear w h e e l r u n o u t Refer to " F R O N T W H E E L " . EB701021 REAR BRAKE I N S P E C T I O N 1. Inspect: • Brake l i n i n g surface Glazed areas-->Polish. Use coarse sand paper. NOTE: After p o l i s h i n g , w i p e the polished particles w i t h a cloth. 2.
,EA, W.EE" A.O .E,, B.,,E I C"Asl 4. 5. Inspect: • Brake drum inner surface • Oil/scratc hes-->Re pair. • Oil Use a rag soaked in lacquer t h i n n e r or solvent. • Scratches Use an e m e r y cloth (lightly and e v e n l y polishing) Inspect: • Cam shaft face. Wea r-->Replace. W h e n inspecting t h e brake lining, do not spill oil or grease on t h e brake lining, Ye ..... REAR BRAKE I N S T A L L A T I O N 1.
HAOOLE.,. IONASI oI HANDLEBAR HANDLEBAR ~;~19Nm(0.9 m.kg, 6.5 ft.lb) I 5 ,) 1~143Nm(4.3 m.k 9, 37 ft.lb) I . 8 10 t-,,., 2 Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q'ty Remarks Remove the parts in order.
.AOOLEBARIC"ASI oI ~ 1 9 N m ( 0 . 9 m.kg, 6.5 5 ,)~D 1~143Nm(4.3 m.kg, 37 . ft.lb) I ftJb)l 8 10 p-.. 2 Order 10 11 12 13 Job name/Part name Q'ty Remarks 1 1 1 1/1 Wire harness strap Brake hose Handlebar comp. Left grip Reverse the removal procedure for installation.
.,,O,EBA, IC"ASI oI HANDLEBAR INSTALLATION 1. Clean: • Steering shaft ® ~!~v~v/±1 --']~ I I ~ [e-]l Proper cables and leads routing is essential to issue safe scooter operation. ® 2. Install: • Handlebar O • Bolt (~) • Nut NOTE: ® I~143Nm(4.3 m.kg, 37ft.lb) Match the bolt (~ on to the steering c o l u m n dent (~. ® CAUTION: There m u s t be a space b after t i g h t i n g bolt ~). 3. Install: • Ba nd NOTE: Clamp the w i r e harness. 4.
.AOO,EBA. IC"ASI oI 6. Install: • Handlebar switch (left) (~ NOTE: Q ® Insert the projection (~ into the hole @ on the handlebar comp. 7. Install: • Master cylinder NOTE: Match the slot w i t h the punched mark @ on the handlebar comp.
STEE.,°OIC"ASI oI STEERING STEERING ~-766Nm(6.6 m.kg, 47.8 ft.lb)] r~122Nm(2.2 m.kg, 16 ft.lb) 21 -J/ I 8 I 38Nm(3.8 m.kg, 27ft.lb) i I I -9 8 5 40Nm(4.0 Order 29 ft.lb) Job name/Part name Q'ty Remove the parts in order Refer to " H A N D L E B A R " section.
STEE.,°O IC"ASI oI STEERING REMOVAL ~WARNING • S e c u r e l y s u p p o r t t h e s c o o t e r so t h a t t h e r e is n o d a n g e r of it falling over. • S t a n d t h e s c o o t e r on a level surface. 1. Removal: • Ring nut 1 ~) • Special w a s h e r (~ • Ring nut 2 (~) • Rubber w a s h e r (~ • Ring nut 3 (~ • Bearing cover (~ • Ball race (~ • Ball (~ • Front fork a s s e m b l y (~ NOTE: • Remove the ring nuts by steering nut wrench.
STEE.,°OIC"ASI oI STEERING I N S P E C T I O N 1. W a s h t h e b e a r i n g races w i t h a s o l v e n t . 2. Inspect: • Ball race • Ball P i t t i n g / D a mage--~Replace. NOTE: A l w a y s r e p l a c e b e a r i n g s a n d races as set. 3. Inspect: • Under bracket (~ Crack/Bend/Damage-->Replace. Q W!~LVAV/±I-'] ~ I I ~ [¢']1 Do not attempt to straighten a bent under b r a c k e t as t h i s m a y d a n g e r o u s l y w e a k e n t h e under bracket. STEERING I N S T A L L A T I O N 1.
STEE.,°O IC"ASI oI , \ 3. Install: • Frontfork assembly (~ • Ball race (Upper) ~) • Bearingcover (~ • Ring nut 3 ~) • Rubberwasher {~) • Ring nut 2 (~ • Specialwasher (~ • Ring nut 1 (~ ® NOTE: Securely support the steering shaft so that there is no danger of it falling down. 4. Tighten: • Ring nuts Tighten steps: • Tightenthe ring nut 3 (~ using the ring nut wrench (~ r~122 am {2.2 m.kg, 16 ft..b~ steor,no,utwrenoho_9 I NOTE: .~...
STEE.,°OIC"ASI oI CAUTION: Slots on t h e ring n u t 2 and ring n u t 3 s h o u l d be align. If not, t u r n t h e ring n u t 2 t o w a r d s t i g h t e n direction until slots a l i g n m e n t . • Install special w a s h e r (~) NOTE: Insert the projections of the special w a s h e r into the slots. • Install ring nut 1 (~ and tighten. [~166Nm(6.6 6-33 47.8 ft.lb)m.
F.O.T FO.K IC"ASI oI F R O N T FORK FRONT FORK 8 Order 1 2 3 4 5 Q'ty Job name/Part name Remarks R e m o v e t h e parts in order. Refer to " S t e e r i n g " section. Front f o r k r e m o v a l Steering Under fender S p e e d o m e t e r cable h o l d e r Cap bolt Pinch bolt Front f o r k 1 1 2 2 2 - l Refer to " F R O N T FORK R E M O V A L / I N - S T A L L A T I O N " section. Reverse the r e m o v a l p r o c e d u r e for installation.
F.O°T FO.K IC"ASI oI FRONT FORK D I S A S S E M B L Y / ® ® @ ® c-~ ® Q [~, 23N m m (2.3 ~ Order t ~ O Job name/Part Front fork disassembly Fork spring ® ® ® ® ® @ ® ® @ Band/Front fork boot Bolt/Copper washer Inner tube Damper rod Rebound spring Oil lock piece Oil seal clip Oil seal Outer tube / '. name Q'ty Remarks Remove the parts in Refer to "FRONT FORK STALLATION" order. REMOVAL/INsection. 1 1/1 1 1/1 Refer to FRONT FORK DISASSEMBLY/ 1 ASSEMBLY" section.
F.O.T FO.K IC"ASI oI Y P ..... f FRONT FORK R E M O V A L ~!~LvAv/_,l -"t ~ I [¢-] I ~ • Securely support the scooter so there is no danger of it falling over. • Stand the scooter on a level surface. • Stand the scooter on its centerstand. 1. Remove: • Under fender (~ 2. Remove: • Cap bolt (~) • Pinch bolt (~ W!~kvAv/±1 -'] ~ I I ~ [¢']1 Fork spring will j u m p out after removing cap bolt. 3. Remove: • Front fork (Left/Right) (~ YP703020 FRONT FORK D I S A S S E M B L Y 1.
F.O.T FO.. IC"ASI . ® O ® oI Remove: • Inner tube (~ • Oil lock pice (~ • Damper rod ® • Rebound spring (~ ® 3. Remove: • Oil seal (~ CAUTION: "7 "°'" i~: N e v e r reuse th e oil seal. ~) Rag YP703030 F R O N T FORK I N S P E C T I O N 1. Inspect: • Inner tube bending I ~ l Inner tube bending limit: 0.2 mm(0.008 in) Scratches/be nds/da m age-->Replace.
F.O.T FO.. IC"ASI \ . Install: • Inner tube (~ Into outer tube ~). . Install: • Plain w a s h e r (~ • Bolt ( d a m p e r rod) (~) 4. Tighten: • Bolt ( d a m p e r rod) (~ A oI ~%O%123Nm(2.3m.kg, 16.6ft.lb) NOTE: Tighten the damper rod bolt ( ~ w h i l e holding the damper rod with a T-handle(~ and holder ~). ~ 5. T-handle YM-01326-A Holder YM-01300-1 Install: • Oil seal (~ • Retaining clip Use the fork seal driver w e i g h t ~) and the a t t a c h m e n t (~).
F.O.T FO.. IC"ASI . 7. oI Inspect: • Inner tube operation U n s m o o t h operation-->Disassembly and recheck. Fill: • Fork oil ( ~ ©1 Oil q u a n t i t y : 88 cc R e c o m m e n d e d oil: Fork oil 10 W or e q u i v a l e n t 0; 8. A f t e r f i l l i n g up, s l o w l y p u m p the f o r k up and d o w n to d i s t r i b u t e the fork oil. 9. Install: • Front f o r k s p r i n g O NOTE: • Install the fork s p r i n g w i t h its s m a l l e r p i t c h ( ~ upward .
E.EOT..OA. OO=,O=E°T= I E'EC I ELECTRICAL ELECTRICAL C O M P O N E N T S (~ (~) (~) (~ (~ (~ (~ Main switch Flasher relay Oil level gauge C.D.I.
Cl.O°lTOlAO.A. IE'EC I I CIRCUIT D I A G R A M , 111L u II i I II~l~ I ~1~2- / ~ I ~ l ------I __i, /--/ i ® ~ I B I __1 ~ ~-I~- ~ " ~4-4- I1~ II I I ®,,® ,, ~ '® i •~ - - - I - - @ 1 _EB I L .... I i-- J b__ L i _J o _E,2 ~ _ _ _ _ I I I , i@ I I L I 7-2 @ I® I - -i-I :~ I ~ III~L I ~ , , :0 i~ ~ I I I ......
c..cu.T o..o..M I E'Ec I (~ (~) (~ (~ (~ (~ (~ (~ (~ @ @ @ (~ @ @ @ (~ (~) (~ (~ (~ (~) (~ @ (~ @ (~ @ @ @ (~ @ @ @ (~ @ @ @ Main switch Main fuse Battery Starter relay Starter motor Rectifier regulator Auto choke C.D.I. magneto C.D.I.
O.EOK.°OSW.TO.ESIE'EC I YP N JJoo r, "~xl CHECKING S W I T C H E S "O" C H E C K I N G STEPS Using pocket tester, check switches for contin u i t y b e t w e e n t h e i r t e r m i n a l s to d e t e r m i n e w h e t h e r t h e y are correctly connected. Replace the switch c o m p o n e n t if any of the c o m b i n a t i o n s does not produce the correct reading. " -- I ~ 1 Pocket tester: YU-03112 NOTE: • Turn the switch to the " O N " , " O F F " positions several times.
O.EOK.°OSW.TO.ESIE'EC I S W I T C H POSITION A N D T E R M I N A L CONNECTION I- Before c h e c k i n g a s w i t c h refer to the checking s w i t c h e s as s h o w n in the left page and check for t h e c o r r e c t t e r m i n a l c o n n e c t i o n s (closed circuit) a c c o r d i n g to the c o l o r c o m b i n a t i o n s s h o w n in the chart. Poor c o n n e c t i o n , fault-->Repair or replace.
c.Ec...o T.E Bo.Bs A.o BO.B SOO.ETS IE'EC I EAS00733 CHECKING THE BULBS A N D BULB SOCKETS Check each b u l b and b u l b socket for d a m a g e or wear, p r o p e r c o n n e c t i o n s , and also for con tinuity between the terminals. D a m a g e / w e a r --~ Repair o r replace t h e bulb, b u l b socket or both. I m p r o p e r l y c o n n e c t e d --~ P r o p e r l y connect. No c o n t i n u i t y --~ Repair o r replace the bulb, b u l b socket or both.
C.EOK..O T.E BO'BS..O BO'B SOCKETSIE'EC I C H E C K I N G THE C O N D I T I O N OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb Since the headlight bulb gets extremely hot, keep f l a m m a b l e p r o d u c t s and y o u r h a n d s a w a y from the bulb until it has cooled d o w n . CAUTION: • Be sure to hold the socket firmly w h e n removing the bulb. Never pull the lead, otherw i s e it may be pulled out of the ter-minal in the coupler.
O.EOK.°O T.E BO'BS A.O BO'B SOCKETS IE'Ecl I C H E C K I N G T H E C O N D I T I O N OF THE B U L B SOCKETS The f o l l o w i n g p r o c e d u r e a p p l i e s to all o f the b u l b sockets. 1. Check: • b u l b socket (for c o n t i n u i t y ) ( w i t h the pocket tester) No c o n t i n u i t y --> Replace.
IE'ECI I IGNITION SYSTEM CIRCUIT D I A G R A M • .... ~-r~', ~ ~ ~ ~L~J~ ~E~ I-- -- -------- . . . . , ~ I I - ~ ,~w ~-~_~ r s- ~or - B 'B~' I ~,BI wa? -- ------7 I I. . . . . . . . . __ I I ~ ~,_ . . . . . . . . I I I. . . . . . . . . . I I I __~ I ---~L ',® . . . . . I r ~ ~® ® " ; ..... __~___J I I I @.___~ ____~ ....... ', ; - - t * ]~- ~ -v- " 2~___] ~ ~B v F--- --- I I I I .... L_ B Io _ _ j L S l F I . . .
.o..T.o° SVSTEMI':":C I I TROUBLESHOOTING IF I G N I T I O N S Y S T E M S H O U L D B E C O M E I N O P E R A T I V E (NO S P A R K OR I N T E R M I T T E N T SPARK) NOTE: • Removethe following parts before troubleshooting. 1) Battery box cover 4) Tail cover 2) Center cowling 5) Side cover 3) Rear carrier 6) Handlebar • Use the following special tools in this troubleshooting. ~ 1 1. • • • Dynamic tester:YM-34487 spark I ~ 1 Spark plug Check the spark plug condition. Check the spark plug type.
IGNITION SYSTEM ELEC +' * l 3. Spark plug cap resistance • Remove the spark plug cap. • Connect the pocket tester (~Q x lk) to the spark plug cap. • Check the spark plug cap for specificated resistance. [~ • J Spark plug cap resistance: 5k£Q at 20°C (68°F) OUT OF SPECIFICATION MEETS SPECIFICATION 4. Ignition coil resistance • Disconnect the ignition coil leads from the ignition coil. • Connect the pocket tester (~ x 1)to the ignition coil. Replace spark plug cap.
,ON,T,OOS STEM IE'EC I 5. Pickup coil resistance • Disconnect the pickup coil coupler from the wireharness. • Connect the pocket tester (~ × 100) to the pickup coil terminal. Tester (+) lead->White/Red lead (~ Tester (-) l e a d , W h i t e / B l u e (~) • Check the pickup coil for specificated resistance. -~ OUT OF SPECIFICATION Pickupcoilresistance: 248~ 372 ~Q at 20°C (68°F) (Wh ite/Red-Wh ite/Blu e) I Pickup coil is faulty, replace it. ~N7 SPECIFICATION MEET 6.
.O..Z.O° SVSTEM IE'EC I I NO CONTINUITY Engine stop switch Refer to "CHECKING SWlTCHS" section. 8. I Engine stop switch is faulty, replace it. CONTINUITY I POOR CONNECTION 9. Wiring connection Check the entire ignition system for conneo tions. Refer to the "WIRING DIAGRAM" section. I Correct. ~ CORRECT I Replace CDI unit.
O,.OSYSTE. IE'Ecl CHARGING CIRCUIT SYSTEM DIAGRAM [- . . . . ~ ~ : L--~ I ______i ~ I _ J I r ,~ ~ R,~. R ,~'- -' ,eeL-' I . .i. . . . ~_~_~_~ -~ ,,® I I l ~,R_, ( ® ~ I 78-',r~ ~ I l £~rq I ® ~- L ....... I I. . . . . . . . . . i ,, . . . . i [ ~ I [ ~ .... ~ ___ i ~ ~-~T~,~ --1---: ,'--@, ~ i- ~ ,' L_ L__ _] B',~ _J L ..... -~ I I i 14~ IHb i L_____ ,' ® ~ ~',D B,,~ '[_~' ', (~) (~ (~ (~ ,'TE --,, ,', ~',~ I [___ I I ~,,1~ ......
O,.OSYSTEMIE'ECI TROUBLESHOOTING THE B A T T E R Y IS N O T C H A R G E D . NOTE: • Remove the following parts before troubleshooting. 1) Front protector bar 4) Tail cover 2) Upper cover 5) Right side cover 3) Rear carrier • Usethe following special tool (s) in this trobleshooting. 1~1 Inductive YU-8036-A tach°meter: Pocket tester: YU-03112 I 1 ~ 1 1. Fuse (main) • Remove the fuse. • Connect the pocket tester (£1 x 1) to the fuse. • Checkthe fuse for continuity.
O,NOS,STEMIE'ECI 3. Charging voltage Connect the inductive tachometer to the spark plug lead. Connect the pocket tester (DC20V) to the battery. Tester (+) lead- >Battery (+) terminal Tester (-) lead- >Battery (-) terminal • Start the engine and accelerate to about 5,000 r/min. • Check charging voltage. ~ Chargingvoltage: 13 ~ 14 at V 4,000 r/min NOTE: MEETS SPECIFICATION Use a full charged battery. l OUT OF SPECIFICATION I Charging circuit is good. 4.
O,OOS STEMIE'ECI Se ] 5. Wiring connection i Check the entire ignition system for connections. Refer to the "WIRING D I A G R A M " section. .~o~ POOR CONNECTION I Correct. Replace rectifier regulator.
E.EOT..O ST..T.°O S STE. I E'EC I ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM IIII clCI~~ .... __ ON~,IIC~--~______I ,', ...... -~',B .....Y-, B L i ---,® f--~, . . . . . , ~~I '-# 71 [r -~ ---1 ~,,@, I I I ' o~_ I .... ~ I ~-',,B I . . . . . ' - . . I. . . , I . . . . . . . "~-~ ° ___J i I!Io,,o ...... ~ " 1 I ~)r----- a ,'--G I ,'~3- --', ," L_ B,,( _J ,'L__ B,,~ _J I . . . . I I S I___ , @ ', L~__ I I I L r . . . .
E.EO*..O STA.*.OO E'EC I S*S*EM I TROUBLESHOOTING J S T A R T E R M O T O R DOES N O T OPERATE. NOTE: • Remove the following parts before troubleshooting. 1)Battery box cover 4)Side covers (left and right) 2)Rear carrier 5)Trunk 3)Tail cover 6)Handlebar cover (front) • Use the following special tool in this troubleshooting. I Pocket tester: YU-03112 1. Fuse • Remove the fuse. • Connect the pocket tester (~ x fuse. • Check the fuse for continuity.
E.EOT..O STA.T.OO S STEM I E'EC I 4. Starter relay • Disconnect the relay unit coupler from the wire harness. • Connect the pocket t e s t e r ( ~ x 1)and battery(12V) to the relay unit coupler terminals. Battery(+)lead--> Blue/White terminal (~ Battery(-)lead--~ Green/Yellow terminal (~) • Check the starter relay for continuity. NO CONTINUITY Tester (+) lead--> (~ terminal Tester ( - ) l e a d ~ (~ terminal , ~ CONTINUITY J Replace the starter relay. NO CONTINUITY 5.
E'EOT..C S*A.*.°O S*S*EM E'EC I I CONTINUITY 8. Brake s w i t c h e s (front and rear) Disco n nect the brake switch leads from the w i r e harness. Connect the pocket tester (~ × 1)to the brake switch leads.
E'ECT..O STA.T.OO S STEM I E'EC I STARTER M O T O R ._._' . ~~. ( Order J o b name/Part name ~ Q'ty ~ 1 Remarks Remove the parts in order. Starter m o t o r removal Rear carrier Tail cover Battery box cover Left/Right side cover Center c o w l i n g Muffler Rear w h e e l Air s h r o u d 3 1 2 ~ [~113 N m(1"3 m "kg' 9"4 ft'l b)~ Refer to "COVER P A N E L " section in CHAPTER 3. m ]Refer to " R E A R W H E E L A N D REAR BRAKE" section in CHAPTER 6.
E,ECTR,OSTART,OOSVSTEM I E'EC I I STARTER M O T O R D I S A S S E M B L Y
E.EOT..C STA.T..O S STEM I E'EC I I YP803034 I N S P E C T I O N A N D REPAIR 1. Inspect: • Commutator Dirt-->Clean it w i t h #600 grit s a n d p a p e r . 2. Measure: • Commutator diameter (~ ® Commutatorwearit I 15.1 m m (0.59 in) . Out of specification-->Replace the starter motor Measure: • Mica u n d e r c u t ( ~ Ilocaun'ercut I 1.05 m m (0.04 in) Out of s p e c i f i c a t i o n ~ S c r a p e the mica to the p r o p e r v a l u e (a h a c k s a w blade can be g r o u n d to fit).
E.EOT.,O STA.T,°O SVSTEM I E'EC I . Measure: • Brush length (~ Out of specification-->Replace. I ~ 1 . 7-25 Brush length wear limit 3.0 mm (0.012 in) Measure: • Brush spring force Fatigue/out of specification-->Replace as a set.
..o.T.oo s sTEM IE'EC I LIGHTING CIRCUIT SYSTEM DIAGRAM [- . . . . ~ ~ : I iI........ L--~ ______1 ~ ...... I ~ I _ J I R,~. R -~ I '-C 1"] I ,BI ------1 I -' ---4- ........ ,,® ® ,, II ® ~ l I<~ ~_Ii~ ...... ~------~ I~L~r ~ I l £~rq I I I.......... I ,, . . . . i [ ~ I [ ~ .... ~ ___ I ,'--@, ,'TE --,, L_ L__ ,', ~',~ _J ,' B',~ _J I I___ i- ~ -~ I I I 14~ IHb L ..... I L_____ ,' ® ~ ~',D B,,~ '[_~' ', Main switch Fuse Battery C.D.I.
..o.T.°o s,,sTE , I':":c I YP805010 TROUBLESHOOTING IF THE H E A D L I G H T , HIGH B E A M I N D I C A T O R LIGHT. T A I L L I G H T A N D / O R M E T E R L I G H T FAIL T O C O M E ON. Procedure Check: 1. Lights switch 2. D i m m e r switch 3. Wiring connection (entire lighting system) NOTE: • Remove the f o l l o w i n g parts before t r o u b l e s h o o t i n g .
IE'ECI I Se YP NO CONTINUITY ..... 4. D i m m e r switch Refer to "CHECKING SWITCHES" section. ~ CONTINUITY i l Replace the left handlebar switch. 5. Lighting coil resistance • Disconnect the lighting coil coupler from the wireharness. • Connect the pocket tester " ~ x 1 to " the lighting coils. • Measure the lighting coil resistances. Tester (+) lead->Yellow/Red lead (~ Tester (-) l e a d , E a r t h - - ~ Lightingcoilresistance: OUT OF SPECIFICATION 0.4 ~ 0.
..o.T.°osvsTEMIE'ECI I Se YP ..... 6. Wiring connection Check the connections of the entire lighting system. Refer to "WIRING DIAGRAM". POOR CONNECTIONS ,~OK I Correct. I Check the condition of each of the lighting system's circuits. Refer to "LIGHTING SYSTEM CHECK" YP805020 L I G H T I N G S Y S T E M CHECK 1. I If the headlight and the high beam indicator light fail to come on. 1. Bulb and bulb socket Refer to "CHECKING SWITCHES" section. 7 NO CONTINUITY CONTINUITY 2.
..o.T.°o s sTEM IE'EC I • Turn the main switch to on. • Start the engine. • Turn the dimmer switch to low beam or high beam. • Checkfor voltage (12V) on the lead at bulb socket connectors. ,• OUT OF SPECIFICATION I The wiring circuit from the main switch to bulb socket connector is faulty. Repair. MEETS SPECIFICATION I This circuit is not faulty. YP805021 2. If t h e m e t e r light f a i l s t o c o m e o n . l I l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.
..o.T.°osvsTEMIE'ECI I Se 3. Licence light does not come on. 1. Bulb and bulb socket • Checkthe bulb and bulb socket for continuity ~ NO CONTINUITY CONTINUITY I Bulb and/or bulb socket are faulty, replace. 2. Voltage • Connect the pocket tester (DC20V)to the bulb socket connector. Tester (+) lead --> Brown @ lead. Tester (-) lead --> Black (~ lead. OUT OF SPECIFICATION • Turn the main switch to on. • Check the voltage (12V) on the " B r o w n " lead at the bulb socket connector.
L.O.T..O SYSTEMIE'EC I YP805022 3. T h e t a i l l i g h t fails t o c o m e o n . NO CONTINUITY I 1. Bulb and bulb socket Refer to "CHECKING SWITCHES" section. 7 CONTINUITY I Replace the bulb and/or bulb socket. 2. V o l t a g e • C o n n e c t t h e p o c k e t t e s t e r (DC20V) t o t h e bulb socket connector. Tester (+) lead--> Brown terminal (~ Tester (-) lead--> Black terminal (~) GH Br ,B Ch Dg OUT OF SPECIFICATION • Turn the main switch to on.
S.O...SVSTE. IE'Ecl SIGNAL SYSTEM CIRCUIT DIAGRAM C IIII _.... ON I ~, ~IIC ~ ~-~___I ,', ...... -~',B .....Y-, B b i ---,® f--~, . . . . , ~~I ,-C?] . [r -~ ---1 I I I ' ,~_~ o~_ I .... I ~-',,B I ,° ' ~ - ' . . . . . ~ I~ ' .,,~ - . . I. . . IT~=~ ,, - ,~I.~ ®,,® ' b --i -= ~ ~/a , I . . . . . . . I ° L ___J i '~ -@-' T!I~IIB ' T l_a~1 1 I ~)r----- ,'- -G I I . . . . ,'~3- I I L_S _J L__ _J I I___ , @ ', L~___I I I b . . . .
S,O.ALSVSTEMIE'ECI I YP806010 TROUBLESHOOTING IF T H E F L A S H E R L I G H T , B R A K E L I G H T A N D / O R I N D I C A T O R FAIL T O C O M E O N . IF T H E H O R N F A I L S T O S O U N D . Procedure Check: 1. Fuse (Main) 2. Battery LIGHT 3.Main switch 4.Wiring connection (entire signal system) NOTE: • Remove the following parts before troubleshooting.
S,O°A.SVSTEMIE'ECI I Se YP ...... 4. Wireharness • Checkthe connections of the entire signal system. Refer to "CIRCUIT SYSTEM WIRING GRAM" section. ~ POOR CONNECTION DIAI Correct. CONTINUITY Check condition of each of the signal system's circuits. Refer to "SIGNAL SYSTEM CHECK" tion.
SIGNAL SYSTEM ELEC '- *' YP806020 SIGNAL SYSTEM CHECK 1. l If the horn fails to sound. NO CONTINUITY l. HORN switch Refer to "CHECKING SWITCHES" section. I Replace the left h a n d l e b a r switch. CONTINUITY 2. Voltage • Connect the pocket tester (DC20V) to the horn lead. Tester (+) l e a d - > B r o w n terminal (~. Tester (-) lead->Frame g r o u n d i • Turn the main switch to on. • Check for voltage (12V) on the " B r o w n " lead at the horn terminal.
S,O.A,S*S*EMIE'Ecl YP806022 2. If t h e b r a k e l i g h t f a i l s t o c o m e o n : NO CONTINUITY J l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section. ~7 CONTINUITY J Replace the bulb and/or bulb socket. NO CONTINUITY J 2. Brake switch (Front/Rear) Refer to "CHECKING SWI SWITCHES" section. , ~ I CONTINUITY 1 J Replace brake switch. 3. Voltage • Connect the pocket tester (DC20V) to the bulb socket connector.
S,ONA, SVSTEM IE'Ecl YP806023 3. If the flasher light and/or turn indicator light fails to blink. NO CONTINUITY J l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section. , ~ CONTINUITY J Replace the bulb and/or bulb socket. NO CONTINUITY J 2. Turn switch Refer to "CHECKING SWITCHES" section. ~ I CONTINUITY 1 J Replace the left handlebar switch. 3. Voltage • Connect the pocket tester (DC20V) to the flasher relay coupler. Tester (+) lead->Brown lead (~.
S,OOA,SVSTEMIE'Ecl 5. Voltage • Connect the pocket tester (DC20V) to the bulb socket connector. At flasher light (left) Tester (+) lead->Chocolate lead (~ Tester (-) lead->Black terminal (~) At flasher light (right) Tester (+) lead--~Dark green lead (~ Tester (-) lead->Black terminal (~ OUT OF SPECIFICATION • Turn the main switch to on. • Turn the turn switch to left or right. • Check for voltage (12V) on the " C h o c o late" lead and " D a r k g r e e n " at the flasher light terminal. 6.
S,°°A,S,S,EM IE'Ecl 3. Voltage • Connect the Pocket Tester (DC20V) to the bulb socket connector. g Tester (+) Lead->Gray lead (~ Tester (-) Lead--~Black lead (~ • Turn the main switch to " * " • Check for voltage (12V) on the "Gray" lead at bulb socket connector. ,• MEETS SPECIFICATION (12V) I b ,BI q~l L OUT OF SPECIFICATION I This circuit is good. 4. Wiring connection • Checkthe entire signal system for connections. Refer to the "WIRING DIAGRAM" section. YP806027 5.
S,O.A,SSTEMIE'Ecl 2. Voltage • Connect the pocket tester (DC20V) to the fuel gauge coupler. ,/ I \ Tester (+) lead->Brown terminal (~ Tester (-) lead->Frame ground II G • Turn the main switch to " O N " . • Check for voltage (12V) of the " B r o w n " lead on the fuel sender lead. ,• Ch I II OUT OF SPECIFICATION l MEETS SPECIFICATION Checkthe connection of the entire signal system. Refer to " C H E C K I N G OF CONNECTIONS". Refer to "CIRCUIT D I A G R A M " . 3.
,UZO O.OKE S STE. IE'Ecl A U T O CHOKE S Y S T E M CIRCUIT DIAGRAM IION CI~~ IIIICc [-__ .... ~, ~--~______I I. . . . . . . . ' I. . . . . . . , B '~ • --,® '~ ' ~#~ / ~,a L . . . . . ~ l ~I ' ! ~__~_8 --~i_ I -i 1 -~- ~ - 6 L I I ~ -l~' L . . . . . . . I ,T I I i 1 I ~)r----I . . . . I I ,'- %71 ,'%- L_ L__ _J I s I___ , e ', I Lit_ - - I I L r . . . . ' L_ , -->' ~ - - I S ®~',D ' fl ~ -~' L ,t_B_j (7) Auto choke (~ C.D.I.
AUTO O.O.E SYSTEM IE'Ecl "y'p ..... TROUBLESHOOTING IF THE A U T O CHOKE FAILS TO OPERATE. Procedure Check: 1. Lighting coil resistance 2. Auto choke unit resistance 3. Wiring connection (entire auto choke system) NOTE: • Remove the following parts before troubleshooting. 1. Battery box cover 2. Rear carrier 3. Tail cover 4. Right side cover • Use the special tools specified in the troubleshooting section. ~ 1 P°cket tester: YU-03112 I 1.
AUTO O.O.E S STEM IE'Ecl YP... 2. Auto choke unit resistance • Disconnect the auto choke unit coupler from the wireharness. • Connect the pocket tester ( ~ x l ) to the auto choke unit coupler lead. Tester (+) l e a d . B l a c k terminal (~ Tester (-) lead->Black terminal (~ ~_~ OUT OF SPECIFICATION Auto choke unit resistance: 8~12~ at 20°C (68°F) ~ MEETS I Replace the auto choke unit. SPECIFICATION 3. Wiring connection • Check the connection of the entire auto choke system.
STARTnNG FAnLURE/HARD ? ITRBLI I ISHTGI STARTnNGI TROUBLESHOOTING NOTE: The f o l l o w i n g t r o u b l e s h o o t i n g does not cover all the possible causes of trouble. It should be helpful, however, as a guide to t r o u b l e s h o o t i n g . Refer to the relative procedure in this manual for inspection, a d j u s t m e n t and replacement of parts.
S T A R T I N G FAILURE/HARD S T A R T I N G IGNITION SYSTEM • • • • • L ? Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap •Broken or shorted primary/secondary coil • Faulty spark plug lead • Broken body CD I unit system L Switches and wiring ISHTGI PROBABLE C A U S E Spark plug Ignition coil ITRBLI • Faulty CD I unit •Faulty source coil • Faulty pick-up coil • Faulty main switch •Broken or shorted wiring / L COMPRESSION SYSTEM PROBAB
PERFORMANCE ITRBLI ? POOR IDLE SPEED POOR IVIIDIUIVI A N D HIGH SPEED P E R F O R M A N C E ISHTGI POOR IDLE SPEED P E R F O R M A N C E P O O R IDLE S P E E D P E R F O R M A N C E PROBABLE CAUSE Carburetor • • • • m • L Auto choke Improperly returned starter plunger Clogged or loose pilot jet Clogged pilot air jet Improperly adjusted idle speed (Throttle stop screw) Improper throttle cable play Flooded carburetor •Starter plunger malfunction • Wax malfunction • Faulty thermister Air cleaner
POOR M I D I U M A N D HIGH SPEED P E R F O R M A N C E ITRBLI ISHTGI '? I FULTY A U T O M A T I C ( V - B E L T TYPE) PROBABLE CAUSE SCOOTER DOES NOT MOVE WHILE ENGINE IS O P E R A T I N G -- V-belt • W o r n , d a m a g e d or s l i p p e d V - b e l t -- Cam, slider • Worn, damaged -- Compression spring • Damaged -- Transmission • Damaged C L U T C H O U T FAILURE -- Clutch w e i g h t spring • Damaged -- Clutch shoe • Pealed l i n i n g -- Primary sheave • S e i z e d p r i m a r
OVER HEAT I POOR SPEED ITRBLI ISHTGI ? I OVER HEAT OVER HEAT PROBABLE C A U S E Ignition system L • I m p r o p e r plug gap • Improper spark plug heat range • Faulty C.D.I.
,MPROPER ITRBLI NG ISHTGI K,CK, ? IMPROPER KICKING SLIPPING PROBABLE C A U S E Kick axle assembly • • • • • • Transmission oil L H A R D KICKING Kick axle assembly Low tension of kick clip Worn kick axle Worn or damaged kick gear Damaged kick clip Kick clip coming off Damaged kick clip stopper • Improper quality (Low viscosity) •Deterioration PROBABLE C A U S E j~ • High tension of kick clip • Seized kick gear - - C y l i n d e r , piston and piston r i n g - - L •Damaged or seized cylinder
ITRBLI FAULTY BRAKE I S H T G I ? FAULTY BRAKE PROBABLE C A U S E POOR B R A K I N G EFFECT Drum brake m Disc b r a k e (Front) • • • • Worn brake shoe Worn or rusty brake drum Improperly adjusted brake free play Improper brake cam lever position • • • • • Improper brake shoe position Fatigue/Damaged return spring Oily or greasy brake shoe Oily or greasy brake drum Broken brake cable • • • • • • • • • • W o r n b r a k e pad W o r n b r a k e disc A i r in brake f l u i d Leaking brake fluid F a
ITRBLI INSTABLE HANDLING ISHTGI ? INSTABLE H A N D L I N G PROBABLE CAUSE INSTABLE HANDLING • Improperly installed or bent Handlebar -- Steering L Front forks L • Uneven tire pressures on both sides •Incorrect tire pressure • Unevenly worn tires L • Damaged bearing •Bent or loose wheel axle • Excessive wheel run-out L • Twisted • D a m a g e d head pipe • Improperly installed bearing race ~Wheels Frame • Bent or damaged m Engine bracket Rear shock absorber • Broken spring • B o n d e d fron
FAULTY SIGNAL AND LIGHTING SYSTEM ITRBLI ISHTGI ? I FAULTY SIGNAL AND LIGHTING SYSTEM PROBABLE C A U S E HEADLIGHT DARK I • • • • • • • PROBABLE C A U S E BULB BURNT OUT I L_ - - • I m p r o p e r bulb •Improperly grounded • Faulty main and/or light switch • Bulb life expires PROBABLE C A U S E FLASHER DOES NOT BLINK I - - I m p r o p e r bulb Too m a n y electric accessories Hard charging (Broken charging coil) Incorrect c o n n e c t i o n Improperly grounded Poor contacts (main or light swi
FAULTY SIGNAL AND LIGHTING SYSTEM FLASHER BLINKS SLOWER ITRBLI ISHTGI ? I PROBABLE C A U S E I • Faulty flasher relay • Insufficient battery capacity (nearly discharged) • Improper bulb • Faulty main and/or flasher switch FLASHER BLINKS QUICKER PROBABLE C A U S E I L HORN DOES NOT S O U N D • Improper bulb • F a u l t y flasher relay PROBABLE C A U S E I • • • • • • 8-10 Faulty battery Faulty fuse Faulty main and/or horn switch I m p r o p e r l y adjusted horn Faulty horn Broken w i r e h a r n
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Yamaha Motor Canada Ltd.
