YQ50 '97 SERVICE MANUAL 5BS-AE2
YQ50 SERVICE MANUAL © 1997 by MBK INDUSTRIE 2st Edition, November 1997 All rights reserved. Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited.
NOTICE This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology.
HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See «illustrated symbols). 1st title 1 This is a chapter with its symbol on the upper right of each page. 2nd title 2 This title appears on the upper of each page on the left of the chapter symbol. (For the chapter «Periodic inspection and adjustment» the 3rd title appears.) 3rd title 3 This is a final title.
W Q ILLUSTRATED SYMBOLS GEN INFO (REFER TO THE ILLUSTRATION) SPEC E Illustrated symbols Q to W are designed as thumb tabs to indicate the chapter’s number and content. R INSP ADJ ENG T Q General information W Specifications E Periodic inspection and adjustment R Engine T Carburetion Y Chassis U Electrical I Troubleshooting Y CARB CHAS U I TRBL SHTG ELEC O P Illustrated symbols O to e are used to identify the specifications appearing in the text. } { T.
INDEX GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC INSPECTION AND ADJUSTMENT INSP ADJ 3 ENGINE OVERHAUL ENG 4 COOLING SYSTEM ENG 5 CARBURETION CARB 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TRBL SHTG 9 TROUBLESHOOTING
GEN INFO 1
GEN INFO CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................... 1-1 ENGINE SERIAL NUMBER ..................................................................... 1-1 IMPORTANT INFORMATION ....................................................................... 1-2 ALL REPLACEMENT PARTS .................................................................
SCOOTER IDENTIFICATION GEN INFO GENERAL INFORMATION SCOOTER IDENTIFICATION 햲 VEHICLE IDENTIFICATION NUMBER The vehicle identification number Q is stamped into the frame. NOTE: The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your state. ENGINE SERIAL NUMBER The engine serial number Q is stamped into the crankcase.
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1.Use only genuine parts for all replacements. Use oil and/or grease recommended by MBK/ YAMAHA for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality. GASKETS, OIL SEALS, AND O-RINGS 1.All gaskets, seals and O-rings should be replaced when an engine is overhauled. All gaskets surfaces, oil seal lips and O-rings must be cleaned. 2.
IMPORTANT INFORMATION GEN INFO CIRCLIPS 1.All circlips should be inspected carefully before reassembly. Always replace piston pin clips once they have been removed. Replace bent circlips. When installing a circlip Q make sure that the sharp edge W is positioned opposite to the thrust E it receives. See the sectional view.
SPECIAL TOOLS GEN INFO EB102000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool N° 90890-01135 Tool name/usage Crankcase separating tool This tool is used to separate the crankcase and remove the crankshaft.
SPECIAL TOOLS Tool N° 9079Q-02218 Tool name/usage Ring nut wrench. This tool is used to loosen and tighten the steering ring nut. 90890-01326 90890-1294 T-handle Damper rod holder These tools are used for holding the damper rod holder when removing or installing the damper rod holder. 90890-01184 90890-01186 Fork seal driver weight. Fork seal driver attachment (ø27) These tools are used wheninstalling the fork seals.
SPEC 2
SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ....................................................................... 2-1 MAINTENANCE SPECIFICATIONS .............................................................. 2-4 ENGINE ................................................................................................... 2-4 CHASSIS ................................................................................................. 2-6 ELECTRICAL ........................................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model YQ50 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance 1.743 mm 690 mm 1.170mm 828 mm 1.256 mm 185 mm Basic weight: With oil and full fuel tank 97 kg Minimum turning radius : 1.
GENERAL SPECIFICATIONS Model YQ50 Carburetor: Type/Manufacturer PHBN12HS / DELL'ORTO Spark plug: Type/Manufacturer Gap BR8HS/NGK 0.5 ~ 0.7 mm Clutch type: Dry, centrifugal automatic Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission Operation Helical gear 52/13 (4.000) Spur gear 43/14 (3.
GENERAL SPECIFICATIONS Model YQ50 Electrical: Ignition system Charging system Battery type/model Battery capacity CDI Flywheel magneto GM4-3B, YB4L-B, FB4L-B 12V 4AH Headlight type: Bulb Bulb wattage / quantity: Headlight Auxiliary light Taillight/brake light Flasher light Front Rear Meter light Warning lights wattage / quantity: “OIL” “HIGH BEAM” “TURN” “Cooling warning light“ 12V 35W/35W x 1 12V 5W x 1 12V 5W/21W x 1 12V 21W x 2 12V 10W x 2 12V 1.2W x 3 12V 1.2W x 1 12V 1.2W x 1 12V 1.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model YQ50 Cylinder head: Warp limit 0.02 mm Lines indicate straight edge measurements. * Cylinder: Bore size Taper limit 39.993 ~ 40.012 mm <40.1 mm> 0.05 mm Piston: Piston size Measuring point 39.957 ~ 39.977 mm 5 mm * Piston clearance Piston pin bore size 0.029 ~ 0.042 mm <0.1 mm> 10.004 ~ 10.019 mm Piston pin: Outside diameter 9.996 ~ 10.
MAINTENANCE SPECIFICATIONS Model YQ50 Automatic centrifugal clutch: Clutch shoe thickness Clutch shoe spring free length Clutch housing inside diameter Clutch-in revolution Clutch-stall revolution 2.0 mm <1.0 mm> 29.9 mm 107.0 mm 107.4 mm 3.950 ~ 4.450 r.p.m. 6.900 ~ 7.700 r.p.m. V-belt: Width 16.5 mm <15.7 mm> Transmission: Main axle runout limit Drive axle runout limit 0.08 mm 0.08 mm Kick starter: Type Kick clip tension Ratchet type 0.15 ~ 0.
MAINTENANCE SPECIFICATIONS CHASSIS Model YQ50 Steering system: Steering bearing type No/Size of steel balls: Ball bearing Upper Lower Front suspension: Front fork travel Spring rate (K1) Stroke (K1) Optional spring Rear suspension: Shock absorber travel Spring free length Spring fitting length Spring rate Stroke 15 pcs (4.75 mm) 15 pcs (4.75 mm) 80 mm 5.7 N/mm 0 ~ 80 mm No (K1) (K2) (K1) (K2) Optional spring 60 mm 234 mm 199.
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Model YQ50 Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) 14° at 5.000 r/min CDI: Pickup coil resistance (color) Source coil resistance (color) 400 ~ 600 Ω at 20°C (68°F) (White/Red-Black) 640 ~ 960 Ω at 20°C (68°F) (Black/Red-Black) Ignition coil: Minimum spark length Primary coil resistance Secondary coil resistance 6 mm 0.56 ~ 0.84 Ω at 20°C (68°F) 5.68 ~ 8.
SPEC CABLE ROUTING A B C D E F G H I J K L CABLE ROUTING Q W E R T Y U I O P { } q w Handlebar end grip Right handlebar switch Left handlebar switch Handlebar Flasher harness Right handlebar grip Wireharness Wireharness cord Starter (choke) cable Front handlebar cover Speedometer case Speedometer cable Front brake hose Rear brake hose A 햲 C 햷 햳 Push the end grip againt the handlebar and tighten to 0.6 ~ 0.8 m.kg. Tighten the front screw first. Apply the left switch handle against the handlebar.
SPEC CABLE ROUTING A B C D E CABLE ROUTING Q W E R T Y U I O P { Fuel sender Fuel tank Fuel overflow pipe Fuel cock Pipe bracket Frame Trunk Carburetor drain hose Fuel pipe Suction pipe Bands F G H I J Insert the fuel sender completly. Turn the fuel sender so that the cable points toward. Pass the fuel lines above the rear brake hose. Pass the fuel overflow pipe in the trunk slot. Push the fuel cock (without turning it) completly in the tank and screw the collar.
SPEC CABLE ROUTING Q W E R T Y U I O P { } q w e r A Set the seat lock adjuster so that there is a gap betwween 8 ~ 9 mm at the seat lock aperture. B Install the starter relay on the footrest board. C Group the connections here. D Turn the connectors towards. E Puch the wiring inside. F Pass the wiring harness through the footrest board. G Turn the ground lead one turn around the starter motor leads. H The water temperature sender lead must go straight to the wiring harness.
CABLE ROUTING Q W E R T Y U I P Wiring harness Resistor Horn Front brake hose Speedometer cable Radiator Water tank Clamps Frame A B C D Install the wiring harness in the middle of the frame. Set the resistor at 45°0/+30’ on the frame bracket. Clip the front brake hose on the front fork bracket. Install the 8 clamps just beside the marks at the end side of the hoses.
CABLE ROUTING Q W E R T Y U I O P Rear brake hose Seat lock cable Wire harness Throttle cable Starter (choke) cable Speedometer cable Frame Oil hose (tank/oil pump) Oil hose (oil pump/carburetor) Water hoses SPEC A Install the rear brake hose in the clip. B Install the oil delivery hose (from oil pump to carburator) under the water hose. C Pass the rear brake hose under the frame reinforcement tube. D Align the mark on the water hose in front of the mark in the water pump housing.
CHK ADJ 3
CHK ADJ CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ............................................................................................ 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............................ 3-1 COVERS ........................................................................................................ 3-3 REMOVAL ................................................................................................ 3-3 HANDLEBAR COVERS ..............................
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS INSP ADJ PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS INSP ADJ NOTE: Brake fluid replacement: 1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3.Replace the brake hoses every four years, or when cracked or damaged.
INSP ADJ COVERS REMOVAL T.R 8 Nm (0,8 m.kg) T.R 2 3 Nm (0,3 m.kg) 1 5 3 4 4 T.R 8 Nm (0,8 m.kg) T.R Mark 1 2 3 4 5 Name of the intervention/ of the part Qty Seat Fuel tank cap Rear seat screws and strap Side cover (left and right) Rear seat 2 Nm (0,2 m.kg) Observation 1 1 2 2 1 CAUTION: When removing the cover, be careful not to damage the mounting clips.
INSP ADJ COVERS REMOVAL T.R T.R 3 Nm (0,3 m.kg) 8 Nm (0,8 m.kg) 4 3 5 T.R 2,5 Nm (0,25 m.kg) 2 3 1 T.R Mark 1 2 3 4 5 Name of the intervention/ of the part Qty Glove compartment cover Oil cover Side cover (left and right) Box Rear mudguard 6 Nm (0,6 m.kg) Observation 1 1 2 1 1 CAUTION: When removing the cover, be careful not to damage the mounting clips.
INSP ADJ COVERS REMOVAL 6,5 Nm (0,65 m.kg) T.R 13 Nm (1,3 m.kg) T.R 1 4 2 T.R T.R 3 Nm (0,3 m.kg) 6,5 Nm (0,65 m.kg) 3 2 Nm (0,2 m.kg) T.R Mark 1 2 3 4 Name of the intervention/ of the part Qty Frame reinforcement Fuel tank Rear lower cover Rear light Observation 1 1 1 1 CAUTION: When removing the cover, be careful not to damage the mounting clips.
COVERS INSP ADJ REMOVAL T.R 3 Nm (0,3 m.kg) T.R 3 Nm (0,3 m.kg) 1 2 T.R 2 2 Nm (0,2 m.kg) 4 T.R 3 Nm (0,3 m.kg) 3 T.R Mark 1 2 3 4 3 Nm (0,3 m.kg) Name of the intervention/ of the part Qty Front cover and headlight Front inner cover Front fender Front inner panel Observation 1 1 1 1 CAUTION: When removing the cover, be careful not to damage the mounting clips.
INSP ADJ COVERS HANDLEBAR COVERS T.R 3 Nm (0,3 m.kg) T.R 3 Nm (0,3m.kg) 3 2 1 4 Mark 1 2 3 4 T.R 3 Nm (0,3 m.kg) Name of the intervention/ of the part Qty Handlebar cover (front) Handlebar cover (rear) Meter Flasher light Observation 1 1 1 1 CAUTION: When removing the cover, be careful not to damage the mounting clips.
INSP ADJ COVERS REMOVAL T.R 3 Nm (0,3 m.kg) 1 T.R 3 Nm (0,3 m.kg) 2 Mark 1 2 Name of the intervention/ of the part Qty Battery cover Lower cover Observation 1 1 CAUTION: When removing the cover, be careful not to damage the mounting clips.
INSP ADJ COVERS REMOVAL T.R 4 Nm (0,4 m.kg) 1 T.R 4 Nm (0,4 m.kg) 2 Mark Name of the intervention/ of the part Qty 1 Inner panel 1 2 Footrest board 1 Observation Main switch ring. Turn the ring anticlockwise to remove it CAUTION: When removing the cover, be careful not to damage the mounting clips.
COVERS INSP ADJ NOTE: Correct routing of cables and wires is essential for a safe operation of this scooter. Refer to the section “CABLE ROUTING” in Chapter 2. NOTE: Be careful not to pinch any wires with the covers. NOTE: When installing the covers, be careful not to damage the mounting clips.
ENGINE IDLE SPEED ADJUSTMENT INSP ADJ ENGINE ENGINE IDLE SPEED ADJUSTMENT 1. Tighten : • Pilot air screw Turn the pilot air screw in until lightly seated. 2. Loosen : • Pilot air screw Back out from the lightly seated position. Pilot air screw position : DELL'ORTO 1-3/8 turns out ± 1/8 (F)(B)(P)(I)(E) 1-3/4 turns out ± 1/8 (D) 1-5/8 turns out ± 1/8 (NL) 2 ± 1/8 turns out (CHE) 3. Start the engine and let it warm up for several minutes.
ENGINE IDLE SPEED ADJUSTMENT/ THROTTLE CABLE FREE PLAY ADJUSTEMENT INSP ADJ 6. Adjust : • Engine idle speed ******************************************************** Adjustment steps : • Turn the throttle stop screw in or out until specified idling speed is obtained. Turning left Idling speed increased. Turning right Idling speed decreased. ******************************************************* THROTTLE CABLE FREE PLAY ADJUSTMENT 1 Check : • Throttle cable free play Out of specification ➞ Adjust.
SPARK PLUG INSPECTION INSP ADJ SPARK PLUG INSPECTION 1. Remove : • Spark plug 2. Inspect : • Electrode Q Wear/Damage ➞ Replace. • Insulator W Abnormal color ➞ Replace. Standard spark plug : BR8HS (NGK) 3. Measure : • Plug gap @ Out of specification ➞ Adjust. Use a wire gauge or feeler gauge. @ Spark plug gap @ : 0,5 ~ 0,7 mm (0.019 ~ 0.027 in) 4. Tighten : • Spark plug Before installing the spark plug, clean the gasket surface and plug surface. NOTE: First tighten by hand, then torque to specification.
AUTOLUBE PUMP AIR BLEEDING INSP ADJ AUTOLUBE PUMP AIR BLEEDING 1. Bleed : • Pump housing and oil hose ******************************************************* Pump bleeding steps : ● Place a rag under the pump. ● Remove the bleed screw . ● Let oil run until there are no more air bubbles in it. ● When there are no more bubbles, tighten the bleed screw. NOTE: Check the condition of the bleed screw gasket. If it is damaged, replace it with a new one. ● Start the engine.
ENGINE OIL LEVEL INSPECTION INSP ADJ ENGINE OIL LEVEL INSPECTION 1. Inspect : • Oil level Oil level low ➞ Add oil to proper level as follows. Q “OIL” indicator light OIL LEVEL AND GAUGE CHECK Turn main switch to " " * "OIL" indicator doesn't light. "OIL" indicator light. Turn main switch to "ON". "OIL" indicator goes Inspect Faulty electrical circuit, Light bulb etc. Engine oil level and electric circuit are OK. "OIL" indicator stays on. Add oil. "OIL" indicator stays on.
TRANSMISSION OIL REPLACEMENT INSP ADJ TRANSMISSION OIL REPLACEMENT 1. Remove : • Drain plug Q • Oil filler plug W Drain the transmission oil. 2. Check : • Gasket (drain plug) • O-ring (oil filler plug) Damaged ➞ Replace. 3. Install : • Gasket • Drain plug T. R Drain plug : 18 Nm (1.8 m.kg) 4. Fill : • Transmission case Transmission oil : SAE 10W30 type SE motor oil. Capacity : Periodic replacement 0.11 L (0.10 Imp qt ; 0.12 US qt) Total amount 0.13 L (0.11 Imp qt ; 0.
COOLANT LEVEL INSPECTION/ COOLANT REPLACEMENT INSP ADJ COOLANT LEVEL INSPECTION NOTE: Install the scooter straight up when inspecting the coolant level. 1.Place the scooter on a level surface. NOTE: Place the scooter on its centerstand. 2.Remove: • Front cover Refer to the section "COVER" 3.Inspect: • Coolant level Coolant level should be between maximum and minimum marks. Coolant level low → Add recommanded coolant to proper level.
COOLANT REPLACEMENT INSP ADJ toward the detent. This allows any residual pressure to escape. When the hissing soound has stopped, press down on the cap while turning counterclockwise and remove it. NOTE: Position the scooter straight up when replacing the coolant. 2.Place the scooter on a level surface. NOTE: Place the scooter on its centerstand if. 3.Remove: • Water pump fixing bold Drain the radiator and engine of its coolant. 4.Install: • Gasket • Water pump fixing bold. T.
AIR CLEANER ELEMENT CLEANING INSP ADJ AIR CLEANER ELEMENT CLEANING 1. Remove : • Air cleaner case cover Q 2. Remove : • Air filter element CAUTION: Never operate the engine with the air cleaner element removed. Unfiltered air will cause rapid wear of engine parts and possible engine damage. 3.Inspect : • Element Q Damage ➞ replace. 4.Clean : • Air filter element ******************************************************* Cleaning steps : • Wash the element gently but thoroughly in solvent.
EXHAUST PIPE ASSEMBLY AND ADJUSTMENT INSP ADJ MUFFLER Q Exhaust pipe W Cylinder E Crankcase R Bolt T Bolt Y Gasket 4.5 Nm (0.45 m.kg) 29 Nm (2.9 m.kg) 7 Nm (0.7 m.
FRONT BRAKE LEVER FREE PLAY ADJUSTEMENT/ REAR BRAKE LEVER FREE PLAY ADJUSTEMENT/ BRAKE PAD INSPECTION INSP ADJ CHASSIS @ FRONT BRAKE LEVER FREE PLAY ADJUSTMENT 1. Check : • Front brake lever free play @ Out of specification ➞ Adjust. Free play : 10 ~ 20 mm (0.40 ~ 0.80 in) WARNING A soft or spongy 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 scooter is operated.
BRAKE FLUID LEVEL INSPECTION INSP ADJ BRAKE FLUID LEVEL INSPECTION NOTE: Position the scooter straight up when inspecting the fluid level, and make sure be turning the handlebar that the top of the master cylinder is horizontal. 1. Inspect : • Brake fluid level Brake fluid level is under “LOWER” level line Q ➞ Fill to proper level. Recommended brake fluid : DOT # 3 or DOT # 4 CAUTION: The brake fluid may corrode painted surfaces or plastic parts. Always clean up spilled fluid immediately.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ STEERING HEAD ADJUSTEMENT INSP ADJ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 346002 1. Bleed : • Brake fluid. ******************************************************* Air bleeding steps : a. Add proper brake fluid into the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect a clear plastic tube Q tightly to the caliper bleed screw. d. Place the other end of the tube into a container. e.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM/ STEERING HEAD ADJUSTEMENT INSP ADJ Securing nut : 23 Nm (2.3 m.kg) NOTE : Install the torque wrench on the ring nut wrench so that it makes a 90° angle with it. ● 354001 Move the handlebar up and down and from front to rear. If steering play is too important, tighten the nut to the specified torque. Stearing head nut : 60 Nm (6.0 m.kg) TIRE INSPECTION 1. Measure : • Air pressure Out of specification ➞ Adjust.
TIRE INSPECTION/WHEEL INSPECTION/ CABLE INSPECTION AND LUBRICATION INSP ADJ 2 Inspect : • Tire surface Wear/Damage/Cracks/Road hazards ➞ Replace. • Aluminum wheels Damage/Bends ➞ Replace. Never attempt even small repairs to the wheel. WARNING Ride conservatively after installing a tire to allow it to seat itself properly on the rim. • If the tire is removed with a tire lever, use a suitable protection to prevent damaging the rim. • When installing the tire, make sure the arrow points to the front. 3.
CABLE INSPECTION AND LUBRICATION/ FRONT FORK INSPECTION/ REAR SHOCK ABSORBER INSP ADJ 2. Check : • Cable movement Stickiness ➞ Lubricate. Recommended lubricant : Engine oil SAE 10W30 NOTE: Hold the cable end up and pour a few drops of oil into the sheath. 3. Lubricate the throttle cable end and the cable guide notch on the throttle grip with grease Q. Recommanded lubricant : Lithium soap based grease LEVER LUBRICATION 1.
BATTERY INSPECTION INSP ADJ ELECTRICAL UPPER LOWER + BATTERY INSPECTION 1. Inspect : • Battery fluid level Fluid level low ➞ Add to proper level. Fluid level should be between upper and lower level marks. Q Upper level W Lower level CAUTION: Refill with distilled water only. Tap water contains minerals which are harmful to a battery. 2. Inspect : • Breather hose Obstruction ➞ Remove. 3.
BATTERY INSPECTION/ FUSE INSPECTION INSP ADJ CAUTION: Always charge a new battery before using it to ensure maximum performance. WARNING Battery electrolyte is dangerous. It contains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures : • Avoid bodily contact with electrolyte as it can cause severe burns and permanent eye injury. • Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL) : • SKIN – Flush with water.
FUSE INSPECTION/ HEADLIGHT BEAM ADJUSTEMENT HEADLIGHT LENS REPLACEMENT INSP ADJ ****************************************************** Fuse replacement steps : ● Turn off the ignition. ● Install a new fuse of the right amperage. ● Turn on the switches to verify the operation of the electric circuit. ● If the fuse immediately blows again, check the electric circuit. ******************************************************* WARNING Never use a fuse with a rating higher than specified.
HEADLIGHT LENS REPLACEMENT HEADLIGHT BULB REPLACEMENT INSP ADJ HEADLIGHT LENS REPLACEMENT 1. Remove : • Front cover Q 2. Remove : • Headlight lens (Pull out the pins) 3. Remove : • Gasket 4. Install : Reverse the “REMOVAL” procedure. HEADLIGHT BULB REPLACEMENT 1. Remove : • Front cover 2. Remove : • Headlight bulb socket Q (Turn one quart of a turn). 3. Remove : • Headlight bulb 4. Install : Reverse the “REMOVAL” procedure.
ENG 4
ENG CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL ....................................................................................... 4-1 COVER REMOVAL .................................................................................. 4-1 COOLING SYSTEM ................................................................................. 4-1 CARBURETOR ........................................................................................ 4-1 CABLES, LEADS AND HOSES ............................................
ENGINE REMOVAL ENG ENGINE OVERHAUL ENGINE REMOVAL COVER REMOVAL 1. Remove : • Covers See “CHAPTER 3 - SIDE COVERS AND FOOTREST BOARD - HANDLEBAR COVER”. COOLING SYSTEM 1. Drain: • Coolant CARBURETOR 1. Remove : • Air cleaner case assembly Q 2. Disconnect : • Carburetor cover • Hoses • Carburetor top • Coolant hose on the cylinder head • Thermostat on the cylinder head 3.Remove : • Carburetor 4.
ENGINE REMOVAL ENG 5. Loosen : • Rear wheel fixing bolts 6. Remove: • Rear wheel 7.Loosen: • Rear wheel axle nut 8.Remove: • Rear caliper • Rear wheel collar assembly CABLES, LEADS AND HOSES 1. Remove : • Oil hose on the oil pump side NOTE: Plug the hose to prevent oil spillage. 2.
ENGINE REMOVAL ENG ENGINE REMOVAL 1. Place a suitable stand under the frame. 2. Remove : • Rear shock absorber bolt (lower) Q • Engine mounting bolt W 3. Remove : • Engine NOTE: Lift up the frame and remove the engine. 4. Place the frame on a suitable stand.
ENGINE DISASSEMBLY ENG ENGINE DISASSEMBLY REAR WHEEL 1. Remove : • Rear wheel Refer to chapter 7 "REAR WHEEL" CENTERSTAND 1. Remove : • Spring • Clip • Plate washer • Axle • Center stand CYLINDER HEAD AND CYLINDER 1. Remove : • Cylinder head • Cylinder head gasket NOTE: • Before loosening the cylinder head nuts, loosen the spark plug. • Loosen the cylinder head nuts crosswise 1/4 of a turn each before removing them. 2. Remove : • Cylinder • Cylinder gasket PISTON PIN AND PISTON 1.
ENGINE DISASSEMBLY ENG 2. Remove : • Piston pin Q • Piston W • Piston pin bearing E CAUTION: Do not use a hammer to drive out the piston pin. 307002 KICKSTARTER 1. Remove : • Kick crank • Transmission cover Q (left) 313001 2. Remove : • Kick pinion gear Q NOTE: To remove the kick pinion gear, push down the kick crank. 3 Unhook : • Kick return spring W 317001 4.
ENGINE DISASSEMBLY ENG PRIMARY SHEAVE 1. Remove : • Oil pump housing 2. Remove : • Nut (primary sheave) NOTE: To loosen the primary sheave nut hold the CDI magneto with a flywheel holder W. Flywheel holder : 90890-01235 3. Remove : • Washer Q • Ratchet W • Special washer E • Fixed primary sheave R • Washer T • V-belt 319001 4. Remove : • Spacer Q • Primary sliding sheave W 319002 SECONDARY SHEAVE 1.
ENGINE DISASSEMBLY ENG 2. Remove : • Clutch housing Q • Secondary sheave W • Crankcase cover gasket • Dowel pins 3. Attach : • Sheave holder Q • Nut wrench (41 mm) 319004 Sheave holder : 90890-01701 4. Loosen : • Clutch securing nut WARNING Loosen the nut but do not remove it yet. 319031 5. Attach : • Clutch spring holder Q NOTE: Compress the secondary sheave using the clutch spring holder Q. Clutch spring holder : 90890-01337 311001 6. Remove : • Clutch securing nut 7.
ENGINE DISASSEMBLY ENG 2. Remove : • Spacer Q • Bearing W • Washer E • Starter motor 317004 TRANSMISSION 1. Remove : • Transmission case Q • Gasket • Dowel pins 319036 2. Remove : • Main shaft Q • Drive shaft W • Plate washer E • Conical spring washer R 319037 3. Remove : • Oil seal Q • Secondary sheave axle W 319032 CDI MAGNETO 1. Remove : • Nut Q (rotor) • Plate washer NOTE: Hold the rotor using a flywheel holder W to loosen the nut.
ENGINE DISASSEMBLY ENG 2. Remove : • Rotor Q • Woodruff key Use the flywheel puller W Flywheel puller : 90890-01189 • Stator assembly • Gasket 321005 AUTOLUBE OIL PUMP 1. Remove : • Autolube oil pump Q 314001 2. Remove : • Circlips Q • Pump drive gear W • Pin E • Circlip R 314002 CRANKCASE AND CRANKSHAFT 1. Remove : • Oil seal stopper • Screws (crankcase) NOTE: Loosen each screw one quart of a turn before beginning to remove them. 2.
ENGINE DISASSEMBLY ENG loosen one screw as much as required to level the tool body. 3. Remove : • Crankcase (right) As pressure is applied, keep tapping carefully on the engine mounting bosses. CAUTION: Use a soft hammer to tap on the case. Tap only on reinforced spots of the case. Never tap on the gasket mating surfaces. Work slowly and carefully. Make sure the cases separate evenly. If one end “hangs up” take the pressure off the push screw, realign the cases and the tool and start again.
INSPECTION AND REPAIR ENG INSPECTION AND REPAIR CYLINDER HEAD 1. Eliminate : • Carbon deposits Use a rounded scraper Q NOTE: Take care to avoid damaging the spark plug threads. Do not use a sharp instrument. Avoid scratching the aluminum. 301002 2. Inspect : • Cylinder head warpage Out of specification ➞ Re-surface. ******************************************************* Warpage measurement and re-surfacement steps : ● Attach a straight edge Q and a thickness gauge W to the cylinder head.
ENG INSPECTION AND REPAIR 5. Inspect : • Piston wall Wear/Scratches/Damage ➞ Replace. 307004 6. Measure : • Piston to cylinder clearance ******************************************************** Piston to cylinder clearance measurement steps : First step : ● Measure the cylinder bore “C” with a cylinder bore gauge. D1 D2 D3 D5 NOTE: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft. Then, calculate the average of the measurements.
INSPECTION AND REPAIR ENG ● If out of specification, replace piston and piston rings as a set. 3rd step : ● Calculate the piston-to-cylinder clearance with following formula: Piston-to cylinder clearance = Cylinder Bore “C” – Piston Skirt Diameter “P” ● If out of specification, replace cylinder, piston and piston rings as a set. Piston-to-cylinder clearance : 0.029 ~ 0.042 mm (0.0011 ~ 0.0016 in) Wear limit : 0.1 mm (0.004 in) ******************************************************* PISTON RINGS 1.
INSPECTION AND REPAIR ENG Standard Limit Top ring 0.15 ~ 0.30 mm (0.005 ~ 0.011 in) 0.70 mm (0.028 in) 2nd ring 0.15 ~ 0.30 mm (0.005 ~ 0.011 in) 0.70 mm (0.028 in) @ Measuring Point 20 mm (0.8 in) PISTON PIN AND PISTON PIN BEARING 1. Inspect : • Piston pin Blue discoloration/Groove ➞ Replace, then inspect lubrication system. 2. Measure : • Outside diameter (piston pin) Out of specification ➞ Replace. a Outside diameter (piston pin) : 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in) 307009 3.
INSPECTION AND REPAIR ENG KICK STARTER 1. Inspect : • Kick gear teeth Q • Kick pinion gear teeth W Burrs/Chips/Roughness/Wear ➞ Replace. 317005 2. Inspect : • Mating dogs (kick pinion gear and one-way clutch) Rounded edges/Damage ➞ Replace. 317006 3. Measure : • Clip tension (kick pinion gear) Q Out of specification ➞ Replace. Use a spring balance W. Standard tension : 150 ~ 250 g (5.3 ~ 8.8 oz.) 317007 TRANSMISSION 1.
INSPECTION AND REPAIR ENG AUTOLUBE PUMP Wear or an internal malfunction may cause the pump output to vary from the factory setting. This situation is, however, extremely rare. If improper output is suspected, inspect the following: 1. Inspect : • Delivery line Obstructions ➞ Blow out. • O-ring Wear/Damage ➞ Replace. 2. Inspect : • Autolube pump drive gear teeth Q • Autolube pump driven gear teeth W Pitting/Wear/Damage ➞ Replace. 314003 CRANKSHAFT 1.
INSPECTION AND REPAIR ENG 2. Check : • Free movement Insert the collar W into the primary sliding sheave Q, and check for free movement. Stick or excessive play ➞ Replace the sheave and/or collar. 319007 3. Measure : • Outside diameter Q (weight) Out of specification ➞ Replace. Outside diameter (weight) : 15.0 mm (0.59 in) : 14.5 mm (0.57 in)> 319008 SECONDARY SHEAVE 1. Inspect : • Secondary fixed sheave Q • Secondary sliding sheave W Scratch/Crack/Damage ➞ Replace as a set.
INSPECTION AND REPAIR ENG 4. Inspect : • Clutch housing inner surface Oil/Scratches ➞ Remove. Oil Use a rag soaked in lacquer thinner or solvent. Scratches Use an emery cloth (lightly and evenly polishing). 319030 5. Measure : • Clutch housing inside diameter @ Out of specification ➞ Replace. Clutch housing inside diameter : 107.0 mm (4.21 in) : 107.4 mm (4.22 in) 319012 6. Inspect : • Clutch shoes Glazed parts ➞ Sand with coarse sandpaper.
INSPECTION AND REPAIR ENG 2. Measure : • V-belt width @ Out of specification ➞ Replace. V-Belt width : 16,5 mm (0.65 in) : 15,7 mm (0.62 in) 312001 STARTER CLUTCH AND GEARS 1. Inspect : • Starter clutch Push the dowel pin in arrow direction. Unsmooth operation ➞ Replace starter clutch assembly. 317008 2. Inspect : • Starter wheel gear teeth Q • Idle gear teeth W Burrs/Chips/Roughness/Wear ➞ Replace. • Bearing E (starter wheel gear) Pitting/Damage ➞ Replace.
ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT AND CRANKCASE Q Oil seal I Crankshaft pin W Oil seal holder O Connecting rod E Crankcase (right) P Crankshaft (left) R Dowel pin { Bearing T Bearing } Engine mount shaft Y Crankshaft (right) q Crankcase (left) U Bearing w Oil seal A CRANKSHAFT: C 8 Nm (0.8 m.kg) A: C: D: E: 13 Nm (1.3 m.kg) 37,90 ~ 37,95 mm 0,03 mm 0,2 ~ 0,5 mm 0,004 ~ 0,017 mm C E D A LS E E E LS 17,5 Nm (1.75 m.
ENGINE ASSEMBLY AND ADJUSTMENT ENG CRANKSHAFT AND CRANKCASE CAUTION: To protect the crankshaft against scratches and to facilitate the engine assembly and installation, apply grease to oil seal lips, and engine oil to bearings. 1. Attach : • Crankshaft installation tool Q, W, E, R Crankshaft installation tool : Q : 90890-01274 W : 90890-01275 E : 90890-01277 R : 90890-01411 308002 2.
ENGINE ASSEMBLY AND ADJUSTMENT ENG 5. Attach : • Crankshaft installation tool Q, W, E, R Crankshaft installation tool : Q : 90890-01274 W : 90890-01275 E : 90890-01277 R : 90890-01411 313007 NOTE: Hold the connecting rod at top dead center with one hand while tightening the nut of the installation tool with the other. Tighten the installation tool until the crankcase halves close with one another. 6. Install : • Right crankcase 7.
ENGINE ASSEMBLY AND ADJUSTMENT ENG AUTOLUBE PUMP AND CDI MAGNETO O Gasket Q Nut P Oil hose W Plain washer { Oil delivery hose E Rotor assembly } Clip R Lighting coil q Autolube pump T Charge coil w O-ring Y Pick up coil e Circlip U Stator assembly r Oil pump drive gear I Oil seal 37.5 Nm (3.75 m.kg) LS 8.5 Nm (0.85 m.kg) LS 4 Nm (0.4 m.
ENGINE ASSEMBLY AND ADJUSTMENT ENG AUTOLUBE PUMP 1. Install : • Circlip Q • Pin W • Pump drive gear E • Circlip R 314004 2. Apply : • Lithium soap base grease (to O-ring ) 3. Install : • Autolube pump T. R 314005 Screw (autolube pump) : 4 Nm (0.4 m.kg) 4. Apply : • Lithium soap base grease (to autolube pump gear) Lithium soap base grease : 15 cc (0.92 cu.in) 314006 CDI MAGNETO 1. Install : • Gasket 2. Apply : • Lithium soap base grease (to oil seal Q) 321001 3.
ENGINE ASSEMBLY AND ADJUSTMENT 5. Install : • Woodruff key Q • Magneto rotor W • Plain washer E • Nut R 321002 ENG NOTE: When installing the magneto rotor, make sure the woodruff key is properly seated in the key way of the crankshaft. Apply a light coating of lithium soap base grease to the tapered portion of the crankshaft end. 6. Tighten : • Nut Q (magneto rotor) Use the flywheel holding tool W. Flywheel holding tool : 90890-01235 T.
ENGINE ASSEMBLY AND ADJUSTMENT TRANSMISSION Q Circlip W Bearing E Oil seal R Drive axle T Bearing Y Main axle U Conical spring washer I Plain washer ENG O Secondary sheave axle P Bearing { Dowel pin } Gasket q Transmission case cover w Circlips e Oil seal E LS E G G LT LS 10 Nm (1.0 m.
ENGINE ASSEMBLY AND ADJUSTMENT ENG TRANSMISSION 1. Apply : • 10W30 Type SE Motor oil (to transmission case cover bearing) 2. Install : • Bearing Q 3. Install : • Oil seal W • Secondary sheave axle E NOTE: Apply lithium soap base grease onto the oil seal lips. 319014 4. Check : • Secondary sheave axle operation Unsmooth operation ➞ Repair. 5. Apply : • 10W30 type SE Motor oil (to main axle bearing and drive axle bearing) 6.
ENGINE ASSEMBLY AND ADJUSTMENT STARTER SYSTEM Q Collar W Starter wheel gear E Bearing R Starter clutch T Plate ENG Y Shaft U Washer I Idle gear O O-Ring P Starter motor LS M 8 Nm (0.8 m.kg) E 13 Nm (1.3 m.
ENGINE ASSEMBLY AND ADJUSTEMENT ENG STARTER SYSTEM 1. Install : • Collar Q • Washer W • Bearing E • Starter wheel gear R • Starter clutch T 317010 NOTE: • Apply lithium soap base grease to the bearing. • Apply molybdenum disulfide oil to the shaft (starter clutch). 317011 2. Install : • Plain washer Q • Idle gear W • Plain washer E • Plate R (idle gear) T. R Screw (idle gear plate) : 8 Nm (0.8 m.kg) 317012 NOTE: Apply engine oil to the idle gear W. 3. Install : • Starter motor Q T.
ENGINE ASSEMBLY AND ADJUSTMENT PRIMARY AND SECONDARY SHEAVE Q Nut } Secondary fixed sheave W Clutch housing q Conical washer E Clutch w One-way clutch R Clutch spring e Special washer T Spring r Primary fixed sheave Y Spring seat t Washer U Oil seal y Spacer I O-Ring u Primary sliding sheave O Secondary sliding sheave i Clutch weights P V-Belt o Slider { Guide pin p Came ENG *Apply BEL-RAY Assembly Lube © 50 Nm (5.0 m.kg) LS 30 Nm (3.0 m.
ENG ENGINE ASSEMBLY AND ADJUSTMENT KICK STARTER Q Kick shaft W Return spring E Collar R Gasket T Transmission case Y Washer U Circlips I Kick crank O Kick clip P Rachet G 12 Nm (1.2 m.kg) LS 150 ~ 250 g 10 Nm (1.0 m.
ENGINE ASSEMBLY AND ADJUSTEMENT ENG SECONDARY SHEAVE When assembling the secondary sheave, reverse the disassembly procedure. Note the following points. 1. Apply : • BEL-RAY Assembly Lube ® (to the sliding parts of the sheave) 319018 2. Install : • Sliding sheave Q NOTE: Wind adhesive tape around the end of the sheave to avoid turning over the oil seal lips when installing the sheave. 319019 3. Install : • Pin Q 4.
ENGINE ASSEMBLY AND ADJUSTEMENT ENG 8. Install : • Dowel pin • Gasket • Secondary sheave assembly Q • Clutch housing W 319022 9. Tighten : • Nut Q (secondary sheave) Use sheave holder W Sheave holder : P/N. 90890-01701 R Nut (secondary sheave) : 30 Nm (3.0 m.kg) PRIMARY SHEAVE 1. Clean : • Primary sliding sheave face Q • Primary fixed sheave face W • Collar E • Weight R • Primary sliding sheave cam surface T T. 319023 319024 319025 2.
ENGINE ASSEMBLY AND ADJUSTEMENT ENG 5. Install : • V-belt Place the V-belt around the secondary sheave, and compress the secondary sheave spring hard so that the V-belt moves toward the clutch hub. NOTE: • The arrow on the V-belt must point to the front. • Make sure the V-belt is not stained with oil or grease. 6. Install : • Shim Q • Primary fixed sheave W • Washer E • One-way clutch R • Washer T • Nut Y 319027 7. Tighten : Nut (primary sheave) T.
ENGINE ASSEMBLY AND ADJUSTEMENT ENG 9. Install : • Fan T. R Screw (fan) : 7 Nm (0.7 m.kg) KICK STARTER 1. Install : • Return spring Q • Kick shaft W • Collar E • Washer R • Circlip T 317014 2. Hook : • Return spring (to the kick gear and boss) 3. Install : • Kick pinion gear Q NOTE: Install the clamp as shown. 317015 4. Install : • Transmission case Q T. R Screw (Transmission case) : 12 Nm (1.2 m.kg) 319029 5. Install : • Kick crank Q T. R 317016 4-35 Bolt (kick crank) : 10 Nm (1.0 m.
ENGINE ASSEMBLY AND ADJUSTMENT ENG PISTON, CYLINDER AND CYLINDER HEAD Q Carburetor joint U Cylinder gasket W Reed valve I Piston ring E Gasket O Piston R Cylinder head P Piston pin T Cylinder head gasket { Piston pin clip Y Cylinder } Bearing A Piston clearance: 0.029 ~ 0.042 mm B Piston rings end gap: 0.15 ~ 0.35 mm C Piston rings side clearance: 0.03 ~ 0.05 mm D Spark plug: Type: BR8HS Manufacturer: NGK 11 Nm (1.1 m.kg) 4 Nm (0.4 m.kg) 16 Nm (1.6 m.kg) LT 20 Nm (2.0 m.
ENGINE ASSEMBLY AND ADJUSTEMENT ENG PISTON PIN AND PISTON 1. Apply : • Engine oil (to crankshaft bearing, connecting rod big end bearing, small end bearing, piston pin, piston ring grooves and piston skirt .) 2. Install : • Small end bearing • Piston Q • Piston pin E • Piston pin clip R 307012 NOTE: • The arrow W on the piston must point to the exhaust side.
ENGINE ASSEMBLY AND ADJUSTEMENT ENG 3. Install : • Cylinder NOTE: Install the cylinder with one hand, while compressing the piston rings with the other hand. 4. Install : • Cylinder head gaskets (new gaskets) 5. Install : • Cylinder head • Spark plug • Thermostat NOTE: • Tighten the cylinder head holding nuts in stages, and crisscross sequence. • The arrow on the cylinder head must point to the front. T. R Nut (cylinder head) : 14 Nm (1.4 m.kg) Spark plug : 20 Nm (2.0 m.
ENGINE ASSEMBLY AND ADJUSTEMENT ENG 8. Install : • Oil hose • Oil delivery hose ENGINE REMOUNTING Reverse the removal procedure. Note the following points. 1. Install : • Engine mounting bolt 2 • Rear shock absorber bolt 1 (lower) These bolts should be temporarily secured. 2. Tighten : • Engine mounting bolt • Rear shock absorber bolt (lower) T. R Engine mounting bolt : 50 Nm (5.0 m.kg) Rear shock absorber bolt (lower) : 16 Nm (1.6 m.kg) 3.
ENGINE ASSEMBLY AND ADJUSTEMENT T. R ENG Rear wheel axle nut : 120 Nm (12 m.kg) 8.Install: • Rear wheel 9.Tighten: • Rear wheel fixing bolt T. R Rear wheel fixing bolt: 47 Nm (4.7 m.kg) 10. Install : • Muffler assembly T. R Bolt (muffler) : 26 Nm (2.6 m.kg) Bolt (exhaust pipe) : 9 Nm (0.9 m.kg) 11. Fill : • Transmission oil Refer to “CHAPTER 3 – TRANSMISSION OIL REPLACEMENT” section. 12. Fill: • Radiator Refer to “CHAPTER 5– "COOLING SYSTEM” section. 13.
COOL 5
COOL CHAPTER 5. COOLING SYSTEM RADIATOR ..................................................................................................... 5-1 REMOVAL ................................................................................................ 5-2 INSPECTION ........................................................................................... 5-2 INSTALLATION ........................................................................................ 5-2 WATER PUMP .................................
COOL COOLING SYSTEM RADIATOR Q Coolant tank cap W Coolant tank E Radiator R Hose T Water pump Y O-Ring 햲 U Impeller O-Ring I Cylinder Head O Cylinder P Thermostatic valve { Thermo switch 햳 7 Nm (0.7 m.kg) 햶 햷 햵 햸 햴 햺 햻 햵 햹 LT LT 햽 16 Nm (1.6 m.
COOLING SYSTEM COOL COOLING SYSTEM RADIATOR REMOVAL 1.Remove: • Air filter • Carburetor assembly Refer to chepter 6 "CABURETOR" 2.Drain: • Radiator Refer to chapter 3 "COOLANT REPLACEMENT" 3.Remove: • Hose • Radiator assembly. INSPECTION 1.Inspect: • Radiator core Obstruction → Blow out with compressed air through rear of the radiator. Flattened fin → Repair/Remplace. 2.Inspect: • Radiator hoses Cracks/Damage → Replace 3.
COOLING SYSTEM WATER PUMP Q Water pump housing W O-Ring E Impeller R Seal T Cover Y Bearing U Spacer COOL I Bearing O Rotor P Circlips { Rubber } Driving plug q Washer 햲 햳 햴 7 Nm (0.7 m.kg) 햵 햶 햷 햸 햹 햺 LS 6.5 Nm (0.65 m.kg) 6.5 Nm (0.65 m.
COOLING SYSTEM COOL WATER PUMP REMOVAL 1.Remove: • Side cover Refer to chapter 3 "COVER" 2.Drain: • Radiator • Hoses Refer to chapter 3 "COOLANT REPLACEMENT" 3.Remove: • Water pump fixing bolds • Water pump • Hoses INSPECTION 1.Inspect: • Impeller 햲 Used/Damaged → Replace Scale deposit → Clean 햲 2.Inspect: • Rotor Used/Damaged → Replace INSTALLATION Reverse the "REMOVAL" procedure. Note the following points.
COOL COOLING SYSTEM THERMOSTATIC VALVE Q Thermostatic switch W Cylinder head E Thermostatic valve R Cylinder 햵 햴 햳 LT LT 햲 16 Nm (1.6 m.
COOLING SYSTEM COOL THERMOSTATIC VALVE REMOVAL 1.Drain: • Coolant Refer to the chapter 3 "COOLANT REMPLACEMENT" 2.Remove: • Cylinder head • Thermostatic valve 햲 햲 INSPECTION 1.Inspect: • Thermostatic valve Valve does not open → Replace 햴 ******************************************************* Inspection steps: • Suspend thermostatic valve in a vessel. • Place reliable thermometer in a water. • Observe thermometer, while stirring water continually.
CARB 6
CARB CHAPTER 6. CARBURETION CARBURETOR .............................................................................................. 6-1 DELL'ORTO CARBURETOR ................................................................... 6-1 REMOVAL ................................................................................................ 6-2 DISASSEMBLY ........................................................................................ 6-2 INSPECTION ........................................................
CARBURETOR DELL'ORTO CARBURETOR Q Carburetor top W Gasket E Throttle valve spring R Needle set T Throttle valve Y Starter plunger spring U Starter plunger I Air screw O Throttle stop screw CARB P Pilot jet { Needle jet } Needle valve q Main jet w Float pin e Float r Float chamber gasket t Float chamber y Drain screw 햲 햳 햴 햷 햶 햸 햵 햺 햹 햽 햿 햻 헁 햾 헀 헂 헃 헄 322034 6-1
CARBURETOR CARB REMOVAL 1. Remove : • Side covers and footrest board Refer to the section “SIDE COVERS AND FOOTREST BOARD” in Chapter 3. • Air filter case assembly 2.Drain: • Coolant Refer to chapter 3 "COOLANT REPLACEMENT" 3. Disconnect : • Fuel hose • Oil hose • Coolant hoses 4. Remove : • Carburetor top • Throttle valve • Starter plunger top • Starter plunger • Carburetor DISASSEMBLY 1. Remove : • Float chamber Q 햲 322007 햳 2.
CARBURETOR 3. Remove : • Pilot jet Q • Main jet W • Main nozzle E • Starter jet R 햳 햲 CARB 햴 햵 322027 햲 4. Remove : • Throttle stop screw Q • Spring (throttle stop screw) • Air screw W • Spring (air screw) 햳 322028 5. Remove : • Needle clip Q • Jet needle W • Throttle valve E 햲 햳 햴 322029 INSPECTION 1. Check : • Carburetor body Q Dirt ➞ Clean. 햲 NOTE: Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. 322006 2.
CARBURETOR 3. Check : • Needle valve Q Wear/Contamination ➞ Replace. • Float W Damage ➞ Replace. • Gasket Damage ➞ Replace. 햳 햲 CARB 322013 4. Check : • Throttle valve Q Wear/Damage ➞ Replace. 햲 322014 햲 5. Check : • Throttle valve free movement Unsmooth/stickiness ➞ Replace. Insert the throttle valve Q into the carburetor body W and check for smooth movement. 햳 322015 햲 6. Check : • Throttle stop screw Q • Air screw W • Needle E • Starter plunger R Wear/Damage ➞ Replace. 햳 햴 햵 322016 7.
CARBURETOR CARB ****************************************************** Float height measurement steps : • Install the needle valve, float and float pin into the carburetor body. • Hold the carburetor upside down. • Measure the height distance between the mating surface of the float chamber (gasket removed) and the top of the float, using a gauge. NOTE: The float arm should be resting on the needle valve. It should not compress the needle valve.
CARBURETOR 햲 햳 CARB 2. Install : • Throttle valve Q • Starter plunger NOTE: Align the groove W of the throttle valve with the projection E of the carburetor body. 햴 322019 3. Install : • Carburetor 햲 NOTE: Align projection Q with projection W. 햳 322020 INSTALLATION To install the carburetor reverse the “REMOVAL” procedures. Note the following points. 1. Install : • Carburetor cover 2.Connect: • Coolant hose. 3.
FUEL COCK/ FUEL FILTER CLEANING/ REED VALVE CARB FUEL COCK INSPECTION 1. Stop the engine. 2. Remove : • Side covers Refer to the section “SIDE COVERS AND FOOTREST BOARD” in Chapter 3. 3. Check : • Fuel cock ******************************************************** Fuel cock inspection steps : ● Disconnect the fuel hose. ● Place a receptacle under the fuel hose end. ● If fuel stops flowing within a few seconds, the fuel cock is in good condition. If not clean or replace the fuel cock.
REED VALVE CARB 3. Remove : • Carburetor joint • Reed valve assembly INSPECTION 1. Check : • Carburetor joint Damage/Cracks ➞ Replace. • Reed valve Wear/Cracks/Damage ➞ Replace. ********************************************************* Reed valve inspection steps : ● Visually inspect the reed valve. NOTE: A reed valve in good condition should be completely or at least nearly flush with the valve seat. ● If in doubt, apply suction to the carburetor side of the assembly.
REED VALVE CARB INSTALLATION To install the reed valve reverse the “REMOVAL” procedure. Note the following points. 1. Install : • Gasket (new) 2. Tighten : • Reed valve assembly bolts T. R Reed valve assembly bolts : 9 Nm (0.9 m.kg) NOTE: Tighten the screws crosswise in several steps to prevent warpage of the read valve assembly and the carburetor joint.
CHAS 7
CHAS CHAPTER 7. CHASSIS FRONT WHEEL ............................................................................................. 7-1 REMOVAL ................................................................................................ 7-2 INSPECTION ........................................................................................... 7-2 INSTALLATION ........................................................................................ 7-3 FRONT BRAKE ............................................
CHAS FRONT WHEEL CHASSIS FRONT WHEEL Q Axle W Speedometer gear E Bearing R Collar T Front rim Y Tire U Valve I Collar O Spacer P Nut A TIRE SIZE: 130/60 - 13 B RIM RUNOUT LIMIT: VERTICAL: 1,0 mm LATERAL: 1,0 mm 햲 햳 햷 햴 햵 햶 햸 B LS 햴 햹 B LS 35 Nm (3.5 m.
FRONT WHEEL 햲 CHAS REMOVAL 1. Remove : • Front caliper fixing bolts • Front caliper • Speedometer cable Q • Axle W • Front wheel 햳 NOTE: Never depress the brake lever when the wheel is off the scooter. Otherwise the brake pads will be forced out. 340003 INSPECTION 1. Inspect : • Front axle runout Out of specification ➞ Replace. Axle runout limit: 0.25 mm (0.01 in) 340006 WARNING Do not attempt to straighten a bent axle. 2. Measure : • Wheel runout Out of specification ➞ Replace.
FRONT WHEEL CHAS INSTALLATION Reverse the “Removal” procedure. Note the following points. 1.Lubricate : • Front wheel axle • Bearings • Oil seal (lips) • Drive/driven gear (speedometer) Recommended lubricant : Lithium soap base grease 햲 2. Install : • Speedometer gear unit Q NOTE: Be sure that the two projections at the gear unit mesh with the two slots on the wheel hub. 340004 3.
FRONT BRAKE FRONT BRAKE Q Disk W Bolt E Caliper R Piston T Piston seals Y Air bleed screw U I O P { } CHAS NOTE: Be sure to install the pads correctly. Pad spring Pad retainer Brake pads O-Ring Bolt Mounting bolt 6 Nm (0.6 m.kg) A Front brake pad wear limit: 2mm B Front disk wear limit: 3.2 mm 햷 햻 햾 햴 햶 햵 햸 햵 21 Nm (2.1 m.kg) 햹 햶 햾 LT 햺 햽 LT 23 Nm (2.3 m.kg) 햲 햳 LT 23 Nm (2.3 m.
FRONT BRAKE FRONT MASTER CYLINDER Q Master cylinder W Master cylinder piston ass'y E Diaphragm R Master cylinder cap T Master cylinder bracket Y Copper washer U Union bolt I Brake hose O Union bolt P Front brake switch { Front brake lever CHAS NOTE: Drain completely before removing the master cylinder. 1.5 Nm (0.15 m.kg) 햵 햲 햴 11 Nm (1.1 m.kg) 14 Nm (1.4 m.kg) 햳 햶 23 Nm (2.3 m.kg) 햽 햷 햸 햻 햹 햷 23 Nm (2.3 m.
FRONT BRAKE CHAS WARNING • Disc brake components rarely require disassembly. Do not disassemble components unless absolutely necessary. If any hydraulic connection is disconnected, the entire system must be disassembled, drained, cleaned, and then properly filled and bleed after reassembly. Do not use solvents on internal brake component. • Solvents will cause seals to swell and distort. Use only clean brake fluid for cleaning. Use care with brake fluid.
FRONT BRAKE CHAS 4. Install : • Brake pads • Pad spring • Axle • Pin NOTE : Be careful to install the brake pads correctly. 5.Lubricate : • Mounting bolt (caliper body) Recommended lubricant : Lithium soap base grease 6.Install : • Wheel axle • Mounting bolt (front caliper) Apply LOCTITE LOCTITE ® T. R Wheel axle : 35 Nm (3.5 m.kg) Mounting bolt : 21 Nm (2.1 m.
FRONT BRAKE CHAS ******************************************************* Removal steps : ● Blow compressed air into the hose joint opening to force out the piston from the caliper body. WARNING • Never try to pry out the piston. • Cover the piston with a rag. Use care so that the piston does not cause injury as it is expelled from the cylinder. 346004 ● Remove the piston seals.
FRONT BRAKE CHAS 4. Remove : • Master cylinder dust boot Q • Master cylinder kit W 햲 햳 347008 INSPECTION AND REPAIR Recommended brake component replacement schedule : Brake pads As required Piston seal, Dust seal Every two years Brake hoses Every four years Brake fluid Replace only when brakes are disassembled WARNING All internal parts should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 햳 1.
FRONT BRAKE CHAS 3. Check : • Brake hose Q Cracks/Wear/Damage ➞ Replace. 햲 346014 4. Measure : • Brake disc deflection Out of specification ➞ Inspect wheel runout. If wheel runout is good, replace the brake disc(s). Maximum deflection : 0.25 mm (0.01 in) 347001 • Brake disc thickness Out of specification ➞ Replace. Minimum thickness : 3,2 mm (0.125 in) T. R Bolt (brake disc) : 23 Nm (2.3 m.kg) LOCTITE® 347002 CALIPER ASSEMBLY WARNING • All internal parts should be cleaned in new brake fluid only.
FRONT BRAKE CHAS 2. Install : • Brake caliper Apply LOCTITE LOCTITE ® T. R 햲 Bolt (brake caliper) : 23 Nm (2.3 m.kg) 3. Install : • Caliper body Q 햳 햵 햴 4. Install : • Brake hose W • Copper washers E • Union bolt R 346005 T. R Union bolt : 23 Nm (2.3 m.kg) CAUTION: When installing the brake hose to the caliper, turn the brake pipe against the projection on the caliper. WARNING • Proper hose routing is essential to insure safe operation. Refer to “CABLE ROUTING”. • Always use new copper washers.
FRONT BRAKE CHAS 1. Install : • Master cylinder Q 햲 CAUTION: • Install the master cylinder holder with the arrow mark pointing upwards. • Tighten the upper bolt first, then the lower bolt. 347010 T. R Bolt (master cylinder holder) : 1.1 Nm (0.11 m.kg) 2. Install : • Brake lever NOTE: Apply lithium soap base grease to the brake lever pivot. 3. Install : • Brake hose • Copper washers • Union bolts • Brake switch T. R Union bolt : 23 Nm (2.3 m.
REAR WHEEL CHAS REAR WHEEL Q W E R T Cover plug Nut Washer Bolt Rear wheel tire Y U I O Valve Rear rim Distance collar Rear brake disk A TIRE SIZE: 140/60 - 13 B RIM RUNOUT LIMIT: VERTICAL: 1,0 mm LATERAL: 1,0 mm 120 Nm (12.0 m.kg) 햶 햲 햳 햷 햴 햸 햵 햹 47 Nm (4.7 m.kg) 햺 LT 23 Nm (2.3 m.
CHAS REAR WHEEL REAR MASTER CYLINDER Q Master cylinder W Master cylinder piston ass'y E Diaphragm R Master cylinder cap T Master cylinder bracket Y Copper washer NOTE: Drain completely before removing the master cylinder. U Union bolt I Brake hose O Union bolt P Rear brake switch { Rear brake lever 1.5 Nm (0.15 m.kg) 햲 햸 햵 햴 14 Nm (1.4 m.kg) 11 Nm (1.1 m.kg) 햶 23 Nm (2.3 m.kg) 햷 햳 햻 햹 햽 햷 23 Nm (2.3 m.
REAR WHEEL CHAS WARNING • Disc brake components rarely require disassembly. Do not disassemble components unless absolutely necessary. If any hydraulic connection is disconnected, the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly. Do not use solvents on internal brake component. • Solvents will cause seals to swell and distort. Use only clean brake fluid for cleaning. Use care with brake fluid.
REAR WHEEL 햲 CHAS 3. Check : • Wheel bearings Refer to the section “FRONT WHEEL INSPECTION”. REAR BRAKE For removal, inspection and assembly refer to the section "FRONT BRAKE" INSTALLATION Reverse the REMOVAL procedure. Note the following points. 1.Install • Rear wheel 2. Tighten : • Rear wheel fixing bolts T. R Rear wheel fixing bolt : 47 Nm (4.7 m.kg) 3. Install : • Muffler T. R Bolt (exhaust pipe) : 7 Nm (0.7 m.kg) Bolt (muffler) : 29 Nm (2.9 m.kg) 4. Adjust : • Rear brake lever free play.
FRONT FORK FRONT FORK Q Steering bracket W Bolt E Circlip R Rubber cap T Circlip Y Spring seat U O-Ring I Spring O Piston CHAS P Spring { Spacer } Plunger q Dust boot w Retainer e Oil seal r Outer fork tube t Washer y Screw A Oil capacity of each fork leg: 75 cc B Oil grade: ISO 6743/4 - LHV 46 or SAE10 22.5 Nm (22.5 m.kg) 햲 햴 햳 햹 햵 햶 햺 햷 햸 햻 햿 햽 헀 헁 햾 헂 헃 헄 23 Nm (2.3 m.kg) 7-17 30 Nm (3.0 m.
FRONT FORK CHAS REMOVAL WARNING Securely support the scooter with a stand under the engine. 1. Place the scooter on an even surface. 2. Disconnect : • Speedometer cable 3. Remove : • Front wheel Refer to section “FRONT WHEEL” in Chapter 7. 4. Remove : • Front fender Refer to section “COVERS - REMOVAL AND INSTALLATION” in Chapter 3. 5. Remove : • Steering head Refer to section “STEERING HEAD AND HANDLEBAR” in Chapter 7. 6.
FRONT FORK CHAS DISASSEMBLY 1. Remove : • Rubber plug Q • Circlip W • Spring seat E • Spring R 햲 햳 햴 햵 342014 2. Remove : • Bolt Q • Copper washer 햴 NOTE: To remove the drain bolt Q, use the T-handle W and the holder E. 햲 햳 T-handle for front fork : 90890-01326 Holder : 90890-01294 342010 3. Remove : • Inner fork tube Q • Piston W • Spring E • Spring seat R 햳 햴 햵 햲 342015 4.
FRONT FORK CHAS INSPECTION 1. Check : • Inner fork tube and fork components • Outer fork tube Wear/Scratches/Damage ➞ Replace. WARNING Never attempt to straighten a bent fork tube as this may dangerously weaken the tube. 2. Measure : • Fork spring free length Q Used/bends/Damage ➞ Replace. ASSEMBLY Reverse the “DISASSEMBLY” procedure. Note the following points.
FRONT FORK 3. Install : • Copper washer • Bolt 햴 NOTE: Tighten the drain bolt Q while holding the piston with the T-handle W and holder E. 햲 햳 CHAS T-handle for front fork : 90890-01326 Holder : 90890-01294 342010 4. Fill : • Fork oil Fork oil type : ISO 6743/4-LHV 46 or SAE 10 Amount (per fork tube): 75 cc 5. Install : • Spring • Spring seat • Circlip • Rubber plug INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.
STEERING HEAD AND HANDLEBAR STEERING HEAD AND HANDLEBAR Q Handlebar W Nut E Bolt R Trottle grip T Throttle cable Y Starter cable (Choke) E 햲 햵 60 Nm (6.0 m.
STEERING HEAD AND HANDLEBAR CHAS STEERING HEAD AND HANDLEBAR REMOVAL WARNING Securely support the scooter so there is no danger of it falling over. 햲 354001 1. Place the scooter on an even surface. 2. Remove : • Front fender • Inner panels • Upper handlebar cover Refer to section “REMOVAL AND INSTALLATION OF COVERS” in Chapter 3. 3. Drain : • Front and rear brakes system Refer to section “FRONT BRAKE” in Chapter 6. 4.
STEERING HEAD AND HANDLEBAR CHAS 11. Remove : • Upper bearing race Q Ring nut wrench : 9079Q-02218 햲 354005 • Steering shaft • Bearing balls INSPECTION 1. Check : • Handlebar Q Bends/Cracks/Damage ➞ Replace. 2. Wash the bearing balls in solvent. 햲 3. Check : • Bearing races Q Pitting/Damage ➞ Replace. • Bearing balls Pitting/Damage ➞ Replace. 354006 NOTE: Always replace the bearing balls and the upper and lower bearing races as a set.
STEERING HEAD AND HANDLEBAR CHAS CAUTION: • Unless installed correctly, the bearing races will damage the frame. • Never hit the bearing races on the ball race surface. ********************************************************* 354008 4. Check : • Steering shaft Bend/Damage ➞ Replace. WARNING Never attempt to straighten a bent steering shaft. 354009 ASSEMBLY AND INSTALLATION Reverse the “REMOVAL” and “DISASSEMBLY” procedure. Note the following points.
STEERING HEAD AND HANDLEBAR CHAS CAUTION: Hold the steering shaft until it is securely attached. 햳 4. Install : • Washer Q • Steering shaft lock nut W 햲 354002 NOTE: Tighten the steering shaft lock nut with the ring nut wrench. Set the torque wrench to the ring nut wrench so that they form a right angle. Ring nut wrench : 9079Q-02218 T. R Steering shaft ring nut : 22.5 Nm (2.25 m.kg) 5.
ELEC 8
ELEC CHAPTER 8. ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS ...................................................................... 8-1 CIRCUIT DIAGRAM ....................................................................................... 8-3 IGNITION AND STARTING SYSTEM ............................................................ 8-5 CIRCUIT DIAGRAM ................................................................................. 8-5 IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM ....................
ELECTRICAL SYSTEM ELEC ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Q Wire harness W Fuel sender E Starter relay R Ignition coil T CDI unit Y Oil sender U Battery I Resistance 햲 햳 햴 햵 햹 햶 햸 햷 ;; ;; ;; 8-1
ELECTRICAL SYSTEM ELEC ELECTRICAL COMPONENTS Q Main switch W Flasher relay E Horn R Rectifier/Regulator 햲 햳 ;;;;;;; ;;; ;;;;;;; ;;;; ;;;; ;;; ;;;; ;;; ;;;; 햴 햵 8-2
ELEC CIRCUIT DIAGRAM CIRCUIT DIAGRAM W } O BW B Q R Br Gy LOCK O B OFF CHECK ON R W/R B/R B B/W Br Gy B E W Y/R R R T Y/R B O I R R R B Y/R L/W U M s Y/B q B P B B YR YB LR L G/Y OFF P0 : ON B { L LR R/Y LR LR LR LR B G/Y LR t a 40 L B LB 70 Br Br B r B 110 Br H C Br Br Br Br J B i F E K P L HI N LOW R Y GB Ch B Dg ] [ B B F Dg Ch w e B Gy Gy G/Y Ch Br/W Dg G Y H Br/W o GB L Br y u D B Y Br A S p B 8-3 G
CIRCUIT DIAGRAM ELEC Q Spark plug W Ignition coil E CDI magneto R CDI unit T Rectifier/regulator Y Dimmer switch U Starter motor I Starter relay O Fuse P Battery { Starter switch } Main switch q Lighting switch w “HIGH BEAM indicator” e Head light r Meter light t Tail/Stop light y Front stop switch u Rear stop switch i Flasher relay o Flasher switch p Flasher indicator [ Rear flasher light (Left) ] Front flasher light (Left) A Front flasher light (Right) S Rear flasher light (Right) D Horn F Horn switch
ELEC IGNITION AND STARTING SYSTEM IGNITION AND STARTING SYSTEM W } O BW B Q R Br Gy LOCK O B OFF CHECK ON R W/R B/R B B/W Br Gy B E W Y/R R R T Y/R B O I R R R B Y/R L/W U M q B s P Y/B B B YR YB LR L G/Y OFF P0 : ON B { L LR R/Y LR LR LR LR B G/Y LR t a 40 L B LB 70 Br Br B r B 110 Br H C Br Br Br Br J B i F E K P L HI N LOW R Y GB Q W E R U I Ch B Dg ] [ B B F Dg Ch w e B Gy Gy G/Y Ch Br/W Dg G Y H Br/W o GB L
ELEC IGNITION AND STARTING SYSTEM IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM } Main switch Q Spark plug a Source coil t Front brake switch W Ignition coil b Pickup coil y Rear brake switch R CDI unit c Wave-shape shaping circuit U Starter Motor d Condenser I Starter relay e Diode O Fuse f SCR P Battery g To oil level switch { Starter switch 햵 B/R O 햳 a e d e f e W/R c b e d 햲 B B B 햾 B/W BW B R Br Gy LOCK OFF CHECK ON 햹 햺 B g R 햸 R 햻 M B B L/W 헃 Br 햽 G/Y 헄 B : Current
ELEC IGNITION AND STARTING SYSTEM TROUBLESHOOTING THE STARTING SYSTEM DOES NOT WORK (NO SPARK OR IRREGULAR SPARKS). NOTE : • Remove the following parts before proceeding with the troubleshooting : 1) Side covers (left and right) • For accurate troubleshooting use the following special tools : Ignition checker : 90890-06754 Pocket tester : 90890-03112 1.Spark plug • Check the spark plug type. • Check the condition of the spark plug. • Check the spark plug gap.
IGNITION AND STARTING SYSTEM ELEC 3.Spark plug cap resistance • Disconnect the spark plug cap. • Connect the pocket tester (Ω x 1 k) to the spark plug cap. • Check the resistance of the spark plug cap. Spark plug cap resistance : 5kΩ at 20°C (68°F) DOES NOT MEET SPECIFICATION Replace the spark plug cap MEETS SPECIFICATION 4.Ignition coil resistance • Disconnect the ignition coil leads. • Connect the pocket tester (Ω x 1) to the ignition coil.
ELEC IGNITION AND STARTING SYSTEM 5.Pickup coil resistance CDI MAGNETO • Disconnect the pickup coil coupler. • Connect the pocket tester (Ω x 100) to the pickup coil. 햳 Pocket tester (+) lead Q ➞ White / Red Pocket tester (-) lead W ➞ Ground - Y/R w W/R B/R 햲 • Check the pickup coil resistance. DOES NOT MEET SPECIFICATION Pickup coil resistance : 400 ~ 600 Ω at 20°C (68°F) MEETS SPECIFICATION Pickup coil defect ➞ Replace. 6.
IGNITION AND STARTING SYSTEM ELEC TROUBLESHOOTING STARTER MOTOR DOES NOT WORK NOTE : • Remove the following parts before proceeding with the troubleshooting: 1) Side covers (left and right) 2) Footrest boards 3) Front panel 4) Handlebar cover • For accurate troubleshooting use the following special tools: Pocket tester : 90890-03112 1.Fuse NO CONTINUITY • Remove the fuse. • Connect the pocket tester (Ω x 1) to the fuse. • Check the fuse for continuity. Defect ➞ Replace fuse. CONTINUITY 2.
IGNITION AND STARTING SYSTEM ELEC 4. Starter relay • Disconnect the Blue/White lead from the wire harness. • Connect the (-) Q terminal of the battery to the Blue/White lead. • Check the starter motor operation. M + - DOES NOT WORK 햲 L/W Starter relay defect ➞ Replace. WORKS 5. Main switch • Disconnect the main switch from the wire harness. • Check for continuity between Red Q and Brown W. BW B R Br Gy R B LOCK OFF DOES NOT MEET SPECIFICATION CHECK ON BW 햲 Main switch defect ➞ Replace.
IGNITION AND STARTING SYSTEM ELEC LW B OFF DOES NOT MEET SPECIFICATION ON 햳 햲 B YB L Starter switch defect ➞ Replace right handlebar switch. LW YR LR MEETS SPECIFICATION POOR CONNECTIONS 7.Connections Check all connections in the starter system. Refer to “WIRING DIAGRAM”. Repair.
ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM W } O BW B Q R Br Gy LOCK O B OFF CHECK ON R W/R B/R B B/W Br Gy B E W Y/R R R T Y/R B O I R R R B Y/R L/W U M Y/B q B s P B B YR YB LR L G/Y OFF P0 : ON B { L LR R/Y LR LR LR LR B G/Y LR t a 40 L B LB 70 Br Br B r B 110 Br H C Br Br Br Br J B i F E Y GB L K P L N LOW R Y GB E T O P Ch B Dg ] [ B B F Dg Ch w e B Gy Gy G/Y Ch Br/W Dg HI H Br/W o G Br y u D B
CHARGING SYSTEM ELEC TROUBLESHOOTING THE BATTERY IS NOT CHARGED NOTE : • Remove the following parts before proceeding with the troubleshooting : 1) Side covers (left and right) and foot rest board. • For accurate troubleshooting use the following special tools : Inductive tachometer : 90890-03113 Pocket tester : 90890-03112 1.Fuse (Main) • Remove the fuse. • Connect the pocket tester (Ω x 1) to the fuse. • Check the fuse for continuity. NO CONTINUITY CONTINUITY 2.Battery Fuse defect ➞ Replace.
CHARGING SYSTEM ELEC 4.Charging coil resistance CDI MAGNETO • Disconnect the CDI magneto coupler from the wire harness. • Connect the pocket tester (Ω x 1) to the charging coil. • Check the charging coil resistance 햳 - Tester (+) lead ➞ White Q Tester (–) lead ➞ Ground W Charging coil resistance : 0.48 ~ 0.72 Ω at 20°C (68°F) Y/R w W/R B/R 햲 OUT OF SPECIFICATION MEETS SPECIFICATION Charging coil defect ➞ Replace. POOR CONNECTIONS 5.Connections Check all connections in the charging system.
ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM W } O BW B Q R Br Gy LOCK O B OFF CHECK ON R W/R B/R B B/W Br Gy B E W Y/R R R T Y/R B O I R R R B Y/R L/W U M Y/B q B s P B B YR YB LR L G/Y OFF P0 : ON B { L LR R/Y LR LR LR LR B G/Y LR t a 40 L B LB 70 Br Br B r B 110 Br H C Br Br Br Br J B i F E K P L HI N LOW R Y GB E Y q w e Ch B Dg ] [ B B F Dg Ch w e B Gy Gy G/Y Ch Br/W Dg G Y H Br/W o GB L Br y u D
ELEC LIGHTING SYSTEM TROUBLESHOOTING THE AUXILIARY LIGHT, HEADLIGHT, HEADLIGHT INDICATOR, TAIL LIGHT OR METER LIGHT DO NOT WORK NOTE : Remove the following parts before proceeding with the troubleshooting : • Side covers and footrest board • Handlebar covers For accurate troubleshooting use the following special tools : Pocket tester : 90890-03112 1. “LIGHTS” switch • Disconnect the right handlebar switch coupler from the wire harness. • Set the switch to “PO” (auxiliary light).
LIGHTING SYSTEM ELEC 3. Lighting coil resistance CDI MAGNETO • Disconnect the lighting coil coupler from the wire harness. • Connect the pocket tester (Ω x 1) to the lighting coil. • Check the lighting coil resistance 햳 - Tester (+) lead ➞ Yellow / Red Q Tester (-) lead ➞ Ground W Lighting coil resistance : 0.4 ~ 0.6 Ω ( at 20°C (68°F) Y/R w 햲 OUT OF SPECIFICATION MEETS SPECIFICATION Lighting coil defect ➞ Replace. 4. Connections • Check all connections in the lighting system.
LIGHTING SYSTEM ELEC LIGHTING SYSTEM INSPECTION 1. Headlight and headlight indicator do not work. 1. Bulb and socket NO CONTINUITY • Check the bulb and socket for continuity. Replace bulb or socket. CONTINUITY 2. Voltage • Connect the pocket tester (AC20V) to the headlight coupler.
LIGHTING SYSTEM ELEC 2. Voltage 햳 • Connect the pocket tester (AC20V) to the meter light coupler. B B Pocket tester (+) lead ➞ Blue / Red Q Pocket tester (-) lead ➞ Black W • Set the main switch to “ON”. • Start the engine. • Check the voltage (12V) between the headlight coupler leads “Blue / Red” and “Black”. G RY LR B G RY LR LR 햲 OUT OF SPECIFICATION MEETS SPECIFICATION There is a defect in the wire harness between the main switch and the meter light coupler ➞ Repair.
ELEC SIGNAL SYSTEM SIGNAL SYSTEM WIRING DIAGRAM W } O BW B Q R Br Gy LOCK O B OFF CHECK ON R W/R B/R B B/W Br Gy B E W R R Y/R T Y/R B O I R R R B Y/R L/W U M Y/B q B s P B B YR YB LR L G/Y OFF P0 : ON B { L LR R/Y LR a 40 LR LR L B LB 70 LR B G/Y LR t Br Br B r B 110 Br H C Br Br Br Br J B i F E Y GB L P L HI N LOW R Y GB O P } t i o p [ ] A Ch B Dg ] [ B B F Dg Ch w e B Gy Gy G/Y Ch Br/W Dg K H Br/W o G Br y
ELEC SIGNAL SYSTEM TROUBLESHOOTING FLASHER LIGHTS, TAIL/BRAKE LIGHT, “OIL” WARNING LIGHT DOES NOT WORK HORN DOES NOT SOUND, FUEL METER DOES NOT WORK NOTE : Remove the following parts before proceeding with the troubleshooting: • Side covers and footrest board • Handlebar cover For accurate troubleshooting use the following special tools : Pocket tester : 90890-03112 1. Fuse • Remove the fuse. • Connect the pocket tester (Ω x 1) to the fuse. • Check the fuse for continuity.
SIGNAL SYSTEM 4. Connections ELEC POOR CONNECTIONS • Check all connections in the signal system. Refer to “WIRING DIAGRAM”. GOOD CONNECTIONS Repair. Check the condition of each circuit of the signal system. Refer to the section “SIGNAL SYSTEM CHECK”. SIGNAL SYSTEM CHECK 1. Horn does not sound 1. “HORN” switch • Disconnect the handlebar switch (left) from the wire harness. • Check for continuity between: Black Q and Pink W.
SIGNAL SYSTEM 햲 Br ELEC P DOES NOT MEET SPECIFICATION Defect in the wire harness between the main switch and the horn ➞ Repair. MEETS SPECIFICATION 3. Horn • Disconnect the “Pink” lead at the horn terminal. • Ground the horn terminal Q with a jumper lead. • Set the main switch to ON. Br 햲 HORN SOUNDS Horn in good condition. HORN DOES NOT SOUND 4. Voltage Br • Connect the pocket tester (DC20V) to the “Pink” lead.
SIGNAL SYSTEM ELEC 2. The tail light does not work. 1. Bulb and socket NO CONTINUITY • Check the bulb and socket for continuity. CONTINUITY Replace bulb or socket. 2. Brake switch • Disconnect the brake switch leads from the wire harness. • Check for continuity between: Brown Q and Green / Yellow W Br GY ON (Pull in) OFF (Free) NO CONTINUITY Br GY 햲 햳 Brake switch is defect ➞ Replace. CONTINUITY 3. Voltage • Connect the pocket tester (DC20V) to the socket.
SIGNAL SYSTEM ELEC 3. Flasher does not work NO CONTINUITY 1. Bulb and socket • Check the bulb and socket for continuity. Replace bulb or socket. CONTINUITY 2. “TURN” switch • Disconnect the handlebar switch (left) from the wire harness. • Check for continuity between : Left side : Brown / White Q and Chocolate W Right side : Brown / White Q and Dark green E Ch BrW Dg L NO CONTINUITY N R 햳 G B Y Ch - Dg 햴 Left handlebar switch is defect ➞ Replace. P BrW L 햲 CONTINUITY 3.
SIGNAL SYSTEM ELEC 4. Voltage • Connect the pocket tester (DC20V) to the flasher relay. Pocket tester (+) lead ➞ Brown / White Q Pocket tester (-) lead ➞ Ground • Turn the main switch to “ON”. • Check the voltage (12V) between Brown / White and the ground. 햲 - Br/W - Br DOES NOT MEET SPECIFICATION Flasher relay defect ➞ Replace. MEETS SPECIFICATION 5. Voltage • Connect the pocket tester (DC20V) to the flasher connector.
SIGNAL SYSTEM ELEC This circuit is in good condition. 4. The “OIL” indicator light does not work. 1. Bulb and socket NO CONTINUITY • Check the bulb and socket for continuity. CONTINUITY Replace bulb or socket. 2. Oil level switch • Disconnect the oil level switch from the oil tank. • Connect the pocket tester (Ω x 1) to the oil level switch. Pocket tester (+) lead ➞ Terminal Q Pocket tester (-) lead ➞ Terminal Q • Check the switch for continuity.
SIGNAL SYSTEM ELEC 3. Voltage • Connect the pocket tester (DC20V) to the bulb socket connector. Pocket tester (+) lead ➞ Grey Q Pocket tester (-) lead ➞ Ground • Turn the main switch to ON. • Check the voltage (12V) between “Grey” and the ground. DOES NOT MEET SPECIFICATION Y Y Gy Dg Ch Dg Ch Gy 햲 4. Connections Br YR • Check all connections in the signal system. Refer to “WIRING DIAGRAM”. MEET SPECIFICATION This circuit is in good condition. 5.The fuel meter does not work. 1.
ELEC COOLING SYSTEM COOLING SYSTEM WIRING DIAGRAM W } O BW B Q R Br Gy LOCK O B OFF CHECK ON R W/R B/R B B/W Br Gy B E W Y/R R R T Y/R B O I R R R B Y/R L/W U M Y/B q B s P B B YR YB LR L G/Y OFF P0 : ON B { L LR R/Y LR LR LR LR B G/Y LR t a 40 L B LB 70 Br Br B r B 110 Br H C Br Br Br Br J B i F E K P L HI N LOW R Y GB O P } a s Ch B Dg ] [ B B F Dg Ch w e B Gy Gy G/Y Ch Br/W Dg G Y H Br/W o GB L Br y u D B
ELEC COOLING SYSTEM TROUBLESHOOTING WATER TEMPERATURE METER DOES NOT MOVE, WHEN THE ENGINE IS WARM. NOTE : Remove the following parts before proceeding with the troubleshooting: • Side covers and footrest board • Handlebar cover For accurate troubleshooting use the following special tools : Pocket tester : 90890-03112 1. Fuse NO CONTINUITY • Remove the fuse. • Connect the pocket tester (Ω x 1) to the fuse. • Check the fuse for continuity. Refer to “FUSE INSPECTION” in Chapter 3. Fuse defect ➞ Replace.
COOLING SYSTEM ELEC 4. Thermo unit • Remove the thermo unit from the head cylinder. • Connect the pocket tester (Ω x100) then (Ω x 10) to the thermo unit 햲. • Immerse the thermo unit in the water. • Measure the resistance. 햲 Thermo unit resistance: 25°C: 504 ~ 614 Ω 100°C: 37.8 ~ 41.6 Ω WARNING • Handle the thermo unit with special care. • Never subject it to strong shock or allow it to be dropped. Should it be dropped, it must be replaced.
TRBL SHTG 9
TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/ HARD STARTING ..................................................... 9-1 FUEL SYSTEM ........................................................................................ 9-1 ELECTRICAL SYSTEM ........................................................................... 9-1 COMPRESSION SYSTEM ...................................................................... 9-2 POOR IDLE SPEED PERFORMANCE .........................................................
STARTING FAILURE/HARD STARTING TRBL SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING/ POOR IDLE SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head • Loose spark plug • Loose cylinder head or cylinder • Broken cylinder head gasket • Broken cylinder gasket • Worn, damaged or seized cylinder Piston and piston rings • Improperly installed piston ring • Worn, fatigued or broken piston ring • Seized piston ring • Seized or damaged piston TRBL SHTG Crankcase and crankshaft • Improperly seated crankcase • Improperly sealed crankcase (damaged oil seal) •
POOR MEDIUM AND HIGH SPEED PERFORMANCE/ FAULTY AUTOMATIC TRBL SHTG POOR MEDIUM AND HIGH SPEED PERFORMANCE FUEL SYSTEM Fuel tank • Clogged fuel filter • Deteriorated fuel or fuel containing water or foreign material • Clogged fuel tank cap Fuel cock • Clogged fuel hose Air cleaner • Clogged air cleaner Carburetor • Deteriorated fuel, fuel containing water or foreign material • Sucked-in air • Deformed float • Groove-worm needle valve • Improperly sealed valve seat • Improperly set clip position of jet nee
FAULTY AUTOMATIC/ OVER HEATING OR OVER-COOLING TRBL SHTG POOR STANDING START (LOW CLIMBING ABILITY) V-belt Secondary sheave • Worn, damaged or slipped v-belt • Fatigued compression spring Primary sheave • Improper operation of secondary sliding sheave • Worn or improper operation of weight POOR ACCELERATION (POOR HIGH SPEED) V-belt • Worn or greasy V-belt Secondary sheave • Worn or greasy clutch shoe • Improper operation of secondary sliding sheave OVER HEATING OR OVER-COOLING OVER HEATING Ignition syst
IMPROPER KICKING/ FAULTY BRAKE TRBL SHTG IMPROPER KICKING SLIPPING 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 Transmission oil • Improper quality (low viscosity) • Deterioration HARD KICKING Kick axle assembly • High tension of kick clip • Seized kick gear Crankcase and crankshaft • Improperly seated crankcase • Improperly seated crankshaft • Damaged or seized crankshaft • Damaged or s
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION/ INSTABLE HANDLING TRBL SHTG FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE • Bent, damaged or rusty inner tube • Damaged or cracked outer tube • Damaged oil seal lip • Improper installed oil seal • Improper oil level (too much) • Loose damper rod holding bolt • Broken cap bolt O-ring MALFUNCTION • Bent, deformed or damaged inner tube • Bent or deformed outer tube • Damaged fork spring • Worn or damaged slide metal • Bent or damaged damper
FAULTY SIGNAL AND LIGHTING SYSTEM TRBL SHTG FAULTY SIGNAL AND LIGHTING SYSTEM Headlight dark • Improper bulb • Too many electric accessories • Hard charging (broken charging coil) • Incorrect connection • Improperly grounded • Poor contacts (main or light switch) • Bulb life expires Flasher does not light • Improperly grounded • Discharged battery • Faulty flasher switch • Faulty flasher relay • Broken wireharness • Loosely connected coupler • Bulb burnt out • Faulty fuse Bulb burnt out • Improper bulb
YQ50 WIRING DIAGRAM Meter with tachometer s Q B F T YR B E Br B B B RY B a OFF OFF OFF P0 CHECK LR ON ON ON LW B I Y R Br Gy LOCK RY LR B R BW B YR YB LR L G G h E W G O U P { - - - B g : L K LR Br B Dg RY Ch Y Gy Gy Br Dg BW B R Y Y Br YR B W R Gy Br Dg B YB L YB YR B W R B Ch Gy Br LW YR LR Gy Br LW YR LR YR B - R Or G B G B G L Br B YR RY B Gy R BW Dg B B B Ch Br YR LR B Gy L LW YB Dg B Dg B Dg B f Dg B B
