XN125 XN150 2000 5MF1-AE2 SERVICE MANUAL
EASM0000 XN125 / XN150 SERVICE MANUAL © 2000 by MBK Industrie 2nd edition, April 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.
EASM0001 NOTICE This manual was produced by the MBK Industrie primarily for use by Yamaha and MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
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. 햲 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". 햳 Each chapter is divided into sections.
햲 EAS00008 햳 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 햲 to 햺 indicate the subject of each chapter. 햲 General information 햳 Specifications 햴 Periodic checks and adjustments 햵 Engine 햶 Cooling system 햷 Carburetor 햸 Chassis 햹 Electrical system 햺 Troubleshooting SPEC 햴 햵 CHK ADJ ENG 햶 햷 COOL CARB 햸 햹 ELEC CHAS 햺 Symbols 햻 to 헃 indicate the following.
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE OVERHAUL ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 SPECIFICATIONS COOLING SYSTEM CARBURETOR CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING
GEN INFO 1
GEN INFO CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................... 1-1 MODEL LABEL ........................................................................................ 1-1 FEATURES ................................................................................................... 1-2 OIL INDICATOR LIGHT ...............................................
SCOOTER IDENTIFICATION GEN INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION 햲 EASM0002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 햲 is stamped into the frame. ZAUM0071 EASM0003 MODEL LABEL The model label 햲 is affixed under the seat. This information will be needed to order spare parts.
FEATURES GEN INFO EASM0004 FEATURES OIL INDICATOR LIGHT • FUNCTION Pulses (travel distance signals) from the speedometer are counted and cause the oil indicator light to come on at 500 km for the first time and thereafter every 3,000 km. In this way, the light indicates the time for oil change. • RESETTING PROCEDURE To reset the oil change indicator light 1) Press the “TRIP” button while turning the key to “ON”. 2) Release the button and the oil change indicator light will go off.
FEATURES GEN INFO THE CLOCK • Setting the clock To set the clock: 1) Make sure that the key is turned to “OFF”. 2) Press the “TRIP” button for two seconds and the hour display will flash. 3) Press the “TRIP” button to set the hours. 4) Press the “TRIP” button for two seconds, and the first minute digit will flash. 5) Press the “TRIP” button to set the first minute digit. 6) Press the “TRIP” button for two more seconds, and the second minute digit will flash.
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 1.After removal, replace all lock washers / plates 햲 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. 햲 EAS00024 BEARINGS AND OIL SEALS 1.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 base grease.
CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1.Disconnect: • lead • coupler • connector 2.Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. 3.Check: • all connections Loose connection → Connect properly. 햲 NOTE: If the pin 햲 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. Tool No.
SPECIAL TOOLS Tool No. 90890-01367 90890-01368 Tool name/usage Fork seal driver weight Frok seal driver attachment These tools are used when installing the fork seal. 90890-01701 Sheave holder This tool is used to hold the secondary sheave when removing or installing the nut. 90890-03111 Valve adjusting tool This tool is necessary for adjusting valve clearance. 90890-03112 Pocket Tester This instrument is invaluable for checking the electrical system.
SPECIAL TOOLS Tool No. 90890-04117 Tool name/usage Valve guide installer This tool is needed to install the valve guide spring. 90890-04118 Valve guide reamer This tool is used to rebore the valve guide. 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. 90890-85505 Yamaha bond No. 1215 This sealant (bond) is used for crankcase mating surface, etc. 90890-03081 Compression gauge This gauge is used to measure the engine compression.
SPEC 2
SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ...................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................. 2-4 ENGINE ................................................................................................... 2-4 CHASSIS ................................................................................................. 2-8 ELECTRICAL ..........................................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item XN125 [XN150] Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 1.868 mm 740 mm 1.096 mm 777 mm 1.315 mm 105 mm 1.
GENERAL SPECIFICATIONS Item SPEC XN125 [XN150] Carburator Type/quantity Manufacturer TK 5DS/1 [TK 5KD/1] TEIKEI Spark plug Type Manufacturer Spark plug gap CR8E 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 type Operation Helical gear 40/15 (2.666) Spur gear 44/12 (3.
GENERAL SPECIFICATIONS Item SPEC XN125 [XN150] Brake Front brake type Front brake operation Rear brake type Rear brake operation Single disc brake Right hand operation Drum brake Left hand operation Suspension Front suspension Rear suspension Telescopic fork Unit swing Shock absorber Front fork type Rear shock absorber assembly type Coil spring/oil damper Coil spring/oil damper Wheel travel Front wheel travel Rear wheel travel 90 mm 80 mm Electrical Ignition system type Charging system type Batte
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE *[XN150] Item Standard Limit Cylinder head Warp limit ••• 0.03 mm Cylinder Bore size Out of round limit 53.700 ~ 53.705 mm [59.500 ~ 59.505mm]* ••• ••• 0.05 mm Camshaft Drive system Cam dimensions Intake “A” “B” “C” Exhaust “A” “B” “C” Camshaft runout limit Chain drive (left) C A B 30.811 ~ 30.911 mm 25.145 ~ 25.245 mm 5.666 m 30.811 ~ 30.911 mm 25.152 ~ 25.252 mm 5.659 m ••• Cam chain Cam chain type/No.
MAINTENANCE SPECIFICATIONS SPEC *[XN150] Item Valve spring Inner spring Free length Set length (valve closed) Compressed pressure Tilt limit Standard IN/EX IN/EX IN/EX IN/EX Piston Piston to cylinder clearence Piston size “D” Measuring point “H” D Piston pin bore inside diameter Piston pin outside diameter Piston rings Top ring: Type End gap (installed) Side clearance (installed) 2 nd ring: Type End gap (installed) Side clearence (installed) Oil ring: End gap (installed) H Limit 41.94 mm 37.5 mm 45.
MAINTENANCE SPECIFICATIONS SPEC *[XN150] Item Standard Limit Carburetor Type I.D mark Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N) Pilot air jet (P.A.J.1) Needle jet (N.J) Pilot jet (P.J) Pilot screw (P.S) Valve seat size (V.S) Starter jet 1 (G.S.1) Float height (F.L) Engine idle speed TK 5DS [TK 5KD]* ••• #116 [#114]* ø1.0 [ø1.4]* 4E31 (3/5) [4E32 (3/5)]* ø1.30 2.590 #38 [#36] 2 1/4 ~ 2 3/4 [2 ~ 4]* ø2.00 #0.45 5 ~ 6 mm 1.600 ~ 1.
MAINTENANCE SPECIFICATIONS Item SPEC Size Crankshaft oil seal (left) Crankshaft oil seal (right) Crankshaft oil seal (right) Camshaft bearing (left) Camshaft bearing (right) Starter clutch bearing Primary drive gear bearing (left) Primary drive gear bearing (right) Primary drive gear oil seal Main axle bearing (left) Main axle bearing (right) Drive axle bearing (left) Drive axle bearing (right) Drive axle oil seal 22 x 32 x 7 19 x 30 x 8 (Reinforced) 19 x 30 x 8 (Double lips) 20 x 42 x 12 15 x 32 x 9 17
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system Steering bearing type No./size of steel balls Upper Lower Ball bearing 15 pcs 4.75 mm 15 pcs 4.
MAINTENANCE SPECIFICATIONS Item Brake lever Brake lever free play (front) Brake lever free play (rear) Throttle cable free play Standard 10 ~ 20 mm 10 ~ 20 mm 1.5 ~ 3.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Ignition timing Ignition timing (B.T.D.C) Advanced timing (B.T.D.C) Advanced type T.C.I Pickup coil resistance/color Source coil resistance/color Standard Limit 10° at 1.700 rpm 32° at 5.000 rpm Digital ••• ••• ••• 248 ~ 372 Ω at 20°C / white / red-white / blue 720 ~ 1080 Ω at 20°C / green/white - brown/black ••• ••• Ignition coil Minimum spark gap Primary winding resistance Secondary winding resistance 6 mm 0.32 ~ 0.
MAINTENANCE SPECIFICATIONS Item Standard SPEC Limit Horn Model/manufacturer Maximum amperage YF-12 / NIKKO 3A ••• ••• Flasher relay Flasher frequency 80 ~ 160 cycle/min ••• Fuel gauge Model/manufacturer Sender unit resistance - full - empty 25.33.06/MAXIMA 4 ~ 10 Ω 90 ~ 100 Ω ••• ••• ••• Circuit breaker Main Radiagtor fan fuse 20 A x 1 pcs 7.
CONVERSION TABLE SPEC AS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER IMPERERIAL ** mm x 0.03937 = ** in 2 mm x 0.03937 = 0.08 in CONVERSION TABLE METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Torque m•kg m•kg cm•kg cm•kg 7.233 86.794 0.0723 0.8679 ft•lb in•lb ft•lb in•lb Weight kg g 2.205 0.03527 lb oz Speed km/h 0.
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00029 GENERAL TIGHTENING TORQUE SPECIFICATIONS 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. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE Item Oil check bolt Spark plug Cylinder, water drain bolt Cylinder head and cylinder Cylinder head and cylinder Cylinder and crankcase Camshaft bearing stopper Camchain guide Valve adjuster nut Camshaft pinion bolt Camshaft tensionner Rocker shaft securing plate Thermostatic valve cover Water pump housing cover Water pump housing Water pump housing Thermostatic valve cover Oil pump Engine drain plug Inlet manifold on cylinder head Air filter cover Exhaust
TIGHTENING TORQUES Item Fastener Rear brake shoes pin pivot Thermo unit Coolant drain bolt on cylinder Starter motor Rotor Nut Bolt Bolt Nut Stator Bolt 2-15 Thread size M10 Pt 1/8 M6 M6 M12 M16 M16 M6 Q'ty 1 1 1 2 1 1 1 3 SPEC Tightening torque Nm m•kg 120 75 8 65 70 225 225 70 12.0 7.5 0.8 6.5 7.0 22.5 22.5 7.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES CHASSIS Item Frame with engine bracket Engine bracket 2 with 3 E/G bracket with E/G (with main stand) Reinforcement tail Rear cushion with frame Rear cushion with engine Steering shaft Handle with steering shaft Master cylinder with handle Seat lock Box with frame Box with reinforcement tail Carrier with frame Carrier with reinforcement tail Footrest board with frame Mud guard with frame Fender on front fork Cover handle with handle Mainstand Rear footrest Front
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips O-ring (Except V-belt drive unit) Cylinder head tightening nut mounting surface Crankshaft pin outside Connecting rod big end thrust surface Rotary filter inner surface Drive gear inner surface Cam chain outside sprocket inner surface Piston pin Piston outside and ring groove Camshaft cam profile Valve stem (IN, EX) Valve stem end (IN, EX) Rocker shaft Valve rocker a
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left/right) Steering head pipe bearing (upper/lower) Tube guide (throttle grip) inner surface Brake cable (brake lever) Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft Brake cam pivot shaft and cam surface 2-18
COOLING SYSTEM DIAGRAMS SPEC EAS00033 COOLING SYSTEM DIAGRAMS A Pass the hose under inlet manifold.
COOLING SYSTEM DIAGRAMS SPEC EAS00033(bis) COOLING SYSTEM DIAGRAMS Radiator Radiator fan Radiator cap Coolant tank Water pump Thermostat A Pass the hose between radiator and radiator filler hose.
LUBRICATION DIAGRAMS SPEC EAS00034 LUBRICATION DIAGRAMS 1Lubrication of the cylinder head Cylinder head Cylinder Crankcase 2Lubrication of the crankshaft Crankshaft 1 2 2-21
LUBRICATION DIAGRAMS SPEC EAS00034(bis) LUBRICATION DIAGRAMS 1Oil flow Cylinder head Cylinder Oil pump 2Lubrication table A Oil pressure flow B Oil return flow 1 2 A B Camshaft Crankshaft Cylinder head Rocker arm Oil pump Oil strainer Crankcase 2-22 Connecting rod
CABLE ROUTING SPEC EAS00035 CABLE ROUTING Thermo switch wire Seat lock cable Speedometer wire Main switch wire Seat lock cable adjuster Radiator Fan Headlight and front flasher connector Front fork assembly Wire harness Horn Horn wire Rear brake cable Throttle cable Band switch A Make the wire harness getting out here. B Place the speedometer wire as shown. C Pass the thermo switch lead between the hoses.
CABLE ROUTING Starter motor CDI unit rectifier/Regulator CDI magneto wire Ignition coil assembly Footrest board Starter relay Battery ground Wire harness SPEC Seat lock assembly Fuel tank Wire lead Mud guard Fuel cock A Place the wire as shown. B Place the sidestand wire as shown (option). C Apply grease on stater motor connector/ terminal.
SPEC CABLE ROUTING Battery Starter relay Frame Fuses box Relay Sender Fuel pipe 21 Engine air breather 22 Fuel cock 23 Seat lock assembly A Connection for anti-thelf (option) B Place the Starter motor ground as shown. C Pass the carburetor breather hose between air duct and air filter case.
CABLE ROUTING Right handlebar switches Inner handlebar cover Left handlebar switches Rear brake lever Front handlebar cover Master cylinder Front brake lever SPEC A Glue the handlebar grip. B Install the handlebar switch as shown. B-B A-A C-C view D B 30¡ 1.
CABLE ROUTING Master cylinder Inner handlebar cover Speedometer assembly Rear brake cable Throttle cable Front brake hose Wire harness Handlebar Speedometer coupler Front handlebar cover A Pass wires behind the turn signal relay bracket B Clip all wires and cables all together C Install the wire harness behind the turn signal relay bracket.
CHK ADJ 3
CHK ADJ CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ............................................................................................ 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .................. 3-1 COVER AND PANEL .................................................................................... 3-3 SIDE COVERS AND SEAT ...................................................................... 3-3 FRONT COVER, INNER PANEL AND INNER FRONT COVER .............
CHK ADJ ELECTRICAL SYSTEM ............................................................................... 3-37 CHECKING THE BATTERY .................................................................. 3-37 CHECKING THE FUSES ....................................................................... 3-40 REPLACING THE HEADLIGHT BULBS AND THE FRONT TURN SIGNAL LIGHT BULBS .......................................................................... 3-41 REPLACING THE REAR TURN SIGNAL LIGHT BULBS .....................
PERIODIC CHECKS AND ADJUSTMENTS 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 CHECKS AND ADJUSTMENTS No. ITEM 16 * Front fork 17 * Rear shock absorber assembly 18 * Carburetor 19 * Engine oil 20 * Engine oil filter strainer 21 * Final gear oil 22 * Coolant system 23 * V-belt 24 Moving parts and cables 25 * Light, signals and switches CHECK, MAINTENANCE AND LUBRICATION • Check operation and for oil leakage. • Check operation and shock absorber for oil leakage. • Check engine idling speed and starter operation. • Change. • Clean.
CHK ADJ COVER AND PANEL EASM0005 COVER AND PANEL SIDE COVERS AND SEAT 2 T.R 8 Nm (0.8 m¥kg) 18.5 Nm (1.85 m¥kg) T.R 4 6 6 5 7 3 T.R 7 Nm (0.7 m¥kg) 1 8 D FW T.R Order I 1 2 II 3 III 4 IV 5 6 Job/Part Q’ty Removing the side covers Remove: Battery cover Box and seat assembly Seat axle circlip Seat axle Seat Gasket Unplug: Fuel tank overflow pipe Remove: Rear carrier Disconnect: Taillight coupler Rear flasher light (left and right) 7 Nm (0.
CHK ADJ COVER AND PANEL 2 T.R 8 Nm (0.8 m¥kg) 18.5 Nm (1.85 m¥kg) T.R 4 6 6 5 7 3 T.R 7 Nm (0.7 m¥kg) 1 8 D FW T.R Order V 7 8 Job/Part Q’ty Remove: Side cover (right) Side cover (left) 7 Nm (0.7 m¥kg) Remarks 1 1 For installation, reverse the removal procedure.
CHK ADJ COVER AND PANEL EASM0007 FRONT COVER, INNER PANEL AND INNER FRONT COVER 2 7 Nm (0.7 m kg) T.R 7 Nm (0.7 m kg) T.R T.R 7 Nm (0.7 m kg) 6 3 1 5 7 4 T.R T.R 7 Nm (0.7 m kg) 7 Nm (0.
CHK ADJ COVER AND PANEL EASM0008 FOOTREST BOARD AND UNDER COVER 1 7 Nm (0.7 m kg) T.R T.R 4 Nm (0.4 m kg) 1 3 2 T.R 13.5 Nm (1.35 m kg) 6 4 7 Nm (0.7 m kg) T.R 5 D FW Order I II 1 2 3 4 5 6 Job/Part Q’ty Removing the footrest board and under cover Remove: Side covers 2 Inner panel 1 Remove: Footrest Battery Fuses box Starter relay Under cover Side under cover/footrest board assembly Remarks Remove the parts in the order listed.
COVER AND PANEL CHK ADJ EASM0009 HANDLEBAR COVERS T.R T.R 7 Nm (0.7 m kg) 2 4.5 Nm (0.45 m kg) 1 3 T.R 4.5 Nm (0.45 m kg) D FW Order I 1 II 2 III 3 Job/Part Q’ty Removing the handlebar covers Remove: Front handlebar cover Disconnect: Speedometer assy’ lead Remove: Inner handlebar cover Remarks Remove the parts in the order listed. 1 1 For installation, reverse the removal procedure.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: • Battery cover • Seat • Side covers • Box Refer to “SIDE COVERS AND SEAT” section.
ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED CHK ADJ 3. Adjust: • valve clearance 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Loosen the locknut . b. Insert a thickness gauge between the end of the adjusting screw and the valve tip. c. Turn the adjusting screw in or out until the specified valve clearance is obtained. → Valve clearance is decreased. Turning out → Valve clearance is increased.
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 2. Attach: • engine tachometer (onto the spark plug lead of the cylinder) Engine tachometer 90890-03113 3. Measure: • engine idling speed Out of specification → Adjust. Engine idling speed 1,400 ~ 1,800 r / min 4. Adjust: • engine idling speed 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Turn the pilot screw in until it is lightly seated. b. Turn the pilot screw out the specified number of turns.
ADJUSTING THE THROTTLE CABLE FREE PLAY / CHECKING THE SPARK PLUG CHK ADJ 1. Check: • throttle cable free play Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3 mm 2. Adjust: • throttle cable free play ZAUM0051 NOTE: When the throttle is opened, the accelerator cable is pulled. 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Turn the adjusting nut in or out until the specified throttle cable free play is obtained.
CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING CHK ADJ 4. Check: • electrodes Damage/wear → Replace the spark plug. • insulator Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6. Measure: • spark plug gap (with a wire gauge) Out of specification → Regap. Spark plug gap 0.5 ~ 0.7 mm ZAUM0037 7. Install: • spark plug T.R 13 Nm (1.
CHECKING THE IGNITION TIMING/ TRANSMISSION OIL REPLACEMENT CHK ADJ 2. Check: • ignition timing 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 1,400 ~ 1,800 r/min a b b. Check that the mark a is within the required firing range b on the timing plate. Incorrect firing range → Check the ignition system. NOTE: The ignition timing is not adjustable.
MEASURING THE COMPRESSION PRESSURE CHK ADJ EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance Out of specification → Adjust Refer to “ADJUSTING THE VALVE CLEARANCE” section. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Disconnect: • spark plug cap 4.
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits. Carbon deposits → Remove. d. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again. Refer to the following table.
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL -20° -10° 0° 10° 20° 30° Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard SE or higher grade (Non-friction modified) 40° 50°C SAE 10W/30 SAE 10W/40 SAE 15W/40 SAE 20W/40 SAE 20W/50 CHK ADJ CAUTION: Do not allow foreign materials to enter the crankcase. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4.
CHECKING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE/ CHK ADJ 7. Reset: • engine oil warning circuit 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Press the “TRIP” button while turning the key to “ON” b. Release the “TRIP” button and oil indicator light will go off NOTE: • If the oil is change before the oil indicator light comes on (i.e.
CLEANING THE AIR FILTER ELEMENT/ CLEANING THE V-BELT CASE AIR FILTER ELEMENT ZAUM0046 CHK ADJ EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: • air filter case cover 2. Clean: • air filter element Apply compressed air to the outer surface of the air filter element. 3. Check: • air filter element Damage → Replace. 4. Install: • air filter element • air filter case cover CAUTION: Never operate the engine without the air filter element installed.
CHECKING THE FUEL AND VACUUM HOSES/ EXHAUST SYSTEM INSPECTION CHK ADJ EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses. 1. Remove: • Seat • Box Refer to “SIDE COVERS AND SEAT” section. 2. Check: • vacuum hose • fuel hose Cracks/damage → Replace. Loose connection → Connect properly. 3. Install: • Box • Seat Refer to “SIDE COVERS AND SEAT” section. EASM0014 EXHAUST SYSTEM INSPECTION 1.
CHECKING THE COOLANT LEVEL CHK ADJ EAS00103 CHECKING THE COOLANT LEVEL 1. Stand the scooter on a level surface. NOTE: Place the scooter on a suitable stand. Make sure the scooter is upright. 2. Remove: • Coolant tank cover Refer to “FRONT COVER, INNER PANEL AND INNER FRONT COVER” section. ZAUM0044 3. Check: • coolant level The coolant level should be between the maximum level mark and minimum level mark . Below the minimum level mark → Add the recommended coolant to the proper level.
CHANGING THE COOLANT CHK ADJ EAS00105 CHANGING THE COOLANT 1. Remove: • Side covers • Seat • Rear carrier • Box Refer to “SIDE COVERS AND SEAT” section. • Front cover • Inner panel Refer to “FRONT COVER, INNER PANEL AND INNER FRONT PANEL” section. 2. Disconnect: • coolant reservoir hose 3. Drain: • coolant (from the coolant reservoir) 4. Remove: • radiator cap WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot.
CHANGING THE COOLANT CHK ADJ 7. Check: • copper washer (coolant drain bolt-engine ) • copper washer (coolant drain bolt-water pump) Damage → Replace. 8. Install: • coolant drain bolt (engine) T.R 10 Nm (1.0m•kg) • coolant drain bolt (water pump) T.R 10 Nm (1.0m•kg) 9. Connect: • coolant reservoir hose 10.
CHANGING THE COOLANT CHK ADJ CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if distilled water is not available, soft water may be used. • If coolant comes into contact with painted surfaces, immediately wash them with water. • Do not mix different types of antifreeze. ZAUM0044 11. Install: • radiator cap 12.
INSPECTING THE COOLANT SYSTEM CHK ADJ EASM0015 INSPECTING THE COOLANT SYSTEM 1. Inspect: • Radiator • Filler hose (radiator) • Outlet hose (radiator) • Pipe • Outlet hose (radiator) Cracks/Damage → Replace Refer to “COOLING SYSTEM” section in chapter 5.
CHECKING THE FRONT BRAKE LEVER FREE PLAY/ ADJUSTING THE REAR BRAKE CHK ADJ EASM0016 CHASSIS CHECKING THE FRONT BRAKE LEVER FREE PLAY 1. Check: • brake lever free play Out of specification → check the front brake system. Refer to “FRONT BRAKE” section in chapter 7. ZAUM0055 Brake lever free play (at the end of the brake lever) 10 ~ 20 mm WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system.
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ CAUTION: After adjusting the brake lever free play, make sure there is no brake drag. 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 EAS00116 CHECKING THE BRAKE FLUID LEVEL 1. Stand the scooter on a level surface. NOTE: • Place the scooter on a suitable stand. • Make sure the scooter is upright. 2. Check: • brake fluid level Below the minimum level mark → Add the recommended brake fluid to the proper level.
CHECKING THE BRAKE PADS/CHECKING THE BRAKE SHOES/ CHECKING THE BRAKE HOSES CHK ADJ EASM0017 A ZAUM0058 CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • brake pad thickness Less than specification → Replace the brake pads as a set. Refer to “FRONT BRAKE” section in chapter 7. Brake pad thickness wear limit 0.8 mm A Front brake EAS00126 ZAUM0059 CHECKING THE BRAKE SHOES 1. Operate the brake. 2.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenever: • the system is disassembled, • a brake hose is loosened, disconnected or replaced, • the brake fluid level is very low, • brake operation is faulty. NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow.
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. T. R Bleed screw 6 Nm (0.6 m•kg) k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL” section. WARNING After bleeding the hydraulic brake system, check the brake operation .
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Remove the lock washer , the upper ring nut , the center ring nut and the rubber washer. b. Loosen the lower ring nut and then tighten it to specification with the ring nut wrench . NOTE: Set the torque wrench at a right angle to the ring nut wrench. Steering nut wrench 90890-01403 T. R Lower ring nut (initial tightening torque) 38 Nm (3.8 m•kg) c.
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK CHK ADJ Ring nut wrench 90890-01268 T. R Upper ring nut 75 Nm (7.5 m•kg) 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 5. Install: • Handlebar Refer to “HANDLEBAR” section in chapter 7. • Handlebar cover Refer to “HANDLEBAR COVERS” section. EAS00151 CHECKING THE FRONT FORK 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 3115 2.
INSPECTING THE REAR SHOCK ABSORBER/ CHECKING THE TYRES CHK ADJ EASM0018 INSPECTING THE REAR SHOCK ABSORBER 1. Remove: • Side covers Refer to “SIDE COVERS AND SEAT” section. 2. Check • Rear shock absorber mount 31.5 Nm (3.15m•kg) Looseness → Tighten Bolt (upper) 17.5 Nm (1.75m•kg) Bolt (lower) T.R T.R Refer to “REAR SHOCK ABSORBER AND EXHAUST PIPE” section in chapter 7. EAS00167 CHECKING THE TYRES The following procedure applies to both of the tyres. 1.
CHECKING THE TYRES CHK ADJ WARNING It is dangerous to ride with a worn-out tyre. When the tyre tread reaches the wear limit, replace the tyre immediately. 2. Check: • tyre surfaces Damage/wear → Replace the tyre. 3101 Minimum tyre tread depth 0.8 mm 3103 Tyre tread depth Side wall Wear indicator WARNING • Do not use a tubeless tyre on a wheel designed only for tube tyres to avoid tyre failure and personal injury from sudden deflation.
CHECKING THE TYRES Front tyre Manufacturer Model Size Rear tyre Manufacturer Model Size CHK ADJ METZELER ME-7 TEEN 120/70-12 METZELER ME-7 TEEN 120/70-12 WARNING • New tyres have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. • After a tyre has been repaired or replaced, be sure to tighten the tyre air valve stem locknut to specification.
CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES CHK ADJ EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: • wheel Damage/out-of-round → Replace. WARNING Never attempt to make any repairs to the wheel. NOTE: After a tyre or wheel has been changed or replaced, always balance the wheel. EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables.
LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE CENTERSTAND CHK ADJ EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Engine oil ZAUM0061 EAS00172 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.
CHECKING THE BATTERY CHK ADJ EAS00177 ELECTRICAL SYSTEM CHECKING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulphuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING THE BATTERY UPPER LOWER + CHK ADJ 4. Check: • electrolyte level The electrolyte level should be between the minimum level mark and the maximum level mark . Below the minimum level mark → Add distilled water to the proper level. CAUTION: Add only distilled water. Tap water contains minerals which are harmful to the battery. 5. Check: • specific gravity Less than 1.280 → Recharge the battery. Specific gravity 1.280 at 20°C 6. Charge: • battery WARNING Do not quick charge a battery.
CHECKING THE BATTERY CHK ADJ • Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it.
CHECKING THE BATTERY/ CHECKING THE FUSES 11. Connect: • battery leads (to the battery terminals) CHK ADJ + CAUTION: First, connect the positive battery lead , and then the negative battery lead . om913(b) 12. Lubricate: • battery terminals Recommended lubricant Dielectric grease 13. Install: • Battery cover Refer to “SIDE COVERS AND SEAT” section. EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses.
CHECKING THE FUSES / REPLACING THE HEADLIGHT BULBS AND THE FRONT TURN SIGNAL LIGHT BULBS CHK ADJ 3. Replace: • blown fuse 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage. c. Set on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 Items Main fuse Fan fuse Amperage 20A 7.
REPLACING THE REAR TURN SIGNAL LIGHT BULBS CHK ADJ 5. Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Attach: • headlight bulb holder 7.
REPLACING THE TAIL/BRAKE LIGHT BULB CHK ADJ CAUTION: Do not overtighten the screw, otherwise the lensmay break. 4. Install: • Turn signal light lens EAS00183 REPLACING THE TAIL/BRAKE LIGHT BULB 1. Remove: • Tail/brake light lens 2. Remove: • Tail/brake bulb (push and turn it counterclockwise) WARNING Since the tail/brake bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 3.
ADJUSTING THE HEADLIGHT BEAMS/ ADJUSTING THE DIGITAL CLOCK CHK ADJ EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Turn the adjusting screw in or out. Turning in → Headlight beam is raised. Turning out → Headlight beam is lowered. 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 EASM0019 ADJUSTING THE DIGITAL CLOCK To adjuste the digital clock, refer to “FEATURES” section in chapter 1.
ENG 4
ENG CHAPTER 4. OVERHAULING THE ENGINE ENGINE ......................................................................................................... 4-1 WIRING HARNESS, CABLE .................................................................... 4-1 HOSES, AIR FILTER, ENGINE MOUNTING BOLT AND ENGINE ......... 4-3 CAMSHAFT ................................................................................................... 4-4 REMOVING THE ROCKER ARMS AND THE CAMSHAFT ....................
ENG CLUTCH ...................................................................................................... 4-28 CRANKCASE COVER ........................................................................... 4-28 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ................. 4-29 SECONDARY SHEAVE ......................................................................... 4-30 REMOVING THE PRIMARY SHEAVE .................................................. 4-31 REMOVING THE SECONDARY SHEAVE AND V-BELT ........
ENG ENGINE EASM0020 (bis) OVERHAULING THE ENGINE ENGINE WIRING HARNESS, CABLE 5 3 4 2 1 10 Nm (1.0 m¥kg) T.R 9 8 6 7 D FW Order Job/Part Q’ty Removing the wire harness and cables Side covers Seat Box Footrest board Under cover Carburetor Remove the parts in the order listed. Refer to “SIDE COVERS AND SEAT” section in chapter 3. Refer to “FOOTREST BOARD, AND UNDER COVER” section in chapter 3. Refer to “CARBURETOR” section in chapter 6. Refer to “CHANGING THE COOLANT” section in chapter 3.
ENG ENGINE 5 3 4 2 1 10 Nm (1.0 m¥kg) T.R 9 8 6 7 D FW Order Job/Part Q’ty 5 6 7 8 9 10 Earth lead Adjuster Rear brake cable Rear brake cable pin Rear brake cable compression spring Cable holder 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure.
ENG ENGINE EASM0021 HOSES, AIR FILTER, ENGINE MOUNTING BOLT AND ENGINE 4 7 5 8 17.5 Nm (1,75 m¥kg) T.R 3 1 T.R WD 2 F Order 1 2 3 4 5 6 7 8 Job/Part Removing the hoses, air filter, engine mounting bolt and engine Crankcase breather hose Pump inlet hose Cylinder head outlet hose Air filter case assembly Rear shock absorber bolt (lower) Self locknut/ Plane washer Engine mounting bolt Engine Q’ty 43 Nm (4,3 m¥kg) 6 Remarks Remove the parts in the order listed.
CAMSHAFT ENG EASM0023 CAMSHAFT 8 T.R 6,5 Nm (0,65 m¥kg) 9 M 1 LS 7 E 3 T.R 10 Nm (1,0 m¥kg) 2 4 LS 6 M M LS E 7 9 1 8 T.R Order 1 2 3 4 5 6 7 8 9 5 6,5 Nm (0,65 m¥kg) Job/Part Q’ty Removing the camshaft Cylinder head Plate bolt Plate Rocker arm shaft (intake) Rocker arm shaft (exhaust) Camshaft retaining plate Camshaft Rocker arms (intake and exhaust) Locknut Adjuster T.R 12 Nm (1,2 m¥kg) Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD” section.
CAMSHAFT ENG EAS00197 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Align: • “T” mark on the generator rotor (with the mark on the generator rotor cover) b 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compression stroke, align the “T” mark a on the generator rotor with the mark b on the crankcase. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 2.
CAMSHAFT ENG 3. Measure: • camshaft lobe dimensions a and b . Out of specification → Replace the camshaft. Camshaft lobe dimension limit Intake a 30.711mm b 25.045 mm Exhaust a 30.711 mm b 25.052 mm 4. Check: • camshaft oil passage Obstruction → Blow out with compressed air. EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: • rocker arm Damage/wear → Replace. 2.
CAMSHAFT ENG 6. Calculate: • rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.037 mm EAS00207 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES 1. Check: • timing chain Damage/stiffness → Replace the timing chain and camshaft sprocket as a set. 2.
CAMSHAFT ENG EAS00212 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER The following procedure applies to both of the tappet covers and O-rings. 1. Check: • tappet covers • O-rings Damage/wear → Replace the defective part(s). INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: • rocker arms and shafts (intake and exhaust) Recommended lubricant Molybdenum disulfide oil 2. Install: • exhaust rocker arm • intake rocker arm 3.
CAMSHAFT ENG CAUTION: Make sure the threaded part of the rocker arm shaft and O-rings faces outwards. 6. Install: • rocker arm shaft clamp and bolt. 10 Nm (1.0m•kg) T.R 7. Install: • timing chain (onto the camshaft sprocket) • camshaft sprocket (onto the camshaft) NOTE: • The notch on the camshaft should face towards the intake side of the engine. • Align the camshaft mark c with the edge of the cylinder head d as shown.
CYLINDER HEAD ENG EASM0020 CYLINDER HEAD T.R 8 Nm (0.8 m¥kg) 8 T.R 10 Nm (1.0 m¥kg) 14 22 Nm (2.2 m¥kg) T.R 12 2 5 1 15 13 10 6 7 D FW 4 9 11 30 Nm (3.0 m¥kg) Job/Part Q’ty Removing the cylinder head Side covers Seat Box Caburetor Refer to “SIDE COVERS AND SEAT” section in chapter 3. Refer to “CARBURETOR” section in chapter 6. Refer to "REAR SHOCKS ABSORBER AND EXHAUST PIPE" section in chapter 7. Refer to “CHANGING THE COOLANT” section in chapter 3.
CYLINDER HEAD ENG 8 Nm (0.8 m¥kg) T.R 8 T.R 10 Nm (1.0 m¥kg) 14 22 Nm (2.2 m¥kg) T.R 12 2 5 1 15 13 10 6 7 D FW 4 9 11 Job/Part 12 Nm (1.2 m¥kg) 3 30 Nm (3.0 m¥kg) T.R Order T.
CYLINDER HEAD ENG EAS00225 REMOVING THE CYLINDER HEAD 1. Remove: • camshaft and rocker arms Refer to “REMOVING THE ROCKER ARMS AND CAMSHAFT” section. NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire. 2. Remove: • cylinder head NOTE: • Loosen the nuts in the proper sequence. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. EAS00229 CHECKING THE CYLINDER HEAD 1.
ENG CYLINDER HEAD d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 EAS00232 INSTALLING THE CYLINDER HEAD 1. Install: • cylinder head gasket • dowel pins 2. Install: • cylinder head • copper washers 22 Nm (2.2m•kg) • cylinder head nuts 12 Nm (1.2m•kg) • cylinder haed bolts T.R T.
VALVES AND VALVE SPRINGS ENG EASM0024 VALVES AND VALVE SPRINGS 5 2 M 1 3 6 7 4 7 6 M 3 2 1 Order 1 2 3 4 5 6 7 Job/Part Removing the valves and valves springs Cylinder head Rocker arm, rocker arm shaft Valve cotters Spring retainer Valve spring Valve (intake) valve (exhaust) Valve guide (oil seals) Spring seat Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD” section Refer to “CAMSHAFT” section.
VALVES AND VALVE SPRINGS ENG EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • valve (for leakage) Leakage at the valve seat → Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS” section. 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a.
VALVES AND VALVE SPRINGS ENG EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: • valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter b Valve stem diameter a b Out of specification → Replace the valve guide. a Valve guide inside diameter: Intake 4.500 ~ 4.512 mm : 4.542 mm Exhaust 4.500 ~ 4.512 mm : 4.542 mm Valve stem diameter: Intake 4.475 ~ 4.
VALVES AND VALVE SPRINGS ENG c. After installing the valve guide, bore the valve guide with the valve guide reamer to obtain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat . Valve guide remover (4.5 mm) 90890-04116 Valve guide installer (4.5 mm) 90890-04117 Valve guide reamer (4.5 mm) 90890-04118 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 a 3. Remove: • carbon deposits (from the valve face and valve seat) 4.
VALVES AND VALVE SPRINGS ENG 3. Measure: • valve seat width a Out of specification → Replace the cylinder head. Valve seat width Intake 0.9 ~ 1.1 mm : 1.6 mm Exhaust 0.9 ~ 1.1 : 1.6 mm) 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Apply Mechanic’s blueing dye (Dykem) onto the valve face . b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impression. d. Measure the valve seat width.
VALVES AND VALVE SPRINGS ENG c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. e. Apply a fine lapping compound to the valve face and repeat the above steps. f.
VALVES AND VALVE SPRINGS ENG Spring compressed pressure (intake and exhaust) 45.1 ~ 50.9 N a 3. Measure: • valve spring tilt a Out of specification → Replace the valve spring. Spring tilt limit Intake and exhaust valve spring 2.5° / 1.9 mm EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2.
VALVES AND VALVE SPRINGS ENG 4. Install: • valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor and attachment. Valve spring compressor 90890-04019 Attachment 90890-04108 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve.
CYLINDER AND PISTON ENG EASM0025 CYLINDER AND PISTON E 6 5 4 3 9 1 T.R 10 11 8 7 12 Nm (1.2 m¥kg) 2 WD F Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Removing the cylinder and piston Cylinder head Cylinder bolts Timing chain guide (lower) Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring (top) Piston ring (2nd) Oil ring Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD” section.
CYLINDER AND PISTON ENG EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clip • piston pin • piston CAUTION: Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. • Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area.
CYLINDER AND PISTON ENG 2. Measure: • piston-to-cylinder clearance 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. D1 D3 D5 Cylinder XN 125 bore “C” XN 150 Taper limit “T” Out-of-round “R” 53.700 ~ 53.705 mm 59.500 ~ 59.505 mm 0.05 mm 0.
CYLINDER AND PISTON ENG EAS00264 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, remove any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.03 ~ 0.07 mm : 0.12 mm 2nd ring 0.02 ~ 0.06 : 0.12 mm a 2.
CYLINDER AND PISTON ENG EAS00265 CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration / grooves → Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 14.991 ~ 15.000 mm 3. Calculate: • piston-pin-to-piston clearance Out of specification → Replace the piston pin and piston as a set.
CYLINDER AND PISTON 2. Install: • piston • piston pin • piston pin clip ENG NOTE: • Lubricate the piston pin with engine oil. • Make sure the arrow mark a on the piston points towards the exhaust side of the cylinder. • Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase. 3. Install: • gasket • dowel pins 4.
ENG CLUTCH EASM0026 CLUTCH CRANKCASE COVER 6 T.R 9 Nm (0.9 m¥kg) 5 4 T.R 3 D FW Order 1 2 T.R Job/Part Q’ty Removing the crankcase cover Side covers 1 2 3 4 5 6 10 Nm (1.0 m¥kg) Air filter crankcase cover Air filter crankcase cover gasket Air filter crankcase element Crankcase cover protector Crankcase cover (left) Crankcase cover gasket 10 Nm (1.0 m¥kg) Remarks Remove the parts in the order listed. Refer SIDE COVERS AND SEAT” section in chapter 3.
V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE ENG EASM0027 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 12 6 T.R 60 Nm (6.0 m¥kg) 5 4 3 10 11 13 8 13 9 7 2 1 T.R 55 Nm (5.5 m¥kg) D FW Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Part Removing the V-belt, clutch and secondary/primary sheave Nut/plain washer/washer Primary fixed sheave Nut Clutch housing Clutch assembly V-belt Washer Primary sliding sheave Collar Cam Weight Slider Oil seal Q’ty Remarks Remove the parts in the order listed.
V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE ENG EASM0028 SECONDARY SHEAVE ** Apply BEL-RAY assembly lube ® T.R 90 Nm (9.0 m¥kg) LS ** ** ** ** D FW Order Job/Part Disassembling the secondary sheave Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave Q’ty Remarks Disassemble the parts in the order listed.
V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE REMOVING THE PRIMARY SHEAVE 1. Remove: • nut (primary sheave) • plate washer • primary fixed sheave ENG NOTE: Loosen the nut (primary fixed sheave) while holding the primary fixed sheave with the rotor holder . Rotor holder 90890-01235 REMOVING THE SECONDARY SHEAVE AND V-BELT 1. Remove: • nut (secondary sheave) • clutch housing NOTE: Loosen the nut (secondary sheave) while holding the clutch housing with the sheave holder .
V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE ENG 3. Remove: • clutch assembly • V-belt NOTE: Remove the V-belt from the primary sheave side with clutch assembly. DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: • nut (secondary sheave) NOTE: Loosen the nut while attaching the clutch spring compressor and clutch spring holder arm and release the compressed spring after removing the nut. CAUTION: Use the spacer (ø 40 mm, thickness: 2~3 mm).
V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE ENG EAS00290 CHECKING THE CLUTCH HOUSING 1. Check: • clutch housing Damage/wearr → Replace. 2. Measure: • clutch housing inside diameter a Out of specification → Replace the clutch housing. a Clutch housing inside diameter XN125: 120 mm XN150: 135 mm : 120.5 mm : 130.5 mm EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1.
V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE ENG CHECKING THE WEIGHTS 1. Check: • weight minimum outside diameter Cracks/wear/scaling/chipping → Replace. Out of specification → Replace. Weight out side diameter 20.0 mm : 19.5 mm CHECKING THE SECONDARY SHEAVE 1. Check: • secondary fixed sheave smooth operation • secondary sliding sheave smooth operation Scratches/damage → Replace as a set. 2. Check: • Torque cam groove Wear/damage → Replace. 3. Check: • Guide pin Wear/damage → Replace.
V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE E E ENG INSTALLING THE SECONDARY SHEAVE 1. Apply: • BEL-RAY assembly lube ® (to the secondary sliding sheave inner surface, grease nipple groove, and oil seals) • BEL-RAY assembly lube ® (to the bearings, oil seals and inner surface of the secondary fixed sheave) 2. Install: • secondary sliding sheave 3. Install: • guide pin 4. Apply: • BEL-RAY assembly lube ® (to the guide pin sliding groove , and oil seal ) 5.
V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE ENG 6. Install: • V-belt • clutch assembly NOTE: Install the V-belt with the clutch assembly to the primary sheave side. CAUTION: Never smear grease to the V-belt, secondary sheave and clutch. 7. Install: • nut (clutch carrier) T.R 90 Nm (9.0m•kg) NOTE: Tighten the nut (clutch carrier), using the locknut wrench whlie holding the clutch carrier with the rotor holder . Rotor holder 90890-01235 8.
STARTER CLUTCH AND GENERATOR ENG EASM0029 STARTER CLUTCH AND GENERATOR MAGNETO COVER AND STATOR COIL 1 2 9 3 T.R 7 Nm (0,7 m•kg) 7 4 10 5 6 T.R 70 Nm (7,0 m•kg) 8 T.R 7 Nm (0,7 m•kg) D FW Order Job/Part Q’ty Removing the magneto cover and stator coil Side cover 1 2 3 4 5 6 7 8 9 10 Flywheel lead coupler Flywheel cover Nut Washer Rotor Stator fixing screws Woodruf key Stator Pick up coil screw Pick up coil Remarks Remove the parts in the order listed.
ENG STARTER CLUTCH AND GENERATOR EASM0030 STARTER CLUTH T.R 65 Nm (6,5 m•kg) T.R 4 7 Nm (0,7 m•kg) 3 2 1 7 WD 6 F 5 Order 1 2 3 4 5 6 7 Job/Part Removing the starter clutch Gear retainer plane Washer Idle gear Washer Starter one way cluth Collar Starter wheel gear Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
STARTER CLUTCH AND GENERATOR ENG EAS00348 CHECKING THE STARTER CLUTCH 1. Check: • starter clutch idle gear • starter clutch wheel gear • starter one way clutch Chips/pitting/roughness/wear → Replace the defective part(s). 2. Check: • starter clutch operation 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Install the starter clutch drive gear onto the starter clutch and hold the starter clutch. b.
OIL PUMP ENG EASM0031 OIL PUMP 1 T.R 7 Nm (0,7 m•kg) 3 4 5 6 8 2 65 Nm (6,5 m•kg) T.R 7 D FW Order Job/Part Q’ty Removing the oil pump Drain Engine oil Remove the parts in the order listed. Refer to “CHANGING THE ENGINE OIL” section in chapter 3. Refer to “STARTER CLUTCH AND GENERATOR” section.
OIL PUMP ENG EAS00363 A CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear • oil pump housing • oil pump housing cover Cracks/damage/wear → Replace the defective part(-s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance A • outer-rotor-to-oil-pump-housing clearance B • Pump housing-to-rotors clearance C Out of specification → Replace the oil pump. Inner rotor Outer rotor Oil pump housing Inner-rotor-to-outer-rotor-tip clearance limit: 0.
ENG CRANKCASE AND CRANKSHAFT EASM0032 CRANKCASE AND CRANKSHAFT T.R 9 Nm (0.9 m¥kg) 4 3 5 E 8 6 E 2 7 1 D FW T.R Order Job/Part Q’ty Removing the crankcase and crankshaft Engine Cylinder head Cylinder and piston 9 Nm (0.9 m¥kg) Remarks Remove the parts in the order listed. V-belt, cluth, secondary/primary sheave CDI magneto Oil pump Water pump Rear wheel 4-42 Refer to “ENGINE” section. Refer to “CYLINDER HEAD” section. Refer to “CYLINDER AND PISTON” section.
ENG CRANKCASE AND CRANKSHAFT T.R 9 Nm (0.9 m¥kg) 4 3 5 E 8 6 E 2 7 1 D FW Order T.R Job/Part Q’ty 1 2 3 4 Bolt Timing chain guide Screws Crankcase (right) 1 1 8 1 5 6 7 8 Dowel pin Crankshaft assembly Timing chain Crankcase (left) 2 1 1 1 9 Nm (0.9 m¥kg) Remarks Refer to “INSTALLING THE CRANKSHAFT AND STARTER CLUTCH” section. For installation, reverse the removal procedure.
CRANKCASE AND CRANKSHAFT ENG EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • right crankcase CAUTION: Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly. 3.
CRANKCASE AND CRANKSHAFT ENG EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: • crankshaft runout Out of specification → Replace the crankshaft, bearing or both. NOTE: Turn the crankshaft slowly. Maximum crankshaft runout 0.03 mm 2. Measure: • big end side clearance Out of specification → Replace the crankshaft. Big end side clearance 0.15 ~ 0.45 mm 3. Measure: • crankshaft width Out of specification → Replace the crankshaft. Crankshaft width 47.95 ~ 48.00 mm 4.
CRANKCASE AND CRANKSHAFT ENG EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase Cracks/damage → Replace. • oil delivery passages Obstruction → Blow out with compressed air. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: • bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. 2.
CRANKCASE AND CRANKSHAFT ENG EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery. 2. Install: • dowel pins 3. Install: • crankshaft 4. Install: • timing chain 5. Install: • left crankcase (onto the right crankcase) NOTE: Tap lightly on the left crankcase with a soft-face hammer. 6. Install: 9 Nm (0.9m•kg) • crankcase bolts 7.
ENG TRANSMISSION EASM0033 TRANSMISSION LS E 9 G 6 8 7 4 E E E G 5 E 3 WD F Order 2 Job/Part Q’ty Removing the transmission Rear wheel 1 T.R 6.5 Nm (0,65 m•kg) Remarks Remove the parts in the order listed. Refer to “REAR WHEEL AND BRAKE” section in chapter 7. Refer to “V-BELT, CLUTH AND SECONDARY/PRIMARY SHEAVE” section. Refer to “TRANSMISSON OIL REPLACEMENT” section in chapter 3.
ENG TRANSMISSION LS E 9 G 6 8 7 4 E E E G 5 E 3 D FW 2 Order Job/Part Q’ty 8 Idle gear 1 9 Main axle 1 1 T.R 6.5 Nm (0,65 m•kg) Remarks For installation, reverse the removal procedure.
COOL 5
COOL CHAPTER 5. COOLING SYSTEM RADIATOR .................................................................................................... 5-1 CHECKING THE RADIATOR .................................................................. 5-3 INSTALLING THE RADIATOR ................................................................ 5-3 THERMOSTAT .............................................................................................. 5-4 CHECKING THE THERMOSTAT ...............................................
RADIATOR COOL EASM0034 COOLING SYSTEM RADIATOR 6 7 2 5 4 2 8 3 1 Order Job/Part Q’ty Drain coolant Refer to “CHANGING THE COOLANT” section in chapter 3. Refer to “FRONT COVER, INNER PANEL AND INNER FRONT COVER” section in chapter 3. Refer to “FOOTREST BOARD AND UNDER COVER” section in chapter 3.
COOL RADIATOR 6 7 2 5 4 2 8 3 1 Order IV 7 8 Job/Part Q’ty Remove: Radiator Radiator fan 1 1 Remarks NOTE: Avoid the radiator of falling For installation, reverse the removal procedure.
RADIATOR COOL EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins 햲 Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. 햲 NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: • radiator hoses • radiator pipes Crack/damage → Replace. 3. Check: • radiator cap Cracks/damage → Replace. 4. Check: • radiator fan Damage → Replace. Malfunction → Check and repair. Refer to “COOLING SYSTEM” section in chapter 8.
THERMOSTAT COOL EASM0036 THERMOSTAT T.R 9 Nm (0,9 m•kg) 3 1 4 2 Order 5 Job/Part Q’ty Removing the thermostat Drain coolant Remove the parts in the order listed. Refer to “CHANGING COOLANT” section in chapter 3. Refer to “SIDE COVERS AND SEAT” section in chapter 3. Box 1 2 3 4 5 Remarks Hose Cylinder head outlet hose Thermostat cover fixing screws Thermostat cover Thermostat 1 1 2 1 1 For installation, reverse the removal procedure.
THERMOSTAT COOL EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat 햲 Does not open at 80.5 ~ 83.5°C → Replace. 햲 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
COOL WATER PUMP EASM0035 WATER PUMP 7 Nm (0.7m¥kg) T.R LS T.R 10 Nm (1.0m¥kg) 햶 햴 4 햵 햸 3 햷 햳 햲 햲 햳 3 햲 1 2 3 Order Job/Part Q’ty Removing the water pump Drain coolant 1 2 3 4 햲 햳 햴 햵 햶 햷 햸 Pump inlet hose Pump outlet hose Water pump fixing screws Water pump assembly Disassembling water pump Water pump mounting screws Bleed screw with copper washer Water pump inner cover O-ring Water pump cover/gasket Impeller shaft Dowel pin T.R 3 7 Nm (0.
WATER PUMP COOL EAS00472 CHECKING THE WATER PUMP 1. Check: • O-ring 햲 Damage/wear → Replace. • oil seal 햳 Damage/wear → Replace the water pump housing assembly. 햲 햳 NOTE: The mark “water side” on the oil seal should be installed outward. 2. Check: • impeller Cracks/damage/wear → Replace the water pump housing assembly. • water pump housing Cracks/damage → Replace the water pump housing assembly. EAS00477 INSTALLING THE WATER PUMP LS NOTE: Always replace the entire water pump assembly. 1.
WATER PUMP COOL 3. Install: • dowel pin • gasket • water pump housing cover 7 Nm (0.7m•kg) • screws • copper washer 햲 • bleed screw 햳 7 Nm (0.7m•kg) 햲 T.R 햳 T.R NOTE: Do not forget to install the copper washer on the bleed screw.
CARB 6
CARB CHAPTER 6. CARBURETOR CARBURETOR .............................................................................................. 6-1 CARBURETOR REMOVAL ..................................................................... 6-1 CARBURETOR DISASSEMBLY .............................................................. 6-2 CHECKING THE CARBURETOR ............................................................ 6-3 ASSEMBLING THE CARBURETOR .......................................................
CARBURETOR CARB EASM0038 CARBURETOR CARBURETOR 6 5 2 4 1 3 5 Order I 1 2 II 3 III 4 5 6 7 Job/Part 7 Q’ty Removing the carburetor Side cover Fuel tank Box Disconnect: Auto choke coupler Carburetor heater connectors Unplug: Fuel hose Remove: Throttle cable Fixing clip Air duct Carburetor assembly Remarks Remove the parts in the order listed. Refer to “SIDE COVERS AND SEAT” in chapter section 3.
CARBURETOR Q CARB Y e E R Y T U q w { } W O P I Order Job/Part 햲 햳 햴 햵 햶 햷 햸 햹 햺 Carburetor disassembly Auto choke unit Throttle stop screw set Pilot screw set Diaphragm cover/spring Throttle valve Needle set Accelerating pump lever Float chamber/gasket Float axle 햻 햽 햾 햿 헀 헁 Float Needle jet Main jet Pilot jet Main nozzle Heater assembly Q’ty Remarks Remove the parts in the order listed. 1 1 1 1/1 1 1 1 1/1 NOTE: 1/1 Remove the float pin from the side of the arrow.
CARBURETOR CARB EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body 햲 • float chamber • jet housing Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. 햲 322006 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air. 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 3. Check: • float chamber body 햲 Dirt → Clean. 4.
CARBURETOR CARB 9. Check: • vacuum chamber cover • piston valve spring • jet needle holder Cracks/damage → Replace. 10. Check: • jet needle kit • main jet 햲 • needle jet 햳 • pilot jet 햴 • pilot screw Bends/damage/wear → Replace. Obstruction → Replace. 햳 햲 햴 322012 11. Check: • piston valve movement Insert the piston valve 햲 into the carburetor body and move it up and down. Tightness → Replace the throttle valve. 12. Check: • starter plunger • starter plunger spring Bends/cracks/damage → Replace. 13.
CARBURETOR CARB EAS00487 ASSEMBLING THE CARBURETOR CAUTION: • Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. • Always use a new gasket. 1. Install: • main jet holder • main jet • pilot jet 2. Install: • needle valve seat 3. Check: • float 햲 • needle valve • float axle 햳 2 NOTE: Install the float pin from the side opposite the arrow. 1 4. Install: • float chamber 햲 • gasket 햳 • pilot screw 5.
CARBURETOR CARB EAS00499 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust Fuel level (below the float chamber mating surface) 5 ~ 6 mm 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Stand the scooter on a level surface. b. Place the scooter on a suitable stand to ensure that the scooter is standing straight up. c. Install the fuel level gauge 햲 onto the fuel drain pipe 햳. Fuel level gauge 90890-01312 d. Loosen the fuel drain screw 햴. e.
CARBURETOR CARB 2. Check: • autochoke unit 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Connect ø 3.3 mm hose to the starter air passage and blow into the hose. NOTE: When the starter plunger is open, air should come out of the other side of the starter air passage. Starter plunger opens → Perform step. Starter plunger closes → Replace the autochoke unit. 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 3. Check: • autochoke unit 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Connect the autochoke unit leads to a 12.0V battery for five minutes.
CHAS 7
CHAS CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISC ............................................................. 7-1 REMOVING THE FRONT WHEEL .......................................................... 7-2 CHECKING THE FRONT WHEEL ........................................................... 7-3 CHECKING THE BRAKE DISC ............................................................... 7-4 CHECKING THE SPEEDOMETER GEAR UNIT ..................................... 7-5 ASSEMBLING THE FRONT WHEEL ......................
CHAS HANDLEBAR .............................................................................................. 7-31 CHECKING THE HANDLEBAR ............................................................. 7-32 INSTALLING THE HANDLEBAR ........................................................... 7-32 STEERING HEAD ........................................................................................ 7-34 REMOVING THE LOWER BRACKET ...................................................
CHAS FRONT WHEEL AND BRAKE DISC EASM0040 CHASSIS FRONT WHEEL AND BRAKE DISC FRONT WHEEL AND BRAKE DISC 4 T.R 23 Nm (2,3 m¥kg) 2 LT 1 3 T.R 70 Nm (7,0 m¥kg) 6 LS 8 7 9 LT 5 T.
FRONT WHEEL AND BRAKE DISC CHAS EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Remove: • brake caliper NOTE: Do not squeeze the brake lever when removing the brake caliper. 3. Elevate: • front wheel NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
FRONT WHEEL AND BRAKE DISC CHAS EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bent → Replace. WARNING Do not attempt to straighten a bent wheel axle. 2. Check: • tyre • front wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: • radial wheel runout • lateral wheel runout Over the specified limits → Replace. Radial wheel runout limit 1.0 mm Lateral wheel runout limit 0.5 mm 4.
FRONT WHEEL AND BRAKE DISC CHAS c. Remove the wheel bearings with a general bearing puller . d. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing inner race or balls . Contact should be made only with the outer race . NOTE: Use a socket that matches the diameter of the wheel bearing outer race and oil seal. 왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖왖 EAS00528 CHECKING THE BRAKE DISC 1.
FRONT WHEEL AND BRAKE DISC CHAS 4. Adjust: • brake disc deflection 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. 23 Nm (2.3m•kg) T.R NOTE: • Tighten the brake disc bolts in stages and in a crisscross pattern. • Apply “Loctite” to the brake disc bolts. d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f.
FRONT WHEEL AND BRAKE DISC CHAS EAS00540 INSTALLING THE FRONT WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips • speedometer gear unit • collar Recommended lubricant Lithium soap base grease 2. Install: • speedometer gear unit NOTE: Make sure that the speedometer gear unit and the wheel hub are installed with the projection meshed. 3. Install: • collar • front wheel • front wheel axle WARNING Be sure to assemble the front wheel as shown on page 7-1. 4. Tighten: • wheel axle nut T.
FRONT WHEEL AND BRAKE DISC CHAS 1. Remove: • balancing weight(s) 2. Find: • front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. X1 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. c. Turn the front wheel 90° so that the “X1” mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an “X2” mark at the bottom of the wheel. f.
REAR WHEEL AND BRAKE CHAS EASM0041 REAR WHEEL AND BRAKE T.R 13.5 Nm (1.35 m•kg) LS LS 8 3 6 7 11 4 T.R 9 10 5 1 103.5 Nm (10.
REAR WHEEL AND BRAKE CHAS EAS00565 CHECKING THE REAR WHEEL 1. Check: • wheel axle • rear wheel • wheel bearings • oil seals Refer to “FRONT WHEEL AND BRAKE DISC” section. 2. Check: • tyre • rear wheel Damage/wear → Replace. Refer to “CHECKING THE TYRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: • radial wheel runout • lateral wheel runout Refer to “FRONT WHEEL AND BRAKE DISC” section. Radial wheel runout limit 1.0 mm Lateral wheel runout limit 0.
REAR WHEEL AND BRAKE CHAS NOTE: Replace the brake shoes as a set, if either is worn to the wear limit. b 3. Measure: • brake drum inside diameter b Out of specification → Replace the wheel. Brake drum inside diameter limit (maximum) 130.5 mm 346008 4. Check: • brake drum inner surface Oil deposits → Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches → Repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: • brake camshaft Damage/wear → Replace.
CHAS REAR WHEEL AND BRAKE LS 346009 NOTE: • Align the punch mark in the brake camshaft with the mark on the brake camshaft lever. • Lubricate the brake camshaft and pin with lithium soap base grease. WARNING After installing the rear brake camshaft, remove any excess grease. 2. Install: • brake shoes • spring plain washer NOTE: Do not to damage the springs during installation. 346012 3. Lubricate: • wheel axle • plain washer Recommended lubricant Lithium soap base grease 4.
FRONT BRAKE CHAS EASM0042 FRONT BRAKE FRONT BRAKE PADS 2 3 6 LS LT 4 1 22Nm (2,2 m¥kg) 5 Order Job/Part Q’ty Removing the front brake pads Front caliper 1 2 3 4 5 6 Caliper fixing bolt Retaining clip Retaining pin Pad spring Brake pads Bleed screw Remarks Remove the parts in the order listed. Refer to “REMOVING THE FRONT WHEEL” section. 2 1 1 1 2 1 For installation, reverse the removal procedure.
FRONT BRAKE CHAS EAS00579 CAUTION: Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. • Never use solvents on internal brake components. • Use only clean or new brake fluid for cleaning brake components.
FRONT BRAKE CHAS 4. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. a Brake pad wear limit 0.8 mm 5. Install: • brake pad spring • brake pads NOTE: • Always install new brake pads and a new brake pad spring as a set. • Make sure the brake pad spring is installed correctly. 6. Push the caliper piston into the brake caliper by finger. CAUTION: When pushing the caliper piston into the brake caliper, brake fluid level in the reservoir tank is increasing higher.
FRONT BRAKE CHAS EASM0043 FRONT BRAKE MASTER CYLINDER T.R 10 Nm (1.0 m¥kg) LS T.R 8.5 Nm (0.85 m¥kg) 6 1 5 2 T.R 23 Nm (2.3 m¥kg) 4 3 Order Job/Part Q’ty Removing the front brake master cylinder Drain brake fluid Remove the parts in the order listed. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” section in chapter 3. Refer to “HANDLEBAR COVERS” section in chapter 3.
FRONT BRAKE CHAS EASM0044 MASTER CYLINDER Order Job/Part Q’ty Disassembling the master cylinder Master cylinder Master cylinder kit Master cylinder spring seat Spring Remarks Disassemble the parts in the order listed. Refer to “FRONT BRAKE MASTER CYLINDER” section. 1 1 1 For assembly, reverse the removal procedure.
FRONT BRAKE CHAS EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: • brake switch coupler (from the brake switch) 2. Remove: • union bolt • copper washers • brake hoses NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. EAS00590 CHECKING THE FRONT BRAKE MASTER CYLINDER 1.
FRONT BRAKE CHAS EAS00596 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDERWARNING Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. WARNING Never use solvents on internal brake components. Recommended brake fluid DOT#3 or DOT#4 1. Install: • copper washers • brake hose • union bolt 26 Nm (2.6m•kg) T.R WARNING Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING”.
FRONT BRAKE CHAS • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
FRONT BRAKE CHAS 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Blow compressed air into the brake hose joint opening to force out the piston from the brake caliper. 346004 WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the piston is expelled from the brake caliper. • Never try to pry out the brake caliper piston. b. Remove the brake caliper piston seals.
FRONT BRAKE CHAS EAS00635 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT#3 or DOT#4 1.
FRONT BRAKE CHAS 4. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT#3 or DOT#4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT BRAKE CHAS EASM0045 FRONT FORK FRONT FORK 1 T.R 33 Nm (3.3m•kg) T.R 45 Nm (4.5 m•kg) 3 2 2 4 T.R Order 23 Nm (2.3 m•kg) LT Job/Part Q’ty Removing the front fork Front wheel 1 Front mudguard 1 2 3 4 Cap bolt/O-ring Bolt (under bracket upper and lower) Front fork leg (right and left) Remarks Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE” section. NOTE: Disconnect the speedometer sensor coupler to remove the front mudguard.
FRONT FORK CHAS EASM0046 FRONT FORK DISASSEMBLY 1 T.R 33 Nm (3.3m•kg) T.R 45 Nm (4.5 m•kg) 3 2 2 4 T.R Order 23 Nm (2.3 m•kg) Job/Part Disassembling the front fork Cap bolt O-ring Fork spring Dust seal Retaining clip Oil seal Bolt (damper rod)/Gasket Inner tube Oil lock piece Damper rod Rebound spring LT Q’ty Remarks Disassemble the parts in the order listed. 1 1 1 1 1 1 1/1 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT FORK CHAS EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2.Remove the front wheel Refer to “REMOVING THE FRONT WHEEL” section. 3.
FRONT FORK CHAS Damper rod holder 90890-01294 T-handle 90890-01326 5. Remove: • inner tube 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vice with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully. CAUTION: • Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced.
FRONT FORK CHAS CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 3. Check: • cap bolt O-ring Damage/wear → Replace. EAS00661 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
FRONT FORK CHAS 2. Lubricate: • inner tube’s outer surface Recommended lubricant Yamaha fork and fork oil SAE 10 or equivalent 3. Tighten: • damper rod assembly bolt T.R NOTE: While holding the damper rod assembly with the damper rod holder , tighten the damper rod assembly bolt. Damper rod holder 90890-01294 T-handle 90890-01326 23 Nm (2.3m•kg) 342010 4.
FRONT FORK CHAS 6. Install: • oil seal clip NOTE: Adjust the oil seal clip so that it fits into the groove of the outer tube. 7. Install: • dust seal (with the fork seal driver weight) 8. Fully compress the front fork leg. 9. Fill: • front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.125 L Recommended oil Yamaha fork and fork oil SAE 20 or equivalent CAUTION: • Be sure to use the recommended fork oil.
FRONT FORK CHAS NOTE: Be sure to bleed the front fork leg of any residual air. 13. Measure: • front fork leg oil level a Out of specification → Correct. Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed, and without the spring) 80 mm 14. Install: • spring NOTE: Install the spring with its denser of pitch to upper side. • O-ring EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1.
CHAS FRONT FORK EASM0047 HANDLEBAR T.R 4 10 Nm (1.0 m•kg) 1 1 6 2 T.R 3 10 Nm (1.0 m•kg) 9 T.R 10 11 10 Nm (1.0 m•kg) 5 8 LS LS 12 T.R T.R Order Job/Part Rear view mirror (right and left) Master cylinder boot Master cylinder Handlebar switch (right) Throttle cable Grip assembly Rear brake cable Brake lever holder (left) Brake lever holder (right) Handlebar switch (left) Handlebar Bolt/nut 7 60 Nm (6.
HANDLEBAR CHAS EAS00668 CHECKING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Check: • handlebar Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken it. 3.Install: • handlebar grip 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b.
HANDLEBAR CHAS NOTE: Align the projection on the left handlebar switch with the hole in the handlebar. 6. Install: • brake lever holder NOTE: Align the mating surfaces of the brake lever holder with the punch mark a in the handlebar. 7. Install: • throttle cable • throttle grip NOTE: Lubricate the inside of the throttle grip with a thin coat of lithium soap base grease and install it onto the handlebar. 8. Install: • right handlebar switch WARNING Make sure the throttle grip operates smoothly.
STEERING HEAD CHAS EASM0048 STEERING HEAD 1 2 3 4 5 6 7 9 T.R T.R Fisrt step: 38 Nm (3.8 m kg) LS 2nd step: Loosen the ring nut 1/4 turn. 3rd step: 22 Nm (2.2 m kg) 11 10 75 Nm (7.
STEERING HEAD CHAS EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: • ring nut (upper) • lock washer • ring nut (center) • rubber washer 3. Remove: • ring nut (lower) NOTE: Hold the lower bracket by hand, then remove by using the exhaust ring and steering nut wrench .
STEERING HEAD CHAS CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. 354008 NOTE: • Always replace the bearings and bearing races as a set. • Whenever the steering head is disassembled, replace the rubber seal. 4. Check: • lower bracket (along with the steering stem) Bends/cracks/damage → Replace. 354009 EAS00684 LS INSTALLING THE STEERING HEAD 1.
CHAS REAR SHOCK ABSORBER AND EXHAUST PIPE EASM0049 REAR SHOCK ABSORBER AND EXHAUST PIPE T.R 4,5 Nm (0,45 m¥kg) 1 4 T.R T.R 31,5 Nm (3,15 m¥kg) 27 Nm (2,7 m¥kg) 1 2 T.R T.R 27 Nm (2,7 m¥kg) 11Nm (1,1 m¥kg) 3 T.
REAR SHOCK ABSORBER AND EXHAUST PIPE CHAS EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Oil leaks → Replace the rear shock absorber assembly. • spring Damage/wear → Replace the rear shock absorber assembly. • bushings Damage/wear → Replace. • dust seals Damage/wear → Replace. • bolts Bends/damage/wear → Replace.
ELEC 8
ELEC CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS ...................................................................... 8-1 SWITCHES .................................................................................................... 8-2 CHECKING SWITCH CONTINUITY ........................................................ 8-2 CHECKING THE SWITCHES ........................................................................ 8-3 CHECKING THE BULBS AND BULB SOCKETS ........................................
ELECTRICAL COMPONENTS ELEC ELECTRICAL COMPONENTS Wire harness Battery Ignition unit (CDI) Main switch Ignition coil Spark plug cap Rectifier/Regulator Fuel sender Starter relay Starter motor Thermo switch Flasher relay Horn Fuses Relays Coolant thermo switch Carburator heater thermo switch 8-1
SWITCHES ELEC EAS00730 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. “ ∞” CAUTION: Never insert the tester probes into the coupler terminal slots a. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY” section. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch.
CHECKING THE BULBS AND BULB SOCKETS ELEC EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. No continuity → Repair or replace the bulb, bulb socket or both. A C TYPES OF BULBS The bulbs used on this scooter are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS ELEC WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. 왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔왔 a. Install a good bulb into the bulb socket. b.
ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM LY CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) R GR B BW Br B B 5 LOCK OPEN OFF CHECK ON B B GyR B LY B B (BLUE) (BLUE) Gy B Br R R Br B 34 B BW LY BW LY Gy R B Br B R - W W W R R 6 8 W W W W W W W W W W W 1 W BR GW GW BR Or Br Br Or WR WL WL WR B YB YB B BR BR Or GW GW Or Br WR WR YB YB WL WL 2 B B LY (1) 4 R Br B B 25 L BW BW L 11 HANDLE SWITCH 2 LB LB Br Br L
IGNITION SYSTEM EAS00736 ELEC EAS00739 TROUBLESHOOTING 2. Battery THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK). • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. Check: 1. Main fuse 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch 8. Pickup coil resistance 9. Wiring (of the entire ignition system) Minimum open-circuit voltage 12.
ELEC IGNITION SYSTEM EAS00742 EAS00746 4.Ignition spark gap 6. Ignition coil resistance • Disconnect the spark plug cap from the spark plug. • Connect the ignition checker/dynamic spark tester as shown. • Spark plug cap • Set the main switch to “ON”. • Measure the ignition spark gap a . • Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. • Disconnect the ignition coil connectors from the ignition coil terminals.
ELEC IGNITION SYSTEM EAS00749 7.Main switch 9. Source coil resistance • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? • Disconnect the source coil coupler from the wire harness. • Connect the pocket tester (Ω X 100) to the charging coil terminal as shown. YES NO Positive tester probe → green/white Negative tester probe → black/red Replace the main switch. EAS00748 WR BR 8.
ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM LY CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) R GR B BW Br B B 5 LOCK OPEN OFF CHECK ON B GyR B B Gy R R Br Br B 34 B LY B B (BLUE) (BLUE) B BW LY BW LY Gy R B Br B R - W W W R R 6 8 W W W W W W W W W W W 1 W BR GW GW BR Or Br Br Or WR WL WL WR B YB YB B BR BR Or GW GW Or Br WR WR YB YB WL WL 2 B B LY (1) 4 R Br B B 25 L BW BW L 11 B HANDLE SWITCH 2
ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery THE STARTER MOTOR FAILS TO TURN. • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. Check: 1. main fuse 2. battery 3. starter motor 4. starter relay 5. main switch 6. front/rear brake switch 7. starter switch 8. wiring (entire starting system) Minimum open-circuit voltage 12.8 V or more at 20°C • Is the battery OK? YES • Clean the battery terminals. • Recharge or replace the battery.
ELECTRIC STARTING SYSTEM EAS00761 ELEC EASM0050 4.Starter relay 6. Front and Rear brake switch • Disconnect the starter relay coupler from the coupler. • Connect the pocket tester (Ω X 1) and battery (12 V) to the starter relay coupler as shown. • Check the front and rear switches for continuity. Refer to “CHECKING THE SWITCHES”.
STARTER MOTOR ELEC EASM0051 STARTER MOTOR T.R 5 Nm (0.5 m.kg) T.R 65 Nm (6.5 m.kg) 3 2 1 Order Job/Part Q’ty Removing the starter motor Remarks Remove/disassemble the parts in the order listed. Refer to “SIDE COVERS AND SEAT” section in chapter 3.
STARTER MOTOR T.R 5 Nm (0.5 m.kg) T.R ELEC 65 Nm (6.5 m.kg) 3 2 1 Order Job/Part Brushes/Springs Brush holder/washer O-ring Starter motor front cover/O-ring Q’ty Remarks 2/2 1/1 1 1/1 For installation/assembly, reverse the removal/disassembly procedure.
STARTER MOTOR ELEC EAS00770 a CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator diameter 22 mm : 21 mm a 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade which has been ground to fit the commutator. Mica undercut 1.
STARTER MOTOR ELEC 5. Measure: • brush length a . Out of specification → Replace the brushes as a set. Brush length 10 mm : 3.5 mm a 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 5.6 ~ 8.3 N 7. Check: • gear teeth Damage/wear → Replace the gear. 8. Check: • bearing • oil seal Damage/wear → Replace the defective part(-s). EAS00772 ASSEMBLING THE STARTER MOTOR 1.
STARTER MOTOR ELEC 3. Install: • O-rings • washers 5 Nm (0.5m•kg) • starter motor mounting bolts • stater motor fixing bolts 65 Nm (6.5m•kg) T.R T.
ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM LY CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) R GR B BW Br B B 5 LOCK OPEN OFF CHECK ON B GyR B B Gy R R Br Br B 34 B LY B B (BLUE) (BLUE) B BW LY BW LY Gy R B Br B R - W W W R R 6 8 W W W W W W W W W W W 1 W BR GW GW BR Or Br Br Or WR WL WL WR B YB YB B BR BR Or GW GW Or Br WR WR YB YB WL WL 2 B B LY (1) 4 R Br B B 25 L BW BW L 11 B HANDLE SWITCH 2 LB LB Br Br
CHARGING SYSTEM EAS00774 ELEC EAS00739 TROUBLESHOOTING 2. Battery THE BATTERY IS NOT BEING CHARGED. • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil resistance 5. wiring (of the entire charging system) Minimum open-circuit voltage 12.
CHARGING SYSTEM ELEC EAS00779 NOTE: Make sure the battery is fully charged. 5. Wiring connections • Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly connected and without defects? • Is the charging voltage within specification? NO YES The charging circuit is OK. NO YES EAS00776 Properly connect or repair the charging system’s wiring. 4.
ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM LY CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) R GR B BW Br B B 5 LOCK OPEN OFF CHECK ON B GyR B B Gy R R Br Br B 34 B LY B B (BLUE) (BLUE) B BW LY BW LY Gy R B Br B R - W W W R R 6 8 W W W W W W W W W W W 1 W BR GW GW BR Or Br Br Or WR WL WL WR B YB YB B BR BR Or GW GW Or Br WR WR YB YB WL WL 2 B B LY (1) 4 R Br B B 25 L BW BW L 11 B HANDLE SWITCH 2 LB LB Br Br
LIGHTING SYSTEM EAS00781 ELEC EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. ANY OF THE FOLLOWING FAIL TO LIGHT: HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT, AUXILIARY LIGHT OR INSTRUMENT LIGHT . Minimum open-circuit voltage 12.8 V or more at 20°C • Is the battery OK? Check: 1. main fuse 2. battery 3. main switch 4. lighting switch 5. dimmer switch 6.
LIGHTING SYSTEM EAS00784 ELEC EAS00788 5.Hi/Lo beam switch • Check the Hi/Lo beam switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the Hi/Lo beam switch OK? YES CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb and socket • Check the headlight bulb and socket for continuity. • Are the headlight bulb and socket OK? NO The Hi/Lo beam switch is faulty. Replace the left handlebar switch.
ELEC LIGHTING SYSTEM EAS00789 • Meter light coupler (wire harness side) • Set the main switch to “ON”. ”. • Set the light switch to “ • Set the dimmer switch to “ ” or “ ”. • Measure the voltage (12 V) of green on the headlight coupler (wire harness side). • Is the voltage within specification? 2. The meter light fails to come on. 1. Meter light bulb and socket • Check the meter light bulb and socket for continuity.
LIGHTING SYSTEM ELEC EAS00790 EAS00791 3. The tail/brake light fails to come on. 4. The front postion light fails to come on. 1.Tail/brake light bulb and socket 1. Auxiliary light bulb and socket • Check the tail/brake light bulb and socket for continuity. • Are the tail/brake light bulb and socket OK? • Check the auxiliary light bulb and socket for continuity. Refer to "CHECKING THE BULBS AND BULB SOCKET".
ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM LY CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) R GR B BW Br B B 5 LOCK OPEN OFF CHECK ON B GyR B B Gy R R Br Br B 34 B LY B B (BLUE) (BLUE) B BW LY BW LY Gy R B Br B R - W W W R R 6 8 W W W W W W W W W W W 1 W BR GW GW BR Or Br Br Or WR WL WL WR B YB YB B BR BR Or GW GW Or Br WR WR YB YB WL WL 2 B B LY (1) 4 R Br B B 25 L BW BW L 11 B HANDLE SWITCH 2 LB LB Br Br
SIGNALING SYSTEM Main switch Fuse (main) Battery C Horn switch E Turn signal switch H Left front flasher J Right front flasher Left rear flasher Right rear flasher Tail/stop light Horn Flasher relay 22 P Coolant thermo indicator light N Fuel sender indicator R Clock and odometer L Flasher light indicator M Flasher light indicator 23 Sender 8-28 ELEC
SIGNALING SYSTEM EAS00794 ELEC EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. ANY OF THE FOLLOWING FAIL TO LIGHT: FLASHER LIGHT, BRAKE LIGHT OR AN INDICATOR LIGHT. THE HORN FAILS TO SOUND. Minimum open-circuit voltage 12.8 V or more at 20°C Check: 1. main fuse 2. battery 3. main switch 4.
SIGNALING SYSTEM ELEC EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM • Disconnect the pink connector at the horn terminal. • Connect a jumper lead to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Does the horn sound? 1. The horn fails to sound. 1.Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? NO YES YES NO The horn is OK. Replace the left handlebar switch. 4. Voltage 2.
SIGNALING SYSTEM ELEC EAS00798 • Set the main switch to “ON”. • Pull in the brake levers. • Measure the voltage (12 V) of yellow on the tail/brake light coupler (wire harness side). • Is the voltage within specification? 2. The tail/brake light fails to come on. 1.Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity.
SIGNALING SYSTEM 3. Voltage ELEC • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Measure the voltage (12 V) on brown/white at the turn signal relay coupler (wire harness side). • Is the voltage within specification? • Connect the pocket tester (DC V 20) to the flasher relay coupler (wire harness side) as shown. Positive tester probe → brown Negative tester probe → ground Br YES The turn signal relay is faulty and must be replaced. BrW NO Br BrW 5.
ELEC SIGNALING SYSTEM EASM0052 EAS00804 4. The Coolant temperature warning light fails to come on. 5. The fuel level gauge fails to operate. 1. Fuel sender 1.Coolant temperature warning light bulb and socket • Remove the fuel sender from the fuel tank. • Connect the pocket tester to the fuel sender coupler (wire harness side) as shown. • Check the coolant temperature warning light bulb and socket for continuity.
SIGNALING SYSTEM ELEC 2.Voltage 4. Wiring • Connect the pocket tester (DC V 20) to the meter light coupler (wire harness side) . • Check the entire signal system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the signalling system’s wiring properly connected and without defects? Positive tester probe → brown Negative tester probe → black • Set the main switch to “ON”. • Measure the voltage (12 V) of brown on the meter light coupler (wire harness side).
SIGNALING SYSTEM EAS00805 6. The clock/odometer fails to come on. 1.Voltage • Connect the pocket tester (DC V 20) to the clock/odometer coupler (wire harness side) as shown. Positive tester probe → red Negative tester probe → ground Br L Y Dg Ch R Dg Y Ch GR L B B G Br P Sb B • Set the main switch to “ON”. • Measure the voltage (12 V). • Is the voltage within specification? YES NO The wiring circuit from the main switch to the clock coupler is faulty and must be repaired. 2.
ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM LY CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) R GR B BW Br B B 5 LOCK OPEN OFF CHECK ON B GyR B B Gy R R Br Br B 34 B LY B B (BLUE) (BLUE) B BW LY BW LY Gy R B Br B R - W W W R R 6 8 W W W W W W W W W W W 1 W BR GW GW BR Or Br Br Or WR WL WL WR B YB YB B BR BR Or GW GW Or Br WR WR YB YB WL WL 2 B B LY (1) 4 R Br B B 25 L BW BW L 11 B HANDLE SWITCH 2 LB LB Br Br OF
COOLING SYSTEM EAS00808 ELEC EAS00739 TROUBLESHOOTING 2. Battery • The radiator fan motor fails to turn. • The water temperature warning light fails to light up when the engine is warm. • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20°C Check: 1. main and radiator fan motor fuses 2. battery 3. main switch 4. radiator fan motor 5. thermo switch 6.
COOLING SYSTEM • Does the radiator fan motor turn? YES ELEC A Thermo switch circuit “ON” B Thermo switch circuit “OFF” NO The radiator fan motor is faulty and must be replaced. A EAS00811 6.Thermo switch • Remove the thermo switch from the radiator. • Connect the pocket tester (Ω x 1) to the thermo switch as shown. • Immerse the thermo switch in a container filled with coolant. • Place a thermometer in the coolant. • Slowly heat the coolant, then let it cool down to the specified temperature.
COOLING SYSTEM EAS00739 Temperature sender resistance 80°C: 47.5 ~ 56.8 Ω 100°C: 26.2 ~ 29.3 Ω 2. Battery • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. WARNING • Handle the temperature sender with special care. • Never subject the temperature sender to strong shocks. If the temperature sender is dropped, replace it. Minimum open-circuit voltage 12.
ELEC CARBURETOR HEATING SYSTEM EAS00820 CARBURETOR HEATING SYSTEM LY CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) R GR B BW Br B B 5 LOCK OPEN OFF CHECK ON B GyR B B Gy R R Br Br B 34 B LY B B (BLUE) (BLUE) B BW LY BW LY Gy R B Br B R - W W W R R 6 8 W W W W W W W W W W W 1 W BR GW GW BR Or Br Br Or WR WL WL WR B YB YB B BR BR Or GW GW Or Br WR WR YB YB WL WL 2 B B LY (1) 4 R Br B B 25 L BW BW L 11 B HANDLE SWITCH
CARBURETOR HEATING SYSTEM EAS00821 ELEC EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. The carburetor heating system fails to operate. Check: 1. Main fuse 2. Battery 3. Main switch 4. Thermo switch 5. Carburetor heater 6. Wiring (of the entire carburetor heating system) NOTE: • Before troubleshooting, remove the following part(s): 1) Side covers 2) Box and seat 3) Battery cover • Troubleshoot with the following special tool(s).
CARBURETOR HEATING SYSTEM EAS00823 ELEC EAS00824 4. Thermo switch 5. Carburetor heater • Disconnect the thermo switch from the wire harness. • Connect the pocket tester (Ω x 1) to the thermo switch lead. • Remove the carburetor heating element from the carburetor. • Connect the pocket tester (Ω x 1) to the carburetor heating element.
TRBL SHTG 9
TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/ HARD STARTING .................................................... 9-1 ENGINE ................................................................................................... 9-1 FUEL SYSTEM ........................................................................................ 9-1 ELECTRICAL SYSTEMS ......................................................................... 9-2 INCORRECT ENGINE IDLING SPEED ...........................................
TRBL SHTG UNSTABLE HANDLING ................................................................................ 9-5 FAULTY LIGHTING OR SIGNALING SYSTEM ............................................ 9-5 HEADLIGHT DOES NOT LIGHT ............................................................. 9-5 HEADLIGHT BULB BURNT OUT ............................................................ 9-5 TAIL/BRAKE LIGHT DOES NOT LIGHT ................................................. 9-5 TAIL/BRAKE LIGHT BULB BURNT OUT ...............
STARTING FAILURE/HARD STARTING TRBL SHTG EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING FAILURE/HARD STARTING/ INCORRECT ENGINE IDLING SPEED/ POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ELECTRICAL SYSTEMS Battery • Improperly charged battery • Faulty battery Fuse(s) • Blown, damaged or incorrect fuse • Improperly installed fuse Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap Ignition coil • Broken or shorted primary or secondary coils • Faulty spark plug lead • Cracke
FAULTY CLUTCH/ OVERHEATING TRBL SHTG EAS00853 FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL NOT MOVE V-belt • Bent, damaged or worn V-belt • Slipping V-belt Primary pulley cam and primary pulley slider • Damaged or worn primary pulley cam • Damaged or worn primary pulley slider Clutch spring(s) • Damaged clutch spring Transmission gear(s) • Damaged transmission gear POOR STARTING PERFORMANCE V-belt • V-belt slips • Oil or grease on the V-belt Primary sliding sheave • Faulty operation • Worn pin groove
OVERCOOLING/ POOR BRAKING/ FAULTY FRONT FORK LEGS TRBL SHTG EAS00856 OVERCOOLING COOLING SYSTEM • Thermostat • Thermostat stays open EAS00859 POOR BRAKING Disc brake • Worn brake pad • Worn brake disc • Air in hydraulic brake system • Leaking brake fluid • Faulty brake caliper kit • Faulty brake caliper seal • Loose union bolt • Damaged brake hose • Oil or grease on the brake disc • Oil or grease on the brake pad • Incorrect brake fluid level Drum brake • Worn brake shoe • Worn or rusty brake drum • I
UNSTABLE HANDLING/ FAULTY LIGHTING OR SIGNALING SYSTEM TRBL SHTG EAS00862 UNSTABLE HANDLING Rear shock absorber assembly • Faulty rear shock absorber spring • Leaking oil or gas Tyres • Uneven tyre pressures (front and rear) • Incorrect tyre pressure • Uneven tyre wear Wheels • Incorrect wheel balance • Deformed cast wheel • Damaged wheel bearing • Bent or loose wheel axle • Excessive wheel runout Frame • Bent frame • Damaged steering head pipe • Improperly installed bearing race Handlebar • Bent or imp
FAULTY LIGHTING OR SIGNALING SYSTEM TURN SIGNAL REMAINS LIT • Faulty turn signal relay • Burnt-out turn signal bulb TRBL SHTG HORN DOES NOT SOUND • Improperly adjusted horn • Damaged or faulty horn • Faulty main switch • Faulty horn switch • Faulty battery • Blown, damaged or incorrect fuse • Faulty wire harness TURN SIGNAL BLINKS QUICKLY • Incorrect turn signal bulb • Faulty turn signal relay • Burnt-out turn signal bulb 9-6
COLOR CODE XN125-150 WIRING DIAGRAM LY WIRE LEAD ON SIDE STAND (OPTION) (BLUE) R GR B BW Br B B 5 LOCK OPEN OFF CHECK ON B Gy R R Br Br B 34 B B GyR B B ............. black Br ............ brown Ch ........... chocolate Dg ........... dark green G ............ green Gy ........... gray L ............. blue O ............ orange P ............. pink R ............. red LY B B (BLUE) (BLUE) B BW BW Sb ........... sky blue W ............ white Y ............. yellow B / L ........
