YJ125S SERVICE MANUAL LIT-11616-17-43 5YR-28197-10
EAS00000 YJ125S 2003 SERVICE MANUAL ©2003 by Yamaha Motor Taiwan Co., Ltd. First edition, November 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd. is expressly prohibited. Printed in U.S.A.
EAS00002 NOTICE This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
EAS00008 1 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 2 3 4 5 6 7 8 9 CHAS 5 6 ENG COOL 7 8 CARB ELEC 9 0 - w e r + Symbols 0 to u indicate the following.
EAS00011 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE CARBURETOR GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 CARB 6 - ELECTRICAL SYSTEM TROUBLESHOOTING + ELEC 7 TRBL SHTG 8
GEN INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ............................................. 1-1 MODEL LABEL .................................................................................. 1-1 IMPORTANT INFORMATION ................................................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ................... 1-2 REPLACEMENT PARTS .......................
SCOOTER IDENTIFICATION GEN INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the steering head pipe. 1 EAS00018 MODEL LABEL The model label 1 is affixed to the seat. This information will be needed to order spare parts.
IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector 2. Check: 8 lead 8 coupler 8 connector Moisture J Dry with an air blower. Rust/stains J Connect and disconnect several times. 3. Check: 8 all connections Loose connection J Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. 4.
SPECIAL TOOLS GEN INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. Tool NO.
SPECIAL TOOLS Tool NO. 90890-01367 YM-A9409-7 90890-01400 YM-A9409-3 90890-01384 YM-33299 90890-01403 YU-33975 90890-01701 YS-01880-A 90890-03079 YM-34483 90890-03081 YU-33223 90890-03132 YU-03112-C 90890-03113 YU-08036-C 90890-03141 YU-03141 90890-04019 YM-04019 90890-04108 YM-04108 Tool name / Function GEN INFO Illustration Fork seal driver weight 1 Fork seal driver attachment(Ø30mm) 2 This tool is used when installing the fork seal.
SPECIAL TOOLS Tool NO. 90890-06754 YM-34487 90890-85505 ACC-11001-05-01 80890-04116 YM-04116 90890-04117 YM-04117 90890-04099 YM-04099 Tool name / Function Ignition checker This instrument is necessary for checking the ignition system components. Yamaha bond NO.1215 This sealant (bond) is used for crankcase mating surface, etc. Valve guide remover (4.5 mm) This tool is used to remove or install the valve guides. Valve guide installer (4.5 mm) This tool is used to install the valve guides.
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................................................................. 2-1 ENGINE SPECIFICATIONS ..................................................................... 2-2 CHASSIS SPECIFICATIONS ................................................................. 2-11 ELECTRICAL SPECIFICATIONS .......................................................... 2-14 CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS .................................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Standard Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Weight Wet (without oil and a full fuel tank) Dry (without oil and fuel) Maximun load (total of cargo, rider, passenger, and accessories) Limit 5YR1 (for USA) 5YR2 (for CAN) … … 1755 mm (69.1 in) 699 mm (27.5 in) 1063 mm (41.8 in) 759 mm (29.8 in) 1230 mm (48.4 in) 95 mm (3.
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Standard Displacement Cylinder arrangement Bore × stroke Compression ratio Engine idle speed Vacuum pressure at engine idle speed Standard compression pressure (at sea level) Forced Air cooled 4-stroke, SOHC 0.125L(125.0 cm3) Forward inclined single cylinder 51.5 × 60.0 mm 9.8±0.4 :1 1600~1700 r/min 30.0 kpa(238.6 mmHg) 950 kPa(9.
ENGINE SPECIFICATIONS Standard Item Oil filter Oil filter type SPEC Limit Wire mesh … Oil pump Oil pump type Inner rotor to outer rotor tip clearance Outer rotor to pump housing clearance Oil pump housing to inner rotor and outer rotor clearance Trochoid 0.15 mm 0.013-0.036 mm 0.06-0.10 mm … 0.23mm 0.106mm 0.17mm Starting system type Electric and kick starter … Spark plug Model (manufacturer) × quantity Spark plug gap CR7E (NGK) × 1 0.7~0.8mm … … Cylinder head Volume Max. warpage 12.3~12.
ENGINE SPECIFICATIONS SPEC Standard Item Camshaft Drive system Intake camshaft lobe dimensions Limit Chain drive (left) … 26.153~26.253 mm 21.015~21.115 mm 5.203mm 26.053 mm 20.915 mm … 26.153~26.253 mm 21.056~21.156 mm 5.203 mm … 26.053 mm 20.956 mm … 0.03 mm C A B Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions C A B Measurement A Measurement B Measurement C Max.
ENGINE SPECIFICATIONS SPEC Standard Item Timing chain Model/number of links Tensioning system Valve, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions Limit Morse 92RH2005 / 88 Automatic … … 0.08~0.12 mm 0.13~0.
ENGINE SPECIFICATIONS Standard Item Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt SPEC Limit 37.30 mm 37.30 mm 35.40 mm 35.40 mm 25.77mm 25.77mm … … 147±11N (15.0 ± 1.1 kgf/mm) 147±11N (15.0 ± 1.1 kgf/mm) … … Intake Exhaust Winding direction (top view) Intake Exhaust … … 2.5°/1.6 mm 2.5°/1.6 mm Clockwise Clockwise … … Valve seat reformed Yes … Forward inclined single cylinder 51.
ENGINE SPECIFICATIONS Standard Limit 0.010~0.030 mm 51.470~51.510 mm 0.150mm … 3.5 mm … 13.002~13.013 mm 0.35~0.65mm Intake side 13.043 mm … … 12.996~13.000 mm 12.976 mm Barrel 1.0 × 2.1mm 0.10~0.20 mm 0.02~0.08 mm … … 0.45mm 0.13 mm Plain 1.0 × 2.1mm 0.20~0.30 mm 0.02~0.06 mm … … 0.65mm 0.12mm 2.0 × 2.2 mm 0.2~0.7 mm 0.06~0.
ENGINE SPECIFICATIONS SPEC Standard Item Limit Rocker arm/rocker arm shaft Rocker arm inside diameter Rocker arm shaft outside diameter Arm-to-shaft clearance 10~10.015mm 9.981~9.991 mm 0.009~0.034 mm … … … Connecting rod Connecting rod length Small end inside diameter 97.95~98.05 mm 13.015~13.028mm … … 45.15~45.20 mm … 0.10~0.40 mm 0~0.010mm … 0.03mm 1.00mm … Crankshaft Width A Max.
ENGINE SPECIFICATIONS SPEC Standard Item Limit Clutch Clutch type Clutch shoe thickness Clutch shoe spring free length Clutch housing inside diameter Compression spring free length Weight outside diameter Clutch-in revolution Clutch-stall revolution Automatic centrifugal 3.4 ± 0.1 mm 28.0 ± 0.4 mm 120 ± 0.1 mm 113.6 mm 20 ± 0.1 mm 3200±300 r/min 5500±500 r/min … 2.0mm … 120.3mm … … … … V-belt V-belt width 21.6 mm 19.
ENGINE SPECIFICATIONS Standard Item Throttle bodys Model (manufacturer) × quantity Intake vacuum pressure Throttle cable free play (at the flange of the throttle grip) ID mark SPEC Limit 5YR (SAFETY CONTROL CABLE) × 2 30.0kpa (238.
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Standard Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0~90 kg 90~197 kg Min.
CHASSIS SPECIFICATIONS Standard Item Front disc brake Brake type Operation Brake lever free play (at lever end) Recommended fluid Brake disc Diameter x thickness Min. thickness Max. deflection Brake pad lining thickness-inner Brake pad lining thickness-outer Master cylinder inside diameter Caliper cylinder inside diameter SPEC Limit Single disc brake Right-hand operation 3~5mm DOT 4 … … … … 180.0 × 4.0 mm … … 6.0 mm 6.0 mm 11mm 34.93mm 180.0 × 3.5 mm 3.5mm 0.10 mm 0.8mm 0.
CHASSIS SPECIFICATIONS Standard Item Rear drum brake Brake type Operation Brake lever free play (at lever end) Brake drum inside diameter Lining thickness SPEC Limit Drum brake Left-hand operation 10~20mm 110 mm 4.
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Standard Item Limit System voltage Ignition system Ignition system type Ignition timing (B.T.D.C.) Advancer type Pickup coil resistance /color C.D.I. unit model (manufacturer) 12V … C.D.I. 5 °/1650 r/min (IDL) Digital 304~456 Ω / WR-WL 5YR00(T-MORIC) … … … … … Ignition coil Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance 2JN (T-MORIC) 6mm 0.184~0.276 Ω at 20 ° C 6.32~9.
ELECTRICAL SPECIFICATIONS Standard Item Bulbs (voltage/wattage × quantity) Headlight Tail/brake light Front turn signal light Rear turn signal light Speedometer light Fuel lever meter light SPEC 12 V 60 W/55 W × 1 12 V 8W/27 W × 1 12 V 10 W × 2 12 V 10 W × 2 14 V 3 W ×1 14 V 3 W ×1 2-15 Limit … … … … … …
ELECTRICAL SPECIFICATIONS Standard Item Electric starting system System type Starter motor Model (manufacturer) Suction voltage Power output Brushes Overall length Quantity Spring force Commutator diameter Commutator resistance Mica undercut (depth) Starter relay Model (manufacturer) Amperage Coil resistance Suction voltage SPEC Limit Constant mesh … 4TE1 (T-MORIC) 12V 0.3 kW … … … 10.0 mm 2 5.52~8.28 N 22 mm 0.0306~0.0374 Ω at 20 °C 1.5 mm 3.5mm … … 21mm … … 3UH1 (SHI LIN) 100 A 3.6-4.
ELECTRICAL SPECIFICATIONS SPEC Standard Item Limit Fuel lever meter Type( manufacturer ) Moving magneto (CHAO LONG) … Fuse (amperage × quantity) Main fuse Reserve fuse 10A×1 10A×1 2-17 … …
CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EB201000 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
TIGHTENING TORQUES SPEC ENGINE TIGHTENING TORQUES Part to be tightened Part name Thread ’ Q ty size Tightening torque Remarks Nm m•kgf ft•lb Cylinder head and cylinder Nut M8 Spark plug _ M10 Cylinder head(timing chain side) Bolt M6 Mainfold stud bolt _ M6 Exhaust pipe stud bolt _ M6 Breather assembly Bolt M6 Stopper plate Bolt M6 Guide stopper2 Bolt M6 Valve clearance adjusting screw lock nut _ M5 Camshaft sprocket Bolt M8 Timing chain tensioner (body) Bolt M6 Timing chain tensioner (plug) plug M8
TIGHTENING TORQUES Part to be tightened Part name Thread ’ Q ty size SPEC Tightening torque Nm m•kgf ft•lb Drain bolt(engine oil ) V-belt case air filter element holder Oil pipe Cylinder stud bolt (case1) Cylinder stud bolt (case2) Crankcase cover3 Plate (V-belt guide) Idle gear plate Kick crank assembly Clutch housing Clutch carrier assembly Primary fixed sheave Starter motor assembly C.D.I.
TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Part to be tightened Thread size Frame and engine bracket 2 Engine bracket 2 and engine bracket 3 Engine bracket, engine and centerstand Rear shock absorber and frame Rear shock absorber and engine Rear arm Sidestand (bolt) Sidestand (nut) Steering shaft(upper nut) Handlebar holder bracket and steering shaft Handlebar holder and handlebar lower holder M10 M10 M10 M10 M8 M8 M8 M8 M25 M10 M10 M8 M6 M10 M5 M8 M6 M12 M14 M6 M10 M10 M8 M10 M7 Handlebar low
LUBRICATION POINTS AND LUBRICANT TYPES SPEC ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Lubricant Oil seal lips LS O-ring (Except V-belt drive unit) LS Cylinder head tightening nut mounting surface 4 Cylinder head stud bolt thread 4 Cylinder head gasket dowel pin 4 Crankshaft pin outside surface 4 Connecting rod 4 Piston outside and ring groove 4 Piston pin outside surface 4 surface and bolt thread 4 Crankshaft journal 4 Piston (balancer) outside surface 4 Pi
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point SPEC Lubricant Primary sheave inside, Collar, Solid bush, LS Secondary fixed inner surface BEL-RAY asembly lube Secondary sheave torque cam ditch BEL-RAY asembly lube Gasket (Cylinder head cover) Sealant Stopper guide (Cylinder head cover) Sealant Crankcase mating surfaces Sealant Oil pipe Sealant C.D.I.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS LUBRICATION POINTS AND LUBRICATION TYPES Lubrication Point Lubricant Front wheel oil seal lips LS Frame head pipe bearing (upper and lower) LS Frame head pipe dust seal lips ( lower) LS Tube guide (throttle grip) inner surface LS Brake lever and lever holder bolt sliding surface LS Sidestand and frame sliding surface LS Centerstand sliding surface and mounting bolt LS Rear footrest (pin) outside surface LS Rear shock absorber
OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 2 3 4 5 Oil strainer Oil pump Oil filter Oil delivery pipe Oil delivery pipe union bolt 2-25 SPEC
OIL FLOW DIAGRAMS 1 Connecting rod big end bearing 2-26 SPEC
CABLE ROUTING CABLE ROUTING 1 Turn signal relay 2 Main switch assembly 3 Seat lock cable 4 Horn 5 Rectifier / regulator assembly 6 Starter motor negative lead 7 Wire (negative lead) 8 Starter motor positive lead 9 C.D.I. magneto lead 0 C.D.I. unit q Pipe 2 w AI. filter assembly e Clamp r Vacuum sensing hose t Wire harness y Side cover (right) u Frame Comp.
SPEC CABLE ROUTING J Fasten the C.D.I. unit lead and wire harness to the frame with a plastic locking tie, point the band tip to upper and the trunk surface. K Fasten the wire harness to the frame and cut the end to be shorter than 5mm. L Pass the seat lock cable along the outside of the reinf tail. M Installing the bend hose 5 to the AI. Filter assembly, into the frame inside. N Route the trail light lead and rear turn signal light lead through the rear cover hole. O The tail light through the base hole.
CABLE ROUTING 1 Lever holder assembly (left side) 2 Rear brake cable 3 Throttle cable 1 (left turn side) 4 Throttle cable2 (right turn side) 5 Breather hose 6 Carburetor air vent hose 7 Spacer 8 Fuel overflow pipe 9 Crankcase cover 3 0 Starter air vent hose q Head light unit w Front turn signal light e Turn signal relay r Fuel lever meter t Main switch assembly y Horn A Pass the speedometer cable left side the inner fender and front fender hole.
CABLE ROUTING 1 Seat lock cable 2 Carburetor heater lead 3 Carburetor autochoke lead 4 Starter switch lead 5 Starter motor positive lead 6 Starter motor negative lead 7 High tension cord 8 Clamp 9 C.D.I. magneto lead 0 Vacuum sensing hose q Joint w Carburetor air vent hose e Starter air vent hose r Wire (positive lead) C Pass the throttle cable, wire harness and rear brake cable under the frame cross tube. D Pass the thermo switch lead under the frame.
CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ....................................................................................... 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ............................................................................................... 3-2 Periodic maintenance chart for the emission control system ........... 3-2 GENERAL MAINTENANCE AND LUBRICATION CHART ................... 3-3 General maintenance and lubrication chart................
CHK ADJ CLEANING THE AIR FILTER ELEMENT/CLEANING THE V-BELT CASE AIR FILTER ELEMENT ............................................................... 3-26 CLEANING THE AIR FILTER ELEMENT ....................................... 3-26 CLEANING THE V-BELT CASE AIR FILTER ELEMENT ............... 3-26 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD .. 3-28 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD ...................................................................................
CHK ADJ LUBRICATING THE SIDESTAND/LUBRICATING THE CENTERSTAND ..................................................................................... 3-45 LUBRICATING THE SIDESTAND ................................................... 3-45 LUBRICATING THE CENTERSTAND ............................................ 3-45 CHECKING AND CHARGING THE BATTERY ..................................... 3-46 ELECTRICAL SYSTEM .........................................................................
INTRODUCTION CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM CHK ADJ EAU17560* Periodic maintenance chart for the emission control system ODOMETER READING NO. 1 2 3 * * * ITEM ROUTINE 600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi (1,000 (4,000 (7,000 (10,000 (13,000 km) km) km) km) km) or or or or or 1 6 12 18 24 month months months months months Fuel line • Check fuel hoses and vacuum hose for cracks or damage. Valves • Check valve clearance. • Adjust if necessary.
GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ EAU32121 General maintenance and lubrication chart * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 12000 mi (18000 km) or 36 months, repeat the maintenance intervals starting from 4000 mi (7000 km) or 12 months. ODOMETER READING NO.
CHK ADJ COVER AND PANEL COVER AND PANEL SEAT AND SIDE COVERS 23Nm(2.3m•kg, 16.6 ft•lb) 9 2 13 4 11 6 5 10 1 7 12 8 3 Order Job/Part Q’ty 1 2 3 4 5 6 7 8 9 10 11 12 13 Removing the seat and side covers Seat Rear carrier Side cover( left ) Side cover( right ) Hook( left ) Hook( right ) Cover Front cover Fuel tank cap Rear cover Tail / brake light License plate Trunk Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
COVER AND PANEL CHK ADJ FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE 3 1 4 7 5 8 2 6 Order Job/Part Q’ty 1 2 3 4 5 6 7 8 Removing the footrest board and footrest board side cover mole Side covers( left and right ) Mat Battery cover Battery negative(-) lead Battery positive(+) lead Battery Footrest board side cover mole( left ) Footrest board side cover mole( right ) Footrest board Remarks Remove the parts in the order listed.
COVER AND PANEL CHK ADJ LEG SHIELD 1 , 2 5 6 3 7 2 4 1 Order Job/Part Q’ty Remove the parts in the order listed. Refer to “FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE” Removing the leg shield 1,2 Footrest board 1 2 3 4 5 6 7 Remarks Headlight cover Headlight assembly Front turn signal light bracket Leg shield 1 Main switch cover Fuel lever meter Leg shield 2 1 1 1 1 1 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: 8 Valve clearance adjustment should be made on a cold engine, at room temperature. 8 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: 8 cover 8 rear carrier 8 side cover (right,left ) 8 hook 8 front cover 8 spark plug cap Refer to “COVER AND PANEL”. 2.
ADJUSTING THE VALVE CLEARANCE ***************************************************** a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compression stroke, align the punch mark in the camshaft sprocket with the stationary on the cylinder head. c. Align the TDC mark 1 on the magneto rotor with the stationary pointer 2 on the crankcase. d. Measure the valve clearance with a thickness gauge. Out of specification J Adjust. ***************************************************** 2 1 4.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 5. Install: 8 cap 8 spark plug T. R. 12.5 Nm (1.25 m • kg, 9 ft • lb) 8 valve cover (exhaust ) 8 engine oil cap 6. Install: 8 spark plug cap 8 front cover 8 hook 8 side cover (right,left ) 8 rear carrier 8 cover Refer to “COVER AND PANEL”.
ADJUSTING THE ENGINE IDLING SPEED CHK ADJ EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Connect: 8engine tachometer 1 (onto the spark plug lead of cylinder) 1 Engine tachometer 90890-03113 (YU-08036-C) 3. Check: 8engine idling speed Out of specification J Adjust Engine idling speed 1600 ~ 1700 r/min 4.
CHECKING THE EXHAUST GAS AT IDLE CHK ADJ CHECKING THE EXHAUST GAS AT IDLE (Measuring the exhaust gas at idle[when air induction system is operation]) 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Install: 8pocket tester1. (onto the engine oil drain bolt) 8engine tachometer (onto the spark plug lead ) Pocket tester 90890-03132 (YU-03112-C) Engine tachometer 90890-03113 (YU-08036-C) 1 3.
CHECKING THE EXHAUST GAS AT IDLE CHK ADJ NOTE: 8 Since it is necessary to insert the sampling probe 600mm into the exhaust pipe, be sure to use a heat-resisant rubber tube as shown in the illustration. 8 Be sure to set the heat-resistant rubber tube so that exhaust gas does not leak out. 8 Before using the carbon monoxide and hydrocarbon tester, be sure to read the user,s manual. 6.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ EAS00057 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check: 8 throttle cable free play a Out of specification J Adjust. a Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Remove: 8 cover 8 rear carrier 8 side cover (right ) Refer to “COVER AND PANEL”. 3.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ Handlebar side a. Loosen the locknut 1. b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. b 1 a Direction a Throttle cable free play is increased. Direction b Throttle cable free play is decreased. 2 c. Tighten the locknut.
CHECKING THE SPARK PLUG CHK ADJ EAS00060 CHECKING THE SPARK PLUG 1. Remove: 8 cover Refer to “COVER AND PANEL”. 2. Disconnect: 8 spark plug cap 3. Remove: 8 spark plug cC Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 4. Check: 8 spark plug type Incorrect J Change. Spark plug type (manufacturer) CR7E (NGK) 5. Check: 8 electrode 1 Damage/wear J Replace the spark plug.
CHECKING THE IGNITION TIMING CHK ADJ EAS00062 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1 1. Remove: cap 1 2. Attach: timing light engine tachometer (onto the spark plug lead of cylinder) Timing light 90890-03141 (YU-03141) Engine tachometer 90890-03113 (YU-08036-C) 3. Check: ignition timing ***************************************************** a.
MEASURING THE COMPRESSION PRESSURE CHK ADJ EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: 8 valve clearance Out of specification J Adjust Refer to “ADJUSTING THE VALVE CLEARANCE”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Remove: 8 cover 8 rear carrier 8 side cover (right,left ) 8 hook 8 front cover Refer to “COVER AND PANEL”. 4. Disconnect: 8 spark plug cap 5.
MEASURING THE COMPRESSION PRESSURE CHK ADJ 7. Measure: 8 compression pressure Out of specification J Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 827 kPa (8.27 kg/cm2, 400r/min) Standard 950 kPa (9.5 kg/cm2, 400r/min) Maximum 1064 kPa (10.64 kg/cm2, 400r/min) ***************************************************** a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.
MEASURING THE COMPRESSION PRESSURE CHK ADJ 11. Install: 8 front cover 8 hook 8 side cover (right,left ) 8 rear carrier 8 cover Refer to “COVER AND PANEL”.
CHECKING THE ENGINE OIL LEVEL CHK ADJ EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Check: 8 engine oil level 1 The engine oil level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark J Add the recommended engine oil to the proper level.
CHECKING THE ENGINE OIL CHK ADJ EAS00076 1 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: 8 engine oil filler cap 1 8 engine oil drain bolt 2 (along with the gasket) 4. Drain: 8 engine oil (completely from the crankcase) 2 3 5. If the oil filter element is also to be cleaned, 8 perform the following procedure. ***************************************************** a.
CHANGING THE ENGINE OIL FILTER ELEMENT CHK ADJ 11. Check: 8 engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 12. Check: 8 engine oil pressure Refer to “CHECKING THE ENGINE OIL PRESSURE”. CHANGING THE ENGINE OIL FILTER ELEMENT 1. Drain: 8 engine oil 2. Remove: 8 oil delivery pipe bolt 1 8 copper washers 1 3. Remove: 8 oil filter element cover1 8 o-ring2 8 oil filter element 3 3 2 1 4.
CHANGING THE ENGINE OIL FILTER ELEMENT CHK ADJ cC Check it under the condition that a check bolt is surely loosened because oil erupts when a check bolt is removed and an engine is started. 5. Fill: 8 crankcase Refer to “CHECKING THE ENGINE OIL “. Quantity Total amount 1.2L (1.10 Imp qt, 1.31 US qt) Without oil filter element replacement 1.2L (1.10 Imp qt, 1.31 US qt) Periodic oil change 1.0 L (0.92 Imp qt, 1.
CHANGING THE TRANSMISSION OIL CHK ADJ CHANGING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. NOTE: 8 Stand the scooter on a suitable stand. 8 Make sure that the scooter up right. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place a container under the transmission. 4. Remove: 8 Oil filler cap 8 Transmission oil drain bolt 1 8 Completely drain the transmission oil 5. Install: 8 transmission oil drain bolt 1 T. R. 23 Nm (2.3 m • kg, 16.6 ft • lb) 6.
MEASURING THE ENGINE OIL PRESSURE CHK ADJ EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: 8 engine oil level Below the minimum level mark J Add the recommended engine oil to the proper level. Refer to “CHECKING THE ENGINE OIL LEVEL”. 2. Start the engine, warm it up for several minutes, and then turn it off. cC When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase.
CLEANING THE AIR FILTER ELEMENT/ CLEANING THE V-BELT CASE AIR FILTER ELEMENT CHK ADJ EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: 8 air filter case cover 1 8 air filter element2 2. Check: 8 air filter element Damage J Replace. 2 1 EAS00091 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: 8 kick starter 1 8 damper cover 2 1 2 2.
CLEANING THE V-BELT CASE AIR FILTER ELEMENT CHK ADJ NOTE: After cleaning, gently squeeze the V-belt case air filter element to remove the excess solvent. cC Do not twist the V-belt case air filter element when squeezing it. 5. Apply the recommended oil to the entire surface of the air filter element and squeeze out the excess oil. The air filter element should be wet but not dripping. Recommanded oil Engine oil 6. Install: 8 element 1 1 7. Install: 8 element holder1 T. R. 7 Nm (0.7 m • kg, 5.
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD CHK ADJ EAS00094 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Remove: 8 cover 8 rear carrier 8 side cover (right,left ) 8 seat 8 hook 8 front cover 8 fuel tank cap 8 rear cover 8 trunk Refer to “COVER AND PANEL”. 2. Check: 8 carburetor joint 1 8 intake manifold 2 Cracks/damage J Replace. Refer to “CARBURETOR” in chapter 6. 3.
CHECKING THE FUEL AND VACUUM HOSES/ CHECKING THE CRANKCASE BREATHER HOSE CHK ADJ EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses. 1. Remove: 8cover 8rear carrier 8side cover (left ) Refer to “COVER AND PANEL”. 2. Check: 8vacuum hose 1 8fuel hose 2 Cracks/damage J Replace. Loose connection J Connect properly. 3. Install: 8side cover (left ) 8rear carrier 8cover Refer to “COVER AND PANEL”.
CHECKING THE EXHAUST SYSTEM CHK ADJ EAS00099 4 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler assembly and gaskets. 1. Remove: 8 hose(from air fi/ter) 8 vacuum hose 8 hose(to cylinder head) 8 air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM”in chapter 6. 2. Check: 8 muffler assembly 1 Cracks/damage J Replace. 8 gasket Exhaust gas leaks J Replace. 3 2 1 3. Check: 8 tightening torque T. R. 4. 3-30 Muffler assembly nut2 2 10 Nm (1.0 m • kg, 7.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE CHK ADJ EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: 8 brake lever free play a a Brake lever free play (at the end of the brake lever) 3 ~ 5mm (0.12 ~ 0.20 in) w A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system.
CHECKING THE BRAKE FLUID LEVEL CHK ADJ EAS00116 CHECKING THE BRAKE FLUID LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Check: 8 brake fluid level Below the minimum level mark a J Add the recommended brake fluid to the proper level. a Recommended brake fluid DOT 4 w 8 Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE SHOES/ CHECKING THE FRONT BRAKE HOSE CHK ADJ EAS00117 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Remove: 8 cap 1 2. Operate the brake. 3. Check: 8 front brake pad Wear indicators 2 almost touch the brake disc J Replace the brake pads as a set. Refer to “REPLACING THE FRONT BRAKE PADS” in chapter 4. 1 2 EAS00126 CHECKING THE REAR BRAKE SHOES 1. Operate the brake. 2.
BRAKE FLUID CHANGE CHK ADJ BRAKE FLUID CHANGE w Should you feel loose when pulling Brake, it is possibly due to leaking of Brake fluid of mixing with air which led to the ineffectiveness of Brake. Since poor performance of Brake caused by mixing with air may trigger accidents, therefore inspection must be carried out prior to riding, and expel the air if necessary. 1. Place the scooter in standing position vertically on a flat floor. NOTE: 8 Use the main stand to place the scooter in upright position.
BRAKE FLUID CHANGE CHK ADJ e. Remove the reservoir diaphragm. f. Fill proper volume of designated brake fluid into the reservoir of the master cylinder. Refer to “CHECKING THE BRAKE FLUID LEVEL”. g. Operate brake lever slowly for several times. Repeat the procedures until the small amount of air (air bubbles) in the reservoir tank disappears, and the brake lever feels heavy. h. Bleed: Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM w Bleed the hydraulic brake system whenever: 8 the system is disassembled. 8 a brake hose is loosened, disconnected or replaced. 8 the brake fluid level is very low. 8 brake operation is faulty. 1. Remove: 8reservoir cap NOTE: 8 Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ h. Tighten the bleed screw and then release the brake lever. 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. Bleed screw 6 Nm (0.6 m • kg, 4.3 ft • lb) R. k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ EAS00148 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Check: 8 steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness J Adjust the steering head. 3.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ c. Loosen the lower ring nut completely and then tighten it to specification with a steering nut wrench . w Do not overtighten the lower ring nut. T. R. Lower ring nut (final tightening torque) 9 Nm (0.9 m • kg, 6.5 ft • lb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings.
CHECKING THE FRONT FORK CHK ADJ EAS00151 CHECKING THE FRONT FORK 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. 2. Check: 8 inner tube Damage/scratches J Replace. 8 oil seal Oil leakage J Replace. 3. Hold the scooter upright and apply the front brake. 4. Check: 8 front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement J Repair.
CHECKING THE TIRES CHK ADJ EAS00163 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 8tire pressure Out of specification J Regulate. w 8 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. 8 The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
CHECKING THE TIRES 2. 1 CHK ADJ Check: 8tire surfaces Damage/wear J Replace the tire. Minimum tire tread depth 0.8 mm (0.03 in) 3 1 Tire tread depth 2 Sidewall 3 Wear indicator 2 w 8 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. 8 When using tube tires, be sure to install the correct tube. 8 Always replace a new tube tire and a new tube as a set.
CHECKING THE TIRES CHK ADJ w New tires 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. NOTE: For tires with a direction of rotation mark 1: 8 Install the tire with the mark pointing in the direction of wheel rotation. 8 Align the mark 2 with the valve installation point.
CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES CHK ADJ EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: 8 wheel Damage/out-of-round J Replace. w Never attempt to make any repairs to the wheel. NOTE: After a tire 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 inner and outer cables.
LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTERSTAND CHK ADJ EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.
CHECKING AND CHARGING THE BATTERY CHK ADJ EAS00179 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY w Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 8 Wear protective eye gear when handling or working near batteries. 8 Charge batteries in a well-ventilated area. 8 Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: 8 mat 8 battery cover Refer to “COVER AND PANEL”. 2.
Open-circuit voltage (V) CHECKING AND CHARGING THE BATTERY 13.0 CHK ADJ b. Check the charge of the battery, as shown in the charts and the following example. Relationship between the open-circuit voltage and the charging time at 20 C 12.5 Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 <-> 30% ***************************************************** 12.0 11.5 5 6.
CHECKING AND CHARGING THE BATTERY CHK ADJ 8 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. 8 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 AND CHARGING THE BATTERY CHK ADJ Charging method using a variable-current (voltage) charger Charger Ammeter Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? NOTE: Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. NOTE: Set the charging voltage to 16-17 V.
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? NO This type of battery charger cannot charge an MF battery. A variablevoltage charger is recommended.
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES CHK ADJ 6. Install: 8 battery 7. Connect: 8 battery leads (to the battery terminals) 2 cC First, connect the positive battery lead 1, and then the negative battery lead 2. 1 8. Check: 8 battery terminals Dirt J Clean with a wire brush. Loose connection J Connect properly. 9. Lubricate: 8 battery terminals Recommended lubricant Dielectric grease 10. Install: 8 battery cover 8 mat Refer to “COVER AND PANEL”.
CHECKING THE FUSES CHK ADJ 2. Check: 8 fuse ***************************************************** a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03132 (YU-03112-C) b. If the pocket tester indicates “∞”, replace the fuse. ***************************************************** 3. Replace: 8 blown fuse ***************************************************** a. Set the main switch to “OFF”. b.
REPLACING THE HEADLIGHT BULB CHK ADJ EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: 8 headlight cover 2. Disconnect: 8 headlight coupler 1 3. Remove: 8 headlight bulb holder rubber2 1 2 4. Remove : 8 headlight bulb holder 1 8 headlight bulb 2 w 2 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 1 5. Install: 8 headlight bulb New Secure the new headlight bulb with the headlight bulb holder.
ADJUSTING THE HEADLIGHT BEAMS CHK ADJ EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlight. 1. Adjust: 8 headlight beam (vertically) a. Loosen the adjusting screw 1and press headlight in direction a or b. ***************************************************** a b 1 Direction a Direction b Headlight beam is raised. Headlight beam is lowered. ***************************************************** 2.
CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC ....................................................... 4-1 FRONT WHEEL ................................................................................. 4-2 REMOVING THE FRONT WHEEL .................................................... 4-3 CHECKING THE FRONT WHEEL .................................................... 4-4 CHECKING THE BRAKE DISC ......................................................... 4-5 ASSEMBLING THE FRONT WHEEL ...........................
CHAS HANDLEBAR .......................................................................................... 4-43 REMOVING THE HANDLEBAR ...................................................... 4-44 CHECKING THE HANDLEBAR ...................................................... 4-44 INSTALLING THE HANDLEBAR..................................................... 4-45 STEERING HEAD ................................................................................... 4-47 LOWER FENDER COVER AND HANDLEBAR LOWER HOLDER ...
FRONT WHEEL AND BRAKE DISC CHAS EAS00513 CHASSIS FRONT WHEEL AND BRAKE DISC 4 1 LS 6 5 2 3 70Nm(7.0m•kg, 50.6 ft•lb) 7 20Nm(2.0m•kg, 14.5 ft•lb) 8 LT Order Job/Part Q’ty Remarks Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
FRONT WHEEL AND BRAKE DISC CHAS EAS00518 FRONT WHEEL 4 3 B B 2 1 Order 1 2 3 4 Job/Part Q’ty Disassembling the front wheel Oil seal Bearing Collar Bearing Remarks Remove the parts in the order listed. 1 1 1 1 4-2 Refer to”REMOVING THE FRONT WHEEL” and “INSTALLING THE FRONT WHEEL” For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE DISC CHAS EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. w 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: 8 speedometer cable 8 brake hose holder Refer to” REMOVING THE FRONT WHEEL AND BRAKE DISC” . 3.
FRONT WHEEL AND BRAKE DISC CHAS EAS00525 CHECKING THE FRONT WHEEL 1. Check: 8 wheel axle Roll the wheel axle on a flat surface. Bends J Replace. w Do not attempt to straighten a bent wheel axle. 2. Check: 8 tire 8 front wheel Damage/wear J Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: 8 radial wheel runout 1 8 lateral wheel runout 2 Over the specified limits J Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm(0.04 in) 4.
FRONT WHEEL AND BRAKE DISC CHAS a. b. Clean the outside of the front wheel hub. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. 2 1 c. Remove the wheel bearings 3 with a general bearing puller. d. Install the new wheel bearings and oil seals in the reverse order of disassembly. ***************************************************** 3 EAS00528 CHECKING THE BRAKE DISC 1.
FRONT WHEEL AND BRAKE DISC CHAS 3. Measure: 8 brake disc thicknessb Measure the brake disc thickness at a few different locations. Out of specification J Replace. Brake disc thickness limit (minimum) 3.5 mm (0.14 in) LT 4. Adjust: 8 brake disc deflection ***************************************************** a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. T. R.
FRONT WHEEL AND BRAKE DISC CHAS EAS00539 ASSEMBLING THE FRONT WHEEL 1. Install: 8 wheel bearings 8 oil seals New ***************************************************** a. Install the new wheel bearings and oil seals in the reverse order of disassembly. cC Do not contact the wheel bearing inner race 1 or balls 2. Contact should be made only with the outer race 3. NOTE: Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal.
FRONT WHEEL AND BRAKE DISC CHAS EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: 8 wheel axle 8 wheel bearings 8 oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: 8 speedometer gear unit 1 NOTE: Make sure the speedometer gear unit and the wheel hub are installed with the two projections 2meshed into the two slots3 respectively. 13 2 3. Install: 8 front wheel 1 1 2 NOTE: Make sure the slot2 in the speedometer gear unit fits over the stopper 3on the outer tube. 3 T. 4.
FRONT WHEEL AND BRAKE DISC CHAS EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: 8 After replacing the tire, wheel or both, the front wheel static balance should be adjusted. 8 Adjust the front wheel static balance with the brake disc installed. 1. Remove: 8 balancing weight(s) 2. Find: 8 front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. X1 ***************************************************** a. Spin the front wheel. b.
FRONT WHEEL AND BRAKE DISC CHAS 3. Adjust: 8 front wheel static balance ***************************************************** a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. 1 NOTE: Start with the lightest weight. X b. Turn the front wheel 90° so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced.
REAR WHEEL AND REAR BRAKE CHAS REAR WHEEL AND REAR BRAKE LS 7 8 11 9 2 10 3 1 LS 6 4 5 105Nm(10.5m•kg, 75.9 ft•lb) Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Q’ty Remarks Removing the rear wheel and rear brake Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. Muffler assembly Refer to “MAINFOLD, AIR FILTER AND MUFFLER ASSEMBLY “in chapter 5.
REAR WHEEL AND REAR BRAKE CHAS EAS00565 CHECKING THE REAR WHEEL 1. Check: 8 wheel axle 8 rear wheel Refer to “CHECKING THE FRONT WHEEL”. 2. Check: 8 tire 8 rear wheel Damage/wear J Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: 8radial wheel runout 8lateral wheel runout Refer to “CHECKING THE FRONT WHEEL”.
REAR WHEEL AND REAR BRAKE CHAS EAS00569 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: 8 brake shoe lining Glazed areas J Repair. Sand the glazed areas with course sandpaper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. 2. Measure: 8 brake shoe lining thickness a Out of specification J Replace. Brake shoe lining thickness limit (minimum) 2.0 mm(0.08 in) a w Do not allow oil or grease to contact the brake shoes.
REAR WHEEL AND REAR BRAKE CHAS EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 8 brake camshaft 1 8 brake shoe wear indicator 2 1 2 ***************************************************** a. Install the brake camshaft so its punch mark a is positioned as shown. b. Align the projection b on the brake shoe wear indicator with the notch in the brake shoe camshaft. c. Check that the brake shoes are properly positioned. ***************************************************** b a 2.
FRONT BRAKE CHAS EAS00576 FRONT BRAKE FRONT BRAKE PADS 35Nm(3.5m•kg, 25.3 ft•lb) 1 6 1 5 7 3 3 5 4 LS 2 22Nm(2.2m•kg, 15.9 ft•lb) Order Job/Part Q’ty 1 2 3 4 5 Removing the front brake pads Caliper brake bracket bolt Caliper brake pad bolt Brake pad Brake pad plate Brake pad spring 2 1 2 1 2 6 7 Caliper brake bracket Caliper assembly 1 1 Remarks Remove the parts in the order listed. Refer to “REPLACING THE FRONT BRAKE PADS”. For installation, reverse the removal procedure.
FRONT BRAKE CHAS EAS00579 cC Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: 8 Never disassemble brake components unless absolutely necessary. 8 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. 8 Never use solvents on internal brake components. 8 Use only clean or new brake fluid for cleaning brake components.
FRONT BRAKE CHAS 3. Remove: 8 brake pad bolt 8 brake pad spring 1 8 brake pads 2 8 brake pad plate 3 2 3 1 4. Measure: 8 brake pad wear limit a Out of specification J Replace the brake pads as a set. a Brake pad wear limit 0.8 mm(0.03 in) 5. Install: 8 brake pad plate 1 8brake pads 2 8brake pad spring 3 1 2 NOTE: Always install new brake pads and a new brake pad spring as a set. 3 ***************************************************** a. Connect a clear plastic hose 2 tightly to the bleed screw 1.
FRONT BRAKE 6. CHAS Lubricate: 8brake caliper guide bar Recommended lubricant Lithium-soap-based grease cC LS 8 Do not allow grease to contact the brake pads. 8 Remove any excess grease. 7. Install: 8brake pad bolt T. R. 22 Nm (2.2 m • kg, 15.9 ft • lb) 8brake caliper bolt T. R. 35 Nm (3.5 m • kg, 23.5 ft • lb) 8. Check: 8brake fluid level Below the MIN level mark a J Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 9.
CHAS FRONT BRAKE EAS00584 FRONT BRAKE MASTER CYLINDER 9Nm(0.9m • kg, 6.5 ft • lb) 1.6Nm(0.16m • kg, 1.2 ft • lb) 6 LS 7 1 2 4 26Nm(2.6m • kg, 18.8 ft • lb) 3 5 4 Order Job/Part Q’ty 1 2 3 4 5 6 7 Removing the front brake master cylinder Brake fluid Brake lever / Compress spring Front brake light switch Union bolt Copper washer Brake hose Master cylinder bracket Master cylinder assembly Remarks Remove the parts in the order listed. Drain.
FRONT BRAKE CHAS EAS00585 DISASSEMBING THE FRONT BRAKE MASTER CYLINDER 2 3 4 1 5 Order Job/Part Q’ty 1 2 3 4 5 Disassembling the front brake master cylinder Reservoir diaphragm Dust boot Circlip / Washer Master cylinder kit Spring Remarks Remove the parts in the order listed. 1 1 1/1 1 1 For assembly, reverse the disassembly 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: 8 brake switch coupler (from the brake switch) 2 2. Remove: 8 union bolt 1 8 copper washer 2 8 brake hose 3 3 1 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 3. Check: 8 brake master cylinder reservoir Cracks/damage J Replace. brake master cylinder reservoir diaphragm 1 Damage/wear J Replace. 1 4. Check: brake hoses 1 Cracks/damage/wear J Replace.
FRONT BRAKE CHAS EAS00597 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER w 8 Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. 8 Never use solvents on internal brake components. Recommended brake fluid DOT 4 2 1 1. Install: 8 spring 1 Install the spring with its smaller diameter to the master cylinder kit. 8 master cylinder kit 2 2. Install: 8 circlip1 New 8 dust boot2 3. Install: 8 brake switch 8 brake lever 2 1 4.
FRONT BRAKE 1 CHAS 5. Install: 8 copper washers1 New 8 brake hose2 8 union bolt3 2 T. R. 26 Nm (2.6 m • kg, 18.8 ft • lb) w 3 Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING”. NOTE: 8 While holding the brake hose, tighten the union bolt as shown. 8 Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. 6.
FRONT BRAKE CHAS 7. Bleed: 8 brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 8. Check: 8 brake fluid level Below the MIN level mark a J Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 9. Check: 8 brake lever operation Soft or spongy feeling J Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT BRAKE CHAS EAS00612 FRONT BRAKE CALIPER 35Nm(3.5m • kg, 25.3 ft • lb) 4 3 5 2 1 23Nm(2.3m • kg, 16.6 ft • lb) Order 1 2 3 4 5 Job/Part Q’ty Removing the front brake caliper Brake fluid Union bolt Copper washer Brake hose Front brake caliper bracket bolt Front brake caliper assembly Remarks Remove the parts in the order listed. Drain. 1 2 1 2 1 For installation, reverse the removal procedure.
FRONT BRAKE CHAS EAS00614 DISASSEMBING THE FRONT BRAKE CALIPER 6Nm(0.6m • kg, 4.3 ft • lb) 2 5 9 3 1 3 LS 4 7 6 22Nm(2.2m • kg, 15.9 ft • lb) 8 Order Job/Part Q’ty 1 2 3 4 5 6 7 8 9 Disassembling the front brake caliper Cap Caliper bracket Brake pad Brake pad plate Brake spring Dust seal Piston seal Caliper piston Bleed screw / Cap Remarks Remove the parts in the order listed. 1 1 2 1 2 1 1 1 1/1 For assembly, reverse the disassembly procedure.
FRONT BRAKE CHAS EAS00619 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: 8 union bolt 1 8 copper washers 2 8 brake hose 3 8 brake caliper pad bolt 4 8 brake caliper bracket bolts 5 8 brake caliper assembly6 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 5 3 1 6 2 4 2.
FRONT BRAKE CHAS EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every 2 years Brake fluid Every 2 year and whenever the brake is disassembled 1. Check: 8 brake caliper piston 1 Rust/scratches/wear J Replace the brake caliper piston assembly. 8 brake caliper cylinder 2 Scratches/wear J Replace the brake caliper assembly. 8 brake caliper body 3 Cracks/damage J Replace the brake caliper assembly.
FRONT BRAKE CHAS EAS00637 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER w 8 Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. 8 Never use solvents on internal brake components as they will cause the piston seals to swell and distort. 8 Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1. Install: 8 brake caliper piston seal 1 New 8 brake caliper dust seal 2 New 2 1 2.
FRONT BRAKE CHAS T. 8brake caliper pad bolt 3 22 Nm (2.2 m • kg, 15.9 ft • lb) 8brake hose 4 8copper washers 5 New 8union bolt 6 23 Nm (2.3 m • kg, 16.6 ft • lb) R. T. R. w Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING”. cC a When installing the brake hose onto the brake caliper 1, make sure the brake pipe a touches the projection b on the brake caliper. b 1 4.
FRONT BRAKE CHAS ter will significantly lower the boiling point of the brake fluid and could cause vapor lock. cC Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: 8 brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 6. Check: 8 brake fluid level Below the MIN level mark a J Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. a 7.
FRONT FORK CHAS EAS00646 FRONT FORK 45Nm(4.5m • kg, 32.5 ft • lb) 5 2 4 3 6 23Nm(2.3m • kg, 16.6 ft • lb) 7 1 Order Job/Part Q’ty Removing the front fork legs Front wheel Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISC”. Refer to “COVER AND PANEL” in chapter 3.
FRONT FORK CHAS EAS00648 DISASSEMBING THE FRONT FORK LEGS 1 2 7 8 9 5 0 6 30Nm(3.0m • kg, 21.7 ft • lb) 4 3 3 LT Order Job/Part 1 2 3 4 5 6 Disassembling the front fork legs Fork oil Fork spring Clamp / Boot Damper rod bolt / Gasket Inner tube Damper rod Rebound spring 7 8 9 0 Oil flow stopper Oil seal clip Oil seal Outer tube Q’ty Remarks Remove the parts in the order listed. Drain.
FRONT FORK CHAS EAS00651 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface. w 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. Loosen: 8pinch bolt 1 3. Remove: 8 cap bolt 2 (with a 10-mm hexagonal wrench3) 3 w 2 8Fork spring will jump out after removing cap bolt.
FRONT FORK CHAS EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: 8fork spring 1 1 2. Drain: 8fork oil 3. Remove: 8damper rod assembly bolt 1 8damper rod assembly 2 3 NOTE: While holding the damper rod with the damper rod holder 2 and T- handle3, loosen the damper rod assembly bolt. 1 Damper rod holder 90890-01294 (YM-01300-1) T- handle 90890-01326 (YM-01326) 4.
FRONT FORK CHAS 5. Remove: 8oil seal clip 1 (with a flat-head screwdriver) cC Do not scratch the inner tube. 1 6. Remove: 8oil seal 1 2 cC Never reuse the oil seal.
FRONT FORK CHAS EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1 1. Check: 8 inner tube 1 8 outer tube 2 Bends/damage/scratches J Replace. 2 w Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: 8 spring free length a Out of specification J Replace. Spring free length 257.5 mm (10.14 in) : 252.4 mm (9.94 in) a 3. Check: 8 damper rod 1 Damage/wear J Replace.
FRONT FORK CHAS EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. w 8 Make sure the oil levels in both front fork legs are equal. 8 Uneven oil levels can result in poor handling and a loss of stability. NOTE: 8 When assembling the front fork leg, be sure to replace the following parts: - oil seal - dust seal 8 Before assembling the front fork leg, make sure all of the components are clean. 2 1.
FRONT FORK CHAS Damper rod holder 90890-01294(YM-01300-1) T-handle 90890-01326(YM-01326) 4. Install: 8oil seal 1 New (with the fork seal driver weight 2 and adapter 3) 2 3 1 Fork seal driver weight 90890-01367(YM-A9409-7) Adapter 90890-01400(YM-A9409-3) cC Make sure the numbered side of the oil seal faces up. 4 NOTE: 8 Before installing the oil seal, lubricate its lips with lithium soap base grease. 8 Lubricate the outer surface of the inner tube with fork oil.
FRONT FORK CHAS 6. Install: 8fork boot 1 1 7. Fill: 8 front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.126 L (0.11 lmp qt, 0.13 US qt) Recommended oil Fork oil 10W or equivalent NOTE: 8 While filling the front fork leg, keep it upright. 8 After filling, slowly pump the front fork leg up and down to distribute the fork oil. 8. Install: 8 fork spring 1 NOTE: 8 Install the spring with the smaller pitch facing up.
FRONT FORK CHAS EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: 8front fork leg NOTE: Pull up the inner tube until it stops, then install the cap bolt. T. 2. Tighten: 8cap bolt 1 45 Nm (4.5 m • kg, 32.5 ft • lb) R. T. 8 pinch bolt 2 23 Nm (2.3 m • kg, 16.6 ft • lb) R.
HANDLEBAR CHAS EAS00664 HANDLEBAR 1 4 9Nm(0.89m • kg, 6.5 ft • lb) 6 30Nm(3.0m • kg, 21.7 ft • lb) 1 LS 11 7 2 11 12 12 LS 5 5 9 7 3 13 10 8 Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Part Q’ty LS Remarks Remove the parts in the order listed.
HANDLEBAR CHAS EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. 2. Remove: 8handlebar switch assembly (right)1 8throttle grip assembly 2 8brake master cylinder assembly 3 3 NOTE: While removing the handlebar switch assembly (right), pull back the rubber cover. 2 1 1 3.
HANDLEBAR CHAS EAS00671 INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. 2. Install: 8 handlebar 1 8 upper handlebar holders 2 T. R. 1 30 Nm (3.0 m • kg, 21.7 ft • lb) 2 cC 8 First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. NOTE: 8The upper handlebar holders should be installed with the arrow marks a facing forward A.
HANDLEBAR 4. Install: 8 left handlebar switch 1 b a CHAS 1 NOTE: Align the projection a on the left handlebar switch with the hole b in the handlebar. 5. Install: 8 throttle grip 1 8 right handlebar switch2 8 throttle cables 3 1 a 2 3 b NOTE: 8 Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar4. 8 Align the projection a on the right handlebar switch with the hole b in the handlebar.
STEERING HEAD CHAS EAS00675 STEERING HEAD LOWER FENDER COVER AND HANDLEBAR LOWER HOLDER 47.5Nm(4.75m • kg, 34.4 ft • lb) 6 8 9 5 2 1 4 7 3 Order Job/Part Q’ty Remove the parts in the order listed. Removing the lower fender cover and handlebar lower holder Front wheel Refer to “FRONT WHEEL AND BRAKE DISC”. Refer to “COVER AND PANEL” in chapter 3. Refer to “FRONT FORK”. Refer to “HANDLEBAR”.
STEERING HEAD CHAS EAS00675 LOWER BRACKET 60Nm(6.0m • kg, 43.4 ft • lb) 75Nm(7.5m • kg, 54.2 ft • lb) 1st 28Nm(2.8m • kg, 20.3 ft • lb) 2nd 9Nm(0.9m • kg, 6.5 ft • lb) 1 2 3 4 5 6 7 8 9 LS 10 12 LS 13 11 14 15 Order Job/Part Q’ty Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISC”. Refer to “LOWER FENDER COVER AND HANDLEBAR LOWER HOLDER”.
STEERING HEAD CHAS 60Nm(6.0m • kg, 43.4 ft • lb) 75Nm(7.5m • kg, 54.2 ft • lb) 1st 28Nm(2.8m • kg, 20.3 ft • lb) 2nd 9Nm(0.9m • kg, 6.5 ft • lb) 1 2 3 4 5 6 7 8 9 LS 10 12 LS 13 11 14 15 Order 15 Job/Part Q’ty Rubber washer Remarks 1 For installation, reverse the removal procedure.
STEERING HEAD CHAS EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. 2. Remove: 8 handlebar holder bracket 1 NOTE: 8 Remove the handlebar holder bracket by loosening the upper ring nut2 gradually. 1 2 3. Remove: 8ring nut 1 (with the ring nut wrench 2) 1 Ring nut wrench 90890-01268(YU-01268) 2 w Securely support the lower bracket so that there is no danger of it falling.
STEERING HEAD CHAS EAS00682 CHECKING THE STEERING HEAD 1. Wash: 8bearings 8bearing races Recommended cleaning solvent Kerosene 2. Check: 8bearings 1 8bearing races 2 Damage/pitting J Replace. 2 1 2 3. Replace: 8bearings 8bearing races ***************************************************** a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c.
STEERING HEAD CHAS EAS00684 INSTALLING THE STEERING HEAD 1. Lubricate: 8 upper bearing 8 lower bearing 8 bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 8 lower ring nut 1 8 rubber washer 2 8 center ring nut 3 8 lock washer 4 8 upper ring nut 5 Refer to “CHECKING THE STEERING HEAD” in chapter 3. 1 2 3 4 3. Install: 8 handlebar holder bracket 1 2 T. R. 3 60 Nm (6.0 m • kg, 43.
REAR SHOCK ABSORBER CHAS EAS00692 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the scooter on a level surface. w 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 rear wheel is elevated. 2. Remove: 8 rear carrier 8 side cover( left ) Refer to “COVER AND PANEL” in chapter 3. 3. Remove: 8 rear shock absorber nut (upper)1 8 rear shock absorber bolt (lower)2 1 2 EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1.
REAR SHOCK ABSORBER CHAS EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: 8 spacer 8 bush Recommended lubricant Molybdenum disulfide grease 2. Install: 8 rear shock absorber assembly 3. Tighten: 8 rear shock absorber assembly upper nut1 1 T. R. 30 Nm (3.0 m • kg, 21.7 ft • lb) 8 rear shock absorber assembly lower bolt2 2 T. R. 18 Nm (1.8 m • kg, 13.0 ft • lb) 4. Install: 8 side cover( left ) 8 rear carrier Refer to “COVER AND PANEL” in chapter 3.
ENG CHAPTER 5 ENGINE ENGINE ..................................................................................................... 5-1 LEADS, HOSES AND REAR BRAKE ............................................... 5-1 INSTALLING THE ENGINE ............................................................... 5-3 MAINFOLD, AIR FILTER AND MUFFLER ASSEMBLY ................... 5-4 CYLINDER HEAD ..................................................................................... 5-5 CYLINDER HEAD ........................
ENG BELT DRIVE............................................................................................ 5-35 CRANKCASE COVER ..................................................................... 5-35 KICKSTARTER ................................................................................ 5-36 INSTALLING THE KICKSTARTER .................................................. 5-37 V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE ......... 5-38 DISASSEMBLING THE SECONDARY SHEAVE ...........................
ENGINE ENG EAS00188 ENGINE ENGINE LEADS, HOSES AND REAR BRAKE 18Nm(1.8m • kg, 13.0 ft • lb) 9 2 6 10 1 5 3 11 12 13 4 15 7 LS 8 42Nm(4.2m • kg, 30.4 ft • lb) Order Job/Part 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Removing the leads, hoses and rear brake Seat/Rear carrier Side cover ( left / right )/Fuel tank cap Rear cover/Hook( left and right ) Front cover/Trunk Spark plug cap Starting motor lead / Earth lead Auto choke lead C.D.I.
ENGINE ENG 18Nm(1.8m • kg, 13.0 ft • lb) 9 2 6 10 1 5 3 11 12 13 4 15 7 LS 8 42Nm(4.2m • kg, 30.4 ft • lb) Order Job/Part Q’ty 14 Remarks For installation, reverse the removal procedure.
ENGINE ENG NOTE: Make sure to reset the oil change indicator when the oil is changed. EAS00192 INSTALLING THE ENGINE 1. Install: 8 engine bracket bolt 1 NOTE: Do not fully tighten the bolts. 1 2. Tighten: 8 engine bracket bolt1 T. R. 55Nm(5.5 m • kg, 39.
ENGINE ENG MAINFOLD, AIR FILTER AND MUFFLER ASSEMBLY 7Nm(0.7m • kg, 5.1 ft • lb) 31Nm(3.1m • kg, 22.4 ft • lb) 1 5 6 4 2 10Nm(1.0m • kg, 7.2 ft • lb) 3 Order Job/Part Q’ty 1 2 3 4 5 6 Removing the mainfold, air filter and muffler assembly Starting motor lead / Earth lead Auto choke lead C.D.I.
CYLINDER HEAD ENG EAS00221 CYLINDER HEAD 8Nm(0.8m • kg, 5.8 ft • lb) 8Nm(0.8m • kg, 5.8 ft • lb) 10Nm(1.0m • kg, 7.2 ft • lb) 5 10 10Nm(1.0m • kg,7.2 ft • lb) 2 3 1 17 16 6 17 8 14 13 4 15 12 11 7 22Nm(2.2m • kg, 15.9 ft • lb) Order 30Nm(3.0m • kg, 21.7 ft • lb) 7 9 12Nm(1.2m • kg, 8.
CYLINDER HEAD ENG 8Nm(0.8m • kg, 5.8 ft • lb) 8Nm(0.8m • kg, 5.8 ft • lb) 10Nm(1.0m • kg, 7.2 ft • lb) 5 10 10Nm(1.0m • kg,7.2 ft • lb) 2 3 1 17 16 6 17 8 14 13 4 15 12 11 7 22Nm(2.2m • kg, 15.9 ft • lb) Order 17 30Nm(3.0m • kg, 21.7 ft • lb) 7 9 12Nm(1.2m • kg, 8.7 ft • lb) Job/Part Q’ty Dowel pin Remarks 2 For installation, reverse the removal procedure.
CYLINDER HEAD ENG EAS00225 REMOVING THE CYLINDER HEAD 1. Remove : 8 oil delivery pipe 8 engine oil cap 8 valve cover 8 Air shroud 1 8 Air shroud 2 8 breather a 2. Align: 8 “I” mark a on the magneto (with the stationary pointer b on the crankcase cover) b ***************************************************** a. Turn the primary sheave counterclockwise. b. When the piston is at TDC on the compression stroke, align the “I” mark c on the camshaft sprocket with the mark d on the cylinder head.
CYLINDER HEAD ENG NOTE: 8 To prevent the timing chain from falling into the crankcase, fasten it with a wire. 8 While holding the C.D.I. magneto bolt with a wrench, remove the camshaft sprocket plate bolt 1. 5. Remove: 8cylinder head 5 3 1 4 6 2 NOTE: 8 Loosen the nuts in the proper sequence as shown. 8 Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
CYLINDER HEAD ENG EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: 8 combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: 8 spark plug bore thread 8 valve seats 2. Check: 8 cylinder head Damage/scratches J Replace. 3. Measure: 8 cylinder head warpage Out of specification J Resurface the cylinder head. Maximum cylinder head warpage Less than0.05 mm(0.002 in) ***************************************************** a.
CYLINDER HEAD ENG EAS00231 3 1 5 4 6 INSTALLING THE CYLINDER HEAD 1. Install: 8 gasket New 8 dowel pins 2. Install: 8 cylinder head 3. Tighten: 8 cylinder head nuts 22 Nm (2.2 m • kg, 15.9 ft • lb) 4 4 2 T. R. 8 cylinder head bolts T. R. 12 Nm (1.2 m • kg, 8.7 ft • lb) NOTE: 8 Lubricate the cylinder head nuts with engine oil. 8 Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages. a 4.
CYLINDER HEAD ENG cC Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. e. While holding the camshaft, temporarily tighten the camshaft sprocket bolts. f. Remove the wire from the timing chain. ***************************************************** 5. Install 8camshaft sprocket plate 1 8camshaft sprocket plate bolt 2 1 2 6. Install: 8timing chain tensioner gasket New 8timing chain tensioner ***************************************************** a.
CYLINDER HEAD ENG 7. Turn: 8crankshaft (several turns counterclockwise) a 8. Check: 8“I” mark a Align the “I” mark on the C.D.I. magneto rotor with the stationary pointer b on the crankcase cover. 8“I” mark c Align the “I” mark on the camshaft sprocket with the stationary pointer d on the cylinder head. Out of alignment J Correct. Refer to the installation steps above. b 9. Tighten: 8camshaft sprocket bolt d T. R. 30 Nm (3.0 m • kg, 21.
THE ROCKER ARMS AND CAMSHAFT ENG THE ROCKER ARMS AND CAMSHAFT 7Nm(0.7m • kg, 5.1 ft • lb) 2 3 5 M 4 6 4 LS 7 5 4 M 6 M 1 3 2 M 4 7Nm(0.7m • kg, 5.1 ft • lb) Order Job/Part Q’ty 1 2 3 4 Removing the rocker arms and camshaft Cylinder head Stopper plate Locknut Adjusting screw Rocker arm shaft 1 2 2 2 5 6 7 O-ring Rocker arm Camshaft 2 2 1 5-13 Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”.
THE ROCKER ARMS AND CAMSHAFT ENG EAS00202 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Remove: 8 locknut 1 8 stopper plate 2 1 2 1 2. Remove: 8 intake rocker arm shaft 8 exhaust rocker arm shaft 8 intake rocker arm 8 exhaust rocker arm 2 NOTE: Remove the rocker arm shafts with the slide hammer bolt 1 and weight2 . Slide hammer bolt 90890-01083 (YU-01083-1) 90890-01085 (YU-01083-2) Weight 90890-01084 (YU-01083-3) 3.
THE ROCKER ARMS AND CAMSHAFT ENG 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: 8 rocker arm Damage/wear J Replace. 2. Check: 8 rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches J Replace or check the lubrication system. 3. Check: 8 camshaft lobe Excessive wear J Replace the camshaft. 4. Measure: 8 rocker arm inside diameter a Out of specification J Replace.
THE ROCKER ARMS AND CAMSHAFT ENG Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.034 mm(0.0004~0.001 in) EAS00205 CHECKING THE CAMSHAFT 1. Check: 8 camshaft bushings Damage/wear J Replace. 2. Check: 8 camshaft lobes Blue discoloration/pitting/scratches J Replace the camshaft. 3. Measure: 8 camshaft lobe dimensions a and b Out of specification J Replace the camshaft. a Camshaft lobe dimension limit Intake a 26.153~26.253 mm (1.030 1.034 in) :26.053mm b 21.015~21.115 mm (0.827 0.
THE ROCKER ARMS AND CAMSHAFT ENG EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: 8 timing chain 1 Damage/stiffness J Replace the timing chain and camshaft sprockets as a set. a 1 2. Check: 8 camshaft sprocket More than 1/4 tooth wear a J Replace the camshaft sprockets and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3.
THE ROCKER ARMS AND CAMSHAFT ENG EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 8 camshaft 1 4 1 Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil M M 2. Lubricate: 8 rocker arm shafts Recommended lubricant Molybdenum disulfide oil 3. Install: 8 exhaust rocker arm 1 8 exhaust rocker arm shaft 2 2 NOTE: Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head. 1 4.
VALVES AND VALVE SPRINGS ENG EAS00236 VALVES AND VALVE SPRINGS 1 2 3 4 7 6 M 5 M M 7 3 M 6 2 1 Order Job/Part Q’ty Removing the valves and valve springs Cylinder head Rocker arm and rocker arm shaft 1 2 3 4 5 6 7 Remove the parts in the order listed. Refer to “CYLINDER HEAD”. Refer to “ ROCKER ARMS AND ROCKER ARMS SHAFTS”.
VALVES AND VALVE SPRINGS ENG EAS00237 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: 8 valve sealing Leakage at the valve seat J Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS”. ***************************************************** a.
VALVES AND VALVE SPRINGS 3. Remove: 8 valve cotter 1 8 valve spring retainer 2 8 valve spring 3 8 valve stem seal 4 8 lower spring seat 5 8 valve 6 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. 6 5 ENG 3 24 1 EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1.
VALVES AND VALVE SPRINGS ENG NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (4.5 mm) 90890-04116 (YM-04116) Valve guide installer (4.5 mm) 90890-04117 (YM-04117) Valve guide reamer (5.0 mm) 90890-04099 ***************************************************** 3. Eliminate: 8 carbon deposits (from the valve face and valve seat) 4. Check: 8 valve face Pitting/wear J Grind the valve face.
VALVES AND VALVE SPRINGS ENG EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: 8 carbon deposits (from the valve face and valve seat) 2. Check: 8 valve seat Pitting/wear J Replace the cylinder head. 3. Measure: 8 valve seat width a Out of specification J Replace the cylinder head. Valve seat width Intake: 0.9 ~ 1.1 mm(0.035 ~ 0.043 in) : 1.6 mm(0.063 in) Exhaust: 0.9 ~1.1 mm(0.035~0.043 in) : 1.6 mm(0.
VALVES AND VALVE SPRINGS ENG a. Apply a coarse lapping compound a to the valve face. cC Do not let the lapping compound enter the gap between the valve stem and the valve guide. a b. Apply molybdenum disulfide oil onto the valve stem. 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.
VALVES AND VALVE SPRINGS ENG EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: 8 valve spring free length a Out of specification J Replace the valve spring. a Valve spring free length 37.30 mm(1.469 in) : 35.40 mm(1.394 in) 2. Measure: 8 compressed valve spring force a Out of specification J Replace the valve spring. b Installed length b a Compressed valve spring force (installed) 147±11N(15.0±1.1 kg) at 25.77 mm (33.075 ± 2.
VALVES AND VALVE SPRINGS ENG EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 8valve stem end (with an oil stone) 2. Lubricate: 8valve stem 8valve stem seal (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 4 3.
VALVES AND VALVE SPRINGS ENG Valve spring compressor 90890-04109 (YM-04109) Valve spring compressor attachment 90890-04108 (YM-04108) 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer. cC Hitting the valve tip with excessive force could damage the valve.
CYLINDER AND PISTON ENG EAS00251 CYLINDER AND PISTON 1 2 8 10 4 9 11 12 8 13 14 13 7 4 5 4 6 3 4 12Nm(1.2m • kg, 8.7 ft • lb) Order Job/Part Q’ty 1 2 3 4 5 6 7 Removing the cylinder and piston Cylinder head Clamp Pipe Timing chain guide (exhaust side) Cylinder O-ring Dowel pin Cylinder gasket 1 1 1 1 1 2 1 8 9 Piston pin clip Piston pin 2 1 10 11 Piston Top ring 1 1 12 13 14 2nd ring Oil ring Expander 1 2 1 Remarks Remove the parts in the order listed.
CYLINDER AND PISTON ENG EAS00253 3 REMOVING THE CYLINDER AND PISTON 1. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 3 cC Do not use a hammer to drive the piston pin out. 2 1 NOTE: 8 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. 8 Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area. 2.
CYLINDER AND PISTON ENG EAS00261* CHECKING THE CYLINDER AND PISTON 1. Check: 8 piston wall 8 cylinder wall Vertical scratches J Replace the cylinder, and the piston and piston rings as a set. 2. Measure: 8 piston-to-cylinder clearance ***************************************************** a. Please carry out the following inspections: 8 cylinder Measure the piston pin in both of its horizontal axis direction a and its right angle direction b at six positions of A, B, C, etc. with a cylinder gauge.
CYLINDER AND PISTON ENG EAS00263 CHECKING THE PISTON RINGS 1. Measure: 8 piston ring side clearance Out of specification J Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.02 ~ 0.08 mm(0.0008~0.0031 in) : 0.13mm(0.0051 in) 2nd ring 0.02 ~ 0.06 mm(0.0008~0.0024 in) :0.12 mm(0.0047 in) 2.
CYLINDER AND PISTON ENG EAS00265 CHECKING THE PISTON PIN 1. Check: 8 piston pin Blue discoloration/grooves J Replace the piston pin and then check the lubrication system. 2. Measure: 8 piston pin outside diameter a Out of specification J Replace the piston pin. Piston pin outside diameter 12.996 ~ 13.000 mm (0.5117~0.5118 in) :12.976 mm (0.5109 in) a 3. Measure: 8 piston pin bore diameter b Out of specificationJ Replace the piston. b Piston pin bore diameter 13.002 ~ 13.013 mm (0.5119 ~ 0.
CYLINDER AND PISTON ENG CHECKING THE TIMING CHAIN GUIDE 1. Check: 8 timing chain guide (exhaust side) Damage/wear J Replace EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: 8 oil ring expander 1 8 oil ring rail 2 8 2nd ring 3 8 top ring 4 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up. 4 3 2 1 2 2. Install: 8 piston 1 8 piston pin 2 8 piston pin clip New 3 1 a NOTE: 8 Apply engineoil the piston pin.
CYLINDER AND PISTON 1 ENG 3. Install: 8 gasket New 1 8 dowel pins 2 2 4. Lubricate: 8 piston 8 piston rings 8 cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: 8 piston ring end gaps b a a b c d A c A Top ring Lower oil ring rail Upper oil ring rail 2nd ring Exhaust side d 6. Install: 8 cylinder 1 NOTE: 8 While compressing the piston rings with one hand, install the cylinder with the other hand.
BELT DRIVE ENG EAS00316 BELT DRIVE CRANKCASE COVER 6 5 10Nm(1.0m • kg, 7.2 ft • lb) 9 2 8 6 7 4 3 1 7Nm(0.7m • kg, 5.1 ft • lb) 23Nm(2.3m • kg, 16.6 ft • lb) Order 1 2 3 4 5 6 7 8 9 Job/Part Q’ty Removing the belt drive Kickstarter Crankcase cover - 3 V-belt case air filter element holder V-belt case filter element Crankcase cover - 1 Dowel pin O-ring Dowel pin O-ring Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
BELT DRIVE ENG EAS00338 KICKSTARTER 7 6 9Nm(0.9m • kg, 6.5 ft • lb) 1 2 8 5 4 3 Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to “CRANKCASE COVER “. Removing the kickstarter Crankcase cover Plate (V-belt guide) Gasket Kick pinion gear Kick pinion gear clip Circlip / Plate washer Kick shaft assembly Torsion spring Solid bush 1 1 1 1 1/1 1 1 1 Refer to “INSTALLING THE KICKSTARTER“. For installation, reverse the removal procedure.
BELT DRIVE ENG EAS00340 2 INSTALLING THE KICKSTARTER 1. Install: 8 solid bush 1 8 kickstarter shaft 2 8 kickstarter spring 3 3 1 2. Hook: 8 kickstarter spring d c NOTE: Hook the spring enda on the kickstarter shaft b as shown, and hook the other end c on the projectiond . b a 3. Install: 8 plain washer1 8 circlip2 New 2 1 1 4. Install: 8 kick pinion gear1 8 kick pinion gear clip 2 2 NOTE: Install the clip at the position shown. 5.
ENG BELT DRIVE V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE 60Nm(6.0m • kg, 43.4 ft • lb) 5 4 13 6 8 3 10 2 12 1 9 11 12 LS LS Order Job/Part Q’ty 1 2 Removing the V-belt, clutch, primary and secondary sheave Primary sheave nut / Plate washer Oneway clutch 3 4 5 6 Primary fixed sheave Secondary sheave nut Clutch housing Secondary sheave assembly 7 8 9 10 11 12 13 V-belt Washer / Collar Primary sliding sheave Cam / Weight Slider Oil seal Gasket 55Nm(5.5m • kg, 39.
BELT DRIVE ENG DISASSEMBLING THE SECONDARY SHEAVE 5 3 4 2 LS 1 90Nm(9.0m • kg, 65.1 ft • lb) 0 6 9 7 8 LS 9 LS Order Job/Part Q’ty 1 2 3 4 5 6 7 8 9 0 Disassembling the secondary sheave Clutch carrier nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave Remarks Disassemble the parts in the order listed.
BELT DRIVE ENG EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: 8 primary sheave nut 1 8 plate washer 8 primary fixed sheave 2 NOTE: While holding the primary fixed sheave with the rotor holding tool 3, loosen the primary fixed sheave nut. Rotor holding tool: 90890-01235 (YU-01235) EAS00318 REMOVING THE SECONDARY SHEAVE AND V-BELT 1. Remove: 8 secondary sheave nut 1 8 clutch housing 2 NOTE: While holding the clutch housing with the sheave holder 3, loosen the secondary sheave nut.
BELT DRIVE ENG 3. Remove: 8 secondary sheave assembly 1 8 V-belt 2 NOTE: Remove the V-belt and clutch assembly from the primary sheave side. 2 1 EAS00319 2 DISASSEMBLING THE SECONDARY SHEAVE 3 1. Remove: 8 clutch carrier nut 1 1 NOTE: Install the clutch spring holder 2 and clutch spring holder arm 3 onto the secondary sheave as shown. Then, compress the spring, and remove the clutch carrier nut 1. Clutch spring holder 90890-01337 (YM-33285) (YM-33285-6) CHECKING THE CLUTCH SHOE 1.
BELT DRIVE ENG EAS00320 CHECKING THE V-BELT 1. Check: 8 V-belt 1 Cracks/damage/wear J Replace. Grease/oil J Clean the primary and secondary sheave. 2. Measure: 8 V-belt width a Out of specification J Replace. 1 V-belt width 21.6 mm (0.0850 in) : 19.5 mm (0.768 in) a CHECKING THE PRIMARY SHEAVE 1. Check: 8 Primary sliding sheave1 8 Primary fixed sheave2 Cracks/damage/wear J Replace the primary sliding sheave, primary fixed sheave and V-belt.
BELT DRIVE ENG CHECKING THE SLIDER 1. Check: slider 1 Damage/wearJ Replace EAS00322 CHECKING THE SECONDARY SHEAVE 1. Check: 8secondary fixed sheave 8secondary sliding sheave Cracks/damage/wear J Replace the secondary fixed and sliding sheaves as a set. 2. Check: 8torque cam groove 1 Damage/wear J Replace the secondary fixed and sliding sheaves as a set. 3. Check: 8guide pin 2 Damage/wear J Replace the secondary fixed and sliding sheaves as a set.
BELT DRIVE ENG 3.
BELT DRIVE ENG EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: 8 secondary fixed sheave’s inner surface 1 8 secondary sliding sheave’s inner surface 2 8 torque cam groove 8 oil seals 8 bearings (with the recommended lubricant) 1 2 Recommended lubricant BEL-RAY assembly lube 3 2. Install: 8 secondary sliding sheave 1 1 NOTE: Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3. 2 Oil seal guide 90890-01384 (YM-33299) 3. Install: 8 guide pin 1 4.
BELT DRIVE 5. Install: 8 secondary sheave 1 8 spring 8 clutch carrier 2 4 2 5 3 ENG NOTE: Attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch carrier nut 5. 1 Clutch spring holder 90890-01337 (YM-33285) ( YM-33285-6) EAS00325 INSTALLING THE BELT DRIVE 1. Install: 8 V-belt 1 8 clutch assembly 2 cC Do not allow grease to contact the V-belt, secondary sheave assembly.
BELT DRIVE ENG 2. Install: 8 clutch carrier nut 1 T. R. 1 90 Nm (9.0 m • kg, 65.1 ft • lb) NOTE: While holding the clutch carrier with the rotor holding tool 2, tighten the clutch carrier nut with the locknut wrench 3. 3 2 Rotor holding tool 90890-01235 Locknut wrench 90890-01348 (YM-01348) 3. Install: 8 clutch housing 1 8 secondary sheave nut2 3 2 T. R. 60 Nm (6.0 m • kg, 43.4 ft • lb) NOTE: Tighten the secondary sheave nut with the sheave holder 3.
ENG STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR 7Nm(0.7m • kg, 5.1 ft • lb) 9 10 7Nm(0.7m • kg, 5.1 ft • lb) 2 3 B 2 11 6 7 8 1 5 4 LS Order Job/Part Q’ty Removing the starter clutch and starter motor Primary sheave 1 2 3 4 5 6 7 8 9 10 11 Idle gear plate Plate washer Idle gear Starter clutch Washer Circlip Bearing Starter wheel gear Starter motor O-ring Shaft Remarks Disassemble the parts in the order listed.
STARTER CLUTCH AND STARTER MOTOR ENG CHECKING THE STARTER WHEEL GEAR 1. Check: 8 starter wheel gear 1 8 idle gear2 Burrs/chips/roughness/wear J Replace 2 1 2. Check: 8 starter clutch operation A ***************************************************** a. Install the starter clutch gear 1 onto the starter clutch2 and hold the starter clutch. b.
C.D.I. MAGNETO ENG C.D.I. MAGNETO 3 2 7Nm(0.7m • kg, 5.1 ft • lb) 1 4 70Nm(7.0m • kg, 50.6 ft • lb) Order 1 2 3 4 Job/Part Q’ty Removing the C.D.I. magneto Air shroud 1 Fan C.D.I. magneto rotor Woodruff key Stator coil assembly Remarks Disassemble the parts in the order listed. Refer to “CYLINDER HEAD”in chapter 3. 1 1 1 1 cC Disconnect the C.D.I. magneto lead coupler. For installation, reverse the removal procedure.
C.D.I. MAGNETO ENG REMOVING THE C.D.I. MAGNETO 1. Remove: 8 nut 1 8 plate washer 1 NOTE: 8 While holding the C.D.I. magneto rotor with the holding tool 2, loosen the C.D.I. magneto nut1. 8 Do not allow the sheave holder to touch the projection on the C.D.I. magneto rotor. 2 Rotor holding tool 90890-01235 (YU-01235) 2. Remove: 8 C.D.I.
C.D.I. MAGNETO ENG INSTALLING THE C.D.I. MAGNETO 1. Install: 8 C.D.I. magneto rotor 1 1 NOTE: 8 Clean the tapered portion of the crankshaft and the magneto rotor hub. 8 When installing the magneto rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft. 2 3 T. 2. Tighten: 8 nut 2 70 Nm (7.0 m • kg, 50.6 ft • lb) R. NOTE: 8 While holding the C.D.I. magneto with the holding tool 3, tighten the C.D.I. magneto rotor nut 2.
OIL PUMP ENG EAS00360 OIL PUMP 2 4 3 1 LS 14 8 7Nm(0.7m • kg, 5.1 ft • lb) 7Nm(0.7m • kg, 5.1 ft • lb) 11 12 13 5 10 6 9 7 Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to “ C.D.I. MAGNETO “ Disassembling the oil pump C.D.I.
OIL PUMP ENG EAS00364 CHECKING THE OIL PUMP 1. Check: 8 oil pump driven gear 1 Cracks/damage/wear J Replace the defective part(s). 1 a 2. Measure: 8 inner-rotor-to-outer-rotor-tip clearance a 8 outer-rotor-to-oil-pump-housing clearance b 8 oil-pump-housing-to-inner-rotor-andouter-rotor clearance c Out of specification J Replace the oil pump. 2 1 Inner rotor 2 Outer rotor 3 Oil pump housing 3 b c 1 Inner-rotor-to-outer-rotor-tip clearance 0.15 mm (0.006 in) : 0.23 mm (0.
OIL PUMP ENG 3. Check: 8 oil pump operation Rough movement J Repeat steps (1) and (2) or replace the defective part(s). EAS00376 2 INSTALLING THE OIL PUMP 1. Install: 8 gasket 1 New 8 oil pump assembly2 8 oil pump bolt 7 Nm (0.7 m • kg, 5.1 ft • lb) 1 T. R. cC After tightening the bolts, make sure the oil pump turns smoothly.
ENG TRANSMISSION EAS00419 TRANSMISSION B 7 G 6 5 6 3 2 1 G 4 G 12Nm(1.2m • kg, 8.7 ft • lb) B Order Job/Part Q’ty Remove the parts in the order listed. Removing the transmission, shift drum assembly, and shift forks Transmission oil Rear wheel 1 2 3 4 5 6 7 Crankcase cover Belt drive Secondary sheave Crankcase cover- 2 Crankcase cover gasket- 2 Dowel pin Primary drive gear shaft Plate washer Main axle Drive axle Remarks Drain. Refer to “REAR WHEEL AND REAR BRAKE “ in chapter 4.
TRANSMISSION ENG EAS00425 CHECKING THE TRANSMISSION 1. Measure: 8 main axle runout (with a centering device and dial gauge ) Out of specification J Replace the main axle. Main axle runout limit 0.02 mm (0.0008 in) 2. Measure: 8 primary drive gear shaft runout (with a centering device and dial gauge ) Out of specification J Replace the drive axle. Primary drive gear shaft runout limit 0.02 mm (0.0008 in) 3.
CRANKCASE AND CRANKSHAFT ENG EAS00381 CRANKCASE AND CRANKSHAFT 12Nm(1.2m • kg, 8.7 ft • lb) 11 10 4 19 9 7 18 11 12 8 17 14 15 16 LS 13 8Nm(0.8m • kg, 5.8 ft • lb) 1 23 6 3 5 Order 4 Job/Part Q’ty Removing the crankshaft assembly Engine Cylinder head Cylinder piston V-belt, clutch, primary / Secondary sheave Starter clutch 1 2 3 4 5 6 7 8 9 10 C.D.I.
CRANKCASE AND CRANKSHAFT ENG 12Nm(1.2m • kg, 8.7 ft • lb) 11 10 4 19 18 9 7 11 12 8 17 14 15 16 LS 13 8Nm(0.8m • kg, 5.8 ft • lb) 1 23 6 3 5 Order Job/Part 4 Q’ty 11 12 Dowel pin Crankshaft 2 1 13 14 Timing chain Crankcase ( left ) 1 1 15 16 17 18 19 Bolt O-ring Timing chain guide Oil pipe O-ring 1 1 1 1 1 2 32Nm(3.2m • kg, 23.1 ft • lb) 1 32Nm(3.2m • kg, 23.
CRANKCASE AND CRANKSHAFT ENG DISASSEMBLING THE CRANKCASE 1. Remove: 8 centerstand assembly 2. Remove: 8 crankcase bolts 1 1 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. 3. 1 Remove: 8 right crankcase1 NOTE: Tap on one side of the crankcase with a softface hammer2. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces.
CRANKCASE AND CRANKSHAFT ENG EAS00389 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: 8 crankshaft assembly 1 8 timing chain 2 1 NOTE: 8 Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. 8 The crankshaft assembly cannot be removed if the timing chain is attached onto the crankshaft sprocket. 2 EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 1. Check: 8 timing chain Damage/stiffness J Replace the timing chain. 2.
CRANKCASE AND CRANKSHAFT ENG EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: 8 crankshaft runout Out of specification J Replace the crankshaft, bearing or both. NOTE: Turn the crankshaft slowly. Maximum crankshaft runout 0.03 mm (0.0012 in) 2. Measure: 8 big end side clearance Out of specification J Replace the big end bearing, crankshaft pin, or connecting rod. Big end side clearance 0.10~0.40 mm (0.004~0.016 in) 3.
CRANKCASE AND CRANKSHAFT ENG 5. Check: 8 crankshaft journal Scratches/wear J Replace the crankshaft. 8 crankshaft journal oil passage Obstruction J Blow out with compressed air. EAS00408 2 3 INSTALLING THE CRANKSHAFT 1. Install: 8 crankshaft assembly 1 8 crankcase2 8 timing chain3 1 cC To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.
CRANKCASE AND CRANKSHAFT ENG EAS00418 ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces. 2. Apply: 8 sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (ACC-11001-05-01) NOTE: Do not allow any sealant to come into contact with the oil gallery. 3. Install: 8 dowel pins 8 timing chain 1 2 NOTE: Install the timing chain so it is not visible through the opening a in the left crankcase 2. 1 a 4.
CARB CHAPTER 6 CARBRETOR CARBURETOR ......................................................................................... 6-1 CHECKING THE CARBURETOR ..................................................... 6-3 ASSEMBLING THE CARBURETOR................................................. 6-5 INSTALLING THE CARBURETOR ................................................... 6-6 MEASURING AND ADJUSTING THE FUEL LEVEL ....................... 6-7 CHECKING THE FUEL COCK .................................................
CARBURETOR CARB CARBURETOR EAS00483 CARBURETOR 3 5 i 4 6 1 0 2 p a u y r w q 8 t o e 7 9 Order 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o Job/Part Q’ty Disassembling the carburetor Auto choke unit Auto choke holder Throttle stop screw / Spring Bracket Clamp Vacuum chamber cover / Piston valve spring Piston valve Jet needle kit Float chamber Gasket Accelerator pump assembly Float pin Float Needle valve Needle valve seat Main jet Main nozzle Main air jet Pilot jet 6-1 Remarks Remove the parts
CARBURETOR CARB 3 5 i 4 6 1 0 2 p a u y r w q 8 t o e 7 9 Order p a Job/Part Q’ty Carburetor heater Ground terminal Remarks 1 1 For assembly, reverse the disassembly procedure.
CARBURETOR CARB EAS00485 CHECKING THE CARBURETOR 1. Check: 8 carburetor body 8 float chamber Cracks/damage J Replace. 2. Check: 8 fuel passages Obstruction J Clean. ***************************************************** a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air. ***************************************************** 3. Check: 8 float chamber body 1 Dirt J Clean. 4.
CARBURETOR 3 2 1 2 CARB 6. Check: 8 needle valve 1 8 needle valve seat 2 Damage/obstruction/wear J Replace the needle valve, needle valve seat and Oring as a set. 7. Check: 8 O-ring 3 Damage/wear J Replace the needle valve, needle valve seat and O-ring as a set. 8. Check: 8 piston valve 1 Damage/scratches/wearJ Replace. 8 piston valve diaphragm 2 Cracks/tears J Replace. 1 9. Check: 8 vacuum chamber cover 1 8 piston valve spring 2 Cracks/damage J Replace. 1 2 5 4 3 2 1 10.
CARBURETOR CARB EAS00487 ASSEMBLING THE CARBURETOR cC 8 Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. 8 Always use a new gasket. 3 1. Install: 8 main nozzle 1 8 main jet 2 8 pilot jet 3 2 1 1 3 2. Install: 8 needle valve seat 1 8 float 2 8 needle valve 3 8 float pin 4 8 screw 5 2 5 4 3. Install: 8 accelerator pump assembly 4.
CARBURETOR CARB EAS00492 INSTALLING THE CARBURETOR 1. Adjust: 8 engine idling speed Engine idling speed 1,600 ~ 1,700r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 2. Adjust: 8 throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.
CARBURETOR CARB EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: 8 fuel level a Out of specification J Adjust. a 1 Fuel level (below the float chamber mating surface) 6.5 ~ 7.5 mm (0.26 ~ 0.30 in) 3 2 ***************************************************** a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. c.
CARBURETOR CARB EAS00505 CHECKING THE FUEL COCK 1. Check: 8fuel cock Cracks/damage/wear J Replace. 2. Check: 8fuel cock strainer 1 obstruction J clean. Blow out the jets with compressed air. Damage J Replace. 1 EAS00503 CHECKING THE AUTOCHOKE UNIT NOTE: When checking the autochoke unit, the ambient temperature must be lower than 45°C (113°F). 1. Remove: 8carburetor 2. Check: 8autochoke unit ***************************************************** a. Connect a 3.
CARBURETOR 2 CARB 3. Check: 8 autochoke unit ***************************************************** a. Connect the autochoke unit leads to a 12.0V battery for five minutes. 1 B B 3 Positive battery lead 1 J black Negative battery lead 2 J black 4 b. Connect a 3.3-mm hose 3 to the starter air passage 4 and blow into the hose. Starter plunger opens. Replace the autochoke unit. Starter plunger closes. Autochoke is OK.
AIR INDUCTION SYSTEM CARB AIR INDUCTION SYSTEM 4Nm(0.4m • kg, 2.9 ft • lb) 1 2 7 6 5 3 4 31Nm(3.1m • kg, 22.4 ft • lb) Order Job/Part Q’ty 1 2 3 4 5 6 7 Removing the air induction system Hose (from AI air filter) Vacuum hose( from mainfold ) Hose (to cylinder head) Muffler assembly Gasket Air cut-off valve bracket Air cut-off valve assembly 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. For installation, reverse the removal procedure.
AIR INDUCTION SYSTEM CARB EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: 8 hoses Loose connection J Connect properly. Cracks/damage J Replace. 8 pipe Cracks/damage J Replace. 2. Check: 8 air cut-off valve Cracks/damage J Replace. 1 NOTE: When the negative pressure is applied to the part 1, check that the continuity in the direction of arrow mark is completely lost. If the negative pressure is not loaded, the continuity can be obtained.
ELEC - + CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS ................................................................ 7-1 WIRING DIAGRAM ................................................................................... 7-2 CHECKING SWITCH CONTINUITY ........................................................ 7-4 CHECKING THE SWITCHES ................................................................... 7-5 CHECKING THE BULBS AND BULB SOCKETS .................................. 7-6 TYPES OF BULBS .............
ELECTRICAL COMPONENTS ELEC EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 0 Wire harness Battery C.D.I.
R Br 6 4 0 8 R B 7 (RED) G B (RED) G B B LW RW 9 l ; (GREEN) L Br B G Br L G B (GREEN) B MOTOR B B B B RW RW B f j k START OFF START y x (BLACK) Dg L B B Y (BLACK) L Dg B Ch OFF RUN E/G STOP u c a BW (BLACK) Ch L P B BrW Dg (BLACK) 3 BW BW Br LW HI LO DIMMER SW h BW BW LW Br (BLUE) L Ch P BrW B Dg Y OFF PUSH HORN SW R W B R YR B R 10A R R R B B R L (ILLUM) 12V3W LW TURN 12V3W L 14V3W B Br G HI BEAM 12V3W B s Y B G (BLACK)
WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g h j k l ; z x c v b n m Main switch C.D.I. magneto Rectifier/Regulator Battery Main fuse Battery (+) lead Battery (-) lead Wire lead Starter relay Starter motor C.D.I.
CHECKING SWITCH CONTINUITY ELEC - + EAS00730 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. cC Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
- ELEC CHECKING THE SWITCHES + 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”. Damage/wear J Repair or replace. Improperly connected J Properly connect. Incorrect continuity reading J 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 J Repair or replace the bulb, bulb socket or both. Improperly connected J Properly connect. No continuity J 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 - + CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 8 bulb w Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. cC 8 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: 8 bulb socket (for continuity) (with the pocket tester) No continuity J Replace. Pocket tester 90890-03132 (YU-03112-C) NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ***************************************************** a. Install a good bulb into the bulb socket. b.
Br 7 0 B (RED) G B (RED) G B B l ; (GREEN) L Br B G Br L G B (GREEN) B MOTOR LW RW B RW RW B f j k START OFF START y x (BLACK) Dg L B B Y (BLACK) L Dg B Ch OFF RUN E/G STOP u c a BW (BLACK) Ch L P B BrW Dg (BLACK) L Ch P BrW B Dg Y OFF PUSH HORN SW 3 BW BW Br LW HI LO DIMMER SW h BW BW LW Br (BLUE) Br R 4 8 9 R W B R YR B R 10A R R 6 R B B B BW R B B R L 14V3W B L (ILLUM) 12V3W s Y B G (BLACK) z P TURN SIGNAL SW L N R YR
IGNITION SYSTEM ELEC - + EAS00736 EAS00738 TROUBLESHOOTING 1. Main Fuse 8 Check the fuse for continuity. Refer to “CHECKING THE FUSE” in chapter 3. 8 Is the fuse OK? The ignition system fails to operate (no spark or intermittent spark). 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. Engine stop switch 9. Sidestand switch 10. Pickup coil resistance 11.
IGNITION SYSTEM EAS00742 ELEC - + EAS00744 4. Ignition spark gap 8 Disconnect the spark plug cap from the spark plug. 8 Connect the ignition checker 1 as shown. 2 Spark plug cap 8 Set the main switch to “ON”. 8 Measure the ignition spark gap a. 8 Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. 5. Spark plug cap resistance 8Remove the spark plug cap from the spark plug lead.
IGNITION SYSTEM ELEC - + EAS00749 7. Main switch 8 Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the main switch OK? YES NO Replace the main switch. 8 Measure the primary coil resistance. EAS00750 8. Engine stop switch 8 Check the engine stopswitch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the engine stop switch OK? Primary coil resistance 0.184 ~ 0.276 Ω at 20°C 8 Connect the pocket tester (Ω × 1k) to the ignition coil as shown.
IGNITION SYSTEM EAS00748 10.Pickup coil resistance 8Disconnect the pickup coil coupler from the wire harness. 8Connect the pocket tester (Ω × 100) to the pickup coil terminal as shown. Positive tester probe J white/red 1 Negative tester probe J white/blue 2 1 W/R W/L 2 8Measure the pickup coil resistance. Pickup coil resistance Ω at 20°C 304 ~456Ω 8Is the pickup coil OK? YES NO Replace the pickup coil. EAS00754 11.Wiring 8Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”.
R R 10A R R 0 8 R B Br (RED) G B (RED) G B B LW RW l ; (GREEN) L Br B G Br L G B (GREEN) B MOTOR B B B 7 B B 4 R 6 B RW RW B L START OFF START y f j (ILLUM) 12V3W 9 HI BEAM 12V3W k x B R LW TURN 12V3W 5 L Dg B Ch OFF RUN E/G STOP u (BLACK) Y (BLACK) Dg L B B c Ch L 14V3W B BW OFF PUSH HORN SW a BW BW R 3 BW BW Br LW HI LO DIMMER SW h BW BW LW Br (BLUE) W B R YR (BLACK) Ch L P B BrW Dg (BLACK) L Ch P BrW B Dg Y B 1 Dg Br
ELECTRIC STARTING SYSTEM ELEC - + EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON” (switchis closed), the starter motor can only operate if at least one of the following conditions is met: 8 The sidesatnd switch is up (the side stand switch is closed), and the brake lever ( front or rear) is pulled to the handlebar (the brake light switch is closed) q 0 9 1 2 3 4 5 6 7 8 9 0 q w 1 2 7 3 6 w 8 5 4 7-15 Battery Main fuse Main switch Front brake light switch R
ELECTRIC STARTING SYSTEM EAS00757 ELEC - + EAS00738 TROUBLESHOOTING 1. Main fuse 8 Check the fuse for continuity. Refer to “CHECKING THE FUSE” in chapter 3. 8 Is the fuse OK? The starter motor fails to turn. Check: 1. Main fuse 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starter relay 6. Main switch 7. Brake light switch (front, rear) 8. Engine stop switch 9. Sidestand switch 10. Start switch 11. Wiring connections (of the entire starting system) YES NO Replace the fuse.
ELECTRIC STARTING SYSTEM EAS00758 ELEC - + EAS00759 3. Starter motor 8 Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead3. 4. Starting circuit cut-off relay 8Disconnect the starting circuit cut-off relay coupler from the wire harness. 8Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cutoff relay coupler as shown.
ELECTRIC STARTING SYSTEM EAS00761 ELEC - + EAS00751 5. Starter relay 8 Disconnect the starter relay coupler from the coupler. 8 Connect the pocket tester (Ω × 1) and battery (12 V) to the starter 8 relay coupler as shown. 7. Brake light switch(front and rear) 8 Check the brake light switch for continuity. Refer to “CHECKING THE SWITCHES”.
ELECTRIC STARTING SYSTEM EAS00766 11. Wiring 8 Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. 8 Is the starting system’s wiring properly connected and without defects? YES The starting system circuit is OK. NO Properly connect or repair the starting system’s wiring or replace the C.D.I. unit.
ELECTRIC STARTING SYSTEM ELEC - + STARTER MOTOR 1 2 5 6 0 3 9 LS q 2 7 7 1 8 8 3.5Nm(0.35m • kg, 2.5 ft • lb) 3 4 Order Job/Part Q’ty Remove the parts in the order listed. Refer to“LEADS, HOSES AND REAR BRAKE ”in chapter 5. Starter motor removal Air filter case 1 2 1 2 3 4 5 6 7 8 9 0 q Remarks 1 1 Starter motor lead Starter motor For installation, reverse the removal procedure. Remove the parts in the order listed.
ELECTRIC STARTING SYSTEM ELEC - + EAS00769 CHECKING THE STARTER MOTOR 1. Check: 8 commutator Dirt J Clean with 600-grit sandpaper. 2. Measure: 8 commutator diameter a Out of specification J Replace the starter motor. Commutator wear limit 21 mm (0.83 in) 3. Measure: 8 mica undercut a Out of specification J Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 1.5 mm (0.
ELECTRIC STARTING SYSTEM ELEC - + 5. Measure: 8 brush length a Out of specification J Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: 8 brush spring force Out of specification J Replace the brush springs as a set. Brush spring force 5.52 ~ 8.28 N 7. Check: 8 gear teeth Damage/wear J Replace the gear.
ELECTRIC STARTING SYSTEM ELEC - + EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: 8 brush spring 1 8 brush 2 8 armature coil 2 2 1 2. Install: 8 gasket 1 8 starter motor front bracket 2 8 starter motor rear bracket 3 3 NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear brackets. 1 1 2 b a 3 . Install: 8 O-ring New 1 8 washer 8 bolts 2 3.5 Nm (0.35 m • kg, 2.5 ft • lb) 2 1 T. R.
Br 7 0 B (RED) G B (RED) G B B l ; (GREEN) L Br B G Br L G B (GREEN) B MOTOR LW RW B RW RW B f j k START OFF START y x (BLACK) Dg L B B Y (BLACK) L Dg B Ch OFF RUN E/G STOP u c a BW (BLACK) Ch L P B BrW Dg (BLACK) L Ch P BrW B Dg Y OFF PUSH HORN SW 3 BW BW Br LW HI LO DIMMER SW h BW BW LW Br (BLUE) Br R 4 8 9 R W B R YR B R 10A R R 6 R B B B BW R B B R L (ILLUM) 12V3W LW TURN 12V3W L 14V3W B Br G HI BEAM 12V3W B s Y B G
CHARGING SYSTEM EAS00774 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The battery is not being charged. Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil resistance 5. wiring connections (of the entire charging system) Minimum open-circuit voltage 12.8 V or more at 20°C 8Is the battery OK? YES NOTE: 8 Before troubleshooting, remove the following part(s): 1. Rear carrier 2.
CHARGING SYSTEM NO YES The charging circuit is OK. Replace the unit rectifier/regulator. EAS00776 4. Stator coil resistance 8 Remove the C.D.I magneto couplers from wireharness. 8Connect the pocket tester (Ω × 1) to the stator coils as shown. Positive tester probe Jgreen/ white 1 Negative tester probe J black/red 2 1 B/R G/W W/R W/L G/W B/R W/L W/R 8Measure the stator coil resistances. Stator coil resistance 688 ~ 1032 Ω at 20°C 8Is the stator coil OK? YES + 5.
R Br 6 4 0 8 R B 7 (RED) G B (RED) G B B LW RW 9 l ; (GREEN) L Br B G Br L G B (GREEN) B MOTOR B B B B RW RW B f j k START OFF START y x (BLACK) Dg L B B Y (BLACK) L Dg B Ch OFF RUN E/G STOP u c a BW (BLACK) Ch L P B BrW Dg (BLACK) 3 BW BW Br LW HI LO DIMMER SW h BW BW LW Br (BLUE) L Ch P BrW B Dg Y OFF PUSH HORN SW R W B R YR B R 10A R R R B B R L 14V3W B L (ILLUM) 12V3W s Y B G (BLACK) z P TURN SIGNAL SW L N R YR W YR B
LIGHTING SYSTEM EAS00781 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Any of the following fail to light: headlight, high beam indicator light, fuel level meter light or meter light. Minimum open-circuit voltage 12.8 V or more at 20°C Check: 1. main fuse 2. battery 3. main switch 4. dimmer switch 5.
LIGHTING SYSTEM EAS00787 ELEC - + EAS00788 5. Wiring 8 Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. 8 Is the lighting system’s wiring properly connected and without defects? YES Check the condition of each of the lighting system’s circuits. Refer to “CIRCUIT DIAGRAM”. CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb and socket 8 Check the headlight bulb and socket for continuity.
LIGHTING SYSTEM YES 3. Voltage 8 Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown. When the dimmer switch is set to “%” When the dimmer switch is set to “&” Headlight coupler (wire harness side) Headlight Positive tester probe J green 1 Negative tester probe J black 2 Positive tester probe J yellow 3 Negative tester probe J black 4 1 3 2 G Y G Y B Y + NO EAS00754 4. Wiring 8 Check the entire lighting system’s wiring.
LIGHTING SYSTEM EAS00789 ELEC - + EAS00841 2. The meter light fails to come on. 1. Meter light bulb and socket 8 Check the meter light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Are the meter light bulb and socket OK? YES 3. Fuel level meter light 8 Check the fuel level meter light bulb and socket for continuity. 8 Are the fuel level meter light bulb and socket OK? YES NO Replace the fuel level meter light bulb, socket or both.
LIGHTING SYSTEM EAS00748 4. Lighting coil resistance 8 Disconnect the lighting coil coupler from the wire harness. 8 Connect the pocket tester (Ω × 1) to the lighting coil terminal as shown. Positive tester probe J yellow/red 1 Negative tester probe J ground 1 Y/R W 8 Measure the lighting coil resistance. Lighting coil resistance 0.28 ~0.42 Ω at 20°C (between yellow/red and ground) 8 Connect the pocket tester (Ω × 1)to the lighting coil terminal as shown.
R R 10A R Br 6 R 0 8 R B R 7 (RED) G B (RED) G B B LW RW 9 l ; (GREEN) L Br B G Br L G B (GREEN) B MOTOR B B 4 R B B B B RW RW B f j k START OFF START y x (BLACK) Dg L B B Y (BLACK) L Dg B Ch OFF RUN E/G STOP u c BW (BLACK) Ch L P B (BLACK) BrW Dg R 3 BW BW Br LW HI LO DIMMER SW h BW BW LW Br (BLUE) L Ch P BrW B Dg Y OFF PUSH HORN SW a BW W B R YR B 5 L (ILLUM) 12V3W LW TURN 12V3W L 14V3W B Br G HI BEAM 12V3W B s Y B G
SIGNALING SYSTEM EAS00794 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. 8Any of the following fail to light: turn signal light, brake light or an indicator light. 8The horn fails to sound. Minimum open-circuit voltage 12.8 V or more at 20°C Check: 1. mainfuse 2. battery 3. main switch 4. wiring connections (of the entire signaling system) 8Is the battery OK? YES NO 8Clean the battery terminals.
SIGNALING SYSTEM EAS00796 The horn fails to sound. 1. Horn switch 8 Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the horn switch OK? YES - + 3. Horn 8Disconnect the pink connector at the horn terminal. 8Connect a jumper lead 1 to the horn terminal and ground the jumper lead. 8Set the main switch to “ON”. 8Push the horn switch. 8Does the horn sound? CHECKING THE SIGNALING SYSTEM 1. ELEC Br NO P Replace the left handlebar switch. 1 2.
SIGNALING SYSTEM EAS00798 2. 1. Tail/brake light bulb and socket 8 Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Are the tail/brake light bulb and socket OK? NO B Replace the tail/brake light bulb, socket or both. 2 The wiring circuit from the main switch to the tail/brake light bulb connector is faulty and must be repaired. Refer to “CIRCUIT DIAGRAM”. + Y L 1 B G/Y L 8 Set the main switch to “ON”. 8 Pull in the brake levers.
SIGNALING SYSTEM EAS00799 1. Turn signal light and turn signal indicator light bulbs and sockets 8 Check the turn signal light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Check the turn signal indicator light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Are the turn signal light bulb and socket OK? + B Br/W Br 1 8Set the main switch to “ON”.
SIGNALING SYSTEM 4. Voltage 8Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. J brown/white 1 Positive tester probeJ Negative tester probe J ground - + 5. Voltage 8Connect the pocket tester (DC 20 V) to the turn signal light connector or meter assembly coupler (wire harness side) as shown.
SIGNALING SYSTEM EAS00804 1. Fuel sender 8 Remove the fuel sender from the fuel tank. 8 Connect the pocket tester (Ω × 1) to the fuel sender coupler (wire harness side) as shown. Positive tester probe J green 1 Negative tester probe J black 2 1 L B 1 G B (E) Br G Br G L B 2 8 Set the main switch to “ON”. 8 Measure the voltage (DC 12 V) of brown 1 on the meter light coupler (wire harness side). 8 Is the voltage within specification? 2 8 Measure the fuel sender resistances.
SIGNALING SYSTEM 3. Fuel level meter 8 Set the main switch to “ON”. 8 Move the float up 1 or down 2. 1 2 8 Check that the fuel level meter needle moves to “F” or “E”. NOTE: Before reading the fuel level meter, leave the float in one position (either up or down) for at least three minutes. 8 Does the fuel level meter needle move appropriately? YES This circuit is OK. 4. NO Replace the fuel level meter.
B R 0 R Br 7 (RED) G B (RED) G B B LW RW 9 l ; (GREEN) L Br B G Br L G B (GREEN) B MOTOR B B 4 8 R B B B B RW RW B f j k START OFF START y x (BLACK) Dg L B B Y (BLACK) L Dg B Ch OFF RUN E/G STOP u c a BW (BLACK) Ch L P B BrW Dg (BLACK) L Ch P BrW B Dg Y OFF PUSH HORN SW R 3 BW BW Br LW HI LO DIMMER SW h BW BW LW Br (BLUE) Br R 10A R R R 6 L 14V3W B L (ILLUM) 12V3W W B R YR B 5 HI BEAM 12V3W B LW TURN 12V3W BW BW Ch 1 Dg
CRABURETOR HEATING SYSTEM EAS00821 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8Check the condition of the battery. Refer to “CHECKING AND CHARGING 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 connections (of the entire carburetor heating system) Minimum open-circuit voltage 12.8 V or more at 20°C 8Is the battery OK? YES NO 8Clean the battery terminals.
CRABURETOR HEATING SYSTEM EAS00823 - ELEC + A The coolant temperature sensor circuit is closed. B The coolant temperature sensor circuit is open. 4. Thermo switch 8 Remove the thermo switch from the thermo switch plate wire harness. 8 Connect the pocket tester to the (Ω × 1) to the thermo switch 1 as shown. NOTE: Make sure that the thermo switch terminals do not get wet. OFF ON 8 Immerse the thermo switch in a container filled with coolant 2. 8 Place a thermometer3 in the coolant.
CRABURETOR HEATING SYSTEM EAS00826 6. Wiring 8 Check the entire carburetor heating system’s wiring. Refer to “CIRCUIT DIAGRAM”. 8 Is the carburetor heating system’s wiring properly connected and without defects? NO Properly connect or repair the carburetor heating system’s wiring.
R Br 6 4 0 8 R B 7 (RED) G B (RED) G B B LW RW 9 l ; (GREEN) L Br B G Br L G B (GREEN) B MOTOR B B B B RW RW B f j k START OFF START y x (BLACK) Dg L B B Y (BLACK) L Dg B Ch OFF RUN E/G STOP u c a BW (BLACK) Ch L P B BrW Dg (BLACK) 3 BW BW Br LW HI LO DIMMER SW h BW BW LW Br (BLUE) L Ch P BrW B Dg Y OFF PUSH HORN SW R W B R YR B R 10A R R R B B R L (ILLUM) 12V3W LW TURN 12V3W L 14V3W B Br G HI BEAM 12V3W B s Y B G (BLACK)
AUTO CHOKE SYSTEM ELEC - + EAS00748 TROUBLESHOOTING 1. Lighting coil resistance 8 Disconnect the lighting coil coupler from the wire harness. 8 Connect the pocket tester (Ω × 1) to the lighting coil terminal as shown. Positive tester probe J yellow/red 1 Negative tester probe J ground The auto choke system fails to operate. Check: 1. Lighting coil resistance 2. Auto choke unit resistance 3.
AUTO CHOKE SYSTEM 2. Auto choke unit resistance 8Disconnect the auto choke unit coupler from wire harness. 8Connect the Pocket tester(Ω × 1) to the Auto choke unit coupler as shown. Positive tester probe Jblack 1 Negative tester probe Jblack 2 B B 8Measure the auto choke unit resistance. Auto choke unit resistance 30 Ω at 20°C 8Is the auto choke unit OK? YES NO Replace the auto choke unit. EAS00826 3. Wiring 8 Check the entire auto choke system’s wiring. Refer to “CIRCUIT DIAGRAM”.
TRBL SHTG CHAPTER 8 TROUBLE SHOOTING STARTING FAILURES ............................................................................. 8-1 ENGINE .............................................................................................. 8-1 FUEL SYSTEM .................................................................................. 8-1 ELECTRICAL SYSTEMS .................................................................. 8-1 STARTING FAILURES/INCORRECT ENGINE IDLING SPEED ............
TRBL SHTG UNSTABLE HANDLING/FAULTY LIGHTING OR SIGNALING SYSTEM .................................................................................................... 8-5 UNSTABLE HANDLING ........................................................................... 8-5 FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 8-5 HEADLIGHT DOES NOT COME ON ................................................ 8-5 HEADLIGHT BULB BURNT OUT .....................................................
STARTING FAILURES TRBL SHTG EAS00844 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 FAILURES/ INCORRECT ENGINE IDLING SPEED TRBL SHTG EAS00846 Ignition system 8Faulty C.D.
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY CLUTCH EAS00849 EAS00853 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE FAULTY CLUTCH TRBL SHTG Refer to “STARTING FAILURES”.
OVERHEATING/POOR BRAKING PERFORMANCE/ FAULTY FRONT FORK LEGS TRBL SHTG EAS00859 POOR SPEED PERFORMANCE V-belt 8Oil or grease on the V-belt POOR BRAKING PERFORMANCE Disc brake 8Worn brake pad 8Worn brake disc 8Air in hydraulic brake system 8Leaking brake fluid 8Faulty brake caliper kit 8Faulty brake caliper seal 8Loose union bolt 8Damaged brake hose 8Oil or grease on the brake disc 8Oil or grease on the brake pad 8Incorrect brake fluid level Primary pulley weight(s) 8Faulty operation 8Worn primary pulle
UNSTABLE HANDLING/ FAULTY LIGHTING OR SIGNALING SYSTEM EAS00862 TRBL SHTG EAS00866 UNSTABLE HANDLING FAULTY LIGHTING OR SIGNALING SYSTEM Handlebar 8Bent or improperly installed handlebar HEADLIGHT DOES NOT COME ON 8Wrong headlight bulb 8Too many electrical accessories 8Hard charging 8Incorrect connection 8Improperly grounded circuit 8Poor contacts (main or light switch) 8Burnt-out headlight bulb Steering head components 8Improperly installed upper bracket 8Improperly installed lower bracket (improper
FAULTY LIGHTING OR SIGNALING SYSTEM TURN SIGNAL REMAINS LIT 8Faulty turn signal relay 8Burnt-out turn signal bulb TURN SIGNAL BLINKS QUICKLY 8Incorrect turn signal bulb 8Faulty turn signal relay 8Burnt-out turn signal bulb HORN DOES NOT SOUND 8Improperly adjusted horn 8Damaged or faulty horn 8Faulty main switch 8Faulty horn switch 8Faulty battery 8Blown, damaged or incorrect fuse 8Faulty wire harness 8-6 TRBL SHTG
YAMAHA MOTOR TAIWAN CO.
