XC50V SERVICE MANUAL LIT-11616-19-49 3D1-F8197-10
EAS00000 XC50V 2005 SERVICE MANUAL ©2005 by Yamaha Motor Taiwan Co., Ltd. First edition, July 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd. is expressly prohibited.
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.
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING CARBURETOR GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 COOL 6 5 7 CARB - ELECTRICAL SYSTEM TROUBLESHOOTING + ELEC 8 TRBL SHTG 9
GEN INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ............................................. 1-1 MODEL LABEL .................................................................................. 1-1 IMPORTANT INFORMATION ................................................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ................... 1-2 REPLACEMENT PARTS .......................
SCOOTER IDENTIFICATION GEN INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION 1 EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the trunk. 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.
IMPORTANT INFORMATION GEN INFO JAS00021 Notes 3 on equipment preparation Push Rivet (Push type) Assembly status of the Push Rivet (Push type) 1 Dissembling 1. Press Center Pin 1 inward to release the Lock. 2. Remove the Push Rivet main body 2. 2 Assembling 1. Restore the Center Pin, replace the Push Rivet main body. 2. Push in the Center Pin until leveling off with the surface position of the Push Rivet main body.
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-A9472 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 Tool name / Function GEN INFO Illustration Fork seal driver weight1 Fork seal driver attachment(Ø30mm)2 This tool is used when installing the fork seal.
SPECIAL TOOLS Tool NO. 90890-04109 YM-04109 90890-04148 YM-04148 90890-04111 YM-04111 90890-04112 YM-04112 Tool name / Function Valve spring compressor Compressor adapter(Ø16.5mm) These tools are used when removing or installing the valve and the valve spring. Valve guide remover (4.0 mm) This tool is used to remove or install the valve guides. Valve guide installer (4.0 mm) This tool is used to install the valve guides.
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................................................................. 2-1 ENGINE SPECIFICATIONS ..................................................................... 2-2 CHASSIS SPECIFICATIONS ................................................................. 2-10 ELECTRICAL SPECIFICATIONS .......................................................... 2-12 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 3D11 (for USA) 3D12 (for CAN) … … 1665 mm( 65.6in ) 630 mm( 24.8in ) 1005 mm( 39.6in ) 715 mm( 28.2in ) 1160 mm( 45.7in ) 85 mm( 3.4in ) 1800mm( 70.
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Standard Item Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Engine idle speed Vacuum pressure at engine idle speed(AI OFF) Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Engine oil Lubrication system Recommended oil -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚ SAE 10W-30 Limit Liquid-cooled, 4-stroke, SOHC 0.049L(49cm3) Forward inclined single cylinder 38.
ENGINE SPECIFICATIONS Standard Item Oil filter Oil filter type 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 Cooling system Radiator capacity Radiator cap opening pressure Valve relief pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Max. impeller shaft tilt SPEC Limit Wire mesh … Trochoid 0.15 mm or less 0.13-0.
ENGINE SPECIFICATIONS SPEC Standard Item Camshaft Drive system Intake camshaft lobe dimensions Limit Chain drive (left) … 30.158~30.258 mm 25.082~25.182 mm 5.2077mm 30.058 mm 24.982 mm … 30.158~30.258 mm 25.020~25.120 mm 5.2077mm … 30.058 mm 24.920 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 / 82 Automatic … … 0.10~0.16 mm 0.18~0.
ENGINE SPECIFICATIONS Standard Item Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust SPEC Limit 39.35 mm 41.57 mm 37.38 mm 39.49 mm 28.0mm 30.0mm … … 91.1~104.9N(9.3~10.7kg) 107.9~124.1N (11.0~12.7kg) … … Intake Exhaust Winding direction (top view) Intake Exhaust … … 2.5 °/1.7 mm 2.5 °/1.8 mm Clockwise Clockwise … … Valve seat reformed Yes … Forward inclined single cylinder 38.0 × 43.5 mm 12:1 38.
ENGINE SPECIFICATIONS Standard Limit 0.010~0.035 mm 37.975~37.990 mm 0.150mm … 5.0 mm … 10.002~10.013 mm 0.35~0.65mm Intake side 10.043 mm … … 9.996~10.000 mm 9.976 mm Barrel 0.8 × 1.65mm 0.05~0.15 mm 0.02~0.08 mm … … 0.40mm 0.13 mm Taper 0.8 × 1.5mm 0.05~0.17 mm 0.02~0.06 mm … … 0.52mm 0.12mm 1.5 × 1.6 mm 0.2~0.7 mm 0.03~0.
ENGINE SPECIFICATIONS SPEC Standard Item Limit Rocker arm/rocker arm shaft Rocker arm inside diameter Rocker arm shaft outside diameter Arm-to-shaft clearance 10.000~10.015mm 9.981~9.991 mm 0.009~0.034 mm … … … Connecting rod Connecting rod length Small end inside diameter 79.95~80.05 mm 10.015~10.028mm … … 42.45~42.50 mm … 0.15~0.45 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 3.7 mm 30.1±0.4mm 107 mm 76.4 mm 15.0 mm 3450~3850 r/min 4350~5350 r/min … 2.0mm … … … 14.5 mm … … V-belt V-belt width 16.8 mm 15.
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) 0~55 kg 55~158 kg Min.
CHASSIS SPECIFICATIONS SPEC Standard Item Limit Front brake Brake type Operation Brake lever free play (at lever end) Brake drum inside diameter Lining thickness Drum brake Right-hand operation 10~20mm 110 mm 4.0mm … … … 110.5mm 2.0mm Rear brake Brake type Operation Brake lever free play (at lever end) Brake drum inside diameter Lining thickness Drum brake Left-hand operation 10~20mm 110 mm 4.0mm … … … 110.5mm 2.
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Standard Item System voltage Limit 12V … C.D.I. 13 ° B.T.D.C. at 2000~2400 r/min Digital 248~372 Ω / WR-WL 5ST (T-MORIC) … … … … … Ignition coil Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance X7A (T-MORIC) 6mm 0.168~0.252 Ω at 20 ° C 2.4~3.
ELECTRICAL SPECIFICATIONS Standard Item Bulbs (voltage/wattage × quantity) Headlight Tail/brake light Front turn signal light Rear turn signal light Speedometer lighting SPEC Limit 12 V 35W/35W × 1 12 V 5W/21 W × 1 12 V 10 W × 2 12 V 10 W × 2 12 V 1.
ELECTRICAL SPECIFICATIONS SPEC Standard Item Limit Throttle position sensor Output voltage (throttle opens) Output voltage (throttle closes) 2.8~3.4V 0.625~0.775V … … Radiator fan Model (manufacturer) Running rpm 5ST-00 (LUNTAI) 10000 r/min … … Thermostat switch Model (manufacturer) 5ST (NIPPON THERMOSTAT) … Thermo unit Model (manufacturer) Coil resistance at 80 °C Coil resistance at 100 °C 5JJ (NIPPON THERMOSTAT) … 3.413~4.007 kΩ … 1.645~1.855 kΩ … Fuse (amperage × quantity) Main fuse 7.
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 TIGHTENING TORQUES ENGINE Part to be tightened Part name Thread ’ Q ty size Tightening torque Remarks Nm m•kg ft•lb Cylinder head and cylinder Spark plug Cylinder head(timing chain side) Exhaust pipe stud bolt Cylinder head cover Oil check bolt Water pump housing cover Water pump assembly Guide stopper2 Thermostat housing air bleed bolt Camshaft sprocket Timing chain tensioner (body) Timing chain tensioner (plug) Thermostat housing Fan case Fan Oil pump assembly Radiator drain
TIGHTENING TORQUES Part to be tightened Part name Thread ’ Q ty size SPEC Tightening torque Remarks Nm m•kg ft•lb Clutch housing Ignition coil Thermo unit Primary fixed sheave Starter motor assembly AC magneto rotor Stator coil Pickup coil Nut Bolt Nut Bolt Nut Bolt Screw Cylinder head tightening sequence 1 5 3 4 2 6 2-17 M10 M5 PT1/8 M10 M6 M12 M5 M6 1 1 1 1 2 1 3 2 40 8 8 30 13 43 4 7 4.0 28.9 0.8 5.8 0.8 5.8 3.0 21.7 1.3 9.4 4.3 31.1 0.4 2.9 0.7 5.
TIGHTENING TORQUES SPEC CHASSIS Part to be tightened Thread size Tightening torque Nm M10 M10 M10 M10 M6 M6 M8 BC BC1 M6 M6 M5 Frame and engine bracket 3 Engine bracket 3 and engine Handlebar and steering shaft Front fork and lower bracket Seat lock assembly Rear carrier(front) Rear carrier(rear) Steering shaft and upper bearing inner race Steering shaft and ring nut Trunk Footrest board Fuel sender Resin part and resin cover Seat lock adjuster Main switch and frame Front brake camshaft lever Front wh
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant Oil seal lips LS O-rings (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 surf
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point SPEC Lubricant Secondary fixed sheave inner surface BEL-RAY asembly lube® Secondary sliding sheave torque cam ditch BEL-RAY asembly lube® Crankcase mating surfaces Sealant 2-20
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS Lubrication Point Lubricant Front wheel oil seal lips LS Steering bearing and bearing races (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 Centerstand pivoting point and sliding surface LS Rear shock absorber backward, bush inner surface and spacer sliding surface M Seat lock cable and rear wheel lock cable inner sur
COOLING SYSTEM DIAGRAMS SPEC EAS00033 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 Raidator cap Coolant reservoir Radiator inlet hose Radiator outlet hose Thermo switch Conduit hose 1 3 6 5 2 4 2-22
COOLING SYSTEM DIAGRAMS 1 2 3 4 5 SPEC Outlet hose(to cylinder) Radiator inlet hose Radiator outlet hose Thermostat Thermostat housing 2 5 1 2-23 4 3
COOLING SYSTEM DIAGRAMS 1 2 3 4 Breather hose Outlet hose(to cylinder) Radiator outlet hose Water pump 1 4 3 2 2-24 SPEC
COOLING SYSTEM DIAGRAMS 1 2 3 4 Thermostat housing Thermostat assembly inlet breather hose Water pump Breather hose 1 2 4 3 2-25 SPEC
OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 2 3 4 5 6 Oil filter Oil pump To cylinder head Oil strainer Oil nozzle Camshaft 2-26 SPEC
OIL FLOW DIAGRAMS 1 2 3 4 SPEC Crankshaft pin Connecting rod big end bearing Oil nozzle Camshaft Cylinder wall Connecting rod big end bearing Crankshaft pin Rocker arm shaft and rocler arm Camshaft Oil nozzle Centrifugal oil filter Oil pump Oil filter Crankcase sump 2-27
CABLE ROUTING A Insert the wire harness plate holder to the T-stud of down tube . B Insert the seat lock cable into the frame, protector part to the hole position. C Insert the L coupler to the ignition coil and installing direction of downward. D Clamp the wire harness, thermo switch lead and conduit hose to the frame. E Fasten the wire harness, AC magneto lead and starter motor lead to the frame with a plastic locking tie and end of plastic locking the upward.
CABLE ROUTING 1 Turn signal relay 2 Horn 3 Head light relay 4 Speedometer cable 5 Front brake cable 6 Starter relay 7 Ignition coil 8 Throttle cable kit 9 Rear wheel lock cable 0 Air cut-off valve assembly q AI filter w Holder e Rectifier/Regulator r Clamp t Frame y Rear brake cable 4 A Fasten the throttle cable kit and rear brake cable to the frame and cut the end to be shorter than 5mm, point the band tip to backward and reserve for a finger clearance.
CABLE ROUTING SPEC M Assemble the horn lead to the best forward of connector cover, do not through back side of the other leads. N Route the turn signal relay lead and front turn signal light lead(left) through backward of the steering head pipe.
CABLE ROUTING 1 Battery negative - lead 2 Battery positive + lead 3 Fuse box 4 Starter motor lead 5 AC magneto lead 6 Fuel sender A Insert the wire harness cable strap into the footrest bracket of hole. B Route the wire harness through concave of the recovery tank and clamp it. C Insert the ignition coil connector into the ignition coil terminal. D Clamp the starter relay to the under cover of rib.
CABLE ROUTING 1 Front brake cable 2 Front brake switch lead 3 Speedometer assembly 4 Speedometer cable 5 Rear brake cable 6 Rear brake switch lead 7 Lever holder lead(left) 8 Handlebar 9 Lever holder lead(right) 0 Lever holder(left) q Grip(left) w Throttle cable kit e Speedometer assembly lead r Front fork t Frame A After locking the right side switch of control lever, confirm the driving status of holder. Turn the holder then release your hand and retrieve the holder quickly.
CABLE ROUTING H After spread with adhesion agent on the inner side, push the grip into the handlebar assembly. I Allow the gain position to arrive at this range. J Install the handlebar cover to the handlebar bracket, and tightening torque 4Nm(0.4m•kg,2.9ft•lb). K To the headlight. L Insert the rear brake cable to the lever holder(left). M When assembling the rear brake cable and speedometer cable, do not interfere. N Install the speedometer assembly to the handlebar bracket, and tightening torque 7Nm (0.
CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ....................................................................................... 3-1 PERIODIC MAINTENANCE AND MINOR REPAIR ................................ 3-2 Periodic maintenance chart for the emission control system ........... 3-2 General maintenance and lubrication chart...................................... 3-3 COVER AND PANEL ................................................................................ 3-5 SEAT AND TRUNK .......
CHK ADJ CHECKING THE TIRES .................................................................. 3-44 CHECKING THE WHEELS.............................................................. 3-47 CHECKING AND LUBRICATING THE CABLES ............................ 3-47 LUBRICATING THE LEVERS AND PEDALS ................................. 3-48 LUBRICATING THE CENTERSTAND ............................................ 3-48 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 AND MINOR REPAIR CHK ADJ EAU17560* PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance chart for the emission control system INITIAL NO. 1 * 2 3 * ITEM ROUTINE 600 mi (1,000 km) or 1 month ODOMETER READING 2,000 mi (4,000 km) or 6 months 4,000 mi 6,000 mi 8,000 mi 10,000 mi (7,000 km) (10,000 km) (13,000 km) (16,000 km) or or or or 12 18 24 30 months months months months Fuel line • Check fuel and vacuum hoses for cracks or damage. • Replace if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR CHK ADJ General maintenance and lubrication chart Maintenance and lubrication, periodic INITIAL NO. 1 * ITEM ROUTINE Air filter element • Replace. 600 mi (1,000 km) or 1 month ODOMETER READING 2,000 mi (4,000 km) or 6 months 4,000 mi 6,000 mi 8,000 mi 10,000 mi (7,000 km) (10,000 km) (13,000 km) (16,000 km) or or or or 12 18 24 30 months months months months √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 2 * Front brake • Check operation.
PERIODIC MAINTENANCE AND MINOR REPAIR CHK ADJ * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 12000 mi ( 19000 km) or 36 months, repeat the maintenance intervals starting from 4000 mi (7000 km) or 12 months. EAU17680 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
COVER AND PANEL CHK ADJ COVER AND PANEL SEAT AND TRUNK 12Nm (1.2 m•kg, 8.7 ft•lb) 12Nm (1.2 m•kg, 8.7 ft•lb) 2 1 10Nm (1.0 m•kg, 7.2 ft•lb) 23Nm (2.3 m•kg, 16.6 ft•lb) 4 3 5 6 7 Order 1 2 3 4 5 6 7 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the seat and trunk Seat Damper Rubber cap Trunk Rear carrier Mat Battery cover 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
COVER AND PANEL CHK ADJ SIDE COVER (LEFT AND RIGHT) 5 6 4 3 1 2 Order 1 2 3 4 5 6 Job/Part Q’ty Removing the side cover(left and right) Seat/Trunk Tail / brake and rear turn signal (left, right) light lead Front cover Side cover(left) Side cover(right) Tail/brake light Rear cover Remarks Remove the parts in the order listed. 1 Refer to “SEAT AND TRUNK”. Disconnect. 1 1 1 1 1 For installation, reverse the removal procedure.
CHK ADJ COVER AND PANEL FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE 4Nm (0.4 m•kg, 2.9 ft•lb) 1 3 2 7 4 6 5 Order Job/Part Q’ty Removing the footrest board and footrest board side cover mole Side cover(left and right) 1 2 3 4 5 6 7 Battery holder 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. Refer to “SIDE COVER(LEFT AND RIGHT)”.
COVER AND PANEL CHK ADJ LEG SHIELD 1 , 2 8 7 9 3 5 6 2 4 10 11 12 1 Order Job/Part Q’ty Removing the leg shield 1,2 Footrest board 1 2 3 4 5 6 7 8 9 10 11 12 Remarks Remove the parts in the order listed. Refer to “FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE”.
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 seat/trunk 8 battery cover 8 battery holder 8 front cover Refer to “COVER AND PANEL”. 2.
ADJUSTING THE VALVE CLEARANCE CHK ADJ d. Measure the valve clearance with a thickness gauge 1. Out of specification J Adjust. ***************************************************** d c 1 6. Adjust: 8valve clearance 2 ***************************************************** a. Remove the valve pad 2 with a magnetic bar 1. NOTE: 8 Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.
ADJUSTING THE VALVE CLEARANCE Last digit 0 or 2 5 8 CHK ADJ Rounded value 0 5 10 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approximation.
ADJUSTING THE VALVE CLEARANCE CHK ADJ INTAKE MEASURED CLEARANCE 0.00∼0.04 0.05∼0.09 0.10∼0.16 0.17∼0.21 0.22∼0.26 0.27∼0.31 0.32∼0.36 0.37∼0.41 0.42∼0.46 0.47∼0.51 0.52∼0.56 0.57∼0.61 0.62∼0.66 0.67∼0.71 0.72∼0.76 0.77∼0.81 0.82∼0.86 0.87∼0.91 0.92∼0.96 0.97∼1.01 1.02∼1.06 1.07∼1.11 1.12∼1.16 1.17∼1.21 1.22∼1.26 1.27∼1.31 1.32∼1.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 7. Install: 8all removed parts NOTE: For installation, reverse the removal procedure. 8. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT”.
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: 8 engine tachometer (onto the spark plug lead of cylinder) Engine tachometer 90890-03113 YU-08036-C 3. Check: 8 engine idling speed Out of specification J Adjust Engine idling speed 2000 ~ 2400 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 3 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. 600mm 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. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.5 mm (0.059 ~ 0.138 in) a 2. Adjust: 8 throttle cable free play ***************************************************** Handlebar side a. Loosen the locknut 1. b.
CHECKING THE SPARK PLUG CHK ADJ EAS00060 CHECKING THE SPARK PLUG 1. Remove: 8 battery cover 8 battery holder 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. Drain: 8coolant (completely from the radiator ) 2. Remove: 8radiator cover 8radiator 8fan case Refer to “RADIATOR”in chapter 6. 3.
CHECKING THE IGNITION TIMING CHK ADJ NOTE: The ignition timing is not adjustable. ***************************************************** 5. Remove: 8timing light 8engine tachometer 6. Install: 8fan case 8radiator 8radiator cover Refer to “RADIATOR”in chapter 6. 7. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT”.
MEASURING THE COMPRESSION PRESSURE CHK ADJ EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: 8valve 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: 8battery cover 8battery holder Refer to “COVER AND PANEL”. 4. Disconnect: 8spark plug cap 5.
MEASURING THE COMPRESSION PRESSURE CHK ADJ Compression pressure (at sea level) Minimum 1262 kPa (12.6 kgf/cm2, 700r/min) Standard 1450 kPa (14.5 kgf/cm2, 700r/min) Maximum 1624 kPa (16.2 kgf/cm2, 700r/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. w To prevent sparking, ground the spark plug lead before cranking the engine. c.
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 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.
CHANGING THE ENGINE OIL CHK ADJ EAS00076 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) 1 4. Drain: 8 engine oil (completely from the crankcase) 2 4 3 5. If the oil filter element is also to be cleaned, perform the following procedure. 2 1 ***************************************************** a.
CHANGING THE ENGINE OIL CHK ADJ 8. Install: 8engine oil filler cap 9. Start the engine, warm it up for several minutes, and then turn it off. 10. Check: 8engine (for engine oil leaks) 11. Check: 8engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 12. Check: 8engine oil pressure Refer to “CHECKING THE ENGINE OIL PRESSURE”.
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: 8transmission oil drain bolt 1 8transmission oil fill bolt Completely drain the transmission oil. 5 Install: 8transmission oil drain bolt 1 T. R. 13 Nm (1.3 m • kg, 9.4 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.
MEASURING THE ENGINE OIL PRESSURE CHK ADJ 6. Install: 8 gallery bolt T. R. 7 Nm (0.7 m • kg, 5.1 ft • lb) 7. Install: 8 front cover 8 battery cover 8 seat/trunk Refer to “COVER AND PANEL”.
CHECKING THE AIR FILTER ELEMENT CHK ADJ EAS00086 1 CHECKING THE AIR FILTER ELEMENT 1. Remove: 8 air filter case cover 1 8 air filter element 2. Check: 8 air filter element Damage/dirty J Replace. 3. Install: 8air filter element 8air filter case cover T. R. 10 Nm (1.0 m • kg, 7.2 ft • lb) cC Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/CHECKING THE FUEL AND VACUUM HOSES CHK ADJ EAS00094 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Remove: 8 seat/trunk 8 rear carrier 8 battery cover 8 front cover 8 side cover (left and right) 8 rear cover Refer to “COVER AND PANEL”. 2. Check: 8 carburetor joint 1 8 intake manifold 2 Cracks/damage J Replace. Refer to “CARBURETOR” in chapter 7. 3.
CHECKING THE FUEL HOSES AND FUEL FILTER CHK ADJ EAS00097 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. 1. Remove: 8battery cover 8seat/trunk 8rear carrier 8front cover 8side cover (left and right) 8rear cover Refer to “COVER AND PANEL”. 2. Check: 8fuel hose 1 Cracks/damage J Replace. 8fuel filter 2 Contaminants/damage J Replace. 1 NOTE: 8 Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident.
CHECKING THE CRANKCASE BREATHER HOSE CHK ADJ EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: 8seat/trunk Refer to “COVER AND PANEL”. 2. 1 Check: 8crankcase breather hose 1 Cracks/damage J Replace. Loose connection J Connect properly. cC Make sure the crankcase breather hose is routed correctly. 3. 3-32 Install: 8seat/trunk Refer to “COVER AND PANEL”.
CHECKING THE EXHAUST SYSTEM CHK ADJ EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler assembly and gaskets. 1. Remove: 8 muffler assembly Refer to “MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY” in chapter 5. 2 . Check: 8 muffler assembly 1 Cracks/damage J Replace. 8 gasket 2 Exhaust gas leaks J Replace. 3 . Check: 8 tightening torque 2 1 3 4 5 T. R. 4. 3-33 Muffler assembly nut 3 13 Nm (1.3 m • kg, 9.4 ft • lb) Muffler and rear arm bolt 4 31 Nm (3.
CHECKING THE COOLANT LEVEL CHK ADJ EAS00103 CHECKING THE COOLANT 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. 3. a b Remove: 8 mat 8 battery cover Refer to “COVER AND PANEL”. Check: 8 coolant level The coolant level should be between the maximum level mark a and minimum level mark b. Below the minimum level mark J Add the recommended coolant to the proper level.
CHECKING THE COOLING SYSTEM CHK ADJ EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: 8 seat/trunk 8 battery cover 8 front cover 8 battery holder/ battery 8 footrest board side cover mole( left and right) 8 mat/footrest board Refer to “COVER AND PANEL”. 8 radiator cover Refer to “COOLING SYSTEM”in chapter 6. 2. Check: 8 radiator 1 8 radiator inlet hose 2 8 radiator outlet hose 3 Cracks/damage J Replace. Refer to “COOLING SYSTEM” in chapter 6. 3.
CHANGING THE COOLANT CHK ADJ EAS00105 CHANGING THE COOLANT 1. Remove: 8 mat 8 battery cover 8 footrest board side cover mole (right) Refer to “COVER AND PANEL”. 8 radiator cover Refer to “COOLING SYSTEM”in chapter 6. 2. Disconnect: 8 coolant reservoir hose 1 3. Drain: 8 coolant (from the coolant reservoir) 8 coolant (from the radiator under drain bolt ) 4. Remove: 8radiator cap 1 w A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot.
CHANGING THE COOLANT CHK ADJ 7. Fill: 8 cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 0.52 L (0.48 Imp qt, 0.57 US qt) Coolant reservoir capacity 0.26 L (0.24 Imp qt, 0.28 US qt) From minimum to maximum level mark 0.10~0.25 L (0.09~0.14 Imp qt, 0.11~0.
CHANGING THE COOLANT CHK ADJ 9. Fill: 8 coolant reservoir (with the recommended coolant to the maximum level mark a) 10.Install: 8 coolant reservoir cap 11.Start the engine, warm it up for several minutes, and then stop it. 12.Check: 8 coolant level Refer to “CHECKING THE COOLANT LEVEL”. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. 13. Install: 8 radiator cover Refer to “COOLING SYSTEM”in chapter 6.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE CHK ADJ EAS00109 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: 8 brake lever free play a Out of specification J Adjust. a Brake lever free play (at the end of the brake lever) 10 ~ 20 mm (0.394 ~ 0.787 in) 2. Adjust: 8 brake lever free play ***************************************************** a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.
CHECKING THE FRONT AND REAR BRAKE SHOES CHK ADJ EAS00127 A CHECKING THE FRONT AND REAR BRAKE SHOES 1. Operate the brake. 2. Check: 8 wear indicator 1 Reaches the wear limit line 2 J Replace the brake shoes as a set. Refer to “FRONT WHEEL AND FRONT BRAKE” and “REAR WHEEL AND REAR BRAKE” in chapter 4.
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 w Do not overtighten the upper bearing inner race. T. R. Upper bearing inner race(final tightening torque) 7 Nm (0.7 m • kg, 5.1 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 upper cover and check the bearing race. Refer to “STEERING HEAD” in chapter 4. e.
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: 8inner tube Damage/scratches J Replace. 8dust seal Damage/scratches J Replace. 3. Hold the scooter upright and apply the front brake. 4. 3-43 Check: 8front 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 CHK ADJ 2. Check: 8tire surfaces Damage/wear J Replace the tire. 1 Minimum tire tread depth 0.8 mm (0.032 in) 3 1 Tire tread depth 2 Sidewall 3 Wear indicator 2 w A 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: 8wheel 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 LEVERS AND PEDALS/ LUBRICATING THE CENTERSTAND CHK ADJ EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant 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 8battery holder 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 FUSE CHK ADJ 6. Install: 8 battery 7. Connect: 8 battery leads (to the battery terminals) 1 cC 2 First, connect the positive battery lead 1, and then the negative battery lead 2. 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 holder 8 battery cover 8 mat Refer to “COVER AND PANEL”.
CHECKING THE FUSE 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 3. Remove: 8 headlight bulb holder rubber1 8 headlight bulb holder 8 headlight bulb 2 1 w 2 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: 8 headlight bulb New Secure the new headlight bulb with the headlight bulb holder.
ADJUSTING THE HEADLIGHT BEAM CHK ADJ EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: 8headlight beam (vertically) ***************************************************** a. Turn the adjusting screw 1 in direction a or b . 1 b a Direction a Direction b Headlight beam is raised. Headlight beam is lowered. ***************************************************** 2. Adjust: 8 headlight beam (horizontally) ***************************************************** a.
CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE ................................................................. 4-1 FRONT WHEEL ................................................................................. 4-2 FRONT BRAKE SHOE PLATE ......................................................... 4-3 REMOVING THE FRONT WHEEL .................................................... 4-4 DISASSEMBLING THE BRAKE SHOE PLATE ................................ 4-4 CHECKING THE FRONT WHEEL ...................................
CHAS REMOVING THE REAR SHOCK ABSORBER ASSEMBLY .......... 4-35 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .......... 4-35 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ........
FRONT WHEEL AND BRAKE CHAS EAS00517 CHASSIS FRONT WHEEL AND BRAKE 7 10 6 1 9 2 48Nm (4.8 m•kg, 34.7 ft•lb) 4 3 8 Order 5 Job/Part Q’ty 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 CHAS EAS00518 FRONT WHEEL 1 2 3 4 Order 1 2 3 4 Job/Part Q’ty Disassembling the front wheel Oil seal Bearing Spacer 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 CHAS FRONT BRAKE SHOE PLATE 2 1 9 0 LS q w LS e 8 LS 6 LS 6 t r 8Nm (0.8 m•kg ,5.
FRONT WHEEL AND BRAKE 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. 5 2. Remove: 8 speedometer cable 1 8 ront brake cable 2 8 front wheel axle nut 3 8 front wheel axle 4 8 front wheel 5 8 collar 8 front brake shoe plate 6 Refer to” FRONT WHEEL AND BRAKE” .
FRONT WHEEL AND BRAKE 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 2 CHAS a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. 1 c. Remove the wheel bearings 4 with a general bearing puller3. d. Install the new wheel bearings and oil seal in the reverse order of disassembly. ***************************************************** 3 4 EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1.
FRONT WHEEL AND BRAKE CHAS EAS00536 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. a a 2. Measure: 8 brake shoe lining thickness a Out of specification JReplace. a Brake shoe lining thickness limit (minimum) 2.0 mm (0.079 in) a w Do not allow oil or grease to contact the brake shoes.
FRONT WHEEL AND BRAKE CHAS 4. Check: 8 brake drum inner surface Oil deposits J Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches J Repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: 8brake camshaft Damage/wear J Replace. EAS00537 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 8brake camshaft 1 8spring 8brake shoe wear indicator 2 ***************************************************** a.
FRONT WHEEL AND BRAKE CHAS EAS00538 ASSEMBLING THE FRONT WHEEL 1. Install: 8 wheel bearing(right)1 New 8 oil seal New 8 spacer 1 8 wheel bearing(left) New ***************************************************** a. Install the new wheel bearings and oil seal 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 CHAS EAS00540 INSTALLING THE FRONT WHEEL 1. Lubricate: 8 wheel axle 8 wheel bearings 8 oil seal lips 8 speedometer drive gear 8 speedometer gear Recommended lubricant Lithium-soap-based grease 2. 2 1 Install: 8front wheel1 NOTE: Make sure the slot2 in the brake shoe plate fits over the stopper3 on the outer tube. 3 3. Tighten: 8 wheel axle nut T. R. 48 Nm (4.8 m • kg, 34.7 ft • lb) w Make sure the brake cable is routed properly.
FRONT WHEEL AND BRAKE 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 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 BRAKE CHAS EAS00555 REAR WHEEL AND BRAKE 5 7 8 7Nm (0.7 m•kg, 5.1 ft•lb) 9 4 10 11 6 7 12 2 12 3 1 104Nm (10.4 m•kg, 75.2 ft•lb) Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Q’ty Remarks Removing the rear wheel 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 “MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY “in chapter 5.
REAR WHEEL AND BRAKE CHAS EAS00564 REMOVING THE REAR 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 rear wheel is elevated. 1 2. Remove: 8brake adjuster 3. Remove: 8muffler assembly 8wheel axle nut 1 4.
REAR WHEEL AND BRAKE CHAS EAS00565 CHECKING THE REAR WHEEL 1. Check: 8 tire 8 rear wheel Damage/wear J Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 2. Measure: 8 radial wheel runout 8 lateral wheel runout Refer to “CHECKING THE FRONT WHEEL”. EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: 8rear wheel drive hub Cracks/damage J Replace.
REAR WHEEL AND 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. a a NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. a 2. Measure: 8 brake shoe lining thickness a Out of specification J Replace. Brake shoe lining thickness limit (minimum) 2.0 mm(0.079 in) a w Do not allow oil or grease to contact the brake shoes.
REAR WHEEL AND BRAKE CHAS EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 8 brake camshaft 1 T. R. 1 2 7 Nm (0.7 m • kg, 5.1 ft • lb) 8 return spring 2 8 brake shoe wear indicator 3 3 ***************************************************** a. Install the brake camshaft 1 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.
REAR WHEEL AND BRAKE CHAS EAS00574 INSTALLING THE REAR WHEEL 1. Lubricate: 8 wheel axle Recommended lubricant Lithium-soap-based grease 2. Install: 8 rear wheel 3. Tighten: 8 wheel axle nut1 1 T. R. 104 Nm (10.4 m • kg, 75.2 ft • lb) 4. Install: 8 muffler assembly 5. Adjust: 8 brake lever free play Refer to “ADJUSTING THE REAR BRAKE” in chapter 3. EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: 8 After replacing the tire, wheel or both, the rear wheel static balance should be adjusted.
FRONT FORK CHAS EAS00646 FRONT FORK 3 2 4 1 30Nm (3.0 m•kg, 21.7 ft•lb) Order 1 2 3 4 Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE”. Refer to “HANDLE BAR”. Refer to “STEERING HEAD”. Refer to “COVER AND PANEL” in chapter 3. Removing the front fork legs Front wheel Handlebar Front fork assembly Headlight cover Leg shield 1 Lower bracket pinch bolt Snap ring Inner tube plug Front fork leg 1 1 1 1 For installation, reverse the removal procedure.
FRONT FORK CHAS EAS00648 1 8 2 9 3 1g 4 3g 4g 5 6 0 7 Order 1 2 3 4 5 6 7 8 9 0 Job/Part Q’ty Remarks Remove the parts in the order listed. Disassembling the front fork legs Band Boot Dust seal Circlip Spring guide Rebound spring Inner tube Damper rubber Fork spring Outer tube 1 1 1 1 1 1 1 1 1 1 Refer to “DISASSEMBLING AND INSTALLING THE FRONT FORK LEGS “ For assembly, reverse the disassembly procedure.
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. 2 3. 1 Loosen: 8lower bracket pinch bolt 1 Remove: 8snap ring 2 8front fork leg3 w Before loosening the lower bracket pinch bolts, support the front fork leg.
FRONT FORK 3. 3 CHAS Remove: 8 damper rubber 1 8 fork spring 2 8 outer tube 3 2 1 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 8 inner tube 8 outer tube Bends/damage/scratches J Replace. 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 125 mm (4.921 in) : 122.5 mm (4.823 in) 3 3.
FRONT FORK CHAS EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: 8 When assembling the front fork leg, be sure to replace the following parts: - dust seal - circlip 8 Before assembling the front fork leg, make sure all of the components are clean. 1. Install: 8 fork spring 1 8 damper rubber2 NOTE: 8 Install the spring with the smaller pitch facing down . 1 2 2.
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 1 8snap ring 2 New 8inner tube plug 8lower bracket pinch bolt 3 NOTE: Pull up the inner tube until it stops, then install the snap ring to groove. 2 3 1 2. Tighten: 8lower bracket pinch bolt T. R. 4-24 30 Nm (3.0 m • kg, 21.
HANDLEBAR CHAS EAS00664 HANDLEBAR 4 3 LS 17 10 4 8 LS 7 14 6 16 LS 5 12 9 11 15 LS 2 60Nm (6.0 m•kg, 43.
HANDLEBAR CHAS 4 3 LS 17 10 4 8 LS 7 14 6 16 LS 5 12 9 11 15 LS 2 60Nm (6.0 m•kg, 43.4 ft•lb) 13 1 Order 15 16 17 Job/Part Handlebar grip Handlebar upper cover Handlebar assembly Q’ty 1 1 1 Remarks For installation, reverse the removal procedure.
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 holder assembly (right)1 8throttle grip assembly 2 NOTE: While removing the handlebar holder assembly (right), pull back the rubber cover. 2 1 3. Remove: 8handlebar grip NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
HANDLEBAR CHAS EAS00673 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. FORWARD 2. Install: 8handlebar 1 NOTE: Align the slot a on the handlebar with the steering shaft 2 surface. RIGHT 2 b 1 LEFT 3. Tighten: 8handlebar a T. R. 60 Nm (6.0 m • kg, 43.4 ft • lb) cC There must be a space b after tighting bolt. 4. Install: 8handlebar upper cover 5.
HANDLEBAR CHAS 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 projectiona on the right handlebar holder assembly with the hole b on the handlebar. w Make sure the throttle grip operates smoothly. 7. Adjust: 8throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.5 mm (0.059 ~ 0.
STEERING HEAD CHAS EAS00675 STEERING HEAD 2 4 5 6 11 8 9 12 10 7 7Nm (0.7 m•kg, 5.1 ft•lb) 1 3 Order Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE”. Refer to “COVER AND PANEL” in chapter 3. Refer to “HANDLEBAR”. Removing the front fork assembly Front wheel Leg shield 1 1 2 3 4 5 6 7 8 9 10 11 12 30Nm (3.0 m•kg, 21.
STEERING HEAD CHAS EAS00678 REMOVING THE FRONT FORK 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 front wheel is elevated. 2 . Remove: 8ball race cover 8ring nut 1 (with the ring nut wrench 2) 1 Ring nut wrench 90890-01268 YU-01268 2 3 .
STEERING HEAD CHAS EAS00682 CHECKING THE STEERING HEAD 1. Wash: 8bearing balls 8bearing races Recommended cleaning solvent Kerosene 1 2. Check: 8bearing balls 1 8bearing races 2 Damage/pitting J Replace. 2 3. Replace: 8bearing balls 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 front fork assembly with a floor chisel 2 and hammer.
STEERING HEAD CHAS EAS00684 INSTALLING THE STEERING HEAD 1. Lubricate: 8 bearing balls 1 8 bearing races LS 1 Recommended lubricant Lithium-soap-based grease 2. 1 Install: 8 front fork assembly 1 8 upper bearing inner race 2 T. R. 7 Nm (0.7 m • kg, 5.1 ft • lb) (with the ring nut wrench 3) 2 3 3. Install: 8 ring nut 1 1 T. R. 30 Nm (3.0 m • kg, 21.7 ft • lb) (with the ring nut wrench 2) Ring nut wrench 90890-01403 YU-A9472 2 Refer to “CHECKING THE STEERING HEAD” in chapter 3.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00685 REAR SHOCK ABSORBER ASSEMBLY 30Nm (3.0 m•kg, 21.7 ft•lb) 1 2 4 3 16Nm (1.6 m•kg, 11.6 ft•lb) Order Job/Part Q’ty Removing the rear shock absorber assembly 1 2 3 4 Rear nut Rear bolt Rear bolt Rear Remarks Remove the parts in the order listed. shock absorber assembly upper 1 shock absorber assembly upper 1 shock absorber assembly lower 1 shock absorber assembly 1 For installation, reverse the removal procedure.
REAR SHOCK ABSORBER ASSEMBLY 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 shock absorber nut (upper) 8 rear shock absorber bolt (lower) EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: 8rear shock absorber rod Bend/damage J Replace the rear shock absorber assembly.
REAR SHOCK ABSORBER ASSEMBLY 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 nut T. R. 30 Nm (3.0 m • kg, 21.7 ft • lb) 8 rear shock absorber assembly lower bolt T. R. 4-36 16 Nm (1.6 m • kg, 11.
ENG CHAPTER 5 ENGINE ENGINE ..................................................................................................... 5-1 LEADS, HOSES AND REAR BRAKE ............................................... 5-1 MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY ................... 5-3 INSTALLING THE ENGINE ............................................................... 5-4 CYLINDER HEAD ..................................................................................... 5-5 REMOVING THE CYLINDER HEAD............
ENG CHECKING THE V-BELT ................................................................. 5-40 CHECKING THE PRIMARY SHEAVE ............................................ 5-40 CHECKING THE PRIMARY SHEAVE WEIGHTS .......................... 5-41 CHECKING THE SLIDER ................................................................ 5-41 CHECKING THE SECONDARY SHEAVE ...................................... 5-41 ASSEMBLING THE PRIMARY SHEAVE ........................................
ENGINE ENG EAS00188 ENGINE ENGINE LEADS, HOSES AND REAR BRAKE 46Nm (4.6 m•kg, 33.3 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 12 12Nm (1.2 m•kg, 8.7 ft•lb) 2 A 5 16Nm (1.6 m•kg, 11.6 ft•lb) 4 B C 1 13 A D 6 3 11 E B E 9 D C 8 7 10 Order Job/Part Q’ty 1 Refer to “COVER AND PANEL”in chapter 3. Drain. Refer to “CHANGING THE COOLANT”in chapter 3. Refer to “COOLING SYSTEM”in chapter 6. 1 5-1 Remarks Remove the parts in the order listed.
ENGINE ENG 46Nm (4.6 m•kg, 33.3 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 12 12Nm (1.2 m•kg, 8.7 ft•lb) 2 A 5 16Nm (1.6 m•kg, 11.
ENGINE ENG MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY 31Nm (3.1 m•kg, 22.4 ft•lb) 6 1 5 10Nm (1.0 m•kg, 7.2 ft•lb) 7 1 5 7 13Nm (1.3 m•kg, 9.4 ft•lb) 3 4 4 2 10Nm (1.0 m•kg, 7.2 ft•lb) 8Nm (0.8 m•kg, 5.
ENGINE 1 ENG EAS00192 INSTALLING THE ENGINE 1. Install: 8engine 1 8engine mounting bolt 2 8self lock nut3 NOTE: Do not fully tighten the bolts. 3 2 2. Tighten: 8self lock nut T. R. 46Nm(4.6 m • kg, 33.3 ft • lb) 3. Tighten: 8rear shock absorber assembly lower bolt1 T. R. 1 5-4 16 Nm (1.6 m • kg, 11.
CYLINDER HEAD ENG EAS00221 CYLINDER HEAD 8Nm (0.8 m•kg, 5.8 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 9Nm (0.9 m•kg, 6.5 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 5 10 3 9 4 6 4 12.5Nm (1.25 m•kg, 9.0 ft•lb) 13 11 8Nm (0.8 m•kg, 5.8 ft•lb) 12 1 2 7 8 10Nm (1.0 m•kg, 7.2 ft•lb) Order 4 30Nm (3.0 m•kg, 21.7 ft•lb) Job/Part Q’ty Remarks Remove the parts in the order listed.
CYLINDER HEAD ENG EAS00225 REMOVING THE CYLINDER HEAD 1. Remove : 8 crankcase cover (left) Refer to “ BELT DRIVE”. 8 cylinder head cover 2. Align: 8 “I” mark a on the magneto rotor (with the stationary pointer b on the crankcase cover) b ***************************************************** a. Turn the primary fixed 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 plate.
CYLINDER HEAD 4. Remove: 8 timing chain tensioner (along with the gasket) 8 camshaft sprocket 1 8 timing chain 2 1 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire. 2 6 5 5. Remove: 8 cylinder head 1 3 4 ENG 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 0.03 mm (0.001 in) ***************************************************** a.
CYLINDER HEAD ENG EAS00231 4 1 4 2 INSTALLING THE CYLINDER HEAD 1. Install: 8 gasket New 8 dowel pins 2. Install: 8 cylinder head 3. Tighten: 8 cylinder head nuts 10 Nm (1.0 m • kg, 7.2 ft • lb) 5 3 6 4 T. R. 8 cylinder head bolts T. R. 10 Nm (1.0 m • kg, 7.2 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. 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 bolt. f. Remove the wire from the timing chain. ***************************************************** 5. Install 8camshaft sprocket bolt 1 1 6. Install: 8timing chain tensioner gasket New 8timing chain tensioner ***************************************************** a. Remove the cap bolt 1 and spring 2. b.
CYLINDER HEAD ENG 7. Turn: 8crankshaft (several turns counterclockwise) 8. Check: 8“I” mark a Align the “I” mark on the AC 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 plate. Out of alignment J Correct. Refer to the installation steps above. b a d c 9. Tighten: 8camshaft sprocket bolt T. R. 30 Nm (3.0 m • kg, 21.
THE ROCKER ARMS AND CAMSHAFT ENG THE ROCKER ARMS AND CAMSHAFT 4 6 6 5 2 1 3 Order Job/Part Q’ty 1 2 3 4 5 6 Removing the rocker arms and camshaft Cylinder head Camshaft Rocker arm shaft(intake) Rocker arm shaft(exhaust) Rocker arm(intake) Rocker arm(exhaust) Spring 4 Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. 1 1 1 1 1 2 For installation, reverse the removal procedure.
THE ROCKER ARMS AND CAMSHAFT ENG EAS00202 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Remove: 8camshaft 1 1 2. Remove: 8intake rocker arm shaft 8exhaust rocker arm shaft 8intake rocker arm 8exhaust rocker arm NOTE: Remove the rocker arm shafts with the clip plier1 . 1 EAS00205 CHECKING THE CAMSHAFT 1. Check: 8camshaft bushings Damage/wear J Replace. 2. Check: 8camshaft lobes Blue discoloration/pitting/scratches J Replace the camshaft. 3.
THE ROCKER ARMS AND CAMSHAFT ENG Camshaft lobe dimension limit Intake a 30.158~30.258 mm (1.187~1.191 in) :30.058mm b 25.082~25.182 mm (0.987~0.991 in) :24.982mm Exhaust a 30.158~30.258 mm (1.187~1.191 in) :30.058mm b 25.020~25.120 mm (0.985~0.989 in) :24.920mm 4. Check: 8camshaft oil passage Obstruction J Blow out with compressed air. EAS00206 1 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts.
THE ROCKER ARMS AND CAMSHAFT ENG 4. Measure: 8rocker arm inside diameter a Out of specification J Replace. a Rocker arm inside diameter 10 ~ 10.015 mm (0.393 ~ 0.394 in) 5. Measure: 8rocker arm shaft outside diameter a Out of specification J Replace. Rocker arm shaft outside diameter 9.981 ~ 9.991 mm (0.392 ~ 0.393 in) a 6. Calculate: 8rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.
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 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 1 Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 4 2. Lubricate: 8 rocker arm shafts Recommended lubricant Molybdenum disulfide oil 3. Install: 8 exhaust rocker arm 1 8 spring 2 8 exhaust rocker arm shaft 3 3 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 9 6 1 2 3 7 4 8 5 5 8 9 4 7 9 3 1 8 2 4 7 2 3 1 Order Job/Part Q’ty Remove the parts in the order listed. Removing the valves and valve springs Cylinder head Rocker arm and rocker arm shaft 1 2 3 4 5 6 7 8 9 Refer to “CYLINDER HEAD”. Refer to “THE ROCKER ARMS AND CANSHAFT”.
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 a ***************************************************** a.
VALVES AND VALVE SPRINGS 4. Remove: 8valve spring retainer 1 8valve spring 2 8valve stem seal 3 8valve spring seat 4 8valve 5 4 2 3 5 ENG 1 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. 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 (4.0 mm) 90890-04111(YM-04111) Valve guide installer (4.0 mm) 90890-04112(YM-04112) Valve guide reamer (4.0 mm) 90890-04113(YM-04113) ***************************************************** 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. a 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 a Do not let the lapping compound enter the gap between the valve stem and the valve guide. 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 Intake valve spring 39.35 mm (1.549 in) : 37.38 mm (1.472 in) Exhaust valve spring 41.57 mm (1.637 in) : 39.49 mm (1.555 in) 2. Measure: 8 compressed valve spring force a Out of specification J Replace the valve spring.
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 1 8valve stem seal 2 (with the recommended lubricant) 2 1 Recommended lubricant Molybdenum disulfide oil 3.
VALVES AND VALVE SPRINGS ENG Valve spring compressor 90890-04109(YM-04109) Valve spring compressor attachment 90890-04148(YM-04148) 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. 6. Install: valve pad 1 NOTE: 8 Lubricate the valve pad with molybdenum disulfide oil. 8 Each valve pad must be reinstalled in its original position.
CYLINDER AND PISTON ENG EAS00251 CYLINDER AND PISTON 7 4 9 8 10 4 7 5 2 4 5 4 6 3 1 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty 1 2 3 4 5 6 Removing the cylinder and piston Cylinder head Timing chain guide(exhaust side) Cylinder Case cap Reed valve assembly Dowel pin Cylinder gasket 1 1 1 1 2 1 7 8 Piston pin clip Piston pin 2 1 9 10 Piston Piston ring set 1 1 Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”.
CYLINDER AND PISTON ENG EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 3 2 1 cC 3 Do not use a hammer to drive the piston pin out. 3 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.
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: 8piston-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, 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 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in) :9.976 mm (0.3928 in) a 3. Measure: 8 piston pin bore diameter b Out of specificationJ Replace the piston. b Piston pin bore diameter 10.002 ~ 10.013 mm (0.3938 ~ 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 2 NOTE: 8 Apply engineoil the piston pin.
CYLINDER AND PISTON ENG 3. Install: 8 gasket New 8 dowel pins 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 timing chain guide (exhaust side) 8cylinder 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 (LEFT) 3 10Nm (1.0 m•kg, 7.2 ft•lb) 2 7 8 10 3 4 11 5 12 9 1 6 6 15Nm (1.5 m•kg, 10.
BELT DRIVE ENG EAS00340 2 INSTALLING THE KICKSTARTER 1. Install: 8 solid bush1 8 kick shaft assembly2 8 torsion spring3 3 1 d 2. Hook: 8 kickstarter spring c NOTE: Hook the spring enda on the kickstarter shaft b as shown, and hook the other end c on the projectiond . a b 3. Install: 8 plain washer 8 circlip1 New 1 4. Install: 8kick pinion gear1 8kick pinion gear clip2 NOTE: Install the clip at the position shown.
ENG BELT DRIVE V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE 5 40Nm (4.0 m•kg, 28.9 ft•lb) 4 7 8 6 3 12 2 10 1 10 11 9 30Nm (3.0 m•kg, 21.7 ft•lb) Order Job/Part Q’ty 1 2 3 4 5 6 7 8 9 10 11 12 Removing the V-belt, clutch, primary and secondary sheave Primary sheave nut/Plate washer Oneway clutch Primary fixed sheave Secondary sheave nut Clutch housing Secondary sheave assembly V-belt Collar Primary sliding sheave Cam/Weight Slider Plate washer Remarks Remove the parts in the order listed.
BELT DRIVE ENG 3 2 4 9 6 3 1 0 55Nm (5.5 m•kg, 39.8 ft•lb) 9 5 7 8 LS LS Order Job/Part Q’ty 1 2 3 4 5 6 7 8 9 0 Disassembling the secondary sheave assembly Clutch carrier nut Clutch carrier Clutch shoe spring Compression spring Secondary spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave Remarks Disassemble the parts in the order listed. 1 1 2 1 1 2 1 2 2 1 Refer to “ REMOVING AND INSTALLING THE SECONDARY SHEAVE “ .
BELT DRIVE ENG EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: 8primary sheave nut 1 8plate washer2 8oneway clutch3 8primary fixed sheave 4 4 5 1 NOTE: While holding the primary fixed sheave with the rotor holding tool 5, loosen the primary fixed sheave nut. 4 Rotor holding tool: 90890-01235 (YU-01235) 3 2 1 EAS00318 1 REMOVING THE SECONDARY SHEAVE AND V-BELT 1.
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. 1 2 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 16.8 mm (0.0661 in) : 15.8 mm (0.622 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. 1 2 2.
BELT DRIVE ENG EAS00321 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the primary sheave weights. 1. Check: 8 primary sheave weight Cracks/damage/wear J Replace. a 2. Measure: 8 primary sheave weight outside diameter a Out of specification J Replace. Primary sheave weight outside diameter 15 mm (0.591 in) : 14.5 mm (0.571 in) CHECKING THE SLIDER 1. Check: 8 slider 1 Damage/wearJ Replace EAS00322 CHECKING THE SECONDARY SHEAVE 1.
BELT DRIVE 1 ENG EAS00323 3 4 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 2 5 NOTE: Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5. 3 2. Install: 8primary sliding sheave 1 8primary sheave weights 2 8collar 3 2 1 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 oil seals 8 bearings (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube® 2. Install: 8 secondary sliding sheave 1 3 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 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. 5 3 ENG 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 2 cC Do not allow grease to contact the V-belt, secondary sheave assembly.
BELT DRIVE ENG 3. Install: 8 clutch housing 1 8 secondary sheave nut2 T. R. 2 1 40 Nm (4.0 m • kg, 28.9 ft • lb) NOTE: Tighten the secondary sheave nut with the sheave holder 3. 3 Sheave holder 90890-01701 (YS-01880-A) 4. Install: 8primary fixed sheave 1 8primary sheave nut 2 T. R. 30 Nm (3.0 m• kg, 21.7 ft• lb) NOTE: While holding the primary fixed sheave with the rotor holding tool 3, tighten the primary fixed sheave nut. 5.
STARTER CLUTCH AND AC MAGNETO ENG EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY 4Nm (0.4 m•kg, 2.9 ft•lb) 2 1 5 LT 9Nm (0.9 m•kg, 6.5 ft•lb) 6 7Nm (0.7 m•kg, 5.1 ft•lb) 4 7 8 7Nm (0.7 m•kg, 5.1 ft•lb) 3 43Nm (4.3 m•kg, 31.
STARTER CLUTCH AND AC MAGNETO ENG 4Nm (0.4 m•kg, 2.9 ft•lb) 2 1 5 LT 9Nm (0.9 m•kg, 6.5 ft•lb) 6 7Nm (0.7 m•kg, 5.1 ft•lb) 4 7 8 7Nm (0.7 m•kg, 5.1 ft•lb) 3 43Nm (4.3 m•kg, 31.1 ft•lb) Order 6 7 8 Job/Part Lock plate Pick up coil Stator coil assembly Q’ty 1 1 1 Remarks For installation, reverse the removal procedure.
STARTER CLUTCH AND AC MAGNETO ENG EAS00342 STARTER CLUTCH 3 2 1 NEW image 9 10Nm (1.0 m•kg, 7.2 ft•lb) 7 90Nm (9.0 m•kg, 65.1 ft•lb) 6 3 8 10 11 M 4 5 4 Order Job/Part Q’ty Removing the starter clutch Engine oil 1 2 3 4 5 6 7 8 9 10 11 Remarks Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL”in chapter 3. Refer to “ REMOVING AND INSTALLING THE AC MAGNETO “.
STARTER CLUTCH AND AC MAGNETO ENG EAS00347 REMOVING THE AC MAGNETO 1. Remove: 8 AC magneto rotor nut1 8 washer NOTE: 8 While holding the AC magneto rotor 2 with the sheave holder 3, loosen the AC magneto rotor nut. 8 Do not allow the sheave holder to touch the projection on the AC magneto rotor. 3 2 1 Sheave holder 90890-01701 YS-01880-A 2.
STARTER CLUTCH AND AC MAGNETO ENG EAS00344 REMOVING THE STARTER CLUTCH 1. Remove: 8crankcase cover (right)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. 1 2. 1 Remove: 8starter clutch nut1 8washer 8starter wheel gear 8roller 8collar 8starter clutch 8idle gear NOTE: The starter clutch nut is left-hand thread.
STARTER CLUTCH AND AC MAGNETO ENG EAS00351 CHECKING THE STARTER CLUTCH 1. Check: 8starter clutch roller 1 Damage/wear J Replace. 2. Check: 8starter clutch idle gear 8starter wheel gear Burrs/chips/roughness/wear J Replace the defective part(s). 3. Check: 8starter wheel gear’s contacting surfaces Damage/pitting/wear J Replace the starter clutch gear. 1 A 4. Check: 8starter clutch operation 2 ***************************************************** a.
STARTER CLUTCH AND AC MAGNETO ENG EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: 8 idle gear 8 starter clutch 8 collar 8 roller 8 starter wheel gear 8 washer 8 starter clutch nut1 90 Nm (9.0 m • kg, 65.1 ft • lb) 1 T. R. NOTE: The starter clutch nut is left-hand thread. 2. Install: 8 gasket New 8 crankcase cover (right)1 1 T. R. 10 Nm (1.0 m • kg, 7.2 ft • lb) EAS00354 INSTALLING THE AC MAGNETO 1.
STARTER CLUTCH AND AC MAGNETO 2. ENG Tighten: 8AC magneto rotor nut 1 T. R. 43 Nm (4.3 m • kg, 31.1 ft • lb) NOTE: 8 While holding the AC magneto rotor 3with the sheave holder 2, tighten the AC magneto rotor nut. 8 Do not allow the sheave holder to touch the projection on the AC magneto rotor.
OIL PUMP ENG EAS00360 OIL PUMP 1 10 9 8 4Nm (0.4 m•kg, 2.9 ft•lb) 7 6 5 1Nm (0.1 m•kg, 0.7 ft•lb) 4 3 4 4 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Q’ty 2 2 Remarks Remove the parts in the order listed. Refer to “RADIATOR”in chapter 6. Refer to “ STARTER CLUTCH AND AC MAGNETO “ .
OIL PUMP ENG EAS00364 CHECKING THE OIL PUMP 1. Check: 8 oil pump drive gear 8 oil pump driven gear 1 8 oil pump housing 8 oil pump housing cover Cracks/damage/wear J Replace the defective part(s). 1 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.
OIL PUMP ENG EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: 8 inner rotor 8 outer rotor 8 oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 5 2. Install: 8 oil pump shaft 1 (to the oil pump housing2) 8 pin 3 8 inner rotor 4 8 outer rotor5 8 oil pump housing cover6 8 oil pump housing screw 4a 1 2 6 3 T. R. 1 Nm (0.1 m • kg, 0.7 ft • lb) NOTE: When installing the inner rotor, align the pin 3 in the oil pump shaft with the groove a in the inner rotor 4. 3.
TRANSMISSION ENG EAS00419 TRANSMISSION LS 4 13Nm (1.3 m•kg, 9.34 ft•lb) 7 4 5 G G 2 6 G 3 1 LS Order Job/Part Q’ty Removing the transmission Transmission oil Remove the parts in the order listed. Drain. Refer to “CHANGING THE TRANSMISSION OIL “ in chapter 3. Refer to “MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY “. Refer to “REAR WHEEL AND 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 0.04 mm (0.0002 in) 2. Measure: 8 drive axle runout (with a centering device and dial gauge ) Out of specification J Replace the drive axle. Primary drive gear shaft runout limit 0.04 mm (0.0002 in) 3 . Check: 8transmission gears Blue discoloration/pitting/wear J Replace the defective gear(s).
CRANKSHAFT ENG EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 10Nm (1.0 m•kg, 7.2 ft•lb) 14 10 4 12 11 16 LS 17 7 9 12 13 18 8 6 18 19 2 LS 2 15 3 32Nm (3.2 m•kg, 23.
CRANKSHAFT ENG 10Nm (1.0 m•kg, 7.2 ft•lb) 14 10 4 12 11 16 LS 17 7 9 12 13 18 8 6 18 19 2 LS 2 15 3 32Nm (3.2 m•kg, 23.
CRANKSHAFT ENG EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 8 centerstand assembly 2. Remove: 8 crankcase bolts1 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. 1 3. Remove: 8 right crankcase1 8 spacer cC Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces.
CRANKSHAFT ENG EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1. Check: 8 timing chain Damage/stiffness J Replace the timing chain. 2. Check: 8 timing chain guide (intake side) Damage/wear J Replace.
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 ( 0.001 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 0.15~0.45 mm (0.006~0.018 in) 3. Measure: 8 crankshaft width Out of specification J Replace the crankshaft.
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. EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: 8crankcase Cracks/damage J Replace. 8oil delivery passages Obstruction J Blow out with compressed air. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1.
CRANKSHAFT ENG EAS00408 INSTALLING THE CRANKSHAFT 1. Install: 8 timing chain guide (intake side) 8 timing chain1 8 crankshaft assembly2 2 NOTE: Install the timing chain so it is not visible through the opening in the left crankcase 3. 1 3 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.
COOL CHAPTER 6 RADIATOR RADIATOR ................................................................................................ 6-1 CHECKING THE RADIATOR ............................................................ 6-2 INSTALLING THE RADIATOR ........................................................... 6-3 THERMOSTAT ASSEMBLY ..................................................................... 6-4 CHECKING THE THERMOSTAT ......................................................
COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 3 7 2 4 5 1 10Nm (1.0 m•kg, 7.2 ft•lb) 6 Order Job/Part Q’ty Remove the parts in the order listed. Removing the radiator Seat/Trunk Battery cover/Battery holder Battery/Front cover Footrest board side cover mole ( left and right ) Mat/Footrest board Coolant 1 2 3 4 5 6 7 Radiator cover Radiator cap Conduit hose Radiator inlet hose Radiator outlet hose Radiator Fan case Remarks Refer to “COVER AND PANEL”in chapter 3. Drain.
RADIATOR COOL EAS00455 CHECKING THE RADIATOR 1. Check: 8 radiator fins Obstruction J Clean. Apply compressed air to the rear of the radiator. Damage J Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: 8 radiator hoses Radiator inlet hose1 8 radiator pipes Radiator outlet hose2 Cracks/damage J Replace. 3. Measure: 8 radiator cap opening pressure Below the specified pressure J Replace the radiator cap. 1 2 Radiator cap opening pressure 93.3 ~ 122.
RADIATOR COOL 4. Check: 8 radiator fan Damage J Replace. Malfunction J Check and repair. EAS00456 INSTALLING THE RADIATOR 1. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: 8cooling system Leaks J Repair or replace any faulty part. 3. Measure: 8radiator cap opening pressure Below the specified pressure J Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
THERMOSTAT ASSEMBLY COOL EAS00460 THERMOSTAT ASSEMBLY 10Nm (1.0 m•kg, 7.2 ft•lb) A 4 1 4 5 A 6 3 2 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remove the parts in the order listed.
THERMOSTAT ASSEMBLY COOL 10Nm (1.0 m•kg, 7.2 ft•lb) A 4 1 4 5 A 6 3 2 10Nm (1.0 m•kg, 7.2 ft•lb) Order 6 Job/Part Q’ty Thermostat assembly Remarks 1 For installation, reverse the removal procedure.
THERMOSTAT ASSEMBLY COOL EAS00462 CHECKING THE THERMOSTAT 1. Check: 8 thermostat 1 Does not open at 65 ~ 80°C J Replace. 1 ***************************************************** a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
THERMOSTAT ASSEMBLY COOL EAS00466 INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: 8thermostat1 8thermostat housing 8thermostat assembly inlet breather hose. 8thermostat assembly outlet breather hose. 2. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 3. Check: 8cooling system Leaks J Repair or replace any faulty part. 4. Measure: 8radiator cap opening pressure Below the specified pressure J Replace the radiator cap.
WATER PUMP COOL EAS00468 WATER PUMP 1 7 5 10 10Nm (1.0 m•kg, 7.2 ft•lb) 4 3 11 9 6 8 7Nm (0.7 m•kg, 5.1 ft•lb) 10Nm (1.0 m•kg, 7.
WATER PUMP COOL 1 7 5 10 10Nm (1.0 m•kg, 7.2 ft•lb) 4 11 3 9 6 8 7Nm (0.7 m•kg, 5.1 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 2 Order 5 6 7 8 9 10 11 Job/Part Q’ty Water pump housing Dowel pin Plate Impeller shaft Oil seal Bearing Gasket Remarks 1 2 1 1 1 1 1 For installation, reverse the removal procedure.
WATER PUMP COOL EAS00471 1 DISASSEMBLING THE WATER PUMP 1. Remove: 8water pump housing cover1 8dowel pin 8gasket 2. Remove: 8plate 2 8impeller shaft 3 8gasket 8oil seal (with a thin, flat-head screwdriver) 8bearing 3 2 NOTE: Remove the oil seal from the inside of the water pump housing. Remove the bearing from the inside of the water pump housing. EAS00474 CHECKING THE WATER PUMP 1. Check: 8water pump housing cover 8water pump housing 8impeller 1 Cracks/damage/wear J Replace. 1 2.
WATER PUMP COOL EAS00475 ASSEMBLING THE WATER PUMP 1. Install: 8oil seal New 1 (into the water pump housing 3) 8bearing 2 2 1 NOTE: 8 Before installing the oil seal, apply tap water or coolant onto its out surface. 8 Install the oil seal with a socket that matches its outside diameter. 3 cC Never lubricate the water pump seal surface with oil or grease. 2. Measure: 8impeller shaft tilt Out of specification J Replace the impeller shaft. 1 Impeller shaft tilt limit 0.15 mm (0.
WATER PUMP COOL EAS00478 INSTALLING THE WATER PUMP 1. Install: a b 8gasket New 8water pump assembly 1 1 T. R. 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Align the slit a on the impeller shaft with the projection b on the camshaft sprocket bolt. 2. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 3. Check: 8cooling system Leaks J Repair or replace the faulty part. 4.
CARB CHAPTER 7 CARBRETOR CARBURETOR ......................................................................................... 7-1 CHECKING THE CARBURETOR ..................................................... 7-4 ASSEMBLING THE CARBURETOR................................................. 7-6 INSTALLING THE CARBURETOR ................................................... 7-7 MEASURING AND ADJUSTING THE FUEL LEVEL ....................... 7-8 CHECKING THE AUTOCHOKE UNIT ............................................
CARBURETOR CARB EAS00480 CARBURETOR CARBURETOR 7 A 10 8 5 A 6 B 2 F F C E B D 9 C E 4 D 3 1 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Q’ty Removing the carburetor Mat/Seat/Trunk Battery cover/Front cover Hose(to cylinder head) Auto choke lead Throttle position sensor lead Fuel hose Compensator hose Thermostat assembly inlet breather hose Throttle cable kit Clamp(air filter assembly ) Manifold clamp screw Carburetor assembly Remarks Remove the parts in the order listed.
CARBURETOR CARB EAS00483 6 5 1 8 7 2 9 3 p 4 a i q w o u 0 t y e r Order 1 2 3 4 5 6 7 8 9 0 q w e r t y Job/Part Q’ty Disassembling the carburetor Auto choke cap Auto choke unit Auto choke holder Auto choke seat Throttle stop screw kit Bracket Vacuum chamber cover/Piston valve spring Piston valve Jet needle kit Float chamber Float chamber rubber gasket Accelerator pump assembly Float pin Float Needle valve Main jet 7-2 Remarks Remove the parts in the order listed.
CARBURETOR CARB 6 5 1 8 7 2 9 3 p 4 a i q w o u 0 t y e r Order u i o p a Job/Part Q’ty Main nozzle Nedle jet Slow air jet Slow jet Throttle position sensor Remarks 1 1 1 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 Dirt J Clean. 4.
CARBURETOR CARB 6. Check: 8 needle valve Damage/obstruction/wearJ Replace. 7. Check: 8 piston valve 1 Damage/scratches/wearJ Replace. 8 piston valve diaphragm 2 Cracks/tears J Replace. 2 1 8. Check: 8 vacuum chamber cover 1 8 piston valve spring 2 Cracks/damage J Replace. 1 2 9. Check: 8jet needle 1 8main jet 2 8main nozzle 3 8slow air jet 4 8slow jet 5 8needle jet 6 Bends/damage/wear J Replace. Obstruction J Clean. Blow out the jets with compressed air. 6 1 4 3 5 2 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. 1. Install: 8 needle jet 1 8 main nozzle2 8 main jet 3 8 slow air jet 4 3 1 4 2 2. Install: 8 float 1 8 needle valve 2 8 float pin 3 8 screw 4 3. Install: 3 4 2 1 8 float chamber rubber gasket New 8 float chamber 4 4.
CARBURETOR CARB 7. Install: 8piston valve spring 8vacuum chamber cover 8. Install: 8bracket 8auto choke unit 8throttle position sensor EAS00492 INSTALLING THE CARBURETOR 1. Adjust: 8 engine idling speed Engine idling speed 2,000 ~ 2,400r/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) 1.5 ~ 3.5 mm (0.059 ~ 0.138 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. Fuel level (below the float chamber mating surface) 6.6~7.6 mm (0.26~0.30 in) a ***************************************************** 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 EAS00503 CHECKING THE AUTOCHOKE UNIT NOTE: When checking the autochoke unit, the ambient temperature must be lower than 45°C. 1. Remove: 8carburetor 2. Check: 8autochoke unit ***************************************************** a. Connect a 3.3-mm hose 2 to the starter air passage 1 and blow into the hose. NOTE: When the starter plunger is open, air should come out of the other side of the starter air passage. 2 1 Starter plunger opens Perform step (3).
CARBURETOR CARB EAS00504 CHECKING THE FUEL COCK 1. Remove: 8 seat/trunk 8 battery cover 8 front cover Refer to “COVER AND PANEL”in chapter 3. 2. Check: 8fuel cock1 ***************************************************** a. Disconnect the fuel cock to carburetor fuel hose2from the carburetor . b. Place a container under the end of the fuel hose. c. Start the engine and check if fuel flows from the fuel hose 2. Fuel flows. Fuel does not flow. Fuel cock is OK. Replace the fuel cock. d.
CARBURETOR CARB CHECKING THE THROTTLE POSITION SENSOR B/L L B/L Y/L NOTE: Before checking the throttle position sensor, the engine idling speed should be properly adjusted. Y/L L 3 2 1 1. Check: 8throttle position sensor ***************************************************** a. Turn the main switch to “ON”. b. Connect the pocket tester (DC 20V) to the throttle position sensor. Tester positive lead J yellow/blue 1 Tester negative lead Jblack/blue2 c.
AIR INDUCTION SYSTEM CARB AIR INDUCTION SYSTEM 10Nm (1.0 m•kg, 7.2 ft•lb) 4 2 1 3 Order Job/Part Q’ty Removing the air induction system Seat/Trunk 1 2 3 4 Hose(from AI air filter ) Vacuum hose(from mainfold ) Hose(to cylinder head ) Air cut-off valve assembly Remarks Remove the parts in the order listed. Refer to “COVER AND PANEL”in chapter 3. 1 1 1 1 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 8 ELECTORICAL ELECTRICAL COMPONENTS ................................................................ 8-1 WIRING DIAGRAM ................................................................................... 8-2 CHECKING SWITCH CONTINUITY ........................................................ 8-4 CHECKING THE SWITCHES ................................................................... 8-5 CHECKING THE BULBS AND BULB SOCKETS .................................. 8-6 TYPES OF BULBS ............
ELECTRICAL COMPONENTS ELEC EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 0 q w e r t y u Rear brake light switch Front brake light switch Main switch Starter relay Thermo unit Fuel sender C.D.I.
8-2 (BLACK) (BLACK) B G GW B g Y Ch h LW LY B LY B f L OFF RUN d r ENG.STOP SW. OFF START R LW R LW s B LW STARTER SW. e R GY R TEMP G FUEL Br 4 R R R R W B R YR (GREEN) ILLUMI j Dg L Ch Y L Dg Y Ch 5 R Br ILLUMI TURN L HI BEAM G B GW Br B G Br 1 7.5A Br GW G B OFF CHECK ON MAIN SW.
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 Main switch AC magneto Rectifier/Regulator Battery Main fuse 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.
CHECKING THE SWITCHES ELEC - + EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. 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.
8-9 (BLACK) (BLACK) B G GW B g Y Ch h LW LY B LY B f L OFF RUN d r ENG.STOP SW. OFF START R LW R LW s B LW STARTER SW.
IGNITION SYSTEM EAS00736 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 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. pickup coil resistance 8. main switch 9. engine stop switch 10.wiring connections (of the entire ignition system) YES NO Replace the fuse.
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 8 Remove the spark plug cap from the spark plug lead.
IGNITION SYSTEM - ELEC + EAS00748 7. Pickup coil resistance 8 Disconnect the pickup coil coupler from the wire harness. 8 Connect the pocket tester (Ω × 100) to the pickup coil terminal as shown. Positive tester probe J white/red 1 2 Negative tester probe J white/blue2 8 Measure the primary coil resistance. 1 W/R Primary coil resistance 0.168 ~ 0.252 Ω at 20°C W/L 8 Connect the pocket tester (Ω × 1k) to the ignition coil as shown.
IGNITION SYSTEM EAS00750 9. Engine stop switch 8 Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the engine stop switch OK? YES NO Replace the right handlebar switch. EAS00754 10.Wiring 8 Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. 8 Is the ignition system’s wiring properly connected and without defects? YES Replace the C.D.I. unit. NO Properly connect or repair the ignition system’s wiring.
8-14 (BLACK) (BLACK) B B TEMP G GW g Y Ch h LW LY B LY B f L OFF RUN d r ENG.STOP SW. OFF START R LW R LW s B LW STARTER SW.
ELECTRIC STARTING SYSTEM ELEC - + EAS00756 9 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON” (switch is closed), the starter motor can only operate if at least one of the following conditions is met: 8 The brake lever ( front or rear) is pulled to the handlebar (the brake light switch is closed).
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. mainfuse 2. battery 3. starter motor 4 starter relay 5 main switch 6 brake light switch (front, rear) 7 engine stop switch 8 start switch 9 wiring connections (of the entire starting system) YES NO Replace the fuse. NOTE: 8 Before troubleshooting, remove the following part(s): 1.
ELECTRIC STARTING SYSTEM EAS00758 ELEC - + EAS00761 3. Starter motor 8 Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead3. 4. 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 relay coupler as shown.
ELECTRIC STARTING SYSTEM EAS00751 6. Brake light switch(front and rear) 8 Check the brake light switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the brake light switch OK? YES NO Replace the brake light switch. EAS00750 7. Engine stop switch 8 Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the engine stop switch OK? YES NO Replace the right handlebar switch. EAS00764 8. Start switch 8 Check the start switch for continuity.
ELECTRIC STARTING SYSTEM ELEC - + EAS00767 STARTER MOTOR 1 2 3 4 5 6 2 7 Order Job/Part 1 Q’ty Remove the parts in the order listed. Removing the starter motor Seat/Trunk Front cover Refer to “COVER AND PANEL”in chapter 3. Battery cover Air filter assembly 1 2 1 2 3 4 5 6 7 Remarks 1 1 Starter motor lead Starter motor Refer to“MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY”in chapter 5. Disconnect. For installation, reverse the removal procedure. Disassemble 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. a Commutator wear limit 16.6 mm (0.654 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 1.35 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) a 6. Measure: 8 brush spring force Out of specification J Replace the brush springs as a set. Brush spring force 3.92 ~ 5.88 N 2 1 7. Check: 8 gear teeth Damage/wear J Replace the gear. 8. Check: 8 bearing1 8 oil seal2 8 bush3 Damage/wear J Replace.
ELECTRIC STARTING SYSTEM ELEC - + EAS00772 1 4 ASSEMBLING THE STARTER MOTOR 1. Install: 8 brush seat 1 2. Install: 8 washer1 8 armature coil 2 8 o-ing New 3 8 stator assembly4 3 2 1 3 . Install: 8 bolts 1 a b T. R. 5 Nm (0.5 m • kg, 3.6 ft • lb) 1 NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers.
8-23 (BLACK) (BLACK) B GW B TEMP G g Y Ch h LW LY B LY B f L OFF RUN d r ENG.STOP SW. OFF START R LW R LW s B LW STARTER SW.
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. Seat/Trunk 2. Battery cover 3.
CHARGING SYSTEM + 5. Wiring 8Check the entire charging system’s wiring. Refer to “CIRCUIT DIAGRAM”. 8Is the charging system’s wiring properly connected and without defects? 8Is the charging voltage within specification? YES YES The charging circuit is OK. Replace the rectifier/regulator. EAS00776 4. Stator coil resistance 8 Remove the starter coil couplers from wireharness. 8Connect the pocket tester (Ω × 1) to the stator coils as shown.
8-26 (BLACK) (BLACK) B B TEMP G GW g Y Ch h LW LY B LY B f L OFF RUN d r ENG.STOP SW. OFF START R LW R LW s B LW STARTER SW.
LIGHTING SYSTEM EAS00781 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8 Check 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 or meter light. Check: 1. main fuse 2. battery 3. lighting coil resistance. 4. main switch 5. dimmer switch 6. headlight relay 7. wiring connections (of the entire lighting system) Minimum open-circuit voltage 12.
LIGHTING SYSTEM EAS00749 ELEC - + EAS00787 4. Main switch 8 Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the main switch OK? YES 7. 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? NO YES Replace the main switch. Check the condition of each of the lighting system’s circuits. Refer to “CIRCUIT DIAGRAM”. EAS00784 5.
LIGHTING SYSTEM EAS00788 1. Headlight bulb and socket 8 Check the headlight bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Are the headlight bulb and socket OK? NO Replace the headlight bulb, socket or both. 1 3 2 G G Y 2. High beam indicator light bulb and socket 8 Check the high beam indicator light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Are the high beam indicator light bulb and socket OK? YES + 3.
LIGHTING SYSTEM YES - ELEC + EAS00789 NO 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? This circuit is OK. The wiring circuit from the main switch to the headlight and hight beam indicator light coupler are faulty and must be repaired. YES NO Replace the meter light bulb, socket or both. 2.
LIGHTING SYSTEM EAS00754 4. 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”. NO Properly connect or repair the lighting system’s wiring.
8-32 B G G GW B g Y Ch h LW LY B LY B f L OFF RUN d r ENG.STOP SW. OFF START R LW R LW TEMP j (BLACK) (BLACK) LW STARTER SW. e R GY R W B R YR (GREEN) ILLUMI s B R R R R ILLUMI TURN L HI BEAM G B Dg L Ch Y FUEL Br 4 7.
SIGNALING SYSTEM EAS00794 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. 8 Any of the following fail to light: turn signal light, brake light or an indicator light. 8 The horn fails to sound. Minimum open-circuit voltage 12.8 V or more at 20°C Check: 1. main fuse 2. battery 3. main switch 4. wiring connections (of the entire signaling system) 8 Is 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 Br NO 1 2. Voltage 8 Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown. Positive tester probe Jbrown 1 Negative tester probe J ground Br NO YES The horn is OK. P 4. Voltage 8 Connect the pocket tester (DC 20 V) to the horn connector at the pink terminal as shown.
SIGNALING SYSTEM EAS00798 2. + 3. Voltage 8 Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe J green/ yellow 1 Negative tester probe J black 2 The tail/brake light fails to come on. 1. Tail/brake light bulb and socket 8 Check the tail/brake light bulb and socket for continuity.
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 8 Set 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 B Br/W Br - + 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 ELEC - + 2. Voltage 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. Positive tester probe J brown 1 Negative tester probe J black 2 4. The fuel level meter fails to operate. 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.
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 speedo meter.
8-40 (BLACK) (BLACK) B B TEMP G GW g Y Ch h LW LY B LY B f L OFF RUN d r ENG.STOP SW. OFF START R LW R LW s B LW STARTER SW.
COOLING SYSTEM EAS00808 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The cooling system fails to operate. Check: 1. main fuse 2. battery 3. main switch 4. thermo switch 5. water temperature indicator light 6. wiring connections (the entire cooling system) Minimum open-circuit voltage 12.8 V or more at 20°C 8 Is the battery OK? YES NO 8Clean the battery terminals. 8Recharge or replace the battery.
COOLING SYSTEM EAS00811 ELEC - + A Cooling phase B Heating phase 4. Thermo switch 8 Remove the thermo switch from the thermostat housing. 8 Connect the pocket tester (Ω × 1) to the thermo switch 1 as shown. 8 Immerse the thermo switch in a container filled with coolant2. 8 Place a thermometer3 in the coolant. 8 Slowly heat the coolant, then let it cool down to the specified temperature. 8 Check the thermo switch for continuity at the temperatures indicated below.
COOLING SYSTEM EAS00812 ELEC - + 2. Voltage 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. Positive tester probe J green/red 1 Negative tester probe J ground 5. The water temperature indicator light fails to operate. 1. Thermo unit 8 Remove the thermo unit from the cylinder head. 8 Connect the pocket tester (Ω × 1k) to the thermo unit as shown.
COOLING SYSTEM 3. Water temperature indicator light 8 Remove the thermo unit coupler . 8 Set the main switch to “ON”. 8 Connect the green/red1 and black/ blue2 with a jumper lead3. 1 G/R B/L 2 3 8 Is the water temperature indicator light OK? YES This circuit is OK. NO Replace the water temperature indicator light EAS00813 6. Wiring 8 Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM”. 8 Is the cooling system’s wiring properly connected and without defects? YES Replace the C.D.I.
8-45 (BLACK) (BLACK) B B TEMP G GW g Y Ch h LW LY B LY B f L OFF RUN d r ENG.STOP SW. OFF START R LW R LW s B LW STARTER SW.
AUTO CHOKE SYSTEM EAS00821 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The auto choke system fails to operate. Check: 1. main fuse 2. battery 3. thermo switch 4. auto choke unit 5. wiring connections (of the entire autochoke system) NOTE: 8 Before troubleshooting, remove the following part(s): 1. Seat/Trunk 2. Battery cover 3. Front cover 8 Troubleshoot with the following special tool(s).
AUTO CHOKE SYSTEM EAS00811 ELEC - + A Cooling phase B Heating phase 3. Thermo switch 8 Remove the thermo switch from the thermostat housing. 8 Connect the pocket tester (Ω × 1) to the thermo switch 1 as shown. 8 Immerse the thermo switch in a container filled with coolant2. 8 Place a thermometer3 in the coolant. 8 Slowly heat the coolant, then let it cool down to the specified temperature. 8 Check the thermo switch for continuity at the temperatures indicated below.
AUTO CHOKE SYSTEM 4. Auto choke unit 8 Disconnect the auto choke unit coupler from wire harness. 8 Connect the pocket tester(Ω × 1) to the Auto choke unit coupler as shown. Positive tester probe JJ JJgreen/black 1 Negative tester probe Jyellow 2 1 2 G/B Y 8Measure the auto choke unit resistance. Auto choke unit resistance 20 Ω at 20°C 8 Is the auto choke unit OK? YES NO Replace the auto choke unit. 5. Wiring 8 Check the entire auto choke system’s wiring. Refer to “CIRCUIT DIAGRAM”.
TRBL SHTG CHAPTER 9 TROUBLE SHOOTING STARTING FAILURE/HARD STARTING................................................. 9-1 ENGINE .............................................................................................. 9-1 FUEL SYSTEM .................................................................................. 9-1 ELECTRICAL SYSTEMS .................................................................. 9-1 INCORRECT ENGINE IDLING SPEED ................................................... 9-2 ENGINE ...
STARTING FAILURE/HARD STARTING TRBL SHTG EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING SPEED TRBL SHTG EAS00847 Ignition system 8Faulty C.D.I.
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY CLUTCH EAS00849 EAS00853 POOR MEDIUM-AND-HIGHSPEED PERFORMANCE FAULTY CLUTCH TRBL SHTG ENGINE OPERATES BUT SCOOTER WILL NOT MOVE Refer to “STARTING FAILURE/HARD STARTING”.
FAULTY CLUTCH/OVERHEATING/OVERCOOLING TRBL SHTG Hose(s) and pipe(s) 8Damaged hose 8Improperly connected hose 8Damaged pipe 8Improperly connected pipe POOR SPEED PERFORMANCE V-belt 8Oil or grease on the V-belt Primary pulley weight(s) 8Faulty operation 8Worn primary pulley weight FUEL SYSTEM Carburetor 8Incorrect main jet setting 8Incorrect fuel level 8Damaged or loose carburetor joint Primary fixed sheave 8Worn primary fixed sheave Primary sliding sheave 8Worn primary sliding sheave Air filter 8Clogge
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING TRBL SHTG EAS00859 EAS00862 POOR BRAKING PERFORMANCE UNSTABLE HANDLING Drum brake 8Worn brake shoe 8Worn or rusty brake drum 8Incorrect brake lever position 8Incorrect brake lever free play 8Incorrect brake camshaft lever position 8Incorrect brake shoe position 8Damaged or fatigued brake shoe spring 8Oil or grease on the brake shoe 8Oil or grease on the brake drum Handlebar 8Bent or improperly installed handlebar Steering head componen
FAULTY LIGHTING OR SIGNALING SYSTEM EAS00866 TRBL SHTG TURN SIGNAL REMAINS LIT 8Faulty turn signal relay 8Burnt-out turn signal bulb FAULTY LIGHTING OR SIGNALING SYSTEM TURN SIGNAL BLINKS QUICKLY 8Incorrect turn signal bulb 8Faulty turn signal relay 8Burnt-out turn signal bulb HEADLIGHT DOES NOT COME ON 8Wrong headlight bulb 8Faulty headlight relay 8Too many electrical accessories 8Hard charging 8Incorrect connection 8Improperly grounded circuit 8Poor contacts (main or light switch) 8Burnt-out headligh
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