YJ50RN SERVICEMANUAL LIT-11616-14-50 5LY-28197-E0
EAS00001 YJ50RN SERVICE MANUAL ©2000 by Yamaha Motor Corporation, U.S.A. First edition, December, 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A.
EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
1 EAS00009 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(s) 6 Chassis 7 Electrical system 8 Troubleshooting ENG 5 6 CHAS CARB 7 8 – ELEC TRBL SHTG + 9 Symbols 9 to F indicate the following.
EAS00011 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE CARBURETION GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 CARB 6 – ELECTRICAL SYSTEM TROUBLESHOOTING + ELEC 7 TRBL SHTG 8
MEMO
CONTENTS CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION..........................................................................1-1 VEHICLE IDENTIFICATION NUMBER .....................................................1-1 MODEL CODE...........................................................................................1-1 IMPORTANT INFORMATION..........................................................................1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ...........................
CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION..............................................................................................3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ....................3-1 GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 CARB 6 SIDE COVERS AND FOOTREST BOARD .....................................................3-3 FRONT PANEL AND LEG SHIELD ................................................................3-5 ADJUSTING THE ENGINE IDLING SPEED ...........
CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE ........................................................................4-1 CHECKING THE FRONT WHEEL ............................................................4-5 CHECKING THE SPEEDOMETER GEAR UNIT.......................................4-6 CHECKING THE BRAKE ..........................................................................4-7 ASSEMBLING THE BRAKE SHOE PLATE ..............................................4-8 INSTALLING THE FRONT WHEEL ........................
CHAPTER 5 ENGINE ENGINE REMOVAL.........................................................................................5-1 INSTALLING THE ENGINE .......................................................................5-3 CYLINDER HEAD, CYLINDER AND PISTON ...............................................5-4 REMOVING THE CYLINDER AND PISTON .............................................5-6 CHECKING THE CYLINDER HEAD .........................................................5-6 CHECKING THE CYLINDER AND PISTON...
CRANKCASE ................................................................................................5-37 DISASSEMBLING THE CRANKCASE ....................................................5-39 CHECKING THE CRANKCASE ..............................................................5-39 CHECKING THE BEARINGS AND OIL SEALS ......................................5-40 CHECKING THE REED VALVE ..............................................................5-40 ASSEMBLING THE CRANKCASE ...............................
STARTER MOTOR ........................................................................................7-17 CHECKING THE STARTER MOTOR .....................................................7-19 ASSEMBLING THE STARTER MOTOR .................................................7-20 CHARGING SYSTEM ....................................................................................7-21 CIRCUIT DIAGRAM ................................................................................7-21 TROUBLESHOOTING................
OVERHEATING ...............................................................................................8-3 ENGINE .....................................................................................................8-3 FUEL SYSTEM ..........................................................................................8-3 CHASSIS ...................................................................................................8-3 ELECTRICAL SYSTEMS .....................................................
SCOOTER IDENTIFICATION GEN INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION 1 EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 stamped into the frame. is EAS00018 MODEL CODE The model code label 1 is affixed to the location shown in the figure. Record the information on this label in the space provided. 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 “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 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 base grease. Oil bearings liberally when installing, if appropriate. 1 Oil seal CAUTION: @ Do not spin the bearing with compressed air because this will damage the bearing surfaces.
IMPORTANT INFORMATION GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. 3. Check: • all connections Loose connection → Connect properly. 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. Tool name/Function Sheave holder YU-01701 This tool is used to hold the clutch housing when removing or installing the clutch housing nut. Pocket tester YU-03112 This tool is used to check the electrical system. Compression gauge YU-33223 This tool is used to measure engine compression. Steering nut wrench YU-33975 This tool is used to loosen or tighten the steering stem ring nut. Inductive tachometer YU-8036-A This tool is used to check engine speed.
SPECIAL TOOLS Tool No. Tool name/Function Quick ACC-1100-15-01 GEN INFO Illustration Gasket® This sealant is used to seal to mating surfaces (e.g., crankcase mating surfaces).
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Standard Limit 5LY1 ---- 1,630 mm (64.1 in) 630 mm (24.8 in) 1,030 mm (40.5 in) 715 mm (28.1 in) 1,150 mm (45.3 in) 85 mm (3.
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Engine Engine type Induction system Displacement Cylinder arrangement Bore × stroke Compression ratio Engine idling speed Fuel Recommended fuel Fuel tank capacity Total (including reserve) Engine oil Lubrication system Oil type or grade Quantity Capacity Air filter oil grade Transmission Recommended oil Periodic oil change Total amount Starting system type Spark plug Model (manufacturer) × quantity Spark plug gap Cylinder head Max.
ENGINE SPECIFICATIONS Item SPEC Standard Piston Piston-to-cylinder clearance Limit 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in) 0.10 mm (0.0039 in) 39.952 ~ 39.969 mm (1.5729 ~ 1.5736 in) ---- Diameter D H D Height H Oversize 1st Oversize 2nd Piston pin bore (in the piston) Diameter 5 mm (0.2 in) ------- ---------- 10.004 ~ 10.015 mm (0.3939 ~ 0.3943 in) 10.045 mm (0.3955 in) 0 mm (0 in) ---- Offset Piston pin Outside diameter 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in) 9.976 mm (0.
ENGINE SPECIFICATIONS Item Standard SPEC Limit Crankshaft F C C E D A Width A Max. runout C Big end side clearance D Big end radial clearance E Small end free play F Clutch Clutch type Clutch shoe Thickness Clutch shoe spring Free length Kickstarter Kickstarter type Kickstarter pinion gear clip force Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Single speed automatic Air filter type 37.90 ~ 37.95 mm (1.
ENGINE SPECIFICATIONS Item Carburetor Model (manufacturer) × quantity Throttle cable free play (at the flange of the throttle grip) ID mark Main jet Main air jet Jet needle Needle jet Cutaway Pilot jet Bypass 1 Valve seat size Starter jet 1 Float height Reed valve Thickness Valve stopper height Valve bending limit Autolube pump Plunger diameter Minimum stroke Maximum stroke SPEC Standard Limit Y14P/1 (TEIKEI) × 1 1.5 ~ 3.5 mm (0.06 ~ 0.14 in) ------- 5LY1 00 #64 2.0 3SOC-3/5 2.090 2.5 #46 0.8 1.
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) Min.
CHASSIS SPECIFICATIONS Item Front brake Brake type Operation Brake lever free play (at lever end) Dram brake type Brake drum inside diameter Lining thickness Rear brake Brake type Operation Brake lever free play (at lever end) Drum brake type Brake drum inside diameter Lining thickness Front suspension Suspension type Front fork type Front fork travel Spring Free length Spring rate (K1) Spring stroke (K1) Spring rate (K2) Spring stroke (K2) Spring rate (K3) Spring stroke (K3) Optional spring available Steer
CHASSIS SPECIFICATIONS Item Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard Unit swing Coil spring/oil damper 45 mm (1.77 in) 173.5 mm (6.83 in) 166.5 mm (6.56 in) 34.5 N/mm (3.45 kgf/mm, 197 lb/in) 0 ~ 45 mm (0 ~ 1.77 in) No 2-8 SPEC Limit ---------170.0 mm (6.
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item System voltage Ignition system Ignition system type Ignition timing Advancer type Pickup coil resistance/color CDI unit model (manufacturer) Ignition coil Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug cap Material Resistance Charging system System type Model (manufacturer) Standard output Stator coil resistance (W-B) Voltage regulator Regulator type Model (manufacturer) No-load regu
ELECTRICAL SPECIFICATIONS Item Electric starting system System type Starter motor Model (manufacturer) Power output Brush Overall length Spring force Armature coil resistance Commutator diameter Mica undercut Starter relay Model (manufacturer) Amperage Coil resistance Horn Horn type Model (manufacturer) × quantity Max.
CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Part to be tightened Spark plug Cylinder head Cylinder head Air shroud Air shroud Fan Autolube pump Air filter Exhaust pipe Muffler Muffler protector Right crankcase Bearing retainer (right crankcase) Transmission cover Sheave cover Air filter case Starter motor ground lead Transmission oil drain bolt Oil filler plug Idle gear plate Kickstarter crank Starter motor Clutch housing Bearing retainer (transmission cover) Primary sheave Stator
TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Part to be tightened Thread size Engine mounting: Engine mounting bolt/nut Rear shock absorber and engine Engine bracket and frame Tail reinforcement Rear shock absorber and frame Lower handlebar holder bracket Upper race Upper steering stem ring nut Fork and relay arm assembly Front shock absorber (upper) Front shock absorber (lower) Front turn signal light Fuel tank (upper) Fuel tank (lower) Fuel sender and fuel tank Seat lock assembly Carrier (upper)
LUBRICATION POINTS AND LUBRICANT TYPES SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips LS O-rings LS Bearings E Piston surface E Piston pin E Cylinder E Transmission case (bearing) LT Right crankcase (bearing retainer) LT Autolube pump LS Starter wheel gear LS Idle gear plate M Secondary drive gear G Kickstarter pinion gear LS Drive axle M Pump drive gear LS Main axle G Main axle (bearing) G 2 - 14 2
LUBRICATION POINTS AND LUBRICANT TYPES SPEC CHASSIS Lubrication Point Symbol Oil seal lips LS O-rings LS Bearings LS Speedometer drive gear LS Front brake camshaft LS Front brake cable LS Throttle cable LS Tube guide (throttle grip) inner surface LS Upper steering stem ring nut LS Upper bearing outer race LS Lower bearing outer race LS Rear brake camshaft LS Centerstand LS 2 - 15
CABLE ROUTING SPEC CABLE ROUTING È Push the brake cable flange in until it contacts the lever holder. É Fasten the handlebar switch leads, brake light switch leads, meter light lead, speedometer cable, brake cables and throttle cable with a plastic locking tie. Ê Pass the left handlebar switch lead, front brake light switch lead, and throttle cable over the cable guide.
CABLE ROUTING SPEC C Crankcase breather hose D Ground lead E Carburetor overflow hose F Rear brake cable G Throttle cable 1 Front turn signal leads (left) 2 Headlight coupler 3 Fuel level gauge coupler 4 Flasher relay lead 5 Horn lead 6 Front turn signal leads (right) 7 Front brake cable 8 Speedometer cable 9 Battery 0 Rectifier/regulator coupler A CDI unit lead coupler B Fuel overflow hose È Fasten the turn signal light leads with the clamp.
CABLE ROUTING SPEC Î Install the fuel tank so that the paint mark on the fuel hose is facing up. Ï Pass the fuel overflow hose through the guide. Ð Pass the crankcase breather hose between the crankcase and rear brake cable. Ñ Pass the carburetor overflow hose on the outside of the rear brake cable. Ê Pass the front brake cable and speedometer cable through the cable guide. Ë Pass the front brake cable and speedometer cable through the hole of the front fender.
CABLE ROUTING B Flasher relay lead C Ignition coil lead D Spark plug lead E Oil hose F Rear turn signal leads G Wire harness 1 Tail/brake light coupler 2 Oil level switch lead 3 Battery leads 4 Battery 5 Starter motor coupler 6 AC magneto coupler 7 Auto choke coupler 8 Headlight coupler 9 Front turn signal leads 0 Horn lead A Main switch lead 2 - 19 SPEC
CABLE ROUTING SPEC Í Pass one end of a plastic clip through the hole of the fuel tank flange, and then fasten the tail/ brake light lead and rear turn signal light leads with the clip. È Fasten the wire harness with a plastic locking tie. É Fasten the wire harness, throttle cable and rear brake cable with plastic locking tie. Ê Fasten the main switch lead with a plastic locking tie. Ë Fasten the wire harness with a plastic locking tie. Ì Pass the wire harness on the inside of the seat bracket.
CABLE ROUTING A CDI unit B Vacuum hose C Rectifier/regulator D Fuel hose E Auto choke lead F Oil delivery hose G Throttle cable H Tail/brake light 1 Ignition coil lead 2 Ignition coil 3 Battery 4 Starter relay 5 Oil hose 6 Oil level switch lead 7 AC magneto lead 8 Fuel sender lead 9 Tail/brake light lead 0 Rear turn signal leads 2 - 21 SPEC
CABLE ROUTING SPEC Ì Fasten the auto choke lead with a plastic clip. Í After connecting the AC magneto coupler and starter motor coupler, cover the couplers with the coupler cover. Î Pass the rear brake cable through the bottom cowling guide. Ï To rear turn signal. È Fasten the wire harness at the white tape marker with a plastic locking tie. É Pass the spark plug lead through the bottom cowling guide.
INTRODUCTION/ PERIODIC MAINTENANCE AND LUBRICATION 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 LUBRICATION CHK ADJ EAU00479 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. EAU03903 NOTE: From 6,000 mi (9,000 km) or 18 months, repeat the maintenance intervals starting from 2,000 mi (3,000 km) or 6 months.
SIDE COVERS AND FOOTREST BOARD CHK ADJ EAS00038 SIDE COVERS AND FOOTREST BOARD 15 Nm (1.5 m • kg, 11 ft • Ib) T. 1 R. 4 3 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 6 2 16 17 14 10 12 15 9 7 7 11 5 11 8 T. R. 18 T. R. Order 1 2 3 4 5 6 7 8 9 10 11 13 7 Nm (0.7 m • kg, 5.1 ft • Ib) 12 Nm (1.2 m • kg, 8.7 ft • Ib) Job/Part Q’ty Remarks Removing the side covers and footRemove the parts in the order listed.
SIDE COVERS AND FOOTREST BOARD 15 Nm (1.5 m • kg, 11 ft • Ib) T. 1 CHK ADJ R. 4 3 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 6 2 16 17 14 10 12 15 9 7 7 11 5 11 8 T. R. 18 T. R. Order 12 13 14 15 16 17 18 Job/Part Rear turn signal bracket Rear turn signal (left) Rear turn signal (right) Tail/brake light Fuel tank cap Tail cover Footrest board Q’ty 1 1 1 1 1 1 1 13 7 Nm (0.7 m • kg, 5.1 ft • Ib) 12 Nm (1.2 m • kg, 8.
FRONT PANEL AND LEG SHIELD CHK ADJ EAS00040 FRONT PANEL AND LEG SHIELD 12 1 11 9 8 2 4 3 10 5 7 13 6 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the front panel and leg shield Footrest board Q’ty Remarks Remove the parts in the order listed. Refer to “SIDE COVERS AND FOOTREST BOARD”.
FRONT PANEL AND LEG SHIELD CHK ADJ 12 1 11 9 8 2 4 3 10 5 7 13 6 Order 11 12 13 Job/Part Fuel level gauge Main switch cover Leg shield Q’ty 1 1 1 Remarks For installation, reverse the removal procedure.
ADJUSTING THE ENGINE IDLING SPEED CHK ADJ EAS00053 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor should be adjusted properly, 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. Remove: • center cover Refer to “SIDE COVERS AND FOOTREST BOARD”. 3.
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 6. Adjust: • throttle cable free play a Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.5 mm (0.06 ~ 0.14 in) EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. @ 1. Check: • throttle cable free play a Out of specification → Adjust.
BLEEDING THE AUTOLUBE PUMP CHK ADJ BLEEDING THE AUTOLUBE PUMP NOTE: The Autolube pump and delivery lines must be bled on the following occasions. • Setting up a new scooter out of the crate. • Whenever the oil tank has run dry. • Whenever any portion of the engine oil system is disconnected. 1. • • • Remove: center cover side cover (right) footrest board Refer to “SIDE COVERS AND FOOTREST BOARD”. • air shroud Refer to “GENERATOR” in chapter 5. 2.
BLEEDING THE AUTOLUBE PUMP/ CHECKING THE SPARK PLUG CHK ADJ NOTE: • Check the bleed screw gasket, and if damaged, replace with a new one. • Place a oil pan under the autolube pump to catch oil. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • air shroud Refer to “GENERATOR AND AUTOLUBE PUMP” in chapter 5. • footrest board • side cover (right) • center cover Refer to “SIDE COVERS AND FOOTREST BOARD”. EAS00060 CHECKING THE SPARK PLUG 1. Disconnect: • spark plug cap 2.
CHECKING THE SPARK PLUG/ MEASURING THE COMPRESSION PRESSURE CHK ADJ 4. Check: • electrodes 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6. Measure: • spark plug gap a (with a wire gauge) Out of specification → Regap. Spark plug gap 0.6 ~ 0.7 mm (0.02 ~ 0.03 in) T. R. 7. Install: • spark plug 20 Nm (2.
MEASURING THE COMPRESSION PRESSURE CHK ADJ CAUTION: @ Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder. 5. Install: • compression gauge 1 Compression gauge YU-33223 3 1 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 600 kPa (6.0 kg/cm, 85.3 psi) Standard 800 kPa (8.0 kg/cm, 113.8 psi) Maximum 1,000 kPa (10.
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ d. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oil Piston wear or damage → Repair. Same as without oil Piston ring(s), cylinder head gasket or piston possibly defective → Repair. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ R.
CHECKING THE ENGINE OIL LEVEL/ REPLACING THE TRANSMISSION OIL CHK ADJ 3. Remove: • oil tank cover Refer to “SIDE COVERS AND FOOTRESTBOARD”. • oil tank cap 1 4. Fill: • engine oil Make sure the engine oil is at the specified level. Fill with oil as necessary. Recommended oil Yamalube 2-cycle oil or 2-stroke engine oil REPLACING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. NOTE: • Place the scooter on a suitable stand. • Make sure the scooter is upright. 2.
REPLACING THE TRANSMISSION OIL CHK ADJ 5. Remove: • transmission oil drain bolt 1 • gasket 1 6. Drain: • transmission oil (completely from the transmission case) 7. Check: • O-ring Damage → Replace. 8. Install: • gasket 1 New • transmission oil drain bolt 2 New T. R. 1 18 Nm (1.8 m · kg, 13 ft · lb) 2 9. Fill: • crankcase (with the specified amount of the recommended transmission oil) Recommended oil SAE 10W30SE Total amount 0.11 L (0.1 Imp qt, 0.12 US qt) 10.
CLEANING THE AIR FILTER ELEMENT CHK ADJ EAS00089 CLEANING THE AIR FILTER ELEMENT NOTE: On the bottom of the air filter case is a check hose 1. If dust or water or both collects in this hose, clean the air filter element and air filter case. @ 1. Remove: • footrest board Refer to “SIDE COVERS AND FOOTREST BOARD”. 2. Remove: • air filter case cover 1 • air filter element 2 3.
CLEANING THE AIR FILTER ELEMENT/ CHECKING THE CARBURETOR JOINT/ CHECKING THE FUEL AND VACUUM HOSES CHK ADJ 6. Install: • air filter element • air filter case cover CAUTION: @ Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating. 7.
CHECKING THE FUEL AND VACUUM HOSES/ CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM CHK ADJ 2. Check: • vacuum hose 1 • fuel hoses 2 Cracks/damage → Replace. Loose connection → Connect properly. 3. Install: • side cover (left) Refer to “SIDE COVERS AND FOOTREST BOARD”. EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1. Check: • crankcase breather hose 1 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: @ Make sure the crankcase breather hose is routed correctly.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE CHK ADJ EAS00109 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 10 ~ 20 mm (0.39 ~ 0.79 in) 2. Adjust: • brake lever free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained. Direction a Brake lever free play is increased.
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE SHOES/ CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ 2. Adjust: • brake lever free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained. Direction a Brake lever free play is increased. Direction b Brake lever free play is decreased. CAUTION: @ After adjusting the brake lever free play, make sure there is no brake drag.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. @ 2. Check: • steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. 3. Remove: • center cover • footrest board Refer to “SIDE COVERS AND FOOTREST BOARD”. • leg shield Refer to “FRONT PANEL AND LEG SHIELD”. 4. Adjust: • steering head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT SHOCK ABSORBER/ CHECKING THE TIRES CHK ADJ 5. Install: • Steering shaft bolt 5 T. R. 42 Nm (4.2 m · kg, 30 ft · lb) 6. Install: • leg shield Refer to “FRONT PANEL AND LEG SHIELD”. • footrest board • center cover Refer to “SIDE COVERS AND FOOTREST BOARD”. 5 EAS00151 CHECKING THE FRONT SHOCK ABSORBER 1. Stand the scooter on a level surface. WARNING @ Securely support the scooter so that there is no danger of it falling over. 2.
CHECKING THE TIRES CHK ADJ WARNING @ • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider and accessories) and the anticipated riding speed. • Operation of an overloaded scooter could cause tire damage, an accident or an injury. NEVER OVERLOAD THE SCOOTER.
CHECKING THE TIRES CHK ADJ WARNING @ È • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • When using tube tires, be sure to install the correct tube. • Always replace a new tube tire and a new tube as a set. • To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. • Patching a punctured tube is not recommended.
CHECKING THE TIRES/CHECKING THE WHEELS CHK ADJ Rear tire Manufacturer Model Size INOUE MB38 80/90-10 (34J) CHENG SHIN C-922 80/90-10 (34J) WARNING @ 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: • Install the tire with the mark pointing in the direction of wheel rotation.
CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS/LUBRICATING THE CENTERSTAND CHK ADJ EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. WARNING @ Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible. 1. Check: • cable sheath Damage → Replace. 2. Check: • cable operation Rough movement → Lubricate.
CHECKING AND CHARGING THE BATTERY CHK ADJ EAS00179 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING @ Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING 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: • center cover Refer to “SIDE COVERS AND FOOTREST BOARD”. • battery box Refer to “ENGINE REMOVAL” in chapter 5. 3 2.
CHECKING AND CHARGING THE BATTERY CHK ADJ b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • battery (refer to the appropriate charging method illustration) WARNING @ Do not quick charge a battery. CAUTION: @ • Never remove the MF battery sealing caps.
CHECKING AND CHARGING THE BATTERY CHK ADJ • 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. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger 3 - 31 CHK ADJ
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger 3 3 - 32
CHECKING AND CHARGING THE BATTERY 6. • 7. • 8. • 9. • CHK ADJ Install: battery Connect: battery lead coupler (to the battery terminals) Check: battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. Lubricate: battery terminal Recommended lubricant Dielectric grease 10.Install: • battery box Refer to “ENGINE REMOVAL” in chapter 5. • center cover Refer to “SIDE COVERS AND FOOTREST BOARD”.
CHECKING THE FUSE CHK ADJ EAS00181 CHECKING THE FUSE CAUTION: @ To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: • center cover Refer to “SIDE COVERS AND FOOTREST BOARD”. • battery Refer to “ENGINE REMOVAL” in chapter 5. 2. Check: • continuity ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. @ Pocket tester YU-03112 b.
CHECKING THE FUSE/REPLACING THE HEADLIGHT CHK ADJ WARNING @ Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Install: • battery Refer to “ENGINE REMOVAL” in chapter 4. • center cover Refer to “SIDE COVERS AND FOOTREST BOARD”. EAS00182 REPLACING THE HEADLIGHT BULB 1.
REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM CHK ADJ 6. Install: • headlight bulb New Secure the new headlight bulb with the headlight bulb holder. CAUTION: @ Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 7.
ADJUSTING THE HEADLIGHT BEAM CHK ADJ 2. Adjust: • headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting knob 2 in direction a or b. Direction a Headlight beam moves to the right. Direction b Headlight beam moves to the left.
FRONT WHEEL AND BRAKE CHAS EAS00517 CHASSIS FRONT WHEEL AND BRAKE 6 9 T. R. 48 Nm (4.8 m • kg, 35 ft • Ib) 5 1 4 7 8 3 4 2 Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. @ 1 2 3 4 5 6 7 Speedometer cable assembly Adjusting nut Front brake cable Pin Axle nut Wheel axle Front wheel assembly 1 1 1 1 1 1 1 4-1 Refer to “INSTALLING THE FRONT WHEEL”.
FRONT WHEEL AND BRAKE CHAS 6 9 T. R. 48 Nm (4.8 m • kg, 35 ft • Ib) 5 1 7 8 3 4 2 Order 8 9 Job/Part Front brake shoe plate Spacer Q’ty 1 1 Remarks For installation, reverse the removal procedure.
FRONT WHEEL AND BRAKE CHAS 1 New 2 4 3 LS 5 6 LS Order 1 2 3 4 5 6 Job/Part Disassembling the front wheel Oil seal Wheel bearing (right) Spacer Collar Wheel bearing (left) Dust seal Q’ty 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “CHECKING THE FRONT WHEEL”. For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE 3 New CHAS LS 1 A 9 4 2 5 New 08 7 LS T. R. Order 1 2 3 4 5 6 7 8 9 0 A 4 Nm (0.4 m • kg, 2.9 ft • Ib) 6 Job/Part Q’ty Remarks Disassembling the front brake shoe Remove the parts in the order listed.
FRONT WHEEL AND BRAKE CHAS EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends → Replace. WARNING @ Do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.
FRONT WHEEL AND BRAKE CHAS 5. Replace: • oil seal New • wheel bearings New 2 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. @ c. Remove the wheel bearings 3 with a general bearing puller. d. Install the new wheel bearings and oil seal in the reverse order of disassembly.
FRONT WHEEL AND BRAKE CHAS EAS00536 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: • brake shoe lining Glazed areas → Repair. Sand the glazed areas with course sandpaper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. @ 2. Measure: • brake shoe lining thickness a Out of specification → Replace. Brake shoe lining thickness limit (minimum) 2 mm (0.08 in) WARNING @ Do not allow oil or grease to contact the brake shoes.
FRONT WHEEL AND BRAKE CHAS EAS00537 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: • brake camshaft 1 • spring • brake shoe wear indicator 2 • brake camshaft lever 3 2 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Align the projection on the brake shoe wear indicator with the notch in the brake camshaft. b. Install the brake camshaft so its punch mark a is positioned as shown. c. Check that the brake shoes are properly positioned. 3 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
FRONT WHEEL AND BRAKE CHAS 5. Tighten: • wheel axle nut T. R. 48 Nm (4.8 m · kg, 35 ft · lb) WARNING @ Make sure the brake cable is routed properly. CAUTION: @ Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.
REAR WHEEL AND BRAKE CHAS EAS00551 REAR WHEEL AND BRAKE T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) 2 New 1 5 6 T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) 4 3 T. R. Order Job/Part Removing the rear wheel and brake Q’ty 105 Nm (10.5 m • kg, 75 ft • lb) Remarks Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.
REAR WHEEL AND BRAKE CHAS LS 4 1 3 A 2 4 0 8 9 5 New LS T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order 1 2 3 4 5 6 7 8 9 0 A 6 New 7 Job/Part Removing the rear brake shoe plate Adjusting nut Rear brake cable Pin Brake shoe Brake shoe spring (pin side) Brake shoe spring (brake camshaft side) Brake camshaft lever Brake shoe wear indicator Spring Brake camshaft O-ring Q’ty Remarks Remove the parts in the order listed. 1 1 1 2 1 1 1 1 1 1 2 For installation, reverse the removal procedure.
REAR WHEEL AND BRAKE CHAS EAS00565 CHECKING THE REAR WHEEL 1. Check: • rear wheel Refer to “CHECKING THE FRONT WHEEL”. 2. Check: • tire • rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: • radial wheel runout • lateral wheel runout Refer to “CHECKING THE FRONT WHEEL”. EAS00569 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: • brake shoe lining Glazed areas → Repair.
REAR WHEEL AND BRAKE CHAS 3. Measure: • brake drum inside diameter a Out of specification → Replace the wheel. Brake drum inside diameter limit (maximum) 110.5 mm (4.35 in) 4. Check: • brake drum inner surface Oil deposits → Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches → Repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: • brake camshaft Damage/wear → Replace. EAS00570 INSTALLING THE BRAKE SHOE PLATE 1.
REAR WHEEL AND BRAKE CHAS EAS00573 INSTALLING THE BRAKE SHOES 1. Install: • brake camshaft lever 1 1 NOTE: • Align the punch mark a in the brake camshaft with the mark b on the brake camshaft lever. • Lubricate the brake camshaft and pin with lithium soap base grease. @ WARNING @ After installing the rear brake camshaft, remove any excess grease. 2. Install: • brake shoes NOTE: Do not to damage the springs during installation. @ INSTALLING THE REAR WHEEL 1. Tighten: • wheel axle nut T. R.
FRONT SHOCK ABSORBER ASSEMBLIES CHAS EAS00647 FRONT SHOCK ABSORBER ASSEMBLIES 4 Order 1 2 3 4 Job/Part Q’ty Remarks Removing the front shock absorber Remove the parts in the order listed. assemblies The following procedure applies to both of the front shock absorbers. Front panel Refer to “FRONT PANEL AND LEG SHIELD” in chapter 3. Front wheel Refer to “FRONT WHEEL AND BRAKE”.
FRONT SHOCK ABSORBER ASSEMBLIES CHAS CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both front shock absorber assemblies. 1. Check: • front shock absorber rod Bends/damage → Replace the front shock absorber assembly. • front shock absorber Oil leaks → Replace the front shock absorber assembly. • spring Damage/wear → Replace the front shock absorber assembly. • bolt Bends/damage/wear → Replace. INSTALLING THE RELAY ARM 1.
HANDLEBAR CHAS EAS00664 HANDLEBAR 4 Order 1 2 3 4 5 6 Job/Part Removing the handlebar switches and handlebar grips Center cover Q’ty Remarks Remove the parts in the order listed. Refer to “SIDE COVERS AND FOOTREST BOARD” in chapter 3. Rear view mirror (left/right) Front brake cable Rear brake cable Throttle cable holder Right handlebar switch Throttle grip 2 1 1 1 1 1 4 - 17 Loosen.
HANDLEBAR Order 7 8 9 10 Job/Part Left handlebar switch Upper handlebar holder Handlebar Handlebar grip CHAS Q’ty Remarks 1 Refer to “INSTALLING THE HANDLE2 BAR”. 1 1 Refer to “REMOVING THE HANDLEBAR”. For installation, reverse the removal procedure.
HANDLEBAR CHAS EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING @ Securely support the scooter so that there is no danger of it falling over. 2. Remove: • handlebar grip 1 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. @ EAS00668 CHECKING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING 1 @ Securely support the scooter so that there is no danger of it falling over. 2.
HANDLEBAR CHAS EAS00671 INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING @ Securely support the scooter so that there is no danger of it falling over. 2. Install: • handlebar 1 • upper handlebar holders 2 1 2 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) CAUTION: @ • First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. NOTE: • Install the upper handlebar holders with the grooves a facing inward.
HANDLEBAR CHAS 4. Install: • throttle grip • throttle cable NOTE: Lubricate the inside of the throttle grip with a thin coat of lithium soap base grease and install it onto the handlebar. @ 5. Install: • right handlebar switch 1 WARNING @ Make sure smoothly. the throttle grip operates NOTE: Align the mating surfaces of the right handlebar switch with the punch mark a on the handlebar. @ 1 6. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.
STEERING HEAD CHAS STEERING HEAD Order Job/Part Removing the lower handlebar holder Footrest board Q’ty Front panel/leg shield Front shock absorber assemblies 1 2 3 4 5 6 Handlebar Meter light lead coupler Speedometer assembly Speedometer cable Lower handlebar holder cover Rubber cover Lower handlebar holder bracket 1 1 1 1 1 1 4 - 22 Remarks Remove the parts in the order listed. Refer to “SIDE COVERS AND FOOTREST BOARD” in chapter 3. Refer to “FRONT PANEL AND LEG SHIELD” in chapter 3.
STEERING HEAD CHAS 4 Order 1 2 3 4 5 6 7 8 Job/Part Removing the fork Cover Upper steering stem ring nut Upper race Fork Upper bearing Lower bearing Upper bearing outer race Lower bearing outer race Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
STEERING HEAD CHAS EAS00680 REMOVING THE FORK 1. Stand the scooter on a level surface. WARNING @ Securely support the scooter so that there is no danger of it falling over. 1 2. Remove: • upper steering stem ring nut 1 • upper race 2 NOTE: Hold the upper race with the steering nut wrench (45 mm), and then remove the upper steering stem ring nut with the steering nut wrench.
STEERING HEAD CHAS 3. Replace: • bearings • bearing races ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Install new bearing races. CAUTION: @ If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: • Always replace the bearings and bearing races as a set. • Whenever the steering head is disassembled, replace the rubber seal. @ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00685 REAR SHOCK ABSORBER ASSEMBLY T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 1 T. R. Order 1 15 Nm (1.5 m • kg, 11 ft • Ib) Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Side cover (left) Refer to “SIDE COVERS AND FOOTREST BOARD” in chapter 3. Rear 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. WARNING @ Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated. @ 2. Remove: • rear shock absorber assembly EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly.
ENGINE REMOVAL ENG ENGINE ENGINE REMOVAL T. R. T. 84 Nm (8.4 m • kg, 61 ft • Ib) R. 28 Nm (2.8 m • kg, 20 ft • Ib) T. R. 15 Nm (1.5 m • kg, 11 ft • Ib) 4 3 14 New 15 2 1 10 11 12 9 8 6 7 16 13 T. R. 1 2 3 4 5 6 7 8 9 R. Order T. 5 13 Nm (1.3 m • kg, 9.4 ft • Ib) 11 Nm (1.1 m • kg, 8.0 ft • Ib) Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed.
ENGINE REMOVAL T. R. T. 84 Nm (8.4 m • kg, 61 ft • Ib) ENG R. 28 Nm (2.8 m • kg, 20 ft • Ib) T. R. 15 Nm (1.5 m • kg, 11 ft • Ib) 4 3 14 New 15 2 1 10 11 12 9 8 6 7 16 13 T. R. R. Order 10 11 12 13 14 15 16 T. 5 Job/Part Adjusting nut Rear brake cable Pin Kickstarter crank Bolt (rear shock absorber-lower) Engine mounting bolt/nut Engine assembly Q’ty 1 1 1 1 1 1/1 1 13 Nm (1.3 m • kg, 9.4 ft • Ib) 11 Nm (1.1 m • kg, 8.
ENGINE REMOVAL ENG EAS00192 INSTALLING THE ENGINE 1. Install: • engine mounting bolt/nut 1 T. R. 84 Nm (8.4 m · kg, 61 ft · lb) • bolt (rear shock absorber-lower) 2 T. R. 15 Nm (1.5 m · kg, 11 ft · lb) 2. Install: • kickstarter crank T. R. 11 Nm (1.1 m · kg, 8.0 ft · lb) T. • muffler • bolts 28 Nm (2.8 m · kg, 20 ft · lb) • exhaust pipe bolts R. T. R. 5-3 13 Nm (1.3 m · kg, 9.
CYLINDER HEAD, CYLINDER AND PISTON ENG CYLINDER HEAD, CYLINDER AND PISTON T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) New T. R. 2 13 Nm (1.3 m • kg, 9.4 ft • Ib) New 13 E New 6 1 5 4 7 8 New 12 11 9 3 T. R. T. R. 1 2 3 4 5 6 7 8 9 5 8 20 Nm (2.0 m • kg, 14 ft • Ib) Order 10 New E E 14 Nm (1.4 m • kg, 10 ft • Ib) Job/Part Q’ty Remarks Removing the cylinder head, cylinRemove the parts in the order listed.
CYLINDER HEAD, CYLINDER AND PISTON ENG T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) New T. R. 2 13 Nm (1.3 m • kg, 9.4 ft • Ib) New 13 E New 6 1 5 4 7 8 New 12 11 9 3 8 T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) T. R. Order 10 11 12 13 10 New E E 14 Nm (1.4 m • kg, 10 ft • Ib) Job/Part Bearing Piston Piston ring set Cylinder gasket Q’ty 1 1 1 1 Remarks For installation, reverse the removal procedure.
CYLINDER HEAD, CYLINDER AND PISTON ENG EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 3 2 CAUTION: @ Do not use a hammer to drive the piston pin out. 1 NOTE: Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. @ 2.
CYLINDER HEAD, CYLINDER AND PISTON ENG ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1 a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows. d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. 2 NOTE: To ensure an even surface, rotate the cylinder head several times.
CYLINDER HEAD, CYLINDER AND PISTON ENG b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer. a 5 mm (0.20 in) from the bottom edge of the piston Piston size “P” Standard 39.952 ~ 39.969 mm (1.5729 ~ 1.5736 in) Oversize 1 40.25 mm (1.58 in) Oversize 2 40.5 mm (1.59 in) d. If out of specification, replace the piston and piston rings as a set. e.
CYLINDER HEAD, CYLINDER AND PISTON ENG Piston ring side clearance Top ring 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in) : 0.10 mm (0.0039 in) 2nd ring 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in) : 0.10 mm (0.0039 in) 2. Install: • piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown. @ a 10 mm (0.39 in) 3. Measure: • piston ring end gap Out of specification → Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured.
CYLINDER HEAD, CYLINDER AND PISTON ENG 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in) : 9.976 mm (0.3928 in) 3. Measure: • piston pin bore diameter (in the piston) 1 Out of specification → Replace the piston pin. Piston pin bore diameter (in the piston) 10.004 ~ 10.015 mm (0.3939 ~ 0.3943 in) : 10.045 mm (0.3955 in) 4.
CYLINDER HEAD, CYLINDER AND PISTON ENG EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: • top ring 1 • 2nd ring 2 NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers face up. • Before installing the cylinder, align the piston ring end gaps to the respective knock pins as shown. @ 1 2 2. • • • • 1 2 3 New Install: bearing piston 1 piston pin 2 piston pin clip 3 New NOTE: • Lubricate the piston pin with engine oil.
CYLINDER HEAD, CYLINDER AND PISTON 3. • 4. • • • 2 1 New ENG Install: cylinder gasket 1 New Lubricate: piston piston rings cylinder (with the recommended lubricant) Recommended lubricant Yamalube 2-cycle oil or 2-stroke engine oil 5. Install: • cylinder 2 NOTE: While compressing the piston rings with one hand, install the cylinder with the other hand. @ • cylinder head gasket • cylinder head T. Cylinder nut 14 Nm (1.4 m · kg, 10 ft · lb) R.
KICKSTARTER ENG EAS00338 KICKSTARTER SHEAVES COVER 6 5 4 3 6 2 T. R. 11 Nm (1.1 m • kg, 8.0 ft • Ib) 1 Order 1 2 3 4 5 6 Job/Part Removing the sheave cover Air filter case assembly Transmission oil Kickstarter crank Cover Damper Ground lead Sheave cover Dowel pin Q’ty Remarks Remove the parts in the order listed. Refer to “CARBURETOR” in chapter 6. Drain. 1 1 1 1 1 2 For installation, reverse the removal procedure.
KICKSTARTER ENG 5 6 2 1 LS 7 4 Order 1 2 3 4 5 6 7 Job/Part Disassembling the kickstarter shaft Kickstarter pinion gear Kickstarter pinion gear clip Circlip Washer Kickstarter shaft Kickstarter spring Spacer Q’ty 3 New Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
KICKSTARTER ENG EAS00339 CHECKING THE KICKSTARTER 1. Check: • kickstarter shaft • kickstarter pinion gear Damage/wear → Replace. 2. Check: • kickstarter spring Damage/wear → Replace. 3. Measure: • kickstarter pinion gear clip force (with the spring gauge) Out of specification → Replace the kickstarter pinion gear clip. Kickstarter pinion gear clip force 0.15 ~ 0.25 kg (0.34 ~ 0.56 lb) EAS00340 INSTALLING THE KICKSTARTER 1.
BELT DRIVE ENG EAS00316 BELT DRIVE 16 New 40 Nm (4.0 m • kg, 29 ft • Ib) T. R. 4 3 13 11 14 2 10 1 9 8 7 6 R. 5 T. 15 30 Nm (3.0 m • kg, 22 ft • Ib) 12 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the V-belt, primary and secondary pulley Sheaves cover Air shroud/fan Q’ty Remarks Remove the parts in the order listed. Refer to “KICK STARTER”. Refer to “GENERATOR AND AUTOLUBE PUMP”.
BELT DRIVE ENG 16 New 40 Nm (4.0 m • kg, 29 ft • Ib) T. R. 4 3 13 11 14 2 10 1 9 8 7 6 R. 5 T. 15 30 Nm (3.0 m • kg, 22 ft • Ib) 12 Order 11 12 13 14 15 16 Job/Part Collar Primary sliding sheave Slider Cam Primary pulley weight Gasket Q’ty 1 1 1 1 6 1 Remarks For installation, reverse the removal procedure.
BELT DRIVE ENG LS 3 New 2 9 6 5 1 4 9 3 New 7 T. R. 50 Nm (5.0 m • kg, 36 ft • Ib) 8 New 0 5 LS LS Order 1 2 3 4 5 6 7 8 9 0 Job/Part Q’ty Remarks Disassembling the secondary pulley Remove the parts in the order listed. Clutch carrier nut 1 Clutch carrier 1 Clutch spring 2 Spring 1 Spring seat 1 Pin 2 Secondary sliding sheave 1 O-ring 2 Oil seal 1 Secondary fixed sheave 1 For assembly, reverse the disassembly procedure.
BELT DRIVE ENG EAS00318 REMOVING THE SECONDARY PULLEY AND V-BELT 1. Remove: • air shroud • fan Refer to “GENERATOR AND AUTOLUBE PUMP”. 2. Remove: • clutch housing nut 1 • clutch housing 2 2 1 3 NOTE: While holding the clutch housing with the sheave holder 3, loosen the clutch housing nut. @ Sheave holder YU-01701 3.
BELT DRIVE ENG EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: • primary sheave nut 1 • conical spring washer • kickstarter one-way clutch • claw washer • primary fixed sheave 2 2 1 NOTE: While holding the generator rotor with the rotor holding tool 3, loosen the primary sheave nut. 3 @ Rotor holding tool YU-01235 EAS00319 DISASSEMBLING THE SECONDARY PULLEY 1. Remove: • clutch carrier nut 1 1 NOTE: Install the clutch spring holder 2 onto the secondary pulley as shown.
BELT DRIVE ENG 2. Measure: • clutch shoe thickness Out of specification → Replace the clutch shoes as a set. Clutch shoe thickness 4.0 mm (0.157 in) : 1.0 mm (0.039 in) 3. Check: • clutch housing inside diameter a Out of specification → Replace the clutch housing. Clutch housing inside diameter 105.0 mm (4.13 in) : 105.5 mm (4.15 in) EAS00322 CHECKING THE SECONDARY PULLEY 1.
BELT DRIVE ENG EAS00320 CHECKING THE V-BELT 1. Check: • V-belt 1 Cracks/damage/wear → Replace. Grease/oil → Check the primary and secondary pulleys. 2. Measure: • V-belt width a Out of specification → Replace. 1 V-belt width 16.6 mm (0.65 in) : 15.0 mm (0.59 in) EAS00321 CHECKING THE PRIMARY PULLEY WEIGHTS The following procedure applies to all of the primary pulley weights. 1. Check: • primary pulley weight Cracks/damage/wear → Replace. 2.
BELT DRIVE ENG EAS00324 1 ASSEMBLING THE SECONDARY PULLEY 1. Lubricate: • secondary fixed sheave’s inner surface 1 • secondary sliding sheave’s inner surface 2 • oil seals (with the recommended lubricant) LS 2 LS Recommended lubricant Lithium soap base grease 2. Install: • secondary sliding sheave 1 3 NOTE: Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3. @ 1 2 Oil seal guide YM-01409 3. Install: • guide pin 1 1 4.
BELT DRIVE 5. • • • • 4 3 5 ENG Install: secondary fixed sheave 1 secondary sliding sheave 2 spring clutch carrier 3 NOTE: Attach the clutch spring holder 4 onto the secondary pulley as shown. Then, compress the spring, and tighten the clutch carrier nut 5. @ 1 2 Clutch spring holder YS-28891 EAS00323 INSTALLING THE PRIMARY PULLEY 1. Clean: • primary fixed sheave • primary sliding sheave • spacer • primary pulley weights 1 3 1 2 3 2. • • • Install: primary pulley weights 1 slider 2 cams 3 3.
BELT DRIVE 0 4. • • • • • • A 7 8 9 0 B Install: washer 7 primary fixed sheave 8 claw washer 9 kickstarter one-way clutch 0 conical spring washer A primary sheave nut B T. R. A ENG 30 Nm (3.0 m · kg, 22 ft · lb) NOTE: • Install the conical spring washer A as shown in the illustration. • While holding the generator rotor with the rotor holding tool, tighten the primary sheave nut. Rotor holding tool YU-01235 EAS00325 INSTALLING THE BELT DRIVE 1. Install: • clutch carrier nut 1 1 T. R.
BELT DRIVE 2. Install: • V-belt 1 • secondary pulley 2 3 1 ENG CAUTION: @ Do not allow grease to contact the V-belt, secondary pulley or clutch assembly. 2 NOTE: • The V-belt must be installed, with the arrow 3 forward. • Install the V-belt on the primary pulley, then install the secondary pulley 2 along with the V-belt 1. @ 3. Install: • clutch housing 1 • clutch housing nut 2 1 T. R. 40 Nm (4.
STARTER CLUTCH AND STARTER MOTOR ENG STARTER CLUTCH AND STARTER MOTOR T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) 8 9 LS New 2 3 2 1 T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) 7 LS 6 4 5 M Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the starter clutch and starter motor Sheaves cover Primary sliding sheave Idle gear plate Washer Idle gear Starter clutch assembly Starter wheel gear Bearing Spacer Starter motor coupler Starter motor Q’ty Remarks Remove the parts in the order listed.
STARTER CLUTCH AND STARTER MOTOR ENG EAS00351 CHECKING THE STARTER CLUTCH 1. Check: • starter clutch rollers 1 • starter clutch spring caps 2 • starter clutch springs 3 Damage/wear → Replace. 1 2 3 2. Check: • starter wheel gear 1 Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: • starter wheel gear contacting surface Damage/pitting/wear → Replace the starter wheel gear. 1 4. Check: • starter clutch operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
STARTER CLUTCH AND STARTER MOTOR ENG 2. Install: • starter wheel gear 1 • starter clutch assembly 2 1 NOTE: Install the starter clutch assembly 1 while turning the starter wheel gear 2 clockwise.
TRANSMISSION ENG EAS00419 TRANSMISSION 8 LT LT 10 3 2 New 1 9 New 3 11 G New LS 7 New T. R. 6 5 9 Nm (0.9 m • kg, 6.5 ft • Ib) 4 5 G T. R. Order 1 2 3 4 5 6 7 8 18 Nm (1.8 m • kg, 13 ft • Ib) Job/Part Removing the transmission Transmission oil Rear wheel Q’ty Secondary pulley Transmission cover Gasket Dowel pin Washer Conical spring washer Main axle Drive axle Secondary drive gear 1 1 2 1 1 1 1 1 5 - 30 Remarks Remove the parts in the order listed. Drain.
TRANSMISSION ENG 8 LT LT 10 3 2 New 1 9 New 3 11 G New LS 7 New T. R. 6 5 9 Nm (0.9 m • kg, 6.5 ft • Ib) 4 G T. R. Order 9 10 11 18 Nm (1.8 m • kg, 13 ft • Ib) Job/Part Circlip Bearing Oil seal Q’ty 1 1 1 Remarks For installation, reverse the removal procedure.
TRANSMISSION ENG EAS00425 CHECKING THE TRANSMISSION 1. Check: • drive axle • main axle • secondary drive gear Damage/wear → Replace. 2. Check: • bearing Rough movement → Replace. 3. Check: • secondary drive gear movement Rough movement → Replace the defective part. 4. Check: • circlips Bends/damage/looseness → Replace.
GENERATOR AND AUTOLUBE PUMP ENG GENERATOR AND AUTOLUBE PUMP STATOR COIL ASSEMBLY 5 1 New 8 6 7 4 2 T. R. 38 Nm (3.8 m • kg, 27 ft • Ib) 3 Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Center cover, side cover (right) and Refer to “SIDE COVERS AND FOOTfootrest board REST BOARD” in chapter 3. Coupler cover 1 Air shroud 1 Fan 1 Generator rotor 1 Stator coil assembly coupler 1 Disconnect.
GENERATOR AND AUTOLUBE PUMP ENG AUTOLUBE PUMP 7 New 3 4 5 6 New 9 New 3 1 8 LS 2 T. R. Order 1 2 3 4 5 6 7 8 9 6 Nm (0.6 m • kg, 4.3 ft • Ib) Job/Part Removing the autolube pump Stator coil assembly Q’ty Spark plug cap Cylinder head cover Circlip Pump drive gear Pin Oil hose Oil delivery hose Autolube pump O-ring Remarks Remove the parts in the order listed. Refer to “GENERATOR AND AUTOLUBE PUMP”. 1 1 2 1 1 1 1 1 1 For installation, reverse the removal procedure.
GENERATOR AND AUTOLUBE PUMP ENG EAS00346 REMOVING THE GENERATOR 1. Remove: • generator rotor nut 1 • washer 2 1 NOTE: While holding the generator rotor 2 with the rotor holding tool 3, loosen the generator rotor nut. @ 3 Rotor holding tool YU-01235 2. Remove: • generator rotor 1 (with the flywheel puller set 2) • woodruff key 1 2 Flywheel puller set YU-90105 CHECKING THE AUTOLUBE PUMP 1. Check: • oil hose 1 Obstruction → Blow out with compressed air. 2.
GENERATOR AND AUTOLUBE PUMP ENG EAS00354 LS INSTALLING THE GENERATOR 1. Install: • gasket 1 New • woodruff key • generator rotor 2 • washer • generator rotor nut 1 NOTE: • Clean the tapered portion of the crankshaft and the generator rotor hub. • When installing the generator rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft. • Do not allow the rotor holding tool to touch the projection on the generator rotor. @ 2 2. Tighten: • generator rotor nut 1 T. R.
CRANKCASE ENG CRANKCASE T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 9 Nm (0.9 m • kg, 6.5 ft • Ib) (6) LT LT 5 7 6 8 9 New 10 11 New 7 1 T. R. 11 Nm (1.1 m • kg, 8.
CRANKCASE T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) ENG T. R. 9 Nm (0.9 m • kg, 6.5 ft • Ib) (6) LT LT 5 7 6 8 9 New 10 11 New 7 1 T. R. 11 Nm (1.1 m • kg, 8.0 ft • Ib) LS 2 3 5 New 4 Order 1 2 3 4 5 6 Job/Part Cover Intake manifold Reed valve assembly Valve seat gasket Bearing retainer Right crankcase 7 8 9 10 11 Dowel pin Engine mount spacer Circlip Bearing Oil seal Q’ty Remarks 1 1 1 1 1 1 Refer to “DISASSEMBLING THE CRANKCASE”.
CRANKCASE ENG EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase screws 1 NOTE: Loosen each screw 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the screws are fully loosened, remove them. @ 2. Remove: • right crankcase 1 CAUTION: @ 2 Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly.
CRANKCASE ENG EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: • bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. 2. Check: • oil seals Damage/wear → Replace. CHECKING THE REED VALVE 1. Measure: • reed valve bending a Out of specification → Replace. Reed valve bending : 0.2 mm (0.008 in) 2. Measure: • valve stopper height b Out of specification → Adjust stopper/ replace valve stopper. Valve stopper height 7.0 ~ 7.4 mm (0.
CRANKCASE ENG EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: • sealant (onto the crankcase mating surfaces) 1 Quick Gasket® ACC-1100-15-01 1 NOTE: Do not allow any sealant to come into contact with the oil gallery. @ 2. Install: • dowel pins 1 2 3. Install: • left crankcase 1 (onto the right crankcase) Use the crankshaft installing tool. 3 4 Crankshaft installer pot 2 YU-90058 Crankshaft installer bolt 3 YU-90060 Crankshaft installer adapter (M10) 4 YU-90062 1 4. Install: • crankcase screws T.
CRANKSHAFT ENG EAS00381 CRANKSHAFT 3 New LS E 2 1 2 5 4 E E New 3 Order 1 2 3 4 Job/Part Removing the crankshaft Engine assembly Crankcase Q’ty Crankshaft Bearing Oil seal Crankcase 1 LS Remarks Remove the parts in the order listed. Refer to “ENGINE REMOVAL”. Separate. Refer to “CRANKCASE”. 1 2 1 1 For installation, reverse the removal procedure.
CRANKSHAFT ENG EAS00388 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • crankshaft assembly 1 NOTE: • Remove the crankshaft assembly with the crankcase separating tool 2. • Make sure the crankcase separating tool is centered over the crankshaft assembly. @ 1 2 Crankcase separating tool YU-01135 EAS00394 CHECKING THE CRANKSHAFT 1. Measure: • crankshaft runout 1 Out of specification → Replace the crankshaft, bearing(s) or both. NOTE: Turn the crankshaft slowly. @ Maximum crankshaft runout 0.03 mm (0.
CRANKSHAFT ENG 4. Check: • bearing Cracks/damage/wear → Replace. EAS00408 5 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft installing tool 4 3 1 Crankshaft installer pot 1 YU-90058 Crankshaft installer bolt 2 YU-90060 Crankshaft installer adapter (M10) 3 YU-90062 2 2. Install: • crankshaft assembly 4 (to the left crankcase 5) CAUTION: @ To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with grease and each bearing with engine oil.
CARBURETOR CARB CARBURETION CARBURETOR 5 4 8 7 2 10 9 3 Order 1 2 3 4 5 6 7 8 9 10 1 6 Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Center cover, side cover (left) and footRefer to “SIDE COVERS AND FOOTrest board REST BOARD” in chapter 3. Air filter case assembly 1 Clip 1 Auto choke coupler 1 Disconnect. Oil delivery hose 1 Clamp screw (intake manifold) 1 Loosen.
CARBURETOR CARB 4 5 1 3 6 2 E D C B A 0 9 8 7 Order Job/Part Disassembling the carburetor Q’ty Remarks Remove the parts in the order listed. NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot air screw is turned out from the seated position to its set position.
CARBURETOR CARB 4 5 1 3 6 2 E D C B A 0 9 8 7 Order 8 9 0 A B C D E Job/Part O-ring Float pivot pin Float Needle valve Main jet Needle jet Pilot jet Carburetor body Q’ty 1 1 1 1 1 1 1 1 Remarks For assembly, reverse the disassembly procedure.
CARBURETOR CARB EAS00485 CHECKING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot air screw is turned out from the seated position to its set position. 1. • • • Check: carburetor body float chamber jet housing Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b.
CARBURETOR CARB 7. Check: • throttle valve 1 Damage/scratches/wear→ Replace. 1 8. • • • • 1 2 3 4 Check: jet needle kit 1 needle jet 2 main jet 3 pilot jet 4 Bends/damage/wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 9. Check: • throttle valve movement Insert the throttle valve into the carburetor body and move it up and down. Tightness → Replace the piston valve. 10.Check: • vacuum hose • fuel hose Cracks/damage/wear → Replace. Obstruction → Clean.
CARBURETOR 2. • • • • 1 4 3 CARB Install: needle valve 1 float 2 float pivot pin 3 screw 4 2 3. Install: • float chamber 1 1 4. • 5. • • • Install: starter plunger kit Install: throttle valve jet needle holder jet needle kit NOTE: Align the groove of the throttle valve with the projection of the carburetor body. 6 6. Install: • throttle cable EAS00492 INSTALLING THE CARBURETOR 1. Adjust: • engine idling speed Engine idling speed 1,800 r/min Refer to “ADJUSTING THE IDLING SPEED” in chapter 3. 2.
CARBURETOR CARB EAS00499 MEASURING AND ADJUSTING THE FLOAT HEIGHT 1. Measure: • float height a Out of specification → Replace the needle valve. Float height 15 ~ 17 mm (0.59 ~ 0.67 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the carburetor. b. Hold the carburetor in an upside down position. c. Measure the distance from the mating surface of the float chamber to the top of the float. d. If the float height is not within specification, check the needle valve. e.
CARBURETOR CARB Starter plunger opens. Perform step (3). Starter plunger closes. Replace the autochoke assembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1 3. Check: • autochoke assembly 2 B ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ B a. Connect the autochoke assembly leads to a 12.0-V battery for five minutes. Positive battery lead 1 → black Negative battery lead 2 → black 4 3 b. Connect a 3.3-mm hose 3 to the starter air passage 4 and blow into the hose. Starter plunger opens.
ELEC ELECTRICAL COMPONENTS – + EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 8 Battery 9 Spark plug cap 0 Ignition coil A Wire harness B Turn signal relay C Horn 1 Main switch 2 Starter relay 3 Fuel sender 4 Oil level switch 5 CDI unit 6 Rectifier/regulator 7 Main fuse 2 1 3 C 4 B 5 6 A 7 9 8 0 7-1
SWITCHES ELEC – + EAS00730 “∞” SWITCHES “0” 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. “Ω×1” CAUTION: @ Never insert the tester probes into the coupler terminal slots 1. 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 → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch.
CHECKING THE SWITCHES ELEC – + 1 Front brake light switch 2 Turn signal switch 3 Dimmer switch 4 Horn switch 5 Main switch 6 Rear brake light switch 7 Start switch 8 Engine stop switch 9 Main fuse 7 7-4
CHECKING THE BULBS AND BULB SOCKETS ELEC – + EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. No continuity → Repair or replace the bulb, bulb socket or both. 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: • bulb WARNING @ Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: @ • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YU-03112 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.
7-8 B (RED) Br G B Br Gy Br Br G (RED) B X ON OFF 1 G B B G G Z Y R B R [ 2 R Br Gy R B T B Br Br/W Y Gy Br B Y Br/W Gy R R R S R 3 R Br Gy B Gy U Br 6 5 R V B Y W L/W L/W B 7 Y/R 4 R W R Br/W L/Y B P P K Br L/Y L/W B L/W M L L/W B L/W B R G/Y R L/W 8 R G/Y R A R R R B N R B (BLACK) A B B 9 L B G Y G Y Y B B B A 0 Y/R B B B Q N O Br Br/W B Dg Ch B Dg Ch Q Br/W Br/W J B P L Ch P Br/W B Dg P (RED) Ch
IGNITION SYSTEM EAS00736 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no spark or intermittent spark). • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse 2. battery 3. spark plug 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. pickup coil resistance 8. main switch 9. engine stop switch 10.wiring (of the entire ignition system) Minimum open-circuit voltage 12.
IGNITION SYSTEM EAS00742 ELEC – + EAS00744 4. Ignition spark gap 5. Spark plug cap resistance • Disconnect the spark plug cap from the spark plug. • Connect the ignition checker/dynamic spark tester 1 as shown. • Remove the spark plug cap from the spark plug lead. • Connect the pocket tester (“Ω × 1k” range) to the spark plug cap as shown. • Measure the spark plug cap resistance. 2 Spark plug cap • Set the main switch to “ON”. • Measure the ignition spark gap a.
ELEC IGNITION SYSTEM EAS00746 – + EAS00748 6. Ignition coil resistance 7. Pickup coil resistance • Disconnect the ignition coil connectors from the ignition coil terminals. • Connect the pocket tester (Ω × 1) to the ignition coil as shown. • Disconnect the stator coil assembly coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the pickup coil terminal as shown.
IGNITION SYSTEM ELEC – + EAS00750 9. Engine stop switch • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? YES NO Replace the right handlebar switch. EAS00754 10.Wiring • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the ignition system’s wiring properly connected and without defects? YES Replace the ignitor unit. NO Properly connect or repair the ignition system’s wiring.
7 - 13 B (RED) Br G B Br Gy Br Br G (RED) B X ON OFF 1 G B B G G Z Y R B R [ 2 R Br Gy R B T B Br Br/W Y Gy Br B Y Br/W Gy R R R S R 3 R Br Gy B Gy U Br 6 5 R V B Y W L/W L/W 7 R 4 B Y/R W R Br/W L/Y B P P K Br L/Y L/W B L/W M L L/W B L/W B R G/Y R L/W 8 R G/Y R A R R R B N R B (BLACK) A B B 9 L B G Y G Y Y B B B A 0 Y/R B B B Q N O Br Br/W B Dg Ch B Dg Ch Q Br/W Br/W J B P L Ch P Br/W B Dg P (RED) C
ELECTRIC STARTING SYSTEM EAS00757 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse 2. battery 3. starter motor 4. starter relay 5. main switch 6. engine stop switch 7. start switch 8. front brake light switch 9. rear brake light switch 10.wiring (of the entire starting system) Minimum open-circuit voltage 12.
ELECTRIC STARTING SYSTEM EAS00761 ELEC – + EAS00750 4. Starter relay 6. Engine stop switch • Remove the starter relay from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay coupler as shown. • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? NO YES Negative battery terminal → green/yellow 1 Positive battery terminal → blue/white 2 Replace the right handlebar switch.
ELECTRIC STARTING SYSTEM ELEC – + 9. Rear brake light switch • Check the rear light switch for continuity. Refer to “CHECKING THE SWITCHES” • Is the rear brake light switch OK? YES NO Replace the rear brake light switch. EAS00766 10.Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? YES The starting system circuit is OK. NO Properly connect or repair the starting system’s wiring.
STARTER MOTOR ELEC – + EAS00767 STARTER MOTOR Order 1 2 Job/Part Removing the starter motor Air shroud Q’ty Starter motor coupler Starter motor assembly Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD, CYLINDER AND PISTON” in chapter 5. 1 1 For installation, reverse the removal procedure.
STARTER MOTOR ELEC – + EAS00768 2 3 4 6 1 New 5 LS Order 1 2 3 4 5 6 Job/Part Disassembling the starter motor O-ring Starter motor yoke Armature assembly Gasket Brush holder Starter motor cover Q’ty Remarks Remove the parts in the order listed. 1 1 1 2 1 1 7 For assembly, reverse the disassembly procedure.
STARTER MOTOR ELEC – + EAS00769 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 14.8 mm (0.58 in) 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 1.15 mm (0.
STARTER MOTOR ELEC – + Armature coil Commutator resistance 1 0.065 ~ 0.079 Ω at 20 °C (68 °F) Insulation resistance 2 Above 1 MΩ at 20 °C (68 °F) b. If any resistance is out of specification, replace the starter motor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 0.9 mm (0.04 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 2.32 ~ 3.48 N (236.
– ELEC CHARGING SYSTEM + EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM R Br Gy W B R Y/R W/L B Y/R W B W/L L/Y O L/W Br (BLACK) R Br Gy W/R W/L W Y/R R 4 R W W Y/R Y/R B L/W R G/Y R W/L W/L 0 O B Br B L/Y B L/W 8 R R L/W G/Y R A R R Y/R 9 R 2 5 R R 6 3 7 (BLACK) (BLACK) L/Y L/W B L/W L/W B L/W B R B R B B (BLACK) A B B R L/W Y/R B B B B R A L/W L/Y B Br Gy Br S Gy Br Gy J K Br/W I Br Y T U V W G B Br Br/W Y Gy G Gy/B Gy/B Br/W L B
CHARGING SYSTEM EAS00774 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse 2. battery 3. charging voltage 4. wiring (of the entire charging system) Minimum open-circuit voltage 12.
CHARGING SYSTEM NOTE: Make sure the battery is fully charged. @ • Is the charging voltage within specification? NO YES The charging circuit is OK. EAS00779 4. Wiring • Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly connected and without defects? YES Replace the rectifier/regulator. NO Properly connect or repair the charging system’s wiring.
7 - 24 B (RED) Br G B Br Gy Br Br G (RED) B X ON OFF 1 G B B G G Z Y R B R [ 2 R Br Gy R B T B Br Br/W Y Gy Br B Y Br/W Gy R R R S R 3 R Br Gy B Gy U Br 6 5 R V B Y W L/W L/W 7 R 4 B Y/R W R Br/W L/Y B P P K Br L/Y L/W B L/W M L L/W B L/W B R G/Y R L/W 8 R G/Y R A R R R B N R B (BLACK) A B B 9 L B G Y G Y Y B B B A 0 Y/R B B B Q N O Br Br/W B Dg Ch B Dg Ch Q Br/W Br/W J B P L Ch P Br/W B Dg P (RED) C
LIGHTING SYSTEM EAS00782 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: Headlight, high beam indicator light, taillight, auxiliary light, and meter light. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) Check: 1. main fuse 2. battery 3. main switch 4. dimmer switch 5.
LIGHTING SYSTEM – ELEC + EAS00787 5. Wiring 2. Voltage • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly connected and without defects? È When the dimmer switch is set to “ É When the dimmer switch is set to “ NO YES Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE LIGHTING SYSTEM”. • Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown.
ELEC LIGHTING SYSTEM – + EAS00776 4. Source coil resistance 2. Voltage • Disconnect the stator coil assembly coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the source coils as shown. • Connect the pocket tester (20 V) to the meter light coupler (wire harness side) as shown.
LIGHTING SYSTEM ELEC – + 2. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe → blue 1 Negative tester probe → black 2 L Y B L G/Y B 1 2 • Set the main switch to “ON”. • Measure the voltage (12 V) of blue 1 on the tail/brake light coupler (tail/brake light side). • Is the voltage within specification? YES This circuit is OK.
7 - 29 B (RED) Br G B Br Gy Br Br G (RED) B X ON OFF 1 G B B G G Z Y R B R [ 2 R Br Gy R B T B Br Br/W Y Gy Br B Y Br/W Gy R R R S R 3 R Br Gy B Gy U Br 6 5 R V B Y W L/W L/W 7 R 4 B Y/R W R Br/W L/Y B P P K Br L/Y L/W B L/W M L L/W B L/W B R G/Y R L/W 8 R G/Y R A R R R B N R B (BLACK) A B B 9 L B G Y G Y Y B B B A 0 Y/R B B B Q N O Br Br/W B Dg Ch B Dg Ch Q Br/W Br/W J B P L Ch P Br/W B Dg P (RED) C
SIGNALING SYSTEM ELEC – + 1 Main switch 2 Battery 3 Main fuse E Rear brake light switch F Front brake light switch G Tail/brake light H Oil level gauge I Diode J Turn signal relay K Horn M Horn switch O Turn signal switch P Rear turn signal light Q Front turn signal light T Oil level warning light W Turn signal indicator light X Fuel gauge assembly Y Fuel level gauge Z Fuel level indicator light [ Fuel sender 7 7 - 30
SIGNALING SYSTEM EAS00794 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: Flasher light, brake light or an indicator light. • The horn fails to sound. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) Check: 1. main fuse 2. battery 3. main switch 4.
SIGNALING SYSTEM ELEC – + EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the pink connector at the horn terminal. • Connect a jumper lead 1 to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Push the horn switch. • Does the horn sound? 1. Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? NO YES Replace the left handlebar switch. 2.
SIGNALING SYSTEM ELEC – + 4. Voltage 2. Brake light switches • Connect the pocket tester (DC 20 V) to the horn connector at the pink terminal as shown. • Check the brake light switches for continuity. Refer to “CHECKING THE SWITCHES”. • Is the brake light switch OK? Positive tester probe → pink 1 Negative tester probe → ground NO YES Replace the brake light switch. 3. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.
SIGNALING SYSTEM ELEC – + EAS00799 3. Voltage 3. The turn signal light, turn signal indicator light or both fail to blink. • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. 1. Turn signal indicator light bulb and socket • Check the turn signal light bulb and socket for continuity. Refer to “CHECKING THE SWITCHES”.
SIGNALING SYSTEM ELEC – + 4. Voltage 5. Voltage • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. • Connect the pocket tester (DC 20 V) to the turn signal light connector (wire harness side) as shown.
ELEC SIGNALING SYSTEM – + EAS00802 3. Diode 5. The oil level warning light fails to come on. • Remove the diode from the wire harness. • Connect the pocket tester (Ω × 1) to the diode terminals as shown. • Check the diode for continuity as follows. 1. Oil level warning light bulb and socket • Check the oil level warning light bulb and socket for continuity. Refer to “CHECKING THE SWITCHES”.
ELEC SIGNALING SYSTEM – + EAS00804 4. Voltage 2. Fuel sender • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. • Remove the fuel sender from the fuel tank. • Connect the pocket tester to the fuel sender coupler (fuel sender side) as shown. Positive tester probe → gray 1 Negative tester probe → black 2 Positive tester probe → green 1 Negative tester probe → black 2 2 Br B Y Br/W Gy 2 B Br Br/W Y Gy 1 B G 1 • Set the main switch to “ON”.
SIGNALING SYSTEM – ELEC + 3. Fuel level gauge 4. Voltage • Set the main switch to “ON”. • Move the float up 1 or down 2. • Check that the fuel level gauge needle moves to “F” or “E”. • Connect the pocket tester (DC 20 V) to the fuel level gauge coupler (wire harness side) as shown.
AUTO CHOKE SYSTEM ELEC – + AUTO CHOKE SYSTEM CIRCUIT DIAGRAM W/L B Y/R W B W/L L/Y O L/W Br (BLACK) W/R W/L W Y/R W W/L W/L 0 Y/R O B O Br B B L/Y B L/W Y/R A B B Y/R B (BLACK) (BLACK) R LACK) B Br Gy Br Gy J Gy/B Br 0 AC magneto A Auto choke F Br/W 7 - 39 B B
ELEC AUTO CHOKE SYSTEM TROUBLESHOOTING – + 2. Source coil resistance The auto choke fails to operate • Disconnect the stator coil assembly coupler from wire harness. • Connect the pocket tester (Ω × 1) to the source coil lead. Check: 1. auto choke resistance 2. lighting coil resistance 3. voltage NOTE: • Before troubleshooting, remove the following part(s): 1) center cover • Troubleshoot with the following special tool(s).
AUTO CHOKE SYSTEM 3. Voltage • Connect the pocket tester (AC 20 V) to the auto choke lead. Tester positive probe → yellow/red 1 Tester negative probe → black 2 B B B Y/R 1 2 • Set the main switch to “ON”. • Start the engine and accelerate to about 3,000 r/min • Check the voltage. Voltage 12.8 V or more at 20 °C (68 °F) YES This auto choke is OK. NO Check the entire auto choke unit for connection. Refer to the “CIRCUIT DIAGRAM”.
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.
INCORRECT ENGINE IDLING SPEED/POOR MEDIUMAND-HIGH-SPEED PERFORMANCE/FAULTY CLUTCH TRBL SHTG EAS00847 INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap Ignition coil • Faulty spark plug lead Ignition system • Faulty ignitor unit • Faulty pickup coil ENGINE Air filter • Clogged air filter ele
OVERHEATING/POOR BRAKING PERFORMANCE/ UNSTABLE HANDLING TRBL SHTG EAS00854 OVERHEATING ENGINE Cylinder head and piston • Heavy carbon buildup Engine oil and transmission oil • Incorrect oil level • Incorrect oil viscosity • Inferior oil quality FUEL SYSTEM Carburetor • Incorrect main jet setting • Incorrect fuel level • Damaged or loose carburetor joint Air filter • Clogged air filter element CHASSIS Brake(s) • Dragging brake ELECTRICAL SYSTEMS Spark plug • Incorrect spark plug gap • Incorrect spark plu
FAULTY LIGHTING OR SIGNALING SYSTEM TRBL SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HORN DOES NOT SOUND • Improperly adjusted horn • Damaged or faulty horn • Faulty main switch • Faulty horn switch • Faulty battery • Blown, damaged or incorrect fuse • Faulty wire harness HEADLIGHT DOES NOT LIGHT • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (main switch) • Burnt-out headlight bulb HEADLIGHT BULB BURNT
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
B (RED) Br G B Br Gy Br Br G (RED) B X ON OFF 1 G B B G G Z Y R B R [ 2 R Br Gy R B T B Br Br/W Y Gy Br B Y Br/W Gy R R R S R 3 R Br Gy U Br V B Y W L/W L/W 7 Y/R R 4 B W R Br/W L/Y B R A R R R P B N R B (BLACK) A B B 9 Gy.......... gray L ............ blue O ........... orange P............ pink R............
