987 MOTORCYCLE SERVICE MANUAL Model : XC200T 1YA281972000 *1YA281972000*
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×C200T SERVUCE MANUAL ©1986 by Yamaha Motor Co., Ltd. 1st Edition, June 1986 ...... ARI rights reserved, Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is e×pressBy prohibited.
NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics, tt is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha scooter have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology_ Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsa
-_ ® iLLUSTRATED SYMBOLS (Refer to the imlustration) Illustrated symbols (_ to _) are designed as thumb tabs to indicate the chapter's number and content. _ ENG I Periodic inspection and adjustment General information ............... [C_B _il _ _ Engine Cooling system _ _ Chassis Carburetion [CHAS_ _) ,_ppter 'ndaIces ® _ 6_) @ @ @ @ (_ _= _ Illustrated _ (_) Filling fluid the specifications (_ Lubricant (_ Tightening ® ± appearing in the text.
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GEN CHAPTER 1. ......... ...... GENERAL mNFORMATiON SCOOTER IDENTIFICATION ....................................... VEHICLE IDENTIFICATION NUMBER .............................. ENGINE SERIAL NUMBER ....................................... 1-1 1-1 1-1 INPORTANT iNFORMATiON ....................................... ALL REPLACEMENT PARTS ..................................... GASKETS, OIL SEALS, AND O-RINGS ............................ LOCK WASHERS/PLATES AND COTTER PINS ....................
[ GEN SCOOTER iDENTiFICATION GENERAL INFORMATmON SCOOTER VEHICLE IDENTIFICATION IDENTmF_CATION NUMBER The vehicle identification number h_to the steering head pipe. _i_ NOTE: The vehicle identification _.-_is stamped number is used to iden- tify your scooter and may be used to register your scooter with the licensing authority in your state.
iMPORTANT iNFORMATiON !ioE° INFO INPORTANT INFORMATION ALL REPLACEMENT PARTS 1. We recommend to useYamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasketsurfaces,oil seallips, and O-ringsmust be cleaned. .... 2. Properlyoil allmating partsand bearingsduring reassembly. Apply grease to the oil seal lips.
iMPORTANT INFORMATION/SPECIAL ................... TOOLS C_RCLIPS fore reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip _, make sure that the sharp-edged corner _) is positioned opo-site to the thrust _} it receives. See the sec1. All circlips should be inspected carefully be- /£_I_ 30000! U _4_ tional Shaft view. SPECIAL TOOLS The proper special tools are necessary for complete and accurate tuneoup and assembly.
SPECIAL TOOLS mNFOI - I J GEN-r _ _] 4. Fuel Level Gauge P/N YM-01312-A I 1 This gauge is used to measure the fuel level in the float chamber. FOR ENGBNE SERVICE 1. Rotor Holder P/N YU-01235 This tool is used to hold the flywheel magneto when removing or installing the flywheel magneto securing nut. 2 Flywheel Magneto Puller P/N YM-01080 This tool is used for removing the flywheel magneto. 3. Primary Sheave Holder P/N YS-01880 This tool is used when holding the clutch hub. 4.
IGN_F_ J__ SPECmAL TOOLS 5. Clutch Compressor Holder P/N YMo33285ol .................... _ _ %:_b_ _i_ _ _ dary sheave. This tool is used to dis-He-assemble the secon6, Locknut Wrench P/N YM-04045-A This tool is used to loosen or tighten the clutch assembly securing nut. 7, #40 Torx Driver P/N YU_29843o7 This tool is used to loosen or tighten the starter wheel securing screw, 8. Valve Spring Compressor P/N YM-04019 This tool is needed to remove and install the valve assemblies. 9.
SPEO'A'TOOL [OE° i° O 10. Cylinder Gauge ........ _ P/N YU-03016 This tool is used to measure cylinder bore. r=m 11. Valve Seat Cutter Set P/N YM-91043 This tool is needed to resurface the valve seat. 12. Valve Guide Remover (7.0 mm) P/N YM-01225 This tool is used to remove the valve guides. 13. Valve Guide Reamer (7.0 mm) P/N YM-01227 This tool is used to rebore the new valve guide. 14. Valve Guide Installer P/N YM-04017 This tool is needed to install the valve guides properly.
[GEN_ JNFO__.__..__SPECIAL TOOLS ........... 15, Piston Pin Puller P/N YU-01304 @ _i_ This tool is used to remove the piston pin. ..... @_ 16. Plain Beanng Handle P/ N YM-04058 ...................... Plain Bearing Installer/Remover P/N YM-33297 ...................... _,) LI_II/, These tools are used for removing and installing the crankshaft plain bearing 17. Plastigage ® Set "Green" P/N YU-33210 This gauge is needed to measure the clearance for the connecting rod bearing. ....... 18.
SPEC'ALTOO lOE° m° O FOR CHASSIS .... SERVICE 1. Ring Nut Wrench P/N YU-01268 ...................... P/N YU-33975 ...................... (_ (_ These tools are used to loosen and tighten the steering ring nut. FOR ELECTRICAL COMPONENTS 1. Electro Tester P/N YU-33260 ...................... (_ This instrument is necessaryfor checking the ignition system components. 2. Pocket Tester P/N YU-33263 .... (_ or YU-03112 .... (_ This instrumentis invaluablefor checkingthe electrical system.
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i JNsPJ ADJ | 1 ......... CHAPTER 2 PERiODiC INSPECTION AND ADJUSTMENTS INTRODUCTION .................................................. PERnOD_C MAiNTENANCE/LUBRICATION ......................... ENGINE ........................................................... CRANKCASE VENTILATION SYSTEM INSPECTION ................ FUEL LINE INSPECTION ......................................... INTAKE MANIFOLD INSPECTION ................................ EXHAUST SYSTEM INSPECTION ................................
LADj LUBRmCATION PERBODIC WNSPECTIONS AND ADJUSTMENTS NTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life, The need for costly overhaul work will be greatly reduced.
PERRODIC MAre NTENANCE/LU B RmCATmON AD J EVERY ......... Item Break-in 1,000 (600) 6,000 (4,000) or 6 months 12,000 (8,000) or 12 months Check all chassis fittings and fasteners. Correct if necessary. 0 0 0 Check operation. Repair if necessary. 0 0 0 Sidestand switch* Check operation. Clean or replace if necessary. 0 0 0 Battery* Check specific gravity. Check breather pipe for proper operation. Correct if necessary.
CRANKCASE ADJ I_NSP]__j VENTmLATION SYSTEM EXHAUST SYSTEM _NSPECTION UNE _NSPECTION/INTAKEMANIFOLD INSPECTION/FUEL _NSPECTION/ ENGINE CRANKCASE VENT_LATION SYSTEM INSPECTION 1. inspect: oCteaner ioint hose _ oAir duct {Outlet) (_) Cracks/Damage_-_ Replace. _Spdng bands _} Damage/Loose-_ Replace. FUEL LiNE iNSPECTiON 1ohspect: oVacuum hose (_} Cracks/Damage--+ Replace. oFuel hose (_!_ INTAKE MANRFOLD iNSPECTiON 1. Inspect: olntake manifold _1_ _ ......-.............
iDLiNG SPEED ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT mNSP]_ I ADJ iDLiNG SPEED ADJUSTMENT 1. Remove: o Front cover Refer to "REMOVING THE COVERS AND PANELS", page 2-12_. 2. Adjust: eldle speed Warm up the engine and turn the throttle stop screw (_ to adjust. Use the Inductive Tachometer (YU-08036). - 1,350 r/rain Idle1,250 Speed: 3_7 mm (0.12 _0.28 inl THROTTLE NOTE: IN CABLE ADJUSTMENT Before adjusting the throttle cable free play, the engine idling speed should be adjusted. 1.
ADJ f lNSP] ENGtNE ENGINE OIL REPLACEMENT OraL LEVEL MNSPECTION/ r, ENGINE OIL LEVEL iNSPECTION 1. Remove: ®Front cover *Side cover (Left) _ Refer to "REMOVING PANELS", THE COVERS AND page 2q2. 2. Inspect: \. / ®Engine oil level Oil level low-_Add Engine [ t |' ! /.... {2b___ oil leve_ inspection I[ *Place the scooter ° *Warm I:1 sufficient oil. steps: on a level place. up the engine for serveral minutes, and *Screw the dipstick _ completely out, and stop it.
ENGINE OIL REPLACEMENT AD J 5. Fill eCrankcase At Recommended 5°C (40°F) or Oil: Higher: SAE 20W40 Type SE Motor Oil At 15°C (60°F) or Lower SAE 10W30 Type SE Motor Oil Periodic Oil Change: 1.0 L (0.88 imp qt, 1.1 US qt) Do not allow foreign material crankcase. to enter the 6. Install: ®Dipstick 7. Inspect: oOil leaks ®Oil level oOil pressure Refer to "OIL PRESSURE INSPECTION" section. Engine Oil Replacement (With Oil Filter) 1.
C=..Gm.E oral.EPLACEME.T 4. Inspect: oGasket (Drain bolt) (1._ ®O-dng (Oil filter cover} (_ Damage -+ Replace, ...... .... 5, Install: ®Oil filter (New) oOil filter cover NOTE: _ Drain bok olnstall the oil filter 0.} with its projection (_ facing towards the engine. ®Before installing the oil filter cover, apply the engine oil to the O-ring on the filter cover. 6. Tighten: Drain bolt oBolt (Oil filter cover) Drain Bolt: 43 Nm {4.3 m.kg, 31 ft,lb) Bolt (Oit Fiffer Cover}: 10 Nm (1.0 m,kg, 7.2 ft,_b) 7.
OiL PRESSURE INSPECTION/V=BELT RNSPECTmON I _NsP] I_ I OIL PRESSURE INSPECTUON 1. Remove: eFront cover Refer to "REMOVING THE COVERS AND PANELS", page 2-12. oAir bleed bolt (_ 2. Start the engine and keep it idling for several minutes. 3. Inspect: cOil condition of the bleed hole Oil flows out--Oil pressure is good. No oil comes out--Oil pressure is bad. If no oil comes out after a lapse of one minute, turn off the engine immediately so it will not seize. 4. Tighten: ®Air bleed bolt [_ ........
ADJ [INSP TRANSMmSSJON TRANSMISSION _] OraL ORL REPLACEMENT LEVEL_NSPECTmON/ TRANSMiSSiON O_L LEVEL _NSPECTION 1_Inspect: _Transmission oil level Oil level Iow-_+Add sufficient oil, 50 H 40 _m_..__._.,,,0 I O 5 50 Transmission o# Jevel inspection stops: oPlace the scooter on a level place: oScrew the dipstick _i_ completely out) and then just rest the dipstick in the hole.
TRANSMiSSiON OIL REPLACEMENT/ COMPRESSION PRESSURE MEASUREMENT ...... RNSP]$ ADJ 18NmCl.8m:kg.13tt.lb._!__w __ Drain Bolt: eApply the oil to the proper level. ,_) Recommended At 5°C 140°F) orOil: Higher: SAE 20W40 Type SE Motor Oil At 15°C (60°F) or Lower: SAE 10W30 Type SE Motor Oil Total Amount: 0.2 L (0.18 imp qt, 0.21 US qt) olnstall the"TRANSMISSION dipstick and inspect oil level. Refer to OILtheLEVEL INSPECTION" section. CONIPRESSION MEASUREMENT ....
COMPRESSION PRESSURE MEASUREMENT Compression [eve[): Pressure {at sea Standard: 1,079 kPa {11 kg/cm Minimum: 981 kPa {10 kg/cm Maximum: 2, 142 psi) 1,177 kPa (12 kg/cm When cranking the engine, 2, 156 psi) 2, 171 psi) ground all of ®If pressure fails below the minimum level: the spark plug lead te prevent sparking. 1. Squirt a few drops of oil into the affected cylinder° 2. Measure the compression Compression (with oh introduced Reading again.
REMOVING THE COVERS AND PANELS /_l I iNSP j_ADJ._! CHASSIS .......... REMOVING THE COVERS AND PANELS (_ Scooterpanel (_ Fronttrunk (_) Front cover (_ Upper cover (_) Side cover (_) Footrestboard !iil _ii_iiiiiiiii eBefore removing the cover(s), make sure that aft hooks are free. ®After installing the cover(s), make sure that all hooks are securely fitted. Front Cover _S __ 2. Remove: ,.O0eot,,oso,.t.
REMOVING THE COVERS AND PANELS Side Covers 1, Remove: -Screws (Side cover) oSide cover (Left and right} ........... _ z/ Lift up the side cover, then unhook the lobs _3-_on the side cover from the receptacles _4_in the upper cover _ Footrest Board t. Remove: ®Bolt (Rear brake pedal) @ ®Brake pedal @ ..... 2, ®Caps Remove: (Lower _ Upper) _. 3. Remove: eBolts (Footrest board) (9 ®Footrest board @ Pull up the footrest board end, and then pull out the footrest board to the backward.
REMOViNGAI R TH EFI LTERCOVERSELEM ENTAN DCLEANIPAN ELS/NGI ADjmNSP _(_L] Front Trunk 1. Remove: -Screws oScrews (_ with clamps _) 2. ®ScrewseCapsRemove:(_(_ with clamps (_) s- 3. Strip the side mold end (_. 4. Remove: ®Screw (Front trank) (_ oClamp _) oFront trunk assembly Scooter Panel 1. Disconnect: ®Flasher lead couplers _) 2. Remove: ®Bolts (Scooter panel) (_ ®Screws (Scooter panel) (_ oScooter panel assembly AiR FILTER ELEMENT CLEANING 1.
FUEL COCK CLEANING AiR FmLTER ELEMENT CLEANING/ Air filter e_ement cleaning steps: ®Apply the Yamalube 2'cycie oil to the entire surface of the element, ®Wrap the element with a clean rag; and oSqueeze the element dry. *Wash theout airthe filterexcess element squeeze oit, with solvent. The element should be wet but not be __ dripping. ®Do not squeeze • .... :.... ;:!i_:.
FUEL COCK CLEANING/ FRONT AND REAR BRAKE INSPECTION INSP i_ i ADJ FUEL IS HIGHLY FLAMMABLE: eAIways turn off the engine when draining. =Take care not to spill any fuel on the engine or exhaust pipemuffler when draining. oNever drain fuel while smoking or in the vi= cinity an open flame. 6. Remove: e Fuel cock assembly oFilter screen (_ 7. oRubber Inspect: gaskets Damage -_ Replace. 8. Clean: oFilter screen oFilter cup Clean it with solvent. 9.
INSP FRONT TIRES AND AND REAR CAST BRAKE WHEEL iNSPECTION/ _NSPECTION 2. Adjust: Free play Turn the adjuster _i_ until the free play is wi,thin the specified range, NOTE: After adjusting, check the operation of the brake light. Rear Brake Pedal Free P_ay Adjustment 1. Check: ®Rear brake pedal free play _J ............. Out of specification-+Adjust. 5_-15 mm {0.20-- 0.60 in) Rear Brake Pedal Free Play: [_ J] 2.
TIRES AND 2. Improper .... ,°sPIJ ADJ CAST WHEEL INSPECTION tire pressures life and handling. prior to each trip greatly affect tire Check tire pressures and adjust properly if necessary. If tire pressures are too high, shocks from the road wgl not be damped and will be carried to the frame and handlebars, thus adversely affecting riding comfort. dition, scooter stability making a turn.
LLNSP 1 t ____ TIRES AND CAST WHEEL iNSPECTiON 2, Inspect: eTire surfaces Wear/Damage-_ Replace. {Front Rear} Minimumarid Tire Tread 1.0 mm {0.04 in) _ Depth _/: (!_ Side wall _2}_Wear indicator _) Tread depth _lf wear indicator to view, e[t the is dangerous to ride (2) withexposed a wornout tire, replace the tire 3.
FRONT WHEEL BEARING CHECK/$TEERmNG HEADADjUSTMENT IADJImNSP[ FRONT WHEEL BEARING CHECK 1. Placethe scooter on its centerstand, then elevate the front wheel. 2. Check: oFront wheel bearings Spin the wheel by hand. Tuch the axle or front fork while spinning the wheel. Excessive vibration--, Replace bearings. ! STEERING HEAD ADJUSTMENT Steering ......... ...... ....... Head Inspection vate the front wheel. 2. 1.
ADJ I INSPLI REAR SHOCK ABSORBER ADJUSTMENT STEERING HEAD ADJUSTMENT/ eHold the lower ring nut _'_ and tighten the upper ring nut (_-_using the Ring Nut Wrench (YU-33975) .......... __ kg; 22ft l eTighten _b/ ttie har, d,ebar securing bo,t g,4s _7 ft e Reinstall the steering nut cover _), N REAR SHOCK ABSORBER ADJUSTMENT 1. Adiust: ®Spring NOTE: _.
CONTROLANO METEROABLESLUBR BRAKEPEO l I LUBRICATION/CENTERSTAND AND SIDESTAND LUBRICATION/FRONT SHOCK ABSORBER LOWER PIVOT LUBRICATION/COMPRESSION ARM PIVOTS LUBRICATION/ FRONT AXLE AND ENGINE PIVOT SHAFT LUBRICATION _NSP ADJ CONTROL AND METER CABLES LUBRICATION Lubricate the inner cable and cable end. [_] SAE 10W30 Motor Oil amaha Chain and Cable Lube or BRAKE LEVER AND BRAKE PEDAL SHAFT LUBRICATmON Lubricate the pivoting parts of the brake lever and pedal shaft. SAE 10W30 Motor Oil .......
IGNIT{ON TmMING CHECK ELECTRICAL i / / _GNITIION TIMING CHECK 1, Remove: eFront cover k_i_) *Side cover (Left and right} _2_) o Footrest board Refer to "REMOVING THE COVERS AND PANELS" section. 2, Remove: aPassenger footrest (Right} _,) 3, Remove: oSocket bolts (Exhaust pipe} oF_ange bolts (Muffler) (_21} eMuffler assembly 4, Remove: ®Screws lAir shroud I) _-} Screws (Fancase cover} _Air shroud 1 (_ with fancase cover @ 5.
UGNmONTiMiNGCHECK ImNsP ADJ ] 6. Check: ........ oIgnition timing The ignition timing is adjusted for maximum performance at the factory. DO NOT attempt to change this setting, ignition timing check steps: ®Connect the Timing Light (_ (YU-33277) to ..... ®Warm up the engine, and keep the engine the spark plug wire. running at the specified idle speed of 1,300 r/min. Use the Inductive Tachometer (YU-08036) to check the engine speed.
JNSP BATTERY NSPECT ON BAKERY INSPECTHON 1. Inspect: _Battery fluid level Battery fluid Jevel Iow-_Fill° Fluid level should be between lower level marks. upper and (_'_ Upper leveJ Lower level Refill with contains water minerals Battery sulfuric highly distilled onmy; tap water harmful to a battryo e_ectroiyte is dangerous; it contains acid and therefore is poisonous and caustic.
BATTERY iNSPECTION I INSPI ADJ 1 2. Remove: ............ oBattery NOTE: Disconnect the negative lead farst. 3. Inspect: oBattery fluid specific gravity Out of specification-_ Charge. Always charge a new battery before using it to ensure maximum performance. Charging Current: 1.0 amps/10 hrs Specific Gravity: 1.280 at 20°C (68°F) 4. Install: e Battery NOTE: Connect the positive lead farst. 5. Inspect: o Breather hose Obstruction _ Remove. Damage-+ Replace. 6. Connect: eBreather hose ........
[uNsP ] SPARK PLUG mNSPECTmON SPARK PLUG WNSPECTION 1. Inspect: _Spark pkJg type lncorrect-_ Replace. ..... Standard Spark Ptug: DPR7EAo9 {NGK} X22EPRoU9 {NOD,} 2. Inspect: o Electrode _'} olnsuJator color _) Normal condition Replace. ksa medium to tight tan Wear/Damage-_ color. Distinctly different color -_ Check the engine ('_ conditions 3. Clean: eSpark plug CIeanthe spark plug with a spark plug clean-. er or wire brush. 4. Measure: _Spark pkJg gap (a} Out of specification-_Regap.
HEADLIGHT BULB ADJUSTMENT/ REPLACEMENT BRAKE LIGHT SWITCH ADJ [INSPI_ BRAKE LIGHT SWBTCH ADJUSTMENT .......... 1. Adjust: ®Brake light operating timing Hold the main body (_ of the switch with your hand so that it does not rotate, and turn the adjuster (_) until the operating timing is correct. HEADLIGHT 1. Remove: BULB REPLACEMENT ®Bolts (Headlight unit) (_) 2. Remove: ®Headlight unit (_) 3. Disconnect: ®Connecter (Headlight lead) (_) 4.
[[_SP ]-_---] HEADUGHT BULB REPLACEMENT/HEADLIGHT BEAM ADJUSTMENT/FUSE INSPECTION 6. Insta!k ®Bulb (New) NOTE: (_} Make sure the projections _-2.._ on the bulb flange are meshed with the slots _3} on the bulb case @. 7. tnstalk ®Components above list (Step "4--1") & Adjust: o Headlight beam Refer to following HEADLIGHT BEAM section. ADJUSTMENT 1o Adjust: ®Headlight beam (Horizontally) HorizontaJ Ii Right I Turn ..... Adjustment screw(_ c-iockwise e 2.
FUSE INSPECTmON I INSP ADJ NOTE: ........ Install new fuses of proper amperage. Description IVlain Reserve Amperage 20A 20A Quantity 1 1 Blown fuse replacement steps: eTurn off ignition and the circuit. olnstall a new fuse of proper amperage. ®Turnon the switches and see if the electrical ®Fuse interrupts the circuit again-* Check elecdevicesystem. operates. trical Refer to "CHAPTER 6. ELECTRICAL" for further information.
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CHAPTER 3 ENGINE OVERHAUL ........ ENGINE REMOVAL ............................................... PREPARATION FOR REMOVAL .................................. BATTERY LEAD ................................................ AIR CLEANER CASE ............................................ CARBURETOR HOSES .......................................... CONNECTORS .................................................. CONTROL CABLES ............................................. ENGINE .......................................
IE"GI% ENGINE ASSEMBLY AND ADJUSTMENT ........................ CRANKSHAFT AND CRANKCASE ............................. TRANSMISSION ............................................... CAMSHAFT AND STARTER CLUTCH ........................... MAINSTAND AND REAR WHEEL ............................... STARTER MOTOR AND FLYWHEEL MAGNETO ................. SECONDARY AND PRIMARY SHEAVES ........................ CYLINDER AND PISTON ...................................... CYLINDER HEAD AND CYLINDER HEAD COVER ............
ENG ENGINE REMOVAL ENGmNE OVERHAUL ENGmNE REMOVAL NOTE: it is not necessary to remove the engine in order to remove the following components. oPdmary _Clutch sheeve and secondary o Flywheel magneto _OH pump e Starter motor ®Carburetor oOil filter oV--Bett e Starter clutch eTransmission PREPARATION t. Remove matedat FOR REMOVAL all dirt, mud, before removal 2. Use proper dust, and disassembly, tools and cleaning Refer to CHAPTER and foreign equipment.
E°O,OE °EOOVAL I0°Oi .l 4. Remove: oFront cover (_ ®Side covers (Left and right) (_ COVERS AND PANELS" section. Refer to "CHAPTER 2 REMOVING THE ...... 5. Remove: oDipstick (Crankcase) (_) ®Drain bolt (Crankcase) (_ Drain the engine oil completely. Refer to "CHAPTER 2. ENGINE OIL REPLACEMENT" section. H 6. Remove: eDipstick (Transmission case) (_ oDrain bolt (Transmission case) (_ Drain the transmission oil completely. Refer to "CHAPTER 2. TRANSMISSION OIL REPLACEMENT" section. ..... BATTERY LEAD 1.
t ENGL%_ ENG_NEREMOVAL 2. Loosen: 3 *Screw (Carburetor-clamp) Remove: _) *Air _ cleaner case assembly CARBURETOR HOSES 1. Dbconnect: * Fuel feed hose _'} *Vacuum hose (_$} From fuel cock side. CONNECTORS 1 Remove: *Starter motor lead (Positive) ®Starter motor lead (Negative) o Band ".2-} "3"} 2o Disconnect: _AC magneto lead connecter _Pickup coil lead connecter *Choke unit lead coupler ®Oil level switch CONTROL (.!} {_ {3"} lead couple_ _4_ CABLES 1. Loosen: Looknut 2.
E°O,OE.EMOV [EO0 oCotter pin 4. Loosen: eNut (Rear wheel axle) (_) 3. Remove: NOTE: Whileapplying therearbrake, fully loosentheaxle nut. 5. Remove: oAdjuster (Rear brake) (_ oPivot pin (_) oBolt (Rear brake cable-clamp) _) 6. Loosen: ®Bolt (Rear brake cable-clamp) (_ 7. Remove: oBolt (Rear brake cable-guide) (_ ®Rear brake cable (_ with guide _) ENGINE 1. Remove: oBolt (Shock absorber-lower) _) ®Pivot shaft (Engine) _) 2. Remove: ®Frame assembly (_ From the engine assembly 3.
E_--_ ENGINE REMOVAL CARBURETOR AND iNTAKE MANIFOLD 1, Loosen: *Screw (Carburetor_ctamp)@ 2, Remove: *Carburetor assemby _) 3. Remove: *Clamp plate (Heat protecter) _} * Heat protecter (2} 4. Remove: _lntake manifold _i_ with O-ring _ MUFFLER 1 Remove: *Socket boJts (Exhaust pipe) _ *Flange bolts (Muffler) -Muffler assembly (_ with gasket FANCASE COVER AND AmR SHROUD 1.
ENGINE REMOVAL//ENGINE DISASSEMBLY I ENG _J 2. Remove: oOil level switch lead (_ From the lead guide oAir shroud 3 (_ ENGINE DISASSEMBLY CYLINDER HEAD COVER AND CYLINDER HEAD 1. Align the "T" mark (_ on the flywheel magneto (_ with the stationary pointer _) on the crankcaseso that the pistonisat TDC on the compression stroke. 2. Remove: oBolts (Cylinder head cover) oCylinder head cover NOTE: Follow numerical order shown in photo. Start by looseningeach bolt 1/2 turn until all are loose. 3.
ENG ENGINE DmSASSEMBL¥ 5_ Remove: ..... _cylinder head assembly _, Tap tightiy the cylinder head sOiid points with a soft.head hammer to remove the cylinder head° NOTE: if it is necessary to pry the cyJinder head loose from the gasket, carefully use a broad, flat,-Made screw driver atthe reinforced points _), shown. _. .... & Remove: .... _Gasket (Cylinder head} @ "Dowei pins 0_) _NoZZle {_) with oil seal ":" .......
Eoo,°0 o,sAssEooLy [E°o "*'1 3. Remove: ...... oPiston pin (_ oPiston (_) NOTE: Before removing the piston pin, deburr the clip groove and pin holearea. If the piston pin groove is deburred and piston pin is still difficult to remove, use Piston Pin Puller (YU-01304). Do not use a hammer to drive the piston pin out. 4. Remove: oDowel pins (_ oNozzle (_) with O-ring (_ eGasket (Cylinder) (_) 5. Remove: .........
E o,oE O,SASSEMOL 2.Remove: oDowel pins (_ * Gasket (Sheave case cover) (_2 _) ...... 3, Straighten: *Tab (Lockwasher)@ 4. Remove: *Nut (Primary sheave assembly} _2) Use the Roter Holder (YU@1235) @_ * Lock washer {_) *Primary fixed sheave (_} * V-.belt @ 5_ Remove: *Primary slidhlg sheave (_-'1} with collar _2_ CLUTCH HOUSING AND SECONDARY SHEAVE 1: RemoVe: _Nut (Secondary sheave} ,_!) Use the Sheave Holder (YS-01880) [)}. oCnteh ho_sing @ 2. Remove: *Secondary sheave assembly (,!"_ 3-9 ....
ENGUNEDnSASSEMBLY ENG ...... FLYWHEEL MAGNETO MOTOR 1. Remove: AND STARTER _Cooling fan oFlange bolt (Flywheel magneto) (_ Use the Roter Holder (YU-01235) _. 2. Remove: eFlywheel magneto (_ Use the Rotor Holder (YU-01235) (_ and Flywheel Magneto Puller (YU-01080) (_). 3. Remove: oStator assembly (_ oWoodruff key (_ eStarter motor (_) REAR WHEEL AND IV]AINSTAND 1. Unhook: eSpring (Mainstand) (_ 2. Loosen: ®Bolts (Mainstand) (_) NOTE: Do not remove the bolts (Mainstand) yet. 3.
E°o I,..l0°o,,0 o,sAssEooL 4. Remove: _Brake shoes _} ..-. eBolts (Brake shoe ptate} (.2) ........... eBrake shoe plate {_ o Bolts (Mainstand) e Mainstand .... ..... i ;}}!3nii!_ STARTER CLUTCH t. Remove: _Starter NOTE: AND CAMSHAFT gear case cover @ _ _........... Working in a crisscross pattern, loosen screw 1/4 turn each, Remove them after all are ioosened_ (_ o Dowet pins (._'_ _Gasket (3!) 2, Remove: eStarter clutch assembly idler gea r (Starter eShaft {i.} motor) _} (Idler gear) (.
ENGgNE D SASSEMBLY ENG I 4. Remove: +O-ring (Crankshaft) (_) oDrive gear (Camshaft) (_ +Woodruff key (_ TRANSMISSION 1. Remove: .... ...... oTransmission case cover (_ with primary drive axle (_ oDowel pins oGasket NOTE: Working in a crisscross pattern, loosen screw 1/4 turn each. Remove them after all are loosened. 2. Remove: oThrust washer (_ ,Main axle (_ eThrust washer (_ 3. Remove: oDrive axle (_ NOTE: Take care not to damage the oil seal. OIL PUMP 1.
EN__@_ ENGINE DMSASSEMBLY CRANKCASE 1. Remove: AND CRANKSHAFT +Botts (Oit filier case) (_) +Guard (Oit revel switch lead) +0[t filler case (3.) 2. Remove: +Oit level switch (1_ 3. Remove: +OiLfilter C0ver (!-_ +oil 4. Remove: +Screws {Crankcase) _++_ NOTE: ............
ENGmNE DISASSEMBLY/INSPECTION AND REPAIR _._ _J 6. Separate: oCrankcase 1 (_ and 2 (_) While tapping the crankcase 2 with a softhead hammer. 7. Remove: eSpacer collar 8. Remove: , _; eBalancer weight assembly oCrankshaft assembly (_) e Dowel pins (_) oNozzle (_ with O-ring (_ E]i 9. Remove: ®Oil strainer (_ oRelief valve (_) INSPECTHON AND REPAUR CYLINDER HEAD COVER, ROCKER ARMS AND ROCKER ARM SHAFTS 1. Remove: eRocker arm shafts (_ Use the Slide Hammer Set (YU-01083) (_) and (_). _'> ii.
_N__®_ INSPECTION AND REPAIR 2. Inspect: oCytinder head cover warpage Use a surface plateo Warp-+ Resurface, Place a 400,--600 grit wet sandpaper on the surface plate, and resurface the head using a figureoeight sanding pattern, NOTE: Rotate the head several times to avoid removing too much materiat from one side. 3. Inspect: ®Rocker arms o Rocker arm shafts Wear/Damage-....v+ Replace o .......
,OSPEOT,O° AO0 OEPA,° I oCalculate the clearance by subtracting the rocker-arm-shaft outside diameter from the rocker-arm inside diameter. ....... Out of specification _ Replace either or both parts. (Standard): Arm=to-shaft Clearance 0.009 - 0.042 m m (0.0004- 0.0017 in) 4. Apply: ®Rocker arm inner surfaces oRocker arm shaft outer surfaces oWave wahsers ®Plate washers 5. Install: __ _ *Wave washers (_) @ ePlate washers e Rocker arm shafts (_ _(___._ .
ENG INSPECTION AND REPAIR PUSH RODS 1° Inspect: oPush rod end ___ Damage/Uneven wear -+ RepLace. P 2o Measure: ,Push rod runout Out of specification --_Replace. 0.3 Rod mm {0.012 Push Runout in)Limit: _ CYLINDER 1, Attach: ,Valve q HEAD Spring Compressor (YU-04019) kl/rW_ Depress the valve springs. 2. Remove: J" _ ---(_! ,Valve _/_" (i} -VaLve spring seat (Upper) ......... _) ,VaLve spring "0ii -- retainers {7_0 _)--_§} ........... @ ......
,°s o°Ao°°EPA,° [ 3. Eliminate: oCarbon deposit Use rounded scraper, and wire brush. NOTE: ..... Do not a sharp instrument and avoid damaging or scratching" oSpark plug threads eExhaust port oCombustion chamber ....... 4. Measure: eCylinder head warpage Use a Straightedge (_ and Feeler Gauge ®. Under specification--, Resurface. Outer specification--, Replace. ..... [_ Less than 0,025 rnm (0,001 in) Cylinder Head Warp Limit: VALVE, VALVE GUIDE AND VALVE SEAT (_ 1.
ENOI,osOOAOOOOPA,O I 4. Measure: Out of specification imum " o--_ Replace. Runout: oValve stem runout 1 _i} Dial gauge 6) V-block 5. Measure: q!J eVatve stem outside diameter Use the Micrometer Out of specificatien-_ LA] (1_o Replace the valve and valve guide as a set. _Valve Stem Outside _amat_r , L_J . _ 5.963 _-5.975 m m 5.920 m m ! {0.2348-o_0.2352 in) {0.233 in} =xnaust \ .... 6_ Measher: _Valve guide inside diameter _ Use the Bore Gauge (_}.
INSPECTION .... AND REPAIR Valve Guide 1. Remove: ........ I ENG _tJ Removal oValve guide Use the Valve Guide Remover (YM-01225) NOTE: Heat the head in an oven to 100°C (212°F) to ease guide removal ..... correct Valve and installation interference Guide and to maintain fit. installation 1. Install: eO-ring (New) (_ eValve guide (Oversize) (_ Use the Valve Guide Remover (YM-01225) with Valve Guide Installer (YM-04017) ®. NOTE: ®Always use a new O-ring when valve guide is replaced.
LENG 1%®_ INSPECTIONAND REPAmR (_}..... 3_Cut: ®Valve guide inside diameter {_} Use the Valve Guide Reame_ (YM@1227) {!/.
.... ,oso°A°o°EPA,° 6, Resu rface: oValve Seats .... Use a 30 °, 45 ° and 60 ° Valve ter(YM-91043) When .... ............ twisting cutter, ward pressure marks. Valve seat Seat Cut- (_. (4-5 keep an even down kg) to prevent recutting chatter steps: oValve seat is uniform around perimeter valve face but too wide or not centered valve face.
ENG mNSPECTMON AND REPAIR Valve/VaJve _M_._ _ Seat AssemMy Lapping . Coarse To valve,appk_g face. compour, d (Sma,, amount) .... II .... disulfide oil 1. eMotybdenum Apply: i: iii? Be sure compound enters into the gap beTo no valve stem. tween the valve stem and guide. 2. Position: oValves Incylinder head° 3. Rotate: ®Valve Turn until valve and valve seat are evenly polished, then clean off all compound.
,o+ooA°°°EPA,° lEN° "+] 10. Clean/Assembly: +All cylinder head parts. 11. Apply: ..... +Solvent (_ Into each intake and exhaust port. NOTE: Pour solvent into intake and exhaust ports only after completion of all valve work and assembly of all head parts. 12. Check: eValve seat to valve face seal (_ Leakage past valve seat_Relap. (See procedure below) Relapping steps: oDisassemble head parts. eRepeat lapping steps using fine lapping +Clean all parts thoroughly. +Reassemble compound.
ENG "_®_1 INSPECTMON AND REPAmR 2. Measure: ®Spring force (Installed length) Out of specification-* Replace° Compression Force {Vanve Closed) _nner Spring: 8°4- 10.2 kg {18°5--22.5 at 30_5 mm {1o201 in} Outer Ib) Spring: 1&6-20.4 kg {36.6-45.0 at 32.0 mm {1o260 in) _') <%_ • Valve Jb} Installation 1. Lubricate: <_} ®Oil seat ®Valve stem _} ...................... (_ Motor Oil or Molybdenum High-Quality MoJybdenum Grease F_ _f _,_,f _ ................................. (_ a .....--..
,osooAoo°EoA,° lEooI'.] CYLINDER 1. Inspect: ®Cylinder wall Wear/Scratches--,Rebore or replace. 2. Measure: oCylinder bore "C" Use a Cylinder Bore Gauge _. Out of specification--,Rebore. Cylinder D2D4 D6 D1D3 E)s __ Dl D2 Ds D6 D4_ D3 4ram .... (0.16 in) i ............... Standard 67.98-68.03 mm Wear Limit 68.04 mm Cylinder _ Taper "'T": C=Maximum D T=Maximum (D] or D2) Bore "C": (2.6764in) -- Minimum (Ds or 2.8783 D6) 0.05 mm (0,002 in) (2.
ENG _®_1 iNSPECTIONAND REPAIR 3, Measure: o Piston clearance Out of specification-+Rebore replace piston, Piston Clearance=C cytinder -- or P: 0o020 -- 0,040 m m (OoOOOI= 0,0011 C: Cylinder Piston boreP:Piston in) outside diameter Ring The oversize top and 2nd ring sizes are stamped on top of the ring° Oversize Oversize 4 2 1,00 mm (0,0394 in) 0,_ rnm (0.
,°soo A°o °EPA,° [E°ol" .I .......... ......... ..... 3. Measure: eEnd gap Insert a ring into the cylinder, and push it approximately 20 mm (0.80 in) into the cylinder with the piston crown. Use Feeler Gauge (_). Out of specification_Replace rings as set. Top Ring 2rid Ring Oil Control (Rails) ........ Standard Limit 0.30-0.45 mm (0.0118-0.0177 in) 0.30-0.45 mm (0.0118-0.0177 in) 0.20-0.70 mm (0.0079-0.0276 in) 0.70 rum (0.0276 in) 0.80 mm (0.0315 in) Piston Pin 1.
E_ "_®l__] INSPECTION AND REPAIR 2:. Remove: oPush rod seat _ *Plunger _ ®Return spring (*_ ..... oValve lifter body@ _6_ Circfip inspection 1, Inspect: o Push rod seat ®Return spring Damage--.-_Reptace_ o Plunger _i_/ Damage/Wear/Scratches-_ Replace valve lifter assemMyo H 2_ Inspect: oVatve lifter body Contact surface of the plunger camshaft° Damage/wear/scratches_* lifter assembly , and camshaft with Replace the vatve as a set. Assembly (_!_,Circlip _') Push rod seat (.
.oso°Aoo,EPA.° IE°o i'.l When reassembling the valve lifter, reverse the disassembly procedure. Note the following points. Valve lifter assembiy should be filled with clean engine oil into the high pressure chamber before reinstallation, if the empty valve lifter is installed, it will create excessive noise and couBd be damaged. How to filh .... ..... ....
E°o I...
'OSPEOT'OO AOO °EPA,° IE°O "*'l PRIMARY __-- SHEAVE Primary Sliding Sheave Disassembly 1. Remove: ePrimary sheave cap (_ oCam plate (_ eSlider bushings (_ eWeights (_ oScrews (Primary sheave cap) (_ .... Inspection 1. Inspect: ®Primary sliding sheave (_) oPrimary fixed sheave (_) oCollar _) Wear/Cracks/Scratches_ Replace. ..... _vJ 2. Position: eCollar (_ Into primary sliding sheave (_. 3. Check: ...............
E°G I ,os000AOOOEOA,O Primary Sliding Sheave Assembly When reassemblk_g the primary sliding sheave, reverse the disassembly procedure. Note the foF _I_ /_ lowing points. 1. Install: oOii seals (New) NOTE: Always . , :!i : (]} use a new oil seal.
.OOPEOT.O° A°O °EPA.° IE°O r'.l SECONDARY SHEAVE Disassembly 1. Attach: oClutch Compressor Holder (YM-33285-1) (_, Hexagon Wrench (YM-01307) (_) or suitable collar and plate washer 2. Loosen: P eLocknut (Clutch assembly) Use the Locknut Wrench(YM-04045-A)(_ and Primary Sheave Holder (YS-01880) (_). Do not remove the clutch Uocknut at this stage yet. 3. Remove: ®Clutch compressor Holder (YM-33285-1) @, Hexagon Wrench (YM-01307) (_) or suitable collar and plate washer 4.
INSPECTION AND REPAIR 8, Remove: ®Clutch assembb_' ®Sliding spring _ (1_ ®Spring seat _ 9. Remove: @ _Guide pin (!} _Guide co/tar {_ _Secondary sliding sheave _} anspection /(2_ 1, l[_spect: _Secondarv oSecondary fixed sheave _i} sliding sheave _2} Scratch / Damage_-+ Replace. 2, Inspect: oTorque cars grooves (Sliding sheave) oGuide pin (_ oGuide collar _'} Wear/Damage 3, inspect: eBall bearing Needb _ RepEace. (.
INSPECTIONANDREPAIR [ENG 4. Measure: .... ®Sliding spring free length Out of specification-* Replace. Sliding Spring Free Length: STD: 96,7 mm (3.81 in) Limit: 93.7 mm (3.69 in) 5. Inspect: eClutch housing (Inner surfaces) Scratch/Damage-* Replace. I_ 136 mm (5.35 in) Clutch Housing Wear Limit: .I 6. Inspect: oClutch body (_ .... oClutch shoe (_ ) ®Clutch spring (_ Damage-*Replace as set. (__ 7. Measure: oClutch shoe thickness (_ Out of specification-* Replace. _ New: 4.0 mm (0.
, sPEcT,oo Aoo OEPA,O 1o Install: A I cOil seals (New) _ To the secondary sheaves. _ (_) Press-in _ OH Seam Depth 1.5 mm _: (&06 in} 2, Lightly grease the oil seal lips, 3. Apply: eShaded areas (as a illustration Lithium-Soap Base Grease SufficientUy __ _) Coat.
INSPECTION AND REPAIR IENG 9, Tighten: oLocknut (Clutch assembly) 90 Nm (Clutch (9,0 mokg, 65 ft°lb) Locknut Assembly): [_ Be sure to remove the any oil and or grease from the secondary sheaves with a thinner. V-BELT 1. Inspect: oV-belt Crack/Wear/Scaling/Chipping-_ Replace. Oil or grease adhered to the V-belt_Check the primary and secondary sheaves. 2. Measure: (_) oV-belt width (_) Out V-belt ofSTD:Limit:Width:20.0 specification 22.6 mm --, Replace. (0.
ENG INSPECTION AND REPAMR 2o Remove: @Screws (Starter wheel) Use the #40 Torx Driver /;_-_ wheel L_J (YU_29843_7)(_1-}. @Starter .... 3. Remove: o Rollers {i} oSpdng caps {8} oSprings (_ _nspeetion 1, Inspect: (_-}._ o Roller {]i) ._) *Spring cap (2_ @ Spring (_) @Cfutch housing _) Deform/Wear/Damage ....... ............. RepJace° 2. inspect: -_} oBushing/Roller contact clutch .gear L1/) /-_ surfaces (Starter ......... ....
BNSPECTUON ANDREPAIRENGI Starter Clutch AssernbBy When reassembling the starter clutch, reversethe disassembly procedure. Note the following points. 1. Oil the all component parts of the starter clutch. ...... 2. Tighten: oScrews (Starter wheel) Use the #40 Torx Driver (YU-29843-7) (_. NOTE: JY_ Always use a new screw. [_ _,_ Screw 30 Nrn (Starter (3.0 m*kg, Wheel): 22 ft-lb) 1 LOCTiTE® 3. Clinch: eScrew head (Starter wheel) Use a center punch. Screw head flattens in the recess in the starter wheel.
ENG INSPECTION AND REPAIR 2, Inspect: oCamshaft holder surfaces Pitting/ Scratches/ Damage-+ Replace crankcase assembty. 3, Inspect: oCamshaft journal surfaces _ Pitting / Scratches/Blue discoloradon----_ Replace camshaft and crankcase a set, eCam lobes _} Pitting/Scratches/Blue place. assembly as d scolorat on--_ R@ ®Cam lobes Use a Micrometer. 4. Measure: Out of specification-->Reptace. intake Exhaust Cam Lobe "A .... Cam Lobe B" 32o37,-32,49 mm 25,9g-_26.01 mm 1.2744-1.2791 in !1.
INSPECTBON ANDEPAIR[ ENG Bearing and Oil Seal 1. Inspect: oBearings Roughness/Damage/Wear-_ °Oil seals Wear/Damage-, Replace. ®Main axle shaft holes .... Pitting/Galling/Wear-, Replace. Replace. OnL PUMP 1. Remove: °Screws lOllpumpl °Oil pump housing cover i eThrust washer ;_ i!iiii,ii!i_!ii_!i_i_ __...... _ _i_!ii_i,_i_ _ 2. Measure: :_ ®Housing (_/Outer rotor (_ clearance Use Feeler Gauge. Out of specification-, Replace oil pump assembly. 0.03-0.08 mm (0.0012-0.0031 in) Limit: 0.15 mm (0.
ENG ID] INSPECTION AND REPAIR -- BALANCER WEIGHT 1. Remow_: ! _' a galancer weight gear component parts @ / From the baiancer weight (_2"}_ 2. Inspect: oWeight _ oBuffer boss eSpdngs _33"} ,j_} , ,,/ i gear (I} _Dowe! pins {_8. _) o Holding plate @ Damage/Wear/Fatigue-_* ..- U Replace. 3. Install: ®Dowel pins ({!.} eSprings _hx (_8_} To the buffer boss {8} ....
'OSPECT'OO A°O °EPA'° 1Eoo CRANKSHAFT, CRANKCASE _ CONNECTING ROE) AND 1. Thoroughly clean all parts. o_:_ Crankshaft 1. Remove: ®Nuts (Rod cap) (_ ®Rod cap (_ oConnecting rod _ 2. Inspect: ®Drive gear teeth (Balancer) (_ Pitting/Galling/Wear-_ Replace crankshaft assembly. oCrankshaft splines (_ Wear/Damage-_ Replace. oCrankshaft journals Pitting / Scratches--> Replace. NI 3. Measure: ..... I(_) ._ )(_ oRounout: Use the V-Blocks (_ and Dial Gauge (_. Out of specification-_Replace.
ENG 11t I INSPECTJONANDREPAJR Crankshaft main urement steps: bearing clearance meas- eMeasure the journal outside diameter _, at two different positions, if it is out of specification limit, replace the crankshaft. o Measure the main bearing inside diameter _} at two different positions, photo the read out down. ®Calculate the oil clearance, specifications, Subtracting _a_ from if it is out of replace the main bearings.
,° PEOT,O°A°O°EP IE°O The diameter of counterbore should be measured at two places, and the average of the two measurements should be used to choose the bearing. Diameter of counterbore in crankcase 34.000-34.010 mm (1.3385-1.3389 in) 34.011-34.020 mm (1.3390- 1.3393 in) ..... Color code Red Black NOTE: If the diameter of the counterbore in the crankcase exceeds 34.020 mm (1.3393 in), the crankcase should be replaced with a new one.
I ENG INSPECTNON AND REPAmR 3. Remove: oTool set NOTE: Make sure tile bearing is positioned correctly in place. Connect#_g Measurement Rod Bearing Clearance 1, Clean alt parts. 2, Instafl: ®Connecting rod bearings Into connecting 3. Attach: rod and cap. .... ®Plasdgage ® (Y U-33210) 4. Install: ®Connecting rod pin. Onto the crank oConnecting rod cap Be sure the letter on both components NOTE: form perfect character, align to 5.
,OSOEOT,O° A°O °EPA,° [E°O 7. Remove: ........... oConnecting rod cap Use care in removing. 8. Measure: oWidth of Plastigage ® (_ Out of specification_Replace bearings and/or replace crankshaft if necessary. Clearance: Connecting Rod Bearing 0.021- 0.045 mm (0.0008- 0.0018 in) Rod Bearing Selection catedconnecting by 3 or 4 and marked in ink onindithe ®The rodare size numbers are connecting rods and caps. oThe rod bearing journal size numbers is indicated by 0.
I ENG mNSPECTmON AND REPAmR Connecting Rod mnstaHation 1, Insta!l: e Connect!ng rod bearings _1-} To the connecting rod and rod cap, NOTE: _ Aligh the tab {_'} with ..... w the sl0t _3_- 2, Apply: oBearing contact surfaces Lightly Coat, Disulfide Molybdenum I_ Grease ] 3, Install: ®Connecting NOTE: rod _!} The stamped "Y" mark _2 _) on the connecting .. rod should face towards the primary sheave side (Left side of the crankshaft} 4.
ENGINE ASSEMBLY ......... CRANKSHAFT (_ Buffer boss AND (_) Weight gear weight _(_)Balancer Crankshaft (_) Plain bearing _) Connecting rod Connecting rod cap (_) Oil pump (_) Crankcase 2. (_ Collar (_ Breather hose AUGN PUNCH A==E=°LY A°o AoJo=T===T I==0 I',.I AND ADJUSTMENT CRANKCASE (_ Crankcase 1 CRANKSHAFT RUNOUT 0.02 mm (0.0008 in) (_ Dipstick Drain bolt @ JOURNAL (_ (_ (_ (_ (_ (_ (_ (_) 0.02-0.05 mm (0.6008-0.0020 in) CONNECTING ROD BEARING CLEARANCE: 0.021-0.045 turn (0.0008-0.
ENG ENGINE ASSEMBLY AND ADJUSTMENT TRANSMISS_ON Fh/wheei magneto _ Stator assembly _{_,Woodruff key (_') Camshaft drive gear _ Camshaft _) Bearing Oil seat _8_ Drive axle _USE ii!!i 3-51 (-_) Thrust washer 1_ Main axle _ Primary drive axle _ Gasket @ Transmission case cover _) Dowel pin 1_,_Starter gear case cover _ Gasket A NEW ONE _ Starter wheel _) Roller _ Spring cap _ Spring _1_ Cluch housing @ Starter clutch gear @ Starter- Idle gear _) Idle gear shaft
E°0,OE ASSEMOLY A°O AOJOSTMEO I0°01" '1 C CRANKSHAFT AND CRANKCASE Oil Strainer and Relief Valve 1. Install: ®O-ring (New) (_ To the relief valve _). NOTE: oAIways use a new O-ring. ®Before installing the relief valve, grease the Oring sparingly. 2. Install" eRelief valve _) oOil strainer (_ NOTE: Before installing the oil strainer thorough wash the oil strainer in a solvent. ° H Crankshaft and Balancer Weight 1.
ENG NE ASSEMBLY AND ADJUSTMENT Crankcase 1. Clean: oCrankcase thinner. mating 2. Apply: ®Quick Gasket ® surfaces with a lacquer (ACC-11001-.05-01/ To the mating surfaces of both case halves. 3. install: ®Nozzle _![ oO_[ing (New) o Dowel pins _3-_ ®Spacer collar _z_ To the crankcase 1 4. Fit the crankcase 2 onto the crankcase 1. Tap lightly the crankcase 2 with a soft-head hammer° 5. Check: ,_Crankshaft smooth Not smooth-_ 6o Tighten: _Screws movement Reset.
ENGmNE ASSEMBLYAND ADJUSTMENT f ENG _-_1 7. Install: ........ oO-ring (New) (_ To the oil filter cover _. ®Oil filter (_ with filter cover (_ NOTE: oInstall the oil filter _) with its projection _ facing towards the engine. oBefore installing the oil filter cover apply the engine oil to the O-ring on the filter cover. 8. Tighten: ®Oil filter cover (_ Nm Cover (1.0 mokg, Oil10Filter @: 7.2-1b) 1_ I 9. Install: oOil level switch (_ .... 10. Install: ®O-ring (New) (_ To the oil filler case (_.
IE.G/ 1E.O..E ASSEMB. A.O AOJOST.E.T "I:"I:T:I:I ::"i:?i:"i:::i:':i:::i: _I,I:I:_,I::,I,_:I::,I.: i,i,i:'_i_i i:':i:i':,i':,!',,!': EEI.::EIT::E ::EEE!EE_EEE,E:E_EEEEEE_:EE_E]E_EE]EEE]E:]]_EE]EE]]E:]]EEE]EE]]EE]]EE]]EE]]EE]]EE]]E]: Apply a liberal amount of 4-stroke engine oil to the oil pump passages @. TRANSMISSION 1. Install: • Drive axle NOTE: • Oil the drive axle bearing and shaft. • Grease the oil seal lip. • Be careful not to damage the oil seal rip when installing the drive axle. 2.
E°°'°E O°L+ A°° A°J°++ME°+ IE°° I'+l 2. Install: oCamshaft assembly +Be careful not to damage the jounal bearing, when installing the camshaft assembly. ®Aligh the punch marks on the drive (_ and driven gear _. carter installing the camshaft assembly remove the knock pin (_) from the driven gear, 3. Install: cO-ring (New) (_ NOTE: Grease the O-ring. 4.
_NG %]DI ENGENE ASSEMBLY AND ADJUSTMENT MAINBTAND AND REAR WHEEL 1. Install oMainstand _) oBolts (Mainstand) _ NOTE: Grease the mainstand bolts: 2. Hook: oSpdng (Mainstand _1_ 3. Tighten: ®Bolts (Mainstand) (2} {_-----[-Bo_t {Mlainstandl ¢: 30 Nm 13i0 m,kg; _ ft-lbl I 4. Instatl' eBrake shoe plate _.3} oBolts (Brake shoe plate) _2} Brake shoes {4} NOTE: Grease the cam and pivot pin on the brake shoe plate, 5.
....... E°O,OE A0SEMOLY AO0 AOJ0STOEO 1 STARTER MOTOR AND FLYWHEEL MAGNETO 1. Install: oStarter motor (_) oWoodruff key (_) ®Stator assembly (_ NOTE: Grease the O-ring on the starter motor. 2. Tighten: oScrews (Starter motor) oScrews (Stator assembly) ...... Screw 7 Nm (Starter (0.7 m okg, Motor) 5.0 ft-lb) Screw (Stator Assembly) 7 Nm (0.7 m ekg, 5.0 ftolb) 3.
I ENG SECONDARY ENGmNE ASSEMBLY AND PRIMARY _i_ Spring seat @ Spring _3_ Clutch assembly _} Lock nut @ Clutch houshng @ Secondary fixed sheave V_-bett Secondary sliding sheave {_ O-ring AND ADJUSTMENT SHEAVES _.i_ Oil seat Guide coHer Guide pin _:3_Holding plate (1_ Primary sheave cap _i_ Slider bushing _ O--ring @ Camplate _ Weight 90 Nm {9.0 m,kg, @ Primary sliding sheave @ Collar _ Primary fixed sheave @ Lock washer _ Dowel pin _z_ Gasket @ Sheave case cover 65 fto_b} [ 1 _ 136 mm (5.
E°o oEMoLY A°o A0 0STMEO [0°Ol''l SECONDARY AND PRIMARY SHEAVES Secondary Sheave and Clutch Housing 1. Install: oSecondary sheave assembly eBefore installing the secondary sheave, remove the any oil and grease from the contact surfaces of the sheaves with a thinner. eBe careful not to damage the oil seal lip on the secondary sheave, when installing the secondary sheave. 2. Install: oClutch housing 3. Tighten: oNut (Secondary ..... @ sheave) (_) Use the Sheave Holder (YS-01880) @. ............
ENG ENGINE ASSEMBLY AND ADJUSTMENT 2. Install: oprimary fixed sheave _ o Lock washer (New) {$} oNut(Primary sheave assembly) {3) ............... ®Remove contact the any oil and g[ease from the surfaces of fi×ed sheave with a thinner_ ®Be sure that the projections washer align with sheave. the slots _)on the Bock _5_ on the fixed _ _i_, 3. Tighten: ®Nut (Primary sheave assembly) Use the Rotor Holder (YU-01235) ._ _ 4. Bend the lock washer tab 5.
ENGINE .......... ASSEMBLY AND ADJUSTMENT 7. Install: [ ENG _-_1 ,Sheave case cover (_) 8. Tighten: ,Bolts (sheave case cover) ==_ 10 Nm (1.0 m*kg, 7.2 ft+lb) Bolts (Sheave Case Cover): NOTE: Thighten the boltsin two stage, usinga crisscross pattern. CYLINDER AND PISTON 1. Install: ,Valve lifters (Intake _ NOTE: and Exhaust (_) Liberally coat the valve lifters with a engine oil. 2. Install: .....
LENG CYUNDER, _ _®_ ENGINE PISTON AND ASSEMBLY CYUNDER COVER _1} Rocker arm shaft @ O-ring _ Wave washer {3} Rocker arm Plate washer _!_Air bleed bolt @ Cylinder head cover _7} O.
EOO,°E ASSEOOLY A°O AOJOSTME° IE°OI .} 3. Install: ....... o Piston (_ oPiston pin (_) oPiston pin clip (New) NOTE: (_ oThe mark on piston crown must side). point to theUPupward (Exthemark faces exhaust ®Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material into the crankcase. eAIways use a new piston pin clip. 4.
ENG ENGmNE ASSEMBLYAND ADJUSTMENT 7o Install: _O_dng (New) {_ To the cylinder skirt. _CyIlnder {_}_ _Socket bolts (cylinder) \lx/a-_ NOTE: ...... olnstatl the cylinder with one hand while compressing the piston nngs with the other hand, eDo not thighten the socket boks ,_ at this point. Finger-tighten the bolts. (_ki!k x _,' cf }k CYUNDER COVER 1, Install: ......... HEAD AND CYLINDER HEAD _Nozzie (--_.) _0[t seal _Oowel pins (2_) _Gasket (New} ,(_) ......
E°O,OE MOLY A°O AOJ0STOEO [E°O ] ..... Bolts 22 Nm (Cylinder (2.2 rn,kg, Head): 16 ft,lb) Socket Bolt (Cylinder): 10 Nrn (1.0 m,kg, 7.2 ft_lb) Socket Bolt (Cylinder Head): 22 Nm (2.2 mokg, 16 ft°lb) NOTE: Thightenthe boltsin two stage, usinga crisscross pattern. 4. Align the "T'" wark (_ on the flywheel magneto (_ with the stationary pointer (_) on the crankcase so that the piston is at TDC on the compression stroke. ...... 5. Install: oNozzle eO-ring (New) @ oDowel pins (_) oPush rods (_ NOTE: ........
ENG _1 ENGmNE ASSEMBLY AND ADJUSTMENT 8. Tighten: _Bolts (Cylinder head cover} BoJt {Cylinder Head Cover): 20 Nm (2.0 m okg, 14 ftolb) NOYE: ] .... Tighten the bolt in numerical order as shown, in two or three steps, ENGINE MOUNTING When remounting the engine, reverse the removal procedure. Note the following points. 1. Instafl: _Maffler assembly _ with new gasket (_4] eFJange bolts (Muffler)_2_ eSocket bolts (Exhaust pipe) (._ _ ...... ....
ENGINE ASSEMBLY AND ADJUSTMENT ENG Nut (Rear wheel axle) (_ 4. Tighten:100 Nm (10.0 m°kg, 72 ft,lb) i_ Nut (Rear wheel A×le) _): l 5. Install: oCotter pin (New) 6. Adjust: oThrottle cable free plays Refer to "CHAPTER 2. THROTTLE CABLE ADJUSTMENT" section. ........ ..... ....... oRear brake pedal free play Refer to "CHAPTER 2. FRONT AND REAR BRAKE INSPECTION" section. 7. Add: oEngine oil Refer to "CHAPTER 2. ENGINE OIL AND OIL FILTER REPLACEMENT" section. 8.
_i_il ii!i _i_il_ !_i 3-69
IoAooI ] ....... CHAPTER 4 CAP,BURETmON CARBURETOR .................................................... SECTION VIEW ................................................. FUEL FLOW DIAGRAMS ........................................ AUTO CHOKE SYSTEM ......................................... REMOVAL ..................................................... DISASSEMBLY ................................................. INSPECTION ................................................... ASSEMBLY ............................
IoAooI 4 cAooooEToo CARBURETION CARBURETOR _) Vacuum chamber cover 6} Vacuum piston spring Jet needle holder @ Spring seat (_ Spring _) Jetneedle Vacuum piston Throttle stop screw _9_ Spring _ Main jet @) Needle valve _ Gasket _1")Float pin _} Needle jet @ Pilot jet _._)Rubber cap @ Float @ Cable homer (1_ Float chamber (_ Spring _ Drain screw' _ Starter ptunger assembly SPECIFICATIONS MAIN JET # 128 MAIN AtR JET @1,5 JET NEEDLE 5C1&3/5 NEEDLE JET #95 PILOT JET #36 PILOT AIR JET @0,8 PILOT OUTLET @0.
CA"OO"0TO [OAO0 1 SECTION ..........
CARBURETOR FUEL FLOW DIAGRAM Pilot outlet Bypass holes (_,33_ Pilot air jet @ Air jet (Coasting enricher) _ Diaphram (Coasting enricher) _') Pilot jet _ Throttel vaJve ___Vacuum piston _ Main air jet 1_(_Needle jet @ Main jet (I_ Jet needle Fuel M ixtu re SLOW METE.,.
CA°00°ETO° IOA°0I ] AUTO .......... (_ (_ (_ (_ (_) (_ (_ CHOKE SYSTEM Choke unit Cam Starter plunger Starter outlet Starter air inlet Cold starter outlet Starter nozzle (_) Starter jet (_ Cold starter plunger (_ Cold starter (_ Cold starter (_) Cold starter nozzle nozzle jet air jet A <_ Air B _ Fuel C _ Mixture E/ Construction 1. Choke unit .... ;....... _i : heater, controls the plunger the engine is started. .......
[CAR CARBURETOR 2, Plunger assembly The plunger assembly is composed of the starterplungerand coldstarterplunger.The starter plungerprovidesair-,fuel an mixturefor startingand idling, the cold starterplunger providesa cold engine with a richfuelmix.° ture for smooth acceleration, _ _ _ _ _ _ _ ............ .......... 3. Choke relay The choke relay provides electric current from .......... the battery to the heater, rpm reaches 600 r/mkl, tivated.
CA°00°ETO° IOA° 4. Accelerating ....... with a cold engine When an engine is not warmed-up sufficiently, the mixture will be lean during accelera- (_ A <:_ Air tion. B _ Fuel provides a rich mixture for smooth accelera- The Cold Engine C _ Mixture tion engine Plunger is cold, is because Cold when Enginethe Starting open duethe to the cold wax in the choke unit. However, fuel will not be supplied celerated.
[CA_I_ CARBURETOR REMOVAL I 1. Remove: ®Front cover F_-._+U +Side covers (Left and right) _2-_ Refer to "REMOVING THE COVERS AND PANELS", page 2-13. 2+ Remove: +Air cleaner case _1_} Refer to "ENGINE REMOVAL-AIR CLEAN+ ER CASE", page 3°2. 3. Disconnect: ............. - +Fuel feed hose @ +Vacuum hose @ From carburetor side. +Choke unit lead coupler @ 4+ Remove: +Throttle cable (_ From carburetor side Refer to '+ENGINE REMOVAL CONTROL CABLES", page 3+3.
CA"OO"ETO ] DISASSEMBLY Never attempt to disassemble the following parts. oThrottne vaave eThrottle shaft 1. Remove: oStarter choke unit eStarter plunger assembly 2. Remove: oVacuum chamber cover (_ oSpring (_ % ._ _J_ ®Vacuum piston (_ eScrew (Jet needle holder) @ oJet needle holder (_ oJet needle (_ NOTE: When removing the jet needlebe sure not ot loose the small spring that may fall out. This spring holds the jet needle. ...... 3. Remove: oFloat chamber oFIoat pin (_ • Float _) oFloat valve 4.
CARBURETOR ,5, Remove: oldie adjusting eCoasting oSpring screw enricher L#i_ cover {2} {3.} ®Diaphragm _4} / INSPECTION 1, Inspect: e Carburetor body Contamination _ Ciean o NOTE: - , oUse a petroleum based solvent for cleaning, ®Blow out all passages and jets with compressed air° 2. inspect: Damage-_ Replace, o Gasket/O--rings Damage-+ Replace. 3, Inspect: oNeedle valve _!_ eVaIve seat _'_ Wear/Contamination-+ Replace (Carburetor Assembly) 4.
...... CA"OO°ETO ICA°OI J 5. Check: • Free movement Stick-* Replace. Isnert the vacuum piston into the carburetor body, and check for free movement. 6. Inspect: oThrottle valve Wear/Damage-* Replace. 7. Check: oVlave free movement Stick-* Replace carburetor assembly. .... 8. Inspect: ®Jet needle Bends/Wear-* Replace. ..... ...... 9. Inspect: oNeedle jet (_ ®Pilot jet (_ Damage/Contamination-* Replace. 10. Inspect: -,Starter plunger Damage/Wear-_ Replace. 11.
[cAoot 1cAoouo0Too ............ 12. Inspect: eDiaphragm (Coasting Damge/Torn-* endcher} Reptace_ 13. Check: oChoke unit operation Refer to "CHAPTER 6. AUTO CHOKE UNF TEST" section. ASSEMBLY To assemble the carburetors, sembty procedures. e Before reverse the disas_ Note the following reassembling, points. wash aimparts in cmean gasoBineo eA_ways use a new gasket° 1. Measure: ®Float height Out of specification-* 26-_28 mm FJoat Height: Float height ........ Adjust. {1.024_- 1.
CA°OO°ETO JOAOO ] oIf the float height is not within specification, inspect the valve seat and needle valve. elf eifher is worn, replace them both. oil both are fine, adjust the float height by bending the float tang (_ on the float. oRecheck the float height. 2. Install: eCoasting enricher (_ oVacuum piston (_) NOTE: There is a tab on the rubber diaphragm and a matching recess in the carburetor body to accept the diaphragm tab. 3. Install: oChoke unit (_ Apply LOCTITE® to the choke unit securing screws.
leA°°ICAOOOO TO0 FueJ Uevemmeasurement steps: ®Place the scooter on a level pJace. ®Use a garage jack under the engk_e to ensure that the carburetor is positioned vertically. eAttach the Fuel Level Gauge G} (YM-01312A) to the float chamber nozzle, to the float chamber nozzle, ....... ®Loosen the drain screw (_) and start the engine. _Measure the fuet level _,} vvkh gauge. ®If the fueElevel is incorrect adjust the fue! level, ( 3-_-_7mm 2.
..... CHAPTER 5 CHASSIS FRONT WHEEL .................................................... REMOVAL ..................................................... INSPECTION ................................................... INSTALLATION ................................................. lo.Asl ol 5-1 5-2 5-3 5-6 REAR WHEEL ..................................................... REMOVAL ..................................................... BRAKE DISASSEMBLY .......................................... INSPECTION .......
CH__® FRONT WHEEL CHASSIS FRONT WH ELL TWRE AiR PRESSURE (_ Spacer collar @ Tension bar COLD TIRE FRONT REAR (_ Oil seal _ Cotter pin PRESStON: Bearing _5_ Oil seal 147 kPa 196 kPa @ Spacer @ Bushing UP TO 90 kg (1.5 kg/cm 2, (2.0 kg/cm 2, @ Spacer flange _ Washer (198 ]b) LOAD* 21 psi) 28 psi) (_@Ckclip @ Speedometer driven gear BASIC WEIGHT: Washer (.
............. oo°T w.EEL 1 REMOVAL 1, Placea suitablestand underthe footrest boad, then elevate the front wheel, 2, Remove: o Brake cable oSpeedometer cable 3. Remove: ®Cotter pin oNut (Tension bar) (_ ®Plain washer (_ oBolt (Tension bar) 4. Remove: ..... ®Cotter pin (_ ®Nut (Front wheel axle) (_ oFront wheel axle eFront wheel Brake Shoe Plate Disassembly 1. Remove: oBrake shoes (_ olnner collar (_ It] 2.
IC"ASt FOOOTW.EOL ] 3. Remove: *Brake cam lever (1_ ®Wear indicator plate _ ®Return spring (3_ *CamShaft (4_ NOTE: .... Put mark (5_)on the camshaft lever before tern,ving out so that it can be reinstalled in the original position. J 4. Remove: *Bushing _ *Washer (_ *Driven gear (Speedometer cable) (3_ Use the Meter Gear Bush Driver: ........
F°OOT W.EEL C"AI Wheel bearing and oil seal replacement steps: ®Clean the outside of the wheel hub. eRemove the oil seal _ driver. use a flat-head screw eDrive out the bearing (_. Eye protection is recommended when using striking tools. olnstall the new bearing and oil seal by reversNOTE: (_ _ Use socket that matches ing athe previous steps. the outside diameter of the race of the bearing and oil seal. ! Do not strike the center race (_) or balls of the bearing.
[CHASinG 1 FRONTWHEEL allow rim. _ the tire to seat itself on the Batance weight Brake @ correctly Shoe 1. inspect: o Glazed Brake shoes parts --_Sand with coarse sand-paper, oBrake shoe (Thickness) (&L_' Out of specification-_Reptace. , ......... 2, Measure: .... STD: Shoe 4.0 mm {0o16 in) Brake Thickness: Limit: 2,0 mm {0.08 in) _ *Shoe springs 3. Inspect: Wear/Damage-* 4o Measure: .....
F°OOT W.EEL [C"AS I 2. Measure: oBrake drum inside diameter Out of specification-* Replace. STD: Drum 138 mm (5=12 in) Brake inside Diameter: Limit: 131 mm (5.18 in) Brake Shoe Plate and Camshaft 1. Inspect: eOil seal (_ Wear/Damage-* Replace oCamshaft (_) eCamshaft hole _) i J_ Scratches/Excessive wear--, Replace. Speedometer _ Gears 1. Inspect: oMeter gear (_ oDrive gear (_ oMeter clutch (_ Wear/Damage-* Replace. When installing the front wheel, reverse the INSTALLATION removal procedure.
Ic. o] FRONTW.EEL 4.
°EA. W.EEL [O°ASI 1 REAR WHEEL ........ (_) (_) (_ (_ (_) (_ Cotter pin Axle nut Plate washer Thrust washer Brake shoe Return spring (_ (_) _ (_ _) (_ (_ Brake camshaft Washer Brake shoe plate Return spring Wear indicator plate Cam lever USE NEW ONE A ] TIRE SIZE: RIM RUNOUT LiMiT: 4.00-10 4PR _ B C Radial: Lateral: 1.0 1.0 mm mm (0.04 (0.04 in) in) BRAKE DRUM WEAR LIMIT: 151 rnrn (5.94 in) AiR VALVE: install the air valve on the right of the scooter ...... 2.0 mm (0.08 in) i18Nm(1.8 m.kg.
._ REAR WHEEL ............ REMOVAL 1. Place the scooter I}. on its centerstand. 2, Remove: ®Front cover {_} ®Side cover (Right) {_) Refer to "REMOVING THE COVERS AND PANELS" section, ,\ 3, Remove: *Socket bolts {Exhaust *Flange *Muffler bolts (Muffler) assembly _) pipe) \[/ @ 4. Remove: e Cotter pin 5, Loosen: *Nut (Rear wheet axle) {_ NOTE: '*: While applying the rear brake, fully to,sen the axle nut, e Nut (Rear "wheel axle} (,]_) ®Plate washer _ 6. Remove: *Rear wheel assembly _.
°EA° W.EEL JO"A ] 2. Remove: eBrake cam lever (_ oWear indicator plate _) oReturn spring (_) NOTE: Put mark (_ on the camshaft lever before removing out so that it can be reinstalled in the original position. _2) _ oCamshaft (_) 3. Remove: oPiate washer (_ INSPECTION (_1_ 1. Inspect: oCamshaft (_) ®Camshaft hole (_) Scratches/Excessive wear-* Replace. oSplines (Rear wheel) (_ 2. Inspect: oSplines (Drive axle) (_ Wear/Damage-* Replace. 3.
C-HAS REAR WHEEL 4. Measure: ®Brake shoe (Thickness} ®Shoe spring free tengh ngh: :0mmi2'6a 1 eBrake drum inside diameter STD: 150 mm (5o91 in) Limit: 151 mm (5og4 in) Brake Drum Inside Diameter: Refer to "FRONT section. WHEELqNSPECTION" INSTALLATION When installing the rear wheel, reverse the removaJ procedure. Note the following points. 1.
°EA° W°EEL NOTE: ....... oThoroughly wipe off the excess grease. oAIways use a new cotter pin. 4. Adjust: oRear brake pedal free play Refer to "CHAPTER 2. REAR BRAKE INSEPCTION" section.
CH_I_®I HANDLEBAR HANDLEBAR AND FRONT FORK AND FRONT FORK S Ring nut nut (Lower) (Upper) Ring _ Collar Compression arm _(_ _} __ _} _8} Bearing Ball race (Upper) cover Bearing (Lower) Front fork Shock absorber Nipple _ Bushing Dust seat _ Dust cover _) Side caps (_ Side cap stay _}_)Cable clamp 5-13
°AOOLEOA° A°O F.OOT FO°K iO"A1 ......... i REMOVAL Handlebar 1. Place the scooter on its centerstand. 2. Remove: eRear view mirrors (_ ®Bolts (Headlight) =Headlight unit (_) .... 3. Remove: oScrew (Handlebar cover-upper) (_ 4. Loosen: eBolts (Handlebar cover=upper) (_ 5. Remove: eSpeedometer cable eAudio pilot @ From upper handlebar cover (_ 6. Disconnect: ®Speedometer lead connecters 7. Remove: oUpper handlebar cover (_ ....... _ .Diode (_ oFlasher relay unit (_ 9.
[CHAS__ 1 HANDLEBAR AND FRONT FORK . 11_ Remove: ®Flange bolt (Handlebar) _}) eHandlebar assemble Shock (_J} [ , /' Absorber and Front Fork 1, Remove: eFront Cover [_ oSide cover (Left and right) (_2-_ _ ®Footrest board _ Front trunk @ Scooter panel @ Refer to "REMOVING THE COVERS AND PANELS" section. 2. Remove: o Front wheel _1_] o Brake cable _'_ eSpeedometer cable oCable damp _-_ with cables 3. Remove: 4. Remove: oS[de caps (_ ....
I _ [] _ 8 4. Remove: ®Bolts (Compression arm-Fork) (_ eStay (Side cap) (_ oCompression arms (_) NOTE: Put mark _ on the compression arms before removing out so that it can be reinstalled in the original position. [] _2___ _ _1_) _ Left 5. Remove: [] Right ®Cotter pin (_ oBolt (_) ®Washer (_) omension arm (_ (_ oWasher (_ -@1 I 6. Remove: *Ring nuts (Upper and Lower) @ Use the Ring Nut Wrench (YU-012681 or (YU-33975) (_).
INSPECT_ON Shock Absorber 1_ b_spect: _Shock absorber Oil bakage/Damage-_ Front RepLace. Fork 1, Inspect: o Front fork Crack/Bend/Damage Do not fork this fork, } (:_ _2: _<_5_ _ _ to straighten may dangerously 2, Inspect: oCompression arm _ Crack/Bend/Damage-* £2} U attempt _2_ -_ Replace. a bent weaken RepLace. olnner collar _} Wear/Pitting/Damage-+ RepLace. eLnner busMng (_ Wear/Pitting/Damage,--* RepLace.
HANDLEBAR [] AND _ FRONT FORK 1 3. When removing the race, drive out by striking it in steps. And fit the race squarely in the head pipe. if the bearing race is fitted not squarely, the head pipe could be damaged. [] [] [] Lower Upper ASSEM BLY When reassembling the front fork assembly, reverse the removal procedure. Note the following poits. ! ifl _,_ _ Front: Fork _'°;_ 1. Grease the races and put the balls in it.
__® HANDLEBAR AND FRONT FORK 3. Tighten: ®Ring nuts (Lower and upper} ....... Ring nuts tightening NOTE: .... steps: Set the Torque Wrench to the Ring Nut Wrench so that they form a right angle. ,Tighten the lower nut (!_ using the Ring Nut Wrench (YU_.33975} _. 30 Nm mokg, Tightening}: 22 ftolb} Ring Nut (&0 {1-_{Bnitial oLoosen the lower dng nut (1_ completeiy and retighten it to specification, Do not over-tightening. .ot¢/ ioo, . 0.too,n0,: kg, 2°2 ftolb} .... , ...........
°AOO'EOA. A°O F°OOT FO°K IO"ASL 1 1. Apply: .......... oCompresion arm-Front fork (_ oShock absorber (Upper)-Front fork (_ oShock absorber (Lower)-Front fork _) Base Grease Lightweight Lithium-soap [_ ] oTension arm-Front fork (_ Molybdenum Disulfide Grease 1 2. Tighten: oBolts and nuts Bolt (Tension arm-Front fork) (_): 40 Nm (4.0 m-kg, 29 ft-lb) Nut (Compresion arm-Front fork) ®: 45 Nm (4.5 m okg, 32 ftoUb) Nut (Shock absorber (Lower)Front fork) (_: 20 Nm (2.
I ABSORBER°AOOLO AND FRONT FOOKJOEA S°OOK 6. Check: oElectrical component operations. 7. Adjust: ®Throttle cable free plays Refer to "CHAPTER 2. THROTTLE CABLE ADJUSTMENT", section. e Front brake lever free play Refer to "CHAPTER 2o FRONT AND REAR BRAKE INSPECTION" section. REAR SHOCK ABSORBER (_) I REMOVAL 1. Remove: ®Front cover ®Side cover (Left) (;2} Refer to "CHAPTER 2. REMOVING THE COVERS AND PANELS" section. / ®Air cleaner case (_1_ 2. Remove: Refer to "CHAPTER CASE" section. 3. AIR CLEANER 3.
°EA° S.OOKOO00° [O"AS[ I INSPECTION 1. Inspect: oShock absorber rod ..... Bends/Damage-_ Replace the shock absorber assembly. ®Shock absorber Oil leakes-_ Replace the shock absorber assembly. ®Spring Fatigue_Replace the shock absorber assembly. Move the spring up and down. INSTALLATION When installing the rear shock absorber, reverse the removal procedure. Note the following points. 1. Apply: eLithium base grease To the pivot points. .....
CHAS _1 5-23
ELECI CHAPTER 6 ELECTRUCAL CIRCUIT DIAGRAM ............................................... ELECTRICAL COMPONENTS ..... ....... ...................................... 6-3 ELECTRIC STARTING SYSTEM .................................... TROUBLESHOOTING ............................................ STARTING CIRCUIT CUT-OFF SYSTEM ........................... STARTER MOTOR ............................................. BATTERY INSPECTION ......................................... STARTER RELAY TEST ...........
ELEC_ _ )CIRCUIT DIAGFIAM ELECTRNCAL C! RCUIT DiAG RAM 64
CIRCUIT ........... ......
I ELEC ELECTRICAL ELECTRICALCOMPONENTS COMPONENTS @ Ignition coi! _ Starter relay Reserve fuse (20A x 1) Fuel _ Battery Main sender fuse (20Ax 1) _) Rectifier/Regulator Ignitor unit Fuel Sender Resistance: nition Coik t Full position: 20[2± 10% at 20°C {68°F} Primary winding resistance: /2o7_ ± 10% at 20°C {68°F) 236_±10% at 20°C {68°F) Empty position: I[13°2k_]±20% Secondary at 20°C {68°F) winding resistance: brake switch switch _ Rear idestand _1_Oil level switch Starter Relay Coil Resistan
ELECTRICALCOMPONENTS [ ELEC ELECTRICAL .........
@ 6_5
ELECT° CSTA.T OO SYSTEO IELEO[ N Aforementioned circuit diagram shows electrical starting circuit in wiring diagram. NOTE: For the encirclednumbers and color codes, see page 6-2.
[ELEC_] ELECTRIC STARTING SYSTEM TROUBLESHOOTING THE STARTER OPERATE°_ MOTOR DOES NOT t; Check the following parts, _Battery and fuse Refer to "CHAPTER 2, BATTERY and FUSE INSPECTION" section, _Main switch oSidestand switch o"ENGtNE STOP" switch e Brake switch e'START" switch FAULTY _m Replace defective parts. .......
ELECT.,C STA°T,°O SYSTEM lELEO 1 Disconnect the starter relay coupler, then connects the "Blue/White" lead (_ to the battery positive (+) lead (_) and "RedGreen" lead (_ to the body earth (_); use a jumper lead (_. .... i __ _l l _ I If the starter motor does not run, replace the starter relay. __ Connect the "Red/White" lead @ to the "Yellow" lead (_) on the starting circuit cutoff relay coupler (_); use a jumper lead @.
ELECt ELECTRIC STARTmNG SYSTEM STARTmNG Engine _ CmRCUIT CUT-OFF Starting m " - _ Operation Turn main switch Set "ENGINE SYSTEM to "ON", STOP" switch to "RUN", J 77 ttActivate starting start the engine. H Fold sidestand circuit cut.ooff relay to in (sidestand switch is "ON"). .U. Apply either front or rear brake. (Brake switch is "ON").
ELECTRmC STARTING SYSTEM __] STARTER MOTOR ........... (_) (_ (_) (_ (_) (_) (_) Bracket Brush holder assembly Brush Brush spring O-ring Housing Armature ALIGN MATCH iViARK A MiNiMUM BRUSH LENGTH: 5.0 mrn (0.20 in) B COMMUTATOR WEAR LliVlIT 22.0 mm (0.87 in) C MICA UNDERCUT: 0.8 mm (0.
I ELECTRIC STARTING ......... SYSTEM Removal 1. Remove: /Front cover _1_} eSide cover (Right} (2_ Footrest board '{;._ Refer to " CHAP T ER 2. REMOVING COVERS AND PANELS" THE section,. \, 2o Remove: _Passenger footrest (Right} _ 3. Remove: eSocket bolts (Exhaust pipe) (11-}} ®Flange bolts (Muffler) eMuffler assembly (3_i , :, 4, Remove: Screws eScrews _Fancase {Air shroud 1) _} (Faro_case cover) ($} cover _3_)with air shroud (_} 5.
ELECTRmC STARTING SYSTEM Inspection and Repair \..___ ..... _ // ,_ \Ylt_'-_ "-__(_),,-Jl/u _ /_'(_ eCommutator Dirty-_Clean (Outer it with surface) #600 grit sandpaper Hold the armature in a vise (_ and copper 1. Inspect: or aluminium plate (_. NOTE: Lightly grip the armature with a vise, 2. Measure: eCommutator (Diameter) Measure the diameter (_ of the commutator at which the brush contacts. Out of specification_ Replace. _ _ Commutator Wear 22.0 mm (0.87 in) Limit (_: 1 3.
I ELECTRmCSTARTING SYSTEM 5. Inspect: e Bearing _) ®O°ring s _8} eBushing (._ eThrust washer _ J'_' ................ 6. Inspect: ................ _Commutator brushes Damage--_Replace. 7. Measure: ®Brush length KL_ } Out of specification--_ Replace, Brush Length: .... .... _ 5,0 mm {0,20 in) 8. Inspect: eBrush springs Compare with new spring. Wear/Damage-_ .... ....
ELECTRICSTARTINGSYSTEM 1 BATTERY INSPECTgON ....... 1. Inspect: e Battery Refer to "CHAPTER 2. BATTERY INSPECTION" section. STARTER RELAY TEST 1. Inspect: oStarter relay Poor condition _ Replace. Starter relay inspection steps: oOpen the seat, and remove the front cover. oDisconnect the starter motor lead _ from the starter relay _. oTurn main switch to "ON", engine "STOP" switch to "RUN" and applyeitherfront or rear brake and sidestand to up.
ELEC I ELECTRICSTARTmNG SYSTEM STARTING CIRCU_T CUT-OFF RELAY TEST 1. Remove: ®Scooter panel Refer to "CHAPTER COVERS AND 2. REMOVING PANELS" oRelay assembly 2. Disconnect: ®Relay assembly THE section. _') connector @} 3o Measure: oStarting circuit out, off relay resistance Use the Pocket Tester {_ (YU.o03112). Out of specification I O _@ -°-_Rep[ace, Starti_ Resistance: [ at20o _ 68OF) ......... J Red/White Yei[ow 4.
ELECTRmCSTARTING SYSTEM I__ ] 2. Check: ............. e Diode continuity/discontinuity Defective Sb G r// B/R G L/W Y W Y _ Checking element Sb W/G _o,l 2 Replace the unit. Pocket tester B/R I_ I ...... element(s)--* W connecting (+ ) Good D1 B/R L/W x D2 Sb L/W (red) Y Y B/R (black) Sb © © × R B/R G 8.29 J 3_ .........
ELEC ELECTRIC STARTING SYSTEM Front Brake Switch t. Remove: Headlight unit Refer to "CHAPTER 2. HEADLIGHT BULB REPLACEMENT" section. 2. Disconnect: ..... o2-pin connector (Green/Yellow, Brown) _) 3. Check: Front brake switch contact Out of specification-_Replace Tester d} switch, 0£_ a rOW[_ @_Green/Yellow Rear Brake Switch 1, Remove: oScooter panel Refer to "CHAPTER 2. REMOVING THE COVERS AND PANELS" section. 2. Disconnect: e2@in connector _.
ELECT°,C STA°T,°O S STEO JELEOI ] I(_) Br L/B R/W Br/R o"ENGINE _ STOP" switch contact Out of specification-_Replace 3. Check: "ENGINE STOP'" switch RUN Tester switch. O FF 0n co (_ Red (_ Brown/White 4. Check: o"START" switch contact Out of specification_Replace ......... "START" switch position Pocket tester connecting point Good oN ® - ® © (Push) _) = _) x ®=® o (_ = ® X OFF (Free) ©: Continuity {0n) (_) ×: Discontinuity (oo) ® ....
ELEC _ ] CHARGING SYSTEM CHAnGiNGSYSTEM u//o' 6-19
ELECI _ CHARGING SYSTEM TROUBLESHOOTING [ THE BAKERY NS NOT CHARGED° 1 g. Measure the battery for voltage gravity_ Battery vokage: More than 12V Specific 1.280 gravity: and specific Recharge the battery. .......... ES .... _Y tot Vottage: _Start the engine and accelerate to about 2,000 More than 15V . g Generator Vo!tage: Less than 14V I Replace rectifier check the Stator stator I coil resistance_ coil resistance 0.44[_±15% g--(White.
' ELEC BATTERY INSPECTION Referto "CHAPTER 2. BATi-ERY INSPECTION" section. CHARGnNG VOLTAGE TEST .......... 1. Open the seatand remove the battery cover. 2. Connect: o Pocket Tester (¥U-03112) To battery terminals. 3. Start the engineand accelerateto about2,000 r/min or more. 4. Measure: oGenerator voltage Out of specification-_ Check battery, stator coil, and rectifier regulator. .... Generator 1 Voltage: 14- 15V _:iiii:.z:.i::ii ::i!;!ii;i;i;i;i .....
I ELECI _ CHARGINGSYSTEM 3, Connect: ®Pocket Tester (YU-03112) 4. Measure: eStator coil resistance Out of specification-_ Replace stator coiJs. 0,449 Coil ± 15% at 20°C {68°F) Stator Resistance: {White--White) _ White RECTIFIER TEST 1, Remove: e Front cover eSide cover (Left) Refer to "CHAPTER COVERS AND 2o REMOVING PANELS" THE section, 2, Disconnect: o6-pin connector (1_ (White, Red, Brown and Black). White, White, _) Rectifier/Regulator 3.
CHARGINGSYSTEM ELEC _ ] Do not overcharge rectifier or damage may result. Avoid: eA short circuit. olnverting + and -- battery Ueads. oDirect connection of rectifier to battery.
ELECI _ mGN_TION SYSTEM IGNIT_ON SYSTEM _ii_!!_i_ !i_!_!_ _ 6_25
IGNrNON Aforementioned circuit diagram shows ignition circuit in wiring SYSTEM [ELEC _ ] diagram. NOTE: For the encircled (_ (_ (_) (_ (_ (_) (_ (_) (_ numbers and color codes, see page 6-2.
ELEC IGNmONSYSTEM TROUBLESHOOTING The entire ignition system can be checked for misfire and weak spark by using the Electro Tester, 1, Warm up the engine so that all of the electrical components are at operating temperature. 2. Connect: o Electro Tester (YU-33260) (,,_ 3, Start the engine, and increase the spark gap until misfire occurs. (Test at various r/min beO G tween ....
ELEC] nGNmON SYSTEM Troubleshooting Chart i ignition Check the Measure entire the battery for connections" voltage and _ I COrrect" I specific 0rav,t . Battery voltage: More than 12V Specific gravity: 1,280 Recharge the battery. i Set the main and "ENGINE STOP" switches ....... tage (12V)and on the "Red/White" lead atfor the volig- _.............................. to "ON", sidestand to up. Check __>1Check the main fuse and wiring circuit. ] nitor unit and ignition coil.
m ,O°,T,O° s o _ iGNiTiON SPARK GAP TEST 1_Open the seat and remove the front cover. 2, Disconnect: olgnition coit connector oSpark plug leads 3. Connect: o Electro Tester (YU-33260). NOTE: Be sure to use a fully charged 12V battery _i}. 4_Turn the spark plug gap adiuster and increase the gap to the maximum limit unless misfire occurs first. _ A_ Minimum .... Spark Gap: mGNiTION 1. Connect:COiL RESISTANCE 1 TEST 2.
iGNiTiON SYSTEM ELEC PICKUP COiL RESISTANCE 1. Remove: ®Front cover J TEST ®Side cover (Right) Refer to "REMOVING THE COVERS AND PANELS" section. 2. Disconnect: ®2-pin connecter (White/Red, White/Black) 3. Measure: oPickup coil resistance Use a Pocket Tester. (YU-03112) Out of specification_ Replace. ........... _ 114.5_3±15% at 20°C (68°F) Pickup Coil Resistance: (White/Red-- White/B0ack) SPARK PLUG iNSPECTiON Refer to "CHAPTER 2. SPARK PLUG INSPECTION" section.
LIGHTINGSYSTEM ELECI _ Aforementioned circuit diagram shows lighting circuit in wiring diagram. NOTE: For the encircled numbers and color codes, see page 6-2.
ELEC I LIGHTINGSYSTEM LIGHTING TESTS AND CHECKS The battery provides power for operation of the headlight, taillight, and meter illumination, if none of the above fail to operate proceed further. Low battery voltage indicates low battery fluid either a faulty level, or a defective battery, charging system. Also check fuse condition. fuses. There are individual cuits (see complete Circuit Replace any "open" fuses for various cirDiagram).
LIGHTINGSYSTEM I ELEC _ 1 Headlight Troubleshooting ON. HEADLIGHT , DOES NOT COME t; Check main fuse. _i [c_eck _e_O,,O_t _u,_. _ .... mainMeasure batterY'switch v°ltage ("ON"(12V) position), °n Br°wn lead fr°m •q ,_OK sition) and "Green" ("Lo" position)leads from Measurevoltage(12V) on"Yellow"("Hi"po-_1 "LIGHTS" (Dimmer) switch. .... 1 _eo,ace. j Check main switch and i Check ,,START,, switch" [ NO VOLTAGE _i NO VOLTAGE from "START" switch ("Free (OFF)" position).
I Taillight oos sTEM Troubleshooting COME ON. Check main fuse. Replace. Check taillight bulbs. Replace. ,_OK " i NO Measure voltage (12V) on "Brown" main switch ("ON" position). lead from Poor ground or poor connection wiring. of taillight 6-35 Check main switch and battery.
LJGHTINGSYSTEM EL_ MEMO _ 1 6-36
I ELEC _ SIGNAL 6-37 I SYSTEM SIGNAL SYSTEM
SmGNAL Aforementioned circuit diagram shows signal circuit in wiring SVS'rEM ELECI _ ] diagram. NOTE: For the encirclednumbers and color codes, see page 6-2. (_ ® @ ® (_ @ .....
ELEC _ 1 SIGNALSYSTEM TROUBLESHOOTmNG {1) [ FLASHER UGHTS DOES NOT COME ON ] ... ........ Check main fuse. Replace. Check flasher lightbulbsand"TURN" indica-____1_ tor light bulbs. _OK I, J f Replace. N0 Measure voltage (12V) on "Brown" main switch ("ON" position), lead from _OK Check main switch and battery. NO Measure voltage (12V)on "Brown/Whke" from flasher relay, VOLTAGE[ lead _| Replace flasher relay.
TROUBLESHOOTING S,OOALSYS [ELEOI 1 (2) COME ON. ....... i BRAKE LIGHT DOES NOT HCheck ma'n' he se. M eo'ace. 1 ,FAULTY, Check the brake light bulbs. _1 I J_OK .... R Replace. NO Measure voltage (12V) on "Brown" main switch ("ON" position). Apply the front and/or switch is "ON".) " lead from Check main switch and battery. 1 rear brake. (Brake J_ NO Measure voltage 112V) on "'GreenYellow" _1 leads from front and/or rear brake switches. _1 Poor ground or poor connection wiring.
ELEC__ SIGNAL SYSTEM AUDIO P|LOT TEST t, Remove: ®Headlight unit Refer to "CHAPTER 2. HEADLIGHT BULB REPLACEMENT" section. 2. Remove: ®Audio pilot 3. Measure: oAudio pilot resistance Use the Pocket Tester (YU-03112) Out of specification-_Reptace. ,o0,o oo.,.toooo ] PHot 40ft ± 10% at 20°C (68°F} ..... SWITCHES TEST "TURN" Switch Switches may be checked for continuity with a Pocket Tester (YU-03112) on the "Ohm x 1" position.
[ ELEC _ ACCESSORY 643 I ACCESSORY SYSTEM SYSTEM
ACCESSORY Aforementioned circuit diagram shows accessory circuit SYSTEM in wiring ELECI _ ] diagram.
ELEC _ 1 ACCESSORYSYSTEM MAMN SW_TCH ILLUMiNATiON Operation With the main switch turned "off" or set in the "lock" position, pushing the horn button causes the main switch illumination light to come on, The light illuminates the green letters on the main swkch panel so that the key hole can be seen even in the dark, TROUBLESHOOTING MAIN NOT SWITCH (1} ILLUM_NATmON DOES COME ON. ,_ FA ULTY Check main fuse. Replace, -'------_K .......
ACCESSORY SYSTEM TROUBLESHOOTING (2) ....i FUEL METER DOES NOT OPERATE. n Check main fuse. _OK main switch ("ON" position). Measure v°ltage (12V) °n "Br°wn" ....... ELEC Replace. I, Check main switch and battery. i J NO lead fr°m _i _OK Disconnect fuel sender connector, and meas- IVOLTAGE _ Check for an open or poor connection harness, sender.
_ '__ ACCESSORY SYSTEM TROUBLESHOOTING (3} OiL LEVEL _NDICATOR LIGHT DOES NOT COME ON, ] FAUkTY _OK main switch ("ON" _ NO position). Check main switch and battery. Disconnect oil level switch coupler, and corn nect "Black/Red" lead _ from diode unit (_ to "Ground" on frame; use a jumper lead _. LIGHT DOES NOT COME ON B/R LtGHT COMES ON IReptace oil level switch.
TROUBLESHOOTING m AOOESSO°Y SYSTEM ELEC (4) i HORN DOES NOT OPERATE. g _ _o VOLTAGE main switch ("ON" position). Measure v°ltage (12V) °n "Br°wn" .... lead fr°m II_l_l Check main switch and battery" I _OK Disconnect "Pink" lead coupler (_) and connect horn terminal (_) at "Pink" lead side to "Ground" on frame; use a jumper lead (_) NOT _[ . tween main switch and horn. Check condition of "Brown" lead be- I IIOK [_ I Replace horn.
IELEC _] ACCESSORYSYSTEM FUEL SENDER TEST 1. Open the seat. 2. Disconnect: ®Fuel sender connector 3. Remove: ®Fuel sender assembly 4. Measure: eFuet sender resistance Use the Pocket Tester (YU-03112). Out of specification-_Replace. Fuel Sender Resistance: FulmPosition _: 20_ ± 10% at 20°C (68°F} Empty Position _: 236_ ± 10% at 20°C (68°F} Black @ Green OIL LEVEL SW_TCH TEST 1o Drain: i ®Engine oil 2. Remove: oOit level switch 3. Measure: .......
AOOESOO.Y i YS 4. Install: oOil level switch 5. Connect: ®Leads 6. Fill: ®Crankcase .......... ........ Refer to "CHAPTER 2 ENGINE REPLACEMENT" section. OIL HORN TEST 1. Measure: (_ .... O_O_ _ Out of specification-_ Replace. Tester's lead wire Standard Red lead Black lead resistance (+) (-) eHorn resistance Brown lead Pink lead terminal terminal 1.05_±10% ® ......... Rx 1 eVolume 2.
LELECI _ AUTOCHOKE SYSTEM AUTOCHOKE SYSTEM _,i_i_ _i_il _i!i _!i_ _ili 'I_ x x 6--51
AUTO Aforementioned circuit diagram CHOKE shows auto choke circuit $YSTEiVl in wiring I ELEC _ ] diagram. NOTE: For the encircled numbers and color codes, see page 6-2.
{ELEC[ I AUTO CHOKE SYSTEM TROUBLESHOOTING After starting the engine, the AUTO CHOKE system provides a leaner fueFair mixture according to the increased engine temparature. Thus, if the cold engine is hard to start, the carburetor unit is defective and an overhaul of the unit is necessary. An electrical trouble in the AUTO CHOKE system causes the engine to be a trouble or hard to start when the engine is warmed up. Check the engine as follows: The engine shows a trouble after warmed up.
AUTO CHOKE SYSTEM IELE ] CHOKE UNBT TEST 1. Remove: oCarburetor assembly oChoke unit From carburetor body. Referto "CHAPTER 4. REMOVAL" section. 2. Measure: eChoke unit resistance Use the Pocket Tester (YU-03112). Out of specification_ Replace. Choke Unit Resistance: 3.0±1.0_ at 25°C (77°F) 3. Connect: e12V Battery (_ 4. Check: oCam movement ..... Incorrect movement_ Replace. [] BATTERY IS NOT CONNECTED (WAX IS COLD) [] BATTERY IS CONNECTED (WAX IS WARM) __,-_ CHOKE RELAY TEST 1.
ELECI ] AUTO CHOKE SYSTEM 3. Inspect: oChoke relay unit Choke unit inspection steps: ,Connect batteries by which the applied voF tage is 18V between DC20V the white _ and the Black {_}, terminals. NOTE: O The relay unit needs at least 13.5V to be activated. o Set the tester selector to "DC2OV" ®Measurement 6VBattery of the voltage between Green/Red {3} and the Black _ should be S2V: 12VBattery position. the terminals is olf less than 12V, replace the choke unit.
CHAPTER 7 APPENDmCE$ ....... SPECIFICATIONS ................................................. GENERAL SPECIFICATIONS ..................................... MAINTENANCE SPECIFICATIONS ................................ GENERAL TORQUE SPECIFICATIONS 7-17 DEFINITnON OF UNITS .......................................... 7-17 LUBRICATION 7-18 DIAGRAMS CABLE ROUTING ......... ........................... 7-1 7-1 7-4 XC2OOT WIRING ...................................... .....................................
IAP--- SPEO.F.OAT.O.S APPENDICES S PEC!FICATi 0 NS GENERAL SPECIFICATIONS Model XC200T Model Code Number: 1YA Engine serial Number IYA-000101 Vehicle Identification Number JYA1YA00_HA000101 Dimensions: Overall Length Overall Width Overall Height Seat Height Wheelbase Minimum Ground Clearance 1,920 715 1,135 775 1,290 133 mm mm mm mm mm mm (75.6 in) (28.1 in) (44.7 in) (30.5 in) (50°8 in) (5.
Model XC200T ! Brake: Front Brake Type Operation Rear Brake Type Operation Drum Right Drum Right Brake Hand Operation Brake Foot Operation Suspension: Front Suspension Rear Suspension Bottom Link Fork Unit Swing Shock Absorber: Front Shock Absorber Rear Shock Absorber Coil Spring, Oil Damper Coil Spring, Oil Damper Wheel Travel: Front Wheel Travel Rear Wheel Travel 76 mm (2,99 in) 70 mm (2.76 in) ......... .... ......
SPECiFmCATmONS APP× MAINTENANCE SPECIFICATIONS Engine Model Cylinder Head: Warp Limit XC200T _ <0.025 mm (0.001 in)> _Lines indicate straightedge measurement. _" Cylinder: Bore Size Taper Limit Out-of-round 67.98-68.03 mm (2.6764-2.6783 <0.05 mm (0.002 in)> <0.01 mm (0.0004 in)> Limit Camshaft: Drive Method Cam Holder Inside Diameter Gear Drive (L) 33.00-33.025 mm (1.299-1.300 in) (R) 7.000-17.018 mm (0.669-0.670 in) (L) 32.959-32.975 mm (1.2976-1.2982 in) (R) 16.967-16.980 mm (0.668-0.
SPEO,F,OAT,ONS Model XC200T "A" Head Dia. IN. EX. 30.9r-31,1 25.9-26.1 "B" Face Width IN. EX. 1.7-2.9 1.7-2.9 "C" Seat Width IN, EX. 0.9-1.1 mm (0.035 - 0.043 in) 0.9- 1.1 mm (0.035- 0.043 in) IN. EX. <1.4 mm (0.055 in)> < 1.4 mm (0.055 in) > IN. EX. 0.8_ 1.2 mm (0.031-0.047 in) 0,8-1,2 mm (0.031 .-0,047 in) IN. EX, <0,7 mm (0.028 in)> <0.7 mm (0.028 in)> IN. EX. 5.978-5.990 5.963-5.975 IN. EX. <5.945 mm (0.234 in) > <5.920 mm (0.233 in)> IN. EX. 6.000 - 6.012 mm (0.2362_0,2367 6.
SPEC, ,CAT,O Model XC200T Tilt Limit* . IN. EX. 2.5°/1.5 2.5°/1.5 mm (0.059 in) mm (0.059 in) IN. EX. Clockwise Clockwise I ,',,\\\\\\\\\\ Direction of Winding ..... Outer Spring: Free Length IN. EX. Set Length (Valve Closed) IN. EX. Compression Force (Valve Closed) IN. EX. Tilt Limit* IN. _EX. 37.20 mm (1.465 in) 37.20 mm (1.465 in) 32.0 mm (1.260 in) 32.0 mm (1.260 in) 16.6-20.4 kg (36.6-45.0 16.6-20.4 kg (36.6-45.0 2.5°/1.6 mm (0.063 in) 2.5°/1.6 mm (0.
SPECIF CATaONS Model XC200T Piston Ring: Top Ring: ............ Dimensions (B ×T) 1_0x2.6 mm (0.0394x 0.1024 in) End Gap (Installed) Type _B < Limit> Side Clearance {Installed) < Limit> 2nd Ring" 0.30-0.45 mm (0.0118-0_0177 Barrel 0.70 mm (0.0276 in) 0.03--0.07 mm (0.0012-0.0028 0.12 mm (0.0047 in) in) in) Dimensions (B x T) End Gap (Installed) < Limit> _ Side Clearance [q_ 0_02- 0.06 mm (0.0008- 0.0024 in) _.__ 0.12 (0.0047 in) x 0.0984 in) 2.0 x mm 2.5 mm (0.0787 0.2_--0.
SPECUFiCATIONSAPPX Model XC200T Clutch: Clutch Shoe Thickness Wear Limit Clutch Shoe Spring Free Length Sliding Spring Free Length Clutch-In Revolution -Stall Revolution 4.0 mm (0.157 in) <2.0 mm (0.079 in)> 28.5 mm (1.12 in) 96.7 mm (3.81 in) 2,200- 2,600 r/min 3,450- 4,050 r/min Transmission: Main Axle Deflection Limit Drive Axle Deflection Limit <0.08 mm (0.003 in)> <0.08 mm (0.003 in)> Air Filter Oil Grade (Oiled Filter) Yamalube 2-cycle oil or equivalent Carburetor: ........
___% 1 SPEO,F,OAT'ONS Model _ XC200T Lubrication chart: Feed Scavenge [ Left Journal} [Connecting _ Balancer shaft _ -L.ifter hole L big-end ] Right Jooinoi"-I _L_ ..... Crankshaft Rocker shaft Rocke r arm ------------..
TIGHTENING TORQUE S0 O,F,CAT,O IAPP×I Tightening torque Part to be tightened ........ ......... Thread size Remarks Nm mokg ft,lb Cylinder Head Cover Spark Plug Cylinder Head Cylinder Head-Cylinder Intake Manifold M10 M12 M 8 M 8 M 6 20 17.5 22 22 10 2.0 1.75 2.2 2.2 1.0 14 12.5 16 16 7.2 Connecting Rod Flywheel Magneto Exhaust Pipe Muffler Mission Cover M 6 M10 M 8 M 8 M 5 18 35 30 25 3 1.8 3.5 3.0 2.5 0.3 13 25 22 18 2.
SPEC'F'CAT'ONS IAPPx Chassis Model XC200T Steering System: Steering Bearing Type No./Size of Steel Balls Ball Bearing Upper Lower 22 pcs/3/16 in 19 pcs/l/4 in Front Suspension" Front Fork Travel Fork Spring Free Length Spring Rate Stroke 55,0 mm (2,17 in) t59.2 mm (6.27 in) <157.7 mm (6.21 in)> KI K2 K3 K1 K2 K3 Optional Spring Oil Capacity K1 K2 KI K2 215,5 26,16 43.11 0-35 35-70 No. mm (8.48 in) N/mm (2,67 kg/mm, 149 Ib/in) N/mm (4A0 kg/mm, 246 Ib/in) mm (0-1.
SPEC,IAPP× ,CAT,O Model XC200T Drum Brake: Type Front Rear Leading and Trailing Leading and Trailing Front 130 mm (5.12 in) <131 mm {5.16 in)> 150 mm (5.91 in) < 151 mm (5.94 in) > 4 mm (0.16 in) <2 mm {0.08 in)> Drum Inside Dia. < Limit> Rear Lining Thickness Shoe Spring Free Length < Limit> Front/Rear Front Rear 36.5 mm (1.44 in) 68.0 mm (2.68 in) Brake Lever 8- Brake Pedal: Brake Lever Free Play/Position Brake Pedal Position 10-20 mm (0.4-0.8 57 mm (2.
APPX SPECmRCATIONS TIGHTENING TORQUE Part to be tightened Front Front Front Front Wheel Brake Shock Shock Thread size Remarks Axle Cam Lever (Upper) (Lower) M12 M 6 M10 M 8 Torque Arm-Fork Torque Arm-Shoe Plate Front Arm Pivot Handle M10 M10 M10 M10 Steering Shaft Engine Pivot Shaft Rear Wheel Axle Rear Brake Cam Lever M25 M14 M14 M 6 10 Rear Shock (Upper) Rear Shock (Lower) Wheel Hub Side Stand Main Stand M10 M12 M 8 M10 MI0 50 50 30 30 30 Rear Stay (Front) M 8 25 Rear Stay (Upper) Rea
SPEC,F,CAT l Electrical Model XC200T Voltage 12V Ignition System: Ignition Timing (B.T.D.C.) Advanced Timing (B.T.D.C.) Advancer Type 12° at 1,200 r/rain 32° at 5,000 r/min Electrical 40 ...... f = _ i _ _ 32°+2°/5"O00r/min"_l o 30 I=:m .=__ 20 14°/2'000+250r/_8 !//_ 0 1 2 301/, 3 EngineSpeed ( J _ I 1 50! 25 - r/"i- inl I 4 5 6 × 103r/min) T.C.I.: ..... Pickup Coil resistance (Color) T.C.I.
IAPP×I sPEo,F,oAT,oos ,] Model Voltage Regulator: Type Model/Manufacturer No Load Regulated Voltage XC200T Short Control SH235_12/SHIN DENGEN 14.0-15.0V Rectifier: Model/Manufacturer Capacity Withstand Voltage S H235q 2/SH INDENGEN 15.0A 200V Battery: Capacity Specific Gravity 12V, 10AH 1.280 Electric Starter System: Type Starter Motor-Model/Manufacturer Constant Mesh Type SM-7/MITS UBA Output Armature Coil Resistance 0.4 kw 0.014£±10% Brush-Overall Length < Limit > 10.5 mm (0.41 in) < 5.
SPEC,F,CAT, IAPPXI Model Starting Circuit Cut-off Relay: Model/Manufacturer Coil Winding Resistance Diode XC200T 25G/TATEISHI 75_±10% No.
APPX DEF|NITmON OF UN|TS -] GENERAL TORQUE SPECIFICATIONS/ GENERAL TORQUE SPEC|FICAT iONS This chart specifies torque for standard fasteners with standard t°S.O, pitch threads_ Torque specifications for special components included in the applicable To avoid warpage, or assemblies are sections of this book. tighten multi-fastener General torque A specifications g (Nut) (BoRt) 10 mm 6 mm Nm 6 m,kg 0.6 ft,lb 4.3 12 mm 8 mm 15 1,5 11 14 mm 10 mm 30 3.0 22 assem- 17 mm 12 mm 55 5.
LUBRiCATiON DIAGRAM ............. (_ (_) _) (_ (_) (_) (_ Rocker arm shaft Bearing Nozzle Cylinder head cover Rocker arm shaft Rocker arm Camshaft Plug _) (_ _) (_) (_ (_ (_ L00,.CAT.O° O.
APPx 1cAoLE.ooT,oo , CABLE ROUTING f ................... \ i i m ,) ,\) \ \ / _ LI:__ _ i ¸! :i::_ _i_ _ ill _jJ \.
CABLE °OOT,°O ....... (_) (_) _) (_ (_ (_) _) (_ (_ (_) (_ (_) (_ (_ (_ (_ (_ (_) Audio pilot Flasher relay Horn Band Throttle cable Front brake switch lead Handlebar switch (Right)lead Audio pilot lead Speedometer cable Handlebar switch (Left) lead Diode unit Main switch illumination lead Main switch Headlight lead Front brake cable Front flasher light (Left) lead Wire harness Front flasher light (Right) lead Starting circuit cut-off relay [] Clamp the wire harness. Do not over-tighten it.
IAPPX _L__ _ \ 7_21 CABLE ROUTING
CABLE.OOT, ........... .........
1c.°
APPX CABLE ROUTmNQ .......... (_ (_ (_ (_ (_ (_) (_ (_) (_ (_ (_) (_ (_) Throttle cable Main switch Starting circuit cut-off relay Horn AC magneto generator lead Starter motor positive lead Starter motor negative lead Fuel sender lead Clamp Battery negative lead Battery Ignition coil Spark plug lead [] Place the wire harness coupler, excluding the horn lead and left flasher light lead, to the right of the steering head pipe. [] Pass the fuel sender lead inside of the seat bracket.
i _ _y '_,i_i_i _i_ii_i!!i_!i_ _I__ i _ii_ii_?iiill _i_i_!i_ii_i_il Y s'i i \, _ : F / i' ,\ B _ " \\ t \ 8 _:_,_ : :_!i_ii:_i!_L_ / '\ _i_i_ 'i!:y!i_!i:ii_ii_i _ // ,J I , _!_i.....
CABL IAPPXI .OOT,°O ..... 6 (_ Front brake cable (_) Speedometer cable (_ Clamp (_ Wire harness (_ Band (_) Throttle cable (_ Rear brake cable (_) Fuse lead (_ Starter relay (]_) Ignition coil (_ Battery (_) Fuse (_ Rectifier/Regulator (_) Ignitor unit (_ Battery breather hose (_) Carburetor breather hose (_ Sidestand switch (_ Sidestand switch lead (_ Front brake switch lead [] Cross section: C-C [] Pass the wire harness outside of the inner fender.
IAPPxlCABLE lROOT NO 7-27
CABLE°OOT, O0APPare .... (_ (_) (_) (_) (_) (_ (_ (_) (_ (_ (_) (_) @ (_ (_) (_ (_ Sidestand switch lead Wire harness Brake switch lead Engine protector Rear brake switch Spark plug Ignition coil Battery negative terminal Battery To fuel sender Rear brake cable Band Clamp Fuse Battery positive terminal Starter relay Throttle cable [] Cross section: A-A [] Pass the brake switch lead, wire harness, and sidestand switch lead, inside of the engine protector without them getting pinched by a rib.
APPX _i_ £ ,'_'i_ _i__ii i_i_ _iii_ _iii 7,-29
XC200T W! RING DlAG RAM LIGHT (RIGHT) FRONT FLASHER ..... "START" SWITCH "TURN" INDICATOR _* LIGHT (RIGHT) "HIGH BEAM" iNDICATOR LIGHT INDICATOR LIGHT "SIDESTAND'" ........... "OIL LEVEL'" INDICATOR LIGHT "'TU RN'" IN DICATO R LIGHT (LEFT) _:_; ......... METER LIGHT CLOCK Fii FUEL LEVEL GAUGE ..............
FRONT BRAKE SWITCH REAR BRAKE SWITCH MAIN SWITCH FUEL SENDER p_... I I I I SID SW m m m -- -- ( i ) } } n rn _, F _i _, AUDIO PILOT FLASHER RELAY ___ "=" HORN OiL LEVEL RECTIFIER/ SWITCH REGULATOR UNIT A.C.
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FRONT BRAKE SWITCH REAR BRAKE SWITCH MAIN SWITCH FUEL SENDER p_... I I I I SID SW m m m -- -- ( i ) } } n rn _, F _i _, AUDIO PILOT FLASHER RELAY ___ "=" HORN OiL LEVEL RECTIFIER/ SWITCH REGULATOR UNIT A.C.
FRONT BRAKE SWITCH REAR BRAKE SWITCH MAIN SWITCH FUEL SENDER p_... I I I I SID SW m m m -- -- ( i ) } } n rn _, F _i _, AUDIO PILOT FLASHER RELAY ___ "=" HORN OiL LEVEL RECTIFIER/ SWITCH REGULATOR UNIT A.C.
ESTAND iTCH IGNITOR UNIT IGNITION COIL REAR FLASHER REAR FLASHER LIGHT (RIGHT) LIGHT (LEFT) G -Ul :USE I BATTERY STARTING CIRCUIT CUT-OFF RELAY -E_I STARTER STARTER RELAY MOTOR COLOR CODE 0 _ @ (_ Black Brown Darkgreen Green/Red Blue Blue/Green White/Black Red Red/Green 0 Black/Red _ Brown/Red O Green _ Green/White O Sky blue _ Blue/White _ White/Green _ Pink _}) Red/White _ _' _ _ 0) C) (_ _ Chocolate Brown/White Green/Blue Green/Yellow Blue/Black White White/Red Yellow Orange
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ESTAND iTCH IGNITOR UNIT IGNITION COIL REAR FLASHER REAR FLASHER LIGHT (RIGHT) LIGHT (LEFT) G -Ul :USE I BATTERY STARTING CIRCUIT CUT-OFF RELAY -E_I STARTER STARTER RELAY MOTOR COLOR CODE 0 _ @ (_ Black Brown Darkgreen Green/Red Blue Blue/Green White/Black Red Red/Green 0 Black/Red _ Brown/Red O Green _ Green/White O Sky blue _ Blue/White _ White/Green _ Pink _}) Red/White _ _' _ _ 0) C) (_ _ Chocolate Brown/White Green/Blue Green/Yellow Blue/Black White White/Red Yellow Orange
ESTAND iTCH IGNITOR UNIT IGNITION COIL REAR FLASHER REAR FLASHER LIGHT (RIGHT) LIGHT (LEFT) G -Ul :USE I BATTERY STARTING CIRCUIT CUT-OFF RELAY -E_I STARTER STARTER RELAY MOTOR COLOR CODE 0 _ @ (_ Black Brown Darkgreen Green/Red Blue Blue/Green White/Black Red Red/Green 0 Black/Red _ Brown/Red O Green _ Green/White O Sky blue _ Blue/White _ White/Green _ Pink _}) Red/White _ _' _ _ 0) C) (_ _ Chocolate Brown/White Green/Blue Green/Yellow Blue/Black White White/Red Yellow Orange
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Yamaha Motor Canada Ltd.
