©YAMAHA XF50W SERVICE MANUAL LIT-11616-20-58 3B3-F8197-10
EAS00000 XF50W 2006 SERVICE MANUAL ©2006 by Yamaha Motor Taiwan Co., Ltd. First edition, September 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd. is expressly prohibited. Printed in U.S.A.
EAS00002 NOTICE This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
EAS00008 1 2 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK i g l ADJ I ^ < \ 5 CHAS (3^3^) 6 ENG COOL j K m % 7 8 FI Ifl 9 1 2 3 4 5 6 7 8 9 General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting +i ELEC 0 TRBL SHTGl f} • q Symbols 0 to u indicate the following.
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM GEN INFO 1 0» SPEC 2 CHK ADJ 3 # % CHAS 4 ENG 5 COOL 6 FI 5 + ELECTRICAL SYSTEM TROUBLESHOOTING ELEC BL SHTG 8
GEN j y * INFO \<^® CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER MODEL LABEL FEATURES OUTLINE OF THE FI SYSTEM FI SYSTEM IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS EQUIPMENT PREPARATION CHECKING THE CONNECTIONS SPECIAL TOOLS 1-1 1-1 1-1 1-2 1-2 1-3 1-4 1-4 1-4 1-4 1-5 1-5 1-5 1-6 1-7 1-8
GEN SCOOTER IDENTIFICATION INFO # ^ EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL LABEL The model label 1 is affixed to the frame trunk. This information will be needed to order spare parts.
FEATURES EAS00896 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
FEATURES EAS00897 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kg/cm2, 35.6 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
IMPORTANT INFORMATION EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
GEN IMPORTANT INFORMATION INFO # ^ EAS00021 EQUIPMENT PREPARATION Push Rivet (Push type) Assembly status of the push rivet(push type). Dissembling 1. Press center p i n 1 inward to release the lock. 2. Remove the push rivet main body2.
CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8lead 8coupler 8connector 2. Check: • lead • coupler • connector Moisture -» Dry with an air blower. Rust/stains -» Connect and disconnect several times. 3. Check: • all connections Loose connection -» Connect properly. NOTE: If the pin © on the terminal is flattened, bend it up. 4. Connect: 8lead 8coupler 8connector k ^Yv» A ? ----.
SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: 8 For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
SPECIAL TOOLS Tool NO. 90890-01384 YM-33299 90890-01403 YU-A9472 90890-01444 YM-A9409-7 90890-01468 YU-33270-B 90890-01493 90890-01701 YS-01880-A 90890-03079 YM-34483 90890-03081 YU-33223 90890-03112 YU-03112-C Tool name / Function Oil seal guide This tool is used for protecting the oil seal lip when installing the secondary sliding sheave. Steering nut wrench This tool is used to loosen and tighten the steering ring nut.
SPECIAL TOOLS Tool NO. 90890-03141 YU-03141 90890-03182 YU-03182 90890-04101 90890-04058 YM-04058 90890-04145 90890-04019 YM-04019 90890-04148 YM-04148 90890-06760 90890-06754 YM-34487 90890-04111 YM-04111 90890-04112 YM-04112 90890-04113 YM-04113 Tool name / Function Illustration Timing light This tool is used to check the ignition timing. FI diagnostic tool Execute CO adjustment, confirm fault Code, self diagnosis tool Valve lapper This tool is needed to remove and install the valve lifters.
SPECIAL TOOLS Tool NO. 90890-01326 YM-01326 90890-01294 YM-01300-1 Tool name / Function 90890-03181 90890-85505 ACC-11001-05-01 # Illustration T-handle1 Damper rid holder2 These tools are used to hold the damper rod when removing or installing the damper rod. © 90890-03153 YU-03153 GEN INFO Pressure gauge This tool is used to measure fuel pressure. Fuel pressure adapter This tool is used to measure fuel pressure. Yamaha bond NO.
SPEC 0* CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2-1 ENGINE SPECIFICATIONS 2-2 CHASSIS SPECIFICATIONS 2-12 ELECTRICAL SPECIFICATIONS 2-15 CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-18 TIGHTENING TORQUES 2-19 ENGINE 2-19 CHASSIS 2-21 LUBRICATION POINTS AND LUBRICANT TYPES 2-23 ENGINE 2-23 CHASSIS 2-25 COOLING SYSTEM DIAGRAMS 2-26 CABLE ROUTING 2-29
GENERAL SPECIFICATIONS SPEC 0 * SPECIFICATIONS GENERAL SPECIFICATIONS Standard Item Limit Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet(without oil and a full fuel tank) Dry(without oil and fuel) Maximun load(total of cargo, rider, passenger, and accessories) 3B32(USA) 3B33(CAN) … … 1905mm(75.00in) 685mm(26.97in) 1045mm(41.14in) 735mm(28.94in) 1280mm(50.39in) 115mm(4.53in) 2000mm(78.
ENGINE SPECIFICATIONS SPEC 0* ENGINE SPECIFICATIONS Standard Item Engine Engine type Displacement Cylinder arrangement Bore×stroke Compression ratio Engine idle speed Vacuum pressure at engine idle speed Standard compression pressure(at sea level) Fuel Recommended fuel Fuel tank capacity Total Engine oil Lubrication system Recommended oil Quantity Periodic oil change Total amount Final gear oil Recommended oil Periodic oil change Total amount Oil filter Oil filter type Limit Liquid-cooled, 4-stroke,
ENGINE SPECIFICATIONS SPEC Standard Item Oil pump Oil pump type Inner rotor to outer rotor tip clearance Trochoid 0.15mm(0.006in) or less Outer rotor to pump housing clearance 0.13~0.18mm(0.005~0.007in) Oil pump housing to inner rotor and outer rotor clearance 0.07~0.12mm(0.003~0.
ENGINE SPECIFICATIONS SPEC Standard Item Camshaft Drive system Intake camshaft lobe dimensions 0* Limit Chain drive(left) … 30.158~30.258mm (1.1873~1.1913in) 25.082~25.182mm (0.9875~0.9914in) 30.058mm (1.1834in) 24.982mm (0.9835in) 30.158~30.258mm (1.1873~1.1913in) 25.020~25.120mm (0.9850~0.9890in) 30.058mm (1.1834in) 24.920mm (0.9811in) 0.03mm (0.
ENGINE SPECIFICATIONS SPEC Standard Item Timing chain Model/number of links Tensioning system Valve, valve seats, valve guides Valve clearance(cold) Intake Exhaust 0* Limit Morse 92RH2005/82 Automatic … … 0.10~0.16mm (0.0039~0.0063in) 0.18~0.24mm (0.0071~0.0094in) … … Valve dimensions y r v V VB \. \.C Head Diameter Face Width Seat Width Valve head diameter A Intake … 1.48~2.19mm (0.0583~0.0862in) 1.48~2.19mm (0.0583~0.0862in) … 0.9~1.1mm (0.0354~0.0433in) 0.9~1.1mm (0.0354~0.
ENGINE SPECIFICATIONS Standard Item Valve stem to valve guide clearance Intake 0.010~0.037mm (0.0004~0.0015in) 0.025~0.052mm (0.0010~0.0020in) ^ 0* Limit … 0.080mm (0.0031in) 0.100mm (0.0039in) 0.010mm (0.0004in) 0.9~1.1mm (0.0354~0.0433in) 0.9~1.1mm (0.0354~0.0433in) 1.6mm (0.0630in) 1.6mm (0.0630in) Exhaust Valve stem runout SPEC % / / / / / / / / / / /w?.
ENGINE SPECIFICATIONS Exhaust Limit 39.35mm(1.5492in) 37.38mm (1.4717in) 39.49mm (1.5547in) 41.57mm(1.6366in) Installed length(valve closed) Intake Exhaust Compressed spring force(installed) Intake Exhaust 0* Standard Item Valve springs Free length Intake SPEC 28.0mm(1.1024in) 30.0mm(1.1811in) … … 91.1~104.9N (9.3~10.7kg, 20.48~23.58lb) 107.9~124.1N (11.0~12.7kg, 24.26~27.90lb) … … 2.5°/1.7mm (2.5°/0.0669in) 2.5°/1.8mm (2.5°/0.
ENGINE SPECIFICATIONS SPEC Standard Item Piston Piston-to-cylinder clearance 0* Limit 0.010~0.035mm (0.0004~0.0014in) 37.975~37.990mm (1.4951~1.4957in) 0.150mm (0.0059in) … 5.0mm(0.1969in) … 10.002~10.013mm (0.3938~0.3942in) 0.35~0.65mm (0.0138~0.0256in) Intake side 10.043mm (0.3954in) … 9.996~10.000mm (0.3935~0.3937in) 9.976mm (0.3928in) Barrel 0.8×1.65mm (0.0315×0.0650in) 0.05~0.15mm (0.0020~0.0059in) 0.03~0.07mm (0.0012~0.0028in) … Taper 0.8×1.5mm (0.0315×0.0591in) 0.05~0.17mm (0.0020~0.
ENGINE SPECIFICATIONS SPEC Standard Item Limit Oil ring i 1 i 1 i B T , Dimensions(B×T) End gap(installed) Ring side clearance 1.5×1.6mm (0.0591×0.0630in) 0.2~0.7mm (0.0079~0.0276in) 0.03~0.15mm (0.0012~0.
ENGINE SPECIFICATIONS SPEC Standard Item 0* Limit Rocker arm/rocker arm shaft Rocker arm inside diameter Rocker arm shaft outside diameter Arm-to-shaft clearance Connecting rod Connecting rod length Small end inside diameter 10.000~10.015mm (0.3937~0.3943in) 9.981~9.991mm (0.3930~0.3933in) 0.009~0.034mm (0.0004~0.0013in) 10.030mm (0.3949in) 9.950mm (0.3917in) … 79.95~80.05mm (3.1476~3.1516in) 10.015~10.028mm (0.3943~0.3948in) … 42.45~42.50mm (1.671~1.
ENGINE SPECIFICATIONS Standard Item Clutch Clutch type Clutch shoe thickness SPEC Automatic centrifugal 3.7mm(0.146in) Clutch shoe spring free length Clutch housing inside diameter 30.1mm(1.185in) 107mm(4.213in) Compression spring free length Weight outside diameter 76.4mm(3.008in) 15.0mm(0.591in) Clutch-in revolution Clutch-stall revolution 3050~3450r/min 5000~6000r/min 0* Limit … 2.0mm (0.079in) … 107.5mm (4.232in) … 14.5mm (0.571in) … … V-belt V-belt width 17.9mm(0.705in) 16.1mm (0.
CHASSIS SPECIFICATIONS SPEC 0* CHASSIS SPECIFICATIONS Standard Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Steel tube backbone 26° 84mm(3.31in) … … … Cast wheel … J10×MT3.00 Aluminum 58mm(2.28in) … … … … 1.0mm (0.04in) 1.0mm (0.04in) 0.25mm (0.
CHASSIS SPECIFICATIONS Standard Item Rear tire Tire type Size Model(manufacturer) Tire pressure(cold) 0~175kg(0~386lb) Minimum tire tread depth Front brake Brake type Operation Brake lever free play(at lever end) Brake drum inside diameter Lining thickness Rear brake Brake type Operation Brake lever free play(at lever end) Brake drum inside diameter Lining thickness Front suspension Suspension type Front fork type Front fork travel Spring Free length Installed length Spring rate(K1) Spring stroke(K1) Optio
CHASSIS SPECIFICATIONS Standard Item Steering system Steering bearing type Lock-to-lock angle(left) Lock-to-lock angle(right) Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate(K1) Spring rate(K2) Spring stroke(K1) Spring stroke(K2) Optional spring available SPEC Angular bearing 46° 46° Limit … … … Unit swing Coil spring 45mm(1.77in) … … … 176.5mm(6.95in) 162.5mm(6.40in) 28.03N/mm (2.85kg/mm, 159.
ELECTRICAL SPECIFICATIONS SPEC 0* ELECTRICAL SPECIFICATIONS Standard Item System voltage Limit 12V … Transistorized coil ignition 5° BTDC at 2000~2200r/min Digita 248~372 at 20°C(68°F)/ white/red-white/blue … … … … Ignition coil Model(manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance 3B3 00(T-MORIC) 6mm(0.24in) 2.16~2.64Q at 20°C(68°F) 8.64~12.
ELECTRICAL SPECIFICATIONS Standard Item Bulbs(voltage/wattage×quantity) Headlight Tail/brake light Front turn signal light Rear turn signal light License plate light Speedometer light Electric starting system System type Starter motor Model(manufacturer) Suction voltage Power output Brushes Overall length Quantity Spring force Commutator diameter Commutator resistance Mica undercut(depth) SPEC 0* Limit 12V 35/35W×1 12V 5/21W×1 12V 10W×2 12V 10W×2 12V 5W×1 12V 1.
ELECTRICAL SPECIFICATIONS Standard Item Fuse(amperage×quantity) Main fuse SPEC Limit 15A×1 … 3B3(AISAN) 4~10Q 90~100£2 … … … Starting circuit cut-off relay Model(manufacturer) Coil resistance Diode 4HC1(MATSU SHITA) 72~88 YES … … … Radiator fan Model(manufacturer) Running rpm 5ST1(LUNTAI) 10000r/min or less … … Fuel gauge Model(manufacturer) Sender unit resistance-full Sender unit resistance-empty Thermostat Type(manufacture) Valve opening temperature Valve full open temperature Valve lift-fu
CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE Part to be tightened Part name Thread Q’ty size Tightening torque Remarks Nm m»kg ft»lb Exhaust pipe stud bolt Oil check bolt Cylinder head cover Cylinder head and cylinder Cylinder head(timing chain side) Spark plug Camshaft sprocket Timing chain tensioner(body) Guide stopper2 Timing chain tensioner(plug) Water pump assembly Thermostat cover air bleed bolt Thermostat cover Fan case Fan Radiator drain bolt Radiator cover Oil pump assembly Engine oil d
TIGHTENING TORQUES Part to be tightened Part name Thread Q’ty size SPEC Tightening torque 0* Remarks Nm m»kg ft»lb Drain bolt(engine oil) Centerstand spring Starter clutch Kickstarter Primary fixed sheave Clutch housing Stator coil Pulser coil AC magneto rotor Starter motor assembly Ignition coil Coolant temperature sensor Hook Nut Bolt Nut Nut Bolt Screw Nut Bolt Bolt - Cylinder head tightening sequence (1 -»2-»3-4-»2-»5-»6) 2-20 M8 M6 M22 M6 M10 M10 M5 M6 M12 M6 M6 M12 1 1 1 1 1 1 3 2 1 2 2 1
TIGHTENING TORQUES SPEC 0*" CHASSIS Thread size Part to be tightened Tightening torque Nm Frame and engine bracket3 Engine bracket3 and engine Handlebar bracket and steering shaft Rear shock absorber and frame Rear shock absorber and engine Steering shaft and upper bearing inner race Steering shaft and ring nut Front fork and lower bracket Handlebar bracket and handlebar lower holder Handlebar lower holder and handlebar upper holder Throttle cable and holder lever2 Throttle cable and throttle body Fron
TIGHTENING TORQUES SPEC 0* NOTE : 1. First,tighten the upper bearing inner race approximately 7Nm(0.7m»kg, 5.1ft»lb) by using the torque wrench and check turn steering shaft smoothly. 2. Second,hold the upper bearing inner race and tighten the ring nut 30Nm(3.0m»kg, 21.7ft»lb) by using the torque wrench. 3. Final,operate the steering shaft together with the steering stem nut now.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC 0* EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant Oil seal lips ^^TLS^P^L O-rings(except V-belt drive unit) ^^LS^^A O-ring(fuel injector assembly) ~~^\4Jl Cylinder head tightening nut mounting surface ~~^%4Jl Cylinder head stud bolt thread ~^l4 Cylinder head gasket dowel pin ^HI4 Crankshaft pin outside surface ~~^\4Jl Connecting rod ^HI4 Piston outside and ring groove —H1C4J Piston pin outside surface ~~
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point SPEC 0* Lubricant Drive axle taper rollor bearing —HI^GJ Transmission bearings ^HICGJ Secondary fixed sheave inner surface BEL-RAY asembly lube® Secondary sliding sheave torque cam ditch BEL-RAY asembly lube® Crankcase mating surfaces Sealant 2-24
LUBRICATION POINTS AND LUBRICANT TYPES SPEC 0*" EAS00032 CHASSIS Lubrication Point Lubricant Front wheel oil seal lips ^^LSp^L Steering bearing and bearing races(upper and lower) ^^LSp^L Frame head pipe dust seal lips(lower) ^^TLS^^^L Tube guide(throttle grip) inner surface ^ L S ^ ^ A Brake lever and lever holder bolt sliding surface ^^LSpn Centerstand pivoting point and sliding surface ^^f LS^^^L Single seat lock cable inner surface ^^TLS^^^L Engine bracket and engine mound bolt sliding
COOLING SYSTEM DIAGRAMS EAS00033 A COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 8 Raidator cap Coolant reservoir hose Radiator inlet hose Air bleed bolt Radiator outlet hose Fan case Damper Raidator cover B C D E F G 2-26 SPEC 0* Insert until contacting with the latch of radiator tank. Install white paint marck of pipe 3 toward the direction of radiator cover. Install clip for the turning knob to face forward. Hand and fix the claw of fan case 1 on the radiator cover.
COOLING SYSTEM DIAGRAMS 1 2 3 4 5 Radiator Radiator inlet hose Radiator outlet hose Thermostat Water pump outlet hose A 2-27 SPEC 0* Install clip for the turning knob to face downward.
COOLING SYSTEM DIAGRAMS 1 2 3 4 5 Thermostat assembly inlet breather hose Breather hose Water pump outlet hose Radiator outlet hose Water pump A B C D E 2-28 SPEC 0* Install the paint mark of hose facing up. Install clip for the turning knob to face downward. Make sure that hose is inserted to the bottom. Align the paint mark of pipe 7 to the stopper of water pump Ass’y. Insert until contacting with the stopper.
CABLE ROUTING EAS00035 CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 q w e Hose3 ECU Ignition coil Sidestand switch lead Main switch Hose Coolant temperature sensor Wiring harness Throttle cable kit Rear brake cable AC magneto lead Hose5 Starter motor lead r t A B C D E Battery positive lead Wire lead cover Assemble cramp on the Tstud at the right of back stay. Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of box bracket 1 . Install crap on the hols of stay 1 .
CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 q w Speedometer Rectifier/Regulator Turn signal relay Throttle cable Ass’y Holder Cable holder Rear brake cable Speedometer cable Front brake cable Headlight Horn Starting circuit cut-off relay A After wiring the cover, cover the coupler. B Enter tail/brake light. C After fixing the rear brake cable, fix crank case 1 . When locking, make sure that the stopper at the front of holder touches the position of crank case 1 .
CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 q w e r t y u Fuel pump FI diagnostic tool connector Fuse box Battery negative lead ECU lead Battery positive lead Starter relay AC magneto lead Tail/brake light lead Starter motor lead Holder Cable holder Lean angle cut-off switch Ignition coil Throttle cable Ass’y Rear brake cable Wiring harness dx ©- D i o p a s A B C D Rear fender Fuel injector lead Sub-wire harness lead ISC(idle speed control) valve lead Crankcase2 Enter slant angle of sensor.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 q w Speedometer Rectifier/Regulator Horn Turn signal relay Front brake cable Rear brake cable Throttle cable Ass’y Speedometer cable Rectifier/Regulator lead Wiring harness Main switch lead Horn lead A B C Penetrate the rear brake cable and throttle cable through the left side of car body. Make sure to install the cramp on the head light stay. Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of head light stay.
CABLE ROUTING G SPEC 0* Let the left and right flasher lights, meter, and right lead wire of handle bar switch to face upward, let the main switch, front and rear brake switchand left lead wire of handle bar switch to face downward, connect to the coupler, and then store in the connector cover.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 q Turn signal light lead(right) Handlebar switch lead(right) Front brake light switch lead Turn signal light lead(left) Handlebar switch lead(left) Rear brake light switch Throttle cable Ass’y Front brake cable Rear brake cable Backward screw Forward screw A B C D E Penetrate the rear brake cable and throttle cable through the left side of car body. Make sure to install the cramp on the head light stay.
CHK ADJ < & CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 3-1 PERIODIC MAINTENANCE AND MINOR REPAIR 3-2 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3-2 GENERAL MAINTENANCE AND LUBRICATION CHART 3-3 COVER AND PANEL 3-5 SIDE COVERS AND TAIL/BRAKE LIGHT 3-5 SINGLE SEAT AND TRUNK 3-7 LEG SHIELD1,2 3-8 FOOTREST BOARD AND INNER FENDER 3-9 ENGINE 3-10 ADJUSTING THE VALVE CLEARANCE 3-10 CHECKING THE ENGINE IDLING SPEED 3-16 ADJUSTING THE THROTTLE CABLE FREE PLAY 3-17 CHECKING THE SPARK PLU
CHK ADJ CHECKING THE WHEELS CHECKING AND LUBRICATING THE CABLES LUBRICATING THE LEVERS AND PEDALS LUBRICATING THE CENTERSTAND ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY CHECKING THE FUSE REPLACING THE HEADLIGHT BULB ADJUSTING THE HEADLIGHT BEAM < & 3-48 3-48 3-49 3-49 3-50 3-50 3-56 3-58 3-59
CHK INTRODUCTION ADJ < & EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INITIAL NO. 1 * 2 ITEM ROUTINE 600 mi (1,000 km) or 1 month ODOMETER READING 2,000 mi (4,000 km) or 6 months 4,000 mi 6,000 mi 8,000 mi 10,000 mi (7,000 km) (10,000 km) (13,000 km) (16,000 km) or or or or 12 18 24 30 months months months months Fuel line • Check fuel and vacuum hoses for cracks or damage. • Replace if necessary.
CHK PERIODIC MAINTENANCE AND MINOR REPAIR ADJ < & GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL NO. 1 * ITEM ROUTINE Air filter element • Replace. 600 mi (1,000 km) or 1 month ODOMETER READING 2,000 mi (4,000 km) or 6 months 4,000 mi 6,000 mi 8,000 mi 10,000 mi (7,000 km) (10,000 km) (13,000 km) (16,000 km) or or or or 12 18 24 30 months months months months v v v v v V V V V V V V V V V V V 2 * Front brake • Check operation.
CHK PERIODIC MAINTENANCE AND MINOR REPAIR ADJ < * & Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 12000mi(19000km) or 36 months, repeat the maintenance intervals starting from 4000mi(7000km) or 12 months. EAU17680 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
CHK COVER AND PANEL ADJ < & EAS00038 COVER AND PANEL SIDE COVERS AND TAIL/BRAKE LIGHT Order 1 2 3 4 5 6 7 8 Job/Part Remarks Q’ty Removing the side covers and tail/ brake light Front cover Side cover(left) Side cover(right) Tail/brake and rear turn signal light(left and right) Battery cover Battery negative lead Battery positive lead Battery 3-5 Remove the parts in the order listed. 1 1 1 1 1 1 1 1 c C 8First, disconnect the negative battery lead, and then the positive battery lead.
CHK COVER AND PANEL ADJ Order Job/Part Q’ty < & Remarks control system. For installation, reverse the removal procedure.
CHK COVER AND PANEL ADJ < & SINGLE SEAT AND TRUNK \y10Nm(1.0m • kg, 7.2 ft • lb) \ l 12Nm(1.2m« kg, 8.7 ft* lb) [s& 7Nm(0.7m• kg, 5.1 ft• lb) "10 / \ / '/* *£® / / / Order Job/Part 1 2 3 4 5 6 7 8 9 10 Single seat Single seat upper cover Bottom plate Frame(single seat) ECU Starter relay Main fuse Single seat lock assembly Helmet holder Trunk 8 / Remarks Q’ty Removing the single seat and trunk Side cover(left and right) \ / Remove the parts in the order listed.
CHK COVER AND PANEL ADJ < & LEG SHIELD1,2 Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Removing the leg shield1,2 Front fork upper cover Reflector(left) Front fork cover(left) Reflector(right) Front fork cover(right) Leg shield1 Main switch cover Leg shield2 Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 1 Caution, do not damage the claw while removing. For installation, reverse the removal procedure.
CHK COVER AND PANEL ADJ < & FOOTREST BOARD AND INNER FENDER Order Job/Part 1 2 3 4 5 6 7 Removing the footrest board and inner fender Single seat/trunk Fuel tank cap cover Fuel tank cap Coolant reservoir cap cover Panel Footrest board Coolant reservoir Inner fender Remarks Q’ty Remove the parts in the order listed. Refer to “SINGLE SEAT AND TRUNK “. 1 1 1 1 1 1 1 When installing the fuel tank cap, align it cap end and the mark on the car body. Disconnect.
ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: • front cover • side cover(left and right) • battery /battery cover • single seat/trunk • footrest board • Refer to”COVER AND PANEL”. 2.
CHK ADJUSTING THE VALVE CLEARANCE ADJ < & ••••••••••••••••••••••• a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compression stroke, align the punch mark a in the camshaft sprocket with the stationary b on the plate. c. Align the TDC mark c on the AC magneto rotor with the stationary pointer d on the crankcase cover. d. Measure the valve clearance with a thickness gauge ® . Out of specification -» Adjust. • • • • • • • • • • • • • • • • • • • • • • • 7.
CHK ADJUSTING THE VALVE CLEARANCE ADJ Last digit 0 or 2 5 8 < & Rounded value 0 5 10 EXAMPLE: Original valve pad number =148(thickness =1.48mm(0.0583in)) Rounded value =150 g. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approximation.
CHK ADJUSTING THE VALVE CLEARANCE ADJ < & n. Install the timing chain tensioner spring and cap bolt . X I 8Nm(0.8m * kg, 5.8ft * lb) o. Measure the valve clearance again. p. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.
ADJUSTING THE VALVE CLEARANCE INTAKE MEASURED CLEARANCE 0.00~0.04 0.05~0.09 0.10~0.16 0.17~0.21 0.22~0.26 0.27~0.31 0.32~0.36 0.37~0.41 0.42~0.46 0.47~0.51 0.52~0.56 0.57~0.61 0.62~0.66 0.67~0.71 0.72~0.76 0.77~0.81 0.82~0.86 0.87~0.91 0.92~0.96 0.97~1.01 1.02~1.06 1.07~1.11 1.12~1.16 1.17~1.21 1.22~1.26 1.27~1.31 1.32~1.
CHK ADJUSTING THE VALVE CLEARANCE ADJ < & 8. Install: 8all removed parts NOTE: For installation, reverse the removal procedure. 9. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to”CHANGING THE COOLANT”.
CHK CHECKING THE ENGINE IDLING SPEED ADJ < & EAS00054 CHECKING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Remove: 8 panel Refer to”FOOTREST BOARD AND INNER FENDER”. 3. Connect: 8 digital circuit tester (onto the spark plug lead of cylinder) Digital circuit tester 90890-06760 4.
ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check: • throttle cable free play a Out of specification ^Adjust. Throttle cable free play (at the flange of the throttle grip) 1.5~3.5mm (0.06~0.14in) 2. Adjust: 8throttle cable free play ••••••••••••••••••••••• Handlebar side a. Loosen the locknut 1 . b.
CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Remove: 8 panel Refer to”FOOTREST BOARD AND INNER FENDER”. 2. Disconnect: 8 spark plug cap w Remove the spark plug cap, the engine is extremely hot. 3. Remove: 8 spark plug cC Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 4. Check: 8 spark plug type Incorrect -* Change. Spark plug type (manufacturer) CR7E(NGK) 5.
CHK CHECKING THE SPARK PLUG ADJ < & 8. Install: • spark plug X I 13Nm(1.3m * kg, 9.4ft * lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • spark plug cap 10. Install: • panel Refer to”FOOTREST BOARD AND INNER FENDER”.
CHK CHECKING THE IGNITION TIMING ADJ < & EAS00062 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: 8front cover 8side cover(left and right) 8battery /battery cover 8single seat/trunk Refer to”COVER AND PANEL”. 2. Drain: 8coolant (completely from the radiator) 3. Remove: 8radiator cover 8radiator 8fan case Refer to”RADIATOR”in chapter 6. 4.
CHK CHECKING THE IGNITION TIMING ADJ < & 5. Check: 8ignition timing • • • • • • • • • • • • • • • • • • • • • • • a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. A Engine idling speed 2000 ~ 2200r/min b. Check that the mark a on the AC magneto rotor is within the firing range b on the right crankcase cover. Incorrect firing range -» Check the ignition system.
CHK MEASURING THE COMPRESSION PRESSURE ADJ < & EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: 8 valve clearance Out of specification -» Adjust Refer to “ADJUSTING THE VALVE CLEARANCE”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Remove: 8 panel Refer to”FOOTREST BOARD AND INNER FENDER”. 4. Disconnect: 8 spark plug cap w Remove the spark plug cap, the engine is extremely hot. 5.
MEASURING THE COMPRESSION PRESSURE ••••••••••••••••••••••• a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. FflWUzWIgM To prevent sparking, ground the spark plug lead before cranking the engine. c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits. Carbon deposits -» Eliminate. d.
CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. -T- V ~///^(S) }yyf(M' \ ^ ^ \ 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Check: 8 engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b . Below the minimum level mark -»Add the recommended engine oil to the proper level.
CHK CHANGING THE ENGINE OIL ADJ < & EAS00076 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: 8engine oil filler cap 1 8engine oil drain bolt 2 (along with the gasket) 4. Drain: 8engine oil (completely from the crankcase) 5. If the oil filter element is also to be replaced or cleaned, perform the following procedure. ••••••••••••••••••••••• a.
CHANGING THE ENGINE OIL 8. Install: 8engine oil filler cap 9. Start the engine, warm it up for several minutes, and then turn it off. 10.Check: 8engine (for engine oil leaks) 11.Check: 8engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 12.Check: engine oil pressure • • • • • • • • • • • • • • • • • • • • • • • a. Slightly loosen the oil gallery bolt . b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt.
CHK CHANGING THE TRANSMISSION OIL ADJ < & CHANGING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. NOTE: • Stand the scooter on a suitable stand. • Make sure that the scooter upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place a container under the transmission oil drain bolt. 4 Remove: • transmission oil fill bolt (along with the gasket) • transmission oil drain bolt© 5. Drain: • transmission oil (completely from the transmission case) 6.
MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: 8 engine oil level Below the minimum level mark -»Add the recommended engine oil to the proper level. Refer to”CHECKING THE ENGINE OIL LEVEL”. 2. Start the engine, warm it up for several minutes, and then turn it off. C When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine. 3.
CHK MEASURING THE ENGINE OIL PRESSURE ADJ < & 6. Install: 8oil gallery bolt X I 7Nm(0.7m * kg, 5.1ft * lb) 7. Install: • panel Refer to”FOOTREST BOARD AND INNER FENDER”.
REPLACING THE AIR FILTER ELEMENT EAS00086 REPLACING THE AIR FILTER ELEMENT 1. Remove: 8front cover 8side cover(left) Refer to”SIDE COVERS AND TAIL/ BRAKE LIGHT”. 2. Remove: 8air filter case c o v e r 1 8air filter element 3. Check: 8 air filter element© Damage/dirty^ Replace. NOTE: 8 Replace the air filter element every 4000km(2000mi) . 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 4. Install: 8 air filter element 8 air filter case cover X I 10Nm(1.
CHK REPLACING THE AIR FILTER ELEMENT ADJ < & 5. Install: 8side cover(left) 8front cover Refer to”SIDE COVERS AND TAIL/ BRAKE LIGHT”.
CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD/CHECKING THE FUEL HOSE EAS00094 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 1. Remove: 8front cover 8side cover(left and right) 8single seat/trunk Refer to”COVER AND PANEL”. 2. Check: • throttle body joint (T) • intake manifold (2) Cracks/damage -» Replace. Refer to “FUEL INJECTION SYSTEM” in chapter 7. 3. Install: •single seat/trunk •side cover(left and right) •front cover Refer to”COVER AND PANEL”.
CHK CHECKING THE BREATHER HOSES ADJ < & EAS00098 CHECKING THE BREATHER HOSES 1. Remove: 8front cover 8side cover(left and right) 8single seat/trunk Refer to”COVER AND PANEL”. 2. Check: 8 breather hose (T) 8 transmission case breather hose (2) Cracks/damage -» Replace. Loose connection -» Connect properly. C Make sure the breather hoses are routed correctly. v^ fera X \ 3. Install: 8single seat/trunk 8side cover(left and right) 8front cover Refer to”COVER AND PANEL”.
CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler assembly and gasket. 1. Remove: 8muffler assembly Refer to”ENGINE REMOVAL”in chapter 5. 2. Check: • muffler assembly (T) Crack/damage -» Replace. • gasket (2) Exhaust gas leak -» Replace. 3. Check: • tightening torque Exhaust pipe nut (3) 13Nm(1.3m • kg, 9.4ft • lb) Muffler and rear arm bolt (4) 31Nm(3.1m • kg, 22.4ft • lb) 4.
CHECKING THE COOLANT LEVEL EAS00103 CHECKING THE COOLANT LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Check: 8 coolant level The coolant level should be between the maximum level mark a and minimum level mark b . Below the minimum level mark -»Add the recommended coolant to the proper level. C 8 Adding water instead of coolant lowers the antifreeze content of the coolant.
CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: 8front cover 8side cover(left and right) 8battery /battery cover 8single seat/trunk 8footrest board Refer to”COVER AND PANEL”. 8radiator cover Refer to”RADIATOR”in chapter 6. Jl " <^Cl& ^ ^ v \ / -/C-^y iy, ^7 ^ ^^\^y^fe^^\^p—\ / ^~ ^ Vg N^gf / ^ I\XMT^ '•'•':\ 2. Check: • radiator© • radiator inlet hose (2) • radiator outlet hose (3) Cracks/damage -» Replace. Refer to “COOLING SYSTEM” in chapter 6. 3.
CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: 8front cover 8side cover(right) 8coolant reservoir cap cover Refer to”COVER AND PANEL”. 8radiator cover Refer to”RADIATOR”in chapter 6. 2. Disconnect: 8coolant reservoir hose 1 3. Drain: 8coolant (from the coolant reservoir) 8coolant (from the radiator under drain bolt) 4. Remove: 8radiator cap 8coolant reservoir cap w A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot.
CHANGING THE COOLANT 7. Fill: 8cooling system (with the specified amount of the recommended coolant) «0 Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 4:6(antifreeze:water) Quantity Total amount 0.50L(0.46 Imp qt, 0.53 US qt) Coolant reservoir capacity 0.26L(0.23 Imp qt, 0.28 US qt) Up to the maximum level mark NOTE: The specified amount of coolant is a standard amount.
CHK CHANGING THE COOLANT ADJ < & 9. Fill: 8coolant reservoir (with the recommended coolant to the maximum level mark 1 ) 10.Install: 8coolant reservoir cap 11.Start the engine, warm it up for several minutes, and then stop it. 12.Check: 8coolant level Refer to “CHECKING THE COOLANT LEVEL”. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. 13.Install: 8radiator cover Refer to”RADIATOR”in chapter 6.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE CHK ADJ < & EAS00109 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: 8 brake lever free play a Out of specification -» Adjust. Brake lever free play (at the end of the brake lever) 10~20mm(0.39~0.79in) 2. Adjust: 8brake lever free play • • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained. Direction a Direction b Brake lever free play is increased.
CHK CHECKING THE FRONT AND REAR BRAKE SHOES ADJ < & EAS00127 CHECKING THE FRONT AND REAR BRAKE SHOES 1. Operate the brake. 2. Check: • wear indicator (T) Reaches the wear limit line (2) -» Replace the brake shoes as a set. Refer to “FRONT WHEEL AND BRAKE” and “REAR WHEEL AND BRAKE” in chapter 4.
CHK CHECKING AND ADJUSTING THE STEERING HEAD ADJ < & EAS00148 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Check: • steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness -» Adjust the steering head. 3.
CHECKING AND ADJUSTING THE STEERING HEAD b. Loosen the upper bearing inner race2 completely and then tighten it to specification with a steering nut wrench3 . Steering nut wrench 90890-01444 YM-A9409-7 ^ w Do not overtighten the upper bearing inner race. Upper bearing inner race(final tightening torque) 7Nm(0.7m • kg, 5.1ft • lb) c. Check the steering head for looseness or binding by turning the front fork all the way in both directions.
CHK CHECKING THE FRONT FORK ADJ < & EAS00151 CHECKING THE FRONT FORK 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. 2. Check: •inner tube Damage/scratches -» Replace. •oil seal Oil leakage -» Replace. 3. Hold the scooter upright and apply the front •brake. 4. Check: •front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement -» Repair.
CHECKING THE TIRES EAS00163 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification -> Regulate. rr\w«:»iwei • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
CHECKING THE TIRES 2. Check: • tire surfaces Damage/wear -» Replace the tire. Minimum tire tread depth 0.8mm(0.03in) 1 2 3 Tire tread depth Sidewall Wear indicator w Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using tube tires, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set.
CHK CHECKING THE TIRES ADJ w < & New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a direction of rotation mark 1 : 8 Install the tire with the mark pointing in the direction of wheel rotation. 8 Align the mark2 with the valve installation point.
CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES CHK ADJ < & EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: • wheel Damage/out-of-round -»Replace. FflWUzWIgM Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel. EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables.
LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE CENTERSTAND CHK ADJ < & EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.
CHECKING AND CHARGING THE BATTERY EAS00179 ELECTRICAL SYSTEM BATTERY INSTRUCTION This is a sealed lype 12 volt battery. No liquid level inspection is ever needed and no refilling water will be required. CHECKING AND CHARGING THE BATTERY IMPORTANT: • Never interfere with the sealed state of the battery. •Check the charging condition with a voltmeter (Normal charging voltage should be above 12.8V) •This battery may be installed in an vehicle only If it replaces a similar sealed type battery.
CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: 8battery cover Refer to”SIDE COVERS AND TAIL/ BRAKE LIGHT”. 2. Disconnect: 8battery leads (from the battery terminals) cC First, disconnect the negative battery lead 1 , and then the positive battery lead 2 .
CHECKING AND CHARGING THE BATTERY 12.5 Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% • • • • • • • • • • • • • • • • • • • • • • • 12.0 11.5 j - 5 6.5 10 Charging time (hours) These values vary with the temperature, the condition of the battery plates, and the electrolyte level. 14 13 < & b. Check the charge of the battery, as shown in the charts and the following example.
CHK CHECKING AND CHARGING THE BATTERY ADJ < & Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it.
CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Ammeter Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. Set the charging voltage to 16-17 V. (If the charging voltage is lower charging will be insufficient, if it is higher, the battery will be over-charged.) Set the timer to the charging time determined by the opencircuit voltage.
CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? NO i This type of battery charger cannot charge an MF battery. A variablevoltage charger is recommended.
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSE CHK ADJ < & 6. Install: 8battery 7. Connect: 8battery leads (to the battery terminals) cC First, connect the positive battery lead 1, and then the negative battery lead 2. 8 After installing the battery, be sure to turn the main switch from “ON” to “OFF” three times in 3 seconds intervals to initialize the idle speed control system. 8. Check: 8 battery terminals Dirt -» Clean with a wire brush. Loose connection -» Connect properly. 9.
CHECKING THE FUSE 2. Check: 8fuse • • • • • • • • • • • • • • • • • • • • • • • a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “ ^ × 1”. Pocket tester 90890-03112(YU-03112-C) b. If the pocket tester indicates “∞”, replace the fuse. • • • • • • • • • • • • • • • • • • • • • • • 3. Replace: 8blown fuse • • • • • • • • • • • • • • • • • • • • • • • a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c.
REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: 8headlight unit 2. Disconnect: 8headlight lead coupler 3. Remove: 8dust b o o t 1 8headlight bulb holder2 8headlight bulb3 w Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: 8headlight bulb New Secure the new headlight bulb with the headlight bulb holder.
CHK ADJUSTING THE HEADLIGHT BEAM ADJ < & EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: headlight beam (vertically) • • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting screw 1 in direction a or b . Direction a Direction b Headlight beam is raised. Headlight beam is lowered. ••••••••••••••••••••••• 2. Adjust: headlight beam (horizontally) • • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting screw2 in direction a or b .
CHAS (3^3^) CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE FRONT WHEEL FRONT BRAKE SHOE PLATE REMOVING THE FRONT WHEEL DISASSEMBLING THE BRAKE SHOE PLATE CHECKING THE FRONT WHEEL CHECKING THE SPEEDOMETER GEAR UNIT CHECKING THE BRAKE ASSEMBLING THE BRAKE SHOE PLATE ASSEMBLING THE FRONT WHEEL INSTALLING THE FRONT WHEEL ADJUSTING THE FRONT WHEEL STATIC BALANCE REAR WHEEL AND BRAKE REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL CHECKING THE REAR WHEEL DRIVE HUB CHECKING THE BRAKE ASSEMBLING THE BRAKE SHOE PLATE INSTA
CHAS (3^3^) REAR SHOCK ABSORBER ASSEMBLY REMOVING THE REAR SHOCK ABSORBER ASSEMBLY CHECKING THE REAR SHOCK ABSORBER ASSEMBLY INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-37 4-38 4-38 4-39
FRONT WHEEL AND BRAKE CHAS (3^3^) EAS00517 CHASSIS FRONT WHEEL AND BRAKE Order Job/Part Removing the front wheel and brake 1 2 3 4 5 6 7 8 9 10 Stop ring Speedometer cable Brake adjuster Front brake cable Adjusting pin Wheel axle nut Wheel axle Collar Front brake shoe plate Front wheel Q’ty 1 1 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
FRONT WHEEL AND BRAKE CHAS (3^3^) EAS00518 FRONT WHEEL Order 1 2 3 4 Job/Part Q’ty Disassembling the front wheel Oil seal Bearing Spacer Bearing Remarks Remove the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE CHAS (3^3^) FRONT BRAKE SHOE PLATE Order Job/Part 1 2 3 4 5 6 7 8 9 0 q w e r t y u Disassembling the front brake shoe plate Brake shoe kit Tension spring Camshaft lever Brake shoe wear indicator Return spring Brake camshaft/O-ring Oil seal Oil seal Circlip Plate washer Speedometer clutch Speedometer drive gear Plate washer Bushing Oil seal Speedometer driven gear Plate washer Q’ty Remarks Remove the parts in the order listed.
FRONT WHEEL AND BRAKE CHAS (3^3^) EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Remove: 8speedometer cable1 8front brake cable2 8front wheel axle n u t 3 8front wheel a x l e 4 8collar 8front wheel5 8front brake shoe plate6 EAS00524 DISASSEMBLING THE BRAKE SHOE PLATE 1.
FRONT WHEEL AND BRAKE EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends -» Replace. Do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel Damage/wear -» Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: • radial wheel runout (T) • lateral wheel runout @ Over the specified limits -» Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm(0.04 in) 4.
FRONT WHEEL AND BRAKE CHAS (3^3^) ••••••••••••••••••••••• a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. c. Remove the wheel bearings 4 with a general bearing puller3. d. Install the new wheel bearings and oil seal in the reverse order of disassembly. • • • • • • • • • • • • • • • • • • • • • • • EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1.
FRONT WHEEL AND BRAKE CHAS (3^3^) EAS00536 (If CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: • brake shoe lining Glazed areas -» Repair. Sand the glazed areas with course sandpaper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. yj' •—Q7\__ ^ w •B" ' •• 12270603 2. Measure: • brake shoe lining thickness a Out of specification ^Replace. Brake shoe lining thickness limit (minimum) 2.0 mm (0.
FRONT WHEEL AND BRAKE 4. Check: • brake drum inner surface Oil deposits -»Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches -» Repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: •brake camshaft Damage/wear -» Replace. EAS00537 ASSEMBLING THE BRAKE SHOE PLATE 1. Lubricate: 8brake camshaft Recommended lubricant Lithium-soap-based grease 2.
FRONT WHEEL AND BRAKE CHAS (3^5^) 3. Install: 8 camshaft lever (T) X I 8Nm(0.8m • kg, 5.8ft • lb) ••••••••••••••••••••••• a. Align the camshaft punch mark a and camshaft lever punch mark b is positioned as shown. • • • • • • • • • • • • • • • • • • • • • • • 4. Install: 8 plate washer 8 speedometer driven gear 8 bushing (with the special tool) Meter gear bush tool 90890-01052 EAS00538 y V \ ) k V~ __JHQ)g k P ASSEMBLING THE FRONT WHEEL 1.
FRONT WHEEL AND BRAKE CHAS (3^3^) EAS00540 INSTALLING THE FRONT WHEEL 1. Lubricate: 8wheel axle 8wheel bearings 8oil seal lips 8speedometer drive gear 8speedometer driven gear Recommended lubricant Lithium-soap-based grease 2. Install: 8front wheel1 NOTE: Make sure the slot® in the brake shoe plate fits over the stopper® on the outer tube. 3. Tighten: 8 wheel axle nut X I 48 Nm (4.8 m * kg, 34.7 ft * lb) Make sure the brake cable is routed properly.
FRONT WHEEL AND BRAKE EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: 8 After replacing the tire, wheel or both, the front wheel static balance should be adjusted. 8 Adjust the front wheel static balance with the brake disc installed. 1 . Remove: 8balancing weight(s) 2. Find: 8front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. ••••••••••••••••••••••• a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. c.
FRONT WHEEL AND BRAKE CHAS (3^% 3. Adjust: 8front wheel static balance • • • • • • • • • • • • • • • • • • • • • • • a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b. Turn the front wheel 90° so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. • • • • • • • • • • • • • • • • • • • • • • • 4.
REAR WHEEL AND BRAKE CHAS (3^3^) EAS00555 REAR WHEEL AND BRAKE Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Remarks Q’ty Removing the rear wheel and brake Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. Muffler Refer to”ENGINE REMOVAL”in chapter 5.
REAR WHEEL AND BRAKE CHAS (3^3^) EAS00564 REMOVING THE REAR WHEEL 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated. 2. Remove: 8muffler Refer to”ENGINE REMOVAL”in chapter 5. 3. Loosen: 8brake adjuster 4. Remove: 8wheel axle nut 1 8plate washer 8rear wheel2 EAS00565 CHECKING THE REAR WHEEL 1. Check: •tire • rear wheel Damage/wear -» Replace.
REAR WHEEL AND BRAKE CHAS (3^3^) EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: • rear wheel drive hub Cracks/damage -» Replace. EAS00569 (If ^v- CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: • brake shoe lining Glazed areas -» Repair. Sand the glazed areas with course sandpaper. /)> ~~~G77\-__ 3^ 12270603 NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. 2.
REAR WHEEL AND BRAKE CHAS (3^3^) 3. Measure: • brake drum inside diameter b Out of specification -» Replace the wheel. Brake drum inside diameter limit (maximum) 110.5 mm(4.35 in) 4. Check: • brake drum inner surface Oil deposits -» Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches -» Repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: • brake camshaft Damage/wear -» Replace. EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1.
REAR WHEEL AND BRAKE CHAS (3^3^) 3. Install: 8brake shoe k i t 1 8tension springs cC Do not put lubricating oil on the brake lining. Change the tension spring at the same time of changing the brake shoe. Refer to the direction in the illustration when assembling the brake shoe and spring. Refer to the illustration with regards to the assembly direction of tension spring, and do not let the spring hook and coil to be damaged by the pliers.
REAR WHEEL AND BRAKE CHAS (3^3^) EAS00574 INSTALLING THE REAR WHEEL 1. Lubricate: 8wheel axle Recommended lubricant Lithium-soap-based grease 2. Install: • rear wheel 3. Tighten: • plate washer • wheel axle nut© X I 120Nm(12.0m * kg, 86.8ft* lb) 4. Install: • muffler Refer to”ENGINE REMOVAL”in chapter 5. 5. Adjust: • brake lever free play Refer to”ADJUSTING THE REAR BRAKE” in chapter 3.
FRONT FORK CHAS (3^3^) EAS00646 FRONT FORK S& 45Nm(4.5m • kg, 32.5 ft • lb) gR 30Nm(3.0m • kg, 21.7 ft • lb) Order 1 2 3 4 5 Job/Part Q’ty Removing the front fork legs Front fork upper cover Reflector Front fork cover(left and right) Front wheel Cable guide Cap bolt O-ring Lower bracket pinch bolt Front fork leg Remarks Remove the parts in the order listed. Refer to”LEG SHIELD1,2 “ in chapter 3. Refer to”FRONT WHEEL AND BRAKE”.
FRONT FORK C H A S (3^3^) EAS00648 (D 3R 23Nm(2.3m • kg, 16.6 ft < lb) Order 1 2 3 4 5 6 7 8 9 Job/Part Q’ty Disassembling the front fork legs Fork oil Fork spring Damper rod bolt/Copper washer Damper rod Rebound spring Inner tube Dust seal Oil seal clip Oil seal Outer tube Remarks Remove the parts in the order listed. Drain. 1 1/1 1 1 1 1 1 1 1 Refer to”DISASSEMBLING THE FRONT FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS” For assembly, reverse the disassembly procedure.
FRONT FORK CHAS (3^3^) EAS00651 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Remove: 8front fork upper cover 8front fork cover (left and right) Refer to “LEG SHIELD1,2”in chapter 3. 8front wheel Refer to “FRONT WHEEL AND BRAKE”. 3.
FRONT FORK 2. Drain: 8fork oil 3. Remove: 8damper rod assembly b o l t 1 NOTE: While holding the damper rod with the damper rod holder 2 and T-handle3, loosen the damper rod assembly bolt. / • Damper rod holder 90890-01294(YM-01300-1) T-handle 90890-01326(YM-01326) 4. Remove: 8damper r o d 1 8spring 8inner t u b e 2 5. Remove: 8dust seal 8oil seal clip 1 (with a flat-head screwdriver) cC Do not scratch the inner tube.
FRONT FORK CHAS (3^% 6. Remove: 8oil s e a l 1 cC Never reuse the oil seal. 8Rag2 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 8 inner tube® 8 outer tube (2) Bends/damage/scratches -* Replace. w Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: 8 spring free length a Out of specification -* Replace. Spring free length 202.2mm(7.96in) :198.2mm(7.80in) 3.
FRONT FORK EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: 8 When assembling the front fork leg, be sure to replace the following parts: - oil seal - dust seal 8 Before assembling the front fork leg, make sure all of the components are clean. y 1. Install: 8damper rod assembly1 8rebound spring 2 ®
FRONT FORK CHAS (3^3^) 4. Install: 8oil seal 1New (with the fork seal driver weight 2 and adapter 3 ) ^ Fork seal driver weight 90890-01367(YM-A9409-7) Adapter 90890-01400(YM-A9409-3 ) cC Make sure the numbered side of the oil seal faces up. NOTE: 8 Before installing the oil seal, lubricate its lips with lithium soap base grease. 8 Lubricate the outer surface of the inner tube with fork oil.
FRONT FORK CHAS (3^3^) NOTE: 8 While filling the front fork leg, keep it upright. 8 After filling, slowly pump the front fork leg up and down to distribute the fork oil. 7. Install: 8fork spring 1 NOTE: 8 Install the spring with the smaller pitch facing down . EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg • o-ring New • cap bolt NOTE: Pull up the inner tube until it stops, then install the cap bolt . 2.
HANDLEBAR CHAS (3^3^) EAS00664 HANDLEBAR -10^ Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Part Remarks Q’ty Removing the handlebar Front fork upper cover Front fork cover(left and right) Leg shield1,2 Rear view mirror(left and right) Band Front brake cable Brake lever(right) Front brake switch Front turn signal light(right) Front turn signal light bracket(right) Handlebar switch(right) Throttle cable Throttle grip assembly Rear brake cable Brake lever(left) Rear brake switch Remove the parts in the orde
HANDLEBAR CHAS (3^3^) -10^ Order 14 15 16 17 18 19 20 Job/Part Front turn signal light(left) Front turn signal light bracket(left) Handlebar switch(left) Handlebar grip Cap Handlebar upper holder Handlebar assembly Q’ty 1 1 1 1 2 2 1 Remarks For installation, reverse the removal procedure.
HANDLEBAR CHAS (3^3^) EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. 2. Remove: 8handlebar switch(right)1 8throttle grip assembly2 NOTE: While removing the handlebar holder assembly (right), pull back the rubber cover. 3.
HANDLEBAR EAS00673 INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. 2. Install: 8 handlebar© 8 handlebar upper holders (2) X I 28Nm(2.8m * kg, 20.3ft * lb) C First, tighten the bolts on the front side of the handlebar holders, and then on the rear side.
HANDLEBAR 5. Install: 8 throttle grip assembly1 8 right handlebar switch2 8 throttle cables 3 NOTE: 8 Align the projectiona on the right handlebar switch with the hole b on the handlebar. 8 Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar4. w Make sure the throttle grip operates smoothly. 6. Adjust: 8 throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.
STEERING HEAD CHAS (3^3^) EAS00675 STEERING HEAD HANDLEBAR BRACKET AND HEADLIGHT STAY BRACKET ®~. S^>48Nm(4.8m • kg, 34.7 ft • lb) S^60Nm(6.0m • kg, 43.4 ft • lb) P^23Nm(2.3m kg, 16.6 ft lb) al4Nm(0.4m • kg, 2.
LOWER BRACKET LOWER BRACKET r V 30Nm(3.0m • kg, 21.7 ft • lb)f Order 1 2 3 4 5 6 7 8 9 Job/Part Q’ty Removing the lower bracket Front fork upper cover Front fork cover(left and right) Leg shield1,2 Front wheel Front fork legs Handlebar assembly Headlight stay bracket Handlebar bracket Front fender Ring nut Upper bearing inner race Upper bearing Lower bracket Lower bearing Upper bearing outer race Lower bearing outer race Lower bearing inner race Remarks Remove the parts in the order listed.
STEERING HEAD CHAS (3^3^) EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. 2 . Remove: 8handlebar bracket1 NOTE: Remove the handlebar bracket by loosening the ring n u t 2 gradually. 3. Remove: 8ring nut 1 (with the ring nut wrench 2 ) Ring nut wrench 90890-01268 YU-01268 4 .
STEERING HEAD CHAS (3^3^) EAS00682 CHECKING THE STEERING HEAD 1. Wash: 8bearing balls 8bearing races Recommended cleaning solvent Kerosene 2. Check: 8bearing balls (T) 8bearing races (2) Damage/pitting -» Replace. 3. Replace: 8bearing balls 8bearing races • • • • • • • • • • • • • • • • • • • • • • • a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the front fork assembly with a floor chisel 2 and hammer. c. Install a new bearing races.
STEERING HEAD CHAS (3^3^) EAS00684 INSTALLING THE STEERING HEAD 1. Lubricate: 8bearing balls 1 8bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 8lower bracket 1 8upper bearing inner r a c e 2 (with the steering nut wrench3) Upper bearing inner race 7Nm(0.7m • kg, 5.1ft • lb) f* Steering nut wrench 90890-01444 YM-A9409-7 3. Install: 8ring nut 1 (with the steering nut wrench2) V % Ring nut 30Nm(3.0m • kg, 21.7ft • lb) Steering nut wrench 90890-01403 YU-A9472 4.
REAR SHOCK ABSORBER ASSEMBLY CHAS (3^3^) EAS00685 REAR SHOCK ABSORBER ASSEMBLY Order 1 2 3 4 Job/Part Q’ty Remarks Removing the rear shock absorber assembly Remove the parts in the order listed. Front cover Side cover(left) Rear shock absorber assembly upper nut Rear shock absorber assembly upper bolt Rear shock absorber assembly lower bolt Rear shock absorber assembly Refer to”SIDE COVERS AND TAIL/ BRAKE LIGHT”in chapter 3. 1 1 1 1 For installation, reverse the removal procedure.
REAR SHOCK ABSORBER ASSEMBLY EAS00692 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the scooter on a level surface. w Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated. 2. Remove: 8front cover 8side cover(left) Refer to”SIDE COVERS AND TAIL/ BRAKE LIGHT”in chapter 3. 3.
REAR SHOCK ABSORBER ASSEMBLY CHAS (3^3^) EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Install: • rear shock absorber assembly 2. Tighten: • rear shock absorber assembly upper nut X | 30Nm(3.0m * kg, 21.7ft * lb) • rear shock absorber assembly lower bolt X | 16Nm(1.6m * kg, 11.6ft * lb) 3. Install: • side cover(left) • front cover Refer to”SIDE COVERS AND TAIL/ BRAKE LIGHT”in chapter 3.
ENG m % CHAPTER 5 ENGINE ENGINE REMOVAL 5-1 LEADS, HOSES AND MUFFLER 5-1 ENGINE 5-3 INSTALLING THE ENGINE 5-4 CYLINDER HEAD 5-5 REMOVING THE CYLINDER HEAD 5-7 CHECKING THE CYLINDER HEAD 5-9 INSTALLING THE CYLINDER HEAD 5-10 THE ROCKER ARMS AND CAMSHAFT 5-13 REMOVING THE ROCKER ARMS AND CAMSHAFT 5-14 CHECKING THE CAMSHAFT 5-15 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5-16 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET, AND TIMING CHAIN GUIDES 5-17 CHECKING THE TIMING CHAIN TENSIONER 5-18 INSTALLING TH
ENG m % REMOVING THE SECONDARY SHEAVE AND V-BELT 5-44 DISASSEMBLING THE SECONDARY SHEAVE 5-45 CHECKING THE CLUTCH SHOES 5-45 CHECKING THE V-BELT 5-46 CHECKING THE PRIMARY SHEAVE 5-46 CHECKING THE PRIMARY SHEAVE WEIGHTS 5-47 CHECKING THE SLIDER 5-47 CHECKING THE SECONDARY SHEAVE 5-47 ASSEMBLING THE PRIMARY SHEAVE 5-48 ASSEMBLING THE SECONDARY SHEAVE 5-49 INSTALLING THE SECONDARY SHEAVE, V-BELT AND PRIMARY SHEAVE 5-50 STARTER CLUTCH AND AC MAGNETO 5-53 STATOR COIL ASSEMBLY 5-53 STARTER CLUTCH 5-55 REMOVING
ENGINE REMOVAL ENG %m EAS00188 ENGINE ENGINE REMOVAL LEADS, HOSES AND MUFFLER r V 10Nm(1.0m • kg, 7.2 ft* lb) r V 10Nm(1.0m • kg, 7.2 ft* lb) Order Job/Part Q’ty Removing the leads, hoses and muffler Front cover/Single seat/Trunk Battery cover/Battery Side cover(left and right) Footrest board Coolant Remove the parts in the order listed. Refer to”COVER AND PANEL”in chapter 3.
ENGINE REMOVAL ENG %m r^10Nm(1.0m • kg, 7.2 ft* lb) 1 * 10Nm(1.0m • kg, 7.2 ft • lb) Order Job/Part 3 Crankshaft position sensor/Stator assembly coupler Ignition primary coil coupler Air filter assembly/Breather hose Bracket Muffler Gasket 4 5 6 7 8 Q’ty 1/1 1 1/1 1 1 1 Remarks Disconnect. Disconnect. For installation, reverse the removal procedure.
ENGINE REMOVAL ENG %m EAS00191 ENGINE Order Job/Part Q’ty Removing the engine Remarks Remove the parts in the order listed. Place a suitable stand under the frame and engine. 1 2 3 4 5 Rear shock absorber assembly lower bolt Engine mounting nut Engine mounting bolt Engine Rear fender 1 1 1 1 1 Refer to”INSTALLING THE ENGINE”. For installation, reverse the removal procedure.
ENGINE REMOVAL ENG m % EAS00192 INSTALLING THE ENGINE 1. Install: 8engine1 8engine mounting b o l t 2 8engine mounting n u t 3 NOTE: 8 Apply lithium-soap-based grease to the unthreaded portion of the engine mounting bolt shaft. 8 Do not fully tighten the engine mounting bolt.. 2. Install: • rear shock absorber assembly lower bolt® NOTE: Do not fully tighten the bolt. 3. Tighten: • engine mounting bolt X I 58Nm(5.8m * kg, 42.0ft * lb) • rear shock absorber assembly lower bolt \ | 16Nm(1.6m * kg, 11.
CYLINDER HEAD ENG %m EAS00221 CYLINDER HEAD P^9Nm(0.9m • kg, 6.5 ft • lb) P|^j8Nm(0.8m • kg, 5.8 ft • lb) n^10Nm(1.0m« kg, 7.2 ft* lb) I 4. i ^ \ [ \ 30Nm(3.0m • kg, 21.7 ft • lb) «13Nm(1.3m • kg, 9.4 ft • lb) Order 7 Job/Part Q’ty Removing the cylinder head Radiator Thermostat 1 2 3 4 5 6 7 8 9 Remarks Remove the parts in the order listed. Refer to”COOLING SYSTEM”in chapter 6.
CYLINDER HEAD ENG m % P^9Nm(0.9m • kg, 6.5 ft • lb) «13Nm(1.3m • kg, 9.4 ft • lb) Order 10 11 12 13 14 15 16 17 Job/Part Q’ty 1 1 2 4 1 1 1 2 Timing chain tensioner gasket Camshaft sprocket Bolt Nut Plate Cylinder head Cylinder head gasket Dowel pin Remarks Refer to”REMOVING THE CYLINDER HEAD” and “INSTALLING THE CYLINDER HEAD”. For installation, reverse the removal procedure.
CYLINDER HEAD ENG %m EAS00225 REMOVING THE CYLINDER HEAD 1. Remove : 8V-belt case cover 8Refer to “BELT DRIVE”. 8cylinder head cover 2. Align: 8“I” mark a on the AC magneto rotor (with the stationary pointer b on the crankcase cover) • • • • • • • • • • • • • • • • • • • • • • • a. Turn the primary fixed sheave counterclockwise. b. When the piston is at TDC on the compression stroke, align the “I” mark c on the camshaft sprocket with the mark d on the plate. ••••••••••••••••••••••• 3.
CYLINDER HEAD ENG %m 4. Remove: 8timing chain tensioner (along with the gasket) 8camshaft sprocket 1 8timing chain 2 NOTE: 8 To prevent the timing chain from falling into the crankcase, fasten it with a wire. 5. Remove: 8cylinder head NOTE: 8 Loosen the nuts in the proper sequence as shown. 8 Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
CYLINDER HEAD ENG %m EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: 8combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore thread • valve seats 2. Check: • cylinder head Damage/scratches -» Replace. 3. Measure: • cylinder head warpage Out of specification -» Resurface the cylinder head. Maximum cylinder head warpage 0.05 mm (0.0020 in) ••••••••••••••••••••••• a.
CYLINDER HEAD ENG %m EAS00231 INSTALLING THE CYLINDER HEAD 1. Install: • gasket New • dowel pins 2. Install: • cylinder head 3. Tighten: • cylinder head nuts X | 10 Nm (1.0 m * kg, 7.2 ft * lb) • cylinder head bolts X | 10 Nm (1.0 m * kg, 7.2 ft * lb) NOTE: • Lubricate the cylinder head nuts with engine oil. • Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages • cylinder head tightening sequence (1 -»2-»3-4-»2-»5-»6) 4.
CYLINDER HEAD ENG %m cC Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. e. While holding the camshaft, temporarily tighten the camshaft sprocket bolt. f. Remove the wire from the timing chain. ••••••••••••••••••••••• 5. Install 8camshaft sprocket bolt 1 6. Install: 8timing chain tensioner gasket New 8timing chain tensioner • • • • • • • • • • • • • • • • • • • • • • • a. Remove the cap bolt 1 and spring 2 . b.
CYLINDER HEAD ENG m % 7. Turn: 8crankshaft (several turns counterclockwise) 8. Check: 8“I” mark a Align the “I” mark on the AC magneto rotor with the stationary pointer b on the crankcase cover. 8“I” mark c Align the “I” mark on the camshaft sprocket with the stationary pointer d on the plate. Out of alignment -» Correct. Refer to the installation steps above. 9. Tighten: 8camshaft sprocket bolt X I 30 Nm (3.0 m * kg, 21.
THE ROCKER ARMS AND CAMSHAFT ENG m % THE ROCKER ARMS AND CAMSHAFT Order Job/Part 1 2 3 4 5 6 Removing the rocker arms and camshaft Cylinder head Camshaft Rocker arm shaft(intake) Rocker arm shaft(exhaust) Rocker arm(intake) Rocker arm(exhaust) Collar Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. 1 1 1 1 1 2 For installation, reverse the removal procedure.
THE ROCKER ARMS AND CAMSHAFT ENG m % EAS00202 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Remove: 8intake rocker arm shaft 8exhaust rocker arm shaft 8intake rocker arm 8exhaust rocker arm 8collar NOTE: Remove the rocker arm shafts with the clip plier. 2. Remove: 8camshaft 1 NOTE: Remove the camshaft with the slide hammer bolt.
THE ROCKER ARMS AND CAMSHAFT ENG EAS00205 CHECKING THE CAMSHAFT 1. Check: •camshaft bushings Damage/wear -» Replace. 2. Check: •camshaft lobes Blue discoloration/pitting/scratches -* Replace the camshaft. ® m§>rgrxn^ X 3. Measure: •camshaft lobe dimensions a and b Out of specification -* Replace the camshaft. \ Camshaft lobe dimension limit Intake a30.158~30.258mm (1.1873~1.1913 in) :30.058mm (1.1834 in) b25.082~25.182mm (0.9875~0.9914 in) :24.982mm (0.9835 in) Exhaust a30.158~30.
THE ROCKER ARMS AND CAMSHAFT EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: • rocker arm (camshaft touch surface©) • rocker arm (valve touch surface®) Damage/wear -» Replace. 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches -» Replace or check the lubrication system. 3. Check: •camshaft lobe Excessive wear -» Replace the camshaft. 4.
THE ROCKER ARMS AND CAMSHAFT 5. Measure: • rocker arm shaft outside diameter a Out of specification -» Replace. Rocker arm shaft outside diameter 9.981 ~ 9.991 mm (0.3930 ~ 0.3933 in) :9.950mm (0.3917 in) 6. Calculate: •rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Above 0.034 mm (0.0013 in) -» Replace the defective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.034 mm (0.
THE ROCKER ARMS AND CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage -» Replace. 2. Check: • one-way cam operation Rough movement -» Replace the timing chain tensioner. 3. Check: • cap bolt • o-ring New • spring • one-way cam • gasket New • timing chain tensioner rod Damage/wear -» Replace the defective part(s). ••••••••••••••••••••••• a. Removing the spring and cap bolt. b. Return cam chain tensioner one way cam.
THE ROCKER ARMS AND CAMSHAFT ENG %m EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 8camshaft 1 Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2. Lubricate: 8rocker arm shafts Recommended lubricant Molybdenum disulfide oil 3. Install: 8exhaust rocker arm 1 8collar2 8exhaust rocker arm shaft 3 NOTE: Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head. 4.
VALVES AND VALVE SPRINGS ENG m % EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Removing the valves and valve springs Cylinder head Rocker arms Rocker arm shafts Camshaft 1 2 3 4 5 6 7 8 9 Valve pad Valve cotter Valve spring retainer Valve spring Valve(intake) Valve(exhaust) Valve stem seal Valve stem seat Valve guide Remove the parts in the order listed. Refer to”CYLINDER HEAD”. Refer to”REMOVING THE ROCKER ARMS AND CAMSHAFT” and “INSTALLING THE CAMSHAFT AND ROCKER ARMS”.
VALVES AND VALVE SPRINGS Order Job/Part Q’ty ENG m % Remarks For installation, reverse the removal procedure.
VALVES AND VALVE SPRINGS ENG %m EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: 8valve pad 1 NOTE: Make a note of the position of each valve pad so that they can be reinstalled in their original place. 2.
VALVES AND VALVE SPRINGS y- Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attachment 90890-04148 YM-04148 4 . Remove: 8valve spring retainer 1 8valve spring 2 8valve stem seal 3 8valve spring seat 4 8valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
VALVES AND VALVE SPRINGS ENG EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1 . Measure: 8valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a Valve stem diameter b Out of specification -* Replace the valve guide. Valve-stem-to-valve-guide clearance Intake 0.010 ~ 0.037 mm(0.0004~0.0015 in) : 0.08 mm(0.0031 in) Exhaust 0.025 ~ 0.052 mm(0.001~0.002 in) : 0.10 mm(0.
VALVES AND VALVE SPRINGS ENG m % 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face Pitting/wear -* Grind the valve face. • valve stem end Mushroom shape or diameter larger than the body of the valve stem -* Replace the valve. 5. Measure: • valve margin thickness a Out of specification -* Replace the valve. ®-~ ODtE Valve margin thickness 0.9~1.1mm(0.0354~0.0433in) 6. Measure: • valve stem runout Out of specification -* Replace the valve.
VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbon deposits (from the valve face and valve seat) 2. Check: • valve seat Pitting/wear -* Replace the cylinder head. 3. Measure: • valve seat width a Out of specification -* Replace the cylinder head. Valve seat width Intake: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) : 1.6 mm(0.063 in) Exhaust: 0.9 ~1.1 mm (0.0354~0.0433 in) : 1.6 mm(0.
VALVES AND VALVE SPRINGS ••••••••••••••••••••••• a. Apply a coarse lapping compound a to the valve face. X"7 V N\ cC a Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound.
VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a Out of specification -» Replace the valve spring. Valve spring free length Intake valve spring 39.35 mm (1.5492 in) : 37.38 mm (1.4717 in) Exhaust valve spring 41.57 mm (1.6366 in) : 39.49 mm (1.5547 in) 2. Measure: • compressed valve spring force a Out of specification -» Replace the valve spring.
VALVES AND VALVE SPRINGS ENG m % EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 8valve stem end (with an oil stone) 2. Lubricate: 8valve stem 1 8valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3.
VALVES AND VALVE SPRINGS ENG m % Valve spring compressor 90890-04019(YM-04019) Valve spring compressor attachment 90890-04148(YM-04148) 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer. cC Hitting the valve tip with excessive force could damage the valve. 6. Install: valve pad 1 NOTE: 8 Lubricate the valve pad with engine oil. 8 Valve pad must be reinstalled in its original position.
CYLINDER AND PISTON ENG m % EAS00251 CYLINDER AND PISTON Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Removing the cylinder and piston Cylinder head Timing chain guide(exhaust side) Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set Remarks Remove the parts in the order listed. Refer to”CYLINDER HEAD”. 1 1 2 1 2 1 1 1 Refer to”REMOVING THE CYLINDER AND PISTON” and “INSTALLING THE PISTON AND CYLINDER”. For installation, reverse the removal procedure.
CYLINDER AND PISTON ENG m % EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: 8piston pin clip 1 8piston pin 2 8piston 3 cC Do not use a hammer to drive the piston pin out. NOTE: 8 Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. 8 Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area.
CYLINDER AND PISTON ENG EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: • piston wall • cylinder wall Vertical scratches -* Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: piston-to-cylinder clearance • • • • • • • • • • • • • • • • • • • • • • • a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements.
CYLINDER AND PISTON ENG m % e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” Piston skirt diameter “P” Piston-to-cylinder clearance 0.010 ~ 0.035mm(0.0004 ~ 0.0014in) :0.15mm(0.0059in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.
CYLINDER AND PISTON EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification -» Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.03 ~ 0.07 mm(0.0012~0.0028 in) : 0.12mm(0.0047 in) 2nd ring 0.02 ~ 0.06 mm(0.0008~0.0024 in) :0.12 mm(0.0047 in) 2.
CYLINDER AND PISTON ENG m % EAS00265 CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves -* Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification -* Replace the piston pin. Piston pin outside diameter 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in) :9.976 mm (0.3928 in) 3. Measure: • piston pin bore diameter b Out of specification^ Replace the piston. Piston pin bore diameter 10.002 ~ 10.013 mm (0.3938 ~ 0.
CYLINDER AND PISTON ENG m % CHECKING THE TIMING CHAIN GUIDE 1. Check: 8 timing chain guide (exhaust side) Damage/wear -» Replace EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: 8oil ring expander 1 8oil ring rail 2 82nd ring 3 8top ring 4 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up. 2. Install: 8piston 1 8piston pin 2 8piston pin clip New 3 NOTE: 8 Apply engineoil the piston pin.
CYLINDER AND PISTON ENG m % 3. Install: 8gasket N e w 8dowel pins 4. Lubricate: 8piston 8piston rings 8cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: 8piston ring end gaps a b c d A Top ring Lower oil ring rail Upper oil ring rail 2nd ring Exhaust side 6. Install: 8cylinder 1 8timing chain guide(exhaust side) NOTE: 8 While compressing the piston rings with one hand, install the cylinder with the other hand.
BELT DRIVE ENG %m EAS00316 BELT DRIVE V-BELT CASE COVER %. 10Nm(1.0m • kg, 7.2 ft • lb) P|« 12Nm(1.2m • kg, 8.7 ft* lb) Order 1 2 3 4 5 Job/Part Q’ty Removing the V-belt case cover Kickstarter Cover V-belt case cover V-belt case cover gasket Dowel pin Remarks Remove the parts in the order listed. 1 1 1 1 2 For installation, reverse the removal procedure.
BELT DRIVE ENG m % EAS00338 KICKSTARTER Order 1 2 3 4 5 6 Job/Part Q’ty Disassembling the kickstarter V-belt case cover Kick pinion gear Kick pinion gear clip Circlip/Plate washer Kickstarter shaft Torsion spring Solid bush Remarks Remove the parts in the order listed. Refer to”V-BELT CASE COVER“. 1 1 1/1 1 1 1 Refer to”INSTALLING THE KICKSTARTER”. For assembly, reverse the disassembly procedure.
BELT DRIVE ENG %m EAS00340 INSTALLING THE KICKSTARTER 1. Install: 8solid b u s h 1 8kick shaft assembly2 8torsion spring3 2. Hook: 8torsion spring NOTE: Hook the spring e n d a on the kickstarter shaft b as shown, and hook the other end c on the projectiond . 3. Install: 8plain washer 8circlip1 N e w 4. Install: 8kick pinion gear1 8kick pinion gear c l i p 2 NOTE: 8 Lubricate the kick pinion gear clip and shaft with molybdenum disulfide oil. 8 Install the kick pinion gear clip at the position shown.
BELT DRIVE ENG %m V-BELT AND PRIMARY/SECONDARY SHEAVE 40Nm (4.0 m«kg, 28.9 fHb) 30Nm (3.0 m«kg, 21.7 fHb) Order Job/Part 1 2 3 Removing the V-belt and primary/secondary sheave Primary sheave nut/Plate washer Oneway clutch Primary fixed sheave 1/1 1 1 4 5 6 7 8 9 10 11 12 13 Secondary sheave nut Clutch housing Secondary sheave V-belt Plate washer Collar Primary sliding sheave Cam/Weight Slider Plate washer 1 1 1 1 1 1 1 1/6 3 1 Q’ty Remarks Remove the parts in the order listed.
BELT DRIVE ENG %m SECONDARY SHEAVE Order Job/Part 1 2 Disassembling sheave Clutch carrier nut Clutch carrier the 3 4 5 6 7 8 9 0 Clutch shoe spring Compression spring Secondary spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave Q’ty secondary Remarks Disassemble the parts in the order listed. 1 1 3 1 1 2 1 2 2 1 Refer to”DISASSEMBLING THE SECONDARY SHEAVE” and “ASSEMBLING THE SECONDARY SHEAVE”. Refer to”ASSEMBLING THE SECONDARY SHEAVE” .
BELT DRIVE ENG %m EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: 8primary sheave nut 1 8plate washer 8oneway clutch 8primary fixed sheave 2 NOTE: While holding the primary fixed sheave with the rotor holding tool 3 , loosen the primary fixed sheave nut. Rotor holding tool 90890-01235 (YU-01235) EAS00318 REMOVING THE SECONDARY SHEAVE AND V-BELT 1. Remove: 8secondary sheave nut 1 8clutch housing 2 NOTE: While holding the clutch housing with the sheave holder 3 , loosen the secondary sheave nut.
BELT DRIVE ENG m % 3. Remove: 8secondary sheave 1 8V-belt 2 NOTE: Remove the V-belt and secondary sheave from the primary sheave side. EAS00319 %-© DISASSEMBLING THE SHEAVE 1. Remove: 8clutch carrier nut 1 1 // / /Py*—\ 1 SECONDARY NOTE: Install the clutch spring holder 2 and clutch spring holder arm 3 onto the secondary sheave as shown. Then, compress the spring, and remove the clutch carrier nut 1 .
BELT DRIVE Clutch shoe thickness 3.7mm(0.146in) :2.0mm(0.079in) NOTE: 8 Inspect clutch shoesa. 8 After removing the clutch shoe spring, do not use them again. 8 Replace the all three as a set. EAS00320 j^ia CHECKING THE V-BELT 1. Check: • V-belt® Cracks/damage/wear -» Replace. Grease/oil -» Clean the primary and secondary sheave. \1J 2. Measure: • V-belt width a Out of specification -» Replace. V-belt width 17.9 mm (0.705 in) : 16.1 mm (0.634 in) CHECKING THE PRIMARY SHEAVE 1.
BELT DRIVE ENG EAS00321 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the primary sheave weights. 1. Check: • primary sheave weight Cracks/damage/wear -* Replace. 2. Measure: • primary sheave weight outside diameter a Out of specification -* Replace. Primary sheave weight outside diameter 15 mm (0.591 in) : 14.5 mm (0.571 in) CHECKING THE SLIDER 1. Check: • slider© Damage/wear^ Replace EAS00322 CHECKING THE SECONDARY SHEAVE 1.
BELT DRIVE ENG %m EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 NOTE: Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5 . 2. Install: 8primary sliding sheave 1 8primary sheave weights 2 8collar 3 3.
BELT DRIVE ENG # 1 1&m\ EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: 8secondary fixed sheave’s inner surface 1 8secondary sliding sheave’s inner surface 2 8oil seals 8bearings (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube® 2. Install: 8secondary sliding sheave 1 NOTE: Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3. m Oil seal guide 90890-01384 (YM-33299) 3. Install: 8guide pin 1 4.
BELT DRIVE ENG m % 5. Install: 8secondary sheave 1 8spring 8clutch carrier 2 I f ' / /F^r~\\ NOTE: Attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch carrier nut 5 . ® © Clutch spring holder 90890-01337 (YM-33285) ( YM-33285-6) EAS00325 INSTALLING THE SECONDARY SHEAVE, VBELT AND PRIMARY SHEAVE 1.
BELT DRIVE ENG %m Rotor holding tool 90890-01235 YU-01235 Socket wrench(39mm) 90890-01493 3. Install: • clutch housing (T) • secondary sheave nut® X I 40Nm(4.0m * kg, 28.9ft * lb) NOTE: Tighten the secondary sheave nut with the sheave holder®. ^ Sheave holder 90890-01701 YS-01880-A 4. Install: • primary fixed sheave© • oneway clutch • plate washer • primary sheave nut® X I 30Nm(3.0m * kg, 21.
BELT DRIVE ENG %m 5. Position: 8V-belt 1 NOTE: Position the V-belt in the primary sheave 2 (when the pulley is at its widest position) and in the secondary sheave 3 (when the pulley is at its narrowest position), and make sure the Vbelt is tight.
STARTER CLUTCH AND AC MAGNETO ENG m % EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY Order Job/Part Q’ty Removing the stator coil assembly Coolant 1 2 3 4 5 Remarks Remove the parts in the order listed. Drain. Refer to”CHANGING THE COOLANT”in chapter 3.
STARTER CLUTCH AND AC MAGNETO Order 6 7 8 Job/Part Q’ty 1 1 1 Lock plate Crankshaft position sensor Stator coil assembly ENG m % Remarks For installation, reverse the removal procedure.
STARTER CLUTCH AND AC MAGNETO ENG %m EAS00342 STARTER CLUTCH Order Job/Part Removing the starter clutch Engine oil 1 2 3 4 5 6 7 8 Remarks Q’ty AC magneto rotor Stator coil assembly Crankcase cover(right) Starter clutch nut Washer Starter wheel gear Roller Collar Starter clutch Idle gear 1 1 1 1 1 1 1 1 5-55 Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL”in chapter 3. Refer to”REMOVING THE AC MAGNETO” and “INSTALLING THE AC MAGNETO”.
STARTER CLUTCH AND AC MAGNETO ENG m % EAS00347 REMOVING THE AC MAGNETO 1. Remove: 8AC magneto rotor n u t 1 8washer NOTE: 8 While holding the AC magneto rotor 2 with the sheave holder 3 , loosen the AC magneto rotor nut. 8 Do not allow the sheave holder to touch the projection on the AC magneto rotor. Sheave holder 90890-01701 YS-01880-A 2.
STARTER CLUTCH AND AC MAGNETO ENG m % EAS00344 REMOVING THE STARTER CLUTCH 1. Remove: 8crankcase cover (right)1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: 8starter clutch n u t 1 8washer 8starter wheel gear 8roller 8collar 8starter clutch 8idle gear NOTE: The starter clutch nut is left-hand thread.
STARTER CLUTCH AND AC MAGNETO ENG %m EAS00351 CHECKING THE STARTER CLUTCH 1. Check: •starter clutch roller Damage/wear -» Replace. 2. Check: •starter clutch idle gear •starter wheel gear Burrs/chips/roughness/wear -» Replace the defective part(s). 3. Check: •starter wheel gear’s contacting surfaces Damage/pitting/wear -» Replace the starter clutch gear. 4. Check: 8starter clutch operation ••••••••••••••••••••••• a. Install the starter wheel gear 1onto the starter clutch 2 and hold the starter clutch.
STARTER CLUTCH AND AC MAGNETO ENG %m EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: • idle gear • starter clutch • collar • roller • starter wheel gear • washer • starter clutch nut® \ | 90 Nm (9.0 m * kg, 65.1 ft * lb) NOTE: The starter clutch nut is left-hand thread. 2. Install: • gasket New • crankcase cover (right)© X I 10 Nm (1.0 m * kg, 7.2 ft * lb) EAS00354 INSTALLING THE AC MAGNETO 1.
STARTER CLUTCH AND AC MAGNETO ENG m % 2. Tighten: •AC magneto rotor nut (T) X I 43 Nm (4.3 m * kg, 31.1 ft * lb) NOTE: • While holding the AC magneto rotor (2)with the sheave holder®, tighten the AC magneto rotor nut. • Do not allow the sheave holder to touch the projection on the AC magneto rotor.
OIL PUMP ENG %m EAS00360 OIL PUMP 4Nm (0.4 m«kg, 2.9 fHb) 3 Order 1 2 3 4 5 Job/Part Q’ty Removing the oil pump Radiator AC magneto Starter clutch Drive gear Circlip/Plate washer Oil pump driven gear Dowel pin Oil pump Remarks Remove the parts in the order listed. Refer to”RADIATOR”in chapter 6. Refer to”STARTER CLUTCH AND AC MAGNETO” . 1 1/1 1 2 1 For installation, reverse the removal procedure.
OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear© • oil pump housing • oil pump housing cover Cracks/damage/wear -» defective part(s). Replace the 2. Measure: • inner-rotor-to-outer-rotor-tip clearance A • outer-rotor-to-oil-pump-housing clearance \B\ • oil-pump-housing-to-inner-rotor-andouter-rotor clearance \c\ Out of specification -» Replace the oil pump. © Inner rotor (2) Outer rotor (3) Oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0.
OIL PUMP ENG %m EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: 8inner rotor 8outer rotor 8oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 8 oil pump shaft (T) (to the oil pump housing®) 8 pin (3) 8 inner rotor® 8 outer rotor© 8 oil pump housing cover® 8 oil pump housing screw X I 4 Nm (0.4 m * kg, 2.9 ft * lb) NOTE: When installing the inner rotor, align the pin (3) in the oil pump shaft with the groove a in the inner rotor (4). 3.
TRANSMISSION ENG m % EAS00419 TRANSMISSION Order Job/Part Q’ty Removing the transmission Transmission oil Remove the parts in the order listed. Drain. Refer to”CHANGING THE TRANSMISSION OIL” in chapter 3. Refer to”ENGINE REMOVAL”. Refer to”REAR WHEEL AND BRAKE” in chapter 4. Refer to”BELT DRIVE”.
TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Measure: • main axle runout (with a centering device and dial gauge ) Out of specification -» Replace the main axle. Main axle runout limit 0.04 mm (0.002 in) 2. Measure: • drive axle runout (with a centering device and dial gauge ) Out of specification -» Replace the drive axle. Primary drive gear shaft runout limit 0.04 mm (0.002 in) 3 . Check: •transmission gears Blue discoloration/pitting/wear -»Replace the defective gear(s).
CRANKSHAFT ENG %m EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 1 * 7Nm (0.7 m»kg, 5.1 fHb) 5 7Nm (0.7 m»kg, 5.1 fHb) Order Job/Part Q’ty Removing the crankshaft assembly Engine Cylinder head Cylinder and piston V-belt case cover V-belt and primary/secondary sheave Radiator Water pump Starter clutch AC magneto Oil pump Transmission Rear wheel 1 2 3 4 Tension spring Circlip/Plate washer Pin Centerstand Remove the parts in the order listed. Refer to”ENGINE REMOVAL” . Refer to”CYLINDER HEAD”.
CRANKSHAFT fV ENG %m 7Nm (0.7 m»kg, 5.1 fHb) 5 7Nm (0.7 m»kg, 5.1 fHb) Order Job/Part 5 6 7 8 9 10 Hook Drain plug Oil strainer Compression spring O-ring Crankcase(right) 11 12 13 14 Spacer Dowel pin Guide Crankshaft 15 16 17 18 19 Timing chain Crankcase(left) Oil seal Bolt/O-ring Timing chain guide (intake side) Remarks Q’ty 1 1 1 1 1 1 Refer to”DISASSEMBLING THE CRANKCASE” and “ASSEMBLING THE CRANKCASE”.
CRANKSHAFT ENG %m EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 8centerstand assembly 2. Remove: 8crankcase bolts1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 3. Remove: 8right crankcase1 8spacer cC Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces.
CRANKSHAFT ENG m % EAS00389 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: 8crankshaft assembly1 8timing chain2 8timing chain guide(intake side) NOTE: 8 Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. 8 The crankshaft assembly cannot be removed if the timing chain is attached onto the crankshaft sprocket. EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: • crankshaft runout Out of specification -» Replace the crankshaft, bearing or both.
CRANKSHAFT ENG m % 3. Measure: • crankshaft width Out of specification -»Replace the crankshaft. Crankshaft width 42.45~42.50mm(1.671~1.673in) ^^^ 4. Check: •crankshaft sprocket (T) Damage/wear -»Replace the crankshaft. •bearing (2) Cracks/damage/wear -» Replace the crankshaft. •oil pump drive gear Damage/wear -» Replace the crankshaft. 5. Check: •crankshaft journal Scratches/wear -» Replace the crankshaft. •crankshaft journal oil passage Obstruction -» Blow out with compressed air.
CRANKSHAFT ENG EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE(INTAKE SIDE) 1. Check: • timing chain Damage/stiffness -> Replace the timing chain and camshaft sprocket as a set. 2. Check: • timing chain guide (intake side) Damage/wear -> Replace. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: •bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement -> Replace. 2. Check: •oil seals Damage/wear -» Replace.
CRANKSHAFT EAS00408 INSTALLING THE CRANKSHAFT 1. Install: 8timing chain guide (intake side) 8timing chain1 8crankshaft assembly2 NOTE: Install the timing chain so it is not visible through the opening in the left crankcase 3 . cC To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.
CRANKSHAFT ENG %m 3. Install: 8dowel pins 8spacer 8right crankcase1 NOTE: Tap lightly on the right crankcase with a softface hammer. 4. Tighten: •crankcase bolts X I 10Nm(1.0m * kg, 7.2ft * lb) NOTE: Tighten the crankcase bolts in stages and in a crisscross pattern. 5. Apply: •engine oil (onto the crankshaft pin, bearing and oil delivery hole) 6. Check: •crankshaft operation Rough movement-*Repair.
COOL J C CHAPTER 6 COOLING SYSTEM RADIATOR CHECKING THE RADIATOR INSTALLING THE RADIATOR THERMOSTAT CHECKING THE THERMOSTAT INSTALLING THE THERMOSTAT WATER PUMP DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP ASSEMBLING THE WATER PUMP INSTALLING THE WATER PUMP 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-9 6-9 6-10 6-11
RADIATOR COOL J C EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Remove the parts in the order listed. Removing the radiator Front cover Side cover(left and right) Single seat/Trunk Footrest board Coolant 1 2 3 4 5 6 7 Remarks Q’ty Refer to”COVER AND PANEL”in chapter 3. Drain. Refer to”CHANGING THE COOLANT”in chapter 3. 1 1 1 1 1 1 1 Radiator cover Radiator cap Conduit hose Radiator inlet hose Radiator outlet hose Radiator Fan case Disconnect. Disconnect. Disconnect.
RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction -» Clean. Apply compressed air to the rear of the radiator. Damage -» Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator inlet hose • radiator outlet hose • conduit hose Cracks/damage -» Replace. 3. Measure: • radiator cap opening pressure Below the specified pressure -» Replace the radiator cap. Radiator cap opening pressure 107.9 ~ 137.3kPa (1.1 ~ 1.4kg/cm2, 15.
RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: 8cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks -» Repair or replace any faulty part. 3 © ^ ^ C • • • • • • • • • • • • • • • • • • • • • • • a. Attach the radiator cap tester 1 to the radiator. y- Radiator cap tester 90890-01325, YU-24460-01 Radiator cap tester adapter 90890-01352, YU-33984 b. Apply 100 kPa (1.0 kg/cm2, 14.22 psi) of pressure. c.
THERMOSTAT COOL J C EAS00460 THERMOSTAT 10Nm (1.0 m«kg, 7.2 fHb) 10Nm (1.0 m«kg, 7.2 fHb) 4 Order Job/Part Removing the thermostat Front cover Side cover(left and right) Single seat/Trunk Footrest board Coolant 1 2 3 4 5 6 Remarks Q’ty Remove the parts in the order listed. Refer to”COVER AND PANEL”in chapter 3. Drain. Refer to”CHANGING THE COOLANT”in chapter 3. Clip Thermostat inlet hose Clip Thermostat outlet hose Thermostat cover Thermostat 1 1 1 1 1 1 Disconnect. Disconnect.
THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat (T) Does not open at 85 ~100°C (185 ~212°F) -» Replace. • • • • • • • • • • • • • • • • • • • • • • • a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
THERMOSTAT COOL J C EAS00466 INSTALLING THE THERMOSTAT 1. Install: • thermostat© • thermostat cover X | 10Nm(1.0m * kg, 7.2ft * lb) NOTE: Align the breather a of thermostat to mark b of thermosat before installation. 2. Fill: • cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 3. Check: • cooling system Leaks -»Repair or replace any faulty part. 4.
WATER PUMP COOL J C EAS00468 WATER PUMP lyJ2|10 10Nm(1.0m« kg, 7.2 ft* lb) dr^ ® Order Job/Part Q’ty Removing the water pump Front cover Side cover(left and right) Single seat/Trunk Footrest board Coolant 1 2 3 4 5 6 7 8 9 4i , / Remarks Remove the parts in the order listed. Refer to”COVER AND PANEL”in chapter 3. Breather hose Thermostat inlet hose Water pump outlet hose Radiator outlet hose Water pump housing cover Gasket Water pump housing Plate Impeller shaft 1 1 1 1 1 1 1 1 1 6-7 Drain.
WATER PUMP COOL J C 6 10Nm(1.0m • kg, 7.2 ft* lb) ®^^ ® Order 10 11 12 Job/Part Q’ty 1 1 1 Oil seal Bearing Gasket Remarks For installation, reverse the removal procedure.
WATER PUMP COOL J C EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: 8water pump housing c o v e r 1 8dowel pin 8gasket 2. Remove: 8plate 2 8impeller shaft 3 8gasket 8oil seal (with a thin, flat-head screwdriver) 8bearing NOTE: 8 Remove the oil seal from the inside of the water pump housing. 8 Remove the bearing from the inside of the water pump housing. EAS00474 CHECKING THE WATER PUMP 1. Check: •water pump housing cover •water pump housing •impeller© Cracks/damage/wear -» Replace. 2.
WATER PUMP COOL J C EAS00475 ASSEMBLING THE WATER PUMP 1. Install: 8bearing1 NOTE: 8 Before installing the oil seal, apply tap water or coolant onto its out surface. 8 Install the oil seal with a socket that matches its outside diameter. 2. Install: 8water pump seal New 1 (into the water pump housing 2 ) cC Never lubricate the water pump seal surface with oil or grease. NOTE: 8 Install the water pump seal with the special tools. 8 Press in depth of water pump and oil seal is 5.5~6.0mm a .
WATER PUMP COOL J C 5. Install: 8gasket New 8water pump housing c o v e r 1 Iae M§ \ \Ji—- b// ^ EAS00478 INSTALLING THE WATER PUMP 1. Install: • water pump assembly (T) X | 10Nm(1.0m * kg, 7.2ft * lb) NOTE: Align the slit a on the impeller shaft with the projection b on the camshaft sprocket bolt. 2. Install: • breather hose • thermostat inlet hose • water pump outlet hose • radiator outlet hose 3.
FI ifl CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 7-1 WIRING DIAGRAM 7-2 ECU’S SELF-DIAGNOSTIC FUNCTION 7-4 CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB 7-5 SELF-DIAGNOSTIC FANCTION TABLE 7-5 Self-diagnostic fanction table 7-5 TROUBLESHOOTING CHART 7-7 DIAGNOSTIC MODE 7-8 TROUBLESHOOTING DETAILS 7-12 THROTTLE BODY AND FUEL INJECTOR 7-26 THROTTLE BODY 7-26 FUEL INJECTOR AND FUEL HOSE 7-27 FUEL TANK 7-28 REMOVING THE FUEL HOSE 7-29 REMOVING THE FUEL PUMP 7-29 CHECKING THE THROTTLE B
FUEL INJECTION SYSTEM FI EAS00894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 2 3 4 5 6 7 8 9 0 ECU Engine trouble warning light Lean angle cut-off switch Fuel hose Ignition coil Fuel injector Intake air pressure sensor ISC(idle speed control) valve Intake air temperature sensor Battery q w e r t y u i 7-1 Air filter case Catalytic converter Crankshaft position sensor Coolant temperature sensor Spark plug Fuel tank Fuel pump Throttle position sensor ifl
FUEL INJECTION SYSTEM FI ifl WIRING DIAGRAM Br/W L x B/L © Br/W < P/W Y B/L x (BETWEEN MAIN 8 SUB Y < P/W -Hi,® 5: ~ G/Y Br L/G BSD "O W W 7-2 mi L H k J — © — t H i- B — 1
FUEL INJECTION SYSTEM 1 3 4 8 9 0 q w e r t y u i o p s f c b n m .
FI FUEL INJECTION SYSTEM ifl ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU.
FUEL INJECTION SYSTEM FI ifl EAS00901 CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB The engine trouble warning light comes on for 2 seconds after the main switch has been turned “ON” and when the start switch is being pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective.
FUEL INJECTION SYSTEM Fault code No. 39 Fuel injector 30 41 Lean angle cut-off switch (latch up detected) (open or short circuit) Speed sensor 42 43 44 46 50 61 _ Symptom Engine startability Vehicle driveability Fuel injector open or short circuit is detected. The vehicle has overturned. Lean angle cut-off switch-open or short circuit is detected. No normal signals are received from the speed sensor. Power supply to the fuel injector, fuel pump and ignition coil are not normal.
FUEL INJECTION SYSTEM FI ifl EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. *Engine trouble warning light may not come on even if the engine operation is not normal. I I I The engine trouble warning light does not come on. The engine trouble warning light comes on. T Check the operation of following sensors and actuators in the diagnostic mode. Refer to “Diagnostic mode table”.
FUEL INJECTION SYSTEM FI ifl EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators with connecting the Fl diagnostic tool to the normal mode or the diagnostic monitoring mode.
FUEL INJECTION SYSTEM FI ifl Setting the diagnostic mode 1. Turn the main switch to “OFF” and the engine stop switch to “RUN”.. 2. Disconnect the self diag signal connector 1 , and then connect the Fl diagnostic-tool 2 as shown. 3. While press the “MODE” button, turn the main switch to “ON”. NOTE: 8 ”DIAG” appears on the LCD of the Fl diagnostic tool. 8 ”POWER” LED (Green) comes on. 4. Press the “UP” button to select the CO adjustment mode “CO” or the diagnostic mode “DIAG”. 5.
FUEL INJECTION SYSTEM FI Fault code table Fault codeNo. Symptom No normal signals are received from the crankshaft position sensor. 12 Intake air pressure sensor-open or short circuit detected. 13 14 Faulty intake air pressure sensor pipe system Throttle position sensor-open or short circuit detected. 15 16 19 21 A stuck throttle position sensor is detected. Open circuit in the input line (blue/ yellow lead) of ECU is detected when the start switch is pressed.
FUEL INJECTION SYSTEM FI ifl EAS00907 Diagnostic mode table NOTE: 8 Check the intake air temperature and coolant temprature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively. 8 If it is not possible to check the intake air temperature, use the ambient temperature as reference.
FUEL INJECTION SYSTEM Communication error with the FI diagnostic tool LCD Display Sympton Waiting for connection... No signals are received from the ECU. ERROR 4 Commands from the Fl diagnostic tool are not accepted by the ECU. Probable cause of malfunction • • • • • Improper installed lead connector in the coupler. The main switch is OFF position. Malfunction in Fl diagnostic tool. Malfunction in ECU. Turn the main switch to “OFF” once, and then turn it back to CO adjustment mode or diagnostic mode.
FUEL INJECTION SYSTEM Fault code No. 12 Symptom FI ifl No normal signals are received from the crankshaft position sensor. Used diagnostic code No. -Order Inspection operation item and probable cause 1 Installed condition of sensor. 2 Connected condition of connector. Inspect the coupler for any pins that may have pulled out. Check that the coupler is connected securely. NOTE: Set the main switch to OFF before connecting or disconnecting the connector. 3 Open or short circuit in wiring harness.
FUEL INJECTION SYSTEM Fault code No. 13 Symptom FI ifl Intake air pressure sensor-open or short circuit detected. Used diagnostic code No. D03 (intake air pressure sensor) Order Inspection operation item and probable cause Operation item and countermeasure 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. NOTE: Set the main switch to OFF before connecting or disconnecting the connector.
FUEL INJECTION SYSTEM FI ifl Intake air pressure sensor-hose system malfunction (clogged or detached hose). tached hose). Used diagnostic code No. D03 (intake air pressure sensor) Fault code No. Order 1 2 14 Symptom Inspection operation item and probable cause Connected state of connector Intake air pressure sensor coupler Main wirring harness ECU coupler Sub-wire harness coupler Defective intake air pressure sensor.
FUEL INJECTION SYSTEM Fault code No. 16 Symptom FI ifl Stuck throttle position sensor detected. Used diagnostic code No. D01 (throttle position sensor) Order Inspection operation item and probable cause 1 Installed condition of throttle position sensor. 2 Defective throttle position sensor 3 When fault code No.15 has been detected Fault code No. 19 Symptom Operation item and countermeasure Check the installed area for looseness or pinching.
FUEL INJECTION SYSTEM Fault code No. 21 Symptom FI ifl Coolant temperature sensor open or short circuit is detected. Used diagnostic code No. D06 (coolant temperature sensor) Order Inspection operation item and probable cause 1 Installed condition of sensor 2 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in wiring harness. 3 4 Defective coolant temperature sensor.
FUEL INJECTION SYSTEM Fault code No. 22 Symptom FI ifl Intake temperature sensor open or short circuit is detected. Used diagnostic code No. D05 (intake air temperature sensor) Order Inspection operation item and probable cause 1 Installed condition of sensor 2 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in wireing harness and/or sub lead.
FUEL INJECTION SYSTEM Fault code No. 30 FI ifl The vehicle has overturned. Symptom Used diagnostic code No. D08 (lean angle cut-off switch) Order 1 2 3 4 Inspection operation item and probable cause The vehicle has overturned. Installed condition of the lean angle cut-off switch Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault codeNo. 33 Symptom FI ifl Open circuit detected in the primary lead of the ignition coil. Used diagnostic code No. D30 Order 1 2 3 Inspection operation item and probable cause Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in lead. Defective ignition coil (test the primary and secondary coils for continuity). Fault code No.
FUEL INJECTION SYSTEM Fault code No. 39 Symptom FI ifl Fuel injector open or short circuit is detected. Used diagnostic code No. D36 (fuel injector) Order 1 2 3 Inspection operation item and probable cause Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in lead wire. Defective fuel injector Fault code No.
FUEL INJECTION SYSTEM Fault code No. 42 Symptom FI ifl No normal signals are received from the speed sensor. Used diagnostic code No. D07 (speed sensor) Order 1 2 Inspection operation item and probable cause Connected condition of speedometer connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in speedometer lead. 3 Breakage speedometer cable or speedometer gear unit. 4 Defective speed sensor.
FUEL INJECTION SYSTEM Fault code No. 43 Symptom FI ifl Power supply to the fuel injector, fuel pump and ignistion coil are not normal. Used diagnostic code No. D09 (fuel system voltage) Order 1 2 3 Inspection operation item and probable cause Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Faulty battery Open or short circuit in wiring harness.
FUEL INJECTION SYSTEM Fault code No. 46 Symptom FI ifl Power supply to FI system is not normal. (red lead) Used diagnostic code No. -Order 1 2 3 4 Inspection operation item and probable cause Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Faulty battery Malfunction in rectifier/ regulator Open or short circuit in wiring harness. Fault code No.
FUEL INJECTION SYSTEM Fault code No. 61 Symptom FI ifl ISC (idle speed control) valve open or short circuit is detected. Used diagnostic code No. -Order 1 2 3 Inspection operation item and probable cause Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in lead.
THROTTLE BODY AND FUEL INJECTOR FI ifl EAS00909 THROTTLE BODY AND FUEL INJECTOR THROTTLE BODY Order Job/Part Removing the throttle body Side cover(left and right) Single seat/Trunk Air filter assembly 1 2 3 4 5 6 Remarks Q’ty Throttle body clamp screw MAQS(modulated air quantity sensor) coupler ISC (idle speed control) valve coupler Throttle cable Throttle body Sub-wire harness 1 1 1 2 1 1 Remove the parts in the order listed. Refer to “COVER AND PANEL”in chapter 3.
THROTTLE BODYAND FUEL INJECTOR FI ifl FUEL INJECTOR AND FUEL HOSE Order Job/Part Removing the fuel injector and fuel hose Footrest board 1 2 3 4 5 6 7 8 Remarks Q’ty Fuel pump coupler Fuel hose connector cover Fuel hose connector Fuel hose holder(to frame) Fuel hose holder(to intake manifold) Clamp Fuel injector coupler Fuel injector Remove the parts in the order listed. Refer to”COVER AND PANEL”in chap1 1 1 1 1 1 1 1 ter 3. Disconnect. Open lock. Disconnect.
THROTTLE BODYAND FUEL INJECTOR FI ifl FUEL TANK «& 4Nm(0.4m • kg, 2.9 ft • lb) Order Job/Part Q’ty Removing the fuel tank Remarks Remove the parts in the order listed. Place the scooter on a suitable stand. Fuel hose 1 Fuel tank 1 2 Fuel pump 1 7-28 Refer to “FUEL INJECTOR AND FUEL HOSE”. Refer to “REMOVING THE FUEL HOSE”. Refer to “REMOVING THE FUEL PUMP”and “INSTALLING THE FUEL PUMP”. For installation, reverse the removal procedure.
THROTTLE BODY AND FUEL INJECTOR FI ifl REMOVING THE FUEL HOSE 1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove: 8fuel hose connector cover 1 3. Disconnect: 8fuel hose 2 cC 8 Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. 8 Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose, since there may be fuel remaining in it.
THROTTLE BODY AND FUEL INJECTOR FI ifl EAS00912 CHECKING THE FUEL INJECTOR 1. Check: 8 fuel injector Damage -» Replace. EAS00913 CHECKING THE THROTTLE BODY 1. Check: 8 throttle body Cracks/damage -» Replace the throttle body. 2. Check: 8 butterfly valve Damage/scratches/wear -» Replace. C Do not adjust the stop screw 1 Do not clean the throttle body using carburetor cleaner or compressed air. When replace the throttle body, the main switch is operated three times turn ON and OFF position.
THROTTLE BODY AND FUEL INJECTOR FI ifl INSTALLING THE FUEL PUMP 1. Install: 8 fuel pump X | 4Nm(0.4m»kg, 2.9ft*Ib) NOTE: 8 Do not damage the installation surfaces of the fuel tank when installing the fuel pump. 8 Always use a new fuel pump gasket. 8 Align the projection a on the fuel pump with the alignment mark b on the fuel tank. 8 Tighten the fuel pump bolts in the proper tightening sequence as shown and torque them in two stages. A Forward INSTALLING THE FUEL HOSE 1.
THROTTLE BODY AND FUEL INJECTOR FI ifl EAS00915 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: 8 pressure regulator operation • • • • • • • • • • • • • • • • • • • • • • • a. Remove the footrest board. Refer to “COVER AND PANEL” in chapter 3. b. Remove the fuel hose connector cover (T) and disconnect the fuel hose (2) from the fuel pump. C Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose, since there may be fuel remaining in it.
THROTTLE BODY AND FUEL INJECTOR FI ifl Positive tester probe -> blue terminal ® Negative tester probe -» black/blue terminal (2) f* Digital circuit tester 90890-03174 b. Measure the throttle position sensor voltage. Out of specification -» Replace or repair the wire harness. U Throttle position sensor voltage 5V (blue-black/blue) c. Connect the digital circuit tester to the terminals of the throttle position sensor. Positive tester probed yellow terminal Negative tester probe black/blue terminal d.
THROTTLE BODY AND FUEL INJECTOR FI ifl EAS00916 CHECKING THE ISC (IDLE SPEED CONTROL) VALVE NOTE: Do not remove the ISC (idle speed control) valve unit completely from the throttle body assembly. 1. Check: 8ISC (idle speed control) valve • • • • • • • • • • • • • • • • • • • • • • • a. Disconnect the ISC (idle speed control) valve coupler from the ISC (idle speed control) valve. b. Connect the digital circuit tester to the terminals of the ISC (idle speed control) valve.
AIR INDUCTION SYSTEM FI ifl EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust pipe reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 2 3 4 5 Air induction system hose Air filter case Air induction system hose (air filter case to air cut-off valve) Air cut-off valve Air induction system hose (air cut-off valve to exhaust pipe) 7-36 FI ifl
AIR INDUCTION SYSTEM FI ifl AIR CUT-OFF VALVE AND AIR FILTER CASE PV 7Nm(0.7m • kg, 5.1 ft • lb) 3R 7Nm(0.7m • kg, 5.1 ft • lb) Order 1 2 3 4 5 Job/Part Q’ty Removing the air cut-off valve and air filter case Front cover Side cover(right) Hose(to air filter case) Air filter case Hose(air cut-off valve to air filter case) Hose(air cut-off valve assembly to exhaust pipe) Air cut-off valve Remarks Remove the parts in the order listed. Refer to”COVER AND PANEL”in chapter 3.
AIR INDUCTION SYSTEM FI ifl EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection -» Connect properly. Cracks/damage -» Replace. 2. Check: • reed valve • reed valve stopper • reed valve seat Cracks/damage -» Replace the reed valve. 3. Check: • air cut-off valve Cracks/damage -» Replace.
ELEC - + CHAPTER 8 ELECTORICAL ELECTRICAL COMPONENTS WIRING DIAGRAM CHECKING SWITCH CONTINUITY CHECKING THE SWITCHES CHECKING THE BULBS AND BULB SOCKETS TYPES OF BULBS CHECKING THE CONDITION OF THE BULBS CHECKING THE CONDITION OF THE BULB SOCKETS IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION TROUBLESHOOTING STARTER MOTOR CHECKING THE STARTER MOTOR ASSEMBLING THE STARTER MOTOR CHARGING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTIN
ELECTRICAL COMPONENTS ELEC EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 Main switch Front brake light switch Rectifier/regulator Rear brake light switch Battery Main fuse ECU Coolant temperature sensor Ignition coil 0 q w e r t y u 8-1 Spark plug cap Fuel pump Starter relay Horn Turn signal relay Starting circuit cut-off relay Stator coil Wire harness +i
WIRING DIAGRAM WIRING DIAGRAM Y L Br/W ^x^ B/L © <— Br/W < P/W rHi' Y T go P/W Y x Br/W R/B x B/L Lg x B/W W/R ' BrT ^ h /R~f| B/L x I I NHM @ (()j— 4= nrn r-rrriTTT—rr L/Y B/R WX f\ B/Y L/B G/Y Sb P B B x ^ gSj 8-2 ELEC +i
WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g h j k l ; z x c v b n m , .
CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. cC Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
CHECKING THE SWITCHES +1 ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear -» Repair or replace. Improperly connected -» Properly connect. Incorrect continuity reading -» Replace the switch.
CHECKING THE BULBS AND BULB SOCKETS EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear -» Repair or replace the bulb, bulb socket or both. Improperly connected -» Properly connect. No continuity -»Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this scooter are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 8bulb w Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. cC Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity -» Replace. Pocket tester 90890-03112 (YU-03112-C) NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ••••••••••••••••••••••• a. Install a good bulb into the bulb socket. b.
IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM -•- 1,® 8-9 ELEC +i
IGNITION SYSTEM EAS00736 EAS00738 TROUBLESHOOTING 1. Main Fuse • Check the fuse for continuity. Refer to “CHECKING THE FUSE” in chapter 3. * Is the fuse OK? The ignition system fails to operate (no spark or intermittent spark). Check: 1. main fuse 2. battery 3. spark plug 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. crankshaft position sensor resistance 8. main switch 9. engine stop switch 10. sidestand switch(optional) 11. lean angle cut-off switch 12.
IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap Disconnect the spark plug cap from the spark plug. Connect the ignition checker 1 as shown. 2Spark plug cap Set the main switch to “ON”. Measure the ignition spark gap a . Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. 5. Spark plug cap resistance • Remove the spark plug cap from the spark plug lead. • Connect the pocket tester (“Q x1k” range) to the spark plug cap as shown.
IGNITION SYSTEM EAS00748 7. Crankshaft position sensor resistance • Disconnect the crankshaft position sensor coupler from the wire harness. • Connect the pocket tester (£2 x100) to the crankshaft position sensor coupler as shown. Positive tester probe g white/red 1 Negative tester probe g white/blue2 • Measure the primary coil resistance. a Primary coil resistance 2.16 ~ 2.64 at 20°C(68°F) • Connect the pocket tester (£1 x1k) to the ignition coil as shown.
IGNITION SYSTEM ELEC +i EAS00750 9. Engine stop switch • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? YES V 4 NO Replace the right handlebar switch. YES V EAS00752 10. Sidestand switch(optional) • Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the sidestand switch OK? YES * Replace the lean angle cut-off switch. NO EAS00754 12. Wiring • Check the entire ignition system’s wiring.
ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main fuse Battery Starter relay Starter motor Start switch Engine stop switch Main switch 8-14 +i
ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ # ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: 8 The brake lever(front or rear) is pulled to the handlebar(the brake light switch is closed) and the sidestand(optional) is up(the sidestand switch(optional) is closed).
ELECTRIC STARTING SYSTEM EAS00757 EAS00738 TROUBLESHOOTING 1. Main Fuse • Check the fuse for continuity. Refer to “CHECKING THE FUSE” in chapter 3. * Is the fuse OK? The starter motor fails to turn. Check: 1. main fuse 2. battery 3. starter motor 4. starting circuit cut-off relay 5. starter relay 6. main switch 7. brake light switch(front and rear) 8. engine stop switch 9. sidestand switch(optional) 10.start switch 11.wiring connections (of the entire starting system) YES V 4 NO Replace the fuse.
ELECTRIC STARTING SYSTEM EAS00758 ELEC +1 I EAS00759 4. Starting circuit cut-off relay • Remove the starting circuit cut-off relay. • Connect the pocket tester (Q x1) and battery (12 V) to the starting circuit cut-off relay coupler as shown.
ELECTRIC STARTING SYSTEM EAS00761 ELEC +i EAS00751 5. Starter relay • Remove the starter relay . • Connect the pocket tester (Q x1) and battery (12 V) to the starter relay coupler as shown. 7. Brake light switch(front and rear) • Check the brake light switches for continuity. Refer to “CHECKING THE SWITCHES”.
ELECTRIC STARTING SYSTEM EAS00766 11. Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? YES V NO * The starting system Properly connect or recircuit is OK. pair the starting system’s wiring.
ELECTRIC STARTING SYSTEM ELEC +i EAS00767 STARTER MOTOR ® MM ® Order Job/Part Q’ty Removing the starter motor Front cover Single seat/Trunk Air filter assembly 1 2 1 2 3 4 5 6 7 8 Starter motor lead coupler Starter motor 1 1 Remarks Remove the parts in the order listed. Refer to “COVER AND PANEL”in chapter 3. Refer to“ENGINE REMOVAL”in chapter 5. Disconnect. For installation, reverse the removal procedure. Disassemble the parts in the order listed.
ELECTRIC STARTING SYSTEM ELEC +1 EAS00769 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt -» Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification -» Replace the starter motor. Commutator wear limit 16.6 mm (0.65 in) 3. Measure: • mica undercut a Out of specification -» Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 1.35 mm (0.
ELECTRIC STARTING SYSTEM ELEC +i b. If any resistance is out of specification, replace the starter motor. • • • • • • • • • • • • • • • • • • • • • • • 5. Measure: • brush length a Out of specification -» Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: • brush spring force Out of specification -» Replace the brush springs as a set. Brush spring force 3.92 ~ 5.88N(400 ~ 600gf, 14.11 ~ 21.16oz) 7. Check: • gear teeth Damage/wear -» Replace the gear. 8.
ELECTRIC STARTING SYSTEM ELEC +i EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: 8brush seat 1 2. Install: 8washer1 8armature coil 2 8o-ing New 3 8stator assembly4 3 . Install: • bracket • bolts (T) X I 5 Nm (0.5 m * kg, 3.6 ft * lb) NOTE: Align the match marks a on the starter motor yoke with the match marks b on the bracket.
CHARGING SYSTEM +i ELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM © © I a I -vJHHL/-' E _ r 1 i« £1 Br 1 ^ h B Y /R —111 © 1 Cry J AC magneto Rectifier/regulator Main fuse Battery Y X B/L l-l x Lg R W B/Y G/Y P B Or it -rfrffr-rr nrn R/B x L/Y B/R nrr x LB Sb —LIUL U-l Gy B x X — Dg 4 0 @ ©@© JL Li" j ii 12V10W LVlAr 1 Ch B/L G/R 12V10W [J -=r L B/L ^ I P/W EH l(S) Br R/W .
CHARGING SYSTEM EAS00774 ELEC +i EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The battery is not being charged. a Check: 1 . main fuse 2. battery 3. charging voltage 4. stator coil resistance 5. wiring connections (of the entire charging system) Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) • Is the battery OK? I YES V NOTE: 8 Before troubleshooting, remove the following part(s): 1.
CHARGING SYSTEM 5. Wiring • Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly connected and without defects? • Is the charging voltage within specification? YES lz * YES The charging circuit is OK. V Replace the rectifier/regulator. EAS00776 4. Stator coil resistance • Disconnect the starter coil coupler from wireharness. • Connect the pocket tester (Q x 1) to the stator coil as shown.
LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM Y L Br/W xB/L © B/L
LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light or meter light. a Check: 1. main fuse 2. battery 3. main switch 4. dimmer switch 5. wiring connections (of the entire lighting system) Minimum open-circuit voltage 12.
LIGHTING SYSTEM EAS00787 5. Wiring • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly connected and without defects? YES V Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE LIGHTING SYSTEM”. NO * Properly connect or repair the lighting system’s wiring.
LIGHTING SYSTEM EAS00788 3. Voltage • Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown. CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb and socket • Check the headlight bulb and socket for continuity.
ELEC LIGHTING SYSTEM YES V This circuit is OK. +i EAS00789 NO 2. The meter light fails to come on. 1. Meter light bulb and socket • Check the meter light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the meter light bulb and socket OK? * The wiring circuit from the main switch to the headlight coupler or meter assembly coupler is faulty and must be repaired. Refer to “CIRCUIT DIAGRAM”. YES V 4 NO Replace the meter light bulb, socket or both. 2.
LIGHTING SYSTEM EAS00790 3. Voltage • Connect the pocket tester (DC 20 V) to the ECU coupler (wire harness side) as shown. 3. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the tail/brake light bulb and socket OK? Positive tester probe -> black/green © Negative tester probe -> black/white (§) YES V © V This circuit is OK.
LIGHTING SYSTEM EAS00792 4. The license plate light fails to come on. 1. License plate light bulb and socket • Check the license plate light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the license plate light bulb and socket OK? YES V NO * Replace the license plate light bulb, socket or both. 2. Voltage • Connect the pocket tester (DC 20 V) to the license plate light coupler (license plate light side) as shown.
SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM (BETWEEN MAIN 8 SUB CIRCUIT DIAGRAM -H" ^<^ ^ ^ W B/R L/B Or/B Main fuse © Battery (D ECU Main switch (3D Fuel pump Horn switch Turn signal switch Tail/brake light Front brake light switch © Rear brake light switch © Horn © Turn signal relay © Front turn signal light(left) Front turn signal light(right) © Fuel level meter © Engine trouble warning © Coolant temperatu light Speed sensor © © Turn signal indicator light © FI diagnostic tool(optional) © Rear t
SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. II Check: 1. main fuse 2. battery 3. main switch 4. wiring connections (of the entire signaling system) Minimum open-circuit voltage 12.
SIGNALING SYSTEM EAS00796 The horn fails to sound. 1. Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? YES T NO V +i 3. Horn • Disconnect the pink connector at the horn terminal. • Connect a jumper lead © to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Push the horn switch. • Does the horn sound? CHECKING THE SIGNALING SYSTEM 1. ELEC Br * -© Replace the left handlebar switch. 2.
SIGNALING SYSTEM EAS00798 2. 3. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity.
SIGNALING SYSTEM EAS00799 3. The turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal indicator light bulb and socket • Check the turn signal indicator light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the turn signal indicator light bulb and socket OK? YES V ELEC +i 4. Voltage • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.
SIGNALING SYSTEM 5. Voltage • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. 6. Voltage • Connect the pocket tester (DC 20 V) to the turn signal light connector or meter assembly coupler (wire harness side) as shown.
SIGNALING SYSTEM EAS00804 +i ELEC 2. Voltage • Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. 4. The fuel level meter fails to operate. 1. Fuel sender • Remove the fuel pump from the fuel tank. • Connect the pocket tester (Q x1) to the fuel sender coupler (wire harness side) as shown.
SIGNALING SYSTEM 3. Fuel level meter • Set the main switch to “ON”. • Move the float u p ® or down (2). • Check that the fuel level meter needle moves to “F” or “E”. NOTE: Before reading the fuel level meter, leave the float in one position (either up or down) for at least three minutes. • Does the fuel level meter needle move appropriately? YES V This circuit is OK. 4 NO Replace the speedo meter.
COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Y L X Br/W B/L © B/L < Y x I ! -H • 8-42 ELEC +i
COOLING SYSTEM EAS00808 +i EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. • The coolant temperature indicator light fails to indicate. • The coolant temperature indicator light fails to indicate when the engine is warm. II Check: 1. main fuse 2. battery 3. main switch 4. coolant temperature sensor 5. wiring connections (the entire cooling system) YES V 4 EAS00749 3.
COOLING SYSTEM ELEC EAS00812 Coolant temperature sensor 22 Nm (2.2 m • kg, 15.9 ft • lb) 4. Coolant temperature sensor Remove the coolant temperature sensor from the cylinder head. Connect the pocket tester ( × 1k ) to the coolant temperature sensor1 as shown. Immerse the coolant temperature sensor in a container filled with coolant2. NOTE: Make sure the coolant temperature sensor terminals do not get wet.
COOLING SYSTEM CHECKING THE COOLING SYSTEM 3. Voltage • Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. 1. The coolant temperature indicator light fails to come on. 1. Coolant temperature indicator light bulb and socket • Check the coolant temperature indicator light bulb and socket for continuity.
COOLING SYSTEM 4. Coolant temperature indicator light • Disconnect the coolant temperature sensor coupler at the coolant temperature sensor. • Connect the green/red® and black/blue® with a jumper lead®. • Set the main switch to “ON”. 2 1 ^ • Is the coolant temperature indicator light OK? YES V This circuit is OK. NO * Replace the coolant temperature indicator light.
TRBL Q SHTGl • CHAPTER 9 TROUBLE SHOOTING STARTING FAILURE/HARD STARTING 9-1 ENGINE 9-1 FUEL SYSTEM 9-1 ELECTRICAL SYSTEMS 9-1 STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING SPEED 9-2 ENGINE 9-2 FUEL SYSTEM 9-2 ELECTRICAL SYSTEMS 9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY CLUTCH 9-3 ENGINE 9-3 FUEL SYSTEM 9-3 FAULTY CLUTCH 9-3 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE 9-3 CLUTCH SLIPS 9-3 POOR STARTING PERFORMANCE 9-3 POOR SPEED PERFORMANCE 9-4 OVERHEATING 9-4 ENGINE 9-4 COOLING SYSTEM 9-4
TRBL Q SHTGl • TURN SIGNAL DOES NOT COME ON TURN SIGNAL BLINKS SLOWLY TURN SIGNAL REMAINS LIT TURN SIGNAL BLINKS QUICKLY HORN DOES NOT SOUND 9-6 9-6 9-6 9-6 9-6
STARTING FAILURE/HARD STARTING TRBL Q SHTGl • EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING SPEED TRBL Q SHTGl • EAS00847 Starting system 8Faulty starter motor 8Faulty starter relay 8Faulty starting circuit cut-off relay 8Faulty starter clutch INCORRECT SPEED ENGINE IDLING ENGINE Cylinder and cylinder head 8Incorrect valve clearance 8Damaged valve train components Air filter 8Clogged air filter element FUEL SYSTEM Throttle body 8Damaged or loose throttle body joint 8Improperly ISC(idle speed control) valve 8Improper throttle cable fre
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY CLUTCH EAS00848 EAS00853 POOR MEDIUM-AND-HIGHSPEED PERFORMANCE FAULTY CLUTCH TRBL Q SHTGl • ENGINE OPERATES BUT SCOOTER WILL NOT MOVE Refer to “STARTING FAILURE/HARD STARTING”.
FAULTY CLUTCH/OVERHEATING/OVERCOOLING POOR SPEED PERFORMANCE V-belt 8Worn V-belt 8Oil or grease on the V-belt TRBL Q SHTGl • Hose(s) and pipe(s) 8Damaged hose 8Improperly connected hose 8Damaged pipe 8Improperly connected pipe Primary pulley weight(s) 8Faulty operation 8Worn primary pulley weight FUEL SYSTEM Throttle body 8Damaged or loose throttle body joint Primary fixed sheave 8Worn primary fixed sheave Air filter 8Clogged air filter element Primary sliding sheave 8Worn primary sliding sheave CHA
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING TRBL Q SHTGl • EAS00859 EAS00862 POOR BRAKING PERFORMANCE UNSTABLE HANDLING Drum brake 8Worn brake shoe 8Worn or rusty brake drum 8Incorrect brake lever position 8Incorrect brake lever free play 8Incorrect brake camshaft lever position 8Incorrect brake shoe position 8Damaged or fatigued brake shoe spring 8Oil or grease on the brake shoe 8Oil or grease on the brake drum Handlebar 8Bent or improperly installed handlebar Steering head com
FAULTY LIGHTING OR SIGNALING SYSTEM EAS00866 TRBL Q SHTGl • TURN SIGNAL REMAINS LIT FAULTY LIGHTING OR SIGNALING SYSTEM 8 F a u l t y t u r n signal relay 8Burnt-out turn signal bulb TURN SIGNAL BLINKS QUICKLY 8Incorrect turn signal bulb 8Faulty turn signal relay 8Burnt-out turn signal bulb HEADLIGHT DOES NOT COME ON 8Wrong headlight bulb 8Too many electrical accessories 8Hard charging 8Incorrect connection 8Improperly grounded circuit 8Poor contacts (main or light switch) 8Burnt-out headlight bulb H
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