EB000000 YP250 SERVICE MANUAL 1996 by Yamaha Motor Co., Ltd. 1st Edition, January 1996 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Repairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit for use.
YP002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol on the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
EB003000 1 2 3 Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 4 5 6 7 8 9 10 11 12 13 14 15 ILLUSTRATED SYMBOLS 16 1 2 3 4 5 6 7 8 9 General information Specifications Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Troubleshooting Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text.
INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9
CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER (for E) . . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES . . . . . . . . . . .
SCOOTER IDENTIFICATION GEN INFO YP100000 GENERAL INFORMATION SCOOTER IDENTIFICATION YP100010 VEHICLE IDENTIFICATION NUMBER (for E) The vehicle identification number 1 is stamped into the right side of the frame. NOTE: The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your country. YP100020 FRAME SERIAL NUMBER (except for E) The frame serial number 1 is stamped into the right side of the frame.
FEATURES GEN INFO FEATURES OIL INDICATOR LIGHT Function Pulses (travel distance signals) from the speedometer are counted and cause the oil indicator light to come on at 1,000 km for the first time and thereafter every 3,000 km. In this way, this light indicates the time for oil change. Circuit diagram Engine stop Ignitor unit switch Main switch Oil indicator light Reset button Fuse Battery Oil indicator light Meter Reset button C.P.
GEN INFO FEATURES AUTO-CHOKE SYSTEM This system is the parallel connection of the ignitor unit circuit and the thermo switch as shown, detecting the engine temperature, and facilitates the restarting with the warm engine. Circuit diagram Igniter unit Main switch Thermo switch Fuse Ignition C.P.
IMPORTANT INFORMATION GEN INFO EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. Refer to the “SPECIAL TOOLS” section. 4. When disassembling the machine, 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. 5.
IMPORTANT INFORMATION GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. OR EB101040 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips.
IMPORTANT INFORMATION GEN INFO EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: S Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector. 6. Connect: S Connector NOTE: The two connectors “click” together. 7. Check for continuity with a tester.
GEN INFO HOW TO USE THE CONVERSION TABLE EB201000 HOW TO USE THE CONVERSION TABLE 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. Ex. METRIC MULTIPLIER IMP **mm 0.03937 = ** in 2 mm 0.03937 = 0.08 in CONVERSION TABLE METRIC TO IMP Known Multiplier Result Torque mSkg mSkg cmSkg cmSkg 7.233 86.794 0.0723 0.8679 ftSlb inSlb ftSlb inSlb Weight kg g 2.205 0.03527 lb oz Distance km/hr km m m cm mm 0.
SPECIAL TOOLS GEN INFO EB102000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. 90890-01084 -01085 Tool name/Usage Weight Rocker arm shaft puller bolt These tools are used when removing or installing the rocker arm shafts.
SPECIAL TOOLS Tool No. 90890-01362 Tool name/Usage Flywheel puller This tool is used for removing the rotor. 90890-01367 -01368 Fork seal driver weight Fork seal driver attachment (ø33) This tool is used when installing the fork seal. 90890-01384 Oil seal guide This tool is used for protecting the oil seal lip when installing the secondary sliding sheave. 90890-01403 Ring nut wrench This tool is used to loosen and tighten the steering ring nut.
SPECIAL TOOLS Tool No. 90890-03141 Tool name/Usage Timing light This tool is needed for detecting ignition timing. 90890-04101 Valve lapper This tool is used for removing and installing the lifter and for lapping the valve. 90890-04019 -04108 Valve spring compressor Attachment These tools are used when removing or installing the valve and the valve spring. 90890-04058 -04078 Middle shaft bearing driver Mechanical seal installer These tools are used for installing mechanical seal.
CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code: YP250 4UC 1 (except for CH, A) 4UD1 (for CH, A) Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,110 mm ,750 mm 1,330 mm ,700 mm 1,500 mm ,115 mm 2,600 mm Basic weight: With oil and full fuel tank 158 kg Engine: Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure (STD) Starting system Lubricat
GENERAL SPECIFICATIONS Model SPEC YP250 Carburetor: Type/quantity Manufacturer Y28V-1A/1 TEIKEI Spark plug: Type Manufacturer Spark plug gap DR8EA NGK 0.6 X 0.7 mm Clutch type: Dry, centrifugal automatic Transmission: Primary reduction system Primary reduction ratio Secondary reduction sytem Secondary reduction ratio Transmission type Operation Single speed automatic Helical gear 40/15 (2.666) Sper gear 37/16 (2.312) Single speed automatic (V-belt type) Centrifugal automatic type 2.20 X 0.
GENERAL SPECIFICATIONS Model Brake: Front brake Rear brake type operation type operation YP250 Single disc brake Right hand operation Drum brake Left hand operation Suspension: Front suspension Rear suspension Telescopic fork Unit swing Shock absorber: Front shock absorber Rear shock absorber Coil spring/Oil damper Coil spring/Oil damper Wheel travel: Front wheel travel Rear wheel travel 85 mm 90 mm Electrical: Ignition system Generator system Battery type Battery capacity T.C.I. (Digital) A.C.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit SSS 0.03 mm Cylinder: Bore size Out of round limit 69.000 X 69.005 mm SSS 69.1 mm 0.03 mm Camshaft: Cam dimensions Intake “A” “B” “C” Exhaust “A” “B” “C” Camshaft runout limit 36.545 X 36.645 mm 30.021 X 30.121 mm 6.524 mm 36.547 X 36.647 mm 30.067 X 30.167 mm 6.48 mm SSS 36.45 mm 29.92 mm SSS 36.45 mm 29.97 mm SSS 0.03 mm Cam chain: Cam chain type/No.
MAINTENANCE SPECIFICATIONS Item Stem-to-guide clearance Stem runout limit Valve seat width Valve spring: Free length (Inner) Free length (Outer) Set length (valve closed) Set length (valve closed) Compressed pressure Tilt limit (Inner) Tilt limit (Outer) Piston: Piston to cylinder clearance Piston size “D” Measuring point “H” Piston pin bore inside diameter Piston pin outside diameter Piston rings: Top ring: Type End gap (installed) Side clearance (installed) 2nd ring: Type End gap (installed) Side clearanc
MAINTENANCE SPECIFICATIONS SPEC Item Standard Limit Automatic centrifugal clutch: Clutch shoe thickness Clutch housing inside diameter Clutch shoe spring free length Weight outside diameter Clutch – in revolution Clutch – stall revolution 3.0 mm 135 mm 28.1 mm 20 mm 2,100 X 2,700 r/min 3,700 X 4,700 r/min 2.0 mm 135.5 mm SSS 19.5 mm SSS SSS V-belt: V-belt width 22.6 mm 21.0 mm Carburetor: Type I.D.
MAINTENANCE SPECIFICATIONS Item Radiator: Type Width/height/thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Thermostatic valve: Type/manufacturer Valve opening temperature Valve full open temperature Valve full open lift SPEC Standard Limit Cooling fin with electric fan 140/238/24 mm 110 X 140 kPa (1.1 X 1.4 kg/cm2, 1.1 X 1.4 bar) 1.4 L 0.35 L SSS SSS 4HC/NIHON THERMOSTAT 80.5 X 83.
MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUES ENGINE g Part to be tightened Oil check bolt Exhaust pipe stud bolt Spark plug Cam sprocket cover Cylinder head and cylinder Cylinder head and cylinder (Cam chain side) Valve cover Rotor Valve adjuster locknut Cam shaft bearing stopper Cam sprocket Cam chain tensioner (Body) (Plug) Guide stopper 2 Water pump housing cover Hose joint Thermostatic valve cover Filler neck supporting Oil pump Oil pump cover Drain plug Carburetor joint Carburetor joint and car
MAINTENANCE SPECIFICATIONS Part to be tightened g Cover (oil pump) Timing check plug One way clutch Clutch housing Grease stopper (Primary sheave) Primary fixed sheave Clutch carrier assembly Stator Pick up coil Starter motor Thermo switch Thermo unit Part name Bolt Plug — Bolt — — — — — Bolt — — 2-9 Thread size Q’ty y M6 M16 M8 M14 M4 M14 M36 M5 M5 M6 M16 Pt 1/8 2 1 3 1 4 1 1 3 2 2 2 1 SPEC Tightening torque Nm mSkg 12 8 30 60 3 60 90 7 7 10 23 8 1.2 0.8 3.0 6.0 0.3 6.0 9.0 0.7 0.7 1.0 2.3 0.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Standard Limit Steering system: Steering bearing type Ball bearing SSS Front suspension: Front fork travel Fork spring free length Spring rate (K1) Stroke (K1) Oil capacity Oil level Oil grade Inner tube vend limit 100 mm 265.8 mm 5.7 N/mm (0.57 kg/mm) 0 X 100 mm 0.142 L (142 cm3) 80 mm Fork oil 15 WT or equivalent SSS SSS 263.5 mm SSS SSS SSS SSS SSS 0.
MAINTENANCE SPECIFICATIONS SPEC Item Standard Limit Rear drum brake: Type Drum inside diameter Shoe thickness Leading, trailing 160 mm 4 mm SSS 161 mm 2 mm Brake lever: Brake lever free play (front at lever side) Brake lever free play (rear) Throttle cable free play 2 X 5 mm 10 X 20 mm 3 X 5 mm SSS SSS SSS Item Size Bearings and oil seals: Front wheel bearing (left) Front wheel bearing (right) Front wheel oil seal (left) Meter gear oil seal (right) Rear wheel bearing (left) Rear wheel oil seal
MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUES CHASSIS Thread size Part to be tightened Frame and engine bracket Engine bracket, compression rod and engine Compression rod and frame Sidestand (bolt and frame) Sidestand (bolt and nut) Rear footrest bracket Swingarm Rear shock absorber and frame Rear shock absorber and engine Steering ring nut Handle holder and steering shaft Handle upper holder and lower holder Brake hose and master cylinder Fuel tank (font) (rear) Fuel cock Fuel sender Filter Roll ov
MAINTENANCE SPECIFICATIONS SPEC NOTE: 1. First, tighten the ring nut (lower) approximately 38 Nm (3.8 mSkg) by using the torque wrench, then loosen the ring nut 1/4 turn. 2. Second, tighten the ring nut (lower) approximately 22 Nm (2.2 mSkg) by using the torque wrench, then finger tighten the ring nut (center). Align the slots both ring nut and install the lock washer. 3. Final, hold the ring nuts (lower and center) and tighten the ring nut (upper) 75 Nm (7.5 mSkg) by using the torque wrench.
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard limit Ignition timing: Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advanced type 10_ at 1,500 r/min 32_ at 5,000 r/min Electrical type SSS SSS SSS 168 X 252 Ω at 20_C/ Yellow – Black J4T069/MITSUBISHI SSS Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance F6T507 /MITSUBISHI 6 mm 3.6 X 4.8 Ω at 20_C 10.7 X 14.
MAINTENANCE SPECIFICATIONS SPEC Item Standard limit Starter relay: Model/manufacturer Amperage rating Coil winding resistance 4FL/JIDECO 100 A 4.2 X 4.6 Ω at 20_C SSS SSS SSS Horn: Model/manufacturer Maximum amperage YF-12/NIKKO 2.
GENERAL TORQUE SPECIFICATIONS SPEC GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads.
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE Lubrication Point Symbol Oil seal lips O-ring (Except V-belt drive unit) Cylinder head tightening nut mounting surface Crankshaft pin outside Connecting rod big end thrust surface Rotary filter inner surface Drive gear inner surface Cam chain outside sprocket inner surface Piston pin Piston outside and ring groove Camshaft cam profile Valve stem (IN, EX) Valve stem end (lN, EX) Rocker shaft Valve rocker arm inn
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC CHASSIS Symbol Lubrication Point Front wheel oil seal lips (left/right) Swingarm oil seal lips (left/right) Steering head pipe bearing (upper/lower) Steering head pipe dust seal lips (upper/lower) Tube guide (throttle grip) inner surface Brake cable (brake lever) Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft Brake cam pivot shaft and cam surface 2-18
CABLE ROUTING SPEC CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Rectifier regulator Fuel sender Fuse (fan) Roll over valve Ignition coil Seat lock cable Handlebar switch 3 lead (right) Front brake switch lead Brake hose Speedometer cable Radiator overflow hose Starter relay / Fuse (main) Battery Battery positive (+) lead 15 16 17 18 19 20 21 22 23 24 25 Battery negative (–) lead Flasher relay Reservoir tank Breather hose Air filter Mainharness Link (engine bracket) A.C.
CABLE ROUTING E Pass the overflow hose from J Keep the clamping clearance the reservoir tank through the over 5 mm. clamp inside the frame. (Bend the metal clamp to keep F Clamp the mainharness, battery the clearance between the (+) lead and (–) lead to clamp metal clamp and link over of the frame. 5 mm.) G Clamp the fuel sender lead to K Install the meter cable with the pipe. its sheaved side facing to the H The mainharness connecting meter gear.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Seat lock Air filter case Breather hose Fuel hose Vacuum hose Sidestand switch lead Thermo switch lead Fan motor lead , Breather hose Overflow hose (fuel tank) Relay Auto choke lead A.C. magneto lead Starter motor lead Engine earth lead Protector (pipe) Seat lock cable A Clamp the mainharness and sidestand switch lead together the frame. B Clamp the sidestand switch lead.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Front flasher light (right) Front flasher light (left) Handlebar switch (right) lead Front brake switch lead Seat lock cable Throttle cable Brake hose Handlebar switch (left) lead Rear brake switch lead Handlebar under cover Brake cable 2 Speedometer cable Stay 1 Horn 15 Brake hose stopper 16 Marking A Clamp the speedometer lead the stay 1. B Pass the speedometer cable and the brake hose through the clamps on the frame.
CABLE ROUTING G Pass the brake hose through the hose holder and clamp. H Clamp the headlight lead and horn lead from mainharness to the stay 1. I Install the brake hose with its marking facing to the stopper side.
CABLE ROUTING Fuel overflow hose (filler neck) Throttle cable 1 (nut white) Throttle cable 2 (nut black) Air vent hose (carburetor) Coolant drain hose (carburetor) 6 Fuel drain hose (carburetor) 7 Fuel overflow hose (fuel tank) 1 2 3 4 5 A Pass the brake cable 2 though the holder and clamp to the crankcase. B Pass the air vent hose, coolant drain hose, and fuel drain C D E F G hose through the “U” clamp on the holder. Put the lock of the band to the center from the line “a”.
CABLE ROUTING 1 2 3 4 5 6 7 Steering head pipe Brake cable 2 Mainharness Downtube Throttle cable Radiator Stay 1 A Pass the brake cable 2 though the clamp on the handlebar holder. B Band the brake cable 2 to the steering head pipe, noting the band direction. (view A) C Band the throttle cable and the right mainharness to the D E F G H downtube, noting the band direction. (view B) Band the brake cable 2 to the frame at the upper part of the radiator, noting the band direction.
SPEC
CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . COVER AND PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAIL COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOOTREST BOARD AND LOWER COVER . . . . . . . . . . . . . . . . . . . . COWLING . . . . . . . . . . . . . . . .
INTRODUCTION / PERIODIC MAINTENANCE/LUBRICATION INTERVALS INSP ADJ EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS INSP ADJ BREAK-IN NO. 15 ITEM Centerstand and sidestand pivot ROUTINE TYPE Check operation and lubricate. 1,000 km Same as engine oil EVERY 6,000 km or 6 months 12,000 km or 12 month 16 * Sidestand switch Check and clean or replace if necessary. — 17 * Front fork Check operation and for oil leakage. — Check bearing assembly for looseness.
COVER AND PANEL INSP ADJ COVER AND PANEL SIDE PANEL AND SEAT Order Job name/Part name Q’ty 1 2 3 4 5 6 7 Side panel and seat removal Rear panel Side panel (left) Side panel (right) Rivet Front panel Clip Damper assembly 1 1 1 2 1 2 1 8 Seat 1 Remarks Remove the parts in order. NOTE: Install the damper assembly to the body with its rod side backward and labels upward. Reverse the removal procedure for installation.
COVER AND PANEL INSP ADJ TAIL COVER AND FUEL TANK 10 Nm (1.0 m kg) 7 Nm (0.7 m kg) 7 Nm (0.7 m kg) Order Job name/Part name Q’ty 1 2 3 4 5 6 7 8 9 Tail cover and fuel tank removal Grab bar Seat lock bracket Screw Tail cover Fuel tank cap Fuel overflow hose Cover Fuel tank cover Coupler (fuel sender lead) 1 1 2 1 1 1 1 1 1 10 11 Fuel overflow hose Fuel hose 1 1 Remarks Remove the parts in order. 3-4 Tail cover Fuel tank NOTE: Disconnect the couplers.
COVER AND PANEL INSP ADJ 10 Nm (1.0 m kg) 7 Nm (0.7 m kg) 7 Nm (0.7 m kg) Order 12 13 14 Job name/Part name Q’ty Vacuum hose Bracket Fuel tank 1 1 1 Remarks Fuel tank Reverse the removal procedure for installation.
COVER AND PANEL INSP ADJ FOOTREST BOARD AND LOWER COVER 7 Nm (0.7 m kg) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name/Part name Q’ty Footrest board and lower cover removal Mat (footrest board) (left/right) Cover 2 Battery negative (-) lead Battery positive (+) lead Battery Flasher relay Starter relay Reservoir tank Footrest Lid Box Lower cover Footrest board Remarks Remove the parts in order. 1/1 1 1 1 1 1 1 1 2 1 1 1 1 3-6 Reverse the removal procedure for installation.
COVER AND PANEL INSP ADJ COWLING 7 Nm (0.7 m kg) 7 Nm (0.7 m kg) Order Job name/Part name Q’ty 1 2 3 4 5 6 7 Cowling removal Upper cover Wind screen Inner panel Cowling body Coupler (headlight lead) Coupler (front flasher light lead (left)) Coupler (front flasher light lead (right)) Remarks Remove the parts in order. 1 1 1 1 1 1 NOTE: Disconnect the couplers. Reverse the removal procedure for installation.
COVER AND PANEL INSP ADJ HANDLE COVER, METER ASSEMBLY AND LEGSHIELD Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Handle cover, meter assembly and legshield removal Handle cover Coupler (meter lead) Meter cable Meter assembly Main switch cover Cover Legshield Remarks Remove the parts in order. 1 1 1 2 1 2 1 NOTE: Disconnect the couplers. Reverse the removal procedure for installation.
VALVE CLEARANCE ADJUSTMENT INSP ADJ YP303004 ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: Valve clearance adjustment should be made with the engine cool, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (T.D.C.) on the compression stroke. 1. Remove: Side panels Tail cover Fuel tank Refer to “COVER AND PANEL” section. 2. Remove: Crankcase filter cover 1 Crankcase filter cover seal Crankcase filter element 2 3.
VALVE CLEARANCE ADJUSTMENT/ IDLING SPEED ADJUSTMENT INSP ADJ 6. Adjust: D Valve clearance ***************************************************** Adjustment steps: D Loosen the locknut 1 . D Turn the adjuster 3 in or out with the valve adjusting tool 2 until specified clearance is obtained. Turning in Valve clearance is decreased. Turning out Valve clearance is increased. Valve adjusting tool: 90890-01311 D Hold the adjuster to prevent it from moving and tighten the locknut. 14 Nm (1.
IDLING SPEED ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT INSP ADJ 3. Check: Engine idling speed Out of specification Adjust. Engine idling speed: 1,450 1,550 r/min 4. Adjust: Engine idle speed ***************************************************** Adjustment steps: Turn the pilot screw 1 until it is lightly seated. Turn the pilot screw out by the specified number of turns. Pilot screw: 1-7/8 turns out Turn the throttle stop screw 2 in or out until the specified idling speed is obtained.
THROTTLE CABLE ADJUSTMENT/ SPARK PLUG INSPECTION INSP ADJ Loosen the locknut 1 on the throttle cable. Turn the adjuster 2 in or out until specified free play is obtained. Turning in Free play is increased. Turning out Free play is decreased. Tighten the locknut. After adjusting, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. ***************************************************** EB303040 SPARK PLUG INSPECTION 1.
SPARK PLUG INSPECTION/ IGNITION TIMING CHECK INSP ADJ Spark plug gap: 0.6 0.7 mm 6. Install: D Spark plug 18 Nm (1.8 mSkg) NOTE: Before installing a spark plug, clean the gasket surface and plug surface. YP303052 IGNITION TIMING CHECK NOTE: Prior to checking the ignition timing, check all electrical connections related to the ignition system. Make sure all connections are tight and free of corrosion and that all ground connections are tight. 1. Remove: D Timing check plug 2.
IGNITION TIMING CHECK/ COMPRESSION PRESSURE MEASUREMENT INSP ADJ NOTE: Ignition timing is not adjustable. 3. Install: Timing check plug YP303060 COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in performance loss. 1. Remove: Side panels Refer to “COVER AND PANEL” section. 2. Check: Valve clearance Out of specification Adjust. Refer to “VALVE CLEARANCE ADJUSTMENT” section. 3. Start the engine and let it warm up for several minutes. 4. Turn off the engine. 5.
COMPRESSION PRESSURE MEASUREMENT/ ENGINE OIL REPLACEMENT INSP ADJ p p Compression pressure (With oil applied into cylinder) Reading Diagnosis Higher than without oil Worn or damaged pistons Same as without oil Possible defective ring(s), valves, cylinder head gasket or piston Repair. Compression pressure (at sea level): Standard: 1,400 kPa (14 kg/cm2, 14 bar) Minimum: 1,120 kPa (11.2 kg/cm2, 11.
ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT INSP ADJ RECOMMENDED ENGINE OIL Refer to the chart for selection of the oils suited to the atomosperic temperature. API STANDARD: API SE or higher grade CAUTION: D Do not put in any chemical sdditives or use oils with a grade of CD a or higher. D Be sure not to use oils labeled “ENERGY CONSERVING II” b or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage. D Be sure no foreign material enters the crankcase. 5.
ENGINE OIL REPLACEMENT/ ENGINE OIL PRESSURE INSPECTION INSP ADJ 5. Fill: Crankcase Oil quantity: 1.4L 6. Check: Engine oil level Refer to “ENGINE OIL LEVEL INSPECTION” section. 7. Reset: Engine oil warning circuit ***************************************************** Resetting steps: Turn the main switch to on. Push and hold in the reset button for 2 to 5 seconds. Release the reset button 1 and the oil indicator light will go off.
ENGINE OIL PRESSURE INSPECTION/ TRANSMISSION OIL REPLACEMENT INSP ADJ D Start the engine after solving the problem(s), and recheck the oil pressure. D Tighten the oil check bolt to specification. 10 Nm (1.0 mSkg) CAUTION: D Start the engine and check the oil pressure with the oil check bolt loosened. D Do not apply at high speeds more than specified when checking the pressure. NOTE: Wipe any spilled oil off the engine.
TRANSMISSION OIL REPLACEMENT/ EXHAUST SYSTEM INSPECTION/AIR FILTER CLEANING INSP ADJ 7. Install: D Oil filler cap 1 D O-ring 2 8. Start the engine for several minutes to warm it up and check for the oil leakage. YP***** EXHAUST SYSTEM INSPECTION 1. Remove: D Side panels Refer to “COVER AND PANEL” section. 2. Inspect: 20 Nm (2.0 mSkg) D Nut 1 (exhaust pipe) Loose/Damage Tighten/replace. D Gasket (exhaust pipe) Exhaust gas leaks Tighten/replace. 3. Inspect: 53 Nm (5.
AIR FILTER CLEANING/ CRANKCASE FILTER CLEANING INSP ADJ 3. Inspect: D Air filter element Damaged Replace. 4. Clean: D Air filter element 1 Use solvent to clean the element NOTE: After cleaning, remove the remaining solvent by squeezing the element. CAUTION: Do not twist the element when squeezing the element. 5. Apply the recommended oil to the entire surface of the filter and squeeze out the excess oil. The element should be wet but not dripping.
CRANKCASE FILTER CLEANING/ COOLANT LEVEL INSPECTION INSP ADJ CAUTION: This element is a dry type. Be careful not to stain with grease or water. 3. Clean: D Crankcase filter element 1 Blow out the dust in the element from the outer surface using compressed air. 4. Install: D Crankcase filter element D Crankcase filter cover seal 7 Nm (0.7 mSkg) D Crankcase filter cover YP303170 COOLANT LEVEL INSPECTION NOTE: Make sure the scooter is upright when inspecting the coolant level. 1.
COOLANT REPLACEMENT INSP ADJ YP303180 COOLANT REPLACEMENT 1. Remove: Side panels Fuel tank Refer to the “COVERS AND PANEL” section. 2. Remove: Hose 1 (reservoir tank) Drain the reservoir tank of its coolant. 3. Remove: Drain bolt 1 Radiator cap Open the front trunk, remove the cover, slowly loosen to remove the radiator cap and drain the coolant. Do not remove the radiator cap when the engine and radiator are hot.
COOLANT REPLACEMENT 5. Install: D Gasket 1 D Drain bolt 2 INSP ADJ 10 Nm (1.0 mSkg) 6. Loosen: D Screw 1 (carburetor bleed) 7. Connect: D Hose (reservoir tank) 8. Fill: D Radiator (to specified level 1 ) Fill the coolant slowly, until the coolant comes out from the carburetor drain pipe. D Reservoir tank (to maximum level a ) Recommended coolant: High quality ethylene glycol anti-freeze containing corrosion inhibitors for aluminium engine.
COOLANT REPLACEMENT INSP ADJ If coolant splashes in your eyes: thoroughly wash your eyes with water and consult a doctor. If coolant splashes on your clothes: quickly wash it away with water and then with soap and water. If coolant is swallowed: quickly make the person who has swallowed it vomit and then take him to a doctor. ***************************************************** CAUTION: Hard water or salt water is harmful to engine parts. Use only distilled water if soft water is not available.
COOLING SYSTEM INSPECTION INSP ADJ YP303190 COOLING SYSTEM INSPECTION 1. Inspect: Radiator 1 Filler hose (radiator) 2 Outlet hose (radiator) 3 Pipe Outlet hose (radiator) 4 Cracks/Damage Replace. Refer to “COOLING SYSTEM” section in chapter 5.
FRONT BRAKE ADJUSTMENT INSP ADJ EB304002 CHASSIS FRONT BRAKE ADJUSTMENT 1. Check: Brake lever free play a Out of specification Adjust. Free play (brake lever): 2 5 mm (at brake lever end) 2. Adjust: Brake lever free play ***************************************************** Adjustment steps: Loosen the locknut 2 . Turn the adjuster 3 in or out until the specified free play is obtained. Turning in Free play is decreased. Turning out Free play is increased. Tighten the locknut.
BRAKE FLUID LEVEL INSPECTION INSP ADJ YP304020 BRAKE FLUID LEVEL INSPECTION 1. Stand the scooter on a level surface. NOTE: Make sure the scooter is upright when inspecting the brake fluid level. 2. Stand the scooter on its centerstand. 3. Inspect: Brake fluid level Brake fluid level is below the “LOWER” level line a Fill to proper level. Recommended brake fluid: DOT#4 NOTE: For a correct reading of the brake fluid level, make sure the top of the handlebar brake fluid reservoir is horizontal.
BRAKE PAD INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP ADJ YP304030 BRAKE PAD INSPECTION 1. Operate the brake lever. 2. Inspect: Brake pad (front) Wear indicators 1 almost touch the brake disc Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKE” in CHAPTER 7.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ REAR BRAKE ADJUSTMENT INSP ADJ NOTE: When bleeding the brake system, make sure that there is always enough brake fluid in the brake fluid reservoir before applying the brake lever. Ignoring this precaution could allow air to enter the brake system, considerably lengthening the bleeding procedure. j. Tighten the bleed screw. 6 Nm (0.6 mSkg) D Bleed screw NOTE: If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours.
REAR BRAKE ADJUSTMENT/ BRAKE SHOE INSPECTION/STEERING HEAD INSPECTION INSP ADJ Tighten the locknut (s). Rear wheel side: Turn the adjuster 3 in or out until the specified free play is obtained. Turning in Free play is decreased. Turning out Free play is increased. CAUTION: Make sure that the brake does not drag after adjusting it. ***************************************************** YP304040 BRAKE SHOE INSPECTION 1. Operate the brake lever. 2.
STEERING HEAD INSPECTION INSP ADJ 5. Remove: D Handlebar lower holder D Woodruff key Refer to “STEERING” section in chapter 7. 6. Adjust: D Steering head ***************************************************** Adjustment steps: D Remove the ring nut (upper) 1 , lock washer 2 , the ring nut (center) 3 and the rubber washer. D Loosen the ring nut 4 (lower). D Tighten the ring nut (lower) using the ring nut 38 Nm (3.8 mSkg) wrench 5 . NOTE: Set the torque wrench at right angles to the ring nut wrench.
STEERING HEAD INSPECTION/ FRONT FORK INSPECTION INSP ADJ D Install the lock washer 1 . NOTE: Make sure the lock washer tabs sit correctly in the ring nut slots. D Hold the ring nut (under and center), using the exhaust and ring nut wrench, and tighten the ring nut (upper) using the ring nut wrench. 75 Nm (7.5 mSkg) Exhaust and ring nut wrench: 90890-01268 ***************************************************** 8. Install: D Woodruff key D Handlebar lower holder Refer to “STEERING” section in CHAPTER 7.
SWINGARM INSPECTION/ REAR SHOCK ABSORBER INSPECTION/ REAR SHOCK ABSORBER ADJUSTMENT INSP ADJ YP***** SWINGARM INSPECTION Securely support the scooter so there is no danger of it falling over. 1. Place the scooter on the level place. 2. Check: D Operation Grasp the end of the swingarm and gently rock the swingarm assembly back and forth. Unsmooth operation Repair. Refer to “REAR SHOCK ABSORBER AND SWINGARM” section in CHAPTER 7. YP****** REAR SHOCK ABSORBER INSPECTION 1.
REAR SHOCK ABSORBER ADJUSTMENT/ TIRE INSPECTION INSP ADJ ***************************************************** Adjustment steps: Turn the adjuster ring in or out. Turning toward a Spring preload is increased. Turning toward b Spring preload is decreased. Hard Adjusting position: 5 4 Standard 3 Soft 2 1 CAUTION: Never turn the adjuster beyond the maximum or minimum setting. Always adjust each shock absorber to the same setting.
TIRE INSPECTION INSP ADJ Basic weight: With oil and full fuel tank 158 kg Maximum load* 197 kg Cold tire pressure Up to 90 kg load* Front Rear 175 kPa 200 kPa (1.75 kg/cm2, 1.75 bar) (2.0 kg / cm2, 2.0 bar) 90 kg maximum. load* (2.0 kg / cm2, 2.0 bar) (2.25 kg/cm2, 2.25 bar) High speed riding (2.0 kg / cm2, 2.0 bar) (2.50 kg/cm2, 2.50 bar) 200 kPa 200 kPa 225 kPa 250 kPa * Load is the total weight of the cargo, rider, passenger and accessories. 2.
TIRE INSPECTION/WHEEL INSPECTION INSP ADJ FRONT: Manufacture Size Type IRC 110 / 90-12 64J MB61 CHENG SHIN 110 / 90-12 64J C922 Manufacture Size Type IRC 130 / 70-12 62L MB61 CHENG SHIN 130 / 70-12 62L C940 REAR: After mounting a tire, ride conservatively for a while to give the tire time to seat itself properly in the rim. Failure to do so could lead to an accident with possible injury to the rider or damage to the scooter. 2.
BATTERY INSPECTION INSP ADJ YP305000 ELECTRICAL BATTERY INSPECTION NOTE: Since the MF battery is a sealed type battery, it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery. Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals. CAUTION: CHARGING METHOD This is a sealed type battery. Never remove the sealing caps.
BATTERY INSPECTION INSP ADJ D Batteries generate explosive hydrogen gas. Always follow the following preventive measures: D Charge batteries in a well-ventilated area. D Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes, etc.) D DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. 1. Remove: D Mat (right) D Cover (battery case) Refer to “COVER AND PANEL” section. 2.
BATTERY INSPECTION D Check the condition of the battery using the charts. Example: Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge condition of the battery = 20 30% Ambient temperature 20_C (68_F) Open-circuit voltage (V) INSP ADJ ***************************************************** 5. Charging method for MF batteries Condition of charge in battery (%) CAUTION: Ambient temperature 20_C (68_F) D If it is impossible to set the standard charging current, be careful not to overcharge.
BATTERY INSPECTION INSP ADJ Charging method using a variable-current (voltage) type charger Charger AMP meter Measure the open-circuit voltage prior to charging. Connect a charger and AMP meter to the battery, and start charging. YES Make sure the current is higher than the standard charging current written on the battery. NOTE: Voltage should be measured 30 minutes after the machine is stopped. NOTE: Set the changing voltage at 16 17 V. (If the setting is lower, charging will be insufficient.
INSP ADJ BATTERY INSPECTION Charging method using a constant-voltage type charger Measure the open-circuit voltage prior to charging. NOTE: Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery, and start charging. YES Make sure the current is higher than the standard charging current written on the battery. Charge the battery until the battery’s charging voltage is 15 volts. NO This type of battery charger cannot charge the MF battery.
BATTERY INSPECTION/FUSE INSPECTION INSP ADJ 6. Inspect: Battery terminals Dirty terminal Clean with wire brush. Poor connection Correct. NOTE: After cleaning the terminals, grease them lightly. 7. Install: Battery 8. Connect: Battery leads CAUTION: Connect the positive lead first and then connect the negative lead. 9. Install: Cover (battery case) Mat (right) Refer to “COVER AND PANEL” section.
FUSE INSPECTION/HEADLIGHT BEAM ADJUSTMENT INSP ADJ 3. Replace: Blown fuse ***************************************************** Replacement steps: Turn off the main switch. Install a new fuse with the proper current rating. Turn on switches to verify operation of related electrical devices. If the fuse blows again immediately, check the electrical circuit. Never use a fuse with a rating other than that specified. Never use other materials in place of a fuse.
INSP ADJ
CHAPTER 4. ENGINE ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIREHARNESS AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT AND ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE REMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT INSPECTION . .
ENGINE REMOVAL ENG EB400000 ENGINE OVERHAUL ENGINE REMOVAL WIREHARNESS, CABLE 10 Nm (1.0 m kg) 7 Nm (0.7 m kg) Order Job name/Part name Q’ty Wireharness and cables removal Side panel Footrest board Fuel tank Drain the coolant. Remove the parts in order. Refer to “COVER AND PANEL” section in CHAPTER 3. Refer to “COOLANT REPLACEMENT” section in CHAPTER 3. Refer to “CARBURETOR” section in CHAPTER 6.
ENGINE REMOVAL ENG 10 Nm (1.0 m kg) 7 Nm (0.7 m kg) Order 8 9 10 11 Job name/Part name Q’ty Pin Compression spring Cable holder Cable holder Remarks 1 1 1 1 Reverse the removal procedure for installation.
ENGINE REMOVAL ENG HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT AND ENGINE 7 Nm (0.7 m kg) 32 Nm (3.2 m kg) 19 Nm (1.9 m kg) 64 Nm (6.4 m kg) Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Hoses, air filter, engine mounting bolt and engine removal Vacuum hose Crankcase breather hose Inlet hose (water pump) Outlet hose (cylinder head) Air filter case assembly Bolt Self locknut/Plane washer Bolt Bolt/Plane washer/Rod assembly Engine Q’ty Remarks Remove the parts in order.
ENGINE REMOVAL ENG YP****** ENGINE REMOUNTING When remounting the engine, reverse the removal procedure in job instruction chart. Note the following points: 1. Install: Engine 1 Plane washer 2 Rod 3 NOTE: Temporarily install the rod and engine, and then tighten the bolts and nuts to specifications. 2. Tighten: 64 Nm (6.4 m kg) Bolt 1 Self locknut (engine and swingarm) 2 32 Nm (3.
CYLINDER HEAD ENG CYLINDER HEAD 22 Nm (2.2 m kg) 10 Nm (1.0 m kg) 60 Nm (6.0 m kg) 8 Nm (0.8 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Cylinder head removal Drain the coolant. Side panel Footrest board Fuel tank Carburetor Thermo unit lead Plug cap Crankcase breather hose Outlet hose (cylinder head) Vacuum hose Breather hose (crankcase) Carburetor joint Joint O-ring Remarks Remove the parts in the order.
CYLINDER HEAD 22 Nm (2.2 m kg) ENG 10 Nm (1.0 m kg) 60 Nm (6.0 m kg) 8 Nm (0.8 m kg) 10 Nm (1.0 m kg) 10 Nm (1.
CYLINDER HEAD ENG YP401030 CYLINDER HEAD REMOVAL 1. Align: S “I” mark a on the rotor (with stationary pointer b on the crank case cover) NOTE: Turn the primary sheave counterclockwise with a wrench and align the “I” mark c with the cylinder head match mark d when the piston is at TDC on the compression stroke. 2. Loosen: S Bolt 1 3. Remove: S Timing chain tensioner assembly S Timing chain tensioner gasket 4.
CYLINDER HEAD ENG 2. Inspect: S Cylinder head Scratches/damage Replace. 3. Measure: S Cylinder head warpage Out of specification Resurface. Cylinder head warpage: Less than 0.03 mm ***************************************************** Warpage measurement and resurfacement steps: D Place a straightedge and a feeler gauge across the cylinder head. D Measure the warpage. If the warpage is out of specification, resurface the cylinder head.
CYLINDER HEAD ENG 3. Install: S Cam sprocket 1 S Timing chain 2 ***************************************************** Installing steps: D Turn the primary sheave counterclockwise until the TDC mark a matches the stationary pointer b . D Align the “I” mark c on the cam sprocket with the stationary pointer d on the cylinder head. D Fit the timing chain onto cam sprocket and install the cam sprocket on the camshaft.
CYLINDER HEAD ENG 5. Install: S Timing chain tensioner ***************************************************** Installation steps: D Remove the tensioner cap bolt 1 and springs 2 . D Release the timing chain tensioner one-way cam 3 and push the tensioner rod 4 all the way in. D Install the tensioner with a new gasket 5 onto the cylinder. D Install the springs 2 and cap bolt 1 . D Tighten the bolt (with gasket) to the specified torque. 10 Nm (1.
CAMSHAFT AND ROCKER ARMS ENG CAMSHAFT AND ROCKER ARMS 14 Nm (1.4 m kg) 8 Nm (0.8 m kg) 14 Nm (1.4 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Camshaft and rocker arms removal Cylinder head Lock washer Plate Rocker arm shaft (intake) Rocker arm shaft (exhaust) Rocker arm Camshaft Locknut Adjuster O-ring Remarks Remove the parts in order. Refer to “CYLINDER HEAD” section. 1 1 1 1 2 1 2 2 1 Refer to “ROCKER ARM AND ROCKER SHAFT REMOVAL AND INSTALLATION” section.
CAMSHAFT AND ROCKER ARMS ENG YP****** ROCKER ARM AND ROCKER ARM SHAFT REMOVAL 1. Remove: Rocker arm shaft (intake) Rocker arm shaft (exhaust) NOTE: Attach a rocker arm shaft puller bolt 1 and weight 2 to the rocker arm shaft and slide out the shaft. Rocker arm shaft puller bolt: 90890-01085 Weight: 90890-01084 YP402052 CAMSHAFT INSPECTION 1. Inspect: Cam lobes Pitting/Scratches/Blue discoloration Replace. 2. Measure: Cam lobes length a and b . Out of specification Replace.
CAMSHAFT AND ROCKER ARMS ENG YP402060 ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 1. Inspect: S Cam lobe contact surface 1 S Adjuster surface 2 Wear/Pitting/Scratches/Blue discoloration Replace. ***************************************************** Inspection steps: D Inspect the two contact areas on the rocker arms for signs of unusual wear. D Rocker arm shaft hole. D Cam-lobe contact surface. Excessive wear Replace. D Inspect the surface condition of the rocker arm shafts.
CAMSHAFT AND ROCKER ARMS ENG 2. Install: Plate 1 Look washer 2 8 Nm (0.8 m kg) Bolt 3 NOTE: Bend the lock washer tabs along the bolt 3 flats. 3. Apply: Molybdenum disulfide oil (onto the rocker arm and rocker arm shaft) Molybdenum disulfide oil 4. Install: Rocker arm 1 Rocker arm shaft 2 (exhaust) NOTE: Exhaust: Install the rocker arm shaft (exhaust) completely pushed in. 5.
VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS Order Job name/Part name Q’ty Valves and valve springs removal Cylinder head Rocker arm, rocker arm shaft Remarks Remove the parts in order. Refer to “CYLINDER HEAD” section. Refer to “ROCKER ARM SHAFT AND ROCKER ARMS” section.
VALVES AND VALVE SPRINGS ENG YP401150 VALVES AND VALVE SPRINGS REMOVAL 1. Remove: Valve cotters 1 NOTE: Attach a valve spring compressor and attachment 2 between the valve spring retainer and cylinder head to remove the valve cotters. CAUTION: Do not compress so much as to avoid damage to the valve spring. Valve spring compressor: 90890-04019 Attachment: 90890-04108 YP****** VALVES AND VALVE SPRINGS INSPECTION 1. Measure: Valve stem diameter Out of specification Replace.
VALVES AND VALVE SPRINGS ENG YP402030 4. Measure: S Spring tilt Out of specification Replace. Spring tilt limit: 1.7 mm (2.5_) 5. Inspect: S Spring contact face Wear/Pitting/Scratches Replace. 6. Measure: S Valve guide inside diameter Out of specification Replace. Valve guide inside diameter: Intake: 6.000 6.012 mm Exhaust: 6.000 6.012 mm YP402010 7.
VALVES AND VALVE SPRINGS ENG 3. Measure: S Valve seat width a Out of specification Reface the valve seat. Valve seat width: Intake: 0.9 1.1 mm Exhaust: 0.9 1.1 mm ***************************************************** Measurement steps: D Apply Mechanic’s blueing dye (Dykem) 1 to the valve face. D Install the valve into the cylinder head. D Press the valve through the valve guide and onto the valve seat to make a clear pattern. D Measure the valve seat width.
VALVES AND VALVE SPRINGS ENG D Turn the valve until the valve face and valve seat are evenly polished, then clean off all compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hand. D Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: Make sure to clean off all compound from the valve face and valve seat after every lapping operation. D Apply Mechanic’s blueing dye (Dykem) b to the valve face.
VALVES AND VALVE SPRINGS ENG 4. Install: Valve cotters 1 NOTE: Install the valve cotters while compressing the valve spring with a valve spring compressor and attachment 2 . Valve spring compressor: 90890-04019 Attachment: 90890-04108 5. Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood. CAUTION: Do not hit so much as to damage the valve.
CYLINDER AND PISTON ENG CYLINDER AND PISTON Order Job name/Part name 1 2 3 4 Cylinder and piston removal Cylinder head Joint O-ring Timing chain guide (exhaust side) Cylinder 5 6 7 8 9 10 11 12 Dowel pin Cylinder gasket Piston pin circlip Piston pin Piston Piston ring (top) Piston ring (2nd) Side rail/Spacer Q’ty Remarks Remove the parts in order. Refer to “CYLINDER HEAD” section. 1 2 1 1 2 1 2 1 1 1 1 2/1 Refer to “PISTON RINGS, PISTON AND CYLINDER INSTALLATION” section.
CYLINDER AND PISTON ENG YP****** PISTON AND PISTON RINGS REMOVAL 1. Remove: S Piston pin circlip 1 S Piston pin 2 S Piston 3 NOTE: Before removing the piston pin circlip, cover the crankcase opening with a clean towel or rag to prevent the circlip from falling into the crankcase cavity. 2. Remove: S Top ring S 2nd ring S Oil ring NOTE: When removing the piston ring, open the end gap of the ring by fingers, and push up the other side of the ring. YP402100 CYLINDER INSPECTION 1.
CYLINDER AND PISTON ENG YP****** PISTON AND PISTON PIN INSPECTION 1. Measure: Piston skirt diameter Out of specification Replace. a 5.0 mm from the piston bottom edge Piston skirt diameter: 68.965 68.980 mm Oversize (2) 69.5 mm Oversize (4) 70.0 mm 2. Calculate: Piston-to-cylinder clearance Piston-to-cylinder clearance = Cylinder bore – Piston skirt diameter Refer to “CYLINDER” section for cylinder bore measurement. Out of specification Replace the piston and piston rings as a set.
CYLINDER AND PISTON ENG YP402111 PISTON RINGS INSPECTION 1. Measure: Side clearance Out of specification Replace the piston and the piston rings as a set. NOTE: Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance. Side clearance (piston ring): Top ring: 0.04 0.08 mm 2nd ring: 0.03 0.07 mm 2.
CYLINDER AND PISTON ENG EB404184 PISTON RINGS, PISTON AND CYLINDER INSTALLATION 1. Install: S Top ring 1 S 2nd ring 2 S Side rails (oil ring) 3 S Expander spacer (oil ring) 4 NOTE: D Make sure to install the piston rings so that the manufactuer’s marks or numbers are located on the upper side of the rings. D Lubricate pistons and piston rings liberally with engine oil. 2. Install: S Piston 1 S Piston pin 2 S Piston pin clip 3 NOTE: D Apply engine oil onto the piston pins.
CYLINDER AND PISTON ENG 4. Position: S Piston rings NOTE: Offset the piston ring end gaps as shown. a b c d Top ring end Oil ring end (lower) Oil ring end (upper) 2nd ring end 5. Lubricate: S Piston outer surface S Piston ring S Cylinder inner surface Engine oil 6. Install: S Cylinder NOTE: D Install the cylinder with one hand while compressing the piston rings with the other hand. D Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE CRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT) 7 Nm (0.7 m kg) 10 Nm (1.0 m kg) 7 Nm (0.7 m kg) Order Job name/Part name Q’ty Crankcase filter cover and crankcase cover (left)removal Side panel 1 2 3 4 5 6 Remarks Remove the parts in order. Refer to “COVER AND PANEL” section in CHAPTER 3.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE *Shell BT grease No. 3 (90890-69927) 60 Nm (6.0 m kg) 3 Nm (0.3 m kg) 60 Nm (6.0 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name V-belt, clutch and secondary/ primary sheave removal Nut/Plain washer Primary fixed sheave Nut Clutch housing Clutch assembly V-belt Primary sliding sheave Collar Primary sheave cap Q’ty Remarks Remove the parts in order.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG *Shell BT grease No. 3 (90890-69927) 60 Nm (6.0 m kg) 3 Nm (0.3 m kg) 60 Nm (6.0 m kg) Order 10 11 12 13 14 Job name/Part name Q’ty Cam Weight Slider Spacer Oil seal 1 8 4 4 1 Remarks Refer to “PRIMARY SHEAVE ASSEMBLY” section. Reverse the removal procedure for installation.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG SECONDARY SHEAVE **Apply BEL-RAY assembly lube 90 Nm (9.0 m kg) Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Q’ty Secondary sheave disassembly Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave Remarks Disassemble the parts in order. 1 1 3 1 1 4 1 2 2 1 Refer to “SECONDARY SHEAVE DISASSEMBLY” section. Refer to “SECONDARY SHEAVE INSTALLATION” section.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG YP****** PRIMARY SHEAVE REMOVAL 1. Remove: Nut 1 (primary sheave) Plate washer Primary fixed sheave 2 NOTE: Loosen the nut (primary fixed sheave) while holding the primary fixed sheave with the rotor holder 3 . Rotor holder: 90890-01235 YP****** SECONDARY SHEAVE AND V-BELT REMOVAL 1. Remove: Nut 1 (secondary sheave) Clutch housing 2 NOTE: Loosen the nut (secondary sheave) while holding the clutch housing with the sheave holder 3.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG 3. Remove: S Clutch assembly 1 S V-belt 2 NOTE: Remove the V-belt from the primary sheave side with clutch assembly. YP****** SECONDARY SHEAVE DISASSEMBLY 1. Remove: S Nut 1 (secondary sheave) NOTE: Loosen the nut 1 while attaching the clutch spring compressor 2 and clutch spring holder arm 3 and release the compressed spring after removing the nut. CAUTION: Use the spacer 4 (ø 30 mm, thickness: 3 mm).
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG YP****** V-BELT INSPECTION 1. Inspect: V-belt 1 Cracks/Wear/Scaling/Chipping Replace. Oil/Grease Check primary sheave and secondary sheave. 2. Measure: V-belt width 2 Out of specification Replace V-belt width: 22.6 mm YP****** WEIGHT INSPECTION 1. Inspect: Weight minimum outside diameter Cracks/Wear/Scaling/Chipping Replace. Out of specification Replace. Weight out side diameter: 20.0 mm
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG YP****** PRIMARY SHEAVE ASSEMBLY 1. Clean: S Primary sliding sheave face 1 S Primary fixed sheave face 2 S Collar 3 S Weight 4 S Primary sliding sheave cam face 5 NOTE: Remove any excess grease. 2. Install: S Weight 1 S Collar 2 NOTE: D Apply Shell BT grease No. 3 (90890-69927) to the all of the outside of the weight and install. D Apply Shell BT grease No. 3 (90890-69927) to the inside of the collar. 3.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG 3. Install: Guide pin 1 4. Apply: BEL-RAY assembly lube (to the guide pin sliding groove 1 , and ) and oil seal 2 5. Install: Secondary sheave complete 1 Compression spring Clutch carrier 2 NOTE: Temporarily tighten the nut 5 while attaching the clutch spring holder 3 and clutch spring holder arm 4 and compress the spring. CAUTION: Use the spacer 6 (ø 30 mm, thickness: 3 mm).
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ENG 7. Install: Nut 1 (clutch carrier) 90 Nm (9.0 m kg) NOTE: Tighten the nut (clutch carrier), using the locknut wrench 3 while holding the clutch carrier with the rotor holder 2 . Rotor holder: 90890-01235 Locknut wrench: 90890-01348 8. Install: Clutch housing 1 Nut 2 (clutch housing) NOTE: Tighten the nut (clutch housing), using the sheave holder 3 . Sheave holder: 90890-01701 9.
A.C. MAGNETO AND STARTER CLUTCH ENG A.C. MAGNETO AND STARTER CLUTCH MAGNETO COVER AND STARTOR COIL 7 Nm (0.7 m kg) 20 Nm (2.0 m kg) 7 Nm (0.7 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in order. Magneto cover and startor coil removal Drain the engine oil. Side panels 1 2 3 4 5 6 7 8 Remarks 2 1 1 2 1 2 1 1 Couplers (A.C.
A.C. MAGNETO AND STARTER CLUTCH ENG A.C. MAGNETO AND STARTER CLUTCH 10 Nm (1.0 m kg) Order Job name/Part name Q’ty 1 A.C. magneto and starter clutch removal Rotor 1 2 3 4 5 6 Shaft (idle gear) Idler gear Starter one way clutch assembly Woodruff key Starter wheel gear 1 1 1 1 1 80 Nm (8.0 m kg) Remarks Remove the parts in order. 4-38 Refer to “A.C. MAGNETO ROTOR REMOVAL/INSTALLATION” section. Refer to “ROTOR INSTALLATION” section. Reverse the removal procedure for installation.
A.C. MAGNETO AND STARTER CLUTCH ENG YP401081 A.C. MAGNETO ROTOR REMOVAL 1. Remove: S Nut 1 (rotor) S Plain washer 2 NOTE: D Loosen the nut (rotor) 1 while holding the rotor with a sheave holder 3 . D Do not allow the sheave holder to touch the projection on the rotor. Sheave holder: 90890-01701 2. Remove: S Rotor 1 S Woodruff key NOTE: D Remove the rotor 2 using the flywheel puller. D Center the flywheel puller over the rotor.
A.C. MAGNETO AND STARTER CLUTCH ENG YP402163 STARTER DRIVE GEAR INSPECTION 1. Inspect: S Starter idle gear teeth S Starter drive gear teeth S Starter wheel gear teeth Burrs/chips/roughness/wear Replace. 2. Check: S Starter clutch operation Push the dowel pins to the arrow direction. Unsmooth operation Replace. ***************************************************** Checking steps: D Hold the starter clutch.
ENG A.C. MAGNETO AND STARTER CLUTCH 3. Tighten: Nut (rotor) 1 80 Nm (8.0 m kg) NOTE: Tighten the nut (rotor) 1 while holding the magneto rotor 2 with a sheave holder 3 .
OIL PUMP ENG OIL PUMP 7 Nm (0.7 m kg) 12 Nm (1.2 m kg) Order Job name/Part name Q’ty Oil pump removal A.C. magneto 1 2 3 4 5 6 7 8 Remarks Remove the parts in order. Refer to the “A.C. MAGNETO AND STARTER CLUTCH” section. Cover Pump driven gear Dowel pin Oil pump assembly Gasket Impeller shaft gear Dowel pin Shaft 1 1 1 1 1 1 1 1 Reverse the removal procedure for installation.
OIL PUMP ENG EB402140 OIL PUMP INSPECTION 1. Inspect: Drive gear (oil pump) Driven gear (oil pump) 1 Pump housing Pump housing cover Wear/cracks/damage Replace 2. Measure: Tip clearance A (between the inner rotor 1 and the outer rotor 2 ) Side clearance B (between the outer rotor 2 and the pump housing 3 ) Out of specification Replace the oil pump assembly. Housing and rotor clearance C (between the pump housing 3 and the rotors 1 2 ) Out of specification Replace the oil pump assembly.
TRANSMISSION ENG TRANSMISSION 16 Nm (1.6 m kg) Order Job name/Part name Q’ty Transmission removal Rear wheel Remove the parts in order. Refer to “REAR WHEEL/REAR BRAKE” section in CHAPTER 7. Refer to “V-BELT, CLUTCH, SECONDARY/PRIMARY SHEAVE” section. Crankcase cover (left) Drain the transmission oil. 1 2 3 4 5 6 7 Remarks Refer to “TRANSMISSION OIL REPLACEMENT” section in CHAPTER 3.
TRANSMISSION ENG 16 Nm (1.6 m kg) Order 8 9 10 11 Job name/Part name Q’ty Drive axle Main axle Primary driven gear Plain washer Remarks 1 1 1 1 Reverse the removal procedure for installation.
CRANKCASE AND CRANKSHAFT ENG CRANKCASE AND CRANKSHAFT 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order. Crankcase and crankshaft removal Engine removal Cylinder head Cylinder, piston Refer to “ENGINE REMOVAL” section. Refer to “CYLINDER HEAD” section. Refer to “CYLINDER AND PISTON” section. Refer to “V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE” section. Refer to “A.C. MAGNETO AND STARTER CLUTCH” section. Refer to “OIL PUMP” section.
CRANKCASE AND CRANKSHAFT ENG 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty 3 4 Timing chain guide (intake) Crankcase (right) 1 1 5 6 7 8 9 Dowel pin Crankshaft assembly Timing chain Crankcase (left) Oil seal 2 1 1 1 1 Remarks Refer to “CRANKSHAFT INSTALLATION” section. Refer to “CRANKSHAFT REMOVAL/ INSTALLATION” section. Reverse the removal procedure for installation.
CRANKCASE AND CRANKSHAFT ENG YP****** CRANKSHAFT REMOVAL 1. Remove: Crankshaft assembly Timing chain 1 NOTE: Before removing the crankshaft assembly, remove the timing chain from the crank shaft sprocket. If the timing chain hooks to the crankshaft sprocket, the crankshaft cannot be removed. YP****** CRANKSHAFT INSPECTION 1. Measure: Crankshaft runout Out of specification Replace crankshaft and/or bearing. NOTE: Measure the crankshaft runout with the crankshaft assembly turning slowly.
CRANKCASE AND CRANKSHAFT ENG 4. Inspect: Crankshaft sprocket 1 Wear/Damage Replace crankshaft. Bearing 2 Wear/Crack/Damage Replace crankshaft. Pump drive gear 3 Wear/Damage Replace crankshaft. 5. Inspect: Crankshaft journal Clogged Blow out the journal with compressed air. YP404073 CRANKCASE INSTALLATION 1. Clean all the gasket mating surface and crankcase mating surface thoroughly. 2. Apply: Sealant (onto the crankcase mating surfaces) Yamaha bond No.
ENG
CHAPTER 5. COOLING SYSTEM RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP INSTALLATION . . . . . . . . . . . . . . .
RADIATOR COOL YP500000 COOLING SYSTEM RADIATOR 23 Nm (2.3 m kg) Order Job name/Part name Q’ty Radiator removal Drain the coolant. 1 2 3 4 5 6 Remarks Remove the parts in order. Refer to “COOLANT REPLACEMENT” section in CHAPTER 3. Fuel tank Footrest board, under cover Cowling body, leg shield Fan motor leads Thermo switch leads Filler hose (radiator) Outlet hose (radiator) Inlet hose (radiator) Radiator Refer to “COVER AND PANEL” section in CHAPTER 3.
RADIATOR COOL YP500030 INSPECTION 1. Inspect: D Radiator 1 Obstruction Blow out with compressed air through the rear of the radiator. Flattened fins Repair or replace. If flattened over the 20 % of radiator fin, repair or replace the radiator. CAUTION: Use only specified adhesive to repair the radiator. 2. Inspect: D Radiator hoses D Radiator pipes Cracks/damage Replace. 3. Measure: D Radiator cap opening pressure D Radiator cap opens at a pressure below the specified pressure Replace.
WATER PUMP COOL WATER PUMP Oil pump side 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Water pump removal Drain the coolant. Remarks Remove the parts in order. Refer to “COOLANT REPLACEMENT” section in CHAPTER 3. Refer to “A.C. MAGNETO AND STARTER CLUTCH” section in CHAPTER 4. A.C.
WATER PUMP COOL Oil pump side 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order 9 10 11 Job name/Part name Q’ty Impeller shaft O-ring O-ring 1 1 1 Remarks Refer to “WATER PUMP INSTALLATION” section. Reverse the removal procedure for installation.
WATER PUMP COOL YP****** NOTE: D It is not necessary to disassemble the water pump, unless there is no abnormality such as excessive change in coolant temperature and/or level, discoloration of coolant, or milky transmission oil. D If necessary, replace water pump as an assembly. YP****** INSPECTION 1. Inspect: D Impeller shaft Wear/damage Replace. Fur deposits Clean. 2. Inspect: D Impeller shaft gear Wear/damage Replace. 3. Inspect: D Mechanical seal 1 Damage/worn/wear Replace.
WATER PUMP COOL 2. Install: D Mechanical seal 1 Apply coolant to the outside of the mechanical seal before installing. NOTE: Do not smear any oils grease on to the ring side of the mechanical seal. 3. Inspect: D Mechanical seal, slip ring side 1 Inspect the slip ring side of the mechanical seal and the impeller 2 for level installation. Incorrect level Reinstall. 4.
THERMOSTAT COOL THERMOSTAT 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Thermostat removal Drain the coolant 1 2 3 4 5 6 Remarks Remove the parts in order. Refer to “COOLANT REPLACEMENT” section in CHAPTER 3. Refer to “COVER AND PANEL” section in CHAPTER 3. Side panel Fuel tank Clip Outlet hose (carburetor) Hose clamp Outlet hose (thermostat) Thermostatic cover Thermostatic valve 1 1 1 1 1 1 5-7 Refer to “THERMOSTAT INSTALLATION” section. Reverse the removal procedure for installation.
THERMOSTAT COOL EB502010 INSPECTION 1. Inspect: D Thermostatic valve Valve does not open at 80.5 83.5_C Replace. ***************************************************** Inspection steps: D Suspend the thermostatic valve in a vessel. D Place a reliable thermometer in water. D Observe the thermometer, while continually stirring the water.
CHAPTER 6. CARBURETION CARBURETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUTO CHOKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR CARB EB600000 CARBURETION CARBURETOR 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Carburetor removal Side panel Fuel tank Drain the coolant 1 2 3 4 5 Auto choke lead coupler Inlet/Outlet hose (carburetor) Fuel hose Throttle cable Air filter joint 6 7 Nut Carburetor ass’y Remarks Remove the parts in order. Refer to “COVER AND PANEL” section in CHAPTER 3. Refer to “COOLANT REPLACEMENT” section in CHAPTER 3.
CARBURETOR CARB CARBURETOR DISASSEMBLY Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Q’ty Carburetor disassembly Auto choke unit Throttle stop screw set Pilot screw set Cover/Diaphragm spring Piston valve Jet needle ass’y Coasting enricher Accererating pump Float chamber Float pin Remarks Disassemble the parts in order. 1 1 1 1/1 1 1 1 1 1 1 6-2 Refer to “CARBURETOR ASSEMBLY” section. Refer to “CARBURETOR ASSEMBLY” section.
CARBURETOR Order 11 12 13 14 15 Job name/Part name CARB Q’ty Remarks 1 1 1 1 1 Refer to “CARBURETOR ASSEMBLY” section. Float Needle valve Main jet Pilot jet Main nozzle Reverse the disassembly procedure for assembly.
CARBURETOR CARB YP600041 ASSEMBLY Reverse the “DISASSEMBLY” procedure. Note the following points. CAUTION: D Before assembling, wash all parts in clean petroleum based solvent. D Always use a new gasket. 1. Install: D Main nozzle 1 D Main jet 2 D Pilot jet 3 2. Install: D Valve seat 1 D Float 2 D Needle valve 3 D Float pin 4 3. Inspect: D Float height a ***************************************************** Inspection and adjustment steps: D Hold the carburetor in an upside down position.
CARBURETOR CARB Float height (F.H.): 27 mm Out of specification Replace. ***************************************************** 5. Install: D Diaphragm 1 NOTE: Align the tab a on the diaphragm with the slot b on the carburetor body. 6. Install: D Compression spring 1 D Cover 2 YP600060 FUEL LEVEL ADJUSTMENT Gasoline (fuel) and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition. 1.
CARBURETOR CARB D Put a garage jack under the engine to ensure that the carburetors are positioned vertically. D Connect the fuel level gauge 1 to the drain pipe 2 . Fuel level gauge: 90890-01312 D Loosen the drain screw 3 . D Hold the gauge vertically next to the float chamber line. D Measure the fuel level a with the gauge. D If the fuel level is incorrect, adjust the fuel level. D Remove the carburetor. D Inspect the valve seat and needle valve. D If either is worn, replace them both.
CARBURETOR CARB YP****** FUEL PUMP INSPECTION 1. Remove: D Side panels Refer to “COVER AND PANEL” section in CHAPTER 3. 2. Inspect: D Fuel pump ***************************************************** Inspection steps: D Place the receptacle under the fuel pipe end. D Start engine, and inspect gasoline to flow out from fuel pipe 1 . Engine is running: Gasoline flows out Good. Engine is stopping: Gasoline does not flow out Good.
CARB
CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL AND BRAKE DISC CHAS CHASSIS FRONT WHEEL AND BRAKE DISC FRONT WHEEL AND BRAKE DISC 70 Nm (7.0 m kg) 23 Nm (2.3 m kg) Order Job name/Part name Q’ty Front wheel and brake disc removal Remarks Remove the parts in order. Securely support the scooter so there is no danger of it falling over. 1 2 3 4 5 6 7 Speedometer cable Axle nut Wheel axle Front wheel assembly Gear unit assembly Collar Brake disc 1 1 1 1 1 1 1 7-1 Refer to “FRONT WHEEL INSTALLATION” section.
FRONT WHEEL AND BRAKE DISC CHAS FRONT WHEEL DISASSEMBLY Order 1 2 3 4 Job name/Part name Q’ty Front wheel disassembly Oil seal Bearing Spacer Bearing 1 1 1 1 Remarks Remove the parts in order. Refer to “FRONT WHEEL DISASSEMBLY /ASSEMBLY” section. Reverse the removal procedure for installation.
FRONT WHEEL AND BRAKE DISC CHAS YP****** FRONT WHEEL DISASSEMBLY 1. Remove: Bearing 1 Spacer Remove the bearing using a general bearing puller 2 . CAUTION: Handle the wheel with care not to damage the brake disc. If the brake disc is damaged, replace. YP700020 FRONT WHEEL INSPECTION 1. Inspect: Front wheel axle (by rolling it on a flat surface) Bends Replace. Do not attempt to straighten a bent axle. Wheel axle bending limit: 0.25 mm 2.
FRONT WHEEL AND BRAKE DISC CHAS 5. Inspect: S Collar Grooved wear Replace the collar and the oil seal as a set. YP****** BRAKE DISC INSPECTION 1. Measure: S Brake disc deflection Maximum deflection: 0.15 mm Out of specification Replace. 2. Measure: S Brake disc thickness Brake disc thickness: 4.0 mm Minimum thickness: 3.5 mm Out of specification Replace. YP****** FRONT WHEEL ASSEMBLY 1.
FRONT WHEEL AND BRAKE DISC 2. Install: Brake disc 1 CHAS 23 Nm (2.3 m kg) NOTE: Tighten the bolts (brake disc) in stage using a crisscross pattern. EB700030 FRONT WHEEL INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1. Lubricate: Front wheel axle Bearings Oil seal (lips) Drive/driven gear (speedometer) Recommended lubricant: Lithium soap base grease 2.
FRONT WHEEL AND BRAKE DISC CHAS YP700040 WHEEL STATIC BALANCE ADJUSTMENT NOTE: D After replacing the tire and/or rim, the wheel static balance should be adjusted. D Adjust the front wheel static balance with the brake disc installed. 1. Remove: S Balancing weight 2. Set: S Wheel (on a suitable stand) 3. Find: S Heavy spot ***************************************************** Procedure: a. Spin the wheel and wait for it to rest. b. Put an “X1” mark on the wheel’s bottom spot. c.
FRONT WHEEL AND BRAKE DISC CHAS 5. Check: S Wheel static balance ***************************************************** Checking steps: D Turn the wheel so that it comes to each point as shown. D Check that the wheel is at rest at each point. If not, readjust the front wheel static balance.
REAR WHEEL AND REAR BRAKE CHAS REAR WHEEL AND REAR BRAKE 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Rear wheel and rear brake removal Swingarm 1 2 3 4 5 6 7 8 9 10 11 Remarks Remove the part in order. Refer to “REAR SHOCK ABSORBER AND SWINGARM” section. Adjuster Brake cable Compression spring Pin Rear wheel assembly Brake lining Tension spring Plate washer Camshaft lever Indicator plate Camshaft 1 1 1 1 1 2 2 1 1 1 1 7-8 Refer to “REAR BRAKE INSTALLATION” section.
REAR WHEEL AND REAR BRAKE CHAS 10 Nm (1.0 m kg) Order 12 13 Job name/Part name Q’ty Camshaft shim Camshaft seal Remarks 1 1 Reverse the removal procedure for installation.
REAR WHEEL AND REAR BRAKE CHAS EB701020 REAR WHEEL INSPECTION 1. Inspect: Rear wheel axle Rear wheel Rear wheel bearings Oil seals Refer to “FRONT WHEEL”. 2. Measure: Rear wheel runout Refer to “FRONT WHEEL”. EB701021 REAR BRAKE INSPECTION 1. Inspect: Brake lining surface Glazed areas Polish. Use coarse sand paper. NOTE: After polishing, wipe the polished particles with a cloth. 2.
REAR WHEEL AND REAR BRAKE CHAS 4. Inspect: S Brake drum inner surface S Oil/scratches Repair. S Oil Use a rag soaked in lacquer thinner or solvent. S Scratches Use an emery cloth (lightly and evenly polishing) 5. Inspect: S Camshaft face. Wear Replace. When inspecting the brake lining, do not spill oil or grease on the brake lining. YP****** REAR BRAKE INSTALLATION 1.
FRONT BRAKE CHAS FRONT BRAKE BRAKE PAD 23 Nm (2.3 m kg) Order 1 2 3 Job name/Part name Q’ty Brake pad removal Caliper support bolt Brake pad Pad support Remarks Remove the parts in order. 1 2 1 Refer to “BRAKE PAD REPLACEMENT” section. Reverse the removal procedure for installation.
FRONT BRAKE CHAS YP702010 BRAKE PAD REPLACEMENT NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Remove: S Bolt (caliper support bolt) 1 Move the direction brake caliper to the arrow mark. 2. Remove: S Brake pads NOTE: D Install new brake pad springs when the brake pads have to be replaced. D Replace the brake pads as a set if either is found to be worn to the wear limit. 3. Push the caliper piston into the brake caliper by finger.
FRONT BRAKE CHAS MASTER CYLINDER 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 26 Nm (2.6 m kg) Order Job name/Part name Q’ty Master cylinder removal Drain the brake fluid 1 2 3 4 5 6 7 8 Rear view mirror (right) Brake lever/compression spring Brake switch Union bolt Plain washer Brake hose Master cylinder bracket Master cylinder Remarks Remove the parts in order. Refer to “BRAKE FLUID REPLACEMENT” section in CHAPTER 3. 1 1/1 1 1 2 1 1 1 Refer to “MASTER CYLINDER INSTALLATION” section.
FRONT BRAKE CHAS MASTER CYLINDER DISASSEMBLY Order 1 2 3 4 Job name/Part name Q’ty Master cylinder disassembly Master cylinder boot Circlip Master cylinder assembly Spring Remarks Remove the parts in order. 1 1 1 1 Refer to “MASTER CYLINDER ASSEMBLY” section. Reverse the disassembly procedure for assembly.
FRONT BRAKE CHAS YP702040 MASTER CYLINDER INSPECTION 1. Inspect: S Master cylinder 1 Wear/scratches Replace the master cylinder assembly. S Master cylinder cup 2 S Cracks/damage Replace. 2. Inspect: S Master cylinder S Scratches/wear/damage Replace the master cylinder assembly. 3. Inspect: S Diaphragm Wear/damage Replace. YP****** MASTER CYLINDER ASSEMBLY D All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
FRONT BRAKE CHAS 2. Install: Spring 1 Install the spring with its smaller diameter to the master cylinder piston. Master cylinder kit 2 3. Install: Circlip 1 Install the circlip securely into the master cylinder groove. Master cylinder boot 2 YP****** MASTER CYLINDER INSTALLATION 1. Install: Master cylinder 1 Master cylinder bracket 2 10 Nm (1.
FRONT BRAKE CHAS 3. Air bleed: S Brake system Refer to “AIR BLEEDING” section in CHAPTER 3. D Use only designated quality brake fluid: Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. D Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor performance. D Be careful that water does not enter the significantly lower the boiling point of the fluid may result in vapor lock. 4.
FRONT BRAKE CHAS CALIPER 26 Nm (2.6 m kg) 23 Nm (2.3 m kg) Order 1 2 3 4 5 6 Job name/Part name Q’ty Caliper removal Drain the brake fluid Brake hose holder Union bolt Plain washer Brake hose Caliper support bolt Caliper assembly 1 1 2 1 1 1 Remarks Remove the parts in order. Refer to “BRAKE FLUID REPLACEMENT” section in CHAPTER 3. Refer to “CALIPER INSTALLATION” section. Reverse the removal procedure for installation.
FRONT BRAKE CHAS CALIPER DISASSEMBLY 6 Nm (0.6 m kg) Order 1 2 3 4 5 6 Job name/Part name Caliper disassembly Brake pad Pad support Caliper piston Dust seal Piston seal Bleed screw/Cap Q’ty Remarks Remove the parts in order. 2 1 2 2 2 1/1 Refer to “BRAKE CALIPER DISASSEMBLY /ASSEMBLY” section. Reverse the disassembly procedure for assembly.
FRONT BRAKE CHAS YP702020 BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling either brake caliper, drain the brake fluid from the brake hose, master cylinder, brake caliper and reservoir tank. 1. Remove: S Brake caliper piston ***************************************************** Removal steps: S Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. D Never try to pry out the caliper piston. D Cover the caliper piston with a rag.
FRONT BRAKE CHAS EB702050 BRAKE CALIPER ASSEMBLY D All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid: DOT #4 D Replace the caliper piston seals whenever a brake caliper is disassembled. 1. Install: S Piston seals 1 S Dust seal 2 2. Install: S Caliper piston 1 Apply brake fluid to the outer surface and install. CAUTION: D Do not force. D Use care to prevent damage on caliper piston. YP****** CALIPER INSTALLATION 1.
FRONT FORK CHAS FRONT FORK FRONT FORK 45 Nm (4.5 m kg) 23 Nm (2.3 m kg) 23 Nm (2.3 m kg) 49 Nm (4.9 m kg) Order 1 2 3 4 5 6 7 Job name/Part name Front fork removal Front wheel Caliper assembly Front fender Inner fender Bolt (under bracket upper) Cap bolt/O-ring Bolt (under bracket lower) Front fork (left/right) Q’ty Remarks Remove the parts in order. Refer to “FRONT WHEEL” section. 1 1 1 2 2/2 2 1/1 Refer to “FRONT FORK REMOVAL/ INSTALLATION” section.
FRONT FORK CHAS FRONT FORK DISASSEMBLY 45 Nm (4.5 m kg) 23 Nm (2.3 m kg) Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Q’ty Front fork disassembly Cap bolt 1 O-ring Fork spring Dust seal Retaining clip Oil seal Bolt (Damper rod)/Gasket Inner tube Oil lock piece Damper rod Rebound spring 1 1 1 1 1 1/1 1 1 1 1 Remarks Remove the parts in order. Refer to “FRONT FORK REMOVAL/ INSTALLATION” section. Refer to “FRONT FORK ASSEMBLY” section. Refer to “FRONT FORK DISASSEMBLY/ASSEMBLY” section.
FRONT FORK CHAS YP****** FRONT FORK REMOVAL D Securely support the scooter so there is no danger of it falling over. D Stand the scooter on a level surface. D Stand the scooter on its centerstand. 1. Loosen: S Bolt (lower bracket upper) 1 NOTE: Loosen only the upper bolt. 2. Remove: S Cap bolt 1 NOTE: Use 17 mm width hexagonal wrench for removing. 3. Loosen the bolt (under bracket lower) to remove the front forks. Support the front fork before loosening the pinch bolts.
FRONT FORK CHAS 2. Remove: Inner tube Oil lock pice 3. Remove: Oil seal 1 CAUTION: Never reuse the oil seal. 2 Rag YP703030 FRONT FORK INSPECTION 1. Inspect: Inner tube bending Inner tube bending limit: 0.2 mm Scratches/bends/damage Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. 2. Measure: Fork spring a Front fork spring free length: 268.5 mm 263.5 mm Over the specified limit Replace.
FRONT FORK CHAS 2. Install: S Inner tube 1 Into outer tube 2 . 3. Install: S Plain washer 1 S Bolt (damper rod) 2 4. Tighten: S Bolt (damper rod) 1 23 Nm (2.3 mSkg) NOTE: Tighten damper rod bolt 1 while holding the damper rod with a T-handle 2 and a damper rod holder 3 . Damper rod holder: 90890-04084 T-handle 90890-01326 6. Install: S Oil seal 1 S Retaining clip S Dust seal Use the fork seal driver weight 3 and the attachment 2 .
FRONT FORK CHAS 7. Inspect: S Inner tube operation Unsmooth operation Disassembly and recheck. 8. Fill: S Fork oil Oil quantity: 0.142 L Recommended oil: Fork oil 15 WT or equivalent 9. After filling up, slowly pump the fork up and down to distribute the fork oil. 10. Measure: S Oil level a Out of specification Adjust. Oil level: 80 mm (from the top of the inner tube fully compressed and without the fork spring) NOTE: Hold the fork in an upright position. 11.
FRONT FORK CHAS EB703050 FRONT FORK INSTALLATION Reverse the “REMOVAL“ procedure. Note the following points. 1. Install: Front fork 1 Temporary tighten the pinch bolts. NOTE: Pull up the inner tube until its end flushes the top of the under bracket 2 , then temporarily tighten the bolt (under bracket lower) 3 . 2. Tighten: 45 Nm (4.5 m kg) Cap bolts 1 Pinch bolts (under bracket upper/lower) 23 Nm (2.
HANDLEBAR CHAS HANDLEBAR 23 Nm (2.3 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Handlebar removal Handlebar upper cover 1 2 3 4 5 6 7 8 9 10 Rear view mirror (right) Rear view mirror (left) Master cylinder bracket Master cylinder Grip end (right) Handlebar switch (right) Throttle cable Grip assembly Brake cable Lever holder (left) 1 1 1 1 1 1 2 1 1 1 Remarks Remove the parts in order. Refer to ”COVER AND PANEL” section in CHAPTER 3. Left-thread screw.
HANDLEBAR CHAS 23 Nm (2.3 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty 11 12 13 Handlebar switch (left) Grip end (left) Grip 1 1 1 14 15 Upper handlebar holder Handlebar 2 1 7-31 Remarks Refer to “HANDLEBAR INSTALLATION” section. Refer to “HANDLEBAR REMOVAL” section. Refer to “HANDLEBAR INSTALLATION” section. Reverse the removal procedure for installation.
HANDLEBAR CHAS YP****** HANDLEBAR REMOVAL 1. Remove: S Grip (Left) ***************************************************** Removal steps: D Remove the grip end (left). D Blow with compressed air between the handlebar and adhesive side of the grip to remove. ***************************************************** YP704020 HANDLEBAR INSPECTION 1. Inspect: S Handlebar Bends/Cracks/Damage Replace. Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.
HANDLEBAR CHAS 4. Install: S Handlebar switch (left) 1 NOTE: Align the handlebar switch mating surface with the punched mark a on the handlebar. 5. Install: S Lever holder (left) 1 NOTE: Align the lever holder mating surface with the punched mark a on the handlebar. 6. Install: S Throttle cable 1 S Grip assembly 2 NOTE: Apply a light coat of lithium soap base grease onto the inside of the grip assembly and install it to the handlebar. 7.
STEERING CHAS STEERING 139 Nm (13.9 m kg) 1st step: 38 Nm (3.8 m kg) 2nd step: Loosen the ring nut 1 / 4 turn. 3rd step: 22 Nm (2.2 m kg) 75 Nm (7.5 m kg) Order Job name/Part name Q’ty Steering removal Handlebar upper cover 1 2 3 4 5 6 7 8 9 10 11 Remarks Remove the parts in order. Refer to “FRONT WHEEL, BRAKE DISC” section. Refer to “FRONT FORK” section. Refer to “HANDLEBAR” section.
STEERING CHAS 139 Nm (13.9 m kg) 1st step: 38 Nm (3.8 m kg) 2nd step: Loosen the ring nut 1 / 4 turn. 3rd step: 22 Nm (2.2 m kg) 75 Nm (7.5 m kg) Order 12 13 14 15 Job name/Part name Q’ty Ball bearing Ball bearing Ball race 1 Ball race 2 22 19 1 1 Remarks Refer to “STEERING INSTALLATION” section. Reverse the removal procedure for installation.
STEERING CHAS YP704010 STEERING REMOVAL D Securely support the scooter so that there is no danger of it falling over. D Stand the scooter on a level surface. 1. Remove: S Handlebar lower holder 1 S Woodruff key 2 NOTE: Remove the handlebar lower holder by loosening the ring nut (upper) 3 gradually. 2. Remove: S Ring nut (upper) S Lock washer 1 S Ring nut (center) 2 S Rubber washer 3.
STEERING CHAS ***************************************************** Bearing race replacement steps: D Remove the bearing races on the head pipe using long rod 1 and the hammer as shown. D Remove the bearing race on the under bracket using the floor chisel 2 and the hammer as shown. D Install the new dust seal and races. ***************************************************** NOTE: D Always replace bearings and races as a set. D Replace the dust seal whenever a steering head disassembled.
REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM 40 Nm (4.0 m kg) 19 Nm (1.9 m kg) 7 Nm (0.7 m kg) 135 Nm (13.5 m kg) 20 Nm (2.0 m kg) 23 Nm (2.3 m kg) 20 Nm (2.0 m kg) 53 Nm (5.3 m kg) Order Job name/Part name Q’ty Rear shock absorber and swingarm removal Side panels Remarks Remove the parts in order.
CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH CONNECTION AS SHOWN IN THIS MANUAL . . . . . . . . . SWITCH POSITION AND TERMINAL CONNECTION . . . .
ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 Main switch Ignition coil Spark plug cap Fuel sender Rectifier/ Regulator Starting circuit cut-off relay Wireharness 8 Thermo unit 9 Ignitor unit 10 Sidestand switch 11 Battery 12 Starter relay 13 Flasher relay 14 Horn 8-1 ELEC
CIRCUIT DIAGRAM CIRCUIT DIAGRAM 8-2 ELEC
ELEC CIRCUIT DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A.C.
CHECKING SWITCHES ELEC YP-N CHECKING SWITCHES CHECKING STEPS Using pocket tester, check switches for continuity between their terminals to determine whether they are correctly connected. Repalce the switch component if any of the combinations does not produce the correct reading. Pocket tester: 90890-03112 NOTE: Turn the switch to the “ON”, “OFF” positions several times. Adjust the pocket tester to correct “0” position before checking switches. Set the pocket tester selector to “ 1” Ω.
CHECKING SWITCHES ELEC YP****** SWITCH POSITION AND TERMINAL CONNECTION Before checking a switch refer to the checking switches as shown in the left page and check for the correct terminal connections (closed circuit) according to the color combinations shown in the chart. Poor connection, fault Repair or replace. * 8-5 Indicates coupler positions.
IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse 10 Ignitor unit 11 Ignition coil 12 Spark plug 13 Pickup coil 14 Sidestand switch 18 Engine stop switch 8-6 ELEC
IGNITION SYSTEM ELEC YP802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE. (NO SPARK OR INTERMITTENT SPARK) Procedure Check: 1. Fuse (Main) 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil 7. 8. 9. 10. 11. Pickup coil resistance Main switch Engine stop switch Sidestand switch Wiring connection (entire ignition system) NOTE: S Remove the following parts before troubleshooting.
IGNITION SYSTEM ELEC : YP****** 4. Ignition spark gap S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker 1 as shown. 2 Spark plug S Turn the main switch to “ON”. S Check the ignition spark gap .a S Check the spark by pushing the starter switch, and increase the spark gap until a misfire occurs. MEETS SPECIFICATION Minimum spark gap: 6 mm (0.24 in) The ignition system is not faulty.
IGNITION SYSTEM ELEC : YP****** Tester (+) lead Red/White Terminal 1 Tester (–) lead Orange Terminal 2 6. Ignition coil resistance S Disconnect the ignition coil connector from the wireharness. S Connect the pocket tester (Ω 1) to the ignition coil. S Check if the primary coil has the specified resistance. Primary coil resistance: 3.6 X 4.8 Ω (20_C) Tester (+) lead Spark plug lead 1 Tester (–) lead Red/White Terminal 2 S Connect the pocket tester (Ω 1 k) to the ignition coil.
IGNITION SYSTEM ELEC : YP****** 7. Pickup coil resistance S Disconnect the pickup coil coupler from the wireharness. S Connect the pocket tester (Ω 100) to the pickup coil coupler. Tester (+) lead Yellow Terminal 1 Tester (–) lead Blue Terminal 2 S Check the pickup coil has the specified resistance. OUT OF SPECIFICATION Pickup coil resistance: 168 X 252 Ω (20_C) Replace the pickup coil. MEETS SPECIFICATION NO CONTINUITY YP****** 8.
CHARGING SYSTEM YP804000 CHARGING SYSTEM CIRCUIT DIAGRAM 1 2 4 5 A.C.
CHARGING SYSTEM ELEC YP804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED Procedure Check: 1. Fuse (Main) 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring system (entire charging system) NOTE: D Remove the following parts before troubleshooting. 1) Side panels 2) Tail cover D Use the special tools specified in the troubleshooting section. Engine tachometer 90890-03113 Pocket tester: 90890-03112 NO CONTINUITY YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Replace the fuse.
CHARGING SYSTEM ELEC : YP****** 3. Charging voltage S Connect the engine tachometer to the spark plug lead 1 . S Connect the pocket tester (DC20 V) to the battery. Tester (+) lead Battery (+) terminal 1 Tester (–) lead Battery (–) terminal 2 S Measure the battery terminal voltage. S Start the engine and accelerate to about 5,000 r/min. S Check the terminal voltage. Charging voltage = measured voltage – terminal voltage: 0.2 X 2.5 V up MEETS SPECIFICATION NOTE: Use a fully charged battery.
CHARGING SYSTEM : YP****** 4. Starter coil resistance S Remove the A.C. magneto coupler from wireharness. S Connect the pocket tester (Ω 1) to the stator coil. Tester (+) lead white terminal Tester (–) lead White terminal OUT OF SPECIFICATION S Measure the stator coil resistance. Stator coil resistance: 0.8 X 1.0 Ω (20_C) Replace the stator coil. MEETS SPECIFICATION YP****** POOR CONNECTION 5. Wiring connection Check the entire charging system for connections. Refer to “CIRCUIT DIAGRAM” section.
ELECTRIC STARTING SYSTEM EB80300 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 3 4 5 6 7 14 15 17 18 23 24 Main switch Battery Main fuse Starter relay Starter motor Sidestand switch Starting circuit cut-off relay Starter switch Engine stop switch Rear brake switch Front brake switch 8-15 ELEC
ELECTRICAL STARTING SYSTEM ELEC YP803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE. Procedure Check: 1. Fuse (Main) 2. Battery 3. Starter motor 4. Starter relay 5. Starting circuit cut-off relay 6. Main switch 7. 8. 9. 10. 11. Engine stop switch Sidestand switch Front/Rear brake switch Starter switch Wiring connection (entire starting system) NOTE: D Remove the following parts before troubleshooting.
ELECTRICAL STARTING SYSTEM ELEC : YP****** 3. Starter motor DOES NOT MOVE S Connect the battery positive terminal and starter motor cable using a jumper lead. S Check the starter motor operation. Repair or replace the starter motor. A wire used as a jumper lead must have the equivalent capacity as that of the battery lead or more, otherwise it may burn. This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity. MOVES YP****** 4.
ELECTRICAL STARTING SYSTEM ELEC : NO CONTINUITY YP****** 6. Main switch Refer to “CHECKING SWITCHES” section. Replace the main switch. CONTINUITY NO CONTINUITY YP****** 7. Engine stop switch Refer to “CHECKING SWITCHES” section. Replace the right handlebar switch. CONTINUITY NO CONTINUITY YP****** 8. Sidestand switch Refer to “CHECKING SWITCHES” section. Replace the sidestand switch. CORRECT NO CONTINUITY YP****** 9. Front/Rear brake switch Refer to “CHECKING SWITCHES” section in CHAPTER 8.
ELECTRICAL STARTING SYSTEM ELEC STARTER MOTOR 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) 5 Nm (0.5 mSkg) Order Job name/Part name Q’ty Starter motor removal Air cleaner case 1 Remarks Remove the parts in order. Refer to “ENGINE REMOVAL AND INSTALLATION” section in CHAPTER 4. Starter motor 1 Reverse the removal procedure for installation.
ELEC ELECTRICAL STARTING SYSTEM YP803034 Inspection and repair 1. Inspect: S Commutator Dirt Clean it with #600 grit sandpaper. 2. Measure: S Commutator diameter a Commutator wear limit: 27 mm Out of specification Replace the starter motor 3. Measure: S Mica undercut a Mica undercut: 0.7 mm Out of specification Scrape the mica to the proper value (a hacksaw blade can be ground to fit). NOTE: The mica insulation of the commutator must be undercut to ensure proper operation of commutator. 4.
ELECTRICAL STARTING SYSTEM ELEC Brush spring force: 570 X 920 g 7. Inspect: S Bearing S Oil seal Wear/damage Repalce. YP****** Assembly Reverse the “Removal” procedure. Note the following points. 1. Install: S Brush holder 1 NOTE: Align the projection a on the brush seat with the slot b on the housing. 2. Install: S Shims 1 S Armature coil 2 3. Install: S Ring 1 S Stator ass’y 2 S Shims 3 S Front bracket 4 5 Nm (0.
LIGHTING SYSTEM EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse 16 Lights switch 29 Dimmer switch 30 Pass switch 32 Tail/ Brake light 33 Licence light 36 Head light 39 Auxiliary light 40 Meter lights 8-22 ELEC
LIGHTING SYSTEM ELEC YP805010 TROUBLESHOOTING IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT, MARKER LIGHT AND/OR METER LIGHT FAIL TO COME ON. Procedure Check: 1. Fuse (Main) 2. Battery 3. Main switch 4. Lights switch 5. Dimmer switch and pass switch 6. Wiring connection (entire lighting system) NOTE: D Remove the following parts before troubleshooting. 1) Tail cover 2) Cowling body D Use the special tools specified in the troubleshooting section.
LIGHTING SYSTEM ELEC : NO CONTINUITY YP****** 5. Dimmer switch/Pass switch Refer to “CHECKING SWITCHES” section. Replace the left handlebar switch. YP****** 6. Wiring connection POOR CONNECTIONS S Check the connections of the entire lighting system. Refer to “WIRING DIAGRAM”. Correct. Check the condition of each of the lighting system’s circuits. Refer to “LIGHTING SYSTEM CHECK” YP805020 LIGHTING SYSTEM CHECK 1. If the headlight and the high beam indicator light fail to come on. 1.
LIGHTING SYSTEM ELEC : S Turn the main switch to on. S Turn the light switch to on position. S Turn the dimmer switch to low beam or high beam. S Pass switch to push in. S Check for voltage (12 V) on the lead at bulb socket connectors. OUT OF SPECIFICATION The wiring circuit from the main switch to bulb socket connector is faulty. Repair. MEETS SPECIFICATION This circuit is not faulty. YP805021 2. If the meter light fails to come on. NO CONTINUITY 1.
LIGHTING SYSTEM ELEC YP805022 3. The taillight fails to come on. NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and/or bulb socket. CONTINUITY 2. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector. Tester (+) lead Blue terminal 1 Tester (–) lead Black terminal 2 OUT OF SPECIFICATION S Turn the main switch to on. S Turn the lights switch to on or pilot position. S Check the voltage (12 V) on the bulb socket connector.
LIGHTING SYSTEM ELEC YP805023 4. If the auxiliary light fails to come on. NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and/or bulb socket. CONTINUITY 2. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector. Tester (+) lead Blue terminal 1 Tester (–) lead Black terminal 2 OUT OF SPECIFICATION S Turn the main switch to on. S Turn the lights switch to on or pilot position. S Check the voltage (12 V) on the bulb socket connector.
SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse 23 Rear brake switch 24 Front brake switch 25 Flasher relay 26 Horn 27 Turn switch 28 Horn switch 33 Tail/ Brake light 34 Rear flasher lights 35 Front flasher lights 38 Turn indicator lights 43 Fuel gauge 49 Fuel sender 8-28 ELEC
SIGNAL SYSTEM ELEC YP806010 TROUBLESHOOTING IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON. IF THE HORN FAILS TO SOUND. Procedure Check: 1. Fuse (Main) 2. Battery 3. Main switch 4. Wiring connection (entire signal system) NOTE: D Remove the following parts before troubleshooting. 1) Cowling body 2) Side panels D Use the special tools in the troubleshooting section. Pocket tester: 90890-03112 NO CONTINUITY YP****** 1. Fuse Refer to “CHECKING SWITCHES” section.
SIGNAL SYSTEM : YP****** 4. Wireharness S Check the connections of the entire signal system. Refer to “CIRCUIT SYSTEM WIRING DIAGRAM” section. POOR CONNECTION Correct. CONTINUITY Check condition of each of the signal system’s circuits. Refer to “SIGNAL SYSTEM CHECK” section.
SIGNAL SYSTEM ELEC YP806020 SIGNAL SYSTEM CHECK 1. If the horn fails to sound. NO CONTINUITY 1. HORN switch Refer to “CHECKING SWITCHES” section. Replace the left handlebar switch. CONTINUITY 2. Voltage S Connect the pocket tester (DC20 V) to the horn lead. Tester (+) lead Brown terminal 1 . Tester (–) lead Frame ground S Turn the main switch to on. S Check for voltage (12 V) on the “Brown” lead at the horn terminal.
SIGNAL SYSTEM ELEC YP806022 2. If the brake light fails to come on: NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY 2. Brake switch (Front/Rear) Refer to “CHECKING SWITCHES” section. Replace brake switch. CONTINUITY 3. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector. Tester (+) lead Blue terminal 1 Tester (–) lead Black terminal 2 S Turn the main switch to on.
SIGNAL SYSTEM ELEC YP806023 3. If the flasher light and/or turn indicator light fails to blink. NO CONTINUITY 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY 2. Turn switch Refer to “CHECKING SWITCHES” section. Replace the left handlebar switch. CONTINUITY 3. Voltage S Connect the pocket tester (DC20 V) to the flasher relay coupler. Tester (+) lead Brown terminal 1 .
SIGNAL SYSTEM ELEC : 5. Voltage S Connect the pocket tester (DC20 V) to the bulb socket connector. At flasher light (left) Tester (+) lead Chocolate lead 1 Tester (–) lead Black terminal 3 At flasher light (right) Tester (+) lead Dark green lead 2 Tester (–) lead Black terminal 3 S Turn the main switch to on. S Turn the turn switch to left or right. S Check for voltage (12 V) on the “Chocolate” lead and “Dark green” at the flasher light terminal. OUT OF SPECIFICATION 6.
SIGNAL SYSTEM ELEC YP806027 4. If the fuel gauge fails to operate. 1. Fuel sender S Remove the fuel sender from the fuel tank. S Disconnect the fuel sender coupler from the wireharness. Connect the pocket tester (Ω 10) to the fuel sender coupler lead. Tester (+) lead Green terminal 1 Tester (–) lead Black terminal 2 S Check the fuel sender for specificated resistance. Float position UP 3 DOWN 4 Specificated resistance 4 X 10 Ω 90 X 100 Ω OUT OF SPECIFICATION Replace the fuel sender.
SIGNAL SYSTEM ELEC : 3. Fuel gauge S Connect the fuel sender to wireharness. S Move the float to “UP” 1 or “DOWN” 2. NOTE: Before reading the meter, stay put the float for more than three minutes respectively at “UP” or “DOWN”. S Turn the main switch to “ON”. S Check the fuel gauge needle moves “F” or “E”. Float position Float “UP” 1 Float “DOWN” 2 DOES NOT MOVE Needle moves “F” “E” Replace the fuel gauge. MOVES This circuit is not faulty.
COOLING SYSTEM YP80700 COOLING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse 20 Fuse (fan) 21 Thermo switch 22 Fan motor 46 Thermo meter 50 Thermo unit 8-37 ELEC
COOLING SYSTEM ELEC YP****** TROUBLESHOOTING IF THE FAN MOTOR FAILS TO TURN. Procedure Check: 1. Fuse (Main, Fan) 2. Battery 3. Fan motor (inspection 1) 4. Fan motor (inspection 2) 5. Thermo switch 6. Wiring connection (entire cooling system) NOTE: D Remove the following parts before troubleshooting. 1) Side panels 2) Footrest board 3) Under cover 4) Drain the cooling water D Use the special tools specified in the troubleshooting section. Pocket tester: 90890-03112 NO CONTINUITY YP****** 1.
COOLING SYSTEM ELEC YP****** 4. Fan motor (inspection 1) Disconnect the fan motor couplers. Cconnect the battery as shown. Battery (+) lead Blue terminal 1 Battery (–) lead Black terminal 2 DOES NOT MOVE Check the fan motor operation. Replace fan motor. MOVES YP****** 5. Fan motor (inspection 2) Turn the main switch to on. Remove the thermo switch lead from thermo switch. Connect jumper lead 1 to thermo switch leads. Turn the main switch to on.
COOLING SYSTEM ELEC S Handle the thermo switch with special care. Never subject it to strong shocks or allow it to be dropped. Should it be dropped, it must be replaced. S Do not touch the thermo switch to the bottom of the heated vessel. OUT OF SPECIFICATION 105"3_C More than 98_C A Thermo switch “ON”. B Thermo switch “OFF”. Replace the thermo switch. CORRECT 7. Wiring connection S Check the connection of the entire cooling system. Refer to “CIRCUIT DIAGRAM” section. POOR CONNECTION Correct.
COOLING SYSTEM ELEC YP807010 TROUBLESHOOTING IF THE WATER TEMPERATURE METER FAILS TO MOVE, WHEN ENGINE IS WARM Procedure Check: 1. Fuse (Main, Fan) 2. Battery 3. Main switch 4. Thermo unit 5. Voltage 6. Wiring connection (entire cooling system) NOTE: D Remove the following parts before troubleshooting. 1) Fuel tank 2) Cowling body D Use the special tools specified in the troubleshooting section. Pocket tester: 90890-03112 NO CONTINUITY YP****** 1. Fuse Refer to “CHECKING SWITCHES” section.
COOLING SYSTEM ELEC : YP****** 4. Thermo unit S Drain the coolant, and remove the thermo unit from the radiator. S Immerse the thermo unit 2 in the coolant 3 . 1 Thermometer D Handle the thermo unit with special care. Never subject it to strong shocks or allow it to be dropped. Should it be dropped, it must be replaced. D Do not touch the thermo unit to the bottom of the heated vessel. OUT OF SPECIFICATION Coolant temperature Resistance 80_C 100_C 47.5 X 56.8 Ω 26.2 X 29.
COOLING SYSTEM : YP****** 6. Wiring connection S Check the connections of the entire cooling system. Refer to “CIRCUIT DIAGRAM” section. POOR CONNECTION Correct. CORRECT Replace the temperature gauge.
AUTO CHOKE SYSTEM YP****** AUTO CHOKE SYSTEM CIRCUIT DIAGRAM 3 4 5 8 9 Main switch Battery Main fuse Thermo switch (auto choke) Auto choke 10 Ignitor unit 18 Engine stop switch 8-44 ELEC
AUTO CHOKE SYSTEM ELEC YP****** TROUBLESHOOTING IF THE AUTO CHOKE FAILS TO OPERATE. Procedure Check: 1. Fuse (Main) 2. Battery 3. Main switch 4. Engine stop switch 5. 6. 7. 8. NOTE: D Remove the following parts before troubleshooting. 1) Fuel tank 2) Footrest board 3) Cowling body D Use the special tools specified in the troubleshooting section. Thermo switch Auto choke unit resistance Voltage Wiring connection (entire auto choke system) Pocket tester: 90890-03112 NO CONTINUITY YP****** 1.
AUTO CHOKE SYSTEM ELEC : YP****** 5. Thermo switch S Disconnect the thermo switch from the radiator. S Connect the pocket tester (Ω 1) to the thermo switch 1 . S Immerse the thermo switch in the coolant 2 . S Check the thermo switch for continuity. NOTE: Note temperatures while heating the water with the temperature gauge 3 . S Handle the thermo switch with special care. Never subject it to strong shocks or allow it to be dropped. Should it be dropped, it must be replaced.
AUTO CHOKE SYSTEM ELEC : YP****** 6. Auto choke unit resistance S Disconnect the auto choke unit coupler from the wireharness. S Connect the pocket tester (Ω 1) to the auto choke unit coupler lead. Tester (+) lead Black terminal 1 Tester (–) lead Black terminal 2 OUT OF SPECIFICATION Auto choke unit resistance: 16 X 24 Ω (20_C) Replace the auto choke unit. MEETS SPECIFICATION YP****** 7. Voltage (temperature under 68_C) S Connect the pocket teser (DC20 V) to the ignitor unit.
ELEC
CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR IDLE SPEED PERFORMANCE . .
STARTING FAILURE/HARD STARTING TRBL SHTG EB90000 TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.
POOR IDLE SPEED PERFORMANCE IGNITION SYSTEM Battery Improperly charged battery Faulty battery Fuse Burnt out, improper connection Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Worn electrodes Faulty spark plug cap Ignition coil Broken or shorted primary/secondary coil Faulty high tension cord Broken ignitin coil body TRBL SHTG Ignition system Faulty ignitor unit Faulty pick up coil Broken magneto woodruff key Switch Faulty ma
POOR MEDIUM AND HIGH SPEED PERFORMANCE TRBL SHTG EB902000 POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to “STARTING FAILURE/HARD STARTING” section.
FAULTY CLUTCH TRBL SHTG YP****** FAULTY CLUTCH WHEN ENGINE IS RUN, SCOOTER DOES NOT RUN V belt POOR SPEED PERFORMANCE Worn/bent/slipping V belt Cam, slider Worn Worn/damaged Oily V belt Compression spring Roller weight Damage Worn/improper operation Gears Primary/secondary sheave Damage Worn YP904000 CLUTCH SLIPPING Clutch weight spring Worn/loose Clutch shoe Worn/damaged Primary sliding sheave Seized YP****** POOR STARTING PERFORMANCE V belt Slipping/oily V belt Primary sliding
OVERHEATING OR OVER COOLING YP905000 OVERHEATING OR OVER COOLING OVERHEATING Ignition system Improper spark plug gap Improper spark plug heat range Faulty ignitor unit Fuel system Improper carburetor setting Improper fuel level adjustment Clogged air cleaner element Compression system Heavy carbon deposit build-up Improperly adjusted valve timing Improperly adjusted valve clearance Engine oil Incorrect engine oil level Improper engine oil quality (High viscosity) Low engine oil quali
FAULTY BRAKE/FRONT FORK MALFUNCTION TRBL SHTG YP906000 YP907000 FAULTY BRAKE FRONT FORK MALFUNCTION POOR BRAKING EFFECT Front brake Worn brake pad Worn brake disc Air in brake fluid Leaking brake fluid Faulty master cylinder kit Faulty caliper seal kit Loose union bolt Broken brake hose Oily or greasy brake pad Oily or greasy brake disc Rear brake Improper brake lever adjustment Worn brake shoe Improper brake shoe contact Worn camshaft Worn brake drum Mud or water into
INSTABLE HANDLING/ STARTER MOTOR DOES NOT OPERATE TRBL SHTG YP908000 YP****** INSTABLE HANDLING STARTER MOTOR DOES NOT OPERATE INSTABLE HANDLING Handlebars Loose handlebar tightening bolt Steering Loose or overtightening steering nut Bent under bracket Damaged bearing or ball race Front forks Uneven oil levels on both sides Broken front fork spring Twisted front forks Wheels Incorrect wheel balance Deformed wheel rim Unevenly worn tires Incorrect tire pressure Loose bearing B
FAULTY SIGNAL AND LIGHTING SYSTEM TRBL SHTG YP909000 FAULTY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DARK Improper bulb Too many electric accesories Hard charging Faulty rectifier/regulator Faulty battery Improperly connected coupler, connector, wireharness Improperly grounded Faulty main switch or Lights (dimmer) switch Bulb life expired BULB BURNT OUT Improper bulb Faulty battery Faulty rectifier/regulator Improperly grounded Faulty main switch Bulb life expired FLASHER DOES N
YP250 WIRING DIAGRAM 1. A.C. magneto 2. Rectifier / regulator 3. Main switch 4. Main fuse 5. Battery 6. Starter relay 7 Starter motor 8 Thermo switch (auto choke) 9. Auto choke 10. Ignitor unit 11. Ignition coil 12. Spark plug 13. Pickup coil 14. Sidestand switch 15. Starting circuit cut-off relay 16. Lights switch 17. Starter switch 18. Engine stop switch 19. Handlebar switches (right) 20. Fuse (fan) 21. Thermo switch 22. Fan motor 23. Rear brake switch 24. Front brake switch 25. Flasher relay 26.
