Yamaha 1996 YP250 Service Manual - 49ccScoot.Com

Administrateur

Note

http://swakkanobi.free.fr

EB000000

YP250SERVICE MANUAL

1996 by Yamaha Motor Co., Ltd.1st Edition, January 1996

All rights reserved. Any reprinting orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir 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 Yamahascooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Re-pairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit foruse.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe scooter operator, a bystander or a person inspecting or repairing the scoot-er.

A CAUTION indicates special precautions that must be taken to avoid damageto the scooter.

NOTE: A NOTE provides key information to make procedures easier or clearer.

12 4 3

5

6

7

6

8

YP002000

HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis 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 eachsection. It is located in the upper left corner of the page.

3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-nied by corresponding illustrations.

EXPLODED DIAGRAMSTo heps identify parts and clarify procedure steps, there are exploded diagrams at start of each remov-al and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs.2. Numbers 5 are given in the order of jobs in the exploded diagram. A number that is enclosed by a

circle indicates a disassembly step.3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6 . The meanings of the symbol marks are given on the next page.4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition

to the exploded diagram and the job instruction chart.

1

3

5

7

9

11

13

15

18

2

4

8

10

12

14

16

6

21

24 25

17

19 20

22 23

EB003000

ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are designed asthumb tabs to indicate the chapter’s numberand content.

1 General information2 Specifications3 Periodic inspection and adjustment4 Engine5 Cooling system6 Carburetion7 Chassis8 Electrical9 Troubleshooting

Illustrated symbols 10 to 17 are used to identifythe specifications appearing in the text.

10 Possible to maintain with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Tightening15 Wear limit, clearance16 Engine speed17 Ω, V, A

Illustrated symbols 18 to 23 in the exploded dia-grams indicate the types of lubricants and lu-brication points.

18 Apply engine oil19 Apply gear oil20 Apply molybdenum disulfide oil21 Apply wheel bearing grease22 Apply lightweight lithium-soap base grease23 Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the exploded dia-grams indicate the where to apply locking agent24 and when to install new parts 25 .

24 Apply locking agent (LOCTITE )25 Use new one

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND ADJUSTMENT

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GENINFO 1SPEC 2INSPADJ 3ENG 4

COOL 5CARB 6CHAS 7ELEC 8TRBLSHTG 9

INDEX

CHAPTER 1GENERAL INFORMATION

SCOOTER IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER (for E) 1-1. . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEATURES 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL INDICATOR LIGHT 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUTO CHOKE SYSTEM 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION CIRCUIT CUT-OFF SYSTEM 1-3. . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL PROCEDURES 1-4. . . . . . . . . . . . . . . REPLACEMENT PARTS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS, AND O-RINGS 1-4. . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-5. . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING OF CONNECTIONS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOW TO USE THE CONVERSION TABLE 1-7. . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

SCOOTER IDENTIFICATIONGENINFO

NOTE:

NOTE:

YP100000

GENERAL INFORMATIONSCOOTER IDENTIFICATION

YP100010

VEHICLE IDENTIFICATION NUMBER (for E)The vehicle identification number 1 is stampedinto the right side of the frame.

The vehicle identification number is used toidentify your scooter and may be used to regis-ter your scooter with the licensing authority inyour country.

YP100020

FRAME SERIAL NUMBER (except for E)The frame serial number 1 is stamped into theright side of the frame.

EB100030

ENGINE SERIAL NUMBERThe engine serial number 1 is stamped into thecrankcase.

Designs and specifications are subject tochange without notice.

MODEL LABELThe model label 1 is affixed under the seat.This information will be needed to order spareparts.

1-2

FEATURESGENINFO

Engine stopswitchMain

switch

Oil indicator light

Fuse

Battery Meter

Reset button

Ignitor unit

C.P.U

Oil indicator lightReset button

NOTE:

FEATURESOIL INDICATOR LIGHTFunctionPulses (travel distance signals) from the speedometer are counted and cause the oil indicator light tocome on at 1,000 km for the first time and thereafter every 3,000 km. In this way, this light indicates thetime for oil change.

Circuit diagram

Resetting procedureTravel distance can be reset if the reset button is held down for 2 to 5 seconds with the main switch“ON”.

1) If the “resetting” is done while the oil light is on, the oil indicator light goes off for resetting con-firmation.

2) If the “resetting” is done while the oil light is off, the oil indicator light comes on for 1.4 secondsfor resetting confirmation.

Failure diagnosis1) Checking oil indicator light for breakage

This oil indicator light is kept on for 1.4 seconds immediately after the main switch is turned on,thereby checking the bulb for breakage.

2) In case of meter pulse failureIf travel distance signals are not detected during running, the oil indicator light flashes and gives awarning of meter signal failure.

This circuit may be activated if the engine is accelerated without load with the mainestand put up.

Battery tending to discharge.If the starting motor is run with the battery tending to discharge, the oil indicator light may come on (for1.4 seconds), but this is noting abnormal.In this case recharge or replace battery.

This light comes on if battery charging becomes poor, thereby causing the engine to runas low as about 200 rpm against 600 rpm or so,

1-3

FEATURESGENINFO

Main switch

Fuse

Battery

Thermoswitch

Auto-choke

Igniter unit

C.P.UIgnition

Main switch Engine stop switch

Brakeswitch

Fuse

Starter relayRelay

Ignitor unit

BatteryStartermotor

Startswitch

Brake lightSidestandswitch

AUTO-CHOKE SYSTEMThis system is the parallel connection of the ignitor unit circuit and the thermo switch as shown, detect-ing the engine temperature, and facilitates the restarting with the warm engine.Circuit diagram

Auto-choke operation

Engine conditionStart with thecold engine

Crank with thecold engine

Crank with thewarm engine

Restart with thewarm engine

Thermo switch OFF OFF ON ON

Ignitor unit circuit OFF ON ON OFF

Auto-choke Activates Activates Not activate Not activate

IGNITION CIRCUIT CUT-OFF SYSTEMA sidestand circuit is added to the existing electric starting circuit, thereby controlling the starter motoroperation and the ignition system of the igniter unit.Circuit diagram

Operating mode

Sidestand switchOperation of brake

lightOperation of starter

motorOperation of igniter

unit control

OFF ON Not operated Misfire(Sidestand in use) OFF Not operated Misfire

ON ON Operated Ignited(Sidestand folded in) OFF Not operated Ignited (ridden)

1-4

IMPORTANT INFORMATIONGENINFO

EB101000

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCE-DURES

1. Remove all dirt, mud, dust and foreign ma-terial before removal and disassembly.

2. Use proper tools and cleaning equipment.3. Refer to the “SPECIAL TOOLS” section.

4. When disassembling the machine, alwayskeep mated parts together. This includesgears, cylinders, pistons and other partsthat have been “mated” through normalwear. Mated parts must always be reusedor replaced as an assembly.

5. During machine disassembly, clean allparts and place them in trays in the order ofdisassembly. This will speed up assemblyand allow for the correct installation of allparts.

6. Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS1. Use only genuine Yamaha parts for all re-

placements. Use oil and grease recom-mended by Yamaha for all lubrication jobs.Other brands may be similar in function andappearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS1. Replace all gaskets, seals and O-rings

when overhauling the engine. All gasketsurfaces, oil seal lips and O-rings must becleaned.

2. Properly oil all mating parts and bearingsduring reassembly. Apply grease to the oilseal lips.

1-5


OR

CAUTION:

EB101030

LOCK WASHERS/PLATES AND COTTER PINS

1. Replace all lock washers/plates and cotterpins after removal. Bend lock tabs along thebolt or nut flats after the bolt or nut has beentightened to specification.

EB101040

BEARINGS AND OIL SEALSInstall bearings and oil seals so that themanufacturer’s marks or numbers are visible.When installing oil seals, apply a light coating oflightweight lithium base grease to the seal lips.Oil bearings liberally when installing, if appropri-ate.

1 Oil seal

Do not use compressed air to spin the bearingsdry. This will damage the bearing surfaces.

1 Bearing

EB101050

CIRCLIPS1. Check all circlips carefully before reas-

sembly. Always replace piston pin clips af-ter one use. Replace distorted circlips.When installing a circlip 1 , make sure thatthe sharp-edged corner 2 is positioned op-posite the thrust 3 it receives. See section-al view.

4 Shaft

1-6


NOTE:

NOTE:

EB801000

CHECKING OF CONNECTIONSDealing with stains, rust, moisture, etc. on theconnector.

1. Disconnect:Connector

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector twoor three.

4. Pull the lead to check that it will not comeoff.

5. If the terminal comes off, bend up the pin 1and reinsert the terminal into the connector.

6. Connect:Connector

The two connectors “click” together.

7. Check for continuity with a tester.

If there is no continuity, clean the terminals. Be sure to perform the steps 1 to 7 listed

above when checking the wireharness. For a field remedy, use a contact revitalizer

available on the market. Use the tester on the connector as shown.

1-7

HOW TO USE THE CONVERSION TABLEGENINFO

EB201000

HOW TO USE THE CONVERSION TABLEAll 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 = ** in2 mm 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMP

Known Multiplier Result

Torque

mkgmkgcmkgcmkg

7.23386.7940.07230.8679

ftlbinlbftlbinlb

Weightkgg

2.2050.03527

lboz

Distance

km/hrkmmmcmmm

0.62140.62143.2811.0940.39370.03937

mphmiftydinin

Volume/Capacity

cc (cm3)cc (cm3)lit (liter)lit (liter)

0.035270.061020.87990.2199

oz (IMP liq.)cuinqt (IMP liq.)gal (IMP liq.)

Miscella-neous

kg/mmkg/cm2

Centigrade

55.99714.22349/5(C) + 32

lb/ inpsi (lb/ in2)Fahrenheit (F)

1-8

SPECIAL TOOLSGENINFO

EB102000

SPECIAL TOOLSThe 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 inappropri-ate tools or improvised techniques.When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/Usage Illustration

90890-01084-01085

WeightRocker arm shaft puller bolt

These tools are used when removingor installing the rocker arm shafts.

90890-01235 Rotor holding tool

This tool is used to remove theflywheel magneto.

90890-01268 Ringnut wrench

This tool is used to loosen and tightenthe exhaust and steering ringnut.

90890-01311 Valve adjusting tool

This tool is necessary for adjustingvalve clearance.

90890-01312 Fuel level gauge

This gauge is used to measure the fuellevel in the float chamber.

90890-01325-01352

Radiator cap testerAdaptor

These tools are used for checking thecooling system.

90890-01326-04084

T-handleDamper rod holder

These tool are used for holding thedamper rod holder when removing orinstalling the damper rod holder.

90890-01337-01464

Clutch spring compressorClutch spring holder arm

These tools are used for removing thenut with holding the compression spring.

90890-01348 Locknut wrench

This tool is used when removing orinstalling the secondary sheave nut.

1-9



90890-01362 Flywheel puller

This tool is used for removing therotor.

90890-01367-01368

Fork seal driver weightFork seal driver attachment (ø33)

This tool is used when installing thefork seal.

90890-01384 Oil seal guide

This tool is used for protecting the oilseal lip when installing the secondarysliding sheave.

90890-01403 Ring nut wrench

This tool is used to loosen and tightenthe steering ring nut.

90890-01701 Sheave holder

This tool is used for holding thesecondary sheave.

90890-01996 Cylinder cup installer set

This tool is used for installing thecylinder cup to the master cylinderpiston.

90890-03079 Thickness gauge

This tool is used to measure the valveclearance.

90890-03081 Compression gauge

These tools are used to measure theengine compression.

90890-03112 Pocket tester

These instruments are invaluable forchecking the electrical system.

90890-03113 Engine tachometer

This tool is needed for detectingengine rpm.

1-10



90890-03141 Timing light

This tool is needed for detectingignition timing.

90890-04101 Valve lapper

This tool is used for removing andinstalling the lifter and for lapping thevalve.

90890-04019-04108

Valve spring compressorAttachment

These tools are used when removingor installing the valve and the valvespring.

90890-04058-04078

Middle shaft bearing driverMechanical seal installer

These tools are used for installingmechanical seal.

90890-06754 Ignition checker

This instrument is necessary for checkingthe ignition system components.

90890-85505 Yamaha bond No. 1215

This sealant (bond) is used for crankcasemating surface, etc.

CHAPTER 2.SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TORQUE SPECIFICATIONS 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION POINTS AND GRADE OF LUBRICANT 2-17. . . . . . . . . . . .

ENGINE 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Model YP250

Model code: 4UC 1 (except for CH, A)4UD1 (for CH, A)

Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum 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 typeCylinder arrangementDisplacementBore strokeCompression ratioCompression pressure (STD)Starting systemLubrication system:

Liquid-cooled 4-stroke, SOHCForward-inclined single cylinder0.249L (249 cm3)69.0 66.8 mm10 : 11,400 kPa (14 kg/cm2, 14 bar) at 500 r/minElectric starterWet sump

Oil type or grade:

Engine oilAPI STANDERD:SE or higher grade

Periodic oil changeTotal amount

Transmission oilTotal amount

1.2 L1.4 L

0.25 L

Radiator capacityTotal amount (including all routes) 1.4 L

Air filter: Carburetor sideCrankcase side

Wet type elementDry type element

Fuel:TypeFuel tank capacity

Regular unleaded gasoline11 L

2-2


Model YP250

Carburetor:Type/quantityManufacturer

Y28V-1A/1TEIKEI

Spark plug:TypeManufacturerSpark plug gap

DR8EANGK0.6 0.7 mm

Clutch type: Dry, centrifugal automatic

Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction sytemSecondary reduction ratioTransmission typeOperationSingle speed automatic

Helical gear40/15 (2.666)Sper gear37/16 (2.312)Single speed automatic (V-belt type)Centrifugal automatic type2.20 0.88:1

Chassis:Frame typeCaster angleTrail

Steel tube underbone28103 mm

Tire:TypeSize front

rearManufacturer front

rearType front

rear

Tubeless110/90-12 64J130/70-12 62LIRC/CHENG SHINIRC/CHENG SHINMB61/C922MB61/C940

Tire pressure (cold tire):Maximum load-except motorcycleLoading condition A*

front rear

Loading condition B*front

rearHigh-speed riding

front rear

197 kg0 90 kg175 kPa (1.75 kg/cm2, 1.75 bar)200 kPa (2.0 kg/cm2, 2.0 bar)90 205 kg200 kPa (2.0 kg/cm2, 2.0 bar)225 kPa (2.25 kg/cm2, 2.25 bar)

200 kPa (2.0 kg/cm2, 2.0 bar)250 kPa (2.5 kg/cm2, 2.5 bar)

*Load is the total weight of cargo, rider, passenger, and accessories.

2-3


Model YP250

Brake:Front brake type

operationRear brake type

operation

Single disc brakeRight hand operationDrum brakeLeft hand operation

Suspension:Front suspensionRear suspension

Telescopic forkUnit swing

Shock absorber:Front shock absorberRear shock absorber

Coil spring/Oil damperCoil spring/Oil damper

Wheel travel:Front wheel travelRear wheel travel

85 mm90 mm

Electrical:Ignition systemGenerator systemBattery typeBattery capacity

T.C.I. (Digital)A.C. magnetoGT7B-512 V 6 AH

Headlight type: Quartz bulb (Halogen)

Bulb wattage quantity:HeadlightMarker lightTail /brake lightFlasher lightMeter lightHigh beam indicator lightOil indicator lightTurn indicator light

License light

12V 60 W/55 W 112V 4 W 112V 5 W/21 W 112V 21W 412V 1.7W 412V 3.4 W 112V 1.7 W 112V 3.4 W 212V 5 W 1

2-4

MAINTENANCE SPECIFICATIONS SPEC

Face Width Seat Width Margin Thickness

MAINTENANCE SPECIFICATIONSENGINE

Item Standard Limit

Cylinder head:Warp limit 0.03 mm

Cylinder:Bore sizeOut of round limit

69.000 69.005 mm

69.1 mm0.03 mm

Camshaft:Cam dimensionsIntake “A”

“B” “C”

Exhaust “A”“B”

“C”Camshaft runout limit

36.545 36.645 mm30.021 30.121 mm6.524 mm36.547 36.647 mm30.067 30.167 mm6.48 mm

36.45 mm29.92 mm

36.45 mm29.97 mm

0.03 mm

Cam chain:Cam chain type/No. of links DID SCA-0404A SDH/104

Rocker arm/rocker armshaft:Rocker arm inside diameterRocker shaft outside diameterRocker arm-to-rocker armshaftclearance

12.000 12.018 mm11.981 11.991 mm

0.009 0.012 mm

12.03 mm11.995 mm

Valve, valve seat, valve guide:Valve clearance (cold) IN

EX0.08 0.12 mm0.16 0.20 mm

Valve dimensions

“A” head diameter INEX

“B” face width INEX

“C” seat width INEX

“D” margin thickness INEX

Stem outside diameter INEX

Guide inside diameter INEX

33.9 34.1 mm28.4 28.6 mm3.394 3.960 mm3.394 3.960 mm0.9 1.1 mm0.9 1.1 mm0.8 1.2 mm0.8 1.2 mm5.975 5.990 mm5.960 5.975 mm6.000 6.012 mm6.000 6.012 mm

5.94 mm5.92 mm6.05 mm6.05 mm

2-5


Item Standard Limit

Stem-to-guide clearance INEX

Stem runout limitValve seat width IN

EX

0.010 0.037 mm0.025 0.052 mm

0.9 1.1 mm0.9 1.1 mm

0.08 mm0.1 mm0.01 mm1.6 mm1.6 mm

Valve spring:Free length (Inner) IN/EXFree length (Outer) IN/EXSet length (valve closed) (Inner) IN/EXSet length (valve closed) (Outer) IN/EXCompressed pressure (Inner) IN/EX

(Outer) IN/EXTilt limit (Inner) IN/EXTilt limit (Outer) IN/EX

38.1 mm36.93 mm30.1 mm31.6 mm7.8 9.0 kg37.22 42.83 kg

36.1 mm35.0 mm

2.5/1.7 mm2.5/1.7 mm

Piston:Piston to cylinderclearancePiston size “D”Measuring point “H”Piston pin boreinside diameterPiston pin outside diameter

0.02 0.04 mm

68.965 68.980 mm5 mm17.004 17.015 mm

16.991 17.000 mm

0.15 mm

17.045 mm

16.975 mm

Piston rings:Top ring:TypeEnd gap (installed)Side clearance (installed)

2nd ring:TypeEnd gap (installed)Side clearance

Oil ring:End gap (installed)

Barrel0.15 0.30 mm0.04 0.08 mm

Taper0.30 0.45 mm0.03 0.07 mm

0.2 0.7 mm

0.45 mm0.12 mm

0.7 mm0.12 mm

Crankshaft:

Crank width “A”Runout limit “C”Big end side clearance “D”

59.95 60.00 mm0.03 mm0.35 0.85 mm

2-6


Item Standard Limit

Automatic centrifugal clutch:Clutch shoe thicknessClutch housing inside diameterClutch shoe spring free lengthWeight outside diameterClutch – in revolutionClutch – stall revolution

3.0 mm135 mm28.1 mm20 mm2,100 2,700 r/min3,700 4,700 r/min

2.0 mm135.5 mm

19.5 mm

V-belt:V-belt width 22.6 mm 21.0 mm

Carburetor:TypeI.D. markVentuly outside diameterMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)Throttle valve size (Th.V)Pilot air jet (P.A.J.1)Needle jet (N.J)Pilot outlet (P.O)Pilot jet (P.J)Bypass (B.P)Pilot screw (P.S)Valve seat size (V.S)Starter jet 1 (G.S.1)Starter jet 2 (G.S.2)Float height (F.H)Engine idle speedIntake vacuum

Oil temperatureCooling water temperature

Y28V-1B-14UC 00 [4UD 00 (CH, A)]ø28#130ø0.95D32-3/511ø1.2ø2.585ø0.8#440.7 417/81.4ø0.45ø0.527 mm1,450 1,550 r/min220 260 mmHg65 75C80C

Fuel pump:TypeModel/manufacturer

Vaccum type4HC/MIKUNI

Oil pump:TypeTip clearanceSide clearanceHousing and rotor clearance

Trochoid type0.1 0.34 mm0.013 0.036 mm0.04 0.09 mm

0.4 mm0.15 mm0.15 mm

2-7


Item Standard Limit

Radiator:TypeWidth/height/ thicknessRadiator cap opening pressure

Radiator capacityReservoir tank capacity

Cooling fin with electric fan140/238/24 mm110 140 kPa (1.1 1.4 kg/cm2,1.1 1.4 bar)1.4 L0.35 L

Thermostatic valve:Type/manufacturerValve opening temperatureValve full open temperatureValve full open lift

4HC/NIHON THERMOSTAT80.5 83.5C95C3 mm

Item Size

Bearings and oil seals:Big end bearingCrankshaft bearing (left)Crankshaft bearing (right)Crankshaft oil seal (left)Crankshaft oil seal (right)Water pump bearingWater pump oil sealMain axle bearing (left)Main axle bearing (right)Drive axle bearing (left)Drive axle bearing (right)Drive axle oil sealCamshaft bearing (left)Camshaft bearing (right)Primary drive gear bearing (left)Primary drive gear bearing (right)Primary drive gear oil seal

32 40 20 (needle bearing)630663/28SD-30-45-5S7-14-27-66000S-10-21-515NQ281515NQ281563036272SD8-32-52-760056202Z62056302SD8-32-52-7

2-8


TIGHTENING TORQUESENGINE

Part to be tightened Part nameThread

sizeQ’ty

Tighteningtorque Remarksg

sizey

Nm mkg

Oil check boltExhaust pipe stud boltSpark plugCam sprocket coverCylinder head and cylinderCylinder head and cylinder(Cam chain side)Valve coverRotorValve adjuster locknutCam shaft bearing stopperCam sprocketCam chain tensioner(Body)(Plug)

Guide stopper 2Water pump housing coverHose jointThermostatic valve coverFiller neck supportingOil pump Oil pump coverDrain plugCarburetor jointCarburetor joint and carburetorAir filter assemblyAir filter coverFuel pumpExhaust pipe assemblyMufflerMuffler and exhaust pipeProtector (Muffler)Protector (Exhaust pipe)Crankcase (left and right)Drain boltOil fillerTransmission case coverCrankcase cover (left)Crankcase filter coverCrankcase cover protectorMagnet cover

———

BoltNutBolt

BoltNutNutBoltBolt

BoltBoltBoltBolt—

BoltBolt

ScrewBoltBoltBoltNutBolt

Screw—

NutBoltBolt

ScrewScrewBoltBoltBoltBoltBolt—

Bolt—

M6M8M12M6M8M6

M6M16M6M6M10

M6M8M6M6M6M6M5M6M3M35M6M6M6M5M6M8M10M8M6M6M6M8M14M8M6M6M6M6

121242

51221

2113221211222522313291161132

10

71318102210

1080148

60

108

10107

10571

32101071

10205320101010223

161077

10

0.71.31.81.02.21.0

1.08.01.40.86.0

1.00.81.01.00.71.00.50.70.13.21.01.00.70.11.02.05.32.01.01.01.02.20.31.61.00.70.71.0

2-9


Part to be tightened Part nameThread

sizeQ’ty

Tighteningtorque Remarksg

sizey

Nm mkg

Cover (oil pump)Timing check plugOne way clutchClutch housingGrease stopper (Primary sheave)Primary fixed sheaveClutch carrier assemblyStatorPick up coilStarter motorThermo switchThermo unit

BoltPlug—

Bolt—————

Bolt——

M6M16M8M14M4M14M36M5M5M6M16

Pt 1/8

213141132221

128

30603

609077

10238

1.20.83.06.00.36.09.00.70.71.02.30.8

2-10


CHASSIS

Item Standard Limit

Steering system:Steering bearing type Ball bearing

Front suspension:Front fork travelFork spring free lengthSpring rate (K1)Stroke (K1)Oil capacityOil levelOil gradeInner tube vend limit

100 mm265.8 mm5.7 N/mm (0.57 kg/mm)0 100 mm0.142 L (142 cm3)80 mmFork oil 15 WT or equivalent

263.5 mm

0.2 mm

Rear suspension:Shock absorber strokeSpring free lengthFitting lengthSpring rate (K1)

(K2)(K3)

Stroke (K1)(K2)(K3)

106 mm265 mm317 mm7.7 N/mm (0.77 kg/mm)10.9 N/mm (1.09 kg/mm)17.6 N/mm (1.76 kg/mm)0 40 mm40 75 mm75 106 mm

260 mm

Front wheel:TypeRim sizeRim materialRim runout limit radialRim runout limit lateral

Cast wheelMT2.75 12Aluminum

2 mm2 mm

Rear wheel:TypeRim sizeRim materialRim runout limit radialRim runout limit lateral

Cast wheelMT3.50 12Aluminum

2 mm2 mm

Front disc brake:TypeDisc outside diameter thicknessPad thicknessMaster cylinder inside diameterCaliper cylinder outside diameterBrake fluid type

Single245 4 mm5.4 mm12.7 mm25.4 + 30.1 mmDOT #4

0.8 mm

2-11


Item Standard Limit

Rear drum brake:TypeDrum inside diameterShoe thickness

Leading, trailing160 mm4 mm

161 mm2 mm

Brake lever:Brake lever free play (front at lever side)Brake lever free play (rear)Throttle cable free play

2 5 mm10 20 mm3 5 mm

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 (inner)Rear wheel oil seal (outer)

6302RS6302RSSD-22-42-7-1SDD-47-58-76302RSSDO-28-35-4DD-26-42-8

2-12


TIGHTENING TORQUESCHASSIS

Part to be tightened Thread sizeTightening

torque RemarksNm mkg

Frame and engine bracketEngine bracket, compression rod and engineCompression rod and frameSidestand (bolt and frame)Sidestand (bolt and nut)Rear footrest bracketSwingarmRear shock absorber and frameRear shock absorber and engineSteering ring nutHandle holder and steering shaftHandle upper holder and lower holderBrake hose and master cylinderFuel tank

(font)(rear)

Fuel cockFuel senderFilterRoll over valveBoxHandle seatSheet lock assemblyPlastic parts & coverCowling staySide cover 1Cowling bodyFootrest boardHeadlight assemblyTail light assemblyFront wheel axle and nutRear wheel axle and nutRear brake cam leverRear pivot pinFront brake caliper and front forkBrake disc and hubBrake hose and caliperBrake caliper and bleed screwWindscreen

M12 1.25M10 1.25M10 1.25M10 1.25M10 1.25M 6 1.0M 8 1.25M10 1.25M 8 1.25M25 1.0M20 1.5M 8 1.25M10 1.25

M 6 1.0M 6 1.0M 6 1.0M 5 0.8M 6 1.0M 5 0.8M 6 1.0M 6 1.0M 6 1.0M 5 1.0M 8 1.25M 6 1.0M 6 1.0M 6 1.0M 6 1.0M 6 1.0M14 1.5M14 1.5M 6 1.0M10 1.25M10 1.25M 8 1.25M10 1.25M 7 1.0M 5 1.0

59326440407

23401922

1392326

10773747

1072

1677777

7013510324923266

0.4

5.93.26.44.04.00.72.34.01.92.2

13.92.32.6

1.00.70.70.30.70.40.71.00.70.21.60.70.70.70.70.77.0

13.51.03.24.92.32.60.6

0.04

See “NOTE”

2-13


NOTE:1. First, tighten the ring nut (lower) approximately 38 Nm (3.8 mkg) 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 mkg) 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 mkg) by

using the torque wrench.

2-14


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/min32 at 5,000 r/minElectrical type

T.C.I.:Pickup coil resistance/color

T.C.I. unit model/manufacturer

168 252 Ω at 20C/Yellow – BlackJ4T069/MITSUBISHI

Ignition coil:Model/manufacturerMinimum spark gapPrimary winding resistanceSecondary winding resistance

F6T507/MITSUBISHI6 mm3.6 4.8 Ω at 20C10.7 14.5 kΩ at 20C

Spark plug cap:TypeResistance

Resin type5 kΩ

Charging system:TypeModel/manufacturerNormal outputStator coil resistance/color

A.C. magneto4HC/MITSUBISHI14 V 16 A at 5,000 r/min0.8 1.0 Ω at 20C/White – White

Rectifire/regulator:Model/manufacturerNo load regulated voltageCapacityWithstand voltage

SH640D-12/SHINDENGEN14.7 V20 A200 V

Battery:Specific gravity 1.310

Electric starter system:TypeStarter motor:Model/manufacturer / ID numberOperation voltageOutputArmature coil resistanceBrush overall lengthBrash quantitySpring forceCommutator diameterMica undercut (depth)

Constant mesh type

SM-13/MITSUBA/SM-1345412 V0.65 kW0.0012 0.0022 Ω at 20C12.5 mm2 pcs.570 920 g28 mm0.7 mm

4 mm

570 g27 mm

2-15


Item Standard limit

Starter relay:Model/manufacturerAmperage ratingCoil winding resistance

4FL/JIDECO100 A4.2 4.6 Ω at 20C

Horn:Model/manufacturerMaximum amperage

YF-12/NIKKO2.5 A

Flasher relay:TypeModel/manufacturerFlasher frequency

Full transistor type4MY/NIPPONDENSO75 95 cycle/min

Fuel gage:Model/manufacturerSender unit resistance – fullSender unit resistance – empty

4HC/NIPPON SEIKI4 10 Ω90 100 Ω

Starting circuit cut-off relay:Model/manufacturerCoil winding resistance

4HC/MATSUSHITA72 88 Ω

Electric fan motor:Model/manufacturer 4HC/MITSUBA

Thermo switch (electric fan):Model/manufacturer 3LN/NIHON THERMOSTAT

Thermo switch (auto choke):Model/manufacturer 4HC/NIHON THERMOSTAT

Thermo unit:Model/manufacturer 2YK/NIPPON SEIKI

Circuit breaker:TypeMAINFANReserve

Fuse20 A 1 pc.3 A 1 pc.20 A 1 pc.3 A 1 pc.

2-16

GENERAL TORQUE SPECIFICATIONS SPEC

GENERAL TORQUE SPECIFICATIONSThis chart specifies torque for standard fasten-ers with standard I.S.O. pitch threads. Torquespecifications for special components or as-semblies are included in the applicable sectionsof this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, inprogressive stages, until full torque is reached.Unless otherwise specified, torque specifica-tions call for clean, dry threads. Componentsshould be at room temperature.

A: Distance across flatsB: Outside thread diameter

A(Nut)

B(Bolt)

General torquespecifications

(Nut) (Bolt)Nm mkg

10 mm 6 mm 6 0.6

12 mm 8 mm 15 1.5

14 mm 10 mm 30 3.0

17 mm 12 mm 55 5.5

19 mm 14 mm 85 8.5

22 mm 16 mm 130 13.0

2-17

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC

LUBRICATION POINT AND GRADE OF LUBRICANTENGINE

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 inner surface

Shaft

Shaft (Oil pump assembly)

Gasket (Oil pump assembly)

Holder

Idle gear 1 thrust surfaces

Shaft 1

Idle gear 2 thrust surfaces

Idle gear 2 inner surface

Main axle thrust surfaces

Crankcase mating surfaces Yamaha bond No. 1215

Crankcase breather plug

Stator grommet Yamaha bond No. 1215

Suction pipe

2-18

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC

CHASSIS

Lubrication Point Symbol

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

Administrateur

Note


2-19

CABLE ROUTING SPEC

1 Rectifier regulator2 Fuel sender3 Fuse (fan)4 Roll over valve5 Ignition coil6 Seat lock cable7 Handlebar switch 3 lead

(right)8 Front brake switch lead9 Brake hose10 Speedometer cable11 Radiator overflow hose12 Starter relay/Fuse (main)13 Battery14 Battery positive (+) lead

15 Battery negative (–) lead16 Flasher relay17 Reservoir tank18 Breather hose19 Air filter20 Mainharness21 Link (engine bracket)22 A.C. magneto lead23 Starter motor lead24 Engine earth lead25 Mudguard

A Clamp the fuel sender lead and auto choke lead to the frame.

B Pass the seat lock cable through the protection pipe.

C Clamp the mainharness andradiator over flow hose together to the frame.

D Install the brake hose to the brake caliper with its markingfacing to the tire side.

CABLE ROUTING

2-20

E Pass the overflow hose fromthe reservoir tank through theclamp inside the frame.

F Clamp the mainharness, battery(+) lead and (–) lead to clampof the frame.

G Clamp the fuel sender lead tothe pipe.

H The mainharness connectingto the taillight assembly to the frame.

I Connect the taillight assembly lead to the mainharness over the mudguard.

CABLE ROUTING SPEC

J Keep the clamping clearanceover 5 mm.(Bend the metal clamp to keepthe clearance between themetal clamp and link over 5 mm.)

K Install the meter cable with its sheaved side facing to the meter gear.

L Separate the thermo switch lead and ather lead forward inside the frame.

2-21

CABLE ROUTING SPEC

1 Seat lock2 Air filter case3 Breather hose4 Fuel hose5 Vacuum hose6 Sidestand switch lead7 Thermo switch lead8 Fan motor lead ,9 Breather hose10 Overflow hose (fuel tank)11 Relay12 Auto choke lead13 A.C. magneto lead14 Starter motor lead15 Engine earth lead16 Protector (pipe)17 Seat lock cable

A Clamp the mainharness andsidestand switch lead together the frame.

B Clamp the sidestand switch lead.

C Install the positive (+) leadbetween the battery and thestarter relay to the starter relayalong the chassis.

D Clamp the seat lock cable tothe the frame.

E Clamp the thermo switch leadand fan motor lead the frame.

F Clamp the overflow hose to the metal clamp on the frame.

G Put the coupler of the A.C.magneto lead and the autochoke lead along the framepipe after connection.

H Clamp the mainharness, A.C.magneto lead, starter motor lead and engine earth leadtogether inside the frame.

I Clamp the A.C. magneto lead,starter motor lead and engineearth lead to the link.

J Pass the breather hosethrough the hole of the airfilter case.

2-22

CABLE ROUTING SPEC

1 Front flasher light (right)2 Front flasher light (left)3 Handlebar switch (right) lead4 Front brake switch lead5 Seat lock cable6 Throttle cable7 Brake hose8 Handlebar switch (left) lead9 Rear brake switch lead10 Handlebar under cover11 Brake cable 212 Speedometer cable13 Stay 114 Horn

15 Brake hose stopper16 Marking

A Clamp the speedometer leadthe stay 1.

B Pass the speedometer cableand the brake hose throughthe clamps on the frame.(Front : Speedometer cableRear : Brake hose)

C Pass the handlebar switch(right) lead and front brakeswitch lead through the plastic“U” clamp.

D Do not interfere each other after installing the handlebarupper cover.

E Pass the handlebar switch(left) lead and rear brakeswitch lead on the left of thespeedometer cable, thenconnect to the mainharness.

F Hook the left and right frontflasher light leads on the pipeof stay 1. (Put the leads downinside of the cowling bodyafter connection.)

2-23

CABLE ROUTING SPEC

G Pass the brake hose through the hose holder and clamp.

H Clamp the headlight lead andhorn lead from mainharnessto the stay 1.

I Install the brake hose with itsmarking facing to the stopperside.

2-24

CABLE ROUTING SPEC

1 Fuel overflow hose (filler neck)2 Throttle cable 1 (nut white)3 Throttle cable 2 (nut black)4 Air vent hose (carburetor)5 Coolant drain hose

(carburetor)6 Fuel drain hose (carburetor)7 Fuel overflow hose (fuel tank)

A Pass the brake cable 2 thoughthe holder and clamp to thecrankcase.

B Pass the air vent hose, coolantdrain hose, and fuel drain

hose through the “U” clampon the holder.

C Put the lock of the band to thecenter from the line “a”.

D Pass the drain hose throughthe clamp (spring hook).

E Pass the overflow hoses fromthe filler neck and the fuel tankthrough the clamp.

F Pass the brake cable 2 throughthe guide ring.

G Pass the overflow hose fromthe tank through the clamp inside the frame pipe.

H Band the throttle cable to theframe, noting the banddirection.

2-25

CABLE ROUTING SPEC

1 Steering head pipe2 Brake cable 23 Mainharness4 Downtube5 Throttle cable6 Radiator7 Stay 1

A Pass the brake cable 2 thoughthe clamp on the handlebarholder.

B Band the brake cable 2 to thesteering head pipe, noting theband direction. (view A)

C Band the throttle cable and theright mainharness to the

downtube, noting the banddirection. (view B)

D Band the brake cable 2 to theframe at the upper part of theradiator, noting the banddirection. (view C)

E Band the brake cable 2 at theleft front of the steering headpipe and set the rest of theband to the left.

F Set the lock of the band in thisrange.

G Clamp the brake cable in frontof the pipe.

H Put the rest of the band end tothe side.

I Pass the brake cable throughthe guide ring.

J Pass the brake cable 2 throughthe guide on the frame.

K Clamp the brake cable 2 to theframe.(Up and down)Align the locating mark of thebrake cable 2 with the underclamp.

SPEC

CHAPTER 3.PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1. . . . . . . . . . .

COVER AND PANEL 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAIL COVER AND FUEL TANK 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOOTREST BOARD AND LOWER COVER 3-6. . . . . . . . . . . . . . . . . . . . COWLING 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE COVER, METER ASSEMBLY AND LEGSHIELD 3-8. . . . . . .

ENGINE 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE ADJUSTMENT 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . IDLING SPEED ADJUSTMENT 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THROTTLE CABLE ADJUSTMENT 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG INSPECTION 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION TIMING CHECK 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION PRESSURE MEASUREMENT 3-14. . . . . . . . . . . . . . . . ENGINE OIL LEVEL INSPECTION 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . RECOMMENDED ENGINE OIL 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL PRESSURE INSPECTION 3-17. . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OIL REPLACEMENT 3-18. . . . . . . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM INSPECTION 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CLEANING 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE FILTER CLEANING 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT LEVEL INSPECTION 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT REPLACEMENT 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM INSPECTION 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE ADJUSTMENT 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE FLUID LEVEL INSPECTION 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD INSPECTION 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 3-28. . . . . . . . . . . . . . . REAR BRAKE ADJUSTMENT 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SHOE INSPECTION 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD INSPECTION 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSPECTION 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWINGARM INSPECTION 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER INSPECTION 3-33. . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER ADJUSTMENT 3-33. . . . . . . . . . . . . . . . . . . . TIRE INSPECTION 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL INSPECTION 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY INSPECTION 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE INSPECTION 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BEAM ADJUSTMENT 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

INTRODUCTION /PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INSPADJ

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.YP301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

BREAK-IN EVERY

NO. ITEM ROUTINE TYPE1,000 km

6,000 kmor

6 months

12,000 kmor

12 months

1 * Valve clearance Check and adjust valve clearance

when engine is coled— Every 12,000 km

2 Spark plug Check condition. Adjust gap and clean.

Refer toSPARK PLUGINSPECTION

3 * Fuel line Check fuel hose and vacuum pipe

for cracks or damage.—

4 * Idle speed Check and adjust engine idle

speed. Adjust throttle cable free play.

—

5 * Engine oil Replace. Refer to ENGINEOIL INSPECTION Replace Replace every 3,000 km.

6 Oil strainer Clean with solvent. — Clean Clean every 3,000 km.

7 Transmission oil Replace. Same asengine oil Replace Replace every 10,000 km.

8 Air filter Clean with solvent and dampen

with oil.Same asengine oil

9 Crankcase filter Clean with compressed air —

10 Cooling system

Check hose for cracks or damage.Replace if necessary.

—

10 Cooling system

Replace coolant. Ethylene glycolantifreeze Replace every 24 months.

11 *Frontbrake system

Adjust free play. Check and replace if necessary. Replace brake fluid every

24,000km or 24 months.

Brake fluid;DOT 4

12 *Rearbrake system

Adjust lever free play. Check and replace shoes

if necessary.—

13 * Control cables Apply oil lightly. Same asengine oil

14 Brake laver pivot Apply oil lightly. Same asengine oil

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJ

NOTE:

BREAK-IN EVERY

NO. ITEM ROUTINE TYPE1,000 km

6,000 kmor

6 months

12,000 kmor

12 month

15Centerstand andsidestand pivot

Check operation and lubricate.Same asengine oil

16 * Sidestand switch Check and clean or replace if necessary.

—

17 * Front fork Check operation and for

oil leakage.—

18 *Steeringbearings

Check bearing assemblyfor looseness.

—

19 * Wheel bearings Check bearing for smooth rotation —

Items marked with an asterisk (*) require special tools data and technical skills for servicing. Take thescooter to a Yamaha dealer.

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Brake fluid replacement:

1. Replace the brake fluid after disassembling the master cylinder or caliper cylinder.Check the brake fluid level and add fluid as required.

2. Replace the master cylinder and caliper cylinder oil seals every two years.3. Replace the brake hoses every four years, or if cracked or damaged.

3-3

Order Job name/Part name Q’ty Remarks

1234567

8

Side panel and seat removalRear panelSide panel (left)Side panel (right)RivetFront panelClipDamper assembly

Seat

1112121

1

Remove the parts in order.

Install the damper assembly to the bodywith its rod side backward and labels up-ward.

Reverse the removal procedure forinstallation.

NOTE:

COVER AND PANELINSPADJ

COVER AND PANELSIDE PANEL AND SEAT

3-4


123456789

1011

Tail cover and fuel tank removalGrab barSeat lock bracketScrewTail coverFuel tank capFuel overflow hoseCoverFuel tank coverCoupler (fuel sender lead)

Fuel overflow hoseFuel hose

112111111

11


Tail cover

Fuel tank

Disconnect the couplers.NOTE:

10 Nm (1.0 mkg)

7 Nm (0.7 mkg)

7 Nm (0.7 mkg)


TAIL COVER AND FUEL TANK

3-5



121314

Vacuum hoseBracketFuel tank

111


Fuel tank

10 Nm (1.0 mkg)

7 Nm (0.7 mkg)

7 Nm (0.7 mkg)

3-6


123456789

10111213

Footrest board and lower coverremovalMat (footrest board) (left /right)Cover 2Battery negative (-) leadBattery positive (+) leadBatteryFlasher relayStarter relayReservoir tankFootrestLidBoxLower coverFootrest board

1/1111111121111



7 Nm (0.7 mkg)


FOOTREST BOARD AND LOWER COVER

3-7


1234567

Cowling removalUpper coverWind screenInner panelCowling bodyCoupler (headlight lead)Coupler (front flasher light lead (left))Coupler (front flasher light lead (right))

111111



Disconnect the couplers.NOTE:

7 Nm (0.7 mkg) 7 Nm (0.7 mkg)


COWLING

3-8


1234567

Handle cover, meter assembly andlegshield removalHandle coverCoupler (meter lead)Meter cableMeter assemblyMain switch coverCoverLegshield

1112121


Disconnect the couplers.


NOTE:


HANDLE COVER, METER ASSEMBLY AND LEGSHIELD

3-9

VALVE CLEARANCE ADJUSTMENTINSPADJ

NOTE:

*****************************************************

*****************************************************

YP303004

ENGINEVALVE CLEARANCE ADJUSTMENT

Valve clearance adjustment should be madewith the engine cool, at room temperature.When the valve clearance is to be measured oradjusted, the piston must be at Top Dead Cen-ter (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. Remove: Spark plug Valve cover (intake side) Valve cover (exhaust side)

4. Remove: Timing check plug

5. Measure: Valve clearance

Out of specification Adjust.

Valve clearance (cold):Intake valve 0.08 0.12 mmExhaust valve 0.16 0.20 mm

Measurement steps: Rotate the primary fixed sheave counter-

clockwise to align the slit a on the rotor withthe stationary pointer b on the crankcover 1when the piston is Top Dead Center (TDC).

Measure the valve clearance by using a feel-er gauge.Out of specification Adjust clearance.

3-10

VALVE CLEARANCE ADJUSTMENT/IDLING SPEED ADJUSTMENT

INSPADJ

*****************************************************

*****************************************************

14 Nm (1.4 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

18 Nm (1.8 mkg)

7 Nm (0.7 mkg)

6. Adjust: Valve clearance

Adjustment steps: Loosen the locknut 1 . Turn the adjuster 3 in or out with the valve

adjusting tool 2 until specified clearance isobtained.

Turning in Valve clearance isdecreased.

Turning out Valve clearance isincreased.

Valve adjusting tool:90890-01311

Hold the adjuster to prevent it from movingand tighten the locknut.

Measure the valve clearance. If the clearance is incorrect, repeat above

steps until specified clearance is obtained.

7. Install: Valve cover (intake side) 1 O-ring 2

8. Install: Valve cover (exhaust side)

O-ring Spark plug Timing check window screw Crankcase filter element Crankcase filter cover seal Crankcase filter cover

YP303022

IDLING SPEED ADJUSTMENT1. Start the engine and let it warm up for sev-

eral minutes.2. Attach:

Inductive tachometer to the spark pluglead.

Inductive tachometer:90890-03113

3-11

IDLING SPEED ADJUSTMENT/THROTTLE CABLE ADJUSTMENT

INSPADJ

*****************************************************

*****************************************************

NOTE:

*************************************

NOTE:

3. Check: Engine idling speed


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 num-

ber of turns.

Pilot screw:1-7/8 turns out

Turn the throttle stop screw 2 in or out untilthe specified idling speed is obtained.

Turning in Idling speed is increased.

Turning out Idling speed is decreased.

5. Adjust: Throttle cable free play

Refer to “THROTTLE CABLE FREEPLAY ADJUSTMENT” section.

YP303032

THROTTLE CABLE ADJUSTMENT

Prior to adjusting the throttle cable free play, theengine idling speed should be adjusted.

1. Check: Throttle cable free play a


Free play (throttle cable):3 5 mm at throttle grip flange

2. Adjust: Throttle cable free play

Adjustment steps:

Never accelerate the throttle when stopping theengine.

3-12

THROTTLE CABLE ADJUSTMENT/SPARK PLUG INSPECTION

INSPADJ

*****************************************************

CAUTION:

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 theright and to the left to ensure that this doesnot cause the engine idling speed tochange.

EB303040

SPARK PLUG INSPECTION1. Remove:

Spark plug cap Spark plug

Before removing the spark plug, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinder.

1. Check: Spark plug type

Incorrect Replace.

Standard spark plug:DR8EA (NGK)

2. Inspect: Electrode 1

Wear/damage Replace. Insulator 2

Abnormal color Replace.Normal color is a medium-to-light tan col-or.

2. Clean: Spark plug

(with spark plug cleaner or wire brush)3. Measure:

Spark plug gap a

(with a wire gauge)Out of specification Adjust gap.

3-13

SPARK PLUG INSPECTION/IGNITION TIMING CHECK

INSPADJ

18 Nm (1.8 mkg)

NOTE:

NOTE:

*****************************************************

*****************************************************

Spark plug gap:0.6 0.7 mm

6. Install: Spark plug

Before installing a spark plug, clean the gasketsurface and plug surface.

YP303052

IGNITION TIMING CHECK

Prior to checking the ignition timing, check allelectrical connections related to the ignitionsystem. Make sure all connections are tight andfree of corrosion and that all ground connec-tions are tight.

1. Remove: Timing check plug

2. Attach: Timing light 1

Engine tachometer 2(to the spark plug lead)

Timing light:90890-03141

Engine tachometer:90890-03113

3. Check: Ignition timing

Checking steps: Start the engine and let it warm up for several

minutes. Let the engine run at the specifiedspeed.

Engine idling speed:1,450 1,550 r/min

Visually check the stationary pointer a toverify it is within the required firing range bindicated on the flywheel.Incorrect firing range Check the ignitionsystem.

3-14

IGNITION TIMING CHECK/COMPRESSION PRESSURE MEASUREMENT

INSPADJ

NOTE:

NOTE:

CAUTION:

Ignition timing is not adjustable.

3. Install: Timing check plug

YP303060

COMPRESSION PRESSUREMEASUREMENT

Insufficient compression pressure will result inperformance loss.

1. Remove: Side panels

Refer to “COVER AND PANEL” section.2. Check:

Valve clearanceOut of specification Adjust.Refer to “VALVE CLEARANCE AD-JUSTMENT” section.

3. Start the engine and let it warm up for sev-eral minutes.

4. Turn off the engine.5. Remove:

Spark plug

Before removing the spark plug, use com-pressed air to blow away any dirt accumu-lated in the spark plug well to prevent it fromfalling into the cylinder.

6. Attach: Compression gauge 1

Compression gauge:90890-03081

7. Measure: Compression pressure

If it exceeds the maximum pressure al-lowed Inspect the cylinder head, valvesurfaces and piston crown for carbon de-posits.If it is below the minimum pressure Squirt a few drops of oil into the affectedcylinder and measure again.

Follow the table below.

3-15

COMPRESSION PRESSURE MEASUREMENT/ENGINE OIL REPLACEMENT

INSPADJ

*****************************************************

*****************************************************

18 Nm (1.8 mkg)

NOTE:

Compression pressurep p(With oil applied into cylinder)

Reading Diagnosis

Higher thanwithout oil

Worn or damaged pistons

Same aswithout oil

Possible defective ring(s),valves,cylinder head gasket orpiston Repair.

Compression pressure (at sea level):Standard:

1,400 kPa (14 kg/cm 2, 14 bar)Minimum:

1,120 kPa (11.2 kg/cm 2, 11.2 bar)

Measurement steps: Crank the engine with the throttle wideopen

until the reading on the compression gaugestabilizes.

Before cranking the engine, ground allspark plug leads to prevent sparking.

8. Install: Spark plug

9. Install: Side panels

Refer to “COVER AND PANEL” section.YP303070

ENGINE OIL LEVEL INSPECTION1. Stand the scooter on a level surface.

Make sure the scooter is upright when inspect-ing the oil level.

2. Start the engine and let it warm up for a fewminutes.

3. Turn off the engine.4. Inspect:

Engine oil levelOil level should be between maximum 1and minimum 2 marks.Oil level is below the minimum mark Add oil up to the proper level.

3-16

ENGINE OIL LEVEL INSPECTION/ENGINE OIL REPLACEMENT

INSPADJ

CAUTION:

NOTE:

32 Nm (3.2 mkg)

NOTE:

RECOMMENDED ENGINE OILRefer to the chart for selection of the oils suitedto the atomosperic temperature.

API STANDARD:API SE or higher grade

Do not put in any chemical sdditives oruse oils with a grade of CD a or higher.

Be sure not to use oils labeled “ENERGYCONSERVING II” b or higher. Engine oilalso lubricates the clutch and additivescould cause clutch slippage.

Be sure no foreign material enters thecrankcase.

5. Start the engine and let it warm up for a fewminutes.

6. Turn off the engine.

Wait a few minutes until the oil settles before in-specting the oil level.

YP*****

ENGINE OIL REPLACEMENT1. Start the engine and let it warm up for sev-

eral minutes.2. Turn off the engine and place an oil pan un-

der the engine.3. Remove:

Oil filler plug Drain plug 1 Compression spring 2 Oil strainer 3 O-ring

Drain the crankcase of its oil.4. Install:

O-ring 1 Compression spring 2 Oil strainer 3 Drain plug 4 Oil filler plug

Check the O-ring (drain plug). If damaged, re-place it with a new one.

3-17

ENGINE OIL REPLACEMENT/ENGINE OIL PRESSURE INSPECTION

INSPADJ

*************************************

*****************************************************

NOTE:

*****************************************************

5. Fill: Crankcase

Oil quantity:1.4L

6. Check: Engine oil level

Refer to “ENGINE OIL LEVEL INSPEC-TION” 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 in-

dicator light will go off.

If the oil is changed before the oil indicator lightcomes on (i.e. before the 3,000 km oil changeinterval is reached), be sure to reset the oil indi-cator light after changing the oil, so that it willcome on at the correct time to indicate the next3,000 km oil replacement.To reset the oil indicator light before it comes on:Release the reset button and the oil indicatorlight will come on for 1.4 seconds.

YP*****

ENGINE OIL PRESSURE INSPECTION1. Remove:

Side panelsRefer to the “COVER AND PANEL” sec-tion.

2. Inspect: Oil pressure

Inspection steps: Slightly loosen the oil check bolt 1 . Start the engine and keep it idling until the oil

begins to seep from the oil check bolt.If no oil comes out after one minute, turn theengine off so it will not seize.

Check oil passages and oil pump for damageor leakage.

3-18

ENGINE OIL PRESSURE INSPECTION/TRANSMISSION OIL REPLACEMENT

INSPADJ

10 Nm (1.0 mkg)

CAUTION:

*****************************************************

NOTE:

NOTE:

22 Nm (2.2 mkg)

CAUTION:

Start the engine after solving the problem(s),and recheck the oil pressure.

Tighten the oil check bolt to specification.

Start the engine and check the oil pres-sure with the oil check bolt loosened.

Do not apply at high speeds more thanspecified when checking the pressure.

Wipe any spilled oil off the engine.

YP******

TRANSMISSION OIL REPLACEMENT

Make sure the scooter is upright when replacingthe oil.

1. Stand the scooter on a level surface.2. Start the engine for several minutes to

warm it up and then stop.3. Place an oil pan under the crankcase.4. Remove:

Oil filler cap Drain bolt 1

Drain the oil.5. Tighten:

Drain bolt 6. Fill:

Crankcase

Recommended oil:SAE 10W30 motor oil

Oil quantity:0.25 L

Wipe any spilled oil off the tire or the wheel.

3-19

TRANSMISSION OIL REPLACEMENT/EXHAUST SYSTEM INSPECTION/AIR FILTER CLEANING

INSPADJ

20 Nm (2.0 mkg)

53 Nm (5.3 mkg)

20 Nm (2.0 mkg)

CAUTION:

7. Install: Oil filler cap 1 O-ring 2

8. Start the engine for several minutes towarm it up and check for the oil leakage.

YP*****

EXHAUST SYSTEM INSPECTION1. Remove:

Side panelsRefer to “COVER AND PANEL” section.

2. Inspect: Nut 1 (exhaust pipe)

Loose/Damage Tighten/replace. Gasket (exhaust pipe)

Exhaust gas leaks Tighten/replace.3. Inspect:

Bolt 2 (muffler) Connecting bolt 3 (muffler)

Loose/Damage Tighten/replace.

YP303123

AIR FILTER CLEANING1. Remove:

Side panels Air filter case cover

Refer to “COVER AND PANEL” section.2. Remove:

Air filter element 1

Never operate the engine without the air fil-ter element installed. Unfiltered air willcause rapid wear of engine parts and maydamage the engine. Operating the enginewithout the filter element will also affect thecarburetor tuning, leading to poor engineperformance and possible overheating.

3-20

AIR FILTER CLEANING/CRANKCASE FILTER CLEANING

INSPADJ

NOTE:

CAUTION:

7 Nm (0.7 mkg)

NOTE:

3. Inspect: Air filter element

Damaged Replace.4. Clean:

Air filter element 1Use solvent to clean the element

After cleaning, remove the remaining solvent bysqueezing the element.

Do not twist the element when squeezingthe element.

5. Apply the recommended oil to the entiresurface of the filter and squeeze out the ex-cess oil. The element should be wet but notdripping.

Recommended oil:Engine oil

Never use low flash point solvents such asgasoline to clean the air filter element. Suchsolvents may cause a fire or an explosion.

6. Install: Air filter element Air filter case cover Side panels

Refer to “ENGINE REMOVAL” section inchapter 4.

YP******

CRANKCASE FILTER CLEANING1. Remove:

Crankcase filter cover 1 Crankcase filter cover seal Crankcase filter element 2

When installing the element in its case, besureits sealing surface matches the sealing surfaceof the case so there is no air leak.

2. Inspect: Crankcase filter element

Damaged Replace.

3-21

CRANKCASE FILTER CLEANING/COOLANT LEVEL INSPECTION

INSPADJ

CAUTION:

7 Nm (0.7 mkg)

NOTE:

CAUTION:

NOTE:

This element is a dry type.Be careful not to stain with grease or water.

3. Clean: Crankcase filter element 1

Blow out the dust in the element from theouter surface using compressed air.

4. Install: Crankcase filter element Crankcase filter cover seal Crankcase filter cover

YP303170

COOLANT LEVEL INSPECTION

Make sure the scooter is upright when inspect-ing the coolant level.

1. Stand the scooter on a level surface.2. Stand the scooter on its centerstand.3. Inspect:

Coolant levelCoolant level should be between themaximum a and minimum b marksCoolant level is below the “LOWER” levelline Add soft water (tap water) up tothe proper level.

Hard water or salt water is harmful to engineparts. Use only distilled water if soft water isnot available. If you use tap water, make sureit is soft water.


5. Turn off the engine and inspect the coolantlevel again.

Wait a few minutes until the coolant settles be-fore inspecting the coolant level.

3-22

COOLANT REPLACEMENTINSPADJ

NOTE:

YP303180

COOLANT REPLACEMENT1. 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 capand drain the coolant.

Do not remove the radiator cap when the en-gine and radiator are hot. Scalding hot fluidand steam may be blown out under pres-sure, which could cause serious injury.When the engine has cooled, open the radia-tor cap as follows:Place a thick rag or a towel over the radiatorcap. Slowly rotate the cap counterclockwisetoward the detent. This allows any residualpressure to escape. When the hissing soundhas stopped, press down on the cap whileturning counterclockwise and remove it.

Remove the radiator cap after removing thedrain bolt.

Place the scooter upright on a level surfacewhen draining the coolant completely.

4. Clean: Radiator

Fill soft water into the filler neck support1 (reservoir tank).

3-23


10 Nm (1.0 mkg)

*****************************************************

5. Install: Gasket 1 Drain bolt 2

6. Loosen: Screw 1 (carburetor bleed)

7. Connect: Hose (reservoir tank)

8. Fill: Radiator

(to specified level 1 )Fill the coolant slowly, until the coolantcomes out from the carburetor drainpipe.

Reservoir tank(to maximum level a )

Recommended coolant:High quality ethylene glycolanti-freeze containingcorrosion inhibitors foraluminium engine.

Coolant 2 and water 3 (softwater):

Mixed ratio: 50%/50%Total amount:

1.4 LReservoir tank capacity:

0.35 L

Handling notes for coolant:Coolant is potentially harmful and should behandled with special care.

3-24


*****************************************************

CAUTION:

NOTE:

If coolant splashes in your eyes:thoroughly wash your eyes with waterand consult a doctor.

If coolant splashes on your clothes:quickly wash it away with water and thenwith soap and water.

If coolant is swallowed:quickly make the person who has swal-lowed it vomit and then take him to a doc-tor.

Hard water or salt water is harmful to en-gine parts. Use only distilled water if softwater is not available.

If you use tap water, make sure it is softwater.

Do not use water containing impurities oroil.

Take care that no coolant splashes ontopainted surfaces. If it does, wash themstraightaway with water.

Do not mix different types of ethylene gly-col antifreeze containing corrosion inhib-itors for aluminum engines.

9. Tighten: Screw (carburetor bleed)

Fill the coolant slowly to the specified lev-el.

10. Install: Radiator cap


12. Stop the engine and inspect the level.Refer to “COOLANT LEVEL INSPECTION”section.

Wait a few minutes until the coolant settles be-fore inspecting the coolant level.

13. Install: Fuel tank Side panels

Refer to “COVER AND PANEL” section.

3-25

COOLING SYSTEM INSPECTIONINSPADJ

YP303190

COOLING SYSTEM INSPECTION1. Inspect:

Radiator 1 Filler hose (radiator) 2 Outlet hose (radiator) 3 Pipe Outlet hose (radiator) 4

Cracks/Damage Replace.Refer to “COOLING SYSTEM” section inchapter 5.

3-26

FRONT BRAKE ADJUSTMENTINSPADJ

***************************************************

*****************************************************

CAUTION:

EB304002

CHASSISFRONT BRAKE ADJUSTMENT

1. Check: Brake lever free play a


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 speci-

fied free play is obtained.

Turning in Free play is decreased.

Turning out Free play is increased.

Tighten the locknut.

Make sure that there is no brake drag afteradjusting the front brake lever free play.

A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. This air must be removed by bleed-ing the brake system before the motorcycleis operated. Air in the brake system will con-siderably reduce braking performance andcould result in loss of control and possiblyan accident. Inspect and bleed the brakesystem if necessary.

3-27

BRAKE FLUID LEVEL INSPECTIONINSPADJ

NOTE:

NOTE:

CAUTION:

YP304020

BRAKE FLUID LEVEL INSPECTION1. Stand the scooter on a level surface.

Make sure the scooter is upright when inspect-ing the brake fluid level.

2. Stand the scooter on its centerstand.3. Inspect:

Brake fluid levelBrake fluid level is below the “LOWER”level line a Fill to proper level.

Recommended brake fluid:DOT#4

For a correct reading of the brake fluid level,make sure the top of the handlebar brakefluid reservoir is horizontal.

If DOT#4 is not available, DOT#3 can beused.

Brake fluid may corrode painted surfaces orplastic parts. Always clean up any split fluid im-mediately.

Use only the designated brake fluid. Otherfluids may deteriorate the rubber seals,causing leakage and poor brake perfor-mance.

Refill with the same type of fluid. Mixingfluids may result in a harmful chemicalreaction leading to poor brake perfor-mance.

Be careful that water does not enter thebrake fluid reservoir during refilling. Wa-ter will significantly lower the boilingpoint of the fluid and may cause vaporlock.

Administrateur

Note


3-28

BRAKE PAD INSPECTION/AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

INSPADJ

*****************************************************

YP304030

BRAKE PAD INSPECTION1. Operate the brake lever.2. Inspect:

Brake pad (front)Wear indicators 1 almost touch thebrake disc Replace the brake pads asa set.Refer to “FRONT AND REAR BRAKE” inCHAPTER 7.

YP304070

AIR BLEEDING(HYDRAULIC BRAKE SYSTEM)

Bleed the brake system whenever: The system is disassembled A brake hose is loosened or removed The brake fluid level is very low Brake operation is faultyLoss of braking performance may occur ifthe brake system is not properly bled.

1. Bleed: Brake system

Air bleeding steps:a. Fill the reservoir with the proper brake fluid.b. Install the diaphragm. Be careful not to spill

any fluid or allow the reservoir to overflow.c. Connect a clear plastic hose 1 tightly to the

caliper bleed screw 2 .d. Place the other end of the hose into a con-

tainer.e. Slowly apply the brake lever several times.f. Pull the lever in. Hold the lever in position.g. Loosen the bleed screw and allow the lever

to travel towards its limit.h. Tighten the bleed screw when the lever limit

has been reached, then release the lever.i. Repeat steps (e) to (h) until all air bubbles

have disappeared from the brake fluid.

3-29

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/REAR BRAKE ADJUSTMENT

INSPADJ

NOTE:

6 Nm (0.6 mkg)

NOTE:

*****************************************************

*****************************************************

When bleeding the brake system, make surethat there is always enough brake fluid in thebrake fluid reservoir before applying the brakelever. Ignoring this precaution could allow air toenter the brake system, considerably lengthen-ing the bleeding procedure.

j. Tighten the bleed screw. Bleed screw

If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours. Repeat thebleeding procedure when the tiny bubbles in thebrake system have disappeared.

k. Fill the brake fluid reservoir to the properlevel.

Refer to “BRAKE FLUID LEVEL IN-SPECTION”.

Check brake operation after bleeding the brakesystem.

YP******

REAR BRAKE ADJUSTMENT1. Check:

Brake lever free play 1 (rear)Out of specification Adjust.

Free play:10 20 mm

2. Adjust: Brake lever free play

Adjustment steps:Handlebar side: Loosen the locknut (s) 1 . Turn the adjuster (s) 2 in or out until the spe-

cified free play is obtained.

Turning in Free play is increased.

Turning out Free play is decreased.

3-30

REAR BRAKE ADJUSTMENT/BRAKE SHOE INSPECTION/STEERING HEAD INSPECTION

INSPADJ

CAUTION:

*****************************************************

NOTE:

Tighten the locknut (s).Rear wheel side: Turn the adjuster 3 in or out until the speci-

fied free play is obtained.

Turning in Free play is decreased.

Turning out Free play is increased.

Make sure that the brake does not drag afteradjusting it.

YP304040

BRAKE SHOE INSPECTION1. Operate the brake lever.2. Inspect:

Brake shoesWear indicator 1 reaches the wear limitline 2 Replace the brake shoes as aset.Refer to “REAR WHEEL” in CHAPTER6.

YP304130

STEERING HEAD INSPECTION

Securely support the scooter so that there is nodanger of it falling over.

1. Stand the scooter on a level surface.

Stand the scooter on its centerstand.

2. Elevate the front wheel by placing a suit-able stand under the engine.

3. Check: Steering assembly bearings

Grasp the bottom of the lower front forktubes and gently rock the fork assembly.Looseness Adjust the steering head.

4. Remove: Handlebar cover

Refer to “COVER AND PANEL” section. Handlebar

Refer to “HANDLEBAR” section in chap-ter 7.

3-31

STEERING HEAD INSPECTIONINSPADJ

*****************************************************

38 Nm (3.8 mkg)

NOTE:

22 Nm (2.2 mkg)

5. Remove: Handlebar lower holder Woodruff key

Refer to “STEERING” section in chapter7.

6. Adjust: Steering head

Adjustment steps: Remove the ring nut (upper) 1 , lock washer

2 , the ring nut (center) 3 and the rubberwasher.

Loosen the ring nut 4 (lower). Tighten the ring nut (lower) using the ring nut

wrench 5 .

Set the torque wrench at right angles to the ringnut wrench.

Ring nut wrench:90890-01403

Loosen the ring nut (lower) 4 completely,then tighten it to specification.

Do not overtighten.

Check the steering head for looseness orbinding by turning it all the way in both direc-tions. If it binds, remove the steering stem as-sembly and inspect the steering bearings.Refer to “STEERING HEAD” in CHAPTER 7.

Install the rubber washer. Install the ring nut (center) 2 . Finger tighten the ring nut (center), then align

the slots of both ring nuts. If necessary, holdthe ring nut (lower) 1 and tighten the ring nut(center) 2 until their slots are aligned.

3-32

STEERING HEAD INSPECTION/FRONT FORK INSPECTION

INSPADJ

NOTE:

75 Nm (7.5 mkg)

*****************************************************

Install the lock washer 1 .

Make sure the lock washer tabs sit correctly inthe ring nut slots.

Hold the ring nut (under and center), usingthe exhaust and ring nut wrench, and tightenthe ring nut (upper) using the ring nut wrench.

Exhaust and ring nut wrench:90890-01268

8. Install: Woodruff key Handlebar lower holder

Refer to “STEERING” section in CHAP-TER 7.

HandlebarRefer to “HANDLEBER” section inCHAPTER 7.

9. Install: Handlebar cover


FRONT FORK INSPECTION

Securely support the scooter so that there is nodanger of it falling over.

1. Stand the scooter on a level surface.2. Check:

Inner tubeScratches/damage Replace.

Oil sealExcessive oil leakage Replace.Hold the scooter upright and apply thefront brake.

3. Check: Operation

Push down hard on the handlebars sev-eral times.Unsmooth operation Repair.Refer to “FRONT FORK” in CHAPTER 7.

3-33

SWINGARM INSPECTION/REAR SHOCK ABSORBER INSPECTION/

REAR SHOCK ABSORBER ADJUSTMENTINSPADJ

40 Nm (4.0 mkg)

16 Nm (1.6 mkg)

NOTE:

YP*****

SWINGARM INSPECTION

Securely support the scooter so there is nodanger of it falling over.

1. Place the scooter on the level place.2. Check:

OperationGrasp the end of the swingarm and gent-ly rock the swingarm assembly back andforth.Unsmooth operation Repair.Refer to “REAR SHOCK ABSORBERAND SWINGARM” section in CHAPTER7.

YP******

REAR SHOCK ABSORBER INSPECTION1. Remove:

Side panel Fuel tank Box

Refer to “COVER AND PANEL” section.2. Check:

Rear shock absorber mountLooseness Tighten.Bolt (upper) 1Bolt (lower) 2Refer to “REAR SHOCK ABSORBERAND SWINGARM” section in chapter 7.

YP304160

REAR SHOCK ABSORBER ADJUSTMENT

Always adjust each rear shock absorberpreload to the same setting. Uneven ad-justment can cause poor handling andloss of stability.

Securely support the scooter so there isno danger of it falling over.

1. Adjust: Spring preload

Turn the adjuster ring 1 to direction a

or b .

Use the special wrench included in the owner’stool kit to adjust the spring preload.

3-34

REAR SHOCK ABSORBER ADJUSTMENT/TIRE INSPECTION

INSPADJ

*****************************************************

b

a

CAUTION:

*****************************************************

Adjustment steps: Turn the adjuster ring in or out.

Turning toward Spring preload isincreased.

Turning toward Spring preload isdecreased.

Hard Standard Soft

Adjustingposition:

5 4 3 2 1

Never turn the adjuster beyond the maximumor minimum setting.

Always adjust each shock absorber to thesame setting.

EB304171

TIRE INSPECTION1. Measure:

Tire inflation pressureOut of specification Adjust.

Tire inflation pressure should only bechecked and adjusted when the tire tem-perature equals the ambient air tempera-ture. Tire inflation pressure and suspen-sion must be adjusted according to thetotal weight of the cargo, rider, passengerand accessories (fairing, saddlebags, etc.if approved for this model), and accordingto whether the scooter will be operated athigh speed or not.NEVER OVERLOAD THE SCOOTER.

Operation of an overloaded scooter couldcause tire damage, accident or injury.

3-35

TIRE INSPECTIONINSPADJ

Basic weight: With oil and full fuel tank

158 kg

Maximum load* 197 kg

Cold tire pressure Front Rear

Up to 90 kg load* 175 kPa(1.75 kg/cm 2, 1.75 bar)

200 kPa(2.0 kg / cm 2, 2.0 bar)

90 kg maximum. load*

200 kPa(2.0 kg / cm 2, 2.0 bar)

225 kPa(2.25 kg/cm 2, 2.25 bar)

High speedriding

200 kPa(2.0 kg / cm 2, 2.0 bar)

250 kPa(2.50 kg/cm 2, 2.50 bar)

*Load is the total weight of the cargo, rider,passenger and accessories.2. Inspect:

Tire surfacesWear/damage Replace.

Minimum tire tread depth(front and rear):

1.6 mm

1 Tread depth2 Side wall3 Wear indicator

It is dangerous to ride with a worn-out tire.When the tire tread begins to show signsof wear, replace the tire immediately.

Do not use tubeless tires on a wheel de-signed for tube type tires only. Tire failureand personal injury may result from sud-den deflation.

Tube type wheel Tube type tire onlyTubeless type wheel Tube type or

tubeless tire.

Be sure to install the correct tube whenusing tube type tires.

After extensive tests, the tires listed be-low have been approved by Yamaha Mo-tor Co., Ltd. for this model. No guaranteeconcerning handling characteristics canbe given if a tire combination other thanone approved by Yamaha is used on thisscooter. The front and rear tires shouldalways be by the same manufacturer andof the same design.

3-36

TIRE INSPECTION/WHEEL INSPECTIONINSPADJ

NOTE:

FRONT:

Manufacture Size Type

IRC 110/90-12 64J MB61

CHENG SHIN 110/90-12 64J C922

REAR:

Manufacture Size Type

IRC 130/70-12 62L MB61

CHENG SHIN 130/70-12 62L C940

After mounting a tire, ride conservatively fora while to give the tire time to seat itselfproperly in the rim. Failure to do so couldlead to an accident with possible injury tothe rider or damage to the scooter.

2. After a tire repair or replacement, besure totighten the valve stem locknut 1 to specifi-cation.

EB304180

WHEEL INSPECTION1. Inspect:

WheelsDamage/Bends Replace.

Always balance the wheel when a tire or wheelhas been changed or replaced.

Never attempt to make any repairs to thewheel.

3-37

BATTERY INSPECTIONINSPADJ

NOTE:

CAUTION:

YP305000

ELECTRICALBATTERY INSPECTION

Since the MF battery is a sealed type battery, itis not possible to measure the specific gravity ofthe electrolyte in order to check the charge stateof the battery. Therefore the charge of the bat-tery has to be checked by measuring the volt-age at the battery terminals.

CHARGING METHOD This is a sealed type battery. Never re-

move the sealing caps. If the sealing capshave been removed, the balance will notbe maintained and battery performancewill deteriorate.

Charging time, charging current andcharging voltage for the MF battery aredifferent from those of batterie of generaltype.

The MF battery should be charged as ex-plained in “CHARGING METHOD”. if thebattery is overcharged, the electrolytelevel will drop considerably. Therefore,take special care when charging the bat-tery.

Battery electrolyte is dangerous; it containssulfuric acid which is poisonous and highlycaustic. Always follow these preventive mea-

sures: Avoid bodily contact with electrolyte as it

can cause severe burns or permanent eyeinjury.

Wear protective eye gear when handlingor working near batteries.

Antidote (EXTERNAL): SKIN-Flush with water. EYES-Flush with water for 15 minutes and

get immediate medical attention.Antidote (INTERNAL): Drink large quantities of water or milk fol-

lowed with milk of magnesia, beaten eggor vegetable oil. Get immediate medicalattention.

3-38

Volt meter

Relationship between open-circuit voltage and charging time at 20C(68F)

*This varies depending on the temperature, the state ofcharge in battery plates and the electrolyte level.

Charging timeHours

Ope

n-ci

rcui

t vol

tage


CAUTION:

*****************************************************

NOTE:

Batteries generate explosive hydrogengas. Always follow the following preven-tive measures:

Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or

open flames (e.g., welding equipment,lighted cigarettes, etc.)

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTE OUTOF REACH OF CHILDREN.

1. Remove: Mat (right) Cover (battery case)

Refer to “COVER AND PANEL” section.2. Disconnect:

Battery leads

Disconnect the negative lead 1 first andthen disconnect the positive lead 2 .

3. Remove: Battery

4. Check: Battery condition

Battery condition checking steps: Connect a digital voltmeter to the battery ter-

minals.

Tester (+) lead Battery (+) terminalTester (-) lead Battery (-) terminal

The charge state of an MF battery can bechecked by measuring the open-circuit voltage(i.e. the voltage when the positive terminal isdisconnected).

Open circuit voltage Charging time

12.8 V or more No charging is neces-sary.

3-39


Ope

n-ci

rcui

t vol

tage

(V

)

Condition of charge in battery (%)

Ambienttemperature20C (68F)

Ope

n-ci

rcui

t vol

tage

(V

)

Charging Ambient temperature20C (68F)

Check the Open-circuit voltageTime (Minutes)

*****************************************************

CAUTION:

Check the condition of the battery using thecharts.

Example:Open-circuit voltage = 12.0 VCharging time = 6.5 hoursCharge condition of the battery = 20 30%

5. Charging method for MF batteries

If it is impossible to set the standardcharging current, be careful not to over-charge.

When charging the battery, be sure to re-move it from the motorcycle. (If charginghas to be done with the battery mountedon the motorcycle, be sure to disconnectthe wire at the negative terminal.)

Never remove the sealing caps of an MFbattery.

Make sure that the charging clips are infull contact with the terminal and that theyare not shorted together. (A corroded clipon the charger may cause the battery togenerate heat in the contact area. A weakclip spring may cause sparks.)

Before removing the clips from the bat-tery terminals, be sure to turn off the char-ger’s power switch.

The open-circuit voltage variation for theMF battery after charging is shown below.As shown in the figure, the open-circuitvoltage stabilizes about 30 minutes aftercharging has been completed.

Therefore, wait 30 minutes after chargingis completed before measuring the open-circuit voltage.

3-40

Measure the open-circuitvoltage prior to charging.

Connect a charger andAMP meter to the battery,and start charging.

Make sure the current ishigher than the standardcharging current written onthe battery.

By turning the charging voltageadjust dial, set the chargingvoltage at 20 25 V.

Adjust the voltage so that cur-rent is at standard charginglevel.

Monitor the amperage for 3 5 minutes to check if the stan-dard charging current isreached.

Set the timer according to thecharging time suitable for theopen-circuit voltage. Refer tothe “Battery condition check-ing steps” section.

If current does notexceed standardcharging currentafter 5 minutes, re-place the battery.

In case that charging requires more than 5 hours, it is advisable tocheck the charging current after a lapse of 5 hours. If there is anychange in the amperage, readjust the voltage to obtain the standardcharging current.

Measure the battery open-circuit voltage after having left the batteryunused for more than 30 minutes.12.8 V or more-Charging is complete.12.7 V or less-Recharging is required.Under 12.0 V-Replace the battery.

NO

YES

NO

NOTE:Voltage should be measured 30 min-utes after the machine is stopped.

NOTE:Set the changing voltage at 16 17 V.(If the setting is lower, charging will beinsufficient. If too high, the battery willbe over-charged.)

ChargerAMP meter

YES


Charging method using a variable-current (voltage) type charger

3-41

Measure the open-circuitvoltage prior to charging.

Connect a charger andAMP meter to the battery,and start charging.

NOTE:Voltage should be measured 30 min-utes after the machine is stopped.

Make sure the current ishigher than the standardcharging current written onthe battery.

Charge the battery until the battery’scharging voltage is 15 volts.

This type of battery charger cannotcharge the MF battery. A variable volt-age charger is recommended.

Check the open-circuit voltage afterhaving left the battery for 30 minutesafter charging.12.8 V or more-Charging is com-plete.12.7 V or less-Recharging is neces-sary.Under 12 V-Replace the battery.

NOTE:Set the charging time at 20 hours (maxi-mum).

YES NO

Charging method using a constant-current type chargerThis type charger cannot charge the MF battery.

Voltmeter

Charger

AMP meter


Charging method using a constant-voltage type charger

3-42

BATTERY INSPECTION/FUSE INSPECTIONINSPADJ

NOTE:

CAUTION:

CAUTION:

*****************************************************

*****************************************************

NOTE:

6. Inspect: Battery terminals

Dirty terminal Clean with wire brush.Poor connection Correct.

After cleaning the terminals, grease them light-ly.

7. Install: Battery

8. Connect: Battery leads

Connect the positive lead first and then connectthe negative lead.

9. Install: Cover (battery case) Mat (right)


FUSE INSPECTION

Always turn off the main switch when checkingor replacing the fuse. Otherwise, a short circuitmay occur.

1. Remove: Mat (right) Cover (battery case)

Refer to “COVER AND PANEL” section.2. Inspect:

Fuse

Inspection steps: Connect the Pocket tester to the fuse and

check it for continuity.

Set the tester selector to “Ω 1” position.

Pocket tester:90890-03112

If the tester is indicated at ∞. Replace thefuse.

3-43

FUSE INSPECTION/HEADLIGHT BEAM ADJUSTMENTINSPADJ

*****************************************************

*****************************************************

3. Replace: Blown fuse

Replacement steps: Turn off the main switch. Install a new fuse with the proper current rat-

ing. 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 thatspecified. Never use other materials in placeof a fuse. An improper fuse may cause ex-tensive damage to the electrical system,malfunction of lighting and ignition systemsand could possibly cause a fire.

4. Install: Side panel Panels

Refer to “COVER AND PANEL” section.

EB305022

HEADLIGHT BEAM ADJUSTMENT1. Adjust

Headlight beam (vertical)Turn the adjuster 1 in or out.

Turning in Headlight beam moves lower.

Turning out Headlight beam moveshigher.

2. Adjust: Headlight beam (horizontal)

Turn the adjuster 2 in or out.

Turning in Headlight beam movesright.

Turning out headlight beam movesleft.

INSPADJ

CHAPTER 4.ENGINE

ENGINE OVERHAUL 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIREHARNESS AND CABLE 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLTAND ENGINE 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE REMOUNTING 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD REMOVAL 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD INSPECTION 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD INSTALLATION 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT AND ROCKER ARMS 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT AND ROCKER ARM SHAFT REMOVAL 4-12. . . . . . . . . . . . CAMSHAFT INSPECTION 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT AND ROCKER ARM SHAFT INSPECTION 4-13. . . . . . . . . CAMSHAFT AND ROCKER ARM INSTALLATION 4-13. . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVES AND VALVE SPRINGS REMOVAL 4-16. . . . . . . . . . . . . . . . . . . . VALVES AND VALVE SPRINGS INSPECTION 4-16. . . . . . . . . . . . . . . . . VALVE SEAT INSPECTION 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVES AND VALVE SPRINGS INSTALLATION 4-19. . . . . . . . . . . . . . . .

CYLINDER AND PISTON 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON AND PISTONRINGS REMOVAL 4-22. . . . . . . . . . . . . . . . . . . . . . CYLINDER INSPECTION 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON AND PISTON PIN INSPECTION 4-23. . . . . . . . . . . . . . . . . . . . . . PISTON RINGS INSPECTION 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON RINGS, PISTON AND CYLINDER INSTALLATION 4-25. . . . . .

V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 4-27. . . . . . . . . CRANKCASE FILTER COVER AND CRANKCASE

COVER (LEFT) 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 4-28. . . . . . . SECONDARY SHEAVE 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY SHEAVE REMOVAL 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECONDARY SHEAVE AND V BELT REMOVAL 4-31. . . . . . . . . . . . . . . SECONDARY SHEAVE DISASSEMBLY 4-32. . . . . . . . . . . . . . . . . . . . . . . CLUTCH INSPECTION 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V BELT INSPECTION 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEIGHT INSPECTION 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECONDARY SHEAVE INSPECTION 4-33. . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY SHEAVE ASSEMBLY 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECONDARY SHEAVE INSTALLATION 4-34. . . . . . . . . . . . . . . . . . . . . . .

A.C. MAGNETO AND STARTER CLUTCH 4-37. . . . . . . . . . . . . . . . . . . . . . . . MAGNETO COVER AND STATOR COIL 4-37. . . . . . . . . . . . . . . . . . . . . . . A.C. MAGNETO AND STARTER CLUTCH 4-38. . . . . . . . . . . . . . . . . . . . . A.C. MAGNETO AND ROTER REMOVAL 4-39. . . . . . . . . . . . . . . . . . . . . . STARTER DRIVE GEAR INSPECTION 4-40. . . . . . . . . . . . . . . . . . . . . . . . A.C. MAGNETO AND ROTER INSTALLATION 4-40. . . . . . . . . . . . . . . . .

OIL PUMP 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP INSPECTION 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE AND CRANKSHAFT 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT REMOVAL 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT INSPECTION 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT INSTALLATION 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

ENGINE REMOVAL ENG


1234567

Wireharness and cablesremovalSide panelFootrest boardFuel tankDrain the coolant.

Carburetor

Spark plug capThermo unit leadStartor coil /Pick up coil leadStarting motor leadEarth leadAdjusterBrake cable

11

1/11111


Refer to “COVER AND PANEL” section in CHAPTER 3.

Refer to “COOLANT REPLACEMENT”section in CHAPTER 3.

Refer to “CARBURETOR” section inCHAPTER 6.

7 Nm (0.7 mkg)10 Nm (1.0 mkg)

EB400000

ENGINE OVERHAULENGINE REMOVALWIREHARNESS, CABLE

4-2

ENGINE REMOVAL ENG


89

1011

PinCompression springCable holderCable holder

1111

Reverse the removal procedure for installation.

7 Nm (0.7 mkg)10 Nm (1.0 mkg)

4-3

ENGINE REMOVAL ENG


123456789

10

Hoses, air filter, engine mountingbolt and engine removalVacuum hoseCrankcase breather hoseInlet hose (water pump)Outlet hose (cylinder head)Air filter case assemblyBoltSelf locknut/Plane washerBoltBolt /Plane washer/Rod assemblyEngine

111112

1/11

1/2/11


(Rear shock absorber – lower)

Refer to “ENGINE REMOUNTING”section.


32 Nm (3.2 mkg)

19 Nm (1.9 mkg)

7 Nm (0.7 mkg)

64 Nm (6.4 mkg)

HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT AND ENGINE

4-4

ENGINE REMOVAL ENG

NOTE:

64 Nm (6.4 mkg)

32 Nm (3.2 mkg)

YP******

ENGINE REMOUNTINGWhen remounting the engine, reverse the re-moval procedure in job instruction chart.Note the following points:

1. Install:Engine 1Plane washer 2Rod 3

Temporarily install the rod and engine, and thentighten the bolts and nuts to specifications.

2. Tighten:Bolt 1Self locknut (engine and swingarm) 2

4-5

CYLINDER HEAD ENG


123456789

Cylinder head removalDrain the coolant.Side panelFootrest boardFuel tankCarburetorThermo unit leadPlug capCrankcase breather hoseOutlet hose (cylinder head)Vacuum hoseBreather hose (crankcase)Carburetor jointJointO-ring

112111112

Remove the parts in the order.

Refer to “CARBURETOR” section in CHAPTER 6.

Refer to the “COVER AND PANELS” section in CHAPTER 3.

10 Nm (1.0 mkg)22 Nm (2.2 mkg)

60 Nm (6.0 mkg)

8 Nm (0.8 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

CYLINDER HEAD

4-6


101112131415161718192021

Crankcase filter cover/seal/elementPlug/O-ringCam sprocket cover/O-ringValve cover (intake side)/O-ringValve cover (exhaust side)/O-ringTiming chain tensioner assemblyTiming chain tensioner gasketBreather plateCam sprocket/Timing chainCylinder headCylinder head gasketDowel pin

1/1/11/11/11/11/1111

1/1112


Refer to “CYLINDER HEAD REMOVAL AND INSTALLATION” section.

22 Nm (2.2 mkg) 10 Nm (1.0 mkg)

60 Nm (6.0 mkg)

10 Nm (1.0 mkg)

8 Nm (0.8 mkg)

10 Nm (1.0 mkg)

CYLINDER HEAD ENG

4-7

CYLINDER HEAD ENG

NOTE:

NOTE:

NOTE:

NOTE:

YP401030

CYLINDER HEAD REMOVAL1. Align:

“I” mark a on the rotor(with stationary pointer b on the crankcase cover)

Turn the primary sheave counterclockwise witha wrench and align the “I” mark c with the cylin-der head match mark d when the piston is atTDC on the compression stroke.

2. Loosen:Bolt 1

3. Remove:Timing chain tensioner assemblyTiming chain tensioner gasket

4. Remove:Breather plate 2Cam sprocket 3Timing chain 4

Fasten a safety wire to the timing chain toprevent it from falling into the crankcase.

Remove the bolt 1 while holding the rotormounting bolt with a wrench.

5. Remove:Cylinder head

Loosen the nuts in their proper loosening se-quence.

Start by loosening each nut 1/2 turn until allare loose.

YP402000

CYLINDER HEAD INSPECTION1. Eliminate:

Carbon deposits(from combustion chambers)Use a rounded scraper.

Do not use a sharp instrument to avoid damag-ing or scratching: Spark plug threads Valve seats

4-8

CYLINDER HEAD ENG

*****************************************************

*****************************************************

NOTE:

NOTE:

22 Nm (2.2 mkg)

10 Nm (1.0 mkg)

2. Inspect:Cylinder headScratches/damage Replace.

3. Measure:Cylinder head warpageOut of specification Resurface.

Cylinder head warpage:Less than 0.03 mm

Warpage measurement and resurfacementsteps: Place a straightedge and a feeler gauge

across the cylinder head. Measure the warpage.

If the warpage is out of specification, resur-face the cylinder head.

Place a 400 600 grit wet abrasive paper onthe surface plate, and resurface the head us-ing a figure-eight sanding pattern.

Rotate the cylinder head several times for aneven resurfacement.

YP404190

CYLINDER HEAD INSTALLATION1. Install:

Gasket (cylinder head) Dowel pinsCylinder head

Apply engine oil onto the nut threads. Tighten the nuts in a crisscross pattern.

2. Tighten:Nuts (cylinder head) Bolts (cylinder)

4-9

CYLINDER HEAD ENG

*****************************************************

*****************************************************

NOTE:

CAUTION:

3. Install:Cam sprocket 1Timing chain 2

Installing steps: Turn the primary sheave counterclockwise

until the TDC mark a matches the stationarypointer b .

Align the “I” mark c on the cam sprocket withthe stationary pointer d on the cylinderhead.

Fit the timing chain onto cam sprocket andinstall the cam sprocket on the camshaft.

When installing the cam sprocket, keep thetiming chain as tense as possible on the ex-haust side.

Align the match mark c on the cam sprocketwith the stationary pointer d on the cylinderhead.

Align the pin on the camshaft with the slot inthe cam sprocket.

Do not turn the crankshaft during installa-tion of the camshaft. Damage or impropervalve timing will result.

While holding the camshaft, temporarilytighten the bolts.

Remove the safety wire from the timingchain.

4. Install:Breather plate 1Plane washer 2

4-10

CYLINDER HEAD ENG

*****************************************************

*****************************************************

10 Nm (1.0 mkg)

8 Nm (0.8 mkg)

60 Nm (6.0 mkg)

5. Install:Timing chain tensioner

Installation steps: Remove the tensioner cap bolt 1 and

springs 2 . Release the timing chain tensioner one-way

cam 3 and push the tensioner rod 4 all theway in.

Install the tensioner with a new gasket 5onto the cylinder.

Install the springs 2 and cap bolt 1 . Tighten the bolt (with gasket) to the specified

torque.Bolt (chain tensioner) Cap bolt (timing chain tensioner)

6. Tighten:Bolt (cam sprocket)

7. Check:Valve timingOut of alignment Adjust.Refer to the above steps 3 5.

8. Check:Valve clearanceOut of specification Adjust.Refer to the “VALVE CLEARANCE AD-JUSTMENT” section in CHAPTER 3.

4-11

CAMSHAFT AND ROCKER ARMS ENG


123456789

Camshaft and rocker armsremovalCylinder headLock washerPlateRocker arm shaft (intake)Rocker arm shaft (exhaust)Rocker armCamshaftLocknutAdjusterO-ring

111121221


Refer to “CYLINDER HEAD” section.

Refer to “ROCKER ARM AND ROCKER SHAFT REMOVAL AND INSTALLATION” section.

Refer to “CAMSHAFT INSTALLATION”section.


14 Nm (1.4 mkg)

14 Nm (1.4 mkg)

8 Nm (0.8 mkg)

CAMSHAFT AND ROCKER ARMS

4-12


NOTE:

YP******

ROCKER ARM AND ROCKER ARM SHAFTREMOVAL

1. Remove:Rocker arm shaft (intake)Rocker arm shaft (exhaust)

Attach a rocker arm shaft puller bolt 1 andweight 2 to the rocker arm shaft and slide outthe shaft.

Rocker arm shaft puller bolt:90890-01085

Weight:90890-01084

YP402052

CAMSHAFT INSPECTION1. Inspect:

Cam lobesPitting/Scratches/Blue discoloration Replace.

2. Measure:Cam lobes length a and b .Out of specification Replace.

Cam lobes length:Intake:

a 36.545 36.645 mm<Limit: 36.45 mm>

b 30.021 30.121 mm<Limit: 29.92 mm>

Exhaust:a 36.547 36.647 mm

<Limit: 36.45 mm>b 30.067 30.167 mm

<Limit: 29.17 mm>

3. Inspect:Camshaft oil passageStuffed Blow out oil passage with com-pressed the air.

4-13


*****************************************************

*****************************************************

YP402060

ROCKER ARMS AND ROCKER ARMSHAFTS INSPECTION

1. Inspect:Cam lobe contact surface 1Adjuster surface 2Wear/Pitting/Scratches/Blue discolor-ation Replace.

Inspection steps: Inspect the two contact areas on the rocker

arms for signs of unusual wear. Rocker arm shaft hole. Cam-lobe contact surface.

Excessive wear Replace. Inspect the surface condition of the rocker

arm shafts.Pitting/scratches/blue discoloration Re-place or check lubrication.

Measure the inside diameter a of the rockerarm holes.Out of specification Replace.

Inside diameter (rocker arm):12.000 12.018 mm<Limit: 12.030 mm>

Measure the outside diameter b of the rockerarm shafts.Out of specification Replace.

Outside diameter(rocker arm shaft):

11.981 11.991 mm<Limit: 11.995 mm>

YP******

CAMSHAFT AND ROCKER ARM INSTALLATION

1. Lubricate:Camshaft 1

Camshaft:Molybdenum disulfide oil

Camshaft bearing:Engine oil

4-14


8 Nm (0.8 mkg)

NOTE:

NOTE:

NOTE:

CAUTION:

2. Install:Plate 1Look washer 2 Bolt 3

Bend the lock washer tabs along the bolt 3flats.

3. Apply:Molybdenum disulfide oil(onto the rocker arm and rocker arm shaft)

Molybdenum disulfide oil

4. Install:Rocker arm 1Rocker arm shaft 2 (exhaust)

Exhaust:Install the rocker arm shaft (exhaust) complete-ly pushed in.

5. Install:Rocker arm 1Rocker arm shaft 2 (intake)

Intake:Insert the guide shaft (8 mm) 3 into the studbolt hole on the cylinder head to the rocker armshaft (intake).

Do not confuse the installation direction ofrocker arm shaft. Be sure to install thethreaded part facing outward.

4-15

VALVES AND VALVE SPRINGS ENG


1

2345678

Valves and valve springs removalCylinder headRocker arm, rocker arm shaft

Valve cotters

Spring retainerValve spring (inner)Valve spring (outer)Valve (intake)Valve (exhaust)Valve guideSpring seat

4

2221122

Remove the parts in order.Refer to “CYLINDER HEAD” section.Refer to “ROCKER ARM SHAFT ANDROCKER ARMS” section.

Refer to “VALVES AND VALVE SPRINGSREMOVAL/INSTALLATION” section

Refer to “VALVES AND VALVE SPRINGS INSTALLATION” section


VALVES AND VALVE SPRINGS

4-16


NOTE:

CAUTION:

YP401150

VALVES AND VALVE SPRINGS REMOVAL1. Remove:

Valve cotters 1

Attach a valve spring compressor and attach-ment 2 between the valve spring retainer andcylinder head to remove the valve cotters.

Do not compress so much as to avoid dam-age to the valve spring.

Valve spring compressor:90890-04019

Attachment:90890-04108

YP******

VALVES AND VALVE SPRINGS INSPECTION1. Measure:

Valve stem diameterOut of specification Replace.

Valve stem diameter:Intake:

5.975 5.990 mm<Limit: 5.94 mm>

Exhaust:5.960 5.975 mm<Limit: 5.92 mm>

YP402010

2. Measure:Runout (valve stem)Out of specification Replace.

Runout limit:0.01 mm

YP402030

3. Measure:Free length (valve spring)Out of specification Replace.

Valve spring free length:Inner spring:

38.1 mm<Limit: 36.1 mm>

Outer spring:36.93 mm<Limit: 35.0 mm>

4-17


YP402030

4. Measure:Spring tiltOut of specification Replace.

Spring tilt limit:1.7 mm (2.5)

5. Inspect:Spring contact faceWear/Pitting/Scratches Replace.

6. Measure:Valve guide inside diameterOut of specification Replace.

Valve guide inside diameter:Intake:

6.000 6.012 mm<Limit: 6.05 mm>


YP402010

7. Measure:

Stem-to-guide clearance =Valve guide inside diameter –Valve stem diameter

Out of specification Replace the valveguide.

Stem-to-guide clearance limit:Intake:

0.08 mmExhaust:

0.10 mmEB402020

VALVE SEATS INSPECTION1. Eliminate:

Carbon deposits(from the valve face and valve seat)

2. Inspect:Valve seatsPitting/wear Reface the valve seat.

4-18


*****************************************************

*****************************************************

NOTE:

*****************************************************

CAUTION:

3. Measure:Valve seat width aOut of specification Reface the valveseat.

Valve seat width:Intake:

0.9 1.1 mm<Limit: 1.6 mm>


Measurement steps: Apply Mechanic’s blueing dye (Dykem) 1 to

the valve face. Install the valve into the cylinder head. Press the valve through the valve guide and

onto the valve seat to make a clear pattern. Measure the valve seat width. Where the

valve seat and valve face made contact,blueing will have been removed.

If the valve seat is too wide, too narrow, or theseat is not centered, the valve seat must bereplaced.

EB402020

4. Lap:Valve faceValve seat

After replacing the valve seat, valve and valveguide, the valve seat and valve face should belapped.

Lapping steps: Apply a coarse lapping compound a to the

valve face.

Do not let compound enter the gap betweenthe valve stem and the guide.

Apply molybdenum disulfide oil to the valvestem.

Install the valve into the cylinder head.

4-19


NOTE:

NOTE:

*****************************************************

NOTE:

Turn the valve until the valve face and valveseat are evenly polished, then clean off allcompound.

For best lapping results, lightly tap the valveseat while rotating the valve back and forth be-tween your hand.

Apply a fine lapping compound to the valveface and repeat the above steps.

Make sure to clean off all compound from thevalve face and valve seat after every lappingoperation.

Apply Mechanic’s blueing dye (Dykem) b tothe valve face.

Install the valve into the cylinder head. Press the valve through the valve guide and

onto the valve seat to make a clear pattern. Measure the valve seat width c again.

EB404032

VALVES AND VALVE SPRINGS INSTALLATION

1. Deburr:Valve stem endUse an oil stone to smooth the stem end.

2. Apply:Molybdenum disulfide oil(onto the valve stem 3 and oil seal 2 )

Molybdenum disulfide oil

3. Install:Valve spring seat 1Valve stem seal 2 Valve 3(into the cylinder head)

Valve spring (inner) 4Valve spring (outer) 5Spring retainer 6

Install the valve spring with the larger pitch afacing upwards.

b Smaller pitch

4-20


NOTE:

CAUTION:

4. Install:Valve cotters 1

Install the valve cotters while compressing thevalve spring with a valve spring compressor andattachment 2 .

Valve spring compressor:90890-04019


5. Secure the valve cotters onto the valvestem by tapping lightly with a piece of wood.

Do not hit so much as to damage the valve.

4-21


1234

56789

101112

Cylinder and piston removalCylinder headJointO-ringTiming chain guide (exhaust side)Cylinder

Dowel pinCylinder gasketPiston pin circlipPiston pinPistonPiston ring (top)Piston ring (2nd)Side rail /Spacer

1211

2121111

2/1

Remove the parts in order.Refer to “CYLINDER HEAD” section.

Refer to “PISTON RINGS, PISTON AND CYLINDER INSTALLATION” section.

Refer to “PISTON AND PISTON RINGS REMOVAL” section.


Refer to “PISTON RINGS, PISTON AND CYLINDER INSTALLATION” section.

CYLINDER AND PISTON ENG

CYLINDER AND PISTON

4-22


NOTE:

NOTE:

NOTE:

YP******

PISTON AND PISTON RINGS REMOVAL1. Remove:

Piston pin circlip 1Piston pin 2Piston 3

Before removing the piston pin circlip, cover thecrankcase opening with a clean towel or rag toprevent the circlip from falling into the crank-case cavity.

2. Remove:Top ring2nd ringOil ring

When removing the piston ring, open the endgap of the ring by fingers, and push up the otherside of the ring.

YP402100

CYLINDER INSPECTION1. Measure:

Cylinder boreOut of specification Rebore or replace

Measure the cylinder bore with a cylinderbore gauge.

Measure the cylinder bore in parallel to and atright angles to the crankshaft. Then, find theaverage of the measurements.

Cylinder bore:69.000 69.005 mm<Limit: 69.1 mm><Defferance limit between A, Band C: 0.03 mm>

2. Measure:WarpageOut of specification Replace.

Cylinder warpage limit:0.03 mm

4-23


YP******

PISTON AND PISTON PIN INSPECTION1. Measure:

Piston skirt diameterOut 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 cylinderbore measurement.Out of specification Replace the pistonand piston rings as a set.

Piston-to-cylinder clearance:0.02 X 0.04 mm

3. Measure:Piston pin bore diameterOut of specification Replace.

Piston pin bore diameter:17.004 17.015 mm<Limit: 17.045 mm>

4. Measure:Piston pin outside diameterOut of specification Replace.

Piston pin outside diameter:16.991 17.000 mm<Limit: 16.975 mm>

5. Inspect:Piston pinBlue discoloration/groove Clean or re-place.

4-24


NOTE:

NOTE:

NOTE:

YP402111

PISTON RINGS INSPECTION1. Measure:

Side clearanceOut of specification Replace the pistonand the piston rings as a set.

Eliminate the carbon deposits from the pistonring grooves and rings before measuring theside clearance.

Side clearance (piston ring):Top ring:

0.04 0.08 mm<Limit: 0.12 mm>

2nd ring:0.03 0.07 mm<Limit: 0.12 mm>

2. Position:Piston ring(into the cylinder)

Push the ring with the piston crown so that thering will be at a right angle to the cylinder bore.

a 5.0 mm3. Measure:

End gapOut of specification Replace.

You cannot measure the end gap on the expan-der spacer of the oil ring. If the oil ring rails showexcessive gap, replace all three rings.

End gap:Top ring:

0.15 0.30 mm<Limit: 0.45 mm>

2nd ring:0.30 0.45 mm<Limit: 0.70 mm>

Oil ring:0.20 0.70 mm

4-25


NOTE:

NOTE:

EB404184

PISTON RINGS, PISTON AND CYLINDERINSTALLATION

1. Install:Top ring 12nd ring 2Side rails (oil ring) 3Expander spacer (oil ring) 4

Make sure to install the piston rings so thatthe manufactuer’s marks or numbers are lo-cated on the upper side of the rings.

Lubricate pistons and piston rings liberallywith engine oil.

2. Install:Piston 1Piston pin 2Piston pin clip 3

Apply engine oil onto the piston pins. The “” mark a on the piston must face the

exhaust side of the cylinder. Before installing the piston pin clip, cover the

crankcase opening with a clean rag to pre-vent the piston pin clip from falling into thecrankcase.

Make sure to install each piston in its respec-tive cylinder.

3. Install:Gasket (cylinder) Dowel pins

4-26


NOTE:

NOTE:

4. Position:Piston rings

Offset the piston ring end gaps as shown.

a Top ring endb Oil ring end (lower)c Oil ring end (upper)d 2nd ring end

5. Lubricate:Piston outer surfacePiston ringCylinder inner surface

Engine oil

6. Install:Cylinder

Install the cylinder with one hand while com-pressing the piston rings with the other hand.

Pass the timing chain and timing chain guide(exhaust side) through the timing chain cav-ity.

4-27


123456

Crankcase filter cover andcrankcase cover (left)removalSide panel

Crankcase filter coverCrankcase filter cover sealCrankcase filter elementCrankcase cover protectorCrankcase cover (left)Crankcase cover gasket

111111




7 Nm (0.7 mkg)

7 Nm (0.7 mkg)

10 Nm (1.0 mkg)

V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE ENG

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVECRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT)

4-28



123456789

V-belt, clutch and secondary/primary sheave removalNut/Plain washerPrimary fixed sheaveNutClutch housingClutch assemblyV-beltPrimary sliding sheaveCollarPrimary sheave cap

1/111111111


Refer to “PRIMARY SHEAVE REMOVAL” section.Refer to “SECONDARY SHEAVE ANDV-BELT REMOVAL” section.Refer to “SECONDARY SHEAVE INSTALLATION” section.

Refer to “PRIMARY SHEAVE ASSEMBLY” section.

60 Nm (6.0 mkg)

60 Nm (6.0 mkg)

3 Nm (0.3 mkg)

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

*Shell BT grease No. 3 (90890-69927)

4-29


1011121314

CamWeightSliderSpacerOil seal

18441

Refer to “PRIMARY SHEAVE ASSEMBLY” section.


60 Nm (6.0 mkg)

60 Nm (6.0 mkg)

3 Nm (0.3 mkg)


*Shell BT grease No. 3 (90890-69927)

4-30



123456789

10

Secondary sheave disassemblyNutClutch carrierClutch shoe springCompression springSpring seatGuide pinSecondary sliding sheaveO-ringOil sealSecondary fixed sheave

1131141221

Disassemble the parts in order.

Refer to “SECONDARY SHEAVE DISASSEMBLY” section.Refer to “SECONDARY SHEAVE INSTALLATION” section.

Refer to “SECONDARY SHEAVE INSTALLATION” section.

Reverse the disassembly procedure for assembly.

90 Nm (9.0 mkg)

SECONDARY SHEAVE

**Apply BEL-RAY assembly lube

4-31


NOTE:

NOTE:

CAUTION:

NOTE:

YP******

PRIMARY SHEAVE REMOVAL1. Remove:

Nut 1 (primary sheave)Plate washerPrimary fixed sheave 2

Loosen the nut (primary fixed sheave) whileholding the primary fixed sheave with the rotorholder 3 .

Rotor holder:90890-01235

YP******

SECONDARY SHEAVE AND V-BELT REMOVAL

1. Remove:Nut 1 (secondary sheave)Clutch housing 2

Loosen the nut (secondary sheave) while hold-ing the clutch housing with the sheave holder3 .

Sheave holder:90890-01701

2. Remove:Nut 1 (clutch carrier)

Do not remove the nut (clutch carrier) yet.

Loosen the nut (clutch carrier) one turn usingthe locknut wrench 3 while holding the clutchcarrier with the rotor holder 2 .


Locknut wrench:90890-01348

4-32


NOTE:

NOTE:

CAUTION:

NOTE:

3. Remove:Clutch assembly 1V-belt 2

Remove the V-belt from the primary sheaveside with clutch assembly.

YP******

SECONDARY SHEAVE DISASSEMBLY1. Remove:

Nut 1 (secondary sheave)

Loosen the nut 1 while attaching the clutchspring compressor 2 and clutch spring holderarm 3 and release the compressed spring afterremoving the nut.

Use the spacer 4 (ø 30 mm, thickness: 2 3 mm).

Clutch spring holder:90890-01337

Clutch spring holder arm:90890-01464

YP******

CLUTCH INSPECTION1. Measure:

Clutch shoe thicknessScratches Glaze using coarse sandpa-per.Wear/Damage Replace

Clutch shoe thickness:3.0 mm<Limit: 2.0 mm>

After using the sandpaper, clean off the pol-ished particles.

Inspect the other clutch shoes. Replace the all three as a set.

4-33


YP******

V-BELT INSPECTION1. Inspect:

V-belt 1Cracks/Wear/Scaling/Chipping Re-place.Oil /Grease Check primary sheave andsecondary sheave.

2. Measure:V-belt width 2Out of specification Replace

V-belt width:22.6 mm<Limit: 21.0 mm>

YP******

WEIGHT INSPECTION1. Inspect:

Weight minimum outside diameterCracks/Wear/Scaling/Chipping Re-place.Out of specification Replace.

Weight out side diameter:20.0 mm<Limit: 19.5 mm>

SECONDARY SHEAVE INSPECTION1. Inspect:

Secondary fixed sheave smooth opera-tion

Secondary sliding sheave smooth opera-tionScratches/Damage Replace as a set.

2. Inspect:Torque cam groove 1Wear/Damage Replace.

3. Inspect:Guide pin 2Wear/Damage Replace.

4-34


NOTE:

NOTE:

3 Nm (0.3 mkg)

NOTE:

YP******

PRIMARY SHEAVE ASSEMBLY1. Clean:

Primary sliding sheave face 1Primary fixed sheave face 2Collar 3Weight 4Primary sliding sheave cam face 5

Remove any excess grease.

2. Install:Weight 1Collar 2

Apply Shell BT grease No. 3 (90890-69927)to the all of the outside of the weight andinstall.

Apply Shell BT grease No. 3 (90890-69927)to the inside of the collar.

3. Install:Spacer 1Slider 2Cam 3Primary sliding sheave cap.

SECONDARY SHEAVE INSTALLATION1. Apply:

BEL-RAY assembly lube

(to the secondary sliding sheave 1 innersurface, grease nipple groove, and oilseals)

BEL-RAY assembly lube

(to the bearings, oil seals and inner sur-face of the secondary fixed sheave 2 )

2. Install:Secondary sliding sheave 1

Install the secondary sliding sheave 1 usingthe oil seal guide 2 to the secondary fixedsheave 3 .

Oil seal guide:90890-01384

4-35


NOTE:

CAUTION:

NOTE:

CAUTION:

3. Install:Guide pin 1

4. Apply:BEL-RAY assembly lube

(to the guide pin sliding groove 1 , andand oil seal 2 )

5. Install:Secondary sheave complete 1Compression springClutch carrier 2

Temporarily tighten the nut 5 while attachingthe clutch spring holder 3 and clutch springholder arm 4 and compress the spring.

Use the spacer 6 (ø 30 mm, thickness: 2 3 mm).

Clutch spring holder:90890-01337

Clutch spring holder arm:90890-01464

6. Install:V-belt 1Clutch assembly 2

Install the V-belt with the clutch assembly to theprimary sheave side.

Never smear grease to the V-belt, secondarysheave and clutch.

4-36


90 Nm (9.0 mkg)

NOTE:

NOTE:

NOTE:

7. Install:Nut 1 (clutch carrier)

Tighten the nut (clutch carrier), using the lock-nut wrench 3 while holding the clutch carrierwith the rotor holder 2 .


Locknut wrench:90890-01348

8. Install:Clutch housing 1Nut 2 (clutch housing)

Tighten the nut (clutch housing), using thesheave holder 3 .


9. Set:V-belt 1

Move the V-belt to minimum diameter of the pri-mary sheave 1 , maximum diameter of the sec-ondary sheave 2 and make the V-belt tense.

4-37


12345678

Magneto cover and startor coilremovalDrain the engine oil.

Side panels

Couplers (A.C. magneto lead)Exhaust pipeExhaust pipe gasketMagneto coverGasket (magneto cover)Dowel pinsStartor coilPick up coil

21121211


NOTE:

Refer to “ENGINE OIL REPLACEMENT”section in CHAPTER 3.Refer to “COVER AND PANEL” sectionin CHAPTER 3.

Disconnect the couplers.


7 Nm (0.7 mkg)

20 Nm (2.0 mkg)

7 Nm (0.7 mkg)

10 Nm (1.0 mkg)

A.C. MAGNETO AND STARTER CLUTCH ENG

A.C. MAGNETO AND STARTER CLUTCHMAGNETO COVER AND STARTOR COIL

4-38



1

23456

A.C. magneto and starter clutchremovalRotor

Shaft (idle gear)Idler gearStarter one way clutch assemblyWoodruff keyStarter wheel gear

1

11111


Refer to “A.C. MAGNETO ROTOR REMOVAL/INSTALLATION” section.

Refer to “ROTOR INSTALLATION” section.


10 Nm (1.0 mkg) 80 Nm (8.0 mkg)

A.C. MAGNETO AND STARTER CLUTCH

4-39


NOTE:

NOTE:

CAUTION:

YP401081

A.C. MAGNETO ROTOR REMOVAL1. Remove:

Nut 1 (rotor)Plain washer 2

Loosen the nut (rotor) 1 while holding the ro-tor with a sheave holder 3 .

Do not allow the sheave holder to touch theprojection on the rotor.


2. Remove:Rotor 1Woodruff key

Remove the rotor 2 using the flywheel pull-er.

Center the flywheel puller over the rotor.Make sure after installing the holding boltsthat the clearance between the flywheel pull-er and the rotor is the same everywhere. Ifnecessary, one holding bolt maybe turnedout slightly to adjust the flywheel puller’sposition.

Cover the crankshaft end with the boxwrench for protection.

Flywheel puller:90890-01362

4-40


*****************************************************

*****************************************************

NOTE:

NOTE:

YP402163

STARTER DRIVE GEAR INSPECTION1. Inspect:

Starter idle gear teethStarter drive gear teethStarter wheel gear teethBurrs/chips/roughness/wear Re-place.

2. Check:Starter clutch operationPush the dowel pins to the arrow direction.Unsmooth operation Replace.

Checking steps: Hold the starter clutch. When turning the starter wheel gear clock-

wise A , the starter clutch and the starterwheel gear should be engaged.

If not, the starter clutch is faulty. Replace it. When turning the starter wheel gear counter-

clockwise, B , it should turn freely. If not, the starter clutch is faulty. Replace it.

YP404131

A.C. MAGNETO ROTOR INSTALLATION1. Install:

Starter wheel gear 1Woodruff key 2

Install the starter wheel gear 1 , then install thewoodruff key 2 .

2. Install:Plain washerRotor 1

Clean the tapered portion of the crankshaftand the rotor hub.

When installing the magneto rotor, makesure the woodruff key is properly seated inthe key way of the crankshaft.

4-41


80 Nm (8.0 mkg)

NOTE:

3. Tighten:Nut (rotor) 1

Tighten the nut (rotor) 1 while holding the mag-neto rotor 2 with a sheave holder 3 .


4-42

OIL PUMP ENG


12345678

Oil pump removalA.C. magneto

CoverPump driven gearDowel pinOil pump assemblyGasketImpeller shaft gearDowel pinShaft

11111111

Remove the parts in order.Refer to the “A.C. MAGNETO AND STARTER CLUTCH” section.


7 Nm (0.7 mkg)

12 Nm (1.2 mkg)

OIL PUMP

4-43

OIL PUMP ENG

EB402140

OIL PUMP INSPECTION1. Inspect:

Drive gear (oil pump)Driven gear (oil pump) 1Pump housingPump housing coverWear/cracks/damage Replace

2. Measure:Tip clearance A(between the inner rotor 1 and the outerrotor 2 )

Side clearance B(between the outer rotor 2 and the pumphousing 3 )Out of specification Replace the oilpump assembly.

Housing and rotor clearance C(between the pump housing 3 and the ro-tors 1 2 )Out of specification Replace the oilpump assembly.

Tip clearance A :0.100.34 mm <Limit: 0.40 mm>

Side clearance B :0.0130.036 mm<Limit: 0.15 mm>

Housing and rotor clearance C :0.040.09 mm <Limit: 0.15 mm>

4-44

TRANSMISSION ENG


1234567

Transmission removalRear wheel

Crankcase cover (left)

Drain the transmission oil.

Transmission case coverGasket (transmission case cover)Dowel pinPrimary drive gearPlain washerPlain washer1st wheel gear

1121111

Remove the parts in order.Refer to “REAR WHEEL/REAR BRAKE”section in CHAPTER 7.Refer to “V-BELT, CLUTCH, SECONDARY/PRIMARY SHEAVE” section.

Refer to “TRANSMISSION OIL REPLACEMENT” section in CHAPTER 3.

16 Nm (1.6 mkg)

TRANSMISSION

4-45


89

1011

Drive axleMain axlePrimary driven gearPlain washer

1111


16 Nm (1.6 mkg)

TRANSMISSION ENG

4-46

CRANKCASE AND CRANKSHAFT ENG


12

Crankcase and crankshaftremovalEngine removalCylinder headCylinder, piston

V-belt, clutch, secondary/primarysheaveA.C. magneto, starter clutch

Oil pumpWater pump

Rear wheel

BoltO-ring

11

Remove the parts in the order.

Refer to “ENGINE REMOVAL” section.Refer to “CYLINDER HEAD” section.Refer to “CYLINDER AND PISTON” sec-tion.

Refer to “V-BELT, CLUTCH AND SEC-ONDARY/PRIMARY SHEAVE” section.Refer to “A.C. MAGNETO AND STARTER CLUTCH” section.Refer to “OIL PUMP” section.Refer to “WATER PUMP” section inCHAPTER 5.Refer to “REAR WHEEL AND REARBRAKE” section in CHAPTER 7.

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

CRANKCASE AND CRANKSHAFT

4-47


34

56789

Timing chain guide (intake)Crankcase (right)

Dowel pinCrankshaft assemblyTiming chainCrankcase (left)Oil seal

11

21111

Refer to “CRANKSHAFT INSTALLATION” section.

Refer to “CRANKSHAFT REMOVAL/INSTALLATION” section.


10 Nm (1.0 mkg)

10 Nm (1.0 mkg)


4-48


NOTE:

NOTE:

YP******

CRANKSHAFT REMOVAL1. Remove:

Crankshaft assemblyTiming chain 1

Before removing the crankshaft assembly,remove the timing chain from the crank shaftsprocket.

If the timing chain hooks to the crankshaftsprocket, the crankshaft cannot be removed.

YP******

CRANKSHAFT INSPECTION1. Measure:

Crankshaft runoutOut of specification Replace crankshaftand/or bearing.

Measure the crankshaft runout with the crank-shaft assembly turning slowly.

Runout limit:0.03 mm

2. Measure:Big end side clearanceOut of specification Replace big endbearing, crank pin and/or connecting rod.

Big end side clearance:0.35 0.85 mm

3. Measure:Crank widthOut of specification Replace crank-shaft.

Crank width:59.95 60.00 mm

4-49


NOTE:

NOTE:

4. Inspect:Crankshaft sprocket 1Wear/Damage Replace crankshaft.

Bearing 2Wear/Crack/Damage Replace crank-shaft.

Pump drive gear 3Wear/Damage Replace crankshaft.

5. Inspect:Crankshaft journalClogged Blow out the journal with com-pressed air.

YP404073

CRANKCASE INSTALLATION1. Clean all the gasket mating surface and

crankcase mating surface thoroughly.2. Apply:

Sealant(onto the crankcase mating surfaces)

Yamaha bond No. 1215

DO NOT ALLOW any sealant to come in con-tact with the oil gallery.

3. Install:Dowel pinsTiming chain 1

Install the timing chain not to be seen throughthe the crankshaft hole a on the crankcase(left) 2 .

ENG

CHAPTER 5.COOLING SYSTEM

RADIATOR 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP INSTALLATION 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1


123456

Radiator removalDrain the coolant.

Fuel tankFootrest board, under coverCowling body, leg shieldFan motor leadsThermo switch leadsFiller hose (radiator)Outlet hose (radiator)Inlet hose (radiator)Radiator

121111

Remove the parts in order.Refer to “COOLANT REPLACEMENT”section in CHAPTER 3.



23 Nm (2.3 mkg)

RADIATOR COOL

YP500000

COOLING SYSTEMRADIATOR

5-2

RADIATOR COOL

CAUTION:

*****************************************************

*****************************************************

YP500030

INSPECTION1. Inspect:

Radiator 1Obstruction Blow out with com-pressed air through the rear of the radia-tor.Flattened fins Repair or replace.If flattened over the 20 % of radiator fin,repair or replace the radiator.

Use only specified adhesive to repair the ra-diator.

2. Inspect: Radiator hoses Radiator pipes

Cracks/damage Replace.3. Measure:

Radiator cap opening pressure Radiator cap opens at a pressure below

the specified pressure Replace.

Radiator cap opening pressure:110140 kPa(1.11.4 kg/cm 2, 1.11.4 bar)

Measurement steps: Attach the radiator cap tester 1 and adapter

2 to the radiator cap 3 .

Radiator cap tester:90890-01325

Adapter:90890-01352

Apply the specified pressure for 10 seconds,and make sure there is no pressure drop.

4. Inspect: Fan motor assembly

Damage Replace.Malfunction Check and repair.Refer to “COOLING SYSTEM” in CHAP-TER 8.

5. Inspect: Pipes

Cracks/damage Replace.

5-3


123

45678

Water pump removalDrain the coolant.

Impeller shaft gearDowel pin/plain washerShaft

Inlet hose (water pump)HolderHousing coverHousing cover gasketWater pump housing

11/11

11111

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.

Refer to “WATER PUMP INSTALLATION” section.

A.C. magneto

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

Oil pump side

WATER PUMP COOL

WATER PUMP

5-4


91011

Impeller shaftO-ringO-ring

111

Refer to “WATER PUMP INSTALLATION” section.


10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

Oil pump side

WATER PUMP COOL

5-5

WATER PUMP COOL

NOTE:

*****************************************************

*****************************************************

YP******

It is not necessary to disassemble the waterpump, unless there is no abnormality such asexcessive change in coolant temperatureand/or level, discoloration of coolant, ormilky transmission oil.

If necessary, replace water pump as an as-sembly.

YP******


Impeller shaftWear/damage Replace.Fur deposits Clean.

2. Inspect: Impeller shaft gear

Wear/damage Replace.

3. Inspect: Mechanical seal 1

Damage/worn/wear Replace.YP******

WATER PUMP INSTALLATION1. Install:

Mechanical seal 1

Installation steps: Apply the Yamaha bond 1215 to the outside

of the mechanical seal. Install the mechanical seal by using the me-

chanical seal installer 2 and middle shaftbearing driver 3 .

Mechanical seal installer:90890-04078

Middle shaft bearing driver:90890-04058

5-6

WATER PUMP COOL

NOTE:

*****************************************************

*****************************************************

NOTE:

10 Nm (1.0 mkg)

2. Install: Mechanical seal 1

Apply coolant to the outside of the me-chanical seal before installing.

Do not smear any oils grease on to the ring sideof the mechanical seal.

3. Inspect: Mechanical seal, slip ring side 1

Inspect the slip ring side of the mechani-cal seal and the impeller 2 for levelinstallation.Incorrect level Reinstall.

4. Install: Impeller shaft 1 Circlip 2

Installation steps: Apply a small amount of grease to the impel-

ler shaft tip. Install the impeller shaft while turning it.

Use care so that the oil seal lip is not dam-aged or the spring does not slip off its posi-tion.

After installing the impeller shaft, check it forsmooth rotation.

5. Install: O-ring 1

6. Install: Water pump housing Housing cover

7. Install: Shaft 1

Align the slot on the impeller shaft withthe projection on the shaft when instal-ling.

Administrateur

Note


5-7


123456

Thermostat removalDrain the coolant

Side panelFuel tankClipOutlet hose (carburetor)Hose clampOutlet hose (thermostat)Thermostatic coverThermostatic valve

111111

Remove the parts in order.Refer to “COOLANT REPLACEMENT”section in CHAPTER 3.


10 Nm (1.0 mkg)


Refer to “THERMOSTAT INSTALLATION” section.

THERMOSTAT COOL

THERMOSTAT

5-8

3mm

95C82”1.5C

THERMOSTAT COOL

*****************************************************

*****************************************************

NOTE:

EB502010


Thermostatic valveValve does not open at 80.5 83.5C Replace.

Inspection steps:

Suspend the thermostatic valve in a vessel. Place a reliable thermometer in water. Observe the thermometer, while continually

stirring the water.

1 Thermostatic valve

2 Vessel

3 Thermometer

4 Water

A CLOSE

B OPEN

The thermostatic valve is sealed and its settingrequires specialized work. If its accuracy is indoubt, replace it. A faulty unit could cause seri-ous overheating or over-cooling.

2. Inspect: Thermostatic cover

Cracks/damage Replace.YP******

INSTALLATION1. Install:

Thermostatic valve 1 Thermostatic cover

CHAPTER 6.CARBURETION

CARBURETION 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR DISASSEMBLY 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LEVEL ADJUSTMENT 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUTO CHOKE INSPECTION 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP INSPECTION 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

Do not bend the air filter joint clampwhen installing the carburetor.


12345

67

Carburetor removalSide panelFuel tankDrain the coolant

Auto choke lead couplerInlet/Outlet hose (carburetor)Fuel hoseThrottle cableAir filter joint

NutCarburetor ass’y

11/1121

21



Refer to “COOLANT REPLACEMENT”section in CHAPTER 3.


CAUTION:

10 Nm (1.0 mkg)

CARBURETOR CARB

EB600000

CARBURETIONCARBURETOR

6-2

Refer to “CARBURETOR ASSEMBLY” section.Refer to “CARBURETOR ASSEMBLY” section.


Carburetor disassemblyAuto choke unitThrottle stop screw setPilot screw setCover/Diaphragm springPiston valveJet needle ass’yCoasting enricherAccererating pumpFloat chamberFloat pin

111

1/1111111

Disassemble the parts in order.12345678910

CARBURETOR CARB

CARBURETOR DISASSEMBLY

6-3


FloatNeedle valveMain jetPilot jetMain nozzle

11111

Refer to “CARBURETOR ASSEMBLY”section.

Reverse the disassembly procedure for assembly.

11

12

13

14

15

CARBURETOR CARB

6-4

CARBURETOR CARB

CAUTION:

*****************************************************

NOTE:

YP600041

ASSEMBLYReverse the “DISASSEMBLY” procedure.Note the following points.

Before assembling, wash all parts inclean petroleum based solvent.

Always use a new gasket.

1. Install: Main nozzle 1 Main jet 2 Pilot jet 3

2. Install: Valve seat 1 Float 2 Needle valve 3 Float pin 4

3. Inspect: Float height a

Inspection and adjustment steps: Hold the carburetor in an upside down posi-

tion. Measure the distance from the mating sur-

face of the float chamber (gasket removed) tothe top of the float.

If the float height is not within specification,inspect the valve seat and valve needle.

If either is worn, replace them both. If both are fine, adjust the float height by

bending the float tang 5 on the float. Check the float height again.

The float arm should be resting on the valveneedle without compressing it.

6-5

CARBURETOR CARB

*****************************************************

NOTE:

*****************************************************

Float height (F.H.):27 mm

Out of specification Replace.

5. Install: Diaphragm 1

Align the tab a on the diaphragm with the slotb on the carburetor body.

6. Install: Compression spring 1 Cover 2

YP600060

FUEL LEVEL ADJUSTMENT

Gasoline (fuel) and its vapors are highlyflammable and explosive. Keep away fromsparks, cigarettes, flames or other sourcesof ignition.

1. Measure: Fuel level a


Fuel level:56 mm below the float chamber line

Measurement and adjustment steps: Place the scooter on a level surface.

6-6

CARBURETOR CARB

*****************************************************

*****************************************************

*****************************************************

Put a garage jack under the engine to ensurethat the carburetors are positioned vertically.

Connect the fuel level gauge 1 to the drainpipe 2 .

Fuel level gauge:90890-01312

Loosen the drain screw 3 . Hold the gauge vertically next to the float

chamber line. Measure the fuel level a with the gauge. If the fuel level is incorrect, adjust the fuel lev-

el. Remove the carburetor. Inspect the valve seat and needle valve. If either is worn, replace them both. If both are fine, adjust float level by bending

the float tang 4 slightly. Install the carburetor. Recheck the fuel level.

YP******

AUTO CHOKE INSPECTION(Ambient temperature lower than 45 C)

1. Remove: Carburetor

2. Inspect: Autochoke unit

Connect ø 3.3 mm pipe 2 to the starter1 , and blow it with the mouth etc.Possible Good condition.Impossible Replace auto choke unit.

3. Inspect: Auto choke unit (with battery)

Inspection and adjustment steps: Connect auto choke unit leads to the 12 V

battery for 5 minutes.Black terminal 12 V battery (+) 1Black terminal 12 V battery (–) 2

Connect ø 3.3 mm pipe 4 to the starter 3 ,and blow it with the mouth etc.Possible Replace auto choke unit.Impossible Good condition.

6-7

CARBURETOR CARB

*****************************************************

*****************************************************

YP******

FUEL PUMP INSPECTION1. Remove:

Side panelsRefer to “COVER AND PANEL” sectionin CHAPTER 3.

2. Inspect: Fuel pump

Inspection steps: Place the receptacle under the fuel pipe end. 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.

Gasoline (fuel) and its vapors are highlyflammable and explosive. Keep awayfrom sparks, cigarettes, flames or othersources of ignition.

Failure to check for fuel leakage may re-sult in fire or explosion.

3. Install: Side panels

Refer to “COVER AND PANEL” sectionin CHAPTER 3.

CARB

CHAPTER 7.CHASSIS

FRONT WHEEL AND BRAKE DISC 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL AND BRAKE DISC 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL DISASSEMBLY 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL DISASSEMBLY 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL INSPECTION 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DISC INSPECTION 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL ASSEMBLY 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL INSTALLATION 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL STATIC BALANCE ADJUSTMENT 7-6. . . . . . . . . . . . . . . . . . . .

REAR WHEEL AND REAR BRAKE 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL INSPECTION 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE INSPECTION 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE INSTALLATION 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD REPLACEMENT 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER DISASSEMBLY 7-15. . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER INSPECTION 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER ASSEMBLY 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER INSTALLATION 7-17. . . . . . . . . . . . . . . . . . . . . . . . . CALIPER 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER DISASSEMBLY 7-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE CALIPER DISASSEMBLY 7-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER INSPECTION 7-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE CALIPER ASSEMBLY 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER INSTALLATION 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FORK 7-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK 7-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK DISASSEMBLY 7-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK REMOVAL 7-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK DISASSEMBLY 7-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSPECTION 7-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK ASSEMBLY 7-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSTALLATION 7-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HANDLEBAR 7-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR REMOVAL 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR INSPECTION 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR INSTALLATION 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING 7-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING REMOVAL 7-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 7-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING INSTALLATION 7-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR SHOCK ABSORBER AND SWING ARM 7-38. . . . . . . . . . . . . . . . . . .

7-1


1234567

Front wheel and brake discremoval

Speedometer cableAxle nutWheel axleFront wheel assemblyGear unit assemblyCollarBrake disc

1111111


Securely support the scooter so thereis no danger of it falling over .

Refer to “FRONT WHEEL ASSEMBLY”section.Reverse the removal procedure forinstallation.

Refer to “FRONT WHEELINSTALLATION” section.

70 Nm (7.0 mkg)

23 Nm (2.3 mkg)

FRONT WHEEL AND BRAKE DISC CHAS

CHASSISFRONT WHEEL AND BRAKE DISCFRONT WHEEL AND BRAKE DISC

7-2

1234


Front wheel disassemblyOil sealBearingSpacerBearing

1111



Refer to “FRONT WHEELDISASSEMBLY /ASSEMBLY” section.


FRONT WHEEL DISASSEMBLY

7-3


CAUTION:

YP******

FRONT WHEEL DISASSEMBLY1. Remove:

Bearing 1SpacerRemove the bearing using a general bear-ing puller 2 .

Handle the wheel with care not to damagethe brake disc. If the brake disc is damaged,replace.

YP700020

FRONT WHEEL INSPECTION1. 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. Inspect:Front tireWear/damage Replace:Refer to “TIRE INSPECTION” in CHAP-TER 3.

Front wheelRefer to “WHEEL INSPECTION” inCHAPTER 3.

3. Measure:Front wheel runoutOver the specified limits Replace.

Front wheel runout limits:Radial 1 : 2.0 mmLateral 2 : 2.0 mm

4. Inspect:Front wheel bearingsBearings allow free play in the wheel hubor the wheel does not turn smoothly Re-place.

Oil sealsWear/damage Replace.

7-4


NOTE:

CAUTION:

5. Inspect:CollarGrooved wear Replace the collar andthe oil seal as a set.

YP******

BRAKE DISC INSPECTION1. Measure:

Brake disc deflection

Maximum deflection:0.15 mm

Out of specification Replace.

2. Measure:Brake disc thickness

Brake disc thickness:4.0 mm

Minimum thickness:3.5 mm

Out of specification Replace.YP******

FRONT WHEEL ASSEMBLY1. Install:

Bearing 1Spacer 2Bearing 3Oil seal 4

Apply the lithium soap base grease on thebearing and oil seal lip when installing.

Use a socket that matches the outside diam-eter of the race of the bearing.

Always use a new oil seal. Install the oil seal with its manufacturer’s

marks or numbers facing outward.

Do not strike the inner race of balls of thebearing. Contact should be made only withthe outer race.

7-5


23 Nm (2.3 mkg)

NOTE:

NOTE:

NOTE:

CAUTION:

2. Install:Brake disc 1

Tighten the bolts (brake disc) in stage using acrisscross pattern.

EB700030

FRONT WHEEL INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.

1. Lubricate:Front wheel axleBearingsOil seal (lips)Drive/driven gear (speedometer)

Recommended lubricant:Lithium soap base grease

2. Install:Speedometer gear unit 1

Make sure that the wheel hub and thespeedometer gear unit are installed with thethree projections 2 meshed into the three slots3 .

3. Install:Front wheel

Make sure that the slot in the speedometer gearunit fits over the stopper on the front fork outertube.

4. Tighten:Front wheel axleAxle nut (front wheel axle) 1

Before tightening the axle nut, stroke thefront fork several times to check for properfork operation.

Make sure that the brake hose is routedproperly.

7-6


NOTE:

*****************************************************

*****************************************************

*****************************************************

*****************************************************

NOTE:

YP700040

WHEEL STATIC BALANCE ADJUSTMENT

After replacing the tire and/or rim, the wheelstatic balance should be adjusted.

Adjust the front wheel static balance with thebrake disc installed.

1. Remove:Balancing weight

2. Set:Wheel(on a suitable stand)

3. Find: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. Turn the wheel so that the “X1” mark is 90

up.d. Release the wheel and wait for it to rest.

Put an “X2” mark on the wheel’s bottomspot.

e. Repeat the above b., c., and d. severaltimes until all marks come to the same spot.

f. This spot is the wheel’s heavy spot “X”.

4. Adjust:Wheel static balance

Adjusting steps: Install a balancing weight 1 on the rim exact-

ly opposite to the heavy spot “X”.

Start with the smallest weight.

Turn the wheel so that the heavy spot is 90up.

Check that the heavy spot is at rest there. Ifnot, try another weight until the wheel is bal-anced.

7-7


*****************************************************

*****************************************************

5. Check:Wheel static balance

Checking steps: Turn the wheel so that it comes to each point

as shown. Check that the wheel is at rest at each point.

If not, readjust the front wheel static balance.

7-8


123456789

1011

Rear wheel and rear brake removalSwingarm

AdjusterBrake cableCompression springPinRear wheel assemblyBrake liningTension springPlate washerCamshaft leverIndicator plateCamshaft

11111221111

Remove the part in order.Refer to “REAR SHOCK ABSORBERAND SWINGARM” section.

Refer to “REAR BRAKEINSTALLATION” section.

10 Nm (1.0 mkg)

REAR WHEEL AND REAR BRAKE CHAS

REAR WHEEL AND REAR BRAKE

7-9



1213

Camshaft shimCamshaft seal

11


10 Nm (1.0 mkg)

7-10


NOTE:

NOTE:

EB701020

REAR WHEEL INSPECTION1. Inspect:

Rear wheel axleRear wheelRear wheel bearingsOil sealsRefer to “FRONT WHEEL”.

2. Measure:Rear wheel runoutRefer to “FRONT WHEEL”.

EB701021

REAR BRAKE INSPECTION1. Inspect:

Brake lining surfaceGlazed areas Polish.Use coarse sand paper.

After polishing, wipe the polished particles witha cloth.

2. Measure:Brake lining thickness

Brake lining thickness a :Standard:

4 mmLimit:

2 mm

Out of specification Replace.Measuring points

Replace the brake shoes as a set if either isworn to the limit.

3. Measure:Brake drum inside diameter a

Out of specification Replace the wheel.

Brake drum inside diameter:Standard:

160 mmLimit:

161 mm

7-11


*****************************************************

*****************************************************

4. Inspect:Brake drum inner surfaceOil/scratches Repair.OilUse a rag soaked in lacquer thinner or sol-vent.

ScratchesUse an emery cloth(lightly and evenly polishing)

5. Inspect:Camshaft face.Wear Replace.

When inspecting the brake lining, do notspill oil or grease on the brake lining.

YP******

REAR BRAKE INSTALLATION1. Install:

Camshaft 1 Indicator plate 2

Installation steps: Set the camshaft with its punched mark a

facing the direction as shown. Align the projection b on the indicator plate

with th camshaft notch and install. Check the proper position of the brake shoe.

2. Install:Camshaft lever 1Install the camshaft lever with its slit andthe indicator plate at right angle as shown.

7-12

FRONT BRAKE CHAS


123

Brake pad removalCaliper support boltBrake padPad support

121


Refer to “BRAKE PADREPLACEMENT” section.


23 Nm (2.3 mkg)

FRONT BRAKEBRAKE PAD

7-13

FRONT BRAKE CHAS

NOTE:

NOTE:

CAUTION:

23 Nm (2.3 mkg)

YP702010

BRAKE PAD REPLACEMENT

It is not necessary to disassemble the brake cal-iper and brake hose to replace the brake pads.

1. Remove:Bolt (caliper support bolt) 1Move the direction brake caliper to the ar-row mark.

2. Remove:Brake pads

Install new brake pad springs when the brakepads have to be replaced.

Replace the brake pads as a set if either isfound to be worn to the wear limit.

3. Push the caliper piston into the brake cali-per by finger.

When pushing the caliper piston into thebrake caliper, brake fluid level in reservoirtank is increasing higher.

4. Install:Brake pad 1Install the brake pad, and move the brakecaliper to the allow mark direction.

5. Install:Bolt (caliper support bolt)

6. Inspect:Brake fluid levelRefer to “BRAKE FLUID LEVEL INSPEC-TION” section in CHAPTER 3.

7. Check:Brake lever operationSoft spongy feeling Bleed the brakesystem.Refer to “AIR BLEEDING (HYDRAULICBRAKE SYSTEM)”in CHAPTER 3.

7-14


12345678

Master cylinder removalDrain the brake fluid

Rear view mirror (right)Brake lever/compression springBrake switchUnion boltPlain washerBrake hoseMaster cylinder bracketMaster cylinder

11/1112111

Remove the parts in order.Refer to “BRAKE FLUID REPLACE-MENT” section in CHAPTER 3.

Refer to “MASTER CYLINDERINSTALLATION” section.


10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

26 Nm (2.6 mkg)

FRONT BRAKE CHAS

MASTER CYLINDER

7-15


1234

Master cylinder disassemblyMaster cylinder bootCirclipMaster cylinder assemblySpring

1111


Refer to “MASTER CYLINDERASSEMBLY” section.

Reverse the disassembly procedurefor assembly.

FRONT BRAKE CHAS

MASTER CYLINDER DISASSEMBLY

7-16

FRONT BRAKE CHAS

YP702040

MASTER CYLINDER INSPECTION1. Inspect:

Master cylinder 1Wear/scratches Replace the mastercylinder assembly.

Master cylinder cup 2Cracks/damage Replace.

2. Inspect:Master cylinderScratches/wear/damage Replace themaster cylinder assembly.

3. Inspect:DiaphragmWear/damage Replace.

YP******

MASTER CYLINDER ASSEMBLY

All internal brake components should becleaned and lubricated with new brakefluid only before installation.

Recommended brake fluid:DOT #4

Replace the piston seals and dust sealswhenever a master cylinder is disas-sembled.

1. Install:Cylinder cup 1Master cylinder piston 2Install cylinder cup 1 by using cylindercup installer 3 .

Cylinder cup installer set:90890-01996

7-17

FRONT BRAKE CHAS

10 Nm (1.0 mkg)

CAUTION:

26 Nm (2.6 mkg)

CAUTION:

2. Install:Spring 1Install the spring with its smaller diameterto the master cylinder piston.

Master cylinder kit 2

3. Install:Circlip 1Install the circlip securely into the mastercylinder groove.

Master cylinder boot 2

YP******

MASTER CYLINDER INSTALLATION1. Install:

Master cylinder 1Master cylinder bracket 2

Align the end of the master cylinder with thepunch mark on the handlebar, then installthe master cylinder bracket 2 with the “UP”mark facing upward.

2. Install:Plain washer 1Brake hose 2Plain washer 3Union bolt 4

Align the plain washer notch and master cyl-inder edge a for assembly.

7-18

FRONT BRAKE CHAS

3. Air bleed:Brake systemRefer to “AIR BLEEDING” section inCHAPTER 3.

Use only designated quality brake fluid:Otherwise, the rubber seals may deterio-rate, causing leakage and poor brake per-formance.

Refill with the same type of brake fluid:mixing fluids may result in a harmfulchemical reaction and lead to poor perfor-mance.

Be careful that water does not enter thesignificantly lower the boiling point of thefluid may result in vapor lock.

4. Inspect:Brake operation

7-19


123456

Caliper removalDrain the brake fluidBrake hose holderUnion boltPlain washerBrake hoseCaliper support boltCaliper assembly

112111

Remove the parts in order.Refer to “BRAKE FLUID REPLACE-MENT” section in CHAPTER 3.

Refer to “CALIPER INSTALLATION”section.


26 Nm (2.6 mkg)

23 Nm (2.3 mkg)

FRONT BRAKE CHAS

CALIPER

7-20


123456

Caliper disassemblyBrake padPad supportCaliper pistonDust sealPiston sealBleed screw/Cap

21222

1/1


Refer to “BRAKE CALIPER DIS-ASSEMBLY /ASSEMBLY” section.


6 Nm (0.6 mkg)

FRONT BRAKE CHAS

CALIPER DISASSEMBLY

7-21

FRONT BRAKE CHAS

NOTE:

*****************************************************

*****************************************************

CAUTION:

CAUTION:

YP702020

BRAKE CALIPER DISASSEMBLY

Before disassembling either brake caliper,drain the brake fluid from the brake hose, mas-ter cylinder, brake caliper and reservoir tank.

1. Remove:Brake caliper piston

Removal steps:Blow compressed air into the hose jointopening to force out the caliper pistonfrom the brake caliper body.

Never try to pry out the caliper piston. Cover the caliper piston with a rag. Be

careful not to get injured when the pistonis expelled from the master cylinder.

Carefully remove the caliper piston to pre-vent damage.

2. Remove:Dust seal 1Piston seal 2When removing, push the seals by yourfinger.

Do not use a sharp instrument. Removeseals by your finger.

Do not re-use removed parts.

YP******

CALIPER INSPECTION1. Inspect:

Caliper cylinder 1Caliper piston 2Scratches, wear Replace caliper as-sembly.

7-22

FRONT BRAKE CHAS

CAUTION:

23 Nm (2.3 mkg)

26 Nm (2.6 m kg)

CAUTION:

EB702050

BRAKE CALIPER ASSEMBLY

All internal brake components should becleaned and lubricated with new brakefluid only before installation.

Recommended brake fluid:DOT #4

Replace the caliper piston seals whenev-er a brake caliper is disassembled.

1. Install:Piston seals 1Dust seal 2

2. Install:Caliper piston 1Apply brake fluid to the outer surface andinstall.

Do not force. Use care to prevent damage on caliper

piston.

YP******

CALIPER INSTALLATION1. Install:

Caliper 1Caliper support bolt 2Brake hose 3Plain washer 4Union bolt 5

When installing the brake hose to the cali-per, lightly touch the brake hose with thestopper a on the caliper.

7-23


1234567

Front fork removalFront wheelCaliper assemblyFront fenderInner fenderBolt (under bracket upper)Cap bolt /O-ringBolt (under bracket lower)Front fork (left /right)

1112

2/22

1/1

Remove the parts in order.Refer to “FRONT WHEEL” section.

Refer to “FRONT FORK REMOVAL/INSTALLATION” section.


45 Nm (4.5 mkg)23 Nm (2.3 mkg)

23 Nm (2.3 m kg)

49 Nm (4.9 mkg)

FRONT FORK CHAS

FRONT FORKFRONT FORK

7-24

FRONT FORK CHAS


1

2345678910

11

Front fork disassemblyCap bolt

O-ringFork springDust sealRetaining clipOil sealBolt (Damper rod)/GasketInner tubeOil lock pieceDamper rodRebound spring

1

11111

1/11111

Remove the parts in order.Refer to “FRONT FORK REMOVAL/INSTALLATION” section.

Refer to “FRONT FORK ASSEMBLY”section.

Refer to “FRONT FORK DISASSEM-BLY/ASSEMBLY” section.

Refer to “FRONT FORK ASSEMBLY”section.


45 Nm (4.5 mkg)

23 Nm (2.3 mkg)

FRONT FORK DISASSEMBLY

7-25

FRONT FORK CHAS

NOTE:

NOTE:

YP******

FRONT FORK REMOVAL

Securely support the scooter so there isno danger of it falling over.

Stand the scooter on a level surface. Stand the scooter on its centerstand.

1. Loosen:Bolt (lower bracket upper) 1

Loosen only the upper bolt.

2. Remove:Cap bolt 1

Use 17 mm width hexagonal wrench for remov-ing.

3. Loosen the bolt (under bracket lower) to re-move the front forks.

Support the front fork before loosening thepinch bolts.

YP703020

FRONT FORK DISASSEMBLY1. Remove:

Bolt (damper rod) 1Loosen the bolt (damper rod) 1 whileholding the damper rod with T-handle 2and holder 3 .

Damper rod holder:90890-04084

T-handle90890-01326

7-26

FRONT FORK CHAS

CAUTION:

2. Remove: Inner tubeOil lock pice

3. Remove:Oil seal 1

Never reuse the oil seal.

2 Rag

YP703030

FRONT FORK INSPECTION1. Inspect:

Inner tube bending

Inner tube bending limit:0.2 mm

Scratches/bends/damage Replace.

Do not attempt to straighten a bent innertube as this may dangerously weaken thetube.

2. Measure:Fork spring a

Front fork spring free length:268.5 mm

<Wear limit>263.5 mm

Over the specified limit Replace.YP******

FRONT FORK ASSEMBLYReverse the “DISASSEMBLY” procedure.Note the following points.

1. Install:Damper rod 1Rebound springOil lock piece 2 Inner tube 3

7-27

FRONT FORK CHAS

23 Nm (2.3 mkg)

NOTE:

NOTE:

CAUTION:

2. Install: Inner tube 1Into outer tube 2 .

3. Install:Plain washer 1Bolt (damper rod) 2

4. Tighten:Bolt (damper rod) 1

Tighten damper rod bolt 1 while holding thedamper rod with a T-handle 2 and a damperrod holder 3 .

Damper rod holder:90890-04084

T-handle90890-01326

6. Install:Oil seal 1Retaining clipDust sealUse the fork seal driver weight 3 and theattachment 2 .

Before installing the oil seal 1 , apply lithiumsoap base grease onto the oil seal lips.

Adjust the retaining clip so that it fits into theouter tube groove.

Make sure that the oil seal numbered sidefaces upward.

Fork seal driver weight:90890-01367


7-28

FRONT FORK CHAS

NOTE:

NOTE:

7. Inspect: Inner tube operationUnsmooth operation Disassembly andrecheck.

8. Fill:Fork oil

Oil quantity:0.142 L

Recommended oil:Fork oil 15 WT or equivalent

9. After filling up, slowly pump the fork up anddown to distribute the fork oil.

10. Measure:Oil level aOut of specification Adjust.

Oil level:80 mm

(from the top of the inner tubefully compressed and withoutthe fork spring)

Hold the fork in an upright position.

11. Install:Front fork spring 1

Install the fork spring with its smaller pitch up-ward.

Before installing the cap bolt, apply grease tothe O-ring.

Temporarily tighten the cap bolt.

7-29

FRONT FORK CHAS

NOTE:

45 Nm (4.5 mkg)

23 Nm (2.3 mkg)

EB703050

FRONT FORK INSTALLATIONReverse the “REMOVAL“ procedure.Note the following points.

1. Install:Front fork 1Temporary tighten the pinch bolts.

Pull up the inner tube until its end flushes the topof the under bracket 2 , then temporarily tightenthe bolt (under bracket lower) 3 .

2. Tighten:Cap bolts 1Pinch bolts (under bracket upper/ lower)

7-30

HANDLEBAR CHAS


123456789

10

Handlebar removalHandlebar upper cover

Rear view mirror (right)Rear view mirror (left)Master cylinder bracketMaster cylinderGrip end (right)Handlebar switch (right)Throttle cableGrip assemblyBrake cableLever holder (left)

1111112111

Remove the parts in order.Refer to ”COVER AND PANEL” sectionin CHAPTER 3.Left-thread screw.

Refer to “HANDLEBARINSTALLATION” section.


10 Nm (1.0 mkg)

23 Nm (2.3 mkg)

HANDLEBAR

7-31

HANDLEBAR CHAS


111213

1415

Handlebar switch (left)Grip end (left)Grip

Upper handlebar holderHandlebar

111

21


Refer to “HANDLEBAR REMOVAL”section.



10 Nm (1.0 mkg)

23 Nm (2.3 mkg)

7-32

HANDLEBAR CHAS

*****************************************************

*****************************************************

NOTE:

23 Nm (2.3 mkg)

NOTE:

NOTE:

YP******

HANDLEBAR REMOVAL1. Remove:

Grip (Left)

Removal steps: Remove the grip end (left). Blow with compressed air between the han-

dlebar and adhesive side of the grip to re-move.

YP704020

HANDLEBAR INSPECTION1. Inspect:

HandlebarBends/Cracks/Damage Replace.

Do not attempt to straighten a bent handle-bar as this may dangerously weaken thehandlebar.

YP******

HANDLEBAR INSTALLATION1. Install:

Handlebar 1

Apply a light coat of lithium soap base greaseonto the handlebar right end.

Align the match marks a on the handlebarwith the lower handlebar holder upper sur-face.

2. Install:Upper handlebar holder 1

The upper handlebar holders should beinstalled with the arrow marks a facing forwarda .

3. Install:Grip 1Grip end (Left) 2

Provide a clearance a of 2.5 mm between thehandlebar grip and handlebar grip end.

7-33

HANDLEBAR CHAS

NOTE:

NOTE:

NOTE:

*****************************************************

*****************************************************

4. Install:Handlebar switch (left) 1

Align the handlebar switch mating surface withthe punched mark a on the handlebar.

5. Install:Lever holder (left) 1

Align the lever holder mating surface with thepunched mark a on the handlebar.

6. Install:Throttle cable 1Grip assembly 2

Apply a light coat of lithium soap base greaseonto the inside of the grip assembly and install itto the handlebar.

7. Install:Grip end (right) 1Handlebar switch (right) 2

Installation steps: Align the handlebar switch (right) mating sur-

face and punched mark a on the handlebar. Provide a clearance b of 2.5 mm between

the grip assembly 3 and handlebar grip.Otherwise, the grip may not move.

Check the throttle grip for smooth opera-tion.

7-34


123456789

1011

Steering removalHandlebar upper cover

Front forkHandlebarNutHandlebar lower holderWoodruff keyRing nut (upper)Lock washerRing nut (center)Rubber washerRing nut (lower)Ball race coverBall race 1Lower bracket

11111111111

Remove the parts in order.Refer to “FRONT WHEEL, BRAKEDISC” section.Refer to “FRONT FORK” section.Refer to “HANDLEBAR” section.

Refer to “STEERING REMOVAL/INSTALLATION” section.

139 Nm (13.9 mkg)

75 Nm (7.5 mkg)

1st step:38 Nm (3.8 mkg)

2nd step:Loosen the ring nut 1 / 4turn.

3rd step:22 Nm (2.2 mkg)

STEERING CHAS

STEERING

7-35

STEERING CHAS


12131415

Ball bearingBall bearingBall race 1Ball race 2

221911

Refer to “STEERINGINSTALLATION” section.


139 Nm (13.9 mkg)

75 Nm (7.5 mkg)

1st step:38 Nm (3.8 mkg)

2nd step:Loosen the ring nut 1 / 4turn.

3rd step:22 Nm (2.2 mkg)

7-36

STEERING CHAS

NOTE:

NOTE:

YP704010

STEERING REMOVAL

Securely support the scooter so thatthere is no danger of it falling over.

Stand the scooter on a level surface.

1. Remove:Handlebar lower holder 1Woodruff key 2

Remove the handlebar lower holder by loosen-ing the ring nut (upper) 3 gradually.

2. Remove:Ring nut (upper)Lock washer 1Ring nut (center) 2Rubber washer

3. Remove:Ring nut (lower) 1

Hold the lower bracket by hand, then remove byusing the exhaust ring and steering nut wrench2 .

Exhaust and steering nut wrench:90890-01268

Securely support the steering shaft so that thereis no danger of it falling down.

INSPECTION1. Wash the bearing and bearing races with a

solvent.2. Inspect:

BearingsBearing racesPitting/Damage Replace.

7-37

STEERING CHAS

*****************************************************

*****************************************************

NOTE:

CAUTION:

139 Nm (13.9 mkg)

NOTE:

Bearing race replacement steps: Remove the bearing races on the head pipe

using long rod 1 and the hammer as shown. Remove the bearing race on the under brack-

et using the floor chisel 2 and the hammeras shown.

Install the new dust seal and races.

Always replace bearings and races as a set. Replace the dust seal whenever a steering

head disassembled.

If the bearing race is fitted not squarely, thehead pipe could be damaged.

EB704030

STEERING INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.

1. Lubricate:Bearings (upper and lower)Bearing races

Recommended lubricant:Lithium-soap base grease

2. Install:Ring nut (lower)Rubber washerRing nut (center)Lock washerRing nut (upper)Refer to “STEERING HEAD INSPEC-TION” section in CHAPTER 3.

3. Install:Woodruff key 1Handlebar lower bracket 2

Align the woodruff key to key groove mark a onthe handlebar lower holder.

7-38


123

456789

Rear shock absorber andswingarm removalSide panels

BoxNutMuffler assembly

Axle nutRear shock absorberSwingarmCollarOil sealBearing

121

111111


Refer to “COVER AND PANEL” sectionin CHAPTER 3.

Loosen.

Remove with the rear brake applied.


NOTE:

NOTE:

40 Nm (4.0 mkg)

19 Nm (1.9 mkg)

135 Nm (13.5 mkg)

7 Nm (0.7 mkg)

20 Nm (2.0 mkg)

23 Nm (2.3 mkg)

20 Nm (2.0 mkg)

53 Nm (5.3 mkg)

REAR SHOCK ABSORBER AND SWINGARM CHAS

REAR SHOCK ABSORBER AND SWINGARM

CHAPTER 8.ELECTRICAL

ELECTRICAL COMPONENTS 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING SWITCHES 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING STEPS 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH CONNECTION AS SHOWN IN THIS MANUAL 8-4. . . . . . . . . SWITCH POSITION AND TERMINAL CONNECTION 8-5. . . . . . . . . . .

IGNITION SYSTEM 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLE SHOOTING 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 8-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLE SHOOTING 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR 8-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 8-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIGNAL SYSTEM 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNAL SYSTEM CHECK 8-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 8-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTO CHOKE SYSTEM 8-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Administrateur

Note


8-1

ELECTRICAL COMPONENTS ELEC

1 Main switch2 Ignition coil3 Spark plug cap4 Fuel sender5 Rectifier /Regulator6 Starting circuit cut-off relay7 Wireharness

8 Thermo unit9 Ignitor unit10 Sidestand switch11 Battery12 Starter relay13 Flasher relay14 Horn

EB800000

ELECTRICALELECTRICAL COMPONENTS

8-2

CIRCUIT DIAGRAM ELEC

CIRCUIT DIAGRAM

8-3

CIRCUIT DIAGRAM ELEC

1 A.C. magneto2 Rectifier regulator3 Main switch4 Battery5 Main fuse6 Starter relay7 Starter motor8 Thermo switch (auto choke)9 Auto choke10 Ignitor unit11 Ignition coil12 Spark plug13 Pickup coil14 Sidestand switch15 Starting circuit cut-off relay16 Lights switch17 Starter switch18 Engine stop switch19 Handlebar switches (right)20 Fuse (fan)21 Thermo switch22 Fan motor23 Rear brake switch24 Front brake switch25 Flasher relay26 Horn

27 Turn switch28 Horn switch29 Dimmer switch30 Pass switch31 Handlebar switches (left)32 Tail /Brake light33 Licence light34 Rear flasher lights35 Front flasher lights36 Head light37 Auxiliary light38 Turn indicator lights39 High beam indicator light40 Meter lights41 Oil indicator light42 Reset switch43 Fuel gauge44 Read switch45 Clock46 Thermometer47 Speedometer48 Meter assembly49 Fuel sender50 Thermo unit

NOTE: Starter switch is closed while the button (switch) is pushed. Sidestand switch is closed while the side stand is upped. Brake switch is closed while the brake is applied.

COLOR CODE

B Black Y Yellow R/B Red/Black

Br Brown W White R/Y Red/Yellow

Ch Chocolate B/R Black/Red R/W Red/White

Dg Dark green Br/W Brown/White Y/R Yellow/White

G Green G/R Green/Red W/G White/Green

L Blue G/Y Green/Yellow

O Orange L/B Blue/Black

Sb Sky blue L/Y Blue/Yellow

P Pink L/W Blue/White

R Red L/R Blue/Red

8-4

CHECKING SWITCHES ELEC

NOTE:

YP-N

CHECKING SWITCHESCHECKING STEPSUsing pocket tester, check switches for continu-ity between their terminals to determine wheth-er they are correctly connected.Repalce the switch component if any of thecombinations does not produce the correctreading.


Turn the switch to the “ON”, “OFF” positionsseveral times.

Adjust the pocket tester to correct “0” positionbefore checking switches.

Set the pocket tester selector to “ 1” Ω.

SWITCH CONNECTION AS SHOWN IN THIS MANUALThis manual contains connection charts, likethe one shown on the left, showing the terminalconnections of switches (e.g. the main switch,handlebar switch, brake switch, lighting switchetc.)

The column on the extreme left indicates the dif-ferent switch positions, the top line indicates thecolors of the leads connected to the terminalson the switch.

“ ” indicates terminals between whichthere is continuity, i.e. a closed circuit, in the giv-en switch position.

In this chart:“Br and R” have continuity with the switch in the“ON” position.

8-5

Before checking a switch refer to the checkingswitches as shown in the left page and check forthe correct terminal connections (closed circuit)according to the color combinations shown inthe chart.Poor connection, fault Repair or replace.

* Indicates coupler positions.

CHECKING SWITCHES ELEC

YP******

SWITCH POSITION AND TERMINAL CONNECTION

8-6

IGNITION SYSTEM ELEC

3 Main switch4 Battery5 Main fuse10 Ignitor unit11 Ignition coil12 Spark plug13 Pickup coil14 Sidestand switch18 Engine stop switch

EB802000

IGNITION SYSTEMCIRCUIT DIAGRAM

8-7


NOTE:

YP******

1. Fuse

Refer to “CHECKING SWITCHES” section inCHAPTER 8. Replace the fuse.

NO CONTINUITY

CONTINUITYYP******

2. Battery

Check the battery condition.Refer to “BATTERY INSPECTION” sectionin CHAPTER 3.

Clean battery terminals.Recharge or replace the battery.

INCORRECT

CORRECTYP******

3. Spark plug

Check the spark plug condition.Check the spark plug type.Check the spark plug gap.Refer to “SPARK PLUG INSPECTION” sec-tion in CHAPTER 3.

Repair or replace the spark plug

OUT OF SPECIFICATION

Standard spark plug:DR8EA/NGK

Spark plug gap:0.6 0.7 mm

YP802010

TROUBLESHOOTING

IF THE IGNITION SYSTEMFAILS TO OPERATE.

(NO SPARK OR INTERMITTENT SPARK)

ProcedureCheck:

1. Fuse (Main)2. Battery3. Spark plug4. Ignition spark gap5. Spark plug cap resistance6. Ignition coil

Remove the following parts before trouble-shooting.1) Footrest board2) Cowling body

Use the special tools specified in the troubleshooting section.

Ignition checker90890-06754


7. Pickup coil resistance8. Main switch9. Engine stop switch

10. Sidestand switch11. Wiring connection

(entire ignition system)

8-8


YP******

4. Ignition spark gap

Disconnect the spark plug cap from thespark plug.

Connect the ignition checker as shown. Spark plug

Turn the main switch to “ON”.Check the ignition spark gap .Check the spark by pushing the starterswitch, and increase the spark gap until amisfire occurs.

MEETS SPECIFICATION

YP******

5. Spark plug cap resistance

Remove the spark plug cap.Connect the pocket tester (Ω 1 k) to thespark plug cap.

When removing the spark plug cap, do notpull the spark plug cap from high tensioncord.

Remove Turning counterclockwise.Connect Turning clockwise.Check the high tension cord when connect-ing the spark plug cap.

When connecting the spark plug cap, cutthe high tension cord about 5 mm.

CORRECT Replace the spark plug cap.


Tester (+) lead Spark plug side

Tester (–) lead High tension cord side

Minimum spark gap:6 mm (0.24 in)

The ignition system is not faulty.

OUT OF SPECIFI-CATION OR NOSPARK

NOTE:

Spark plug cap resistance:5 kΩ (20C)

12

a

1

2

8-9


YP******

6. Ignition coil resistance

Disconnect the ignition coil connector fromthe wireharness.

Connect the pocket tester (Ω 1) to theignition coil.

Check if the primary coil has the specified re-sistance.

Connect the pocket tester (Ω 1 k) to theignition coil.

Check the secondary has the specified re-sistance.

BOTH MEETSPECIFICATION

Replace the ignition coil.


Tester (+) lead Red/White Terminal

Tester (–) lead Orange Terminal

Secondary coil resistance:10.7 14.5 kΩ (20C)

1

2

Primary coil resistance:3.6 4.8 Ω (20C)

Tester (+) lead Spark plug lead

Tester (–) lead Red/White Terminal

1

2

8-10


YP******

7. Pickup coil resistance

Disconnect the pickup coil coupler from thewireharness.

Connect the pocket tester (Ω 100) to thepickup coil coupler.

Pickup coil resistance:168 252 Ω (20C)

YP******

8. Main switch

Refer to “CHECKING SWITCHES” section inthe CHAPTER 8.

NO CONTINUITY

Replace the main switch.

Tester (+) lead Yellow Terminal

Tester (–) lead Blue Terminal

1

2

Check the pickup coil has the specified re-sistance.

MEETSSPECIFICATION

Replace the pickup coil.


CONTINUITY

YP******

9. Engine stop switch

Refer to “CHECKING SWITCHES” section.

NO CONTINUITY

Replace the right handlebar switch.

CONTINUITYYP******

10. Sidestand switch


NO CONTINUITY

Replace the sidestand switch.

CORRECTYP******

11. Wiring connection

Check the connection of the entire ignitionsystem.Refer to “CIRCUIT DIAGRAM”.

POOR CONNECTIONS

Correct.

CORRECT

Replace the ignitor unit.

8-11

CHARGING SYSTEM ELEC

1 A.C. magneto2 Rectifier regulator4 Battery5 Main fuse

YP804000

CHARGING SYSTEMCIRCUIT DIAGRAM

8-12


NOTE:

YP******

1. Fuse

Refer to “CHECKING SWITCHES” section.Replace the fuse.

NO CONTINUITY

CONTINUITYYP******

2. Battery


Clean battery terminals.Recharge or replace the battery.

INCORRECT

CORRECT

YP804010

TROUBLESHOOTING

IF THE BATTERY IS NOT CHARGED

ProcedureCheck:

1. Fuse (Main)2. Battery3. Charging voltage

Remove the following parts before trouble-shooting.1) Side panels2) Tail cover

Use the special tools specified in the trouble-shooting section.

Engine tachometer90890-03113


4. Stator coil resistance5. Wiring system (entire charging system)

8-13

YP******

3. Charging voltage

Connect the engine tachometer to the sparkplug lead .

Connect the pocket tester (DC20 V) to thebattery.

Measure the battery terminal voltage.Start the engine and accelerate to about5,000 r/min.

Check the terminal voltage.


The charging circuit is not faulty.Replace the battery.

MEETS SPECIFICATION

Tester (+) lead Battery (+) terminal

Tester (–) lead Battery (–) terminal

NOTE:

Charging voltage =measured voltage – terminalvoltage:

0.2 2.5 V up

1

1

2

Use a fully charged battery.


8-14


YP******

4. Starter coil resistance

Remove the A.C. magneto coupler fromwireharness.

Connect the pocket tester (Ω 1) to the sta-tor coil.

Measure the stator coil resistance.

Replace the stator coil.


Tester (+) lead white terminalTester (–) lead White terminal

Stator coil resistance:0.8 1.0 Ω (20C)

MEETS SPECIFICATION

YP******


Check the entire charging system for connec-tions.Refer to “CIRCUIT DIAGRAM” section.

POOR CONNECTION

CORRECT

Correct.

Replace the rectifier/regulator.

8-15

ELECTRIC STARTING SYSTEM ELEC

3 Main switch4 Battery5 Main fuse6 Starter relay7 Starter motor14 Sidestand switch15 Starting circuit cut-off relay17 Starter switch18 Engine stop switch23 Rear brake switch24 Front brake switch

EB80300

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

8-16

ELECTRICAL STARTING SYSTEM ELEC

NOTE:

YP******

1. Fuse

Refer to “CHECKING SWITCHES” section inCHAPTER 8. Replace the fuse.

NO CONTINUITY

CONTINUITYYP******

2. Battery


Clean the battery terminals.Recharge or replace battery.

INCORRECT

CORRECT

YP803020

TROUBLESHOOTING

IF THE STARTER MOTOR FAILS TOOPERATE.

ProcedureCheck:

1. Fuse (Main)2. Battery3. Starter motor4. Starter relay5. Starting circuit cut-off relay6. Main switch

Remove the following parts before trouble-shooting.1) Side panels2) Tail cover3) Box


Pocket tester: 90890-03112

7. Engine stop switch8. Sidestand switch9. Front/Rear brake switch

10. Starter switch11. Wiring connection (entire starting system)

8-17


YP******

3. Starter motor

Connect the battery positive terminal andstarter motor cable using a jumper lead.

Check the starter motor operation.

CONTINUITY

Repair or replace the starter motor.

DOES NOT MOVE

YP******

4. Starter relay

Disconnect the relay unit coupler from thewireharness.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the relay unit coupler terminals.

Battery (+) lead Green/Yellow terminal

Battery (–) lead Blue/White terminal

1

2

MOVES

A wire used as a jumper lead must have theequivalent capacity as that of the batterylead or more, otherwise it may burn.This check is likely to produce sparks, so besure that no flammable gas or fluid is in thevicinity.

Check the starter relay for continuity.

Tester (+) lead terminalTester (–) lead terminal

34

Replace the starter relay.

NO CONTINUITY

CONTINUITYYP******

5. Starting circuit cut-off relay

Disconnect the starting circuit cut-off relaycoupler from the wireharness.

Connect the the pocket tester (Ω 1) andbattery (12 V) to the starting circuit cut-offrelay coupler terminals.

Battery (+) lead terminalBattery (–) lead terminal

24

Check the starting circuit cut-off relay forcontinuity.

Tester (+) lead terminalTester (–) lead terminal

13 Replace the starting circuit cut-off relay.

NO CONTINUITY

8-18

YP******

6. Main switch


NO CONTINUITY

Replace the main switch.

CONTINUITY

YP******



NO CONTINUITY


CONTINUITYYP******

8. Sidestand switch


NO CONTINUITY

Replace the sidestand switch.

CORRECTYP******

9. Front/Rear brake switch

Refer to “CHECKING SWITCHES” section inCHAPTER 8.

NO CONTINUITY

Replace the brake switch.

CORRECT

YP******

10. Starter switch


NO CONTINUITY

Replace the right handlebar switch.CORRECT

YP******


Check the connections of the entire startingsystem.Refer to “CIRCUIT DIAGRAM”.

POOR CONNECTION

Correct.


8-19



1

Starter motor removalAir cleaner case

Starter motor 1

Remove the parts in order.Refer to “ENGINE REMOVAL ANDINSTALLATION” section in CHAPTER 4.

Reverse the removal procedure for instal-lation.

7 Nm (0.7 mkg)

7 Nm (0.7 mkg)

10 Nm (1.0 mkg)

5 Nm (0.5 mkg)

123456789

Starter motor disassemblyFront bracketRingShimsRear bracketRingShimsBrush holder setArmature ass’yStator ass’y

111111111

Disassembly the parts in order.

Refer to “Starter motor assembly”

Reverse the disassembly procedure forassembly.

STARTER MOTOR

8-20


NOTE:

Goodcondition

Bad condition

AB

YP803034

Inspection and repair1. Inspect:

CommutatorDirt Clean it with #600 grit sandpaper.

2. Measure:Commutator diameter a

Commutator wear limit: 27 mm

Out of specification Replace the startermotor

3. Measure:Mica undercut a

Mica undercut: 0.7 mm

Out of specification Scrape the mica tothe proper value (a hacksaw blade can beground to fit).

The mica insulation of the commutator must beundercut to ensure proper operation of commu-tator.

4. Inspect:Armature coil resistances(installation/continuity)Defects Replace the starter motor.If commutator is dirty, clean it with sandpa-per.

: Continuity: No continuityBad condition Replace.

5. Measure:Brush length aOut of specification Replace.

Brush length wear limit: 4.0 mm

6. Measure:Brush spring forceFatigue/out of specification Replace asa set.

8-21


NOTE:

5 Nm (0.5 mkg)

NOTE:

Brush spring force: 570 920 g

7. Inspect:BearingOil sealWear/damage Repalce.

YP******

AssemblyReverse the “Removal” procedure.Note the following points.

1. Install:Brush holder 1

Align the projection a on the brush seat withthe slot b on the housing.

2. Install:Shims 1Armature coil 2

3. Install:Ring 1 Stator ass’y 2Shims 3Front bracket 4

Apply molybdenum grease lightly on to thebearings of the starter motor.

Align the match marks on the yoke with thematch marks on the brackets.

8-22

3 Main switch4 Battery5 Main fuse16 Lights switch29 Dimmer switch30 Pass switch32 Tail /Brake light33 Licence light36 Head light39 Auxiliary light40 Meter lights

LIGHTING SYSTEM ELEC

EB804000

LIGHTING SYSTEMCIRCUIT DIAGRAM

8-23


NOTE:

YP******

1. Fuse

Refer to “CHECKING SWITCHES” section.Repalce the fuse.

NO CONTINUITY

CONTINUITY

YP******

2. Battery


Clean battery terminals.Recharge or replace battery.

INCORRECT

CORRECTYP******

3. Main switch

Refer to “CHECKING SWITCHES” section.Replace the main switch.

NO CONTINUITY

CONTINUITYYP******

4. Lights switch



NO CONTINUITY

CONTINUITY

YP805010

TROUBLESHOOTING

IF THE HEADLIGHT, HIGH BEAMINDICATOR LIGHT, TAILLIGHT,

MARKER LIGHT AND/OR METER LIGHTFAIL TO COME ON.

ProcedureCheck:

1. Fuse (Main)2. Battery3. Main switch

Remove the following parts before trouble-shooting.1) Tail cover2) Cowling body



4. Lights switch5. Dimmer switch and pass switch6. Wiring connection (entire lighting system)

8-24

YP******

5. Dimmer switch/Pass switch

Refer to “CHECKING SWITCHES” section.Replace the left handlebar switch.

NO CONTINUITY

YP******


Check the connections of the entire lightingsystem.Refer to “WIRING DIAGRAM”. Correct.

POOR CONNECTIONS

Check the condition of each of the lightingsystem’s circuits.Refer to “LIGHTING SYSTEM CHECK”


1. Bulb and bulb socket


Replace the bulb and/or bulb socket.

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC20 V) to theheadlight and high beam indicator light cou-plers.

When the dimmer switch is on low beam.When dimmer switch is on high beam orthe Pass switch is pushed.

Headlight:Tester (+) lead Green or YellowleadTester negative (–) lead Blacklead

High beam indicator light:Tester (+) lead Yellow leadTester (–) lead Black lead

4

CONTINUITY

A

B

1

3

2

5

YP805020

LIGHTING SYSTEM CHECK1. If the headlight and the high beam indicator light fail to come on.

8-25


YP805021


Refer to “CHECKING SWITCHES” section.Replace the bulb and/or bulb socket.

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC20 V) to thebulb socket coupler.

Tester (+) lead Blue terminal

Tester (–) lead Black terminal

Turn the main switch to on.Turn the lights switch to on or pilot position.Check the voltage (12 V) of the leads on thebulb socket connector.

CONTINUITY

1

Turn the main switch to on.Turn the light switch to on position.Turn the dimmer switch to low beam or highbeam.

Pass switch to push in.Check for voltage (12 V) on the lead at bulbsocket connectors.

This circuit is not faulty.

MEETSSPECIFICATION

The wiring circuit from the main switch tobulb socket connector is faulty. Repair.


2. If the meter light fails to come on.

2

MEETSSPECIFICATION


The wiring circuit from main switch to bulbsocket is faulty. Repair.


8-26




NO CONTINUITY

2. Voltage

Connect the pocket tester (DC20 V) to thebulb socket connector.

Tester (+) lead Blue terminal

Tester (–) lead Black terminal

Turn the main switch to on.Turn the lights switch to on or pilot position.Check the voltage (12 V) on the bulb socketconnector.

CONTINUITY

1

2

MEETSSPECIFICATION


The wiring circuit from main switch to bulbconnector is faulty. Repair.


YP805022

3. The taillight fails to come on.

8-27




NO CONTINUITY

2. Voltage


Tester (+) lead Blue terminalTester (–) lead Black terminal

Turn the main switch to on.Turn the lights switch to on or pilot position.Check the voltage (12 V) on the bulb socketconnector.

CONTINUITY

12

MEETSSPECIFICATION


The wiring circuit from main switch to bulbconnector is faulty. Repair.


YP805023

4. If the auxiliary light fails to come on.

8-28

SIGNAL SYSTEM ELEC

3 Main switch4 Battery5 Main fuse23 Rear brake switch24 Front brake switch25 Flasher relay26 Horn27 Turn switch28 Horn switch33 Tail /Brake light34 Rear flasher lights35 Front flasher lights

38 Turn indicator lights43 Fuel gauge49 Fuel sender

EB806000

SIGNAL SYSTEMCIRCUIT DIAGRAM

8-29

SIGNAL SYSTEM ELEC

NOTE:

YP******

1. Fuse


NO CONTINUITY

CONTINUITY

YP******

2. Battery



INCORRECT

CORRECTYP******

3. Main switch


NO CONTINUITY

CONTINUITY

YP806010

TROUBLESHOOTING

IF THE FLASHER LIGHT, BRAKE

LIGHT AND/OR INDICATOR LIGHT

FAIL TO COME ON.

IF THE HORN FAILS TO SOUND.

ProcedureCheck:

1. Fuse (Main)2. Battery

Remove the following parts before trouble-shooting.1) Cowling body2) Side panels

Use the special tools in the troubleshootingsection.


3. Main switch4. Wiring connection (entire signal system)

8-30

SIGNAL SYSTEM ELEC

YP******

4. Wireharness

Check the connections of the entire signalsystem.Refer to “CIRCUIT SYSTEM WIRING DIA-GRAM” section. Correct.

POOR CONNECTION

Check condition of each of the signal sys-tem’s circuits.Refer to “SIGNAL SYSTEM CHECK” section.

CONTINUITY

8-31

SIGNAL SYSTEM ELEC

1. HORN switch


CONTINUITY

Replace the left handlebar switch.

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC20 V) to thehorn lead.

Tester (+) lead Brown terminal .Tester (–) lead Frame ground

1

MEETSSPECIFICATION

Turn the main switch to on.Check for voltage (12 V) on the “Brown” leadat the horn terminal.

The wiring circuit from the main switch to thehorn is faulty. Repair.


3. Horn

Connect the pocket tester (DC20 V) to thehorn at the “Pink” terminal.

Tester (+) lead Pink terminal.Tester (–) lead Frame ground

1

Turn the main switch to on.Check for voltage on the “Pink” lead to frameground.

Replace the horn.

NO CONTINUITY

CONTINUITY

Adjust or replace horn.

YP806020

SIGNAL SYSTEM CHECK1. If the horn fails to sound.

8-32



NO CONTINUITY

3. Voltage


Tester (+) lead Blue terminalTester (–) lead Black terminal

Turn the main switch to on.The brake lever is pulled in.Check for voltage (12 V) of the “Yellow” leadon the bulb socket connector.

CONTINUITY

12

MEETSSPECIFICATION



2. Brake switch (Front/Rear)

Refer to “CHECKING SWITCHES” section.Replace brake switch.

NO CONTINUITY

CONTINUITY


Wiring circuit from the main switch to thebulb socket connector is faulty. Repair.Refer to “SIGNAL SYSTEM WIRING DIA-GRAM”.

SIGNAL SYSTEM ELEC

YP806022

2. If the brake light fails to come on:

8-33



MEETSSPECIFICATION

Replace the bulb and/or bulb socket.

NO CONTINUITY

3. Voltage

Connect the pocket tester (DC20 V) to theflasher relay coupler.

Tester (+) lead Brown terminal .Tester (–) lead Frame ground

1

MEETS SPECIFICATION

Turn the main switch to on.Check for voltage (12 V) of the “Brown”

lead at the flasher relay terminal.

The wiring circuit from main switch to flasherrelay connector is faulty. Repair.


4. Voltage

Connect the pocket tester (DC20 V) to theflasher relay coupler.

Tester (+) lead Brown/White terminal .

Tester (–) lead Frame ground1

Turn the main switch to on.Check for voltage (12 V) on the “Brown/White” lead at the flasher relay terminal.

The flasher relay is faulty. Replace.


CONTINUITY

2. Turn switch

Refer to “CHECKING SWITCHES” section.Replace the left handlebar switch.

NO CONTINUITY

CONTINUITY

1

SIGNAL SYSTEM ELEC

YP806023

3. If the flasher light and/or turn indicator lightfails to blink.

8-34


Wiring circuit from the turn switch to bulbsocket connector is fault. Repair.Refer to “CIRCUIT DIAGRAM”.

5. Voltage


At flasher light (left)Tester (+) lead Chocolate leadTester (–) lead Black terminal

Turn the main switch to on.Turn the turn switch to left or right.Check for voltage (12 V) on the “Chocolate”lead and “Dark green” at the flasher light ter-minal.

13

MEETSSPECIFICATION



At flasher light (right)Tester (+) lead Dark green leadTester (–) lead Black terminal

23

SIGNAL SYSTEM ELEC

8-35

SIGNAL SYSTEM ELEC

Float positionSpecificatedresistance

UP 4 10 Ω90 100 ΩDOWN

1. Fuel sender

Remove the fuel sender from the fuel tank.Disconnect the fuel sender coupler from thewireharness.Connect the pocket tester (Ω 10) to thefuel sender coupler lead.

2. Voltage

Connect the pocket tester (DC20 V) to thefuel gauge coupler.

Tester (+) lead Green terminalTester (–) lead Black terminal

1

3

Check the fuel sender for specificated resis-tance.

Replace the fuel sender.


Turn the main switch to “ON”.Check for voltage (12 V) of the “Brown” leadon the fuel sender lead.


Check the connection of the entire signalsystem.Refer to “CHECKING OF CONNECTIONS”.Refer to “CIRCUIT DIAGRAM”.

MEETSSPECIFICATION

4

BOTH MEETSPECIFICATION

Tester (+) lead Brown terminal

Tester (–) lead Frame ground

1

2

YP806027

4. If the fuel gauge fails to operate.

8-36

Float “UP” “F”“E”Float “DOWN”

3. Fuel gauge

Connect the fuel sender to wireharness.Move the float to “UP” or “DOWN” .

1

Turn the main switch to “ON”.Check the fuel gauge needle moves “F” or“E”.

Replace the fuel gauge.

DOES NOT MOVE

2

MOVES

Float position Needle moves


NOTE:Before reading the meter, stay put the float formore than three minutes respectively at “UP”or “DOWN”.

1 2

SIGNAL SYSTEM ELEC

8-37

3 Main switch4 Battery5 Main fuse20 Fuse (fan)21 Thermo switch22 Fan motor46 Thermo meter50 Thermo unit

COOLING SYSTEM ELEC

YP80700

COOLING SYSTEMCIRCUIT DIAGRAM

8-38

COOLING SYSTEM ELEC

NOTE:

YP******

1. Fuse


NO CONTINUITY

CONTINUITY

YP******

2. Battery



INCORRET

CORRECTYP******

3. Main switch


NO CONTINUITY

CONTINUITY

YP******

TROUBLESHOOTING

IF THE FAN MOTOR FAILS TO TURN.

ProcedureCheck:

1. Fuse (Main, Fan)2. Battery3. Fan motor (inspection 1)

Remove the following parts before trouble-shooting.1) Side panels2) Footrest board3) Under cover4) Drain the cooling water



4. Fan motor (inspection 2)5. Thermo switch6. Wiring connection (entire cooling system)

8-39

COOLING SYSTEM ELEC

4. Fan motor (inspection 1)

Disconnect the fan motor couplers.Cconnect the battery as shown.

Battery (+) lead Blue terminalBattery (–) lead Black terminal

1

MOVES

Check the fan motor operation.

Replace fan motor.

DOES NOT MOVE

5. Fan motor (inspection 2)

Turn the main switch to on.Remove the thermo switch lead from thermoswitch.

Connect jumper lead to thermo switchleads.

Turn the main switch to on.

The wiring circuit from battery to fan motor isfaulty. Repair.

DOES NOT MOVE

YP******

YP******

2

1

6. Thermo switch

Remove the thermo switch from the radiator.Connect the pocket tester (Ω 1) to thethermo switch .

Immerse the thermo switch in the water.

Check the thermo switch for continuity.

Measure temperatures while heating thecoolant with the temperature gauge .

YP807012

MOVES

NOTE:

1

2

3

8-40

COOLING SYSTEM ELEC

Handle the thermo switch with specialcare.Never subject it to strong shocks or allowit to be dropped. Should it be dropped, itmust be replaced.

Do not touch the thermo switch to thebottom of the heated vessel.


Check the connection of the entire coolingsystem.Refer to “CIRCUIT DIAGRAM” section.

Replace the thermo switch.


Thermo switch “ON”.Thermo switch “OFF”.

AB

CORRECT

Correct.

POOR CONNECTION

More than 98C 1053C

Administrateur

Note


8-41

COOLING SYSTEM ELEC

NOTE:

YP******

1. Fuse


NO CONTINUITY

CONTINUITY

YP******

2. Battery



INCORRET

CORRECTYP******

3. Main switch


NO CONTINUITY

CONTINUITY

YP807010

TROUBLESHOOTING

IF THE WATER TEMPERATUREMETER FAILS TO MOVE,WHEN ENGINE IS WARM

ProcedureCheck:

1. Fuse (Main, Fan)2. Battery3. Main switch

Remove the following parts before trouble-shooting.1) Fuel tank2) Cowling body



4. Thermo unit5. Voltage6. Wiring connection (entire cooling system)

8-42

Handle the thermo unit with special care.Never subject it to strong shocks or al-low it to be dropped. Should it bedropped, it must be replaced.

Do not touch the thermo unit to the bot-tom of the heated vessel.

80C 47.5 56.8 Ω26.2 29.3 Ω100C

4. Thermo unit

Drain the coolant, and remove the thermounit from the radiator.

Immerse the thermo unit in the cool-ant .

Thermometer

Replace the thermo unit.


MEETSSPECIFICATION

Coolant temperature Resistance

YP******

CORRECT

5. Voltage

Connect the pocket tester (DC20 V) to thetemperature gauge coupler.

YP******

Tester (+) lead Green/Red terminalTester (–) lead Frame ground

1

1

23

Turn the main switch to on.Check for voltage (12 V) on the temperaturegauge lead.

The wiring circuit from main switch to tem-perature gauge is faulty. Repair.


COOLING SYSTEM ELEC

8-43

YP******


Check the connections of the entire coolingsystem.Refer to “CIRCUIT DIAGRAM” section.

Correct.

POOR CONNECTION

Replace the temperature gauge.

CORRECT

COOLING SYSTEM ELEC

8-44

3 Main switch4 Battery5 Main fuse8 Thermo switch (auto choke)9 Auto choke10 Ignitor unit18 Engine stop switch

AUTO CHOKE SYSTEM ELEC

YP******

AUTO CHOKE SYSTEMCIRCUIT DIAGRAM

8-45


NOTE:

YP******

1. Fuse

Refer to “CHECKING SWITCHES” section.Repalce the fuse.

NO CONTINUITY

CONTINUITY

YP******

2. Battery



INCORRECT

CORRECTYP******

3. Main switch


NO CONTINUITY

CONTINUITYYP******




NO CONTINUITY

CONTINUITY

YP******

TROUBLESHOOTING

IF THE AUTO CHOKE FAILSTO OPERATE.

ProcedureCheck:

1. Fuse (Main)2. Battery3. Main switch4. Engine stop switch

Remove the following parts before trouble-shooting.1) Fuel tank2) Footrest board3) Cowling body



5. Thermo switch6. Auto choke unit resistance7. Voltage8. Wiring connection

(entire auto choke system)

8-46


Disconnect the thermo switch from the ra-diator.

Connect the pocket tester (Ω 1) to thethermo switch .

Immerse the thermo switch in the coolant.

Check the thermo switch for continuity.

Note temperatures while heating the waterwith the temperature gauge .

Handle the thermo switch with specialcare.Never subject it to strong shocks or allowit to be dropped. Should it be dropped, itmust be replaced.

Do not touch the thermo switch to bot-tom of the heated vessel.

Replace the thermo switch.


Thermo switch on.Thermo switch off.

AB

CORRECT

5. Thermo switch

NOTE:

2

1

3

More than 68C 753C

YP******

8-47

YP******

6. Auto choke unit resistance

Disconnect the auto choke unit coupler fromthe wireharness.

Connect the pocket tester (Ω 1) to theauto choke unit coupler lead.

Auto choke unit resistance:16 24 Ω (20C)

Tester (+) lead Black terminalTester (–) lead Black terminal

12

Replace the auto choke unit.


YP******


Check the connection of the entire autochoke system.Refer to “CIRCUIT DIAGRAM” section.

POOR CONNECTION

Correct.

YP******

7. Voltage (temperature under 68C)

Connect the pocket teser (DC20 V) to the ig-nitor unit.

Tester (+) lead Yellow/Red terminal (1 terminal)

Tester (–) lead Frame ground1

Replace the ignitor unit.

OUT OF SPECIFICATIONTurn the main switch to on, and start the en-gine.

Check for voltage (12 V) on “Yellow/Red”terminal at the ignitor unit.

MEETSSPECIFICATION

MEETSSPECIFICATION


ELEC

CHAPTER 9.TROUBLESHOOTING

STARTING FAILURE/HARD STARTING 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR IDLE SPEED PERFORMANCE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . POOR IDLE SPEED PERFORMANCE 9-2. . . . . . . . . . . . . . . . . . . . . . . .

POOR MEDIUM AND HIGH SPEED PERFORMANCE 9-3. . . . . . . . . . . . . POOR MEDIUM AND HIGH SPEED PERFORMANCE 9-3. . . . . . . . . .

POOR SPEED PERFORMANCE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR SPEED PERFORMANCE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY CLUTCH 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEN ENGINE IS RUN, SCOOTER DOES NOT RUN 9-4. . . . . . . . . . POOR SPEED PERFORMANCE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR STARTING PERFORMANCE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . .

OVERHEATING OR OVER COOLING 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHEATING 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVER COOLING 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY BRAKE 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR BRAKING EFFECT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FORK MALFUNCTION 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL LEAKAGE 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MALFUNCTION 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTABLE HANDLING 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTABLE HANDLING 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER MOTOR DOES NOT OPERATE 9-7. . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR DOES NOT OPERATE 9-7. . . . . . . . . . . . . . . . . . . . .

FAULTY SIGNAL AND LIGHTING SYSTEM 9-8. . . . . . . . . . . . . . . . . . . . . . HEADLIGHT DARK 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BULB BURNT OUT 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER DOES NOT BLINK 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER KEEPS ON 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER BLINKS SLOWER 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER BLINKS QUICKER 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN DOES NOT SOUND 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM

9-1

STARTING FAILURE/HARD STARTINGTRBLSHTG

NOTE:

EB90000

TROUBLESHOOTING

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.

YP90000

STARTING FAILURE/HARD STARTINGFUEL SYSTEMFuel tank Empty Clogged fuel tank cap breather hole Deteriorated fuel or fuel containing water or

foreign materialFuel pump Clogged fuel hose Clogged fuel pump Broken vacuum hose or improperly hose set-

tingCarburetor Deteriorated fuel or fuel containing water or

foreign material Clogged pilot jet Clogged air passage Improperly set pilot air screw Clogged pilot air passage Improperly sealed valve seat Improperly adjusted fuel level Clogged starter jet Clogged emulsion (heated water) tube Sucked-in air

Auto choke Starter plunger malfunction Wax malfunction P.T.C. thermister malfunction Ignitor unit malfunction Thermo switch malfunctionAir cleaner Clogged air cleaner element Improper air cleaner setting

COMPRESSION SYSTEMCylinder and cylinder head Loose spark plug Loose cylinder head Broken cylilnder head gasket Broken cylinder gasket Worn, damaged or seized cylinderPiston and piston ring Worn piston Worn, fatigued or broken piston ring Seized piston ring Seized or damaged piston

Valve system Improperly adjusted valve clearance Improperly sealed valve Improperly contacted valve and valve seat Improper valve timing Broken valve spring Seized valve

9-2

POOR IDLE SPEED PERFORMANCETRBLSHTG

IGNITION SYSTEMBattery Improperly charged battery Faulty batteryFuse Burnt out, improper connectionSpark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Worn electrodes Faulty spark plug capIgnition coil Broken or shorted primary/secondary coil Faulty high tension cord Broken ignitin coil body

Ignition system Faulty ignitor unit Faulty pick up coil Broken magneto woodruff keySwitch Faulty main switch Faulty “ENGINE STOP” switch Faulty front and/or rear brake switch Faulty sidestand switchWiring Loose battery terminal Loose coupler connection Improperly grounded Broken wireharness

YP901000

POOR IDLE SPEED PERFORMANCEPOOR IDLE SPEED PERFORMANCECarburetor Loose or clogged pilot jet Damaged carburetor joint Improperly tightened carburetor joint clamp

hose Improperly adjusted idle speed

(Pilot screw), (Throttle stop screw), (CO test) Improperly adjusted throttle cable Flooded carburetorAuto choke Faulty starter plunger Improper wax operation Faulty ignitor unit Faulty P.T.C. thermister

Air cleaner Clogged air cleaner elementIgnition system Faulty spark plug Faulty high tension cord Faulty ignitor unit Faulty pick up coil Faulty ignition coilValve system Improperly adjusted valve clearance

9-3

POOR MEDIUM AND HIGH SPEED PERFORMANCETRBLSHTG

EB902000

POOR MEDIUM AND HIGH SPEED PERFORMANCEPOOR MEDIUM AND HIGH SPEED PERFORMANCERefer to “STARTING FAILURE/HARD STARTING” section. (Fuel system, electrical system, compres-sion system and valve train)Carburetor Improperly adjusted fuel level Clogged main nozzle Clogged or loose pilot jet

Air cleaner Clogged air cleaner element

YP******

POOR SPEED PERFORMANCEPOOR SPEED PERFORMANCEIgnition system Dirty spark plug Improper heat range Faulty ignitor unit Faulty pick up coilFuel system Clogged fuel tank cap breather hole Clogged air cleaner element Clooged jet Improperly adjusted fuel level Improper carburetor air vent hose setting

Compression system Worn cylinder Worn or seized piston ring Cylinder head gasket broken Cylinder gasket broken Carbon deposit build-up Improperly adjusted valve clearance Improperly contacted valve and valve seat Faulty valve timingClutch Refer to “CLUTCH SLIPPING/DRAGGING”

sectionEngine oil Improper oil level (low or over oil level) Improper quality (Low oil viscosity) Deterioration Clogged oil passageBrakes Dragging brake

9-4

FAULTY CLUTCHTRBLSHTG

YP******

FAULTY CLUTCHWHEN ENGINE IS RUN, SCOOTER DOES NOT RUNV belt Worn/bent/slippingCam, slider Worn/damagedCompression spring DamageGears DamageYP904000

CLUTCH SLIPPINGClutch weight spring Worn/looseClutch shoe Worn/damagedPrimary sliding sheave SeizedYP******

POOR STARTING PERFORMANCEV belt Slipping/oily V beltPrimary sliding sheave Improper operation DamageCompression spring Worn/looseSecondary sliding sheave Improper operation Worn guide pin groove Worn guide pinClutch shoe Worn/bent

POOR SPEED PERFORMANCEV belt Worn Oily V beltRoller weight Worn/improper operationPrimary/secondary sheave Worn

9-5

OVERHEATING OR OVER COOLINGTRBLSHTG

YP905000

OVERHEATING OR OVER COOLINGOVERHEATINGIgnition system Improper spark plug gap Improper spark plug heat rangeFaulty ignitor unitFuel system Improper carburetor setting Improper fuel level adjustment Clogged air cleaner elementCompression system Heavy carbon deposit build-up Improperly adjusted valve timing Improperly adjusted valve clearanceEngine oil Incorrect engine oil level Improper engine oil quality (High viscosity) Low engine oil qualityBrakes Dragging brakeCooling system Inoperative fan motor Faulty thermostat Faulty thermo switch Incorrect coolant level (low coolant level) Faulty radiator (Clogged, damage) Faulty radiator cap Impeller shaft gear malfunction (bent dowel

pin, gear) Damaged impeller shaft Disconnected fan motor connector

OVER COOLINGCooling system Faulty cooling fan Faulty thermostat Faulty thermo switch

9-6

FAULTY BRAKE/FRONT FORK MALFUNCTIONTRBLSHTG

YP906000

FAULTY BRAKEPOOR BRAKING EFFECTFront 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 discRear brake Improper brake lever adjustment Worn brake shoe Improper brake shoe contact Worn camshaft Worn brake drum Mud or water into brake drum inside Oily or greasy brake lining Faulty brake cable Broken or fatigued tension spring Faulty camshaft, cam lever

YP907000

FRONT FORK MALFUNCTIONOIL LEAKAGE Bent, damaged or rusty inner tube Damaged or cracked outer tube Damaged oil seal lip Loose hexagon bolt Damage cap bolt O-ringMALFUNCTION Bent inner tube Deformed outer tube Damaged fork spring Bent cylinder complete Improper oil viscosity (High viscosity) Improper oil level

9-7

INSTABLE HANDLING/STARTER MOTOR DOES NOT OPERATE

TRBLSHTG

YP908000

INSTABLE HANDLINGINSTABLE HANDLINGHandlebars Loose handlebar tightening boltSteering Loose or overtightening steering nut Bent under bracket Damaged bearing or ball raceFront forks Uneven oil levels on both sides Broken front fork spring Twisted front forksWheels Incorrect wheel balance Deformed wheel rim Unevenly worn tires Incorrect tire pressure Loose bearing Bent or loose wheel axleFrame Twisted Damaged head pipe bearingsRear arm Faulty bearings Bent rear armRear shock absorber Fatigued spring Improperly adjusted spring preload Oil leakageCowling Damage Improper mounting

YP******

STARTER MOTOR DOES NOTOPERATESTARTER MOTOR DOES NOT OPERATEBattery Insufficient battery capacity Faulty batteryFuse Burnt out, improper connectionSwitch Faulty main switch Faulty sidestand switch Faulty front and/or rear brake switch Faulty starting circuit cut-off relay Faulty starter relayWireharness Loose battery terminal Loosely connected coupler Improperly grounded Broken wireharnessStarter motor Worn brush Faulty commutator Broken armature coilEngine Seized engine

9-8

FAULTY SIGNAL AND LIGHTING SYSTEMTRBLSHTG

YP909000

FAULTY SIGNAL AND LIGHTING SYSTEMHEADLIGHT 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 expiredBULB BURNT OUT Improper bulb Faulty battery Faulty rectifier/regulator Improperly grounded Faulty main switch Bulb life expiredFLASHER DOES NOT BLILNK Improperly grounded Insufficient battery capacity Faulty fuse Faulty turn switch Faulty flasher relay Broken wireharness, incorrect coupler con-

nection Bulb burnt outFLASHER KEEPS ON Faulty flasher relay Insufficient battery capacity

(nearly discharged) Bulb burnt out (front or rear)

FLASHER BLINKS SLOWER Faulty flasher relay Insufficient battery capacity

(nearly discharged) Improper bulb Faulty main and/or turn switchFLASHER BLINKS QUICKER Improper bulb Faulty flasher relayHORN DOES NOT SOUND Faulty battery Faulty fuse Faulty main and/or horn switch Improper horn adjustment Faulty horn (burnt coil, connector) Broken wireharness

1. A.C. magneto2. Rectifier / regulator3. Main switch4. Main fuse5. Battery6. Starter relay7 Starter motor8 Thermo switch (auto choke)9. Auto choke

10. Ignitor unit11. Ignition coil12. Spark plug13. Pickup coil14. Sidestand switch15. Starting circuit cut-off relay16. Lights switch17. Starter switch18. Engine stop switch19. Handlebar switches (right)20. Fuse (fan)21. Thermo switch22. Fan motor23. Rear brake switch24. Front brake switch25. Flasher relay26. Horn27. Turn switch28. Horn switch29. Dimmer switch30. Pass switch31. Handlebar switches (left)32. Tail /Brake light33. Licence light34. Rear flasher lights35. Front flasher lights36. Head light37. Auxiliary light38. Turn indicator lights39. High beam indicator light40. Meter lights41. Cil indicator light42. Reset switch43. Fuel gauge44. Read switch45. Clock46. Thermometer47. Speedometer48. Meter assembly49. Fuel sender50. Thermo unit

COLOR CODEB Black. . . . . . . . Br Brown. . . . . . . Ch Chocolate. . . . . . Dg Dark green. . . . . . G Green. . . . . . . L Blue. . . . . . . . O Orange. . . . . . . Sb Sky blue. . . . . . . P Pink. . . . . . . . R Red. . . . . . . . Y Yellow. . . . . . . . W White. . . . . . . B /R Black /Red. . . . . .

Br /W Brown/White. . . . . G/R Green/Red. . . . . G/Y Green/Yellow. . . . . . L /B Blue/Black. . . . . . L /Y Blue/Yellow. . . . . . L /W Blue/White. . . . . L /R Blue/Red. . . . . . R/B Red/Black. . . . . . R/Y Red/ Yellow. . . . . . R/W Red/White. . . . . Y /W Yellow/White. . . . . W/G White/Green. . . . .

YP250 WIRING DIAGRAM

Yamaha 1996 YP250 Service Manual - 49ccScoot.Com

Documents