b ws 100 service
DESCRIPTION
en inglesTRANSCRIPT
YW1004VP-ME1
EB000000
YW100ESERVICE MANUAL
©1999 by Yamaha Motor TAIWAN Co., Ltd.1st Edition, March 1999
All rights reserved. Any reprinting orunauthorized use without the written
permission of Yamaha Motor Taiwan Co., Ltd.is expressly prohibited.
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 each
section. 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 accom-
panied by corresponding illustrations.
EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at start of eachremoval 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.
4
5
67
8
12 3
INDEXGENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION ANDADJUSTMENT
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
1
2
3
4
5
6
7
8
– +
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 0 to u are used to iden-tify the specifications appearing in the text.0 Possible to maintain with engine mountedq Filling fluidw Lubricante Special toolr Tighteningt Wear limit, clearancey Engine speedu Ω, V, A
Illustrated symbols i to d in the exploded dia-grams indicate the types of lubricants and lu-brication points.i Apply engine oilo Apply gear oilp Apply molybdenum disulfide oila Apply wheel bearing greases Apply lightweight lithium-soap base greased Apply molybdenum disulfide grease
Illustrated symbols f to g in the explodeddiagrams indicate the where to apply lockingagent f and when to install new parts g .f Apply locking agent (LOCTITE ®)g Use new one
GENINFO SPEC
INSPADJ ENG
COOL CARB
CHAS – +ELEC
TRBLSHTG
B LS M
LT New
E G M
1 2
3 4
5 6
7 8
9 0
T R..
q w
e r
t y u
i o p
a s d
f g
EB001000
NOTICEThis manual was produced by the Yamaha Motor Taiwan Company primarily for use by Yamaha/MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of amechanic in one manual, so it is assumed that anyone who uses this book to perform maintenanceand repairs on Yamaha/MBK scooter has a basic understanding of the mechanical ideas and theprocedures of scooter repair. Repairs attempted by anyone without this knowledge are likely torender the scooter unsafe and unfit for use.
Yamaha Motor Taiwan Company, Ltd. is continually striving to improve all its models. Modifica-tions and significant changes in specifications or procedures will be forwarded to all authorizedYamaha/MBK dealers and will appear in future editions of this manual where applicable.
NOTE:
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 deathto the scooter operator, a bystander or a person inspecting or repairing thescooter.
A CAUTION indicates special precautions that must be taken to avoid dam-age to the scooter.
A NOTE provides key information to make procedures easier or clearer.
w
Q
NOTE:
cC
CHAPTER 1.GENERAL INFORMATION
SCOOTER IDENTIFICATION ............................................................................................................. 1-1FRAME SERIAL NUMBER ............................................................................................................. 1-1ENGINE SERIAL NUMBER ............................................................................................................ 1-2
IMPORTANT INFORMATION ............................................................................................................ 1-3PREPARATION FOR REMOVAL PROCEDURES........................................................................... 1-3REPLACEMENT PARTS ................................................................................................................. 1-3GASKETS, OIL SEALS, AND O-RINGS ........................................................................................ 1-3LOCK WASHERS/PLATES AND COTTER PINS ........................................................................... 1-3BEARINGS AND OIL SEALS ......................................................................................................... 1-4CIRCLIPS ........................................................................................................................................ 1-4
CHECKING OF CONNECTIONS ........................................................................................................ 1-5HOW TO USE THE CONVERSION TABLE ....................................................................................... 1-6SPECIAL TOOLS ................................................................................................................................ 1-7
CHAPTER 2.SPECIFICATIONS
GENERAL SPECIFICATIONS ............................................................................................................. 2-1MAINTENANCE SPECIFICATIONS ................................................................................................... 2-4
ENGINE .......................................................................................................................................... 2-4CHASSIS ........................................................................................................................................ 2-7ELECTRICAL ................................................................................................................................... 2-9
GENERAL TORQUE SPECIFICATIONS........................................................................................... 2-11LUBRICATION POINTS AND LUBRICANT TYPE ........................................................................... 2-12
ENGINE ........................................................................................................................................ 2-12CHASSIS ...................................................................................................................................... 2-12
CABLE ROUTING ............................................................................................................................. 2-13
CHAPTER 3.PERIODIC INSPECTION AND ADJUSTMENTS
NTRODUCTION ................................................................................................................................. 3-1PERIODIC MAINTENANCE/ LUBRICATION INTERVALS ............................................................... 3-1
SIDECOVER AND SEAT ................................................................................................................ 3-3JOB INSTRUCTION CHART .......................................................................................................... 3-3LOWER COWLING ,UPPER COVER, LEG SHIELD1,2 AND FOOTREST BOARD ....................... 3-4HANDLEBAR COVER(FRONT AND REAR) ................................................................................... 3-5
ENGINE .............................................................................................................................................. 3-6IDLING SPEED ADJUSTMENT ..................................................................................................... 3-6THROTTLE CABLE FREE ADJUSTMENT ..................................................................................... 3-7AUTOLUBE PUMP AIR BLEEDING ............................................................................................... 3-8AUTOLUBE PUMP CABLE ADJUSTMENT .................................................................................. 3-8SPARK PLUG INSPECTION ........................................................................................................... 3-9ENGINE OIL LEVEL INSPECTION ............................................................................................... 3-10TRANSMISSION OIL REPLACEMENT ........................................................................................ 3-11AIR FILTER ELEMENT CLEANING .............................................................................................. 3-12V-BELT INSPECTION ................................................................................................................... 3-14
CHASSIS .......................................................................................................................................... 3-15FRONT BRAKE LEVER FREE PLAY CHECK ................................................................................ 3-15REAR BRAKE LEVER FREE PLAY CHECK................................................................................... 3-15BRAKE PAD INSPECTION ........................................................................................................... 3-15BRAKE SHOE INSPECTION ........................................................................................................ 3-16BRAKE FLUID LEVEL INSPECTION ............................................................................................ 3-16AIR BLEEDING(HYDRAULIC BRAKE SYSTEM) ......................................................................... 3-17STEERING ADJUSTMENT .......................................................................................................... 3-18TIRE INSPECTION ........................................................................................................................ 3-19WHEEL INSPECTION ................................................................................................................... 3-20FRONT FORK INSPECTION ......................................................................................................... 3-20REAR SHOCK ABSORBER INSPECTION .................................................................................... 3-20SEAT LOCK CABLE ADJUSTMENT ........................................................................................... 3-20
ELECTRICAL ..................................................................................................................................... 3-21BATTERY INSPECTION ............................................................................................................... 3-21FUSE INSPECTION ...................................................................................................................... 3-26HEADLIGHT BEAM ADJUSTMENT ............................................................................................ 3-27HEADLIGHT BULB REPLACEMENT............................................................................................ 3-27TAILLIGHT BULB/REAR FLASHER BULB REPLACEMENT ....................................................... 3-28TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT ........................................................... 3-28LICENCE LIGHT BULB REPLACEMENT...................................................................................... 3-29
CHAPTER 4.ENGINE
ENGINE OVERHAUL ......................................................................................................................... 4-1WIREHARNESS AND CABLES ...................................................................................................... 4-1
CYLINDER HEAD, CYLINDER AND PISTON .................................................................................... 4-3CYLINDER HEAD CYLINDER AND PISTON ................................................................................. 4-3PISTON PIN AND PISTON REMOVAL .......................................................................................... 4-4CYLINDER HEAD INSPECTION ..................................................................................................... 4-4CYLINDER AND PISTON INSPECTION ........................................................................................ 4-5PISTON RINGS INSPECTION ........................................................................................................ 4-7PISTON PIN AND PISTON PIN BEARING .................................................................................... 4-7PISTON PIN AND PISTON INSTALLATION ................................................................................. 4-8CYLINDER AND CYLINDER HEAD ................................................................................................ 4-9
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHAVE ............................................................. 4-11KICK STARTER AND CRANKCASE COVER(LEFT)..................................................................... 4-11KICK STARTER ............................................................................................................................. 4-12KICK STARTER INSTALLATION ................................................................................................. 4-13V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................ 4-14SECONDARY SHEAVE ................................................................................................................ 4-15PRIMARY SHEAVE REMOVAL .................................................................................................... 4-16SECONDARY SHEAVE REMOVAL.............................................................................................. 4-16CLUTCH INSPECTION ................................................................................................................. 4-17V-BELT INSPECTION ................................................................................................................... 4-18PRIMARY SHEAVE INSPECTION ................................................................................................ 4-19SECONDARY SHEAVE ................................................................................................................ 4-20SECONDARY SHEAVE INSTALLATION ..................................................................................... 4-21PRIMARY SHEAVE ...................................................................................................................... 4-22
STARTER CLUTCH AND STARTER MOTOR ................................................................................. 4-24STARTER CLUTCH AND STARTER MOTOR.............................................................................. 4-24STARTER CLUTCH AND GEARS ................................................................................................ 4-26
C.D.I. MAGNETO ............................................................................................................................. 4-27C.D.I. MAGNETO ......................................................................................................................... 4-27C.D.I. MAGNETO REMOVAL ....................................................................................................... 4-28C.D.I. MAGNETO INSTALLATION .............................................................................................. 4-28
AUTOLUBE PUMP ........................................................................................................................... 4-29AUTOLUBE PUMP ....................................................................................................................... 4-29AUTOLUBE PUMP INSTALLATION ........................................................................................... 4-30
TRANSMISSION .............................................................................................................................. 4-31TRANSMISSION .......................................................................................................................... 4-31
CRANKCASE AND REED VALUE ................................................................................................... 4-33CRANKCASE AND REED VALUE ................................................................................................ 4-33CRANKCASE(RIGHT)REMOVAL ................................................................................................. 4-35REED VALVE INSPECTION ......................................................................................................... 4-35CRANKCASE(RIGHT)INSTALLATION ........................................................................................ 4-36
CRANKSHAFT .................................................................................................................................. 4-38CRANKSHAFT .............................................................................................................................. 4-38CRANKSHAFT REMOVAL ........................................................................................................... 4-39CRANKSHAFT INSPECTION ....................................................................................................... 4-39CRANKSHAFT INSTLLATION ..................................................................................................... 4-40
CHAPTER 5CARBURETION
CARBURETION .................................................................................................................................. 5-1CARBURETOR ................................................................................................................................ 5-1CARBURETOR DISASSEMBLY ..................................................................................................... 5-2CARBURETOR INSPECTION ......................................................................................................... 5-3CARBURETOR ASSEMBLY ........................................................................................................... 5-3FUEL LEVEL ADJUSTMENT ......................................................................................................... 5-4AUTO CHOKE INSPECTION .......................................................................................................... 5-5FUEL COCK INSPECTION ............................................................................................................. 5-6
CHAPTER 6CHASSIS
FRONT WHEEL AND BRAKE DISC ................................................................................................... 6-1FRONT WHEEL AND BRAKE DISC ............................................................................................... 6-1FRONT WHEEL DISASSEMBLY .................................................................................................... 6-2FRONT WHEEL DISASSEMBLY .................................................................................................... 6-3FRONT WHEEL INSPECTION ........................................................................................................ 6-3BRAKE DISC INSPECTION ............................................................................................................ 6-4FRONT WHEEL ASSEMBLY .......................................................................................................... 6-4FRONT WHEEL INSTALLATION ................................................................................................... 6-5WHEEL STATIC BALANCE ADJUSTMENT .................................................................................. 6-6
FRONT BRAKE ................................................................................................................................... 6-8BRAKE PAD .................................................................................................................................... 6-8BRAKE PAD REPLACEMENT ........................................................................................................ 6-9
MASTER CYLINDER ........................................................................................................................ 6-12MASTER CYLINDER DISASSEMBLY ............................................................................................. 6-13
MASTER CYLINDER INSPECTION.............................................................................................. 6-14MASTER CYLINDER ASSEMBLY................................................................................................ 6-14MASTER CYLINDER INSTALLATION ......................................................................................... 6-15
CALIPER ........................................................................................................................................... 6-17CALIPER DISASSEMBLY................................................................................................................. 6-18
BRAKE CALIPER DISASSEMBLY ................................................................................................ 6-19CALIPER INSPECTION ................................................................................................................. 6-19BRAKE CALIPER ASSEMBLY ...................................................................................................... 6-20CALIPER INSTALLATION ............................................................................................................ 6-20
REAR WHEEL AND REAR BRAKE .................................................................................................. 6-21REAR WHEEL AND REAR BRAKE............................................................................................... 6-21REAR WHEEL ............................................................................................................................... 6-21REAR BRAKE ................................................................................................................................ 6-22REAR WHEEL INSPECTION ........................................................................................................ 6-23REAR BRAKE INSPECTION ......................................................................................................... 6-23REAR BRAKE INSTALLATION .................................................................................................... 6-24
HANDLEBAR .................................................................................................................................... 6-25HANDLEBAR ................................................................................................................................ 6-25HANDLEBAR INSTALLATION ..................................................................................................... 6-27
STEERING ........................................................................................................................................ 6-29STEERING .................................................................................................................................... 6-29STEERING REMOVAL ................................................................................................................. 6-30STEERING INSPCTION ................................................................................................................ 6-31STEERING INSTALLATION ......................................................................................................... 6-31
FRONT FORK ...................................................................................................................................6-34FRONT FORK ............................................................................................................................... 6-34
FRONT FORK DISASSEMBLY.........................................................................................................6-35FRONT FORK REMOVAL ............................................................................................................. 6-36FRONT FORK DISASSEMBLY ..................................................................................................... 6-36FRONT FORK INSPECTION ......................................................................................................... 6-37FRONT FORK ASSEMBLY ........................................................................................................... 6-37FRONT FORK INSTALLATION .................................................................................................... 6-39
CHAPTER 7ELECTRICAL
ELECTRICAL COMPONENTS ........................................................................................................... 7-1CIRCUIT DIAGRAM ....................................................................................................................... 7-2
CHECKING SWITCHES ..................................................................................................................... 7-4CHECKING STEPS ........................................................................................................................ 7-4
SWITCH CONNECTION AS SHOWN IN THIS MANUAL ............................................................... 7-4SWITCH POSITION AND TERMINAL CONNECTION ..................................................................... 7-5IGNITION SYSTEM ........................................................................................................................... 7-6
CIRCUIT DIAGRAM ....................................................................................................................... 7-6TROUBLESHOOTING ................................................................................................................... 7-7
CHARGING SYSTEM ...................................................................................................................... 7-10CIRCUIT DIAGRAM ..................................................................................................................... 7-10TROUBLE SHOOTING ................................................................................................................ 7-11
ELECTRIC STARTING SYSTEM ..................................................................................................... 7-14CIRCUIT DIAGRAM ..................................................................................................................... 7-14TROUBLE SHOOTING ................................................................................................................ 7-15
STARTER MOTOR .......................................................................................................................... 7-19STARTER DISASSEMBLY .......................................................................................................... 7-20JOB INSTRUCTION CHART ....................................................................................................... 7-20INSPECTION AND REPAIR ......................................................................................................... 7-21
LIGHTING SYSTEM ........................................................................................................................ 7-23CIRCUIT DIAGRAM ..................................................................................................................... 7-23TROUBLESHOOTING ................................................................................................................. 7-24
SIGNAL SYSTEM............................................................................................................................ 7-29CIRCUIT DIAGRAM ..................................................................................................................... 7-29TROUBLESHOOTING ................................................................................................................. 7-30SIGNAL SYSTEM CHECK ........................................................................................................... 7-32
AUTO CHOKE SYSTEM ................................................................................................................. 7-38CIRCUIT DIAGRAM ..................................................................................................................... 7-38TROUBLESHOOTING ................................................................................................................. 7-39
CHAPTER 8TROUBLESHOOTING
STARTING FAILURE/HARD STARTING........................................................................................... 8-1FUEL SYSTEM ............................................................................................................................... 8-1IGNITION SYSTEM ........................................................................................................................ 8-2COMPRESSION SYSTEM ............................................................................................................. 8-2
POOR IDLE SPEED PERFORMANCE ................................................................................................ 8-3POOR IDLE SPEED PERFORMANCE ............................................................................................ 8-3
POOR MEDIUM AND HIGH SPEED PERFORMANCE...................................................................... 8-3POOR MEDIUM AND HIGH SPEED PERFORMANCE .................................................................. 8-3
FAULTY AUTOMATIC(V-BELT TYPE) .............................................................................................. 8-4SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING .................................................. 8-4CLUTCH OUT FAILURE ................................................................................................................. 8-4POOR STANDING START(LOW CLIMBING ABILITY) ................................................................. 8-4POOR ACCELERATION(POOR HIGH SPEED) .............................................................................. 8-4
OVERHEAT/POOR SPEED ................................................................................................................ 8-5OVERHEAT ..................................................................................................................................... 8-5
POOR SPEED ..................................................................................................................................... 8-5POOR SPEED ................................................................................................................................. 8-5
IMPROPER KICKING .......................................................................................................................... 8-6SLIPPING ........................................................................................................................................ 8-6HARD KICKING .............................................................................................................................. 8-6KICK CRANK NOT RETURNING ................................................................................................... 8-6
FAULTY BRAKE ................................................................................................................................. 8-7POOR BRAKING EFFECT ............................................................................................................... 8-7MALFUNCTION ............................................................................................................................. 8-7
INSATABLE HANDLING .................................................................................................................... 8-8INSATABLE HANDLING ................................................................................................................ 8-8
FAULTY SIGNAL AND LIGHTING SYSTEM .................................................................................... 8-9HEADLIGHT DARK ......................................................................................................................... 8-9BULB BURNT OUT ........................................................................................................................ 8-9FLASHER DOES NOT BLINK ......................................................................................................... 8-9FLASHER KEEPS ON ..................................................................................................................... 8-9FLASHER BLINKS SLOWER ........................................................................................................ 8-10FLASHER BLINKS QUICKER ....................................................................................................... 8-10HORN DOES NOT SOUND ......................................................................................................... 8-10
WIRING DIAGRAM
GENINFO
1-1
SCOOTER INDENTIFICATION
1GENERAL INFORMATION
SCOOTER IDENTIFICATIONFRAME SERIAL NUMBERThe frame serial number 1 is stamped into theplate on the frame.
Initial serial number:YW100E1(I)
*LPRSB0210**00000101*
YW100E1(F)*LPRSB0210**00000101*
YW100E2(I)*LPRSB0220**00100101*
YW100E2(F)*LPRSB0220**00100101*
YW100E3(G)*LPRSB0210**00300101*
YW100E4(G)*LPRSB0220**00400101*
YW100E5(P)*LPRSB0210**00200101*
YW100E5(Es)*LPRSB0210**00200101*
YW100E6(A)*LPRSB0210**00500101*
YW100E7(Che)*LPRSB0210**00600101*
YW100E8(Che)*LPRSB0220**00700101*
GENINFO
1-2
SCOOTER INDENTIFICATION
1
ENGINE SERIAL NUMBERThe engine serial number 1 is stamped intothe transmission case.
Initial serial number:YW100E1(I,F):
B103E-000101YW100E2(I,F):
B103E-100101YW100E3(G):
B103E-300101YW100E4(G):
B103E-400101YW100E5(P,S):
B103E-200101YW100E6(A):
B103E-500101YW100E7(Che):
B103E-600101YW100E8(Che):
B103E-700101
GENINFO
1-3
EB101000
IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCEDURES1. 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, always
keep 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 orderof disassembly. This will speed up assem-bly and allow for the correct installationof all parts.
6. Keep all parts away from any source offire.
EB101010
REPLACEMENT PARTS1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-mended by Yamaha for all lubricationjobs. Other brands may be similar in func-tion and appearance, but inferior in qual-ity.
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 theoil seal lips.
IMPORTANT INFORMATION
300-008
300-016
GENINFO
1-4
IMPORTANT INFORMATIONEB101030
LOCK WASHERS/PLATES AND COTTER PINS1. Replace all lock washers/plates and cot-
ter pins after removal. Bend lock tabsalong the bolt or nut flats after the bolt ornut has been tightened to specification.
1 Lock washer
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 coatingof lightweight lithium base grease to the seallips. Oil bearings liberally when installing, ifappropriate.
1 Oil seal
cCDo not use compressed air to spin the bear-ings dry. This will damage the bearing surfaces.
1 Bearing
EB101050
CIRCLIPS1. Check all circlips carefully before reassem-
bly. Always replace piston pin clips afterone use. Replace distorted circlips. Wheninstalling a circlip 1 , make sure that thesharp-edged corner 2 is positioned op-posite the thrust 3 it receives. See sec-tional view.
4 Shaft
OR
GENINFO
1-5
IMPORTANT INFORMATIONEB801000
CHECKING OF CONNECTIONSDealing with stains, rust, moisture, etc. on theconnector.1. Disconnect:8 Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector twoor three.
4. Pull the read to check that it will not comeoff.
5. If the terminal comes off, bend up the pin1 and reinsert the terminal into the con-nector.
6. Connect:8 Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
8 If there is no continuity, clean the termi-nals.
8 Be sure to perform the steps 1 to 7 listedabove when checking the wireharness.
8 For a field remedy, use a contact revitalizeravailable on the market.
8 Use the tester on the connector as shown.
GENINFO
1-6
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 = 0.083 in
CONVERSION TABLEMETRIC TO IMP
Known Multiplier Result
7.23386.7940.07230.8679
2.2050.03527
0.62140.62143.2811.0940.39370.03937
0.035270.061020.87990.2199
55.99714.22349/5(°C)+32
ft.lbin.lbft.lbin.lb
lboz
mphmiftydinin
oz (IMP liq.)cu.inqt(IMP liq.)gal(IMP liq.)
lb/inpsi(lb/in2)Fahrenheit (°F)
Torque
Weight
Distance
Volume/Capacity
Miscellaneous
m.kgm.kgcm.kgcm.kg
kgg
km/hkmmmcmmm
cc(cm3)cc(cm3)lit(liter)lit(liter)
kg/mmkg/cm2
Centigrade
HOW TO USE THE CONVERSION TABLE
GENINFO
1-7
EE102000
SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly 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.
SPECIAL TOOLS
Tool name / Usage
Rotor holding tool
This tool is used to remove the flywheelmagneto.
Ringnut wrench
This tool is used to loosen and tighten theexhaust and steering ringnut.
Clutch spring compressor
These tools are used for removing the nutwith holding the compression spring.
Crankshaft Installer pot 1Crankshaft Installer bolt 2Adapter 3 ,Spacer 4These tools are used to install the crank-shaft.
Flywheel puller
This tool is used for removing the rotor.
Crankcase Separating tool
This tool is used to remove the crankshaftor separate the crankcase.
Oil seal guide
This tool is used for protecting the oil seallip when installing the secondary slidingsheave.
Ring nut wrench
This tool is used to loosen and tighten thesteering ring nut.
Sheave holder
This tool is used for holding the secondarysheave.
Thickness gauge
This tool is used to measure the clearance
Tool No.
90890-01235
90890-01268
90890-01337
90890 -01274-01275-01277-01288
90890-01189
90890- 01135
90890-01384
90890-01403
90890-01701
90890-03079
Illustration
GENINFO
1-8
IllustrationTool No.
90890-03112
90890-03113
90890-01409
90890-01410
90890-06754
90890-85505
90890-01348
90890-01367 1-01400 2
Tool name / Usage
Pocket tester
These instruments are invaluable for check-ing the electrical system.
Engine tachometer
This tool is needed for detecting enginerpm.
Oil seal guide
This tool is used to install the left side crank-case oil seal.
Oil seal installer
This tool is used to install the left side crank-case oil seal.
Ignition checker
This instrument is necessary for checkingthe ignition system components.
Yamaha bond No. 1215
This sealant (bond) is used for crankcasemating surface, etc.
Locknut wrench
This tool is used to loosen and tighten theclutch carrier locknut of the secondarysheave.
Front fork seal driverWeight 1Adapter 2
These tools are used when installing thefork seal.
SPECIAL TOOLS
1 2
SPEC
2-1
YW100E1/2/3/4/5/6/7/8
4VPB/F/G/H/J/K/L/M
1,890mm660mm1,115mm765mm1,270mm119mm1,800mm
96kg
Air cooled 2 strcke, gasoline torque inductionForward- inclined single cylinder101cm3
52.0 × 47.6 mm6.6:1Electric and kick starterSeparate lubrication
For YAMAHA brand:Yamalube 2 or Air cooled 2-stroke engine oil (JASOFC grade or ISO EG-C, EG-D grade)For MBK brand:Semi synthetic oil in accordance to the API TS3standardSAE 85W/140
1.4L
0.11L0.13L
Wet type element
Regular unleaded gasoline5.7L
VM16SS/MIKUNI
GENERAL SPECIFICATION
SPECIFICATIONGENERAL SPECIFICATION
Model
Model code:
Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius
Basic weight:With oil and full fuel tank
Engine:Engine typeCylinder arrangementDisplacementBore × strokeCompression ratioStarting systemLubrication system:
Oil Type or Grade:Engine Oil
Transmission Oil
Oil Capacity:Oil Tank (Engine Oil)Transmission Oil:Periodic Oil ChangeTotal Amount
Air Filter:
Fuel:TypeTank Capacity
Carburetor:Type / Manufacturer
SPEC
2-2
Model
Spark Plug:Type/ManufacturerGap
Clutch Type
Transmission:Primary Reduction SystemPrimary Reduction RatioSecondary Reduction SystemSecondary Reduction RatioTransmission TypeOperation
Chassis:Frame typeCaster angleTrail
Tire:TypeSize front
rearManufacturer front
rearType front
rear
Maximum load*Cold tire Pressure:
Up to 90 kgFrontRear
90 kgload~Maximum load*FrontRear
Brake:Front brake type
operationRear brake type
operation
Suspension:Front suspensionRear suspension
Shock absorber:Front shock absorberRear shock absorber
Wheel travel:Front wheel travelRear wheel travel
Electrical:Ignition systemGenerator systemBattery typeBattery capacity
YW100E1/2/3/4/5/6/7/8
BPR7HS/NGK0.9 ~ 1.0 mm
Dry, Centrifugal automatic
Herical gear47/15 (3.133)Spur gear43/13 (3.308)V-beltAutomatic
Steel tube underbone26˚86mm
Tubeless120/90-10130/90-10CHENG SHINCHENG SHIN56J59J
160 kg
200kpa(2.0 kg/cm2, 2.0 bar)200kpa(2.0 kg/cm2, 2.0 bar)
200kpa(2.0 kg/cm2, 2.0 bar)200kpa(2.0 kg/cm2, 2.0 bar)
Single disc brakeRight hand operationDrum brakeLeft hand operation
Telescopic forkUnit swing
Coil spring/oil damperCoil spring/oil damper
70 mm55 mm
C.D.IFlywheel MagnetoYTX5L-BS12V 4AH
GENERAL SPECIFICATION
SPEC
2-3
Model
Headlight type:
Bulb wattage x quantity:HeadlightTail/brake lightFlasher lightAuxiliary lightLicence plate lightMeter light
High beam indicator lightOil indicator lightTurn indicator light
YW100E1/2/3/4/5/6/7/8
Bulb S1
25W/25W×25W/21W×110W×45W×25W×13.4W×1/1.7W×11.7W×11.7W×11.7W×1
GENERAL SPECIFICATION
SPEC
2-4
Standard
...
52.002~52.012......
0.044~0.045 mm
51.958~51.967 mm10 mm52.52 mm52.50 mm14.004~14.015 mm
13.996~14.000 mm
1.2 × 2.05 mm/keystone1.2 × 2.05 mm/keystone
0.15~0.35 mm0.15~0.35 mm
0.03~0.05 mm0.03~0.05 mm
37.90~37.95 mm0.03 mm
0.2~0.5 mm0.4~0.8 mm
MAINTENANCE SPECIFICATION
MAINTENANCE SPECIFICATIONENGINE
Item
Cylinder head:Warp limit
*Lines indicate straightedge measurement
Cylinder:Bore sizeTaper limitOut of round limit
Piston:Piston to cylinderclearancePiston size “D”Measuring point “H”Oversize 1st
2ndPiston pin boreinside diameterPiston pin outside diameter
Piston Ring:Sectional Sketch (B × T)/Type
Top Ring2nd Ring
End Gap (Installed):Top Ring2nd Ring
Side Clearance ( Installed):Top Ring2nd Ring
Crankshaft:
Crank Width “A”Run Out Limit “C”Connecting Rod Big End Side
Clearance “D”Small End Free Play “F”
Limit
0.05 mm
52.10 mm0.05 mm0.03 mm
0.10 mm...............14.045 mm
13.975 mm
0.10 mm0.10 mm
0.60 mm0.60 mm
...
...
1.0 mm...
H
D
SPEC
2-5
Item
Automatic centrifugal clutch:Clutch shoe thicknessClutch housing inside diameterClutch shoe spring free lengthClutch - in revolutionClutch - stall revolution
V-belt:V-belt width
Transmission:Main Axle Runout LimitDrive Axle Runout Limit
Kick Starter:TypeKick Clip Tension
Carburetor:I.D. MarkMain Jet (M .J .)Main nozzle (NJ)
Jet Needle-clip Position (J.N.)Main Air Jet ( M .A .J .)Cutaway (C.A.)Pilot Jet (P.J.)Pilot Air Screw (A.S .)Valve Seat Size (V.S.)Starter Jet (G .S.)Float HeightFuel level heightEngine Idling Speed
Reed Valve:Valve Stopper HeightReed Valve Clearance
Standard
4.0 mm112 mm26.2 mm2,800~3,400 r/min4,500~5,500 r/min
17.7 mm
0.08 mm0.08 mm
Ratchet type150~250 g
4VP-30 (4VPL/M:4VP-40)#75E-34DM7-3ø0.73.5#32.51and1/4±1/4ø1.5#3016.5 mm3.0~4.0 mm1,750~1,850 r/min
6.0~6.4 mmLess than 0.2 mm
MAINTENANCE SPECIFICATION
Limit
2.5 mm122.5 mm.........
16.0 mm
SPEC
2-6
MAINTENANCE SPECIFICATION
2.01.41.70.70.20.70.41.10.90.20.92.60.91.11.31.21.21.20.70.71.80.30.80.91.34.04.50.84.3
TIGHTENING TORQUESENGINE
Tighteningtorque
Nm m•kg
Threadsize
Part name Q’ty RemarksPart to be tightened
Spark plugCylinder head and cylinderCylinderAir shroud 3Air shroud 1×3FanAutolube pumpReed valveAir filterCarburetor capExhaust pipeMufflerExhaust protectorCap and pipeExhaust coverCrankcase 1×2Crankcase cover 2Crankcase cover 1Air ductCrankcase holderDrain boltOil plugIdle gear plateKick crankStarter motorClutch housingPrimary sheeveMagnet baseMagnet rotor
—NutStud boltScrewScrewScrewScrewBoltScrewScrewScrewBoltBoltBoltBoltBoltBoltBoltScrewScrewBoltPlugScrewBoltBoltNutNutScrewNut
M 14M 7M 7M 66.0M 6M 5M 6M 6M 4M 6M 8M 6M 6M6M 6M 6M 6M 6M 6M 8M 14M 6M 6M 6M 10M 12M 6M 12
144313241222335661222112121121
20141772741192926911131212127718389134045843
LT
LT
LT
SPEC
2-7
MAINTENANCE SPECIFICATION
CHASSIS
Item
Steering system:Steering bearing typeNo /size of steel balls: Upper
Lower
Front suspension:Front fork travelFork free lengthFork length (Installed)Spring rate (K1)
(K2)Oil capacityOil gradeInner tube vend limit
Rear suspension:Shock absorber strokeShock absorber free length (Installed)Spring free length (Installed)Spring rate (K1)
Front wheel:TypeRim sizeRim materialRim runout limit radial
lateral
Rear wheel:TypeRim sizeRim materialRim runout limit radial
lateral
Front disc brake:TypeDisc outside diameter × thicknessPad thicknessMaster cylinder inside diameterCaliper cylinder outside diameterBrake fluid type
Rear drum brake:TypeDrum inside diameterShoe thickness
Brake lever:Brake lever free play (front at lever side)Brake lever free play (rear)Throttle cable free play
Standard
Ball bearing22 pcs19 pcs
70 mm350.8 mm212.1 mm15.68 Nm/mm(1.6 kg/mm)23.5 Nm/mm(2.43 kg/mm)88 c.cFork oil 10W or equivalent...
55 mm281.8 mm159.8 mm71.15 N/mm(7.26 kg/mm)
Cast wheelMT3.50×10Aluminum......
Cast wheelMT3.50×10Aluminum......
Single180×4.06 mm11 mm34.93 mmDOT #4
Leading, trailing130 mm4 mm
2~5 mm10~20 mm3~5 mm
Limit
...
...
...
...212.1 mm............
0.2 mm
...
...
...
...
...
...
...
...1 mm1 mm
...
...
...1 mm1 mm
...180×3.5 mm0.8 mm.........
...131 mm2 mm
...
...
...
SPEC
2-8
TIGHTENING TORQUESCHASSIS
Tighteningtorque
Nm m•kg
Threadsize
RemarksPart to be tightened
8.44.51.01.35.53.01.62.24.32.01.00.70.40.70.70.20.77.012.01.02.32.00.51.10.70.6
Frame and engine bracketEngine bracket, compression rod and engineProtect barRear gripSidestandRear shock absorber and frameRear shock absorber and engineSteering ring nutHandle holder and steering shaftBrake hose and master cylinderFuel tankFuel cockFuel senderBoxSeat lock assemblyPlastic parts & coverFootrest boardFront wheel axle and nutRear wheel axle and nutRear brake cam leverFront brake caliper and front forkBrake disc and hubBrake hose and front fork(lower)-boltBrake hose and front fork(lower)-nutBrake hose and front fork(upper)-boltBrake caliper and bleed screw
M 12M 10M 6M 6M 10M 10M 8M 25M 10M 8M 6M 6M 5M 6M 6M 5M 6M 10M 14M 6M 8M10M 6M 6M 6M 5
84451013553016224320107447277012010232051176
See”page6-29”
LT
MAINTENANCE SPECIFICATION
SPEC
2-9
ELECTRICAL
MAINTENANCE SPECIFICATION
Standard
14˚ at 5,000 r/minElectrical type
400~600Ω at 20˚C/(Black-White/Red)640~960 Ω(Black/ Red ,Black)4VP/TIIC
4VP/TIIC6 mm0.32~0.48 Ω at 20˚C5.68~8.52kΩ at 20˚C
Resin type5 kΩ
Flywheel magneto
4VP/TIIC12V 85W/5,000 rpm0.6A at 3,000r/min1.2A at 8,000r/min13~14V at 4,000 rpm0.48~0.72 Ω (White-Black)0.4~0.6 Ω (Yellow/Red- Black)12~15V (3,000~8,000 rpm)
3GF/Taichung8A18V
1.320
Constant mesh type
4VP/TIIC12V0.2 kw0.03~0.04 Ω at 20˚C7 mm2 pcs400~600g17.6 mm1.35 mm
3 KW/Shulin100A3.87~4.73 Ω at 20˚C
Item
Ignition timing:Ignition timing (B.T.D.C.)Advanced type
C.D.I.:Pickup coil resistance/color
Source coil resistance/color
C.D.I. unit model/manufacturer
Ignition coil:Model/manufacturerMinimum spark gapPrimary winding resistanceSecondary winding resistance
Spark plug cap:TypeResistance
Charging System/Type:
C.D.I. Magneto:Model/ManufacturerNominal outputCharging current
Charging voltageCharging Coil Resistance (Color)Lighting Coil Resistance (Color)Lighting VoltageRectifier:
Model/ManufacturerCapacityWithstand voltage
Battery:Specific gravity
Electric starter system:TypeStarter motor:
Model/manufacturer/ID numberOperation voltageOutputArmature coil resistanceBrush overall lengthBrash quantitySpring forceCommutator diameterMica undercut (depth)
Starter relay:Model/manufacturerAmperage ratingCoil winding resistance
limit
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...3.5 mm...400g16.6 mm...
...
...
...
SPEC
2-10
Item
Horn:Model/manufacturerMaximum amperage
Flasher relay:TypeFlasher frequency
Fuel gage:Model/manufacturerSender unit resistance - full
- empty
Oil level gauge:Model/manufacturer
Circuit breaker:TypeMAIN
Standard
4VP/Asian1.5A
Capacitor60~120 Cycle/min
4VP/San Chu4~10 Ω90~100 Ω
4VP/Lun Ping
Fuse7Ax1pc.
limit
...
...
...
...
...
...
...
...
...
...
MAINTENANCE SPECIFICATION
SPEC
2-11
General torquespecifications
Nm m.kg6 0.6
15 1.5
30 3.0
55 5.5
85 8.5
130 13.0
GENERAL TORQUE SPECIFICATIONS
GENERAL TORQUESPECIFICATIONSThis 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 B
A(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
B(Bolt)
6 mm
8 mm
10 mm
12 mm
14 mm
16 mm
SPEC
2-12
Lubrication Points (Part name)
Oil Seal Lip (All)
O-ring (All)
Small End Bearing
Big End Bearing
Starter Idle Bearing
Primary Drive Gear Bearing
Kick Axle Bearing
Drive Axle Bearing
Main Axle Bearing
Starter Clutch
Piston, Piston Ring Piston Pin and Cylinder
Oil Pump Drive and Driven Gear
Sliding Surface (Secondary Sheave)
Oil Seal and O-ring (Secondary Sheave)
Cam Groove (Secondary Sheave)
Crankcase Matching Surface
LUBRICATION POINTS AND LUBRICATION TYPE
LUBRICATION POINTS AND LUBRICATION TYPEENGINE
Lubrication Points
Steering Shaft Bearing
Throttle Grip Inner Surface
Brake Cables End
Brake Cam Shaft and Pin
Wheel Bearing
Speedometer Drive and Driven Gear
Wheel Axles
Lublicant Type
BEL-LAY Assembly Lube®
BEL-LAY Assembly Lube®
BEL-LAY Assembly Lube®
Yamaha Bond No. 1215
LS
LS
LS
CHASSIS
LS
Lubricant Type
B
LS
LS
LS
LS
LS
E
E
G
G
G
G
G
M
E
SPEC
2-13
CABLE ROUTING1 Horn2 Rectifier regulator3 Main switch4 Resistor5 Headlight leads6 Speedometer cable7 Ignition coil8 Throttle cable9 Battery negative(-)0 Autolube pump cableq Fuel sender leadw Seat lock cablee Oil tank hose
CABLE ROUTINGr C.D.I. unitt Throttle cable 1y Wire harnessA Pass the speedometer cable
through the right hole of frontfender, then through theguide.
B Pass the wire harnessthrough the inside of ignitioncoil.
C Secure the ground lead andthe ignition coil base to theignition coil stay.
D Pass the wire harnessthrough the inside of oil tank.
E Pass the seat cable throughthe inside of frame.
F Align the clip with the whitebrand.
G Clamp the wire harnessH Insert the seat cable through
the frame tube.I Clamp wireharness, autolube
pump cable, rear brake cablethrottle cable 2.
J Position the cylinder betweenthe supporter and mainswitch.
SPEC
2-14
CABLE ROUTING
1 Brake cable2 Speedometer cable3 Fuel tank overflow hose4 Brake cable holder5 Air induct pipe6 Brake hose7 Brake hose holder8 License bracket9 Flasher relay0 Resistanceq Fuel tank breather hose
A Pass the brake hose through the holder.B Insert the fuel overflowhose bottom.C Pass the fuel overflowhose through the rear
fender hole.D Pass the fuel overflowhose through the
holder.E Hold the fuel overflowhose with a clamp.F Pass the brake cable through the holder.G Pass the brake cable through the hook.
9
0
6 1
2
7
A G 5
F4
8
E
D
C
3B
q
SPEC
2-15
CABLE ROUTING
1 Brake hose2 Front fender3 Front fork assembly4 Nut5 Plate washer6 Brake hose holder7 Flange bolt8 Bolt9 Brake hose holder0 Flange bolt
A Pass the brake hose through the holder.
1
2
3
3
7
5
45
6
86
1
9
0
3
1
7
5
1
54
A
SPEC
2-16
CABLE ROUTING
1 Ignition coil2 Spark plug lead3 Starter relay leads4 Auto choke leads5 Starter relay6 Bind7 C.D.I. unit8 Autolube hose9 Seat lock cable0 Bracketq Fuel tank breather hosew Bind 2e Cooling pipe
r Battery(–)leadt Battery(+)leadA Pass battery leads through
the slot of footrestboard.B Cover them after securing
starter relay leads.C Pass the seat lock cable
through the hole of bracket.D Pass the fuel tank breath
hose over seat lock cable.E Clamp carburetor vacuum
hose, fuel hose and fuelcock vacuum hose.
F Clamp autochoke leads andautolube hose on to carburetorthrottle cable.
G Pass the battery leads over framemember.
H Put fuse box on to footrest boardholder.
I Pass throttle cable2, wireharness,autolube pump cable, brake cablethrough the outside of batterybox.
EwF
eG
rtH
I
1 A
B
2
3
4
56 7 8
90
C
D
q
SPEC
2-17
1 Flasher relay2 Speedometer3 Brake cable4 Handlebar switch(left)5 Front flasher leads6 Speedometer cable7 Wire harness8 Brake hose9 Handlebar switch(right)0 Throttle cable1
A Pass brake cable through the slot of bracket.B Avoid clamping front flasher leads when in-
stalling handlebar covers.C Pass throttle cable1 through between
handlebar and wireharness.D Hang the wireharness bind on to the bracket.
CABLE ROUTING
INSPADJ
3-1
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 vehicleoperation and a longer service life. The need for costly overhaul work will be greatly reduced. Thisinformation applies to vehicles already in service as well as to new vehicles that are being pre-pared for sale. All service technicians should be familiar with this entire chapter.YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INTRODUCTION/PERIODICMAINTENANCE/LUBLICATION INTERVALS
• Check fuel hoses and vacuumhose for cracks or damage.
• Replace if necessary.
• Check condition.• Clean, regap or replace if neces-
sary.
• Clean or replace if necessary.
• Check operation, fluide level andvehicle for fluid leakage.
• Correct accordingly.• Replace brake pads if necessary.
• Check operation.• Adjust brake lever free play and
replace brake shoes if necessary.
• Check balance, runout and fordamage.
• Rebalance or replace if necessary.
• Check tread depth and for dam-age.
• Replace if necesssary.• Check air pressure.• Correct if necessary.
• Check Bearing for looseness ordamage.
• Replace if necessary.
• Check bearing play and steeringfor roughness.
• Correct accordingly.• Lubricate with lithium soap base
greese every 24,000 km or 24months (whichever comes first).
• Make sure that all nuts, bolts andscrews are properly tightened.
• Tighten if necessary.
Fuel line
Spark plug
Air filter
Front brake
Rear brake
Wheels
Tires
Wheel bearings
Steering bearings
Chassis fasteners
ITEM ROUTINE TYPE
BREAK-IN EVERY
INITIAL(1,000km)
12,000 kmor
12months(whichevercomes first)
6,000 kmor
6 months(whichevercomes first)
NO.
*
*
*
*
*
*
*
*
*
1
2
3
4
5
6
7
8
9
10
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
–
–
–
–
–
–
–
Refer to SPARKPLUG INSPECTION
Same as engine oil
Brake fluid DOT 4
INSPADJ
3-2
Items marked with an asterisk (*) require special tools, data and technical skills for servicing. Takethe scooter to a Yamaha/MBK dealer.
NOTE:
•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.
ITEM ROUTINE TYPE
BREAK-IN EVERY
NO.
PERIODICINSPECTION AND ADJUSTMENTS
11
12
13
14
15
16
17
18
*
*
*
*
*
*
*
*
Sidestand/centerstand
Sidestand switch
Front fork
Rear shock ab-sorber assembly
Carburetor
Autolube pump
Final gear oil
V-belt
• Check operation.• Replace if necessary.
• Check operation.• Replace if necessary.
• Check operation and for oil leak-age.
• Correct accordingly.
• Check operation and shock ab-sorber for oil leakage.
• Replace shock absorber assemblyif necessary.
• Check engine idling speed andstarter operation.
• Adjust if necessary.
• Check operation.• Correct if necessary.• Bleed if necessary.
• Check oil level and vehicle for oilleakage.
• Change oil at initial 1,000 km andthereafter every 24,000 km or 24months.
• Check for wear and damage.• Replace if necessary.
12,000 kmor
12months(whichevercomes first)
6,000 kmor
6 months(whichevercomes first)
SAE 85W 140
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
?
–
–
–
–
–
–
Same as engine oil
INITIAL(1,000km)
INSPADJ
3-3
Job name/Part name
Sidecover and seat removalBattery box cover
SeatSeat hangeRear carrierLeft side coverRight side coverCenter cover
COVER AND PANELSIDECOVER AND SEAT
Remarks
Remove the parts in order.NOTE:
Insert the (-) screwdriver into the slot ofbattery cover and pickup then remove.
Reverse the removal procedure for instal-lation.
Order
1.
2.3.4.5.6.7.
Q’ty
1
111111
COVER AND PANEL
T R..
13Nm(1.3 kg.m)
2
6
7
1
5
4
3
INSPADJ
3-4
LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD
Order
1.2.3.4.5.6.7.8.9.
Q’ty
11141
1/1112
Job name/ part name
Lower cowling, upper cover, legshield 1,2 and footrest board re-movalLower cowlingProtector barUpper coverBoltLeg shield 1Main switch cover/ leg shield 2BatteryFootrest boardFlap
Remarks
Remove the parts in order.
Reverse the removal procedure for instal-lation.
COVER AND PANEL
4
5
2 3
6 7
8
9
1
T R..
10Nm(1.0kg.m)
T R..
7Nm(0.7kg.m)
INSPADJ
3-5
HANDLEBAR COVER(FRONT AND REAR)
Order
1.2.3.4.
Q’ty
211
1/1
Job name / Part name
Handlebar cover(Front and Rear) re-moval.MirrorsFront handlebar coverRear handlebar coverFlasher light(Left/Right)
Remarks
Remove the part in order.
Reverse the removal procedure for instal-lation.
COVER AND PANEL
1
4
2
4
3
INSPADJ
3-6
ENGINEIDLE SPEED ADJUSTMENT1. Remove
8 Battery box cover2. Tighten:
8 Pilot air screw 1Turn the pilot air screw in until lightlyseated.
3. Loosen:8 Pilot air screw
Back it out from its lightly seated posi-tion.
Pilot air screw turns out:1and1/4±1/4
3. Start the engine and let it warm up.
wBefore starting the engine, be sure to use thecenterstand for safety.
4. Attach:8 Inductive tachometer 1
To the spark plug lead
Inductive tachometer:90890-03113
5. Check:8 Engine idle speed
Out of specification→Adjust.
Engine idle speed:1,750~1,850 r/min
6. Adjust:8 Engine idle speed
***************************************Adjustment steps.8 Turn the throttle stop screw 1 in or out until
specified idle speed is obtained.
Turn in Idle speed becomes higher.Turn out Idle speed becomes lower.
***************************************
ENGINE IDLE SPEED ADJUSTMENT
1
1
1
INSPADJ
3-7
THROTTLE CABLE FREE ADJUSTMENT1. Check:
8 Throttle cable free play aOut of specification→Adjust.
Free play:3 ~ 5 mm
***************************************Throttle cable free play adjustment steps;NOTE:
Before adjusting the throttle cable free play, theengine idle speed should be adjusted.
First step:8 Remove the adjuster cover 18 Loosen the locknut 2 on the throttle cable.8 Turn the adjuster 3 in or out until the speci-
fied free play is obtained.
Turning in→Free play is increased.
Turning out→Free play is decreased.
8 Tighten the locknuts.8 Install the adjuster coverNOTE:
If the free play cannot be adjusted here, adjustit at the carburetor side of the cable. (secondstep)
Second step:8 Remove the left/right side covers and center
cover.8 Remove the adjuster cover 18 Loosen the lockout 28 Turn the adjuster 3 in or out until the speci-
fied free play is obtained.
Free play:1~2 mm
Turn in Free play is increased.
Turn out Free play is decreased.
8 Tighten the lockout.8 Install the adjuster cover.8 Install left/right side covers and center cover.
wAfter adjusting, turn the handlebar to right andleft and make sure that the engine idling doesnot run faster.***************************************
THROTTLE CABLE FREE ADJUSTMENT
a
1
3
21
31 2
INSPADJ
3-8
AUTOLUBE PUMP AIR BLEEDING1. Remove
8 Lower cowling8 Air shroud 3 1
2. Air bleeding:8 Pump case and / or oil hose.
***********************************Air bleeding steps:8 Place a rag under the autolube pump to catch
the oil.8 Remove the bleed screw 1.8 Keep the oil running out until air bubbles dis-
appear.8 When air bubbles are expelled completely,
tighten the bleed screw.NOTE:
Check the bleed screw gasket. If damaged, re-place with a new one.
*************************************3. Air bleeding:
8 Pump distributor and/or delivery hose*************************************Air bleeding steps:8 Start the engine.8 Pull the pump cable 1 all the way out set the
pump stroke to a maximum.8 Run the engine for 2-3 minutes at 2000 r/ min.
This will completely remove autolube pumpsystem of air.
*************************************AUTOLUBE PUMP CABLE ADJUSTMENTNOTE:
Engine idling speed and throttle cable free playshould be adjusted properly before adjustingthe autolube pump cable.
1. Close the throttle completely.2. Check:
8 Alignment markOut of specification→Adjust autolubepump Cable.
NOTE:
The mark “I”a on the swing plate should bealigned with the mark “I”b on the autolubepump body.
AUTOLUBE PUMP AIR BLEEDING/AUTOLUBE PUMP CABLE ADJUSTMENT
1
1
1
a
b
INSPADJ
3-9
3. Adjust:8 Autolube pump cable
***************************************Adjustment steps:8 Remove the adjuster cover 1.8 Loosen the locknut 3.8 Turn the adjuster 2 in or out until the align-
ment mark is specified.8 Tighten the locknut 38 Install the adjuster cover.***************************************SPARK PLUG INSPECTION1. Remove:
8 Battery box cover2. Inspect:
8 Spark plug typeIncorrect→Replace.
Standard spark plug:BPR7HS/NGK
3. Inspect:8 Electrode 1
Wear/Damage→Replace.8 Insulator 2
Abnormal color→Replace.Normal color is a medium-to-light tancolor.
4. Clean the spark plug with a spark plugcleaner or wire brush.
5. Measure:8 Plug gap a
Use a wire gauge or feeler gauge.Out of specification→Regap.
Spark plug gap:0.9~1.0 mm
6. Tighten:8 Spark plug 20 Nm (2.0 m.kg)
7. Install:8 Battery box cover.
SPARK PLUG INSPECTION
123
a2
1
T R..
INSPADJ
3-10
ENGINE OIL LEVEL INSPECTION1. Inspect:
8 Engine oil level Oil level low→Add suf-ficient oil by the following inspectionsteps.
1 “OIL” indicator light
Recommended oil:For Yamaha:Yamalube 2 or 2-stroke engine oil(JASO FC grade or ISO EG-C, EG-D grade)For MBK:Semi synthetic oil in accordanceto the API TS C3 standard
Total:1.4L
NOTE:
Install the oil tank filler cap 1 and push it fullyinto the filler.
Engine oil level visual inspection steps:
Turn main switch to ”*”position.
“OIL” indicator light doesnot comes on.
Inspect faulty electricalcircuit, light bulbs etc.
“OIL” indicator lightcomes on.
Turn main switch to“ON” position.
“OIL” indicator light doesnot come on.
Engine oil level and elec-trical circuit are OK.
“OIL” indicator lightcomes on.
Supply engine oil.
“OIL” indicator light comes on.
ENGINE OIL LEVEL INSPECTION
km/h20
10
4060 80
100
120
140000010
1
1
INSPADJ
3-11
TRANSMISSION OIL REPLACEMENT1. Warm up the engine for several minutes,
then stop the engine.2. Place a container under the drain hole.3. Remove:
8 Oil filler plug 18 Drain bolt (with gasket) 2
NOTE:
Drain the transmission oil completely.While draining, slightly tilt the scooter tothe right and to the left.
4. Inspect:
8 Gasket (drain bolt) 4 New8 O-ring (oil filler plug) 3
Damage→Replace.
5. Install:8 Drain bolt 18 Nm (1.8 m.kg)
6. Fill:8 Transmission case
Recommended oil:SAE 85W/140
Oil capacity:0.13 L
cC8 Always use the same type of oil; mixing oils
may result in a harmful chemical reaction andlead to poor performance.
8 Do not allow foreign material to enters thetransmission case.
7. Install:8 Oil filler plug (with O-ring)
8. Inspect:8 Oil leaks8 Oil level
NOTE:
Wipe off any oil spilt on the transmission, tireor wheel.
TRANSMISSION OIL REPLACEMENT
1
4
2
New
T R..
3
INSPADJ
3-12
AIR FILTER ELEMENT CLEANING1. Remove:
8 Battery box cover2. Remove:
8 Caburetor jont clamp 1
3. Remove:8 Screw 18 Screw(for clamp) 28 Air filter 3
4. Remove:8 Air filter case 18 Air filter element
cCNever operate the engine with the air filter el-ement removed. This will allow unfiltered airto enter, causing rapid wear and possible en-gine damage. Additionally, operation withoutthe cleaner element will affect carburetor jet-ting with subsequent poor performance andpossible engine overheating.Be careful not to have rags or the like blockingthe intake area of the air filter.
5. Inspect:8 Element 1
Damage→Replace.6. Clean:
8 Air filter element*************************************Air filter element cleaning steps:8 Wash the element gently, but thoroughly in
solvent.
AIR FILTER ELEMENT CLEANING
3
1
2
1
1
1
INSPADJ
3-13
wNever use low flash point solvents such asgasoline to clean the element. Such solventmay lead to a fire or explosion.
8 Squeeze the excess solvent out of the ele-ment and let dry.
cCDo not twist the element when squeezing theelement.
8 Apply the foam -air filter oil or engine oil .8 Squeeze out the excess oil.NOTE:
The element should be wet but not dripping.
7. Install:8 Air filter8 Battery box cover
AIR FILTER ELEMENT CLEANING
INSPADJ
3-14
V-BELT INSPECTION1. Remove:
8 Air cleaner joint clamp 18 Screws(left crankcase cover) 28 Crankcase cover(left) 3
2. Inspect8 V-belt 1
Cracks/Wear/Damage→Replace.Oil or grease adhere to theV-belt→Check the primary and second-ary sheaves.Refer to “ENGINE OVERHAUL - INSPEC-TION AND REPAIR” section in the CHAP-TER 4.
3. Measure:8 V-belt width a
Out of specification→Replace.Refer to “ENGINE OVERHAUL” sectionin the CHAPTER 4.
V-belt width:17.7 mm
<Limit> 16.0 mm
NOTE:
Measure the V-belt width on several points.
4. Install:8 Crankcase cover(left) 12Nm(1.2kg.m)
8 Air cleaner joint clamp
V-BELT INSPECTION
13
1
a
2
T R..
INSPADJ
3-15
CHASSISFRONT BRAKE LEVER FREE PLAY CHECK1. Check:
8 Front brake lever free play
2~5 mm
wA soft or spongy feeling in the brake lever canindicate the presence of air in the brake sys-tem. This air must be removed by bleeding thebrake system before the motorcycle is oper-ated. Air in the system will cause greatly di-minished braking capability and can result inloss of control and an accident. Inspect andbleed the system if necessary.
FRONT BRAKE LEVER FREE PLAY CHECK/REAR BRAKELEVER FREE PLAY CHECK/BRAKE PAD INSPECTION
a
1
1
1
3 2
REAR BRAKE LEVER FREE PLAY CHECK1. Check:
8 Rear brake lever free play aOut of specification→Adjust.
10 ~ 20 mm
***************************************Rear brake lever free play adjustment steps:8 Turn the adjuster 1 in or out until the cor-
rect free play is obtained.***************************************
BRAKE PAD INSPECTION1. Activate the brake lever.2. Inspect:
8 Brake padWear indicator 1 nearly contactingbrake disc→Replace brake pads as a set.Refer to the “BRAKE PAD REPLACE-MENT” section in the CHAPTER 6.2 Brake disc3 Brake pads
INSPADJ
3-16
BRAKE SHOE INSPECTION1. Activate the brake lever.2. Inspect:
8 Wear indicator 1Indicator at wear limit line 2→Replacebrake shoes.
BRAKE FLUID LEVEL INSPECTIONNOTE:
Position the scooter straight up when inspect-ing the fluid level.
1. Inspect:8 Fluid level is under “LOWER” level line1→Fill to proper level.
Recommended fluid:DOT#4
cCThe fluid may corrode painted surfaces or plas-tic parts. Always clean up spilled fluid immedi-ately.
w8Use only the designated quality fluid. Other-wise ,the rubberseals may deteriorate caus-ing leakage and poor brake performance.
8Refill with the same type of fluid. Mixing flu-ids may result in a harmful chemical reactionleading to poor brake performance.
8Be careful that water does not enter the mas-ter cylinder when refilling. Water will signifi-cantly lower the boiling point of the fluid andmay result in vapor lock.
BRAKE SHOE INSPECTION/BRAKE FLUID LEVEL INSPECTION
1
1
2
INSPADJ
3-17
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)1. Bleed:
8 Brake fluid***************************************Air bleeding steps:
a. Add proper brake fluid to the reservoir.b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir tooverflow.
c. Connect the clear plastic tube 1 tightly tothe caliper bleed screw.
d. Place the other end of the tube into a con-tainer.
e. Slowly apply the brake lever several times.f. Pull the lever in. Hold the lever in posi-
tion.g. Loosen the bleed screw and allow the le-
ver to travel towards its limit.h. Tighten the bleed screw when the limit
has been reached, then release the lever.i. Repeat steps (e) to (h) until the air bubbles
have been removed from the system.j. Add brake fluid to proper level.
wCheck the operation of the brake after bleed-ing the brake system.
*************************************
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
1
INSPADJ
3-18
STEERING ADJUSTMENT1. Check:
8 Steering assembly bearingsGap the bottom of the forks and gentlyrock the fork assembly back and forth.Loosen→Adjust.
***************************************Adjustment steps:8 Remove upper cover, lower cowling, leg
shield 1,2. refer to “COVER AND PANEL” sec-tion.
8 Remove all ringnuts using ringnut wrench.
Ring nut wrench:90890-01403
8 Tighten the ring nut 3 1 using nut wrench.28 Nm(2.8 kg.m)
NOTE:
Set the torque wrench to the ring nut wrenchso that they form a right angle.
8 Loosen the ring nut 3 1 1/4 turn.8 Install rubber ring 2 and ring nut 2 3, then
tighten the ring nut 2 until it contacts withrubber ring.
cCAligning the slot of ring nut 2 with the slot ofring nut 3. If not, slightly tighten ring nut 2 un-til the slots alignment.
8 Install special washer 4NOTE:
Insert the projections of special washer into theslots of ring nut 3, 2
8 Install ring nut 1 5 66Nm(6.6 kg.m)
8 Move the handlebar up and down, and/orback and forth. If handlebar play is excess,remove the front fork assembly and checkthe balls/ball races. Refer to chapter 6.
***************************************
STEERING ADJUSTMENT
1
T R..
2
34
5
T R..
INSPADJ
3-19
TIRE INSPECTION
w8 Do not attempt to use tubeless tires on a
wheel designed for tube type tires only.Tire failure and personal injury may resultfrom sudden deflation.
Wheel Tire
Tube type Tube type only
Tubeless type Tube type ortubeless type
8 Be sure to install the correct tube when us-ing tube type tires.
1. Measure:8 Air pressure
Out of specification→Adjust.
TIRE INSPECTION
Maximum load*Cold tire pressureUp to 90 kg90 kg load~ Maximumload
* Load is the total weight of cargo, rider, pas-senger and accessories.
2. Inspect:8 Tire surfaces
Wear/Damage→Replace.
Minimum tire tread depth 1 (front and rear):
1.6 mm (0.06 in)
1 Tread depth2 Side wall3 Wear indicator
160 kg Front Rear200 kpa(2.00 kg/cm2,2.00 bar)
FRONT
Manufacturec Size Type
CHENG SHIN 120/90-10 56J
FRONT
Manufacturec Size Type
CHENG SHIN 130/90-10 59J
INSPADJ
3-20
WHEEL INSPECTION1. Inspect:
8 wheelsDamage/Bends→Replace.
wNever attempt even small repairs to the wheel.
FRONT FORK INSPECTION1. Inspect:
8 Front fork1Bends/Damage→Replace inner tubecomp, fork ass’y.Grease leakage→Replace inner tubecomp. fork ass’y.Unsmooth operation→Replace forkass’y.
REAR SHOCK ABSORBER INSPECTION1. Inspection:
8 Rear shock absorber1Oil leaks/Damage→Replace.
2. Check8 Tightening torque
Upper(nut) 30Nm (3.0 m.kg)
Lower (bolt) 16 Nm(1.6 m.kg)
SEAT LOCK CABLE ADJUSTMENT1. Remove:
8 Protector bar8 Upper cover
Refer to “COVER AND PANEL” section.2. Adjust:
8 Seat cable***************************************Seat cable adjustment steps:8 Loosen lock nut 18 Turn adjuster 2 in or out to adjust the seat
lock cable.8 Tighten the lock nut.***************************************3. Install:
8 Upper cover8 Protector bar
WHEEL INSPECTION/FRONT FORK INSPECTION
REAR SHOCK ABSORBER INSPECTION/SEAT LOCK CABLEADJUSTMENT
1T R.
.
1
2
1
INSPADJ
3-21
BATTERY INSPECTION
ELECTRICALBATTERY INSPECTIONNOTE:
Since the MF battery is of a sealed-type con-struction, it is impossible to measure the spe-cific gravity of the electrolyte in order to checkthe state of charge in the battery. Therefore, tocheck the state of charge in the battery, volt-age must be measured at the battery terminals.
cCCHARGING METHOD8This battery is sealed type. Never remove
sealing caps even when charging. With thesealing cap removed, this balancing will notbe maintained, and battery performance willlower gradually.
8Never add water. If distilled water is added,chemical reaction in the battery will not pro-ceed in the normal way, thus making it im-possible for the battery to operate regularly.
8The charging time, charging current andcharging voltage for the MF battery is differ-ent than general type batteries.The MF battery should be charged as in-structed in the “Charging method”. Shouldthe battery be overcharged, the electrolytelevel will lower extremely. Therefore, usespecial care when charging the battery.
8Avoid using any electrolyte other than speci-fied. The specific gravity of the MF batteryelectrolyte is 1.32 at 20°C (68°F). (The spe-cific gravity of the general type battery elec-trolyte is 1.28. ) If the electrolyte whose spe-cific gravity is less than 1.32, the sulfuric acidwill decrease and thus low battery perfor-mance will result.Should any electrolyte, whose specific grav-ity is 1.32 or more, be used, the battery plateswill corrode and battery life will shorten.
1. Remove:8 Battery box coverRefer to “COVER AND PANEL” section.
2. Remove:8 Battery
NOTE:
Remove the (–) lead first.
INSPADJ
3-22
wBattery electrolyte is dangerous; it containssulfuric acid and therefore is poisonous andhighly caustic.Always follow these preventive measures:8Avoid bodily contact with electrolyte as it can
cause severe burns or permanent eye injury.8Wear protective eye gear when handling or
working near batteries.Antidote (EXTERNAL):8SKIN-Flush with water.8EYES-Flush with water for 15 minutes and
get immediate medical attention.Antidote (INTERNAL):8Drink large quantities of water or milk fol-
low with milk of magnesia, beaten egg, orvegetable oil. Get immediate medical atten-tion .Batteries also generate explosive hydrogengas, therefore you should always followthese preventive measures:
8Charge batteries in a well-ventilated area.8Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,lighted cigarettes, etc.)
8DO NOT SMOKE When charging or handlingbatteries.
KEEP BATTERIES AND ELECTROLYTE OUTOF REACH OF CHILDREN.
3. Check:8 Battery condition
***************************************Battery condition checking steps:8 Connect a digital volt meter to the battery ter-
minals.
Tester (+) lead Battery (+) terminal.Tester (-) lead Battery (–) terminal.
NOTE:
The state of a discharged MF battery can bechecked by measuring open circuit voltage (thevoltage measured with the positive terminalsbeing disconnected).
12.8VVolt meter
Relationship between open-circuitvoltage and charging time 20°C(68°C)
Charging time(hours)•This varies depending on the temperature, the state of charge in battery plates and the electrolyte level.
Ope
n-ci
rcui
t vol
tage
(v)13.0
12.5
12.0
11.5
5 6.5 10
BATTERY INSPECTION
INSPADJ
3-23
BATTERY INSPECTION
14
13
12
11
10
100 75 50 30 25 20 0
Condition of charge in battery(%)
Ambienttemperature20°C
Ope
n-ci
rcui
t vol
tage
(v)
Time(Minutes)
Ope
n-ci
rcui
t vol
tage
(v)
Ambient temperature20°C
Check the open-circuitvoltage
18
17
16
15
14
13
12
11
100 10 20 30 40
Charging
Open circuit voltage Charging time
12.8 v or more No charging is necessary.
8 Check the battery condition using figures.EXAMPLE:Open circuit voltage = 12.0vCharging time = 6.5 hoursCondition of charge in battery = 20 ~ 30%***************************************2. Charging method of MF battery
cC8 If it is impossible to set the standard charg-
ing current, be careful not to overcharge.8When charging the battery, be sure to re-
move it from the motorcycle. (If charging hasto be done with the battery mounted on themotorcycle for some reason, be sure to dis-connect the wire at the negative terminal.)
8Never remove the sealing plug from the MFbattery.
8Use special care so that charging clips are ina full contact with the terminal and that theyare not shorted. (A corroded clip of thecharger may cause the battery to generateheat at the contact area. A weak clip springmay cause sparks.)
8Before removing the clips from the batteryterminals, be sure to turn off the powerswitch of the charger.
8Change in the open-circuit voltage of the MFbattery after being charged is shown below.As shown in the figure, the open circuit volt-age is stabilized 30 minutes after charginghas been completed.Therefore, to check the condition of the bat-tery, measure the open-circuit voltage 30minutes after has been completed.
INSPADJ
3-24
BATTERY INSPECTION
Charging method using a variable-current (voltage) type charger
Measure the open-circuit volt-age prier to charging.
Connect a charger and AMPmeter to the battery and startcharging.
Make sure the current is higherthan the standard chargingcurrent written on the battery.
Adjust the voltage so that currentis at standard charging level.
Set the timer according to thecharging time suitable for theopen-circuit voltage. Refer to“Battery condition checkingsteps”.
By turning the charging voltageadjust dial, set the charging volt-age at 20 - 25 V.
Monitor the amperage for 3-5minutes to check if the standardcharging current is reached.
If current doesnot exceed stan-dard chargingcurrent after 5minutes, replacethe 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.
NOTE:Voltage should be measured30 minutes after the machineis stopped.
NOTE:Set the changing voltage at16-17 V. (If the setting is lower,charging Will be insufficient.If too high, the battery Will beover-charged.)
Measure the battery open-circuit voltage after having left the bat-tery unused for more than 30 minutes.12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is required.Under12.0 V --- Replace the battery.
NOYES
YES
NO
Charger AMPmeter
INSPADJ
3-25
BATTERY INSPECTION
Charging method using a constant current type charger This type if battery charger Can not charge the MF battery.
Charging method using a constant-voltage type charger
Measure the open-circuit volt-age prier to charging.
Connect a charger and AMPmeter to the battery, and startcharging.
Make sure the current is higherthan the standard chargingcurrent written on the battery.
Charge the battery until thebattery’s charging voltage is 15volts.
Check the open-circuit voltage after hav-ing left the battery for 30 minutesafter charging.12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is neces-
sary.Under 12 V --- Replace the battery.
This type of battery charger Cannot charge the MF battery. Avariable voltage charger is rec-ommended.
NOTE:Voltage should be measured 30 min-utes after the machine is stopped.
NOTE:Set the charging time at 20 hours(maximum).
YES NO
Charger
AMP meterVolt meter
INSPADJ
3-26
FUSE INSPECTION1. Remove:
8 Battery box coverRefer to “COVER AND PANEL” section.
2. Remove:8 Fuse 1
3. Inspect:8 Fuse 1
defective→Replace***************************************Blown fuse procedure steps:8 Turn off ignition and the circuit.8 Install a new fuse of proper amperage.8 Turn on switches to verify operation of elec-
trical device.8 If fuse blows immediately again, check cir-
cuit in question.***************************************
wDo not use fuses of higher amperage ratingthan recommended. Extensive electrical sys-tem damage and fire could result from substi-tution of a fuse of improper amperage.
Description Amperage Quantity
Main 7A 1
4. Install:8 Fuse8 Battery box cover
4. Inspect:8 Battery terminal
Dirty terminal→Clean with wire brush.Poor connection→Correct.
NOTE:
After cleaning terminals, apply lightly to theterminals.
5. Install8 Battery8 Battery box cover
FUSE INSPECTION
1
INSPADJ
3-27
HEAD LIGHT BEAM ADJUSTMENT1. Adjust:
8 Head light (vertically)Turn the adjusting screw in or out toadjust headlight beam.
HEADLIGHT BULB REPLACEMENT1. Remove:
8 Protector bar8 Upper cover
Refer to “COVER AND PANEL” section.
HEADLIGHT BEAM ADJUSTMENT/HEADLIGHT BULB REPLACEMENT
1
12. Remove:
8 Headlight leads coupler 1
3. Remove:8 Bulb holder 1
Turn the bulb holder counterclockwiseto remove it.
4. Remove:8 Bulb(defective)1
Push bulb in and turn it counterclock-wise to remove it
wKeep flamble products and your hand awayfrom the bulb while it is on, since it is veryhot. Do not touch the bulb until it cools down.
1
1
INSPADJ
3-28
5. Install:8 Bulb(new)
cCAvoid touching the glass part of bulb. keep itfree from oil; oil could adversely and illuminousflux. If oil gets on bulb, clean it with a cloththoroughly moistened with alcohol or lacquerthinner.
6. Install:8 Bulb holder
7. Connect:8 Headlight leads coupler
8. Install:8 Upper8 Protector bar
9. Adjust:8 Headlight beam
Refer to “HEADLIGHT BEAMADJUSTMENT”section
TAILLIGHT BULB / REAR FLASHER BULB REPLACEMENTFRONT FLASHER BULB REPLACEMENT
2
TURN SIGNAL AND TAILLIGHT BULB RE-PLACEMENT1. Remove:
8 Lense 18 Bulb 2
2. Replace:8 Bulb 2
3. Install:8 Lense 1
2
1
1
INSPADJ
3-29
TAILLIGHT BULB / REAR FLASHER BULB REPLACEMENTFRONT FLASHER BULB REPLACEMENT
cCDo not over-tighten the screws as the lensemay break.
2
2
1
1
LICENSE LIGHT BULB REPLACEMENT1. Remove:
8 Lense 18 Bulb 2
2. Replace:8 Bulb (defective) 2
3. Install:8 Lense 1
4-1
ENGEB400000
ENGINE OVERHAULENGINE REMOVALWIREHARNESS AND CABLES
ENGINE REMOVAL
Remarks
Remove the parts in order.
Refer to “COVER AND PANEL” sectionin CHAPTER 3.
Refer to “CARBURETOR” section inCHAPTER 6.
Job name/Part name
Wireharness and cables removalRear carrierTail coverLeft side panelRight side panelBattery box coverCenter cowlingAir filter caseCarburetor
Air shroud 3Rear fender screwAutolube delivery hoseAutolube pump cable
Order
1234
Q’ty
1111
45Nm(4.5kg.m)T R..14
1 10
4
6 57
15
38
1211
2
13
9
120Nm(12.0kg.m)T R..
4-2
ENG
Order
56789
101112131415
Job name/Part name
Spark plug capBattery (-) leadC.D.I magneto leads couplerStarter motor leads couplerRear wheel nut
Rear brake adjusterRear brake cablePinBoltEngine mount boltEngine
Q’ty
11111
111111
Remarks
NOTE:Loosen the rear wheel nut.
Reverse the removal procesure for in-stallation.
ENGINE REMOVAL
45Nm(4.5kg.m)T R..14
1 10
4
6 57
15
38
1211
2
13
9
120Nm(12.0kg.m)T R..
4-3
ENGCYLINDER HEAD, CYLINDER AND PISTON
CYLINDER HEAD, CYLINDER AND PISTON
Job name/Part name
Cylinder head, Cylinder and pistonremovalEngineMuffler/GasketAir shroud (cylinder head)Spark plugCylinder head/Cylinder head gasketCylinderPiston pin clipPiston pin/ BearingPistonPiston ring setCylinder gasket
Remarks
Remove the parts in the order.
Refer to the “ENGINE REMOVAL” sec-tion
Reverse the removal procedure for in-stallation.
Order
123456789
10
Q’ty
1/111
1/112
1/1111
4
5
6
7
10 1
2
3
26Nm(2.6kg.m)T R..
14Nm(1.4kg.m)T R..
12Nm(1.2kg.m)T R..
New
New
New
E
89
CYLINDER HEAD, CYLINDER AND PISTON
4-4
ENG
PISTON PIN AND PISTON REMOVAL1. Remove:8 Piston pin clip 1
NOTE:
Before removing the piston pin clip, cover thecrankcase with a clean rag so you will not acci-dentally drop the clip into the crankcase.
2. Remove:8 Piston pin 18 Piston 28 Piston pin bearing 3
cCDo not use a hammer to drive the piston pinout.
CYLINDER HEAD INSPECTION1. Eliminate:8 Carbon deposits
Use a rounded scrapper 1.
2. Inspect:8 Cylinder head warpage
Out of specification→Re-surface.*************************************Warpage measurement and re-surfacementsteps:8 Attach a straight edge 1 and a thickness
gauge 2 on the cylinder head.8Measure the warpage limit.
Warpage limit:0.05 mm
8 If the warpage is out of specification, refacethe cylinder head.
NOTE:
Rotate the head severai tires to avoid remov-ing too much material from one side.
*************************************
CYLINDER HEAD, CYLINDER, PISTON
2
1
4-5
ENG
CYLINDER AND PISTON INSPECTION1. Eliminate:8 Carbon deposits
Use a rounded scraper 1.2. Inspect:8 Cylinder wall
Wear/Scratches→Rebore or replace.
3. Eliminate:8 Carbon deposits 1
From the piston crown and ringgrooves.
4. Remove:8 Score markes and lacquer deposits
From the sides of piston.5. Inspect:8 Piston wall
Wear/Scratches/Damage→Replace.
6. Measure:8 Piston-to cylinder clearance
*************************************Piston to cylinder clearance measurementsteps: First step:8Measure the cylinder bore “C” with a cylin-
der bore gauge.NOTE:
Measure the cylinder bore “C” in parallel to andat right angles to the crankshaft. Then, find theaverage of the measurements.
CYLINDER AND PISTON INSPECTION
D1
D2
D3
D4
D5D6
1
1
1
4-6
ENGCYLINDER HEAD, CYLINDER AND PISTON
Standard Wear limit
C = Maximum DT=( Maximum D1 or D2 ) - ( Maximum D5 orD6 )R=( Maximum D1 D3 or D5 ) - ( Maximum D2D4 or D6 )
Cylinder bore“C”
Taper “T”
Out of round“R”
52.002~52.012mm
–
–
8 If out of specification, rebore or replace cyl-inder, and replace piston and piston ringsas a set.
2nd step:8Measure the piston skirt diameter “p” with
a micrometer.a 10 mm from the piston bottom edge.
Piston size P
51.958~51.967 mm52.25 mm52.50 mm
StandardOversize 1Oversize 2
8 If out of specification, replace piston and pis-ton rings as a set.
3rd step:8 Calculate the piston-to cylinder clearance
with following formula:
Piston-to cylinder clearance = Cylinder bore“ C ”- Piston skirt diameter “p”
8 If out of specification, rebore or replace cyl-inder, and replace piston and piston rings asa set.
Piston-to cylinder clearance:0.044~0.045mmLimit : 0.1 mm
a
52.10 mm
0.05 mm
0.03 mm
4-7
ENGCYLINDER HEAD, CYLINDER AND PISTON
a Measuring Point 20 mm4. Oversize piston ring size:
Ring size is stamped on top of the ring.
Oversize piston ring
Oversize 1 25
Oversize 2 50
PISTON PIN AND PISTON PIN BEARING1. Inspect:8 Piston pin
Blue discoloration/Groove→Replace,then inspect lubrication system.
PISTON RINGS INSPECTION1. Measure:8 Side clearance
Out of specification→Replace pistonand/or rings.Use a feeler gauge 1
Top ring 0.03 ~ 0.05 mm 0.60 mm
2nd ring 0.03 ~ 0.05 mm 0.60 mm
Standard Limit
2. Install:8 Piston ring
Into the cylinderPush the ring with the piston crown.
3. Measure:8 End gap
Out of specification→Replace rings asa set.Use a feeler gauge 1.
Top ring 0.15 ~ 0.35 mm 0.10 mm
2nd ring 0.15 ~ 0.35 mm 0.10 mm
a
Standard Limit
4-8
ENG
2. Measure:8 Outside diameter a (piston pin)
Out of specification→Replace.
Out side diameter (piston pin):13.996~14.000 mm
3. Measure:8 Piston pin-to-piston clearance
Out of specification→Replace piston.
Piston pin-to-piston clearance =Bore size (piston pin)Outside diameter (piston pin)
Piston pin-to-piston clearance:0.008~0.015 mm<Limit: 0.07 mm>
4. Inspect:8 Bearing(piston pin)
Pitting/Damage→Replace.
PISTON PIN AND PISTON INSTALLATION1. Apply:8 Engine oil
(to the crankshaft bearing, connectingrod big end bearing, small end bearing,piston pin, piston ring grooves and pis-ton skirt areas.)
2. Install:8 Reed valve gasket8 Reed valve8 Carburetor joint 1 11Nm(1.1 m.kg)
CYLINDER HEAD, CYLINDER AND PISTON
1
E
E
T R..
→ a ←
4-9
ENG
3. Install:8 Small end bearing8 Piston 18 Piston pin 2
8 Piston pin clip 3 NewNOTE:
8 The arrow a on the piston to the exhaustside.8 Before installing the piston pin clip, cover the
crankcase with a clean towel or rag so youwill not accidentally drop the pin clip mate-rial into the crankcase.8 Always use a new piston pin clip.
CYLINDER AND CYLINDER HEAD1. Install:8 Cylinder gasket (new gasket)
2. Check:8 Piston rings
1 1st ring2 2nd ringNOTE:
Make sure the ring ends 1 are properly fittedaround the ring locating pins 3 in the pistongrooves.
CYLINDER HEAD, CYLINDER AND PISTON
3. Install:8 Cylinder 1
NOTE:
Install the cylinder with one hand while com-pressing the piston rings with the other hand.
a New
1
New
4-10
ENG
4. Install:8 Cylinder head gasket (new gasket)
5. Install:8 Cylinder head 1 14Nm(1.4m.kg
8 Spark plug 2 20Nm(2.0m.kg
8 Air shroudNOTE:
Tighten the cylinder head holding nuts in stage,using a crisscross pattern.
INSPECTION AND REPAIR
1
2
T R..
T R..
4-11
ENG
Remarks
Remove the parts in order.
Reverse the removal procedure for in-stallation.
Order
123456
Q’ty
111112
Job name/Part name
Kick starter and crankcase cover (left)removalAir cleaner assembly mounting screwScrew(Bind)Kick starterCrankcase (left)GasketPin
V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVEKICK STARTER AND CRANKCASE COVER (LEFT)
1
12Nm(1.2kg.m)T R..
23
4
5
6
New
90Nm(0.9kg.m)T R..
90Nm(0.9kg.m)T R..
4-12
ENG
Order
1
2
3
4
5
6
Q’ty
11
1/1111
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVEKICK STARTER
V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE
Job name/Part name
Kick starter removalKickstarter pinion gearKickstarter pinion gear clipCirclip/Plain washerKickstarter segment gearReturn springCollar
Remarks
Remove the parts in order.
Reverse the removal procedure for in-stallation.
New
1
2
45
3
6
B
4-13
ENG
KICK STARTER INSTALLATION1. Install:8 Return spring 18 Kick starter segment gear 28 Collar 38 Plain washer 48 Circlip 5
***************************************Installation steps:
a. Install return spring 6 and segment gear7 as shown.
b. Install clip 5.c. Hook the spring onto the crankcase pro-
jection 8.d. Install the kick starter pinion gear 9 and
the kick starter.***************************************
KICK STARTER
2
1
5
3
4
7
6
2
5
8
9
6
4-14
ENG
Order
123456789
10
Q’ty
111
1/111
1/11
1/36
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVEV-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE
Remarks
Remove the parts in order.
Refer to “COVER AND PANEL” sectionin chapter 3.
Refer to “ENGINE REMOVAL” section.Refer to “SECONDARY SHEAVE AND V-BELT REMOVAL ” section.
Refer to “PRIMARY SHEAVE REMOVALASSEMBLY” section.
Reverse the removal procedure for in-stallation
Job name/Part name
V-belt, clutch and secondary/primarysheave removalLower cowlingAir shroud 3
Crankcase (left)Clutch housingSecondary sheave assemblyV-beltConical washer/One-way clutchCrow washerPrimary fixed sheaveCollar/WasherPrimary sliding sheaveCam/ SliderWeight
V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE
1
23
45
67
810
940Nm(4.0kg.m)T R.
.
45Nm(4.5kg.m)T R..
4-15
ENG
Order
1
2
3
4
5
6
7
8
9
0
Q’ty
1131121221
SECONDARY SHEAVESECONDARY SHEAVE
Remarks
Disassemble the parts in order.
Refer to “SECONDARY SHEAVE DISAS-SEMBLY” section.Refer to “SECONDARY SHEAVE IN-STALLATION” section.
Refer to “SECONDARY SHEAVE IN-STALLATION” section.
Reverse the disassembly procedure forassembly.
Job name/Part name
Secondary sheave disassemblyNutClutch carrierClutch shoe springCompression springSpring seatGuide pinSecondary sliding sheaveO-ringOil sealSecondary fixed sheave
V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE
1
2
3
4
5
6
7
8
9
0
New
LS
LS
9
50Nm(5.0kg.m)T R..
4-16
ENG
PRIMARY SHEAVE REMOVAL1. Remove:8 Fan
2. Remove:8 Nut 1 (primary sheave)
NOTE:
When loosening the nut (primary sheave), holdthe C.D.I. magneto using flywheel holding tool2.
Flywheel holding tool:90890-01235
3. Remove:8 Conical spring washer 18 One-way clutch 28Washer 38 Primary fixed sheave 48 Shim 58 V-Belt
4. Remove:8 Collar 18 Primary sheave assembly 2
V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE
SECONDARY SHEAVE REMOVAL1. Remove:8 Nut 1 (secondary sheave)
NOTE:
Hold the secondary sheave using sheave holder2.
Sheave holder:90890-01701
2. Remove:8 Clutch housing8 Secondary sheave assembly8 Dowel pins
1
2
1
2
1
2
4-17
ENGV-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
4. Attach:8 Clutch spring holder 1
Clutch spring holder:90890-01337
5. Remove:8 Clutch securing nut 2
6. Remove:8 Clutch assembly 18 Clutch spring 28 Spring seat 38 Guide pins8 Secondary sliding sheave
Clutch Inspection1. Inspect:8 Clutch shoes
Glazed parts→Sand with coarse sand-paper.
NOTE:
After using the sand paper, clean of the pol-ished particles with cloth.
3. Loosen:8 Nut(Clutch carrier)1
NOTE:
Install the secondary sheave to primary driveshaft as shown, and hold the secondary sheaveby Universal Roter Holder 2 to loosen the nut1.
Universal Roter Holder:90890-01235
cCDo not remove the clutch securing nut yet.If the nut is removed without compressiong thesecondary sheave. It jumps and causes injury.
4-18
ENG
2. Measure:8 Clutch shoe thickness a
Out of specification→Replace.
Clutch shoe thickness:4 mm
< Wear limit>:2.5 mm
V-BELT INSPECTION1. Inspect:8 V-belt1
Crack→Replace.NOTE:
Replace the V-belt smeared with a lot of oil orgrease.
2. Measure:8 V-belt width a
Out of specification→Replace.
V-belt width:17.7 mm
<Wear limit>:16.0 mm
a
V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE
4-19
ENGV-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
PRIMARY SHEAVE INSPECTION1. Inspect:8 Primary sliding sheave 18 Primary fixed sheave 2
Wear/Cracks/Scratch/Damage→Replace.
2. Check:8 Free movement
Insert the collar 1into the primary slid-ing sheave2, and check for free move-ment.Stick or excessive play→Replace thesheave or collar.
3. Measure:8 Out side diameter 1 (weight)
Out of specification→Replace.
Out side diameter (weight)15.0 mm
<Limit 14.5 mm>
1
4-20
ENGV-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
SECONDARY SHEAVE1. Inspect:8 Secondary fixed sheave 18 Secondary sliding sheave 2
Scratch/Crack/Damage→Replace as aset.8 Oil seal 3
Damage→Replace
2. Inspect:8 Torque cam grove 18 Guide pin 2
Wear/Damage→Replace as a set.8 O-rings 3
Damage→Replace.
3. Measure:8 Clutch spring free length
Out of specification→Replace.
Clutch spring free length:81 mm<Limit>:73 mm
4. Inspect:8 Clutch housing inner surface
Oil/Scratches→Remove.
5. Measure:8 Clutch housing inside diameter a
Out of specification→Replace.
Clutch housing inside diameter:112.0 mm
<Wear limit>:112.5 mm
Use a rag soaked in lacquerthinner or solvent.Use an emery cloth (lightlyand evenly polishing).
Oil
Scratchesa
a
4-21
ENGV-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
SECONDARY SHEAVE INSTALLATIONWhen assembling the secondary sheave, re-verse the disassembly procedure. Note the fol-lowing points.
1. Apply:8 BEL-RAY assembly lube®
(to the inside of the sliding/fixed sheave)
2. Install:8 Sliding sheave 1
NOTE:
Be careful so that the oil seal 2 lips are notturned over when installing the sheave.
3. Apply:8 BEL-RAY assembly lube®
(to the torque cam grooves and O-rings)
4. Install:8 Guide pin 1
5. Check:8 Sliding sheave
Unsmooth operation→Repair.
6. Install:8 Clutch securing nut 1
Use clutch spring holder 2
Clutch spring holder:90890-01337
7. Tighten:8 Clutch securing nut 1 50 Nm(5.0 m.kg)
Use Flywheel holding tool 2
Fly holding tool90890-01235
E
E
T R..
4-22
ENGV-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
9. Tighten:8 Nut 1 (secondary sheave) 40 Nm(4.0 m.kg)
Use sheaveholder 2
Sheave holder:90890-01701
PRIMARY SHEAVE1. Clean:8 Primary sliding sheave face 18 Primary fixed sheave face 28 Collar 38Weight 48 Primary sliding sheave cam surface 5
2. Install:8Weight 18 Cam 28 Slider 38 Collar 4
3. Check:8 Cam operation
Not smooth→Repair.
4. Install:8 Primary sheave assembly 18 Collar 2
5. Install:8 V-belt
8. Install:8 Secondary sheave assembly8 Clutch housing 18 V-belt 2
NOTE:
The V-belt must be installed with the arrowfrontward.
T R..
2
1
1
2
1
2
4-23
ENGV-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE
6. Install:8 Shim 18 Primary fixed sheave 28Washer 38 One-way clutch 48 Conical spring washer 58 Nut 6
7. Tighten:8 Nut 1 (primary sheave)
45 Nm(4.5 kg.m)
NOTE:
When tightening the nut (primary sheave), holdthe C.D.I. magneto using Flywheel Holding Tool2 .
Flywheel holding90890-01235
8. Adjust:8 V-belt 1
Tense the V-belt by turning the primarysheave several times.
9. Install:8 Fan 7 Nm (0.7 kg.m)T R.
.
1
2
T R..
1
4-24
ENG
Order
12345
Q’ty
21121
STARTER CLUTCH AND STARTER MOTOR
STARTER CLUTCH AND STARTER MOTOR
Remarks
Remove the parts in order.
Refer to “COVERS AND PANEL” sectionin chapter 3.
Refer to “C.D.I. MAGNETO ” section
Refer to “REAR WHEEL” section in chap-ter 6.Refer to “KICKER STARTER ” section.
Refer to “V-BELT, PRIMARY SHEAVE ”section.
Job name/Part name
Starter clutch and starter motor re-movalLeft/Right side coverCenter coverLower cowlingAir shroud 3Cooling fanRear wheel
Crankcase cover (left)
Primary sheave
PlatePlain washerIdle gearPlain washerStarter clutch
10
9
8
7 65
4
3
2
1
New
B
M
13Nm(1.3kg.m)T R..
8Nm(0.8kg.m)T R..
STARTER CLUTCH AND STARTER MOTOR
4-25
ENG
Order
6789
10
Job name/Part name
Plain washerStarter wheel gearCollarStarter motorStarter motor coupler
Q’ty
21112
Remarks
Reverse the removal procedure forinstalation
10
9
8
7 65
4
3
2
1
New
B
M
13Nm(1.3kg.m)T R..
8Nm(0.8kg.m)T R..
STARTER CLUTCH AND STARTER MOTOR
4-26
ENG
STARTER CLUTCH AND GEARS1. Inspect:8 Starter clutch
Push the dowel pin to arrow direction.Unsmooth operation→Replace starterclutch assembly.
2. Inspect:8 Starter wheel gear teeth 18 Idle gear teeth 2
Burrs/Chips/Roughness/Wear→Replace.
3. Inspect:8 Starter clutch operation
***************************************Clutch operation checking steps:8 Install the starter wheel gear to the starter
clutch, and hold the starter clutch.8When turning the wheel gear clockwise A
the starter clutch and the wheel gear shouldbe engaged.If not the starter clutch is faulty. Replace it.8When turning the wheel gear counter clock-
wise B, the wheel gear should turn freely. Ifnot, the starter clutch is faulty. Replace it.
***************************************
INSPECTION AND REPAIR
12
4-27
ENG
Order
12345678
Q’ty
11/1111111
C.D.I. MAGNET
C.D.I. MAGNET
Remarks
Remove the parts in order.
Refer to “COVER AND PANEL” sectionin chapter 3.
Reverse the removal procedure for in-stallation.
Job name/Part name
C.D.I. magneto removalRear carrierTail coverLeft side coverRight side coverCenter coverLower cowlingAir shroud 3Fan /O-ringMagneto rotorBindCouplers (magneto leads)Stator coilWood ruff keyGasket (Magneto cover)
1
2
3
45
6
7
8 New
43Nm(4.3kg.m)T R..
8Nm(0.8kg.m)T R..
C.D.I. MAGNET
7Nm(0.7kg.m)T R..
4-28
ENG
C.D.I. MAGNETO REMOVAL1. Remove:8 Nut 1(rotor)8 Plain washer
NOTE:
Hold the rotor to loosen the nut by the flywheelholding tool 2.
Flywheel holding tool:90890-01235
2. Remove:8 Rotor 18Woodruff key
Use the flywheel magneto puller 2.
Flywheel magneto puller:90890-01189
8 Stator assembly8 Gasket
ENGINE DISASSEMBLY
C.D.I. MAGNETO INSTALLATION1. Install:8 Gasket 1
2. Apply:8 Lithium soap base grease
(to oil seal)3. Pass the C.D.I. magneto lead through the
crankcase hole.4. Install:8 Stator assembly 8 Nm(0.8 kg.m)
5. Install:8Woodruff key8 C.D.I. magneto Rotor 18 Plain washer8 Nut 43Nm(4.3 kg.m)
T R..
1
2
1
2
1
B
1
T R..
4-29
ENG
Order
12345678
Q’ty
11111111
AUTOLUBE PUMP
AUTOLUBE PUMP
Remarks
Remove the parts in order.Refer to “C.D.I. magneto” section.
Refer to “Autolube pump installation”section
Reverse the removal procedure for in-stallation.
Job name/Part name
Autolube pump removalC.D.I. magnetoAir shroud 2.CirclipPump drive gearPinOil hoseOil delivery hoseAutolube pump cableAutolube pump ass’y
1
2 3
4
5
6
7
8
4Nm(0.4kg.m)T R..
AUTOLUBE PUMP
4-30
ENGAUTOLUBE PUMP
AUTOLUBE PUMP INSTALLATION
cCAfter installing autolube pump, it must bebleeded.
1. Install8 Pin 18 Pump drive gear 2
8 Circlip 3 New2. Apply:8 Lithium soap base grease
(to O-ring)3. Install:8 Autolube pump 1 4 Nm(0.4m.kg)
4. Apply:8 Lithium soap base grease
(to autolube pump gear 1,2)
15 cc (0.92 cu • in)
1
23
1
B
1
2
B
T R..
New
4-31
ENG
Order
1234567
Q’ty
1121111
TRANSMISSION
TRANSMISSION
Remarks
Remove the parts in order.Refer to “REAR WHEEL/REAR BRAKE ”section in chapter 7.Refer to “V-BELT, CLUTCH, SECOND-ARY/ PRIMARY SHEAVE” sectionRefer to “TRANSMISSION OIL RE-PLACEMENT ” section in chapter 3.
Job name/Part name
Transmission removalRear wheel
Secondary sheave
Drain the transmission oil.
Transmission case coverGasket (transmission case cover)Dowel pinPrimary drive gearPlain washerConical spring washerDrive gear
New
New
18Nm(1.8kg.m)T R..
12Nm(1.2kg.m)T R..
12
3
4
5
6
78
9
10
B
TRANSMISSION
New
4-32
ENG
New
New
18Nm(1.8kg.m)T R..
12Nm(1.2kg.m)T R..
12
3
4
5
6
78
9
10
B
TRANSMISSION
Order
8910
Job name/Part name
CirclipMain axleDrive axle
Q’ty
111
Remarks
Reverse the removal procedure for in-stallation.
New
4-33
ENG
New
New
New
9Nm(0.9kg.m)T R.. 12Nm(1.2kg.m)T R.
.
3
4
1
2
65
7
8
109
B
Order Q’ty
CRANKCASE AND REED VALVECRANKCASE AND REED VALVE
CRANKCASE AND REED VALVE
Remarks
Remove the parts in order.
Refer to “ENGINE REMOVAL” section.Refer to “CYLINDER HEAD CYLINDERAND PISTON” section.Refer to “KICK STARTER AND CRANK-CASE COVER (LEFT) ” section.Refer to “V-BELT, CLUTCH AND SEC-ONDARY/PRIMARY SHEAVE ” section.Refer to “C.D.I. MAGNETO” section.Refer to “STARTOR CLUTCH ANDSTARTOR MOTOR” section.Refer to “AUTOLUBE PUMP” section.Refer to “REAR WHEEL AND REARBRAKE” section in chapter 6.Refer to “TRANSMISSION” section.
Job name/Part name
Crankcase and Reed valve removal
Engine removalCylinder head, cylinder, piston
Crankcase cover (left)
V-belt, clutch, secondary/primarysheaveC.D.I . magnetoStarter clutch, starter motor
Autolube pumpRear wheel
Transmission
4-34
ENGCRANKCASE AND REED VALVE
Order
123456789
10
Job name/Part name
Intake manifoldReed valveValve seat gasketStopperCrankcase 2Dowel pinEngine mount spacerCirclipBearingOil seal
Q’ty
1111121111
Remarks
Reverse the removal procedure for in-stallation.
New
New
New
9Nm(0.9kg.m)T R..
12Nm(1.2kg.m)T R..
3
4
1
2
65
7
8
109
B
4-35
ENG
2. Attach:8 Crankcase separating tool 1
Crankcase separating tool:90890-01135
NOTE:
Fully tighten the tool holding bolts, but makesure the tool body is parallel with the case. Ifnecessary, one screw may be backed outslightly to level tool body.
3. Remove8 Crankcase (right)
As pressure is applied, alternately tapon the engine mounting bosses.
CRANKCASE AND REED VALVE
CRANKCASE(RIGHT) REMOVAL1. Remove:8 Oil seal stopper 18 Screws (crankcase) 9Nm(0.9 kg.m)
NOTE:
Loosen each screw 1/4 turn, and remove themafter all are loosened.
REED VALVE INSPECTION1. Measure:8 Valve stopper height 1
Out of specification→Adjust stopper/Re-place valve stopper.
Valve stopper height 16.0~6.4 mm
2. Measure:8 Reed valve clearance 2
Out of specification→Replace reedvalve.
Reed valve clearance 2Less than 0.2 mm
T R..
4-36
ENG
CRANKCASE (RIGHT) INSTALLATION1. Install:8 Dowel pins 18 Engine mount spacer 2
2. Apply:8 Yamaha Bond No.1215 3
To the mating surfaces of both casehelves.
Yamaha bond No.1215:90890-85505
3. Attach:8 Crankshaft installing tool 1,2,3
Crankshaft installing tool:90890-01274190890-01275290890-01277
CRANKCASE AND REED VALVE
4. Tighten:8 Crankcase holding screws
12 Nm(1.2 kg.m)
NOTE:
Tighten the crankcase holding screws in stage,using a crisscross pattern.
5. Check:8 Crankshaft operation
Unsmnoth operation Repair.6. Install:
8 Oil seal (right crank case) 1 NewApply grease on to oil seal lip.
T R..
2
1
7. Install:8 Oil seal stopper plate 1
9 Nm (0.9 kg.m)
New
B
2
3
1
T R..
4-37
ENGCRANKCASE AND REED VALVE
8. Install:8 Gasket8 Reed valve8 Reed valve 1 11 Nm(1.1 kg.m)T R.
.
1
4-38
ENG
Order
1234
Q’ty
1221
CRANKSHAFT
Remarks
Remove the parts in order.Refer to “CRANK CASE AND REEDVALVE” section.
Reverse the removal procedure for in-stallation.
Job name/Part name
Crankshaft removalRight crankcase removal
CrankshaftBearingOil sealCrankcase cover (left)
CRANKSHAFT
1
2
3
4
2
3E
E
B
B
CRANKSHAFT
4-39
ENGCRANKSHAFT
CRANKSHAFT REMOVAL1. Attach:8 Crankcase separating tool 1
Crankcase separating tool:90890-01135
2. Remove:8 Crankshaft 2
CRANKSHAFT INSPECTION1. Measure:8 Runout limit “ C”8 Connecting rod big end side clearance
“D”8 Small end free play limit “F”
Out of specification→Replace.Use V-blocks, dial gauge and thicknessgauge.
Runout limit “C”:0.03 mm
Connecting rod big end side clear-ance “D”:
0.2 ~ 0.5 mmSmall end free play “ F”:
0.4 ~ 0.8 mm
2. Inspect:8 Bearings (crankshaft)
Spin the bearing inner race.Excessive play/Roughness→Replace.Pitting/Damage→Replace.
12
D
F
C C
4-40
ENG
CRANKSHAFT INSTLATION1. Attach:8 Crankshaft Installing Tool
Crankshaft installing tool:90890-0127490890-0127590890-01277190890-012882
2. Install:8 Crankshaft3
(to the crankcase4)
CRANKSHAFT
3. Install:8 Oil seal 18 Apply lithium soap base grease onto
the oil seal lip.Use the guide 2 and seal driver 3 toinstall the oil seal
Oil seal driver90890-01410
Oil seal guide90890-01409
New
3
4
12
3
1
2
5-1
CARB
Order
1234567
Q’ty
1111111
CARBURETIONCARBURETOR
CARBURETOR
Remarks
Remove the parts in order.
Refer to “COVER AND PANEL” sectionin CHAPTER 3.
Reverse the removal procedure for instal-lation.
Job name/Part name
Carburetor removalBattery box coverGripEnd coverLeft/Right coverCenter coverAir cleaner case assemblyCarburetor assemblyAuto choke lead couplerFuel hoseVacuum hoseOil delivery pipeThrottle cable
T R..
9Nm(0.9kg.m)1
2
3
45
6
7
5-2
CARB
Order
1
2
3
4
5
6
7
8
9
0
q
w
e
r
Q’ty
1111111
1/1111111
CABURETOR DISASSEMBLY
Remarks
Disassemble the parts in order.
Reverse the removal procedure for in-stallation.
Job name/Part name
Carburetor disassemblyThrottle valveThrottle cableNeedle setCarburetor top coverThrottle stop screwPilot air screwAuto choke unit assemblyFloat chamber/Seal ringFloat pinFloat/Needle valveMain jetPilot jetMain nozzleCarburetor body
CARBURETOR
6
7
8
9
0q
w
e
1
2
3
5
r
4
5-3
CARB
CABURETOR INSPECTIONMeasure:8 Float height a
Out of specification→Inspect needle valve,float and valve seat.
Float height:16.5 mm
***************************************Float height measurement steps:8 Install the needle valve, float and float pin to
the carburetor body.8 Hold the carburetor in an upside down posi-
tion.8Measure the distance between the mating
surface of the float chamber (gasket re-moved) and top of the float using a gauge.
NOTE:
The float arm should be resting on the needlevalve, but not compressing the needle valve.
8 If the float height is not within specification,inspect the needle valve, float and valve seat.8 If it is worn, replace it.*************************************NOTE:
The float height is properly adjusted at the Yamaha/MBK factory. Never attempt to adjust it.
CARBURETOR ASSEMBLYTo assemble the carburetor, reverse the disas-sembly procedures.Note the following points.
cC8 Before reassembling, wash all parts in clean
gasoline.8 Always use a new gasket.
1. Install:8 Throttle valve 18 Jet needle 28 Clip 38 Spring seat 4
Jet needle clip position:3/5
CARBURETOR
5-4
CARBCARBURETOR
FUEL LEVEL ADJUSTMENT1. Measure:8 Fuel level a
Out of specifications→Adjust.
Fuel level a:3.0~4.0 mm(Below the float cham-ber line
***************************************Measurement steps:8 Place the scooter on a level surface.8 Use a garage jack under the engine to en-
sure that the carburetor is positioned verti-cally.8 Connect the fuel level gauge 1 to the drain
pipe 2.
Fuel level gauge:90890-01312
8 Loosen the drain screw 3.8Measure the fuel level a with the gauge.8 If the fuel level is incorrect, adjust the fuel
level:8 Remove the float chamber, float, valve seat
and the needle valve.8 Inspect the valve seat and needle valve.8 If either is worn, replace them both.
2. Install:8 Throttle valve 1
NOTE:
Align the groove of the throttle valve with theprojection a of the carburetor body.
3. Install:8 Carburetor assembly
NOTE:
Align the projection a with the projections b.
1
a
a
b
a
1
2
3
↓↑
5-5
CARB
8 If both are fine, adjust float level by bendingthe float tang b slightly.8 Install the carburetor.8 Recheck the fuel level.***************************************
AUTO CHOKE INSPECTION(Ambient temperature lower than 45°C)1. Remove:8 Carburetor
2. Inspect:8 Autochoke unitConnect a suitable pipe 2 to the starter 1,
and blow it with the mouth etc. Possible→Goodcondition.
Impossible→Replace auto choke unit.3. Inspect:8 Auto choke unit (with battery)
***************************************Inspection and adjustment steps:8 Connect auto choke unit leads to the 12 V
battery for 5 minutes.Black terminal→12 V battery (+) 1Black terminal→12 V battery (–) 28 Connect a suitable pipe 4 to the starter 5,
and blow it with the mouth etc.Possible→Replace auto choke unit.Impossible→Good condition.
***************************************
CARBURETOR
B B
5-6
CARBCARBURETOR
FUEL COCK INSPECTION1. Stop the engine.2. Remove:8 Grip8 End cover8 Left side cover8 Battery box cover
Refer to “COVER AND PANEL” sectionin chapter 3.
3. Inspect:8 Fuel cock
***************************************Fuel cock inspection steps:8 Disconnect the fuel hose 1.8 Place the receptacle under the fuel hose end.8 If fuel stops flowing out in a few seconds,
the fuel cock is in good condition. If not, cleanor replace the fuel cock.8 Disconnect the vacuum hose 2 and breathe
in the vacuum hose with the mouth etc. forvacuum .8 If fuel flows out of the fuel hose under
vacuum and stops under non-vacuum, thefuel cock is in good condition.If not, clean or replace the vacuum hose, fuelhose and fuel cock.
*************************************4. Install:8 Battery box cover8 Left side cover8 End cover8 Grip
1
2
6-1
CHAS
Order
12345678
Q’ty
11111111
CHASSISFRONT WHEEL AND BRAKE DISC
FRONT WHEEL AND BRAKE DISC
Remarks
Remove the parts in order.
wSecurely support the scooter so there isno danger of it falling over.
Refer to “FRONT WHEEL INSTALLA-TION” section.
Refer to “FRONT WHEEL ASSEMBLY”section.Reverse the removal procedure for in-stallation.
Job name/Part name
Front wheel and brake disc removal
Speedometer cableFront brake hose holderBrake caliperWheel axleFront wheel assemblyGear unit assemblyCollarBrake disc
T R..
7Nm(0.7kg.m)T R.
.
23Nm(2.3kg.m)
T R..
7Nm(0.7kg.m)
T R..
20Nm(2.0kg.m)
B
LT
1
2
3
4
5
6
7
8
6-2
CHAS
Order
1
2
3
4
5
Q’ty
11111
FRONT WHEEL DISASSEMBLY
FRONT WHEEL AND BRAKE DISC
Remarks
Remove the parts in order.Refer to “FRONT WHEEL DISASSEM-BLY/ASSEMBLY” section.
Reverse the removal procedure for in-stallation.
Job name/Part name
Front wheel disassemblyOil sealBearingCollarSpacerBearing
1
2
3
4
5
New
B
B
6-3
CHASFRONT WHEEL AND BRAKE DISCYP ......
FRONT WHEEL DISASSEMBLY1. Remove:8 Bearing 18 Spacer
Remove the bearing using a generalbearing puller 2.
cCHandle the wheel with care not to damage thebrake disc. If the brake disc is damaged, replace.
YP700020
FRONT WHEEL INSPECTION1. Inspect:8 Front wheel axle
(by rolling it on a flat surface)Bends→Replace.
wDo not attempt to straighten a bent axle.
Wheel axle bending limit:0.25 mm
2. Inspect:8 Front tire
Wear/damage→Replace.Refer to “TIRE INSPECTION” in CHAP-TER 3.8 Front wheel
Refer to “WHEEL INSPECTION” inCHAPTER 3.
3. Measure:8 Front wheel runout
Over the specified limits→Replace.
Front wheel runout limits:Radial 1: 1.0 mmLateral 2 : 1.0 mm
4. Inspect:8 Front wheel bearings
Bearings allow free play in the wheelhub or the wheel does not turnsmoothly→ Replace.8 Oil seals
Wear / damage→Replace.
6-4
CHASFRONT WHEEL AND BRAKE DISC
4. Inspect:8 Collar
Grooved wear→Replace the collar andthe oil seal as a set.
YP.....
BRAKE DISC INSPECTION1. Measure:8 Brake disc deflection1
Maximum deflection:0.15 mm
Out of specification→Replace.
2. Measure:8 Brake disc thicknessa
Brake disc thickness:4.0 mm
Minimum thickness:3.5 mm
Out of specification→Replace.YP.....
FRONT WHEEL ASSEMBLY1. Install:8 Bearing 18 Collar 28 Spacer 38 Bearing 48 Oil seal 5
NOTE:
8 Apply the lithium soap base grease on thebearing and oil seal lip when installing.8 Use a socket that matches the outside diam-
eter of the race of the bearing.8 Always use a new oil seal.8 Install the oil seal with its manufacturer’s
marks or numbers facing outward.
cCDo not strike the inner race of balls of the bear-ing. Contact should be made only with the outerrace.
a
New
1
5
B
43
2
6-5
CHASFRONT WHEEL AND BRAKE DISC
EB700030
FRONT WHEEL INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Lubricate:8 Front wheel axle8 Bearings8 Oil seal (lips)8 Drive/driven gear (speedometer)
Recommended lubricant:Lithium soap base grease
2. Install:8 Speedometer gear unit 1
NOTE:
Make sure that the wheel hub and the speed-ometer gear unit are installed with the threeprojections meshed into the two slots.
T R..
2. Install:8 Brake disc 1 20 Nm(2.0 m.kg)
NOTE:
Tighten the bolts (brake disc) in stage using acrisscross pattern.
3. Install:8 Front wheel
NOTE:Make sure that the slot in the speedometer gearunit fits over the stopper on the front fork outertube.
4. Tighten:8 Front wheel axle 18 Axle nut (front wheel axle)
70 Nm(7.0kg.m)
cCBefore tightening the axle nut, stroke the frontfork several times to check for proper fork op-eration.
wMake sure that the brake hose is routed prop-erly.
T R..
1
1
1
6-6
CHASFRONT WHEEL AND BRAKE DISC
YP700040
WHEEL STATIC BALANCE ADJUSTMENTNOTE:
8 After replacing the tire and/or rim, the wheelstatic balance should be adjusted.8 Adjust the front wheel static balance with the
brake disc installed.
1. Remove:8 Balancing weight
2. Set:8Wheel
(on a suitable stand)3. Find:8 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 samespot.
f. This spot is the wheel’s heavy spot “X”.***************************************4. Adjust:8Wheel static balance
***************************************Adjusting steps:8 Instail a balancing weight 1 on the rim ex-
actly opposite to the heavy spot “X”.NOTE:
Start with the smallest weight.
8 Turn the wheel so that the heavy spot is 90°up.8 Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-anced.
***************************************
X1
X1
X
X
X
6-7
CHASFRONT WHEEL AND BRAKE DISC
5. Check:8Wheel static balance
***************************************Checking steps:8 Turn the wheel so that it comes to each point
as shown.8 Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.***************************************X
X
X X
6-8
CHAS
Order
1234
Q’ty
1122
FRONT BRAKEBRAKE PAD
FRONT BRAKE
Remarks
Remove the parts in order.Refer to “ BRAKE PAD REPLACEMENT“ section .
Reverse the removal procedure for in-stallation.
Job name/Part name
Brake pad removalCaliper support boltCaliperBrake padPad spring
T R..
23Nm(2.3kg.m)
T R..
23Nm(2.3kg.m)
B
B
1
2
3
4
6-9
CHASFRONT BRAKE
cCDisc brake components rarely require disas-sembly. DO NOT:8 Disassembly components unless absolutely
necessary.8 Use solvents in internal brake component.8 Use contaminated brake fluid for cleaning.8 Use only clean fluid.8 Allow brake fluid to come in contact with the
eyes otherwise eye injury may occur.8 Allow brake fluid to contact painted surfaces
or plastic parts otherwise damage may oc-cur.8 Disconnect any hydraulic connection other-
wise the entire system must be disas-sembled, drained, cleaned, and then prop-erly filled and bled after reassembly.
BRAKE PAD REPLACEMENTNOTE:
It is not necessary to disassemble the brakecaliper and brake hose to replace the brakepads.
1. Loosen:8 Retaining bolt 1
2. Remove:8 Brake caliper 28 Holder (brake hose) 3
3. Remove:8 Retaining bolt8 Pads 18 Pad spring 2
NOTE:
8 Replace the pad spring if the pad replacementis required.8 Replace the pads as a set if either is found to
be worn to the wear limit.
Wear limit a:0.8 mm (0.03 in)
1
2
3
1
2
a
6-10
CHAS
4. Install:8 Pad springs8 Brake pads (new)
***************************************Installation steps:8 Connect a suitable hose 1 tightly to the cali-
per bleed screw 2. Then, place the other endof this hose into an open container.8 Loosen the caliper bleed screw and push the
piston 3 into the caliper by your finger.8 Tighten the capliper bleed screw.
6 Nm (0.6 kg.m)
8 Install the pad spring (new) and brake pad(new) 48 Tighten retaining bolt 5 23 Nm (2.3 kg.m)
8 Install brake hose holder 6 7 Nm (0.7 kg.m)
8 Install caliper 7 23 Nm (2.3 kg.m)
***************************************
5. Inspect:8 Brake fluid level
Refer to the “BRAKE FLUID INSPEC-TION” section in the CHAPTER 3.
1 “LOWER” level line
T R..
T R..
FRONT BRAKE
12
3
4
T R..
T R..
1
5
7
6
6-11
CHAS
6. Check:8 Brake lever operation
A softy or spongy feeling Bleed→brakesystem.Refer to “ AIR BLEEDING ” section inthe CHAPTER 3.
FRONT BRAKE
6-12
CHASFRONT BRAKE
Order
1234567
Q’ty
1/1112111
MASTER CYLINDER
Remarks
Remove the parts in order.Refer to “BRAKE FLUID REPLACE-MENT” section in CHAPTER 3.
Refer to “MASTER CYLINDER INSTAL-LATION” section.
Reverse the removal procedure for in-stallation.
Job name/Part name
Master cylinder removalDrain the brake fluid
Brake lever/compression springBrake switchUnion boltCopper washerBrake hoseMaster cylinder bracketMaster cylinder
New
T R..
9Nm(0.9kg.m)T R.
.
25Nm(2.5kg.m)
B
1
2
5
4
7
3
6
6-13
CHAS
Order
1
2
3
4
Q’ty
1111
MASTER CYLINDER DISASSEMBLY
FRONT BRAKE
Remarks
Remove the parts in order.
Refer to “MASTER CYLINDER ASSEM-BLY” section.
Reverse the disassembly procedure forassembly.
Job name/Part name
Master cylinder disassemblyMaster cylinder bootCirclipMaster cylinder kitSpring
21
4
3
New
6-14
CHASFRONT BRAKE
2. Inspect:8 Master cylinder 18 Scratches/wear/damage→Replace the
master cylinder assembly.
3. Inspect:8 Diaphragm 1
Wear/damage→Replace.
YP.....
MASTER CYLINDER ASSEMBLY
w8 All internal brake components should be
cleaned and lubricated with new brake fluidonly before installation.
Recommended brake fluid:DOT #4
8 Replace the piston seals and dust seals when-ever a master cylinder is disassembled.
1. Install:8 Cylinder cup 18 Master cylinder piston 2
Install cylinder cup 1 by using cylindercup installer 3.
Cylinder cup installer set:90890-01996
YP702040
MASTER CYLINDER INSPECTION1. Inspect:8 Master cylinder kit 1
Wear/scratches→Replace the mastercylinder assembly.8 Master cylinder boot
Cracks/damage→Replace.
1
1
6-15
CHASFRONT BRAKE
2. Install:8 Spring 1
Install the spring with its smaller diam-eter to the master cylinder piston.8 Master cylinder kit 2
3. Install:8 Circlip 1
Install the circlip securely into the mas-ter cylinder groove.8 Master cylinder boot 2
YP.....
MASTER CYLINDER INSTALLATION1. Install:8 Master cylinder 18 Master cylinder bracket 2 9 Nm (0.9 kg.m)
cC8 Install the master cylinder bracket 2 with the
“UP” mark a facing upward.8 Align the end of the holder with the punch
mark b on the handle bar.
New
T R..
New
1
2
a
b
6-16
CHAS
2. Air bleed:8 Brake system
Refer to “AIR BLEEDING” section inCHAPTER 3.
w8 Use only designated quality brake fluid:
Otherwise, the rubber seals may deteriorate,causing leakage and poor brake perforrmance.8 Refill with the same type of brake fluid:
Mixing fluids may result in a harmful chemi-cal reaction and lead to poor perforrmance.8 Be careful that water does not enter the sig-
nificantly lower the boiling point of the fluidmay result in vapor lock.
3. Inspect:8 Brake operation
FRONT BRAKE
6-17
CHAS
Order
12345
Q’ty
12111
CALIPER
FRONT BRAKE
Remarks
Remove the parts in order.Refer to “BRAKE FLUID REPLACE-MENT” section in CHAPTER 3.
Refer to “CALIPER INSTALLATION” sec-tion.
Reverse the removal procedure for in-stallation.
Job name/Part name
Caliper removalDrain the brake fluid
Union boltCopper washerBrake hoseCaliper support boltCaliper assembly
T R..
25Nm(2.5kg.m)
T R..
23Nm(2.3kg.m)
T R..
23Nm(2.3kg.m)
1
2
3
4
5
New
6-18
CHAS
Order
1
2
3
4
5
6
7
Q’ty
1221111
CALIPER DISASSEMBLY
FRONT BRAKE
Remarks
Remove the parts in order.
Refer to “BRAKE CALIPER DISASSEM-BLY/ASSEMBLY” section.
Reverse the disassembly procedure forassembly.
Job name/Part name
Caliper disassemblyCaliper bracketBrake padPad springCaliper pistonDust sealPiston sealBleed screw
T R..
6Nm(0.6kg.m)
New
B
1
2
3
4
5
6
7
6-19
CHASFRONT BRAKEYP702020
BRAKE CALIPER DISASSEMBLYNOTE:
Before disassembling either brake caliper, drainthe brake fluid from the brake hose, mastercylinder, brake caliper and reservoir tank.
1. Remove:8 Brake caliper piston
***************************************Removal steps:8 Blow compressed air into the hose joint
opening to force out the caliper piston fromthe brake caliper body.
w8 Never try to pry out the caliper piston.8 Cover the caliper piston with a rag. Be care-
ful not to get injured when the piston is ex-pelled from the master cylinder.
cCCarefully remove the caliper piston to preventdamage.
***************************************
2. Remove:8 Dust seal 18 Piston seal 2
When removing, push the seals by yourfinger.
cC8 Do not use a sharp instrument. Remove seals
by your finger.8 Do not re-use removed parts.
YP...
CALIPER INSPECTION1. Inspect:8 Caliper cylinder 18 Caliper piston 2
Scratches, wear→Replace caliper as-sembly.
6-20
CHASEB702050
BRAKE CALIPER ASSEMBLY
w8 All internal brake components should be
cleaned and lubricated with new brake fluidonly before installation.
Recommended brake fluid:DOT #4
8 Replace the caliper piston seals whenever abrake caliper is disassembled.
1. Install:8 Piston seal 1 New8 Dust seal 2 New
FRONT BRAKE
2. Install:8 Caliper piston 1
Apply brake fluid to the outer surfaceand install.
cC8 Do not force.8 Use care to prevent damage on caliper pis-
ton.
YP.....
CALIPER INSTALLATION1. Install:8 Caliper 18 Caliper support bolt 23Nm(2.3m.kg)
8 Brake hose 28 Copper washer 3 New8 Union bolt 4 25Nm(2.5 m.kg)
cCWhen installing the brake hose to the caliper,lightly touch the brake hose with the stoppera on the caliper.
T R..
New
1
2
3
4a
T R..
6-21
CHAS
Order
1234
Q’ty
1/1111
REAR WHEEL AND REAR BRAKE
REAR WHEEL AND REAR BRAKE
Remarks
Remove the parts in order.
Reverse the disassembly procedure forinstallation.
Job name/Part name
Rear wheel and rear brake removalMuffler assembly/GasketNut/Plain washerRear wheel assemblyPlain washer
T R..
12Nm(1.2kg.m)
T R..
26Nm(2.6kg.m)T R.
.
120Nm(12kg.m)
New
2
1
43
REAR WHEEL
6-22
CHASREAR WHEEL AND REAR BRAKE
Order
12345678
Q’ty
11111111
Remarks
Reverse the removal procedure for in-stallation.
Job name/Part name
AdjusterBrake cablePinReturn springBrake shoeCamshaft leverWear indicatorBrake camshaft
T R..
8Nm(0.8kg.m)
New
5
82
4
1
3
76
REAR BRAKE
6-23
CHASREAR WHEEL AND REAR BRAKEEB701020
REAR WHEEL INSPECTION1 Inspect:8 Rear wheel axle8 Rear wheel8 Rear wheel bearings8 Oil seals
Refer to “FRONT WHEEL”.2. Measure:8 Rear wheel runout
Refer to “FRONT WHEEL”.EB701021
REAR BRAKE INSPECTION1. Inspect:8 Brake lining surface
Glazed areas→Polish.Use coarse sand paper.
NOTE:
After polishing, wipe the polished particles witha cloth.
2. Measure:8 Brake lining thickness a
Brake lining thickness a :Standard:
4 mmLimit:
2 mm
Out of specification→Replace.Measuring points “ ”
NOTE:
Replace the brake shoes as a set if either is wornto the limit.
3. Measure:8 Brake drum inside diameter a
Out of specification→Replace the wheel.
Brake drum inside diameter:Standard:
130 mmLimit:
131 mm
6-24
CHASREAR WHEEL AND REAR BRAKE
4. Inspect:8 Brake drum inner surface8 Oil/scratches→Repair.8 Oil
Use a rag soaked in lacquer thinner orsolvent.8 Scratches
Use an emery cloth (lightly and evenlypolishing)
5. Inspect:8 Cam shaft face.
Wear→Replace.
wWhen inspecting the brake lining, do not spilloil or grease on the brake lining.
YP.....
REAR BRAKE INSTALLATION1. Install:8 Camshaft 18 Indicator plate 2
***************************************Installation steps:8 Set the camshaft with its punched mark a
facing the direction as shown.8 Align the projection b on the indicator plate
with the camshaft notch and install.8 Check the proper position of the brake shoe.***************************************
2. Install:8 Camshaft lever 1
NOTE:
Set the camshaft with its punched mark a fac-ing the direction on the cam shaft lever b.
1
2
1
b
a
a
b
6-25
CHAS
Order
123456789
Q’ty
111111111
HANDLEBARHANDLEBAR
Remarks
Remove the parts in order.
Refer to “COVERS AND PANEL” INCHAPTER 3.
Job name/Part name
Handlebar removalLeft/Right bake mirrorFront protector barUpper coverFront/Rear handlebar coverLeft/Right flasherBrake master cylinderFront brake switchHandlebar switch (Right)Throttle cableRear brake cableRear brake switchHandlebar switch (Left)BindWire harness strap
HANDLEBAR
B
B
B
T R..
23Nm(2.3kg.m)
T R..
43Nm(4.3kg.m)
1
2
3
4
5
6
7
8
9
10
11
12
12
6-26
CHAS
Order
101112
Job name/Part name
Brake hoseHandlebar comp.Left/Right grip
Q’ty
11
1/1
Remarks
Reverse the removal procedure for in-stallation.
HANDLEBAR
B
B
B
T R..
23Nm(2.3kg.m)
T R..
43Nm(4.3kg.m)
1
2
3
4
5
6
7
8
9
10
11
12
12
6-27
CHASHANDLEBAR
HANDLEBAR INSTALLATION1. Clean:8 Steering shaft a
wProper cables and leads routing is essential toissue safe scooter operation.
2. Install:8 Handlebar 18 Bolt 28 Nut 43Nm(4.3 kg.m)
NOTE:
Match the bolt 2 on to the steering columndent a.
cCThere must be a space b after tighting bolt 2.
3. Install:8 Band
NOTE:
Clamp the wire harness.
4. Apply:8 Lithium soap base grease (to throttle
cable end and handlebar right end).
T R..
5. Install:8 Handlebar switch (right) 1
NOTE:
Insert the projection a into the slot b on thehandlebar comp.
a
a
1
2
1
a
b
b
6-28
CHAS
6. Install:8 Handlebar switch (left) 1
NOTE:
Insert the projection a into the slot b on thehandlebar comp.
HANDLEBAR
b
1
a
7. Install:8 Master cylinder
NOTE:
Match the slot with the punched mark b onthe handlebar comp.
b
6-29
CHAS
STEERING
Order
123456789
Q’ty
1/11/111
1/111
22/193
STEERING
Remarks
Remove the parts in orderRefer to “HANDLEBAR” section.Refer to “FRONT WHEEL AND BRAKEDISC” section
Refer to “STEERING REMOVAL/INSTAL-LATION” section.
Reverse the removal procedure for in-stallation.
Job name/Part name
Steering removalHandlebarFront wheel
Ring nut 1/ Special washerRing nut 2/ Rubber washerRing nut 3Under bracketFront fork (Left/Right)Bearing coverBall raceBall (Upper/Lower)Ball race
T R..
45Nm(4.5kg.m)
T R..
45Nm(4.5kg.m)
B
B
12
3
4
5
67
8
9
9
8
9
STEERING
6-30
CHASSTEERING
STEERING REMOVAL
w8 Securely support the scooter so that there is
no danger of it falling over.8 Stand the scooter on a level surface.
1. Removal:8 Ring nut 1 18 Special washer 28 Ring nut 2 38 Rubber washer 48 Ring nut 3 58 Bearing cover 68 Ball race 78 Ball 88 Front fork assembly 9
NOTE:
8 Remove the ring nuts by steering nut wrench.
Steering nut wrench 090890-01268
8 Hold the lower bracket by hand, then removeby using the steering nut wrench 0.8 Do not loss the balls (Upper: 22 pcs, Lower:
19 pcs).
2. Remove8 Front fork assembly
Refer to “FRONT FORK” section.3. Remove8 Ball race
***************************************Ball race replacement steps:8 Remove the ball races on the head pipe us-
ing long rod 1 and the harmmer as shown.8 Remove the ball races on the under bracket
using the floor chisel 2 and the harmmer asshown.
***************************************
1
2
3
4
5
6
7
8
1
2
9
6-31
CHASSTEERING
3. Inspect:8 Under bracket 1
Crack/Bend/Damage→Replace.
wDo not attempt to straighten a bent underbracket as this may dangerously weaken theunder bracket.
STEERING INSTALLATION1. Install:8 Ball 1
NOTE:
Upper.......22 pcsLower...... 19 pcs
2. Lubricate8 Ball8 Ball race
Wheel bearing grease
STEERING INSPECTION1. Wash the bearing races with a solvent.2. Inspect:8 Ball race8 Ball
Pitting/Damage→Replace.NOTE:
Always replace bearings and races as set.
1
1
6-32
CHAS
3. Install:8 Front fork assembly 18 Ball race (Upper) 28 Bearing cover 38 Ring nut 3 48 Rubber washer 58 Ring nut 2 68 Special washer 78 Ring nut 1 8
NOTE:
Securely support the steering shaft so thatthere is no danger of it falling down.
4. Tighten:8 Ring nuts
***************************************Tighten steps:8 Tighten the ring nut 3 2 using the ring nut
wrench 1 28 Nm (2.8 kg.m)
Ring nut wrench:90890-01403
NOTE:
Set the torque wrench 3 to ring nut wrench 1so that they form right angle.
wDo not over-tightening.
8 Loosen the ring nut 3 2 1/4 turn.8 Check the front fork by turning it lock to lock.
If there is any binding, remove the front forkassembly and inspect the steering ball bear-ings and ball races.8 Install rubber washer 4 and ring nut 2 5,
then turn the ring nut 2 until it contacts withrubber washer.
STEERING
8
7
6
5
4
3
2
1
3
2
1
7
6
5
4
2
T R..
6-33
CHAS
cCSlots on the ring nut 2 and ring nut 3 should bealign. If not, turn the ring nut 2 towards tightendirection until slots alignment.
8 Install special washer 6NOTE:
Insert the projections of the special washer intothe slots.
8 Install ring nut 1 7 and tighten. 66Nm(6.6 kg.m)
***************************************
STEERING
T R..
6-34
CHAS
Order
12345
Q’ty
11222
FRONT FORKFRONT FORK
FRONT FORK
Remarks
Remove the parts in order.Refer to “Steering” section.
Refer to “FRONT FORK REMOVAL/IN-STALLATION” section.
Reverse the removal procedure for in-stallation.
Job name/Part name
Front fork removalSteeringUnder fenderSpeedometer cable holderCap boltPinch boltFront fork
T R..
40Nm(4.0kg.m) T R..
45Nm(4.5kg.m)
2
3
1
5
4
6-35
CHASFRONT FORK
Order
1
2
3
4
5
6
7
8
9
0
Q’ty
1
11/11
1/11
1/1111
FRONT FORK DISASSEMBLY
Remarks
Remove the parts in order.Refer to “FRONT FORK REMOVAL/IN-STALLATION” section.
Refer to “ FRONT FORK DISASSEMBLY/ASSEMBLY” section.
Reverse the disassembly procedure forassembly.
Job name/Part name
Front fork disassemblyFork spring
Band/Front fork bootBolt/Copper washerInner tubeDamper rodRebound springOil lock pieceOil seal clipOil sealOuter tube
T R..
23Nm(2.3kg.m)
LT
New
New
New
New
1
2
3
4
5
6
7
8
9
0
6-36
CHAS
2. Remove:8 Cap bolt 18 Pinch bolt 2
wFork spring will jump out after removing capbolt.
3. Remove:8 Front fork (Left/Right) 3
FRONT FORKYP.....
FRONT FORK REMOVAL
w8 Securely support the scooter so there is no
danger of it falling over.8 Stand the scooter on a level surface.8 Stand the scooter on its centerstand.1. Remove:8 Under fender 1
1
11
2
3
2
1
3
YP703020
FRONT FORK DISASSEMBLY1. Remove:8 Bolt (damper rod) 1
Loosen the bolt (damper rod) 2 whileholding the damper rod with T-handle3 and 8 mm hexagon bolt.
T-handle90890-01326
6-37
CHASFRONT FORK
2. Remove:8 Inner tube 18 Oil lock pice 28 Damper rod 38 Rebound spring 4
3. Remove:
8 Oil seal 1 New
cCNever reuse the oil seal.
2 Rag
YP703030
FRONT FORK INSPECTION1. Inspect:8 Inner tube bending
Inner tube bending limit:0.2 mm
Scratches/bends/damage→Replace.
wDo not attempt to straighten a bent inner tubeas this may dangerously weaken the tube.
YP.....
FRONT FORK ASSEMBLYReverse the “ DISASSEMBLY” procedure.Note the following points.1. Install:8 Damper rod 18 Rebound spring 28 Oil lock piece 38 Inner tube 4
1 3
4
2
New
4 1
2
3
6-38
CHASFRONT FORK
2. Install:8 Inner tube 1
Into outer tube 2.
3. Install:8 Plain washer 1 New8 Bolt (damper rod) 2
New
32
LT T R..
5. Install:
8 Oil seal 1 New8 Retaining clip
Use the fork seal driver weight 2 andthe attachment 3.
NOTE:
8 Before installing the oil seal 1, apply lithiumsoap base grease onto the oil seal lips.8 Adjust the retaining clip so that it fits into the
outer tube groove.
cCMake sure that the oil seal numbered side facesupward.
Fork seal driver weight:90890-01367
Attachment:90890-01400
4. Tighten:8 Bolt (damper rod) 1 23Nm(2.3 m.kg)
NOTE:
Tighten the damper rod bolt 1 while holdingthe damper rod with a T-handle 2 and a 8 mmhexagon bolt 3.
T-handle90890-01326
1
New
6-39
CHASFRONT FORK
6. Inspect:8 Inner tube operation
Unsmooth operation→Disassembly andrecheck.
7. Fill:8 Fork oil 1
Oil quantity:88 cc
Recommended oil:Fork oil 10 W or equivalent
8. After filling up, slowly pump the fork upand down to distribute the fork oil.
9. Install:8 Front fork spring 1
NOTE:
8 Install the fork spring with its smaller pitchaupward .8 Before installing the cap bolt, apply grease
to the O-ring.8 Temporarily tighten the cap bolt.
1
a
EB703050
FRONT FORK INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Install:8 Front fork 1
NOTE:
Apply grease onto cap bolt O-ring before in-stalling cap bolt.
2. Tighten:8 Cap bolts 2 45Nm(4.5 kg.m)
8 Pinch bolts 3 40Nm(4.0 kg.m)
T R..
T R..
22
3
1
7-1
– +ELEC
ELECTRICALELECTRICAL COMPONENTS1Main switch2Resister3Audio pilot4Flasher relay5Oil level gauge6C.D.I. UNIT7Fuel level gauge
8Starter relay9Fuse0BatteryqIgnition coilwRectifier/RegulatoreHorn
1
2
3
4
5
6
7
8
9
0
qw
e
ELECTRICAL COMPONENTS
7-2
– +ELEC
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
LOCKOPENOFF
CHECKON
B
Gy
R
Br
R
Br
B
Gy
Y/R
L/W
L/R
L
L/G
G/R
L
L/G
G/R
Y/R
L/W
L/R
OFFSTART
8
'
:
LW
RW
LW
GY B
R
B
R
B
B
Y/R
B
B
B
Y/B
B
W
Y/R
B
W
Y/R
B
Gy
Br
Gy
Br
Br
G
Br
G
Dg
Ch
Dg
Ch
L
Gy
B
L
Gy
B
G
B
G
B
Y
B
Y
B
G
L/R
G
L/R
G/R
P
B
G/R
P
B
Ch
Br/W
Dg
Ch
Br/W
Dg
Y
G
Y
G
Ch
Dg
B
Ch
Dg
B
Ch
B
Ch
B
G/Y
B
G/Y
B
L
-
L
-
Dg
B
Dg
B
OFFPUSH
&
%
Br/W
Br
4
N6
Or
B
Or
B
Gy
Br R B
B/W
RR
R
R
LW
B LW LG YR
R
GY
R
B
W
Y/R
RB
YB
L/R L
G/R
BrP
Br
Br/
/W
P
G/R
Br/
W
B G Y Ch
Dg
G Y LRB
Ch
Dg
B
BY
B
W
Y/R
YR
B
B
B
B B
Ch
Dg
G/Y
B B
Ch
Dg
G/Y
G/Y
GY
Br
Br
Br
B
L/G
L/Y
B
OrOr
B
W/R
B/R
B/W
W/R
B/R
L/Y
Br
Gy L
Gy
Br
Y Y
Ch
Dg
BGG
BG
1
3
24
n
b
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6
5
s
7
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9
.
8
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Q
W
R
B
Y/R
m
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f
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7-3
– +ELECCIRCUIT DIAGRAM
Black
Brown
Chocolate
Dark Green
Green
Blue
Orange
Sky blue
Pink
Red
1 Main switch2 Main fuse3 Battery4 Starter relay5 Starter motor6 Rectifier regulator7 Auto choke8 C.D.I. magneto9 C.D.I. unit0 Ignitionq Spark plugw Resistere Rear brake switchr Front brake switcht Tail/Brake lighty Rear flasher light(right)u Rear flasher light(left)i Audio piloto Front flasher light(right)p Front flasher light(left)
a Head lights Flasher relayd Hornf Handlebar switch (left)g Horn switchh Dimmer switchj Turn switchk Fuel senderl Meter; Fuel gaugez Oil indicator lightx Meter lightc High beam indicator lightv Turn indicator lightb Oil level gaugen Handlebar switch (right)m Starter switch, Light switch. Sidestand switch/ Auxiliary light
B
Br
Ch
Dg
G
L
Or
Sb
P
R
COLOR CODE
Gy
Y
W
B/R
Br/W
G/R
G/Y
L/B
L/Y
L/W
L/R
R/B
R/Y
R/W
Y/R
W/G
G/W
W/R
L/G
Gray
Yellow
White
Black/Red
Brown/White
Green/Red
Green/Yellow
Blue/Black
Blue/Yellow
Blue/White
Blue/ Red
Red/Black
Red/Yellow
Red/white
Yellow/White
White/Green
Green/White
White/Red
Blue/Green
7-4
– +ELECYP-N
CHECKING SWITCHESCHECKING STEPSUsing pocket tester, check switches for conti-nuity between their terminals to determinewhether they are correctly connected.Replace the switch component if any of thecombinations does not produce the correctreading.
Pocket tester:90890-03112
NOTE:
8 Turn the switch to the “ON”, “OFF” positionsseveral times.
8 Adjust the pocket tester to correct “0” posi-tion before checking switches.
8 Set the pocket tester selector to “×1”Ω.
SWITCH CONNECTION AS SHOWN IN THISMANUALThis manual contains connection charts, likethe one shown on the left, showing the termi-nal connections of switches (e.g. the mainswitch, handlebar switch, brake switch, light-ing switch etc.)
The column on the extreme left indicates thedifferent switch positions, the top line indicatesthe colors of the leads connected to the termi-nals on the switch.
“?—?” indicates terminals between whichthere is continuity, i.e. a closed circuit, in thegiven switch position.
In this chart:“Br and R” have continuity with the switch inthe “ON” position.
CHECKING SWITCHES
“Ω×1”
“∞” “0”
OFFON
Br R
Br R
7-5
– +ELEC
SWITCH POSITION AND TERMINAL CONNECTION
Before checking a switch refer to the check-ing switches as shown in the left page andcheck for the correct terminal connections(closed circuit) according to the color combi-nations shown in the chart.Poor connection, fault→Repair or replace.
CHECKING SWITCHES
Rear brake switch
Horn switch
Dimmer switch
Turn switch
Main switch
Front brake switch
Start switch
Light switch
Fuse
B RGy Br
LOCKOPENOFF
*ON
Gy Br R B B/W
G/R Ch P Br/W B Dg
ReleasePush in
YG
P B
&%
G G/R Y
4–6
Ch Br/W DgReleasePush in
L/W L/G
8
'
:
Y/R Y/B L/R L G/R
L Y/R L/G L/WG/R L/R
7-6
– +ELEC
IGNITION SYSTEMCIRCUIT DIAGRAM
1 Main switch8 C.D.I. magneto9 C.D.I. unit0 Ignition coilq Spark plug
LOCKOPENOFF
CHECKON
B
Gy
R
Br
R
Br
B
Gy
Y/R
L/W
L/R
L
L/G
G/R
L
L/G
G/R
Y/R
L/W
L/R
OFFSTART
8
'
:
LW
RW
LW
GY B
R
B
R
B
B
Y/R
B
B
B
Y/B
B
W
Y/R
B
W
Y/R
B
Gy
Br
Gy
Br
Br
G
Br
G
Dg
Ch
Dg
Ch
L
Gy
B
L
Gy
B
G
B
G
B
Y
B
Y
B
G
L/R
G
L/R
G/R
P
B
G/R
P
B
Ch
Br/W
Dg
Ch
Br/W
Dg
Y
G
Y
G
Ch
Dg
B
Ch
Dg
B
Ch
B
Ch
B
G/Y
B
G/Y
B
L
-
L
-
Dg
B
Dg
B
OFFPUSH
&
%
Br/W
Br
4
N6
Or
B
Or
B
Gy
Br R B
B/W
RR
R
R
LW
B LW LG YR
R
GY
R
B
W
Y/R
RB
YB
L/R L
G/R
BrP
Br
Br/
/W
P
G/R
Br/
W
B G Y Ch
Dg
G Y LRB
Ch
Dg
B
BY
B
W
Y/R
YR
B
B
B
B B
Ch
Dg
G/Y
B B
Ch
Dg
G/Y
G/Y
GY
Br
Br
Br
B
L/G
L/Y
B
OrOr
B
W/R
B/R
B/W
W/R
B/R
L/Y
Br
Gy L
Gy
Br
Y Y
Ch
Dg
BGG
BG
1
3
24
n
b
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l
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6
5
s
7
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9
.
8
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Q
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R
B
Y/R
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7-7
– +ELEC
Ignition checker:90890-06754
1. Spark plug8 Check the spark plug condition.8 Check the spark plug type.8 Check the spark plug gap.
Refer to the “SPARK PLUG INSPECTION”section in the CHAPTER 3.
CORRECT
2. Ignition spark gap8 Disconnect the spark plug cap from spark
plug.8 Connect the ignition checker 1 as shown.
2 Spark plug cap3 Spark gap
8 Check the ignition spark gap.8 Start engine, and increase spark gap until
misfire occurs.
Minimum spark gap:6.0 mm (0.24 in)
OUT OF SPECIFI-CATION OR NOSPARK
IGNITION SYSTEM
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE(NO SPARK OR INTERMITTENT SPARK)
NOTE:
8 Remove the following parts before troubleshooting.1) Battery box cover 4) Tail cover2) Center cowling 5) Side cover (right)3) Rear carrier
8 Use the following special tools in this troubleshooting.
Pocket tester: Pocket tester:90890-03112
Standard spark plug:BPR7HS (NGK)
Spark plug gap:0.9~1.0 mm
INCORRECT
Spark plug is faulty, replace it or repair pluggap.
MEETS SPECIFICATION
Ignition system is good.*
7-8
– +ELECIGNITION SYSTEM
*
3. Spark plug cap resistance8 Remove the spark plug cap.8 Connect the pocket tester (Ω × 1k) to the
spark plug cap.8 Check the spark plug cap for specificated
resistance.
Spark plug cap resistance:5kΩ at 20°C (68°F)
MEETSSPECIFICATION
4. Ignition coil resistance8 Disconnect the ignition coil leads from the
ignition coil.8 Connect the pocket tester (Ω × 1) to the
ignition coil.
Ignition coil:Tester (+) lead→Terminal 1Tester (–) lead→Coil base 2
8 Check the primary coil for specificationresistance.
Primary coil resistance:0.32~0.48 Ω at 20°C (68°F)
8 Connect the pocket tester (Ω × 1 k) to theignition coil.
Tester (+) lead→Spark plug lead 1Tester (-) lead→Coil base 2
8 Check the secondary coil for specificatedresistance.
Secondary coil resistance:5.68 ~ 8.52 k Ω at 20°C (68°F)(Spark plug lead - Coil base)
BOTH MEETSPECIFICATIONS
*
OUT OF SPECIFICATION
Replace spark plug cap.
OUT OF SPECIFICATION
Ignition coil is faulty, replace it.
Ω×1k
7-9
– +ELECIGNITION SYSTEM
5. Pickup coil resistance8 Disconnect the pickup coil coupler from
the wireharness.8 Connect the pocket tester (Ω × 100) to the
pickup coil terminal.
Tester (+) lead→White/Red lead 1Tester (-) lead→Black 2
8 Check the pickup coil for specificated re-sistance.
Pickup coil resistance:400~ 600 Ω at 20°C (68°F)(White/Red-Black)
MEETSPECIFICATION
6. Source resistance8 Disconnect the source coil coupler from
the wireharness.8 Connect the pocket tester (Ω × 100) to the
source coil terminal.
Tester (+) lead→Black/Red lead 1Tester (–) lead→Black 2
8 Check the source coil for specificated re-sistance.
Source coil resistance:640 ~ 960 Ω at 20°C (68°F)(Black/Red - Black )
MEETSPECIFICATION
7. Wiring connectionCheck the entire ignition system for connec-tions.Refer to the “WIRING DIAGRAM” section.
CORRECT
Replace CDI unit.
*
OUT OF SPECIFICATION
Pickup coil is faulty, replace it.
OUT OF SPECIFICATION
Source coil is faulty, replace it.
POOR CONFECTION
Correct.
CDIMagneto
WY/RB
1 2
B/R
W/R
CDIMagneto
WY/RB
1
2
B/R
W/R
7-10
– +ELEC
CHARGING SYSTEMCIRCUIT DIAGRAM
CHARGING SYSTEM
2 Main fuse3 Battery6 Rectifier Regulator8 CDI magnet
LOCKOPENOFF
CHECKON
B
Gy
R
Br
R
Br
B
Gy
Y/R
L/W
L/R
L
L/G
G/R
L
L/G
G/R
Y/R
L/W
L/R
OFFSTART
8
'
:
LW
RW
LW
GY B
R
B
R
B
B
Y/R
B
B
B
Y/B
B
W
Y/R
B
W
Y/R
B
Gy
Br
Gy
Br
Br
G
Br
G
Dg
Ch
Dg
Ch
L
Gy
B
L
Gy
B
G
B
G
B
Y
B
Y
B
G
L/R
G
L/R
G/R
P
B
G/R
P
B
Ch
Br/W
Dg
Ch
Br/W
Dg
Y
G
Y
G
Ch
Dg
B
Ch
Dg
B
Ch
B
Ch
B
G/Y
B
G/Y
B
L
-
L
-
Dg
B
Dg
B
OFFPUSH
&
%
Br/W
Br
4
N6
Or
B
Or
B
Gy
Br R B
B/W
RR
R
R
LW
B LW LG YR
R
GY
R
B
W
Y/R
RB
YB
L/R L
G/R
BrP
Br
Br/
/W
P
G/R
Br/
W
B G Y Ch
Dg
G Y LRB
Ch
Dg
B
BY
B
W
Y/R
YR
B
B
B
B B
Ch
Dg
G/Y
B B
Ch
Dg
G/Y
G/Y
GY
Br
Br
Br
B
L/G
L/Y
B
OrOr
B
W/R
B/R
B/W
W/R
B/R
L/Y
Br
Gy L
Gy
Br
Y Y
Ch
Dg
BGG
BG
1
3
24
n
b
g
l
k
6
5
s
7
w
9
.
8
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B
Y/R
m
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7-11
– +ELECCHARGING SYSTEM
Inductive tachometer:90890-03113
1. Fuse (main)8 Remove the fuse.8 Connect the pocket tester (Ω × 1) to the
fuse.8 Check the fuse for continuity.
CONTINUITY
2. Battery8 Check the battery condition
Refer to the “BATTERY INSPECTION” sec-tion in the CHAPTER 3.
Open circuit voltage:12.8V or more at 20°C (68°F)
CORRECT
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED.
NOTE:
8 Remove the following parts before troubleshooting.1) Front protector bar 4) Tail cover2) Upper cover 5) Right side cover3) Rear carrier8 Use the following special tool (s) in this trobleshooting.
Pocket tester:90890-03112
NO CONTINUITY
Fuse is faulty, replace it.
INCORRECT
8 Clean battery terminals.8 Recharge or replace battery.
*
7-12
– +ELEC
3. Charging voltage8 Connect the inductive tachometer to the
spark plug lead.8 Connect the pocket tester (DC20V) to the
battery.
Tester (+) lead→Battery (+) terminalTester (-) lead→Battery (–) terminal
8 Start the engine and accelerate to about5,000 r/min.
8 Check charging voltage.
Charging voltage:13 ~ 14 V at 4,000 r/min
NOTE:
Use a full charged battery.
OUT OF SPECIFICATION
4. Charging coil and lighting coil resistance8 Disconnect the charging coil coupler from
the wireharness.8 Connect the pocket tester “Ω × 1” to the
charging coils.8 Measure the charging coil and lighting coil
resistance.
Charging coil resistance:Tester (+) lead→White lead 1Tester (–) lead→BLACK 3
Lighting coil resistance:Tester (+) lead→Yellow/Red 2Tester (–) lead→BLACK 3
Charging coil resistance:0.5~0.7 Ω at 20°C (68°F)
Lighting coil resistance:0.4~0.6 Ω at 20°C (68°F)
MEETSPECIFICATION
*
MEETS SPECIFICATION
Charging circuit is good.
CHARGING SYSTEM
OUT OF SPECIFICATION
Charging coil is faulty, replace it.
*
CDIMagneto
WY/RB
12
B/R
W/R
3
7-13
– +ELEC
5. Wiring connectionCheck the entire ignition system for con-nections.Refer to the “WIRING DIAGRAM” section.
OK
Replace rectifier regulator.
POOR CONNECTION
Correct.
*
CHARGING SYSTEM
7-14
– +ELEC
ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
1 Main switch2 Main fuse3 Battery4 Starter relay5 Starter motor9 CDI unit
e Front brake switchr Rear brake switchm Starter switch. Sidestand switch
LOCKOPENOFF
CHECKON
B
Gy
R
Br
R
Br
B
Gy
Y/R
L/W
L/R
L
L/G
G/R
L
L/G
G/R
Y/R
L/W
L/R
OFFSTART
8
'
:
LW
RW
LW
GY B
R
B
R
B
B
Y/R
B
B
B
Y/B
B
W
Y/R
B
W
Y/R
B
Gy
Br
Gy
Br
Br
G
Br
G
Dg
Ch
Dg
Ch
L
Gy
B
L
Gy
B
G
B
G
B
Y
B
Y
B
G
L/R
G
L/R
G/R
P
B
G/R
P
B
Ch
Br/W
Dg
Ch
Br/W
Dg
Y
G
Y
G
Ch
Dg
B
Ch
Dg
B
Ch
B
Ch
B
G/Y
B
G/Y
B
L
-
L
-
Dg
B
Dg
B
OFFPUSH
&
%
Br/W
Br
4
N6
Or
B
Or
B
Gy
Br R B
B/W
RR
R
R
LW
B LW LG YR
R
GY
R
B
W
Y/R
RB
YB
L/R L
G/R
BrP
Br
Br/
/W
P
G/R
Br/
W
B G Y Ch
Dg
G Y LRB
Ch
Dg
B
BY
B
W
Y/R
YR
B
B
B
B B
Ch
Dg
G/Y
B B
Ch
Dg
G/Y
G/Y
GY
Br
Br
Br
B
L/G
L/Y
B
OrOr
B
W/R
B/R
B/W
W/R
B/R
L/Y
Br
Gy L
Gy
Br
Y Y
Ch
Dg
BGG
BG
1
3
24
n
b
g
l
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6
5
s
7
w
9
.
8
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B
Y/R
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7-15
– +ELECELECTRIC STARTING SYSTEM
Pocket tester:90890-03112
1. Fuse8 Remove the fuse.8 Connect the pocket tester (Ω × 1 ) to the
fuse.8 Check the fuse for continuity.
CONTINUITY
2. Battery8 Check the battery condition.
Refer to the “BATTERY INSPECTION” sec-tion in the CHAPTER 3.
Open circuit voltage:12.8 V or more at 20°C (68°F)
CORRECT
3. Starter motor8 Connect the battery1positive terminal
and starter motor cable 2 using a jumperlead 3 * .
8 Check the starter motor for operation.
MOVES
TROUBLESHOOTING
STARTER MOTOR DOES NOT OPERATE.
NOTE:
8 Remove the following parts before troubleshooting.1)Battery box cover 4)Side covers (left and right)2)Rear carrier 5)Trunk3)Tail cover 6)Handlebar cover (front)
8 Use the following special tool in this troubleshooting.
NO CONTINUITY
Fuse is faulty, replace it.
INCORRECT
8 Clean battery terminals.8 Recharge or replace battery.
w8 A wire for the jumper lead must have the
equivalent capacity as that of the battery leador more, otherwise it may cause the jumperlead to be burned.
8 This check is likely to produce sparks, so besure that no flammable gas or fluid is in thevicinity.
DOES NOT MOVE
Starter motor is faulty, repair or replace it.
*
M
7-16
– +ELEC
L/WG/Y
ELECTRIC STARTING SYSTEM
*
4. Starter relay8 Disconnect the relay unit coupler from the
wire harness.8 Connect the pocket tester(Ω × 1)and
battery(12V) to the relay unit coupler ter-minals.
Battery(+)lead→Blue/White terminal 1
Battery(–)lead→Green/Yellow terminal 2
8 Check the starter relay for continuity.
Tester (+) lead→ 3 terminalTester (-) lead→ 4 terminal
CONTINUITY
5. Main switchRefer to “CHECKING SWITCHS” section.
CONTINUITY
6. “START” switchRefer to “CHECKING SWITCHS” section.
CORRECT
NO CONTINUITY
Replace the starter relay.
NO CONTINUITY
Main switch is faulty, replace it.
NO CONTINUITY
“START” switch is faulty, replace handlebarswitch (right).
13
4 2
*
7-17
– +ELECELECTRIC STARTING SYSTEM
*
7. Sidestand switch 8 Disconnect the sidestand switch coupler
from the wire harness.8 Check the switch component for the con-
tinuity between “Blue/Yellow 1 and Black2”.
POOR CONNECTION
Correct.
8. Brake switches (front and rear) 8 Disconnect the brake switch leads from the
wire harness.8 Connect the pocket tester (Ω × 1 )to the
brake switch leads.
8 Check the brake switch for continuity
SwitchPosition
Goodcondition
Bad condition
Brake isapplied
Brake isnot applied
:Continuity :No continuity
*
BAD CONDITION
Replace brake switch(es).
CORRECT
GOODCONDITION
L/Y
B
BrG/Y
1
2
12
7-18
– +ELEC
*
9. Wiring connection 8 Check the entire electrical starting system
for connections.Refer to “WIRING DIAGRAM” section.
ELECTRIC STARTING SYSTEM
GOODCONDITION
Replace CDI unit.
POOR CONNECTION
Correct.
7-19
– +ELECELECTRIC STARTING SYSTEM
Order
12
Q’ty
21
STARTER MOTOR
Remarks
Remove the parts in order.
Refer to “COVER PANEL” section inCHAPTER 3.
Refer to “REAR WHEEL AND REARBRAKE” section in CHAPTER 6.Refer to “ENGINE REMOVAL” sectionchapter 4.
Job name/Part name
Starter motor removalRear carrierTail coverBattery box coverLeft/Right side coverCenter cowlingMufflerRear wheelAir shroud 3
Starter motor couplerStarter motor
T R..
13Nm(1.3kg.m)
1
2
3
4
5
2
1
7-20
– +ELEC
STARTER MOTOR DISASSEMBLY
Order
1
2
3
4
5
Job name/Part name
Starter motor disassemblyO-ringRear bracketArmature ass’yRingBrush holder set
Q’ty
11111
Remarks
Reverse the removal procedure for in-stallation.Disassembly the parts in order.
Refer to “Starter motor assembly”
Reverse the disassembly procedure forassembly.
ELECTRIC STARTING SYSTEM
T R..
13Nm(1.3kg.m)
1
2
3
4
5
2
1
7-21
– +ELECELECTRIC STARTING SYSTEMYP803034
INSPECTION AND REPAIR1. Inspect:
8 CommutatorDirt→Clean it with #600 grit sandpaper.
2. Measure:8 Commutator diameter a
Commutator wear limit:16.6 mm
Out of specification→Replace the startermotor
3. Measure:8 Mica undercut a
Mica undercut:1.35 mm
Out of specification→Scrape the mica tothe proper value (a hacksaw blade canbe ground to fit).
NOTE:
The mica insulation of the commutator mustbe undercut to ensure proper operation of com-mutator.
4. Inspect:8 Armature coil resistances (installation/
continuity)Defects→Replace the starter motor.If commutator is dirty, clean it with sand-paper.
O: Continuityx: No continuityBad condition→Replace.
Good Bad conditioncondition
A
B ×? ?
? ?×× ×
a
a
A
AB
B
7-22
– +ELEC
5. Measure:8 Brush length a
Out of specification→Replace.
Brush length wear limit1.0 mm
6. Measure:8 Brush spring force
Fatigue/out of specification→Replace asa set.
ELECTRIC STARTING SYSTEM
a
7-23
– +ELEC
LIGHTING SYSTEMCIRCUIT DIAGRAM
LIGHTING SYSTEM
8 C.D.I. magnetot Tail lighta Head lighth Light dimmer switchx Meter light
c High beam indicator light, Light switch/ Auxiliary light
LOCKOPENOFF
CHECKON
B
Gy
R
Br
R
Br
B
Gy
Y/R
L/W
L/R
L
L/G
G/R
L
L/G
G/R
Y/R
L/W
L/R
OFFSTART
8
'
:
LW
RW
LW
GY B
R
B
R
B
B
Y/R
B
B
B
Y/B
B
W
Y/R
B
W
Y/R
B
Gy
Br
Gy
Br
Br
G
Br
G
Dg
Ch
Dg
Ch
L
Gy
B
L
Gy
B
G
B
G
B
Y
B
Y
B
G
L/R
G
L/R
G/R
P
B
G/R
P
B
Ch
Br/W
Dg
Ch
Br/W
Dg
Y
G
Y
G
Ch
Dg
B
Ch
Dg
B
Ch
B
Ch
B
G/Y
B
G/Y
B
L
-
L
-
Dg
B
Dg
B
OFFPUSH
&
%
Br/W
Br
4
N6
Or
B
Or
B
Gy
Br R B
B/W
RR
R
R
LW
B LW LG YR
R
GY
R
B
W
Y/R
RB
YB
L/R L
G/R
BrP
Br
Br/
/W
P
G/R
Br/
W
B G Y Ch
Dg
G Y LRB
Ch
Dg
B
BY
B
W
Y/R
YR
B
B
B
B B
Ch
Dg
G/Y
B B
Ch
Dg
G/Y
G/Y
GY
Br
Br
Br
B
L/G
L/Y
B
OrOr
B
W/R
B/R
B/W
W/R
B/R
L/Y
Br
Gy L
Gy
Br
Y Y
Ch
Dg
BGG
BG
1
3
24
n
b
g
l
k
6
5
s
7
w
9
.
8
q
a
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p o
r
e
t
yu
d
Q
W
R
B
Y/R
m
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h
;
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/
0
f
j
L
7-24
– +ELECLIGHTING SYSTEM
Pocket tester:90890-03112
YP .....
1. Lights switchRefer to “CHECKING SWITCHES” section.
CONTINUITY
YP .....
2. Dimmer switchRefer to “CHECKING SWITCHES” section.
3. Lighting coil resistance8 Disconnect the lighting coil coupler from
the wireharness.8 Connect the pocket tester “ Ω x 1 “ to the
lighting coils.8 Measure the lighting coil resistances.
Tester (+) lead→Yellow/Red lead 1Tester (–) lead→Black 2
Lighting coil resistance:0.4 ~ 0.6 Ω at 20°C (68°F)
MEETSPECIFICATION
YP805010
TROUBLESHOOTING
IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHTAND/OR METER LIGHT FAIL TO COME ON.
ProcedureCheck:
1. Lights switch2. Dimmer switch3. Wiring connection (entire lighting system)
NOTE:
8 Remove the following parts before troubleshooting.1) Front handlebar cover2) Rear carrier3) Right side cover
8 Use the special tools specified in the troubleshooting section.
NO CONTINUITY
Replace the right handlebar switch.
NO CONTINUITY
Replace the left handlebar switch.
OUT OF SPECIFICATION
Lighting coil is faulty, replace it.*
CDIMagneto
WY/RB
1
B/R
W/R
2
7-25
– +ELEC
Y
B
G
L/R
*
YP.....
4. Wiring connection8 Check the connections of the entire light-
ing system.Refer to “WIRING DIAGRAM”.
OK
Check the condition of each of the lightingsystem’s circuits.Refer to “LIGHTING SYSTEM CHECK”
YP805020
LIGHTING SYSTEM CHECK1. If the headlight and the high beam indi-
cator light fail to come on.
1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.
CONTINUITY
2. Voltage8 Connect the pocket tester (DC20V) to the
headlight and high beam indicator lightcouplers.
AWhen the dimmer switch is on low beam.BWhen dimmer switch is on high beam.
Headlight:Tester (+) lead→Green 1 or Yellow 2 leadTester negative (–) lead→Black 3 lead
High beam indicator light:Tester I+) lead→Yellow 4 leadTester (–) lead→Black 5 lead
LIGHTING SYSTEM
POOR CONNECTIONS
Correct.
NO CONTINUITY
Replace the bulb and/or bulb socket.
*
A
B 12
3
L
Gy
B
Y
4
5
7-26
– +ELECLIGHTING SYSTEM
8 Turn the main switch to on.8 Turn the light switch to on position.8 Turn the dimmer switch to low beam or
high beam.8 Check for voltage (12V) on the lead at bulb
socket connectors.
MEETSSPECIFICATION
This circuit is not faulty.
YP805021
2. If the meter light fails to come on.
1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.
CONTINUITY
2. Voltage8 Connect the pocket tester (DC20V) to the
bulb socket coupler.
Tester (+) lead→Blue terminal 1
Tester (-) lead→Black terminal 2
8 Turn the main switch to on.8 Turn the lights switch to on.8 Check the voltage (12V) of the leads on
the bulb socket connector.
MEETSSPECIFICATION
This circuit is not faulty.
*OUT OF SPECIFICATION
The wiring circuit from the main switch tobulb socket connector is faulty. Repair.
NO CONTINUITY
Replace the bulb and/or bulb socket.
OUT OF SPECIFICATION
The wiring circuit from main switch to bulbsocket is faulty. Repair.
L
Gy
B
1
2
7-27
– +ELECLIGHTING SYSTEM
3. Auxilialy light does not come on.
1. Bulb and bulb socket 8 Check the bulb and bulb socket for conti-
nuity
CONTINUITY
2. Voltage8 Connect the pocket tester (DC20V) to the
bulb socket connector.
Tester (+) lead → Blue / Red 1 lead.Tester (-) lead → Black 2 lead.
8 Turn the main switch to on.8 Turn the lights switch to “PO” or “ON”.8 Check the voltage (12V) on the “Blue” lead
at the bulb socket connector.MEETSSPECIFICATION(12V)
This circuit is not faulty.
NO CONTINUITY
Bulb and/or bulb socket are faulty, replace.
OUT OF SPECIFICATION
Wiring circuit from main switch to bulbsocket connector is faulty. Repair.
Y
B
G
L/R
12
7-28
– +ELEC
L
-
G/Y
B
LIGHTING SYSTEMYP805022
4. The taillight fails to come on.
1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.
CONTINUITY
2. Voltage8 Connect the pocket tester (DC20V) to the
bulb socket connector.
Tester (+) lead→Blue terminal 1Tester (-) lead→Black terminal 2
8 Turn the main switch to on.8 Turn the lights switch to on8 Check the voltage (12V) on the bulb socket
connector.MEETSSPECIFICATION
This circuit is not faulty.
NO CONTINUITY
Replace the bulb and/or bulb socket.
OUT OF SPECIFICATION
The wiring circuit from main switch to bulbconnector is faulty. Repair.
2
1
7-29
– +ELEC
SIGNAL SYSTEMCIRCUIT DIAGRAM
SIGNAL SYSTEM
1 Main switch2 Main fuse3 Batterye Rear brake switchr Front brake switcht Brake lighty Rear flasher light(right)
u Rear flasher light(left)i Audio piloto Front flasher light(right)p Front flasher light(left)s Flasher relayd Hornf Handlebar switch (Left)
g Horn switchj Turn switchk Fuel sender; Fuel meterz Oil indicator lightv Turn indicator lightb Oil level gauge
LOCKOPENOFF
CHECKON
B
Gy
R
Br
R
Br
B
Gy
Y/R
L/W
L/R
L
L/G
G/R
L
L/G
G/R
Y/R
L/W
L/R
OFFSTART
8
'
:
LW
RW
LW
GY B
R
B
R
B
B
Y/R
B
B
B
Y/B
B
W
Y/R
B
W
Y/R
B
Gy
Br
Gy
Br
Br
G
Br
G
Dg
Ch
Dg
Ch
L
Gy
B
L
Gy
B
G
B
G
B
Y
B
Y
B
G
L/R
G
L/R
G/R
P
B
G/R
P
B
Ch
Br/W
Dg
Ch
Br/W
Dg
Y
G
Y
G
Ch
Dg
B
Ch
Dg
B
Ch
B
Ch
B
G/Y
B
G/Y
B
L
-
L
-
Dg
B
Dg
B
OFFPUSH
&
%
Br/W
Br
4
N6
Or
B
Or
B
Gy
Br R B
B/W
RR
R
R
LW
B LW LG YR
R
GY
R
B
W
Y/R
RB
YB
L/R L
G/R
BrP
Br
Br/
/W
P
G/R
Br/
W
B G Y Ch
Dg
G Y LRB
Ch
Dg
B
BY
B
W
Y/R
YR
B
B
B
B B
Ch
Dg
G/Y
B B
Ch
Dg
G/Y
G/Y
GY
Br
Br
Br
B
L/G
L/Y
B
OrOr
B
W/R
B/R
B/W
W/R
B/R
L/Y
Br
Gy L
Gy
Br
Y Y
Ch
Dg
BGG
BG
1
3
24
n
b
g
l
k
6
5
s
7
w
9
.
8
q
a
i
p o
r
e
t
yu
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Q
W
R
B
Y/R
m
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0
f
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7-30
– +ELECSIGNAL SYSTEM
Pocket tester:90890-03112
YP.....
1. FuseRefer to “CHECKING SWITCHES” section.
CONTINUITY
YP.....
2. Battery8 Check the battery condition.
Refer to “BATTERY INSPECTION” sectionin CHAPTER 3.
CORRECT
YP.....
3. Main switchRefer to “CHECKING SWITCHES” section.
CONTINUITY
YP806010
TROUBLESHOOTING
IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHTFAIL TO COME ON. IF THE HORN FAILS TO SOUND.
ProcedureCheck:1. Fuse (Main) 3.Main switch2. Battery 4.Wiring connection (entire signal system)
NOTE:
8 Remove the following parts before troubleshooting.1) Battery box cover 5) Tail cover2) Front protector bar 6) Side covers(Left/Right)3) Upper cover 7) Center cover4) Rear carrier
8 Use the special tools in the troubleshooting section .
NO CONTINUITY
Replace the fuse.
IN CORRECT
8 Clean battery terminals.8 Recharge or replace battery.
NO CONTINUITY
Replace the main switch.*
7-31
– +ELECSIGNAL SYSTEM
*
YP......
4. Wireharness8 Check the connections of the entire sig-
nal system.Refer to “CIRCUIT SYSTEM WIRING DIA-GRAM” section.
CONTINUITY
Check condition of each of the signalsystem’s circuits.Refer to “SIGNAL SYSTEM CHECK” sec-tion.
POOR CONNECTION
Correct.
7-32
– +ELECSIGNAL SYSTEMYP806020
SIGNAL SYSTEM CHECK1. If the horn fails to sound.
1. HORN switchRefer to “CHECKING SWITCHES” section.
CONTINUITY
2. Voltage8 Connect the pocket tester (DC20V) to the
horn lead.
Tester (+) lead→Brown terminal 1.Tester (-) lead→Frame ground
8 Turn the main switch to on.8 Check for voltage (12V) on the “Brown”
lead at the horn terminal.
MEETSSPECIFICATION
3. Horn8 Connect the pocket tester (DC20V) to the
horn at the “Pink” terminal.
Tester (+) lead→Pink 1 terminal.Tester (-) lead→Frame ground
8 Turn the main switch to on.8 Check for voltage on the “Pink” lead at
the horn terminal.
CONTINUITY
Adjust or replace horn.
NO CONTINUITY
Replace the left handlebar switch.
OUT OF SPECIFICATION
The wiring circuit from the main switch to thehorn is faulty. Repair.
NO CONTINUITY
Replace the horn.
Br P
Br P
7-33
– +ELEC
L
-
G/Y
B
SIGNAL SYSTEMYP806022
2. If the brake light fails to come on:
1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.
CONTINUITY
2. Brake switch (Front/Rear)Refer to “CHECKING SWITCHES” section.
CONTINUITY
3. Voltage8 Connect the pocket tester (DC20V) to the
bulb socket connector.
Tester (+) leadGreen/Yellow terminal 1Tester (-) leadBlack terminal 2
8 Turn the main switch to on.8 The brake lever is pulled in.8 Check for voltage (12V) of the “ Yellow”
lead on the bulb socket connector.
MEETSSPECIFICATION
This circuit is not faulty.
NO CONTINUITY
Replace the bulb and/or bulb socket.
NO CONTINUITY
Replace brake switch.
OUT OF SPECIFICATION
4. Wiring connection8 Wiring circuit from the main switch to the
bulb socket connector is faulty. Repair.Refer to “SIGNAL SYSTEM WIRING DIA-GRAM “ .
2
1
7-34
– +ELECSIGNAL SYSTEMYP806023
3. If the flasher light and/or turn indicatorlight fails to blink.
1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.
CONTINUITY
2. Turn switchRefer to “CHECKING SWITCHES” section.
CONTINUITY
3. Voltage8 Connect the pocket tester (DC20V) to the
flasher relay coupler.
Tester (+) lead→Brown terminal 1.Tester (-) lead→Frame ground
8 Turn the main switch to on.8 Check for voltage (12V) of the “Brown”
lead at the flasher relay terminal.
MEETSSPECIFICATION
4. Voltage8 Connect the pocket tester (DC20V) to the
flasher relay coupler.
Tester (+) lead→Brown/White terminal 1.Tester (-) lead→Frame ground
8 Turn the main switch to on.8 Check for voltage (12V) on the “Brown/
White” lead at the flasher relay terminal.
MEETSSPECIFICATION
NO CONTINUITY
Replace the bulb and/or bulb socket.
NO CONTINUITY
Replace the left handlebar switch.
OUT OF SPECIFICATION
The wiring circuit from main switch to flasherrelay connector is faulty. Repair.
OUT OF SPECIFICATION
The flasher relay is faulty. Replace.*
FLASHER
RELAY
Br/W
Br
–
–
FLASHER
RELAY
Br/W
Br
–
–
1
1
7-35
– +ELECSIGNAL SYSTEM
5. Voltage8 Connect the pocket tester (DC20V) to the
bulb socket connector.
At flasher light (left)Tester (+) lead→Chocolate lead 1Tester (-) lead→Black terminal 3
At flasher light (right)Tester (+) lead→Dark green lead 2Tester (-) lead→Black terminal 3
8 Turn the main switch to on.8 Turn the turn switch to left or right.8 Check for voltage (12V) on the “Choco-
late” lead and “Dark green” at the flasherlight terminal.
MEETSSPECIFICATION
This circuit is not faulty.
4. “OIL” indicator light does not come on.
1. Bulb and bulb socket8 Check the bulb and bulb socket for conti-
nuity.
CONTINUITY
2. Oil level switch8 Remove the oil level switch from the oil
tank.8 Connect the Pocket Tester (Ω x 1) to the
oil level switch.
Tester (+) Lead→Brown 1Tester (–) Lead→Gray 2
8 Check the oil level gauge for continuity.
GOOD CONDITION
*
OUT OF SPECIFICATION
6. Wiring connection8 Wiring circuit from the turn switch to bulb
socket connector is fault. Repair.Refer to “CIRCUIT DIAGRAM”.
NO CONTINUITY
Replace bulb and/or bulb socket.
BAD CONDITION
Replace oil level switch.
Bad condition
A Upright positionB Upside down
position
?: Continuity ×: No continuity
Goodcondition
Switch position
?× ?×××? ?
*
Ch B Dg B
Ch B Dg B
2133
A
B
Br Gy
Ch B Dg B
7-36
– +ELECSIGNAL SYSTEM
3. Voltage8 Connect the Pocket Tester (DC20V) to the
bulb socket connector.
Tester (+) Lead→Gray lead 1Tester (-) Lead→Frame ground 2
8 Turn the main switch to “*”8 Check for voltage (12V) on the “Gray” lead
at bulb socket connector.
MEETSSPECIFICATION(12V)
This circuit is good.
YP806027
5. If the fuel gauge fails to operate.
1. Fuel sender8 Remove the fuel sender from the fuel tank.8 Disconnect the fuel sender coupler from
the wireharness.Connect the pocket tester (Ω ×10) to thefuel sender coupler lead.
Tester (+) lead→Green terminal 1Tester (–) lead→Black terminal 2
8 Check the fuel sender for specificated re-sistance.
BOTH MEETSPECIFICATION
OUT OF SPECIFICATION
4. Wiring connection8 Check the entire signal system for connec-
tions.Refer to the “WIRING DIAGRAM” section.
OUT OF SPECIFICATION
Replace the fuel sender.
Float position
UP 3DOWN 4
Specificatedresistance
4~10Ω90~100Ω
B Gy L
2
B G
1
7-37
– +ELECSIGNAL SYSTEM
2. Voltage8 Connect the pocket tester (DC20V) to the
fuel gauge coupler.
Tester (+) lead→Brown terminal 1Tester (-) lead→Frame ground
8 Turn the main switch to “ON”.8 Check for voltage (12V) of the “Brown”
lead on the fuel sender lead.
MEETSSPECIFICATION
3. Fuel gauge8 Connect the fuel sender to wireharness.8 Move the float to “UP” 1 or “DOWN” 2.
8 Turn the main switch to “ON”.8 Check the fuel gauge needle moves “F”
or “E”.
Float position Needle moves
Float “UP” 1 “F”
Float “DOWN”2 “E”
MOVES
This circuit is not faulty.
OUT OF SPECIFICATION
Check the connection of the entire signal sys-tem .Refer to “CHECKING OF CONNECTIONS”.Refer to “CIRCUIT DIAGRAM”.
NOTE:
Before reading the meter, stay put the floatfor more than three minutes respectively at“UP” or “DOWN”.
DOES NOT MOVE
Replace the fuel gauge.
F
E
L Gy B Br DgG Ch
1
7-38
– +ELEC
AUTO CHOKE SYSTEMCIRCUIT DIAGRAM
AUTO CHOKE SYSTEM
7 Auto choke8 C.D.I. magneto
LOCKOPENOFF
CHECKON
B
Gy
R
Br
R
Br
B
Gy
Y/R
L/W
L/R
L
L/G
G/R
L
L/G
G/R
Y/R
L/W
L/R
OFFSTART
8
'
:
LW
RW
LW
GY B
R
B
R
B
B
Y/R
B
B
B
Y/B
B
W
Y/R
B
W
Y/R
B
Gy
Br
Gy
Br
Br
G
Br
G
Dg
Ch
Dg
Ch
L
Gy
B
L
Gy
B
G
B
G
B
Y
B
Y
B
G
L/R
G
L/R
G/R
P
B
G/R
P
B
Ch
Br/W
Dg
Ch
Br/W
Dg
Y
G
Y
G
Ch
Dg
B
Ch
Dg
B
Ch
B
Ch
B
G/Y
B
G/Y
B
L
-
L
-
Dg
B
Dg
B
OFFPUSH
&
%
Br/W
Br
4
N6
Or
B
Or
B
Gy
Br R B
B/W
RR
R
R
LW
B LW LG YR
R
GY
R
B
W
Y/R
RB
YB
L/R L
G/R
BrP
Br
Br/
/W
P
G/R
Br/
W
B G Y Ch
Dg
G Y LRB
Ch
Dg
B
BY
B
W
Y/R
YR
B
B
B
B B
Ch
Dg
G/Y
B B
Ch
Dg
G/Y
G/Y
GY
Br
Br
Br
B
L/G
L/Y
B
OrOr
B
W/R
B/R
B/W
W/R
B/R
L/Y
Br
Gy L
Gy
Br
Y Y
Ch
Dg
BGG
BG
1
3
24
n
b
g
l
k
6
5
s
7
w
9
.
8
q
a
i
p o
r
e
t
yu
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Q
W
R
B
Y/R
m
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;
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0
f
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L
7-39
– +ELECAUTO CHOKE SYSTEM
Pocket tester:90890-03112
1. Lighting coil resistance8 Disconnect the CDI magneto couple from
wire harness.8 Connect the pocket tester (Ω x1) to the
lighting coil coupler
Tester (+) Lead→Yellow/Red 1 terminalTester (-) Lead→Frame earth
2 C.D.I. magneto8 Check the lighting coil for specificated re-
sistance
Lighting coil resistance0.4~0.6 Ω 20°C (68°F)
MEETSSPECIFICATION
YP.....
TROUBLESHOOTING
IF THE AUTO CHOKE FAILS TO OPERATE.
ProcedureCheck:1. Lighting coil resistance2. Auto choke unit resistance3. Wiring connection (entire auto choke system)
NOTE:
8 Remove the following parts before troubleshooting.1. Battery box cover2. Rear carrier3. Tail cover4. Right side cover
8 Use the special tools specified in the troubleshooting section.
OUT OF SPECIFICATION
Replace the lighting coil
*
CDIMagneto
W
Y/R
B
12
7-40
– +ELECAUTO CHOKE SYSTEM
YP...
2. Auto choke unit resistance8 Disconnect the auto choke unit coupler
from the wireharness.8 Connect the pocket tester (Ωx1) to the auto
choke unit coupler lead.
Tester (+) lead→Black terminal 1Tester (-) lead→Black terminal 2
Auto choke unit resistance:16~24Ω(20˚C)
MEETSSPECIFICATION
3. Wiring connection8 Check the connection of the entire auto
choke system.Refer to “CIRCUIT DIAGRAM” section.
*
OUT OF SPECIFICATION
Replace the auto choke unit.
POOR CONNECTION
Correct.
B B
8-1
TRBLSHTG
TROUBLESHOOTINGNOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should behelpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual forinspection, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING
STARTING FAILURE/HARD STARTING
PROBABLE CAUSE
8Empty8Clogged fuel filter8Deteriorated fuel or fuel containing water or
foreign material8Clogged fuel tank cap
8Clogged fuel hose8Clogged fuel cock8Faulty fuel cock operation8Broken or disconnected fuel cock
8Deteriorated fuel, fuel containing water orforeign material8Clogged pilot jet8Clogged pilot air passage8Sucked-in air8Deformed float8Groove-worn needle valve8 Improperly sealed valve seat8 Improperly adjusted fuel level8 Improperly set pilot jet8Clogged starter jet8 Improperly adjusted pilot air screw
8Starter plunger malfunction8Wax malfunction8Faulty thermister
8Clogged air filter
FUEL SYSTEM
Fuel tank
Fuel cock
Carburetor
Auto choke
Air cleaner
8-2
TRBLSHTGSTARTING FAILURE/HARD STARTING
IGNITION SYSTEM
Spark plug
Ignition coil
CD I unit system
Switches and wiring
PROBABLE CAUSE
8 Improper plug gap8 Worn electrodes8 Wire between terminals broken8 Improper heat range8 Faulty spark plug cap
8 Broken or shorted primary/secondary coil8 Faulty spark plug lead8 Broken body
8 Faulty CD I unit8 Faulty source coil8 Faulty pick-up coil
8 Faulty main switch8 Broken or shorted wiring8 Faulty sidestand switch
COMPRESSION SYSTEM
Cylinder and cylinder head
Piston and piston rings
Crankcase and crankshaft
Reed valve
PROBABLE CAUSE
8Loose spark plug8Loose cylinder head or cylinder8Broken cylinder head gasket8Broken cylinder gasket8Worn, damaged or seized cylinder
8 Improperly installed piston ring8Worn, fatigued or broken piston ring8Seized piston ring8Seized or damaged piston
8 Improperly seated crankcase8 Improperly sealed crankcase (Damaged oil
seal)8Seized crankshaft
8Deformed reed valve stopper8 Improperly seated read valve8Loose intake manifold8Broken gasket8Broken reed valve
8-3
TRBLSHTG
POOR IDLE SPEED PERFORMANCE
Carburetor
Auto choke
Air cleaner
Ignition system
POOR IDLE SPEED PERFORMANCEPOOR MIDIUM AND HIGH SPEED PERFORMANCE
PROBABLE CAUSE
8 Improperly returned starter plunger8Clogged or loose pilot jet8Clogged pilot air jet8 Improperly adjusted idle speed
(Throttle stop screw)8 Improper throttle cable play8Flooded carburetor
8Starter plunger malfunction8Wax malfunction8Faulty thermister
8Clogged air cleaner
8Faulty spark plug8Faulty spark plug read8Faulty C.D.I. unit8Faulty source coil8Faulty ignition coil
POOR MEDIUM AND HIGH SPEED PERFOR-MANCE
Carburetor
Air cleaner
Muffler
PROBABLE CAUSE8Refer to starting failure/Hard starting item
(Fuel system, Ignition system, compressionsystem)8Clogged or loose main nozzle8Clogged or loose main jet8 Improperly set clip position of jet needle8 Improperly adjust fuel level8Sucked-in air
8Clogged air filter
8Clogged
POOR MIDIUM AND HIGH SPEEDPERFORMANCE
POOR IDLE SPEED PERFORMANCE
8-4
TRBLSHTGPOOR MIDIUM AND HIGH SPEED PERFORMANCE
FULTY AUTOMATIC(V-BELT TYPE)SCOOTER DOES NOT MOVE WHILE ENGINEIS OPERATING
V-belt
Cam, slider
Compression spring
Transmission
CLUTCH OUT FAILURE
Clutch weight spring
Clutch shoe
Primary sheave
PROBABLE CAUSE
8Worn, damaged or slipped V-belt
8Worn, damaged
8Damaged
8Damaged
8 Damaged
8 Pealed lining
8 Seized primary sliding sheave and collar
POOR STANDING START(LOW CLIMBINGABILITY)
V-belt
Primary sheave
Compression spring
Secondary sheave
Clutch shoe
POOR ACCELERATION(POOR HIGH SPEED)
V-belt
Weight
Primary/ Secondary seave
PROBABLE CAUSE
8 Worn or slipped V-belt
8 Improper operation8 Damaged
8 Damaged
8 Improper operation8 Worn guide pin
8 Plealed lining
PROBABLE CAUSE
8 Worn8 Greasy
8 Worn8 Improper operation8 Worn
8-5
TRBLSHTG
PROBABLE CAUSE
8 Faulty spark plug8 Improper spark plug heat range8 Faulty C.D.I. unit8 Faulty source coil
8 Clogged fuel tank cap8 Clogged air filter8 Clogged carburetor
8 Worm cylinder8 Worm, fatigued or broken piston ring8 Broken cylinder head gasket8 Broken cylinder gasket8 Carbon accumulation of cylinder head
8 Clogged
8 Refer to “FAULTY AUTOMATIC”
8 Drag
OVER HEAT / POOR SPEED
OVER HEATOVER HEAT
Ignition system
Fuel system
Compression system
Muffler, Exhaust pipe
Oil pimp
Brake
Cooling system
PROBABLE CAUSE
8 Improper plug gap8 Improper spark plug heat range8Faulty C.D.I. unit
8 Improper carburetor setting8Clogged air filter
8Carbon accumulation of cylinder head
8Clogged
8Faulty oil pump8Faulty oil quality8Drag
8Fan damaged
POOR SPEEDPOOR SPEED
Ignition system
Fuel system
Compression system
Muffler, Exhaust pipe
Clutch
Brake
8-6
TRBLSHTGIMPROPER KICKING
IMPROPER KICKINGSLIPPING
Kick axle assembly
Transmission oil
HARD KICKING
Kick axle assembly
Cylinder, piston and piston ring
Crankcase and crankshaft
KICK CRANK NOT RETURNING
Kick axle assembly
PROBABLE CAUSE
8Low tension of kick clip8Worn kick axle8Worn or damaged kick gear8Damaged kick clip8Kick clip coming off8Damaged kick clip stopper
8 Improper quality (Low viscosity)8Deterioration
PROBABLE CAUSE
8High tension of kick clip8Seized kick gear
8Damaged or seized cylinder8Damaged or seized piston8Damaged or seized piston ring
8 Improperly seated crankcase8 Improperly seated crankshaft8Damaged or seized crankshaft8Damaged or seized crankshaft bearing
PROBABLE CAUSE
8Damaged kick return spring8Kick return spring coming off8Kick clip coming off8Damaged kick return spring stopper
8-7
TRBLSHTG
FAULTY BRAKEPOOR BRAKING EFFECT
Drum brake
Disc brake(Front)
MALFUNCTION
FAULTY BRAKE
PROBABLE CAUSE
8Worn brake shoe8Worn or rusty brake drum8 Improperly adjusted brake free play8 Improper brake cam lever position8 Improper brake shoe position8Fatigue/Damaged return spring8Oily or greasy brake shoe8Oily or greasy brake drum8Broken brake cable
8Worn brake pad8Worn brake disc8Air in brake fluid8Leaking brake fluid8Faulty master cylinder kit8Faulty caliper seal kit8Loose union bolt8Broken brake hose8Oily or greasy brake pad8Oily or greasy brake disc
PROBABLE CAUSE
8Bent, deformed or damaged inner tube8Bent or deformed outer tube8Damaged fork spring8Worn or damaged slide metal8 Improper oil viscosity8 Improper oil level
8-8
TRBLSHTG
INSTABLE HANDLINGINSTABLE HANDLING
Handlebar
Steering
Front forks
Tires
Wheels
Frame
Engine bracket
Rear shock absorber
INSTABLE HANDLING
PROBABLE CAUSE
8 Improperly installed or bent
8 Improperly installed steering column(Improperly tightened ringnut)8Bent steering column8Damaged ball bearing or bearing race
8Broken spring8Bonded front forks
8Uneven tire pressures on both sides8 Incorrect tire pressure8Unevenly worn tires
8Damaged bearing8Bent or loose wheel axle8Excessive wheel run-out
8Twisted8Damaged head pipe8 Improperly installed bearing race
8Bent or damaged
8Fatigued spring8Oil leakage
8-9
TRBLSHTG
FAULTY SIGNAL AND LIGHTINGSYSTEM
HEADLIGHT DARK
BULB BURNT OUT
FLASHER DOES NOT BLINK
FLASHER KEEPS ON
FAULTY SIGNAL AND LIGHTING SYSTEM
PROBABLE CAUSE
8 Improper bulb8Too many electric accessories8Hard charging (Broken charging coil)8 Incorrect connection8 Improperly grounded8Poor contacts (main or light switch)8Bulb life expires
PROBABLE CAUSE
8 Improper bulb8 Improperly grounded8Faulty main and/or light switch8Bulb life expires
PROBABLE CAUSE
8 Improperly grounded8Discharged battery8Faulty flasher switch8Faulty flasher relay8Broken wireharness8Loosely connected coupler8Bulb burnt out8Faulty fuse
PROBABLE CAUSE
8Faulty flasher relay8 Insufficient battery capacity (nearly dis-
charged)8Bulb burnt out
8-10
TRBLSHTG
FLASHER BLINKS SLOWER
FLASHER BLINKS QUICKER
HORN DOES NOT SOUND
FAULTY SIGNAL AND LIGHTING SYSTEM
PROBABLE CAUSE
8Faulty flasher relay8 Insufficient battery capacity
(nearly discharged)8 Improper bulb8Faulty main and/or flasher switch
PROBABLE CAUSE
8 Improper bulb8Faulty flasher relay
PROBABLE CAUSE
8Faulty battery8Faulty fuse8Faulty main and/or horn switch8 Improperly adjusted horn8Faulty horn8Broken wireharness
LOCKOPENOFF
CHECKON
B
Gy
R
Br
R
Br
B
Gy
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L/W
L/R
L
L/G
G/R
L
L/G
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LW
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Br
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Br
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WIRING DIAGRAM 1 Main switch2 Main fuse3 Battery4 Starter relay5 Starter motor6 Rectifier regulator7 Auto choke8 C.D.I. magneto9 C.D.I. unit0 Ignitionq Spark plugw Resistere Rear brake switchr Front brake switcht Tail/Brake lighty Rear flasher light(right)u Rear flasher light(left)i Audio piloto Front flasher light(right)p Front flasher light(left)a Head lights Flasher relayd Hornf Handlebar switch (left)g Horn switchh Dimmer switchj Turn switchk Fuel senderl Meter; Fuel gaugez Oil indicator lightx Meter lightc High beam indicator lightv Turn indicator lightb Oil level gaugen Handlebar switch (right)m Starter switch, Light switch. Sidestand switch/ Auxiary light
BBrChDgGLOrSbPRGyYWB/RBr/wG/RG/YL/BL/YL/WL/RR/BR/YR/WY/RW/GG/WW/RL/G
BlackBrownChocolateDark GreenGreenBlueOrangeSky bluePinkRedGrayYellowWhiteBlack/RedBrown/WhiteGreen/RedGreen/YellowBlue/BlackBlue/YellowBlue/WhiteBlue/ RedRed/BlackRed/YellowRed/whiteYellow/WhiteWhite/GreenGreen/WhiteWhite/RedBlue/Green