mbk doodo-yamaha-xn-125150-2000-en.pdf

XN125 2000

XN1505MF1-AE2

SERVICE MANUAL

EASM0000

XN125 / XN150SERVICE MANUAL

© 2000 by MBK Industrie2nd edition, April 2001

All rights reserved.Any reproduction or unauthorized

use without the writtenpermission of MBK Industrie

is expressly prohibited.

EAS00005

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETYIS INVOLVED!

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

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

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

WARNING

CAUTION:

EASM0001

NOTICEThis manual was produced by the MBK Industrie primarily for use by Yamaha and MBK dealers andtheir qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual.Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBKvehicles should have a basic understanding of mechanics and the techniques to repair these typesof vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely torender the vehicle unsafe and unfit for use.

MBK Industrie is continually striving to improve all of its models. Modifications and significant chan-ges in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers andwill appear in future editions of this manual where applicable.

NOTE:Designs and specifications are subject to change without notice.

TECHNICAL DOCUMENTATIONMBK INDUSTRIE

EAS00007

HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures arelaid out with the individual steps in sequential order.

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage indicate the current chapter. Refer to "SYMBOLS".

Each chapter is divided into sections. The current section title is shown at the top of each page,except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s)appears.

Sub-section titles appear in smaller print than the section title.

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of eachremoval and disassembly section.

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicatesa disassembly step.

Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS".

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

Jobs requiring more information (such as special tools and technical data) are describedsequentially.

ENG ENGEASM0025

CYLINDER AND PISTON

Removing the cylinder and piston Remove the parts in the order listed.Cylinder head Refer to “CYLINDER HEAD” section.

1 Cylinder bolt 22 Timing chain guide (exhaust side) 13 Cylinder 14 Dowel pin 25 Cylinder gasket 16 Piston pin clip 27 Piston pin 18 Piston 19 Piston ring (top) 110 Piston ring (2nd) 111 Oil ring 1

For installation, reverse the removalprocedure.

EAS00253

REMOVING THE CYLINDER AND PISTON1. Remove:

• piston pin clip • piston pin • piston

CAUTION:Do not use a hammer to drive the piston pinout.

NOTE:• Before removing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe piston pin clip from falling into the crankcase.

• Before removing the piston pin, deburr thepiston pin clip’s groove and the piston’s pinbore area. If both areas are deburred and thepiston pin is still difficult to remove, remove itwith the piston pin puller.

Piston pin puller90890-01304

2. Remove:• top ring• 2nd ring• oil ring

NOTE:When removing a piston ring, open the end gapwith your fingers and lift the other side of the ringover the piston crown.

EAS00255

CHECKING THE CYLINDER AND PISTON1. Check:

• piston wall• cylinder wallVertical scratches → Rebore or replace thecylinder, and replace the piston and pistonrings as a set.

4 - 23 4 - 24

CYLINDER AND PISTON CYLINDER AND PISTON

Order Job/Part Q’ty Remarks

FWD

1

2

3

45

6

78

910 11

T.R12 Nm (1.2 m•kg)

COOL

GENINFO

ENG

SPEC

22 23

21

24 25

EAS00008

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols to indicate the subject of eachchapter. General information Specifications Periodic checks and adjustments Engine Cooling system Carburetor Chassis Electrical system Troubleshooting

Symbols to indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data

Symbols to 23 in the exploded diagrams indicatethe types of lubricants and lubrication points. Engine oil Gear oil Molybdenum disulfide oil21 Wheel bearing grease22 Lithium soap base grease23 Molybdenum disulfide grease

Symbols 24 to 25 in the exploded diagramsindicate the following.24 Apply locking agent (LOCTITE®)25 Use a new one

T.R

TRBLSHTG

ELECCHAS

CARB

CHKADJ

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS ANDADJUSTMENTS

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETOR

CHASSIS

ELECTRICAL SYSTEM

TROUBLESHOOTING

1

2

3

4

6

7

8

9TRBLSHTG

GENINFO

SPEC

CHKADJ

ENG

CARB

ELEC

CHAS

5COOL

EAS00010

TABLE OF CONTENTS

1GENINFO

CHAPTER 1.GENERAL INFORMATION

SCOOTER IDENTIFICATION ........................................................................1-1VEHICLE IDENTIFICATION NUMBER ....................................................1-1MODEL LABEL ........................................................................................1-1

FEATURES ................................................................................................... 1-2OIL INDICATOR LIGHT ...........................................................................1-2ODOMETER/TRIPMETER READING MODE .........................................1-2BATTERY VOLTAGE/FUEL GAUGE ......................................................1-2THE CLOCK .............................................................................................1-3AUTO-CHOKE SYSTEM .........................................................................1-3

IMPORTANT INFORMATION ...................................................................... 1-4PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ 1-4REPLACEMENT PARTS ........................................................................ 1-4GASKETS, OIL SEALS AND O-RINGS .................................................. 1-4LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-5BEARINGS AND OIL SEALS .................................................................. 1-5CIRCLIPS ................................................................................................ 1-5

CHECKING THE CONNECTIONS ............................................................... 1-6

SPECIAL TOOLS ..........................................................................................1-7

GENINFO

GENINFOSCOOTER IDENTIFICATION

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GENERAL INFORMATIONSCOOTER IDENTIFICATIONEASM0002

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number is stampedinto the frame.

EASM0003

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

1-1

ZAUM0071

ZAUM0072

GENINFO

1-2

FEATURESEASM0004

FEATURESOIL INDICATOR LIGHT• FUNCTIONPulses (travel distance signals) from the speedometer are counted and cause the oil indicator lightto come on at 500 km for the first time and thereafter every 3,000 km. In this way, the light indicatesthe time for oil change.

• RESETTING PROCEDURETo reset the oil change indicator light

1) Press the “TRIP” button while turning the key to “ON”.2) Release the button and the oil change indicator light will go off.

NOTE:To reset the oil change indicator light before the periodic oil change interval has been reached, followthe above procedure.

ODOMETER/TRIPMETER READING MODEThe odometer and tripmeter can be set to count in either miles or kilometers according to the followingprocedure.

1) Turn the key to “ON”.2) Press the “TRIP” button until the current mode appears in the dispaly:

“CONT” (continental) for kilometer mode and “EnGL” (English) for the mile mode.3) Press the “TRIP” button to switch mode.4) Press the “TRIP” button for two seconds to confirm the setting.

NOTE:• The odometer/tripmeter reading mode can be changed any number of times while the odometerreading is below 10, but it cannot changed anymore after the reading has reached 10.

• Switching between the mile and the kilometer mode does not change or convert the current odometer/tripmeter reading.

BATTERY VOLTAGE/FUEL GAUGEWhen the key is turned to “OFF”, the voltage/fuel gauge indicates the battery voltage.

NOTE:If the battery voltage drops to 10V, refer to “CHECKING THE BATTERY” section in chapter 3.

When the key is turned to “ON”, the voltage/fuel gauge indicates the amount of fuel in the fuel tankafter indicating the battery voltage for two seconds.

GENINFO

THE CLOCK• Setting the clockTo set the clock:

1) Make sure that the key is turned to “OFF”.2) Press the “TRIP” button for two seconds and the hour display will flash.3) Press the “TRIP” button to set the hours.4) Press the “TRIP” button for two seconds, and the first minute digit will flash.5) Press the “TRIP” button to set the first minute digit.6) Press the “TRIP” button for two more seconds, and the second minute digit will flash.7) Press the “TRIP” button to set the second minute digit.8) Press the “TRIP” button for two seconds to set the clock.

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

• Auto-choke operation

FEATURES

Main switch

Fuse

Battery

Thermoswitch

Auto-choke

Ignitor unit

C.P.UIgnition

Engine condition Start with the Crank with the Crank with the Restart with thecold engine cold engine warm engine warm engine

Thermo switch OFF OFF ON ON

Ignitor unit circuit OFF ON ON OFFAuto-choke Activates Activates Not activate Not activate

1-3

GENINFO

EAS00020

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL ANDDISASSEMBLY1.Before removal and disassembly, remove all

dirt, mud, dust and foreign material.2.Use only the proper tools and cleaning equip-

ment.Refer to the “SPECIAL TOOLS”.

3.When disassembling, always keep mated partstogether. This includes gears, cylinders, pis-tons and other parts that have been “mated”through normal wear. Mated parts must al-ways be reused or replaced as an assembly.

4.During disassembly, clean all of the parts andplace them in trays in the order of disassem-bly. This will speed up assembly and allow forthe correct installation of all parts.

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

EAS00021

REPLACEMENT PARTS1.Use only genuine Yamaha and MBK parts for

all replacements. Use oil and grease recom-mended by Yamaha or MBK for all lubricationjobs. Other brands may be similar in functionand appearance, but inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS1.When overhauling the engine, replace all gas-

kets, seals and O-rings. All gasket surfaces,oil seal lips and O-rings must be cleaned.

2.During reassembly, properly oil all matingparts and bearings and lubricate the oil seallips with grease.

IMPORTANT INFORMATION

1-4

GENINFO

IMPORTANT INFORMATION

EAS00023

LOCK WASHERS / PLATES AND COTTERPINS1.After removal, replace all lock washers / plates

and cotter pins. After the bolt or nut hasbeen tightened to specification, bend the locktabs along a flat of the bolt or nut.

EAS00024

BEARINGS AND OIL SEALS1.Install bearings and oil seals so that the manu-

facturer’s marks or numbers are visible. Wheninstalling oil seals, lubricate the oil seal lipswith a light coat of lithium soap base grease.Oil bearings liberally when installing, if appro-priate.

Oil seal

EAS00025

CIRCLIPS1.Before reassembly, check all circlips carefully

and replace damaged or distorted circlips.Always replace piston pin clips after one use.When installing a circlip , make sure thesharp-edged corner is positioned oppositethe thrust that the circlip receives.

Shaft

Do not spin the bearing with compressed airbecause this will damage the bearing surfaces.

Bearing

CAUTION:

1-5

GENINFOCHECKING THE CONNECTIONS

+-

+-

EAS00026

CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1.Disconnect:• lead• coupler• connector

2.Check:• lead• coupler• connectorMoisture → Dry with an air blower.Rust/stains → Connect and disconnect sev-eral times.

3.Check:• all connectionsLoose connection → Connect properly.

NOTE:If the pin on the terminal is flattened, bend itup.

4.Connect:• lead• coupler• connector

NOTE:Make sure all connections are tight.

5.Check:• continuity(with the pocket tester)

Pocket tester90890-03112

NOTE:• If there is no continuity, clean the terminals.• When checking the wire harness, perform steps1 to 3.

• As a quick remedy, use a contact revitalizeravailable at most part stores.

1-6

GENINFOSPECIAL TOOLS

EAS00027

SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the appropriate special tools as this will help prevent damage caused by the use of inappropriatetools or improvised techniques. Special tools, part numbers or both may differ depending on thecountry.When placing an order, refer to the list provided below to avoid any mistakes.

Slide hammer bolt (M6)Weight

These tools are used to remove orinstalling the rocker arms shafts.

Rotor holding tool

This tool is used to remove the flywheelmagneto.

Ring nut wrench Steering nut wrench

These tools are used to loosen and tightenthe steering ring nuts.

Damper rod holderT-handle

These tools are used for disassemblingor assembling the front fork.

Piston pin puller

This tool is used to remove the piston pins.

Fuel level gauge

This tool is used to measure the fuel levelin the float chamber.

Clutch spring holderClutch spring holder arm

These tools are used for removing the nutwith holding the compression spring.

90890-0108390890-01084

90890-01235

90890-0126890890-01403

90890-0129490890-01326

90890-01304

90890-01312

90890-0133790890-01464

Tool No. Tool name/usage Illustration

1-7

GENINFO

Fork seal driver weightFrok seal driver attachment

These tools are used when installing thefork seal.

Sheave holder

This tool is used to hold the secondarysheave when removing or installing thenut.

Valve adjusting tool

This tool is necessary for adjusting valveclearance.

Pocket Tester

This instrument is invaluable for checkingthe electrical system.

Engine tachometer

This tool is needed for detecting theengine rpm.

Timing light

This tool is needed for detecting ignitiontiming.

Valve spring compressorAttachment

These tools are used when removing orinstalling the valve and the valve spring.

Valve guide remover

This tool is used to remove the valveguide.

90890-0136790890-01368

90890-01701

90890-03111

90890-03112

90890-03113

90890-03141

90890-0401990890-04108

90890-04116

SPECIAL TOOLS


1-8

GENINFO

Valve guide installer

This tool is needed to install the valveguide spring.

Valve guide reamer

This tool is used to rebore the valve guide.

Ignition checker

This instrument is necessary for checkingthe ignition system components.

Yamaha bond No. 1215

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

Compression gauge

This gauge is used to measure the enginecompression.

90890-04117

90890-04118

90890-06754

90890-85505

90890-03081


SPECIAL TOOLS

1-9

CHAPTER 2.SPECIFICATIONS

GENERAL SPECIFICATIONS ......................................................................2-1

MAINTENANCE SPECIFICATIONS .............................................................2-4ENGINE ...................................................................................................2-4CHASSIS .................................................................................................2-8ELECTRICAL .........................................................................................2-10

CONVERSION TABLE ............................................................................... 2-12

GENERAL TIGHTENING TORQUE SPECIFICATIONS ............................ 2-13

TIGHTENING TORQUES ........................................................................... 2-14TIGHTENING TORQUES (ENGINE) ..................................................... 2-14TIGHTENING TORQUES (CHASSIS) ...................................................2-16

LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-17ENGINE .................................................................................................2-17CHASSIS ...............................................................................................2-18

COOLING SYSTEM DIAGRAMS ............................................................... 2-19

LUBRICATION DIAGRAMS ....................................................................... 2-21

CABLE ROUTING .......................................................................................2-23

SPEC

2-1

SPECGENERAL SPECIFICATIONS

SPECIFICATIONSGENERAL SPECIFICATIONS

DimensionsOverall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

WeightWet (with oil and a full fuel tank)Dry (without oil and fuel)

EngineEngine typeCylinder arrangementDisplacementBore x strokeCompression ratioStandard compression pressure (at sea level)Starting system typeLubrication system

Oil capacityEngine oil

Periodic oil changeTotal amountFinal gear case oilTotal amount

Coolant systemRadiator capacity (including all routes)Coolant reservoir capacity<from low to full level>

Air filter type

FuelRecommended fuelFuel tank capacity

1.868 mm740 mm

1.096 mm777 mm

1.315 mm105 mm

1.800 mm

123 kg116 kg

Liquid cooled 4-stroke, SOHCForward inclined single cylinder124 cm3 [152 cm3]53.7 x 54.8 mm [59.5 x 54.8 mm]11: 011.400kPa/500r/min (14kgf/cm2/500r/min)Electric starterWet sump

API STANDARD: SE or higher grade

1.2 L1.4 L

0.15 L

1.1 L0.35 L<0.25 L>

Dry element

Regular unleaded gasoline10 L

Item XN125 [XN150]

Temp.-20 -10 0 10 20 30 40

10W/30

10W/40

20W/40

20W/50

2-2

SPECGENERAL SPECIFICATIONS

CarburatorType/quantityManufacturer

Spark plugTypeManufacturerSpark plug gap

Clutch type

TransmissionPrimary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperation

ChassisFrame typeCaster angleTrail

TyreTyre typeSize (front)Size (rear)Manufacturer (front)Manufacturer (rear)Type (front)Type (rear)

Tyre pressure (cold)Maximum load*-except motorcycleLoading condition AFrontRearLoading condition BFrontRear

Front wheelWheel typeRim size

Rear wheelWheel typeRim size

TK 5DS/1 [TK 5KD/1]TEIKEI

CR8ENGK0.5~0.7 mm

Dry, centrifugal automatic

Helical gear40/15 (2.666)Spur gear44/12 (3.666) [42/14 (3)]V-belt automaticCentrifugal automatic type

Steel tube backbone26°80 mm

Tubeless120/70-12120/70-12METZELERMETZELER7-TEEN7-TEEN

187 kg

180 kPa (1.80 kgf/cm2)200 kPa (2.00 kgf/cm2)

200 kPa (2.00 kgf/cm2)220 kPa (2.20 kgf/cm2)

Cast wheel12 x MT3.50

Cast wheel12 x MT3.50

Item XN125 [XN150]

2-3

SPEC

BrakeFront brake typeFront brake operationRear brake typeRear brake operation

SuspensionFront suspensionRear suspension

Shock absorberFront fork typeRear shock absorber assembly type

Wheel travelFront wheel travelRear wheel travel

ElectricalIgnition system typeCharging system typeBattery typeBattery voltage/capacity

Headlight typeBulbs (voltage/wattage x quantity)HeadlightPosition lightBrake/tail lightFront flasher lightRear flasher lightMeter lightHigh beam indicator lightTurn indicator lightCoolant temperature warning light

Amperage for fusesMain fuseRadiator fan fuse

Single disc brakeRight hand operationDrum brakeLeft hand operation

Telescopic forkUnit swing

Coil spring/oil damperCoil spring/oil damper

90 mm80 mm

C.D.IFlywheel magnetoCB7L-B2 or YB7L-B212V 8Ah

Bulb

12V 35W/35W x 212V 5W x 112V 21W/5W x 112V 21W x 212V 10W x 212V 1.2W x 212V 1.2W x 112V 1.2W x 212V 1.2W x 1

20 A7.5 A

Item XN125 [XN150]

GENERAL SPECIFICATIONS

2-4

SPEC

MAINTENANCE SPECIFICATIONSENGINE

Cylinder headWarp limit

CylinderBore sizeOut of round limit

CamshaftDrive systemCam dimensions Intake “A”

“B”“C”

Exhaust “A”“B”“C”

Camshaft runout limit

Cam chainCam chain type/No. of links

Rocker arm/rocker armshaftRocker arm inside diameterRocker shaft outside diameter

Valve,valve seat, valve guideValve clearance (cold) IN

EXValve dimensions

“A” head diameter INEX

“B” face width INEX

“C” seat width INEX

Stem outside diameter INEX

Guide inside diameter INEX

Stem-to-guide clearence INEX

Stem runout limitValve seat width IN

EX

A

C

B

A

B C

Face width Seat width

Item Standard Limit

MAINTENANCE SPECIFICATIONS

*[XN150]

••• 0.03 mm

53.700 ~ 53.705 mm [59.500 ~ 59.505mm]* •••••• 0.05 mm

Chain drive (left) •••

30.811 ~ 30.911 mm 30.711 mm25.145 ~ 25.245 mm 25.045 mm5.666 m •••30.811 ~ 30.911 mm 30.711 mm25.152 ~ 25.252 mm 25.052 mm5.659 m •••••• 0.03 mm

82 RH2005/94 •••

12.000 ~ 12.018 mm 12.030mm11.981 ~ 11.991 mm 11.950 mm

0.10 ~ 0.14 mm •••0.16 ~ 0.20 mm •••

26.9 ~ 27.1 mm •••22.9 ~ 23.1 mm •••2.687 ~ 3.252 mm •••2.687 ~ 3.252 mm •••0.9 ~ 1.1 mm •••0.9 ~ 1.1 mm 1.6 mm4.475 ~ 4.490 mm 4.445 mm4.460 ~ 4.475 mm 4.430 mm4.500 ~ 4.512 mm 4.542 mm4.500 ~ 4.512 mm 4.542 mm0.01 ~ 0.037 mm 0.08 mm0.025 ~ 0.052 0.10 mm••• 0.01 mm0.9 ~ 1.1 mm 1.6 mm0.9 ~ 1.1 mm 1.6 mm

2-5

SPEC

Valve springInner springFree length IN/EXSet length (valve closed) IN/EXCompressed pressure IN/EXTilt limit IN/EX

PistonPiston to cylinderclearencePiston size “D”Measuring point “H”Piston pin bore inside diameterPiston pin outside diameter

Piston ringsTop ring: Type End gap (installed) Side clearance (installed)2 nd ring: Type End gap (installed) Side clearence (installed)Oil ring: End gap (installed)

Crankshaft

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

Automatic centrifugal clutchClutch shoe thicknessClutch housing inside diameterWeight outside diameterClutch-in revolutionClutch-stall revolution

V-BeltV-belt width

41.94 mm 39.84 mm37.5 mm •••45.1 ~ 50.9 N •••2.5° / 1.9 mm •••

0.025 ~ 0.035 mm 0.15 mm

53.670 ~ 53.687 mm [59.470 ~ 59.487 mm]* •••4.5 mm •••15.002 ~ 15.013 mm 15.045 mm14.991 ~ 15.000 mm 14.975 mm

Barrel •••0.15 ~ 0.25 mm 0.50 mm0.03 ~ 0.07 mm 0.12 mm

Taper •••0.15 ~ 0.30 mm 0.65 mm0.02 ~ 0.06 mm 0.12 mm

0.2 ~ 0.7 mm •••

47.950 ~ 48.000 mm •••••• 0.03 mm0.15 ~ 0.45 mm •••

2.0 mm 1.0 mm120 mm [135 mm]* 120.5 [135.5 ]*20.0 mm 19.5 mm3,550 ~ 4,050 rpm [3,250 ~ 3,750 rpm]* •••5,900 ~ 6,900 rpm [5,600 ~ 6,400 rpm]* •••

22 mm 19 mm

Item Standard Limit

H

D

MAINTENANCE SPECIFICATIONS*[XN150]

2-6

SPEC

CarburetorTypeI.D markMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)Pilot air jet (P.A.J.1)Needle jet (N.J)Pilot jet (P.J)Pilot screw (P.S)Valve seat size (V.S)Starter jet 1 (G.S.1)Float height (F.L)Engine idle speed

Oil pumpTypeTip clearenceSide clearanceHousing and rotor clearence

RadiatorTypeWidth/height thicknessRadiator cap opening pressureReservoir tank capacity

Thermostatic valveManufacturerValve opening temperatureValve full open temperature

TK 5DS [TK 5KD]*••• •••#116 [#114]* •••ø1.0 [ø1.4]* •••4E31 (3/5) [4E32 (3/5)]* •••ø1.30 •••2.590 •••#38 [#36] •••2 1/4 ~ 2 3/4 [2 ~ 4]* •••ø2.00 •••#0.45 •••5 ~ 6 mm •••1.600 ~ 1.800 rpm •••

Trochoid •••••• 0.15 mm••• 0.15 mm••• 0.17 mm

Cooling fin with electric fan •••170 / 282 / 29 mm •••90 ~ 110 kPa •••0.35 L •••

ANGLI •••82 ±3°C •••95 ±3°C •••

Item Standard Limit

MAINTENANCE SPECIFICATIONS*[XN150]

2-7

SPEC

Crankshaft oil seal (left)Crankshaft oil seal (right)Crankshaft oil seal (right)Camshaft bearing (left)Camshaft bearing (right)Starter clutch bearingPrimary drive gear bearing (left)Primary drive gear bearing (right)Primary drive gear oil sealMain axle bearing (left)Main axle bearing (right)Drive axle bearing (left)Drive axle bearing (right)Drive axle oil seal

22 x 32 x 719 x 30 x 8 (Reinforced)19 x 30 x 8 (Double lips)20 x 42 x 1215 x 32 x 917 x 35 x 1025 x 52 x 1517 x 40 x 1225 x 42 x 6 (Double lips)15 x 25 x 12 (Needle bearing)12 x 37 x 1217 x 47 x 14 (Sphere)22 x 50 x 14 (Sphere)32 x 52 x 7

Item Size


2-8

SPEC

Steering systemSteering bearing typeNo./size of steel balls Upper

Lower

Front suspensionFront fork travelSpring rate (K1)Stroke (K1)Oil capacityOil gradeInner tube outer diameterOptional spring

Rear suspensionShock absorber travelFitting lengthSpring rate (K1)

(K2)Stroke (K1)

(K2)

Front wheelTypeRim sizeRim materialRim runout limit Radial

Lateral

Rear wheelTypeRim sizeRim materialRim runout limit Radial

Lateral

Front disc brakeTypeDisc outside diameter x thicknessPad thicknessMaster cylinder inside diameterCaliper cylinder outside diameterBrake fluid type

Rear drum brakeTypeDrum inside diameterShoe thicknessShoe spring free length

MAINTENANCE SPECIFICATIONSCHASSIS

Item Standard Limit


Ball bearing •••15 pcs 4.75 mm •••15 pcs 4.75 mm •••

90 mm •••11 N/mm •••0 ~ 90 mm •••125 cm3 •••SAE20 •••33 mm •••No •••

80 mm •••229 mm •••18 N/mm •••53.5 N/mm •••0 ~ 60 mm •••60 ~ 80 mm •••

Cast wheel •••MT 3.50 x 12 •••Aluminium •••••• 1 mm••• 0.5 mm

Cast wheel •••MT 3.50 x 12 •••Aluminium •••••• 1 mm••• 0.5 mm

Single •••220 x 4.5 mm •••4 mm 0.8 mm11 mm •••32 mm •••DOT #3 or DOT #4 •••

Leading, trailing •••130 mm 130.5 mm4.0 mm 2.0 mm54 mm •••

2-9

SPEC

Brake leverBrake lever free play (front)Brake lever free play (rear)Throttle cable free play

Item Standard Limit


10 ~ 20 mm •••10 ~ 20 mm •••1.5 ~ 3.0 mm •••

2-10

SPEC

Ignition timingIgnition timing (B.T.D.C)Advanced timing (B.T.D.C)Advanced type

T.C.IPickup coil resistance/color

Source coil resistance/color

Ignition coilMinimum spark gapPrimary winding resistanceSecondary winding resistance

Spark plug capTypeResistance

Charging systemTypeNormal outputStator coil resistance/color

Rectifier/regulatorModel/manufacturerNo load regulated voltageCapacityWithstand voltage

BatterySpecific gravity

Electric starting systemTypeStarter motor:Operation voltageOutputArmature coil resistanceBrush overall lengthBrush quantitySpring forceCommutator diameterMica undercut (depth)

Starter relayModel/manufacturerAmperage ratingCoil winding resistance

MAINTENANCE SPECIFICATIONSELECTRICAL


Item Standard Limit

10° at 1.700 rpm •••32° at 5.000 rpm •••Digital •••

248 ~ 372 Ω at 20°C / •••white / red-white / blue720 ~ 1080 Ω at 20°C / •••green/white - brown/black

6 mm •••0.32 ~ 0.48 Ω at 20°C •••5.7 ~ 8.5 kΩ at 20°C •••

Resin type •••10 kΩ •••

Flywheel magneto •••14 V 10.5 A at 5.000 rpm •••0.6 ~ 0.9 Ω at 20°C/white - white - white

14.5 V •••25 A •••200 V •••

1.280 •••

Constant mesh type •••

12 V •••0.3 kW •••0.0306 ~ 0.0374 Ω at 20°C •••10 mm 3.5 mm2 •••5.6 ~ 8.3 N •••22 mm 21 mm1.5 mm •••

9768054/JIDECO •••100 A •••4.2 ~ 4.6 Ω at 20°C •••

2-11

SPEC

HornModel/manufacturerMaximum amperage

Flasher relayFlasher frequency

Fuel gaugeModel/manufacturerSender unit resistance - full

- empty

Circuit breakerMainRadiagtor fan fuse

YF-12 / NIKKO •••3 A •••

80 ~ 160 cycle/min •••

25.33.06/MAXIMA •••4 ~ 10 Ω •••90 ~ 100 Ω •••

20 A x 1 pcs •••7.5 A x 1 pcs •••


Item Standard Limit

2-12

SPEC

METRIC TO IMPERIALMetric unit Multiplier Imperial unit

Torque m•kg 7.233 ft•lbm•kg 86.794 in•lbcm•kg 0.0723 ft•lbcm•kg 0.8679 in•lb

Weight kg 2.205 lbg 0.03527 oz

Speed km/h 0.6214 mph

km 0.6214 mim 3.281 ft

Distance m 1.094 ydcm 0.3937 inmm 0.03937 in

cc (cm3) 0.03527 oz(IMP liq.)

Volume/ Capacitycc (cm3) 0.06102 cu•inL (liter) 0.8799 qt(IMP liq.)L (liter) 0.2199 gal(IMP liq.)

kg/mm 55.997 lb/inMisc. kg/cm2 14.2234 psi(lb/in2)

Centigrade (°C) 9/5+32 Fahrenheit (°F)

CONVERSION TABLEAS00028

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 IMPERERIAL** mm x 0.03937 = ** in2 mm x 0.03937 = 0.08 in

CONVERSION TABLE

2-13

SPEC

EAS00029

GENERAL TIGHTENING TORQUE SPECIFICATIONSThis chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.Tightening torque specifications for special components or assemblies are provided for each chapterof this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern andprogressive stages until the specified tightening torque is reached. Unless otherwise specified,tightening torque specifications require clean, dry threads. Components should be at roomtemperature.

A: Width across flatsB: Thread diameter

BA

A B General tightening(nut) (bolt) torques

Nm m•kg10 mm 6 mm 6 0.6

12 mm 8 mm 15 1.5

14 mm 10 mm 30 3.0

17 mm 12 mm 55 5.5

19 mm 14 mm 85 8.5

22 mm 16 mm 130 13.0

GENERAL TIGHTENING TORQUE SPECIFICATIONS

2-14

SPEC

Oil check bolt Bolt M6 1 9 0.9Spark plug - M10 1 13 1.3Cylinder, water drain bolt Bolt M6 1 8 0.8Cylinder head and cylinder Nut M8 4 22 2.2Cylinder head and cylinder Bolt M6 2 12 1.2Cylinder and crankcase Bolt M6 1 12 1.2Camshaft bearing stopper Bolt M6 1 12 1.2Camchain guide Bolt M6 1 6.5 0.65Valve adjuster nut Nut M5 2 6.5 0.65Camshaft pinion bolt Bolt M8 1 30 0.3Camshaft tensionner Bolt M6 2 10 1.0Rocker shaft securing plate Bolt M6 1 10 1.0Thermostatic valve cover Bolt M6 1 9 0.9Water pump housing cover Bolt M6 4 10 1.0Water pump housing Bolt M6 2 7 0.7Water pump housing Bolt M6 1 7 0.7Thermostatic valve cover Bolt M6 2 9 0.9Oil pump Bolt M6 3 65 6.5Engine drain plug M35 1 32 3.2Inlet manifold on cylinder head Bolt M6 2 10 1.0Air filter cover Bolt M6 8 6.5 0.65Exhaust pipe stud bolt on cylinder Nut M6 2 11 1.1Muffler on bracket Bolt M8 2 27 2.7Muffler bracket on crankcase Bolt M8 2 27 2.7Muffler protector Bolt M6 2 4.5 0.45Crankcase (left) Bolt M6 8 9 0.9Cover, crankcase 1 Bolt M6 11 10 1.0Cover, crankcase 2 Bolt M6 6 10 1.0Cover, oil pump Bolt M6 3 6.5 0.65Duct, air Bolt M6 3 7 0.7Cover, magneto Bolt M6 3 7 0.7Cylinder head stud bolt Stud M8 4 13 1.3Transmission oil drain plug Plug M8 1 22 2.2Engine oil drain plug Plug M8 1 22 2.2Cover, crankcase 3 Bolt M6 2 6.5 0.65Starter idle gear plate Bolt M6 2 7 0.7Primary fixed sheave Nut M14 1 60 6.0Clutch carrier assembly Nut M36 1 90 9.0Clutch housing Nut M12 1 55 5.5

TIGHTENING TORQUESENGINE

TIGHTENING TORQUES

Item FastenerThread

size Q'tyTightening

torque

Nm m•kgRemarks

2-15

SPEC

Rear brake shoes pin pivot Nut M10 1 120 12.0Thermo unit - Pt 1/8 1 75 7.5Coolant drain bolt on cylinder Bolt M6 1 8 0.8Starter motor Bolt M6 2 65 6.5Rotor Nut M12 1 70 7.0

M16 1 225 22.5M16 1 225 22.5

Stator Bolt M6 3 70 7.0

Item FastenerThread

size Q'tyTightening

torque

Nm m•kgRemarks

TIGHTENING TORQUES

2-16

SPECTIGHTENING TORQUES

Frame with engine bracket Bolt M10 1 42 4.2Engine bracket 2 with 3 Bolt M10 2 55 5.5E/G bracket with E/G (with main stand) Bolt M10 2 32 3.2Reinforcement tail Bolt M6 4 6.5 0.65Rear cushion with frame Nut M10 1 32 3.2Rear cushion with engine Nut M8 1 18 1.8 See chapter 7Steering shaft Nut M25 3 “STEERINGHandle with steering shaft Nut M10 1 60 6.0 HEAD”

Master cylinder with handle Bolt M6 2 8.5 0.85Seat lock Bolt M6 2 4 0.4Box with frame Bolt M6 2 8 0.8Box with reinforcement tail Bolt M6 2 8 0.8Carrier with frame Bolt M8 1 19 1.9Carrier with reinforcement tail Bolt M8 2 19 1.9Footrest board with frame Bolt M6 4 4 0.4Mud guard with frame Bolt M6 2 7 0.7Fender on front fork Bolt M6 3 4 0.4Cover handle with handle Bolt M5 2 4.5 0.45Mainstand Nut M10 2 42 4.2Rear footrest Nut M8 2 14 1.4Front wheel axle Nut M12 1 70 7.0Rear wheel axle Nut M14 1 104 10.4Rear brake cam lever Nut M6 1 14 1.4Rear brake pin pivot Nut M10 1 12 1.2Front caliper on front fork Bolt M8 2 23 2.3Front brake disc on wheel Bolt M8 4 23 2.3Union bolt with caliper Bolt M10 1 23 2.3Union bolt with master cylinder Bolt M10 1 23 2.3

TIGHTENING TORQUESCHASSIS

Item FastenerThread

size Q'tyTightening

torque

Nm m•kgRemarks

2-17

SPEC

Lubrication Point Symbol

Oil seal lips

O-ring (Except V-belt drive unit)

Cylinder head tightening nut mounting surface

Crankshaft pin outside

Connecting rod big end thrust surface

Rotary filter inner surface

Drive gear inner surface

Cam chain outside sprocket inner surface

Piston pin

Piston outside and ring groove

Camshaft cam profile

Valve stem (IN, EX)

Valve stem end (IN, EX)

Rocker shaft

Valve rocker arm inner surface

Shaft

Shaft (Oil pump assembly)

Gasket (Oil pump assembly)

Holder

Idle gear 1 thrust surfaces

Shaft 1

Idle gear 2 thrust surfaces

Idle gear 2 inner surface

Main axle thrust surfaces

Crankcase mating surfaces Yamaha bond No. 1215

Crankcase breather plug

Stator grommet Yamaha bond No. 1215

Suction pipe

LUBRICATION POINTS AND LUBRICANT TYPESEAS00031

LUBRICATION POINTS AND LUBRICANT TYPESENGINE

2-18

SPECLUBRICATION POINTS AND LUBRICANT TYPESEAS00032

CHASSIS

Lubrication Point Symbol

Front wheel oil seal lips (left/right)

Steering head pipe bearing (upper/lower)

Tube guide (throttle grip) inner surface

Brake cable (brake lever)

Brake lever and lever holder bolt sliding surface

Sidestand sliding surface

Centerstand sliding surface and mounting bolt

Centerstand stopper pivot shaft

Brake cam pivot shaft and cam surface

2-19

SPECCOOLING SYSTEM DIAGRAMSEAS00033

COOLING SYSTEM DIAGRAMS Radiator cap Radiator Radiator fan Thermo switch Coolant tank Water pump Cylinder Inlet manifold

A

A Pass the hose under inlet manifold.

2-20

SPECCOOLING SYSTEM DIAGRAMSEAS00033(bis)

COOLING SYSTEM DIAGRAMS Radiator Radiator fan Radiator cap Coolant tank Water pump Thermostat

A

A Pass the hose between radiator and radiatorfiller hose.

2-21

SPECLUBRICATION DIAGRAMSEAS00034

LUBRICATION DIAGRAMS 1Lubrication of the cylinder head

Cylinder head Cylinder Crankcase

2Lubrication of the crankshaft Crankshaft

2

1

2-22

SPECEAS00034(bis)

LUBRICATION DIAGRAMS 1Oil flow

Cylinder head Cylinder Oil pump

2Lubrication tableA Oil pressure flowB Oil return flow

LUBRICATION DIAGRAMS

Rocker arm

Camshaft

Cylinder head

Oil pump

Oil strainer

Crankcase

Crankshaft

Connecting rod

AB

1

2

2-23

SPECEAS00035

CABLE ROUTING Thermo switch wire Seat lock cable Speedometer wire Main switch wire Seat lock cable adjuster Radiator Fan Headlight and front flasher connector Front fork assembly

Wire harness Horn Horn wire Rear brake cable Throttle cable Band switch

A Make the wire harness getting out here.BPlace the speedometer wire as shown.CPass the thermo switch lead between the

hoses.

CABLE ROUTING

FA

FA

A

AA

A-A

B

5~10 mm

C

2-24

SPECCABLE ROUTING Starter motor CDI unit rectifier/Regulator CDI magneto wire Ignition coil assembly Footrest board Starter relay Battery ground Wire harness

Seat lock assembly Fuel tank Wire lead Mud guard Fuel cock

A Place the wire as shown.BPlace the sidestand wire as shown (option).C Apply grease on stater motor connector/

terminal.

1

6

A

A-A B-B

C-CA

B

D

D-D

D

C

C

B

B

A

~110 mm

5~10 mm 5~10 mm

C

2-25

SPEC

Rear left flasher Rear brake cable adjuster Rear brake cable Fuel overflowed pipe Fan Radiator Main switch Sidestand wire (option) Fueal gauge wire Rear right flasher Taillight Seat lock cable Throttle cable

Battery Starter relay Frame Fuses box Relay Sender Fuel pipe21 Engine air breather22 Fuel cock23 Seat lock assemblyA Connection for anti-thelf (option)BPlace the Starter motor ground as shown.CPass the carburetor breather hose between

air duct and air filter case.

A

B

C

10

19

23

22

20

21

2013

18

8

7

65

17 16

13

12

14 15

11

9

3

1

2

3

4

CABLE ROUTING

2-26

SPECCABLE ROUTING

B

B C

C

A - A B - B C - C

D

view D

1.5 ~ 3 mm30¡

2 ~ 3 mm

A

A

A

B

Right handlebar switches Inner handlebar cover Left handlebar switches Rear brake lever Front handlebar cover Master cylinder Front brake lever

A Glue the handlebar grip.B Install the handlebar switch as shown.

2-27

SPECCABLE ROUTING

D

D

B

E

GG - G

E

E - E

B - BA - A

G

C - C D - D

F

CA

view F

RIGHT

LEFT

FRONT

A

C

B

A

B

C

Master cylinder Inner handlebar cover Speedometer assembly Rear brake cable Throttle cable Front brake hose Wire harness Handlebar Speedometer coupler Front handlebar cover

A Pass wires behind the turn signal relay bracketB Clip all wires and cables all togetherCInstall the wire harness behind the turn signal

relay bracket.

3CHKADJ

CHAPTER 3.PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION ............................................................................................3-1

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ..................3-1

COVER AND PANEL ....................................................................................3-3SIDE COVERS AND SEAT ......................................................................3-3FRONT COVER, INNER PANEL AND INNER FRONT COVER ............. 3-5FOOTREST BOARD AND UNDER COVER ............................................3-6HANDLEBAR COVERS ...........................................................................3-7

ENGINE .........................................................................................................3-8ADJUSTING THE VALVE CLEARANCE .................................................3-8ADJUSTING THE ENGINE IDLING SPEED ............................................3-9ADJUSTING THE THROTTLE CABLE FREE PLAY .............................3-10CHECKING THE SPARK PLUG ............................................................3-11CHECKING THE IGNITION TIMING .....................................................3-12TRANSMISSION OIL REPLACEMENT .................................................3-13MEASURING THE COMPRESSION PRESSURE ................................3-14CHECKING THE ENGINE OIL LEVEL ..................................................3-15CHANGING THE ENGINE OIL ..............................................................3-16MEASURING THE ENGINE OIL PRESSURE .......................................3-17CLEANING THE AIR FILTER ELEMENT ..............................................3-18CLEANING THE V-BELT CASE AIR FILTER ELEMENT ......................3-18CHECKING THE FUEL AND VACUUM HOSES ...................................3-19EXHAUST SYSTEM INSPECTION .......................................................3-19CHECKING THE COOLANT LEVEL .....................................................3-20CHANGING THE COOLANT .................................................................3-21INSPECTING THE COOLANT SYSTEM ...............................................3-24

CHASSIS .....................................................................................................3-25CHECKING THE FRONT BRAKE LEVER FREE PLAY ........................3-25ADJUSTING THE REAR BRAKE ..........................................................3-25CHECKING THE BRAKE FLUID LEVEL ...............................................3-26CHECKING THE BRAKE PADS ............................................................3-27CHECKING THE BRAKE SHOES .........................................................3-27CHECKING THE BRAKE HOSES .........................................................3-27BLEEDING THE HYDRAULIC BRAKE SYSTEM .................................. 3-28CHECKING AND ADJUSTING THE STEERING HEAD ........................3-29CHECKING THE FRONT FORK ............................................................3-31INSPECTING THE REAR SHOCK ABSORBER ...................................3-32CHECKING THE TYRES .......................................................................3-32CHECKING THE WHEELS ....................................................................3-35CHECKING AND LUBRICATING THE CABLES ...................................3-35LUBRICATING THE LEVERS AND PEDALS ........................................3-36LUBRICATING THE CENTERSTAND ...................................................3-36

CHKADJ

ELECTRICAL SYSTEM ...............................................................................3-37CHECKING THE BATTERY ..................................................................3-37CHECKING THE FUSES .......................................................................3-40REPLACING THE HEADLIGHT BULBS AND THE FRONT TURNSIGNAL LIGHT BULBS..........................................................................3-41REPLACING THE REAR TURN SIGNAL LIGHT BULBS ......................3-42REPLACING THE TAIL/BRAKE LIGHT BULBS ....................................3-43ADJUSTING THE HEADLIGHT BEAMS ...............................................3-44ADJUSTING THE DIGITAL CLOCK ......................................................3-44

CHKADJ

3-1

CHKADJ

EAS00037

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

PERIODIC CHECKS AND ADJUSTMENTSEAS00036

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments. Iffollowed, these preventive maintenance procedures will ensure more reliable vehicle operation, alonger service life and reduce the need for costly overhaul work. This information applies to vehiclesalready in service as well as to new vehicles that are being prepared for sale. All service techniciansshould be familiar with this entire chapter.

No. ITEM

1 * Fuel line

2 Spark plug

3 * Valves

4 Air filter

5 V-belt (crankcase) air filter

6 * Battery

7 * Front brake (disc)

8 * Rear brake (drum)

9 * Brake hose

10 * Wheels

11 * Tires

12 * Wheel bearings

13 * Steering bearings

14 Chassis fasteners

15 Centerstand

CHECK, MAINTENANCE AND LUBRICATION

• Check fuel hoses and vacuum hose for cracksor damage.

• Check condition.• Clean, regap.• Replace.• Check valve clearance.• Adjust.• Clean.• Replace.• Clean.• Check electrolyte level and specific gravity.• Make sure that the breather hose is properly

routed.

• Check operation, fluid level and vehicle for fluidleakage.(See NOTE on page 6-4)

• Replace brake pads.• Check operation and adjust brake lever freeplay.• Replace brake shoes.• Check for cracks or damage.• Replace.• Check runout and for damage.• Check tread depth and for damage.• Replace if necessary.• Check air pressure.• Correct if necessary.• Checks bearing for looseness or damage.• Check bearing play and steering for roughness.• Lubricate with lithium soap base grease.

• Make sure that all nuts, bolts and screws areproperly tightened.

• Check operation.• Lubricate.

Whenever necessary

Whenever necessary

Every 4 years.

ODMETER READING (x1,000km)

0.5 6 12 18 24Annualcheck

3-2

CHKADJPERIODIC CHECKS AND ADJUSTMENTS

NOTE:• The air filters need 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.2. Check the brake fluid level and add fluid as required.3. Replace the brake hoses every four years or if cracked or damaged.

16 * Front fork17 * Rear shock absorber

assembly18 * Carburetor19 * Engine oil20 * Engine oil filter strainer

21 * Final gear oil

22 * Coolant system

23 * V-belt

24 Moving parts and cables

25 * Light, signals and switches

• Check operation and for oil leakage.

• Check operation and shock absorber for oilleakage.

• Check engine idling speed and starter operation.• Change.• Clean.• Check vehicle for oil leakage• Change.• Check coolant level and vehicle for coolant

leakage.• Change.• Check wear and damage.• Replace.• Lubricate.• Check operation.• Adjust headlight beam.

No. ITEM CHECK, MAINTENANCE AND LUBRICATIONODMETER READING (x1,000km)

0.5 6 12 18 24Annualcheck

Every 3,000 km.

Every 3 years.

Every 18,000 km.

* Since these items require special tools, data and technical skills, they should be serviced bya Yamaha or MBK dealer.

3-3

CHKADJCOVER AND PANEL

Removing the side covers Remove the parts in the order listed.I Remove:1 Battery cover 12 Box and seat assembly 1

Seat axle circlip 1Seat axle 1Seat 1Gasket 1

II Unplug:3 Fuel tank overflow pipe 1III Remove:4 Rear carrier 1IV Disconnect:5 Taillight coupler 16 Rear flasher light (left and right) 1

NOTE:Open the seat to remove it.

EASM0005

COVER AND PANELSIDE COVERS AND SEAT


FWD

1

2

3

6

6

7

8

5

4

T.R7 Nm (0.7 m¥kg)

T.R7 Nm (0.7 m¥kg)

T.R18.5 Nm (1.85 m¥kg)

T.R8 Nm (0.8 m¥kg)

3-4


V Remove:7 Side cover (right) 18 Side cover (left) 1



FWD

1

2

3

6

6

7

8

5

4

T.R7 Nm (0.7 m¥kg)

T.R7 Nm (0.7 m¥kg)

T.R18.5 Nm (1.85 m¥kg)

T.R8 Nm (0.8 m¥kg)

3-5


EASM0007

FRONT COVER, INNER PANEL AND INNER FRONT COVER

Removing the front cover, inner Remove the parts in the order listed.panel and the inner front coverRemove:

1 Coolant tank cover 12 Main switch cap 13 Helmet holder 1II Untight:4 Front cover 1III Disconnect5 Headlight lead 1IV Remove:6 Front cover / Radiator panel 1/17 Inner panel 1



FWD

1

2

3

4

5

6

7

T.R7 Nm (0.7 mkg)

T.R7 Nm (0.7 mkg)

T.RT.R7 Nm (0.7 mkg)

T.R7 Nm (0.7 mkg)

7 Nm (0.7 mkg)

3-6


EASM0008

FOOTREST BOARD AND UNDER COVER

Removing the footrest board Remove the parts in the order listed.and under cover

I Remove:Side covers 2 Refer to “SIDE COVERS AND SEAT”

section.Inner panel 1 Refer to “FRONT COVER, INNER PANEL

AND INNER FRONT COVER” section.II Remove:1 Footrest 2 1 washer/1 spring washer/1 washer2 Battery 13 Fuses box4 Starter relay 15 Under cover 16 Side under cover/footrest board 1/1

assembly For installation, reverse the removalprocedure.


FWD

1

1

2

3

4

5

6

T.R13.5 Nm (1.35 mkg)

T.R7 Nm (0.7 mkg)

T.R

4 Nm (0.4 mkg) T.R

7 Nm (0.7 mkg)

3-7


EASM0009

HANDLEBAR COVERS

Removing the handlebar covers Remove the parts in the order listed.I Remove:1 Front handlebar cover 1II Disconnect:2 Speedometer assy’ leadIII Remove:3 Inner handlebar cover 1



FWD

1

2

3

T.R

T.R4.5 Nm (0.45 mkg)

4.5 Nm (0.45 mkg)

T.R7 Nm (0.7 mkg)

3-8

CHKADJADJUSTING THE VALVE CLEARANCE

EAS00049

ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.

NOTE:• Valve clearance adjustment should be madeon a cold engine, at room temperature.

• When the valve clearance is to be measured oradjusted, the piston must be at top dead center(TDC) on the compression stroke.

1. Remove:• Battery cover• Seat• Side covers• BoxRefer to “SIDE COVERS AND SEAT” sec-tion.

• Spark plug• Plug on magneto cover• Valve cover “inlet”• Valve cover “exhaust”

2. Measure:• valve clearanceOut of specification → Adjust.

Valve clearance (cold)Intake valve0.10 ~ 0.14 mmExhaust valve0.16 ~ 0.20 mm

a. Turn the crankshaft counterclockwise.b. When the piston is at TDC on the compres-

sion stroke, align the mark a on the generatorrotor with the stationary pointer b on thecrankcase.

c. Measure the valve clearance with a thicknessgauge .Out of specification → Adjust.

b

a

3-9

CHKADJ

ADJUSTING THE VALVE CLEARANCE/ADJUSTING THE ENGINE IDLING SPEED

EASM0010

ADJUSTING THE ENGINE IDLING SPEED

NOTE:Prior to adjusting the engine idling speed, the airfilter element should be clean, and the engineshould have adequate compression.

1. Start the engine and let it warm up for severalminutes.

T.R

3. Adjust:• valve clearance

a. Loosen the locknut .b. Insert a thickness gauge between the end of

the adjusting screw and the valve tip.c. Turn the adjusting screw in or out until the

specified valve clearance is obtained.

Turning in → Valve clearance isdecreased.

Turning out → Valve clearance isincreased.

Valve adjusting tool 90890-01311

Hold the adjusting screw to prevent it frommoving and tighten the locknut to specification.

Locknut6.5 Nm (0.65 m•kg)

d. Measure the valve clearance again.e. If the valve clearance is still out of specification,

repeat all of the valve clearance adjustmentsteps until the specified clearance is obtained.

4. Install:• Box• Side covers• Seat• Battery coverRefer to “SIDE COVERS AND SEAT” sec-tion.

3-10

CHKADJ

2. Attach:• engine tachometer(onto the spark plug lead of the cylinder)

Engine tachometer 90890-03113

3. Measure:• engine idling speedOut of specification → Adjust.

Engine idling speed1,400 ~ 1,800 r / min

4. Adjust:• engine idling speed

a. Turn the pilot screw in until it is lightly seated.b. Turn the pilot screw out the specified number

of turns.

Pilot screw settingXN 125: 2 1/4 ~ 2 3/4XN 150: 2 ~ 4

c. Turn the throttle stop screw in or out until thespecified engine idling speed is obtained.

Turning in → Engine idling speed isincreased.

Turning out → Engine idling speed isdecreased.

5. Adjust:• throttle cable free playRefer to “ADJUSTING THE THROTTLE CA-BLE FREE PLAY”.

Throttle cable free play(at the flange of the throttle grip)

1.5 ~ 3 mm

ADJUSTING THE ENGINE IDLING SPEED/ADJUSTING THE THROTTLE CABLE FREE PLAY

EASM0011

ADJUSTING THE THROTTLE CABLE FREEPLAY

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

3-11

CHKADJ

1. Check:• throttle cable free play Out of specification → Adjust.


1.5 ~ 3 mm

2. Adjust:• throttle cable free play

NOTE:When the throttle is opened, the acceleratorcable is pulled.

a. Turn the adjusting nut in or out until thespecified throttle cable free play is obtained.

Turning in →→→→→ Throttle cable free play isincreased.

Turning out →→→→→ Throttle cable free play isdecreased.

WARNING After adjusting the throttle cable free play,start the engine and turn the handlebar tothe right and to the left to ensure that thisdoes not cause the engine idling speed tochange.

ADJUSTING THE THROTTLE CABLE FREE PLAY /CHECKING THE SPARK PLUG

EAS00060

CHECKING THE SPARK PLUG1. Disconnect:

• spark plug cap 2. Remove:

• spark plug

CAUTION:Before removing the spark plug, blow awayany dirt accumulated in the spark plug wellwith compressed air to prevent it from fallinginto the cylinder.

3. Check:• spark plug typeIncorrect → Change.

Spark plug type (manufacturer)CR8E (NGK)

ZAUM0035

ZAUM0051

3-12

CHKADJ

5. Clean:• spark plug(with a spark plug cleaner or wire brush)

6. Measure:• spark plug gap (with a wire gauge)Out of specification → Regap.

Spark plug gap0.5 ~ 0.7 mm

7. Install:• spark plug

NOTE:Before installing the spark plug, clean the sparkplug and gasket surface.

8. Connect:• spark plug cap

CHECKING THE SPARK PLUG/CHECKING THE IGNITION TIMING

4. Check:• electrodes Damage/wear → Replace the spark plug.

• insulator Abnormal color → Replace the spark plug.Normal color is medium-to-light tan.

ZAUM0037

EAS00061

CHECKING THE IGNITION TIMING

NOTE:Prior to checking the ignition timing, check thewiring connections of the entire ignition system.Make sure all connections are tight and free ofcorrosion.

1. Attach:• timing light • engine tachometer (onto the spark plug lead of the cylinder)

Timing light90890-03141

Engine tachometer90890-03113

T.R 13 Nm (1.3m•kg)

3-13

CHKADJ

2. Check:• ignition timing

a. Start the engine, warm it up for several minu-tes, and then let it run at the specified engineidling speed.

Engine idling speed1,400 ~ 1,800 r/min

b. Check that the mark a is within the requiredfiring range b on the timing plate.Incorrect firing range → Check the ignitionsystem.

NOTE:The ignition timing is not adjustable.

CHECKING THE IGNITION TIMING/TRANSMISSION OIL REPLACEMENT

TRANSMISSION OIL REPLACEMENT

NOTE:Make sure the scooter is upright when replacingthe oil.

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

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

• oil filler cap• drain bolt Drain the oil.

5. Tighten:• drain bolt

6. Fill:• crankcase

Recommended oil:SAE 10W30 motor oil (API, SE)

Oil quantity:0.15L

CAUTION:Wipe any spilled oil off the tire or the wheel.

7. Install:• oil filler cap • O-ring

8. Start the engine for several minutes to warmit up and check for the oil leakage.

T.R 22 Nm (2.2m•kg)

a

b

3-14

CHKADJMEASURING THE COMPRESSION PRESSURE

EAS00067

MEASURING THE COMPRESSIONPRESSURE

NOTE:Insufficient compression pressure will result in aloss of performance.

1. Measure:• valve clearanceOut of specification → AdjustRefer to “ADJUSTING THE VALVE CLEA-RANCE” section.

2. Start the engine, warm it up for several minu-tes, and then turn it off.

3. Disconnect:• spark plug cap

4. Remove:• spark plug

CAUTION:Before removing the spark plug, usecompressed air to blow away any dirtaccumulated in the spark plug well to preventit from falling into the cylinder.

5. Install:• compression gauge

Compression gauge90890-03081

6. Measure:• compression pressureOut of specification → Refer to steps (c) and(d).

• Compression pressure (at sea level)

Minimum1,120 kPa (11.20 kg/cm2)

Standard1,400 kPa (14.00 kg/cm2)

a. Set the main switch to “ON”.b. With the throttle wide open, crank the engine

until the reading on the compression gaugestabilizes.

WARNING To prevent sparking, ground the spark pluglead before cranking the engine.

3-15

CHKADJ

c. If the compression pressure is above themaximum specification, check the cylinderhead, valve surfaces, and piston crown forcarbon deposits.Carbon deposits → Remove.

d. If the compression pressure is below theminimum specification, squirt a few drops ofoil into the cylinder and measure again.Refer to the following table.

Compression pressure(with oil applied into the cylinder)

Reading DiagnosisHigher than Piston wear or damagewithout oil → Repair.

Piston ring(s), valves,Same as cylinder head gasket orwithout oil piston possibly

defective → Repair.

7. Install:• spark plug

8. Connect:• spark plug cap

EAS00070

CHECKING THE ENGINE OIL LEVEL1. Stand the scooter on a level surface.

NOTE:• Place the scooter on a suitable stand.• Make sure the scooter is upright.


NOTE:• Before checking the engine oil level, wait a fewminutes until the oil has settled.

• Do not screw the dipstick in when inspectingthe oil level.

3. Check:• engine oil levelThe engine oil level should be between theminimum level mark and maximum levelmark .Below the minimum level mark → Add therecommended engine oil to the proper level.

MEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVEL

ZAUM0038

T.R 13 Nm (1.3m•kg)

ZAUM0035

3-16

CHKADJ

EASM0012

CHANGING THE ENGINE OIL1. Start the engine and let it warm up for several

minutes.2. Turn off the engine and place an oil pan under

the engine.3. Remove:

• Oil filler plug• Drain plug • Compression spring • Oil strainer • O-ringDrain the crankcase of its oil.

4. Install:• O-ring • Compression spring • Oil strainer • Drain plug • Oil filler plug

5. Fill:• Crankcase

Oil quantity:1.2 L

6. Check:• Engine oil levelRefer to “CHECKING THE ENGINE OILLEVEL” section.

CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL

ZAUM0040

ZAUM0040

T.R32 Nm (3.2m•kg)

T.R 32 Nm (3.2m•kg)

Recommended oilRefer to the chart for the engine oilgrade which is best suited forcertain atmospheric temperatures.API standard

SE or higher grade(Non-friction modified)

CAUTION:Do not allow foreign materials to enter thecrankcase.

NOTE:Before checking the engine oil level, wait a fewminutes until the oil has settled.


5. Check the engine oil level again.

NOTE:Before checking the engine oil level, wait a fewminutes until the oil has settled.

-20° -10° 10° 20° 30° 40° 50°C0°

SAE 10W/30

SAE 10W/40

SAE 15W/40

SAE 20W/40

SAE 20W/50

3-17

CHKADJ

EASM0013

MEASURING THE ENGINE OIL PRESSURE1. Remove:

• side coversRefer to “SIDE COVERS AND SEAT” sec-tion.

2. Inspect:• oil pressure

a. Slightly loosen the oil check bolt .b. Start the engine and keep it idling until the oil

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

c. Check oil passages and oil pump for damageor leakage.

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

e. Tighten the oil check bolt to specification.

Oil check bolt10Nm (1.0m•kg)

CAUTION:• Start the engine and check the oil pressure

with the oil check bolt loosened.• Do not apply at high speeds more than

specified when checking the pressure.

NOTE:Wipe any spilled oil off the engine.

CHECKING THE ENGINE OIL/MEASURING THE ENGINE OIL PRESSURE/

7. Reset:• engine oil warning circuit

a. Press the “TRIP” button while turning thekey to “ON”

b. Release the “TRIP” button and oil indicatorlight will go off

NOTE:• If the oil is change before the oil indicator lightcomes on (i.e. before the 3,000 km oil changeinterval is reached), be sure to reset the oilindicator light after changing oil, so that it willindicate the next 3,000 km oil remplacement atthe correct time.

• To reset the oil change indicator light before theperiodic oil change interval has been reached,follow the above procedure.

T.R10 Nm (1.0 mkg)

T.R

ZAUM0007

3-18

CHKADJ

EAS00091

CLEANING THE V-BELT CASE AIR FILTERELEMENT1. Remove:

• V-belt case air filter cover • V-belt case air filter element

2. Clean:• V-belt case air filter element Apply compressed air to the outer surface ofthe primary fixed sheave air filter element.

3. Check:• V-belt case air filter elementDamage → Replace.

CAUTION:Since the V-belt case air filter element is a drytype, do not let grease or water contact it.

4. Install:• V-belt case air filter element• V-belt case air filter cover

CLEANING THE AIR FILTER ELEMENT/CLEANING THE V-BELT CASE AIR FILTER ELEMENT

ZAUM0048

ZAUM0050

EAS00086

CLEANING THE AIR FILTER ELEMENT1. Remove:

• air filter case cover 2. Clean:

• air filter element Apply compressed air to the outer surface ofthe air filter element.

3. Check:• air filter element Damage → Replace.

4. Install:• air filter element • air filter case cover

CAUTION:Never operate the engine without the air filterelement installed. Unfiltered air will causerapid wear of engine parts and may damagethe engine. Operating the engine without theair filter element will also affect thecarburetor tuning, leading to poor engineperformance and possible overheating.

NOTE:When installing the air filter element into the airfilter case cover, make sure their sealing surfacesare aligned to prevent any air leaks.

T.R 7 Nm (0.7m•kg)

ZAUM0046

3-19

CHKADJ

EASM0014

EXHAUST SYSTEM INSPECTION1. Remove:

• Side coversRefer to “SIDE COVERS AND SEAT” section.

2. Inspect:• Nut (exhaust pipe)Loose/Damage → Tighten/Replace.

• Gasket (exhaust pipe)Exhaust gas leaks → Tighten/Replace

3. Inspect:• Bolt (mufler)Loose/Damage → Tighten/Replace

CHECKING THE FUEL AND VACUUM HOSES/EXHAUST SYSTEM INSPECTION

EAS00096

CHECKING THE FUEL AND VACUUMHOSESThe following procedure applies to all of the fueland vacuum hoses.1. Remove:

• Seat• BoxRefer to “SIDE COVERS AND SEAT” section.

2. Check:• vacuum hose• fuel hoseCracks/damage → Replace.Loose connection → Connect properly.

3. Install:• Box• SeatRefer to “SIDE COVERS AND SEAT” section.

T.R 27 Nm (2.7 m•kg)

T.R 11 Nm (1.1 m•kg)

3-20

CHKADJ

EAS00103

CHECKING THE COOLANT LEVEL1. Stand the scooter on a level surface.

NOTE:Place the scooter on a suitable stand.Make sure the scooter is upright.

2. Remove:• Coolant tank cover Refer to “FRONT COVER, INNER PANELAND INNER FRONT COVER” section.

3. Check:• coolant levelThe coolant level should be between themaximum level mark and minimum levelmark .Below the minimum level mark → Add therecommended coolant to the proper level.

CAUTION:• Adding water instead of coolant lowers the

antifreeze content of the coolant. If wateris used instead of coolant check, and ifnecessary, correct the antifreeze concen-tration of the coolant.

• Use only distilled water. However, if distilledwater is not available, soft water may beused.


5. Check:• coolant level

NOTE:Before checking the coolant level, wait a fewminutes until it settles.

6. Install:• Coolant tank coverRefer to “FRONT COVER, INNER PANELAND INNER FRONT COVER” section.

CHECKING THE COOLANT LEVEL

ZAUM0044

3-21

CHKADJ

EAS00105

CHANGING THE COOLANT1. Remove:

• Side covers• Seat• Rear carrier• BoxRefer to “SIDE COVERS AND SEAT” sec-tion.

• Front cover• Inner panelRefer to “FRONT COVER, INNER PANELAND INNER FRONT PANEL” section.

2. Disconnect:• coolant reservoir hose

3. Drain:• coolant(from the coolant reservoir)

4. Remove:• radiator cap

WARNING A hot radiator is under pressure. Therefore,do not remove the radiator cap when theengine is hot. Scalding hot fluid and steammay be blown out, which could causeserious injury. When the engine has cooled,open the radiator cap as follows:Place a thick rag or a towel over the radiatorcap and slowly turn the radiator capcounterclockwise toward the detent to allowany residual pressure to escape. When thehissing sound has stopped, press down onthe radiator cap and turn it counterclockwiseto remove.

The following procedure applies to all of thecoolant drain bolts and copper washers.5. Remove:

• coolant drain bolt (water pump)(along with the copper washer)

• coolant drain bolt (engine)(along with the copper washer)

6. Drain:• coolant(from the engine and radiator)

CHANGING THE COOLANT

3-22

CHKADJ

7. Check:• copper washer (coolant drain bolt-engine )• copper washer (coolant drain bolt-waterpump)Damage → Replace.

8. Install:• coolant drain bolt (engine)

• coolant drain bolt (water pump)

9. Connect:• coolant reservoir hose

10. Fill:• cooling system(with the specified amount of therecommended coolant)

Recommended antifreezeHigh-quality ethylene glycolantifreeze containing corrosioninhibitors for aluminum engines

Mixing ratio1:1 (antifreeze:water)

QuantityTotal amount1.1 LCoolant reservoir capacity0.35 L

Handling notes for coolantCoolant is potentially harmful and should behandled with special care.

CHANGING THE COOLANT

T.R 10 Nm (1.0m•kg)

T.R 10 Nm (1.0m•kg)

WARNING • If coolant splashes in your eyes, thoroughly

wash them with water and consult a doctor.• If coolant splashes on your clothes, quickly

wash it away with water and then with soapand water.

• If coolant is swallowed, induce vomitingand get immediate medical attention.

3-23

CHKADJCHANGING THE COOLANT

CAUTION:• Adding water instead of coolant lowers the

antifreeze content of the coolant. If wateris used instead of coolant check, and ifnecessary, correct the antifreeze concen-tration of the coolant.

• Use only distilled water. However, if distilledwater is not available, soft water may beused.

• If coolant comes into contact with paintedsurfaces, immediately wash them withwater.

• Do not mix different types of antifreeze.

11. Install:• radiator cap

12. Fill:• coolant reservoir(with the recommended coolant to the maxi-mum level mark )

13. Install:• coolant reservoir cap

14. Start the engine, warm it up for severalminutes, and then stop it.

15. Check:• coolant levelRefer to “CHECKING THE COOLANT LEVEL”section.

NOTE:Before checking the coolant level, wait a fewminutes until the coolant has settled.

16. Install:• Inner panel• Front coverRefer to “FRONT COVER, INNER PANELAND INNER FRONT PANEL” section.

• Box• Rear carrier• Seat• Side coversRefer to “SIDE COVERS AND SEAT” sec-tion.

ZAUM0044

3-24

CHKADJ

EASM0015

INSPECTING THE COOLANT SYSTEM1. Inspect:

• Radiator• Filler hose (radiator)• Outlet hose (radiator)• Pipe• Outlet hose (radiator)Cracks/Damage → ReplaceRefer to “COOLING SYSTEM” section inchapter 5.

INSPECTING THE COOLANT SYSTEM

3-25

CHKADJ

EASM0016

CHASSISCHECKING THE FRONT BRAKE LEVERFREE PLAY1. Check:

• brake lever free play Out of specification → check the front brakesystem.Refer to “FRONT BRAKE” section in chapter7.

Brake lever free play (at the end ofthe brake lever)

10 ~ 20 mm

WARNING A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system willconsiderably reduce braking performanceand could result in loss of control andpossibly an accident. Therefore, check and,if necessary, bleed the brake system.

EAS00114

ADJUSTING THE REAR BRAKE1. Check:

• brake lever free play aOut of specification → Adjust.

Brake lever free play10 ~ 20 mm

2. Adjust:• brake lever free play• Handlebar side• Rear wheel side

a. Turn the adjusting nut in direction A or Buntil the specified brake lever free play isobtained.

Direction A → Brake lever free play isincreased.

Direction B → Brake lever free play isdecreased.

CHECKING THE FRONT BRAKE LEVER FREE PLAY/ADJUSTING THE REAR BRAKE

ZAUM0055

ZAUM0056

a

B

AZAUM0057

3-26

CHKADJ

CAUTION:After adjusting the brake lever free play,make sure there is no brake drag.

ADJUSTING THE REAR BRAKE/CHECKING THE BRAKE FLUID LEVEL

ZAUM0060

A

EAS00116

CHECKING THE BRAKE FLUID LEVEL1. Stand the scooter on a level surface.

NOTE:• Place the scooter on a suitable stand.• Make sure the scooter is upright.

2. Check:• brake fluid levelBelow the minimum level mark → Add therecommended brake fluid to the proper level.

Recommended brake fluidDOT#3 or DOT#4

A Front brake

WARNING • Use only the designated brake fluid. Other

brake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.

• Refill with the same type of brake fluid thatis already in the system. Mixing brake fluidsmay result in a harmful chemical reaction,leading to poor brake performance.

• When refilling, be careful that water doesnot enter the reservoir. Water willsignificantly lower the boiling point of thebrake fluid and could cause vapor lock.

CAUTION:Brake fluid may damage painted surfacesand plastic parts. Therefore, always clean upany spilt brake fluid immediately.

NOTE:In order to ensure a correct reading of the brakefluid level, make sure the top of the reservoir ishorizontal.

3-27

CHKADJ

EASM0017

CHECKING THE BRAKE PADSThe following procedure applies to all of thebrake pads.1. Operate the brake.2. Check:

• brake pad thickness Less than specification → Replace the brakepads as a set.Refer to “FRONT BRAKE” section in chapter7.

Brake pad thickness wear limit0.8 mm

A Front brake

EAS00126

CHECKING THE BRAKE SHOES1. Operate the brake.2. Check:

• wear indicator Reaches the wear limit line → Replace thebrake shoes as a set.Refer to “REAR WHEEL AND BRAKE” sectionin chapter 7.

CHECKING THE BRAKE PADS/CHECKING THE BRAKESHOES/

CHECKING THE BRAKE HOSES

ZAUM0058

ZAUM0059

A

EAS00131

CHECKING THE BRAKE HOSESThe following procedure applies to all of thebrake hoses and brake hose clamps.1. Check:

• brake hoseCracks/damage/wear → Replace.

2. Check:• brake hose clampLoose → Tighten the clamp bolt.

3. Hold the motorcycle upright and apply thebrake several times.

4. Check:• brake hoseActivate the brake several times.Brake fluid leakage → Replace the damagedhose.Refer to “FRONT WHEEL AND BRAKE DISC”and “REAR WHEEL AND BRAKE” section inchapter 7.

3-28

CHKADJ

EAS00133

BLEEDING THE HYDRAULIC BRAKE SY-STEM

WARNING Bleed the hydraulic brake system whenever:• the system is disassembled,• a brake hose is loosened, disconnected or

replaced,• the brake fluid level is very low,• brake operation is faulty.

NOTE:• Be careful not to spill any brake fluid or allow thebrake master cylinder reservoir to overflow.

• When bleeding the hydraulic brake system,make sure there is always enough brake fluidbefore applying the brake. Ignoring thisprecaution could allow air to enter the hydraulicbrake system, considerably lengthening thebleeding procedure.

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

1. Bleed:• hydraulic brake system

a. Fill the brake fluid reservoir to the proper levelwith the recommended brake fluid.

b. Install the brake master cylinder reservoirdiaphragm.

c. Connect a clear plastic hose tightly to thebleed screw .

d. Place the other end of the hose into a contai-ner.

e. Slowly squeeze the brake lever several times.f. Fully squeeze the brake lever without re-

leasing it.g. Loosen the bleed screw.

NOTE:Loosening the bleed screw will release thepressure and cause the brake lever to contactthe throttle grip.

h. Tighten the bleed screw and then release thebrake lever.

BLEEDING THE HYDRAULIC BRAKE SYSTEM

346002(a)

3-29

CHKADJ

i. Repeat steps (e) to (h) until all of the airbubbles have disappeared from the brakefluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw6 Nm (0.6 m•kg)

k. Fill the brake fluid reservoir to the proper levelwith the recommended brake fluid.Refer to “CHECKING THE BRAKE FLUIDLEVEL” section.

WARNING After bleeding the hydraulic brake system,check the brake operation .

BLEEDING THE HYDRAULIC BRAKE SYSTEM/CHECKING AND ADJUSTING THE STEERING HEAD

EAS00148

CHECKING AND ADJUSTING THESTEERING HEAD1. Stand the scooter on a level surface.

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

NOTE:Place the scooter on a suitable stand so that thefront wheel is elevated.

2. Check:• steering headGrasp the bottom of the front fork legs andgently rock the front fork.Binding/looseness → Adjust the steeringhead.

3. Remove:• Handlebar coverRefer to “HANDLEBAR COVERS” section.

• HandlebarRefer to “HANDLEBAR” section in chapter 7.

4. Adjust:• steering head

T.R

3-30

CHKADJCHECKING AND ADJUSTING THE STEERING HEAD

a. Remove the lock washer , the upper ringnut , the center ring nut and the rubberwasher.

b. Loosen the lower ring nut and then tightenit to specification with the ring nut wrench .

NOTE:Set the torque wrench at a right angle to the ringnut wrench.

Steering nut wrench90890-01403

Lower ring nut (initial tighteningtorque)

38 Nm (3.8 m•kg)

c. Loosen the lower ring nut completely andthen tighten it to specification with a ring nutwrench .

WARNING Do not overtighten the lower ring nut.

Lower ring nut (final tighteningtorque)

22 Nm (2.2 m•kg)

d. Check the steering head for looseness orbinding by turning the front fork all the way inboth directions. If any binding is felt, removethe lower bracket and check the upper andlower bearings.Refer to “STEERING HEAD” section inchapter 7.

e. Install the rubber washer.f. Install the centre ring nut .g. Finger tighten the centre ring nut, then align

the slots of both ring nuts. If necessary, holdthe lower ring nut and tighten the centrering nut until their slots are aligned.

h. Install the lock washer .

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

i. Hold the lower and centre ring nuts with aexhaust and ring nut wrench and tighten theupper ring nut with a ring nut wrench.

T.R

T.R

3-31

CHKADJ

Ring nut wrench90890-01268

Upper ring nut75 Nm (7.5 m•kg)

5. Install:• HandlebarRefer to “HANDLEBAR” section in chapter 7.

• Handlebar coverRefer to “HANDLEBAR COVERS” section.

EAS00151

CHECKING THE FRONT FORK1. Stand the scooter on a level surface.


2. Check:• inner tubeDamage/scratches → Replace.

• oil sealOil leakage → Replace.

3. Hold the scooter upright and apply the frontbrake.

4. Check:• front fork operationPush down hard on the handlebar severaltimes and check if the front fork reboundssmoothly.Rough movement → Repair.Refer to “FRONT FORK” section in chapter 7.

CHECKING AND ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORK

T.R

3115

3-32

CHKADJ

EASM0018

INSPECTING THE REAR SHOCK ABSOR-BER1. Remove:

• Side coversRefer to “SIDE COVERS AND SEAT” sec-tion.

2. Check• Rear shock absorber mountLooseness → TightenBolt (upper)Bolt (lower)

Refer to “REAR SHOCK ABSORBER ANDEXHAUST PIPE” section in chapter 7.

EAS00167

CHECKING THE TYRESThe following procedure applies to both of thetyres.1. Measure:

• tyre pressureOut of specification → Regulate.

WARNING • The tyre pressure should only be checked

and regulated when the tyre temperatureequals the ambient air temperature.

• The tyre pressure and the suspension mustbe adjusted according to the total weight(including cargo, rider, passenger andaccessories) and the anticipated ridingspeed.

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

• NEVER OVERLOAD THE SCOOTER.

INSPECTING THE REAR SHOCK ABSORBER/CHECKING THE TYRES

Basic weight(with oil and 123 kga full fuel tank)Maximum load* 187 kgCold tyre pressure Front Rear

Up to 90 kg load*180 kPa 200 kPa(1.8 kgf/cm2) (2.0 kgf/cm2)

90 kg ~ 200 kPa 220 kPamaximum load* (2.0 kgf/cm2) (2.2 kgf/cm2)

High-speed 200 kPa 220 kPariding (2.0 kgf/cm2) (2.2 kgf/cm2)

* total of cargo, rider, passenger and accessories(execpt the motorcycle)

T.R 31.5 Nm (3.15m•kg)

T.R 17.5 Nm (1.75m•kg)

3-33

CHKADJ

WARNING It is dangerous to ride with a worn-out tyre.When the tyre tread reaches the wear limit,replace the tyre immediately.

2. Check:• tyre surfacesDamage/wear → Replace the tyre.

Minimum tyre tread depth0.8 mm

Tyre tread depth Side wall Wear indicator

WARNING • Do not use a tubeless tyre on a wheel

designed only for tube tyres to avoid tyrefailure and personal injury from suddendeflation.

• When using tube tyres, be sure to installthe correct tube.

• Always replace a new tube tyre and a newtube as a set.

• To avoid pinching the tube, make sure thewheel rim band and tube are centered inthe wheel groove.

• Patching a punctured tube is notrecommended. If it is absolutely necessaryto do so, use great care and replace thetube as soon as possible with a goodquality replacement.

Tube wheel → → → → → Tube tyre only Tubeless wheel → → → → → Tube or tubeless tyre

• After extensive tests, the tyres listed belowhave been approved by MBK Industrie forthis model. The front and rear tyres shouldalways be by the same manufacturer andof the same design. No guaranteeconcerning handling characteristics can begiven if a tyre combination other than oneapproved by MBK Industrie is used on thisscooter.

CHECKING THE TYRES

3101

3103

3-34

CHKADJ

Front tyreManufacturer METZELER

Model ME-7 TEENSize 120/70-12

Rear tyreManufacturer METZELER

Model ME-7 TEENSize 120/70-12

WARNING • New tyres have a relatively low grip on the

road surface until they have been slightlyworn. Therefore, approximately 100 kmshould be traveled at normal speed beforeany high-speed riding is done.

• After a tyre has been repaired or replaced,be sure to tighten the tyre air valve stemlocknut to specification.

NOTE:For tyres with a direction of rotation mark:• Install the tyre with the mark pointing in thedirection of wheel rotation.

• Align the mark with the valve installation point.

CHECKING THE TYRES

3-35

CHKADJ

EAS00168

CHECKING THE WHEELSThe following procedure applies to both of thewheels.1. Check:

• wheelDamage/out-of-round → Replace.

WARNING Never attempt to make any repairs to thewheel.

NOTE:After a tyre or wheel has been changed orreplaced, always balance the wheel.

EAS00170

CHECKING AND LUBRICATING THECABLESThe following procedure applies to all of thecable sheaths and cables.

WARNING Damaged cable sheaths may cause the cableto corrode and interfere with its movement.Replace damaged cable sheaths and cablesas soon as possible.

1. Check:• cable sheathDamage → Replace.

2. Check:• cable operationRough movement → Lubricate.

Recommended lubricantEngine oil or a suitable cablelubricant

NOTE:Hold the cable end upright and pour a few dropsof lubricant into the cable sheath or use a suitablelubricating device.

CHECKING THE WHEELS/CHECKING AND LUBRICATING THE CABLES

E

3-36

CHKADJ

EAS00171

LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedals.

Recommended lubricantEngine oil

EAS00172

LUBRICATING THE CENTERSTANDLubricate the pivoting point and metal-to-metalmoving parts of the centerstand.


LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE CENTERSTAND

ZAUM0061

ZAUM0062

3-37

CHKADJ

EAS00177

ELECTRICAL SYSTEMCHECKING THE BATTERY

WARNING Batteries generate explosive hydrogen gasand contain electrolyte which is made ofpoisonous and highly caustic sulphuric acid.Therefore, always follow these preventivemeasures:• Wear protective eye gear when handling or

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

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

• DO NOT SMOKE when charging or handlingbatteries.

• KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.

• Avoid bodily contact with electrolyte as itcan cause severe burns or permanent eyeinjury.

FIRST AID IN CASE OF BODILY CONTACT:EXTERNAL• Skin - Wash with water.• Eyes - Flush with water for 15 minutes and

get immediate medical attention.INTERNAL• Drink large quantities of water or milk

followed with milk of magnesia, beaten eggor vegetable oil. Get immediate medical at-tention.

1. Remove:• Battery coverRefer to “SIDE COVERS AND SEAT” sec-tion.

2. Disconnect:• battery leads(from the battery terminals)

CAUTION:First, disconnect the negative battery lead, and the positive battery lead .

3. Remove:• battery

CHECKING THE BATTERY

+

om913(b)

ZAUM0063

+UPPERLOWER

3-38

CHKADJ

4. Check:• electrolyte levelThe electrolyte level should be between theminimum level mark and the maximumlevel mark .Below the minimum level mark → Add distilledwater to the proper level.

CAUTION:Add only distilled water. Tap water containsminerals which are harmful to the battery.

5. Check:• specific gravityLess than 1.280 → Recharge the battery.

Specific gravity1.280 at 20°C

6. Charge:• battery

WARNING Do not quick charge a battery.

CAUTION:• Loosen the battery sealing caps.• Make sure the battery breather hose and

battery vent are free of obstructions.• To ensure maximum performance, always

charge a new battery before using it.• Do not use a high-rate battery charger. They

force a high-amperage current into thebattery quickly and can cause batteryoverheating and battery plate damage.

• If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.

• When charging a battery, be sure to removeit from the scooter. (If charging has to bedone with the battery mounted on the scoo-ter, disconnect the negative battery leadfrom the battery terminal.)

• To reduce the chance of sparks, do not plugin the battery charger until the battery char-ger leads are connected to the battery.

• Before removing the battery charger leadclips from the battery terminals, be sure toturn off the battery charger.

CHECKING THE BATTERY

+UPPERLOWER

3-39

CHKADJCHECKING THE BATTERY

• Make sure the battery charger lead clips arein full contact with the battery terminal andthat they are not shorted. A corrodedbattery charger lead clip may generate heatin the contact area and a weak clip springmay cause sparks.

• If the battery becomes hot to the touch atany time during the charging process,disconnect the battery charger and let thebattery cool before reconnecting it. Hotbatteries can explode!

NOTE:Replace the battery whenever:• battery voltage does not rise to specification orbubbles fail to rise during charging,

• sulphation of one or more battery cells occurs(as indicated by the battery plates turning whiteor material accumulating in the bottom of thebattery cell),

• specific gravity readings after a long, slowcharge indicate that one battery cell’s charge islower than the rest,

• warpage or buckling of the battery plates orinsulators is evident.

7. Check:• battery breather hose and battery ventObstruction → Clean.Damage → Replace.

8. Install:• battery

9. Connect:• battery breather hose

CAUTION:When checking the battery, make sure thebattery breather hose is properly installedand routed correctly. If the battery breatherhose is positioned so as to allow electrolyteor hydrogen gas from the battery to contactthe frame, the scooter and its finish may bedamaged.

10. Check:• battery terminalsDirt Clean with a wire brush.Loose connection Connect properly.

+

om913(a)

3-40

CHKADJ

EAS00181

CHECKING THE FUSESThe following procedure applies to all of the fu-ses.

CAUTION:To avoid a short circuit, always set the mainswitch to “OFF” when checking or replacinga fuse.

1. Remove:• Battery coverRefer to “SIDE COVERS AND SEAT” sec-tion.

2. Check:• continuity

a. Connect the pocket tester to the fuse andcheck the continuity.

NOTE:Set the pocket tester selector to “Ω x 1”.


b. If the pocket tester indicates “∞”, replace thefuse.

11. Connect:• battery leads(to the battery terminals)

CAUTION:First, connect the positive battery lead ,and then the negative battery lead .

12. Lubricate:• battery terminals

Recommended lubricantDielectric grease

13. Install:• Battery coverRefer to “SIDE COVERS AND SEAT” sec-tion.

CHECKING THE BATTERY/CHECKING THE FUSES

+

om913(b)

3-41

CHKADJ

3. Replace:• blown fuse

a. Set the main switch to “OFF”.b. Install a new fuse of the correct amperage.c. Set on the switches to verify if the electrical

circuit is operational.d. If the fuse immediately blows again, check

the electrical circuit.

Items Amperage Q’tyMain fuse 20A 1Fan fuse 7.5A 1

WARNING Never use a fuse with an amperage ratingother than that specified. Improvising orusing a fuse with the wrong amperage ratingmay cause extensive damage to the electricalsystem, cause the lighting and ignitionsystems to malfunction and could possiblycause a fire.

4. Install:• Battery coverRefer to “SIDE COVERS AND SEAT” sec-tion.

EAS00183

REPLACING THE HEADLIGHT BULBS ANDTHE FRONT TURN SIGNAL LIGHT BULBS.The following procedure applies to both of theheadlight bulbs.1. Remove:

• Front coverRefer to “FRONT COVER, INNER PANELAND FRONT INNER PANEL” section.

2. Disconnect:• Healight coupler

3. Detach:• Headlight bulb holder

4. Remove:• Headlight bulb •Turn signal light bulbs

WARNING Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

CHECKING THE FUSES / REPLACING THE HEADLIGHTBULBS AND THE FRONT TURN SIGNAL LIGHT BULBS

3-42

CHKADJ

5. Install:• headlight bulb Secure the new headlight bulb with theheadlight bulb holder.

CAUTION:Avoid touching the glass part of theheadlight bulb to keep it free from oil,otherwise the transparency of the glass, thelife of the bulb, and the luminous flux will beadversely affected. If the headlight bulb getssoiled, thoroughly clean it with a clothmoistened with alcohol or lacquer thinner.

6. Attach:• headlight bulb holder

7. Connect:• Headlight coupler

8. Install:• Front coverRefer to “FRONT COVER, INNER PANELAND FRONT INNER PANEL” section.

REPLACING THE REAR TURN SIGNAL LIGHT BULBS

EAS00183

REPLACING THE REAR TURN SIGNALLIGHT BULBSThe following procedure applies to both of theturn signal light bulbs.1. Remove:

• Turn signal light lens 2. Remove:

• Turn signal bulb (push and turn itcounterclockwise)

WARNING Since the turn signal light bulb gets extremelyhot, keep flammable products and your handsaway from the bulb until it has cooled down.

3. Install:• Turn signal light bulb (push and turnit clockwise until it stops)

CAUTION:Avoid touching the glass part of theheadlight bulb to keep it free from oil,otherwise the transparency of the glass, thelife of the bulb, and the luminous flux will beadversely affected. If the headlight bulb getssoiled, thoroughly clean it with a clothmoistened with alcohol or lacquer thinner.

3-43

CHKADJ

CAUTION:Do not overtighten the screw, otherwise thelensmay break.

4. Install:• Turn signal light lens

EAS00183

REPLACING THE TAIL/BRAKE LIGHTBULB1. Remove:

• Tail/brake light lens 2. Remove:

• Tail/brake bulb (push and turn itcounterclockwise)

WARNING Since the tail/brake bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

3. Install:• Tail/brake light bulb (push and turn itclockwise until it stops)

CAUTION:Avoid touching the glass part of the tail/brakebulb to keep it free from oil, otherwise thetransparency of the glass, the life of the bulb,and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

4. Install:• Tail/brake light lens

REPLACING THE TAIL/BRAKE LIGHT BULB

3-44

CHKADJ

EAS00185

ADJUSTING THE HEADLIGHT BEAMSThe following procedure applies to both of theheadlights.1. Adjust:

• headlight beam (vertically)

a. Turn the adjusting screw in or out.

Turning in → Headlight beam is raised.Turning out → Headlight beam is lowered.

EASM0019

ADJUSTING THE DIGITAL CLOCKTo adjuste the digital clock, refer to “FEATURES”section in chapter 1.

ADJUSTING THE HEADLIGHT BEAMS/ADJUSTING THE DIGITAL CLOCK

CHAPTER 4.OVERHAULING THE ENGINE

ENGINE .........................................................................................................4-1WIRING HARNESS, CABLE ....................................................................4-1HOSES, AIR FILTER, ENGINE MOUNTING BOLT AND ENGINE .........4-3

CAMSHAFT ...................................................................................................4-4REMOVING THE ROCKER ARMS AND THE CAMSHAFT ....................4-5CHECKING THE CAMSHAFT .................................................................4-5CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS .........4-6CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETAND TIMING CHAIN GUIDES .................................................................4-7CHECKING THE TIMING CHAIN TENSIONER ......................................4-7CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKETCOVER ....................................................................................................4-8INSTALLING THE CAMSHAFT AND ROCKER ARMS ...........................4-8

CYLINDER HEAD ........................................................................................4-10REMOVING THE CYLINDER HEAD .....................................................4-12CHECKING THE CYLINDER HEAD ......................................................4-12INSTALLING THE CYLINDER HEAD ....................................................4-13

VALVES AND VALVE SPRINGS ................................................................4-14REMOVING THE VALVES ....................................................................4-15CHECKING THE VALVES AND VALVE GUIDES .................................4-16CHECKING THE VALVE SEATS...........................................................4-17CHECKING THE VALVE SPRINGS ......................................................4-19INSTALLING THE VALVES ...................................................................4-20

CYLINDER AND PISTON ............................................................................4-22REMOVING THE CYLINDER AND PISTON .........................................4-23CHECKING THE CYLINDER AND PISTON ..........................................4-23CHECKING THE PISTON RINGS .........................................................4-25CHECKING THE PISTON PIN ...............................................................4-26INSTALLING THE PISTON AND CYLINDER ........................................4-26

ENG

CLUTCH ......................................................................................................4-28CRANKCASE COVER ...........................................................................4-28V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE .................4-29SECONDARY SHEAVE .........................................................................4-30REMOVING THE PRIMARY SHEAVE ..................................................4-31REMOVING THE SECONDARY SHEAVE AND V-BELT ......................4-31DISASSEMBLING THE SECONDARY SHEAVE ..................................4-32CHECKING THE CLUTCH ....................................................................4-32CHECKING THE CLUTCH HOUSING ...................................................4-33CHECKING THE CLUTCH SPRINGS ...................................................4-33CHECKING THE V-BELT ......................................................................4-33CHECKING THE WEIGHTS ..................................................................4-33CHECKING THE SECONDARY SHEAVE .............................................4-34ASSEMBLING THE PRIMARY SHEAVE...............................................4-34INSTALLING THE SECONDARY SHEAVE ...........................................4-35

STARTER CLUTCH AND GENERATOR ....................................................4-37MAGNETO COVER AND STATOR COIL ..............................................4-37STARTER CLUTH .................................................................................4-38CHECKING THE STARTER CLUTCH ...................................................4-39INSTALLING THE GENERATOR ..........................................................4-39

OIL PUMP ....................................................................................................4-40CHECKING THE OIL PUMP ..................................................................4-41

CRANKCASE AND CRANKSHAFT ...........................................................4-42DISASSEMBLING THE CRANKCASE ..................................................4-44REMOVING THE CRANKSHAFT ASSEMBLY......................................4-44CHECKING THE CRANKSHAFT AND CONNECTING ROD ................4-45CHECKING THE CRANKCASE.............................................................4-46CHECKING THE BEARINGS AND OIL SEALS ....................................4-46CHECKING THE CIRCLIPS AND WASHERS .......................................4-46INSTALLING THE CRANKSHAFT .........................................................4-46ASSEMBLING THE CRANKCASE ........................................................4-47

TRANSMISSION ..........................................................................................4-48

ENG

ENG

4-1

ENGINE

Removing the wire harness and Remove the parts in the order listed.cablesSide covers

Refer to “SIDE COVERS AND SEAT”Seat

section in chapter 3.BoxFootrest board Refer to “FOOTREST BOARD, ANDUnder cover UNDER COVER” section in chapter 3.Carburetor Refer to “CARBURETOR” section in

chapter 6.Drain coolant Refer to “CHANGING THE COOLANT”

section in chapter 3.I Remove:1 Spark plug cap 12 Thermo unit lead 13 Startor coil/Pick up coil lead 1/14 Starting motor lead 1

EASM0020 (bis)

OVERHAULING THE ENGINEENGINEWIRING HARNESS, CABLE


FWD

1

2

3 45

6

7

89

10 Nm (1.0 m¥kg) T.R

ENG

4-2

ENGINE

5 Earth lead 16 Adjuster 17 Rear brake cable 18 Rear brake cable pin 19 Rear brake cable compression spring 1

10 Cable holder 1For installation, reverse the removalprocedure.


FWD

1

2

3 45

6

7

89

10 Nm (1.0 m¥kg) T.R

ENG

4-3

ENGINEEASM0021

HOSES, AIR FILTER, ENGINE MOUNTING BOLT AND ENGINE

Removing the hoses, air filter, Remove the parts in the order listed.engine mounting bolt and engine

1 Crankcase breather hose 12 Pump inlet hose 13 Cylinder head outlet hose 14 Air filter case assembly 15 Rear shock absorber bolt (lower) 16 Self locknut/ Plane washer 1/17 Engine mounting bolt 18 Engine 1



FWD2

3

4

8

5

6

7

1T.R

43 Nm (4,3 m¥kg)

T.R17.5 Nm (1,75 m¥kg)

Place the scooter on a suitable stand sothat teh rear wheel is elevated.

CAUTION:

ENG

4-4

CAMSHAFTEASM0023

CAMSHAFT

Removing the camshaft Remove the parts in the order listed.Cylinder head Refer to “CYLINDER HEAD” section.

1 Plate bolt 22 Plate 13 Rocker arm shaft (intake) 1 Slide hammer bolt: 90890-010834 Rocker arm shaft (exhaust) 1 Weight: 90890-010845 Camshaft retaining plate 16 Camshaft 17 Rocker arms (intake and exhaust) 28 Locknut 29 Adjuster 2



89

7

5

6

LS

E

E

M

M

3

4

2

89

7

M

10 Nm (1,0 m¥kg)

T.R6,5 Nm (0,65 m¥kg)

T.R6,5 Nm (0,65 m¥kg) T.R

12 Nm (1,2 m¥kg)

T.R

LS

LS

1

1

ENG

4-5

CAMSHAFTEAS00197

REMOVING THE ROCKER ARMS AND CAMSHAFT1. Align:

• “T” mark on the generator rotor(with the mark on the generator rotor cover)


sion stroke, align the “T” mark a on the

generator rotor with the mark b on thecrankcase.

NOTE:TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

2. Loosen:• locknuts • adjusting screws

3. Remove:• timing chain tensioner assembly

NOTE:Remove the timing chain tensioner adjustingscrew and spring to release the spring tensionand then remove the timing chain tensionerbody.

4. Remove:• bolt• camshaft sprocket• Rocker arms shaft

5. Remove:• camshaft retaining plate and bolt• camshaft

Slide hammer bolt90890-01083 (M6)

Weight90890-01084

6. Remove:• rocker arms

EAS00205

CHECKING THE CAMSHAFT1. Check:

• camshaft bearingsDamage/wear → Replace.

2. Check:• camshaft lobesBlue discoloration/pitting/scratches → Re-place the camshaft.

b

a

ENG

4-6

CAMSHAFT

EAS00206

CHECKING THE ROCKER ARMS ANDROCKER ARM SHAFTSThe following procedure applies to all of the roc-ker arms and rocker arm shafts.1. Check:

• rocker armDamage/wear → Replace.

2. Check:• rocker arm shaftBlue discoloration/excessive wear/pitting/scratches → Replace or check the lubricationsystem.

3. Check:• camshaft lobeExcessive wear → Replace the camshaft.

4. Measure:• rocker arm inside diameterOut of specification → Replace.

Rocker arm inside diameter12.000 ~ 12.018 mm<Limit>:12.030mm

5. Measure:• rocker arm shaft outside diameterOut of specification → Replace.

Rocker arm shaft outside diameter11.981 ~ 11.991 mm<Limit>:11.950 mm

3. Measure:• camshaft lobe dimensions a and b .Out of specification → Replace the camshaft.

Camshaft lobe dimension limitIntake a 30.711mm b 25.045 mmExhaust a 30.711 mm b 25.052 mm

4. Check:• camshaft oil passageObstruction → Blow out with compressed air.

ENG

4-7

6. Calculate:• rocker-arm-to-rocker-arm-shaft clearance

NOTE:Calculate the clearance by subtracting the rockerarm shaft outside diameter from the rocker arminside diameter.

Rocker-arm-to-rocker-arm-shaftclearance

0.009 ~ 0.037 mmEAS00207

CHECKING THE TIMING CHAIN,CAMSHAFT SPROCKET AND TIMINGCHAIN GUIDES1. Check:

• timing chainDamage/stiffness → Replace the timing chainand camshaft sprocket as a set.

2. Check:• camshaft sprocketMore than 1/4 tooth a wear → Replace thecamshaft sprocket and the timing chain as aset.

a 1/4 toothb Correct

Timing chain roller Camshaft sprocket3. Check:

• timing chain guide (exhaust side)• timing chain guide (intake side)Damage/wear → Replace the defectivepart(s).

EAS00210

CHECKING THE TIMING CHAINTENSIONER1. Check:

• timing chain tensionerCracks/damage → Replace.

2. Check:• one-way cam operationRough movement → Replace the timing chaintensioner housing.

3. Check:• cap bolt • O-ring• spring • one-way cam • gasket • timing chain tensioner rod Damage/wear → Replace the defective part(-s).

CAMSHAFT

ENG

4-8

EAS00212

CHECKING THE TAPPET COVERS ANDCAMSHAFT SPROCKET COVERThe following procedure applies to both of thetappet covers and O-rings.1. Check:

• tappet covers• O-ringsDamage/wear → Replace the defectivepart(s).

CAMSHAFT

INSTALLING THE CAMSHAFT ANDROCKER ARMS1. Lubricate:

• rocker arms and shafts (intake and exhaust)

Recommended lubricantMolybdenum disulfide oil

2. Install:• exhaust rocker arm• intake rocker arm

3. Lubricate:• camshaft

Recommended lubricantCamshaft

Molybdenum disulfide oilCamshaft bearing

Engine oil

4. Align:• “T” mark on the generator rotor(with the mark on the generator rotor cover)


sion stroke, align the “T” mark a on thegenerator rotor with the mark b ont thegenerator rotor cover.

NOTE:Be sure to keep the timing chain as tight aspossible.

5. Install:• camshaft• camshaft retaining plate• bolt• O-rings (onto the intake and exhaust rockerarm shafts)

• exhaust rocker arm shaft• intake rocker arm shaft

T.R 12Nm (1.2m•kg)

a

b

ENG

4-9

CAMSHAFT

CAUTION:

Make sure the threaded part of the rocker armshaft and O-rings faces outwards.

6. Install:• rocker arm shaft clamp and bolt.

7. Install:• timing chain (onto the camshaft sprocket)

• camshaft sprocket (onto the camshaft)

NOTE:• The notch on the camshaft should face towardsthe intake side of the engine.

• Align the camshaft mark c with the edge of thecylinder head d as shown.

CAUTION:

Do not turn the crankshaft when installingthe camshaft to avoid damage or impropervalve timing.

8. Install:• camshaft sprocket bolt

9. Adjust:• valves clearanceRefer to “ADJUSTING THE VALVES CLEA-RANCE” section in chapter 3.

10. Lubricate:• cylinder head components


11. Turn:• crankshaft

NOTE:Turn the crankshaft several full turns to makesure the camshaft is properly timed.

T.R 10 Nm (1.0m•kg)

T.R 30 Nm (3.0m•kg)

ENG

4-10

CYLINDER HEAD

Removing the cylinder head Remove the parts in the order listed.Side covers

Refer to “SIDE COVERS AND SEAT”Seat

section in chapter 3.BoxCaburetor Refer to “CARBURETOR”

section in chapter 6.Exhaust pipe Refer to "REAR SHOCKS ABSORBER

AND EXHAUST PIPE" section in chapter 7.Drain coolant Refer to “CHANGING THE COOLANT”

section in chapter 3.I Remove:1 Spark plug cap 12 Thermo switch connector 13 Pump inlet hose 14 Pump outlet hose 15 Cylinder head outlet hose 1

EASM0020

CYLINDER HEAD


FWD

1

2

34

5

8

7

9

1013

15

T.R22 Nm (2.2 m¥kg)

T.R10 Nm (1.0 m¥kg)

T.R8 Nm (0.8 m¥kg)

T.R12 Nm (1.2 m¥kg)

T.R30 Nm (3.0 m¥kg)

6

11

12

14

ENG

4-11

6 Crankcase breather hose 1

7 Water pump 1

8 Timing chain tensioner 19 Camshaft sprocket 1

10 Timing chain 111 Cylinder head bolts 212 Cylinder head nuts 413 Cylinder head 114 Dowel pin 2

15 Cylinder head gasket 1For installation, reverse the removalprocedure.

CYLINDER HEAD


FWD

1

2

34

5

8

7

9

1013

15

T.R22 Nm (2.2 m¥kg)

T.R10 Nm (1.0 m¥kg)

T.R8 Nm (0.8 m¥kg)

T.R12 Nm (1.2 m¥kg)

T.R30 Nm (3.0 m¥kg)

6

11

12

14

Follow the arrowsWARNING

NOTE:Lock the flywheel with the special tool.

NOTE:Avoid the dowel pin falling in the cylinder.

ENG

4-12

CYLINDER HEADEAS00225

REMOVING THE CYLINDER HEAD1. Remove:

• camshaft and rocker armsRefer to “REMOVING THE ROCKER ARMSAND CAMSHAFT” section.

NOTE:To prevent the timing chain from falling into thecrankcase, fasten it with a wire.

2. Remove:• cylinder head

NOTE:• Loosen the nuts in the proper sequence.• Loosen each nut 1/2 of a turn at a time. After allof the nuts are fully loosened, remove them.

EAS00229

CHECKING THE CYLINDER HEAD1. Remove:

• combustion chamber carbon deposits(with a rounded scraper)

NOTE:Do not use a sharp instrument to avoiddamaging or scratching:• spark plug bore threads• valve seats

2. Check:• cylinder headDamage/scratches → Replace.

• cylinder head water jacketMineral deposits/rust → Remove.

3. Measure:• cylinder head warpageOut of specification → Resurface the cylinderhead.

Maximum cylinder head warpage0.03mm

a. Place a straightedge and a thickness gaugeacross the cylinder head.

b. Measure the warpage.c. If the limit is exceeded, resurface the cylinder

head as follows.

ENG

4-13

EAS00232

INSTALLING THE CYLINDER HEAD1. Install:

• cylinder head gasket • dowel pins

2. Install:• cylinder head• copper washers• cylinder head nuts• cylinder haed bolts

NOTE:• Lubricate the cylinder head nuts with engineoil.

• Tighten the cylinder head nuts in the propertightening sequence as shown and torque themin two stages.

3. Install:• camshaft• rocker armsRefer to “INSTALLING THE CAMSHAFTSAND ROCKER ARMS” section.

d. Place a 400 ~ 600 grit wet sandpaper on thesurface plate and resurface the cylinder headusing a figure-eight sanding pattern.

NOTE:To ensure an even surface, rotate the cylinderhead several times.

CYLINDER HEAD

T.R 22 Nm (2.2m•kg)

T.R 12 Nm (1.2m•kg)

ENG

4-14

VALVES AND VALVE SPRINGSEASM0024

VALVES AND VALVE SPRINGS

Removing the valves and valves Remove the parts in the order listed.springsCylinder head Refer to “CYLINDER HEAD” sectionRocker arm, rocker arm shaft Refer to “CAMSHAFT” section.

1 Valve cotters 42 Spring retainer 23 Valve spring 2 Valve spring compressor: 90890-040194 Valve (intake) 1 Attachement: 90890-041085 valve (exhaust) 16 Valve guide (oil seals) 27 Spring seat 2



5

4

1

1

2

3

67

2

3

67

M

M

NOTE:After installation, refer to "Adjusting valve"section in chapter 3.

ENG

4-15

EAS00238

REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.

NOTE:Before removing the internal parts of the cylinderhead (e.g., valves, valve springs, valve seats),make sure the valves properly seal.

1. Check:• valve(for leakage)Leakage at the valve seat → Check the valveface, valve seat, and valve seat width.Refer to “CHECKING THE VALVE SEATS”section.

a. Pour a clean solvent a into the intake andexhaust ports.

b. Check that the valves properly seal.

NOTE:There should be no leakage at the valve seat b .

2. Remove:• valve cotters

NOTE:Remove the valve cotters by compressing thevalve springs with the valve spring compressorand attachment .

Valve spring compressor90890-04019

Attachment90890-04108

3. Remove:• spring retainer • valve springs • oil seal • spring seat • valve

NOTE:Identify the position of each part very carefully sothat it can be reinstalled in its original place.


b

ENG

4-16

VALVES AND VALVE SPRINGSEAS00239

CHECKING THE VALVES AND VALVEGUIDESThe following procedure applies to all of thevalves and valve guides.1. Measure:

• valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance = Valve guide inside diameter b - Valve stem diameter a

Out of specification → Replace the valveguide.

Valve guide inside diameter:Intake 4.500 ~ 4.512 mm <Limit>: 4.542 mmExhaust 4.500 ~ 4.512 mm <limit>: 4.542 mm

Valve stem diameter:Intake4.475 ~ 4.490 mm<limit>: 4.445 mmExhaust4.460 ~ 4.475 mm<limit>: 4.430 mm

Valve-stem-to-valve-guide clearanceIntake0.01 ~ 0.037mm<Limit>: 0.08 mmExhaust0.025 ~ 0.052 mm<Limit>: 0.10mm

2. Replace:• valve guide

NOTE:To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100°C in an oven.

a. Remove the valve guide with the valve guideremover .

b. Install the new valve guide with the valveguide installer and valve guide remover .

a

b

ENG

4-17

c. After installing the valve guide, bore the valveguide with the valve guide reamer to obtainthe proper valve-stem-to-valve-guide clea-rance.

NOTE:After replacing the valve guide, reface the valveseat .

Valve guide remover (4.5 mm)90890-04116

Valve guide installer (4.5 mm)90890-04117

Valve guide reamer (4.5 mm)90890-04118

3. Remove:• carbon deposits(from the valve face and valve seat)

4. Check:• valve facePitting/wear → Grind the valve face.

• valve stem endMushroom shape or diameter larger than thebody of the valve stem → Replace the valve.

5. Measure:• valve margin thickness aOut of specification → Replace the valve.

6. Measure:• valve stem runoutOut of specification → Replace the valve.

NOTE:• When installing a new valve, always replacethe valve guide.

• If the valve is removed or replaced, alwaysreplace the oil seal.

Valve stem runout0.01 mm

EAS00240

CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Remove:

• carbon deposits(from the valve face and valve seat)

2. Check:• valve seatPitting/wear → Replace the cylinder head.


a

ENG

4-18


3. Measure:• valve seat width aOut of specification → Replace the cylinderhead.

Valve seat widthIntake0.9 ~ 1.1 mm<limit>: 1.6 mmExhaust0.9 ~ 1.1<limit>: 1.6 mm)

a. Apply Mechanic’s blueing dye (Dykem) ontothe valve face .

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

onto the valve seat to make a clear impres-sion.

d. Measure the valve seat width.

NOTE:Where the valve seat and valve face contactedone another, the blueing will have been removed.

4. Lap:• valve face• valve seat

NOTE:After replacing the cylinder head or replacing thevalve and valve guide, the valve seat and valveface should be lapped.

a. Apply a coarse lapping compound a to thevalve face.

CAUTION:Do not let the lapping compound enter thegap between the valve stem and the valveguide.

b. Apply molybdenum disulfide oil onto the valvestem.

a

ENG

4-19

c. Install the valve into the cylinder head.d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all ofthe lapping compound.

NOTE:For the best lapping results, lightly tap the valveseat while rotating the valve back and forthbetween your hands.

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

f. After every lapping procedure, be sure toclean off all of the lapping compound from thevalve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem) ontothe valve face.

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

onto the valve seat to make a clear impres-sion.

j. Measure the valve seat width c again. If thevalve seat width is out of specification, refaceand lap the valve seat.

EAS00241

CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure:

• valve spring free length aOut of specification → Replace the valvespring.

Valve spring free length (intakeand exhaust)

Valve spring41.94 mm<Limit>: 39.84mm

2. Measure:• compressed valve spring force aOut of specification → Replace the valvespring.b Installed length


ENG

4-20


EAS00245

INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:

• valve stem end(with an oil stone)

2. Lubricate:• valve stem• oil seal(with the recommended lubricant)

Recommended lubricantMolybdenum disulfide oil

3. Install:• valve spring seat • valve stem seal • valve • valve spring • spring retainer (into the cylinder head)

NOTE:Install the valve spring with the larger pitch afacing up.

b Smaller pitch

Spring compressed pressure(intake and exhaust)

45.1 ~ 50.9 N

3. Measure:• valve spring tilt aOut of specification → Replace the valvespring.

Spring tilt limitIntake and exhaust valve spring2.5° / 1.9 mm

a

a

b

ENG

4-21

4. Install:• valve cotters

NOTE:Install the valve cotters by compressing thevalve spring with the valve spring compressor and attachment.

Valve spring compressor90890-04019

Attachment90890-04108

5. To secure the valve cotters onto the valvestem, lightly tap the valve tip with a soft-facehammer.

CAUTION:Hitting the valve tip with excessive forcecould damage the valve.


ENG

4-22

CYLINDER AND PISTONEASM0025

CYLINDER AND PISTON

Removing the cylinder and piston Remove the parts in the order listed.Cylinder head Refer to “CYLINDER HEAD” section.

1 Cylinder bolts 22 Timing chain guide (lower) 13 Cylinder 14 Dowel pin 25 Cylinder gasket 16 Piston pin clip 27 Piston pin 18 Piston 19 Piston ring (top) 1

10 Piston ring (2nd) 111 Oil ring 1



FWD

1

2

3

45

6

78

910 11

T.R12 Nm (1.2 m¥kg)

E

ENG

4-23

EAS00253

REMOVING THE CYLINDER AND PISTON1. Remove:

• piston pin clip • piston pin • piston

CAUTION:Do not use a hammer to drive the piston pinout.

NOTE:• Before removing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe piston pin clip from falling into the crankcase.

• Before removing the piston pin, deburr thepiston pin clip’s groove and the piston’s pinbore area. If both areas are deburred and thepiston pin is still difficult to remove, remove itwith the piston pin puller.

Piston pin puller90890-01304

2. Remove:• top ring• 2nd ring• oil ring

NOTE:When removing a piston ring, open the end gapwith your fingers and lift the other side of the ringover the piston crown.

EAS00255

CHECKING THE CYLINDER AND PISTON1. Check:

• piston wall• cylinder wallVertical scratches → Rebore or replace thecylinder, and replace the piston and pistonrings as a set.

CYLINDER AND PISTON

ENG

4-24

CYLINDER AND PISTON

D1

D2

D3

D4

D5D6

2. Measure:• piston-to-cylinder clearance

a. Measure cylinder bore “C” with the cylinderbore gauge.

NOTE:Measure cylinder bore “C” by taking side-to-sideand front-to-back measurements of the cylinder.Then, find the average of the measurements.

Cylinder XN 125 53.700 ~ 53.705 mmbore “C” XN 150 59.500 ~ 59.505 mmTaper limit “T” 0.05 mmOut-of-round “R” 0.05 mm

“C” = maximum of D1 ~ D2

“T” = maximum of D1 or D2 - maximumof D5 or D6

“R” = maximum of D1, D3 or D5

- minimum of D2, D4 or D6

b. If out of specification, rebore or replace thecylinder, and replace the piston and pistonrings as a set.

c. Measure piston skirt diameter “P” with themicrometer.

Piston size “P”

StandardXN 125 53.670 ~ 53.687 mmXN 150 59.470 ~ 59.487 mm

Oversize 2XN 125 53.92 mmXN 150 59.72 mm

Oversize 4XN 125 54.17 mmXN 150 59.97 mm

d. If out of specification, replace the piston andpiston rings as a set.

e. Calculate the piston-to-cylinder clearance withthe following formula.

Piston-to-cylinder clearance =Cylinder bore “C” -Piston skirt diameter “P”

Piston-to-cylinder clearance0.025 ~ 0.035 mm<Limit>: 0.15mm

f. If out of specification, rebore or replace thecylinder, and replace the piston and pistonrings as a set.

ENG

4-25

EAS00264

CHECKING THE PISTON RINGS

1. Measure:• piston ring side clearance Out of specification → Replace the piston andpiston rings as a set.

NOTE:Before measuring the piston ring side clearance,remove any carbon deposits from the piston ringgrooves and piston rings.

Piston ring side clearanceTop ring0.03 ~ 0.07 mm<Limit>: 0.12 mm2nd ring0.02 ~ 0.06<Limit>: 0.12 mm

2. Install:• piston ring(into the cylinder)

NOTE:Level the piston ring into the cylinder with thepiston crown.

a 0.5 mm

3. Measure:• piston ring end gap Out of specification → Replace the pistonring.

NOTE:The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is excessive,replace all three piston rings.

Piston ring end gapTop ring 0.15 ~ 0.25 mm <Limit>: 0.50 mm2nd ring 0.15 ~ 0.30 mm <Limit>: 0.65 mmOil ring 0.20 ~ 0.70 mm

CYLINDER AND PISTON

a

ENG

4-26

CYLINDER AND PISTONEAS00265

CHECKING THE PISTON PIN1. Check:

• piston pinBlue discoloration / grooves → Replace thepiston pin and then check the lubricationsystem.

2. Measure:• piston pin outside diameter aOut of specification → Replace the piston pin.

Piston pin outside diameter14.991 ~ 15.000 mm

3. Calculate:• piston-pin-to-piston clearanceOut of specification → Replace the piston pinand piston as a set.

Piston-pin-to-piston clearance = Piston pin bore size b - Piston pin outside diameter a

Piston-pin-to-piston clearance0.002 ~ 0.022 mm

EAS00267

INSTALLING THE PISTON AND CYLINDER1. Install:

• top ring • 2nd ring • lower oil ring rail • upper oil ring rail • oil ring expander

NOTE:Be sure to install the piston rings so that themanufacturer’s marks or numbers face up.

ENG

4-27

2. Install:• piston • piston pin • piston pin clip

NOTE:• Lubricate the piston pin with engine oil.• Make sure the arrow mark a on the pistonpoints towards the exhaust side of the cylinder.

• Before installing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe clip from falling into the crankcase.

3. Install:• gasket • dowel pins

4. Lubricate:• piston• piston rings• cylinder(with the recommended lubricant)


5. Offset:• piston ring end gaps

a Top ringb Lower oil ring railc Upper oil ring raild 2nd ring6. Install:

• cylinder

NOTE:• While compressing the piston rings with onehand, install the cylinder with the other hand.

• Pass the timing chain and timing chain guide(lower) through the timing chain cavity.

CYLINDER AND PISTON

ENG

4-28

CLUTCHEASM0026

CLUTCHCRANKCASE COVER

Removing the crankcase cover Remove the parts in the order listed.Side covers Refer SIDE COVERS AND SEAT”

section in chapter 3.1 Air filter crankcase cover 12 Air filter crankcase cover gasket 13 Air filter crankcase element 14 Crankcase cover protector 15 Crankcase cover (left) 16 Crankcase cover gasket 1



FWD1

2

3

4

5

6

T.R10 Nm (1.0 m¥kg)

T.R9 Nm (0.9 m¥kg)

T.R10 Nm (1.0 m¥kg)

ENG

4-29

EASM0027

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

Removing the V-belt, clutch and Remove the parts in the order listed.secondary/primary sheave

1 Nut/plain washer/washer 1/1/1 Refer to “REMOVING THE PRIMARY2 Primary fixed sheave 1 SHEAVE” section.3 Nut 1 Refer to “REMOVING THE SECONDARY4 Clutch housing 1 SHEAVE AND V-BELT” section.5 Clutch assembly 1 Refer to “INSTALLING THE6 V-belt 1 SECONDARY SHEAVE” section.7 Washer 18 Primary sliding sheave 19 Collar 1

Refer to “ASSEMBLING THE PRIMARY10 Cam 1 SHEAVE” section.11 Weight 6

12 Slider 313 Oil seal 2


V-BELT, CLUTCH AND SECONDARY / PRIMARYSHEAVE


FWD

12

43

56

7

8

9

12

1113

13

10

T.R55 Nm (5.5 m¥kg)

T.R60 Nm (6.0 m¥kg)

ENG

4-30


EASM0028

SECONDARY SHEAVE

Disassembling the secondary Disassemble the parts in the order listed.sheave

Nut 1 Refer to “DISASSEMBLING THE Clutch carrier 1 SECONDARY SHEAVE” section. Clutch shoe spring 3 Refer to “INSTALLING THE Compression spring 1 SECONDARY SHEAVE” section. Spring seat 1

Guide pin 3 Secondary sliding sheave 1

Refer to “INSTALLING THE O-ring 2 SECONDARY SHEAVE” section. Oil seal 2

Secondary fixed sheave 1For assembly, reverse the disassemblyprocedure.


FWD

T.R90 Nm (9.0 m¥kg)

* *

* *

* *

* *

LS

Apply BEL-RAY assembly lube ®**

ENG

4-31

REMOVING THE PRIMARY SHEAVE1. Remove:

• nut (primary sheave)• plate washer• primary fixed sheave

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

Rotor holder90890-01235

REMOVING THE SECONDARY SHEAVEAND V-BELT1. Remove:

• nut (secondary sheave)• clutch housing

NOTE:Loosen the nut (secondary sheave) while holdingthe clutch housing with the sheave holder .

Sheave holder90890-01701

2. Remove:• nut (clutch carrier)

CAUTION:Do not remove the nut (clutch carrier) yet.

NOTE:Loosen the nut (clutch carrier) one turn using thelocknut wrench while holding the clutch carrierwith the rotor holder .



ENG

4-32


3. Remove:• clutch assembly • V-belt

NOTE:Remove the V-belt from the primary sheave sidewith clutch assembly.

DISASSEMBLING THE SECONDARYSHEAVE1. Remove:

• nut (secondary sheave)

NOTE:Loosen the nut while attaching the clutchspring compressor and clutch spring holderarm and release the compressed spring afterremoving the nut.

CAUTION:

Use the spacer (ø 40 mm, thickness:2~3 mm).

Clutch spring holder90890-01337

Clutch spring holder arm90809-01464

CHECKING THE CLUTCH1. Measure:

• clutch shoe thickness.Scratches → Glaze using coarse sandpaper.Wear/damage → Replace.

Clutch shoe thickness2.0 mm<Limit>: 1.0 mm

NOTE:• After using the sandpaper, clean off the polishedparticles.

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

ENG

4-33


EAS00290

CHECKING THE CLUTCH HOUSING1. Check:

• clutch housingDamage/wearr → Replace.

2. Measure:• clutch housing inside diameter aOut of specification → Replace the clutchhousing.

Clutch housing inside diameterXN125: 120 mmXN150: 135 mm<Limit XN125>: 120.5 mm<Limit XN150>: 130.5 mm

EAS00282

CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of theclutch springs.1. Check:

• clutch springDamage → Replace the clutch springs as aset.

2. Measure:• clutch spring free lengthOut of specification → Replace the clutchsprings as a set.

Clutch spring free lengthXN125: 28 mmXN150: 31.3 mm

CHECKING THE V-BELT1. Check:

• V-belt Cracks/wear/scaling/chipping → Replace.Oil/grease → Check the secondary sheave.

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

V-belt width22 mm<Limit>: 19 mm

a

ENG

4-34


CHECKING THE WEIGHTS1. Check:

• weight minimum outside diameterCracks/wear/scaling/chipping → Replace.Out of specification → Replace.

Weight out side diameter20.0 mm<Limit>: 19.5 mm

CHECKING THE SECONDARY SHEAVE1. Check:

• secondary fixed sheave smooth operation• secondary sliding sheave smooth operationScratches/damage → Replace as a set.

2. Check:• Torque cam groove Wear/damage → Replace.

3. Check:• Guide pin Wear/damage → Replace.

ASSEMBLING THE PRIMARY SHEAVE1. Clean:

• primary sliding sheave face • primary fixed sheave face • collar • weight • primary sliding sheave cam face

2. Install:• weight • collar

3. Install:• slider • cam

ENG

4-35

3. Install:• guide pin

4. Apply:• BEL-RAY assembly lube ®(to the guide pin sliding groove , and oil seal )

5. Install:• secondary sheave complete • compression spring• clutch carrier

NOTE:Temporarily tighten the nut while attachingthe clutch spring holder and clutch springholder arm and compress the spring.

CAUTION:

Use the spacer (ø 40 mm, thickness: 2~3 mm).

Clutch spring holder90890-01337

Clutch spring holder arm90890-01464


E

E

INSTALLING THE SECONDARY SHEAVE1. Apply:

• BEL-RAY assembly lube ®(to the secondary sliding sheave inner sur-face, grease nipple groove, and oil seals)

• BEL-RAY assembly lube ®(to the bearings, oil seals and inner surface ofthe secondary fixed sheave)

2. Install:• secondary sliding sheave

ENG

4-36


T.R 90 Nm (9.0m•kg)

T.R 60 Nm (6.0 m•kg)

6. Install:• V-belt • clutch assembly

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

CAUTION:

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

7. Install:• nut (clutch carrier)

NOTE:Tighten the nut (clutch carrier), using the locknutwrench whlie holding the clutch carrier with therotor holder .


8. Install:• clutch housing • nut (clutch housing)

NOTE:Tighten the nut (clutch housing), using the sheaveholder .

Sheave holder90890-01701

9. Set:• V-belt

NOTE:Move the V-belt to minimum diameter of theprimary sheave , maximum diameter of thesecondary sheave and make the V-belt tense.

ENG

4-37

EASM0029

STARTER CLUTCH AND GENERATORMAGNETO COVER AND STATOR COIL

Removing the magneto cover and Remove the parts in the order listed.stator coilSide cover Refer to “SIDE COVERS AND SEAT”

section in chapter 3.1 Flywheel lead coupler 22 Flywheel cover 13 Nut 14 Washer 25 Rotor 16 Stator fixing screws 37 Woodruf key 18 Stator 19 Pick up coil screw 2

10 Pick up coil 1For installation, reverse the removalprocedure.

STARTER CLUTCH AND GENERATOR


FWD

12

34

56

8

10

7

9

T.R70 Nm (7,0 m•kg)

T.R7 Nm (0,7 m•kg)

T.R7 Nm (0,7 m•kg)

ENG

4-38

STARTER CLUTCH AND GENERATOREASM0030

STARTER CLUTH

Removing the starter clutch Remove the parts in the order listed.1 Gear retainer plane 12 Washer 13 Idle gear 14 Washer 15 Starter one way cluth 16 Collar 17 Starter wheel gear 1



FWD

1

2

5

7 6

43

T.R7 Nm (0,7 m•kg)

T.R65 Nm (6,5 m•kg)

ENG

4-39

EAS00348

CHECKING THE STARTER CLUTCH1. Check:

• starter clutch idle gear• starter clutch wheel gear• starter one way clutchChips/pitting/roughness/wear → Replace thedefective part(s).

2. Check:• starter clutch operation

a. Install the starter clutch drive gear onto thestarter clutch and hold the starter clutch.

b. When turning the starter clutch drive gearcounter-clockwise, the starter clutch and thestarter clutch drive gear should engage,otherwise the starter clutch is faulty and mustbe replaced.

c. When turning the starter clutch drive gearclockwise, it should turn freely, otherwise thestarter clutch is faulty and must be replaced.

STARTER CLUTCH AND GENERATOR

EAS00354

INSTALLING THE GENERATOR1. Install:

• woodruff key • generator rotor • washers • generator rotor nut

NOTE:• Clean the tapered portion of the crankshaft andthe generator rotor hub.

• When installing the generator rotor, make surethe woodruff key is properly seated in the keyway of the crankshaft.

2. Tighten:• generator rotor nut

NOTE:While holding the generator rotor with the rotorholder , tighten the generator rotor bolt.


321050

T.R 70 Nm (7.0m•kg)

ENG

4-40

OIL PUMPEASM0031

OIL PUMP

Removing the oil pump Remove the parts in the order listed.Drain Engine oil Refer to “CHANGING THE ENGINE

OIL” section in chapter 3.Flywheel Refer to “STARTER CLUTCH AND

GENERATOR” section.1 Oil pump cover fixing screws 32 Oil pump cover 13 Oil pump clip 14 Washer 15 Oil pump gear 16 Oil pump gear dowel pin 17 Oil pump fixing screws 28 Oil pump assembly 1



FWD

2

1

3 45

68

7T.R65 Nm (6,5 m•kg)

T.R7 Nm (0,7 m•kg)

ENG

4-41

OIL PUMPEAS00363

CHECKING THE OIL PUMP1. Check:

• oil pump drive gear• oil pump driven gear • oil pump housing• oil pump housing coverCracks/damage/wear → Replace thedefective part(-s).

2. Measure:• inner-rotor-to-outer-rotor-tip clearance A• outer-rotor-to-oil-pump-housing clearance B• Pump housing-to-rotors clearance COut of specification → Replace the oil pump.

Inner rotor Outer rotor Oil pump housing

Inner-rotor-to-outer-rotor-tipclearance

limit: 0.15 mmOuter-rotor-to-oil-pump-housingclearance

limit: 0.15 mmPump housing-to-rotors clearance

limit: 0.17 mm

3. Check:• oil pump operationRough movement → Replace the defectivepart(s).

A

B

C

ENG

4-42

CRANKCASE AND CRANKSHAFTEASM0032

CRANKCASE AND CRANKSHAFT

Removing the crankcase and Remove the parts in the order listed.crankshaftEngine Refer to “ENGINE” section.Cylinder head Refer to “CYLINDER HEAD” section.Cylinder and piston Refer to “CYLINDER AND

PISTON” section.V-belt, cluth, secondary/primary sheave Refer to “V-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE”section.

CDI magneto Refer to ”STARTER CLUTCHAND GENERATOR” section.

Oil pump Refer to “OIL PUMP” section.Water pump Refer to “WATER PUMP” section in

chapter 5.Rear wheel Refer to “REAR WHEEL AND BRAKE”

section in chapter 7.


FWD

3 4

5

6

8

1

T.R9 Nm (0.9 m¥kg)

T.R9 Nm (0.9 m¥kg)

E

E

2

7

ENG

4-43

1 Bolt 12 Timing chain guide 13 Screws 84 Crankcase (right) 1 Refer to “INSTALLING THE CRANK-

SHAFT AND STARTER CLUTCH” section.5 Dowel pin 26 Crankshaft assembly 17 Timing chain 18 Crankcase (left) 1




FWD

3 4

5

6

8

1

T.R9 Nm (0.9 m¥kg)

T.R9 Nm (0.9 m¥kg)

E

E

2

7

ENG

4-44

CRANKCASE AND CRANKSHAFTEAS00385

DISASSEMBLING THE CRANKCASE1. Remove:

• crankcase bolts

NOTE:Loosen each bolt 1/4 of a turn at a time, in stagesand in a crisscross pattern. After all of the boltsare fully loosened, remove them.

2. Remove:• right crankcase

CAUTION:Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced por-tions of the crankcase, not on the crankcasemating surfaces. Work slowly and carefullyand make sure the crankcase halvesseparate evenly.

3. Remove:• timing chain from crankshaft sprocket

EAS00388

REMOVING THE CRANKSHAFTASSEMBLY1. Remove:

• crankshaft assembly

CAUTION:

Tap on one side of the crankshaft with a soft-face hammer. Work slowly and carefully andmake sure the crankshaft separate evenlyfrom the crankcase.

ENG

4-45

EAS00394

CHECKING THE CRANKSHAFT ANDCONNECTING ROD1. Measure:

• crankshaft runoutOut of specification → Replace the crankshaft,bearing or both.

NOTE:Turn the crankshaft slowly.

Maximum crankshaft runout0.03 mm

2. Measure:• big end side clearanceOut of specification → Replace the crankshaft.

Big end side clearance0.15 ~ 0.45 mm

3. Measure:• crankshaft widthOut of specification → Replace the crankshaft.

Crankshaft width47.95 ~ 48.00 mm

4. Check:• crankshaft sprocket Damage/wear → Replace the crankshaft.

• bearing Cracks/damage/wear → Replace thecrankshaft.

• oil pump drive gear Damage/wear → Replace the crankshaft.

5. Check:• crankshaft journalScratches/wear → Replace the crankshaft.

• crankshaft journal oil passageObstruction → Blow out with compressed air.


ENG

4-46


CHECKING THE CRANKCASE1. Thoroughly wash the crankcase halves in a

mild solvent.2. Thoroughly clean all the gasket surfaces and

crankcase mating surfaces.3. Check:

• crankcaseCracks/damage → Replace.

• oil delivery passagesObstruction → Blow out with compressed air.

EAS00401

CHECKING THE BEARINGS AND OILSEALS1. Check:

• bearings Clean and lubricate the bearings, then rotatethe inner race with your finger.Rough movement → Replace.

2. Check:• oil seals Damage/wear → Replace.

EAS00402

CHECKING THE CIRCLIPS AND WASHERS1. Check:

• circlips Bends/damage/looseness → Replace.

• washers Bends/damage → Replace.

EAS00408

INSTALLING THE CRANKSHAFT1. Install:

• crankshaft assembly• timing chain

CAUTION:

To avoid scratching the crankshaft and toease the installation procedure, apply areaseonto the oil seal lips and apply engine oil ontoeach bearing.

ENG

4-47


ASSEMBLING THE CRANKCASE1. Apply:

• sealant(onto the crankcase mating surfaces)

Yamaha bond No. 121590890-85505

NOTE:Do not allow any sealant to come into contactwith the oil gallery.

2. Install:• dowel pins

3. Install:• crankshaft

4. Install:• timing chain

5. Install:• left crankcase(onto the right crankcase)

NOTE:Tap lightly on the left crankcase with a soft-facehammer.

6. Install:• crankcase bolts

7. Apply:• engine oil(onto the crankshaft bearings, conrod andcrank pin)

8. Check:• crankshaft operationRough movement → Repair.

• timing chain position

T.R 9 Nm (0.9m•kg)

ENG

4-48

EASM0033

TRANSMISSION

Removing the transmission Remove the parts in the order listed.Rear wheel Refer to “REAR WHEEL AND

BRAKE” section in chapter 7.Crankcase cover (left) Refer to “V-BELT, CLUTH AND

SECONDARY/PRIMARY SHEAVE”section.

Drain the transmission oil Refer to “TRANSMISSON OILREPLACEMENT” section in chapter 3.

1 Transmission cover screws 62 Transmission case cover 13 Gasket 14 Dowel pin 2 Refer to “INSTALLING THE CRANK-

SHAFT AND STARTER CLUTCH” section.5 Primary drive gear 16 Plain washer 17 Secondary drive gear axle 1

TRANSMISSION


FWD2

1

3

4

6

7

9

5

T.R6.5 Nm (0,65 m•kg)

EE

E

E

E

G

G

LS

8

ENG

4-49

8 Idle gear 1

9 Main axle 1For installation, reverse the removalprocedure.

TRANSMISSION


FWD2

1

3

4

6

7

9

5

T.R6.5 Nm (0,65 m•kg)

EE

E

E

E

G

G

LS

8

CHAPTER 5.COOLING SYSTEM

RADIATOR ....................................................................................................5-1CHECKING THE RADIATOR ..................................................................5-3INSTALLING THE RADIATOR ................................................................5-3

THERMOSTAT ..............................................................................................5-4CHECKING THE THERMOSTAT ............................................................5-5INSTALLING THE THERMOSTAT ..........................................................5-5

WATER PUMP ...............................................................................................5-6CHECKING THE WATER PUMP .............................................................5-7INSTALLING THE WATER PUMP ...........................................................5-7

COOL

COOL

5-1

RADIATOREASM0034

COOLING SYSTEMRADIATOR

Drain coolant Refer to “CHANGING THE COOLANT”section in chapter 3.

Front cover Refer to “FRONT COVER, INNERPANEL AND INNER FRONT COVER”section in chapter 3.

Footrest board Refer to “FOOTREST BOARD ANDUNDER COVER” section in chapter 3.

I Disconnet:1 Fan motor coupler 12 Thermo switch connectors 4II Unplug:3 Radiator outlet hose 14 Radiator inlet hose 15 Radiator filler hose 1III Untight:6 Radiator bracket (frame) 1


1

2

3

4

2

8

7

6

5

COOL

5-2

RADIATOR

IV Remove:7 Radiator 18 Radiator fan 1



1

2

3

4

2

8

7

6

5

NOTE:Avoid the radiator of falling

COOL

5-3

RADIATOREAS00455

CHECKING THE RADIATOR1. Check:

• radiator fins Obstruction → Clean.Apply compressed air to the rear of theradiator.Damage → Repair or replace.

NOTE:Straighten any flattened fins with a thin, flat-head screwdriver.

2. Check:• radiator hoses• radiator pipesCrack/damage → Replace.

3. Check:• radiator capCracks/damage → Replace.

4. Check:• radiator fanDamage → Replace.Malfunction → Check and repair.Refer to “COOLING SYSTEM” section inchapter 8.

EAS00456

INSTALLING THE RADIATOR1. Fill:

• cooling system(with the specified amount of therecommended coolant)Refer to “CHANGING THE COOLANT” sec-tion in chapter 3.

2. Check:• cooling systemLeaks → Repair or replace any faulty part.

COOL

5-4

THERMOSTATEASM0036

THERMOSTAT

Removing the thermostat Remove the parts in the order listed.Drain coolant Refer to “CHANGING COOLANT”

section in chapter 3.Box Refer to “SIDE COVERS AND SEAT”

section in chapter 3.1 Hose 12 Cylinder head outlet hose 13 Thermostat cover fixing screws 24 Thermostat cover 15 Thermostat 1



1

2

3

4

5

T.R9 Nm (0,9 m•kg)

COOL

5-5

THERMOSTATEAS00462

CHECKING THE THERMOSTAT1. Check:

• thermostat Does not open at 80.5 ~ 83.5°C → Replace.

a. Suspend the thermostat in a container filledwith water.

b. Slowly heat the water.c. Place a thermometer in the water.d. While stirring the water, observe the ther-

mostat and thermometer ’s indicatedtemperature.

Thermometer Water Thermostat Container A Fully closed B Fully open

NOTE:If the accuracy of the thermostat is in doubt,replace it. A faulty thermostat could cause seriousoverheating or overcooling.

2. Check:• thermostat housing cover • thermostat housingCracks/damage → Replace.

EASM0037

INSTALLING THE THERMOSTAT1. Install:

• thermostat• thermostat cover• hoses

3mm

B

A

COOL

5-6

WATER PUMPEASM0035

WATER PUMP


1

4

3

2

T.R10 Nm (1.0m¥kg)

T.R7 Nm (0.7m¥kg)

T.R7 Nm (0.7m¥kg)

3

3

3

LS

Removing the water pump Remove the parts in the order listed.Drain coolant Refer to “CHANGING THE COOLANT”

section in chapter 3.1 Pump inlet hose 12 Pump outlet hose 13 Water pump fixing screws 34 Water pump assembly 1

Disassembling water pump Water pump mounting screws 4 Bleed screw with copper washer 1/1 Water pump inner cover 1 O-ring 1 Water pump cover/gasket 1/1 Impeller shaft 1 Dowel pin 1

For installation, reverse the removal procedure.

NOTE:Follow the arrows

COOL

5-7

WATER PUMPEAS00472

CHECKING THE WATER PUMP1. Check:

• O-ring Damage/wear → Replace.

• oil seal Damage/wear → Replace the water pumphousing assembly.

NOTE:The mark “water side” on the oil seal should beinstalled outward.

2. Check:• impellerCracks/damage/wear → Replace the waterpump housing assembly.

• water pump housingCracks/damage → Replace the water pumphousing assembly.

EAS00477

INSTALLING THE WATER PUMP

NOTE:Always replace the entire water pump assembly.

1. Install:• impeller• water pump inner cover• screw

NOTE:After installation, check that the impeller shaftrotates smoothly.

2. Install:• O-ring

NOTE:Lubricate the O-ring with a thin coat of lithiumsoap base grease.

LS

T.R 7 Nm (0.7m•kg)

COOL

5-8

WATER PUMP

3. Install:• dowel pin• gasket • water pump housing cover• screws• copper washer • bleed screw

NOTE:Do not forget to install the copper washer on thebleed screw.

T.R 7 Nm (0.7m•kg)

T.R 7 Nm (0.7m•kg)

CHAPTER 6.CARBURETOR

CARBURETOR ..............................................................................................6-1CARBURETOR REMOVAL .....................................................................6-1CARBURETOR DISASSEMBLY ..............................................................6-2CHECKING THE CARBURETOR ............................................................6-3ASSEMBLING THE CARBURETOR .......................................................6-5MEASURING AND ADJUSTING THE FUEL LEVEL ...............................6-6CHECKING THE AUTOCHOKE UNIT .....................................................6-6CHECKING THE FUEL COOK ................................................................6-7

CARB

CARB

6-1

CARBURETOREASM0038

CARBURETORCARBURETOR

Removing the carburetor Remove the parts in the order listed.Side cover

Refer to “SIDE COVERS AND SEAT”Fuel tank

in chapter section 3.Box

I Disconnect:1 Auto choke coupler 12 Carburetor heater connectors 2II Unplug:3 Fuel hose 1III Remove:4 Throttle cable 15 Fixing clip 26 Air duct 17 Carburetor assembly 1


CAUTION:

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


4

6

5

57

31

2

CARB

6-2

CARBURETOR

Carburetor disassembly Remove the parts in the order listed. Auto choke unit 1 Throttle stop screw set 1 Pilot screw set 1 Diaphragm cover/spring 1/1 Throttle valve 1 Needle set 1 Accelerating pump lever 1 Float chamber/gasket 1/1 Float axle 1/1

Float 1 Needle jet 1 Main jet 1 Pilot jet 1 Main nozzle 1 Heater assembly 1 For assembly, reverse the disassembly procedure.


Y

Q

U

I

R

T

e

qw

P

O

Y

E

W

NOTE:Remove the float pin from the side of thearrow.

CARB

6-3

EAS00485

CHECKING THE CARBURETOR1. Check:

• carburetor body • float chamber• jet housingCracks/damage → Replace.

2. Check:• fuel passagesObstruction → Clean.

a. Wash the carburetor in a petroleum-basedsolvent. Do not use any caustic carburetorcleaning solution.

b. Blow out all of the passages and jets withcompressed air.

CARBURETOR

12

3. Check:• float chamber body Dirt → Clean.

4. Check:• float chamber rubber gasketCracks/damage/wear → Replace.

5. Check:• float Damage → Replace.

6. Check:• needle valve • needle valve seat Damage/obstruction/wear → Replace theneedle valve, needle valve seat and O-ring asa set.

7. Check:• o-ring Damage/wear → Replace the needle valve,needle valve seat and o-ring as a set.

8. Check:• piston valveDamage/scratches/wear → Replace.

• Piston valve diaphragmCracks/Tears → Replace.

322006

1

2

1

CARB

6-4

CARBURETOR

9. Check:• vacuum chamber cover• piston valve spring• jet needle holderCracks/damage → Replace.

322012

10. Check:• jet needle kit• main jet • needle jet • pilot jet • pilot screwBends/damage/wear → Replace.Obstruction → Replace.

322015

11. Check:• piston valve movementInsert the piston valve into the carburetorbody and move it up and down.Tightness → Replace the throttle valve.

12. Check:• starter plunger• starter plunger springBends/cracks/damage → Replace.

13. Check:• hose jointsCracks/damage → Replace.

14. Check:• vacuum hoses• fuel hosesCracks/damage/wear → Replace.Obstruction → Clean.Blow out the hoses with compressed air.

CARB

6-5

CARBURETOREAS00487

ASSEMBLING THE CARBURETOR

• Before assembling the carburetor, wash allof the parts in a petroleum-based solvent.

• Always use a new gasket.

1. Install:• main jet holder• main jet• pilot jet

2. Install:• needle valve seat

3. Check:• float • needle valve• float axle

NOTE:Install the float pin from the side opposite thearrow.

4. Install:• float chamber • gasket • pilot screw

5. Install:• O-ring• accelerator pump diaphragm• accelerator pump spring• accelerator pump cover

6. Install:• starter plunger kit

7. Install:• piston valve• jet needle holder• jet needle

8. Install:• throttle cable lever arm

9. Install:• vacuum chamber cover

10. Install:• Carburetor on engineRefer to “CARBURETOR REMOVAL ANDDISASSEMBLY” section.

CAUTION:

2 1

1

W

CARB

6-6

CARBURETOR

EAS00503

CHECKING THE AUTOCHOKE UNIT

NOTE:When checking the autochoke unit, the ambienttemperature must be lower than 45°C.

1. Remove:• carburetorRefer to "CARBURETOR REMOVAL" section.

EAS00499

MEASURING AND ADJUSTING THE FUELLEVEL1. Measure:

• fuel level aOut of specification → Adjust

Fuel level (below the float chambermating surface)

5 ~ 6 mm

a. Stand the scooter on a level surface.b. Place the scooter on a suitable stand to

ensure that the scooter is standing straightup.

c. Install the fuel level gauge onto the fueldrain pipe .

Fuel level gauge90890-01312

d. Loosen the fuel drain screw .e. Hold the fuel level gauge vertically next to the

float chamber.f. Measure the fuel level a .

2. Adjust:• fuel level

a. Remove the carburetor.b. Check the needle valve seat and needle

valve.c. If either is worn, replace them as a set.d. If both are fine, adjust the float level by slightly

bending the float tang.e. Install the carburetor.f. Measure the fuel level again.g. Repeat steps (a) to (f) until the fuel level is

within specification.

CARB

6-7

CARBURETOR

2. Check:• autochoke unit

a. Connect ø 3.3 mm hose to the starter airpassage and blow into the hose.

NOTE:When the starter plunger is open, air shouldcome out of the other side of the starter airpassage.

Starter plunger opens →→→→→Perform step.Starter plunger closes →→→→→Replace the

autochoke unit.

3. Check:• autochoke unit

a. Connect the autochoke unit leads to a12.0V battery for five minutes.

Positive battery lead →→→→→ blackNegative battery lead →→→→→ black

b. Connect ø 3.3-mm hose to the starter airpassage and blow into the hose.

Starter plunger opens → → → → → Replace the autochoke unit.

Starter plunger closes → → → → → Autochoke unit is OK.

EAS00505

CHECKING THE FUEL COCK1. Check:

• fuel cockCracks/damage/wear → Replace.

2. Check:• fuel cock strainer(with compressed air)Dirt/obstruction → Clean.Damage → Replace.

CHAPTER 7.CHASSIS

FRONT WHEEL AND BRAKE DISC .............................................................7-1REMOVING THE FRONT WHEEL ..........................................................7-2CHECKING THE FRONT WHEEL ...........................................................7-3CHECKING THE BRAKE DISC ...............................................................7-4CHECKING THE SPEEDOMETER GEAR UNIT .....................................7-5ASSEMBLING THE FRONT WHEEL ......................................................7-5INSTALLING THE FRONT WHEEL .........................................................7-6ADJUSTING THE FRONT WHEEL STATIC BALANCE ..........................7-6

REAR WHEEL AND BRAKE ........................................................................7-8CHECKING THE REAR WHEEL .............................................................7-9CHECKING THE REAR BRAKE ..............................................................7-9ASSEMBLING THE BRAKE SHOE PLATE ...........................................7-10INSTALLING THE REAR WHEEL .........................................................7-10ADJUSTING THE REAR WHEEL STATIC BALANCE .......................... 7-11

FRONT BRAKE ...........................................................................................7-12FRONT BRAKE PADS ...........................................................................7-12REPLACING THE FRONT BRAKE PADS .............................................7-13FRONT BRAKE MASTER CYLINDER ..................................................7-15MASTER CYLINDER .............................................................................7-16DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............7-17CHECKING THE FRONT BRAKE MASTER CYLINDER ......................7-17ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTERCYLINDER - WARNING ........................................................................7-18DISASSEMBLING THE FRONT BRAKE CALIPER...............................7-19CHECKING THE FRONT BRAKE CALIPER .........................................7-20ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER ......7-21

FRONT FORK ..............................................................................................7-23FRONT FORK DISASSEMBLY .............................................................7-24REMOVING THE FRONT FORK LEGS ................................................7-25DISASSEMBLING THE FRONT FORK LEGS .......................................7-25CHECKING THE FRONT FORK LEGS .................................................7-26ASSEMBLING THE FRONT FORK LEGS .............................................7-27INSTALLING THE FRONT FORK LEGS ...............................................7-30

CHAS

HANDLEBAR ..............................................................................................7-31CHECKING THE HANDLEBAR .............................................................7-32INSTALLING THE HANDLEBAR ...........................................................7-32

STEERING HEAD ........................................................................................7-34REMOVING THE LOWER BRACKET ...................................................7-35CHECKING THE STEERING HEAD ......................................................7-35INSTALLING THE STEERING HEAD....................................................7-36

REAR SHOCK ABSORBER AND EXHAUST PIPE ...................................7-37CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ..................7-38

CHAS

CHAS

7-1

Removing the front wheel and brake Remove the parts in the order listed.disc

1 Front caliper mounting bolt 22 Front caliper 13 Front wheel axle nut 1

4 Front wheel axle 15 Front wheel collar 16 Speedometer sensor 17 Front wheel 18 Front brake disc mounting screws 49 Front brake disc 1


FRONT WHEEL AND BRAKE DISC

NOTE:Place the scooter on a suitable stand sothat the front wheel is elevated.

EASM0040

CHASSISFRONT WHEEL AND BRAKE DISCFRONT WHEEL AND BRAKE DISC


LS

23 Nm (2,3 m¥kg) T.R

23 Nm (2,3 m¥kg) T.R

LT

7

6

9

5

4

2

70 Nm (7,0 m¥kg) T.R

8

3

1

LT

CHAS

7-2

FRONT WHEEL AND BRAKE DISCEAS00520

REMOVING THE FRONT WHEEL1. Stand the scooter on a level surface.

WARNING

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


2. Remove:• brake caliper

NOTE:Do not squeeze the brake lever when removingthe brake caliper.

3. Elevate:• front wheel


CHAS

7-3


CHECKING THE FRONT WHEEL1. Check:

• wheel axleRoll the wheel axle on a flat surface.Bent → Replace.

WARNING Do not attempt to straighten a bent wheelaxle.

@

@

2. Check:• tyre• front wheelDamage/wear → Replace.Refer to “CHECKING THE TIRES” and“CHECKING THE WHEELS” in chapter 3.

3. Measure:• radial wheel runout • lateral wheel runout Over the specified limits → Replace.

Radial wheel runout limit1.0 mm

Lateral wheel runout limit0.5 mm

4. Check:• wheel bearingsFront wheel turns roughly or is loose → Re-place the wheel bearings.

• oil sealsDamage/wear → Replace.

5. Replace:• wheel bearings • oil seals

a. Clean the outside of the front wheel hub.b. Remove the oil seals with a flat-head

screwdriver.

NOTE:To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface.

CHAS

7-4


EAS00528

CHECKING THE BRAKE DISC1. Check:

• brake discDamaged/galling → Replace.

2. Measure:• brake disc deflectionOut of specification → Correct the brake discdeflection or replace the brake disc.

Brake disc deflection limit(maximum)

0.15 mm

a. Place the scooter on a suitable stand so thatthe front wheel is elevated.

b. Before measuring the front brake discdeflection, turn the handlebar to the left orright to ensure that the front wheel is stationary.

c. Remove the brake caliper.d. Hold the dial gauge at a right angle against

the brake disc surface.e. Measure the deflection 2 ~ 3 mm below the

edge of the brake disc.

3. Measure:• brake disc thicknessMeasure the brake disc thickness at a fewdifferent locations.Out of specification → Replace.

Brake disc thickness limit(minimum)

4 mm

c. Remove the wheel bearings with a generalbearing puller .

d. Install the new wheel bearings and oil seals inthe reverse order of disassembly.

Do not contact the wheel bearing inner race or balls . Contact should be made onlywith the outer race .

NOTE:Use a socket that matches the diameter of thewheel bearing outer race and oil seal.

347001

347002

CAUTION:

CHAS

7-5

4. Adjust:• brake disc deflection

a. Remove the brake disc.b. Rotate the brake disc by one bolt hole.c. Install the brake disc.

NOTE:• Tighten the brake disc bolts in stages and in acrisscross pattern.

• Apply “Loctite” to the brake disc bolts.

d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment

steps until the brake disc deflection is withinspecification.

f. If the brake disc deflection cannot be broughtwithin specification, replace the brake disc.


EAS00535

CHECKING THE SPEEDOMETER GEARUNIT1. Check:

• speedometer gear unitBends/damage/wear → Replace.

EAS00539

ASSEMBLING THE FRONT WHEEL1. Install:

• wheel bearings• oil seals

a. Install the new wheel bearings and oil seals inthe reverse order of disassembly.

23 Nm (2,3 m¥kg) T.R

LT

T.R 23 Nm (2.3m•kg)

CHAS

7-6


INSTALLING THE FRONT WHEEL1. Lubricate:

• wheel axle• wheel bearings• oil seal lips• speedometer gear unit• collar

Recommended lubricantLithium soap base grease

2. Install:• speedometer gear unit

NOTE:Make sure that the speedometer gear unit andthe wheel hub are installed with the projectionmeshed.

3. Install:• collar• front wheel• front wheel axle

WARNING Be sure to assemble the front wheel asshown on page 7-1.

4. Tighten:• wheel axle nut

WARNING Make sure the brake hose is routed properly.

Before tightening the wheel axle nut, pushdown hard on the handlebar several timesand check if the front fork reboundssmoothly.

EAS00548

ADJUSTING THE FRONT WHEEL STATICBALANCE

NOTE:• After replacing the tyre, wheel or both, the frontwheel static balance should be adjusted.

• Adjust the front wheel static balance with thebrake disc installed.

T.R 70 Nm (7.0m•kg)

CAUTION:

CHAS

7-7


1. Remove:• balancing weight(s)

2. Find:• front wheel’s heavy spot

NOTE:Place the front wheel on a suitable balancingstand.

a. Spin the front wheel.b. When the front wheel stops, put an “X1” mark

at the bottom of the wheel.c. Turn the front wheel 90° so that the “X1” mark

is positioned as shown.d. Release the front wheel.e. When the wheel stops, put an “X2” mark at

the bottom of the wheel.f. Repeat steps (d) through (f) several times

until all the marks come to rest at the samespot.

g. The spot where all the marks come to rest isthe front wheel’s heavy spot “X”.

3. Adjust:• front wheel static balance

a. Install a balancing weight onto the rimexactly opposite the heavy spot “X”.

NOTE:Start with the lightest weight.

b. Turn the front wheel 90° so that the heavyspot is positioned as shown.

c. If the heavy spot does not stay in that posi-tion, install a heavier weight.

d. Repeat steps (b) and (c) until the front wheelis balanced.

4. Check:• front wheel static balance

a. Turn the front wheel and make sure it stays ateach position shown.

b. If the front wheel does not remain stationaryat all of the positions, rebalance it.

X1

X2

X1

X

X

X

X

X

X

CHAS

7-8

Removing the rear wheel and brake Remove the parts in the order listed.Exhaust pipe (cylinder) 1Exhaust pipe (bracket holder) 1

1 Rear brake adjuster 12 Rear brake cable/spring 1/13 Rear wheel axle nut 1

4 Plate washer 15 Rear wheel 16 Brake shoes lining 27 Tension spring 28 Plate washer 19 Brake cam lever 1

10 Indicator plate 111 Brake cam 1 For installation, reverse the removal

procedure.

REAR WHEEL AND BRAKEEASM0041

REAR WHEEL AND BRAKE

NOTE:Place the scooter on a suitable stand sothat the rear wheel is elevated.


FWD

T.R103.5 Nm (10.35 m•kg)

T.R13.5 Nm (1.35 m•kg)

LS

LS

3 4

5

8 7 6

10

11

9

2

1

CHAS

7-9

REAR WHEEL AND BRAKEEAS00565

CHECKING THE REAR WHEEL1. Check:

• wheel axle• rear wheel• wheel bearings• oil sealsRefer to “FRONT WHEEL AND BRAKE DISC”section.

2. Check:• tyre• rear wheelDamage/wear → Replace.Refer to “CHECKING THE TYRES” and“CHECKING THE WHEELS” in chapter 3.

3. Measure:• radial wheel runout • lateral wheel runout Refer to “FRONT WHEEL AND BRAKE DISC”section.

Radial wheel runout limit1.0 mm

Lateral wheel runout limit0.5 mm

EAS00569

CHECKING THE REAR BRAKEThe following procedure applies to all of thebrake shoes.1. Check:

• brake shoe liningGlazed areas → Repair.Sand the glazed areas with course sandpaper.

NOTE:After sanding the glazed areas, clean the brakeshoe with a cloth.

346007

a

2. Measure:• brake shoe lining thickness aOut of specification → Replace.

Brake shoe lining thickness limit(minimum)

2 mm

WARNING Do not allow oil or grease to contact thebrake shoes.

CHAS

7-10


NOTE:Replace the brake shoes as a set, if either isworn to the wear limit.

3. Measure:• brake drum inside diameter bOut of specification → Replace the wheel.

Brake drum inside diameter limit(maximum)

130.5 mm

4. Check:• brake drum inner surfaceOil deposits → Clean.Remove the oil with a rag soaked in lacquerthinner or solvent.Scratches → Repair.Lightly and evenly polish the scratches withan emery cloth.

5. Check:• brake camshaftDamage/wear → Replace.

EAS00570

ASSEMBLING THE BRAKE SHOE PLATE1. Install:

• brake camshaft • spring• brake shoe wear indicator

a. Install the brake camshaft so its punch markis positioned as shown.

b. Align the projection on the brake shoe wearindicator with the notch in the brake shoecamshaft.

c. Check that the brake shoes are properlypositioned.

EAS00573

INSTALLING THE REAR WHEEL1. Install:

• brake camshaft• brake shoe wear indicator• brake camshaft lever

346008

b

346011(a)

CHAS

7-11

NOTE:• Align the punch mark in the brake camshaftwith the mark on the brake camshaft lever.

• Lubricate the brake camshaft and pin withlithium soap base grease.

WARNING After installing the rear brake camshaft,remove any excess grease.

2. Install:• brake shoes• spring plain washer

NOTE:Do not to damage the springs during installation.

3. Lubricate:• wheel axle• plain washer


4. Tighten:• plain washer • wheel axle nut

5. Adjust:• brake lever free playRefer to “ADJUSTING THE REAR BRAKE”section in chapter 3.


EAS00575

ADJUSTING THE REAR WHEEL STATICBALANCE

NOTE:• After replacing the tire, wheel or both, the rearwheel static balance should be adjusted.

• Adjust the rear wheel static balance with thebrake disc and rear wheel drive hub installed.

1. Adjust:• rear wheel static balanceRefer to “FRONT WHEEL AND BRAKE DISC”section.

346009

LS

346012

346013

T.R 103.5 Nm (10.35m•kg)

CHAS

7-12

FRONT BRAKEEASM0042

FRONT BRAKEFRONT BRAKE PADS

Removing the front brake pads Remove the parts in the order listed.Front caliper Refer to “REMOVING THE FRONT

WHEEL” section.1 Caliper fixing bolt 22 Retaining clip 13 Retaining pin 14 Pad spring 15 Brake pads 26 Bleed screw 1



6

2

1

4

3

5

22Nm (2,2 m¥kg)

LS LT

CHAS

7-13

FRONT BRAKEEAS00579

Disc brake components rarely requiredisassembly.Therefore, always follow these preventivemeasures:• Never disassemble brake components

unless absolutely necessary.• If any connection on the hydraulic brake

system is disconnected, the entire brakesystem must be disassembled, drained,cleaned, properly filled, and bled afterreassembly.

• Never use solvents on internal brakecomponents.

• Use only clean or new brake fluid forcleaning brake components.

• Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.

• Avoid brake fluid coming into contact withthe eyes as it can cause serious injury.

FIRST AID FOR BRAKE FLUID ENTERINGTHE EYES:• Flush with water for 15 minutes and get

immediate medical attention.

EAS00581

REPLACING THE FRONT BRAKE PADS

NOTE:When replacing the brake pads, it is not necessaryto disconnect the brake hose or disassemble thebrake caliper.

1. Remove:• caliper fixing bolts


3. Remove:• retaining clip • retaining pin • brake pad spring • brake pads

CAUTION:

CHAS

7-14

FRONT BRAKE

4. Measure:• brake pad wear limit aOut of specification → Replace the brakepads as a set.

Brake pad wear limit0.8 mm

5. Install:• brake pad spring• brake pads

NOTE:• Always install new brake pads and a new brakepad spring as a set.

• Make sure the brake pad spring is installedcorrectly.

6. Push the caliper piston into the brake caliperby finger.

When pushing the caliper piston into thebrake caliper, brake fluid level in the reservoirtank is increasing higher.

7. Install:• retaining pin • retaining clip

Do not allow grease to contact the brake pads.

8. Install:• brake caliper• brake caliper fixing bolt

9. Check:• brake fluid levelBelow the minimum level mark → Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” section in chapter 3.

10. Check:• brake lever operationSoft or spongy feeling → Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” section in chapter 3.

a

LT

T.R 23 Nm (2.3m•kg)

ZAUM0060

CAUTION:

CAUTION:

CHAS

7-15

FRONT BRAKEEASM0043

FRONT BRAKE MASTER CYLINDER

Removing the front brake master Remove the parts in the order listed.cylinderDrain brake fluid Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” section in chapter 3.Handlebar covers Refer to “HANDLEBAR COVERS”

section in chapter 3.1 Front brake lever 12 Front brake switch 13 Hose union bolt 14 Plain washer/hose 2/15 Master cylinder bracket 16 Master cylinder 1



LS

T.R8.5 Nm (0.85 m¥kg)

T.R10 Nm (1.0 m¥kg)

T.R23 Nm (2.3 m¥kg)

2

1

4

6

5

3

CHAS

7-16

FRONT BRAKEEASM0044

MASTER CYLINDER

Disassembling the master cylinder Disassemble the parts in the order listed.Master cylinder Refer to “FRONT BRAKE MASTER

CYLINDER” section. Master cylinder kit 1 Master cylinder spring seat 1 Spring 1

For assembly, reverse the removalprocedure.


CHAS

7-17

FRONT BRAKE

EAS00590

CHECKING THE FRONT BRAKE MASTERCYLINDER1. Check:

• brake master cylinder Damage/scratches/wear → Replace.

• brake fluid delivery passages (brake master cylinder body)Obstruction → Blow out with compressed air.

2. Check:• brake master cylinder kit Damage/scratches/wear → Replace.

3. Check:• brake master cylinder reservoir Cracks/damage → Replace.

• brake master cylinder reservoir diaphragm Damage/wear → Replace.

4. Check:• brake hosesCracks/damage/wear → Replace.

EAS00588

DISASSEMBLING THE FRONT BRAKEMASTER CYLINDER

NOTE:Before disassembling the front brake mastercylinder, drain the brake fluid from the entirebrake system.

1. Disconnect:• brake switch coupler (from the brake switch)

2. Remove:• union bolt • copper washers • brake hoses

NOTE:To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

CHAS

7-18

FRONT BRAKEEAS00596

ASSEMBLING AND INSTALLING THEFRONT BRAKE MASTER CYLINDER-WARNINGBefore installation, all internal brakecomponents should be cleaned and lubricatedwith clean or new brake fluid.

WARNING Never use solvents on internal brakecomponents.


1. Install:• copper washers • brake hose • union bolt

WARNING Proper brake hose routing is essential toinsure safe scooter operation. Refer to “CA-BLE ROUTING”.

NOTE:• While holding the brake hose, tighten the unionbolt as shown.

• Turn the handlebar to the left and to the right tomake sure the brake hose does not touch otherparts (e.g., wire harness, cables, leads). Correctif necessary.

3. Fill:• brake master cylinder reservoir(with the specified amount of therecommended brake fluid)




30°

T.R 26 Nm (2.6m•kg)

CHAS

7-19

FRONT BRAKE


• When refilling, be careful that water doesnot enter the brake master cylinderreservoir. Water will significantly lower theboiling point of the brake fluid and couldcause vapor lock.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always clean upany spilt brake fluid immediately.

4. Bleed:• brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

5. Check:• brake fluid levelBelow the minimum level mark → Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.

6. Check:• brake lever operationSoft or spongy feeling → Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

EAS00618

DISASSEMBLING THE FRONT BRAKECALIPER

NOTE:Before disassembling the brake caliper, drainthe brake fluid from the entire brake system.

1. Remove:• union bolt• copper washers• brake hose

NOTE:Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:• brake caliper piston • brake caliper piston seals

ZAUM0060

CAUTION:

CHAS

7-20

FRONT BRAKE

a. Blow compressed air into the brake hose jointopening to force out the piston from the brakecaliper.

WARNING • Cover the brake caliper piston with a rag.

Be careful not to get injured when the pis-ton is expelled from the brake caliper.

• Never try to pry out the brake caliper pis-ton.

b. Remove the brake caliper piston seals.

EAS00631

CHECKING THE FRONT BRAKE CALIPERRecommended brake component replacementschedule

Brake pads If necessaryPiston seals Every two yearsBrake hoses Every two yearsBrake fluid Every two years and

whenever the brake isdisassembled

1. Check:• brake caliper pistons Rust/scratches/wear → Replace the brakecaliper.

• brake caliper cylinders Scratches/wear → Replace the brake caliper.

• brake caliper body Cracks/damage → Replace the brake caliper.

• brake fluid delivery passages(brake caliper body)Obstruction → Blow out with compressed air.

WARNING Whenever a brake caliper is disassembled,replace the piston seals.

2. Check:• brake caliper bracket Cracks/damage → Replace.

346004

CHAS

7-21

FRONT BRAKEEAS00635

ASSEMBLING AND INSTALLING THEFRONT BRAKE CALIPER

WARNING • Before installation, all internal brake

components should be cleaned andlubricated with clean or new brake fluid.

• Never use solvents on internal brakecomponents as they will cause the pistonseals to swell and distort.

• Whenever a brake caliper is disassembled,replace the brake caliper piston seals.


1. Install:• brake caliper (temporarily)• copper washers • brake hose • union bolt

WARNING Proper brake hose routing is essential toinsure safe scooter operation. Refer to “CA-BLE ROUTING”.

When installing the brake hose onto thebrake caliper , make sure the brake pipetouches the projection on the brake caliper.


3. Install:• brake pads• brake pad springs• brake caliper retaining bolt• brake caliper• brake hose holderRefer to “REPLACING THE FRONT BRAKEPADS” section.

T.R26 Nm (2.6 mkg)

T.R 26 Nm (2.6m•kg)

T.R 22 Nm (2.2m•kg)

CAUTION:

CHAS

7-22

FRONT BRAKE

4. Fill:• brake master cylinder reservoir(with the specified amount of therecommended brake fluid)





• When refilling, be careful that water doesnot enter the brake master cylinderreservoir. Water will significantly lower theboiling point of the brake fluid and couldcause vapor lock.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always clean upany spilt brake fluid immediately.

5. Bleed:• brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

6. Check:• brake fluid levelBelow the minimum level mark → Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.

7. Check:• brake lever operationSoft or spongy feeling → Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

ZAUM0060

CAUTION:

CHAS

7-23

FRONT BRAKEEASM0045

FRONT FORK

Removing the front fork Remove the parts in the order listed.Front wheel Refer to “FRONT WHEEL AND BRAKE”

section.1 Front mudguard 1

2 Cap bolt/O-ring 1/13 Bolt (under bracket upper and lower) 24 Front fork leg (right and left) 2


FRONT FORK


22

4

3

1

LTT.R23 Nm (2.3 m•kg)

T.R45 Nm (4.5 m•kg) T.R

33 Nm (3.3m•kg)

NOTE:Disconnect the speedometer sensor couplerto remove the front mudguard.

CHAS

7-24

FRONT FORKEASM0046

FRONT FORK DISASSEMBLY

Disassembling the front fork Disassemble the parts in the order listed. Cap bolt 1 O-ring 1 Fork spring 1 Dust seal 1 Retaining clip 1 Oil seal 1 Bolt (damper rod)/Gasket 1/1 Inner tube 1 Oil lock piece 1 Damper rod 1 Rebound spring 1

For assembly, reverse the disassemblyprocedure.


22

4

3

1

LTT.R23 Nm (2.3 m•kg)

T.R45 Nm (4.5 m•kg) T.R

33 Nm (3.3m•kg)

CHAS

7-25

FRONT FORKEAS00649

REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the scooter on a level surface.



2.Remove the front wheelRefer to “REMOVING THE FRONT WHEEL”section.

3. Loosen:• upper bracket pinch bolt • cap bolt • lower bracket pinch bolt

WARNING Before loosening the upper and lowerbracket pinch bolts, support the front forkleg.

4. Remove:• front fork leg

EAS00653

DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Remove:

• cap bolt (from the damper adjusting rod)

2. Remove:• O-ring

3. Drain:• fork oil

4. Remove:• damper rod assembly bolt • damper rod assembly

NOTE:While holding the damper rod with the damperrod holder , loosen the damper rod assemblybolt.

342010

CHAS

7-26

FRONT FORK

EAS00657

CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check:

• inner tube • outer tube Bends/damage/scratches → Replace.

WARNING Do not attempt to straighten a bent inner tubeas this may dangerously weaken it.

2. Check:• oil seal • Dust seal Damage → Replace.

Damper rod holder 90890-01294

T-handle 90890-01326

5. Remove:• inner tube

a. Hold the front fork leg horizontally.b. Securely clamp the brake caliper bracket in a

vice with soft jaws.c. Separate the inner tube from the outer tube

by pulling the inner tube forcefully but carefully.

• Excessive force will damage the oil sealand bushing. A damaged oil seal orbushing must be replaced.

• Avoid bottoming the inner tube into theouter tube during the above procedure, asthe oil flow stopper will be damaged.

6. Remove:• Dust seal • Retaining clip • Oil seal

Do not scratch the inner tube.

CAUTION:

CAUTION:

CHAS

7-27

FRONT FORK

• The front fork leg has a built-in damperadjusting rod and a very sophisticatedinternal construction, which areparticularly sensitive to foreign material.

• When disassembling and assembling thefront fork leg, do not allow any foreignmaterial to enter the front fork.

3. Check:• cap bolt O-ringDamage/wear → Replace.

EAS00661

ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

WARNING • Make sure the oil levels in both front fork

legs are equal.• Uneven oil levels can result in poor

handling and a loss of stability.

NOTE:When assembling the front fork leg, be sure toreplace the following parts:• oil seal• dust sealBefore assembling the front fork leg, make sureall of the components are clean.

1. Install:• piston

WARNING Always use new copper washers.

Allow the damper rod assembly to slideslowly down the inner tube until it protrudesfrom the bottom of the inner tube. Be carefulnot to damage the inner tube.

CAUTION:

CAUTION:

CHAS

7-28

FRONT FORK

2. Lubricate:• inner tube’s outer surface

Recommended lubricantYamaha fork and fork oil SAE 10or equivalent

3. Tighten:• damper rod assembly bolt

NOTE:While holding the damper rod assembly withthe damper rod holder , tighten the damperrod assembly bolt.

Damper rod holder 90890-01294

T-handle 90890-01326

4. Install:• outer tube bushing (with the fork seal driver weight and adap-ter )

Fork seal driver weight90890-01367

Fork seal driver attachment90890-01368

5. Install:• washer• oil seal(with the fork seal driver weight and adapter)

Make sure the numbered side of the oil sealfaces up.

NOTE:• Before installing the oil seal, lubricate its lipswith lithium soap base grease.

• Lubricate the outer surface of the inner tubewith fork oil.

• Before installing the oil seal, cover the top of thefront fork leg with a plastic bag to protect the oilseal during installation.

342010

T.R 23 Nm (2.3m•kg)

CAUTION:

CHAS

7-29

FRONT FORK

6. Install:• oil seal clip

NOTE:Adjust the oil seal clip so that it fits into thegroove of the outer tube.

7. Install:• dust seal (with the fork seal driver weight)

8. Fully compress the front fork leg.

9. Fill:• front fork leg(with the specified amount of therecommended fork oil)

Quantity (each front fork leg)0.125 L

Recommended oilYamaha fork and fork oil SAE 20or equivalent

• Be sure to use the recommended fork oil.Other oils may have an adverse effect onfront fork performance.

• When disassembling and assembling thefront fork leg, do not allow any foreignmaterial to enter the front fork.

10. After filling the front fork leg, slowly stroke thedamper rod up and down (at least ten times)to distribute the fork oil.

NOTE:Be sure to stroke the damper rod slowly becausethe fork oil may spurt out.

11. Slowly stroke the inner tube up and down todistribute the fork oil once more (1 stroke =about 150 mm).

NOTE:Be careful not to stroke the inner tube over150 mm as this will cause air to enter. If the innertube is stroked more than 150 mm, repeat steps(12) and (13).

12. Before measuring the fork oil level, wait tenminutes until the oil has settled and the airbubbles have dispersed.

CAUTION:

CHAS

7-30

FRONT FORK

NOTE:Be sure to bleed the front fork leg of any residualair.

13. Measure:• front fork leg oil level aOut of specification → Correct.

Front fork leg oil level (from the topof the inner tube, with the innertube fully compressed, and withoutthe spring)

80 mm

14. Install:• spring

NOTE:Install the spring with its denser of pitch to upperside.

• O-ring EAS00663

INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install:

• front fork leg • cap bolt• under bracket • bracket bolt

NOTE:Pull up the inner tube until it stops, then installthe cap bolt.

2. Tighten:• cap bolt • lower bracket pinch bolt

T.R 45 Nm (4.5m•kg)

T.R 33 Nm (3.3m•kg)

CHAS

7-31

FRONT FORKEASM0047

HANDLEBAR

Removing the handlebar Remove the parts in the order listed.Handlebar covers Refer to “HANDLEBAR COVERS”

section in chapter 3.1 Rear view mirror (right and left) 22 Master cylinder boot 13 Master cylinder 14 Handlebar switch (right) 15 Throttle cable 16 Grip assembly 17 Rear brake cable 18 Brake lever holder (left) 19 Brake lever holder (right) 1

10 Handlebar switch (left) 111 Handlebar 112 Bolt/nut 1/1



LS

12

6

4

7

119

8

1

1

10

2

3

5

T.R10 Nm (1.0 m•kg)

T.R10 Nm (1.0 m•kg)

T.R60 Nm (6.0 m•kg)

T.R10 Nm (1.0 m•kg)

T.R10 Nm (1.0 m•kg)

LS

CHAS

7-32

HANDLEBAREAS00668

CHECKING THE HANDLEBAR1. Stand the scooter on a level surface.


2. Check:• handlebar Bends/cracks/damage → Replace.

WARNING Do not attempt to straighten a bent handlebaras this may dangerously weaken it.

3.Install:• handlebar grip

a. Apply a thin coat of rubber adhesive onto theleft end of the handlebar.

b. Slide the handlebar grip over the left end ofthe handlebar.

c. Wipe off any excess rubber adhesive with aclean rag.

WARNING Do not touch the handlebar grip until therubber adhesive has fully dried.

T.R60 Nm (6.0 mkg)

EAS00673

INSTALLING THE HANDLEBAR1. Stand the scooter on a level surface.


2. Install:• handlebar

NOTE:Align the slot in the handlebar with the steeringshaft surface.

3. Tighten:• nut

4. Fasten:• wire harness

5. Install:• left handlebar switch

T.R 60 Nm (6.0m•kg)

CHAS

7-33

HANDLEBAR

NOTE:Align the projection on the left handlebar switchwith the hole in the handlebar.

6. Install:• brake lever holder

NOTE:Align the mating surfaces of the brake leverholder with the punch mark a in the handlebar.

7. Install:• throttle cable • throttle grip

NOTE:Lubricate the inside of the throttle grip with a thincoat of lithium soap base grease and install itonto the handlebar.

8. Install:• right handlebar switch

WARNING Make sure the throttle grip operatessmoothly.

NOTE:• Align the projection on the right handlebarswitch with the hole a in the handlebar.

• There should be 2.5 mm of clearance betweenthe throttle grip and the right grip end .

9. Adjust:• throttle cable free play Refer to “ADJUSTING THE THROTTLE CA-BLE FREE PLAY” in chapter 3.


1.5 ~ 3.0 mm

ZAUM0051

CHAS

7-34

STEERING HEADEASM0048

STEERING HEAD

Removing the steering head Remove the parts in the order listed.Front covers Refer to “FRONT COVERS” section in

chapter 3.Front wheel Refer to “FRONT WHEEL” section.Front fork legs Refer to “FRONT FORK” section.Handlebar Refer to “HANDLEBAR” section.

1 Ring nut 12 Lock washer 13 Ring nut (middle) 14 Rubber washer 15 Ring nut (lower) 16 Ball race cover7 Ball race (upper) 18 Lower bracket 19 Ball bearing 2210 Bearing 111 Ball races (in lower bracket) 212 Ball race (lower) 113 Steering oil seal 1 For installation, reverse the removal procedure.


1

23

45

67

8

9

10

1213

11

T.R75 Nm (7.5 mkg)

T.RFisrt step:

38 Nm (3.8 mkg)

2nd step:Loosen the ring nut1/4 turn.

3rd step:22 Nm (2.2 mkg)

LS

LS

CHAS

7-35

EAS00678

REMOVING THE LOWER BRACKET1. Stand the scooter on a level surface.


2. Remove:• ring nut (upper)• lock washer • ring nut (center) • rubber washer

3. Remove:• ring nut (lower)

NOTE:Hold the lower bracket by hand, then remove byusing the exhaust ring and steering nut wrench.

Ring nut wrench90890-01268

WARNING Securely support the steering shaft so thatthere is no danger of it falling down.

EAS00681

CHECKING THE STEERING HEAD1. Wash:

• bearings• bearing races

Recommended cleaning solventKerosene

2. Check:• bearings• bearing racesDamage/pitting → Replace.

3. Replace:• bearings• bearing races

a. Remove the bearing races from the steeringhead pipe with a long rod and hammer.

b. Remove the bearing race from the lowerbracket with a floor chisel and hammer.

c. Install a new rubber seal and new bearingraces.

STEERING HEAD

354007

CHAS

7-36

STEERING HEAD

EAS00684

INSTALLING THE STEERING HEAD1. Lubricate:

• upper bearing• lower bearing• bearing races


2. Install:• lower ring nut • rubber washer • ring nut • lock washer • upper ring nut Refer to “CHECKING AND ADJUSTING THESTEERING HEAD” section in chapter 3.

3. Install:• handlebar• bolt• nut

If the bearing race is not installed properly,the steering head pipe could be damaged.

NOTE:• Always replace the bearings and bearing racesas a set.

• Whenever the steering head is disassembled,replace the rubber seal.

4. Check:• lower bracket(along with the steering stem)Bends/cracks/damage → Replace.

354009

LS

354008

T.R 60 Nm (6.0m•kg)

CAUTION:

CHAS

7-37

REAR SHOCK ABSORBER AND EXHAUST PIPEEASM0049

REAR SHOCK ABSORBER AND EXHAUST PIPE

Removing the rear shock absorber Remove the parts in the order listed. and exhaust pipeSide covers Refer to “SIDE COVERS AND SEAT”

section in chapter 3.Box 1

1 Exhaust pipe bolt (bracket) 22 Exhaust pipe nut (engine) 23 Rear shock absorber bolt (engine) 14 Rear shock absorber bolt (frame) 1



T.R 27 Nm (2.7m•kg)

17.5 Nm (1.75m•kg)T.R

T.R 31.5 Nm (3.15m•kg)

T.R 11 Nm (1.1m•kg)

T.R31,5 Nm (3,15 m¥kg)

T.R17,5 Nm (1,75 m¥kg)

T.R4,5 Nm (0,45 m¥kg)

T.R27 Nm (2,7 m¥kg)

T.R27 Nm (2,7 m¥kg)

T.R11Nm (1,1 m¥kg)

3

1

1

2

4

CHAS

7-38

REAR SHOCK ABSORBER AND EXHAUST PIPE

EAS00695

CHECKING THE REAR SHOCK ABSORBERASSEMBLY1. Check:

• rear shock absorber rodBends/damage → Replace the rear shockabsorber assembly.

• rear shock absorberOil leaks → Replace the rear shock absorberassembly.

• springDamage/wear → Replace the rear shockabsorber assembly.

• bushingsDamage/wear → Replace.

• dust sealsDamage/wear → Replace.

• boltsBends/damage/wear → Replace.

CHAPTER 8.ELECTRICAL

ELECTRICAL COMPONENTS ......................................................................8-1

SWITCHES ....................................................................................................8-2CHECKING SWITCH CONTINUITY ........................................................8-2

CHECKING THE SWITCHES ........................................................................8-3

CHECKING THE BULBS AND BULB SOCKETS ........................................8-4TYPES OF BULBS...................................................................................8-4CHECKING THE CONDITION OF THE BULBS ......................................8-4CHECKING THE CONDITION OF THE BULB SOCKETS ......................8-6

IGNITION SYSTEM .......................................................................................8-7CIRCUIT DIAGRAM .................................................................................8-7TROUBLESHOOTING .............................................................................8-8

ELECTRIC STARTING SYSTEM ................................................................8-11CIRCUIT DIAGRAM ...............................................................................8-11TROUBLESHOOTING ...........................................................................8-12

STARTER MOTOR ......................................................................................8-14CHECKING THE STARTER MOTOR ....................................................8-16ASSEMBLING THE STARTER MOTOR ...............................................8-17

CHARGING SYSTEM ..................................................................................8-19CIRCUIT DIAGRAM ...............................................................................8-19TROUBLESHOOTING ...........................................................................8-20

LIGHTING SYSTEM ....................................................................................8-22CIRCUIT DIAGRAM ...............................................................................8-22TROUBLESHOOTING ...........................................................................8-23CHECKING THE LIGHTING SYSTEM ..................................................8-24

SIGNALING SYSTEM .................................................................................8-27CIRCUIT DIAGRAM ...............................................................................8-27TROUBLESHOOTING ...........................................................................8-29CHECKING THE SIGNALING SYSTEM ................................................8-30

COOLING SYSTEM .....................................................................................8-36CIRCUIT DIAGRAM ...............................................................................8-36TROUBLESHOOTING ...........................................................................8-37

CARBURETOR HEATING SYSTEM ...........................................................8-40CIRCUIT DIAGRAM ...............................................................................8-40TROUBLESHOOTING ...........................................................................8-41

ELEC

ELEC

8-1

ELECTRICAL COMPONENTS

ELECTRICAL COMPONENTS

Wire harness Battery Ignition unit (CDI) Main switch Ignition coil Spark plug cap Rectifier/Regulator Fuel sender Starter relay

Starter motor Thermo switch Flasher relay Horn Fuses Relays Coolant thermo switch Carburator heater thermo switch

ELEC

8-2

SWITCHESEAS00730

SWITCHESCHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity reading is incorrect, checkthe wiring connections and if necessary, replacethe switch.

CAUTION:Never insert the tester probes into the cou-pler terminal slots a. Always insert the pro-bes from the opposite end of the coupler,taking care not to loosen or damage theleads.


NOTE:• Before checking for continuity, set the pockettester to “0” and to the “x 1Ω” range.

• When checking for continuity, switch back andforth between the switch positions a few times.The terminal connections for switches (e.g.,main switch, engine stop switch) are shown inan illustration similar to the one on the left.The switch positions a are shown in the far leftcolumn and the switch lead colors b are shownin the top row in the switch illustration.

NOTE:“ ” indicates a continuity of electricity betweenswitch terminals (i.e., a closed circuit at therespective switch position).

The example illustration on the left showsthat:There is continuity between “black” and “black/white” when the switch is set to “OFF”.There is continuity between “red” and “brown” when the switch is set to “ON”.

“Ω x 1”

“∞”“0”

BBrR

OFFON

R Br B B/W

ELEC

8-3

CHECKING THE SWITCHESEAS00731

CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between theterminals. Refer to “CHECKING SWITCH CONTINUITY” section.Damage/wear → Repair or replace.Improperly connected → Properly connect.Incorrect continuity reading → Replace the switch. Horn switch Dimmer switch Turn signal switch Main switch Front brake light switch

Light switch Start switch Fuses Rear brake light switch

B

Br BR BW

CHECK

GR

OPENOFF

ONBr

GyR

R

LOCK

GY

Br

GY

Br

B

B

B

LY

B(BLUE) (BLUE)

LY

(OPTION)

B

B

(BLUE)B

B

Ch

PG

BrWBY Dg

LB

RNL

Ch

LO

HIPUSH

OFF GY LBBrW Dg

ONGY

L

Br

LB

POS

OFF

START

OFF

L LBBrBrGY

Indicates coupler position

(option)

ELEC

8-4

CHECKING THE BULBS AND BULB SOCKETS

TYPES OF BULBSThe bulbs used on this scooter are shown in theillustration on the left.• Bulbs A and B are used for the headlights and

usually use a bulb holder which must bedetached before removing the bulb. Themajority of these types of bulbs can be removedfrom their respective socket by turning themcounterclockwise.

• Bulb C is used for turn signal and tail/brakelights and can be removed from the socket bypushing and turning the bulb counterclockwise.

• Bulbs D and E are used for meter and indi-cator lights and can be removed from theirrespective socket by pushing and turning thebulb conterclockwise for D and carefullypulling them out for E .

EAS00733

CHECKING THE BULBS ANDBULB SOCKETSCheck each bulb and bulb socket for damage orwear, proper connections, and also for continuitybetween the terminals.Damage/wear → Repair or replace the bulb, bulbsocket or both.Improperly connected → Properly connect.No continuity → Repair or replace the bulb, bulbsocket or both.

A B

CD E

CHECKING THE CONDITION OF THEBULBSThe following procedure applies to all of thebulbs.1. Remove:

• bulb

ELEC

8-5


WARNING Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

CAUTION:• Be sure to hold the socket firmly when

removing the bulb. Never pull the lead,otherwise it may be pulled out of theterminal in the coupler.

• Avoid touching the glass part of theheadlight bulb to keep it free from oil,otherwise the transparency of the glass,the life of the bulb, and the luminous fluxwill be adversely affected. If the headlightbulb gets soiled, thoroughly clean it witha cloth moistened with alcohol or lacquerthinner.

2. Check:• bulb (for continuity)(with the pocket tester)No continuity → Replace.


NOTE:Before checking for continuity, set the pockettester to “0” and to the “x 1 Ω” range.

a. Connect the positive tester probe to terminal and the negative tester probe to terminal, and check the continuity.

b. Connect the positive tester probe to terminal and the negative tester probe to terminal, and check the continuity.

c. If either of the readings indicate no continuity,replace the bulb.

ELEC

8-6

CHECKING THE CONDITION OF THE BULBSOCKETSThe following procedure applies to all of the bulbsockets.1. Check:

bulb socket (for continuity)(with the pocket tester)No continuity → Replace.


NOTE:Check each bulb socket for continuity in thesame manner as described in the bulb section;however, note the following.

a. Install a good bulb into the bulb socket.b. Connect the pocket tester probes to the res-

pective leads of the bulb socket.c. Check the bulb socket for continuity. If any of

the readings indicate no continuity, replacethe bulb socket.


ELEC

8-7

EAS00734

IGNITION SYSTEMCIRCUIT DIAGRAM

CDI magneto CDI unit Ignition coil Spark plug Main switch Fuse (main) Battery Front brake stop switch Rear brake stop switch21 Relay

IGNITION SYSTEM

23

13

A

B21

5

G

21

32

25

PN K O L MR

27

26

29

19 20

16H

28

12

2217

8

F

18

11

30

10

6

79

35J

24

3

4

31

C DE

F

33

34

14 15

G

B

LW

LW

(NATURAL)

RW

BB

L

L

P

CLO

CK

OD

OM

ET

ER

LW

P

B R - W W

Y

LW

LGY

ON

Br BR BW

HANDLE SWITCH 2

HANDLESWITCH 1

LGW BRGW

WL

BR

W

Br Br

B

WR

CHECK

GR

Br OrBr

YB

Or

B YB

B

B

Br

Gy

OPENOFF

ONRBr

GyR

BW

Br

Br

R

Gy

L

R

LOCK

L

B

R

L

B

Or

YRR

L

Br

Gy

NO-CONNECTION

Y

GR

Ch

PG

BrWBY

DgLB Ch BrW

Dg

P

B

GY

LY

LB

-BW L

BW

L

GYY

GY

L

Br

LB

L

Br

L

GY

LB

L

Dg

Br

LR

B

B

B

B

B

Or

WL

WR

GW

B Y G

BR

(BLACK)

(BLACK)

Dg

Ch

Ch

LW

LW

LW

LW

Dg

Ch

Br Br

G

Ch Ch

LW

R

B

LW

LW

Dg

BR

NO-CONNECTIONBr

Ch

GW

WR

WL

NO-CONNECTION

B

NO-CONNECTION

(RED)

NO-CONNECTION

B

NO-CONNECTION

METERASSY.

Br

R

ANTI-THEFT

ALARM

(OPTION)

B

Dg

LW

LW

L

R

L

Br

RW

W

HEAD LIGHT ASSY.

Sb

Dg

BNO-CONNECTION

LW

LW

(RED)

L

Ch

G

B

Dg

Y

LW

L

Ch

G

B

Dg

Y

B

L

Y

Br

Y

GY

GY

Br

Br

YBYB

Br

L

LL

Y

Ch

G

DgCh

BWB

LW

B

Dg

Ch

ILLU

MI

Y

R

WIRE LEAD surANTI-THEFT 1 et 4

WIRE LEAD sur SIDE STAND

B

B

RW

TH

ER

MO

. MO

TO

R

TU

RN

L

TU

RN

R

HI B

EA

M

ILLU

MI

FU

EL

ME

TE

R

Br B

r

BrW

Br

W

BW

W W

W

W W

W (1)

Dg

(4)

Y

G

GR

W

W

W

Y

B

Br

Br

RNL

BrW

LW

Ch

LB

P

LO

HIPUSH

OFF

RW

LBBrGY

POS

OFF

START

OFF

LW

R

B

R

R

R

B

LW

BRW

LW

R

Y

B

Dg

GR

Dg

YR

LY

YR

BB

B

B

Ch

B

B

Or

WRWL

L

Y

LY

LYLY

LYLY

LY

LY

LY

LY

GY LBBrW

LY

Y G

BR

Br

L LB

B

Br

B

B

P

Dg

For LW/LWand LY/LY

BrGY

R

Sb

Sb

B

L

B

LY

B

B

LY

B(BLUE) (BLUE)

LY

LW

(OPTION)

BB

B

B

(BLUE)B

B

Ch

B

ELEC

8-8

EAS00736

TROUBLESHOOTING

THE IGNITION SYSTEM FAILS TOOPERATE (NO SPARK ORINTERMITTENT SPARK).

Check:1. Main fuse2. Battery3. Spark plug4. Ignition spark gap5. Spark plug cap resistance6. Ignition coil resistance7. Main switch8. Pickup coil resistance9. Wiring (of the entire ignition system)

NOTE:• Before troubleshooting, remove the followingpart(s):

1) Side covers2) Footrest board3) Seat and box• Troubleshoot with the following special tool(s).

Ignition checker90890-06754


EAS00738

1.Main fuse

• Check the main fuse for continuity.• Refer to “CHECKING THE FUSES” in chapter3.

• Is the main fuse OK?

Replace the fuse.

• Clean the batteryterminals.

• Recharge or re-place the battery.

YES NO

EAS00739

2.Battery

• Check the condition of the battery.Refer to “CHECKING THE BATTERY” inchapter 3.

Minimum open-circuit voltage12.8 V or more at 20°C

• Is the battery OK?

YES NO

EAS00740

3.Spark plug

• Check the condition of the spark plug.• Check the spark plug type.• Measure the spark plug gap.Refer to “CHECKING THE SPARK PLUG” inchapter 3.

Standard spark plugCR8E (NGK)

Spark plug gap0.5 ~ 0.7 mm

•Is the spark plug in good condition, is it of thecorrect type, and is its gap within specifica-tion?

Re-gap or replace thespark plug.

YES NO

IGNITION SYSTEM

ELEC

8-9

IGNITION SYSTEMEAS00742

4.Ignition spark gap

• Disconnect the spark plug cap from the sparkplug.

• Connect the ignition checker/dynamic sparktester as shown.

• Spark plug cap• Set the main switch to “ON”.• Measure the ignition spark gap a .• Crank the engine by pushing the starterswitch and gradually increase the spark gapuntil a misfire occurs.

Minimum ignition spark gap6 mm

• Is there a spark and is the spark gap withinspecification?

The ignition system isOK.

EAS00744

5.Spark plug cap resistance

• Remove the spark plug cap from the sparkplug lead.

• Connect the pocket tester (“Ω X 1k” range)to the spark plug cap.

• Measure the spark plug cap resistance.

Spark plug cap resistance10 x kΩ at 20°C

• Is the spark plug cap OK?

Replace the sparkplug cap.

EAS00746

6. Ignition coil resistance

• Disconnect the ignition coil connectors fromthe ignition coil terminals.

• Connect the pocket tester (Ω X 1) to theignition coil as shown.

• Measure primary coil resistance.

Positive tester probe →→→→→ blackNegative tester probe →→→→→ orange

• Measure the primary coil resistance.

Primary coil resistance0.32 ~ 0.48 Ω at 20°C

• Connect the pocket tester (Ω X 1k) to theignition coil as shown.

• Measure the secondary coil resistance.

Negative tester probe →→→→→ blackPositive tester probe →→→→→ spark plug lead

• Measure the secondary coil resistance.

Secondary coil resistance5.7 ~ 8.5 kΩ at 20°C

• Is the ignition coil OK?

Replace the ignitioncoil.

YES NO

YES NO

a

‰ x 1

‰ x 1k

YESNO

ELEC

8-10

9. Source coil resistance

• Disconnect the source coil coupler from thewire harness.

• Connect the pocket tester (Ω X 100) to thecharging coil terminal as shown.

Positive tester probe →→→→→ green/white Negative tester probe →→→→→ black/red

• Measure the source coil resistance.

Source coil resistance720 ~ 1080 Ω at 20°C(between brown/black andgreen/white)

• Is the source coil OK?

IGNITION SYSTEMEAS00749

7.Main switch

• Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.

• Is the main switch OK?

EAS00748

8.Pickup coil resistance

• Disconnect the pickup coil coupler from thewire harness.

• Connect the pocket tester (Ω X 100) to thepickup coil terminal as shown.

Positive tester probe →→→→→ red/black Negative tester probe →→→→→ green/white

• Measure the pickup coil resistance.

Pickup coil resistance248 ~ 372 Ω at 20°C(between white/red and white/green)

• Is the pickup coil OK?

EAS00754

10. Wiring

• Check the entire ignition system’s wiring.Refer to “CIRCUIT DIAGRAM”.

• Is the ignition system’s wiring properly con-nected and without defects?

Replace the ignitionunit. (CDI unit)

Replace the stator. Properly connect orrepair the ignition sys-tem’s wiring.

YES NO

YES NO

Replace the mainswitch.

YESNO

GW

WL

BR

WR

BR

GW

WR

WL

GW

BRWR

WL

YES NO

Replace the stator.

ELEC

8-11

EAS00755

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

Main switch Fuse (main) Battery Starter relay Starter motor A Starter switch Front brake stop switch Rear brake stop switch21 Relay32 Anti-theft alarm (option)

ELECTRIC STARTING SYSTEM

23

13

A

B21

5

G

21

32

25

PN K O L MR

27

26

29

19 20

16H

28

12

2217

8

F

18

11

30

10

6

79

35J

24

3

4

31

C DE

F

33

34

14 15

G

B

LW

LW

(NATURAL)

RW

BB

L

L

P

CLO

CK

OD

OM

ET

ER

LW

P

B R - W W

Y

LW

LGY

ON

Br BR BW

HANDLE SWITCH 2

HANDLESWITCH 1

LGW BRGW

WL

BR

W

Br Br

B

WR

CHECK

GR

Br OrBr

YB

Or

B YB

B

B

Br

Gy

OPENOFF

ONRBr

GyR

BW

Br

Br

R

Gy

L

R

LOCK

L

B

R

L

B

Or

YRR

L

Br

Gy

NO-CONNECTION

Y

GR

Ch

PG

BrWBY

DgLB Ch BrW

Dg

P

B

GY

LY

LB

-BW L

BW

L

GYY

GY

L

Br

LB

L

Br

L

GY

LB

L

Dg

Br

LR

B

B

B

B

B

Or

WL

WR

GW

B Y G

BR

(BLACK)

(BLACK)

Dg

Ch

Ch

LW

LW

LW

LW

Dg

Ch

Br Br

G

Ch Ch

LW

R

B

LW

LW

Dg

BR

NO-CONNECTIONBr

Ch

GW

WR

WL

NO-CONNECTION

B

NO-CONNECTION

(RED)

NO-CONNECTION

B

NO-CONNECTION

METERASSY.

Br

R

ANTI-THEFT

ALARM

(OPTION)

B

Dg

LW

LW

L

R

L

Br

RW

W

HEAD LIGHT ASSY.

Sb

Dg

BNO-CONNECTION

LW

LW

(RED)

L

Ch

G

B

Dg

Y

LW

L

Ch

G

B

Dg

Y

B

L

Y

Br

Y

GY

GY

Br

Br

YBYB

Br

L

LL

Y

Ch

G

DgCh

BWB

LW

B

Dg

Ch

ILLU

MI

Y

R



B

B

RW

TH

ER

MO

. MO

TO

R

TU

RN

L

TU

RN

R

HI B

EA

M

ILLU

MI

FU

EL

ME

TE

R

Br B

r

BrW

Br

W

BW

W W

W

W W

W (1)

Dg

(4)

Y

G

GR

W

W

W

Y

B

Br

Br

RNL

BrW

LW

Ch

LB

P

LO

HIPUSH

OFF

RW

LBBrGY

POS

OFF

START

OFF

LW

R

B

R

R

R

B

LW

BRW

LW

R

Y

B

Dg

GR

Dg

YR

LY

YR

BB

B

B

Ch

B

B

Or

WRWL

L

Y

LY

LYLY

LYLY

LY

LY

LY

LY

GY LBBrW

LY

Y G

BR

Br

L LB

B

Br

B

B

P

Dg

For LW/LWand LY/LY

BrGY

R

Sb

Sb

B

L

B

LY

B

B

LY

B(BLUE) (BLUE)

LY

LW

(OPTION)

BB

B

B

(BLUE)B

B

Ch

B

ELEC

8-12

EAS00739

2.Battery




EAS00757

TROUBLESHOOTING

THE STARTER MOTOR FAILS TO TURN.

Check:1. main fuse2. battery3. starter motor4. starter relay5. main switch6. front/rear brake switch7. starter switch8. wiring (entire starting system)

NOTE:Before troubleshooting, remove the followingpart(-s)1) Side covers2) Box and seatTroubleshoot with the following special tool(-s).


EAS00738

1.Main fuse



Replace the fuse.


• Recharge or replacethe battery.

YES NO

YES NO

EAS00758

3.Starter motor

• Connect the positive battery terminal andstarter motor lead with a jumper lead .

WARNING • A wire that is used as a jumper lead musthave at least the same capacity or moreas that of the battery lead, otherwise thejumper lead may burn.

• This check is likely to produce sparks,therefore make sure nothing flammableis in the vicinity.

• Does the starter motor turn?

Repair or replace thestarter motor.

YES NO


+ -

ELEC

8-13

EAS00761

4.Starter relay

• Disconnect the starter relay coupler from thecoupler.

• Connect the pocket tester (Ω X 1) and battery(12 V) to the starter relay coupler as shown.

Positive battery terminal →→→→→ red/white Negative battery terminal →→→→→ blue/white

Positive tester probe →→→→→ red Negative tester probe →→→→→ red

• Does the starter relay have continuity be-tween red and black when it clicks?

EASM0050

6.Front and Rear brake switch

• Check the front and rear switches for conti-nuity.Refer to “CHECKING THE SWITCHES”.

• Is the front and rear switches OK?

EAS00764

7.Starter switch

• Check the starter switch for continuity.Refer to “CHECKING THE SWITCHES”.

• Is the starter switch OK?

EAS00766

8.Wiring

• Check the entire starting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

• Is the starting system’s wiring properly con-nected and without defects?

Replace the starterrelay.

Replace the front orrear brake switch.

The starting systemcircuit is OK.

YES NO

EAS00749

5.Main switch



YES NO


YES NO

Replace the right han-dlebar switch.

YES NO

Properly connect orrepair the starting sys-tem’s wiring.

YESNO


R

R

LW LW

BRW

ELEC

8-14

EASM0051

STARTER MOTOR

Removing the starter motor Remove/disassemble the parts inthe order listed.

Side covers Refer to “SIDE COVERS AND SEAT”Box and seat section in chapter 3.

1 Starter connector and coupler 1/12 Starter motor fixing bolts/washer 2/23 Starter motor 1

Disassembling the starter motor Starter motor mounting bolts 2 Washers/o-rings 2/2 Starter motor rear cover 1 O-ring 1 Stator assembly 1 Armature assembly 1

STARTER MOTOR


1

2

3

T.R65 Nm (6.5 m.kg)

T.R5 Nm (0.5 m.kg)

ELEC

8-15

Brushes/Springs 2/2 Brush holder/washer 1/1 O-ring 1 Starter motor front cover/O-ring 1/1

For installation/assembly, reverse theremoval/disassembly procedure.

STARTER MOTOR


1

2

3

T.R65 Nm (6.5 m.kg)

T.R5 Nm (0.5 m.kg)

ELEC

8-16

4. Measure:• armature assembly resistances (commutatorand insulation)Out of specification → Replace the startermotor.

a. Measure the armature assembly resistanceswith the pocket tester.


Armature coilCommutator resistance 0.0306 ~ 0.0374 Ω at 20°C

Insulation resistance Above 1 MΩ at 20°C

b. If any resistance is out of specification, re-place the starter motor.

EAS00770

CHECKING THE STARTER MOTOR1. Check:

• commutatorDirt → Clean with 600 grit sandpaper.

2. Measure:• commutator diameter aOut of specification → Replace the startermotor.

Commutator diameter22 mm<Limit>: 21 mm

3. Measure:• mica undercut aOut of specification → Scrape the mica to theproper measurement with a hacksaw bladewhich has been ground to fit the commutator.

Mica undercut1.5 mm

NOTE:The mica of the commutator must be undercutto ensure proper operation of the commutator.

STARTER MOTOR

a

a

ELEC

8-17

5. Measure:• brush length a .Out of specification → Replace the brushesas a set.

Brush length10 mm<Limit>: 3.5 mm

EAS00772

ASSEMBLING THE STARTER MOTOR1. Install:

• Washer• Brush• Brush seat

NOTE:Align the tab on the brush seat with the slot in thestarter motor rear cover.

2. Install:• Armature assembly• Stator assembly• starter motor front cover• starter motor rear cover

NOTE:Align the match marks a on the starter motoryoke with the match marks b on the front andstarter motor rear covers.

6. Measure:• brush spring forceOut of specification → Replace the brushsprings as a set.

Brush spring force5.6 ~ 8.3 N

7. Check:• gear teethDamage/wear → Replace the gear.

8. Check:• bearing• oil sealDamage/wear → Replace the defective part(-s).

STARTER MOTOR

a b

a

ELEC

8-18

3. Install:• O-rings • washers• starter motor mounting bolts• stater motor fixing bolts

STARTER MOTOR

T.R 5 Nm (0.5m•kg)

T.R 65 Nm (6.5m•kg)

ELEC

8-19

EAS00773

CHARGING SYSTEMCIRCUIT DIAGRAM

CDI magneto Fuse (main) Battery Rectifier/regulator

CHARGING SYSTEM

23

13

A

B21

5

G

21

32

25

PN K O L MR

27

26

29

19 20

16H

28

12

2217

8

F

18

11

30

10

6

79

35J

24

3

4

31

C DE

F

33

34

14 15

G

B

LW

LW

(NATURAL)

RW

BB

L

L

P

CLO

CK

OD

OM

ET

ER

LW

P

B R - W W

Y

LW

LGY

ON

Br BR BW

HANDLE SWITCH 2

HANDLESWITCH 1

LGW BRGW

WL

BR

W

Br Br

B

WR

CHECK

GR

Br OrBr

YB

Or

B YB

B

B

Br

Gy

OPENOFF

ONRBr

GyR

BW

Br

Br

R

Gy

L

R

LOCK

L

B

R

L

B

Or

YRR

L

Br

Gy

NO-CONNECTION

Y

GR

Ch

PG

BrWBY

DgLB Ch BrW

Dg

P

B

GY

LY

LB

-BW L

BW

L

GYY

GY

L

Br

LB

L

Br

L

GY

LB

L

Dg

Br

LR

B

B

B

B

B

Or

WL

WR

GW

B Y G

BR

(BLACK)

(BLACK)

Dg

Ch

Ch

LW

LW

LW

LW

Dg

Ch

Br Br

G

Ch Ch

LW

R

B

LW

LW

Dg

BR

NO-CONNECTIONBr

Ch

GW

WR

WL

NO-CONNECTION

B

NO-CONNECTION

(RED)

NO-CONNECTION

B

NO-CONNECTION

METERASSY.

Br

R

ANTI-THEFT

ALARM

(OPTION)

B

Dg

LW

LW

L

R

L

Br

RW

W

HEAD LIGHT ASSY.

Sb

Dg

BNO-CONNECTION

LW

LW

(RED)

L

Ch

G

B

Dg

Y

LW

L

Ch

G

B

Dg

Y

B

L

Y

Br

Y

GY

GY

Br

Br

YBYB

Br

L

LL

Y

Ch

G

DgCh

BWB

LW

B

Dg

Ch

ILLU

MI

Y

R



B

B

RW

TH

ER

MO

. MO

TOR

TU

RN

L

TU

RN

R

HI B

EA

M

ILLU

MI

FU

EL

ME

TE

R

Br B

r

BrW

Br

W

BW

W W

W

W W

W (1)

Dg

(4)

Y

G

GR

W

W

W

Y

B

Br

Br

RNL

BrW

LW

Ch

LB

P

LO

HIPUSH

OFF

RW

LBBrGY

POS

OFF

START

OFF

LW

R

B

R

R

R

B

LW

BRW

LW

R

Y

B

Dg

GR

Dg

YR

LY

YR

BB

B

B

Ch

B

B

Or

WRWL

L

Y

LY

LYLY

LYLY

LY

LY

LY

LY

GY LBBrW

LY

Y G

BR

Br

L LB

B

Br

B

B

P

Dg

For LW/LWand LY/LY

BrGY

R

Sb

Sb

B

L

B

LY

B

B

LY

B(BLUE) (BLUE)

LY

LW

(OPTION)

BB

B

B

(BLUE)B

B

Ch

B

ELEC

8-20

EAS00738

1.Main fuse



Replace the fuse.

EAS00774

TROUBLESHOOTING

THE BATTERY IS NOT BEING CHARGED.

Check:1. main fuse2. battery3. charging voltage4. stator coil resistance5. wiring (of the entire charging system)

NOTE:Before troubleshooting, remove the followingpart(s):1) Side covers2) Box and seatTroubleshoot with the following special tool(s).

Engine tachometer90890-03113


YES NO



EAS00739

2.Battery




YES NO

EAS00775

3.Charging voltage

• Connect the engine tachometer to the sparkplug lead of the cylinder.

• Connect the pocket tester (DC V 20) to thebattery as shown.

Positive tester probe →→→→→ positive batteryterminal

Negative tester probe →→→→→negative batteryterminal

• Start the engine and let it run at approxi-mately 5,000 r/min.

• Measure the charging voltage.

Charging voltagemeasured voltage - terminal14 V at 5,000 r/min

CHARGING SYSTEM

- +

ELEC

8-21

EAS00776

4.Stator coil resistance

• Disconnect the stator coil coupler from thewire harness.

• Connect the pocket tester (Ω x 1) to the statorcoils assembly coupler as shown.

Positive tester probe →→→→→ white Negative tester probe →→→→→ white

Positive tester probe →→→→→ white Negative tester probe →→→→→ white

• Measure the stator coil resistances.

Stator coil resistance0.6 ~ 0.9 Ω at 20°C

• Is the stator coil OK?

EAS00779

5.Wiring connections

• Check the wiring connections of the entirecharging system.Refer to “CIRCUIT DIAGRAM”.

• Is the charging system’s wiring properly con-nected and without defects?

Replace the stator coilassembly.

Properly connect orrepair the chargingsystem’s wiring.

Replace the rectifier/regulator.

NOTE:Make sure the battery is fully charged.

• Is the charging voltage within specification?

YESNO

The charging circuitis OK.

YES NO

YESNO

CHARGING SYSTEM

1 2

3

W W

W

ELEC

8-22

LIGHTING SYSTEMEAS00780

LIGHTING SYSTEMCIRCUIT DIAGRAM

Main switch Fuse (main) Battery B Light switch E Flasher switch F Headlight Tail/stop light22 K Meter light

23

13

A

B21

5

G

21

32

25

PN K O L MR

27

26

29

19 20

16H

28

12

2217

8

F

18

11

30

10

6

79

35J

24

3

4

31

C DE

F

33

34

14 15

G

B

LW

LW

(NATURAL)

RW

BB

L

L

P

CLO

CK

OD

OM

ET

ER

LW

P

B R - W W

Y

LW

LGY

ON

Br BR BW

HANDLE SWITCH 2

HANDLESWITCH 1

LGW BRGW

WL

BR

W

Br Br

B

WR

CHECK

GR

Br OrBr

YB

Or

B YB

B

B

Br

Gy

OPENOFF

ONRBr

GyR

BW

Br

Br

R

Gy

L

R

LOCK

L

B

R

L

B

Or

YRR

L

Br

Gy

NO-CONNECTION

Y

GR

Ch

PG

BrWBY

DgLB Ch BrW

Dg

P

B

GY

LY

LB

-BW L

BW

L

GYY

GY

L

Br

LB

L

Br

L

GY

LB

L

Dg

Br

LR

B

B

B

B

B

Or

WL

WR

GW

B Y G

BR

(BLACK)

(BLACK)

Dg

Ch

Ch

LW

LW

LW

LW

Dg

Ch

Br Br

G

Ch Ch

LW

R

B

LW

LW

Dg

BR

NO-CONNECTIONBr

Ch

GW

WR

WL

NO-CONNECTION

B

NO-CONNECTION

(RED)

NO-CONNECTION

B

NO-CONNECTION

METERASSY.

Br

R

ANTI-THEFT

ALARM

(OPTION)

B

Dg

LW

LW

L

R

L

Br

RW

W

HEAD LIGHT ASSY.

Sb

Dg

BNO-CONNECTION

LW

LW

(RED)

L

Ch

G

B

Dg

Y

LW

L

Ch

G

B

Dg

Y

B

L

Y

Br

Y

GY

GY

Br

Br

YBYB

Br

L

LL

Y

Ch

G

DgCh

BWB

LW

B

Dg

Ch

ILLU

MI

Y

R



B

B

RW

TH

ER

MO

. MO

TO

R

TU

RN

L

TU

RN

R

HI B

EA

M

ILLU

MI

FU

EL

ME

TE

R

Br B

r

BrW

Br

W

BW

W W

W

W W

W (1)

Dg

(4)

Y

G

GR

W

W

W

Y

B

Br

Br

RNL

BrW

LW

Ch

LB

P

LO

HIPUSH

OFF

RW

LBBrGY

POS

OFF

START

OFF

LW

R

B

R

R

R

B

LW

BRW

LW

R

Y

B

Dg

GR

Dg

YR

LY

YR

BB

B

B

Ch

B

B

Or

WRWL

L

Y

LY

LYLY

LYLY

LY

LY

LY

LY

GY LBBrW

LY

Y G

BR

Br

L LB

B

Br

B

B

P

Dg

For LW/LWand LY/LY

BrGY

R

Sb

Sb

B

L

B

LY

B

B

LY

B(BLUE) (BLUE)

LY

LW

(OPTION)

BB

B

B

(BLUE)B

B

Ch

B

ELEC

8-23

EAS00781

TROUBLESHOOTING

ANY OF THE FOLLOWING FAIL TOLIGHT: HEADLIGHT, HIGH BEAMINDICATOR LIGHT, TAILLIGHT,AUXILIARY LIGHT OR INSTRUMENTLIGHT .

Check:1. main fuse2. battery3. main switch4. lighting switch5. dimmer switch6. wiring (of the entire lighting system)

NOTE:Before troubleshooting, remove the followingpart(s):1)Side covers2)Box and seat3)Front cover and handlebar coversTroubleshoot with the following special tool(s).


EAS00738

1.Main fuse

• Check the main fuse for continuity.• Refer to “CHECKING THE FUSES” in chap-ter 3.


Replace the fuse.

YES NO



EAS00739

2.Battery




YES NO

EAS00749

3.Main switch



YES NO


EAS00783

4.Lighting switch

• Check the lighting switch for continuity.Refer to “CHECKING THE SWITCHES”.

• Is the lighting switch OK?

YES NO

The lighting switch isfaulty. Replace theright handlebarswitch.

LIGHTING SYSTEM

ELEC

8-24

LIGHTING SYSTEMEAS00784

5.Hi/Lo beam switch

• Check the Hi/Lo beam switch for continuity.Refer to “CHECKING THE SWITCHES”.

• Is the Hi/Lo beam switch OK?

EAS00787

6.Wiring (of the entire lighting system)

• Check the entire lighting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

• Is the lighting system’s wiring properly con-nected and without defects?

EAS00788

CHECKING THE LIGHTING SYSTEM1. The headlight and the high beam indicator

light fail to come on.

1.Headlight bulb and socket

• Check the headlight bulb and socket forcontinuity.

• Are the headlight bulb and socket OK?

YES NO

The Hi/Lo beamswitch is faulty.Replace the lefthandlebar switch.

YESNO

Check the conditionof each of the lightingsystem’s circuits.Refer to “CHECKINGTHE LIGHTINGSYSTEM”.

Properly connect orrepair the lightingsystem’s wiring.

YES NO

2.Voltage

• Connect the pocket tester (DC V 20) to theheadlight and high beam indicator light cou-plers as shown.

A When the dimmer switch is set to “ ”B When the dimmer switch is set to “ ”

• Headlight coupler (wire harness side)

HeadlightPositive tester probe →

yellow or green Negative tester probe →

black High beam indicator light

Positive tester probe → yellow Negative tester probe → black

Replace the headlightbulb, socket or both.

L

Br

BrG

YDg

Ch

B

L

Ch

G

B

Dg

Y

Y G

B

A B

ELEC

8-25

• Meter light coupler (wire harness side)• Set the main switch to “ON”.• Set the light switch to “ ”.• Set the dimmer switch to “ ” or “ ”.• Measure the voltage (12 V) of green on theheadlight coupler (wire harness side).

• Is the voltage within specification?

EAS00789

2. The meter light fails to come on.

1.Meter light bulb and socket

• Check the meter light bulb and socket forcontinuity.

• Are the meter light bulb and socket OK?

YESNO

This circuit is OK.The wiring circuit fromthe main switch to theheadlight coupler isfaulty and must berepaired.

2.Voltage

• Connect the pocket tester (20 V) to the meterlight coupler (wire harness side) as shown.

Positive tester probe → blue Negative tester probe → black

• Set the main switch to “ON”.• Set the light switch to “ ” or “ ”.• Measure the voltage (12 V) of blue on themeter light coupler (wire harness side).


YES NO

Replace the meterlight bulb, socket orboth.

YESNO

This circuit is OK.The wiring circuit fromthe main switch to themeter light coupler isfaulty and must berepaired.

LIGHTING SYSTEM

L

P

B

L

Br

YDg Ch

G

METERASSY.

SbGR

YDg

Ch

BR

Br

ELEC

8-26

EAS00790

3. The tail/brake light fails to come on.

1.Tail/brake light bulb and socket

• Check the tail/brake light bulb and socket forcontinuity.

• Are the tail/brake light bulb and socket OK?

YES NO

Replace the tail/brakelight bulb, socket orboth.

LIGHTING SYSTEM

2.Voltage

• Connect the pocket tester (DC V 20) to thetail/brake light coupler (wire harness side) asshown.


• Set the main switch to “ON”.• Set the light switch to “ ” or “ ”.• Measure the voltage (12 V) of blue on thetail/brake light coupler (tail/brake light side).


YESNO

This circuit is OK.The wiring circuit fromthe main switch to thetail/brake light coupleris faulty and must berepaired.

B

L

B

Y

EAS00791

4. The front postion light fails to come on.

1.Auxiliary light bulb and socket

• Check the auxiliary light bulb and socket forcontinuity.

Refer to "CHECKING THE BULBS ANDBULB SOCKET".• Are the auxiliary light bulb and socket OK?

YES NO

Replace the auxiliarylight bulb, socket orboth.

2.Voltage

• Connect the pocket tester (DC V 20) to theauxiliary light coupler (wire harness side) asshown.


• Set the main switch to “ON”.• Set the light switch to “ ” or “ ”.• Measure the voltage (12 V) of blue on theauxiliary light coupler (wire harness side).


YESNO

This circuit is OK.The wiring circuit fromthe main switch to theauxiliary lightconectors is faulty andmust be repaired.

L

B

ELEC

8-27

SIGNALING SYSTEMEAS00793

SIGNALING SYSTEMCIRCUIT DIAGRAM

23

13

A

B21

5

G

21

32

25

PN K O L MR

27

26

29

19 20

16H

28

1222

17

8

F

18

11

30

10

6

79

35J

24

3

4

31

C DE

F

33

34

14 15

G

B

LW

LW

(NATURAL)

RW

BB

L

L

P

CLO

CK

OD

OM

ET

ER

LW

P

B R - W W

Y

LW

LGY

ON

Br BR BW

HANDLE SWITCH 2

HANDLESWITCH 1

LGW BRGW

WL

BR

W

Br Br

B

WR

CHECK

GR

Br OrBr

YB

Or

B YB

B

B

Br

Gy

OPENOFF

ONRBr

GyR

BW

Br

Br

R

Gy

L

R

LOCK

L

B

R

L

B

Or

YRR

L

Br

Gy

NO-CONNECTION

Y

GR

Ch

PG

BrWBY

DgLB Ch BrW

Dg

P

B

GY

LY

LB

-BW L

BW

L

GYY

GY

L

Br

LB

L

Br

L

GY

LB

L

Dg

Br

LR

B

B

B

B

B

Or

WL

WR

GW

B Y G

BR

(BLACK)

(BLACK)

Dg

Ch

Ch

LW

LW

LW

LW

Dg

Ch

Br Br

G

Ch Ch

LW

R

B

LW

LW

Dg

BR

NO-CONNECTIONBr

Ch

GW

WR

WL

NO-CONNECTION

B

NO-CONNECTION

(RED)

NO-CONNECTION

B

NO-CONNECTION

METERASSY.

Br

R

ANTI-THEFT

ALARM

(OPTION)

B

Dg

LW

LW

L

R

L

Br

RW

W

HEAD LIGHT ASSY.

Sb

Dg

BNO-CONNECTION

LW

LW

(RED)

L

Ch

G

B

Dg

Y

LW

L

Ch

G

B

Dg

Y

B

L

Y

Br

Y

GY

GY

Br

Br

YBYB

Br

L

LL

Y

Ch

G

DgCh

BWB

LW

B

Dg

Ch

ILLU

MI

Y

R



B

B

RW

TH

ER

MO

. MO

TO

R

TU

RN

L

TU

RN

R

HI B

EA

M

ILLU

MI

FU

EL

ME

TE

R

Br B

r

BrW

Br

W

BW

W W

W

W W

W (1)

Dg

(4)

Y

G

GR

W

W

W

Y

B

Br

Br

RNL

BrW

LW

Ch

LB

P

LO

HIPUSH

OFF

RW

LBBrGY

POS

OFF

START

OFF

LW

R

B

R

R

R

B

LW

BRW

LW

R

Y

B

Dg

GR

Dg

YR

LY

YR

BB

B

B

Ch

B

B

Or

WRWL

L

Y

LY

LYLY

LYLY

LY

LY

LY

LY

GY LBBrW

LY

Y G

BR

Br

L LB

B

Br

B

B

P

Dg

For LW/LWand LY/LY

BrGY

R

Sb

Sb

B

L

B

LY

B

B

LY

B(BLUE) (BLUE)

LY

LW

(OPTION)

BB

B

B

(BLUE)B

B

Ch

B

ELEC

8-28

SIGNALING SYSTEM

Main switch Fuse (main) Battery C Horn switch

E Turn signal switch H Left front flasher

J Right front flasher Left rear flasher Right rear flasher Tail/stop light Horn Flasher relay22 P Coolant thermo indicator light

N Fuel sender indicatorR Clock and odometerL Flasher light indicatorM Flasher light indicator

23 Sender

ELEC

8-29

EAS00794

TROUBLESHOOTING

ANY OF THE FOLLOWING FAIL TOLIGHT: FLASHER LIGHT, BRAKE LIGHTOR AN INDICATOR LIGHT.THE HORN FAILS TO SOUND.

Check:1. main fuse2. battery3. main switch4. wiring (of the entire signalling system)


1) Side covers2) Box and seat3) Battery cover• Troubleshoot with the following special tool(s).


EAS00738

1.Main fuse



Replace the fuse.



YES NO

EAS00739

2.Battery




YES NO

EAS00749

3.Main switch



YES NO


SIGNALING SYSTEM

EAS00795

4.Wiring

• Check the entire signal system’s wiring.Refer to “CIRCUIT DIAGRAM”.

• Is the signalling system’s wiring properlyconnected and without defects?

YESNO

Check the conditionof each of the signal-ling system’s circuits.Refer to “CHECKINGTHE SIGNALLINGSYSTEM”.

Properly connect orrepair the signallingsystem’s wiring.

ELEC

8-30


CHECKING THE SIGNALING SYSTEM

1. The horn fails to sound.

1.Horn switch

• Check the horn switch for continuity.Refer to “CHECKING THE SWITCHES”.

• Is the horn switch OK?

3.Horn

• Disconnect the pink connector at the hornterminal.

• Connect a jumper lead to the horn terminaland ground the jumper lead.

• Set the main switch to “ON”.• Does the horn sound?

YES NO

2.Voltage

• Connect the pocket tester (DC V 20) to thehorn connector at the horn terminal as shown.

Positive tester probe →→→→→ pink Negative tester probe →→→→→ ground

• Set the main switch to “ON”.• Push the horn switch.• Measure the voltage (12 V) of brown at thehorn terminal.


Replace the lefthandlebar switch.

YES NO

The wiring circuit fromthe main switch to thehorn connector isfaulty and must berepaired.

YESNO

The horn is OK.

4.Voltage

• Connect the pocket tester (DC V 20) to thehorn connector at the black terminal as shown.

Positive tester probe →→→→→ brown Negative tester probe →→→→→ ground

• Set the main switch to “ON”.• Measure the voltage (12 V) of brown at thehorn terminal.


YESNO

Repair or replace thehorn.

Replace the horn.

Br P

Br P

ELEC

8-31


2. The tail/brake light fails to come on.

1.Tail/brake light bulb and socket

• Check the tail/brake light bulb and socket forcontinuity.

• Are the tail/brake light bulb and socket OK?

EAS00799

3. The turn signal light, turn signal indicator lightor both fail to blink.

1.Turn signal indicator light bulb and socket

• Check the turn signal light bulb and socketfor continuity.

• Are the turn signal light bulb and socket OK?

YES NO

Replace the tail/brakelight bulb, socket orboth.

2.Brake light switches

• Check the brake light switches for continuity.Refer to “CHECKING THE SWITCHES”.

• Is the brake light switch OK?

YES NO

Replace the brakelight switch.

3.Voltage

• Connect the pocket tester (DC V 20) to thetail/brake light coupler (wire harness side) asshown.

Positive tester probe → yellow Negative tester probe → black

• Set the main switch to “ON”.• Pull in the brake levers.• Measure the voltage (12 V) of yellow onthe tail/brake light coupler (wire harness side).


YESNO

This circuit is OK.The wiring circuit fromthe main switch to thetail/brake light coupleris faulty and must berepaired.

YES NO

Replace the turn sig-nal light bulb, socketor both.

2.Turn signal switch

• Check the turn signal switch for continuity.Refer to “CHECKING THE SWITCHES”.

• Is the turn signal switch OK?

YES NO

Replace the left han-dlebar switch.

B

L

B

Y

ELEC

8-32

SIGNALING SYSTEM

3.Voltage

• Connect the pocket tester (DC V 20) to theflasher relay coupler (wire harness side) asshown.

Positive tester probe → brown Negative tester probe → ground

• Set the main switch to “ON”.• Measure the voltage (12 V) on brown atthe turn signal relay coupler (wire harnessside).


YES NO

The wiring circuit fromthe main switch to theturn signal relaycoupler is faulty andmust be repaired.

4.Voltage

• Connect the pocket tester (DC V 20) to theflasher relay coupler (wire harness side) asshown.

Positive tester probe → brown/white Negative tester probe → ground

• Set the main switch to “ON”.• Set the turn signal switch to “ ” or “ ”.• Measure the voltage (12 V) on brown/white

at the turn signal relay coupler (wire har-ness side).


YES NO

The turn signal relayis faulty and must bereplaced.

5.Voltage

• Connect the pocket tester (DC V 20) to theturn signal light connector as shown.

A Turn signal light B Turn signal indicator light

Left turn signal light Positive tester probe → chocolate Negative tester probe → ground Right turn signal light Positive tester probe → dark green Negative tester probe → ground

• Set the main switch to “ON”.• Set the turn signal switch to “ ” or “ ”.• Measure the voltage (12 V) of the chocolate

or dark green at the turn signal lightconnector (wire harness side).


YESNO

This circuit is OK.The wiring circuit fromthe turn signal switchto the turn signal lightconnector is faultyand must be repaired.

Br

BrW

Br

BrW

B

Br

BrW

Br

BrW

B

ELEC

8-33

SIGNALING SYSTEMEASM0052

4. The Coolant temperature warning light failsto come on.

1.Coolant temperature warning light bulb andsocket

• Check the coolant temperature warning lightbulb and socket for continuity.

• Are coolant temperature warning light bulband socket OK?

EAS00804

5. The fuel level gauge fails to operate.

1.Fuel sender

• Remove the fuel sender from the fuel tank.• Connect the pocket tester to the fuel sendercoupler (wire harness side) as shown.

Positive tester probe → green Negative tester probe → black

• Measure the fuel sender resistances.

Fuel sender resistance(up position)

(Ω x 1)1.5 ~ 7.5 Ω at 20°C

Fuel sender resistance(down position)

(Ω x 10)90 ~ 100 Ω at 20°C

• Is the fuel sender OK?

YES NO

Replace the coolanttemperature warninglight bulb, socket orboth.

YES NO

Replace the fuelsender.

ELEC

8-34

SIGNALING SYSTEM

2.Voltage

• Connect the pocket tester (DC V 20) to themeter light coupler (wire harness side) .

Positive tester probe → brownNegative tester probe → black

• Set the main switch to “ON”.• Measure the voltage (12 V) of brown on themeter light coupler (wire harness side).


YES NO

Check the wiringconnections of theentire signalingsystem.

3.Fuel level gauge

• Set the main switch to “ON”.• Move the float up or down.• Check that the fuel level gauge needle movesto up or down.

NOTE:Before reading the fuel level gauge, leave thefloat in one position (either up or down) for atleast three minutes.

• Does the fuel level gauge needle move ap-propriately?

YES NO

Replace the speedo-meter unit.

4.Wiring

• Check the entire signal system’s wiring.Refer to “CIRCUIT DIAGRAM”.

• Is the signalling system’s wiring properlyconnected and without defects?

YESNO

Check the conditionof each of the signal-ling system’s circuits.Refer to “CHECKINGTHE SIGNALLINGSYSTEM”.

Properly connect orrepair the signallingsystem’s wiring.

ELEC

8-35


6. The clock/odometer fails to come on.

1.Voltage

• Connect the pocket tester (DC V 20) to theclock/odometer coupler (wire harness side)as shown.

Positive tester probe → red Negative tester probe → ground

• Set the main switch to “ON”.• Measure the voltage (12 V).• Is the voltage within specification?

YES NO

The wiring circuit fromthe main switch to theclock coupler is faultyand must be repaired.

2.Clock

• Check that the clock is operating properly.• When setting the clock after its power sourcehas been disconnected (e.g., when the bat-tery is removed), first set the clock to 1:00 AMand then to the correct time.

• Is the clock operating properly?

YESNO

This circuit is OK.Replace the clock/odometer.

L

P

B

L

Br

YDg Ch

G

SbGR

YDg

Ch

B

BR

Br

ELEC

8-36

COOLING SYSTEMEAS00807

COOLING SYSTEMCIRCUIT DIAGRAM

Main switch Fuse (main) Battery26 Thermo fan switch27 Fan28 Coolant thermo switch29 Fan Fuse

23

13

A

B21

5

G

21

32

25

PN K O L MR

27

26

29

19 20

16H

28

1222

17

8

F

18

11

30

10

6

79

35J

24

3

4

31

C DE

F

33

34

14 15

G

B

LW

LW

(NATURAL)

RW

BB

L

L

P

CLO

CK

OD

OM

ET

ER

LW

P

B R - W W

Y

LW

LGY

ON

Br BR BW

HANDLE SWITCH 2

HANDLESWITCH 1

LGW BRGW

WL

BR

W

Br Br

B

WR

CHECK

GR

Br OrBr

YB

Or

B YB

B

B

Br

Gy

OPENOFF

ONRBr

GyR

BW

Br

Br

R

Gy

L

R

LOCK

L

B

R

L

B

Or

YRR

L

Br

Gy

NO-CONNECTION

Y

GR

Ch

PG

BrWBY

DgLB Ch BrW

Dg

P

B

GY

LY

LB

-BW L

BW

L

GYY

GY

L

Br

LB

L

Br

L

GY

LB

L

Dg

Br

LR

B

B

B

B

B

Or

WL

WR

GW

B Y G

BR

(BLACK)

(BLACK)

Dg

Ch

Ch

LW

LW

LW

LW

Dg

Ch

Br Br

G

Ch Ch

LW

R

B

LW

LW

Dg

BR

NO-CONNECTIONBr

Ch

GW

WR

WL

NO-CONNECTION

B

NO-CONNECTION

(RED)

NO-CONNECTION

B

NO-CONNECTION

METERASSY.

Br

R

ANTI-THEFT

ALARM

(OPTION)

B

Dg

LW

LW

L

R

L

Br

RW

W

HEAD LIGHT ASSY.

Sb

Dg

BNO-CONNECTION

LW

LW

(RED)

L

Ch

G

B

Dg

Y

LW

L

Ch

G

B

Dg

Y

B

L

Y

Br

Y

GY

GY

Br

Br

YBYB

Br

L

LL

Y

Ch

G

DgCh

BWB

LW

B

Dg

Ch

ILLU

MI

Y

R



B

B

RW

TH

ER

MO

. MO

TO

R

TU

RN

L

TU

RN

R

HI B

EA

M

ILLU

MI

FU

EL

ME

TE

R

Br B

r

BrW

Br

W

BW

W W

W

W W

W (1)

Dg

(4)

Y

G

GR

W

W

W

Y

B

Br

Br

RNL

BrW

LW

Ch

LB

P

LO

HIPUSH

OFF

RW

LBBrGY

POS

OFF

START

OFF

LW

R

B

R

R

R

B

LW

BRW

LW

R

Y

B

Dg

GR

Dg

YR

LY

YR

BB

B

B

Ch

B

B

Or

WRWL

L

Y

LY

LYLY

LYLY

LY

LY

LY

LY

GY LBBrW

LY

Y G

BR

Br

L LB

B

Br

B

B

P

Dg

For LW/LWand LY/LY

BrGY

R

Sb

Sb

B

L

B

LY

B

B

LY

B(BLUE) (BLUE)

LY

LW

(OPTION)

BB

B

B

(BLUE)B

B

Ch

B

ELEC

8-37

COOLING SYSTEMEAS00808

TROUBLESHOOTING

• The radiator fan motor fails to turn.• The water temperature warning lightfails to light up when the engine is warm.

Check:1. main and radiator fan motor fuses2. battery3. main switch4. radiator fan motor5. thermo switch6. wiring connections

(the entire cooling system)

NOTE:• Before troubleshooting, remove the followingpart(-s):

1) Side covers2) Box and seat3) Battery cover4) Front cover• Troubleshoot with the following special tool (-s).


EASM0053

1. The radiator fan motor fails to turn.

1.Main and radiator fan motor fuses

• Check the fuses for continuity.Refer to “CHECKING THE FUSES” inchapter 3.

• Are the fuses OK?



EAS00739

2.Battery




YES NO

EAS00749

3.Main switch



YES NO


EAS00809

4.Radiator fan motor

• Disconnect the radiator fan motor couplerfrom the wire harness.

• Connect the battery (12 V) as shown.

Positive battery lead → black Negative battery lead → blue

Replace the fuses.

YES NO

ELEC

8-38

COOLING SYSTEM

EAS00811

6.Thermo switch

• Remove the thermo switch from the radiator.• Connect the pocket tester (Ω x 1) to thethermo switch as shown.

• Immerse the thermo switch in a containerfilled with coolant.

• Place a thermometer in the coolant.• Slowly heat the coolant, then let it cool downto the specified temperature.

• Check the thermo switch for continuity at thetemperatures indicated below.

A Thermo switch circuit “ON” B Thermo switch circuit “OFF”

• Does the thermo switch operate properly asdescribed above?

• Does the radiator fan motor turn?

YES NO

The radiator fan motoris faulty and must bereplaced.

WARNING • Handle the thermo switch with special

care.• Never subject the thermo switch to

strong shocks. If the thermo switch isdropped, replace it.

YES NO

Replace the thermoswitch.

B

A

EAS00813

7.Wiring

• Check the entire cooling system’s wiring.Refer to “CIRCUIT DIAGRAM”.

•Is the cooling system’s wiring properly con-nected and without defects?

YESNO

This circuit is OK.Properly connect orrepair the cooling sys-tem’s wiring.

EASM0053

2. The water temperature warning light fails tolight up when the engine is warm.

1.Main fuse

• Check the fuse for continuity.Refer to “CHECKING THE FUSES” inchapter 3.

• is the fuse OK?

Replace the fuse.

YES NO

ELEC

8-39

COOLING SYSTEM



EAS00739

2.Battery




YES NO

EAS00749

3.Main switch



YES NO


EAS00812

4.Temperature sender

• Remove the temperature sender from theradiator.Connect the pocket tester (Ω x 10) to thetemperature sender.

• Immerse the temperature sender in a con-tainer filled with coolant.

NOTE:Make sure the thermo switch terminals do notget wet.

• Place a thermometer in the coolant.• Slowly heat the coolant, and then let it coolto the specified temperature indicated in thetable.

• Check the thermo switch for continuity at thetemperatures indicated in the table.

Temperature sender resistance80°C: 47.5 ~ 56.8 Ω100°C: 26.2 ~ 29.3 Ω

WARNING • Handle the temperature sender with

special care.• Never subject the temperature sender to

strong shocks. If the temperature senderis dropped, replace it.

A Thermo switch circuit is open and thetemperature warning light is “OFF”

B Thermo switch circuit is closed and thetemperature warning light is “ON”

• Does the temperature sender operate prop-erly?

YES NO

Replace the tempera-ture sender.

EAS00813

5.Wiring (of the entire cooling system).

• Check the entire cooling system’s wiring.Refer to “CIRCUIT DIAGRAM”.

•Is the cooling system’s wiring properly con-nected and without defects?

YESNO

This circuit is OK.Properly connect orrepair the cooling sys-tem’s wiring.

ELEC

8-40

CARBURETOR HEATING SYSTEMEAS00820

CARBURETOR HEATING SYSTEMCIRCUIT DIAGRAM

Main switch Fuse (main) Battery30 Carburetor heater switch31 Carburetor heater

23

13

A

B21

5

G

21

32

25

PN K O L MR

27

26

29

19 20

16H

28

12

2217

8

F

18

11

30

10

6

79

35J

24

3

4

31

C DE

F

33

34

14 15

G

B

LW

LW

(NATURAL)

RW

BB

L

L

P

CLO

CK

OD

OM

ET

ER

LW

P

B R - W W

Y

LW

LGY

ON

Br BR BW

HANDLE SWITCH 2

HANDLESWITCH 1

LGW BRGW

WL

BR

W

Br Br

B

WR

CHECK

GR

Br OrBr

YB

Or

B YB

B

B

Br

Gy

OPENOFF

ONRBr

GyR

BW

Br

Br

R

Gy

L

R

LOCK

L

B

R

L

B

Or

YRR

L

Br

Gy

NO-CONNECTION

Y

GR

Ch

PG

BrWBY

DgLB Ch BrW

Dg

P

B

GY

LY

LB

-BW L

BW

L

GYY

GY

L

Br

LB

L

Br

L

GY

LB

L

Dg

Br

LR

B

B

B

B

B

Or

WL

WR

GW

B Y G

BR

(BLACK)

(BLACK)

Dg

Ch

Ch

LW

LW

LW

LW

Dg

Ch

Br Br

G

Ch Ch

LW

R

B

LW

LW

Dg

BR

NO-CONNECTIONBr

Ch

GW

WR

WL

NO-CONNECTION

B

NO-CONNECTION

(RED)

NO-CONNECTION

B

NO-CONNECTION

METERASSY.

Br

R

ANTI-THEFT

ALARM

(OPTION)

B

Dg

LW

LW

L

R

L

Br

RW

W

HEAD LIGHT ASSY.

Sb

Dg

BNO-CONNECTION

LW

LW

(RED)

L

Ch

G

B

Dg

Y

LW

L

Ch

G

B

Dg

Y

B

L

Y

Br

Y

GY

GY

Br

Br

YBYB

Br

L

LL

Y

Ch

G

DgCh

BWB

LW

B

Dg

Ch

ILLU

MI

Y

R



B

B

RW

TH

ER

MO

. MO

TOR

TU

RN

L

TU

RN

R

HI B

EA

M

ILLU

MI

FU

EL

ME

TE

R

Br B

r

BrW

Br

W

BW

W W

W

W W

W (1)

Dg

(4)

Y

G

GR

W

W

W

Y

B

Br

Br

RNL

BrW

LW

Ch

LB

P

LO

HIPUSH

OFF

RW

LBBrGY

POS

OFF

START

OFF

LW

R

B

R

R

R

B

LW

BRW

LW

R

Y

B

Dg

GR

Dg

YR

LY

YR

BB

B

B

Ch

B

B

Or

WRWL

L

Y

LY

LYLY

LYLY

LY

LY

LY

LY

GY LBBrW

LY

Y G

BR

Br

L LB

B

Br

B

B

P

Dg

For LW/LWand LY/LY

BrGY

R

Sb

Sb

B

L

B

LY

B

B

LY

B(BLUE) (BLUE)

LY

LW

(OPTION)

BB

B

B

(BLUE)B

B

Ch

B

ELEC

8-41


TROUBLESHOOTING

The carburetor heating system fails tooperate.

Check:1. Main fuse2. Battery3. Main switch4. Thermo switch5. Carburetor heater6. Wiring (of the entire carburetor heating system)


1) Side covers2) Box and seat3) Battery cover• Troubleshoot with the following special tool(s).


EAS00738

1.Main fuse



Replace the fuse.

YES NO



EAS00739

2.Battery




YES NO

EAS00749

3.Main switch



YES NO


ELEC

8-42


4. Thermo switch

• Disconnect the thermo switch from the wireharness.

• Connect the pocket tester (Ω x 1) to thethermo switch lead.

Positive tester probe → black Negative tester probe → black

EAS00824

5.Carburetor heater

• Remove the carburetor heating element fromthe carburetor.

• Connect the pocket tester (Ω x 1) to thecarburetor heating element.

Positive tester probe →→→→→ heating element Negative tester probe → heating element

body

EAS00826

6. Wiring (of the entire carburetor heating system)

• Check the entire carburetor heating sys-tem’s wiringRefer to “CIRCUIT DIAGRAM”

• Is the carburetor heating system properlyconnected and without defects?

YES NO

Replace the thermoswitch.

YES NO

Replace the carbu-retor heating element.

YESNO

This circuit is OK.Properly connect orrepair the carburetorheating system’s wir-ing.

• Check the thermo switch for continuity at thetemperatures indicated below.

8¡C – 4¡C 19¡C – 3¡C

A COOL DOWNB HEAT UP

• Does the thermo switch operated properly ?

• Measure the carburetor heater resistance.

Carburetor heating elementresistance:

6 ~ 12 Ω at 20°C

• Is the carburetor heating element OK?

9TRBLSHTG

CHAPTER 9.TROUBLESHOOTING

STARTING FAILURE/ HARD STARTING ....................................................9-1ENGINE ...................................................................................................9-1FUEL SYSTEM ........................................................................................9-1ELECTRICAL SYSTEMS .........................................................................9-2

INCORRECT ENGINE IDLING SPEED .........................................................9-2ENGINE ...................................................................................................9-2FUEL SYSTEM ........................................................................................9-2ELECTRICAL SYSTEMS .........................................................................9-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ...............................9-2ENGINE ...................................................................................................9-2FUEL SYSTEM ........................................................................................9-2

FAULTY CLUTCH .........................................................................................9-3ENGINE OPERATES BUT SCOOTER WILL NOT MOVE ......................9-3CLUTCH SLIPS .......................................................................................9-3POOR STARTING PERFORMANCE ......................................................9-3POOR SPEED PERFORMANCE ............................................................9-3

OVER HEATING ............................................................................................9-3ENGINE ...................................................................................................9-3COOLING SYSTEM .................................................................................9-3FUEL SYSTEM ........................................................................................9-3CHASSIS .................................................................................................9-3ELECTRICAL SYSTEMS .........................................................................9-3

OVERCOOLING ............................................................................................9-4COOLING SYSTEM .................................................................................9-4

POOR BRAKING ...........................................................................................9-4

FAULTY FRONT FORK LEGS ......................................................................9-4LEAKING OIL ...........................................................................................9-4MALFUNCTION .......................................................................................9-4

TRBLSHTG

UNSTABLE HANDLING ................................................................................9-5

FAULTY LIGHTING OR SIGNALING SYSTEM ............................................9-5HEADLIGHT DOES NOT LIGHT .............................................................9-5HEADLIGHT BULB BURNT OUT ............................................................9-5TAIL/BRAKE LIGHT DOES NOT LIGHT .................................................9-5TAIL/BRAKE LIGHT BULB BURNT OUT ................................................9-5TURN SIGNAL DOES NOT LIGHT ..........................................................9-5TURN SIGNAL BLINKS SLOWLY ...........................................................9-5TURN SIGNAL REMAINS LIT .................................................................9-6TURN SIGNAL BLINKS QUICKLY ..........................................................9-6HORN DOES NOT SOUND .....................................................................9-6

TRBLSHTG

TRBLSHTG

9-1

STARTING FAILURE/HARD STARTINGEAS00845

TROUBLESHOOTINGNOTE:The following guide for troubleshooting does not cover all the possible causes of trouble. It should behelpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manualfor checks, adjustments, and replacement of parts.

ENGINECylinder and cylinder head• Loose spark plug• Loose cylinder head or cylinder• Damaged cylinder head gasket• Damaged cylinder base gasket• Worn or damaged cylinder• Incorrect valve clearance• Improperly sealed valve• Incorrect valve-to-valve-seat contact• Incorrect valve timing• Faulty valve spring• Seized valvePiston and piston ring(s)• Improperly installed piston ring• Damaged, worn or fatigued piston ring• Seized piston ring• Seized or damaged pistonAir filter• Improperly installed air filter• Clogged air filter elementCrankcase and crankshaft• Improperly assembled crankcase• Seized crankshaft

STARTING FAILURE/HARD STARTINGFUEL SYSTEMFuel tank• Empty fuel tank• Clogged fuel tank cap breather hole• Deteriorated or contaminated fuel• Clogged or damaged fuel hoseCarburetor• Deteriorated or contaminated fuel• Clogged pilot jet• Clogged pilot air passage• Sucked-in air• Damaged float• Worn needle valve• Improperly installed needle valve seat• Incorrect fuel level• Improperly adjusted pilot air screw• Improperly installed pilot jet• Clogged starter jet• Clogged emulsion tubeAutochoke unit• Faulty starter plunger• Faulty ignitor unit• Faulty thermo switch

TRBLSHTG

9-2

STARTING FAILURE/HARD STARTING/INCORRECT ENGINE IDLING SPEED/

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

ELECTRICAL SYSTEMSBattery• Improperly charged battery• Faulty batteryFuse(s)• Blown, damaged or incorrect fuse• Improperly installed fuseSpark plug• Incorrect spark plug gap• Incorrect spark plug heat range• Fouled spark plug• Worn or damaged electrode• Worn or damaged insulator• Faulty spark plug capIgnition coil• Broken or shorted primary or secondary coils• Faulty spark plug lead• Cracked or broken ignition coil body

Ignition system• Faulty ignition unit• Faulty pickup coil• Broken generator rotor woodruff key/slippedtiming

Switches and wiring• Faulty main switch• Broken or shorted wiring• Faulty front, rear or both brake switches• Faulty start switch• Improperly grounded circuit• Loose connectionsStarting system• Faulty starter motor• Faulty starter relay• Faulty starter clutch

EAS00847

INCORRECT ENGINE IDLING SPEEDENGINECylinder and cylinder head• Incorrect valve clearance• Damaged valve train componentsAir filter• Clogged air filter element

FUEL SYSTEMCarburetor• Faulty starter plunger• Loose or clogged pilot jet• Loose or clogged pilot air jet• Damaged or loose carburetor joint• Improperly adjusted engine idling speed(throttle stop screw)

• Improper throttle cable free play• Flooded carburetorAutochoke unit• Faulty starter plunger• Faulty ignitor unit

EAS00848

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCERefer to “STARTING FAILURE/HARD STARTING” section.ENGINEAir filter• Clogged air filter element

FUEL SYSTEMCarburetor• Faulty diaphragm• Incorrect fuel level• Loose or clogged main jet

ELECTRICAL SYSTEMSBattery• Discharged battery• Faulty batterySpark plug• Incorrect spark plug gap• Incorrect spark plug heat range• Fouled spark plug• Worn or damaged electrode• Worn or damaged insulator• Faulty spark plug capIgnition coil• Faulty spark plug leadIgnition system• Faulty ignitor unit• Faulty pickup coil

TRBLSHTG

9-3

FAULTY CLUTCH/OVERHEATING

ENGINE OPERATES BUT SCOOTER WILLNOT MOVEV-belt• Bent, damaged or worn V-belt• Slipping V-beltPrimary pulley cam and primary pulley slider• Damaged or worn primary pulley cam• Damaged or worn primary pulley sliderClutch spring(s)• Damaged clutch springTransmission gear(s)• Damaged transmission gear

CLUTCH SLIPSClutch shoe spring(s)• Damaged, loose or worn clutch shoe springClutch shoe(s)• Damaged or worn clutch shoePrimary sliding sheave• Seized primary sliding sheave

EAS00853

FAULTY CLUTCH

EAS00855

OVERHEATINGENGINEClogged coolant passagesCylinder head and piston• Heavy carbon buildupEngine oil• Incorrect oil level• Incorrect oil viscosity• Inferior oil quality

COOLING SYSTEMCoolant• Low coolant levelRadiator• Leaking coolant system• Damaged or leaking radiator• Faulty radiator cap• Bent or damaged radiator finWater pump• Damaged or faulty water pumpThermostat• Thermostat stays closed

FUEL SYSTEMCarburetor• Incorrect main jet setting• Incorrect fuel level• Damaged or loose carburetor jointAir filter• Clogged air filter element

CHASSISBrake(s)• Dragging brake

ELECTRICAL SYSTEMSSpark plug• Incorrect spark plug gap• Incorrect spark plug heat rangeIgnition system• Faulty ignition unit

POOR STARTING PERFORMANCEV-belt• V-belt slips• Oil or grease on the V-beltPrimary sliding sheave• Faulty operation• Worn pin groove• Worn pinClutch shoe(s)• Bent, damaged or worn clutch shoe

POOR SPEED PERFORMANCEV-belt• Oil or grease on the V-beltPrimary pulley weight(s)• Faulty operation• Worn primary pulley weightPrimary fixed sheave• Worn primary fixed sheavePrimary sliding sheave• Worn primary sliding sheaveSecondary fixed sheave• Worn secondary fixed sheaveSecondary sliding sheave• Worn secondary sliding sheave

TRBLSHTG

9-4

OVERCOOLING/POOR BRAKING/

FAULTY FRONT FORK LEGSEAS00856

OVERCOOLINGCOOLING SYSTEM• Thermostat• Thermostat stays open

EAS00859

POOR BRAKINGDisc brake• Worn brake pad• Worn brake disc• Air in hydraulic brake system• Leaking brake fluid• Faulty brake caliper kit• Faulty brake caliper seal• Loose union bolt• Damaged brake hose• Oil or grease on the brake disc• Oil or grease on the brake pad• Incorrect brake fluid level

Drum brake• Worn brake shoe• Worn or rusty brake drum• Incorrect brake camshaft lever position• Incorrect brake shoe position• Damaged or fatigued brake shoe spring• Oil or grease on the brake shoe• Oil or grease on the brake drum• Broken brake torque rod• Improper brake lever adjustement

EAS00860

FAULTY FRONT FORK LEGSLEAKING OIL• Bent, damaged or rusty inner tube• Cracked or damaged outer tube• Improperly installed oil seal• Damaged oil seal lip• Incorrect oil level (high)• Loose damper rod assembly bolt• Damaged damper rod assembly bolt copperwasher

• Cracked or damaged cap bolt O-ring• Loose drain bolt• Damaged drain bolt gasket

MALFUNCTION• Bent or damaged inner tube• Bent or damaged outer tube• Damaged fork spring• Worn or damaged outer tube• Bent or damaged damper rod• Incorrect oil viscosity• Incorrect oil level

TRBLSHTG

9-5

UNSTABLE HANDLING/FAULTY LIGHTING OR SIGNALING SYSTEM

EAS00862

UNSTABLE HANDLINGHandlebar• Bent or improperly installed handlebarSteering head components• Improperly installed lower bracket(improperly tightened ring nut)

• Bent steering stem• Damaged ball bearing or bearing racFront fork leg(s)• Uneven oil levels (both front fork legs)• Unevenly tensioned fork spring (both front forklegs)

• Broken fork spring• Bent or damaged inner tube• Bent or damaged outer tubeSwingarm• Worn bearing or bushing• Bent or damaged swingarm

Rear shock absorber assembly• Faulty rear shock absorber spring• Leaking oil or gasTyres• Uneven tyre pressures (front and rear)• Incorrect tyre pressure• Uneven tyre wearWheels• Incorrect wheel balance• Deformed cast wheel• Damaged wheel bearing• Bent or loose wheel axle• Excessive wheel runoutFrame• Bent frame• Damaged steering head pipe• Improperly installed bearing race

HEADLIGHT DOES NOT LIGHT• Wrong headlight bulb• Too many electrical accessories• Hard charging• Incorrect connection• Improperly grounded circuit• Poor contacts (main or light switch)• Burnt-out headlight bulb

HEADLIGHT BULB BURNT OUT• Wrong headlight bulb• Faulty battery• Faulty rectifier/regulator• Improperly grounded circuit• Faulty main switch• Faulty light switch• Headlight bulb life expired

TAIL/BRAKE LIGHT DOES NOT LIGHT• Wrong tail/brake light bulb• Too many electrical accessories• Incorrect connection• Burnt-out tail/brake light bulb

TAIL/BRAKE LIGHT BULB BURNT OUT• Wrong tail/brake light bulb• Faulty battery• Incorrectly adjusted rear brake light switch• Tail/brake light bulb life expired

TURN SIGNAL DOES NOT LIGHT• Faulty turn signal switch• Faulty turn signal relay• Burnt-out turn signal bulb• Incorrect connection• Damaged or faulty wire harness• Improperly grounded circuit• Faulty battery• Blown, damaged or incorrect fuse

TURN SIGNAL BLINKS SLOWLY• Faulty turn signal relay• Faulty main switch• Faulty turn signal switch• Incorrect turn signal bulb• Faulty charging circuit

EAS00866

FAULTY LIGHTING OR SIGNALING SYSTEM

TRBLSHTG

9-6

TURN SIGNAL REMAINS LIT• Faulty turn signal relay• Burnt-out turn signal bulb

TURN SIGNAL BLINKS QUICKLY• Incorrect turn signal bulb• Faulty turn signal relay• Burnt-out turn signal bulb

HORN DOES NOT SOUND• Improperly adjusted horn• Damaged or faulty horn• Faulty main switch• Faulty horn switch• Faulty battery• Blown, damaged or incorrect fuse• Faulty wire harness

FAULTY LIGHTING OR SIGNALING SYSTEM

23

13

A

B21

5

G

21

32

25

PN K O L MR

27

26

29

19 20

16H

28

12

2217

8

F

18

11

30

10

6

79

35J

24

3

4

31

C DE

F

33

34

14 15

27

26

25

24

23

P

O

N

M

L

14

K

15

16

28

29

30

31

32

22

21

J

H

G

F

13

20

19

18

1

2

3

4

5

6

7

8

9

10

11

A

17

33

E

D

C

12

B

34

R

35

G

B

LW

LW

(NATURAL)

RW

BB

L

FAN

L

TH. SWITCH FAN

TH.SWITCH AUTO CHOKE

AUTO CHOKE

SENDER

P

CLO

CK

OD

OM

ET

ER

LW

P

TH. WATER INDICATOR

HIGH BEAM INDICATOR 12V-1.2W

FUEL METER

FLASHER INDICATOR L 12V-1.2W

FLASHER INDICATOR R 12V-1.2W

RR FLASHER L 12V-10W

FR FLASHER R 12V-21W

FR FLASHER L 12V-21W

POSITION LAMP 12V-5W

B

HEAD LIGHT 2X12V-35X35W

HEAD LIGHT ASSY.

R

METER LIGHT 2X12V-1.2W

- W W

Y

LW

LGY

ON

Br BR BW

HANDLE SWITCH 2

HANDLESWITCH 1

L

GW BRGW

WL

BR

W

Br Br

CDI MAGNETO

B

RR FLASHER R 12V-10W

TAIL/STOP LIGHT 12V-5/21W

HORN

TH. SWITCH WATER

FUSE FAN

TH.SWITCH CARB.HEATER

CARB.HEATER

ANTI THEFT UNIT ( OPTION )

WR

METER ASSY.

RELAY

REAR STOP SWITCH

FRONT STOP SWITCH

CHECK

GR

CDI UNIT

IGN COIL

SPARK PLUG

MAIN SWITCH ASSY.

FUSE(MAIN)

BATTERY

RECTIFIER/REGULATOR

STARTER RELAY

STARTING MOTOR

HANDLE SWITCH (2)

STARTER SWITCH

Br OrBr

YB

Or

B YB

FLASHER RELAY

B

B

Br

Gy

OPENOFF

ONRBr

GyR

BW

Br

Br

R

Gy

L

R

LOCK

L

B

R LIGTING SWITCH

L

B

Or

YRR

L

Br

Gy

NO-CONNECTION

Y

GR

Ch

PG

BrWBY

DgLB Ch BrW

Dg

P

B

GY

LY

LB

-BW L

BW

L

GYY

GY

L

Br

LB

L

Br

L

GY

LB

L

Dg

Br

LR

B

B

B

B

B

Or

WL

WR

GW

B Y G

BR

(BLACK)

(BLACK)

Dg

Ch

Ch

LW

LW

LW

LW

Dg

Ch

Br Br

G

Ch Ch

LW

R

B

LW

LW

Dg

BR

NO-CONNECTIONBr

Ch

GW

WR

WL

NO-CONNECTION

B

NO-CONNECTION

(RED)

NO-CONNECTION

B

NO-CONNECTION

METERASSY.

Br

R

ANTI-THEFT

ALARM

(OPTION)

B

Dg

LW

LW

L

R

L

Br

RW

W

HEAD LIGHT ASSY.

Sb

Dg

BNO-CONNECTION

LW

LW

(RED)

L

Ch

G

B

Dg

Y

LW

L

Ch

G

B

Dg

Y

B

L

Y

Br

Y

GY

GY

Br

Br

YBYB

Br

L

LL

Y

Ch

G

DgCh

BWB

LW

B

Dg

Ch

ILLU

MI

Y

R

WIRE LEAD ONANTI-THEFT 1 et 4

WIRE LEAD ON SIDE STAND

SENSOR SPEED

B

B

RW

TH

ER

MO

. MO

TO

R

TU

RN

L

TU

RN

R

HI B

EA

M

ILLU

MI

FU

EL

ME

TE

R

Br B

rBrW

Br

W

BW

W W

W

W W

W (1)

Dg

(4)

Y

G

GR

W

W

W

Y

B

FLASHER SWITCH

Br

DIMMER SWITCH

HORN SWITCH

HANDLE SWITCH (1)

Br

RNL

BrW

LW

Ch

LB

P

LO

HIPUSH

OFF

RW

LBBrGY

POS

OFF

START

OFF

LW

R

B

R

R

R

B

LW

BRW

LW

R

Y

B

Dg

GR

Dg

YR

LY

YR

BB

B

B

Ch

B

B

Or

WRWL

L

Y

LY

LYLY

LYLY

LY

LY

LY

LY

GY LBBrW

LY

Y G

BR

Br

L LB

B

Br

B

B

P

SIDE STAND SW. ( OPTION )

Dg

For LW/LWand LY/LY

BrGY

R

Sb

Sb

B

L

B

LY

B

B

LY

B(BLUE) (BLUE)

LY

LW

(OPTION)

BB

B

B

(BLUE)B

B

Ch

BLED ( OPTION )

CLOCK AND ODOMETER

XN125-150 WIRING DIAGRAM COLOR CODEB ............. black Sb ........... sky blue G / R ....... green / red R / L ....... red / blueBr ............ brown W ............ white G / W ...... green / white R / W ...... red / whiteCh........... chocolate Y ............. yellow G / Y ....... green / yellow R / Y ....... red / yellowDg........... dark green B / L ........ brack / blue L / B ........ blue / black W / B ...... white / blackG ............ green B / R ....... brack / red L / R ....... blue / red W / G ...... white / greenGy........... gray B / W ...... black / white L / W ....... blue / white W / Y ....... white / yellowL ............. blue B / Y ........ black / yellow L / Y ........ blue / yellow Y / B ....... yellow / blackO ............ orange Br / L ...... brown / blue O / R ....... orange / red Y / L ........ yellow / blueP ............. pink Br / R ...... brown / red R / B ....... red / blackR............. red Br / W ..... brown / white R / G ....... red / green

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