Manual de Taller YAMAHA BWS YW50X MANUAL TALLER 2008

2008

MOTORCYCLE

SERVICE MANUAL

Model : YW50X_

5PNF81972100

*5PNF81972100*

EAS00000

YW50X 2007

SUPPLEMENTARY SERVICE MANUAL

First edition, June 2007

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Taiwan Co., Ltd.

is expressly prohibited.

Printed in CANADA

FORWORD

This supplementary service manual has been prepared to introduce new service and data for YW50BP

2001. For complete service manual procedures it is necessary to use this supplementary service

manual together with the following manual.

YW50BP 2001 SERVICE MANUAL : 5PN1-ME1

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha

dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in

one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

Yamaha Motor Taiwan Company, Ltd. is continually striving to improve all of its models. Modifications

and significant changes in specifications or procedures will be forwarded to all authorized Yamaha

dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death

to the scooter operator, a bystander or a person checking or repairing the

scooter.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the scooter.

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

NOTE:

w

cC

Q

4-3

ENG

CYLINDER HEAD, CYLINDER AND PISTON

Job name/Part name

Cylinder head, Cylinder and piston

removal

Engine

Muffler/Gasket

Air shroud 2

Spark plug

Cylinder head/Cylinder head gasket

Cylinder

Piston pin clip

Piston pin/ Bearing

Piston

Piston ring set

Cylinder gasket

Remarks

Remove the parts in the order.

Refer to the “ENGINE REMOVAL” sec-

tion

Reverse the removal procedure for in-

stallation.

Order

1

2

3

4

5

6

7

8

9

10

Q’ty

1/1

1

1/1

1

2

1/1

1

4

5

6

7

10

1

2

3

26Nm(2.6 m.kg, 18.2 ft.lb)

T

R

.

14Nm(1.4 m.kg, 10 ft.lb)

T

R

.

9Nm(0.9 m.kg,6.5 ft.lb)

T

R

.

New

E

8

9

CYLINDER HEAD, CYLINDER AND PISTON

4-4

ENG

PISTON PIN AND PISTON REMOVAL

1. Remove:

8 Piston pin clip 1

NOTE:

Before removing the piston pin clip, cover the

crankcase with a clean rag so you will not acci-

dentally drop the clip into the crankcase.

2. Remove:

8 Piston pin 1

8 Piston 2

8 Piston pin bearing 3

cC

Do not use a hammer to drive the piston pin

out.

CYLINDER HEAD INSPECTION

1. Eliminate:

8 Carbon deposits

Use a rounded scrapper 1.

2. Inspect:

8 Cylinder head warpage

Out of specification∅Re-surface.

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

Warpage measurement and re-surfacement

steps:

8 Attach a straight edge 1 and a thickness

gauge 2 on the cylinder head.

8 Measure the warpage limit.

Warpage limit:

0.03 mm(0.0012 in)

8 If the warpage is out of specification, reface

the cylinder head.

NOTE:

Rotate the head severai tires to avoid remov-

ing too much material from one side.

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

CYLINDER HEAD, CYLINDER, PISTON

2

1

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

2 Each chapter is divided into sections. 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.

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

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates

a disassembly step.

6 Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described se-

quentially.

8

4

5

7

1

3

26

GEN

INFO

SPEC

CHK

ADJ

ENG

TRBL

SHTG

CHAS

-+

ELEC

4

M

B

LS

New

M

G

COOL

12

34

56

78

90

qw

er

i

s

hj

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1 to 9 indicate the subject of each

chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Chassis

5 Engine

6 Cooling system

7 Carburetor

8 Electrical system

9 Troubleshooting

Symbols 0 to u indicate the following.

0 Serviceable with engine mounted

q Filling fluid

w Lubricant

e Special tool

r Tightening torque

t Wear limit, clearance

y Engine speed

u Electrical data

Symbols i to g in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

i Engine oil

o Gear oil

p Molybdenum-disulfide oil

a Brake fluid

s Wheel-bearing grease

d Lithium-soap- based grease

f Molybdenum-disulfide grease

g Silicone grease

Symbols h to j in the exploded diagrams indi-

cate the following.

h Apply locking agent (LOCTITE

®

)

j Replace the part

T

R

.

t y u

LT

CARB

BF

opa

S

dfg

EAS00010

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

CARBURETOR

GEN

INFO

SPEC

CHK

ADJ

CARB

1

2

3

4

5

6

5

7

8

9

1-8

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

SCOOTER IDENTIFICATION ................................................................... 1-1

VEHICLE IDENTIFICATION NUMBER ............................................. 1-1

MODEL LABEL .................................................................................. 1-1

IMPORTANT INFORMATION ................................................................... 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY ................... 1-2

REPLACEMENT PARTS ................................................................... 1-2

GASKETS, OIL SEALS AND O-RINGS ............................................ 1-2

LOCK WASHERS/PLATES AND COTTER PINS ............................. 1-3

BEARINGS AND OIL SEALS ............................................................ 1-3

CIRCLIPS ........................................................................................... 1-3

CHECKING THE CONNECTIONS ........................................................... 1-4

SPECIAL TOOLS ...................................................................................... 1-5

1-1

GEN

INFO

1

SCOOTER IDENTIFICATION

EAS00015

GENERAL INFORMATION

SCOOTER IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped

into the frame.

EAS00018

MODEL LABEL

The model label 1 is affixed to the seat. This

information will be needed to order spare parts.

1-2

GEN

INFO

IMPORTANT INFORMATION

EAS00020

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISAS-

SEMBLY

1. Before removal and disassembly, remove

all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to the “SPECIAL TOOLS”.

3. When disassembling, always keep mated

parts together. This includes gears, cylin-

ders, pistons and other parts that have been

“mated” through normal wear. Mated parts

must always be reused or replaced as an

assembly.

4. During disassembly, clean all of the parts

and place them in trays in the order of dis-

assembly. This will speed up assembly and

allow for the correct installation of all parts.

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

EAS00021

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace-

ments. Use oil and grease recommended by

Yamaha for all lubrication jobs. Other brands may

be similar in function and appearance, but infe-

rior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-

faces, oil seal lips and O-rings must be

cleaned.

2. During reassembly, properly oil all mating

parts and bearings and lubricate the oil seal

lips with grease.

1-3

GEN

INFO

IMPORTANT INFORMATION

EAS00023

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

1 and cotter pins. After the bolt or nut has been

tightened to specification, bend the lock tabs

along a flat of the bolt or nut.

EAS00024

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the

manufacturer’s marks or numbers are visible.

When installing oil seals, lubricate the oil seal

lips with a light coat of lithium-soap-based

grease. Oil bearings liberally when installing, if

appropriate.

1 Oil seal

cC

Do not spin the bearing with compressed

air because this will damage the bearing

surfaces.

1 Bearing

EAS00025

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips. Al-

ways replace piston pin clips after one use. When

installing a circlip 1, make sure the sharp-edged

corner 2 is positioned opposite the thrust 3

that the circlip receives.

4 Shaft

1-4

GEN

INFO

CHECKING THE CONNECTIONS

EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for

stains, rust, moisture, etc.

1. Disconnect:

8lead

8coupler

8connector

2. Check:

8lead

8coupler

8connector

Moisture Dry with an air blower.

Rust/stains Connect and disconnect

several times.

3. Check:

8all connections

Loose connection Connect properly.

NOTE:

If the pin 1 on the terminal is flattened, bend it

up.

4. Connect:

8lead

8coupler

8connector

NOTE:

Make sure all connections are tight.

5. Check:

8continuity

(with the pocket tester)

Pocket tester

90890-03112(YU-03112-C)

NOTE:

8 If there is no continuity, clean the terminals.

8 When checking the wire harness, perform

steps (1) to (3).

8 As a quick remedy, use a contact revitalizer

available at most part stores.

1-5

GEN

INFO

Tool NO.

Tool name / Function Illustration

SPECIAL TOOLS

EAS00027

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use

only the appropriate special tools as this will help prevent damage caused by the use of inappropri-

ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the

country.

When placing an order, refer to the list provided below to avoid any mistakes.

NOTE:

8 For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

8 For others, use part number starting with “90890-”.

Rotor holding tool

This tool is used to hold the generator rotor

when removing or installing and generator

rotor bolt.

Clutch spring holder

These tool are used for removing the nut with

holding the compression spring.

Crankshaft installer set 1

Adapter 2

These tools are used to install the crank-

shaft.

Flywheel puller

This tool is used to remove the generator

rotor.

Crankcase separating tool

This tool is used to remove the crankshaft

or separate the crankcase.

Oil seal guide

This tool is used for protecting the oil seal

lip when installing the secondary sliding

sheave.

Steering nut wrench

This tool is used to loosen and tighten the

steering ring nut.

Sheave holder

This tool is used for holding the secondary

sheave.

90890-01235

YU-01235

90890-01337

YM-33285

YM-33285-6

90890-01284

YU-90050

90890-01383

YU-90062

90890-01189

YU-01189

90890-01135

YU-01135-B

90890-01384

YM-33299

90890-01403

YU-A9472

90890-01701

YS-01880-A

1

2

1-6

GEN

INFO

Tool NO.

Tool name / Function Illustration

SPECIAL TOOLS

90890-06760

90890-03112

YU-03112-C

90890-01409

YM-01409

90890-01410

YM-01410

90890-06754

YM-34487

90890-85505

ACC-11001-05-01

90890-01348

YM-01348

90890-01268

YU-01268

90890-01367

YM-A9409-7

90890-01400

YM-A9409-3

90890-01326

YM-01326

90890-01294

YM-01300-1

Digital tachometer

This tool is needed for detecting engine rpm.

Pocket tester

This instrument is invaluable for checking

the electrical system.

Oil seal guide

This tool is used to install the left side crank-

case oil seal.

Oil seal installer

This tool is used to install the left side crank-

case oil seal.

Ignition checker

This tool is used to check the ignition sys-

tem components.

Yamaha bond NO.1215

Sealant (Quick Gasket ®)

This sealant (bond) is used on crankcase

mating surfaces (e.g., crankcase mating

surfaces).

Locknut wrench

This tool is used when removing or install-

ing the secondary sheave nut.

Ring nut wrench

This tool is used to loosen and tighten the

steering ring nut.

Fork seal driver weight 1

Fork seal driver attachment 2

These tools are used when installing the fork

seal.

T-handle 1

Damper rod holder 2

These tools are used to hold the damper rod

when removing or installing the damper rod.

1

2

1

2

41

46

1-7

GEN

INFO

Tool NO.

Tool name / Function Illustration

SPECIAL TOOLS

90890-01312

YM-01312-A

Fuel level gauge

This gauge is used to measure the fuel le-

ver in the float chamber.

2-23

SPEC

CHAPTER 2

SPECIFICATIONS

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

ENGINE SPECIFICATIONS ..................................................................... 2-2

CHASSIS SPECIFICATIONS ................................................................... 2-6

ELECTRICAL SPECIFICATIONS ............................................................ 2-9

CONVERTION TABLE ............................................................................ 2-12

GENERAL TIGHTENING TORQUE SPECIFICATIONS ....................... 2-12

TIGHTENING TORQUES........................................................................ 2-13

ENGINE ............................................................................................ 2-13

CHASSIS.......................................................................................... 2-14

LUBRICATION POINTS AND LUBRICANT TYPES............................. 2-16

ENGINE ............................................................................................ 2-16

CHASSIS.......................................................................................... 2-17

CABLE ROUTING .................................................................................. 2-18

2-1

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard Limit

GENERAL SPECIFICATIONS

Model

Code 5PJ5 (USA) …

5PN6 (CAN) …

Dimensions

Overall length 1890mm (74.41in) …

Overall width 705mm (27.76in) …

Overall height 1110mm (43.70in) …

Seat height 765mm (30.12in) …

Wheelbase 1275mm (50.20in) …

Minimum ground clearance 120mm (4.72in) …

Minimum turning radius 1800mm (70.87in) …

Weight

Wet (without oil and a full fuel tank) 94kg (207lb) …

Dry (without oil and fuel) 90kg (198lb) …

Maximun load (total of cargo, rider, 143kg (315lb) …

passenger, and accessories)

2-2

SPEC

Engine

Engine type Air-cooled 2-stroke reed valve …

Displacement 0.049L (49cm³, 2.99cu-in) …

Cylinder arrangement Forward inclined single cylinder …

Bore × stroke 40.0 × 39.2mm (1.57 × 1.54in) …

Compression ratio 7.01:1 …

Engine idle speed 1800 ~ 1900r/min …

Fuel

Recommended fuel Unleaded gasoline only (USA) …

Regular unleaded gasoline …

only (CAN)

Fuel tank capacity

Total 5.7L (1.25 Imp gal, 1.50 US gal) …

Engine oil

Lubrication system Separate lubrication …

Recommended oil YAMALUBE 2 or air cooled …

2-stroke engine oil

Quantity

Oil tank 1.4L (1.23 Imp qt, 1.48 US qt) …

Final gear oil

Recommended oil SAE85W140 hypoid gear oil …

Periodic oil change 0.11L (0.10 Imp qt, 0.12 US qt) …

Total amount 0.13L (0.12 Imp qt, 0.14 US qt) …

Air filter

Air filter type Wet element …

Starting system type Electric and kick starter …

Carburetor

Type Y14P-13E …

Manufacturer TEIKEI …

Spark plug

Model (manufacturer) × quantity BPR7HS (NGK ) × 1 …

Spark plug gap 0.6 ~ 0.7mm (0.024 ~ 0.028in) …

Cylinder head

Volume 5.54 ~ 5.84cm³ …

(0.34 ~ 0.36cu-in)

Maximum warpage … 0.05mm

(0.0020in)

* Lines indicate straighedge measurement

ENGINE SPECIFICATIONS

Item

Standard Limit

ENGINE SPECIFICATIONS

2-3

SPEC

Item

Standard

Limit

ENGINE SPECIFICATIONS

Cylinder

Bore 40.000 ~ 40.014mm …

(1.5748 ~ 1.5754in)

Maximum taper … 0.05mm

(0.0020in)

Maximum out-of-round … 0.05mm

(0.0020in)

Piston

Piston-to-cylinder clearance 0.035 ~ 0.040mm 0.10mm

(0.0014 ~ 0.0016in) (0.0039in)

Diameter D 39.960 ~ 39.979mm …

(1.5732 ~ 1.5739in)

Height H 5.0mm (0.1969in) …

Piston pin bore (in the piston)

Diameter 10.004 ~ 10.015mm 10.045mm

(0.3939 ~ 0.3943in) (0.3955in)

Piston pin

Outside diameter 9.996 ~ 10.000mm 9.976mm

(0.3935 ~ 0.3937in) (0.3928in)

Piston rings

Section sketch (B × T)/type

Top ring 1.2 × 1.6mm/keystone …

(0.0472 × 0.0630in)

2nd ring 1.2 × 1.6mm/keystone …

(0.0472 × 0.0630in)

End gap (installed)

Top ring 0.15 ~ 0.35mm 0.6mm

(0.0059 ~ 0.0138in) (0.0236in)

2nd ring 0.15 ~ 0.35mm 0.7mm

(0.0059 ~ 0.0138in) (0.0276in)

Side clearance (installed)

Top ring 0.03 ~ 0.05mm 0.1mm

(0.0012 ~ 0.0020in) (0.0039in)

2nd ring 0.03 ~ 0.05mm 0.11mm

(0.0012 ~ 0.0020in) (0.0043in)

Connecting rod

Connecting rod length 79.9~80.1mm …

(3.1457~3.1535in)

Small end inside diameter 13.996~14.007mm …

(0.5510~0.5515in)

H

D

2-4

SPEC

Item

Standard

Limit

Crankshaft

Width “A” 37.90 ~ 37.95mm …

(1.4921 ~ 1.4941in)

Maximum runout “C” … 0.03mm

(0.0012in)

Big end side clearance “D” 0.20 ~ 0.50mm 1.00mm

(0.0079 ~ 0.0197in) (0.0394in)

Big end radial clearance 0.004 ~ 0.017mm …

(0.0002 ~ 0.0007in)

Small end free play “F” 0.40 ~ 0.80mm …

(0.0157 ~ 0.0315in)

Clutch

Clutch type Automatic centrifugal …

Clutch shoe thickness 2.5mm (0.10in) 1.0mm

(0.04in)

Clutch shoe spring free length 26.2mm (1.03in) …

Clutch housing inside diameter 105mm (4.13in) 105.5mm

(4.15in)

Compression spring free length 65.1mm (2.56in) 61.8mm

(2.43in)

Weight outside diameter 15.0mm (0.59in) 14.5mm

(0.57in)

Clutch - in revolution 2800 ~ 3200r/min …

Clutch - stall revolution 4500 ~ 5500r/min …

V-belt

V-belt width 16.5mm (0.65in) 14.8mm

(0.58in)

Kickstarter

Type Ratchet …

Kick clip tension 0.7 ~ 2N (0.07 ~ 0.2kgf) …

(0.15 ~ 0.44lb)

Transmission

Transmission type V-belt automatic …

Primary reduction system Helical gear …

Primary reduction ratio 52/13 (4.000) …

Secondary reduction system Super gear …

Secondary reduction ratio 43/13(3.307) …

Single speed automatic 2.693 ~ 0.889:1 …

Maximum main axle runout … 0.02mm

(0.0008in)

Maximum drive axle runout … 0.02mm

(0.0008in)

ENGINE SPECIFICATIONS

2-5

SPEC

Item

Standard

Limit

ENGINE SPECIFICATIONS

Carburetor

ID mark 5PJ5 00 …

Main jet (M.J.) # 80 …

Needle jet (N.J.) 2.085 …

Jet needle-clip position (J.N.) 3N24-1/1 …

Main air jet (M.A.J.) 2.0 …

Cutaway (C.A.) 3.0 …

Pilot jet (P.J.) # 44 …

Bypass 0.8 …

Valve seat size (V.S.) 1.8 …

Starter jet (St.J.) 0.45 …

Float height 15 ~ 17mm (0.59 ~ 0.67in) …

Fuel level height 3.0 ~ 4.0mm (0.12 ~ 0.16in) …

Engine idle speed 1800 ~ 1900r/min …

Reed valve

Thickness 0.132 ~ 0.172mm

(0.0052 ~ 0.0068in) …

Valve stopper height 5.9 ~ 6.5mm (0.23 ~ 0.26in) …

Valve bending limit … 0.2mm

(0.0078in)

2-6

SPEC

CHASSIS SPECIFICATIONS

Item

Standard

Limit

Frame

Frame type Steel tube underbone …

Caster angle 26.5° …

Trail 93mm (3.66in) …

Front wheel

Wheel type Cast wheel …

Rim

Size J10 × MT3.50 …

Material Aluminum …

Wheel travel 61mm (2.40in) …

Wheel runout

Maximum radial wheel runout … 1.0mm

(0.04in)

Maximum lateral wheel runout … 1.0mm

(0.04in)

Wheel axle bending limit … 0.45mm

(0.02in)

Rear wheel

Wheel type Cast wheel …

Rim

Size J10 × MT3.50 …

Material Aluminum …

Wheel travel 76mm (2.99in) …

Wheel runout

Maximum radial wheel runout … 1.0mm

(0.04in)

Maximum lateral wheel runout … 0.5mm

(0.02in)

Front tire

Tire type Tubeless …

Size 120/90-10 56J …

Model (manufacturer) C-6022 (CHENG SHIN) …

Tire pressure (cold)

Up to 90kg (198lb) load 200kPa (2.00kgf/cm², 29psi) …

90kg (198lb) load ~ Maximum load* 200kPa (2.00kgf/cm², 29psi) …

Minimum tire tread depth … 0.8mm

(0.03in)

2-7

SPEC

Item

Standard

Limit

CHASSIS SPECIFICATIONS

Rear tire

Tire type Tubeless …

Size 130/90-10 59J …

Model (manufacturer) C-924 (CHENG SHIN) …

Tire pressure (cold)

Up to 90kg (198lb) load 200kPa (2.00kgf/cm², 29psi) …

90kg (198lb) load ~ Maximum load* 200kPa (2.00kgf/cm², 29psi) …

Minimum tire tread depth … 0.8mm

(0.03in)

Front brake

Brake type Single disk brake …

Operation Right-hand operation …

Disk outside diameter × thickness 180 × 4.0mm 180 × 3.5mm

(7.09 × 0.16in) (7.09 × 0.14in)

Pad thickness 4.0mm (0.16in) 0.8mm

(0.03in)

Master cylinder inside diameter 11mm (0.43in) …

Caliper cylinder inside diameter 30.16mm (1.19in) …

Brake fluid type DOT 4 or DOT3 …

Rear brake

Brake type Drum brake …

Operation Left-hand operation …

Brake drum inside diameter 130mm (5.12in) 131mm

(5.16in)

Lining thickness 4.0mm (0.16in) 2.0mm

(0.08in)

Brake lever

Brake lever free play (front lever end) 2 ~ 5mm (0.08 ~ 0.20in) …

Brake lever free play (rear lever end) 10 ~ 20mm (0.39 ~ 0.79in) …

Throttle cable free play 1.5 ~ 3.5mm (0.06 ~ 0.14in) …

2-8

SPEC

CHASSIS SPECIFICATIONS

Item

Standard

Limit

Front suspension

Suspension type Telescopic fork …

Front fork type Coil spring/oil damper …

Front fork travel 70mm (2.76in) …

Spring

Free length 217.1mm (8.55in) 212.8mm

(8.38in)

Installed length 212.1mm (8.35in) …

Spring rate (K1) 15.69N/mm …

(1.60kg/mm, 90lb/in)

Spring rate (K2) 23.8N/mm …

(2.43kg/mm, 136lb/in)

Spring stroke (K1) 0 ~ 40mm (0 ~ 1.57in) …

Spring stroke (K2) 40 ~ 70mm (1.57 ~ 2.76in) …

Optional spring available No …

Fork oil

Recommended oil Fork oil 10W or equivalent …

Quantity (each front fork leg) 0.088L …

(0.084 Imp qt, 0.092 US qt)

Inner tube outer diameter 30mm (1.18in) …

Inner tube bending limit … 0.2mm

(0.01in)

Steering system

Steering bearing type Angular bearing …

Lock-to-lock angle (left) 45° …

Lock-to-lock angle (right) 45° …

Rear suspension

Suspension type Unit swing …

Rear shock absorber assembly type Coil spring / oil damper …

Rear shock absorber assembly travel 55mm (2.17in) …

Spring

Free length 159.8mm (6.29in) …

Installed length 152.8mm (6.02in) …

Spring rate (K1) 71.15N/mm …

(7.26kg/mm, 407lb/in)

Spring stroke (K1) 0 ~ 55mm (0 ~ 2.17in) …

Optional spring available No …

2-9

SPEC

Item

Standard

Limit

ELECTRICAL SPECIFICATIONS

System voltage 12V …

Ignition system

Ignition system type C.D.I. …

Ignition timing 14° BTDC at 5000r/min …

Advancer type Fixed …

Pick coil resistance/color 400 ~ 600Ωat 20°C (68°F)/ …

black - white/red

C.D.I. unit model (manufacturer) 5PJ (T-MORIC) …

Ignition coil

Model (manufacturer) 2JN (T-MORIC) …

Minimum ignition spark gap 6mm (0.24in) …

Primary coil resistance 0.184 ~ 0.276Ω at 20°C (68°F) …

Secondary coil resistance 6.32 ~ 9.48kΩ at 20°C (68°F) …

Spark plug cap

Material Resin …

Resistance 4 ~ 6kΩ at 20°C (68°F) …

Charging system

System type AC magneto …

Model (manufacturer) F5PJ (T-MORIC) …

Nominal output 12V 85W/5000r/min …

Charging current 0.6A at 3000r/min …

1.2A at 8000r/min …

Charging coil resistance/color 0.48 ~ 0.72Ω/white - black …

Lighting voltage 12V at 3000r/min …

15V at 8000r/min …

Lighting coil resistance/color 0.4 ~ 0.6Ω/yellow/red - black …

Source coil resistance/color 640 ~ 960Ω at 20°C (68°F)/ …

black - black/red

Rectifier

Model (manufacturer) SH614-12 (SHIN DEN GEN) …

No load regulated voltage (DC) 14 ~ 15V …

No load regulated voltage (AC) 13 ~ 14V …

Rectifier capacity 8A …

Withstand voltage 18V …

Battery

Battery type (manufacturer) GTX5L-BS (GS) …

Battery voltage/capacity 12V/4AH …

Specific gravity 1.330 …

Ten hour rate amperage 0.4A …

2-10

SPEC

ELECTRICAL SPECIFICATIONS

Item

Standard

Limit

Headlight type Halogen bulb …

Indicator light (voltage/wattage × quantity)

Turn signal indicator light 12V 1.7W × 1 …

High beam indicator light 12V 1.7W × 1 …

Oil level indicator light 12V 1.7W × 1 …

Bulbs (voltage/wattage × quantity)

Headlight 12V 35/35W × 1 …

Tail/brake light 12V 5/21W × 1 …

Front turn signal light 12V 10W × 2 …

Rear turn signal light 12V 10W × 2 …

License plate light 12V 5W × 1 …

Speedometer light 12V 3.4W × 1, 1.7W × 1 …

Electric starting system

System type Constant mesh …

Starter motor

Model (manufacturer) 4WX 01 (SHINLIN) …

Suction voltage 12V …

Power output 0.14kW …

Brushes

Overall length 6.5mm (0.26in) 3.0mm

(0.12in)

Spring force 5.49 ~ 8.24N …

(360 ~ 540gf, 12.69 ~ 19.04oz)

Commutator diameter 16.1mm (0.63in) 15.1mm

(0.59in)

Armature coil resistance 0.063 ~ 0.077Ω at 20°C (68°F) …

Mica undercut (depth) 1.05mm (0.04in) …

Starter relay

Model (manufacturer) 4WX 00 (SHINLIN) …

Amperage 20A …

Coil resistance 54 ~ 66Ω …

Horn

Horn type Plane …

Model (manufacturer) AH-368 (SAKURA) …

Maximum amperage 1.5A …

Performance 95 ~ 105dB/2m …

Coil resistance 4.05 ~ 4.55Ω at 20°C (68°F) …

Turn signal relay

Relay type Condenser …

Model (manufacturer) 5PJ1 (TAYOUNG) …

Self-cancelling device built-in NO …

Turn signal blinking frequency 75 ~ 95cycles/minute …

Wattage 10W × 2 + 1.7W+ AP …

2-11

SPEC

Item

Standard

Limit

ELECTRICAL SPECIFICATIONS

Fuse (amperage × quantity)

Main fuse 7A × 1 …

Fuel sender

Model (manufacturer) 4VP (TATUNG) …

Sender unit resistance - full 4 ~ 10Ω …

Sender unit resistance - empty 90 ~ 100Ω …

Oil lever gauge

Model (manufacturer) 4VP (LUN PING) …

2-12

SPEC

EAS00028

CONVERSION TABLE

All specification data in this manual are listed

in SI and METRIC UNITS.

Use this table to convert METRIC unit data to

IMPERIAL unit data.

CONVERSION TABLE

EAS00030

GENERAL TIGHTENING TORQUE

SPECIFICATIONS

This chart specifies tightening torques for stan-

dard fasteners with a standard ISO thread

pitch. Tightening torque specifications for spe-

cial components or assemblies are provided

for each chapter of this manual. To avoid

warpage, tighten multi-fastener assemblies in

a crisscross pattern and progressive stages

until the specified tightening torque is reached.

Unless otherwise specified, tightening torque

specifications require clean, dry threads. Com-

ponents should be at room temperature.

A: Width across flats

B: Thread diameter

Ex.

METRIC MULTIPLIER IMPERIAL

** mm 0.03937 ** in

2 mm 0.03937 0.08 in

METRIC TO IMPERIAL

Tighten-

ing torque

Metric unit Multiplier Imperial unit

m·kg

cm·kg

7.233

86.794

0.0723

0.8679

ft·lb

in·lb

ft·lb

in·lb

Weight

kg

g

2.205

0.03527

lb

oz

Speed km/hr 0.6214 mph

Distance

km

m

cm

mm

0.6214

3.281

1.094

0.3937

0.03937

mi

ft

yd

in

Volume/

Capacity

cc (cm

3

)

cc (cm

3

)

lt (liter)

0.03527

0.06102

0.8799

0.2199

oz (IMP liq.)

cu-in

qt (IMP liq.)

gal (IMP liq.)

Misc.

kg/mm

kg/cm

2

Centigrade

(°C)

55.997

14.2234

9/5+32

lb/in

psi (lb/in

2

)

Fahrenheit (°F)

A

(nut)

B

(bolt)

General tightening

torques

Nm m•kg ft•lb

10 mm 6 mm 6 0.6 4.3

12 mm 8 mm 15 1.5 11

14 mm 10 mm 30 3.0 22

17 mm 12 mm 55 5.5 40

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13.0 94

CONVERTION TABLE / GENERAL TIGHTENING

TORQUE SPECIFICATIONS

2-13

SPEC

Part to be tightened

Part name

Thread

size

Q

’

ty

Tightening

torque

Nm m•kg ft•lb

Remarks

TIGHTENING TORQUES

ENGINE

2.0

1.4

1.0

0.7

0.2

0.7

0.4

1.1

0.9

0.2

0.9

2.6

1.1

0.9

1.2

0.7

1.8

0.3

0.8

0.9

1.3

4.0

3.0

0.8

3.8

Spark plug

Cylinder head and cylinder

Cylinder

Air shroud 1

Air shroud 1× 2

Fan

Autolube pump

Reed valve

Air filter

Carburetor cap

Exhaust pipe

Muffler

Exhaust protector

Protector

Crankcase 1× 2

Transmission case cover

Crankcase cover 1(left)

Bolt(case2)

Crankcase cover2(left)

Drain bolt

Oil plug

Idle gear plate

Kick crank

Starter motor

Clutch housing

Clutch weight

Magnet base

C.D.I. rotor

—

Nut

Stud bolt

Screw

Bolt

Screw

Bolt

Screw

Bolt

Screw

Bolt

Plug

Screw

Bolt

Nut

Screw

Nut

M 14

M 7

M 6

6.0

M 6

M 5

M 6

M 4

M 6

M 8

M 6

M 8

M 14

M 6

M 10

M 6

M 10

1

4

3

1

3

2

4

2

3

1

6

12

1

3

1

2

1

2

1

2

1

20

14

10

7

2

7

4

11

9

2

9

26

11

9

12

7

18

3

8

9

13

40

30

8

38

14

10

7

5.1

1.4

5.1

2.8

8.0

6.5

1.4

6.5

18.2

8.0

6.5

8.4

5.1

13

22

5.8

6.5

9.4

29

22

5.8

27

LT

2-14

SPEC

Part to be tightened

Thread

size

Tightening

torque

Nm m•kg ft•lb

Remarks

TIGHTENING TORQUES

CHASSIS

8.4

4.5

1.3

3.0

1.6

6.0

2.0

1.0

0.7

0.4

0.7

0.2

0.7

7.0

12.0

1.0

2.3

2.0

2.3

0.6

Frame and engine bracket

Engine bracket, compression rod and engine

Rear carrier

Rear shock absorber and frame

Rear shock absorber and engine

Steering ring nut

Handle holder and steering shaft

Brake hose and master cylinder

Fuel tank

Fuel cock

Fuel sender

Box

Seat lock assembly

Plastic parts & cover

Footrest board

Front wheel axle and nut

Rear wheel axle and nut

Rear brake cam lever

Front brake caliper and front fork

Brake disc and hub

Brake hose and caliper

Brake caliper and bleed screw

M 12

M 10

M 6

M 10

M 8

M 25

M 10

M 8

M 6

M 5

M 6

M 5

M 6

M 10

M 14

M 6

M 8

M10

M 8

M 5

84

45

13

30

16

60

20

10

7

4

7

2

7

70

120

10

23

20

23

6

See “NOTE”

61

31

9.4

22

12

43.4

14

7

5.1

2.9

5.1

1.4

5.1

51

87

7.2

16.6

14.5

16.6

4.3

LT

2-15

SPEC

TIGHTENING TORQUES

1 Lower ring nut

2 Rubber washer

3 Center ring nut

4 Lock washer

5 Upper ring nut

NOTE :

1. First, tighten the ring nut(lower) approximately 38Nm(3.8m•kg, 27.5ft•lb) by using the torque

wrench, then loosen the ring nut 1/4 turn.

2. Second, tighten the ring nut(lower) approximately 12Nm(1.2m•kg, 8.7ft•lb) by using the torque

wrench.

3. Installing the rubber washer.

4. Then finger tighten the center ring nut and touch rubber washer. Align the slots both ring nut and

install the lock washer.

5. Final, hold the ring nuts(lower and center) and tighten the ring nut(upper) 75Nm(7.5m•kg, 54.2ft•lb)

by using the torque wrench.

6. Confirm, adjust the direction handlebar to the right direction, front wheel suspended. Push di-

rection handlebar lightly with the finger (approximately 1.5kgf • cm), direction handlebar should

turn slowly without interference or hindrance.

2-16

SPEC

Lubrication Point Lubricant

LUBRICATION POINTS AND LUBRICANT TYPES

EAS00031

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

LS

E

G

M

Oil seal lips

O-rings

Bearings

Piston surface

Piston pin

Cylinder

Transmission case (bearing)

Autolube pump

Starter wheel gear

Idle gear plate

Secondary drive gear

Kickstarter pinion gear

Drive axle

Pump drive gear

Main axle

Main axle (bearing)

LS

M

LS

G

LS

E

2-17

SPEC

LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication Point Lubricant

EAS00032

CHASSIS

Oil seal lips

O-rings

Bearings

Speedometer drive gear

Front brake lever pivot shaft

Rear brake lever pivot shaft

Front brake camshaft

Front brake cable

Throttle cable

Tube guide (throttle grip) inner surface

Upper steering stem ring nut

Upper bearing outer race

Lower bearing outer race

Rear brake camshaft

Centerstand

LS

S

2-18

SPEC

CABLE ROUTING

EAS00035

CABLE ROUTING

1 Horn

2 Rectifier regulator

3 Main switch

4 Headlight leads

5 Speedometer cable

6 Ignition coil

7 Throttle cable 1

8 Throttle cable 3

9 Battery negative lead

0 Wire brake

q Fuel sender lead

w Seat lock cable

e Oil tank hose

r C.D.I. unit

t Wire harness

A Pass the speedometer cable

through the right hole of front

fender, then through the

guide.

B Pass the wire harness

through the inside of ignition

coil.

C Secure the ground lead and

the ignition coil base to the

ignition coil stay.

D Pass the wire harness

through the inside of oil tank.

E Pass the seat cable through

the inside of frame.

F Align the clip with the white

brand.

G Clamp the wire harness.

H Insert the seat cable through

the frame tube.

I Clamp wireharness, rear

brake cable throttle cable

1,3.

J Position the cylinder be-

tween the supporter and

main switch.

0

8

7

q

4

2

1

8

7

9

6

3

r

e

w

q

2-19

SPEC

CABLE ROUTING

1 Brake cable

2 Speedometer cable

3 Fuel tank overflow hose

4 Brake cable holder

5 Brake hose

6 Brake hose holder

7 License bracket

8 Flasher relay

9 Fuel tank breather hose

0 Fuel hose

q Breather hose

A Pass the brake hose through

the holder.

B Insert the fuel overflowhose

bottom.

C Pass the fuel overflowhose

through the rear fender hole.

D Pass the fuel overflowhose

through the holder.

E Hold the fuel overflowhose

with a clamp.

F Pass the brake cable through

the holder.

6

0

q

2

1

5

4

7

3

9

8

2-20

SPEC

CABLE ROUTING

1 Brake hose

2 Front fender

3 Front fork assembly

4 Nut

5 Plate washer

6 Brake hose holder 1

7 Flange bolt

8 Brake hose holder 2

9 Bolt

0 Grommet

q Flange bolt

w Brake hose holder

e Brake hose holder 3

A Tighting torque:3.5 ~ 5.5Nm.

B Assemble the brake hose

holder 3 hang hook must cer-

tainty hook the brake hose

holder.

C Tighting torque:8.5 ~ 14Nm.

D Tighting torque:3.5 ~ 5Nm.

E Tighting torque:3.5 ~ 5.5Nm.

F Pass the brake hose through

the brake hose holder.

1

2

3

7

5

4

5

6

9

6

3

1

q

5

4

9A

0

8

q

w

e

E

C

D

F

B

2-21

SPEC

CABLE ROUTING

1 Ignition coil

2 Spark plug lead

3 Starter relay leads

4 Auto choke leads

5 Starter relay

6 Band

7 C.D.I. unit

8 Autolube hose

9 Seat lock cable

0 Bracket

q Fuel tank breather hose

w Band 2

e Battery - lead

r Battery + lead

A Pass battery leads through

the slot of footrestboard.

B Cover them after securing

starter relay leads.

C Pass the seat lock cable

through the hole of bracket.

D Pass the fuel tank breath

hose over seat lock cable.

E Clamp carburetor vacuum

hose, fuel hose and fuel cock

vacuum hose.

F Clamp autochoke leads and

autolube hose on to carbu-

retor throttle cable.

G Pass the battery leads

through the forward of cross

pipe.

H Put fuse box on to footrest

board holder.

I Pass throttle cable1,3

wireharness, autolube pump

cable, brake cable through

the outside of battery box.

1

2

4

3

5

6

7

8

9

0

q

w

e

r

A

B

C

D

E

I

H

G

F

2-22

SPEC

CABLE ROUTING

1 Grip assembly

2 Handlebar switch(right)

3 Front brake light switch

4 Speedometer

5 Rear brake cable

6 Handlebar switch(left)

7 Grip

8 Handlebar assembly

9 Wire harness

0 Throttle cable 1

q Throttle cable 3

w Speedometer cable

e Brake hose

A Route the front brake light

switch lead through between

the handlebar pipe and the

brake hose.

B Route the front brake light

switch lead, left handlebar

switch lead and front turn sig-

nal light lead through the

backward of speedometer

cable .

C Route the front turn signal

light lead through the slot of

handlebar bracket and

through the backward of rear

brake cable.

D Route the left handlebar

switch lead through the back-

ward of handlebar pipe.

E Fasten the throttle cables,

brake hose, wire harness,

speedometer cable and rear

brake cable to the frame and

cut the end to be shorter than

5mm and reserve for a fin-

ger clearance, the position on

the above of guide wire and

align white point mark of wire

harness.

F Route the speedometer

cable through between the

frame and the brake hose to

right side.

G Route the throttle cable1,3

through between the handle-

bar, wire harness and brake

hose to left side.

H Connect the couplers se-

curely in rear of the brake

hose.

I Pass the throttle cable1,3

through the hole in the

handlebar cover1.

J After adjusting the throttle

cable free play, insert into the

boots.

K After tightening must has

clearance, and tightening

torque 60Nm(6.0m • kg,

43.4ft • lb).

9

e

w

0

q

5

K

2

q

0

I

G

8

D

9

7

5

C

4

6

E

F

H

J

1

3

A

B

3-10

CHK

ADJ

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

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

PERIODIC MAINTENANCE AND MINOR REPAIR ................................ 3-1

Periodic maintenance chart for the emission control system ........... 3-1

General maintenance and lubrication chart...................................... 3-2

COVER AND PANEL ................................................................................ 3-4

SEAT AND SIDE COVERS................................................................ 3-4

LOWER COWLING, UPPER COVER AND LEG SHIELD 1 ............ 3-5

LEG SHIELD 2 AND FOOTREST BOARD ....................................... 3-6

HANDLEBAR COVER(FRONT AND REAR).................................... 3-7

ADJUSTING THE ENGINE IDLING SPEED ........................................... 3-8

3-1

CHK

ADJ

INTRODUCTION/PERIODIC MAINTENANCE AND

MINOR REPAIR

EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments.

If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a

longer service life and reduce the need for costly overhaul work. This information applies to vehicles

already in service as well as to new vehicles that are being prepared for sale. All service technicians

should be familiar with this entire chapter.

EAS00037

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17570

Periodic maintenance chart for the emission control system

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform

the service.

NO. ITEM ROUTINE

INITIAL ODOMETER READING

1,000 km

(600 mi)

or

1

month

4,000 km

(2,000 mi)

or

6

months

7,000 km

(4,000 mi)

or

12

months

10,000km

(6,000 mi)

or

18

months

13,000 km

(8,000 mi)

or

24

months

16,000 km

(10,000 mi))

or

30

months

1

*

Fuel line

• Check fuel and vacuum hoses for

cracks or damage.

• Replace if necessary.



2

*

Idle speed

• Check and adjust engine idle

speed.



3

*

Exhaust system

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.



4

*

Air induction system

• Check the air cut-off valve, reed

valve, and hose for damage.

• Replace any damaged parts.



3-2

CHK

ADJ

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU32115

General maintenance and lubrication chart

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the

service.

NOTE:

From 19000 km (12000 mi) or 36 months, repeat the maintenance intervals starting from 7000 km

(4000 mi) or 12 months.

NO. ITEM ROUTINE

INITIAL ODOMETER READING

1,000 km

(600 mi)

or

1

month

4,000 km

(2,000 mi)

or

6

months

7,000 km

(4,000 mi)

or

12

months

10,000km

(6,000 mi)

or

18

months

13,000 km

(8,000 mi)

or

24

months

16,000 km

(10,000 mi))

or

30

months

1

*

Air filter element

• Clean with solvent.

• Replace if necessary.



2

*

Front brake

• Check operation, fluid level, and for

fluid leakage.

• Replace brake pads if necessary.



3

*

Rear brake

• Check operation.

• Adjust cable and replace brake

shoes if necessary.



4

*

Wheels

• Check runout and for damage.

• Replace if necessary.



5

*

Tires

• Check tread depth and for damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.



6

*

Wheel bearings

• Check bearings for smooth

operation.

• Replace if necessary.



7

*

Steering bearings

• Check bearing assemblies for

looseness.

• Moderately repack with lithium-

soap-based grease every 16000

km (10000 mi) or 18 months.

Repack. 

8

*

Chassis fasteners

• Check all chassis fitting and

fasteners.

• Correct if necessary.



9

Front brake lever

pivot shaft

• Apply silicone grease lightly. 

10

Rear brake lever

pivot shaft

• Apply lithium-soap-based grease

(all-purpose grease) lightly.



11 Centerstand

• Check operation.

• Lubricate.



12

*

Front fork

• Check operation and for oil

leakage.

• Replace if necessary.



13

*

Shock absorber

assembly

• Check operation and for oil

leakage.

• Replace if necessary.



14

*

Autolube pump

• Check operation.

• Bleed if necessary.



15

Final transmission

oil

• Check vehicle for oil leakage.

• Change.



16

*

V-belt • Replace. Every 10000 km(6250 mi)

17

*

Control and meter

cables

• Apply Yamaha chain and cable

lube or engine oil 10W-30

thoroughly.



18

*

Throttle grip housing

and cable

• Check operation and free play.

• Adjust the throttle cable free play if

necessary.

• Lubricate the throttle grip housing

and cable.



19

*

Lights, signals and

switches

• Check operation.

• Adjust headlight beam.



3-3

CHK

ADJ

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17620

NOTE:

● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

● Hydraulic brake system

• When disassembling the master cylinder or caliper cylinder, always replace the

brake fluid. Check the brake fluid level regularly and fill as required.

• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder

every two years.

• Replace the brake hoses every four years or if cracked or damaged.

3-4

CHK

ADJ

RemarksOrder Job/Part Q’ty

1

2

3

4

5

6

7

8

1

COVER AND PANEL

EAS00038

COVER AND PANEL

SEAT AND SIDE COVERS

Removing the seat and side covers

Battery box cover

Seat

Seat hanger

Rear carrier

Rear cover

Side cover(left)

Side cover(right)

Center cover

Remove the parts in the order listed.

NOTE:

Insert the (-) screwdriver into the slot of

battery box cover and pickup then re-

move.

For installation, reverse the removal pro-

cedure.

1

2

3

4

5

6

7

8

13Nm (1.3 m•kg, 9.4 ft•lb)

3-5

CHK

ADJ

1

2

3

5

4

RemarksOrder Job/Part Q’ty

1

2

3

4

5

1

COVER AND PANEL

LOWER COWLING, UPPER COVER AND LEG SHIELD 1

Removing the lower cowling, upper

cover, and leg shield 1

Lower cowling

Head light lead coupler(low)

Head light lead coupler(high)

Upper cover

Leg shield 1

Remove the parts in the order listed.

Disconnect.

For installation, reverse the removal pro-

cedure.

3-6

CHK

ADJ

1

2

3

4

5

6

7

8

7Nm (0.7 m•kg, 5.1 ft•lb)

RemarksOrder Job/Part Q’ty

1

2

3

4

5

6

7

8

1

COVER AND PANEL

LEG SHIELD 2 AND FOOTREST BOARD

Removing the leg shield 2 and foot-

rest board

Leg shield 1

Main switch cover

Leg shield 2

Footrest(left)

Footrest(right)

Battery negative lead

Battery positive lead

Battery

Footrest board

Remove the parts in the order listed.

Refer to “LOWER COWLING, UPPER

COVER AND LEG SHIELD 1”.

w

First, disconnect the battery negative

lead, and then the battery positive lead.

For installation, reverse the removal pro-

cedure.

3-7

CHK

ADJ

RemarksOrder Job/Part Q’ty

1

2

3

1

COVER AND PANEL

HANDLEBAR COVER(FRONT AND REAR)

Removing the handlebar cover(front

and rear)

Handlebar cover(front)

Speedometer cable

Handlebar cover(rear)

Remove the parts in the order listed.

Disconnect.

For installation, reverse the removal pro-

cedure.

2

1

3

3-8

CHK

ADJ

1

ADJUSTING THE ENGINE IDLING SPEED

EAS00054

ADJUSTING THE ENGINE IDLING

SPEED

NOTE:

Prior to adjusting the engine idling speed, the air

filter element should be clean, and the engine

should have adequate compression.

1. Start the engine and let it warm up for sev-

eral minutes.

w

Before starting the engine, be sure to use

the centerstand for safety.

2. Remove:

8 battery box cover 1

Refer to “SEAT AND SIDE COVERS”.

3. Connect:

8 digital tachometer 1

(onto the spark plug lead of cylinder )

Digital tachometer

90890-06760

4. Check:

8 engine idling speed

Out of specification Adjust

Engine idling speed

1800 ~ 1900 r/min

1

3-9

CHK

ADJ

ADJUSTING THE ENGINE IDLING SPEED

5. Adjust:

8engine idling speed

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Turn the throttle stop screw 1 in direction

a or b until the specified engine idling

speed is obtained.

Direction a Engine idling speed is increased.

Direction b Engine idling speed is decreased.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6 . Install:

8battery box cover

Refer to “SEAT AND SIDE COVERS”.

1

b

a

4-4

CARB

CHAPTER 4

CARBURETOR

AIR INDUCTION SYSTEM ....................................................................... 4-1

AIR FILTER CASE ASSEMBLY......................................................... 4-1

CHECKING THE AIR INDUCTION SYSTEM ................................... 4-3

4-1

CARB

AIR INDUCTION SYSTEM

RemarksOrder Job/Part Q’ty

1

2

3

1

Remove the parts in the order listed.

Disconnect.

For installation, reverse the removal pro-

cedure.

AIR INDUCTION SYSTEM

AIR FILTER CASE ASSEMBLY

Removing the air filter case assem-

bly

Hose(to air filter)

Pipe(to exhaust pipe)

Air filter case assembly

2

3

1

4-2

CARB

8

9

0

q

w

2

1

3

7

4

5

6

AIR INDUCTION SYSTEM

RemarksOrder Job/Part Q’ty

1

2

3

4

5

6

7

8

9

0

q

w

1

Remove the parts in the order listed.

For assembly, reverse the disassembly

procedure.

Disassembling the air filter case as-

sembly

Cap

Damper

Air filter case cap

Reed valve

Reed valve stopper

Reed valve seat

Reed valve assembly

Element

Plate

O-ring

Air filter case body

Damper

4-3

CARB

AIR INDUCTION SYSTEM

EAS00510

CHECKING THE AIR INDUCTION SYSTEM

1. Check:

8 hoses

Loose connection Connect properly.

Cracks/damage Replace.

8 pipes

Cracks/damage Replace.

2. Check:

8 reed valve 1

8 reed valve stopper

8 reed valve seat

Cracks/damage Replace the reed valve

assembly.

3. Measure:

8 reed valve bending limit a

Out of specification Replace the reed

valve assembly.

Reed valve bending limit

0.2 mm (0.0078 in)

1 Surface plate

4. Check:

8 air filter case assembly 1

Cracks/damage Replace.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Start the engine and let it warm up for sev-

eral minutes.

b. Dismount the intake tube 2 of air filter case

assembly, and put a piece of thin paper 3

at the opening of the body, the paper will not

pulsate (sucking and releasing).

c. If there is no pulsation, turn off the engine

and check if there is any leakage or clog in

the air filter case assembly or not. If there if,

repair and repeat the inspection steps in a

and b.

d. If it is still not pulsating, replace the air filter

case assembly.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3

2

1

A, B, C,

LOCK

OPEN

OFF

CHECK

ON

OFF

START

OFF

PUSH

B

1

3

2

4

n

b

g

l

k

6

5

s

7

9

8

q

a

o

i

e

w

d

,

m

h

z

x

c

v

0

f

j

12V 7A

12V 1.7W OIL

12V 3.4W ILUMI

12V 1.7W BEAM

12V 1.7W TURN

p

y

t

r

u

;

8

(GREEN)

(BLACK)

(RED)

(RED)(RED)

(BLACK)

(BROWN)

(GREEN)

(RED)

(RED) (RED)

(GREEN)

YW50X WIRING DIAGRAM

EXPLANATION

COLOR CODE

CONNECTING WITH GRD. WIRE

GRD.

CONNECTOR MARK

(BETWEEN MAIN & SUB HARNESS)

CONNECTOR SYMBOL

Black

Green

Blue

Orange

Gray

Green/Yellow

Red

Brown

Chocolate

Pink

Blue/White

Black/Red

Pink/White

MARK

R, Br, BrW...

1 Main switch

2 Main fuse

3 Battery

4 Starter relay

5 Starter motor

6 Rectifier/regulator

7 Auto choke

8 C.D.I. magneto

9 C.D.I. Unit

0 Ignition coil

q Spark plug

w Front brake light switch

e Rear brake light switch

r Tail/brake light

t Rear turn signal light(left)

y Rear turn signal light(right)

u License plate light

i Front turn signal light(right)

o Front turn signal light(left)

p Headlight(high)

a Headlight(low)

s Turn signal relay

d Horn

f Handlebar switch(left)

g Horn switch

h Dimmer switch

j Turn signal switch

k Fuel sender

l Speedometer

; Fuel gauge

z Oil level indicator light

x Speedometer light

c High beam indicator light

v Turn signal indicator light

b Oil lever gauge

n Handlebar switch(right)

m Engine stop switch

, Start switch

Yellow/Red

White

Yellow

Dark green

Brown/White

Black/White

White/Red

EBO00000

YW50BP

SERVICE MANUAL

First edition, November 2001

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Taiwan Co,.Ltd.

is expressly prohibited.

EB001000

NOTICE

This manual was produced bythe Yamaha Motor Company, Ltd. primarily for use byYamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in

one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications

and significant changes in specifications or procedures will be forwarded to all authorized Yamaha

deal-ers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

ZL

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

~'~,WARNING

Failure to folIowWARNING instructions could result in severe injury or death

to the scooter operator, a bystander or a person checking or repairing the

scooter.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the scooter.

NOTE:

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

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

(~ The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter. Refer to "SYMBOLS".

(~ 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-sec-

tion 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

each removal and disassembly section.

(~ Numbers are given in the order of the jobs in the exploded diagram. A circled number indi-

cates a 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

of parts, notes in jobs, etc.

(~ Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

®

Cvlinder

head.

Cylinder and piston

removal

Engine

1

Muffler/Gasket

2 Air ~hroud (cylTnder head)

3 Spark IJlug

4 Cylinder head/Cylinder head gasket

Cylinder

6 Piston pin clip

7

Piston pin/Bearing

8

Piston

9 Piston

ring set

10

CyITnder gasket

Q'ty Rurllark~

Remove the pa~s En the order

Refer to the

"ENGINE REMOVAL"

sec-

tion

1/1

1

1/1

1

2

1

Reverse the removal procedure for in

stallatien.

CYLINDEB HEAD" CYF~:N::R: P~~

1.

Remove:

• san nc

NoTE PI t pT IIp~)

Begore removing tha piston pin celt,, cover the

' crankcase with a

clean rag so you will not acci

Z. Ro,,,ovo:

•

Piston pTn

1~

• Piston ®

• Piston pin bearing ~

GA~ON~

Donot use a hammer to drive the piston pin

out_

CYUNDER HEAD INSPECTION

~. Elhxlin~te:

• Carbon deposits

Use a rounded ~crapper

@

•

Cylinder head

war~3age

Out of specification

>Re 8ur'0ce.

Warpage measurement and re surfacement

• Attach a

=traight edge ~ and a thickness

gauge (~ on the cylinder head.

•

Measure the warpage

limit.

I

• If the warpage is out of

specification, reface

the cylinder head.

NOTE:

Rotate the head severaT tTres to avoid remov-

ing too much moteriol from one side.

4-4 ..................................... --

Q ®

®

GEN

INFO

INSP

CARB

ELEC

~=]

®

@

-n~

SPEC

®

ENG

~)~

®

CHAS (~®

®

TRBL w.~

SHTG •

@

©

@

® i i 1

® ® @

@ @

EAS00009

SYMBOLS

The following symbols are not relevant to ev-

ery vehicle.

Symbols (~to (~ are designed as thumb tabs

to indicate the chapter's number and content.

(~ General information

(~ Specifications

(~ Periodic inspection and adjustment

Engine

(~) Carburetor(s)

(~ 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 @ in the exploded diagrams in-

dicate the types of lubricants and lubrication

points.

(~ Engine oil

@ Gear oil

(~) Molybdenum disulfide oil

(~ Wheel bearing grease

(~ Lithium soap base grease

(~) Molybdenum disulfide grease

Symbols@ to @ in the exploded diagrams

indicate the following.

(~ Apply locking agent (LOCTITE ®)

(~ Replace the part

I~lew

CHAPTER 1.

GENERAL INFORMATION

SCOOTER INDENTIFICATION

........................................................................................................... 1-1

VEHICLE IDENTIFICATION NUMBER ........................................................................................... 1-1

MODEL CODE ................................................................................................................................ 1-1

IMPORTANT INFORMATION

............................................................................................................ 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY ................................................................ 1-2

REPLACEMENT PARTS ................................................................................................................. 1-2

GASKETS, OIL SEALS AND O-RINGS .......................................................................................... 1-2

LOCK WASHERS/PLATES AND COTTER PINS ........................................................................... 1-2

BEARINGS AND OIL SEALS ......................................................................................................... 1-3

CIRCLIPS ........................................................................................................................................ 1-3

CHECKING OF CONNECTIONS

........................................................................................................ 1-4

HOW TO USE

THE CONVERSION TABLE

....................................................................................... 1-5

CONVERSION TABLE .................................................................................................................... 1-5

SPECIAL TOOLS

................................................................................................................................ 1-6

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATION ............................................................................................................... 2-1

MAINTENANCE SPECIFICATION

..................................................................................................... 2-4

ENGINE .......................................................................................................................................... 2-4

TIGHTENING TORQUES ............................................................................................................... 2-6

ENGINE .......................................................................................................................................... 2-6

MAINTENANCE SPECIFICATION

..................................................................................................... 2-7

CHASSIS ........................................................................................................................................ 2-7

TIGHTENING TORQUES ............................................................................................................... 2-8

CHASSIS ........................................................................................................................................ 2-8

MAINTENANCE SPECIFICATION ..................................................................................................... 2-9

ELECTRICAL ................................................................................................................................... 2-9

GENERAL TORQUE SPECIFICATIONS

........................................................................................... 2-1 1

LUBRICATION POINTS AND LUBRICATION TYPE

....................................................................... 2-12

ENGINE ........................................................................................................................................ 2-12

CHASSIS ...................................................................................................................................... 2-13

CABLE ROUTING

............................................................................................................................. 2-14

CHAPTER 3.

PERIODIC INSPECTION AND ADJUSTMENTS

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

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

COVER AND PANEL

.......................................................................................................................... 3-3

SIDECOVER AND SEAT ................................................................................................................ 3-3

LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD ..................... 3-4

HANDLEBAR COVER(FRONT AND REAR) ................................................................................... 3-5

ENGINE

.............................................................................................................................................. 3-6

IDLE SPEED ADJUSTMENT .......................................................................................................... 3-6

THROTTLE CABLE FREE ADJUSTMENT ..................................................................................... 3-7

AUTOLUBE PUMP AIR BLEEDING ............................................................................................... 3-8

SPARK PLUG INSPECTION ........................................................................................................... 3-9

ENGINE OIL LEVEL INSPECTION ............................................................................................... 3-10

TRANSMISSION OIL REPLACEMENT ........................................................................................ 3-11

AIR FILTER ELEMENT CLEANING .............................................................................................. 3-12

V-BELT INSPECTION ................................................................................................................... 3-14

CHASSIS

.......................................................................................................................................... 3-15

FRONT BRAKE LEVER FREE PLAY CHECK ................................................................................ 3-15

REAR BRAKE LEVER FREE PLAY CHECK ................................................................................... 3-15

BRAKE PAD INSPECTION ........................................................................................................... 3-15

BRAKE SHOE INSPECTION ........................................................................................................ 3-16

BRAKE FLUID LEVEL INSPECTION ............................................................................................ 3-16

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ........................................................................ 3-17

STEERING ADJUSTMENT .......................................................................................................... 3-18

TIRE INSPECTION ........................................................................................................................ 3-19

WHEEL INSPECTION ................................................................................................................... 3-22

FRONT FORK INSPECTION ......................................................................................................... 3-22

REAR SHOCK ABSORBER INSPECTION .................................................................................... 3-22

SEAT LOCK CABLE ADJUSTMENT ........................................................................................... 3-22

CABLE CHECKING AND LUBRICATING ..................................................................................... 3-23

LEVERS LUBRICATING ............................................................................................................... 3-23

CENTERSTAND LUBRICATING .................................................................................................. 3-23

ELECTRICAL

..................................................................................................................................... 3-24

BATTERY INSPECTION ............................................................................................................... 3-24

FUSE INSPECTION ...................................................................................................................... 3-29

HEADLIGHT BEAM ADJUSTMENT ............................................................................................ 3-30

HEADLIGHT BULB REPLACEMENT ............................................................................................ 3-30

TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT ........................................................... 3-31

TAILLIGHT BULB REPLACEMENT .............................................................................................. 3-32

LICENSE LIGHT BULB REPLACEMENT ...................................................................................... 3-32

CHAPTER 4.

ENGINE

ENGINE OVERHAUL

......................................................................................................................... 4-1

WlREHARNESS AND CABLES ...................................................................................................... 4-1

CYLINDER HEAD, CYLINDER AND PISTON

.................................................................................... 4-3

CYLINDER HEAD, CYLINDER AND PISTON ................................................................................ 4-3

PISTON PIN AND PISTON REMOVAL .......................................................................................... 4-4

CYLINDER HEAD INSPECTION ..................................................................................................... 4-4

CYLINDER AND PISTON INSPECTION ........................................................................................ 4-5

PISTON RINGS INSPECTION ........................................................................................................ 4-7

PISTON PIN AND PISTON PIN BEARING .................................................................................... 4-7

PISTON PIN AND PISTON INSTALLATION ................................................................................. 4-8

CYLINDER AND CYLINDER HEAD ................................................................................................ 4-9

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

........................................................... 4-1

1

KICK STARTER AND CRANKCASE COVER(LEFT) ..................................................................... 4-1 1

KICK STARTER ............................................................................................................................. 4-12

KICK STARTER INSTALLATION ................................................................................................. 4-13

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................ 4-14

SECONDARY SHEAVE ................................................................................................................ 4-15

PRIMARY SHEAVE REMOVAL .................................................................................................... 4-16

SECONDARY SHEAVE REMOVAL .............................................................................................. 4-16

CLUTCH INSPECTION ................................................................................................................. 4-17

V-BELT INSPECTION ................................................................................................................... 4-18

PRIMARY SHEAVE INSPECTION ................................................................................................ 4-19

SECONDARY SHEAVE ................................................................................................................ 4-20

SECONDARY SHEAVE INSTALLATION ..................................................................................... 4-21

PRIMARY SHEAVE ...................................................................................................................... 4-22

STARTER CLUTCH AND STARTER MOTOR

................................................................................. 4-24

STARTER CLUTCH AND STARTER MOTOR .............................................................................. 4-24

STARTER CLUTCH AND GEARS INSPECTION ......................................................................... 4-26

C.D.I. MAGNET ................................................................................................................................ 4-27

C.D.I. MAGNETO ......................................................................................................................... 4-27

C.D.I. MAGNETO REMOVAL ....................................................................................................... 4-28

C.D.I. MAGNETO INSTALLATION .............................................................................................. 4-28

AUTOLUBE PUMP

........................................................................................................................... 4-29

AUTOLUBE PUMP ....................................................................................................................... 4-29

AUTOLUBE PUMP INSTALLATION ........................................................................................... 4-30

TRANSMISSION

.............................................................................................................................. 4-31

TRANSMISSION .......................................................................................................................... 4-31

CRANKCASE AND REED VALVE

.................................................................................................... 4-33

CRANKCASE AND REED VALVE ................................................................................................ 4-33

CRANKCASE(RIGHT) REMOVAL ................................................................................................ 4-35

CHECKING THE CRANKCASE .................................................................................................... 4-35

CHECKING THE BEARINGS AND OIL SEALS ............................................................................ 4-35

REED VALVE INSPECTION ......................................................................................................... 4-36

CRANKCASE (RIGHT) INSTALLATION ...................................................................................... 4-36

CRANKSHAFT

.................................................................................................................................. 4-38

CRANKSHAFT .............................................................................................................................. 4-38

CRANKSHAFT REMOVAL ........................................................................................................... 4-39

CRANKSHAFT INSPECTION ....................................................................................................... 4-39

CRANKSHAFT INSTALLATION ................................................................................................... 4-40

CHAPTER 5

CARBURETION

CARBURETION .................................................................................................................................. 5-1

CARBURETOR ................................................................................................................................ 5-1

CABURETOR DISASSEMBLY ....................................................................................................... 5-2

CABURETOR INSPECTION ........................................................................................................... 5-3

CARBURETOR ASSEMBLY ........................................................................................................... 5-5

FUEL LEVEL ADJUSTMENT ......................................................................................................... 5-6

AUTO CHOKE INSPECTION .......................................................................................................... 5-7

FUEL COCK INSPECTION ............................................................................................................. 5-8

CHAPTER 6

CHASSIS

FRONT WHEEL AND BRAKE DISC

................................................................................................... 6-1

FRONT WHEEL AND BRAKE DISC ............................................................................................... 6-1

FRONT WHEEL DISASSEMBLY .................................................................................................... 6-2

FRONT WHEEL DISASSEMBLY .................................................................................................... 6-3

FRONT WHEEL INSPECTION ........................................................................................................ 6-3

BRAKE DISC INSPECTION ............................................................................................................ 6-4

FRONT WHEEL ASSEMBLY .......................................................................................................... 6-4

FRONT WHEEL INSTALLATION ................................................................................................... 6-5

WHEEL STATIC BALANCE ADJUSTMENT .................................................................................. 6-6

FRONT BRAKE ................................................................................................................................... 6-8

BRAKE PAD .................................................................................................................................... 6-8

BRAKE PAD REPLACEMENT ........................................................................................................ 6-9

MASTER CYLINDER

........................................................................................................................ 6-12

MASTER CYLINDER DISASSEMBLY

............................................................................................. 6-13

MASTER CYLINDER INSPECTION .............................................................................................. 6-14

MASTER CYLINDER ASSEMBLY ................................................................................................ 6-14

MASTER CYLINDER INSTALLATION ......................................................................................... 6-15

CALIPER

........................................................................................................................................... 6-17

CALIPER DISASSEMBLY ................................................................................................................. 6-18

BRAKE CALIPER DISASSEMBLY ................................................................................................ 6-19

CALIPER INSPECTION ................................................................................................................. 6-19

BRAKE CALIPER ASSEMBLY ...................................................................................................... 6-20

BRAKE CALIPER INSTALLATION ............................................................................................... 6-20

REAR WHEEL AND REAR BRAKE

.................................................................................................. 6-21

REAR WHEEL ............................................................................................................................... 6-21

REAR BRAKE ................................................................................................................................ 6-22

REAR WHEEL INSPECTION ........................................................................................................ 6-23

REAR BRAKE INSPECTION ......................................................................................................... 6-23

REAR BRAKE INSTALLATION .................................................................................................... 6-24

HANDLEBAR

.................................................................................................................................... 6-25

HANDLEBAR ................................................................................................................................ 6-25

HAN DLE BAR I NSTALLATIO N ..................................................................................................... 6-27

STEERING

........................................................................................................................................ 6-29

STEERING .................................................................................................................................... 6-29

STEERING REMOVAL ................................................................................................................. 6-30

STEERING INSPCTION ................................................................................................................ 6-31

STEERING INSTALLATION ......................................................................................................... 6-31

FRONT FORK

................................................................................................................................... 6-34

FRONT FORK ............................................................................................................................... 6-34

FRONT FORK DISASSEMBLY ..................................................................................................... 6-35

FRONT FORK REMOVAL ............................................................................................................. 6-36

FRONT FORK DISASSEMBLY ..................................................................................................... 6-36

FRONT FORK INSPECTION ......................................................................................................... 6-37

FRONT FORK ASSEMBLY ........................................................................................................... 6-37

FRONT FORK INSTALLATION .................................................................................................... 6-39

CHAPTER 7

ELECTRICAL

ELECTRICAL COMPONENTS

............................................................................................................ 7-1

ELECTRICAL COMPONENTS ........................................................................................................ 7-1

CIRCUIT DIAGRAM ........................................................................................................................ 7-2

CHECKING SWITCHES

...................................................................................................................... 7-4

CHECKING STEPS ......................................................................................................................... 7-4

SWITCH CONNECTION AS SHOWN IN THIS MANUAL ............................................................. 7-4

SWITCH POSITION AND TERMINAL CONNECTION ...................................................................... 7-5

CHECKING THE BLUBS AND BULB SOCKETS ............................................................................... 7-5

CHECKING THE BULBS AND BULB SOCKETS ........................................................................... 7-6

TYPES OF BULBS .......................................................................................................................... 7-6

CHECKING THE CONDITION OF THE BULBS .............................................................................. 7-7

CHECKING THE CONDITION OF THE BULB SOCKETS .............................................................. 7-8

IGNITION SYSTEM

............................................................................................................................ 7-9

CIRCUIT DIAGRAM ........................................................................................................................ 7-9

TROUBLESHOOTING .................................................................................................................. 7-10

CHARGING SYSTEM

....................................................................................................................... 7-14

CIRCUIT DIAGRAM ...................................................................................................................... 7-14

TROUBLESHOOTING .................................................................................................................. 7-15

ELECTRIC STARTING SYSTEM

...................................................................................................... 7-18

CIRCUIT DIAGRAM ...................................................................................................................... 7-18

TROUBLESHOOTING .................................................................................................................. 7-19

STARTER MOTOR ....................................................................................................................... 7-22

STARTER MOTOR DISASSEMBLY ............................................................................................. 7-23

INSPECTION AND REPAIR .......................................................................................................... 7-24

LIGHTING SYSTEM

......................................................................................................................... 7-26

CIRCUIT DIAGRAM ...................................................................................................................... 7-26

TROUBLESHOOTING .................................................................................................................. 7-27

LIGHTING SYSTEM CHECK ........................................................................................................ 7-29

SIGNAL SYSTEM

............................................................................................................................. 7-33

CIRCUIT DIAGRAM ...................................................................................................................... 7-33

TROUBLESHOOTING .................................................................................................................. 7-34

SIGNAL SYSTEM CHECK ............................................................................................................ 7-36

AUTO CHOKE SYSTEM

.................................................................................................................. 7-42

CIRCUIT DIAGRAM ...................................................................................................................... 7-42

TROUBLESHOOTING .................................................................................................................. 7-43

CHAPTER 8

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING

........................................................................................... 8-1

FUEL SYSTEM ............................................................................................................................... 8-1

IGNITION SYSTEM ........................................................................................................................ 8-2

COMPRESSION SYSTEM ............................................................................................................. 8-2

POOR IDLE SPEED PERFORMANCE

................................................................................................ 8-3

POOR IDLE SPEED PERFORMANCE ............................................................................................ 8-3

POOR MIDIUM AND HIGH SPEED PERFORMANCE

....................................................................... 8-3

POOR MIDIUM AND HIGH SPEED PERFORMANCE ................................................................... 8-3

FULTY AUTOMATIC(V-BELT TYPE)

................................................................................................. 8-4

SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING .................................................. 8-4

CLUTCH OUT FAILURE ................................................................................................................. 8-4

POOR STANDING START(LOW CLIMBING ABILITY) ................................................................. 8-4

POOR ACCELERATION(POOR HIGH SPEED) .............................................................................. 8-4

OVER HEAT ........................................................................................................................................ 8-5

OVERHEAT ..................................................................................................................................... 8-5

POOR SPEED ..................................................................................................................................... 8-5

POOR SPEED ................................................................................................................................. 8-5

IMPROPER KICKING

.......................................................................................................................... 8-6

SLIPPING ........................................................................................................................................ 8-6

HARD KICKING .............................................................................................................................. 8-6

KICK CRANK NOT RETURNING ................................................................................................... 8-6

FAULTY BRAKE

................................................................................................................................. 8-7

POOR BRAKING EFFECT ............................................................................................................... 8-7

MALFUNCTION ............................................................................................................................. 8-7

INSTABLE HANDLING

...................................................................................................................... 8-8

INSTABLE HANDLING .................................................................................................................. 8-8

FAULTY SIGNAL AND LIGHTING

SYSTEM .................................................................................... 8-9

HEADLIGHT DARK ......................................................................................................................... 8-9

BULB BURNT OUT ........................................................................................................................ 8-9

FLASHER DOES NOT BLINK ......................................................................................................... 8-9

FLASHER KEEPS ON ..................................................................................................................... 8-9

FLASHER BLINKS SLOWER ........................................................................................................ 8-10

FLASHER BLINKS QUICKER ....................................................................................................... 8-10

HORN DOES NOT SOUND ......................................................................................................... 8-10

SCOOTER INDENTIFICATION

I GEN

f

EAS00015

GENERAL INFORMATION

SCOOTER IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number (~) is stamped

into the frame.

EAS00018

MODEL CODE

The model code label ~) is affixed to the loca-

tion shown in the figure. Record the informa-

tion on this label in the space provided. This

information will be needed to order spare parts.

1-1

IMPORTANT INFORMATION

I GEN

300-008

300-016

EAS00020

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISAS-

SEMBLY

1. Before removal and disassembly, remove

all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to "SPECIAL TOOLS".

3. When disassembling, always keep mated

parts together. This includes gears, cylin-

ders, pistons and other parts that have

been

"mated" through normal wear. Mated

parts must always be reused or replaced

as an assembly.

4. During disassembly, clean all ofthe parts

and place them in trays in the order of dis-

assembly. This will speed up assembly

and allow for the correct installation of all

parts.

5. Keep all parts away from any source of

fire.

EAS00021

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace-

ments. Use oil and grease recom-mended by

Yamaha for all lubrication jobs.

Other brands may be similar in function and

appearance, but inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-

faces, oil seal lips and O-rings must be

cleaned.

2. During reassembly, properly oil all mat-

ing parts and bearings and lubricate the

oil seal lips with grease.

EAS00023

LOCK WASHERS/PLATES AND COTTER PINS

After removal, replace all lock washers/plates

~)and cotter pins. After the bolt or nut has been

tightened to specification, bend the lock tabs

along a flat ofthe bolt or nut.

1-2

IMPORTANT INFORMATION

I GEN

,NFOI I

~\\\\\\\\~1

EAS00024

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu

facturer's marks or numbers are visible. When

installing 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

CAUTION:

Do not spin the bearing with compressed air

because this will damage the bearing surfaces.

(~ Bearing

EAS00025

CIRCLIPS

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 the

sharp-edged corner (~) is positioned opposite

the thrust ~ that the circlip receives.

(~ Shaft

1-3

IMPORTANT INFORMATION

I GEN

EB801000

CHECKING OF CONNECTIONS

Dealing with stains, rust, moisture, etc. on the

connector.

1. Disconnect:

• Connector

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector two

or three.

4. Pull the read to checkthat it will not come

off.

5. If the terminal comes off, bend up the pin

(~ and reinsert the terminal into the con-

Rector.

6. Connect:

• Connector

NOTE:

The two connectors "click" together.

7. Check for continuity with a tester.

NOTE:

• If there is no continuity, clean the termi-

nals.

• Be sure to perform the steps 1 to 7 listed

above when checking the wireharness.

• For a field remedy, use a contact revitalizer

available on the market.

• Use the tester on the connector as shown.

1-4

HOW TO USE THE CONVERSION TABLE

I GEN

EB201000

HOW TO USE THE CONVERSION TABLE

All specification data in this manual are listed in SI and METRIC UNITS.

Use this table to convert METRIC unit data to IMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMP

** mm x 0.03937 = ** in

2 mm x 0.03937 = 0.083 in

CONVERSION TABLE

METRIC TO IMP

Known Multiplier Result

m.kg 7.233 ft.lb

Torque m.kg 86.794 in.lb

cm.kg 0.0723 ft.lb

cm.kg 0.8679 in.lb

Weight kg 2.205 Ib

g 0.03527 oz

Distance

Volume/

Capacity

Miscellaneous

km/h

km

m

ca

mm

cc(cm 3)

lit(liter)

kg/mm

kg/cm 2

Centigrade

0.6214

3.281

1.094

0.3937

0.03937

0.03527

0.06102

0.8799

0.2199

55.997

14.2234

9/5(°C)+32

mph

mi

ft

yd

in

oz (IMP liq.)

cu.in

qt(IMP liq.)

gal(IMP liq.)

Ib/in

psi(Ib/in 2)

Fahrenheit (°F)

1-5

SPECIAL TOOLS I GEN

EEl02000

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use

onlythe appropriate special tools; this Will help prevent damage caused bythe use of inappropri-

ate tools or improvised techniques.

When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name / Function Illustration

YU-01235

YS-28891

YU -90050

-90062

YU-01189

YU-01135-A

YM-33299

YU-33975

YU-01701

YU-8036-A

Rotor holding tool

This tool is used to hold the generator ro-

torwhen removing or installing the genera-

tor rotor bolt.

Clutch spring holder

This tool is used to disassembly and assem-

bly the secondary pulley.

Crankshaft Installation set (~

Adapter (~)

These tools are used to install the crank-

shaft.

Flywheel puller

This tool is used for removing the rotor.

Crankcase Separating tool

This tool is used to remove the crankshaft

or separate the crankcase.

Oil seal guide

This tool is used for protecting the oil seal

lip when installing the secondary sliding

sheave.

Steering nut wrench

This tool is used to loosen or tighten the

steering stem ring nut.

Sheave holder

This tool is used to hold the clutch hous-

ing when removing or installing the clutch

housing nut.

Inductive tachometer

This tool is used to check engine speed.

u

0

1-6

SPECIAL TOOLS I GEN

,.,o1 1

Tool No.

YU-03112

YM-1409

YM-1410

YM-34487

ACC-1100-15-01

90890-01348

YU-33963

-1400

T-handle (~

YM-01326

Holder

YM-01300-1 (~

YM-01312-A

Tool name / Function

Pocket tester

This tool is used to checkthe electrical sys-

tem.

Oil seal guide

This tool is used to install the left side crank-

case oil seal.

Oil seal driver

This tool is used to install the left side crank-

case oil seal.

Dynamic spark tester

This instrument is necessary for checking

the ignition system components.

Quick Gasket ®

This sealant is used to seal to mating sur-

faces (e.g., crankcase mating sur-faces).

Lockn ut wrench

This tool is used to loosen and tighten the

clutch carrier Iocknut of the secondary

sheave.

Front fork seal driver

Weight (~

Adapter Q2~

These tools are used when installing the fork

seal.

T-handle (~)/Damper rod holder (~

These tools are needed to loosen and

tighten the damper rod holding bolt.

Fuel level gauge

This gauge is used to nleasure the fuel level

in the float chamber.

I llustratio n

dJ / ~//

®

1-7

GENERAL SPECIFICATION

IsPEcl.-I

GENERAL SPECIFICATION

SPECIFICATION

Model YW50AP

Model code: 5P J1

Dimensions:

Overall length

Overall width

Overall height

Seat height

Wheelbase

1,890 mm(74.4 in)

705 mm(27.8 in)

1,110 mm(43.7 in)

765 mm(30.1 in)

1,275 mm(50.2 in)

Minimum ground clearance

Minimum turning radius

120 mm(4.7 in)

2,000 mm(78.7 in)

Basic weight:

With oil and full fuel tank 94 kg(207 Ib)

Engine:

Engine type

Cylinder arrangement

Displacement

Bore x stroke

Compression ratio

Starting system

Lubrication system:

Oil Type or Grade:

Engine Oil

Transmission Oil

Oil Capacity:

Oil Tank (Engine Oil)

Transmission Oil:

Periodic Oil Change

Total Amount

Air cooled 2 strcke, gasoline torque induction

Forward- inclined single cylinder

49cm 3 (2.99 cu.in)

40.0 x 39.2 mm(1.57 x 1.54 in)

7.2:1

Electric and kick starter

Separate lubrication

For YAMAHA brand:

Yamalube 2 or Air cooled 2-stroke engine oil (ISO

EG-C, EG-D grade)

Yamalube 4 SAE 10W/30 SE or GL gear oil

1.4 L (1.23 Imp°qt, 1.48 US qt)

0.11 L(0.096 Imp.qt, 0.12 US qt)

0.13 L(0.11 Imp.qt, 0.13 US qt)

Air Filter: Wet type element

Fuel:

Type Regular unleaded gasoline

Tank Capacity 5.7 L (1.25 Imp.gal, 1.5 US gal)

Carburetor:

Type / Manufacturer Y14P/1/TEIKEI

2-1

GENERAL SPECIFICATION

Model YW50A

Spark Plug:

Type/Manufacturer BPRTHS/NGK

Gap 0.6 ~ 0.7 mm(0.02 ~ 0.03 in)

Clutch Type Dry, Centrifugal automatic

Transmission:

Primary Reduction System

Primary Reduction Ratio

Secondary Reduction System

Secondary Reduction Ratio

Transmission Type

Operation

Chassis:

Frame type

Caster angle

Trail

Tire:

Type

Size front

rear

Manufacturer front

rear

Type front

rear

Maximum load*

Cold tire Pressure:

Up to 90 kg

Front

Rear

90 kg load~Maximum load*

Front

Rear

IsPEcl.-I

Brake:

Front brake

Rear brake

type

operation

type

operation

Suspension:

Front suspension

Rear suspension

Shock absorber:

Front shock absorber

Rear shock absorber

Wheel travel:

Front wheel travel

Rear wheel travel

Electrical:

Ignition system

Generator system

Battery type

Battery capacity

Helical gear

4.000

Supur gear

3.666

V-belt

Automatic

Steel tube underbone

26.5 °

93mm(3.7 in)

Tubeless

120/90-10

130/90-10

CHENG SHIN

56J

59J

143 kg(315 Ib)

200kpa(2.0 kg/crn 2, 29 psi)

200kpa(2.0 kg/cm 2, 29 psi)

Single disc brake

Right hand operation

Drum brake

Left hand operation

Telescopic fork

Unit swing

Coil spring/oil damper

65 rnrn(2.56 in)

60 mm(2.36 in)

C.D.I

Flywheel Magneto

YTX5L-BS

12V 4AH

2-2

GENERAL SPECIFICATION

IsPEcl.-I

Model YW50A

Headlight type: Bulb

Bulb wattage x quantity:

Headlight

Tail/brake light

Flasher light

Licence plate light

Meter light

High beam indicator light

Oil indicator light

Turn indicator light

12V 35W/35Wx2

12 V 5W/21Wx1

10Wx4

5Wx 1

3.4Wxl/1.7Wxl

1.7Wx 1

2-3

MA...E°A.OE SPEO.F.OA -.O° ISPEcl I

MAINTENANCE SPECIFICATION

ENGINE

Cylinder head:

Warp limit "~

Item Sta nda rd Limit

*Lines indicate straightedge measurement

Cylinder:

Bore size

Taper limit

40.000~40.014mm

(1.5748~1.5754 in)

Out of round Ih-nit

Piston:

Piston to cylinder clearance

Piston size "D"

Measuring point "H"

Piston pin bore inside diameter

Piston pin outside diameter

Piston Ring:

Sectional Sketch (B × T)/'l-ype

Top Ring

2nd Ring

End Gap (Installed):

Top Ring

2nd Ring

Side Clearance ( Installed):

Top Ring

2nd Ring

I~ Yl

0.035~0.040 mm

(0.0014~0.0016 in)

39.958~39.972 mm

(1.5731~1.5737 in)

5 mm(O.2 in)

10.004~10.015 mm

(0.3939~0.3943 in)

9.996~10.000 rnrn

(0.3935~0.3937 in)

1.2 × 1.6 mm/keystone

(0.05 × 0.06 in)

1.2 × 1.6 ram/keystone

(0.05 × 0.06 in)

0.15~0.35 mm

(0.005~0.01 in)

0.15~0.35 mm

(0.005~0.01 in)

0.03~0.05 mm

(0.0012~0.0020 in)

0.03~0.05 mm

(0.0012~0.0020 in)

0.03 mm

(0.0012 in)

40.10 mm

(1.5787 in)

0.05 mm

(0.0020 in)

0.03 rnm

(0.0012 in)

0.10 mm

(0.0039 in)

10.045 mm

(0.4 in)

9.975 mm

(0.39 in)

0.6 mm(O.02 in)

0.1 mm(O.O039 in)

2-4

MA..TE°A°OE SPEO.F.OAT.O° ISPEcl " I

Crankshaft:

Item Standard Limit

F

Crank Width

"A"

Run Out Limit "C"

Connecting Rod Big End Side

Clearance

"D"

Small End Free Play

"F"

Automatic centrifugal clutch:

Clutch shoe thickness

Clutch housing inside diameter

Clutch shoe spring free length

Clutch - in revolution

Clutch - stall revolution

V-belt:

V-belt width

Kick Starter:

Type

Kick Clip Tension

Carburetor:

I.D. Mark

Main Jet

Needle jet

Jet Needle-clip Position

Main Air Jet

Cutaway

Pilot Jet

Bypass

Valve Seat Size

Starter Jet

Float Height

Fuel level height

Engine Idling Speed

Reed Valve:

Thickness

Valve Stopper Height

Valve bending limit

- "--D

.q- .~p

A

(M.J.)

(N J)

(J.N.)

(M.A.J.)

(C.A.)

(P.J.)

(V.S.)

(G.S.)

37.90~37.95 mm(1.49~1.49 in)

0.03 mm(0.0012 in)

0.2~0.5 mm

(0.0029~0.020 in)

0.4~0.8 mm

(0.016~0.031 in)

4.0 mm(0.16 in)

105 mm

(4.13 in)

94 mm(3.7 in)

3,300~3,700 r/min

5,500~6,500 r/rain

16.6 mm(0.65 in)

Ratchet type

1.5~2.5 N (0.15~0.25 kgf)

(0.34~0.56 Ib)

5DA-01

#8O

2.085

3N24-3/5

2.0

3.5

#44

0.8

1.8

#48

15 ~17 ram(0.59 ~ 0.67 in)

3.0~4.0 rnrn(0.12 ~0.16 in)

1,750~1,850 r/rain

0.150~0.154 mm(0.059~0.0060 in)

6.0~6.4 mm(0.24~0.25 in)

0.2 mm (0.0078)

1.0 mm(0.04 in)

2.5 mm(0.1 in)

105.5 mm

(4.15 in)

91 mm(3.58 in)

14.6 mm(0.57 in)

2-5

M..°TE°..OE SPEO.F.C.T.O. ISPEcl "" I

TIGHTENING TORQUES

ENGINE

Part to be tightened

Spark plug

Cylinder head and cylinder

Cylinder

Air shroud 1

Air shroud lx2

Fan

Autolube pump

Reed valve

Air filter

Carburetor cap

Exhaust pipe

Muffler

Exhaust protector

Protector

Crankcase lx2

Transmission case cover

Crankcase cover 1(left)

Bolt(case2)

Crankcase cover2(left)

Part name

m

Nut

Stud bolt

Screw

Sc rew

Screw

Bolt

Sc rew

Screw

Bolt

Screw

Bolt

Screw

Bolt

Drain bolt

Oil plug

Idle gear plate

Kick crank

Starter motor

Clutch housing

Clutch weight

Magnet base

C.D.I. rotor

Bolt

Plug

Screw

Bolt

Nut

Screw

Nut

Tightening

Thread Q'ty torque

size

Nm m°kg ft°lb

M 14 1 20 2.0 14

M 7 4 14 1.4 10

M 7 4 10 1.0 7

M 6 3 7 0.7 5.1

6.0 1 2 0.2 1.4

M 6 3 7 0.7 5.1

M 5 2 4 0.4 2.8

M 6 4 11 1.1 8.0

M 6 2 9 0.9 6.5

M 4 2 2 0.2 1.4

M 6 2 9 0.9 6.5

M 8 2 26 2.6 18.2

M 6 3 11 1.1 8.0

M 6 1 9 0.9 6.5

M 6 6 12 1.2 8.4

M 6 12 12 1.2 8.4

M 6 1 7 0.7 5.1

M 6 3 7 0.7 5.1

M 8 1 18 1.8 13

M 14 1 3 0.3 22

M 6 2 8 0.8 5.8

M 6 1 9 0.9 6.5

M 6 2 13 1.3 9.4

M 10 1 40 4.0 29

M 10 1 30 3.0 22

M 6 2 8 0.8 5.8

M 10 1 38 3.8 27

Remarks

2-6

MA. A.OE SPEO.F.OAT.O. ISPEcl " I

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Ball and race bearing ...

No/size of steel balls: Upper 22 pcs ...

Lower 19 pcs ...

Front suspension:

Front fork travel

Fork spring free length

Fork length (Installed)

Spring rate (K1)

(K2)

Inner tube vend limit

Rear suspension:

Shock absorber stroke

Shock absorber free length (Installed)

Spring free length (Installed)

Spring rate (K1)

Front wheel:

Type

Rim size

Rim material

Rim runout limit

Rear wheel:

Type

Rim size

Rim material

Rim runout limit

radial

lateral

radial

lateral

Front disc brake:

Type

Disc outside diameter x thickness

Pad thickness

Master cylinder inside diameter

Caliper cylinder outside diameter

Brake fluid type

Rear drum brake:

Type

Drum inside diameter

Shoe thickness

Brake lever:

Brake lever free play (front at lever side)

Brake lever free play (rear)

Throttle cable free play

70 rnrn(2.8 in)

236.6 mm(9.31 in)

212.1 mm(8.35 in)

15.68 Nm/mm(1.6 kg/mm,901b/in)

23.5 Nm/mm(2.43

kg/mm,1361b/in)

55 mm(2.2 in)

281.8 rnrn(11.1 in)

159.8 mm(6.29 in)

71.15 N/mm(7.26 kg/mm,4071b/in)

Cast wheel

MT3.50xl 0

Aluminum

Cast wheel

MT3.50xl 0

Aluminum

Single

180x4.0mm

(7.1x0.16 in)

6 ram(0.24 in)

11 mm(0.4 in)

34.93 mm(1.38 in)

DOT #4(or DOT #3)

Leading, trailing

130 mm(5.12 in)

4 ram(0.16 in)

2~5 mm(0.08~0.20 in)

10~20 mm(0.39~0.79 in)

3~5 mm(0.12~0.20 in)

233.6 mm

0.2 mm

(0.008 in)

1 mm(0.04 in)

1 ram(0.04 in)

1 mm(0.04 in)

180x3.5 mm

(7.1x0.14in)

0.8 mm(0.03 in)

131 mm(5.16 in)

2 ram(0.08 in)

2-7

MA. A.OE SPEO.F.OAT.O. ISPEcl "" I

TIGHTENING TORQUES

CHASSIS

Part to be tightened

Frame and engine bracket

Engine bracket, compression rod and engine

Rear carrier

Rear shock absorber and frame

Rear shock absorber and engine

Steering ring nut

Handle holder and steering shaft

Brake hose and master cylinder

Fuel tank

Fuel cock

Fuel sender

Box

Seat lock assembly

Plastic parts & cover

Footrest board

Front wheel axle and nut

Rear wheel axle and nut

Rear brake cam lever

Front brake caliper and front fork

Brake disc and hub

Brake hose and caliper

Brake caliper and bleed screw

Tightening

Th read torque Remarks

size

Nm m,kg ft°lb

M 12 84 8.4 61

M 10 45 4.5 31

M 6 13 1.3 9.4

M 10 30 3.0 22

M 8 16 1.6 12

M 25 22 2.2 16 See

M 10 43 4.3 37 "page3-18"

M 8 20 2.0 14

M 6 10 1.0 7

M 6 7 0.7 5.1

M 5 4 0.4 2.9

M 6 7 0.7 5.1

M 5 2 0.2 1.4

M 6 7 0.7 5.1

M 10 70 7.0 51

M 14 120 12.0 87

M 6 10 1.0 7.2

M 8 23 2.3 16.6 41~

MIO 20 2.0 14.5

M 8 23 2.3 16.6

M 5 6 0.6 4.3

2-8

MA. A.OE SPEO.F.OAT.O. ISPEcl " I

ELECTRICAL

Item Standard limit

Ignition timing:

Ignition timing (B.T.D.C.) 14 ° at 5,000 r/min ...

Advanced type Fixed ...

C.D.I.:

Pickup coil resistance/color

Source coil resistance/color

C.D.I. unit model/manufacturer

Ignition coil:

Model/man ufacturer

Minimum spark gap

Primary winding resistance

Secondary winding resistance

248 ~ 372~ at 20°C (68°F)

(W/R-W/L)

640 ~ 960 ~ at 20°C (68°F)

(B/R-G/W)

5PJ/TIIC

4WX/TI I C

6 rnrn (0.24 in)

0.32~0.48 ~ at 20°C (68°F)

5.68~8.52k~ at 20°C (68°F)

Spark plug cap:

Type Resin ...

Resistance 5 kE2 ...

Charging System/Type: Flywheel magneto ...

5PJ/TIIC

12V 85W/5,000 rpm

0.6A at 3,000r/min

1.2A at 8,000r/min

13~14V at 4,000 rpm

0.48~0.72 ~ (White-Black)

0.4~0.6 ~ (Yellow/Red- Black)

12~15V (3,000~8,000 rpm)

3GF/Taichung

8A

18V

C.D.I. Magneto:

Model/Man ufacturer

Nominal output

Charging current

Charging voltage

Charging Coil Resistance (Color)

Lighting Coil Resistance (Color)

Lighting Voltage

Rectifier:

Model/Ma n ufactu rer

Capacity

Withstand voltage

Battery:

Specific gravity 1.320 ...

Constant mesh type

4WX/shulin

0.14 kw

0.0648 ~ 0.0792 E2 at 20°C (68°F)

6.5 mm (0.26 in)

5.49 ~ 8.24 N

(360~540 g) (12.69~19.04 oz)

16.1 mm (0.63 in)

1.05 mm (0.04 in)

4WX/Shulin

20A

54~66 E2

Electric starter system:

Type

Starter motor:

Model/ma n ufactu rer/ID n umber

Output

Armature coil resistance

Brush overall length

Spring force

Commutator diameter

Mica undercut (depth)

Starter relay:

Model/man ufacturer

Amperage rating

Coil resistance

3 mm (0.12 in)

400g

15.1 mm (0.59 in)

2-9

MA. A.OE SPEO.F.OAT.O. ISPEcl " I

Item

Horn:

Model/man ufacturer

Maximum amperage

Flasher relay:

Type

Flasher frequency

Fuel gage:

Model/man ufacturer

Sender unit resistance

Standard

4KP/Asian

1.5A

Capacitor

60~ 120 Cycle/min

4VP/Sa n Chu

4~10 ~

90~100 ~

- full

- empty

Oil level gauge:

Model/man ufacturer 4VP/Lun Ping ...

Circuit breaker:

Type Fuse ...

MAIN 7Axl pc ....

limit

2-10

OEOERA" TOROOE SPEC,F,CAT,ONS ISPEcl " I

GENERAL TORQUE

SPECIFICATIONS

This chart specifies torque for standard fasten-

ers with standard I.S.O. pitch threads. Torque

specifications for special components or as-

semblies are included in the applicable sections

of this book. To avoid warpage, tighten multi-

fastener assemblies in a crisscross fashion, in

progressive stages, until full torque is reached.

Unless otherwise specified, torque specifica-

tions call for clean, dry threads. Components

should be at room temperature.

A B

(Nut) (Bolt)

10 mm 6 mm

12 mm 8 mm

14 mm 10 mm

17 mm 12 mm

19 mm 14 mm

22 mm 16 mm

General torque

specifications

Nm

6

15

30

55

85

130

m°kg ft°lb

0.6 4.3

1.5 11

3.0 22

5.5 40

8.5 61

13.0 94

F--

A

Am

A: Distance across flats

B: Outside thread diameter

2-11

LUB..OAT.O° PO.°TS A.O LUB..OAT.O° T'.PE ISPEcl "" I

LUBRICATION POINTS AND LUBRICATION TYPE

ENGINE

Lubrication Point Lublicant Type

Oil seal lips

O-rings

Bearings --~11~

Piston surface --411~

Piston pin --411~

Cyl i n d e r --~11~

Transmission case (bearing) ---411~

Autolube pump

Starter wheel gear

Idle gear plate --~11~

Secondary drive gear ----II1~

Kickstarter pinion gear

Drive axle ---~11~

Pump drive gear

Main axle --'qG

Main axle (bearing) ---~11~

2-12

• OB"'OAT'O" PO'°TS A"O'OB"'OAT'O° T PE ISPEcl " I

CHASSIS

Lubrication Point Lubricant Type

Oil seal lips

O-rings

Bearings

Speedometer drive gear

Front brake camshaft

Front brake cable

Throttle cable

Tube guide (throttle grip) inner surface

Upper steering stem ring nut

Upper bearing outer race

Lower bearing outer race

Rear brake camshaft

Centersta nd

2-13

CAB'E.OOT,.O ISPEcl " I

CABLE ROUTING

(~ Horn

(~ Rectifier regulator

(~ Main switch

(~ Headlight leads

(~) Speedometer cable

(~ Ignition coil

(~ Throttle cable 1

(~ Throttle cable 3

(~ Battery negative(-)

@ Wire brake

(~) Fuel sender lead

(~) Seat lock cable

(~) Oil tank hose

@ C.D.I. unit

(~) Wire harness

[] Pass the speedometer cable

through the right hole of front

fender, then through the

guide.

[] Pass the wire harness through

the inside of ignition coil.

[] Secure the ground lead and

the ignition coil base to the

ignition coil stay.

[] Pass the wire harness through

the inside of oil tank.

[] Pass the seat cable through

the inside of frame.

[] Align the clip with the white

brand.

[] Clamp the wire harness.

[] Insert the seat cable through

the frame tube.

[]Clamp wireharness, rear

brake cable throttle cable 1,3.

[] Position the cylinder between

the supporter and main

switch.

2-14

OAB'E.OOT,°O ISPEcl " I

(~ Brake cable

(~) Speedometer cable

(~ Fuel tank overflow hose

(~ Brake cable holder

(~ Brake hose

(~ Brake hose holder

(~ License bracket

(~ Flasher relay

(~ Fuel tank breather hose

@ Fuel hose

@ Breather hose

[] Pass the brake hose through the holder.

[] Insert the fuel overflowhose bottom.

[] Pass the fuel overflowhose through the rear

fender hole.

[] Pass the fuel overflowhose through the

holder.

[] Hold the fuel overflowhose with a clamp.

[] Pass the brake cable through the holder.

2-15

CAB'E.OOT,°O IS"Eel " I

(~ Brake hose

(~) Front fender

(~ Front fork assembly

(~ Nut

(~ Plate washer

(~ Brake hose holder

(~ Flange bolt

(~ Bolt

(~ Brake hose holder

@ Flange bolt

[] Pass the brake hose through the holder.

Q

./

/ /

t /

/

/(~

ff

2-16

C,B'E.OOT,°O IS"Eel " I

(~ Ignition coil

(~) Spark plug lead

(~ Starter relay leads

(~ Auto choke leads

(~ Starter relay

(~ Bind

(~ C.D.I. unit

(~ Autolube hose

(~ Seat lock cable

@ Bracket

@ Fuel tank breather hose

@ Bind 2

(~ Battery(-)lead

@ Battery(+)lead

[] Pass battery leads through

the slot of footrestboard.

[] Cover them after securing

starter relay leads.

[] Pass the seat lock cable

through the hole of bracket.

[] Pass the fuel tank breath

hose over seat lock cable.

[] Clamp carburetor vacuum

hose, fuel hose and fuel

cock vacuum hose.

[]Clamp autochoke leads

and autolube hose on to carbure-

tor throttle cable.

[] Pass the battery leads over frame

member.

[] Put fuse box on to footrest board

holder.

[] Pass throttle cable1,3 wireharness,

autolube pump cable, brake cable

through the outside of battery box.

B r iJ "

~i~ ~ ~, ~ ......... ~ ~q~-~l

..q-.~,J I I ~ *~/'~ ....... I •

@~.

D

~, ~.,~J ',~

2-17

CAB'E ROOT,OO ISPEcl " I

(~ Handlebar switch(right)

(~) Speedometer

(~ Wire brake

(~ Handlebar switch(left)

(~ Wire harness

(~ Brake hose

(~ Speedometer cable

(~ Throttle cable1

(~ Throttle cable 3

@ Front flasher leads

[] Pass brake cable through the slot of bracket.

[] Avoid clamping front flasher leads when in-

stalling handlebar covers.

[]Pass throttle cable1,3 through between

handlebar and wireharness.

[] Hang the wireharness bind on to the bracket.

:'7 ~ L

[j}j~ ...............

f

I F

" ~I .... ! i i

~', JI ...... #

]3

B

C

2-18

INTRODUCTION/

PERIODICIVIAINTENANCE/LUBLICATION INTERVALS

I INSP

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary'to perform recommended inspections and adjust-

ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle

operation and a longer service life. The need for costly" overhaul work will be greatly" reduced. This

information applies to vehicles already' in service as well as to new vehicles that are being pre-

pared for sale. All service technicians should be familiar with this entire chapter.

YP301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NO. ITEM

1 *

3

4 *

5 *

6 *

7 *

8 ~

9 *

1C *

ROUTINE

TYPE

BREAK-IN

INITIAL

1,000 km

(600 mi)

0

0 0

0

0 0

EVERY

3,000 km

(2,000 mi)

or

6 months

(whichever

co mes first

6,000 km

(4,000 mi)

or

12months

(wh]chever

comes fi rst

• Check fuel hoses and vacuum hose

Fuel line for cracks or damage. - O

• Replace if necessary.

• Check condition.

Refer to SPARK

Spark plug • Clean, regap or replace if neces-

PLUG INSPECTION O

sa ry.

Air filter element • Clean or replace if necessary,

s ....... ginooil O

• Check operation, fluide level and Brake fluid DOT 4

Front brake vehicle for fluid leakage. Ior DOT

3) O

•

Replace brake pads.

Whenever worn to the limit.

• Check operation.

Rear brake • Adjust brake lever free play. - O O O

•

Replace brake shoes.

Whenever worn to the limit.

• Check balance, runout and for

Wheels damage. - O O

• Replace if necessary.

• Checktread depth and for damage.

Tires - Replace if necesssary. - O O O

• Check air pressure.

• Correct if necessary.

• Check Bearing for looseness or

Wheel bearings damage. - O O

• Replace if necessary.

Steering bear- • Check bearing play and steering for 0 0 0

ings roughness.

• Lubricate with lithium soap base - Every 12,000 km(8,000 mi)or 24

greese,

months(whichever occurs first).

Chassis fasteners •Make sure that all nuts, bolts and - 0 0

screws are properly tightened.

3-1

PERIODICINSPECTION AND

ADJUSTMENTS I INSP D

I I

NO.

11

12"

13"

14 *

15"

16"

17 *

ITEM ROUTINE

TYPE

BREAK-IN

INITIAL

1,000 km

(600 mi)

EVERY

3,000 km

(2,000 mi)

or

6 months

(whichever

comes first)

6,000 km

(4,000 mi)

or

12months

(wh ichever

comes fi rst

• Check operation.

Centerstand • Lubricate with lithium soap base

Sarne as engine oil O O

greese (all purpose grease).

Front fork - Check operation and for oil leakage. - O O

-Check operation and shock ab-

Rear shock ab- sorber for oil leakage. - O O

sorberassembly - Replace shock absorber assembly

if necessary.

Carburetor • Check engine idling speed. - O O O

• Adjust if necessary.

• Check operation.

Autolube pump - Correct if necessary. - O @ O

• Bleed if necessary.

Final transmis- -Checkoil level and vehicle for oil - O O O

sion oil leakage.

Every 12,000 km(8,000

•

Replace.

Yarnalubel0W 30 SE 4orSAEGL O mi)or 24 mont hs(whichever

gear oil Occurs first).

V-belt o Replace.

Every 9,000 kin(6,000 mi)

Items marked with an asterisk (*) require special tools, data and technical skills for servicing. Take

the scooter to a Yamaha dealer.

NOTE:

• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

• Brake fluid replacement:

1. Replace the brake fluid after disassembling the master cylinder or caliper cylinder. Check the

brake fluid level and add fluid as required.

2. Replace the master cylinder and caliper cylinder oil seals every two years.

3. Replace the brake hoses every four years, or if cracked or damaged.

NOTE:

From 6,000 mi (9,000 km)-or 18 months, repeat the maintenance intervals starting 2,000 mi (3,000

mi) or 6 months.

3-2

COVER AND PANEL

I

INSP

COVER AND PANEL

SIDECOVER AND SEAT

8

' i

~,~/~ ~m.kg, 9.4ft.lb)

y---// j j

@

Order Job name/Part name

.

3.

4.

5.

6.

7.

8.

Sidecover and seat removal

Battery box cover

Seat

Seat hange

Rear carrier

Rear cover

Left side cover

Right side cover

Center cover

Q'ty

Remarks

Remove the parts in order.

NOTF"

Insert the (-) screwdriver into the slot of

battery cover and pickup then remove.

Reverse the removal procedure for instal-

lation.

3-3

COVER AND PANEL

I

INSP

LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD

4

[~1 7Nm(0.7m.kg, 5.1ft.lb)

.. o ~ "" ~ I /

5

6

//

Order Job name/part name

.

2.

3.

4.

5.

6.

Q'ty

Lower cowling, upper cover, leg

shield 1,2 and footrest board re-

moval

Lower cowling 1

Upper cover 1

Leg shield 1 1

Main switch cover/leg shield 2 1/1

Battery 1

Footrest board 1

Remarks

Remove the parts in order.

Reverse the removal procedure for instal-

lation.

3-4

COVER AND PANEL

I

INSP

HANDLEBAR COVER(FRONT AND REAR)

1

Order Job name/Part name

1.

2.

3.

4.

Q'ty

Handlebar cover(Front and Rear) re-

moval.

Mirrors 2

Front handlebar cover 1

Rear handlebar cover 1

Flasher light(Left/Right) 1/1

Remarks

Remove the part in order.

Reverse the removal procedure for instal-

lation.

3-5

ENGINE IDLE SPEED ADJUSTMENT

I INSP

\

ENGINE

IDLE SPEED ADJUSTMENT

1. Remove

• Battery box cover (~

2. Tighten:

• Pilot air screw (~)

Turn the pilot air screw in until lightly

seated.

3. Loosen:

• Pilot air screw

Back it out from its lightly seated posi-

tion.

I Pilot air screw turn out: I

load 1-1/4

2. Start the engine and let it warm up.

r!~VAVL, W --'] ~ I I ~ [¢-!

Before starting the engine, be sure to use the

centerstand for safety.

.

Attach:

• Inductive tachometer (~

To the spark plug lead

I<~1 Inductive tachometer:

YU-8036-A

4.

Check:

• Engine idle speed

Out of specification-->Adjust.

I-~1 Engine idle speed

1,750~1,850 r/min

5. Adjust:

• Engine idle speed

Adjustment steps.

• Turn the throttle stop screw(~ in or out until

specified idle speed is obtained.

I Turn i:u t Idle speed becomes higher. I

Turn Idle speed becomes lower.

3-6

THROTTLE CABLE FREE ADJUSTMENT

I INSP

THROTTLE CABLE FREE ADJUSTMENT

1. Check:

• Throttle cable free play (~

Out of specification-->Adjust.

ree o I

3 ~ 5 mm(0.12 ~ 0.20 in)

Throttle cable free play adjustment steps;

NOTE:

Before adjusting the throttle cable free play, the

engine idle speed should be adjusted.

• Remove the adjuster cover (~

• Loosen the Iocknut @~) on the throttle cable.

• Turn the adjuster (~ in or out until the speci-

fied free play is obtained.

I Turning in--~Free play is increased. I

Turning out->Free play is decreased.

• Tighten the Iocknuts.

• Install the adjuster cover

After adjusting the throttle cable free play, start

the engine and turn the handlebar to the right

and to the left to ensure that this does not cause

the engine idling speed to change.

3-7

AUTOLUBE PUMP AIR BLEEDING

I INSP

AUTOLUBE PUMP AIR BLEEDING

1. Remove

• Lower cowling

• Air shroud 1 (~

2. Air bleeding:

• Pump case and / or oil hose.

* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

Air bleeding steps:

• Place a rag under the autolube pumpto catch

the oil.

• Remove the bleed screw (~.

• Keepthe oil running out until air bubbles dis-

appear.

• When air bubbles are expelled completely,

tighten the bleed screw.

NOTE:

Check the bleed screw gasket. If damaged, re-

place with a new one.

Place a oil pan under the autolube pump to

catch oil.

3. Air bleeding:

• Pump distributor and/or delivery hose

Air bleeding steps:

• Start the engine.

• Run the engine for 2-3 minutes at 2000 r/min.

This will completely remove autolube pump

system of air.

3-8

SPARK PLUG INSPECTION I INSP

SPARK PLUG INSPECTION

1. Remove:

• Battery box cover

2. Inspect:

• Spark plug type

I nco rrect-->Replace.

I Standard spark plug: I

BPR7HS/NGK

3. Inspect:

• Electrode (~

Wea r/Da m ag e-->Re place.

• Insulator (~)

Abnormal color->Replace.

Normal color is a medium-to-light tan

color.

4. Clean the spark plug with a spark plug

cleaner or wire brush.

5. Measure:

• Plug gap (~

Use a wire gauge or feeler gauge.

Out of specification-->Regap.

I l'0ar'0u00ao

I

0.6 ~ 0.7 mm (0.02 ~ 0.03 in)

6. Tighten:

• Spark plug I~4~i 20Nm(2"0m'kg'14ft'lb) I

7. Install:

• Battery box cover.

3-9

ENGINE OIL LEVEL INSPECTION

I

INSP

ENGINE OIL LEVEL INSPECTION

1. Inspect:

• Engine oil level Oil level Iow--~Add suf-

ficient oil by the following inspection

steps.

(~ "OIL"

indicator light

Engine oil level visual inspection steps:

Turn main switch to "*"

position.

t

|

"OIL"

indicator light does I

I

not comes on.

"OIL" indicator

comes on.

light

Inspect faulty electrical

circuit, light bulbs etc.

Turn main switch to

"ON"

position.

t

/

"OIL"

indicator light does I_

C

not come on.

Engine oil level and elec-

trical circuit are OK.

1

"OIL"

indicator

comes on.

Supply engine oil.

"OIL" indicator light comes on.

light

©1

Recommended oil:

For Yamaha:

Yamalube 2 or 2-stroke engine oil

(ISO EG-C, EG-D grade)

Total:

1.4L(1.23 Imp.qt, 1.48 US.qt)

NOTE:

Install the oil tank filler cap (~ and push it fully

into the filler.

3-10

TRANSMISSION OIL REPLACEMENT

I INSP

TRANSMISSION OIL REPLACEMENT

1. Warm up the engine for several minutes,

then stop the engine.

2. Place a container under the drain hole.

3. Remove:

• Oil filler plug (~

• Drain bolt (with gasket) ~)

NOTE:

Drain the transmission oil completely.

While draining, slightly tilt the scooter to

the right and to the left.

4. Inspect:

• Gasket (drain bolt) (~

• O-ring (oil filler plug) (~

Damage--~Replace.

5. Install:

Drain bolt

H 18 .m m,g. 13.,,)1

6. Fill:

• Transmission case

©1

Recommended oil:

Yamalube 4 SAE 10W 30SE or GL gear

oil

Oil capacity:

Total amount

0.13 L (0.11 Imp.qt, 0.13 US.qt)

Periodic oil change

0.11 L(0.096 Imp.qt, 0.12 US qt)

CAUTION:

• Always use the same type of oil; mixing

oils may result in a harmful chemical re-

action and lead to poor performance.

• Do not allow foreign material to enters

the transmission case.

7. Install:

• Oil filler plug (with O-ring)

8. Inspect:

• Oil leaks

• Oil level

NOTE:

Wipe off any oil spilt on the transmission, tire

or wheel.

3-11

AIR FILTER ELEMENT CLEANING

I INSP

AIR FILTER ELEMENT CLEANING

1. Remove:

• Battery box cover

2. Remove:

• Caburetor jont clamp ~)

3. Remove:

• Screw

• Air filter (~

4. Remove:

• Air filter case (~)

• Air filter element

CAUTION:

Never operate the engine with the air filter el-

ement removed. This will allow unfiltered air

to enter, causing rapid wear and possible en-

gine damage. Additionally, operation without

the cleaner element will affect carburetor jet-

ting with subsequent poor performance and

possible engine overheating.

Be careful not to have rags or the like blocking

the intake area of the air filter.

5. Inspect:

• Element (~

Da mage-->Replace.

6. Clean:

• Air filter element

Air filter element cleaning steps:

• Wash the element gently, but thoroughly in

solvent.

3-12

AIR FILTER ELEMENT CLEANING

I

INSP

AWARNING

Never use low flash point solvents such as

gasoline to clean the element. Such solvent

may lead to a fire or explosion.

• Squeeze the excess solvent out of the ele-

ment and let dry.

CAUTION:

Do not twist the element when squeezing the

element.

• Apply the foam -air filter oil or engine oil.

• Squeeze out the excess oil.

NOTE:

The element should be wet but not dripping.

7. Install:

• Air filter

• Battery box cover

3-13

V-BELT INSPECTION

I INSP

V-BELT INSPECTION

1. Remove:

• Kick crank (~

• Screws (~

• Crankcase cover 2(left) (~)

• Screws(Air cleaner and left crankcase

cover (~

• Crankcase cover 1(left) (~

.

Inspect

• V-belt (~

Cracks/Wea r/Da mage-->Replace.

Oil or grease adhere to the

V-belt-->Check the primary and second-

ary sheaves.

Refer to "ENGINE OVERHAUL -INSPEC-

TION AND REPAIR" section in the CHAP-

TER 4.

.

Measure:

• V-belt width (~

Out of specification-->Replace.

Refer to "ENGINE OVERHAUL" section

in the CHAPTER 4.

~ V-belt width"

16.6 mm (0.65 in)

<Limit> 14.6 mm (0.57 in)

NOTE:

Measure the V-belt width on several points.

3-14

4.

Install:

• Crankcase cover 1 (left)

I~%l 12Nm(1.2m.kg, 8.4 ft.lb) I

• Air cleaner [~l 9N m(0.9m.kg, 6.5 ft.lb) I

• Crankcase cover 2 (left)

• Kick crank

F"O"T B"A"E'EVE" F"EE P'AY C"EC"'"EA" B"A"E I,.Sp I I

LEVER FREE PLAY CHECK/BRAKE PAD INSPECTION ADJ

CHASSIS

FRONT BRAKE LEVER FREE PLAY CHECK

1. Check:

• Front brake lever free play

I~1 2~5 mm(0.08~0.20 in) I

xkWARNING

A soft or spongy feeling in the brake lever can

indicate the presence of air in the brake sys-

tem. This air must be removed by bleeding the

brake system before the motorcycle is oper-

ated. Air in the system will cause greatly di-

minished braking capability and can result in

loss of control and an accident. Inspect and

bleed the system if necessary.

REAR BRAKE LEVER FREE PLAY CHECK

1. Check:

• Rear brake lever free play (~

Out of specification-->Adjust.

I~110~20 mm,o 3~0 79,n, I

<

X o

to

Rear brake lever free play adjustment steps:

• Turn the adjuster (~ in or out until the cor-

rect free play is obtained.

j

3-15

BRAKE PAD INSPECTION

1. Activate the brake lever.

2. Inspect:

• Brake pad

Wear indicator (~ nearly contacting

brake disc-->Replace brake pads as a set.

Refer to the "BRAKE PAD REPLACE-

MENT" section in the CHAPTER 6.

(~ Brake disc

(~ Brake pads

B"AKE S"OE'"SPECT'O°' I'"SP I I

BRAKE FLUID LEVEL INSPECTION

\

BRAKE SHOE INSPECTION

1. Activate the brake lever.

2. Inspect:

• Wear indicator (~

Indicator at wear limit line (~)-->Replace

brake shoes.

G

-L

m

BRAKE FLUID LEVEL INSPECTION

NOTE:

Position the scooter straight up when inspect-

ing the fluid level.

.

Inspect:

• Fluid level is under "LOWER" level line

(~-->Fill to proper level.

Ii~l Recommended fluid:

DOT#4(or DOT#3)

CAUTION:

The fluid may corrode painted surfaces or plas-

tic parts. Always clean up spilled fluid imme-

diately.

~!~LvAv/±1-'] ~ I I~ [¢!

eUse only the designated quality fluid. Other-

wise ,the rubberseals may deteriorate caus-

ing leakage and poor brake performance.

eRefill with the same type of fluid. Mixing flu-

ids may result in a harmful chemical reaction

leading to poor brake performance.

eBe careful that water does not enter the mas-

ter cylinder when refilling. Water will signifi-

cantly lower the boiling point of the fluid and

may result in vapor lock.

3-16

AIR BLEEDING (HYDRAULIC BRAKE

SYSTEIVI) I INSP

1

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

1. Bleed:

• Brake fluid

Air bleeding steps:

a. Add proper brake fluid to the reservoir.

b. Install the diaphragm. Be careful not to

spill any fluid or allow the reservoir to

overflow.

c. Connect the clear plastic tu be (~ tightly to

the caliper bleed screw.

d. Place the other end ofthetube into a con-

tainer.

e. Slowly applythe brake lever several times.

f. Pull the lever in. Hold the lever in posi-

tion.

g. Loosen the bleed screw and allow the le-

ver to travel towards its limit.

h. Tighten the bleed screw when the limit

has been reached, then release the lever.

i. Repeat steps (e)to (h) until the air bubbles

have been removed from the system.

j. Add brake fluid to proper level.

~!~LvAv/±1 -'t ~ I I ~ [¢-!

Check the operation of the brake after bleed-

ing the brake system.

3-17

STEERING ADJUSTMENT

I INSP

!

STEERING ADJUSTMENT

1. Check:

• Steering assembly bearings

Gap the bottom of the forks and gently

rock the fork assembly back and forth.

Loosen-->Adjust.

* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

Adjustment steps:

• Remove upper cover, lower cowling, leg

shield 1,2. refer to "COVER AND PANEL" sec-

tion.

• Remove all ringnuts using ringnut wrench.

::~1 Ring nut wrench: I

YU-33975

• Tighten the ring nut 3 (~ using nut wrench.

[~122 Nm(2.2 m.kg, 16 f-t.lb) I

NOTE:

Set the torque wrench to the ring nut wrench

so that they form a right angle.

• Loosen the ring nut 3 (~ 1/4 turn.

• Install rubber ring (~) and ring nut 2 (~, then

tighten the ring nut 2 until it contacts with

rubber ring.

CAUTION:

Aligning the slot of ring nut 2 with the slot of

ring nut 3. If not, slightly tighten ring nut 2 un-

til the slots alignment.

• Install special washer (~

NOTE:

Insert the projections of special washer into the

slots of ring nut 3, 2

• Install ring nut 1(~ r~166Nm(6.6 m.kg, 478~.b> I

• Move the handlebar up and down, and/or

back and forth. If handlebar play is excess,

remove the front fork assembly and check

the balls/ball races. Refer to chapter 6.

3-18

TIRE INSPECTION

I INSP

FRONT

Manufacturec Size

CHENG SHIN 120/90-10

REAR

Manufacturec Size

CHENG SHIN 130/90-10

Type

56J

Type

59J

>

®

TIRE INSPECTION

WARNING

• The tire pressure should only be checked and

regulated when the tire temperature equals

the ambient air temperature,

• The tire pressure must be adjusted accord-

ing to the total weight (including cargo, rider

passenger and accessories) and the antici-

pated riding speed,

• Operation of an overloaded scooter could

cause tire damage, an accident or an injury,

NEVER OVERLOAD THE SCOOTER,

Basic weight

(with oil and a 94kg(2071b)

full uel tank)

Maximum load* 143kg(3151b)

Front Rear

Cold tire pres-

sure

200 kpa 200 kpa

(2.0 kgf/cm 2, (2.0 kgf/cm<

29 psi) 29 psi)

* Total of cargo, rider, passenger and acces-

sories.

•WARNING

It is dangerous to ride with a worn-out tire.

When the tire tread reaches the wear limit, re-

place the tire immediately.

.

Inspect:

• Tire surfaces

Wea r/Da m age-->Re place.

Minimum tire tread depth (~

(front and rear):

1.6 mm (0.06 in)

(~ Tread depth

(~) Side wall

(~) Wear indicator

3-19

CHECKING THE

TmES l INSP I I

a__l

BI

•WARNING

• Do not use a tubeless tire on a wheel de-

signed only for tube tires to avoid tire fail-

ure and personal injury from sudden defla-

tion.

• When using tube tires, be sure to install the

correct tube.

• Always replace a new tube tire and a new

tube as a set.

• To avoid pinching the tube, make sure the

wheel rim band and tube are centered in the

wheel groove.

• Patching a punctured tube is not recom-

mended. If it is absolutely necessary to do

so, use great care and replace the tube as

soon as possible with a good quality replace-

ment.

[] Tire

IB] Wheel

Tube wheel Tube tire only

Tubeless wheel Tube or tubeless tire

• After extensive tests, the tires listed below

have been approved by Yamaha Motor Co.,

Ltd. for this model. The front and rear tires

should always be by the same manufacturer

and of the same design. No guarantee con-

cerning han-dling characteristics can be

given if a tire combination other than one

approved by Yamaha is used on this scooter.

3-20

CHECKING THE TIRES/CHECKING THE

WHEELS I INSP

New tires have a relatively low grip on the road

surface until they have been slightly worn.

Therefore, approximately 100 km should be

traveled at normal speed before any high-

speed riding is done.

NOTE:

For tires with a direction of rotation mark (~:

• Install the tire with the mark pointing in the

direction of wheel rotation.

• Align the mark (~)with the valve installation

point.

3-21

WHEEL INSPECTION/FRONT FORK INSPECTION

REAR SHOCK ABSORBER INSPECTION/SEAT LOCK CABLEADJUSTMENT

I

INSP

WHEEL INSPECTION

1. Inspect:

• wheels

Da mage/Bends-->Replace.

Never attempt to make any repairs to the wheel.

NOTE:

After a tire or wheel has been changed or re-

placed, always balance the wheel.

FRONT FORK INSPECTION

1. Inspect:

• Front fork~

Bends/Damage-->Replace inner tube

comp, fork ass'y.

Grease leakage--~Replace inner tube

comp. fork ass'y.

Unsmooth operation-->Replace fork

ass'y.

REAR SHOCK ABSORBER INSPECTION

1. Inspection:

• Rear shock absorber(~)

Oil leaks/Da mage-->Re place.

2. Check

• Tightening torque

%~ Upper(nut) 30Nm (3.0 m.kg, 22ft.lb',

Lower (bolt) 16 Nm(1.6 m.kg, 12ft.lb',

SEAT LOCK CABLE ADJUSTMENT

1. Remove:

• Upper cover

Refer to "COVER AND PANEL" section.

2. Adjust:

• Seat cable

Seat cable adjustment steps:

• Loosen lock nut (~

• Turn adjuster (~ in or out to adjust the seat

lock cable.

• Tighten the lock nut.

3. Install:

• Upper cover

3-22

CABLE C°EOK.°O A°O "UB..OAT.°O. "EVE.S "UB..OAT.°O "'"SP''"' '

CENTERSTAND LUBRICATING ADJ

I I~1

EAS00170

CABLE CHECKING AND LUBRICATING

The following

procedure

applies to all of the

cable sheaths and cables.

r!~VAVL, W --'t~ I I ~ [¢-!

Damaged cable sheaths may cause the cable

to corrode and interfere with its movement.

Replace damaged cable sheaths and cables as

soon as possible.

.

Check:

• cable sheath

Damage --> Replace.

Check:

• cable operation

Rough movement --> Lubricate.

Recommended lubricant t

Engine oil or a suitable cable lubri

ca nt

NOTE:

Hold the cable end upright and pour a few

drops of lubricant into the cable sheath or use

a suitable lubricating device.

EAS00171

LEVERS LUBRICATING

Lubricate the pivoting point and metal-to-metal

moving parts of the levers.

Recommended lubricant

Lithium soap base grease

EAS00173

CENTERSTAND LUBRICATING

Lubricate the pivoting point and metal-to-metal

moving parts of the centerstand.

Recommended lubricant

Lithium soap base grease

3-23

BATTERY INSPECTION

I INSP

ELECTRICAL

BATTERY INSPECTION

NOTE:

Since the MF battery is of a sealed-type con-

struction, it is impossible to measure the spe-

cific gravity of the electrolyte in order to check

the state of charge in the battery. Therefore, to

check the state of charge in the battery, volt-

age must be measured at the batteryterminals.

CAUTION:

CHARGING METHOD

• This battery is sealed type. Never remove

sealing caps even when charging. With the

sealing cap removed, this balancing will not

be maintained, and battery performance will

lower gradually.

• Never add water. If distilled water is added,

chemical reaction in the battery will not pro-

ceed in the normal way, thus making it im-

possible for the battery to operate regularly.

• The charging time, charging current and

charging voltage for the MF battery is differ-

ent than general type batteries.

The MF battery should be charged as in-

structed in the "Charging method". Should

the battery be overcharged, the electrolyte

level will lower extremely. Therefore, use

special care when charging the battery.

• Avoid using any electrolyte other than speci-

fied. The specific gravity of the MF battery

electrolyte is 1.32 at 20°C (68°F). (The spe-

cific gravity of the general type battery elec-

trolyte is 1.28. ) If the electrolyte whose spe-

cific gravity is less than 1.32, the sulfuric acid

will decrease and thus low battery perfor-

mance will result.

Should any electrolyte, whose specific grav-

ity is 1.32 or more, be used, the battery plates

will corrode and battery life will shorten.

1. Remove:

• Battery box cover

Refer to "COVER AND PANEL" section.

2. Remove:

• Battery

NOTE:

Remove the (-) lead first.

3-24

BATTERY INSPECTION

//

Volt meter

(v)

13.0

&

12.5

o

12.0

~, 11.5

0

Relationship between open-circuit

8°C)

i

5 6.5 ~0

Charging time(hours)

• This varies depending on the temperature, the state of

charge in battery plates and the electrolyte level.

3-25

I

INSP

Batteries generate explosive hydrogen gas and

contain electrolyte which is made of poison-

ous and highly caustic sulfuric acid.

Therefore, always follow these preventive

measures:

• 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 han-dling

batteries.

• KEEP BATTERIES AND ELECTROLYTE OUT

OF REACH OF CHILDREN.

• Avoid bodily contact with electrolyte as it

can cause severe burns or permanent eye

injury.

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 fol

lowed with milk of magnesia, beaten egg or

vegetable oil. Get immediate medical atten-

tion.

3. Check:

• Battery condition

Battery condition checking steps:

• Connect a digital volt meter to the batteryter-

minals.

I Tester (+) lead Battery (+) terminal. I

Tester (-) lead Battery (-) terminal.

I

NOTE:

The state of a discharged MF battery can be

checked by measuring open circuit voltage (the

voltage measured with the positive terminals

being disconnected).

INSPECTION

I INSP

BATTERY ~1(~1

14

.~ 11

&

o

2

&

o

| |

|

I I

B B

100 75 50 30 25 20

Condition of charge in battel~J(%)

Ambient

temperature

20°C

Charging

Ambient temperature

20oc

\

Time(Minutes)

~1~ Check the open circuit

voltage

Open circuit voltage Charging time

12.8 v or more No charging is necessary.

• Check the battery condition using figures.

EXAMPLE:

Open circuit voltage = 12.0v

Charging time = 6.5 hours

Condition of charge in battery = 20 ~ 30%

2. Charging method of MF battery

CAUTION:

• If it is impossible to set the standard charg-

ing current, be careful not to overcharge.

e When charging the battery, be sure to re-

move it from the motorcycle. (If charging has

to be done with the battery mounted on the

motorcycle for some reason, be sure to dis-

connect the wire at the negative terminal.)

• Never remove the sealing plug from the MF

battery.

• Use special care so that charging clips are in

a full contact with the terminal and that they

are not shorted. (A corroded clip of the

charger may cause the battery to generate

heat at the contact area. A weak clip spring

may cause sparks.)

• Before removing the clips from the battery

terminals, be sure to turn off the power

switch of the charger.

• Change in the open-circuit voltage of the MF

battery after being charged is shown below.

As shown in the figure, the open circuit volt-

age is stabilized 30 minutes after charging

has been completed.

Therefore, to check the condition of the bat-

tery, measure the open-circuit voltage 30

minutes after has been completed.

3-26

BATTERY INSPECTION

I INSP

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

Charger AMP

meter

YES

Measure the open-circuit volt-

age prier to charging.

t

Connect a charger and AMP

meter to the battery and start

charging.

+

Make sure the current is higher

than the standard charging

current written on the battery.

Adjust the voltage so that current 4

is at standard charging level.

1

YES

Set the timer according to the

charging time suitable for the

open-circuit voltage. Refer to

"Battery condition checking

steps".

NOTE:

Voltage should be measured

30 minutes after the machine

is stopped.

NOTE:

Set the changing voltage at

16 17 V. (Ifthe setting is lower,

charging Will be insufficient.

If too high, the battery Will be

over-charged.)

l

NO

1

By turning the charging voltage

adjust dial, set the charging volt-

age at 20 - 25 V.

+

Monitor the amperage for 3-5

minutes to check if the standard

charging current is reached.

NO

1

If current does

not exceed stan-

dard charging

current after 5

minutes, replace

the battery.

In case that charging requires more than 5 hours, it is advisable to

check the charging current after a lapse of 5 hours. If there is any

change in the amperage, readjust the voltage to obtain the standard

charging current.

I

J

Measure the battery open-circuit voltage after having left the bat-

tery unused for more than 30 minutes.

12.8 V or more --- Charging is complete.

12.7 V or less --- Recharging is required.

Under12.0 V --- Replace the battery.

3-27

BATTERY INSPECTION

I INSP

Charging method using a constant-voltage type charger

Volt meter

Charger

Measure the open-circuit volt-

age prier to charging.

AMP meter

II

~ Connect a charger and AMP

meter to the battery, and start

I charging.

NOTE:

Voltage should be measured 30 min-

utes after the machine is stopped.

YES

1

Charge the battery until the

battery's charging voltage is 15

volts.

Make sure the current is higher

than the standard charging

current written on the battery.

NOTE:

Set the charging time at 20 hours

(maximum).

NO

1

This type of battery charger Can

not charge the MF battery. A

variable voltage charger is rec-

ommended.

Checkthe open-circuit voltage after hav-

ing left the battery for 30 minutes

after charging.

12.8 V or more--- Charging is complete.

12.7 V or less --- Recharging is neces-

sary.

Under 12 V --- Replace the battery.

Charging method using a constant current type charger

This type if battery charger Can not charge the MF battery.

3-28

FUSE INSPECTION I INSP

4. Inspect:

• Battery terminal

Dirty terminal-->Clean with wire brush.

Poor co n nection-->Co rrect.

NOTE:

After cleaning terminals, apply lightly to the

terminals.

.

Install

• Battery

• Battery box cover

3-29

FUSE INSPECTION

1. Remove:

• Battery box cover

Refer to "COVER AND PANEL" section.

2. Remove:

• Fuse (~

3. Inspect:

• Fuse (~

defective--~Replace

* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

Blown fuse procedure steps:

• Turn off ignition and the circuit.

• Install a new fuse of proper amperage.

• Turn on switches to verify operation of elec-

trical device.

• If fuse blows immediately again, check cir-

cuit in question.

~!~Lvlv/±1 :] ~11 ~ [¢-!

Never use a fuse with an amperage rating other

than that specified. Improvising or using a fuse

with the wrong amperage rat-ing may cause

extensive damage to the electrical system,

cause the lighting and ignition systems to mal-

function and could possibly cause a fire.

Description Amperage Quantity

Main 7A 1

.

Install:

• Fuse

• Battery box cover

HEADLIGHT BEAM ADJUSTMENT

I

INSP

/HEADLIGHT BULB REPLACEIVIENT I

I

\ j)

HEAD LIGHT BEAM ADJUSTMENT

1. Adjust:

• Head light (vertically)

Turn the adjusting screw(~ in or out to

adjust headlight beam.

• Head light (Horizontal)

Turn the adjusting screw(~ in or out to

adjust headlight beam.

HEADLIGHT BULB REPLACEMENT

1. Remove:

• Upper cover

Refer to "COVER AND PANEL" section.

2. Disconnect:

• Headlight coupler (~

3. Remove:

• Bulb holder cover (~

4. Remove:

• Headlight bulb holder (~

Turn the bulb holder counterclockwise

to remove it.

5. Remove:

• Bulb(defective) (~

W!~VAV/±I -'| ~ I I ~ [¢']1

Since the headlight bulb gets extremely hot,

keep flammable products and your hands

away from the bulb until it has cooled down.

3-30

i,.S.l l

HEADLIGHT BULB / TURN SIGNAL BULB REPLACEMENT ADJ

6. Install:

• Bulb(new)

CAUTION:

Avoid touching the glass part of the head-light

bulb to keep it free from oil, otherwise the

transparency of the glass, the life of the bulb

and the luminous flux will be adversely af-

fected. If the headlight bulb gets soiled, thor-

oughly clean it with a cloth moistened with

alcohol or lacquer thinner.

7. Install:

• Bulb holder

• Turn the bulb holder clockwise to install

it.

8. Install:

• Bulb holder cover

9. Connect:

• Headlight coupler

10. Install:

• Upper cover

11. Adjust:

• Headlight beam

Refer to "HEADLIGHT BEAM

ADJ USTMENT"section

_ /REAR

®

TURN SIGNAL BULB REPLACEMENT

1. Remove:

• Screw (~

• Lens (~

2. Replace:

• Bulb (defective)(~

3. Install:

• Lens (~)

• Screw (~

CAUTION:

Do not over-tighten the screws as the lens may

break.

3-31

i,.s l l

TAILLIGHT BULB / LICENCE LIGHT BULB REPLACEMENT ADJ

CAUTION:

Avoid touching the glass part of the head-light

bulb to keep it free from oil, otherwise the

transparency of the glass, the life of the bulb

and the luminous flux will be adversely af-

fected. If the headlight bulb gets soiled, thor-

oughly clean it with a cloth moistened with

alcohol or lacquer thinner.

TAILLIGHT BULB REPLACEMENT

1. Remove:

• Screws (~

• Lens (~

2. Replace:

• Bulb (defective) (~

3. Install:

• Lens (~)

• Screws ~)

LICENSE LIGHT BULB REPLACEMENT

1. Remove:

• Screws (~

• Lens (~)

2. Replace:

• Bulb (defective) (~

3. Install:

• Lens (~)

• Screws (~

3-32

E.O..E.EMOVA" I E"O I o '1

EB400000

ENGINE REMOVAL

WlREHARNESS AND CABLES

ENGINE OVERHAUL

12

1~145Nm( 4-5

m.kg, 31ft.lb) I

~120Nm(12.0 m.kg, 87 ft.lb)

7

Order Job name/Part name

1

2

Wireharness and cables removal

Rear carrier

Tail cover

Left side panel

Right side panel

Battery box cover

Center cowling

Air filter case

Carburetor

Air shroud 1

Autolube delivery hose

Q'ty

Remarks

Remove the parts in order.

Refer to "COVER AND PANEL" section

in CHAPTER 3.

Refer to "CARBURETOR" section in

CHAPTER 6.

4-1

ENGINE REMOVAL

m ENG m ~)~,mm

\

//

12

[~q45Nm(4.5

m.kg, 31ft.lb) I

[~m120Nm(12.0 m.kg, 87 ft.lb)

~

7

Order Job name/Part name

8

9

10

11

12

13

Spark plug cap

Battery (-) lead

C.D.I magneto leads coupler

Starter motor leads coupler

Rear wheel nut

Rear brake adjuster

Rear brake cable

Bolt

Engine mount bolt

Engine

Q'ty

1

Remarks

NOTF"

Loosen the rear wheel nut.

Reverse the removal procesure for instal-

lation.

4-2

CYLINDER HEAD, CYLINDER AND PISTON

I ENG I ~>]DI

CYLINDER HEAD, CYLINDER AND PISTON

~126Nm(2.6 m.kg, 18.2 ft.lb) I

10[]~ 1 ..~ ~_.~

~~ 9N m(0.9 m

'

H1,Nm(1. m.kg, 10 ft.'bll

2 9 l 7

Order Job name/Part name

1

2

3

4

5

6

7

8

9

10

Q'ty Rema rks

Cylinder head, Cylinder and piston

removal

Engine

Muffler/Gasket 1/1

Air shroud 2 1

Spark plug 1

Cylinder head/Cylinder head gasket 1/1

Cylinder 1

Piston pin clip 2

Piston pin/Bearing 1/1

Piston 1

Piston ring set 1

Cylinder gasket 1

Remove the parts in the order.

Refer to the "ENGINE REMOVAL" sec-

tion

Reverse the removal procedure for in-

stallation.

4-3

CV'..OE..EAO. OV'..OE.. P.STO. I E"O Io .1

PISTON PIN AND PISTON REMOVAL

1. Remove:

• Piston pin clip (~

NOTE:

Before removing the piston pin clip, cover the

crankcase with a clean rag so you will not acci-

dentally drop the clip into the crankcase.

2. Remove:

• Piston pin (~

• Piston ~)

• Piston pin bearing (~

CAUTION:

Do not

use a hammer to drive the piston pin

out.

CYLINDER HEAD INSPECTION

1. Eliminate:

• Carbon deposits

Use a rounded scrapper (~.

2. Inspect:

• Cylinder head warpage

Out of specification-->Re-surface.

Warpage measurement and re-surfacement

steps:

• Attach a straight edge (~ and a thickness

gauge (~ on the cylinder head.

• Measure the warpage limit.

I l aroaoe" 't"

I

0.03 mm(0.0012 in)

• If the warpage is out of specification, reface

the cylinder head.

NOTE:

Rotate the head severai tires to avoid remov-

ing too much material from one side.

4-4 ~~~~~~

CYLINDER AND PISTON INSPECTION

I ENG I TDI

Q

CYLINDER AND PISTON INSPECTION

1. Eliminate:

• Carbon deposits

Use a rounded scraper (~.

2. Inspect:

• Cylinder wall

Wear/Scratches-->Rebore or replace.

I~...~ / -----~ ~

.

Eliminate:

• Carbon deposits (~

From the piston

grooves.

crown and ring

4. Remove:

• Score markes and lacquer deposits

From the sides of piston.

5. Inspect:

• Piston wall

Wea r/Scratches/Da m age-->Re place.

6. Measure:

• Piston-to cylinder clearance

Piston to cylinder clearance measurement

steps: First step:

• Measure the cylinder bore "C" with a cylin-

der bore gauge.

NOTE:

Measure the cylinder bore "C" in parallel to and

at right angles to the crankshaft. Then, find the

average of the measurements.

4-5

CYLINDER HEAD, CYLINDER AND PISTON

I ENG I

®

Cylinder bore

IJCF,

Standard

40.000~40.014mm

(1.5748~ 1.5754 in)

Wear limit

40.10 mm

(1.5787 in)

- 0.05

mm

(0.0020 in)

Taper "T"

Out of round - 0.03 mm

"

R" (0.0012 in)

C = Maximum D

T=( Maximum D1 or D2 ) - ( Maximum D5 or

D6 )

R=( Maximum D1 D3 or D5 )- ( Maximum D2

D4 or D6 )

• If out of specification, rebore or replace cyl-

inder, and replace piston and piston rings

as a set.

2nd step:

• Measure the piston skirt diameter

"p"

with

a micrometer.

(~ 10 mm from the piston bottom edge.

I l st°nsze

I

39.958~39.972 mm(1.5731~1.5737 in)

• If out of specification, replace piston and pis-

ton rings as a set.

3rd step:

• Calculate the piston-to cylinder clearance

with following formula:

I Piston-to cylinder clearance = Cylinder bore I

I

"

C "- Piston skirt diameter

"p"

I

• If out of specification, rebore or replace cyl-

inder, and replace piston and piston rings as

a set.

Piston-to cylinder clearance:

0.035 - 0.040mm (0.014 - 0.0016 in)

Limit : 0.10 mm (0.0039 in)

4-6

OV'.°OE..EAO. OV'..OE. A°O P.STO. I E"O I o =1

PISTON RINGS INSPECTION

1. Measure:

• Side clearance

Out of specification-->Replace piston

and/or rings.

Use a feeler gauge (~

Standard mit Li

Top ring 0.03~0.05mm 0.1 mm

(0.0012 ~ 0.002 in) (0.0039 in)

2nd ring 0.03-0.05mm 0.1 mm

(0.0012 ~ 0.002 in) (0.0039 in)

2. Install:

• Piston ring

Into the cylinder

Push the ring with the piston crown.

L

.

Measure:

• End gap

Out of specification-->Replace rings as

a set.

Use a feeler gauge (~.

Stand rd Li it

a

m

Top ring 0.15- 0.35 mm 0.6ram

(0.005 ~ 0.01 in) (0.02 in)

2nd ring 0.15~0.35mm 0.6ram

(0.005 ~ 0.01 in) (0.02 in)

(~ Measuring Point 20 mm(0.79 in)

PISTON PIN AND PISTON PIN BEARING

1. Inspect:

• Piston pin

Blue

discoloration/Groove-->Replace,

then inspect lubrication system.

4-7

CV'..OE..EAO CV'..OE. A.O P.STO. I E"O I o '1

f

"2

.

Measure:

• Outside diameter (~ (piston pin)

Out of specification-->Replace.

ootsdedameter,0ston on' '

9.996~ 10.000 m m(0.3935~0.3937in t

.

Measure:

• Piston pin-to-piston clearance

Out of specification-->Replace piston.

Piston pin-to-piston clearance =

Bore size (piston pin)

Outside diameter (piston pin)

Piston pin-to-piston clearance" I

0.004-0.019 mm(0.0016-0.00075 in

1

<Limit: 0.07 mm>(0.003 in)

4. Inspect:

• Bearing(piston pin)

Pitting/Da mage~Replace.

4-8

PISTON PIN AND PISTON INSTALLATION

1. Apply:

• Engine oil

(to the crankshaft bearing, connecting

rod big end bearing, small end bearing,

piston pin, piston ring grooves and pis-

ton skirt areas.)

.

Install:

• Reed valve gasket

• Reed valve

• Carburetor joint (~

~l 11Nrn(1.1

m.kg, 8ft.lb~

OV',.OE..EAO. CV',°OE. A.O ,,StO. I E"O I0 '1

Q~ °-, J

3. Install:

• Small end bearing

• Piston (~

• Piston pin (~)

• Piston pin clip ~)

NOTE:

• The arrow (~ on the piston to the exhaust

side.

• Before installing the piston pin clip, cover the

crankcase with a clean towel or rag so you

will not accidentally drop the pin clip mate-

rial into the crankcase.

• Always use a new piston pin clip.

CYLINDER AND CYLINDER HEAD

1. Install:

• Cylinder gasket (new gasket)

2. Check:

• Piston rings

(~ 1st ring

(~ 2nd ring

NOTE:

Make sure the ring ends (~ are properly fitted

around the ring locating pins (~) in the piston

grooves.

r 0

• /

4-9

3. Install:

• Cylinder (~

NOTE:

Install the cylinder with one hand while com-

pressing the piston rings with the other hand.

O*'.°OE..EAO. C*'.°OE. A°O P.S*O. I' "0 I0 .1

4. Install:

• Cylinder head gasket (new gasket)

5. Install:

• Cylinder head (~ ~114Nm(1.4m.kg,10ft.lb)

• Spark plug (~)

r~120Nm(2.0m.kg,14ft.lb)

• Air shroud

NOTE:

Tighten the cylinder head holding nuts in stage,

using a crisscross pattern.

4-10

V-BELT, CLUTCH AND

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

KICK STARTER AND CRANKCASE COVER (LEFT)

4~

3

12Nm(1.2m.kg, 8.4 ft.lb)~

//

I~l 7Nm(0.Tm.kg, 5.1 ft.lb

I~190Nm(0.9m.kg, 6.5 ft.lb) I

Order Job name/Part name

1

2

3

4

5

Kick starter and crankcase cover (left)

removal

Kick starter

Crankcase cover 2 (left)

Crankcase cover 1 (left)

Gasket

Q'ty

Remarks

Remove the parts in order.

Reverse the removal procedure for in-

stallation.

4-11

®

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

KICK STARTER

V-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

I ENG

Order Job name/Part name

(#

®

Kick starter removal

Crankcase cover 1 (left) removal

Kickstarter pinion gear

Kickstarter pinion gear clip

Circlip/Plain washer

Kickstarter segment gear

Return spring

Collar

Q'ty Remarks

1

1/1

1

Remove the parts in order.

Reverse the removal procedure for in-

stallation.

4-12

V-BELT, CLUTCH AND

SECONDARY/PRIIVIARY SHEAVE I ENG I ~>= I

KICK STARTER INSTALLATION

1. Install:

Return spring

• Kickstarter segment gear (~

• Collar (~

• Plain washer (~

• Circlip (~

4-13

Installation steps:

a. Install return spring (~ and segment gear

(~ as shown.

b. Install clip (~.

c. Hook the spring onto the crankcase pro-

jection (~.

d. Install the kick starter pinion gear (~ and

the kick starter.

V-BELT" CLUTCH AND I I~)~1

SECONDARY/PRIMARY SHEAVE

ENG

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

3

2

t/~ ~ /

<i

10 8~ v

7

4 /

,~ ~QI40 N m(4.0 m.kg,29ft.lb)

~145Nm(4.5m.kg,33ft.lb)

Order Job name/Part name

1

2

3

4

5

6

7

8

9

10

V-belt, clutch and secondary/primary

sheave removal

Lower cowling

Air shroud 3

Crankcase cover (left)

Clutch housing

Secondary sheave assembly

V-belt

Conical washer/One-way clutch

Crow washer

Primary fixed sheave

Collar/Washer

Primary sliding sheave

Cam/Slider

Weight

Q'ty

1

1/1

-

1

1/1

1

1/3

6

Remarks

Remove the parts in order.

]Refer to "COVER AND PANEL" section

in chapter 3.

Refer to "ENGINE REMOVAL" section.

-I Refer to "SECONDARY SHEAVE AND V-

J

BELT REMOVAL " section.

Refer to "PRIMARY SHEAVE REMOVAL

ASSE M BLY" section.

Reverse the removal procedure for in-

stallation

4-14

V-BELT, CLUTCH AND I

SECONDARY/PRIMARY SHEAVE

I ENG

SECONDARY SHEAVE

""-4

/

[~150Nm(5.0m.kg, 36ft.lb) I

Order Job name/Part name

(#

®

@

®

Q'ty

Secondary sheave disassembly

Nut 1

Clutch carrier 1

Clutch shoe spring 2

Compression spring 1

Spring seat 1

Guide pin 2

Secondary sliding sheave 1

O-ring 2

Oil seal 2

Secondary fixed sheave 1

Remarks

Disassemble the parts in order.

Refer to "SECONDARY SHEAVE DISAS-

SEMBLY" section.

Refer to "SECONDARY SHEAVE IN-

STALLATION" section.

Refer to

"SECONDARY SHEAVE IN-

STALLATION" section.

Reverse the disassembly procedure for

assembly.

4-15

V-BE'T" O'UTC" A"O I Io =1

SECONDARY/PRIMARY SHEAVE

ENG

/

i

®

PRIMARY SHEAVE REMOVAL

1. Remove:

• Fan

2. Remove:

• Nut (~ (primary sheave)

NOTE:

When loosening the nut (primary sheave), hold

the C.D.I. magneto using flywheel holding tool

®.

I~ I Rotor holdiyu_01235ng tool: I

3. Remove:

• Conical spring washer (~

• One-way clutch ®

• Washer (~

• Primary fixed sheave (~

• Shim (~

• V-Belt

4. Remove:

• Collar (~

• Primary sheave assembly®

SECONDARY SHEAVE REMOVAL

1. Remove:

• Nut (~ (secondary sheave)

NOTE:

Hold the secondary sheave using sheave holder

®.

I<~1 Sh eave holder:

I

YU-01701

2. Remove:

• Clutch housing

• Secondary sheave assembly

• Dowel pins

4-16

V-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

I ENG I{ =l

3. Loosen:

• Nut(Clutch carrier)(~

NOTE:

Install the secondary sheave to primary drive

shaft as shown, and hold the secondary sheave

by Universal Roter Holder(~to loosen the nut

(#.

~ Roter holding tool" ]

YU-01235

CAUTION:

Do not remove the clutch securing nut yet.

If the nut is removed without compressiong

the secondary sheave. It jumps and causes in-

jury.

4. Attach:

• Clutch spring holder (~

I<~l CI utch spring holder:ys_28891

5. Remove:

• Clutch securing nut (~)

6. Remove:

• Clutch assembly (~

• Clutch spring (~

• Spring seat (~

• Guide pins

• Secondary sliding sheave

CLUTCH INSPECTION

1. Inspect:

• Clutch shoes

Glazed parts-->Sand with coarse sand-

paper.

NOTE:

After using the sand paper, clean of the pol-

ished particles with cloth.

4-17

V-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

I ENG

.

Measure:

• Clutch shoe thickness (~

Out of specification-->Replace.

Clutch shoe thickness:

4 mm (0.16 in)

< Wear limit>:

2.5 mm (0.1 in)

V-BELT INSPECTION

1. Inspect:

• V-belt(~

Crack->Replace.

NOTE:

Replace the V-belt smeared with a lot of oil or

grease.

.

Measure:

• V-belt width (~

Out of specification-->Replace.

~1 V-belt width"

16.6 mm(0.65 in)

<Wear limit>:

14.6 mm(0.57 in)

4-18

V-BELT, CLUTCH AND I

SECONDARY/PRIMARY SHEAVE

i ENG

PRIMARY SHEAVE INSPECTION

1. Inspect:

• Primary sliding sheave (~

• Primary fixed sheave (~)

Wea r/Cracks/Scratch/Da mage

-->Replace.

.

Check:

• Free movement

Insert the collar (~into the primary slid-

ing sheave(~, and check for free move-

ment.

Stick or excessive play->Replace the

sheave or collar.

.

Measure:

• Out side diameter (~) (weight)

Out of specification-->Replace.

----~Out side diameter (weight)

15.0 mm(0.59 in)

<Limit 14.5 mm>(0.57 in)

4-19

V-BELT, CLUTCH AND I

SECONDARY/PRIMARY SHEAVE

I ENG

SECONDARY SHEAVE

1. Inspect:

• Secondary fixed sheave (~

• Secondary sliding sheave (~

Scratch/Crack/Damage-->Replace

as a

set.

• Oil seal (~

Da mage-->Replace

.

Inspect:

• Torque cam grove (~

• Guide pin (~)

Wear/Damage-->Replace as a set.

•

O-rings (~)

Damage-->Replace.

.

Measure:

• Clutch spring free length

Out of specification-->Replace.

Clutch spring free length:

94 mm(3.7 in)

<Limit>:

91 mm(3.58 in)

4. Inspect:

• Clutch housing inner surface

Oil/Scratches--~Remove.

Use a rag soaked in lacquer

Oil

thinner or solvent.

Use an emery cloth (lightly

Scratches

and evenly polishing).

4-20

.

Measure:

• Clutch housing inside diameter (~

Out of specification-->Replace.

Clutch housing inside diameter:

105 mm(4.13 in)

<Wear limit>:

105.5 mm(4.15 in)

V-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

I ENG I~=1

SECONDARY SHEAVE INSTALLATION

When assembling the secondary sheave, re-

verse the disassembly procedure. Note the fol-

lowing points.

.

Apply:

• Lithium soap base grease

(to the inside of the sliding/fixed sheave)

2. Install:

• Sliding sheave (~

NOTE:

Be careful so that the oil seal (~ lips are not

turned over when installing the sheave.

3. Apply:

• Lithium soap base grease

(to the torque cam grooves and O-rings)

4. Install:

• Guide pin (~

5. Check:

• Sliding sheave

Unsmooth operation-->Repair.

.

Install:

• Clutch securing nut (~

Use clutch spring holder (~

c,utchs0r,n0ho,der s288 l I

.

Tighten:

• Clutch securing nut (~

I%~%150 Nm(5.0 m.kg, 36 ft.lb) I

Use Flywheel holding tool

otorho,d,n0too, o01 `0 I

4-21

V-BELT, CLUTCH AND I

SECONDARY/PRIMARY SHEAVE

I ENG

.

8. Install:

• Secondary sheave assembly

• Clutch housing (~

• V-belt (~)

NOTE:

The V-belt must be installed with the arrow

fro ntwa rd.

@

Tighten:

• Nut (~ (secondary sheave)

1~140

Nm(4.0 m.kg, 29

ft.,b) I

Use sheaveholder (~

Sheaveho'der: I

YU-01701

4-22

PRIMARY SHEAVE

1. Clean:

• Primary sliding sheave face (~

• Primary fixed sheave face (~

• Collar (~

• Weight (~

• Primary sliding sheave cam surface (~)

.

4.

.

Install:

• Weight (~

• Cam@

• Slider (~

• Collar (~

Check:

• Cam operation

Not smooth.Repair.

Install:

• Primary sheave assembly (~

• Collar (~)

Install:

• V-belt

V-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

I ENG

I%=I

/

.

Install:

• Shim (~

• Primary fixed sheave ~)

• Washer (~

• One-way clutch (~

• Conical spring washer (~)

• Nut(~

J

i

.

Tighten:

• Nut (~ (primary sheave)

[%l 45 Nm(4.5 m.kg, 31ft.lb)

NOTE:

When tightening the nut (primary sheave), hold

the C.D.I. magneto using Flywheel Holding Tool

®.

~l ~°t°r h°'d'n° t°°':¥~-01 ~ I

.

Adjust:

• V-belt O

Tense the V-belt by turning the primary

sheave several times.

9. Install:

• Fan

~I 7 Nm (0.7 m.kg, 5.1

~.,bl I

4-23

STARTER CLUTCH AND STARTER MOTOR

I ENG I~ll

STARTER CLUTCH AND STARTER MOTOR

~TARTER CLUTCH AND STARTER MOTOR

11

~, ,10

9.4 ft.lb

9 J

6

4 3

Ns,ml0 8m k0.5 8,t,b

8

Order Job name/Part name

1

2

3

4

5

Starter clutch and starter motor re-

moval

Left/Right side cover

Center cover

Lower cowling

Air shroud 3

Cooling fan

Rear wheel

Crankcase cover (left)l,2

Primary sheave

Plate

Plain washer

Idle gear

Plain washer

Starter clutch

4-24

Q'ty

]

Remarks

Remove the parts in order.

Refer to "COVERS AND PANE L" section

in chapter 3.

Refer to "C.D.I. MAGNETO " section

Refer to "REAR WHEEL" section in chap-

ter 6.

Refer to "KICKER STARTER " section.

Refer to "V-BELT, PRIMARY SHEAVE "

section.

STARTER CLUTCH AND STARTER MOTOR I ENG I ~TDI

11

~. .10

9.4 ft.lb

9

4 3

Ns.ml0.sm.k0.5.8 ft.,b

8

Order Job name/Part name

6

7

8

9

10

11

Gear boss

Bearing

Starter wheel gear

Plate washer

Starter motor

Starter motor coupler

Q'ty

1

2

Remarks

Reverse the removal procedure for

instalation

4-25

STARTER CLUTCH AND STARTER IVIOTOR I ENG I {~ I

STARTER CLUTCH AND GEARS INSPECTION

1. Inspect:

• Starter clutch

Push the dowel pin to arrow direction.

Unsmooth operation-->Replace starter

clutch assembly.

2. Inspect:

• Starter wheel gear teeth (~

• Idle gear teeth (~)

B u rrs/C h i ps/Ro u g h n ess/Wea r-->Re p la ce.

c::C> F~

3. Inspect:

• Starter clutch operation

Clutch operation checking steps:

• Install the starter wheel gear to the starter

clutch, and hold the starter clutch.

• When turning the wheel gear clockwise []

the starter clutch and the wheel gear should

be engaged.

If not the starter clutch is faulty. Replace it.

• When turning the wheel gear counter clock-

wise [~], the wheel gear should turn freely. If

not, the starter clutch is faulty. Replace it.

4-26

C.O.'."'°"ETO I ENO I O '1

C.D.I. MAGNETO

.'.D.I. MAGNETO

5

. 4 7

,0i80

m(3.8 m.kg, 27 ft.lb) I

[~17Nm(0.7m.kg" 5.1ft.lb) i

17Nm(0.7

m.kg, 5.1 ft.I ) I

1

Order Job name/Part name

1

2

3

4

5

6

7

8

C.D.I. magneto removal

Rear carrier

Tail cover

Left side cover

Right side cover

Center cover

Lower cowling

Air shroud 1

Fan/O-ring

Magneto rotor

Bind

Couplers (magneto leads)

Stator coil

Wood ruff key

Gasket (Magneto cover)

Q'ty R e m a r ks

1

1/1

1

Remove the parts in order.

Refer to "COVER AND PANEL" section

in chapter 3.

Reverse the removal procedure for in-

stallation.

4-27

co, MAo.ETol E"° I o --I

C.D.I. MAGNETO REMOVAL

1. Remove:

• N

ut (~(roto

r)

• Plain washer

NOTE:

Hold the rotor to loosen the nut bythe flywheel

holding tool (~.

I<~l Rotor holdiyu_01235ng tool: I

2. Remove:

• Rotor O

• Wood ruff key

Use the flywheel magneto puller (~.

I<~l Flywheel puller: I

YU-01189

• Stator assembly

• Gasket

C.D.I. MAGNETO INSTALLATION

1. Install:

• Gasket (~

2. Apply:

• Lithium soap base grease

(to oil seal)

3. Pass the C.D.I. magneto lead through the

crankcase hole.

4. Install:

• Stator assembly[R e 8 Nm(0.8

m.kg, 5.8 ft.lb) I

5. Install:

• Wood ruff key

• C.D.I. magneto Rotor (~

• Plain washer

•

Nut ~~;~l

38Nm(3.S m.kg, 31.1ft.lb) I

NOTE:

• Clean the tapered portion of the crankshaft

and the magneto rotor hub.

• When installing the magneto rotor, make

sure the woodruff key is properly seated in

the keyway of the crankshaft.

• Do not allow the rotor holding tool to touch

the projection on the magneto rotor.

4-28

AOTO'OBE PUMP I E"O I O '1

AUTOLUBE PUMP F~

AUTOLUBE PUMP

5

JZ

2 ,~314N m(0.4m.kg, 2.8ft.l~b) i / \'~ ~

7

// \ '~ 1

Order Job name/Part name

1

2

3

4

5

6

7

Q'ty

Autolube pump removal

C.D.I. magneto

Air shroud 2. 1

Circlip 1

Pump drive gear 1

Pin 1

Oil hose 1

Oil delivery hose 1

Autolube pump ass'y 1

Remarks

Remove the parts in order.

Refer to "C.D.I. magneto" section.

Refer to "Autolube pump installation"

section

Reverse the removal procedure for in-

stallation.

4-29

AUTOLUBE PUMP

I ENG I{~]DI

AUTOLUBE PUMP INSTALLATION

CAUTION:

After installing autolube pump, it must be

bleeded.

1. Install

• Pin O

• Pump drive gear (~)

• Circlip ~

2. Apply:

• Lithium soap base grease

(to O-ring)

3. Install:

• Autolube pump (~ [~J4 Nm(0.4m.kg, 2.8ft.lb~

4. Apply:

• Lithium soap base grease

(to autolube pump gear (~,(~)

15 cc (0.92 cu o in)

4-30

T.A.SM.SS.O. I E"O I o '1

TRANSMISSION

/" 2

/ 4/~ O I~112N m(1.2 m.kg, 8.4ft.lb)

[~418Nm(1.8 m.kg, 13ft.lb I

I

Order Job name/Part name

1

2

3

4

5

6

7

Transmission removal

Rear wheel

Secondary sheave

Drain the transmission oil.

Transmission case cover 1

Gasket (transmission case cover) 1

Dowel pin 2

Primary drive gear 1

Drive gear 1

Circlip 1

Main axle 1

Q'ty R e m a r ks

Remove the parts in order.

Refer to "REAR WHEEL/REAR BRAKE

"

section in chapter 7.

Refer to "V-BELT, CLUTCH, SECOND-

ARY/ PRIMARY SHEAVE" section

Refer to "TRANSMISSION OIL RE-

PLACEMENT " section in chapter 3.

4-31

TRANSMISSION I ENG I~>]DI

- 3

5

/ 4/ I.~..~ ~ [~112Nm(1"2 m'kg • 8"4ft'lb:

1

[~'~1 8Nm(1.8 m.kg, 13ft.lb I

Order Job name/Part name

8 Drive axle

Q'ty

1

Remarks

Reverse the removal procedure for in-

stallation.

4-32

CRANKCASE AND REED VALVE

I ENG I TDI

CRANKCASE AND REED VALVE

~19Nm(0.9m.kg,6.5ft.lb)l ~112Nm(1.2m.kg,

8.4ft.lb) I

4

11Nm(11 m kg,8ft Ib) I ~ ~

~

j 3 j,

J"

j-J

Order Job name/Part name

Crankcase and Reed valve removal

Engine removal

Cylinder head, cylinder, piston

Crankcase cover (left)

V-belt, clutch, secondary/primary

sheave

C.D.I. magneto

Starter clutch, starter motor

Autolube pump

Rear wheel

Transmission

Q'ty R e m a r ks

Remove the parts in order.

Refer to "ENGINE REMOVAL" section.

Refer to "CYLINDER HEAD CYLINDER

AND PISTON" section.

Refer to "KICK STARTER AND CRANK-

CASE COVER (LEFT) " section.

Refer to "V-BELT, CLUTCH AND SEC-

ONDARY/PRIMARY SHEAVE " section.

Refer to "C.D.I. MAGNETO" section.

Refer to "STARTOR CLUTCH AND

STARTOR MOTOR" section.

Refer to "AUTOLUBE PUMP" section.

Refer to "REAR WHEEL AND REAR

BRAKE" section in chapter 6.

Refer to "TRANSMISSION" section.

4-33

CRANKCASE AND REEDVALVE

I ENG I >]DI

~19Nm(0.9m.kg,6.5ft.lb)l ~112Nm(1.2m.kg, 8.4ft.lb) I

4

11Nm(1 lm kg,8ft Ib) I ~ ~

~

j 3 j.

J"

j-J

Order Job name/Part name

1

2

3

4

5

6

7

8

9

10

Q'ty Remarks

Intake manifold 1

Reed valve 1

Valve seat gasket 1

Stopper 1

Crankcase 2 1

Dowel pin 2

Engine mount spacer 1

Circlip 1

Bearing 1

Oil seal 1

Reverse the removal procedure for in-

stallation.

4-34

O.A°KOASE A°O.EEOVA'VE I E"O Io =1

=~r~ri

CRANKCASE(RIGHT) REMOVAL

1. Remove:

• Oil seal stopper (~

• Screws (crankcase~ 19Nm(0.9

m.kg,6.5ft.lb !

NOTE:

Loosen each screw 1/4turn, and remove them

after all are loosened.

2. Attach:

• Crankcase separating tool (~

I<~l CrankcaSeyu_01135se pa rating tool: I

NOTE:

Fully tighten the tool holding bolts, but make

sure the tool body is parallel with the case. If

necessary, one screw may be backed out

slightly to level tool body.

.

Remove

• Crankcase (right)

As pressure is applied, alternately tap

on the engine mounting bosses.

4-35

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in

a mild solvent.

2. Thoroughly clean all the gasket surfaces

and crankcase mating surfaces.

3. Check:

• crankcase

Cracks/damage --> Replace.

• oil delivery passages

Obstruction --> Blow out with com-

pressed air.

CHECKING THE BEARINGS AND OIL SEALS

1. Check:

• bearings

Clean and lubricate the bearings, then

rotate the inner race with your finger.

Rough movement --> Replace.

2. Check:

• oil seals

Damage/wear ~ Replace.

CRANKCASE AND REED VALVE

I ENG I TDI

REED VALVE INSPECTION

1. Measure:

• Valve stopper height (~

Out of specification-->Adjust stopper/Re-

place valve stopper.

I~l Valve stopper height (~

6.0~6.4 mm(0.24~0.25 in)

.

Measure:

• Reed valve clearance @)

Out of specification-->Replace reed

va lye.

I lReedvavecearance

I

Less than 0.2 mm(0.0079 in)

-ii -I;

" I

CRANKCASE (RIGHT) INSTALLATION

1. Install:

• Dowel pins (~

• Engine mount spacer (~

2. Apply:

• Sealant (~)

To the mating surfaces of both case

helves.

~1 Quick gasket®: I

ACC-1100-15-01

NOTE:

Do not allow any sealant to come into contact

with the oil galley.

3. Attach:

• Crankshaft installing tool (~,~)

Crankshaft installation set (~

YU-90050

Crankshaft installer adapter

(M 10)~)

YU-90062

4-36

.OASE A.O.EEO VA'VE I E"O Io .1

,4

4. Tighten:

• Crankcase holding screws

[~l 12 Nm(1.2 m.kg,8.4 ft.lb) I

NOTE:

Tighten the crankcase holding screws in stage,

using a crisscross pattern.

5. Check:

• Crankshaft operation

Unsmnothoperation Repair.

6. Install:

• Oil seal (right crank case) (~

Apply grease on to oil seal lip.

.

Install:

• Oil seal stopper plate (~

H 9 .ml09

m.kg, 6.5

ft.lb) I

.

Install:

• Gasket

• Reed valve

• Intake manifold (~I~111 Nm(1.1 m.kg, 8 ft.lb) I

4-37

KS.AFT I ENO I O ,,I

CRANKSHAFT

~ 4

2

Order Job name/Part name

1

2

3

4

Crankshaft removal

Right crankcase removal

Crankshaft 1

Bearing 2

Oil seal 2

Crankcase cover (left) 1

Q'ty R e m a r ks

Remove the parts in order.

Refer to "CRANK CASE AND REED

VALVE" section.

Reverse the removal procedure for in-

stal lation.

4-38

KS.AFT I E"O I o '1

CRANKSHAFT REMOVAL

1. Attach:

• Crankcase separating tool (~

~l Crankcase separating tool:

YU-01135-A

2. Remove:

• Crankshaft (~

NOTE:

Make sure the crankcase separating tool is cen-

tered over the crankshaft assembly.

F

--H ~-- D

CRANKSHAFT INSPECTION

1. Measure:

• Runout limit

" C"

• Connecting rod big end side clearance

iJ g rr

• Small end free play limit

"F"

Out of specification-->Replace.

Use V-blocks, dial gauge and thickness

gauge.

Runout limit

"C":

0.03 mm(0.0012 in)

Connecting rod big end side clear-

ance

"D":

0.2 ~ 0.5 mm(0.0079 ~ 0.020 in)

Small end free play " F':

0.4 ~ 0.8 mm(0.016 ~ 0.031 in)

2. Inspect:

• Bearings (crankshaft)

Spin the bearing inner race.

Excessive play/Ro ugh n ess-->Replace.

Pitting/Da mage--~Replace.

4-39

CRANKSHAFT I ENG I{ ll

CRANKSHAFT INSTALLATION

1. Attach:

• Crankshaft Installing Tool

Q

Crankshaft installation set (~

YU-90050

Crankshaft installer adapter

(M10) ~)

YU-90062

2. Install:

• Crankshaft ®

(to the crankcase (~)

CAUTION:

To avoid scratching the crankshaft and to ease

the installation procedure, lubricate the oil seal

lips with grease and each bear-ing with engine

oil.

NOTE:

Hold the connecting rod at top dead center

(TDC) with one hand while turning the nut of

the crankshaft installing tool with the other.

Turn the crankshaft installing tool until the

crankshaft assembly bottoms against the bear-

ing.

i ~ P

J

.

Install:

• Oil seal (~

• Apply lithium soap base grease onto

the oil seal lip.

Use the guide (~ and seal driver ~) to

install the oil seal

Oil seal driver

YM-1410

Oil seal guide

YM-1409

4-40

CARBURETION

CARBURETOR

4

/

2

1 kl9Nml0.9 m.kg, 6.5 ft.lb) I

Order Job name/Part name

1

2

3

4

5

6

Carbu retor removal

Battery box cover

Grip

End cover

Left/Right cover

Center cover

Air cleaner case assembly

Auto choke lead coupler

Fuel hose/vacuum hose

Oil delivery pipe assembly

Carburetor

Throttle cable

Q'ty R e m a r ks

Remove the parts in order.

Refer to "COVER AND PANEL" section

in CHAPTER 3.

Reverse the removal procedure for instal-

lation.

5-1

• I

CABURETOR DISASSEMBLY

'

~,_ .~'~

Order Job name/Part name

O

®

@

®

@

Carburetor disassembly

Throttle cable

Throttle valve

Needle set

Carburetor top cover/o-ring

Throttle stop screw

Auto choke unit assembly

Float chamber/Seal ring

Float pin

Float/Needle valve

Main jet

Pilot jet

Main nozzle

Carburetor body

Q'ty Remarks

1

1/1

1

Disassemble the parts in order.

Reverse the removal procedure for in-

stallation.

5-2

O'"'O"'TO" Ic""'l V I

CABURETOR INSPECTION

1. Check:

• Carburetor body

• Float chamber

• Jet housing

Cracks/damage --> Replace.

Q

2. Check:

• Fuel passages

Obstruction --~ Clean.

a. Wash the carburetor in a petroleum-based

solvent. Do not use any caustic carbure-

tor cleaning solution.

b. Blow out all of the passages and jets with

compressed air.

3. Check:

• Float chamber body

Dirt --> Clean.

4. Check:

• Float chamber rubber gasket

Cracks/damage/wear --> Replace.

5. Check:

• Float

Damage --> Replace.

.

Check:

• Needle valve O

Damage/obstruction/wear --~ Replace

the needle valve.

.

Check:

• Throttle valve (~

Damage/scratches/wear--> Replace.

5-3

OA"BO"ETO" ICA"BI V I

.

Check:

• Jet needle kit (~

• Main nozzle ~)

• Main jet (~

• Pilot jet (~

Bends/damage/wear --> Replace.

Obstruction --> Clean.

Blow out the jets with compressed air.

9. Check:

• Throttle valve movement

Insert the throttle valve into the carbu-

retor

Body and move it up and down.

Tightness --> Replace the piston valve.

10. Check:

• Vacuum hose

• Fuel hose

Cracks/damage/wear --> Replace.

Obstruction --> Clean.

Blowoutthe hoses with compressed air.

11. Measure:

• Float height (~)

Out of specification-->lnspect needle

valve, float and valve seat.

Feat he0ht I

15 - 17 mm (0.59 ~ 0.67 in)

* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

Float height measurement steps:

• Install the needle valve, float and float pin to

the carburetor body.

• Hold the carburetor in an upside down posi-

tion.

• Measure the distance between the mating

surface of the float chamber (gasket re-

moved) and top of the float using a gauge.

5-4

CARBURETOR

NOTE:

Ic..,I • I

The float arm should be resting on the needle

valve, but not compressing the needle valve.

• If the float height is not within specification,

inspect the needle valve, float and valve seat.

• If it is worn, replace it.

NOTE:

The float height is properly adjusted at the Yama ha

factory. Never attempt to adjust it.

CARBURETOR ASSEMBLY

To assemble the carburetor, reverse the disas-

sembly procedures.

Note the following points.

CAUTION:

• Before reassembling, wash all parts in clean

gasoline.

• Always use a new gasket.

5-5

OA"BU"ETO" IOA"BI V I

1.

Install:

• Throttle cable (~

2. Install:

• Carburetor assembly

NOTE:

Align the projection (~with the projections@.

FUEL LEVEL ADJUSTMENT

1. Measure:

• Fuel level (~

Out of specifications-->Adjust.

Fuel level (~:

3.0~4.0 mm(0.12~0.16 in)

(Below the float chamber line)

Measurement steps:

• Place the scooter on a level surface.

• Use a garage jack under the engine to en-

sure that the carburetor is positioned verti-

cally.

• Connect the fuel level gauge (~ to the drain

pipe (~.

Fuel level gauge:

I

YM-01312-A

• Loosen the drain screw ~).

• Measure the fuel level (~with the gauge.

• If the fuel level is incorrect, adjust the fuel

level:

Remove the float chamber float and the

needle valve.

Inspect the needle valve.

If it is worn, replace it.

5-6

• Install the carburetor.

• Recheck the fuel level.

* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

B

AUTO CHOKE INSPECTION

(Ambient temperature lower than 45°C)

1. Remove:

• Carburetor

2. Inspect:

• Autochoke unit

Connect a suitable hose (~ to the starter

(~, and blow it with the mouth etc.

Possible--~Good condition.

Impossible-->Replace

auto choke unit.

3. Inspect:

• Auto choke unit (with battery)

Inspection and adjustment steps:

• Connect auto choke unit leads to the 12 V

battery for 5 minutes.

Black terminal-->12 V battery (+) (~

Black terminal-->12 V battery (-) (~

• Connect a suitable hose (~ to the starter (~),

and blow it with the mouth etc.

Possible-->Replace auto choke unit.

Im possible-->Good condition.

5-7

CA"BO"ETO" IOA"BI V I

FUEL COCK INSPECTION

1. Stop the engine.

2. Remove:

• Rear carrier

• Tail cover

• Left side cover

• Battery box cover

Refer to "COVER AND PANEL" section

in chapter 3.

3. Inspect:

• Fuel cock

Fuel cock inspection steps:

• Disconnect the fuel hose (~.

• Place the receptacle under the fuel hose end.

• If fuel stops flowing out in a few seconds,

the fuel cock is in good condition. If not, clean

or replace the fuel cock.

• Disconnect the vacuum hose ~)and breathe

in the vacuum hose with the mouth etc. for

vacuum .

• If fuel flows out of the fuel hose under

vacuum and stops under non-vacuum, the

fuel cock is in good condition.

If not, clean or replace the vacuum hose, fuel

hose and fuel cock.

* * * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

4. Install:

• Battery box cover

• Left side cover

• Tail cover

• Rear carrier

5-8

F.O°T W.EEL A.O B.AKE O.SC IC"ASI oI

CHASSIS

FRONT WHEEL AND BRAKE DISC

4__ ~--/~ /1 -'~'I~.~.~I7~N m (0.7 m.kg, 5. lft.i b) '

: ,/ ~"'- ~ %~ZJ70 N m(7 m.kg, 5 lft.I b)l

~1-O" ( .0 . g, .5ft.lb) I ~

Order Job name/Part name

Front wheel and brake disc removal

~WARNIN(

1

2

3

4

5

6

7

8

Speedometer cable 1

Front brake hose holder 1 -

Brake caliper 1

Wheel axle 1

Front wheel assembly 1

Gear unit assembly 1 -

Collar 1

Brake disc 1

Q'ty R e m a r ks

Remove the parts in order.

Securely support the scooter so there

is no danger of it falling over.

Refer to "FRONT WHEEL INSTALLA-

TION" section.

Refer to "FRONT WHEEL ASSEMBLY"

section.

Reverse the removal procedure for in-

stallation.

6-1

FROOT W.EEL AO0 BRAKE O,SC IC"ASI oI

FRONT WHEEL DISASSEMBLY

Order Job name/Part name

(#

®

Front wheel disassembly

Oil seal

Bearing

Collar

Spacer

Bearing

Q'ty

1 m

1

1 -

Remarks

Remove the parts in order.

Refer to "FRONT WHEEL DISASSEM-

BLY/ASSEMBLY" section.

Reverse the removal procedure for in-

stallation.

6-2

F.OOT W.EE. AO0 B.A.E O.SC IC'ASI oI

fff

-f

YP ......

FRONT WHEEL DISASSEMBLY

1. Remove:

• Bearing (~

• Spacer

Remove the bearing using a general

bearing puller (~).

CAUTION:

Handle the wheel with care not to damage the

brake disc. If the brake disc is damaged, re-

place.

YP700020

FRONT WHEEL INSPECTION

1. Inspect:

• Front wheel axle

(by rolling it on a flat surface)

Bends-->Replace.

W!~VAV/±I -'| ~ I I ~ [¢']1

Do not attempt to straighten a bent wheel axle.

I l heeaxe endn0

I

0.25 mm (0.0098 in)

2. Inspect:

• Front tire

Wea r/da mag e--~ Re place.

Refer to "TIRE INSPECTION" in CHAP-

TER 3.

• Front wheel

Refer to "WHEEL INSPECTION" in

CHAPTER 3.

3. Measure:

• Front wheel runout

Over the specified limits--~Replace.

Front wheel runout limits:

Radial (~: 1.0 mm (0.04 in)

Lateral (~ " 1.0 mm (0.04 in)

4. Inspect:

• Front wheel bearings

Bearings allow free play in the wheel

hub or the wheel does not turn

smoothly--> Replace.

• Oil seals

Wear / damage-->Replace.

6-3

F.O°T W.EE. A°O B.A.E O.SO IC"ASI oI

4. Inspect:

• Collar

Grooved wear-->Replace the collar and

the oil seal as a set.

Ye .....

BRAKE DISC INSPECTION

1. Measure:

• Brake disc deflection(~

I~1 Maximum deflection:

0.15 mm (0.0059 in)

Out of specification-->Replace.

2. Measure:

• Brake disc thickness(~

Brake disc thickness:

4.0 mm (0.16 in)

Minimum thickness:

3.5 mm(0.14 in)

Out of specification-->Replace.

6-4

Ye .....

FRONT WHEEL ASSEMBLY

1. Install:

• Bearing (~

• Collar @~)

• Spacer (~)

• Bearing (~

• Oil seal (~

NOTE:

• Apply the lithium soap base grease on the

bearing and oil seal lip when installing.

• Use a socket that matches the outside diam-

eter of the race of the bearing.

• Always use a new oil seal.

• Install the oil seal with its manufacturer's

marks or numbers facing outward.

CAUTION:

Do not strike the inner race of balls of the bear-

ing. Contact should be made only with the

outer race.

F.O°T W.EE..°O B...E O.SO IC"ASI oI

i

2. Install:

• Brake disc

OH 20 Nm~20

~k~,

14

ft.lb) I

NOTE:

Tighten the bolts (brake disc) in stage using a

crisscross pattern.

@

EB700030

FRONT WHEEL INSTALLATION

Reverse the "REMOVAL" procedure.

Note the following points.

1. Lubricate:

• Front wheel axle

• Bearings

• Oil seal (lips)

• Drive/driven gear (speedometer)

Recommended lubricant:

Lithium soap base grease

2. Install:

• Speedometer gear unit (~

NOTE:

Make sure that the wheel hub and the speed-

ometer gear unit are installed with the three

projections meshed into the two slots.

3. Install:

• Front wheel

NOTE:

Make sure that the slot in the speedometer gear

unit fits over the stopper on the front forkouter

tube.

4. Tighten:

• Front wheel axle (~

• Axle nut (front wheel axle)

H 70 NmCT0 m.kg, 51 "'btl

CAUTION:

Before tightening the axle nut, stroke the front

fork several times to check for proper fork op-

eration,

6-5

•WARNING

Make sure that the brake hose is routed prop-

erly.

F.OOT W.EE..O0 B...E O.SO IONASI oI

YP700040

WHEEL STATIC BALANCE ADJUSTMENT

NOTE:

• After replacing the tire and/or rim, the wheel

static balance should be adjusted.

• Adjust the front wheel static balance with the

brake disc installed.

/

1. Remove:

• Balancing weight

2. Set:

• Wheel

(on a suitable stand)

3. Find:

• Heavy spot

Procedure:

a. Spin the wheel and wait for it to rest.

b. Put an "X~" mark on the wheel's bottom

spot.

c. Turn the wheel so that the "X~" mark is

90 ° up.

d. Release the wheel and wait for it to rest.

Put an "X2" mark on the wheel's bottom

spot.

e. Repeat the above b., c., and d. several

times until all marks come to the same

spot.

f. This spot is the wheel's heavy spot "X".

4. Adjust:

• Wheel static balance

Adjusting steps:

• Instail a balancing weight (~ on the rim ex-

actly opposite to the heavy spot "X'.

NOTE:

Start with the smallest weight.

• Turn the wheel so that the heavy spot is 90 °

up.

• Check that the heavy spot is at rest there. If

not, try another weight until the wheel is bal-

anced.

6-6

F.OOT W.EE. AOO B.A.E O.SC IC"ASI oI

X X

X

5. Check:

• Wheel static balance

* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

Checking steps:

• Turn the wheel so that it comes to each point

as shown.

• Checkthat the wheel is at rest at each point.

If not, readjust the front wheel static balance.

6-7

F.O°T B.AKE IC"ASI oI

FRONT BRAKE

BRAKE PAD

~ H23Nm(2.3

m.kg, 16.6 ft.lb) I

~ ~~ [~423NmI2.3 m.kg, 16.6 ft.lb) I

Order Job name/Part name

1

2

3

4

Q'ty R e m a r ks

Brake pad removal

Caliper support bolt 1 --I

Caliper 1

J

Brake pad 2

Pad spring 2

Remove the parts in order.

Refer to

"

BRAKE PAD REPLACEMENT

"

section .

Reverse the removal procedure for in-

stallation.

6-8

F.ONT B.A.E IC"ASI oI

CAUTION:

Disc brake components rarely require disas-

sembly. DO

NOT:

• Disassembly components unless absolutely

necessary.

• Use solvents in internal brake component.

• Use contaminated brake fluid for cleaning.

• Use only clean fluid.

• Allow brake fluid to come in contact with

the eyes otherwise eye injury may occur.

• Allow brake fluid to contact painted surfaces

or plastic parts otherwise damage may oc-

cur.

•

Disconnect any hydraulic connection other-

wise the entire system must be disas-

sembled, drained, cleaned, and then prop-

erly filled and bled after reassembly.

e o o

®

BRAKE PAD REPLACEMENT

NOTE:

It is not necessary to disassemble the brake

caliper and brake hose to replace the brake

pads.

1. Loosen:

• Retaining bolt (~

2. Remove:

• Brake caliper (~)

• Holder (brake hose) (~

3. Remove:

• Retaining bolt

• Pads (~

• Pad spring (~

NOTE:

• Replacethe pad spring ifthe pad replacement

is required.

• Replace the pads as a set if either is found to

be worn to the wear limit.

Wear JmJt I

0.8 mm (0.03 in)

6-9

,.o°T B.AKE Ic"AsI ol

/

i

/

I

t

4. Install:

• Pad springs

• Brake pads (new)

Installation steps:

• Connect a suitable hose (~ tightly to the cali-

per bleed screw (~. Then, place the other end

of this hose into an open container.

• Loosen the caliper bleed screw and push the

piston (~ into the caliper by your finger.

• Tighten the capliper bleed screw.

H ~

~ (0.~

~.k~, 4.3 ~.'~ i

• Install the pad spring (new) and brake pad

(new) (~

• Tighten retaining bolt (~

~123 Nm (2.3 m.kg, 16.6 ft.lb) I

• Install brake hose holder (~

l~l 7 Nm (0.7 m.k~, 5.15 ft.lb) I

• Install caliper (~ [~23 Nm (2.3 m.kg, 16.6 ft.ib) I

5. Inspect:

• Brake fluid level

Refer to the "BRAKE FLUID INSPEC-

TION" section in the CHAPTER 3.

(~ "LOWER" level line

6-10

.

F.O.T B.A.E IC"ASI oI

Check:

• Brake lever operation

A softy or spongy feeling Bleed-->brake

system.

Refer to

"

AIR BLEEDING " section in

the CHAPTER 3.

6-11

F.O°T B.AKE IC"ASI oI

MASTER CYLINDER

6 6

] 3

l~120Nm(2.0

m.kg, 14 ft.lb)

Order Job name/Part name

1

2

3

4

5

6

7

Master cylinder removal

Drain the brake fluid

Brake lever/compression spring

Brake switch

Union bolt

Copper washer

Brake hose

Master cylinder bracket

Master cylinder

Q'ty Remarks

1/1

1

2

1

Remove the parts in order.

Refer to "BRAKE FLUID REPLACE-

MENT" section in CHAPTER 3.

Refer to "MASTER CYLINDER INSTAL-

LATION" section.

Reverse the removal procedure for in-

stallation.

6-12

F.O°T B.AKE IC"ASI oI

MASTER CYLINDER DISASSEMBLY

Order Job name/Part name

O

®

Master cylinder disassembly

Master cylinder boot

Circlip

Master cylinder kit

Spring

Q'ty R e m a r ks

Remove the parts in order.

1 -

1 Refer to "MASTER CYLINDER ASSEM-

1 BLY" section.

1 -

Reverse the disassembly procedure for

assembly.

6-13

F.ONT B.A.E IC"ASI oI

YP702040

MASTER CYLINDER INSPECTION

1. Inspect:

• Master cylinder kit O

Wear/scratches-->Replace the master

cylinder assembly.

• Master cylinder boot

Cracks/da m age-->Re pla ce.

.

Inspect:

• Master cylinder O

• Scratches/wear/damage-->Replace the

master cylinder assembly.

.

Inspect:

• Diaphragm (~

Wea r/da mag e--> Re place.

YP .....

MASTER CYLINDER ASSEMBLY

WARNING

• All internal brake components should be

cleaned and lubricated with new brake fluid

only before installation.

16~)1

Recommended brake fluid:

DOT #4(or DOT #3)

• Replace the piston seals and dust seals

whenever a master cylinder is disassembled.

1. Install:

• Cylinder cup (~

• Master cylinder piston (~

Install cylinder cup (~ by using cylinder

cup installer (~).

::~1 Cylinder cup installer set: I

90890-01996

6-14

F.O.T B.A.E IC"ASI oI

.

Install:

• Spring (~

Install the spring with its smaller diam-

eter to the master cylinder piston.

• Master cylinder kit (~

.

Install:

• Circlip (~)

Install the circlip securely into the mas-

ter cylinder groove.

• Master cylinder boot (~

/

Ye .....

MASTER CYLINDER INSTALLATION

1. Install:

• Master cylinder (~

• Master cylinder bracket (~

~l 9 Nm (0.9 m.kg, 6.5 ft.lb) I

CAUTION:

• Install the master cylinder bracket (~ with

the "UP" mark ~ facing upward.

• Align the end of the holder with the punch

mark b on the handle bar.

6-15

F.O.T B.A.E IC"ASI oI

2. Air bleed:

• Brake system

Refer to "AIR BLEEDING" section in

CHAPTER 3.

r!~vAvg_,W --'] ~ I I ~ [¢-]

• Use only designated quality brake fluid:

Otherwise, the rubber seals may deteriorate,

causing leakage and poor brake

perforrmance.

• Refill with the same type of brake fluid:

Mixing fluids may result in a harmful chemi-

cal reaction and lead to poor perforrmance.

• Be careful that water does not enter the sig-

nificantly lower the boiling point of the fluid

may result in vapor lock.

3. Inspect:

• Brake operation

6-16

F.O.T..AKE IC"ASI oI

CALIPER

lh%123Nm(2.3 m.k,g, 16.6

ft.lb)l

........ i ....... 3

Order Job name/Part name

1

2

3

4

5

Caliper removal

Drain the brake fluid

Q'ty Remarks

Union bolt 1 -

Copper washer 2

Brake hose 1

Caliper support bolt 1

Caliper assembly 1

Remove the parts in order.

Refer to "BRAKE FLUID REPLACE-

MENT" section in CHAPTER 3.

Refer to "CALl PER INSTALLATION" sec-

tion.

Reverse the removal procedure for in-

stallation.

6-17

F.O°T B.AKE IC"ASI oI

CALIPER DISASSEMBLY

~~~ j~J'~ ~~ ~ [~0"6m~ "4"3ft'lb) l

Order Job name/Part name

(#

®

@

Q'ty R e m a r ks

Caliper disassembly

Caliper bracket 1

Brake pad 2

Pad spring 2 --I

J

Caliper piston 1

Dust seal 1

Piston seal 1

Bleed screw 1

Remove the parts in order.

Refer to "BRAKE CALIPER DISASSEM-

BLY/ASSEMBLY" section.

Reverse the disassembly procedure for

assembly.

6-18

F.ONT B.A.E IC"ASI oI

YP702020

BRAKE CALIPER DISASSEMBLY

NOTE:

Before disassembling either brake caliper, drain

the brake fluid from the brake hose, master

cylinder, brake caliper and reservoir tank.

1. Remove:

• Brake caliper piston

Removal steps:

• Blow compressed air into the hose joint

opening to force out the caliper piston from

the brake caliper body.

~!~LVAV/_'I -"] ~ I I ~ [¢']

• Never try to pry out the caliper piston.

• Cover the caliper piston with a rag. Be care-

ful not to get injured when the piston is ex-

pelled from the master cylinder.

CAUTION:

Carefully remove the caliper piston to prevent

damage.

2. Remove:

• Dust seal ~)

• Piston seal ~)

When removing, push the seals by your

finger.

CAUTION:

• Do not use a sharp instrument. Remove seals

by your finger.

• Do not re-use removed parts.

YP...

CALIPER INSPECTION

1. Inspect:

• Caliper cylinder

• Caliper piston ~)

Scratches, wear--~Replace caliper as-

sembly.

6-19

F.O.T B.A.E IC"ASI oI

O(

)

EB702050

BRAKE CALIPER ASSEMBLY

r!~vAvg_,1 --'t ~ I I ~ [¢-!

• All internal brake components should be

cleaned and lubricated with new brake fluid

only before installation.

DOT #4(or DOT #3)

•

Replace the caliper piston seals whenever

a

brake caliper is disassembled.

1. Install:

• Piston seal (~

• Dust seal (~

2. Install:

• Caliper piston (~

Apply brake fluid to the outer surface

and install.

CAUTION:

• Do not force.

• Use care to prevent damage on caliper pis-

ton.

YP .....

BRAKE CALIPER INSTALLATION

1. Install:

• Caliper (~

• Caliper support bolt

P~123Nm(2.3m.kg, 16.6ft.lb) I

• Brake hose (~)

• Copper washer (~

• Union bolt (~ H 25Nm(2.5 m.kg,18ft.lb) I

CAUTION:

When installing the brake hose to the caliper,

lightly touch the brake hose with the stopper

(~ on the caliper.

6-20

,E,, w.EE, A°0,E,, =,,KE IC"A=I oI

REAR WHEEL AND REAR BRAKE

REAR WHEEL

<

2 [;;l~i~]((;16~i:18:8f.?liilb)~" 1

Order Job name/Part name

Rear wheel and rear brake removal

1

2

3

4

Muffler assem bly/Gasket

Nut/Plain washer

Rear wheel assembly

Plain washer

Q'ty

1/1

1

Remarks

Remove the parts in order.

NOTE"

Place the scooter on a suitable atand so

that the rear wheel is elevated.

Reverse the disassembly procedure for

installation.

6-21

,E,, w,EE,,.o,EA, B,AKE IC"Asl

REAR BRAKE

kllONm(1.0

m.kg,

7.2 ft.lb) I

8

./

\ t3 -

. /

J

Order Job name/Part name

1

2

3

4

5

6

7

8

Adjuster

Brake cable

Return spring

Brake shoe

Camshaft lever

Wear indicator

Brake camshaft

Q'ty

1

Remarks

Reverse the removal procedure for in-

stallation.

6-22

.EA. W.EE" A.O .EA. B.A.E I C"Asl

EB701020

REAR WHEEL INSPECTION

1 Inspect:

• Rear wheel axle

• Rear wheel

• Rear wheel bearings

• Oil seals

Refer to "FRONT WHEEL".

2. Measure:

• Rear wheel runout

Refer to "FRONT WHEEL".

EB701021

REAR BRAKE INSPECTION

1. Inspect:

• Brake lining surface

Glazed areas-->Polish.

Use coarse sand paper.

NOTE:

After polishing, wipe the polished particles with

a cloth.

2. Measure:

• Brake lining thickness (~

~1 Brake lining thickness (~ •

Standard:

4 mm (0.16 in)

Limit:

2 mm (0.08 in)

Out of specification-->Replace.

Measuring points " t "

NOTE:

Replace the brake shoes as a set, if either is

worn to the wear limit.

®

.

Measure:

• Brake drum inside diameter (~

Out of specification-->Replace the wheel

Brake drum inside diameter:

Standard:

130 mm (5.12 in)

Limit:

131 mm (5.16 in)

6-23

,EA, W.EE" A.O .E,, B.,,E I C"Asl

4. Inspect:

• Brake drum inner surface

• Oil/scratc hes-->Re pair.

•

Oil

Use a rag soaked in lacquer thinner or

solvent.

• Scratches

Use an emery cloth (lightly and evenly

polishing)

5. Inspect:

• Cam shaft face.

Wea r-->Replace.

When inspecting the brake lining, do not spill

oil or grease on the brake lining,

Ye .....

REAR BRAKE INSTALLATION

1. Install:

• Camshaft (~

• Indicator plate (~

Installation steps:

• Set the camshaft with its punched mark (~

facing the direction as shown.

• Align the projection @ on the indicator plate

with the camshaft notch and install.

• Checkthe proper position of the brake shoe.

6-24

2. Install:

• Camshaft lever(~

r~ll0Nm(1.0 m.kg,

7.2ft.lb~

NOTE:

Set the camshaft with its punched mark(~ fac-

ing the direction on the cam shaft lever @.

HAOOLE.,. IONASI oI

HANDLEBAR

5

t-,,.,

10

2

~;~19Nm(0.9 m.kg, 6.5

ft.lb) I

1~143Nm(4.3 m.k 9, 37 ft.lb) I

,)

. 8

Order Job name/Part name

1

2

3

4

5

6

7

8

9

Handlebar removal

Left/Right bake mirror

Front protector bar

Upper cover

Front/Rear handlebar cover

Left/Rig ht flasher

Brake master cylinder

Front brake switch

Handlebar switch (Right)

Throttle cable

Right grip

Brake cable

Rear brake switch

Handlebar switch (Left)

Bind

Q'ty

1

1/1

1

Remarks

Remove the parts in order.

Refer to "COVERS AND PANEL" IN

CHAPTER 3.

6-25

.AOOLEBAR IC"ASI oI

5

p-..

10

2

~19Nm(0.9 m.kg, 6.5

ft.lb) I

~D 1~143Nm(4.3 m.kg, 37

ftJb)l

,)

. 8

Order Job name/Part name

10

11

12

13

Wire harness strap

Brake hose

Handlebar comp.

Left grip

Q'ty

1

1/1

Remarks

Reverse the removal procedure for in-

stallation.

6-26

.,,O,EBA, IC"ASI oI

®

HANDLEBAR INSTALLATION

1. Clean:

• Steering shaft ®

~!~v~v/±1 --'] ~ I I ~ [e-]l

Proper cables and leads routing is essential to

issue safe scooter operation.

2. Install:

• Handlebar O

• Bolt (~)

• Nut I~143Nm(4.3 m.kg, 37ft.lb) I

NOTE:

Match the bolt (~ on to the steering column

dent (~.

CAUTION:

There must be a space b after tighting bolt ~).

3. Install:

• Ba nd

NOTE:

Clamp the wire harness.

4. Apply:

• Lithium soap base grease (to throttle

cable end and handlebar right end).

6-27

5. Install:

• Handlebar switch (right) (~

NOTE:

Insert the projection (~ into the hole (~ on the

handlebar comp.

.AOO,EBA. IC"ASI oI

®

Q

6. Install:

• Handlebar switch (left) (~

NOTE:

Insert the projection (~ into the hole @ on the

handlebar comp.

7. Install:

• Master cylinder

NOTE:

Match the slot with the punched mark @ on

the handlebar comp.

6-28

STEE.,°O IC"ASI oI

STEERING

38Nm(3.8 m.kg, 27ft.lb)

~-766Nm(6.6 m.kg, 47.8 ft.lb)]

r~122Nm(2.2 m.kg, 16 ft.lb)

-J/

I

i

21

8

I

5

-9

8

40Nm(4.0 29 ft.lb)

Order Job name/Part name

1

2

3

4

5

6

7

8

9

Steering removal

Handlebar

Front wheel

Ring nut 1/Special washer

Ring nut 2/Rubber washer

Ring nut 3

Under bracket

Front fork (Left/Right)

Bearing cover

Ball race

Ball (Upper/Lower)

Ball race

Q'ty

1/1 -

1/1

1

1 -

1/1

1

22/19

3

Remarks

Remove the parts in order

Refer to "HANDLEBAR" section.

Refer to "FRONT WHEEL AND BRAKE

DISC" section

Refer to "STEERING REMOVAL/INSTAL-

LATION" section.

Reverse the removal procedure for in-

stal lation.

6-29

STEE.,°O IC"ASI oI

STEERING REMOVAL

~WARNING

• Securely support the scooter so that there

is no danger of it falling over.

• Stand the scooter on a level surface.

1. Removal:

• Ring nut 1 ~)

• Special washer (~

• Ring nut 2 (~)

• Rubber washer (~

• Ring nut 3 (~

• Bearing cover (~

• Ball race (~

• Ball (~

• Front fork assembly (~

NOTE:

• Remove the ring nuts by steering nut wrench.

~:c~l Steering nut wrench (~ YU-33975 I

• Hold the lower bracket by hand, then remove

by using the steering nut wrench @.

• Do not loss the balls (Upper: 22 pcs, Lower:

19 pcs).

2. Remove

• Front fork assembly

Refer to "FRONT FORK" section.

3. Remove

• Ball race

Ball race replacement steps:

• Remove the ball races on the head pipe us-

ing long rod (~ and the harmmer as shown.

• Remove the ball races on the under bracket

using the floor chisel (~and the harmmer as

shown.

6-30

STEE.,°O IC"ASI oI

STEERING INSPECTION

1. Wash the bearing races with a solvent.

2. Inspect:

• Ball race

• Ball

Pitting/Da mage--~Replace.

NOTE:

Always replace bearings and races as set.

Q

3. Inspect:

• Under bracket (~

Crack/Bend/Damage-->Replace.

W!~LVAV/±I -'] ~ I I ~ [¢']1

Do not attempt to straighten a bent under

bracket as this may dangerously weaken the

under bracket.

STEERING INSTALLATION

1. Install:

• Ball <~

NOTE:

Upper ....... 22 pcs

Lower ...... 19 pcs

2. Lubricate

• Ball

• Ball race

Lithium soap base grease

6-31

STEE.,°O IC"ASI oI

, \ ®

3. Install:

• Front fork assembly (~

• Ball race (Upper) ~)

• Bearing cover (~

• Ring nut 3 ~)

• Rubber washer {~)

• Ring nut 2 (~

• Special washer (~

• Ring nut 1 (~

NOTE:

Securely support the steering shaft so that

there is no danger of it falling down.

4. Tighten:

• Ring nuts

Tighten steps:

• Tighten the ring nut 3 (~ using the ring nut

wrench (~

r~122 am {2.2 m.kg, 16 ft..b~ I

steor,no, utwrenoh o_ 9 I

NOTE:

Set the torque wrench (~ to ring nut wrench (~

.~...~~ ~ @@ ~ so that they form right angle.

, ~!~Lvlv/±~ --{ ~11

~, [ ,¢-]1

Do not over-tightening.

• Loosen the ring nut 3 @) 1/4 turn.

/// / ~) • Checkthe front fork by turning it lock to lock.

If there is any binding, remove the front fork

, assembly and inspect the steering ball bear-

~,~ ~ ings and ball races.

• Install rubber washer (~ and ring nut 2 (~,

then turn the ring nut 2 until it contacts with

rubber washer.

6-32

STEE.,°O IC"ASI oI

CAUTION:

Slots on the ring nut 2 and ring nut 3 should

be align. If not, turn the ring nut 2 towards

tighten direction until slots alignment.

• Install special washer (~)

NOTE:

Insert the projections of the special washer into

the slots.

• Install ring nut 1 (~ and tighten.

[~166Nm(6.6 m.kg, 47.8 ft.lb) I

6-33

F.O.T FO.K IC"ASI oI

FRONT FORK

8

Order Job name/Part name

1

2

3

4

5

Q'ty Remarks

Front fork removal

Steering

Under fender 1

Speedometer cable holder 1

Cap bolt 2 -

Pinch bolt 2

Front fork 2 -

Remove the parts in order.

Refer to "Steering" section.

l

Refer to "FRONT FORK REMOVAL/IN-

STALLATION" section.

Reverse the removal procedure for in-

stallation.

6-34

F.O°T FO.K IC"ASI oI

FRONT FORK DISASSEMBLY

®

@

/

® c-~

[~, 23 N m (2.3 m~t~ / '.

®

Q

Order Job name/Part name

O

®

@

®

@

Front fork disassembly

Fork spring

Q'ty

Band/Front fork boot 1

Bolt/Copper washer 1/1 -

Inner tube 1

Damper rod 1/1

Rebound spring 1

Oil lock piece 1/1

Oil seal clip 1

Oil seal 1

Outer tube 1 -

Remarks

Remove the parts in order.

Refer to "FRONT FORK REMOVAL/IN-

STALLATION" section.

Refer to

"

FRONT FORK DISASSEMBLY/

ASSEMBLY" section.

Reverse the disassembly procedure for

assembly.

6-35

F.O.T FO.K IC"ASI oI

f

YP .....

FRONT FORK REMOVAL

~!~LvAv/_,l -"t ~ I I ~ [¢-]

• Securely support the scooter so there is no

danger of it falling over.

• Stand the scooter on a level surface.

• Stand the scooter on its centerstand.

1. Remove:

• Under fender (~

2. Remove:

• Cap bolt (~)

• Pinch bolt (~

W!~kvAv/±1 -'] ~ I I ~ [¢']1

Fork spring will jump out after removing cap

bolt.

3. Remove:

• Front fork (Left/Right) (~

YP703020

FRONT FORK DISASSEMBLY

1. Remove:

• Bolt (damper rod) (~

Loosen the bolt (damper rod) (~ while

holding the damper rod with T-handle

~) and holder (~).

~1 T-handle

YM-1326

Holder

YM-01300-1

6-36

F.O.T FO.. IC"ASI oI

O

®

.

Remove:

• Inner tube (~

• Oil lock pice (~

• Damper rod ®

• Rebound spring (~

"7 "°'" i~:

3. Remove:

• Oil seal (~

CAUTION:

Never reuse the oil seal.

~) Rag

- U

YP703030

FRONT FORK INSPECTION

1. Inspect:

• Inner tube bending

I~l Inner tube bending limit:

0.2 mm(0.008 in)

Scratches/be nds/da m age-->Replace.

W!~VAV/±I -'| ~ I I ~ [¢']1

Do not attempt to straighten a bent inner tube

as this may dangerously weaken the tube.

®

Q

®

YP .....

FRONT FORK ASSEMBLY

Reverse the

"

DISASSEMBLY" procedure.

Note the following points.

1. Install:

• Damper rod (~

• Rebound spring (~

• Oil lock piece (~

• Inner tube L~

6-37

F.O.T FO.. IC"ASI oI

.

Install:

• Inner tube (~

Into outer tube ~).

A

.

Install:

• Plain washer (~

• Bolt (damper rod) (~)

4. Tighten:

• Bolt (damper rod) (~

~%O%123Nm(2.3 m.kg, 16.6ft.lb) I

NOTE:

Tighten the damper rod bolt (~while holding the

damper rod with a T-handle(~ and holder ~).

~ T-handle

YM-01326-A

Holder

YM-01300-1

5. Install:

• Oil seal (~

• Retaining clip

Use the fork seal driver weight ~) and

the attachment (~).

NOTE:

\

• Before installing the oil seal (~, apply lithium

soap base grease onto the oil seal lips.

• Adjust the retaining clip so that it fits into the

outer tube groove.

6-38

CAUTION:

Make sure that the oil seal numbered side faces

upward.

~

Fork seal driver weight:

YM-33963

Attachment:

YM-01400

F.O.T FO.. IC"ASI oI

.

Inspect:

• Inner tube operation

Unsmooth operation-->Disassembly and

recheck.

0;

7.

Fill:

• Fork oil (~

©1

Oil quantity:

88 cc

Recommended oil:

Fork oil 10 W or equivalent

8. After filling up, slowly pump the fork up

and down to distribute the fork oil.

9. Install:

• Front fork spring O

NOTE:

• Install the fork spring with its smaller pitch(~

upward .

• Before installing the cap bolt, apply grease

to the O-ring.

• Temporarily tighten the cap bolt.

EB703050

FRONT FORK INSTALLATION

Reverse the "REMOVAL" procedure.

Note the following points.

1. Install:

• Front fork(~

NOTE:

Apply grease onto cap bolt O-ring before in-

stalling cap bolt.

.

Tighten:

• Cap bolts (~)

• Pinch bolts (~)

~1

38Nm(3.8 m.kg, 27 ft.lb) I

I 40Nm(4.0 m.kg, 29 ft.lb)~

6-39

E.EOT..OA. OO=,O=E°T= I E'EC I I

ELECTRICAL COMPONENTS

(~ Main switch

(~) Flasher relay

(~) Oil level gauge

(~ C.D.I. UNIT

(~ Fuel level gauge

(~ Starter relay

(~ Fuse

ELECTRICAL

(~ Battery

(~ Ignition coil

@ Rectifier/Regulator

(~) Horn

®

@

®

F

®

, ®

0

Y

7-1

Cl.O°lT OlAO.A. IE'EC I I

CIRCUIT DIAGRAM

, 111L u i

- -i-I

@

/--/

i ® i~

~l ------I

:0

__1

: ~I~ ~

'®

I I ~ III~L

I ~ II~l~

I I ~1~2-

/

I ~ @

__i, , I ®

, I ~ ~4-4-

......

~IBI ~-I~- "

I1~ II

~ ®,,® ,,

• ~---I-- 1

_EB

I

I ,

i@

I

L

I I I

I I

i

I I i-- i

L .... J b__ _J

o

L

_E,2 ~____

I

7-2

c..cu.T o..o..M I E'Ec I I

(~ Main switch

(~) Main fuse

(~ Battery

(~ Starter relay

(~ Starter motor

(~ Rectifier regulator

(~ Auto choke

(~ C.D.I. magneto

(~ C.D.I. unit

@ Ignition coil

@ Spark plug

@ Rear brake switch

(~ Front brake switch

@ Tail/Brake light

@ Rear flasher light(left)

@ Rear flasher light(right)

(~ Licence light

(~) Front flasher light(right)

(~ Front flasher light(left)

(~ Head light(for high beam)

COLOR CODE

B Black

Br Brown

Ch Chocolate

Dg Dark Green

G Green

L Blue

Or Orange

Sb Sky blue

P Pink

R Red

Gy

Y

W

B/R

Br/W

G/R

G/Y

L/B

L/Y

L/W

(~ Head light(for low beam)

(~) Flasher relay

(~ Horn

@ Handlebar switch (left)

(~ Horn switch

@ Dimmer switch

(~ Turn switch

@ Fuel sender

@ Meter

@ Fuel gauge

(~ Oil indicator light

@ Meter light

@ High beam indicator light

@ Turn indicator light

(~ Oil level gauge

@ Handlebar switch (right)

@ Starter switch

@ Engine stop switch

G ray

Yellow

White

Black/Red

Brown/White

G ree n/Red

Green/Yellow

Blue/Black

Blue/Yellow

Blue/White

L/R Blue/Red

R/B Red/Black

R/Y Red/Yel low

R/W Red/wh ite

Y/R Yellow/White

W/G White/Green

G/W Green/White

W/R White/Red

L/G Blue/Green

7-3

O.EOK.°O SW.TO.ES IE'EC I I

JJoo r,

"~xl " --

YP N

CHECKING SWITCHES

CHECKING STEPS

Using pocket tester, check switches for conti-

nuity between their terminals to determine

whether they are correctly connected.

Replace the switch component if any of the

combinations does not produce the correct

reading.

I~1 Pocket tester:

YU-03112

NOTE:

• Turn the switch to the

"ON", "OFF"

positions

several times.

• Adjust the pocket tester to correct

"0"

posi-

tion before checking switches.

• Set the pocket tester selector to

"xl'E2.

X",•

Br R

OFF

ON O--O

"O"

SWITCH CONNECTION AS SHOWN IN THIS

MANUAL

This manual contains connection charts, like

the one shown on the left, showing the termi-

nal connections of switches (e.g. the main

switch, handlebar switch, brake switch, light-

ing switch etc.)

The column on the extreme left indicates the

different switch positions, the top line ind icates

the colors of the leads connected to the termi-

nals on the switch.

"0~0"

indicates terminals between which

there is continuity, i.e. a closed circuit, in the

given switch position.

In this chart:

"Br

and R" have continuity with the switch in

the

"ON"

position.

7-4

O.EOK.°O SW.TO.ES IE'EC I I

SWITCH POSITION AND TERMINAL CONNECTION

Before checking a switch refer to the check-

ing switches as shown in the left page and

check for the correct terminal connections

(closed circuit) according to the color combi-

nations shown in the chart.

Poor connection, fault-->Repair or replace.

7

Rear brake switch

I- I

Horn switch

--'~P B ~

Release

Push in O- 0

Dimmer switch

~G L Y

-C> O-43

gO 00

Turn switch

Ch Br/VV Dg

<~ O--O

~> O--O

L

J

I

I I",,t

,,,,,,,,,,, "~

<

/

\

I-

I

L

Main switch

LOCK

~ OPEN

OFF

Gy Br R B B/VV

C)---O

ON C)-O0

-O

r Front brake switch

I

L

<

i I

L

Start switch

L/W L/G

Release

Push in O--O

Engine stop switch

B/W B/W L/G B

OFF

RUN 0--0 0--0

F

Fuse

J

7-5

c.Ec...o T.E Bo.Bs A.o BO.B SOO.ETS IE'EC I I

EAS00733

CHECKING THE BULBS AND BULB

SOCKETS

Check each bulb and bulb socket for damage

or wear, proper connections, and also for con

tinuity between the terminals.

Damage/wear --~ Repair or replace the bulb,

bulb socket or both.

Improperly connected --~ Properly connect.

No continuity --~ Repair or replace the bulb,

bulb socket or both.

@

©

18410603

18410004

TYPES OF BULBS

The bulbs used on this scooter are shown in

the illustration on the left.

• Bulbs @ and (~ are used for the headlights

and usually use a bulb holder that must be

detached before removing the bulb. The ma-

jority of these types of bulbs can be removed

from their respective socket byturning them

co u nterclockwise.

brake lights and can be removed from the

socket by pushing and turning the bulb coun-

te rcl ockwise.

• Bulbs (~ and (~ are used for meter and indi-

cator lights and can be removed from their

respective socket by carefully pulling them

out.

7-6

C.EOK..O T.E BO'BS..O BO'B SOCKETS IE'EC I I

CHECKING THE CONDITION OF THE BULBS

The following procedure applies to all of the

bulbs.

1. Remove:

• bulb

Since the headlight bulb gets extremely hot,

keep flammable products and your hands

away from the bulb until it has cooled down.

CAUTION:

• Be sure to hold the socket firmly when re-

moving the bulb. Never pull the lead, other-

wise it may be pulled out of the ter-minal in

the coupler.

• Avoid touching the glass part of the head-

light bulb to keep it free from oil, other-wise

the transparency of the glass, the life of the

bulb, and the luminous flux will be adversely

affected. If the headlight bulb gets soiled,

thoroughly clean it with a cloth moistened

with alcohol or lacquer thinner.

.

Check:

• bulb (for continuity)

(with the pocket tester)

No continuity --> Replace.

~1 Pocket tester

YU-03112

NOTE:

Before checking for continuity, set the pocket

tester to

"0"

and to the

"El x 1"

range.

18410002

7-7

a. Connect the positive tester probe to termi-

nal (~ and the negative tester probe to ter-

minal (~, and check the continuity.

b. Connect the positive tester probe to termi-

nal 1 and the negative tester probe to ter-

minal (~, and check the continuity.

c. If either of the readings indicate no

continu-ity, replace the bulb.

O.EOK.°O T.E BO'BS A.O BO'B SOCKETS IE'Ecl I

CHECKING THE CONDITION OF THE BULB

SOCKETS

The following procedure applies to all of the

bulb sockets.

1. Check:

• bulb socket (for continuity)

(with the pocket tester)

No continuity --> Replace.

P°ckettester I

YU-03112

NOTE:

Check each bulb socket for continuity in the

same manner as described in the bulb section;

however, note the following.

a. Install a good bulb into the bulb socket.

b. Connect the pocket tester probes to the

respective leads of the bulb socket.

c. Check the bulb socket for continuity. If any

of the readings indicate no continuity, re-

place the bulb socket.

7-8

IE'ECI I

IGNITION SYSTEM

CIRCUIT DIAGRAM

• .... ~-r~', ~

~ ~ ~L~J~ ~E~

- ~

~-~_~

I I r s- ------7

I

I __~ I

I I I

B

~ ,~w

I-- -- -------- .... I .........

I

, __ ~,B

I

wa? ~or I

-- - B B I

'B~'

I I ~ I I

~,_ ........ I ..........

I

---~L ..... ~®

',®

I r~ ® "

; ..... __~___J

@.___~ ____~ ....... 2~___]

', ;--t * ~ ~B

]~- -v- " v

~ F--- --- ....

l

-

r .... --q ~ --I

',

I I

....

L_ ~ '

I

I ,

I

L_

S

~_ ___

,,',#~

I I

®I Io I

__j L .... J

S

F ~ -~ ~ ~ ____

I@l b

L .......... I

(~) Main switch

(~ C.D.I. magneto

(~) C.D.I. unit

@ Ignition coil

(~) Spark plug

(~3 Engine stop switch

7-9

.o..T.o° SVSTEM I':":C I I

TROUBLESHOOTING

IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE

(NO SPARK OR INTERMITTENT SPARK)

NOTE:

• Remove the following parts before troubleshooting.

1) Battery box cover 4) Tail cover

2) Center cowling 5) Side cover (right)

3) Rear carrier 6) Handlebar cover (front)

• Use the following special tools in this troubleshooting.

~1 Dynamic spark tester:YM-34487 I ~1 Pocket tester:Yu-03112

1. Spark plug

• Check the spark plug condition.

• Check the spark plug type.

• Checkthe spark plug gap.

Refer to the "SPARK PLUG INSPECTION"

section in the CHAPTER 3.

~ CORRECT

2. Ignition spark gap

• Disconnect the spark plug cap from spark

plug.

• Connect the dynamic spark tester (~ as

shown.

(~ Spark plug cap

• Checkthe ignition spark gap (~.

• Start engine, and increase spark gap until

misfire occurs.

~ Minimum spark gap:

6.0 mm (0.24 in)

I OUT OF SPECIFI-

CATION OR NO

SPARK

*

Standard spark plug:

BPR7HS (NGK)

Spark plug gap:

0.6~0.7 mm(0.02~0.03 in)

INCORRECT

I Spark plug is faulty, replace it or repair plug

gap.

lgll0201

MEETS SPECIFICATION

I Ignition system is good.

7-10

IGNITION SYSTEM ELEC +'

*

l

3. Spark plug cap resistance

• Remove the spark plug cap.

• Connect the pocket tester (~Q x lk) to the

spark plug cap.

• Check the spark plug cap for specificated

resistance.

[~ Spark plug cap resistance:

5k£Q at 20°C (68°F)

MEETS

SPECIFICATION

4. Ignition coil resistance

• Disconnect the ignition coil leads from the

ignition coil.

• Connect the pocket tester (~ x 1) to the

ignition coil.

Ignition coil:

Tester (+) lead->Terminal (~

Tester (-) lead->Coil base (~)

• Check the primary coil for specification

resistance.

Primary coil resistance:

0.32~0.48 E2 at 20°C (68°F)

• Connect the pocket tester (£Q x 1 k) to the

ignition coil.

Tester (+) lead--~Spark plug lead (~

Tester (-) lead->Coil base (~)

• Check the secondary coil for specificated

resistance.

Secondary coil resistance:

5.68 ~ 8.52 k ~ at 20°C (68°F)

(Spark plug lead - Coil base)

BOTH MEET

SPECIFICATIONS

• J

OUT OF SPECIFICATION

Replace spark plug cap.

///"

© ©

OUT OF SPECIFICATION

I Ignition coil is faulty, replace it.

7-11

,ON,T,OO S STEM IE'EC I I

5. Pickup coil resistance

• Disconnect the pickup coil coupler from

the wireharness.

• Connect the pocket tester (~ × 100) to the

pickup coil terminal.

Tester (+) lead->White/Red lead (~

Tester (-) lead,White/Blue (~)

• Check the pickup coil for specificated re-

sistance.

-~ Pickup coil resistance:

248~ 372 ~Q at 20°C (68°F)

(Wh ite/Red-Wh ite/Blu e)

~N7 MEET

SPECIFICATION

6. Source resistance

• Disconnect the source coil coupler from

the wireharness.

• Connect the pocket tester (~ × 100) to the

source coil terminal.

Tester (+) lead->Black/Red lead (~

Tester (-) lead,Green/White (~

• Check the source coil for specificated re-

sistance.

-~ Source coil resistance:

640 ~ 960 E2 at 20°C (68°F)

(Black/Red - Green/White )

~7 MEET

SPECIFICATION

7.

Main switch

Refer to "CHECKING SWlTCHS" section.

CONTINUITY

OUT OF SPECIFICATION

I Pickup coil is faulty, replace it.

OUT OF SPECIFICATION

I Source coil is faulty, replace it.

NO CONTINUITY

I Main switch is faulty, replace it.

7-12

.O..Z.O° SVSTEM IE'EC I I

8.

Engine stop switch

Refer to "CHECKING SWlTCHS" section.

CONTINUITY

9. Wiring connection

Check the entire ignition system for conneo

tions.

Refer to the "WIRING DIAGRAM" section.

~ CORRECT

I Replace CDI unit.

NO CONTINUITY

I Engine stop switch is faulty, replace it. I

POOR CONNECTION

I Correct. I

7-13

O,.OSYSTE. IE'Ecl

CHARGING SYSTEM

CIRCUIT DIAGRAM

I

[- .... ~ ~:

L--~ ______i ~ i ...... i

I I r -~ ------1

,~ ~

~_~_~_~

_ J R,~. R I

,eeL-' ~r ~

,~'

- -' ---4-

........ ~-

,,® ® ,,

,, ~,,1~

II

........ £~rq ....

i I _t _ll

l ...... l i [~I[~

i<~ ~_li~

~------~ .... ~ ___

~ ~-~T~,~ --1---: ~

[___

I

14~ IHb

L ..... i

,'

®~ ~',D

'[_~'

',

B,,~

i

I J--~

'-C 1"]

I I

,BI,

I I

I

,' ........ ~,rm' ....... 78-',r~

i ~, ~$~ I I I o,d-E-~--~ -I

~,R_, ( ® ~

~ I ~ ~',

I

L ....... I .......... i

,'--@, ,'TE --,,

,',

~',~

,' B',~

L_ _] L__ _J

i- ~ -~

L_____

,,

' ~i~

I I

I

i

(~) Main fuse

(~ Battery

(~ Rectifier Regulator

(~ CDI magnet

7-14

O,.OSYSTEM IE'ECI

TROUBLESHOOTING

THE BATTERY IS NOT CHARGED.

NOTE:

• Remove the following parts before troubleshooting.

1) Front protector bar 4) Tail cover

2) Upper cover 5) Right side cover

3) Rear carrier

• Use the following special tool (s) in this trobleshooting.

1~1 Inductive tach°meter: YU-8036-A I1~1

Pocket tester:

YU-03112

1. Fuse (main)

• Remove the fuse.

• Connect the pocket tester (£1 x 1) to the

fuse.

• Check the fuse for continuity.

~ CONTINUITY

2. Battery

• Check the battery condition

Refer to the "BATTERY INSPECTION" sec-

tion in the CHAPTER 3.

[~ Open circuit voltage:

12.8V or more at 20°C (68°F)

7 CORRECT

*

NO CONTINUITY

I Fuse is faulty, replace it.

INCORRECT

I o Clean battery terminals.

• Recharge or replace battery.

J/

/J

7-15

O,NOS,STEM IE'ECI

3. Charging voltage

Connect the inductive tachometer to the

spark plug lead.

Connect the pocket tester (DC20V) to the

battery.

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

Tester (-) lead- >Battery (-) terminal

• Start the engine and accelerate to about

5,000 r/min.

• Check charging voltage.

~ Charging voltage:

13 ~ 14 V at 4,000 r/min

NOTE:

Use a full charged battery.

l

OUT OF

SPECIFICATION

4. Charging coil and lighting coil resistance

• Disconnect the charging coil coupler from

the wireharness.

• Connect the pocket tester

"~

x 1" to the

charging coils.

• Measurethe charging coil and lighting coil

resistance.

Charging coil resistance:

Tester (+) lead->White lead (~

Tester (-) lead->Earth

Lighting coil resistance:

Tester (+) lead->Yellow/Red (~

Tester (-) lead->Earth

-~ Charging coil resistance:

0.48~0.72 ~ at 20°C (68°F)

Lighting coil resistance:

0.4-0.6 ~, at 20°C (68°F)

~=, MEET

SPECIFICATION

*

MEETS SPECIFICATION

I Charging circuit is good.

~z

J

OUT OF SPECIFICATION

I Charging coil is faulty, replace it.

7-16

O,OOS STEM IE'ECI

Se

5. Wiring connection i

]

Check the entire ignition system for con-

nections.

Refer to the "WIRING DIAGRAM" section.

.~o~

Replace rectifier regulator.

POOR CONNECTION

I Correct.

7-17

E.EOT..O ST..T.°O S STE. I E'EC I I

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

IIII ON IIC CI~~ cl- __ .... ~, ~--~______I

B ~/a

L .....

i ---,® [r -~ ---1

--i-" "~-~ °

,,~~~',~

L ___J

I!Io,,o ...... "

'~ -~-' ~

~)r-----

I

I___

I

L~__ I

'-# 71

I I

~,,@,

I ' '

1

I

.... I

r .... --~' ~--I s

'

®~',D ' fl

-~'

, ,t_B_j

L_ ~ L

,',

...... -~',B ..... Y-- ~-',,B

, f--~, ~ ~ .... I I , o,d-Z-~S4~ -'

,

~~I ~ I~ ITZ:~=~

I ' --

,@~ ......

o~_ .,,~ ,,

®,,®

,

I

L ....... I .......... I

I

i

a

,'--G I ,'~3- --',

," B,,( ,' B,,~

L_ _J L__ _J

S

, @

',

I

L I

®l

0B8

I

(~ Main switch

(~

Main fuse

(~ Battery

(~ Starter relay

(~ Starter motor

(~ Rear brake sv~ switch

(~) Front brake switch

(~ Engine stop switch

(~) Starter switch

7-18

E.EO*..O STA.*.OO S*S*EM I E'EC I I

TROUBLESHOOTING

J STARTER MOTOR DOES NOT OPERATE.

NOTE:

• Remove the following parts before troubleshooting.

1)Battery box cover 4)Side covers (left and right)

2)Rear carrier 5)Trunk

3)Tail cover 6)Handlebar cover (front)

• Use the following special tool in this troubleshooting.

Pocket tester:

I

YU-03112

1. Fuse

• Remove the fuse.

• Connect the pocket tester (~ x 1 ) to the

fuse.

• Check the fuse for continuity.

S CONTINUITY

2. Battery

• Check the battery condition.

Refer to the "BATTERY INSPECTION" sec-

tion in the CHAPTER 3.

Open circuit voltage:

12.8 V or more at 20°C (68°F)

S CORRECT

3. Starter motor

• Connect the battery@positive terminal

and starter motor cable ~) using a jumper

lead (~ *

t

J

• Check the starter motor for operation.

S MOVES

*

NO CONTINUITY

I Fuse is faulty, replace it.

INCORRECT

l e Clean battery terminals.

• Recharge or replace battery.

~WARNING

• A wire for the jumper lead must have the

equivalent capacity as that of the battery

lead or more, otherwise it may cause the

jumper lead to be burned.

• This check is likely to produce sparks, so be

sure that no flammable gas or fluid is in the

vicinity.

DOES NOT MOVE

I Starter motor is faulty, repair or replace it. I

I

7-19

E.EOT..O STA.T.OO S STEM I E'EC I I

4. Starter relay

• Disconnect the relay unit coupler from the

wire harness.

• Connect the pocket tester(~ x 1)and

battery(12V) to the relay unit coupler ter-

minals.

Battery(+)lead-->

Blue/White terminal (~

Battery(-)lead--~

Green/Yellow terminal (~)

• Check the starter relay for continuity.

Tester (+) lead--> (~ terminal

Tester (-)lead~ (~ terminal

,~ CONTINUITY

5. Main switch

Refer to "CHECKING SWITCHS" section.

,~ CONTINUITY

6. "START" switch

Refer to "CHECKING SWlTCHS" section.

~

!;7 CONTINUITY

7. Engine stop switch

Refer to "CHECKING SWlTCHS" section.

9$

CONTINUITY

NO CONTINUITY

J Replace the starter relay.

NO CONTINUITY

J Main switch is faulty, replace it.

NO CONTINUITY

1

"START" switch is faulty, replace handlebar

switch (right).

J Engine stop switch is faulty, replace it.

7-20

E'EOT..C S*A.*.°O S*S*EM I E'EC I I

CONTINUITY

8. Brake switches (front and rear)

Disco n nect the brake switch leads from the

wire harness.

Connect the pocket tester (~ × 1 )to the

brake switch leads.

/f \\\

Check the brake switch for continuity

Switch

Position

Good

condition

Brake is

applied 0

Brake is X

not applied

Bad condition

O:Continuity X

GOOD

CONDITION

9• Wiring connection

Checkthe entire electrical starting system

for connections•

Refer to "WIRING DIAGRAM" section.

I Replace brake switch(es)•

POOR CONNECTION

I Correct•

7-21

E'ECT..O STA.T.OO S STEM I E'EC I I

STARTER MOTOR

._._' .

~- [~113 N m(1"3 m "kg' 9"4 ft'l b)~

~. (~~~ 1

Order Job name/Part name

1

2

Starter motor removal

Rear carrier

Tail cover

Battery box cover

Left/Right side cover

Center cowling

Muffler

Rear wheel

Air shroud 3

Starter motor coupler

Starter motor

Q'ty

m

Remarks

Remove the parts in order.

Refer to "COVER PANEL"

CHAPTER 3.

section in

]Refer to "REAR WHEEL AND REAR

BRAKE" section in CHAPTER 6.

Refer to "ENGINE REMOVAL" section

chapter 4.

Reverse the removal procedure for in-

stallation.

7-22

E,ECTR,O START,OO SVSTEM I E'EC I I

STARTER MOTOR DISASSEMBLY

<C_

k~ ry~,113N m(1.3 m.kg, 9.4 ft.lb)l

<. (~..~~ ~~=~ 1

Order Job name/Part name

Cb

®

Starter motor disassembly

O-ring

Rear bracket

Armature ass'y

Ring

Brush holder set

Q'ty Re marks

1 m

1

1-

Disassembly the parts in order.

Refer to "Starter motor assembly"

Reverse the disassembly procedure for

assembly.

7-23

E.EOT..C STA.T..O S STEM I E'EC I I

®

YP803034

INSPECTION AND REPAIR

1. Inspect:

• Commutator

Dirt-->Clean it with #600 grit sandpaper.

2. Measure:

• Commutator diameter (~

Commutator wear

it I

15.1 mm (0.59 in)

.

Out of specification-->Replace the starter

motor

Measure:

• Mica undercut (~

I locaun'ercut

I

1.05 mm (0.04 in)

Out of specification~Scrape the mica to

the proper value (a hacksaw blade can

be ground to fit).

NOTE:

The mica insulation of the commutator must

be undercut to ensure proper operation of com-

mutator.

®

(~ m 4-(

J

4. Inspect:

• Armature coil resistances (installation/

continuity)

Defects-->Replace the starter motor.

If commutator is dirty, clean it with sand-

paper.

Good

condition

[] ©

[] ×

Bad condition

0 x x

0 x 0

O: Continuity

x: No continuity

Bad condition-->Replace.

7-24

E.EOT.,O STA.T,°O SVSTEM I E'EC I I

.

Measure:

• Brush length (~

Out of specification-->Replace.

I~1 Brush length wear limit

3.0 mm (0.012 in)

.

Measure:

• Brush spring force

Fatigue/out of specification-->Replace as

a set.

7-25

..o.T.oo s sTEM IE'EC I I

LIGHTING SYSTEM

CIRCUIT DIAGRAM

I

[- .... ~ ~:

L--~ ______1 ~ I ...... I

I I r -~ ------1

~ ~

_ J R,~. R I

,~'

- -' ---4-

........ ~-

,,® ® ,,

,,

4~ ,,1~

II

........ £~rq ....

i I _t _ll

l ...... l i [~I[~

I<~ ~_Ii~ ~------~ .... ~ ___

I___

I

14~ IHb

L ..... I

,'

®~ ~',D

'[_~'

',

B,,~

I J--~

'-C 1"]

I I

,BI

I I

I

iI ........ 4~lr ml ....... ~-',r~

i I 'UL~- ~ I ~L~r ®

~,R_, ( ® ~ ~ I ~ ~ll

I

L ....... I .......... I

,'--@, ,'TE --,,

,',

~',~

,' B',~

L_ _J L__ _J

i- ~ -~

L_____

~i~

I I

I

(~) Main switch

(~ Fuse

(~ Battery

(~ C.D.I. magneto

@

Tail light

(~ Licence light

(~ Head light(for high beam)

(~ Head light(for low beam)

(~ Light dimmer switch

(~) Meter light

(~) High beam indicator light

7-26

..o.T.°o s,,sTE , I':":c I I

YP805010

TROUBLESHOOTING

IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHT. TAILLIGHT

AND/OR METER LIGHT FAIL TO COME ON.

Procedure

Check:

1. Lights switch

2. Dimmer switch

3. Wiring connection (entire lighting system)

NOTE:

• Remove the following parts before troubleshooting.

1) Front handlebar cover

2) Rear carrier

3) Right side cover

• Use the special tools specified in the troubleshooting section.

°ckettester I

YU-03112

YP .....

1. Fuse

NO CONTINUITY

Refer to "CHECKING SWITCHES"

sectionlIII

CONTINUITY

I

Replace the fuse.

YP .....

2. Battery

• Check the battery condition.

Refer to "BATTERY INSPECTION" sectior

in CHAPTER 3.

~ CORRECT

IN CORRECT

D

o Clean battery terminals.

• Recharge or replace battery.

YP .....

3. Main switch I NOCONTINUlTY

Refer to "CHECKING SWITCHES" section

~ CONTINUITY

* i Replace the main switch.

i

I

7-27

IE'ECI I

YP .....

Se

4. Dimmer switch

Refer to "CHECKING SWITCHES" section.

~ CONTINUITY

5. Lighting coil resistance

• Disconnect the lighting coil coupler from

the wireharness.

• Connect the pocket tester

" ~ x 1 "

to the

lighting coils.

• Measure the lighting coil resistances.

Tester (+) lead->Yellow/Red lead (~

Tester (-) lead,Earth

--~ Lighting coil resistance:

0.4 ~ 0.6 ~ at 20°C (68°F)

~

MEET

SPECIFICATION

*

NO CONTINUITY

i l

Replace the left handlebar switch.

OUT OF SPECIFICATION

I Lighting coil is faulty, replace it.

7-28

..o.T.°o svsTEM IE'EC I I

YP .....

Se

6. Wiring connection

Check the connections of the entire light-

ing system.

Refer to "WIRING DIAGRAM".

,~OK

Check the condition of each of the lighting

system's circuits.

Refer to "LIGHTING SYSTEM CHECK"

POOR CONNECTIONS

I Correct. I

YP805020

LIGHTING SYSTEM CHECK

1. If the headlight and the high beam indi-

cator light fail to come on.

I

1. Bulb and bulb socket

Refer to "CHECKING SWITCHES" section.

7 CONTINUITY

2. Voltage

• Connect the pocket tester (DC20V) to the

headlight and high beam indicator light

couplers.

[~]When the dimmer switch is on low beam.

IBIWhen dimmer switch is on high beam.

Headlight(low beam):

Tester (+) lead,Green O lead

Tester (-) lead->Black (~) lead

Headlight(high beam):

Tester (+) lead-->Yellow (~ lead

Tester (-) lead,Black (~ lead

High beam indicator light:

Tester (+) lead->Yellow ~ lead

Tester (-) lead->Black (~ lead

g

NO CONTINUITY

I Replace the bulb and/or bulb socket.

m ~ ~ ~ \ n

~i:, ii,~i,i~ ~

~

G/~ :]]

B

h

--®

7-29

..o.T.°o s sTEM IE'EC I I

• Turn the main switch to on.

• Start the engine.

• Turn the dimmer switch to low beam or

high beam.

• Checkfor voltage (12V) on the lead at bulb

socket connectors.

,•

MEETS

SPECIFICATION

I This circuit is not faulty.

YP805021

2. If the meter light fails to come on.

l

l. Bulb and bulb socket

Refer to "CHECKING SWITCHES" section.

7 CONTINUITY

2. Voltage

• Connect the pocket tester (DC20V) to the

bulb socket coupler.

Tester (+) lead-->

Blue terminal (~

Tester (-) lead-->

Black terminal (~)

%

-- L

G_~y

,B

• Turn the main switch to on.

• Start the engine.

• Check the voltage (12V) of the leads on

the bulb socket connector.

g MEETS

SPECIFICATION

I This circuit is not faulty.

OUT OF SPECIFICATION

I The wiring circuit from the main switch to

bulb socket connector is faulty. Repair.

I NO CONTINUITY

1

I Replace the bulb and/or bulb socket.

OUT OF SPECIFICATION

I

7-30

The wiring circuit from main switch to bulb

socket is faulty. Repair.

..o.T.°o svsTEM IE'EC I I

Se

3. Licence light does not come on.

1. Bulb and bulb socket

• Checkthe bulb and bulb socket for conti-

nuity

~ CONTINUITY

2. Voltage

• Connect the pocket tester (DC20V) to the

bulb socket connector.

Tester (+) lead --> Brown @ lead.

Tester (-) lead --> Black (~ lead.

• Turn the main switch to on.

• Check the voltage (12V) on the "Brown"

lead at the bulb socket connector.

~ MEETS

SPECIFICATION

(12V)

I This circuit is not faulty.

NO CONTINUITY

I Bulb and/or bulb socket are faulty, replace. I

OUT OF SPECIFICATION

l

I Wiring circuit from main switch to bulb

socket connector is faulty. Repair.

7-31

L.O.T..O SYSTEM IE'EC I I

YP805022

3. The taillight fails to come on.

I

1. Bulb and bulb socket

Refer to "CHECKING SWITCHES" section.

7 CONTINUITY

2. Voltage

• Connect the pocket tester (DC20V) to the

bulb socket connector.

Tester (+) lead-->

Brown terminal (~

Tester (-) lead-->

Black terminal (~)

• Turn the main switch to on.

GH Br

,B

Ch Dg

Checkthe voltage (12V) on the bulb socket

connector.

,•

MEETS

SPECIFICATION

I This circuit is not faulty.

NO CONTINUITY

I Replace the bulb and/or bulb socket.

OUT OF SPECIFICATION

I The wiring circuit from main switch to bulb I

I

connector is faulty. Repair.

I

7-32

S.O...SVSTE. IE'Ecl I

SIGNAL SYSTEM

CIRCUIT DIAGRAM

IIII

ON IIC CI~~ CI

_ .... ~, ~-~___I

B ~/a

b .....

i ---,® [r -~ ---1

--i -= ,~_~ °

L ___J

T!I ~IIB ' T l_a~1

'~ -@-'

~)r-----

I

I___

I

L~___I

,-C ?]

I I

I ' '

r

.... -->' ~--I

I I ~)~ I~IIB

' _I__Bj

I I

• _

~

1

I

.... I

1

[ -@ ,-

LI_B_j~

,'

L

,',

...... -~',B ..... Y-- ~-',,B

, f--~, ~ .... I I , °'~-'

,

~~I ~ I~ IT~=~

I ' -- ,~I.~ ......

o~_ .,,~ ,,

®,,®

,

I

b ....... I .......... I

i

,'- -G I ,'~3-

L_ _J L__

S

, @

',

I

b I

®l

0B8

I

_J

(~ Main switch

(~ Main fuse

(~) Battery

@ Rear brake switch

@ Front brake switch

@ Brake light

(~) Rear flasher light(right)

(~ Rear flasher light(left)

(~) Front flasher light(right)

@) Front flasher light(left)

@ Flasher relay

(~ Horn

(~ Handlebar switch (Left)

(~) Horn switch

(~ Turn switch

@ Fuel sender

(~ Fuel meter

(~) Oil indicator light

@ Turn indicator light

(~ Oil level gauge

7-33

S,O.ALSVSTEM IE'ECI I

YP806010

TROUBLESHOOTING

IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT

FAIL TO COME ON. IF THE HORN FAILS TO SOUND.

Procedure

Check:

1. Fuse (Main)

2. Battery

NOTE:

3.Main switch

4.Wiring connection (entire signal system)

• Remove the following parts before troubleshooting.

1 ) Battery box cover 5) Tail cover

2) Front protector bar 6) Side covers(Left/Right)

3) Upper cover 7) Center cover

4) Rear carrier

• Use the special tools in the troubleshooting section.

P°cket tester: I

YU-03112

¥P

.....

NO CONTINUITY

I

1.

Fuse

Refer to "CHECKING SWITCHES" section.

~ CONTINUITY

YP .....

2. Battery

• Check the battery condition.

Refer to "BATTERY INSPECTION" section

in CHAPTER 3.

~ CORRECT

3. Main switch

YP .....

Refer to "CHECKING SWITCHES" section.

.-X-

CONTINUITY

I Replace the fuse.

IN CORRECT

l e Clean battery terminals.

• Recharge or replace battery.

NO CONTINUITY

I Replace the main switch.

7-34

S,O°A. SVSTEM IE'ECI I

YP ......

Se

4. Wireharness

• Check the connections of the entire sig-

nal system.

Refer to "CIRCUIT SYSTEM WIRING DIA-

GRAM" section.

~ CONTINUITY

Check condition of each of the signal

system's circuits.

Refer to "SIGNAL SYSTEM CHECK" sec-

tion.

POOR CONNECTION

I Correct. I

7-35

SIGNAL SYSTEM ELEC

'- *'

YP806020

SIGNAL SYSTEM CHECK

1. If the horn fails to sound.

l

l. HORN switch

Refer to "CHECKING SWITCHES" section.

NO CONTINUITY

CONTINUITY

2. Voltage

• Connect the pocket tester (DC20V) to the

horn lead.

Tester (+) lead->Brown terminal (~.

Tester (-) lead->Frame ground

• Turn the main switch to on.

• Check for voltage (12V) on the "Brown"

lead at the horn terminal.

,•

MEETS

SPECIFICATION

3. Horn

• Connect the pocket tester (DC20V) to the

horn at the "Pink" terminal.

Tester (+) lead->Pink (~ terminal.

Tester (-) lead->Frame ground

• Turn the main switch to on.

• Check for voltage on the "Pink" lead at

the horn terminal.

@ CONTINUITY

i Adjust or replace horn.

I Replace the left handlebar switch.

_L

i

LoLI

OUT OF SPECIFICATION

I The wiring circuit from the main switch to the e

n

horn is faulty. Repair.

I

1- "Y

_L

NO CONTINUITY

I Replace the horn.

7-36

S,O.A,S*S*EM IE'Ecl I

YP806022

2. If the brake light fails to come on:

J l. Bulb and bulb socket

Refer to "CHECKING SWITCHES" section.

~7 CONTINUITY

J

2. Brake switch (Front/Rear)

Refer to "CHECKING SWI SWITCHES" section.

,~ CONTINUITY

NO CONTINUITY

J Replace the bulb and/or bulb socket.

NO CONTINUITY

I 1

J Replace brake switch.

3. Voltage

• Connect the pocket tester (DC20V) to the

bulb socket connector.

Tester (+) lead~>Green/Yellow terminal (~

Tester (-) lead~>Black terminal (~

--

/ %'

• Turn the main switch to on.

• The brake lever is pulled in.

• Check for voltage (12V) of the "Green/Yel-

low" lead on the bulb socket connector.

~ MEETS

SPECIFICATION

J

This circuit is not faulty.

OUT OF SPECIFICATION

4. Wiring connection

Wiring circuit from the main switch to the

bulb socket connector is faulty. Repair.

Refer to "SIGNAL SYSTEM WIRING DIA-

GRAM

"

7-37

S,ONA, SVSTEM IE'Ecl I

YP806023

3. If the flasher light and/or turn indicator

light fails to blink.

J l. Bulb and bulb socket

Refer to "CHECKING SWITCHES" section.

,~ CONTINUITY

J

2. Turn switch

Refer to "CHECKING SWITCHES" section.

~ CONTINUITY

NO CONTINUITY

J Replace the bulb and/or bulb socket.

NO CONTINUITY

I 1

J Replace the left handlebar switch.

3. Voltage

• Connect the pocket tester (DC20V) to the

flasher relay coupler.

Tester (+) lead->Brown lead (~.

Tester (-) lead->Black lead(~)

• Turn the main switch to on.

• Check for voltage (12V) of the "Brown"

lead at the flasher relay terminal.

OUT OF SPECIFICATION

,•

MEETS

SPECIFICATION

4. Voltage

• Connect the pocket tester (DC20V) to the

flasher relay coupler.

Tester (+) lead->Brown/White lead (~.

Tester (-) lead->Black lead(~)

• Turn the main switch to on.

• Check for voltage (12V) on the

"Brown/

White" lead at the flasher relay terminal.

~7 MEETS

SPECIFICATION

*

The wiring circuit from main switch to flasher

relay connector is faulty. Repair.

G

OUT OF SPECIFICATION

J The flasher relay is faulty. Replace.

7-38

S,OOA, SVSTEM IE'Ecl I

5. Voltage

• Connect the pocket tester (DC20V) to the

bulb socket connector.

At flasher light (left)

Tester (+) lead->Chocolate lead (~

Tester (-) lead->Black terminal (~)

At flasher light (right)

Tester (+) lead--~Dark green lead (~

Tester (-) lead->Black terminal (~

• Turn the main switch to on.

• Turn the turn switch to left or right.

• Check for voltage (12V) on the "Choco-

late" lead and "Dark green" at the flasher

light terminal.

J ~ MEETS

SPECIFICATION

I This circuit is not faulty.

OUT OF SPECIFICATION

6. Wiring connection

• Wiring circuit from theturn switch to bulb

socket connector is fault. Repair.

Refer to "CIRCUIT DIAGRAM".

4. "OIL" indicator light does not come on.

1. Bulb and bulb socket

• Checkthe bulb and bulb socket for conti-

nuity.

~ CONTINUITY

2. Oil level switch

• Remove the oil level switch from the oil

tank.

• Connect the Pocket Tester (~ x 1) to the

oil level switch.

Tester (+) Lead--~Brown (~

Tester (-) Lead->Gray (~

• Check the oil level gauge for continuity.

Switch position

[] Upright position X

[]Upside down

position

C): Continuity

Good

Bad condition

condition

X: No continuity

GOODCONDITION

NO CONTINUITY

l

I Replace bulb and/or bulb socket.

~,2 .... "-

BAD CONDITION

I Replace oil level switch.

7-39

S,°°A,S,S,EM IE'Ecl I

3. Voltage

• Connect the Pocket Tester (DC20V) to the

bulb socket connector.

Tester (+) Lead->Gray lead (~

Tester (-) Lead--~Black lead (~

• Turn the main switch to

"*"

• Check for voltage (12V) on the "Gray" lead

at bulb socket connector.

g

b

,BI q~l L

,•

MEETS

SPECIFICATION

(12V)

I This circuit is good.

YP806027

5. If the fuel gauge fails to operate.

1. Fuel sender

Remove the fuel sender from the fuel tank.

Disconnect the fuel sender coupler from

the wireharness.

Connect the pocket tester (~ xl0) to the

fuel sender coupler lead.

Tester (+) lead->Green terminal (~

Tester (-) lead--~Black terminal (~

• Check the fuel sender for specificated re-

sistance.

~Jl Float position Specificated

resista nce

UP (~ 4~10~

DOWN (~ 90~100£~

~7 BOTH MEET

SPECIFICATION

OUT OF SPECIFICATION

4. Wiring connection

• Checkthe entire signal system for connec-

tions.

Refer to the "WIRING DIAGRAM" section.

OUT OF SPECIFICATION

I Replace the fuel sender.

7-40

S,O.A,S STEM IE'Ecl I

2. Voltage

• Connect the pocket tester (DC20V) to the

fuel gauge coupler.

Tester (+) lead->Brown terminal (~

Tester (-) lead->Frame ground

• Turn the main switch to

"ON".

• Check for voltage (12V) of the "Brown"

lead on the fuel sender lead.

,•

MEETS

SPECIFICATION

3. Fuel gauge

• Connect the fuel sender to wireharness.

• Move the float to

"UP" (~

or "DOWN" (~.

I

• Turn the main switch to

"ON".

• Check the fuel gauge needle moves

"F"

or

"E"

Float position Needle moves

Float "UP" (~

"F"

Float

"

DOWN "(~

"E"

~7 MOVES

I This circuit is not faulty.

,/ \

II G I Ch II

OUT OF SPECIFICATION

l

Checkthe connection of the entire signal sys-

tem.

Refer to

"CHECKING

OF CONNECTIONS".

Refer to "CIRCUIT DIAGRAM".

NOTE:

Before reading the meter, stay put the float

for more than three minutes respectively at

"UP" or "DOWN".

DOES NOT MOVE

I Replace the fuel gauge.

7-41

,UZO O.OKE S STE. IE'Ecl I

AUTO CHOKE SYSTEM

CIRCUIT DIAGRAM

IIII ON IIC CI~~ c

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(7) Auto choke

(~ C.D.I. magneto

7-42

AUTO O.O.E SYSTEM IE'Ecl I

"y'p .....

TROUBLESHOOTING

IF THE AUTO CHOKE FAILS TO OPERATE.

Procedure

Check:

1. Lighting coil resistance

2. Auto choke unit resistance

3. Wiring connection (entire auto choke system)

NOTE:

• Remove the following parts before troubleshooting.

1. Battery box cover

2. Rear carrier

3. Tail cover

4. Right side cover

• Use the special tools specified in the troubleshooting section.

~1 P°cket tester: I

YU-03112

1. Lighting coil resistance

• Disconnectthe CDI magneto couple from

wire harness.

• Connect the pocket tester (E2 xl) to the

lighting coil coupler

Tester (+) Lead->Yellow/Red (~ terminal

Tester (-) Lead--~Frame earth

(~ C.D.I. magneto

w

Y/R

$

• Checkthe lighting coil for specificated re-

sistance

Lighting coil resistance

0.4~0.6 ~ 20°C (68°F)

MEETS

SPECIFICATION

OUT OF SPECIFICATION

I Replace the lighting coil

7-43

AUTO O.O.E S STEM IE'Ecl I

YP...

2. Auto choke unit resistance

• Disconnect the auto choke unit coupler

from the wireharness.

• Connect the pocket tester (~xl) to the auto

choke unit coupler lead.

Tester (+) lead.Black terminal (~

Tester (-) lead->Black terminal (~

~_~ Auto choke unit resistance:

8~12~ at 20°C (68°F)

~ MEETS

SPECIFICATION

3. Wiring connection

• Check the connection of the entire auto

choke system.

Refer to "CIRCUIT DIAGRAM" section.

OUT OF SPECIFICATION

I Replace the auto choke unit.

POOR CONNECTION

I Correct.

7-44

ITRBLI

?

I

STARTnNG FAnLURE/HARD STARTnNG ISHTGI I

NOTE:

TROUBLESHOOTING

The following troubleshooting does not cover all the possible causes of trouble. It should be

helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for

inspection, adjustment and replacement of parts.

STARTING FAILURE/HARD STARTING

FUEL SYSTEM PROBABLE CAUSE

Fueltank

Fuelcock

• Empty

• Clogged fuel filter

• Deteriorated fuel or fuel containing water or

foreign material

• Clogged fuel tank cap

L •Clogged fuel hose

• Clogged fuel cock

• Faulty fuel cock operation

• Broken or disconnected fuel cock

Carburetor

Auto choke

Air cleaner

/-

• Deteriorated fuel, fuel containing water or

foreign material

• Clogged pilot jet

• Clogged pilot air passage

•

Sucked-in air

• Deformed float

• Groove-worn needle valve

• Improperly sealed valve seat

• Improperly adjusted fuel level

• Improperly set pilot jet

• Clogged starter jet

Starter plunger malfunction

Wax malfunction

Faulty thermister

• Clogged air filter

8-1

ITRBLI

?

I

STARTING FAILURE/HARD STARTING

ISHTGI

I

IGNITION SYSTEM PROBABLE CAUSE

Spark plug

Ignition coil

CD I unit system

• Improper plug gap

• Worn electrodes

• Wire between terminals broken

• Improper heat range

• Faulty spark plug cap

Switches and wiring

L • Broken or shorted primary/secondary coil

• Faulty spark plug lead

• Broken body

• Faulty CD I unit

L • Faulty source coil

• Faulty pick-up coil

• Faulty main switch

/

L • Broken or shorted wiring

COMPRESSION SYSTEM PROBABLE CAUSE

Cylinder and cylinder head

Piston and piston rings

Crankcase and crankshaft

L"

L

•

/"

Loose spark plug

Loose cylinder head or cylinder

Broken cylinder head gasket

Broken cylinder gasket

Worn, damaged or seized cylinder

Improperly installed piston ring

Worn, fatigued or broken piston ring

Seized piston ring

Seized or damaged piston

Improperly seated crankcase

Improperly sealed crankcase (Damaged oil

seal)

Seized crankshaft

Reed valve • Deformed reed valve stopper

• Improperly seated read valve

• Loose intake manifold

• Broken gasket

• Broken reed valve

8-2

POOR IDLE SPEED

PERFORMANCE ITRBLI ? I

POOR IVIIDIUIVI AND HIGH SPEED PERFORMANCE

ISHTGI

POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE PROBABLE CAUSE

Carburetor

m •

• Improperly returned starter plunger

• Clogged or loose pilot jet

• Clogged pilot air jet

• Improperly adjusted idle speed

(Throttle stop screw)

Improper throttle cable play

Flooded carburetor

Auto choke

Air cleaner

Ignition system

POOR MIDIUM AND HIGH SPEED

PERFORMANCE

POOR MEDIUM AND HIGH SPEED PERFOR-

MANCE

Carburetor

-- Air cleaner

Muffler

L • Starter plunger malfunction

• Wax malfunction

• Faulty thermister

• Clogged air cleaner

• Faulty spark plug

• Faulty spark plug read

• Faulty C.D.I. unit

• Faulty source coil

• Faulty ignition coil

/

PROBABLE CAUSE

• Refer to starting failure/Hard starting item

(Fuel system, Ignition system, compression

system)

• Clogged or loose main nozzle

• Clogged or loose main jet

• Improperly adjust fuel level

•

Sucked-in air

•

Clogged air filter

• Clogged

8-3

ITRBLI I

POOR MIDIUM AND HIGH SPEED PERFORMANCE

ISHTGI '?

FULTY AUTOMATIC(V-BELT TYPE)

SCOOTER DOES NOT MOVE WHILE ENGINE

IS OPERATING

-- V-belt

-- Cam, slider

-- Compression spring

--

Transmission

CLUTCH OUT FAILURE

-- Clutch weight spring

-- Clutch shoe

-- Primary sheave

POOR STANDING START(LOW CLIMBING

ABILITY)

V-belt

Primary sheave

Compression spring

-- Secondary sheave

Clutch shoe

POOR ACCELERATION(POOR HIGH SPEED)

-- V-belt

Weight

m Primary/Secondary seave

/

PROBABLE CAUSE

• Worn, damaged or slipped V-belt

• Worn, damaged

• Damaged

• Pealed lining

• Seized primary sliding sheave and collar

PROBABLE CAUSE

• Worn or slipped V-belt

• Improper operation

• Damaged

• Improper operation

• Worn guide pin

• Plealed lining

PROBABLE CAUSE

• Worn

• Greasy

• Worn

• Improper operation

• Worn

8-4

ITRBLI I

OVER HEAT I POOR SPEED

ISHTGI ?

OVER HEAT

PROBABLE CAUSE

Ignition system

-- Fuel system

-- Compression system

m Muffler, Exhaust pipe

Oil pimp

Brake

-- Cooling system

POOR SPEED

-- Ignition system

L •Improper plug gap

• Improper spark plug heat range

• Faulty C.D.I. unit

Fuel system

-- Compression system

Muffler, Exhaust pipe

Clutch

m Brake

L •Improper carburetor setting

• Clogged air filter

/

• Carbon accumulation of cylinder head

•

Clogged

• Faulty oil pump

• Faulty oil quality

• Drag

• Fan damaged

PROBABLE CAUSE

L • Faulty spark plug

• Improper spark plug heat range

• Faulty C.D.I. unit

• Faulty source coil

L • Clogged fuel tank cap

• Clogged air filter

• Clogged carburetor

L • Worn cylinder

• Worn, fatigued or broken piston ring

• Broken cylinder head gasket

• Broken cylinder gasket

• Carbon accumulation of cylinder head

• Clogged

• Refer to "FAULTY AUTOMATIC"

• Drag

8-5

ITRBLI

?

I

,MPROPER K,CK, NG ISHTGI I

IMPROPER KICKING

SLIPPING

Kick axle assembly

Transmission oil

PROBABLE CAUSE

• Low tension of kick clip

• Worn kick axle

• Worn or damaged kick gear

• Damaged kick clip

• Kick clip coming off

• Damaged kick clip stopper

• Improper quality (Low viscosity)

L • Deterioration

HARD KICKING

Kick axle assembly

--Cylinder, piston and piston ring--

m Crankcase and crankshaft

PROBABLE CAUSE

j~ • High tension of kick clip

• Seized kick gear

L •Damaged or seized cylinder

• Damaged or seized piston

• Damaged or seized piston ring

• Improperly seated crankcase

L •Improperly seated crankshaft

• Damaged or seized crankshaft

• Damaged or seized crankshaft bearing

KICK CRANK NOT RETURNING

L Kick axle assembly

PROBABLE CAUSE

L • Damaged kick return spring

• Kick return spring coming off

• Kick clip coming off

• Damaged kick return spring stopper

8-6

ITRBLI

?

I

FAULTY BRAKE ISHTGI I

FAULTY BRAKE

POOR BRAKING EFFECT

Drum brake

m Disc brake

(Front)

MALFUNCTION

PROBABLE CAUSE

• Worn brake shoe

• Worn or rusty brake drum

• Improperly adjusted brake free play

• Improper brake cam lever position

• Improper brake shoe position

• Fatigue/Damaged return spring

• Oily or greasy brake shoe

• Oily or greasy brake drum

• Broken brake cable

• Worn brake pad

• Worn brake disc

• Air in brake fluid

• Leaking brake fluid

• Faulty master cylinder kit

• Faulty caliper seal kit

• Loose union bolt

• Broken brake hose

• Oily or greasy brake pad

• Oily or greasy brake disc

PROBABLE CAUSE

• Bent, deformed or damaged inner tube

• Bent or deformed outer tube

• Damaged fork spring

• Worn or damaged slide metal

• Improper oil viscosity

• Improper oil level

8-7

ITRBLI

?

I

INSTABLE HANDLING ISHTGI I

INSTABLE HANDLING

Handlebar

-- Steering

Front forks

PROBABLE CAUSE

• Improperly installed or bent

• Improperly installed steering column

L (Improperly tightened ringnut)

• Bent steering column

• Damaged ball bearing or bearing race

• Broken spring

L •Bonded front forks

Tires

~Wheels

• Uneven tire pressures on both sides

L •Incorrect tire

pressure

• Unevenly worn tires

• Damaged bearing

L • Bent or loose wheel axle

• Excessive wheel run-out

-- Frame

m Engine bracket

Rear shock absorber

• Twisted

L •Damaged head pipe

• Improperly installed bearing race

• Bent or damaged

• Fatigued spring

/

L •Oil leakage

8-8

ITRBLI I

FAULTY SIGNAL AND LIGHTING SYSTEM

ISHTGI ?

FAULTY SIGNAL AND

SYSTEM

HEADLIGHT DARK

I

LIGHTING

BULB BURNT OUT

I

-- FLASHER DOES NOT BLINK

I

-- FLASHER KEEPS ON

I

PROBABLE CAUSE

• Improper bulb

• Too many electric accessories

• Hard charging (Broken charging coil)

• Incorrect connection

• Improperly grounded

• Poor contacts (main or light switch)

• Bulb life expires

PROBABLE CAUSE

• Improper bulb

L_ •Improperly grounded

• Faulty main and/or light switch

• Bulb life expires

PROBABLE CAUSE

• Improperly grounded

• Discharged battery

• Faulty flasher switch

• Faulty flasher relay

• Broken wireharness

• Loosely connected coupler

• Bulb burnt out

• Faulty fuse

PROBABLE CAUSE

• Faulty flasher relay

L •Insufficient battery

charged)

• Bulb burnt out

capacity (nearly dis-

8-9

ITRBLI I

FAULTY SIGNAL AND LIGHTING SYSTEM

ISHTGI ?

FLASHER BLINKS SLOWER

I

FLASHER BLINKS QUICKER

I

HORN DOES NOT SOUND

I

PROBABLE CAUSE

• Faulty flasher relay

• Insufficient battery capacity

(nearly discharged)

• Improper bulb

• Faulty main and/or flasher switch

PROBABLE CAUSE

• Improper bulb

L •Faulty flasher relay

PROBABLE CAUSE

• Faulty battery

• Faulty fuse

• Faulty main and/or horn switch

• Improperly adjusted horn

• Faulty horn

• Broken wireharness

8-10

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Yamaha Motor Canada Ltd.

480 Gordon Baker Road

Toronto, ON M2H 3B4