Yamaha Zuma Scooter Repair and Maintenance Manual

2008
MOTORCYCLE
SERVICE MANUAL
Model : YW50X_
5PNF81972100 *5PNF81972100*
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
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YW50X 2007 SUPPLEMENTARY SERVICE MANUAL 2007 by Yamaha Motor Taiwan Co., Ltd. First edition, June 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd. is expressly prohibited. Printed in CANADA
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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.
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IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
Q w cC
NOTE:
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 damage to the scooter. A NOTE provides key information to make procedures easier or clearer.
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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 sequentially. 6 2 1
CYLINDER HEAD, CYLINDER, PISTON
CYLINDER HEAD, CYLINDER AND PISTON ENG CYLINDER HEAD, CYLINDER AND PISTON
CYLINDER HEAD, CYLINDER AND PISTON 26Nm(2.6 m.kg, 18.2 ft.lb)
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 accidentally drop the clip into the crankcase.
T.
R.
4
10 New 1 5 4
New
2. Remove: 8 Piston pin 1 8 Piston 2 8 Piston pin bearing 3
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3 6 9Nm(0.9 m.kg,6.5 ft.lb)

T.
Do not use a hammer to drive the piston pin out.
New
CYLINDER HEAD INSPECTION 1. Eliminate: 8 Carbon deposits Use a rounded scrapper 1.
14Nm(1.4 m.kg, 10 ft.lb) 8 9

E
R.
T.
R.
Order
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
Qty
Remarks Remove the parts in the order. Refer to the ENGINE REMOVAL section
1 2
1 2 3 4 5 6 7 8 9 10
1/1 1 1 1/1 1 2 1/1 1 1 1
2. Inspect: 8 Cylinder head warpage Out of specificationRe-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:
Reverse the removal procedure for installation.
Rotate the head severai tires to avoid removing too much material from one side. 4-4 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
4-3
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SYMBOLS
The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 2 3 4 5 6 7 8 9
+
GEN INFO
3
SPEC
4
CHK ADJ
5
CHAS
6
ENG
7
COOL
8
General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Carburetor Electrical system Troubleshooting
CARB
9
ELEC
0
TRBL SHTG
q w
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
r
T.
R.
u Symbols i to g in the exploded diagrams indicate 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 indicate the following. h Apply locking agent (LOCTITE) j Replace the part
i
4
o
G
p
M
a
BF
s
B
d
LS
f
M
g
S
h
LT
New
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TABLE OF CONTENTS
GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CARBURETOR
GEN INFO
1 2 3 4 5 6 5 7 8 9
SPEC
CHK ADJ
CARB
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
1-8
SCOOTER IDENTIFICATION
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GEN INFO
GENERAL INFORMATION
1
SCOOTER IDENTIFICATION
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VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame.
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MODEL LABEL The model label 1 is affixed to the seat. This information will be needed to order spare parts.
1-1
IMPORTANT INFORMATION
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GEN INFO
PREPARATION FOR REMOVAL AND DISASSEMBLY 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, cylinders, 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 disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire.
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REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
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GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, 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.
1-2
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GEN INFO
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.
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BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturers 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
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Do not spin the bearing with compressed air because this will damage the bearing surfaces.
1 Bearing
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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 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives. 4 Shaft
1-3
CHECKING THE CONNECTIONS

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GEN INFO
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector 2. Check: 8 lead 8 coupler 8 connector Moisture i Dry with an air blower. Rust/stains i Connect and disconnect several times.
3. Check: 8 all connections Loose connection i Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up.
4. Connect: 8 lead 8 coupler 8 connector NOTE: Make sure all connections are tight. 5. Check: 8 continuity (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.
1-4
SPECIAL TOOLS
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GEN INFO
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 inappropriate 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-. Tool NO.
90890-01235 YU-01235
Tool name / Function

Rotor holding tool This tool is used to hold the generator rotor when removing or installing and generator rotor bolt. Clutch spring holder
Illustration
90890-01337 YM-33285 YM-33285-6
90890-01284 YU-90050 90890-01383 YU-90062 90890-01189 YU-01189
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 crankshaft. Flywheel puller
90890-01135 YU-01135-B
This tool is used to remove the generator rotor. Crankcase separating tool
90890-01384 YM-33299
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
90890-01403 YU-A9472
90890-01701 YS-01880-A
This tool is used to loosen and tighten the steering ring nut. Sheave holder
This tool is used for holding the secondary sheave.
1-5
SPECIAL TOOLS
Tool NO.
90890-06760
GEN INFO

Digital tachometer
Illustration
90890-03112 YU-03112-C
This tool is needed for detecting engine rpm. Pocket tester
90890-01409 YM-01409
This instrument is invaluable for checking the electrical system. Oil seal guide
90890-01410 YM-01410
This tool is used to install the left side crankcase oil seal. Oil seal installer
90890-06754 YM-34487
This tool is used to install the left side crankcase oil seal. Ignition checker
90890-85505 ACC-11001-05-01
90890-01348 YM-01348
This tool is used to check the ignition system components. Yamaha bond NO.1215 Sealant (Quick Gasket ) This sealant (bond) is used on crankcase mating surfaces (e.g., crankcase mating surfaces). Locknut wrench
46
41
90890-01268 YU-01268
This tool is used when removing or installing the secondary sheave nut. Ring nut wrench
90890-01367 YM-A9409-7 90890-01400 YM-A9409-3 90890-01326 YM-01326 90890-01294 YM-01300-1
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.
1-6
SPECIAL TOOLS
Tool NO.
90890-01312 YM-01312-A
GEN INFO

Fuel level gauge
Illustration
This gauge is used to measure the fuel lever in the float chamber.
1-7
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
2-23
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Model Code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (without oil and a full fuel tank) Dry (without oil and fuel) Maximun load (total of cargo, rider, passenger, and accessories) Standard 5PJ5 (USA) 5PN6 (CAN) 1890mm (74.41in) 705mm (27.76in) 1110mm (43.70in) 765mm (30.12in) 1275mm (50.20in) 120mm (4.72in) 1800mm (70.87in) 94kg (207lb) 90kg (198lb) 143kg (315lb) Limit
2-1
ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS

Item Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Engine idle speed Fuel Recommended fuel Standard
SPEC
Limit
Air-cooled 2-stroke reed valve 0.049L (49cm, 2.99cu-in) Forward inclined single cylinder 40.0 39.2mm (1.57 1.54in) 7.01:1 1800 ~ 1900r/min
Unleaded gasoline only (USA) Regular unleaded gasoline only (CAN) 5.7L (1.25 Imp gal, 1.50 US gal) Separate lubrication YAMALUBE 2 or air cooled 2-stroke engine oil 1.4L (1.23 Imp qt, 1.48 US qt)
Fuel tank capacity Total Engine oil Lubrication system Recommended oil Quantity Oil tank Final gear oil Recommended oil Periodic oil change Total amount Air filter Air filter type Starting system type Carburetor Type Manufacturer Spark plug Model (manufacturer) quantity Spark plug gap Cylinder head Volume Maximum warpage
SAE85W140 hypoid gear oil 0.11L (0.10 Imp qt, 0.12 US qt) 0.13L (0.12 Imp qt, 0.14 US qt) Wet element Electric and kick starter Y14P-13E TEIKEI
BPR7HS (NGK ) 1 0.6 ~ 0.7mm (0.024 ~ 0.028in) 5.54 ~ 5.84cm (0.34 ~ 0.36cu-in) 0.05mm (0.0020in)
* Lines indicate straighedge measurement

2-2
ENGINE SPECIFICATIONS
Item Cylinder Bore Maximum taper Maximum out-of-round Piston Piston-to-cylinder clearance Diameter D
H
SPEC
Limit 0.05mm (0.0020in) 0.05mm (0.0020in) 0.10mm (0.0039in) 10.045mm (0.3955in) 9.976mm (0.3928in)
Standard 40.000 ~ 40.014mm (1.5748 ~ 1.5754in)
Height H Piston pin bore (in the piston) Diameter Piston pin Outside diameter Piston rings Section sketch (B T)/type Top ring 2nd ring End gap (installed) Top ring 2nd ring Side clearance (installed) Top ring 2nd ring Connecting rod Connecting rod length Small end inside diameter
0.035 ~ 0.040mm (0.0014 ~ 0.0016in) 39.960 ~ 39.979mm (1.5732 ~ 1.5739in) 5.0mm (0.1969in) 10.004 ~ 10.015mm (0.3939 ~ 0.3943in) 9.996 ~ 10.000mm (0.3935 ~ 0.3937in)
1.2 1.6mm/keystone (0.0472 0.0630in) 1.2 1.6mm/keystone (0.0472 0.0630in) 0.15 ~ 0.35mm (0.0059 ~ 0.0138in) 0.15 ~ 0.35mm (0.0059 ~ 0.0138in) 0.03 ~ 0.05mm (0.0012 ~ 0.0020in) 0.03 ~ 0.05mm (0.0012 ~ 0.0020in) 79.9~80.1mm (3.1457~3.1535in) 13.996~14.007mm (0.5510~0.5515in)
0.6mm (0.0236in) 0.7mm (0.0276in) 0.1mm (0.0039in) 0.11mm (0.0043in)
2-3
Item Crankshaft Standard
SPEC
Limit
Width A Maximum runout C Big end side clearance D Big end radial clearance Small end free play F Clutch Clutch type Clutch shoe thickness Clutch shoe spring free length Clutch housing inside diameter Compression spring free length Weight outside diameter Clutch - in revolution Clutch - stall revolution V-belt V-belt width Kickstarter Type Kick clip tension Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Single speed automatic Maximum main axle runout Maximum drive axle runout
37.90 ~ 37.95mm (1.4921 ~ 1.4941in) 0.20 ~ 0.50mm (0.0079 ~ 0.0197in) 0.004 ~ 0.017mm (0.0002 ~ 0.0007in) 0.40 ~ 0.80mm (0.0157 ~ 0.0315in) Automatic centrifugal 2.5mm (0.10in) 26.2mm (1.03in) 105mm (4.13in) 65.1mm (2.56in) 15.0mm (0.59in) 2800 ~ 3200r/min 4500 ~ 5500r/min 16.5mm (0.65in)
0.03mm (0.0012in) 1.00mm (0.0394in)
1.0mm (0.04in) 105.5mm (4.15in) 61.8mm (2.43in) 14.5mm (0.57in) 14.8mm (0.58in)
Ratchet 0.7 ~ 2N (0.07 ~ 0.2kgf) (0.15 ~ 0.44lb) V-belt automatic Helical gear 52/13 (4.000) Super gear 43/13(3.307) 2.693 ~ 0.889:1
0.02mm (0.0008in) 0.02mm (0.0008in)
2-4
Item Carburetor ID mark Main jet (M.J.) Needle jet (N.J.) Jet needle-clip position (J.N.) Main air jet (M.A.J.) Cutaway (C.A.) Pilot jet (P.J.) Bypass Valve seat size (V.S.) Starter jet (St.J.) Float height Fuel level height Engine idle speed Reed valve Thickness Valve stopper height Valve bending limit Standard
SPEC
Limit
5PJ5 00 # 80 2.085 3N24-1/1 2.0 3.0 # 44 0.8 1.8 0.45 15 ~ 17mm (0.59 ~ 0.67in) 3.0 ~ 4.0mm (0.12 ~ 0.16in) 1800 ~ 1900r/min 0.132 ~ 0.172mm (0.0052 ~ 0.0068in) 5.9 ~ 6.5mm (0.23 ~ 0.26in)
0.2mm (0.0078in)
2-5
CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS

Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Maximum lateral wheel runout Wheel axle bending limit Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Maximum lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) Up to 90kg (198lb) load 90kg (198lb) load ~ Maximum load* Minimum tire tread depth Standard Steel tube underbone 26.5 93mm (3.66in) Cast wheel J10 MT3.50 Aluminum 61mm (2.40in)
SPEC
Limit 1.0mm (0.04in) 1.0mm (0.04in) 0.45mm (0.02in) 1.0mm (0.04in) 0.5mm (0.02in) 0.8mm (0.03in)
Cast wheel J10 MT3.50 Aluminum 76mm (2.99in)
Tubeless 120/90-10 56J C-6022 (CHENG SHIN) 200kPa (2.00kgf/cm, 29psi) 200kPa (2.00kgf/cm, 29psi)
2-6
CHASSIS SPECIFICATIONS
Item Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) Up to 90kg (198lb) load 90kg (198lb) load ~ Maximum load* Minimum tire tread depth Front brake Brake type Operation Disk outside diameter thickness Pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear brake Brake type Operation Brake drum inside diameter Lining thickness Brake lever Brake lever free play (front lever end) Brake lever free play (rear lever end) Throttle cable free play Standard Tubeless 130/90-10 59J C-924 (CHENG SHIN)
SPEC
Limit 0.8mm (0.03in) 180 3.5mm (7.09 0.14in) 0.8mm (0.03in) 131mm (5.16in) 2.0mm (0.08in)
200kPa (2.00kgf/cm, 29psi) 200kPa (2.00kgf/cm, 29psi)
Single disk brake Right-hand operation 180 4.0mm (7.09 0.16in) 4.0mm (0.16in) 11mm (0.43in) 30.16mm (1.19in) DOT 4 or DOT3 Drum brake Left-hand operation 130mm (5.12in) 4.0mm (0.16in)
2 ~ 5mm (0.08 ~ 0.20in) 10 ~ 20mm (0.39 ~ 0.79in) 1.5 ~ 3.5mm (0.06 ~ 0.14in)
2-7
CHASSIS SPECIFICATIONS
Item Front suspension Suspension type Front fork type Front fork travel Spring Free length Installed length Spring rate (K1) Spring rate (K2) Spring stroke (K1) Spring stroke (K2) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Inner tube outer diameter Inner tube bending limit Steering system Steering bearing type Lock-to-lock angle (left) Lock-to-lock angle (right) Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard Telescopic fork Coil spring/oil damper 70mm (2.76in) 217.1mm (8.55in) 212.1mm (8.35in) 15.69N/mm (1.60kg/mm, 90lb/in) 23.8N/mm (2.43kg/mm, 136lb/in) 0 ~ 40mm (0 ~ 1.57in) 40 ~ 70mm (1.57 ~ 2.76in) No Fork oil 10W or equivalent 0.088L (0.084 Imp qt, 0.092 US qt) 30mm (1.18in)
SPEC
Limit 212.8mm (8.38in) 0.2mm (0.01in)
Angular bearing 45 45 Unit swing Coil spring / oil damper 55mm (2.17in) 159.8mm (6.29in) 152.8mm (6.02in) 71.15N/mm (7.26kg/mm, 407lb/in) 0 ~ 55mm (0 ~ 2.17in) No
2-8
ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS

Item System voltage Ignition system Ignition system type Ignition timing Advancer type Pick coil resistance/color C.D.I. unit model (manufacturer) Ignition coil Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug cap Material Resistance Charging system System type Model (manufacturer) Nominal output Charging current Charging coil resistance/color Lighting voltage Lighting coil resistance/color Source coil resistance/color Rectifier Model (manufacturer) No load regulated voltage (DC) No load regulated voltage (AC) Rectifier capacity Withstand voltage Battery Battery type (manufacturer) Battery voltage/capacity Specific gravity Ten hour rate amperage 12V C.D.I. 14 BTDC at 5000r/min Fixed 400 ~ 600at 20C (68F)/ black - white/red 5PJ (T-MORIC) Standard
SPEC
Limit
2JN (T-MORIC) 6mm (0.24in) 0.184 ~ 0.276 at 20C (68F) 6.32 ~ 9.48k at 20C (68F) Resin 4 ~ 6k at 20C (68F) AC magneto F5PJ (T-MORIC) 12V 85W/5000r/min 0.6A at 3000r/min 1.2A at 8000r/min 0.48 ~ 0.72/white - black 12V at 3000r/min 15V at 8000r/min 0.4 ~ 0.6/yellow/red - black 640 ~ 960 at 20C (68F)/ black - black/red SH614-12 (SHIN DEN GEN) 14 ~ 15V 13 ~ 14V 8A 18V GTX5L-BS (GS) 12V/4AH 1.330 0.4A
2-9
ELECTRICAL SPECIFICATIONS
Item Headlight type Indicator light (voltage/wattage quantity) Turn signal indicator light High beam indicator light Oil level indicator light Bulbs (voltage/wattage quantity) Headlight Tail/brake light Front turn signal light Rear turn signal light License plate light Speedometer light Electric starting system System type Starter motor Model (manufacturer) Suction voltage Power output Brushes Overall length Spring force Commutator diameter Armature coil resistance Mica undercut (depth) Starter relay Model (manufacturer) Amperage Coil resistance Horn Horn type Model (manufacturer) Maximum amperage Performance Coil resistance Turn signal relay Relay type Model (manufacturer) Self-cancelling device built-in Turn signal blinking frequency Wattage Standard Halogen bulb 12V 1.7W 1 12V 1.7W 1 12V 1.7W 1 12V 35/35W 1 12V 5/21W 1 12V 10W 2 12V 10W 2 12V 5W 1 12V 3.4W 1, 1.7W 1 Constant mesh 4WX 01 (SHINLIN) 12V 0.14kW 6.5mm (0.26in)
SPEC
Limit 3.0mm (0.12in)
5.49 ~ 8.24N (360 ~ 540gf, 12.69 ~ 19.04oz) 16.1mm (0.63in) 15.1mm (0.59in) 0.063 ~ 0.077 at 20C (68F) 1.05mm (0.04in) 4WX 00 (SHINLIN) 20A 54 ~ 66 Plane AH-368 (SAKURA) 1.5A 95 ~ 105dB/2m 4.05 ~ 4.55 at 20C (68F) Condenser 5PJ1 (TAYOUNG) NO 75 ~ 95cycles/minute 10W 2 + 1.7W+ AP
2-10
ELECTRICAL SPECIFICATIONS
Item Fuse (amperage quantity) Main fuse Fuel sender Model (manufacturer) Sender unit resistance - full Sender unit resistance - empty Oil lever gauge Model (manufacturer) 7A 1 4VP (TATUNG) 4 ~ 10 90 ~ 100 4VP (LUN PING) Standard
SPEC
Limit
2-11
CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS

EAS00028 EAS00030
SPEC
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 ** mm 2 mm MULTIPLIER 0.03937 0.03937 IMPERIAL ** in 0.08 in
GENERAL TIGHTENING TORQUE SPECIFICATIONS

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each 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. Components should be at room temperature.
CONVERSION TABLE
METRIC TO IMPERIAL Metric unit mkg Tightening torque mkg cmkg cmkg Weight Speed kg g km/hr km m m cm mm cc (cm3) cc (cm3) lt (liter) lt (liter) kg/mm kg/cm2 Centigrade (C) Multiplier 7.233 86.794 0.0723 0.8679 2.205 0.03527 0.6214 0.6214 3.281 1.094 0.3937 0.03937 0.03527 0.06102 0.8799 0.2199 55.997 14.2234 9/5+32 Imperial unit ftlb inlb ftlb inlb lb oz mph mi ft yd in in oz (IMP liq.) cu-in qt (IMP liq.) gal (IMP liq.) lb/in psi (lb/in2) Fahrenheit (F)
Distance
A: Width across flats B: Thread diameter A (nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B (bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General tightening torques Nm 6 15 30 55 85 130 mkg 0.6 1.5 3.0 5.5 8.5 13.0 ftlb 4.3 11 22 40 61 94
Volume/ Capacity
Misc.
2-12
TIGHTENING TORQUES TIGHTENING TORQUES

ENGINE Part to be tightened Part name Thread Q ty size M 14 M7 M7 M6 6.0 M6 M5 M6 M6 M4 M6 M8 M6 M6 M6 M6 M6 M6 M6 M8 M 14 M6 M6 M6 M 10 M 10 M6 M 10 1 4 4 3 1 3 2 4 2 2 2 2 3 1 6 6 12 1 3 1 1 2 1 2 1 1 2 1
SPEC
Tightening torque Nm mkg ftlb 20 14 10 7 2 7 4 11 9 2 9 26 11 9 12 12 12 7 7 18 3 8 9 13 40 30 8 38 2.0 14 1.4 10 7 1.0 0.7 5.1 0.2 1.4 0.7 5.1 0.4 2.8 1.1 8.0 0.9 6.5 0.2 1.4 0.9 6.5 2.6 18.2 1.1 8.0 0.9 6.5 1.2 8.4 1.2 8.4 1.2 8.4 0.7 5.1 0.7 5.1 1.8 13 0.3 22 0.8 5.8 0.9 6.5 1.3 9.4 4.0 29 3.0 22 0.8 5.8 3.8 27
Remarks
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 Screw Screw Screw Bolt Screw Screw Screw Bolt Bolt Screw Bolt Bolt Bolt Screw Bolt Bolt Plug Screw Bolt Bolt Nut Nut Screw Nut
LT
LT
2-13
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 Thread size M 12 M 10 M6 M 10 M8 M 25 M 10 M8 M6 M6 M5 M6 M6 M5 M6 M 10 M 14 M6 M8 M10 M8 M5 Tightening torque Nm 84 45 13 30 16 60 20 10 7 4 7 7 2 7 70 120 10 23 20 23 6
SPEC
Remarks 61 31 9.4 22 12
See NOTE
mkg ftlb 8.4 4.5 1.3 3.0 1.6 6.0 2.0 1.0 0.7 0.4 0.7 0.7 0.2 0.7 7.0 12.0 1.0 2.3 2.0 2.3 0.6
43.4 14 7 5.1 2.9 5.1 5.1 1.4 5.1 51 87 7.2 16.6 14.5 16.6 4.3
LT
2-14
TIGHTENING TORQUES
SPEC
NOTE : 1. First, tighten the ring nut(lower) approximately 38Nm(3.8mkg, 27.5ftlb) by using the torque wrench, then loosen the ring nut 1/4 turn. 2. Second, tighten the ring nut(lower) approximately 12Nm(1.2mkg, 8.7ftlb) 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(7.5mkg, 54.2ftlb) by using the torque wrench. 6. Confirm, adjust the direction handlebar to the right direction, front wheel suspended. Push direction handlebar lightly with the finger (approximately 1.5kgf cm), direction handlebar should turn slowly without interference or hindrance. 1 2 3 4 5 Lower ring nut Rubber washer Center ring nut Lock washer Upper ring nut
2-15
LUBRICATION POINTS AND LUBRICANT TYPES

EAS00031
SPEC

ENGINE Lubrication Point 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
Lubricant
LS
LS
E E E E
G
LS
LS
G
LS
G G
2-16

EAS00032
SPEC
CHASSIS Lubrication Point 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 Lubricant
LS
LS
LS
LS
S
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
2-17
CABLE ROUTING
EAS00035
SPEC
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 between the supporter and main switch.
8 7 q
1
w e r
2 4
7 9 6
2-18
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.
SPEC
5 8
1 2
3 9
q 6 0 7
2-19
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 certainty 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.
SPEC
w e F 2 B 3 0 1 4 5 1 q 5
9A 3 E9 8 3 6
7D 5 6
5 C4
2-20
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.
SPEC
F Clamp autochoke leads and autolube hose on to carburetor throttle cable. G Pass the batter y 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 A 2 B 3 I H r e G F 9 0 w E C D q 7 8 4
5 6
2-21
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 signal 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 backward 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 finger clearance, the position on the above of guide wire and align white point mark of wire harness.
SPEC
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 handlebar, wire harness and brake hose to left side. H Connect the couplers securely 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 K e w 5 0 q 3 2 1 A B 4 C 5 6 7
q 0 J I H G E F 9
2-22
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
3-10
INTRODUCTION/PERIODIC MAINTENANCE AND MINOR REPAIR

EAS00036
CHK ADJ
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.
INITIAL NO. ITEM ROUTINE 1,000 km (600 mi) or 1 month 4,000 km (2,000 mi) or 6 months ODOMETER READING 7,000 km (4,000 mi) or 12 months 10,000km (6,000 mi) or 18 months 13,000 km 16,000 km (8,000 mi) (10,000 mi)) or or 24 30 months months
1 2 3
* Fuel line * Idle speed * Exhaust system * Air induction system
Check fuel and vacuum hoses for cracks or damage. Replace if necessary. Check and adjust engine idle speed. Check for leakage. Tighten if necessary. Replace gasket(s) if necessary. Check the air cut-off valve, reed valve, and hose for damage. Replace any damaged parts.
3-1

EAU32115
CHK ADJ
General maintenance and lubrication chart

INITIAL NO. ITEM ROUTINE 1,000 km (600 mi) or 1 month 4,000 km (2,000 mi) or 6 months ODOMETER READING 7,000 km (4,000 mi) or 12 months 10,000km (6,000 mi) or 18 months 13,000 km 16,000 km (8,000 mi) (10,000 mi)) or or 24 30 months months
1 2
* Air filter element * Front brake * Rear brake * Wheels * Tires * Wheel bearings
Clean with solvent. Replace if necessary. Check operation, fluid level, and for fluid leakage. Replace brake pads if necessary. Check operation. Adjust cable and replace brake shoes if necessary. Check runout and for damage. Replace if necessary. Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. Check bearings for smooth operation. Replace if necessary. Check bearing assemblies for looseness. Moderately repack with lithiumsoap-based grease every 16000 km (10000 mi) or 18 months. Check all chassis fitting and fasteners. Correct if necessary. Apply silicone grease lightly. Apply lithium-soap-based grease (all-purpose grease) lightly. Check operation. Lubricate. Check operation and for oil leakage. Replace if necessary. Check operation and for oil leakage. Replace if necessary. Check operation. Bleed if necessary. Check vehicle for oil leakage. Change. Replace. Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly. Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. Check operation. Adjust headlight beam. Every 10000 km(6250 mi)
3 4
* Steering bearings
Repack.
8 9 10 11 12
* Chassis fasteners
Front brake lever pivot shaft Rear brake lever pivot shaft Centerstand
* Front fork * assembly

Shock absorber
13 14 15 16 17
* Autolube pump
Final transmission oil
* V-belt * cables
Control and meter
18
Throttle grip housing and cable Lights, signals and
19
* switches
* 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.
3-2

EAU17620
CHK ADJ
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.
3-3
COVER AND PANEL

EAS00038
CHK ADJ
COVER AND PANEL

SEAT AND SIDE COVERS
13Nm (1.3 mkg, 9.4 ftlb)
2 5 3 7
1 6
Order 1 2 3 4 5 6 7 8
Job/Part Removing the seat and side covers Battery box cover Seat Seat hanger Rear carrier Rear cover Side cover(left) Side cover(right) Center cover
Qty 1 1 1 1 1 1 1 1
Remarks Remove the parts in the order listed. NOTE: Insert the (-) screwdriver into the slot of battery box cover and pickup then remove.
For installation, reverse the removal procedure.
3-4
COVER AND PANEL

LOWER COWLING, UPPER COVER AND LEG SHIELD 1
CHK ADJ
Order
Job/Part 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
Qty
Remarks Remove the parts in the order listed.
1 2 3 4 5
1 1 1 1 1
Disconnect. Disconnect.
For installation, reverse the removal procedure.
3-5
COVER AND PANEL

LEG SHIELD 2 AND FOOTREST BOARD 1
CHK ADJ
7Nm (0.7 mkg, 5.1 ftlb)
6 7
4 3
Order
Job/Part Removing the leg shield 2 and footrest board Leg shield 1
Qty
Remarks Remove the parts in the order listed. Refer to LOWER COWLING, UPPER COVER AND LEG SHIELD 1.
1 2 3 4 5 6 7 8
Main switch cover Leg shield 2 Footrest(left) Footrest(right) Battery negative lead Battery positive lead Battery Footrest board
1 1 1 1 1 1 1 1
w
First, disconnect the battery negative lead, and then the battery positive lead. For installation, reverse the removal procedure.
3-6
COVER AND PANEL

HANDLEBAR COVER(FRONT AND REAR)
CHK ADJ
Order
Job/Part Removing the handlebar cover(front and rear) Handlebar cover(front) Speedometer cable Handlebar cover(rear)
Qty
1 2 3
1 1 1
Disconnect. For installation, reverse the removal procedure.
3-7
ADJUSTING THE ENGINE IDLING SPEED

EAS00054
CHK ADJ

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 several 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 i Adjust Engine idling speed 1800 ~ 1900 r/min
3-8

b a
CHK ADJ
5. Adjust: 8engine idling speed

1
a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained.
Direction a Direction b
Engine idling speed is increased. Engine idling speed is decreased.
6 . Install: 8 battery box cover Refer to SEAT AND SIDE COVERS.
3-9
CARB
CHAPTER 4 CARBURETOR AIR INDUCTION SYSTEM ....................................................................... 4-1 AIR FILTER CASE ASSEMBLY ......................................................... 4-1 CHECKING THE AIR INDUCTION SYSTEM ................................... 4-3
4-4
AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM

AIR FILTER CASE ASSEMBLY
CARB
Order
Job/Part Removing the air filter case assembly Hose(to air filter) Pipe(to exhaust pipe) Air filter case assembly
Qty
1 2 3
1 1 1
Disconnect. Disconnect. For installation, reverse the removal procedure.
4-1
AIR INDUCTION SYSTEM
CARB
8 1
9 2 0
3 w 4 5 7
Order
Job/Part Disassembling the air filter case assembly 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
Qty
1 2 3 4 5 6 7 8 9 0 q w
1 1 1 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
4-2
AIR INDUCTION SYSTEM

EAS00510
CARB
CHECKING THE AIR INDUCTION SYSTEM 1. Check: 8 hoses Loose connection i Connect properly. Cracks/damage i Replace. 8 pipes Cracks/damage i Replace.
2. Check: 8 reed valve 1 8 reed valve stopper 8 reed valve seat Cracks/damage i Replace the reed valve assembly.
3. Measure: 8 reed valve bending limit a Out of specification i 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 i Replace. a. Start the engine and let it warm up for several 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
4-3
YW50X WIRING DIAGRAM

1
LOCK OPEN OFF CHECK ON
(GREEN)
0 6 7 8 9 q
2
12V 7A
4 5
(BLACK)(BLACK)
n ,
OFF START
1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g h j k l ; z x c v b n m ,
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 Front brake light switch Rear brake light switch Tail/brake light Rear turn signal light(left) Rear turn signal light(right) License plate light Front turn signal light(right) Front turn signal light(left) Headlight(high) Headlight(low) Turn signal relay Horn Handlebar switch(left) Horn switch Dimmer switch Turn signal switch Fuel sender Speedometer Fuel gauge Oil level indicator light Speedometer light High beam indicator light Turn signal indicator light Oil lever gauge Handlebar switch(right) Engine stop switch Start switch
d
(BLACK)
f g
OFF PUSH
12V 3.4W ILUMI 12V 1.7W OIL 12V 1.7W BEAM
MARK
EXPLANATION
R, Br, BrW... COLOR CODE CONNECTING WITH GRD. WIRE
12V 1.7W TURN
e
A, B, C,
GRD. CONNECTOR MARK (BETWEEN MAIN & SUB HARNESS) CONNECTOR SYMBOL
(RED)
(RED)
z ;
x c
(RED) (RED)
(RED) (RED)
(RED)
(RED)
Black Green Blue
Yellow/Red White Yellow Dark green Brown/White Black/White White/Red
k u
r t y
Orange Gray
(GREEN) (GREEN)
B
Green/Yellow Red Brown Chocolate
a p
(BLACK) (BLACK)
Pink
i
(GREEN) (GREEN)
Blue/White Black/Red
(BROWN) (BROWN)
Pink/White
EBO00000
YW50BP SERVICE M A N U A L 2001 by Yamaha M o t o r Taiwan Co,.Ltd. First edition, November 2001 All rights reserved. A n y reprinting or unauthorized use w i t h o u t the w r i t t e n permission of Yamaha M o t o r Taiwan Co,.Ltd. is expressly prohibited.
EB001000
NOTICE
T h i s m a n u a l w a s p r o d u c e d b y t h e Y a m a h a M o t o r C o m p a n y , Ltd. p r i m a r i l y for use b y Y a m a h a dealers and t h e i r q u a l i f i e d m e c h a n i c s . It is not p o s s i b l e to i n c l u d e all t h e k n o w l e d g e o f a m e c h a n i c in one m a n u a l . Therefore, a n y o n e w h o uses t h i s b o o k to p e r f o r m m a i n t e n a n c e and repairs on Y a m a h a v e h i c l e s s h o u l d have a basic u n d e r s t a n d i n g of m e c h a n i c s and the t e c h n i q u e s to repair these t y p e s of vehicles. Repair and m a i n t e n a n c e w o r k a t t e m p t e d by a n y o n e w i t h o u t t h i s k n o w l e d g e is likely to r e n d e r t h e v e h i c l e u n s a f e and unfit for use. Y a m a h a M o t o r C o m p a n y , Ltd. is c o n t i n u a l l y s t r i v i n g to i m p r o v e all of its m o d e l s . M o d i f i c a t i o n s and s i g n i f i c a n t c h a n g e s in s p e c i f i c a t i o n s or p r o c e d u r e s w i l l be f o r w a r d e d to all a u t h o r i z e d Y a m a h a deal-ers and w i l l a p p e a r in f u t u r e e d i t i o n s of t h i s m a n u a l w h e r e applicable. NOTE: D e s i g n s and s p e c i f i c a t i o n s are subject to c h a n g e w i t h o u t notice.
IMPORTANT MANUAL INFORMATION

P a r t i c u l a r l y i m p o r t a n t i n f o r m a t i o n is d i s t i n g u i s h e d in t h i s m a n u a l by the f o l l o w i n g .
ZL
~'~,WARNING
The Safety Alert Symbol means ATTENTION! SAFETY IS INVOLVED!
BECOME ALERT! Y O U R
Failure to f o l I o w W A R N I N G i n s t r u c t i o n s could result in severe i n j u r y or death to the s c o o t e r o p e r a t o r , a b y s t a n d e r or a p e r s o n c h e c k i n g or r e p a i r i n g the scooter. A C A U T I O N i n d i c a t e s special p r e c a u t i o n s t h a t m u s t be taken to a v o i d d a m age to the scooter. A NOTE p r o v i d e s key i n f o r m a t i o n to make p r o c e d u r e s easier or clearer.
CAUTION:
NOTE:
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. C o m p r e h e n s i v e 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 " S Y M B O L S " . (~ Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 ("PERIODIC CHECKS A N D A D J U S T M E N T S " ) , w h e r e the sub-section title(s) appears. (~ Sub-section titles appear in smaller print than the section title. (~ To help identify parts and clarify procedure steps, there are exploded d i a g r a m s at the start of each removal and disassembly section. (~ N u m b e r s are given in the order of the jobs in the exploded diagram. A circled n u m b e r indicates a disassembly step. (~ S y m b o l s indicate parts to be lubricated or replaced. Refer to " S Y M B O L S " . (~) 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 sequentially.
CYLINDEB HEAD" CYF~:N::R: P 1.

Remove:
san
N o T E PI t
pT
nc
IIp~)
rag so y o u will not acci
Begore removing tha piston pin celt,, cover the

' crankcase
with a clean
Z. Ro,,,ovo: Piston pTn 1~ Piston

Piston pin bearing ~ GA~ON~ Donot use a h a m m e r t o d r i v e t h e piston pin
out_
CYUNDER
~. Elhxlin~te:
HEAD INSPECTION
Carbon deposits Use a rounded ~crapper
Q'ty Cvlinder head. Cylinder and piston removal
Rurllark~ Remove the pa~s Enthe order
Cylinder head war~3age Out of specification >Re8ur'0ce. measurement a n d re s u r f a c e m e n t
1 3
4 6 2
Engine
Muffler/Gasket A i r ~hroud (cylTnder head)
SparkIJlug
7 8 9 10
Cylinder head/Cylinder head gasket Cylinder Piston pin clip Piston p i n / B e a r i n g Piston Pistonring set CyITnder gasket
1/1 1 1 1/1 1 2 1
1
Refer to the tion
"ENGINE REMOVAL" sec-
Warpage
Attach a =traight
e d g e ~ a n d a thickness g a u g e ( ~ on the cylinder head. M e a s u r e the w a r p a g e limit.
I
If the w a r p a g e is out of specification, t h e cylinder head. NOTE: Reverse the r e m o v a l procedure f o r in stallatien.
reface
Rotate the head severaT tTres t o a v o i d r e m o v ing too m u c h moteriol f r o m o n e side. 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - -
EAS00009
GEN INFO
SYMBOLS
SPEC
INSP

ENG
~)~
CARB ELEC
CHAS ( ~
~=]
TRBL SHTG
@
w.~
The following symbols are not relevant to every 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
-n~ @
@ @ @ @ @ @ @
Symbols (~ to (~) indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data
i
@
Symbols @to @ in the exploded diagrams indicate 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 GENERAL SCOOTER INDENTIFICATION

VEHICLE MODEL IDENTIFICATION CODE
1.
INFORMATION
1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-4 1-5 1-5 1-6
........................................................................................................... NUMBER ...........................................................................................
................................................................................................................................ ............................................................................................................ AND DISASSEMBLY ................................................................ FOR REMOVAL PARTS
PREPARATION REPLACEMENT GASKETS, BEARINGS CIRCLIPS
................................................................................................................. AND O-RINGS .......................................................................................... P I N S ...........................................................................
OIL SEALS AND
LOCK WASHERS/PLATES
AND
COTTER
OIL SEALS
.........................................................................................................
........................................................................................................................................
CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H O W T O U S E THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERSION TABLE ....................................................................................................................
SPECIAL TOOLS
................................................................................................................................
C H A P T E R 2. SPECIFICATIONS
GENERAL SPECIFICATION MAINTENANCE
ENGINE TIGHTENING ENGINE
............................................................................................................... 2-1
..................................................................................................... 2-4 2-4 2-6 2-6 2-7 2-7 2-8 2-8
SPECIFICATION
TORQUES
.......................................................................................................................................... ...............................................................................................................
..........................................................................................................................................
MAINTENANCE
CHASSIS TIGHTENING CHASSIS
SPECIFICATION
TORQUES
.....................................................................................................
........................................................................................................................................ ...............................................................................................................
........................................................................................................................................
MAINTENANCE
ELECTRICAL
SPECIFICATION
..................................................................................................... 2-9
2-9 2-1 1 2-12 2-12 2-13 2-14 ...........................................................................................
...................................................................................................................................
GENERAL TORQUE LUBRICATION

ENGINE CHASSIS
SPECIFICATIONS
POINTS AND LUBRICATION
TYPE
.......................................................................
........................................................................................................................................ ...................................................................................................................................... .............................................................................................................................
CABLE ROUTING
CHAPTER 3. PERIODIC I N S P E C T I O N A N D A D J U S T M E N T S
INTRODUCTION PERIODIC COVER AND ................................................................................................................................ INTERVALS ................................................................ 3-1 3-1
MAINTENANCE/LUBRICATION PANEL
AND SEAT
.......................................................................................................................... 3-3 ................................................................................................................ 3-3 LEG SHIELD 1, 2 A N D FOOTREST BOARD ..................... 3-4 AND REAR) ................................................................................... 3-5 UPPER COVER,
SIDECOVER LOWER HANDLEBAR
COWLING,
COVER(FRONT
ENGINE
..............................................................................................................................................3 - 6 .......................................................................................................... 3-6 ..................................................................................... 3-7 ............................................................................................... 3-8 ............................................................................................... 3-10 ........................................................................................ 3-11 .............................................................................................. 3-12 CABLE PUMP FREE ADJUSTMENT AIR BLEEDING
IDLE SPEED ADJUSTMENT THROTTLE AUTOLUBE SPARK ENGINE
PLUG
INSPECTION
........................................................................................................... 3-9
OIL LEVEL INSPECTION CLEANING
TRANSMISSION V-BELT
OIL REPLACEMENT
AIR FILTER ELEMENT INSPECTION BRAKE
................................................................................................................... 3-14
CHASSIS
FRONT BRAKE BRAKE BRAKE
..........................................................................................................................................3-15 LEVER FREE PLAY CHECK ................................................................................ 3-15 LEVER FREE PLAY CHECK ................................................................................... 3-15 ........................................................................................................... 3-15 ........................................................................................................ 3-16 ............................................................................................ 3-16 SYSTEM) ........................................................................ 3-17 BRAKE INSPECTION (HYDRAULIC
REAR BRAKE SHOE
PAD INSPECTION
FLUID LEVEL INSPECTION ADJUSTMENT
AIR BLEEDING STEERING WHEEL FRONT SEAT CABLE LEVERS
.......................................................................................................... 3-18
TIRE INSPECTION
........................................................................................................................3-19 ................................................................................................................... 3-22 ......................................................................................................... 3-22 INSPECTION LUBRICATING .................................................................................... 3-22 ..................................................................................... 3-23 ........................................................................................... 3-22
INSPECTION
FORK INSPECTION ABSORBER AND LOCK CABLE CHECKING
REAR SHOCK
ADJUSTMENT
LUBRICATING
............................................................................................................... 3-23 .................................................................................................. 3-23
CENTERSTAND
LUBRICATING
ELECTRICAL
BATTERY HEADLIGHT HEADLIGHT TURN TAILLIGHT LICENSE
.....................................................................................................................................3-24 INSPECTION BEAM BULB AND BULB LIGHT ............................................................................................................... 3-24 ............................................................................................ 3-30 ............................................................................................ 3-30 REPLACEMENT ........................................................... 3-31 .............................................................................................. 3-32 ...................................................................................... 3-32 BULB ......................................................................................................................3-29 ADJUSTMENT REPLACEMENT TAILLIGHT REPLACEMENT BULB
FUSE INSPECTION
SIGNAL
REPLACEMENT
C H A P T E R 4. ENGINE
E N G I N E O V E R H A U L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
WlREHARNESS CYLINDER PISTON CYLINDER CYLINDER PISTON PISTON PISTON AND CABLES ...................................................................................................... AND PISTON ................................................................................ 4-1 4-3 4-4 4-4 4-5 4-7 4-7 4-9
C Y L I N D E R HEAD, C Y L I N D E R A N D P I S T O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
HEAD, HEAD AND CYLINDER PISTON PISTON PISTON PISTON CYLINDER AND INSPECTION INSPECTION PIN AND REMOVAL INSPECTION PIN BEARING INSTALLATION HEAD .......................................................................................... ........................................................................................ ....................................................................................
..................................................................................................... ........................................................................................................
RINGS
PIN AND PIN AND AND
................................................................................. 4-8
CYLINDER
................................................................................................ COVER(LEFT)
V-BELT, C L U T C H A N D S E C O N D A R Y / P R I M A R Y S H E A V E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1
KICK STARTER KICK STARTER KICK STARTER V-BELT, PRIMARY CLUTCH V-BELT PRIMARY CLUTCH SHEAVE SECONDARY SECONDARY CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1 4-12 4-13 4-15 4-16 4-16 4-17 4-18 4-19 4-20 4-21 4-22 ............................................................................................................................. INSTALLATION AND SHEAVE SHEAVE ................................................................................................. SHEAVE SECONDARY/PRIMARY
........................................................ 4-14
................................................................................................................ .................................................................................................... .............................................................................................. REMOVAL
REMOVAL
INSPECTION INSPECTION SHEAVE SHEAVE SHEAVE
................................................................................................................. ................................................................................................................... ................................................................................................ .....................................................................................
INSPECTION
SECONDARY SECONDARY PRIMARY STARTER STARTER
................................................................................................................ INSTALLATION
SHEAVE CLUTCH CLUTCH
...................................................................................................................... AND AND STARTER GEARS MOTOR
STARTER CLUTCH A N D STARTER M O T O R ................................................................................. 4-24

.............................................................................. 4-24 ......................................................................... 4-26 4-27 4-27 4-28 4-28 4-29 4-30 4-31 4-33 4-35 4-35 4-36 4-36 4-38 4-39 4-39 4-40 INSPECTION
C.D.I. MAGNET
................................................................................................................................ ......................................................................................................................... REMOVAL ....................................................................................................... .............................................................................................. INSTALLATION
C.D.I. MAGNETO C.D.I. MAGNETO C.D.I. MAGNETO AUTOLUBE AUTOLUBE PUMP PUMP
A U T O L U B E P U M P ........................................................................................................................... 4-29
....................................................................................................................... INSTALLATION ...........................................................................................
T R A N S M I S S I O N .............................................................................................................................. 4-31
TRANSMISSION CRANKCASE CHECKING CHECKING CRANKCASE CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT AND .......................................................................................................................... REED VALVE REMOVAL AND ................................................................................................ ................................................................................................ .................................................................................................... OIL SEALS ......................................................................................................... ......................................................................................
C R A N K C A S E A N D REED V A L V E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 3
CRANKCASE(RIGHT) THE
THE CRANKCASE BEARINGS INSPECTION (RIGHT)
............................................................................ 4-35
REED VALVE
INSTALLATION
C R A N K S H A F T .................................................................................................................................. 4-38
.............................................................................................................................. REMOVAL INSPECTION INSTALLATION ........................................................................................................... ....................................................................................................... ...................................................................................................
CHAPTER 5 CARBURETION
CARBURETION .................................................................................................................................. 5-1
CARBURETOR CABURETOR CABURETOR CARBURETOR
................................................................................................................................ DISASSEMBLY INSPECTION ASSEMBLY ....................................................................................................... ........................................................................................................... ........................................................................................................... ......................................................................................................... .......................................................................................................... .............................................................................................................
5-1 5-2 5-3 5-5 5-6 5-7 5-8
FUEL LEVEL ADJUSTMENT AUTO CHOKE INSPECTION
FUEL COCK
INSPECTION
CHAPTER 6 CHASSIS
F R O N T W H E E L A N D B R A K E D I S C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
FRONT FRONT FRONT FRONT BRAKE FRONT FRONT WHEEL WHEEL WHEEL WHEEL WHEEL AND BRAKE D I S C ............................................................................................... .................................................................................................... .................................................................................................... ........................................................................................................ 6-1 6-2 6-3 6-3 6-4 6-4 6-5 DISASSEMBLY DISASSEMBLY INSPECTION
DISC INSPECTION WHEEL WHEEL STATIC ASSEMBLY BALANCE
............................................................................................................ .......................................................................................................... ................................................................................................... ADJUSTMENT
INSTALLATION
.................................................................................. 6-6
F R O N T B R A K E ...................................................................................................................................
BRAKE BRAKE P A D .................................................................................................................................... PAD REPLACEMENT ........................................................................................................
6-8
6-8 6-9 6-12 6-13 6-14 6-14
MASTER MASTER
CYLINDER CYLINDER
........................................................................................................................
DISASSEMBLY
INSPECTION ASSEMBLY
............................................................................................. .............................................................................................. ................................................................................................
MASTER MASTER MASTER
CYLINDER CYLINDER CYLINDER
INSTALLATION
......................................................................................... 6 - 1 5
CALIPER ........................................................................................................................................... 6 - 1 7 CALIPER DISASSEMBLY

BRAKE BRAKE BRAKE CALIPER CALIPER INSPECTION
.................................................................................................................
................................................................................................
6-18
6-19 6-20
DISASSEMBLY
................................................................................................................. 6 - 1 9 ...................................................................................................... ............................................................................................... 6 - 2 0 6-21 6-22 6-23 6-23 6-24 6-25 6-25 6-27 6-29 6-29
CALIPER ASSEMBLY CALIPER
INSTALLATION
REAR W H E E L A N D REAR BRAKE .................................................................................................. 6-21

REAR WHEEL ............................................................................................................................... R E A R B R A K E ................................................................................................................................ REAR WHEEL REAR BRAKE REAR BRAKE INSPECTION INSPECTION INSTALLATION ........................................................................................................ ......................................................................................................... ....................................................................................................
HANDLEBAR
HANDLEBAR
.................................................................................................................................... ................................................................................................................................ N .....................................................................................................
HAN DLE BAR INSTALLATIO
STEERING
........................................................................................................................................ .................................................................................................................................... REMOVAL INSPCTION
STEERING STEERING STEERING STEERING
................................................................................................................. 6 - 3 0 ................................................................................................................ 6-31 ......................................................................................................... 6-31
INSTALLATION
F R O N T FORK ................................................................................................................................... 6 - 3 4
FRONT FRONT FRONT FRONT FRONT FRONT FRONT FORK ............................................................................................................................... ..................................................................................................... ..................................................................................................... ............................................................................................................. 6-34 6-35 6-36 6-36 FORK DISASSEMBLY FORK REMOVAL FORK DISASSEMBLY FORK INSPECTION FORK ASSEMBLY
......................................................................................................... 6-37 ........................................................................................................... 6-37 .................................................................................................... 6-39
FORK INSTALLATION
CHAPTER 7 ELECTRICAL
ELECTRICAL COMPONENTS
ELECTRICAL CIRCUIT CHECKING SWITCH COMPONENTS DIAGRAM STEPS ............................................................................................................ ........................................................................................................ 7-1 7-1 7-2 7-4 7-4 7-4
........................................................................................................................ ......................................................................................................................... AS SHOWN IN THIS MANUAL .............................................................
CHECKING SWITCHES ......................................................................................................................

CONNECTION
S W I T C H P O S I T I O N A N D T E R M I N A L C O N N E C T I O N ...................................................................... C H E C K I N G T H E B L U B S A N D B U L B S O C K E T S ...............................................................................
CHECKING TYPES THE BULBS AND BULB SOCKETS ........................................................................... OF BULBS THE THE .......................................................................................................................... CONDITION CONDITION OF THE OF THE BULBS BULB .............................................................................. SOCKETS ..............................................................
7-5 7-5
7-6 7-6 7-7 7-8 7-9 7-9 7-10 7-14 7-14 7-15 7-18 7-18 7-19 7-22 7-23 7-24 7-26 7-26 7-27 7-29 7-33 7-33 7-34 7-36 7-42 7-42 7-43
CHECKING CHECKING
IGNITION SYSTEM ............................................................................................................................

CIRCUIT DIAGRAM ........................................................................................................................ .................................................................................................................. ...................................................................................................................... .................................................................................................................. TROUBLESHOOTING
CHARGING
CIRCUIT
SYSTEM .......................................................................................................................
DIAGRAM
TROUBLESHOOTING
ELECTRIC STARTING SYSTEM ......................................................................................................

CIRCUIT STARTER STARTER DIAGRAM MOTOR MOTOR AND ...................................................................................................................... .................................................................................................................. ....................................................................................................................... DISASSEMBLY REPAIR ............................................................................................. .......................................................................................................... TROUBLESHOOTING
INSPECTION
LIGHTING SYSTEM .........................................................................................................................

CIRCUIT LIGHTING CIRCUIT DIAGRAM SYSTEM DIAGRAM ...................................................................................................................... .................................................................................................................. CHECK ........................................................................................................ TROUBLESHOOTING
SIGNAL SYSTEM .............................................................................................................................

...................................................................................................................... .................................................................................................................. CHECK ............................................................................................................ TROUBLESHOOTING SIGNAL CIRCUIT SYSTEM DIAGRAM
AUTO CHOKE SYSTEM

TROUBLESHOOTING
.................................................................................................................. ..................................................................................................................
......................................................................................................................
CHAPTER 8 TROUBLESHOOTING
STARTING FAILURE/HARD
FUEL SYSTEM IGNITION COMPRESSION POOR SYSTEM
S T A R T I N G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1 8-2 8-2 8-3
............................................................................................................................... ........................................................................................................................ ............................................................................................................. ................................................................................................ SYSTEM
P O O R IDLE S P E E D P E R F O R M A N C E
IDLE SPEED PERFORMANCE
............................................................................................ 8-3 ....................................................................... 8-3 ................................................................... 8-3 .................................................. 8-4 8-4
POOR MIDIUM
POOR
AND HIGH SPEED PERFORMANCE

AND NOT HIGH SPEED MOVE PERFORMANCE ENGINE
MIDIUM
FULTY AUTOMATIC(V-BELT
SCOOTER CLUTCH DOES OUT FAILURE
TYPE) ................................................................................................. 8-4

WHILE IS O P E R A T I N G
................................................................................................................. CLIMBING ABILITY) HIGH SPEED)
POOR STANDING
START(LOW
................................................................. 8-4
POOR ACCELERATION(POOR
.............................................................................. 8-4
O V E R H E A T ........................................................................................................................................
OVERHEAT ..................................................................................................................................... .................................................................................................................................
8-5
8-5
P O O R S P E E D .....................................................................................................................................
POOR SPEED SLIPPING HARD
8-5
8-5 8-6 8-6 8-6 8-7 8-7 8-8 8-8 8-9 8-9 8-9 8-9 8-10 8-10 8-10
I M P R O P E R KICKING .......................................................................................................................... 8-6

........................................................................................................................................ .............................................................................................................................. RETURNING ................................................................................................... KICKING
KICK CRANK POOR
NOT
F A U L T Y BRAKE ................................................................................................................................. 8-7

BRAKING E F F E C T ............................................................................................................... ............................................................................................................................. ...................................................................................................................... .................................................................................................................. MALFUNCTION
INSTABLE HANDLING
INSTABLE HEADLIGHT BULB BURNT FLASHER FLASHER FLASHER FLASHER HORN HANDLING
FAULTY SIGNAL AND LIGHTING SYSTEM

OUT
.................................................................................... 8-9
D A R K ......................................................................................................................... ........................................................................................................................ B L I N K ......................................................................................................... NOT
DOES
K E E P S O N ..................................................................................................................... BLINKS BLINKS SLOWER QUICKER ........................................................................................................ ....................................................................................................... .........................................................................................................
DOES
NOT SOUND
SCOOTER INDENTIFICATION
f EAS00015
I GEN
GENERAL INFORMATION SCOOTER IDENTIFICATION

EAS00017
VEHICLE I D E N T I F I C A T I O N N U M B E R The vehicle identification number (~) is stamped into the frame.
f
EAS00018
M O D E L CODE The model code label ~) is affixed to the location s h o w n in the figure. Record the information on this label in the space provided. This information will be needed to order spare parts.
1-1
EAS00020
I GEN
P R E P A R A T I O N FOR R E M O V A L A N D D I S A S SEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use o n l y the proper tools and cleaning equipment. Refer to "SPECIAL TOOLS". 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been " m a t e d " t h r o u g h normal wear. M a t e d parts must always be reused or replaced as an assembly. 4. During disassembly, clean all o f t h e parts and place them in trays in the order of disassembly. This will speed up a s s e m b l y and allow for the correct installation of all parts. 5. Keep all parts a w a y from any source of fire.
EAS00021
300-008
R E P L A C E M E N T PARTS Use o n l y genuine Yamaha parts for all replacements. 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.
300-016
EAS00022
G A S K E T S , OIL SEALS A N D O - R I N G S 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, 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 w i t h grease.
EAS00023
LOCK W A S H E R S / P L A T E S A N D C O T T E R PINS After removal, replace all lock washers/plates ~ ) a n d cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat o f t h e bolt or nut.
1-2
I ,NFOI GEN
~\\\\\\\\~1
EAS00024
BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu facturer's marks or n u m b e r s are visible. W h e n installing oil seals, lubricate the oil seal l i p s w i t h a light coat of lithium soap base grease. Oil bearings liberally w h e n 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 d a m a g e d or distorted circlips, A l w a y s replace piston pin clips after one use. W h e n installing a circlip (~), make sure the s h a r p - e d g e d corner (~) is positioned o p p o s i t e the t h r u s t ~ that the circlip receives. (~ Shaft
1-3
EB801000
I GEN
CHECKING OF C O N N E C T I O N S
D e a l i n g w i t h stains, rust, m o i s t u r e , etc. on t h e connector. 1. D i s c o n n e c t : Connector 2. D r y each t e r m i n a l w i t h an air b l o w e r .
3. 4. 5.
C o n n e c t and d i s c o n n e c t t h e c o n n e c t o r t w o or t h r e e . Pull t h e read to c h e c k t h a t it w i l l not c o m e off. If t h e t e r m i n a l c o m e s off, b e n d up t h e pin ( ~ a n d r e i n s e r t t h e t e r m i n a l into t h e c o n Rector.
6.
Connect: Connector
NOTE:
The two connectors "click" together.
7.
Check for continuity with a tester.
NOTE:
If t h e r e is no c o n t i n u i t y , c l e a n t h e t e r m i nals. Be s u r e to p e r f o r m t h e s t e p s 1 to 7 listed above when checking the wireharness. For a field r e m e d y , use a c o n t a c t revitalizer a v a i l a b l e on t h e m a r k e t . Use t h e t e s t e r on t h e c o n n e c t o r as s h o w n .
1-4
H O W TO USE THE C O N V E R S I O N TABLE

EB201000
I GEN
H O W TO USE THE C O N V E R S I O N TABLE

All s p e c i f i c a t i o n data in t h i s m a n u a l are listed in SI and M E T R I C U N I T S . Use t h i s t a b l e to c o n v e r t M E T R I C u n i t data t o I M P E R I A L u n i t data. Ex. METRIC MULTIPLIER IMP ** mm x 0.03937 = * * in 2 mm x 0.03937 = 0.083 in CONVERSION TABLE METRIC TO IMP Known Torque m.kg m.kg cm.kg cm.kg kg g km/h km Distance
m m ca mm
Multiplier 7.233 86.794 0.0723 0.8679 2.205 0.03527 0.6214 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 ft.lb in.lb ft.lb in.lb Ib oz mph mi ft yd in in oz (IMP liq.) cu.in qt(IMP liq.) gal(IMP liq.)
Result
Weight
Volume/ Capacity
cc(cm 3) cc(cm 3) lit(liter) lit(liter) kg/mm kg/cm 2 Centigrade
Miscellaneous
Ib/in psi(Ib/in 2) Fahrenheit (F)
1-5
SPECIAL TOOLS I GEN

EEl02000
SPECIAL TOOLS
T h e f o l l o w i n g s p e c i a l t o o l s are n e c e s s a r y f o r c o m p l e t e and a c c u r a t e t u n e - u p and a s s e m b l y . Use o n l y t h e a p p r o p r i a t e s p e c i a l t o o l s ; t h i s Will h e l p p r e v e n t d a m a g e c a u s e d b y t h e use o f i n a p p r o p r i ate t o o l s or i m p r o v i s e d t e c h n i q u e s . W h e n p l a c i n g an o r d e r , r e f e r to t h e list p r o v i d e d b e l o w to a v o i d a n y m i s t a k e s . Tool No. YU-01235 Tool name / Function Rotor holding tool This tool is used to hold the generator rot o r w h e n removing or installing the generator rotor bolt. YS-28891 Clutch spring holder This tool is used to disassembly and assembly the secondary pulley. YU -90050 -90062 Crankshaft Installation set (~ Adapter (~) These tools are used to install the crankshaft. Flywheel puller YU-01189 This tool is used for removing the rotor. YU-01135-A Crankcase Separating tool This tool is used to remove the crankshaft or separate the crankcase. YM-33299 Oil seal guide This tool is used for protecting the oil seal lip w h e n installing the secondary sliding sheave. YU-33975 Steering nut wrench This tool is used to loosen or tighten the steering stem ring nut. YU-01701 Sheave holder This tool is used to hold the clutch housing w h e n removing or installing the clutch housing nut. YU-8036-A Inductive tachometer Illustration
This tool is used to check engine speed.
1-6
SPECIAL TOOLS I GEN

Tool No. YU-03112 Tool name / Function Pocket tester This tool is used to c h e c k t h e electrical system. YM-1409 Oil seal guide This tool is used to install the left side crankcase oil seal. YM-1410 Oil seal d r i v e r I llustratio n
,.,o1 1
This tool is used to install the left side crankcase oil seal. YM-34487 D y n a m i c spark tester This i n s t r u m e n t is necessary for checking the ignition s y s t e m c o m p o n e n t s . ACC-1100-15-01 Quick Gasket
This sealant is used to seal to m a t i n g surfaces (e.g., crankcase m a t i n g sur-faces). 90890-01348 Lockn ut w r e n c h This tool is used to loosen and t i g h t e n the c l u t c h c a r r i e r I o c k n u t of t h e s e c o n d a r y sheave. YU-33963 -1400 Front fork seal d r i v e r Weight (~ A d a p t e r Q2~ These tools are used w h e n installing the fork seal. T-handle ( ~ YM-01326 Holder YM-01300-1 ( ~ YM-01312-A T-handle ( ~ ) / D a m p e r rod holder ( ~ T h e s e t o o l s are n e e d e d to l o o s e n and tighten the d a m p e r rod holding bolt. Fuel level gauge This gauge is used to nleasure the fuel level in the float chamber. dJ / ~//
1-7
G E N E R A L SPECIFICATION
SPECIFICATION
GENERAL SPECIFICATION
Model Model code: Dimensions: Overall length Overall w i d t h Overall height Seat height Wheelbase M i n i m u m ground clearance M i n i m u m turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system: Oil Type or Grade: Engine Oil 5P J1 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) 120 mm(4.7 in) 2,000 mm(78.7 in) 94 kg(207 Ib) YW50AP
IsPEcl.-I
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 Y A M A H A 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 Impqt, 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) Wet type element Regular unleaded gasoline 5.7 L (1.25 Imp.gal, 1.5 US gal) Y14P/1/TEIKEI
Transmission Oil Oil Capacity: Oil Tank (Engine Oil) Transmission Oil: Periodic Oil Change Total A m o u n t Air Filter: Fuel: Type Tank Capacity Carburetor: Type / Manufacturer
2-1
Model Spark Plug: Type/Manufacturer Gap Clutch Type 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 Manufacturer Type YW50A BPRTHS/NGK 0.6 ~ 0.7 mm(0.02 ~ 0.03 in) Dry, Centrifugal automatic 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 CHENG SHIN 56J 59J 143 kg(315 Ib)
IsPEcl.-I
front rear front rear front rear
Maximum load* Cold tire Pressure: Up to 90 kg Front Rear 90 kg load~Maximum load* Front Rear 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
200kpa(2.0 kg/crn 2, 29 psi) 200kpa(2.0 kg/cm 2, 29 psi) 200kpa(2.0 kg/cm 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 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
Model Headlight type: 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 Bulb 12V 35W/35Wx2 12 5W/21Wx1 V
10Wx4
IsPEcl.-I
YW50A
5Wx 1 3.4Wxl/1.7Wxl 1.7Wx 1 1.7Wx 1 1.7Wx 1
2-3
MA...EA.OE SPEO.F.OA-.O ISPEcl

M A I N T E N A N C E SPECIFICATION
ENGINE
Item C y l i n d e r head: Warp l i m i t "~ Sta nda rd Limit 0.03 m m (0.0012 in)
*Lines indicate s t r a i g h t e d g e m e a s u r e m e n t Cylinder: Bore size Taper l i m i t Out of round Ih-nit Piston: Piston to c y l i n d e r clearance Piston size " D " M e a s u r i n g point " H " Piston pin bore inside d i a m e t e r Piston pin outside d i a m e t e r 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
40.000~40.014mm (1.5748~1.5754 in)
40.10 m m (1.5787 in) 0.05 m m (0.0020 in) 0.03 rnm (0.0012 in) 0.10 m m (0.0039 in)
0.035~0.040 m m (0.0014~0.0016 in) 39.958~39.972 m m (1.5731~1.5737 in) 5 mm(O.2 in) 10.004~10.015 m m (0.3939~0.3943 in) 9.996~10.000 rnrn (0.3935~0.3937 in)
10.045 m m (0.4 in) 9.975 m m (0.39 in)
1.2 (0.05 1.2 (0.05
1.6 m m / k e y s t o n e 0.06 in) 1.6 r a m / k e y s t o n e 0.06 in) 0.6 mm(O.02 in) 0.6 mm(O.02 in)
0.15~0.35 m m (0.005~0.01 in) 0.15~0.35 m m (0.005~0.01 in) 0.03~0.05 m m (0.0012~0.0020 in) 0.03~0.05 m m (0.0012~0.0020 in)
0.1 mm(O.O039 in) 0.1 mm(O.O039 in)
2-4
MA..TEAOESPEO.F.OAT.OISPEcl "
Item Crankshaft:
F
Standard
Limit
Crank Width " A " Run Out Limit " C " Connecting Rod Big End Side Clearance " D " Small End Free Play " F " A u t o m a t i c centrifugal clutch: Clutch shoe thickness Clutch housing inside d i a m e t e r Clutch shoe spring free length Clutch - in r e v o l u t i o n Clutch - stall r e v o l u t i o n V-belt: V-belt w i d t h Kick Starter: Type Kick Clip Tension Carburetor: I.D. Mark Main Jet Needle jet Jet Needle-clip Position Main A i r 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 l i m i t
.q-
"--D
.~p
37.90~37.95 mm(1.49~1.49 in) 0.03 mm(0.0012 in) 0.2~0.5 m m (0.0029~0.020 in) 0.4~0.8 m m (0.016~0.031 in) 4.0 mm(0.16 in) 105 m m (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 t y p e 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 m m (0.0078) 1.0 mm(0.04 in)
2.5 mm(0.1 in) 105.5 m m (4.15 in) 91 mm(3.58 in)
14.6 mm(0.57 in)
(M.J.) (N J) (J.N.) (M.A.J.) (C.A.) (P.J.) (V.S.) (G.S.)
2-5
M..TE..OE SPEO.F.C.T.O. ISPEcl "" I

TIGHTENING TORQUES ENGINE
Tightening torque Nm 1 20 4 14 4 3 2 3 2 4 11 2 2 2 2 26 3 11 1 6 6 12 1 3 1 18 1 2 1 2 140 1 30 2 1 38 mkg ftlb 2.0 1.4 10 1.0 0.7 7 0.2 0.7 7 0.4 4 1.1 0.9 9 0.2 2 0.9 9 2.6 1.1 0.9 9 12 1.2 12 1.2 1.2 12 0.7 7 0.7 7 1.8 0.3 3 0.8 8 0.9 9 13 1.3 4.0 3.0 0.8 8 3.8 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 8.4 8.4 5.1 5.1 13 22 5.8 6.5 9.4 29 22 5.8 27 Part to be tightened Part name Thread size M M M M 6.0 M M M M M M M M M M M M M M M M M M M M M M M 14 7 7 6 1 6 5 6 6 4 6 8 6 6 6 6 6 6 6 8 14 6 6 6 10 10 6 10 Q'ty Remarks
Spark plug Cylinder head and cylinder Cylinder Air shroud 1 Air shroud l x 2 Fan Autolube pump Reed valve Air filter Carburetor cap Exhaust pipe Muffler Exhaust protector Protector Crankcase l x 2 T r a n s m i s s i o n case cover Crankcase cover 1(left) Bolt(case2) Crankcase cover2(left) Drain bolt Oil plug Idle gear plate Kick crank Starter m o t o r Clutch housing Clutch w e i g h t Magnet base C.D.I. rotor
Nut Stud bolt Screw Sc rew Screw Screw Bolt Sc rew Screw Screw Bolt Bolt Screw Bolt Bolt Bolt Screw Bolt Bolt Plug Screw Bolt Bolt Nut Nut Screw Nut
2-6
MA.
CHASSIS
Item Steering system: Steering bearing type No/size of steel balls: 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
A.OE SPEO.F.OAT.O. ISPEcl "

Standard Ball and race bearing 22 pcs 19 pcs 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) ... ... ... Limit
Upper Lower
233.6 mm
0.2 mm (0.008 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 radial lateral Cast wheel MT3.50xl 0 Aluminum radial lateral 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) 1 mm(0.04 in) 1 mm(0.04 in) 1 mm(0.04 in) 1 ram(0.04 in)
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
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.
TIGHTENING TORQUES CHASSIS
A.OE SPEO.F.OAT.O. ISPEcl "" I

Tightening torque Nm 84 45 13 30 16 22 43 20 10 7 4 7 7 2 7 70 120 10 23 20 23 6 m,kg 8.4 4.5 1.3 3.0 1.6 2.2 4.3 2.0 1.0 0.7 0.4 0.7 0.7 0.2 0.7 7.0 12.0 1.0 2.3 2.0 2.3 0.6 ftlb 61 31 9.4 22 12 16 37 14 7 5.1 2.9 5.1 5.1 1.4 5.1 51 87 7.2 16.6 14.5 16.6 4.3
Part to be t i g h t e n e d
Th read size M 12 M 10 M 6 M 10 M 8 M 25 M 10 M 8 M 6 M 6 M 5 M 6 M 6 M 5 M 6 M 10 M 14 M 6 M 8 MIO M 8 M 5
Remarks
Frame and e n g i n e bracket E n g i n e bracket, c o m p r e s s i o n rod and e n g i n e Rear carrier Rear s h o c k a b s o r b e r and f r a m e Rear s h o c k a b s o r b e r and e n g i n e S t e e r i n g ring nut Handle h o l d e r and s t e e r i n g shaft Brake hose and m a s t e r c y l i n d e r Fuel t a n k Fuel cock Fuel s e n d e r Box Seat lock a s s e m b l y Plastic parts & c o v e r Footrest board Front w h e e l axle and nut Rear w h e e l axle and n u t Rear brake cam lever Front brake caliper and f r o n t fork Brake disc and h u b Brake hose and caliper Brake caliper and bleed s c r e w
See "page3-18"
41~
2-8
MA.
ELECTRICAL
Item Ignition t i m i n g : Ignition t i m i n g (B.T.D.C.) Advanced type C.D.I.: Pickup coil resistance/color Source coil resistance/color C.D.I. unit m o d e l / m a n u f a c t u r e r Ignition coil: M o d e l / m a n ufacturer M i n i m u m spark gap P r i m a r y w i n d i n g resistance S e c o n d a r y w i n d i n g resistance Spark plug cap: Type Resistance Charging System/Type: C.D.I. Magneto: M o d e l / M a n ufacturer Nominal output Charging current Charging v o l t a g e Charging Coil Resistance (Color) Lighting Coil Resistance (Color) Lighting Voltage Rectifier: M o d e l / M a n ufactu rer Capacity Withstand voltage Battery: Specific g r a v i t y Electric starter system: Type Starter motor: M o d e l / m a n ufactu rer/ID n u m b e r Output A r m a t u r e coil resistance Brush overall length Spring force Commutator diameter Mica undercut (depth) Starter relay: M o d e l / m a n ufacturer A m p e r a g e rating Coil resistance

Standard 14 at 5,000 r/min Fixed 248 ~ 372~ at 20C (68F) (W/R-W/L) 640 ~ 960 ~ at 20C (68F) (B/R-G/W) 5PJ/TIIC 4WX/TI I C 6 rnrn (0.24 in) 0.32~0.48 ~ at 20C (68F) 5.68~8.52k~ at 20C (68F) Resin 5 kE2 Flywheel m a g n e t o 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 1.320 Constant mesh t y p e 4WX/shulin 0.14 kw 0.0648 ~ 0.0792 E2 at 20C (68F) 6.5 m m (0.26 in) 5.49 ~ 8.24 N (360~540 g) (12.69~19.04 oz) 16.1 m m (0.63 in) 1.05 m m (0.04 in) 4WX/Shulin 20A 54~66 E2 ... ... ... ... ... ... limit
3 m m (0.12 in) 400g 15.1 m m (0.59 in)
2-9
MA.
Item Horn: M o d e l / m a n ufacturer Maximum amperage Flasher relay: Type Flasher f r e q u e n c y Fuel gage: M o d e l / m a n ufacturer S e n d e r unit resistance Oil level g a u g e : M o d e l / m a n ufacturer Circuit breaker: Type MAIN

Standard limit 4KP/Asian 1.5A Capacitor 60~ 120 C y c l e / m i n 4VP/Sa n Chu 4~10 ~ 90~100 ~ 4VP/Lun Ping Fuse 7 A x l pc . ... ... . . .
full - empty
-
2-10
OEOERA"TOROOESPEC,F,CAT,ONS ISPEcl "

GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasteners w i t h standard I.S.O. pitch threads. Torque specifications for special c o m p o n e n t s or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, t o r q u e specifications call for clean, dry threads. C o m p o n e n t s should be at room temperature. A (Nut) 10 m m 12 m m 14 m m 17 m m 19 m m 22 m m B (Bolt) 6 mm 8 mm 10 m m 12 m m 14 m m 16 m m General t o r q u e specifications mkg ftlb Nm 6 15 30 55 85 130 0.6 1.5 3.0 5.5 8.5 13.0 4.3 11 22 40 61 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 ""

L U B R I C A T I O N POINTS A N D L U B R I C A T I O N TYPE
ENGINE
Lubrication Point Oil seal lips O-rings Bearings Piston surface Piston pin Cyl i n d e r 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)
Lublicant Type
--~11~ --411~ --411~ --~11~ ---411~
--~11~ ----II1~ ---~11~
--'qG ---~11~
2-12
OB"'OAT'O" PO'TS A"O'OB"'OAT'O T PE ISPEcl "

CHASSIS
Lubrication Point 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
Lubricant Type
2-13
CAB'E.OOT,.O ISPEcl "

CABLE R O U T I N G
(~ 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 t h r o u g h 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. [ ] C l a m p w i r e h a r n e s s , rear brake cable throttle cable 1,3. [ ] Position the cylinder between the s u p p o r t e r and main switch.
2-14
OAB'E.OOT,O
(~ (~) (~ (~ (~ (~ (~ (~ (~ @ @ 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 o v e r f l o w h o s e t h r o u g h the holder. [ ] Hold the fuel overflowhose with a clamp. [ ] Pass the brake cable through the holder.
ISPEcl
2-15
CAB'E.OOT,O IS"Eel "

(~ (~) (~ (~ (~ (~ (~ (~ (~ @ Brake hose Front fender Front fork assembly Nut Plate washer Brake holder hose Flange bolt Bolt Brake holder hose Flange bolt [ ] Pass the brake hose through the holder.
./
/ t / /
/
/
/(~
f f
2-16
C,B'E.OOT,O IS"Eel "

@ Battery(+)lead (~ Ignition coil [ ] Pass battery leads through (~) Spark plug lead the slot of footrestboard. (~ Starter relay leads [ ] Cover them after securing (~ Auto choke leads starter relay leads. (~ Starter relay [ ] Pass the seat lock cable (~ Bind through the hole of bracket. (~ C.D.I. unit [ ] Pass the fuel tank breath (~ Autolube hose hose over seat lock cable. (~ Seat lock cable [ ] Clamp carburetor vacuum @ Bracket hose, fuel hose and fuel @ Fuel tank breather hose cock vacuum hose. @ Bind 2 []Clamp a u t o c h o k e leads (~ Battery(-)lead and autolube hose on to carburetor 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.
iJ
"
~i~
~~,~ .........
~ ~ q ~ - ~ l
~,
..q-.~,J I I *~/'~ . . . . . . . ~ I
~.,~J ',~
@~.
2-17
CAB'E ROOT,OO ISPEcl "

(~ 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 installing handlebar covers. [ ] P a s s throttle cable1,3 t h r o u g h between handlebar and wireharness. [ ] Hang the wireharness bind on to the bracket.
I
" ~I .... ! i i
:'7 [j}j~. . . . . . . . . . . . . . .
~ L
~', JI . . . . . .
]3
2-18
INTRODUCTION/ PERIODICIVIAINTENANCE/LUBLICATION INTERVALS

EB300000
I INSP
PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION

T h i s c h a p t e r i n c l u d e s all i n f o r m a t i o n ments. These preventive operation information
YP301000
necessary'to perform procedures,
recommended
inspections and adjust-
maintenance
if f o l l o w e d ,
will ensure more reliable vehicle
a n d a l o n g e r s e r v i c e life. T h e n e e d f o r costly" o v e r h a u l w o r k w i l l be g r e a t l y " r e d u c e d . T h i s a p p l i e s t o v e h i c l e s a l r e a d y ' in s e r v i c e as w e l l as t o n e w v e h i c l e s t h a t a r e b e i n g p r e s h o u l d be f a m i l i a r w i t h t h i s e n t i r e c h a p t e r .
pared for sale. All service technicians
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

BREAK-IN NO. ITEM ROUTINE TYPE
INITIAL 1,000 km (600 mi)
EVERY
3,000 km (2,000 mi) or 6 months (whichever co mes first 6,000 km (4,000 mi) or 12months (wh]chever c o m e s fi rst
Fuel line
Check fuel hoses and v a c u u m hose f o r cracks or d a m a g e . Replace if necessary.
0 0 0 0
Whenever
Spark p l u g 3
4 *
Check c o n d i t i o n . Refer to SPARK Clean, regap or replace if neces- PLUGINSPECTION sa ry. Clean or replace if necessary,
s. . . . . . . ginooil
Air filter element Front brake
Check o p e r a t i o n , f l u i d e level and Brake fluid DOT4 v e h i c l e f o r f l u i d leakage. Ior DOT3)
Replace brake pads. -
worn to the limit.
* Rear brake
Check o p e r a t i o n . A d j u s t brake lever free play.
O
Whenever
O
worn to the limit.
Replace brake shoes. and for -
Wheels
Check balance, runout damage. Replace if necessary.
* Tires
C h e c k t r e a d d e p t h and f o r d a m a g e . Replace if necesssary. Check air pressure. Correct if necessary.
Wheel bearings Steering ings bear-
Check Bearing for looseness or damage. Replace if necessary. Check b e a r i n g play and steering for roughness. L u b r i c a t e w i t h l i t h i u m soap base greese,
0 -
O 0 0
Every 12,000 km(8,000 mi)or 24

months(whichever occurs first).
1C *
Chassis fasteners
M a k e sure t h a t all nuts, bolts and s c r e w s are p r o p e r l y t i g h t e n e d .
3-1
PERIODICINSPECTION AND
ADJUSTMENTSI INSPDI
BREAK-IN EVERY
3,000 km (2,000 mi) or 6 months (whichever comes first) O 6,000 km (4,000 mi) or 12months (wh ichever comes fi rst
I
O
NO.
ITEM
ROUTINE
TYPE
INITIAL 1,000 km (600 mi)
11 12" 13"
Centerstand Front fork Rear s h o c k absorberassembly * Carburetor
Check operation. Lubricate with lithium soap base greese (all purpose grease). - Check operation and for oil leakage. - C h e c k o p e r a t i o n and shock absorber for oil leakage. - Replace shock absorber assembly if necessary. Check engine idling speed. Adjust if necessary. Check operation. - Correct if necessary. Bleed if necessary. - C h e c k o i l level and vehicle for oil leakage.
Sarne as engine
oil
O O
O O
14
15" 16"
A u t o l u b e pump Final t r a n s m i s sion oil
Yarnalubel0W 4orSAEGL 30 SE gear oil
O O
O
@ O
O O
Replace.
E v e r y 12,000 k m ( 8 , 0 0 0 mi)or 24 mont hs(whichever Occurs first). Every 9,000 kin(6,000 mi)
17 *
V-belt
o Replace.
I t e m s m a r k e d w i t h an a s t e r i s k (*) r e q u i r e s p e c i a l t o o l s , d a t a a n d t e c h n i c a l skills f o r s e r v i c i n g . T a k e t h e s c o o t e r to a Y a m a h a d e a l e r .
NOTE:
T h e air f i l t e r n e e d s m o r e f r e q u e n t s e r v i c e if y o u are r i d i n g in u n u s u a l l y w e t or d u s t y areas. Brake f l u i d r e p l a c e m e n t : 1. R e p l a c e t h e b r a k e f l u i d a f t e r d i s a s s e m b l i n g t h e m a s t e r c y l i n d e r or c a l i p e r c y l i n d e r . C h e c k t h e b r a k e f l u i d level a n d a d d f l u i d as r e q u i r e d . 2. R e p l a c e t h e m a s t e r c y l i n d e r a n d c a l i p e r c y l i n d e r oil seals e v e r y t w o years. 3. R e p l a c e t h e b r a k e h o s e s e v e r y f o u r y e a r s , o r if c r a c k e d o r d a m a g e d .
NOTE:
F r o m 6,000 mi (9,000 k m ) - o r 18 m o n t h s , r e p e a t t h e m a i n t e n a n c e i n t e r v a l s s t a r t i n g 2,000 mi (3,000 mi) o r 6 m o n t h s .
3-2
COVER AND PANEL COVER AND PANEL

SIDECOVER A N D SEAT
INSP
'
8
i
~,~/~ ~ m . k g , 9.4ft.lb)
y---//
j
@
Order .
J o b name/Part n a m e Sidecover and seat removal Battery box cover
Q'ty
Remarks Remove the parts in order. NOTF" Insert the (-) s c r e w d r i v e r into the slot of battery cover and pickup then remove.
3. 4. 5. 6. 7. 8.
Seat Seat hange Rear carrier Rear cover Left side cover Right side cover Center cover
Reverse the removal procedure for installation. 3-3
COVER AND PANEL
INSP
LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 A N D FOOTREST BOARD
4 5
[~1 7Nm(0.7m.kg, 5.1ft.lb)

6
..
""
/ //
Order
Job n a m e / p a r t name L o w e r c o w l i n g , u p p e r cover, leg shield 1,2 and f o o t r e s t board removal Lower c o w l i n g Upper cover Leg shield 1 Main switch c o v e r / l e g shield 2 Battery Footrest board
Q'ty
Remarks Remove the parts in order.
2. 3. 4. 5. 6.
1 1 1 1/1 1 1 Reverse the removal procedure for installation.
3-4
COVER AND PANEL

H A N D L E B A R C O V E R ( F R O N T A N D REAR)
INSP
Order
Job name/Part name H a n d l e b a r c o v e r ( F r o n t and Rear) removal. Mirrors Front h a n d l e b a r c o v e r Rear h a n d l e b a r c o v e r Flasher light(Left/Right)
Q'ty
Remarks R e m o v e t h e part in order.
1.
2. 3. 4.
2 1 1 1/1 Reverse the r e m o v a l p r o c e d u r e for installation.
3-5
ENGINE
IDLE SPEED ADJUSTMENT ENGINE
I INSP
IDLE SPEED A D J U S T M E N T
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 position. I Pilot air screw turn out: load 1-1/4 I
2. Start the engine and let it warm up.
r!~VAVL, --']~ I [-! W I ~

Before starting t h e engine, be sure to use t h e c e n t e r s t a n d for safety.
. Attach: Inductive tachometer (~ To the spark plug lead I<~1

4.
Inductive tachometer: YU-8036-A Check: Engine idle speed Out of specification-->Adjust. Engine idle speed 1,750~1,850 r/min
I-~1
5. Adjust: Engine idle speed Adjustment steps. Turn the throttle stop screw(~ in or out until specified idle speed is obtained. I Turn Turn i:u t speed Idle becomes speed becomes Idle higher. lower.
3-6
THROTTLE CABLE FREE A D J U S T M E N T

1.
I INSP
I
T H R O T T L E CABLE FREE A D J U S T M E N T
Check: Throttle cable free play (~ Out of specification-->Adjust.
ree o~ mm(0.12 3 5
~ 0.20 in)
Throttle cable free play a d j u s t m e n t 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 specified free play is obtained. I T u r n i n g in--~Free play is increased. T u r n i n g 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 h a n d l e b a r to the right and to the left to ensure that this does not cause the engine idling speed to change. I
3-7
A U T O L U B E P U M P AIR BLEEDING
I INSP
A U T O L U B E P U M P AIR BLEEDING 1. Remove Lower cowling A i r shroud 1 (~ 2. Air bleeding: Pump case and / or oil hose.
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~
Air bleeding steps: Place a rag under the autolube p u m p t o catch the oil. Remove the bleed screw (~. Keepthe oil running out until air bubbles disappear. When air bubbles are expelled completely, tighten the bleed screw. NOTE: Check the bleed screw gasket. If damaged, replace w i t h a new one. Place a oil pan under the autolube p u m p to catch oil.
3.
Air bleeding: Pump d i s t r i b u t o r and/or delivery hose
Air bleeding steps: Start the engine. Run the engine for 2-3 minutes at 2000 r / m i n . This will c o m p l e t e l y r e m o v e autolube p u m p system of air.
3-8
SPARK PLUG INSPECTION INSP

SPARK PLUG I N S P E C T I O N
1. 2.
Remove: Battery box cover Inspect: Spark plug type I nco rrect-->Replace. Standard spark plug: BPR7HS/NGK I
I 3.
4. 5.
I l'0ar'0u00ao
6. 7.
Inspect: Electrode (~ Wea r/Da m ag e-->Re place. Insulator (~) A b n o r m a l color->Replace. Normal color is a medium-to-light tan color. Clean the spark plug w i t h a spark plug cleaner or wire brush. Measure: Plug gap (~ Use a wire gauge or feeler gauge. Out of specification-->Regap. 0.6 ~ 0.7 m m (0.02 ~ 0.03 in)
Tighten: Spark plug I~4~i20Nm(2"0m'kg'14ft'lb) I Install: Battery box cover.
3-9
E N G I N E OIL LEVEL I N S P E C T I O N
E N G I N E OIL LEVEL I N S P E C T I O N 1. Inspect: Engine oil level Oil level Iow--~Add sufficient oil by the f o l l o w i n g inspection steps.
INSP
(~ "OIL" indicator light
Engine oil level visual inspection steps: Turn main switch to " * " position.
"OIL" indicator light does I not comes on.
"OIL" indicator comes on.
light
Turn main switch " O N " position.
to
"OIL" indicator light does I _ not come on.
Inspect f a u l t y electrical circuit, light bulbs etc.
Engine oil level and electrical circuit are OK.
"OIL" indicator comes on.
light
S u p p l y engine oil.
"OIL" indicator light comes on.
1
NOTE:
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)
Install the oil tank filler cap (~ and push it fully into the filler.
3-10
T R A N S M I S S I O N OIL R E P L A C E M E N T
TRANSMISSION
I INSP
OIL R E P L A C E M E N T
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 t r a n s m i s s i o n 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.
1.
5. 6.
Install: Drain bolt H 18 .m Fill: Transmission case
m,g. 13.,,)1
Recommended oil: Yamalube 4 SAE 10W 30SE or GL gear oil Oil capacity: Total a m o u n t 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:
A l w a y s use t h e s a m e t y p e of oil; m i x i n g oils m a y r e s u l t in a h a r m f u l c h e m i c a l reaction a n d lead t o p o o r p e r f o r m a n c e . Do n o t a l l o w f o r e i g n m a t e r i a l t o e n t e r s t h e t r a n s m i s s i o n case.
Install: Oil filler plug (with O-ring) 8. Inspect: Oil leaks Oil level NOTE: Wipe off any oil spilt on the t r a n s m i s s i o n , tire or wheel. 3-11
7.
AIR FILTER E L E M E N T C L E A N I N G
I INSP
AIR FILTER E L E M E N T C L E A N I N G 1. Remove: Battery b o x c o v e r 2. Remove: Caburetor jont clamp ~)
3.
Remove: Screw A i r filter ( ~
4.
Remove: A i r filter case (~) A i r filter e l e m e n t
CAUTION:
N e v e r o p e r a t e t h e e n g i n e w i t h t h e air f i l t e r ele m e n t r e m o v e d . T h i s w i l l a l l o w u n f i l t e r e d air t o enter, c a u s i n g r a p i d w e a r and p o s s i b l e engine damage. Additionally, operation without t h e c l e a n e r e l e m e n t w i l l affect c a r b u r e t o r jett i n g w i t h s u b s e q u e n t p o o r p e r f o r m a n c e and possible engine overheating. Be careful n o t t o h a v e rags or t h e like b l o c k i n g t h e i n t a k e area of t h e air filter.
5.
6.
Inspect: Element (~ Da mage-->Replace. Clean: A i r filter e l e m e n t
A i r filter e l e m e n t c l e a n i n g steps: W a s h the e l e m e n t g e n t l y , but t h o r o u g h l y in solvent. 3-12
AIR FILTER E L E M E N T C L E A N I N G AWARNING
INSP
N e v e r use l o w flash p o i n t s o l v e n t s such as gasoline t o clean t h e e l e m e n t . Such s o l v e n t m a y lead to a fire or explosion.

S q u e e z e t h e e x c e s s s o l v e n t o u t of t h e elem e n t a n d let dry.
CAUTION:
Do not t w i s t t h e e l e m e n t w h e n s q u e e z i n g t h e element.
A p p l y t h e f o a m -air f i l t e r oil or e n g i n e o i l . S q u e e z e o u t t h e e x c e s s oil. NOTE: T h e e l e m e n t s h o u l d be w e t b u t n o t d r i p p i n g .
7.
Install: Air filter Battery box cover
3-13
V-BELT I N S P E C T I O N
I INSP
V-BELT INSPECTION 1. Remove: Kick crank ( ~ Screws (~ Crankcase c o v e r 2(left) (~) S c r e w s ( A i r c l e a n e r and left crankcase cover (~ Crankcase c o v e r 1(left) ( ~
Inspect V-belt ( ~ Cracks/Wea r/Da mage-->Replace. Oil or grease a d h e r e to t h e V-belt-->Check the p r i m a r y and s e c o n d ary sheaves. Refer to "ENGINE OVERHAUL -INSPECTION A N D REPAIR" section in the CHAPTER 4. Measure: V-belt w i d t h ( ~ Out of specification-->Replace. Refer to " E N G I N E O V E R H A U L " section in the CHAPTER 4. V-belt w i d t h " 16.6 m m (0.65 in) < L i m i t > 14.6 m m (0.57 in)
NOTE:
M e a s u r e the V-belt w i d t h on several points.

4.
Install: Crankcase c o v e r 1 (left)
A i r cleaner
I~%l [ ~ l 9N
12Nm(1.2m.kg,ft.lb) I m(0.9m.kg, ft.lb) I 6.5
Crankcase c o v e r 2 (left) 3-14 Kick crank
F"O"T B"A"E'EVE" CHECK/BRAKE PAD INSPECTION I,.Sp I F"EE P'AY C"EC"'"EA" B"A"E A D J LEVER FREE PLAY
CHASSIS
F R O N T BRAKE LEVER FREE PLAY CHECK
1.
Check: Front brake lever free play 2~5 mm(0.08~0.20 in) I
I ~ 1
xkWARNING
A soft or s p o n g y feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished 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,o3~0 79,n,
<
o to
Rear brake lever free play adjustment steps: Turn the adjuster (~ in or out until the correct free play is obtained.
BRAKE PAD I N S P E C T I O N
3-15
1. Activate the brake lever. 2. Inspect: Brake pad Wear i n d i c a t o r (~ nearly c o n t a c t i n g brake disc-->Replace brake pads as a set. Refer to the "BRAKE PAD REPLACEMENT" section in the CHAPTER 6. (~ Brake disc (~ Brake pads
BRAKE FLUID LEVEL INSPECTION
B"AKES"OE'"SPECT'O'I'"SP I
BRAKE SHOE I N S P E C T I O N
1. 2.
Activate the brake lever. Inspect: W e a r indicator (~ Indicator at w e a r limit line (~)-->Replace brake shoes.
BRAKE FLUID LEVEL I N S P E C T I O N NOTE:
Position the scooter straight up w h e n inspecting the fluid level.
G -L
Inspect: Fluid level is under " L O W E R " level line (~-->Fill to proper level. R e c o m m e n d e d fluid: DOT#4(or DOT#3)
Ii~l
CAUTION:
The fluid m a y corrode p a i n t e d surfaces or plastic parts. A l w a y s clean up spilled fluid i m m e diately.
~!~LvAv/1-'] I [! ~ I~
e U s e o n l y t h e d e s i g n a t e d q u a l i t y fluid. Otherw i s e ,the r u b b e r s e a l s m a y d e t e r i o r a t e causing leakage and p o o r brake p e r f o r m a n c e . eRefill w i t h t h e s a m e t y p e of fluid. M i x i n g fluids m a y result in a harmful chemical reaction leading to p o o r brake p e r f o r m a n c e . eBe careful t h a t w a t e r does n o t enter t h e master cylinder w h e n refilling. W a t e r w i l l significantly l o w e r t h e boiling p o i n t of t h e fluid and m a y result in v a p o r lock. 3-16
AIR BLEEDING
(HYDRAULIC
BRAKE
SYSTEIVI)I INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1. Bleed: Brake f l u i d Air bleeding steps: a. A d d p r o p e r brake f l u i d to the reservoir. b. Install the d i a p h r a g m . Be careful not to spill a n y f l u i d or a l l o w t h e r e s e r v o i r to overflow. c. C o n n e c t t h e clear plastic tu be ( ~ t i g h t l y to the caliper bleed screw. d. Place the o t h e r end o f t h e t u b e into a container. e. S l o w l y a p p l y t h e brake lever several times. f. Pull the lever in. Hold the lever in position. g. Loosen the bleed s c r e w and a l l o w the lever to t r a v e l t o w a r d s its limit. h. T i g h t e n the bleed s c r e w w h e n the l i m i t has been reached, t h e n release the lever. i. Repeat steps ( e ) t o (h) until the air b u b b l e s have been r e m o v e d f r o m t h e s y s t e m . j. A d d brake f l u i d to p r o p e r level.
~!~LvAv/1 ~ I [-! -'t I ~

Check the operation of the brake after bleeding 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.
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~
A d j u s t m e n t steps: Remove u p p e r cover, l o w e r c o w l i n g , leg shield 1,2. refer to "COVER AND PANEL" section. Remove all ringnuts using ringnut wrench. ::~1 Ring nut wrench: 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 w r e n c h 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 w i t h rubber ring.
CAUTION:
Aligning the slot of ring nut 2 w i t h the slot of ring nut 3. If not, slightly t i g h t e n ring nut 2 until the slots a l i g n m e n t .
Install special w a s h e r (~ NOTE: Insert the projections of special w a s h e r 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 d o w n , 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 I N S P E C T I O N
FRONT Manufacturec CHENG SHIN REAR Manufacturec CHENG SHIN Size 130/90-10 Type 59J Size 120/90-10 Type 56J
TIRE I N S P E C T I O N
I INSP
WARNING
The tire pressure should only be checked and r e g u l a t e d w h e n t h e tire t e m p e r a t u r e equals t h e a m b i e n t air t e m p e r a t u r e , T h e tire pressure m u s t be adjusted according to t h e total w e i g h t (including cargo, rider passenger and accessories) and t h e anticip a t e d riding speed, O p e r a t i o n of an o v e r l o a d e d scooter could cause tire d a m a g e , an accident or an injury, N E V E R O V E R L O A D THE SCOOTER,
Basic weight ( w i t h oil and a 9 4 k g ( 2 0 7 1 b ) full uel tank) M a x i m u m load* 1 4 3 k g ( 3 1 5 1 b ) Front Rear Cold t i r e pres- 200 kpa 200 kpa (2.0 kgf/cm 2, (2.0 kgf/cm< sure 29 psi) 29 psi) * Total of cargo, rider, passenger and accessories.
WARNING
It is d a n g e r o u s to ride w i t h a w o r n - o u t tire. When the tire tread reaches the w e a r limit, replace the tire immediately. . Inspect: Tire surfaces Wea r/Da m age-->Re place. M i n i m u m tire tread depth (~ (front and rear): 1.6 mm (0.06 in) (~ Tread depth (~) Side wall (~) Wear indicator
>
3-19
CHECKING THE WARNING
TmESl INSP I I
a__l
BI
Do not use a tubeless tire on a w h e e l designed only for t u b e tires t o avoid tire failure and personal injury f r o m sudden deflation. When using t u b e tires, be sure t o install t h e correct tube. A l w a y s replace a n e w t u b e tire and a n e w t u b e as a set. To avoid pinching the tube, make sure t h e w h e e l rim band and t u b e are centered in t h e w h e e l groove. Patching a p u n c t u r e d t u b e is n o t r e c o m mended. If it is a b s o l u t e l y necessary t o do so, use great care and replace t h e t u b e as soon as possible w i t h a good quality replacement. [ ] Tire IB] Wheel Tube wheel Tubeless wheel Tube tire o n l y Tube or tubeless tire
After e x t e n s i v e tests, the tires listed b e l o w have been a p p r o v e d by Y a m a h a M o t o r Co., Ltd. for t h i s model. The f r o n t and rear tires s h o u l d a l w a y s be by t h e same m a n u f a c t u r e r and of t h e same design. No guarantee conc e r n i n g h a n - d l i n g c h a r a c t e r i s t i c s can be given if a tire c o m b i n a t i o n o t h e r t h a n one approved by Yamaha is used on this scooter.
3-20
CHECKING THE T I R E S / C H E C K I N G THE
WHEELSI INSP
N e w tires have a relatively l o w grip on the road surface until t h e y have been s l i g h t l y w o r n . Therefore, a p p r o x i m a t e l y 100 km should be t r a v e l e d at n o r m a l speed b e f o r e any highspeed riding is done.
NOTE:
For tires w i t h a direction of rotation mark (~: Install the tire w i t h 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 C A B L E A D J U S T M E N T
WHEEL INSPECTION 1. Inspect: wheels Da mage/Bends-->Replace.
INSP
Never attempt to make any repairs to the wheel.

NOTE:
After a tire or wheel has been changed or replaced, always balance the wheel.
FRONT FORK INSPECTION 1. Inspect: Front f o r k ~ Bends/Damage-->Replace inner t u b e comp, fork ass'y. Grease leakage--~Replace inner t u b e comp. fork ass'y. U n s m o o t h operation-->Replace f o r k 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 A D J U S T M E N T 1. Remove: Upper cover Refer to "COVER A N D 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 CEOK.O A O " U B . . O A T . O .

C E N T E R S T A N D LUBRICATING
"EVE.S "UB..OAT.O "'"SP''"'
'
I
EAS00170
ADJ
I~1
CABLE C H E C K I N G A N D L U B R I C A T I N G The f o l l o w i n g procedure applies to all of the cable sheaths and cables.
r!~VAVL, W --'t~ [-!I I ~

D a m a g e d cable sheaths m a y cause the cable to corrode and interfere w i t h its m o v e m e n t . Replace d a m a g e d cable sheaths and cables as soon as possible. . Check: cable sheath Damage --> Replace. Check: cable operation Rough m o v e m e n t --> Lubricate. Recommended lubricant t Engine oil or a suitable cable lubri ca nt NOTE: Hold the cable end u p r i g h t and pour a f e w drops of lubricant into the cable sheath or use a suitable lubricating device.
EAS00171
LEVERS L U B R I C A T I N G Lubricate the pivoting point and metal-to-metal m o v i n g parts of the levers. Recommended lubricant Lithium soap base grease
EAS00173
CENTERSTAND LUBRICATING Lubricate the pivoting point and metal-to-metal m o v i n g parts of the centerstand. Recommended lubricant Lithium soap base grease
3-23
BATTERY I N S P E C T I O N ELECTRICAL
BATTERY INSPECTION NOTE:
I INSP
Since the MF battery is of a sealed-type construction, it is impossible to measure the specific g r a v i t y of the electrolyte in order to check the state of charge in the battery. Therefore, to check the state of charge in the battery, voltage must be measured at the batteryterminals.
CAUTION:
CHARGING METHOD This b a t t e r y is sealed type. Never r e m o v e sealing caps even w h e n charging. W i t h t h e sealing cap removed, t h i s balancing w i l l n o t be m a i n t a i n e d , and b a t t e r y performance w i l l l o w e r gradually. Never add w a t e r . If distilled w a t e r is added, chemical reaction in the b a t t e r y w i l l not proceed in the normal w a y , t h u s m a k i n g it impossible for t h e b a t t e r y t o operate regularly. The c h a r g i n g t i m e , c h a r g i n g c u r r e n t and charging v o l t a g e for t h e MF b a t t e r y is different t h a n general t y p e batteries. The MF b a t t e r y s h o u l d be c h a r g e d as instructed in t h e " C h a r g i n g m e t h o d " . Should the b a t t e r y be overcharged, t h e electrolyte level w i l l l o w e r e x t r e m e l y . Therefore, use special care w h e n charging t h e battery. A v o i d using any electrolyte other than specified. The specific g r a v i t y of t h e MF b a t t e r y electrolyte is 1.32 at 20C (68F). (The specific g r a v i t y of the general t y p e b a t t e r y elect r o l y t e is 1.28. ) If the electrolyte w h o s e specific g r a v i t y is less than 1.32, the sulfuric acid w i l l decrease and t h u s l o w b a t t e r y performance w i l l result. Should any electrolyte, w h o s e specific gravity is 1.32 or more, be used, the b a t t e r y plates w i l l corrode and b a t t e r y life w i l l shorten. Remove: Battery b o x cover Refer to "COVER A N D PANEL" section. 2. Remove: Battery NOTE: 3-24 Remove the (-) lead first. 1.
BATTERY I N S P E C T I O N
INSP
//
Batteries g e n e r a t e e x p l o s i v e h y d r o g e n gas and c o n t a i n e l e c t r o l y t e w h i c h is m a d e of p o i s o n o u s a n d h i g h l y c a u s t i c s u l f u r i c acid. Therefore, always follow these preventive measures: W e a r p r o t e c t i v e eye gear w h e n h a n d l i n g or w o r k i n g near b a t t e r i e s . C h a r g e b a t t e r i e s in a w e l l - v e n t i l a t e d area. Keep b a t t e r i e s a w a y f r o m fire, sparks or o p e n f l a m e s (e.g., w e l d i n g e q u i p m e n t , l i g h t e d cigarettes). DO NOT SMOKE w h e n c h a r g i n g or h a n - d l i n g batteries. KEEP BATTERIES A N D ELECTROLYTE O U T OF REACH OF CHILDREN. A v o i d b o d i l y c o n t a c t w i t h e l e c t r o l y t e as it can cause s e v e r e b u r n s or p e r m a n e n t eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL Skin ~ Wash with water. Eyes - - Flush w i t h w a t e r for 15 m i n u t e s and get immediate medical attention. INTERNAL D r i n k large q u a n t i t i e s of w a t e r or m i l k fol l o w e d w i t h m i l k of m a g n e s i a , b e a t e n egg or v e g e t a b l e oil. G e t i m m e d i a t e medical a t t e n tion. 3. Check: Battery c o n d i t i o n
Volt meter
Battery c o n d i t i o n c h e c k i n g steps: Connect a digital v o l t m e t e r to the b a t t e r y t e r minals. I Tester (+) lead Battery (+) t e r m i n a l . Tester (-) lead Battery (-) t e r m i n a l . (v)
13.0 8 12.0
11.5
& 12.5 o
~,
0
Relationshipbetweenopen-circuit C )
NOTE: The state of a d i s c h a r g e d MF b a t t e r y can be checked by m e a s u r i n g o p e n circuit v o l t a g e (the v o l t a g e m e a s u r e d w i t h the p o s i t i v e t e r m i n a l s being d i s c o n n e c t e d ) .
i 5 6.5 ~0 Chargingtime(hours) Thisvariesdependingon the temperature,the stateof chargein batteryplatesand the electrolytelevel.
3-25
BATTERYINSPECTION I INSP 1 ~1(~

14 Ambient temperature 20C
Open circuit voltage Charging time 12.8 or v more No charging is necessary.
.~ 11
|
I B
|
I B
100
75
50
30 25 20
Condition of charge in battel~J(%)
Check the b a t t e r y c o n d i t i o n u s i n g f i g u r e s . EXAMPLE: Open circuit v o l t a g e = 12.0v C h a r g i n g t i m e = 6.5 h o u r s C o n d i t i o n of c h a r g e in b a t t e r y = 20 ~ 30% 2. C h a r g i n g m e t h o d of MF b a t t e r y
CAUTION:
If it is i m p o s s i b l e t o set t h e s t a n d a r d c h a r g ing c u r r e n t , be careful n o t t o o v e r c h a r g e . e W h e n c h a r g i n g t h e b a t t e r y , be s u r e t o rem o v e it f r o m t h e m o t o r c y c l e . (If c h a r g i n g has t o be d o n e w i t h t h e b a t t e r y m o u n t e d on t h e m o t o r c y c l e for s o m e reason, be s u r e t o disc o n n e c t t h e w i r e at t h e n e g a t i v e t e r m i n a l . ) Never remove the sealing plug from the MF battery. Use special care so t h a t c h a r g i n g clips are in a full c o n t a c t w i t h t h e t e r m i n a l and t h a t t h e y are n o t s h o r t e d . (A c o r r o d e d c l i p of t h e c h a r g e r m a y cause t h e b a t t e r y t o g e n e r a t e heat at t h e c o n t a c t area. A w e a k clip s p r i n g m a y cause sparks.) Before r e m o v i n g t h e clips f r o m t h e b a t t e r y t e r m i n a l s , be s u r e t o t u r n off t h e p o w e r s w i t c h of t h e charger. C h a n g e in t h e o p e n - c i r c u i t v o l t a g e of t h e M F b a t t e r y after b e i n g c h a r g e d is s h o w n b e l o w . As s h o w n in t h e f i g u r e , t h e o p e n c i r c u i t v o l t age is s t a b i l i z e d 30 m i n u t e s after c h a r g i n g has been c o m p l e t e d . T h e r e f o r e , t o c h e c k t h e c o n d i t i o n of t h e batt e r y , m e a s u r e t h e o p e n - c i r c u i t v o l t a g e 30 m i n u t e s after has b e e n c o m p l e t e d .
Charging
Ambient temperature 20oc
& o
2 o
\
Time(Minutes) Check the open circuit voltage
&
~1~
3-26
BATTERY INSPECTION
C h a r g i n g m e t h o d u s i n g a v a r i a b l e - c u r r e n t (voltage) t y p e c h a r g e r Charger AMP meter Measure the open-circuit voltage prier to c h a r g i n g .
I INSP
NOTE: Voltage should be measured 30 minutes after the machine is stopped. NOTE: Set the c h a n g i n g v o l t a g e at 16 V. (Ifthe setting is lower, 17 charging Will be insufficient. If t o o high, the battery Will be over-charged.)
t
C o n n e c t a c h a r g e r and A M P m e t e r to the b a t t e r y and start charging.
+
YES Make sure the c u r r e n t is h i g h e r than the standard charging c u r r e n t w r i t t e n on the battery.
NO
By t u r n i n g the c h a r g i n g v o l t a g e a d j u s t dial, set the c h a r g i n g v o l t age at 20 - 25 V.
A d j u s t the v o l t a g e so t h a t c u r r e n t 4 is at s t a n d a r d c h a r g i n g level.
YES
M o n i t o r t h e a m p e r a g e f o r 3-5 m i n u t e s to check if the s t a n d a r d c h a r g i n g c u r r e n t is reached. NO
1
Set the t i m e r a c c o r d i n g to the c h a r g i n g t i m e s u i t a b l e for the o p e n - c i r c u i t v o l t a g e . Refer to "Battery condition checking steps".
In case t h a t c h a r g i n g r e q u i r e s m o r e t h a n 5 h o u r s , it is a d v i s a b l e to check the c h a r g i n g c u r r e n t after a lapse of 5 h o u r s . If t h e r e is a n y c h a n g e in the a m p e r a g e , r e a d j u s t the v o l t a g e to o b t a i n the s t a n d a r d c h a r g i n g current.

I
J
If c u r r e n t d o e s not exceed standard charging current after 5 m i n u t e s , replace the battery.
M e a s u r e the b a t t e r y o p e n - c i r c u i t v o l t a g e after h a v i n g left t h e batt e r y u n u s e d for m o r e t h a n 30 m i n u t e s . 12.8 V o r m o r e --- C h a r g i n g is c o m p l e t e . 12.7 V o r less --- R e c h a r g i n g is r e q u i r e d . U n d e r 1 2 . 0 V --- Replace t h e battery. 3-27
BATTERY I N S P E C T I O N
Charging method using a constant-voltage type charger Measure the open-circuit voltage prier to charging. AMP meter
I INSP
Charger
NOTE: V o l t a g e s h o u l d be m e a s u r e d 30 minutes after the m a c h i n e is s t o p p e d .
Volt meter
II
~ I
Connect a c h a r g e r and A M P meter to the battery, and start charging.
YES
Charge the battery until the battery's charging voltage is 15 volts.

NOTE: Set the c h a r g i n g t i m e at 20 h o u r s (maximum).
Make sure the current is higher than the standard charging current w r i t t e n on the battery.
NO
This type of battery charger Can not charge the MF b a t t e r y . A variable voltage charger is recommended.
Checkthe open-circuit voltage after having left the battery for 30 minutes after charging. 12.8 V or m o r e - - - Charging is complete. 12.7 V or less --- Recharging is necessary. Under 12 --- Replace the battery. V
Charging method using a constant current type charger This t y p e if battery charger Can not charge the MF battery.
3-28
FUSE INSPECTION I INSP

Inspect: Battery terminal D i r t y terminal-->Clean w i t h w i r e brush. Poor co n nection-->Co rrect. NOTE: A f t e r cleaning t e r m i n a l s , a p p l y terminals. . Install Battery Battery box cover l i g h t l y to the 4.
FUSE I N S P E C T I O N 1. R e m o v e : Battery box cover Refer to " C O V E R A N D P A N E L " section. 2. R e m o v e : Fuse ( ~ 3. Inspect: Fuse ( ~ defective--~Replace
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
B l o w n fuse p r o c e d u r e steps: T u r n off i g n i t i o n and the circuit. Install a n e w fuse of p r o p e r a m p e r a g e . T u r n on s w i t c h e s to v e r i f y o p e r a t i o n of electrical device. If fuse b l o w s i m m e d i a t e l y again, check circuit in q u e s t i o n .
~!~Lvlv/1 ~11 [-! :] ~

Never use a fuse w i t h an a m p e r a g e rating other t h a n t h a t specified. Improvising or using a fuse w i t h t h e w r o n g a m p e r a g e rat-ing m a y cause e x t e n s i v e d a m a g e t o t h e electrical s y s t e m , cause t h e lighting and ignition systems to malf u n c t i o n and could possibly cause a fire.
Description Amperage Main 7A . Install: Fuse Battery box cover 3-29 Quantity 1
HEADLIGHT BEAM A D J U S T M E N T I INSP /HEADLIGHT BULB REPLACEIVIENT I

I
HEAD LIGHT BEAM A D J U S T M E N T
\ j)
1.
Adjust: Head l i g h t (vertically) T u r n t h e a d j u s t i n g s c r e w ( ~ in or o u t to a d j u s t h e a d l i g h t beam. Head l i g h t (Horizontal) T u r n t h e a d j u s t i n g s c r e w ( ~ in or o u t to a d j u s t h e a d l i g h t beam.
HEADLIGHT BULB REPLACEMENT

1. Remove: Upper cover Refer to "COVER A N D P A N E L " section.
2. 3.
Disconnect: Headlight coupler (~ Remove: Bulb h o l d e r c o v e r ( ~
4.
Remove: Headlight bulb holder (~ T u r n the b u l b h o l d e r c o u n t e r c l o c k w i s e to r e m o v e it. Remove: Bulb(defective) (~
5.
W!~VAV/I -'| ~ I [']1 I ~ Since the headlight bulb gets extremely hot, keep f l a m m a b l e p r o d u c t s and y o u r hands a w a y from the bulb until it has cooled down.
3-30
HEADLIGHT BULB / TURN SIGNAL BULB REPLACEMENT

6. Install: Bulb(new)
i,.S.l l
ADJ
CAUTION:
A v o i d t o u c h i n g t h e glass p a r t of t h e h e a d - l i g h t b u l b t o keep it free f r o m oil, o t h e r w i s e t h e t r a n s p a r e n c y of t h e glass, t h e life of t h e b u l b a n d t h e l u m i n o u s f l u x w i l l be a d v e r s e l y affected. If t h e h e a d l i g h t b u l b g e t s s o i l e d , t h o r o u g h l y clean it w i t h a c l o t h m o i s t e n e d w i t h a l c o h o l or l a c q u e r t h i n n e r . 7. Install: Bulb h o l d e r T u r n the b u l b h o l d e r c l o c k w i s e to install it. 8. Install: Bulb h o l d e r c o v e r 9. Connect: Headlight coupler 10. Install: Upper cover 11. A d j u s t : H e a d l i g h t beam Refer to " H E A D L I G H T BEAM ADJ U S T M E N T " s e c t i o n
TURN SIGNAL BULB REPLACEMENT 1. Remove: Screw (~ Lens ( ~ 2. Replace: Bulb ( d e f e c t i v e ) ( ~ 3. Install: Lens (~) Screw (~
/REAR _
3-31
CAUTION:
Do n o t o v e r - t i g h t e n t h e s c r e w s as t h e lens m a y break.
TAILLIGHT BULB / LICENCE LIGHT BULB REPLACEMENT CAUTION:
i,.s l l
ADJ
A v o i d t o u c h i n g the glass part of t h e head-light bulb t o keep it free f r o m oil, o t h e r w i s e t h e t r a n s p a r e n c y of t h e glass, t h e life of t h e bulb and t h e l u m i n o u s f l u x w i l l be a d v e r s e l y affected. If t h e h e a d l i g h t bulb gets soiled, t h o r o u g h l y clean it w i t h a cloth m o i s t e n e d w i t h alcohol or lacquer thinner.
T A I L L I G H T BULB R E P L A C E M E N T 1. Remove: Screws (~ Lens (~ 2. Replace: Bulb (defective) (~ 3. Install: Lens (~) Screws ~) LICENSE LIGHT BULB R E P L A C E M E N T 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 OVERHAUL
ENGINE R E M O V A L
W l R E H A R N E S S A N D CABLES
~ 1 2 0 N m ( 1 2 . 0 m.kg, 87 ft.lb) 7 12
1~145Nm(4-5 m.kg, 31ft.lb) I
Order
Job name/Part name

W i r e h a r n e s s and cables r e m o v a l Rear carrier Tail cover Left side panel Right side panel Battery b o x cover Center c o w l i n g Air filter case Carburetor
Q'ty
Remarks Remove the parts in order. Refer to "COVER A N D PANEL" section in CHAPTER 3.
Refer to " C A R B U R E T O R " CHAPTER 6.
s e c t i o n in
1 2
Air shroud 1 A u t o l u b e delivery hose
4-1
ENGINE R E M O V A L
m m ENG ~)~,mm
7
[~m120Nm(12.0 m.kg, 87 ft.lb)
12
[~q45Nm(4.5m.kg,
31ft.lb)
\
//
Order
J o b name/Part name Spark plug cap Battery (-) lead C.D.I magneto leads coupler Starter m o t o r leads coupler Rear wheel nut
Q'ty 1 1 1 1 1
Remarks
NOTF" Loosen the rear wheel nut.
8 9 10 11 12 13
Rear brake adjuster Rear brake cable Pin Bolt Engine m o u n t bolt Engine Reverse the removal procesure for installation.
4-2
CYLINDER HEAD, CYLINDER A N D PISTON CYLINDER HEAD, CYLINDER A N D PISTON

C Y L I N D E R HEAD, C Y L I N D E R A N D P I S T O N
I ENG I~>]DI
18.2 ft.lb) I
~126Nm(2.6 m.kg,
10[]~
1 ..~ ~
9N m(0.9
'
H1,Nm(1.
2
m.kg, 10
ft.'bll
9 l 7
Order
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
Q'ty
Rema rks Remove the parts in the order.
1 2 3
4
5
6
7
8
9 10
1/1 1 1 1/1 1 2 1/1 1 1 1
Refer to the "ENGINE tion
REMOVAL"
Reverse the removal procedure for installation. 4-3
CV'..OE..EAO. OV'..OE.. P.STO. E"O Io .1 I

P I S T O N PIN A N D P I S T O N R E M O V A L 1. Remove: Piston pin clip ( ~ NOTE:
Before r e m o v i n g the p i s t o n pin clip, c o v e r the crankcase w i t h a clean rag so y o u w i l l not accid e n t a l l y d r o p t h e clip into the crankcase.
2.
Remove: Piston pin ( ~ Piston ~ ) Piston pin b e a r i n g ( ~
CAUTION:
Do not use a h a m m e r t o d r i v e t h e p i s t o n pin out.
CYLINDER HEAD INSPECTION 1. E l i m i n a t e : Carbon deposits Use a r o u n d e d s c r a p p e r (~.
2.
Inspect: C y l i n d e r head w a r p a g e Out of specification-->Re-surface.
I l aroaoe" 't"
W a r p a g e m e a s u r e m e n t and r e - s u r f a c e m e n t steps: A t t a c h a s t r a i g h t e d g e ( ~ and a t h i c k n e s s g a u g e ( ~ on the c y l i n d e r head. M e a s u r e the w a r p a g e limit.
0.03 m m ( 0 . 0 0 1 2 in)
If the w a r p a g e is o u t of s p e c i f i c a t i o n , reface the c y l i n d e r head. NOTE: Rotate the head severai tires to a v o i d r e m o v ing t o o m u c h material f r o m one side.
4-4
CYLINDER AND PISTON INSPECTION
I ENG I TDI
CYLINDER AND PISTON INSPECTION 1. E l i m i n a t e : Carbon deposits Use a r o u n d e d scraper (~. 2. Inspect: Cylinder wall Wear/Scratches-->Rebore or replace.
Eliminate: Carbon d e p o s i t s ( ~ From the piston grooves.
crown
and
ring
4.
5.
Remove: Score markes and lacquer d e p o s i t s From the sides of piston. Inspect: Piston w a l l Wea r/Scratches/Da m age-->Re place.
6.
Measure: Piston-to c y l i n d e r clearance
Piston to c y l i n d e r c l e a r a n c e m e a s u r e m e n t steps: First step: M e a s u r e the c y l i n d e r bore " C " w i t h a c y l i n der bore g a u g e . NOTE:
I~...~ / -----~ ~
M e a s u r e the c y l i n d e r bore " C " in parallel to and at r i g h t a n g l e s to the crankshaft. Then, find the a v e r a g e of the m e a s u r e m e n t s .
4-5
CYLINDER HEAD, CYLINDER A N D PISTON

Standard C y l i n d e r bore IJCF, Taper "T" O u t of r o u n d " R" C = aximum M T=( M a x i m u m D6 ) R=( M a x i m u m D4 or D6 )
I ENG I
Wear limit
40.10 m m (1.5787 in)
0.05 mm (0.0020 in)
40.000~40.014mm (1.5748~ 1.5754 in)

-
0.03 mm (0.0012 in)
D D1 o r D2 ) - M a x i m u m (
D5 or D2
D1 D3 or D5 ) - ( M a x i m u m
I l stnsze
I
If o u t o f s p e c i f i c a t i o n , r e b o r e or r e p l a c e cylinder, a n d r e p l a c e p i s t o n a n d p i s t o n r i n g s as a set. 2 n d step: M e a s u r e t h e p i s t o n skirt d i a m e t e r " p " w i t h a micrometer. ( ~ 10 m m f r o m t h e p i s t o n b o t t o m edge. 3 9 . 9 5 8 ~ 3 9 . 9 7 2 m m ( 1 . 5 7 3 1 ~ 1 . 5 7 3 7 in)
I
I
If o u t of s p e c i f i c a t i o n , replace p i s t o n a n d pist o n r i n g s as a set. 3rd step: Calculate the piston-to cylinder clearance with following formula: P i s t o n - t o c y l i n d e r c l e a r a n c e = C y l i n d e r bore I " C "- Piston skirt d i a m e t e r " p "
If o u t of s p e c i f i c a t i o n , r e b o r e or r e p l a c e cyli n d e r , a n d r e p l a c e p i s t o n a n d p i s t o n r i n g s as a set. Piston-to cylinder clearance: 0.035 - 0 . 0 4 0 m m (0.014 - 0.0016 in) L i m i t : 0.10 m m (0.0039 in)
4-6
OV'.OE..EAO. OV'..OE. AO P.STO. E"O IIo =1

PISTON R I N G S I N S P E C T I O N 1. Measure: Side clearance O u t of s p e c i f i c a t i o n - - > R e p l a c e a n d / o r rings. Use a feeler g a u g e ( ~
Standard T o p ring 2nd ring 0.03~0.05mm (0.0012 ~ 0.002 in) 0.03-0.05mm (0.0012 ~ 0.002 in) 2. Li m i t 0.1 m m (0.0039 in) 0.1 m m (0.0039 in) piston
Install: Piston ring Into the c y l i n d e r Push t h e ring w i t h the piston c r o w n .
Measure: End gap Out of specification-->Replace a set. Use a feeler g a u g e (~. Stand a rd
r i n g s as
Li m it 0.6ram (0.02 in) 0.6ram (0.02 in)
T o p ring 2nd ring
0 . 1 5 - 0.35 m m (0.005 ~ 0.01 in) 0.15~0.35mm (0.005 ~ 0.01 in)
( ~ M e a s u r i n g Point 20 m m ( 0 . 7 9 in)
PISTON PIN A N D P I S T O N PIN B E A R I N G 1. Inspect: Piston pin B l u e discoloration/Groove-->Replace, t h e n inspect l u b r i c a t i o n s y s t e m .
4-7
CV'..OE..EAO CV'..OE. A.O P.STO. E"O IIo '1

.
f
Measure: Outside d i a m e t e r (~ (piston pin) Out of specification-->Replace.
"2
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 d i a m e t e r (piston pin) Piston pin-to-piston clearance" I 0.004-0.019 mm(0.0016-0.00075 in <Limit: 0.07 mm>(0.003 in)
4.
Inspect: Bearing(piston pin) Pitting/Da m a g e ~ R e p l a c e .
P I S T O N PIN A N D P I S T O N I N S T A L L A T I O N
1.
Apply: Engine oil (to the crankshaft bearing, connecting rod big end bearing, small end bearing, piston pin, piston ring g r o o v e s and piston skirt areas.)
Install: Reed valve gasket Reed valve Carburetor joint (~ ~ l 11Nrn(1.1m.kg,
8ft.lb~
4-8
OV',.OE..EAO. CV',OE. A.O ,,StO. I E"O I0 '1

3. Install: Small end bearing Piston (~ Piston pin (~)
Q~
-, J
Piston pin clip ~) NOTE: The a r r o w (~ on the piston to the e x h a u s t side. Before installing the piston pin clip, cover the crankcase w i t h a clean towel or rag so you will not accidentally drop the pin clip material into the crankcase. A l w a y s use a n e w 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/
Install: Cylinder (~ NOTE: Install the cylinder w i t h one hand w h i l e compressing the piston rings w i t h the other hand.
3.
4-9
O*'.OE..EAO. C*'.OE. AO P.S*O. I' "0 I0 .1

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.
4-10
V-BELT, CLUTCH A N D V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE

KICK STARTER AND CRANKCASE COVER (LEFT)
12Nm(1.2m.kg, 8.4 ft.lb)~
4 ~
3
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 Kick starter and crankcase cover (left) removal Kick starter Crankcase cover 2 (left) Crankcase cover 1 (left) Gasket Pin
Q'ty
1 2 3 4 5
4-11
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE

KICK STARTER
I ENG
Order
J o b name/Part n a m e Kick starter r e m o v a l Crankcase c o v e r 1 (left) r e m o v a l Kickstarter p i n i o n gear Kickstarter p i n i o n gear clip Circlip/Plain w a s h e r Kickstarter s e g m e n t gear Return s p r i n g Collar
Q'ty
Remarks R e m o v e the parts in order.
(#
1 1 1/1 1 1 1 Reverse the r e m o v a l p r o c e d u r e for installation.
4-12
SECONDARY/PRIIVIARY SHEAVEI ENG I ~>= I

KICK S T A R T E R I N S T A L L A T I O N 1. Install: Return spring Kickstarter segment gear (~ Collar (~ Plain w a s h e r (~ Circlip (~
V-BELT, CLUTCH AND
Installation steps: a. Install return spring (~ and s e g m e n t gear (~ as s h o w n . b. Install clip (~. c. Hook the spring onto the crankcase projection (~. d. Install the kick starter pinion gear (~ and the kick starter.
4-13
V-BELT" CLUTCH AND I I~)~1 ENG SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE
3 2
t/~ / ~
<i
4 /
,~
~QI40 N m(4.0 m.kg,29ft.lb)
10
Order
8 ~
v
Q'ty
~145Nm(4.5m.kg,33ft.lb)
J o b name/Part name V-belt, clutch and s e c o n d a r y / p r i m a r y sheave removal Lower cowling Air s h r o u d 3 Crankcase cover (left) Clutch h o u s i n g S e c o n d a r y sheave a s s e m b l y V-belt Conical w a s h e r / O n e - w a y clutch Crow washer Primary fixed sheave Collar/Washer Primary sliding sheave Cam/Slider Weight
Remarks Remove the parts in order. ]Refer to "COVER A N D PANEL" section in chapter 3. Refer to "ENGINE R E M O V A L " section. -I Refer to "SECONDARY SHEAVE A N D VJ BELT REMOVAL " section.
-
1 2 3 4 5 6 7 8 9 10
1 1 1 1/1
1
Refer to " P R I M A R Y SHEAVE REMOVAL ASSE M BLY" section.
1 1/1 1 1/3 6 Reverse the removal procedure for installation 4-14
V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE

SECONDARY SHEAVE
I ENG
[~150Nm(5.0m.kg,
36ft.lb)
""-4
Order Job name/Part name Secondary sheave d i s a s s e m b l y Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave Q'ty 1 1 2 1 1 2 1 2 2 1 Remarks Disassemble the parts in order. Refer to "SECONDARY SHEAVE DISASS E M B L Y " section. Refer to " S E C O N D A R Y SHEAVE INS T A L L A T I O N " section. Refer to " S E C O N D A R Y S T A L L A T I O N " section. SHEAVE IN-
(# @
Reverse the d i s a s s e m b l y procedure for assembly.
4-15
S E C O N D A R Y / P R I M A R Y SHEAVE
/
V-BE'T" O'UTC" A"O I ENG Io =1

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 iyu_01235ngtool: hold 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: YU-01701
2. Remove: Clutch housing Secondary sheave assembly Dowel pins
4-16
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE

3.
I ENG I{ =l
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 r e m o v e the clutch securing nut yet. If the nut is r e m o v e d w i t h o u t c o m p r e s s i o n g the secondary sheave. It j u m p s and causes injury.
4. Attach: Clutch spring holder (~ I<~l 5. CI utch spring holder:ys_28891 Remove: Clutch securing nut (~)
6.
Remove: Clutch assembly (~ Clutch spring (~ Spring seat (~ Guide pins Secondary sliding sheave
CLUTCH I N S P E C T I O N
1. Inspect: Clutch shoes Glazed parts-->Sand with coarse sandpaper.

NOTE:
After using the sand paper, clean of the polished particles with cloth.
4-17

.
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 I N S P E C T I O N 1. Inspect: V-belt(~ Crack->Replace. NOTE:
Replace the V-belt smeared w i t h a lot of oil or grease. . Measure: V-belt w i d t h (~ Out of specification-->Replace. V-belt width" 16.6 mm(0.65 in) <Wear limit>: 14.6 mm(0.57 in)
~ 1
4-18

1.
i ENG
PRIMARY SHEAVE INSPECTION
Inspect: Primary sliding sheave (~ Primary fixed sheave (~) Wea r/Cracks/Scratch/Da mage -->Replace.
Check: Free m o v e m e n t Insert the collar (~into the p r i m a r y sliding sheave(~, and check for free movement. Stick or excessive p l a y - > R e p l a c e the sheave or collar.
Measure: Out side d i a m e t e r (~) (weight) Out of specification-->Replace. side d i a m e t e r (weight) 15.0 mm(0.59 in) <Limit 14.5 mm>(0.57 in)
----~Out
4-19

SECONDARY SHEAVE
I ENG
1.
Inspect: S e c o n d a r y fixed s h e a v e ( ~ Secondary sliding sheave (~
Scratch/Crack/Damage-->Replace
set. Oil seal ( ~ Da mage-->Replace
as a
Inspect: T o r q u e cam g r o v e ( ~ G u i d e pin (~) Wear/Damage-->Replace as a set. O - r i n g s (~) Damage-->Replace.
Measure: Clutch s p r i n g free l e n g t h Out of specification-->Replace. Clutch s p r i n g free length: 94 m m ( 3 . 7 in) <Limit>: 91 m m ( 3 . 5 8 in)
4.
Inspect: Clutch h o u s i n g i n n e r surface Oil/Scratches--~Remove. Oil Use a rag soaked in lacquer t h i n n e r or s o l v e n t . Use an e m e r y cloth ( l i g h t l y and e v e n l y p o l i s h i n g ) .
Scratches
Measure: Clutch h o u s i n g i n s i d e d i a m e t e r ( ~ Out of specification-->Replace. Clutch h o u s i n g inside d i a m e t e r : 105 m m ( 4 . 1 3 in) < W e a r limit>: 105.5 m m ( 4 . 1 5 in)
4-20

SECONDARY SHEAVE
I ENG I~=1
INSTALLATION
When assembling the secondary sheave, reverse the d i s a s s e m b l y procedure. Note the following 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 w h e n installing the sheave. 3. Apply: Lithium soap base grease (to the torque cam grooves and O-rings) Install: Guide pin (~ Check: Sliding sheave U n s m o o t h operation-->Repair.
4. 5.
Install: Clutch securing nut (~ Use clutch spring holder (~
c,utchs0r,n0ho,der l I s288
. Tighten: Clutch securing nut (~ I%~%150Nm(5.0 m.kg, 36 ft.lb) Use Flywheel holding tool
otorho,d,n0too, `0 o01
4-21

8.
I ENG
Install: Secondary sheave assembly Clutch h o u s i n g ( ~ V-belt (~)
NOTE:
The V-belt m u s t be i n s t a l l e d w i t h t h e a r r o w fro ntwa rd.
Tighten: Nut ( ~ (secondary sheave)
1~140 Nm(4.0 m.kg, 29 ft.,b)I

Use s h e a v e h o l d e r ( ~
Sheaveho'der:
YU-01701
PRIMARY SHEAVE
1.
Clean: P r i m a r y s l i d i n g s h e a v e face ( ~ P r i m a r y fixed s h e a v e face ( ~ Collar ( ~ Weight (~ P r i m a r y s l i d i n g s h e a v e cam surface (~)
Install: Weight (~ Cam@ Slider (~ Collar ( ~ Check: Cam o p e r a t i o n Not s m o o t h . R e p a i r . Install: Primary sheave assembly (~ Collar (~) Install: V-belt
4.
4-22

.
I ENG I%=I
/
J
Install: Shim (~ Primary fixed sheave ~) Washer (~ One-way clutch (~ Conical spring washer (~) Nut(~
. Tighten: Nut (~ (primary sheave) [%l 45 Nm(4.5 m.kg, 31ft.lb)

N O T E :
When tightening the nut (primary sheave), hold the C.D.I. magneto using Flywheel Holding Tool
~l
~tr ~ 'n t':~-01 h'd
Adjust: V-belt O Tense the V-belt by turning the primary sheave several times. Install: Fan
9.
~I
7 Nm
(0.7 m.kg, 5.1
~.,bl I
4-23
S T A R T E R CLUTCH A N D STARTER M O T O R S T A R T E R CLUTCH A N D STARTER M O T O R

~TARTER C L U T C H A N D S T A R T E R M O T O R 11
I ENG I~ll
~,
,10
9.4 ft.lb 4 3
Ns,ml0 8mk0.58,t,b
6
Order
Job name/Part name S t a r t e r clutch and s t a r t e r m o t o r removal Left/Right side cover Center cover Lower cowling Air shroud 3 Cooling fan Rear wheel Crankcase cover (left)l,2 Primary sheave
Q'ty
Refer to "COVERS A N D PANE L " section in chapter 3. Refer to "C.D.I. M A G N E T O

"
section
Refer to "REAR WHEEL" section in chapter 6. Refer to "KICKER STARTER " section. Refer to "V-BELT, PRIMARY SHEAVE " section.
1 2 3 4 5
Plate Plain w a s h e r Idle gear Plain w a s h e r Starter clutch 4-24
STARTERCLUTCH AND STARTERMOTOR I ENG I ~TDI

11
~.
.10
9.4 ft.lb 4 3
Ns.ml0.sm.k0.5.8 ft.,b
8
Order 6 7 8 9 10 11
Job name/Part name Gear boss Bearing Starter wheel gear Plate w a s h e r Starter m o t o r Starter m o t o r coupler
Q'ty 1 1 1 1 1 2
Remarks
Reverse the removal instalation
procedure for
4-25
STARTERCLUTCHAND STARTERIVIOTORI ENG I {~
STARTER CLUTCH AND GEARS INSPECTION 1. Inspect: Starter c l u t c h Push t h e d o w e l pin to a r r o w d i r e c t i o n . U n s m o o t h operation-->Replace starter clutch a s s e m b l y .
2. Inspect: Starter w h e e l gear teeth ( ~ Idle gear teeth (~) B rrs/C h ps/Ro u g ess/Wea r-->Re la ce. p u i h n
c::C> F~
3. Inspect: Starter clutch o p e r a t i o n Clutch o p e r a t i o n c h e c k i n g steps: Install the starter w h e e l gear to the starter clutch, and hold t h e starter clutch. W h e n t u r n i n g t h e w h e e l gear c l o c k w i s e [ ] the starter c l u t c h and the w h e e l gear s h o u l d be e n g a g e d . If not the starter c l u t c h is faulty. Replace it. W h e n t u r n i n g the w h e e l gear c o u n t e r clockw i s e [~], the w h e e l gear s h o u l d t u r n freely. If not, the starter c l u t c h is faulty. Replace it.
4-26
C.O.'."'"ETO ENO I O '1 I

C.D.I. M A G N E T O
.'.D.I. M A G N E T O .
,0i80
m(3.8 m.kg, 27 ft.lb) I
[ ~ 1 7 N m ( 0 . 7 m . k g " 5.1ft.lb) i 1
17Nm(0.7m.kg,
5.1 ft.I ) I
Order
Job name/Part name C.D.I. m a g n e t o r e m o v a l Rear c a r r i e r Tail c o v e r Left side c o v e r Right side cover Center cover Lower cowling Air shroud 1 Fan/O-ring Magneto rotor Bind C o u p l e r s ( m a g n e t o leads) S t a t o r coil W o o d ruff key Gasket ( M a g n e t o c o v e r )
Q'ty
R e m a r ks R e m o v e t h e parts in o r d e r .
Refer to " C O V E R A N D P A N E L " s e c t i o n in c h a p t e r 3.
1 2 3 4 5 6 7 8
1 1/1 1 1 1 1 1 1 R e v e r s e t h e r e m o v a l p r o c e d u r e f o r installation.
4-27
co, MAo.ETol E" I o --I

C.D.I. M A G N E T O REMOVAL
1.
Remove: N (~(roto r) ut Plain washer
NOTE:
Hold the rotor to loosen the nut bythe flywheel holding tool (~. I<~l 2. Rotor iyu_01235ng tool: hold Remove: Rotor O Wood ruff key Use the flywheel magneto puller (~. Flywheel puller: YU-01189 Stator assembly Gasket
C.D.I. M A G N E T O INSTALLATION
I<~l
1. 2.
3. 4. 5.
Install: Gasket (~ Apply: Lithium soap base grease (to oil seal) Pass the C.D.I. magneto lead through the crankcase hole. Install: Stator assembly[R e Nm(0.8 m.kg, 5.8 ft.lb) I 8 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'OBEPUMP I E"O I O '1

AUTOLUBE PUMPF ~
AUTOLUBE PUMP
JZ
// \
'~
,~314N m(0.4m.kg, 2.8ft.l~b)i /\ ' ~ 7
Order
Job name/Part name Autolube pump removal C.D.I. magneto Air shroud 2. Circlip Pump drive gear Pin Oil hose Oil delivery hose Autolube pump ass'y
Q'ty
Remarks Remove the parts in order. Refer to "C.D.I. magneto" section.
1 2 3 4 5 6 7
1 1 1 1 1 1 1
Refer to "Autolube pump installation" section Reverse the removal procedure for installation.
4-29
AUTOLUBE PUMP CAUTION:
I ENG I{~]DI
AUTOLUBE PUMP INSTALLATION
A f t e r installing a u t o l u b e p u m p , it m u s t be bleeded.
1.
Install Pin O P u m p d r i v e gear (~) Circlip ~ Apply: L i t h i u m soap base (to O-ring) Install: Autolube pump (~ Apply: L i t h i u m soap base (to a u t o l u b e p u m p
2.
grease
3. 4.
[~J4 Nm(0.4m.kg, 2.8ft.lb~ grease gear (~,(~)
15 cc (0.92 cu o in)
4-30
T.A.SM.SS.O. I E"O I o '1

TRANSMISSION
TRANSMISSION
/"
2 I~112N m(1.2 m.kg, 8.4ft.lb)
[~418Nm(1.8
m.kg,
13ft.lb
Order
Job name/Part name Transmission removal Rear wheel Secondary sheave Drain the transmission oil.
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, SECONDARY/ PRIMARY SHEAVE" section Refer to " T R A N S M I S S I O N OIL REPLACEMENT " section in chapter 3.
"
1 2 3
4
5
6
Transmission case cover Gasket (transmission case cover) Dowel pin Primary drive gear Drive gear Circlip Main axle
1 1 2 1 1 1 1
4-31
TRANSMISSIONI ENGI~>]DI
3
4/
I.~..~ ~
[~112Nm(1"2m'kg 8"4ft'lb:
[~'~11 8Nm(1.8 m.kg, 13ft.lb I
Order 8
J o b name/Part name Drive axle
Q'ty 1
Remarks Reverse the r e m o v a l p r o c e d u r e for installation.
4-32
C R A N K C A S E A N D REED V A L V E C R A N K C A S E A N D REED V A L V E
C R A N K C A S E A N D REED V A L V E
I ENG I TDI
~19Nm(0.9m.kg,6.5ft.lb)l ~112Nm(1.2m.kg,8.4ft.lb) I
1 1 N m ( 1 1 m kg,8ft Ib) I
~
Order
3 J"
j,
j - J
J o b name/Part n a m e Crankcase a n d Reed valve r e m o v a l Engine removal C y l i n d e r head, c y l i n d e r , p i s t o n Crankcase c o v e r (left) V-belt, clutch, secondary/primary sheave C.D.I. m a g n e t o Starter clutch, starter m o t o r Autolube pump Rear w h e e l Transmission
Q'ty
R e m a r ks R e m o v e the parts in order. Refer to " E N G I N E R E M O V A L " section. Refer to "CYLINDER HEAD CYLINDER A N D PISTON" section. Refer to " K I C K STARTER A N D CRANKCASE COVER (LEFT) " section. Refer to "V-BELT, CLUTCH A N D SECO N D A R Y / P R I M A R Y SHEAVE " section. Refer to "C.D.I. M A G N E T O " section. Refer to "STARTOR CLUTCH AND STARTOR M O T O R " section. Refer to " A U T O L U B E P U M P " section. Refer to " R E A R W H E E L A N D REAR BRAKE" section in c h a p t e r 6. Refer to " T R A N S M I S S I O N " section.
4-33
CRANKCASE AND REEDVALVE
I ENG I >]DI
~19Nm(0.9m.kg,6.5ft.lb)l
~ 1 1 2 N m ( 1 . 2 m . k g , 8.4ft.lb) I
11Nm(1 l m kg,8ft Ib) I
~
Order 1 2 3
4
3 J"
j.
j-J
Job name/Part name Intake manifold Reed valve Valve seat gasket Stopper Crankcase 2 Dowel pin Engine m o u n t spacer Circlip Bearing Oil seal
Q'ty 1 1 1 1 1 2 1 1 1 1
Remarks
5
6
7
8 9
10
4-34
O.AKOASEAO.EEOVA'VE I E"O Io =1
CRANKCASE(RIGHT) REMOVAL
Remove: Oil seal s t o p p e r (~ Screws ( c r a n k c a s e ~ 19Nm(0.9 m.kg,6.5ft.lb ! NOTE:

=~r~ri
1.
Loosen each s c r e w 1/4turn, and remove t h e m after all are loosened.
2.
Attach: Crankcase separating tool (~ CrankcaSeyu_01135se rating tool: pa I
I<~l
NOTE:
Fully tighten the tool holding bolts, but make sure the tool b o d y is parallel w i t h the case. If n e c e s s a r y , o n e s c r e w m a y be b a c k e d o u t slightly to level tool body. . Remove Crankcase (right) As pressure is applied, alternately tap on the engine m o u n t i n g bosses.
C H E C K I N G THE C R A N K C A S E
4-35
T h o r o u g h l y w a s h the crankcase halves in a mild solvent. 2. T h o r o u g h l y clean all the gasket surfaces and crankcase mating surfaces. 3. Check: crankcase Cracks/damage --> Replace. oil delivery passages O b s t r u c t i o n --> B l o w o u t w i t h c o m pressed air. C H E C K I N G THE B E A R I N G S A N D OIL SEALS 1. Check: bearings Clean and lubricate the bearings, then rotate the inner race w i t h y o u r finger. Rough m o v e m e n t --> Replace. 2. Check: oil seals D a m a g e / w e a r ~ Replace.
1.
C R A N K C A S E A N D REED V A L V E
1.
I ENG I TDI
REED V A L V E I N S P E C T I O N
Measure: Valve stopper height (~ Out of specification-->Adjust stopper/Replace valve stopper. Valve stopper height (~ 6.0~6.4 mm(0.24~0.25 in)
I ~ l
lReedvavecearance I I
Less than 0.2 mm(0.0079 in)
C R A N K C A S E (RIGHT) I N S T A L L A T I O N
. Measure: Reed valve clearance @) Out of specification-->Replace va lye.
reed
Install: Dowel pins (~ Engine mount spacer (~ 2. Apply: Sealant (~) To the mating surfaces of both case helves. ~ 1
NOTE:
1.
Quick gasket: ACC-1100-15-01
Do not allow any sealant to come into contact with the oil galley.
-ii -I;
" I
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. Tighten: Crankcase holding screws [ ~ l 12 Nm(1.2 m.kg,8.4 ft.lb) I
NOTE:
T i g h t e n t h e c r a n k c a s e h o l d i n g s c r e w s in stage, using a crisscross pattern.

,4
5.
6.
Check: Crankshaft operation Unsmnothoperation Install:
Repair.
Oil seal ( r i g h t c r a n k case) ( ~ A p p l y g r e a s e on to oil seal lip.
Install: Oil seal s t o p p e r plate ( ~
.ml09 9
m.kg, 6.5
ft.lb)
Install: Gasket Reed v a l v e Intake m a n i f o l d (~I~111 Nm(1.1
m.kg,
8 ft.lb)
4-37
KS.AFT I ENO I O ,,I

CRANKSHAFT
CRANKSHAFT
Order
Job name/Part name Crankshaft removal Right crankcase r e m o v a l
Q'ty
R e m a r ks R e m o v e the parts in order. Refer to " C R A N K C A S E A N D V A L V E " section. REED
1 2 3 4
Crankshaft Bearing Oil seal Crankcase c o v e r (left)
1 2 2 1 Reverse the r e m o v a l p r o c e d u r e for instal lation.
4-38
KS.AFT I E"O I o '1

CRANKSHAFT REMOVAL 1. Attach: Crankcase s e p a r a t i n g tool ( ~ ~ l Crankcase s e p a r a t i n g t o o l : YU-01135-A
Remove: Crankshaft (~ NOTE: Make sure the crankcase s e p a r a t i n g tool is centered o v e r t h e c r a n k s h a f t a s s e m b l y .
2.
CRANKSHAFT INSPECTION 1. Measure: Runout limit " C" C o n n e c t i n g rod big end side clearance
iJ g rr
--H ~-- D
Small end free play l i m i t " F " Out of specification-->Replace. Use V-blocks, dial g a u g e and t h i c k n e s s gauge. Runout limit "C": 0.03 m m ( 0 . 0 0 1 2 in) C o n n e c t i n g rod big end side clearance " D " : 0.2 ~ 0.5 m m ( 0 . 0 0 7 9 ~ 0.020 in) Small end free play " F ' : 0.4 ~ 0.8 m m ( 0 . 0 1 6 ~ 0.031 in) 2. Inspect: B e a r i n g s (crankshaft) Spin the b e a r i n g i n n e r race. Excessive play/Ro ugh n ess-->Replace. Pitting/Da mage--~Replace.
4-39
CRANKSHAFTI ENGI{ ll
CRANKSHAFT INSTALLATION 1. Attach: Crankshaft Installing Tool
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 w i t h grease and each bear-ing w i t h engine oil. NOTE: Hold the connecting rod at t o p dead center (TDC) w i t h one hand w h i l e t u r n i n g the nut of the crankshaft installing tool w i t h the other. Turn the crankshaft installing tool until the crankshaft assembly b o t t o m s against the bearing. .
i ~ P
Install: Oil seal (~ A p p l y lithium soap base grease onto the oil seal lip. Use the guide (~ and seal d r i v e r ~) to install the oil seal Oil seal driver YM-1410 Oil seal guide YM-1409
4-40
CARBURETION
CARBURETOR
1
Order Job name/Part name Carbu retor removal Battery b o x cover Grip End cover Left/Right cover Center cover Air cleaner case a s s e m b l y A u t o choke lead coupler Fuel hose/vacuum hose Oil delivery pipe a s s e m b l y Carburetor Throttle cable Q'ty
k l 9 N m l 0 . 9 m.kg, 6.5 ft.lb) I

R e m a r ks
Remove the parts in order.
Refer to "COVER A N D PANEL" section in CHAPTER 3.
1 2 3 4 5 6
5-1

CABURETOR DISASSEMBLY
'
~,_ .~'~
Order Job name/Part name Carburetor d i s a s s e m b l y Throttle cable Throttle valve Needle set Carburetor top cover/o-ring Throttle stop screw A u t o choke unit assembly Float chamber/Seal ring Float pin Float/Needle valve Main jet Pilot jet Main nozzle Carburetor b o d y Q'ty 1 1 1 1 1 1 1/1 1 1 1 1 1 1 Reverse the removal procedure for installation. Remarks Disassemble the parts in order.
O @ @ @
5-2
O'"'O"'TO" Ic""'l V
CABURETOR INSPECTION
1.
Check: Carburetor b o d y Float c h a m b e r Jet housing Cracks/damage --> Replace.
2.
Check: Fuel passages Obstruction --~ Clean.
a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets w i t h compressed air. 3. Q 4. Check: Float c h a m b e r b o d y Dirt --> Clean. Check: Float c h a m b e r rubber gasket Cracks/damage/wear --> Replace. Check: Float Damage --> Replace. Check: Needle valve O D a m a g e / o b s t r u c t i o n / w e a r --~ Replace the needle valve.
5.
Check: Throttle valve ( ~ Damage/scratches/wear--> Replace.
5-3
OA"BO"ETO" ICA"BI
.
Check: Jet n e e d l e kit ( ~ M a i n nozzle ~ ) M a i n jet ( ~ Pilot jet ( ~ B e n d s / d a m a g e / w e a r --> Replace. O b s t r u c t i o n --> Clean. B l o w o u t the jets w i t h c o m p r e s s e d air.
9.
Check: Throttle valve movement Insert the t h r o t t l e v a l v e into t h e c a r b u retor B o d y and m o v e it up and d o w n . T i g h t n e s s --> Replace the p i s t o n valve. 10. Check: V a c u u m hose Fuel hose C r a c k s / d a m a g e / w e a r --> Replace. O b s t r u c t i o n --> Clean. B l o w o u t t h e hoses w i t h c o m p r e s s e d air.
11. M e a s u r e : Float h e i g h t (~) Out of specification-->lnspect needle v a l v e , float and v a l v e seat.
Feathe0ht
* * * * * * * * * * * * *
15 - 17 m m (0.59 ~ 0.67 in)

* * * * * * * ~ ~ ~ ~ ~
I
~ ~ ~ ~
Float height measurement
steps:
Install the n e e d l e v a l v e , float and float pin to the c a r b u r e t o r body. Hold the c a r b u r e t o r in an u p s i d e d o w n position. M e a s u r e the d i s t a n c e b e t w e e n t h e m a t i n g s u r f a c e o f t h e f l o a t c h a m b e r ( g a s k e t rem o v e d ) and t o p of t h e float u s i n g a g a u g e .
5-4
CARBURETOR
NOTE:
Ic..,I
The float arm should be resting on the needle valve, but not compressing the needle valve. If the float height is not w i t h i n specification, inspect the needle valve, float and valve seat. If it is w o r n , 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 disass e m b l y procedures. Note the f o l l o w i n g points.
CAUTION:
Before r e a s s e m b l i n g , w a s h all parts in clean gasoline. A l w a y s use a n e w gasket.
5-5
OA"BU"ETO" IOA"BI V
1. Install: T h r o t t l e cable ( ~
Install: Carburetor assembly NOTE: A l i g n the p r o j e c t i o n ( ~ w i t h t h e p r o j e c t i o n s @ .
2.
FUEL LEVEL A D J U S T M E N T 1. Measure: Fuel level ( ~ Out of specifications-->Adjust. Fuel level (~: 3.0~4.0 m m ( 0 . 1 2 ~ 0 . 1 6 in) ( B e l o w the float c h a m b e r line)
M e a s u r e m e n t steps: Place the s c o o t e r on a level surface. Use a g a r a g e jack u n d e r the e n g i n e to ensure that t h e c a r b u r e t o r is p o s i t i o n e d v e r t i cally. C o n n e c t the fuel level g a u g e ( ~ to the d r a i n pipe (~. Fuel level g a u g e : YM-01312-A Loosen t h e d r a i n s c r e w ~). M e a s u r e the fuel level ( ~ w i t h the gauge. If the fuel level is incorrect, a d j u s t t h e fuel level: R e m o v e t h e f l o a t c h a m b e r f l o a t and t h e needle v a l v e . Inspect the needle valve. If it is w o r n , replace it. 5-6
Install the c a r b u r e t o r . Recheck the fuel level.

* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
AUTO CHOKE INSPECTION (Ambient temperature lower than 45C) 1. Remove: Carburetor 2. Inspect: Autochoke unit C o n n e c t a s u i t a b l e hose ( ~ to t h e starter (~, a n d b l o w it w i t h t h e m o u t h etc. Possible--~Good c o n d i t i o n . Impossible-->Replace auto choke unit. 3. Inspect: A u t o choke unit (with battery)
I n s p e c t i o n and a d j u s t m e n t steps: C o n n e c t a u t o choke u n i t leads to t h e 12 V b a t t e r y for 5 m i n u t e s . Black terminal-->12 V b a t t e r y (+) ( ~ Black terminal-->12 V b a t t e r y (-) ( ~ C o n n e c t a s u i t a b l e hose ( ~ to t h e starter (~), and b l o w it w i t h the m o u t h etc. Possible-->Replace auto choke unit. Im possible-->Good c o n d i t i o n .
5-7
CA"BO"ETO" IOA"BI V
FUEL COCK INSPECTION
1. 2. Stop the engine. Remove: Rear c a r r i e r Tail c o v e r Left s i d e c o v e r Battery box cover R e f e r to " C O V E R A N D P A N E L " s e c t i o n in c h a p t e r 3. Inspect: Fuel c o c k
3.
Fuel cock inspection steps:

D i s c o n n e c t t h e fuel h o s e (~. Place t h e r e c e p t a c l e u n d e r t h e fuel h o s e e n d . If fuel s t o p s f l o w i n g o u t in a f e w s e c o n d s , t h e fuel cock is in g o o d c o n d i t i o n . If not, clean or r e p l a c e t h e fuel cock. Disconnect the vacuum hose ~)and breathe in t h e v a c u u m h o s e w i t h t h e m o u t h etc. f o r vacuum . If f u e l f l o w s o u t o f t h e f u e l h o s e u n d e r vacuum and stops under non-vacuum, the fuel c o c k is in g o o d c o n d i t i o n . If not, clean o r r e p l a c e t h e v a c u u m hose, fuel h o s e a n d fuel cock.
* * * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~
4.
Install: Battery box cover Left s i d e c o v e r Tail c o v e r Rear c a r r i e r
5-8
F.OT W.EEL A.O B.AKE O.SC IC"ASI

CHASSIS F R O N T W H E E L A N D BRAKE DISC
oI
4 _ _
~--/~
/1
-'~'I~.~.~I7~N
m (0.7 m.kg, 5. lft.i b) '
,/
~ " ' - ~ %~ZJ70 Nm(7 m.kg,
b)l lft.I 5
~1-O" Order
.0
g,.
.5ft.lb) I Q'ty
~ R e m a r ks Remove the parts in order.
Job name/Part name Front wheel and brake disc removal
~WARNIN(
S e c u r e l y s u p p o r t t h e s c o o t e r so t h e r e is no d a n g e r of it falling over.
1 2 3
4
5
6
7 8
Speedometer cable Front brake hose holder Brake caliper Wheel axle Front wheel assembly Gear unit assembly Collar Brake disc
1 1 1 1 1 1 1 1
Refer to "FRONT WHEEL INSTALLATION" section. Refer to "FRONT WHEEL ASSEMBLY" section. Reverse the removal procedure for installation.
6-1
FROOT W.EEL AO0 BRAKE O,SC IC"ASI

FRONT WHEEL DISASSEMBLY
oI
Order
Job name/Part name Front wheel disassembly Oil seal Bearing Collar Spacer Bearing
Q'ty
1 m
Remarks Remove the parts in order. Refer to "FRONT WHEEL DISASSEMBLY/ASSEMBLY" section.
(#
1 1 1 1 -
6-2
F.OOT W.EE. AO0 B.A.E O.SC IC'ASI

f f f YP ......
f
oI
FRONT W H E E L D I S A S S E M B L Y 1. Remove: Bearing ( ~ Spacer Remove the bearing using a general bearing p u l l e r (~).
CAUTION:
Handle the wheel w i t h care not to d a m a g e the brake disc. If the brake disc is d a m a g e d , replace.
YP700020
FRONT W H E E L INSPECTION 1. Inspect: Front w h e e l axle (by r o l l i n g it on a flat surface) Bends-->Replace. W!~VAV/I -'| ~ I [']1 I ~ Do not a t t e m p t to straighten a bent wheel axle.
I l heeaxe endn0
2.
0.25 m m (0.0098 in)
3.
Inspect: Front tire Wea r/da mag e--~ Re place. Refer to "TIRE INSPECTION" in CHAPTER 3. Front w h e e l R e f e r t o " W H E E L I N S P E C T I O N " in CHAPTER 3. Measure: Front w h e e l r u n o u t O v e r the specified limits--~Replace. Front w h e e l r u n o u t limits: Radial (~: 1.0 m m (0.04 in) Lateral ( ~ " 1.0 m m (0.04 in)
4.
Inspect: Front w h e e l b e a r i n g s B e a r i n g s a l l o w free p l a y in the w h e e l hub or the wheel does not turn s m o o t h l y - - > Replace. Oil seals W e a r / damage-->Replace.
6-3
F.OT W.EE. AO B.A.E O.SO IC"ASI

4.
oI
Inspect: Collar Grooved wear-->Replace the collar and the oil seal as a set.
Ye
.....
BRAKE DISC I N S P E C T I O N 1. Measure: Brake disc deflection(~
I ~ 1
M a x i m u m 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) M i n i m u m thickness: 3.5 mm(0.14 in) Out of specification-->Replace.
Ye
.....
FRONT WHEEL ASSEMBLY 1. Install: Bearing (~ Collar @~) Spacer (~) Bearing (~ Oil seal (~ NOTE:
A p p l y the lithium soap base grease on the bearing and oil seal lip w h e n installing. Use a socket that matches the outside diameter of the race of the bearing. A l w a y s use a n e w oil seal. Install the oil seal w i t h its m a n u f a c t u r e r ' s marks or numbers facing o u t w a r d .
CAUTION:
Do n o t strike t h e inner race of balls of t h e bearing. C o n t a c t s h o u l d be m a d e only w i t h t h e outer race.
6-4
F.OT W . E E . . O
2.
B . . . E O.SO IC"ASI
Install: Brake disc O H
oI
14
20 Nm~20 ~k~,
ft.lb)
i
@
NOTE: T i g h t e n the bolts (brake disc) in stage u s i n g a c r i s s c r o s s pattern.
EB700030
FRONT WHEEL INSTALLATION Reverse the " R E M O V A L " p r o c e d u r e . Note t h e f o l l o w i n g points. 1. Lubricate: Front w h e e l axle Bearings Oil seal (lips) D r i v e / d r i v e n gear ( s p e e d o m e t e r ) Recommended lubricant: L i t h i u m soap base grease Install: S p e e d o m e t e r gear u n i t ( ~ NOTE: Make sure t h a t t h e w h e e l h u b and the speedo m e t e r gear unit are installed w i t h the t h r e e p r o j e c t i o n s m e s h e d into the t w o slots. Install: Front w h e e l NOTE: Make sure that the slot in the s p e e d o m e t e r gear unit fits o v e r the s t o p p e r on the f r o n t f o r k o u t e r tube. 4. Tighten: Front w h e e l axle ( ~ A x l e nut (front w h e e l axle) 3. 2.
70
NmCT0 51 "'btl m.kg,
CAUTION:
Before t i g h t e n i n g t h e axle nut, stroke t h e front fork several t i m e s to check for proper fork operation,
WARNING
M a k e sure t h a t t h e brake hose is r o u t e d properly. 6-5
F.OOT W . E E . . O 0 B . . . E O.SO IONASI

YP700040
oI
WHEEL STATIC BALANCE ADJUSTMENT NOTE:

After replacing the tire and/or rim, the wheel static balance should be adjusted. A d j u s t the front wheel static balance with the brake disc installed. 1. 2. Remove: Balancing w e i g h t Set: Wheel (on a suitable stand) Find: Heavy spot
3.
Procedure: a. Spin the wheel and w a i t for it to rest. b. Put an "X~" mark on the w h e e l ' s b o t t o m 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 " X 2 " mark on the w h e e l ' s b o t t o m spot. e. Repeat the above b., c., and d. several times until all marks come to the same spot. f. This spot is the w h e e l ' s heavy spot " X " .
4.
Adjust: Wheel static balance
A d j u s t i n g steps: Instail a balancing w e i g h t (~ on the rim exactly opposite to the heavy spot " X ' . NOTE: Start w i t h 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 w e i g h t until the wheel is balanced.
6-6
F.OOT W.EE. AOO B.A.E O.SC IC"ASI

X
*
oI
* ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
5.
* *
Check: W h e e l static balance

* * * * * * * * * * * * * * * *
Checking steps: T u r n the w h e e l so t h a t it c o m e s to each p o i n t as s h o w n . C h e c k t h a t the w h e e l is at rest at each point. If not, readjust the f r o n t w h e e l static balance.
6-7
F.OT B.AKE IC"ASI

F R O N T BRAKE
BRAKE PAD
oI
~
~
Order 1 2 3 4 J o b name/Part n a m e Brake pad r e m o v a l Caliper s u p p o r t bolt Caliper Brake pad Pad s p r i n g
H3 m3 2N (. 2
~ ~
Q'ty
m.kg, 16.6 ft.lb) I
[~423NmI2.3 16.6 I m.kg, ft.lb)

R e m a r ks
R e m o v e the parts in order. BRAKE PAD R E P L A C E M E N T 1 --I Refer to 1 J section . 2 2 Reverse the r e m o v a l p r o c e d u r e for installation.
" "
6-8
F.ONT B.A.E IC"ASI

CAUTION:
oI
Disc b r a k e c o m p o n e n t s r a r e l y r e q u i r e disass e m b l y . DO NOT: Disassembly components unless absolutely necessary. Use s o l v e n t s in i n t e r n a l brake c o m p o n e n t . Use c o n t a m i n a t e d b r a k e f l u i d for c l e a n i n g . Use o n l y clean fluid. A l l o w brake f l u i d t o c o m e in c o n t a c t w i t h t h e eyes o t h e r w i s e eye i n j u r y m a y occur. A l l o w brake f l u i d t o c o n t a c t p a i n t e d surfaces or p l a s t i c p a r t s o t h e r w i s e d a m a g e m a y occur. Disconnect any hydraulic connection otherw i s e t h e e n t i r e s y s t e m m u s t be disass e m b l e d , drained, cleaned, and then properly filled and bled after reassembly.
BRAKE PAD R E P L A C E M E N T NOTE:

It is not n e c e s s a r y to d i s a s s e m b l e the brake c a l i p e r and brake h o s e to replace t h e brake pads. Loosen: Retaining bolt ( ~ 2. Remove: Brake caliper (~) H o l d e r (brake hose) ( ~ 3. Remove: Retaining bolt Pads ( ~ Pad s p r i n g ( ~ NOTE: R e p l a c e t h e pad s p r i n g i f t h e pad r e p l a c e m e n t is r e q u i r e d . Replace the pads as a set if e i t h e r is f o u n d to be w o r n to t h e w e a r limit. 1.
WearJmJt(0.03 in) 0.8 m m
6-9
,.oT B.AKE Ic"AsI

4. Install: Pad springs Brake pads (new)
ol
Installation steps: Connect a suitable hose (~ t i g h t l y to the caliper 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 y o u r finger. Tighten the capliper bleed screw.
/ i
H ~ (0.~ ~.k~, 4.3 ~.'~ i ~ Install the pad spring (new) and brake pad (new) (~ Tighten retaining bolt (~ ~ 1 2 3 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)
5. Inspect: Brake fluid level Refer to the "BRAKE FLUID INSPECTION" section in the CHAPTER 3. (~ "LOWER" level line
t
6-10
F.O.T B.A.E IC"ASI

.
oI
Check: Brake lever o p e r a t i o n A s o f t y or s p o n g y feeling Bleed-->brake system. AIR BLEEDING " section in Refer to the CHAPTER 3.
"
6-11
F.OT B.AKE IC"ASI

MASTER CYLINDER
oI
l~120Nm(2.0m.kg, 14 ft.lb)
Order
J o b name/Part n a m e Master cylinder removal Drain the brake f l u i d
Q'ty
Remarks R e m o v e the parts in order. R e f e r t o " B R A K E F L U I D REPLACEM E N T " section in CHAPTER 3.
1 2 3 4 5 6 7
Brake l e v e r / c o m p r e s s i o n s p r i n g Brake s w i t c h U n i o n bolt Copper washer Brake hose M a s t e r c y l i n d e r bracket Master cylinder
1/1 1 1 2 1 1 1
Refer to " M A S T E R CYLINDER INSTALL A T I O N " section.
Reverse the r e m o v a l p r o c e d u r e for installation.
6-12
F.OT B.AKE IC"ASI

M A S T E R CYLINDER D I S A S S E M B L Y
oI
Order
Job name/Part name Master cylinder disassembly Master cylinder boot Circlip M a s t e r c y l i n d e r kit Spring
Q'ty 1 1 1 1 -
R e m a r ks R e m o v e the parts in order. Refer to " M A S T E R CYLINDER A S S E M B L Y " section. Reverse the d i s a s s e m b l y p r o c e d u r e for assembly.
6-13
F.ONT B.A.E IC"ASI

YP702040
oI
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.
Y P .....
MASTER CYLINDER A S S E M B L Y
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: 90890-01996 6-14 I
F.O.T B.A.E IC"ASI

.
oI
Install: Spring (~ Install the s p r i n g w i t h its s m a l l e r d i a m eter to the m a s t e r c y l i n d e r piston. M a s t e r c y l i n d e r kit ( ~
Install: Circlip (~) Install the circlip s e c u r e l y into the master c y l i n d e r g r o o v e . M a s t e r c y l i n d e r boot ( ~
Ye
.....
MASTER CYLINDER INSTALLATION 1. Install: Master cylinder (~ M a s t e r c y l i n d e r bracket ( ~ ~ l 9 Nm (0.9
m.kg, 6.5 ft.lb)
CAUTION:
Install the master cylinder bracket ( ~ w i t h the " U P " m a r k ~ facing u p w a r d . Align the end of the holder w i t h the punch m a r k b on the handle bar.
6-15
F.O.T B.A.E IC"ASI

2.
oI
Air bleed: Brake s y s t e m Refer to " A I R B L E E D I N G " s e c t i o n in CHAPTER 3.
r!~vAvg_,W --']~ I [-] I ~

Use o n l y d e s i g n a t e d q u a l i t y brake fluid: O t h e r w i s e , t h e r u b b e r seals m a y d e t e r i o r a t e , causing leakage and poor brake perforrmance. Refill w i t h t h e s a m e t y p e of brake f l u i d : M i x i n g f l u i d s m a y r e s u l t in a h a r m f u l c h e m i cal r e a c t i o n a n d lead t o p o o r p e r f o r r m a n c e . Be careful t h a t w a t e r d o e s n o t e n t e r t h e sign i f i c a n t l y l o w e r t h e b o i l i n g p o i n t of t h e f l u i d m a y r e s u l t in v a p o r lock. 3. Inspect: Brake o p e r a t i o n
6-16
F.O.T..AKE IC"ASI oI
CALIPER lh%123Nm(2.3 m.k,g, 16.6
ft.lb)l
........
i .......
Order
Job name/Part name Caliper removal Drain the brake fluid
Q'ty
Remarks Remove the parts in order. Refer t o " B R A K E F L U I D REPLACEM E N T " section in CHAPTER 3.
1 2 3 4 5
Union bolt Copper w a s h e r Brake hose Caliper s u p p o r t bolt Caliper assembly
1 2 1 1 1
Refer to "CALl PER INSTALLATION" section.
6-17
F.OT B.AKE IC"ASI

CALIPER D I S A S S E M B L Y
oI
~ ~ ~ j~J'~
[~0"6m~
"4"3ft'lb) l
Order
Job name/Part name Caliper disassembly Caliper bracket Brake pad Pad spring Caliper piston Dust seal Piston seal Bleed screw
Q'ty 1 2 2 1 1 1 1
R e m a r ks Remove the parts in order. Refer to "BRAKE CALIPER --I BLY/ASSEMBLY" section.
(# @
DIS
Reverse the disassembly procedure for assembly.
6-18
F.ONT B.A.E IC"ASI

YP702020
oI
BRAKE CALIPER D I S A S S E M B L Y 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: B l o w c o m p r e s s e d air into the hose joint opening to force out the caliper piston from the brake caliper body.
~!~LVAV/_'I-"] ~ I ['] I ~ N e v e r try to pry out the caliper piston. Cover the caliper piston w i t h a rag. Be careful not to get injured w h e n the piston is expelled from the m a s t e r cylinder.
CAUTION:
Carefully r e m o v e 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. R e m o v e seals by your finger. Do not re-use r e m o v e d parts.
YP...
CALIPER I N S P E C T I O N 1. Inspect: Caliper cylinder Caliper piston ~) Scratches, wear--~Replace caliper assembly.
6-19
F.O.T B.A.E IC"ASI

EB702050
oI
BRAKE CALIPER ASSEMBLY
r!~vAvg_,1--'t~ I [-! I ~
All i n t e r n a l brake c o m p o n e n t s s h o u l d be cleaned and lubricated w i t h n e w brake fluid o n l y before installation.
DOT #4(or DOT #3)

Replace the caliper piston seals w h e n e v e r a
brake caliper is disassembled. 1. Install: Piston seal (~ Dust seal (~
O( )
2. Install: Caliper piston (~ A p p l y brake fluid to the outer surface and install.
CAUTION:
Do n o t force. Use care t o p r e v e n t damage on caliper piston.
Y P .....
BRAKE CALIPER INSTALLATION
1. Install: Caliper (~ Caliper s u p p o r t bolt
P~123Nm(2.3m.kg, 16.6ft.lb) I
Brake hose (~) Copper w a s h e r (~ Union bolt (~ H 25Nm(2.5 m.kg,18ft.lb) I
CAUTION:
When installing the brake hose t o the caliper, l i g h t l y t o u c h t h e brake hose w i t h t h e s t o p p e r (~ on t h e caliper.
6-20
, E , , w.EE, A 0 , E , ,
REAR WHEEL AND REAR BRAKE
REAR W H E E L
=,,KE IC"A=I
oI
<
2 [;;l~i~]((;16~i:18:8f.?liilb)~" 1 Order J o b name/Part name Rear w h e e l and rear brake removal Q'ty Remarks Remove the parts in order. NOTE" Place the scooter on a suitable atand so that the rear wheel is elevated. 1 2 3 4 Muffler assem bly/Gasket Nut/Plain w a s h e r Rear w h e e l a s s e m b l y Plain w a s h e r 1/1 1 1 1 Reverse the d i s a s s e m b l y procedure for installation.
6-21
,E,, w,EE,,.o,EA,
REAR BRAKE
B,AKE IC"Asl
kllONm(1.0
m.kg,
7.2 ft.lb) I
./
t3
Order 1 2 3 4 5 6 7 8
Job name/Part name Adjuster Brake cable Pin Return s p r i n g Brake shoe C a m s h a f t lever Wear indicator Brake c a m s h a f t
Q'ty 1 1 1 1 1 1 1 1
Remarks
Reverse the r e m o v a l p r o c e d u r e for installation.
6-22
.EA. W.EE" A.O .EA. B.A.E I C"Asl

EB701020
REAR W H E E L I N S P E C T I O N 1 Inspect: Rear w h e e l axle Rear w h e e l Rear w h e e l b e a r i n g s Oil seals Refer to " F R O N T WHEEL". 2. Measure: Rear w h e e l r u n o u t Refer to " F R O N T W H E E L " .
EB701021
REAR BRAKE I N S P E C T I O N 1. Inspect: Brake l i n i n g surface Glazed areas-->Polish. Use coarse sand paper. NOTE: After p o l i s h i n g , w i p e the polished particles w i t h a cloth. 2. Measure: Brake l i n i n g t h i c k n e s s ( ~ Brake l i n i n g t h i c k n e s s ( ~ Standard: 4 m m (0.16 in) Limit: 2 m m (0.08 in)
~ 1
Out of specification-->Replace. Measuring points " t " NOTE: Replace the brake s h o e s as a set, if e i t h e r is w o r n to the w e a r limit.
Measure: Brake d r u m i n s i d e d i a m e t e r ( ~ Out of specification-->Replace the w h e e l Brake d r u m i n s i d e d i a m e t e r : Standard: 130 m m (5.12 in) Limit: 131 m m (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 t h i n n e r or solvent. Scratches Use an e m e r y cloth (lightly and e v e n l y polishing) Inspect: Cam shaft face. Wea r-->Replace.
5.
W h e n inspecting t h e brake lining, do not spill oil or grease on t h e brake lining,
Ye
.....
REAR BRAKE I N S T A L L A T I O N 1. Install: Camshaft (~ Indicator plate (~
Installation steps: Set the camshaft w i t h its punched mark (~ facing the direction as shown. Align the projection @ on the indicator plate w i t h the camshaft notch and install. C h e c k t h e proper position of the brake shoe.
Install: Camshaft l e v e r ( ~ NOTE:
2.
r~ll0Nm(1.0 m.kg,7.2ft.lb~
Set the camshaft w i t h its punched m a r k ( ~ facing the direction on the cam shaft lever @.
6-24
HAOOLE.,. IONASI oI
HANDLEBAR
HANDLEBAR
~;~19Nm(0.9 m.kg, 6.5 5 ,)
ft.lb) I
1~143Nm(4.3 m.k 9, 37 ft.lb) I . 8
10
t-,,.,
Order
Job name/Part name Handlebar removal Left/Right bake m i r r o r 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
Remarks Remove the parts in order. Refer to " C O V E R S A N D P A N E L " IN CHAPTER 3.
1 2 3 4 5 6 7 8 9
1 1 1 1 1/1 1 1 1 1
6-25
.AOOLEBARIC"ASI oI
~ 1 9 N m ( 0 . 9 m.kg, 6.5
5
ft.lb) I
,)~D
1~143Nm(4.3 m.kg, 37 .
ftJb)l
8
10
p-..
Order
10
Job name/Part name Wire harness strap Brake hose Handlebar comp. Left grip
Q'ty 1 1 1 1/1
Remarks
11 12 13
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.
Install: Handlebar O Bolt (~) Nut NOTE:
2.
I~143Nm(4.3 m.kg,
37ft.lb)
Match the bolt (~ on to the steering c o l u m n dent (~.
CAUTION:
There m u s t be a space b after t i g h t i n g bolt ~).
3.
Install:
Ba nd NOTE:
Clamp the w i r e harness. 4. Apply: Lithium soap base grease (to t h r o t t l e cable end and h a n d l e b a r right end).
Install: Handlebar switch (right) (~ NOTE: Insert the projection (~ into the hole (~ on the h a n d l e b a r comp.
5.
6-27
.AOO,EBA. IC"ASI oI
Q
Install: Handlebar switch (left) (~ NOTE: Insert the projection (~ into the hole @ on the handlebar comp. 6.
Install: Master cylinder NOTE: Match the slot w i t h the punched mark @ on the handlebar comp.
7.
6-28
STEE.,OIC"ASI oI
STEERING
STEERING
~-766Nm(6.6 m.kg, 47.8 ft.lb)] r~122Nm(2.2 m.kg, 16 ft.lb) 21
-J/
I I
38Nm(3.8 m.kg, 27ft.lb)

i
-9 8
5 40Nm(4.0 29 ft.lb)
Order
Job name/Part name Steering removal Handlebar Front wheel
Q'ty
Remarks Remove the parts in order Refer to " H A N D L E B A R " section. Refer to "FRONT WHEEL A N D BRAKE DISC" section
1 2 3
4
5
6
7 8 9
Ring nut 1/Special w a s h e r Ring nut 2 / R u b b e r w a s h e r Ring nut 3 Under bracket Front fork (Left/Right) Bearing cover Ball race Ball (Upper/Lower) Ball race
1/1 -
Refer to "STEERING REMOVAL/INSTAL1 LATION" section. 1 1/1 1 1 22/19 3 Reverse the removal procedure for instal lation.
1/1
6-29
STEE.,O IC"ASI oI
STEERING REMOVAL
~WARNING
S e c u r e l y s u p p o r t t h e s c o o t e r so t h a t t h e r e is n o d a n g e r of it falling over. S t a n d t h e s c o o t e r on a level surface.
1.
Removal: Ring nut 1 ~) Special w a s h e r (~ Ring nut 2 (~) Rubber w a s h e r (~ Ring nut 3 (~ Bearing cover (~ Ball race (~ Ball (~ Front fork a s s e m b l y (~
NOTE:
Remove the ring nuts by steering nut wrench. ~:c~l Steering nut w r e n c h (~ YU-33975 I
Hold the lower bracket by hand, then remove by using the steering nut w r e n c h @. Do not loss the balls (Upper: 22 pcs, Lower: 19 pcs). 2. Remove Front fork a s s e m b l y Refer to "FRONT FORK" section. Remove Ball race
3.
Ball race r e p l a c e m e n t steps: Remove the ball races on the head pipe using long rod (~ and the h a r m m e r as s h o w n . Remove the ball races on the under bracket using the floor chisel ( ~ a n d the h a r m m e r as shown.
6-30
STEE.,OIC"ASI oI
STEERING I N S P E C T I O N 1. W a s h t h e b e a r i n g races w i t h a s o l v e n t . 2. Inspect: Ball race Ball P i t t i n g / D a mage--~Replace. NOTE: A l w a y s r e p l a c e b e a r i n g s a n d races as set.
3.
Inspect: Under bracket (~
Crack/Bend/Damage-->Replace.
W!~LVAV/I-'] ~ I I ~ [']1
Do not attempt to straighten a bent under b r a c k e t as t h i s m a y d a n g e r o u s l y w e a k e n t h e under bracket.
STEERING I N S T A L L A T I O N 1. Install: Ball <~ NOTE: U p p e r ....... 22 pcs L o w e r ...... 19 pcs 2. Lubricate
Ball
Ball race L i t h i u m s o a p base g r e a s e
6-31
STEE.,O IC"ASI oI
, \
3. Install: Front fork assembly (~ Ball race (Upper) ~) Bearingcover (~ 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: Tightenthe ring nut 3 (~ using the ring nut wrench (~ r~122 am {2.2 m.kg, 16 ft..b~
steor,no,utwrenoho_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 lock. to If there is any binding, remove the front fork assembly and inspect steering ball bearthe ings ball races. and Install rubber washer (~ and ring 2 (~, nut then turn the ring nut 2 until it contacts with rubber washer.
6-32
STEE.,OIC"ASI oI
CAUTION:
Slots on t h e ring n u t 2 and ring n u t 3 s h o u l d be align. If not, t u r n t h e ring n u t 2 t o w a r d s t i g h t e n direction until slots a l i g n m e n t . Install special w a s h e r (~) NOTE: Insert the projections of the special w a s h e r into the slots. Install ring nut 1 (~ and tighten. [~166Nm(6.6
47.8 ft.lb) m.kg, I
6-33
F.O.T FO.K IC"ASI

F R O N T FORK
FRONT FORK
8
oI
Order
Job name/Part name Front f o r k r e m o v a l Steering Under fender S p e e d o m e t e r cable h o l d e r Cap bolt Pinch bolt Front f o r k
Q'ty
Remarks R e m o v e t h e parts in order. Refer to " S t e e r i n g " section.
1 2 3 4 5
1 1 2 2 2
Refer to " F R O N T FORK R E M O V A L / I N - S T A L L A T I O N " section. Reverse the r e m o v a l p r o c e d u r e for installation.
6-34
F.OT FO.K IC"ASI

FRONT FORK D I S A S S E M B L Y
oI
/
@ c-~
[~, 23N m m ~ (2.3 Order

O @ @
/ '. name Q'ty Remarks Remove the parts in Refer to "FRONT FORK STALLATION"
Job name/Part Front fork disassembly Fork spring Band/Front fork boot Bolt/Copper washer Inner tube Damper rod Rebound spring Oil lock piece Oil seal clip Oil seal Outer tube
order. REMOVAL/INsection.
1 1/1 1 1/1 Refer to FRONT FORK DISASSEMBLY/ 1 ASSEMBLY" section. 1/1 1 1 1 Reverse the disassembly procedure for assembly.
"
6-35
F.O.T FO.K IC"ASI
oI
Y P .....
FRONT FORK R E M O V A L
~!~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 j u m p out after removing cap bolt. 3. Remove: Front fork (Left/Right) (~
YP703020
FRONT FORK D I S A S S E M B L Y 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
Remove: Inner tube (~ Oil lock pice (~ Damper rod Rebound spring (~
3.
Remove: Oil seal (~
"7 "'" i~:
CAUTION:
N e v e r reuse th e oil seal.
~) Rag
YP703030
F R O N T FORK I N S P E C T I O N 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 a t t e m p t to straighten a bent inner t u b e as this m a y d a n g e r o u s l y w e a k e n th e tube.
YP.....
Q
F R O N T FORK A S S E M B L Y 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

. Install: Inner tube (~ Into outer tube ~).
oI
Install: Plain w a s h e r (~ Bolt ( d a m p e r rod) (~)
4.
Tighten: Bolt ( d a m p e r rod) (~
~%O%123Nm(2.3m.kg, 16.6ft.lb)
NOTE:
Tighten the damper rod bolt ( ~ w h i l e holding the damper rod with a T-handle(~ and holder ~). ~ T-handle YM-01326-A Holder YM-01300-1 Install:
5.
Oil seal (~ Retaining clip Use the fork seal driver w e i g h t ~) and the a t t a c h m e n t (~). NOTE: Before installing the oil seal (~, apply lithium soap base grease onto the oil seal lips. A d j u s t the retaining clip so that it fits into the outer tube groove.
CAUTION:
M a k e sure t h a t t h e oil seal n u m b e r e d side faces upward.
~
6-38
Fork seal driver w e i g h t : YM-33963 Attachment: YM-01400
F.O.T FO.. IC"ASI

.
oI
Inspect: Inner tube operation U n s m o o t h operation-->Disassembly and recheck.
7.
Fill: Fork oil ( ~ Oil q u a n t i t y : 88 cc R e c o m m e n d e d oil: Fork oil 10 W or e q u i v a l e n t
1
8.
A f t e r f i l l i n g up, s l o w l y p u m p the f o r k up and d o w n to d i s t r i b u t e the fork oil. Install: Front f o r k s p r i n g O
0;
9.
NOTE:
Install the fork s p r i n g w i t h its s m a l l e r p i t c h ( ~ upward . Before i n s t a l l i n g the cap bolt, a p p l y grease to the O-ring. T e m p o r a r i l y t i g h t e n t h e cap bolt.
EB703050
FRONT
FORK INSTALLATION
Reverse the " R E M O V A L " p r o c e d u r e . Note t h e f o l l o w i n g points. 1. Install: Front f o r k ( ~

NOTE:
A p p l y grease o n t o cap bolt O-ring before ins t a l l i n g 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=ET= I E'EC I

ELECTRICAL
ELECTRICAL C O M P O N E N T S
(~ (~) (~) (~ (~ (~ (~
Main switch Flasher relay Oil level gauge C.D.I. UNIT Fuel level gauge Starter relay Fuse
(~ (~ @ (~)
Battery Ignition coil Rectifier/Regulator Horn
0
Y
7-1
Cl.OlTOlAO.A. IE'EC I
CIRCUIT D I A G R A M
111L
i
~ l ------I
II
I
I II~l~ I ~1~2- /
III~L
I ~ @
/--/
__i,
i~
__1
,
, I
~-I~"
I
~
:0
~ I B I
,,
I
I1~
II
I
~4-4-
......
,,
- -i-I
:~ I ~
~ '
i
~ - - - I - -
_EB
i--
L .... L
b__ o
_J
_E,2 ~ _ _ _ _
I I I
i@
I I
7-2
c..cu.T o..o..M I E'Ec 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 switch brake 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) (~ (~) (~ @ (~ @ (~ @ @ @ (~ @ @ @ (~ @ @ @ 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
COLOR CODE
B Br Ch Dg G L Or Sb P R
Black Brown Chocolate Dark Green Blue Orange Sky blue Pink Red Green
Yellow White B/R Black/Red Br/W Brown/White n/Red G/R G ree G/Y Green/Yellow L/B L/Y L/W Blue/Black Blue/Yellow Blue/White
Gy Y W
G ray
L/R R/B R/Y R/W Y/R W/G
Blue/Red Red/Black Red/Yel low Red/wh Yellow/White White/Green ite
G/W Green/White W/R White/Red L/G Blue/Green
7-3
O.EOK.OSW.TO.ESIE'EC I
YP N JJoo r,
"O"
CHECKING S W I T C H E S
C H E C K I N G STEPS Using pocket tester, check switches for contin u i t y b e t w e e n t h e i r t e r m i n a l s to d e t e r m i n e w h e t h e r t h e y are correctly connected. Replace the switch c o m p o n e n t if any of the c o m b i n a t i o n s does not produce the correct reading.
"~xl
" --
I ~ 1
NOTE:
Pocket tester: YU-03112
Turn the switch to the " O N " , " O F F " positions several times. A d j u s t the pocket tester to correct " 0 " position before checking switches. Set the pocket tester selector to " x l ' E 2 .
S W I T C H C O N N E C T I O N A S S H O W N IN THIS MANUAL This manual contains connection charts, like the one s h o w n on the left, s h o w i n g the terminal c o n n e c t i o n s of s w i t c h e s (e.g. the main switch, handlebar switch, brake switch, lighting switch etc.)
X",
Br R
OFF ON O - - O
The column on the extreme left indicates the different switch positions, the top line ind icates the colors of the leads connected to the terminals on the switch.
"0~0" indicates terminals between w h i c h there is c o n t i n u i t y , i.e. a closed circuit, in the given switch position.
In this chart: " B r and R" have c o n t i n u i t y w i t h the switch in the " O N " position.
7-4
O.EOK.OSW.TO.ESIE'EC I
S W I T C H POSITION A N D T E R M I N A L
Before c h e c k i n g a s w i t c h refer to the checking s w i t c h e s as s h o w n in the left page and check for t h e c o r r e c t t e r m i n a l c o n n e c t i o n s (closed circuit) a c c o r d i n g to the c o l o r c o m b i n a t i o n s s h o w n in the chart. Poor c o n n e c t i o n , fault-->Repair or replace.
7
I
B B/VV
CONNECTION
I-
I I
Main switch
Gy Br R
LOCK
OPEN OFF
ON C)---O C ) - O 0 -O
J
I I
L
Rear brake s w i t c h
r Front brake s w i t c h
I I I
I-
--'~P
Horn s w i t c h
Release Push in O- 0 Dimmer switch

~ G L Y
<
I
-C> O-43 gO 00 Turn switch

Ch Br/VV Dg
I I",,t ,,,,,,"~
iI
Start s w i t c h
L/W L/G Release Push in O - - O
<~ ~>
L
O--O O--O
J OFF RUN L
E n g i n e stop s w i t c h
B/W B/W L/G 0--0 0--0 B
<
/ /
\
Fuse
7-5
c.Ec...o T.E Bo.Bs A.o BO.B SOO.ETS IE'EC I

EAS00733
CHECKING THE BULBS A N D BULB SOCKETS

Check each b u l b and b u l b socket for d a m a g e or wear, p r o p e r c o n n e c t i o n s , and also for con tinuity between the terminals. D a m a g e / w e a r --~ Repair o r replace t h e bulb, b u l b socket or both. I m p r o p e r l y c o n n e c t e d --~ P r o p e r l y connect. No c o n t i n u i t y --~ Repair o r replace the bulb, b u l b socket or both.
18410603
TYPES OF BULBS The b u l b s used on t h i s s c o o t e r are s h o w n in the i l l u s t r a t i o n on the left. Bulbs @ and ( ~ are used for the h e a d l i g h t s and u s u a l l y use a b u l b h o l d e r t h a t m u s t be detached before r e m o v i n g t h e bulb. The maj o r i t y of these t y p e s of b u l b s can be r e m o v e d f r o m t h e i r respective socket b y t u r n i n g t h e m co u n t e r c l o c k w i s e . Bulbs are used for t u r n s i g n a l and tail/ brake l i g h t s and can be r e m o v e d f r o m t h e socket by p u s h i n g and t u r n i n g the bulb counte rcl ockwise. Bulbs ( ~ and ( ~ are used for m e t e r and indicator l i g h t s and can be r e m o v e d f r o m t h e i r respective socket by c a r e f u l l y p u l l i n g t h e m out.
18410004
7-6
C.EOK..O T.E BO'BS..O BO'B SOCKETSIE'EC I

C H E C K I N G THE C O N D I T I O N OF THE BULBS
The following procedure applies to all of the bulbs. 1. Remove: bulb Since the headlight bulb gets extremely hot, keep f l a m m a b l e p r o d u c t s and y o u r h a n d s a w a y from the bulb until it has cooled d o w n .
CAUTION:
Be sure to hold the socket firmly w h e n removing the bulb. Never pull the lead, otherw i s e it may be pulled out of the ter-minal in the coupler. Avoid touching the glass part of the headlight 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, t h o r o u g h l y clean it w i t h a cloth moistened w i t h 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.
a. Connect the positive tester probe to terminal (~ and the negative tester probe to terminal (~, and check the continuity. b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal (~, and check the continuity. c. If e i t h e r of t h e r e a d i n g s i n d i c a t e no continu-ity, replace the bulb.
18410002
7-7
O.EOK.O T.E BO'BS A.O BO'B SOCKETS IE'Ecl
C H E C K I N G T H E C O N D I T I O N OF THE B U L B SOCKETS The f o l l o w i n g p r o c e d u r e a p p l i e s to all o f the b u l b sockets. 1. Check: b u l b socket (for c o n t i n u i t y ) ( w i t h the pocket tester) No c o n t i n u i t y --> Replace.
Pckettester YU-03112
NOTE:
Check each b u l b socket for c o n t i n u i t y in the same m a n n e r as d e s c r i b e d in the b u l b section; h o w e v e r , note t h e f o l l o w i n g .
a. Install a g o o d b u l b into t h e b u l b socket. b. C o n n e c t t h e pocket tester p r o b e s to t h e respective leads of t h e b u l b socket. c. Check the bulb socket for c o n t i n u i t y . If a n y of the r e a d i n g s indicate no c o n t i n u i t y , replace the b u l b socket.
7-8
IE'ECI I
IGNITION SYSTEM
CIRCUIT D I A G R A M
....
~ ~
~-r~',
~L~J~ ~E~
I---------- . . . . I. . . . . . . . .
,
I
__
~,BI
~or I
~
I
,~w
--
wa?
I I __~ I
~-~_~
r s------7
'B~'
I ~,_
. . . . . . . .
I. . . . . . . . . .
---~L
',
I r ~
. . . . .
"
; ..... __~___J
I I I
@.___~
____~ .......
2~___]
', ; - - t *
]~-v" v
~B
....
I I I I
L_ S
I
,
_ _ j
Io
L . . S . .
I
J
F---
---
l
(~) (~ (~) @ (~) (~3 Main switch C.D.I. magneto C.D.I. unit Ignition coil Spark plug Engine stop switch
-~ ~ ~
~ ___ _
I@l b
r . . . .
',
I
--q
--I
. . . .
,,',#~
~ _ _ _ _
L_
'
7-9
.o..T.o SVSTEMI':":C I
TROUBLESHOOTING IF I G N I T I O N S Y S T E M S H O U L D B E C O M E I N O P E R A T I V E (NO S P A R K OR I N T E R M I T T E N T SPARK) NOTE:
Remove following parts the before troubleshooting. 1) Battery box cover 4) Tail cover 2) Center cowling 5) Side cover 3) Rear carrier 6) Handlebar Use the following special tools in this troubleshooting. ~ 1 Dynamic spark tester:YM-34487 I ~ 1 Pocket tester:Yu-03112
(right) cover
(front)
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
Standard spark BPR7HS (NGK)
plug:
Spark plug gap: 0.6~0.7 mm(0.02~0.03 in) INCORRECT
I Spark gap. 2. Ignition spark gap Disconnect spark the cap from spark plug plug. Connectthe dynamic spark tester (~ as shown. (~ Spark cap plug Checkthe ignition spark (~. gap Start engine, and increase spark gap until misfire occurs. ~ Minimum spark 6.0 mm (0.24 in) I * gap:
is faulty, replace it or repair plug plug
lgll0201
MEETS SPECIFICATION
OUTOF SPECIFICATION OR NO SPARK
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: 5kQ at 20C (68F) OUT OF SPECIFICATION MEETS SPECIFICATION 4. Ignition coil resistance Disconnect the ignition coil leads from the ignition coil. Connect the pocket tester (~ x 1) the to ignition coil. Ignition coil: Tester (+) lead->Terminal (~ Tester (-) lead->Coil base (~) Check the p r i m a r y coil for specification resistance. Primary coil resistance: 0.32~0.48 E2 at 20C (68F) Connect the pocket tester (Q x ignition coil. Tester (+) lead--~Spark plug lead (~ Tester (-) lead->Coil base (~) Check the s e c o n d a r y coil for specificated resistance. S e c o n d a r y coil resistance: 5.68 ~ 8.52 k ~at 20C (68F) (Spark plug lead - Coil base)
B O T H MEET SPECIFICATIONS
Replace spark plug cap.
1 to the k)
///"
OUT OF SPECIFICATION
I Ignition coil is faulty, replace it.
7-11
,ON,T,OOS STEM IE'EC 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 (-) l e a d , W h i t e / B l u e (~) Check the pickup coil for specificated resistance. OUT OF SPECIFICATION
-~
Pickup resistance: coil
248~ 372 ~Q at 20C (68F) (Wh ite/Red-Wh ite/Blu e)
~N7 SPECIFICATION MEET

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 (-) l e a d , G r e e n / W h i t e (~ Check the source coil for specificated resistance.
I Pickup coil is faulty, replace it.
-~
Sourcecoilresistance:
640 ~ 960 E2 at 20C (68F) (Black/Red - Green/White )
~ 7 SPECIFICATION MEET
7. Main switch
I Source coil is faulty, replace it.
NO CONTINUITY Refer to "CHECKING SWlTCHS" section. CONTINUITY I Main switch is faulty, replace it.
7-12
.O..Z.O SVSTEM IE'EC I

NO CONTINUITY
8.
Engine stop switch Refer to "CHECKING SWlTCHS" section. I Engine stop switch is faulty, replace it. POOR CONNECTION I
CONTINUITY
9. Wiring connection Check the entire ignition system for conneo tions. Refer to the "WIRING DIAGRAM" section.
~ C RET ORC
I Replace CDI unit.
I Correct.
7-13
O,.OSYSTE. IE'Ecl
CHARGING
CIRCUIT DIAGRAM
I
SYSTEM
[- . . . . ~ ~ :
L--~
______i
. .i. . . .
,' ........
~,R_, (
I
~,rm' .......
~$~
78-',r~
~
I
i ~ ,
I
_ J R,~.
,~ ~
R I
-~
~_~_~_~
------1
~ ~ ' ,
o,d-E-~--~ - I
' - C 1"]
I
I I
,BI, I
L ....... I. . . . . . . . . .
I
i
,~' ,eeL-'-'
---4,,
~r ~
........
~rq
~-
,,
,,
~,,1~
. . . .
II
i I_t _ll i<~ ~_li~
l ~------~
. . . . . . . .
...... ....
i [ ~ I [ ~ ~ ___
~ ~-~T~,~ --1---:
[___
~
i- ~
,'--@,
L_
,', ~',~
_]
,'TE --,,
,'
L__
B',~
_J
I
-~
I I i
14~ IHb L ..... i
L_____
i i
,'
',
'[_~'
~ ~',D B,,~
' ,, ~ i ~
I J - - ~
(~) (~ (~ (~
Main fuse Battery Rectifier Regulator CDI magnet
7-14
O,.OSYSTEMIE'ECI
TROUBLESHOOTING THE B A T T E R Y IS N O T C H A R G E D . 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 following special tool (s) in this trobleshooting. the 1~1 Inductive tachmeter: YU-8036-A I 1 ~ 1 Pocket tester: YU-03112
1. Fuse (main) Remove the fuse. Connect the pocket tester (1 x 1) to the fuse. Check fuse for continuity. the ~ CONTINUITY
NO CONTINUITY
I Fuse is faulty, replace
it.
2. Battery Check the battery condition Refer to the "BATTERY INSPECTION" tion in the CHAPTER 3. [~ Open circuit voltage: 12.8V or more at 20C 7 * CORRECT
INCORRECT sec-
battery terminals. (68F) I o Clean Rechargeor replace battery.
/ J
J/
7-15
O,NOS,STEMIE'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.
~
NOTE:
Charging voltage:
13 ~
14 at V 4,000 r/min MEETS SPECIFICATION
Use a full charged battery.
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
OUT OF SPECIFICATION I Charging circuit is good.
-~
Charging resistance: coil
0.48~0.72 ~ at 20C (68F) Lighting coil resistance: 0.4-0.6 ~, at 20C (68F) I Charging coil is faulty, replace it. ~=, * MEET SPECIFICATION
7-16
O,OOS STEMIE'ECI
Se 5. Wiring connection i Check the entire ignition system for connections. Refer to the "WIRING D I A G R A M " section.
.~o~
POOR CONNECTION
I Correct.
Replace rectifier regulator.
7-17
E.EOT..O ST..T.O S STE. I E'EC I

ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
clCI~~ IIII~, ~--~______I .... __IIC ON
,', -~',B Y-...... .....

,
B L . . . . . ~/a
~-',,B
, o,d-Z-~S4~ -'
f--~,
.... I ~
---,
[r -~ ---1
~,,@,
I I
'-# 71
I '
, ~~I
I
~ I~
ITZ:~=~
,@ ,, ~
, I
o~_
. .
'
L . . . . .
,,
I. . . . . . . . . .
.,,~
'
......
--i-"
'~ -~-'
,,~~~',~
"~-~
L ___J
~
1
i
I!Io,,o
~)r----I
......
"
. . . .
,'--G I ,'~3- --', ," B,,( ,' B,,~ L_ _J L__ _J
I___
,
',
I
L~__ I
I
I
L
r . . . .
' ~',D
L_
--~'
~--I
' fl
~
-~'
L ,t_B_j
I I I I
0B8
I
(~ (~ (~ (~ (~ (~
(~) Front brake switch Main switch (~ Engine stop switch Main fuse (~) Starter switch Battery Starter relay Starter motor Rear brake sv~ switch 7-18
E.EO*..O
TROUBLESHOOTING J NOTE:
STA.*.OO E'EC I S*S*EM I
S T A R T E R M O T O R DOES N O T OPERATE.
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: YU-03112 1. Fuse Remove the fuse. Connect the pocket tester (~ x fuse. Check the fuse for continuity. S
NO CONTINUITY 1 to ) the
CONTINUITY
I Fuse is faulty, replace it.
2. Battery Check the battery condition. Refer to the "BATTERY INSPECTION" section in the CHAPTER 3. Open circuit voltage: 12.8 V or more at 20C (68F)
INCORRECT
S 3. Startermotor
CORRECT
l eClean battery terminals. Recharge or replace battery.
Connect the battery@positive terminal and starter motor cable ~) using a jumper lead (~ *
~WARNING
Aw i r e for t h e j u m p e r lead m u s t have t h e e q u i v a l e n t capacity as t h a t of t h e b a t t e r y lead or more, o t h e r w i s e it m a y cause t h e j u m p e r lead t o be burned. This check is likely t o p r o d u c e sparks, so be sure t h a t no f l a m m a b l e gas or fluid is in t h e vicinity.
t J
DOES NOT MOVE
Check the starter motor for operation. S * MOVES 7-19 I Starter motor is faulty, repair or replace it.
I
E.EOT..O STA.T.OO S STEM I E'EC I
4. Starter relay Disconnect the relay unit coupler from the wire harness. Connect the pocket t e s t e r ( ~ x 1)and battery(12V) to the relay unit coupler terminals. Battery(+)lead--> Blue/White terminal (~ Battery(-)lead--~ Green/Yellow terminal (~) Check the starter relay for continuity. Tester (+) lead--> terminal (~ Tester ( - ) l e a d ~ (~ terminal , ~ CONTINUITY J Replace the starter relay. 5. Main switch Refer to "CHECKING SWITCHS" section. NO CONTINUITY NO CONTINUITY
, ~
CONTINUITY J Main switch is faulty, replace it.
6. "START" switch Refer to "CHECKING SWlTCHS" section.
NO CONTINUITY
!;7 CONTINUITY
1
"START" switch is faulty, replace handlebar switch (right). J Engine stop switch is faulty, replace it.
7. Engine stop switch Refer to "CHECKING SWlTCHS" section. CONTINUITY 9$
7-20
E'EOT..C S*A.*.O S*S*EM E'EC I I

CONTINUITY 8. Brake s w i t c h e s (front and rear) Disco n nect the brake switch leads from the w i r e harness. Connect the pocket tester (~ 1 the )to brake switch leads.
/f
\\\
Check the brake switch for c o n t i n u i t y Switch Position Brake is applied Brake is not applied O:Continuity Good condition 0 X X GOOD CONDITION 9 Wiring connection C h e c k t h e entire electrical starting system for connections Refer to "WIRING D I A G R A M " section. I Replace brake switch(es) Bad condition
POOR CONNECTION
I Correct
7-21
E'ECT..O STA.T.OO S STEM I E'EC I

STARTER M O T O R
._._' . ~~. ( ~ ~ ~ [~113 N m(1"3 m "kg' 9"4 ft'l b)~ 1
Order
J o b name/Part name Starter m o t o r removal Rear carrier Tail cover Battery box cover Left/Right side cover Center c o w l i n g Muffler Rear w h e e l Air s h r o u d 3
Q'ty
Remarks Remove the parts in order. Refer to "COVER P A N E L " section in CHAPTER 3.
]Refer to " R E A R W H E E L A N D REAR BRAKE" section in CHAPTER 6. Refer to "ENGINE R E M O V A L " section chapter 4.
1 2
Starter m o t o r c o u p l e r Starter m o t o r Reverse the removal procedure for installation.
7-22
E,ECTR,OSTART,OOSVSTEM I E'EC I
STARTER M O T O R D I S A S S E M B L Y
<C_
k~
<. ( ~ . . ~ ~ ~ ~ =
ry~,113N m(1.3
~ 1
9.4 ft.lb)l m.kg,
Order
Job name/Part name Starter motor disassembly O-ring Rear bracket Armature ass'y Ring Brush holder set
Q'ty
1 m
Re marks Disassembly the parts order. in
Cb
1 1 1 1-
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

YP803034
I N S P E C T I O N A N D REPAIR 1. Inspect: Commutator Dirt-->Clean it w i t h #600 grit s a n d p a p e r . 2. Measure: Commutator diameter (~
Commutator it wear
15.1 m m (0.59 in) . Out of specification-->Replace the starter motor Measure: Mica u n d e r c u t ( ~ 1.05 m m (0.04 in)
Ilocaun'ercut
NOTE:
Out of s p e c i f i c a t i o n ~ S c r a p e the mica to the p r o p e r v a l u e (a h a c k s a w blade can be g r o u n d to fit). The mica i n s u l a t i o n of the c o m m u t a t o r m u s t be u n d e r c u t to ensure proper o p e r a t i o n of c o m mutator.
4.
(~ m 4-(
Inspect: A r m a t u r e coil resistances ( i n s t a l l a t i o n / continuity) Defects-->Replace the starter m o t o r . If c o m m u t a t o r is dirty, clean it w i t h sandpaper. Good condition Bad c o n d i t i o n
[] []
0 0
x x
x 0
O: C o n t i n u i t y x: No c o n t i n u i t y Bad condition-->Replace.
7-24
E.EOT.,O STA.T,O SVSTEM I E'EC I

. Measure: Brush length (~ Out of specification-->Replace. Brush length wear limit 3.0 mm (0.012 in) I ~ 1
Measure: Brush spring force Fatigue/out of specification-->Replace as a set.
7-25
..o.T.oo s sTEM IE'EC I

LIGHTING
CIRCUIT
SYSTEM
DIAGRAM
I
[- . . . . ~ ~ :
iI ........
L--~ ______1 ~ ...... I I
i
4~lr....... ml
I'UL~- ~
~-',r~
~ I
I~L~r
~,R_, (
I
_ J R,~.
~ ~ l l
~
R
r
I
~
-~
~~
------1
'-C 1"]
I
I I
,BI
I
L ....... I.......... I
,~'
-
-'
,,
---4-
........
~-
,,
,,
4~ ,,1~
~rq . . . .
II
i I _t _ll
I<~ ~_Ii~ l ~------~
. . . . . . . .
...... ....
i [ ~ I [ ~ ~ ___
,'--@,
L_
,', ~',~
_J
I___
,'TE --,,
,'
B',~
_J
L__
I
i- ~ -~
I I I
14~ IHb L ..... I
L_____
I I
,' ',
'[_~'
~ ~',D B,,~
J - - ~
~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

YP805010
TROUBLESHOOTING IF THE H E A D L I G H T , HIGH B E A M I N D I C A T O R LIGHT. T A I L L I G H T A N D / O R M E T E R L I G H T FAIL T O C O M E ON.
Procedure Check: 1. Lights switch 2. D i m m e r switch 3. Wiring connection (entire lighting system) NOTE: Remove the f o l l o w i n g parts before t r o u b l e s h o o t i n g . 1) Front h a n d l e b a r cover 2) Rear carrier 3) Right side cover Use the special tools specified in the t r o u b l e s h o o t i n g section.
ckettester
YU-03112
YP
I
NO CONTINUITY
1.Fuse
Referto "CHECKING SWITCHES"
.....
sectionlIII
I Replace the fuse.
IN CORRECT
CONTINUITY
YP .....
2. Battery Check the battery condition. Refer to "BATTERY INSPECTION" sectior in CHAPTER 3.
~
YP .....
C RET O RC
3. Main switch I Refer to "CHECKING SWITCHES" section
D
i
o Clean battery terminals. Recharge or replace battery.
NOCONTINUlTY
~
*
C N I UT O TN I Y
i Replace the main switch. I
7-27
IE'ECI I
Se
YP .....
NO CONTINUITY
4. D i m m e r switch Refer to "CHECKING SWITCHES" section.
CONTINUITY
l
Replace the left handlebar switch.
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 (-) l e a d , E a r t h
- - ~ Lighting resistance: coil
0.4 ~ 0.6 ~ at 20C (68F)
~
*
MEET SPECIFICATION I Lighting coil is faulty, replace it.
7-28
..o.T.osvsTEMIE'ECI
Se
YP .....
6. Wiring connection Check the connections of the entire lighting system. Refer to "WIRING DIAGRAM". ,~OK Check the condition of each of the lighting system's circuits. Refer to "LIGHTING SYSTEM CHECK"
YP805020
POOR CONNECTIONS
I Correct.
L I G H T I N G S Y S T E M CHECK
1.
If the headlight and the high beam indicator light fail to come on. NO CONTINUITY
1. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.

7 2. V o l t a g e CONTINUITY
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 (+) l e a d , G r e e n O lead Tester (-) lead->Black (~) lead Headlight(high beam): Tester (+) lead-->Yellow (~ lead Tester (-) l e a d , B l a c k (~ lead High beam indicator light: Tester (+) lead->Yellow ~ lead Tester (-) lead->Black (~ lead
I Replace the bulb and/or bulb socket.

m ~ ~ ~ \ n
h
--
~i:,i,~ i,~
G/~ :]] B
g
7-29
..o.T.o s sTEM IE'EC 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. OUT OF SPECIFICATION
MEETS SPECIFICATION
I The wiring circuit from the main switch to bulb socket connector is faulty. Repair.
I This circuit is not faulty.

YP805021
2. If t h e m e t e r light f a i l s t o c o m e o n .
I l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.

7 CONTINUITY
NO CONTINUITY
1
2. V o l t a g e C o n n e c t t h e p o c k e t t e s t e r (DC20V) t o t h e 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. 7-30
The wiring circuit from main switch to bulb socket is faulty. Repair.
..o.T.osvsTEMIE'ECI
Se 3. Licence light does not come on. 1. Bulb and bulb socket Checkthe bulb and bulb socket for continuity NO CONTINUITY
CONTINUITY
I Bulb and/or bulb socket are faulty, replace.
2. Voltage Connect the pocket tester (DC20V)to the bulb socket connector.
Tester (+) lead --> Brown @ lead. Tester (-) lead --> Black (~ lead.
OUT OF SPECIFICATION Turn the main switch to on. Check the voltage (12V) on the " B r o w n " lead at the bulb socket connector.
MEETS
SPECIFICATION (12V)
l
I W i r i n g circuit f r o m main s w i t c h to bulb socket connector is faulty. Repair.
7-31
L.O.T..O SYSTEMIE'EC
YP805022
3. T h e t a i l l i g h t fails t o c o m e o n .
NO CONTINUITY
1. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.

7 CONTINUITY

2. V o l t a g e C o n n e c t t h e p o c k e t t e s t e r (DC20V) t o t h e bulb socket connector.
Tester (+) lead--> Brown terminal (~ Tester (-) lead--> Black terminal (~)
GH Br ,B Ch Dg
OUT OF SPECIFICATION Turn the main switch to on. Checkthe voltage (12V) on the bulb socket connector. MEETS SPECIFICATION
I The wiring circuit from main switch to bulb I connector is faulty. Repair.
7-32
S.O...SVSTE. IE'Ecl
SIGNAL SYSTEM
CIRCUIT DIAGRAM
C_~, ~-~___I IIII~IIC .... ON~ I
,', -~',B Y-...... .....

,
B b . . . . . ~/a
~-',,B
I , ' ~ - '
f--~,
.... I
---,
[r -~ ---1
,-C?]
I I
, ~~I
I
~ I~
' .,,~ -
IT~=~
,~I.~
,
I
o~_
. .
'
'
b . . . . .
,,
I. . . . . . . . . .
,,
......
--i -=
,~_~
L
___J
i
T!I~IIB
'~ -@-'
'
T l_a~1
1
~)r----I
. . . .
,'- -G I
I
,'~3-
I___
,
L_ _J L__ _J S
@
',
L~___I
I
I
b I
. . . . -->'~--I I I~ ) ~ I~IIB
r
'
I
_I__Bj
LI_B_j~
[ 1 -@ ,-
,'
0B8
I
(~ (~ (~) @ @ @ (~)
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
7-33
(~ @ (~ (~) @ (~
Turn switch Fuel sender Fuel meter Oil indicator light Turn indicator light Oil level gauge
S,O.ALSVSTEM IE'ECI I
YP806010
TROUBLESHOOTING
IF T H E F L A S H E R L I G H T , B R A K E L I G H T A N D / O R I N D I C A T O R FAIL T O C O M E O N . IF T H E H O R N F A I L S T O S O U N D . LIGHT
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.
Pckettester:
YU-03112 P
. . . . .
I
NO CONTINUITY
I
YP
1. Fuse
Refer to "CHECKING SWITCHES" section.
~ C NI UY OT I NT
I Replace the fuse.
.....
2. Battery Check the battery condition. Refer to "BATTERY INSPECTION" section in CHAPTER 3.
IN CORRECT
~ C RET ORC
YP .....
l eClean battery terminals. Recharge or replace battery. NO CONTINUITY
3. Main switch Refer to "CHECKING SWITCHES" section. CONTINUITY .-X-
I Replace the main switch.
7-34
S,OA.SVSTEMIE'ECI
Se
YP ......
4. Wireharness Checkthe connections of the entire signal system. Refer to "CIRCUIT SYSTEM WIRING GRAM" section. ~ CONTINUITY
POOR CONNECTION DIAI Correct. I
Check condition of each of the signal system's circuits. Refer to "SIGNAL SYSTEM CHECK" tion.
sec-
7-35
SIGNAL SYSTEM
YP806020
ELEC
'-
*'
SIGNAL SYSTEM CHECK
1.
If the horn fails to sound.
NO CONTINUITY
l. HORN switch Refer to "CHECKING SWITCHES" section.
I Replace the left h a n d l e b a r switch. CONTINUITY
2. Voltage Connect the pocket tester (DC20V) to the horn lead. Tester (+) l e a d - > B r o w n terminal (~. Tester (-) lead->Frame g r o u n d Turn the main switch to on. Check for voltage (12V) on the " B r o w n " lead at the horn terminal.
_L
i
LoLI
n
MEETS
SPECIFICATION
I The w i r i n g circuit from the main switch to the e horn is faulty. Repair.
13. Horn Connect the pocket tester (DC20V) to the horn at the " P i n k " terminal. Tester (+) lead->Pink (~ terminal. Tester (-) lead->Frame g r o u n d Turn the main switch to on. Check for voltage on the " P i n k " lead at the horn terminal.
"Y
_L
NO CONTINUITY
@ C NI UY OT I NT
i A d j u s t or replace horn. I Replace the horn.
7-36
S,O.A,S*S*EM IE'Ecl
YP806022
2.
If t h e b r a k e l i g h t f a i l s t o c o m e o n :
NO CONTINUITY
J l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.
~7
CONTINUITY
J Replace the bulb and/or bulb socket. NO CONTINUITY
2. Brake switch (Front/Rear) Refer to "CHECKING SWI SWITCHES" section.
I
J Replace brake switch.
, ~
CONTINUITY
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. T h e b r a k e l e v e r is p u l l e d in. C h e c k f o r v o l t a g e (12V) o f t h e " G r e e n / Y e l low" lead on the bulb socket connector.
MEETS SPECIFICATION
JThis circuit is not faulty.
4. Wiring connection Wiring circuit from the main switch to the bulb socket connector is faulty. Repair. Refer to "SIGNAL SYSTEM WIRING DIAGRAM
"
7-37
S,ONA, SVSTEM IE'Ecl

YP806023
3.
If the flasher light and/or turn indicator light fails to blink.
NO CONTINUITY
J l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.
, ~
CONTINUITY
J Replace the bulb and/or bulb socket. NO CONTINUITY
2. Turn switch Refer to "CHECKING SWITCHES" section.
1
J Replace the left handlebar switch.
CONTINUITY
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
The wiring circuit from main switch to flasher relay connector is faulty. Repair.
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 * 7-38 MEETS SPECIFICATION
G
OUT OF SPECIFICATION J The flasher relay is faulty. Replace.
S,OOA,SVSTEM IE'Ecl
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 " C h o c o late" lead and " D a r k g r e e n " at the flasher light terminal. OUT OF SPECIFICATION
J ~ MEETS
I This circuit is not faulty. 4.
SPECIFICATION
6. Wiring connection Wiring circuit from t h e t u r n switch to bulb socket c o n n e c t o r is fault. Repair. Refer to "CIRCUIT D I A G R A M " .
"OIL" indicator light does not c o m e on.
NO CONTINUITY
1. Bulb and bulb socket C h e c k t h e bulb and bulb socket for continuity.
~ CONTINUITY
2. Oil level Remove tank. Connect oil level switch the oil level switch from the oil the Pocket Tester (~ x switch. 1) the to
l
I Replace bulb and/or bulb socket.
Tester (+) Lead--~Brown (~ Tester (-) Lead->Gray (~ Check the oil level gauge for continuity.
~,2
....
"-
Good Bad condition condition BAD CONDITION [ ] U p r i g h t position X []Upside down x x position Switch position C): C o n t i n u i t y X : No c o n t i n u i t y I Replace oil level switch. GOODCONDITION 7-39
S,A,S,S,EM IE'Ecl
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.
I
b
,BI q~l L
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,
I This circuit is good.
YP806027
MEETS SPECIFICATION (12V)
4. Wiring connection Checkthe entire signal system for connections. Refer to the "WIRING DIAGRAM" section.
5. If t h e fuel g a u g e fails t o o p e r a t e .
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 resistance. ~Jl Float position UP (~ DOWN (~ ~7 Specificated resista nce 4~10~ 90~100~ BOTH MEET SPECIFICATION OUT OF SPECIFICATION
I Replace the fuel sender.
7-40
S,O.A,S IE'Ecl STEM

2. Voltage Connect the pocket tester (DC20V) to the fuel gauge coupler. Tester (+) lead->Brown terminal (~ Tester (-) lead->Frame ground
,/ \
I
Ch II I
II G
Turn the main switch to " O N " . Check for voltage (12V) of the " B r o w n " lead on the fuel sender lead.
,
I
MEETS SPECIFICATION
l
Checkthe connection of the entire signal system. Refer to " C H E C K I N G OF CONNECTIONS". Refer to "CIRCUIT D I A G R A M " .
NOTE:
3. Fuel gauge Connect the fuel sender to wireharness. M o v e the float to " U P " ( ~ or " D O W N " (~.
Before reading the meter, stay put the float for more than three minutes respectively at " U P " or " D O W N " .
Turn the main switch to " O N " . Check the fuel gauge needle moves " F " or " E " Float position Float " U P " (~ Float " DOWN " ( ~ Needle moves
"F" "E"
DOES NOT MOVE
I Replace the fuel gauge.
~7 M V S OE
7-41
,UZO O.OKE S STE. IE'Ecl

A U T O CHOKE S Y S T E M
CIRCUIT DIAGRAM
CI~~ IONIICc II I
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(7) Auto choke (~ C.D.I. magneto
7-42
AUTO O.O.E SYSTEM IE'Ecl

"y'p .....
TROUBLESHOOTING
IF THE A U T O 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 Pcket tester: YU-03112 I
1. Lighting coil resistance Disconnectthe CDI magneto couple from wire harness. Connect the pocket tester (E2 x l ) to the lighting coil coupler Tester (+) Lead->Yellow/Red (~ terminal Tester (-) Lead--~Frame earth
Y/R
(~ C.D.I. magneto Checkthe lighting coil for specificated resistance Lighting coil resistance 0.4~0.6 ~ 20C (68F)
I Replace the lighting coil MEETS SPECIFICATION
7-43
AUTO O.O.E S STEM IE'Ecl

YP...
2. Auto choke unit resistance Disconnect the auto choke unit coupler from the wireharness. Connect the pocket tester ( ~ x l ) to the auto choke unit coupler lead. Tester (+) l e a d . B l a c k terminal (~ Tester (-) lead->Black terminal (~ ~_~ Auto choke unit resistance: 8~12~ at 20C (68F) OUT OF SPECIFICATION
~ MES ET
I Replace the auto choke unit.
SPECIFICATION POOR CONNECTION
3. Wiring connection Check the connection of the entire auto choke system. Refer to "CIRCUIT DIAGRAM" section.
I Correct.
7-44
STARTnNG FAnLURE/HARD
TROUBLESHOOTING
NOTE:
ITRBLI II ISHTGI STARTnNG
The f o l l o w i n g t r o u b l e s h o o t i n g does not cover all the possible causes of trouble. It should be helpful, however, as a guide to t r o u b l e s h o o t i n g . Refer to the relative procedure in this manual for inspection, a d j u s t m e n t and replacement of parts.
STARTING FAILURE/HARD STARTING FUEL S Y S T E M PROBABLE CAUSE
Fueltank
Empty Clogged fuel filter Deteriorated fuel or fuel containing w a t e r or foreign material Clogged fuel tank cap L C l o g g e d fuel hose Clogged fuel cock Faulty fuel cock operation Broken or disconnected fuel cock Deteriorated fuel, fuel c o n t a i n i n g w a t e r or foreign material Clogged pilot jet Clogged pilot air passage Sucked-in air Deformed float G r o o v e - w o r n needle valve I m p r o p e r l y sealed valve seat I m p r o p e r l y adjusted fuel level I m p r o p e r l y set pilot jet Clogged starter jet
Fuelcock
Carburetor
A u t o choke
/-
Starter plunger malfunction W a x malfunction Faulty t h e r m i s t e r Clogged air filter
Air cleaner
8-1
S T A R T I N G FAILURE/HARD S T A R T I N G
IGNITION SYSTEM PROBABLE C A U S E
ITRBLI
ISHTGI
II
Spark plug
Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap
Ignition coil
Broken or shorted primary/secondary coil Faulty spark plug lead Broken body Faulty CD I unit Faulty source coil Faulty pick-up coil Faulty main switch Broken or shorted wiring
CD I unit system L
Switches and wiring
COMPRESSION SYSTEM
PROBABLE C A U S E
Cylinder and cylinder head
L"
Piston and piston rings
Loose spark plug Loose cylinder head or cylinder Broken cylinder head gasket Broken cylinder gasket Worn, damaged or seized cylinder
L
/"
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
Crankcase and crankshaft
Reed valve
Deformed reed valve stopper Improperly seated read valve Loose intake manifold Broken gasket Broken reed valve
8-2
POOR IDLE SPEED POOR IVIIDIUIVI A N D HIGH SPEED P E R F O R M A N C E POOR IDLE SPEED P E R F O R M A N C E
P O O R IDLE S P E E D P E R F O R M A N C E PROBABLE CAUSE
PERFORMANCE ITRBLI ?
ISHTGI
Carburetor
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
Starter plunger malfunction Wax malfunction Faulty thermister Clogged air cleaner Faulty Faulty Faulty Faulty Faulty spark plug spark plug read C.D.I. unit source coil ignition coil
Air cleaner Ignition system
POOR M I D I U M A N D HIGH SPEED PERFORMANCE

POOR MEDIUM MANCE AND HIGH SPEED PERFORPROBABLE CAUSE
Carburetor
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
--
Air cleaner Muffler
Clogged air filter
Clogged
8-3
POOR M I D I U M A N D HIGH SPEED P E R F O R M A N C E FULTY A U T O M A T I C ( V - B E L T TYPE)

SCOOTER DOES NOT MOVE WHILE ENGINE IS O P E R A T I N G
---V-belt Cam, slider Compression spring Transmission
ITRBLI '? I ISHTGI
PROBABLE CAUSE
W o r n , d a m a g e d or s l i p p e d V - b e l t Worn, damaged Damaged Damaged
--
C L U T C H O U T FAILURE
---Clutch w e i g h t spring Clutch shoe Primary sheave Damaged Pealed l i n i n g S e i z e d p r i m a r y s l i d i n g s h e a v e and c o l l a r
POOR STANDING ABILITY)

V-belt
START(LOW
CLIMBING PROBABLE CAUSE

W o r n or s l i p p e d V - b e l t Improper operation Damaged Damaged
Primary sheave
Compression spring -Secondary sheave
Improper operation W o r n g u i d e pin
Clutch shoe
Plealed l i n i n g
P O O R A C C E L E R A T I O N ( P O O R H I G H SPEED)
-V-belt
PROBABLE CAUSE
/ /
Worn Greasy Worn Improper operation Worn
Weight m Primary/Secondary seave
8-4
OVER HEAT I POOR SPEED OVER HEAT

OVER HEAT PROBABLE C A U S E
ITRBLI ? I ISHTGI
Ignition system
I m p r o p e r plug gap Improper spark plug heat range Faulty C.D.I. unit I m p r o p e r carburetor setting Clogged air filter Carbon accumulation of cylinder head
--
Fuel system
-m
Compression system Muffler, Exhaust pipe Oil pimp Brake
Clogged
Faulty oil pump Faulty oil quality Drag Fan damaged
--
Cooling system
POOR SPEED
POOR SPEED PROBABLE C A U S E
--
Ignition system
Faulty spark plug Improper spark plug heat range Faulty C.D.I. unit Faulty source coil Clogged fuel tank cap Clogged air filter Clogged carburetor Worn cylinder Worn, fatigued or broken piston ring Broken cylinder head gasket Broken cylinder gasket Carbon accumulation of cylinder head
Fuel system
--
Compression system
Muffler, Exhaust pipe Clutch m Brake
Clogged Refer to "FAULTY AUTOMATIC" Drag
8-5
,MPROPER
IMPROPER KICKING
SLIPPING PROBABLE C A U S E
ITRBLI NG ISHTGI K,CK,
Kick axle assembly
Low tension of kick clip Worn kick axle Worn or damaged kick gear Damaged kick clip Kick clip coming off Damaged kick clip stopper
Transmission oil L
Improper quality (Low viscosity) Deterioration
H A R D KICKING
PROBABLE C A U S E
Kick axle assembly
j~
High tension of kick clip Seized kick gear Damaged or seized cylinder Damaged or seized piston Damaged or seized piston ring Improperly seated crankcase I m p r o p e r l y seated crankshaft Damaged or seized crankshaft Damaged or seized crankshaft bearing
- - C y l i n d e r , piston and piston r i n g - - L
m Crankcase and crankshaft L
KICK C R A N K N O T R E T U R N I N G
PROBABLE C A U S E
Kick axle assembly
Damaged kick return spring Kick return spring coming off Kick clip coming off Damaged kick return spring stopper
8-6
FAULTY BRAKE I S H T G I FAULTY BRAKE

POOR B R A K I N G EFFECT
Drum brake
ITRBLI
PROBABLE C A U S E
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 W o r n b r a k e pad W o r n b r a k e disc A i r in brake f l u i d Leaking brake fluid F a u l t y m a s t e r c y l i n d e r kit F a u l t y c a l i p e r seal kit Loose union bolt Broken brake hose O i l y o r g r e a s y b r a k e pad O i l y o r g r e a s y b r a k e disc
Disc b r a k e (Front)
MALFUNCTION
PROBABLE C A U S E
Bent, d e f o r m e d o r d a m a g e d i n n e r t u b e B e n t or d e f o r m e d o u t e r t u b e Damaged fork spring W o r n o r d a m a g e d slide m e t a l I m p r o p e r oil v i s c o s i t y I m p r o p e r oil level
8-7
ITRBLI INSTABLE HANDLING ISHTGI

INSTABLE H A N D L I N G
INSTABLE HANDLING PROBABLE CAUSE
II
Handlebar -Steering L
Improperly installed or bent Improperly installed steering column (Improperly tightened ringnut) Bent steering column Damaged ball bearing or bearing race Broken spring B o n d e d front forks Uneven tire pressures on both sides Incorrect tire pressure Unevenly worn tires Damaged bearing Bent or loose wheel axle Excessive wheel run-out Twisted D a m a g e d head pipe Improperly installed bearing race Bent or damaged
/
Front forks L Tires L
~Wheels L
--
Frame L
m Engine bracket Rear shock absorber
Fatigued spring O i l leakage
8-8
FAULTY SIGNAL AND LIGHTING SYSTEM FAULTY SIGNAL AND LIGHTING SYSTEM
HEADLIGHT DARK
PROBABLE C A U S E
ITRBLI ? I ISHTGI
I m p r o p e r bulb Too m a n y electric accessories Hard charging (Broken charging coil) Incorrect c o n n e c t i o n Improperly grounded Poor contacts (main or light switch) Bulb life expires
BULB BURNT OUT
PROBABLE C A U S E
I
L_
I m p r o p e r bulb Improperly grounded Faulty main and/or light switch Bulb life expires
PROBABLE C A U S E
- -
FLASHER DOES NOT BLINK
Improperly grounded Discharged battery Faulty flasher switch Faulty flasher relay Broken w i r e h a r n e s s Loosely connected c o u p l e r Bulb burnt out Faulty fuse
- -
FLASHER KEEPS ON
PROBABLE C A U S E
I
L
Faulty flasher relay I n s u f f i c i e n t b a t t e r y c a p a c i t y ( n e a r l y discharged) Bulb burnt out
8-9
FAULTY SIGNAL AND LIGHTING SYSTEM

FLASHER BLINKS SLOWER
PROBABLE C A U S E
ITRBLI ? I ISHTGI
Faulty flasher relay Insufficient battery capacity (nearly discharged) Improper bulb Faulty main and/or flasher switch
PROBABLE C A U S E
FLASHER BLINKS QUICKER
I
L HORN DOES NOT S O U N D
Improper bulb F a u l t y flasher relay

PROBABLE C A U S E
Faulty battery Faulty fuse Faulty main and/or horn switch I m p r o p e r l y adjusted horn Faulty horn Broken w i r e h a r n e s s
8-10
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Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, ON M2H 3B4

Yamaha Zuma Scooter Repair and Maintenance Manual

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Yamaha Zuma Scooter Repair and Maintenance Manual

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2008

IMPORTANT MANUAL INFORMATION

HOW TO USE THIS MANUAL

2. Remove: 8 Piston pin 1 8 Piston 2 8 Piston pin bearing 3

3 6 9Nm(0.9 m.kg,6.5 ft.lb)

Do not use a hammer to drive the piston pin out.

14Nm(1.4 m.kg, 10 ft.lb) 8 9

1/1 1 1 1/1 1 2 1/1 1 1 1

Reverse the removal procedure for installation.

CHECKING THE CONNECTIONS

CHECKING THE CONNECTIONS

Tool name / Function

90890-01337 YM-33285 YM-33285-6

90890-01284 YU-90050 90890-01383 YU-90062 90890-01189 YU-01189

This tool is used for holding the secondary sheave.

Tool name / Function

This tool is needed for detecting engine rpm. Pocket tester

90890-01367 YM-A9409-7 90890-01400 YM-A9409-3 90890-01326 YM-01326 90890-01294 YM-01300-1

Tool name / Function

ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS

* Lines indicate straighedge measurement

Standard 40.000 ~ 40.014mm (1.5748 ~ 1.5754in)

0.6mm (0.0236in) 0.7mm (0.0276in) 0.1mm (0.0039in) 0.11mm (0.0043in)

0.03mm (0.0012in) 1.00mm (0.0394in)

0.02mm (0.0008in) 0.02mm (0.0008in)

CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS

Cast wheel J10 MT3.50 Aluminum 76mm (2.99in)

200kPa (2.00kgf/cm, 29psi) 200kPa (2.00kgf/cm, 29psi)

ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS

CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS

GENERAL TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUES TIGHTENING TORQUES

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

INTRODUCTION/PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE AND MINOR REPAIR

* Fuel line * Idle speed * Exhaust system * Air induction system

PERIODIC MAINTENANCE AND MINOR REPAIR

General maintenance and lubrication chart

* Front fork * assembly

Throttle grip housing and cable Lights, signals and

PERIODIC MAINTENANCE AND MINOR REPAIR

COVER AND PANEL

COVER AND PANEL

13Nm (1.3 mkg, 9.4 ftlb)

For installation, reverse the removal procedure.

COVER AND PANEL

Remarks Remove the parts in the order listed.

For installation, reverse the removal procedure.

COVER AND PANEL

7Nm (0.7 mkg, 5.1 ftlb)

COVER AND PANEL

Remarks Remove the parts in the order listed.

Disconnect. For installation, reverse the removal procedure.

ADJUSTING THE ENGINE IDLING SPEED

ADJUSTING THE ENGINE IDLING SPEED

2. Remove: 8 battery box cover 1 Refer to SEAT AND SIDE COVERS.

ADJUSTING THE ENGINE IDLING SPEED

5. Adjust: 8engine idling speed

Engine idling speed is increased. Engine idling speed is decreased.

6 . Install: 8 battery box cover Refer to SEAT AND SIDE COVERS.