1999 - 2002

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MOTORCYCLE

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SERVICE MANUAL

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Model : CW50L, CW50M, CW50N, CW50P

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4RW281972K00 *4RW281972K00*
 IA-21
NOTICE

This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA dealers and their
qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is
assumed that persons using this book to perform maintenance and repairs on YAMAHA scooters
have a basic understanding of the mechanical concepts and procedures inherent in scooter repair
technology. Without such knowledge, attempted repairs or service to this model may render it unfit to
use and/or unsafe.

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MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and sig-

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nificant changes in specifications or procedures will be forwarded to allAuthorized YAMAHA dealers

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and will, where applicable, appear in future editions of this manual.
DOCUMENTATION TECHNIQUE

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MBK INDUSTRIE

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PARTICULARLY IMPORTANT INFORMATION

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This material is distinguished by the following notation:

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/_ The safetyAlert Symbol meansATTENTION! BECOMEALERT! YOUR

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SAFETY IS INVOLVED!

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r. IIY/-'1:I_11_[]1 Failure to follow WARNING instructions could result in severe injury or
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repairing the scooter.
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CAUT}ONi: A CAUTION indicates special precautions that must be taken to avoid

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

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CW50
SERVICE MANUAL
1997 by MBK INDUSTRIE
3st Edition, April 1997
All rights reserved. Any
reprinting or unauthorized use
without the written
)ermission of MBK INDUSTRIE
is expressly prohibited.
 IA-31
HOW TO USE THIS MANUAL ILLUSTRATEDSYMBOLS

CONSTRUCTION OF THIS MANUAL

This manual consists of chapters for the main categories of subjects. (See <<illustratedsymbols). Illustrated symbols _ to _ are designed as
1st title (_) This is a chapter with its symbol on the upper right of each page. (_ L_ thumb tabs to indicate the chapter's number and

the chapter (<Periodic inspection and adjustment)) the 3rd title appears.) I_
2nd tiUe
3rd title Q
_) This
This tiUeappears
is a final title.on the upper of each page on the left of the chapter symbol. (For I=-I I _ content.
_ General information
z(t_Specifications

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MANUAL FORMAT _ _ _ Periodic inspection and adjustment

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tion has been compiled to provide the mechanic with an easy to read, handy reference that contains @ Carburetion

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comprehensive explanations of all disassembly, repair, assembly, and inspections. _ Chassis
A set of particularly important procedure (_)is placed between a line of asterisks "* "with each step _ _ Electrical

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II :1

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IMPORTANT
by" FEATUREsPreceded
" "" _)Troubleshooting

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Data and a special tools are framed in a box preceded by a relevant symbol . _ _ Illustrated symbols _ to _ are used to identify

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alignments mark Q, the others being indicated by an alphabetical letter in a box_), the specifications appearing in the text.

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An
A condition
encircledofnumeral
a faulty component
indicateswill
a part
precede
name,
an and
arrow
ansymbol
encircled
andalphabetical
the course of
letter
action
data
required
for an _
thesymbol (_). ' _ Filling
fluid

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@ i @ _ Lubricant

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Each chapter provides exploded diagrams are before each disassembly section for ease in identify- @ Tightening
EXPLODED DIAGRAM <_ i_ @ Special tool
ing correct disassembly and assembly procedures. @ Wear limit, clearance

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@ Engine speed

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OVA
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' _. :_-_.,_.._,';__
..... :;"--L'..'._,
_ _ _ _ Illustrated symbols _ to @ in the exploded dia-
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lubrication point.
"",_ gram indicate grade of lubricant and location of
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_- .- _';"
............. !_ .... _ _ _I @ I _ , _ Apply engine oil
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__,_., --i --| --_ @ Apply molybdenum

_) gear oil disulfide oil
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__--:5: , Apply lightweight lithium-soap base

_---- _--_1'_ :,T_...:.:....C.__,_I_:;-_,..,_tF-.-"'_
":_""';_"- I _:_'_ ...... J _1___
_ _ @ _ Apply wheel bearing grease
grease
r/,_, j _| [ E,;2_;c_E _-- _ _ @ Apply molybdenum disulfide grease
-_-_, :_"':'_- _ _ _ @Applylockingagent(THREADLOCK)
@ Use new one
 A-4 I
INDEX

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SPECIFICATIONS

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PERIODIC INSPECTION I _ I

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AND ADJUSTMENT I '"sP

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ENGINEOVERHAUL

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CARBURETION

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CHASSIS
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ELECTRICAL
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TROUBLESHOOTING
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 I GEN

CHAPTER 1.
GENERAL INFORMATION

SCOOTER IDENTIFICATION ....................................................................... A-8

VEHICLE IDENTIFICATION NUMBER ................................................... A-8
ENGINE SERIAL NUMBER .................................................................... A-8

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IMPORTANT INFORMATION ...................................................................... A-8

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ALL REPLACEMENT PARTS ................................................................ A-8

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GASKETS, OIL SEALS, AND O-RINGS ................................................. A-8
LOCK WASHERS/PLATES AND CO'I-I'ER PINS .................................. A-8

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BEARINGS AND OIL SEALS .................................................................. A-8

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CIRCLIPS ................................................................................................ A-9

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SPECIAL TOOLS .......................................................................................... A-9

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FOR TUNE UP ........................................................................................ A-9

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FOR ENGINE SERVICE ......................................................................... A-9
FOR CHASSIS SERVICE ..................................................................... A-10

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FOR ELECTRICAL COMPONENTS ..................................................... A-10

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 SCOOTER IDENTIFICATION IGE" I
INFO A- 8 1 IMPORTANT INFORMATION IE"
INFO

INFORMATION ALL REPLACEMENT PARTS

1. Use only genuine parts for all replacements.
SCOOTER IDENTIFICATION Useoil and/or grease recommended by MBK/
VEHICLE IDENTIFICATION NUMBER _'-.._ _ _O YAMAHAforassemblyandadjustment.Other

The vehicle identification numbere is stamped _._ __ _ brands may be similar in function and appear-
_ _ _ NOTE:
into the frame, ance, but inferior in quality.

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The vehicle identification number is used to

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your scooter with the licensing authority in your 1.All gaskets, seals and O-rings should be re-
state, placed when an engine is overhauled. All

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gaskets surfaces, oil seal lips and O-rings

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2.Properly oil all mating parts and bearing dur-

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VG54RWN0*WA101301 ing reassembly. Apply grease to the oil seal
I Initial serial number: I must be cleaned.

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lips.
identifyyourscooterand maybe usedto register _(_ GASKETS, OIL SEALS, AND O-RINGS

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The engine serial number@ is stamped into the PINS

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_ crankcase. _ 1.All lock washers/plates (_ and cotter pins

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must be replaced when they are removed.
NOTE: _ Lock tab(s) should be bent along the bolt or nut

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The first three digits of these numbers are for _MHr,IH' flat(s) after the bolt or nut has been properly

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model identifications; the remaining digits are tightened.
the unit production number.
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I 4UY-200101
Initial serial number: 1. Install the bearing(s) (_ and oil seal(s) with
their manufacturer's marks or numbers facing
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NOTE: outward. (In other words, the stamped letters

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Designs and specifications are subjectto change must be on the side exposed to view.) When
without notice, installing oil seal(s), apply a light coating of
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lightweight lithium base grease to the seal

lip(s). Oil the bearings liberally when installing.
O_ BEARINGS AND OIL SEALS
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CAUTION: _

__ bearings dry. This causes damage to the

bearing surfaces.

Do not use compressedair to spin the

1 -1 1 -2
 IMPORTANT INFORMATION/SPECIAL TOOLS IE"
_ I
INFO A" 9 J SPECIAL TOOLS IGE"I
INFO
CIRCLIPS Flywheel magneto puller

c_) [_ clips once

fore they have
reassembly. Always

care,u,, 08
been removed.
replace piston

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Replace
pin
bent circlips. When installing a circlip _) make
sure that the sharp edge _ is positioned
opposite to the thrust L_ it receives. See the
sectional view.
FOR ENGINE SERVICE

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Shaft

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Crankcase separating tool Flywheel holding tool

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SPECIAL TOOLS 90890-01135 90890_0t_'_ f{_

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plete and accurate tune-up and assembly. Us-

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ing the correct special tool will help prevent

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damage caused by the use of improper tools or
improvised techniques.

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The proper special tools are necessary for com- _ _ (_

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Inductive tachometer ] Crankshaft installing tool set Clutch serving nut
wrenc_

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90890-01277 (_) ._

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FOR TUNE UP 90890-01411 (_ \_';_:i"

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90890-03113
__ fro 1
90890-01275 _)
90890-01274 _) ;_'#--'_ 90890-01348
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Ignition checker Sheave holder Clutch spring holderri a f_ c-_

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g0890_0_4
_ go8go.01_01 00890_01010g8901_
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Oil Seal Guide

90890-01409 (D
Oil Seal Driver _/

1-3 1-4
 GEN
SPECIAL TOOLS
I 'NFO
I _1_1 IA- _ol II.FO_1
Ring nut wrench
90890-01268 _ ,_ _
90890-01403 _)

FOR CHASSIS SERVICE

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Damper rod holder T-Handle

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90890o01294 90890-01326

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Oil seal guide Oil seal guide adapter
90890-01184 90890-01186

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Pocket Tester
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FOR
COMPONENT
ELECTRICAL 90890-03112 _
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-/___/
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 IsPEc
_'1tA-131 IsPEc
_1
CHAPTER 2.
SPECIFICATIONS

GENERAL SPECIFICATIONS .................................................................... A-14

MAINTENANCE SPECIFICATIONS ........................................................... A-15

ENGINE ................................................................................................ A-15
CHASSIS .............................................................................................. A-16

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ELECTRICAL .......................................................................................... B-1

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CABLE ROUTING ......................................................................................... B-2

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 GENERAL SPECIFICATIONS I SPEc /'(_'1 IA-41 GENERAL SPECIFICATIONS I SPEC /(_i'

SPECIFICATIONS Model CW50

GENERAL SPECIFICATIONS Clutch type: Dry, centrifugal automatic
Transmission:
Model CW50 Primary reduction system Helical gear
Dimensions: Primary reduction ratio 52/13 (4.000)
Overall length 1,740 mm (68.5 in) Secondary reduction system Spur gear
Overall width 665 mm (26.2 in) Secondary reduction ratio 43/13 (3.3077)
Overall height 1,050 mm (41.3 in) Transmission V-belt
Seat height 745 mm (29.3 in) Operation Automatic

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Wheelbase 1,170 mm (46.0 in) Chassis:

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Minimum ground clearance 125 mm (4.9 in) Frame type Steel tube underbone

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Basicweight: Casterangle 27

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With oil and full fuel tank 78 kg (172 Ib) Trail 90 mm (3.54 in)
Minimum
turningradius: 1,800mm(70.9in) Tire:

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Engine: Type Tubeless

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Type Air-cooled 2-stroke, gasoline torque induction. Size front 120/90 - 10

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Cylinder arrangement Single cylinder, Vertical rear 130/90 -10
Displacement 49 cm3 Manufacturer front DUNLOP (TRAIL MAX)

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Bore x stroke 40 x 39.2 mm (1.57 x 1.54 in) MICHELIN (REGGAE TL)

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Compression ratio 7.01 : 1 rear DUNLOP (TRAIL MAX)
Starting system Electric and kick starter MICHELIN (REGGAE TL)

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Lubricationsystem: Separatelubrication (Yamaha Autolube ) Tire pressure (cold tire):
Maximumload-exceptscooter 152 kg (335Ibs)

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Oil type or grade: Up to 90 kg (198 Ibs) load

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Engine oil Semi-synthetic oil in accordance to the Front 100 kPa (1.00 kgf/cm2, 15 psi)
API TC TS C3 standard. Rear 125 kPa (1.25 kgf/cm2, 18 psi)

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Transmission oil SAE 10W30 type SE motor oil 90 kg (198 Ibs) ~ maximum load
Oil capacity:
Engine oil:
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Rear
100 kPa (1.00 kgf/cm2, 15 psi)
150 kPa (1.50 kgf/cm2, 21 psi)
Total amount 1.3 L (1.14 Imp qt, 1.37 US qt) Brake:
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Transmission oil: Front brake type Disc brake

Periodic oil change 0.11 L (0.10 Impqt, 0.12 US qt) Operation Right hand operation
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Total amount 0.13 L (0.11 Impqt, 0.13 US qt) Rear brake type Drum brake
Airfilter: Wettypeelement Operation Lefthand operation
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Fuel: Suspension:
Type Regular unleaded gazoline (RON 91 mini) Front Telescopic fork
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Tank capacity 4.6L(1.01Impgal,1.21USgal) Rear Unitswing

Carburetor: Shock absorber:
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Type PHBN12HS Front Coil spring/Oil damper

Manufacturer DELL'ORTO Rear Coil spring/Oil damper
Spark plug: !Wheel travel:
Type/Manufacturer BR8HS/NGK Front wheel travel 62 mm (2.44 in)
Gap 0.5 - 0.7 mm (0.020 ~ 0.028 in) Rear wheel travel 60 mm (2.36 in)

2-1 2-2
 I P'=c IA-lSI MAINTENANCE SPECIFICATIONS I SPEc /'_'1
Model CW50 MAINTENANCESPECIFICATIONS
Electrical: ENGINE
Ignitionsystem CDI Model CW50
Charging system Flywheel magneto
Battery type/model GM4-3B/YB4L-B/FB4L-B Cylinder head:
Battery capacity 12V 4AH Warp limit 0.03 mm (0.0012 in)
,k * Lines indicate straight edge measurements.
Headlight type: Bulb __
Bulb wattage / quantity:

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Taillight/brake light 12V 5W/21 W x 1

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Flasher light Front 12V 10W x 2 -_'_ _'_
Rear 12V 10W x 2 Cylinder:

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Meter light 12V 3W x 1 Bore size 39.993 - 40.012 mm (1.574 ~ 1.575 in)

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Warning lights wattage / quantity: <Limit> <40.1 mm (1.579 in)>

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"OIL" 12V 3W x 1 Taper limit 0.006 mm (0.0002 in)
"TURN" 12V 3W x 1 Piston:

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"HIGH BEAM" 12V 3W x 1 MeasuringPiStn
size point . _ _' 39.952 - 39.9725.0
mmmm(0.2(1.573in)
~ 1.574 in)

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Piston clearance 0.034 ~ 0.047 mm (0.0013 - 0.0018 in)

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<Limit> <0.1 mm (0.004 in)>

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Piston pin bore size 10,004 ~ 10.015 mm (0.3938 - 0.3943 in)
Piston pin:

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Outside diameter 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in)
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Top ring 1.2 ~ 1.8 mm (0.047 ~ 0.070 in)

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Sectional sketch (B x T)/Type: L_j_ B
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2ndring - T - 1.2 -1.8 mm (0.047~ 0.070 in)

End gap (installed):
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Top ring 0.15 ~ 0.30 mm (0.006 - 0.012 in)

2nd ring 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
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Side clearance (installed):

Top ring 0.03 - 0.05 mm (0.0012 - 0.0020 in)
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2nd ring 0.03 - 0.05 mm (0.0012 ~ 0.0020 in)

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2-3 2-4
 MAINTENANCE SPECIFICATIONS IsPECIA-161 MAINTENANCE SPECIFICATIONS

Model CW50 CHASSIS

Crankshaft: Model CW50

Steeringbearingtype Ballbearing
E- No/Size of steel balls:
B__:J Steering system:
Upper 22 pcs (3/16 in)
Crank width "A" 37.90 - 37.95 mm (1.492 - 1.494 in) Lower 22 pcs (3/16 in)
Runout limit "C" 0.03 mm (0.0012 in) Front suspension:

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Connecting rod big end side clearance "D" 0.2 - 0.5 mm (0.008 - 0.020 in) Front fork travel 70 mm (2.75 in)
i Automatic centrifugal clutch: Spring Rate (K1) 10.8 N/ram (1.08 kg/mm, 60.46 Ib/in)

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Shoe thickness 4.0 mm (0.16 in) Stroke (K1) 0 ~ 40 mm (0 ~ 1.57 in)

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<Wear limit> <2.5 mm (0.10 in)> Spring Rate (K2) 14.4 N/ram (1.44 kg/mm, 80.61 Ib/mm)

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Clutch shoe spring free length 26.2 mm (1.03 in) Stroke (K2) 40 ~ 77 mm (1.57 in ~ 3.03 in)
Clutch-in revolution 3.200 ~ 3.600 r.p.m. Optional spring No

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Clutch-stall revolution 6.300 - 6.900 r.p.m. Rear suspension:

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V-belt: Shock absorber travel 60 mm (2.36 in)
Width 15 mm (0.59 in) Spring free length 202 mm (7.95 in)

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<Wear limit> <13.5mm(0.53in)> Springfittinglength 187.5mm(7.38in)

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Transmission: Spring Rate 32.5 N/ram (3.25 kg/mm, 181.93 Ib/mm)
Main axle runout limit 0.08 mm (0.003 in) Stroke 0 ~ 44 mm (0 ~ 1.73 in)

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Drive axlerunout limit 0.08mm(0.003 in) Optional
spring No

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Kick starter: Wheels:

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Type Ratchet type Front wheel type Cast wheel
Kick clip tension 150 ~ 250 g (5.3 - 8.8 oz) Rear wheel type Cast wheel

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Carburetor: Front wheel size MT 3.50 xl0

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I.D. mark PHBN12HS Material Aluminium
Main jet (M.J.) # 93 Front wheel size MT 3.50 xl0
Main air jet (M.A.J.) 2.0
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Jet needle (J.N.) A21-3/5 Rim runout limit:
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Needle jet (N.J.) 2.110 Front 2.0 mm (0.08 in)
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Cutaway (C.A.) 4.0 Rear 2.0 mm (0.08 in)

Pilot jet (P.J.) # 36 Front disk brake:
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Bypass (B. P.1) 0.8 Type Single disk

Pilot air screw (A.S.) 1-5/8 _+114out Diameter & thickness 155 x 3.5 mm (6.102 x 0.137 in)
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Valve seat size (V.S.) 1.2 Pad thickness 3.25 mm (0.127 in)
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Starter jet (G.S.1) # 40 <Wear limit> <0.8 mm (0.03 in)>

Float height (F.H.) 15 - 17 mm (0.59 ~ 0.67 in) Master cylinder inside diameter 11 mm (0.43 in)
Fuel height (F.L.) 20.5 ~ 22.5 mm (0.80 ~ 0.88 in) Caliper cylinder inside diameter 30 mm (1.18 in)
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(Center of float chamber / Fuel height) Brake fluid type DOT #3 or DOT #4
Engine idlespeed 1800_+
200rpm Reardrumbrake:
Reedvalve: Type Leading,trailing
Valve stopper height 4.0 ~ 4.4 mm (0.157 ~ 0.173 in) Drum inside diameter 110 mm (4.33 in)
Reed valve clearance 0.2 mm (0.008 in) <Wear limit> <110.5 mm (4.35 in)>
Lubrication system: Autolube pump Lining thickness 4.0 mm (0.16 in)
Stroke 2.62 mm (0.10 in) <Wear limit> <2.0 mm (0.08 in)>
Bore 0.5 mm (0.02 in) Spring free length 54 mm (2.125 in)
Front brake lever freeplay: 10 ~ 20 mm (0.4 ~ 0.8 in)
Rear brake lever freeplay: 10 ~ 20 mm (0.4 - 0.8 in)

2-5 2-6
ELECTRICAL
M.,.TE.A.OE.PEC,..C..,O.S
Is Ec B-1I M.,.TE...CES.EC,F,C
ISPEC Model CW50
Model CW50 Battery:
Voltage: 12 V Capacity 12V, 4 Ah
Ignition system: Specific gravity 1.280
Ignition timing (B.T.D.C.) 14 at 5.000 r/rain Starter motor:
Output 0.14 kW
CDI: Armature coil resistance 0.072 _ a 20C (68F)
Pickup coil resistance (color) 400 ~ 600 Q at 20C (68F) (White/Red-Black) Brush length 6.8 mm (0.27 in)
Source coil resistance (color) 640 ~ 960 Q at 20C (68F) (Black/Red-Black) <Wear limit> <5.3 mm (0.21 in)>

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Ignition coil: Brush spring pressure 150 - 650 gr (5.29 ~ 22.92 oz)

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Minimum spark length 6 mm (0.23 in) Commutator diameter 15.8 mm (0.62 in)

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Primary coil resistance 0.56 ~ 0.84 Q at 20C (68F) <Wear limit> <15.0 mm (0.60 in)>

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Secondary coil resistance 5.68 - 8.52 Qk at 20C (68F) Mica undercut 1.15 mm (0.045 in)
Spark plug cap: Starter relay:

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Resistance 5 k.Qat 20C (68F) Amperage rating 20 A

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CDI Magneto: Coil resistance 54 - 66 _ at 20C (68F)

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Lighting coil resistance 0.32 ~ 0.48 Q at 20C (68F)(Yellow/Red-Black) Horn:
Lighting coil resistance 0.48 ~ 0.72 Q at 20C (68F)(White-Black) Type/Quantity Plain type/1 pc.

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Voltage regulator/Rectifier: Model/Manufacturer TR9/FRANSVAL
Type Semi-conductor, short-circuit type Maximum amperage 2.5 A

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No load regulated voltage 13 ~ 14 V Flasher relay:

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Capacity 8A Type Condenser type

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Withstand voltage 600 V Self cancelling device No
Flasher frequency 70 - 90 cycle/rain

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Wattage 2 x 10W + 4 W

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Circuit breaker:
Type Fuse
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Main 7Ax1
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Fuel sender unit:
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Resistance (full) 4 - 10 _ at 20C (68F)

(empty) 90 - 100 _ at 20C (68F)
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2-7 2-8
_3) Rim []
CA..E.OUT,.O
IS" clPI
IB'2
Do not cover the frame number. _) Handlebar []
CALE.OT,.O
IS"EclP
The right handlebar switch leads must pass along the underside
_) Tire [] Attach the brake hose, starter switch cable and the brake cable _) Left handle bar switch of the handlebar, then behind the boss on the lower handlebar
Brake disc together behind the horn bracket. Right handlebar switch cover.
Brake caliper [] The throttle cable must have sufficient free play. _) Handlebar wire harness holder [] Pass the couplers behind the speedometer cable, and after
_) Brake hose guide (Lower) [] Clamp the brake hose into the upper holder. _ Flasher relay connecting them, fit them under the right side of the
Brake hose guide (Upper) [] With a band tie the choke cable, the throotle cable and the rear _) Speedometer cable speedometer.
Throttle cable brake cable to the left side, the wire harness to the right side of _) Throttle cable [] The left handlebar switch leads must pass along the underside of
Wire harness the frame. Lower handlebar cover the handlebar, then in front of the boss on the lower handlebar
Speedometer cable (9) Front brake hose cover.
Brake hose _ Flasher ground [] Attach the front flasher ground to the handlebar.

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_) Choke cable [] The throttle cable must pass in front of the handlebar.
[] Pass the flasher relay leads under the handlebar.
@ Rear brake cable [] The brake light leads must pass along the underside of the

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handlebar (left and right).

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[] The wire harness holder must pass over the handlebar.

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[] The brake hose union bolt must touch the right side of the boss.

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2-9 2-10
(_) Choke cable []
OASLEROT,
NO
ISPECl;]
IB'3
Tie the choke cable,throttle cable, rear brake cable, and speedometer
Is'c
(_) Throttle cable cable to the left side of the handlebar.
Rear brake cable [] Pass the wire harness along the right side of the handlebar.
(_ Speedometer cable [] Clamp the front brake hose to the lower cover.
Front brake hose [] The speedometer cable must pass belween the steering tube and the
(_ Main switch main switch bracket.
(_) Wire harness [] Attach the wire harness to the side of the main switch bracket with a band.
Horn [] The wire harness must run straight (no loops)between the two bands.
Steedng tube [] Attach the wire hamess with a band to the steedng tube just above the
Lower cover wire bracket.

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[] The speedometer cable must pass through the hole in the front fender.
[] The speedometer cable must pass through the hole in the lower fender.

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[] The horn leads must pass behind the horn bracket and behind the wire

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bracket.

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[] The front brake hose must pass through the wire bracket.
[] The front brake hosde must pass through the hole in the fender.

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II = .....

2-11
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 I INSP BEI
- I I
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION ........................................................................................... B-7

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................... B-7

COVERS ....................................................................................................... B-7

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REMOVAL ............................................................................................... B-7

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INSTALLATION ....................................................................................... B-8

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ENGINE ........................................................................................................ B-9

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ENGINE IDLE SPEED ADJUSTMENT ................................................... B-9

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THROTTLE CABLE FREE PLAY ADJUSTMENT .................................. B-9

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SPARK PLUG INSPECTION ................................................................ B-10
AUTOLUBE PUMP AIR BLEEDING ..................................................... B-10

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ENGINE OIL LEVEL INSPECTION ...................................................... B-11

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TRANSMISSION OIL REPLACEMENT ................................................ B-11
AIR CLEANER ELEMENT CLEANING ................................................. B-12

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CHASSIS .................................................................................................... B-12

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FRONT BRAKE LEVER FREE PLAY ADJUSTMENT .......................... B-12

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REAR BRAKE LEVER FREE PLAY ADJUSTMENT ............................ B-12

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BRAKE PADS INSPECTION ................................................................ B-12
BRAKE SHOES INSPECTION ............................................................. B-13

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AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ................................ B-13
fro STEERING HEAD ADJUSTMENT ........................................................
TIRE INSPECTION ...............................................................................
B-14
S-14
WHEEL INSPECTION .......................................................................... B-15
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CABLE INSPECTION AND LUBRICATION .......................................... B-15
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LEVER LUBRICATION ......................................................................... B-15

CENTERSTAND LUBRICATION .......................................................... B-15
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REAR SHOCK ABSORBER ................................................................. B-15

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ELECTRICAL .............................................................................................. B-16

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BATTERY INSPECTION ....................................................................... B-16

FUSE INSPECTION .............................................................................. B-16
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HEADLIGHT BEAM ADJUSTMENT ....................................................... C-1

 LUBRICATION
INTRODUCTIONIPERIOOIC INTERVALS
MAINTENANCEI I ADJ
INSP IF_ I I B- 7 COVERS I_
INSP _ I
PERIODIC INSPECTION AND ADJUSTMENT _ I __ COVERS

, -! 1. Remove:
ments. Theseincludes
This chapter
INTRODUCTION preventive maintenance
all information procedures,
necessary if followed,
to perform will ensureinspections
recommended more reliable
and vehicle
adjust- i_ d Seat C)
REMOVAL

information applies to vehicles already in service as well as new vehicles that are being prepared for ,/___I_ .Helmet holder (_)
sale. All service technicians should be familiar with this entire chapter.
I
operation and a longer service life. The need for cosUy overhaul work will be greaUy reduced. This i_<_
(___ _ _ __

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Unit : Km(miles)
EVERY
_ Taillight leads

light

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BREAK-IN 3,000 8.000 Flasher leads
ITEM ROUTINE 1,000(600) (2,000)or
8 months
(4,000)or
12 months
3. Remove:

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Check condition. O Rear carrier C)
PERIODIC MAINTENANCE/LUBRICATION _ _!_
-_ ::=_ 2. Disconnect:

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2 Air filter Replace if necessary.

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Check idle speed/choke operation.
3 Carburetor Adjust if necessary. O O

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1 Spark plug Clean.Clean
Check or
fuelreplace if necessary.
hose and vacuum pipe for cracks or O O _J _ _ Washer
4 Fuel line damage. O O

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Replace if necessary, 4. Remove:
S i Transmission oll Correct if necessary. REPLACE O Central cover (_

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Replace every 12,000 (8,000) or 24 months.
(Warm engine before draining.)

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Check operation.
6 Autolube pump Correct if necessary. O

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Bleed the air.

7 Front brake system Check operation/fluid leakage/See NOTE. (Page 9-3).

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Correct
Check if necessary.
for oil leakage, O O O

8 Rear brake system Check

Adjust ifoperation,
necessary. O O __

9 Wheels Check damage/runout/tightening

Replace/tighten if necessary.
torque.
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fro

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1( Wheel bearings Check bearing assembly for looseness/damage.
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Check bearing assembly for looseness.

11 Steering bearing Correct if necessary. O Front cover (D
Moderately repack every 12,000 (8,000) or 24 months.** 6. Disconnect:
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1". Rear shock absorber Check operation/oil

Replace if necessary.leakage, O o Headlight leads
1,'. V-belt Check damage and wear.
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Replace if necessary. O
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IL Fitting/Fasteners Check all chassis fittings and fasteners.

33ghtan if necessary, O

1,= Centerstand Repair if necessary. O O e_.

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Check operation.
Replace
Check specific gravity,
if damaged, O _ _ -- 5. Remove:
1( Battery Check breather pipe for proper operation. O O
Correct if necessary.
Items marked with an asterisk I I require special tools, data and technical skills for servicing. 7. Remove:
Take the scooter to a Yamaha Dealer or refer to the Service Manual when servicing these items. Main switch cover (D

* : Medium weight wheel bearing grease. _ NOTE:

NOTE: Turn the main switch cover counterclockwise
Brake fluid replacement: and pull it out.
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally

check the brake fluid level and add fluid as required. _ Front panel (_
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or when cracked or damaged.

3-1 3-2
 COVERS I INSP
_ _ffr_ I B-8 I COVERS I INSP_ _1

, _ Footrest board (D Front panel (D

Bottom cover (_) Main switch cover (_)

:__ . _ NOTE:
Insert the main switch cover and turn it clockwise.

Insert the projections of the front panel into the

t_ _
_ 8. Remove: ___ 4. Install:
slot
NOTE:of the footrest board.

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Screws (Handlebar cover) (D : ::_' ; Headlight leads

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eove Conn
Speedometer cable (_) 6. Install:

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Couplers Front fender
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11.
Remove: NOTE:
o Handlebar cover (Upper) (_) Insert the projection "a" of side cover into the slot

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"b" of footrest board.

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10. Disconnect :

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/ INSTALLATION: f 7. Install:
Reverse the "REMOVAL" procedure. Note Central coverO

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the following points.

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1. Connect: NOTE:

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o Speedometer cable Insert the projection "a" of central cover into the
Couplers [l_'_:_"_ _ _ slot "b" of footrest board.

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for
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Correct routing of cables and wires is essential
NOTE:
a safe operation of this scooter. Refer to _(D
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Rear carrier (D
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Handlebar cover _ Seat

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NOTE: NOTE:
2."CABLEInstaIt:ROUTING"
in Chapter 2. ___"_ "\_ __ 8. Install:
Be careful not to pinch any wires with the covers. After con necting the tail and flasher light lead,
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D

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locate
Helmet
the couplers
holder inside the rear fender.
17 (Rear
Nm (1.7 m.kg, 12.3 ft.lb)
carrier):
Bottom cover (_) 15.5 Nm (1.55 m.kg, tl.21 ff.lb)
' Footrest board (_) Nut (Seat):
8 Nm (0.8 rn.kg, 5.8 ft.lb)
NOTE:
Mesh the projections of footrest board and bot- NOTE:
_ tom cover. When installing the covers, be careful not to
_ _ __ _ 3. Install: damage the mounting
- Nut clips.
(Rear carrier):

3-3 3-4
 ENGINE IDLE SPEED ADJUSTMENT I'"sP II
_ _ B - 9 THROTTLE CABLE FREE PLAY ADJUSTMENT I'"sP I
_

ij j 1. Tighten: 1. Check:
Pilot air screw O -Throttle cable free play @
Turn the pilot air screw in until lightly seated. Out of specification ---*Adjust.

2. Loosen: --_Free 1.5play

~ 3.0@:
mm (0.06 ~ 0.12 in)
o Pilot air screw
__ ENGINE IDLE
Back out SPEED
from ADJUSTMENT
the lightly seated position. MENT
.-.:=::::::==::::=_xx=_==:_x-,=:=:=__

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Throttle cable free play adjustment steps:

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1-518turns
air screwout -+114 NOTE:

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f_ Pilot position: I
Before adjusting the throttle cable free play, the

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3. Start the engine and let itwarm up for several engine idle speed should be adjusted.
minutes.

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V!IW_,I;1 _11_
[]I First step:
Loosen the Iocknut (_) on the throttle cable.

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For safety reasons, place the scooter on Turn the adjuster (_) in or out until the speci-
the center stand before starting the engine, fled free play is obtained.

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4, Attach: Turn in Free play increased.
Inductive tachometer

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(to the spark plug lead) Turn out Free play decreased.

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'ndut'vetac'meter:
.ef:..0.03t
1, I T0 tent,e

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_WARNING
After adjusting, turn the handlebar to the
fro right and left, making sure that the engine
idling speed does not change.
5. Check:
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Engine idle speed ::::::::":::::::==::":::::::=::*_**_::::::::::*"*"*

Out of specification -) Adjust.
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1800 + 200 rlmin I

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6. Adjust:
Engine idle speed
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Turn the throttle stop screw O in or out until

__ specified idling
Adjustment steps: speed is obtained.

Turning left Idling speed increased.

Turning right Idling speed decreased.

3-5 3-6
 I INSP
SPARK PLUG INSPECTION
SPARK PLUG INSPECTION
I IB-101 /_ .4 AUTOLUBE PUMP AIR BLEEDING
I
Spark plug ;_ ,i,/_ " Fan cover (_
2. Check: _,_'_-_H_'/I_
'
Spark plug type
Incorrect _ Replace
1. Remove: _ _ 1, Remove:

i BR8HS (NGK) I

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_, '_ .... 2. Bleed:

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Wear/Damage _ Replace. *......................................................

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. Insulator
Electrode(_)
O ___ _ Pump bleeding steps:

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Abnormal color _ Replace. -_ //_-_(,_.=_E_i ll\ \ \\_\ _ Place a rag under the pump.

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@ Normal color is a medium-to-light tan color, __/_i_
'_ ""' i__ Remove
Let oil runthe bleed
until therescrew
are no(_.
more air bubbles

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3. Inspect: '/_- \\_ ' '\ \\- Pump housing and oil hose

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4. Measure:
Plug gap @ __ When
init. there are no more bubbles, tighten the
Out of specification .-, Adjust gap. bleed screw.

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Use a wire gauge or feeler gauge. NOTE:

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I_ 0.5 ~plug
Spark 0.7 mm
gap (0.020
@: ~ 0.028 in) If it is damaged,
Check replace
the condition it with
of the bleeda screw
new one.
gasket.

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5. Tighten: Start theengine.

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Spark plug Let the engine run two or three minutes at
2000 rpm. This will force out any air in the
NOTE: fro
Before installing the spark plug, clean the gasket
hose.
........ , ................. ******............. , .........
surface and plug surface.
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NOTE:
First tighten by hand, then torque to specifica-
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tion.
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I_ 20 Nm
Spark (2.0 m.kg, 14ft.lb)
plug: I
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3-7 3-8
 ENGINE OIL LEVEL INSPECTION
ENGINE OIL LEVEL INSPECTION
B - 11 I _ _
TRANSMISSION OIL REPLACEMENT
" ' __ TRANSMISSION OIL REPLACEMENT
I'"sPI
_ _

_ Oil level _ -_) Drain plug @

30 Oillevellow --Add oiltoproperlevelas 'i
II
II 20_'?_- _ 8o ,= ,_-_l follows. ' Drain the transmission oil.

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_'_'_h,40
50 60 70 _-- _ .(_ ,, __!_//: / "Oil
Gasket
filler (drain
plug_ plug)
t __"_" _'_'El_-_ II O "OIL" indicator light 2. Check:
_J"" O-ring (oil filler plug)

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Damaged _ Replace.

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OIL LEVEL AND GAUGE CHECK "_-,,"_ _ 3. Install:

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_, ,_,_ -Gas ket(_
Turn
main
T
switch _
Drain plug:
Drain plug (_)

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_ 17.5 Nm (1.75 m.kg, 12.6 ft.lb)

to. I

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I doesn't
"OIL" light,
indicator I light.
"OIL"indicator 4. Fill:

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Transmission case

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ITrn
a'n
switch
to "ON". ,r--m,.,on
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SAE 10W30 type SE motor oil

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I Periodic replacement
_ 0.11 L (0.10 Imp qt, 0.12 US qt)

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stays on. I i Capacity:
0.13 L (0.11 Imp qt. 0.13 US qt)

_ ' fro NOTE:

electrical circuit, and electric circuit Wipe off any oil spilt on the crankcase, tire or
I"OIL" indicatorgoes_ _ "OIL" indicator I Total amount
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I Inspect FaulW Engine
are oil
OK.level Add_ oil. J
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Light bulb etc. wheel.

t I "OlL'indicstor
J 5 Install:
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stays on. Oil filler plug

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to theAPITCTSC3standard.
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Capacity :
Total:
t.3 L (1.14 Imp qt, 1.37 US qt)

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

into the filler.
NOTE:

Always use the same type of engine oil;

mixing oils may result in a harmful chemical
reaction and lead to poor performance.

3-9 3-10
 FRONT BRAKE LEVER FREE PLAYADJUSTMENT/

AIR FILTER ELEMENT CLEANING

-J-_ AIR FILTER ELEMENT CLEANING
I _ _ IIB - 12 I BRAKE PAD INSPECTION
CHASSIS
_ _r_ I
z _ _ 1. Remove: _(_) FRONT BRAKE LEVER FREE PLAY AD-

/ 2. Remove: _ 1. Check:
/ Air filter element Front brake lever free play @

: CAU_i0N_:: Out of specification _ Adjust.

Air cleaner case cover (_) _ JUSTMENT
/ element removed.
Never operate Unfiltered
the engine air will
with the cause
air cleaner _ 10 play:
Free ~ 20 mm (0.4 ~ 0.8 in) I

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/ rapid wear of engine parts and possible
._ J engine damage. :CAUTiONi

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JJ A soft or spongy feeling in the brake lever can
3. Inspect: indicate the presence of air in the brake

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Element (T) system. Thisairmustberemoved bybleeding

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Damage-* replace, the brake system before the scooter Is
4. Clean: operated. Air in the system will reduce brake

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Air filter element performance and can result in loss of control

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and an accident. Inspect and bleed the system
// ::=:::::::::=:::::::::::::::::=::::::=::::==:::::::"_ if necessary.

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r' Cleaning steps:
Wash the element gently but thoroughly in REAR BRAKE LEVER FREE PLAY AD-

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solvent. (_)__ JUSTMENT
1. Check:

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_l.*liW,_l;l_ll_,[Hll __=_ Rear brake lever free play @

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gasoline to clean the element. Such solvents h=,
may lead to fire or explosion. _ Free play:

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10 ~ 20 mm (0.4 ~ 0.8 in)
Never use low flashpoint solvents such as
Squeeze excess solvent out of the element
and let dry.
fro ___ r'_'xIOutof specification --*Adjust. I
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....... ........ Front brake lever free play

Do not twist the element ....................................................
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,_ =b Adjustment steps:
Apply foam air filter oil or SAE 10W30 typ SE Turn the adjuster (_) in or out until the speci-
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Sqeeze out the excess oil. , ..................................................

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_ _ _//_ 2. Adjust:
Q_ oil on the element, fled free play is obtained.
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NOTE:

Out of specificatin _ Replace brake pads.

The element should be wet but not dripping. /_,_ __'__ INSPECTION1..Measure:Brake
BRAKE PADS
pads @

.OTE
Replace the brake pads and spring as a set
when replacing the brake pads.

_70o_ _ Brake pads wear limit:

0.8 mm (0.03 in)

3-11 3-12
 BRAKE "E'"S"OE''"SPEC"O"'I'"SP
FLUID IIB = 13 I
LEVEL INSPECTION -A_ R_ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) I'"sp [
A-_

J
// 1. pp,y
therear
bra e,ever. (.YD OL,C
1. Bleed:
SYSTEM)

2. Inspect: Brake fluid.

Wear indicator O _=:_="_::_`"_`_`"_`"_"_-`_"_"_"_=_=_=_=_=_=_:_
Indicator reaches the wear limit line (_) .-, Air bleeding steps:
Replace brake shoes, a. Add proper brake fluid into the reservoir.
b. Install the diaphragm. Be careful not to spill
I .RAKE
S.OE,NSPECT.ON A,R=EEO..O
any fluid or allow the reservoir to overflow.

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c. Connect a clear plastic tube O tightly to the

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BRAKE FLUID LEVEL INSPECTION / /// //_ _ _I\
' caliper bleed screw.

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NOTE: / , , \ d. Place the other end of the tube into a con-

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the fluid level, and make sure be turning the O f. Pull the lever as far as possible and hold it
handlebar that the top of the master cylinder is there.

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horizontal, g. Loosen the bleed screw and pull the lever all

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Position the scooter straight up when inspecting _ the way.
e. Slowly apply the brake lever several times.
\I_ tainer.the lever is completely pulled, tighten

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"_ -_ _ 3,6co_ h. When
the bleed screw, then release the lever.

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Brake fluid level been removed from the system.

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Brake fluid level is under"LOWER" level line j. Add brake fluid to proper level.

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J [_ _ (D "-* Fill to proper level.
1. Inspect: i. Repeat steps (e) to (h) until all air bubbles have

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R __ DOT # 3 or DOT # 4 bleeding the brake system.

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b/j_._ _/ _ i,_l Recommended
brake
flu,d: fro I ******************************************************
Check the operation of the brake after
CAU_ioNi
The brake fluid may corrode painted surfaces
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or plastic parts. Always clean up spilled fluid
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immediately.
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_lvAvL,l ;I _11_
[rll
Use only the designated quality fluid.
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Otherwise, the rubber seals may deteriorate

causing leakage and poor brake performance.
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Refill with the same type of fluid. Mixing

fluids may result in a harmful chemical re-
action leading to poor brake performance.
Be careful that water does no enter the
master cylinder when refilling. Water will sig-
niflcantly lower the boiling point of the fluid
and may result in vapor lock.

3- 13 3- 14
 I'"sP I I'"sp I
1. Check: Proper loading of your scooter is Important
Steering assembly bearings for the handling, braking, and other perform-
Grasp the bottom of the forks and gently rock ance and safety characteristics of your
the fork assembly back and forth, scooter. Do not carry loosely packed Items
Looseness _ Adjust steering head. that can shift.
*************************************************** Securely pack your heaviest items close to
Steering head adjustment steps: the center of the scooter, and distribute the
STEERING HEAD ADJUSTMENT VT_W_,_I-I_.II_,[!
Remove the front fender and the front panel, weight evenly from side to side. And check

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Refer to "COVERS" section, the condition and pressure of your tires.

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e.
, Tighten the nut (D Makesurethetotalweightofthecargo, rider,

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C)__ Ref : 90890-01268 saddlebags, etc. If approved for this model)

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/ I_=_ Ref:90890-01403
Steering headwrench: doesnot
passenger,exceed
and the maximumloadof
accessories the
(fairing,
scooter. Operation of an overloaded scooter

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NOTE: could cause tire damage, an accident, or

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Tighten the ring nut until no play can be seen. even injury.
_._/ _ Unscrew the securing nut I NEVER OVERLOAD YOUR SCOOTER.

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Install the securing nut _re pressure(oald) Front Rear
Tighten the securing nut (_ Upto 90kg 100kPa 125kPa

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22.5 Nmnut:
(2.25 m.kg, 16.2 ft.lb) 90 kg- maximum 100kPa 150kPa

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I_ I Securing 'I 15psi) 18psi)
load* (1.0Okgflcm_, (1.50kgflcmz,

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NOTE: 15psi) 21 psi)
Set the torque wrench (_) to the ring nut wrench Maximumload: 152kg(335Ib)

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SO that they form a right angle.
Maximumload is the total weightof cargo,rider,pas-

Move the handlebar up and down, and / or

fro (1.00kgf/cm=, (1.25kgflcm',
sengerandaccessories.

back and forth. If the handlebar free play is

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Tire surface

torque. _.'="_i' WearlDamagelCrackslRoad hazards-_ Re-

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Handlebarsecuring
60 Nm (6.0 bolt:
m.kg, 43.4 ft.lb) , . Wheels
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Instal the front panel and front fender. Never attempt even small repairs to the
***************************************************** wheel.
//j/_ ".//).; Damage/Bends --_Replace.
excess, tighten the bolt (_)to the specifiedI _'_'___'i'_" 2. Inspect:
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TIRE INSPECTION Ride conservatively after installing a tire to

Out of specification _ Adjust, If the tire is removed with a tire lever, use a
suitable protection to prevent damaging the
rim.
When installing the tire, make sure the
arrow points to the front.
1. Measure:.
Air pressure allow it to seat itself properly on the rim.

3-15 3-16
 CABLE INSPECTION AND LUBRICATION
TIRE INSPECTION/WHEEL INSPECTION/ I _
INSP _ I IB - 15 I REAR AND
CABLE INSPECTION SHOCK ABSORBER
LUBRICATION/ I _
INSP I

I:_ Tire tread depth 1. Lubricate rotating parts of the levers

Out of specification ._ Replace.

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Recommended lubricant:

(_ I_ (front and
Minimum tire rear):
tread depth Engine oil SAE 10W30
I 0.8 mm (0.03 in) CENTERSTAND LUBRICATION
1. Lubricate rotating parts
(D Tread depth

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(_) Wear
Side wall
indicator I_=_ Recmmended lubricant:
Engine oil SAE 10W30 I

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WHEEL INSPECTION

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1. Inspect:
Wheels

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Damage/Bends _ Replace.

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Never attempt even small repairs tothe wheel.

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CABLE INSPECTION AND LUBRICATION F'==_=_ .___ REAR SHOCK ABSORBER

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1. Check:

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VIIYL, I-'I_II_.[tt Rear shock absorber (D

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A damaged cable sheath will rapidly corrode. Oil leaks/Damage _ Replace.
As a result, the cable cannot move smoothly 2. Check:

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inside the sheath. Since this situation is Tightening torque

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immediately.
dangerous,
1. Check:
replace a damaged fro
cable
I
31.5 bolt:
Upper Nm (3.t 5 m.kg, 22.8 ft.lb)
Lower bolt:
I| 17.5 Nm (1.75 m.kg, 12.6 ff.lb)
Cable sheath
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Cable end
Damage --* Replace.
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2. Check:
Cable movement
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Stickness --* Lubricate.

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Engine oil SAE lOW30

I_ Recommended lubricant:
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NOTE:

into the sheath.

_._ Hold the cable end up and pour a few drops of oil
,,: 3. Lubricate the throttle cable end and the cable

guide notch on thesoap

Lithium throttle grip with
based grease (D.
grease
I_:_ Recommended lubricant:

3-17 3-18
 BATTERY INSPECTION IINSPIIB I
ADJ _ - 1 6 BATTERYINSPECTIONI
FUSE INSPECTION IINSP
_ I
ELECTRICAL :CAgTiONi
I_ I t _ _'_ /_) BATI'ERY INSPECTION

LOWER Battery
fluidlevel it to ensuremaximum
performance.
Fluid level low --_Add to proper level. _IW:I--I_JI_[_
Fluid level should be between upper and
lower level marks. Battery electrolyte is dangerous. It contains
-- UPPER -__ 1. Inspect:
_) Upper level Always
sulfuric charge a new
acid which is battery before
poisonous andusing
highly
caustic.

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Lower
level Alwaysfollowthesepreventive measures:

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Avoid bodily contact with electrolyte as it

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Refill with distilled water only. Tap water can cause severe burns and permanent
contains minerals which are harmful to a eye injury.

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battery. Wear protective eye gear when handling
or working near batteries.

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Antidote (EXTERNAL) :

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- SKIN- Flush with water.
EYES - Flush with water for 15 minutes

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and get immediate medical attention.

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Antidote (INTERNAL) :
2. Inspect: Drink large quantities of water or milk.

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Breather hose Followwith milkof magnesia, beaten egg,
Obstruction _ Remove. or vegetable oil. Get immediate medical

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3. Inspect: attention.

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Battery Batteries generate explosive hydrogen gas.

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Always follow these preventive measures:
........................................................ Charge batteries in a well-ventilated area.

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Replace the battery if: Keep batteries away from fire, sparks, or
Batteryvoltagewillnotrisetoaspecificvalue
or bubbles fail to rise during charging,
fro open flames (e.g., welding equipment,
lighted cigarettes, etc.)
Sulfation of one or more cells occurs. (As DO NOT SMOKE when charging or han-
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indicated by the plates turning white, or an dling batteries.

accumulation of material in the bottom of the KEEP BATTERIES AND ELECTROLYTE OUT
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sell.) OFREACH
OFCHILDREN.
Specific gravity readings after a long, slow
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charge indicate that one cell is lower than the

rest.
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Warpage or buckling of plates or insulators is

evident.
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*******--***--*********************--*********

Specific gravity 1. Open the seat.

Less than 1.280 .-_ Recharge battery. 2. Inspect:
Fuse

_1 0.4 amps/10
Charging hrs
Current: Blown --, Replace,

1.280 at 20C (68 F)

i Specific Gravity:

3- 19 3-20
HEADLIGHT BEAMOS'"SPEOT'O"'I'"SP
I
ADJUSTMENT
***************************************************
_ _ C - 1 I I'"sp I
Fuse replacement steps:
Turn off the ignition,
install a new fuse of the right amperage.
Turn on the switches to verify the operation
of the electric circuit.
if the fuse immediately blows again, check
the electric circuit.

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Never use a fuse with a rating higher than

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specified. An improper fuse may cause

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damage to the electrical circuit, and possibly

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cause a fire.
*****************************************************

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Main circuit: 7A

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1. Adjust:

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Headlight beam

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Higher Turn out screw O

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Lower Turn In screw (_)

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HEADLIGHT
BEAMADJUSTMENT fro
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D

3 - 21 3 - 22
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 I lc-l CHAPTER 4.
I
ENGINE OVERHAUL

ENGINE REMOVAL ...................................................................................... C-5

COVER REMOVAL ................................................................................. C-5
CARBURETOR ....................................................................................... C-5
CABLES, LEADS AND HOSES .............................................................. C-5
ENGINE REMOVAL ................................................................................ C-6

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ENGINE DISASSEMBLY .............................................................................. C-6

e.
REAR WHEEL ........................................................................................ C-6
CENTER STAND .................................................................................... C-6

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CYLINDER HEAD AND CYLINDER ....................................................... C-6

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PISTON PIN AND PISTON ..................................................................... C-6
KICK STARTER ...................................................................................... C-7

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PRIMARY SHEAVE ................................................................................ C-7

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SECONDARY SHEAVE .......................................................................... C-7
STARTER SYSTEM ................................................................................ C-8

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TRANSMISSION ..................................................................................... C-8
CDI MAGNETO ....................................................................................... C-8

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AUTOLUBE OIL PUMP ........................................................................... C-9

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CRANKCASE AND CRANKSHAFT ........................................................ C-9

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INSPECTION AND REPAIR ....................................................................... C-10

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CYLINDER HEAD ................................................................................. C-10

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CYLINDER AND PISTON ..................................................................... C-10
PISTON RINGS .................................................................................... C-11
fro PISTON PIN AND PISTON PIN BEARING ........................................... C-11
KICK STARTER .................................................................................... C-12
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TRANSMISSION ................................................................................... C-12
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AUTOLUBE PUMP ............................................................................... C-12

CRANKSHAFT ...................................................................................... C-12
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PRIMARY SHEAVE .............................................................................. C-12

SECONDARY SHEAVE ........................................................................ C-13
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V-BELT .................................................................................................. C-13

STARTER CLUTCH AND GEARS ........................................................ C-14
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ENGINE ASSEMBLY AND ADJUSTMENT ................................................ C-14

D

CRANKSHAFT AND CRANKCASE ...................................................... C-14

AUTOLUBE PUMP ............................................................................... C-16
CDI MAGNETO ..................................................................................... C-16
TRANSMISSION ..................................................................................... D-I
STARTER SYSTEM ................................................................................ D-2
SECONDARY SHEAVE .......................................................................... D4
PRIMARY SHEAVE ................................................................................ D-5
KICK STARTER ...................................................................................... D-6
PISTON PIN AND PISTON ..................................................................... D-7
CYLINDER AND CYLINDER HEAD ....................................................... D-7
ENGINE REMOUNTING ......................................................................... D-8
 E.O,.E.EMOV.L
IE"O
''1 IC'I E.O,.E.EMOV.L
ENGINE REMOVAL 1. Remove:
Oil hose (_ on oil pump side
COVER REMOVAL
1. Remove: NOTE:
Covers Plug the hose to prevent oil spillage.
Refer to "COVERS" in CHAPTER 3.

ENGINE OVERHAUL CABLES,

LEADS
ANDHOSES

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e.
1. Remove: Earth (ground lead)

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Air cleaner case assembly (_) Spark plug cap 0
Starter motor lead (_)

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CDI magneto lead (_)

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CA RBUR ETOR ______,__ 2. Disconnect:

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Carburetor cover _ - _._ \ Rear brake cable (_

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Hoses __ %

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3. Remove:

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Carburetor (_
Carburetor top __
fro
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/_ 4. Remove:
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Air shroud (_)

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(_) Muffler assembly (_)

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__ Exhaust protector
D

o Rear axle nut (_

NOTE:
Apply the rear brake while loosening the rear
axle nut

5. Loosen:

4-1 4-2
_rJ. 1. Place a suitable stand under the frame. REAR WHEEL
_-_ 2, Remove: 1, Remove:
Left pillion footrest Rear wheel nut
Rear shock absorber bolt (lower) (D Rear wheel washer
. Engine mounting bolt _) Rear wheel
_ .f_(_ Brake shoes (_)
_ -_._ 34S001 Plate washer (_)

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3. Remove: j_ _ CENTERSTAND

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Spring (_)

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NOTE: Clip 0

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Rubber washer (_)
Lift up the frame and remove the engine. Axle (_)

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Clamp (_)

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4. Place the frame on a suitable stand. Center stand (_)
Engine _ 1. Remove:

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358(;O1

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1. Remove:

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Air shroud

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Cylinder head C)
- Cylinder head gasket

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NOTE:
Beforeloosening the cylinder head nuts, loosen
the spark plug.
Loosen the cylinder head nuts crosswise 1/4 of
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D

(_) _ 2.a .Remve:tUrnCylinder

Cylinder
each before(_gasket
removing(_)
them.

1. Remove:

Piston pin clip (_

NOTE:
Before removing the piston pin clip, cover the

_, _ cannot accidentally fall into the crankcase.

307OO1 PISTON
crankcasePIN
with
ANDa PISTON
clean rag, so that the clip

4-3 4-4
 E.O,NEO,..SSE.SLY
IE"O
_'1IC'_]
2. Remove:
E.O,NEO,SASS
IE"O
''1
PRIMARY
SHEAVE

Piston (_) Fan

Piston pin bearing (_) :j: 2. Remove:
Nut C) (primary sheave)
NOTE:
Do not use a hammer to drive out the piston To loosen the primary sheave nut hold the CDI
pin. magneto with a flywheel holder (_).
__)(__) 3070O2 Piston pin(_ __ 319035 1. Remove:

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e.
KIGKSTARTER I_ Flywhee190890.01235holder: I

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_--------_ _V _---J'-"==_-
_(_).._F_ Transmission
Kick crank cover O (teft)

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_/_ pinion gear (D Ratchet (_)

2.
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NOTE: Washer (_)
To remove the kick pinion gear, push down the Fixed primary sheave (_)

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kickcrank. Washer (_

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3. Unhook: @ V-belt
_ Kick return spring (_)
fro 3,goo,
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cirdi0s_
Plate washer (_)
"_/__ .S0_cer_
Primary sliding sheave (_)
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Kick shaft (_)

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D

317O02

SECONDARY SHEAVE

-(_ 1. Remove:

Hold the secondary sheave with a sheave holder

(_)to loosen the nut.

c c 319003
c
I_
NOTE:'
sheave h'der:
Nut 0 90890-01701
(secondary sheave)
I
4-5 4-6
 2. Remove:
l..olo,..l
Crankcase cover gasket _ Starter motor

Dowel pins
3. Attach:
Sheave holder (_)
\ _._" /_ 2" Remove:
Nut wrench (41 mm) _/_ Bearing _
_/ o,utc,
housing

Secondary sheave (_) _ _______
__ Spacer
- Washer
(_

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90890-01701
l_ sheave hlder: t _--'--_ o._ Transmission case O
TRANSMISSION

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___'_L 1. Remove:

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Clutch securing nut ___II tc_ _, Dowel pins

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Loosen the nut but do not remove it yet,

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_o3 4. Loosen: __ = Gasket

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2 Attach _ _ _ \ 2 Remove
- Main shaft _)

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Plate washer
/_ _ __ washer (_)

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NOTE: _ t;_'
__ _ ;_ Conicalspring

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Compressthe secondary sheave using the clutch _ \_._ ....
spring holder (_. (_)

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Clutch spring holder: ____,
____(_ _ ......
_o_ 90890-01337 fro 3. Remove:
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Clutch securing nut Secondary sheave axle _)
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Clutch assembly (_)

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6. Remove:
Spring seat (_ _ Oil seal (_)
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Guide
Clutch pin (_) (_)
spring 3_,o_
Secondary sliding sheave (_) CDI MAGNETO
D

Nut O (rotor)
STARTER SYSTEM . Plate washer

_(_/___---(_) 1. Remove:
Starter clutch assembly _ (_ NOTE:
loosen the nut.
Idle gear (_)
_0_/_. /_ Plate (_ (idle gear) Hold the rotor using the flywheel holder (_) t

32_ 90890-01235
_@0@ _ Starter wheel gear (_) _ F,ywheel holder: I

4-8
4-7
 I..o"-.I c-91 I'" "1
Rotor (_ level the tool body.
?_ Woodruff key
L/ Use the flywheel puller (_) 3. Remove:
Crankcase (right)

90890-01189 I As pressure
fully is applied,
on the engine keepbosses.
mounting tapping care-

_ 32'005 2. Remove:
Stator assembly
Gasket
:sary,
CAUTION:
loosen :one screw as much as required to

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Use a soft hammer to tap on the case. Tap

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Autolube oil pump (D slowly and carefully. Make sure the cases

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I _ 1. Remove: tap
separate
on theevenly.
gasket
If one
mating
end "hangs
surfaces.up" Work
take

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the pressure off the push screw, realign the
cases and the tool and start again. If the

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cases do not separate at all, check for a

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remaining case screw or fitting. Do not force.
] AUTOLUBE OIL PUMP only on reinforced spots of the case. Never
314001 1

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eove
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Pin (_) Crankcase separating tool:
Circlip (_) 90890-01135

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3140C_
fro _ 3O04
_ Remove:
Crankshaft (_)
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Oil seal stopper (_)

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Screws (crankcase)

NOTE:
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Loosen each screw one quart of a turn before

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beginning to remove them.

D

_ 300g 1 CRANKCASEANDCRANKsHAFT1.
Remove:

Crankcase separating tool (D

Crankcase separating tool:

90890-01135

NOTE:
Fully tighten the tool holding bolts. Insure that
313oo2 the tool body is parallel with the case. If neces-

4-9 4-10
 I..o Ic-01 I..o.-I
1. Eliminate: Wear/Scratches/Damage --*Replace.
Carbon deposits
Use a rounded scraper (_)

NOTE:
__ Take care toHEAD
CYLINDER avoid damaging the spark plug Piston wall
3o,ool threads. Do not use a sharp instrument. Avoid _ .J 3o7oo,
J

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scratching the aluminium.

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J 2. Inspect: Piston to cylinder clearance

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Cylinder head warpage ..................................................... **

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Out of specification --* Resurface, Piston to cylinder clearance measurement
****************************************************** steps:

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Warpage measurement and re-surfacement First step:

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steps: Measure the cylinder bore "C" with a cylinder

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Attach a straight edge C) and a thickness bore gauge.
__________o_ gauge (_)to the cylinder head. f._---- _, NOTE:
6. Measura:

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Measure the warpage limit. _ ___- /I Measure the cylinder bore "C" in parallel to and

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/ I t,e t,e
veraoeo,
ea ure

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If the warpage is out of specification, resur-

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face the cylinder head. P'_"X] Standard Wear limit

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NOTE:. Cylinder 39.993~ 49.912mm 40.10 mm
Rotate the head several times to avoid removing
_o 3 too muchWarpage
material from
limit: one side. fro _ 3o7oos at Bore
right angles
"C" to(1.574~
the crankshaft,
1.575in) Then,
(1.579
calculate
in)

Taper _ 0,006 mm
d
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1. Eliminate: C=Maximum
D
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Carbon deposits T = (Maximum D1,D3or Ds) -

Use a rounded scraper C) (Maximum D2,D4or Ds )
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2. Inspect:
Cylinder wall If out of specification, replace cylinder, pis-
ow

Wear/Scratches --, Replace. ton and piston rings as a set.

3O4O01 CYLINDER AND PISTON "T" (0.0002in)
D

Fromthe piston crown (_)and ring grooves 0. micrometer.

.;,, ,_:: 4. Remove: @ 5 mm (0.2 in) from the piston bottom edge.
Score marks and lacquer deposits
From the sides of piston. _ Piston Size: I

I
Standard:
NOTE:
Carbon deposits __ Measure39.952 ~ 39.972
the piston mm
skirt diameter"P" with a

3o7oo3
Sand3" a crisscross pattern. Do not sand exces-
Eliminate:in
sively. 3o_oo6
r,l,2nd
I
I step: (1.573 ~ 1.574 in)

4 - 11 4 - 12
 If out of specification, replace piston and
piston rings as a set. (_,X'%I Standard Limit

3rd step: Top 0.15 ~ 0.30 mm 0.70 mm

Calculate the piston-to-cylinder clearance ring (0.006 ~ 0.012 in) (0.028 in)
with following formula:
B 2nd 0.15 ~ 0.30 mm 0.70 mm

Cylinder Bore "C" -

Piston Skirt Diameter "P" I @ Measuring(0.006-0.012
Point 20 mmin)
(0.8 in) (0.028 in)

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I Piston-to cylinder clearance= I ring

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If out of specification, replace cylinder, pis- PISTON PIN AND PISTON PIN BEARING

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ton and piston rings as a set. 1. Inspect:
Piston pin

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I_ Piston=to-cylinder clearance: I Blue discoloration/Groove _ Replace, then

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Wear limit : 0.1 mm (0.004 in)
i 0.034
(0.0013~ 0.047
~ 0.0018
mmin) I inspect lubrication system.

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1. Measure: Outside diameter (piston pin)

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'// - Side clearance Out of specification --* Replace.

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Out of specification .-.*Replace piston and/or Outside diameter (piston pin):

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rings. 9.996 ~10.000 mm
Use a Feeler Gauge (D (0.3935 ~ 0.3937 in)

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307OO7

Top
S=,ar.mt
0.03 ~ 0.05 mm
fro
0.10 mm
3O7OO9
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ring (0.0012~ 0.0020 in) (0.004 in) __ 3. Measure:
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Piston pin-to-piston clearance

2nd 0.03 ~ 0.05 mm 0.10 mm Out of specification _ Replace piston.
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ring (0.0012~ 0.0020 in) (0.004 in) Piston pin-to-piston clearance =

nl

Bore (piston pin) b -

" Outside diameter (piston pin) e
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D

2. Install: Piston pin-to-piston

0.004~0.019 mmclearance:
.... Piston ring I <Limit: 0.07 (0.028 in)>
, , Into the cylinder
l Push the ring with the piston crown. 4. Inspect:
Bearing (piston pin)
3. Measure: Pitting/Damage_ Replace

Out of specification --*Replace rings as a set.

_,. _ End gap
'----------J" _o_ooo Use a feeler gauge Q 307011

4-13 4- 14
 ,.SPECT,O...O.EP...
IC'121
KICK STARTER
,.SPECT,O...O.EP
IE"O
AUTOLUBE PUMP

Kick gear teeth (_) pump output to vary from the factory setting.
Kick pinion gear teeth (_) This situation is, however, extremely rare. If
Burrs/Chips/Roughness/Wear _ Replace. improper output is suspected, inspect the follow-

(_ 1. Inspect: Wear or an internal malfunction may cause the

1. Inspect:
ing:
31_5 Delivery line

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Obstructions .-.*Blow out.

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2. Inspect: O-ring

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Mating dogs (kick pinion gear and one-way WeadDamage _ Replace.
clutch)

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Autolube pump drive gear teeth (_)

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oAutolube pump driven gear teeth (_)

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Pitting/Wear/Damage _ Replace.

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_ _ Rounded edges/Damage -'_ Replace. _ _ 2. Inspect:

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317006 314003

3. Measure: CRANKSHAFT

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i,! i i i i ' .I Use a spring balance c_). [ Runout limit "C"
Connecting rod big end side clearance D"

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.,_,
. L_ Clip tension (kick pinion gear) C) __ 1.Measure:
150~ 250g (5.3~8.8oz.) D

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__] _ Out ofStandard
specification _ Replace.
tension: I _ UseoCrankshaft width
V-blocks, dial "A" and thickness gauge.
gauge

317007
fro _oo_
_ Crankshaft width mm
37.90 ~ 37.95
(1.492 ~ 1.494 in)
"A":
Runout limit "C":
d
TRANSMISSION 0.03 mm (0,0012 in)
de

1. Inspect: Connecting rod big end side

oa

Main axle (_ 0.2 ~ 0.5 mm (0.008 ~ 0.020 in)

nl

Burrs/Chips/Roughness/Wear _ Replace.
ow

_ _ _ Secondary
Drive axle (_)
sheave axle (_) clearance "D":
D

319005

Secondary
sheave
axlebearing
(D 1. Inspect:
f_- :_ .... _ Main axle bearing @ Primary sliding sheave (_
_,_-/,_\_ . Drive axle bearing (_) Primary fixed sheave (_)
WearlCrackslScretchlDamage .-_ Replace.
L'i; Excessive play/Roughness ...*Replace.
Pitting/Damage _ Replace.
Spin the bearing inner race.

4-15 4-16
 Free movement oClutch housing inner surface
Insert the collar (_) into the primary sliding Oil/Scratches _ Remove.
sheave 0, and check for free movement.
Stickorexcessive play_ Replace the sheave Oil Use a rag soaked in lacquer
and/or collar, thinner or solvent.

Use an emery cloth (lightly

Scratchesand evenlypolishing).
319OO7 319O30

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3. Measure: L,., ,_ 5. Measure:

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e.
Out of specification -.-*Replace. Out of specification --* Replace,

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I_1 Outsidelimit>:
<Wear diameter (weight): _- 105.0 mm (4.13 in)

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I 14.5 mm (0.59
(0.57 in)
in) _ ' ' _u_ <Wear Limit>:

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15.0 mm _ I Clutch housing inside diameter:
_ 319008
. Outside diameter (_ (weight) i jj_j1J _ _r__ 319012
. Clutch105.4
housing
mminside
(4.15diameter
in) @

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.S
SECONDARY SHEAVE 6. Inspect:
1. Inspect: Clutch shoes

w
w
o Secondary sliding sheave (_) per.
Scratch/Crack/Damage _ Replace as a set.

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Oil seal (_) NOTE:
__ Secondary fixed sheave (_ Glazed
After using parts _ Sand
the sand withclean
paper, coarse
off sandpa-
the pol-

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Damage _ Replace. ished particles with a cloth.
319009
fro
d
de

o Torque cam groove 0 Clutch shoe thickness @

o Guide pin (_) Out of specification _ Replace.
oa

Wear/Damage --, Replace as a set.

O-rings (_) Clutch shoe thickness:
nl

Damage _ Replace. 4.0 mm (0.16 In)

<Wear Limit>:
ow

2.5 mm (0.10 in)

D

319010 9013

Clutch spring free length 1. Inspect:

Outofspecification _ Replace. V-belt

--_ 121,7spring
Clutch mm (4.79
free in)
length: NOTE:
Crack/Wear _ Replace.

i 106.7limit>:
<Wear mm (4.20 in) Replace the V-belt if it is greasy or oily.
_ 3. Measure: I V-BELT
319011

4- 17 4- 18
 ,.s..c.,o...o....,.
I..o"-.IIc- 41 ..o,.. ..o.o,us....T "1
V-belt width @ CRANKCASE AND CRANKSHAFT
Out of specification --* Replace. (_ Oil seal Crankshaft pin
Oil seal holder _ Connecting rod

-- (_---_ i_ 15.0 width:

13.5
j Measure:
V'Belt
<Wear mm (0.59 in)
(0.53
Limit>: J _ Dowel
Bearingpin
Crankshaft (right)
@Crankcase(right)
_ @
@ Bearing
_ Crankcase
Engine
Crankshaft (left)
mount
(left)
shaft
2. ENGINE ASSEMBLY AND ADJUSTMENT
3120o_ _ Bearing _ Oil seal

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STARTER CLUTCH AND GEARS 9 Nm (0.9 m.kg, 6.5 ft.lb) I J13 Nm (1.3 m.kg, 9.4 ft.lb) I A CRANKSHAFT:

e.
o Starter clutch 37.90 - 37.95 mm

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Push the dowel pin in arrow direction. _ _ (1.492 ~ 1.492 in)

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Unsmooth operation _ Replace starter clutch Runout limit:
assembly. <0.03 ram>

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1. Inspect: (_ _....._._ (0.0012 in)
Crank width:

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Big end side clearance:
3_oo8 0.2 - 0.5 mm

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(0.008 ~ 0.020 in)

.S
2. Inspect:

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Idle gear teeth (_)
.v

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Burrs/Chips/Roughness/Wear --* Replace.

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Bearing (starter
Pitting/Damage wheel gear)
_ Replace. _
<It _ ./%

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_ _ _ . Starter wheel gear teeth (_)
3170_
fro
d
de
oa
nl
ow
D

31_oe

4- 19 4-20
 Crankshaft installation tool C), (_, (_), @

To protect the crankshaft against scratches Crankshaft installation tool :

and to facilitate the engine assembly and (D : 90890-01274
installation, apply grease to oil seal lips, (_) : 90890-01275
and engine oil to bearings. (_) : 90890-01277
(_): 90890-01411
3007

NOTE:

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Crankshaft installation tool (D, (_),(:_, (_ one hand while tightening the nut of the installa-

e.
tion tool with the other. Tighten the installation

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Ti
I<_ (_ : 90890-01274
Crankshaft installation tool: another.
tool until the crankcase halves close with one
I (_ : 90890-01275 6. Install:

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I (_ : 90890-01277 Right crankcase

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(_ : 90890-01411
3O8OO2 1. Attach: Hold the connecting rod at top dead center with

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2. Install: _ 7. Tighten:

.S
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(to left crankcase) NOTE:

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NOTE: Tighten the crankcase holding screws in stages,

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Hold the connecting rod at top dead center with using a crisscross pattern.
one hand while tightening the nut of the installa-

m
tool until the crankshaft bottoms against the 13 Nm (1.3 m.kg, 9.4 ft.lb)
tion tool
bearing. with the other. Tighten the installation
Crankshaft fro _ 31_oo, I'_l Crankcase
Crankcase holding
holding screw=
screws
d
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I o Dowel pins C) _ Crankshaft operation

- Spacer (_) Unsmooth operation --, Repair.
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CAU_ON:
nl

Never hit on the crankshaft.

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D

__ 3005 3. Install: ___<__,]-_ , 308003 8. Check:

HEATPROOF or Yamaha Bond No.1215 Oil seal stopper plate @

(_ Screw (oil seal stopper plate):

I<_ HEATPROOF r Yamaha Bnd

N0.1215 9 Nm (0.9 m.kg, 6.5 ft.lb)

To the matingsurfacesof bothcase halves.

313006 313009

4 - 21 4 - 22
 ..O,...SS...'_'"O'O'OS'M'"'
I'"" ,-IIc-_6l ..o....ss...._..o.o,os.....
I,.o"-I
_Fan
(_ Plain washer @Gasket
_Oil hose /_ 1. Install:
Circlip @
@ Rotor assembly @ Oil delivery hose Pin (_)
(_ Lighting coil @Clip :. o Pump drive gear@
_)Charge coil _Autolube pump Circlip (_
Pick Upcoil _ O-ring
Stator assembly _ Circlip
(_ Oil seal _) Oil pump drive gear 3,,oo4

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2. Apply:

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e.
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3. Install:

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_-_ _\ (to O-ring @)

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'_ _ _/_) Autolube pump (_)

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[4 Nm(0.4 m.kg. 2.9 ft.lb) _ __/ _ Screw (autolube pump):

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4. Apply:

.S
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(to autolube pump gear@, (_))

.
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(_b_ 6"5 Nm (0"65 m'kg' 4"7 ft'lb, _ _ I_ _,,,.O..0_.....=

m
-
fro .' CDI MAGNETO
d
_ _ _ 314006
de

(_ _(_/J/_.. " "'_ _ "_ i_ Gasket

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Lithium soap base grease

nl

(to oil seal @)

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321001
1. Install:
D

3. Pass the CDI magneto lead through the

J _ crankcase hole.

/ " Stator assembly

_ _
8Nm (0.8 m.kg, 5.8 _,b) I I%_> I Screw8
4. Install:
Nm(Statr(0.8
m.kg,aSsembly):5.8
ft.lb) [[

4-23 4- 24
 E"O'"EASSE"B'Y'"O'O'ST"E"T
IE"o O11 E.O,.E.SS. LY..OAOJ
5. Install: TRANSMISSION

Magneto rotor (_) (_ Bearing _ Secondary sheave axle

Plain washer (_) _ Oil seal @ Bearing
Nut (_) _ Drive axle @ Dowel pin

NOTE: (_ Main axle _ Transmission case cover

_)(_ When Woodruff
installingkey
the(_magneto rotor, make sure _
_ Circlip
Conical spring washer _
_ Bearing
Oil seal
_ Bearing _ Gasket
the woodruff key is properly seated in the key Plain washer
_1_ way of the crankshaft. Apply a light coating of

et
lithium soap base grease to the tapered portion

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of the crankshaft end.

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\

.S
Nut (D (magneto rotor)

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0. Z Use the flywheel holding tool (_).

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Flywheel holding tool:

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90890-01235

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Tighten:37.5 Nm (3.75 m.kg, 27.1 ft.lb) I
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D

319033

4 - 25 4 - 26
 _.O..E,SSE.LYA.O,O,
OST.E.T
_ 0-21 TRANSMISSION STARTER SYSTEM
E"O'"EASS_--_'"O,O,0
IE"O_I
1. Apply: (_ Collar _ Plate
10W30 Type SE Motor oil (_ Washer _ Shaft
(to transmission case cover bearing) _ Bearing _ Plain washer
_) Starter wheel gear _ Idle gear
2. Install: _ Collar @ O-ring
BearingC) _ Starterclutch @ Startermotor

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Secondary sheave axle (_) _-

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,' _ _l NOTE:.

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3. Install:
Apply lithium soap base grease onto the oil seal

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lips.

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_C_, 1 j_/_ 0,, seal (_) f-

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319O14 i

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Secondary sheave axle operation ./.

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4. Check:

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Unsmooth operation _ Repair. _

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10W30 type SE Motor oil
(to main axle bearing and drive axle bearing)

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5. Apply: - !
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: Main axle (_
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Conical spring washer (_) 113 Nm (1.3 m.kg, 9.4 ft.lb)l

._-__ *Drive axle C)

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-6.Apply lithium soap base grease onto the oil seal

Install: (_b
/ L _ ,/_
D

s19o16 Always use a new gasket.

Transmission case cover O

lips. _ ii

_ (_).__(_.
_.__._:2)
"

__._----_
I_lso_
,..e
o.., I
Dowel pins

7. Install:
Gasket12(_)
Nm (1.2 m.kg, 8.7 ft.lb) 4 _'L_i-}
-I 8 Nm (0"8 m'kg' 5"8 ft"

4 - 27 4 - 28
 E"O"E'SSE"BLY'"O'O'0STME"T
,_ ,
I 1I0 3 E.O.E,,,EMLY,.O,O,
USTM
IE"O
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STARTER SYSTEM PRIMARY AND SECONDARY SHEAVE

. Collar (D _Clutch washer _Cam

Washer (_) _Clutch shoe spring @One-way clutch *Apply BEL-RAY Assembly Lube
- Bearing (_) _Clutch spring _Washer
Starter wheel gear (_) _Spring seat _Primary fixed sheave
1. Install:
Starter clutch O _Clutch
Gasket housing @Conical
@Plate spring
washer @Slider

NOTE: Secondary sliding sheave _Primary sliding

__(_ 317010 Apply lithium soap base grease to the bear- @Oil seal
@V-belt _Spacer
sheave

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ing @Guide pin _Clutch weights

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' _f _ 50Nm 50 .2 ft.lb)/I
/_ (,_ I ( . m.kg, 36/

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__3
"_ 17O11 1 Apply clutch).
(starter molybdenum disulfide oil to the shaft _Secondary fixed sheave

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2. Install:

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(__ j.tq{_ o Idle gear
Plain (_) (D
washer

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Plate (E)(idle gear)

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8 Nm (0.8 m.kg, 5.8 ft.lb)
Screw (idle gear plate): I ' "___
_3_4 _ Plain washer (_)
fro ____/t (_g (_)
NOTE: _ "
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Starter motor O
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13 Nm (1.3 m.kg, 9.4 ft.lb) i

3, Install: {_ _ _,_. __

_ Apply engine oil to the idle gear (_). /_ _(_ __ "_

D

Apply lithium soap base grease to the O-ring of B

the starter motor. C sh_! we_rli _ it: /"_,/'_ _, I_1 ' "' " ft "Ib)luich
I

ov;!_,,:o_
_,_,
limit: 14.5 mm (0.57 in)

E Weight outside diarneter _ (_ _/ _,,,,_

319034

4 - 29 4 - 30
KICK
STARTER
E"O'"E'SSE"O_'"O'O'UST"E"T
I--__-] O''J E"O'"E'SSE''YA"O'O'O
IE"_1 SECONDARY
SHEAVE

Return spring Transmission case verse the disassembly procedure. Note the fol-

csa
oowein ena--e
(_Collar (_Kickcrank lowing points.
(_ Plain washer 1. Apply:
Circlip BEL-RAY Assembly Lube
Gasket (tothesliding partsofthesheave)

319018

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2. Install:

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rA ! KICK CLIP FRICTION FO_R_RCE
: 0,15 ~ 0,25 kg(5.3 ~ 8.8 ozI _ Sliding sheave (_)
Wind adhesive tape around the end of the sheave

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to avoid turning over the oil seal lips when

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installing the sheave,

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319019

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/ Pin (_)

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J _ 4. Apply:

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(to the torque cam grooves and O-rings)

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t_ /__'__ 3. Install:
5. Check:

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Sliding sheave

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-- 31_o2o Unsmooth operation --_Repair.
.BEL-RAY Assembly Lube
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Remove excessive grease.

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Clutch securing nut

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clutch spring holder

(_ /_ 6. Install:

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112
Nm(12mkg,87ftIb)I _
I_ c'utch-h'_r
I 90890-01337
D

f 319021

J 7. Tighten:

Use sheave holder (41mm).

V_t S"eave h''er:

90890-01701
I
18.5 Nm (0.85 m.kg, 6.15 ft.lb)l_ i_ _ _, Clutch securing nut
,_ _/" 317o,8 3,go3, I_ 50 Nm
I Clutch (5.0 m.kg,
securing nut:36.2 ft.lb) I

4 - 31 4 - 32
 E.O..E.SSE.B..O.O,
OST"E"T
IE"OI'IO'SI UST"E"T
I "O1 '1
I XJ _ Gasket Place the V-belt around the secondary sheave,
Secondary sheave assembly(_) and compress the secondary sheave spring
Clutch housing (D hard so that the V-belt moves toward the clutch
hub.

NOTE:
The arrow on the V-belt must point to the front.
_0o2_ 8. Instalh Make
5. sure the V-belt is not stained with oil or
Install:
I Dowel pin V-belt

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grease.

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9. Tighten:
Use sheave holder _ Shim (_)

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c c c Sheave holder: Washer (_)

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PIN. 90890-01701 One-way clutch (_)

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I_ Primary
Washer fixed
(_) sheave @

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I_ Nut (_)40
I Nut Nm (4.0 m.kg,
(secondary
(secondary 28.9 ft.lb)
sheave)
sheave): II / _3_4(_5(_3 31_o_, 6. Install:
,Nut (_

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PRIMARY
SHEAVE 7. Tighten:

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Primary fixed sheave face (_ Nut (primary sheave):

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Collar
Primary_)sliding sheave face (D i_>1 30 Nm (3.0 m.kg, 21.7 ft.tb)

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Weight (_
Primary sliding sheave cam surface (_ NOTE:

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When tightening the nut (primary sheave), hold
_ (_ (_ _{_l_ 31_4 1. Clean: fro 3190_ the Nut
.
O (primary
magneto sheave)
rotor using the flywheel holding tool

2. Install:
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Slider (_)
Collar (_
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3, Check:
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oCam operation
31,o_., Unsmooth operation _ Repair.
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4. Install: 8. Adjust:

_ 319026 319O28

4-33 4-34
 Fan O _ Carburetor joint _ Cylinder gasket
Reed valve @ Piston ring

_ 9. Install: 6.5 Nm (0.65 m.kg, 4.7 ff.lb) _PISTON, CYLINDER AND CYLINDER
Cylinder Piston pinHEAD
Screw (fan): I _ Gasket head (_
@Piston

_!__ (_ Cylinder (_ Bearing

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CST i
Return spring (_)

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Kick shaft (_)

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Collar (_)
Washer (_

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Return spring __ ,_-_ / _-_/

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Kick pinion gear (D (_ _-_ _'_

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3. (to the kick gear and boSS)lnstall: ___ __
-'- _ - _ _o,_ Install the spring as shown. fro
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4. Install: (_L_,,
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f_)_,,_J _L;_' _,_J Transmission case C)

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(_ B 0.034- 0.047mm
Piston rings (0.0013 - 0.0018in)
end gap:
D

3_9o_ 0.15 ~ 0.30mm (0.006 ~ 0.012 in)

_ C Pistonrings side clearance:
_,,_) A Pistonclearance:

Kick crank (_) D Spark plug:

Bolt (kick crank): Manufacturer:NGK

8.5 Nm (6.85 m.kg, 6.15 ft.lb)

3040O3
317016

4 - 35 4 - 36
 E.O,.E.'SE.BLY'"O'O'UST
D' I E"T
E"O'"E'SSEMBLYA"O
IE"o
_ Engine oil O - J// NOTE:
1. Apply: C) CylinderO
(to crankshaft bearing, connecting rod big
end bearing, small end bearing, piston pin, Install the cylinder with one hand, while corn-

, _ piston ring grooves and piston skirt.) pressing the piston rings with the other hand.
3aoo4
I __ PISTON PIN AND PISTON :" 3. Install:

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Small end bearing Cylinder head gasket (new gasket)
Piston O

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Piston pin (_) 5. Install:

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Piston pin clip (_) Cylinder head (_

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NOTE: Spark plug (_)
The arrow _) on the piston must point to the NOTE:

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exhaust side. Tighten the cylinder head holding nuts instages,

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_o7o1_ o Before installing the piston pin clip, cover the 3o,
c_ and crisscross sequence.
crankcase with a clean towel or rag so you will The arrow@ on the cylinder head must point to

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not accidentally drop the pin clip and material the front.
into the crankcase.

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(c,,,o.r,o.,,

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The ends of the piston pin clip must not 10 Nm (1.0 m.kg, 7.2 ft.lb)
come together at the slot in the piston 20 Nm (2.0 m.kg, 14.0 ft.lb)

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i Spark plug:
groove.
Always use a new piston pin clip. fro
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1. Install: _ Center stand (_)

o Cylinder gasket (new gasket) Shaft (_)

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2. Check: Clamp_)
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NOTE: (_ Clip (_)

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Make sure the ring ends (_) are propedy fitted Spring (_)
around the ring locating pins inthe piston grooves.
D

3o7o13 Be sure
Piston
to rings
check the manufacturer's marks or (_ 358oo2 Rubber washer (_
numbers stamped on the rings are on the top
Brake shoes 0
Plain washer @

Plate washer
Nut

side of the rings. _ _ 7. Install:

3480O1 Rear wheel

4- 37 4- 38
 E"O'"E'SSE"B,.O,O,
OSTME.T
IE"O 10"8
8. Install:
E"O'"E'SSE
=j
OSTME.T
B ,.O,O,
_, 5. Tighten:

Oil hose
Oil delivery hose NOTE:.
When tightening the rear wheel axle nut, apply
NOTE: the rear brake.

Pass the oil delivery hose and oil hose asshown. Rear
103.5wheelNm
axle(10.35nUt:m.kg,
74.8 ft.lb) I

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Air shroud _ Rear wheel axle nut (T)

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9. Air bleeding: ___._ 6. Install:

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Refer to "AUTOLUBE PUMP AIR BLEEDING" Muffler assembly 0
in CHAPTER
Autolube 3.
pump (_)__ ProtectorMuffler
Air shroud (_). assembly

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29 Nm (2.9 m.kg, 21.0 ft.lb)
Bolt (exhaust pipe):

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6.5 Nm (0.85 m.kg, 6.15 ft.lb)

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7. Fill:

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Reverse the removal procedure. Refer to "TRANSMISSION OIL REPLACE-

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Note the following points. MENT" in CHAPTER 3.

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1, Install: 8. Adjust:
Engine mounting bolt 0 Brake lever free play

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Rear shock absorber bolt (_)(lower) Refer to "FRONT/REAR BRAKE LEVER FREE
Theseboltsshouldbe temporarilysecured. PLAYADJUSTMENT" in CHAPTER3.

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____ 2.
ENGINE
Tighten:
REMOUNTING
Engine mounting bolt
Rearshockabsorberbolt(lower)
fro Transmission
Engine idle
Throttle speed
cable
Referto "THROTTLE
oil
free play
CABLEFREEPLAYAD-
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\ _ Engine mounting bolt: JUSTMENT" in CHAPTER 3.
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42 Nm (4.2 m.kg, 30.4 ft.lb)

/ Rear shock absorber bolt (lower):
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17.5 Nm (1.75 m.kg, 12.6 ft.lb)

3. Install:
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Carburetor top togetherwith throttle valve0

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o Fuel hose (_)Nacuum hose (_)

Rear brake cable
D

NOTE:

with the projection of the carburetor.

carburetor, align the groove of the throttle valve
4. Connect:
Spark plug cap (D
Starter motor (_

_ _ \ When installing
.CDI
Earth (groundthe
magneto leadthrottle

lead) valve into the

4- 39 4-40
plyDo
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 L_.B_ I Io-_l I
c OI
R"
CHAPTER 5.
CARBURETION

CARBURETOR ........................................................................................... D-12

REMOVAL ............................................................................................. D-12
DISASSEMBLY ..................................................................................... D-12
INSPECTION ........................................................................................ D-13

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ASSEMBLY ........................................................................................... D-14

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INSTALLATION ..................................................................................... D-14

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FUEL COCK ................................................................................................ D-15

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INSPECTION ........................................................................................ D-15

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REED VALVE .............................................................................................. D-15

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REMOVAL ............................................................................................. D-15

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INSPECTION ........................................................................................ D-15
INSTALLATION ..................................................................................... D-16

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D
CARBURETOR REMOVAL
(_ Carburetor top _ Pilot jet 1. Remove:
Gasket _ Needle jet Covers and footrest board
Throttlevalvespring _ Needlevalve Referto" COVERS" in CHAPTER
3.
Needle set _ Main jet Air filter case assembly
Throttle valve _ Float pin
Starter plunger spring _ Float
Starter plunger _ Float chamber gasket
Air screw @ Float chamber

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Throttle stop screw _ Drain screw

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I.D. mark PHBN12HS _'_, _(_ 2. Disconnect:

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Main jet (M.J.) # 93 ,=_fT'_:_ i \_____-k._) j Fuel hose (_)

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Jet needle (J.N.) A21-3/5 _ 3. Remove:

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Needle jet (N.J.) 2.110 Carburetor top
% 0ElL LO_O Pilot jet
Cutaway (P.J.)
(C.A.) 4.0
# 36 _ Throttle valve

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Main air jet (M.A.J.) 2.0 _ J Oil hose (_)

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Pilot air screw (A,S.) 1-5/8 _+1/4out Starter plunger
Valve seat size (V.S.) 1.2
___ Bypassjet
Starter (B.P.1)
(G.S.1) 0.8
#40 -- ___322_ -Starter plunger top
Carburetor

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Float height (F.H.) 15 ~ 17 mm

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%_ Fuel height (F.L.) 20,5 ~ 22,5 turn
(___ (0'59 ~ 0"67 in) _ DISASSEMBLY

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(_) -_._ Engine idle speed 1800 +-200 rpm _ Float chamber (_)

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_ (0.80~0.88in) fro _ 322007 1. Remove:
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_____ __._ 2. Remove:
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1 ,Nooo,ev ,ve
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D

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,eove:
Main jet (_)
- Main nozzle (_)
__P _ : oStarter jet (_)

322034 322027

5-1 5-2
 Throttle stop screw C) Throttle valve 0
Spring (throttle stop screw) Wear/Damage --* Replace.
Air screw (_)
Spring (air screw)

__ 4. Remove: _j,j,j 4. Check:

322028 322014

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5. Remove ( _/_\\ 5. Check:

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Needle clip (_) \\ oThrottle valve free movement

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Throttle valve _) Insert the throttle valve C) into the carburetor
body (_) and check for smooth movement.

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2_ 322029
Jet needle (_) 322015
Unsmooth/stickiness --, Replace.

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1. Check: . Throttle stop screw (T)
Carburetor body (D Air screw (_)

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L Dirt --, Clean. Needle (_)

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Starter plunger (_

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NOTE: Wear/Damage _ Replace.
Use a petroleum based solvent for cleaning.

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Blow out all passages and jets with compressed
air. fro _2o18

2. Inspect: 7. Measure:
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. Main nozzle _ Iill Out of specification -* inspect needle valve,

Starter jet
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Contamination _ Clean. @ _ Float height @:

(_ Pilot jet _ /I [_] float, and valve
15.0 seat.mm (0.59 ~ 0.67 In)
- 17.0
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_(oMainjetC) 322012 I 322017 Float height @

D

Needle valve 0 Float height measurement steps:

Wear/Contamination ---*Replace, Install the needle valve, float and float pin
Float (_) into the carburetor body.
Damage .-_ Replace. Hold the carburetor upside down.
Gasket Measure the height distance between the
Damage -._ Replace. mating surface of the float chamber (gasket
removed) and the top of the float, using a
322013 3. Check: ....................................................
gauge. **

5-3 5-4
 C,.BO.ETO.
IC'"B
0 IID'I'I C,.BO.ETO.
IOA"B
01
NOTE: _ Carburetor
The float arm should be resting on the needle NOTE:
valve. It should not compress the needle valve. Align projection (D with projection (_).

If the float height is not within specification,

inspect the needle valve, float and valve
seat. 3. Install:

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If one of these parts is worn, replace the

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If both parts are in good condition, replace To installthe carburetorreversethe"REMOVAL"

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the float. (T_ _ procedures. Note the following points.

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.... Check:he**float.height.aga_n.................. 1. Install:

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Carburetor cover O
NOTE: Airhose (_)

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The float height is factory-adjusted. Never try to Pass the air hose through the hole _ in the

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adjust it yourself, carburetor cover.
whole set. _"_ _ INSTALLATION

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ASSEMBLY 2.Adjust:
Reversethe"DISASSEMBLY" procedures. Note Throttle cable free play

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Refer to 'q'HROTTLE CABLE FREE PLAY AD-
the following points. JUSTMENT" in CHAPTER 3.

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o Before reassembling the carburetor wash

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all its components in clean gasoline.
Always use new gaskets.
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(_ I_ Needle _ Air filter case assembly

_ Clip (_)
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Throttle valve (i)

Spring seat (_)
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Spring
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(_ 3_o_8 _ Jet315
1. Install: needleclip position: _ 3. Install:
D

Throttle valve (D
Starter plunger
NOTE:
Align the groove (_)of the throttle valve with the
projection (_) of the carburetor body.

3_3019 2. Install:

5-5 5-6
 FUELCOCK/
REEDVALVEI CARB [ D-15 ] REED VALVECARB
FUELCOCK/ I
FUEL
COCK iNSPECTiON
1. Check:
INSPECTION Carburetor joint
1. Stop the engine, Damage/Cracks _ Replace.
Reed valve
2. Remove: Wear/Cracks/Damage-._ Replace.

Refer to "COVERS" in CHAPTER 3. Reed valve inspection steps:

Visually inspect the reed valve.

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NOTE:

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Fuel cock pletely or at least nearly flush with the valve seat.

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Fuel cock inspection steps: If in doubt, apply suction to the carburetor

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Disconnect the fuel hose (_. side of the assembly.

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Place a receptacle under the fuel hose end. Leakage should be minimal to moderate.
If fuel stops flowing within a few seconds, the ......................... *******************....... ***

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fuel cock is in good condition. If not clean or

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3. Check:
replace the fuel cock. A reed valve in good condition should be corn-
Disconnect the vacuum hose and breathe in

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Valve stopper height C)

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. fuel
If fuelcock.
flows out of the fuel hose when vacuum _ Out of specification _ Replace valve stop-

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is applied and stops flowing when vacuum _ per.

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stops, the fuel cock is in good condition. " _/'_ I
If not, clean or replace the vacuum hose, the rJ L} F_"_I valve stopper height: I

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fuel hose and the fuel cock. _ 4.0 - 4.4 mm (0.157 - 0.173 in)

__ _r'_ \ _"_r--':'_ fro

through the hose to create a vacuum in the I
322_3 2. Measure:
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REED VALVE 3. Measure:
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Reed valve clearance (_)

REMOVAL Out of specification --* Replace reed valve.

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Side covers Reed valve clearance:

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Refer to "COVERS" in CHAPTER 3. (.j Less than 0.2 mm (0.008 in)

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2. Remove:
Carburetor
D

Refer to section "CARBURETOR REMOVAL". 3_o2,

Carburetor joint
Reed valve assembly

_(_: ___) 3_Z20"22 3. Remove:

5-7 5-8
 _v,,wIC'R_
INSTALLATION
0 I ID'_sl I_'_ 01
TOinstall the reed valve reverse the "REMOVAL"
procedure. Note the following points.
1. Install:
Gasket (new)

2, Tighten:
Reed valve assembly bolts

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8.5 Nm (0.85 m.kg, 6.15 fLIb)

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NOTE:

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Tighten the screws crosswise inseveral steps to
preventwarpage of the read valve assembly and

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the carburetor joint.

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D

5-9 5-10
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I .............

D
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 CHAPTER 6.
CHASSIS

FRONT WHEEL ............................................................................................ E-4

REMOVAL ............................................................................................... E-4
INSPECTION .......................................................................................... E-4
INSTALLATION ...................................................................................... E-5

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FRONT BRAKE ............................................................................................. E-5

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BRAKE PADS REPLACEMENT ............................................................. E-6

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CALIPER DISASSEMBLY ...................................................................... E-7

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MASTER CYLINDER DISASSEMBLY .................................................... E-7
INSPECTION AND REPAIR ................................................................... E-8

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CALIPER ASSEMBLY ............................................................................ E-8

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MASTER CYLINDER ASSEMBLY .......................................................... E-9

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REAR WHEEL ............................................................................................ E-10

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REMOVAL ............................................................................................. E-10
INSPECTION ........................................................................................ E-10

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ASSEMBLY ........................................................................................... E-11
INSTALLATION ..................................................................................... E-11

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FRONT FORK ............................................................................................. E-12

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REMOVAL ............................................................................................. E-13
DISASSEMBLY ..................................................................................... E-13

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INSPECTION ........................................................................................ E-14
fro ASSEMBLY
INSTALLATION
...........................................................................................
.....................................................................................
E-14
E-14
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STEERING HEAD AND HANDLEBAR ....................................................... E-15
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REMOVAL ............................................................................................. E-15

INSPECTION ........................................................................................ E-16
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ASSEMBLY AND INSTALLATION ........................................................ E-16

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REAR SHOCK ABSORBER ......................................................................... F-2

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REMOVAL ............................................................................................... F-2

INSPECTION .......................................................................................... F-2
D

INSTALLATION ....................................................................................... F-2

 CHASSIS
.O.TW.EEL
IC"'SI E-'] ,_
F.O.T..EEL
REMOVAL
IO"'S
FRONT
WHEEL 1. Remove:
D
Front caliper fixing bolts
_) Axle _ Oil seal /!_
Speedometer gear (_ Collar (3.)_i _ o
Speedometer cable
Bearing (_ Axle nut v _,_/_ o Axle
(_ Flange _ Front wheel
(_ Collar _ Tire /_ Front wheel
Valve \_ NOTE:
Front caliper
_3 Never depress the brake lever when the wheel

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A TIRESIZE: JL is Offthe scooter. Otherwise the brake pads will

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120/90- 10 _ be forced shut.

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V
B RIMRUNOUTLIMIT:

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RADIAL:2.0 mm(0.05in) INSPECTION

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LATERAL:2.0 mm(0.08in) _1_ o Front axle runout
1. Inspect:

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0.25mm(0.01in) Out of specification --* Replace.

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_oo_ 0.25
(_ Axle mm (0.01
runout limit: in) I

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Do not attempt to straighten a bent axle.

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1_ 2. Measure:
Wheel runout

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Out of specification --, Replace.

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//_ _
Radial: 2.0 mm (0.08 in)
Rim runout limit: I
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_ Bearings allow play in the wheel hub or

_ _(_J_ (_ 4. oWear/Cracks/Warpage
Replace.inspeCt:wheel
bearings --,
__ __ __I_(_ _ _ 34ii 7 13. Inspect:Tire
Laterah 2.0 mm (0.08 in)
D

/, _j/_,__ __ ...... 34ooo8 5. wheel

tUcheck:rns roughly .--_Replace.
147 Nm (4.7 m.kg, 34 ft.lb)l _ ,_ Speedometer gear (T)
Wear/Damage
-, Replace.

6-1 6-2
 F--.EEL
IC"'SI E-SI
INSTALLATION FRONTBRAKE
..O.,,.,.E
IC"'S
NOTE:
Reverse the =Removal" procedure. _ Disc _ Pad spring Be sure to install the pads correctly.
Note the following points. Bolt Pad retainer
1. Lubricate: _ Caliper _) Brake pads
Front wheel axle _ Piston _i_O. ring
Bearings @ Piston seals @ Bolt
Oil seal (lips) _ Air bleed screw @ Mounting bolt
- Drive/driven gear (speedometer)

et
I

n
Lithium soap base grease D_ _ 3.Omm

e.
m
Speedometer gear unit C) /

Ti
NOTE: -- _'_ _[ ....... ]

er
Be sure that the two projections at the gear unit I _ \ _'_ I /21.SNm(2.15m.kg, 16ft.lb)l

ot
mesh with the two slots on the wheel hub. _.._% 00_)/_ /
2. Install: | 6 Nm (0.6 m.kg, 4ft.lb)l

co
.S
Front wheel 0 /

w
w
Front caliper (_) _ ':,_i "

w
Be sure that the slot (torque stopper) of the gear
unit housing is positioned correctly.

m
//
k_)_ l NOTE:
fro
d
4. Tighten:
de

Front wheel axle

/___ 3. Install:
o Front caliper mounting botts ')'t;;_ !
oa

,, .4v
nl

I_ 47 Nm
I Front (4.7axle:
wheel m.kg, 34 ft.lb) "_,_
--""_,__.-_-
J_-;-:-_--'-"-
"\', 123 Nm (2.3 m.kg, 17ft.lb)l
ow

23 Nm (2.3 m.kg, 16.6 ft.lb) "\_ _, _/'_ '__, Ii

i Front caliper mounting bolts: t "_" -'- ":" ' _
--/7"
D

properly. _'4!_"j '{"/f":'""/;"

,_"- -'.." #tJ" YV

__/ 23 Nm (2.3 m.kg, 17ft.lb)l

6-3 6-4
MASTER CYLINDER DISASSEMBLY
Master cylinder
Master cylinder piston ass'y
Diaphragm
Master cylinder cap
Screw
Master cylinder bracket
_'!!w-'_;l_ _[dl
Q Bolt NOTE: Disc brake components rarely require dis-
_ Brake hose Drain completely before removing the master assembly. Do not disassemble components
_ Bolt cylinder, unless absolutely necessary. If any hydrau-
@ Bolt lic connection is disconnected, the entire
_ Copper washer system must be disassembled, drained,
cleaned, and then properly filled and bled
after reassembly. Do not use solvents on
internal brake component.

et
Solvents will cause seals to swell and dis-

n
I1.5 Nm (0.15 m.kg, l.lft.lb) _ tort. Use only clean brake fluid for cleaning.

e.
the Brake
fluidtocome
with incontact
brake fluid.with
Never eyes.

m
..... ____ Use care allow brake

Ti
er
ot
_ _tl m./kg,
110.8Nm (1.08 8 ft.lb)] fluidparts,
tic can damage painted su rfa ces and plas-

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I

.S
BRAKE PADREPLACEMENT
/ It is not necessary to disassemble the brake

w
L... caliper and brake hose to replace the brake

w
pads.
1. Remove:

w
Pin (D

m
BRAKE FLUID _ \ Axle _)
A
DOT# 3 or DOT# 4
fro ',, ._ _:.. 2. Remove:
}
23 "
d
o Brake pads (_)
de

NOTE:
Replace the brake pads as a set when either one
oa

is worn to the limit.

_ Nm(2.3m.kg,
17ft.lb)] Padspring (_)
nl
ow
D

oBrake pads
Out of specification -_ Replace.
NOTE:

(_) Replace the brake pad and spring as a set when

replacing the brake pads.
(2.3 m.kg, 17 ft.lb)l _X,

3,7007 __ 0.8 Brake

3, Measure:
_ Frnt mm (0.03 in) Wear
Pads Limit
@: I

6-5 6-6
 F.O.TB.,KE E'I
4. Install:
.O.TB,,KE
IC"'S
.......................................................
o Brake pads Removal steps:

oAxle 'oo_ ing to force out the piston from the caliper

Pad spring
Pin _ _ _J_O\_y_/Z
_ Blow compressed air into the hosejoint open-
body.

Be careful to install the brake pads correctly. _'_' _ _ Never try to pry out the piston.
'\ _ _,_o. Cover the piston with a rag. Use care so that

et
the piston does not cause injury as it is
5. Lubricate: expelled from the cylinder.

n
Mounting bolt (caliper body)

e.
m
I =1Ramended
'ubr'cant:I
Lithium soap base grease
Removethe
piston
sea,s
....................................................

Ti
6. Install:

er
Wheel axle

ot
Mounting bolt

co
47 Nm (4.7 m.kg, 34 ft.lb)

"'" I

.S
Mounting bolt: MASTER
CYLINDER
DISASSEMBLY
I 23 Nm (2.3 m.kg, 17 ff.lb) NOTE:

w
Before disassembling the front brake master

w
cylinder, drain all brake fluid from the brake

w
hose, master cylinder, brake caliper and reser-
voir tank.

m
fro 1. Remove:
CALIPER DISASSEMBLY Upper handlebar cover
d
de

j/" //_ "//_:\ ,_ NOTE:

/ __/_/_ drain
Beforealldisassembling
brake fluid fromthe
the front
brakebrake
hose, caliper,
master Brake switch
2. Remove:
oa

_. cylinder,brake caliperand tank. Brake lever

nl

1. Remove:
ow

Union bolt (_) NOTE:

(_)__t Copper washers(_) Release
Unionthebolt
brake switch by pushing with a
screw driver into the hole on the lower side of the
D

__J _ _s_-_ NOTE: brake lever and pull out the brake switch.
Place the open end of the drain hose into a
container and pump out the remaining brake 3. Remove:

2. Remove: Master
cylinder
Caliper body
Caliper bracket
__ _ fluid carefully. Master cylinder holder
3. Remove:
_7co5 Piston (_
Piston seals (_)

6-7 6-8
 .O.TB,,KE
IC"'S 1E-81 F.O.TB.,K
IC"'S
o Master cylinder dust boot 0 , Brake hose (_)
Master cylinder kit (_) CrackslWearlDamage .._Replace.

_ 4. Remove: _ 3. Check:
34700e 34e014

n et
INSPECTION AND REPAIR /_._ \ 4. Measure:

e.
schedule: Out of specification _ Inspect wheel runout.

m
If wheel runout is good, replace the brake
Brake pads As required disc.

Ti
Piston seal,

er
Dust seal Every two years _1 Brake Disc Maximum Deflection: I
I

ot
Brake hoses Every four years F_,] 0.25 mm (0.01 in)
Recommended brake component replacement _ 3470O1 Brake disc deflection

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Brake fluid Replace only when - Brake disc thickness

.S
w
_1W_'1;10117_[]1 _ 3 mm
Brake (0.12
Disc in)
Minimum Thickness: I

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All internal parts should be cleaned in new

w
brakefluid only.Donot usesolventsas they _ Bolt (brakedisc):
will cause seals to swell and distort. 23 Nm (2.3 m.kg, 17 ft.lb)
LOCTITE

m
fro
brakes are disassembled _[ _ _ I _)lOutof specification ---,Replace. I
d
1. Inspect : CALIPER ASSEMBLY
de

Caliper piston C)
oa

assembly. All internal parts should be cleaned in new

Caliper body _) brake fluid only.
nl

Wear/Scratches/Cracks/Damage_Reptace Internal parts should be lubricated with

ow

__ _ caliper assembly,
Scratches/Rust/Wear _ Replace caliper clean brake fluid when installed.
_'y11'i,L,1;l_ll_[!

I
D

3,7oo_ Replacethe piston sealswheneverthecaliper DOT #3 or DOT #4

is disassembled.

Master cylinder is disassembled.

Wear/Scratches -_ Replace the master 1. Install:
cylinder assembly. Piston seals (_
Master cylinder body/Diaphragm Caliper piston (_)
Cracks/Damage _ Replace. _'!_I'A'/-'I;I_IR[_
Master cylinder kit Always use new piston seals.
_ 3470o6 2. Inspect:
Scratches/Wear/Damage--* Replace asa set. __ 346ols , Replace the piston seals whenever a caliper

6-9 6-10
 .O.TB
IC"'S
2. Install:
.E E-'] _'_"
.O.TB
IC"'SI
1. Install:
.E
I<_1 23 (brake
Bolt Nm (2,3 m.kg, 17 ft.lb)
caliper): ! 'I:CAUTiONil
install the master cylinder holder with the
arrow mark pointing upwards.
3. Install: Tightenthe upperboltfirst,thenthelower
Caliper body (_) bolt.
Brake caliper ___o 10 Master cylinder (_)

et
4. Install: I_J Bolt (master
9 Nm cylinder
(0.9 m.kg, 6.5 holder):
ft.lb) I

n
e.
/'/_ _\ /_ Brake hose

m
' J o7. Copper washers
Brake lever

Ti
er
23 Nm (2.3 m.kg, 17 ft.lb) Apply lithium soap base grease to the brake
lever pivot.

ot
(_)_ _ Union bolt (_) I 2. Install:

co
When installing the brake hose to the caliper,

.S
turn the brake pipe against the projection on 3. Install:
the caliper. Brake hose

w
o Copper washers

w
o Union bolts

w
Proper hose routing is essential to insure Brake switch

m
safe
Always use new
operation. copper washers.
Referto"CABLE ROUTING". I'_1 23 Nm
Union bolt:(2.3 m.kg, 17 ft.lb) I'
MASTER CYLINDER ASSEMBLY
_.lV_Vl_,l
:|_11_.
[eE
fro
d
All internal parts should be cleaned in new _1|w_,1;1_11_,[11
de

brake fluid only.

Internal parts should be lubricated with Proper hose routing is essential to insure
clean brake fluid when installed,
oa

safe operation. Refer to "CABLE ROUTING"

in CHAPTER 2.
nl

I_1 Recmmended
fluid:DOT
#3 or DOT
brake
#4 I Always use new copper washers.
ow
D

4. Check that the brake hose does not touch

other parts (throttle cable, wire harness, etc.)
when the handlebar is turned to the left or
right. Repair if necessary.

6 - 11 6 - 12
REAR
WHEEL
.--.EEL
IC--I IE'101 --W.EEL
REMOVAL
IC"'S
1. Remove:
Rear wheel ass'y _ O-ring _ Wear indicator Muffler ass'y
Tire _ Brake shoe _ Bolt
Valve (_ Spring _ Washer
(_ Axle (_ Brake camshaft _ Nut
Nut _ Brake camshaft lever _ Washer

n et
A TIRE SIZE: t ----_. oRear axle nut (D

e.
130/90 - 10 _ NOTE:

m
B DRUM BRAKE WEAR LIMIT." __{/(("__ 2PullLoosen

Ti
110.5 mm (4.40 in) I/!/1 the rear brake to loosen the axle nut.

er
o BRAKE L,N,N_ WEARL,M,_ _'_ _=_/

ot
11o5Nm (10.5 Kg.m, 76 ft.lb) (_ D 2,0
RIM mm (0.08
RUNOUT in)
LIMIT: Rear wheel

co
\ ,_ VERTICAL : 2.0 mm (0.08in) _o_

.S
_ LININGS
REPLACE BRAKE 7 _, \ 4. Remove:
Brake cable

w
__ II I I SPRING.._.
AND SASASET J Brake shoes (_)

w
w
(_)"-_'_ _)} ) )) )/ - Plain washer (_)

m
fro a4r_l_

INSPECTION
d
de

1. Check:
Rear wheel
oa
nl

(_'('('('('('('('(_ (_) Wheel runout

ow

__L,> _ I )....
7 Kg m 5 ft Ib) I 2.SPECTION"'Measure:Refer
to the section "FRONT WHEEL IN-
D

(__'___"_'d (__ SPECTION".Refar

to the section "FRONT WHEEL IN-

"" _"_'1_ "_ I

..o,,,L,..
Lateral: 2.0 mm (0.08 In)
Radial: 2.0 mm (0.08 in) I
._ f" j. N/

6- 13 6 - 14
 IC"ASIIE'111 .E,.W,EE"
whee
earn0s
Refer to the section "FRONT WHEEL IN-

SPECTION". NOTE:
Br keshoesO
Return spring (_)

4. Check: The arrow mark must point outwards.

Brake lining surface ......
Glazed spots _ Eliminate with sandpaper. CAUTION_
lo When installing the springs and the brake
NOTE: shoes, takecarenotto damage thesprings

et
After sanding the brake lining remove dust parti-

n
e.
Wear indicator (_
Camshaft lever 0

cesoeresoewieanco
nt

m
5. Measure:
Brake lining thickness NOTE:

Ti
Out of specification _ Replace Align the wear indicator tipO with the line "A"

er
4.0 mm (0.16 in) Align the punch marks C_).

ot
co
i --_ Brake
Wear Lining Thickness:
limit: I 11 as shown.
6. Check: 2.0 mm (0.08 in) 7 Nm (0.7 m.kg,Bolt:
5.1 ft.lb)

.S
I_>1 Camshaft Lever

w
Oil/Scratches _ Repair. _ 4. Install:
Plain washer C)

w
7. Measure:

w
Brake drum inside diameter @ t Brake cable

m
Out of specification _ Replace, /C)

34S006
_
t10.5 mm (4.35 in)
Brake Drum Wear limit:
Brake drum inner surfaca
fro I
"__ _012
d
ASSEMBLY INSTALLATION
de

Notethefollowing
points. Notethefollowing
points.
oa

1. Install: 1. Clean:
nl

Brake camshaft O Rear wheel axle

ow

NOTE:
Apply lithium soap base grease onto the brake
D

_L___ camshaft (_)and

Reverse the pin (_). procedure.
=REMOVAL" Reverse the REMOVAL procedure.

\_ 2. Install:

Plain washer
the excess of grease. Nut

E Make sure the splines on the wheel hub fit onto

the rear drive axle.
After installing the brake camshaft, remove _ _ 346O13
Rear wheel
NOTE:.

6-15 6-16
 REARWHEEL I CHAS (_r'(g] IE-121 FRONTFORK I CHAs (_)

.u,,.r
Wh.--,
105 Nm (10.5 m.kg, 76 ft.lb) ..ONT
FO.
_ Steering bracket
Bolt
@ Inner fork tube (right)
@ Inner fork tube (left)
3. Install: _ Circlip _ Dust boot
Muffler _ Tube cap _ Retainer
Oil seal _ Oil seal

I_ I Bolt (exhaust pipe): I (_ Circlip _ Outer fork tube (right)

i Bolt
9 Nm
(muffler):
Nm(0.9
(2.6m.kg,
m.kg,6.5
19ft.lb) I _ Washer
Plunger
Oil seal guide @ Brake
_ Outer fork
Brake hosetube
bracket
(left)

et
26 ft.lb) _ _ hose bracket

n
4. Adjust: _ Bolt (_ Steering race set

e.
o Rear brake lever free play. ! A FRONT FORK TUBE CAPACITY:
I

m
Ti
ADJUSTMENT"in CHAPTER 3. FRONT FORK OIL GRADE: J_
Refer to "REAR BRAKE LEVER FREE PLAY i B SO
48 3743/4-LHV46
cc (1.69 Imp oz, 1.62 US oz)l ' _' '_
-

er
'(_//

/ /

ot
co
j ,t,,,_,

.S
w
w
w
m
\,
fro
d
/ /
de
oa
nl
ow
D

/' I,i'l W

6-17 6-18
 ICH' l IE-131 FRONTFORK

1. Remove:
Securely support the scooter with a stand Rubber plug (D
under
REMOVALthe engine. _ Circlip (_
DISASSEMBLY

1. Place
2. the scooter on an even surface.
Disconnect: Spring (_)

Speedometer cable
3. Remove:
Front wheel _ol, Spring seat (_)

et
Refer to "FRONT WHEEL".

n
e.
- Front fender (_) Bolt (D
Refer to "COVERS" in CHAPTER 3 Copper washer

emow 2emo

m
5 Remove: NOTE:

Ti
Steering head To remove the drain bolt _, use the T-handle
Referto "STEERING HEADANDHANDLE-

er
andtheholder_
BAR"

ot
6 Remove:

co
Securing nut ..... _<_ T-handle for front fork:
Holder:

.S
NOTE: 90890-01294
Ring nut C) I 90890-01326

w
I

w
w
I_l 90790-0t
Ring 268
Nut Wrench:

m
Support the steering shaft to prevent it from
falling. fro
Usethe Ring Nut Wrench (_ to loosenthe ring nut.
d
7, Remove: 3, Remove:
de

Washer (_) _ Inner fork tube (_

oa

Steering collumn Spring (_)

__ (_) % Upper
bearing race (top)(_)
Bearings (_/_/ -Piston (_)
Spring seat(_
nl
ow

Take care not to loose the bearings. (Upper: 22 _'T). /_

pieces, Lower: 22 pieces). -_/// _,2o_s
D

Circlip 0 Dust boot (D

Retainer @
9 Loosen: Oil seal (_)
Pinch bolt (_)

10. Remove: _--_

Fork leg (complete)
_ 8. Remove: (_)_ 4. Remove:

6- 19 6-20
 .O.TO.K
IC"'SI [E-I']
INSPECTION
F.O.TO.K
3. Install:

Inner fork tube and fork components Drain bolt

Outer fork tube NOTE:
Wear/Scratches/Damage --, Replace. Tighten the drain boltO while holding the piston
_'1._ with the T-handle _ and holder (_.
Never attempt to straighten a bent fork tube i

as this may dangerously weaken the tube. _ (_/'_:_1T-handle for front fork:
1. Check: _i_ (New),
^,Copper washer
1o I_// I 90890-01326

et
2. Measure: 90890-01294

n
i Holder :

e.
m
(_) Out of specification -_ Replace. I_> 23 Nm
I Drain Bolt:(2.3 m.kg, 17ft.lb) I

Ti
Right
Front forkside: 206 free
spring mm length:
(8.11 in) 4. Fill:

er
I Left side: 225 mm (8.85 in) Fork oil

ot
- Fork spring free length (_) i

co
_2o. ISO 674314-LHV 46

.S
ASSEMBLY i 48 cc (1.69
Amount Imp tube):
(per fork oz, 1.62 US oz)
Reverse the "DISASSEMBLY" procedure

w
Note the following points. 5. Install:

w
NOTE: Spring

w
When reassembling the front fork, make sure - Spring seat
you use following new parts: - Circlip

m
Oil seals Rubber plug
. Circlips and retainers fro
Make sure that all components are clean be-
forereassembling. INSTALLATION
d
de

1. Install: Note the following points.

oa

Oilseal 1. Install:
Retainer Left and right fork tube into the steering
nl

Dust boot crown.

ow

NOTE:
Before installing the oil seal, apply lithium soap 2. Install:
Reverse the (_
"REMOVAL" procedure.
D

grease onto the oil seal lips. Circlips

3. Install:
2. Install: Pinch
bolts
(_)
Inner fork tube

-Spring
Spring seat I_ 30 Nm
I Pinch bolt:(3.0 m.kg, 21.7 ft.lb)
- Piston

6 - 21 6 - 22
 STEERING HEAD AND HANDLEBAR _ IE-151 STEERING HEAD AND HANDLEBAR
STEERING HEAD AND HANDLEBAR STEERING HEAD AND
_) Handlebar
Nut HANDLEBAR
_) Bolt REMOVAL
Grip
Throttle grip Securely support thescootersothereisno
Throttle cable danger of it falling over.
Screw 1, Place the scooter on an even surface.
Brake cable

et
Starter cable
2. Remove:

n
Front fender

e.
m
Upper
Refer handlebarin cover
to "COVERS" CHAPTER 3.

Ti
3. Drain:

er
Front brake system
Refer to "FRONT BRAKE".

ot
__ Inner panels

co
_ 60 Nm (6"0 m'kg' 43 ff'lb)l 4. Remove:

.S
Front brake master cylinder

w
w
Front brake caliper mounting bolts

w
6. Remove:
Front wheel

m
Refer to "FRONT BRAKE".
% __ fro 5.Refer
Remove
to "FRONT: BRAKE".
d
de

Rear brake cable (D

, Throttle grip
oa

8. Disconnect:
Ground wire
nl

....... .... All couplers

Wire harness band
ow

Clamp
_ 7. Remove:
D

9. Remove:

Bolt
Handlebar

/__ Nut (D

6 - 23 6 - 24
 10. Remove:
Ic.As IE-lel JA
STEE.,.O.EAOA.O...O **......... ******************************************

Ring nut 0 Drive out the bearing race from the steering
Washer tube by hitting on it in several places.
Remove the bearing race on the steering
NOTE: shaft with a hammer and a chisel Q as
Use the Ring Nut Wrench (_) to loosen the ring shown.
nut. Drive in the new bearing races evenly by
Securing nut Bearing race replacement steps:

et
I<_ Ring
wrench:90890-01268
Nut I .... hitting on them in several places.
Support the front fork so that it may not fall down. _ CAUTION;;

n
Unless the ball race is installed evently, it

e.
Washer (_) will damage the frame or steering column.

m
Upper bearing race (_ Do not hit the face of the ball race.

Ti
Bearing balls

er
'X_ Steering shaft I .....................................................
NOTE:

ot
Take care not to loose the bearing balls. (Upper: _0o8

co
22 pieces, Lower: 22 pieces).

.S
INSPECTION _ 4. Check:

w
w
Bends/Cracks/Damage _ Replace. VTI_?7_[E_Tr_

w
Never attempt to straighten a bent steering
2. Wash the bearing balls in solvent, shaft.

m
1. Check: Bend/Damage
Steering shaft--* Replace.
Handlebar O fro _ 354OO9

3. Check: ASSEMBLY AND INSTALLATION

d
de

Bearing races (_ Reverse the"REMOVAL" and "DISASSEMBLY"

oa

Bearing balls (_ Note the following points.

Pitting/Damage --*Replace. V.I_i_--'_,I]]]_
nl

C) NOTE: Proper cable and hose routing is essential to

ow

_ _(_ Always replace the bearing

Pitting/Damage balls and the upper
-.*Replace. insure
procedure.safe scooter operation. Refer to
and lower bearing races as a set. "CABLE ROUTING" in CHAPTER 2.
D

Upper: 3/16 in _.,D_, 1. Install:

Lower: 3116in JIL_J=m Bearing balls

Lower: 22 pcs Wheel bearing grease (to upper and lower

bearing).

I Upper:quantity:
Bearing
Bearing 22 pcs
size: 3_ olo
1 2. Apply:

6- 25 6- 26
 3. Install:
IC"'S [I S.EE.,.O.E.O..O...O.
C"'S9. Clamp:
Steering shaft Speedometer cable
Upper bearing race (Top) (D Front brake cable
Bearing race cover (_) (to head pipe with the band)
Washer NOTE:
Ring nut Refer to "CABLE ROUTING" in CHAPTER 2.
NOTE:
Hold the steering column until it is secured. 10. Apply:

et
Lithium soap base grease
4. Tighten: (to throttle cable end and handlebar right

n
e.
Ring nut end).
11. Install:

m
NOTE: oThrottle grip
Refer to "STEARING HEAD ADJUSTMENT" in Throttle cable

Ti
CHAPTER 3. Bracket

er
Front brake lever assembly
Handlebar switch (right)

ot
NOTE:

co
Refer to "CABLE ROUTING" in CHAPTER 2.
7. Install:

.S
_
r_:, - (_ oHandlebar_ 12.Connect:

w
(_) - Bolt (_) (New) Rear brake cable

w
Nut (_) (New) Handlebar switch leads

w
NOTE: Brake switch lead
Fit the handlebar bridge (_) into the steering

m
column notcher (_). 13.Install:
Front fender
NOTE:
fro
Refer to "CABLE ROUTING" in CHAPTER 2 for NOTE:
d
proper cable and lead routing. Refer to "COVERS" in CHAPTER 3.
de

13. Adjust:
oa

...... Front brake freeplay

Before installing the handlebar, wipe the oil Rear brake lever free play
nl

off the insertion portion using thinner, etc. Throttle free play
Install the bolt (_)from the left as shown.
ow

Handlebar Bolt O:
60 Nm (6.0 m.kg, 43.4 ft.lb) 10 ~Brake
20 mmLever
(0.4 ~Free
0.8 Play:
in)
D

I<_ _--_ Front

Rear Brake Free Play:
10 ~ 20 mm (0.4 ~ 0.8 in)
8. Install: Throttle Cable Free Play:
Band 1.5 ~ 3.0 mm (0.06 ~ 0.12 in)

NOTE:
Refer to "CABLE ROUTING" in CHAPTER 2. NOTE:
Refer to "FRONT BRAKE ADJ USTMENT-REAR
BRAKE ADJUSTMENT-THROTTLE CABLE
ADJUSTMENT" in CHAPTER 3.

6 - 27 6 - 28
 RE,RS.OCK,BSOR_ER
IC"'S_II F'2I
REAR SHOCK ABSORBER
c.,s_1
REMOVAL
1. Place the scooter on its centerstand
2. Remove:
Mole
Refer to "COVERS" in CHAPTER 3.

et
n
;' - Rear shock absorber 0

e.
m
Ti
=

er
ot
_ 3. Remove:

co
INSPECTION

.S
1. Inspect:
Rear shock absorber

w
Oil leaks/Damage _ Replace.

w
w
m
fro
INSTALLATION
d
de

When installing the rear shock absorber, re-

verse the removal procedure. Note the following
oa

points.
1. Install:
nl

Rear shock absorber

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31.5 Nm 13.15 m.kg, 22.8 lt.lb) I

D

Rear Shock Absorber Bolt (Lower): I

I 17.5 Nm (1.75 m.kg, 12.6 ft.lb) I

6- 29
D
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 IELEC
_1 I F-S IE_EC
_ I
CHAPTER 7.
ELECTRICAL COMPONENTS

ELECTRICAL COMPONENTS ..................................................................... F-6

SWITCH INSPECTION ................................................................................. F-6

SWITCH INSPECTION ........................................................................... F-6

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SWITCH CONTINUITY INSPECTION .................................................... F-7

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CIRCUIT DIAGRAM ...................................................................................... F-8

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IGNITION AND STARTING SYSTEM ........................................................... F-g

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CIRCUIT DIAGRAM ................................................................................ F-9
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM ................... F-9

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TROUBLESHOOTING .......................................................................... F-IO

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CHARGING SYSTEM ................................................................................. F-14

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CIRCUIT DIAGRAM .............................................................................. F-14
TROUBLESHOOTING .......................................................................... F-14

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LIGHTING SYSTEM ................................................................................... F-15
CIRCUIT DIAGRAM .............................................................................. F-15

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TROUBLESHOOTING .......................................................................... F-16

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SIGNAL SYSTEM ......................................................................................... G-1

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WIRING DIAGRAM ................................................................................. G-1
fro TROUBLESHOOTING ............................................................................ G-2
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ELECTRICAL
E'ECT..C.LCO.PO.E.TS
IE' c I F'6I SW,TO.,.SPEOT
IE'Ec
SWITCH
INSPECTION
ELECTRICAL COMPONENTS ,,,, "0" SWITCH INSPECTION
Flasher relay _ Battery Use a pocket tester to check the terminals for
Wire harness _ Fuel sender continuity. If the continuity is faulty as any point,
Oil sender _ Horn replace the switch.
(_ Starter relay _ Rectifier/regulator

_)Ignition
cOilcDi
unit _ Main switch I_l Pocket
tester:90890.03112 I

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NOTE:

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Set the pocket tester to"0" before starting the

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range when testing the switch for continuity.

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Turn the switch on and off a few times when

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checking it.

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test.

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% The pocket tester should be set to the"x I"Q
"" INSPECTING
ASWITCH
SHOWN
INTHE

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I_1, I.,I I_1 _ MANUAL

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switch, handlebar switch, engine stop switch,
light switch, etc.) are shown in a chart similar to

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the one on the left.

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This chart shows the switch positions in the
column and the switch lead colors inthe top row.
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terminals with continuity.
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(_ The example chart shows that:
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(____ (_
ForThere
each switch
is continuity
position,between
"0--0" theindicates
"black and
the
Black/White" leads when the switch is set to
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"OFF".
(_ There is continuity between the "Red and
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_ Brown" leads when the switch is set to "ON".

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7-1 7-2
SWITCH CONTINUITY INSPECTION
SW,.C"'"S"ECT'O"
IE'EC
-------
I F'_I _ Horn switch
SW..C.,.S.ECT,
_
Refer to "SWITCH INSPECTION" and check for continuity between lead terminals. _ Dimmer switch
Poor connection, no continuity _ Correct or replace. @ Turn switch
* The coupler locations are circled. (_Main switch
Start switch
Engine stop switch
Front stop switch
Rear stop switch
Fuse

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Oil lever gauge
@ Fuel sender

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7-3 7-4
CIRCUIT DIAGRAM
c,.co,To..o...
IELEc
'11 -8 _ C.D.I Magneto
C,.CU,TO,AO..
IE'ECJ
_ Left front flasher light
C.D.I Unit _ Right front flasher light
Ignition coil @ Left rear flasher light
Spark plug @ Right rear flasher light
Main switch _ Tail/Stop light
Fuse @ Horn
Battery L_ Flasher relay
Rectifier/regulator _ Front stop switch
Starter relay @ Rear stop switch

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[_ _ _ Starting motor _ Oil level gauge

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_ _ _ Right handle switch _ Meter
' _) _ Left handle switch _ Sender

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_i _ _ _ Head light

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__'' :_i COLOR CODE

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__ __!I _ R Red L Blue

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B Black Y/R Yellow/Red

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_ W White L/W Blue/White

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'_[_ _ .... I , Br Brown B/W Black/White

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_ : ..........-_ " _ Gy
Y Gray
Yellow B/R
G/Y Black/Red
Green/Yellow
O Orange W/R White/Red
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Dg Darkgreen Y/B Yellow/Black
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G Green G/W Green/White
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I_ P Pink _._.
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7-5 7-6
 .O.,T.O...OST..T,.OSYSTE.
IGNITION AND STARTING SYSTEM
IE'EC
------
I 1_"9I ,O.,T,O...OST..T,.OS
IE'EC
" I
IGNITION
ANDSTARTING
SYSTEMCIRCUIT
DIAGRAM
CIRCUIT DIAGRAM (_ C,D.I magneto @ Starting motor [] Source coil
_) C.D.I unit @ Right handle switch [] Pickup coil
Ignition coil _ Front brake switch [] Wave-shape shaping circuit
Spark plug _ Rear brake switch [] Condenser
Mainswitch [] Diode
Fuse [] SCR
Battery [] To oil level switch
Starter relay

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<=4 <=_ -_"

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-- -- (_) B/W

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CHECK
O0
ON
LOCK00_0
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: Current flow in ignition control circuit

: Current flow in starter motor control circuit

7-7 7-8
 IE'Ec [F-10I IELEc
TROUBLESHOOTING 3.Spark
plugcapresistance:

I (NO
THE SPARK OR
STARTING IRREGULAR
SYSTEM DOES SPARKS).
NOT WORK Connect thethe
Disconnect pocket
sparktester (_ x 1 k) to the
plug cap.
spark plug cap.

NOTE: Check the resistance of the spark plug cap.

Remove the following parts before proceeding with the troubleshooting: _ _ Spark plug cap resistance:
1) Mole _ I 5 k_ at 20C (68F)
For accurate troubleshooting use the following special tools:

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I_=_ IgnitiOn
checker:90890-06754 I '_ POcket
tastar:90890-03112 _._ _ OUTOF SPECIFICATION
1.Spark plug: 3_ool I Replace the spark plug cap. I

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Check the spark plug type. rl MEETS

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Check the condition of the spark plug. _ SPECIFICATION
Check the spark plug gap.

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Refer to "SPARK PLUG INSPECTION" in 4.Ignition coil resistance:

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Standard spark plug: _ Connect the pocket tester (_ x 1) to the

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BR8HS (NGK) ignition coil.

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--_ Spark
0.5 ~plug
0.7 mm
gap: (0.020 ~ 0.027 in) I Replace or adjust the spark plug gap. I Ignition tester
Pocket coil: (+) lead _ Orange

Chapter 3.
CORRECT
INCORRECT _ fro Disconnect the ignition coil leads.
Pocket
Checktester
the primary
(-) leadcoil
--_Ground
resistance.
_1_1
3720_
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Remove the spark plug cap. _1 0.56- 0.84 E_at 20C (68F)
Connect the ignition checkerO.
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Connect the pocket tester (Q x lk) to the

(_Spark plug cap ignition coil.
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(_)Spark Pocket tester (+) lead _ Ground (_'_----_1- _:_ _ I

resistance:
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Check the length of the spark gap.
Start the engine and increase the spark
length until the engine begins to misfire.
2.Spark check:
Pocket tester (-) lead _ Spark plug lead
Check the secondary coil resistance.
_ Primary coil
D

372003

_ 6.0 rnm spark

M,nimum (0.24 in)
gap; MEETS SPECIFICATION _1 5.68 ~ 8.52
Secondary coilk_ resistance:
at 20C (68F) OUT OF SPECIFICATION

._ SPECIFICATION
OUT OF
OR NO SPARK
' I Ignition system in good condition. I
SPECIFICATION
MEETS
II Replace the ignition coil. II

7-9 7-10
 'O"'T'O"'"OSTA.T,.OSYSTE.
IE'EC
------I
[F-11 'O"'T'O"'"OST..T,.O
5. Pickup
-0-
coil resistance:
I sT,,TE,.oTo.
OOES.OTWO.K I
NOTE:

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Check the pickup coil resistance. For accurate troubleshooting use the following special tools:

e.
pickup
Pocket
Disconnect
Connect
tester
teeter
coil.
thethe
(+)
(')
pocket
lead
pickup
leadtester
(_
(!)c_oil
--_(Q
coupler.
Ground
White
x 100)/ Red
to the _9_L--_ _ 2)
4)
1)Remve
3) Footrest
Front
Handlebar
Mole panel
the
boards
cover
following parts before proceeding with the troubleshooting:

1,c.upco,,r.,s=o. ..o,=t.r

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400 ~ 600 _ at 2OC (68F) OUT OF SPECIFICATION 90890o031t2

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I [

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,_ MEETS 1.Fuse: NO CONTINUITY
SPECIFICATION I Replace pickup coil. I Refer to "SWITCH INSPECTION".

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6.Source coil resistance: ,.EL CONTINUITY

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Disconnect the source coil coupler from the Y I Replace fuse. I

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Connect the pocket tester (_ x 100) to the Check the condition of the battery. I

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source coil. Refer to "BATTERY INSPECTION" in I

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Pocket tester (+) lead C) --* Black / Red CHAPTER 3. I OUT OF SPECIFICATION

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Pocket tester (-) lead (_)--* Ground ='_ _ J Open circuit voltage: I
Check the source coil resistance.
wire harness. _ _ fro H 12.8 Y or more at b 20C (68F)
2.Battery: III
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640 - cil
960 resistance:
_ at 20C (68F) OUT OF SPECIFICATION ,_ CORRECT J Charge
Clean battery
or replace
terminals.
the battery. I
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3. Starter motor:
MEETS
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,_ Use ajumper lead (_)* to connect the (+)(:_ iii_i_i_ !

SPECIFICATION I Replace source coil defect. I terminal of the battery to the starter motor If the gauge of the jumper lead is smaller
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POOR CONNECTIONS terminal (_). than that of the battery leads, the jumper
7.Connections: lead might melt or burn.
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Check all connections in the ignition sys- (13

T perform
This test It could
near acause
gas source
sparks. orNever
near
D

tern. -...... _ flammable products.

Refer to "WIRING DIAGRAM". I Repair. I n_-"l:E--_
i _E_/--'_I

_ CONNECTIONS
GOOD _ r __J_
-
3_oo_ DOES NOT WORK
I Replace CDI unit. I Check the starter motor operation.

"_v CORRECT I Repair r replace the starter motr" I

7-11 7-12
 STARTER MOTOR
4. Starter relay: (_ O-ring
Disconnect the Blue/White lead from the _ Brush
wire harness. _ Armature coil
Connect the (-) _ terminal of the battery to _ O-ring
the Blue/White lead.
Check the starter motor operation.

A COMMUTATOR UNDER

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CUT:

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DOES
NOT
WORK 1.15
mm (0.045
in)

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- B COMMUTATOR DIAMETER
WEAR LIMIT:

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--I::>uw 37_ I Replace the starter relay. I, C 15.0 mm
BRUSH (0.60LIMIT:
WEAR in)

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5.3 mm (0.21 in)

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_ CORRECT _::_::::_ ..................._3(_

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I Refer to "SWITCH INSPECTION". _ kg, 9.4 _

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,_ CORRECT I Replace the main switch. I

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I 5. Main switch: J INCORRECT _/(_) _m_.
I Refer to "SWITCH INSPECTION". ,8,
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,_ CORRECT I Replace right handlebar switch. I
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I 6. Engine stop switch: I INCORRECT ___@ !

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Refer to "SWITCH INSPECTION". _

17Startersw,tc.:
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INCORRECT _/_,-_,
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8.Connections: POORCONNECTIONS
,_ CORRECT i Replace right handlebar switch. I ___/
Check all connections in the starter system. _ _/
Refer to "CIRCUIT DIAGRAM". T
IRepa'r. I

7-13 7-14
 ,ON,T,ON.NOST.RT,NOSYSTEM
IE'Ec ['131 ,ON,T,ON.NOST.RT
IE' C
Commutator Out of specification --, Replace.
Dirty _ Clean it with #600 grit sandpaper.
2. Measure: Brush lengthlimit@:
Commutator diameter @ 5.30 mm (0.21 in)
Out of specification _ Replace starter motor
@/_ 1. Inspect: - Brush length @
REMOVAL _ 5. Measure: J
15.0 mm (0.60
wearin)limit:

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_ Commutator I
3. Measure: 6. Measure:

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Mica under cut @ Brush spring force

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@ proper measurement use a hacksaw blade set.

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which has been grounded to fit the commu-
tator, _ Brush spring force:

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Out of specification _ To scrape the mica to 150 ~
Fatigue/out of650 gr (5.29 ~_ 22.92
specification oz) as a
Replace

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_ 1.15 mm (0.045 in)
Micaundercut@: I

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NOTE: 7. Inspect:

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The mica insulation of the commutator must be Bearing

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undercut to ensure proper operation of Roughness--* Replace.

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commutator. O-rings
Wear/damage _ Replace.

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4. Inspect:
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_; *****************************************************

Inspecting steps:
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Connect the pocket tester to perform the

continuity
Armature check.
coil (resistance)
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Measure the armature resistance.

._ii_; Defect --, Replace starter motor
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0.072 _ at 20C
I
If the resistance is incorrect, replace the
starter motor.
*****************************************************

7- 15 7- 16
CHARGING
SYSTEM
C...O,.OS*STEM
IE'ECIF'141 TROUBLESHOOTING
C...O,.OS*STE.
CIRCUIT
DIAGRAM I THE
BATTERY
ISNOT
CHARGED I
NOTE:
Remove the following parts before proceeding with the troubleshooting :
1 ) Mole.
For accurate troubleshooting use the following special tools :

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90890-03113 90890-03112

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I<_ Inductive tachometer: I I<_ Pocket tester:

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INOC

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Refer to "SWITCH INSPECTION".

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_@i_ ,_ CONTINUITY I Reptace fuse. I
2. Battery

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OUT OF SPECIFICATION
Check the condition of the battery.

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Refer to "BATTERY INSPECTION" in
CHAPTER 3.

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_ i[_i i _1 Open circuit vltage: i : Clean battery terminals' I
_=i =_;_:i t2.8 V or_more at 20C (68F) Charge or replace the battery.

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_,,_,_:;,_,:,,_
......... L ........ ; "JL_
CORRECT

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,,'_f ! _ E 3. Charging voltage
__ !_ ! Connecttheenginetachometertothespark
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plug lead.the pocket tester (DC20V) to the

Connect _--L_:_ ___
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i_.__ I**_;" Pockettester(+)lead_

battery terminals, Battery(+)terminal ___._
_r_._ _j_- Pocket tester (-) lead _ Battery (-) terminal
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_'_'-_' __"<" * Start the engine and accelerate to about _/

5000 rpm.
Check the charging voltage,
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_i_ I_-------'}lCharging voltage:

I _l__Jl 14 ~15 V at 5.000 tr/mn

I Use a fully charged battery, n

I _i; INOTE:--_
41OUTO SPECIFICATION
MEETS
SPECIFICATION
4"
I Charging circuit is OK, !

7-17 7-18
 4.Charging coil resistance
C.A.O,.OSY.TEM
1'151 LIGHTING SYSTEM
.,O.T,.OSYSTE
IE'"c
Disconnect the CDI magneto coupler from ,_L-_ _ CIRCUITDIAGRAM
the wire harness.
Connect the pocket tester (_ x 1) to the
charging coil.
Check the charging coil resistance
Tester (+) lead --, White O
Tester (-) lead ---,Ground Q

net
I_ I Charging coil resistance : OUT OF SPECIFICATION

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0.48 ~ 0.72 E2at 20C (68F) .._

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_ SPECIFICATION
MEETS I Replace charging coil. I

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15"Cnnections I POOR CONNECTIONS _,Z(_#).[_ i_,_{!_ _ii_"

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I Check all connections in the charging system. _ E ;_,_ , - ....

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I Refer to "CIRCUIT DIAGRAM". I _

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_[llv CORRECT IRepair" I .... i

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I Replace the rectifier/regulator. I

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7- 19 7-20
TROUBLESHOOTING LIGHTING SYSTEM INSPECTION
1. Headlight, headlight indicator or meter light do not work.

I THE HEADLIGHT, HEADLIGHT

LIGHT DOINDICATOR,
NOT WORKTAlL LIGHT OR METER I I 1. Bulb and socket
I
I NO CONTINUITY

NOTE:
Remove the following parts before proceeding with the troubleshooting:
I " Check the bulb and socket for continuity. I
Mole and footrest board J_
Handlebar covers _#- CONTINUITY I Replace bulb or socket. I

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For accurate troubleshooting use the following special tools:

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I_:_1 90890-03112
Pocket tester: I Connect the pocket tester (AC20V) to the ............ _;--1 _
2. Voltage _ '-_I;_ "

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Headlight:

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1. "HI/LO" switch
I
I NO CONTINUITY "LO":
Pocket tester (+) lead _ Green 0

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I Refer to "SWITCH INSPECTION". Pocket tester (-) lead _ Black (_) _
headlight
"HI": coupler. %____4_, ili]i -

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,_y CONTINUITY I Replace left handlebar switch. I HeadlightPcketPcket
tester (+)
(_)testerindicator
(') lead:
lead __ Black
Yellow(_) _(_ __.
_':

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2. Lighting coil resistance Pocket tester (+) lead -* Yellow (_) f
Disconnect the lighting coil coupler from the Pocket tester (-) lead _ Black (_ __

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Connect the pocket tester (_ x 1) to the Pocket tester (+) lead _ Blue (_)
lighting coil. R Pocket tester (-) lead -=, Black (_)

wire
ms m --r
Check the lighting coil resistance Start the engine, _ _,,
Tester (+) lead _ Yellow I Red (D
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"_'_ Switch from "HI" to "LO" and back.
Tester (-) lead _ Ground (_) Check the voltage (12V) between the head-
d
light coupler leads.
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Lighting coil resistance:

0.32 ~ 0.48_ ( at 20C (68F) OUT OF SPECIFICATION "_ SPECIFICATIoNMEETS,IWidng circuit between C.D.I magneto and I
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I
I socket
connector
isfaulty
_ Repair.
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CORRECT I The circuit is good. I

I Replace lighting coil. I
ow

Check all connections inthe lighting system. POOR CONNECTIONS

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Refer to "CIRCUIT DIAGRAM".

4. Connections I

CORRECT i Repair, I
Check condition of each circuit for lighting
system.
Refer to "LIGHTING SYSTEM CHECK".

7 - 21 7 -22
3. The tail light does not work.
',.T,.S*STEM
IG'II SIGNAL SYSTEM
S'"A'S*'TE"
IELECI
1. Bulb and socket j NO CONTINUITY _ WIRING DIAGRAM
Check the bulb and socket for continuity.
I
JReplace bulb or socket. [
,_ CONTINUITY

2. Voltage _, c-_-_ - _=_

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Connectthe pocket tester (AC20V)to the ,,__ .... [

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J i

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taillight
coupler. ',_) [_ ',0
Pocket tester (+) lead --* Blue (_ , ,

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Pocket tester (-) lead _ Black (_) ',

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Setthemainswitch
to"ON". 8
Start the engine.

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Check the voltage (12V) between the head- "._E_::_

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light coupler leads "Blue" and "Black". OUT OF SPECIFICATION

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SPECIFICATION JWiring circuit between C.DJ magneto and[
I

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JThe circuit is good. I I taillight coupler--, Repair.

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7-23 7- 24
 TROUBLESHOOTING
S,O..LSYSTE.
IELECG'2 SIGNAL SYSTEM CHECK
..O.ALSYSTEM
IELEC
1. Horn does not sound

I HORN
FLASHER LIGHTS, BRAKE DOES
LIGHT, NOTWARNING
"OIL" SOUND LIGHT DO NOT WORK I I 1. "HORN" switch I INCORRECT
I
NOTE:
Remove the following parts before proceeding with the troubleshooting:
I Refer to "SWITCH iNSPECTION". I
" boardHandlebar
Mole and footrest
cover ,_ CONTINUITY I Replace left handlebar switch. I
For accurate troubleshooting use the following special tools:

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2. Voltage

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e.
90890-03112 Connect the pocket tester (DC20V) to the
horn lead.

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Pocket tester (+) lead _ Brown (_)

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1. Fuse I NO CONTINUITY Pocket tester (-) lead _ Ground

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I Refer to "SWITCH INSPECTION". B Turn the main switch to "ON".
Check for voltage (12V) between "Brown" _72o_5

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_r CONTINUITY I Replace fuse" I and the ground. OUT OF SPECIFICATION

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2._
L Battery INCORRECT "_

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Refer
Checkto the conditionINSPECTION"
of the battery, in m "_ SPECIFICATIoNMEETS Wiring circuiffrom main switch to horn is faulty I
I "BAI-rERY ,_

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Repair. I
I CHAPTER 3.

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I .Vo,a0e
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Battery voltage : Charge or replace the battery. T
t2.8 V or more at 2OC (68F) Connect the pocket tester (DC20V) to the Br

CORRECT
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,,_ Pocket tester () lead ---*Pink (_)
d
Pocket tester (-) lead --* Ground
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Refer to "SWITCH INSPECTION". "Pink"

Presslead.
the "HORN" switch.
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3. Mainswitch INCORRECT Turnthemainswitch toON.

Check the voltage (12V) between "Pink" and
ground. DOESNOTMEETSPECIFICATION 3_7
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_ CORRECT I Replace main switch" I _ SPECIFICATION

MEETS "_
D

Check all connections in the signal system. I POOR CONNECTIONS I Adjust or replace the horn. I I Replace horn. I
4. Wiring
Refer to "WIRING
connections
DIAGRAM". I

_. CORRECT I Repair. _ I
l

signal system. I

I Check
ReCfHEtcOK
the t.he
condition
sectionof "SIGNAL SYSTEM
each circuit of the lI

7 - 25 7 - 26
2. The tail light does not work.
S,O..LSYSTEM
IE'Ec G-3I 3. Flasher does not work
S,O..LSYSTEM
IE'Ec
I1.
Refer
INCORREcTBrake
to.SWiTCH
switch ,NSPECT,ON.. I Ii Refer
1. "TURN" switch INSPECTION..
to .SWITCH I INCORRECT "_

.J_ CORRECT .J_ CORRECT IRep lace left handlebar switch"

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Connect the pocket tester (DC20V) to the Connect the pocket tester (DC20V) to the
socket, flasher relay. --'.

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Pocket tester (+) lead --*Green / Yellow (_ Pocket tester (+) lead -_ Brown (_)
Pocket tester (-) |cad _ B|ack _ Pocket tester (-) lead _ Ground (_

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Turn the main switch to 'ON" Turn the main switch to ON

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2.
Pull
Voltage
the brake lever. I Replace brake switch. I 2.Check
Voltage
the voltage (12V) between the"Brown"

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Check the voltage (12V) between" Green lead and the ground. )UT OF SPECIFICATION
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Yellow" (_ and "Black" (_). MEETS
SPECIFICATIONS

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_ _" .... ', 3. Voltage I Wiring circuit from main switch to flasher relay I
" ,' Y I connector is faulty "-* Replair. I
, , L Connect the pocket tester (DC2OV) to the

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flasher relay.

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Pocket tester (+) lead -_ Brown/White O

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B OUT OF SPECIFICATION Pocket tester (-) lead _ Ground (_

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Turn the main switch to ON

,_ MEETS
SPECIFICATION
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_Wiring circuit from main switch to bulb socket I Checkthe voltage
White" lead (12V)
and the between the"Brown/
ground.
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I Circuit is good. I I connector is faulty..-* Repair. I n MEETS OUT OF SPECIFICATION
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SPECIFICATIONS
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I Replace flasher relay. I

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7 - 27 7 - 28
 S.O.ALSY.TE.
IE'EC [G'41 S,O.ALSYSTE.
I'Eo-----J
,_ 4. The "OIL" indicator light does not work.
m

4.Voltage Flasher
light Turnindicator
light I 1.Bulb
and
socket I NOCONTINUITY

I
flasher bulb : J_. Replace bulb or socket.
Pocket tester (+) lead _ Chocolate (_)
Pocket tester (-) lead _ Ground 2. Oil level switch

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Left
Connect
flasher connector.
the bulb
pocket: tester (DC2OV)to the Cllg _ I = Check the bulb
the and
oilcontinuity...=,v
socketCONTINUITY
for from the oil

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Right flasher Disconnect level switch _
Pocket tester (+) lead _ Dark green (_) tank.

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I Pocket tester (o) lead --*Ground Connect the pocket tester (Q x 1) to the oil

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Turn the main switch to "ON". level switch.

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Set the "TURN" switch to "L", then to "R". Pocket tester (-) lead --_Terminal (_

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Check the voltage (12V) between "Choco- Pocket tester (+) lead --_Terminal (_)
late" and the ground, then "Dark green" and OUTOF SPECIFICATION 37_s

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the ground. Check the switch for continuity.
Float Good Bad

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I II Wiring

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I Thiscircuitisgod" SPECIFICATION connector
circuitisfrom
faulty --* switch
turn Repair.to bulb socket Ii LOW
HIGH O
X X
O] X
xJ O
O OUT OF SPECIFICATION

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O : Continuity X : No continuity

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,_ SPECIFICATION
MEETS I Replace il level switch" I
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Connect the connector.
bulb socket pocket tester (DC20V) to the (_)k_ z
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Pocket tester (+) lead _ Grey (_

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Pocket tester (.) lead .--*Ground

Turn the main switch to "*".
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3.Check the voltage (12V) between "Grey" and

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the ground.
OUT OF SPECIFICATION
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SPECIFICATION ,_

I This circuit is in gd cnditin" I 14' Cnnectins I

Check all connections in the signal system.
IRefer to "WIRING DIAGRAM". I

7 - 29 7 - 30
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 I TRBL

CHAPTER 8.
TROUBLESHOOTING

STARTING FAILURE/HARD STARTING .................................................... G-8

FUEL SYSTEM ....................................................................................... G-8
ELECTRICAL SYSTEM .......................................................................... G-8
COMPRESSION SYSTEM ..................................................................... G-8

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POOR IDLE SPEED PERFORMANCE ........................................................ G-8

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POOR IDLE SPEED PERFORMANCE .................................................. G-8

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POOR MEDIUM AND HIGH SPEED PERFORMANCE ............................... G-9

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FUEL SYSTEM ....................................................................................... G-9
ELECTRICAL SYSTEM .......................................................................... G-9

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COMPRESSION SYSTEM ..................................................................... G-9

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FAULTY AUTOMATIC (V-BELT TYPE) ........................................................ G-9

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SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING ......... G-9
CLUTCH -OUT FAILURE........................................................................ G-9

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POOR STANDING START (LOW CLIMBING ABILITY) ......................... G-9

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POOR ACCELERATION (POOR HIGH SPEED) ................................... G-9

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IMPROPER KICKING ................................................................................. G-10

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SLIPPING .............................................................................................. G-10
HARD KICKING .................................................................................... G-10

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KICK CRANK NOT RETURNING ......................................................... G-10
fro FAULTY BRAKE ........................................................................................... G-4
POOR BRAKING EFFECT ..................................................................... G-4
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MALFUNCTION ...................................................................................... G-4
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FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION ........ G-10
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OIL LEAKAGE ....................................................................................... G-10

MALFUNCTION .................................................................................... G-10
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INSTABLE HANDLING ............................................................................... G-10

INSTABLE HANDLING ......................................................................... G-10
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FAULTY SIGNAL AND LIGHTING SYSTEM .............................................. G-10

OVERHEATING .......................................................................................... G-11

OVERHEATING .................................................................................... G-11

WIRING DIAGRAM ..................................................................................... G-12

 STARTING FAILURE/HARD STARTING SHTG
ITRBL _ I G- 8 I POOR IDLE
STARTING SPEED PERFORMANCE
FAILURE/HARD STARTING/ SHTG
TRBL --
ep I
TROUBLESHOOTING COMPRESSION
SYSTEM
Cylinder and cylinder head Crankcase and crankshaft
NOTE: Loose spark plug Improperly seated crankcase
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, Loose cylinder head or cylinder Improperly sealed crankcase
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, - Broken cylinder head gasket (damaged oil seal)
adjustment and replacement of parts. Broken cylinder gasket Seized crankshaft
Worn, damaged or seized cylinder Reed valve
STARTING FAILURE/HARD STARTING Piston and piston rings Deformed reed valve stopper
FUEL SYSTEM Improperly installed piston ring Improperly seated reed valve

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Fuel tank Carburetor Worn, fatigued or broken piston ring Loose intake manifold

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Empty Deteriorated fuel, fuel containing, water or o Seized piston ring Broken gasket

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Clogged fuel filter foreign material Seized or damaged piston Broken reed valve
Deteriorated fuel or fuel containing water or - Clogged pilot jet

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foreign material Clogged pilot air passage

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Clogged fuel tank cap Sucked-in air
Fuel cock Deformed float

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Clogged fuel hose Groove-worm needle valve

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Air cleaner Improperly sealed valve seat POOR IDLE SPEED PERFORMANCE
Clogged air filter Improperly adjusted fuel level POOR IDLE SPEED PERFORMANCE

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Improperly set pilot jet Carburetor

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Clogged starter jet o Improperly returned starter plunger
Starter plunger malfunction Clogged or loose pilot jet

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Improperly adjusted pilot air screw Clogged pilot air jet

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Improperly adjusted idle speed ( throttle stop screw)
Improper throttle cable play

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ELECTRICAL
SYSTEM Flooded
carburetor

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Sparkplug CDIunitsystem
Improper plug gap
Worm electrodes
Faulty CDI unit
Faulty source coil
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Wire between terminals broken Faulty pick-up coil
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Improper heat range Switches and wiring
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Faulty spark plug cap Faulty main switch

Ignition coil Broken or shorted wiring
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Broken or shorted primary/secondary Faulty" ENGINE STOP" switch

Faulty spark plug lead
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Broken body
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8-1 8-2
 POOR MEDIUM AND HIGH SPEED PERFORMANCE ISHTG
TRBL L _ I G =9 I FAULTY AUTOMATIC T. L
SHTG

POOR MEDIUM AND HIGH SPEED PERFORMANCE FAULTY AUTOMATIC (V-BELT TYPE)
FUEL SYSTEM SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING.
Fuel tank Carburetor V-belt Secondary sheave
- Clogged fuel filter Deteriorated fuel, fuel containing water or Worn, damaged or slipped v-belt Broken compression spring
Deteriorated fuel or fuel containing water or foreign material Primary sheave Pealed lining from clutch shoe
foreign material Sucked-in air Worn or damaged cam plate o Worn spline of clutch housing
Clogged fuel tank cap Deformed float Worn or damaged slider bushing
Fuel cook Groove-worm needle valve
Clogged fuel hose Improperly sealed valve seat

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Air cleaner Improperly set clip position of jet needle CLUTCH-OUT FAILURE

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Clogged air cleaner Improperly adjusted fuel _evel Primary sheave Secondary sheave

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Clogged or loose main jet Seized primary sliding sheave and collar o Broken or fatigued clutch shoe spring
Clogged or loose main nozzle

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POOR STANDING START (LOW CLIMBING ABILITY)

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ELECTRICAL SYSTEM V-belt Secondary sheave

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Spark plug CDI unit system Worn, damaged or slipped v-belt Fatigued compression spring

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Improper plug gap Faulty CDI unit Primary sheave Improper operation of secondary sliding sheave
Worm electrodes Faulty source coil Worn or improper operation of weight

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Wire between terminals broken Faulty pick-up coil
improper heat range

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Faulty spark plug cap POOR ACCELERATION (POOR HIGH SPEED)
V-belt

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Worn or greasy V-belt

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Secondary sheave

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Worn or greasy clutch shoe
Improper operation of secondary sliding sheave

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COMPRESSION SYSTEM fro
Cylinder and cylinder head Crankcase and crankshaft
Loose spark plug - Improperly seated crankcase
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Loose cylinder head or cylinder Improperly sealed crankcase

Broken cylinder head gasket (damaged oil seal)
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Broken cylinder gasket . Seized crankshaft

Worn, damaged or seized cylinder
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Piston and piston rings Reed valve

Impropedy installed piston ring Deformed reed valve stopper
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Worn, fatigued or broken piston ring Improperly seated reed valve

Seized piston ring Loose intake manifold
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Seized or damaged piston Broken gasket

Broken reed valve

8-3 8-4
 IMPROPER KICKING/FAULTY BRAKE
I TRBL
I "
INSTABLE HANDLING/
FAULTY SIGNALAND LIGHTING SYSTEM
Ii TRBL
IMPROPER
KICKING INSTABLE
HANDLING
SLIPPING INSTABLE HANDLING
Kick axle assembly Transmission oil Handlebar Wheels
Low tension of kick clip o Improper quality (low viscosity) Improperly installed or bent Damaged bearing
Worn kick axle Deterioration Bent or loose wheel axle
Worn or damaged kick gear Excessive wheel run-out
Damaged kick clip
Kick clip coming off Steering Frame
Damaged kick clip stopper Improperly installed steering column Twisted

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(Improperly tightened ring nut) Damaged head pipe
HARD KICKING Bent steering column o Improperly installed bearing race

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Kick axle assembly Crankcase and crankshaft Damaged ball bearing or bearing race

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High tension of kick clip Improperly seated crankcase

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Seized kick gear Improperly seated crankshaft Front forks Engine bracket
Damaged or seized crankshaft Broken spring Bent or damaged

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Cylinder, piston and piston ring Damaged or seized crankshaft bearing Bended front forks

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Damaged or seized cylinder
Damaged or seized piston Tires Rear shock absorber

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Damaged or seized piston ring Uneven tire pressures on both sides Fatigued spring

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Incorrecttire pressure Oil leakage
KICKCRANK NOTRETURNING Unevenly worntires

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Kick axle assembly
Damaged kick return spring

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Kick return spring coming off

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Kick clip coming off

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Damaged kick return spring stopper FAULTY SIGNAL AND LIGHTING SYSTEM

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FAULTY BRAKE Headlight dark Flasher does not light
POOR BRAKING EFFECT
Disc brake Drum brake
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Too many electric accessories
Improperly grounded
Discharged battery
Worn nbrake pads Worn brake shoe Hard charging (broken charging coil) Faulty flasher switch
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Worn disc Worn or rusty brake drum Incorrect connection , Faulty flasher relay
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Air in brake fluid Improperly adjusted brake free play o Improperly grounded Broken wireharness
Leaking brake fluid Improper brake cam lever position Poor contacts (main or light switch) Loosely connected coupler
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Faulty cylinder cup kit Improper brake shoe position Bulb life expires Bulb burnt out
Faulty caliper seal kit Fatigued / Damaged return spring Faulty fuse
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Loose union bolt Oily or greasy brake shoe

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Broken brake hose Oily or greasy brake drum Bulb bumt out Flasher keeps on
Oily or greasy disc/brake pads Broken brake cable Improper bulb Faulty flasher relay
Improper brake fluid level Improperly grounded Insufficient battery capacity
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Faulty main and/or light switch (nearly discharged)

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION Bulb life expires
OIL LEAKAGE MALFUNCTION Bulb burnt out
Bent, damaged or rusty inner tube Bent, deformed or damaged inner tube
Damaged or cracked outer tube Bent or deformed outer tube
Damaged oil seal lip Damaged fork spring
Improper installed oil seal Worn or damaged slide metal
Improper oil level (too much) Bent or damaged damper rod
Loose damper rod holding bolt Improper oil viscosity
Broken cap bolt O-ring Improper oil level

8-5 8-6
 FAULTY SIGNAL AND LIGHTING SYSTEM/
OVERHEATING I TRBL I TRBL
Flasher winks slower Horn is inoperative
Faulty flasher relay Faulty battery
Insufficient battery capacity (nearly discharged) o Faulty fuse
Improper bulb Faulty main and/or horn switch
Faulty main and/or flasher switch Improperly adjusted horn
Faulty horn
Broken wirehamess
Flasher winks quicker
Improper bulb
Faulty flasher relay

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OVERHEATING

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OVERHEATING
Ignition system Compression system

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Improper spark plug gap Heavy carbon buildup

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Improper spark plug heat range
Improper ignition timing"

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Faulty system Cooling fan
Improper carburetor main jet (Improper setting) Damaged cooling fan

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Clogged air cleaner element Damaged air shrouds
Lean mixture (faulty autolube pump setting)

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Brake

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Dragging brake

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8-7
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 IG-12 I
WIRING DIAGRAM _ C,D.I Magneto

_(_c,_ _ Ignition
C.D.I Unit
coil
_:: i [_ @ Spark plug
8w @ Main switch

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8 r_ _!_] -- r- _::1_
.... _ Battery
@Fuse

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....... _i_'_ _ _ _ I _-I_1 @ Rectifier/regulator

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.... @Starter
motor

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-, _ _ Right handle switch

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' _ ........ @ Lefthandle switch

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_-_ _ Head light

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L......
_B i-_-i i _ i _6"_-__
......... i _ _
_ Starter relay
Left front flasher light

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- --L_; ...................... L_,
_ I_ _ Right front flasher light
L_

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__ _ ............. _ Right rear flasher light

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'i__ _ E _} i' _
_ Leftrearflasherlight
Tail/Stop light

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_ _ _ Flasher relay
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" _ Rear stop switch

' ',-_-_B_ _ (_ Front stop switch
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@ ' _ Oil level gauge

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...............
.ORN _,._ER
_ ......._.E. ]_ -:_ _ Meter
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....... ,__,---
-, _,..........
_o,_ SenderY/_
........
Yo,,o_/_,_c_
....... --_

I_::_
(GREEN) I
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_
_!

I_! _____
_

________
(

_[
B
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--
) i"""
__
_@

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_
ii 'iiiiii
...........
Bown.......
Gre
0 ........... Orange
Ch .......... Chocolate

B/R ........ BlacldRed

B/W
.......
Dg ..........
Black/White
Dark green
L/W ........ Blue/White
Y/R ........ YellowlRed

Br/W .......
W/R ...... White/Red
Brown/White
Br/Y ....... Brown/Yellow
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Yamaha Motor Canada Ltd.

480 Gordon Baker Road
Toronto, ON M2H 3B4