2 Manual de Servicio Bws YW100 '00 - '06 Part 2 PDF

CRANKCASE AND REED VALVE ENG
CRANKCASE(RIGHT) REMOVAL
1. Remove:
8 Oil seal stopper 1
8 Screws (crankcase) 9Nm(0.9 kg.m)
T.
R.
NOTE:
Loosen each screw 1/4 turn, and remove them
after all are loosened.
2. Attach:
8 Crankcase separating tool 1
Crankcase separating tool:

90890-01135
NOTE:
Fully tighten the tool holding bolts, but make
sure the tool body is parallel with the case. If
necessary, one screw may be backed out
slightly to level tool body.
3. Remove
8 Crankcase (right)
As pressure is applied, alternately tap
on the engine mounting bosses.
REED VALVE INSPECTION

1. Measure:
8 Valve stopper height 1
Out of specification→Adjust stopper/Re-
place valve stopper.
Valve stopper height 1

6.0~6.4 mm
2. Measure:
8 Reed valve clearance 2
Out of specification→Replace reed
valve.
Reed valve clearance 2

Less than 0.2 mm
4-35
CRANKCASE (RIGHT) INSTALLATION
3 1. Install:
8 Dowel pins 1
1 2 8 Engine mount spacer 2
2. Apply:
8 Yamaha Bond No.1215 3
To the mating surfaces of both case
helves.
Yamaha bond No.1215:

90890-85505
2
3. Attach:
1
8 Crankshaft installing tool 1,2,3
Crankshaft installing tool:

90890-012741
90890-012752
90890-01277
4. Tighten:
8 Crankcase holding screws
12 Nm(1.2 kg.m)
T.
R.
NOTE:
Tighten the crankcase holding screws in stage,
using a crisscross pattern.
5. Check:
8 Crankshaft operation
Unsmnoth operation Repair.
New 6. Install:
8 Oil seal (right crank case) 1 New
Apply grease on to oil seal lip.
7. Install:
8 Oil seal stopper plate 1
9 Nm (0.9 kg.m)
T.
R.
4-36
8. Install:
1 8 Gasket
8 Reed valve
8 Reed valve 1 11 Nm(1.1 kg.m)
T.
R.
4-37
CRANKSHAFT ENG
CRANKSHAFT
CRANKSHAFT
B
2
2
3
E
E
B
Order Job name/Part name Q’ty Remarks

Crankshaft removal Remove the parts in order.
Right crankcase removal Refer to “CRANK CASE AND REED
VALVE” section.
1 Crankshaft 1
2 Bearing 2
3 Oil seal 2
4 Crankcase cover (left) 1
Reverse the removal procedure for in-
stallation.
4-38
CRANKSHAFT ENG
CRANKSHAFT REMOVAL
1 1. Attach:
2
8 Crankcase separating tool 1
Crankcase separating tool:

90890-01135
2. Remove:
8 Crankshaft 2
CRANKSHAFT INSPECTION
F
1. Measure:
C C 8 Runout limit “ C”
8 Connecting rod big end side clearance
“D”
8 Small end free play limit “F”
Out of specification→Replace.
Use V-blocks, dial gauge and thickness
D
gauge.
Runout limit “C”:

0.03 mm
Connecting rod big end side clear-
ance “D”:
0.2 ~ 0.5 mm
Small end free play “ F”:
0.4 ~ 0.8 mm
2. Inspect:
8 Bearings (crankshaft)
Spin the bearing inner race.
Excessive play/Roughness→Replace.
Pitting/Damage→Replace.
4-39
CRANKSHAFT ENG
CRANKSHAFT INSTLATION
4
1. Attach:
3 8 Crankshaft Installing Tool
Crankshaft installing tool:

1 90890-01274
90890-01275
2
90890-012771
90890-012882
2. Install:
8 Crankshaft3
(to the crankcase4)
3. Install:
8 Oil seal 1 New
8 Apply lithium soap base grease onto
the oil seal lip.
Use the guide 2 and seal driver 3 to
install the oil seal
2 Oil seal driver

1 90890-01410
Oil seal guide
90890-01409
4-40
CARBURETOR CARB
CARBURETION
CARBURETOR
3 6
5 4
9Nm(0.9kg.m)
T.
R.

Carburetor removal Remove the parts in order.
Battery box cover
Grip
End cover Refer to “COVER AND PANEL” section
Left/Right cover in CHAPTER 3.
Center cover
1 Air cleaner case assembly 1
2 Carburetor assembly 1
3 Auto choke lead coupler 1
4 Fuel hose 1
5 Vacuum hose 1
6 Oil delivery pipe 1
7 Throttle cable 1
Reverse the removal procedure for instal-
lation.
5-1
CARBURETOR CARB
CABURETOR DISASSEMBLY
4
2
7 1
w
0
6 eq

Carburetor disassembly Disassemble the parts in order.
1 Throttle valve 1
2 Throttle cable 1
3 Needle set 1
4 Carburetor top cover 1
5 Throttle stop screw 1
6 Pilot air screw 1
7 Auto choke unit assembly 1
8 Float chamber/Seal ring 1/1
9 Float pin 1
0 Float/Needle valve 1
q Main jet 1
w Pilot jet 1
e Main nozzle 1
r Carburetor body 1
stallation.
5-2
CARBURETOR CARB
CABURETOR INSPECTION
Measure:
8 Float height a
Out of specification→Inspect needle valve,
float and valve seat.
Float height:
16.5 mm
***************************************
Float height measurement steps:
8 Install the needle valve, float and float pin to
the carburetor body.
8 Hold the carburetor in an upside down posi-
tion.
8 Measure the distance between the mating
surface of the float chamber (gasket re-
moved) and top of the float using a gauge.
NOTE:
The float arm should be resting on the needle
valve, but not compressing the needle valve.
8 If the float height is not within specification,

inspect the needle valve, float and valve seat.
8 If it is worn, replace it.
*************************************
NOTE:
The float height is properly adjusted at the Yamaha
/MBK factory. Never attempt to adjust it.
CARBURETOR ASSEMBLY
To assemble the carburetor, reverse the disas-
sembly procedures.
Note the following points.
cC
8 Before reassembling, wash all parts in clean
gasoline.
8 Always use a new gasket.
1. Install:
8 Throttle valve 1
8 Jet needle 2
8 Clip 3
8 Spring seat 4
Jet needle clip position:

3/5
5-3
CARBURETOR CARB
2. Install:
1
8 Throttle valve 1
a
NOTE:
Align the groove of the throttle valve with the
projection a of the carburetor body.
3. Install:
8 Carburetor assembly
a NOTE:
Align the projection a with the projections b.
FUEL LEVEL ADJUSTMENT

1. Measure:
8 Fuel level a
Out of specifications→Adjust.
Fuel level a:
3.0~4.0 mm(Below the float cham-
ber line
↓
a
↑ ***************************************
Measurement steps:
3 8 Place the scooter on a level surface.
1
8 Use a garage jack under the engine to en-
sure that the carburetor is positioned verti-
2
cally.
8 Connect the fuel level gauge 1 to the drain
pipe 2.
Fuel level gauge:

90890-01312
8 Loosen the drain screw 3.

8 Measure the fuel level a with the gauge.
8 If the fuel level is incorrect, adjust the fuel
level:
8 Remove the float chamber, float, valve seat
and the needle valve.
8 Inspect the valve seat and needle valve.
8 If either is worn, replace them both.
5-4
CARBURETOR CARB
8 If both are fine, adjust float level by bending
the float tang b slightly.
8 Install the carburetor.
8 Recheck the fuel level.
***************************************
AUTO CHOKE INSPECTION

(Ambient temperature lower than 45°C)
1. Remove:
8 Carburetor
2. Inspect:
8 Autochoke unit
Connect a suitable pipe 2 to the starter 1,
and blow it with the mouth etc. Possible→Good
condition.
Impossible→Replace auto choke unit.
3. Inspect:
B B
8 Auto choke unit (with battery)
***************************************
Inspection and adjustment steps:
8 Connect auto choke unit leads to the 12 V
battery for 5 minutes.
Black terminal→12 V battery (+) 1
Black terminal→12 V battery (–) 2
8 Connect a suitable pipe 4 to the starter 5,
and blow it with the mouth etc.
Possible→Replace auto choke unit.
Impossible→Good condition.
***************************************
5-5
CARBURETOR CARB
FUEL COCK INSPECTION
1. Stop the engine.
2. Remove:
8 Grip
8 End cover
8 Left side cover
8 Battery box cover
Refer to “COVER AND PANEL” section
in chapter 3.
3. Inspect:
8 Fuel cock
2 ***************************************
Fuel cock inspection steps:
8 Disconnect the fuel hose 1.
8 Place the receptacle under the fuel hose end.
8 If fuel stops flowing out in a few seconds,
1 the fuel cock is in good condition. If not, clean
or replace the fuel cock.
8 Disconnect the vacuum hose 2 and breathe
in the vacuum hose with the mouth etc. for
vacuum .
8 If fuel flows out of the fuel hose under
vacuum and stops under non-vacuum, the
fuel cock is in good condition.
If not, clean or replace the vacuum hose, fuel
hose and fuel cock.
*************************************
4. Install:
8 Battery box cover
8 Left side cover
8 End cover
8 Grip
5-6
FRONT WHEEL AND BRAKE DISC CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC
1
4
7Nm(0.7kg.m)
T.
R.
3
23Nm(2.3kg.m)
T.
R.
7Nm(0.7kg.m)
T.
R.
6
LT
B
8
7
5
20Nm(2.0kg.m)
T.
R.

Front wheel and brake disc removal Remove the parts in order.
w
Securely support the scooter so there is
no danger of it falling over.
1 Speedometer cable 1
2 Front brake hose holder 1
3 Brake caliper 1 Refer to “FRONT WHEEL INSTALLA-
4 Wheel axle 1 TION” section.
5 Front wheel assembly 1
6 Gear unit assembly 1
7 Collar 1 Refer to “FRONT WHEEL ASSEMBLY”
8 Brake disc 1 section.
stallation.
6-1
FRONT WHEEL DISASSEMBLY
5
4
3
B
2
New
1

Front wheel disassembly Remove the parts in order.
1 Oil seal 1 Refer to “FRONT WHEEL DISASSEM-
2 Bearing 1 BLY/ASSEMBLY” section.
3 Collar 1
4 Spacer 1
5 Bearing 1
stallation.
6-2
YP ......
FRONT WHEEL DISASSEMBLY

1. Remove:
8 Bearing 1
8 Spacer
Remove the bearing using a general
bearing puller 2.
cC
Handle the wheel with care not to damage the
brake disc. If the brake disc is damaged, replace.
YP700020
FRONT WHEEL INSPECTION

1. Inspect:
8 Front wheel axle
(by rolling it on a flat surface)
Bends→Replace.
w
Do not attempt to straighten a bent axle.
Wheel axle bending limit:

0.25 mm
2. Inspect:
8 Front tire
Wear/damage→Replace.
Refer to “TIRE INSPECTION” in CHAP-
TER 3.
8 Front wheel
Refer to “WHEEL INSPECTION” in
CHAPTER 3.
3. Measure:
8 Front wheel runout
Over the specified limits→Replace.
Front wheel runout limits:

Radial 1: 1.0 mm
Lateral 2 : 1.0 mm
4. Inspect:
8 Front wheel bearings
Bearings allow free play in the wheel
hub or the wheel does not turn
smoothly→ Replace.
8 Oil seals
Wear / damage→Replace.
6-3
4. Inspect:
8 Collar
Grooved wear→Replace the collar and
the oil seal as a set.
YP.....
BRAKE DISC INSPECTION

1. Measure:
8 Brake disc deflection1
Maximum deflection:
0.15 mm
2. Measure:
8 Brake disc thicknessa
Brake disc thickness:

4.0 mm
Minimum thickness:
3.5 mm
a Out of specification→Replace.
YP.....
FRONT WHEEL ASSEMBLY

4 1. Install:
3 8 Bearing 1
2 8 Collar 2
8 Spacer 3
8 Bearing 4
8 Oil seal 5
NOTE:
8 Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
8 Use a socket that matches the outside diam-
eter of the race of the bearing.
8 Always use a new oil seal.
8 Install the oil seal with its manufacturer’s
1 marks or numbers facing outward.
5 New
cC
B Do not strike the inner race of balls of the bear-
ing. Contact should be made only with the outer
6-4 race.
2. Install:
8 Brake disc 1 20 Nm(2.0 m.kg)
T.
1
R.
NOTE:
Tighten the bolts (brake disc) in stage using a
crisscross pattern.
EB700030
FRONT WHEEL INSTALLATION

Reverse the “REMOVAL” procedure.
1. Lubricate:
8 Front wheel axle
8 Bearings
8 Oil seal (lips)
8 Drive/driven gear (speedometer)
Recommended lubricant:
1
Lithium soap base grease
2. Install:
8 Speedometer gear unit 1
NOTE:
Make sure that the wheel hub and the speed-
ometer gear unit are installed with the three
projections meshed into the two slots.
3. Install:
8 Front wheel
NOTE:
Make sure that the slot in the speedometer gear
unit fits over the stopper on the front fork outer
tube.
1 4. Tighten:
8 Front wheel axle 1
8 Axle nut (front wheel axle)
70 Nm(7.0kg.m)
T.
R.
cC
Before tightening the axle nut, stroke the front
fork several times to check for proper fork op-
eration.
w
Make sure that the brake hose is routed prop-
6-5 erly.
YP700040
WHEEL STATIC BALANCE ADJUSTMENT

NOTE:
8 After replacing the tire and/or rim, the wheel
static balance should be adjusted.
8 Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
8 Balancing weight
2. Set:
8 Wheel
(on a suitable stand)
3. Find:
8 Heavy spot
***************************************
Procedure:
X1 a. Spin the wheel and wait for it to rest.
b. Put an “X1” mark on the wheel’s bottom
spot.
c. Turn the wheel so that the “X1” mark is
90° up.
d. Release the wheel and wait for it to rest.
X1 Put an “X2” mark on the wheel’s bottom
spot.
e. Repeat the above b., c., and d. several
X times until all marks come to the same
spot.
f. This spot is the wheel’s heavy spot “X”.
***************************************
4. Adjust:
8 Wheel static balance
***************************************
Adjusting steps:
8 Instail a balancing weight 1 on the rim ex-
actly opposite to the heavy spot “X”.
NOTE:
X
Start with the smallest weight.
8 Turn the wheel so that the heavy spot is 90°

up.
8 Check that the heavy spot is at rest there. If
X not, try another weight until the wheel is bal-
anced.
***************************************
6-6
X 5. Check:
8 Wheel static balance
***************************************
Checking steps:
X X 8 Turn the wheel so that it comes to each point
as shown.
8 Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
X ***************************************
6-7
FRONT BRAKE CHAS
FRONT BRAKE
BRAKE PAD
4
2
1
23Nm(2.3kg.m)
T.
R.
23Nm(2.3kg.m)
T.
R.

Brake pad removal Remove the parts in order.
1 Caliper support bolt 1 Refer to “ BRAKE PAD REPLACEMENT
2 Caliper 1 “ section .
3 Brake pad 2
4 Pad spring 2
stallation.
6-8
FRONT BRAKE CHAS
cC
Disc brake components rarely require disas-
sembly. DO NOT:
8 Disassembly components unless absolutely
necessary.
8 Use solvents in internal brake component.
8 Use contaminated brake fluid for cleaning.
8 Use only clean fluid.
8 Allow brake fluid to come in contact with the
eyes otherwise eye injury may occur.
8 Allow brake fluid to contact painted surfaces
or plastic parts otherwise damage may oc-
cur.
8 Disconnect any hydraulic connection other-
wise the entire system must be disas-
sembled, drained, cleaned, and then prop-
erly filled and bled after reassembly.
BRAKE PAD REPLACEMENT

NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
2
3 1. Loosen:
8 Retaining bolt 1
1 2. Remove:
8 Brake caliper 2
8 Holder (brake hose) 3
3. Remove:
2 8 Retaining bolt
1
8 Pads 1
8 Pad spring 2
NOTE:
8 Replace the pad spring if the pad replacement
is required.
8 Replace the pads as a set if either is found to
be worn to the wear limit.
Wear limit a:
0.8 mm (0.03 in)
6-9
FRONT BRAKE CHAS
4. Install:
2 8 Pad springs
1
8 Brake pads (new)
***************************************
Installation steps:
8 Connect a suitable hose 1 tightly to the cali-
per bleed screw 2. Then, place the other end
of this hose into an open container.
8 Loosen the caliper bleed screw and push the
piston 3 into the caliper by your finger.
8 Tighten the capliper bleed screw.
6 Nm (0.6 kg.m)
T.
3
R.
8 Install the pad spring (new) and brake pad
(new) 4
8 Tighten retaining bolt 5 23 Nm (2.3 kg.m)
T.
R.
8 Install brake hose holder 6 7 Nm (0.7 kg.m)
T.
R.
8 Install caliper 7 23 Nm (2.3 kg.m)
T.
R.
***************************************
5. Inspect:
8 Brake fluid level
Refer to the “BRAKE FLUID INSPEC-
TION” section in the CHAPTER 3.
1
1 “LOWER” level line
6-10
FRONT BRAKE CHAS
6. Check:
8 Brake lever operation
A softy or spongy feeling Bleed→brake
system.
Refer to “ AIR BLEEDING ” section in
the CHAPTER 3.
6-11
FRONT BRAKE CHAS
MASTER CYLINDER
9Nm(0.9kg.m)
T.
R.
B
4 New
25Nm(2.5kg.m)
T.
R.
1 5 3

Master cylinder removal Remove the parts in order.
Drain the brake fluid Refer to “BRAKE FLUID REPLACE-
MENT” section in CHAPTER 3.
1 Brake lever/compression spring 1/1
2 Brake switch 1
3 Union bolt 1
4 Copper washer 2 Refer to “MASTER CYLINDER INSTAL-
5 Brake hose 1 LATION” section.
6 Master cylinder bracket 1
7 Master cylinder 1
stallation.
6-12
FRONT BRAKE CHAS
MASTER CYLINDER DISASSEMBLY
1
2 New

Master cylinder disassembly Remove the parts in order.
1 Master cylinder boot 1
2 Circlip 1 Refer to “MASTER CYLINDER ASSEM-
3 Master cylinder kit 1 BLY” section.
4 Spring 1
Reverse the disassembly procedure for
assembly.
6-13
FRONT BRAKE CHAS
YP702040
MASTER CYLINDER INSPECTION

1. Inspect:
8 Master cylinder kit 1
Wear/scratches→Replace the master
cylinder assembly.
8 Master cylinder boot
Cracks/damage→Replace.
2. Inspect:
8 Master cylinder 1
8 Scratches/wear/damage→Replace the
master cylinder assembly.
3. Inspect:
8 Diaphragm 1
1 Wear/damage→Replace.
YP.....
MASTER CYLINDER ASSEMBLY

w
8 All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
Recommended brake fluid:

DOT #4
8 Replace the piston seals and dust seals when-

ever a master cylinder is disassembled.
1. Install:
8 Cylinder cup 1
8 Master cylinder piston 2
Install cylinder cup 1 by using cylinder
cup installer 3.
Cylinder cup installer set:

90890-01996
6-14
FRONT BRAKE CHAS
2. Install:
8 Spring 1
Install the spring with its smaller diam-
eter to the master cylinder piston.
8 Master cylinder kit 2
3. Install:
8 Circlip 1 New
Install the circlip securely into the mas-
ter cylinder groove.
New 8 Master cylinder boot 2
YP.....
1
MASTER CYLINDER INSTALLATION
1. Install:
8 Master cylinder 1
2
8 Master cylinder bracket 2
9 Nm (0.9 kg.m)
T.
R.
cC
a
8 Install the master cylinder bracket 2 with the
“UP” mark a facing upward.
8 Align the end of the holder with the punch
mark b on the handle bar.
6-15
FRONT BRAKE CHAS
2. Air bleed:
8 Brake system
Refer to “AIR BLEEDING” section in
CHAPTER 3.
w
8 Use only designated quality brake fluid:
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake perforrmance.
8 Refill with the same type of brake fluid:
Mixing fluids may result in a harmful chemi-
cal reaction and lead to poor perforrmance.
8 Be careful that water does not enter the sig-
nificantly lower the boiling point of the fluid
may result in vapor lock.
3. Inspect:
8 Brake operation
6-16
FRONT BRAKE CHAS
CALIPER
3
5
25Nm(2.5kg.m)
T.
R.
1
2 New
23Nm(2.3kg.m)
T.
R.
23Nm(2.3kg.m)
T.
R.

Caliper removal Remove the parts in order.
Drain the brake fluid Refer to “BRAKE FLUID REPLACE-
MENT” section in CHAPTER 3.
1 Union bolt 1
2 Copper washer 2 Refer to “CALIPER INSTALLATION” sec-
3 Brake hose 1 tion.
4 Caliper support bolt 1
5 Caliper assembly 1
stallation.
6-17
FRONT BRAKE CHAS
CALIPER DISASSEMBLY
1
B
6Nm(0.6kg.m)
T.
R.
7
New
2
5
6
4

Caliper disassembly Remove the parts in order.
1 Caliper bracket 1
2 Brake pad 2
3 Pad spring 2 Refer to “BRAKE CALIPER DISASSEM-
4 Caliper piston 1 BLY/ASSEMBLY” section.
5 Dust seal 1
6 Piston seal 1
7 Bleed screw 1
assembly.
6-18
FRONT BRAKE CHAS
YP702020
BRAKE CALIPER DISASSEMBLY

NOTE:
Before disassembling either brake caliper, drain
the brake fluid from the brake hose, master
cylinder, brake caliper and reservoir tank.
1. Remove:
8 Brake caliper piston
***************************************
Removal steps:
8 Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.
w
8 Never try to pry out the caliper piston.
8 Cover the caliper piston with a rag. Be care-
ful not to get injured when the piston is ex-
pelled from the master cylinder.
cC
Carefully remove the caliper piston to prevent
damage.
***************************************
2. Remove:
8 Dust seal 1
8 Piston seal 2
When removing, push the seals by your
finger.
cC
8 Do not use a sharp instrument. Remove seals
by your finger.
8 Do not re-use removed parts.
YP...
CALIPER INSPECTION
1. Inspect:
8 Caliper cylinder 1
8 Caliper piston 2
Scratches, wear→Replace caliper as-
sembly.
6-19
FRONT BRAKE CHAS
EB702050
BRAKE CALIPER ASSEMBLY

w
8 All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
Recommended brake fluid:

DOT #4
8 Replace the caliper piston seals whenever a

brake caliper is disassembled.
New
1. Install:
8 Piston seal 1 New
8 Dust seal 2 New
2. Install:
8 Caliper piston 1
Apply brake fluid to the outer surface
and install.
cC
8 Do not force.
8 Use care to prevent damage on caliper pis-
ton.
YP.....
2
CALIPER INSTALLATION
3 1. Install:
1
8 Caliper 1
8 Caliper support bolt 23Nm(2.3m.kg)
T.
R.
8 Brake hose 2
a 8 Copper washer 3 New
4
8 Union bolt 4 25Nm(2.5 m.kg)
T.
R.
cC
When installing the brake hose to the caliper,
lightly touch the brake hose with the stopper
a on the caliper.
6-20
REAR WHEEL AND REAR BRAKE CHAS
REAR WHEEL AND REAR BRAKE
REAR WHEEL
3 4
New
1
2 120Nm(12kg.m)
T.
R.
26Nm(2.6kg.m)
T.
R.
12Nm(1.2kg.m)
T.
R.

Rear wheel and rear brake removal Remove the parts in order.
1 Muffler assembly/Gasket 1/1
2 Nut/Plain washer 1
3 Rear wheel assembly 1
4 Plain washer 1
installation.
6-21
REAR BRAKE
T.
R. 8Nm(0.8kg.m)
6
7
3 4
2
8
New

1 Adjuster 1
2 Brake cable 1
3 Pin 1
4 Return spring 1
5 Brake shoe 1
6 Camshaft lever 1
7 Wear indicator 1
8 Brake camshaft 1
stallation.
6-22
EB701020
REAR WHEEL INSPECTION

1 Inspect:
8 Rear wheel axle
8 Rear wheel
8 Rear wheel bearings
8 Oil seals
Refer to “FRONT WHEEL”.
2. Measure:
8 Rear wheel runout
Refer to “FRONT WHEEL”.
EB701021
REAR BRAKE INSPECTION

1. Inspect:
8 Brake lining surface
Glazed areas→Polish.
Use coarse sand paper.
NOTE:
After polishing, wipe the polished particles with
a cloth.
2. Measure:
8 Brake lining thickness a
Brake lining thickness a :

Standard:
4 mm
Limit:
2 mm
Measuring points “ M”
NOTE:
Replace the brake shoes as a set if either is worn
to the limit.
3. Measure:
8 Brake drum inside diameter a
Out of specification→Replace the wheel.
Brake drum inside diameter:

Standard:
130 mm
Limit:
131 mm
6-23
4. Inspect:
8 Brake drum inner surface
8 Oil/scratches→Repair.
8 Oil
Use a rag soaked in lacquer thinner or
solvent.
8 Scratches
Use an emery cloth (lightly and evenly
polishing)
5. Inspect:
8 Cam shaft face.
Wear→Replace.
w
When inspecting the brake lining, do not spill
oil or grease on the brake lining.
YP.....
b REAR BRAKE INSTALLATION
1. Install:
8 Camshaft 1
8 Indicator plate 2
***************************************
1
Installation steps:
2 8 Set the camshaft with its punched mark a
a
facing the direction as shown.
8 Align the projection b on the indicator plate
with the camshaft notch and install.
8 Check the proper position of the brake shoe.
***************************************
2. Install:
8 Camshaft lever 1
NOTE:
Set the camshaft with its punched mark a fac-
a ing the direction on the cam shaft lever b.
b
6-24
HANDLEBAR CHAS
HANDLEBAR
HANDLEBAR
3
12
23Nm(2.3kg.m)
T.
R.
B
7
43Nm(4.3kg.m)
T.
R.
9 11
12
6
B
4
B
1
8
5
10

Handlebar removal Remove the parts in order.
Left/Right bake mirror
Front protector bar Refer to “COVERS AND PANEL” IN
Upper cover CHAPTER 3.
Front/Rear handlebar cover
Left/Right flasher
1 Brake master cylinder 1
2 Front brake switch 1
3 Handlebar switch (Right) 1
4 Throttle cable 1
5 Rear brake cable 1
6 Rear brake switch 1
7 Handlebar switch (Left) 1
8 Bind 1
9 Wire harness strap 1
6-25
HANDLEBAR CHAS
3
12
23Nm(2.3kg.m)
T.
R.
B
7
43Nm(4.3kg.m)
T.
R.
9 11
12
6
B
4
B
1
8
5
10

10 Brake hose 1
11 Handlebar comp. 1
12 Left/Right grip 1/1
stallation.
6-26
HANDLEBAR CHAS
HANDLEBAR INSTALLATION
1. Clean:
8 Steering shaft a
w
a Proper cables and leads routing is essential to
issue safe scooter operation.
2. Install:
2
8 Handlebar 1
1
8 Bolt 2
◗b
8 Nut 43Nm(4.3 kg.m)
M
T.
R.
NOTE:
Match the bolt 2 on to the steering column
dent a.
a
cC
There must be a space b after tighting bolt 2.
3. Install:
8 Band
NOTE:
Clamp the wire harness.
4. Apply:
8 Lithium soap base grease (to throttle
cable end and handlebar right end).
1 5. Install:
8 Handlebar switch (right) 1
a
NOTE:
Insert the projection a into the slot b on the
handlebar comp.
6-27
HANDLEBAR CHAS
1 6. Install:
8 Handlebar switch (left) 1
a NOTE:
Insert the projection a into the slot b on the
handlebar comp.
b
7. Install:
8 Master cylinder
NOTE:
b Match the slot with the punched mark b on
the handlebar comp.
6-28
STEERING CHAS
STEERING
STEERING
1
2
3
6
7
4
B
8
45Nm(4.5kg.m) 9
T.
R.
B
9
8
5
45Nm(4.5kg.m)
T.
R.

Steering removal Remove the parts in order
Handlebar Refer to “HANDLEBAR” section.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISC” section
1 Ring nut 1/ Special washer 1/1
2 Ring nut 2/ Rubber washer 1/1 Refer to “STEERING REMOVAL/INSTAL-
3 Ring nut 3 1 LATION” section.
4 Under bracket 1
5 Front fork (Left/Right) 1/1
6 Bearing cover 1
7 Ball race 1
8 Ball (Upper/Lower) 22/19
9 Ball race 3
stallation.
6-29
STEERING CHAS
STEERING REMOVAL
w
8 Securely support the scooter so that there is
no danger of it falling over.
8 Stand the scooter on a level surface.
1. Removal:
8 Ring nut 1 1
8 Special washer 2
8 Ring nut 2 3
9 1
8 Rubber washer 4
2 8 Ring nut 3 5
3 8 Bearing cover 6
4 8 Ball race 7
8 Ball 8
5 8 Front fork assembly 9
NOTE:
6
8 Remove the ring nuts by steering nut wrench.
7 Steering nut wrench 0

90890-01268
8 8 Hold the lower bracket by hand, then remove

by using the steering nut wrench 0.
8 Do not loss the balls (Upper: 22 pcs, Lower:
19 pcs).
2. Remove
8 Front fork assembly
Refer to “FRONT FORK” section.
1 3. Remove
8 Ball race
***************************************
Ball race replacement steps:
8 Remove the ball races on the head pipe us-
ing long rod 1 and the harmmer as shown.
8 Remove the ball races on the under bracket
using the floor chisel 2 and the harmmer as
shown.
***************************************
2
6-30
STEERING CHAS
STEERING INSPECTION
1. Wash the bearing races with a solvent.
2. Inspect:
8 Ball race
8 Ball
Pitting/Damage→Replace.
NOTE:
Always replace bearings and races as set.
3. Inspect:
8 Under bracket 1
Crack/Bend/Damage→Replace.
1
w
Do not attempt to straighten a bent under
bracket as this may dangerously weaken the
under bracket.
STEERING INSTALLATION
1. Install:
8 Ball 1
NOTE:
Upper.......22 pcs
Lower...... 19 pcs
1 2. Lubricate
8 Ball
8 Ball race
Wheel bearing grease
6-31
STEERING CHAS
3. Install:
1 8
8 Front fork assembly 1
7 8 Ball race (Upper) 2
6 8 Bearing cover 3
5 8 Ring nut 3 4
8 Rubber washer 5
4 8 Ring nut 2 6
8 Special washer 7
3 8 Ring nut 1 8
NOTE:
2
Securely support the steering shaft so that
there is no danger of it falling down.
4. Tighten:
1 8 Ring nuts
3 ***************************************
Tighten steps:
8 Tighten the ring nut 3 2 using the ring nut
wrench 1 28 Nm (2.8 kg.m)
T.
R.
2
Ring nut wrench:
90890-01403
NOTE:
7 Set the torque wrench 3 to ring nut wrench 1
so that they form right angle.
6
5
4 w
Do not over-tightening.
2
8 Loosen the ring nut 3 2 1/4 turn.

8 Check the front fork by turning it lock to lock.
If there is any binding, remove the front fork
assembly and inspect the steering ball bear-
ings and ball races.
8 Install rubber washer 4 and ring nut 2 5,
then turn the ring nut 2 until it contacts with
rubber washer.
6-32
STEERING CHAS
cC
Slots on the ring nut 2 and ring nut 3 should be
align. If not, turn the ring nut 2 towards tighten
direction until slots alignment.
8 Install special washer 6

NOTE:
Insert the projections of the special washer into
the slots.
8 Install ring nut 1 7 and tighten.

66Nm(6.6 kg.m)
T.
R.
***************************************
6-33
FRONT FORK CHAS
FRONT FORK
FRONT FORK
40Nm(4.0kg.m) 3 45Nm(4.5kg.m)
T.
T.
R.
R.
1

Front fork removal Remove the parts in order.
Steering Refer to “Steering” section.
1 Under fender 1
2 Speedometer cable holder 1
3 Cap bolt 2
4 Pinch bolt 2 Refer to “FRONT FORK REMOVAL/IN-
5 Front fork 2 STALLATION” section.

stallation.
6-34
FRONT FORK CHAS
FRONT FORK DISASSEMBLY
New
5
6 2
New 8
New 9
4
New 1
3
23Nm(2.3kg.m)
T.
R.
LT

Front fork disassembly Remove the parts in order.
1 Fork spring 1 Refer to “FRONT FORK REMOVAL/IN-
STALLATION” section.
2 Band/Front fork boot 1
3 Bolt/Copper washer 1/1
4 Inner tube 1
5 Damper rod 1/1 Refer to “ FRONT FORK DISASSEMBLY/
6 Rebound spring 1 ASSEMBLY” section.
7 Oil lock piece 1/1
8 Oil seal clip 1
9 Oil seal 1
0 Outer tube 1
assembly.
6-35
FRONT FORK CHAS
YP.....
1 FRONT FORK REMOVAL

w
8 Securely support the scooter so there is no
danger of it falling over.
8 Stand the scooter on a level surface.
8 Stand the scooter on its centerstand.
1. Remove:
8 Under fender 1
2. Remove:
1 1 8 Cap bolt 1
8 Pinch bolt 2
w
2 Fork spring will jump out after removing cap
bolt.
3
3. Remove:
8 Front fork (Left/Right) 3
YP703020
FRONT FORK DISASSEMBLY

1
1. Remove:
8 Bolt (damper rod) 1
Loosen the bolt (damper rod) 2 while
holding the damper rod with T-handle
3 3 and 8 mm hexagon bolt.
2
T-handle
90890-01326
6-36
FRONT FORK CHAS
2. Remove:
8 Inner tube 1
1 3 8 Oil lock pice 2
8 Damper rod 3
4 8 Rebound spring 4
2
3. Remove:
8 Oil seal 1 New
cC
Never reuse the oil seal.
New
2 Rag
YP703030
FRONT FORK INSPECTION

1. Inspect:
8 Inner tube bending
Inner tube bending limit:

0.2 mm
Scratches/bends/damage→Replace.
w
Do not attempt to straighten a bent inner tube
as this may dangerously weaken the tube.
YP.....
FRONT FORK ASSEMBLY

4 1 Reverse the “ DISASSEMBLY” procedure.
2 1. Install:
8 Damper rod 1
3 8 Rebound spring 2
8 Oil lock piece 3
8 Inner tube 4
6-37
FRONT FORK CHAS
2. Install:
8 Inner tube 1
Into outer tube 2.
3. Install:
8 Plain washer 1 New
8 Bolt (damper rod) 2
New
4. Tighten:
LT 8 Bolt (damper rod) 1 23Nm(2.3 m.kg)
T.
R.
NOTE:
Tighten the damper rod bolt 1 while holding
the damper rod with a T-handle 2 and a 8 mm
hexagon bolt 3.
2
3
1 T-handle
90890-01326
5. Install:
8 Oil seal 1 New
8 Retaining clip
Use the fork seal driver weight 2 and
New the attachment 3.
NOTE:
8 Before installing the oil seal 1, apply lithium
soap base grease onto the oil seal lips.
8 Adjust the retaining clip so that it fits into the
outer tube groove.
cC
Make sure that the oil seal numbered side faces
upward.
Fork seal driver weight:

90890-01367
Attachment:
6-38 90890-01400
FRONT FORK CHAS
6. Inspect:
8 Inner tube operation
Unsmooth operation→Disassembly and
recheck.
7. Fill:
8 Fork oil 1
Oil quantity:
88 cc
Recommended oil:
Fork oil 10 W or equivalent
8. After filling up, slowly pump the fork up

and down to distribute the fork oil.
9. Install:
M
a 8 Front fork spring 1
◗
NOTE:
1 8 Install the fork spring with its smaller pitcha
upward .
8 Before installing the cap bolt, apply grease
to the O-ring.
8 Temporarily tighten the cap bolt.
EB703050
2 2 FRONT FORK INSTALLATION
Reverse the “REMOVAL” procedure.
1. Install:
3 8 Front fork 1
1 NOTE:
Apply grease onto cap bolt O-ring before in-
stalling cap bolt.
2. Tighten:
8 Cap bolts 2 45Nm(4.5 kg.m)
T.
R.
8 Pinch bolts 3 40Nm(4.0 kg.m)

T.
R.
6-39
– +
ELECTRICAL COMPONENTS ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1Main switch 8Starter relay
2Resister 9Fuse
3Audio pilot 0Battery
4Flasher relay qIgnition coil
5Oil level gauge wRectifier/Regulator
6C.D.I. UNIT eHorn
7Fuel level gauge
7
4
8
1
0
e
w
q
7-1
– +
CIRCUIT DIAGRAM ELEC
CIRCUIT DIAGRAM
1 B R R B
LOCK Gy Br Br Gy
OPEN
OFF B/W
B/W
CHECK
ON
Or Or
B B
0
Gy
Br
R
B
W B
R Y/R Or
R W W W/R W/R Or
B 6 Y/R Y/R 8 B
B/R B/R
9 B
q
YR
W W
R
7 Y/R Y/R
R
2 Q
B B
4 LW LW
5 Y/R B
B
RW GY B B B B
R R R
L/G
L/Y
R
LW GY
L/Y
R
B
R
3
YB
YB
.
LW
LG
YR
n w
B
, B Y/B
B
Y/R L L Y/R
OFF 8 B B
L/W L/G L/G L/W
START '
L/R G/R G/R L/R
:
m
B
G/R
L/R
L
Br
Br
b P
d Br s Br/W
Br
Br//W
Gy Gy
Br Br
Br/W
G/R
P
f
Gy
g h j G/R Ch Ch G/R
P Br/W Br/W P
OFF & 4
B Dg Dg B
PUSH % N
Gy
Br
Br
Br
6
l Y Y
Y Y
Dg Br Br Dg G G
Br r
Ch G G Ch
Ch
Dg
e
G
Y
B
L L
;
GY
Gy Gy
z x c v
B B
G/Y
G/Y
Dg
Ch
G
G/Y
LR
G
L
G
a / t
k G/Y L L G/Y
G G G Y Y G B - - B
B B L/R B B L/R
B
B
Ch
Dg
Ch
Dg
p o u y
Ch Ch Dg Dg
Ch i B B B B
Ch Ch
Dg
Dg Dg
B B
B
B
B
7-2
– +
CIRCUIT DIAGRAM ELEC
1 Main switch a Head light
2 Main fuse s Flasher relay
3 Battery d Horn
4 Starter relay f Handlebar switch (left)
5 Starter motor g Horn switch
6 Rectifier regulator h Dimmer switch
7 Auto choke j Turn switch
8 C.D.I. magneto k Fuel sender
9 C.D.I. unit l Meter
0 Ignition ; Fuel gauge
q Spark plug z Oil indicator light
w Resister x Meter light
e Rear brake switch c High beam indicator light
r Front brake switch v Turn indicator light
t Tail/Brake light b Oil level gauge
y Rear flasher light(right) n Handlebar switch (right)
u Rear flasher light(left) m Starter switch
i Audio pilot , Light switch
o Front flasher light(right) . Sidestand switch
p Front flasher light(left) / Auxiliary light
COLOR CODE
B Black Gy Gray L/R Blue/ Red
Br Brown Y Yellow R/B Red/Black
Ch Chocolate W White R/Y Red/Yellow
Dg Dark Green B/R Black/Red R/W Red/white
G Green Br/W Brown/White Y/R Yellow/White
L Blue G/R Green/Red W/G White/Green
Or Orange G/Y Green/Yellow G/W Green/White
Sb Sky blue L/B Blue/Black W/R White/Red
P Pink L/Y Blue/Yellow L/G Blue/Green
R Red L/W Blue/White
7-3
– +
CHECKING SWITCHES ELEC
YP-N
“∞” “0” CHECKING SWITCHES

CHECKING STEPS
Using pocket tester, check switches for conti-
nuity between their terminals to determine
“Ω×1” whether they are correctly connected.
Replace the switch component if any of the
combinations does not produce the correct
reading.
Pocket tester:
90890-03112
NOTE:
8 Turn the switch to the “ON”, “OFF” positions
several times.
8 Adjust the pocket tester to correct “0” posi-
tion before checking switches.
8 Set the pocket tester selector to “×1”Ω.
SWITCH CONNECTION AS SHOWN IN THIS

MANUAL
Br R
This manual contains connection charts, like
OFF the one shown on the left, showing the termi-
ON nal connections of switches (e.g. the main
switch, handlebar switch, brake switch, light-
ing switch etc.)
Br R
The column on the extreme left indicates the

different switch positions, the top line indicates
the colors of the leads connected to the termi-
nals on the switch.
“?—?” indicates terminals between which

there is continuity, i.e. a closed circuit, in the
given switch position.
In this chart:
“Br and R” have continuity with the switch in
the “ON” position.
7-4
– +
CHECKING SWITCHES ELEC
SWITCH POSITION AND TERMINAL CONNECTION
Before checking a switch refer to the check- Main switch

ing switches as shown in the left page and
Gy Br R B B/W
check for the correct terminal connections
LOCK
(closed circuit) according to the color combi- OPEN
B R
nations shown in the chart. Gy Br OFF
Poor connection, fault→Repair or replace. *
ON
Rear brake switch
Front brake switch
Horn switch
P B G/R Ch
Release P Br/W
Push in B Dg
Dimmer switch
G G/R Y
& Y
% G Start switch
L Y/R L/W L/G
Turn switch L/G L/W Release
Ch Br/W Dg G/R L/R Push in
4
–
6 Light switch
Y/R Y/B L/R L G/R
8
'
:
Fuse
7-5
– +
ELEC
IGNITION SYSTEM
CIRCUIT DIAGRAM
1 B R R B
LOCK Gy Br Br Gy
OPEN
OFF B/W
B/W
CHECK
ON
Or Or
B B
0
Gy
Br
R
B
W B
R Y/R Or
R W W W/R W/R Or
B 6 Y/R Y/R 8 B
B/R B/R
9 B
q
YR
W W
R
7 Y/R Y/R
R
2 Q
B B
4 LW LW
5 Y/R B
B
RW GY B B B B
R R R
L/G
L/Y
R
LW GY
L/Y
R
B
R
3
YB
YB
.
LW
LG
YR
n w
B
, B Y/B
B
Y/R L L Y/R
OFF 8 B B
L/W L/G L/G L/W
START '
L/R G/R G/R L/R
:
m
B
G/R
L/R
L
Br
Br
b P
d Br s Br/W
Br
Br//W
Gy Gy
Br Br
Br/W
G/R
P
f
Gy
g h j G/R Ch Ch G/R
P Br/W Br/W P
OFF & 4
B Dg Dg B
PUSH % N
Gy
Br
Br
Br
l 6
Y Y
Y Y
Dg Br Br Dg G G
Br
Ch G G Ch r
Ch
Dg
e
G
Y
B
L L
;
GY
Gy Gy
z x c v
B B
G/Y
G/Y
Dg
Ch
G
G/Y
LR
G
L
G
a / t
k G/Y L L G/Y
G G G Y Y G B - - B
B B L/R B B L/R
B
B
Ch
Dg
Ch
Dg
p o u y
Ch Ch Dg Dg
Ch i B B B B
Ch Ch
Dg
Dg Dg
B B
B
B
B
1 Main switch
8 C.D.I. magneto
9 C.D.I. unit
0 Ignition coil
q Spark plug
7-6
– +
IGNITION SYSTEM ELEC
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE

(NO SPARK OR INTERMITTENT SPARK)
NOTE:
8 Remove the following parts before troubleshooting.
1) Battery box cover 4) Tail cover
2) Center cowling 5) Side cover (right)
3) Rear carrier
8 Use the following special tools in this troubleshooting.
Ignition checker: Pocket tester: Pocket tester:

90890-06754 90890-03112
1. Spark plug Standard spark plug:

8 Check the spark plug condition. BPR7HS (NGK)
8 Check the spark plug type.
Spark plug gap:
8 Check the spark plug gap.
0.9~1.0 mm
Refer to the “SPARK PLUG INSPECTION”
section in the CHAPTER 3. INCORRECT
CORRECT
Spark plug is faulty, replace it or repair plug

gap.
2. Ignition spark gap

8 Disconnect the spark plug cap from spark
plug.
8 Connect the ignition checker 1 as shown.
2 Spark plug cap
3 Spark gap
8 Check the ignition spark gap.
8 Start engine, and increase spark gap until
misfire occurs.
Minimum spark gap:

MEETS SPECIFICATION
6.0 mm (0.24 in)
OUT OF SPECIFI-
CATION OR NO
SPARK
Ignition system is good.
*
7-7
– +
*
3. Spark plug cap resistance

8 Remove the spark plug cap.
8 Connect the pocket tester (Ω × 1k) to the Ω×1k
spark plug cap.
8 Check the spark plug cap for specificated
resistance.
Spark plug cap resistance:

5kΩ at 20°C (68°F)
OUT OF SPECIFICATION
MEETS
SPECIFICATION
4. Ignition coil resistance

8 Disconnect the ignition coil leads from the Replace spark plug cap.
ignition coil.
8 Connect the pocket tester (Ω × 1) to the
ignition coil.
Ignition coil:
Tester (+) lead→Terminal 1
Tester (–) lead→Coil base 2
8 Check the primary coil for specification

resistance.
Primary coil resistance:

0.32~0.48 Ω at 20°C (68°F)
8 Connect the pocket tester (Ω × 1 k) to the

ignition coil.
Tester (+) lead→Spark plug lead 1

Tester (-) lead→Coil base 2
8 Check the secondary coil for specificated

resistance.
Secondary coil resistance: OUT OF SPECIFICATION

5.68 ~ 8.52 k Ω at 20°C (68°F)
(Spark plug lead - Coil base)
BOTH MEET
SPECIFICATIONS
Ignition coil is faulty, replace it.
7-8
– +
*
5. Pickup coil resistance

8 Disconnect the pickup coil coupler from
the wireharness.
8 Connect the pocket tester (Ω × 100) to the B/R W
CDI
pickup coil terminal. Magneto Y/R
W/R
B
Tester (+) lead→White/Red lead 1
Tester (-) lead→Black 2 1 2
8 Check the pickup coil for specificated re-
sistance. OUT OF SPECIFICATION
Pickup coil resistance:

400~ 600 Ω at 20°C (68°F)
(White/Red-Black)
Pickup coil is faulty, replace it.

MEET
SPECIFICATION
1
6. Source resistance
8 Disconnect the source coil coupler from B/R W
CDI
the wireharness. Magneto Y/R
8 Connect the pocket tester (Ω × 100) to the W/R
B
source coil terminal.
2
Tester (+) lead→Black/Red lead 1
Tester (–) lead→Black 2
8 Check the source coil for specificated re- OUT OF SPECIFICATION

sistance.
Source coil resistance:

640 ~ 960 Ω at 20°C (68°F)
(Black/Red - Black )
Source coil is faulty, replace it.
MEET
SPECIFICATION
POOR CONFECTION
7. Wiring connection
Check the entire ignition system for connec-
tions.
Refer to the “WIRING DIAGRAM” section.
Correct.
CORRECT
Replace CDI unit.
7-9
– +
CHARGING SYSTEM ELEC
CHARGING SYSTEM
CIRCUIT DIAGRAM
1 B R R B
LOCK Gy Br Br Gy
OPEN
OFF B/W
B/W
CHECK
ON
Or Or
B B
0
Gy
Br
R
B
W B
R Y/R Or
R W W W/R W/R Or
B 6 Y/R Y/R 8 B
B/R B/R
9 B
q
YR
W W
R
7 Y/R Y/R
R
2 Q
B B
4 LW LW
5 Y/R B
B
RW GY B B B B
R R R
L/G
L/Y
R
LW GY
L/Y
R
B
R
3
YB
YB
.
LW
LG
YR
n w
B
, B Y/B
B
Y/R L L Y/R
OFF 8 B B
L/W L/G L/G L/W
START '
L/R G/R G/R L/R
:
m
B
G/R
L/R
L
Br
Br
b P
d Br s Br/W
Br
Br//W
Gy Gy
Br Br
Br/W
G/R
P
f
Gy
g h j G/R Ch Ch G/R
P Br/W Br/W P
OFF & 4
B Dg Dg B
PUSH % N
Gy
Br
Br
Br
l 6
Y Y
Y Y
Dg Br Br Dg G G
Br
Ch G G Ch r
Ch
Dg
e
G
Y
B
L L
;
GY
Gy Gy
z x c v
B B
G/Y
G/Y
Dg
Ch
G
G/Y
LR
G
L
G
a / t
k G/Y L L G/Y
G G G Y Y G B - - B
B B L/R B B L/R
B
B
Ch
Dg
Ch
Dg
p o u y
Ch Ch Dg Dg
Ch i B B B B
Ch Ch
Dg
Dg Dg
B B
B
B
B
2 Main fuse
3 Battery
6 Rectifier Regulator
8 CDI magnet
7-10
– +
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED.
NOTE:
1) Front protector bar 4) Tail cover
2) Upper cover 5) Right side cover
3) Rear carrier
8 Use the following special tool (s) in this trobleshooting.
Inductive tachometer: Pocket tester:

90890-03113 90890-03112
1. Fuse (main) NO CONTINUITY

8 Remove the fuse.
8 Connect the pocket tester (Ω × 1) to the
fuse.
8 Check the fuse for continuity.
Fuse is faulty, replace it.
CONTINUITY
2. Battery
INCORRECT
8 Check the battery condition
Refer to the “BATTERY INSPECTION” sec-
tion in the CHAPTER 3.
Open circuit voltage:

12.8V or more at 20°C (68°F) 8 Clean battery terminals.
8 Recharge or replace battery.
CORRECT
7-11
– +
*
3. Charging voltage
8 Connect the inductive tachometer to the
spark plug lead.
8 Connect the pocket tester (DC20V) to the
battery.
Tester (+) lead→Battery (+) terminal

Tester (-) lead→Battery (–) terminal
8 Start the engine and accelerate to about

5,000 r/min.
8 Check charging voltage.
Charging voltage:
13 ~ 14 V at 4,000 r/min
NOTE:
MEETS SPECIFICATION
Use a full charged battery.
OUT OF
SPECIFICATION
Charging circuit is good.
4. Charging coil and lighting coil resistance
8 Disconnect the charging coil coupler from
the wireharness. 1
2
8 Connect the pocket tester “Ω × 1” to the B/R W
charging coils. CDI
Magneto Y/R
8 Measure the charging coil and lighting coil W/R
B
resistance.
3
Charging coil resistance:
Tester (+) lead→White lead 1
Tester (–) lead→BLACK 3
Lighting coil resistance:

Tester (+) lead→Yellow/Red 2
Tester (–) lead→BLACK 3 OUT OF SPECIFICATION
Charging coil resistance:

0.5~0.7 Ω at 20°C (68°F)
0.4~0.6 Ω at 20°C (68°F)
Charging coil is faulty, replace it.
MEET
SPECIFICATION
*
7-12
– +
*
Check the entire ignition system for con- POOR CONNECTION
nections.
OK
Correct.
Replace rectifier regulator.
7-13
– +
ELECTRIC STARTING SYSTEM ELEC
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
1 B R R B
LOCK Gy Br Br Gy
OPEN
OFF B/W
B/W
CHECK
ON
Or Or
B B
0
Gy
Br
R
B
W B
R Y/R Or
R W W W/R W/R Or
B 6 Y/R Y/R 8 B
B/R B/R
9 B
q
YR
W W
R
7 Y/R Y/R
R
2 Q
B B
4 LW LW
5 Y/R B
B
RW GY B B B B
R R R
L/G
L/Y
R
LW GY
L/Y
R
B
R
3
YB
YB
.
LW
LG
YR
n w
B
, B Y/B
B
Y/R L L Y/R
OFF 8 B B
L/W L/G L/G L/W
START '
L/R G/R G/R L/R
:
m
B
G/R
L/R
L
Br
Br
b P
d Br s Br/W
Br
Br//W
Gy Gy
Br Br
Br/W
G/R
P
f
Gy
g h j G/R Ch Ch G/R
P Br/W Br/W P
OFF & 4
B Dg Dg B
PUSH % N
Gy
Br
Br
Br
6
l Y Y
Y Y
Dg Br Br Dg G G
Br
Ch G G Ch r
Ch
Dg
e
G
Y
B
L L
;
GY
Gy Gy
z x c v
B B
G/Y
G/Y
Dg
Ch
G
G/Y
LR
G
L
G
a / t
k G/Y L L G/Y
G G G Y Y G B - - B
B B L/R B B L/R
B
B
Ch
Dg
Ch
Dg
p o u y
Ch Ch Dg Dg
Ch i B B B B
Ch Ch
Dg
Dg Dg
B B
B
B
B
1 Main switch e Front brake switch

2 Main fuse r Rear brake switch
3 Battery m Starter switch
4 Starter relay . Sidestand switch
5 Starter motor
9 CDI unit
7-14
– +
TROUBLESHOOTING
STARTER MOTOR DOES NOT OPERATE.
NOTE:
1)Battery box cover 4)Side covers (left and right)
2)Rear carrier 5)Trunk
3)Tail cover 6)Handlebar cover (front)
8 Use the following special tool in this troubleshooting.
Pocket tester:
90890-03112
1. Fuse
8 Remove the fuse. NO CONTINUITY
8 Connect the pocket tester (Ω × 1 ) to the
fuse.
8 Check the fuse for continuity.
CONTINUITY Fuse is faulty, replace it.
2. Battery
8 Check the battery condition.
Refer to the “BATTERY INSPECTION” sec- INCORRECT
tion in the CHAPTER 3.
Open circuit voltage:

12.8 V or more at 20°C (68°F)
8 Clean battery terminals.
CORRECT 8 Recharge or replace battery.
3. Starter motor
w
8 Connect the battery1positive terminal
and starter motor cable 2 using a jumper 8 A wire for the jumper lead must have the
lead 3 * . equivalent capacity as that of the battery lead
or more, otherwise it may cause the jumper
lead to be burned.
8 This check is likely to produce sparks, so be
sure that no flammable gas or fluid is in the
vicinity.
M DOES NOT MOVE
8 Check the starter motor for operation.
MOVES Starter motor is faulty, repair or replace it.
* 7-15
– +
*
4. Starter relay
8 Disconnect the relay unit coupler from the
wire harness. 3 1
8 Connect the pocket tester(Ω × 1)and
battery(12V) to the relay unit coupler ter-
L/W
minals.
G/Y
Battery(+)lead→
Blue/White terminal 1 4 2
Battery(–)lead→
Green/Yellow terminal 2
8 Check the starter relay for continuity.

NO CONTINUITY
Tester (+) lead→ 3 terminal
Tester (-) lead→ 4 terminal
CONTINUITY
Replace the starter relay.
5. Main switch NO CONTINUITY

Refer to “CHECKING SWITCHS” section.
CONTINUITY
Main switch is faulty, replace it.
6. “START” switch NO CONTINUITY

Refer to “CHECKING SWITCHS” section.
CORRECT
“START” switch is faulty, replace handlebar

* switch (right).
7-16
– +
*
7. Sidestand switch
8 Disconnect the sidestand switch coupler
from the wire harness.
8 Check the switch component for the con-
tinuity between “Blue/Yellow 1 and Black
2”.
1
L/Y
POOR CONNECTION
2
Correct.
CORRECT
8. Brake switches (front and rear)

8 Disconnect the brake switch leads from the
wire harness.
8 Connect the pocket tester (Ω × 1 )to the
brake switch leads.
G/Y Br
2 1
8 Check the brake switch for continuity

Switch Good
Bad condition
Position condition
Brake is
applied ❍ ✕ ✕ ❍
BAD CONDITION
Brake is
not applied
✕ ❍ ✕ ❍
❍:Continuity ✕:No continuity

Replace brake switch(es).
GOOD
CONDITION
* 7-17
– +
*
8 Check the entire electrical starting system POOR CONNECTION
for connections.
Refer to “WIRING DIAGRAM” section.
GOOD
CONDITION Correct.
Replace CDI unit.
7-18
– +
STARTER MOTOR
2 13Nm(1.3kg.m)
T.
R.
5
1
3
1

Starter motor removal Remove the parts in order.
Rear carrier
Tail cover Refer to “COVER PANEL” section in
Battery box cover CHAPTER 3.
Left/Right side cover
Center cowling
Muffler Refer to “REAR WHEEL AND REAR
Rear wheel BRAKE” section in CHAPTER 6.
Air shroud 3 Refer to “ENGINE REMOVAL” section
chapter 4.
1 Starter motor coupler 2
2 Starter motor 1
7-19
– +
STARTER MOTOR DISASSEMBLY
2 13Nm(1.3kg.m)
T.
R.
5
1
3
1

stallation.
Starter motor disassembly Disassembly the parts in order.
1 O-ring 1
2 Rear bracket 1
3 Armature ass’y 1 Refer to “Starter motor assembly”
4 Ring 1
5 Brush holder set 1
assembly.
7-20
– +
YP803034
INSPECTION AND REPAIR

a 1. Inspect:
8 Commutator
Dirt→Clean it with #600 grit sandpaper.
2. Measure:
8 Commutator diameter a
Commutator wear limit:

16.6 mm
Out of specification→Replace the starter

motor
3. Measure:
a 8 Mica undercut a
Mica undercut:
1.35 mm
Out of specification→Scrape the mica to

the proper value (a hacksaw blade can
be ground to fit).
NOTE:
The mica insulation of the commutator must
be undercut to ensure proper operation of com-
mutator.
4. Inspect:
8 Armature coil resistances (installation/
continuity)
A Defects→Replace the starter motor.
B
If commutator is dirty, clean it with sand-
paper.
A Good Bad condition

B
condition
A ? ? × ×
B × ? × ?
O: Continuity
x: No continuity
Bad condition→Replace.
7-21
– +
5. Measure:
8 Brush length a
Brush length wear limit

1.0 mm
6. Measure:
a 8 Brush spring force
Fatigue/out of specification→Replace as
a set.
7-22
– +
LIGHTING SYSTEM ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM
1 B R R B
LOCK Gy Br Br Gy
OPEN
OFF B/W
B/W
CHECK
ON
Or Or
B B
0
Gy
Br
R
B
W B
R Y/R Or
R W W W/R W/R Or
B 6 Y/R Y/R 8 B
B/R B/R
9 B
q
YR
W W
R
7 Y/R Y/R
R
2 Q
B B
4 LW LW
5 Y/R B
B
RW GY B B B B
R R R
L/G
L/Y
R
LW GY
L/Y
R
B
R
3
YB
YB
.
LW
LG
YR
n w
B
, B Y/B
B
Y/R L L Y/R
OFF 8 B B
L/W L/G L/G L/W
START '
L/R G/R G/R L/R
:
m
B
G/R
L/R
L
Br
Br
b P
d Br s Br/W
Br
Br//W
Gy Gy
Br Br
Br/W
G/R
P
f
Gy
g h j G/R Ch Ch G/R
P Br/W Br/W P
OFF & 4
B Dg Dg B
PUSH % N
Gy
Br
Br
Br
l 6
Y Y
Y Y
Dg Br Br Dg G G
Br
Ch G G Ch r
Ch
Dg
e
G
Y
B
L L
;
GY
Gy Gy
z x c v
B B
G/Y
G/Y
Dg
Ch
G
G/Y
LR
G
L
G
a / t
k G/Y L L G/Y
G G G Y Y G B - - B
B B L/R B B L/R
B
B
Ch
Dg
Ch
Dg
p o u y
Ch Ch Dg Dg
Ch i B B B B
Ch Ch
Dg
Dg Dg
B B
B
B
B
8 C.D.I. magneto c High beam indicator light

t Tail light , Light switch
a Head light / Auxiliary light
h Light dimmer switch
x Meter light
7-23
– +
YP805010
TROUBLESHOOTING
IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT

AND/OR METER LIGHT FAIL TO COME ON.
Procedure
Check:
1. Lights switch
2. Dimmer switch
3. Wiring connection (entire lighting system)
NOTE:
1) Front handlebar cover
2) Rear carrier
3) Right side cover
8 Use the special tools specified in the troubleshooting section.
Pocket tester:
90890-03112
YP ..... NO CONTINUITY
1. Lights switch
Refer to “CHECKING SWITCHES” section.
CONTINUITY
Replace the right handlebar switch.
YP ..... NO CONTINUITY
2. Dimmer switch
Replace the left handlebar switch.

3. Lighting coil resistance
8 Disconnect the lighting coil coupler from
the wireharness.
1
8 Connect the pocket tester “ Ω x 1 “ to the
lighting coils. B/R W
CDI
8 Measure the lighting coil resistances. Magneto Y/R
W/R
B
Tester (+) lead→Yellow/Red lead 1
Tester (–) lead→Black 2 2

0.4 ~ 0.6 Ω at 20°C (68°F) OUT OF SPECIFICATION
MEET
SPECIFICATION
* Lighting coil is faulty, replace it.

7-24
– +
*
YP.....
4. Wiring connection POOR CONNECTIONS

8 Check the connections of the entire light-
ing system.
Refer to “WIRING DIAGRAM”.
OK Correct.
Check the condition of each of the lighting

system’s circuits.
Refer to “LIGHTING SYSTEM CHECK”
YP805020
LIGHTING SYSTEM CHECK

1. If the headlight and the high beam indi-
cator light fail to come on.
1. Bulb and bulb socket NO CONTINUITY

CONTINUITY
2. Voltage Replace the bulb and/or bulb socket.

headlight and high beam indicator light
couplers. B 1
2
A When the dimmer switch is on low beam.
G Y
B When dimmer switch is on high beam. L/R B
Headlight: A
Tester (+) lead→Green 1 or Yellow 2 lead 3
Tester negative (–) lead→Black 3 lead
High beam indicator light:
Tester I+) lead→Yellow 4 lead
Tester (–) lead→Black 5 lead 4
* Y
L
Gy
B
7-25
– +
*
8 Turn the main switch to on. OUT OF SPECIFICATION
8 Turn the light switch to on position.
8 Turn the dimmer switch to low beam or
high beam.
8 Check for voltage (12V) on the lead at bulb
socket connectors. The wiring circuit from the main switch to
bulb socket connector is faulty. Repair.
MEETS
SPECIFICATION
This circuit is not faulty.
YP805021
2. If the meter light fails to come on.

CONTINUITY
2. Voltage Replace the bulb and/or bulb socket.

bulb socket coupler.
Tester (+) lead→

Blue terminal 1
Tester (-) lead→
Black terminal 2
L
Gy
B
8 Turn the main switch to on.

8 Turn the lights switch to on. OUT OF SPECIFICATION
8 Check the voltage (12V) of the leads on
the bulb socket connector.
MEETS
SPECIFICATION The wiring circuit from main switch to bulb
socket is faulty. Repair.
7-26
– +
3. Auxilialy light does not come on.

8 Check the bulb and bulb socket for conti-
nuity
CONTINUITY
Bulb and/or bulb socket are faulty, replace.
2. Voltage
bulb socket connector.
Tester (+) lead → Blue / Red 1 lead.

Tester (-) lead → Black 2 lead.
Y G
B L/R
2
1 OUT OF SPECIFICATION
8 Turn the lights switch to “PO” or “ON”.
8 Check the voltage (12V) on the “Blue” lead
at the bulb socket connector.
MEETS Wiring circuit from main switch to bulb
SPECIFICATION socket connector is faulty. Repair.
(12V)
7-27
– +
YP805022
4. The taillight fails to come on.

NO CONTINUITY
1. Bulb and bulb socket
CONTINUITY
Replace the bulb and/or bulb socket.
2. Voltage
Tester (+) lead→

Blue terminal 1
Tester (-) lead→
Black terminal 2
L G/Y
- B
2

8 Turn the lights switch to on
8 Check the voltage (12V) on the bulb socket
The wiring circuit from main switch to bulb
connector.
connector is faulty. Repair.
MEETS
SPECIFICATION
7-28
– +
SIGNAL SYSTEM ELEC
SIGNAL SYSTEM
CIRCUIT DIAGRAM
1 B R R B
LOCK Gy Br Br Gy
OPEN
OFF B/W
B/W
CHECK
ON
Or Or
B B
0
Gy
Br
R
B
W B
R Y/R Or
R W W W/R W/R Or
B 6 Y/R Y/R 8 B
B/R B/R
9 B
q
YR
W W
R
7 Y/R Y/R
R
2 Q
B B
4 LW LW
5 Y/R B
B
RW GY B B B B
R R R
L/G
L/Y
R
LW GY
L/Y
R
B
R
3
YB
YB
.
LW
LG
YR
n w
B
, B Y/B
B
Y/R L L Y/R
OFF 8 B B
L/W L/G L/G L/W
START '
L/R G/R G/R L/R
:
m
B
G/R
L/R
L
Br
Br
b P
d Br s Br/W
Br
Br//W
Gy Gy
Br Br
Br/W
G/R
P
f
Gy
g h j G/R Ch Ch G/R
P Br/W Br/W P
OFF & 4
B Dg Dg B
PUSH % N
Gy
Br
Br
Br
6
l Y Y
Y Y
Dg Br Br Dg G G
Br
Ch G G Ch r
Ch
Dg
e
G
Y
B
L L
;
GY
Gy Gy
z x c v
B B
G/Y
G/Y
Dg
Ch
G
G/Y
LR
G
L
G
a / t
k G/Y L L G/Y
G G G Y Y G B - - B
B B L/R B B L/R
B
B
Ch
Dg
Ch
Dg
p o u y
Ch Ch Dg Dg
Ch i B B B B
Ch Ch
Dg
Dg Dg
B B
B
B
B
1 Main switch u Rear flasher light(left) g Horn switch

2 Main fuse i Audio pilot j Turn switch
3 Battery o Front flasher light(right) k Fuel sender
e Rear brake switch p Front flasher light(left) ; Fuel meter
r Front brake switch s Flasher relay z Oil indicator light
t Brake light d Horn v Turn indicator light
y Rear flasher light(right) f Handlebar switch (Left) b Oil level gauge
7-29
– +
SIGNAL SYSTEM ELEC
YP806010
TROUBLESHOOTING
IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT

FAIL TO COME ON. IF THE HORN FAILS TO SOUND.
Procedure
Check:
1. Fuse (Main) 3.Main switch
2. Battery 4.Wiring connection (entire signal system)
NOTE:
1) Battery box cover 5) Tail cover
2) Front protector bar 6) Side covers(Left/Right)
3) Upper cover 7) Center cover
4) Rear carrier
8 Use the special tools in the troubleshooting section .
Pocket tester:
90890-03112
YP..... NO CONTINUITY
1. Fuse
CONTINUITY
Replace the fuse.
YP.....
2. Battery IN CORRECT
8 Check the battery condition.
Refer to “BATTERY INSPECTION” section
in CHAPTER 3.
CORRECT 8 Clean battery terminals.

8 Recharge or replace battery.
YP.....
3. Main switch NO CONTINUITY

CONTINUITY
Replace the main switch.

*
7-30
– +
SIGNAL SYSTEM ELEC
*
YP......
4. Wireharness
8 Check the connections of the entire sig- POOR CONNECTION
nal system.
Refer to “CIRCUIT SYSTEM WIRING DIA-
GRAM” section.
CONTINUITY Correct.
Check condition of each of the signal

system’s circuits.
Refer to “SIGNAL SYSTEM CHECK” sec-
tion.
7-31
– +
SIGNAL SYSTEM ELEC
YP806020
SIGNAL SYSTEM CHECK

1. If the horn fails to sound.
NO CONTINUITY
1. HORN switch
Replace the left handlebar switch.

CONTINUITY
Br P
2. Voltage
horn lead.
Tester (+) lead→Brown terminal 1.

Tester (-) lead→Frame ground

8 Check for voltage (12V) on the “Brown” OUT OF SPECIFICATION
lead at the horn terminal.
MEETS The wiring circuit from the main switch to the

SPECIFICATION horn is faulty. Repair.
Br P
3. Horn
horn at the “Pink” terminal.
Tester (+) lead→Pink 1 terminal.


8 Check for voltage on the “Pink” lead at
NO CONTINUITY
the horn terminal.
CONTINUITY
Adjust or replace horn.

Replace the horn.
7-32
– +
SIGNAL SYSTEM ELEC
YP806022
2. If the brake light fails to come on:

NO CONTINUITY
CONTINUITY Replace the bulb and/or bulb socket.
NO CONTINUITY
2. Brake switch (Front/Rear)
CONTINUITY Replace brake switch.
3. Voltage
Tester (+) leadGGreen/Yellow terminal 1

Tester (-) leadGBlack terminal 2
L G/Y
- B

8 The brake lever is pulled in.
8 Check for voltage (12V) of the “ Yellow”
lead on the bulb socket connector.
MEETS
SPECIFICATION
8 Wiring circuit from the main switch to the
bulb socket connector is faulty. Repair.
Refer to “SIGNAL SYSTEM WIRING DIA-
GRAM “ .
7-33
– +
SIGNAL SYSTEM ELEC
YP806023
3. If the flasher light and/or turn indicator

light fails to blink.
NO CONTINUITY
CONTINUITY Replace the bulb and/or bulb socket.
NO CONTINUITY
2. Turn switch
CONTINUITY Replace the left handlebar switch.
FLASHER
3. Voltage RELAY
flasher relay coupler. – Br/W
– Br
Tester (+) lead→Brown terminal 1.
Tester (-) lead→Frame ground 1
8 Check for voltage (12V) of the “Brown” OUT OF SPECIFICATION
lead at the flasher relay terminal.
MEETS The wiring circuit from main switch to flasher

SPECIFICATION relay connector is faulty. Repair.
FLASHER 1
4. Voltage RELAY
– Br/W
flasher relay coupler.
– Br
Tester (+) lead→Brown/White terminal 1.

8 Check for voltage (12V) on the “Brown/
White” lead at the flasher relay terminal.
MEETS
SPECIFICATION
The flasher relay is faulty. Replace.
*
7-34
– +
SIGNAL SYSTEM ELEC
*
5. Voltage
Ch B Dg B
At flasher light (left)
Tester (+) lead→Chocolate lead 1 Ch B Dg B
Tester (-) lead→Black terminal 3 Ch B Dg B
3 3
At flasher light (right) 1 2
Tester (+) lead→Dark green lead 2
Tester (-) lead→Black terminal 3
8 Turn the turn switch to left or right.
8 Check for voltage (12V) on the “Choco-
late” lead and “Dark green” at the flasher
light terminal. 6. Wiring connection
MEETS 8 Wiring circuit from the turn switch to bulb
SPECIFICATION socket connector is fault. Repair.
Refer to “CIRCUIT DIAGRAM”.
4. “OIL” indicator light does not come on. NO CONTINUITY

8 Check the bulb and bulb socket for conti-
nuity.
CONTINUITY Replace bulb and/or bulb socket.
2. Oil level switch

8 Remove the oil level switch from the oil
Br Gy
tank.
8 Connect the Pocket Tester (Ω x 1) to the
A
oil level switch.
Tester (+) Lead→Brown 1 B

Tester (–) Lead→Gray 2
8 Check the oil level gauge for continuity.

Good
Switch position Bad condition
condition BAD CONDITION
A Upright position × ? × ?
× ×
B Upside down
? ?
position
?: Continuity ×: No continuity
Replace oil level switch.
GOOD CONDITION
7-35
*
– +
SIGNAL SYSTEM ELEC
3. Voltage
8 Connect the Pocket Tester (DC20V) to the
Tester (+) Lead→Gray lead 1

Tester (-) Lead→Frame ground 2
B Gy L
8 Turn the main switch to “*”

8 Check for voltage (12V) on the “Gray” lead 2 1
at bulb socket connector.
MEETS OUT OF SPECIFICATION

SPECIFICATION
(12V)
This circuit is good.

8 Check the entire signal system for connec-
tions.
YP806027
5. If the fuel gauge fails to operate.
1. Fuel sender
8 Remove the fuel sender from the fuel tank.
8 Disconnect the fuel sender coupler from
the wireharness.
Connect the pocket tester (Ω ×10) to the
fuel sender coupler lead.
B G
Tester (+) lead→Green terminal 1

Tester (–) lead→Black terminal 2
8 Check the fuel sender for specificated re-

sistance.
Float position Specificated
resistance OUT OF SPECIFICATION
UP 3 4~10Ω
DOWN 4 90~100Ω
BOTH MEET
SPECIFICATION
Replace the fuel sender.
7-36
– +
SIGNAL SYSTEM ELEC
2. Voltage
fuel gauge coupler. F
1
E
Tester (+) lead→Brown terminal 1
Tester (-) lead→Frame ground Br Dg
L Gy B
G Ch
8 Turn the main switch to “ON”.

8 Check for voltage (12V) of the “Brown”
lead on the fuel sender lead.
MEETS
SPECIFICATION
Check the connection of the entire signal sys-

tem .
3. Fuel gauge
Refer to “CHECKING OF CONNECTIONS”.
8 Connect the fuel sender to wireharness.
Refer to “CIRCUIT DIAGRAM”.
8 Move the float to “UP” 1 or “DOWN” 2.
NOTE:
Before reading the meter, stay put the float
for more than three minutes respectively at
“UP” or “DOWN”.
8 Turn the main switch to “ON”.

8 Check the fuel gauge needle moves “F” DOES NOT MOVE
or “E”.
Float position Needle moves

Float “UP” 1 “F”
Float “DOWN”2 “E” Replace the fuel gauge.
MOVES
7-37
– +
AUTO CHOKE SYSTEM ELEC
AUTO CHOKE SYSTEM
CIRCUIT DIAGRAM
1 B R R B
LOCK Gy Br Br Gy
OPEN
OFF B/W
B/W
CHECK
ON
Or Or
B B
0
Gy
Br
R
B
W B
R Y/R Or
R W W W/R W/R Or
B 6 Y/R Y/R 8 B
B/R B/R
9 B
q
YR
W W
R
7 Y/R Y/R
R
2 Q
B B
4 LW LW
5 Y/R B
B
RW GY B B B B
R R R
L/G
L/Y
R
LW GY
L/Y
R
B
R
3
YB
YB
.
LW
LG
YR
n w
B
, B Y/B
B
Y/R L L Y/R
OFF 8 B B
L/W L/G L/G L/W
START '
L/R G/R G/R L/R
:
m
B
G/R
L/R
L
Br
Br
b P
d Br s Br/W
Br
Br//W
Gy Gy
Br Br
Br/W
G/R
P
f
Gy
g h j G/R Ch Ch G/R
P Br/W Br/W P
OFF & 4
B Dg Dg B
PUSH % N
Gy
Br
Br
Br
6
l Y Y
Y Y
Dg Br Br Dg G G
Br
Ch G G Ch r
Ch
Dg
e
G
Y
B
L L
;
GY
Gy Gy
z x c v
B B
G/Y
G/Y
Dg
Ch
G
G/Y
LR
G
L
G
a / t
k G/Y L L G/Y
G G G Y Y G B - - B
B B L/R B B L/R
B
B
Ch
Dg
Ch
Dg
p o u y
Ch Ch Dg Dg
Ch i B B B B
Ch Ch
Dg
Dg Dg
B B
B
B
B
7 Auto choke
8 C.D.I. magneto
7-38
– +
YP.....
TROUBLESHOOTING
IF THE AUTO CHOKE FAILS TO OPERATE.
Procedure
Check:
2. Auto choke unit resistance
3. Wiring connection (entire auto choke system)
NOTE:
1. Battery box cover
2. Rear carrier
3. Tail cover
4. Right side cover
8 Use the special tools specified in the troubleshooting section.
Pocket tester:
90890-03112

8 Disconnect the CDI magneto couple from
wire harness.
8 Connect the pocket tester (Ω x1) to the
lighting coil coupler
Tester (+) Lead→Yellow/Red 1 terminal

Tester (-) Lead→Frame earth
W
CDI
Magneto
Y/R
B
2 1
2 C.D.I. magneto OUT OF SPECIFICATION

8 Check the lighting coil for specificated re-
sistance
Lighting coil resistance

0.4~0.6 Ω 20°C (68°F)
Replace the lighting coil
MEETS
SPECIFICATION
*
7-39
– +
*
YP...
2. Auto choke unit resistance

8 Disconnect the auto choke unit coupler
B B
from the wireharness.
8 Connect the pocket tester (Ωx1) to the auto
choke unit coupler lead.
Tester (+) lead→Black terminal 1 OUT OF SPECIFICATION

Tester (-) lead→Black terminal 2
Auto choke unit resistance:

16~24Ω(20˚C)
MEETS Replace the auto choke unit.

SPECIFICATION
3. Wiring connection POOR CONNECTION

8 Check the connection of the entire auto
choke system.
Refer to “CIRCUIT DIAGRAM” section.
Correct.
7-40
TRBL
STARTING FAILURE/HARD STARTING SHTG
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for
inspection, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING

FUEL SYSTEM PROBABLE CAUSE
Fuel tank 8 Empty

8 Clogged fuel filter
8 Deteriorated fuel or fuel containing water or
foreign material
8 Clogged fuel tank cap
Fuel cock 8 Clogged fuel hose

8 Clogged fuel cock
8 Faulty fuel cock operation
8 Broken or disconnected fuel cock
Carburetor 8 Deteriorated fuel, fuel containing water or

foreign material
8 Clogged pilot jet
8 Clogged pilot air passage
8 Sucked-in air
8 Deformed float
8 Groove-worn needle valve
8 Improperly sealed valve seat
8 Improperly adjusted fuel level
8 Improperly set pilot jet
8 Clogged starter jet
8 Improperly adjusted pilot air screw
Auto choke 8 Starter plunger malfunction

8 Wax malfunction
8 Faulty thermister
Air cleaner 8 Clogged air filter
8-1
TRBL
STARTING FAILURE/HARD STARTING SHTG
IGNITION SYSTEM PROBABLE CAUSE
Spark plug 8 Improper plug gap

8 Worn electrodes
8 Wire between terminals broken
8 Improper heat range
8 Faulty spark plug cap
Ignition coil 8 Broken or shorted primary/secondary coil

8 Faulty spark plug lead
8 Broken body
CD I unit system 8 Faulty CD I unit

8 Faulty source coil
8 Faulty pick-up coil
Switches and wiring 8 Faulty main switch

8 Broken or shorted wiring
8 Faulty sidestand switch
COMPRESSION SYSTEM PROBABLE CAUSE
Cylinder and cylinder head 8 Loose spark plug

8 Loose cylinder head or cylinder
8 Broken cylinder head gasket
8 Broken cylinder gasket
8 Worn, damaged or seized cylinder
Piston and piston rings 8 Improperly installed piston ring

8 Worn, fatigued or broken piston ring
8 Seized piston ring
8 Seized or damaged piston
Crankcase and crankshaft 8 Improperly seated crankcase

8 Improperly sealed crankcase (Damaged oil
seal)
8 Seized crankshaft
Reed valve 8 Deformed reed valve stopper

8 Improperly seated read valve
8 Loose intake manifold
8 Broken gasket
8 Broken reed valve
8-2
POOR IDLE SPEED PERFORMANCE TRBL
POOR MIDIUM AND HIGH SPEED PERFORMANCE SHTG
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE PROBABLE CAUSE
Carburetor 8 Improperly returned starter plunger

8 Clogged or loose pilot jet
8 Clogged pilot air jet
8 Improperly adjusted idle speed
(Throttle stop screw)
8 Improper throttle cable play
8 Flooded carburetor
Auto choke 8 Starter plunger malfunction

8 Wax malfunction
8 Faulty thermister
Air cleaner 8 Clogged air cleaner
Ignition system 8 Faulty spark plug

8 Faulty spark plug read
8 Faulty C.D.I. unit
8 Faulty ignition coil
POOR MIDIUM AND HIGH SPEED

PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFOR- PROBABLE CAUSE
MANCE 8 Refer to starting failure/Hard starting item
(Fuel system, Ignition system, compression
system)
Carburetor 8 Clogged or loose main nozzle
8 Clogged or loose main jet
8 Improperly set clip position of jet needle
8 Improperly adjust fuel level
8 Sucked-in air
Air cleaner 8 Clogged air filter
Muffler 8 Clogged
8-3
TRBL
POOR MIDIUM AND HIGH SPEED PERFORMANCE SHTG
FULTY AUTOMATIC(V-BELT TYPE)
SCOOTER DOES NOT MOVE WHILE ENGINE PROBABLE CAUSE
IS OPERATING
V-belt 8 Worn, damaged or slipped V-belt
Cam, slider 8 Worn, damaged
Compression spring 8 Damaged
Transmission 8 Damaged
CLUTCH OUT FAILURE
Clutch weight spring 8 Damaged
Clutch shoe 8 Pealed lining
Primary sheave 8 Seized primary sliding sheave and collar
POOR STANDING START(LOW CLIMBING

ABILITY) PROBABLE CAUSE
V-belt 8 Worn or slipped V-belt
Primary sheave 8 Improper operation

8 Damaged
Compression spring 8 Damaged
Secondary sheave 8 Improper operation

8 Worn guide pin
Clutch shoe 8 Plealed lining
POOR ACCELERATION(POOR HIGH SPEED) PROBABLE CAUSE
V-belt 8 Worn
8 Greasy
Weight 8 Worn
8 Improper operation
Primary/ Secondary seave 8 Worn
8-4
TRBL
OVER HEAT / POOR SPEED SHTG
OVER HEAT
OVER HEAT PROBABLE CAUSE
Ignition system 8 Improper plug gap

8 Improper spark plug heat range
Fuel system 8 Improper carburetor setting

8 Clogged air filter
Compression system 8 Carbon accumulation of cylinder head
Muffler, Exhaust pipe 8 Clogged
Oil pimp 8 Faulty oil pump

8 Faulty oil quality
Brake 8 Drag
Cooling system 8 Fan damaged
POOR SPEED
POOR SPEED PROBABLE CAUSE
Ignition system 8 Faulty spark plug

8 Improper spark plug heat range
Fuel system 8 Clogged fuel tank cap

8 Clogged air filter
8 Clogged carburetor
Compression system 8 Worm cylinder

8 Worm, fatigued or broken piston ring
8 Broken cylinder head gasket
8 Broken cylinder gasket
8 Carbon accumulation of cylinder head
Muffler, Exhaust pipe 8 Clogged
Clutch 8 Refer to “FAULTY AUTOMATIC”
Brake 8 Drag
8-5
TRBL
IMPROPER KICKING SHTG
IMPROPER KICKING
SLIPPING PROBABLE CAUSE
Kick axle assembly 8 Low tension of kick clip

8 Worn kick axle
8 Worn or damaged kick gear
8 Damaged kick clip
8 Kick clip coming off
8 Damaged kick clip stopper
Transmission oil 8 Improper quality (Low viscosity)

8 Deterioration
HARD KICKING PROBABLE CAUSE
Kick axle assembly 8 High tension of kick clip

8 Seized kick gear
Cylinder, piston and piston ring 8 Damaged or seized cylinder

8 Damaged or seized piston
8 Damaged or seized piston ring
Crankcase and crankshaft 8 Improperly seated crankcase

8 Improperly seated crankshaft
8 Damaged or seized crankshaft
8 Damaged or seized crankshaft bearing
KICK CRANK NOT RETURNING PROBABLE CAUSE
Kick axle assembly 8 Damaged kick return spring

8 Kick return spring coming off
8 Kick clip coming off
8 Damaged kick return spring stopper
8-6
TRBL
FAULTY BRAKE SHTG
FAULTY BRAKE
POOR BRAKING EFFECT PROBABLE CAUSE
Drum brake 8 Worn brake shoe

8 Worn or rusty brake drum
8 Improperly adjusted brake free play
8 Improper brake cam lever position
8 Improper brake shoe position
8 Fatigue/Damaged return spring
8 Oily or greasy brake shoe
8 Oily or greasy brake drum
8 Broken brake cable
Disc brake 8 Worn brake pad

(Front) 8 Worn brake disc
8 Air in brake fluid
8 Leaking brake fluid
8 Faulty master cylinder kit
8 Faulty caliper seal kit
8 Loose union bolt
8 Broken brake hose
8 Oily or greasy brake pad
8 Oily or greasy brake disc
MALFUNCTION PROBABLE CAUSE
8 Bent, deformed or damaged inner tube

8 Bent or deformed outer tube
8 Damaged fork spring
8 Worn or damaged slide metal
8 Improper oil viscosity
8 Improper oil level
8-7
TRBL
INSTABLE HANDLING SHTG
INSTABLE HANDLING
INSTABLE HANDLING PROBABLE CAUSE
Handlebar 8 Improperly installed or bent
Steering 8 Improperly installed steering column

(Improperly tightened ringnut)
8 Bent steering column
8 Damaged ball bearing or bearing race
Front forks 8 Broken spring

8 Bonded front forks
Tires 8 Uneven tire pressures on both sides

8 Incorrect tire pressure
8 Unevenly worn tires
Wheels 8 Damaged bearing

8 Bent or loose wheel axle
8 Excessive wheel run-out
Frame 8 Twisted
8 Damaged head pipe
8 Improperly installed bearing race
Engine bracket 8 Bent or damaged
Rear shock absorber 8 Fatigued spring

8 Oil leakage
8-8
TRBL
FAULTY SIGNAL AND LIGHTING SYSTEM SHTG
FAULTY SIGNAL AND LIGHTING
SYSTEM
HEADLIGHT DARK PROBABLE CAUSE
8 Improper bulb
8 Too many electric accessories
8 Hard charging (Broken charging coil)
8 Incorrect connection
8 Improperly grounded
8 Poor contacts (main or light switch)
8 Bulb life expires
BULB BURNT OUT PROBABLE CAUSE
8 Improper bulb
8 Faulty main and/or light switch
8 Bulb life expires
FLASHER DOES NOT BLINK PROBABLE CAUSE
8 Discharged battery
8 Faulty flasher switch
8 Faulty flasher relay
8 Broken wireharness
8 Loosely connected coupler
8 Bulb burnt out
8 Faulty fuse
FLASHER KEEPS ON PROBABLE CAUSE

8 Insufficient battery capacity (nearly dis-
charged)
8 Bulb burnt out
8-9
TRBL
FAULTY SIGNAL AND LIGHTING SYSTEM SHTG
FLASHER BLINKS SLOWER PROBABLE CAUSE

8 Insufficient battery capacity
(nearly discharged)
8 Improper bulb
8 Faulty main and/or flasher switch
FLASHER BLINKS QUICKER PROBABLE CAUSE
8 Improper bulb
HORN DOES NOT SOUND PROBABLE CAUSE
8 Faulty battery
8 Faulty fuse
8 Faulty main and/or horn switch
8 Improperly adjusted horn
8 Faulty horn
8 Broken wireharness
8-10
WIRING DIAGRAM 1 Main switch
2 Main fuse
B
Br
Black
Brown
3 Battery Ch Chocolate
4 Starter relay Dg Dark Green
1 B R R B
5 Starter motor G Green
LOCK Gy Br Br Gy
OPEN
OFF B/W
6 Rectifier regulator L Blue
B/W
CHECK
ON
7 Auto choke Or Orange
Or Or
B B
0 8 C.D.I. magneto Sb Sky blue
Gy
Br
R
B
W B
R Y/R Or
R
B 6
W
Y/R Y/R
W
8
W/R W/R Or
B
9 C.D.I. unit P Pink
B/R B/R
9 B
q 0 Ignition R Red
YR
W W
R
7 Y/R Y/R
R
2
q Spark plug
B B
4 LW LW
5 Q
Y/R B
Gy Gray
B
RW GY B B B B
R R R
w Resister Y Yellow
L/G
L/Y
R
LW GY
L/Y
R
e Rear brake switch W White

B
R
3
r Front brake switch B/R Black/Red
t Tail/Brake light Br/w Brown/White
YB
YB
.
LW
LG
YR
n w
B
,
y Rear flasher light(right) G/R Green/Red
B Y/B
u Rear flasher light(left)
B
Y/R L L Y/R
L/W L/G
L/R G/R
L/G L/W
G/R L/R
OFF
START
8
'
B B
G/Y Green/Yellow
:
m
i Audio pilot L/B Blue/Black
B
o Front flasher light(right) L/Y Blue/Yellow

G/R
L/R
L
p Front flasher light(left) L/W Blue/White

Br
a Head light L/R Blue/ Red

Br
b P
d Br s Br/W
Br
s Flasher relay R/B Red/Black

Br//W
Gy Gy
Br Br
Br/W
d Horn
G/R
R/Y Red/Yellow
P
f
Gy
g h j
f Handlebar switch (left)
G/R Ch Ch G/R
OFF & 4
P
B Dg
Br/W Br/W
Dg B
P R/W Red/white
PUSH % N
g Horn switch Y/R Yellow/White
Gy
Br
Br
Br
l 6
Y Y
Y Y
Dg Br
Ch G
Br Dg
G Ch
G G Br
r h Dimmer switch W/G White/Green
Ch
Dg
e
G
Y
B
L L
; j Turn switch G/W Green/White
GY
Gy Gy
z x c v
B B k Fuel sender W/R White/Red
G/Y
G/Y
l Meter L/G Blue/Green

Dg
Ch
G
G/Y
LR
G
; Fuel gauge
G
a / t
k G/Y L L G/Y
G
B
G
B
G Y
L/R B
Y G
B L/R
B - - B
z Oil indicator light
x Meter light
B
c High beam indicator light

B
v Turn indicator light

b Oil level gauge
n Handlebar switch (right)
Ch
Dg
Ch
Dg
p o u y
Ch Ch Dg Dg
m Starter switch
Ch i B B B B
, Light switch
Ch Ch
Dg
Dg Dg
B B
B
B
. Sidestand switch
B
/ Auxiary light

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CRANKCASE AND REED VALVE ENG

Crankcase separating tool:

REED VALVE INSPECTION

Valve stopper height 1

Reed valve clearance 2

Yamaha bond No.1215:

Crankshaft installing tool:

Order Job name/Part name Q’ty Remarks

Crankcase separating tool:

Runout limit “C”:

Crankshaft installing tool:

2 Oil seal driver

Order Job name/Part name Q’ty Remarks

Order Job name/Part name Q’ty Remarks

8 If the float height is not within specification,

Jet needle clip position:

FUEL LEVEL ADJUSTMENT

Fuel level gauge:

8 Loosen the drain screw 3.

AUTO CHOKE INSPECTION

Order Job name/Part name Q’ty Remarks

Order Job name/Part name Q’ty Remarks

FRONT WHEEL DISASSEMBLY

FRONT WHEEL INSPECTION

Wheel axle bending limit:

Front wheel runout limits:

BRAKE DISC INSPECTION

Brake disc thickness:

FRONT WHEEL ASSEMBLY

FRONT WHEEL INSTALLATION

WHEEL STATIC BALANCE ADJUSTMENT

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

Order Job name/Part name Q’ty Remarks

BRAKE PAD REPLACEMENT

1 “LOWER” level line

Order Job name/Part name Q’ty Remarks

MASTER CYLINDER DISASSEMBLY

Order Job name/Part name Q’ty Remarks

MASTER CYLINDER INSPECTION

MASTER CYLINDER ASSEMBLY

Recommended brake fluid:

8 Replace the piston seals and dust seals when-

Cylinder cup installer set:

Order Job name/Part name Q’ty Remarks

Order Job name/Part name Q’ty Remarks

BRAKE CALIPER DISASSEMBLY

BRAKE CALIPER ASSEMBLY

Recommended brake fluid:

8 Replace the caliper piston seals whenever a

Order Job name/Part name Q’ty Remarks

Order Job name/Part name Q’ty Remarks

REAR WHEEL INSPECTION

REAR BRAKE INSPECTION

Brake lining thickness a :

Brake drum inside diameter:

Order Job name/Part name Q’ty Remarks

Order Job name/Part name Q’ty Remarks

Order Job name/Part name Q’ty Remarks

7 Steering nut wrench 0

8 8 Hold the lower bracket by hand, then remove

Wheel bearing grease

8 Loosen the ring nut 3 2 1/4 turn.

8 Install special washer 6