Documente Academic
Documente Profesional
Documente Cultură
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MOTORCYCLE
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SERVICE MANUAL
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5RU281972000 *5RU281972000*
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EAS00000
YP400T
SERVICE MANUAL
©2004 by Yamaha Motor Co., Ltd.
First edition, June 2004
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
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EAS00005
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WARNING Failure to follow WARNING instructions could result in severe injury or death to
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to the scooter.
NOTE: A NOTE provides key information to make procedures easier or clearer.
EAS00007
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disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
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Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
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parts, notes in jobs, etc.
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8 Jobs requiring more information (such as special tools and technical data) are described sequen-
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tially.
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EAS00008
1 2 SYMBOLS
The following symbols are not relevant to
GEN
INFO SPEC every vehicle.
Symbols 1 to 9 indicate the subject of each
3 4 chapter.
1 General information
CHK CHAS 2 Specifications
3 Periodic checks and adjustments
ADJ 4 Chassis
5 6 5 Engine
6 Cooling system
7 Fuel injection system
ENG COOL 8 Electrical system
9 Troubleshooting
7 8
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– +
FI ELEC
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Symbols 0 to G indicate the following.
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9 0
0 Serviceable with engine mounted
TRBL er
A Filling fluid
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B Lubricant
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D Tightening torque
A B
E Wear limit, clearance
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F Engine speed
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G Electrical data
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H I J
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.
E G M H Engine oil
I Gear oil
K L M J Molybdenum-disulfide oil
K Wheel-bearing grease
B LS M L Lithium-soap-based grease
M Molybdenum-disulfide grease
SCOOTER IDENTIFICATION..........................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
INSTRUMENT FUNCTIONS ..................................................................... 1-4
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PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-10
REPLACEMENT PARTS.........................................................................1-10
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GASKETS, OIL SEALS AND O-RINGS .................................................. 1-10
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LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-11
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BEARINGS AND OIL SEALS .................................................................. 1-11
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CIRCLIPS ................................................................................................1-11
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GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
EAS00018
MODEL LABEL
1 The model label 1 is affixed inside the storage
box. Record the information on this label in the
space provided. This information will be
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needed when ordering spare parts.
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1-1
GEN
FEATURES INFO
EAS00896
FEATURES
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-
ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-
ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-
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ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
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air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
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injection volume according to the engine operating conditions detected by various sensors.
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The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
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response, better fuel economy, and reduced exhaust emissions.
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1-2
GEN
FEATURES INFO
EAS00897
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains
the fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kg/cm2, 35.6 psi). Accord-
ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens,
causing the fuel to be injected into the intake manifold only during the time the passage remains
open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the
greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector
is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake tempera-
ture sensor and coolant temperature sensor enable the ECU to determine the injection duration.
The injection timing is determined through the signals from the crankshaft position sensor. As a
result, the volume of fuel that is required by the engine can be supplied at all times in accordance
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with the driving conditions.
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1-3
GEN
FEATURES INFO
INSTRUMENT FUNCTIONS
Multifunction display
1
2 WARNING
3 Be sure to stop the vehicle before making any
4 setting changes to the multifunction display.
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4 Oil change indicator “OIL”
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The multifunction display is equipped with the
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following:
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• a fuel meter
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• a coolant temperature meter
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• an odometer (which shows the total dis-
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tance traveled)
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• a clock
• an ambient temperature display
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NOTE:
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CAUTION:
If bars 1 appear where the odometer and
tripmeters are normally displayed, the
multi-function display is malfunctioning.
Replace the entire multi-function display.
1
1-4
GEN
FEATURES INFO
Odometer and tripmeter modes
Pushing the “SELECT” button switches the
display between the odometer mode “ODO”
and the tripmeter modes “TRIP” in the follow-
ing order:
ODO → TRIP (top) → TRIP (bottom) → ODO
When approximately 2.8 L (0.62 Imp gal,
0.74 US gal) of fuel remains in the fuel tank, the
bottom segment of the fuel meter and fuel level
warning symbol will start flashing, and the dis-
play will automatically change to the fuel reserve
tripmeter mode “TRIP F” and start counting the
distance traveled from that point. In that case,
pushing the “SELECT” button switches the dis-
play between the various tripmeter and odome-
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ter modes in the following order:
TRIP F → TRIP (top) → TRIP (bottom) →
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ODO → TRIP F
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1 Fuel reserve tripmeter
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To reset a tripmeter, select it by pushing the
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“SELECT” button, until “TRIP” or “TRIP F”
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Fuel meter
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1-5
GEN
FEATURES INFO
Coolant temperature meter
With the key in the “ON” position, the coolant
temperature meter indicates the temperature
of the coolant. The coolant temperature varies
with changes in the weather and engine load.
If the top segment and coolant temperature
symbol flash, stop the vehicle and let the
engine cool.
CAUTION:
Do not operate the engine if it is over-
heated.
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(600 mi), then at 5,000 km (3,000 mi) and
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every 5,000 km (3,000 mi) thereafter to indi-
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cate that the engine oil should be changed.
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After changing the engine oil, reset the oil
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change indicator. Refer to “To reset the oil
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change indicator”. If the engine oil is changed
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before the oil change indicator comes on (i.e.
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NOTE:
The oil change indicator may flash when the
engine is revved with the scooter on the cen-
terstand, but this does not indicate a malfunc-
tion.
1-6
GEN
FEATURES INFO
To reset the oil change indicator
1. Turn the key to “ON”.
2. Hold the reset button pushed for two to
eight seconds.
1 Reset button “OIL CHANGE”
3. Release the reset button, and the oil
change indicator will go off.
1 NOTE:
If the engine oil is changed before the oil
change indicator comes on (i.e. before the
periodic oil change interval has been reached),
the indicator must be reset after the oil change
for the next periodic oil change to be indicated
at the correct time. To reset the oil change
indicator before the periodic oil change interval
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has been reached, follow the above proce-
dure, but note that the indicator will come on
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for 1.4 seconds after releasing the reset but-
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ton, otherwise repeat the procedure.
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V-belt replacement indicator “V-BELT”
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replaced.
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1-7
GEN
FEATURES INFO
Self-diagnosis device
This model is equipped with a self-diagnosis
device for various electrical circuits.
If any of those circuits are defective, the multi-
function display will indicate a two-digit error
code (e.g., 12, 13, 14).
If the multifunction display indicates an error
code, note the code number, and then check
the vehicle. Refer to “FUEL INJECTION SYS-
TEM” in chapter 7.
CAUTION:
If the multifunction display indicates an
error code, the vehicle should be checked
as soon as possible in order to avoid
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engine damage.
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Clock mode
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temperature display.
1-8
GEN
FEATURES INFO
Ambient temperature display
This display shows the ambient temperature
from –10 °C to 50 °C in 1 °C increments. The
temperature displayed may vary from the
ambient temperature. Pushing the “RESET”
button for at least two seconds switches the
ambient temperature display to the clock dis-
play.
• When the ambient temperature falls below
–10.0 °C, “–10.0 °C” is displayed.
• When the ambient temperature climbs
above 50.0 °C, “50.0” is displayed.
NOTE:
• If “– – °C” is displayed or “50.0” flashes while
the ambient temperature is between –10.0 °C
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and 50.0 °C, there is a problem with the elec-
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trical circuit. Check or repair the electric cir-
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cuit or replace the thermistor.
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• The accuracy of the temperature reading
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may be affected when riding slowly (approxi-
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mately under 20 km/h) or when stopped at
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1-9
GEN
IMPORTANT INFORMATION INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
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ders, pistons and other parts that have been
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“mated” through normal wear. Mated parts
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must always be reused or replaced as an
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assembly.
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4. During disassembly, clean all of the parts
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and place them in trays in the order of dis-
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EAS00021
REPLACEMENT PARTS
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EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1 - 10
GEN
IMPORTANT INFORMATION INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
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with a light coat of lithium-soap-based grease.
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Oil bearings liberally when installing, if appro-
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priate.
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1 Oil seal
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CAUTION:
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surfaces.
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2 Bearing
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EAS00025
CIRCLIPS
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1 - 11
GEN
CHECKING THE CONNECTIONS INFO
EAS00026
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
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Rust/stains → Connect and disconnect sev-
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eral times.
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3. Check:
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• all connections
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NOTE:
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4. Connect:
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• lead
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• coupler
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• connector
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NOTE:
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5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112, YU-03112-C
NOTE:
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1 - 12
GEN
SPECIAL TOOLS INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
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90890-01235
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YU-01235
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This tool is used to hold the primary fixed
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sheave and clutch shoe assembly.
Ring nut wrench er
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90890-01268
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YU-01268
This tool is used to loosen or tighten the
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90890-01304
YU-01304
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pins.
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YU-24460-01
Radiator cap tester
D
adapter
90890-01352 These tools are used to check the cooling
YU-33984 system.
T-handle
T-handle Damper rod holder
90890-01326
Damper rod holder These tools are used to hold the damper
90890-01460 rod when removing or installing the
damper rod.
Locknut wrench
90890-01348
YM-01348
This tool is used to remove or install the
clutch shoe assembly nut.
1 - 13
GEN
SPECIAL TOOLS INFO
Tool No. Tool name/Function Illustration
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90890-01396
This tool is used for protecting the oil seal
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lip when installing the secondary sliding
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sheave.
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Steering nut wrench ot
90890-01403
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YU-A9472
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YM-01471
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90890-01476
frame adjusting bolt.
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Sheave holder
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90890-01701
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YS-01880-A
This tool is used to hold the generator
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90890-03112
YU-03112-C
This tool is used to check the electrical
system.
1 - 14
GEN
SPECIAL TOOLS INFO
Tool No. Tool name/Function Illustration
Timing light
90890-03141
YU-03141
This tool is used to check the ignition tim-
ing.
Pressure gauge
90890-03153
YU-03153
This tool is used to measure fuel pres-
sure.
Adapter
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90890-03181
YM-03181
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This tool is used to measure fuel pres-
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sure.
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Valve spring compres- Valve spring compressor
sor Valve spring compressor attachment
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90890-04019
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YM-04019
Valve spring compres-
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90890-04058
YM-04058
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Mechanical seal
installer These tools are used to install the water
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90890-04145
pump seal.
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YM-04145
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90890-04097
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YM-04097
This tool is used to remove or install the
D
valve guides.
Valve guide installer (5 mm)
90890-04098
YM-04098
This tool is used to install the valve
guides.
Valve guide reamer (5 mm)
90890-04099
YM-04099
This tool is used to rebore the new valve
guides.
1 - 15
GEN
SPECIAL TOOLS INFO
Tool No. Tool name/Function Illustration
Valve lapper
90890-04101
This tool is needed to remove and install
the valve lifters.
Sheave spring com- Sheave spring compressor
pressor Sheave fixed block
90890-04134
YM-04134
Sheave fixed block This tool is used to hold the compression
90890-04135 spring when removing or installing the
YM-04135 clutch shoe assembly nut.
Plane bearing installer/remover
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90890-04146
YM-04146
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This tool is used to install or remove the
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crankshaft journal bearings.
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Ignition checker ot
90890-06754
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YM-34487
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tem components.
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90890-85505
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Sealant
ACC-11001-05-01 This bond is used to seal two mating sur-
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1 - 16
SPEC
CHAPTER 2
SPECIFICATIONS
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GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-17
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TIGHTENING TORQUES .............................................................................. 2-18
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ENGINE TIGHTENING TORQUES......................................................... 2-18
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CHASSIS TIGHTENING TORQUES.......................................................2-21
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Weight
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Wet (with oil and a full fuel tank) 212 kg (467 lb) ----
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Maximum load (total of cargo, rider, 196 kg (432 lb) ----
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passenger, and accessories)
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2-1
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Liquid-cooled, 4-stroke, DOHC ----
Displacement 394.9 cm3 (24.10 cu.in) ----
Cylinder arrangement Forward-inclined single cylinder ----
Bore × stroke 83.0 × 73.0 mm (3.27 × 2.87 in) ----
Compression ratio 10.6 : 1 ----
Engine idling speed 1,300 ~ 1,500 r/min ----
Vacuum pressure at engine idling 35.0 ~ 41.0 kPa ----
speed (263 ~ 308 mmHg, 10.4 ~ 12.1 inHg)
Compression pressure (at sea level) ----
2
Standard 1,400 kPa (14.0 kg/cm , 199.1 psi) at ----
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500 r/min
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Minimum 1,100 kPa (11.0 kg/cm2, 156.5 psi) ----
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Maximum 1,650 kPa (16.5 kg/cm2, 234.7 psi) ----
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Fuel
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Recommended fuel Unleaded gasoline only (USA)
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Regular unleaded gasoline only (CDN) ----
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Engine oil
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Recommended oil
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0 10 30 50 70 90 110 130 ˚F
Refer to the chart for the engine oil grade. ----
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YAMALUBE 4 (20W40)
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or SAE 20W40
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YAMALUBE 4 (10W30)
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or SAE 10W30
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–20 –10 0 10 20 30 40 50 ˚C
Recommended engine oil grade API service SE, SF, SG type or higher ----
Quantity
Total amount 1.70 L (1.50 Imp qt, 1.80 US qt) ----
Without oil filter element replace- 1.50 L (1.32 Imp qt, 1.59 US qt) ----
ment
With oil filter element replacement 1.70 L (1.50 Imp qt, 1.80 US qt) ----
Engine oil temperature 70 ~ 80 °C (158 ~ 176 °F) ----
Final transmission oil
Type SAE10W-30 type SE motor oil ----
Quantity 0.25 L (0.22 Imp qt, 0.26 US qt) ----
2-2
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Oil pump
Oil pump type Trochoid ----
Inner-rotor-to-outer-rotor-tip clear- 0.07 mm 0.15 mm
ance (0.0028 in) (0.0059 in)
Outer-rotor-to-oil-pump-housing 0.013 ~ 0.036 mm 0.106 mm
clearance (0.0005 ~ 0.0014 in) (0.0042 in)
Oil-pump-housing-to-inner-and-outer 0.040 ~ 0.096 mm 0.166 mm
rotor clearance (0.0016 ~ 0.0038 in) (0.0065 in)
Cooling system
Radiator capacity 1.57 L (1.38 Imp qt, 1.66 US qt) ----
Radiator cap opening pressure 110.0 ~ 140.0 kPa ----
(1.10 ~ 1.40 kg/cm2, 15.6 ~ 19.9 psi)
Radiator core
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Width 260 mm (10.24 in) ----
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Height 148 mm (5.83 in) ----
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Depth 24 mm (0.94 in) ----
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Coolant reservoir
Capacity er
0.32 L (0.28 Imp qt, 0.34 US qt) ----
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Water pump
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Spark plug
Model (manufacturer) × quantity CR7E (NGK) × 1
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----
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) ----
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Cylinder head
Volume 30.3 ~ 31.1 cm3 (1.85 ~ 1.90 cu.in) ----
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2-3
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Camshafts
Drive system Chain drive (right) ----
Camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ----
Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) ----
Camshaft-journal-to-camshaft-cap 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) 0.08 mm
clearance (0.0031 in)
Intake camshaft lobe dimensions
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B
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Measurement A 34.350 ~ 34.450 mm (1.352 ~ 1.356 in) 34.250 mm
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(1.3484 in)
Measurement B er
24.950 ~ 25.050 mm (0.982 ~ 0.986 in) 24.850 mm
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(0.9783 in)
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(1.3130 in)
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(0.9786 in)
Maximum camshaft runout ---- 0.03 mm
(0.0012 in)
2-4
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Timing chain
Model/number of links DID SCR-0409 SV/136LE ----
Tensioning system Automatic ----
Valves, valve seats, valve guides
Valve clearance (cold)
Intake 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) ----
Exhaust 0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in) ----
Valve dimensions
B C
D
A
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Head Diameter Face Width Seat Width Margin Thickness
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Valve head diameter A
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Intake 30.9 ~ 31.1 mm (1.2165 ~ 1.2244 in) ----
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Exhaust 27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in) ----
Valve face width B
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Intake 1.838 ~ 2.687 mm (0.0724 ~ 0.1058 in) ----
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(0.06 in)
Exhaust 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm
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(0.06 in)
Valve margin thickness D
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(0.1947 in)
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2-5
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Valve stem runout ---- 0.01 mm
(0.0004 in)
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Free length
Intake 46.45 mm (1.83 in) 44.13 mm
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(1.74 in)
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Exhaust 46.45 mm (1.83 in) 44.13 mm
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Installed length (valve closed)
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2-6
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Winding direction (top view)
Intake Clockwise ----
Exhaust Clockwise ----
Cylinder
Cylinder arrangement Forward-inclined single cylinder ----
Bore × stroke 83.0 × 73.0 mm (3.27 × 2.87 in) ----
Compression ratio 10.6 : 1 ----
Bore 83.000 ~ 83.010 mm (3.2677 ~ 3.2681 in) ----
Maximum taper ---- 0.05 mm
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(0.002 in)
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Piston
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Piston-to-cylinder clearance 0.060 ~ 0.075 mm (0.0024 ~ 0.0030 in) 0.15 mm
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(0.0059 in)
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Diameter D 82.930 ~ 82.945 mm (3.2650 ~ 3.2656 in)
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D
m
Piston pin
D
B
T
2-7
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
2nd ring
B
T
t
ne
T
e.
Dimensions (B × T) 2.00 × 2.25 mm (0.08 × 0.09 in) ----
m
End gap (installed) 0.10 ~ 0.40 mm (0.0039 ~ 0.0157 in) ----
Ti
Ring side clearance 0.040 ~ 0.140 mm (0.0016 ~ 0.0055 in) ----
Crankshaft er
ot
co
.S
C C
w
w
w
E
m
D
fro
A
d
de
(0.0012 in)
ow
Big end side clearance D 0.350 ~ 0.850 mm (0.0138 ~ 0.0335 in) ----
Big end radial clearance E 0.010 ~ 0.024 mm (0.0004 ~ 0.0009 in) ----
D
2-8
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Automatic centrifugal clutch
Clutch shoe thickness 4.0 mm (0.16 in) 2.5 mm
(0.10 in)
Clutch shoe spring free length 34.7 mm (1.37 in) ----
Clutch housing inside diameter 160 mm (6.30 in) 160.5 mm
(6.32 in)
Compression spring free length 103.5 mm (4.075 in) 91 mm
(3.58 in)
Weight outside diameter 25 mm (0.98 in) 24.5 mm
(0.96 in)
Clutch-in revolution 1,700 ~ 2,300 r/min ----
Clutch-stall revolution 4,000 ~ 5,000 r/min ----
V-belt
t
ne
V-belt width 30 mm (1.18 in) 27 mm
e.
(1.06 in)
m
Transmission
Ti
Primary reduction system Helical gear ----
Primary reduction ratio 31/14 (2.214) er ----
ot
Secondary reduction system Helical gear ----
co
Air filter
Air filter element Oil-coated paper element ----
d
de
Throttle body
Manufacturer AISAN ----
ID mark 5RU4 10 ----
Throttle cable free play (at the flange 3 ~ 5 mm (0.12 ~ 0.20 in) ----
of the throttle grip)
2-9
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Aluminum die-cast and steel tube back- ----
bone
Caster angle 27° ----
Trail 100.0 mm (3.94 in) ----
Front wheel
Wheel type Cast wheel ----
Rim
Size 14 M/C × MT3.00 ----
Material Aluminum ----
Wheel travel 107 mm (4.21 in) ----
t
Wheel runout
ne
Maximum radial wheel runout ---- 1.0 mm
e.
(0.04 in)
m
Maximum lateral wheel runout ---- 0.5 mm
Ti
(0.02 in)
er
ot
Wheel axle bending limit ---- 0.25 mm
co
(0.01 in)
.S
Rear wheel
w
Rim
w
Wheel runout
de
(0.04 in)
nl
(0.02 in)
Front tire
D
2 - 10
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Rear tire
Tire type Tubeless ----
Size 150/70-13M/C 64S ----
Model (manufacturer) MB 67 (IRC) ----
D305L (DUNLOP) ----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.50 kgf/cm2, 36 psi) ----
90 ~ 196 kg (198 ~ 432 lb) 250 kPa (2.50 kgf/cm2, 36 psi) ----
High-speed riding 250 kPa (2.50 kgf/cm2, 36 psi) ----
Minimum tire tread depth ---- 1.0 mm
(0.04 in)
Front brake
Brake type Single-disc brake ----
t
ne
Operation Right-hand operation ----
e.
Recommended fluid DOT 4 ----
m
Brake discs
Ti
Diameter × thickness 267 × 5 mm (10.51 × 0.20 in) ----
Minimum thickness ---- er 4.5 mm
ot
(0.18 in)
co
(0.006 in)
w
w
(0.03 in)
m
fro
d
de
2 - 11
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Rear brake
Brake type Single-disc brake ----
Operation Left-hand operation ----
Recommended fluid DOT 4 ----
Brake discs
Diameter × thickness 267 × 5 mm (10.51 × 0.20 in) ----
Minimum thickness ---- 4.5 mm
(0.18 in)
Maximum deflection ---- 0.15 mm
(0.006 in)
Brake pad lining thickness 8.3 mm (0.33 in) 0.8 mm
(0.03 in)
t
ne
e.
m
Master cylinder inside diameter 14.0 mm (0.55 in) ----
Ti
Caliper cylinder inside diameter 38.1 mm (1.50 in) ----
er
ot
Front suspension
co
Spring
w
(12.22 in)
fro
Spring rate (K1) 14.09 N/mm (1.44 kg/mm, 80.45 lb/in) ----
de
Spring rate (K2) 26.67 N/mm (2.72 kg/mm, 152.28 lb/in) ----
oa
2 - 12
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Steering
Steering bearing type Angular and taper roller bearings ----
Lock-to-lock angle (left) 40° ----
Lock-to-lock angle (right) 40° ----
Rear suspension
Suspension type Unit swing ----
Rear shock absorber assembly type Coil spring/oil damper ----
Rear shock absorber assembly travel 130 mm (5.12 in) ----
Spring
Free length 306.6 mm (12.07 in) 300.0 mm
(11.81 in)
Installed length 290.6 mm (11.44 in) ----
Spring rate (K1) 6.22 N/mm (0.63 kg/mm, 35.52 lb/in) ----
t
ne
Spring rate (K2) 11.80 N/mm (1.20 kg/mm, 67.38 lb/in) ----
e.
Spring rate (K3) 22.50 N/mm (2.29 kg/mm, 128.47 lb/in) ----
m
Spring stroke (K1) 0 ~ 29 mm (0 ~ 1.14 in) ----
Ti
Spring stroke (K2) 29 ~ 90 mm (1.14 ~ 3.54 in) ----
Spring stroke (K3) er
90 ~ 130 mm (3.54 ~ 5.12 in) ----
ot
Optional spring available No
co
----
Swingarm
.S
arm)
w
(0.04 in)
fro
2 - 13
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V ----
Ignition system
Ignition system type Transistorized coil ignition (digital) ----
Ignition timing 5° BTDC at 1,400 r/min ----
Advancer type Digital ----
Crankshaft position sensor resis- 248 ~ 372 Ω at 20 °C (68 °F)/red–white ----
tance/color
ECU
Model (manufacturer) 5RU30/MORIC ----
Ignition coil
Model (manufacturer) 2JN (MORIC) ----
t
Minimum ignition spark gap 6 mm (0.24 in) ----
ne
Primary coil resistance 2.16 ~ 2.64 Ω at 20 °C (68 °F) ----
e.
Secondary coil resistance 8.64 ~ 12.96 kΩ at 20 °C (68 °F) ----
m
Spark plug cap
Ti
er
Material Resin ot ----
Resistance 10.0 kΩ at 20 °C (68 °F) ----
co
Charging system
.S
white–white
fro
Rectifier/regulator
d
Battery
Battery type GT9B-4 ----
Battery voltage/capacity 12 V/8 Ah ----
Specific gravity 1.320 ----
Manufacturer GS ----
Ten hour rate amperage 0.8 A ----
Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) ----
Headlight
Headlight type Halogen bulb ----
2 - 14
ELECTRICAL SPECIFICATIONS SPEC
Item Standard Limit
Bulbs (voltage/wattage × quantity)
Headlight 12 V 60/55 W × 2 ----
Tail/brake light LED × 1 ----
Front turn signal/position light 12 V 21 W/5 W × 2 ----
Rear turn signal light 12 V 21 W × 2 ----
Licence plate light 12 V 5 W × 1 ----
Meter light 12 V 2.0 W × 3 ----
Indicator light
(voltage/wattage × quantity)
High beam indicator light 12 V 1.4 W × 1 ----
Turn signal indicator light 12 V 1.4 W × 2 ----
Engine trouble warning light 12 V 1.4 W × 1 ----
Electric starting system
t
ne
System type Constant mesh ----
e.
Starter motor
m
Model (manufacturer) SM-13 (MITSUBA) ----
Ti
Power output 0.65 kW ----
Brushes er
ot
Overall length 12 mm (0.47 in)
co
4.0 mm
(0.16 in)
.S
Starter relay
Model (manufacturer) 2768098-A (JIDECO) ----
nl
ow
2 - 15
ELECTRICAL SPECIFICATIONS SPEC
Item Standard Limit
Fuses (amperage × quantity)
Main fuse 40 A × 1 ----
Fuel injection system fuse 10 A × 1 ----
Headlight fuse 20 A × 1 ----
Signaling system fuse 10 A × 1 ----
Ignition fuse 10 A × 1 ----
Radiator fan motor fuse 10 A × 1 ----
Backup fuse (storage box light and 10 A × 1 ----
meter assembly)
Turn signal/position light fuse 10 A × 1 ----
Spare fuse 40 A × 1, 20 A × 1, 10 A × 2 ----
Fuel gauge
Model (manufacturer) 5RU (AISAN) ----
t
ne
Sender unit resistance-full 19 ~ 21 Ω ----
e.
Sender unit resistance-empty 137 ~ 143 Ω ----
m
Starting circuit cut-off relay
Ti
Model (manufacturer) ACA12115-4 (MATSUSHITA) ----
Coil resistance 72 ~ 88 Ω er ----
ot
Diode Yes
co
----
Radiator fan motor
.S
Speed sensor
Output voltage
When sensor is on DC 4.8 V or more ----
When sensor is off DC 0.6 V or less ----
Throttle position sensor
Voltage/color 5 V/blue–black/blue ----
Voltage (closed position)/color 0.4 ~ 0.9 V/yellow/blue–black/blue ----
ISC (idle speed control) valve
Resistance/color 27 ~ 33 Ω at 20 °C (68 °F)/ ----
pink–light green or gray–sky blue
Lean angle cut-off switch
Voltage
Less than 45° Approximately 1 V ----
More than 45° Approximately 4 V ----
2 - 16
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC
EAS00028 EAS00030
t
Metric unit Multiplier Imperial unit
ne
m·kg 7.233 ft·lb
e.
Tighten-
ing torque m·kg 86.794 in·lb
m
cm·kg 0.0723 ft·lb
Ti
cm·kg 0.8679 in·lb
kg 2.205 lb
er
ot
Weight
g 0.03527 oz
co
km 0.6214 mi
w
m 3.281 ft
w
mm 0.03937 in
General tightening
fro
14.2234
Misc.
12 mm 8 mm 15 1.5 11
ow
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2 - 17
TIGHTENING TORQUES SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
t
ne
cap
Oil gallery bolt — M6 1 10 1.0 7.2
e.
m
Cylinder and crankcase Bolt M6 1 10 1.0 7.2
Ti
Generator rotor Nut M18 1 130 13.0 94
Camshaft sprocket (intake and
Bolt M7 4er 20 2.0 14
ot
exhaust)
co
2 - 18
TIGHTENING TORQUES SPEC
Thread Tightening torque
Item Fastener Q’ty Remarks
size Nm m · kg ft · lb
Exhaust pipe Nut M8 2 20 2.0 14
Air induction system pipe Bolt M6 2 12 1.2 8.7
Air induction system pipe stay Bolt M6 1 7 0.7 5.1
Air cut-off valve Bolt M6 2 10 1.0 7.2
Muffler mount Bolt M10 3 53 5.3 38
V-belt case air duct 1 and 2 Bolt M6 4 7 0.7 5.1
Crankcase Bolt M6 7 10 1.0 7.2
Crankcase Bolt M8 5 16 1.6 11
Crankcase Bolt M8 1 30 3.0 22
Cylinder head stud bolt — M10 4 13 1.3 9.4
Transmission oil drain bolt — M8 1 20 2.0 14
t
Bearing retainer Screw M6 1 10 1.0 7.2
ne
LT
e.
V-belt case Bolt M8 1 22 2.2 16
m
V-belt case Bolt M6 9
Ti
10 1.0 7.2
V-belt case cover Bolt M6 6
er 7 0.7 5.1
ot
Generator rotor cover inner bracket Bolt M6 2 7 0.7 5.1 LT
co
LT
2 - 19
TIGHTENING TORQUES SPEC
Camshaft cap tightening sequence:
t
ne
e.
m
Ti
Cylinder head tightening sequence:
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
2 - 20
TIGHTENING TORQUES SPEC
CHASSIS TIGHTENING TORQUES
Tightening torque
Item Thread size Remarks
Nm m · kg ft · lb
Bottom cover and sub-frame M6 7 0.7 5.1
Radiator cover and frame M6 7 0.7 5.1
Front cowling and front cowling stay M6 7 0.7 5.1
Footrest board and footrest board stay M6 7 0.7 5.1
Footrest board and sub-frame M6 7 0.7 5.1
Rear reflector and reflector bracket M5 4 0.4 2.9
Rear fender and licence plate bracket M6 4 0.4 2.9
Front reflector and reflector bracket M6 7 0.7 5.1
Storage compartment and frame M6 7 0.7 5.1
Rear fender and frame M6 10 1.0 7.2
t
ne
Sub-frame adjusting bolt M18 4 0.4 2.9
Sub-frame front upper mounting nut M10 54 5.4 39
e.
Sub-frame front lower mounting bolt M10 54
m
5.4 39 LT
Ti
Sub-frame rear mounting bolt M10 54 5.4 39 LT
LT
2 - 21
TIGHTENING TORQUES SPEC
Tightening torque
Item Thread size Remarks
Nm m · kg ft · lb
Rear brake master cylinder and rear brake mas-
M6 10 1.0 7.2
ter cylinder holder
Grip end M16 26 2.6 19
Right handlebar switch M5 4 0.4 2.9
Rear brake lock lever and left handlebar switch M5 6 0.6 4.3
Storage box and frame M6 11 1.1 8.0
Rider seat and bottom plate M6 7 0.7 5.1
Seat lock assembly and frame M6 10 1.0 7.2
Grab bar bracket and frame M8 30 3.0 22
Grab bar and grab bar bracket M8 23 2.3 17
Grab bar and frame M8 23 2.3 17
t
Passenger seat and grab bar M6 7 0.7 5.1
ne
Seat bracket and frame M8 30 3.0 22
e.
Gas spring assembly bracket and frame M8 30 3.0 22
m
Front brake hose holder and lower bracket M6 7 0.7 5.1
Ti
er
Front brake hose holder and outer tube M6 ot 7 0.7 5.1
Sidestand and sub-frame M10 39 3.9 28
co
M10 27 2.7 19
bracket
D
2 - 22
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EAS00031
Bearings E
O-rings LS
Crankshaft pin E
t
Crankshaft thrust surface E
ne
Crankshaft journals E
e.
m
Crankshaft end (generator rotor side) E
Ti
Generator rotor nut and washer E
E
w
Camshaft lobes M
w
Camshaft journals M
m
fro
BEL-RAY
Primary sheave
assembly lube®
BEL-RAY
Secondary sheave
assembly lube®
2 - 23
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
Lubrication point Lubricant
Water pump seal lip LS
Yamaha bond
Cylinder head cover (guide stopper mating surface)
No. 1215
Yamaha bond
Crankcase mating surface
No. 1215
Yamaha bond
Generator rotor cover (grommet mating surface)
No. 1215
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
2 - 24
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EAS00032
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Brake lever pivoting point and metal-to-metal moving parts (left and right) LS
Rear brake lock lever cable and rear brake lock lever (cable connection LS
area)
Front wheel oil seal LS
Rear axle LS
t
ne
Sidestand pivoting point, metal-to-metal moving parts and collar outer sur-
e.
LS
face
m
Centerstand shaft pivoting point and metal-to-metal moving parts LS
Ti
er
Centerstand stopper pivoting point ot LS
2 - 25
COOLING SYSTEM DIAGRAMS SPEC
EAS00033
1 2
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
3
d
7 6 5 4
de
oa
nl
ow
D
7 6
2 - 26
COOLING SYSTEM DIAGRAMS SPEC
1 Radiator pipe assembly B Water jacket inlet pipe
2 Oil cooler outlet hose C Oil cooler pipe
3 Oil cooler cover
4 Water pump outlet hose
5 Water pump cover
6 Water pump inlet hose
7 Thermostat inlet hose
8 Cooling system air bleed hose
9 Thermostat outlet hose
0 Thermostat
A Thermostat cover
t
ne
6 7 8 9
e.
A 0
m
A-A
Ti
er 1
ot
co
.S
A
w
w
w
m
fro
d
de
5 C
oa
nl
ow
B
D
C 4 3 2
2
B
C-C B
2 - 27
CABLE ROUTING SPEC
EAS00035
CABLE ROUTING
1 Rear brake lock lever cable È Route the handlebar switch leads to the left of
2 Rear brake hose the cable guide (lower handlebar holder).
3 Cable guide (lower handlebar holder) É Route the throttle cables in front of the handle-
4 Throttle cable (accelerator cable) bar.
5 Throttle cable (decelerator cable) Ê Fasten the right handlebar switch lead to the
6 Front brake hose handlebar with a plastic locking tie.
7 Handlebar switch leads
Ð 1
t
ne
e.
È 3
m
2 4 5 4
Ti
1 6 5
A
er Ñ
ot
co
B
.S
w
A B
w
w
m
fro
Ë Ê
d
Ì É
de
oa
nl
ow
2
D
Ï
Î
7
C
1 6
5
C 4
Ï
6 C-C
Í
2 - 28
CABLE ROUTING SPEC
Ë Fasten the left handlebar switch lead to the han- Ï Install the grommet on the front brake hose in
dlebar with a plastic locking tie. the hole in the lower handlebar cover before
Ì Route the rear brake lock lever cable in front of connecting the hose.
the handlebar. Ð Pass the rear brake lock lever cable through the
Í Route the throttle cables under the rear brake hole in the lower handlebar cover.
hose, rear brake lock lever cable, and front Ñ Pass the throttle cables through the hole in the
brake hose, and then to the right side of the lower handlebar cover.
scooter.
Î Pass the throttle cables, rear brake hose, and
rear brake lock lever cable through the cable
guide (lower handlebar holder).
Ð 1
t
ne
e.
È 3
m
2 4 5 4
Ti
1 6 5
A
er Ñ
ot
co
B
.S
w
A B
w
w
m
fro
Ë Ê
d
Ì É
de
oa
nl
ow
2
D
Ï
Î
7
C
1 6
5
C 4
Ï
6 C-C
Í
2 - 29
CABLE ROUTING SPEC
1 Meter assembly B Rectifier/regulator
2 Handlebar switch leads C Speed sensor lead
3 Throttle cable (accelerator cable) D Front turn signal/position light lead (right)
4 Throttle cable (decelerator cable) E Front turn signal/position light lead (left)
5 Front brake hose F Front turn signal/position light lead coupler
6 Rear brake lock lever cable (right)
7 Rear brake hose G Headlight lead
8 Wire harness H Front turn signal/position light lead coupler (left)
9 Fuel overflow hose I Starting circuit cut-off relay
0 Radiator fan motor lead J Headlight relay 2
A Radiator K Turn signal relay
D 8 E
È 1 2
D
I
t
ne
I 3
e.
A B 4
C
m
5
6
Ti
7
HG A F er É
ot
Ê
co
JKLM Ë
I J N
.S
K C É
Ì 8
w
O E
w
J K
G F H
w
D
E F
m
P H
fro
R G
d
de
Î Q
B
oa
S 7
nl
4 B Í
ow
3 6 A 0 9
T
5
D
B Ó
Ð
Ï Ö 8
Ñ 0
G
C J-J
8
5
34 E Ô
F-F
H-H
S 8
G ×
U 0 E Õ
T Ò
7 F-F K-K
6 D I-I D
2 - 30
CABLE ROUTING SPEC
L Radiator fan motor relay È After connecting the meter assembly coupler,
M Fuel injection system relay install its cover.
N Headlight relay 1 É Fasten the wire harness to the frame with a plas-
O Meter assembly lead tic locking tie. Face the end of the plastic locking
P Lean angle cut-off switch tie down.
Q Horn Ê The paint marks on the rear brake lock lever
R ECU cable and the rear brake hose should be within
S Right handlebar switch lead 20 mm (0.79 in) above or below the upper edge
T Left handlebar switch lead of the hole in the frame.
U Rectifier/regulator lead
D 8 E
È 1 2
D
I
t
ne
I 3
e.
A B 4
C
m
5
6
Ti
7
HG A F er É
ot
Ê
co
JKLM Ë
I J N
.S
K C É
Ì 8
w
O E
w
J K
G F H
w
D
E F
m
P H
fro
R G
d
de
Î Q
B
oa
S 7
nl
4 B Í
ow
3 6 A 0 9
T
5
D
B Ó
Ð
Ï Ö 8
Ñ 0
G
C J-J
8
5
34 E Ô
F-F
H-H
S 8
G ×
U 0 E Õ
T Ò
7 F-F K-K
6 D I-I D
2 - 31
CABLE ROUTING SPEC
Ë Pass the rear brake lock lever cable and rear Ð Route the handlebar switch leads in front of the
brake hose through the hole in the frame so that front brake hose.
the rear brake lock lever cable is to the outside Ñ Route the rear brake hose and rear brake lock
of the rear brake hose. lever cable in front of the front brake hose and
Ì Route the throttle cable (decelerator cable) throttle cables.
above the throttle cable (accelerator cable). Ò Fasten the rectifier/regulator lead and radiator
Í Connect the wire harness to the rectifier/regula- fan motor lead to the sub-frame with a plastic
tor. band. Face the end of the plastic band towards
Î Fasten the wire harness with a cable holder. the rear of the scooter.
Ï Route the front brake hose in front of the throttle
cables.
D 8 E
È 1 2
D
I
t
ne
I 3
e.
A B 4
C
m
5
6
Ti
7
HG A F er É
ot
Ê
co
JKLM Ë
I J N
.S
K C É
Ì 8
w
O E
w
J K
G F H
w
D
E F
m
P H
fro
R G
d
de
Î Q
B
oa
S 7
nl
4 B Í
ow
3 6 A 0 9
T
5
D
B Ó
Ð
Ï Ö 8
Ñ 0
G
C J-J
8
5
34 E Ô
F-F
H-H
S 8
G ×
U 0 E Õ
T Ò
7 F-F K-K
6 D I-I D
2 - 32
CABLE ROUTING SPEC
Ó Pass the radiator fan motor lead through the cut- Ö Fasten the wire harness to the front cowling stay
out in the left side of the bottom cover. with a plastic band. The end of the plastic band
Ô Face the end of the plastic locking tie away from should be towards the rear of the scooter facing
the scooter. down.
Õ Fasten the headlight lead, front turn signal/posi- × Fasten the wire harness at the white tape to the
tion light lead (left), and front turn signal/position front cowling stay with a plastic band. The end of
light lead (right) to the front cowling with a plastic the plastic band should be towards the rear of
band. The end of the plastic band should be the scooter facing down.
towards the rear of the scooter facing down.
D 8 E
È 1 2
D
I
t
ne
I 3
e.
A B 4
C
m
5
6
Ti
7
HG A F er É
ot
Ê
co
JKLM Ë
I J N
.S
K C É
Ì 8
w
O E
w
J K
G F H
w
D
E F
m
P H
fro
R G
d
de
Î Q
B
oa
S 7
nl
4 B Í
ow
3 6 A 0 9
T
5
D
B Ó
Ð
Ï Ö 8
Ñ 0
G
C J-J
8
5
34 E Ô
F-F
H-H
S 8
G ×
U 0 E Õ
T Ò
7 F-F K-K
6 D I-I D
2 - 33
CABLE ROUTING SPEC
1 Sidestand switch lead B Starter motor
2 Crankshaft position sensor lead coupler C Fuel hose
3 Sub-wire harness D Spark plug lead
4 Crankshaft position sensor/stator coil lead E Sidestand switch
5 Storage box light switch lead F Stator coil lead
6 Storage box light G Wire harness
7 Negative battery lead H Throttle cable (accelerator cable)
8 Starter motor lead I Throttle cable (decelerator cable)
9 Fuse box J Stator coil lead coupler
0 Tail/brake light lead K Storage box light lead
A Rear turn signal/license plate light lead L Turn signal/position light fuse
1 6 Ê 7 8 9
F
G
É G H
t
ne
I
e.
H 5
m
4 F
Ti
Ï G 3
A-A
F
D E er
ot
D 7
0
co
È 2 A
1 C Ë 7 8 Ü
Ì
.S
B L L
Û
w
A K
w
C Ú
w
Ù L
Í
m
A
B
fro
B
Ø K Þ Ý
d
M H
de
Ö
oa
7
B
nl
G
8
ow
ß
D
J Î E D C
3
Ô F-F I
5 I Õ
Ð
3 5 Á
Ó M
B
G 4 4
B-B 3 8
O
À G
G Ñ N
7
7 8 J
4 3 J K-K
E ×
78 AA
6
5 K G
Ò 8
N
C-C D-D G L-L
2 - 34
CABLE ROUTING SPEC
M Battery band Ë Route the tail/brake light lead and rear turn sig-
N Positive battery lead nal/license plate light lead below the bracket on
O V-belt replacement indicator reset coupler lead the frame.
Ì Fasten the wire harness, starter motor lead, and
È After connecting the stator coil lead coupler, negative battery lead to the frame with plastic
slide the cover over the coupler. locking ties. Face the end of each plastic locking
É Route the storage box light lead through the two tie away from the scooter.
guides in the storage box. Í Pass the sub-wire harness, crankshaft position
Ê Route the wire harness, starter motor lead, and sensor/stator coil lead, and fuel injector lead
negative battery lead on the outside of the grab between the starter motor and the throttle body.
bar bracket.
1 6 Ê 7 8 9
F
G
É G H
t
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I
e.
H 5
m
4 F
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Ï G 3
A-A
F
D E er
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D 7
0
co
È 2 A
1 C Ë 7 8 Ü
Ì
.S
B L L
Û
w
A K
w
C Ú
w
Ù L
Í
m
A
B
fro
B
Ø K Þ Ý
d
M H
de
Ö
oa
7
B
nl
G
8
ow
ß
D
J Î E D C
3
Ô F-F I
5 I Õ
Ð
3 5 Á
Ó M
B
G 4 4
B-B 3 8
O
À G
G Ñ N
7
7 8 J
4 3 J K-K
E ×
78 AA
6
5 K G
Ò 8
N
C-C D-D G L-L
2 - 35
CABLE ROUTING SPEC
Î Connect the orange lead to the upper terminal of Ò Fasten the sub-wire harness, crankshaft position
the ignition coil and connect the red/black lead to sensor/stator coil lead, and storage box light
the lower terminal. switch lead with a plastic locking tie. Place the
Ï Fasten the throttle cables, sidestand switch lead, end of the plastic locking tie between the frame
and wire harness with a plastic holder as shown. and the leads (negative battery lead and starter
³ Fasten the sub-wire harness, stator coil lead motor lead).
coupler, and wire harness with a plastic locking Ó Fasten the sub-wire harness at the white tape
tie. Face the end of the plastic locking tie down. and the crankshaft position sensor/stator coil
Ñ Install the plastic locking tie in the hole above lead to the engine bracket with a plastic locking
the footrest bracket. tie. Face the end of the plastic locking tie away
from the scooter.
1 6 Ê 7 8 9
F
G
É G H
t
ne
I
e.
H 5
m
4 F
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Ï G 3
A-A
F
D E er
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D 7
0
co
È 2 A
1 C Ë 7 8 Ü
Ì
.S
B L L
Û
w
A K
w
C Ú
w
Ù L
Í
m
A
B
fro
B
Ø K Þ Ý
d
M H
de
Ö
oa
7
B
nl
G
8
ow
ß
D
J Î E D C
3
Ô F-F I
5 I Õ
Ð
3 5 Á
Ó M
B
G 4 4
B-B 3 8
O
À G
G Ñ N
7
7 8 J
4 3 J K-K
E ×
78 AA
6
5 K G
Ò 8
N
C-C D-D G L-L
2 - 36
CABLE ROUTING SPEC
Ô Route the rear brake hose and rear brake lock × Connect the storage box light lead coupler
lever cable through the two engine bracket securely.
guides so that the rear brake lock lever cable is Ø Route the negative battery lead below the
towards the outside of the scooter. bracket on the frame.
Õ Align the paint mark on the rear brake lock lever Ù Route the starter motor lead and wire harness
cable with the engine bracket guide. over the boss of the upper rear cover.
Ö Fasten the wire harness, starter motor lead, and Ú Route the positive battery lead between the
negative battery lead to the frame with a plastic leads and the battery.
locking tie. Face the end of the plastic locking tie Û Install the cover over the positive battery termi-
away from the scooter. nal.
1 6 Ê 7 8 9
F
G
É G H
t
ne
I
e.
H 5
m
4 F
Ti
Ï G 3
A-A
F
D E er
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D 7
0
co
È 2 A
1 C Ë 7 8 Ü
Ì
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B L L
Û
w
A K
w
C Ú
w
Ù L
Í
m
A
B
fro
B
Ø K Þ Ý
d
M H
de
Ö
oa
7
B
nl
G
8
ow
ß
D
J Î E D C
3
Ô F-F I
5 I Õ
Ð
3 5 Á
Ó M
B
G 4 4
B-B 3 8
O
À G
G Ñ N
7
7 8 J
4 3 J K-K
E ×
78 AA
6
5 K G
Ò 8
N
C-C D-D G L-L
2 - 37
CABLE ROUTING SPEC
Ü Route the starter motor lead, wire harness, and À Route the starter motor lead and negative bat-
positive battery lead over the boss of the upper tery lead below the boss on the left engine
rear cover. bracket as shown.
Ý Route the negative battery lead between the Á Install the battery band with its projection in the
leads and the battery. recess in the top of the battery case.
Þ Fasten the V-belt replacement indicator reset A A Fasten the starter motor lead, wire harness,
coupler with the battery band. and positive battery lead with a plastic band.
ß Install the negative battery lead terminal to the Face the end of the plastic band towards the
starter motor bolt hole that is closest to the cylin- front of the scooter.
der.
1 6 Ê 7 8 9
F
G
É G H
t
ne
I
e.
H 5
m
4 F
Ti
Ï G 3
A-A
F
D E er
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D 7
0
co
È 2 A
1 C Ë 7 8 Ü
Ì
.S
B L L
Û
w
A K
w
C Ú
w
Ù L
Í
m
A
B
fro
B
Ø K Þ Ý
d
M H
de
Ö
oa
7
B
nl
G
8
ow
ß
D
J Î E D C
3
Ô F-F I
5 I Õ
Ð
3 5 Á
Ó M
B
G 4 4
B-B 3 8
O
À G
G Ñ N
7
7 8 J
4 3 J K-K
E ×
78 AA
6
5 K G
Ò 8
N
C-C D-D G L-L
2 - 38
CABLE ROUTING SPEC
1 Rear brake lock lever cable È Route the seat lock cable through the cable
2 Rear brake hose cover.
3 Throttle cable (accelerator cable) É Pass the throttle cables through the hole in the
4 Throttle cable (decelerator cable) frame.
5 Seat lock cable Ê The paint marks on the throttle cables should be
6 Main switch within 20 mm (0.79 in) above or below the upper
7 Thermistor lead coupler edge of the hole in the frame.
8 Front brake hose Ë Route the speed sensor lead over the lower tube
9 Speed sensor lead of the front cowling stay.
0 Coolant reservoir
A Front cowling stay
Ë Ì
Î
5
t
ne
e.
6
m
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A-A 5 F 7
5
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4
F
.S
Ï 3
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B-B 8
Ê
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m
É A
fro
5
È
d
A 9
de
2 Í
C-C B
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1
nl
D B
ow
E E
D
D
C
E-E
Ñ A
Ò
F-F
0
2 - 39
CABLE ROUTING SPEC
Ì Route the speed sensor lead as shown. Ð Hook the end of the cable cover in the hole in
Í Route the front brake hose and speed sensor the frame.
lead through the guide on the front cowling stay Ñ Fasten a plastic band around the middle of the
so that the speed sensor lead is towards the out- coupler cover, and then face the end of the plas-
side of the scooter. tic band down.
Î Hook the end of the cable cover in the hole in Ò After connecting the main switch lead and speed
the frame. sensor lead, put the cover on the couplers.
Ï Attach the cable cover by installing the quick fas-
tener in the hole in the frame.
Ë Ì
Î
5
t
ne
e.
6
m
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A-A 5 F 7
5
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co
4
F
.S
Ï 3
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B-B 8
Ê
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m
É A
fro
5
È
d
A 9
de
2 Í
C-C B
oa
1
nl
D B
ow
E E
D
D
C
E-E
Ñ A
Ò
F-F
0
2 - 40
CABLE ROUTING SPEC
1 Seat lock cable È Fasten the rear brake hose with the brake hose
2 Rear brake lock lever cable holder and route the rear brake lock lever cable
3 Rear brake hose through the guide.
4 Fuel overflow hose É Fasten the rear brake hose with the plastic
5 Coolant reservoir breather hose holder.
Ê Route the seat lock cable above the rear brake
lock lever cable.
Ë Align the white paint mark on the fuel overflow
hose with the holder on the bottom cover.
2 Ë 4 Ì
t
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e.
É
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3
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A-A
.S
1 Ê
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2
m
Ï
fro
3
d
C
de
É
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B-B Î 5 Í
nl
ow
1
2
D
3
A
A B
2 - 41
CABLE ROUTING SPEC
Ì Route the fuel overflow hose to the outside of
the hose guide.
Í Fasten the coolant reservoir breather hose with
the two holders on the bottom cover.
Î Route the coolant reservoir breather hose to the
outside of the hose guide.
Ï The end of the coolant reservoir breather hose
should extend 15 ± 10 mm (0.59 ± 0.39 in) past
the end of the bottom cover.
2 Ë 4 Ì
t
ne
e.
É
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3
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A-A
.S
1 Ê
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2
m
Ï
fro
3
d
C
de
É
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B-B Î 5 Í
nl
ow
1
2
D
3
A
A B
2 - 42
CABLE ROUTING SPEC
1 Seat lock cable È Route the throttle cables above the seat lock
2 Throttle cable (decelerator cable) cable guide.
3 Throttle cable (accelerator cable) É Route the seat lock cable, rear brake lock lever
4 Rear brake lock lever cable cable, rear brake hose, throttle cables, and wire
5 Rear brake hose harness so that they do not cause the rubber
6 Wire harness sheet to be folded or turned over.
7 Thermistor Ê Fasten the wire harness with a plastic locking
8 Thermistor lead tie.
Ë 20 mm (0.79 in)
2 3 Î 1 8 1 Ï
5 7
t
ne
e.
4
m
C
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A B C Ð
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B
m
fro
6 È
d
de
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5
nl
1
ow
4
D
3
Í
Ì A
2 É
2 - 43
CABLE ROUTING SPEC
Ì Route the throttle cables below the gas spring
assembly.
Í Route the throttle cable (decelerator cable)
above the throttle cable (accelerator cable).
Î Route the throttle cables above the rear brake
hose and rear brake lock lever cable.
Ï Pass the seat lock cable through the space
between the storage compartment and seat lock
cable guide.
Ð Route the seat lock cable through the lower sec-
tion of the seat lock cable guide.
2 3 Î 1 8 1 Ï
5 7
t
ne
e.
4
m
C
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A B C Ð
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B
m
fro
6 È
d
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5
nl
1
ow
4
D
3
Í
Ì A
2 É
2 - 44
CABLE ROUTING SPEC
1 Spark plug cap B Fuel injector lead
2 Seat lock cable C Storage box light switch lead
3 Seat lock assembly D Storage box light switch
4 ISC (idle speed control) valve lead E Sub-wire harness
5 Rear brake lock lever cable F Crankshaft position sensor/stator coil lead
6 Rear brake hose G Crankshaft position sensor lead coupler
7 Wire harness H Throttle cable (decelerator cable)
8 Starter motor lead I Stator coil lead coupler
9 Positive battery lead
0 Negative battery leads
A Intake air temperature sensor
7
1
I
t
ne
H
e.
2
m
Í
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G 3
er
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F
co
4
E
.S
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Ì
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5
w
m
D 6
fro
C
d
de
B
oa
Ë
nl
ow
A
D
0
È
8
0 9
7
8
Ê
2 - 45
CABLE ROUTING SPEC
È Do not pinch any hoses, leads, etc., when Ë Route the starter motor lead and negative bat-
installing the storage box. tery lead between the two projections on the
É After connecting the positive battery lead, starter frame.
motor lead, and wire harness, install the starter Ì Pass the fuel hose through the hose guide on
relay cover. the sub-frame.
Ê 30° Í After installing the spark plug cap, fasten the
Connect the positive battery lead to the starter spark plug lead to the cylinder head with the
relay within the angle shown. Route the starter lead holder.
motor lead parallel to the positive battery lead.
7
1
I
t
ne
H
e.
2
m
Í
Ti
G 3
er
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F
co
4
E
.S
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Ì
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5
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m
D 6
fro
C
d
de
B
oa
Ë
nl
ow
A
D
0
È
8
0 9
7
8
Ê
2 - 46
CABLE ROUTING SPEC
Canister A Plastic clip
1 Canister B Guide
2 Fuel overflow hose
3 Rollover valve to canister hose
4 Rollover valve
5 Fuel tank to rollover valve hose
6 Fuel tank
7 Throttle body
8 Canister to throttle body hose
9 Plastic holder
0 Fuel hose
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2 - 47
CABLE ROUTING SPEC
È Install the rollover valve to canister hose with the Ì Route the canister to throttle body hose through
paint mark facing up. the guide.
É Install the fuel tank to rollover valve hose with Í Install the canister to throttle body hose and the
the paint mark facing to the left. rollover valve to canister hose onto the canister,
Ê Fasten the canister to throttle body hose with the making sure they contact the canister body.
plastic holder between the stoppers on the hose.
Ë Align the plastic clips with the paint marks on the
canister to throttle body hose.
t
ne
e.
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2 - 48
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
t
ne
SIDE COVER MOULDINGS AND FOOTREST BOARDS ........................3-7
e.
FRONT COWLING .................................................................................... 3-8
m
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AIR FILTER CASES ......................................................................................3-10
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ENGINE .........................................................................................................3-11
ADJUSTING THE VALVE CLEARANCE ................................................ 3-11
.S
t
ne
CHECKING AND CHARGING THE BATTERY....................................... 3-49
e.
CHECKING THE FUSES ........................................................................3-54
m
REPLACING THE HEADLIGHT BULBS ................................................. 3-56
Ti
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-58
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INTRODUCTION/PERIODIC MAINTENANCE CHART CHK
FOR THE EMISSION CONTROL SYSTEM ADJ
EAS00036
t
ne
Fuel line • Check fuel hoses for cracks or damage.
1 * √ √ √ √ √
(See page 3-30.) • Replace if necessary.
e.
• Check condition.
m
Spark plug • Adjust gap and clean.
2 √ √ Replace. √ √
Ti
(See page 3-18.) • Replace every 19000 km (12000 mi) or
18 months.
Valve clearance • Check and adjust valve clearance when er
ot
3 * Every 42000 km (26600 mi)
(See page 3-11.) engine is cold.
co
Crankcase
• Check breather hose for cracks or damage.
.S
4 * breather system √ √ √ √ √
• Replace if necessary.
(See page 3-31.)
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Electronic fuel
√ √ √ √ √ √
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Evaporative emis-
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Air induction sys- • Check the air cut-off valve, reed valve, and
√
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* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
D
3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CHK
CONTROL SYSTEM ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL ODOMETER READINGS
1000 km 7000 km 13000 km 19000 km 25000 km 31000 km
NO. ITEM ROUTINE (600 mi) (4000 mi) (8000 mi) (12000 mi) (16000 mi) (20000 mi)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
Air filter elements
1 • Replace. Every 19000 km (12000 mi)
(See page 3-28.)
V-belt case air fil-
2 ter element • Clean. √ √ √ √ √
(See page 3-29.)
Front brake • Check operation, fluid level, and for fluid leak-
3 * (See pages 3-38, age. √ √ √ √ √ √
39, 40.) • Replace brake pads if necessary.
Rear brake • Check operation, fluid level, and for fluid leak-
4 * (See pages 3-38, age. √ √ √ √ √ √
39, 40.) • Replace brake pads if necessary.
• Check for cracks or damage. √ √ √ √ √
t
Brake hoses
ne
5 *
(See page 3-39.) • Replace. Every 4 years
e.
Rear brake lock • Check operation.
6 √ √ √ √ √ √
m
(See page 3-37.) • Adjust.
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Wheels • Check runout and for damage.
7 * √ √ √ √ √
(See page 3-47.) • Replace if necessary.
• Check tread depth and for damage. er
ot
Tires • Replace if necessary.
√ √ √ √ √
co
8 *
(See page 3-44.) • Check air pressure.
• Correct if necessary.
.S
9 * √ √ √ √ √
(See page 4-4.) • Replace if necessary.
w
√ √ √ √ √ √
w
Sidestand switch
14 * • Check operation and replace if necessary. √ √ √ √ √ √
(See page 8-4.)
Front fork • Check operation and for oil leakage.
15 * √ √ √ √ √
(See page 3-43.) • Replace if necessary.
Shock absorber
• Check operation and for oil leakage.
16 * assemblies √ √ √ √ √
• Replace if necessary.
(See page 4-67.)
3-2
PERIODIC MAINTENANCE CHART FOR THE EMISSION CHK
CONTROL SYSTEM ADJ
INITIAL ODOMETER READINGS
1000 km 7000 km 13000 km 19000 km 25000 km 31000 km
NO. ITEM ROUTINE (600 mi) (4000 mi) (8000 mi) (12000 mi) (16000 mi) (20000 mi)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
Final transmission
• Check vehicle for oil leakage.
20 oil √ √ √
• Change.
(See page 3-27.)
V-belt
21 * • Replace. Every 20000 km (12500 mi)
(See page 5-37.)
Front and rear
22 * brake switches • Check operation. √ √ √ √ √ √
(See page 8-4.)
Throttle grip hous- • Check operation and free play.
ing and cable • Adjust the throttle cable free play if neces-
23 * √ √ √ √ √
(See pages 3-18, sary.
47.) • Lubricate the throttle grip housing and cable.
Lights, signals and
• Check operation.
24 * switches √ √ √ √ √ √
t
• Adjust headlight beam.
ne
(See page 3-58.)
e.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
m
NOTE:
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From 37000 km (24000 mi) or 36 months, repeat the maintenance intervals starting from 13000 km
(8000 mi) or 12 months.
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NOTE:
.S
● The air filters and V-belt filter need more frequent service if you are riding in unusually wet or dusty
w
areas.
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• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
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check the brake fluid levels and fill the reservoirs as required.
fro
• Every two years replace the internal components of the brake master cylinders and calipers, and
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• Replace the brake hoses every four years and if cracked or damaged.
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D
3-3
CHK
COWLING AND COVERS ADJ
COWLING AND COVERS
PASSENGER SEAT AND SIDE COVERS
T.
R.
4 3
5 7
6
t
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6
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1
.S
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2
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7
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nl
Removing the passenger seat and Remove the parts in the order listed.
D
side covers
1 Upper rear cover 1
2 Lower rear cover 1
3 Grab bar cover 1
4 Passenger seat 1
5 Grab bar 1
6 Cap 2
7 Side cover (left and right) 2
For installation, reverse the removal pro-
cedure.
3-4
CHK
COWLING AND COVERS ADJ
T.
R.
13
12
3
T.
R.
5
6
t
ne
1 14
e.
(4)
m
2 30 Nm (3.0 m • kg, 22 ft • Ib)
15
Ti
T.
R.
11
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10
.S
9
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8
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nl
Removing the rider seat and storage Remove the parts in the order listed.
D
box
Side cover (left and right) Refer to “PASSENGER SEAT AND SIDE
COVERS”.
1 Fuel tank cap 1
2 Cover 1
3 Rider seat 1
4 Upper cover 1
5 Clip 1
6 Gas spring assembly 1 NOTE:
Install the gas spring assembly to the
frame and bottom plate with its rod side
backward and labels upward.
3-5
CHK
COWLING AND COVERS ADJ
T.
R.
13
12
3
T.
R.
5
6
t
ne
1 14
e.
(4)
m
2 30 Nm (3.0 m • kg, 22 ft • Ib)
15
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T.
R.
11
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10
.S
9
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7 Bottom plate 1
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3-6
CHK
COWLING AND COVERS ADJ
EAS00040
2
R.
t
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5
e.
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1
3
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2
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nl
Removing the side cover mouldings Remove the parts in the order listed.
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3-7
CHK
COWLING AND COVERS ADJ
EAS00042
FRONT COWLING
T.
R.
11
12
6
t
ne
3
e.
7
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8
1
5
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4
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.S
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13
m
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9 10
d
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nl
Removing the front cowling Remove the parts in the order listed.
D
3-8
CHK
COWLING AND COVERS ADJ
T.
R.
11
12
6
t
ne
3
e.
7
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8
1
5
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4
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13
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9 10
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12 Storage compartment 1
13 Radiator cover 1
For installation, reverse the removal pro-
cedure.
3-9
CHK
AIR FILTER CASES ADJ
AIR FILTER CASES
5 2
t
ne
3
e.
m
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7
.S
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Removing the air filter cases Remove the parts in the order listed.
D
3 - 10
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00048
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
_
1 1. Remove:
• storage box
Refer to “RIDER SEAT AND STORAGE
t
ne
BOX”.
e.
2. Remove:
• V-belt case air filter cover 1
m
Ti
• V-belt case air filter element
er
ot
3. Remove:
co
2 • timing plug
.S
• spark plug
w
1 • rubber sheet 1
w
4. Measure:
• valve clearance
nl
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the primary sheave nut on the left side
of the crankshaft counterclockwise to turn
the crankshaft.
b. Align the “I” mark a on the generator rotor
with the stationary pointer b on the genera-
tor rotor cover to position the piston at TDC
on the compression stroke.
3 - 11
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
NOTE:
_
t
ne
measured reading.
e.
1
m
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Ti
5. Remove:
er
• intake camshaft
ot
• exhaust camshaft
co
NOTE:
.S
6. Adjust:
• valve clearance
nl
ow
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve lifter 1 and the valve pad
D
Valve lapper
90890-04101
NOTE:
_
3 - 12
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
b. Select the proper valve pad from the follow-
ing table.
NOTE:
_
t
ne
nally installed, the valve pad number must be
rounded in order to reach the closest equiva-
e.
lent to the original.
m
Ti
er
c. Round off the original valve pad number
ot
according to the following table.
co
0 or 2 0
w
w
5 5
m
8 10
fro
EXAMPLE:
d
3 - 13
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
NOTE:
_
t
T.
R.
ne
NOTE:
e.
_
m
Ti
• Lubricate the camshaft bearings, camshaft
er
lobes and camshaft journals.
ot
• First, install the exhaust camshaft.
co
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
nl
ow
D
3 - 14
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
INTAKE
MEASURED INSTALLED PAD NUMBER
CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.10 ~ 0.14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.15 ~ 0.20 STANDARD CLEARANCE
0.21 ~ 0.25 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.26 ~ 0.30 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.31 ~ 0.35 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.36 ~ 0.40 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.41 ~ 0.45 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.46 ~ 0.50 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.51 ~ 0.55 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.56 ~ 0.60 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.61 ~ 0.65 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.66 ~ 0.70 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.71 ~ 0.75 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.76 ~ 0.80 180 185 190 195 200 205 210 215 220 225 230 235 240
t
ne
0.81 ~ 0.85 185 190 195 200 205 210 215 220 225 230 235 240
0.86 ~ 0.90 190 195 200 205 210 215 220 225 230 235 240 VALVE CLEARANCE (cold):
e.
0.91 ~ 0.95 195 200 205 210 215 220 225 230 235 240 0.15
~ 0.20 mm (0.0059 ~ 0.0079 in)
m
0.96 ~ 1.00 200 205 210 215 220 225 230 235 240
Example: 175 pad is installed
1.01 ~ 1.05 205 210 215 220 225 230 235 240
Ti
1.06 ~ 1.10 210 215 220 225 230 235 240 Measured clearance is 0.27 mm
1.11 ~ 1.15 215 220 225 230 235 240
er(0.0106 in)
ot
1.16 ~ 1.20 220 225 230 235 240 Replace pad 175 with pad 185
co
1.21 ~ 1.25 225 230 235 240 Pad number: (example)
1.26 ~ 1.30 230 235 240 Pad No. 175 = 1.75 mm (0.0689 in)
.S
1.31 ~ 1.35 235 240 Pad No. 185 = 1.85 mm (0.0728 in)
w
EXHAUST
w
m
0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
d
0.10 ~ 0.14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
de
0.15 ~ 0.19 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
oa
0.20 ~ 0.24 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.25 ~ 0.30 STANDARD CLEARANCE
nl
0.31 ~ 0.35 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
ow
0.36 ~ 0.40 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.41 ~ 0.45 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
D
0.46 ~ 0.50 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.51 ~ 0.55 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.56 ~ 0.60 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.61 ~ 0.65 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.66 ~ 0.70 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.71 ~ 0.75 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.76 ~ 0.80 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.81 ~ 0.85 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.86 ~ 0.90 180 185 190 195 200 205 210 215 220 225 230 235 240
0.91 ~ 0.95 185 190 195 200 205 210 215 220 225 230 235 240
0.96 ~ 1.00 190 195 200 205 210 215 220 225 230 235 240 VALVE CLEARANCE (cold):
1.01 ~ 1.05 195 200 205 210 215 220 225 230 235 240 0.25
~ 0.30 mm (0.0098 ~ 0.0118 in)
1.06 ~ 1.10 200 205 210 215 220 225 230 235 240
Example: 175 pad is installed
1.11 ~ 1.15 205 210 215 220 225 230 235 240
1.16 ~ 1.20 210 215 220 225 230 235 240 Measured clearance is 0.37 mm
1.21 ~ 1.25 215 220 225 230 235 240 (0.0146 in)
1.26 ~ 1.30 220 225 230 235 240 Replace pad 175 with pad 185
1.31 ~ 1.35 225 230 235 240 Pad number: (example)
1.36 ~ 1.40 230 235 240 Pad No. 175 = 1.75 mm (0.0689 in)
1.41 ~ 1.45 235 240 Pad No. 185 = 1.85 mm (0.0728 in)
1.46 ~ 1.50 240
3 - 15
ADJUSTING THE VALVE CLEARANCE/ CHK
ADJUSTING THE EXHAUST GAS VOLUME ADJ
7. Install:
• all removed parts
Refer to “CYLINDER HEAD” in chapter 5.
NOTE:
_
EAS00869
ADJUSTING THE EXHAUST GAS VOLUME
NOTE:
_
t
ne
1. Turn the main switch to “OFF” and set the
e.
engine stop switch to “ON”.
m
Ti
2. Simultaneously press and hold the
er
“SELECT” and “RESET” buttons, turn the
ot
main switch to “ON”, and continue to press
co
NOTE:
_
w
mode “dIAG”.
4. After selecting “CO”, simultaneously press
D
3 - 16
ADJUSTING THE EXHAUST GAS VOLUME/ CHK
CHECKING THE ENGINE IDLING SPEED ADJ
5. Check that “C1” appears on the odometer
LCD, and then simultaneously press the
“SELECT” and “RESET” buttons for 2 sec-
onds or more.
6. Change the CO adjustment volume by
pressing the “SELECT” and “RESET” but-
tons.
NOTE:
_
t
ne
7. Release the “RESET” and “SELECT” but-
e.
tons to execute the selection.
m
8. Turn the main switch to “OFF” to cancel the
Ti
mode.
er
ot
EAS00054
co
CHECKING THE ENGINE IDLING SPEED
.S
NOTE:
_
2. Remove:
• storage box lower plate
oa
BOX”.
ow
3. Check:
D
4. Install:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
3 - 17
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHK
CHECKING THE SPARK PLUG ADJ
EAS00056
ADJUSTING THE THROTTLE CABLE FREE
PLAY
1. Check:
• throttle cable free play a
Out of specification → Adjust.
a
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
• throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting nut 2 in direction a or
t
a b until the specified throttle cable free play
ne
is obtained.
e.
m
1b 2 Throttle cable free play
Ti
Direction a
is increased.
er
ot
Throttle cable free play
Direction b
co
is decreased.
.S
WARNING
w
change.
oa
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
nl
ow
D
EAS00060
CHECKING THE SPARK PLUG
1. Remove:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Disconnect:
• spark plug cap
3 - 18
CHK
CHECKING THE SPARK PLUG ADJ
3. Remove:
• spark plug
CAUTION:
_
4. Check:
• spark plug type
Incorrect → Change.
t
ne
5. Check:
• electrode 1
e.
Damage/wear → Replace the spark plug.
m
Ti
• insulator 2
er
Abnormal color → Replace the spark plug.
ot
Normal color is medium-to-light tan.
co
6. Clean:
.S
• spark plug
w
7. Measure:
w
8. Install:
ow
NOTE:
_
9. Connect:
• spark plug cap
10.Install:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
3 - 19
CHK
CHECKING THE IGNITION TIMING ADJ
EAS00064
CHECKING THE IGNITION TIMING
NOTE:
_
1. Remove:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
1 2. Remove:
• timing plug
3. Connect:
t
• timing light 1
ne
e.
Timing light
m
90890-03141, YU-03141
Ti
4. Check:
er
ot
• ignition timing
co
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
.S
system.
ow
NOTE:
D
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• timing plug 8 Nm (0.8 m · kg, 5.8 ft · lb)
T.
R.
6. Install:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
3 - 20
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
EAS00067
MEASURING THE COMPRESSION
PRESSURE
NOTE:
_
1. Remove:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
t
ne
CLEARANCE”.
3. Start the engine, warm it up for several min-
e.
utes, and then turn it off.
m
4. Disconnect:
Ti
• spark plug cap
er
ot
5. Remove:
co
• spark plug
.S
CAUTION:
w
6. Install:
• compression gauge 1
nl
1
ow
Compression gauge
D
90890-03081, YU-33223
Adapter (compression gauge)
90890-04082
3 - 21
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
7. Measure:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
t
ne
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
e.
m
b. With the throttle wide open, crank the
Ti
engine until the reading on the compression
er
gauge stabilizes.
ot
WARNING
co
measure again.
D
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Higher than with- Piston wear or
out oil damage → Repair.
Piston rings,
valves, cylinder
Same as without
head gasket or pis-
oil
ton possibly defec-
tive → Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 22
MEASURING THE COMPRESSION PRESSURE/ CHK
CHECKING THE ENGINE OIL LEVEL ADJ
8. Install:
• spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.
9. Connect:
• spark plug cap
10.Install:
• storage box lower plate
Refer to “RIDER SEAT AND STORAGE
BOX”.
EAS00072
CHECKING THE ENGINE OIL LEVEL
1. Stand the scooter on a level surface.
NOTE:
_
t
ne
• Make sure the scooter is upright.
e.
2. Start the engine, warm it up for several min-
m
Ti
utes, and then turn it off.
er
3. Check:
ot
• engine oil level
co
1
w
mark b.
fro
Recommended oil
oa
0 10 30 50 70 90 110 130 ˚F
At 5 °C (40 °F) or higher
nl
3 - 23
CHECKING THE ENGINE OIL LEVEL/ CHK
CHANGING THE ENGINE OIL ADJ
NOTE:
_
t
ne
e.
m
Ti
er
ot
EAS00076
co
CHANGING THE ENGINE OIL
1. Remove:
.S
1
Refer to “RIDER SEAT AND STORAGE
w
w
BOX”.
m
bolt.
de
4. Remove:
oa
5. Drain:
• engine oil
(completely from the crankcase)
3 - 24
CHK
CHANGING THE ENGINE OIL ADJ
6. If the oil filter element is also to be replaced,
perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Remove the oil filter element cover 1 and
oil filter element 2.
b. Install new O-rings 3.
c. Install the new oil filter element and the oil
filter element cover.
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
t
ne
e.
1 3 2 3
m
Ti
er
ot
7. If the oil strainer is also to be cleaned, per-
co
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
w
3 strainer 2.
w
1 1
Oil strainer cover
d
de
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
nl
8. Check:
ow
9. Install:
• engine oil drain bolt
(along with the gasket)
20 Nm (2.0 m · kg, 14 ft · lb)
T.
R.
3 - 25
CHK
CHANGING THE ENGINE OIL ADJ
10.Fill:
• crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
1.70 L (1.50 Imp qt, 1.80 US qt)
Without oil filter element
replacement
1.50 L (1.32 Imp qt, 1.59 US qt)
With oil filter element replace-
ment
1.70 L (1.50 Imp qt, 1.80 US qt)
11.Install:
• engine oil filler cap
t
ne
12.Start the engine, warm it up for several min-
e.
utes, and then turn it off.
m
13.Check:
Ti
• engine
er
(for engine oil leaks)
ot
14.Check:
co
LEVEL”.
w
15.Check:
w
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil gallery bolt 1.
d
seize.
c. Check the engine oil passages, the oil filter
D
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 26
CHANGING THE ENGINE OIL/ CHK
CHANGING THE TRANSMISSION OIL ADJ
16.Reset:
• engine oil change indicator
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the key to “ON”.
b. Hold the reset button 1 pushed for two to
eight seconds.
c. Release the reset button and the engine oil
1 change indicator will go off.
NOTE:
If the engine oil is changed before the engine
oil change indicator comes on (i.e. before the
periodic engine oil change interval has been
reached), the indicator must be reset after the
engine oil change for the next periodic engine
oil change to be indicated at the correct time.
t
ne
To reset the engine oil change indicator before
e.
the periodic engine oil change interval has
m
been reached, follow the above procedure, but
Ti
note that the indicator will come on for 1.4 sec-
er
onds after releasing the reset button, other-
ot
wise repeat the procedure.
co
.S
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
w
17.Install:
w
BOX”.
fro
d
de
oa
NOTE:
• Place the scooter on a suitable stand.
D
3 - 27
CHANGING THE TRANSMISSION OIL/ CHK
REPLACING THE AIR FILTER ELEMENTS ADJ
7. Fill:
• transmission case
(with the specified amount of the recom-
mended transmission oil)
Recommended oil
SAE 10W30 type SE motor oil
Quantity
0.25 L (0.22 Imp qt, 0.26 US qt)
8. Install:
• transmission oil filler plug 1
1 1 • O-ring 2
9. Start the engine, warm it up for several min-
2 utes, and then turn it off.
10.Check:
t
ne
• transmission case
e.
(for transmission oil leaks)
m
Ti
er
ot
EAS00088
È
co
REPLACING THE AIR FILTER ELEMENTS
The following procedure applies to both air fil-
.S
ter elements.
w
1
1. Remove:
w
w
É
nl
ow
1
D
2. Check:
1 • air filter element 1
Damage → Replace.
NOTE:
Replace the air filter element every 20,000 km.
The air filter needs more frequent service if
you are riding in unusually wet or dusty areas.
3 - 28
REPLACING THE AIR FILTER ELEMENTS/ CHK
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ADJ
3. Install:
• air filter element
• air filter case cover
(along with the gasket)
CAUTION:
_
t
ne
NOTE:
_
e.
filter case cover, be sure their sealing surfaces
m
are aligned to prevent any air leaks.
Ti
er
ot
EAS00091
co
CLEANING THE V-BELT CASE AIR FILTER
ELEMENT
.S
1 1. Remove:
w
BOX”.
fro
2. Remove:
• V-belt case air filter cover 1
d
3. Clean:
nl
5. Install:
• V-belt case air filter element
• V-belt case air filter cover seal
• V-belt case air filter cover
• V-belt case air filter cover screw
3 - 29
CLEANING THE V-BELT CASE AIR FILTER ELEMENT/
CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD/ CHK
CHECKING THE FUEL HOSE
ADJ
6. Install:
• footrest board (left)
Refer to “RIDER SEAT AND STORAGE
BOX”.
EAS00094
CHECKING THE THROTTLE BODY JOINT
AND INTAKE MANIFOLD
1. Remove:
• storage box
t
Refer to “RIDER SEAT AND STORAGE
ne
1
BOX”.
e.
2 2. Check:
m
• throttle body joint 1
Ti
• intake manifold 2
er
Cracks/damage → Replace.
ot
Refer to “CYLINDER HEAD” in chapter 5.
co
3. Install:
.S
• storage box
w
BOX”.
m
fro
d
de
oa
EAS00096
1. Remove:
ow
• storage box
D
3 - 30
CHK
CHECKING THE BREATHER HOSES ADJ
EAS00098
CHECKING THE BREATHER HOSES
1. Remove:
• storage box
Refer to “RIDER SEAT AND STORAGE
BOX”.
2. Check:
3 • crankcase breather hose 1
• transmission case breather hose 2
Cracks/damage → Replace.
Loose connection → Connect properly.
t
ne
CAUTION:
e.
1 _
m
correctly.
Ti
3. er
Remove:
ot
catch tank 3
co
•
4. Clean:
.S
• catch tank
w
2
w
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
w
clean water.
fro
3 - 31
CHECKING THE EXHAUST SYSTEM/ CHK
CHECKING THE COOLANT LEVEL ADJ
EAS00099
CHECKING THE EXHAUST SYSTEM
3 The following procedure applies to all of the
exhaust pipes and gaskets.
1. Remove:
1 • footrest board (right)
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
2. Check:
• exhaust pipe 1
• muffler 2
Cracks/damage → Replace.
5 • gasket
Exhaust gas leaks → Replace.
3. Check:
t
• tightening torque
ne
e.
5 Exhaust pipe nut 3
m
2 20 Nm (2.0 m · kg, 14 ft · lb)
5 4 T.
Ti
R.
er
14 Nm (1.4 m · kg, 10 ft · lb)
Muffler mounting bolt 5
ot
53 Nm (5.3 m · kg, 38 ft · lb)
co
.S
4. Install:
w
FOOTREST BOARDS”.
m
fro
d
de
oa
EAS00103
CHECKING THE COOLANT LEVEL
nl
NOTE:
D
2. Remove:
• coolant reservoir cover
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
a b 3. Check:
• coolant level
The coolant level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.
3 - 32
CHECKING THE COOLANT LEVEL/ CHK
CHECKING THE COOLING SYSTEM ADJ
CAUTION:
_
t
ne
NOTE:
_
e.
minutes until it settles.
m
Ti
er
6. Install:
ot
• coolant reservoir cover
co
FOOTREST BOARDS”.
w
w
w
m
fro
d
de
oa
EAS00104
4 CHECKING THE COOLING SYSTEM
nl
1. Remove:
ow
3 - 33
CHECKING THE COOLING SYSTEM/ CHK
CHANGING THE COOLANT ADJ
3. Install:
• footrest boards (left and right)
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
EAS00105
CHANGING THE COOLANT
1. Remove:
• storage box
• footrest board (right)
t
Refer to “SIDE COVER MOULDINGS AND
ne
FOOTREST BOARDS”.
e.
2. Disconnect:
m
1 • coolant reservoir hose 1
Ti
3. Drain:
• coolant er
ot
(from the coolant reservoir)
co
4. Remove:
.S
• radiator cap 1
w
w
WARNING
m
5. Remove:
• coolant drain bolt 1
1 (along with the copper washer)
6. Drain:
• coolant
(from the engine and radiator)
3 - 34
CHK
CHANGING THE COOLANT ADJ
7. Install:
• copper washer New
• coolant drain bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
1 8. Connect:
• coolant reservoir hose
9. Remove:
• air bleed bolt (coolant) 1
10.Fill:
• cooling system
(with the specified amount of the recom-
mended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
t
ne
inhibitors for aluminum engines
e.
Mixing ratio
m
1:1 (antifreeze:water)
Quantity
Ti
Total amount
er 1.57 L (1.38 Imp qt, 1.66 US qt)
ot
Coolant reservoir capacity
co
NOTE:
w
WARNING
_
3 - 35
CHK
CHANGING THE COOLANT ADJ
CAUTION:
_
t
11.Install:
ne
• air bleed bolt (coolant)
e.
6 Nm (0.6 m · kg, 4.3 ft · lb)
m T.
R.
12.Install:
Ti
• radiator cap
13.Fill:er
ot
• coolant reservoir
co
a
(with the recommended coolant to the maxi-
.S
14.Install:
w
w
• coolant level
de
LEVEL”.
nl
NOTE:
ow
17.Install:
• storage box
• footrest board (right)
Refer to “SIDE COVER MOULDINGS AND
FOOTREST BOARDS”.
3 - 36
CHK
ADJUSTING THE REAR BRAKE LOCK LEVER CABLE ADJ
EAS00116
CHASSIS
ADJUSTING THE REAR BRAKE LOCK
LEVER CABLE
NOTE:
• Place the scooter on a suitable stand.
• Before adjusting the rear brake lock lever,
check the rear brake fluid level.
1. Measure:
• rear brake lock lever cable length a
a Out of specification → Adjust.
1
Rear brake lock lever cable length
b 45 ~ 47 mm (1.77 ~ 1.85 in)
t
ne
2. Adjust:
e.
c • rear brake lock lever cable length
m
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Ti
a. Turn the adjusting nut 1 in direction b or
er
c until the rear brake lock lever cable
ot
length a is 42 ~ 44 mm (1.65 ~ 1.73 in)
co
than 5 minutes.
d. Release the rear brake lock lever.
m
increased.
D
3 - 37
CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
È CHECKING THE BRAKE FLUID LEVEL
a 1. Stand the scooter on a level surface.
NOTE:
_
2. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
É level.
a
Recommended brake fluid
DOT 4
t
È Front brake
ne
É Rear brake
e.
WARNING
m
_
Ti
• Use only the designated brake fluid.
er
Other brake fluids may cause the rubber
ot
seals to deteriorate, causing leakage and
co
performance.
fro
CAUTION:
D
NOTE:
_
3 - 38
CHECKING THE FRONT AND REAR BRAKE PADS/ CHK
CHECKING THE FRONT AND REAR BRAKE HOSES ADJ
EAS00118
È CHECKING THE FRONT AND REAR BRAKE
PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• front brake pad
Wear indicator groove a almost disap-
peared → Replace the brake pads as a set.
Refer to “REPLACING THE FRONT
É BRAKE PADS” in chapter 4.
• rear brake pad
Wear indicator a almost touch the brake
disc → Replace the brake pads as a set.
t
Refer to “REPLACING THE REAR BRAKE
ne
PADS” in chapter 4.
e.
È Front brake
m
É Rear brake
Ti
er
ot
EAS00132
È
co
CHECKING THE FRONT AND REAR BRAKE
1 HOSES
.S
1. Check:
• brake hose 1
m
Cracks/damage/wear → Replace.
fro
È Front brake
d
É Rear brake
de
2. Check:
oa
1
ow
4. Check:
• brake hose
Brake fluid leakage → Replace the dam-
aged hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
3 - 39
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00134
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
_
NOTE:
_
t
ne
flow.
e.
• When bleeding the hydraulic brake system,
m
make sure there is always enough brake
Ti
fluid before applying the brake. Ignoring this
er
precaution could allow air to enter the
ot
hydraulic brake system, considerably length-
co
È 1. Bleed:
• hydraulic brake system
nl
ow
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2 a. Fill the brake master cylinder reservoir to
D
3 - 40
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
g. Loosen the bleed screw.
NOTE:
_
Bleed screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
t
T.
R.
ne
k. Fill the brake fluid reservoir to the proper
e.
level with the recommended brake fluid.
m
Refer to “CHECKING THE BRAKE FLUID
Ti
LEVEL”.
er
ot
WARNING
co
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
w
m
fro
d
de
oa
EAS00148
CHECKING AND ADJUSTING THE
nl
STEERING HEAD
ow
WARNING
_
NOTE:
_
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3 - 41
CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
3. Remove:
• lower handlebar holder
Refer to “STEERING HEAD” in chapter 4.
4. Adjust:
• steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the upper steering ring nut 1, the
lock washer 2, the center steering ring nut
3 and the rubber washer.
b. Loosen the lower steering ring nut 4 and
then tighten it to specification with the steer-
ing nut wrench 5.
NOTE:
_
t
ne
e.
Steering nut wrench
m
90890-01403, YU-A9472
Ti
er
ot
Lower steering ring nut (initial
co
tightening torque)
T.
R.
WARNING
d
_
de
T.
R.
3 - 42
CHECKING AND ADJUSTING THE STEERING HEAD/ CHK
CHECKING THE FRONT FORK ADJ
g. Finger tighten the center steering ring nut,
and then align the slots of both ring nuts. If
necessary, hold the lower steering ring nut
and tighten the center steering ring nut until
their slots are aligned.
h. Install the lock washer 1.
NOTE:
_
t
ne
Steering nut wrench
e.
90890-01403, YU-A9472
m
Ti
er
Upper steering ring nut
ot
90 Nm (9.0 m · kg, 65 ft · lb)
T.
co R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
.S
5. Install:
w
w
EAS00151
CHECKING THE FRONT FORK
nl
WARNING
D
2. Check:
• inner tube
Damage/scratches → Replace.
• oil seal
Oil leakage → Replace.
3. Hold the scooter upright and apply the front
brake.
3 - 43
CHECKING THE FRONT FORK/ CHK
CHECKING THE TIRES ADJ
4. Check:
• front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 4.
EAS00165
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
t
• tire pressure
ne
Out of specification → Regulate.
e.
m
WARNING
Ti
_
riding speed.
m
injury.
de
Basic weight
ow
Maximum
196 kg (432 lb)
load*
Cold tire pres-
Front Rear
sure
200 kPa 250 kPa
Up to 90 kg
(2.00 kgf/cm2, (2.50 kgf/cm2,
load*
29 psi) 36 psi)
200 kPa 250 kPa
90 kg ~ maxi-
(2.00 kgf/cm2, (2.50 kgf/cm2,
mum load*
29 psi) 36 psi)
200 kPa 250 kPa
High-speed
(2.00 kgf/cm2, (2.50 kgf/cm2,
riding
29 psi) 36 psi)
* Total weight of rider, passenger, cargo and
accessories
3 - 44
CHK
CHECKING THE TIRES ADJ
WARNING
_
2. Check:
• tire surfaces
Damage/wear → Replace the tire.
t
ne
WARNING
e.
_
m
designed only for tube tires to avoid tire
Ti
failure and personal injury from sudden
er
deflation.
ot
• When using tube tires, be sure to install
co
tube as a set.
w
È Tire
ow
É Wheel
D
3 - 45
CHK
CHECKING THE TIRES ADJ
Front tire
Manufacturer Size Model
120/80-
DUNLOP 14M/C D305FL
58S
120/80-
IRC 14M/C MB 67
58S
Rear tire
Manufacturer Size Model
150/70-
DUNLOP 13M/C D305L
64S
t
ne
150/70-
e.
IRC 13M/C MB 67
m
64S
Ti
er
ot
WARNING
co
NOTE:
ow
3 - 46
CHECKING THE WHEELS/ CHK
CHECKING AND LUBRICATING THE CABLES ADJ
EAS00168
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
• wheel
Damage/out-of-round → Replace.
WARNING
_
NOTE:
_
t
ne
e.
m
Ti
er
ot
EAS00170
co
CHECKING AND LUBRICATING THE
CABLES
.S
WARNING
m
1. Check:
ow
• outer cable
Damage → Replace.
D
2. Check:
• cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
_
3 - 47
LUBRICATING THE LEVERS/LUBRICATING THE CHK
SIDESTAND/LUBRICATING THE CENTERSTAND ADJ
EAS00171
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Recommended lubricant
Lithium-soap-based grease
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
t
ne
Lithium-soap-based grease
e.
m
Ti
er
ot
EAS00173
co
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
.S
Recommended lubricant
w
Lithium-soap-based grease
m
fro
d
de
oa
nl
ow
D
3 - 48
CHK
CHECKING AND CHARGING THE BATTERY ADJ
EAS00179
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
_
t
ne
lighted cigarettes).
e.
• DO NOT SMOKE when charging or han-
m
dling batteries.
Ti
• KEEP BATTERIES AND ELECTROLYTE
er
OUT OF REACH OF CHILDREN.
ot
• Avoid bodily contact with electrolyte as it
co
injury.
w
EXTERNAL
w
INTERNAL
de
attention.
D
CAUTION:
_
3 - 49
CHK
CHECKING AND CHARGING THE BATTERY ADJ
NOTE:
_
1. Remove:
• upper rear cover
1 Refer to “PASSENGER SEAT AND SIDE
2 COVERS”.
2. Disconnect:
• battery leads
(from the battery terminals)
t
ne
CAUTION:
e.
_
m
1, and then the positive battery lead 2.
Ti
er
ot
3. Remove:
co
• battery
.S
4. Check:
• battery charge
w
w
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
w
nals.
fro
NOTE:
ow
3 - 50
CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging 5. Charge:
Ambient temperature 20 °C (68 °F)
• battery
Open-circuit voltage (V)
t
ne
damage.
e.
• If it is impossible to regulate the charging
m
current on the battery charger, be careful
Ti
Charging condition of the battery (%)
not to overcharge the battery.
er
• When charging a battery, be sure to
ot
remove it from the scooter. (If charging
co
battery.
d
3 - 51
CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging method using a variable-current (voltage) charger
Charger
Ammeter NOTE:
Leave the battery unused for
Measure the open-circuit more than 30 minutes before
voltage prior to charging. measuring its open-circuit voltage.
NOTE:
Set the charging voltage to
Connect a charger and
16 ~ 17 V. (If the charging
ammeter to the battery and
voltage is lower, charging will
start charging.
be insufficient, if it is higher,
the battery will be over-
charged.)
Is the amperage higher
YES than the standard charging NO
amperage written on the
battery?
t
ne
e.
Adjust the charging voltage to
m
20 ~ 25 V.
Ti
er
ot
co
NO
m
fro
d
Leave the battery unused for more than 30 minutes before measuring its
open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
3 - 52
CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging method using a constant voltage charger
NOTE:
Measure the open-circuit Leave the battery unused for
voltage prior to charging. more than 30 minutes before
measuring its open-circuit voltage.
t
than the standard charging
ne
amperage written on the
e.
battery?
m
Ti
er
ot
Charge the battery until the charging This type of battery charger cannot
co
mum of 20 hours.
w
m
fro
Charger
d
de
voltage.
nl
CAUTION:
Constant amperage chargers are
not suitable for charging MF bat-
teries.
3 - 53
CHECKING AND CHARGING THE BATTERY/ CHK
CHECKING THE FUSES ADJ
6. Install:
2
1 • battery
7. Connect:
• battery leads
(to the battery terminals)
CAUTION:
_
8. Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
t
• battery terminals
ne
e.
Recommended lubricant
m
Dielectric grease
Ti
10.Install:
er
ot
• upper rear cover
co
COVERS”.
w
w
w
m
fro
d
de
oa
EAS00181
CHECKING THE FUSES
nl
fuses.
D
CAUTION:
_
1. Remove:
• side covers (left and right)
Refer to “PASSENGER SEAT AND SIDE
COVERS”.
3 - 54
CHK
CHECKING THE FUSES ADJ
2. Check:
• fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
_
Pocket tester
90890-03112, YU-03112-C
t
3. Replace:
ne
• blown fuse
e.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
m
a. Set the main switch to “OFF”.
Ti
b. Install a new fuse of the correct amperage
rating.er
ot
c. Set on the switches to verify if the electrical
co
circuit is operational.
.S
Amperage
m
Fuses Q’ty
rating
fro
Main 40 A 1
d
de
Headlight 20 A 1
oa
Signaling system 10 A 1
nl
ow
Ignition 10 A 1
D
3 - 55
CHECKING THE FUSES/ CHK
REPLACING THE HEADLIGHT BULBS ADJ
WARNING
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• side covers (left and right)
Refer to “PASSENGER SEAT AND SIDE
COVERS”.
t
ne
e.
m
Ti
er
ot
EAS00183
co
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
.S
headlight bulbs.
w
1. Remove:
w
w
• front cowling
m
2. Disconnect:
• headlight coupler 1
nl
ow
2 3. Remove:
• headlight bulb holder cover 2
D
4. Detach:
• headlight bulb holder 1
1
3 - 56
CHK
REPLACING THE HEADLIGHT BULBS ADJ
5. Remove:
• headlight bulb 1
1
WARNING
_
6. Install:
• headlight bulb New
Secure the new headlight bulb with the
headlight bulb holder.
CAUTION:
_
t
ne
light bulb to keep it free from oil, otherwise
e.
the transparency of the glass, the life of the
m
bulb and the luminous flux will be
Ti
adversely affected. If the headlight bulb
er
gets soiled, thoroughly clean it with a cloth
ot
moistened with alcohol or lacquer thinner.
co
.S
7. Attach:
w
8. Install:
w
9. Connect:
fro
• headlight coupler
d
10.Install:
de
• front cowling
oa
3 - 57
CHK
ADJUSTING THE HEADLIGHT BEAMS ADJ
EAS00185
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1 1 1. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a b a b
a. Turn the adjusting screw 1 in direction a
or b.
Headlight beam is
Direction a
raised.
Headlight beam is low-
Direction b
ered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
t
ne
e.
m
Ti
er
ot
2. Adjust:
co
1 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b b
w
or b.
w
Direction a
fro
to the right.
Headlight beam moves
d
Direction b
de
to the left.
oa
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
nl
ow
D
3 - 58
CHAS
CHAPTER 4
CHASSIS
t
ne
e.
FRONT AND REAR BRAKES....................................................................... 4-11
m
FRONT BRAKE PADS ............................................................................4-11
Ti
REAR BRAKE PADS............................................................................... 4-12
er
REPLACING THE FRONT BRAKE PADS .............................................. 4-13
ot
REPLACING THE REAR BRAKE PADS................................................. 4-15
co
FRONT FORK................................................................................................4-44
REMOVING THE FRONT FORK LEGS.................................................. 4-48
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-48
CHECKING THE FRONT FORK LEGS .................................................. 4-50
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-50
INSTALLING THE FRONT FORK LEGS ................................................ 4-53
HANDLEBAR ................................................................................................4-54
REMOVING THE HANDLEBAR..............................................................4-56
CHECKING THE HANDLEBAR ..............................................................4-56
INSTALLING THE HANDLEBAR ............................................................ 4-56
CHAS
STEERING HEAD.......................................................................................... 4-60
LOWER BRACKET ................................................................................. 4-60
REMOVING THE LOWER BRACKET.....................................................4-62
CHECKING THE STEERING HEAD .......................................................4-63
INSTALLING THE STEERING HEAD .....................................................4-64
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
FRONT WHEEL AND BRAKE DISC CHAS
EAS00513
CHASSIS
FRONT WHEEL AND BRAKE DISC
T.
R.
T.
R.
1
3
t
2
ne
e.
6
m
Ti
7
er
ot
co
LT
4
.S
w
w
w
m
fro
5
d
de
Removing the front wheel and brake Remove the parts in the order listed.
D
disc
NOTE:
_
4-1
FRONT WHEEL AND BRAKE DISC CHAS
EAS00518
LS
1
2
3
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
2
fro
d
de
oa
nl
Disassembling the front wheel Remove the parts in the order listed.
D
1 Oil seal 1
2 Bearing 2
3 Collar 1
For assembly, reverse the disassembly
procedure.
4-2
FRONT WHEEL AND BRAKE DISC CHAS
EAS00520
REMOVING THE FRONT WHEEL
1. Stand the scooter on a level surface.
WARNING
_
2. Elevate:
• front wheel
NOTE:
_
t
ne
e.
m
Ti
er
ot
EAS00525
co
CHECKING THE FRONT WHEEL
1. Check:
.S
• wheel axle
w
Bends → Replace.
m
WARNING
fro
axle.
de
oa
2. Check:
nl
• tire
ow
• front wheel
Damage/wear → Replace.
D
3. Measure:
• radial wheel runout 1
• lateral wheel runout 2
Over the specified limits → Replace.
4-3
FRONT WHEEL AND BRAKE DISC CHAS
4. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
Damage/wear → Replace.
5. Replace:
• wheel bearings New
• oil seal New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
t
ne
b. Remove the oil seals 1 with a flat-head
e.
screwdriver.
m
NOTE:
Ti
_
CAUTION:
_
NOTE:
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00532
CHECKING THE BRAKE DISCS
The following procedure applies to each brake
disc.
1. Check:
• brake disc
Damage/galling → Replace.
4-4
FRONT WHEEL AND BRAKE DISC CHAS
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the scooter on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is sta-
t
ne
tionary.
c. Remove the brake caliper.
e.
m
d. Hold the dial gauge at a right angle against
Ti
the brake disc surface.
er
e. Measure the deflection 1.5 mm (0.06 in)
ot
below the edge of the brake disc.
co
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
.S
w
w
w
m
fro
d
de
oa
3. Measure:
• brake disc thickness
nl
ow
4-5
FRONT WHEEL AND BRAKE DISC CHAS
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
_
T.
LOCTITE®
R.
d. Measure the brake disc deflection.
t
ne
e. If out of specification, repeat the adjustment
e.
steps until the brake disc deflection is within
m
specification.
Ti
f. If the brake disc deflection cannot be
er
brought within specification, replace the
ot
brake disc.
co
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
.S
w
w
w
m
fro
d
de
oa
EAS00542
INSTALLING THE FRONT WHEEL
nl
1. Lubricate:
ow
• wheel axle
D
• wheel bearings
• oil seal lips
• speed sensor
Recommended lubricant
Lithium-soap-based grease
4-6
FRONT WHEEL AND BRAKE DISC CHAS
2. Install:
• spacer
• speed sensor
• front wheel
NOTE:
_
a 3. Tighten:
• front wheel axle
55 Nm (5.5 m · kg, 40 ft · lb)
T.
R.
• front wheel axle pinch bolt
t
ne
b 20 Nm (2.0 m · kg, 14 ft · lb)
T.
R.
e.
WARNING
m
_
Ti
er
erly. ot
co
CAUTION:
.S
smoothly.
m
fro
d
de
oa
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
nl
BALANCE
ow
NOTE:
D
1. Remove:
• balancing weight(s)
4-7
FRONT WHEEL AND BRAKE DISC CHAS
2. Find:
• front wheel’s heavy spot
NOTE:
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
b. When the front wheel stops, put an “X1”
mark at the bottom of the wheel.
c. Turn the front wheel 90° so that the “X1”
mark is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
t
ne
f. Repeat steps (d) through (f) several times
e.
until all the marks come to rest at the same
m
spot.
Ti
g. The spot where all the marks come to rest
er
is the front wheel’s heavy spot “X”.
ot
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
co
3. Adjust:
.S
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
w
NOTE:
fro
wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays
at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-8
REAR WHEEL AND BRAKE DISC CHAS
EAS00552
t
ne
e.
m
LS
Ti
er LT
ot
co
.S
w
2
w
1 LT
w
m
fro
Removing the rear wheel and brake Remove the parts in the order listed.
D
disc
NOTE:
_
4-9
REAR WHEEL AND BRAKE DISC CHAS
EAS00561
REMOVING THE REAR WHEEL
1. Stand the scooter on a level surface.
WARNING
_
NOTE:
_
t
ne
e.
m
Ti
er
ot
EAS00565
co
CHECKING THE REAR WHEEL
1. Check:
.S
• tire
w
• rear wheel
w
w
Damage/wear → Replace.
m
WHEEL”.
ow
D
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
_
1. Adjust:
• rear wheel static balance
Refer to “ADJUSTING THE FRONT
WHEEL STATIC BALANCE”.
4 - 10
FRONT AND REAR BRAKES CHAS
EAS00577
T.
R.
t
ne
e.
m
Ti
1
er
ot
6
2
co
4
.S
w
w
5 6
w
3
m
fro
d
de
oa
nl
Removing the front brake pads Remove the parts in the order listed.
D
4 - 11
FRONT AND REAR BRAKES CHAS
t
ne
e.
LS
m
Ti
4
er
ot
co
2
.S
w
1
w
w
LS
m
fro
d
Removing the rear brake pads Remove the parts in the order listed.
D
4 - 12
FRONT AND REAR BRAKES CHAS
EAS00579
CAUTION:
_
t
ne
• Use only clean or new brake fluid for
e.
cleaning brake components.
m
• Brake fluid may damage painted surfaces
Ti
and plastic parts. Therefore, always clean
er
up any spilt brake fluid immediately.
ot
• Avoid brake fluid coming into contact
co
injury.
w
THE EYES:
w
EAS00581
REPLACING THE FRONT BRAKE PADS
nl
NOTE:
ow
1. Remove:
2 • front brake caliper retaining bolts 1
• front brake caliper 2
• brake pad spring
2. Remove:
• brake pads 1
• brake pad springs 2
2
1 • brake pad shims 3
4 - 13
FRONT AND REAR BRAKES CHAS
3. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
4. Install:
3 • brake pad shims 1
• brake pads 2
1 • brake pad springs 3
NOTE:
t
ne
2 _
e.
shims, and a new brake pad springs as a set.
m
3
Ti
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
er
a. Connect a clear plastic hose 4 tightly to the
ot
bleed screw 5. Put the other end of the
co
your finger.
w
Bleed screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
d
T.
R.
de
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ow
5. Lubricate:
D
Recommended lubricant
Lithium-soap-based grease
CAUTION:
_
4 - 14
FRONT AND REAR BRAKES CHAS
6. Install:
• front brake caliper 1
• front brake caliper retaining bolts 2
27 Nm (2.7 m · kg, 19 ft · lb)
T.
R.
2
7. Check:
a • brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
t
ne
Refer to “CHECKING THE BRAKE FLUID
e.
LEVEL” in chapter 3.
m
8. Check:
Ti
• brake lever operation
er
Soft or spongy feeling → Bleed the brake
ot
system.
co
EAS00583
2 REPLACING THE REAR BRAKE PADS
nl
NOTE:
ow
4 - 15
FRONT AND REAR BRAKES CHAS
3. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
4. Install:
1 • brake pad springs 1
• brake pads 2
• rear brake caliper
NOTE:
t
ne
Always install new brake pads, and new brake
e.
pad springs as a set.
m
2
Ti
er
ot
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
co
NOTE:
oa
illustration.
D
3
a
4 - 16
FRONT AND REAR BRAKES CHAS
d. Install new brake pads, new pad springs,
and the rear brake caliper.
È NOTE:
Align the projection c on the piston side of the
brake pad with the lower recess in the brake
caliper piston.
c È Up
É É Down
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Lubricate:
• rear brake caliper retaining bolts
Recommended lubricant
Lithium-soap-based grease
t
ne
CAUTION:
e.
m
• Do not allow grease to contact the brake
Ti
pads.
er
• Remove any excess grease.
ot
co
6. Install:
.S
7. Check:
• brake fluid level
nl
a
Below the minimum level mark a → Add
ow
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 17
FRONT AND REAR BRAKES CHAS
EAS00584
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Removing the front brake master Remove the parts in the order listed.
D
cylinder
Upper handlebar cover Refer to “HANDLEBAR”.
Brake fluid Drain.
1 Brake master cylinder reservoir cap 1
2 Brake master cylinder reservoir dia- 1
phragm holder
3 Brake master cylinder reservoir dia- 1
phragm
4 Brake lever 1
5 Front brake light switch connector 2 Disconnect.
6 Union bolt 1 Refer to “DISASSEMBLING THE
7 Brake hose 1 FRONT BRAKE MASTER CYLINDER”
8 Copper washer 2 and “ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYLIN-
DER”.
4 - 18
FRONT AND REAR BRAKES CHAS
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
4 - 19
FRONT AND REAR BRAKES CHAS
EAS00585
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Disassembling the front brake mas- Remove the parts in the order listed.
D
ter cylinder
1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4 Brake master cylinder body 1
For assembly, reverse the disassembly
procedure.
4 - 20
FRONT AND REAR BRAKES CHAS
EAS00586
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Removing the rear brake master cyl- Remove the parts in the order listed.
D
inder
Upper handlebar cover Refer to “HANDLEBAR”.
Brake fluid Drain.
1 Brake master cylinder reservoir cap 1
2 Brake master cylinder reservoir dia- 1
phragm holder
3 Brake master cylinder reservoir dia- 1
phragm
4 Brake lever 1
5 Rear brake light switch connector 2 Disconnect.
6 Union bolt 1 Refer to “DISASSEMBLING THE REAR
7 Brake hose 1 BRAKE MASTER CYLINDER” and
8 Copper washer 2 “ASSEMBLING AND INSTALLING THE
REAR BRAKE MASTER CYLINDER”.
4 - 21
FRONT AND REAR BRAKES CHAS
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
4 - 22
FRONT AND REAR BRAKES CHAS
EAS00587
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Disassembling the rear brake mas- Remove the parts in the order listed.
D
ter cylinder
1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4 Brake master cylinder body 1
For assembly, reverse the disassembly
procedure.
4 - 23
FRONT AND REAR BRAKES CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
_
1. Remove:
2 • union bolt 1
• copper washers 2
• brake hoses 3
NOTE:
t
ne
_
e.
1 container under the master cylinder and the
m
end of the brake hose.
3
Ti
er
ot
EAS00589
co
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
.S
w
NOTE:
_
w
brake system.
fro
d
de
oa
1. Remove:
2 • union bolt 1
nl
copper washers 2
ow
•
• brake hose 3
D
NOTE:
_
4 - 24
FRONT AND REAR BRAKES CHAS
EAS00592
È CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
• brake master cylinder 1
Damage/scratches/wear → Replace.
• brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed
É air.
È Front
É Rear
t
ne
e.
m
Ti
er
ot
2. Check:
co
Damage/scratches/wear → Replace.
w
w
w
m
fro
d
de
oa
3. Check:
• brake master cylinder reservoir cap 1
nl
Cracks/damage → Replace.
ow
1
• brake master cylinder reservoir diaphragm
D
holder 2
2
• brake master cylinder diaphragm 3
3 Damage/wear → Replace.
4. Check:
• brake hoses
Cracks/damage/wear → Replace.
4 - 25
FRONT AND REAR BRAKES CHAS
EAS00596
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
_
1. Install:
• brake master cylinder kit 1
t
ne
• circlip 2 New
e.
• dust boot 3
m
Ti
er
ot
2. Install:
co
R.
NOTE:
w
bar.
ow
3. Install:
• copper washers New
• brake hose
• union bolt 30 Nm (3.0 m · kg, 22 ft · lb)
T.
R.
WARNING
_
4 - 26
FRONT AND REAR BRAKES CHAS
NOTE:
_
t
ne
4. Fill:
• brake master cylinder reservoir
e.
(with the specified amount of the recom-
m
Ti
mended brake fluid)
er
Recommended brake fluid
ot
DOT 4
co
.S
WARNING
w
_
w
performance.
ow
CAUTION:
_
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 27
FRONT AND REAR BRAKES CHAS
6. Check:
a • brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
t
ne
e.
m
Ti
er
ot
EAS00596
co
ASSEMBLING AND INSTALLING THE
REAR BRAKE MASTER CYLINDER
.S
w
WARNING
w
components.
de
oa
DOT 4
ow
1. Install:
D
4 - 28
FRONT AND REAR BRAKES CHAS
2. Install:
1
• brake master cylinder 1
2 • brake master cylinder holder 2
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
NOTE:
• Make sure to install the brake master cylin-
a der holder that has the “L” mark.
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Align the end of the brake master cylinder
holder with the punch mark a on the handle-
bar.
• First, tighten the upper bolt, then the lower
bolt.
t
ne
3. Install:
e.
• copper washers New
m
• brake hose
Ti
• union bolt 30 Nm (3.0 m · kg, 22 ft · lb)
T.
er
R.
WARNING
ot
_
co
NOTE:
m
CAUTION:
D
4 - 29
FRONT AND REAR BRAKES CHAS
4. Fill:
• brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
_
t
ne
brake fluids may result in a harmful
e.
chemical reaction, leading to poor brake
m
performance.
Ti
• When refilling, be careful that water does
er
not enter the brake master cylinder reser-
ot
voir. Water will significantly lower the
co
CAUTION:
w
5. Bleed:
oa
• brake system
nl
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 30
FRONT AND REAR BRAKES CHAS
EAS00612
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Removing the front brake caliper Remove the parts in the order listed.
D
4 - 31
FRONT AND REAR BRAKES CHAS
EAS00614
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Disassembling the front brake cali- Remove the parts in the order listed.
D
per
1 Brake caliper retaining bolt 2
2 Brake caliper bracket 1
3 Bleed screw 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake pad spring 1
7 Brake pad spring 2
8 Brake caliper piston 2 Refer to “DISASSEMBLING THE
9 Dust seal 2 FRONT BRAKE CALIPER” and
0 Brake caliper piston seal 2 “ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPER”.
A Brake caliper body 1
For assembly, reverse the disassembly
procedure.
4 - 32
FRONT AND REAR BRAKES CHAS
EAS00616
11
27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
5
7
t
ne
6
e.
m
New
Ti
9 10 er
ot
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
co
.S
w
8 12
13
w
2 13
w
1 3 4
m
8
fro
d
LS
de
oa
nl
Removing the rear brake caliper Remove the parts in the order listed.
D
4 - 33
FRONT AND REAR BRAKES CHAS
11
27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
5
7
t
ne
6
e.
m
New
Ti
9 10 er
ot
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
co
.S
w
8 12
13
w
2 13
w
1 3 4
m
8
fro
d
LS
de
oa
nl
4 - 34
FRONT AND REAR BRAKES CHAS
EAS00617
2 New
4
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
1
t
ne
e.
m
5
Ti
3 New
er
ot
co
.S
6
w
w
w
m
d
de
oa
nl
Disassembling the rear brake cali- Remove the parts in the order listed.
D
per
1 Brake caliper piston 1 Refer to “DISASSEMBLING THE REAR
2 Dust seal 1 BRAKE CALIPER” and “ASSEMBLING
3 Brake caliper piston seal 1 AND INSTALLING THE REAR BRAKE
CALIPER”.
4 Bleed screw 1
5 Rear brake lock lever cable holder 1
6 Brake caliper body 1
For assembly, reverse the disassembly
procedure.
4 - 35
FRONT AND REAR BRAKES CHAS
EAS00619
DISASSEMBLING THE FRONT BRAKE
CALIPER
NOTE:
_
1. Remove:
• union bolt 1
• copper washers 2
• brake hose 3
NOTE:
t
ne
_
e.
and pump out the brake fluid carefully.
m
Ti
er
ot
2. Remove:
co
• dust seals 2
w
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
w
WARNING
de
per.
D
EAS00626
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
_
4 - 36
FRONT AND REAR BRAKES CHAS
1. Remove:
1 3 • union bolt 1
• copper washers 2
• brake hose 3
NOTE:
_
2. Remove:
• brake caliper piston 1
• dust seal 2
• brake caliper piston seal 3
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
t
3
ne
1 a. Operate the rear brake lock lever 4 contin-
e.
uously in the direction shown by the arrow
m
until the piston comes out.
Ti
b. Remove the dust seal and brake caliper pis-
er
ton seal.
ot
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
co
.S
w
w
w
m
fro
4
d
de
oa
EAS00633
CHECKING THE FRONT AND REAR BRAKE
nl
CALIPERS
ow
replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Every two years
and whenever the
Brake fluid
brake is disassem-
bled
4 - 37
FRONT AND REAR BRAKES CHAS
È 1. Check:
• brake caliper pistons 1
Rust/scratches/wear → Replace the brake
caliper pistons.
• brake caliper cylinders 2
Scratches/wear → Replace the brake cali-
per assembly.
• brake caliper body 3
Cracks/damage → Replace the brake cali-
per assembly.
É • brake fluid delivery passages
3 (brake caliper body)
2 Obstruction → Blow out with compressed
1 air.
WARNING
t
ne
_
e.
replace the brake caliper piston seals.
m
Ti
È Front
É Rear er
ot
co
.S
w
w
w
m
fro
d
de
oa
È 2. Check:
• brake caliper brackets 1
nl
Cracks/damage → Replace.
ow
È Front
D
É Rear
4 - 38
FRONT AND REAR BRAKES CHAS
EAS00635
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPER
WARNING
_
t
Recommended brake fluid
ne
DOT 4
e.
m
Ti
er
ot
1. Install:
co
2. Install:
w
T.
R.
d
de
oa
3. Install:
• brake caliper (temporarily)
nl
•
• brake hose 2
D
WARNING
_
CAUTION:
_
4 - 39
FRONT AND REAR BRAKES CHAS
4. Remove:
• brake caliper
5. Install:
• brake pad springs
• brake pads
• brake caliper retaining bolts
27 Nm (2.7 m · kg, 19 ft · lb)
T.
R.
Refer to “REPLACING THE FRONT
BRAKE PADS”.
6. Fill:
• brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
t
DOT 4
ne
e.
WARNING
m
_
Ti
• Use only the designated brake fluid.
er
Other brake fluids may cause the rubber
ot
seals to deteriorate, causing leakage and
co
performance.
fro
CAUTION:
D
7. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 40
FRONT AND REAR BRAKES CHAS
8. Check:
a • brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
9. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
t
ne
e.
m
Ti
er
ot
ASSEMBLING AND INSTALLING THE
co
WARNING
w
_
w
seals.
ow
DOT 4
1. Install:
• brake caliper piston seal 1 New
• dust seal 2 New
2 New
1 New
4 - 41
FRONT AND REAR BRAKES CHAS
2. Install:
• brake caliper piston 1
Turn the brake caliper piston clockwise until
section a of the brake caliper piston is level
with the surface of the brake caliper body.
NOTE:
1 Align the recesses b in the brake caliper pis-
ton with the brake caliper body as shown in the
illustration.
3. Install:
1 • brake caliper bracket
a 40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
t
ne
e.
b
m
Ti
er
ot
4. Install:
co
• brake hose 1
w
T.
R.
WARNING
m
_
fro
CAUTION:
nl
ow
3 a 5. Remove:
• brake caliper
6. Install:
• brake pad springs
• brake pads
• brake caliper retaining bolts
27 Nm (2.7 m · kg, 19 ft · lb)
T.
R.
WARNING
_
t
not enter the brake master cylinder reser-
ne
voir. Water will significantly lower the
e.
boiling point of the brake fluid and could
m
cause vapor lock.
Ti
er
ot
CAUTION:
co
_
8. Bleed:
m
• brake system
fro
9. Check:
oa
a
ow
4 - 43
FRONT FORK CHAS
EAS00646
FRONT FORK
T.
R.
R.
7
8 New
9 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
1
t
ne
e.
m
10
Ti
er
ot
co
3
.S
4
w
6
2
w
w
m
5
T.
R.
6
d
4
T.
R.
oa
nl
Removing the front fork legs Remove the parts in the order listed.
D
4 - 44
FRONT FORK CHAS
T.
R.
R.
7
8 New
9 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
1
t
ne
e.
m
10
Ti
er
ot
co
3
.S
4
w
6
2
w
w
m
5
T.
R.
6
d
4
T.
R.
oa
nl
4 - 45
FRONT FORK CHAS
EAS00648
A New
t
3
ne
1
4
e.
B New
m
C
Ti
2 D New
er9
ot
co
.S
E
w
7
w
w
m
New 6
fro
5 LT
d
de
Disassembling the front fork legs Remove the parts in the order listed.
D
4 - 46
FRONT FORK CHAS
A New
t
3
ne
1
4
e.
B New
m
C
Ti
2 D New
er9
ot
co
.S
E
w
7
w
w
m
New 6
fro
5 LT
d
de
4 - 47
FRONT FORK CHAS
EAS00651
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the scooter on a level surface.
WARNING
_
NOTE:
_
1 2. Remove:
2 • cap bolt 1
t
ne
(with a 17-mm hexagonal wrench)
e.
3. Loosen:
m
• lower bracket pinch bolt 2
Ti
er
WARNING
ot
_
4. Remove:
w
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
nl
1. Remove:
• fork spring seat
• fork spring
2. Drain:
• fork oil
NOTE:
Stroke the outer tube several times while
draining the fork oil.
4 - 48
FRONT FORK CHAS
3. Remove:
• dust seal 1
• oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
_
4. Remove:
• damper rod bolt 1
NOTE:
_
t
ne
damper rod bolt.
e.
m
Damper rod holder
Ti
90890-01460
er
T-handle
ot
90890-01326
co
.S
w
w
w
m
fro
d
de
oa
5. Remove:
• inner tube
nl
ow
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the front fork leg horizontally.
D
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 49
FRONT FORK CHAS
EAS00656
CHECKING THE FRONT FORK LEGS
1 The following procedure applies to both of the
2 front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
WARNING
_
2. Measure:
• spring free length a
Out of specification → Replace.
t
ne
Spring free length
e.
316.7 mm (12.47 in)
m
<Limit>: 310.4 mm (12.22 in)
Ti
er
ot
3. Check:
co
• damper rod 1
.S
Damage/wear → Replace.
1
w
Damage → Replace.
fro
d
de
oa
EAS00659
ASSEMBLING THE FRONT FORK LEGS
nl
WARNING
_
4 - 50
FRONT FORK CHAS
NOTE:
_
1. Install:
• damper rod 1
1
3 • rebound spring 2
t
CAUTION:
ne
_
e.
the inner tube 3 until it protrudes from the
m
2 bottom of the inner tube. Be careful not to
Ti
er
damage the inner tube.
ot
co
2. Lubricate:
• inner tube’s outer surface
.S
w
Recommended lubricant
w
3. Tighten:
• copper washer New
nl
LOCTITE®
R.
NOTE:
_
4 - 51
FRONT FORK CHAS
4. Install:
• outer tube bushing 1 New
• washer 2
(with the fork seal driver weight 3 and fork
seal driver attachment 4)
5. Install:
• oil seal 1 New
(with the fork seal driver weight 2 and fork
seal driver attachment 3)
t
ne
CAUTION:
e.
_
m
faces up.
Ti
er
ot
NOTE:
_
co
6. Install:
• oil seal clip 1
nl
ow
NOTE:
_
7. Install:
• dust seal 1
(with the fork seal driver weight 2)
4 - 52
FRONT FORK CHAS
8. Fill:
• front fork leg
(with the specified amount of the recom-
mended fork oil)
t
ne
NOTE:
e.
_
m
• After filling, slowly pump the front fork leg up
Ti
er
and down to distribute the fork oil.
ot
co
9. Install:
• fork spring 1
.S
NOTE:
w
ing up.
fro
d
de
oa
EAS00663
INSTALLING THE FRONT FORK LEGS
nl
1. Install:
• front fork leg
NOTE:
_
2. Tighten:
• lower bracket pinch bolt 1
30 Nm (3.0 m · kg, 22 ft · lb)
T.
R.
1
R.
4 - 53
HANDLEBAR CHAS
EAS00664
HANDLEBAR
T.
R.
2
1
10 5
2
18
11 17
9 6
t
ne
19 7 3
8
e.
15
m
4
Ti
14
er 5
ot
12
co
16
.S
w
3
T.
R.
T.
R.
m
T.
R.
oa
nl
4 - 54
HANDLEBAR CHAS
T.
R.
2
1
10 5
2
18
11 17
9 6
t
ne
19 7 3
8
e.
15
m
4
Ti
14
er 5
ot
12
co
16
.S
w
3
T.
R.
T.
R.
m
T.
R.
oa
nl
4 - 55
HANDLEBAR CHAS
EAS00666
REMOVING THE HANDLEBAR
1. Stand the scooter on a level surface.
WARNING
_
2. Remove:
• handlebar grip 1
NOTE:
_
t
ne
e.
m
Ti
er
ot
EAS00668
co
CHECKING THE HANDLEBAR
1. Check:
.S
• handlebar 1
w
Bends/cracks/damage → Replace.
w
w
WARNING
m
EAS00671
INSTALLING THE HANDLEBAR
nl
WARNING
D
4 - 56
HANDLEBAR CHAS
2. Install:
1 • handlebar 1
• upper handlebar holders 2
23 Nm (2.3 m · kg, 17 ft · lb)
T.
R.
CAUTION:
_
NOTE:
_
t
ne
with the upper surface of the lower handlebar
holder.
e.
m
Ti
er
ot
3. Install:
co
• handlebar grip
.S
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
w
the handlebar.
fro
clean rag.
de
WARNING
oa
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• rear brake master cylinder 1
• rear brake master cylinder holder 2
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
NOTE:
• Make sure to install the brake master cylin-
1 der holder that has the “L” mark.
2 • Install the rear brake master cylinder holder
with the “UP” mark facing up.
• Align the end of the rear brake master cylin-
der holder with the punch mark a in the han-
dlebar.
a • First, tighten the upper bolt, then the lower
bolt.
4 - 57
HANDLEBAR CHAS
5. Install:
• rear brake lock lever cable 1
NOTE:
Lubricate the inside of the rear brake lock lever
cable and rear brake lock lever with a thin coat
of lithium-soap-based grease.
LS
1
6. Install:
a • left handlebar switch 1
b 6 Nm (0.6 m · kg, 4.3 ft · lb)
T.
R.
NOTE:
Align the projection a on the left handlebar
t
ne
switch with the hole b in the handlebar.
e.
m
Ti
1
er
ot
7. Install:
1
co
R.
NOTE:
w
dlebar.
ow
8. Install:
LS
• throttle grip
• throttle cables 1
NOTE:
_
4 - 58
HANDLEBAR CHAS
9. Install:
b • right handlebar switch 1
WARNING
_
t
ne
e.
m
Ti
er
ot
10.Install:
co
NOTE:
w
grip end.
m
fro
d
de
oa
11.Install:
• grip end (right)
nl
ow
NOTE:
There should be 2.4 ~ 4.4 mm (0.09 ~ 0.17 in)
D
12.Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
4 - 59
STEERING HEAD CHAS
EAS00675
STEERING HEAD
LOWER BRACKET
T.
R.
2
3
90 Nm (9.0 m • kg, 65 ft • Ib)
T.
R.
4
1st 36 Nm (3.6 m • kg, 25 ft • lb) 6
7
T.
2nd 24 Nm (2.4 m • kg, 17 ft • lb)
R.
8
LS 9
15 10
12
16 13
t
ne
LS
14
18 17
e.
m
Ti
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
5 er
ot
co
.S
11
w
w
w
m
fro
1
d
de
oa
nl
Removing the lower bracket Remove the parts in the order listed.
D
4 - 60
STEERING HEAD CHAS
T.
R.
2
3
90 Nm (9.0 m • kg, 65 ft • Ib)
T.
R.
4
1st 36 Nm (3.6 m • kg, 25 ft • lb) 6
7
T.
2nd 24 Nm (2.4 m • kg, 17 ft • lb)
R.
8
LS 9
15 10
12
16 13
t
ne
LS
14
18 17
e.
m
Ti
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
5 er
ot
co
.S
11
w
w
w
m
fro
1
d
de
oa
nl
4 - 61
STEERING HEAD CHAS
EAS00680
REMOVING THE LOWER BRACKET
1. Stand the scooter on a level surface.
WARNING
_
2. Remove:
• handlebar lower holder 1
• woodruff key 2
NOTE:
Remove the handlebar lower holder by loosen-
t
ne
ing the upper steering ring nut 3 gradually.
e.
m
Ti
er
ot
3. Remove:
co
• lock washer 2
w
• rubber washer
m
fro
4. Remove:
• lower steering ring nut 1
nl
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
4 - 62
STEERING HEAD CHAS
EAS00681
CHECKING THE STEERING HEAD
1. Wash:
• bearings
• bearing races
2. Check:
• bearings 1
• bearing races 2
Damage/pitting → Replace.
t
ne
e.
m
Ti
er
ot
3. Replace:
co
• bearings
.S
• bearing races
w
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
w
races.
oa
CAUTION:
nl
NOTE:
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
4 - 63
STEERING HEAD CHAS
EAS00684
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
Recommended lubricant
Lithium-soap-based grease
2. Clean:
a • lower bracket
• lower handlebar holder
NOTE:
Clean the area a of the lower bracket indi-
t
ne
cated in the illustration and the inner surfaces
e.
of the lower handlebar holder.
m
Ti
3. Install:
•
er
lower steering ring nut 1
ot
• rubber washer
co
• lock washer 3
w
4. Install:
• woodruff key 1
• lower handlebar holder 2
140 Nm (14.0 m · kg, 100 ft · lb)
T.
R.
NOTE:
_
4 - 64
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM CHAS
EAS00685
T.
R.
3
t
ne
5
e.
m
Ti
4 11
7
LS 10
er
ot
9
co
4
LS 8 6
.S
1
w
LS
w
w
T.
R.
T.
R.
R.
oa
nl
Removing the rear shock absorber Remove the parts in the order listed.
D
4 - 65
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM CHAS
T.
R.
3
t
ne
5
e.
m
Ti
4 11
7
LS 10
er
ot
9
co
4
LS 8 6
.S
1
w
LS
w
w
T.
R.
T.
R.
R.
oa
nl
4 - 66
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM CHAS
EAS00693
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLIES
1. Stand the scooter on a level surface.
WARNING
_
NOTE:
_
2. Remove:
• rear shock absorber assemblies 1
1
t
ne
e.
m
Ti
er
ot
EAS00695
co
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES
.S
1. Check:
m
absorber assembly.
d
absorber assembly.
nl
• spring
ow
absorber assembly.
• bolts
Bends/damage/wear → Replace.
EAS00699
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLIES
1 1. Install:
• rear shock absorber assembly upper nuts 1
34 Nm (3.4 m · kg, 24 ft · lb)
T.
R.
4 - 67
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM CHAS
EAS00702
REMOVING THE SWINGARM
1. Stand the scooter on a level surface.
WARNING
_
NOTE:
_
t
ne
• rear shock absorber assembly lower bolt
e.
(right) 4
m
4 NOTE:
Ti
1
Do not squeeze the brake lever when remov-
er
ing the brake caliper.
ot
co
3. Remove:
.S
• swingarm
w
w
w
m
fro
d
de
oa
EAS00708
CHECKING THE SWINGARM
nl
1. Check:
ow
• swingarm
D
Bends/cracks/damage → Replace.
2 2. Check:
3 • spacer 1
• collar 2
43 • oil seals 3
1
• bearing 4
• bushing
Damage/wear → Replace.
• dust seal
Damage/wear → Replace.
4 - 68
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM CHAS
EAS00711
INSTALLING THE SWINGARM
1. Lubricate:
• bearing
• oil seal lips
• drive axle splines
Recommended lubricant
Lithium-soap-based grease
2. Install:
4 3
• swingarm 1 46 Nm (4.6 m · kg, 33 ft · lb)
T.
R.
• rear shock absorber assembly lower bolt
(right) 2 29 Nm (2.9 m · kg, 21 ft · lb)
T.
R.
• brake hose holder 3
t
ne
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
• rear brake caliper 4
e.
m
40 Nm (4.0 m · kg, 29 ft · lb)
2
T.
R.
Ti
5 1 • rear axle nut 5
T.
R.
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
4 - 69
ENG
CHAPTER 5
ENGINE
CAMSHAFTS...................................................................................................5-6
CYLINDER HEAD COVER........................................................................ 5-6
CAMSHAFTS ............................................................................................ 5-7
REMOVING THE CAMSHAFTS................................................................5-9
CHECKING THE CAMSHAFTS ..............................................................5-10
CHECKING THE CAMSHAFT SPROCKETS .........................................5-12
t
ne
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-12
e.
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-13
m
INSTALLING THE CAMSHAFTS ............................................................ 5-13
Ti
er
CYLINDER HEAD.......................................................................................... 5-17
ot
REMOVING THE CYLINDER HEAD.......................................................5-19
co
t
ne
PRIMARY SHEAVE................................................................................ 5-47
e.
m
STARTER CLUTCH AND GENERATOR......................................................5-49
Ti
GENERATOR ROTOR COVER AND STATOR COIL ............................ 5-49
er
STARTER CLUTCH AND GENERATOR................................................ 5-51
ot
REMOVING THE GENERATOR ............................................................. 5-52
co
CRANKSHAFT ..............................................................................................5-59
nl
TRANSMISSION............................................................................................ 5-71
CHECKING THE TRANSMISSION ......................................................... 5-73
INSTALLING THE PRIMARY DRIVE GEAR OIL SEAL.......................... 5-73
ENGINE REMOVAL ENG
EAS00188
ENGINE
ENGINE REMOVAL
LEADS, HOSES, EXHAUST PIPE AND MUFFLER
t
ne
1
e.
m
Ti
4
er
ot
co
.S
w
7 New
w
6
w
m
fro
T.
R.
Removing the leads, hoses, exhaust Remove the parts in the order listed.
D
Air filter case (left and right) Refer to “AIR FILTER CASES” in chapter
3.
Throttle body and fuel injector Refer to “THROTTLE BODY AND FUEL
INJECTOR” in chapter 7.
5-1
ENGINE REMOVAL ENG
t
ne
1
e.
m
Ti
4
er
ot
co
.S
7 New
w
6
w
w
fro
8.
Thermostat cover and thermostat Refer to “THERMOSTAT” in chapter 6.
Rear brake caliper Refer to “FRONT AND REAR BRAKES”
in chapter 4.
1 Spark plug cap 1 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
3 Crankshaft position sensor/stator 2 Disconnect.
assembly coupler
4 Water pump inlet hose 1 Disconnect.
5 Muffler 1
6 Exhaust pipe 1
7 Gasket 1
For installation, reverse the removal pro-
cedure.
5-2
ENGINE REMOVAL ENG
EAS00191
ENGINE
LS
56 Nm (5.6 m • kg, 40 ft • Ib) 65 Nm (6.5 m • kg, 47 ft • Ib)
T.
T.
7
R.
R.
LT
LT 8
LS 6
LS 6
10
1 5
59 Nm (5.9 m • kg, 43 ft • Ib)
9
T.
R.
29 Nm (2.9 m • kg, 21 ft • Ib)
T.
R.
LT
7
t
ne
5
e.
2 5
m
Ti
3
er
ot 4
co
2
.S
11
w
5 4
w
w
3
m
LT
fro
d
de
NOTE:
_
5-3
ENGINE REMOVAL ENG
LS
56 Nm (5.6 m • kg, 40 ft • Ib) 65 Nm (6.5 m • kg, 47 ft • Ib)
T.
T.
7
R.
R.
LT
LT 8
LS 6
LS 6
10
1 5
59 Nm (5.9 m • kg, 43 ft • Ib)
9
T.
R.
29 Nm (2.9 m • kg, 21 ft • Ib)
T.
R.
LT
7
t
ne
5
e.
2 5
m
Ti
3
er
ot 4
co
2
.S
11
w
5 4
w
w
3
m
LT
fro
d
de
11 Engine 1
For installation, reverse the removal pro-
cedure.
5-4
ENGINE REMOVAL ENG
EAS00192
5 2 5 3 4 INSTALLING THE ENGINE
1. Install:
1
4 • right engine bracket 1
• center engine bracket 2
6 • left engine bracket 3
• engine mounting bolt/nut 4
6
• engine bracket bolts 5 LT
NOTE:
_
t
ne
2. Tighten:
• engine mounting nut 4
e.
6 65 Nm (6.5 m · kg, 47 ft · lb)
m T.
R.
8 7 • engine bracket bolts 5
Ti
er
56 Nm (5.6 m · kg, 40 ft · lb)
T.
R.
3. Install:
ot
co
• washers 7
w
LT
m
NOTE:
fro
4. Tighten:
• engine bracket upper mounting nuts 6
oa
T.
R.
5-5
CAMSHAFTS ENG
EAS00194
CAMSHAFTS
CYLINDER HEAD COVER
New 4
3
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
t
ne
e.
m
5
Ti
(9)
er
ot
co
.S
2
1
w
w
w
m
d
de
oa
nl
Removing the cylinder head cover Remove the parts in the order listed.
D
5-6
CAMSHAFTS ENG
EAS00196
CAMSHAFTS
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R.
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
1
T.
R.
5
E
4 M
6 New
4 12 9
8 13
11
(8) 14
t
ne
10
e.
E
m
8 M
Ti
er
7 ot
co
3 2
.S
w
w
w
fro
(4) (4)
d
de
oa
nl
1 Timing plug 1
2 V-belt case air filter cover 1
3 V-belt case air filter element 1
4 Camshaft sprocket bolt 4 Loosen.
5 Timing chain tensioner assembly 1 Refer to “REMOVING
6 Gasket 1 THE CAMSHAFTS” and
7 Camshaft cap 1 “INSTALLING THE CAM-
8 Dowel pin 2 SHAFTS”.
9 Intake camshaft 1
10 Exhaust camshaft 1
11 Intake camshaft sprocket 1
12 Exhaust camshaft sprocket 1
5-7
CAMSHAFTS ENG
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R.
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
1
T.
R.
5
E
4 M
6 New
4 12 9
8 13
11
(8) 14
t
ne
10
e.
E
m
8 M
Ti
er
7 ot
co
3 2
.S
w
w
w
fro
(4) (4)
d
de
oa
nl
5-8
CAMSHAFTS ENG
EAS00198
REMOVING THE CAMSHAFTS
1. Remove:
1 • timing plug
• V-belt case air filter cover 1
• V-belt case air filter element
2. Align:
• TDC mark on the generator rotor
(with the stationary pointer on the generator
rotor cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the primary sheave nut on the left side
of the crankshaft counterclockwise to turn
the crankshaft.
b. Align the “I” mark a on the generator rotor
t
with the stationary pointer b on the genera-
ne
tor rotor cover to position the piston at TDC
e.
on the compression stroke.
m
NOTE:
Ti
_
the illustration.
d
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
de
oa
3. Loosen:
• camshaft sprocket bolts 1
nl
ow
D
1
1
4. Loosen:
• timing chain tensioner cap bolt 1
5. Remove:
1 • timing chain tensioner 2
• gasket
5-9
CAMSHAFTS ENG
6. Remove:
• camshaft cap 1
• dowel pins
5
8
1
3
2
NOTE:
_
1
on the camshaft cap.
• Loosen each camshaft cap bolt 1/2 of a turn
6
7. Remove:
3 • intake camshaft 1
1 • exhaust camshaft 2
t
NOTE:
ne
_
e.
2 crankcase, fasten it with a wire 3.
m
Ti
8. Remove:
er
• camshaft sprockets
ot
co
.S
w
w
w
m
fro
d
de
oa
EAS00204
CHECKING THE CAMSHAFTS
nl
1. Check:
ow
• camshaft lobes
D
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• camshaft lobe dimensions a and b
Out of specification → Replace the cam-
shaft.
5 - 10
CAMSHAFTS ENG
3. Measure:
• camshaft runout
Out of specification → Replace.
4. Measure:
1 • camshaft-journal-to-camshaft-cap clear-
ance
Out of specification → Measure the cam-
shaft journal diameter.
t
ne
Camshaft-journal-to-camshaft-
e.
cap clearance limit
m
0.08 mm (0.0031 in)
Ti
er
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ot
a. Install the camshaft into the cylinder head
co
NOTE:
m
_
4
5 - 11
CAMSHAFTS ENG
5. Measure:
• camshaft journal diameter a
Out of specification → Replace the cam-
shaft.
Within specification → Replace the cylinder
head and the camshaft cap as a set.
t
ne
e.
m
Ti
er
ot
CHECKING THE CAMSHAFT SPROCKETS
co
1. Check:
.S
• camshaft sprockets
w
a 1/4 of a tooth
m
b Correct
fro
1 Roller
2 Sprocket
d
de
oa
1
2
ow
1. Check:
• decompression system
D
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the decompressor lever pin 1
projects from the camshaft.
b. Check that the decompressor cam 2
moves smoothly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 12
CAMSHAFTS ENG
EAS00210
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage/rough movement →
Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
t
housing smoothly. If there is rough move-
ne
ment, replace the timing chain tensioner.
e.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
m
Ti
er
ot
EAS00217
co
INSTALLING THE CAMSHAFTS
1. Install:
.S
• decompressor lever 2
w
w
• exhaust camshaft 3
m
NOTE:
fro
2 1 2. Install:
nl
NOTE:
• Make sure that the punch marks a on the
camshaft sprockets are in the position shown
in the illustration.
a a
• Temporarily tighten the camshaft sprocket
bolts.
5 - 13
CAMSHAFTS ENG
3. Install:
• intake camshaft 1
3 • exhaust camshaft 2
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the primary sheave nut on the left side
of the crankshaft counterclockwise to turn
2 the crankshaft.
b. When piston is at TDC on the compression
stroke, align the “I” mark a on the genera-
tor rotor with the stationary pointer b on the
generator rotor cover.
c. Install the timing chain 3 onto both cam-
shaft sprockets, and then install the cam-
shafts onto the cylinder head.
NOTE:
t
ne
The camshafts should be installed onto the
e.
cylinder head so that the punch marks c on
m
the intake camshaft sprocket and the punch
Ti
mark d on the exhaust camshaft sprocket
er
align with the cylinder head mating surface, as
ot
shown in the illustration.
co
.S
CAUTION:
w
_
w
valve timing.
c d
fro
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d
de
oa
4. Install:
• dowel pins
nl
ow
• camshaft cap
5
8
NOTE:
• Lubricate the camshaft cap bolt threads with
4
engine oil.
• Finger tighten the camshaft cap bolts.
6
5. Tighten:
• camshaft cap bolts
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
NOTE:
_
5 - 14
CAMSHAFTS ENG
CAUTION:
_
6. Install:
• timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
t
ne
fully clockwise with a thin screwdriver 1.
e.
b. With the timing chain tensioner rod turned
m
all the way into the timing chain tensioner
Ti
housing (with the thin screwdriver still
er
installed), install the gasket and the timing
ot
chain tensioner 2 onto the cylinder block.
co
3
WARNING
.S
2
Timing chain tensioner bolt
d
T.
R.
oa
Cap bolt
7 Nm (0.7 m · kg, 5.1 ft · lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Tighten:
• camshaft sprocket bolts 1
20 Nm (2.0 m · kg, 14 ft · lb)
T.
R.
1
1
5 - 15
CAMSHAFTS ENG
8. Turn:
• crankshaft
(turn the primary sheave nut on the left side
of the crankshaft several turns counter-
clockwise)
9. Check:
• “I” mark
Make sure the “I” mark on the generator
rotor is aligned with the stationary pointer
on the generator rotor cover.
• camshaft sprocket punch marks
Make sure the punch marks on the cam-
shaft sprockets are aligned with the cylinder
head mating surface.
Out of alignment → Adjust.
t
ne
Refer to the installation steps above.
10.Measure:
e.
m
• valve clearance
Out of specification → Adjust.
Ti
er
Refer to “ADJUSTING THE VALVE
ot
CLEARANCE” in chapter 3.
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
5 - 16
CYLINDER HEAD ENG
EAS00221
CYLINDER HEAD
T.
T.
R.
R.
5
4
6 10
t
ne
1
e.
New
m
7 9
Ti
er 3
ot
8 New
co
.S
2
w
9
w
w
m
E
fro
d
de
oa
nl
Removing the cylinder head Remove the parts in the order listed.
D
5 - 17
CYLINDER HEAD ENG
T.
T.
R.
R.
5
4
6 10
t
ne
1
e.
New
m
7 9
Ti
er 3
ot
8 New
co
.S
2
w
9
w
w
m
E
fro
d
de
oa
nl
5 - 18
CYLINDER HEAD ENG
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:
4 2 • cylinder head nuts
NOTE:
_
EAS00229
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
t
ne
NOTE:
e.
_
m
ing or scratching:
Ti
• spark plug bore threads
er
• valve seats
ot
co
2. Check:
.S
• cylinder head
w
Damage/scratches → Replace.
w
w
3. Measure:
fro
der head.
oa
nl
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 19
CYLINDER HEAD ENG
CHECKING THE TIMING CHAIN GUIDE
(EXHAUST SIDE)
1. Check:
• timing chain guide (exhaust side)
Damage/wear → Replace.
EAS00232
INSTALLING THE CYLINDER HEAD
1. Install:
• timing chain guide (exhaust side)
• cylinder head gasket New
t
• dowel pins
ne
2. Install:
e.
• cylinder head
m
Ti
NOTE:
_
er
Pass the timing chain through the timing chain
ot
cavity.
co
3. Tighten:
.S
1
R.
w
NOTE:
_
oil.
• Tighten the cylinder head nuts in the proper
oa
5 - 20
VALVES AND VALVE SPRINGS ENG
EAS00236
1
2
E 3 1
3 2
4
M 3
4
5
3 E
5
6
M 7 6 M
t
New
ne
e.
10
New M
m
10
Ti
er
ot
co
.S
w
w
w
m
M
fro
8
d
M
de
9
oa
nl
Removing the valves and valve Remove the parts in the order listed.
D
springs
Cylinder head Refer to “CYLINDER HEAD”.
1 Valve lifter 4
2 Adjusting pad 4
3 Valve cotter 8
4 Upper valve spring seat 4
5 Valve spring 4 Refer to “REMOVING THE VALVES”
6 Stem seal 4 and “INSTALLING THE VALVES”.
7 Lower valve spring seat 4
8 Exhaust valve 2
9 Intake valve 2
10 Valve guide 4
For installation, reverse the removal pro-
cedure.
5 - 21
VALVES AND VALVE SPRINGS ENG
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
NOTE:
_
1. Remove:
• valve lifter 1
• valve pad 2
NOTE:
_
t
ne
their original place.
e.
m
2. Check:
Ti
• valve sealing
er
Leakage at the valve seat → Check the
ot
valve face, valve seat, and valve seat width.
co
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
w
exhaust ports.
w
NOTE:
fro
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
nl
2 3. Remove:
ow
• valve cotters 1
3
D
NOTE:
_
5 - 22
VALVES AND VALVE SPRINGS ENG
4. Remove:
• upper spring seat 1
• valve spring 2
• valve stem seal 3
• lower spring seat 4
• valve 5
NOTE:
_
t
ne
e.
m
Ti
er
ot
EAS00239
co
CHECKING THE VALVES AND VALVE
GUIDES
.S
1. Measure:
m
• valve-stem-to-valve-guide clearance
fro
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
d
de
guide.
ow
Valve-stem-to-valve-guide clear-
D
ance
Intake
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
<Limit>: 0.080 mm (0.0031 in)
Exhaust
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
<Limit>: 0.100 mm (0.0039 in)
5 - 23
VALVES AND VALVE SPRINGS ENG
2. Replace:
• valve guide
NOTE:
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve
guide remover 1.
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3
t
ne
to obtain the proper valve-stem-to-valve-
e.
guide clearance.
m
NOTE:
Ti
_
90890-04097, YM-04097
w
90890-04098, YM-04098
w
90890-04099, YM-04099
fro
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d
de
3. Eliminate:
• carbon deposits
oa
4. Check:
ow
• valve face
D
5. Measure:
• valve margin thickness a
Out of specification → Replace the valve.
5 - 24
VALVES AND VALVE SPRINGS ENG
6. Measure:
• valve stem runout
Out of specification → Replace the valve.
NOTE:
_
t
ne
e.
m
Ti
er
ot
EAS00240
co
CHECKING THE VALVE SEATS
The following procedure applies to all of the
.S
1. Eliminate:
w
w
• carbon deposits
m
2. Check:
• valve seat
d
3. Measure:
oa
head.
D
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
5 - 25
VALVES AND VALVE SPRINGS ENG
NOTE:
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• valve face
• valve seat
NOTE:
_
t
ne
the valve and valve guide, the valve seat and
e.
valve face should be lapped.
m
Ti
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
er
a. Apply a coarse lapping compound a to the
ot
valve face.
co
CAUTION:
.S
guide.
m
fro
NOTE:
D
5 - 26
VALVES AND VALVE SPRINGS ENG
j. Measure the valve seat width again. If the
valve seat width is out of specification,
reface and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
t
• valve spring free length a
ne
Out of specification → Replace the valve
e.
spring.
m
Ti
Valve spring free length
er
46.45 mm (1.83 in)
ot
<Limit>: 44.13 mm (1.74 in)
co
.S
w
w
w
m
fro
d
de
oa
2. Measure:
• compressed valve spring force a
nl
spring.
D
b Installed length
5 - 27
VALVES AND VALVE SPRINGS ENG
3. Measure:
• valve spring tilt a
Out of specification → Replace the valve
spring.
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:
t
• valve lifter
ne
Damage/scratches → Replace the valve lift-
e.
ers and cylinder head.
m
Ti
er
ot
EAS00245
co
INSTALLING THE VALVES
The following procedure applies to all of the
.S
1. Deburr:
w
w
2. Lubricate:
• valve stem 1
nl
Recommended lubricant
Molybdenum disulfide oil
3. Install:
5 • valve 1
2 • lower spring seat 2
4 • valve stem seal 3
• valve spring 4
1 • upper spring seat 5
(into the cylinder head)
3
5 - 28
VALVES AND VALVE SPRINGS ENG
NOTE:
_
b Smaller pitch
4. Install:
2 • valve cotters 1
NOTE:
3
_
t
ne
2 and the valve spring compressor attach-
e.
1 ment 3.
m
Ti
Valve spring compressor
er90890-04019, YM-04019
ot
Valve spring compressor attach-
co
ment
.S
90890-01243, YM-01253-1
w
w
w
m
fro
d
de
oa
hammer.
D
CAUTION:
_
6. Install:
• valve pad 1
• valve lifter 2
NOTE:
_
5 - 29
CYLINDER AND PISTON ENG
EAS00251
7 New 9
10
New 7
E
t
ne
6
e.
E
m
4
Ti
er
ot
co
.S
6
w
w
LS
w
New
5 New
m
2
fro
1
d
T.
R.
R.
oa
nl
Removing the cylinder and piston Remove the parts in the order listed.
D
5 - 30
CYLINDER AND PISTON ENG
EAS00253
REMOVING THE PISTON
1. Remove:
2 • piston pin clip 1
• piston pin 2
1 • piston 3
CAUTION:
_
NOTE:
_
t
ne
• Before removing the piston pin, deburr the
e.
piston pin clip’s groove and the piston’s pin
m
bore area. If both areas are deburred and the
Ti
piston pin is still difficult to remove, remove it
er
with the piston pin puller set 4.
ot
co
.S
2. Remove:
• top ring
nl
ow
• 2nd ring
• oil ring
D
NOTE:
_
EAS00255
CHECKING THE CYLINDER AND PISTON
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
5 - 31
CYLINDER AND PISTON ENG
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
_
83.000 ~ 83.010 mm
Cylinder bore “C”
(3.2677 ~ 3.2681 in)
Taper limit “T” 0.05 mm (0.002 in)
t
ne
e.
“C” = maximum of D1 ~ D2
m
“T” = maximum of D1 or D2 – maximum of
Ti
D5 or D6
er
ot
b. If out of specification, rebore or replace the
co
rings as a set.
w
micrometer.
w
ton
fro
82.930 ~ 82.945 mm
Standard
oa
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.060 ~ 0.075 mm
(0.0024 ~ 0.0030 in)
<Limit>: 0.15 mm (0.0059 in)
5 - 32
CYLINDER AND PISTON ENG
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
• piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
_
t
<Limit>: 0.100 mm (0.0039 in)
ne
2nd ring
e.
0.020 ~ 0.055 mm
m
(0.0008 ~ 0.0022 in)
Ti
<Limit>: 0.100 mm (0.0039 in)
er
ot
2. Install:
co
• piston ring
.S
NOTE:
w
piston crown.
m
fro
a 40 mm (1.6 in)
d
3. Measure:
de
ring.
ow
NOTE:
_
5 - 33
CYLINDER AND PISTON ENG
EAS00265
CHECKING THE PISTON PIN
1. Check:
• piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication
system.
2. Measure:
• piston pin outside diameter a
Out of specification → Replace the piston
pin.
t
ne
3. Measure:
e.
• piston pin bore diameter b (in the piston)
m
Out of specification → Replace the piston.
Ti
er
Piston pin bore diameter
ot
20.004 ~ 20.015 mm
co
4. Calculate:
w
• piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston
m
fro
Piston-pin-to-piston-pin-bore clearance =
de
Piston-pin-to-piston-pin-bore
clearance
D
0.004 ~ 0.024 mm
(0.0002 ~ 0.0009 in)
<Limit>: 0.074 mm (0.0029 in)
EAS00267
INSTALLING THE PISTON AND CYLINDER
1. Install:
• top ring
• 2nd ring
• lower oil ring rail
• upper oil ring rail
• oil ring expander
5 - 34
CYLINDER AND PISTON ENG
NOTE:
_
3 2. Install:
New • piston 1
a • piston pin 2
1 • piston pin clips 3 New
NOTE:
_
t
ne
vent the clip from falling into the crankcase.
e.
m
3. Install:
Ti
• cylinder gasket New
• er
dowel pins
ot
4. Lubricate:
co
• piston
.S
• piston rings
w
• cylinder
w
Recommended lubricant
fro
Engine oil
d
de
oa
5. Position:
• top ring
nl
ow
• 2nd ring
• oil ring
D
5 - 35
CYLINDER AND PISTON ENG
6. Install:
• dowel pins
• cylinder gasket New
• cylinder
• cylinder bolt 10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
NOTE:
_
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
5 - 36
BELT DRIVE ENG
EAS00316
BELT DRIVE
V-BELT CASE COVER
T.
R.
LT
LT
7
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
(9)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
6
t
ne
e.
m
(6)
Ti
5
er
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
ot
co
4
22 Nm (2.2 m • kg, 16 ft • Ib)
.S
T.
R.
3
w
(4)
w
1
m
2
fro
d
(4)
de
oa
nl
Removing the V-belt case cover Remove the parts in the order listed.
D
5 - 37
BELT DRIVE ENG
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Removing the V-belt and primary/ Remove the parts in the order listed.
D
secondary sheave
1 Primary sheave nut/collar 1/1 Refer to “REMOVING THE PRIMARY
2 Primary fixed sheave 1 SHEAVE” and “INSTALLING THE SEC-
ONDARY SHEAVE, V-BELT AND PRI-
MARY SHEAVE”.
3 Secondary sheave nut 1
Refer to “REMOVING THE SECOND-
4 Collar 1
ARY SHEAVE AND V-BELT” and
5 Clutch housing 1
“INSTALLING THE SECONDARY
6 Secondary sheave assembly 1
SHEAVE, V-BELT AND PRIMARY
7 V-belt 1
SHEAVE”.
8 Primary sliding sheave 1
9 Spacer 1
10 Cam 1
5 - 38
BELT DRIVE ENG
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
11 Weight 8
D
12 Slider 4
13 Spacer 1
14 O-ring 1
For installation, reverse the removal
procedure.
5 - 39
BELT DRIVE ENG
SECONDARY SHEAVE
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
sheave
1 Clutch shoe assembly nut 1 Refer to “DISASSEMBLING THE SEC-
2 Clutch shoe assembly 1 ONDARY SHEAVE” and “ASSEMBLING
THE SECONDARY SHEAVE”.
3 Clutch shoe spring 3
4 Compression spring 1
5 Spring seat 1
6 Guide pin 4
Refer to “ASSEMBLING THE SECOND-
7 Secondary sliding sheave 1
ARY SHEAVE”.
8 O-ring 2
9 Oil seal 2
0 Secondary fixed sheave 1
A Bearing 1
5 - 40
BELT DRIVE ENG
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
B Circlip 1
D
C Bearing 1
For assembly, reverse the disassembly
procedure.
5 - 41
BELT DRIVE ENG
EAS00317
REMOVING THE PRIMARY SHEAVE
1. Remove:
3 • primary sheave nut 1
• collar
• primary fixed sheave 2
NOTE:
_
t
ne
e.
m
Ti
er
ot
EAS00318
co
REMOVING THE SECONDARY SHEAVE
AND V-BELT
.S
2
1. Remove:
w
1 • collar
• clutch housing 2
m
fro
NOTE:
_
sheave nut.
oa
nl
ow
Sheave holder
90890-01701, YS-01880-A
D
5 - 42
BELT DRIVE ENG
2. Loosen:
2 • clutch shoe assembly nut 1
CAUTION:
_
NOTE:
_
t
ne
Locknut wrench
90890-01348, YM-01348
e.
m
Ti
er
ot
3. Remove:
co
• V-belt 2
w
NOTE:
w
2 1
d
de
oa
EAS00319
DISASSEMBLING THE SECONDARY
nl
2
SHEAVE
ow
1. Remove:
D
5 - 43
BELT DRIVE ENG
EAS00320
CHECKING THE V-BELT
1. Check:
• V-belt 1
Cracks/damage/wear → Replace.
Grease/oil → Clean the primary and sec-
ondary sheaves.
2. Measure:
• V-belt width 2
Out of specification → Replace.
V-belt width
30 mm (1.18 in)
<Limit>: 27 mm (1.06 in)
t
ne
CHECKING THE V-BELT CASE AIR DUCTS
1. Check:
e.
• V-belt case air ducts
m
Cracks/damage → Replace.
Ti
er
ot
CHECKING THE PRIMARY SHEAVE
co
1. Check:
• primary fixed sheave
.S
• spacer
w
Cracks/damage/wear → Replace.
m
NOTE:
fro
EAS00321
CHECKING THE PRIMARY SHEAVE
nl
WEIGHTS
ow
5 - 44
BELT DRIVE ENG
EAS00322
CHECKING THE SECONDARY SHEAVE
1. Check:
• secondary fixed sheave
• secondary sliding sheave
Cracks/damage/wear → Replace the sec-
ondary fixed and sliding sheaves as a set.
2. Check:
• torque cam groove 1
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
• guide pin 2
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
t
ne
e.
m
Ti
er
ot
CHECKING THE CLUTCH SHOES
co
clutch shoes.
w
1. Check:
w
• clutch shoe
w
NOTE:
After sanding the glazed areas, clean the
clutch with a cloth.
2. Measure:
• clutch shoe thickness
Out of specification → Replace the clutch
shoes and springs as a set.
5 - 45
BELT DRIVE ENG
EAS00323
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
• primary fixed sheave 1
• primary sliding sheave 2
• collar 3
• primary sheave weights 4
• cam
2. Lubricate:
• collar’s inner and outer surface
Recommended lubricant
BEL-RAY assembly lube
3. Install:
• primary sheave weights
t
ne
• collar
4. Install:
e.
m
• sliders
Ti
• cam
er
ot
EAS00324
co
ASSEMBLING THE SECONDARY SHEAVE
1. Lubricate:
.S
• oil seals
m
• bearings
fro
Recommended lubricant
de
3 2. Install:
nl
1
• secondary sliding sheave 1
ow
2
NOTE:
D
5 - 46
BELT DRIVE ENG
3. Install:
• guide pin 1
4. Lubricate:
• guide pin groove 2
• O-ring 3 New
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube
5. Install:
• spring seat
2 • compression spring
• clutch shoe assembly
• clutch shoe assembly nut 1
1
t
NOTE:
ne
_
e.
3 sheave fixed block 3 onto the secondary
m
sheave assembly as shown. Then, compress
Ti
the spring, and tighten the clutch shoe assem-
bly nut. er
ot
co
.S
90890-04134, YM-04134
w
90890-04135, YM-04135
m
fro
d
de
oa
EAS00325
INSTALLING THE SECONDARY SHEAVE,
nl
1. Install:
D
• V-belt 1
• secondary sheave assembly 2
CAUTION:
_
NOTE:
_
5 - 47
BELT DRIVE ENG
2. Tighten:
2 • clutch shoe assembly nut 1
90 Nm (9.0 m · kg, 65 ft · lb)
T.
R.
NOTE:
_
1
Rotor holding tool
90890-01235, YU-01235
Locknut wrench
90890-01348, YM-01348
1
3. Install:
• clutch housing 1
t
2
ne
• collar
secondary sheave nut 2
e.
•
m
60 Nm (6.0 m · kg, 43 ft · lb)
T.
R.
3
Ti
NOTE:
er
While holding the clutch housing with the
ot
sheave holder 3, tighten the secondary
co
sheave nut.
.S
w
w
Sheave holder
w
90890-01701, YS-01880-A
m
fro
d
de
oa
4. Install:
• V-belt
nl
ow
NOTE:
1 • Install the V-belt onto the primary sheave 1
2 (when the pulley is at its widest position) and
onto the secondary sheave assembly 2
(when the pulley is at its narrowest position),
and make sure the V-belt is tight.
• While holding the primary fixed sheave with
the rotor holding tool, tighten the primary
sheave nut.
5 - 48
STARTER CLUTCH AND GENERATOR ENG
EAS00341
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Removing the generator rotor cover Remove the parts in the order listed.
D
5 - 49
STARTER CLUTCH AND GENERATOR ENG
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
5 - 50
STARTER CLUTCH AND GENERATOR ENG
EAS00343
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Removing the starter clutch and Remove the parts in the order listed.
D
generator
1 Generator rotor 1 Refer to “REMOVING THE GENERA-
2 Starter clutch 1 TOR”, “INSTALLING THE STARTER
3 Woodruff key 1 CLUTCH” and “INSTALLING THE GEN-
4 Starter clutch gear 1 ERATOR”.
5 Starter clutch idle gear shaft 1
6 Starter clutch idle gear 1
For installation, reverse the removal pro-
cedure.
5 - 51
STARTER CLUTCH AND GENERATOR ENG
EAS00347
REMOVING THE GENERATOR
1. Remove:
• generator rotor cover bolts
• generator rotor cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
2 1 2. Remove:
• generator rotor nut 1
• washer
4 • starter clutch bolts 2
t
ne
3 NOTE:
_
e.
2 sheave holder 4, loosen the generator rotor
m
Ti
nut and all starter clutch bolts.
er
• Do not allow the sheave holder to touch the
ot
projection on the generator rotor.
co
Sheave holder
w
90890-01701, YS-01880-A
m
fro
d
de
oa
3. Remove:
2 • generator rotor 1
nl
• woodruff key
D
NOTE:
_
5 - 52
STARTER CLUTCH AND GENERATOR ENG
Flywheel puller
90890-01362
Flywheel puller attachment
90890-04089, YM-33282
4. Remove:
• starter clutch bolts
• starter clutch
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch rollers 1
Damage/wear → Replace.
t
2. Check:
ne
• starter clutch idle gear
e.
• starter clutch gear
m
Burrs/chips/roughness/wear → Replace the
Ti
defective part(s).
3. Check: er
ot
• starter clutch gear’s contacting surfaces
co
clutch gear.
w
w
w
m
fro
d
de
oa
4. Check:
• starter clutch operation
nl
ow
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch drive gear 1 onto
D
5 - 53
STARTER CLUTCH AND GENERATOR ENG
EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:
• starter clutch bolts 1 LT
T.
R.
NOTE:
_
Sheave holder
90890-01701, YS-01880-A
t
ne
e.
m
Ti
er
ot
EAS00354
co
INSTALLING THE GENERATOR
1 1. Install:
.S
• woodruff key 2
w
w
2 • generator rotor
m
• washer
fro
_
de
2. Tighten:
3 • generator rotor nut 1
2 130 Nm (13.0 m · kg, 94 ft · lb)
T.
R.
NOTE:
_
Sheave holder
90890-01701, YS-01880-A
5 - 54
STARTER CLUTCH AND GENERATOR ENG
3. Apply:
• sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)
4. Install:
• generator rotor cover
• generator rotor cover bolts
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
NOTE:
• Align the projection a on the impeller shaft
t
ne
with the slit b on the balancer shaft.
e.
a b • Tighten the generator rotor cover bolts in
m
stages and in a crisscross pattern.
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
5 - 55
OIL PUMP ENG
EAS00356
OIL PUMP
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Removing the oil pump Remove the parts in the order listed.
D
5 - 56
OIL PUMP ENG
EAS00364
CHECKING THE OIL PUMP
1. Check:
• oil pump drive sprocket
• oil pump driven sprocket
• oil pump housing
• oil pump housing cover
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance a
• outer-rotor-to-oil-pump-housing clearance
b
• oil-pump-housing-to-inner-rotor-and-outer-
t
ne
rotor clearance c
Out of specification → Replace the oil
e.
m
pump.
Ti
1 Inner rotor
2 Outer rotor
er
3 Oil pump housing
ot
co
Inner-rotor-to-outer-rotor-tip
.S
clearance
w
Outer-rotor-to-oil-pump-housing
clearance
m
0.013 ~ 0.036 mm
fro
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
oa
0.040 ~ 0.096 mm
nl
3. Check:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
5 - 57
OIL PUMP ENG
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:
• oil pump shaft 1
(to the oil pump cover 2)
• pin 3
• inner rotor 4
t
ne
• outer rotor 5
• oil pump housing 6
e.
m
• screw
Ti
NOTE:
er
_
inner rotor 4.
.S
w
3. Check:
w
EAS00376
INSTALLING THE OIL PUMP
nl
a 1. Install:
ow
CAUTION:
b _
NOTE:
_
5 - 58
CRANKSHAFT ENG
EAS00381
CRANKSHAFT
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ASSEMBLY
New
8
LT E
5
E 9
2
LT
4
t
ne
3
e.
12
1
m
6 New
Ti
7
er
New
8
ot
11
co
E 10
.S
(3)
w
w
E (7)
w
13
m
T.
R.
R.
de
Removing the crankshaft assembly Remove the parts in the order listed.
D
5 - 59
CRANKSHAFT ENG
New
8
LT E
5
E 9
2
LT
4
t
ne
3
e.
12
1
m
6 New
Ti
7
er
New
8
ot
11
co
E 10
.S
(3)
w
w
E (7)
w
13
m
T.
R.
R.
de
6 Dowel pin 1
D
7 O-ring 1
8 Dowel pin 2
9 Left crankcase 1
10 Relief valve assembly 1
11 Oil pump drive gear 1
12 Oil pump drive gear shaft 1
13 Oil pump driven gear 1
14 Oil pump driven gear shaft 1
For installation, reverse the removal pro-
cedure.
5 - 60
CRANKSHAFT ENG
CRANKCASE BEARINGS
E
3
t
ne
e.
m
2
Ti
1 er
ot
co
E
.S
w
w
w
LS
m
fro
4 New
d
de
oa
nl
Removing the crankcase bearings Remove the parts in the order listed.
D
5 - 61
CRANKSHAFT ENG
EAS00385
DISASSEMBLING THE CRANKCASE
1. Remove:
• crankcase bolts
NOTE:
_
2. Remove:
• right crankcase
CAUTION:
_
t
soft-face hammer. Tap only on reinforced
ne
portions of the crankcase, not on the
e.
crankcase mating surfaces. Work slowly
m
and carefully and make sure the crankcase
Ti
halves separate evenly.
er
ot
co
.S
w
w
w
m
fro
d
de
oa
EAS00387
REMOVING THE CRANKSHAFT JOURNAL
nl
BEARINGS
ow
2
1. Remove:
1
D
NOTE:
2 Identify the position of each crankshaft journal
bearing so that they can be reinstalled in their
original places.
5 - 62
CRANKSHAFT ENG
EAS00394
CHECKING THE CRANKSHAFT AND
CONNECTING ROD
1. Measure:
• crankshaft runout
Out of specification → Replace the crank-
shaft, bearing or both.
NOTE:
_
2. Check:
• crankshaft journal surfaces
t
ne
Scratches/wear → Replace the crankshaft.
e.
m
Ti
er
ot
3. Measure:
co
0.350 ~ 0.850 mm
fro
4. Measure:
de
• crankshaft-journal-to-crankshaft-journal-
oa
bearing clearance
Out of specification → Replace the crank-
nl
ow
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
0.030 ~ 0.077 mm
(0.0012 ~ 0.0030 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The following procedure applies to each
crankshaft journal and its corresponding
journal bearing.
a. Clean the surface of the journal and the
journal bearing.
b. Check the bearing surface. If the bearing
surface is worn or scratched, replace the
bearings as a set.
5 - 63
CRANKSHAFT ENG
NOTE:
If either the left or right journal bearing is worn
or scratched, replace both bearings as a set.
a
c. Measure the crankshaft journal outside
diameter a in two places. If it is out of spec-
ification, replace the crankshaft.
d. Measure the journal bearing inside diame-
ter b in two places.
CAUTION:
When calculating the journal oil clearance,
use the larger of the two values from the
crankshaft journal and use the smaller of
the two values from the journal bearing.
t
ne
e. If the journal bearing inside diameter is
e.
“35.064” and the crankshaft journal outside
m
b
Ti
diameter is “35.014”, then the journal oil
er
clearance is:
ot
Journal oil clearance:
co
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d
de
oa
È 5. Select:
• crankshaft journal bearings
nl
1
ow
NOTE:
The numbers 1 on the crankcase are used to
D
É
1
5 - 64
CRANKSHAFT ENG
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Select the crankshaft journal bearings from the
following table according to the number
stamped on the inside of the crankcase.
Left crankshaft journal bearing:
BEARING COLOR BEARING
CODE THICKNESS
1.981 ~ 1.991 mm
0 white
(0.0780 ~ 0.0784 in)
1.977 ~ 1.987 mm
1 blue
(0.0778 ~ 0.0782 in)
1.973 ~ 1.983 mm
2 black
(0.0777 ~ 0.0781 in)
1.969 ~ 1.979 mm
3 brown
t
ne
(0.0775 ~ 0.0779 in)
e.
1.965 ~ 1.975 mm
4 green
m
(0.0774 ~ 0.0778 in)
Ti
Right crankshaft journal bearing:
er
ot
BEARING COLOR BEARING
co
CODE THICKNESS
.S
1.985 ~ 1.995 mm
0 white
w
1.981 ~ 1.991 mm
w
1 blue
(0.0780 ~ 0.0784 in)
m
1.977 ~ 1.987 mm
fro
2 black
(0.0778 ~ 0.0782 in)
d
1.973 ~ 1.983 mm
de
3 brown
(0.0777 ~ 0.0781 in)
oa
1.969 ~ 1.979 mm
4 green
nl
6. Measure:
• crankshaft width
Out of specification → Replace the crank-
shaft.
Crankshaft width
63.95 ~ 64.00 mm
(2.518 ~ 2.520 in)
5 - 65
CRANKSHAFT ENG
7. Check:
2 • crankshaft sprocket 1
Damage/wear → Replace the crankshaft.
• balancer drive gear 2
Damage/wear → Replace the crankshaft.
8. Check:
• crankshaft journal
Scratches/wear → Replace the crankshaft.
• crankshaft journal oil passage
Obstruction → Blow out with compressed
t
ne
air.
e.
m
Ti
er
ot
CHECKING THE BALANCER SHAFT
co
ASSEMBLY
.S
1. Check:
w
Cracks/damage → Replace.
w
m
fro
d
de
oa
EAS00399
CHECKING THE CRANKCASE
nl
mild solvent.
D
5 - 66
CRANKSHAFT ENG
EAS00207
CHECKING THE TIMING CHAIN AND
TIMING CHAIN GUIDE (INTAKE SIDE)
1. Check:
• timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprockets as a set.
2. Check:
• timing chain guide (intake side)
Damage/wear → Replace.
CHECKING THE OIL PUMP GEARS AND
SHAFTS
1. Check:
• oil pump drive gear
• oil pump driven gear
t
ne
• oil pump drive gear shaft
e.
• oil pump driven gear shaft
Cracks/damage/wear → Replace the defec-
m
Ti
tive part(s).
er
ot
EAS00365
co
CHECKING THE RELIEF VALVE
1. Check:
.S
3
• relief valve body 1
w
• relief valve 2
w
2
w
• spring 3
Damage/wear → Replace the defective
m
fro
1 part(s).
d
de
oa
EAS00401
CHECKING THE BEARINGS AND OIL
nl
SEALS
ow
1. Check:
D
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
2. Check:
• oil seals
Damage/wear → Replace.
5 - 67
CRANKSHAFT ENG
EAS00402
CHECKING THE CIRCLIPS AND WASHERS
1. Check:
• circlips
Bends/damage/looseness → Replace.
• washers
Bends/damage → Replace.
t
ne
Attach the crankshaft journal bearing to the
e.
installer 2.
m
Ti
er
Plane bearing installer/remover
90890-04146, YM-04146
ot
co
2. Install:
.S
NOTE:
w
1
w
facing inward.
• To install the crankshaft journal bearings,
d
3 Left crankcase
4 Right crankcase
D
b b 3
5 - 68
CRANKSHAFT ENG
EAS00410
t
ne
e.
m
Ti
er
ot
EAS00418
co
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating sur-
.S
2. Apply:
w
w
• sealant
m
90890-85505
de
NOTE:
ow
5 - 69
CRANKSHAFT ENG
3. Tighten:
2 3 5
• crankcase bolts
NOTE:
Tighten the crankcase bolts in stages and in a
4 crisscross pattern.
1
• M8 × 100 mm (3.94 in) bolt: 1
5 • M8 × 90 mm (3.54 in) bolt: 2
5 • M8 × 80 mm (3.15 in) bolt: 3
• M8 × 60 mm (2.36 in) bolts: 4
• M6 × 70 mm (2.76 in) bolts: 5
Crankcase bolt
Bolt 1
T.
R.
30 Nm (3.0 m · kg, 22 ft · lb)
Bolt 2 ~ 4
t
ne
16 Nm (1.6 m · kg, 11 ft · lb)
e.
Bolt 5
m
10 Nm (1.0 m · kg, 7.2 ft · lb)
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
5 - 70
TRANSMISSION ENG
EAS00419
TRANSMISSION
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
5 - 71
TRANSMISSION ENG
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
8 Drive axle 1
D
9 Main axle 1
10 Washer 1
11 Primary driven gear 1
12 Washer 1
For installation, reverse the removal
procedure.
5 - 72
TRANSMISSION ENG
EAS00425
CHECKING THE TRANSMISSION
1. Check:
• transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
2. Check:
• transmission gear movement
Rough movement → Replace the defective
part(s).
3. Check:
• circlips
Bends/damage/looseness → Replace.
t
ne
e.
m
Ti
er
ot
INSTALLING THE PRIMARY DRIVE GEAR
co
OIL SEAL
.S
1. Install:
w
NOTE:
w
a tration.
1
d
de
5 - 73
COOL
CHAPTER 6
COOLING SYSTEM
THERMOSTAT ................................................................................................6-4
CHECKING THE THERMOSTAT.............................................................. 6-5
INSTALLING THE THERMOSTAT............................................................ 6-6
t
ne
CHECKING THE OIL COOLER ................................................................6-9
ASSEMBLING THE WATER PUMP........................................................ 6-10
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
RADIATOR COOL
EAS00454
COOLING SYSTEM
RADIATOR
5
7
t
ne
e.
m
Ti
4
1
er
ot
7 Nm (0.7 m • kg, 5.1 ft • Ib)
co
T.
6
R.
3
.S
w
8 2
w
w
m
fro
d
de
oa
nl
6-1
RADIATOR COOL
EAS00455
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radi-
ator.
Damage → Repair or replace.
NOTE:
_
2. Check:
• radiator inlet hose
• radiator outlet hose
t
ne
• radiator filler hose
• coolant reservoir hose
e.
• radiator pipe assembly
m
Cracks/damage → Replace.
Ti
er
ot
3. Measure:
co
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester 1 and radiator
oa
90890-01325, YU-24460-01
Radiator cap tester adapter
90890-01352, YU-33984
6-2
RADIATOR COOL
EAS00456
INSTALLING THE RADIATOR
1. Fill:
• cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
• cooling system
Leaks → Repair or replace any faulty part.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
t
ne
90890-01325, YU-24460-01
e.
Radiator cap tester adapter
90890-01352, YU-33984
m
Ti
b. Apply 100 kPa (1.0 kg/cm2, 14.22 psi) of
er
pressure.
ot
c. Measure the indicated pressure with the
co
gauge.
.S
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
w
w
3. Measure:
w
6-3
THERMOSTAT COOL
EAS00460
THERMOSTAT
T.
R.
4
5
2
t
ne
e.
m
3
Ti
er
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co
.S
w
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m
1
fro
d
de
oa
nl
6-4
THERMOSTAT COOL
EAS00462
CHECKING THE THERMOSTAT
1. Check:
• thermostat 1
Does not open at 70.5 ~ 73.5 °C (158.9 ~
164.3 °F) → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the ther-
mostat and thermometer’s indicated tem-
perature.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
t
1 Thermostat
ne
2 Container
e.
3 Thermometer
m
4 Water
Ti
È Fully closed
er
É Fully open
ot
NOTE:
_
co
2. Check:
m
• thermostat cover
fro
Cracks/damage → Replace.
3. Check:
d
de
Cracks/damage → Replace.
nl
ow
D
6-5
THERMOSTAT COOL
EAS00467
INSTALLING THE THERMOSTAT
1 1. Install:
• thermostat 1
• thermostat cover
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
2. Fill:
• cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
3. Check:
• cooling system
Leaks → Repair or replace any faulty part.
t
4. Measure:
ne
• radiator cap opening pressure
e.
Below the specified pressure → Replace
m
the radiator cap.
Ti
Refer to “CHECKING THE RADIATOR”.
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
6-6
WATER PUMP AND OIL COOLER COOL
EAS00469
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
9 New
New 5 4
LS
t
ne
LT 6
e.
12
m
New
Ti
10
New 13
er
1 E
11
ot
New New 8
co
LT
7
.S
w
w
w
2 New
m
LT
fro
de
oa
nl
Removing the water pump and oil Remove the parts in the order listed.
D
cooler
Generator rotor cover Refer to “STARTER CLUTCH AND GEN-
ERATOR” in chapter 5.
1 Oil cooler pipe 1
2 O-ring 2
3 Water pump outlet hose 1
4 Oil cooler cover 1
5 Oil cooler cover gasket 1
6 Generator rotor cover inner bracket 1
7 Water pump cover 1
8 O-ring 1
9 Circlip 1
10 Impeller shaft 1
6-7
WATER PUMP AND OIL COOLER COOL
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
9 New
New 5 4
LS
t
ne
LT 6
e.
12
m
New
Ti
10
New 13
er
1 E
11
ot
New New 8
co
LT
7
.S
w
w
w
2 New
m
LT
fro
de
oa
nl
12 Circlip 1
13 Bearing 1
For installation, reverse the removal pro-
cedure.
6-8
WATER PUMP AND OIL COOLER COOL
EAS00473
CHECKING THE WATER PUMP
1. Check:
• water pump cover
• impeller shaft
• water pump seal
Cracks/damage/wear → Replace.
2. Check:
• bearing
Rough movement → Replace.
3. Check:
• water pump inlet hose
• water pump outlet hose
• thermostat inlet hose
Cracks/damage → Replace.
t
ne
e.
m
Ti
er
ot
CHECKING THE OIL COOLER
co
1. Check:
1
.S
Cracks/damage → Replace.
w
w
m
fro
d
de
oa
2. Check:
• oil cooler cover 1
nl
Cracks/damage → Replace.
ow
3. Check:
D
6-9
WATER PUMP AND OIL COOLER COOL
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
• bearing New
• circlip New
• water pump seal 1 New
(into the generator rotor cover 2)
NOTE:
_
t
ne
È Push down.
e.
m
Ti
er
ot
2. Lubricate:
co
Recommended lubricant
w
w
Lithium-soap-based grease
w
m
fro
d
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nl
ow
D
6 - 10
FI
CHAPTER 7
FUEL INJECTION SYSTEM
t
ne
THROTTLE BODY AND FUEL INJECTOR............................................. 7-25
e.
FUEL HOSE ............................................................................................ 7-27
m
FUEL TANK............................................................................................. 7-28
Ti
REMOVING THE FUEL HOSE ...............................................................7-30
er
REMOVING THE FUEL PUMP ...............................................................7-30
ot
CHECKING THE FUEL INJECTOR ........................................................ 7-31
co
CANISTER..................................................................................................... 7-41
FUEL INJECTION SYSTEM FI
EAS00894
t
ne
e.
m
Ti
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3
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7 9 A
B
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8 0
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2
6
m
4
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1 5
d
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D
J H F C
I D
G E
7-1
A B C
8 9
R/G R R R
2 W/R
W/L O Gy Sb R L Y/G P/W
O/B P Lg W R/W B/R Br/W R/L
W/L W/R G/B W/B B/L L/Y W/R Y G/R R
R W Q
R/Y G/Y B B/W Y/L L/B W/L
(BLACK) (BLACK) R/B
R R L B/L Y/L
W W L/W G/Y O O
W W R R (GRAY) W/R R
1 3 (BLACK)
W W W/L
WIRING DIAGRAM
R R R/B R
B R L
W W W R R K Y/L Y/L B Y Y P B P R
W W W W W W 0
B B/L L L B L L Lg B Lg
(BLACK) S R/L
D B A
L P/W
B/L
P/W B P/W
G/R B
P/W
G/R
Gy
Sb
B
B
Gy
Sb
Lg Sb
R/B R/Y
G/W B/L P/W L
G/Y R/B
L/G R/G R/G R P Gy
B B G/Y (BLACK) G/R B/L T
B B (BLACK)
L/W
4 B E B/L O (GREEN)
ow
R R B R/Y R/L
R L/G ON Br/L Br/L G/Y Br/W Br/W B Br/W Br/W R/Y
5 OFF
B
B L/Y G/W
L/W D R/L
R/B G/Y Br/W B/L M
L/B L/Y C (BLACK) (BLACK) (BLACK)
L/G L/Y L/Y B
(RED) (GREEN) B/L
nl
(RED) L/W G/Y L/Y B/L B B/L B/L U L Y O/B R/L
Br/L L/Y
L/Y Y/G P O/B B O/B R/L B R/L
oa
L Y/G B/L W/B G/B R/L G
6 B/R
7 L Y/G B/L
W
B/R B/R
Br/L R/W
de
N G B
B d L/Y R/L B
G/Y B B
R/W R/W
F R/B G/W L/Y
Y/L
B B L/B W W
G H I J L V
(BLUE)
Br G/W R/W R/W L/W Br B/L
fro
G/Y L/B R/B R/B B G/Y
B B/W B
B L/Y
m (BLUE)
W R
B
L W
B/L
L/B Br G/Y
~ w
Br/L R/Y
å w
R Br
7-2
ç w
Br/L Br
Br G/B
†
2 Crankshaft position C C
N Lean angle cut-off
Br Br
Br Br G/B
.S sensor L switch
Br Br
Br R/W G/Y
Br R/W
R/YR/Y Br
Br Main switch X L
4
\
O Coolant tempera-
co
R/Y
Br G/B
G/L Br/W
b Br P a ^
R/Y W/B (BLACK) Br
7 Ignition fuse ture sensor
(BLACK) L G/B
P
ot
G/LW/B L G/Y
L
Br/W
9 Fuel injection sys- P ECU
R/Y P Br/W Br G/Y L
er
d tem fuse Y OFF Br LQ Ignition coil
ON L L
e f g B B
(RED) (RED)
L L
Ti
OFF
G/L
m 0] Battery L
R Spark plug
(BLACK) (BLACK)
Y h L
G/B G B R/Y Br/W G/B Dg B
A Main fuse S ISC (idle speed
R/W P Br B G/Y Ch
q R/G Y/L G Gy L Y Dg Ch L L
(BLACK) (BLACK)
L L
G/B B Ch Dg control) valve
e.
E Starting circuitZ cut-
Dg G/B Br/W R/Y (BLUE) (BLUE)
FUEL INJECTION SYSTEM
c Ch G/Y B Br P
r L
Y G (BLACK) off relay L
T Fuel injection sys-
ne
B G/B
Gy
u v w x y z {
L L
s t [
G Engine stop switch t L B
tem relay
} B B B Gy (BLUE) (BLUE)
J Sidestand switch B
U Fuel injector
B
B/L
B
B
Y G K Throttle position V Speed sensor
| Ch Dg Y R/W R/G G
C
FI
B B/L B B A A
L Y/L B/L Gy B
(GRAY) (GRAY) Y G B
L Ch L Dg i Ch Dg Br Br G/Y sensor W Fuel pump
B Y G Y G
o n jk l
G
p p G L Dg B
L Intake air pressure r Multifunction meter
Y B
L Ch B
Y B
(BLACK)
B Ch L
B B
B Dg L
m sensor w Engine trouble
(BLACK)
B B Dg L/R
L Y warning light
Ch B
B
B
M Intake air tempera-
A B B
B Br Dg G/Y Br ture sensor
B Ch B
FUEL INJECTION SYSTEM FI
ECU’S SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys-
tem is operating normally. If this function detects a malfunction in the system, it immediately oper-
ates the engine under substitute characteristics and illuminates the engine trouble warning light to
alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected,
a fault code is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning correctly, the engine trouble
warning light flashes when the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, this mode provides an
appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by
illuminating the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the LCD meter.
Once a fault code has been displayed, it remains stored in the memory of the ECU until it is
deleted.
t
ne
EAS00900
Engine trouble warning light indication and FI system operating condition
e.
m
Warning light
ECU’s operation FI operation Vehicle operation
Ti
indication
Flashing* Warning provided er
Operation stopped Unable
ot
when unable to start
co
engine
.S
w
function
d
* The warning light flashes when any one of the conditions listed below is present and the start
de
switch is pushed.
oa
nl
7-3
FUEL INJECTION SYSTEM FI
EAS00901
Checking for a defective engine trouble warning light bulb
The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned
“ON” and when the start switch is being pushed. If the warning light does not come on under these
conditions, the warning light bulb may be defective.
Initialize
t
ne
EAS00902
ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION)
e.
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu-
m
minates the engine trouble warning light and provides the engine with alternate operating instruc-
Ti
tions that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values thater
ot
are programmed for each sensor in order to provide the engine with alternate operating instructions
co
that enable the engine to continue to operate or stop operating, depending on the conditions.
.S
The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed
w
value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions
w
Crankshaft position No normal signals are • Stops the engine (by stop-
oa
12 sensor received from the crankshaft ping the injection and igni- Unable Unable
position sensor. tion).
nl
ow
Intake air pressure Intake air pressure sensor- • Fixes the intake air pres-
13 sensor (open or short open or short circuit detected. sure to 101.3 kPa
Able Able
(1.01 kgf/cm2, 14.4 psi).
D
7-4
FUEL INJECTION SYSTEM FI
Fault Engine start- Vehicle drive-
Item Symptom Fail-safe action
code No. ability ability
ISC (idle speed con- Engine speed is high when the --
37 trol) valve (stuck fully engine is idling. Able Able
open)
Fuel injector Fuel injector open or short cir- --
39 Unable Unable
cuit is detected.
Lean angle cut-off The scooter has overturned. --
30 switch (latch up Lean angle cut-off switch-open
Unable Unable
41 detected) (open or or short circuit is detected.
short circuit)
Speed sensor No normal signals are --
42 received from the speed sen- Able Able
sor.
Fuel system voltage Supply power to the fuel injec- • Fixes the battery voltage
43 (monitoring voltage) tor and fuel pump is not nor- to 12 V. Able Able
mal.
Error in reading from or An error is detected while --
t
ne
writing on EEPROM reading from or writing on
EEPROM (CO adjustment
44 Able Able
e.
value, code re-registering key
m
code, and throttle valve fully
closed notification value).
Ti
Vehicle system power Power supply to the FI system --
46 supply (monitoring volt- not normal
er Able Able
ot
age)
co
50 Unable Unable
error) the code number might not
w
Start unable warning Relay is not activated even if Engine trouble warning light
the crank signal is input while flashes when the start
the start switch is pushed. The switch is turned ON.
d
7-5
FUEL INJECTION SYSTEM FI
EAS00904
TROUBLESHOOTING CHART
Engine operation is not normal or the engine trouble warning light is on.
* Engine trouble warning light may not come on even if the engine operation is not normal.
The engine trouble warning light comes on. The engine trouble warning light does not come on.
Check the fault code number displayed on the meter. Check the operation of following sensors and actua-
tors in the diagnostic mode. Refer to “Diagnostic
mode table”.
01: Throttle position sensor (throttle angle)
Identify the system with the malfunction. Refer to 30: Ignition coil
“FAIL-SAFE ACTIONS TABLE”. 36: Fuel injector
t
ne
Identify the probable cause of malfunction. Refer to
e.
“Fault code table”.
m
OK NG
Ti
Check and repair the probable cause of malfunction. er
Engine malfunction Defective sensor or
ot
actuator
co
Refer to “TROUBLE- Refer to “FAIL-SAFE Check and repair the Check and repair the
w
OK NG OK
de
Repairs completed
7-6
FUEL INJECTION SYSTEM FI
EAS00905
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators without
connecting the measurement equipment by
simply switching the meter indication from the
normal mode to the diagnostic monitoring
mode.
t
ne
3. Simultaneously press and hold the
e.
“SELECT” and “RESET” buttons, turn the
m
main switch to “ON”, and continue to press
Ti
the buttons for 8 seconds or more.
NOTE:
er
ot
• All displays on the meter disappear except
co
mode “dIAG”.
fro
NOTE:
• The diagnostic code number appears on the
LCD meter (01-70).
• To decrease the selected diagnostic code
01 70 70 01 number, press the “RESET” button. Press
the “RESET” button for 1 second or longer to
automatically decrease the diagnostic code
numbers.
• To increase the selected diagnostic code
number, press the “SELECT” button. Press
the “SELECT” button for 1 second or longer
to automatically increase the diagnostic code
numbers.
7-7
FUEL INJECTION SYSTEM FI
7. Verify the operation of the sensor or actua-
tor.
• Sensor operation
The data representing the operating condi-
tions of the sensor appears on the trip LCD.
• Actuator operation
Set the engine stop switch to “ON” to oper-
ate the actuator.
* If the engine stop switch is set to “ON”, set it
to “OFF”, and then set it to “ON” again.
8. Turn the main switch to “OFF” to cancel the
the diagnostic mode.
NOTE:
To perform a reliable diagnosis, make sure to
turn “OFF” the power supply before every
t
ne
check and then start right from the beginning.
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
7-8
FUEL INJECTION SYSTEM FI
Fault code table
Fault
Symptom Probable cause of malfunction Diagnostic code
Code No.
No normal signals are received from • Open or short circuit in wiring harness.
the crankshaft position sensor. • Defective crankshaft position sensor.
12 • Malfunction in pickup rotor. —
• Malfunction in ECU.
• Improperly installed sensor.
Intake air pressure sensor-open or • Open or short circuit in wiring sub lead.
short circuit detected. • Open or short circuit in wiring harness.
13 03
• Defective intake air pressure sensor.
• Malfunction in ECU.
Faulty intake air pressure sensor pipe • Intake air pressure sensor hose is disconnected,
system clogged, kinked, or pinched.
14 03
• disconnected hose • Malfunction in ECU.
• clogged hose
Throttle position sensor-open or short • Open or short circuit in wiring sub lead.
circuit detected. • Open or short circuit in wiring harness.
t
ne
15 • Defective throttle position sensor. 01
• Malfunction in ECU.
e.
• Improperly installed throttle position sensor.
m
A stuck throttle position sensor is • Stuck throttle position sensor.
16 01
Ti
detected. • Malfunction in ECU.
er
Open circuit in the input line (blue/yel- • Open circuit in wiring harness (ECU coupler).
19 low lead) of ECU is detected when • Malfunction in ECU. 20
ot
the start switch is pressed.
co
• Malfunction in ECU.
fro
• Malfunction in ECU.
de
33 • Malfunction in ECU. 30
nl
tem.
The ISC (idle speed control) valve is • Defective speed sensor.
D
7-9
FUEL INJECTION SYSTEM FI
Fault
Symptom Probable cause of malfunction Diagnostic code
Code No.
An error is detected while reading or • Malfunction in ECU. (The CO adjustment value and
44 writing on EEPROM. throttle valve fully closed notification value are not prop- 60
erly written on or read from the internal memory.)
Power supply to the FI system is not • Malfunction in charging system.
46 —
normal.
Faulty ECU memory. When this mal- • Malfunction in ECU. (The program and data are not
50 function is detected, the code number properly written on or read from the internal memory.) —
might not appear on the meter.
ISC (idle speed control) valve open or • Open or short circuit in wiring harness.
61 short circuit is detected. • Defective ISC (idle speed control) valve. 54
• Malfunction in ECU.
No signals are received from the • Open or short circuit in wiring sub lead.
Er-1 ECU. • Malfunction in meter. —
• Malfunction in ECU.
No signals are received from the ECU • Improper connection in wiring sub lead.
Er-2 within the specified duration. • Malfunction in meter. —
t
ne
• Malfunction in ECU.
Data from the ECU cannot be • Improper connection in wiring sub lead.
e.
Er-3 received correctly. • Malfunction in meter. —
m
• Malfunction in ECU.
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Non-registered data has been • Improper connection in wiring sub lead.
er
Er-4 received from the meter. • Malfunction in meter. —
• Malfunction in ECU.
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EAS00907
Diagnostic mode table
.S
Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer
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to “DIAGNOSTIC MODE”.
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NOTE:
m
• Check the intake air temperature and coolant temperature as close as possible to the intake air
fro
01 • Check with throttle fully closed. • Fully closed position (15 ~ 16)
• Check with throttle fully open. • Fully open position (97 ~ 102)
D
Pressure difference Displays the pressure difference (atmospheric pres- When engine is stopped:
(atmospheric pressure- sure-intake air pressure). Atmospheric pressure 101.3 kPa
intake air pressure) Engine stop switch is on. (760 mmHg, 30 inHg) when cranking
03
• Generate the pressure difference by cranking the the engine with the start switch.
engine with the starter, without actually starting the 0 ~ 126 kPa (1.26 kgf/cm2, 17.9 psi)
engine.
Intake air temperature Displays the intake air temperature. Compare it to the value displayed on
05
• Check the temperature in the air cleaner case. the meter.
Coolant temperature Displays the coolant temperature. Compare it to the value displayed on
06
• Check the temperature of the coolant. the meter.
Vehicle speed pulse Displays the accumulation of the vehicle pulses that (0 ~ 999; resets to 0 after 999)
07 are generated when the tire is spun. OK if the numbers appear on the
meter.
Lean angle cut-off switch Displays the lean angle cut-off switch values. Upright: 0.4 ~ 1.4 V
08
Overturned: 3.8 ~ 4.2 V
7 - 10
FUEL INJECTION SYSTEM FI
Diagnostic Data displayed on meter
Item Description of action
code (reference value)
Fuel system voltage Displays the fuel system voltage (battery voltage). 0 ~ 18.7 V
09
(battery voltage) Engine stop switch is on. Normally, approximately 12.0 V
Sidestand switch Displays that the switch is ON or OFF. Stand retracted: ON
20
Stand extended: OFF
Ignition coil When the engine stop switch is turned from OFF to Check that spark is generated,
ON, the ignition coil is actuated five times per sec- 5 times with the engine stop switch
ond and the engine trouble warning light comes on. ON.
30
• Connect an ignition checker.
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
Fuel injector When the engine stop switch is turned from OFF to Check the operating sound of the fuel
ON, the fuel injector is actuated five times per sec- injector five times with engine stop
36 ond and the engine trouble warning light comes on. switch ON.
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
Fuel injection system When the engine stop switch is turned from OFF to Check the fuel injection system relay
t
relay ON, the fuel injection system relay is actuated five operating sound 5 times with the
ne
times per second and the engine trouble warning engine stop switch ON.
50 light comes on (the light is OFF when the relay is
e.
ON, and the light is ON when the relay is OFF).
m
• If the engine stop switch is ON, turn it OFF, and
Ti
then turn it back ON.
Radiator fan motor relay
er
When the engine stop switch is turned from OFF to Check the radiator fan motor relay
ot
ON, the radiator fan motor relay is actuated five operating sound 5 times with the
times every 5 seconds and the engine trouble warn- engine stop switch ON.
co
51
ing light comes on. (ON 2 seconds, OFF 3 seconds) (At that time, the fan motor rotates.)
.S
Headlight relay 1 When the engine stop switch is turned from OFF to Check the headlight relay operating
w
ON, the headlight relay is actuated five times every sound 5 times with the engine stop
w
comes on. (ON 2 seconds, OFF 3 seconds) (At that time, the headlight turns ON.)
• If the engine stop switch is ON, turn it OFF, and
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valve ON, the ISC (idle speed control) valve fully closes, unit vibrates when the ISC (idle speed
and then it opens until it is at the standby opening control) valve operates.
oa
pleted.
ow
Grip warmer relay When the engine stop switch is turned from OFF to Check the grip warmer relay operat-
ON, the grip warmer relay is actuated and the ing sound 1 time with the engine stop
engine trouble warning light comes on. (the light is switch ON.
57 OFF when the relay is OFF, and the light is ON
when the relay is ON).
• If the engine stop switch is ON, turn it OFF, and
then turn it back ON.
EEPROM fault code dis- • Transmits the abnormal portion of the data in the 01 CO adjustment value is detected.
play EEPROM that has been detected as a fault code 04 Throttle valve fully closed notifica-
44. tion value is detected.
60
• If multiple malfunctions have been detected, differ- (00) Displays when there is no mal-
ent codes are displayed at 2-second intervals, and function.
this process is repeated.
7 - 11
FUEL INJECTION SYSTEM FI
Diagnostic Data displayed on meter
Item Description of action
code (reference value)
Malfunction history code • Displays the codes of the history of the self-diag- 12 ~ 61
display nosis malfunctions (i.e., a code of a malfunction (00) Displays when there is no mal-
that occurred once and which has been corrected). function.
61
• If multiple malfunctions have been detected, differ-
ent codes are displayed at 2-second intervals, and
this process is repeated.
Malfunction history code • Displays the total number of codes that are being 00 ~ 19
erasure detected through self diagnosis and the fault codes (00) Displays when there is no mal-
in the past history. function.
62 • Erases only the history codes when the engine
stop switch is turned from OFF to ON. If the engine
stop switch is ON, turn it OFF once, and then turn
it back ON.
70 Control number • Displays the program control number. 00 ~ 255
EAS00908
TROUBLESHOOTING DETAILS
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ne
This section describes the countermeasures per fault code number displayed on the meter. Check
and service the items or components that are the probable cause of the malfunction following the
e.
m
order given.
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After the check and service of the malfunctioned part has been completed, reset the meter display
according to the “Reinstatement method”.
er
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Fault code No.:
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Fault code number displayed on the meter when the engine failed to work normally. Refer to “Fault
.S
code table”.
Diagnostic code No.:
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Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOS-
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TIC MODE”.
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7 - 12
FUEL INJECTION SYSTEM FI
Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor.
Used diagnostic code No. – –
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Installed condition of sensor. Check the installed area for looseness or pinching. Reinstated by
cranking the
2 Connected condition of connector. If there is a malfunction, repair it and connect it
engine.
Inspect the coupler for any pins securely.
that may have pulled out. Crankshaft position sensor coupler
Check that the coupler is con- Main wiring harness ECU coupler
nected securely.
NOTE:
Set the main switch to OFF before
connecting or disconnecting the
connector.
3 Open or short circuit in wiring har- Repair or replace if there is an open or short circuit
t
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ness. between the main wiring harnesses.
Between sensor coupler and ECU coupler.
e.
white/blue – white/blue
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white/red – white/red
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4 Defective crankshaft position sen- Replace if defective.
sor.
er
Refer to “IGNITION SYSTEM” in chapter 8.
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.S
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7 - 13
FUEL INJECTION SYSTEM FI
Fault code No. 13 Symptom Intake air pressure sensor - open or short circuit detected.
Used diagnostic code No. 03 (intake air pressure sensor)
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by turn-
Inspect the coupler for any pins securely. ing the main switch
that may have pulled out. Intake air pressure sensor coupler ON.
Check the locking condition of the Main wiring harness ECU coupler
coupler. Sub-wire harness coupler
NOTE:
Set the main switch to OFF before
connecting or disconnecting the
connector.
2 Open or short circuit in wiring har- Repair or replace if there is an open or short circuit.
ness and/or sub lead. Between sensor coupler and ECU coupler
t
black/blue – black/blue
ne
pink/white – pink/white
e.
blue – blue
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3 Defective intake air pressure sen- Execute the diagnostic mode (code No. 03)
Ti
sor Replace if defective.
er
1. Connect the pocket tester (DC 20 V) to the intake
air pressure sensor coupler as shown.
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voltage.
D
7 - 14
FUEL INJECTION SYSTEM FI
Fault code No. 14 Symptom Intake air pressure sensor - hose system malfunction (clogged or detached
hose).
Used diagnostic code No. 03 (intake air pressure sensor)
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Intake air pressure sensor hose Repair or replace the sensor hose. Reinstated by
detached, clogged, kinked, or Inspect and repair the connection. starting the engine
pinched. and operating it at
Intake air pressure sensor mal- idle.
function at intermediate electrical
potential.
2 Connected state of connector Check the coupler for any pins that may have pulled
Intake air pressure sensor coupler out.
Main wiring harness ECU coupler Check that the coupler is connected securely.
If there is a malfunction, repair it and connect it
securely.
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ne
3 Defective intake air pressure sen- Execute the diagnostic mode (code No. 03)
sor. Replace if defective.
e.
Refer to “Fault code No. 13”.
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Fault code No. 15 Symptom Throttle position sensor - open or short circuit detected.
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ot
Used diagnostic code No. 01 (throttle position sensor)
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Order Inspection operation item and Operation item and countermeasure Reinstatement
.S
1 Installed condition of throttle posi- Check the installed area for looseness or pinching. Reinstated by turn-
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tion sensor. Check that it is installed in the specified position. ing the main switch
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Check the locking condition of the Main wiring harness ECU coupler
coupler. Sub-wire harness coupler
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3 Open or short circuit in wiring har- Repair or replace if there is an open or short circuit.
nl
ness and/or sub lead. Between sensor coupler and ECU coupler
ow
black/blue – black/blue
yellow – yellow, yellow/blue – yellow/blue
D
blue – blue
4 Throttle position sensor lead wire Check for open circuit and replace the throttle posi-
open circuit output voltage check. tion sensor.
black/blue – yellow/blue
5 Defective throttle position sensor. Execute the diagnostic mode (code No. 01)
Replace if defective.
Refer to “THROTTLE BODY AND FUEL INJEC-
TOR”.
7 - 15
FUEL INJECTION SYSTEM FI
Fault code No. 16 Symptom Stuck throttle position sensor detected.
Used diagnostic code No. 01 (throttle position sensor)
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Installed condition of throttle posi- Check the installed area for looseness or pinching. Reinstated by
tion sensor. Check that it is installed in the specified position. starting the engine,
Refer to “THROTTLE BODY AND FUEL INJEC- operating it at idle,
TOR”. and then racing it.
2 Defective throttle position sensor Execute the diagnostic mode (code No. 01)
Replace if defective.
Refer to “THROTTLE BODY AND FUEL INJEC-
TOR”.
3 When fault code No. 15 has been Refer to “Fault code No. 15”. Refer to “Fault
detected. code No. 15”.
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ne
Fault code No. 19 Symptom Open circuit in the input line of ECU (blue/yellow lead) detected.
e.
Used diagnostic code No. 20 (sidestand switch)
m
Order Inspection operation item and Operation item and countermeasure Reinstatement
Ti
probable cause method
1 Connected state of connector
er
Execute the diagnostic mode (code No. 20) Reinstated by
ot
Main wiring harness ECU coupler Check the coupler for any pins that may have pulled reconnecting the
co
(blue/yellow connector) out. wiring and retract-
Check the locking condition of the coupler. ing the sidestand.
.S
securely.
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2 Open or short circuit in wiring har- Repair or replace if there is an open circuit.
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ness and/or sub lead. Sidestand switch signal input line of ECU coupler
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blue/yellow
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Fault code No. 21 Symptom Coolant temperature sensor open or short circuit is detected.
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Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
nl
ow
1 Installed condition of sensor Check the installed area for looseness or pinching. Reinstated by turn-
ing the main switch
D
7 - 16
FUEL INJECTION SYSTEM FI
Fault code No. 22 Symptom Intake temperature sensor open or short circuit is detected.
Used diagnostic code No. 05 (intake air temperature sensor)
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Installed condition of sensor Check the installed area for looseness or pinching. Reinstated by turn-
ing the main switch
2 Connected condition of connector If there is a malfunction, repair it and connect it
ON.
Inspect the coupler for any pins securely.
that may have pulled out. Intake air temperature sensor coupler
Check the locking condition of the Main wiring harness ECU coupler
coupler. Sub-wire harness coupler
3 Open or short circuit in wiring har- Repair or replace if there is an open or short circuit.
ness and/or sub lead. Between sensor coupler and ECU coupler
black/blue – black/blue
brown/white – brown/white
4 Defective intake air temperature Execute the diagnostic mode (code No. 05)
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sensor. Replace if defective.
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1. Remove the intake air temperature sensor from
e.
the air filter case.
2. Connect the pocket tester (Ω × 100) to the intake
m
air temperature sensor terminal as shown.
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er
Positive tester probe → brown/white 1
Negative tester probe → black/blue 2
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Br/W B/L
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2 1
d
tance.
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resistance
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WARNING
• Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature sen-
sor to strong shocks. If the intake air temper-
ature sensor is dropped, replace it.
7 - 17
FUEL INJECTION SYSTEM FI
Fault code No. 30 Symptom The scooter has overturned.
Used diagnostic code No. 08 (lean angle cut-off switch)
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 The scooter has overturned. Raise the scooter upright. Reinstated by turn-
ing the main switch
2 Installed condition of the lean Check the installed area for looseness or pinching.
ON (however, the
angle cut-off switch
engine cannot be
3 Connected condition of connector If there is a malfunction, repair it and connect it restarted unless
Inspect the coupler for any pins securely. the main switch is
that may have pulled out. Lean angle cut-off switch coupler first turned OFF).
Check the locking condition of the Main wiring harness ECU coupler
coupler.
4 Defective lean angle cut-off switch Execute the diagnostic mode (code No. 08)
Replace if defective.
1. Remove the lean angle cut-off switch from the
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scooter.
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2. Connect the lean angle cut-off switch coupler to
e.
the wire harness.
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3. Connect the pocket tester (DC 20 V) to the lean
angle cut-off switch terminals as shown.
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er
Positive tester probe → blue 1
Negative tester probe → yellow/green 2
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fro
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Fault code No. 33 Symptom Open circuit detected in the primary lead of the ignition coil.
D
7 - 18
FUEL INJECTION SYSTEM FI
Fault code No. 37 Symptom Engine speed is high when the engine is idling.
Used diagnostic code No. 54 (ISC (idle speed control) valve)
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Incorrect speed sensor signal Check the speed sensor. Reinstated if the
Check the speed sensor leads. engine idle speed
Check the speed sensor coupler. is within specifica-
tion after starting
2 Throttle valve does not fully close Check the throttle body.
the engine.
Refer to “THROTTLE BODY AND FUEL INJEC-
TOR”.
Check the throttle cables.
Refer to “ADJUSTING THE THROTTLE CABLE
FREE PLAY” in chapter 3.
3 ISC (idle speed control) valve The ISC (idle speed control) valve is stuck fully open
stuck fully open if it does not operate when the main switch is set to
OFF.
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ne
(Touch the ISC (idle speed control) valve unit with
your hand and check if it is vibrating to confirm if the
e.
ISC (idle speed control) valve is operating.)
m
NOTE:
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Do not remove the ISC (idle speed control) valve
unit.
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4 ISC (idle speed control) valve not Execute the diagnostic mode (code No. 54)
moving correctly After the ISC (idle speed control) valve is fully
.S
Fault code No. 39 Symptom Fuel injector open or short circuit is detected.
d
de
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
nl
ow
7 - 19
FUEL INJECTION SYSTEM FI
Fault code No. 41 Symptom Lean angle cut-off switch open or short circuit is detected.
Used diagnostic code No. 08 (lean angle cut-off switch)
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by turn-
Inspect the coupler for any pins securely. ing the main switch
that may have pulled out. Lean angle cut-off switch coupler ON.
Check the locking condition of the Main wiring harness ECU coupler
coupler.
2 Open or short circuit in wiring har- Repair or replace if there is an open or short circuit.
ness. Between switch coupler and ECU coupler
black/blue – black/blue
yellow/green – yellow/green
blue – blue
3 Defective lean angle cut-off switch Execute the diagnostic mode (code No. 08)
Replace if defective.
t
ne
Refer to Fault code No. 30.
e.
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Fault code No. 42 Symptom No normal signals are received from the speed sensor.
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Used diagnostic code No. 07 (speed sensor)
Order Inspection operation item and er
Operation item and countermeasure Reinstatement
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probable cause method
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1 Connected condition of speed sen- If there is a malfunction, repair it and connect it Reinstated by
.S
Inspect the coupler for any pins Speed sensor coupler and inputting the
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that may have pulled out. Main wiring harness ECU coupler vehicle speed sig-
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speed of 20 to
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2 Open or short circuit in speed sen- Repair or replace if there is an open or short circuit.
30 km/h.
sor lead. Between sensor coupler and ECU coupler
d
blue – blue
de
white – white
black/blue – black/blue
oa
3 Defective speed sensor Execute the diagnostic mode (code No. 07)
nl
Replace if defective.
ow
7 - 20
FUEL INJECTION SYSTEM FI
Fault code No. 43 Symptom Supply power to the fuel injector and fuel pump is not normal.
Used diagnostic code No. 09 (fuel system voltage)
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by
Inspect the coupler for any pins securely. starting the engine
that may have pulled out. Fuel injection system relay coupler and operating it at
Check the locking condition of the Fuel pump coupler idle.
coupler. Fuel injector coupler
ECU coupler
2 Malfunction in ECU Fuel injection system relay is on.
3 Open or short circuit in the wiring Repair or replace if there is an open or short circuit.
harness. Between battery and ECU coupler
red – red
red/blue – red/blue
t
4 Malfunction or open circuit in fuel Execute the diagnostic mode (code No. 09)
ne
injection system relay
NOTE:
e.
When the leads are disconnected, the voltage check
m
by the code No. 09 is impossible.
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Replace if defective.
er
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1. Remove the fuel injection system relay.
2. Connect the pocket tester (Ω × 1) and battery
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as shown.
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3
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de
4
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2 1
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R/Y R/B
ow
R/L
R
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7 - 21
FUEL INJECTION SYSTEM FI
Fault code No. 44 Symptom Error is detected while reading from or writing on EEPROM
(code re-registering key code and throttle valve fully closed notification value).
Used diagnostic No. 60 (EEPROM improper cylinder indication)
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Malfunction in ECU Execute diagnostic mode (code No. 60) Reinstated by turn-
• 01 is displayed on meter. ing the main switch
Readjust the CO of the displayed cylinder. ON.
Refer to “ADJUSTING THE EXHAUST GAS
VOLUME” in chapter 3.
Replace ECU if defective.
• 03 is displayed on meter.
Replace the ECU.
• 04 is displayed on meter.
Turn the main switch to ON, and turn the throt-
tle grip to full open and then to full close posi-
tion.
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ne
Replace ECU if defective.
e.
m
Fault code No. 46 Symptom Power supply to the FI system relay is not normal.
Ti
Used diagnostic code No. – –
Order Inspection operation item and er
Operation item and countermeasure Reinstatement
ot
probable cause method
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Inspect the coupler for any pins securely. starting the engine
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coupler.
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3 Open or short circuit in wiring har- Repair or replace if there is an open or short circuit.
de
red – red
• Between main switch and fuse (ignition)
nl
brown/blue – brown/blue
ow
7 - 22
FUEL INJECTION SYSTEM FI
Fault code No. 50 Symptom Faulty ECU memory. (When this malfunction is detected in the ECU, the fault
code number might not appear on the meter.)
Used diagnostic code No. – –
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Malfunction in ECU Replace the ECU. Reinstated by turn-
ing the main switch
ON.
Fault code No. 61 Symptom ISC (idle speed control) valve open or short circuit is detected.
Used diagnostic code No. – –
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by set-
Inspect the coupler for any pins securely.
t
ting the main
ne
that may have pulled out. ISC (idle speed control) valve coupler switch to ON. The
e.
Check the locking condition of the Main wiring harness ECU coupler ISC (idle speed
coupler. Sub-wire harness coupler control) valve fully
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closes, and then it
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2 Open or short circuit in lead. Repair or replace if there is an open or short circuit.
opens until it is at
er
Between ISC (idle speed control) valve and ECU
the standby open-
coupler/main harness
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ing position when
pink – pink
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the engine is
light green – light green
started.
.S
gray – gray
sky blue – sky blue
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3 Detective ISC (idle speed control) Execute diagnostic mode (code No. 54)
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TOR”.
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d
Fault code No. Er-1 Symptom No signals are received from the ECU.
de
Order Inspection operation item and Operation item and countermeasure Reinstatement
nl
1 Connected condition of connector If there is a malfunction, repair it and connect it Reinstated if nor-
D
7 - 23
FUEL INJECTION SYSTEM FI
Fault code No. Er-2 Symptom No signals are received from the ECU within the specified duration.
Used diagnostic code No. – –
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
1 Connected condition of connector If there is a malfunction, repair it and connect it Reinstated if nor-
Inspect the coupler for any pins securely. mal signal is
that may have pulled out. Main wiring harness ECU coupler received from the
Check the locking condition of the Sub-wire harness coupler ECU when the
coupler. main switch is set
to ON.
2 Open or short circuit in wiring har- Repair or replace if there is an open or short circuit.
ness and/or sub lead. Between meter coupler and ECU coupler
yellow/blue – yellow/blue
3 Malfunction in meter Replace the meter.
4 Malfunction in ECU Replace the ECU.
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ne
Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly.
e.
Used diagnostic code No. – –
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Order Inspection operation item and Operation item and countermeasure Reinstatement
Ti
probable cause method
1 Connected condition of connector er
If there is a malfunction, repair it and connect it Reinstated if nor-
ot
Inspect the coupler for any pins securely. mal signal is
co
that may have pulled out. Main wiring harness ECU coupler received from the
.S
Check the locking condition of the Sub-wire harness coupler ECU when the
coupler. main switch is set
w
to ON.
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2 Open or short circuit in wiring har- Repair or replace if there is an open or short circuit.
w
ness and/or sub lead. Between meter coupler and ECU coupler
yellow/blue – yellow/blue
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fro
Fault code No. Er-4 Symptom Non-registered data has been received from the meter.
nl
Order Inspection operation item and Operation item and countermeasure Reinstatement
probable cause method
D
1 Connected condition of connector If there is a malfunction, repair it and connect it Reinstated if nor-
Inspect the coupler for any pins securely. mal signal is
that may have pulled out. Main wiring harness ECU coupler received from the
Check the locking condition of the Sub-wire harness coupler ECU when the
coupler. main switch is set
to ON.
2 Open or short circuit in wiring har- Repair or replace if there is an open or short circuit.
ness and/or sub lead. Between meter coupler and ECU coupler
yellow/blue – yellow/blue
3 Malfunction in meter Replace the meter.
4 Malfunction in ECU Replace the ECU.
7 - 24
THROTTLE BODY AND FUEL INJECTOR FI
EAS00909
T.
T.
R.
R.
2
6
3
LT
LT
13 12 1
7
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ne
e.
8
m
New
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11
4 er
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5
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9
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fro
10
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Removing the throttle body and fuel Remove the parts in the order listed.
D
injector
Air filter case (left and right) Refer to “AIR FILTER CASES” in chapter
3.
1 ISC (idle speed control) valve coupler 1 Disconnect.
2 Throttle position sensor coupler 1 Disconnect.
3 Intake air pressure sensor 1
4 Throttle body clamp screw 1 Loosen.
5 Throttle body 1
6 Vacuum chamber cover 1
7 Piston valve spring 1
8 Piston valve 1
9 Throttle cable 2 Disconnect.
10 Air filter case to throttle body hose 1 Disconnect.
7 - 25
THROTTLE BODY AND FUEL INJECTOR FI
T.
T.
R.
R.
2
6
3
LT
LT
13 12 1
7
t
ne
e.
8
m
New
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11
4 er
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5
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9
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fro
10
d
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nl
7 - 26
THROTTLE BODY AND FUEL INJECTOR FI
FUEL HOSE
3
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
10
7
8
6 3
9 2
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ne
e.
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1
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11
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4
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Removing the fuel hose Remove the parts in the order listed.
D
7 - 27
THROTTLE BODY AND FUEL INJECTOR FI
FUEL TANK
T.
R.
5
6 LT
LT (6)
6 10
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
9
t
New
ne
1
e.
m
7
Ti
er
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
ot
co
3
LT
1
.S
2 4
w
w
w
8
m
4
fro
LT
7
d
2 3
de
Removing the fuel tank Remove the parts in the order listed.
D
NOTE:
Place a suitable stand under the frame
and engine.
7 - 28
THROTTLE BODY AND FUEL INJECTOR FI
T.
R.
5
6 LT
LT (6)
6 10
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
9
t
New
ne
1
e.
m
7
Ti
er
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
ot
co
3
LT
1
.S
2 4
w
w
w
8
m
4
fro
LT
7
d
2 3
de
7 Sub-frame adjusting bolt (left and right) 2 Refer to “INSTALLING THE SUB-
D
7 - 29
THROTTLE BODY AND FUEL INJECTOR FI
REMOVING THE FUEL HOSE
1. Extract the fuel in the fuel tank through the
1
fuel tank filler hole with a pump.
2. Remove:
• fuel hose connector cover 1
2
3. Disconnect:
• fuel hose 2
CAUTION:
• Be sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the
hose with tools.
• Although the fuel has been removed from
the fuel tank, be careful when removing
the fuel hose, since there may be fuel
t
remaining in it.
ne
• Do not disconnect the fuel hose from the
e.
fuel hose connector. Disconnect the con-
m
nector from the fuel pump.
Ti
er
ot
NOTE:
co
3. Remove:
w
• fuel tank
m
fro
d
de
oa
• fuel pump
D
CAUTION:
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
EAS00911
CAUTION:
_
7 - 30
THROTTLE BODY AND FUEL INJECTOR FI
EAS00912
CHECKING THE FUEL INJECTOR
1. Check:
• fuel injector
Damage → Replace.
EAS00913
CHECKING THE THROTTLE BODY
1. Check:
2 • throttle body
Cracks/damage → Replace the throttle
t
body.
ne
2. Check:
e.
1 • piston valve 1
m
Damage/scratches/wear → Replace.
Ti
• piston valve diaphragm 2
er
Cracks/tears → Replace.
ot
co
.S
w
w
w
m
fro
d
de
oa
3. Check:
• vacuum chamber cover 1
nl
Cracks/damage → Replace.
D
4. Check:
• piston valve movement
Insert the piston valve into the throttle body
and move it up and down.
Tightness → Replace the piston valve.
7 - 31
THROTTLE BODY AND FUEL INJECTOR FI
INSTALLING THE FUEL PUMP
2 1. Install:
4
• fuel pump 4 Nm (0.4 m · kg, 2.9 ft · lb)
T.
R.
5 NOTE:
6
• Do not damage the installation surfaces of
È
the fuel tank when installing the fuel pump.
1 3 • Always use a new fuel pump gasket.
b • Align the projection a on the fuel pump with
a
the alignment mark b on the fuel tank.
• Tighten the fuel pump bolts in the proper
tightening sequence as shown and torque
them in two stages.
È Forward
t
ne
e.
m
Ti
er
ot
INSTALLING THE SUB-FRAME
co
1. Install:
2 2
.S
NOTE:
fro
2. Tighten:
oa
3 1
ow
NOTE:
Tighten the bolts on the left side of the scooter
D
first.
3
3. Tighten:
1
• sub-frame front lower mounting bolts
54 Nm (5.4 m · kg, 39 ft · lb)
T.
R.
NOTE:
Tighten the bolt on the left side of the scooter
first.
7 - 32
THROTTLE BODY AND FUEL INJECTOR FI
4. Tighten:
• sub-frame adjusting bolts
4 Nm (0.4 m · kg, 2.9 ft · lb)
T.
R.
1 2 NOTE:
• Tighten the bolt on the left side of the scooter
a first.
• Use the pivot shaft wrench 1 and pivot shaft
wrench adapter 2 to tighten the sub-frame
adjusting bolts.
• When tightening the sub-frame adjusting
bolts, make sure that the gap a shown
between the frame and the sub-frame is the
same on both sides of the scooter.
t
Pivot shaft wrench
ne
90890-01471, YM-01471
e.
Pivot shaft wrench adapter
m
90890-01476
Ti
er
5. Tighten:
ot
• sub-frame front upper mounting nuts
co
T.
R.
.S
NOTE:
w
first.
w
m
fro
d
de
oa
• fuel hose
• fuel hose connector cover
D
CAUTION:
Be sure to connect the fuel hose securely
and install the fuel hose connector cover in
the correct position, otherwise the fuel
hose will not be properly installed.
NOTE:
• Install the fuel hose connector securely onto
the fuel tank until a distinct “click” is heard,
1
and then make sure that it does not come
loose.
• After installing the fuel hose connector cover
1, make sure that it is installed securely.
7 - 33
THROTTLE BODY AND FUEL INJECTOR FI
EAS00915
CHECKING THE FUEL PUMP AND
1 PRESSURE REGULATOR OPERATION
1. Check:
• pressure regulator operation
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the storage box.
Refer to “COWLING AND COVERS” in
chapter 3.
b. Remove the fuel hose connector cover 1
and disconnect the fuel hose 2 from the
fuel pump.
CAUTION:
Although the fuel has been removed from
the fuel tank, be careful when removing the
t
ne
fuel hose, since there may be fuel remain-
e.
ing in it.
m
Ti
NOTE:
er
Before removing the hose, place a few rags in
ot
the area under where it will be removed.
co
4 3
.S
Pressure gauge
m
90890-03153, YU-03153
fro
Adapter
90890-03181, YM-03181
d
de
Fuel pressure
246 ~ 254 kPa
D
EAS00916
CHECKING THE THROTTLE POSITION
SENSOR
1. Check:
• throttle position sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
terminals of the throttle position sensor.
7 - 34
THROTTLE BODY AND FUEL INJECTOR FI
Positive tester probe → blue terminal 1
Negative tester probe →
Y/L B/L L black/blue terminal 2
Pocket tester
90890-03112, YU-03112-C
t
ne
c. Connect the pocket tester (DC 20 V) to the
e.
terminals of the throttle position sensor.
m
Positive tester probe →
Ti
yellow/blue terminal 3
er
Negative tester probe →
ot
black/blue terminal 2
co
.S
increased.
w
sensor.
Out of specification (closed position) →
d
de
(closed position)
ow
0.4 ~ 0.9 V
(yellow/blue–black/blue)
D
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 35
THROTTLE BODY AND FUEL INJECTOR FI
EAS00916
CHECKING THE ISC (IDLE SPEED
CONTROL) VALVE
NOTE:
Do not remove the ISC (idle speed control)
valve unit completely from the throttle body
assembly.
1. Check:
• ISC (idle speed control) valve
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ISC (idle speed control)
valve coupler from the ISC (idle speed con-
trol) valve.
b. Connect the pocket tester (Ω × 10) to the
t
ne
terminals of the ISC (idle speed control)
valve.
e.
m
Positive tester probe → pink terminal 1
Ti
Negative tester probe →
er light green terminal 2
ot
co
Lg Sb
Positive tester probe → gray terminal 3
.S
P Gy
Negative tester probe →
sky blue terminal 4
w
w
1 3
w
Pocket tester
m
90890-03112, YU-03112-C
fro
resistance.
de
body.
nl
ow
27 ~ 33 Ω at 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 36
AIR INDUCTION SYSTEM FI
EAS00507
t
ne
e.
m
Ti
er
ot
EAS00917
co
filter.
w
w
7 - 37
AIR INDUCTION SYSTEM FI
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1 Air induction system hose (air filter case to air cut-off valve)
2 Air cut-off valve
3 Air induction system hose (air cut-off valve to cylinder head)
4 Air induction system pipe
5 Air filter case cover (right)
t
ne
e.
m
Ti
1 er
ot
co
.S
1
w
B
w
B 2
w
m
fro
d
de
oa
3
nl
ow
D
A
2
5 4
7 - 38
AIR INDUCTION SYSTEM FI
t
ne
3
e.
m
Ti
er
ot
co
.S
w
w
2
w
m
fro
d
de
oa
nl
Removing the air cut-off valve and Remove the parts in the order listed.
D
7 - 39
AIR INDUCTION SYSTEM FI
EAS00918
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
• hoses
Loose connections → Connect properly.
Cracks/damage → Replace.
• pipes
Cracks/damage → Replace.
2. Check:
• reed valve
• reed valve stopper
• reed valve seat
Cracks/damage → Replace the reed valve.
3. Check:
• air cut-off valve
Cracks/damage → Replace.
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
7 - 40
CANISTER FI
CANISTER
t
ne
e.
m
2
5
Ti
4
er
ot
co
.S
w
w
R.
w
m
fro
d
1
de
oa
nl
1 Canister 1
2 Rollover valve 1
3 Fuel tank to rollover valve hose 1
4 Rollover valve to canister hose 1
5 Canister to throttle body hose 1
For installation, reverse the removal pro-
cedure.
7 - 41
– +
ELEC
CHAPTER 8
ELECTRICAL SYSTEM
t
ne
e.
IGNITION SYSTEM ......................................................................................... 8-8
m
CIRCUIT DIAGRAM .................................................................................. 8-8
Ti
TROUBLESHOOTING ..............................................................................8-9
er
ot
co
TROUBLESHOOTING ............................................................................8-16
w
w
m
CHARGING SYSTEM....................................................................................8-23
CIRCUIT DIAGRAM ................................................................................ 8-23
nl
TROUBLESHOOTING ............................................................................8-24
ow
D
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1 Starting circuit cut-off relay 8 Rear brake light switch
2 Headlight relay 1 9 Storage box light switch
3 Turn signal relay 0 Starter relay
4 Radiator fan motor relay A Main fuse
5 Headlight relay 2 B Battery
6 Main switch C Fuse box
7 Front brake light switch D Diode
1 2 3 4 5
6
9
t
ne
e.
A
m
Ti
er
0
L 7 8
ot
co
.S
w
B
w
w
m
fro
K
d
M
de
oa
nl
ow
C
D
J D
I
E
H
F
G
8-1
– +
ELECTRICAL COMPONENTS ELEC
E Stator coil
F Sidestand switch
G Ignition coil
H Radiator fan motor
I Rectifier/regulator
J Horn
K Thermistor
L ECU
M Wire harness
1 2 3 4 5
6
9
t
ne
e.
A
m
Ti
er
0
L 7 8
ot
co
.S
w
B
w
w
m
fro
K
d
M
de
oa
nl
ow
C
D
J D
I
E
H
F
G
8-2
– +
CHECKING SWITCH CONTINUITY ELEC
EAS00730
Pocket tester
t
ne
90890-03112, YU-03112-C
e.
NOTE:
m
_
Ti
• Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
er
ot
• When checking for continuity, switch back
co
a
ON The terminal connections for switches (e.g.,
w
OFF
main switch, engine stop switch) are shown in
m
R L/B L/Y
an illustration similar to the one on the left.
fro
NOTE:
_
8-3
– +
CHECKING THE SWITCHES ELEC
EAS00731
1 3
R/W R/B
2 B L/W
4
Br G/Y R
R Br/L L/Y L/B
ON Br/L
t
OFF
ne
R/W L/W Br 5
R/B B G/Y L/B L/Y B
e.
B
(RED) (BLUE)
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
7 6
8
R L/G
A P B 9 G/B R/Y
0 Ch Br/W Dg G/Y Br
OFF
R/Y Br/W G/B Dg
P Br B G/Y Ch
(BLACK)
8-4
– +
CHECKING THE BULBS AND BULB SOCKETS ELEC
EAS00733
t
ne
e.
m
Ti
er
ot
TYPES OF BULBS
co
clockwise.
ow
8-5
– +
CHECKING THE BULBS AND BULB SOCKETS ELEC
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
WARNING
_
CAUTION:
_
t
ne
removing the bulb. Never pull the lead,
e.
otherwise it may be pulled out of the ter-
m
minal in the coupler.
Ti
• Avoid touching the glass part of the head-
er
light bulb to keep it free from oil, other-
ot
wise the transparency of the glass, the
co
thinner.
m
fro
2. Check:
d
No continuity → Replace.
nl
Pocket tester
ow
90890-03112, YU-03112-C
D
NOTE:
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 2, and check the continuity.
b. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 3, and check the continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-6
– +
CHECKING THE BULBS AND BULB SOCKETS ELEC
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112, YU-03112-C
NOTE:
_
t
however, note the following.
ne
e.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
m
a. Install a good bulb into the bulb socket.
Ti
b. Connect the pocket tester probes to the
er
respective leads of the bulb socket.
ot
c. Check the bulb socket for continuity. If any
co
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
w
w
m
fro
d
de
oa
nl
ow
D
8-7
A B C
(GRAY) (GRAY)
B B
EAS00734
WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 3
8 9
R/G R R R
2 W/R
W/L O Gy Sb R L Y/G P/W
O/B P Lg W R/W B/R Br/W R/L
W/L W/R G/B W/B B/L L/Y W/R Y G/R R
R W Q
R/Y G/Y B B/W Y/L L/B W/L
(BLACK) (BLACK) R/B
R R L B/L Y/L
W W L/W G/Y O O
W W R R (GRAY) W/R R
1 3 (BLACK)
W W R R W/L R/B R
L
CIRCUIT DIAGRAM
B R
W W W R R K Y/L Y/L B Y Y P B P R
W W W W W W 0
B B/L L L B L L Lg B Lg
(BLACK) S R/L
D B A
L P/W
B/L
P/W B P/W
G/R B
P/W
G/R
Gy
Sb
B
B
Gy
Sb
Lg Sb
R/B R/Y
G/W B/L P/W L
G/Y R/B
L/G R/G R/G R P Gy
IGNITION SYSTEM
Y/L
B B L/B W W
G H I J L V
(BLUE)
Br G/W R/W R/W L/W Br B/L
fro
G/Y L/B R/B R/B B G/Y
B B/W B
B L/Y
m (BLUE)
W R
B
L W
B/L
L/B Br G/Y
~ w
Br/L R/Y
å w
R Br
8-8
ç w
Br/L Br
Br G/B
† C C
Br Br
Br Br G/B
.S
L
Br Br
Br R/W G/Y
Br R/W
R/YR/Y Br
Br X
\ L
co
R/Y
Br G/B
G/L Br/W
2 Crankshaft position b Br P a ^
R/Y W/B (BLACK) Br
sensor (BLACK) L G/B
P
ot
G/LW/B L G/Y
L
Br/W
4 Main switch R/Y P Br/W Br G/Y L
Y
er
d OFF Br L
ON L L
7 Ignition fuse e f g B B
] (RED) (RED)
L L
Ti
G/L OFF L
0 Battery Y h
m B
(BLACK) (BLACK)
L
G/B G B R/Y Br/W G/B Dg
R/W P Br B G/Y Ch
q R/G Y/L G Gy L Y Dg Ch L L
A Main fuse (BLACK) (BLACK) Z
L L
G/B B Ch Dg
e.
Dg G/B Br/W R/Y (BLUE) (BLUE)
IGNITION SYSTEM
c Ch G/Y B Br P
L
E Starting circuit cut- r Y G (BLACK)
L
ne
B G/B
Gy
off relay u v w x y z {
L L
stop switch
s t
t [
L B
}
G Engine B B B Gy (BLUE) (BLUE)
B
B
B/L
B
J Sidestand switch B
Y G
Ch Dg Y R/W R/G G
B B/L B B A A C
L Y/L B/L Gy B
(GRAY) (GRAY) Y G B
N Lean angle cut-off |
L Ch L Dg i Ch Dg Br Br G/Y
switch B Y G Y G
ELEC
o n jk l
G
p p G L Dg B
Y B
L Ch B
Y B
(BLACK)
P ECU
–
B B m
B Ch L B Dg L
(BLACK)
Q Ignition coil B B Dg L/R
L Y
Ch B B
B
A
R Spark plug B B
+
B Br Dg G/Y Br
B Ch B
– +
IGNITION SYSTEM ELEC
EAS00736 EAS00739
TROUBLESHOOTING
2. Battery
The ignition system fails to operate (no • Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING AND CHARGING
Check: THE BATTERY” in chapter 3.
1. main and ignition fuses Minimum open-circuit voltage
2. battery 12.8 V or more at 20°C (68°F)
3. spark plug
4. ignition spark gap • Is the battery OK?
5. spark plug cap resistance YES NO
6. ignition coil resistance
7. crankshaft position sensor resistance
8. main switch • Clean the battery
9. engine stop switch terminals.
t
• Recharge or
ne
10.sidestand switch
11.starting circuit cut-off relay replace the battery.
e.
12.lean angle cut-off switch
m
EAS00740
13.wiring connections (of the entire ignition
Ti
system) 3. Spark plug
er
ot
NOTE: • Check the condition of the spark plug.
co
_
• Before troubleshooting, remove the following • Check the spark plug type.
.S
tool(s).
CR7E (NGK)
fro
Ignition checker
de
Pocket tester
90890-03112, YU-03112-C the correct type, and is its gap within spec-
nl
ification?
ow
EAS00738
YES NO
D
YES NO
8-9
– +
IGNITION SYSTEM ELEC
EAS00742 EAS00744
t
ne
e.
m
Spark plug cap resistance
Ti
10 kΩ at 20 °C (68 °F)
er
• Is the spark plug cap OK?
ot
co
plug cap.
m
YES NO
fro
d
is OK.
oa
nl
ow
D
8 - 10
– +
IGNITION SYSTEM ELEC
EAS00746 EAS00748
1 2
R W
t
ne
e.
m
Ti
• Measure the primary coil resistance.
er
• Measure the crankshaft position sensor
ot
Primary coil resistance
2.16 ~ 2.64 Ω at 20 °C (68 °F) resistance.
co
Negative tester probe → spark plug lead 1 (between red and white)
w
Replace crankshaft
position sensor/stator
nl
assembly.
ow
D
EAS00749
8. Main switch
• Check the main switch for continuity.
Secondary coil resistance Refer to “CHECKING THE SWITCHES”.
8.64 ~ 12.96 kΩ at 20 °C (68 °F) • Is the main switch OK?
• Is the ignition coil OK? YES NO
YES NO
Replace the main
switch.
Replace the ignition
coil.
8 - 11
– +
IGNITION SYSTEM ELEC
EAS00750 EAS00753
t
ne
• Check the sidestand switch for continuity. Negative tester probe → continuity
e.
Refer to “CHECKING THE SWITCHES”. blue/yellow 1
m
• Is the sidestand switch OK?
Ti
2
er
YES NO ot
co
R/B G/Y
w
m
fro
NOTE:
_
NO
D
YES
8 - 12
– +
IGNITION SYSTEM ELEC
EAS00754
12.Lean angle cut-off switch
13.Wiring
• Remove the lean angle cut-off switch.
• Connect the pocket tester (Ω × 1) to the • Check the entire ignition system’s wiring.
lean angle cut-off switch terminals as Refer to “CIRCUIT DIAGRAM”.
shown. • Is the ignition system’s wiring properly
connected and without defects?
Positive tester probe → blue 1
Negative tester probe → yellow/green 2 YES NO
t
ne
e.
m
Lean angle cut-off switch voltage
Ti
Less than 45° a →
Approximately 1 V
er
ot
More than 45° b →
co
Approximately 4 V
.S
a a
w
ON ON
w
w
m
fro
d
de
oa
b
nl
YES NO
D
8 - 13
A B
P O/B R/L Y
Y B B Y
Sb Gy Lg G/R
G G Br/W L B/L P/W
EAS00755
(GRAY)
WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS
8 9
R/G R R R
2 W/R
W/L O Gy Sb R L Y/G P/W
O/B P Lg W R/W B/R Br/W R/L
W/L W/R G/B W/B B/L L/Y W/R Y G/R R
R W Q
R/Y G/Y B B/W Y/L L/B W/L
(BLACK) (BLACK) R/B
CIRCUIT DIAGRAM
R R L B/L Y/L
W W L/W G/Y O O
W W R R (GRAY) W/R
1
W W
3
D R R
(BLACK) W/L
R
B R L
W W W R R K Y/L Y/L B Y Y P B P
W W W W W W 0
B B/L L L B L L Lg B Lg
ow
(BLACK)
L P/W P/W B P/W P/W Gy B Gy
S
B A B/L G/R B G/R Sb B Sb
G/W B/L P/W L Lg
G/Y R/B
L/G R/G R/G R P
B B G/Y (BLACK) G/R B/L
nl
B B (BL
L/W
4 B E B/L O
R R B (GREEN)
R L/G ON Br/L Br/L G/Y Br/W Br/W B Br/W Br/W R/Y
oa
5 OFF
B
B L/Y G/W
L/W D R/L
R/B G/Y Br/W B/L M
L/B L/Y C (BLACK) (BLACK) (
L/G L/Y L/Y B
(RED) (GREEN) B/L
de
(RED) L/W G/Y L/Y B/L B B/L B/L U L Y
Br/L L/Y
L/Y
d Y/G P O/B B O/B
7 L Y/G B/L
fro
Br/L R/W B/R B/R
m N
B L/Y
G/Y
R/W R/W
F R/B G/W w L/Y
Y/L
B B L/B W W
G H I
w J L V
(BLUE)
Br G/W R/W R/W L/W Br B/L
R/B B G/Y
8 - 14
G/Y L/B R/B B B/W B
w B L/Y W R L W
(BLUE) B B/L
L/B Br G/Y
.S
~
Br/L R/Y
co
å
R Br
ç 4 Main switch
ot
Br/L Br
Br G/B
†
7 Ignition fuse C C
er
Br Br
Br Br G/B
0 Battery L
Ti
Br Br
R/W G/Y
R/YR/Y
Br
Br
m A Main fuse Br R/W
X Br
\ L
R/Y relay Br G/B
G/L Br/W
B Starter
b Br P a ^
e.
R/Y W/B (BLACK) Br
ELECTRIC STARTING SYSTEM
(BLACK)
C Starter motor L G/B
G/LW/B P L G/Y
ne
L
Br/W t D Diode
R/Y P Br/W Br G/Y L
Y
d E Starting circuit cut-off relay OFF Br
ON L
e f g B B
] stop switch
G Engine (RED) (
L L
G/L OFF L
(BLACK) (BLACK)
Y h H Start switch L
G/B G B R/Y Br/W G/B Dg B
R/W P Br B G/Y Ch
q R/G Y/L G Gy L Y Dg Ch L
(BLACK) (BLACK)
ELEC
r L
Y G (BLACK)
L
B G/B
h Rear brake light switch
Gy
u v w x y z {
s t ç Signaling system fuse [ L
L
+
} B B B Gy (BLUE) (B
B
– +
ELECTRIC STARTING SYSTEM ELEC
EAS00756
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the engine stop switch is set to “ ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if
the following conditions are met:
• A brake lever is pulled to the handlebar (the
brake light switch is closed) and the side-
stand is up (the sidestand switch is closed).
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cut-off relay
t
7 Sidestand switch
ne
8 Signaling system fuse
e.
9 Front brake light switch
m
0 Rear brake light switch
Ti
A Start switch
B Starter relay
er
C Starter motor
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
8 - 15
– +
ELECTRIC STARTING SYSTEM ELEC
EAS00757 EAS00739
TROUBLESHOOTING
2. Battery
The starter motor fails to turn. • Check the condition of the battery.
Check: Refer to “CHECKING AND CHARGING
1. main, ignition, and signaling system fuses THE BATTERY” in chapter 3.
2. battery Minimum open-circuit voltage
3. starter motor 12.8 V or more at 20 °C (68 °F)
4. starting circuit cut-off relay
5. starter relay • Is the battery OK?
6. main switch YES NO
7. engine stop switch
8. brake light switch (front and rear)
9. sidestand switch • Clean the battery
10.start switch terminals.
t
• Recharge or
ne
11.wiring connections
(of the entire starting system) replace the battery.
e.
m
NOTE:
_ EAS00758
Ti
• Before troubleshooting, remove the following
3. Starter motor
part(s):
er
ot
1. storage box • Connect the positive battery terminal 1
co
tool(s).
w
w
Pocket tester
m
90890-03112, YU-03112-C
fro
d
EAS00738
de
chapter 3. _
YES NO
8 - 16
– +
ELECTRIC STARTING SYSTEM ELEC
EAS00759 EAS00761
t
ne
2 4
e.
L/Y G/W
m
Ti
R/B G/Y
er
ot
• Does the starting circuit cut-off relay have
co
continuity between green/yellow and • Does the starter relay have continuity
.S
YES NO YES NO
w
m
fro
EAS00749
oa
6. Main switch
nl
ow
YES NO
8 - 17
– +
ELECTRIC STARTING SYSTEM ELEC
EAS00750 EAS00766
YES NO
YES NO
t
ne
• Check the brake light switches for continu-
e.
ity.
m
Refer to “CHECKING THE SWITCHES”.
Ti
• Is each brake light switch OK?
YES NO er
ot
co
.S
light switch(s).
w
w
EAS00752
m
9. Sidestand switch
fro
YES NO
nl
ow
stand switch.
EAS00764
10.Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES NO
8 - 18
– +
STARTER MOTOR ELEC
EAS00767
STARTER MOTOR
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Removing the starter motor Remove the parts in the order listed.
D
8 - 19
– +
STARTER MOTOR ELEC
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
Disassembling the starter motor Remove the parts in the order listed.
D
1 Front bracket 1
2 O-ring 1
3 Shim 1
4 Lock washer 1
5 Rear bracket 1 Refer to “ASSEMBLING THE STARTER
6 O-ring 1 MOTOR”.
7 Shim 1
8 Brush holder set 1
9 Armature assembly 1
0 Starter motor yoke 1
For assembly, reverse the disassembly
procedure.
8 - 20
– +
STARTER MOTOR ELEC
EAS00770
CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification → Replace the starter
motor.
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
t
ne
the proper measurement with a hacksaw
blade that has been grounded to fit the
e.
m
commutator.
Ti
Mica undercut
er
0.7 mm (0.028 in)
ot
co
NOTE:
.S
4. Measure:
fro
motor.
oa
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
nl
Pocket tester
90890-03112, YU-03112-C
Armature coil
Commutator resistance 1
0.0012 ~ 0.0022 Ω at 20 °C
(68 °F)
Insulation resistance 2
Above 1 MΩ at 20 °C (68 °F)
8 - 21
– +
STARTER MOTOR ELEC
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
t
ne
7. Check:
e.
• gear teeth
m
Damage/wear → Replace the gear.
Ti
er
ot
8. Check:
co
• bearing 1
.S
• oil seal 2
w
• bushing 3
w
part(s).
m
fro
d
de
oa
EAS00772
ASSEMBLING THE STARTER MOTOR
nl
1. Install:
ow
• front bracket 2
• rear bracket 3
NOTE:
_
8 - 22
EAS00773
8 9
R/G R R R
2 W/R
CIRCUIT DIAGRAM
W/L O Gy Sb R
D O/B P Lg
W/L W/R G/B W/B B/L
R W
R/Y G/Y B
(BLACK) (BLACK)
R R L B/L Y/L
ow
W W L/W G/Y
CHARGING SYSTEM
W W R R (GRAY)
1 3 (BLACK)
W W R R
nl
B R L
W W W R R K Y/L Y/
W W W W W W 0 B/L L L
oa
B
(BLACK) P/W P/
L
B A B/L
G/W B/L P/W L
de
G/Y R/B
L/G R/G R/G R d B B G/Y (BLACK)
B B
L/W
4 B E B/L
R R B
R L/G ON Br/L Br/L G/Y Br/W Br/W B B
5 OFF
B
B L/Y G/W
fro
L/W D
m R/B G/Y Br/W B/L M
L/B L/Y C (BLACK)
L/G L/Y L/Y B
(RED) (GREEN) B/L
(RED) L/W G/Y L/Y B/L B
Br/L L/Y
L/Y
w
w L Y/G B/L
8 - 23
6 B/R
7
w L Y/G B/L
Br/L R/W B/R
.S N
B
R/W
co
F R/B G/W L/Y
ot
J B B
G H I (BLUE)
Br G/W R/W R/W L/W Br
er
G/Y L/B R/B R/B B G/Y
B
B L/Y
Ti
m (BLUE)
L/B Br G/Y
~
e.
Br/L R/Y
CHARGING SYSTEM
ne
å
R Br t
ç
Br/L Br
†
Br Br
ELEC
1 A.C. magneto Br
R/YR/Y
3 Rectifier/regulator Br
–
R/Y
0 Battery G/L Br/W
b Br P a ^
R/Y W/B (BLACK) Br
+
A Main fuse
(BLACK)
G/LW/B P
– +
CHARGING SYSTEM ELEC
EAS00774 EAS00739
TROUBLESHOOTING
2. Battery
The battery is not being charged. • Check the condition of the battery.
Check: Refer to “CHECKING AND CHARGING
1. main fuse THE BATTERY” in chapter 3.
2. battery Minimum open-circuit voltage
3. charging voltage 12.8 V or more at 20 °C (68 °F)
4. stator coil resistance
5. wiring connections • Is the battery OK?
(of the entire charging system) YES NO
NOTE:
_
t
• Recharge or
ne
• Troubleshoot with the following special
tool(s). replace the battery.
e.
m
Ti
Pocket tester
90890-03112, YU-03112-C er
ot
co
EAS00738
.S
1. Main fuse
w
w
chapter 3.
fro
YES NO
de
oa
8 - 24
– +
CHARGING SYSTEM ELEC
EAS00775 EAS00776
t
ne
23
e.
m
W W W
Ti
• Start the engine and let it run at approxi-
mately 5,000 r/min. er
1
ot
• Measure the charging voltage. • Measure the stator coil resistances.
co
Charging voltage
.S
NOTE:
w
_
• Is the stator coil OK?
Make sure the battery is fully charged.
m
YES NO
fro
tion?
de
NO YES
stator assembly.
nl
ow
EAS00779
The charging circuit
D
is OK. 5. Wiring
• Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly
connected and without defects?
YES NO
8 - 25
A B C
(GRAY) (GRAY)
B B
EAS00780
WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 3
8 9
R/G R R R
2 W/R
W/L O Gy Sb R L Y/G P/W
O/B P Lg W R/W B/R Br/W R/L
W/L W/R G/B W/B B/L L/Y W/R Y G/R R
R W Q
R/Y G/Y B B/W Y/L L/B W/L
(BLACK) (BLACK) R/B
R R L B/L Y/L
W W L/W G/Y O O
W W R R (GRAY) W/R R
1 3 (BLACK)
W W R R W/L R/B R
B R L
CIRCUIT DIAGRAM
W W W R R K Y/L Y/L B Y Y P B P R
W W W W W W 0
B B/L L L B L L Lg B Lg
(BLACK) S R/L
D B A
L P/W
B/L
P/W B P/W
G/R B
P/W
G/R
Gy
Sb
B
B
Gy
Sb
Lg Sb
R/B R/Y
G/W B/L P/W L
G/Y R/B
L/G R/G R/G R P Gy
B B G/Y (BLACK) G/R B/L T
B B (BLACK)
L/W
LIGHTING SYSTEM
4 B E B/L O (GREEN)
ow
R R B R/Y R/L
R L/G ON Br/L Br/L G/Y Br/W Br/W B Br/W Br/W R/Y
5 OFF
B
B L/Y G/W
L/W D R/L
R/B G/Y Br/W B/L M
L/B L/Y C (BLACK) (BLACK) (BLACK)
L/G L/Y L/Y B
(RED) (GREEN) B/L
(RED)
nl
L/W G/Y L/Y B/L B B/L B/L U L Y O/B R/L
Br/L L/Y P
L/Y Y/G O/B B O/B R/L B R/L
oa
L Y/G B/L W/B G/B 4 Main switch R/L G
6 B/R
7 L Y/G B/L
W
B/R B/R
Br/L R/W 5 Storage box light switch
de
N G B
B L/Y R/L B
G/Y
F R/W
R/B G/W
d L/Y R/W
6 Storage box light B B
Y/L
L/B W W
J B B
8 Backup fuse (storage
G H I (BLUE) V L
Br G/W R/W R/W L/W Br B/L
fro
R/B B G/Y
G/Y L/B R/B B B/W B
box light and meter
B L/Y
m (BLUE)
W R
assembly) B
L W
B/L
L/B Br G/Y
~ w
Br/L R/Y
0 Battery
å w
R Br A Main fuse
ç
8 - 26
Br/L Br
w P ECU Br G/B
† C C
Br Br
Br Br G/B
.S b Headlight relay 1
L
Br Br
Br R/W G/Y
Br R/W
R/YR/Y Br
X
c Headlight relay 2
Br
\ L
co
R/Y
Br G/B
G/L Br/W
b Br P a ^
e Dimmer switch
R/Y W/B (BLACK) Br
(BLACK) L G/B
P
ot l License plate light
G/LW/B L G/Y
L
Br/W
B Y G Y G
ELEC
o n jk l ~ Headlight fuse
G
p p G L Dg B
Y B
L Ch B
Y B
(BLACK)
ç Signaling system fuse
–
B B m
B Ch L B Dg L
(BLACK)
B B Dg L/R
L Y
† Turn signal/position
Ch B B
B
A B B
light fuse
+
B Br Dg G/Y Br
B Ch B
– +
LIGHTING SYSTEM ELEC
EAS00781 EAS00739
TROUBLESHOOTING
2. Battery
Any of the following fail to light: head- • Check the condition of the battery.
lights, high beam indicator light, tail/ Refer to “CHECKING AND CHARGING
brake light, license plate light, front turn THE BATTERY” in chapter 3.
signal/position light, storage box light or
meter light. Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
Check:
1. main, headlight, signaling system, turn sig- • Is the battery OK?
nal/position light, and backup fuses YES NO
2. battery
3. main switch
4. dimmer switch • Clean the battery
5. storage box light switch terminals.
t
• Recharge or
ne
6. headlight relay 1
7. headlight relay 2 replace the battery.
e.
8. wiring connections
m
EAS00749
(of the entire lighting system)
Ti
3. Main switch
NOTE:
_
er
ot
• Before troubleshooting, remove the following • Check the main switch for continuity.
co
2. front cowling
w
switch.
d
Pocket tester
de
EAS00784
90890-03112, YU-03112-C
oa
4. Dimmer switch
EAS00738
nl
1. Main, headlight, signaling system, turn sig- Refer to “CHECKING THE SWITCHES”.
nal/position light, and backup fuses
D
YES NO
8 - 27
– +
LIGHTING SYSTEM ELEC
5. Storage box light switch 7. Headlight relay 2
• Check the storage box light switch for con- • Remove the headlight relay 2.
tinuity. • Connect the pocket tester (Ω × 1) and bat-
Refer to “CHECKING THE SWITCHES”. tery (12 V) to the headlight relay 2 terminal
• Is the storage box light switch OK? as shown.
• Check the headlight relay 2 for continuity.
YES NO
Positive tester probe → green/blue 1
Negative tester probe → green 2
The storage box light
switch is faulty. 1
Replace the storage
box light switch.
2
t
6. Headlight relay 1 B G G/B
ne
Y
• Remove the headlight relay 1.
e.
G/L
• Connect the pocket tester (Ω × 1) and bat-
m
Ti
tery (12 V) to the headlight relay 1 terminals
Positive battery terminal → green/black 3
er
as shown.
Negative battery terminal → black 4
ot
• Check the headlight relay 1 for continuity.
Positive tester probe → green/blue 5
co
6 +
m
3
fro
4 3
4 +
d
B G G/B
de
Y
2 1
oa
G/L
nl
W/B R/Y
ow
8 - 28
– +
LIGHTING SYSTEM ELEC
EAS00787 EAS00788
CHECKING THE LIGHTING SYSTEM
8. Wiring 1. The headlights and the high beam indicator
• Check the entire lighting system’s wiring. light fail to come on.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly 1. Headlight bulb and socket
connected and without defects? • Check the headlight bulb and socket for
continuity.
YES NO Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
Check the condition Properly connect or • Are the headlight bulb and socket OK?
of each of the lighting repair the lighting
YES NO
system’s circuits. system’s wiring.
Refer to “CHECK-
ING THE LIGHTING Replace the head-
t
SYSTEM”. light bulb, socket or
ne
both.
e.
m
Ti
2. High beam indicator light bulb and socket
er
• Check the high beam indicator light bulb
ot
and socket for continuity.
co
BULB SOCKETS”.
w
socket OK?
w
m
YES NO
fro
d
8 - 29
– +
LIGHTING SYSTEM ELEC
3. Voltage • Set the main switch to “ON”.
• Connect the pocket tester (DC 20 V) to the • Start the engine.
headlight and meter assembly couplers as • Set the dimmer switch to “ ” or “ ”.
shown. • Measure the voltage (DC 12 V) of yellow
1 (green 2) on the headlight coupler and
È When the dimmer switch is set to “ ” yellow 4 on the meter assembly coupler
É When the dimmer switch is set to “ ”
(wire harness side).
Headlight • Is the voltage within specification?
Positive tester probe →
yellow 1 or green 2 YES NO
Negative tester probe → black 3
Headlight coupler This circuit is OK. The wiring circuit
from the main switch
È to the headlight cou-
t
pler or meter assem-
ne
DC 20V 2 bly coupler is faulty
e.
+ G
and must be
m
Y B
É repaired.
Ti
1 3
EAS00789
er
ot
2. The meter light fails to come on.
High beam indicator light
co
Negative tester probe → black 5 • Check the meter light bulb and socket for
w
w
BULB SOCKETS”.
fro
YES NO
de
Ch Dg Y R/W R/G G
oa
L Y/L B/L Gy B
Replace the meter
nl
both.
D
8 - 30
– +
LIGHTING SYSTEM ELEC
2. Voltage 2. Voltage
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness tail/brake light coupler (wire harness side)
side) as shown. as shown.
Positive tester probe → blue 1 Positive tester probe → brown 1
Negative tester probe → black 2 Negative tester probe → black 2
L Y G/Y Br
Ch Dg Y R/W R/G G B B
L Y/L B/L Gy B
t
1 2
ne
e.
• Set the main switch to “ON”. • Set the main switch to “ON”.
m
• Measure the voltage (DC 12 V) of blue 1 • Measure the voltage (DC 12 V) of brown
Ti
on the meter assembly coupler (wire har- 1 on the tail/brake light coupler (wire har-
ness side). er
ness side).
ot
• Is the voltage within specification? • Is the voltage within specification?
co
.S
YES NO YES NO
w
w
w
This circuit is OK. The wiring circuit This circuit is OK. The wiring circuit
m
repaired.
oa
EAS00791
4. The front turn signal/position lights fail to
nl
EAS00790
3. The tail/brake light fails to come on. come on.
ow
D
YES NO
8 - 31
– +
LIGHTING SYSTEM ELEC
EAS00792
2. Voltage 5. The license plate light fails to come on.
• Connect the pocket tester (DC 20 V) to the
1. License plate light bulb and socket
front turn signal/position light coupler (wire
harness side) as shown. • Check the license plate light bulb and
socket for continuity.
È Front turn signal/position light (left)
É Front turn signal/position light (right) Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Positive tester probe → blue 1 • Are the license plate light bulb and socket
Negative tester probe → black 2 OK?
È É
YES NO
t
socket or both.
ne
B Ch L B Dg L
e.
2 1 2 1
m
2. Voltage
Ti
• Set the main switch to “ON”. • Connect the pocket tester (DC 20 V) to the
• Measure the voltage (DC 12 V) of blue 1 er
rear turn signal/license plate light coupler
ot
on the front turn signal/position light cou- (wire harness side) as shown.
co
YES NO
w
m
fro
B L/R Br B
to the front turn sig-
de
must be repaired.
ow
YES NO
8 - 32
– +
LIGHTING SYSTEM ELEC
EAS00792
6. The storage box light fails to come on.
1. Storage box light bulb and socket
• Check the storage box light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the storage box light bulb and socket
OK?
YES NO
t
or both.
ne
e.
2. Voltage
m
Ti
• Connect the pocket tester (DC 20 V) to the
storage box light connectors (wire harness
er
ot
side) as shown.
co
L/G B
d
de
1 2
oa
nl
ow
YES NO
8 - 33
D
ow
nl
oa
de
d
fro
m
w
w
8 - 34
w
.S
co
ot
er
Ti
m
e.
LIGHTING SYSTEM
ne
t
ELEC –
+
A B C
(GRAY) (GRAY)
B B
EAS00793
WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 3
8 9
R/G R R R
2 W/R
W/L O Gy Sb R L Y/G P/W
O/B P Lg W R/W B/R Br/W R/L
W/L W/R G/B W/B B/L L/Y W/R Y G/R R
R W Q
R/Y G/Y B B/W Y/L L/B W/L
(BLACK) (BLACK) R/B
R R L B/L Y/L
W W L/W G/Y O O
W W R R (GRAY) W/R R
1 3 (BLACK)
W W R R W/L R/B R
B R L
CIRCUIT DIAGRAM
W W W R R K Y/L Y/L B Y Y P B P R
W W W W W W 0
B B/L L L B L L Lg B Lg
(BLACK) S R/L
D B A
L P/W
B/L
P/W B P/W
G/R B
P/W
G/R
Gy
Sb
B
B
Gy
Sb
Lg Sb
R/B R/Y
G/W B/L P/W L
G/Y R/B
L/G R/G R/G R P Gy
B B G/Y (BLACK) G/R B/L T
B B (BLACK)
L/W
4 B E B/L O (GREEN)
ow
R R B R/Y R/L
R L/G ON Br/L Br/L G/Y Br/W Br/W B Br/W Br/W R/Y
5 OFF
B
B L/Y G/W
D R/L
SIGNALING SYSTEM
L/W
R/B G/Y Br/W B/L M
L/B L/Y C (BLACK) (BLACK) (BLACK)
L/G L/Y L/Y B
(RED) (GREEN) B/L
(RED)
nl
L/W G/Y L/Y B/L B B/L B/L U L Y O/B R/L
Br/L L/Y
L/Y Y/G P O/B B O/B R/L B R/L
oa
L Y/G B/L W/B G/B R/L G
6 B/R
7 L Y/G B/L
W
B/R B/R
Br/L R/W
de
N G B
B L/Y R/L B
G/Y
F R/W
R/B G/W
d L/Y R/W
B B
Y/L
B B L/B W W
G H I J L V
(BLUE)
Br G/W R/W R/W L/W Br B/L
fro
G/Y L/B R/B R/B B G/Y
B B/W B
B L/Y
m (BLUE)
W R
B
L W
B/L
L/B Br G/Y
~ w
Br/L R/Y
å w
R Br
8 - 35
Br/L Br
w Br G/B
† C C
Br Br
Br Br G/B
.S
L
Br Br
Br R/W G/Y
Br R/W
R/YR/Y Br
Br X
\ L
co
R/Y
Br G/B
G/L Br/W
b Br P a ^
R/Y W/B (BLACK) Br
(BLACK) L G/B
P
ot
G/LW/B L G/Y
L
Br/W
c Ch G/Y B Br P
r L
Y G (BLACK)
L
ne
B G/B
Gy
u v w x y z {
L L
s t
t [
L B
} B B B Gy (BLUE) (BLUE)
B
B
B/L
B
B
Y G
| Ch Dg Y R/W R/G G
B B/L B B A A C
L Y/L B/L Gy B
(GRAY) (GRAY) Y G B
L Ch L Dg i Ch Dg Br Br G/Y
B Y G Y G
ELEC
o n jk l
G
p p G L Dg B
Y B
L Ch B
Y B
(BLACK)
–
B B m
B Ch L B Dg L
(BLACK)
B B Dg L/R
L Y
Ch B B
B
A B B
+
B Br Dg G/Y Br
B Ch B
– +
SIGNALING SYSTEM ELEC
4 Main switch
7 Ignition fuse
8 Backup fuse (storage box light and meter assembly)
0 Battery
A Main fuse
I Front brake light switch
P ECU
V Speed sensor
_ Turn signal relay
a Horn
f Horn switch
g Turn signal switch
h Rear brake light switch
j Rear turn signal light (left)
k Rear turn signal light (right)
m Tail/brake light
n Front turn signal/position light (right)
o Front turn signal/position light (left)
t
ne
r Multifunction meter
e.
s Speedometer
u Engine oil change indicator
m
v V-belt replacement indicator
Ti
w Engine trouble warning light
z Right turn signal indicator light er
ot
{ Left turn signal indicator light
co
8 - 36
– +
SIGNALING SYSTEM ELEC
EAS00794 EAS00739
TROUBLESHOOTING
2. Battery
• Any of the following fail to light: turn • Check the condition of the battery.
signal light, brake light or an indicator Refer to “CHECKING AND CHARGING
light. THE BATTERY” in chapter 3.
• The horn fails to sound.
Minimum open-circuit voltage
Check: 12.8 V or more at 20 °C (68 °F)
1. main, ignition, signaling system, turn signal/
position light, and backup fuses • Is the battery OK?
2. battery YES NO
3. main switch
4. wiring connections
(of the entire signaling system) • Clean the battery
NOTE: terminals.
t
• Recharge or
_
ne
• Before troubleshooting, remove the following
part(s): replace the battery.
e.
m
1. storage box EAS00749
Ti
2. front cowling
3. Main switch
3. meter assembly
er
ot
• Troubleshoot with the following special • Check the main switch for continuity.
co
Pocket tester
w
YES NO
90890-03112, YU-03112-C
w
m
EAS00738
Replace the main
fro
EAS00795
• Check the main, ignition, signaling system,
oa
4. Wiring
turn signal/position light, and backup fuses
nl
YES NO
Check the condition Properly connect or
of each of the signal- repair the signaling
Replace the fuse(s). ing system’s circuits. system’s wiring.
Refer to “CHECK-
ING THE SIGNAL-
ING SYSTEM”.
8 - 37
– +
SIGNALING SYSTEM ELEC
EAS00796
CHECKING THE SIGNALING SYSTEM 3. Horn
1. The horn fails to sound. • Disconnect the horn coupler at the horn.
• Connect a jumper lead 1 to the brown ter-
1. Horn switch
minal in the horn coupler and the horn ter-
• Check the horn switch for continuity. minal.
Refer to “CHECKING THE SWITCHES”. • Connect a jumper lead 2 to the horn ter-
• Is the horn switch OK? minal and ground.
• Set the main switch to “ON”.
YES NO
• Does the horn sound?
t
ne
• Connect the pocket tester (DC 20 V) to the P
e.
horn coupler as shown.
m
Positive tester probe → brown 1 2
Ti
Negative tester probe → ground
er NO YES
ot
co
1
.S
• Measure the voltage (DC 12 V) of brown at 2. The tail/brake light fails to come on.
the horn coupler.
nl
YES NO
• Are the tail/brake light LEDs OK?
8 - 38
– +
SIGNALING SYSTEM ELEC
EAS00799
2. Brake light switches 3. The turn signal light, turn signal indicator
• Check the brake light switches for continu- light or both fail to blink.
ity.
1. Turn signal light bulb and socket
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK? • Check the turn signal light bulb and socket
for continuity.
YES NO Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
Replace the brake • Are the turn signal light bulb and socket
light switch(s). OK?
YES NO
3. Voltage
• Connect the pocket tester (DC 20 V) to the Replace the turn sig-
t
tail/brake light coupler (wire harness side) nal light bulb, socket
ne
as shown. or both.
e.
Positive tester probe → green/yellow 1
m
Negative tester probe → black 2
Ti
2. Turn signal indicator light bulb and socket
er
• Check the turn signal indicator light bulb
ot
1 and socket for continuity.
co
B B
socket OK?
w
m
2 YES NO
fro
d
8 - 39
– +
SIGNALING SYSTEM ELEC
4. Voltage 5. Voltage
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness turn signal relay coupler (wire harness
side) as shown. side) as shown.
Positive tester probe → brown 1 Positive tester probe → brown/white 1
Negative tester probe → ground Negative tester probe → ground
Br/W Br/W
Br Br
1
1
t
ne
e.
• Set the main switch to “ON”. • Set the main switch to “ON”.
m
• Measure the voltage (DC 12 V) on brown • Measure the voltage (DC 12 V) on brown/
Ti
1 at the turn signal relay coupler (wire white 1 at the turn signal relay coupler
harness side). er
(wire harness side).
ot
• Is the voltage within specification? • Is the voltage within specification?
co
.S
YES NO YES NO
w
w
w
and must be
de
repaired.
oa
nl
ow
D
8 - 40
– +
SIGNALING SYSTEM ELEC
6. Voltage • Set the main switch to “ON”.
• Connect the pocket tester (DC 20 V) to the • Set the turn signal switch to “ ” or “ ”.
front turn signal/position light coupler, rear • Measure the voltage (DC 12 V) of the
turn signal/license plate light coupler or chocolate 1 or dark green 2 at the front
meter assembly coupler (wire harness turn signal/position light coupler, rear turn
side) as shown. signal/license plate light coupler or meter
assembly coupler (wire harness side).
È Front turn signal/position light (left) • Is the voltage within specification?
É Front turn signal/position light (right)
Ê Rear turn signal/license plate light YES NO
Ë Meter assembly
Left turn signal light
This circuit is OK. The wiring circuit
Positive tester probe → chocolate 1
from the turn signal
Negative tester probe → ground
switch to the front
Right turn signal light
t
turn signal/position
ne
Positive tester probe → dark green 2 light coupler, rear
e.
Negative tester probe → ground turn signal/license
m
È É plate light coupler or
Ti
meter assembly cou-
er pler is faulty and
ot
must be repaired.
co
.S
B Ch L B Dg L
4. The V-belt replacement indicator fails to
w
come on.
w
B Ch L B Dg L
w
socket
Ê
fro
YES NO
ow
D
1
Ch Dg Y R/W R/G G
L Y/L B/L Gy B
8 - 41
– +
SIGNALING SYSTEM ELEC
2. V-belt replacement indicator reset coupler 3. Voltage
• Connect the pocket tester (Ω × 1) to the V- • Connect the pocket tester (DC 20 V) to the
belt replacement indicator reset coupler as meter assembly coupler (wire harness
shown. side) as shown.
• Check the V-belt replacement indicator Positive tester probe → gray 1
reset coupler for continuity. Negative tester probe → ground
Positive tester probe → black 1
Negative tester probe → black 2
1 2
Ch Dg Y R/W R/G G
B B L Y/L B/L Gy B
t
1
ne
e.
• Set the main switch to “ON”.
m
• Measure the voltage (12 V) of gray 1 at
Ti
• Is the V-belt replacement indicator reset the meter assembly coupler.
coupler OK? er
• Is the voltage within specification?
ot
co
YES NO YES NO
.S
w
must be repaired.
nl
ow
D
8 - 42
– +
SIGNALING SYSTEM ELEC
EAS00803 EAS00806
5. The engine oil change indicator fails to 6. The speedometer fails to operate.
come on.
1. Speed sensor
1. Engine oil change indicator bulb and • Connect the pocket tester (DC 20 V) to the
socket speed sensor coupler (wire harness side)
• Check the engine oil change indicator bulb as shown.
and socket for continuity. Positive tester probe → white 1
Refer to “CHECKING THE BULBS AND Negative tester probe → blue 2
BULB SOCKETS”.
• Are the engine oil change indicator bulb
and socket OK?
YES NO
t
Replace the meter Replace the engine
ne
assembly. oil change indicator
e.
bulb, socket or both.
m
Ti
• Set the main switch to “ON”.
er
• Elevate the front wheel and slowly rotate
ot
it.
co
YES NO
d
de
sensor.
nl
ow
D
8 - 43
– +
SIGNALING SYSTEM ELEC
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness
side) as shown.
Positive tester probe → yellow/blue 1
Negative tester probe → black 2
Ch Dg Y R/W R/G G
L Y/L B/L Gy B
t
1 2
ne
e.
• Set the main switch to “ON”.
m
• Measure the voltage (DC 12 V) of yellow/
Ti
blue 1 on the meter assembly coupler
(wire harness side). er
ot
• Is the voltage within specification?
co
.S
YES NO
w
w
w
assembly.
fro
d
de
oa
nl
ow
D
8 - 44
A B C
(GRAY) (GRAY)
B B
EAS00807
WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 3
8 9
R/G R R R
2 W/R
W/L O Gy Sb R L Y/G P/W
O/B P Lg W R/W B/R Br/W R/L
W/L W/R G/B W/B B/L L/Y W/R Y G/R R
R W Q
R/Y G/Y B B/W Y/L L/B W/L
(BLACK) (BLACK) R/B
R R L B/L Y/L
W W L/W G/Y O O
W W R R (GRAY) W/R R
1 3 (BLACK)
W W R R W/L R/B R
B R L
CIRCUIT DIAGRAM
W W W R R K Y/L Y/L B Y Y P B P R
W W W W W W 0
B B/L L L B L L Lg B Lg
(BLACK) S R/L
D B A
L P/W
B/L
P/W B P/W
G/R B
P/W
G/R
Gy
Sb
B
B
Gy
Sb
Lg Sb
R/B R/Y
G/W B/L P/W L
G/Y R/B
L/G R/G R/G R P Gy
B B G/Y (BLACK) G/R B/L T
B B (BLACK)
COOLING SYSTEM
L/W
4 B E B/L O (GREEN)
ow
R R B R/Y R/L
R L/G ON Br/L Br/L G/Y Br/W Br/W B Br/W Br/W R/Y
5 OFF
B
B L/Y G/W
L/W D R/L
R/B G/Y Br/W B/L M
L/B L/Y C (BLACK) (BLACK) (BLACK)
L/G L/Y L/Y B
(RED) (GREEN) B/L
(RED)
nl
L/W G/Y L/Y B/L B B/L B/L U L Y O/B R/L
Br/L L/Y P
L/Y Y/G O/B B O/B R/L B R/L
oa
L Y/G B/L W/B G/B R/L G
6 B/R
7 L Y/G B/L
W
B/R B/R
Br/L R/W
de
N G B
B L/Y R/L B
G/Y
F R/W
R/B G/W
d L/Y R/W
B B
Y/L
B B L/B W W
G H I J L V
(BLUE)
Br G/W R/W R/W L/W Br B/L
fro
G/Y L/B R/B R/B B G/Y
B B/W B
B L/Y
m (BLUE)
W R
B
L W
B/L
L/B Br G/Y
~ w
Br/L R/Y
å w
R Br
8 - 45
Br/L Br
w Br G/B
† C C
Br Br
Br Br G/B
.S
L
Br Br
Br R/W G/Y
Br R/W
R/YR/Y Br
Br X
\ L
co
R/Y
Br G/B
G/L Br/W
b Br P a ^
R/Y W/B (BLACK) Br
(BLACK) L G/B
P
ot
G/LW/B L G/Y
L
Br/W
c Ch G/Y B Br P
r L
4 Main switch Y G (BLACK)
L
ne
B G/B
Gy
7 Ignition fuse u v w x y z {
L L
s t
t [
L B
}
0 Battery B B B Gy (BLUE) (BLUE)
B
B
B/L
B
A Main fuse B
Y G
| Ch Dg Y R/W R/G G
B B/L B B A A C
L Y/L B/L Gy B
Y G
O Coolant temperature sensor (GRAY) (GRAY) B
L Ch L Dg i Ch Dg Br Br G/Y
B Y G Y G
ELEC
P ECU o n jk l
G
p p G L Dg B
Y B
L Ch B
Y B
\ Radiator fan motor relay (BLACK)
–
B B m
B Ch L B Dg L
(BLACK)
Dg L/R
] Radiator fan motor B B L Y
Ch B B
B
å Radiator fan motor fuse A B B
+
B Br Dg G/Y Br
B Ch B
– +
COOLING SYSTEM ELEC
EAS00808 EAS00739
TROUBLESHOOTING
2. Battery
• The radiator fan motor fails to turn. • Check the condition of the battery.
• The coolant temperature meter (meter Refer to “CHECKING AND CHARGING
assembly) fails to indicate. THE BATTERY” in chapter 3.
Check: Minimum open-circuit voltage
1. main, ignition, and radiator fan motor fuses 12.8 V or more at 20 °C (68 °F)
2. battery
3. main switch • Is the battery OK?
4. radiator fan motor YES NO
5. radiator fan motor relay
6. coolant temperature sensor
7. wiring connections • Clean the battery
(the entire cooling system) terminals.
t
• Recharge or
ne
NOTE:
replace the battery.
_
e.
m
ing part(s): EAS00749
Ti
1. storage box
3. Main switch
2. front cowling
er
ot
3. radiator cover • Check the main switch for continuity.
co
YES NO
Pocket tester
w
90890-03112, YU-03112-C
m
EAS00738
switch.
d
chapter 3.
D
YES NO
8 - 46
– +
COOLING SYSTEM ELEC
EAS00809
t
ne
e.
m
• Does the radiator fan motor turn?
Ti
YES NO
er
ot
co
must be replaced. • Does the radiator fan motor relay have con-
w
YES NO
fro
d
8 - 47
– +
COOLING SYSTEM ELEC
EAS00812
t
ne
the table.
• Check the coolant temperature sensor for
e.
continuity at the temperatures indicated
m
below.
Ti
Coolant temperature sensor
er
ot
resistance
co
WARNING
_
m
it. YES NO
nl
ow
temperature sensor.
EAS00813
7. Wiring
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly
connected and without defects?
YES NO
8 - 48
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
t
ne
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .................................9-3
ENGINE..................................................................................................... 9-3
e.
FUEL SYSTEM.......................................................................................... 9-3
m
Ti
er
FAULTY CLUTCH ........................................................................................... 9-3
ot
ENGINE OPERATES BUT SCOOTER WILL NOT MOVE........................9-3
co
OVERHEATING............................................................................................... 9-4
m
ENGINE..................................................................................................... 9-4
fro
CHASSIS...................................................................................................9-4
de
t
ne
e.
m
Ti
er
ot
co
.S
w
w
w
m
fro
d
de
oa
nl
ow
D
TRBL
STARTING FAILURE/HARD STARTING SHTG
EAS00845
TROUBLESHOOTING
NOTE:
_
The following guide for troubleshooting does not cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man-
ual for checks, adjustments, and replacement of parts.
t
• Worn or damaged cylinder Fuel pump
ne
• Incorrect valve clearance • Faulty fuel pump
e.
• Improperly sealed valve • Faulty fuel injection system relay
m
• Incorrect valve-to-valve-seat contact • Improperly routed hose
Ti
• Incorrect valve timing Throttle body
• Faulty valve spring er
• Deteriorated or contaminated fuel
ot
• Seized valve • Sucked-in air
co
Air filter
fro
• Seized crankshaft
ow
D
9-1
STARTING FAILURE/HARD STARTING/ TRBL
INCORRECT ENGINE IDLING SPEED SHTG
ELECTRICAL SYSTEMS
Battery Ignition system
• Discharged battery • Faulty ECU
• Faulty battery • Faulty crankshaft position sensor
Fuse(s) • Broken generator rotor woodruff key
• Blown, damaged or incorrect fuse Switches and wiring
• Improperly installed fuse • Faulty main switch
Spark plug • Faulty engine stop switch
• Incorrect spark plug gap • Broken or shorted wiring
• Incorrect spark plug heat range • Faulty front, rear or both brake light
• Fouled spark plug switches
• Worn or damaged electrode • Faulty start switch
• Worn or damaged insulator • Faulty sidestand switch
• Faulty spark plug cap • Improperly grounded circuit
Ignition coil • Loose connections
t
ne
• Cracked or broken ignition coil body Starting system
• Broken or shorted primary or secondary • Faulty starter motor
e.
m
coils • Faulty starter relay
Ti
• Faulty spark plug lead • Faulty starting circuit cut-off relay
er
• Faulty starter clutch
ot
co
EAS00847
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL
FAULTY CLUTCH SHTG
EAS00848
EAS00853
FAULTY CLUTCH
ENGINE OPERATES BUT SCOOTER WILL POOR STARTING PERFORMANCE
NOT MOVE V-belt
V-belt • V-belt slips
• Bent, damaged or worn V-belt • Oil or grease on the V-belt
t
• Slipping V-belt Primary sliding sheave
ne
Primary pulley cam and primary pulley • Worn primary sliding sheave
e.
slider(s) Clutch shoe
m
• Damaged or worn primary pulley cam • Bent, damaged or worn clutch shoe
Ti
• Damaged or worn primary pulley slider POOR SPEED PERFORMANCE
Transmission gear(s) V-belt er
ot
• Damaged transmission gear • Oil or grease on the V-belt
co
• Damaged, loose or worn clutch shoe spring • Worn primary pulley weight
w
w
9-3
OVERHEATING/ TRBL
OVERCOOLING SHTG
EAS00855
OVERHEATING
ENGINE FUEL SYSTEM
Clogged coolant passages Throttle body
• Cylinder head and piston • Damaged or loose throttle body joint
• Heavy carbon buildup Air filter
Engine oil • Clogged air filter element
• Incorrect oil level CHASSIS
• Incorrect oil viscosity Brake(s)
• Inferior oil quality • Dragging brake
COOLING SYSTEM ELECTRICAL SYSTEMS
Coolant Spark plug
• Low coolant level • Incorrect spark plug gap
Radiator • Incorrect spark plug heat range
• Damaged or leaking radiator Ignition system
t
ne
• Faulty radiator cap • Faulty radiator fan motor relay
• Bent or damaged radiator fin • Faulty coolant temperature sensor
e.
Water pump • Faulty ECU
m
• Damaged or faulty water pump
Ti
er
• Thermostat ot
• Thermostat stays closed
co
• Oil cooler
• Hose(s) and pipe(s)
.S
• Damaged hose
w
w
• Damaged pipe
m
EAS00856
d
OVERCOOLING
de
COOLING SYSTEM
oa
Thermostat
nl
9-4
POOR BRAKING PERFORMANCE/ TRBL
FAULTY FRONT FORK LEGS/UNSTABLE HANDLING SHTG
EAS00857
EAS00861
t
ne
LEAKING OIL MALFUNCTION
e.
• Bent, damaged or rusty inner tube • Bent or damaged inner tube
m
• Cracked or damaged outer tube • Bent or damaged outer tube
Ti
• Improperly installed oil seal • Damaged fork spring
• Damaged oil seal lip er
• Worn or damaged outer tube bushing
ot
• Incorrect oil level (high) • Bent or damaged damper rod
co
washer
w
w
EAS00862
UNSTABLE HANDLING
d
• Improperly installed lower bracket • Uneven tire pressures (front and rear)
(improperly tightened steering ring nut) • Incorrect tire pressure
D
9-5
TRBL
FAULTY LIGHTING OR SIGNALING SYSTEM SHTG
EAS00866
t
ne
• Improperly grounded circuit • Incorrect turn signal bulb
• Faulty main switch TURN SIGNAL REMAINS LIT
e.
• Headlight bulb life expired • Faulty turn signal relay
m
TAIL/BRAKE LIGHT DOES NOT COME ON • Burnt-out turn signal bulb
Ti
TURN SIGNAL BLINKS QUICKLY
er
• Too many electrical accessories ot
• Incorrect connection • Incorrect turn signal bulb
co
9-6
YP400T WIRING DIAGRAM
1 A.C. magneto n Front turn signal/position light COLOR CODE
2 Crankshaft position sensor (right) B............ Black
3 Rectifier/regulator o Front turn signal/position light Br .......... Brown
4 Main switch (left) Ch ......... Chocolate
5 Storage box light switch p Headlight Dg ......... Dark green
6 Storage box light q Meter assembly G ........... Green
7 Ignition fuse r Multifunction meter Gy ......... Gray
8 Backup fuse (storage box light s Speedometer L ............ Blue
and meter assembly) t Tachometer Lg .......... Light green
9 Fuel injection system fuse u Engine oil change indicator O ........... Orange
0 Battery v V-belt replacement indicator P............ Pink
A Main fuse w Engine trouble warning light R ........... Red
B Starter relay x Meter light Sb.......... Sky blue
C Starter motor y High beam indicator light W........... White
D Diode z Right turn signal indicator light Y............ Yellow
E Starting circuit cut-off relay { Left turn signal indicator light B/L......... Black/Blue
t
ne
F Right handlebar switch | Thermistor B/R ........ Black/Red
G Engine stop switch } V-belt replacement indicator B/W ....... Black/White
e.
H Start switch reset coupler Br/L ....... Brown/Blue
m
I Front brake light switch ~ Headlight fuse Br/W ...... Brown/White
Ti
J Sidestand switch å Radiator fan motor fuse G/B ........ Green/Black
K Throttle position sensor ç Signaling system fuse
er G/L ........ Green/Blue
ot
L Intake air pressure sensor † Turn signal/position light fuse G/R........ Green/Red
co
8 9
R/G R R R
2 W/R
W/L O Gy Sb R L Y/G P/W
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