Yamaha Cw50n 1999-2002 Full Service Repair Manual – PDF DOWNLOAD

1999 - 2002 MOTORCYCLE

SERVICE MANUAL

Model : CW50L, CW50M, CW50N, CW50P

4RW281972K00 *4RW281972K00*

IA-21 NOTICE This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe.

MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and significant changes in specifications or procedures will be forwarded to allAuthorized YAMAHA dealers and will, where applicable, appear in future editions of this manual.

DOCUMENTATION TECHNIQUE MBK INDUSTRIE

PARTICULARLY

IMPORTANT

INFORMATION

This material is distinguished by the following notation:

/_

The safetyAlert Symbol meansATTENTION! BECOMEALERT! YOUR SAFETY IS INVOLVED!

r. IIY/-'1:I_11_[¢]1

Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander, or a person inspecting or repairing the scooter.

CAUT}ONi:

NOTE:

CW50 SERVICE MANUAL © 1997 by MBK INDUSTRIE 3st Edition, April 1997 All rights reserved. Any reprinting or unauthorized use without the written )ermission of MBK INDUSTRIE is expressly prohibited.

A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.

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

IA-31 HOW TO USE THIS MANUAL

®

®

ILLUSTRATEDSYMBOLS

(_

L_

Illustrated symbols _ to _ are designed as thumb tabs to indicate the chapter's number and

CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See <<illustratedsymbols).

1st title (_) This is a chapter with its symbol on the upper right of each page.

2nd tiUe 3rd title

Q _)

the chapter (<Periodic inspection and adjustment)) the 3rd title appears.)

This This tiUeappears is a final title.on the upper of each page on the left of the chapter symbol. (For

MANUAL FORMAT

I_

I=-I

I

_

_

tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections.

A set of particularly important procedure (_)is placed between a line of asterisks "* "with each step

_

content. _ General information z(t_Specifications

_

_ Periodic inspection and adjustment

®

@ Carburetion _ Chassis _ Electrical

II

IMPORTANT by" FEATUREsPreceded " "" • Data and a special tools are framed in a box preceded by a relevant symbol ®.

_

:1

_

alignments mark Q, the others being indicated by an alphabetical letter in a box_), •A Ancondition encircledofnumeral a faulty component ® indicateswill a part precede name, an and arrow ansymbol encircled andalphabetical the course of letter action data required for an thesymbol (_).

_)Troubleshooting Illustrated symbols _ to _ are used to identify the specifications appearing in the text.

_ @

i

Each chapter provides exploded diagrams are before each disassembly section for ease in identifyEXPLODED DIAGRAM ing correct disassembly and assembly procedures.

'

_ Filling fluid _ Lubricant

i_

@ Tightening @ Special tool @ Wear limit, clearance @ Engine speed

@

<_

OVA ' _.

:_-_.,_.._,';__ .....

:;"--L'..'._, _

_

_

_

Illustrated symbols _ to @ in the exploded dialubrication point. gram indicate grade of lubricant and location of

"",_ _-

.-

_';" .............

!_ .... _

_

_I

__,_.,

®_----

_--_1'¢_ r/,_,

@ I --i

:,T_...:.:....C.__,_I_:;-_,..,_tF-.-"'_ ":_""';_"I j _| [ E,;2_;c_E

_--

-_-_,

_

__--:5: _:_'_ ...... :_"':'_-

_

_1___ _

J _

_

--|

_ _

,

_ Apply engine oil

--_

@ Apply molybdenum gear oil _) disulfide oil

@ _

, Apply lightweight lithium-soap _ Apply wheel bearing grease grease

base

@ Apply molybdenum disulfide grease @Applylockingagent(THREADLOCK®) @ Use new one

A-4 I

INDEX

SPECIFICATIONS PERIODIC INSPECTION I _ AND ADJUSTMENT I '"sP ENGINEOVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING

I

I

I1 II! [!

1

I GEN CHAPTER 1.

GENERAL INFORMATION SCOOTER IDENTIFICATION ....................................................................... A-8 VEHICLE IDENTIFICATION NUMBER ................................................... A-8 ENGINE SERIAL NUMBER .................................................................... A-8 IMPORTANT INFORMATION ......................................................................

ALL REPLACEMENT PARTS ................................................................

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

LOCK WASHERS/PLATES AND CO'I-I'ER PINS ..................................

BEARINGS AND OIL SEALS ..................................................................

CIRCLIPS ................................................................................................

A-8 A-8 A-8 A-8 A-8 A-9

SPECIAL TOOLS .......................................................................................... A-9 FOR TUNE UP ........................................................................................ A-9 FOR ENGINE SERVICE ......................................................................... A-9 FOR CHASSIS SERVICE ..................................................................... A-10 FOR ELECTRICAL COMPONENTS ..................................................... A-10

SCOOTER IDENTIFICATION

IGE" I INFO

A-

8

1

IMPORTANT INFORMATION

INFORMATION SCOOTER

_

IDENTIFICATION

The vehicle identification numbere is stamped NOTE: into the frame, The vehicle identification number is used to

_

_'-.._

_

_._

__

_O

YAMAHAforassemblyandadjustment.Other

_

brands may be similar in function and appearance, but inferior in quality.

your scooter with the licensing authority in your state,

VG54RWN0*WA101301 I Initial serial number: I identifyyourscooterand maybe usedto register

1.All gaskets, seals and O-rings should be replaced when an engine is overhauled. All gaskets surfaces, oil seal lips and O-rings 2.Properly oil all mating parts and bearing during reassembly. Apply grease to the oil seal must be cleaned. lips.

GASKETS, OIL SEALS, AND O-RINGS

_(_

The engine serial number@ is stamped into the crankcase.

_

PINS 1.All lock washers/plates (_ and cotter pins must be replaced when they are removed.

Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

_

NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.

I

INFO

ALL REPLACEMENT PARTS 1. Use only genuine parts for all replacements.

Useoil and/or grease recommended by MBK/

VEHICLE IDENTIFICATION NUMBER

_

I°E"

_ _MHr,IH'

4UY-200101 Initial serial number:

1. Install the bearing(s) (_ and oil seal(s) ÂŽ with their manufacturer's marks or numbers facing

NOTE:

outward. (In other words, the stamped letters

Designs and specifications are subjectto change without notice,

must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

BEARINGS AND OIL SEALS

O_

CAUTION: _ __

bearings dry. This causes damage to the bearing surfaces.

Do not use compressedair to spin the 1 -1

1 -2

IMPORTANT

INFORMATION/SPECIAL

I°E" _ I INFO

TOOLS

A"

9

J

SPECIAL

CIRCLIPS

c_) [_

TOOLS

IGE"I INFO

Flywheel magneto puller

care,u,, 08 e- 0-

clips once they have been removed.

Replace fore reassembly.

Always replace piston pin bent circlips. When installing a circlip _) make sure that the sharp edge _ is positioned opposite to the thrust L_ it receives. See the sectional view.

Shaft SPECIAL

FOR ENGINE SERVICE

Crankcase separating tool 90890-01135

TOOLS

Flywheel holding tool 90890_0t_'_

f{_

plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.

The proper special tools are necessary for com-

Inductive tachometer

]

_ _

(_

Crankshaft installing tool set

Clutch serving nut wrenc_

90890-01277 (_) FOR

TUNE

UP

._

90890-01411 (_ __ 90890-03113

1

\_';_:i"

90890-01275 _) 90890-01274 _)

;_'#--'_

Ignition checker

Sheave

g0890_0_4 _

go8go.01_01

90890-01348

holder

Clutch spring holderri a

1-3

c-_

00890_01010®g°890°1_

Oil Seal Guide 90890-01409 (D Oil Seal Driver

f_

_/

1-4

SPECIAL

GEN I 'NFO

TOOLS

I

_1_1

Ring nut wrench 90890-01268 _ 90890-01403 _)

,_

FOR CHASSIS SERVICE

Damper rod holder 90890o01294

T-Handle 90890-01326

Oil seal guide 90890-01184

Oil seal guide adapter 90890-01186

Pocket Tester

FOR COMPONENT ELECTRICAL

90890-03112

1-5

_

_

IA- _ol

II.FO_1

{J

Ill

-/___/

IsPEc _'1tA-131

IsPEc _1 CHAPTER 2.

SPECIFICATIONS GENERAL SPECIFICATIONS .................................................................... A-14 MAINTENANCE SPECIFICATIONS ........................................................... A-15 ENGINE ................................................................................................ A-15 CHASSIS .............................................................................................. A-16 ELECTRICAL .......................................................................................... B-1 CABLE ROUTING .........................................................................................

B-2

GENERAL

SPECIFICATIONS

I SPEc

/'(_'1

IA-41

GENERAL

SPECIFICATIONS

SPECIFICATIONS

Model

GENERAL SPECIFICATIONS

CW50

Clutch type: Transmission:

Model Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance

CW50 1,740 mm (68.5 in) 665 mm (26.2 in) 1,050 mm (41.3 in) 745 mm (29.3 in) 1,170 mm (46.0 in) 125 mm (4.9 in)

Basic weight: With oil and full fuel tank

78 kg (172 Ib)

Minimum turningradius:

1,800mm(70.9in)

Engine: Type Cylinder arrangement Displacement Bore x stroke

Air-cooled 2-stroke, gasoline torque induction.

Single cylinder, Vertical 49 cm3 40 x 39.2 mm (1.57 x 1.54 in)

Compression ratio Starting system Lubricationsystem:

7.01 : 1 Electric and kick starter Separatelubrication (Yamaha Autolube )

Oil type or grade: Engine oil

Semi-synthetic oil in accordance to the API TC TS C3 standard.

SAE 10W30 type SE motor oil

Transmission oil Oil capacity: Engine oil: Total amount

1.3 L (1.14 Imp qt, 1.37 US qt)

Transmission oil: Periodic oil change Total amount Airfilter: Fuel: Type Tank capacity Carburetor:

0.11 L (0.10 Impqt, 0.12 US qt) 0.13 L (0.11 Impqt, 0.13 US qt) Wettypeelement Regular unleaded gazoline (RON 91 mini) 4.6L(1.01Impgal,1.21USgal)

Type Manufacturer

PHBN12HS DELL'ORTO

Spark plug:

I SPEC

Dry, centrifugal automatic

Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission Operation Chassis: Frame type

Helical gear 52/13 (4.000) Spur gear 43/13 (3.3077) V-belt Automatic Steel tube underbone

Caster angle Trail

27 ° 90 mm (3.54 in)

Tire: Type Size Manufacturer

Tubeless 120/90 - 10 130/90 -10 DUNLOP (TRAIL MAX) MICHELIN (REGGAE TL)

front rear front rear

DUNLOP (TRAIL MAX) MICHELIN (REGGAE TL)

Tire pressure (cold tire): Maximumload-exceptscooter Up to 90 kg (198 Ibs) load

152 kg (335Ibs) Front Rear

100 kPa (1.00 kgf/cm2, 15 psi) 125 kPa (1.25 kgf/cm2, 18 psi)

Front Rear

100 kPa (1.00 kgf/cm2, 15 psi) 150 kPa (1.50 kgf/cm2, 21 psi)

90 kg (198 Ibs) ~ maximum load

Brake: Front brake type Operation Rear brake type Operation Suspension: Front Rear Shock absorber:

Disc brake Right hand operation Drum brake Lefthand operation Telescopic fork Unitswing

Front Rear

Coil spring/Oil damper Coil spring/Oil damper

!Wheel travel:

Type/Manufacturer Gap

BR8HS/NGK 0.5 - 0.7 mm (0.020 ~ 0.028 in)

2-1

Front wheel travel Rear wheel travel

62 mm (2.44 in) 60 mm (2.36 in)

2-2

/(_i'

I P'=c Model

CW50

Electrical:

MAINTENANCE SPECIFICATIONS

I SPEc

/'_'1

MAINTENANCESPECIFICATIONS ENGINE

Ignition system Charging system Battery type/model Battery capacity

CDI Flywheel magneto GM4-3B/YB4L-B/FB4L-B 12V 4AH

Headlight type: Bulb wattage / quantity: Taillight/brake light Flasher light

IA-lSI

Model Cylinder head: Warp limit

Bulb

12V 5W/21 W x 1 12V 10W x 2

Front Rear

12V 10W x 2 12V 3W x 1

Meter light Warning lights wattage / quantity: "OIL" "TURN"

12V 3W x 1 12V 3W x 1

"HIGH BEAM"

12V 3W x 1

CW50

0.03 mm (0.0012 in) * Lines indicate straight edge measurements.

,k __

-_'_

_'_

Cylinder: Bore size <Limit> Taper limit Piston:

MeasuringPiSt°n size point .

39.993 - 40.012 mm (1.574 ~ 1.575 in) <40.1 mm (1.579 in)> 0.006 mm (0.0002 in)

_

_¢'

39.952 - 39.9725.0 mmmm(0.2(1.573in) ~ 1.574 in)

Piston clearance <Limit> Piston pin bore size

0.034 ~ 0.047 mm (0.0013 - 0.0018 in) <0.1 mm (0.004 in)> 10,004 ~ 10.015 mm (0.3938 - 0.3943 in)

Piston pin: Outside diameter Piston

Top ring Sectional sketch (B x T)/Type: L_j_ 2ndring - T End gap (installed): Top ring 2nd ring Side clearance (installed): Top ring 2nd ring

2-3

9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in)

ring: 1.2 ~ 1.8 mm (0.047 ~ 0.070 in)

B -

1.2 -1.8 mm (0.047~ 0.070 in) 0.15 ~ 0.30 mm (0.006 - 0.012 in) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.03 - 0.05 mm (0.0012 - 0.0020 in) 0.03 - 0.05 mm (0.0012 ~ 0.0020 in)

2-4

MAINTENANCE

SPECIFICATIONS

Model

IsPECIA-161 CW50

MAINTENANCE

SPECIFICATIONS

CHASSIS

Crankshaft:

Model

EB__:J Crank width "A"

37.90 - 37.95 mm (1.492 - 1.494 in)

Runout limit "C" Connecting rod big end side clearance "D" i Automatic centrifugal clutch: Shoe thickness <Wear limit> Clutch shoe spring free length Clutch-in revolution

0.03 mm (0.0012 in) 0.2 - 0.5 mm (0.008 - 0.020 in) 4.0 mm (0.16 in) <2.5 mm (0.10 in)> 26.2 mm (1.03 in) 3.200 ~ 3.600 r.p.m.

CW50

Steeringbearingtype No/Size of steel balls: Steering system: Upper Lower

Ballbearing 22 pcs (3/16 in) 22 pcs (3/16 in)

Front suspension: Front fork travel Spring Rate (K1) Stroke (K1) Spring Rate (K2) Stroke (K2) Optional spring

70 mm (2.75 in) 10.8 N/ram (1.08 kg/mm, 60.46 Ib/in) 0 ~ 40 mm (0 ~ 1.57 in) 14.4 N/ram (1.44 kg/mm, 80.61 Ib/mm) 40 ~ 77 mm (1.57 in ~ 3.03 in) No

Clutch-stall revolution V-belt: Width <Wear limit> Transmission:

6.300 - 6.900 r.p.m.

Main axle runout limit Drive axlerunout limit Kick starter:

0.08 mm (0.003 in) 0.08mm(0.003 in)

Stroke Optional spring Wheels:

0 ~ 44 mm (0 ~ 1.73 in) No

Ratchet type 150 ~ 250 g (5.3 - 8.8 oz)

Front wheel type Rear wheel type Front wheel size Material

Cast wheel Cast wheel MT 3.50 xl0 Aluminium

15 mm (0.59 in) <13.5mm(0.53in)>

Type Kick clip tension Carburetor: I.D. mark

PHBN12HS

Main jet (M.J.) Main air jet (M.A.J.) Jet needle (J.N.) Needle jet (N.J.) Cutaway (C.A.) Pilot jet (P.J.) Bypass (B. P.1) Pilot air screw (A.S.) Valve seat size (V.S.) Starter jet (G.S.1) Float height (F.H.) Fuel height (F.L.) (Center of float chamber / Fuel height) Engine idlespeed

# 93 2.0 A21-3/5 2.110 4.0 # 36 0.8 1-5/8 _+114out 1.2 # 40 15 - 17 mm (0.59 ~ 0.67 in) 20.5 ~ 22.5 mm (0.80 ~ 0.88 in) 1800_+ 200rpm

Reed valve: Valve stopper height Reed valve clearance

4.0 ~ 4.4 mm (0.157 ~ 0.173 in) 0.2 mm (0.008 in)

Lubrication system: Stroke Bore

Autolube pump 2.62 mm (0.10 in) 0.5 mm (0.02 in)

Rear suspension: Shock absorber travel Spring free length Springfittinglength Spring Rate

60 mm (2.36 in) 202 mm (7.95 in) 187.5mm(7.38in) 32.5 N/ram (3.25 kg/mm, 181.93 Ib/mm)

Front wheel size Material Rim runout limit: Front Rear Front disk brake: Type Diameter & thickness Pad thickness <Wear limit> Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Reardrumbrake:

MT 3.50 xl0 Aluminium 2.0 mm (0.08 in) 2.0 mm (0.08 in) Single disk 155 x 3.5 mm (6.102 x 0.137 in) 3.25 mm (0.127 in) <0.8 mm (0.03 in)> 11 mm (0.43 in) 30 mm (1.18 in) DOT #3 or DOT #4

Type Drum inside diameter <Wear limit>

Leading, trailing 110 mm (4.33 in) <110.5 mm (4.35 in)>

Lining thickness <Wear limit> Spring free length

4.0 mm (0.16 in) <2.0 mm (0.08 in)> 54 mm (2.125 in)

Front brake lever freeplay: Rear brake lever freeplay: 2-5

10 ~ 20 mm (0.4 ~ 0.8 in) 10 ~ 20 mm (0.4 - 0.8 in) 2-6

M.,.TE.A.OE.PEC,..C..,O.S Is Ec B-1I M.,.TE...CES.EC,F,C ISPEC ELECTRICAL

Model Model

CW50

Voltage:

12 V

Ignition system: Ignition timing (B.T.D.C.) CDI: Pickup coil resistance (color) Source coil resistance (color) Ignition coil: Minimum spark length Primary coil resistance Secondary coil resistance

14° at 5.000 r/rain

400 ~ 600 Q at 20°C (68°F) (White/Red-Black) 640 ~ 960 Q at 20°C (68°F) (Black/Red-Black) 6 mm (0.23 in) 0.56 ~ 0.84 Q at 20°C (68°F) 5.68 - 8.52 Qk at 20°C (68°F)

Spark plug cap: Resistance CDI Magneto: Lighting coil resistance Lighting coil resistance Voltage regulator/Rectifier: Type

5 k.Qat 20°C (68°F) 0.32 ~ 0.48 Q at 20°C (68°F)(Yellow/Red-Black) 0.48 ~ 0.72 Q at 20°C (68°F)(White-Black) Semi-conductor, short-circuit type

No load regulated voltage Capacity Withstand voltage

13 ~ 14 V 8A 600 V

Capacity

12V, 4 Ah

Specific gravity Starter motor: Output Armature coil resistance Brush length <Wear limit> Brush spring pressure Commutator diameter <Wear limit> Mica undercut

1.280 0.14 kW 0.072 _ a 20°C (68°F) 6.8 mm (0.27 in) <5.3 mm (0.21 in)> 150 - 650 gr (5.29 ~ 22.92 oz) 15.8 mm (0.62 in) <15.0 mm (0.60 in)> 1.15 mm (0.045 in)

Starter relay: Amperage rating Coil resistance

20 A 54 - 66 _ at 20°C (68°F)

Horn: Type/Quantity Model/Manufacturer Maximum amperage

Plain type/1 pc.

TR9/FRANSVAL 2.5 A

Flasher relay: Type Self cancelling device Flasher frequency Wattage Circuit breaker: Type Amperage for individual circuit x Quantity: Main Fuel sender unit: Resistance

2-7

CW50

Battery:

Condenser type No 70 - 90 cycle/rain 2 x 10W + 4 W Fuse 7Ax1

(full) (empty)

4 - 10 _ at 20°C (68°F) 90 - 100 _ at 20°C (68°F)

2-8

CA..E.OUT,.O IS" clPI IB'2 _3) Rim _) Tire ® Brake disc Brake caliper _) Brake hose guide (Lower) ® Brake hose guide (Upper) Throttle cable ® Wire harness Speedometer cable Brake hose _) Choke cable

[] [] [] [] []

Do not cover the frame number.

Attach the brake hose, starter switch cable and the brake cable together behind the horn bracket.

The throttle cable must have sufficient free play.

Clamp the brake hose into the upper holder.

With a band tie the choke cable, the throotle cable and the rear brake cable to the left side, the wire harness to the right side of the frame.

@ Rear brake cable

CA°LE.O°T,.O IS"EclP _) _) ® _) _ _) _) ® (9) _

Handlebar Left handle bar switch Right handlebar switch Handlebar wire harness holder Flasher relay Speedometer cable Throttle cable Lower handlebar cover Front brake hose Flasher ground

[]

[]

[]

[] [] [] [] [] []

o

The right handlebar switch leads must pass along the underside of the handlebar, then behind the boss on the lower handlebar cover.

Pass the couplers behind the speedometer cable, and after connecting them, fit them under the right side of the speedometer.

The left handlebar switch leads must pass along the underside of the handlebar, then in front of the boss on the lower handlebar cover.

Attach the front flasher ground to the handlebar.

The throttle cable must pass in front of the handlebar.

Pass the flasher relay leads under the handlebar.

The brake light leads must pass along the underside of the handlebar (left and right).

The wire harness holder must pass over the handlebar.

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

I

% []

2-9

2-10

OASLERO°T, NO ISPECl;] IB'3 (_) (_) ® (_

Choke cable Throttle cable Rear brake cable Speedometer cable

® (_ (_) ® ®

Front brake hose Main switch Wire harness Horn Steedng tube Lower cover

[] [] [] [] [] [] [] [] [] [] [] []

Tie the choke cable,throttle cable, rear brake cable, and speedometer cable to the left side of the handlebar.

Pass the wire harness along the right side of the handlebar.

Clamp the front brake hose to the lower cover.

The speedometer cable must pass belween the steering tube and the main switch bracket.

Attach the wire harness to the side of the main switch bracket with a band.

The wire harness must run straight (no loops)between the two bands.

Attach the wire hamess with a band to the steedng tube just above the wire bracket.

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

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

The horn leads must pass behind the horn bracket and behind the wire bracket.

The front brake hose must pass through the wire bracket.

The front brake hosde must pass through the hole in the fender.

T

II

2-11

=

.....

Is'c

I INSP

BEI -

I

I

CHAPTER 3.

PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ...........................................................................................

B-7

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

REMOVAL ...............................................................................................

INSTALLATION .......................................................................................

B-7 B-7 B-8

ENGINE ........................................................................................................ B-9 ENGINE IDLE SPEED ADJUSTMENT ................................................... B-9 THROTTLE CABLE FREE PLAY ADJUSTMENT .................................. B-9 SPARK PLUG INSPECTION ................................................................ B-10 AUTOLUBE PUMP AIR BLEEDING ..................................................... B-10 ENGINE OIL LEVEL INSPECTION ...................................................... B-11 TRANSMISSION OIL REPLACEMENT ................................................ B-11 AIR CLEANER ELEMENT CLEANING ................................................. B-12 CHASSIS ....................................................................................................

FRONT BRAKE LEVER FREE PLAY ADJUSTMENT ..........................

REAR BRAKE LEVER FREE PLAY ADJUSTMENT ............................

BRAKE PADS INSPECTION ................................................................

BRAKE SHOES INSPECTION .............................................................

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ................................

STEERING HEAD ADJUSTMENT ........................................................

TIRE INSPECTION ...............................................................................

WHEEL INSPECTION ..........................................................................

CABLE INSPECTION AND LUBRICATION ..........................................

LEVER LUBRICATION .........................................................................

CENTERSTAND LUBRICATION ..........................................................

REAR SHOCK ABSORBER .................................................................

B-12 B-12 B-12 B-12 B-13 B-13 B-14 S-14 B-15 B-15 B-15 B-15 B-15

ELECTRICAL ..............................................................................................

BATTERY INSPECTION .......................................................................

FUSE INSPECTION ..............................................................................

HEADLIGHT BEAM ADJUSTMENT .......................................................

B-16 B-16 B-16 C-1

LUBRICATION INTERVALS INTRODUCTIONIPERIOOIC MAINTENANCEI PERIODIC

INSPECTION

I ADJ INSP

IF_

I

I

B-

7

COVERS

AND ADJUSTMENT

_ I __

i_ d

information applies to vehicles already in service as well as new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.

,/___I_

ITEM

PERIODIC

BREAK-IN 1,000(600)

ROUTINE Check condition.

O

Replace if necessary.

Check idle speed/choke operation.

Adjust if necessary.

Clean.Clean if necessary.

Check or fuelreplace hose and vacuum pipe for cracks or damage.

O

MAINTENANCE/LUBRICATION

2

Air filter

3 1 4

Carburetor Spark plug Fuel line

-!

_ _

©

O O

O O O

O

©

1. Remove: • Seat C) REMOVAL

__

_

Unit : Km(miles) EVERY 3,000 8.000 (2,000)or (4,000)or 8 months 12 months

©

i Transmission

oll

Autolube pump

7

Front brake system

Check operation/fluid leakage/See NOTE. (Page 9-3).

Correct if necessary.

Check for oil leakage,

8

Rear brake system

Check ifoperation, Adjust necessary.

9

Wheels

Check damage/runout/tightening Replace/tighten if necessary.

1(

Wheel bearings

Check bearing assembly for looseness/damage.

11

Steering bearing

Check bearing assembly for looseness.

Correct if necessary.

Moderately repack every 12,000 (8,000) or 24 months.**

REPLACE

©

O

torque.

©

_

light

leads

_J

• Rear carrier C) 2. Disconnect:

_!_::=_ -_

_

_

• Washer

•

Rear shock absorber

Check Replaceoperation/oil if necessary.leakage,

1,'.

V-belt

Check damage and wear.

Replace if necessary.

IL

Fitting/Fasteners

Check all chassis fittings and fasteners.

33ghtan if necessary,

©

1,=

Centerstand

Repair if necessary.

O

Battery

Check gravity, Replacespecific Check operation. if damaged, Check breather pipe for proper operation.

Correct if necessary.

Central cover (_

O

O

O

O

O

O

©

O

©

__

6.

1".

O

o

• Front cover Disconnect:

(D

• Headlight leads

O O

©

O

©

© O

O O

e_.

_

_

5. Remove:

--

7. Remove: • Main switch cover (D

Items marked with an asterisk I I require special tools, data and technical skills for servicing.

Take the scooter to a Yamaha Dealer or refer to the Service Manual when servicing these items.

•*

leads

• Flasher

4. Remove:

Correct if necessary.

Replace every 12,000 (8,000) or 24 months.

(Warm engine before draining.)

Check operation.

Correct if necessary.

Bleed the air.

6

1(

• Taillight 3. Remove:

Replace if necessary, S

I

.Helmet holder (_)

I i_<_ (___

operation and a longer service life. The need for cosUy overhaul work will be greaUy reduced. This

_

COVERS

,

ments.

Theseincludes preventive maintenance procedures, if followed, will ensureinspections more reliable This chapter all information necessary to perform recommended and vehicle adjustINTRODUCTION

I_ INSP

: Medium weight wheel bearing grease.

NOTE: Turn the main switch cover counterclockwise and pull it out.

_

NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required.

2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.

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

3-1

_

• Front panel (_

3-2

COVERS ,

:__

_

B-8

I

COVERS I INSP_ _1

• Footrest board (D • Bottom cover (_)

.

t_

I INSP _ _ffr_ I

• Front panel (D • Main switch cover (_)

_

_ _

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

8. Remove:

• Screws (Handlebar cover) (D

eove

Insert the projections of the front panel into the 4. Install: slot of the footrest board.

NOTE:

___

: ::_'

;

• Headlight leads

Conn

• Speedometer cable (_) • Couplers

6. Install: • Front fender 0

11.

Remove:

NOTE:

o Handlebar cover (Upper) (_)

10.

Disconnect : INSTALLATION: Reverse the "REMOVAL" procedure. Note the following points.

1. Connect: o Speedometer cable • Couplers

/

Correct routing of cables and wires is essential NOTE: for a safe operation of this scooter. Refer to

Insert the projection "a" of side cover into the slot "b" of footrest board.

f

7. Install: • Central coverO

[l_'_:_"_

_

_

NOTE: Insert the projection "a" of central cover into the slot "b" of footrest board.

_(D

• Rear carrier (D • Handlebar cover NOTE: 2."CABLEInstaIt:ROUTING" in Chapter 2.

Be careful not to pinch any wires with the covers.

_ ___"_

• Seat "\_

__

NOTE: 8. Install: After con necting the tail and flasher light lead,

I'1

locate • Helmet the couplers holder inside the rear fender.

• Bottom cover (_) • Footrest board (_)

'

15.5 Nm (1.55 m.kg, tl.21 ff.lb) Nut (Seat): 8 Nm (0.8 rn.kg, 5.8 ft.lb)

NOTE: _ _

_

__

_

17 (Rear Nm (1.7 m.kg, 12.3 ft.lb) carrier):

Mesh the projections of footrest board and bot-

NOTE:

tom cover.

When installing the covers, be careful not to damage the mounting clips.

- Nut (Rear carrier):

3. Install:

3-3

3-4

ENGINE

ij

IDLE

SPEED

j

__

I'"sP II

ADJUSTMENT

_

_

B

- 9

THROTTLE

CABLE

FREE

PLAY

I'"sP I

ADJUSTMENT

_

1. Tighten: • Pilot air screw O Turn the pilot air screw in until lightly seated.

1. Check: -Throttle cable free play @ Out of specification ---*Adjust.

2. Loosen: o Pilot air screw ENGINE IDLE SPEED ADJUSTMENT Back out from the lightly seated position.

MENT .-.:=::::::==::::=_xx=_==:_x-,=:=:=__

~ 3.0@: mm (0.06 ~ 0.12 in) --_Free 1.5play

Throttle cable free play adjustment steps: 1-518turns -+114 f_ Pilot air screwout position:

NOTE:

I

Before adjusting the throttle cable free play, the engine idle speed should be adjusted.

3. Start the engine and let itwarm up for several minutes.

V!IW_,I;1 _11_ [¢]I

First step: Loosen the Iocknut (_) on the throttle cable.

• Turn the adjuster (_) in or out until the specifled free play is obtained.

For safety reasons, place the scooter on the center stand before starting the engine, 4, Attach: • Inductive tachometer (to the spark plug lead)

I

'ndu°t'vetac'°meter: .ef:..0.03t 1,

Turn in

Free play increased.

Turn out

Free play decreased.

T0 tent,e _WARNING After adjusting, turn the handlebar to the right and left, making sure that the engine idling speed does not change.

5. Check: • Engine idle speed Out of specification -) Adjust.

1800 + 200 rlmin 6. Adjust: • Engine

::::::::":::::::==::":::::::=::*_**_::::::::::*"*"*

I

idle speed

Turn the throttle stop screw O in or out until specified idling speed is obtained.

Adjustment steps:

__

Turning

left

Turning right

3-5

Idling

speed increased.

Idling speed decreased.

3-6

I SPARK

PLUG

INSPECTION

INSP

IB-101

I

I

SPARK PLUG INSPECTION

/_

• Spark plug 2. Check: • Spark plug type Incorrect _ Replace

;_ ,i,/_ _,_'_-_H_'/I_ '

1. Remove:

_

i

I

BR8HS (NGK)

.4

AUTOLUBE PUMP AIR BLEEDING " Fan cover (_

_

_,

1, Remove:

'_ ....

2. Bleed:

Wear/Damage _ Replace.

@

*......................................................

•. Insulator Electrode(_) O Abnormal color _ Replace.

___ -_ //_-_(,_.=_E_i

Normal color is a medium-to-light tan color,

__/_i_ '_

3. Inspect: Plug gap @ 4. •Measure: Out of specification .-, Adjust gap.

'/___

Use a wire gauge or feeler gauge.

I_

_ ll\ \

\\_\ _ ""'

\\_

'

'\ \\-

i__

Pump bleeding steps: Place a rag under the pump. °

Remove bleed Let oil runthe until therescrew are no(_. more air bubbles

•

• Pump housing and oil hose When init. there are no more bubbles, tighten the bleed screw.

NOTE:

0.5 ~plug 0.7 mm ~ 0.028 in) Spark gap (0.020 @:

If it is damaged, replace it with new one.

Check the condition of the bleeda screw gasket.

5. Tighten: • Spark plug NOTE: Before installing the spark plug, clean the gasket surface and plug surface.

Start theengine.

Let the engine run two or three minutes at 2000 rpm. This will force out any air in the hose. ........ , ................. ******............. , .........

NOTE: First tighten tion.

I_

3-7

by hand,

then torque

to specifica-

20 Nm (2.0 m.kg, 14ft.lb) Spark plug:

I

3-8

ENGINE OIL LEVEL INSPECTION

B - 11

I

TRANSMISSION OIL REPLACEMENT

ENGINE OIL LEVEL INSPECTION _ II

II

30 20_'?_-

t __"_"

_

• Oil level Oillevellow --Add oiltoproperlevelas

_

8o

,= ,_-_l

_-- _ _'_'°°El_-_

_e_ _'_'_h,40 50 60 70

.(_

,, II

__!_//:

O "OIL" indicator light

I

to.

Drain the transmission oil.

•"Oil Gasket filler (drain plug_ plug) 2. Check: • O-ring (oil filler plug) Damaged _ Replace.

/

_

_,

T

3. Install:

,_,_

-Gas ket(_ Drain plug: •Drain plug (_) 17.5 Nm (1.75 m.kg, 12.6 ft.lb)

_ _ light.

"OIL"indicator

4. Fill:

,r--m,.,on o.

to "ON".

SAE 10W30 type SE motor oil

I

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

_

I

Inspect FaulW Light bulb etc.

and electric circuit I"OIL" indicatorgoes_ Engine are oil OK.level

t

_

stays on.

I

i

_

'

NOTE:

"OIL" indicator Add_ oil.

I

Wipe off any oil spilt on the crankcase, tire or Total amount wheel.

J

I "OlL'indicstor J

Capacity: 0.13 L (0.11 Imp qt. 0.13 US qt)

5 Install:

stays on.

• Oil filler plug

.°..n,..,co.,n.ccor°-to theAPITCTSC3standard.

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

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

NOTE: Always use the same type of engine oil; mixing oils may result in a harmful chemical reaction and lead to poor performance.

3-9

I

° Transmission case

IT°rn a'n switch electrical circuit,

_

• Drain plug @

_J""

"_-,,"_

_

TRANSMISSION OIL REPLACEMENT

'

Turn main switch

doesn't light, "OIL" indicator

" ' __

_ -_) 'i

follows.

OIL LEVEL AND GAUGE CHECK

I

_

I'"sPI

3-10

FRONT BRAKE LEVER FREE PLAYADJUSTMENT/ AIR FILTER ELEMENT CLEANING -J-_ z

I _

_

IIB

- 12

I

BRAKE PAD INSPECTION

AIR FILTER ELEMENT CLEANING _ _

1. Remove:

: CAU_i0N_:: • Air cleaner case cover (_) element removed.

Unfiltered air will cause Never operate the engine with the air cleaner rapid wear of engine parts and possible engine damage.

/ / ._

J

_

1. Check: • Front brake lever free play @ Out of specification _ Adjust.

JUSTMENT 10 play: ~ 20 mm (0.4 ~ 0.8 in) _ Free

_

A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system.

Thisairmustberemoved bybleeding the brake system before the scooter Is operated. Air in the system will reduce brake performance and can result in loss of control and an accident. Inspect and bleed the system

::=:::::::::=:::::::::::::::::=::::::=::::==:::::::"_ Cleaning steps: Wash the element gently but thoroughly in solvent.

if necessary.

REAR BRAKE LEVER FREE PLAY AD(_)__

JUSTMENT 1. Check:

_l.*liW,_l;l_ll_,[Hll gasoline to clean the element. Such solvents may lead to fire or explosion.

__=_

Never use low flashpoint solvents such as • Squeeze excess solvent out of the element and let dry.

___

• Rear brake lever free play @ h=, _

Free play: 10 ~ 20 mm (0.4 ~ 0.8 in) r'_'xIOutof specification --*Adjust.

....... ........

Do not twist the element .................................................... ,_

=b

Adjustment steps: Turn the adjuster (_) in or out until the speci-

Sqeeze out the excess oil. _

_

oil on the element, NOTE:

I

Front brake lever free play

Apply foam air filter oil or SAE 10W30 typ SE

Q_

I

:CAUTiONi

3. Inspect: • Element (T) • Damage-* replace, 4. Clean: • Air filter element

r'

I

FRONT BRAKE LEVER FREE PLAY AD-

JJ

//

_r_

CHASSIS _(_)

2. Remove: • Air filter element

/ /

_

, .................................................. _//_

2. Adjust: fled free play is obtained.

Out of specificatin _ Replace brake pads.

The element should be wet but not dripping.

/_,_

__'__

INSPECTION1..Measure:Brake BRAKE PADS pads @ Replace the brake pads and spring as a set when replacing the brake pads. _70o_

3-11

3-12

.OTE _

Brake pads wear limit: 0.8 mm (0.03 in)

"E'"S"OE''"SPEC"O"'I'"SP IIB = 13 I

BRAKE

FLUID

//

J

LEVEL

INSPECTION

-A_

R_

AIR

BLEEDING

(HYDRAULIC

BRAKE

1. pp,y therear bra e,ever.

Air bleeding steps: a. Add proper brake fluid into the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect a clear plastic tube O tightly to the

.RAKE S.OE,NSPECT.ON

A,R=EEO..O

BRAKE FLUID LEVEL INSPECTION NOTE:

/

/// /

_ _I\ '

//_ ,

,

caliper bleed screw. d. Place the other end of the tube into a con-

\

the fluid level, and make sure be turning the handlebar that the top of the master cylinder is

O

f. Pull the lever as far as possible and hold it there.

horizontal, Position the scooter straight up when inspecting

_ \I_

• Brake fluid level Brake fluid level is under"LOWER" level line "-* Fill to proper level.

1. (D Inspect:

_ R

b/j_._ _/

__

i,_l Recommended brake flu,d: CAU_ioNi

"_

-_

_

3,6co_

g. Loosen the bleed screw and pull the lever all the way. e. Slowly apply the brake lever several times. tainer.the lever is completely pulled, tighten h. When the bleed screw, then release the lever.

been removed from the system. j. Add brake fluid to proper level. i. Repeat steps (e) to (h) until all air bubbles have

DOT # 3 or DOT # 4

_

bleeding the brake system.

I

****************************************************** Check the operation of the

The brake fluid may corrode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

_lvAvL,l ;I _11_ [rll • Use only the designated quality fluid.

Otherwise, the rubber seals may deteriorate causing leakage and poor brake performance.

• Refill with the same type of fluid. Mixing fluids may result in a harmful chemical reaction leading to poor brake performance.

• Be careful that water does no enter the master cylinder when refilling.

Water will signiflcantly lower the boiling point of the fluid and may result in vapor lock.

3- 13

A-_

SYSTEM) 1. Bleed: • Brake fluid. _=:_="_::_`"_`_`"_`"_"_-`_"_"_"_=_=_=_=_=_=_:_

Indicator reaches the wear limit line (_) .-, Replace brake shoes,

J [_

I'"sp [

(.YD OL,C

2. Inspect: • Wear indicator O

I

SYSTEM)

3- 14

brake after

I'"sP I 1. Check: • Steering assembly bearings Grasp the bottom of the forks and gently rock the fork assembly back and forth, Looseness _ Adjust steering head.

Proper loading of your scooter is Important for the handling, braking, and other performance and safety characteristics of your scooter. Do not carry loosely packed Items that can shift.

*************************************************** Steering head adjustment steps: STEERING HEAD ADJUSTMENT Remove the front fender and the front panel, Refer to "COVERS" section,

Securely pack your heaviest items close to the center of the scooter, and distribute the VT_W_,_I-I_.II_,[¢! weight evenly from side to side. And check the condition and pressure of your tires.

,

Makesurethetotalweightofthecargo,

Tighten the nut (D

C)__

/

_._/

I'"sp I

I_=_

Ref : 90890-01268 Ref:90890-01403 Steering headwrench:

saddlebags, etc. If approved for this model) doesnot maximumloadof the passenger,exceed and the accessories (fairing, scooter. Operation of an overloaded scooter could cause tire damage, an accident, or even injury.

NEVER OVERLOAD YOUR SCOOTER.

NOTE: Tighten the ring nut until no play can be seen.

Unscrew the securing nut I

_

Install the securing nut Tighten the securing nut (_

I_

22.5 Nmnut: (2.25 m.kg, 16.2 ft.lb) I Securing

rider,

_re pressure(oald) Upto 90kg

Front 100kPa

Rear 125kPa

90 kg- maximum 100kPa 150kPa 15psi) 18psi) load* (1.0Okgflcm_, (1.50kgflcmz, 15psi) 21 psi) Maximumload: 152kg(335Ib)

'I

NOTE: Set the torque wrench (_) to the ring nut wrench SO that they form a right angle.

• Maximumload is the total weightof cargo,rider,pas(1.00kgf/cm=, (1.25kgflcm', sengerandaccessories.

Move the handlebar up and down, and / or back and forth. If the handlebar free play is • Tire surface torque.

_.'="_i'

Handlebar securing bolt: 60 Nm (6.0 m.kg, 43.4 ft.lb)

WearlDamagelCrackslRoad hazards-_ Re,

.

• Wheels

Instal the front panel and front fender. ***************************************************** excess, tighten the bolt (_)to the specifiedI

//j/_ _'_'___'i'_"

Never attempt even small repairs to the wheel.

Damage/Bends --_Replace.

2. Inspect:

".//).;

Fv_

TIRE INSPECTION

Ride conservatively

Out of specification _ Adjust,

a tire to

• If the tire is removed with a tire lever, use a suitable protection to prevent damaging the rim.

• When installing the tire, make sure the arrow points to the front. allow it to seat itself properly on the rim.

1. Measure:.

Air pressure

3-15

after installing

3-16

CABLE INSPECTION AND LUBRICATION TIRE INSPECTION/WHEEL INSPECTION/ I:_

I _ INSP

_

I I B - 15

REAR SHOCK ABSORBER CABLE INSPECTION AND LUBRICATION/

I

• Tire tread depth Out of specification ._ Replace.

ivuco Recommended

(front and Minimum tire rear): tread depth 0.8 mm (0.03 in)

I_ I

lubricant:

Engine oil SAE 10W30 CENTERSTAND LUBRICATION 1. Lubricate rotating parts

(D Tread depth

(_) Wear Side wall ® indicator

I_=_

Rec°mmended lubricant: Engine oil SAE 10W30

WHEEL INSPECTION 1. Inspect: • Wheels Damage/Bends _ Replace.

Fv_ Never attempt

even small repairs tothe

wheel.

CABLE INSPECTION AND LUBRICATION

F'==_=_

.___

REAR SHOCK ABSORBER 1. Check:

VIIYL, I-'I_II_.[tt A damaged cable sheath will rapidly corrode.

As a result, the cable cannot move smoothly inside the sheath. Since this situation is

immediately. dangerous,

replace

a damaged

• Rear shock absorber (D Oil leaks/Damage _ Replace.

2. Check: • Tightening torque

cable I

1.

Check: • Cable sheath ° Cable end Damage --* Replace.

2. Check: • Cable movement Stickness --* Lubricate.

I_

I|

Engine oil SAE lOW30 Recommended lubricant:

NOTE: into the sheath. _._

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

,,:

guide notch on thesoap throttle grip with grease (D. Lithium based grease I_:_ Recommended lubricant: 3-17

I

1. Lubricate rotating parts of the levers

esr

(_

I _ INSP

3-18

31.5 bolt: Nm (3.t 5 m.kg, 22.8 ft.lb) Upper Lower bolt: 17.5 Nm (1.75 m.kg, 12.6 ff.lb)

I

BATTERY

I_ I

t _ _'_ /_)

INSPECTION

UPPER -__

ADJ

_

-

1 6

FUSE INSPECTION _ BATTERYINSPECTIONI IINSP

ELECTRICAL BATI'ERY INSPECTION

LOWER

--

IINSPIIB I

I

:CAgTiONi

• Battery fluidlevel

it to ensuremaximum performance.

Fluid level low --_Add to proper level.

Fluid level should be between upper and lower level marks.

1. Inspect: _) Upper level

_IW:I--I_JI_[_ Battery electrolyte is dangerous. It contains Always a new before sulfuric charge acid which is battery poisonous andusing highly caustic.

Alwaysfollowthesepreventive measures:

Lower level

• Refill with distilled water only. Tap water contains minerals which are harmful to a

Avoid bodily contact with electrolyte as it can cause severe burns and permanent eye injury.

battery.

•

Wear protective eye gear when handling or working near batteries.

Antidote (EXTERNAL) : - SKIN- Flush with water.

• EYES - Flush with water for 15 minutes and get immediate medical attention.

Antidote (INTERNAL) :

2. Inspect: • Breather hose Obstruction _ Remove.

•

3. Inspect: • Battery

attention.

Batteries generate explosive hydrogen gas.

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

........................................................

Replace the battery if: Batteryvoltagewillnotrisetoaspecificvalue or bubbles fail to rise during charging, Sulfation of one or more cells occurs. (As indicated by the plates turning white, or an accumulation of material in the bottom of the

°

Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.) ° DO NOT SMOKE when charging or handling batteries.

KEEP BATTERIES AND ELECTROLYTE OUT

sell.)

Specific gravity readings after a long, slow charge indicate that one cell is lower than the rest.

Warpage evident.

or buckling of plates or insulators

Drink large quantities of water or milk.

Followwith milkof magnesia, beaten egg, or vegetable oil. Get immediate medical

OFREACH OFCHILDREN.

is

*******--***--*********************--*********

• Specific gravity Less than 1.280 .-_ Recharge battery.

_1 i

3- 19

1. Open the seat.

2. Inspect: • Fuse

0.4 amps/10 hrs Charging Current:

Blown --, Replace,

1.280 at 20°C (68 ° F) Specific Gravity:

3-20

HEADLIGHT

OS'"SPEOT'O"'I'"SP I

BEAM

ADJUSTMENT

_

_

C

-

1

I'"sp I

I

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

Fuse replacement steps: Turn off the ignition, • install a new fuse of the right amperage.

• Turn on the switches to verify the operation of the electric circuit. if the fuse immediately blows again, check the electric circuit.

Never use a fuse with a rating higher than specified. An improper fuse may cause damage to the electrical circuit, and possibly cause a fire. *****************************************************

Main circuit:

1. Adjust: • Headlight

7A

beam

Higher

Turn out screw O

Lower

Turn In screw (_)

HEADLIGHT BEAMADJUSTMENT

3 - 21

3 - 22

I

lc-l

CHAPTER 4.

I

ENGINE OVERHAUL ENGINE REMOVAL ......................................................................................

COVER REMOVAL .................................................................................

CARBURETOR .......................................................................................

CABLES, LEADS AND HOSES ..............................................................

ENGINE REMOVAL ................................................................................

C-5 C-5 C-5 C-5 C-6

ENGINE DISASSEMBLY ..............................................................................

REAR WHEEL ........................................................................................

CENTER STAND ....................................................................................

CYLINDER HEAD AND CYLINDER .......................................................

PISTON PIN AND PISTON .....................................................................

KICK STARTER ......................................................................................

PRIMARY SHEAVE ................................................................................

SECONDARY SHEAVE ..........................................................................

STARTER SYSTEM ................................................................................

TRANSMISSION .....................................................................................

CDI MAGNETO .......................................................................................

AUTOLUBE OIL PUMP ...........................................................................

CRANKCASE AND CRANKSHAFT ........................................................

C-6 C-6 C-6 C-6 C-6 C-7 C-7 C-7 C-8 C-8 C-8 C-9 C-9

INSPECTION AND REPAIR .......................................................................

CYLINDER HEAD .................................................................................

CYLINDER AND PISTON .....................................................................

PISTON RINGS ....................................................................................

PISTON PIN AND PISTON PIN BEARING ...........................................

KICK STARTER ....................................................................................

TRANSMISSION ...................................................................................

AUTOLUBE PUMP ...............................................................................

CRANKSHAFT ......................................................................................

PRIMARY SHEAVE ..............................................................................

SECONDARY SHEAVE ........................................................................

V-BELT ..................................................................................................

STARTER CLUTCH AND GEARS ........................................................

C-10 C-10 C-10 C-11 C-11 C-12 C-12 C-12 C-12 C-12 C-13 C-13 C-14

ENGINE ASSEMBLY AND ADJUSTMENT ................................................

CRANKSHAFT AND CRANKCASE ......................................................

AUTOLUBE PUMP ...............................................................................

CDI MAGNETO .....................................................................................

C-14 C-14 C-16 C-16

TRANSMISSION .....................................................................................

STARTER SYSTEM ................................................................................

SECONDARY SHEAVE ..........................................................................

PRIMARY SHEAVE ................................................................................

KICK STARTER ......................................................................................

PISTON PIN AND PISTON .....................................................................

CYLINDER AND CYLINDER HEAD .......................................................

ENGINE REMOUNTING .........................................................................

D-I D-2 D4 D-5 D-6 D-7 D-7 D-8

E.O,.E.EMOV.L IE"O ''1 IC'I

E.O,.E.EMOV.L

ENGINE REMOVAL

1. Remove: • Oil hose (_ on oil pump side

COVER REMOVAL 1. Remove: • Covers Refer to "COVERS" in CHAPTER 3.

NOTE: Plug the hose to prevent oil spillage.

ENGINE OVERHAUL

CABLES, LEADS ANDHOSES

1. Remove: • Air cleaner case assembly (_)

CA

RBUR ETOR

• Earth (ground lead) • Spark plug cap 0 • Starter motor lead (_) • CDI magneto lead (_)

______,__

• Carburetor cover

_

• Hoses

__

2. Disconnect:

- _._

\

• Rear brake cable (_

%

3. Remove: • Carburetor (_ • Carburetor top

/_

__

4. Remove: ° Air shroud (_) • Muffler assembly (_)

(_)

__

° Exhaust protector

o Rear axle nut (_ NOTE: Apply the rear brake while loosening the rear axle nut

5. Loosen: 4-1

4-2

_rJ.

1. Place a suitable stand under the frame.

REAR WHEEL

_-_

2, Remove:

1, Remove:

• Left pillion footrest • Rear shock absorber bolt (lower) (D . Engine mounting bolt _) _ .f_(_ _ -_._

• Rear wheel nut • Rear wheel washer • Rear wheel • Brake shoes (_) • Plate washer (_)

34S001

3. Remove:

j_

_

CENTERSTAND • Spring (_) • Clip 0 • Rubber washer (_) ° Axle (_) • Clamp (_) • Center stand (_) 1. Remove:

NOTE: Lift up the frame and remove the engine.

4. Place the frame on a suitable stand.

• Engine

_

358(;O1

1. Remove: • Air shroud • Cylinder head C) - Cylinder head gasket

• S'

3o_c_s

NOTE: • Beforeloosening the cylinder head nuts, loosen the spark plug.

• Loosen the cylinder head nuts crosswise 1/4 of

(_)

_

2.a .°Rem°ve:tUrnCylinder Cylinder each before(_gasket removing(_) them.

1. Remove: • Piston pin clip (_ NOTE: Before removing the piston pin clip, cover the _, _

cannot accidentally fall into the crankcase.

307OO1

4-3

PISTON crankcase PIN with AND a clean PISTON rag, so that the clip 4-4

E.O,NEO,..SSE.SLY IE"O _'1IC'_]

E.O,NEO,SASS IE"O ''1

2. Remove:

• Piston (_) • Piston pin bearing (_)

PRIMARY SHEAVE

• Fan 2. Remove: • Nut C) (primary sheave)

:j:

NOTE:

__)(__)

3070O2

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

•Piston pin(_

__

319035

KIGKSTARTER _--------_

_V

_---J'-"==__(_).._F_

o o-

To loosen the primary sheave nut hold the CDI magneto with a flywheel holder (_).

1. Remove:

I_

Flywhee190890.01235holder:

I

Kick crank •• Transmission cover O (teft)

_-_T_

® _/_

•

pinion gear (D

• Ratchet (_) • Washer (_) • Fixed primary sheave (_) • Washer (_

2.

NOTE: To remove the kick pinion gear, push down the kick crank.

3. Unhook: _

@

• Kick return spring (_)

•cirdi0s_ • Plate washer (_) • Kick shaft (_)

• V-belt 3,goo,

"_/__

.S0_cer_ ° Primary sliding sheave (_)

317O02

SECONDARY SHEAVE -(_

1. Remove:

Hold the secondary sheave with a sheave holder (_)to loosen the nut.

c c 319003 c 4-5

4-6

NOTE:' Nut 0 90890-01701 (secondary sheave) I_ sheave h°'der:

I

l..olo,..l 2. Remove:

• Crankcase cover gasket

\

_._"

/_

_/

_

• Dowel pins 3. Attach: • Sheave holder (_) 2" Remove: • Nut wrench (41 mm) • Secondary sheave (_)

_/_

•o,utc, housing ® 90890-01701 sheave h°lder:

l_

• Starter motor

° Bearing _

_ _______ __

t

_--'--_ ___'_L

• Clutch securing nut

- Washer ® (_ •Spacer • Transmission case O TRANSMISSION 1. Remove:

o._

___II

tc_

_,

• Dowel pins

Loosen the nut but do not remove it yet, _o3

4. Loosen:

__

= Gasket

2 Attach

_

_ _ \

NOTE: Compressthe secondary sheave using the clutch spring holder (_.

/_ _ __ _ t;_' __ _ ;_ _ \_._ ....

Main shaft _) 2 -Remove • Plate washer

Clutch spring holder: 90890-01337

_o_

washer (_) • Conicalspring (_)

____, ____(_

_

......

3. Remove:

• Clutch securing nut

• Secondary sheave axle _)

• Clutch assembly (_) 6. Remove: • Spring seat (_ (_) (_) •• Guide Clutch pin spring • Secondary sliding sheave (_)

_

• Oil seal (_) 3_,o_ CDI MAGNETO • Nut O (rotor) . Plate washer

STARTER SYSTEM _(_/___---(_)

1. Remove: • Starter clutch assembly _

_0_/_.

_@0@

(_

NOTE:

• • Idle gear (_) Plate (_ (idle gear)

/_

_

• Starter wheel gear (_)

loosen the nut.

Hold the rotor using the flywheel holder (_) t° 32_

_ 4-8

4-7

90890-01235 F,ywheel holder:

I

I..o"-.I c-91 ?_ L/

• Rotor (_ • Woodruff key

level the tool body.

Use the flywheel puller (_)

3. Remove: ° Crankcase

I

90890-01189 _

32'005

I

_

314001

]

1

I'"° "1 As pressure is applied, keepbosses. tapping carefully on the engine mounting

Stator assembly 2. ••Remove: Gasket

:sary, CAUTION: loosen :one screw as much as required to Use a soft hammer to tap on the case. Tap

• Autolube oil pump (D 1. Remove:

slowly and carefully. Make sure the cases tap separate on the evenly. gasket If one mating end "hangs surfaces.up" Work take the pressure off the push screw, realign the cases and the tool and start again. If the cases do not separate at all, check for a remaining case screw or fitting. Do not force. only on reinforced spots of the case. Never

AUTOLUBE OIL PUMP

eove • Pin (_) • Circlip (_)

3140C_

Crankcase separating tool: 90890-01135

_

Crankshaft (_) _ •Remove: 3O04

• Oil seal stopper (_) • Screws (crankcase) NOTE: Loosen each screw one quart of a turn before beginning to remove them. _

300g

1

CRANKCASEANDCRANKsHAFT1.

Remove:

• Crankcase separating tool (D Crankcase separating 90890-01135

313oo2

(right)

tool:

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

4-9

4-10

I..o

Ic-01

I..o°.-I

1. Eliminate:

Wear/Scratches/Damage --*Replace.

• Carbon deposits Use a rounded scraper (_) NOTE: Take care toHEAD avoid damaging CYLINDER

__ 3o,ool

J

• Piston wall _ .J

3o7oo, J

2. Inspect: • Cylinder head warpage Out of specification --* Resurface, •******************************************************

• Piston to cylinder clearance ..................................................... ** Piston to cylinder clearance measurement steps:

Warpage measurement steps:

First step: Measure the cylinder bore "C" with a cylinder

__________o_

/ _o

the spark plug

threads. Do not use a sharp instrument. Avoid scratching the aluminium.

and re-surfacement

Attach a straight edge C) and a thickness gauge (_)to the cylinder head.

f._----

Measure the warpage limit.

_

bore gauge.

NOTE: 6.

Measura:

_,

___-

/I

Measure the cylinder bore "C" in parallel to and

If the warpage is out of specification, resur-

t,e t,e veraoeo, ea ure

face the cylinder head.

I

P'_"X]

NOTE:.

Rotate the head several times to avoid removing too muchWarpage material from limit: one side.

3

Cylinder _

3o7oos

Standard

39.993~ 49.912mm 40.10 mm

at Bore right angles "C" to(1.574~ the crankshaft, 1.575in) Then, (1.579 calculate in) Taper

3O4O01

,_::

C=Maximum D

• Carbon deposits Use a rounded scraper C) 2. Inspect: • Cylinder wall Wear/Scratches --, Replace.

T = (Maximum D1,D3or Ds) (Maximum D2,D4or Ds )

CYLINDER AND PISTON

"T"

NOTE: • Carbon deposits a crisscross pattern. Do not sand excesSand3" Eliminate:in sively.

4 - 11

0,006 mm

If out of specification, replace cylinder, piston and piston rings as a set.

(0.0002in)

micrometer.

4. Remove: • Score marks and lacquer deposits From the sides of piston.

3o7oo3

_

1. Eliminate:

Fromthe piston crown (_)and ring grooves 0. .;,,

Wear limit

@ 5 mm (0.2 in) from the piston bottom edge. _ __

• I 3o_oo6

Piston Size: I Standard: ~ 39.972 mm Measure39.952 the piston skirt diameter"P" with a step: (1.573 ~ 1.574 in)

r,l,2nd I

4 - 12

I

If out of specification, replace piston and piston rings as a set.

(_,X'%I

3rd step: Calculate the piston-to-cylinder clearance with following formula: B

I

Cylinder Bore "C" Piston Skirt Diameter "P" Piston-to cylinder clearance=

I

If out of specification, replace cylinder, piston and piston rings as a set.

Piston=to-cylinder

i

Wear limit : 0.1 mm (0.004 in) 0.034 ~ ~ (0.0013 0.047 0.0018 mmin)

clearance:

Top ring

0.15 ~ 0.30 mm (0.006 ~ 0.012 in)

0.70 mm (0.028 in)

2nd

0.15 ~ 0.30 mm

0.70 mm

PISTON PIN AND PISTON PIN BEARING 1. Inspect: • Piston pin

I

Blue discoloration/Groove _ Replace, then

I

inspect lubrication system.

1. Measure: - Side clearance

'//

• Outside diameter (piston pin) Out of specification --* Replace.

Out of specification .-.*Replace piston and/or rings.

Use a Feeler Gauge (D

Outside diameter (piston pin): 9.996 ~10.000 mm (0.3935 ~ 0.3937 in)

S=,ar.mt

307OO7

Top ring

0.03 ~ 0.05 mm (0.0012~ 0.0020 in)

0.10 mm (0.004 in)

2nd

0.03 ~ 0.05 mm

0.10 mm

ring

(0.0012~ 0.0020 in)

(0.004 in)

3O7OO9

__

3. Measure: • Piston pin-to-piston clearance Out of specification _ Replace piston.

Piston pin-to-piston clearance = Bore (piston pin) b Outside diameter (piston pin) e

"

Piston pin-to-piston 0.004 ~0.019 mmclearance:

2. Install: ....

Limit

@ Measuring(0.006-0.012 Point 20 mmin) (0.8 in) (0.028 in) ring

I

I_

Standard

I

,

Piston ring , Into the cylinder

l

Push the ring with the piston crown.

4. Inspect: • Bearing (piston pin) Pitting/Damage_ Replace

3. Measure: _,.

'----------J"

_

_o_ooo 4-13

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

• End gap Use a feeler gauge Q

307011 4- 14

<Limit: 0.07

(0.028 in)>

,.SPECT,O...O.EP...

IC'121

,.SPECT,O...O.EP IE"O

KICK STARTER

AUTOLUBE PUMP

• Kick gear teeth (_) • Kick pinion gear teeth (_) Burrs/Chips/Roughness/Wear _ Replace.

(_

pump output to vary from the factory setting.

This situation is, however, extremely rare. If improper output is suspected, inspect the follow-

1. Inspect:

Wear or an internal malfunction may cause the 1. Inspect: ing: • Delivery line Obstructions .-.*Blow out.

31_5 2. Inspect: • Mating dogs (kick pinion gear and one-way clutch)

• O-ring WeadDamage _ Replace.

• Autolube pump drive gear teeth (_) oAutolube pump driven gear teeth (_) Pitting/Wear/Damage _ Replace. _

_

Rounded edges/Damage -'_ Replace.

_

_

317006

2. Inspect: 314003

3. Measure:

i,! i i i i '

.I .,_, .

L_

__]

_

CRANKSHAFT

Use a spring balance c_).

[

• Clip tension (kick pinion gear) C)

__

150~ 250g (5.3~8.8oz.)

Out ofStandard specification _ Replace. tension:

317007

I

• Runout limit "C" • Connecting rod big end side clearance °D" 1.Measure: D _ _oo_

TRANSMISSION 1. Inspect:

width "A" and thickness gauge.

UseoCrankshaft V-blocks, dial gauge 37.90 ~ 37.95 _ Crankshaft width mm "A": (1.492 ~ 1.494 in) Runout limit "C": 0.03 mm (0,0012 in) Connecting rod big end side

• Main axle (_

0.2 ~ 0.5 mm (0.008 ~ 0.020 in)

Burrs/Chips/Roughness/Wear _ Replace.

_

_

_

• Secondary Drive axle (_) sheave axle (_)

clearance "D":

319005

• Secondary sheave axlebearing (D f_-

:_ .... _

1. Inspect:

• Main axle bearing @ . Drive axle bearing (_)

_,_-/,_\_ L'i;

• Primary sliding sheave (_ ° Primary fixed sheave (_) WearlCrackslScretchlDamage .-_ Replace.

Excessive play/Roughness ...*Replace.

Pitting/Damage _ Replace.

Spin the bearing inner race.

4-15

4-16

• Free movement Insert the collar (_) into the primary sliding sheave 0, and check for free movement.

Stickorexcessive play_ Replace the sheave and/or collar,

oClutch housing inner surface Oil/Scratches _ Remove.

Oil

Use a rag soaked in lacquer thinner or solvent.

Use an emery cloth (lightly Scratchesand evenly polishing).

319OO7

319O30

3. Measure:

L,.,

,_

5. Measure:

Out of specification -.-*Replace.

I_1 I _

319008

Out of specification --* Replace,

Outsidelimit>: diameter (weight): <Wear 14.5 15.0 mm mm (0.57 (0.59 in) in) . Outside diameter (_ (weight)

_-

i

jj_j1J

_ _

_° '

'

_u_ _r__

105.0 mm (4.13 in) I 319012

SECONDARY SHEAVE 1. Inspect:

6. Inspect: • Clutch shoes

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

• Oil seal (_) • Secondary fixed sheave (_

__

<Wear Limit>: Clutch housing inside diameter: . Clutch105.4 housing @ mminside (4.15diameter in)

per.

NOTE: Glazed _ Sand withclean coarse After using parts the sand paper, off sandpathe polished particles with a cloth.

Damage _ Replace.

319009

o Torque cam groove 0

• Clutch shoe thickness @

o Guide pin (_) Wear/Damage --, Replace as a set.

Out of specification _ Replace.

• O-rings (_) Damage _ Replace.

Clutch shoe thickness: 4.0 mm (0.16 In) <Wear Limit>: 2.5 mm (0.10 in)

319010

9013

° Clutch spring free length Outofspecification _ Replace.

--_

121,7spring mm (4.79 Clutch free in) length:

106.7limit>: mm (4.20 in) i <Wear 3. Measure:

_

1. Inspect: • V-belt

NOTE: Crack/Wear _ Replace.

I

Replace the V-belt if it is greasy or oily.

V-BELT

319011

4- 17

4- 18

,.s..c.,o...o....,.

I..o"-.IIc- 41 -- (_---_ 3120o_

..o,.. ..o.o,us....T °"1

• V-belt width @

CRANKCASE AND CRANKSHAFT

Out of specification --* Replace.

(_ Oil seal Oil seal holder

® Crankshaft pin _ Connecting rod

Dowel _ Crankshaft (right) @Crankcase(right) _ Bearingpin ENGINE ASSEMBLY _ Bearing

Bearing @ (left) _ Crankcase @ Crankshaft Engine mount (left) shaft AND ADJUSTMENT _ Oil seal

15.0 width: (0.59 in) 13.5 mm (0.53 i_ Measure: j2.

V'Belt <Wear Limit>:

J

STARTER CLUTCH AND GEARS

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

o Starter clutch Push the dowel pin in arrow direction.

Unsmooth operation _ Replace starter clutch assembly.

1. Inspect:

_

(_

J13 Nm (1.3 m.kg, 9.4 ft.lb) I

A CRANKSHAFT: 37.90 - 37.95 mm (1.492 ~ 1.492 in) Runout limit: <0.03 ram>

_

(0.0012 in) Crank width: Big end side clearance: 0.2 - 0.5 mm (0.008 ~ 0.020 in)

_....._._

3_oo8 2. Inspect: • Idle gear teeth (_) Burrs/Chips/Roughness/Wear --* Replace.

• Bearing ® (starter wheel gear) Pitting/Damage _ Replace. _

_

_

.v _ <It

_

./%

. Starter wheel gear teeth (_) 3170_

31_oe

4- 19

4-20

• Crankshaft To protect the crankshaft against scratches and to facilitate the engine assembly and installation, apply grease to oil seal lips, and engine oil to bearings.

installation

tool C), (_, (_), @

Crankshaft installation tool : (D : 90890-01274 (_) : 90890-01275 (_) : 90890-01277 (_): 90890-01411 3007

NOTE: • Crankshaft installation tool (D, (_),(:_, (_

(_ : 90890-01274 Crankshaft installation tool: (_ : 90890-01275

I<_ I

3O8OO2

I

one hand while tightening the nut of the installation tool with the other. Tighten the installation another. tool until the crankcase halves close with one 6. Install:

(_ : 90890-01277 (_ : 90890-01411

• Right crankcase

1. Attach:

2. Install:

Hold the connecting rod at top dead center with _

7. Tighten:

(to left crankcase) NOTE: Hold the connecting rod at top dead center with one hand while tightening the nut of the installatool until the crankshaft bottoms against the tion with the other. Tighten the installation bearing.

• tool Crankshaft

I

NOTE: Tighten the crankcase holding screws in stages, using a crisscross pattern.

_

o Dowel pins C) - Spacer (_)

31_oo,

13 Nm (1.3 m.kg, 9.4 ft.lb) I'_l • Crankcase Crankcase holding screw= holding screws

_

• Crankshaft operation Unsmooth operation --, Repair.

CAU_ON: Never hit on the crankshaft.

__

3005

3.

Install:

___<__,]-_

,

•

308003

8.

• HEATPROOF or Yamaha Bond No.1215

• Oil seal stopper plate @ (_

I<_

Screw (oil seal stopper plate):

HEATPROOF °r Yamaha B°nd N0.1215

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

To the matingsurfacesof bothcase halves.

313006

4 - 21

Check:

313009

4 - 22

..O,...SS...'_'"O'O'OS'M'"' I'"" °,-IIc-_6l _Fan (_ Plain washer @ Rotor assembly (_ Lighting coil _)Charge coil ® Pick Upcoil Stator assembly (_ Oil seal

@Gasket _Oil hose @ Oil delivery hose @Clip _Autolube pump _ O-ring _ Circlip _) Oil pump drive gear

..o....ss...._..o.o,os.....

I,.o"-I /_

1. Install: • Circlip @ • Pin (_) o Pump drive gear@ • Circlip (_

:.

3,,oo4 2. Apply:

3. Install: _-_

_\ '_

[4 Nm(0.4 m.kg. 2.9 ft.lb) _

__/

_

(to O-ring @) • Autolube pump (_)

_/_) _

Screw (autolube pump): 4. Apply:

(to autolube pump gear@, (_))

.

(_b_ 6"5 Nm (0"65 m'kg' 4"7 ft'lb,

_

-

_

(_

_(_/J/_..

£

_

"'_ _ "_

I_

.'

_

"

_

_,,,.O..0_.....=

CDI MAGNETO 314006

°i_

•Gasket • Lithium soap base grease (to oil seal @) 321001

J

_

/ _

1. Install: 3. Pass the CDI magneto lead through the crankcase hole.

• Stator assembly

" 8Nm (0.8 m.kg, 5.8 _,b) I

_

4-23

I%_> I Screw8 Nm(Stat°r(0.8 m.kg,aSsembly):5.8 ft.lb) 4. Install: 4- 24

[[

E"O'"EASSE"B'Y'"O'O'°ST"E"T IE"o O11 E.O,.E.SS. LY..OAOJ 5. Install:

TRANSMISSION

• Magneto rotor (_) • Plain washer (_) • Nut (_)

_)(_ _1_

NOTE: • Woodruff When installingkey the(_magneto rotor, make sure the woodruff key is properly seated in the key way of the crankshaft. Apply a light coating of lithium soap base grease to the tapered portion of the crankshaft end.

(_ Bearing _ Oil seal _ Drive axle

_ Secondary sheave axle @ Bearing @ Dowel pin

(_ _ _ _ ®

_ _ _ _

Main axle Circlip Conical spring washer Bearing Plain washer

Transmission case cover Bearing Oil seal Gasket

\

• Nut (D (magneto rotor) 0.

Z

Use the flywheel holding tool (_).

Flywheel holding tool: 90890-01235

__

_,oo,

;.

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

I '

__

319033

4 - 25

4 - 26

_.O..E,SSE.LYA.O,O, OST.E.T _ 0-21 TRANSMISSION 1. Apply: • 10W30 Type SE Motor oil (to transmission case cover bearing) 2. Install: • Bearing C)

• Secondary sheave axle (_) ,' _

_C_,

_l

E"O'"EASS_--_'"O,O,0 IE"O _I

STARTER SYSTEM (_ Collar (_ Washer _ Bearing _) Starter wheel gear _ Collar _ Starterclutch

_ Plate _ Shaft _ Plain washer _ Idle gear @ O-ring @ Startermotor

_-

NOTE:.

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

1 j_/_

• 0,, seal (_)

f-

319O14

i

• Secondary sheave axle operation

./.

4. Check: Unsmooth operation _ Repair.

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

5. Apply:

:

• Main axle (_ • Conical spring washer (_) *Drive axle C)

._-__

--;'P"'n--° -6.Apply lithium soap base grease onto the oil seal Install:

s19o16

_

-

¢

!

113 Nm (1.3 m.kg, 9.4 ft.lb)l

(_b / L

_

,/_

• Always use a new gasket.

• Transmission case cover O

_

lips.

• Dowel pins

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

__._----_

I_lso_ ,°..e °o.., I 7. •Install: Nm (1.2 m.kg, 8.7 ft.lb) Gasket12(_)

4 - 27

_

ii 4

4 - 28

_'L_i-} -I 8 Nm (0"8 m'kg' 5"8 ft"

E"O"E'SSE"BLY'"O'O'0STME"T I 1I0 3 E.O.E,,,EMLY,.O,O, USTM IE"O .TI

,_

,

STARTER SYSTEM

-

__(_

317010

PRIMARY AND SECONDARY SHEAVE

. Collar (D • Washer (_) • Bearing (_) • Starter wheel gear (_) 1. •Install: Starter clutch O

_Clutch _Clutch _Clutch _Spring _Clutch ®Gasket

NOTE: • Apply lithium soap base grease to the bearing

®Secondary sliding sheave @Oil seal @V-belt

_Primary sliding _Spacer sheave

@Guide pin

_Clutch weights

'

17O11 1

__3 "_

• Apply clutch). (starter molybdenum disulfide oil to the shaft

washer @One-way clutch _Washer _Primary fixed sheave @Conical spring @Plate washer

shoe spring spring seat housing

_f _ /_ (,_

I

50Nm

_Cam *Apply BEL-RAY Assembly Lube ®

@Slider

50 .2 ft.lb)/I ( . m.kg, 36/

_Secondary fixed sheave

2. Install: j.tq{_

(__

o Idle gear (_) (D •Plain washer • Plate (E)(idle gear)

I'1

8 Nm (0.8 m.kg, 5.8 ft.lb) Screw (idle gear plate):

_3_4

_

I

'

• Plain washer (_) NOTE:

____/t _

"___ (_g

(_)

"

• Starter motor O

13 Nm (1.3 m.kg, 9.4 ft.lb) 3,

_

Install:

{_

Apply engine oil to the idle gear (_).

/_

Apply lithium soap base grease to the O-ring of

B

the starter motor.

C

sh_!

_(_

we_rli

_ it:

_

_,_.

i

__

__

"_

_,

/"_,/'_

I_1

'

"'

"

ft "Ib)luich I

ov;!_,,:o_ _,_, limit: 14.5 mm (0.57 in) E Weight outside diarneter

_

(_

_/

_,,,,_ 319034

4 - 29

4 - 30

E"O'"E'SSE"O_'"O'O'UST"E"T I--__-] O''J E"O'"E'SSE''YA"O'O'O IE"°_1

KICK STARTER ® Return spring (_Collar (_ Plain washer Circlip ® Gasket

SECONDARY SHEAVE

® Transmission case (_Kick crank

verse the disassembly procedure. Note the following points.

1. Apply: • BEL-RAY Assembly Lube ® (tothesliding parts ofthesheave)

csa oowein

ena--e

319018

2. Install:

rA ! KICK CLIP FRICTION FO_R_RCE : 0,15 ~ 0,25 kg(5.3 ~ 8.8 ozI

_

• Sliding sheave (_) Wind adhesive tape around the end of the sheave to avoid turning over the oil seal lips when installing the sheave,

319019

/

• Pin (_)

J

_

4. Apply: (to the torque cam grooves and O-rings) t_

/__'__

3. Check: Install: 5.

--

<_

• Sliding sheave Unsmooth operation --_Repair. .BEL-RAY Assembly Lube ®

31_o2o

__

Remove

(_

/_

112 Nm(12mkg,87ftIb)I

_ f

excessive

grease.

° Clutch securing nut clutch spring holder 6. Install:

.

®

I_ c'utch-°h°'°_r I 90890-01337

319021

J

7. Tighten:

Use sheave holder • (41mm).

90890-01701 V_t S"eave h°''er: 18.5 Nm (0.85 m.kg, 6.15 ft.lb)l_ ,_ 4 - 31

i_ _/"

_

317o,8

_,

3,go3,

I_

4 - 32

Clutch securing nut 50 Nm (5.0 m.kg, I Clutch securing nut:36.2 ft.lb)

I I

E.O..E.SSE.B..O.O, OST"E"T IE"OI'IO'SI I XJ

_

• Gasket ° Secondary sheave assembly(_) • Clutch housing (D

_0o2_

I

UST"E"T I "O1 '1 Place the V-belt around the secondary sheave, and compress the secondary sheave spring hard so that the V-belt moves toward the clutch hub.

NOTE: • The arrow on the V-belt must point to the front.

• Make sure the V-belt is not stained with oil or 5.

Install: • V-belt grease.

8. •Instalh Dowel pin

9. Tighten: Use sheave holder _ c c c

• Shim (_)

Sheave holder: PIN. 90890-01701

• Washer (_) • One-way clutch (_) Washer fixed (_) sheave @ •• Primary

I_ Nm (4.0 m.kg, 28.9 ft.lb) (_)40 (secondary sheave) I_ • Nut I Nut (secondary sheave):

II

/

_3_4(_5(_3

31_o_,

PRIMARY SHEAVE

7. Tighten:

• Primary fixed sheave face (_ •• Collar Primary_)sliding sheave face (D • Weight (_ • Primary sliding sheave cam surface (_ _

(_

(_

_{_l_ 31_4

1. Clean:

6. ,Nut Install:(_

i_>1

3190_

Nut (primary sheave): 30 Nm (3.0 m.kg, 21.7 ft.tb)

NOTE: When tightening the nut (primary sheave), hold O (primary sheave) the Nut magneto rotor using the flywheel holding tool

®.

2. Install:

• Slider (_) • Collar (_ 3, Check: oCam operation 31,o_.,

Unsmooth operation _ Repair.

4. Install:

_

319026

8. Adjust:

319O28

4-33

4-34

• Fan O

_

9. Install: 6.5 Nm (0.65 m.kg, 4.7 ff.lb) Screw (fan):

_ Carburetor joint Reed valve I

_!__

CYLINDER AND CYLINDER _PISTON, Cylinder (_ Piston pinHEAD _ Gasket head @Piston

(_ Cylinder

(_ Bearing

CST •c,rc,, o

i

• Return spring (_) • Kick shaft (_) • Collar (_) • Washer (_

• Return spring

• Kick pinion gear (D

-'-

_

-

_

_o,_

3. (to the kick gear and boSS)lnstall: Install the spring as shown.

4. Install:

f_)_,,_J

_L;_'

_,_J

_ Cylinder gasket @ Piston ring

__

,_-_

(_

/

_-_ ___

_-_/

_'_

__

(_L_,,

•Transmission case C)

(_

B

3_9o_ _,,_)

_

C A

• Kick crank (_)

0.0340.047mm (0.0013 - 0.0018in) Piston rings end gap: 0.15 ~ 0.30mm (0.006 ~ 0.012 in) Pistonrings side clearance: Pistonclearance:

D Spark plug:

Bolt (kick crank): 8.5 Nm (6.85 m.kg, 6.15 ft.lb)

Manufacturer:NGK

3040O3

317016

4 - 35

4 - 36

E.O,.E.'SE.BLY'"O'O'UST D' I E"T E"O'"E'SSEMBLYA"O IE"o _

• Engine oil O 1. Apply: (to crankshaft bearing, connecting rod big end bearing, small end bearing, piston pin,

, _ I

__

- J//

C)

NOTE: • CylinderO Install the cylinder with one hand, while corn-

piston ring grooves and piston skirt.)

3¢aoo4

pressing the piston rings with the other hand.

PISTON PIN AND PISTON

• • • •

:"

3. Install:

Small end bearing Piston O Piston pin (_) Piston pin clip (_)

• Cylinder head gasket (new gasket) 5. Install: • Cylinder head (_

NOTE:

_o7o1_

• Spark plug (_)

• The arrow _) on the piston must point to the exhaust side. o Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material into the crankcase.

NOTE: •Tighten the cylinder head holding nuts instages, and crisscross sequence.

•The arrow@ on the cylinder head must point to the front.

3o, c_

J' t.u, (c,,,o°.r,o.,,

• The ends of the piston pin clip must not

10 Nm (1.0 m.kg, 7.2 ft.lb)

come together at the slot in the piston groove.

• Always use a new piston pin clip.

i

1. Install: o Cylinder gasket (new gasket) 2. Check:

3o7o13

_

c__c_ NOTE: • Make sure the ring ends (_) are propedy fitted around the ring locating pins inthe piston grooves.

Piston • Be• sure to rings check the manufacturer's marks or

20 Nm (2.0 m.kg, 14.0 ft.lb) Spark plug:

• Center stand (_) • Shaft (_) • Clamp_)

ns

(_

• Clip (_) • Spring (_)

(_

• Rubber washer (_

358oo2

numbers stamped on the rings are on the top

• Brake shoes 0 • Plain washer @ • Plate washer • Nut side of the rings.

_

_ 3480O1

4- 37

7. Install: • Rear wheel

4- 38

E"O'"E'SSE"B,.O,O, OSTME.T IE"O 10"8

E"O'"E'SSE OSTME.T B ,.O,O,

8. Install:

=j

_,

5. Tighten:

• Oil hose • Oil delivery hose

NOTE:.

When tightening the rear wheel axle nut, apply the rear brake.

NOTE:

Pass the oil delivery hose and oil hose asshown.

• Air shroud

9. Air bleeding: Refer to "AUTOLUBE PUMP AIR BLEEDING" in CHAPTER • Autolube 3. pump

Rear 103.5wheelNm axle(10.35nUt:m.kg, 74.8 ft.lb) I • Rear wheel axle nut (T)

_

___._ (_)__

6. Install: • Muffler assembly 0 •• Air shroud (_). assembly ProtectorMuffler 29 Nm (2.9 m.kg, 21.0 ft.lb) Bolt (exhaust pipe): 6.5 Nm (0.85 m.kg, 6.15 ft.lb) 7. Fill:

____

Reverse the removal procedure.

Note the following points.

1, Install: • Engine mounting bolt 0 • Rear shock absorber bolt (_)(lower) Theseboltsshouldbe temporarilysecured.

Refer to "TRANSMISSION OIL REPLACEMENT" in CHAPTER 3.

8. Adjust: • Brake lever free play Refer to "FRONT/REAR BRAKE LEVER FREE PLAYADJUSTMENT" in CHAPTER3.

2.

ENGINE Tighten: REMOUNTING • Engine mounting bolt

•• Transmission Engine idle speed oil Throttle cable free play Referto "THROTTLE CABLEFREEPLAYAD-

• Rearshockabsorberbolt(lower) \

_ /

I'll

Engine mounting bolt: 42 Nm (4.2 m.kg, 30.4 ft.lb) Rear shock absorber bolt (lower): 17.5 Nm (1.75 m.kg, 12.6 ft.lb)

3. Install:

I'

,usTNT an,,OL JUSTMENT" in CHAPTER 3.

• Carburetor top togetherwith throttle valve0 o Fuel hose (_)Nacuum hose (_) • Rear brake cable NOTE:

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

_

\

When installing throttle valve into the magneto lead ® •.CDI Earth (groundthe lead) 4- 39

4-40

tU

ply

I c OI R"

L_.B_ I Io-_l CHAPTER 5.

CARBURETION

CARBURETOR ...........................................................................................

REMOVAL .............................................................................................

DISASSEMBLY .....................................................................................

INSPECTION ........................................................................................

ASSEMBLY ...........................................................................................

INSTALLATION .....................................................................................

D-12 D-12 D-12 D-13 D-14 D-14

FUEL COCK ................................................................................................

INSPECTION ........................................................................................

D-15 D-15

REED VALVE ..............................................................................................

REMOVAL .............................................................................................

INSPECTION ........................................................................................

INSTALLATION .....................................................................................

D-15 D-15 D-15 D-16

CARBURETOR (_ Carburetor

REMOVAL top

_ Pilot jet

1. Remove:

Gasket Throttlevalvespring Needle set ® Throttle valve

_ _ _ _

• Covers and footrest board Referto" COVERS" in CHAPTER 3. ° Air filter case assembly

® Starter plunger Starter plunger Air screw

_ Float _ Float chamber gasket @ Float chamber

spring

Throttle stop screw

%

Needle jet Needlevalve Main jet Float pin

_ Drain screw

0ElL

LO_O

___

%_ (___ (_)

-_._

I.D. mark Main jet

(M.J.)

PHBN12HS # 93

Jet needle

(J.N.)

A21-3/5

Needle jet

(N.J.)

2.110

Pilot jet Cutaway Main air jet Pilot air screw Valve seat size Bypassjet Starter

(P.J.) (C.A.) (M.A.J.) (A,S.) (V.S.) (B.P.1) (G.S.1)

# 36 4.0 2.0 1-5/8 _+1/4out 1.2 0.8 #40

Float height Fuel height

(F.H.) (F.L.)

15 ~ 17 mm 20,5 ~ 22,5 turn

Engine idle speed

_

_____

_'_, ,=_fT'_:_

j

2. Disconnect: • Fuel hose (_)

_

3. Remove: • Carburetor

_ _

--

top

° Throttle valve • Oil hose (_) • Starter plunger

J

___322_

(0'59 ~ 0"67 in) 1800 +-200 rpm

(0.80~0.88in)

_(_ i \_____-k._)

plunger top •-Starter Carburetor

_

DISASSEMBLY • Float chamber

_

_

(_)

1. Remove:

322007

__._

2.

1

Remove:

,Nooo,ev ,ve®

op,,o ,et

,eove:

• Main jet (_) __P

_

322034

5-1

- Main nozzle (_) oStarter jet (_)

:

322027

5-2

• • • •

__

Throttle stop screw C) Spring (throttle stop screw) Air screw (_) Spring (air screw)

4. Remove:

• Throttle valve 0 Wear/Damage --* Replace.

_j,j,j

4. Check:

322028

322014

5. Remove

(

_/_\\

• Needle clip (_)

5. Check: \\

oThrottle valve free movement

• Throttle valve _)

2_

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

• Jet needle (_)

322029

Unsmooth/stickiness --, Replace.

322015

1. Check: • Carburetor body (D Dirt --, Clean.

. Throttle stop screw (T) • Air screw (_) • Needle (_) • Starter plunger (_ Wear/Damage _ Replace.

sco

L

cec

NOTE: Use a petroleum based solvent for cleaning.

Blow out all passages and jets with compressed air.

_2o18

2. Inspect:

7. Measure:

. Main nozzle _ • Starter jet Contamination _ Clean.

• Pilot jet _

(_ _(oMainjetC)

Iill

/I

Out of specification -* inspect needle valve, @

[_]

I

322012

_

• Float height @

322017

• Needle valve 0 Wear/Contamination ---*Replace, • Float (_) Damage .-_ Replace.

• Gasket Damage -._ Replace.

322013 5-3

Float height @: float, and valve seat.mm (0.59 ~ 0.67 In) 15.0 - 17.0

Float height measurement steps: • Install the needle valve, float and float pin into the carburetor body.

Hold the carburetor upside down.

Measure the height distance between the mating surface of the float chamber (gasket removed) and the top of the float, using a .................................................... ** gauge.

3. Check: 5-4

C,.BO.ETO. IC'"B 0 IID'I'I

C,.BO.ETO. IOA"B 01

NOTE:

_

• Carburetor

The float arm should be resting on the needle valve. It should not compress the needle valve.

NOTE: Align projection (D with projection (_).

If the float height is not within specification, inspect the needle valve, float and valve seat.

If one of these parts is worn, replace the

3. Install:

If both parts are in good condition, replace the float.

(T_

To installthe carburetorreversethe"REMOVAL" procedures. Note the following points.

_

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

NOTE:

1. Install: • Carburetor cover O •Airhose (_)

The float height is factory-adjusted. Never try to adjust it yourself, whole set.

Pass the air hose through the hole _ in the carburetor cover.

INSTALLATION

_"_

_

ASSEMBLY

2.Adjust:

Reversethe"DISASSEMBLY" procedures. Note

• Throttle cable free play Refer to 'q'HROTTLE CABLE FREE PLAY ADJUSTMENT" in CHAPTER 3.

the following points. o Before reassembling the carburetor wash all its components in clean gasoline.

• Always use new gaskets.

(_

(_

I_ _

• Needle _ •Clip (_) • Throttle valve (i) • Spring seat (_) • Spring

3_o_8

_ Jet315 needleclip position: 1. Install:

• Air filter case assembly

_

3. Install:

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

3_3019

2. Install:

5-5

5-6

REED FUELCOCK/ VALVEI CARB

[

D-15

REED VALVECARB FUELCOCK/ iNSPECTiON

]

FUEL COCK

I

1. Check:

INSPECTION 1. Stop the engine,

• Carburetor joint Damage/Cracks _ Replace.

• Reed valve Wear/Cracks/Damage-._ Replace.

2. Remove: Refer to "COVERS" in CHAPTER 3.

Reed valve inspection steps: Visually inspect the reed valve.

NOTE:

• Fuel cock

pletely or at least nearly flush with the valve seat.

Fuel cock inspection steps: • Disconnect the fuel hose (_.

Place a receptacle under the fuel hose end.

If fuel stops flowing within a few seconds, the fuel cock is in good condition. If not clean or 3. Check: replace the fuel cock.

Disconnect the vacuum hose and breathe in

.

If in doubt, apply suction to the carburetor side of the assembly.

Leakage should be minimal to moderate. ......................... *******************....... *** A reed valve in good condition should be corn-

fuel If fuelcock. flows out of the fuel hose when vacuum is applied and stops flowing when vacuum stops, the fuel cock is in good condition.

• __

_r'_

\ _"_r--':'_

If not, clean or replace the vacuum hose, the fuel hose and the fuel cock.

_

per.

" rJ

through the hose to create a vacuum in the

_

_/'_ L}

F_"_I I

322_3

REED VALVE

2. Measure:

• Side covers

Refer to "COVERS" in CHAPTER 3.

2. Remove: • Carburetor Refer to section "CARBURETOR REMOVAL".

Reed valve clearance: (.j

Less than 0.2 mm (0.008 in)

3_o2,

• Carburetor joint • Reed valve assembly

_(_:

___)

3_Z20"22

3. Remove:

5-7

I valve stopper height: 4.0 - 4.4 mm (0.157 - 0.173 in)

3. Measure: • Reed valve clearance (_) Out of specification --* Replace reed valve.

REMOVAL

• emove

• Valve stopper height C) Out of specification _ Replace valve stop-

_

5-8

I

_v,,wIC'R_ 0 I ID'_sl

I_'_ 01

INSTALLATION TOinstall the reed valve reverse the "REMOVAL" procedure. Note the following points.

1. Install: • Gasket (new) 2, Tighten: • Reed valve assembly bolts

8.5 Nm (0.85 m.kg, 6.15 fLIb) NOTE: Tighten the screws crosswise inseveral steps to preventwarpage of the read valve assembly and the carburetor joint.

5-9

5-10

! pv v

I

wuu--M--_m.mmm.,J_

I .............

CHAPTER 6.

CHASSIS FRONT WHEEL ............................................................................................

REMOVAL ...............................................................................................

INSPECTION ..........................................................................................

INSTALLATION ......................................................................................

E-4 E-4 E-4 E-5

FRONT BRAKE .............................................................................................

BRAKE PADS REPLACEMENT .............................................................

CALIPER DISASSEMBLY ......................................................................

MASTER CYLINDER DISASSEMBLY ....................................................

INSPECTION AND REPAIR ...................................................................

CALIPER ASSEMBLY ............................................................................

MASTER CYLINDER ASSEMBLY ..........................................................

E-5 E-6 E-7 E-7 E-8 E-8 E-9

REAR

WHEEL REMOVAL INSPECTION ASSEMBLY INSTALLATION

............................................................................................ ............................................................................................. ........................................................................................ ........................................................................................... .....................................................................................

E-10 E-10 E-10 E-11 E-11

FRONT FORK .............................................................................................

REMOVAL .............................................................................................

DISASSEMBLY .....................................................................................

INSPECTION ........................................................................................

ASSEMBLY ...........................................................................................

INSTALLATION .....................................................................................

E-12 E-13 E-13 E-14 E-14 E-14

STEERING HEAD AND HANDLEBAR .......................................................

REMOVAL .............................................................................................

INSPECTION ........................................................................................

ASSEMBLY AND INSTALLATION ........................................................

E-15 E-15 E-16 E-16

REAR SHOCK ABSORBER .........................................................................

REMOVAL ...............................................................................................

INSPECTION ..........................................................................................

INSTALLATION .......................................................................................

F-2 F-2 F-2 F-2

.O.TW.EEL IC"'SI E-']

CHASSIS

F.O.T..EEL IO"'S

,_

REMOVAL

FRONT WHEEL _) Axle

_ Oil seal

Speedometer gear Bearing (_ Flange (_ Collar

(_ (_ _ _

1. Remove: D Front caliper fixing

/!_

Collar Axle nut Front wheel Tire

(3.)_i v

_ _,_/_

o o

/_

Valve TIRESIZE: 120/90- 10 B RIMRUNOUTLIMIT:

_3

V

LATERAL:2.0 mm(0.08in) 0.25mm(0.01in)

®

NOTE: • Front caliper Never depress the brake lever when the wheel is Offthe scooter. Otherwise the brake pads will be forced shut.

JL _

RADIAL:2.0 mm(0.05in)

Speedometer cable Axle ®

• Front wheel

\_ A

bolts

INSPECTION o Front axle runout 1. Inspect:

_1_

Out of specification --* Replace. _oo_

0.25 mm (0.01 (_ Axle runout limit: in) Do not attempt to straighten

1_

I a bent axle.

2. Measure: • Wheel runout Out of specification --, Replace.

//_

_

_ __

_ __

_(_J_ __I_(_

/, _j/_,__ 147 Nm (4.7 m.kg, 34 ft.lb)l

6-1

Bearings allow play in the wheel hub or 4. Replace.inspeCt:wheel oWear/Cracks/Warpage bearings --, 13. °Inspect:Tire Laterah 2.0 mm (0.08 in)

(_ _

_ __

34°°ii

...... _

°7

34ooo8 ,_

Radial: 2.0 mm (0.08 in) Rim runout limit:

5. tUcheck:rns wheel roughly .--_Replace.

• Speedometer gear (T)

Wear/Damage -, Replace.

6-2

I

F--.EEL IC"'SI E-SI

..O.,,.,.E IC"'S

INSTALLATION

FRONTBRAKE

Reverse the =Removal" procedure.

Note the following points.

1. Lubricate: • Front wheel axle • Bearings • Oil seal (lips) - Drive/driven gear (speedometer)

_ Disc ® Bolt _ Caliper _ Piston @ Piston seals _ Air bleed screw

Lithium soap base grease

I

D_

_

NOTE: _ Pad spring ® Pad retainer _) Brake pads _i_O. ring @ Bolt @ Mounting bolt

Be sure to install the pads correctly.

3.Omm

/

• Speedometer gear unit C)

NOTE: Be sure that the two projections at the gear unit

--

_'_ _[ ....... ]

I

mesh with the two slots on the wheel hub.

2. Install:

• Front wheel 0 • Front caliper (_)

_

\

_'_

_.._%

00_)/_

I /21.SNm(2.15m.kg, / | 6 Nm (0.6 m.kg, 4ft.lb)l

/ _

':,_i

"

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

l

//

NOTE:

4. Tighten: ° Front wheel axle 3. Install: o Front caliper mounting botts

/___

I_

')'t;;_ ,, .4v "_,_ J_-;-:-_--'-"--""_,__.-_"\',

47 Nm (4.7axle: m.kg, 34 ft.lb) I Front wheel

i

properly.

23 Nm (2.3 m.kg, 16.6 ft.lb) Front caliper mounting bolts:

t

!

123 Nm (2.3 m.kg, 17ft.lb)l

"\_ _, _/'_ '__, Ii "_" -'- ":" ' _

--/7"

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

,_"- -'.."

#tJ" YV __/

6-3

16ft.lb)l

6-4

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

MASTER CYLINDER DISASSEMBLY Master cylinder ® Master cylinder piston ass'y Diaphragm Master cylinder cap Screw Master cylinder bracket

• Disc brake components

_ Brake hose _ Bolt @ Bolt _ Copper washer

Drain completely before removing the master cylinder,

assembly. Do not disassemble components unless absolutely necessary. If any hydraulic connection is disconnected, the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly. Do not use solvents on internal brake component.

• Solvents will cause seals to swell and dis-

.....

rarely require dis-

_

tort. Use only clean brake fluid for cleaning.

____

the Brake fluid tocome Use care with incontact brake fluid.with Never eyes. allow brake

_tl

I

m./kg, 110.8Nm (1.08

8 ft.lb)]

fluidparts, tic can damage painted su rfa ces and plasBRAKE PADREPLACEMENT It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads.

1. Remove: • Pin (D

/ L...

A

_[dl

NOTE:

I1.5 Nm (0.15 m.kg, l.lft.lb)

_

_'!!w-'_;l_

Q Bolt

BRAKE FLUID

_

DOT# 3 or DOT# 4

\

• Axle _) ',,

23 }

"

._

_:..

2. Remove: o Brake pads (_) NOTE:

_

Replace the brake pads as a set when either one is worn to the limit.

• Padspring (_)

Nm(2.3m.kg, 17ft.lb)]

oBrake pads Out of specification NOTE: (_) (2.3 m.kg, 17 ft.lb)l

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

_X, 3,7007

6-5

-_ Replace.

0.8 mm (0.03 in) Wear 3, Measure: _ Fr°nt Brake Pads Limit @: I

__ 6-6

F.O.TB.,KE E'I

.O.TB,,KE IC"'S

4. Install: o Brake pads

.......................................................

Removal steps:

oAxle

'oo_

Pad spring • Pin

_

Be careful to install the brake pads correctly.

_'_'

_

ing to force out the piston from the caliper _J_O\_y_/Z _

'\

_

_ _

Blow compressed air into the hosejoint openbody.

• Never try to pry • Cover the piston the piston does expelled from the

_,_o.

5. Lubricate: • Mounting bolt (caliper body)

I =1Ra°°m°ended 'ubr'cant:I

out the piston. with a rag. Use care so that not cause injury as it is cylinder.

Removethe piston sea,s

Lithium soap base grease

....................................................

6. Install: • Wheel axle • Mounting bolt 47 Nm (4.7 m.kg, 34 ft.lb) Mounting bolt:

"'"

I

23 Nm (2.3 m.kg, 17 ff.lb)

I

MASTER CYLINDER DISASSEMBLY NOTE: Before disassembling the front brake master cylinder, drain all brake fluid from the brake hose, master cylinder, brake caliper and reservoir tank.

1. Remove: CALIPER DISASSEMBLY j/" /

•//_

"//_:\

,_

° Upper handlebar cover

NOTE: drain brake fluid fromthe the front brakebrake hose, caliper, master Beforealldisassembling cylinder,brake caliperand tank.

__/_/_ _.

• Brake switch 2. Remove: • Brake lever

1. Remove: • Union bolt (_) ° Copper washers(_)

(_)__t __J

__

_ _s_-_

NOTE: Release brake switch by pushing with a •Unionthebolt screw driver into the hole on the lower side of the brake lever and pull out the brake switch.

NOTE: Place the open end of the drain hose into a container and pump out the remaining brake

_ _7co5

6-7

3. Remove:

2. Remove: • Caliper body • Caliper bracket

•Master cylinder

fluid carefully.

3. Remove:

• Master cylinder holder

• Piston (_ • Piston seals (_) 6-8

.O.TB,,KE IC"'S 1E-81

F.O.TB.,K IC"'S

o Master cylinder dust boot 0 • Master cylinder kit (_)

_

, Brake hose (_) CrackslWearlDamage .._Replace.

4. Remove:

_

3. Check:

34700e

34e014

INSPECTION AND REPAIR

/_._

\

4. Measure:

schedule: Brake pads Piston seal, Dust seal

Out of specification _ Inspect wheel runout.

If wheel runout is good, replace the brake disc.

As required Every two years

_1

Brake hoses Every four years Recommended brake component replacement Brake fluid Replace only when

_1W_'1;10117_[¢]1 All internal parts should

be cleaned

_

3470O1

in new

brakefluid only.Donot usesolventsas they will cause seals to swell and distort.

brakes are disassembled

_[

_

_

__

3,7oo_

_

3470o6 6-9

3 mm (0.12 in) Brake Disc Minimum

_

Bolt (brakedisc): 23 Nm (2.3 m.kg, 17 ft.lb) LOCTITE ®

_)lOutof specification ---,Replace.

I

I

I

• All internal parts should be cleaned in new brake fluid only.

• Internal parts should be lubricated with clean brake fluid when installed. _'y11'i,L,1;l_ll_[¢!

Replacethe piston sealswheneverthecaliper is disassembled.

DOT #3 or DOT #4

• Master cylinder

is disassembled.

Wear/Scratches -_ Replace the master cylinder assembly. ° Master cylinder body/Diaphragm

1. Install: • Piston seals (_ • Caliper piston (_)

Cracks/Damage _ Replace.

• Master cylinder kit 2. Scratches/Wear/Damage--* Inspect: Replace asa set.

Thickness:

I

CALIPER ASSEMBLY

assembly.

• Caliper body _) Wear/Scratches/Cracks/Damage_Reptace caliper assembly, Scratches/Rust/Wear _ Replace caliper

_

_

I

1. Inspect : • Caliper piston C) •

Brake Disc Maximum Deflection:

F_,] 0.25 mm (0.01 in) • Brake disc deflection - Brake disc thickness

__

346ols 6-10

_'!_I'A'/-'I;I_IR[¢_ Always use new piston seals. , Replace the piston seals whenever a caliper

I

.O.TB IC"'S .E E-'] 2. Install:

I<_1

.O.TB IC"'SI .E _'_"

23 (brake Nm (2,3 m.kg, 17 ft.lb) Bolt caliper):

1. Install:

'I:CAUTiONil install the master cylinder holder with the arrow mark pointing upwards.

• Tightenthe upperboltfirst,thenthelower bolt.

!

3. Install: • Caliper body (_) • Brake caliper

___o

I_J

4. Install: /'/_ ' J

_\

/_

Bolt (master cylinder 9 Nm (0.9 m.kg, 6.5 holder): ft.lb)

I

• Brake hose ®

o7.

• Copper washers ®

• Brake lever

23 Nm (2.3 m.kg, 17 ft.lb) (_)_

• Master cylinder (_)

10

_

• Union bolt (_)

Apply lithium soap base grease to the brake lever pivot.

I

When installing the brake hose to the caliper, turn the brake pipe against the projection on the caliper.

2. Install: 3. Install: • Brake hose o Copper washers o Union bolts • Brake switch

• Proper hose routing is essential to insure •safe Always use new copper washers. operation.

Referto"CABLE ROUTING".

MASTER CYLINDER ASSEMBLY

23 Nm Union bolt:(2.3 m.kg, 17 ft.lb)

I'_1

I'

_.lV_Vl_,l :|_11_. [eE • All internal parts should be cleaned in new brake fluid only.

• Internal parts should be lubricated with clean brake fluid when installed,

_1|w_,1;1_11_,[¢11

I_1

• Always use new copper washers.

Rec°mmended fluid:DOT #3 or DOT brake #4

I

• Proper hose routing is essential to insure safe operation. Refer to "CABLE ROUTING" in CHAPTER 2.

4. Check that the brake hose does not touch other parts (throttle cable, wire harness, etc.) when the handlebar is turned to the left or right.

6 - 11

6 - 12

Repair

if necessary.

.--.EEL IC--I IE'101

--W.EEL IC"'S

REAR WHEEL Rear wheel ass'y Tire Valve (_ Axle Nut

REMOVAL 1. Remove: _ _ (_ (_ _

O-ring Brake shoe Spring Brake camshaft Brake camshaft lever

_ Wear indicator _ Bolt _ Washer _ Nut _ Washer

• Muffler ass'y

A

TIRE SIZE:

B

130/90 - 10 DRUM BRAKE WEAR LIMIT." 110.5 mm (4.40 in)

11o5Nm (10.5 \

LININGS REPLACE BRAKE

• __

II

_)}

) )) )/

(_)"-_'_

I

I SPRING.._.

AND

SASASET

NOTE:

2PullLoosen the rear brake to loosen the axle nut.

I/!/1

_'_ _=_/

VERTICAL : 2.0 mm (0.08in)

_

oRear axle nut (D _

__{/(("__

o BRAKE L,N,N_ WEAR L,M,_ D 2,0 RIMmm RUNOUT (0.08 in) LIMIT:

Kg.m, 76 ft.lb) (_ ,_

----_.

t

• Rear wheel _o_

7

_,

Brake cable 4. •Remove:

\

J

Brake shoes (_) -

• Plain washer (_)

a4r_l_

INSPECTION 1. Check: • Rear wheel

(_'('('('('('('('(_ __L,>

(_) _

I

(__'___"_'d

(__ ""

._

f"

° Wheel runout 2.SPECTION"'Measure:Refer to the section "FRONT WHEEL IN-

)....

7 Kg m 5 ft Ib) I

j.

_"_'1_

SPECTION".Refar to the section "FRONT WHEEL IN"_

I

N/

6- 13

6 - 14

..o,,,L,°..

Lateral: 2.0 mm (0.08 In) Radial: 2.0 mm (0.08 in)

I

IC"ASIIE'111

.E,.W,EE"

whee earn0s

Br keshoesO

Refer to the section "FRONT WHEEL IN-

• Return spring (_)

SPECTION".

NOTE:

4. Check:

The arrow mark ® must point outwards.

• Brake lining surface Glazed spots _ Eliminate with sandpaper.

......

CAUTION_ When installing the springs and the brake shoes, takecarenotto damage thesprings

lo NOTE: After sanding the brake lining remove dust parti-

• Wear indicator (_ • Camshaft lever 0

cesoeresoewieanco nt 5. Measure:

• Brake lining thickness Out of specification _ Replace

NOTE: • Align the wear indicator tipO with the line "A"

4.0 mm (0.16 in)

i

--_

• Align the punch marks C_).

Brake Lining Thickness: Wear limit:

I

I_>1

Oil/Scratches _ Repair.

7. Measure: • Brake drum inside diameter @

_

_

t10.5 mm (4.35 in) Brake Drum Wear limit: • Brake drum inner surfaca

t

• Brake cable /C)

I

"__

_012

ASSEMBLY

INSTALLATION

Notethefollowing points.

Notethefollowing points.

1. Install:

1. Clean:

• Brake camshaft O NOTE: Apply lithium soap base grease _L___

7 Nm (0.7 m.kg,Bolt: 5.1 ft.lb) Camshaft Lever

4. Install: • Plain washer C)

Out of specification _ Replace, 34S006

as shown.

11

6. Check: 2.0 mm (0.08 in)

• Rear wheel axle onto the brake

camshaft (_)and pin (_). procedure.

Reverse the =REMOVAL"

Reverse the REMOVAL procedure. \_

2. Install: • Plain washer • • Nut

the excess of grease.

E After installing the brake camshaft, remove

6-15

_

Make sure the splines on the wheel hub fit onto the rear drive axle. _

346O13

• Rear wheel NOTE:.

6-16

REARWHEEL

I CHAS

(_r'(g]

IE-121

.u,,.r Wh.--,

..ONT FO.

105 Nm (10.5 m.kg, 76 ft.lb)

_ Steering bracket Bolt _ Circlip _ Tube cap Oil seal

@ Inner fork tube (right) @ Inner fork tube (left) _ Dust boot _ Retainer _ Oil seal

I

(_ Circlip

_ Outer fork tube (right)

I

_ Washer ® Plunger Oil seal guide _

@ Brake _ Outer fork Brake hosetube bracket (left) _ hose bracket

_ Bolt

(_ Steering race set

3. Install: • Muffler

I_ i

I Bolt (exhaust pipe): Bolt 9 Nm (muffler): 26 Nm(0.9 (2.6m.kg, m.kg,6.5 19ft.lb) ft.lb)

FRONTFORK

4. Adjust: o Rear brake lever free play.

ADJUSTMENT"in CHAPTER 3.

Refer to "REAR BRAKE LEVER FREE PLAY

I CHAs

CAPACITY: I

! A

FRONT FORK TUBE

i B

FRONT FORK OIL GRADE: SO 48 3743/4-LHV46 cc (1.69 Imp oz, 1.62 US oz)l

J_ ' _'

/

/

j ,t¢,,,_,

®\,

/ /

/'

6-17

'_

'(_//

6-18

I,i'l

W

(_)

ICH' ®l IE-131

FRONTFORK 1. Remove:

Securely support the scooter under the engine.

REMOVAL

with a stand

• Rubber plug (D • Circlip (_ DISASSEMBLY

_

1. Disconnect: Place the scooter on an even surface.

2.

• Spring (_)

• Speedometer cable 3. Remove: • Front wheel Refer to "FRONT WHEEL".

• Spring seat (_)

_ol,

- Front fender Refer to "COVERS" in CHAPTER 3

(_)

emow

• Bolt (D • Copper washer

2emo

5 Remove:

NOTE:

• Steering head Referto "STEERING HEADANDHANDLEBAR" 6 Remove:

To remove the drain bolt _, use the T-handle andtheholder_

• Securing nut

.....

_<_

NOTE: • Ring nut C)

I_l

90790-0t 268 Ring Nut Wrench:

I

T-handle for front fork: Holder: 90890-01294 90890-01326

I

Support the steering shaft to prevent it from falling.

Usethe Ring Nut Wrench (_ to loosenthe ring nut.

7, Remove:

__

(_)

%

3, Remove:

• Washer (_)

_

• Inner fork tube (_

• Steering collumn •Upper bearing race (top)(_) • Bearings

(_/_/

• Spring (_) -Piston (_) •Spring seat (_

Take care not to loose the bearings. (Upper: 22

_'T). /_

pieces, Lower: 22 pieces).

-_///

_,2o_s

• Circlip 0 9

_

• Dust boot (D • Retainer @ • Oil seal (_)

Loosen: • Pinch bolt (_)

10. Remove: • Fork leg (complete)

_--_

8. Remove:

(_)_

6- 19

4. Remove: 6-20

.O.TO.K IC"'SI [E-I']

F.O.TO.K

INSPECTION

3. Install:

• Inner fork tube and fork components

• Drain bolt

• Outer fork tube Wear/Scratches/Damage --, Replace.

NOTE: Tighten the drain boltO while holding the piston

_'1._ Never attempt to straighten a bent fork tube as this may dangerously weaken the tube.

1. Check:

with the T-handle _ and holder (_. i

_i_

2. Measure:

(_)

I_>

Right 206 free mm length: (8.11 in) Front forkside: spring Left side: 225 mm (8.85 in) - Fork spring free length (_)

90890-01294 Holder :

i

Out of specification -_ Replace.

I

1o

_ (_/'_:_1T-handle for front fork: (New), • ^,Copper washer I_// I 90890-01326

23 Nm I Drain Bolt:(2.3 m.kg, 17ft.lb)

I I

4. Fill: • Fork oil i

_2o.

ISO 674314-LHV 46 ASSEMBLY Reverse the "DISASSEMBLY" procedure Note the following points.

48 cc (1.69 Imp tube): oz, 1.62 US oz) Amount (per fork

i

5. Install:

NOTE:

• Spring

• When reassembling the front fork, make sure you use following new parts: • Oil seals

- Spring seat - Circlip • Rubber plug

. Circlips and retainers • Make sure that all components are clean beforereassembling.

INSTALLATION

1. Install: • Oilseal

Note the following points.

1. Install:

• Retainer • Dust boot

• Left and right fork tube into the steering crown.

NOTE: Before installing the oil seal, apply lithium soap grease onto the oil seal lips.

2. Install: Reverse the (_ "REMOVAL" procedure.

• Circlips 3.

2. Install: • Inner fork tube •-Spring Spring seat - Piston

6 - 21

Install: •Pinch bolts (_)

I_

6 - 22

30 Nm I Pinch bolt:(3.0 m.kg, 21.7 ft.lb)

STEERING

HEAD

AND

HANDLEBAR

_

IE-151

STEERING

HEAD

AND

STEERING HEAD AND HANDLEBAR _) Handlebar Nut _) Bolt Grip Throttle grip Throttle cable Screw Brake cable Starter cable

HANDLEBAR

STEERING

HEAD AND

HANDLEBAR REMOVAL Securely support thescooter sothereisno danger of it falling over.

1, Place the scooter on an even surface.

2. Remove: • Front fender

• Upper handlebarin cover Refer to "COVERS" CHAPTER 3.

3. Drain: ° Front brake system Refer to "FRONT BRAKE". __

• Inner panels _ 60 Nm (6"0 m'kg' 43 ff'lb)l

4. Remove: • Front brake master cylinder

• Front brake caliper mounting bolts 6. Remove: • Front wheel Refer to "FRONT BRAKE". %

__

5.Refer Remove to "FRONT: BRAKE".

• Rear brake cable (D • Throttle grip 8. Disconnect: • Ground wire

,

....... ....

• All couplers • Wire harness • Clamp

_

7. Remove: 9. Remove: • Bolt • Handlebar

/__ 6 - 23

• Nut (D 6 - 24

band

10. Remove:

Ic.As IE-lel

JA

STEE.,.O.EAOA.O...O **.........

• Ring nut 0 • Washer

Drive out the bearing race from the steering tube by hitting on it in several places.

Remove the bearing race on the steering shaft with a hammer and a chisel Q as shown.

NOTE: Use the Ring Nut Wrench (_) to loosen the ring nut.

• Securing nut

Drive in the new bearing races evenly by Bearing race replacement steps:

I<_ Ring wrench:90890-01268 Nut I Support the front fork so that it may not fall down.

....

hitting on them in several places.

CAUTION;; • Unless the ball race is installed evently, it

_

• Washer (_) • Upper bearing race (_ • Bearing balls • Steering shaft NOTE:

'X_

will damage the frame or steering column.

• Do not hit the face of the ball race.

I

.....................................................

Take care not to loose the bearing balls. (Upper: 22 pieces, Lower: 22 pieces).

INSPECTION

_0o8

_

4. Check:

Bends/Cracks/Damage _ Replace.

VTI_?7_[E_Tr_ Never attempt to straighten shaft.

2. Wash the bearing balls in solvent, 1. Check: • Handlebar O

_

_

_(_

a bent steering

•Bend/Damage Steering shaft--* Replace.

354OO9

3. Check:

C)

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

ASSEMBLY AND INSTALLATION

• Bearing races (_

Reverse the"REMOVAL" and "DISASSEMBLY"

• Bearing balls (_

Note the following points.

Pitting/Damage --*Replace.

V.I_i_--'_,I]]]_

NOTE:

Proper cable and hose routing is essential to

Always replace the bearing balls and the upper Pitting/Damage -.*Replace. and lower bearing races as a set.

insure procedure.safe scooter operation. Refer to "CABLE ROUTING" in CHAPTER 2.

Upper: 3/16 in Lower: 3116in

_.,D_,

1. Install:

JIL_J=m

• Bearing balls

Lower: 22 pcs

I 6- 25

Upper:quantity: 22 pcs Bearing Bearing size:

• Wheel bearing grease (to upper and lower bearing).

3_

olo

1

2. Apply:

6- 26

IC"'S [I

S.EE.,.O.E.O..O...O. C"'S

3. Install: • Steering shaft • Upper bearing race (Top) (D • Bearing race cover (_)

9. Clamp: • Speedometer cable ° Front brake cable (to head pipe with the band)

° Washer • Ring nut NOTE:

NOTE: Refer to "CABLE ROUTING" in CHAPTER 2.

Hold the steering column until it is secured.

10. Apply: • Lithium soap base grease

4. Tighten: • Ring nut

(to throttle cable end and handlebar right end).

11. Install: oThrottle grip • Throttle cable • Bracket

NOTE: Refer to "STEARING HEAD ADJUSTMENT" in CHAPTER 3.

• Front brake lever assembly • Handlebar switch (right) NOTE: Refer to "CABLE ROUTING" in CHAPTER 2.

7. Install: _ r_:,

-

(_

oHandlebar_ - Bolt (_) (New) ° Nut (_) (New)

(_)

12.Connect: • Rear brake cable ° Handlebar switch leads

NOTE:

• Brake switch lead

• Fit the handlebar bridge (_) into the steering column notcher (_).

13.Install: • Front fender

NOTE: Refer to "CABLE ROUTING" in CHAPTER 2 for

NOTE:

proper cable and lead routing.

Refer to "COVERS" in CHAPTER 3.

13. Adjust: • Front brake freeplay • Rear brake lever free play • Throttle free play

......

• Before installing the handlebar, wipe the oil off the insertion portion using thinner, etc.

• Install the bolt (_)from the left as shown.

I<_

Handlebar Bolt O: 60 Nm (6.0 m.kg, 43.4 ft.lb)

_--_

8. Install: ° Band

10 ~Brake 20 mmLever (0.4 ~Free 0.8 Play: in) Front Rear Brake Free Play: 10 ~ 20 mm (0.4 ~ 0.8 in) Throttle Cable Free Play: 1.5 ~ 3.0 mm (0.06 ~ 0.12 in)

NOTE: Refer to "CABLE ROUTING" in CHAPTER 2.

6 - 27

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

6 - 28

RE,RS.OCK,BSOR_ER IC"'S_II F'2I REAR

SHOCK

ABSORBER

REMOVAL 1. Place the scooter on its centerstand 2. Remove: • Mole Refer to "COVERS" in CHAPTER 3.

;' -

• Rear shock absorber 0

=

_

3. Remove: INSPECTION 1. Inspect: • Rear shock absorber Oil leaks/Damage _ Replace.

INSTALLATION When installing the rear shock absorber, reverse the removal procedure. Note the following points.

1. Install: • Rear shock absorber

I

6- 29

31.5 Nm 13.15 m.kg, 22.8 lt.lb) I Rear Shock Absorber Bolt (Lower): I 17.5 Nm (1.75 m.kg, 12.6 ft.lb) I

c.,s_1

+

IELEC _1 I F-S

IE_EC _ I CHAPTER 7.

ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS .....................................................................

F-6

SWITCH INSPECTION ................................................................................. F-6 SWITCH INSPECTION ........................................................................... F-6 SWITCH CONTINUITY INSPECTION .................................................... F-7 CIRCUIT DIAGRAM ......................................................................................

F-8

IGNITION AND STARTING SYSTEM ........................................................... F-g CIRCUIT DIAGRAM ................................................................................ F-9 IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM ................... F-9 TROUBLESHOOTING .......................................................................... F-IO CHARGING SYSTEM .................................................................................

CIRCUIT DIAGRAM ..............................................................................

TROUBLESHOOTING ..........................................................................

F-14 F-14 F-14

LIGHTING SYSTEM ...................................................................................

CIRCUIT DIAGRAM ..............................................................................

TROUBLESHOOTING ..........................................................................

F-15 F-15 F-16

SIGNAL SYSTEM .........................................................................................

WIRING DIAGRAM .................................................................................

TROUBLESHOOTING ............................................................................

G-1 G-1 G-2

E'ECT..C.LCO.PO.E.TS IE' c I F'6I

SW,TO.,.SPEOT IE'Ec

ELECTRICAL

SWITCH INSPECTION

ELECTRICAL COMPONENTS Flasher relay Wire harness Oil sender (_ Starter relay

_ _ _ _

_)®Ignition cOilcDi unit

_ Main switch

"0"

,,,,

SWITCH INSPECTION

Battery Fuel sender Horn Rectifier/regulator

Use a pocket tester to check the terminals for continuity. If the continuity is faulty as any point, replace the switch.

I_l

Pocket tester:90890.03112

I

NOTE: •

Set the pocket tester to"0" before starting the

•

range when testing the switch for continuity.

Turn the switch on and off a few times when checking it. test.

%

•

"" I_1,

I.,I • I_1

The pocket tester should be set to the"x I"Q

INSPECTING ASWITCH SHOWN INTHE MANUAL

_

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

This chart shows the switch positions in the column and the switch lead colors inthe top row. terminals with continuity.

The example chart shows that: (_ ForThere each is switch continuity position, between "0--0" theindicates "black and the Black/White" leads when the switch is set to "OFF".

(_ (____

(_ There is continuity between the "Red and _

Brown" leads when the switch is set to "ON".

7-1

7-2

SW,.C"'"S"ECT'O" IE'EC ------I F'_I

SWITCH CONTINUITY INSPECTION Refer to "SWITCH INSPECTION" and check for continuity between lead terminals.

Poor connection, no continuity _ Correct or replace. * The coupler locations are circled.

L ......

i®

®

/" z"

_,

/

Horn switch Dimmer switch Turn switch Main switch Start switch Engine stop switch Front stop switch Rear stop switch Fuse Oil lever gauge @ Fuel sender

SW..C.,.S.ECT, _

@_

/i

_ _ @ (_

i@o I .....

7-3

7-4

c,.co,To..o...

IELEc '11 -8 CIRCUIT

DIAGRAM

[_ _ _ _ ' _)

®

_i _

_

_

, GY

°

__''

° __

_ Left front flasher light _ Right front flasher light @ Left rear flasher light @ Right rear flasher light _ Tail/Stop light @ Horn L_ Flasher relay _ Front stop switch @ Rear stop switch

_ Starting motor _ Right handle switch _ Left handle switch

_ Oil level gauge _ Meter _ Sender

@

:_i

COLOR CODE _ _

'_[_ :

_ C.D.I Magneto C.D.I Unit Ignition coil Spark plug Main switch Fuse Battery Rectifier/regulator Starter relay

_ Head light

__!I

_

C,.CU,TO,AO..

IE'ECJ

_ ..........-_

.... I

,

"

_

I_

7-5

R B

Red Black

L Y/R

Blue Yellow/Red

W

White

L/W

Blue/White

Br Gy Y O Ch Dg G

Brown Gray Yellow Orange Chocolate Darkgreen Green

B/W B/R G/Y W/R Br/W Y/B G/W

Black/White Black/Red Green/Yellow White/Red Brown/White Yellow/Black Green/White

P

Pink

_._.

7-6

.O.,T.O...OST..T,.OSYSTE. IE'EC -----I 1_"9I ,O.,T,O...OST..T,.OS IE'EC " I IGNITION AND STARTING SYSTEM

IGNITION ANDSTARTING SYSTEMCIRCUIT DIAGRAM

CIRCUIT DIAGRAM

(_ C,D.I magneto _) C.D.I unit Ignition coil Spark plug Mainswitch Fuse Battery Starter relay

@ @ _ _

Starting motor Right handle switch Front brake switch Rear brake switch

[] [] [] [] [] [] []

Source coil Pickup coil Wave-shape shaping circuit Condenser Diode SCR To oil level switch

速

速

o_ <=4 --

<=_

--

-_" (_)

B/W

OFF O0 CHECK O0 ON LOCK 00_0

速

速_

(_

_

R

_

T

.B : Current flow in ignition control circuit : Current flow in starter motor control circuit

7-7

7-8

IE'Ec TROUBLESHOOTING

3.Spark plugcapresistance:

(NO SPARK OR IRREGULAR THE STARTING SYSTEM DOES SPARKS).

NOT WORK

I

IELEc

[F-10I •• Connect thethe pocket Disconnect sparktester plug (_ cap.x 1 k) to the spark plug cap.

NOTE:

• Check the resistance of the spark plug cap.

Remove the following parts before proceeding with the troubleshooting: 1) Mole For accurate troubleshooting use the following special tools:

I_=_ IgnitiOn checker:90890-06754 1.Spark plug:

I

'_

_ _

POcket tastar:90890-03112

_._

• Check the spark plug type.

• Check the condition of the spark plug.

• Check the spark plug gap.

_ rl _

Refer to "SPARK PLUG INSPECTION" in

_

Spark 0.5 ~plug 0.7 mm gap: (0.020 ~ 0.027 in)

I Replace or adjust the spark plug gap.

Chapter 3.

INCORRECT

I

_

Ignition tester Pocket coil: (+) lead _ Orange • Disconnect the ignition coil leads.

•Pocket Checktester the primary (-) leadcoil --_Ground resistance.

• Remove the spark plug cap.

• Connect the ignition checkerO. (_Spark plug cap

_1 0.56- 0.84 E_at 20°C (68°F) • Connect the pocket tester (Q x lk) to the ignition coil.

(_)Spark • Check the length of the spark gap.

• Start the engine and increase the spark length until the engine begins to misfire.

2.Spark check:

Pocket tester (+) lead _ Ground Pocket tester (-) lead _ Spark plug lead

SPECIFICATION OUT OF OR NO SPARK

3720_

(_'_----_1-

_:_

resistance:

MEETS SPECIFICATION

_1

'

5.68 ~ 8.52 at 20°C (68°F) Secondary coilk_ resistance:

_ I

372003

OUT OF SPECIFICATION

SPECIFICATION MEETS I Ignition system in good condition.

7-9

_1_1

• Check the secondary coil resistance.

Primary coil

_

6.0 rnm spark (0.24 in) M,nimum gap;

._

I

MEETS SPECIFICATION

• Connect the pocket tester (_ x 1) to the ignition coil.

CORRECT

_

OUTOF SPECIFICATION I Replace the spark plug cap.

3_ool

4.Ignition coil resistance:

Standard spark plug: BR8HS (NGK) --_

_ Spark plug cap resistance: I 5 k_ at 20°C (68°F)

I

II Replace the ignition coil.

7-10

II

'O"'T'O"'"OSTA.T,.OSYSTE. IE'EC ------I [F-11 'O"'T'O"'"OST..T,.O 5. Pickup

-0-

I

coil resistance:

• Check the pickup coil resistance.

•° pickup Pocket Disconnect Connect tester teeter coil. thethe (+) (') pocket lead pickup leadtester (_ (!)c_oil --_(Q coupler.

Ground White x 100) / Red to the

_9_L--_

400 ~ 600 _ at 2O°C (68°F)

For accurate troubleshooting use the following special tools: ° 2) 4) 1)Rem°ve 3) Mole panel Footrest Front Handlebar the boards cover following parts before proceeding with the troubleshooting:

_

®1,c.upco,,r.,s=o. ,_

sT,,TE,.oTo. OOES.OTWO.K I

NOTE:

.°.o,=t.r

OUT OF SPECIFICATION

MEETS SPECIFICATION

90890o031t2

I Replace pickup coil.

I

I

6.Source coil resistance:

,.EL

Disconnect the source coil coupler from the

NO CONTINUITY

CONTINUITY

Y

Connect the pocket tester (_ x 100) to the source coil.

Pocket tester (+) lead C) --* Black / Red

I Replace fuse.

° Check the condition of the battery.

Refer to "BATTERY INSPECTION" CHAPTER 3.

Pocket tester (-) lead (_)--* Ground • Check the source coil resistance. wire harness.

_

r-_l I S°urcs 640 - c°il 960 resistance: _ at 20°C (68°F)

='_

OUT OF SPECIFICATION

,_ 3. Starter

,_ SPECIFICATION

I Replace source coil defect.

I

POOR CONNECTIONS

7.Connections:

CONNECTIONS GOOD

III J•• Charge Clean battery or replace terminals. the battery.

Use ajumper lead (_)* to connect the (+)(:_ terminal of the battery to the starter motor terminal (_).

I

than that of the battery leads, the jumper lead might melt or burn.

n_-"l:E--_ i

(13 T

• This perform test It could near acause gas source sparks. orNever near flammable products.

_E_/--'_I

r

_ I

__J_ -

DOES NOT WORK

• Check the starter motor operation.

"_v

7-11

I

iii_i_i_ ! ° If the gauge of the jumper lead is smaller

3_oo_ I Replace CDI unit.

OUT OF SPECIFICATION

I

CORRECT

-...... _ I Repair.

I

motor:

• Check all connections in the ignition systern.

Refer to "WIRING DIAGRAM".

I in I I

_ J Open circuit voltage: H 12.8 Y or more at b 20°C (68°F) 2.Battery:

_

MEETS

_

[

1.Fuse: Refer to "SWITCH INSPECTION".

CORRECT

I Repair °r replace the starter mot°r"

7-12

I

STARTER MOTOR 4. Starter relay: • Disconnect the Blue/White lead from the wire harness.

• Connect the (-) _ terminal of the battery to the Blue/White lead.

• Check the starter motor operation.

(_ _ _ _

O-ring Brush Armature coil O-ring

A COMMUTATOR UNDER CUT: DOES NOT WORK

1.15 mm (0.045 in) B COMMUTATOR DIAMETER WEAR LIMIT:

-

--I::>uw

I Replace the starter relay.

37_

I,

C

15.0 mm (0.60LIMIT: in) BRUSH WEAR 5.3 mm (0.21 in)

_

CORRECT

_::_::::_

I Refer to "SWITCH INSPECTION". ,_

_

CORRECT

I 5. Main switch:

I Replace the main switch.

J

Refer to "SWITCH INSPECTION".

8.Connections: ,_

CORRECT

_/(_)

I Replace right handlebar switch.

I

17Startersw,tc.:

I

_m_.

,8,

CORRECT

I 6. Engine stop switch:

kg, 9.4 _

INCORRECT

I Refer to "SWITCH INSPECTION". ,_

..................._3(_

I

INCORRECT

___@

!

_ INCORRECT

_/_,-_,

POORCONNECTIONS i Replace right handlebar switch.

Check all connections in the starter system.

Refer to "CIRCUIT DIAGRAM".

I

___/

_

_/

T

IRepa'r.

7-13

I

7-14

,ON,T,ON.NOST.RT,NOSYSTEM IE'Ec ['131 ,ON,T,ON.NOST.RT IE' C • Commutator Dirty _ Clean it with #600 grit sandpaper.

2. Measure: • Commutator diameter @ Out of specification _ Replace starter motor 1. Inspect: REMOVAL 15.0 mm (0.60 _ Commutator wearin)limit: I 3. Measure:

@/_

@

Out of specification --, Replace.

Brush length limit@: 5.30 mm (0.21 in)

_

- Brush length @ 5. Measure: 6. Measure:

• Mica under cut @

• Brush spring force

proper measurement use a hacksaw blade which has been grounded to fit the commutator,

set. _

Out of specification _ To scrape the mica to _

1.15 mm (0.045 in) Micaundercut@:

7. Inspect: • Bearing Roughness--* Replace.

• O-rings Wear/damage _ Replace.

4. Inspect:

_;

._ii_;

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

Inspecting steps: Connect the pocket tester to perform the •continuity Armature check. coil (resistance) • Measure the armature resistance.

Defect --, Replace starter motor 0.072 _ at 20°C •

I

If the resistance is incorrect, replace the starter motor.

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

7- 15

Brush spring force: 150 ~ gr (5.29 ~_ 22.92 oz) as a Fatigue/out of650 specification Replace

I

NOTE: The mica insulation of the commutator must be undercut to ensure proper operation of commutator.

J

7- 16

CHARGING SYSTEM

C...O,.OS*STEM IE'ECIF'141

TROUBLESHOOTING

CIRCUIT DIAGRAM

I

C...O,.OS*STE.

THE BATTERY ISNOT CHARGED

I

NOTE: • Remove the following parts before proceeding with the troubleshooting : 1 ) Mole.

• For accurate troubleshooting use the following special tools :

I<_

90890-03113 Inductive tachometer:

Refer to "SWITCH

_@i_

INSPECTION".

,_

I

I<_

90890-03112 Pocket tester:

INOC

CONTINUITY

I Reptace fuse.

I

2. Battery OUT OF SPECIFICATION

• Check the condition of the battery.

Refer to "BATTERY INSPECTION" in CHAPTER 3.

_ i[_i i _=i =_;_:i _,,_,_:;,_,:,,_ .........

L ........ ; ,,'_f ! _ __ !_

E !

_1

Open circuit v°ltage: t2.8 V or_more at 20°C (68°F) CORRECT "JL_

_--L_:_

i_.__ I**_;" _r_._ _j_-

Pockettester(+)lead_ battery terminals, Battery(+)terminal Pocket tester (-) lead _ Battery (-) terminal

___._

_'_'-_' _°_"<"

* Start the engine and accelerate to about 5000 rpm.

• Check the charging voltage,

_/

n

41OUTO SPECIFICATION

INOTE:--_ 7-17

___

I_-------'}lCharging voltage: I _l__£Jl 14 ~15 V at 5.000 tr/mn I Use a fully charged battery,

_i;

I

3. Charging voltage • Connecttheenginetachometertothespark plug lead.the pocket tester (DC20V) to the • Connect

_i_

I

i : Clean battery terminals' Charge or replace the battery.

4"

I Charging circuit is OK,

MEETS SPECIFICATION

7-18

!

C.A.O,.OSY.TEM 1'151 4.Charging coil resistance

.,O.T,.OSYSTE IE'"c

LIGHTING

• Disconnect the CDI magneto coupler from the wire harness.

,_L-_

_

SYSTEM

CIRCUITDIAGRAM

• Connect the pocket tester (_ x 1) to the charging coil.

• Check the charging coil resistance Tester (+) lead --, White O Tester (-) lead ---,Ground Q

I_

I Charging coil resistance : 0.48 ~ 0.72 E2at 20°C (68°F) _

15"C°nnections

OUT OF SPECIFICATION .._

SPECIFICATION MEETS

I Replace charging coil.

I

POOR CONNECTIONS

I Check all connections in the charging system. _ I Refer to "CIRCUIT DIAGRAM".

I

_[llv CORRECT I Replace the rectifier/regulator.

I

I

_,Z(_#).[_ E

;_,_

i_,_{!_

, - ....

_

IRepair"

7- 19

I

....

7-20

i

_ii_"

TROUBLESHOOTING

LIGHTING SYSTEM INSPECTION 1. Headlight, headlight indicator or meter light do not work.

I

THE HEADLIGHT, HEADLIGHT LIGHT DOINDICATOR, NOT WORKTAlL LIGHT OR METER

NOTE: Remove the following

I 1. Bulb and socket

I

I

I " Check the bulb and socket for continuity. parts before proceeding

• Mole and footrest board • Handlebar covers For accurate troubleshooting

I_:_1

I

with the troubleshooting: J_ _#-

use the following

90890-03112 Pocket tester:

special

I

CONTINUITY

NO CONTINUITY

I Replace bulb or socket.

I

tools:

Connect the pocket tester (AC20V) to the 2. Voltage

I

_

............

'-_I;_

_;--1

_

"

Headlight: 1. "HI/LO" switch

I

I

I Refer to "SWITCH INSPECTION".

,_y CONTINUITY 2. Lighting coil resistance • Disconnect the lighting coil coupler from the

NO CONTINUITY

• "LO": Pocket tester (+) lead _ Green 0 Pocket tester (-) lead _ Black (_) coupler.

•headlight "HI":

I Replace left handlebar switch.

I

Connect the pocket tester (_ x 1) to the lighting coil.

wire ms

--r

OUT OF SPECIFICATION

CORRECT

I Replace lighting coil.

• Check all connections inthe lighting system.

Refer to "CIRCUIT DIAGRAM".

4. Connections I

"_

_

-

__. _':

I

I The circuit is good.

_,,

SPECIFICATIoNMEETS,IWidng circuit between C.D.I magneto and I I

I

Check condition of each circuit for lighting system.

Refer to "LIGHTING SYSTEM CHECK".

7 - 21

f __

_

POOR CONNECTIONS

i Repair,

CORRECT

_(_

• Start the engine, • Switch from "HI" to "LO" and back.

• Check the voltage (12V) between the headlight coupler leads.

"_'_

Lighting coil resistance: 0.32 ~ 0.48_ ( at 20°C (68°F)

• HeadlightP°cketP°cket tester (') (_)testerindicator (+) lead: lead __ Black Yellow(_) Pocket tester (+) lead -* Yellow (_) Pocket tester (-) lead _ Black (_

ili]i

Pocket tester (+) lead _ Blue (_) Pocket tester (-) lead -=, Black (_)

R

Check the lighting coil resistance Tester (+) lead _ Yellow I Red (D Tester (-) lead _ Ground (_)

%____4_,

7 -22

I

socket connector isfaulty _ Repair.

I

',°.T,.°S*STEM IG'II 3. The tail light does not work.

1. Bulb and socket

j

• Check the bulb and socket for continuity.

I

NO CONTINUITY

_

[

CONTINUITY

2. Voltage

_,

c-_-_ - _=_

• Connectthe pocket tester (AC20V)to the

,,__ ....

taillight coupler.

Pocket tester (+) lead --* Blue (_ Pocket tester (-) lead _ Black (_)

',_) [_ ',0 , , ',

J

• Setthemainswitch to"ON".

[ i

8

• Start the engine.

• Check the voltage (12V) between the headlight coupler leads "Blue" and "Black".

"._E_::_ OUT OF SPECIFICATION

SPECIFICATION JThe circuit is good.

SYSTEM

WIRING DIAGRAM

JReplace bulb or socket. ,_

S'°"A'S*'TE" IELEC I SIGNAL

JWiring circuit between C.DJ magneto and[ I

I taillight coupler--, Repair.

7-23

I

7- 24

S,O..LSYSTE. IELECG'2

TROUBLESHOOTING

I

HORN DOES NOTWARNING SOUND LIGHT DO NOT WORK FLASHER LIGHTS, BRAKE LIGHT, "OIL"

I

NOTE: Remove the following parts before proceeding with the troubleshooting:

..O.ALSYSTEM IELEC

SIGNAL SYSTEM CHECK 1. Horn does not sound I 1. "HORN" switch I

I

I

I Refer to "SWITCH iNSPECTION".

•" boardHandlebar Mole and footrest cover

,_

INCORRECT

CONTINUITY

I Replace left handlebar switch.

I

For accurate troubleshooting use the following special tools: 2. Voltage 90890-03112

Connect the pocket tester (DC20V) to the horn lead.

Pocket tester (+) lead _ Brown (_)

1. Fuse I Refer to "SWITCH INSPECTION".

_r

I

Pocket tester (-) lead _ Ground • Turn the main switch to "ON".

• Check for voltage (12V) between "Brown"

B

CONTINUITY

I Replace fuse"

2._ L Battery

I

NO CONTINUITY

I

_72o_5

and the ground.

OUT OF SPECIFICATION

INCORRECT

•Refer Check conditionINSPECTION" of the battery, in to the "BAI-rERY

"_ m ,_

"_

SPECIFICATIoNMEETS Wiring circuiffrom main switch to horn is faulty I Repair.

I

I CHAPTER 3.

Battery voltage : t2.8 V or more at 2O°C (68°F)

Charge or replace the battery.

I

.Vo,a0e

T Br

• Connect the pocket tester (DC20V) to the

CORRECT ,,_

Pocket tester (÷) lead ---*Pink (_) Pocket tester (-) lead --* Ground

Refer to "SWITCH INSPECTION".

3. Mainswitch

•"Pink" Presslead. the "HORN" switch.

• Turnthemainswitch toON.

INCORRECT

• Check the voltage (12V) between "Pink" and ground.

_

CORRECT

I Replace main switch"

I

• Check all connections in the signal system.

4. Wiring Refer to "WIRING connections DIAGRAM".

I

_.

CORRECT

I

POOR CONNECTIONS

I Repair.

_

_ I Adjust or replace the horn.

DOESNOTMEETSPECIFICATION 3_7

SPECIFICATION MEETS

"_ I

I Replace horn.

I

l

signal system.

I

SYSTEM I

I ReCfHE Check tcOK the t.he condition sectionof "SIGNAL each circuit of the l

7 - 25

7 - 26

I

S,O..LSYSTEM IE'Ec G-3I 2. The tail light does not work.

3. Flasher does not work

I1.

Refer INCORREcTBrake to.SWiTCH switch ,NSPECT,ON.. .J_

S,O..LSYSTEM IE'Ec

Ii Refer 1. "TURN" switch INSPECTION.. to .SWITCH

I

CORRECT

.J_

CORRECT

• Connect the pocket tester (DC20V) to the socket,

• Connect the pocket tester (DC20V) to the flasher relay.

Pocket tester (+) lead --*Green / Yellow (_ Pocket tester (-) |cad _ B|ack _

Pocket tester (+) lead -_ Brown (_) Pocket tester (-) lead _ Ground (_

° Turn the main switch to 'ON" 2.

• Pull Voltage the brake lever.

I Replace brake switch.

I

• Check the voltage (12V) between" Green

INCORRECT

IRep lace left handlebar switch"

--'.

lead and the ground.

n

', ,' Y , L

)UT OF SPECIFICATION MEETS SPECIFICATIONS

3. Voltage Connect the pocket tester (DC2OV) to the flasher relay.

B

"_

• Turn the main switch to ON •2.Check Voltage the voltage (12V) between the"Brown"

Yellow" (_ and "Black" (_).

_ _" .... " ,

I

I Wiring circuit from main switch to flasher relay I I connector is faulty "-* Replair.

I

Pocket tester (+) lead -_ Brown/White O Pocket tester (-) lead _ Ground (_

OUT OF SPECIFICATION

• Turn the main switch to ON ,_ I Circuit is good.

MEETS SPECIFICATION

_Wiring circuit from main switch to bulb socket I I

I

connector is faulty..-* Repair.

I

• Checkthe voltage (12V) between the"Brown/ White" lead and the ground. n

MEETS SPECIFICATIONS

OUT OF SPECIFICATION

I Replace flasher relay.

7 - 27

7 - 28

I

S.O.ALSY.TE. IE'EC [G'41 ,_

S,O.ALSYSTE. I'Eo-----J

4. The "OIL" indicator light does not work. m

4.Voltage

Flasher light

Turnindicator light

flasher bulb : Pocket tester (+) lead _ Chocolate (_) Pocket tester (-) lead _ Ground

I 1.Bulb and socket

I

I

J_.

Replace bulb or socket.

2. Oil level switch

Cllg

Left Connect flasher connector. the bulb pocket Right flasher : tester (DC2OV)to the Pocket tester (+) lead _ Dark green (_)

_

I= • Disconnect Check the bulb and continuity...=,v socket CONTINUITY for from the oil the oil level switch tank.

I Pocket tester (o) lead --*Ground • Turn the main switch to "ON".

• Connect the pocket tester (Q x 1) to the oil level switch.

• Set the "TURN" switch to "L", then to "R".

• Check the voltage (12V) between "Chocolate" and the ground, then "Dark green" and the ground.

Pocket tester (-) lead --_Terminal (_ Pocket tester (+) lead --_Terminal (_) OUTOF SPECIFICATION

MEETS SPECIFICATION

position

I

II Wiring connector faulty --* switch Repair.to bulb socket Ii circuitisfrom turn

_

37_s

• Check the switch for continuity.

Float

I Thiscircuitisgo°d"

NOCONTINUITY

LOW HIGH O : Continuity

Good

Bad

condition O X

condition X O]

X xJ

O O

OUT OF SPECIFICATION

X : No continuity

,_

SPECIFICATION MEETS

I Replace °il level switch"

• Connect the connector. pocket tester (DC20V) to the bulb socket

I

(_)k_

z

Pocket tester (+) lead _ Grey (_ Pocket tester (.) lead .--*Ground • Turn the main switch to "*".

•3.Check the voltage (12V) between "Grey" and Voltage the ground.

OUT OF SPECIFICATION _v

MEETS SPECIFICATION

I This circuit is in g°°d c°nditi°n"

7 - 29

,_ I

14' C°nnecti°ns I • Check all connections in the signal system.

IRefer to "WIRING DIAGRAM".

I

7 - 30

c,-Ju

............ u lull=

..................

I ,,ii

A

:

I TRBL CHAPTER 8.

TROUBLESHOOTING STARTING FAILURE/HARD STARTING ....................................................

FUEL SYSTEM .......................................................................................

ELECTRICAL SYSTEM ..........................................................................

COMPRESSION SYSTEM .....................................................................

G-8 G-8 G-8 G-8

POOR IDLE SPEED PERFORMANCE ........................................................ G-8 POOR IDLE SPEED PERFORMANCE .................................................. G-8 POOR MEDIUM AND HIGH SPEED PERFORMANCE ...............................

FUEL SYSTEM .......................................................................................

ELECTRICAL SYSTEM ..........................................................................

COMPRESSION SYSTEM .....................................................................

G-9 G-9 G-9 G-9

FAULTY AUTOMATIC (V-BELT TYPE) ........................................................ G-9 SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING ......... G-9 CLUTCH -OUT FAILURE........................................................................ G-9 POOR STANDING START (LOW CLIMBING ABILITY) ......................... G-9 POOR ACCELERATION (POOR HIGH SPEED) ................................... G-9 IMPROPER KICKING .................................................................................

SLIPPING ..............................................................................................

HARD KICKING ....................................................................................

KICK CRANK NOT RETURNING .........................................................

G-10 G-10 G-10 G-10

FAULTY BRAKE ........................................................................................... G-4 POOR BRAKING EFFECT ..................................................................... G-4 MALFUNCTION ...................................................................................... G-4 FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION ........ G-10 OIL LEAKAGE ....................................................................................... G-10 MALFUNCTION .................................................................................... G-10 INSTABLE HANDLING ............................................................................... G-10 INSTABLE HANDLING ......................................................................... G-10 FAULTY SIGNAL AND LIGHTING SYSTEM .............................................. G-10 OVERHEATING .......................................................................................... G-11 OVERHEATING .................................................................................... G-11 WIRING DIAGRAM ..................................................................................... G-12

STARTING FAILURE/HARD STARTING TROUBLESHOOTING

SHTG ITRBL

_

NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.

STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank • Empty • Clogged fuel filter • Deteriorated fuel or fuel containing water or foreign material • Clogged fuel tank cap Fuel cock • Clogged fuel hose

Carburetor • Deteriorated fuel, fuel containing, water or foreign material - Clogged pilot jet • Clogged pilot air passage • Sucked-in air • Deformed float • Groove-worm needle valve

Air cleaner • Clogged air filter

I G-

8

I

POOR IDLE SPEED PERFORMANCE STARTING FAILURE/HARD STARTING/ Cylinder and cylinder head • Loose spark plug • Loose cylinder head or cylinder - Broken cylinder head gasket • Broken cylinder gasket • Worn, damaged or seized cylinder Piston and piston rings • Improperly installed piston ring • Worn, fatigued or broken piston ring o Seized piston ring • Seized or damaged piston

Crankcase and crankshaft • Improperly seated crankcase • Improperly sealed crankcase (damaged oil seal) • Seized crankshaft Reed valve • Deformed reed valve stopper • Improperly seated reed valve • Loose intake manifold • Broken gasket • Broken reed valve

• Improperly sealed valve seat • Improperly adjusted fuel level • Improperly set pilot jet

POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor

• Clogged starter jet • Starter plunger malfunction • Improperly adjusted pilot air screw

o Improperly returned starter plunger ° Clogged or loose pilot jet • Clogged pilot air jet • Improperly adjusted idle speed ( throttle stop screw) • Improper throttle cable play

ELECTRICAL SYSTEM

° Flooded carburetor

Sparkplug ° Improper plug gap • Worm electrodes • Wire between terminals broken • Improper heat range ° Faulty spark plug cap Ignition coil • Broken or shorted primary/secondary • Faulty spark plug lead • Broken body

CDIunitsystem ° Faulty CDI unit ° Faulty source coil • Faulty pick-up coil Switches and wiring • Faulty main switch • Broken or shorted wiring • Faulty" ENGINE STOP" switch

8-1

SHTG TRBL

COMPRESSION SYSTEM

8-2

-ep

I

POOR

MEDIUM

AND

HIGH

SPEED

PERFORMANCE

I

SHTG TRBL

L

_•

POOR MEDIUM AND HIGH SPEED PERFORMANCE FUEL SYSTEM Fuel tank Carburetor - Clogged fuel filter • Deteriorated fuel, fuel containing water or • Deteriorated fuel or fuel containing water or foreign material foreign material • Sucked-in air • Clogged fuel tank cap • Deformed float Fuel cook • Groove-worm needle valve • Clogged fuel hose Air cleaner ° Clogged air cleaner

• Improperly sealed valve seat • Improperly set clip position of jet needle • Improperly adjusted fuel _evel • Clogged or loose main jet • Clogged or loose main nozzle

G =9

I

FAULTY AUTOMATIC

°

FAULTY AUTOMATIC (V-BELT TYPE) SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING. V-belt Secondary sheave • Worn, damaged or slipped v-belt • Broken compression spring Primary sheave • Pealed lining from clutch shoe • Worn or damaged cam plate o Worn spline of clutch housing • Worn or damaged slider bushing

CLUTCH-OUT FAILURE Primary sheave • Seized primary sliding sheave and collar

Secondary sheave o Broken or fatigued clutch shoe spring

CDI unit system • Faulty CDI unit • Faulty source coil • Faulty pick-up coil

• Worn, damaged or slipped v-belt Primary sheave • Worn or improper operation of weight

• Fatigued compression spring • Improper operation of secondary sliding sheave

POOR ACCELERATION (POOR HIGH SPEED) V-belt • Worn or greasy V-belt Secondary sheave • Worn or greasy clutch shoe • Improper operation of secondary sliding sheave

COMPRESSION SYSTEM Cylinder and cylinder head • Loose spark plug • Loose cylinder head or cylinder • Broken cylinder head gasket • Broken cylinder gasket • Worn, damaged or seized cylinder Piston and piston rings • Impropedy installed piston ring • Worn, fatigued or broken piston ring • Seized piston ring • Seized or damaged piston

T. L

SHTG

POOR STANDING START (LOW CLIMBING ABILITY) V-belt Secondary sheave

ELECTRICAL SYSTEM Spark plug • Improper plug gap • Worm electrodes • Wire between terminals broken • improper heat range • Faulty spark plug cap

I

Crankcase and crankshaft - Improperly seated crankcase • Improperly sealed crankcase (damaged oil seal) . Seized crankshaft Reed valve • Deformed reed valve stopper • Improperly seated reed valve • Loose intake manifold • Broken gasket • Broken reed valve

8-3

8-4

I TRBL IMPROPER KICKING/FAULTY BRAKE

I

IMPROPER KICKING

Cylinder, piston and piston ring • Damaged or seized cylinder • Damaged or seized piston • Damaged or seized piston ring

FAULTY SIGNALAND LIGHTING SYSTEM

Ii TRBL

INSTABLE HANDLING Transmission oil o Improper quality (low viscosity) • Deterioration

Worn or damaged kick gear Damaged kick clip Kick clip coming off Damaged kick clip stopper HARD KICKING Kick axle assembly • High tension of kick clip • Seized kick gear

"

INSTABLE HANDLING

SLIPPING Kick axle assembly Low tension of kick clip Worn kick axle

INSTABLE HANDLING/

Handlebar • Improperly installed or bent

Wheels • Damaged bearing • Bent or loose wheel axle • Excessive wheel run-out

Crankcase and crankshaft ° Improperly seated crankcase • Improperly seated crankshaft • Damaged or seized crankshaft • Damaged or seized crankshaft bearing

KICKCRANK NOTRETURNING Kick axle assembly • Damaged kick return spring • Kick return spring coming off • Kick clip coming off

Steering • Improperly installed steering column (Improperly tightened ring nut) ° Bent steering column • Damaged ball bearing or bearing race

Frame • Twisted • Damaged head pipe o Improperly installed bearing race

Front forks • Broken spring • Bended front forks

Engine bracket • Bent or damaged

Tires • Uneven tire pressures on both sides • Incorrecttire pressure • Unevenly worntires

Rear shock absorber • Fatigued spring • Oil leakage

• Damaged kick return spring stopper

FAULTY

FAULTY BRAKE

Headlight dark • Improper bulb ° Too many electric accessories ° Hard charging (broken charging coil) • Incorrect connection o Improperly grounded • Poor contacts (main or light switch) • Bulb life expires

Flasher does not light • Improperly grounded • Discharged battery • Faulty flasher switch , Faulty flasher relay • Broken wireharness • Loosely connected coupler • Bulb burnt out • Faulty fuse

Bulb bumt out • Improper bulb • Improperly grounded • Faulty main and/or light switch • Bulb life expires • Bulb burnt out

Flasher keeps on • Faulty flasher relay • Insufficient battery capacity (nearly discharged)

POOR BRAKING EFFECT Disc brake • Worn nbrake pads • Worn disc •Air in brake fluid • Leaking brake fluid • Faulty cylinder cup kit • Faulty caliper seal kit • Loose union bolt • Broken brake hose • Oily or greasy disc/brake pads • Improper brake fluid level

Drum brake • Worn brake shoe • Worn or rusty brake drum • Improperly adjusted brake free play • Improper brake cam lever position ° Improper brake shoe position • Fatigued / Damaged return spring • Oily or greasy brake shoe • Oily or greasy brake drum • Broken brake cable

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE • Bent, damaged or rusty inner tube • Damaged or cracked outer tube • Damaged oil seal lip • Improper installed oil seal • Improper oil level (too much) • Loose damper rod holding bolt • Broken cap bolt O-ring

MALFUNCTION • Bent, deformed or damaged inner tube • Bent or deformed outer tube • Damaged fork spring • Worn or damaged slide metal • Bent or damaged damper rod • Improper oil viscosity • Improper oil level 8-5

SIGNAL

AND

LIGHTING

SYSTEM

8-6

FAULTY SIGNAL AND LIGHTING SYSTEM/ OVERHEATING

I TRBL

Flasher winks slower

Horn is inoperative

• • • •

• Faulty battery o Faulty fuse • Faulty main and/or horn switch • Improperly adjusted horn • Faulty horn • Broken wirehamess

Faulty flasher relay Insufficient battery capacity (nearly discharged) Improper bulb Faulty main and/or flasher switch

Flasher winks quicker • Improper bulb • Faulty flasher relay

OVERHEATING OVERHEATING Ignition system • Improper spark plug gap • Improper spark plug heat range • Improper ignition timing"

Compression system • Heavy carbon buildup

Faulty system • Improper carburetor main jet (Improper setting) • Clogged air cleaner element • Lean mixture (faulty autolube pump setting) Brake • Dragging brake

8-7

Cooling fan • Damaged cooling fan • Damaged air shrouds

I TRBL

IG-12 I WIRING DIAGRAM ®

_(_c,_ _:: i [_

r_ .......

_!_]

_i_'_

_

--

_::1_ ....

r-

_

C.D.I Unit Ignition coil

_

I

_-I_1

@ Rectifier/regulator @Starter motor

-,

'

• _

L...... _B i-_-i

i _

i

_

_ Right handle switch @ Lefthandle switch

........ _-_ _6"_-__ .........

i

--L_; ......................

__

_ _

L_,

I_

L_

_ 'i__

............. _

E _}

i'

'

_ " ',-_-_B_

_

@

'

]

," ............... .ORN _,._ER _ ......._.E.

_

_ _ _

Head light Starter relay Left front flasher light

_

Right front flasher light

_ Right rear flasher light _ Leftrearflasherlight _ Tail/Stop light

®

_

t

_

_ Battery @Fuse

,w ....

-

C,D.I

@ Spark plug @ Main switch

8w

8

Magneto

_

-:_

_ _ (_ _

Flasher relay Rear stop switch Front stop switch Oil level gauge

_

Meter

i t

....... ....... --_ I_::_ ' ,

_! i

(GREEN) I

I I

, B

_

(

_i

_ I_! _____

________

_[ B

,__,---, _@

__ -) i"""

_ "

_,.......... _o,_ SenderY/_ ........

Yo,,o_/_,_c_

ii 'iiiiii ...........

Bown .......

Gre 0 ........... Orange

Ch .......... Chocolate

Y/R ........ YellowlRed

B/R ........ Black/White BlacldRed B/W .......

Dg ..........

Dark green L/W ........ Blue/White

Br/W ....... ...... White/Red Brown/White W/R Br/Y ....... Brown/Yellow

Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, ON M2H 3B4