Yamaha Ew50 & Ew 50N 2003-2006 Workshop Service Repair Manual – PDF DOWNLOAD

EW50 EW50N

2003→2006 1S01-AE1

SERVICE MANUAL

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EW50 / EW50N SERVICE MANUAL ©2005 by MBK INDUSTRIE First edition, January 2005 All rights reserved.

Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.

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NOTICE This manual was produced by MBK INDUSTRIE primarily for use by Yamaha and MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.

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

NOTE: Designs and specifications are subject to change without notice. _

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IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING CAUTION: NOTE:

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

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

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

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HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”.

2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) appears.

3 Sub-section titles appear in smaller print than the section title.

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.

6 Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequentially.

1

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2

GEN INFO

SYMBOLS The following symbols are not relevant to every vehicle.

SPEC

3

Symbols 1 to 8 indicate the subject of each chapter.

4

CHK ADJ

CHAS

5

1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor 7 Electrical system 8 Troubleshooting

6

CARB

ENG 7

8 –

ELEC

TRBL SHTG

+

0

Symbols 9 to F indicate the following.

A

B

9 Serviceable with engine mounted 0 Filling fluid A Lubricant B Special tool C Tightening torque D Wear limit, clearance E Engine speed F Electrical data

C

D

9

T.

R.

E

Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points.

F

G

H

I

G

E J

M

K B

L M

LS

M

Symbols M to N in the exploded diagrams indicate the following.

N

LT

G Engine oil H Gear oil I Molybdenum disulfide oil J Wheel bearing grease K Lithium soap base grease L Molybdenum disulfide grease

New

M Apply locking agent (LOCTITEÂŽ) N Replace the part

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TABLE OF CONTENTS

GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE CARBURETOR

GEN INFO

1

SPEC

2

CHK ADJ

3

CHAS

4

ENG

5

CARB

6

–

ELECTRICAL SYSTEM TROUBLESHOOTING

+

ELEC

7

TRBL SHTG

8

GEN INFO

1

GEN INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION.......................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1 MODEL LABEL.......................................................................................... 1-1 FEATURES...................................................................................................... 1-2 AUTOMATIC HEADLIGHT ON (AHLO) .................................................... 1-2 AIR INDUCTION SYSTEM (EU2 models) ................................................. 1-3 TEMPERATURE COMPENSATOR UNIT (EU2 models) .......................... 1-3 INSTRUMENT FUNCTION (EW50N)........................................................ 1-5 OUTLINE OF THE INSTRUMENT FUNCTION SYSTEM ......................... 1-5 SPEED SENSOR UNIT (EW50N) ............................................................. 1-6 HALL EFFECT DESCRIPTION ................................................................. 1-6 SPEEDOMETER AND ODOMETER FUNCTION (EW50N) ..................... 1-6 FUELMETER FUNCTION (EW50N) ......................................................... 1-7 IMPORTANT INFORMATION ......................................................................... 1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-8 REPLACEMENT PARTS........................................................................... 1-8 GASKETS, OIL SEALS AND O-RINGS .................................................... 1-8 LOCK WASHERS /PLATES AND COTTER PINS .................................... 1-9 BEARINGS AND OIL SEALS .................................................................... 1-9 CIRCLIPS .................................................................................................. 1-9 CHECKING THE CONNECTIONS ................................................................1-10 SPECIAL TOOLS ..........................................................................................1-11

GEN INFO

SCOOTER IDENTIFICATION

GEN INFO

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GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017

VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the bottom of the frame as shown.

NOTE: The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your state.

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MODEL LABEL The model label 1 is affixed to the bottom of the seat. This information will be needed to ordering spare parts.

1-1

FEATURES

GEN INFO

FEATURES AUTOMATIC HEADLIGHT ON (AHLO) The headlight, meter lighting and taillight come on automatically when the engine is started. + Lighting coil , Pick-up coil - To CDI unit . To front and rear brake switch

1 AC magneto 2 Rectifier/regulator 3 Dimmer switch 4 Meter illumination light 5 Hi-beam indicator light 6 Head light 7 Tail light

1-2

FEATURES

GEN INFO

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AIR INDUCTION SYSTEM (EU2 models) AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons.

When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700 °C. 1 Air induction system filter element 2 Air induction system valve

TEMPERATURE COMPENSATOR UNIT (EU2 models) In order to fulfill the EU2 regulation, the carburetor setting of the engine must be on the lean side, having as consequences cold starting difficulties.

This is solved on this model by the usage of a temperature compensator unit.

2

1

3

1 Temperature compensator unit 2 Air filter 3 Carburetor

1-3

FEATURES

GEN INFO

Function description of the temperature compensator unit : Starting with the principle that the carburetor setting are normal → stoichiometric ratio (14 g of air for 1 g of gasoline), the temperature compensator will lean up the mixture by adding air in excess.

This is achieved by using a wax element which expend relative to the temperature and open a valve.

The valve opening allows supplementary air intake in the carburetor.

Temperature compensator unit operation.

The compensator system is composed of a wax element 1 and a valve 2. a) Temperatures less or equal to 0 °C: The wax element is tensed and so the valve is closed.

- Air is not inducting a

b) Temperature increase (up to 0 °C): Relatives to the ambient temperature, the wax element expands progressively, thus opening the valve b.

Sucked air flows in the carburetor intake c, leaning the air/gasoline mixture.

1-4

FEATURES

GEN INFO

INSTRUMENT FUNCTION (EW50N) Multi-function display The multi-function display is equipped with the following: • a speedometer (which shows the riding speed) • an odometer (which shows the total distance traveled) • a fuel gauge (which indicates the amount of fuel in the fuel tank.

• indicator and warning lights as follows: - a fuel indicator light (comes on when the remaining quantity of fuel in the fuel tank is 1.4 L (0.31 Imp gal, 0.37 US gal)) - a turn indicator light (which flashes when the turn signal switch is pushed to the left or right) - a high beam indicator light (comes on when the high beam of the head light is switched on).

- an oil level warning light (comes on when the oil level in the 2-stroke engine oil tank is low during operation).

1 Speedometer 2 Odometer 3 Fuel gauge 4 Fuel warning light 5 Turn indicator light 6 High beam indicator light 7 Oil level warning light

OUTLINE OF THE INSTRUMENT FUNCTION SYSTEM

The instrument function system is made of the following components : È a multi-function display É a fuel sender (in the fuel tank) Ê a speed sensor unit Ë a high beam information signal (comes on when the Dimmer switch is set to “ ”) Ì a turn signal information signal (comes on when the turn signal switch is set to “ ” or “ ”) Í an oil level warning light signal (comes on when the main switch is set to the “ ” position or when the oil level in the 2-stroke engine oil tank is low during operation).

1-5

FEATURES

GEN INFO

SPEED SENSOR UNIT (EW50N) The speed sensor 1 unit is located on the right side of the front wheel 2. It’s appearance is the same as the mechanical type.

This electrical device is based on the Hall effect. The main advantage of this system is that it is contactless, magnetically activated and accurate.

HALL EFFECT DESCRIPTION Hall effect devices are activated by a magnetic field. The basic Hall sensor is a small sheet of a semiconductor material.

A constant voltage source will force a constant bias current to flow in the semiconductor sheet.

The output will take the form of a voltage means-red across the width of the sheet that will have a negligible value in the absence of a magnetic field.

If the biased Hall sensor is placed in a magnetic field with flux lines at right angles to the Hall current, the voltage output is directly proportional to the strength of the magnetic field.

This is the Hall effect, discovered by E. F. Hall in 1879.

1 Magnetic field 2 Hall sensor 3 Voltmeter

SPEEDOMETER AND ODOMETER FUNCTION (EW50N) The magnets motion is activated by the rotation of the front wheel. Each time the front wheel makes one turn, each magnet cross the semiconductor one time. That means that for each rotation of the front wheel, 2 pulses are generated by the sensor unit.

These pulses are analyzed by the speedometer in order to indicate an accurate information for the speed and total traveled distance.

1 Speedometer 2 Odometer È Multi-function display É Speed sensor unit

1-6

FEATURES

GEN INFO

FUELMETER FUNCTION (EW50N) The remaining fuel quantity in the fuel tank is measured by the way of a fuel sender. The fuel sender is a variable resistance.

The fuelmeter convert the fuel sender resistance value, using a scale, to a visual indication on the display (fuel meter bars).

The resistance range value of the fuel gauge are approximately from 8 Ω for a full fuel tank to 90 Ω for an empty fuel tank.

1 Fuelmeter È Multi-function display É Fuel sender

When the remaining amount of fuel in the tank reach the “reserve value”, the two bottom bars 2 of fuelmeter display start to flash, together the fuel warning light indicator 1 comes on until refueling.

1 Fuel warning light indicator 2 Two bottom bars

1-7

IMPORTANT INFORMATION

GEN INFO

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IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS”.

3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

4. During disassembly, clean all of the parts and place them in trays in the order of disassembly.

This will speed up assembly and allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

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REPLACEMENT PARTS 1. Use only genuine Yamaha/MBK parts for all replacements. Use oil and grease recommended by Yamaha/MBK for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

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GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.

1-8

IMPORTANT INFORMATION

GEN INFO

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LOCK WASHERS /PLATES AND COTTER PINS 1. After removal, replace all lock washers/ plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

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BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium soap base grease. Oil bearings liberally when installing, if appropriate.

1 Bearing

CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces.

2 Oil seal

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CIRCLIPS 1. Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1 make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.

4 Shaft

1-9

CHECKING THE CONNECTIONS

GEN INFO

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2

CHECKING THE CONNECTIONS

1

3

Check the leads, couplers, and connectors for stains, rust, moisture, etc.

1. Disconnect: • lead 1 • coupler 2 • connector 3 2.

• • •

Check: lead coupler connector Moisture → Dry with an air blower.

Rust/stains → Connect and disconnect several times.

3. Check: • all connections Loose connection → Connect properly.

NOTE: If the pin 4 on the terminal is flattened, bend it up.

4.

• • •

Connect: lead coupler connector

NOTE: Make sure all connections are tight.

5. Check: • continuity (with the pocket tester) Pocket tester 90890-03112 NOTE: If there is no continuity, clean the terminals.

NOTE: When checking the wire harness, perform steps 1 to 3.

NOTE: As a quick remedy, use a contact revitalizer available at most part stores.

1 - 10

SPECIAL TOOLS

GEN INFO

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SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.

When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. 90890-01135

Tool name/Function Crankcase separating tool

This tool is used to separate the crankcase and remove the crankshaft.

90890-01235

Rotor holding tool

This tool is used to remove the flywheel magneto.

90890-01268 90890-01403

Ring nut wrench 1 Steering nut wrench 2

These tools are used to loosen and tighten the steering ring nuts.

90890-01274 90890-01275 90890-01277 90890-01411

Crankshaft installer set.

These tools are used to install the crankshaft.

90890-01326 90890-01294

T-handle Damper rod holder These tools are used to hold the damper rod when removing or installing the damper rod.

90890-01337

Clutch spring holder.

This tool is used for compressing the spring of the secondary sheave when removing the nut.

90890-01348

Locknut wrench

This tool is used when removing or installing the secondary sheave nut.

1 - 11

Illustration

SPECIAL TOOLS Tool No. 90890-01362

Tool name/Function Flywheel puller

This tool is used to remove the flywheel magneto.

90890-01367 90890-01368

Fork seal driver weight.

Fork seal driver attachment (ø33)

These tools are used when installing the fork seals.

90890-01701

Sheave holder

This tool is used to hold the secondary sheave when removing or installing the nut.

90890-03007

Micrometer (25 ~ 50 mm (0.98 ~ 1.97 in)

This tool is used to measure the piston 90890-03079

Thickness gauge

This tool is used to measure the clearance.

90890-03112

Pocket Tester

This instrument is invaluable for checking the electrical system.

90890-03113

Engine tachometer.

This tool is needed for detecting the engine rpm.

90890-06754

Ignition checker.

This instrument is necessary for checking the ignition system components.

1 - 12

GEN INFO

Illustration

SPECIAL TOOLS Tool No. 90890-85505

Tool name/Function Yamaha bond No.1215

This bond is used to seal two mating surfaces (e.g. crankcase mating surfaces)

1 - 13

GEN INFO

Illustration

SPEC

2

SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................ 2-2 CHASSIS SPECIFICATIONS .......................................................................... 2-7 ELECTRICAL SPECIFICATIONS ................................................................. 2-10 CONVERSION TABLE ..................................................................................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-12 TIGHTENING TORQUES ..............................................................................2-13 ENGINE ...................................................................................................2-13 CHASSIS .................................................................................................2-14 LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-15 ENGINE ...................................................................................................2-15 CHASSIS .................................................................................................2-16 CABLE ROUTING .........................................................................................2-17

SPEC

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS Item Model code

Dimensions Overall length Overall width Overall height

Standard

Limit

5WK1 (YAMAHA) 5WK2 (MBK) EW50 EU2: 1S11 (YAMAHA) 1S12 (MBK) 1S14 (MBK) EW50N EU1: 5YX1 (YAMAHA) 5YX2 (MBK) 5YN1 (YAMAHA) EW50N EU2: 1S01 (YAMAHA) 1S02 (MBK) 1S03 (YAMAHA) 1S05 (YAMAHA)

-------------

1,785 mm (70.3 in) 668 mm (26.3 in) (EW50) 714 mm (28.1 in) (EW50N) 1,077 mm (42.4 in) (EW50) 1,080 mm (42.5 in) (EW50N) 787 mm (31.0 in) 1,202 mm (47.3 in) 155 mm (6.1 in) 1,870 mm (73.6 in)

----------------------------

EW50 EU1:

Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (With oil and fuel) 81 kg (179 lb) Dry (Without oil and fuel) 75 kg (165 lb) Maximum load (total of cargo, rider, 184 kg (406 lb) passenger and accessories)

2-1

----------------------

-------

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS Item Engine Engine type Induction system Displacement Cylinder arrangement Bore × stroke Compression ratio Starting system Fuel Recommended fuel Fuel tank capacity Fuel warning light amount Engine oil Lubrication system Recommended oil

Quantity Transmission oil Type Quantity Autolube pump Plunger diameter Minimum stroke Spark plug(s) Manufacturer/model Spark plug gap Cylinder head Volume Max. warpagex

Cylinder Bore Taper limit

Standard

Limit

Air cooled 2-stroke Reed valve 49.2 cm3 (3.00 cu · in) Vertical single cylinder 40.0 × 39.2 mm (1.57 × 1.54 in) 11.2 :1 Electric starter and kickstarter

----------------------

Regular unleaded gasoline only 6.5 L (1.43 Imp gal, 1.72 US gal) EW50N 1.4 L (0.31 Imp gal, 0.37 US gal)

----------

Separate lubrication (Yamaha auto lube) YAMALUBE 2-cycle oil or 2-stroke engine oil (JASO FC grade) or (ISO EG-C or EGD grade) 1.3 L (1.14 Imp qt, 1.37 US qt)

-------

SAE10W30 type SE motor oil 0.11 L (0.10 Imp qt, 0.12 US qt)

-------

2.62 mm (0.10 in) 0.50 mm (0.02 in)

-------

NGK/BR8HS 0.6 ~ 0.7 mm (0.02 ~ 0.03 in)

-------

5.15 ~ 5.45 cm3 (0.314 ~ 0.333 cu · in) ---* Lines indicate straight edge measurements.

39.993 ~ 40.012 mm (1.5745 ~ 1.5753 in) ----

2-2

----

---0.05 mm (0.002 in)

40.100 mm (1.5787 in) 0.05 mm (0.002 in)

ENGINE SPECIFICATIONS Item Piston Piston-to-cylinder clearance

SPEC

Standard 0.036 ~ 0.049 mm (0.0014 ~ 0.0019 in)

Diameter D Height H*

39.952 ~ 39.969 mm (1.5729 ~ 1.5736 in) 5.0 mm (0.2 in)

Piston pin bore inside diameter

10.004 ~ 10.019 mm (0.3939 ~0.3944 in)

Offset Piston pin outside diameter

0.00 mm (0.00 in) 9.996 ~ 10.000 mm (0.3935 ~0.3937 in)

Limit 0.10 mm (0.0039 in) -------

10.049 mm (0.3956 in) ---9.976 mm (0.3927 in)

Piston ring Top ring

Ring type Dimensions (B × T) End gap (installed)

Keystone 1.20 × 1.80 mm (0.0472 × 0.0709 in) 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in)

Ring side clearance

0.030 ~ 0.050 mm (0.0012 ~ 0.0020 in)

------0.55 mm (0.0217 in) 0.100 mm (0.0039 in)

2nd ring

Ring type Dimensions (B × T) End gap (installed)

Keystone 1.20 × 1.80 mm (0.0472 × 0.0709 in) 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in)

Ring side clearance

0.030 ~ 0.050 mm (0.0012 ~ 0.0020 in)

Connecting rod Small end inside diameter

13.998 ~ 14.009 mm (0.5511 ~ 0.5515 in)

2-3

------0.65 mm (0.0256 in) 0.11 mm (0.0043 in) ----

ENGINE SPECIFICATIONS Item

SPEC

Standard

Limit

Crankshaft EU1 model

Width A Max. runout C Big end side clearance D Big end radial clearance E Clutch type Crankshaft EU2 model Width A Max. runout C

37.90 ~ 37.95 mm (1.4921 ~ 1.4941 in) ---0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) 0.004 ~ 0.017 mm (0.0002 ~ 0.0007 in) Dry, centrifugal automatic 37.90 ~ 37.95 mm (1.4921 ~ 1.4941 in) ----

Big end side clearance D 0.20 ~ 0.50 mm (0.0079 ~ 0.01968 in) Big end radial clearance E 0.004 ~ 0.017 mm (0.0002 ~ 0.0007 in) Clutch type Dry, centrifugal automatic Automatic centrifugal clutch EU1 model Clutch shoe thickness 2.0 mm (0.08 in) Clutch shoe spring free length Clutch housing inside diameter

29.0 mm (1.1417 in) 107.0 mm (4.2126 in)

Compression spring free length

121.7 mm (4.7913 in)

Clutch weight spring free length Primary pulley weight outside diameter Clutch-in revolution Clutch-stall revolution

26.3 mm (1.0354 in) 15.0 mm (0.5906 in) 3,850 ~ 4,350 r/min 6,600 ~ 7,400 r/min

2-4

---0.030 mm (0.0012 in) ------------0.030 mm (0.0012 in) ----------

1.0 mm (0.04 in) ---107.2 mm (4.2205 in) 115.6 mm (4.5512 in) ---14.5 mm (0.5709 in) -------

ENGINE SPECIFICATIONS Item

SPEC

Standard

Automatic centrifugal clutch EU2 model Clutch shoe thickness 2.0 mm (0.08 in) Clutch shoe spring free length Clutch housing inside diameter

29.0 mm (1.1417 in) 107.0 mm (4.2126 in)

Compression spring free length

134.3 mm (5.2874 in)

Clutch weight spring free length Clutch-in revolution Clutch-stall revolution V-belt V-belt width Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Kickstarter Kickstarter type Kick clip friction force P Air filter Air filter element Air filter oil grade Carburetor Type × quantity Manufacturer ID mark Main jet Main air jet Jet needle Jet needle position Needle jet Pilot jet Bypass 1 Air screw turns out Valve seat size Starter jet 1

29.0 mm (1.14 in) 3,650 ~ 4,100 r/min 6,020 ~ 6,650 r/min 16.5 mm (0.6496 in)

Limit

1.0 mm (0.04 in) ---107.2 mm (4.2205 in) 127.6 mm (4.5512 in) ---------14.9 mm (0.5709 in)

V-belt automatic Helical gear 52 × 13 (4.000) Spur gear 42 × 13 (3.230) Centrifugal automatic type

-------------------

Ratchet 1.50 ~ 2.50 N (0.15 ~ 0.25 kg, 0.34 ~ 0.56 lb)

-------

Wet element Foam air-filter oil or SAE10W30SE EU1 models EU2 models * TK-12 × 1 TK-12 × 1 TEKEI TEKEI T.K. 5LH-10 T.K. 5RJ-00 #70 #84 200 200 3S14 3S0P 3/5 3/5 2.080 2.100 #42 #38 0.8 0.8 1-1/4 ± 1/8 7/8 ± 1/8 150 150 #46 #46

-------

2-5

----------------------------------------

ENGINE SPECIFICATIONS Item Idling condition Engine idle speed Throttle cable free play Reed valve Thickness Valve stopper height Valve bending limit

SPEC

Standard

Limit

EU1 models EU2 models 1,800 ~ 2,200 r/min 1,100 ~ 2,300 r/min 1.5 ~ 3.0 mm 1.5 ~ 3.0 mm (0.0590 ~ 0.1181 in) (0.0590 ~ 0.1181 in)

-------

0.150 ~ 0.154 mm (0.0059 ~ 0.0061 in) 5.4 ~ 6.0 mm (0.2126 ~ 0.2362 in) ----

------0.2 mm (0.08 in)

* For EU2 models, the carburetor is associated with a temperature compensator unit localized inside air filter box. (See Temperature compensator unit section page “TEMPERATURE COMPENSATOR UNIT (EU2 models)�.

2-6

CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS Item Chassis Frame type Caster angle Trail Front wheel Wheel type Rim size Rim material Wheel travel Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim size Rim material Wheel travel Max. radial wheel runout Max. lateral wheel runout Front tire Size

Manufacturer/model

Standard Steel tube underbone 27° 90 mm (3.54 in) Cast wheel 12 × MT2.75 Aluminum 104.0 mm (4.09 in) -------

Cast wheel 10 × MT3.00 Aluminum 70.0 mm (2.76 in) -------

Manufacturer/model

---------------------1.0 mm (0.04 in) 1.0 mm (0.04 in) ------------1.0 mm (0.04 in) 1.0 mm (0.04 in)

120/80-12 55J (CHENG SHIN) 120/80-12 55L (MICHELIN) 120/80-12 55J (PIRELLI) CHENG SHIN / MAXXIS MICHELIN / BOPPER TL/TT PIRELLI / SL26

------------------1.6 mm (0.06 in)

130/90-10 61J (CHENG SHIN) 130/90-10 61L (MICHELIN) 130/90-10 61J (PIRELLI) CHENG SHIN / MAXXIS MICHELIN / BOPPER TL/TT PIRELLI / SL26

------------------1.6 mm (0.06 in)

Wear limit (front) Rear tire Size

Limit

Wear limit (rear)

2-7

CHASSIS SPECIFICATIONS Item Tire air pressure (measured on cold tires) 0 ~ 90 kg (0 ~ 198 lb) Front Rear 90 (198 lb) ~ Maximum load * Front Rear * load is total weight of rider, passenger, cargo and accessories Front brake Type Operation Front brake lever free play Front disc brake Disc outside diameter × thickness Brake pad lining thickness

Standard

Lining thickness Shoe spring free length Steering Steering bearing type Lock to lock angle (left) Lock to lock angle (Right)

Limit

150 kPa (1.50 kgf/cm, 21.33 psi) 150 kPa (1.50 kgf/cm, 21.33 psi)

-------

150 kPa (1.50 kgf/cm, 21.33 psi) 160 kPa (1.6 kgf/cm, 22.7 psi)

-------

Single disc brake Right hand operation 10.0 ~ 20.0 mm (0.39 ~ 0.79 in)

----------

190.0 × 3.5 mm (7.48 ~ 0.14 in)

3.0 mm (0.12 in) * 3.1 mm (0.12 in)

6.3 mm (0.25 in)

Brake disc deflection limit Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Rear brake Type Operation Rear brake lever free play Rear drum brake Drum brake type Brake drum inside diameter

SPEC

11.0 mm (0.43 in) 30.0 mm (1.18 in) DOT 3 or 4 Drum brake Left hand operation 10.0 ~ 20.0 mm (0.39 ~ 0.79 in) Leading, trailing 110.0 mm (4.33 in) 4.0 mm (0.16 in) 50.5 mm (1.99 in) Angular bearing 45.0° 45.0°

2-8

0.15 mm (0.006 in) -------------------

110.5 mm (4.35 in) 2.0 mm (0.08 in) -------------

CHASSIS SPECIFICATIONS Item Front suspension Type Spring/shock absorber type Front fork travel Spring Spring free length Spring rate (K 1) Spring rate (K 2) Spring stroke (K 1) Spring stroke (K 2) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Inner tube outer diameter Inner tube bending limit Rear suspension Type Spring/shock absorber type Rear shock absorber assembly travel Installed length Spring rate (K 1) Spring rate (K 2) Spring stroke (K 1) Spring stroke (K 2) Optional spring available

SPEC

Standard Telescopic fork Coil spring/oil damper 104 mm (4.09 in) 253.0 mm (9.96 in) 5.00 N/mm (0.51 kg/mm, 28.55 lb/in) 7.90 N/mm (0.81 kg/mm, 45.11 lb/in) -10 ~ 90.0 mm (-0.39 ~ 3.54 in) 90.0 ~ 104.0 mm (3.54 ~ 4.09 in) No Fork oil 10W or equivalent 115 cm3 (7.02 cu ¡ in) 33 mm (1.3 in) ----

Unit swing Coil spring/oil damper 100.0 mm (3.94 in) 265.5 mm (10.45 in) 21.00 N/mm (2.14 kg/mm, 119.91 lb/in) 26.00 N/mm (2.65 kg/mm, 148.46 lb/in) 0.0 ~ 75.0 mm (0.00 ~ 2.95 in) 75.0 ~ 122.0 mm (2.95 ~ 4.80 in) No

2-9

Limit ---------228.0 mm (8.98 in) ------------------------0.2 mm (0.008 in) ----------------------------

ELECTRICAL SPECIFICATIONS

SPEC

ELECTRICAL SPECIFICATIONS Item System voltage Ignition system Ignition system Ignition timing (B.T.D.C.) Advancer type DC. C.D.I. Pickup coil resistance C.D.I. unit model/manufacturer Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug cap Material Resistance A.C. magneto Model/manufacturer Standard output Charging coil resistance / color Lighting coil resistance / color Rectifier/regulator Regulator type Model/manufacturer No load regulated voltage (DC) No load regulated voltage (AC) Rectifier capacity (DC) Rectifier capacity (AC) Withstand voltage Battery Model Voltage, capacity Specific gravity Manufacturer Ten hour rate amperage Headlight Bulb type Bulb (voltage/wattage × quantity) Headlight Tail/brake light Front turn signal light Rear turn signal light Meter lighting

Standard

Limit

12 V DC. C.D.I. 14.0° BTDC at 5,000 r/min Constant

----------

248 ~ 372 Ω / W/L-W/R 5BM / MORIYAMA

-------

4KJ (ID MARK 2JN) / MORIYAMA 6.0 mm (0.24 in) 0.18 ~ 0.28 Ω 6.32 ~ 9.48 kΩ

-------------

Resin 5.0 kΩ

-------

F5BM / MORIYAMA 14 V / 120 W at 5,000 r/min 0.29 ~ 0.43 Ω / W-B 0.18 ~ 0.26 Ω / Y/R-B

-------------

Semi conductor-short circuit SH671-12/SHINDENGEN 14.1 ~14.9 V 12.3 ~13.3 V 8A 12 A 200 V

----------------------

CB4-LB(GS), YB4L-B(YUASA) 12 V / 4 Ah 1.280 GS, YUASA 0.2 Ah

----------------

Incandescence

----

12 V 25 W/25 W × 1 12 V 21/5 W × 1 12 V 10 W × 2 12 V 10 W × 2 EW50 12 V 1.2 W × 2 EW50N LED

-------------------

2 - 10

ELECTRICAL SPECIFICATIONS Item Indicator light Turn signal indicator light Oil level warning light High beam indicator light Fuel level warning light License plate light Electric starting system System type Starter motor Model/manufacturer Power output Armature coil resistance Brush overall length Brush spring force Commutator diameter Mica undercut (depth) Starter relay Model/manufacturer Amperage Coil resistance Horn Horn type Model/manufacturer × quantity Max. amperage Coil resistance Performance Turn signal relay Relay type Model/manufacturer Self cancelling device built-in Turn signal blinking frequency Wattage Oil level gauge Model/manufacturer Fuel gauge Model/manufacturer Sender unit resistance-full Sender unit resistance-empty Fuses Main fuse

Standard

SPEC Limit

EW50 12V 2.0 W × 2 EW50N LED EW50 12 V 2.0 W × 1 EW50N LED EW50 12 V 2.0 W × 1 EW50N LED EW50N LED 12 V 5.0 W ×1 (5WK1 Dest UK only)

-------------------

Constant mesh

----

4SB / MORIYAMA 0.14 kW 0.065 ~ 0.079 Ω 6.1 mm (0.24 in) 2.32 ~ 3.48 N (236 ~ 355 gf, 8.35 ~ 12.52 oz) 15.8 mm (0.62 in) 1.15 mm (0.045 in)

----

---------2.5 mm (0.098 in) ---14.8 mm (0.583 in) ----

020373G / GUILERA 20 A 72 ~ 88 Ω

----------

Plane YG-F / NIKKO × 1 1A 3.96 ~ 4.10 Ω 101 ~ 108 dB/2m

----------------

Condenser FZ 222 SD / DENSO No 75 ~ 95 cyl/min 10 W × 2 + 3.4 W

----------------

5JH / PAIOLI

----

5JH / MONT.EL 7.4 ~ 9 Ω 82.9 ~ 98.9 Ω

----------

7.5 A

----

2 - 11

CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS

SPEC

EAS00028

EAS00029

CONVERSION TABLE

GENERAL TIGHTENING TORQUE SPECIFICATIONS

All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data.

Ex. METRIC

MULTIPLIER

IMPERIAL

** mm

×

0.03937

=

** in

2 mm

×

0.03937

=

0.08 in

CONVERSION TABLE METRIC TO IMPERIAL Metric unit m·kg Tightening torque m·kg cm·kg cm·kg Weight

kg g

Multiplier

Imperial unit

7.233 86.794 0.0723 0.8679

ft·lb in·lb ft·lb in·lb

2.205 0.03527

lb oz

Speed

km/hr

0.6214

mph

Distance

km m m cm mm

0.6214 3.281 1.094 0.3937 0.03937

mi ft yd in in

Volume/ Capacity

cc (cm3) cc (cm3) lt (liter) lt (liter)

0.03527 0.06102 0.8799 0.2199

oz (IMP liq.) cu·in qt (IMP liq.) gal (IMP liq.)

Misc.

kg/mm kg/cm2 Centigrade (°C)

55.997 14.2234 9/5+32

lb/in psi (lb/in2) Fahrenheit (°F)

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.

A: Width across flats B: Thread diameter

2 - 12

A (nut)

B (bolt)

10 mm 12 mm

General tightening torques Nm

m·kg

ft · lb

6 mm

6

0.6

4.3

8 mm

15

1.5

11

14 mm 10 mm

30

3.0

22

17 mm 12 mm

55

5.5

40

19 mm 14 mm

85

8.5

61

22 mm 16 mm

130

13.0

94

TIGHTENING TORQUES

SPEC

TIGHTENING TORQUES ENGINE Part to be tightened Spark plug Cylinder head with cylinder body Cylinder stud bolt with cylinder body Air shroud (fan cover) Fan Air shroud (cylinder cover) Oil pump assembly Reed valve assembly Engine mounting bolt Air filter Exhaust pipe with cranckase Exhaust pipe with cylinder Crankcase holder Idle gear plate Transmission case Crankcase cover Engine oil drain bolt Engine oil plug Oil seal stopper plate Starter motor Secondary sheave nut Primary sheave nut Clutch securing nut AC magneto stator AC magneto rotor Rear brake pin pivot

Part name

Tightening torque Threa Q’ty d size Nm m · kg ft · lb

Nut

M14 M6

1 4

-

M6

4

Screw Bolt Bolt Screw Bolt Bolt Screw Screw Bolt Bolt Bolt Bolt Bolt Bolt Oil plug Bolt Bolt Nut Nut Nut Bolt Nut Nut

M6 M6 M6 M5 M6 M10 M6 M8 M6 M6 M6 M6 M6 M8 M14 M6 M6 M10 M10 M28 M6 M10 M10

2 3 3 2 4 1 2 2 2 6 2 3 10 1 1 1 1 1 1 1 2 1 1

2 - 13

20 2.0 10 1.0 Fixed till end 6.5 0.65 6.5 0.65 6.5 0.65 3 0.3 8.5 0.85 50 5.0 6.5 0.65 29 2.9 8.5 0.85 13 1.3 8 0.8 6.5 0.65 9 0.90 17.5 1.75 8 0.8 8 0.8 40 4.0 30 3.0 45 4.5 8 0.80 35 3.5 12 1.2

14.5 7.2

4.7 4.7 4.7 2.2 6.1 36.2 4.7 20.9 6.1 9.4 5.8 4.7 6.5 12.7 5.8 5.8 28.9 21.6 32.5 5.8 25.3 8.7

Remarks

SPEC

TIGHTENING TORQUES CHASSIS Part to be tightened

Thread size

Exhaust pipe with crankcase Exhaust pipe with cylinder Air Induction air filter with frame Air Induction system valve with exhaust pipe Frame with engine bracket Engine mounting bolt Rear shock absorber (frame side) Rear shock absorber (engine side) Steering upper ring nut center ring nut lower ring nut

M8 M6 M6 M6 M10 M10 M10 M8 M25 M25 M25

Handlebar with steering shaft Front master cylinder with handlebar Seat lock with frame Fuel cock with tank Footrest board with frame Under cover with frame Oil tank with frame Lower fender inner with front fork Front wheel axle nut Front brake caliper with front fork Front brake disc with front wheel Brake hose union bolt (front brake) Rear wheel axle nut Kick starter pedal bolt Rear brake cam lever bolt Rear brake pin pivot nut Front flashers (EW50N only) Rear flashers Handle switches with handlebar Speedometer unit with handlebar (EW50N) Upper handlebar holder with lower handlebar holder (EW50N) Lower handlebar holder with handlebar holder bracket (EW50N) Handlebar holder cover with lower handlebar bracket

Tightening torque Nm

m ¡ kg

ft ¡ lb

2.9 0.85 0.65 0.65 4.2 5.0 3.15 1.75 7.5 3.8 2.2 6.0 0.85 1.0 0.25 0.4 0.4 0.5 0.35 3.5 2.3 2.3 2.3 10.4 1.3 1.35 1.2 0.98 0.45 0.7 0.4

21 6.1 4.7 4.7 30.3 36.1 22.8 12.7 54.2

M10 M6 M6 / M6 M6 M6 M6 M10 M8 M8 M10 M14 M5 M6 M10 M5 M5 M5 M5

29 8.5 6.5 6.5 42 50 31.5 17.5 75 38 22 60 8.5 10 2.5 4 4 5 3.5 35 23 23 23 104 13 13.5 12 9.75 4.5 7 4

M6

19

1.9

13.7

M6

31

3.1

22.8

M5

2.0

0.2

1.4

2 - 14

27.5 15.9 43.4 6.1 7.2 1.8 2.9 2.9 3.6 2.5 25.3 16.6 16.6 16.6 75.2 9.4 9.8 8.7 7.1 3.3 5.1 2.9

Remarks

1st tightening loosen 1/4 turn final tightening

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

EAS00031L

LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point

Symbol

Oil seal lips

LS

O-ring

LS

Crankshaft bearings

E

Needle bearings (connecting rod)

E

Main axle bearings

G M

Drive axle bearings

G M

Secondary sheave axle bearing

G M

Piston rings, piston pin and piston

E

Kick pinion gear

LS

Kick shaft

LS

Starter idle bearing

M

Starter clutch pin

M

Oil pump driven gear and drive gear

LS

Secondary sliding sheave cam groove

BEL-RAY® assembly lube

Secondary fixed sheave inside diameter

BEL-RAY® assembly lube

Crankcase surface

Yamaha No.1215

2 - 15

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

EAS00032

CHASSIS Lubrication Point

Symbol

Steering bearing and bearing race (upper/lower)

LS

Throttle grip inner surface

LS

Brake lever pivots and brake cable end

LS

Oil seal lips (front wheel)

LS

Speedometer gear (EW50) and sensor unit (EW50N)

LS

Center stand pivot

LS

Brake cam pivot shaft and cam surface

LS

2 - 16

CABLE ROUTING

SPEC

CABLE ROUTING 1 Head light 2 Rectifier / regulator 3 Horn 4 Main switch / steering lock 5 Wire harness 6 Starter relay 7 Fuse 8 Battery 9 Starter motor coupler 0 AC magneto coupler A Starter cable B Throttle cable C Rear brake cable D Mud guard E Oil hose F Tail/brake light coupler

G Rear right turn signal light coupler H Oil level switch I 2-stroke engine oil tank J 2-stroke engine oil hose K Ignition coil L Fuel sender coupler M Rear left turn signal light coupler È Hold the starter wire and the throttle wire on the engine bracket with the plastic locking tie. É The oil hose must pass between the two ribs of mud guard. Ê The oil hose must pass impertively under the ignition coil lead.

2 - 17

CABLE ROUTING 1 Rectifier / regulator 2 Main switch / steering lock 3 Horn 4 Speedometer cable 5 Wire harness 6 Front brake hose 7 Head light coupler 8 Throttle cable 9 Starter cable 0 Turn signal relay A Head light B Rear brake cable

SPEC

C Frame D Front under cover Ăˆ Rectifier / regulator wires must pass in front of front under cover.

2 - 18

CABLE ROUTING 1 Starter cable 2 Throttle cable 3 Tail / brake light coupler 4 Oil level switch coupler 5 Fuel sender coupler 6 Ignition coil 7 Wire harness 8 2-stroke engine oil hose 9 Starter motor lead 0 AC magneto lead A Frame B Starter motor C Rear brake cable D Brake cable guide E Main stand shaft F Main stand

SPEC

G Cranckase È Respect the distance of 30±10 mm between clip and starter cable coating. É The plastic locking tie must be positionned against the frame bracket. Ê Install the round terminal with the lead oriented up. Ë Connect the DC/CDI unit before installing the side protector. Ì The fuel sender coupler must be positionned in front of the frame bracket. Í The plastic locking tie must be positionned on the the wire harness white mark.

2 - 19

CABLE ROUTING

SPEC

EU2 MODELS ONLY 1 Air induction valve 2 Air induction hose from air induction filter to air induction valve 3 Air induction hose from air induction valve to exhaust system 4 Air induction hose from air induction mouth to air induction filter 5 Air induction filter 6 Exhaust system air induction pipe

È Mark position of repere 2 (aligned down with axle). É Mark position of repere 3 (aligned down with axle). Ê Mark axles must be parallel to air induction valve side. Ë Marks positions of repere 2 and 4 must be align up with fixation brackets of repere 5.

2 - 20

CABLE ROUTING

SPEC

EU2 MODELS ONLY 1 Air induction hose from air induction mouth to air induction filter 2 Air induction filter 3 Air induction hose from air induction filter to air induction valve 4 Air induction hose from air induction valve to exhaust system 5 Air induction valve 6 Frame

È Angle of approximatively 20 degree between the two axles.

2 - 21

CABLE ROUTING

SPEC

EW50N models only 1 Wire harness 2 Speed sensor unit lead 3 Left handlebar switch coupler 4 Front brake switch coupler 5 Rear brake switch coupler 6 Right front turn signal light coupler 7 Left front turn signal light coupler 8 Right handlebar switch coupler 9 Multi-function display couplers 0 Couplers protection house A Horn coupler B Rectifier/regulator coupler C Main switch coupler D Turn signal relay coupler

E Frame F Front under cover È Connections localised in repere 0. É Respect a distance of 30 to 40 mm between the plastic locking tie and the connectors. Ê Bring together all connections coming from handle and clamp them on the frame bracket. Ë Layout of speed sensor unit lead.

Note: W = white; G = green; B = black

2 - 22

CABLE ROUTING

SPEC

EW50 models only 1 Front brake hose 2 Rear brake cable 3 Rear brake switch lead 4 Left handlebar switches lead 5 Speedometer cable 6 Throttle cable 7 Front brake switch lead 8 Wire harness 9 Right handlebar switch lead 0 Right handlebar switch coupler A Left handlebar switches coupler B Left turn signal light coupler C Speedometer coupler D Right turn signal light coupler

E Frame F Starter cable È Regroup all the connections at the back of handlebar and under the speedometer. É Put the front brake hose in the hook and close it. Ê The hooking thread of wire harness must be hook on the handle bracket. Ë Don’t take the speedometer cable and the front brake hose.

2 - 23

CABLE ROUTING

SPEC

EW50N models only 1 Throttle cable 2 Left handlebar switch lead 3 Rear brake cable 4 Digital display lead 5 Rear brake switch lead 6 Starter cable 7 Right handlebar switches lead 8 Right front turn signal light lead 9 Front brake hose 0 Front brake switch lead A Frame B Left front turn signal light lead

Ăˆ The hose brake is engage by way of grommet on bracket handle stem. É All cables and leads must be passed inside metallic wire guide.

2 - 24

CHK ADJ

3

CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION.............................................................................................. 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .................... 3-1 COVERS AND PANELS.................................................................................. 3-3 SEAT AND BATTERY COVER ................................................................. 3-3 SIDE COVERS .......................................................................................... 3-4 COVER FILLER AND FUEL TANK ........................................................... 3-5 FOOTREST BOARD AND UNDER COVER ............................................. 3-6 MUD GUARD ............................................................................................ 3-7 FRONT COVERS ...................................................................................... 3-8 HANDLEBAR COVERS ............................................................................ 3-9 ENGINE .........................................................................................................3-10 ADJUSTING THE ENGINE IDLING SPEED ........................................... 3-10 ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-11 CHECKING THE SPARK PLUG .............................................................3-12 CHECKING THE ENGINE OIL LEVEL....................................................3-14 CHANGING THE TRANSMISSION OIL ..................................................3-15 AUTOLUBE PUMP AIR BLEEDING........................................................ 3-15 CLEANING THE AIR FILTER ELEMENT................................................3-16 CHECKING THE EXHAUST SYSTEM....................................................3-17 CHASSIS .......................................................................................................3-18 ADJUSTING THE FRONT BRAKE .........................................................3-18 ADJUSTING THE REAR BRAKE ............................................................3-18 CHECKING THE BRAKE FLUID LEVEL.................................................3-19 CHECKING THE FRONT BRAKE PADS ................................................3-20 CHECKING THE BRAKE SHOES...........................................................3-20 BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-20 CHECKING AND ADJUSTING THE STEERING HEAD .........................3-21 CHECKING THE FRONT FORK .............................................................3-23 CHECKING THE TIRES .......................................................................... 3-24 CHECKING THE WHEELS .....................................................................3-27 CHECKING AND LUBRICATING THE CABLES ....................................3-27 LUBRICATING THE CENTERSTAND ....................................................3-28 LUBRICATING THE REAR SUSPENSION............................................. 3-28 ELECTRICAL SYSTEM.................................................................................3-29 CHECKING THE BATTERY ....................................................................3-29 CHECKING THE FUSE ...........................................................................3-33 REPLACING THE HEADLIGHT BULB....................................................3-34 ADJUSTING THE HEADLIGHT BEAM ...................................................3-35

CHK ADJ

INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

CHK ADJ

EAS00036

PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments.

If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS NOTE: • The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.

• From 30000 km, repeat the maintenance intervals starting from 6000 km.

• Items marked with an asterisk should be performed by a Yamaha or MBK dealer as they require special tools, data and technical skills.

No.

ITEM

CHECK OR MAINTENANCE JOB

ODOMETER READING (× 1000 km) 1

6

12

18

24

ANNUAL CHECK

1 * Fuel line

• Check fuel and vacuum hoses for cracks or damage.

√

√

√

√

√

2

Spark plug

• Replace.

√

√

√

√

√

3

Air filter element

• Clean.

√

4 * Battery

5 * Front brake

• Check electrolyte level and specific gravity.

• Make sure that the breather hose is properly routed • Check operation, fluid level and vehicle for fluid leakage.

√

7 * Brake hose

√

√

√

√

√

√

√

√

√

√

√

• Replace brake pads.

6 * Rear brake

√ √

• Replace

Whenever worn to the limit

• Check operation and adjust brake lever free play.

√

√

• Replace brake shoes.

√

√

√

√

• Check for cracks or damage.

• Replace.

√

√

√

• Check runout and for damage.

√

√

√

√

9 * Tires

• • • •

√

√

√

√

10 * Wheel bearings

• Check bearing for looseness or damage.

√

√

√

√

√

√

√

12 * Chassis fasteners

√

Every 4 years

8 * Wheels

11 * Steering bearings

√

Whenever worn to the limit

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.

• Check bearing play and steering for roughness.

√

√

• Lubricate with lithium-soap-based grease.

• Make sure that all nuts, bolts and screws are properly tightened.

3-1

√

Every 24000 km √

√

√

√

√

INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

CHK ADJ

ODOMETER READING (× 1000 km) 6

12

18

24

ANNUAL CHECK

• Check operation.

• Lubricate.

√

√

√

√

√

14 * Front fork

• Check operation and for oil leakage.

√

√

√

√

Shock absorber 15 * assembly

• Check operation and shock absorber for oil leakage.

√

√

√

√

16 * Carburetor

• Check starter (choke) operation.

• Adjust engine idling speed.

√

√

√

√

√

√

17 * Autolube pump

• Check operation.

• Bleed if necessary.

√

√

√

No. 13

18

ITEM Centerstand

CHECK OR MAINTENANCE JOB

√

Final transmission • Check vehicle for oil leakage. oil • Change.

19 * V-belt

1

√ √

√

√ √

• Replace.

√

Every 10000 km

20 *

Front and rear brake switches

• Check operation.

21

Moving parts and cables

• Lubricate.

22 *

• Check operation and free play.

Throttle grip hous• Adjust the throttle cable free play if necessary. ing and cable • Lubricate the throttle grip housing and cable.

23 *

Lights, signals and • Check operation. switches • Adjust headlight beam.

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level.

• Every two years change the brake fluid.

• Replace the brake hoses every four years and if cracked or damaged.

3-2

COVERS AND PANELS

CHK ADJ

EAS00038

COVERS AND PANELS SEAT AND BATTERY COVER

Order

1 2 3 4

Job/Part Removing the seat and battery cover Battery cover Clip Seat pin Seat

Q’ty

Remarks Remove the parts in the order listed.

1 1 1 1

For installation, reverse the removal procedure.

3-3

COVERS AND PANELS

CHK ADJ

SIDE COVERS

Order

1 2 3

Job/Part Removing the side covers Battery cover Seat Side protector Side cover Passenger footrest board

Q’ty

Remarks Remove the parts in the order listed.

Refer to “SEAT AND BATTERY COVER”.

1 1 1

For installation, reverse the removal procedure.

3-4

COVERS AND PANELS

CHK ADJ

COVER FILLER AND FUEL TANK

Order

1 2 3 4 5 6

Job/Part Removing the cover filler and fuel tank Side covers Fuel tank cap Fuel tank gasket Oil tank cap Oil tank gasket Cover filler Fuel tank

Q’ty

Remarks Remove the parts in the order listed.

Refer to “SIDE COVERS”.

1 1 1 1 1 1

Disconnect fuel hoses

For installation, reverse the removal procedure.

3-5

COVERS AND PANELS

CHK ADJ

FOOTREST BOARD AND UNDER COVER

Order

1 2

Job/Part Removing the footrest board and under cover Passenger footrest board Battery negative lead (-) Battery positive lead (+) Battery Footrest board Under cover

Q’ty

Remarks Remove the parts in the order listed.

Refer to “SIDE COVERS”.

Disconnect Disconnect

1 1 1

For installation, reverse the removal procedure.

3-6

COVERS AND PANELS

CHK ADJ

MUD GUARD

Order

1 2 1

Job/Part Removing the mud guard Side covers Tail / Brake light Rear turn signal light Mud guard Rear shock absorber Mud guard

Q’ty

1 2 1 1 1

Remarks Remove the parts in the order listed.

Refer to “SIDE COVERS”.

Disconnect Disconnect Untight Remove

For installation, reverse the removal procedure.

3-7

COVERS AND PANELS

CHK ADJ

FRONT COVERS

Order 1 2 3 4

Job/Part Removing the front covers Headlight assembly Front side protector Main switch cap Leg shield Front under cover

Q’ty

2 1 1 1

Remarks Remove the parts in the order listed.

Disconnect the headlight coupler.

Remove

For installation, reverse the removal procedure.

3-8

COVERS AND PANELS

CHK ADJ

HANDLEBAR COVERS (EW50 Models only)

Order

1

Job/Part Removing the Handlebar covers Headlight assembly Upper handlebar cover

2 3 4

Front turn signal light Side handlebar panel Under handlebar cover

Q’ty

2 1 1

Remarks Remove the parts in the order listed.

Refer to “FRONT COVERS”.

Disconnect speedometer coupler and speedometer gear wire Disconnect coupler and remove

For installation, reverse the removal procedure.

3-9

ADJUSTING THE ENGINE IDLING SPEED

CHK ADJ

EAS00054

ENGINE ADJUSTING THE ENGINE IDLING SPEED CAUTION: For safety reasons, place the scooter on the center stand before starting the engine.

1. Start the engine and let it warm up for several minutes.

2. Attach: • engine tachometer (onto the spark plug lead) Engine tachometer 90890-03113 3. Measure: • engine idling speed Out of specification → Adjust.

Engine idling speed 2000 ± 200 r/mn EU1 models 1700 ± 600 r/mn EU2 models 4. Adjust: • engine idling speed a. Turn the Air screw 1 in until it is lightly seated. b. Turn the Air screw out the specified number of turns.

Air screw setting: 1 1/4 ± 1/8 (EU1 models) 7/8 ± 1/8 (EU2 models) c. Turn the throttle stop screw 2 in direction left or right until the specified engine idling speed is obtained.

Direction a

Engine idling speed is increased.

Direction b

Engine idling speed is decreased.

5. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”.

3 - 10

ADJUSTING THE THROTTLE CABLE FREE PLAY

CHK ADJ

Throttle cable free play (at the / flange of the throttle grip) @ 1.5 ~ 3.0 mm (0.06 ~ 0.12 in) EAS00058

ADJUSTING THE THROTTLE CABLE FREE PLAY

@

NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted.

1. Check: • throttle cable free play @ Out of specification → Adjust.

Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.0 mm (0.06 ~ 0.12 in)

@

2. Adjust: • throttle cable free play NOTE: When the throttle is opened, the accelerator cable is pulled.

Carburetor side a. Loosen the locknut 1 on the accelerator cable. b. Turn the adjusting nut 2 in direction left or right until the specified throttle cable free play is obtained.

2

1

Direction a

Throttle cable free play is increased.

Direction b

Throttle cable free play is decreased.

c. Tighten the locknut.

NOTE: If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side.

3 - 11

ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG

CHK ADJ

Handlebar side a. Loosen the locknut 1. b. Turn the adjusting nut 2 in direction left or ought until the specified throttle cable free play is obtained.

Direction a

Throttle cable free play is increased.

Direction b

Throttle cable free play is decreased.

c. Tighten the locknut.

WARNING After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.

EAS00060

1

2

CHECKING THE SPARK PLUG 1. Disconnect: • spark plug cap 1 2. Remove: • spark plug 2 CAUTION: Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder.

3. Check: • spark plug type Incorrect → Change.

Spark plug type (manufacturer) BR8HS (NGK)

4. Check: • electrodes 1 Damage/wear→ Replace the spark plug.

• insulator 2 Abnormal color → Replace the spark plug.

Normal color is medium-to-light tan.

3 - 12

ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG

1

CHK ADJ

5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6. Measure: • spark plug gap 1 (with a wire gauge or feeler gauge) Out of specification → Adjust.

Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) 7. Install: • spark plug

T.

Spark plug 20 Nm (2 m · kg, 14 ft · lb)

R.

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

• First tighten by hand, then torque to specification.

8. Connect: • spark plug cap

3 - 13

CHECKING THE ENGINE OIL LEVEL

CHK ADJ

EAS00070

CHECKING THE ENGINE OIL LEVEL 1. Inspect: • Oil level Oil level low → Add oil to proper level as follows.

1 “OIL” indicator light.

OIL LEVEL AND GAUGE CHECK Turn main switch to “ ”

“ ” indicator light.

“ ” indicator doesn’t light.

Turn main switch to “ ”

“ ” indicator stays on.

“ ” indicator goes.

Engine oil level and electric circuit are OK.

Inspect Faulty electrical circuit, Light bulb etc.

Add oil.

“ ” indicator stays on.

Recommended oil: Yamalube 2 or 2 stroke engine oil (JASO FC or EG-C, EG-D grade) Capacity: Total: 1.4 L (1.23 Imp qt, 1.48 US qt) NOTE: Install the oil tank filler cap 1 and push it fully into the filler.

1

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

3 - 14

CHANGING THE TRANSMISSION OIL/ AUTOLUBE PUMP AIR BLEEDING

2

1

CHK ADJ

CHANGING THE TRANSMISSION OIL 1. Remove: • drain plug 1 • oil filler plug 2 Drain the transmission oil.

2. Check: • gasket (drain plug) • O-ring (oil filler plug) Damage → Replace.

3. Install: • gasket New • drain plug

T.

Drain plug: 18 Nm (1.8 m · kg, 13 ft · lb)

R.

4. Fill: • transmission case Transmission oil: SAE 10W30 type SE motor oil.

Capacity: 0.11 L (0.097 Imp qt, 0.116 US qt) Total amount: 0.13 L (0.114 Imp qt, 0.137 US qt) NOTE: Wipe off any oil split on the crankcase, tire or wheel.

5. Install: • oil filler plug.

AUTOLUBE PUMP AIR BLEEDING 1. Remove: • fan cover 1

1

3 - 15

AUTOLUBE PUMP AIR BLEEDING/ CLEANING THE AIR FILTER ELEMENT

1

CHK ADJ

2.

• a. b. c.

Bleed: Pump housing and oil hose Place a rag under the pump.

Remove the bleed screw 1 Let oil run until there are no more air bubbles in it. d. When there are no more bubbles, tighten the bleed screw.

NOTE: Check the condition of bleed screw gasket. If it is damaged, replace it with a new one. e. Start the engine. f. Let engine run two or three minutes at 2,000 rpm. This will force out any air in the hose.

EAS00089

CLEANING THE AIR FILTER ELEMENT 1. Remove: • air cleaner case cover 1

1

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

2.

• • 3.

• • 4.

•

Remove: air filter case cover air filter element Inspect: air filter element 1 Damage → Replace Clean: air filter element 1 (with solvent) 1 Wash the element gently but thoroughly in a solvent.

1

1

3

2

4

WARNING Never use low flash point solvents, such as gasoline, to clean the air filter element.

Such solvents may cause a fire or an explosion.

3 - 16

CLEANING THE AIR FILTER ELEMENT/ CHECKING THE EXHAUST SYSTEM 1

CHK ADJ

2 Squeeze excess solvent out of the element and let dry.

2

CAUTION: Do not twist the element.

3

4

3 Apply foam air filter oil or SAE 10W30 type SE oil on the element.

4 Squeeze out the excess oil.

NOTE: The element should be wet but not dripping.

EAS00100

CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes, mufflers and gaskets.

1. Remove: • exhaust pipe bolt (cylinder) • exhaust pipe bolt (engine) 2. Check: • exhaust pipe 1 • muffler 2 • Air induction system (EU2 models) Cracks/damage → Replace.

• gasket 3 Exhaust gas leaks → Replace.

3. Loosen: • exhaust pipe bolt (engine) • exhaust pipe bolt (cylinder) 4. Tighten: • exhaust pipe bolt (engine) 4 • exhaust pipe bolt (cylinder) 5

4

2 T.

R.

5

3 1

3 - 17

Exhaust pipe bolt (engine) 29 Nm (2.9 m · kg, 21 ft · lb) Exhaust pipe bolt (cylinder) 8.5 Nm (0.85 m · kg, 6.1 ft · lb)

ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE

CHK ADJ

EAS00108

CHASSIS a

ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play a Out of specification → Adjust.

Brake lever free play (at the end of the brake lever) 10 ~ 20 mm (0.39 ~ 0.79 in) WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the scooter is operated. Air in the system will reduce brake performance and can result in lost of control and an accident. Inspect and bleed the system if necessary.

EAS00114

a

ADJUSTING THE REAR BRAKE 1. Check: • brake lever free play a Out of specification → Adjust.

Brake lever free play 10 ~ 20 mm (0.39 ~ 0.79 in) 2. Adjust: • brake lever free play Rear wheel side a. Turn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained.

Direction a

Brake lever free play is increased.

Direction b

Brake lever free play is decreased.

CAUTION: After adjusting the brake lever free play, make sure there is no brake drag.

3 - 18

CHECKING THE BRAKE FLUID LEVEL

CHK ADJ

EAS00116

CHECKING THE BRAKE FLUID LEVEL 1. Stand the scooter on a level surface.

NOTE: • Place the scooter on a suitable stand.

• Make sure the scooter is upright.

• In order to ensure a correct reading of the brake fluid level, make sure the top of the reservoir is horizontal.

1

2. Check: • brake fluid level Below the minimum level mark 1 → Add the recommended brake fluid to the proper level.

Recommended brake fluid DOT #3 or DOT #4 WARNING • Use only the designated brake fluid.

Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

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

• When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any split brake fluid immediately.

3 - 19

CHECKING THE FRONT BRAKE PADS/ CHECKING THE BRAKE SHOES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK ADJ

EAS00123

CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads.

1. Operate the brake.

2. Check: • brake pad Out of specification → Replace.

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

Wear limit 1 : 3.1 mm (0.12 in) Refer to “FRONT BRAKE” in chapter 4.

EAS00126

1

2

CHECKING THE BRAKE SHOES 1. Operate the brake.

2. Check: • wear indicator 1 Reaches the wear limit line 2 → Replace the brake shoes as a set.

Refer to “REAR WHEEL AND BRAKE” in chapter 4.

EAS00133

BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: • brake fluid. a. Add proper brake fluid into the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir overflow. c. Connect a clear plastic tube a tightly to the caliper bleed screw. d. Place the other end of the tube 1 into container. e. Slowly apply the brake lever several times. f. Pull the lever as far as possible and hold it there. g. Loosen the bleed screw and pull the lever all the way. h. When the lever is completely pulled, tighten the bleed screw, then release the lever.

3 - 20

BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHECKING AND ADJUSTING THE STEERING HEAD

CHK ADJ

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

WARNING Check the operation of the brake after bleeding the brake system.

EAS00148

CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the scooter on a level surface.

WARNING Securely support the scooter so that there is no danger of it falling over.

NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.

2. Check: • steering head Grasp the bottom of the front fork legs and gently rock the front fork.

Binding/looseness → Adjust the steering head.

385

1

2 3 4 5

3. Remove: • front cover Refer to “FRONT COVERS”.

• handlebar Refer to “HANDLEBAR” in chapter 4.

4. Adjust: • steering head a. Remove the upper ring nut 1, the lock washer 2, the center ring nut 3 and the rubber washer 4. b. Loosen the lower ring nut 5 and then tighten it to specification with the ring nut wrench.

NOTE: Set the torque wrench at a right angle to the ring nut wrench.

3 - 21

CHECKING AND ADJUSTING THE STEERING HEAD

CHK ADJ

Steering nut wrench 90890-01403

T.

R.

Lower ring nut (initial tightening torque) 38 Nm (3.8 m · kg, 27 ft · lb)

c. Loosen the lower ring nut 5 of 1/4 turn and then tighten it to specification with a steering nut wrench.

CAUTION: Do not overtighten the lower ring nut.

T.

R.

1

2 3 4 5

Lower ring nut (final tightening torque) 22 Nm (2.2 m · kg, 16 ft · lb)

d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings.

Refer to “STEERING HEAD” in chapter 4. e. Install the rubber washer. f. Install the center ring nut. g. Finger tighten the center ring nut 3, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the center ring nut until their slots are aligned. h. Install the lock washer 1.

NOTE: Make sure the lock washer tabs a sit correctly in the ring nut slots. i. Hold the lower and center ring nuts with a ring nut wrench and tighten the upper ring nut with a steering nut wrench.

Steering nut wrench 90890-01403 Ring nut wrench 90890-01268

T.

R.

3 - 22

Upper ring nut 75 Nm (7.5 m · kg, 54 ft · lb)

CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK

CHK ADJ

5. Install: • front cover Refer “FRONT COVERS”.

• Handlebar Refer “HANDLEBAR” in chapter 4.

T.

Handlebar holder bolt 60 Nm (6.0 m · kg, 43 ft · lb)

R.

EAS00151

CHECKING THE FRONT FORK 1. Stand the scooter on a level surface.

WARNING Securely support the scooter so that there is no danger of it falling over.

2. Check: • inner tube Damage/scratches → Replace.

• oil seal Oil leakage (left tube) → Replace.

3. Hold the scooter upright and apply the front brake.

4. Check: • front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly.

Rough movement → Repair.

Refer to “FRONT FORK” in chapter 4.

3115

3 - 23

CHK ADJ

CHECKING THE TIRES EAS00165

CHECKING THE TIRES The following procedure applies to both of the tires.

1. Check: • tire pressure Out of specification → Regulate.

WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.

• The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.

• Operation of an overloaded scooter could cause tire damage, an accident or an injury.

NEVER OVERLOAD THE SCOOTER. Basic weight (with oil and a full fuel tank)

81 kg (179 lb)

Maximum load*

184 kg (406 lb)

Cold tire pressure Up to 90 kg load*

Front

Rear

150 kPa 150 kPa (1.50 kgf/cm2, (1.50 kgf/cm2, 1.50 bar) 1.50 bar)

150 kPa 160 kPa 90 kg ~ max2 (1.50 kgf/cm , (1.60 kgf/cm2, imum load* 1.50 bar) 1.60 bar) * Total weight of cargo, rider, passenger, and accessories.

WARNING It is dangerous to ride with a worn-out tire.

When the tire tread reaches the wear limit, replace the tire immediately.

3 - 24

CHECKING THE TIRES

2. Check: • tire surfaces Damage/wear → Replace the tire.

1

2

CHK ADJ

Minimum tire tread depth 1.6 mm (0.063 in)

3

3103

1 Tire tread depth 2 Sidewall 3 Wear indicator

WARNING • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation.

• When using tube tires, be sure to install the correct tube.

• Always replace a new tube tire and a new tube as a set.

• To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove.

• Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. È Tire É Wheel

Tube wheel

Tube tire only

Tubeless wheel

Tube or tubeless tire

• After extensive tests, the tires listed below have been approved by MBK industrie for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha or MBK is used on this scooter.

3 - 25

CHECKING THE TIRES

CHK ADJ

Front tire Manufacturer

Size

Model

CHENG CHIN

120/80-12 55J

MAXXIS

PIRELLI

120/80-12 55J

SL26

MICHELIN

120/80-12 55L

BOPPER

Manufacturer

Size

Model

CHENG CHIN

130/90-10 61J

MAXXIS

PIRELLI

130/90-10 61J

SL26

MICHELIN

130/90-10 61L

BOPPER

Rear tire

NOTE: For tires with a direction of rotation mark 1, install the tire with the mark pointing in the direction of wheel rotation.

3 - 26

CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES

CHK ADJ

EAS00168

CHECKING THE WHEELS The following procedure applies to both of the wheels.

1. Check: wheel Damage/out-of-round → Replace.

WARNING Never attempt to make any repairs to the wheel.

NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.

EAS00170

CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables.

WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its movement.

Replace damaged cable sheaths and cables as soon as possible.

E

1. Check: cable sheath Damage → Replace.

2. Check: cable operation Rough movement → Lubricate.

Recommended lubricant Engine oil or a suitable cable lubricant NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device.

3 - 27

LUBRICATING THE CENTERSTAND/ LUBRICATING THE REAR SUSPENSION

CHK ADJ

EAS00173

LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.

Recommended lubricant Engine oil

EAS00174

LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension.

Recommended lubricant Molybdenum disulfide grease

3 - 28

CHECKING THE BATTERY

CHK ADJ

EAS00177

ELECTRICAL SYSTEM CHECKING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid.

Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.

• Charge batteries in a well-ventilated area.

• Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).

• DO NOT SMOKE when charging or handling batteries.

KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.

FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL • Skin - Wash with water.

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

INTERNAL • Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.

1. Remove: • battery cover Refer to “COVERS AND PANELS”.

2. Disconnect: • battery leads (from the battery terminals) CAUTION: First, disconnect the negative battery lead, and the positive battery lead.

3. Remove: • battery

3 - 29

CHECKING THE BATTERY 1 UPPER LOWER

+ 2

CHK ADJ

4. Check: • electrolyte level The electrolyte level should be between the minimum level mark 2 and the maximum level mark 1.

Below the minimum level mark → Add distilled water to the proper level.

CAUTION: Add only distilled water. Tap water contains minerals which are harmful to the battery.

5. Check: • specific gravity Less than 1.280 → Recharge the battery.

Specific gravity 1.280 at 20 °C (68 °F) 6. Charge: • battery Battery charging amperage and time 0.2 amps/10 hrs WARNING Do not quick charge a battery.

CAUTION: • Loosen the battery sealing caps.

• Make sure the battery breather hose and battery vent are free of obstructions.

• To ensure maximum performance, always charge a new battery before using it.

• Do not use a high-rate battery charger.

They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.

• If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery.

• When charging a battery, be sure to remove it from the scooter. (If charging has to be done with the battery mounted on the scooter, disconnect the negative battery lead from the battery terminal.)

3 - 30

CHECKING THE BATTERY

CHK ADJ

• To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.

• Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.

• Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.

• If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode!

NOTE: Replace the battery whenever: • battery voltage does not rise to specification or bubbles fail to rise during charging, • sulphation of one or more battery cells occurs (as indicated by the battery plates turning white or material accumulating in the bottom of the battery cell), • specific gravity readings after a long, slow charge indicate that one battery cell’s charge is lower than the rest, • warpage or buckling of the battery plates or insulators is evident.

3 - 31

CHECKING THE BATTERY

CHK ADJ

7. Check: • battery breather hose and battery vent Obstruction → Clean.

Damage → Replace.

8. Connect: • battery breather hose 1 9. Install: • battery 2

1

+

om913(a)

CAUTION: When checking the battery, make sure the battery breather hose is properly installed and routed correctly. If the battery breather hose is positioned so as to allow electrolyte or hydrogen gas from the battery to contact the frame, the scooter and its finish may be damaged.

10.Check: • battery terminals Dirt → Clean with a wire brush.

Loose connection → Connect properly.

3 - 32

CHECKING THE BATTERY/ CHECKING THE FUSE

CHK ADJ

11.Connect: • battery leads (to the battery terminals) CAUTION: First connect the positive battery lead 1, and then the negative battery lead 2.

12.Lubricate: • battery terminals Recommended lubricant Dielectric grease 13.Install: • battery cover Refer to “COVERS AND PANELS”.

EAS00181

CHECKING THE FUSE The following procedure applies to all of the fuses.

CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse.

1. Remove: • battery cover Refer to “COVERS AND PANELS”.

2. Check: • continuity a. Connect the pocket tester to the fuse 1 and check the continuity.

1

NOTE: Set the pocket tester selector to “Ω × 1”.

Pocket tester 90890-03112 b. If the pocket tester indicates “∞”, replace the fuse.

sm3245

3 - 33

CHECKING THE FUSE/ REPLACING THE HEADLIGHT BULB

1

CHK ADJ

3. Replace: blown fuse 1 a. Set the main switch to “ ”. b. Install a new fuse of the correct amperage. c. Set on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit.

Fuse main circuit : 7.5 A WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

4. Install: • battery cover Refer to “COVERS AND PANELS”.

EAS00182

REPLACING THE HEADLIGHT BULB 1. Disconnect: • front cover • Refer to “COVERS AND PANELS”.

2. Detach: • headlight lens 1 3. Remove: • headlight bulb holder 2 and headlight bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

3 - 34

REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM

CHK ADJ

4. Install: • headlight bulb New Secure the new headlight bulb with the headlight bulb holder.

CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

5.

• 6.

• 7.

•

Attach: headlight bulb holder Connect: headlight bulb Install: front cover Refer to “COVERS AND PANELS”.

EAS00184

ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam a. Turn the adjusting screw 1 in higher or lower position.

1

3 - 35

Direction a

Headlight beam is raised.

Direction b

Headlight beam is lowered.

CHAS

4

CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC............................................................... 4-1 FRONT WHEEL AND BRAKE DISC ......................................................... 4-1 FRONT WHEEL ........................................................................................ 4-2 REMOVING THE FRONT WHEEL............................................................ 4-3 DISASSEMBLING THE FRONT WHEEL .................................................. 4-3 CHECKING THE FRONT WHEEL ............................................................ 4-4 CHECKING THE BRAKE DISC................................................................. 4-6 CHECKING THE SPEEDOMETER GEAR UNIT (EW50) ......................... 4-7 CHECKING THE SPEED SENSOR UNIT (EW50N) ................................. 4-7 ASSEMBLING THE FRONT WHEEL ........................................................ 4-8 INSTALLING THE FRONT WHEEL .......................................................... 4-8 ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-9 REAR WHEEL AND BRAKE ........................................................................4-11 CHECKING THE REAR WHEEL.............................................................4-13 CHECKING THE BRAKE ........................................................................4-13 INSTALLING THE REAR BRAKE ...........................................................4-14 INSTALLING THE REAR WHEEL...........................................................4-15 FRONT BRAKE .............................................................................................4-16 FRONT BRAKE PADS ............................................................................ 4-16 BRAKE PAD REPLACEMENT ................................................................4-18 FRONT BRAKE MASTER CYLINDER ....................................................4-19 CHECKING THE FRONT BRAKE MASTER CYLINDER........................4-20 INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-21 FRONT BRAKE CALIPER.......................................................................4-23 CHECKING THE FRONT BRAKE CALIPER ..........................................4-24 INSTALLING THE FRONT BRAKE CALIPER ........................................4-24 FRONT FORK................................................................................................ 4-27 FRONT FORK .........................................................................................4-27 REMOVING THE FRONT FORK LEGS ..................................................4-30 DISASSEMBLING THE FRONT FORK LEGS ........................................4-30 CHECKING THE FRONT FORK LEGS ..................................................4-32 ASSEMBLING THE FRONT FORK LEGS ..............................................4-33 INSTALLING THE FRONT FORK LEGS ................................................4-36 HANDLEBAR ................................................................................................ 4-37 REMOVING THE HANDLEBAR GRIP ....................................................4-41 CHECKING THE HANDLEBAR ..............................................................4-41 INSTALLING THE HANDLEBAR (EW50) ...............................................4-42 INSTALLING THE HANDLEBAR (EW50N)............................................. 4-45

CHAS LOWER HANDLEBAR HOLDER..................................................................4-48 STEERING HEAD..........................................................................................4-49 REMOVING THE LOWER BRACKET.....................................................4-51 CHECKING THE STEERING HEAD .......................................................4-51 INSTALLING THE STEERING HEAD .....................................................4-52 REAR SHOCK ABSORBER ASSEMBLY ....................................................4-53 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-54

FRONT WHEEL AND BRAKE DISC

CHAS

EAS00513

CHASSIS FRONT WHEEL AND BRAKE DISC FRONT WHEEL AND BRAKE DISC

23 Nm (2.3 m·kg, 16.6 ft·lb)

35 Nm (3.5 m·kg, 25.3 ft·lb)

Order

I 1

II 2 3 4 5 6 7 8

Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. disc WARNING Disconnect: Securely support the scooter so there Speedometer cable (EW50) or 1 is no danger of it falling over. speedometer lead (EW50N)

Remove: Front brake caliper Wheel axle nut Wheel axle Front wheel assembly Speedometer gear (EW50) or sensor unit (EW50N) Spacer Brake disc

1 1 1 1 1

NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.

Refer to “FRONT WHEEL”.

1 1 For installation, reverse the removal procedure.

4-1

FRONT WHEEL AND BRAKE DISC

CHAS

EAS00518

FRONT WHEEL

Order

I 1 2 3

Job/Part Disassembling the front wheel Remove: Oil seal Bearing Collar

Q’ty

1 2 1

Remarks Remove the parts in the order listed.

Refer to “DISASSEMBLING THE FRONT FORK LEGS/ASSEMBLING THE FRONT WHEEL”.

For assembly, reverse the disassembly procedure.

4-2

FRONT WHEEL AND BRAKE DISC

CHAS

EAS00520

REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over.

NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

2. Disconnect: • Speedometer cable (EW50) or speedometer lead (EW50N) 3. Remove: • Front brake caliper 4. Loosen: • Axle nut 5. Remove: • Axle nut • Front wheel axle • Front wheel assembly • Speedometer gear (EW50) or speed sensor (EW50N) • Collar • Front wheel • Brake disc NOTE: Never depress the brake lever when the wheel is off the scooter. Otherwise the brake pads will be forced out.

CAUTION: Handle the wheel with care not to damage the brake disc. If the brake disc is damaged, replace it.

EAS00523

DISASSEMBLING THE FRONT WHEEL 1. Remove: • Oil seal • Wheel bearings

4-3

FRONT WHEEL AND BRAKE DISC

CHAS

a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver.

NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface.

2

1

c. Remove the wheel bearings 1 with a general bearing puller 2.

2. Remove: • Collar

2

1

EAS00525

CHECKING THE FRONT WHEEL 1. Check: • Wheel axle Roll the wheel axle on a flat surface.

Bends → Replace.

WARNING Do not attempt to straighten a bent wheel axle.

2. Check: • Tire • Front wheel Damage/wear → Replace.

Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3.

3. Measure: • Radial wheel runout 1 • Lateral wheel runout 2 Over the specified limits → Replace.

Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.04 in)

4-4

FRONT WHEEL AND BRAKE DISC

CHAS

4. Check: • Wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings.

• Oil seals Damage/wear → Replace.

5. Replace: • Wheel bearings New • Oil seals New a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver.

NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface.

2

1

c. Remove the wheel bearings 1 with a general bearing puller 2.

2

1

d. Install the new wheel bearings and oil seals in the reverse order of disassembly.

CAUTION: Do not contact the wheel bearing inner race 1 or balls 2. Contact should be made only with the outer race 3.

NOTE: Use a socket that matches the diameter of the wheel bearing outer race and oil seal.

5. Inspect: • Collar Wear/Damage → Replace collar and oil seal as set.

4-5

FRONT WHEEL AND BRAKE DISC

CHAS

EAS00528

CHECKING THE BRAKE DISC 1. Check: • Brake disc Damage/galling → Replace.

2. Measure: • Brake disc deflection Out of specification → Inspect wheel runout.

If wheel runout is in good condition, correct the brake disc deflection or replace the brake disc.

Brake disc deflection limit (maximum) 0.15 mm (0.006 in) a. Place the scooter on a suitable stand so that the front wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary. c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the deflection 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) below the edge of the brake disc.

3. Measure: • Brake disc thickness Measure the brake disc thickness at a few different locations.

Out of specification → Replace.

Brake disc thickness limit (minimum) 3.0 mm (0.12 in) 4.

• a. b. c.

Adjust: Brake disc deflection Remove the brake disc.

Rotate the brake disc by one bolt hole.

Install the brake disc.

NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.

4-6

FRONT WHEEL AND BRAKE DISC

CHAS

Brake disc bolt 23 Nm (2.3 m · kg, 16.6 ft · lb) d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.

23 Nm (2.3 m·kg, 16.6 ft·lb)

EAS00535

CHECKING THE SPEEDOMETER GEAR UNIT (EW50) 1. Check: • Speedometer clutch Bends/damage/wear → Replace.

1

2. Check: • Speedometer drive gear 1 • Speedometer driven gear 2 Damage/wear → Replace the speedometer gear unit.

2

340004(a)

EAS00535

CHECKING THE SPEED SENSOR UNIT (EW50N) 1. Check: • Speedometer clutch (Wheel side) Bends/damage/wear → Replace.

2. Check: • Speedometer drive 1 • Hall sensor 2 Damage/wear → Replace the speed sensor unit.

4-7

FRONT WHEEL AND BRAKE DISC

CHAS

EAS00539

ASSEMBLING THE FRONT WHEEL 1. Install: • Wheel bearings • Oil seals New a. Install the new wheel bearings and oil seals in the reverse order of disassembly.

CAUTION: Do not contact the wheel bearing inner race 1 or balls 2. Contact should be made only with the outer race 3.

NOTE: Use a socket that matches the diameter of the wheel bearing outer race and oil seal.

EAS00542*

INSTALLING THE FRONT WHEEL 1. Lubricate: • Wheel axle • Wheel bearings • Oil seal lips • Speedometer drive gear • Speedometer driven gear 23 Nm (2.3 m·kg, 16.6 ft·lb)

Recommended lubricant Lithium soap base grease 2. Install: • Brake disc Brake disc bolt 23 Nm (2.3 m · kg, 16.6 ft · lb) NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.

3. Install: • Speedometer gear unit or speed sensor unit NOTE: Make sure the speedometer gear unit or speed sensor unit and the wheel hub are installed with the two projections meshed into the two slots respectively.

4-8

FRONT WHEEL AND BRAKE DISC

CHAS

4. Install: • Front wheel

1

NOTE: Make sure the slots 1 in the speedometer gear unit or speed sensor unit fits over the stopper on the outer tube.

WARNING Be sure to assemble the front wheel as shown.

Difference between A and B < 3 mm

5. Tighten: • Wheel axle • Brake caliper bolts Wheel axle 35 Nm (3.5 m · kg, 25.3 ft · lb) Brake caliper bolt 23 Nm (2.3 m · kg, 16.6 ft · lb) WARNING Make sure the brake hose is routed properly.

CAUTION: Before tightening the axle nut, stroke the front fork several times to check for proper fork operation.

EAS00548

ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the front wheel static balance should be adjusted.

• Adjust the front wheel static balance with the brake disc installed.

4-9

FRONT WHEEL AND BRAKE DISC 1.

• 2.

•

CHAS

Remove: Balancing weight(s) Find: Front wheel’s heavy spot

NOTE: Place the front wheel on a suitable balancing stand.

X1

X1

X1

1

a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. c. Turn the front wheel 90° so that the “X1” mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an “X2” mark at the bottom of the wheel. f. Repeat steps (c) through (f) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest is the front wheel’s heavy spot “X”.

3. Adjust: • Front wheel static balance a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”.

NOTE: Start with the lightest weight.

X

b. Turn the front wheel 90° so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced.

X

X

X

X

4.Check: • Front wheel static balance a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it.

X

4 - 10

REAR WHEEL AND BRAKE

CHAS

EAS00555

REAR WHEEL AND BRAKE

104 Nm (10.4 m·kg, 75.2 ft·lb)

Order

I

1 2 3 4 5 6 7 8 9

Job/Part Q’ty Remarks Removing the rear wheel and the Remove the parts in the order listed. rear brake Battery cover Refer to “COVERS AND PANELS” in chapter 3.

Exhaust pipe Refer to “ENGINE” in Chapter 5.

NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.

Remove:

Rear axle nut (Nylstop) Plate Washer Rear wheel Brake shoe/brake shoe spring Plate washer Adjuster Brake cable Compression spring Pin

1 1 1 2/2 1 1 1 1 1

4 - 11

Refer to “INSTALLING THE FRONT WHEEL”.

REAR WHEEL AND BRAKE

CHAS

104 Nm (10.4 m·kg, 75.2 ft·lb)

Order 10 11 12

Job/Part Camshaft lever Wear indicator Brake camshaft

Q’ty 1 1 1

Remarks Refer to “INSTALLING THE REAR BRAKE”.

NOTE: If the scooter is equipped with brake shoes with a pin on one side, be sure to install the brake shoe with the pin orientated outwards.

For installation, reverse the removal procedure.

4 - 12

REAR WHEEL AND BRAKE

CHAS

EAS00565

CHECKING THE REAR WHEEL 1. Check: • Wheel axle • Rear wheel Refer to “FRONT WHEEL”.

2. Check: • Tire • Rear wheel Damage/wear → Replace.

Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3.

3. Measure: • Radial wheel runout 1 • Lateral wheel runout 2 Refer to “FRONT WHEEL”.

Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.04 in)

EAS00569

CHECKING THE BRAKE The following procedure applies to all of the brake shoes.

1. Check: • Brake shoe lining Glazed areas → Repair.

Sand the glazed areas with course sandpaper.

NOTE: After sanding the glazed areas, clean the brake shoe with a cloth.

2. Measure: • Brake shoe lining thickness @ Out of specification → Replace.

Brake shoe lining thickness limit (minimum) 2.0 mm (0.08 in) WARNING Do not allow oil or grease to contact the brake shoes.

@

NOTE: Replace the brake shoes as a set, if either is worn to the wear limit.

346007

4 - 13

REAR WHEEL AND BRAKE

CHAS

3. Measure: • Brake drum inside diameter a Out of specification → Replace the wheel.

Brake drum inside diameter limit (maximum) 110.5 mm (4.35 in)

a

346008

4. Check: • Brake drum inner surface Oil deposits → Clean.

Remove the oil with a rag soaked in lacquer thinner or solvent.

Scratches → Repair.

Lightly and evenly polish the scratches with an emery cloth.

5. Check: • Brake camshaft Damage/wear → Replace.

WARNING When inspecting the brake lining, do not spill oil or grease on the brake lining.

2 LS

1 346009

INSTALLING THE REAR BRAKE Reverse the removal procedure.

Note the following points.

1. Install: • Brake camshaft 1 NOTE: Apply lithium soap base grease onto the brake camshaft 1 and pin 2.

CAUTION: After installing the brake camshaft, remove the excess of grease.

2. Install: • Tension springs 2 • Brake shoes 1 NOTE: The brake shoes pin 3 must be orientated outwards (if the scooter is equipped with brake shoe with pin on one side).

CAUTION: When installing the springs and the brake shoes, take care not to damage the springs.

4 - 14

REAR WHEEL AND BRAKE

CHAS

3.

• • a.

Install: Wear indicator 1 Camshaft lever 2 Align the projection 1 on the wear indicator with the camshaft notch and install. b. Align the punch marks 2. c. Check the proper position of the brake shoe.

INSTALLING THE REAR WHEEL Reverse the removal procedure.

Note the following points.

1. Clean: • Rear wheel axle

2.

• • • •

Install: Plain washer 1 Rear wheel Plain washer 2 Axle nut 3

1 T.

Rear axle nut: 104 Nm (10.4 m · kg, 75.2 ft · lb)

R.

346012

3

2

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

3. Install: • Muffler

T.

R.

4.

• • • • 5.

•

4 - 15

Bolt (exhaust pipe/with engine): 8.5 Nm (0.85 m · kg, 6.1 ft · lb) Bolt (exhaust pipe with cylinder): 29 Nm (2.9 m · kg, 21 ft · lb)

Install: Pin Compression spring Brake cable Adjuster Adjust: Rear brake lever free play Refer to “ADJUSTING THE REAR BRAKE” in Chapter 3.

FRONT BRAKE

CHAS

EAS00576

FRONT BRAKE FRONT BRAKE PADS

Order I 1 2 3 4

Job/Part Removing the front brake pads Remove: Retaining clip Retaining pin Pad spring Brake pad

Q’ty Remarks 1 Remove the parts in the order listed.

1 1 1 2

Refer to “BRAKE PAD REPLACEMENT”.

For installation, reverse the removal procedure.

4 - 16

FRONT BRAKE

CHAS

EAS00579

CAUTION: Disc brake components rarely require disassembly.

Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary.

• If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.

• Never use solvents on internal brake components.

• Use only clean or new brake fluid for cleaning brake components.

• Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any split brake fluid immediately.

• Avoid brake fluid coming into contact with the eyes as it can cause serious injury.

FIRST AID FOR BRAKE FLUID ENTERING THE EYES: Flush with water for 15 minutes and get immediate medical attention.

Recommended brake component replacement schedule: Brake pads

If necessary

Brake hose

Every two years

Brake fluid

Every two years or whenever the brake is disassembled

WARNING All internal parts should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort.

4 - 17

FRONT BRAKE

CHAS

BRAKE PAD REPLACEMENT NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads.

1. Remove: • Brake pads NOTE: • Do not depress the brake lever when the wheel is off the scooter otherwise the brake pads will be forced shut.

• Install new brake pad springs when the brake pads have to be replaced.

• Replace the pads as a set if either is found to be worn to the wear limit 1.

Wear limit 1: 3.1 mm (0.12 in) 2. Push the caliper piston into the brake caliper by finger.

CAUTION: When pushing the caliper piston into the brake caliper, brake fluid level in reservoir tank is increasing higher.

3.

• • 4.

•

Install: Brake pads New Pad spring New Inspect: Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” section in Chapter 3.

5. Check: • Brake level inspection Soft spongy feeling - Bleed the brake system.

Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” section in Chapter 3.

4 - 18

FRONT BRAKE

CHAS

EAS00584

FRONT BRAKE MASTER CYLINDER

Order

Job/Part Qâ&#x20AC;&#x2122;ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Drain the brake fluid

I 1 2 3 4 5

Remove: Brake switch Brake lever Union bolt Copper washer/Brake hose Master cylinder bracket

II 6

Remove: Master cylinder

1 1 2 4/1 1

1 For installation, reverse the removal procedure.

4 - 19

FRONT BRAKE

CHAS

EAS00590

CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: • brake master cylinder Damage/scratches/wear → Replace.

• brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air.

2. Check: • brake master cylinder reservoir 1 Cracks/damage → Replace the master cylinder.

• brake master cylinder reservoir diaphragm 2 Damage/wear → Replace cap and diaphragm.

3. Check: • brake hoses Cracks/damage/wear → Replace.

346014(a)

4 - 20

FRONT BRAKE

CHAS

EAS00596

INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • brake master cylinder • brake master cylinder bracket NOTE: • Install the brake master cylinder holder with the “FORWARD” mark pointed forward.

• Position the front brake lever in the middle of the handle switch notch.

T.

R.

2.

• • •

Brake master cylinder bracket screw: 8.5 Nm (0.85 m · kg, 6.1 ft · lb)

Install: copper washers New brake hose union bolt

T.

Union bolt 23 Nm (2.3 m · kg, 16.6 ft · lb)

R.

WARNING Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING” in Chapter 2.

NOTE: • While holding the brake hose, tighten the union bolt as shown.

• Turn the handlebar to the left and to the right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary.

4 - 21

FRONT BRAKE

CHAS

3. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT #3 or DOT #4 WARNING • Use only the designated brake fluid.

Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

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

• When refilling, be careful that water does not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any split brake fluid immediately.

1

4. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.

5. Check: • brake fluid level Below the minimum level mark 1 → Add the recommended brake fluid to the proper level.

Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3.

6. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system.

Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.

4 - 22

FRONT BRAKE

CHAS

EAS00612

FRONT BRAKE CALIPER

23 Nm (2.3 m·kg, 16.6 ft·lb)

23 Nm (2.3 m·kg, 16.6 ft·lb)

Order

Job/Part Removing the front brake caliper Drain the brake fluid

Q’ty

I 1 2 3 4

Remove: Union bolt Copper washer Brake hose Copper washer

1 1 1 1

II 5

Remove: Brake caliper

1

Remarks Remove the parts in the order listed.

For installation, reverse the removal procedure.

4 - 23

CHAS

FRONT BRAKE EAS00631

CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule: Brake pads

If necessary

Brake hose

Every two years

Brake fluid

Every two years or whenever the brake is disassembled

1. Check: • brake caliper Cracks/damaged/wear → Replace brake caliper.

2. Check: • brake caliper bracket 1 Cracks/damage → Replace.

the

EAS00635

INSTALLING THE FRONT BRAKE CALIPER WARNING Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid.

Recommended brake fluid DOT #3 or DOT #4 1. Install: • brake caliper 1 (temporarily) • copper washers New • brake hose 2 • union bolt 3

T.

Union bolt 23 Nm (2.3 m · kg, 16.6 ft · lb)

R.

WARNING Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING” in chapter 2.

4 - 24

FRONT BRAKE 2.

• 3.

• • • • •

CHAS

Remove: brake caliper Install: brake pads 1 brake pads spring 2 brake pads retaining pin 3 brake pads retaining clip 4 brake caliper 5 Refer to “BRAKE PAD REPLACEMENT”.

T.

Brake caliper bolt 23 Nm (2.3 m · kg, 16.6 ft · lb)

R.

4. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT #3 or DOT #4 WARNING • Use only the designated brake fluid.

Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

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

• When refilling, be careful that water does not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any split brake fluid immediately.

4 - 25

FRONT BRAKE

1

CHAS

5. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.

6. Check: • brake fluid level Below the minimum level mark 1 → Add the recommended brake fluid to the proper level.

Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3.

7. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system.

Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.

4 - 26

FRONT FORK

CHAS

EAS00646

FRONT FORK FRONT FORK

23 Nm (2.3 m·kg, 16.6 ft·lb)

Order

Job/Part Removing the front fork leg Front wheel

Q’ty

I 1 2

Remove: Caliper assembly Front fender

1 1

II 3 4 5 6

Remove: Front fork leg cap Clip Pinch bolt Front fork leg

2 2 2 2

Remarks Remove the parts in the order listed.

Refer to “FRONT WHEEL AND BRAKE DISC”.

Refer to “REMOVING THE FRONT FORK LEGS”.

For installation, reverse the removal procedure.

4 - 27

FRONT FORK

CHAS

30 Nm (3.0 m·kg, 21.6 ft·lb)

Order 1 2 3 4 5 6 7 8 9

Job/Part Disassembling the front fork legs Clip Front fork cap O-ring Fork spring Dust seal Oil seal clip Damper rod bolt/copper washer Damper rod/damper rod spring Inner tube

Q’ty 2 2 2 2 2 2 2 2 2

4 - 28

Remarks Remove the parts in the order listed.

FRONT FORK

CHAS

30 Nm (3.0 m·kg, 21.6 ft·lb)

Order 0 A

Job/Part Oil flow stopper Oil seal

Q’ty 1 2

Remarks

For assembly, reverse the disassembly procedure.

4 - 29

FRONT FORK

CHAS

EAS00649

REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

1. Stand the scooter on a level surface.

WARNING Securely support the scooter so that there is no danger of it falling over.

NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.

2. Loosen: • lower bracket pinch bolts WARNING Before loosening the lower bracket pinch bolts, support the front fork leg.

3. Remove: • front fork leg

EAS00652

DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

1. Remove: • fork spring 2. Remove: • dust seal 1 • oil seal clip 2 (with a flathead screwdriver) CAUTION: Do not scratch the inner tube.

4 - 30

FRONT FORK

CHAS

3. Drain: • fork oil NOTE: Stroke the outer tube several times while draining the fork oil.

4.

• • •

Remove: damper rod assembly bolt 1 damper rod rebound spring

NOTE: While holding the damper rod assembly with the damper rod holder 3 and T-handle 2, loosen the damper rod assembly bolt.

Damper rod holder 90890-01294 T-handle 90890-01326

5. Remove: • inner tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully.

CAUTION: • Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced.

• Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4 - 31

FRONT FORK

CHAS

EAS00657

CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace.

WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

2. Measure: • spring free length a Out of specification → Replace.

Spring free length 253 mm (9.961 in) <Limit>: 228 mm (8.976 in)

3. Check: • damper rod 1 Damage/wear → Replace.

Obstruction → Blow out all of the oil passages with compressed air.

• oil flow stopper 2 Damage → Replace.

CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material.

• When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.

4 - 32

FRONT FORK

CHAS

EAS00659

ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

WARNING • Make sure the oil levels in both front fork legs are equal.

• Uneven oil levels can result in poor handling and a loss of stability.

NOTE: • When assembling a front fork leg, be sure to replace the following parts: - copper washer - o-ring - oil seal - dust seal • Before assembling a front fork leg, make sure all of the components are clean.

1. Install: • damper rod assembly 1 • rebound spring 2

1

2

3

CAUTION: Allow the damper rod assembly to slide slowly down the inner tube 3 until it protrudes from the bottom of the inner tube.

Be careful not to damage the inner tube.

2. Lubricate: • inner tube’s outer surface Recommended lubricant Fork oil 10W or equivalent

3. Install: • oil flow stopper 1 (on damper rod end 2) • inner tube 3 (into the outer tube 4)

4 - 33

FRONT FORK

CHAS

4. Install: • copper washer 1 New • damper rod bolt 2

5. Tighten: • damper rod assembly bolt 1 LT T.

R.

30 Nm (3.0 m · kg, 21.6 ft · lb)

NOTE: While holding the damper rod assembly with the damper rod holder 2 and T-handle 3, tighten the damper rod assembly bolt.

Damper rod holder 90890-01294 T-handle 90890-01326

4 - 34

FRONT FORK

CHAS

6. Install: • oil seal 1 New (with the fork seal driver weight 2 and fork seal driver attachment 3) CAUTION: Make sure the numbered side of the oil seal faces up.

Fork seal driver weight 90890-01367 Fork seal driver attachment (ø33) 90890-01368 NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease.

• Lubricate the outer surface of the inner tube with fork oil.

• Before installing the oil seal, cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation.

7. Install: • oil seal clip 1 NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove.

8. Install: • dust seal 1 (with the fork seal driver weight 2) Fork seal driver weight 90890-01367

4 - 35

FRONT FORK

CHAS

9. Fill: • front fork leg (with the specified amount of the recommended fork oil) Recommended oil Yamaha fork and shock oil 10W or equivalent Quantity (each front fork leg) 115 cm3 (7.02 cu · in) NOTE: • While filling the front fork leg, keep it upright.

• After filling, slowly stroke the front fork leg up and down to distribute the fork oil.

10.Install: • spring 1 NOTE: • Install the spring with the smaller pitch facing up.

• Before installing the spring seat, lubricate its O-ring with grease.

EAS00663

INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

1. Install: • front fork leg • lower bracket pinch bolts NOTE: Pull up the inner tube until it stops, and then tighten the lower bracket pinch bolts.

4 - 36

HANDLEBAR

CHAS

HANDLEBAR EW50 Model

60 Nm (6.0 m·kg, 43.4 ft·lb)

Order

I

II 1 2 3 4 5 6

Job/Part Removing the handlebar Handlebar covers Front covers

Q’ty

Disconnect: Brake stop switch Handlebar switch

2 2

Remove: Rear view mirror Brake stop switch Front master cylinder Right handlebar switch Throttle cable Throttle grip assembly

1 2 1 1 1 1

4 - 37

Remarks Remove the parts in the order listed.

Refer to “COVERS AND PANELS” in Chapter 3.

HANDLEBAR

CHAS

60 Nm (6.0 m·kg, 43.4 ft·lb)

Order 7 8 9 10 11

Job/Part Rear brake cable Starter cable Handlebar switch (left) Left handle grip Handlebar

Q’ty 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

4 - 38

HANDLEBAR

CHAS

EW50N Model

19 Nm (1.9 m·kg, 13.7 ft·lb)

Order

I

II 1 2 3 4 5 6

Job/Part Removing the handlebar

Q’ty

Disconnect: Brake stop switch Handlebar switch Multi function display Front turn signal light

2 2 1 2

Remove: Rear view mirror Brake stop switch Front master cylinder

1 2 1

Handlebar switch (right) Throttle cable Throttle grip assembly

1 1 1

4 - 39

Remarks Remove the parts in the order listed.

Refer to “FRONT BRAKE MASTER CYLINDER“.

Refer to “INSTALLING THE HANDLEBAR (EW50N)“.

HANDLEBAR

CHAS

19 Nm (1.9 m·kg, 13.7 ft·lb)

Order 7 8 9 10 11 12 13 14

Job/Part Multi-function display Rear brake cable Starter cable Handlebar switch (left) Left handle grip Front turn signal light Upper handlebar holder Handlebar

Q’ty 1 1 1 1 1 2 2 1

Remarks

Refer to “INSTALLING THE HANDLEBAR (EW50N)”.

For installation, reverse the removal procedure.

4 - 40

HANDLEBAR

CHAS

EAS00666

REMOVING THE HANDLEBAR GRIP 1. Stand the motorcycle on a level surface.

WARNING Securely support the scooter so that there is no danger of it falling over.

2. Remove: • handlebar grip NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

EAS00668

EW50

CHECKING THE HANDLEBAR 1. Check: • handlebar Bends/cracks/damage → Replace.

WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken it.

EW50N

2. Install: • handlebar grip a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.

WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried.

4 - 41

HANDLEBAR

CHAS

EAS00673

INSTALLING THE HANDLEBAR (EW50) 1. Stand the scooter on a level surface.

WARNING Securely support the scooter so that there is no danger of it falling over.

2. Install: • handlebar NOTE: Install the handlebar onto the steering shaft notch.

CAUTION: • Before installing the handlebar, wipe off any trace of oil from the inserted section of the shaft with solvent.

• Insert the bolt from the left as shown.

3. Tighten: • handlebar holder

T.

Handlebar holder bolt 60 Nm (6.0 m · kg, 43.7 ft · lb)

R.

4. Fasten: • wire harness (to the handlebar bracket) Refer to “CABLE ROUTING” in chapter 2.

5. Install: • left handlebar switch NOTE: Align the projection on the left handlebar switch with the hole in the handlebar.

T.

Left handlebar switch bolt 7 Nm (0.7 m · kg, 5.1 ft · lb)

R.

• Starter cable • Rear brake cable

4 - 42

HANDLEBAR LS

1

CHAS

6. Install: • throttle cable 1 • throttle grip assembly NOTE: • Lubricate the inside of the throttle grip with a thin coat of lithium soap base grease and install it onto the handlebar.

• Apply lithium soap base grease onto the cable end and throttle cable support.

7. Install: • right handlebar switch WARNING Make sure smoothly.

the

throttle

grip

operates

NOTE: Align the projection on the right handlebar switch with the hole a in the handlebar.

Right handlebar switch bolt 7 Nm (0.7 m · kg, 5.1 ft · lb) 8. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.

Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.0 mm (0.06 ~ 0.12 in)

4 - 43

HANDLEBAR

CHAS

9. Install: • master cylinder • master cylinder bracket NOTE: • Install the brake master cylinder holder with the “FORWARD” mark pointed forward 1.

• Position the front brake lever in the middle of the handle switch notch.

T.

Front master cylinder bolt 8.5 Nm (0.85 m · kg, 6.1 ft · lb)

R.

10.Install: • brake stop switch 11.Connect: • brake stop switches connectors • Handlebar switches connectors 12.Fasten: • cables and wires Refer to “CABLE ROUTING” in chapter 2.

4 - 44

HANDLEBAR

CHAS

EAS00673

INSTALLING THE HANDLEBAR (EW50N) 1. Stand the scooter on a level surface.

WARNING Securely support the scooter so that there is no danger of it falling over.

2. Install: • handlebar • Upper handlebar holders NOTE: Install the handlebar onto the lower handlebar holder.

CAUTION: Before installing the handlebar, wipe off any trace of oil from the inserted section of the shaft with solvent.

3. Tighten: • Upper handlebar holders

T.

Upper handlebar holder bolt 19 Nm (1.9 m · kg, 13.7 ft · lb)

R.

4. Fasten: • wire harness (to the handlebar bracket) Refer to “CABLE ROUTING” in chapter 2.

5. Install: • Front turn signal lights

T.

Front turn signal light bolt 9.75 Nm (1.0 m · kg, 7.2 ft · lb)

R.

• Left handle grip • Left handlebar switch

T.

Left handlebar switch bolt 7 Nm (0.7 m · kg, 5.1 ft · lb)

R.

NOTE: Align the projection on the left handlebar switch with the hole in the handlebar.

4 - 45

HANDLEBAR

CHAS

• Starter cable • Rear brake cable • Multi function display NOTE: Align the projection on the multifunction display with the hole in the handlebar.

T.

Multi-function display bolt 4.0 Nm (0.4 m · kg, 2.9 ft · lb)

R.

LS

1

6. Install: • throttle cable 1 • throttle grip assembly NOTE: • Lubricate the inside of the throttle grip with a thin coat of lithium soap base grease and install it onto the handlebar.

• Apply lithium soap base grease onto the cable end and throttle cable support.

7. Install: • right handlebar switch WARNING Make sure smoothly.

the

throttle

grip

operates

NOTE: Align the projection on the right handlebar switch with the hole a in the handlebar.

T.

R.

4 - 46

Right handlebar switch bolt 7 Nm (0.7 m · kg, 5.1 ft · lb)

HANDLEBAR

CHAS

8. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.

Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.0 mm (0.06 ~ 0.12 in) 9. Install: • master cylinder • master cylinder bracket NOTE: • Install the brake master cylinder holder with the “FORWARD” mark pointed forward a.

• Position the front brake lever in the middle of the handle switch notch.

T.

Front master cylinder bolt 8.5 Nm (0.85 m · kg, 6.1 ft · lb)

R.

10.Install: • brake stop switches • Rear view mirror 11.Connect: • brake stop switches connectors • Handlebar switches connectors 12.Fasten: • cables and wires Refer to “CABLE ROUTING” in chapter 2.

4 - 47

LOWER HANDLEBAR HOLDER

CHAS

LOWER HANDLEBAR HOLDER (EW50N only)

31 Nm (3.1 m·kg, 22.8 ft·lb)

31 Nm (3.1 m·kg, 22.8 ft·lb)

Order Removing holder

I 1 2 3

Job/Part the lower

Handlebar Remove: Handlebar holder cover Lower handlebar holder Handlebar holder bracket

Q’ty handlebar

Remarks Remove the parts in the order listed.

Refer to “HANDLEBAR”.

1 2 1

For installation, reverse the removal procedure.

4 - 48

STEERING HEAD

CHAS

EAS00675

STEERING HEAD

75 Nm (7.5 m·kg, 54.2 ft·lb)

First step: 38 Nm (3.8 m·kg, 27.5 ft·lb) 2nd step: Loosen the ring nut 1/4 turn.

3rd step:

22 Nm (2.2 m·kg, 15.9 ft·lb)

Order

Job/Part Removing the lower bracket

Q’ty

Remarks Remove the parts in the order listed.

WARNING Securely support the scooter so that there is no danger of it falling over.

I 1 2 3 4 5 6

Front fork Handlebar Remove: Ring nut (upper) Lock washer Ring nut (center) Rubber washer Ring nut (lower) Bearing cover

Refer to “FRONT FORK”.

Refer to “HANDLEBAR”.

1 1 1 1 1 1

4 - 49

Refer to “REMOVING THE LOWER BRACKET”.

STEERING HEAD

CHAS

75 Nm (7.5 m·kg, 54.2 ft·lb)

First step:

38 Nm (3.8 m·kg, 27.5 ft·lb) 2nd step: Loosen the ring nut 1/4 turn.

3rd step:

22 Nm (2.2 m·kg, 15.9 ft·lb)

Order 7 8 9 10 11 12 13

Job/Part Upper bearing inner race Lower bracket Upper bearing Lower bearing Upper bearing outer race Lower bearing outer race Lower bearing inner race

Q’ty 1 1 1 1 1 1 1

Remarks

Refer to “REMOVING THE LOWER BRACKET”.

For installation, reverse the removal procedure.

4 - 50

STEERING HEAD

CHAS

EAS00680

REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface.

WARNING Securely support the scooter so that there is no danger of it falling over.

2.

• • 3.

• • •

Remove: upper ring nut 1 lock washer 2 Remove: center ring nut 3 rubber washer 4 lower ring nut 5

NOTE: Hold the lower ring nut 1 with the steering nut wrench 2, and then remove the center ring nut with the ring nut wrench.

Ring nut wrench 90890-01268 Steering nut wrench 90890-01403 WARNING Securely support the lower bracket so that there is no danger of it falling.

EAS00682

CHECKING THE STEERING HEAD 1. Wash: • bearing balls • bearing races Recommended cleaning solvent Kerosene 2. Check: • bearing balls 1 • bearing races 2 Damage/pitting → Replace.

4 - 51

STEERING HEAD

CHAS

3. Replace: • bearing balls • bearing races ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel and hammer. c. Install a new dust seal and new bearing races. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged.

354008

NOTE: • Always replace the bearing balls and bearing races as a set.

• Whenever the steering head is disassembled, replace the dust seal.

4. Check: • lower bracket (along with the steering stem) Bends/cracks/damage → Replace.

354009

EAS00684

LS

INSTALLING THE STEERING HEAD 1. Lubricate: • upper bearing • lower bearing • bearing races Recommended lubricant Lithium soap base grease 2.

• • • • •

4 - 52

Install: lower ring nut rubber washer center ring nut lock washer upper ring nut Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3.

REAR SHOCK ABSORBER ASSEMBLY

CHAS

EAS00685

REAR SHOCK ABSORBER ASSEMBLY

Order

I 1

Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Rear covers Refer to “COVERS AND PANELS” in chapter 3.

Remove: Rear shock absorber 1

For installation, reverse the removal procedure.

4 - 53

REAR SHOCK ABSORBER ASSEMBLY

CHAS

EAS00695

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly.

• rear shock absorber Oil leaks → Replace the rear shock absorber assembly.

• spring Damage/wear → Replace the rear shock absorber assembly.

• bushings Damage/wear → Replace.

• dust seals Damage/wear → Replace.

• bolts Bends/damage/wear → Replace.

4 - 54

ENG

5

ENG CHAPTER 5 OVERHAULING THE ENGINE ENGINE ........................................................................................................... 5-1 LEADS AND HOSES (EU1 models).......................................................... 5-1 ENGINE (EU1 models).............................................................................. 5-3 LEADS AND HOSES (EU2 models).......................................................... 5-4 ENGINE (EU2 models).............................................................................. 5-6 CYLINDER HEAD............................................................................................ 5-7 CHECKING THE CYLINDER HEAD ......................................................... 5-8 CYLINDER AND PISTON................................................................................ 5-9 REMOVING THE CYLINDER AND PISTON........................................... 5-10 CHECKING THE CYLINDER AND PISTON ........................................... 5-10 CHECKING THE PISTON RINGS...........................................................5-12 PISTON PIN AND PISTON PIN BEARING INSPECTION ......................5-13 INSTALLING THE PISTON AND CYLINDER .........................................5-14 BELT DRIVE.................................................................................................. 5-16 REMOVING THE PRIMARY PULLEY.....................................................5-19 REMOVING THE SECONDARY PULLEY AND V-BELT ........................5-19 DISASSEMBLING THE SECONDARY PULLEY ....................................5-20 CHECKING THE V-BELT ........................................................................5-20 CHECKING THE PRIMARY PULLEY WEIGHTS ...................................5-21 CHECKING THE SECONDARY PULLEY ...............................................5-21 ASSEMBLING THE PRIMARY PULLEY .................................................5-23 ASSEMBLING THE SECONDARY PULLEY ..........................................5-24 INSTALLING THE BELT DRIVE .............................................................5-25 KICKSTARTER .............................................................................................5-27 KICKSTARTER ....................................................................................... 5-27 CHECKING THE KICKSTARTER ...........................................................5-28 INSTALLING THE KICKSTARTER .........................................................5-28 STARTER CLUTCH AND GENERATOR...................................................... 5-29 REMOVING THE GENERATOR .............................................................5-31 CHECKING THE STARTER CLUTCH ....................................................5-31 INSTALLING THE GENERATOR............................................................5-32 INSTALLING THE STARTER CLUTCH ..................................................5-33 OIL PUMP......................................................................................................5-35 CHECKING THE OIL PUMP ...................................................................5-36 INSTALLING THE OIL PUMP ................................................................. 5-36

ENG CRANKSHAFT ..............................................................................................5-37 CRANKSHAFT ASSEMBLY ....................................................................5-37 DISASSEMBLING THE CRANKCASE....................................................5-39 CHECKING THE CRANKSHAFT AND CONNECTING ROD .................5-40 CHECKING THE BEARINGS AND OIL SEALS ......................................5-40 CHECKING THE CRANKCASE ..............................................................5-41 ASSEMBLING THE CRANKCASE..........................................................5-41 TRANSMISSION............................................................................................5-43 REMOVING THE TRANSMISSION ........................................................ 5-44 CHECKING THE TRANSMISSION .........................................................5-44 INSTALLING THE TRANSMISSION .......................................................5-45

OVERHAULING THE ENGINE

ENG

EAS00188

OVERHAULING THE ENGINE ENGINE LEADS AND HOSES (EU1 models)

6

1

5

4

3

2 FW

Order

1 2

D

Job/Part Disconnecting the leads and hoses Seat Fuel tank covers Rear side covers Air filter Carburetor Negative battery lead Positive battery lead

Q’ty

Remarks Disconnect the parts in the order listed.

Refer to “COVERS AND PANELS” in chapter 3.

Refer to “CARBURETOR” in chapter 6.

1 1

5-1

CAUTION: • First disconnect the negative battery lead, and then the positive battery lead.

• For connecting, reverse the disconnection procedure.

OVERHAULING THE ENGINE

ENG

6

1

5

4

3

2 FW

Order 3 4 5 6

D

Job/Part AC Magneto coupler Starter motor coupler Spark plug cap Oil hose

Qâ&#x20AC;&#x2122;ty Remarks 1 disconnect 1 disconnect 1 1 NOTE: Plug the hose to prevent oil spillage.

For installation, reverse the removal procedure.

5-2

OVERHAULING THE ENGINE

ENG

ENGINE (EU1 models)

50 Nm (5.0 m·kg, 36.2 ft·lb)

Order

Job/Part Removing the engine Rear brake cable

1 2 3 4

Exhaust pipe Gasket Rear shock absorber lower bolt Engine mounting bolt

5

Engine

Q’ty

1 1 1 1

Remarks Remove the parts in the order listed.

Refer to “REAR WHEEL AND BRAKE” in chapter 4.

NOTE: Place a suitable stand under the frame.

For installation, reverse the removal procedure.

5-3

OVERHAULING THE ENGINE

ENG

LEADS AND HOSES (EU2 models)

7

6

5 1

4

2

3

D

FW

Order

1

Job/Part Disconnecting the leads and hoses Seat Fuel tank covers Rear side covers Air filter Carburetor Negative battery lead

Q’ty

Remarks Disconnect the parts in the order listed.

Refer to “COVERS AND PANELS” in chapter 3.

Refer to “CARBURETOR” in chapter 6.

CAUTION: • First disconnect the negative battery lead, and then the positive battery lead.

• For connecting, reverse the disconnection procedure.

5-4

OVERHAULING THE ENGINE

ENG

7

6

5 1

4

2

3

D

FW

Order 2 3 4 5 6 7

Job/Part Positive battery lead AC Magneto coupler Starter motor coupler Spark plug cap Oil hose Air induction hose

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1

Remarks disconnect disconnect NOTE: Plug the hose to prevent oil spillage.

For installation, reverse the removal procedure.

5-5

OVERHAULING THE ENGINE

ENG

ENGINE (EU2 models)

50 Nm (5.0 m·kg, 36.2 ft·lb)

Order

Job/Part Removing the engine Rear brake cable

1 2 3 4

Exhaust pipe Gasket Rear shock absorber lower bolt Engine mounting bolt

5

Engine

Q’ty

1 1 1 1

Remarks Remove the parts in the order listed.

Refer to “REAR WHEEL AND BRAKE” in chapter 4.

NOTE: Place a suitable stand under the frame.

For installation, reverse the removal procedure.

5-6

CYLINDER HEAD

ENG

EAS00222

CYLINDER HEAD

20 Nm (2.0 m·kg, 14.5 ft·lb)

Order

Job/Part Removing the cylinder head Rear side covers

Q’ty

Exhaust pipe I 1

Remove: • Cylinder cover • the cylinder head nuts

1 1 1

2 3

• Spark plug cap • Spark plug

1 1

II 4 5

Remove: • Cylinder head • Cylinder head gasket

1 1

5-7

Remarks Remove the parts in the order listed.

Refer to “COVERS AND PANELS” in chapter 3.

Refer to “ENGINE”.

NOTE: Loosen the nuts in the proper sequence as shown.

Loosen each nut 1/2 of a turn at a time.

After all of the nuts are fully loosened, remove them.

For installation, reverse the removal procedure.

CYLINDER HEAD

ENG

EAS00222

CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper 1)

1

NOTE: Do not use a sharp instrument to avoid damaging or scratching the spark plug bore thread.

2. Check: • cylinder head 1 Damage/scratches → Replace.

1

301050

3. Measure: • cylinder head warpage Out of specification → Resurface the cylinder head.

1 2

Cylinder head warpage limit 0.05 mm (0.002 in) a. Place a straight edge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows. d. Place a 400 → 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern.

NOTE: To ensure an even surface, rotate the cylinder head several times.

5-8

CYLINDER AND PISTON

ENG

EAS00251

CYLINDER AND PISTON

5

E

4

E

3

3

6

1

2

Order

Job/Part Removing the cylinder and piston Rear side covers

Q’ty

I 1 2 II 3

Exhaust pipe Cylinder head Remove: • Cylinder • Cylinder gasket Remove: • Piston pin clip

2

4

• Piston pin

1

5

• Piston

1

6

• Piston pin bearing

1 1

Remarks Remove the parts in the order listed.

Refer to “COVERS AND PANELS” in chapter 3.

Refer to “ENGINE”.

Refer to “CYLINDER HEAD”.

NOTE: Cover the crankcase to prevent the clip to fall in it.

CAUTION: Don’t use a hammer to drive out the piston pin.

For installation, reverse the removal procedure.

5-9

CYLINDER AND PISTON

ENG

EAS00253

4 1

2 1

REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 • piston pin bearing 4

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

NOTE: • Before removing the piston pin clip 1, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.

• Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller 4.

1

Piston pin puller 90890-01304 2. Remove: • top ring • 2nd ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.

EAS00255

CHECKING THE CYLINDER AND PISTON 1. Check: • piston wall • cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set.

307052

5 - 10

CYLINDER AND PISTON

ENG

2. Measure: • piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge.

NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements.

Cylinder bore gauge 90890-03016 Cylinder bore “C” 39.993 ~ 40.012 mm (1.5745 ~ 1.5753 in) Taper limit “T” 0.05 mm (0.002 in)

D1 D2

“C” = maximum of D1 ~ D2 D3

D5

D4

“T” = maximum of D1 or D2 - maximum of D5 or D6 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer.

D6

Micrometer 90890-03007 @ 5 mm from the bottom edge of the piston

@

Piston size “P” Standard 39.952 ~ 39.969 mm (1.5729 ~ 1.5736 in)

307052

5 - 11

CYLINDER AND PISTON 2

3

ENG

d. If out of specification, replace the piston (1) and piston rings (2 and 3) as a set. e. Calculate the piston-to-cylinder clearance with the following formula.

Piston-to-cylinder clearance = Cylinder bore “C” Piston skirt diameter “P” Piston-to-cylinder clearance : 0.036 ~ 0.049 mm (0.0014 ~ 0.0019 in) <Limit>: 0.1 mm (0.004 in)

1 307053

f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

EAS00263

CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance 1 Out of specification → Replace the piston and piston rings as a set.

NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves 1 and piston rings.

1

Piston ring side clearance Top ring 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in) <Limit>: 0.10 mm (0.004 in) 2nd ring 0.03 ~ 0.05 mm (0.0012 ~ 0.0020) <Limit>: 0.11 mm (0.0043 in) 2. Install: • piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown.

5 - 12

CYLINDER AND PISTON

ENG

3. Measure: • piston ring end gap Use a feeler gauge.

Out of specification → Replace the piston rings as a set.

a

Piston ring end gap Top ring 0.15 ~ 0.30 mm (0.0059 ~ 0.1181 in) <Limit>: 0.55 mm (0.0217 in) 2nd ring 0.15 ~ 0.30 mm (0.0059 ~ 0.1181 in) <Limit>: 0.65 mm (0.0256 in)

YP402202

PISTON PIN AND PISTON PIN BEARING INSPECTION 1. Inspect: • Piston pin 1 Blue discoloration/Groove → Replace, then inspect lubrication system.

1

307050

2. Measure: • Outside diameter (piston pin) Out of specification → Replace

a

Outside diameter (piston pin): 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in) <Limit>: 9.976 mm (0.3927 in) 307009

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

b

Piston pin-to-piston clearance = Bore (piston pin29) b Outside diameter (piston pin) a

307010

5 - 13

CYLINDER AND PISTON

ENG

Piston pin-to-piston clearance : 0.008 ~ 0.019 mm (0.00031 ~ 0.00075)

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

EAS00267

1

INSTALLING THE PISTON AND CYLINDER 1. Install: • dowel pins 1 • top ring • 2nd ring NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.

• Make sure the rings ends are properly fitted around the ring locating pinsin the piston grooves.

2 4

3 4 1 307002(a)

2

3

2.

• • • •

Install: piston 1 piston pin bearing 2 piston pin 3 Piston pin clip 4 New

NOTE: Lubricate the piston pin with engine oil.

Make sure the arrow mark on the piston points towards the exhaust side of the cylinder.

Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase.

3.

• • •

Lubricate: piston 1 piston rings 2 and 3 cylinder (with the recommended lubricant) Recommended lubricant Engine oil

1 307053

5 - 14

CYLINDER AND PISTON

ENG

4. Install: • cylinder gasket New • cylinder 1 NOTE: While compressing the piston rings with one hand, install the cylinder with the other hand.

1

307054 T.

R.

5 - 15

Cylinder bolt 10 Nm (1.0 m · kg, 7.2 ft · lb)

BELT DRIVE

ENG

EAS00316

BELT DRIVE

45 Nm (4.5 m·kg, 32.5 ft·lb)

40 Nm (4.0 m·kg, 28.9 ft·lb)

30 Nm (3.0 m·kg, 21.6 ft·lb)

Order

Job/Part Removing the belt drive Rear side covers

Q’ty

Crankcase cover (left)/gasket A I 1 2 3 4 5 6 7

Primary sheave Remove: • Primary sheave nut • Washer • One way clutch • Special washer • Primary fixed sheave • V-belt • Spacer

8

• Primary sliding sheave

Remarks Remove the parts in the order listed.

Refer to “COVERS AND PANELS” in chapter 3.

Refer to “KICKSTARTER”.

NOTE: To loosen the primary sheave nut, hold the AC magneto with the flywheel holder.

Flywheel holder: 90890-01235 Refer to “STARTER CLUTCH AND GENERATOR”.

For installation, reverse the removal procedure.

5 - 16

BELT DRIVE

ENG

45 Nm (4.5 m·kg, 32.5 ft·lb)

40 Nm (4.0 m·kg, 28.9 ft·lb)

30 Nm (3.0 m·kg, 21.6 ft·lb)

Order B

9 10 11

Job/Part Removing the belt drive Secondary sheave Remove: • Secondary sheave nut • Housing • Secondary sheave

Q’ty

1 1 1

Remarks Remove the parts in the order listed.

NOTE: To loosen the secondary sheave nut, hold the secondary sheave with the holder.

Sheave holder : 90890-01701

II

Attach: • Clutch

Sheave holder : 90890-01701

5 - 17

BELT DRIVE

ENG

45 Nm (4.5 m·kg, 32.5 ft·lb)

40 Nm (4.0 m·kg, 28.9 ft·lb)

30 Nm (3.0 m·kg, 21.6 ft·lb)

Order III 12 IV V

Job/Part Loosen: • Clutch securing nut Remove: • Clutch Attach:

Q’ty

VI 12 13 14

• Clutch Remove: • Clutch securing nut • Clutch shoe • Clutch shoe spring

1 2 2

15 16 17 18 19

• Clutch spring • Spring seat • Guide pin • Secondary sliding sheave • Secondary fixed sheave

1 1 1 1 1

Remarks WARNING Loosen the nut, do not remove it yet.

Clutch spring holder : 90890-01337

5 - 18

Refer to “STARTER CLUTCH AND GENERATOR”.

For installation, reverse the removal procedure.

BELT DRIVE

ENG

EAS00317

2

REMOVING THE PRIMARY PULLEY 1. Remove: • primary pulley nut 1 • washer • primary fixed sheave 2

3

1 319035(a)

NOTE: While holding the primary fixed sheave with the flywheel holder 3, loosen the primary fixed sheave nut.

Flywheel holder 90890-01235

EAS00318

REMOVING THE SECONDARY PULLEY AND V-BELT 1. Remove: • secondary pulley nut 1 • clutch housing 2 • secondary pulley

2

3

NOTE: While holding the clutch housing 2 with the sheave holder 3, loosen the secondary pulley nut 1.

1

Sheave holder 90890-01701 2. Loosen: • clutch shoe plate nut 1 WARNING

3

Do not remove the clutch shoe plate nut at this stage.

2 NOTE: While holding the clutch carrier with the sheave holder 2, loosen the clutch carrier nut one full turn with the locknut wrench 3.

319031(a)

5 - 19

BELT DRIVE

ENG

3. Remove: • V-belt NOTE: Remove the V-belt from the primary sheave side first, then from the secondary sheave.

EAS00319

DISASSEMBLING THE SECONDARY PULLEY NOTE: Install the clutch spring holder 1 and clutch spring holder arm 2 onto the secondary pulley as shown. Then, compress the spring, and remove the clutch shoe plate nut 3.

Clutch spring holder 90890-01337

4

6

5 1 3 2

1.

• • • • • • •

Remove: clutch shoe plate nut clutch assembly 1 clutch spring 2 clutch sprint seat 3 guide pin 4 secondary sliding sheave 5 secondary fixed sheave 6

EAS00320

CHECKING THE V-BELT 1. Check: • V-belt 1 Cracks/damage/wear → Replace.

Grease/oil → Check the primary and secondary pulleys.

1

312001(b)

2. Measure: • V-belt width @ Out of specification → Replace.

@

V-belt width 16.5 mm (0.65 in) <Limit>: 14.9 mm (0.587 in) 312001(a)

5 - 20

BELT DRIVE

ENG

EAS00321

CHECKING THE PRIMARY PULLEY WEIGHTS The following procedure applies to all of the primary pulley weights.

1 319024(a)

1. Check: • primary pulley weight 1 Cracks/damage/wear → Replace.

2. Measure: • primary pulley weight outside diameter 1 Out of specification → Replace.

Primary pulley weight outside diameter 15.0 mm (0.59 in) <Limit>: 14.5 mm (0.57 in)

1 319008

3. Check: • primary sliding sheave 1 • primary fixed sheave 2 Wear/Crack/Scratch/Damage → Replace.

1

2

EAS00322

1

2

3

CHECKING THE SECONDARY PULLEY 1. Check: • secondary fixed sheave 1 • secondary sliding sheave 2 Cracks/damage/wear → Replace the secondary fixed and sliding sheaves as a set.

• Oil seal 3 Damage → Replace.

2. Check: • torque cam groove 1 Damage/wear → Replace the secondary fixed and sliding sheaves as a set.

3

2

1

319010

5 - 21

BELT DRIVE

ENG

3. Check: • guide pin 2 Damage/wear → Replace the secondary fixed and sliding sheaves as a set.

3

2

1

319010

4. Check : • O-ring 3 Damage → Replace.

5. Measure: • clutch spring free length Out of specification → Replace.

3

2

1

EU1 model Clutch spring free length: 121.7 mm (4.791 in) <Limit> 115.6 mm (4.551 in)

319010

EU2 model Clutch spring free length: 134.3 mm (5.287 in) <Limit> 127.6 mm (5.023 in) 6. Inspect: • clutch housing inner surface Oil/Scratches → Clean/repair.

Use a rag soaked in lacquer thinner or solvent.

Oil

Scratches

319030

Use an emery cloth lightly and evenly polishing.

7. Measure: • clutch housing inside diameter @ Out of specification → Replace.

Clutch housing inside diameter: 107.0 mm (4.212 in) <Wear Limit>: 107.2 mm (4.220 in)

5 - 22

BELT DRIVE

ENG

8. Check: • clutch shoe 1 Glazed parts → Sand with coarse sandpaper.

2

NOTE: After using the sand paper, clean off the polished particles with a cloth.

1 319050

• clutch shoe spring free length 2 Out of specification → Replace as a set.

2

Clutch shoe spring free length: 29 mm (1.14 in)

1 319050

9. Check: • clutch shoe thickness a Out of specification → Replace

a

Clutch shoe thickness: 2.0 mm (0.08 in) <Wear Limit>: 1.0 mm (0.04 in)

a a EAS00323

5

1

2

3

4 319024

13

2

1

3

ASSEMBLING THE PRIMARY PULLEY 1. Clean: • primary sliding sheave 1 • primary fixed sheave 2 • collar 3 • weight 4 • primary sliding sheave cam surface 5 2. Install: • primary pulley weights 1 • cam 2 • slider 3 • collar 4 3. Check: • cam operation Unsmooth operation → Repair

4 1

3

5 - 23

BELT DRIVE

ENG

4. Install: • primary sheave assembly 1 • collar 2

1

2 EAS00324

ASSEMBLING THE SECONDARY PULLEY 1. Lubricate: • secondary fixed sheave’s inner surface 1 • secondary sliding sheave’s inner surface 2 • oil seal New • o-ring New (with the recommended lubricant)

1

2

319018

Recommended lubricant BEL-RAY assembly lube® 2. Install: • secondary sliding sheave 1

1

319019

3

2

1

NOTE: • Install the secondary sliding sheave onto the secondary fixed sheave with the oil seals.

• Wind adhesive tape around the end of the fixed sheave to avoid turning over the oil seal lips when installing the sheave.

3. Install: • guide pin 1 4.

• • •

319020

Lubricate: guide pin groove 2 o-ring 3 New oil seal New (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube®

5 - 24

BELT DRIVE

ENG

5. Check: • sliding sheave Unsmooth operation → Repair CAUTION: Remove excessive grease.

319010(a)

6. Install: • clutch securing nut Use the clutch spring holder 1.

1

Clutch spring holder: 90890-01337

319021

7. Tighten: • clutch securing nut 1 Use sheave holder Sheave holder 90890-01701 Clutch securing nut 45 Nm (4.5 m · kg, 32.5 ft · lb) EAS00325

1

2

INSTALLING THE BELT DRIVE 1. Install: • V-belt 1 • clutch assembly 2 CAUTION: Do not allow grease to contact the V-belt, secondary pulley or clutch assembly.

319028(b)

NOTE: Install the V-belt and clutch assembly onto the primary pulley side.

5 - 25

BELT DRIVE 2.

• 3.

•

2

Install: clutch housing Tighten clutch housing nut 1 T.

R.

1

2

1

ENG

40 Nm (0.4 m · kg, 28.9 ft · lb)

NOTE: Tighten the clutch housing nut with the sheave holder 2.

319023

Sheave holder 90890-01701

3

4. Position: • V-belt 1 Tense the V-belt by turning the primary sheave several times.

319028(c)

NOTE: Position the V-belt in the primary pulley 2 (when the pulley is at its widest position) and in the secondary pulley 3 (when the pulley is at its narrowest position), and make sure the Vbelt is tight.

5 - 26

ENG

KICKSTARTER EAS00338

KICKSTARTER KICKSTARTER

10

11

9

G

LS

1

5 8 7 6 3

4 2

Order

1 2 3 4 5 6 7 8 9 10 11

Job/Part Removing the Kickstarter Rear side covers Kick crank Crankcase cover (left) Crankcase gasket Dowel pin Ratchet Clip Circlip Plain washer Spacer Kick shaft Return spring

Q’ty

1 1 1 2 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed.

Refer to “COVERS AND PANELS” in chapter 3.

NOTE: To remove the kick shaft, unhook the return spring first.

For installation, reverse the removal procedure.

5 - 27

KICKSTARTER

ENG

EAS00339

CHECKING THE KICKSTARTER 1. Check: • ratchet gear 1 • kickstarter ratchet 2 Damage/wear → Replace.

317005

2. Check: • kickstarter spring Damage/wear → Replace.

• Mating dogs (kick pinion gear b and oneway clutch a) Rounded edges/damage → Replace

3. Measure: • kickstarter pinion gear clip force 1 (with the spring gauge 2) Out of specification → Replace the kickstarter pinion gear clip.

Kickstarter pinion gear clip force 150 ~ 250 g (5.3 ~ 8.8 oz.)

317007

EAS00340

3 2

4

5

1

317014

INSTALLING THE KICKSTARTER 1. Install: • return spring 1 • kickstarter shaft 2 • collar 3 • washer 4 • Circlip 5 NOTE: Turn the kickstarter spring clockwise and install its end into the hole 1 in the crankcase.

2. Hook: • return spring (to the kick gear and boss) 3. Install: • kick pinion gear 1.

317015

NOTE: Install the clamp as shown.

5 - 28

STARTER CLUTCH AND GENERATOR

ENG

EAS00341

STARTER CLUTCH AND GENERATOR 35 Nm (3.5 m·kg, 25.3 ft·lb)

Order

Job/Part Q’ty Remarks Removing the starter clutch and Remove the parts in the order listed. generator Rear side covers Refer to “COVERS AND PANELS” in chapter 3.

I 1

Remove: • Generator motor nut

1

2 3

• Plate washer • Rotor (flywheel)

1 1

4

• Woodruff key

1

5 6

• Stator assembly • Gasket

1 1

5 - 29

Flywheel holder: 90890-01235 Flywheel puller: 90890-01189

For installation, reverse the removal procedure.

STARTER CLUTCH AND GENERATOR

ENG

35 Nm (3.5 m·kg, 25.3 ft·lb)

Order II 7 8 9 10 11 12 13 14 15 16

Job/Part Remove: Primary pulley • Starter motor • O-ring • Plate • Shaft • Idle gear • Starter clutch • Spacer • Bearing • Starter wheel gear • Washer

Q’ty

1 1 1 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed.

Refer to “BELT DRIVE”.

Refer to “INSTALLING THE STARTER CLUTCH”.

For installation, reverse the removal procedure.

5 - 30

STARTER CLUTCH AND GENERATOR

ENG

EAS00346

REMOVING THE GENERATOR 1. Remove: • generator rotor bolt 1 • washer

2

1

321004

NOTE: While holding the generator rotor with the sheave holder 2, loosen the generator rotor bolt. Do not allow the sheave holder to touch the projection on the generator rotor.

Sheave holder 90890-01235 2. Remove: • generator rotor 1 (with the flywheel puller set 2) • woodruff key

2

1 Flywheel puller set 90890-01362 3. Remove: • stator assembly 1 • gasket

1 321001(a)

EAS00348

CHECKING THE STARTER CLUTCH 1. Check: • starter clutch Push the dowel pin in arrow direction.

Unsmooth operation → Replace starter clutch assembly.

317008

2. Check: • starter wheel gear teeth 1 • idle gear teeth 2 Chips/pitting/roughness/wear → Replace the defective part(s).

• Bearing 3 Pitting/Damage → Replace.

317009

5 - 31

STARTER CLUTCH AND GENERATOR

ENG

3. Check: • starter clutch operation

317011

a. Install the starter clutch drive gear 4 onto the starter clutch 5 and hold the starter clutch. b. When turning the starter clutch drive gear clockwise, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear counterclockwise, it should turn freely, otherwise the starter clutch is faulty and must be replaced.

EAS00354

INSTALLING THE GENERATOR 1. Install: • gasket New 2. Lubricate: • oil seal 1 with lithium soap base grease.

3. Pass the CDI magneto lead 2 through the crankcase hole.

2 1 LS 321001

4. Install: • stator assembly 1.

T.

Screw (stator assembly) 8 Nm (0.8 m · kg, 5.8 ft · lb)

R.

1 321001(a)

4

5.

• • • •

Install: woodruff key 1 generator rotor 2 plain washer 3 nut 4

NOTE: Clean the tapered portion of the crankshaft and the generator rotor hub.

When installing the generator rotor, make sure the woodruff key is properly seated in the key way of the crankshaft.

2 1

3

321002

5 - 32

STARTER CLUTCH AND GENERATOR

ENG

6. Tighten: • generator rotor nut 1 NOTE: While holding the generator rotor with the sheave holder 2, tighten the generator rotor bolt.

Do not allow the sheave holder to touch the projection on the generator rotor.

2 1

321050

Sheave holder 90890-01235

T.

Generator rotor nut 35 Nm (3.5 m · kg, 25.3 ft · lb)

R.

INSTALLING THE STARTER CLUTCH 1. Install: • collar 1 • washer 2 • bearing 3 • starter wheel gear • starter clutch 317010(a)

NOTE: • Apply lithium soap base grease to the bearing.

• Apply molybdenum bisulfide oil to the shaft (starter clutch) 2.

• • • •

Install: plain washer 1 idle gear 2 plain washer 3 plate (idle gear) 4

NOTE: Apply engine oil to the idle gear 2.

T.

R.

5 - 33

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

STARTER CLUTCH AND GENERATOR

ENG

3. Install: • starter motor 1

1 LS

T.

Screw (starter motor) 8 Nm (0.8 m · kg, 5.8 ft · lb)

R.

NOTE: Apply lithium soap base grease to the O-ring of the starter motor.

317013

5 - 34

OIL PUMP

ENG

EAS00360

OIL PUMP

Order

Job/Part Removing the oil pump Rear side covers

Q’ty

Generator I 1

Remove: • Autolube oil pump assembly

II 2 3 4 5

Remove: • Circlips • Pump drive gear • Pin • Circlips

Remarks Remove the parts in the order listed.

Refer to “COVERS AND PANELS” in chapter 3.

Refer to “STARTER CLUTCH AND GENERATOR”.

Refer to “INSTALLING THE OIL PUMP”.

For installation, reverse the removal procedure.

5 - 35

OIL PUMP

ENG

EAS00363

CHECKING THE OIL PUMP Wear or an internal malfunction may cause the pump output to vary from the factory setting.

This situation is, however, extremely rare. If improper output is suspected, inspect the following: 1. Inspect: • delivery line Obstructions → Blow out.

• O-ring Wear/Damage → Replace.

2. Inspect: • autolube pump drive gear teeth 1 • autolube pump driven gear teeth 2 Pitting/Wear/Damage → Replace.

1 2 314003

EAS00376

INSTALLING THE OIL PUMP 1. Install: • circlips 1 • pin 2 • pump drive gear 3 • circlips 4

12 3

4 314004

2.

• 3.

•

Lubricate: O-ring 1 with lithium soap base grease.

Install: Autolube oil pump 2

T.

Oil pump bolt 3 Nm (0.3 m · kg, 2.2 ft · lb)

R.

4. Lubricate: • autolube pump gear (1 and 2) with lithium soap base gear Lithium soap base grease: 15 cc (0.92 cu · in)

1

2 314006(a)

5 - 36

CRANKSHAFT

ENG

EAS00381

CRANKSHAFT CRANKSHAFT ASSEMBLY

Order

Job/Part Removing the crankshaft assembly Cylinder head Cylinder and piston V-belt, primary and secondary pulley Starter clutch and generator

Q’ty

Oil pump Rear wheel Transmission I 1 2

Remove: • Oil seal stopper • Screws

1 6

5 - 37

Remarks Remove the parts in the order listed.

Refer to “CYLINDER HEAD”.

Refer to “CYLINDER AND PISTON”.

Refer to “BELT DRIVE”.

Refer to “STARTER CLUTCH AND GENERATOR”.

Refer to “OIL PUMP”.

Refer to “REAR WHEEL AND BRAKE” in chapter 4.

Refer to “TRANSMISSION”.

CRANKSHAFT

Order II

Job/Part Install • Crankcase separating tool

III 3

Remove: • Crankcase (right)

IV

Install • Crankcase separating tool

V 4

Remove • Crankshaft assembly

Q’ty

ENG

Remarks Crankcase separating tool: 90890-01135

1

Crankcase separating tool: 90890-01135 1

For installation, reverse the removal procedure.

5 - 38

CRANKSHAFT

ENG

EAS00385

DISASSEMBLING THE CRANKCASE 1. Remove: • oil seal stopper 1 • crankcase screws 2

2 2 1

NOTE: Loosen each screw one quart of turn before beginning to remove them.

313009(a)

2. Attach: • crankcase separating tool 1 Crankcase separating tool 90890-01135 NOTE: Fully tighten the tool holding bolts. Insure that the tool body is parallel with the case. If necessary, loosen one screw as much as required to level the tool body.

3. Remove: • crankcase (right) 1 As pressure is applied, keep tapping carefully on the engine mounting bosses.

1

CAUTION: 313050

Use a soft hammer to tap on the case. Tap only on reinforced spots of the case. Never tap on the gasket mating surfaces. Work slowly and carefully. Make sure the cases separate evenly. If one end “hang up” 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 remaining case screw or fitting. Do not force.

4. Attach: • Crankcase separating tool 1 Crankcase separating tool : 90890-01135 5. Remove: • Crankshaft 2

5 - 39

CRANKSHAFT

ENG

EAS00394

CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: • crankshaft runout “C” Out of specification → Replace the crankshaft, bearing or both.

308001(a)

NOTE: Turn the crankshaft slowly.

T.

Maximum crankshaft runout 0.03 mm (0.001 in)

R.

2. Measure: • big end side clearance “D” Out of specification → Replace the big end bearing, crankshaft pin, or connecting rod.

308001(b) T.

Big end side clearance 0.2 ~ 0.5 mm (0.008 ~ 0.020 in)

R.

3. Measure: • crankshaft width “A” Out of specification → Replace the crankshaft.

T.

R.

Crankshaft width 37.90 ~ 37.95 mm (1.492 ~ 1.494 in)

308001(c)

EAS00401

2

1 1 2

308050

CHECKING THE BEARINGS AND OIL SEALS 1. Check: • bearings 1 Clean and lubricate the bearings, then rotate the inner race with your finger.

Rough movement → Replace.

2. Check: • oil seals 2 Damage/wear → Replace.

5 - 40

CRANKSHAFT

ENG

EAS00399

CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent.

2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces.

3. Check: • crankcase Cracks/damage → Replace.

313006

EAS00402

CHECKING THE CIRCLIPS AND WASHERS 1. Check: • circlips Bends/damage/looseness → Replace.

• washers Bends/damage → Replace.

EAS00416

ASSEMBLING THE CRANKCASE CAUTION:

1 34

2

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

1. Attach: • crankshaft installation tool 1, 2, 3, 4 Crankshaft installation tool: 1 90890-01274 2 90890-01275 3 90890-01277 4 90890-01411 2. Install: • crankshaft (to left crankcase) NOTE: Hold the connecting rod at top lead center with one hand while tightening the nut of the installation tool with the other. Tighten the installation tool until the crankshaft bottoms against the bearing.

NOTE:

5 - 41

CRANKSHAFT 3.

• • 4.

•

ENG

Install: dowel pin 1 spacer 2 Lubricate: the mating surfaces of the both case halves.

HEATPROOF or Yamaha Bond N° 1215

5. Attach: • crankshaft installation tool 1, 2, 3, 4 Crankshaft installation tool: 1 90890-01274 2 90890-01275 3 90890-01277 4 90890-01411

1

4

3

2

NOTE: Hold the connecting rod at top lead center with one hand while tightening the nut of the installation tool with the other. Tighten the installation tool until the crankshaft bottoms against the bearing.

6.

• 7.

•

Check: right crankcase Tighten: crankcase holding screws 1

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

1

Crankcase holding screw: 13 Nm (1.3 m · kg, 9.4 ft · lb)

1

313009(B)

8. Check: • crankcase operation Unsmooth → Repair CAUTION: Never hit on the crankcase.

9. Install: • oil seal stopper plate 1

1

Oil seal stopper plate: 8 Nm (0.8 m · kg, 5.8 ft · lb) 313009(c)

5 - 42

TRANSMISSION

ENG

EAS00419

TRANSMISSION

Order

I 1 2 3 4 5 6 7 II 8 9

Job/Part Removing the transmission.

Rear side cover Secondary sheave Remove • Transmission case • Gasket • Dowel pin • Drive shaft • Main shaft • Plate washer • Conical spring washer Remove • Oil seal • Secondary sheave axle

Q’ty

Remarks Remove the parts in the order listed.

Refer to “COVERS AND PANELS” in chapter 3.

Refer to “BELT DRIVE”.

1 1 2 1 1 1 1 1 1

5 - 43

For installation, reverse the removal procedure.

TRANSMISSION

ENG

EAS00420

REMOVING THE TRANSMISSION 1. Remove: • transmission case 1 • gasket • dowel pin

1

319036

2.

• • • •

2

Remove: drive shaft 1 main shaft 2 plate washer 3 conical spring washer 4

1

3

2

4 319037

3. Remove: • oil seal 1 • secondary sheave axle 2

1

319032

EAS00423

CHECKING THE TRANSMISSION 1. Measure: • main axle runout 1 (with a centering device and dial gauge) Out of specification → Replace the main axle.

1 319005(a)

T.

Main axle deflection limit 0.08 mm (0.0031 in)

R.

2. Measure: • drive axle runout 1 (with a centering device and dial gauge) Out of specification → Replace the drive axle.

T.

R.

1

319005(b)

5 - 44

Drive axle deflection limit 0.08 mm (0.0031 in)

TRANSMISSION 3.

• • •

1

3 2

ENG

Check: secondary sheave axle bearing 1 main axle bearing 2 drive axle bearing 3 Spin the bearing inner race.

Excessive play/Roughness → Replace.

Pitting/Damage → Replace.

319038

EAS00428

2

3 1

INSTALLING THE TRANSMISSION 1. Lubricate: • transmission case cover bearing with 10W30 Type SE Motor oil 2. Install: • bearing 1 • oil seal 2 New • secondary sheave axle 3 NOTE: Apply lithium soap base grease onto the oil seal lips.

3. Check: • secondary sheave axle operation Unsmooth operation → Repair.

4. Lubricate: • main axle bearing • drive axle bearing with 10W30 Type SE Motor oil

2

1

3

4

5.

• • • •

Install: main axle 1 drive axle 2 conical spring washer 3 New plain washer 4 New

NOTE: • Apply lithium soap base grease onto the oil seal lips • Always use a new gasket.

5 - 45

TRANSMISSION 6.

• • •

Install: Gasket 1 New dowel pins 2 transmission case cover 3

T.

R.

5 - 46

ENG

screw (case cover): 6.5 Nm (0.65 m · kg, 4.7 ft · lb)

CARB

CARB CHAPTER 6 CARBURETOR CARBURETOR................................................................................................ 6-1 CARBURETOR DISASSEMBLY ............................................................... 6-2 CHECKING THE CARBURETOR ............................................................. 6-4 ASSEMBLING THE CARBURETOR ......................................................... 6-5 INSTALLING THE CARBURETOR ........................................................... 6-6 FUEL COCK .................................................................................................... 6-7 FUEL COCK INSPECTION ....................................................................... 6-7 CLEANING THE FUEL FILTER ................................................................ 6-7 REED VALVE .................................................................................................. 6-8 CHECKING THE REED VALVE ................................................................ 6-9 INSTALLING THE REED VALVE .............................................................. 6-9 AIR INDUCTION SYSTEM (EU2 models only)............................................6-10 AIR INJECTION....................................................................................... 6-10 CHECKING THE AIR INDUCTION SYSTEM..........................................6-11

CARB

CARBURETOR

CARB

EAS00480

CARBURETOR CARBURETOR

Order

1 2 3 4 5 6 7 8

Job/Part Removing the carburetor Air filter box Fuel hose Vacuum hose Oil delivery hose Choke cable Temperature compositor pipe Air filter joint Throttle cable Carburetor

Qâ&#x20AC;&#x2122;ty

1 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed.

Unhook

For installation, reverse the removal procedure.

6-1

CARBURETOR

CARB

EAS000483

CARBURETOR DISASSEMBLY

Order 1 2 3 4 5 6 7 8 9 0 A B C

Job/Part TEIKEI Carburetor disassembly Carburetor top Gasket Throttle valve spring Needle set Throttle valve Starter plunger spring Starter plunger Air screw Throttle stop screw Drain screw Float chamber Float chamber gasket Float pin

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 1 1 1 1 1 1

6-2

Remarks Remove the parts in the order listed.

CARBURETOR

Order D E F G H

Job/Part Float Needle valve Pilot jet Main jet Main nozzle

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1

CARB

Remarks

For installation, reverse the removal procedure.

6-3

CARBURETOR

CARB

EAS00485

CHECKING THE CARBURETOR 1. Check: • carburetor body 1 • float chamber • jet housing • fuel passages Durt/Obstruction → Clean Cracks/damage → Replace. a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air.

2. Check: • float chamber rubber gasket Cracks/damage/wear → Replace.

1

322006

3.

• • •

2 3

1

Check: main jet 1 needle jet 2 pilot jet 3 Contamination → Clean.

322012

4. Check: • float 2 Damage → Replace.

• needle valve 1 Wear/Contamination → Replace • gasket Damage → Replace.

2

1

322013

5. Check: • Throttle valve Damage/Wear → Replace.

6-4

CARBURETOR

1

CARB

6. Check: • Throttle valve free movement Unsmooth/Stickiness → Replace.

Insert the throttle valve 1 into the carburetor body 2 and check for smooth movement.

2

322015

7.

• • • •

Check: throttle stop screw 1 air screw 2 needle 3 starter plunger 4 Damage/Wear → Replace.

8. Measure: • needle valve • valve seat NOTE: The float height is factory-adjusted. Never try to adjust it yourself.

EAS00487

ASSEMBLING THE CARBURETOR CAUTION: Before assembling the carburetor, wash all of the parts in a petroleum-based solvent.

Always use a new gasket.

1.

• • • • •

Install: needle 2 clip 3 throttle valve 1 spring seat 4 spring Jet needle clip position: 3/5

6-5

CARBURETOR

CARB

2. Install: • throttle valve 1 • starter plunger NOTE: Align the groove 2 of the throttle valve with the projection 3 of the carburetor.

3. Install: • Carburetor

1

NOTE: Align projection 1 with projection 2.

2

322020

EAS00492

INSTALLING THE CARBURETOR 1. Adjust: engine idling speed Engine idling speed EU1 models 1,800 ~ 2,200 r/min EU2 models 1,100 ~ 2,300 r/min Refer to “ADJUSTING THE IDLING SPEED” in chapter 3.

2. Adjust: throttle cable free play

ENGINE

Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.0 mm (0.06 ~ 0.12 in) Refer to “ADJUSTING THE REAR BRAKE” in chapter 3.

6-6

FUEL COCK

CARB

FUEL COCK FUEL COCK INSPECTION 1. Stop the engine.

2. Remove: • Rearside covers Refer to “COVERS AND PANELS” in Chapter 3.

3. Inspect: • Fuel cock

1

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Fuel cock inspection steps: • Disconnect the fuel hose 1.

• Place the receptacle under the fuel hose end.

• If fuel stops flowing out in a few seconds, the fuel cock is in good condition.

If not, clean or replace the fuel cock.

• Disconnect the vacuum hose and breathe in through the vacuum hose, for vacuum.

• If fuel flows out of the fuel hose under vacuum and stops under non-vacuum, the fuel cock is in good condition.

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

322031

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

CLEANING THE FUEL FILTER The fuel filter 1 is fitted inside the fuel tank. If not in good condition, clean it or replace it.

6-7

REED VALVE

CARB

REED VALVE

Order

1 2

Job/Part Removing the reed valve Carburetor Carburetor joint Reed valve assembly

Q’ty

Remarks Remove the parts in the order listed.

Refer to “CARBURETOR”.

1 1

For installation, reverse the removal procedure.

6-8

REED VALVE

CARB

YP600051

CHECKING THE REED VALVE 1. Inspect: • Carburetor joint Damage/Cracks → Replace.

• Reed valve Fatigue/Cracks → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Inspection steps: • Visually inspect the reed valve.

NOTE: Correct reed valve should fit flush or nearly flush against valve seat.

• If in doubt as to sealing ability, apply suction to carburetor side of assembly.

• Leakage should be slight to moderate. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Measure: • Valve stopper height 1 Out of specification → Replace valve stopper.

Valve stopper height 1: 5.4 ~ 6.0 mm (0.212 ~ 0.236 in)

3. Measure: • Reed valve clearance 1 Out of specification → Replace reed valve.

1

Reed valve clearance 1: Less than 0.2 mm (0.008 in) 322024

INSTALLING THE REED VALVE Reserve the removal procedure.

Note the following points.

1.

• 2.

•

Install: Gasket New Tighten: Reed valve securing bolts T.

R.

8.5 Nm (0.85 m · kg, 6.1 ft · lb)

NOTE: Tighten the bolts gradually to avoid warping.

6-9

AIR INDUCTION SYSTEM (EU2 models only)

CARB

EAS05070

AIR INDUCTION SYSTEM (EU2 models only) AIR INJECTION

The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons.

When there is negative pressure at the exhaust port, the Air induction, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700 °C (1112 to 1292 °F).

1 Air induction filter element 2 Air induction valve 3 Exhaust system

6 - 10

AIR INDUCTION SYSTEM (EU2 models only)

CARB

CHECKING THE AIR INDUCTION SYSTEM 1. Check: • Hoses Loose connection → Connect properly Cracks/Damage → Replace • Pipes Cracks/Damage → Replace 2. Check: • Air induction valve assy.

Cracks/Damage → Replace • Air induction valve operation Does not operate → Replace ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Blow in the air induction valve hose. (from air filter) to check that air flow (see 1). b. Blow in the air induction valve hose (from exhaust system) to check that air doesn’t flow (see 2). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Check: • Air induction system air filter element Cracks/Damage → Replace Does not operate → Replace

6 - 11

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ELEC

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ELEC CHAPTER 7 ELECTRICAL COMPONENTS CHECKING SWITCH CONTINUITY................................................................ 7-3 CHECKING THE SWITCHES.......................................................................... 7-4 CHECKING THE BULBS AND BULB SOCKETS .......................................... 7-5 TYPES OF BULBS .................................................................................... 7-5 CHECKING THE CONDITION OF THE BULBS ....................................... 7-5 CHECKING THE CONDITION OF THE BULB SOCKETS ....................... 7-6 IGNITION SYSTEM ......................................................................................... 7-8 CIRCUIT DIAGRAM .................................................................................. 7-8 TROUBLESHOOTING ............................................................................ 7-10 ELECTRIC STARTING SYSTEM ..................................................................7-13 CIRCUIT DIAGRAM ................................................................................7-13 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................7-15 TROUBLESHOOTING ............................................................................ 7-16 STARTER MOTOR .................................................................................7-18 CHECKING THE STARTER MOTOR .....................................................7-19 ASSEMBLING THE STARTER MOTOR .................................................7-20 CHARGING SYSTEM....................................................................................7-21 CIRCUIT DIAGRAM ................................................................................7-21 TROUBLESHOOTING ............................................................................ 7-23 LIGHTING SYSTEM ......................................................................................7-25 CIRCUIT DIAGRAM ................................................................................7-25 TROUBLESHOOTING ............................................................................ 7-27 CHECKING THE LIGHTING SYSTEM (EW50) ......................................7-28 CHECKING THE LIGHTING SYSTEM (EW50N) ....................................7-30 SIGNALING SYSTEM ...................................................................................7-33 CIRCUIT DIAGRAM ................................................................................7-33 TROUBLESHOOTING ............................................................................ 7-35 CHECKING THE SIGNALING SYSTEM (EW50) ....................................7-36 CHECKING THE SIGNALING SYSTEM (EW50N) .................................7-41

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ELEC

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ELECTRICAL COMPONENTS

ELEC

EAS07290

ELECTRICAL COMPONENTS (EW50 model) 1 Warning oil level switch 2 Fuel sender 3 Main switch 4 Front and rear brake switch 5 Horn 6 Rectifier/regulator 7 Turn signal relay

8 Wire harness 9 Battery 0 Fuse A Starter relay B Starter motor C AC magneto D DC/CDI unit

7-1

E Ignition coil

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ELECTRICAL COMPONENTS EAS07290

(EW50N model) 0 Battery A Fuse B Starter relay C Stator motor D AC magneto E DC/CDI unit FIgnition coil

1 Warning oil level switch 2 Fuel sender 3 Main switch 4 Front and rear brake switch 5 Horn 6 Rectifier/regulator 7 Turn signal relay 8 Speed sensor 9 Wire harness

7-2

ELEC

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ELECTRICAL COMPONENTS

ELEC

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EAS07300

CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.

CAUTION: Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

Pocket tester 90890-03112 NOTE: • Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.

• When checking for continuity, switch back and forth between the switch positions a few times.

The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration.

NOTE: “ ” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position).

The example illustration on the left shows that: There is continuity between Grey (gy) and Red when the switch is set to “CHECK”.

There is continuity between Red and Brown when the switch is set to “ON”.

7-3

CHECKING THE SWITCHES

ELEC

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EAS07310

CHECKING THE SWITCHES Damage/wear → Repair or replace.

Improperly connected → Properly connect.

Incorrect continuity reading → Replace the switch.

Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.

1 Rear brake switch 2 Horn switch 3 Dimmer switch

4 Turn signal switch 5 Oil level sender 6 Main switch

7-4

7 Front brake switch 8 Start switch 9 Fuse

CHECKING THE BULBS AND BULB SOCKETS

ELEC

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EAS07330

CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals.

Damage/wear → Repair or replace the bulb, bulb socket or both.

Improperly connected → Properly connect.

No continuity → Repair or replace the bulb, bulb socket or both.

TYPES OF BULBS The bulbs used on this scooter are shown in the illustration on the left.

• Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb. The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise.

• Bulb C is used for turn signal and tail/brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise.

• Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out.

CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs.

1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

CAUTION: • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.

7-5

CHECKING THE BULBS AND BULB SOCKETS

ELEC

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• Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

2. Check: • bulb (for continuity) (with the pocket tester) No continuity → Replace.

Pocket tester 90890-03112 NOTE: Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity. b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3,and check the continuity. c. If either of the readings indicate no continuity, replace the bulb. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets.

1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace.

Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Install a good bulb into the bulb socket.

7-6

CHECKING THE BULBS AND BULB SOCKETS

ELEC

–

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b. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7-7

IGNITION SYSTEM EAS07340

IGNITION SYSTEM (EW50 model) CIRCUIT DIAGRAM

5 Main switch 6 Fuse 7 Battery

1 AC magneto (pickup coil) 2 DC-CDI unit 3 Ignition coil 4 Spark plug

7-8

ELEC

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IGNITION SYSTEM EAS07340

(EW50N model)

5 Main switch 6 Fuse 7 Battery

1 AC magneto (pickup coil) 2 DC-CDI unit 3 Ignition coil 4 Spark plug

7-9

ELEC

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IGNITION SYSTEM EAS07360

ELEC

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EAS07380

TROUBLESHOOTING

1. Fuse

The ignition system fails to operate (no spark or intermittent spark).

Check: 1. Fuse 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch 8. Pickup coil resistance 9. Wiring connections (of the entire ignition system)

• Check the fuse for continuity.

Refer to “CHECKING THE FUSE” in chapter 3.

• Is the fuse OK? NO

YES

• Replace the fuse.

EAS07390

2. Battery • Check the condition of the battery.

Refer to “CHECKING THE BATTERY” in chapter 3.

NOTE: • Before troubleshooting, remove the following part(s): 1. Front upper cover 2. Footrest board • Troubleshoot with the following special tool(s).

Electrolyte specific gravity 1,280 at 20 °C (68 °F) • Is the battery OK? YES

NO • Clean the battery terminals.

• Recharge or replace the battery.

Ignition checker: 90890-06754 Pocket tester: 90890-03112 EAS07400

3. Spark plug • Check the condition of the spark plug.

• Check the spark plug type.

• Measure the spark plug gap.

Refer to “CHECKING THE SPARK PLUG” in chapter 3.

Standard spark plug BR8HS (NGK) Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) • Is the spark plug in good condition, is it of the correct type, and is its gap within specification?

YES

NO Re-gap or replace the spark plug.

7 - 10

ELEC

IGNITION SYSTEM EAS07420

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EAS00744

4. Ignition spark gap

5. Spark plug cap resistance

• Disconnect the spark plug cap from the spark plug.

• Connect the ignition checker 1 as shown.

• Remove the spark plug cap from the spark plug lead.

• Connect the pocket tester (“Ω × 1k” range) to the spark plug cap as shown.

• Measure the spark plug cap resistance.

a

2 Spark plug cap • Set the main switch to “ ”.

• Measure the ignition spark gap.

• Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.

Spark plug cap resistance 5 KΩ at 20 °C (68 °F) • Is the spark plug cap OK? NO

YES

Minimum ignition spark gap 6.0 mm (0.24 in)

Replace the plug cap.

• Is there a spark and is the spark gap within specification?

spark

EAS07460

NO

YES

6. Ignition coil resistance • Disconnect the ignition coil connectors from the ignition coil terminals.

• Connect the pocket tester (Ω × 1) to the ignition coil as shown.

The ignition system is OK.

Positive tester probe → ground terminal Negative tester probe → terminal (orange)

• Measure the primary coil resistance.

Primary coil resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F)

7 - 11

ELEC

IGNITION SYSTEM • Connect the pocket tester (Ω × 1k) to the ignition coil as shown.

–

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EAS07480

8. Pickup coil resistance (AC magneto A) • Disconnect the pickup coil coupler from the wire harness.

• Connect the pocket tester (Ω × 100) to the pickup coil terminal as shown.

Positive tester probe → ground terminal Negative tester probe → spark plug lead

Positive tester probe → White/Blue (L) Negative tester probe → White/Red

• Measure the secondary coil resistance.

Secondary coil resistance 6.32 ~ 9.48 kΩ at 20 °C (68 °F) • Is the ignition coil OK

• Measure the pickup coil resistance.

NO

YES

Pickup coil resistance 248 ~ 372 Ω at 20 °C (68 °F) • Is the pickup coil OK?

Replace the ignition coil.

YES

NO

EAS07490

7. Main switch

Replace the pickup coil.

• Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the main switch OK?

EAS07540

9. Wiring NO

YES Replace switch.

the

• Check the entire ignition system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the ignition system’s wiring properly connected and without defects?

main

YES Replace the DC-CDI unit.

7 - 12

NO Properly connect or repair the ignition system’s wiring.

ELECTRIC STARTING SYSTEM

ELEC

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EAS07550

ELECTRIC STARTING SYSTEM (EW50 model) CIRCUIT DIAGRAM

2 DC-CDI unit 5 Main switch 6 Fuse

7 Battery 9 Starter relay 0 Starter motor

7 - 13

A Right handlebar switch A Start switch K Front brake switch L Rear brake switch

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ELECTRIC STARTING SYSTEM

ELEC

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(EW50N model)

2 DC-CDI unit 5 Main switch 6 Fuse

7 Battery 9 Starter relay 0 Starter motor

7 - 14

A Right handlebar switch A Start switch K Front brake switch L Rear brake switch

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ELECTRIC STARTING SYSTEM

ELEC

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EAS07560

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ ” the starter motor can only operate if at least one of the following conditions is met: • The front brake switch is ON. • The rear brake switch is ON. When at least one of the above conditions has been met the starter relay is closed and the engine can be started by pressing the starter switch.

1 Battery 2 Fuse 3 Main switch 4 Front brake switch 5 Rear brake switch 6 Starter relay 7 Start switch 8 DC-CDI unit 9 Starter motor 0 Sidestand circuit cut off jumper lead

7 - 15

ELECTRIC STARTING SYSTEM EAS07570

ELEC

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EAS07390

TROUBLESHOOTING

2. Battery

The starter motor fails to turn.

• Check the condition of the battery.

Refer to “CHECKING THE BATTERY” in chapter 3.

Check: 1. fuse 2. battery 3. starter motor 4. starter relay 5. main switch 6. start switch 7. wiring connections (of the entire starting system)

Electrolyte specific gravity 1,280 at 20 °C (68 °F) • Is the battery OK? NO

YES

NOTE: • Before troubleshooting, remove the following part(s): 1. Front upper cowling 2. Center cover 3. Footrest board 4. Upper handlebar cover (EW50) • Troubleshoot with the following special tool(s).

• Clean the battery terminals.

• Recharge or replace the battery.

EAS07580

3. Starter motor • Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3.

Pocket tester 90890-03112

EAS07380

1. Fuse • Check the fuse for continuity.

Refer to “CHECKING THE FUSE” in chapter 3.

• Is the fuse OK? YES

NO Replace the fuse.

WARNING • A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn.

• This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity.

• Does the starter motor turn?

YES

NO Repair or replace the starter motor.

7 - 16

ELECTRIC STARTING SYSTEM EAS07610

ELEC

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EAS07640

6. Start switch

4. Starter relay

• Check the start switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the start switch OK?

• Disconnect the starter relay coupler from the coupler.

• Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay coupler as shown.

YES

NO Replace the right handlebar switch.

EAS07660

7. Wiring • Check the entire starting system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the starting system’s wiring properly connected and without defects?

Positive battery terminal → Green/Yellow 1 Negative battery terminal → Blue (L)/White 2 Positive tester probe → Red 3 Negative tester probe → Red 4

YES Replace the DC-CDI unit.

• Does the starter relay have continuity between red and red?

NO

YES

Replace the starter relay.

EAS07490

5. Main switch • Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES. • Is the main switch OK? NO

YES Replace switch.

the

main

7 - 17

NO Properly connect or repair the starting system’s wiring.

ELECTRIC STARTING SYSTEM

ELEC

EAS07670

STARTER MOTOR 1 O-ring 2 Starter motor front cover 3 Rubber seal 4 Brush holder /brushes

5 Armature assembly 6 Starter motor rear cover

Brush wear limit: 2.5 mm (0.10 in) Commutator wear limit: 14.8 mm (0.58 in) Mica lower cut-off: 1.15 mm (0.05 in)

7 - 18

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ELECTRIC STARTING SYSTEM

ELEC

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EAS07690

CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper.

2. Measure: • commutator diameter a Out of specification → Replace the starter motor.

Commutator wear limit 14.8 mm (0.58 in) 3. Measure: • Mica undercut a Out of specification → Scrap the mica using hacksaw blade.

Mica undercut 1.15 mm (0.05 in) NOTE: Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator 4. Measure: • armature assembly resistances (commutator and insulation) Out of specification → Replace the starter motor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Measure the armature assembly resistances with the pocket tester.

Pocket tester 90890-03112 Armature coil Commutator resistance 1 0.064 ~ 0.079 Ω at 20 °C (68 °F) Insulation resistance 2 Above 1 MΩ at 20 °C (68 °F) b. If any resistance is out of specification, replace the starter motor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7 - 19

ELECTRIC STARTING SYSTEM

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5. Measure: • brush length a Out of specification → Replace the brushes as a set.

Brush length wear limit 2.5 mm (0.10 in)

EAS0772

ASSEMBLING THE STARTER MOTOR 1. Install: • brush set 1 • rubber seal 2 • starter motor front cover 3

2. Install: • Armature assembly • starter motor rear cover 1

3. Install: • Starter motor bolts 1 T.

R.

8 Nm (0.8 m · kg, 5.8 ft · lb)

NOTE: The ground terminal a must be installed on the upper screw.

7 - 20

CHARGING SYSTEM EAS07730

CHARGING SYSTEM (EW50 models) CIRCUIT DIAGRAM

1 AC Magneto (charging coil) 6 Fuse 7 Battery 8 Rectifier/regulator

7 - 21

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CHARGING SYSTEM (EW50N model)

1 AC Magneto (charging coil) 6 Fuse 7 Battery 8 Rectifier/regulator

7 - 22

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CHARGING SYSTEM

ELEC

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EAS07740

TROUBLESHOOTING

NO

YES

The battery is not being charged.

Check: 1. charging voltage 2. fuse 3. battery 4. charging coil resistance 5. wiring connections (of the entire charging system) NOTE: • Before troubleshooting, remove the following part(s): 1. Front upper cowling 2. Footrest board • Troubleshoot with the following special tool(s).

The charging circuit is OK. EAS07380

2. Fuse • Check the fuse for continuity.

Refer to to “CHECKING THE FUSE” in chapter 3.

• Is the fuse OK? NO

YES

Replace the fuse.

EAS07390

3. Battery • Check the condition of the battery.

Refer to “CHECKING THE BATTERY” in chapter 3.

Engine tachometer 90890-03113 Pocket tester 90890-03112

Electrolyte specific gravity 1,280 at 20 °C (68 °F)

EAS07750

1. Charging voltage

• Is the battery OK?

• Connect the engine tachometer to the spark plug lead.

• Connect the pocket tester (DC 20 V) to the battery.

Positive tester probe → positive battery terminal Negative tester probe → negative battery terminal • Start the engine and let it run at approximately 5,000 r/min.

• Measure the charging voltage.

Charging voltage 14 V or more at 5,000 r/min NOTE: Make sure the battery is fully charged • Is the charging voltage within specification?

7 - 23

YES

NO • Clean the battery terminals.

• Recharge or replace the battery.

CHARGING SYSTEM EAS07760

4. Charging coil resistance (AC magneto A) • Disconnect the AC magneto coupler.

• Connect the pocket tester (Ω × 1) to the charging coils as shown.

Positive tester probe → White 1 Negative tester probe → White / Red 2 • Measure the charging coil resistance.

Charging coil resistance 0.29 ~ 0.43 Ω at 20 °C (68 °F) • Is the charging coil OK? NO

YES Replace the stator assembly.

EAS07790

5. Wiring • Check the wiring connections of the entire charging system.

Refer to “CIRCUIT DIAGRAM”.

• Is the charging connected and without defects?

YES Replace the rectifier/ regulator.

NO Properly connect or repair the charging system’s wiring.

7 - 24

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LIGHTING SYSTEM

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EAS07800

LIGHTING SYSTEM (EW50 Model) CIRCUIT DIAGRAM R

Gy

Or LW Br

Br

W B R YR R R

R R

LW

W YR

8

B

Gy

W YR

RAR Gy LW

R R

R

7 12V 4Ah

BAB

10

B B

LW

23

11 A

(BLACK)

LW LW

Gy

LW LW

OFF ON

(BLACK)

LW LW

LW

YR LR

LR Br

Br

Br BrW Br

20

19

22

21

Gy

LR

25

B

HI LOW

12V 2W

12V 1.2W

E

F

B 12V 2W

Ch Y

5WK1 UK destination only

13

G 24

G B

G B

Dg

(Green)

Y G B

GY

G

H G

Y B G Dg Ch LR BrW P

Dg

12V 2W

B J

G B Y Ch Dg P BrW L Ch

G

Y

12

D

L N R

C

B G Br Ch Dg Y Gy LR B

Ch Br Dg

Y LR G

B P B OFF ON

BrW

LR

P

Br

L

LR

(Green)

B Ch Ch

B Dg Dg

B Ch Ch

B Dg Dg

B Ch

Dg B

Ch B

Dg B

(Green) 12V 10W

12V 35/35W

(Green) 12V 10W

12V 10W

14

18 12V 21W/5W

12V 10W

16

15

GY

LR

17

B GY

LR

L

LR

B

B

B

B

B

B

18 12V 21W/5W

12V 5W

26

B

1 AC magneto (lighting coil) B Left handlebar switches C Dimmer switch C Head light

2

LW

B

9

Br

WL Br

WL B

1

B

R 6

WR WL WL B W YR YR W

B

H Tail/brake light O Meter assembly E Meter light H High beam indicator light

7 - 25

B

B

B

B

LIGHTING SYSTEM

ELEC

(EW50N)

1 AC magneto (lighting coil) B Left handlebar switches C Dimmer switch C Head light

H Tail/brake light O Meter assembly K Meter light I High beam indicator light

7 - 26

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LIGHTING SYSTEM

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EAS07820

TROUBLESHOOTING

YES

Any of the following fail to light: headlight, high beam indicator light, taillight, and meter light.

NO Replace the stator assembly.

Check: 1. lighting coil resistance 2. dimmer switch 3. wiring connections (of the entire charging system) NOTE: • Before troubleshooting, remove the following part(s): 1. Front upper cowling 2. Footrest board 3. Upper handlebar cover (EW50) • Troubleshoot with the following special tool(s).

EAS07840

2. Dimmer switch • Check the dimmer switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the dimmer switch OK? YES

NO The dimmer switch is faulty. Replace the left handlebar switch.

EAS07870

3. Wiring • Check the entire lighting system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the lighting system’s wiring properly connected and without defects?

Pocket tester 90890-03112 1. Lighting coil resistance (AC Magneto A) • Disconnect the AC magneto coupler.

• Connect the pocket tester (Ω × 1) to the lighting coil as shown.

YES Check the condition of each of the lighting system’s circuits.

Refer to “CHECKING THE LIGHTING SYSTEM”.

Positive tester probe → Yellow/Red 1 Negative tester probe → White/Red 2 • Measure the lighting coil resistance.

Lighting coil resistance: 0.18 ~ 0.26 Ω at 20 °C (68 °F) • Is the lighting coil OK?

7 - 27

NO Properly connect or repair the lighting system’s wiring.

ELEC

LIGHTING SYSTEM EAS07880

CHECKING THE LIGHTING SYSTEM (EW50) 1. The headlight and the high beam indicator light fail to come on.

1. Headlight bulb and socket • Check the headlight bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the headlight bulb and socket OK?

Meter light coupler (wire harness side) • Set the main switch to “ ”.

• Start the engine.

• Set the dimmer switch to “ ” or “ • Measure the voltage (DC 12 V) • Is the voltage within specification?

This circuit is OK.

Replace the headlight bulb, socket or both.

2. Voltage (Headlight A and high beam indicator light B)

”

The wiring circuit from the main switch to the headlight coupler is faulty and must be repaired.

EAS07890

2. The meter light fails to come on.

1. Meter light bulb and socket • Check the meter light bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the meter light bulb and socket OK?

• Connect the pocket tester ((DC 20 V) to the headlight and high beam indicator light couplers as shown (wire harness side).

Headlight A Positive tester probe → Yellow 1 and then Green 2 Negative tester probe →Black 3 High beam indicator light B Positive tester probe → Yellow 4 Negative tester probe → Black 5

+

NO

YES

NO

YES

–

NO

YES

Replace the meter light bulb, socket or both.

2. Voltage (Meter light A) • Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown.

Positive tester probe → Blue (L)/Red 1 Negative tester probe → Black 4

7 - 28

LIGHTING SYSTEM • • • •

• • • •

Set the main switch to “ ”.

Start the engine.

Measure the voltage (DC 12 V) Is the voltage within specification?

NO

YES This circuit is OK.

This circuit is OK.

EAS07900

3. The tail light fails to come on.

1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the tail/brake light bulb and socket OK? YES

NO Replace the tail/ brake light bulb, socket or both.

2. Voltage (Tail light A) • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.

Positive tester probe → Blue (L)/Red 1 Negative tester probe → Black 2

7 - 29

–

+

Set the main switch to “ ”.

Start the engine.

Measure the voltage (DC 12 V).

Is the voltage within specification?

YES

The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired.

ELEC

NO Wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.

ELEC

LIGHTING SYSTEM EAS07880

• • • • •

CHECKING THE LIGHTING SYSTEM (EW50N) 1. The headlight and the high beam indicator light fail to come on.

1. Headlight bulb and socket • Check the headlight bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the headlight bulb and socket OK?

Set the main switch to “ ” Start the engine.

Set the dimmer switch to “ ” or “ Measure the voltage (DC 12 V) Is the voltage within specification?

This circuit is OK.

+

”

NO

YES

NO

YES

–

The wiring circuit from the main switch to the headlight coupler is faulty and must be repaired.

EAS07890

Replace the headlight bulb, socket or both.

2. The meter light fails to come on.

2. Voltage (Meter light A) • Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown.

2. Voltage (Headlight A and high beam indicator light B) • Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown (wire harness side).

Positive tester probe → Blue (L)/Red 1 Negative tester probe → Black 2

Headlight A Positive tester probe → Yellow 1 and then Green 2 Negative tester probe → Black 3 High beam indicator light B Positive tester probe → Yellow 4 Negative tester probe → Black 5

7 - 30

LIGHTING SYSTEM • • • •

• • • •

Set the main switch to “ ” Start the engine.

Measure the voltage (DC 12 V) Is the voltage within specification?

NO

YES This circuit is OK.

This circuit is OK.

EAS07900

3. The tail light fails to come on.

1. Tail light bulb and socket • Check the tail/brake light bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the tail/brake light bulb and socket OK? YES

NO Replace the tail/ brake light bulb, socket or both.

2. Voltage (Tail light A) • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.

Positive tester probe → Blue (L)/Red 1 Negative tester probe → Black 2

7 - 31

–

+

Set the main switch to “ ”.

Start the engine.

Measure the voltage (DC 12 V) Is the voltage within specification?

YES

The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired.

ELEC

NO Wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.

LIGHTING SYSTEM EAS07900

4. The license light fails to come on. (5WK1 UK destination only) 1. License light bulb and socket • Check the tail/brake light bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the tail/brake light bulb and socket OK? NO

YES

Replace the tail/ brake light bulb, socket or both.

2. Voltage (License light A) • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.

Positive tester probe → Blue (L) 1 Negative tester probe → Black 2

• • • •

Set the main switch to “ ”.

Start the engine.

Measure the voltage (DC 12 V) Is the voltage within specification?

YES

This circuit is OK.

NO Wiring circuit from the main switch to the license light coupler is faulty and must be repaired.

7 - 32

ELEC

–

+

SIGNALING SYSTEM

ELEC

â&#x20AC;&#x201C;

EAS07930

SIGNALING SYSTEM (EW50 Model) CIRCUIT DIAGRAM

5 Main switch 6 Fuse 7 Battery B Left handlebar switches B Horn switch D Turn signal light switch D Left front turn signal light

E Right front turn signal light F Left rear turn signal light G Right rear turn signal light H Tail / brake light I Horn J Flasher relay K Front stop switch L Rear stop switch

7 - 33

M Oil level gauge N Fuel sender O Meter assembly J Fuel meter F Engine oil warning light G Turn signal indicator

+

SIGNALING SYSTEM

ELEC

â&#x20AC;&#x201C;

(EW50N Model)

5 Main switch 6 Fuse 7 Battery B Left handlebar switches B Horn switch D Flasher switch D Left front turn signal light

E Right front flasher F Left rear flasher G Right rear flasher H Tail / brake light I Horn J Flasher relay K Front stop switch L Rear stop switch

7 - 34

M Oil level gauge N Fuel sender O Meter assembly J Fuel meter F Engine oil warning light G Turn signal/indicator P Speed sensor unit

+

SIGNALING SYSTEM

–

ELEC

+

EAS07940

TROUBLESHOOTING

NO

YES

• Any of the following fail to light: flasher light, brake light or an indicator light.

• The horn fails to sound.

Check: 1. fuse 2. battery 3. main switch 4. wiring connections (of the entire signaling system) NOTE: • Before troubleshooting, remove the following part(s): 1. Front upper cowling 2. Footrest board 3. Upper handlebar cover • Troubleshoot with the following special tool(s)

• Clean the battery terminals.

• Recharge or replace the battery.

EAS07490

3. Main switch • Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the main switch OK? NO

YES Replace switch.

the

main

EAS07950

4. Wiring

Pocket tester 90890-03112

• Check the entire ignition system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the signaling system’s wiring properly connected and without defects?

EAS07380

1. Fuse

YES

• Check the fuse for continuity.

Refer to “CHECKING THE FUSE” in chapter 3.

• Is the fuse OK? NO

YES

Check the condition of each of the signaling system’s circuits.

Refer to “CHECKING THE SIGNAL SYSTEM”.

Replace the fuse.

EAS07390

2. Battery • Check the condition of the battery.

Refer to “CHECKING THE BATTERY” in chapter 3.

Electrolyte specific gravity 1,280 at 20 °C (68 °F) • Is the battery OK?

7 - 35

NO Properly connect or repair the signaling system’s wiring.

ELEC

SIGNALING SYSTEM

–

+

EAS07960

3. Horn

CHECKING THE SIGNALING SYSTEM (EW50) 1. The horn fails to sound.

• Disconnect the pink connector at the horn terminal.

• Connect a jumper lead to the horn terminal and ground the jumper lead.

• Set the main switch to “ ”.

• Does the horn sound?

1. Horn switch • Check the horn switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the horn switch OK?

Replace the left handlebar switch.

Replace the horn.

4. Voltage (Horn output) • Connect the pocket tester (DC 20 V) to the horn connector at the black terminal as shown.

2. Voltage (Horn input) • Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown.

Positive tester probe → Brown 1 Negative tester probe → ground

Positive tester probe → Pink 1 Negative tester probe → ground

• Set the main switch to “ ”.

• Measure the voltage (DC 12 V) of pink 1 at the horn terminal.

• Is the voltage within specification?

• Set the main switch to “ ”.

• Measure the voltage (DC 12 V) of brown 1 at the horn terminal.

• Is the voltage within specification?

YES

NO

YES

NO

YES

YES

NO

NO The wiring circuit from the main switch to the horn connector is faulty and must be repaired.

Repair or replace the horn.

7 - 36

Replace the horn.

SIGNALING SYSTEM EAS07980

• • • •

2. The brake light fails to come on.

1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the tail/brake light bulb and socket OK?

Replace the tail/ brake light bulb, socket or both.

–

+

Set the main switch to “ ”.

Pull in the brake levers.

Measure the voltage (DC 12 V).

Is the voltage within specification?

NO

YES This circuit is OK.

NO

YES

ELEC

The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.

EAS07990

3. The turn signal light, turn signal indicator light or both fail to blink.

1. Turn signal light bulb and socket

2. Brake light switches

• Check the turn signal light bulb and socket THE for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the turn signal light bulb and socket OK?

• Check the brake light switches for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the brake light switch OK? NO

YES

YES Replace the brake light switch.

Replace the turn signal light bulb, socket or both.

3. Voltage (Brake light A) • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.

NO

2. Turn signal switch

Positive tester probe → Green/Yellow 1 Negative tester probe → Black 2

• Check the turn signal switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the turn signal switch OK? YES

NO Replace the left handlebar switch.

7 - 37

CHECKING THE SWITCHES

ELEC

–

+

• Set the main switch to “ ”.

• Set the turn signal switch to “ ” or “ ”.

• Measure the voltage (DC 12 V) on brown/ white 1 at the turn signal relay coupler (wire harness side).

• Is the voltage within specification?

3. Voltage (Flasher relay input) • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.

Positive tester probe → Brown (Br) 1 Negative tester probe → ground

NO

YES

The turn signal relay is faulty and must be replaced.

5. Voltage

• Set the main switch to “ ”.

• Measure the voltage (DC 12 V) on brown 1 at the turn signal relay coupler (wire harness side).

• Is the voltage within specification?

NO

YES

• Connect the pocket tester (DC 20 V) to the turn signal light connector or meter coupler (wire harness side) as shown.

Turn signal light A B C D Turn signal indicator lights E Left turn signal light (Front A and Rear B) Positive tester probe → Chocolate (Ch) 1 or 2 Negative tester probe → ground Right turn signal light (Front C and Rear D)

The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be repaired.

Positive tester probe → Dark Green 3 or 2 Negative tester probe → ground

4. Voltage (Flasher relay output) • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.

Positive tester probe → pink 1 Negative tester probe → ground

Turn signal indicator light E Negative tester probe → Chocolate (Ch) 5 or Dark Green 6 Positive tester probe → Black 7

7 - 38

SIGNALING SYSTEM • Set the main switch to “ ”.

• Set the turn signal switch to “ ” or “ ”.

• Measure the voltage (DC12V) of the chocolate 1, 2 or 5 or dark green 3, 4 or 6 at the turn signal light connector or meter assembly connector (wire harness side).

• Is the voltage within specification?

+

3. Voltage (Engine oil warning light A) • Connect the pocket tester (DC 20 V) to the meter coupler (wire harness side) as shown.

Positive tester probe → Green/Yellow 1 Negative tester probe → Black 2

The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.

• Set the main switch to “ ” (Oil tank empty).

• Measure the voltage (DC 12 V) of green/ yellow 1 and black 2 at the meter coupler.

• Is the voltage within specification?

EAS08020

4. The oil level warning light fails to come on.

1. Oil level warning light bulb and socket • Check the oil level warning light bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the oil level warning light bulb and socket OK?

Replace the oil level warning light bulb, socket or both.

NO

YES This circuit is OK.

NO

YES

The wiring circuit from the main switch to the meter coupler is faulty and must be repaired.

EAS08040

5. The fuel level gauge fails to operate.

1. Fuel sender

2. Engine oil level switch • Drain the engine oil and remove the engine oil level switch from the oil pan.

• Check the engine oil level switch for continuity.

Refer to “SIGNALING SYSTEM”.

• Is the engine oil level switch OK? YES

–

NO

YES This circuit is OK.

ELEC

• Remove the fuel sender from the fuel tank.

• Connect the pocket tester to the fuel sender coupler (wire harness side) as shown.

Positive tester probe → Green 1 Negative tester probe → Black 2

NO Replace the engine oil level switch.

7 - 39

SIGNALING SYSTEM • Measure the fuel sender resistance.

–

+

3. Fuel level gauge

Fuel sender resistance (up position “F”) (Ω × 1) 7.4 ~ 9 Ω at 20 °C (68 °F) Fuel sender resistance (down position “E”) (Ω × 10) 82.9 ~ 98.9 Ω at 20 °C (68 °F)

• Set the main switch to “ ”.

• Move the float up or down.

• Check that the display segments of the fuel level gauge increase or decrease to “F” or “E”.

NOTE: Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes.

• Is the fuel sender OK? NO

YES

ELEC

• Does the fuel level gauge needle move appropriately?

Replace sender.

the

fuel YES

2. Voltage (Fuel meter A) • Connect the pocket tester (DC 20 V) to the meter coupler (wire harness side) as shown.

Replace the fuel level gauge.

4. Wiring

Positive tester probe → Green 1 or Brown (Br) 2 Negative tester probe → Black 3

• Set the main switch to “ ”.

• Measure the voltage (DC 12 V) of green 1 or brown 2 on the meter light coupler (wire harness side).

• Is the voltage within specification?

YES

NO

NO Check the wiring connections of the entire signaling system.

7 - 40

• Check the entire signaling system’s wiring.

ELEC

SIGNALING SYSTEM

–

+

EAS07960

3. Horn

CHECKING THE SIGNALING SYSTEM (EW50N) 1. The horn fails to sound.

• Disconnect the pink connector at the horn terminal.

• Connect a jumper lead to the horn terminal and ground the jumper lead.

• Set the main switch to “ ”.

• Does the horn sound?

1. Horn switch • Check the horn switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the horn switch OK? YES

Replace the left handlebar switch.

The horn is OK. 4. Voltage (Horn output) • Connect the pocket tester (DC 20 V) to the horn connector at the black terminal as shown.

2. Voltage (Horn input) • Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown.

Positive tester probe → Brown (Br) 1 Negative tester probe → ground

Positive tester probe → Pink 1 Negative tester probe → ground

• Set the main switch to “ ”.

• Measure the voltage (DC 12 V) of pink 1 at the horn terminal.

• Is the voltage within specification?

• Set the main switch to “ ”.

• Measure the voltage (DC 12 V) of brown 1 at the horn terminal.

• Is the voltage within specification?

YES

NO

YES

NO

YES

NO

NO The wiring circuit from the main switch to the horn connector is faulty and must be repaired.

Repair or replace the horn.

7 - 41

Replace the horn.

SIGNALING SYSTEM EAS00797

• • • •

2. The brake light fails to come on.

1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the tail/brake light bulb and socket OK?

Replace the tail/ brake light bulb, socket or both.

–

+

Set the main switch to “ ”.

Pull in the brake levers.

Measure the voltage (DC 12 V).

Is the voltage within specification?

NO

YES This circuit is OK.

NO

YES

ELEC

The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.

EAS07990

3. The turn signal light, turn signal indicator light or both fail to blink.

1. Turn signal light bulb and socket

2. Brake light switches

• Check the turn signal light bulb and socket for continuity.

Refer to “CHECKING THE BULBS AND BULB SOCKETS”.

• Are the turn signal light bulb and socket OK?

• Check the brake light switches for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the brake light switch OK? NO

YES

YES Replace the brake light switch.

Replace the turn signal light bulb, socket or both.

3. Voltage (Brake light A) • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.

NO

2. Turn signal switch

Positive tester probe → Green/Yellow 1 Negative tester probe → Black 2

• Check the turn signal switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the turn signal switch OK? YES

NO Replace the left handlebar switch.

7 - 42

CHECKING THE SWITCHES

ELEC

–

+

• Set the main switch to “ ”.

• Set the turn signal switch to “ ” or “ ”.

• Measure the voltage (DC 12 V) on brown/ white 1 at the turn signal relay coupler (wire harness side).

• Is the voltage within specification?

3. Voltage (Flasher relay input) • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.

Positive tester probe → Brown (Br) 1 Negative tester probe → ground

YES

NO The turn signal relay is faulty and must be replaced.

5. Voltage

• Set the main switch to “ ”.

• Measure the voltage (DC 12 V) on brown 1 at the turn signal relay coupler (wire harness side).

• Is the voltage within specification?

NO

YES

• Connect the pocket tester (DC 20 V) to the turn signal light connector or meter coupler (wire harness side) as shown.

Turn signal light A B C D Turn signal indicator lights E Left turn signal light (Front A and Rear B) Positive tester probe → Chocolate (Ch) 1 or 2 Negative tester probe → ground Right turn signal light (Front C and Rear D)

The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be repaired.

Positive tester probe → Dark Green 3 or 2 Negative tester probe → ground

4. Voltage (Flasher relay output) • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.

Positive tester probe → Brown (Br)/White 1 Negative tester probe → ground

7 - 43

CHECKING THE SWITCHES Turn signal indicator light E

ELEC

–

+

2. Voltage (Engine oil warning light A)

Negative tester probe → Chocolate (Ch) 5 or Dark Green 6 Positive tester probe → Black 7

• Connect the pocket tester (DC 20 V) to the meter coupler (wire harness side) as shown.

Positive tester probe → Green/Yellow 1 Negative tester probe → Black 2

• Set the main switch to “ ”.

• Set the turn signal switch to “ ” or “ ”.

• Measure the voltage (DC12V) of the chocolate 1, 2 or 5 or dark green 3, 4 or 6 at the turn signal light connector or meter assembly connector (wire harness side).

• Is the voltage within specification?

NO

YES This circuit is OK.

• Set the main switch to “ ” (Oil tank empty).

• Measure the voltage (DC 12 V) of green/ yellow 1 and black 2 at the meter coupler.

• Is the voltage within specification?

The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.

This circuit is OK.

EAS08020

4. The oil level warning light fails to come on.

The wiring circuit from the main switch to the meter coupler is faulty and must be repaired.

EAS08040

5. The fuel level gauge fails to operate.

1. Engine oil level switch • Drain the engine oil and remove the engine oil level switch from the oil pan.

• Check the engine oil level switch for continuity.

• Is the engine oil level switch OK? YES

NO

YES

1. Fuel sender • Remove the fuel sender from the fuel tank.

• Connect the pocket tester to the fuel sender coupler (wire harness side) as shown.

Positive tester probe → Green 1 Negative tester probe → Black 2

NO Replace the engine oil level switch.

7 - 44

SIGNALING SYSTEM • Measure the fuel sender resistance.

NOTE: Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes.

NO the

• Does the fuel level gauge needle move appropriately? fuel

• Connect the pocket tester (DC 20 V) to the meter coupler (wire harness side) as shown.

Positive tester probe → Green 1 Negative tester probe → Black 2

Replace the fuel level gauge.

4. Wiring Check the entire signaling system’s wiring.

EAS08060

6. The speedometer fails to come on.

1. Voltage (speedometer and odometer A) • Connect the pocket tester (DC 20 V) to the multi-function meter socket coupler (wire harness side) as shown.

A

- Y G Pu YB Br W Gy P -

Positive tester probe → Red 1 or Blue (L) 2 Negative tester probe → Black 3

Br LR Gy Ch - Y G Dg B

햳

• Set the main switch to “ ”.

• Measure the voltage (DC 12 V) of green 1 or brown 2 on the meter light coupler (wire harness side).

• Is the voltage within specification?

YES

NO

YES

2. Voltage (Fuel warning light and fuel meter A)

햲

+

• Set the main switch to “ ”.

• Move the float up or down.

• Check that the display segments of the fuel level gauge increase or decrease to “E” or “F”.

• Is the fuel sender OK?

Replace sender.

–

3. Fuel level gauge

Fuel sender resistance (up position “F”) (Ω × 1) 7.4 ~ 9 Ω at 20 °C (68 °F) Fuel sender resistance (down position “E”) (Ω × 10) 82.9 ~ 98.9 Ω at 20 °C (68 °F)

YES

ELEC

NO Check the wiring connections of the entire signaling system.

7 - 45

SIGNALING SYSTEM • Set the main switch to “ ”.

• Measure the voltage (DC 5 V) of Red 1 or Blue (L) 2 on the multi-function meter coupler (wire harness side).

• Is the voltage within specification?

NO

YES

The wiring circuit from the main switch to the multifunction meter coupler (wire harness side) is faulty.

Repair it.

2. Speed sensor supply • Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown.

Positive tester probe → Red/Yellow 1 Negative tester probe → Black/Yellow 2

• Set the main switch to “ ”.

• Elevate the front wheel and slowly rotate it.

• Measure the voltage (DC 5 V) of Red/ Yellow 1 and Black/Yellow 2. With each full rotation of the front wheel, the voltage reading should cycle from 0 V to 5 V to 0 V to 5 V. • Does the voltage reading cycle correctly?

YES This circuit is OK.

NO Replace the speed sensor.

7 - 46

ELEC

–

+

TRBL SHTG

TRBL SHTG CHAPTER 8 TROUBLESHOOTING STARTING FAILURE/HARD STARTING ....................................................... 8-1 ENGINE ..................................................................................................... 8-1 FUEL SYSTEM.......................................................................................... 8-1 ELECTRICAL SYSTEMS .......................................................................... 8-2 INCORRECT ENGINE IDLING SPEED........................................................... 8-2 ENGINE ..................................................................................................... 8-2 ELECTRICAL SYSTEMS .......................................................................... 8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ................................. 8-3 ENGINE ..................................................................................................... 8-3 FUEL SYSTEM.......................................................................................... 8-3 FAULTY CLUTCH ........................................................................................... 8-3 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE........................ 8-3 POOR STARTING PERFORMANCE ........................................................ 8-3 OVERHEATING............................................................................................... 8-4 ENGINE ..................................................................................................... 8-4 COOLING SYSTEM .................................................................................. 8-4 FUEL SYSTEM.......................................................................................... 8-4 CHASSIS ................................................................................................... 8-4 ELECTRICAL SYSTEMS .......................................................................... 8-4 IMPROPER KICKING...................................................................................... 8-4 SLIPPING .................................................................................................. 8-4 HARD KICKING......................................................................................... 8-4 KICK CRANK NOT RETURNING.............................................................. 8-4 FAULTY FRONT FORK LEGS........................................................................ 8-5 LEAKING OIL ............................................................................................ 8-5 MALFUNCTION......................................................................................... 8-5 POOR BRAKING PERFORMANCE................................................................ 8-5 INSTABLE HANDLING ................................................................................... 8-5 INSTABLE HANDLING.............................................................................. 8-5

TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM.............................................. 8-6 HEADLIGHT DOES NOT COME ON ........................................................ 8-6 HEADLIGHT BULB BURNT OUT.............................................................. 8-6 TAIL/BRAKE LIGHT DOES NOT COME ON ............................................ 8-6 TAIL/BRAKE LIGHT BULB BURNT OUT .................................................. 8-6 TURN SIGNAL DOES NOT COME ON .................................................... 8-6 TURN SIGNAL BLINKS SLOWLY............................................................. 8-6 TURN SIGNAL REMAINS LIT ................................................................... 8-6 TURN SIGNAL BLINKS QUICKLY ............................................................ 8-6 HORN DOES NOT SOUND ...................................................................... 8-6

STARTING FAILURE/HARD STARTING

TRBL SHTG

EAS08450

TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.

STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank • Empty fuel tank • Clogged fuel tank cap breather hole • Deteriorated or contaminated fuel • Clogged or damaged fuel hose Carburetor • Deteriorated or contaminated fuel • Clogged pilot jet • Clogged pilot air passage • Sucked-in air • Damaged float • Worn needle valve • Improperly installed needle valve seat • Incorrect fuel level • Improperly adjusted pilot air screw • Improperly installed pilot jet • Clogged starter jet • Faulty starter plunger • Improperly adjusted starter cable • Faulty temperature compensator system

ENGINE Cylinder(s) and cylinder head(s) • Loose spark plug • Loose cylinder head or cylinder • Damaged cylinder head gasket • Damaged cylinder gasket • Worn or damaged cylinder Piston(s) and piston ring(s) • Improperly installed piston ring • Damaged, worn or fatigued piston ring • Seized piston ring • Seized or damaged piston Air filter • Improperly installed air filter • Clogged air filter element Crankcase and crankshaft • Improperly assembled crankcase • Seized crankshaft

8-1

STARTING FAILURE/HARD STARTING/ INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery Fuse • Blown, damaged or incorrect fuse • Improperly installed fuse Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap Ignition coil • Cracked or broken ignition coil body • Broken or shorted primary or secondary coils • Faulty spark plug lead

TRBL SHTG

Ignition system • Faulty DC-CDI unit • Faulty pickup coil • Broken generator rotor woodruff key Switches and wiring • Faulty main switch • Faulty engine stop switch • Broken or shorted wiring • Faulty front, rear or both brake light switches • Faulty start switch • Improperly grounded circuit • Loose connections Starting system • Faulty starter motor • Faulty starter relay • Faulty starter clutch DC-CDI unit system • Faulty DC-CDI unit • Faulty Source coil • Faulty Pick-up coil

EAS00847

INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap Ignition coil • Faulty spark plug lead Ignition system • Faulty DC-CDI unit • Faulty pickup coil • Broken generator rotor woodruff key

ENGINE Cylinder and cylinder head • Incorrect valve clearance • Damaged valve train components Air filter • Clogged air filter element FUEL SYSTEM Carburetor • Faulty starter plunger • Loose or clogged pilot jet • Loose or clogged pilot air jet • Damaged or loose carburetor joint • Improperly adjusted engine idling speed (throttle stop screw) • Improper throttle cable free play • Flooded carburetor • Faulty temperature compensator system

8-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY CLUTCH

TRBL SHTG

EAS08490

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURE/HARD STARTING”.

ENGINE Air filter • Clogged air filter element Air intake system • Bent, clogged or disconnected carburetor air vent hose • Clogged or leaking air duct

FUEL SYSTEM Carburetor • Faulty diaphragm • Incorrect fuel level • Loose or clogged main jet

EAS08530

FAULTY CLUTCH POOR STARTING PERFORMANCE V-belt • V-belt slips • Oil or grease on the V-belt Primary sliding sheave • Faulty operation • Worn pin groove • Worn pin Clutch shoe(s) • Bent, damaged or worn clutch shoe POOR SPEED PERFORMANCE V-belt • Oil or grease on the V-belt Primary pulley weight(s) • Faulty operation • Worn primary pulley weight Primary fixed sheave • Worn primary fixed sheave Primary sliding sheave • Worn primary sliding sheave Secondary fixed sheave • Worn secondary fixed sheave Secondary sliding sheave • Worn secondary sliding sheave

ENGINE OPERATES BUT SCOOTER WILL NOT MOVE V-belt • Bent, damaged or worn V-belt • Slipping V-belt Primary pulley cam and primary pulley slider • Damaged or worn primary pulley cam • Damaged or worn primary pulley slider Clutch spring(s) • Damaged clutch spring Transmission gear(s) • Damaged clutch spring CLUTCH SLIPS Clutch shoe spring(s) • Damaged, loose or worn clutch shoe spring Clutch shoe(s) • Damaged or worn clutch shoe Primary sliding sheave • Seized primary sliding sheave

8-3

OVERHEATING/ IMPROPER KICKING

TRBL SHTG

EAS08550

OVERHEATING FUEL SYSTEM Carburetor • Incorrect main jet setting • Incorrect fuel level • Damaged or loose carburetor joint Air filter • Clogged air filter element CHASSIS Brake(s) • Dragging brake ELECTRICAL SYSTEMS Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range Ignition system • Faulty ignitor unit

ENGINE Clogged coolant passages • Cylinder head(s) and piston(s) • Heavy carbon buildup Engine oil • Improper engine oil quality (high viscosity) • Low engine oil quality COOLING SYSTEM Cooling fan • Damaged cooling fan • Damaged air shrouds

IMPROPER KICKING SLIPPING Kick axle assembly • Low tension of kick clip • Worn kick axle • Worn or damaged kick gear • Damaged kick clip • Kick clip coming off • Damaged kick clip stopper HARD KICKING Kick axle assembly • High tension of kick clip • Seized kick gear Cylinder, piston and piston ring • Damaged or seized cylinder • Damaged or seized piston • Damaged or seized piston ring KICK CRANK NOT RETURNING Kick axle assembly • Damaged kick return spring • Kick return spring coming off • Kick clip coming off • Damaged kick return spring stopper

Transmission oil • Improper quality (low viscosity) • Deterioration

Crankcase and crankshaft • Improperly seated crankcase • Improperly seated crankshaft • Damaged or seized crankshaft • Damaged or seized crankshaft bearing

8-4

FAULTY FRONT FORK LEGS/ POOR BRAKING PERFORMANCE/INSTABLE HANDLING

TRBL SHTG

EAS08600

FAULTY FRONT FORK LEGS MALFUNCTION • Bent or damaged inner tube • Bent or damaged outer tube • Damaged fork spring • Worn or damaged outer tube bushing • Bent or damaged damper rod • Incorrect oil viscosity • Incorrect oil level

LEAKING OIL • Bent, damaged or rusty inner tube • Cracked or damaged outer tube • Improperly installed oil seal • Damaged oil seal lip • Incorrect oil level (high) • Loose damper rod assembly bolt • Damaged damper rod assembly bolt copper washer • Loose drain bolt • Damaged drain bolt gasket

EAS08570

POOR BRAKING PERFORMANCE Rear drum brake • Worn brake shoe • Worn or rusty brake drum • Improperly adjuster brake play • Improper brake cam lever • Improper brake shoe position • Fatigue/damaged return spring • Oily or greasy brake shoe • Oily or greasy brake drum • Broken brake cable

Front disc brake • Worn brake pad • Worn brake disc • Air in hydraulic brake system • Leaking brake fluid • Faulty brake caliper kit • Faulty brake caliper seal • Loose union bolt • Damaged brake hose • Oil or grease on the brake disc • Oil or grease on the brake pad • Incorrect brake fluid level

INSTABLE HANDLING INSTABLE HANDLING Handlebar • Improperly installed or bent

Wheels • Damaged bearing • Bent or loose wheel axle • Excessive wheel run-out Frame • Twisted • Damaged head pipe • Improperly installed bearing race

Steering • Improperly installed steering column (Improperly tightened ring nut) • Bent steering column • Damaged ball bearing or bearing race Front forks • Broken damper spring • Bent or deformed suspension arm and pivots • Oil level Tires • Incorrect tire pressure • Uneven tire pressures on both sides • Unevenly worn tires

Engine bracket • Bent or damaged

Rear shock absorber • Fatigued spring • Oil leakage

8-5

FAULTY LIGHTING OR SIGNALING SYSTEM

TRBL SHTG

EAS08660

FAULTY LIGHTING OR SIGNALING SYSTEM TURN SIGNAL DOES NOT COME ON • Faulty turn signal switch • Faulty turn signal relay • Burnt-out turn signal bulb • Incorrect connection • Damaged or faulty wire harness • Improperly grounded circuit • Faulty battery • Blown, damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY • Faulty turn signal relay • Faulty main switch • Faulty turn signal switch • Incorrect turn signal bulb TURN SIGNAL REMAINS LIT • Faulty turn signal relay • Burnt-out turn signal bulb TURN SIGNAL BLINKS QUICKLY • Incorrect turn signal bulb • Faulty turn signal relay • Burnt-out turn signal bulb HORN DOES NOT SOUND • Improperly adjusted horn • Damaged or faulty horn • Faulty main switch • Faulty horn switch • Faulty battery • Blown, damaged or incorrect fuse • Faulty wire harness

HEADLIGHT DOES NOT COME ON • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (main or light switch) • Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT • Wrong headlight bulb • Faulty battery • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Faulty light switch • Headlight bulb life expired TAIL/BRAKE LIGHT DOES NOT COME ON • Wrong tail/brake light bulb • Too many electrical accessories • Incorrect connection • Burnt-out tail/brake light bulb TAIL/BRAKE LIGHT BULB BURNT OUT • Wrong tail/brake light bulb • Faulty battery • Incorrectly adjusted rear brake light switch • Tail/brake light bulb life expired

8-6

EW50 WIRING DIAGRAM 1 A.C. magneto

2 D.C./C.D.I. unit 3 Ignition coil 4 Spark plug 5 Main switch 6 Fuse 7 Battery 8 Rectifier / Regulator 9 Starter relay 0 Starter motor A Right handlebar switch A Starter switch B Left handlebar switches B Horn switch C Dimmer switch D Turn signal switch C Head light D Left front turn signal light E Right front turn signal light F Left rear turn signal light G Right rear turn signal light H Tail / brake light I Horn J Flasher relay K Front brake switch L Rear brake switch M Oil level switch N Fuel sender O Meter assembly E Meter lights F Oil level warning light G Turn signal indicator light H High beam indicator light J Fuel meter P License light (5WK1 UK only)

5WK1 UK destination only

COLOR CODE B............ Black Br .......... Brown Ch ......... Chocolate Dg ......... Dark green G ........... Green Gy ......... Grey L ............ Blue Or .......... Orange P............ Pink R ........... Red W........... White Y............ Yellow Br/W ...... Brown/White G/Y........ Green/Yellow L/R ........ Blue/Red

L/W ........ Blue/White W/R ....... White/Red Y/R ........ Yellow/Red

EW50N WIRING DIAGRAM 1 A.C. magneto

2 D.C./C.D.I. unit 3 Ignition coil 4 Spark plug 5 Main switch 6 Fuse 7 Battery 8 Rectifier / Regulator 9 Starter relay 0 Starter motor A Right handlebar switch A Starter switch B Left handlebar switches B Horn switch C Dimmer switch D Turn signal switch C Head light D Left front turn signal light E Right front turn signal light F Left rear turn signal light G Right rear turn signal light H Tail / brake light I Horn J Flasher relay K Front brake switch L Rear brake switch M Oil level switch N Fuel sender O Meter assembly E Digital display F Fuel warning indicator G Oil warning indicator I High beam indicator J Turn signal indicator K Screen lightening P Speed sensor unit

COLOR CODE B ............Black Br ...........Brown Ch ..........Chocolate Dg ..........Dark green G............Green Gy ..........Grey L ............Blue Or ..........Orange P ............Pink Pu ..........Purple R ............Red W ...........White Y ............Yellow Br/W.......Brown/White G/Y ........Green/Yellow

L/R ........ Blue/Red L/W ....... Blue/White W/R ....... White/Red Y/R ........ Yellow/Red