YW1004VP-ME1

EB000000

YW100ESERVICE MANUAL

©1999 by Yamaha Motor TAIWAN Co., Ltd.1st Edition, March 1999

All rights reserved. Any reprinting orunauthorized use without the written

permission of Yamaha Motor Taiwan Co., Ltd.is expressly prohibited.

YP002000

HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See”Illustrated symbols”)1st title 1: This is the title of the chapter with its symbol on the upper right corner of each page.2nd title 2: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accom-

panied by corresponding illustrations.

EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at start of eachremoval and disassembly section.1. An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs.2. Numbers 5 are given in the order of jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol

marks 6. The meanings of the symbol marks are given on the next page.4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs,

names of parts, notes in jobs, etc.5. For jobs requiring more information, the step-by-step format supplements 8 are given in

addition to the exploded diagram and the job instruction chart.

4

5

67

8

12 3

INDEXGENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION ANDADJUSTMENT

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

1

2

3

4

5

6

7

8

– +

EB003000

ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are designed asthumb tabs to indicate the chapter’s numberand content.1 General information2 Specifications3 Periodic inspection and adjustment4 Engine5 Cooling system6 Carburetion7 Chassis8 Electrical9 Troubleshooting

Illustrated symbols 0 to u are used to iden-tify the specifications appearing in the text.0 Possible to maintain with engine mountedq Filling fluidw Lubricante Special toolr Tighteningt Wear limit, clearancey Engine speedu Ω, V, A

Illustrated symbols i to d in the exploded dia-grams indicate the types of lubricants and lu-brication points.i Apply engine oilo Apply gear oilp Apply molybdenum disulfide oila Apply wheel bearing greases Apply lightweight lithium-soap base greased Apply molybdenum disulfide grease

Illustrated symbols f to g in the explodeddiagrams indicate the where to apply lockingagent f and when to install new parts g .f Apply locking agent (LOCTITE ®)g Use new one

GENINFO SPEC

INSPADJ ENG

COOL CARB

CHAS – +ELEC

TRBLSHTG

B LS M

LT New

E G M

1 2

3 4

5 6

7 8

9 0

T R..

q w

e r

t y u

i o p

a s d

f g

EB001000

NOTICEThis manual was produced by the Yamaha Motor Taiwan Company primarily for use by Yamaha/MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of amechanic in one manual, so it is assumed that anyone who uses this book to perform maintenanceand repairs on Yamaha/MBK scooter has a basic understanding of the mechanical ideas and theprocedures of scooter repair. Repairs attempted by anyone without this knowledge are likely torender the scooter unsafe and unfit for use.

Yamaha Motor Taiwan Company, Ltd. is continually striving to improve all its models. Modifica-tions and significant changes in specifications or procedures will be forwarded to all authorizedYamaha/MBK dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOURSAFETY IS INVOLVED!

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

A CAUTION indicates special precautions that must be taken to avoid dam-age to the scooter.

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

w

Q

NOTE:

cC

CHAPTER 1.GENERAL INFORMATION

SCOOTER IDENTIFICATION ............................................................................................................. 1-1FRAME SERIAL NUMBER ............................................................................................................. 1-1ENGINE SERIAL NUMBER ............................................................................................................ 1-2

IMPORTANT INFORMATION ............................................................................................................ 1-3PREPARATION FOR REMOVAL PROCEDURES........................................................................... 1-3REPLACEMENT PARTS ................................................................................................................. 1-3GASKETS, OIL SEALS, AND O-RINGS ........................................................................................ 1-3LOCK WASHERS/PLATES AND COTTER PINS ........................................................................... 1-3BEARINGS AND OIL SEALS ......................................................................................................... 1-4CIRCLIPS ........................................................................................................................................ 1-4

CHECKING OF CONNECTIONS ........................................................................................................ 1-5HOW TO USE THE CONVERSION TABLE ....................................................................................... 1-6SPECIAL TOOLS ................................................................................................................................ 1-7

CHAPTER 2.SPECIFICATIONS

GENERAL SPECIFICATIONS ............................................................................................................. 2-1MAINTENANCE SPECIFICATIONS ................................................................................................... 2-4

ENGINE .......................................................................................................................................... 2-4CHASSIS ........................................................................................................................................ 2-7ELECTRICAL ................................................................................................................................... 2-9

GENERAL TORQUE SPECIFICATIONS........................................................................................... 2-11LUBRICATION POINTS AND LUBRICANT TYPE ........................................................................... 2-12

ENGINE ........................................................................................................................................ 2-12CHASSIS ...................................................................................................................................... 2-12

CABLE ROUTING ............................................................................................................................. 2-13

CHAPTER 3.PERIODIC INSPECTION AND ADJUSTMENTS

NTRODUCTION ................................................................................................................................. 3-1PERIODIC MAINTENANCE/ LUBRICATION INTERVALS ............................................................... 3-1

SIDECOVER AND SEAT ................................................................................................................ 3-3JOB INSTRUCTION CHART .......................................................................................................... 3-3LOWER COWLING ,UPPER COVER, LEG SHIELD1,2 AND FOOTREST BOARD ....................... 3-4HANDLEBAR COVER(FRONT AND REAR) ................................................................................... 3-5

ENGINE .............................................................................................................................................. 3-6IDLING SPEED ADJUSTMENT ..................................................................................................... 3-6THROTTLE CABLE FREE ADJUSTMENT ..................................................................................... 3-7AUTOLUBE PUMP AIR BLEEDING ............................................................................................... 3-8AUTOLUBE PUMP CABLE ADJUSTMENT .................................................................................. 3-8SPARK PLUG INSPECTION ........................................................................................................... 3-9ENGINE OIL LEVEL INSPECTION ............................................................................................... 3-10TRANSMISSION OIL REPLACEMENT ........................................................................................ 3-11AIR FILTER ELEMENT CLEANING .............................................................................................. 3-12V-BELT INSPECTION ................................................................................................................... 3-14

CHASSIS .......................................................................................................................................... 3-15FRONT BRAKE LEVER FREE PLAY CHECK ................................................................................ 3-15REAR BRAKE LEVER FREE PLAY CHECK................................................................................... 3-15BRAKE PAD INSPECTION ........................................................................................................... 3-15BRAKE SHOE INSPECTION ........................................................................................................ 3-16BRAKE FLUID LEVEL INSPECTION ............................................................................................ 3-16AIR BLEEDING(HYDRAULIC BRAKE SYSTEM) ......................................................................... 3-17STEERING ADJUSTMENT .......................................................................................................... 3-18TIRE INSPECTION ........................................................................................................................ 3-19WHEEL INSPECTION ................................................................................................................... 3-20FRONT FORK INSPECTION ......................................................................................................... 3-20REAR SHOCK ABSORBER INSPECTION .................................................................................... 3-20SEAT LOCK CABLE ADJUSTMENT ........................................................................................... 3-20

ELECTRICAL ..................................................................................................................................... 3-21BATTERY INSPECTION ............................................................................................................... 3-21FUSE INSPECTION ...................................................................................................................... 3-26HEADLIGHT BEAM ADJUSTMENT ............................................................................................ 3-27HEADLIGHT BULB REPLACEMENT............................................................................................ 3-27TAILLIGHT BULB/REAR FLASHER BULB REPLACEMENT ....................................................... 3-28TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT ........................................................... 3-28LICENCE LIGHT BULB REPLACEMENT...................................................................................... 3-29

CHAPTER 4.ENGINE

ENGINE OVERHAUL ......................................................................................................................... 4-1WIREHARNESS AND CABLES ...................................................................................................... 4-1

CYLINDER HEAD, CYLINDER AND PISTON .................................................................................... 4-3CYLINDER HEAD CYLINDER AND PISTON ................................................................................. 4-3PISTON PIN AND PISTON REMOVAL .......................................................................................... 4-4CYLINDER HEAD INSPECTION ..................................................................................................... 4-4CYLINDER AND PISTON INSPECTION ........................................................................................ 4-5PISTON RINGS INSPECTION ........................................................................................................ 4-7PISTON PIN AND PISTON PIN BEARING .................................................................................... 4-7PISTON PIN AND PISTON INSTALLATION ................................................................................. 4-8CYLINDER AND CYLINDER HEAD ................................................................................................ 4-9

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHAVE ............................................................. 4-11KICK STARTER AND CRANKCASE COVER(LEFT)..................................................................... 4-11KICK STARTER ............................................................................................................................. 4-12KICK STARTER INSTALLATION ................................................................................................. 4-13V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................ 4-14SECONDARY SHEAVE ................................................................................................................ 4-15PRIMARY SHEAVE REMOVAL .................................................................................................... 4-16SECONDARY SHEAVE REMOVAL.............................................................................................. 4-16CLUTCH INSPECTION ................................................................................................................. 4-17V-BELT INSPECTION ................................................................................................................... 4-18PRIMARY SHEAVE INSPECTION ................................................................................................ 4-19SECONDARY SHEAVE ................................................................................................................ 4-20SECONDARY SHEAVE INSTALLATION ..................................................................................... 4-21PRIMARY SHEAVE ...................................................................................................................... 4-22

STARTER CLUTCH AND STARTER MOTOR ................................................................................. 4-24STARTER CLUTCH AND STARTER MOTOR.............................................................................. 4-24STARTER CLUTCH AND GEARS ................................................................................................ 4-26

C.D.I. MAGNETO ............................................................................................................................. 4-27C.D.I. MAGNETO ......................................................................................................................... 4-27C.D.I. MAGNETO REMOVAL ....................................................................................................... 4-28C.D.I. MAGNETO INSTALLATION .............................................................................................. 4-28

AUTOLUBE PUMP ........................................................................................................................... 4-29AUTOLUBE PUMP ....................................................................................................................... 4-29AUTOLUBE PUMP INSTALLATION ........................................................................................... 4-30

TRANSMISSION .............................................................................................................................. 4-31TRANSMISSION .......................................................................................................................... 4-31

CRANKCASE AND REED VALUE ................................................................................................... 4-33CRANKCASE AND REED VALUE ................................................................................................ 4-33CRANKCASE(RIGHT)REMOVAL ................................................................................................. 4-35REED VALVE INSPECTION ......................................................................................................... 4-35CRANKCASE(RIGHT)INSTALLATION ........................................................................................ 4-36

CRANKSHAFT .................................................................................................................................. 4-38CRANKSHAFT .............................................................................................................................. 4-38CRANKSHAFT REMOVAL ........................................................................................................... 4-39CRANKSHAFT INSPECTION ....................................................................................................... 4-39CRANKSHAFT INSTLLATION ..................................................................................................... 4-40

CHAPTER 5CARBURETION

CARBURETION .................................................................................................................................. 5-1CARBURETOR ................................................................................................................................ 5-1CARBURETOR DISASSEMBLY ..................................................................................................... 5-2CARBURETOR INSPECTION ......................................................................................................... 5-3CARBURETOR ASSEMBLY ........................................................................................................... 5-3FUEL LEVEL ADJUSTMENT ......................................................................................................... 5-4AUTO CHOKE INSPECTION .......................................................................................................... 5-5FUEL COCK INSPECTION ............................................................................................................. 5-6

CHAPTER 6CHASSIS

FRONT WHEEL AND BRAKE DISC ................................................................................................... 6-1FRONT WHEEL AND BRAKE DISC ............................................................................................... 6-1FRONT WHEEL DISASSEMBLY .................................................................................................... 6-2FRONT WHEEL DISASSEMBLY .................................................................................................... 6-3FRONT WHEEL INSPECTION ........................................................................................................ 6-3BRAKE DISC INSPECTION ............................................................................................................ 6-4FRONT WHEEL ASSEMBLY .......................................................................................................... 6-4FRONT WHEEL INSTALLATION ................................................................................................... 6-5WHEEL STATIC BALANCE ADJUSTMENT .................................................................................. 6-6

FRONT BRAKE ................................................................................................................................... 6-8BRAKE PAD .................................................................................................................................... 6-8BRAKE PAD REPLACEMENT ........................................................................................................ 6-9

MASTER CYLINDER ........................................................................................................................ 6-12MASTER CYLINDER DISASSEMBLY ............................................................................................. 6-13

MASTER CYLINDER INSPECTION.............................................................................................. 6-14MASTER CYLINDER ASSEMBLY................................................................................................ 6-14MASTER CYLINDER INSTALLATION ......................................................................................... 6-15

CALIPER ........................................................................................................................................... 6-17CALIPER DISASSEMBLY................................................................................................................. 6-18

BRAKE CALIPER DISASSEMBLY ................................................................................................ 6-19CALIPER INSPECTION ................................................................................................................. 6-19BRAKE CALIPER ASSEMBLY ...................................................................................................... 6-20CALIPER INSTALLATION ............................................................................................................ 6-20

REAR WHEEL AND REAR BRAKE .................................................................................................. 6-21REAR WHEEL AND REAR BRAKE............................................................................................... 6-21REAR WHEEL ............................................................................................................................... 6-21REAR BRAKE ................................................................................................................................ 6-22REAR WHEEL INSPECTION ........................................................................................................ 6-23REAR BRAKE INSPECTION ......................................................................................................... 6-23REAR BRAKE INSTALLATION .................................................................................................... 6-24

HANDLEBAR .................................................................................................................................... 6-25HANDLEBAR ................................................................................................................................ 6-25HANDLEBAR INSTALLATION ..................................................................................................... 6-27

STEERING ........................................................................................................................................ 6-29STEERING .................................................................................................................................... 6-29STEERING REMOVAL ................................................................................................................. 6-30STEERING INSPCTION ................................................................................................................ 6-31STEERING INSTALLATION ......................................................................................................... 6-31

FRONT FORK ...................................................................................................................................6-34FRONT FORK ............................................................................................................................... 6-34

FRONT FORK DISASSEMBLY.........................................................................................................6-35FRONT FORK REMOVAL ............................................................................................................. 6-36FRONT FORK DISASSEMBLY ..................................................................................................... 6-36FRONT FORK INSPECTION ......................................................................................................... 6-37FRONT FORK ASSEMBLY ........................................................................................................... 6-37FRONT FORK INSTALLATION .................................................................................................... 6-39

CHAPTER 7ELECTRICAL

ELECTRICAL COMPONENTS ........................................................................................................... 7-1CIRCUIT DIAGRAM ....................................................................................................................... 7-2

CHECKING SWITCHES ..................................................................................................................... 7-4CHECKING STEPS ........................................................................................................................ 7-4

SWITCH CONNECTION AS SHOWN IN THIS MANUAL ............................................................... 7-4SWITCH POSITION AND TERMINAL CONNECTION ..................................................................... 7-5IGNITION SYSTEM ........................................................................................................................... 7-6

CIRCUIT DIAGRAM ....................................................................................................................... 7-6TROUBLESHOOTING ................................................................................................................... 7-7

CHARGING SYSTEM ...................................................................................................................... 7-10CIRCUIT DIAGRAM ..................................................................................................................... 7-10TROUBLE SHOOTING ................................................................................................................ 7-11

ELECTRIC STARTING SYSTEM ..................................................................................................... 7-14CIRCUIT DIAGRAM ..................................................................................................................... 7-14TROUBLE SHOOTING ................................................................................................................ 7-15

STARTER MOTOR .......................................................................................................................... 7-19STARTER DISASSEMBLY .......................................................................................................... 7-20JOB INSTRUCTION CHART ....................................................................................................... 7-20INSPECTION AND REPAIR ......................................................................................................... 7-21

LIGHTING SYSTEM ........................................................................................................................ 7-23CIRCUIT DIAGRAM ..................................................................................................................... 7-23TROUBLESHOOTING ................................................................................................................. 7-24

SIGNAL SYSTEM............................................................................................................................ 7-29CIRCUIT DIAGRAM ..................................................................................................................... 7-29TROUBLESHOOTING ................................................................................................................. 7-30SIGNAL SYSTEM CHECK ........................................................................................................... 7-32

AUTO CHOKE SYSTEM ................................................................................................................. 7-38CIRCUIT DIAGRAM ..................................................................................................................... 7-38TROUBLESHOOTING ................................................................................................................. 7-39

CHAPTER 8TROUBLESHOOTING

STARTING FAILURE/HARD STARTING........................................................................................... 8-1FUEL SYSTEM ............................................................................................................................... 8-1IGNITION SYSTEM ........................................................................................................................ 8-2COMPRESSION SYSTEM ............................................................................................................. 8-2

POOR IDLE SPEED PERFORMANCE ................................................................................................ 8-3POOR IDLE SPEED PERFORMANCE ............................................................................................ 8-3

POOR MEDIUM AND HIGH SPEED PERFORMANCE...................................................................... 8-3POOR MEDIUM AND HIGH SPEED PERFORMANCE .................................................................. 8-3

FAULTY AUTOMATIC(V-BELT TYPE) .............................................................................................. 8-4SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING .................................................. 8-4CLUTCH OUT FAILURE ................................................................................................................. 8-4POOR STANDING START(LOW CLIMBING ABILITY) ................................................................. 8-4POOR ACCELERATION(POOR HIGH SPEED) .............................................................................. 8-4

OVERHEAT/POOR SPEED ................................................................................................................ 8-5OVERHEAT ..................................................................................................................................... 8-5

POOR SPEED ..................................................................................................................................... 8-5POOR SPEED ................................................................................................................................. 8-5

IMPROPER KICKING .......................................................................................................................... 8-6SLIPPING ........................................................................................................................................ 8-6HARD KICKING .............................................................................................................................. 8-6KICK CRANK NOT RETURNING ................................................................................................... 8-6

FAULTY BRAKE ................................................................................................................................. 8-7POOR BRAKING EFFECT ............................................................................................................... 8-7MALFUNCTION ............................................................................................................................. 8-7

INSATABLE HANDLING .................................................................................................................... 8-8INSATABLE HANDLING ................................................................................................................ 8-8

FAULTY SIGNAL AND LIGHTING SYSTEM .................................................................................... 8-9HEADLIGHT DARK ......................................................................................................................... 8-9BULB BURNT OUT ........................................................................................................................ 8-9FLASHER DOES NOT BLINK ......................................................................................................... 8-9FLASHER KEEPS ON ..................................................................................................................... 8-9FLASHER BLINKS SLOWER ........................................................................................................ 8-10FLASHER BLINKS QUICKER ....................................................................................................... 8-10HORN DOES NOT SOUND ......................................................................................................... 8-10

WIRING DIAGRAM

GENINFO

1-1

SCOOTER INDENTIFICATION

1GENERAL INFORMATION

SCOOTER IDENTIFICATIONFRAME SERIAL NUMBERThe frame serial number 1 is stamped into theplate on the frame.

Initial serial number:YW100E1(I)

*LPRSB0210**00000101*

YW100E1(F)*LPRSB0210**00000101*

YW100E2(I)*LPRSB0220**00100101*

YW100E2(F)*LPRSB0220**00100101*

YW100E3(G)*LPRSB0210**00300101*

YW100E4(G)*LPRSB0220**00400101*

YW100E5(P)*LPRSB0210**00200101*

YW100E5(Es)*LPRSB0210**00200101*

YW100E6(A)*LPRSB0210**00500101*

YW100E7(Che)*LPRSB0210**00600101*

YW100E8(Che)*LPRSB0220**00700101*

GENINFO

1-2

SCOOTER INDENTIFICATION

1

ENGINE SERIAL NUMBERThe engine serial number 1 is stamped intothe transmission case.

Initial serial number:YW100E1(I,F):

B103E-000101YW100E2(I,F):

B103E-100101YW100E3(G):

B103E-300101YW100E4(G):

B103E-400101YW100E5(P,S):

B103E-200101YW100E6(A):

B103E-500101YW100E7(Che):

B103E-600101YW100E8(Che):

B103E-700101

GENINFO

1-3

EB101000

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCEDURES1. Remove all dirt, mud, dust and foreign ma-

terial before removal and disassembly.2. Use proper tools and cleaning equipment.3. Refer to the “SPECIAL TOOLS” section.4. When disassembling the machine, always

keep mated parts together. This includesgears, cylinders, pistons and other partsthat have been “mated” through normalwear. Mated parts must always be reusedor replaced as an assembly.

5. During machine disassembly, clean allparts and place them in trays in the orderof disassembly. This will speed up assem-bly and allow for the correct installationof all parts.

6. Keep all parts away from any source offire.

EB101010

REPLACEMENT PARTS1. Use only genuine Yamaha parts for all re-

placements. Use oil and grease recom-mended by Yamaha for all lubricationjobs. Other brands may be similar in func-tion and appearance, but inferior in qual-ity.

EB101020

GASKETS, OIL SEALS AND O-RINGS1. Replace all gaskets, seals and O-rings

when overhauling the engine. All gasketsurfaces, oil seal lips and O-rings must becleaned.

2. Properly oil all mating parts and bearingsduring reassembly. Apply grease to theoil seal lips.

IMPORTANT INFORMATION

300-008

300-016

GENINFO

1-4

IMPORTANT INFORMATIONEB101030

LOCK WASHERS/PLATES AND COTTER PINS1. Replace all lock washers/plates and cot-

ter pins after removal. Bend lock tabsalong the bolt or nut flats after the bolt ornut has been tightened to specification.

1 Lock washer

EB101040

BEARINGS AND OIL SEALSInstall bearings and oil seals so that themanufacturer’s marks or numbers are visible.When installing oil seals, apply a light coatingof lightweight lithium base grease to the seallips. Oil bearings liberally when installing, ifappropriate.

1 Oil seal

cCDo not use compressed air to spin the bear-ings dry. This will damage the bearing surfaces.

1 Bearing

EB101050

CIRCLIPS1. Check all circlips carefully before reassem-

bly. Always replace piston pin clips afterone use. Replace distorted circlips. Wheninstalling a circlip 1 , make sure that thesharp-edged corner 2 is positioned op-posite the thrust 3 it receives. See sec-tional view.

4 Shaft

OR

GENINFO

1-5

IMPORTANT INFORMATIONEB801000

CHECKING OF CONNECTIONSDealing with stains, rust, moisture, etc. on theconnector.1. Disconnect:8 Connector

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector twoor three.

4. Pull the read to check that it will not comeoff.

5. If the terminal comes off, bend up the pin1 and reinsert the terminal into the con-nector.

6. Connect:8 Connector

NOTE:

The two connectors “click” together.

7. Check for continuity with a tester.

NOTE:

8 If there is no continuity, clean the termi-nals.

8 Be sure to perform the steps 1 to 7 listedabove when checking the wireharness.

8 For a field remedy, use a contact revitalizeravailable on the market.

8 Use the tester on the connector as shown.

GENINFO

1-6

EB201000

HOW TO USE THE CONVERSION TABLEAll 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 IMP** mm × 0.03937 = ** in2 mm × 0.03937 = 0.083 in

CONVERSION TABLEMETRIC TO IMP

Known Multiplier Result

7.23386.7940.07230.8679

2.2050.03527

0.62140.62143.2811.0940.39370.03937

0.035270.061020.87990.2199

55.99714.22349/5(°C)+32

ft.lbin.lbft.lbin.lb

lboz

mphmiftydinin

oz (IMP liq.)cu.inqt(IMP liq.)gal(IMP liq.)

lb/inpsi(lb/in2)Fahrenheit (°F)

Torque

Weight

Distance

Volume/Capacity

Miscellaneous

m.kgm.kgcm.kgcm.kg

kgg

km/hkmmmcmmm

cc(cm3)cc(cm3)lit(liter)lit(liter)

kg/mmkg/cm2

Centigrade

HOW TO USE THE CONVERSION TABLE

GENINFO

1-7

EE102000

SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the appropriate special tools; this Will help prevent damage caused by the use of inappropri-ate tools or improvised techniques.When placing an order, refer to the list provided below to avoid any mistakes.

SPECIAL TOOLS

Tool name / Usage

Rotor holding tool

This tool is used to remove the flywheelmagneto.

Ringnut wrench

This tool is used to loosen and tighten theexhaust and steering ringnut.

Clutch spring compressor

These tools are used for removing the nutwith holding the compression spring.

Crankshaft Installer pot 1Crankshaft Installer bolt 2Adapter 3 ,Spacer 4These tools are used to install the crank-shaft.

Flywheel puller

This tool is used for removing the rotor.

Crankcase Separating tool

This tool is used to remove the crankshaftor separate the crankcase.

Oil seal guide

This tool is used for protecting the oil seallip when installing the secondary slidingsheave.

Ring nut wrench

This tool is used to loosen and tighten thesteering ring nut.

Sheave holder

This tool is used for holding the secondarysheave.

Thickness gauge

This tool is used to measure the clearance

Tool No.

90890-01235

90890-01268

90890-01337

90890 -01274-01275-01277-01288

90890-01189

90890- 01135

90890-01384

90890-01403

90890-01701

90890-03079

Illustration

GENINFO

1-8

IllustrationTool No.

90890-03112

90890-03113

90890-01409

90890-01410

90890-06754

90890-85505

90890-01348

90890-01367 1-01400 2

Tool name / Usage

Pocket tester

These instruments are invaluable for check-ing the electrical system.

Engine tachometer

This tool is needed for detecting enginerpm.

Oil seal guide

This tool is used to install the left side crank-case oil seal.

Oil seal installer

This tool is used to install the left side crank-case oil seal.

Ignition checker

This instrument is necessary for checkingthe ignition system components.

Yamaha bond No. 1215

This sealant (bond) is used for crankcasemating surface, etc.

Locknut wrench

This tool is used to loosen and tighten theclutch carrier locknut of the secondarysheave.

Front fork seal driverWeight 1Adapter 2

These tools are used when installing thefork seal.

SPECIAL TOOLS

1 2

SPEC

2-1

YW100E1/2/3/4/5/6/7/8

4VPB/F/G/H/J/K/L/M

1,890mm660mm1,115mm765mm1,270mm119mm1,800mm

96kg

Air cooled 2 strcke, gasoline torque inductionForward- inclined single cylinder101cm3

52.0 × 47.6 mm6.6:1Electric and kick starterSeparate lubrication

For YAMAHA brand:Yamalube 2 or Air cooled 2-stroke engine oil (JASOFC grade or ISO EG-C, EG-D grade)For MBK brand:Semi synthetic oil in accordance to the API TS3standardSAE 85W/140

1.4L

0.11L0.13L

Wet type element

Regular unleaded gasoline5.7L

VM16SS/MIKUNI

GENERAL SPECIFICATION

SPECIFICATIONGENERAL SPECIFICATION

Model

Model code:

Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

Basic weight:With oil and full fuel tank

Engine:Engine typeCylinder arrangementDisplacementBore × strokeCompression ratioStarting systemLubrication system:

Oil Type or Grade:Engine Oil

Transmission Oil

Oil Capacity:Oil Tank (Engine Oil)Transmission Oil:Periodic Oil ChangeTotal Amount

Air Filter:

Fuel:TypeTank Capacity

Carburetor:Type / Manufacturer

SPEC

2-2

Model

Spark Plug:Type/ManufacturerGap

Clutch Type

Transmission:Primary Reduction SystemPrimary Reduction RatioSecondary Reduction SystemSecondary Reduction RatioTransmission TypeOperation

Chassis:Frame typeCaster angleTrail

Tire:TypeSize front

rearManufacturer front

rearType front

rear

Maximum load*Cold tire Pressure:

Up to 90 kgFrontRear

90 kgload~Maximum load*FrontRear

Brake:Front brake type

operationRear brake type

operation

Suspension:Front suspensionRear suspension

Shock absorber:Front shock absorberRear shock absorber

Wheel travel:Front wheel travelRear wheel travel

Electrical:Ignition systemGenerator systemBattery typeBattery capacity

YW100E1/2/3/4/5/6/7/8

BPR7HS/NGK0.9 ~ 1.0 mm

Dry, Centrifugal automatic

Herical gear47/15 (3.133)Spur gear43/13 (3.308)V-beltAutomatic

Steel tube underbone26˚86mm

Tubeless120/90-10130/90-10CHENG SHINCHENG SHIN56J59J

160 kg

200kpa(2.0 kg/cm2, 2.0 bar)200kpa(2.0 kg/cm2, 2.0 bar)

200kpa(2.0 kg/cm2, 2.0 bar)200kpa(2.0 kg/cm2, 2.0 bar)

Single disc brakeRight hand operationDrum brakeLeft hand operation

Telescopic forkUnit swing

Coil spring/oil damperCoil spring/oil damper

70 mm55 mm

C.D.IFlywheel MagnetoYTX5L-BS12V 4AH

GENERAL SPECIFICATION

SPEC

2-3

Model

Headlight type:

Bulb wattage x quantity:HeadlightTail/brake lightFlasher lightAuxiliary lightLicence plate lightMeter light

High beam indicator lightOil indicator lightTurn indicator light

YW100E1/2/3/4/5/6/7/8

Bulb S1

25W/25W×25W/21W×110W×45W×25W×13.4W×1/1.7W×11.7W×11.7W×11.7W×1

GENERAL SPECIFICATION

SPEC

2-4

Standard

...

52.002~52.012......

0.044~0.045 mm

51.958~51.967 mm10 mm52.52 mm52.50 mm14.004~14.015 mm

13.996~14.000 mm

1.2 × 2.05 mm/keystone1.2 × 2.05 mm/keystone

0.15~0.35 mm0.15~0.35 mm

0.03~0.05 mm0.03~0.05 mm

37.90~37.95 mm0.03 mm

0.2~0.5 mm0.4~0.8 mm

MAINTENANCE SPECIFICATION

MAINTENANCE SPECIFICATIONENGINE

Item

Cylinder head:Warp limit

*Lines indicate straightedge measurement

Cylinder:Bore sizeTaper limitOut of round limit

Piston:Piston to cylinderclearancePiston size “D”Measuring point “H”Oversize 1st

2ndPiston pin boreinside diameterPiston pin outside diameter

Piston Ring:Sectional Sketch (B × T)/Type

Top Ring2nd Ring

End Gap (Installed):Top Ring2nd Ring

Side Clearance ( Installed):Top Ring2nd Ring

Crankshaft:

Crank Width “A”Run Out Limit “C”Connecting Rod Big End Side

Clearance “D”Small End Free Play “F”

Limit

0.05 mm

52.10 mm0.05 mm0.03 mm

0.10 mm...............14.045 mm

13.975 mm

0.10 mm0.10 mm

0.60 mm0.60 mm

...

...

1.0 mm...

H

D

SPEC

2-5

Item

Automatic centrifugal clutch:Clutch shoe thicknessClutch housing inside diameterClutch shoe spring free lengthClutch - in revolutionClutch - stall revolution

V-belt:V-belt width

Transmission:Main Axle Runout LimitDrive Axle Runout Limit

Kick Starter:TypeKick Clip Tension

Carburetor:I.D. MarkMain Jet (M .J .)Main nozzle (NJ)

Jet Needle-clip Position (J.N.)Main Air Jet ( M .A .J .)Cutaway (C.A.)Pilot Jet (P.J.)Pilot Air Screw (A.S .)Valve Seat Size (V.S.)Starter Jet (G .S.)Float HeightFuel level heightEngine Idling Speed

Reed Valve:Valve Stopper HeightReed Valve Clearance

Standard

4.0 mm112 mm26.2 mm2,800~3,400 r/min4,500~5,500 r/min

17.7 mm

0.08 mm0.08 mm

Ratchet type150~250 g

4VP-30 (4VPL/M:4VP-40)#75E-34DM7-3ø0.73.5#32.51and1/4±1/4ø1.5#3016.5 mm3.0~4.0 mm1,750~1,850 r/min

6.0~6.4 mmLess than 0.2 mm

MAINTENANCE SPECIFICATION

Limit

2.5 mm122.5 mm.........

16.0 mm

SPEC

2-6

MAINTENANCE SPECIFICATION

2.01.41.70.70.20.70.41.10.90.20.92.60.91.11.31.21.21.20.70.71.80.30.80.91.34.04.50.84.3

TIGHTENING TORQUESENGINE

Tighteningtorque

Nm m•kg

Threadsize

Part name Q’ty RemarksPart to be tightened

Spark plugCylinder head and cylinderCylinderAir shroud 3Air shroud 1×3FanAutolube pumpReed valveAir filterCarburetor capExhaust pipeMufflerExhaust protectorCap and pipeExhaust coverCrankcase 1×2Crankcase cover 2Crankcase cover 1Air ductCrankcase holderDrain boltOil plugIdle gear plateKick crankStarter motorClutch housingPrimary sheeveMagnet baseMagnet rotor

—NutStud boltScrewScrewScrewScrewBoltScrewScrewScrewBoltBoltBoltBoltBoltBoltBoltScrewScrewBoltPlugScrewBoltBoltNutNutScrewNut

M 14M 7M 7M 66.0M 6M 5M 6M 6M 4M 6M 8M 6M 6M6M 6M 6M 6M 6M 6M 8M 14M 6M 6M 6M 10M 12M 6M 12

144313241222335661222112121121

20141772741192926911131212127718389134045843

LT

LT

LT

SPEC

2-7

MAINTENANCE SPECIFICATION

CHASSIS

Item

Steering system:Steering bearing typeNo /size of steel balls: Upper

Lower

Front suspension:Front fork travelFork free lengthFork length (Installed)Spring rate (K1)

(K2)Oil capacityOil gradeInner tube vend limit

Rear suspension:Shock absorber strokeShock absorber free length (Installed)Spring free length (Installed)Spring rate (K1)

Front wheel:TypeRim sizeRim materialRim runout limit radial

lateral

Rear wheel:TypeRim sizeRim materialRim runout limit radial

lateral

Front disc brake:TypeDisc outside diameter × thicknessPad thicknessMaster cylinder inside diameterCaliper cylinder outside diameterBrake fluid type

Rear drum brake:TypeDrum inside diameterShoe thickness

Brake lever:Brake lever free play (front at lever side)Brake lever free play (rear)Throttle cable free play

Standard

Ball bearing22 pcs19 pcs

70 mm350.8 mm212.1 mm15.68 Nm/mm(1.6 kg/mm)23.5 Nm/mm(2.43 kg/mm)88 c.cFork oil 10W or equivalent...

55 mm281.8 mm159.8 mm71.15 N/mm(7.26 kg/mm)

Cast wheelMT3.50×10Aluminum......

Cast wheelMT3.50×10Aluminum......

Single180×4.06 mm11 mm34.93 mmDOT #4

Leading, trailing130 mm4 mm

2~5 mm10~20 mm3~5 mm

Limit

...

...

...

...212.1 mm............

0.2 mm

...

...

...

...

...

...

...

...1 mm1 mm

...

...

...1 mm1 mm

...180×3.5 mm0.8 mm.........

...131 mm2 mm

...

...

...

SPEC

2-8

TIGHTENING TORQUESCHASSIS

Tighteningtorque

Nm m•kg

Threadsize

RemarksPart to be tightened

8.44.51.01.35.53.01.62.24.32.01.00.70.40.70.70.20.77.012.01.02.32.00.51.10.70.6

Frame and engine bracketEngine bracket, compression rod and engineProtect barRear gripSidestandRear shock absorber and frameRear shock absorber and engineSteering ring nutHandle holder and steering shaftBrake hose and master cylinderFuel tankFuel cockFuel senderBoxSeat lock assemblyPlastic parts & coverFootrest boardFront wheel axle and nutRear wheel axle and nutRear brake cam leverFront brake caliper and front forkBrake disc and hubBrake hose and front fork(lower)-boltBrake hose and front fork(lower)-nutBrake hose and front fork(upper)-boltBrake caliper and bleed screw

M 12M 10M 6M 6M 10M 10M 8M 25M 10M 8M 6M 6M 5M 6M 6M 5M 6M 10M 14M 6M 8M10M 6M 6M 6M 5

84451013553016224320107447277012010232051176

See”page6-29”

LT

MAINTENANCE SPECIFICATION

SPEC

2-9

ELECTRICAL

MAINTENANCE SPECIFICATION

Standard

14˚ at 5,000 r/minElectrical type

400~600Ω at 20˚C/(Black-White/Red)640~960 Ω(Black/ Red ,Black)4VP/TIIC

4VP/TIIC6 mm0.32~0.48 Ω at 20˚C5.68~8.52kΩ at 20˚C

Resin type5 kΩ

Flywheel magneto

4VP/TIIC12V 85W/5,000 rpm0.6A at 3,000r/min1.2A at 8,000r/min13~14V at 4,000 rpm0.48~0.72 Ω (White-Black)0.4~0.6 Ω (Yellow/Red- Black)12~15V (3,000~8,000 rpm)

3GF/Taichung8A18V

1.320

Constant mesh type

4VP/TIIC12V0.2 kw0.03~0.04 Ω at 20˚C7 mm2 pcs400~600g17.6 mm1.35 mm

3 KW/Shulin100A3.87~4.73 Ω at 20˚C

Item

Ignition timing:Ignition timing (B.T.D.C.)Advanced type

C.D.I.:Pickup coil resistance/color

Source coil resistance/color

C.D.I. unit model/manufacturer

Ignition coil:Model/manufacturerMinimum spark gapPrimary winding resistanceSecondary winding resistance

Spark plug cap:TypeResistance

Charging System/Type:

C.D.I. Magneto:Model/ManufacturerNominal outputCharging current

Charging voltageCharging Coil Resistance (Color)Lighting Coil Resistance (Color)Lighting VoltageRectifier:

Model/ManufacturerCapacityWithstand voltage

Battery:Specific gravity

Electric starter system:TypeStarter motor:

Model/manufacturer/ID numberOperation voltageOutputArmature coil resistanceBrush overall lengthBrash quantitySpring forceCommutator diameterMica undercut (depth)

Starter relay:Model/manufacturerAmperage ratingCoil winding resistance

limit

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...3.5 mm...400g16.6 mm...

...

...

...

SPEC

2-10

Item

Horn:Model/manufacturerMaximum amperage

Flasher relay:TypeFlasher frequency

Fuel gage:Model/manufacturerSender unit resistance - full

- empty

Oil level gauge:Model/manufacturer

Circuit breaker:TypeMAIN

Standard

4VP/Asian1.5A

Capacitor60~120 Cycle/min

4VP/San Chu4~10 Ω90~100 Ω

4VP/Lun Ping

Fuse7Ax1pc.

limit

...

...

...

...

...

...

...

...

...

...

MAINTENANCE SPECIFICATION

SPEC

2-11

General torquespecifications

Nm m.kg6 0.6

15 1.5

30 3.0

55 5.5

85 8.5

130 13.0

GENERAL TORQUE SPECIFICATIONS

GENERAL TORQUESPECIFICATIONSThis chart specifies torque for standard fasten-ers with standard I.S.O. pitch threads. Torquespecifications for special components or as-semblies are included in the applicable sectionsof this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, inprogressive stages, until full torque is reached.Unless otherwise specified, torque specifica-tions call for clean, dry threads. Componentsshould be at room temperature.

A: Distance across flatsB: Outside thread diameter

A B

A(Nut)

10 mm

12 mm

14 mm

17 mm

19 mm

22 mm

B(Bolt)

6 mm

8 mm

10 mm

12 mm

14 mm

16 mm

SPEC

2-12

Lubrication Points (Part name)

Oil Seal Lip (All)

O-ring (All)

Small End Bearing

Big End Bearing

Starter Idle Bearing

Primary Drive Gear Bearing

Kick Axle Bearing

Drive Axle Bearing

Main Axle Bearing

Starter Clutch

Piston, Piston Ring Piston Pin and Cylinder

Oil Pump Drive and Driven Gear

Sliding Surface (Secondary Sheave)

Oil Seal and O-ring (Secondary Sheave)

Cam Groove (Secondary Sheave)

Crankcase Matching Surface

LUBRICATION POINTS AND LUBRICATION TYPE

LUBRICATION POINTS AND LUBRICATION TYPEENGINE

Lubrication Points

Steering Shaft Bearing

Throttle Grip Inner Surface

Brake Cables End

Brake Cam Shaft and Pin

Wheel Bearing

Speedometer Drive and Driven Gear

Wheel Axles

Lublicant Type

BEL-LAY Assembly Lube®

BEL-LAY Assembly Lube®

BEL-LAY Assembly Lube®

Yamaha Bond No. 1215

LS

LS

LS

CHASSIS

LS

Lubricant Type

B

LS

LS

LS

LS

LS

E

E

G

G

G

G

G

M

E

SPEC

2-13

CABLE ROUTING1 Horn2 Rectifier regulator3 Main switch4 Resistor5 Headlight leads6 Speedometer cable7 Ignition coil8 Throttle cable9 Battery negative(-)0 Autolube pump cableq Fuel sender leadw Seat lock cablee Oil tank hose

CABLE ROUTINGr C.D.I. unitt Throttle cable 1y Wire harnessA Pass the speedometer cable

through the right hole of frontfender, then through theguide.

B Pass the wire harnessthrough the inside of ignitioncoil.

C Secure the ground lead andthe ignition coil base to theignition coil stay.

D Pass the wire harnessthrough the inside of oil tank.

E Pass the seat cable throughthe inside of frame.

F Align the clip with the whitebrand.

G Clamp the wire harnessH Insert the seat cable through

the frame tube.I Clamp wireharness, autolube

pump cable, rear brake cablethrottle cable 2.

J Position the cylinder betweenthe supporter and mainswitch.

SPEC

2-14

CABLE ROUTING

1 Brake cable2 Speedometer cable3 Fuel tank overflow hose4 Brake cable holder5 Air induct pipe6 Brake hose7 Brake hose holder8 License bracket9 Flasher relay0 Resistanceq Fuel tank breather hose

A Pass the brake hose through the holder.B Insert the fuel overflowhose bottom.C Pass the fuel overflowhose through the rear

fender hole.D Pass the fuel overflowhose through the

holder.E Hold the fuel overflowhose with a clamp.F Pass the brake cable through the holder.G Pass the brake cable through the hook.

9

0

6 1

2

7

A G 5

F4

8

E

D

C

3B

q

SPEC

2-15

CABLE ROUTING

1 Brake hose2 Front fender3 Front fork assembly4 Nut5 Plate washer6 Brake hose holder7 Flange bolt8 Bolt9 Brake hose holder0 Flange bolt

A Pass the brake hose through the holder.

1

2

3

3

7

5

45

6

86

1

9

0

3

1

7

5

1

54

A

SPEC

2-16

CABLE ROUTING

1 Ignition coil2 Spark plug lead3 Starter relay leads4 Auto choke leads5 Starter relay6 Bind7 C.D.I. unit8 Autolube hose9 Seat lock cable0 Bracketq Fuel tank breather hosew Bind 2e Cooling pipe

r Battery(–)leadt Battery(+)leadA Pass battery leads through

the slot of footrestboard.B Cover them after securing

starter relay leads.C Pass the seat lock cable

through the hole of bracket.D Pass the fuel tank breath

hose over seat lock cable.E Clamp carburetor vacuum

hose, fuel hose and fuelcock vacuum hose.

F Clamp autochoke leads andautolube hose on to carburetorthrottle cable.

G Pass the battery leads over framemember.

H Put fuse box on to footrest boardholder.

I Pass throttle cable2, wireharness,autolube pump cable, brake cablethrough the outside of batterybox.

EwF

eG

rtH

I

1 A

B

2

3

4

56 7 8

90

C

D

q

SPEC

2-17

1 Flasher relay2 Speedometer3 Brake cable4 Handlebar switch(left)5 Front flasher leads6 Speedometer cable7 Wire harness8 Brake hose9 Handlebar switch(right)0 Throttle cable1

A Pass brake cable through the slot of bracket.B Avoid clamping front flasher leads when in-

stalling handlebar covers.C Pass throttle cable1 through between

handlebar and wireharness.D Hang the wireharness bind on to the bracket.

CABLE ROUTING

INSPADJ

3-1

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicleoperation and a longer service life. The need for costly overhaul work will be greatly reduced. Thisinformation applies to vehicles already in service as well as to new vehicles that are being pre-pared for sale. All service technicians should be familiar with this entire chapter.YP301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INTRODUCTION/PERIODICMAINTENANCE/LUBLICATION INTERVALS

• Check fuel hoses and vacuumhose for cracks or damage.

• Replace if necessary.

• Check condition.• Clean, regap or replace if neces-

sary.

• Clean or replace if necessary.

• Check operation, fluide level andvehicle for fluid leakage.

• Correct accordingly.• Replace brake pads if necessary.

• Check operation.• Adjust brake lever free play and

replace brake shoes if necessary.

• Check balance, runout and fordamage.

• Rebalance or replace if necessary.

• Check tread depth and for dam-age.

• Replace if necesssary.• Check air pressure.• Correct if necessary.

• Check Bearing for looseness ordamage.

• Replace if necessary.

• Check bearing play and steeringfor roughness.

• Correct accordingly.• Lubricate with lithium soap base

greese every 24,000 km or 24months (whichever comes first).

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

• Tighten if necessary.

Fuel line

Spark plug

Air filter

Front brake

Rear brake

Wheels

Tires

Wheel bearings

Steering bearings

Chassis fasteners

ITEM ROUTINE TYPE

BREAK-IN EVERY

INITIAL(1,000km)

12,000 kmor

12months(whichevercomes first)

6,000 kmor

6 months(whichevercomes first)

NO.

*

*

*

*

*

*

*

*

*

1

2

3

4

5

6

7

8

9

10

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

–

–

–

–

–

–

–

Refer to SPARKPLUG INSPECTION

Same as engine oil

Brake fluid DOT 4

INSPADJ

3-2

Items marked with an asterisk (*) require special tools, data and technical skills for servicing. Takethe scooter to a Yamaha/MBK dealer.

NOTE:

•The air filter needs more frequent service if you are riding in unusually wet or dusty areas.•Brake fluid replacement:1. Replace the brake fluid after disassembling the master cylinder or caliper cylinder. Check the

brake fluid level and add fluid as required.2. Replace the master cylinder and caliper cylinder oil seals every two years.3. Replace the brake hoses every four years, or if cracked or damaged.

ITEM ROUTINE TYPE

BREAK-IN EVERY

NO.

PERIODICINSPECTION AND ADJUSTMENTS

11

12

13

14

15

16

17

18

*

*

*

*

*

*

*

*

Sidestand/centerstand

Sidestand switch

Front fork

Rear shock ab-sorber assembly

Carburetor

Autolube pump

Final gear oil

V-belt

• Check operation.• Replace if necessary.

• Check operation.• Replace if necessary.

• Check operation and for oil leak-age.

• Correct accordingly.

• Check operation and shock ab-sorber for oil leakage.

• Replace shock absorber assemblyif necessary.

• Check engine idling speed andstarter operation.

• Adjust if necessary.

• Check operation.• Correct if necessary.• Bleed if necessary.

• Check oil level and vehicle for oilleakage.

• Change oil at initial 1,000 km andthereafter every 24,000 km or 24months.

• Check for wear and damage.• Replace if necessary.

12,000 kmor

12months(whichevercomes first)

6,000 kmor

6 months(whichevercomes first)

SAE 85W 140

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

?

–

–

–

–

–

–

Same as engine oil

INITIAL(1,000km)

INSPADJ

3-3

Job name/Part name

Sidecover and seat removalBattery box cover

SeatSeat hangeRear carrierLeft side coverRight side coverCenter cover

COVER AND PANELSIDECOVER AND SEAT

Remarks

Remove the parts in order.NOTE:

Insert the (-) screwdriver into the slot ofbattery cover and pickup then remove.

Reverse the removal procedure for instal-lation.

Order

1.

2.3.4.5.6.7.

Q’ty

1

111111

COVER AND PANEL

T R..

13Nm(1.3 kg.m)

2

6

7

1

5

4

3

INSPADJ

3-4

LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD

Order

1.2.3.4.5.6.7.8.9.

Q’ty

11141

1/1112

Job name/ part name

Lower cowling, upper cover, legshield 1,2 and footrest board re-movalLower cowlingProtector barUpper coverBoltLeg shield 1Main switch cover/ leg shield 2BatteryFootrest boardFlap

Remarks

Remove the parts in order.

Reverse the removal procedure for instal-lation.

COVER AND PANEL

4

5

2 3

6 7

8

9

1

T R..

10Nm(1.0kg.m)

T R..

7Nm(0.7kg.m)

INSPADJ

3-5

HANDLEBAR COVER(FRONT AND REAR)

Order

1.2.3.4.

Q’ty

211

1/1

Job name / Part name

Handlebar cover(Front and Rear) re-moval.MirrorsFront handlebar coverRear handlebar coverFlasher light(Left/Right)

Remarks

Remove the part in order.

Reverse the removal procedure for instal-lation.

COVER AND PANEL

1

4

2

4

3

INSPADJ

3-6

ENGINEIDLE SPEED ADJUSTMENT1. Remove

8 Battery box cover2. Tighten:

8 Pilot air screw 1Turn the pilot air screw in until lightlyseated.

3. Loosen:8 Pilot air screw

Back it out from its lightly seated posi-tion.

Pilot air screw turns out:1and1/4±1/4

3. Start the engine and let it warm up.

wBefore starting the engine, be sure to use thecenterstand for safety.

4. Attach:8 Inductive tachometer 1

To the spark plug lead

Inductive tachometer:90890-03113

5. Check:8 Engine idle speed

Out of specification→Adjust.

Engine idle speed:1,750~1,850 r/min

6. Adjust:8 Engine idle speed

***************************************Adjustment steps.8 Turn the throttle stop screw 1 in or out until

specified idle speed is obtained.

Turn in Idle speed becomes higher.Turn out Idle speed becomes lower.

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

ENGINE IDLE SPEED ADJUSTMENT

1

1

1

INSPADJ

3-7

THROTTLE CABLE FREE ADJUSTMENT1. Check:

8 Throttle cable free play aOut of specification→Adjust.

Free play:3 ~ 5 mm

***************************************Throttle cable free play adjustment steps;NOTE:

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

First step:8 Remove the adjuster cover 18 Loosen the locknut 2 on the throttle cable.8 Turn the adjuster 3 in or out until the speci-

fied free play is obtained.

Turning in→Free play is increased.

Turning out→Free play is decreased.

8 Tighten the locknuts.8 Install the adjuster coverNOTE:

If the free play cannot be adjusted here, adjustit at the carburetor side of the cable. (secondstep)

Second step:8 Remove the left/right side covers and center

cover.8 Remove the adjuster cover 18 Loosen the lockout 28 Turn the adjuster 3 in or out until the speci-

fied free play is obtained.

Free play:1~2 mm

Turn in Free play is increased.

Turn out Free play is decreased.

8 Tighten the lockout.8 Install the adjuster cover.8 Install left/right side covers and center cover.

wAfter adjusting, turn the handlebar to right andleft and make sure that the engine idling doesnot run faster.***************************************

THROTTLE CABLE FREE ADJUSTMENT

a

1

3

21

31 2

INSPADJ

3-8

AUTOLUBE PUMP AIR BLEEDING1. Remove

8 Lower cowling8 Air shroud 3 1

2. Air bleeding:8 Pump case and / or oil hose.

***********************************Air bleeding steps:8 Place a rag under the autolube pump to catch

the oil.8 Remove the bleed screw 1.8 Keep the oil running out until air bubbles dis-

appear.8 When air bubbles are expelled completely,

tighten the bleed screw.NOTE:

Check the bleed screw gasket. If damaged, re-place with a new one.

*************************************3. Air bleeding:

8 Pump distributor and/or delivery hose*************************************Air bleeding steps:8 Start the engine.8 Pull the pump cable 1 all the way out set the

pump stroke to a maximum.8 Run the engine for 2-3 minutes at 2000 r/ min.

This will completely remove autolube pumpsystem of air.

*************************************AUTOLUBE PUMP CABLE ADJUSTMENTNOTE:

Engine idling speed and throttle cable free playshould be adjusted properly before adjustingthe autolube pump cable.

1. Close the throttle completely.2. Check:

8 Alignment markOut of specification→Adjust autolubepump Cable.

NOTE:

The mark “I”a on the swing plate should bealigned with the mark “I”b on the autolubepump body.

AUTOLUBE PUMP AIR BLEEDING/AUTOLUBE PUMP CABLE ADJUSTMENT

1

1

1

a

b

INSPADJ

3-9

3. Adjust:8 Autolube pump cable

***************************************Adjustment steps:8 Remove the adjuster cover 1.8 Loosen the locknut 3.8 Turn the adjuster 2 in or out until the align-

ment mark is specified.8 Tighten the locknut 38 Install the adjuster cover.***************************************SPARK PLUG INSPECTION1. Remove:

8 Battery box cover2. Inspect:

8 Spark plug typeIncorrect→Replace.

Standard spark plug:BPR7HS/NGK

3. Inspect:8 Electrode 1

Wear/Damage→Replace.8 Insulator 2

Abnormal color→Replace.Normal color is a medium-to-light tancolor.

4. Clean the spark plug with a spark plugcleaner or wire brush.

5. Measure:8 Plug gap a

Use a wire gauge or feeler gauge.Out of specification→Regap.

Spark plug gap:0.9~1.0 mm

6. Tighten:8 Spark plug 20 Nm (2.0 m.kg)

7. Install:8 Battery box cover.

SPARK PLUG INSPECTION

123

a2

1

T R..

INSPADJ

3-10

ENGINE OIL LEVEL INSPECTION1. Inspect:

8 Engine oil level Oil level low→Add suf-ficient oil by the following inspectionsteps.

1 “OIL” indicator light

Recommended oil:For Yamaha:Yamalube 2 or 2-stroke engine oil(JASO FC grade or ISO EG-C, EG-D grade)For MBK:Semi synthetic oil in accordanceto the API TS C3 standard

Total:1.4L

NOTE:

Install the oil tank filler cap 1 and push it fullyinto the filler.

Engine oil level visual inspection steps:

Turn main switch to ”*”position.

“OIL” indicator light doesnot comes on.

Inspect faulty electricalcircuit, light bulbs etc.

“OIL” indicator lightcomes on.

Turn main switch to“ON” position.

“OIL” indicator light doesnot come on.

Engine oil level and elec-trical circuit are OK.

“OIL” indicator lightcomes on.

Supply engine oil.

“OIL” indicator light comes on.

ENGINE OIL LEVEL INSPECTION

km/h20

10

4060 80

100

120

140000010

1

1

INSPADJ

3-11

TRANSMISSION OIL REPLACEMENT1. Warm up the engine for several minutes,

then stop the engine.2. Place a container under the drain hole.3. Remove:

8 Oil filler plug 18 Drain bolt (with gasket) 2

NOTE:

Drain the transmission oil completely.While draining, slightly tilt the scooter tothe right and to the left.

4. Inspect:

8 Gasket (drain bolt) 4 New8 O-ring (oil filler plug) 3

Damage→Replace.

5. Install:8 Drain bolt 18 Nm (1.8 m.kg)

6. Fill:8 Transmission case

Recommended oil:SAE 85W/140

Oil capacity:0.13 L

cC8 Always use the same type of oil; mixing oils

may result in a harmful chemical reaction andlead to poor performance.

8 Do not allow foreign material to enters thetransmission case.

7. Install:8 Oil filler plug (with O-ring)

8. Inspect:8 Oil leaks8 Oil level

NOTE:

Wipe off any oil spilt on the transmission, tireor wheel.

TRANSMISSION OIL REPLACEMENT

1

4

2

New

T R..

3

INSPADJ

3-12

AIR FILTER ELEMENT CLEANING1. Remove:

8 Battery box cover2. Remove:

8 Caburetor jont clamp 1

3. Remove:8 Screw 18 Screw(for clamp) 28 Air filter 3

4. Remove:8 Air filter case 18 Air filter element

cCNever operate the engine with the air filter el-ement removed. This will allow unfiltered airto enter, causing rapid wear and possible en-gine damage. Additionally, operation withoutthe cleaner element will affect carburetor jet-ting with subsequent poor performance andpossible engine overheating.Be careful not to have rags or the like blockingthe intake area of the air filter.

5. Inspect:8 Element 1

Damage→Replace.6. Clean:

8 Air filter element*************************************Air filter element cleaning steps:8 Wash the element gently, but thoroughly in

solvent.

AIR FILTER ELEMENT CLEANING

3

1

2

1

1

1

INSPADJ

3-13

wNever use low flash point solvents such asgasoline to clean the element. Such solventmay lead to a fire or explosion.

8 Squeeze the excess solvent out of the ele-ment and let dry.

cCDo not twist the element when squeezing theelement.

8 Apply the foam -air filter oil or engine oil .8 Squeeze out the excess oil.NOTE:

The element should be wet but not dripping.

7. Install:8 Air filter8 Battery box cover

AIR FILTER ELEMENT CLEANING

INSPADJ

3-14

V-BELT INSPECTION1. Remove:

8 Air cleaner joint clamp 18 Screws(left crankcase cover) 28 Crankcase cover(left) 3

2. Inspect8 V-belt 1

Cracks/Wear/Damage→Replace.Oil or grease adhere to theV-belt→Check the primary and second-ary sheaves.Refer to “ENGINE OVERHAUL - INSPEC-TION AND REPAIR” section in the CHAP-TER 4.

3. Measure:8 V-belt width a

Out of specification→Replace.Refer to “ENGINE OVERHAUL” sectionin the CHAPTER 4.

V-belt width:17.7 mm

<Limit> 16.0 mm

NOTE:

Measure the V-belt width on several points.

4. Install:8 Crankcase cover(left) 12Nm(1.2kg.m)

8 Air cleaner joint clamp

V-BELT INSPECTION

13

1

a

2

T R..

INSPADJ

3-15

CHASSISFRONT BRAKE LEVER FREE PLAY CHECK1. Check:

8 Front brake lever free play

2~5 mm

wA soft or spongy feeling in the brake lever canindicate the presence of air in the brake sys-tem. This air must be removed by bleeding thebrake system before the motorcycle is oper-ated. Air in the system will cause greatly di-minished braking capability and can result inloss of control and an accident. Inspect andbleed the system if necessary.

FRONT BRAKE LEVER FREE PLAY CHECK/REAR BRAKELEVER FREE PLAY CHECK/BRAKE PAD INSPECTION

a

1

1

1

3 2

REAR BRAKE LEVER FREE PLAY CHECK1. Check:

8 Rear brake lever free play aOut of specification→Adjust.

10 ~ 20 mm

***************************************Rear brake lever free play adjustment steps:8 Turn the adjuster 1 in or out until the cor-

rect free play is obtained.***************************************

BRAKE PAD INSPECTION1. Activate the brake lever.2. Inspect:

8 Brake padWear indicator 1 nearly contactingbrake disc→Replace brake pads as a set.Refer to the “BRAKE PAD REPLACE-MENT” section in the CHAPTER 6.2 Brake disc3 Brake pads

INSPADJ

3-16

BRAKE SHOE INSPECTION1. Activate the brake lever.2. Inspect:

8 Wear indicator 1Indicator at wear limit line 2→Replacebrake shoes.

BRAKE FLUID LEVEL INSPECTIONNOTE:

Position the scooter straight up when inspect-ing the fluid level.

1. Inspect:8 Fluid level is under “LOWER” level line1→Fill to proper level.

Recommended fluid:DOT#4

cCThe fluid may corrode painted surfaces or plas-tic parts. Always clean up spilled fluid immedi-ately.

w8Use only the designated quality fluid. Other-wise ,the rubberseals may deteriorate caus-ing leakage and poor brake performance.

8Refill with the same type of fluid. Mixing flu-ids may result in a harmful chemical reactionleading to poor brake performance.

8Be careful that water does not enter the mas-ter cylinder when refilling. Water will signifi-cantly lower the boiling point of the fluid andmay result in vapor lock.

BRAKE SHOE INSPECTION/BRAKE FLUID LEVEL INSPECTION

1

1

2

INSPADJ

3-17

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)1. Bleed:

8 Brake fluid***************************************Air bleeding steps:

a. Add proper brake fluid to the reservoir.b. Install the diaphragm. Be careful not to

spill any fluid or allow the reservoir tooverflow.

c. Connect the clear plastic tube 1 tightly tothe caliper bleed screw.

d. Place the other end of the tube into a con-tainer.

e. Slowly apply the brake lever several times.f. Pull the lever in. Hold the lever in posi-

tion.g. Loosen the bleed screw and allow the le-

ver to travel towards its limit.h. Tighten the bleed screw when the limit

has been reached, then release the lever.i. Repeat steps (e) to (h) until the air bubbles

have been removed from the system.j. Add brake fluid to proper level.

wCheck the operation of the brake after bleed-ing the brake system.

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

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

1

INSPADJ

3-18

STEERING ADJUSTMENT1. Check:

8 Steering assembly bearingsGap the bottom of the forks and gentlyrock the fork assembly back and forth.Loosen→Adjust.

***************************************Adjustment steps:8 Remove upper cover, lower cowling, leg

shield 1,2. refer to “COVER AND PANEL” sec-tion.

8 Remove all ringnuts using ringnut wrench.

Ring nut wrench:90890-01403

8 Tighten the ring nut 3 1 using nut wrench.28 Nm(2.8 kg.m)

NOTE:

Set the torque wrench to the ring nut wrenchso that they form a right angle.

8 Loosen the ring nut 3 1 1/4 turn.8 Install rubber ring 2 and ring nut 2 3, then

tighten the ring nut 2 until it contacts withrubber ring.

cCAligning the slot of ring nut 2 with the slot ofring nut 3. If not, slightly tighten ring nut 2 un-til the slots alignment.

8 Install special washer 4NOTE:

Insert the projections of special washer into theslots of ring nut 3, 2

8 Install ring nut 1 5 66Nm(6.6 kg.m)

8 Move the handlebar up and down, and/orback and forth. If handlebar play is excess,remove the front fork assembly and checkthe balls/ball races. Refer to chapter 6.

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

STEERING ADJUSTMENT

1

T R..

2

34

5

T R..

INSPADJ

3-19

TIRE INSPECTION

w8 Do not attempt to use tubeless tires on a

wheel designed for tube type tires only.Tire failure and personal injury may resultfrom sudden deflation.

Wheel Tire

Tube type Tube type only

Tubeless type Tube type ortubeless type

8 Be sure to install the correct tube when us-ing tube type tires.

1. Measure:8 Air pressure

Out of specification→Adjust.

TIRE INSPECTION

Maximum load*Cold tire pressureUp to 90 kg90 kg load~ Maximumload

* Load is the total weight of cargo, rider, pas-senger and accessories.

2. Inspect:8 Tire surfaces

Wear/Damage→Replace.

Minimum tire tread depth 1 (front and rear):

1.6 mm (0.06 in)

1 Tread depth2 Side wall3 Wear indicator

160 kg Front Rear200 kpa(2.00 kg/cm2,2.00 bar)

FRONT

Manufacturec Size Type

CHENG SHIN 120/90-10 56J

FRONT

Manufacturec Size Type

CHENG SHIN 130/90-10 59J

INSPADJ

3-20

WHEEL INSPECTION1. Inspect:

8 wheelsDamage/Bends→Replace.

wNever attempt even small repairs to the wheel.

FRONT FORK INSPECTION1. Inspect:

8 Front fork1Bends/Damage→Replace inner tubecomp, fork ass’y.Grease leakage→Replace inner tubecomp. fork ass’y.Unsmooth operation→Replace forkass’y.

REAR SHOCK ABSORBER INSPECTION1. Inspection:

8 Rear shock absorber1Oil leaks/Damage→Replace.

2. Check8 Tightening torque

Upper(nut) 30Nm (3.0 m.kg)

Lower (bolt) 16 Nm(1.6 m.kg)

SEAT LOCK CABLE ADJUSTMENT1. Remove:

8 Protector bar8 Upper cover

Refer to “COVER AND PANEL” section.2. Adjust:

8 Seat cable***************************************Seat cable adjustment steps:8 Loosen lock nut 18 Turn adjuster 2 in or out to adjust the seat

lock cable.8 Tighten the lock nut.***************************************3. Install:

8 Upper cover8 Protector bar

WHEEL INSPECTION/FRONT FORK INSPECTION

REAR SHOCK ABSORBER INSPECTION/SEAT LOCK CABLEADJUSTMENT

1T R.

.

1

2

1

INSPADJ

3-21

BATTERY INSPECTION

ELECTRICALBATTERY INSPECTIONNOTE:

Since the MF battery is of a sealed-type con-struction, it is impossible to measure the spe-cific gravity of the electrolyte in order to checkthe state of charge in the battery. Therefore, tocheck the state of charge in the battery, volt-age must be measured at the battery terminals.

cCCHARGING METHOD8This battery is sealed type. Never remove

sealing caps even when charging. With thesealing cap removed, this balancing will notbe maintained, and battery performance willlower gradually.

8Never add water. If distilled water is added,chemical reaction in the battery will not pro-ceed in the normal way, thus making it im-possible for the battery to operate regularly.

8The charging time, charging current andcharging voltage for the MF battery is differ-ent than general type batteries.The MF battery should be charged as in-structed in the “Charging method”. Shouldthe battery be overcharged, the electrolytelevel will lower extremely. Therefore, usespecial care when charging the battery.

8Avoid using any electrolyte other than speci-fied. The specific gravity of the MF batteryelectrolyte is 1.32 at 20°C (68°F). (The spe-cific gravity of the general type battery elec-trolyte is 1.28. ) If the electrolyte whose spe-cific gravity is less than 1.32, the sulfuric acidwill decrease and thus low battery perfor-mance will result.Should any electrolyte, whose specific grav-ity is 1.32 or more, be used, the battery plateswill corrode and battery life will shorten.

1. Remove:8 Battery box coverRefer to “COVER AND PANEL” section.

2. Remove:8 Battery

NOTE:

Remove the (–) lead first.

INSPADJ

3-22

wBattery electrolyte is dangerous; it containssulfuric acid and therefore is poisonous andhighly caustic.Always follow these preventive measures:8Avoid bodily contact with electrolyte as it can

cause severe burns or permanent eye injury.8Wear protective eye gear when handling or

working near batteries.Antidote (EXTERNAL):8SKIN-Flush with water.8EYES-Flush with water for 15 minutes and

get immediate medical attention.Antidote (INTERNAL):8Drink large quantities of water or milk fol-

low with milk of magnesia, beaten egg, orvegetable oil. Get immediate medical atten-tion .Batteries also generate explosive hydrogengas, therefore you should always followthese preventive measures:

8Charge batteries in a well-ventilated area.8Keep batteries away from fire, sparks, or

open flames (e.g., welding equipment,lighted cigarettes, etc.)

8DO NOT SMOKE When charging or handlingbatteries.

KEEP BATTERIES AND ELECTROLYTE OUTOF REACH OF CHILDREN.

3. Check:8 Battery condition

***************************************Battery condition checking steps:8 Connect a digital volt meter to the battery ter-

minals.

Tester (+) lead Battery (+) terminal.Tester (-) lead Battery (–) terminal.

NOTE:

The state of a discharged MF battery can bechecked by measuring open circuit voltage (thevoltage measured with the positive terminalsbeing disconnected).

12.8VVolt meter

Relationship between open-circuitvoltage and charging time 20°C(68°C)

Charging time(hours)•This varies depending on the temperature, the state of charge in battery plates and the electrolyte level.

Ope

n-ci

rcui

t vol

tage

(v)13.0

12.5

12.0

11.5

5 6.5 10

BATTERY INSPECTION

INSPADJ

3-23

BATTERY INSPECTION

14

13

12

11

10

100 75 50 30 25 20 0

Condition of charge in battery(%)

Ambienttemperature20°C

Ope

n-ci

rcui

t vol

tage

(v)

Time(Minutes)

Ope

n-ci

rcui

t vol

tage

(v)

Ambient temperature20°C

Check the open-circuitvoltage

18

17

16

15

14

13

12

11

100 10 20 30 40

Charging

Open circuit voltage Charging time

12.8 v or more No charging is necessary.

8 Check the battery condition using figures.EXAMPLE:Open circuit voltage = 12.0vCharging time = 6.5 hoursCondition of charge in battery = 20 ~ 30%***************************************2. Charging method of MF battery

cC8 If it is impossible to set the standard charg-

ing current, be careful not to overcharge.8When charging the battery, be sure to re-

move it from the motorcycle. (If charging hasto be done with the battery mounted on themotorcycle for some reason, be sure to dis-connect the wire at the negative terminal.)

8Never remove the sealing plug from the MFbattery.

8Use special care so that charging clips are ina full contact with the terminal and that theyare not shorted. (A corroded clip of thecharger may cause the battery to generateheat at the contact area. A weak clip springmay cause sparks.)

8Before removing the clips from the batteryterminals, be sure to turn off the powerswitch of the charger.

8Change in the open-circuit voltage of the MFbattery after being charged is shown below.As shown in the figure, the open circuit volt-age is stabilized 30 minutes after charginghas been completed.Therefore, to check the condition of the bat-tery, measure the open-circuit voltage 30minutes after has been completed.

INSPADJ

3-24

BATTERY INSPECTION

Charging method using a variable-current (voltage) type charger

Measure the open-circuit volt-age prier to charging.

Connect a charger and AMPmeter to the battery and startcharging.

Make sure the current is higherthan the standard chargingcurrent written on the battery.

Adjust the voltage so that currentis at standard charging level.

Set the timer according to thecharging time suitable for theopen-circuit voltage. Refer to“Battery condition checkingsteps”.

By turning the charging voltageadjust dial, set the charging volt-age at 20 - 25 V.

Monitor the amperage for 3-5minutes to check if the standardcharging current is reached.

If current doesnot exceed stan-dard chargingcurrent after 5minutes, replacethe battery.

In case that charging requires more than 5 hours, it is advisable tocheck the charging current after a lapse of 5 hours. If there is anychange in the amperage, readjust the voltage to obtain the standardcharging current.

NOTE:Voltage should be measured30 minutes after the machineis stopped.

NOTE:Set the changing voltage at16-17 V. (If the setting is lower,charging Will be insufficient.If too high, the battery Will beover-charged.)

Measure the battery open-circuit voltage after having left the bat-tery unused for more than 30 minutes.12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is required.Under12.0 V --- Replace the battery.

NOYES

YES

NO

Charger AMPmeter

INSPADJ

3-25

BATTERY INSPECTION

Charging method using a constant current type charger This type if battery charger Can not charge the MF battery.

Charging method using a constant-voltage type charger

Measure the open-circuit volt-age prier to charging.

Connect a charger and AMPmeter to the battery, and startcharging.

Make sure the current is higherthan the standard chargingcurrent written on the battery.

Charge the battery until thebattery’s charging voltage is 15volts.

Check the open-circuit voltage after hav-ing left the battery for 30 minutesafter charging.12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is neces-

sary.Under 12 V --- Replace the battery.

This type of battery charger Cannot charge the MF battery. Avariable voltage charger is rec-ommended.

NOTE:Voltage should be measured 30 min-utes after the machine is stopped.

NOTE:Set the charging time at 20 hours(maximum).

YES NO

Charger

AMP meterVolt meter

INSPADJ

3-26

FUSE INSPECTION1. Remove:

8 Battery box coverRefer to “COVER AND PANEL” section.

2. Remove:8 Fuse 1

3. Inspect:8 Fuse 1

defective→Replace***************************************Blown fuse procedure steps:8 Turn off ignition and the circuit.8 Install a new fuse of proper amperage.8 Turn on switches to verify operation of elec-

trical device.8 If fuse blows immediately again, check cir-

cuit in question.***************************************

wDo not use fuses of higher amperage ratingthan recommended. Extensive electrical sys-tem damage and fire could result from substi-tution of a fuse of improper amperage.

Description Amperage Quantity

Main 7A 1

4. Install:8 Fuse8 Battery box cover

4. Inspect:8 Battery terminal

Dirty terminal→Clean with wire brush.Poor connection→Correct.

NOTE:

After cleaning terminals, apply lightly to theterminals.

5. Install8 Battery8 Battery box cover

FUSE INSPECTION

1

INSPADJ

3-27

HEAD LIGHT BEAM ADJUSTMENT1. Adjust:

8 Head light (vertically)Turn the adjusting screw in or out toadjust headlight beam.

HEADLIGHT BULB REPLACEMENT1. Remove:

8 Protector bar8 Upper cover

Refer to “COVER AND PANEL” section.

HEADLIGHT BEAM ADJUSTMENT/HEADLIGHT BULB REPLACEMENT

1

12. Remove:

8 Headlight leads coupler 1

3. Remove:8 Bulb holder 1

Turn the bulb holder counterclockwiseto remove it.

4. Remove:8 Bulb(defective)1

Push bulb in and turn it counterclock-wise to remove it

wKeep flamble products and your hand awayfrom the bulb while it is on, since it is veryhot. Do not touch the bulb until it cools down.

1

1

INSPADJ

3-28

5. Install:8 Bulb(new)

cCAvoid touching the glass part of bulb. keep itfree from oil; oil could adversely and illuminousflux. If oil gets on bulb, clean it with a cloththoroughly moistened with alcohol or lacquerthinner.

6. Install:8 Bulb holder

7. Connect:8 Headlight leads coupler

8. Install:8 Upper8 Protector bar

9. Adjust:8 Headlight beam

Refer to “HEADLIGHT BEAMADJUSTMENT”section

TAILLIGHT BULB / REAR FLASHER BULB REPLACEMENTFRONT FLASHER BULB REPLACEMENT

2

TURN SIGNAL AND TAILLIGHT BULB RE-PLACEMENT1. Remove:

8 Lense 18 Bulb 2

2. Replace:8 Bulb 2

3. Install:8 Lense 1

2

1

1

INSPADJ

3-29

TAILLIGHT BULB / REAR FLASHER BULB REPLACEMENTFRONT FLASHER BULB REPLACEMENT

cCDo not over-tighten the screws as the lensemay break.

2

2

1

1

LICENSE LIGHT BULB REPLACEMENT1. Remove:

8 Lense 18 Bulb 2

2. Replace:8 Bulb (defective) 2

3. Install:8 Lense 1

4-1

ENGEB400000

ENGINE OVERHAULENGINE REMOVALWIREHARNESS AND CABLES

ENGINE REMOVAL

Remarks

Remove the parts in order.

Refer to “COVER AND PANEL” sectionin CHAPTER 3.

Refer to “CARBURETOR” section inCHAPTER 6.

Job name/Part name

Wireharness and cables removalRear carrierTail coverLeft side panelRight side panelBattery box coverCenter cowlingAir filter caseCarburetor

Air shroud 3Rear fender screwAutolube delivery hoseAutolube pump cable

Order

1234

Q’ty

1111

45Nm(4.5kg.m)T R..14

1 10

4

6 57

15

38

1211

2

13

9

120Nm(12.0kg.m)T R..

4-2

ENG

Order

56789

101112131415

Job name/Part name

Spark plug capBattery (-) leadC.D.I magneto leads couplerStarter motor leads couplerRear wheel nut

Rear brake adjusterRear brake cablePinBoltEngine mount boltEngine

Q’ty

11111

111111

Remarks

NOTE:Loosen the rear wheel nut.

Reverse the removal procesure for in-stallation.

ENGINE REMOVAL

45Nm(4.5kg.m)T R..14

1 10

4

6 57

15

38

1211

2

13

9

120Nm(12.0kg.m)T R..

4-3

ENGCYLINDER HEAD, CYLINDER AND PISTON

CYLINDER HEAD, CYLINDER AND PISTON

Job name/Part name

Cylinder head, Cylinder and pistonremovalEngineMuffler/GasketAir shroud (cylinder head)Spark plugCylinder head/Cylinder head gasketCylinderPiston pin clipPiston pin/ BearingPistonPiston ring setCylinder gasket

Remarks

Remove the parts in the order.

Refer to the “ENGINE REMOVAL” sec-tion

Reverse the removal procedure for in-stallation.

Order

123456789

10

Q’ty

1/111

1/112

1/1111

4

5

6

7

10 1

2

3

26Nm(2.6kg.m)T R..

14Nm(1.4kg.m)T R..

12Nm(1.2kg.m)T R..

New

New

New

E

89

CYLINDER HEAD, CYLINDER AND PISTON

4-4

ENG

PISTON PIN AND PISTON REMOVAL1. Remove:8 Piston pin clip 1

NOTE:

Before removing the piston pin clip, cover thecrankcase with a clean rag so you will not acci-dentally drop the clip into the crankcase.

2. Remove:8 Piston pin 18 Piston 28 Piston pin bearing 3

cCDo not use a hammer to drive the piston pinout.

CYLINDER HEAD INSPECTION1. Eliminate:8 Carbon deposits

Use a rounded scrapper 1.

2. Inspect:8 Cylinder head warpage

Out of specification→Re-surface.*************************************Warpage measurement and re-surfacementsteps:8 Attach a straight edge 1 and a thickness

gauge 2 on the cylinder head.8Measure the warpage limit.

Warpage limit:0.05 mm

8 If the warpage is out of specification, refacethe cylinder head.

NOTE:

Rotate the head severai tires to avoid remov-ing too much material from one side.

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

CYLINDER HEAD, CYLINDER, PISTON

2

1

4-5

ENG

CYLINDER AND PISTON INSPECTION1. Eliminate:8 Carbon deposits

Use a rounded scraper 1.2. Inspect:8 Cylinder wall

Wear/Scratches→Rebore or replace.

3. Eliminate:8 Carbon deposits 1

From the piston crown and ringgrooves.

4. Remove:8 Score markes and lacquer deposits

From the sides of piston.5. Inspect:8 Piston wall

Wear/Scratches/Damage→Replace.

6. Measure:8 Piston-to cylinder clearance

*************************************Piston to cylinder clearance measurementsteps: First step:8Measure the cylinder bore “C” with a cylin-

der bore gauge.NOTE:

Measure the cylinder bore “C” in parallel to andat right angles to the crankshaft. Then, find theaverage of the measurements.

CYLINDER AND PISTON INSPECTION

D1

D2

D3

D4

D5D6

1

1

1

4-6

ENGCYLINDER HEAD, CYLINDER AND PISTON

Standard Wear limit

C = Maximum DT=( Maximum D1 or D2 ) - ( Maximum D5 orD6 )R=( Maximum D1 D3 or D5 ) - ( Maximum D2D4 or D6 )

Cylinder bore“C”

Taper “T”

Out of round“R”

52.002~52.012mm

–

–

8 If out of specification, rebore or replace cyl-inder, and replace piston and piston ringsas a set.

2nd step:8Measure the piston skirt diameter “p” with

a micrometer.a 10 mm from the piston bottom edge.

Piston size P

51.958~51.967 mm52.25 mm52.50 mm

StandardOversize 1Oversize 2

8 If out of specification, replace piston and pis-ton rings as a set.

3rd step:8 Calculate the piston-to cylinder clearance

with following formula:

Piston-to cylinder clearance = Cylinder bore“ C ”- Piston skirt diameter “p”

8 If out of specification, rebore or replace cyl-inder, and replace piston and piston rings asa set.

Piston-to cylinder clearance:0.044~0.045mmLimit : 0.1 mm

a

52.10 mm

0.05 mm

0.03 mm

4-7

ENGCYLINDER HEAD, CYLINDER AND PISTON

a Measuring Point 20 mm4. Oversize piston ring size:

Ring size is stamped on top of the ring.

Oversize piston ring

Oversize 1 25

Oversize 2 50

PISTON PIN AND PISTON PIN BEARING1. Inspect:8 Piston pin

Blue discoloration/Groove→Replace,then inspect lubrication system.

PISTON RINGS INSPECTION1. Measure:8 Side clearance

Out of specification→Replace pistonand/or rings.Use a feeler gauge 1

Top ring 0.03 ~ 0.05 mm 0.60 mm

2nd ring 0.03 ~ 0.05 mm 0.60 mm

Standard Limit

2. Install:8 Piston ring

Into the cylinderPush the ring with the piston crown.

3. Measure:8 End gap

Out of specification→Replace rings asa set.Use a feeler gauge 1.

Top ring 0.15 ~ 0.35 mm 0.10 mm

2nd ring 0.15 ~ 0.35 mm 0.10 mm

a

Standard Limit

4-8

ENG

2. Measure:8 Outside diameter a (piston pin)

Out of specification→Replace.

Out side diameter (piston pin):13.996~14.000 mm

3. Measure:8 Piston pin-to-piston clearance

Out of specification→Replace piston.

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

Piston pin-to-piston clearance:0.008~0.015 mm<Limit: 0.07 mm>

4. Inspect:8 Bearing(piston pin)

Pitting/Damage→Replace.

PISTON PIN AND PISTON INSTALLATION1. Apply:8 Engine oil

(to the crankshaft bearing, connectingrod big end bearing, small end bearing,piston pin, piston ring grooves and pis-ton skirt areas.)

2. Install:8 Reed valve gasket8 Reed valve8 Carburetor joint 1 11Nm(1.1 m.kg)

CYLINDER HEAD, CYLINDER AND PISTON

1

E

E

T R..

→ a ←

4-9

ENG

3. Install:8 Small end bearing8 Piston 18 Piston pin 2

8 Piston pin clip 3 NewNOTE:

8 The arrow a on the piston to the exhaustside.8 Before installing the piston pin clip, cover the

crankcase with a clean towel or rag so youwill not accidentally drop the pin clip mate-rial into the crankcase.8 Always use a new piston pin clip.

CYLINDER AND CYLINDER HEAD1. Install:8 Cylinder gasket (new gasket)

2. Check:8 Piston rings

1 1st ring2 2nd ringNOTE:

Make sure the ring ends 1 are properly fittedaround the ring locating pins 3 in the pistongrooves.

CYLINDER HEAD, CYLINDER AND PISTON

3. Install:8 Cylinder 1

NOTE:

Install the cylinder with one hand while com-pressing the piston rings with the other hand.

a New

1

New

4-10

ENG

4. Install:8 Cylinder head gasket (new gasket)

5. Install:8 Cylinder head 1 14Nm(1.4m.kg

8 Spark plug 2 20Nm(2.0m.kg

8 Air shroudNOTE:

Tighten the cylinder head holding nuts in stage,using a crisscross pattern.

INSPECTION AND REPAIR

1

2

T R..

T R..

4-11

ENG

Remarks

Remove the parts in order.

Reverse the removal procedure for in-stallation.

Order

123456

Q’ty

111112

Job name/Part name

Kick starter and crankcase cover (left)removalAir cleaner assembly mounting screwScrew(Bind)Kick starterCrankcase (left)GasketPin

V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVEKICK STARTER AND CRANKCASE COVER (LEFT)

1

12Nm(1.2kg.m)T R..

23

4

5

6

New

90Nm(0.9kg.m)T R..

90Nm(0.9kg.m)T R..

4-12

ENG

Order

1

2

3

4

5

6

Q’ty

11

1/1111

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVEKICK STARTER

V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE

Job name/Part name

Kick starter removalKickstarter pinion gearKickstarter pinion gear clipCirclip/Plain washerKickstarter segment gearReturn springCollar

Remarks

Remove the parts in order.

Reverse the removal procedure for in-stallation.

New

1

2

45

3

6

B

4-13

ENG

KICK STARTER INSTALLATION1. Install:8 Return spring 18 Kick starter segment gear 28 Collar 38 Plain washer 48 Circlip 5

***************************************Installation steps:

a. Install return spring 6 and segment gear7 as shown.

b. Install clip 5.c. Hook the spring onto the crankcase pro-

jection 8.d. Install the kick starter pinion gear 9 and

the kick starter.***************************************

KICK STARTER

2

1

5

3

4

7

6

2

5

8

9

6

4-14

ENG

Order

123456789

10

Q’ty

111

1/111

1/11

1/36

V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVEV-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

Remarks

Remove the parts in order.

Refer to “COVER AND PANEL” sectionin chapter 3.

Refer to “ENGINE REMOVAL” section.Refer to “SECONDARY SHEAVE AND V-BELT REMOVAL ” section.

Refer to “PRIMARY SHEAVE REMOVALASSEMBLY” section.

Reverse the removal procedure for in-stallation

Job name/Part name

V-belt, clutch and secondary/primarysheave removalLower cowlingAir shroud 3

Crankcase (left)Clutch housingSecondary sheave assemblyV-beltConical washer/One-way clutchCrow washerPrimary fixed sheaveCollar/WasherPrimary sliding sheaveCam/ SliderWeight

V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE

1

23

45

67

810

940Nm(4.0kg.m)T R.

.

45Nm(4.5kg.m)T R..

4-15

ENG

Order

1

2

3

4

5

6

7

8

9

0

Q’ty

1131121221

SECONDARY SHEAVESECONDARY SHEAVE

Remarks

Disassemble the parts in order.

Refer to “SECONDARY SHEAVE DISAS-SEMBLY” section.Refer to “SECONDARY SHEAVE IN-STALLATION” section.

Refer to “SECONDARY SHEAVE IN-STALLATION” section.

Reverse the disassembly procedure forassembly.

Job name/Part name

Secondary sheave disassemblyNutClutch carrierClutch shoe springCompression springSpring seatGuide pinSecondary sliding sheaveO-ringOil sealSecondary fixed sheave

V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE

1

2

3

4

5

6

7

8

9

0

New

LS

LS

9

50Nm(5.0kg.m)T R..

4-16

ENG

PRIMARY SHEAVE REMOVAL1. Remove:8 Fan

2. Remove:8 Nut 1 (primary sheave)

NOTE:

When loosening the nut (primary sheave), holdthe C.D.I. magneto using flywheel holding tool2.

Flywheel holding tool:90890-01235

3. Remove:8 Conical spring washer 18 One-way clutch 28Washer 38 Primary fixed sheave 48 Shim 58 V-Belt

4. Remove:8 Collar 18 Primary sheave assembly 2

V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE

SECONDARY SHEAVE REMOVAL1. Remove:8 Nut 1 (secondary sheave)

NOTE:

Hold the secondary sheave using sheave holder2.

Sheave holder:90890-01701

2. Remove:8 Clutch housing8 Secondary sheave assembly8 Dowel pins

1

2

1

2

1

2

4-17

ENGV-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

4. Attach:8 Clutch spring holder 1

Clutch spring holder:90890-01337

5. Remove:8 Clutch securing nut 2

6. Remove:8 Clutch assembly 18 Clutch spring 28 Spring seat 38 Guide pins8 Secondary sliding sheave

Clutch Inspection1. Inspect:8 Clutch shoes

Glazed parts→Sand with coarse sand-paper.

NOTE:

After using the sand paper, clean of the pol-ished particles with cloth.

3. Loosen:8 Nut(Clutch carrier)1

NOTE:

Install the secondary sheave to primary driveshaft as shown, and hold the secondary sheaveby Universal Roter Holder 2 to loosen the nut1.

Universal Roter Holder:90890-01235

cCDo not remove the clutch securing nut yet.If the nut is removed without compressiong thesecondary sheave. It jumps and causes injury.

4-18

ENG

2. Measure:8 Clutch shoe thickness a

Out of specification→Replace.

Clutch shoe thickness:4 mm

< Wear limit>:2.5 mm

V-BELT INSPECTION1. Inspect:8 V-belt1

Crack→Replace.NOTE:

Replace the V-belt smeared with a lot of oil orgrease.

2. Measure:8 V-belt width a

Out of specification→Replace.

V-belt width:17.7 mm

<Wear limit>:16.0 mm

a

V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE

4-19

ENGV-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

PRIMARY SHEAVE INSPECTION1. Inspect:8 Primary sliding sheave 18 Primary fixed sheave 2

Wear/Cracks/Scratch/Damage→Replace.

2. Check:8 Free movement

Insert the collar 1into the primary slid-ing sheave2, and check for free move-ment.Stick or excessive play→Replace thesheave or collar.

3. Measure:8 Out side diameter 1 (weight)

Out of specification→Replace.

Out side diameter (weight)15.0 mm

<Limit 14.5 mm>

1

4-20

ENGV-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

SECONDARY SHEAVE1. Inspect:8 Secondary fixed sheave 18 Secondary sliding sheave 2

Scratch/Crack/Damage→Replace as aset.8 Oil seal 3

Damage→Replace

2. Inspect:8 Torque cam grove 18 Guide pin 2

Wear/Damage→Replace as a set.8 O-rings 3

Damage→Replace.

3. Measure:8 Clutch spring free length

Out of specification→Replace.

Clutch spring free length:81 mm<Limit>:73 mm

4. Inspect:8 Clutch housing inner surface

Oil/Scratches→Remove.

5. Measure:8 Clutch housing inside diameter a

Out of specification→Replace.

Clutch housing inside diameter:112.0 mm

<Wear limit>:112.5 mm

Use a rag soaked in lacquerthinner or solvent.Use an emery cloth (lightlyand evenly polishing).

Oil

Scratchesa

a

4-21

ENGV-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

SECONDARY SHEAVE INSTALLATIONWhen assembling the secondary sheave, re-verse the disassembly procedure. Note the fol-lowing points.

1. Apply:8 BEL-RAY assembly lube®

(to the inside of the sliding/fixed sheave)

2. Install:8 Sliding sheave 1

NOTE:

Be careful so that the oil seal 2 lips are notturned over when installing the sheave.

3. Apply:8 BEL-RAY assembly lube®

(to the torque cam grooves and O-rings)

4. Install:8 Guide pin 1

5. Check:8 Sliding sheave

Unsmooth operation→Repair.

6. Install:8 Clutch securing nut 1

Use clutch spring holder 2

Clutch spring holder:90890-01337

7. Tighten:8 Clutch securing nut 1 50 Nm(5.0 m.kg)

Use Flywheel holding tool 2

Fly holding tool90890-01235

E

E

T R..

4-22

ENGV-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

9. Tighten:8 Nut 1 (secondary sheave) 40 Nm(4.0 m.kg)

Use sheaveholder 2

Sheave holder:90890-01701

PRIMARY SHEAVE1. Clean:8 Primary sliding sheave face 18 Primary fixed sheave face 28 Collar 38Weight 48 Primary sliding sheave cam surface 5

2. Install:8Weight 18 Cam 28 Slider 38 Collar 4

3. Check:8 Cam operation

Not smooth→Repair.

4. Install:8 Primary sheave assembly 18 Collar 2

5. Install:8 V-belt

8. Install:8 Secondary sheave assembly8 Clutch housing 18 V-belt 2

NOTE:

The V-belt must be installed with the arrowfrontward.

T R..

2

1

1

2

1

2

4-23

ENGV-BELT, CLUTCH AND

SECONDARY/PRIMARY SHEAVE

6. Install:8 Shim 18 Primary fixed sheave 28Washer 38 One-way clutch 48 Conical spring washer 58 Nut 6

7. Tighten:8 Nut 1 (primary sheave)

45 Nm(4.5 kg.m)

NOTE:

When tightening the nut (primary sheave), holdthe C.D.I. magneto using Flywheel Holding Tool2 .

Flywheel holding90890-01235

8. Adjust:8 V-belt 1

Tense the V-belt by turning the primarysheave several times.

9. Install:8 Fan 7 Nm (0.7 kg.m)T R.

.

1

2

T R..

1

4-24

ENG

Order

12345

Q’ty

21121

STARTER CLUTCH AND STARTER MOTOR

STARTER CLUTCH AND STARTER MOTOR

Remarks

Remove the parts in order.

Refer to “COVERS AND PANEL” sectionin chapter 3.

Refer to “C.D.I. MAGNETO ” section

Refer to “REAR WHEEL” section in chap-ter 6.Refer to “KICKER STARTER ” section.

Refer to “V-BELT, PRIMARY SHEAVE ”section.

Job name/Part name

Starter clutch and starter motor re-movalLeft/Right side coverCenter coverLower cowlingAir shroud 3Cooling fanRear wheel

Crankcase cover (left)

Primary sheave

PlatePlain washerIdle gearPlain washerStarter clutch

10

9

8

7 65

4

3

2

1

New

B

M

13Nm(1.3kg.m)T R..

8Nm(0.8kg.m)T R..

STARTER CLUTCH AND STARTER MOTOR

4-25

ENG

Order

6789

10

Job name/Part name

Plain washerStarter wheel gearCollarStarter motorStarter motor coupler

Q’ty

21112

Remarks

Reverse the removal procedure forinstalation

10

9

8

7 65

4

3

2

1

New

B

M

13Nm(1.3kg.m)T R..

8Nm(0.8kg.m)T R..

STARTER CLUTCH AND STARTER MOTOR

4-26

ENG

STARTER CLUTCH AND GEARS1. Inspect:8 Starter clutch

Push the dowel pin to arrow direction.Unsmooth operation→Replace starterclutch assembly.

2. Inspect:8 Starter wheel gear teeth 18 Idle gear teeth 2

Burrs/Chips/Roughness/Wear→Replace.

3. Inspect:8 Starter clutch operation

***************************************Clutch operation checking steps:8 Install the starter wheel gear to the starter

clutch, and hold the starter clutch.8When turning the wheel gear clockwise A

the starter clutch and the wheel gear shouldbe engaged.If not the starter clutch is faulty. Replace it.8When turning the wheel gear counter clock-

wise B, the wheel gear should turn freely. Ifnot, the starter clutch is faulty. Replace it.

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

INSPECTION AND REPAIR

12

4-27

ENG

Order

12345678

Q’ty

11/1111111

C.D.I. MAGNET

C.D.I. MAGNET

Remarks

Remove the parts in order.

Refer to “COVER AND PANEL” sectionin chapter 3.

Reverse the removal procedure for in-stallation.

Job name/Part name

C.D.I. magneto removalRear carrierTail coverLeft side coverRight side coverCenter coverLower cowlingAir shroud 3Fan /O-ringMagneto rotorBindCouplers (magneto leads)Stator coilWood ruff keyGasket (Magneto cover)

1

2

3

45

6

7

8 New

43Nm(4.3kg.m)T R..

8Nm(0.8kg.m)T R..

C.D.I. MAGNET

7Nm(0.7kg.m)T R..

4-28

ENG

C.D.I. MAGNETO REMOVAL1. Remove:8 Nut 1(rotor)8 Plain washer

NOTE:

Hold the rotor to loosen the nut by the flywheelholding tool 2.

Flywheel holding tool:90890-01235

2. Remove:8 Rotor 18Woodruff key

Use the flywheel magneto puller 2.

Flywheel magneto puller:90890-01189

8 Stator assembly8 Gasket

ENGINE DISASSEMBLY

C.D.I. MAGNETO INSTALLATION1. Install:8 Gasket 1

2. Apply:8 Lithium soap base grease

(to oil seal)3. Pass the C.D.I. magneto lead through the

crankcase hole.4. Install:8 Stator assembly 8 Nm(0.8 kg.m)

5. Install:8Woodruff key8 C.D.I. magneto Rotor 18 Plain washer8 Nut 43Nm(4.3 kg.m)

T R..

1

2

1

2

1

B

1

T R..

4-29

ENG

Order

12345678

Q’ty

11111111

AUTOLUBE PUMP

AUTOLUBE PUMP

Remarks

Remove the parts in order.Refer to “C.D.I. magneto” section.

Refer to “Autolube pump installation”section

Reverse the removal procedure for in-stallation.

Job name/Part name

Autolube pump removalC.D.I. magnetoAir shroud 2.CirclipPump drive gearPinOil hoseOil delivery hoseAutolube pump cableAutolube pump ass’y

1

2 3

4

5

6

7

8

4Nm(0.4kg.m)T R..

AUTOLUBE PUMP

4-30

ENGAUTOLUBE PUMP

AUTOLUBE PUMP INSTALLATION

cCAfter installing autolube pump, it must bebleeded.

1. Install8 Pin 18 Pump drive gear 2

8 Circlip 3 New2. Apply:8 Lithium soap base grease

(to O-ring)3. Install:8 Autolube pump 1 4 Nm(0.4m.kg)

4. Apply:8 Lithium soap base grease

(to autolube pump gear 1,2)

15 cc (0.92 cu • in)

1

23

1

B

1

2

B

T R..

New

4-31

ENG

Order

1234567

Q’ty

1121111

TRANSMISSION

TRANSMISSION

Remarks

Remove the parts in order.Refer to “REAR WHEEL/REAR BRAKE ”section in chapter 7.Refer to “V-BELT, CLUTCH, SECOND-ARY/ PRIMARY SHEAVE” sectionRefer to “TRANSMISSION OIL RE-PLACEMENT ” section in chapter 3.

Job name/Part name

Transmission removalRear wheel

Secondary sheave

Drain the transmission oil.

Transmission case coverGasket (transmission case cover)Dowel pinPrimary drive gearPlain washerConical spring washerDrive gear

New

New

18Nm(1.8kg.m)T R..

12Nm(1.2kg.m)T R..

12

3

4

5

6

78

9

10

B

TRANSMISSION

New

4-32

ENG

New

New

18Nm(1.8kg.m)T R..

12Nm(1.2kg.m)T R..

12

3

4

5

6

78

9

10

B

TRANSMISSION

Order

8910

Job name/Part name

CirclipMain axleDrive axle

Q’ty

111

Remarks

Reverse the removal procedure for in-stallation.

New

4-33

ENG

New

New

New

9Nm(0.9kg.m)T R.. 12Nm(1.2kg.m)T R.

.

3

4

1

2

65

7

8

109

B

Order Q’ty

CRANKCASE AND REED VALVECRANKCASE AND REED VALVE

CRANKCASE AND REED VALVE

Remarks

Remove the parts in order.

Refer to “ENGINE REMOVAL” section.Refer to “CYLINDER HEAD CYLINDERAND PISTON” section.Refer to “KICK STARTER AND CRANK-CASE COVER (LEFT) ” section.Refer to “V-BELT, CLUTCH AND SEC-ONDARY/PRIMARY SHEAVE ” section.Refer to “C.D.I. MAGNETO” section.Refer to “STARTOR CLUTCH ANDSTARTOR MOTOR” section.Refer to “AUTOLUBE PUMP” section.Refer to “REAR WHEEL AND REARBRAKE” section in chapter 6.Refer to “TRANSMISSION” section.

Job name/Part name

Crankcase and Reed valve removal

Engine removalCylinder head, cylinder, piston

Crankcase cover (left)

V-belt, clutch, secondary/primarysheaveC.D.I . magnetoStarter clutch, starter motor

Autolube pumpRear wheel

Transmission

4-34

ENGCRANKCASE AND REED VALVE

Order

123456789

10

Job name/Part name

Intake manifoldReed valveValve seat gasketStopperCrankcase 2Dowel pinEngine mount spacerCirclipBearingOil seal

Q’ty

1111121111

Remarks

Reverse the removal procedure for in-stallation.

New

New

New

9Nm(0.9kg.m)T R..

12Nm(1.2kg.m)T R..

3

4

1

2

65

7

8

109

B

4-35

ENG

2. Attach:8 Crankcase separating tool 1

Crankcase separating tool:90890-01135

NOTE:

Fully tighten the tool holding bolts, but makesure the tool body is parallel with the case. Ifnecessary, one screw may be backed outslightly to level tool body.

3. Remove8 Crankcase (right)

As pressure is applied, alternately tapon the engine mounting bosses.

CRANKCASE AND REED VALVE

CRANKCASE(RIGHT) REMOVAL1. Remove:8 Oil seal stopper 18 Screws (crankcase) 9Nm(0.9 kg.m)

NOTE:

Loosen each screw 1/4 turn, and remove themafter all are loosened.

REED VALVE INSPECTION1. Measure:8 Valve stopper height 1

Out of specification→Adjust stopper/Re-place valve stopper.

Valve stopper height 16.0~6.4 mm

2. Measure:8 Reed valve clearance 2

Out of specification→Replace reedvalve.

Reed valve clearance 2Less than 0.2 mm

T R..

4-36

ENG

CRANKCASE (RIGHT) INSTALLATION1. Install:8 Dowel pins 18 Engine mount spacer 2

2. Apply:8 Yamaha Bond No.1215 3

To the mating surfaces of both casehelves.

Yamaha bond No.1215:90890-85505

3. Attach:8 Crankshaft installing tool 1,2,3

Crankshaft installing tool:90890-01274190890-01275290890-01277

CRANKCASE AND REED VALVE

4. Tighten:8 Crankcase holding screws

12 Nm(1.2 kg.m)

NOTE:

Tighten the crankcase holding screws in stage,using a crisscross pattern.

5. Check:8 Crankshaft operation

Unsmnoth operation Repair.6. Install:

8 Oil seal (right crank case) 1 NewApply grease on to oil seal lip.

T R..

2

1

7. Install:8 Oil seal stopper plate 1

9 Nm (0.9 kg.m)

New

B

2

3

1

T R..

4-37

ENGCRANKCASE AND REED VALVE

8. Install:8 Gasket8 Reed valve8 Reed valve 1 11 Nm(1.1 kg.m)T R.

.

1

4-38

ENG

Order

1234

Q’ty

1221

CRANKSHAFT

Remarks

Remove the parts in order.Refer to “CRANK CASE AND REEDVALVE” section.

Reverse the removal procedure for in-stallation.

Job name/Part name

Crankshaft removalRight crankcase removal

CrankshaftBearingOil sealCrankcase cover (left)

CRANKSHAFT

1

2

3

4

2

3E

E

B

B

CRANKSHAFT

4-39

ENGCRANKSHAFT

CRANKSHAFT REMOVAL1. Attach:8 Crankcase separating tool 1

Crankcase separating tool:90890-01135

2. Remove:8 Crankshaft 2

CRANKSHAFT INSPECTION1. Measure:8 Runout limit “ C”8 Connecting rod big end side clearance

“D”8 Small end free play limit “F”

Out of specification→Replace.Use V-blocks, dial gauge and thicknessgauge.

Runout limit “C”:0.03 mm

Connecting rod big end side clear-ance “D”:

0.2 ~ 0.5 mmSmall end free play “ F”:

0.4 ~ 0.8 mm

2. Inspect:8 Bearings (crankshaft)

Spin the bearing inner race.Excessive play/Roughness→Replace.Pitting/Damage→Replace.

12

D

F

C C

4-40

ENG

CRANKSHAFT INSTLATION1. Attach:8 Crankshaft Installing Tool

Crankshaft installing tool:90890-0127490890-0127590890-01277190890-012882

2. Install:8 Crankshaft3

(to the crankcase4)

CRANKSHAFT

3. Install:8 Oil seal 18 Apply lithium soap base grease onto

the oil seal lip.Use the guide 2 and seal driver 3 toinstall the oil seal

Oil seal driver90890-01410

Oil seal guide90890-01409

New

3

4

12

3

1

2

5-1

CARB

Order

1234567

Q’ty

1111111

CARBURETIONCARBURETOR

CARBURETOR

Remarks

Remove the parts in order.

Refer to “COVER AND PANEL” sectionin CHAPTER 3.

Reverse the removal procedure for instal-lation.

Job name/Part name

Carburetor removalBattery box coverGripEnd coverLeft/Right coverCenter coverAir cleaner case assemblyCarburetor assemblyAuto choke lead couplerFuel hoseVacuum hoseOil delivery pipeThrottle cable

T R..

9Nm(0.9kg.m)1

2

3

45

6

7

5-2

CARB

Order

1

2

3

4

5

6

7

8

9

0

q

w

e

r

Q’ty

1111111

1/1111111

CABURETOR DISASSEMBLY

Remarks

Disassemble the parts in order.

Reverse the removal procedure for in-stallation.

Job name/Part name

Carburetor disassemblyThrottle valveThrottle cableNeedle setCarburetor top coverThrottle stop screwPilot air screwAuto choke unit assemblyFloat chamber/Seal ringFloat pinFloat/Needle valveMain jetPilot jetMain nozzleCarburetor body

CARBURETOR

6

7

8

9

0q

w

e

1

2

3

5

r

4

5-3

CARB

CABURETOR INSPECTIONMeasure:8 Float height a

Out of specification→Inspect needle valve,float and valve seat.

Float height:16.5 mm

***************************************Float height measurement steps:8 Install the needle valve, float and float pin to

the carburetor body.8 Hold the carburetor in an upside down posi-

tion.8Measure the distance between the mating

surface of the float chamber (gasket re-moved) and top of the float using a gauge.

NOTE:

The float arm should be resting on the needlevalve, but not compressing the needle valve.

8 If the float height is not within specification,inspect the needle valve, float and valve seat.8 If it is worn, replace it.*************************************NOTE:

The float height is properly adjusted at the Yamaha/MBK factory. Never attempt to adjust it.

CARBURETOR ASSEMBLYTo assemble the carburetor, reverse the disas-sembly procedures.Note the following points.

cC8 Before reassembling, wash all parts in clean

gasoline.8 Always use a new gasket.

1. Install:8 Throttle valve 18 Jet needle 28 Clip 38 Spring seat 4

Jet needle clip position:3/5

CARBURETOR

5-4

CARBCARBURETOR

FUEL LEVEL ADJUSTMENT1. Measure:8 Fuel level a

Out of specifications→Adjust.

Fuel level a:3.0~4.0 mm(Below the float cham-ber line

***************************************Measurement steps:8 Place the scooter on a level surface.8 Use a garage jack under the engine to en-

sure that the carburetor is positioned verti-cally.8 Connect the fuel level gauge 1 to the drain

pipe 2.

Fuel level gauge:90890-01312

8 Loosen the drain screw 3.8Measure the fuel level a with the gauge.8 If the fuel level is incorrect, adjust the fuel

level:8 Remove the float chamber, float, valve seat

and the needle valve.8 Inspect the valve seat and needle valve.8 If either is worn, replace them both.

2. Install:8 Throttle valve 1

NOTE:

Align the groove of the throttle valve with theprojection a of the carburetor body.

3. Install:8 Carburetor assembly

NOTE:

Align the projection a with the projections b.

1

a

a

b

a

1

2

3

↓↑

5-5

CARB

8 If both are fine, adjust float level by bendingthe float tang b slightly.8 Install the carburetor.8 Recheck the fuel level.***************************************

AUTO CHOKE INSPECTION(Ambient temperature lower than 45°C)1. Remove:8 Carburetor

2. Inspect:8 Autochoke unitConnect a suitable pipe 2 to the starter 1,

and blow it with the mouth etc. Possible→Goodcondition.

Impossible→Replace auto choke unit.3. Inspect:8 Auto choke unit (with battery)

***************************************Inspection and adjustment steps:8 Connect auto choke unit leads to the 12 V

battery for 5 minutes.Black terminal→12 V battery (+) 1Black terminal→12 V battery (–) 28 Connect a suitable pipe 4 to the starter 5,

and blow it with the mouth etc.Possible→Replace auto choke unit.Impossible→Good condition.

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

CARBURETOR

B B

5-6

CARBCARBURETOR

FUEL COCK INSPECTION1. Stop the engine.2. Remove:8 Grip8 End cover8 Left side cover8 Battery box cover

Refer to “COVER AND PANEL” sectionin chapter 3.

3. Inspect:8 Fuel cock

***************************************Fuel cock inspection steps:8 Disconnect the fuel hose 1.8 Place the receptacle under the fuel hose end.8 If fuel stops flowing out in a few seconds,

the fuel cock is in good condition. If not, cleanor replace the fuel cock.8 Disconnect the vacuum hose 2 and breathe

in the vacuum hose with the mouth etc. forvacuum .8 If fuel flows out of the fuel hose under

vacuum and stops under non-vacuum, thefuel cock is in good condition.If not, clean or replace the vacuum hose, fuelhose and fuel cock.

*************************************4. Install:8 Battery box cover8 Left side cover8 End cover8 Grip

1

2

6-1

CHAS

Order

12345678

Q’ty

11111111

CHASSISFRONT WHEEL AND BRAKE DISC

FRONT WHEEL AND BRAKE DISC

Remarks

Remove the parts in order.

wSecurely support the scooter so there isno danger of it falling over.

Refer to “FRONT WHEEL INSTALLA-TION” section.

Refer to “FRONT WHEEL ASSEMBLY”section.Reverse the removal procedure for in-stallation.

Job name/Part name

Front wheel and brake disc removal

Speedometer cableFront brake hose holderBrake caliperWheel axleFront wheel assemblyGear unit assemblyCollarBrake disc

T R..

7Nm(0.7kg.m)T R.

.

23Nm(2.3kg.m)

T R..

7Nm(0.7kg.m)

T R..

20Nm(2.0kg.m)

B

LT

1

2

3

4

5

6

7

8

6-2

CHAS

Order

1

2

3

4

5

Q’ty

11111

FRONT WHEEL DISASSEMBLY

FRONT WHEEL AND BRAKE DISC

Remarks

Remove the parts in order.Refer to “FRONT WHEEL DISASSEM-BLY/ASSEMBLY” section.

Reverse the removal procedure for in-stallation.

Job name/Part name

Front wheel disassemblyOil sealBearingCollarSpacerBearing

1

2

3

4

5

New

B

B

6-3

CHASFRONT WHEEL AND BRAKE DISCYP ......

FRONT WHEEL DISASSEMBLY1. Remove:8 Bearing 18 Spacer

Remove the bearing using a generalbearing puller 2.

cCHandle the wheel with care not to damage thebrake disc. If the brake disc is damaged, replace.

YP700020

FRONT WHEEL INSPECTION1. Inspect:8 Front wheel axle

(by rolling it on a flat surface)Bends→Replace.

wDo not attempt to straighten a bent axle.

Wheel axle bending limit:0.25 mm

2. Inspect:8 Front tire

Wear/damage→Replace.Refer to “TIRE INSPECTION” in CHAP-TER 3.8 Front wheel

Refer to “WHEEL INSPECTION” inCHAPTER 3.

3. Measure:8 Front wheel runout

Over the specified limits→Replace.

Front wheel runout limits:Radial 1: 1.0 mmLateral 2 : 1.0 mm

4. Inspect:8 Front wheel bearings

Bearings allow free play in the wheelhub or the wheel does not turnsmoothly→ Replace.8 Oil seals

Wear / damage→Replace.

6-4

CHASFRONT WHEEL AND BRAKE DISC

4. Inspect:8 Collar

Grooved wear→Replace the collar andthe oil seal as a set.

YP.....

BRAKE DISC INSPECTION1. Measure:8 Brake disc deflection1

Maximum deflection:0.15 mm

Out of specification→Replace.

2. Measure:8 Brake disc thicknessa

Brake disc thickness:4.0 mm

Minimum thickness:3.5 mm

Out of specification→Replace.YP.....

FRONT WHEEL ASSEMBLY1. Install:8 Bearing 18 Collar 28 Spacer 38 Bearing 48 Oil seal 5

NOTE:

8 Apply the lithium soap base grease on thebearing and oil seal lip when installing.8 Use a socket that matches the outside diam-

eter of the race of the bearing.8 Always use a new oil seal.8 Install the oil seal with its manufacturer’s

marks or numbers facing outward.

cCDo not strike the inner race of balls of the bear-ing. Contact should be made only with the outerrace.

a

New

1

5

B

43

2

6-5

CHASFRONT WHEEL AND BRAKE DISC

EB700030

FRONT WHEEL INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Lubricate:8 Front wheel axle8 Bearings8 Oil seal (lips)8 Drive/driven gear (speedometer)

Recommended lubricant:Lithium soap base grease

2. Install:8 Speedometer gear unit 1

NOTE:

Make sure that the wheel hub and the speed-ometer gear unit are installed with the threeprojections meshed into the two slots.

T R..

2. Install:8 Brake disc 1 20 Nm(2.0 m.kg)

NOTE:

Tighten the bolts (brake disc) in stage using acrisscross pattern.

3. Install:8 Front wheel

NOTE:Make sure that the slot in the speedometer gearunit fits over the stopper on the front fork outertube.

4. Tighten:8 Front wheel axle 18 Axle nut (front wheel axle)

70 Nm(7.0kg.m)

cCBefore tightening the axle nut, stroke the frontfork several times to check for proper fork op-eration.

wMake sure that the brake hose is routed prop-erly.

T R..

1

1

1

6-6

CHASFRONT WHEEL AND BRAKE DISC

YP700040

WHEEL STATIC BALANCE ADJUSTMENTNOTE:

8 After replacing the tire and/or rim, the wheelstatic balance should be adjusted.8 Adjust the front wheel static balance with the

brake disc installed.

1. Remove:8 Balancing weight

2. Set:8Wheel

(on a suitable stand)3. Find:8 Heavy spot

***************************************Procedure:

a. Spin the wheel and wait for it to rest.b. Put an “X1” mark on the wheel’s bottom

spot.c. Turn the wheel so that the “X1” mark is

90° up.d. Release the wheel and wait for it to rest.

Put an “X2” mark on the wheel’s bottomspot.

e. Repeat the above b., c., and d. severaltimes until all marks come to the samespot.

f. This spot is the wheel’s heavy spot “X”.***************************************4. Adjust:8Wheel static balance

***************************************Adjusting steps:8 Instail a balancing weight 1 on the rim ex-

actly opposite to the heavy spot “X”.NOTE:

Start with the smallest weight.

8 Turn the wheel so that the heavy spot is 90°up.8 Check that the heavy spot is at rest there. If

not, try another weight until the wheel is bal-anced.

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

X1

X1

X

X

X

6-7

CHASFRONT WHEEL AND BRAKE DISC

5. Check:8Wheel static balance

***************************************Checking steps:8 Turn the wheel so that it comes to each point

as shown.8 Check that the wheel is at rest at each point.

If not, readjust the front wheel static balance.***************************************X

X

X X

6-8

CHAS

Order

1234

Q’ty

1122

FRONT BRAKEBRAKE PAD

FRONT BRAKE

Remarks

Remove the parts in order.Refer to “ BRAKE PAD REPLACEMENT“ section .

Reverse the removal procedure for in-stallation.

Job name/Part name

Brake pad removalCaliper support boltCaliperBrake padPad spring

T R..

23Nm(2.3kg.m)

T R..

23Nm(2.3kg.m)

B

B

1

2

3

4

6-9

CHASFRONT BRAKE

cCDisc brake components rarely require disas-sembly. DO NOT:8 Disassembly components unless absolutely

necessary.8 Use solvents in internal brake component.8 Use contaminated brake fluid for cleaning.8 Use only clean fluid.8 Allow brake fluid to come in contact with the

eyes otherwise eye injury may occur.8 Allow brake fluid to contact painted surfaces

or plastic parts otherwise damage may oc-cur.8 Disconnect any hydraulic connection other-

wise the entire system must be disas-sembled, drained, cleaned, and then prop-erly filled and bled after reassembly.

BRAKE PAD REPLACEMENTNOTE:

It is not necessary to disassemble the brakecaliper and brake hose to replace the brakepads.

1. Loosen:8 Retaining bolt 1

2. Remove:8 Brake caliper 28 Holder (brake hose) 3

3. Remove:8 Retaining bolt8 Pads 18 Pad spring 2

NOTE:

8 Replace the pad spring if the pad replacementis required.8 Replace the pads as a set if either is found to

be worn to the wear limit.

Wear limit a:0.8 mm (0.03 in)

1

2

3

1

2

a

6-10

CHAS

4. Install:8 Pad springs8 Brake pads (new)

***************************************Installation steps:8 Connect a suitable hose 1 tightly to the cali-

per bleed screw 2. Then, place the other endof this hose into an open container.8 Loosen the caliper bleed screw and push the

piston 3 into the caliper by your finger.8 Tighten the capliper bleed screw.

6 Nm (0.6 kg.m)

8 Install the pad spring (new) and brake pad(new) 48 Tighten retaining bolt 5 23 Nm (2.3 kg.m)

8 Install brake hose holder 6 7 Nm (0.7 kg.m)

8 Install caliper 7 23 Nm (2.3 kg.m)

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

5. Inspect:8 Brake fluid level

Refer to the “BRAKE FLUID INSPEC-TION” section in the CHAPTER 3.

1 “LOWER” level line

T R..

T R..

FRONT BRAKE

12

3

4

T R..

T R..

1

5

7

6

6-11

CHAS

6. Check:8 Brake lever operation

A softy or spongy feeling Bleed→brakesystem.Refer to “ AIR BLEEDING ” section inthe CHAPTER 3.

FRONT BRAKE

6-12

CHASFRONT BRAKE

Order

1234567

Q’ty

1/1112111

MASTER CYLINDER

Remarks

Remove the parts in order.Refer to “BRAKE FLUID REPLACE-MENT” section in CHAPTER 3.

Refer to “MASTER CYLINDER INSTAL-LATION” section.

Reverse the removal procedure for in-stallation.

Job name/Part name

Master cylinder removalDrain the brake fluid

Brake lever/compression springBrake switchUnion boltCopper washerBrake hoseMaster cylinder bracketMaster cylinder

New

T R..

9Nm(0.9kg.m)T R.

.

25Nm(2.5kg.m)

B

1

2

5

4

7

3

6

6-13

CHAS

Order

1

2

3

4

Q’ty

1111

MASTER CYLINDER DISASSEMBLY

FRONT BRAKE

Remarks

Remove the parts in order.

Refer to “MASTER CYLINDER ASSEM-BLY” section.

Reverse the disassembly procedure forassembly.

Job name/Part name

Master cylinder disassemblyMaster cylinder bootCirclipMaster cylinder kitSpring

21

4

3

New

6-14

CHASFRONT BRAKE

2. Inspect:8 Master cylinder 18 Scratches/wear/damage→Replace the

master cylinder assembly.

3. Inspect:8 Diaphragm 1

Wear/damage→Replace.

YP.....

MASTER CYLINDER ASSEMBLY

w8 All internal brake components should be

cleaned and lubricated with new brake fluidonly before installation.

Recommended brake fluid:DOT #4

8 Replace the piston seals and dust seals when-ever a master cylinder is disassembled.

1. Install:8 Cylinder cup 18 Master cylinder piston 2

Install cylinder cup 1 by using cylindercup installer 3.

Cylinder cup installer set:90890-01996

YP702040

MASTER CYLINDER INSPECTION1. Inspect:8 Master cylinder kit 1

Wear/scratches→Replace the mastercylinder assembly.8 Master cylinder boot

Cracks/damage→Replace.

1

1

6-15

CHASFRONT BRAKE

2. Install:8 Spring 1

Install the spring with its smaller diam-eter to the master cylinder piston.8 Master cylinder kit 2

3. Install:8 Circlip 1

Install the circlip securely into the mas-ter cylinder groove.8 Master cylinder boot 2

YP.....

MASTER CYLINDER INSTALLATION1. Install:8 Master cylinder 18 Master cylinder bracket 2 9 Nm (0.9 kg.m)

cC8 Install the master cylinder bracket 2 with the

“UP” mark a facing upward.8 Align the end of the holder with the punch

mark b on the handle bar.

New

T R..

New

1

2

a

b

6-16

CHAS

2. Air bleed:8 Brake system

Refer to “AIR BLEEDING” section inCHAPTER 3.

w8 Use only designated quality brake fluid:

Otherwise, the rubber seals may deteriorate,causing leakage and poor brake perforrmance.8 Refill with the same type of brake fluid:

Mixing fluids may result in a harmful chemi-cal reaction and lead to poor perforrmance.8 Be careful that water does not enter the sig-

nificantly lower the boiling point of the fluidmay result in vapor lock.

3. Inspect:8 Brake operation

FRONT BRAKE

6-17

CHAS

Order

12345

Q’ty

12111

CALIPER

FRONT BRAKE

Remarks

Remove the parts in order.Refer to “BRAKE FLUID REPLACE-MENT” section in CHAPTER 3.

Refer to “CALIPER INSTALLATION” sec-tion.

Reverse the removal procedure for in-stallation.

Job name/Part name

Caliper removalDrain the brake fluid

Union boltCopper washerBrake hoseCaliper support boltCaliper assembly

T R..

25Nm(2.5kg.m)

T R..

23Nm(2.3kg.m)

T R..

23Nm(2.3kg.m)

1

2

3

4

5

New

6-18

CHAS

Order

1

2

3

4

5

6

7

Q’ty

1221111

CALIPER DISASSEMBLY

FRONT BRAKE

Remarks

Remove the parts in order.

Refer to “BRAKE CALIPER DISASSEM-BLY/ASSEMBLY” section.

Reverse the disassembly procedure forassembly.

Job name/Part name

Caliper disassemblyCaliper bracketBrake padPad springCaliper pistonDust sealPiston sealBleed screw

T R..

6Nm(0.6kg.m)

New

B

1

2

3

4

5

6

7

6-19

CHASFRONT BRAKEYP702020

BRAKE CALIPER DISASSEMBLYNOTE:

Before disassembling either brake caliper, drainthe brake fluid from the brake hose, mastercylinder, brake caliper and reservoir tank.

1. Remove:8 Brake caliper piston

***************************************Removal steps:8 Blow compressed air into the hose joint

opening to force out the caliper piston fromthe brake caliper body.

w8 Never try to pry out the caliper piston.8 Cover the caliper piston with a rag. Be care-

ful not to get injured when the piston is ex-pelled from the master cylinder.

cCCarefully remove the caliper piston to preventdamage.

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

2. Remove:8 Dust seal 18 Piston seal 2

When removing, push the seals by yourfinger.

cC8 Do not use a sharp instrument. Remove seals

by your finger.8 Do not re-use removed parts.

YP...

CALIPER INSPECTION1. Inspect:8 Caliper cylinder 18 Caliper piston 2

Scratches, wear→Replace caliper as-sembly.

6-20

CHASEB702050

BRAKE CALIPER ASSEMBLY

w8 All internal brake components should be

cleaned and lubricated with new brake fluidonly before installation.

Recommended brake fluid:DOT #4

8 Replace the caliper piston seals whenever abrake caliper is disassembled.

1. Install:8 Piston seal 1 New8 Dust seal 2 New

FRONT BRAKE

2. Install:8 Caliper piston 1

Apply brake fluid to the outer surfaceand install.

cC8 Do not force.8 Use care to prevent damage on caliper pis-

ton.

YP.....

CALIPER INSTALLATION1. Install:8 Caliper 18 Caliper support bolt 23Nm(2.3m.kg)

8 Brake hose 28 Copper washer 3 New8 Union bolt 4 25Nm(2.5 m.kg)

cCWhen installing the brake hose to the caliper,lightly touch the brake hose with the stoppera on the caliper.

T R..

New

1

2

3

4a

T R..

6-21

CHAS

Order

1234

Q’ty

1/1111

REAR WHEEL AND REAR BRAKE

REAR WHEEL AND REAR BRAKE

Remarks

Remove the parts in order.

Reverse the disassembly procedure forinstallation.

Job name/Part name

Rear wheel and rear brake removalMuffler assembly/GasketNut/Plain washerRear wheel assemblyPlain washer

T R..

12Nm(1.2kg.m)

T R..

26Nm(2.6kg.m)T R.

.

120Nm(12kg.m)

New

2

1

43

REAR WHEEL

6-22

CHASREAR WHEEL AND REAR BRAKE

Order

12345678

Q’ty

11111111

Remarks

Reverse the removal procedure for in-stallation.

Job name/Part name

AdjusterBrake cablePinReturn springBrake shoeCamshaft leverWear indicatorBrake camshaft

T R..

8Nm(0.8kg.m)

New

5

82

4

1

3

76

REAR BRAKE

6-23

CHASREAR WHEEL AND REAR BRAKEEB701020

REAR WHEEL INSPECTION1 Inspect:8 Rear wheel axle8 Rear wheel8 Rear wheel bearings8 Oil seals

Refer to “FRONT WHEEL”.2. Measure:8 Rear wheel runout

Refer to “FRONT WHEEL”.EB701021

REAR BRAKE INSPECTION1. Inspect:8 Brake lining surface

Glazed areas→Polish.Use coarse sand paper.

NOTE:

After polishing, wipe the polished particles witha cloth.

2. Measure:8 Brake lining thickness a

Brake lining thickness a :Standard:

4 mmLimit:

2 mm

Out of specification→Replace.Measuring points “ ”

NOTE:

Replace the brake shoes as a set if either is wornto the limit.

3. Measure:8 Brake drum inside diameter a

Out of specification→Replace the wheel.

Brake drum inside diameter:Standard:

130 mmLimit:

131 mm

6-24

CHASREAR WHEEL AND REAR BRAKE

4. Inspect:8 Brake drum inner surface8 Oil/scratches→Repair.8 Oil

Use a rag soaked in lacquer thinner orsolvent.8 Scratches

Use an emery cloth (lightly and evenlypolishing)

5. Inspect:8 Cam shaft face.

Wear→Replace.

wWhen inspecting the brake lining, do not spilloil or grease on the brake lining.

YP.....

REAR BRAKE INSTALLATION1. Install:8 Camshaft 18 Indicator plate 2

***************************************Installation steps:8 Set the camshaft with its punched mark a

facing the direction as shown.8 Align the projection b on the indicator plate

with the camshaft notch and install.8 Check the proper position of the brake shoe.***************************************

2. Install:8 Camshaft lever 1

NOTE:

Set the camshaft with its punched mark a fac-ing the direction on the cam shaft lever b.

1

2

1

b

a

a

b

6-25

CHAS

Order

123456789

Q’ty

111111111

HANDLEBARHANDLEBAR

Remarks

Remove the parts in order.

Refer to “COVERS AND PANEL” INCHAPTER 3.

Job name/Part name

Handlebar removalLeft/Right bake mirrorFront protector barUpper coverFront/Rear handlebar coverLeft/Right flasherBrake master cylinderFront brake switchHandlebar switch (Right)Throttle cableRear brake cableRear brake switchHandlebar switch (Left)BindWire harness strap

HANDLEBAR

B

B

B

T R..

23Nm(2.3kg.m)

T R..

43Nm(4.3kg.m)

1

2

3

4

5

6

7

8

9

10

11

12

12

6-26

CHAS

Order

101112

Job name/Part name

Brake hoseHandlebar comp.Left/Right grip

Q’ty

11

1/1

Remarks

Reverse the removal procedure for in-stallation.

HANDLEBAR

B

B

B

T R..

23Nm(2.3kg.m)

T R..

43Nm(4.3kg.m)

1

2

3

4

5

6

7

8

9

10

11

12

12

6-27

CHASHANDLEBAR

HANDLEBAR INSTALLATION1. Clean:8 Steering shaft a

wProper cables and leads routing is essential toissue safe scooter operation.

2. Install:8 Handlebar 18 Bolt 28 Nut 43Nm(4.3 kg.m)

NOTE:

Match the bolt 2 on to the steering columndent a.

cCThere must be a space b after tighting bolt 2.

3. Install:8 Band

NOTE:

Clamp the wire harness.

4. Apply:8 Lithium soap base grease (to throttle

cable end and handlebar right end).

T R..

5. Install:8 Handlebar switch (right) 1

NOTE:

Insert the projection a into the slot b on thehandlebar comp.

a

a

1

2

1

a

b

b

6-28

CHAS

6. Install:8 Handlebar switch (left) 1

NOTE:

Insert the projection a into the slot b on thehandlebar comp.

HANDLEBAR

b

1

a

7. Install:8 Master cylinder

NOTE:

Match the slot with the punched mark b onthe handlebar comp.

b

6-29

CHAS

STEERING

Order

123456789

Q’ty

1/11/111

1/111

22/193

STEERING

Remarks

Remove the parts in orderRefer to “HANDLEBAR” section.Refer to “FRONT WHEEL AND BRAKEDISC” section

Refer to “STEERING REMOVAL/INSTAL-LATION” section.

Reverse the removal procedure for in-stallation.

Job name/Part name

Steering removalHandlebarFront wheel

Ring nut 1/ Special washerRing nut 2/ Rubber washerRing nut 3Under bracketFront fork (Left/Right)Bearing coverBall raceBall (Upper/Lower)Ball race

T R..

45Nm(4.5kg.m)

T R..

45Nm(4.5kg.m)

B

B

12

3

4

5

67

8

9

9

8

9

STEERING

6-30

CHASSTEERING

STEERING REMOVAL

w8 Securely support the scooter so that there is

no danger of it falling over.8 Stand the scooter on a level surface.

1. Removal:8 Ring nut 1 18 Special washer 28 Ring nut 2 38 Rubber washer 48 Ring nut 3 58 Bearing cover 68 Ball race 78 Ball 88 Front fork assembly 9

NOTE:

8 Remove the ring nuts by steering nut wrench.

Steering nut wrench 090890-01268

8 Hold the lower bracket by hand, then removeby using the steering nut wrench 0.8 Do not loss the balls (Upper: 22 pcs, Lower:

19 pcs).

2. Remove8 Front fork assembly

Refer to “FRONT FORK” section.3. Remove8 Ball race

***************************************Ball race replacement steps:8 Remove the ball races on the head pipe us-

ing long rod 1 and the harmmer as shown.8 Remove the ball races on the under bracket

using the floor chisel 2 and the harmmer asshown.

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

1

2

3

4

5

6

7

8

1

2

9

6-31

CHASSTEERING

3. Inspect:8 Under bracket 1

Crack/Bend/Damage→Replace.

wDo not attempt to straighten a bent underbracket as this may dangerously weaken theunder bracket.

STEERING INSTALLATION1. Install:8 Ball 1

NOTE:

Upper.......22 pcsLower...... 19 pcs

2. Lubricate8 Ball8 Ball race

Wheel bearing grease

STEERING INSPECTION1. Wash the bearing races with a solvent.2. Inspect:8 Ball race8 Ball

Pitting/Damage→Replace.NOTE:

Always replace bearings and races as set.

1

1

6-32

CHAS

3. Install:8 Front fork assembly 18 Ball race (Upper) 28 Bearing cover 38 Ring nut 3 48 Rubber washer 58 Ring nut 2 68 Special washer 78 Ring nut 1 8

NOTE:

Securely support the steering shaft so thatthere is no danger of it falling down.

4. Tighten:8 Ring nuts

***************************************Tighten steps:8 Tighten the ring nut 3 2 using the ring nut

wrench 1 28 Nm (2.8 kg.m)

Ring nut wrench:90890-01403

NOTE:

Set the torque wrench 3 to ring nut wrench 1so that they form right angle.

wDo not over-tightening.

8 Loosen the ring nut 3 2 1/4 turn.8 Check the front fork by turning it lock to lock.

If there is any binding, remove the front forkassembly and inspect the steering ball bear-ings and ball races.8 Install rubber washer 4 and ring nut 2 5,

then turn the ring nut 2 until it contacts withrubber washer.

STEERING

8

7

6

5

4

3

2

1

3

2

1

7

6

5

4

2

T R..

6-33

CHAS

cCSlots on the ring nut 2 and ring nut 3 should bealign. If not, turn the ring nut 2 towards tightendirection until slots alignment.

8 Install special washer 6NOTE:

Insert the projections of the special washer intothe slots.

8 Install ring nut 1 7 and tighten. 66Nm(6.6 kg.m)

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

STEERING

T R..

6-34

CHAS

Order

12345

Q’ty

11222

FRONT FORKFRONT FORK

FRONT FORK

Remarks

Remove the parts in order.Refer to “Steering” section.

Refer to “FRONT FORK REMOVAL/IN-STALLATION” section.

Reverse the removal procedure for in-stallation.

Job name/Part name

Front fork removalSteeringUnder fenderSpeedometer cable holderCap boltPinch boltFront fork

T R..

40Nm(4.0kg.m) T R..

45Nm(4.5kg.m)

2

3

1

5

4

6-35

CHASFRONT FORK

Order

1

2

3

4

5

6

7

8

9

0

Q’ty

1

11/11

1/11

1/1111

FRONT FORK DISASSEMBLY

Remarks

Remove the parts in order.Refer to “FRONT FORK REMOVAL/IN-STALLATION” section.

Refer to “ FRONT FORK DISASSEMBLY/ASSEMBLY” section.

Reverse the disassembly procedure forassembly.

Job name/Part name

Front fork disassemblyFork spring

Band/Front fork bootBolt/Copper washerInner tubeDamper rodRebound springOil lock pieceOil seal clipOil sealOuter tube

T R..

23Nm(2.3kg.m)

LT

New

New

New

New

1

2

3

4

5

6

7

8

9

0

6-36

CHAS

2. Remove:8 Cap bolt 18 Pinch bolt 2

wFork spring will jump out after removing capbolt.

3. Remove:8 Front fork (Left/Right) 3

FRONT FORKYP.....

FRONT FORK REMOVAL

w8 Securely support the scooter so there is no

danger of it falling over.8 Stand the scooter on a level surface.8 Stand the scooter on its centerstand.1. Remove:8 Under fender 1

1

11

2

3

2

1

3

YP703020

FRONT FORK DISASSEMBLY1. Remove:8 Bolt (damper rod) 1

Loosen the bolt (damper rod) 2 whileholding the damper rod with T-handle3 and 8 mm hexagon bolt.

T-handle90890-01326

6-37

CHASFRONT FORK

2. Remove:8 Inner tube 18 Oil lock pice 28 Damper rod 38 Rebound spring 4

3. Remove:

8 Oil seal 1 New

cCNever reuse the oil seal.

2 Rag

YP703030

FRONT FORK INSPECTION1. Inspect:8 Inner tube bending

Inner tube bending limit:0.2 mm

Scratches/bends/damage→Replace.

wDo not attempt to straighten a bent inner tubeas this may dangerously weaken the tube.

YP.....

FRONT FORK ASSEMBLYReverse the “ DISASSEMBLY” procedure.Note the following points.1. Install:8 Damper rod 18 Rebound spring 28 Oil lock piece 38 Inner tube 4

1 3

4

2

New

4 1

2

3

6-38

CHASFRONT FORK

2. Install:8 Inner tube 1

Into outer tube 2.

3. Install:8 Plain washer 1 New8 Bolt (damper rod) 2

New

32

LT T R..

5. Install:

8 Oil seal 1 New8 Retaining clip

Use the fork seal driver weight 2 andthe attachment 3.

NOTE:

8 Before installing the oil seal 1, apply lithiumsoap base grease onto the oil seal lips.8 Adjust the retaining clip so that it fits into the

outer tube groove.

cCMake sure that the oil seal numbered side facesupward.

Fork seal driver weight:90890-01367

Attachment:90890-01400

4. Tighten:8 Bolt (damper rod) 1 23Nm(2.3 m.kg)

NOTE:

Tighten the damper rod bolt 1 while holdingthe damper rod with a T-handle 2 and a 8 mmhexagon bolt 3.

T-handle90890-01326

1

New

6-39

CHASFRONT FORK

6. Inspect:8 Inner tube operation

Unsmooth operation→Disassembly andrecheck.

7. Fill:8 Fork oil 1

Oil quantity:88 cc

Recommended oil:Fork oil 10 W or equivalent

8. After filling up, slowly pump the fork upand down to distribute the fork oil.

9. Install:8 Front fork spring 1

NOTE:

8 Install the fork spring with its smaller pitchaupward .8 Before installing the cap bolt, apply grease

to the O-ring.8 Temporarily tighten the cap bolt.

1

a

EB703050

FRONT FORK INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Install:8 Front fork 1

NOTE:

Apply grease onto cap bolt O-ring before in-stalling cap bolt.

2. Tighten:8 Cap bolts 2 45Nm(4.5 kg.m)

8 Pinch bolts 3 40Nm(4.0 kg.m)

T R..

T R..

22

3

1

7-1

– +ELEC

ELECTRICALELECTRICAL COMPONENTS1Main switch2Resister3Audio pilot4Flasher relay5Oil level gauge6C.D.I. UNIT7Fuel level gauge

8Starter relay9Fuse0BatteryqIgnition coilwRectifier/RegulatoreHorn

1

2

3

4

5

6

7

8

9

0

qw

e

ELECTRICAL COMPONENTS

7-2

– +ELEC

CIRCUIT DIAGRAM

CIRCUIT DIAGRAM

LOCKOPENOFF

CHECKON

B

Gy

R

Br

R

Br

B

Gy

Y/R

L/W

L/R

L

L/G

G/R

L

L/G

G/R

Y/R

L/W

L/R

OFFSTART

8

'

:

LW

RW

LW

GY B

R

B

R

B

B

Y/R

B

B

B

Y/B

B

W

Y/R

B

W

Y/R

B

Gy

Br

Gy

Br

Br

G

Br

G

Dg

Ch

Dg

Ch

L

Gy

B

L

Gy

B

G

B

G

B

Y

B

Y

B

G

L/R

G

L/R

G/R

P

B

G/R

P

B

Ch

Br/W

Dg

Ch

Br/W

Dg

Y

G

Y

G

Ch

Dg

B

Ch

Dg

B

Ch

B

Ch

B

G/Y

B

G/Y

B

L

-

L

-

Dg

B

Dg

B

OFFPUSH

&

%

Br/W

Br

4

N6

Or

B

Or

B

Gy

Br R B

B/W

RR

R

R

LW

B LW LG YR

R

GY

R

B

W

Y/R

RB

YB

L/R L

G/R

BrP

Br

Br/

/W

P

G/R

Br/

W

B G Y Ch

Dg

G Y LRB

Ch

Dg

B

BY

B

W

Y/R

YR

B

B

B

B B

Ch

Dg

G/Y

B B

Ch

Dg

G/Y

G/Y

GY

Br

Br

Br

B

L/G

L/Y

B

OrOr

B

W/R

B/R

B/W

W/R

B/R

L/Y

Br

Gy L

Gy

Br

Y Y

Ch

Dg

BGG

BG

1

3

24

n

b

g

l

k

6

5

s

7

w

9

.

8

q

a

i

p o

r

e

t

yu

d

Q

W

R

B

Y/R

m

,

h

;

z x c v

/

0

f

jL

7-3

– +ELECCIRCUIT DIAGRAM

Black

Brown

Chocolate

Dark Green

Green

Blue

Orange

Sky blue

Pink

Red

1 Main switch2 Main fuse3 Battery4 Starter relay5 Starter motor6 Rectifier regulator7 Auto choke8 C.D.I. magneto9 C.D.I. unit0 Ignitionq Spark plugw Resistere Rear brake switchr Front brake switcht Tail/Brake lighty Rear flasher light(right)u Rear flasher light(left)i Audio piloto Front flasher light(right)p Front flasher light(left)

a Head lights Flasher relayd Hornf Handlebar switch (left)g Horn switchh Dimmer switchj Turn switchk Fuel senderl Meter; Fuel gaugez Oil indicator lightx Meter lightc High beam indicator lightv Turn indicator lightb Oil level gaugen Handlebar switch (right)m Starter switch, Light switch. Sidestand switch/ Auxiliary light

B

Br

Ch

Dg

G

L

Or

Sb

P

R

COLOR CODE

Gy

Y

W

B/R

Br/W

G/R

G/Y

L/B

L/Y

L/W

L/R

R/B

R/Y

R/W

Y/R

W/G

G/W

W/R

L/G

Gray

Yellow

White

Black/Red

Brown/White

Green/Red

Green/Yellow

Blue/Black

Blue/Yellow

Blue/White

Blue/ Red

Red/Black

Red/Yellow

Red/white

Yellow/White

White/Green

Green/White

White/Red

Blue/Green

7-4

– +ELECYP-N

CHECKING SWITCHESCHECKING STEPSUsing pocket tester, check switches for conti-nuity between their terminals to determinewhether they are correctly connected.Replace the switch component if any of thecombinations does not produce the correctreading.

Pocket tester:90890-03112

NOTE:

8 Turn the switch to the “ON”, “OFF” positionsseveral times.

8 Adjust the pocket tester to correct “0” posi-tion before checking switches.

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

SWITCH CONNECTION AS SHOWN IN THISMANUALThis manual contains connection charts, likethe one shown on the left, showing the termi-nal connections of switches (e.g. the mainswitch, handlebar switch, brake switch, light-ing switch etc.)

The column on the extreme left indicates thedifferent switch positions, the top line indicatesthe colors of the leads connected to the termi-nals on the switch.

“?—?” indicates terminals between whichthere is continuity, i.e. a closed circuit, in thegiven switch position.

In this chart:“Br and R” have continuity with the switch inthe “ON” position.

CHECKING SWITCHES

“Ω×1”

“∞” “0”

OFFON

Br R

Br R

7-5

– +ELEC

SWITCH POSITION AND TERMINAL CONNECTION

Before checking a switch refer to the check-ing switches as shown in the left page andcheck for the correct terminal connections(closed circuit) according to the color combi-nations shown in the chart.Poor connection, fault→Repair or replace.

CHECKING SWITCHES

Rear brake switch

Horn switch

Dimmer switch

Turn switch

Main switch

Front brake switch

Start switch

Light switch

Fuse

B RGy Br

LOCKOPENOFF

*ON

Gy Br R B B/W

G/R Ch P Br/W B Dg

ReleasePush in

YG

P B

&%

G G/R Y

4–6

Ch Br/W DgReleasePush in

L/W L/G

8

'

:

Y/R Y/B L/R L G/R

L Y/R L/G L/WG/R L/R

7-6

– +ELEC

IGNITION SYSTEMCIRCUIT DIAGRAM

1 Main switch8 C.D.I. magneto9 C.D.I. unit0 Ignition coilq Spark plug

LOCKOPENOFF

CHECKON

B

Gy

R

Br

R

Br

B

Gy

Y/R

L/W

L/R

L

L/G

G/R

L

L/G

G/R

Y/R

L/W

L/R

OFFSTART

8

'

:

LW

RW

LW

GY B

R

B

R

B

B

Y/R

B

B

B

Y/B

B

W

Y/R

B

W

Y/R

B

Gy

Br

Gy

Br

Br

G

Br

G

Dg

Ch

Dg

Ch

L

Gy

B

L

Gy

B

G

B

G

B

Y

B

Y

B

G

L/R

G

L/R

G/R

P

B

G/R

P

B

Ch

Br/W

Dg

Ch

Br/W

Dg

Y

G

Y

G

Ch

Dg

B

Ch

Dg

B

Ch

B

Ch

B

G/Y

B

G/Y

B

L

-

L

-

Dg

B

Dg

B

OFFPUSH

&

%

Br/W

Br

4

N6

Or

B

Or

B

Gy

Br R B

B/W

RR

R

R

LW

B LW LG YR

R

GY

R

B

W

Y/R

RB

YB

L/R L

G/R

BrP

Br

Br/

/W

P

G/R

Br/

W

B G Y Ch

Dg

G Y LRB

Ch

Dg

B

BY

B

W

Y/R

YR

B

B

B

B B

Ch

Dg

G/Y

B B

Ch

Dg

G/Y

G/Y

GY

Br

Br

Br

B

L/G

L/Y

B

OrOr

B

W/R

B/R

B/W

W/R

B/R

L/Y

Br

Gy L

Gy

Br

Y Y

Ch

Dg

BGG

BG

1

3

24

n

b

g

l

k

6

5

s

7

w

9

.

8

q

a

i

p o

r

e

t

yu

d

Q

W

R

B

Y/R

m

,

h

;

z x c v

/

0

f

j

L

7-7

– +ELEC

Ignition checker:90890-06754

1. Spark plug8 Check the spark plug condition.8 Check the spark plug type.8 Check the spark plug gap.

Refer to the “SPARK PLUG INSPECTION”section in the CHAPTER 3.

CORRECT

2. Ignition spark gap8 Disconnect the spark plug cap from spark

plug.8 Connect the ignition checker 1 as shown.

2 Spark plug cap3 Spark gap

8 Check the ignition spark gap.8 Start engine, and increase spark gap until

misfire occurs.

Minimum spark gap:6.0 mm (0.24 in)

OUT OF SPECIFI-CATION OR NOSPARK

IGNITION SYSTEM

TROUBLESHOOTING

IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE(NO SPARK OR INTERMITTENT SPARK)

NOTE:

8 Remove the following parts before troubleshooting.1) Battery box cover 4) Tail cover2) Center cowling 5) Side cover (right)3) Rear carrier

8 Use the following special tools in this troubleshooting.

Pocket tester: Pocket tester:90890-03112

Standard spark plug:BPR7HS (NGK)

Spark plug gap:0.9~1.0 mm

INCORRECT

Spark plug is faulty, replace it or repair pluggap.

MEETS SPECIFICATION

Ignition system is good.*

7-8

– +ELECIGNITION SYSTEM

*

3. Spark plug cap resistance8 Remove the spark plug cap.8 Connect the pocket tester (Ω × 1k) to the

spark plug cap.8 Check the spark plug cap for specificated

resistance.

Spark plug cap resistance:5kΩ at 20°C (68°F)

MEETSSPECIFICATION

4. Ignition coil resistance8 Disconnect the ignition coil leads from the

ignition coil.8 Connect the pocket tester (Ω × 1) to the

ignition coil.

Ignition coil:Tester (+) lead→Terminal 1Tester (–) lead→Coil base 2

8 Check the primary coil for specificationresistance.

Primary coil resistance:0.32~0.48 Ω at 20°C (68°F)

8 Connect the pocket tester (Ω × 1 k) to theignition coil.

Tester (+) lead→Spark plug lead 1Tester (-) lead→Coil base 2

8 Check the secondary coil for specificatedresistance.

Secondary coil resistance:5.68 ~ 8.52 k Ω at 20°C (68°F)(Spark plug lead - Coil base)

BOTH MEETSPECIFICATIONS

*

OUT OF SPECIFICATION

Replace spark plug cap.

OUT OF SPECIFICATION

Ignition coil is faulty, replace it.

Ω×1k

7-9

– +ELECIGNITION SYSTEM

5. Pickup coil resistance8 Disconnect the pickup coil coupler from

the wireharness.8 Connect the pocket tester (Ω × 100) to the

pickup coil terminal.

Tester (+) lead→White/Red lead 1Tester (-) lead→Black 2

8 Check the pickup coil for specificated re-sistance.

Pickup coil resistance:400~ 600 Ω at 20°C (68°F)(White/Red-Black)

MEETSPECIFICATION

6. Source resistance8 Disconnect the source coil coupler from

the wireharness.8 Connect the pocket tester (Ω × 100) to the

source coil terminal.

Tester (+) lead→Black/Red lead 1Tester (–) lead→Black 2

8 Check the source coil for specificated re-sistance.

Source coil resistance:640 ~ 960 Ω at 20°C (68°F)(Black/Red - Black )

MEETSPECIFICATION

7. Wiring connectionCheck the entire ignition system for connec-tions.Refer to the “WIRING DIAGRAM” section.

CORRECT

Replace CDI unit.

*

OUT OF SPECIFICATION

Pickup coil is faulty, replace it.

OUT OF SPECIFICATION

Source coil is faulty, replace it.

POOR CONFECTION

Correct.

CDIMagneto

WY/RB

1 2

B/R

W/R

CDIMagneto

WY/RB

1

2

B/R

W/R

7-10

– +ELEC

CHARGING SYSTEMCIRCUIT DIAGRAM

CHARGING SYSTEM

2 Main fuse3 Battery6 Rectifier Regulator8 CDI magnet

LOCKOPENOFF

CHECKON

B

Gy

R

Br

R

Br

B

Gy

Y/R

L/W

L/R

L

L/G

G/R

L

L/G

G/R

Y/R

L/W

L/R

OFFSTART

8

'

:

LW

RW

LW

GY B

R

B

R

B

B

Y/R

B

B

B

Y/B

B

W

Y/R

B

W

Y/R

B

Gy

Br

Gy

Br

Br

G

Br

G

Dg

Ch

Dg

Ch

L

Gy

B

L

Gy

B

G

B

G

B

Y

B

Y

B

G

L/R

G

L/R

G/R

P

B

G/R

P

B

Ch

Br/W

Dg

Ch

Br/W

Dg

Y

G

Y

G

Ch

Dg

B

Ch

Dg

B

Ch

B

Ch

B

G/Y

B

G/Y

B

L

-

L

-

Dg

B

Dg

B

OFFPUSH

&

%

Br/W

Br

4

N6

Or

B

Or

B

Gy

Br R B

B/W

RR

R

R

LW

B LW LG YR

R

GY

R

B

W

Y/R

RB

YB

L/R L

G/R

BrP

Br

Br/

/W

P

G/R

Br/

W

B G Y Ch

Dg

G Y LRB

Ch

Dg

B

BY

B

W

Y/R

YR

B

B

B

B B

Ch

Dg

G/Y

B B

Ch

Dg

G/Y

G/Y

GY

Br

Br

Br

B

L/G

L/Y

B

OrOr

B

W/R

B/R

B/W

W/R

B/R

L/Y

Br

Gy L

Gy

Br

Y Y

Ch

Dg

BGG

BG

1

3

24

n

b

g

l

k

6

5

s

7

w

9

.

8

q

a

i

p o

r

e

t

yu

d

Q

W

R

B

Y/R

m

,

h

;

z x c v

/

0

f

j

L

7-11

– +ELECCHARGING SYSTEM

Inductive tachometer:90890-03113

1. Fuse (main)8 Remove the fuse.8 Connect the pocket tester (Ω × 1) to the

fuse.8 Check the fuse for continuity.

CONTINUITY

2. Battery8 Check the battery condition

Refer to the “BATTERY INSPECTION” sec-tion in the CHAPTER 3.

Open circuit voltage:12.8V or more at 20°C (68°F)

CORRECT

TROUBLESHOOTING

THE BATTERY IS NOT CHARGED.

NOTE:

8 Remove the following parts before troubleshooting.1) Front protector bar 4) Tail cover2) Upper cover 5) Right side cover3) Rear carrier8 Use the following special tool (s) in this trobleshooting.

Pocket tester:90890-03112

NO CONTINUITY

Fuse is faulty, replace it.

INCORRECT

8 Clean battery terminals.8 Recharge or replace battery.

*

7-12

– +ELEC

3. Charging voltage8 Connect the inductive tachometer to the

spark plug lead.8 Connect the pocket tester (DC20V) to the

battery.

Tester (+) lead→Battery (+) terminalTester (-) lead→Battery (–) terminal

8 Start the engine and accelerate to about5,000 r/min.

8 Check charging voltage.

Charging voltage:13 ~ 14 V at 4,000 r/min

NOTE:

Use a full charged battery.

OUT OF SPECIFICATION

4. Charging coil and lighting coil resistance8 Disconnect the charging coil coupler from

the wireharness.8 Connect the pocket tester “Ω × 1” to the

charging coils.8 Measure the charging coil and lighting coil

resistance.

Charging coil resistance:Tester (+) lead→White lead 1Tester (–) lead→BLACK 3

Lighting coil resistance:Tester (+) lead→Yellow/Red 2Tester (–) lead→BLACK 3

Charging coil resistance:0.5~0.7 Ω at 20°C (68°F)

Lighting coil resistance:0.4~0.6 Ω at 20°C (68°F)

MEETSPECIFICATION

*

MEETS SPECIFICATION

Charging circuit is good.

CHARGING SYSTEM

OUT OF SPECIFICATION

Charging coil is faulty, replace it.

*

CDIMagneto

WY/RB

12

B/R

W/R

3

7-13

– +ELEC

5. Wiring connectionCheck the entire ignition system for con-nections.Refer to the “WIRING DIAGRAM” section.

OK

Replace rectifier regulator.

POOR CONNECTION

Correct.

*

CHARGING SYSTEM

7-14

– +ELEC

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

ELECTRIC STARTING SYSTEM

1 Main switch2 Main fuse3 Battery4 Starter relay5 Starter motor9 CDI unit

e Front brake switchr Rear brake switchm Starter switch. Sidestand switch

LOCKOPENOFF

CHECKON

B

Gy

R

Br

R

Br

B

Gy

Y/R

L/W

L/R

L

L/G

G/R

L

L/G

G/R

Y/R

L/W

L/R

OFFSTART

8

'

:

LW

RW

LW

GY B

R

B

R

B

B

Y/R

B

B

B

Y/B

B

W

Y/R

B

W

Y/R

B

Gy

Br

Gy

Br

Br

G

Br

G

Dg

Ch

Dg

Ch

L

Gy

B

L

Gy

B

G

B

G

B

Y

B

Y

B

G

L/R

G

L/R

G/R

P

B

G/R

P

B

Ch

Br/W

Dg

Ch

Br/W

Dg

Y

G

Y

G

Ch

Dg

B

Ch

Dg

B

Ch

B

Ch

B

G/Y

B

G/Y

B

L

-

L

-

Dg

B

Dg

B

OFFPUSH

&

%

Br/W

Br

4

N6

Or

B

Or

B

Gy

Br R B

B/W

RR

R

R

LW

B LW LG YR

R

GY

R

B

W

Y/R

RB

YB

L/R L

G/R

BrP

Br

Br/

/W

P

G/R

Br/

W

B G Y Ch

Dg

G Y LRB

Ch

Dg

B

BY

B

W

Y/R

YR

B

B

B

B B

Ch

Dg

G/Y

B B

Ch

Dg

G/Y

G/Y

GY

Br

Br

Br

B

L/G

L/Y

B

OrOr

B

W/R

B/R

B/W

W/R

B/R

L/Y

Br

Gy L

Gy

Br

Y Y

Ch

Dg

BGG

BG

1

3

24

n

b

g

l

k

6

5

s

7

w

9

.

8

q

a

i

p o

r

e

t

yu

d

Q

W

R

B

Y/R

m

,

h

;

z x c v

/

0

f

j

L

7-15

– +ELECELECTRIC STARTING SYSTEM

Pocket tester:90890-03112

1. Fuse8 Remove the fuse.8 Connect the pocket tester (Ω × 1 ) to the

fuse.8 Check the fuse for continuity.

CONTINUITY

2. Battery8 Check the battery condition.

Refer to the “BATTERY INSPECTION” sec-tion in the CHAPTER 3.

Open circuit voltage:12.8 V or more at 20°C (68°F)

CORRECT

3. Starter motor8 Connect the battery1positive terminal

and starter motor cable 2 using a jumperlead 3 * .

8 Check the starter motor for operation.

MOVES

TROUBLESHOOTING

STARTER MOTOR DOES NOT OPERATE.

NOTE:

8 Remove the following parts before troubleshooting.1)Battery box cover 4)Side covers (left and right)2)Rear carrier 5)Trunk3)Tail cover 6)Handlebar cover (front)

8 Use the following special tool in this troubleshooting.

NO CONTINUITY

Fuse is faulty, replace it.

INCORRECT

8 Clean battery terminals.8 Recharge or replace battery.

w8 A wire for the jumper lead must have the

equivalent capacity as that of the battery leador more, otherwise it may cause the jumperlead to be burned.

8 This check is likely to produce sparks, so besure that no flammable gas or fluid is in thevicinity.

DOES NOT MOVE

Starter motor is faulty, repair or replace it.

*

M

7-16

– +ELEC

L/WG/Y

ELECTRIC STARTING SYSTEM

*

4. Starter relay8 Disconnect the relay unit coupler from the

wire harness.8 Connect the pocket tester(Ω × 1)and

battery(12V) to the relay unit coupler ter-minals.

Battery(+)lead→Blue/White terminal 1

Battery(–)lead→Green/Yellow terminal 2

8 Check the starter relay for continuity.

Tester (+) lead→ 3 terminalTester (-) lead→ 4 terminal

CONTINUITY

5. Main switchRefer to “CHECKING SWITCHS” section.

CONTINUITY

6. “START” switchRefer to “CHECKING SWITCHS” section.

CORRECT

NO CONTINUITY

Replace the starter relay.

NO CONTINUITY

Main switch is faulty, replace it.

NO CONTINUITY

“START” switch is faulty, replace handlebarswitch (right).

13

4 2

*

7-17

– +ELECELECTRIC STARTING SYSTEM

*

7. Sidestand switch 8 Disconnect the sidestand switch coupler

from the wire harness.8 Check the switch component for the con-

tinuity between “Blue/Yellow 1 and Black2”.

POOR CONNECTION

Correct.

8. Brake switches (front and rear) 8 Disconnect the brake switch leads from the

wire harness.8 Connect the pocket tester (Ω × 1 )to the

brake switch leads.

8 Check the brake switch for continuity

SwitchPosition

Goodcondition

Bad condition

Brake isapplied

Brake isnot applied

:Continuity :No continuity

*

BAD CONDITION

Replace brake switch(es).

CORRECT

GOODCONDITION

L/Y

B

BrG/Y

1

2

12

7-18

– +ELEC

*

9. Wiring connection 8 Check the entire electrical starting system

for connections.Refer to “WIRING DIAGRAM” section.

ELECTRIC STARTING SYSTEM

GOODCONDITION

Replace CDI unit.

POOR CONNECTION

Correct.

7-19

– +ELECELECTRIC STARTING SYSTEM

Order

12

Q’ty

21

STARTER MOTOR

Remarks

Remove the parts in order.

Refer to “COVER PANEL” section inCHAPTER 3.

Refer to “REAR WHEEL AND REARBRAKE” section in CHAPTER 6.Refer to “ENGINE REMOVAL” sectionchapter 4.

Job name/Part name

Starter motor removalRear carrierTail coverBattery box coverLeft/Right side coverCenter cowlingMufflerRear wheelAir shroud 3

Starter motor couplerStarter motor

T R..

13Nm(1.3kg.m)

1

2

3

4

5

2

1

7-20

– +ELEC

STARTER MOTOR DISASSEMBLY

Order

1

2

3

4

5

Job name/Part name

Starter motor disassemblyO-ringRear bracketArmature ass’yRingBrush holder set

Q’ty

11111

Remarks

Reverse the removal procedure for in-stallation.Disassembly the parts in order.

Refer to “Starter motor assembly”

Reverse the disassembly procedure forassembly.

ELECTRIC STARTING SYSTEM

T R..

13Nm(1.3kg.m)

1

2

3

4

5

2

1

7-21

– +ELECELECTRIC STARTING SYSTEMYP803034

INSPECTION AND REPAIR1. Inspect:

8 CommutatorDirt→Clean it with #600 grit sandpaper.

2. Measure:8 Commutator diameter a

Commutator wear limit:16.6 mm

Out of specification→Replace the startermotor

3. Measure:8 Mica undercut a

Mica undercut:1.35 mm

Out of specification→Scrape the mica tothe proper value (a hacksaw blade canbe ground to fit).

NOTE:

The mica insulation of the commutator mustbe undercut to ensure proper operation of com-mutator.

4. Inspect:8 Armature coil resistances (installation/

continuity)Defects→Replace the starter motor.If commutator is dirty, clean it with sand-paper.

O: Continuityx: No continuityBad condition→Replace.

Good Bad conditioncondition

A

B ×? ?

? ?×× ×

a

a

A

AB

B

7-22

– +ELEC

5. Measure:8 Brush length a

Out of specification→Replace.

Brush length wear limit1.0 mm

6. Measure:8 Brush spring force

Fatigue/out of specification→Replace asa set.

ELECTRIC STARTING SYSTEM

a

7-23

– +ELEC

LIGHTING SYSTEMCIRCUIT DIAGRAM

LIGHTING SYSTEM

8 C.D.I. magnetot Tail lighta Head lighth Light dimmer switchx Meter light

c High beam indicator light, Light switch/ Auxiliary light

LOCKOPENOFF

CHECKON

B

Gy

R

Br

R

Br

B

Gy

Y/R

L/W

L/R

L

L/G

G/R

L

L/G

G/R

Y/R

L/W

L/R

OFFSTART

8

'

:

LW

RW

LW

GY B

R

B

R

B

B

Y/R

B

B

B

Y/B

B

W

Y/R

B

W

Y/R

B

Gy

Br

Gy

Br

Br

G

Br

G

Dg

Ch

Dg

Ch

L

Gy

B

L

Gy

B

G

B

G

B

Y

B

Y

B

G

L/R

G

L/R

G/R

P

B

G/R

P

B

Ch

Br/W

Dg

Ch

Br/W

Dg

Y

G

Y

G

Ch

Dg

B

Ch

Dg

B

Ch

B

Ch

B

G/Y

B

G/Y

B

L

-

L

-

Dg

B

Dg

B

OFFPUSH

&

%

Br/W

Br

4

N6

Or

B

Or

B

Gy

Br R B

B/W

RR

R

R

LW

B LW LG YR

R

GY

R

B

W

Y/R

RB

YB

L/R L

G/R

BrP

Br

Br/

/W

P

G/R

Br/

W

B G Y Ch

Dg

G Y LRB

Ch

Dg

B

BY

B

W

Y/R

YR

B

B

B

B B

Ch

Dg

G/Y

B B

Ch

Dg

G/Y

G/Y

GY

Br

Br

Br

B

L/G

L/Y

B

OrOr

B

W/R

B/R

B/W

W/R

B/R

L/Y

Br

Gy L

Gy

Br

Y Y

Ch

Dg

BGG

BG

1

3

24

n

b

g

l

k

6

5

s

7

w

9

.

8

q

a

i

p o

r

e

t

yu

d

Q

W

R

B

Y/R

m

,

h

;

z x c v

/

0

f

j

L

7-24

– +ELECLIGHTING SYSTEM

Pocket tester:90890-03112

YP .....

1. Lights switchRefer to “CHECKING SWITCHES” section.

CONTINUITY

YP .....

2. Dimmer switchRefer to “CHECKING SWITCHES” section.

3. Lighting coil resistance8 Disconnect the lighting coil coupler from

the wireharness.8 Connect the pocket tester “ Ω x 1 “ to the

lighting coils.8 Measure the lighting coil resistances.

Tester (+) lead→Yellow/Red lead 1Tester (–) lead→Black 2

Lighting coil resistance:0.4 ~ 0.6 Ω at 20°C (68°F)

MEETSPECIFICATION

YP805010

TROUBLESHOOTING

IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHTAND/OR METER LIGHT FAIL TO COME ON.

ProcedureCheck:

1. Lights switch2. Dimmer switch3. Wiring connection (entire lighting system)

NOTE:

8 Remove the following parts before troubleshooting.1) Front handlebar cover2) Rear carrier3) Right side cover

8 Use the special tools specified in the troubleshooting section.

NO CONTINUITY

Replace the right handlebar switch.

NO CONTINUITY

Replace the left handlebar switch.

OUT OF SPECIFICATION

Lighting coil is faulty, replace it.*

CDIMagneto

WY/RB

1

B/R

W/R

2

7-25

– +ELEC

Y

B

G

L/R

*

YP.....

4. Wiring connection8 Check the connections of the entire light-

ing system.Refer to “WIRING DIAGRAM”.

OK

Check the condition of each of the lightingsystem’s circuits.Refer to “LIGHTING SYSTEM CHECK”

YP805020

LIGHTING SYSTEM CHECK1. If the headlight and the high beam indi-

cator light fail to come on.

1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.

CONTINUITY

2. Voltage8 Connect the pocket tester (DC20V) to the

headlight and high beam indicator lightcouplers.

AWhen the dimmer switch is on low beam.BWhen dimmer switch is on high beam.

Headlight:Tester (+) lead→Green 1 or Yellow 2 leadTester negative (–) lead→Black 3 lead

High beam indicator light:Tester I+) lead→Yellow 4 leadTester (–) lead→Black 5 lead

LIGHTING SYSTEM

POOR CONNECTIONS

Correct.

NO CONTINUITY

Replace the bulb and/or bulb socket.

*

A

B 12

3

L

Gy

B

Y

4

5

7-26

– +ELECLIGHTING SYSTEM

8 Turn the main switch to on.8 Turn the light switch to on position.8 Turn the dimmer switch to low beam or

high beam.8 Check for voltage (12V) on the lead at bulb

socket connectors.

MEETSSPECIFICATION

This circuit is not faulty.

YP805021

2. If the meter light fails to come on.

1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.

CONTINUITY

2. Voltage8 Connect the pocket tester (DC20V) to the

bulb socket coupler.

Tester (+) lead→Blue terminal 1

Tester (-) lead→Black terminal 2

8 Turn the main switch to on.8 Turn the lights switch to on.8 Check the voltage (12V) of the leads on

the bulb socket connector.

MEETSSPECIFICATION

This circuit is not faulty.

*OUT OF SPECIFICATION

The wiring circuit from the main switch tobulb socket connector is faulty. Repair.

NO CONTINUITY

Replace the bulb and/or bulb socket.

OUT OF SPECIFICATION

The wiring circuit from main switch to bulbsocket is faulty. Repair.

L

Gy

B

1

2

7-27

– +ELECLIGHTING SYSTEM

3. Auxilialy light does not come on.

1. Bulb and bulb socket 8 Check the bulb and bulb socket for conti-

nuity

CONTINUITY

2. Voltage8 Connect the pocket tester (DC20V) to the

bulb socket connector.

Tester (+) lead → Blue / Red 1 lead.Tester (-) lead → Black 2 lead.

8 Turn the main switch to on.8 Turn the lights switch to “PO” or “ON”.8 Check the voltage (12V) on the “Blue” lead

at the bulb socket connector.MEETSSPECIFICATION(12V)

This circuit is not faulty.

NO CONTINUITY

Bulb and/or bulb socket are faulty, replace.

OUT OF SPECIFICATION

Wiring circuit from main switch to bulbsocket connector is faulty. Repair.

Y

B

G

L/R

12

7-28

– +ELEC

L

-

G/Y

B

LIGHTING SYSTEMYP805022

4. The taillight fails to come on.

1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.

CONTINUITY

2. Voltage8 Connect the pocket tester (DC20V) to the

bulb socket connector.

Tester (+) lead→Blue terminal 1Tester (-) lead→Black terminal 2

8 Turn the main switch to on.8 Turn the lights switch to on8 Check the voltage (12V) on the bulb socket

connector.MEETSSPECIFICATION

This circuit is not faulty.

NO CONTINUITY

Replace the bulb and/or bulb socket.

OUT OF SPECIFICATION

The wiring circuit from main switch to bulbconnector is faulty. Repair.

2

1

7-29

– +ELEC

SIGNAL SYSTEMCIRCUIT DIAGRAM

SIGNAL SYSTEM

1 Main switch2 Main fuse3 Batterye Rear brake switchr Front brake switcht Brake lighty Rear flasher light(right)

u Rear flasher light(left)i Audio piloto Front flasher light(right)p Front flasher light(left)s Flasher relayd Hornf Handlebar switch (Left)

g Horn switchj Turn switchk Fuel sender; Fuel meterz Oil indicator lightv Turn indicator lightb Oil level gauge

LOCKOPENOFF

CHECKON

B

Gy

R

Br

R

Br

B

Gy

Y/R

L/W

L/R

L

L/G

G/R

L

L/G

G/R

Y/R

L/W

L/R

OFFSTART

8

'

:

LW

RW

LW

GY B

R

B

R

B

B

Y/R

B

B

B

Y/B

B

W

Y/R

B

W

Y/R

B

Gy

Br

Gy

Br

Br

G

Br

G

Dg

Ch

Dg

Ch

L

Gy

B

L

Gy

B

G

B

G

B

Y

B

Y

B

G

L/R

G

L/R

G/R

P

B

G/R

P

B

Ch

Br/W

Dg

Ch

Br/W

Dg

Y

G

Y

G

Ch

Dg

B

Ch

Dg

B

Ch

B

Ch

B

G/Y

B

G/Y

B

L

-

L

-

Dg

B

Dg

B

OFFPUSH

&

%

Br/W

Br

4

N6

Or

B

Or

B

Gy

Br R B

B/W

RR

R

R

LW

B LW LG YR

R

GY

R

B

W

Y/R

RB

YB

L/R L

G/R

BrP

Br

Br/

/W

P

G/R

Br/

W

B G Y Ch

Dg

G Y LRB

Ch

Dg

B

BY

B

W

Y/R

YR

B

B

B

B B

Ch

Dg

G/Y

B B

Ch

Dg

G/Y

G/Y

GY

Br

Br

Br

B

L/G

L/Y

B

OrOr

B

W/R

B/R

B/W

W/R

B/R

L/Y

Br

Gy L

Gy

Br

Y Y

Ch

Dg

BGG

BG

1

3

24

n

b

g

l

k

6

5

s

7

w

9

.

8

q

a

i

p o

r

e

t

yu

d

Q

W

R

B

Y/R

m

,

h

;

z x c v

/

0

f

j

L

7-30

– +ELECSIGNAL SYSTEM

Pocket tester:90890-03112

YP.....

1. FuseRefer to “CHECKING SWITCHES” section.

CONTINUITY

YP.....

2. Battery8 Check the battery condition.

Refer to “BATTERY INSPECTION” sectionin CHAPTER 3.

CORRECT

YP.....

3. Main switchRefer to “CHECKING SWITCHES” section.

CONTINUITY

YP806010

TROUBLESHOOTING

IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHTFAIL TO COME ON. IF THE HORN FAILS TO SOUND.

ProcedureCheck:1. Fuse (Main) 3.Main switch2. Battery 4.Wiring connection (entire signal system)

NOTE:

8 Remove the following parts before troubleshooting.1) Battery box cover 5) Tail cover2) Front protector bar 6) Side covers(Left/Right)3) Upper cover 7) Center cover4) Rear carrier

8 Use the special tools in the troubleshooting section .

NO CONTINUITY

Replace the fuse.

IN CORRECT

8 Clean battery terminals.8 Recharge or replace battery.

NO CONTINUITY

Replace the main switch.*

7-31

– +ELECSIGNAL SYSTEM

*

YP......

4. Wireharness8 Check the connections of the entire sig-

nal system.Refer to “CIRCUIT SYSTEM WIRING DIA-GRAM” section.

CONTINUITY

Check condition of each of the signalsystem’s circuits.Refer to “SIGNAL SYSTEM CHECK” sec-tion.

POOR CONNECTION

Correct.

7-32

– +ELECSIGNAL SYSTEMYP806020

SIGNAL SYSTEM CHECK1. If the horn fails to sound.

1. HORN switchRefer to “CHECKING SWITCHES” section.

CONTINUITY

2. Voltage8 Connect the pocket tester (DC20V) to the

horn lead.

Tester (+) lead→Brown terminal 1.Tester (-) lead→Frame ground

8 Turn the main switch to on.8 Check for voltage (12V) on the “Brown”

lead at the horn terminal.

MEETSSPECIFICATION

3. Horn8 Connect the pocket tester (DC20V) to the

horn at the “Pink” terminal.

Tester (+) lead→Pink 1 terminal.Tester (-) lead→Frame ground

8 Turn the main switch to on.8 Check for voltage on the “Pink” lead at

the horn terminal.

CONTINUITY

Adjust or replace horn.

NO CONTINUITY

Replace the left handlebar switch.

OUT OF SPECIFICATION

The wiring circuit from the main switch to thehorn is faulty. Repair.

NO CONTINUITY

Replace the horn.

Br P

Br P

7-33

– +ELEC

L

-

G/Y

B

SIGNAL SYSTEMYP806022

2. If the brake light fails to come on:

1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.

CONTINUITY

2. Brake switch (Front/Rear)Refer to “CHECKING SWITCHES” section.

CONTINUITY

3. Voltage8 Connect the pocket tester (DC20V) to the

bulb socket connector.

Tester (+) leadGreen/Yellow terminal 1Tester (-) leadBlack terminal 2

8 Turn the main switch to on.8 The brake lever is pulled in.8 Check for voltage (12V) of the “ Yellow”

lead on the bulb socket connector.

MEETSSPECIFICATION

This circuit is not faulty.

NO CONTINUITY

Replace the bulb and/or bulb socket.

NO CONTINUITY

Replace brake switch.

OUT OF SPECIFICATION

4. Wiring connection8 Wiring circuit from the main switch to the

bulb socket connector is faulty. Repair.Refer to “SIGNAL SYSTEM WIRING DIA-GRAM “ .

2

1

7-34

– +ELECSIGNAL SYSTEMYP806023

3. If the flasher light and/or turn indicatorlight fails to blink.

1. Bulb and bulb socketRefer to “CHECKING SWITCHES” section.

CONTINUITY

2. Turn switchRefer to “CHECKING SWITCHES” section.

CONTINUITY

3. Voltage8 Connect the pocket tester (DC20V) to the

flasher relay coupler.

Tester (+) lead→Brown terminal 1.Tester (-) lead→Frame ground

8 Turn the main switch to on.8 Check for voltage (12V) of the “Brown”

lead at the flasher relay terminal.

MEETSSPECIFICATION

4. Voltage8 Connect the pocket tester (DC20V) to the

flasher relay coupler.

Tester (+) lead→Brown/White terminal 1.Tester (-) lead→Frame ground

8 Turn the main switch to on.8 Check for voltage (12V) on the “Brown/

White” lead at the flasher relay terminal.

MEETSSPECIFICATION

NO CONTINUITY

Replace the bulb and/or bulb socket.

NO CONTINUITY

Replace the left handlebar switch.

OUT OF SPECIFICATION

The wiring circuit from main switch to flasherrelay connector is faulty. Repair.

OUT OF SPECIFICATION

The flasher relay is faulty. Replace.*

FLASHER

RELAY

Br/W

Br

–

–

FLASHER

RELAY

Br/W

Br

–

–

1

1

7-35

– +ELECSIGNAL SYSTEM

5. Voltage8 Connect the pocket tester (DC20V) to the

bulb socket connector.

At flasher light (left)Tester (+) lead→Chocolate lead 1Tester (-) lead→Black terminal 3

At flasher light (right)Tester (+) lead→Dark green lead 2Tester (-) lead→Black terminal 3

8 Turn the main switch to on.8 Turn the turn switch to left or right.8 Check for voltage (12V) on the “Choco-

late” lead and “Dark green” at the flasherlight terminal.

MEETSSPECIFICATION

This circuit is not faulty.

4. “OIL” indicator light does not come on.

1. Bulb and bulb socket8 Check the bulb and bulb socket for conti-

nuity.

CONTINUITY

2. Oil level switch8 Remove the oil level switch from the oil

tank.8 Connect the Pocket Tester (Ω x 1) to the

oil level switch.

Tester (+) Lead→Brown 1Tester (–) Lead→Gray 2

8 Check the oil level gauge for continuity.

GOOD CONDITION

*

OUT OF SPECIFICATION

6. Wiring connection8 Wiring circuit from the turn switch to bulb

socket connector is fault. Repair.Refer to “CIRCUIT DIAGRAM”.

NO CONTINUITY

Replace bulb and/or bulb socket.

BAD CONDITION

Replace oil level switch.

Bad condition

A Upright positionB Upside down

position

?: Continuity ×: No continuity

Goodcondition

Switch position

?× ?×××? ?

*

Ch B Dg B

Ch B Dg B

2133

A

B

Br Gy

Ch B Dg B

7-36

– +ELECSIGNAL SYSTEM

3. Voltage8 Connect the Pocket Tester (DC20V) to the

bulb socket connector.

Tester (+) Lead→Gray lead 1Tester (-) Lead→Frame ground 2

8 Turn the main switch to “*”8 Check for voltage (12V) on the “Gray” lead

at bulb socket connector.

MEETSSPECIFICATION(12V)

This circuit is good.

YP806027

5. If the fuel gauge fails to operate.

1. Fuel sender8 Remove the fuel sender from the fuel tank.8 Disconnect the fuel sender coupler from

the wireharness.Connect the pocket tester (Ω ×10) to thefuel sender coupler lead.

Tester (+) lead→Green terminal 1Tester (–) lead→Black terminal 2

8 Check the fuel sender for specificated re-sistance.

BOTH MEETSPECIFICATION

OUT OF SPECIFICATION

4. Wiring connection8 Check the entire signal system for connec-

tions.Refer to the “WIRING DIAGRAM” section.

OUT OF SPECIFICATION

Replace the fuel sender.

Float position

UP 3DOWN 4

Specificatedresistance

4~10Ω90~100Ω

B Gy L

2

B G

1

7-37

– +ELECSIGNAL SYSTEM

2. Voltage8 Connect the pocket tester (DC20V) to the

fuel gauge coupler.

Tester (+) lead→Brown terminal 1Tester (-) lead→Frame ground

8 Turn the main switch to “ON”.8 Check for voltage (12V) of the “Brown”

lead on the fuel sender lead.

MEETSSPECIFICATION

3. Fuel gauge8 Connect the fuel sender to wireharness.8 Move the float to “UP” 1 or “DOWN” 2.

8 Turn the main switch to “ON”.8 Check the fuel gauge needle moves “F”

or “E”.

Float position Needle moves

Float “UP” 1 “F”

Float “DOWN”2 “E”

MOVES

This circuit is not faulty.

OUT OF SPECIFICATION

Check the connection of the entire signal sys-tem .Refer to “CHECKING OF CONNECTIONS”.Refer to “CIRCUIT DIAGRAM”.

NOTE:

Before reading the meter, stay put the floatfor more than three minutes respectively at“UP” or “DOWN”.

DOES NOT MOVE

Replace the fuel gauge.

F

E

L Gy B Br DgG Ch

1

7-38

– +ELEC

AUTO CHOKE SYSTEMCIRCUIT DIAGRAM

AUTO CHOKE SYSTEM

7 Auto choke8 C.D.I. magneto

LOCKOPENOFF

CHECKON

B

Gy

R

Br

R

Br

B

Gy

Y/R

L/W

L/R

L

L/G

G/R

L

L/G

G/R

Y/R

L/W

L/R

OFFSTART

8

'

:

LW

RW

LW

GY B

R

B

R

B

B

Y/R

B

B

B

Y/B

B

W

Y/R

B

W

Y/R

B

Gy

Br

Gy

Br

Br

G

Br

G

Dg

Ch

Dg

Ch

L

Gy

B

L

Gy

B

G

B

G

B

Y

B

Y

B

G

L/R

G

L/R

G/R

P

B

G/R

P

B

Ch

Br/W

Dg

Ch

Br/W

Dg

Y

G

Y

G

Ch

Dg

B

Ch

Dg

B

Ch

B

Ch

B

G/Y

B

G/Y

B

L

-

L

-

Dg

B

Dg

B

OFFPUSH

&

%

Br/W

Br

4

N6

Or

B

Or

B

Gy

Br R B

B/W

RR

R

R

LW

B LW LG YR

R

GY

R

B

W

Y/R

RB

YB

L/R L

G/R

BrP

Br

Br/

/W

P

G/R

Br/

W

B G Y Ch

Dg

G Y LRB

Ch

Dg

B

BY

B

W

Y/R

YR

B

B

B

B B

Ch

Dg

G/Y

B B

Ch

Dg

G/Y

G/Y

GY

Br

Br

Br

B

L/G

L/Y

B

OrOr

B

W/R

B/R

B/W

W/R

B/R

L/Y

Br

Gy L

Gy

Br

Y Y

Ch

Dg

BGG

BG

1

3

24

n

b

g

l

k

6

5

s

7

w

9

.

8

q

a

i

p o

r

e

t

yu

d

Q

W

R

B

Y/R

m

,

h

;

z x c v

/

0

f

j

L

7-39

– +ELECAUTO CHOKE SYSTEM

Pocket tester:90890-03112

1. Lighting coil resistance8 Disconnect the CDI magneto couple from

wire harness.8 Connect the pocket tester (Ω x1) to the

lighting coil coupler

Tester (+) Lead→Yellow/Red 1 terminalTester (-) Lead→Frame earth

2 C.D.I. magneto8 Check the lighting coil for specificated re-

sistance

Lighting coil resistance0.4~0.6 Ω 20°C (68°F)

MEETSSPECIFICATION

YP.....

TROUBLESHOOTING

IF THE AUTO CHOKE FAILS TO OPERATE.

ProcedureCheck:1. Lighting coil resistance2. Auto choke unit resistance3. Wiring connection (entire auto choke system)

NOTE:

8 Remove the following parts before troubleshooting.1. Battery box cover2. Rear carrier3. Tail cover4. Right side cover

8 Use the special tools specified in the troubleshooting section.

OUT OF SPECIFICATION

Replace the lighting coil

*

CDIMagneto

W

Y/R

B

12

7-40

– +ELECAUTO CHOKE SYSTEM

YP...

2. Auto choke unit resistance8 Disconnect the auto choke unit coupler

from the wireharness.8 Connect the pocket tester (Ωx1) to the auto

choke unit coupler lead.

Tester (+) lead→Black terminal 1Tester (-) lead→Black terminal 2

Auto choke unit resistance:16~24Ω(20˚C)

MEETSSPECIFICATION

3. Wiring connection8 Check the connection of the entire auto

choke system.Refer to “CIRCUIT DIAGRAM” section.

*

OUT OF SPECIFICATION

Replace the auto choke unit.

POOR CONNECTION

Correct.

B B

8-1

TRBLSHTG

TROUBLESHOOTINGNOTE:

The following troubleshooting does not cover all the possible causes of trouble. It should behelpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual forinspection, adjustment and replacement of parts.

STARTING FAILURE/HARD STARTING

STARTING FAILURE/HARD STARTING

PROBABLE CAUSE

8Empty8Clogged fuel filter8Deteriorated fuel or fuel containing water or

foreign material8Clogged fuel tank cap

8Clogged fuel hose8Clogged fuel cock8Faulty fuel cock operation8Broken or disconnected fuel cock

8Deteriorated fuel, fuel containing water orforeign material8Clogged pilot jet8Clogged pilot air passage8Sucked-in air8Deformed float8Groove-worn needle valve8 Improperly sealed valve seat8 Improperly adjusted fuel level8 Improperly set pilot jet8Clogged starter jet8 Improperly adjusted pilot air screw

8Starter plunger malfunction8Wax malfunction8Faulty thermister

8Clogged air filter

FUEL SYSTEM

Fuel tank

Fuel cock

Carburetor

Auto choke

Air cleaner

8-2

TRBLSHTGSTARTING FAILURE/HARD STARTING

IGNITION SYSTEM

Spark plug

Ignition coil

CD I unit system

Switches and wiring

PROBABLE CAUSE

8 Improper plug gap8 Worn electrodes8 Wire between terminals broken8 Improper heat range8 Faulty spark plug cap

8 Broken or shorted primary/secondary coil8 Faulty spark plug lead8 Broken body

8 Faulty CD I unit8 Faulty source coil8 Faulty pick-up coil

8 Faulty main switch8 Broken or shorted wiring8 Faulty sidestand switch

COMPRESSION SYSTEM

Cylinder and cylinder head

Piston and piston rings

Crankcase and crankshaft

Reed valve

PROBABLE CAUSE

8Loose spark plug8Loose cylinder head or cylinder8Broken cylinder head gasket8Broken cylinder gasket8Worn, damaged or seized cylinder

8 Improperly installed piston ring8Worn, fatigued or broken piston ring8Seized piston ring8Seized or damaged piston

8 Improperly seated crankcase8 Improperly sealed crankcase (Damaged oil

seal)8Seized crankshaft

8Deformed reed valve stopper8 Improperly seated read valve8Loose intake manifold8Broken gasket8Broken reed valve

8-3

TRBLSHTG

POOR IDLE SPEED PERFORMANCE

Carburetor

Auto choke

Air cleaner

Ignition system

POOR IDLE SPEED PERFORMANCEPOOR MIDIUM AND HIGH SPEED PERFORMANCE

PROBABLE CAUSE

8 Improperly returned starter plunger8Clogged or loose pilot jet8Clogged pilot air jet8 Improperly adjusted idle speed

(Throttle stop screw)8 Improper throttle cable play8Flooded carburetor

8Starter plunger malfunction8Wax malfunction8Faulty thermister

8Clogged air cleaner

8Faulty spark plug8Faulty spark plug read8Faulty C.D.I. unit8Faulty source coil8Faulty ignition coil

POOR MEDIUM AND HIGH SPEED PERFOR-MANCE

Carburetor

Air cleaner

Muffler

PROBABLE CAUSE8Refer to starting failure/Hard starting item

(Fuel system, Ignition system, compressionsystem)8Clogged or loose main nozzle8Clogged or loose main jet8 Improperly set clip position of jet needle8 Improperly adjust fuel level8Sucked-in air

8Clogged air filter

8Clogged

POOR MIDIUM AND HIGH SPEEDPERFORMANCE

POOR IDLE SPEED PERFORMANCE

8-4

TRBLSHTGPOOR MIDIUM AND HIGH SPEED PERFORMANCE

FULTY AUTOMATIC(V-BELT TYPE)SCOOTER DOES NOT MOVE WHILE ENGINEIS OPERATING

V-belt

Cam, slider

Compression spring

Transmission

CLUTCH OUT FAILURE

Clutch weight spring

Clutch shoe

Primary sheave

PROBABLE CAUSE

8Worn, damaged or slipped V-belt

8Worn, damaged

8Damaged

8Damaged

8 Damaged

8 Pealed lining

8 Seized primary sliding sheave and collar

POOR STANDING START(LOW CLIMBINGABILITY)

V-belt

Primary sheave

Compression spring

Secondary sheave

Clutch shoe

POOR ACCELERATION(POOR HIGH SPEED)

V-belt

Weight

Primary/ Secondary seave

PROBABLE CAUSE

8 Worn or slipped V-belt

8 Improper operation8 Damaged

8 Damaged

8 Improper operation8 Worn guide pin

8 Plealed lining

PROBABLE CAUSE

8 Worn8 Greasy

8 Worn8 Improper operation8 Worn

8-5

TRBLSHTG

PROBABLE CAUSE

8 Faulty spark plug8 Improper spark plug heat range8 Faulty C.D.I. unit8 Faulty source coil

8 Clogged fuel tank cap8 Clogged air filter8 Clogged carburetor

8 Worm cylinder8 Worm, fatigued or broken piston ring8 Broken cylinder head gasket8 Broken cylinder gasket8 Carbon accumulation of cylinder head

8 Clogged

8 Refer to “FAULTY AUTOMATIC”

8 Drag

OVER HEAT / POOR SPEED

OVER HEATOVER HEAT

Ignition system

Fuel system

Compression system

Muffler, Exhaust pipe

Oil pimp

Brake

Cooling system

PROBABLE CAUSE

8 Improper plug gap8 Improper spark plug heat range8Faulty C.D.I. unit

8 Improper carburetor setting8Clogged air filter

8Carbon accumulation of cylinder head

8Clogged

8Faulty oil pump8Faulty oil quality8Drag

8Fan damaged

POOR SPEEDPOOR SPEED

Ignition system

Fuel system

Compression system

Muffler, Exhaust pipe

Clutch

Brake

8-6

TRBLSHTGIMPROPER KICKING

IMPROPER KICKINGSLIPPING

Kick axle assembly

Transmission oil

HARD KICKING

Kick axle assembly

Cylinder, piston and piston ring

Crankcase and crankshaft

KICK CRANK NOT RETURNING

Kick axle assembly

PROBABLE CAUSE

8Low tension of kick clip8Worn kick axle8Worn or damaged kick gear8Damaged kick clip8Kick clip coming off8Damaged kick clip stopper

8 Improper quality (Low viscosity)8Deterioration

PROBABLE CAUSE

8High tension of kick clip8Seized kick gear

8Damaged or seized cylinder8Damaged or seized piston8Damaged or seized piston ring

8 Improperly seated crankcase8 Improperly seated crankshaft8Damaged or seized crankshaft8Damaged or seized crankshaft bearing

PROBABLE CAUSE

8Damaged kick return spring8Kick return spring coming off8Kick clip coming off8Damaged kick return spring stopper

8-7

TRBLSHTG

FAULTY BRAKEPOOR BRAKING EFFECT

Drum brake

Disc brake(Front)

MALFUNCTION

FAULTY BRAKE

PROBABLE CAUSE

8Worn brake shoe8Worn or rusty brake drum8 Improperly adjusted brake free play8 Improper brake cam lever position8 Improper brake shoe position8Fatigue/Damaged return spring8Oily or greasy brake shoe8Oily or greasy brake drum8Broken brake cable

8Worn brake pad8Worn brake disc8Air in brake fluid8Leaking brake fluid8Faulty master cylinder kit8Faulty caliper seal kit8Loose union bolt8Broken brake hose8Oily or greasy brake pad8Oily or greasy brake disc

PROBABLE CAUSE

8Bent, deformed or damaged inner tube8Bent or deformed outer tube8Damaged fork spring8Worn or damaged slide metal8 Improper oil viscosity8 Improper oil level

8-8

TRBLSHTG

INSTABLE HANDLINGINSTABLE HANDLING

Handlebar

Steering

Front forks

Tires

Wheels

Frame

Engine bracket

Rear shock absorber

INSTABLE HANDLING

PROBABLE CAUSE

8 Improperly installed or bent

8 Improperly installed steering column(Improperly tightened ringnut)8Bent steering column8Damaged ball bearing or bearing race

8Broken spring8Bonded front forks

8Uneven tire pressures on both sides8 Incorrect tire pressure8Unevenly worn tires

8Damaged bearing8Bent or loose wheel axle8Excessive wheel run-out

8Twisted8Damaged head pipe8 Improperly installed bearing race

8Bent or damaged

8Fatigued spring8Oil leakage

8-9

TRBLSHTG

FAULTY SIGNAL AND LIGHTINGSYSTEM

HEADLIGHT DARK

BULB BURNT OUT

FLASHER DOES NOT BLINK

FLASHER KEEPS ON

FAULTY SIGNAL AND LIGHTING SYSTEM

PROBABLE CAUSE

8 Improper bulb8Too many electric accessories8Hard charging (Broken charging coil)8 Incorrect connection8 Improperly grounded8Poor contacts (main or light switch)8Bulb life expires

PROBABLE CAUSE

8 Improper bulb8 Improperly grounded8Faulty main and/or light switch8Bulb life expires

PROBABLE CAUSE

8 Improperly grounded8Discharged battery8Faulty flasher switch8Faulty flasher relay8Broken wireharness8Loosely connected coupler8Bulb burnt out8Faulty fuse

PROBABLE CAUSE

8Faulty flasher relay8 Insufficient battery capacity (nearly dis-

charged)8Bulb burnt out

8-10

TRBLSHTG

FLASHER BLINKS SLOWER

FLASHER BLINKS QUICKER

HORN DOES NOT SOUND

FAULTY SIGNAL AND LIGHTING SYSTEM

PROBABLE CAUSE

8Faulty flasher relay8 Insufficient battery capacity

(nearly discharged)8 Improper bulb8Faulty main and/or flasher switch

PROBABLE CAUSE

8 Improper bulb8Faulty flasher relay

PROBABLE CAUSE

8Faulty battery8Faulty fuse8Faulty main and/or horn switch8 Improperly adjusted horn8Faulty horn8Broken wireharness

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