This manual was produced bythe Yamaha Motor Company, Ltd. primarily for use
... in specifications or procedures will be forwarded to all authorized Yamaha.
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MOTORCYCLE
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2002 - 2005
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SERVICE MANUAL
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Model : YW50P, YW50R, YW50S, YW50T
5PNF81972000 *5PNF81972000*
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YW50BP SERVICE M A N U A L ©2001 by Yamaha M o t o r Taiwan Co,.Ltd. First edition, November 2001 All rights reserved. A n y reprinting or unauthorized use w i t h o u t the w r i t t e n permission of Yamaha M o t o r Taiwan Co,.Ltd. is expressly prohibited.
EB001000
NOTICE T h i s m a n u a l w a s p r o d u c e d b y t h e Y a m a h a M o t o r C o m p a n y , Ltd. p r i m a r i l y for use b y Y a m a h a dealers and t h e i r q u a l i f i e d m e c h a n i c s . It is not p o s s i b l e to i n c l u d e all t h e k n o w l e d g e o f a m e c h a n i c in one m a n u a l . Therefore, a n y o n e w h o uses t h i s b o o k to p e r f o r m m a i n t e n a n c e and repairs on Y a m a h a v e h i c l e s s h o u l d have a basic u n d e r s t a n d i n g of m e c h a n i c s and the t e c h n i q u e s to repair these t y p e s of vehicles. Repair and m a i n t e n a n c e w o r k a t t e m p t e d by a n y o n e w i t h o u t t h i s k n o w l e d g e is likely to r e n d e r t h e v e h i c l e u n s a f e and unfit for use. Y a m a h a M o t o r C o m p a n y , Ltd. is c o n t i n u a l l y s t r i v i n g to i m p r o v e all of its m o d e l s . M o d i f i c a t i o n s and s i g n i f i c a n t c h a n g e s in s p e c i f i c a t i o n s or p r o c e d u r e s w i l l be f o r w a r d e d to all a u t h o r i z e d Y a m a h a deal-ers and w i l l a p p e a r in f u t u r e e d i t i o n s of t h i s m a n u a l w h e r e applicable.
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D e s i g n s and s p e c i f i c a t i o n s are subject to c h a n g e w i t h o u t notice.
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IMPORTANT MANUAL INFORMATION
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P a r t i c u l a r l y i m p o r t a n t i n f o r m a t i o n is d i s t i n g u i s h e d in t h i s m a n u a l by the f o l l o w i n g . The Safety Alert Symbol means ATTENTION! SAFETY IS INVOLVED!
BECOME ALERT! Y O U R
~'~,WARNING
Failure to f o l I o w W A R N I N G i n s t r u c t i o n s could result in severe i n j u r y or death to the s c o o t e r o p e r a t o r , a b y s t a n d e r or a p e r s o n c h e c k i n g or r e p a i r i n g the scooter.
CAUTION:
A C A U T I O N i n d i c a t e s special p r e c a u t i o n s t h a t m u s t be taken to a v o i d d a m age to the scooter.
NOTE:
A NOTE p r o v i d e s key i n f o r m a t i o n to make p r o c e d u r e s easier or clearer.
HOW TO USE THIS MANUAL
CYLINDEB HEAD" CYF~:N::R: P 1.
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® ®
•
SparkIJlug Cylinder head/Cylinder head gasket Cylinder Piston pin clip Piston p i n / B e a r i n g Piston Pistonring set CyITnder gasket
6
7 8 9 10
IIp~) rag so y o u will not acci
• Piston pin bearing ~ GA~ON~ Donot
use a h a m m e r t o d r i v e t h e piston pin
out_
ow 3 4
nc
pT
with a clean
Z. Ro,,,ovo: • Piston pTn 1~ • Piston ®
HEAD INSPECTION
• Carbon deposits Use a rounded ~crapper
D Engine Muffler/Gasket A i r ~hroud (cylTnder head)
~
~. Elhxlin~te:
Q'ty
1
san
N o T E PI t
crankcase
CYUNDER
Cvlinder head. Cylinder and piston removal
2
~
Remove:
Begore removing tha piston pin celt,, cover the '
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This manual is intended as a handy, easy-to-read reference book for the mechanic. C o m p r e h e n s i v e explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. (~ The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to " S Y M B O L S " . (~ Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 ("PERIODIC CHECKS A N D A D J U S T M E N T S " ) , w h e r e the sub-section title(s) appears. (~ Sub-section titles appear in smaller print than the section title. (~ To help identify parts and clarify procedure steps, there are exploded d i a g r a m s at the start of each removal and disassembly section. (~ N u m b e r s are given in the order of the jobs in the exploded diagram. A circled n u m b e r indicates a disassembly step. (~ S y m b o l s indicate parts to be lubricated or replaced. Refer to " S Y M B O L S " . (~) A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. (~ Jobs requiring more information (such as special tools and technical data) are described sequentially.
•
Rurllark~
@
Cylinder head war~3age Out of specification >Re8ur'0ce.
Remove the pa~s Enthe order
1/1 1 1 1/1 1 2
Refer to the tion
"ENGINE REMOVAL" sec-
Warpage
measurement
a n d re s u r f a c e m e n t
• Attach a =traight •
e d g e ~ a n d a thickness g a u g e ( ~ on the cylinder head. M e a s u r e the w a r p a g e limit.
I
1
• If the w a r p a g e is out of specification, t h e cylinder head. NOTE:
1
1 Reverse the r e m o v a l procedure f o r in stallatien.
reface
Rotate the head severaT tTres t o a v o i d r e m o v ing too m u c h moteriol f r o m o n e side. 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- -
Q
®
EAS00009
SYMBOLS
SPEC
®
The following symbols are not relevant to every vehicle. Symbols (~to (~ are designed as thumb tabs to indicate the chapter's number and content. (~ General information (~ Specifications (~ Periodic inspection and adjustment Engine (~) Carburetor(s) (~ Chassis (~ Electrical system (~ Troubleshooting
®
INSP
ENG
®
~)~
®
CHAS ( ~ ®
CARB
®
@
®
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TRBL SHTG
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©
Symbols (~ to (~) indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data
® @ @ @ @ @ @ @
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GEN INFO
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I~lew
Symbols @to @ in the exploded diagrams indicate the types of lubricants and lubrication points. (~ Engine oil @ Gear oil (~) Molybdenum disulfide oil (~ Wheel bearing grease (~ Lithium soap base grease (~) Molybdenum disulfide grease Symbols@ to @ in the exploded diagrams indicate the following. (~ Apply locking agent (LOCTITE ®) (~ Replace the part
INDEX GENERAL INFORMATION
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CHASSIS
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CARBURETION
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ENGINE O V E R H A U L
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PERIODIC INSPECTION AND ADJUSTMENT
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SPECIFICATIONS
ELECTRICAL TROUBLESHOOTING
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CHAPTER GENERAL SCOOTER INDENTIFICATION VEHICLE MODEL
...........................................................................................................
1-1
...........................................................................................
1-1
................................................................................................................................
1-1
IMPORTANT INFORMATION PREPARATION
............................................................................................................
FOR REMOVAL
REPLACEMENT GASKETS,
INFORMATION
NUMBER
IDENTIFICATION CODE
1.
PARTS
OIL SEALS
1-2
.................................................................................................................
1-2
AND
O-RINGS
..........................................................................................
1-2
.........................................................................................................
1-3
........................................................................................................................................
1-3
CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H O W T O U S E THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
OIL SEALS
....................................................................................................................
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TABLE
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D
CONVERSION
SPECIAL TOOLS
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CIRCLIPS
AND
COTTER
1-2
P I N S ...........................................................................
BEARINGS
AND
DISASSEMBLY
1-2
................................................................
LOCK WASHERS/PLATES
AND
1-5 1-5 1-6
C H A P T E R 2. SPECIFICATIONS GENERAL SPECIFICATION MAINTENANCE TIGHTENING
TORQUES
MAINTENANCE CHASSIS
SPECIFICATION
CHASSIS
TORQUES
...............................................................................................................
........................................................................................................................................
MAINTENANCE ELECTRICAL
SPECIFICATION
SPECIFICATIONS
...........................................................................................
POINTS AND LUBRICATION
TYPE
.......................................................................
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LUBRICATION
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D
CABLE ROUTING
2-4 2-4 2-6 2-6 2-7 2-7 2-8 2-8
..................................................................................................... 2-9
...................................................................................................................................
GENERAL TORQUE
CHASSIS
.....................................................................................................
........................................................................................................................................
TIGHTENING
ENGINE
...............................................................................................................
..........................................................................................................................................
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ENGINE
.....................................................................................................
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ENGINE
............................................................................................................... 2-1
SPECIFICATION
2-9 2-1 1 2-12 2-12 2-13 2-14
CHAPTER 3. PERIODIC I N S P E C T I O N A N D A D J U S T M E N T S INTRODUCTION PERIODIC
AND
PANEL
SIDECOVER LOWER
AND
SEAT
3-1
................................................................................................................ 3-3
UPPER COVER,
COVER(FRONT
LEG SHIELD
AND
1, 2 A N D
FOOTREST
BOARD
..................... 3-4
REAR) ................................................................................... 3-5
..............................................................................................................................................3 - 6
IDLE SPEED ADJUSTMENT CABLE
AUTOLUBE
PUMP
PLUG
OIL LEVEL INSPECTION
TRANSMISSION
CLEANING
........................................................................................ 3-11
.............................................................................................. 3-12
................................................................................................................... 3-14
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INSPECTION
CHASSIS
............................................................................................... 3-10
OIL REPLACEMENT
AIR FILTER ELEMENT V-BELT
............................................................................................... 3-8
........................................................................................................... 3-9
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ENGINE
AIR BLEEDING
INSPECTION
..................................................................................... 3-7
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SPARK
.......................................................................................................... 3-6
FREE ADJUSTMENT
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THROTTLE
BRAKE
LEVER FREE PLAY CHECK ................................................................................ 3-15 LEVER FREE PLAY CHECK ................................................................................... 3-15
PAD INSPECTION
BRAKE
SHOE
BRAKE
FLUID LEVEL INSPECTION
INSPECTION (HYDRAULIC
INSPECTION
FRONT
FORK INSPECTION
......................................................................................................... 3-22
INSPECTION
.................................................................................... 3-22
........................................................................................... 3-22
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ADJUSTMENT
..................................................................................... 3-23
LUBRICATING
.................................................................................................. 3-23
CHECKING
AND
LUBRICATING
............................................................................................................... 3-23
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LUBRICATING
D
CENTERSTAND
........................................................................ 3-17
................................................................................................................... 3-22
ABSORBER
LOCK CABLE
LEVERS
SYSTEM)
........................................................................................................................3-19
WHEEL
CABLE
BRAKE
.......................................................................................................... 3-18
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TIRE INSPECTION
............................................................................................ 3-16
m
ADJUSTMENT
REAR SHOCK
........................................................................................................ 3-16
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AIR BLEEDING STEERING
........................................................................................................... 3-15
.S
BRAKE
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REAR BRAKE
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..........................................................................................................................................3-15
FRONT
SEAT
3-1
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ENGINE
................................................................
.......................................................................................................................... 3-3
COWLING,
HANDLEBAR
INTERVALS
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COVER
................................................................................................................................
MAINTENANCE/LUBRICATION
ELECTRICAL
.....................................................................................................................................3-24
BATTERY
INSPECTION
FUSE INSPECTION
............................................................................................................... 3-24
......................................................................................................................3-29
HEADLIGHT
BEAM
ADJUSTMENT
............................................................................................ 3-30
HEADLIGHT
BULB
REPLACEMENT
............................................................................................ 3-30
TURN
SIGNAL
TAILLIGHT LICENSE
AND
BULB LIGHT
TAILLIGHT
REPLACEMENT BULB
BULB
REPLACEMENT
........................................................... 3-31
.............................................................................................. 3-32
REPLACEMENT
...................................................................................... 3-32
C H A P T E R 4. ENGINE E N G I N E O V E R H A U L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 WlREHARNESS
AND
CABLES
......................................................................................................
4-1
C Y L I N D E R HEAD, C Y L I N D E R A N D P I S T O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 PISTON
HEAD,
CYLINDER
PIN AND
CYLINDER
HEAD
CYLINDER
AND
AND
PISTON
RINGS
PISTON
PIN AND
PISTON
PIN AND
................................................................................
4-3
..........................................................................................
4-4
.....................................................................................................
4-4
INSPECTION
INSPECTION
AND
PISTON
REMOVAL
INSPECTION
PISTON
CYLINDER
PISTON
........................................................................................
4-5
........................................................................................................
4-7
PISTON
PIN BEARING
PISTON
INSTALLATION
CYLINDER
HEAD
....................................................................................
4-7
................................................................................. 4-8
................................................................................................
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CYLINDER
4-9
AND
KICK STARTER
.............................................................................................................................
4-12
KICK STARTER
INSTALLATION
4-13
SHEAVE
INSPECTION
4-16
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..............................................................................................
4-16 4-17
...................................................................................................................
4-18 4-19
SHEAVE
INSPECTION
................................................................................................................
4-20
SECONDARY
SHEAVE
INSTALLATION
.....................................................................................
4-21
......................................................................................................................
4-22
SHEAVE
m
................................................................................................
SECONDARY PRIMARY
SHEAVE
REMOVAL
4-15
.................................................................................................................
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PRIMARY
....................................................................................................
w
V-BELT
........................................................ 4-14
................................................................................................................
REMOVAL
INSPECTION
SHEAVE
co ot
SECONDARY CLUTCH
SECONDARY/PRIMARY
.S
SHEAVE
.................................................................................................
w
PRIMARY
AND
SHEAVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1
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CLUTCH
SECONDARY
COVER(LEFT)
im
KICK STARTER
V-BELT,
CRANKCASE
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V-BELT, C L U T C H A N D S E C O N D A R Y / P R I M A R Y S H E A V E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1
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STARTER CLUTCH A N D STARTER M O T O R ................................................................................. 4-24 STARTER
CLUTCH
AND
STARTER
STARTER
CLUTCH
AND
GEARS
.............................................................................. 4-24 .........................................................................
4-26
................................................................................................................................
INSPECTION
4-27
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C.D.I. MAGNET
MOTOR
.........................................................................................................................
4-27
C.D.I. MAGNETO
REMOVAL
4-28
.......................................................................................................
D
C.D.I. MAGNETO
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C.D.I. MAGNETO
INSTALLATION
..............................................................................................
4-28
A U T O L U B E P U M P ........................................................................................................................... 4-29 AUTOLUBE
PUMP
.......................................................................................................................
4-29
AUTOLUBE
PUMP
INSTALLATION
4-30
...........................................................................................
T R A N S M I S S I O N .............................................................................................................................. 4-31 TRANSMISSION
..........................................................................................................................
4-31
C R A N K C A S E A N D REED V A L V E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 3 CRANKCASE
AND
REED VALVE
CRANKCASE(RIGHT)
................................................................................................
4-33
................................................................................................
4-35
....................................................................................................
4-35
REMOVAL
CHECKING
THE CRANKCASE
CHECKING
THE
BEARINGS
REED VALVE
INSPECTION
CRANKCASE
(RIGHT)
AND
OIL SEALS
............................................................................ 4-35
.........................................................................................................
INSTALLATION
......................................................................................
4-36 4-36
C R A N K S H A F T .................................................................................................................................. 4-38 CRANKSHAFT
..............................................................................................................................
4-38
CRANKSHAFT
REMOVAL
...........................................................................................................
4-39
CRANKSHAFT
INSPECTION
.......................................................................................................
4-39
CRANKSHAFT
INSTALLATION
...................................................................................................
4-40
CHAPTER 5 CARBURETION CARBURETION
..................................................................................................................................
CARBURETOR
................................................................................................................................
CABURETOR
DISASSEMBLY
CABURETOR
5-1
5-1
.......................................................................................................
5-2
INSPECTION
...........................................................................................................
5-3
ASSEMBLY
...........................................................................................................
5-5
FUEL LEVEL ADJUSTMENT
.........................................................................................................
5-6
..........................................................................................................
5-7
.............................................................................................................
5-8
CARBURETOR
CHOKE
INSPECTION
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INSPECTION
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FUEL COCK
D
AUTO
CHAPTER 6 CHASSIS F R O N T W H E E L A N D B R A K E D I S C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 FRONT
WHEEL
AND
FRONT
WHEEL
DISASSEMBLY
BRAKE
D I S C ...............................................................................................
6-1
....................................................................................................
6-2
FRONT
WHEEL
DISASSEMBLY
FRONT
WHEEL
INSPECTION
BRAKE
DISC INSPECTION
FRONT
WHEEL
ASSEMBLY
FRONT
WHEEL
INSTALLATION
WHEEL
STATIC
BALANCE
....................................................................................................
6-3
........................................................................................................
6-3
............................................................................................................
6-4
..........................................................................................................
6-4
...................................................................................................
ADJUSTMENT
6-5
.................................................................................. 6-6
F R O N T B R A K E ...................................................................................................................................
6-8
P A D ....................................................................................................................................
6-8
BRAKE
PAD REPLACEMENT
6-9
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BRAKE
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........................................................................................................
CYLINDER
........................................................................................................................
MASTER
CYLINDER
DISASSEMBLY
im
MASTER
6-12
.............................................................................................
6-13
..............................................................................................
6-14
................................................................................................
6-14
CYLINDER
INSPECTION
MASTER
CYLINDER
ASSEMBLY
MASTER
CYLINDER
INSTALLATION
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MASTER
......................................................................................... 6 - 1 5
CALIPER ........................................................................................................................................... 6 - 1 7
INSPECTION
.S
................................................................................................
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CALIPER
.................................................................................................................
DISASSEMBLY
6-18 6-19
................................................................................................................. 6 - 1 9
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CALIPER
BRAKE
CALIPER ASSEMBLY
BRAKE
CALIPER
w
BRAKE
......................................................................................................
INSTALLATION
6-20
............................................................................................... 6 - 2 0
m
CALIPER DISASSEMBLY
...............................................................................................................................
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REAR W H E E L A N D REAR BRAKE .................................................................................................. 6-21 6-21 6-22
REAR WHEEL
INSPECTION
........................................................................................................
6-23
REAR BRAKE
INSPECTION
.........................................................................................................
6-23
REAR BRAKE
INSTALLATION
....................................................................................................
6-24
....................................................................................................................................
6-25
................................................................................................................................
6-25
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HANDLEBAR
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R E A R B R A K E ................................................................................................................................
D
HANDLEBAR
HAN DLE BAR INSTALLATIO
STEERING
N .....................................................................................................
6-27
........................................................................................................................................
6-29
STEERING
....................................................................................................................................
STEERING
REMOVAL
STEERING
INSPCTION
STEERING
INSTALLATION
6-29
................................................................................................................. 6 - 3 0 ................................................................................................................ 6-31 ......................................................................................................... 6-31
F R O N T FORK ................................................................................................................................... 6 - 3 4 FRONT
FORK
FRONT
FORK DISASSEMBLY
...............................................................................................................................
FRONT
FORK REMOVAL
FRONT
FORK DISASSEMBLY
FRONT
FORK INSPECTION
FRONT
FORK ASSEMBLY
FRONT
FORK INSTALLATION
6-34
.....................................................................................................
6-35
.............................................................................................................
6-36
.....................................................................................................
6-36
......................................................................................................... 6-37 ........................................................................................................... 6-37 .................................................................................................... 6-39
CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS
............................................................................................................
7-1
........................................................................................................
7-1
........................................................................................................................
7-2
CHECKING SWITCHES ......................................................................................................................
7-4
ELECTRICAL CIRCUIT
COMPONENTS
DIAGRAM
CHECKING SWITCH
STEPS
.........................................................................................................................
CONNECTION
AS
SHOWN
IN THIS
MANUAL
.............................................................
S W I T C H P O S I T I O N A N D T E R M I N A L C O N N E C T I O N ...................................................................... C H E C K I N G T H E B L U B S A N D B U L B S O C K E T S ............................................................................... BULBS
OF BULBS
AND
BULB
SOCKETS
...........................................................................
..........................................................................................................................
CHECKING
THE
CONDITION
OF THE
BULBS
CHECKING
THE
CONDITION
OF THE
BULB
..............................................................................
et
TYPES
THE
SOCKETS
..............................................................
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CHECKING
CIRCUIT
DIAGRAM
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IGNITION SYSTEM ............................................................................................................................ ........................................................................................................................
7-6 7-6 7-7 7-8 7-9 7-9
SYSTEM .......................................................................................................................
7-14
DIAGRAM
......................................................................................................................
7-14
TROUBLESHOOTING
..................................................................................................................
7-15
ELECTRIC STARTING SYSTEM ......................................................................................................
7-18
......................................................................................................................
7-18
TROUBLESHOOTING
..................................................................................................................
7-19
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DIAGRAM
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CIRCUIT
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CIRCUIT
7-5 7-5
7-10
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CHARGING
7-4
..................................................................................................................
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TROUBLESHOOTING
7-4
MOTOR
.......................................................................................................................
7-22
STARTER
MOTOR
DISASSEMBLY
.............................................................................................
7-23
..........................................................................................................
7-24
LIGHTING SYSTEM .........................................................................................................................
7-26
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REPAIR
DIAGRAM
......................................................................................................................
7-26
TROUBLESHOOTING
..................................................................................................................
7-27
LIGHTING
SYSTEM
CHECK
........................................................................................................
7-33
......................................................................................................................
7-33
..................................................................................................................
7-34
DIAGRAM
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TROUBLESHOOTING
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SIGNAL SYSTEM ............................................................................................................................. CIRCUIT
7-29
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CIRCUIT
AND
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INSPECTION
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STARTER
............................................................................................................
AUTO CHOKE SYSTEM
..................................................................................................................
7-42
DIAGRAM
......................................................................................................................
7-42
TROUBLESHOOTING
..................................................................................................................
7-43
SIGNAL
CIRCUIT
SYSTEM
CHECK
7-36
CHAPTER 8 TROUBLESHOOTING STARTING FAILURE/HARD SYSTEM
COMPRESSION
........................................................................................................................
SYSTEM
.............................................................................................................
P O O R IDLE S P E E D P E R F O R M A N C E POOR
IDLE SPEED
POOR MIDIUM POOR
PERFORMANCE
AND
HIGH SPEED
FULTY AUTOMATIC(V-BELT SCOOTER
DOES OUT
NOT
POOR STANDING
8-3
................................................................... 8-3
WHILE
ENGINE
IS O P E R A T I N G
.................................................. 8-4
.................................................................................................................
START(LOW
CLIMBING
ABILITY)
HIGH SPEED)
8-4
................................................................. 8-4
.............................................................................. 8-4
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POOR ACCELERATION(POOR
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P O O R S P E E D ..................................................................................................................................... POOR SPEED
8-2
....................................................................... 8-3
PERFORMANCE
O V E R H E A T ........................................................................................................................................ OVERHEAT
8-2
TYPE) ................................................................................................. 8-4
MOVE
FAILURE
8-1
............................................................................................ 8-3
AND HIGH SPEED PERFORMANCE
MIDIUM
CLUTCH
................................................................................................
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IGNITION
S T A R T I N G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
...............................................................................................................................
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FUEL SYSTEM
.................................................................................................................................
8-5 8-5
8-5 8-5
I M P R O P E R KICKING .......................................................................................................................... 8-6
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........................................................................................................................................
KICKING
KICK CRANK
..............................................................................................................................
NOT
RETURNING
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HARD
...................................................................................................
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SLIPPING
8-6 8-6 8-6
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F A U L T Y BRAKE ................................................................................................................................. 8-7 E F F E C T ...............................................................................................................
8-7
.............................................................................................................................
8-7
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BRAKING
MALFUNCTION
INSTABLE HANDLING INSTABLE
......................................................................................................................
HANDLING
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POOR
..................................................................................................................
FAULTY SIGNAL AND LIGHTING SYSTEM BULB
BURNT
D A R K ......................................................................................................................... OUT
........................................................................................................................
DOES
B L I N K .........................................................................................................
FLASHER
K E E P S O N .....................................................................................................................
FLASHER
BLINKS
SLOWER
FLASHER
BLINKS
QUICKER
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FLASHER
HORN
NOT
DOES
NOT SOUND
8-8
.................................................................................... 8-9
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HEADLIGHT
8-8
8-9 8-9 8-9 8-9
........................................................................................................
8-10
.......................................................................................................
8-10
.........................................................................................................
8-10
I GEN
SCOOTER INDENTIFICATION f
EAS00015
GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017
VEHICLE I D E N T I F I C A T I O N N U M B E R The vehicle identification number (~) is stamped into the frame.
f EAS00018
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M O D E L CODE The model code label ~) is affixed to the location s h o w n in the figure. Record the information on this label in the space provided. This information will be needed to order spare parts.
1-1
IMPORTANT INFORMATION
I GEN
EAS00020
IMPORTANT INFORMATION
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P R E P A R A T I O N FOR R E M O V A L A N D D I S A S SEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use o n l y the proper tools and cleaning equipment. Refer to "SPECIAL TOOLS". 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been " m a t e d " t h r o u g h normal wear. M a t e d parts must always be reused or replaced as an assembly. 4. During disassembly, clean all o f t h e parts and place them in trays in the order of disassembly. This will speed up a s s e m b l y and allow for the correct installation of all parts. 5. Keep all parts a w a y from any source of fire.
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300-008
EAS00021
300-016
EAS00022
G A S K E T S , OIL SEALS A N D O - R I N G S 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips w i t h grease.
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R E P L A C E M E N T PARTS Use o n l y genuine Yamaha parts for all replacements. Use oil and grease recom-mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
EAS00023
LOCK W A S H E R S / P L A T E S A N D C O T T E R PINS After removal, replace all lock washers/plates ~ ) a n d cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat o f t h e bolt or nut.
1-2
IMPORTANT INFORMATION
I ,NFOI GEN
I
EAS00024
~\\\\\\\\~1
BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu facturer's marks or n u m b e r s are visible. W h e n installing oil seals, lubricate the oil seal l i p s w i t h a light coat of lithium soap base grease. Oil bearings liberally w h e n installing, if appro priate. ~) Oil seal
CAUTION:
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(~ Bearing
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Do not spin the bearing with compressed air because this will damage the bearing surfaces.
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EAS00025
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CIRCLIPS Before reassembly, check all circlips carefully and replace d a m a g e d or distorted circlips, A l w a y s replace piston pin clips after one use. W h e n installing a circlip (~), make sure the s h a r p - e d g e d corner (~) is positioned o p p o s i t e the t h r u s t ~ that the circlip receives. (~ Shaft
1-3
IMPORTANT INFORMATION
I GEN
EB801000
CHECKING OF C O N N E C T I O N S D e a l i n g w i t h stains, rust, m o i s t u r e , etc. on t h e connector. 1. D i s c o n n e c t : • Connector 2. D r y each t e r m i n a l w i t h an air b l o w e r .
3.
C o n n e c t and d i s c o n n e c t t h e c o n n e c t o r t w o or t h r e e . Pull t h e read to c h e c k t h a t it w i l l not c o m e off. If t h e t e r m i n a l c o m e s off, b e n d up t h e pin ( ~ a n d r e i n s e r t t h e t e r m i n a l into t h e c o n Rector.
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4.
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6.
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5.
Connect: • Connector
The two connectors "click" together.
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NOTE:
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7.
Check for continuity with a tester.
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NOTE:
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1-4
If t h e r e is no c o n t i n u i t y , c l e a n t h e t e r m i nals. Be s u r e to p e r f o r m t h e s t e p s 1 to 7 listed above when checking the wireharness. For a field r e m e d y , use a c o n t a c t revitalizer a v a i l a b l e on t h e m a r k e t . Use t h e t e s t e r on t h e c o n n e c t o r as s h o w n .
H O W TO USE THE C O N V E R S I O N TABLE
I GEN
EB201000
H O W TO USE THE C O N V E R S I O N TABLE All s p e c i f i c a t i o n data in t h i s m a n u a l are listed in SI and M E T R I C U N I T S . Use t h i s t a b l e to c o n v e r t M E T R I C u n i t data t o I M P E R I A L u n i t data. Ex. METRIC MULTIPLIER IMP ** mm x 0.03937 = * * in 2 mm x 0.03937 = 0.083 in CONVERSION
TABLE METRIC TO IMP Known
Multiplier
Result
7.233 86.794 0.0723 0.8679
kg g
2.205 0.03527
km/h km
mm
0.6214 0.6214 3.281 1.094 0.3937 0.03937
Volume/ Capacity
cc(cm 3) cc(cm 3) lit(liter) lit(liter)
0.03527 0.06102 0.8799 0.2199
oz (IMP liq.) cu.in qt(IMP liq.) gal(IMP liq.)
Miscellaneous
kg/mm kg/cm 2 Centigrade
55.997 14.2234 9/5(°C)+32
Ib/in psi(Ib/in 2) Fahrenheit (°F)
Distance
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Ib oz
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Weight
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Torque
ft.lb in.lb ft.lb in.lb
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m.kg m.kg cm.kg cm.kg
1-5
mph mi ft yd in in
SPECIAL TOOLS I GEN EEl02000
SPECIAL TOOLS T h e f o l l o w i n g s p e c i a l t o o l s are n e c e s s a r y f o r c o m p l e t e and a c c u r a t e t u n e - u p and a s s e m b l y . Use o n l y t h e a p p r o p r i a t e s p e c i a l t o o l s ; t h i s Will h e l p p r e v e n t d a m a g e c a u s e d b y t h e use o f i n a p p r o p r i ate t o o l s or i m p r o v i s e d t e c h n i q u e s . W h e n p l a c i n g an o r d e r , r e f e r to t h e list p r o v i d e d b e l o w to a v o i d a n y m i s t a k e s . Tool No. YU-01235
Tool name / Function
Illustration
Rotor holding tool
-90050 -90062
Crankshaft Installation set (~ Adapter (~) These tools are used to install the crankshaft.
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YU
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This tool is used to disassembly and assembly the secondary pulley.
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Clutch spring holder
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YS-28891
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This tool is used to hold the generator rot o r w h e n removing or installing the generator rotor bolt.
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Flywheel puller
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YU-01189
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Crankcase Separating tool
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YU-01135-A
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This tool is used for removing the rotor.
YM-33299
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This tool is used to remove the crankshaft or separate the crankcase. Oil seal guide
Steering nut wrench
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YU-33975
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This tool is used for protecting the oil seal lip w h e n installing the secondary sliding sheave.
This tool is used to loosen or tighten the steering stem ring nut. YU-01701
Sheave holder This tool is used to hold the clutch housing w h e n removing or installing the clutch housing nut.
YU-8036-A
Inductive tachometer
This tool is used to check engine speed.
1-6
0
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SPECIAL TOOLS I GEN Tool No. YU-03112
I llustratio n
Tool name / Function Pocket tester This tool is used to c h e c k t h e electrical system.
YM-1409
Oil seal guide This tool is used to install the left side crankcase oil seal.
YM-1410
Oil seal d r i v e r
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This i n s t r u m e n t is necessary for checking the ignition s y s t e m c o m p o n e n t s . Quick Gasket ®
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ACC-1100-15-01
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D y n a m i c spark tester
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YM-34487
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This tool is used to install the left side crankcase oil seal.
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Lockn ut w r e n c h
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90890-01348
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This sealant is used to seal to m a t i n g surfaces (e.g., crankcase m a t i n g sur-faces).
Front fork seal d r i v e r Weight (~ A d a p t e r Q2~
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YU-33963 -1400
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This tool is used to loosen and t i g h t e n the c l u t c h c a r r i e r I o c k n u t of t h e s e c o n d a r y sheave.
YM-01312-A
T-handle ( ~ ) / D a m p e r rod holder ( ~
®
D
T-handle ( ~ YM-01326 Holder YM-01300-1 ( ~
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These tools are used w h e n installing the fork seal.
T h e s e t o o l s are n e e d e d to l o o s e n and tighten the d a m p e r rod holding bolt. Fuel level gauge This gauge is used to nleasure the fuel level in the float chamber.
1-7
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G E N E R A L SPECIFICATION
SPECIFICATION
IsPEcl.-I
GENERAL SPECIFICATION Model
YW50AP 5P J1
Dimensions: Overall length Overall w i d t h Overall height Seat height Wheelbase M i n i m u m ground clearance M i n i m u m turning radius
1,890 mm(74.4 in) 705 mm(27.8 in) 1,110 mm(43.7 in) 765 mm(30.1 in) 1,275 mm(50.2 in) 120 mm(4.7 in) 2,000 mm(78.7 in)
Basic weight: With oil and full fuel tank
94 kg(207 Ib)
Engine: Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system:
Air cooled 2 strcke, gasoline torque induction Forward- inclined single cylinder 49cm 3 (2.99 cu.in) 40.0 x 39.2 mm(1.57 x 1.54 in) 7.2:1 Electric and kick starter Separate lubrication
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Oil Type or Grade: Engine Oil
For Y A M A H A brand: Yamalube 2 or Air cooled 2-stroke engine oil (ISO EG-C, EG-D grade)
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Air Filter:
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Transmission Oil Oil Capacity: Oil Tank (Engine Oil) Transmission Oil: Periodic Oil Change Total A m o u n t
Fuel: Type Tank Capacity
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Model code:
Carburetor: Type / Manufacturer
Yamalube 4 SAE 10W/30 SE or GL gear oil 1.4 L (1.23 Imp°qt, 1.48 US qt) 0.11 L(0.096 Imp.qt, 0.12 US qt) 0.13 L(0.11 Imp.qt, 0.13 US qt) Wet type element Regular unleaded gasoline 5.7 L (1.25 Imp.gal, 1.5 US gal) Y14P/1/TEIKEI
2-1
G E N E R A L SPECIFICATION Model
YW50A BPRTHS/NGK 0.6 ~ 0.7 mm(0.02 ~ 0.03 in)
Clutch Type
Dry, Centrifugal automatic
Transmission: Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type Operation
Helical gear 4.000 Supur gear 3.666 V-belt Automatic
Chassis: Frame type Caster angle Trail
Steel tube underbone 26.5 ° 93mm(3.7 in)
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143 kg(315 Ib)
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200kpa(2.0 kg/crn 2, 29 psi) 200kpa(2.0 kg/cm 2, 29 psi) 200kpa(2.0 kg/cm 2, 29 psi) 200kpa(2.0 kg/cm 2, 29 psi)
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Maximum load* Cold tire Pressure: Up to 90 kg Front Rear 90 kg load~Maximum load* Front Rear
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Type
type
Single disc brake Right hand operation Drum brake Left hand operation
D
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operation
Rear brake
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Tubeless 120/90-10 130/90-10 CHENG SHIN CHENG SHIN 56J 59J
front rear front rear front rear
Manufacturer
Brake: Front brake
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Spark Plug: Type/Manufacturer Gap
Tire: Type Size
IsPEcl.-I
operation
Suspension: Front suspension Rear suspension
Telescopic fork Unit swing
Shock absorber: Front shock absorber Rear shock absorber
Coil spring/oil damper Coil spring/oil damper
Wheel travel: Front wheel travel Rear wheel travel
65 rnrn(2.56 in) 60 mm(2.36 in)
Electrical: Ignition system Generator system Battery type Battery capacity
C.D.I Flywheel Magneto YTX5L-BS 12V 4AH 2-2
G E N E R A L SPECIFICATION Model
IsPEcl.-I
YW50A
Headlight type:
Bulb
Bulb wattage x quantity: Headlight Tail/brake light Flasher light Licence plate light Meter light High beam indicator light Oil indicator light Turn indicator light
12V 35W/35Wx2 12 V 5W/21Wx1 10Wx4
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5Wx 1 3.4Wxl/1.7Wxl 1.7Wx 1 1.7Wx 1 1.7Wx 1
2-3
MA...E°A.OE SPEO.F.OA-.O° ISPEcl M A I N T E N A N C E SPECIFICATION ENGINE Item C y l i n d e r head: Warp l i m i t
Sta nda rd
Limit 0.03 m m (0.0012 in)
"~
40.000~40.014mm (1.5748~1.5754 in)
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Taper l i m i t
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Cylinder: Bore size
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*Lines indicate s t r a i g h t e d g e m e a s u r e m e n t
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Out of round Ih-nit
0.035~0.040 m m (0.0014~0.0016 in) 39.958~39.972 m m (1.5731~1.5737 in) 5 mm(O.2 in) 10.004~10.015 m m (0.3939~0.3943 in) 9.996~10.000 rnrn (0.3935~0.3937 in)
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Piston: Piston to c y l i n d e r clearance
0.10 m m (0.0039 in)
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Piston size " D "
40.10 m m (1.5787 in) 0.05 m m (0.0020 in) 0.03 rnm (0.0012 in)
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M e a s u r i n g point " H " Piston pin bore inside d i a m e t e r
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Piston pin outside d i a m e t e r Piston Ring: Sectional Sketch (B × T)/'l-ype Top Ring
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1.2 × (0.05 1.2 × (0.05
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2nd Ring
D
End Gap (Installed): Top Ring 2nd Ring
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Side Clearance ( Installed): Top Ring 2nd Ring
2-4
10.045 m m (0.4 in) 9.975 m m (0.39 in)
1.6 m m / k e y s t o n e × 0.06 in) 1.6 r a m / k e y s t o n e × 0.06 in)
0.15~0.35 m m (0.005~0.01 in) 0.15~0.35 m m (0.005~0.01 in)
0.6 mm(O.02 in)
0.03~0.05 m m (0.0012~0.0020 in) 0.03~0.05 m m (0.0012~0.0020 in)
0.1 mm(O.O039 in)
0.6 mm(O.02 in)
0.1 mm(O.O039 in)
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MA..TE°A°OE SPEO.F.OAT.O° ISPEcl " Item
Standard
Crankshaft:
Limit
F
Crank Width " A " Run Out Limit " C " Connecting Rod Big End Side Clearance " D "
-
37.90~37.95 mm(1.49~1.49 in) 0.03 mm(0.0012 in)
"--D .q-
.~p
A 1.0 mm(0.04 in)
A u t o m a t i c centrifugal clutch: Clutch shoe thickness Clutch housing inside d i a m e t e r
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4.0 mm(0.16 in) 105 m m (4.13 in) 94 mm(3.7 in) 3,300~3,700 r/min 5,500~6,500 r/rain
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Small End Free Play " F "
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0.2~0.5 m m (0.0029~0.020 in) 0.4~0.8 m m (0.016~0.031 in)
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Clutch shoe spring free length Clutch - in r e v o l u t i o n Clutch - stall r e v o l u t i o n
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V-belt: V-belt w i d t h
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16.6 mm(0.65 in)
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Kick Starter: Type Kick Clip Tension
D
Ratchet t y p e 1.5~2.5 N (0.15~0.25 kgf) (0.34~0.56 Ib)
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5DA-01 #8O 2.085 3N24-3/5 2.0 3.5 #44 0.8 1.8 #48 15 ~17 ram(0.59 ~ 0.67 in) 3.0~4.0 rnrn(0.12 ~0.16 in) 1,750~1,850 r/rain
(M.J.) (N J) (J.N.) (M.A.J.) (C.A.) (P.J.)
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Carburetor: I.D. Mark Main Jet Needle jet Jet Needle-clip Position Main A i r Jet Cutaway Pilot Jet Bypass Valve Seat Size Starter Jet Float Height Fuel level height Engine Idling Speed
2.5 mm(0.1 in) 105.5 m m (4.15 in) 91 mm(3.58 in)
(V.S.) (G.S.)
Reed Valve: Thickness Valve Stopper Height Valve bending l i m i t
0.150~0.154 mm(0.059~0.0060 in) 6.0~6.4 mm(0.24~0.25 in) 0.2 m m (0.0078)
2-5
14.6 mm(0.57 in)
I
M..°TE°..OE SPEO.F.C.T.O. ISPEcl "" I TIGHTENING TORQUES ENGINE
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2-6
20 14 10 7 2 7 4 11 9 2 9 26 11 9 12 12 12 7 7 18 3 8 9 13 40 30 8 38
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1 4 4 3 1 3 2 4 2 2 2 2 3 1 6 6 12 1 3 1 1 2 1 2 1 1 2 1
m°kg 2.0 1.4 1.0 0.7 0.2 0.7 0.4 1.1 0.9 0.2 0.9 2.6 1.1 0.9 1.2 1.2 1.2 0.7 0.7 1.8 0.3 0.8 0.9 1.3 4.0 3.0 0.8 3.8
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Nm
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Nut Stud bolt Screw Sc rew Screw Screw Bolt Sc rew Screw Screw Bolt Bolt Screw Bolt Bolt Bolt Screw Bolt Bolt Plug Screw Bolt Bolt Nut Nut Screw Nut
M 14 M 7 M 7 M 6 6.0 M 6 M 5 M 6 M 6 M 4 M 6 M 8 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 8 M 14 M 6 M 6 M 6 M 10 M 10 M 6 M 10
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Spark plug Cylinder head and cylinder Cylinder Air shroud 1 Air shroud l x 2 Fan Autolube pump Reed valve Air filter Carburetor cap Exhaust pipe Muffler Exhaust protector Protector Crankcase l x 2 T r a n s m i s s i o n case cover Crankcase cover 1(left) Bolt(case2) Crankcase cover2(left) Drain bolt Oil plug Idle gear plate Kick crank Starter m o t o r Clutch housing Clutch w e i g h t Magnet base C.D.I. rotor
Part name
Tightening torque
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Part to be tightened
Thread size
ft°lb 14 10 7 5.1 1.4 5.1 2.8 8.0 6.5 1.4 6.5 18.2 8.0 6.5 8.4 8.4 8.4 5.1 5.1 13 22 5.8 6.5 9.4 29 22 5.8 27
Remarks
MA.
A.OE SPEO.F.OAT.O. ISPEcl "
CHASSIS Item Steering system: Steering bearing type No/size of steel balls:
Standard
Limit
Ball and race bearing 22 pcs 19 pcs
Upper Lower
Front suspension: Front fork travel Fork spring free length Fork length (Installed) Spring rate (K1) (K2) Inner tube vend limit
... ... ...
et
70 rnrn(2.8 in) 236.6 mm(9.31 in) 212.1 mm(8.35 in) 15.68 Nm/mm(1.6 kg/mm,901b/in) 23.5 Nm/mm(2.43 kg/mm,1361b/in)
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55 mm(2.2 in) 281.8 rnrn(11.1 in) 159.8 mm(6.29 in) 71.15 N/mm(7.26 kg/mm,4071b/in)
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Front wheel: Type Rim size Rim material Rim runout limit
0.2 mm (0.008 in)
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Rear suspension: Shock absorber stroke Shock absorber free length (Installed) Spring free length (Installed) Spring rate (K1)
233.6 mm
.S
Cast wheel MT3.50xl 0 Aluminum
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1 mm(0.04 in) 1 ram(0.04 in)
Cast wheel MT3.50xl 0 Aluminum 1 mm(0.04 in) 1 mm(0.04 in)
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radial lateral
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Rear wheel: Type Rim size Rim material Rim runout limit
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radial lateral
Front disc brake: Type Disc outside diameter x thickness
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Single 180x4.0mm (7.1x0.16 in) 6 ram(0.24 in) 11 mm(0.4 in) 34.93 mm(1.38 in) DOT #4(or DOT #3)
D
Pad thickness Master cylinder inside diameter Caliper cylinder outside diameter Brake fluid type Rear drum brake: Type Drum inside diameter Shoe thickness
Leading, trailing 130 mm(5.12 in) 4 ram(0.16 in)
Brake lever: Brake lever free play (front at lever side) Brake lever free play (rear) Throttle cable free play
2~5 mm(0.08~0.20 in) 10~20 mm(0.39~0.79 in) 3~5 mm(0.12~0.20 in)
2-7
180x3.5 mm (7.1x0.14in) 0.8 mm(0.03 in)
131 mm(5.16 in) 2 ram(0.08 in)
I
MA.
A.OE SPEO.F.OAT.O. ISPEcl "" I
TIGHTENING TORQUES CHASSIS Tightening torque
Th read size
.S 2-8
Remarks
m,kg
ft°lb
84 45 13 30 16 22 43 20 10 7 4 7 7 2 7 70 120 10 23 20 23 6
8.4 4.5 1.3 3.0 1.6 2.2 4.3 2.0 1.0 0.7 0.4 0.7 0.7 0.2 0.7 7.0 12.0 1.0 2.3 2.0 2.3 0.6
61 31 9.4 22 12 16 37 14 7 5.1 2.9 5.1 5.1 1.4 5.1 51 87 7.2 16.6 14.5 16.6 4.3
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M 12 M 10 M 6 M 10 M 8 M 25 M 10 M 8 M 6 M 6 M 5 M 6 M 6 M 5 M 6 M 10 M 14 M 6 M 8 MIO M 8 M 5
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Frame and e n g i n e bracket E n g i n e bracket, c o m p r e s s i o n rod and e n g i n e Rear carrier Rear s h o c k a b s o r b e r and f r a m e Rear s h o c k a b s o r b e r and e n g i n e S t e e r i n g ring nut Handle h o l d e r and s t e e r i n g shaft Brake hose and m a s t e r c y l i n d e r Fuel t a n k Fuel cock Fuel s e n d e r Box Seat lock a s s e m b l y Plastic parts & c o v e r Footrest board Front w h e e l axle and nut Rear w h e e l axle and n u t Rear brake cam lever Front brake caliper and f r o n t fork Brake disc and h u b Brake hose and caliper Brake caliper and bleed s c r e w
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Part to be t i g h t e n e d
See "page3-18"
41~
MA.
A.OE SPEO.F.OAT.O. ISPEcl "
ELECTRICAL Item
Standard
Ignition t i m i n g : Ignition t i m i n g (B.T.D.C.) Advanced type
limit
14 ° at 5,000 r/min Fixed
C.D.I.: Pickup coil resistance/color
... ...
C.D.I. unit m o d e l / m a n u f a c t u r e r
248 ~ 372~ at 20°C (68°F) (W/R-W/L) 640 ~ 960 ~ at 20°C (68°F) (B/R-G/W) 5PJ/TIIC
Ignition coil: M o d e l / m a n ufacturer M i n i m u m spark gap P r i m a r y w i n d i n g resistance S e c o n d a r y w i n d i n g resistance
4WX/TI IC 6 rnrn (0.24 in) 0.32~0.48 ~ at 20°C (68°F) 5.68~8.52k~ at 20°C (68°F)
Spark plug cap: Type Resistance
Resin 5 kE2
Charging System/Type:
Flywheel m a g n e t o
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... ... ...
5PJ/TIIC 12V 85W/5,000 rpm 0.6A at 3,000r/min 1.2A at 8,000r/min 13~14V at 4,000 rpm 0.48~0.72 ~ (White-Black) 0.4~0.6 ~ (Yellow/Red- Black) 12~15V (3,000~8,000 rpm)
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Charging v o l t a g e Charging Coil Resistance (Color) Lighting Coil Resistance (Color) Lighting Voltage Rectifier: M o d e l / M a n ufactu rer Capacity Withstand voltage
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C.D.I. Magneto: M o d e l / M a n ufacturer Nominal output Charging current
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3GF/Taichung 8A 18V
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Battery: Specific g r a v i t y
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Source coil resistance/color
1.320
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Electric starter system: Type Starter motor: M o d e l / m a n ufactu rer/ID n u m b e r Output A r m a t u r e coil resistance Brush overall length Spring force
...
Constant mesh t y p e 4WX/shulin 0.14 kw 0.0648 ~ 0.0792 E2 at 20°C (68°F) 6.5 m m (0.26 in) 5.49 ~ 8.24 N (360~540 g) (12.69~19.04 oz) 16.1 m m (0.63 in) 1.05 m m (0.04 in)
Commutator diameter Mica undercut (depth) Starter relay: M o d e l / m a n ufacturer A m p e r a g e rating Coil resistance
4WX/Shulin 20A 54~66 E2
2-9
3 m m (0.12 in) 400g 15.1 m m (0.59 in)
I
MA.
A.OE SPEO.F.OAT.O. ISPEcl "
Horn: M o d e l / m a n ufacturer Maximum amperage
4KP/Asian 1.5A
Flasher relay: Type Flasher f r e q u e n c y
Capacitor 60~ 120 C y c l e / m i n
Fuel gage: M o d e l / m a n ufacturer S e n d e r unit resistance
limit
Standard
Item
4VP/Sa n Chu 4~10 ~ 90~100 ~
full - empty -
4VP/Lun Ping
Circuit breaker: Type MAIN
Fuse 7 A x l pc .
...
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Oil level g a u g e : M o d e l / m a n ufacturer
.
...
I
OEOERA"TOROOESPEC,F,CAT,ONS ISPEcl " GENERAL TORQUE SPECIFICATIONS
A (Nut)
General t o r q u e specifications Nm m°kg ft°lb
10 m m
6 mm
6
0.6
4.3
12 m m
8 mm
15
1.5
11
14 m m
10 m m
30
3.0
22
17 m m
12 m m
55
5.5
40
19 m m
14 m m
85
8.5
61
22 m m
16 m m
130
13.0
94
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et
This chart specifies torque for standard fasteners w i t h standard I.S.O. pitch threads. Torque specifications for special c o m p o n e n t s or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, t o r q u e specifications call for clean, dry threads. C o m p o n e n t s should be at room temperature.
B (Bolt)
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Am
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A: Distance across flats B: Outside thread diameter
2-11
I
LUB..OAT.O° PO.°TS A.O LUB..OAT.O° T'.PE ISPEcl "" L U B R I C A T I O N POINTS A N D L U B R I C A T I O N TYPE ENGINE
Lubrication Point
Lublicant Type
Oil seal lips O-rings --~11~
Piston surface
--411~
Piston pin
--411~
Cyl i n d e r
--~11~
Transmission case (bearing)
---411~
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Bearings
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Autolube pump
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Starter wheel gear
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Idle gear plate Secondary drive gear
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Kickstarter pinion gear
----II1~
---~11~
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Drive axle
--~11~
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Pump drive gear
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Main axle
---~11~
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Main axle (bearing)
--'qG
2-12
I
• OB"'OAT'O" PO'°TS A"O'OB"'OAT'O° T PE ISPEcl " CHASSIS
Lubrication Point
Lubricant Type
Oil seal lips O-rings Bearings Speedometer drive gear Front brake camshaft Front brake cable
et
Throttle cable
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Tube guide (throttle grip) inner surface
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Upper steering stem ring nut
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Upper bearing outer race
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Lower bearing outer race Rear brake camshaft
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Centersta nd
2-13
I
CAB'E.OOT,.O ISPEcl "
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(~ Horn (~ Rectifier regulator (~ Main switch (~ Headlight leads (~) Speedometer cable (~ Ignition coil (~ Throttle cable 1 (~ Throttle cable 3 (~ Battery negative(-) @ Wire brake (~) Fuel sender lead (~) Seat lock cable (~) Oil tank hose @ C.D.I. unit
brand. [ ] Clamp the wire harness. [ ] Insert the seat cable through the frame tube. [ ] C l a m p w i r e h a r n e s s , rear brake cable throttle cable 1,3. [ ] Position the cylinder between the s u p p o r t e r and main switch.
e. n
(~) Wire harness [ ] Pass the speedometer cable through the right hole of front fender, then t h r o u g h the guide. [ ] Pass the wire harness through the inside of ignition coil. [ ] Secure the ground lead and the ignition coil base to the ignition coil stay. [ ] Pass the wire harness through the inside of oil tank. [ ] Pass the seat cable through the inside of frame. [ ] Align the clip with the white
CABLE R O U T I N G
2-14
I
OAB'E.OOT,°O ISPEcl " Brake cable Speedometer cable Fuel tank overflow hose Brake cable holder Brake hose Brake hose holder License bracket Flasher relay Fuel tank breather hose Fuel hose Breather hose
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[ ] Pass the brake hose through the holder. [ ] Insert the fuel overflowhose bottom. [ ] Pass the fuel overflowhose through the rear fender hole. [ ] Pass the fuel o v e r f l o w h o s e t h r o u g h the holder. [ ] Hold the fuel overflowhose with a clamp. [ ] Pass the brake cable through the holder.
D
(~ (~) (~ (~ (~ (~ (~ (~ (~ @ @
I
2-15
CAB'E.OOT,°O IS"Eel " Brake hose Front fender Front fork assembly Nut Plate washer Brake hose holder Flange bolt Bolt Brake hose holder Flange bolt
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[ ] Pass the brake hose through the holder.
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/(~
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(~ (~) (~ (~ (~ (~ (~ (~ (~ @
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2-16
I
C,B'E.OOT,°O IS"Eel " (~ Ignition coil @ Battery(+)lead (~) Spark plug lead [ ] Pass battery leads through (~ Starter relay leads the slot of footrestboard. (~ Auto choke leads [ ] Cover them after securing (~ Starter relay starter relay leads. (~ Bind [ ] Pass the seat lock cable (~ C.D.I. unit through the hole of bracket. (~ Autolube hose [ ] Pass the fuel tank breath (~ Seat lock cable hose over seat lock cable. @ Bracket [ ] Clamp carburetor vacuum @ Fuel tank breather hose hose, fuel hose and fuel @ Bind 2 cock vacuum hose. (~ Battery(-)lead []Clamp a u t o c h o k e leads
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and autolube hose on to carburetor throttle cable. [ ] Pass the battery leads over frame member. [ ] Put fuse box on to footrest board holder. [ ] Pass throttle cable1,3 wireharness, autolube pump cable, brake cable through the outside of battery box.
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"
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~~,~ .........
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~, ..q-.~,J
I I
~*~/'~ . . . . . . .
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2-17
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I
•
~.,~J ',~
CAB'E ROOT,OO ISPEcl " (~ Handlebar switch(right) (~) Speedometer (~ Wire brake (~ Handlebar switch(left) (~ Wire harness (~ Brake hose (~ Speedometer cable (~ Throttle cable1 (~ Throttle cable 3 @ Front flasher leads
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[ ] Pass brake cable through the slot of bracket. [ ] Avoid clamping front flasher leads when installing handlebar covers. [ ] P a s s throttle cable1,3 t h r o u g h between handlebar and wireharness. [ ] Hang the wireharness bind on to the bracket.
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2-18
INTRODUCTION/ PERIODICIVIAINTENANCE/LUBLICATION INTERVALS
I INSP
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION T h i s c h a p t e r i n c l u d e s all i n f o r m a t i o n ments. These preventive operation
necessary'to perform
maintenance
procedures,
recommended
if f o l l o w e d ,
inspections and adjust-
will ensure more reliable vehicle
a n d a l o n g e r s e r v i c e life. T h e n e e d f o r costly" o v e r h a u l w o r k w i l l be g r e a t l y " r e d u c e d . T h i s
information
a p p l i e s t o v e h i c l e s a l r e a d y ' in s e r v i c e as w e l l as t o n e w v e h i c l e s t h a t a r e b e i n g p r e -
pared for sale. All service technicians
s h o u l d be f a m i l i a r w i t h t h i s e n t i r e c h a p t e r .
YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS BREAK-IN ROUTINE
TYPE
Fuel line
• Check fuel hoses and v a c u u m hose f o r cracks or d a m a g e . • Replace if necessary.
-
Spark p l u g
• Check c o n d i t i o n . Refer to SPARK • Clean, regap or replace if neces- PLUGINSPECTION sa ry.
Air filter element
• Clean or replace if necessary,
Front brake
• Check o p e r a t i o n , f l u i d e level and Brakefluid DOT4 v e h i c l e f o r f l u i d leakage. Ior DOT3)
INITIAL 1,000 km (600 mi)
et
ITEM
4
*
• Check balance, runout damage. • Replace if necessary.
Wheels
• • •
C h e c k t r e a d d e p t h and f o r d a m a g e . Replace if necesssary. Check air pressure. Correct if necessary.
~
Wheel bearings
• Check Bearing for looseness or damage. • Replace if necessary.
9
*
Steering ings
• Check b e a r i n g play and steering for roughness.
D
8
Chassis fasteners
O
0
O
worn to the limit.
O
O
O
worn to the limit.
-
Tires
1C *
0
and for
7 *
bear-
O
0
Whenever
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*
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Replace brake shoes.
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0
Whenever
• Check o p e r a t i o n . • A d j u s t brake lever free play.
Rear brake
0
ginooil
Replace brake pads.
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•
5 *
s. . . . . . .
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6,000 km (4,000 mi) or 12months (wh]chever c o m e s fi rst
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NO.
EVERY 3,000 km (2,000 mi) or 6 months (whichever co mes first
-
0
• L u b r i c a t e w i t h l i t h i u m soap base greese,
-
• M a k e sure t h a t all nuts, bolts and s c r e w s are p r o p e r l y t i g h t e n e d .
-
3-1
O
O
O
O
O
O
O
0
0
Every 12,000 km(8,000 mi)or 24 months(whichever
occurs first).
0
0
PERIODICINSPECTION AND
ADJUSTMENTSI INSPDI BREAK-IN
NO.
ROUTINE
TYPE
INITIAL 1,000 km (600 mi)
EVERY 3,000 km (2,000 mi) or 6 months (whichever comes first)
6,000 km (4,000 mi) or 12months (wh ichever comes fi rst
11
Centerstand
• Check operation. • Lubricate with lithium soap base greese (all purpose grease).
Sarne as engine oil
O
O
12"
Front fork
- Check operation and for oil leakage.
-
O
O
13"
Rear s h o c k absorberassembly
- C h e c k o p e r a t i o n and shock absorber for oil leakage. - Replace shock absorber assembly if necessary.
-
O
O
14 *
Carburetor
et
ITEM
I
O
O
15"
A u t o l u b e pump
• Check operation. - Correct if necessary. • Bleed if necessary.
O
@
O
16"
Final t r a n s m i s sion oil
- C h e c k o i l level and vehicle for oil leakage.
-
O
O
O
Yarnalubel 300W SE 4orSAEGL gear oil
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o Replace.
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V-belt
Replace.
O
E v e r y 12,000 k m ( 8 , 0 0 0 mi)or 24 mont hs(whichever Occurs first). Every 9,000 kin(6,000 mi)
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17 *
-
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•
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• Check engine idling speed. • Adjust if necessary.
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I t e m s m a r k e d w i t h an a s t e r i s k (*) r e q u i r e s p e c i a l t o o l s , d a t a a n d t e c h n i c a l skills f o r s e r v i c i n g . T a k e t h e s c o o t e r to a Y a m a h a d e a l e r .
NOTE:
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• T h e air f i l t e r n e e d s m o r e f r e q u e n t s e r v i c e if y o u are r i d i n g in u n u s u a l l y w e t or d u s t y areas. • Brake f l u i d r e p l a c e m e n t : 1. R e p l a c e t h e b r a k e f l u i d a f t e r d i s a s s e m b l i n g t h e m a s t e r c y l i n d e r or c a l i p e r c y l i n d e r . C h e c k t h e b r a k e f l u i d level a n d a d d f l u i d as r e q u i r e d . 2. R e p l a c e t h e m a s t e r c y l i n d e r a n d c a l i p e r c y l i n d e r oil seals e v e r y t w o years. 3. R e p l a c e t h e b r a k e h o s e s e v e r y f o u r y e a r s , o r if c r a c k e d o r d a m a g e d .
NOTE: F r o m 6,000 mi (9,000 k m ) - o r 18 m o n t h s , r e p e a t t h e m a i n t e n a n c e i n t e r v a l s s t a r t i n g 2,000 mi (3,000 mi) o r 6 m o n t h s .
3-2
I
COVER AND PANEL
INSP
COVER AND PANEL SIDECOVER A N D SEAT
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~,~/~
9.4ft.lb)
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.
J o b name/Part n a m e
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Order
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Sidecover and seat removal Battery box cover
Remarks Remove the parts in order. NOTF" Insert the (-) s c r e w d r i v e r into the slot of battery cover and pickup then remove.
.
3. 4. 5. 6. 7. 8.
Seat Seat hange Rear carrier Rear cover Left side cover Right side cover Center cover
Reverse the removal procedure for installation. 3-3
I
COVER AND PANEL
INSP
LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 A N D FOOTREST BOARD
4 5
[~1 7Nm(0.7m.kg, 5.1ft.lb)
o
~
""
~
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/ //
.
2. 3. 4. 5. 6.
Job n a m e / p a r t name
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6
L o w e r c o w l i n g , u p p e r cover, leg shield 1,2 and f o o t r e s t board removal Lower c o w l i n g Upper cover Leg shield 1 Main switch c o v e r / l e g shield 2 Battery Footrest board
Q'ty
Remarks Remove the parts in order.
1 1 1 1/1 1 1 Reverse the removal procedure for installation.
3-4
I
COVER AND PANEL
INSP
H A N D L E B A R C O V E R ( F R O N T A N D REAR)
Order
1.
2. 3. 4.
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1
Job name/Part name H a n d l e b a r c o v e r ( F r o n t and Rear) removal. Mirrors Front h a n d l e b a r c o v e r Rear h a n d l e b a r c o v e r Flasher light(Left/Right)
Q'ty
Remarks R e m o v e t h e part in order.
2 1 1 1/1 Reverse the r e m o v a l p r o c e d u r e for installation.
3-5
ENGINE
I INSP
IDLE SPEED ADJUSTMENT ENGINE
IDLE SPEED A D J U S T M E N T
et
1. Remove • Battery box cover (~ 2. Tighten: • Pilot air screw (~) Turn the pilot air screw in until lightly seated. 3. Loosen: • Pilot air screw Back it out from its lightly seated position. Pilot air screw turn out: load 1-1/4
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2. Start the engine and let it warm up.
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r!~VAVL,W--']~ I I~ [¢-! Before starting t h e engine, be sure to use t h e c e n t e r s t a n d for safety.
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. Attach: • Inductive tachometer (~ To the spark plug lead
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IAdjust. Engine idle speed 1,750~1,850 r/min
5. Adjust: • Engine idle speed Adjustment steps. • Turn the throttle stop screw(~ in or out until specified idle speed is obtained. I Turn i:u t Turn
3-6
Idle speed becomes higher. Idle speed becomes lower.
I
THROTTLE CABLE FREE A D J U S T M E N T
I INSP
T H R O T T L E CABLE FREE A D J U S T M E N T
1.
Check: • Throttle cable free play (~ Out of specification-->Adjust.
ree3 ~o5 mm(0.12
~ 0.20 in)
I
Throttle cable free play a d j u s t m e n t steps; NOTE:
et
Before adjusting the throttle cable free play, the engine idle speed should be adjusted.
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• Remove the adjuster cover (~ • Loosen the Iocknut @~)on the throttle cable. • Turn the adjuster (~ in or out until the specified free play is obtained.
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I T u r n i n g in--~Free play is increased. T u r n i n g out->Free play is decreased.
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• Tighten the Iocknuts. • Install the adjuster cover
3-7
After adjusting the throttle cable free play, start the engine and turn the h a n d l e b a r to the right and to the left to ensure that this does not cause the engine idling speed to change.
I
A U T O L U B E P U M P AIR BLEEDING
I INSP
A U T O L U B E P U M P AIR BLEEDING 1. Remove • Lower cowling • A i r shroud 1 (~ 2. Air bleeding: • Pump case and / or oil hose. * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
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Air bleeding steps: • Place a rag under the autolube p u m p t o catch the oil. • Remove the bleed screw (~. • Keepthe oil running out until air bubbles disappear. • When air bubbles are expelled completely, tighten the bleed screw. NOTE:
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Check the bleed screw gasket. If damaged, replace w i t h a new one. Place a oil pan under the autolube p u m p to catch oil.
3.
Air bleeding: • Pump d i s t r i b u t o r and/or delivery hose
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Air bleeding steps: • Start the engine. • Run the engine for 2-3 minutes at 2000 r / m i n . This will c o m p l e t e l y r e m o v e autolube p u m p system of air.
3-8
SPARK PLUG INSPECTION I INSP SPARK PLUG I N S P E C T I O N
1. 2.
I
Remove: • Battery box cover Inspect: • Spark plug type I nco rrect-->Replace. Standard spark plug: BPR7HS/NGK Inspect: • Electrode (~ Wea r/Da m ag e-->Re place. • Insulator (~) A b n o r m a l color->Replace. Normal color is a medium-to-light tan color. Clean the spark plug w i t h a spark plug cleaner or wire brush. Measure: • Plug gap (~ Use a wire gauge or feeler gauge. Out of specification-->Regap.
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3.
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0.6 ~ 0.7 m m (0.02 ~ 0.03 in)
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3-9
I
Tighten: • Spark plug I~4~i20Nm(2"0m'kg'14ft'lb) I Install: • Battery box cover.
I
E N G I N E OIL LEVEL I N S P E C T I O N
INSP
E N G I N E OIL LEVEL I N S P E C T I O N 1. Inspect: • Engine oil level Oil level Iow--~Add sufficient oil by the f o l l o w i n g inspection steps.
(~ "OIL" indicator light
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Engine oil level visual inspection steps:
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Turn main switch to " * " position.
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"OIL" indicator light does I not comes on.
"OIL" indicator comes on.
Turn main switch " O N " position.
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I
light
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"OIL" indicator light does I _ not come on.
Engine oil level and electrical circuit are OK.
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Inspect f a u l t y electrical circuit, light bulbs etc.
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"OIL" indicator comes on.
1
light
S u p p l y engine oil.
D
"OIL" indicator light comes on.
Recommended oil: For Yamaha: Yamalube 2 or 2-stroke engine oil (ISO EG-C, EG-D grade) Total: 1.4L(1.23 Imp.qt, 1.48 US.qt)
©1 NOTE:
Install the oil tank filler cap (~ and push it fully into the filler.
3-10
T R A N S M I S S I O N OIL R E P L A C E M E N T TRANSMISSION
I INSP
OIL R E P L A C E M E N T
1.
Warm up the engine for several minutes, then stop the engine. 2. Place a container under the drain hole. 3. Remove: • Oil filler plug (~ • Drain bolt (with gasket) ~) NOTE: Drain the t r a n s m i s s i o n oil completely. While draining, slightly tilt the scooter to the right and to the left. Inspect:
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• Gasket (drain bolt) (~
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• O-ring (oil filler plug) (~ Damage--~Replace.
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Install: Drain bolt H 18 .m Fill: • Transmission case
m,g. 13.,,)1
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Recommended oil: Yamalube 4 SAE 10W 30SE or GL gear oil Oil capacity: Total a m o u n t 0.13 L (0.11 Imp.qt, 0.13 US.qt) Periodic oil change 0.11 L(0.096 Imp.qt, 0.12 US qt)
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CAUTION: •
•
A l w a y s use t h e s a m e t y p e of oil; m i x i n g oils m a y r e s u l t in a h a r m f u l c h e m i c a l reaction a n d lead t o p o o r p e r f o r m a n c e . Do n o t a l l o w f o r e i g n m a t e r i a l t o e n t e r s t h e t r a n s m i s s i o n case.
7.
Install: • Oil filler plug (with O-ring) 8. Inspect: • Oil leaks • Oil level NOTE: Wipe off any oil spilt on the t r a n s m i s s i o n , tire or wheel. 3-11
I INSP
AIR FILTER E L E M E N T C L E A N I N G
AIR FILTER E L E M E N T C L E A N I N G 1. Remove: • Battery b o x c o v e r 2. Remove: • Caburetor jont clamp ~)
Remove: • Screw • A i r filter ( ~
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3.
Remove: • A i r filter case (~) • A i r filter e l e m e n t
CAUTION: N e v e r o p e r a t e t h e e n g i n e w i t h t h e air f i l t e r ele m e n t r e m o v e d . T h i s w i l l a l l o w u n f i l t e r e d air t o enter, c a u s i n g r a p i d w e a r and p o s s i b l e engine damage. Additionally, operation without t h e c l e a n e r e l e m e n t w i l l affect c a r b u r e t o r jett i n g w i t h s u b s e q u e n t p o o r p e r f o r m a n c e and possible engine overheating. Be careful n o t t o h a v e rags or t h e like b l o c k i n g t h e i n t a k e area of t h e air filter.
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4.
5.
6.
Inspect: • Element (~ Da mage-->Replace. Clean: • A i r filter e l e m e n t
A i r filter e l e m e n t c l e a n i n g steps: • W a s h the e l e m e n t g e n t l y , but t h o r o u g h l y in solvent. 3-12
I
AIR FILTER E L E M E N T C L E A N I N G
INSP
AWARNING N e v e r use l o w flash p o i n t s o l v e n t s such as gasoline t o clean t h e e l e m e n t . Such s o l v e n t m a y lead to a fire or explosion.
• S q u e e z e t h e e x c e s s s o l v e n t o u t of t h e elem e n t a n d let dry.
CAUTION:
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Do not t w i s t t h e e l e m e n t w h e n s q u e e z i n g t h e element.
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• A p p l y t h e f o a m -air f i l t e r oil or e n g i n e o i l . • S q u e e z e o u t t h e e x c e s s oil. NOTE:
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T h e e l e m e n t s h o u l d be w e t b u t n o t d r i p p i n g .
3-13
Install: • Air filter • Battery box cover
V-BELT I N S P E C T I O N
I INSP
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V-BELT INSPECTION 1. Remove: • Kick crank ( ~ • Screws (~ • Crankcase c o v e r 2(left) (~) • S c r e w s ( A i r c l e a n e r and left crankcase cover (~ • Crankcase c o v e r 1(left) ( ~
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Inspect • V-belt ( ~ Cracks/Wea r/Da mage-->Replace. Oil or grease a d h e r e to t h e V-belt-->Check the p r i m a r y and s e c o n d ary sheaves. Refer to "ENGINE OVERHAUL -INSPECTION A N D REPAIR" section in the CHAPTER 4. Measure: • V-belt w i d t h ( ~ Out of specification-->Replace. Refer to " E N G I N E O V E R H A U L " section in the CHAPTER 4.
~
V-belt w i d t h " 16.6 m m (0.65 in) < L i m i t > 14.6 m m (0.57 in)
NOTE:
M e a s u r e the V-belt w i d t h on several points. 4.
Install: • Crankcase c o v e r 1 (left)
• A i r cleaner
I~%l 12Nm(1.2m.kg, 8.4 ft.lb) I [ ~ l 9N m(0.9m.kg, 6.5 ft.lb) I
• Crankcase c o v e r 2 (left) 3-14
• Kick crank
F"O"T B"A"E'EVE" F"EE P'AY C"EC"'"EA" B"A"E I,.Sp I LEVER FREE PLAY CHECK/BRAKE PAD INSPECTION A D J
I
CHASSIS F R O N T BRAKE LEVER FREE PLAY CHECK
1.
Check: • Front brake lever free play
I ~ 1
2~5 mm(0.08~0.20 in)
I
xkWARNING
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A soft or s p o n g y feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Inspect and bleed the system if necessary.
REAR BRAKE LEVER FREE PLAY CHECK
Check: • Rear brake lever free play (~ Out of specification-->Adjust.
I~110~20 mm,o3~0 79,n,
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Rear brake lever free play adjustment steps: • Turn the adjuster (~ in or out until the correct free play is obtained.
Replace brake pads as a set. Refer to the "BRAKE PAD REPLACEMENT" section in the CHAPTER 6. (~ Brake disc (~ Brake pads
B"AKES"OE'"SPECT'O°' I'"SP I
BRAKE FLUID LEVEL INSPECTION
\
I
BRAKE SHOE I N S P E C T I O N
Activate the brake lever. Inspect: • W e a r indicator (~ Indicator at w e a r limit line (~)-->Replace brake shoes.
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BRAKE FLUID LEVEL I N S P E C T I O N NOTE:
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Position the scooter straight up w h e n inspecting the fluid level.
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Inspect: • Fluid level is under " L O W E R " level line (~-->Fill to proper level. R e c o m m e n d e d fluid: DOT#4(or DOT#3)
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CAUTION:
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The fluid m a y corrode p a i n t e d surfaces or plastic parts. A l w a y s clean up spilled fluid i m m e diately.
~!~LvAv/±1-']~ II~ [¢! e U s e o n l y t h e d e s i g n a t e d q u a l i t y fluid. Otherw i s e ,the r u b b e r s e a l s m a y d e t e r i o r a t e causing leakage and p o o r brake p e r f o r m a n c e . eRefill w i t h t h e s a m e t y p e of fluid. M i x i n g fluids m a y result in a harmful chemical reaction leading to p o o r brake p e r f o r m a n c e . eBe careful t h a t w a t e r does n o t enter t h e master cylinder w h e n refilling. W a t e r w i l l significantly l o w e r t h e boiling p o i n t of t h e fluid and m a y result in v a p o r lock. 3-16
AIR BLEEDING
(HYDRAULIC
BRAKE
SYSTEIVI)I INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1. Bleed: • Brake f l u i d
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Air bleeding steps: a. A d d p r o p e r brake f l u i d to the reservoir. b. Install the d i a p h r a g m . Be careful not to spill a n y f l u i d or a l l o w t h e r e s e r v o i r to overflow. c. C o n n e c t t h e clear plastic tu be ( ~ t i g h t l y to the caliper bleed screw. d. Place the o t h e r end o f t h e t u b e into a container. e. S l o w l y a p p l y t h e brake lever several times. f. Pull the lever in. Hold the lever in position. g. Loosen the bleed s c r e w and a l l o w the lever to t r a v e l t o w a r d s its limit. h. T i g h t e n the bleed s c r e w w h e n the l i m i t has been reached, t h e n release the lever. i. Repeat steps ( e ) t o (h) until the air b u b b l e s have been r e m o v e d f r o m t h e s y s t e m . j. A d d brake f l u i d to p r o p e r level.
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3-17
~!~LvAv/±1-'t ~ I I~ [¢-! Check the operation of the brake after bleeding the brake system.
STEERING ADJUSTMENT
I INSP
STEERING ADJUSTMENT 1. Check: • Steering assembly bearings Gap the bottom of the forks and gently rock the fork assembly back and forth. Loosen-->Adjust. * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
A d j u s t m e n t steps: • Remove u p p e r cover, l o w e r c o w l i n g , leg shield 1,2. refer to "COVER AND PANEL" section. • Remove all ringnuts using ringnut wrench.
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::~1 Ring nut wrench: YU-33975
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• Tighten the ring nut 3 (~ using nut wrench. [~122 Nm(2.2 m.kg, 16 f-t.lb) I NOTE:
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Set the torque wrench to the ring nut w r e n c h so that they form a right angle. • Loosen the ring nut 3 (~ 1/4 turn. • Install rubber ring (~) and ring nut 2 (~, then tighten the ring nut 2 until it contacts w i t h rubber ring.
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Aligning the slot of ring nut 2 w i t h the slot of ring nut 3. If not, slightly t i g h t e n ring nut 2 until the slots a l i g n m e n t .
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• Install special w a s h e r (~ NOTE: Insert the projections of special w a s h e r into the slots of ring nut 3, 2 • Install ring nut 1 ( ~ r~166Nm(6.6 m.kg, 478~.b> I • Move the handlebar up and d o w n , and/or back and forth. If handlebar play is excess, remove the front fork assembly and check the balls/ball races. Refer to chapter 6.
3-18
TIRE I N S P E C T I O N FRONT
TIRE I N S P E C T I O N
Manufacturec CHENG SHIN
Size
WARNING
Type
120/90-10
56J
• The tire pressure should only be checked and r e g u l a t e d w h e n t h e tire t e m p e r a t u r e equals t h e a m b i e n t air t e m p e r a t u r e , • T h e tire pressure m u s t be adjusted according to t h e total w e i g h t (including cargo, rider passenger and accessories) and t h e anticip a t e d riding speed, • O p e r a t i o n of an o v e r l o a d e d scooter could cause tire d a m a g e , an accident or an injury, N E V E R O V E R L O A D THE SCOOTER,
REAR Manufacturec
Size
Type 59J
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130/90-10
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Basic weight ( w i t h oil and a 9 4 k g ( 2 0 7 1 b ) full uel tank) M a x i m u m load* 1 4 3 k g ( 3 1 5 1 b ) Front Rear Cold t i r e pres- 200 kpa 200 kpa (2.0 kgf/cm 2, (2.0 kgf/cm< sure 29 psi) 29 psi)
* Total of cargo, rider, passenger and accessories.
•WARNING
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It is d a n g e r o u s to ride w i t h a w o r n - o u t tire. When the tire tread reaches the w e a r limit, replace the tire immediately.
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CHENG SHIN
I INSP
.
>
Inspect: • Tire surfaces Wea r/Da m age-->Re place. M i n i m u m tire tread depth (~ (front and rear): 1.6 mm (0.06 in)
®
(~ Tread depth (~) Side wall (~) Wear indicator
3-19
CHECKING THE
TmESl INSP I I
•WARNING • Do not use a tubeless tire on a w h e e l designed only for t u b e tires t o avoid tire failure and personal injury f r o m sudden deflation. • When using t u b e tires, be sure t o install t h e correct tube. • A l w a y s replace a n e w t u b e tire and a n e w t u b e as a set. • To avoid pinching the tube, make sure t h e w h e e l rim band and t u b e are centered in t h e w h e e l groove. • Patching a p u n c t u r e d t u b e is n o t r e c o m mended. If it is a b s o l u t e l y necessary t o do so, use great care and replace t h e t u b e as soon as possible w i t h a good quality replacement. [ ] Tire IB] Wheel
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Tube wheel
3-20
Tubeless wheel
Tube tire o n l y Tube or tubeless tire
• After e x t e n s i v e tests, the tires listed b e l o w have been a p p r o v e d by Y a m a h a M o t o r Co., Ltd. for t h i s model. The f r o n t and rear tires s h o u l d a l w a y s be by t h e same m a n u f a c t u r e r and of t h e same design. No guarantee conc e r n i n g h a n - d l i n g c h a r a c t e r i s t i c s can be given if a tire c o m b i n a t i o n o t h e r t h a n one approved by Yamaha is used on this scooter.
CHECKING THE T I R E S / C H E C K I N G THE
WHEELSI INSP
N e w tires have a relatively l o w grip on the road surface until t h e y have been s l i g h t l y w o r n . Therefore, a p p r o x i m a t e l y 100 km should be t r a v e l e d at n o r m a l speed b e f o r e any highspeed riding is done. NOTE:
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For tires w i t h a direction of rotation mark (~: • Install the tire w i t h the mark pointing in the direction of wheel rotation. • Align the mark (~)with the valve installation point.
3-21
WHEEL INSPECTION/FRONT FORK INSPECTION
I
REAR SHOCK ABSORBER INSPECTION/SEAT LOCK C A B L E A D J U S T M E N T
INSP
WHEEL INSPECTION 1. Inspect: • wheels Da mage/Bends-->Replace.
Never attempt to make any repairs to the wheel. NOTE:
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After a tire or wheel has been changed or replaced, always balance the wheel.
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FRONT FORK INSPECTION 1. Inspect: • Front f o r k ~ Bends/Damage-->Replace inner t u b e comp, fork ass'y. Grease leakage--~Replace inner t u b e comp. fork ass'y. U n s m o o t h operation-->Replace f o r k ass'y. REAR SHOCK ABSORBER INSPECTION 1. Inspection: • Rear shock absorber(~) Oil leaks/Da mage-->Re place. 2. Check • Tightening torque
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Upper(nut)
30Nm (3.0 m.kg, 22ft.lb',
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Lower (bolt) 16 Nm(1.6 m.kg, 12ft.lb',
D
SEAT LOCK CABLE A D J U S T M E N T 1. Remove: • Upper cover Refer to "COVER A N D PANEL" section. 2. Adjust: • Seat cable
Seat cable adjustment steps: • Loosen lock nut (~ • Turn adjuster (~ in or out to adjust the seat lock cable. • Tighten the lock nut. 3.
3-22
Install: • Upper cover
CABLE C°EOK.°O A ° O " U B . . O A T . ° O .
"EVE.S "UB..OAT.°O
"'"SP''"'
I
C E N T E R S T A N D LUBRICATING
ADJ
'
I~1
EAS00170
CABLE C H E C K I N G A N D L U B R I C A T I N G The f o l l o w i n g procedure applies to all of the cable sheaths and cables.
r!~VAVL, W--'t~ I I ~ [¢-! D a m a g e d cable sheaths m a y cause the cable to corrode and interfere w i t h its m o v e m e n t . Replace d a m a g e d cable sheaths and cables as soon as possible. Check: • cable sheath Damage --> Replace. Check: • cable operation Rough m o v e m e n t --> Lubricate.
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Recommended lubricant t Engine oil or a suitable cable lubri ca nt
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NOTE:
Hold the cable end u p r i g h t and pour a f e w drops of lubricant into the cable sheath or use a suitable lubricating device.
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LEVERS L U B R I C A T I N G Lubricate the pivoting point and metal-to-metal m o v i n g parts of the levers.
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Recommended lubricant Lithium soap base grease EAS00173
CENTERSTAND LUBRICATING Lubricate the pivoting point and metal-to-metal m o v i n g parts of the centerstand. Recommended lubricant Lithium soap base grease
3-23
BATTERY I N S P E C T I O N
I INSP
ELECTRICAL BATTERY INSPECTION NOTE:
Since the MF battery is of a sealed-type construction, it is impossible to measure the specific g r a v i t y of the electrolyte in order to check the state of charge in the battery. Therefore, to check the state of charge in the battery, voltage must be measured at the batteryterminals.
CAUTION:
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CHARGING METHOD • This b a t t e r y is sealed type. Never r e m o v e sealing caps even w h e n charging. W i t h t h e sealing cap removed, t h i s balancing w i l l n o t be m a i n t a i n e d , and b a t t e r y performance w i l l l o w e r gradually. • Never add w a t e r . If distilled w a t e r is added, chemical reaction in the b a t t e r y w i l l not proceed in the normal w a y , t h u s m a k i n g it impossible for t h e b a t t e r y t o operate regularly. • The c h a r g i n g t i m e , c h a r g i n g c u r r e n t and charging v o l t a g e for t h e MF b a t t e r y is different t h a n general t y p e batteries. The MF b a t t e r y s h o u l d be c h a r g e d as instructed in t h e " C h a r g i n g m e t h o d " . Should the b a t t e r y be overcharged, t h e electrolyte level w i l l l o w e r e x t r e m e l y . Therefore, use special care w h e n charging t h e battery. • A v o i d using any electrolyte other than specified. The specific g r a v i t y of t h e MF b a t t e r y electrolyte is 1.32 at 20°C (68°F). (The specific g r a v i t y of the general t y p e b a t t e r y elect r o l y t e is 1.28. ) If the electrolyte w h o s e specific g r a v i t y is less than 1.32, the sulfuric acid w i l l decrease and t h u s l o w b a t t e r y performance w i l l result. Should any electrolyte, w h o s e specific gravity is 1.32 or more, be used, the b a t t e r y plates w i l l corrode and b a t t e r y life w i l l shorten. 1.
Remove: • Battery b o x cover Refer to "COVER A N D PANEL" section. 2. Remove: • Battery NOTE: 3-24
Remove the (-) lead first.
BATTERY I N S P E C T I O N
Batteries g e n e r a t e e x p l o s i v e h y d r o g e n gas and c o n t a i n e l e c t r o l y t e w h i c h is m a d e of p o i s o n o u s a n d h i g h l y c a u s t i c s u l f u r i c acid. Therefore, always follow these preventive measures: • W e a r p r o t e c t i v e eye gear w h e n h a n d l i n g or w o r k i n g near b a t t e r i e s . • C h a r g e b a t t e r i e s in a w e l l - v e n t i l a t e d area. • Keep b a t t e r i e s a w a y f r o m fire, sparks or o p e n f l a m e s (e.g., w e l d i n g e q u i p m e n t , l i g h t e d cigarettes). • DO NOT SMOKE w h e n c h a r g i n g or h a n - d l i n g batteries. • KEEP BATTERIES A N D ELECTROLYTE O U T OF REACH OF CHILDREN. • A v o i d b o d i l y c o n t a c t w i t h e l e c t r o l y t e as it can cause s e v e r e b u r n s or p e r m a n e n t eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL • Skin ~ Wash with water. • Eyes - - Flush w i t h w a t e r for 15 m i n u t e s and get immediate medical attention. INTERNAL • D r i n k large q u a n t i t i e s of w a t e r or m i l k fol l o w e d w i t h m i l k of m a g n e s i a , b e a t e n egg or v e g e t a b l e oil. G e t i m m e d i a t e medical a t t e n tion. 3.
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Volt meter
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//
I
INSP
Check: • Battery c o n d i t i o n
Battery c o n d i t i o n c h e c k i n g steps: • Connect a digital v o l t m e t e r to the b a t t e r y t e r minals. I Tester (+) lead Battery (+) t e r m i n a l . Tester (-) lead Battery (-) t e r m i n a l .
(v)
13.0 8
Relationshipbetweenopen-circuit ° C )
The state of a d i s c h a r g e d MF b a t t e r y can be checked by m e a s u r i n g o p e n circuit v o l t a g e (the v o l t a g e m e a s u r e d w i t h the p o s i t i v e t e r m i n a l s being d i s c o n n e c t e d ) .
12.0
0
I
NOTE:
& 12.5 o ~,
I
11.5
i 5 6.5 ~0 Chargingtime(hours) •Thisvariesdependingon the temperature,the stateof chargein batteryplatesand the electrolytelevel.
3-25
BATTERYINSPECTION I INSP ~1(~1 14
Open circuit voltage Charging time
Ambient temperature 20°C
.~ 11
100
75
50
|
| |
I B
I B
12.8 v or more
No charging is necessary.
• Check the b a t t e r y c o n d i t i o n u s i n g f i g u r e s . EXAMPLE: Open circuit v o l t a g e = 12.0v C h a r g i n g t i m e = 6.5 h o u r s C o n d i t i o n of c h a r g e in b a t t e r y = 20 ~ 30%
30 25 20
Condition of charge in battel~J(%)
2.
C h a r g i n g m e t h o d of MF b a t t e r y
CAUTION:
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Ambient temperature 20oc
Charging
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• If it is i m p o s s i b l e t o set t h e s t a n d a r d c h a r g ing c u r r e n t , be careful n o t t o o v e r c h a r g e . e W h e n c h a r g i n g t h e b a t t e r y , be s u r e t o rem o v e it f r o m t h e m o t o r c y c l e . (If c h a r g i n g has t o be d o n e w i t h t h e b a t t e r y m o u n t e d on t h e m o t o r c y c l e for s o m e reason, be s u r e t o disc o n n e c t t h e w i r e at t h e n e g a t i v e t e r m i n a l . ) • Never remove the sealing plug from the MF battery. • Use special care so t h a t c h a r g i n g clips are in a full c o n t a c t w i t h t h e t e r m i n a l and t h a t t h e y are n o t s h o r t e d . (A c o r r o d e d c l i p of t h e c h a r g e r m a y cause t h e b a t t e r y t o g e n e r a t e heat at t h e c o n t a c t area. A w e a k clip s p r i n g m a y cause sparks.) • Before r e m o v i n g t h e clips f r o m t h e b a t t e r y t e r m i n a l s , be s u r e t o t u r n off t h e p o w e r s w i t c h of t h e charger. • C h a n g e in t h e o p e n - c i r c u i t v o l t a g e of t h e M F b a t t e r y after b e i n g c h a r g e d is s h o w n b e l o w . As s h o w n in t h e f i g u r e , t h e o p e n c i r c u i t v o l t age is s t a b i l i z e d 30 m i n u t e s after c h a r g i n g has been c o m p l e t e d . T h e r e f o r e , t o c h e c k t h e c o n d i t i o n of t h e batt e r y , m e a s u r e t h e o p e n - c i r c u i t v o l t a g e 30 m i n u t e s after has b e e n c o m p l e t e d .
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Time(Minutes) Check the open circuit voltage
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3-26
I INSP
BATTERY INSPECTION C h a r g i n g m e t h o d u s i n g a v a r i a b l e - c u r r e n t (voltage) t y p e c h a r g e r Charger
AMP meter
NOTE: Voltage should be measured 30 minutes after the machine is stopped.
Measure the open-circuit voltage prier to c h a r g i n g .
t NOTE: Set the c h a n g i n g v o l t a g e at 16 17 V. (Ifthe setting is lower, charging Will be insufficient. If t o o high, the battery Will be over-charged.)
C o n n e c t a c h a r g e r and A M P m e t e r to the b a t t e r y and start charging.
+
NO
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et
Make sure the c u r r e n t is h i g h e r than the standard charging c u r r e n t w r i t t e n on the battery.
YES
1
A d j u s t the v o l t a g e so t h a t c u r r e n t 4 is at s t a n d a r d c h a r g i n g level.
+
M o n i t o r t h e a m p e r a g e f o r 3-5 m i n u t e s to check if the s t a n d a r d c h a r g i n g c u r r e n t is reached.
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Set the t i m e r a c c o r d i n g to the c h a r g i n g t i m e s u i t a b l e for the o p e n - c i r c u i t v o l t a g e . Refer to "Battery condition checking steps".
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If c u r r e n t d o e s not exceed standard charging current after 5 m i n u t e s , replace the battery.
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By t u r n i n g the c h a r g i n g v o l t a g e a d j u s t dial, set the c h a r g i n g v o l t age at 20 - 25 V.
l
In case t h a t c h a r g i n g r e q u i r e s m o r e t h a n 5 h o u r s , it is a d v i s a b l e to check the c h a r g i n g c u r r e n t after a lapse of 5 h o u r s . If t h e r e is a n y c h a n g e in the a m p e r a g e , r e a d j u s t the v o l t a g e to o b t a i n the s t a n d a r d c h a r g i n g current. I J
M e a s u r e the b a t t e r y o p e n - c i r c u i t v o l t a g e after h a v i n g left t h e batt e r y u n u s e d for m o r e t h a n 30 m i n u t e s . 12.8 V o r m o r e --- C h a r g i n g is c o m p l e t e . 12.7 V o r less --- R e c h a r g i n g is r e q u i r e d . U n d e r 1 2 . 0 V --- Replace t h e battery. 3-27
BATTERY I N S P E C T I O N
I INSP
Charging method using a constant-voltage type charger
Charger
NOTE: V o l t a g e s h o u l d be m e a s u r e d 30 minutes after the m a c h i n e is s t o p p e d .
AMP meter
~
Connect a c h a r g e r and A M P meter to the battery, and start charging.
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Volt meter
Measure the open-circuit voltage prier to charging.
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Make sure the current is higher than the standard charging current w r i t t e n on the battery.
YES
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This type of battery charger Can not charge the MF b a t t e r y . A variable voltage charger is recommended.
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Charge the battery until the battery's charging voltage is 15 volts.
NO
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NOTE: Set the c h a r g i n g t i m e at 20 h o u r s (maximum).
Checkthe open-circuit voltage after having left the battery for 30 minutes after charging. 12.8 V or m o r e - - - Charging is complete. 12.7 V or less --- Recharging is necessary. Under 12 V --- Replace the battery.
Charging method using a constant current type charger This t y p e if battery charger Can not charge the MF battery.
3-28
FUSE INSPECTION I INSP 4.
Inspect: • Battery terminal D i r t y terminal-->Clean w i t h w i r e brush. Poor co n nection-->Co rrect. NOTE: A f t e r cleaning t e r m i n a l s , a p p l y terminals. Install • Battery • Battery box cover
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l i g h t l y to the
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FUSE I N S P E C T I O N 1. R e m o v e : • Battery box cover Refer to " C O V E R A N D P A N E L " section. 2. R e m o v e : • Fuse ( ~ 3. Inspect: • Fuse ( ~ defective--~Replace
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* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
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B l o w n fuse p r o c e d u r e steps: • T u r n off i g n i t i o n and the circuit. • Install a n e w fuse of p r o p e r a m p e r a g e . • T u r n on s w i t c h e s to v e r i f y o p e r a t i o n of electrical device. • If fuse b l o w s i m m e d i a t e l y again, check circuit in q u e s t i o n .
~!~Lvlv/±1:] ~11~[¢-! Never use a fuse w i t h an a m p e r a g e rating other t h a n t h a t specified. Improvising or using a fuse w i t h t h e w r o n g a m p e r a g e rat-ing m a y cause e x t e n s i v e d a m a g e t o t h e electrical s y s t e m , cause t h e lighting and ignition systems to malf u n c t i o n and could possibly cause a fire. Description Amperage Main 7A . Install: • Fuse • Battery box cover 3-29
Quantity 1
HEADLIGHT BEAM A D J U S T M E N T I INSP /HEADLIGHT BULB REPLACEIVIENT I I
HEAD LIGHT BEAM A D J U S T M E N T 1.
\ j)
Adjust: • Head l i g h t (vertically) T u r n t h e a d j u s t i n g s c r e w ( ~ in or o u t to a d j u s t h e a d l i g h t beam. • Head l i g h t (Horizontal) T u r n t h e a d j u s t i n g s c r e w ( ~ in or o u t to a d j u s t h e a d l i g h t beam.
HEADLIGHT BULB REPLACEMENT Remove: • Upper cover Refer to "COVER A N D P A N E L " section.
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2.
4.
Remove: • Headlight bulb holder (~ T u r n the b u l b h o l d e r c o u n t e r c l o c k w i s e to r e m o v e it.
5.
Remove: • Bulb(defective) (~
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Disconnect: • Headlight coupler (~ Remove: • Bulb h o l d e r c o v e r ( ~
W!~VAV/±I -'| ~ I I ~ [¢']1 Since the headlight bulb gets extremely hot, keep f l a m m a b l e p r o d u c t s and y o u r hands a w a y from the bulb until it has cooled down.
3-30
HEADLIGHT BULB / TURN SIGNAL BULB REPLACEMENT 6.
i,.S.l l ADJ
Install: • Bulb(new)
CAUTION: A v o i d t o u c h i n g t h e glass p a r t of t h e h e a d - l i g h t b u l b t o keep it free f r o m oil, o t h e r w i s e t h e t r a n s p a r e n c y of t h e glass, t h e life of t h e b u l b a n d t h e l u m i n o u s f l u x w i l l be a d v e r s e l y affected. If t h e h e a d l i g h t b u l b g e t s s o i l e d , t h o r o u g h l y clean it w i t h a c l o t h m o i s t e n e d w i t h a l c o h o l or l a c q u e r t h i n n e r . Install: • Bulb h o l d e r • T u r n the b u l b h o l d e r c l o c k w i s e to install it. 8. Install: • Bulb h o l d e r c o v e r 9. Connect: • Headlight coupler 10. Install: • Upper cover 11. A d j u s t : • H e a d l i g h t beam Refer to " H E A D L I G H T BEAM ADJ U S T M E N T " s e c t i o n
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TURN SIGNAL BULB REPLACEMENT 1. Remove: • Screw (~ • Lens ( ~ 2. Replace: • Bulb ( d e f e c t i v e ) ( ~ 3. Install: • Lens (~) • Screw (~
CAUTION:
/REAR _
Do n o t o v e r - t i g h t e n t h e s c r e w s as t h e lens m a y break.
®
3-31
TAILLIGHT BULB / LICENCE LIGHT BULB REPLACEMENT
i,.s l l ADJ
CAUTION: A v o i d t o u c h i n g the glass part of t h e head-light bulb t o keep it free f r o m oil, o t h e r w i s e t h e t r a n s p a r e n c y of t h e glass, t h e life of t h e bulb and t h e l u m i n o u s f l u x w i l l be a d v e r s e l y affected. If t h e h e a d l i g h t bulb gets soiled, t h o r o u g h l y clean it w i t h a cloth m o i s t e n e d w i t h alcohol or lacquer thinner.
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T A I L L I G H T BULB R E P L A C E M E N T 1. Remove: • Screws (~ • Lens (~ 2. Replace: • Bulb (defective) (~ 3. Install: • Lens (~) • Screws ~)
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LICENSE LIGHT BULB R E P L A C E M E N T 1. Remove: • Screws (~ • Lens (~) 2. Replace: • Bulb (defective) (~ 3. Install: • Lens (~) • Screws (~
3-32
E.O..E.EMOVA" I E"O I o '1 EB400000
ENGINE OVERHAUL ENGINE R E M O V A L W l R E H A R N E S S A N D CABLES
~ 1 2 0 N m ( 1 2 . 0 m.kg, 87 ft.lb) 7
1~145Nm(4-5 m.kg, 31ft.lb) I
Order
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12
Job name/Part name
Q'ty
Remove the parts in order.
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W i r e h a r n e s s and cables r e m o v a l Rear carrier Tail cover Left side panel Right side panel Battery b o x cover Center c o w l i n g Air filter case Carburetor
1 2
Remarks
Refer to "COVER A N D PANEL" section in CHAPTER 3.
Refer to " C A R B U R E T O R " CHAPTER 6.
Air shroud 1 A u t o l u b e delivery hose
4-1
s e c t i o n in
ENGINE R E M O V A L
mENG m~)~,mm
[~m120Nm(12.0 m.kg, 87 ft.lb)
12
[~q45Nm(4.5m.kg,
31ft.lb)
~
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J o b name/Part name
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//
1 1 1 1 1
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Spark plug cap Battery (-) lead C.D.I magneto leads coupler Starter m o t o r leads coupler Rear wheel nut
8 9 10 11 12 13
Remarks
NOTF" Loosen the rear wheel nut.
Rear brake adjuster Rear brake cable Pin Bolt Engine m o u n t bolt Engine Reverse the removal procesure for installation.
4-2
CYLINDER HEAD, CYLINDER A N D PISTON
I ENG I~>]DI
CYLINDER HEAD, CYLINDER A N D PISTON C Y L I N D E R HEAD, C Y L I N D E R A N D P I S T O N
~126Nm(2.6 m.kg, 18.2 ft.lb) I
1 ..~ ~
_
.
~
9N m(0.9 m
.S
~
H1,Nm(1.
m.kg, 10 ft.'bll
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10[]~
9
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7
Job name/Part name
Q'ty
Cylinder head, Cylinder and piston removal Engine Muffler/Gasket Air shroud 2 Spark plug Cylinder head/Cylinder head gasket Cylinder Piston pin clip Piston pin/Bearing Piston Piston ring set Cylinder gasket
D
1 2 3 4
5 6
7 8
9 10
Rema rks Remove the parts in the order.
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1/1 1 1 1/1 1 2 1/1 1 1 1
Refer to the "ENGINE REMOVAL" section
Reverse the removal procedure for installation. 4-3
CV'..OE..EAO. OV'..OE.. P.STO. I E"O Io .1 P I S T O N PIN A N D P I S T O N R E M O V A L 1. Remove: • Piston pin clip ( ~ NOTE:
Before r e m o v i n g the p i s t o n pin clip, c o v e r the crankcase w i t h a clean rag so y o u w i l l not accid e n t a l l y d r o p t h e clip into the crankcase.
Remove: • Piston pin ( ~ • Piston ~ ) • Piston pin b e a r i n g ( ~
im
CAUTION:
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Do not use a h a m m e r t o d r i v e t h e p i s t o n pin out.
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CYLINDER HEAD INSPECTION 1. E l i m i n a t e : • Carbon deposits Use a r o u n d e d s c r a p p e r (~.
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Inspect: • C y l i n d e r head w a r p a g e Out of specification-->Re-surface.
D
W a r p a g e m e a s u r e m e n t and r e - s u r f a c e m e n t steps: • A t t a c h a s t r a i g h t e d g e ( ~ and a t h i c k n e s s g a u g e ( ~ on the c y l i n d e r head. • M e a s u r e the w a r p a g e limit.
I l aroaoe" 't"
0.03 m m ( 0 . 0 0 1 2 in)
• If the w a r p a g e is o u t of s p e c i f i c a t i o n , reface the c y l i n d e r head. NOTE: Rotate the head severai tires to a v o i d r e m o v ing t o o m u c h material f r o m one side.
4-4
~
~
~
~
~
~
I
CYLINDER AND PISTON INSPECTION
I ENG I TDI
CYLINDER AND PISTON INSPECTION 1. E l i m i n a t e : • Carbon deposits Use a r o u n d e d scraper (~. 2. Inspect: • Cylinder wall Wear/Scratches-->Rebore or replace.
Q
Eliminate: • Carbon d e p o s i t s ( ~ From the piston grooves.
crown
and
ring
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5.
Remove: • Score markes and lacquer d e p o s i t s From the sides of piston. Inspect: • Piston w a l l Wea r/Scratches/Da m age-->Re place.
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6.
Piston to c y l i n d e r c l e a r a n c e m e a s u r e m e n t steps: First step: • M e a s u r e the c y l i n d e r bore " C " w i t h a c y l i n der bore g a u g e . NOTE:
D I~...~
/
Measure: • Piston-to c y l i n d e r clearance
M e a s u r e the c y l i n d e r bore " C " in parallel to and at r i g h t a n g l e s to the crankshaft. Then, find the a v e r a g e of the m e a s u r e m e n t s .
-----~ ~
4-5
CYLINDER HEAD, CYLINDER A N D PISTON
I ENG I
Standard C y l i n d e r bore IJCF,
40.000~40.014mm (1.5748~ 1.5754 in)
Taper "T" O u t of r o u n d " R"
40.10 m m (1.5787 in) mm (0.0020 in)
-
0.05
-
0.03 mm (0.0012 in)
D D1 o r D2 ) - ( M a x i m u m
D5 or
et
D1 D3 or D5 ) - ( M a x i m u m
D2
e. n
C = Maximum T=( M a x i m u m D6 ) R=( M a x i m u m D4 or D6 )
Wear limit
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• If o u t o f s p e c i f i c a t i o n , r e b o r e or r e p l a c e cylinder, a n d r e p l a c e p i s t o n a n d p i s t o n r i n g s as a set. 2 n d step: • M e a s u r e t h e p i s t o n skirt d i a m e t e r " p " w i t h a micrometer. ( ~ 10 m m f r o m t h e p i s t o n b o t t o m edge.
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I l st°nsze
3 9 . 9 5 8 ~ 3 9 . 9 7 2 m m ( 1 . 5 7 3 1 ~ 1 . 5 7 3 7 in)
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• If o u t of s p e c i f i c a t i o n , replace p i s t o n a n d pist o n r i n g s as a set. 3rd step: • Calculate the piston-to cylinder clearance with following formula:
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P i s t o n - t o c y l i n d e r c l e a r a n c e = C y l i n d e r bore I " C "- Piston skirt d i a m e t e r " p "
• If o u t of s p e c i f i c a t i o n , r e b o r e or r e p l a c e cyli n d e r , a n d r e p l a c e p i s t o n a n d p i s t o n r i n g s as a set. Piston-to cylinder clearance: 0.035 - 0 . 0 4 0 m m (0.014 - 0.0016 in) L i m i t : 0.10 m m (0.0039 in)
4-6
I
OV'.°OE..EAO. OV'..OE. A°O P.STO. I E"O I o =1 PISTON R I N G S I N S P E C T I O N 1. Measure: • Side clearance O u t of s p e c i f i c a t i o n - - > R e p l a c e a n d / o r rings. Use a feeler g a u g e ( ~ Standard T o p ring
0.1 m m
(0.0012 ~ 0.002 in)
(0.0039 in)
0.03-0.05mm
0.1 m m
(0.0012 ~ 0.002 in)
(0.0039 in)
Install: • Piston ring Into the c y l i n d e r Push t h e ring w i t h the piston c r o w n .
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Li m i t
0.03~0.05mm
et
2nd ring
piston
Measure: • End gap Out of specification-->Replace a set. Use a feeler g a u g e (~.
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2nd ring
r i n g s as
Li m it
0 . 1 5 - 0.35 m m
0.6ram
(0.005 ~ 0.01 in)
(0.02 in)
0.15~0.35mm
0.6ram
(0.005 ~ 0.01 in)
(0.02 in)
D
( ~ M e a s u r i n g Point 20 m m ( 0 . 7 9 in)
PISTON PIN A N D P I S T O N PIN B E A R I N G 1. Inspect: • Piston pin B l u e discoloration/Groove-->Replace, t h e n inspect l u b r i c a t i o n s y s t e m .
4-7
CV'..OE..EAO CV'..OE. A.O P.STO. I E"O I o '1 . f
"2
Measure: • Outside d i a m e t e r (~ (piston pin) Out of specification-->Replace.
ootsdedameter,0ston
on'
'
9.996~ 10.000 m m(0.3935~0.3937in t .
Measure: • Piston pin-to-piston clearance Out of specification-->Replace piston.
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Piston pin-to-piston clearance = Bore size (piston pin) Outside d i a m e t e r (piston pin)
1
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Piston pin-to-piston clearance" I 0.004-0.019 mm(0.0016-0.00075 in (0.003 in)
Inspect: • Bearing(piston pin) Pitting/Da m a g e ~ R e p l a c e .
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4.
1.
Apply: • Engine oil (to the crankshaft bearing, connecting rod big end bearing, small end bearing, piston pin, piston ring g r o o v e s and piston skirt areas.)
.
Install: • Reed valve gasket • Reed valve • Carburetor joint (~ ~ l 11Nrn(1.1m.kg, 8ft.lb~
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P I S T O N PIN A N D P I S T O N I N S T A L L A T I O N
4-8
OV',.OE..EAO. CV',°OE. A.O ,,StO. I E"O I0 '1 3.
°-, J
• Piston pin clip ~) NOTE:
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• The a r r o w (~ on the piston to the e x h a u s t side. • Before installing the piston pin clip, cover the crankcase w i t h a clean towel or rag so you will not accidentally drop the pin clip material into the crankcase. • A l w a y s use a n e w piston pin clip.
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CYLINDER AND CYLINDER HEAD 1. Install: • Cylinder gasket (new gasket) 2. Check: • Piston rings (~ 1st ring (~ 2nd ring NOTE:
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Make sure the ring ends (~ are properly fitted around the ring locating pins (~) in the piston grooves.
D
Q~
Install: • Small end bearing • Piston (~ • Piston pin (~)
3.
Install: • Cylinder (~ NOTE: •
r/
0
Install the cylinder w i t h one hand w h i l e compressing the piston rings w i t h the other hand.
4-9
O*'.°OE..EAO. C*'.°OE. A°O P.S*O. I' "0 I0 .1 4.
Install: • Cylinder head gasket (new gasket) 5. Install: • Cylinder head (~ ~114Nm(1.4m.kg,10ft.lb) • Spark plug (~) r~120Nm(2.0m.kg,14ft.lb) • Air shroud NOTE:
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Tighten the cylinder head holding nuts in stage, using a crisscross pattern.
4-10
V-BELT, CLUTCH A N D V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE KICK STARTER AND CRANKCASE COVER (LEFT)
12Nm(1.2m.kg, 8.4 ft.lb)~
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I ~ l 7Nm(0.Tm.kg, 5.1 ft.lb
Job name/Part name
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I~190Nm(0.9m.kg, 6.5 ft.lb) I
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Remove the parts in order.
D
1 2 3 4 5
Kick starter and crankcase cover (left) removal Kick starter Crankcase cover 2 (left) Crankcase cover 1 (left) Gasket Pin
Remarks
Reverse the removal procedure for installation.
4-11
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE
I ENG
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE
®
J o b name/Part n a m e
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KICK STARTER
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R e m o v e the parts in order. 1 1 1/1 1 1 1
D
(# ® ® ® ® ®
Kick starter r e m o v a l Crankcase c o v e r 1 (left) r e m o v a l Kickstarter p i n i o n gear Kickstarter p i n i o n gear clip Circlip/Plain w a s h e r Kickstarter s e g m e n t gear Return s p r i n g Collar
Remarks
Reverse the r e m o v a l p r o c e d u r e for installation.
4-12
V-BELT, CLUTCH AND
SECONDARY/PRIIVIARY SHEAVEI ENG I ~>= I KICK S T A R T E R I N S T A L L A T I O N 1. Install: Return spring • Kickstarter segment gear (~ • Collar (~ • Plain w a s h e r (~ • Circlip (~
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Installation steps: a. Install return spring (~ and s e g m e n t gear (~ as s h o w n . b. Install clip (~. c. Hook the spring onto the crankcase projection (~. d. Install the kick starter pinion gear (~ and the kick starter.
4-13
V-BELT" CLUTCH AND I I~)~1 SECONDARY/PRIMARY SHEAVE ENG V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE
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R e p l a c e the sheave or collar.
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Inspect: • Primary sliding sheave (~ • Primary fixed sheave (~) Wea r/Cracks/Scratch/Da mage -->Replace.
Measure: • Out side d i a m e t e r (~) (weight) Out of specification-->Replace.
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4-19
----~Out
side d i a m e t e r (weight) 15.0 mm(0.59 in) (0.57 in)
V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE SECONDARY
1.
I
I ENG
SHEAVE
Inspect: • S e c o n d a r y fixed s h e a v e ( ~ • Secondary sliding sheave (~
Scratch/Crack/Damage-->Replace
as a
set. • Oil seal ( ~ Da mage-->Replace
Inspect: • T o r q u e cam g r o v e ( ~ • G u i d e pin (~) Wear/Damage-->Replace as a set. • O - r i n g s (~) Damage-->Replace.
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Measure: • Clutch s p r i n g free l e n g t h Out of specification-->Replace.
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Clutch s p r i n g free length: 94 m m ( 3 . 7 in) : 91 m m ( 3 . 5 8 in)
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4.
Inspect: • Clutch h o u s i n g i n n e r surface Oil/Scratches--~Remove. Oil
Scratches
.
Use a rag soaked in lacquer t h i n n e r or s o l v e n t . Use an e m e r y cloth ( l i g h t l y and e v e n l y p o l i s h i n g ) .
Measure: • Clutch h o u s i n g i n s i d e d i a m e t e r ( ~ Out of specification-->Replace. Clutch h o u s i n g inside d i a m e t e r : 105 m m ( 4 . 1 3 in) < W e a r limit>: 105.5 m m ( 4 . 1 5 in)
4-20
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE SECONDARY
SHEAVE
I ENG I~=1
INSTALLATION
When assembling the secondary sheave, reverse the d i s a s s e m b l y procedure. Note the following points. . Apply: • Lithium soap base grease (to the inside of the sliding/fixed sheave)
2.
Install: • Sliding sheave (~
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NOTE:
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Apply: • Lithium soap base grease (to the torque cam grooves and O-rings)
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Be careful so that the oil seal (~ lips are not turned over w h e n installing the sheave.
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Install: • Guide pin (~ Check: • Sliding sheave U n s m o o t h operation-->Repair.
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Install: • Clutch securing nut (~ Use clutch spring holder (~
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Tighten: • Clutch securing nut (~ I%~%150Nm(5.0 m.kg, 36 ft.lb) I Use Flywheel holding tool
otorho,d,n0too,o01`0 4-21
I
V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE 8.
I
I ENG
Install: • Secondary sheave assembly • Clutch h o u s i n g ( ~ • V-belt (~)
NOTE:
The V-belt m u s t be i n s t a l l e d w i t h t h e a r r o w fro ntwa rd.
.
Tighten: • Nut ( ~ (secondary sheave)
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1~140 Nm(4.0 m.kg, 29 ft.,b)I
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Use s h e a v e h o l d e r ( ~
Sheaveho'der: co ot
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YU-01701
PRIMARY
Install: • Weight (~ • Cam@ • Slider (~ • Collar ( ~
.
Check: • Cam o p e r a t i o n Not s m o o t h . R e p a i r .
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4.
.
4-22
SHEAVE
Clean: • P r i m a r y s l i d i n g s h e a v e face ( ~ • P r i m a r y fixed s h e a v e face ( ~ • Collar ( ~ • Weight (~ • P r i m a r y s l i d i n g s h e a v e cam surface (~)
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1.
Install: • Primary sheave assembly (~ • Collar (~) Install: • V-belt
I
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE
I ENG I%=I
Install: • Shim (~ • Primary fixed sheave ~) • Washer (~ • One-way clutch (~ • Conical spring washer (~) • Nut(~
.
/
. Tighten: • Nut (~ (primary sheave) [%l 45 Nm(4.5 m.kg, 31ft.lb)
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N O T E :
®.
~°t°r t°°':¥~-01 h°'d~'n°
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When tightening the nut (primary sheave), hold the C.D.I. magneto using Flywheel Holding Tool
Adjust: • V-belt O Tense the V-belt by turning the primary sheave several times.
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9.
4-23
Install: • Fan
~I
7 Nm
(0.7 m.kg, 5.1
~.,blI
S T A R T E R CLUTCH A N D STARTER M O T O R
I ENG I~ll
S T A R T E R CLUTCH A N D STARTER M O T O R ~TARTER C L U T C H A N D S T A R T E R M O T O R 11
~,
,10
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9.4 ft.lb
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Ns,ml0 8mk0.58,t,b
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Job name/Part name
Remarks
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S t a r t e r clutch and s t a r t e r m o t o r removal Left/Right side cover Center cover Lower cowling Air shroud 3 Cooling fan Rear wheel Crankcase cover (left)l,2
]
Refer to "COVERS A N D PANE L " section in chapter 3. Refer to "C.D.I. M A G N E T O
"
section
Refer to "REAR WHEEL" section in chapter 6. Refer to "KICKER STARTER " section. Refer to "V-BELT, PRIMARY SHEAVE " section.
Primary sheave 1 2 3 4 5
Remove the parts in order.
Plate Plain w a s h e r Idle gear Plain w a s h e r Starter clutch 4-24
STARTERCLUTCH AND STARTERMOTOR I ENG I ~TDI 11
~.
.10
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9.4 ft.lb
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Ns.ml0.sm.k0.5.8 ft.,b
Job name/Part name
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1 1 1 1 1 2
Gear boss Bearing Starter wheel gear Plate w a s h e r Starter m o t o r Starter m o t o r coupler
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6 7 8 9 10 11
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Remarks
Reverse the removal instalation
4-25
procedure for
STARTERCLUTCHAND STARTERIVIOTORI ENG I {~
I
STARTER CLUTCH AND GEARS INSPECTION 1. Inspect: • Starter c l u t c h Push t h e d o w e l pin to a r r o w d i r e c t i o n . U n s m o o t h operation-->Replace starter clutch a s s e m b l y .
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2. Inspect: • Starter w h e e l gear teeth ( ~ • Idle gear teeth (~) B u rrs/C h i ps/Ro u g h n ess/Wea r-->Re p la ce.
3. Inspect: • Starter clutch o p e r a t i o n
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c::C> F~
4-26
Clutch o p e r a t i o n c h e c k i n g steps: • Install the starter w h e e l gear to the starter clutch, and hold t h e starter clutch. • W h e n t u r n i n g t h e w h e e l gear c l o c k w i s e [ ] the starter c l u t c h and the w h e e l gear s h o u l d be e n g a g e d . If not the starter c l u t c h is faulty. Replace it. • W h e n t u r n i n g the w h e e l gear c o u n t e r clockw i s e [~], the w h e e l gear s h o u l d t u r n freely. If not, the starter c l u t c h is faulty. Replace it.
C.O.'."'°"ETO I ENO I O '1 C.D.I. M A G N E T O .'.D.I. M A G N E T O
5 .
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m(3.8 m.kg, 27 ft.lb) I
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[ ~ 1 7 N m ( 0 . 7 m . k g " 5.1ft.lb) i
5.1 ft.I ) I
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17Nm(0.7m.kg,
R e m o v e t h e parts in o r d e r .
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C.D.I. m a g n e t o r e m o v a l Rear c a r r i e r Tail c o v e r Left side c o v e r Right side cover Center cover Lower cowling Air shroud 1 Fan/O-ring Magneto rotor Bind C o u p l e r s ( m a g n e t o leads) S t a t o r coil W o o d ruff key Gasket ( M a g n e t o c o v e r )
Refer to " C O V E R A N D P A N E L " s e c t i o n in c h a p t e r 3.
D
1 2 3 4 5 6 7 8
R e m a r ks
1 1/1 1 1 1 1 1 1 R e v e r s e t h e r e m o v a l p r o c e d u r e f o r installation.
4-27
co, MAo.ETol E"° I o --I C.D.I. M A G N E T O
1.
REMOVAL
Remove: • N ut (~(roto r)
• Plain washer NOTE:
Hold the rotor to loosen the nut bythe flywheel holding tool (~. IReplace. Pitting/Da mage--~Replace.
4-39
CRANKSHAFTI ENG I{ ll CRANKSHAFT INSTALLATION 1. Attach: • Crankshaft Installing Tool Crankshaft installation set (~ YU-90050 Crankshaft installer adapter (M10) ~) YU-90062
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2. Install: • Crankshaft ® (to the crankcase (~)
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CAUTION:
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To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips w i t h grease and each bear-ing w i t h engine oil.
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Hold the connecting rod at t o p dead center (TDC) w i t h one hand w h i l e t u r n i n g the nut of the crankshaft installing tool w i t h the other. Turn the crankshaft installing tool until the crankshaft assembly b o t t o m s against the bearing. Install: • Oil seal (~ • A p p l y lithium soap base grease onto the oil seal lip. Use the guide (~ and seal d r i v e r ~) to install the oil seal Oil seal driver YM-1410 Oil seal guide YM-1409
J
4-40
CARBURETION CARBURETOR
4
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Job name/Part name
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Order
1
Refer to "COVER A N D PANEL" section in CHAPTER 3.
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1 2 3 4 5 6
Re m a r ks Remove the parts in order.
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Carbu retor removal Battery b o x cover Grip End cover Left/Right cover Center cover Air cleaner case a s s e m b l y A u t o choke lead coupler Fuel hose/vacuum hose Oil delivery pipe a s s e m b l y Carburetor Throttle cable
k l 9 N m l 0 . 9 m.kg, 6.5 ft.lb) I
Reverse the removal procedure for installation.
5-1
• I CABURETOR DISASSEMBLY
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Remarks Disassemble the parts in order.
Carburetor d i s a s s e m b l y Throttle cable Throttle valve Needle set Carburetor top cover/o-ring Throttle stop screw A u t o choke unit assembly Float chamber/Seal ring Float pin Float/Needle valve Main jet Pilot jet Main nozzle Carburetor b o d y
1 1 1 1 1 1 1/1 1 1 1 1 1 1
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O ® ® ® ® ® @ ® ® ® ® @ @
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Job name/Part name
D
Order
~,_ .~'~
Reverse the removal procedure for installation.
5-2
O'"'O"'TO" Ic""'l V I CABURETOR
INSPECTION
Check: • Carburetor b o d y • Float c h a m b e r • Jet housing Cracks/damage --> Replace.
2.
Check: • Fuel passages Obstruction --~ Clean.
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a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets w i t h compressed air.
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4.
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Check: • Needle valve O D a m a g e / o b s t r u c t i o n / w e a r --~ Replace the needle valve.
.
Check: • Throttle valve ( ~ Damage/scratches/wear--> Replace.
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5-3
Check: • Float c h a m b e r b o d y Dirt --> Clean. Check: • Float c h a m b e r rubber gasket Cracks/damage/wear --> Replace. Check: • Float Damage --> Replace.
OA"BO"ETO" ICA"BI V I .
Check: • Jet n e e d l e kit ( ~ • M a i n nozzle ~ ) • M a i n jet ( ~ • Pilot jet ( ~ B e n d s / d a m a g e / w e a r --> Replace. O b s t r u c t i o n --> Clean. B l o w o u t the jets w i t h c o m p r e s s e d air.
Check: • Throttle valve movement Insert the t h r o t t l e v a l v e into t h e c a r b u retor B o d y and m o v e it up and d o w n . T i g h t n e s s --> Replace the p i s t o n valve. 10. Check: • V a c u u m hose • Fuel hose C r a c k s / d a m a g e / w e a r --> Replace. O b s t r u c t i o n --> Clean. B l o w o u t t h e hoses w i t h c o m p r e s s e d air.
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9.
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11. M e a s u r e : • Float h e i g h t (~) Out of specification-->lnspect needle v a l v e , float and v a l v e seat.
Feathe0ht
15 - 17 m m (0.59 ~ 0.67 in)
I
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
Float height measurement
steps:
• Install the n e e d l e v a l v e , float and float pin to the c a r b u r e t o r body. • Hold the c a r b u r e t o r in an u p s i d e d o w n position. • M e a s u r e the d i s t a n c e b e t w e e n t h e m a t i n g s u r f a c e o f t h e f l o a t c h a m b e r ( g a s k e t rem o v e d ) and t o p of t h e float u s i n g a g a u g e .
5-4
CARBURETOR
Ic..,I • I
NOTE:
The float arm should be resting on the needle valve, but not compressing the needle valve. • If the float height is not w i t h i n specification, inspect the needle valve, float and valve seat. • If it is w o r n , replace it. NOTE:
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The float height is properly adjusted at the Yama ha factory. Never attempt to adjust it.
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CARBURETOR ASSEMBLY
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To assemble the carburetor, reverse the disass e m b l y procedures. Note the f o l l o w i n g points.
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CAUTION:
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• Before r e a s s e m b l i n g , w a s h all parts in clean gasoline. • A l w a y s use a n e w gasket.
5-5
OA"BU"ETO"IOA"BI V I 1.
Install: • T h r o t t l e cable ( ~
Install: • Carburetor assembly NOTE:
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2.
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A l i g n the p r o j e c t i o n ( ~ w i t h t h e p r o j e c t i o n s @ .
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FUEL LEVEL A D J U S T M E N T 1. Measure: • Fuel level ( ~ Out of specifications-->Adjust.
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Fuel level (~: 3.0~4.0 m m ( 0 . 1 2 ~ 0 . 1 6 in) ( B e l o w the float c h a m b e r line)
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M e a s u r e m e n t steps: • Place the s c o o t e r on a level surface. • Use a g a r a g e jack u n d e r the e n g i n e to ensure that t h e c a r b u r e t o r is p o s i t i o n e d v e r t i cally. • C o n n e c t the fuel level g a u g e ( ~ to the d r a i n pipe (~. Fuel level g a u g e : YM-01312-A • Loosen t h e d r a i n s c r e w ~). • M e a s u r e the fuel level ( ~ w i t h the gauge. • If the fuel level is incorrect, a d j u s t t h e fuel level: R e m o v e t h e f l o a t c h a m b e r f l o a t and t h e needle v a l v e . Inspect the needle valve. If it is w o r n , replace it. 5-6
I
• Install the c a r b u r e t o r . • Recheck the fuel level. * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
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AUTO CHOKE INSPECTION (Ambient temperature lower than 45°C) 1. Remove: • Carburetor 2. Inspect: • Autochoke unit C o n n e c t a s u i t a b l e hose ( ~ to t h e starter (~, a n d b l o w it w i t h t h e m o u t h etc. Possible--~Good c o n d i t i o n . Impossible-->Replace auto choke unit. 3. Inspect: • A u t o choke unit (with battery)
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5-7
I n s p e c t i o n and a d j u s t m e n t steps: • C o n n e c t a u t o choke u n i t leads to t h e 12 V b a t t e r y for 5 m i n u t e s . Black terminal-->12 V b a t t e r y (+) ( ~ Black terminal-->12 V b a t t e r y (-) ( ~ • C o n n e c t a s u i t a b l e hose ( ~ to t h e starter (~), and b l o w it w i t h the m o u t h etc. Possible-->Replace auto choke unit. Im possible-->Good c o n d i t i o n .
CA"BO"ETO"IOA"BI V I FUEL COCK INSPECTION 1. 2.
3.
Stop the engine. Remove: • Rear c a r r i e r • Tail c o v e r • Left s i d e c o v e r • Battery box cover R e f e r to " C O V E R A N D P A N E L " s e c t i o n in c h a p t e r 3. Inspect: • Fuel c o c k
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Fuel cock inspection steps:
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• D i s c o n n e c t t h e fuel h o s e (~. • Place t h e r e c e p t a c l e u n d e r t h e fuel h o s e e n d . • If fuel s t o p s f l o w i n g o u t in a f e w s e c o n d s , t h e fuel cock is in g o o d c o n d i t i o n . If not, clean or r e p l a c e t h e fuel cock. • Disconnect the vacuum hose ~)and breathe in t h e v a c u u m h o s e w i t h t h e m o u t h etc. f o r vacuum . • If f u e l f l o w s o u t o f t h e f u e l h o s e u n d e r vacuum and stops under non-vacuum, the fuel c o c k is in g o o d c o n d i t i o n . If not, clean o r r e p l a c e t h e v a c u u m hose, fuel h o s e a n d fuel cock.
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* * * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
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5-8
Install: • Battery box cover • Left s i d e c o v e r • Tail c o v e r • Rear c a r r i e r
F.O°T W.EEL A.O B.AKE O.SC IC"ASI
oI
CHASSIS F R O N T W H E E L A N D BRAKE DISC
~--/~
/1
-'~'I~.~.~I7~N
m (0.7 m.kg, 5. lft.i b) '
,/
~ " ' - ~ %~ZJ70 Nm(7 m.kg, 5 lft.I b)l
. g,
.5ft.lb) I Q'ty
Job name/Part name
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4 _ _
Front wheel and brake disc removal
~WARNIN(
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5 6
7 8
Re m a r ks Remove the parts in order. S e c u r e l y s u p p o r t t h e s c o o t e r so t h e r e is no d a n g e r of it falling over.
D 1 2 3
~
Speedometer cable Front brake hose holder Brake caliper Wheel axle Front wheel assembly Gear unit assembly Collar Brake disc
1 1 1 Refer to "FRONT WHEEL INSTALLA1 TION" section. 1 1 Refer to "FRONT WHEEL ASSEMBLY" 1 1 section. Reverse the removal procedure for installation.
6-1
FROOT W.EEL AO0 BRAKE O,SC IC"ASI
oI
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Front wheel disassembly Oil seal Bearing Collar Spacer Bearing
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Job name/Part name
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FRONT WHEEL DISASSEMBLY
Remarks Remove the parts in order. Refer to "FRONT WHEEL DISASSEMBLY/ASSEMBLY" section.
1 1 1
-
Reverse the removal procedure for installation.
6-2
F.OOT W.EE. AO0 B.A.E O.SC IC'ASI YP ...... -
f
FRONT W H E E L D I S A S S E M B L Y 1. Remove: • Bearing ( ~ • Spacer Remove the bearing using a general bearing p u l l e r (~).
CAUTION:
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Handle the wheel w i t h care not to d a m a g e the brake disc. If the brake disc is d a m a g e d , replace.
YP700020
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FRONT W H E E L INSPECTION 1. Inspect: • Front w h e e l axle (by r o l l i n g it on a flat surface) Bends-->Replace. W!~VAV/±I -'| ~ I I ~ [¢']1
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Do not a t t e m p t to straighten a bent wheel axle.
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0.25 m m (0.0098 in)
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Inspect: • Front tire Wea r/da mag e--~ Re place. Refer to "TIRE INSPECTION" in CHAPTER 3. • Front w h e e l R e f e r t o " W H E E L I N S P E C T I O N " in CHAPTER 3. Measure: • Front w h e e l r u n o u t O v e r the specified limits--~Replace. Front w h e e l r u n o u t limits: Radial (~: 1.0 m m (0.04 in) Lateral ( ~ " 1.0 m m (0.04 in)
4.
6-3
I
Inspect: • Front w h e e l b e a r i n g s B e a r i n g s a l l o w free p l a y in the w h e e l hub or the wheel does not turn s m o o t h l y - - > Replace. • Oil seals W e a r / damage-->Replace.
F.O°T W.EE. A°O B.A.E O.SO IC"ASI 4.
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Inspect: • Collar Grooved wear-->Replace the collar and the oil seal as a set.
.....
M a x i m u m deflection: 0.15 mm (0.0059 in)
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BRAKE DISC I N S P E C T I O N 1. Measure: • Brake disc deflection(~
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Out of specification-->Replace.
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Measure: • Brake disc thickness(~
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Brake disc thickness: 4.0 mm (0.16 in) M i n i m u m thickness: 3.5 mm(0.14 in)
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Out of specification-->Replace. Ye
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FRONT WHEEL ASSEMBLY 1. Install: • Bearing (~ • Collar @~) • Spacer (~) • Bearing (~ • Oil seal (~ NOTE:
• A p p l y the lithium soap base grease on the bearing and oil seal lip w h e n installing. • Use a socket that matches the outside diameter of the race of the bearing. • A l w a y s use a n e w oil seal. • Install the oil seal w i t h its m a n u f a c t u r e r ' s marks or numbers facing o u t w a r d .
CAUTION:
6-4
Do n o t strike t h e inner race of balls of t h e bearing. C o n t a c t s h o u l d be m a d e only w i t h t h e outer race.
F.O°T W . E E . . ° O 2.
i
B . . . E O.SO IC"ASI Install: • Brake disc O H
20 Nm~20 ~k~,
oI 14
ft.lb) I
NOTE: T i g h t e n the bolts (brake disc) in stage u s i n g a c r i s s c r o s s pattern.
EB700030
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FRONT WHEEL INSTALLATION Reverse the " R E M O V A L " p r o c e d u r e . Note t h e f o l l o w i n g points. 1. Lubricate: • Front w h e e l axle • Bearings • Oil seal (lips) • D r i v e / d r i v e n gear ( s p e e d o m e t e r ) Recommended lubricant: L i t h i u m soap base grease
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2.
Install: • S p e e d o m e t e r gear u n i t ( ~ NOTE:
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Make sure t h a t t h e w h e e l h u b and the speedo m e t e r gear unit are installed w i t h the t h r e e p r o j e c t i o n s m e s h e d into the t w o slots. Install: • Front w h e e l NOTE: Make sure that the slot in the s p e e d o m e t e r gear unit fits o v e r the s t o p p e r on the f r o n t f o r k o u t e r tube.
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3.
4.
Tighten: • Front w h e e l axle ( ~ • A x l e nut (front w h e e l axle)
H
70 NmCT0 m.kg, 51 "'btl
CAUTION: Before t i g h t e n i n g t h e axle nut, stroke t h e front fork several t i m e s to check for proper fork operation,
•WARNING M a k e sure t h a t t h e brake hose is r o u t e d properly. 6-5
F.OOT W . E E . . O 0 B . . . E O.SO IONASI
oI
YP700040
WHEEL STATIC BALANCE ADJUSTMENT NOTE: • After replacing the tire and/or rim, the wheel static balance should be adjusted. • A d j u s t the front wheel static balance with the brake disc installed.
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Remove: • Balancing w e i g h t Set: • Wheel (on a suitable stand) Find: • Heavy spot
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Procedure: a. Spin the wheel and w a i t for it to rest. b. Put an "X~" mark on the w h e e l ' s b o t t o m spot. c. Turn the wheel so that the "X~" mark is 90 ° up. d. Release the wheel and wait for it to rest. Put an " X 2 " mark on the w h e e l ' s b o t t o m spot. e. Repeat the above b., c., and d. several times until all marks come to the same spot. f. This spot is the w h e e l ' s heavy spot " X " . Adjust: • Wheel static balance
A d j u s t i n g steps: • Instail a balancing w e i g h t (~ on the rim exactly opposite to the heavy spot " X ' . NOTE: Start w i t h the smallest weight.
• Turn the wheel so that the heavy spot is 90 ° up. • Check that the heavy spot is at rest there. If not, try another w e i g h t until the wheel is balanced.
6-6
F.OOT W.EE. AOO B.A.E O.SC IC"ASI 5.
X
oI
Check: • W h e e l static balance
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
X
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X
Checking steps: • T u r n the w h e e l so t h a t it c o m e s to each p o i n t as s h o w n . • C h e c k t h a t the w h e e l is at rest at each point. If not, readjust the f r o n t w h e e l static balance.
6-7
F.O°T B.AKE IC"ASI
oI
F R O N T BRAKE
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BRAKE PAD
H23Nm(23.
m.kg, 16.6 ft.lb) I
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[~423NmI2.3m.kg,16.6ft.lb)I
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Brake pad r e m o v a l Caliper s u p p o r t bolt Caliper Brake pad Pad s p r i n g
R e m a r ks
R e m o v e the parts in order. BRAKE PAD R E P L A C E M E N T 1 --I Refer to 1 J section . 2 2 Reverse the r e m o v a l p r o c e d u r e for installation. "
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1 2 3 4
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J o b name/Part n a m e
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Order
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6-8
F.ONT B.A.E IC"ASI
oI
CAUTION:
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Disc b r a k e c o m p o n e n t s r a r e l y r e q u i r e disass e m b l y . DO NOT: • Disassembly components unless absolutely necessary. • Use s o l v e n t s in i n t e r n a l brake c o m p o n e n t . • Use c o n t a m i n a t e d b r a k e f l u i d for c l e a n i n g . • Use o n l y clean fluid. • A l l o w brake f l u i d t o c o m e in c o n t a c t w i t h t h e eyes o t h e r w i s e eye i n j u r y m a y occur. • A l l o w brake f l u i d t o c o n t a c t p a i n t e d surfaces or p l a s t i c p a r t s o t h e r w i s e d a m a g e m a y occur. • Disconnect any hydraulic connection otherw i s e t h e e n t i r e s y s t e m m u s t be disass e m b l e d , drained, cleaned, and then properly filled and bled after reassembly.
.S
BRAKE PAD R E P L A C E M E N T NOTE:
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Loosen: • Retaining bolt ( ~ 2. Remove: • Brake caliper (~) • H o l d e r (brake hose) ( ~ 3. Remove: • Retaining bolt • Pads ( ~ • Pad s p r i n g ( ~ NOTE:
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It is not n e c e s s a r y to d i s a s s e m b l e the brake c a l i p e r and brake h o s e to replace t h e brake pads.
• R e p l a c e t h e pad s p r i n g i f t h e pad r e p l a c e m e n t is r e q u i r e d . • Replace the pads as a set if e i t h e r is f o u n d to be w o r n to t h e w e a r limit.
Wear JmJt 0.8 m m (0.03 in)
®
6-9
I
,.o°T B.AKE Ic"AsI 4.
ol
Install: • Pad springs • Brake pads (new)
Installation steps: • Connect a suitable hose (~ t i g h t l y to the caliper bleed screw (~. Then, place the other end of this hose into an open container. • Loosen the caliper bleed screw and push the piston (~ into the caliper by y o u r finger. • Tighten the capliper bleed screw.
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H ~ ~ (0.~ ~.k~, 4.3 ~.'~ i • Install the pad spring (new) and brake pad (new) (~ • Tighten retaining bolt (~ ~ 1 2 3 Nm (2.3 m.kg, 16.6 ft.lb) I • Install brake hose holder (~ l ~ l 7 Nm (0.7 m.k~, 5.15 ft.lb) I • Install caliper (~ [~23 Nm (2.3 m.kg, 16.6 ft.ib) I
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5. Inspect: • Brake fluid level Refer to the "BRAKE FLUID INSPECTION" section in the CHAPTER 3. (~ "LOWER" level line
t 6-10
F.O.T B.A.E IC"ASI
Check: • Brake lever o p e r a t i o n A s o f t y or s p o n g y feeling Bleed-->brake system. Refer to AIR BLEEDING " section in the CHAPTER 3.
.
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"
6-11
oI
F.O°T B.AKE IC"ASI
oI
MASTER CYLINDER
6
3
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6
J o b name/Part n a m e
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Order
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l~120Nm(2.0m.kg, 14 ft.lb)
R e m o v e the parts in order. R e f e r t o " B R A K E F L U I D REPLACEM E N T " section in CHAPTER 3.
ow
Master cylinder removal Drain the brake f l u i d Brake l e v e r / c o m p r e s s i o n s p r i n g Brake s w i t c h U n i o n bolt Copper washer Brake hose M a s t e r c y l i n d e r bracket Master cylinder
1/1 1 1 2 1 1 1
D
1 2 3 4 5 6 7
Remarks
Refer to " M A S T E R CYLINDER INSTALL A T I O N " section.
Reverse the r e m o v a l p r o c e d u r e for installation.
6-12
F.O°T B.AKE IC"ASI
oI
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R e m a r ks R e m o v e the parts in order.
Master cylinder disassembly Master cylinder boot Circlip M a s t e r c y l i n d e r kit Spring
1 1 1 1 -
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O ® ® ®
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Job name/Part name
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M A S T E R CYLINDER D I S A S S E M B L Y
Refer to " M A S T E R CYLINDER A S S E M B L Y " section. Reverse the d i s a s s e m b l y p r o c e d u r e for assembly.
6-13
F.ONT B.A.E IC"ASI
oI
YP702040
MASTER CYLINDER INSPECTION 1. Inspect: • Master cylinder kit O Wear/scratches-->Replace the master cylinder assembly. • Master cylinder boot Cracks/da m age-->Re pla ce.
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. Inspect: • Master cylinder O • Scratches/wear/damage-->Replace the master cylinder assembly.
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. Inspect: • Diaphragm (~ Wea r/da mag e-->Re place.
Y P .....
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MASTER CYLINDER A S S E M B L Y
WARNING
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• All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
D
16~)1
Recommended brake fluid: DOT #4(or DOT #3)
• Replace the piston seals and dust seals whenever a master cylinder is disassembled. 1.
Install: • Cylinder cup (~ • Master cylinder piston (~ Install cylinder cup (~ by using cylinder cup installer (~). ::~1 Cylinder cup installer set: 90890-01996
6-14
I
F.O.T B.A.E IC"ASI
oI
Install: • Spring (~ Install the s p r i n g w i t h its s m a l l e r d i a m eter to the m a s t e r c y l i n d e r piston. • M a s t e r c y l i n d e r kit ( ~
.
Install: • Circlip (~) Install the circlip s e c u r e l y into the master c y l i n d e r g r o o v e . • M a s t e r c y l i n d e r boot ( ~
.....
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MASTER CYLINDER INSTALLATION 1. Install: • Master cylinder (~ • M a s t e r c y l i n d e r bracket ( ~ ~ l 9 Nm (0.9 m.kg, 6.5 ft.lb) I
CAUTION: • Install the master cylinder bracket ( ~ w i t h the " U P " m a r k ~ facing u p w a r d . • Align the end of the holder w i t h the punch m a r k b on the handle bar.
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6-15
F.O.T B.A.E IC"ASI 2.
oI
Air bleed: • Brake s y s t e m Refer to " A I R B L E E D I N G " s e c t i o n in CHAPTER 3.
r!~vAvg_,W --']~ I I ~ [¢-]
Inspect: • Brake o p e r a t i o n
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• Use o n l y d e s i g n a t e d q u a l i t y brake fluid: O t h e r w i s e , t h e r u b b e r seals m a y d e t e r i o r a t e , causing leakage and poor brake perforrmance. • Refill w i t h t h e s a m e t y p e of brake f l u i d : M i x i n g f l u i d s m a y r e s u l t in a h a r m f u l c h e m i cal r e a c t i o n a n d lead t o p o o r p e r f o r r m a n c e . • Be careful t h a t w a t e r d o e s n o t e n t e r t h e sign i f i c a n t l y l o w e r t h e b o i l i n g p o i n t of t h e f l u i d m a y r e s u l t in v a p o r lock.
6-16
F.O.T..AKE IC"ASI oI CALIPER lh%123Nm(2.3 m.k,g, 16.6
i .......
3
Job name/Part name
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........
ft.lb)l
Remove the parts in order. Refer t o " B R A K E F L U I D REPLACEM E N T " section in CHAPTER 3.
Union bolt Copper w a s h e r Brake hose Caliper s u p p o r t bolt Caliper assembly
1 Refer to "CALl PER INSTALLATION" sec2 tion. 1 1 1 Reverse the removal procedure for installation.
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Caliper removal Drain the brake fluid
D
1 2 3 4 5
Remarks
6-17
F.O°T B.AKE IC"ASI
oI
CALIPER D I S A S S E M B L Y
~
~
~
[~0"6m~
"4"3ft'lb) l
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Rem a r ks Remove the parts in order.
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Caliper disassembly Caliper bracket Brake pad Pad spring Caliper piston Dust seal Piston seal Bleed screw
1 2 2 --I Refer to "BRAKE CALIPER DISASSEM1 BLY/ASSEMBLY" section. 1 1 1 Reverse the disassembly procedure for assembly.
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(# ® ® ® ® ® @
Job name/Part name
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Order
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~ ~ ~ j~J'~
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6-18
F.ONT B.A.E IC"ASI
oI
YP702020
BRAKE CALIPER D I S A S S E M B L Y NOTE:
Before disassembling either brake caliper, drain the brake fluid from the brake hose, master cylinder, brake caliper and reservoir tank. 1.
Remove: • Brake caliper piston
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Removal steps: • B l o w c o m p r e s s e d air into the hose joint opening to force out the caliper piston from the brake caliper body.
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• N e v e r try to pry out the caliper piston. • Cover the caliper piston w i t h a rag. Be careful not to get injured w h e n the piston is expelled from the m a s t e r cylinder.
Carefully r e m o v e the caliper piston to prevent damage.
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CAUTION:
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2.
Remove: • Dust seal ~) • Piston seal ~) When removing, push the seals by your finger.
CAUTION: • Do not use a sharp instrument. R e m o v e seals by your finger. • Do not re-use r e m o v e d parts.
YP...
CALIPER I N S P E C T I O N 1. Inspect: • Caliper cylinder • Caliper piston ~) Scratches, wear--~Replace caliper assembly.
6-19
F.O.T B.A.E IC"ASI
oI
EB702050
BRAKE CALIPER ASSEMBLY
r!~vAvg_,1--'t~ I I ~ [¢-! • All i n t e r n a l brake c o m p o n e n t s s h o u l d be cleaned and lubricated w i t h n e w brake fluid o n l y before installation.
DOT #4(or DOT #3) • Replace the caliper piston seals w h e n e v e r a
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Install: • Piston seal (~ • Dust seal (~
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brake caliper is disassembled.
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2.
Install: • Caliper piston (~ A p p l y brake fluid to the outer surface and install.
CAUTION:
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• Do n o t force. • Use care t o p r e v e n t damage on caliper piston.
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BRAKE CALIPER INSTALLATION
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1. Install: • Caliper (~ • Caliper s u p p o r t bolt
P~123Nm(2.3m.kg, 16.6ft.lb) I • Brake hose (~) • Copper w a s h e r (~ • Union bolt (~ H
25Nm(2.5 m.kg,18ft.lb) I
CAUTION: When installing the brake hose t o the caliper, l i g h t l y t o u c h t h e brake hose w i t h t h e s t o p p e r (~ on t h e caliper.
6-20
, E , , w.EE, A ° 0 , E , ,
=,,KE IC"A=I
oI
REAR WHEEL AND REAR BRAKE
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REAR W H E E L
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Polish. Use coarse sand paper. NOTE:
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After p o l i s h i n g , w i p e the polished particles w i t h a cloth.
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2.
Measure: • Brake l i n i n g t h i c k n e s s ( ~ Brake l i n i n g t h i c k n e s s ( ~ • Standard: 4 m m (0.16 in) Limit: 2 m m (0.08 in)
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Out of specification-->Replace. Measuring points " t " NOTE:
D
Replace the brake s h o e s as a set, if e i t h e r is w o r n to the w e a r limit.
.
®
Measure: • Brake d r u m i n s i d e d i a m e t e r ( ~ Out of specification-->Replace the w h e e l Brake d r u m i n s i d e d i a m e t e r : Standard: 130 m m (5.12 in) Limit: 131 m m (5.16 in)
6-23
,EA, W.EE" A.O .E,, B.,,E I C"Asl 4.
et
5.
Inspect: • Brake drum inner surface • Oil/scratc hes-->Re pair. • Oil Use a rag soaked in lacquer t h i n n e r or solvent. • Scratches Use an e m e r y cloth (lightly and e v e n l y polishing) Inspect: • Cam shaft face. Wea r-->Replace.
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W h e n inspecting t h e brake lining, do not spill oil or grease on t h e brake lining,
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REAR BRAKE I N S T A L L A T I O N 1. Install: • Camshaft (~ • Indicator plate (~
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Installation steps: • Set the camshaft w i t h its punched mark (~ facing the direction as shown. • Align the projection @ on the indicator plate w i t h the camshaft notch and install. • C h e c k t h e proper position of the brake shoe.
2.
Install: • Camshaft l e v e r ( ~ NOTE:
r~ll0Nm(1.0 m.kg,7.2ft.lb~
Set the camshaft w i t h its punched m a r k ( ~ facing the direction on the cam shaft lever @.
6-24
.AOOLEBARIC"ASI oI
~ 1 9 N m ( 0 . 9 m.kg, 6.5 5
,)~D
1~143Nm(4.3 m.kg, 37
ftJb)l 8
et
.
ft.lb) I
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11 12 13
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Wire harness strap Brake hose Handlebar comp. Left grip
Remarks
1 1 1 1/1
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Job name/Part name
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Order
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Reverse the removal procedure for installation.
6-26
HAOOLE.,. IONASI oI HANDLEBAR HANDLEBAR
~;~19Nm(0.9 m.kg, 6.5
ft.lb) I
5 ,)
1~143Nm(4.3 m.k 9, 37 ft.lb) I 8
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Job name/Part name
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2
Remove the parts in order.
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Handlebar removal Left/Right bake m i r r o r Front protector bar Upper cover Front/Rear handlebar cover Left/Rig ht flasher Brake master cylinder Front brake switch Handlebar switch (Right) Throttle cable Right grip Brake cable Rear brake switch Handlebar switch (Left) Bind
Refer to " C O V E R S A N D P A N E L " IN CHAPTER 3.
D
1 2 3 4 5 6 7 8 9
Remarks
1 1 1 1 1/1 1 1 1 1
6-25
.,,O,EBA, IC"ASI oI HANDLEBAR INSTALLATION
1.
Clean: • Steering shaft ®
~!~v~v/±1 --']~ I I~ [e-]l Proper cables and leads routing is essential to issue safe scooter operation.
®
Install: • Handlebar O • Bolt (~) • Nut NOTE:
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2.
I~143Nm(4.3 m.kg, 37ft.lb) I
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Match the bolt (~ on to the steering c o l u m n dent (~.
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CAUTION:
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There m u s t be a space b after t i g h t i n g bolt ~).
3.
Install:
• Ba nd NOTE:
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Clamp the w i r e harness. Apply: • Lithium soap base grease (to t h r o t t l e cable end and h a n d l e b a r right end).
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4.
5.
Install: • Handlebar switch (right) (~ NOTE: Insert the projection (~ into the hole (~ on the h a n d l e b a r comp.
6-27
.AOO,EBA. IC"ASI oI 6.
Install: • Handlebar switch (left) (~ NOTE:
Q ®
Insert the projection (~ into the hole @ on the handlebar comp.
Install: • Master cylinder NOTE:
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7.
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Match the slot w i t h the punched mark @ on the handlebar comp.
6-28
STEE.,°O IC"ASI oI STEERING STEERING
~-766Nm(6.6 m.kg, 47.8 ft.lb)] r~122Nm(2.2 m.kg, 16 ft.lb) 21
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38Nm(3.8 m.kg, 27ft.lb)
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29 ft.lb)
Job name/Part name
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Order
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Remove the parts in order Refer to " H A N D L E B A R " section. Refer to "FRONT WHEEL A N D BRAKE DISC" section
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Steering removal Handlebar Front wheel 1 2 3 4
5 6
7 8 9
Ring nut 1/Special w a s h e r Ring nut 2 / R u b b e r w a s h e r Ring nut 3 Under bracket Front fork (Left/Right) Bearing cover Ball race Ball (Upper/Lower) Ball race
Remarks
1/1 -
Refer to "STEERING REMOVAL/INSTAL1 LATION" section. 1 1/1 1 1 22/19 3 Reverse the removal procedure for instal lation. 1/1
6-29
STEE.,°O IC"ASI oI STEERING REMOVAL
~WARNING • S e c u r e l y s u p p o r t t h e s c o o t e r so t h a t t h e r e is n o d a n g e r of it falling over. • S t a n d t h e s c o o t e r on a level surface.
Removal: • Ring nut 1 ~) • Special w a s h e r (~ • Ring nut 2 (~) • Rubber w a s h e r (~ • Ring nut 3 (~ • Bearing cover (~ • Ball race (~ • Ball (~ • Front fork a s s e m b l y (~
NOTE:
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• Remove the ring nuts by steering nut wrench. Steering YU-33975 nut w r e n c h (~
I
• Hold the lower bracket by hand, then remove by using the steering nut w r e n c h @. • Do not loss the balls (Upper: 22 pcs, Lower: 19 pcs).
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3.
Remove • Front fork a s s e m b l y Refer to "FRONT FORK" section. Remove • Ball race
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Ball race r e p l a c e m e n t steps: • Remove the ball races on the head pipe using long rod (~ and the h a r m m e r as s h o w n . • Remove the ball races on the under bracket using the floor chisel ( ~ a n d the h a r m m e r as shown.
6-30
STEE.,°O IC"ASI oI STEERING I N S P E C T I O N 1. W a s h t h e b e a r i n g races w i t h a s o l v e n t . 2. Inspect: • Ball race • Ball P i t t i n g / D a mage--~Replace. NOTE: A l w a y s r e p l a c e b e a r i n g s a n d races as set.
3.
Inspect: • Under bracket (~
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Crack/Bend/Damage-->Replace.
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Do not attempt to straighten a bent under b r a c k e t as t h i s m a y d a n g e r o u s l y w e a k e n t h e under bracket.
U p p e r ....... 22 pcs L o w e r ...... 19 pcs
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STEERING I N S T A L L A T I O N 1. Install: • Ball Repair or replace.
I I
Main switch Gy Br R B B/VV
LOCK
~
OPEN OFF
7
C)---O C ) - O 0 -O
ON
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Rear brake s w i t c h
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Start s w i t c h L/W L/G Release Push in O - - O
O--O
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O--O
E n g i n e stop s w i t c h
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B/W B/W L/G OFF RUN
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O-43 gO 00 Turn switch Replace.
P°ckettester YU-03112
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NOTE:
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Check each b u l b socket for c o n t i n u i t y in the same m a n n e r as d e s c r i b e d in the b u l b section; h o w e v e r , note t h e f o l l o w i n g .
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a. Install a g o o d b u l b into t h e b u l b socket. b. C o n n e c t t h e pocket tester p r o b e s to t h e respective leads of t h e b u l b socket. c. Check the bulb socket for c o n t i n u i t y . If a n y of the r e a d i n g s indicate no c o n t i n u i t y , replace the b u l b socket.
7-8
IE'ECI I IGNITION SYSTEM CIRCUIT D I A G R A M • ....
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Main switch C.D.I. magneto C.D.I. unit Ignition coil Spark plug Engine stop switch 7-9
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.o..T.o° SVSTEMI':":C I
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TROUBLESHOOTING IF I G N I T I O N S Y S T E M S H O U L D B E C O M E I N O P E R A T I V E (NO S P A R K OR I N T E R M I T T E N T SPARK) NOTE:
• Remove the following parts before troubleshooting. 1) Battery box cover 4) Tail cover 2) Center cowling 5) Side cover (right) 3) Rear carrier 6) Handlebar cover (front) • Use the following special tools in this troubleshooting. I
~ 1
Pocket tester:Yu-03112
et
Dynamic tester:YM-34487 spark
Standard spark plug: BPR7HS (NGK)
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Spark plug Check the spark plug condition. Check the spark plug type. Checkthe spark plug gap. Refer to the "SPARK PLUG INSPECTION" section in the CHAPTER 3.
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Spark plug gap: 0.6~0.7 mm(0.02~0.03 in)
INCORRECT
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I Spark plug is faulty, replace it or repair plug gap.
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2. Ignition spark gap • Disconnect the spark plug cap from spark plug. • Connect the dynamic spark tester (~ as shown. (~ Spark plug cap • Checkthe ignition spark gap (~. • Start engine, and increase spark gap until misfire occurs. ~
lgll0201
Minimum spark gap: 6.0 mm (0.24 in) I
MEETS SPECIFICATION
OUT OF SPECIFICATION OR NO SPARK
I Ignition system is good.
*
7-10
E.EOT..OA. OO=,O=E°T= I E'EC I ELECTRICAL ELECTRICAL C O M P O N E N T S
Main switch Flasher relay Oil level gauge C.D.I. UNIT Fuel level gauge Starter relay Fuse
(~ (~ @ (~)
Battery Ignition coil Rectifier/Regulator Horn
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7-1
I
IGNITION SYSTEM
ELEC
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l 3. Spark plug cap resistance • Remove the spark plug cap. • Connect the pocket tester (~Q x lk) to the spark plug cap. • Check the spark plug cap for specificated resistance.
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Spark plug cap resistance: 5k£Q at 20°C (68°F)
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OUT OF SPECIFICATION
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MEETS SPECIFICATION 4. Ignition coil resistance • Disconnect the ignition coil leads from the ignition coil. • Connect the pocket tester (~ x 1) to the ignition coil.
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Replace spark plug cap.
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Ignition coil: Tester (+) lead->Terminal (~ Tester (-) lead->Coil base (~)
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• Check the p r i m a r y coil for specification resistance.
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Primary coil resistance: 0.32~0.48 E2 at 20°C (68°F)
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• Connect the pocket tester (£Q x 1 k) to the ignition coil.
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Tester (+) lead--~Spark plug lead (~ Tester (-) lead->Coil base (~) • Check the s e c o n d a r y coil for specificated resistance. S e c o n d a r y coil resistance: 5.68 ~ 8.52 k ~ at 20°C (68°F) (Spark plug lead - Coil base)
OUT OF SPECIFICATION
B O T H MEET SPECIFICATIONS
I Ignition coil is faulty, replace it.
7-11
©
,ON,T,OOS STEM IE'EC I 5. Pickup coil resistance • Disconnect the pickup coil coupler from the wireharness. • Connect the pocket tester (~ × 100) to the pickup coil terminal. Tester (+) lead->White/Red lead (~ Tester (-) l e a d , W h i t e / B l u e (~)
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OUT OF SPECIFICATION
Pickupcoilresistance:
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• Check the pickup coil for specificated resistance.
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248~ 372 ~Q at 20°C (68°F) (Wh ite/Red-Wh ite/Blu e)
I Pickup coil is faulty, replace it.
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6. Source resistance • Disconnect the source coil coupler from the wireharness. • Connect the pocket tester (~ × 100) to the source coil terminal.
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~N7 SPECIFICATION MEET
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Tester (+) lead->Black/Red lead (~ Tester (-) l e a d , G r e e n / W h i t e (~
• Check the source coil for specificated resistance.
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Sourcecoilresistance:
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OUT OF SPECIFICATION
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640 ~ 960 E2 at 20°C (68°F) (Black/Red - Green/White ) I Source coil is faulty, replace it.
~ 7 SPECIFICATION MEET
NO CONTINUITY 7. Main switch
Refer to "CHECKING SWlTCHS" section. CONTINUITY I Main switch is faulty, replace it.
7-12
I
.O..Z.O° SVSTEM IE'EC I
I
NO CONTINUITY Engine stop switch Refer to "CHECKING SWlTCHS" section.
8.
I Engine stop switch is faulty, replace it.
CONTINUITY
I
POOR CONNECTION
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9. Wiring connection Check the entire ignition system for conneo tions. Refer to the "WIRING DIAGRAM" section.
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I Replace CDI unit.
7-13
I
O,.OSYSTE. IE'Ecl CHARGING DIAGRAM
[- . . . . ~ ~ :
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,~'- -' ,eeL-' iI _t _ll iClean it w i t h #600 grit s a n d p a p e r . 2. Measure: • Commutator diameter (~
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Commutatorwearit
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15.1 m m (0.59 in)
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Out of specification-->Replace the starter motor Measure: • Mica u n d e r c u t ( ~
Ilocaun'ercut e. n
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Out of s p e c i f i c a t i o n ~ S c r a p e the mica to the p r o p e r v a l u e (a h a c k s a w blade can be g r o u n d to fit).
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The mica i n s u l a t i o n of the c o m m u t a t o r m u s t be u n d e r c u t to ensure proper o p e r a t i o n of c o m mutator.
Inspect: • A r m a t u r e coil resistances ( i n s t a l l a t i o n / continuity) Defects-->Replace the starter m o t o r . If c o m m u t a t o r is dirty, clean it w i t h sandpaper.
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4.
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Bad c o n d i t i o n
Good condition
[]
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0
x
x
[]
×
0
x
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O: C o n t i n u i t y x: No c o n t i n u i t y Bad condition-->Replace.
7-24
E.EOT.,O STA.T,°O SVSTEM I E'EC I .
Measure: • Brush length (~ Out of specification-->Replace.
I ~ 1
Brush length wear limit 3.0 mm (0.012 in)
Measure: • Brush spring force Fatigue/out of specification-->Replace as a set.
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7-25
I
..o.T.oo s sTEM IE'EC I LIGHTING CIRCUIT
SYSTEM DIAGRAM
[- . . . . ~ ~ :
I
iI........ L--~
______1
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I......
4~lrml .......
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- - ~ Lightingcoilresistance:
OUT OF SPECIFICATION
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MEET SPECIFICATION
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0.4 ~ 0.6 ~ at 20°C (68°F)
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7-28
I Lighting coil is faulty, replace it.
..o.T.°o svsTEMIE'ECI
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YP .....
6. Wiring connection Check the connections of the entire lighting system. Refer to "WIRING DIAGRAM".
POOR CONNECTIONS
,~OK
I Correct.
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Check the condition of each of the lighting system's circuits. Refer to "LIGHTING SYSTEM CHECK"
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YP805020
L I G H T I N G S Y S T E M CHECK
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1. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.
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CONTINUITY
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NO CONTINUITY
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If the headlight and the high beam indicator light fail to come on.
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I Replace the bulb and/or bulb socket.
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2. V o l t a g e
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• Connect the pocket tester (DC20V) to the headlight and high beam indicator light couplers.
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[~]When the dimmer switch is on low beam. IBIWhen dimmer switch is on high beam.
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Headlight(low beam): Tester (+) l e a d , G r e e n O lead Tester (-) lead->Black (~) lead Headlight(high beam): Tester (+) lead-->Yellow (~ lead Tester (-) l e a d , B l a c k (~ lead
D
--®
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High beam indicator light: Tester (+) lead->Yellow ~ lead Tester (-) lead->Black (~ lead
~
G/~ :]] B
g 7-29
..o.T.°o s sTEM IE'EC I • Turn the main switch to on. • Start the engine. • Turn the dimmer switch to low beam or high beam. • Checkfor voltage (12V) on the lead at bulb socket connectors.
I The wiring circuit from the main switch to bulb socket connector is faulty. Repair.
MEETS SPECIFICATION
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OUT OF SPECIFICATION
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YP805021
2. If t h e m e t e r light f a i l s t o c o m e o n .
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CONTINUITY
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NO CONTINUITY
1
I Replace the bulb and/or bulb socket.
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Tester (+) lead--> Blue terminal (~ Tester (-) lead--> Black terminal (~)
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2. V o l t a g e • C o n n e c t t h e p o c k e t t e s t e r (DC20V) t o t h e bulb socket coupler.
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I l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.
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• Turn the main switch to on. • Start the engine. • Check the voltage (12V) of the leads on the bulb socket connector. g
OUT OF SPECIFICATION
MEETS SPECIFICATION
I
I This circuit is not faulty. 7-30
The wiring circuit from main switch to bulb socket is faulty. Repair.
I
..o.T.°o svsTEMIE'ECI
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Se
3. Licence light does not come on. 1. Bulb and bulb socket • Checkthe bulb and bulb socket for continuity
~
NO CONTINUITY
CONTINUITY
I Bulb and/or bulb socket are faulty, replace.
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2. Voltage • Connect the pocket tester (DC20V)to the bulb socket connector.
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Tester (+) lead --> Brown @ lead. Tester (-) lead --> Black (~ lead.
OUT OF SPECIFICATION
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MEETS
I W i r i n g circuit f r o m main s w i t c h to bulb socket connector is faulty. Repair.
SPECIFICATION (12V)
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• Turn the main switch to on. • Check the voltage (12V) on the " B r o w n " lead at the bulb socket connector.
I This circuit is not faulty.
7-31
I
L.O.T..O SYSTEMIE'EC I
I
YP805022
3. T h e t a i l l i g h t fails t o c o m e o n .
NO CONTINUITY
I
1. Bulb and bulb socket Refer to "CHECKING SWITCHES" section. 7
CONTINUITY
I Replace the bulb and/or bulb socket. 2. V o l t a g e • C o n n e c t t h e p o c k e t t e s t e r (DC20V) t o t h e bulb socket connector.
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Tester (+) lead--> Brown terminal (~ Tester (-) lead--> Black terminal (~)
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I
I The wiring circuit from main switch to bulb I connector is faulty. Repair.
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• Turn the main switch to on. Checkthe voltage (12V) on the bulb socket connector. MEETS SPECIFICATION
7-32
S.O...SVSTE. IE'Ecl SIGNAL
SYSTEM
CIRCUIT DIAGRAM
IIII C _.... ON I ~, ~IIC ~ ~-~___I
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(~ (~ (~) @ @ @ (~)
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Main switch Main fuse Battery Rear brake switch Front brake switch Brake light Rear flasher light(right)
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Rear flasher light(left) Front flasher light(right) Front flasher light(left) Flasher relay Horn Handlebar switch (Left) Horn switch 7-33
I
(~ @ (~ (~) @ (~
Turn switch Fuel sender Fuel meter Oil indicator light Turn indicator light Oil level gauge
......
I
S,O.ALSVSTEMIE'ECI I YP806010
TROUBLESHOOTING IF T H E F L A S H E R L I G H T , B R A K E L I G H T A N D / O R I N D I C A T O R FAIL T O C O M E O N . IF T H E H O R N F A I L S T O S O U N D .
Procedure Check: 1. Fuse (Main) 2. Battery
LIGHT
3.Main switch 4.Wiring connection (entire signal system)
NOTE:
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YU-03112
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P°ckettester:
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• Remove the following parts before troubleshooting. 1 ) Battery box cover 5) Tail cover 2) Front protector bar 6) Side covers(Left/Right) 3) Upper cover 7) Center cover 4) Rear carrier • Use the special tools in the troubleshooting section.
¥P
NO CONTINUITY
. . . . .
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Refer to "CHECKING SWITCHES" section.
~ CONTINUITY .....
I Replace the fuse.
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1. Fuse
2. Battery • Check the battery condition. Refer to "BATTERY INSPECTION" section in CHAPTER 3.
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~ CORRECT
D
l e Clean battery terminals. • Recharge or replace battery.
YP .....
3. Main switch Refer to "CHECKING SWITCHES" section.
NO CONTINUITY
CONTINUITY .-X-
I Replace the main switch.
7-34
S,O°A. SVSTEMIE'ECI
I
Se
......
4. Wireharness • Check the connections of the entire signal system. Refer to "CIRCUIT SYSTEM WIRING DIAGRAM" section. ~
POOR CONNECTION
I Correct.
CONTINUITY
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Check condition of each of the signal system's circuits. Refer to "SIGNAL SYSTEM CHECK" section.
D
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7-35
SIGNAL SYSTEM
ELEC
'-
*'
YP806020
SIGNAL SYSTEM CHECK
1.
l
If the horn fails to sound.
NO CONTINUITY
l. HORN switch Refer to "CHECKING SWITCHES" section.
I Replace the left h a n d l e b a r switch. CONTINUITY
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Tester (+) l e a d - > B r o w n terminal (~. Tester (-) lead->Frame g r o u n d
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• Turn the main switch to on. • Check for voltage (12V) on the " B r o w n " lead at the horn terminal.
MEETS
n
I The w i r i n g circuit from the main switch to the e horn is faulty. Repair.
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SPECIFICATION
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2. Voltage • Connect the pocket tester (DC20V) to the horn lead.
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3. Horn • Connect the pocket tester (DC20V) to the horn at the " P i n k " terminal.
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Tester (+) lead->Pink (~ terminal. Tester (-) lead->Frame g r o u n d
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• Turn the main switch to on. • Check for voltage on the " P i n k " lead at the horn terminal.
NO CONTINUITY
@ CONTINUITY i A d j u s t or replace horn.
I Replace the horn.
7-36
S,O.A,S*S*EMIE'Ecl YP806022
2.
If t h e b r a k e l i g h t f a i l s t o c o m e o n :
NO CONTINUITY
J l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.
~7
CONTINUITY
J Replace the bulb and/or bulb socket. NO CONTINUITY
J
1
CONTINUITY
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J Replace brake switch.
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2. Brake switch (Front/Rear) Refer to "CHECKING SWI SWITCHES" section.
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3. Voltage • Connect the pocket tester (DC20V) to the bulb socket connector.
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Turn the main switch to on. T h e b r a k e l e v e r is p u l l e d in. C h e c k f o r v o l t a g e (12V) o f t h e " G r e e n / Y e l low" lead on the bulb socket connector.
OUT OF SPECIFICATION
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Tester (+) lead~>Green/Yellow terminal (~ Tester (-) lead~>Black terminal (~
~
MEETS SPECIFICATION
4. Wiring connection Wiring circuit from the main switch to the bulb socket connector is faulty. Repair. Refer to "SIGNAL SYSTEM WIRING DIAGRAM
JThis circuit is not faulty.
"
7-37
I
S,ONA, SVSTEM IE'Ecl YP806023
3.
If the flasher light and/or turn indicator light fails to blink.
NO CONTINUITY
J l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.
, ~
CONTINUITY
J Replace the bulb and/or bulb socket. NO CONTINUITY
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CONTINUITY
J Replace the left handlebar switch.
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2. Turn switch Refer to "CHECKING SWITCHES" section.
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Tester (+) lead->Brown lead (~. Tester (-) lead->Black lead(~)
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3. Voltage • Connect the pocket tester (DC20V) to the flasher relay coupler.
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• Turn the main switch to on. • Check for voltage (12V) of the "Brown" lead at the flasher relay terminal.
The wiring circuit from main switch to flasher relay connector is faulty. Repair.
MEETS SPECIFICATION
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OUT OF SPECIFICATION
G
4. Voltage • Connect the pocket tester (DC20V) to the flasher relay coupler. Tester (+) lead->Brown/White lead (~. Tester (-) lead->Black lead(~) • Turn the main switch to on. • Check for voltage (12V) on the "Brown/ White" lead at the flasher relay terminal. ~7
OUT OF SPECIFICATION
MEETS SPECIFICATION
J The flasher relay is faulty. Replace.
* 7-38
I
S,OOA,SVSTEMIE'Ecl 5. Voltage • Connect the pocket tester (DC20V) to the bulb socket connector. At flasher light (left) Tester (+) lead->Chocolate lead (~ Tester (-) lead->Black terminal (~)
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At flasher light (right) Tester (+) lead--~Dark green lead (~ Tester (-) lead->Black terminal (~
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OUT OF SPECIFICATION
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• Turn the main switch to on. • Turn the turn switch to left or right. • Check for voltage (12V) on the " C h o c o late" lead and " D a r k g r e e n " at the flasher light terminal.
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6. Wiring connection • Wiring circuit from t h e t u r n switch to bulb socket c o n n e c t o r is fault. Repair. Refer to "CIRCUIT D I A G R A M " .
J ~ MEETS
.S
SPECIFICATION
"OIL" indicator light does not c o m e on.
NO CONTINUITY
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4.
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I This circuit is not faulty.
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1. Bulb and bulb socket • C h e c k t h e bulb and bulb socket for continuity.
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~ CONTINUITY nl o
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switch the oil level switch from the oil
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2. Oil level • Remove tank. • Connect oil level
I Replace bulb and/or bulb socket.
the Pocket Tester (~ x 1) to the switch.
Tester (+) Lead--~Brown (~ Tester (-) Lead->Gray (~
~,2
....
"-
• Check the oil level gauge for continuity. Good Bad condition condition © × © [ ] U p r i g h t position X []Upside down © x x © position Switch position
C): C o n t i n u i t y
BAD CONDITION
X : No c o n t i n u i t y I Replace oil level switch. GOODCONDITION 7-39
I
S,°°A,S,S,EM IE'Ecl 3. Voltage • Connect the Pocket Tester (DC20V) to the bulb socket connector.
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Tester (+) Lead->Gray lead (~ Tester (-) Lead--~Black lead (~ • Turn the main switch to " * " • Check for voltage (12V) on the "Gray" lead at bulb socket connector.
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OUT OF SPECIFICATION
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MEETS SPECIFICATION (12V)
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I This circuit is good.
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4. Wiring connection • Checkthe entire signal system for connections. Refer to the "WIRING DIAGRAM" section. YP806027
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1. Fuel sender Remove the fuel sender from the fuel tank. Disconnect the fuel sender coupler from the wireharness. Connect the pocket tester (~ xl0) to the fuel sender coupler lead.
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If t h e fuel g a u g e fails t o o p e r a t e .
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5.
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Tester (+) lead->Green terminal (~ Tester (-) lead--~Black terminal (~
Float position
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• Check the fuel sender for specificated resistance.
UP (~ DOWN (~ ~7
Specificated resista nce 4~10~ 90~100£~
OUT OF SPECIFICATION
BOTH MEET SPECIFICATION
I Replace the fuel sender.
7-40
S,O.A,SSTEMIE'Ecl 2. Voltage • Connect the pocket tester (DC20V) to the fuel gauge coupler.
,/
\
Tester (+) lead->Brown terminal (~ Tester (-) lead->Frame ground
II G I Ch II • Turn the main switch to " O N " . • Check for voltage (12V) of the " B r o w n " lead on the fuel sender lead.
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MEETS SPECIFICATION
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OUT OF SPECIFICATION
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Checkthe connection of the entire signal system. Refer to " C H E C K I N G OF CONNECTIONS". Refer to "CIRCUIT D I A G R A M " .
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3. Fuel gauge • Connect the fuel sender to wireharness. • M o v e the float to " U P " ( ~ or " D O W N " (~.
NOTE:
Before reading the meter, stay put the float for more than three minutes respectively at " U P " or " D O W N " .
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• Turn the main switch to " O N " . • Check the fuel gauge needle moves " F " or " E "
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DOES NOT MOVE
Needle moves
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Float position
D
Float " U P " (~ Float " DOWN " ( ~
"F"
I Replace the fuel gauge.
"E"
~7 MOVES I This circuit is not faulty.
7-41
I
,UZO O.OKE S STE. IE'Ecl A U T O CHOKE S Y S T E M CIRCUIT
DIAGRAM
I[-CI~~ I__.... ON II~,IIC~--~______I c I. . . . . . . . '
I. . . . . . .
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Lit_ - - I
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-->' ~ - - I
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(7) Auto choke (~ C.D.I. magneto
7-42
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AUTO O.O.E SYSTEM IE'Ecl "y'p .....
TROUBLESHOOTING IF THE A U T O CHOKE FAILS TO OPERATE.
Procedure Check: 1. Lighting coil resistance 2. Auto choke unit resistance 3. Wiring connection (entire auto choke system)
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1. Lighting coil resistance • Disconnectthe CDI magneto couple from wire harness. • Connect the pocket tester (E2 x l ) to the lighting coil coupler
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P°cket tester: YU-03112
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• Remove the following parts before troubleshooting. 1. Battery box cover 2. Rear carrier 3. Tail cover 4. Right side cover • Use the special tools specified in the troubleshooting section.
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NOTE:
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Tester (+) Lead->Yellow/Red (~ terminal Tester (-) Lead--~Frame earth
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(~ C.D.I. magneto • Checkthe lighting coil for specificated resistance
OUT OF SPECIFICATION
Lighting coil resistance 0.4~0.6 ~ 20°C (68°F) I Replace the lighting coil MEETS SPECIFICATION
7-43
I
AUTO O.O.E S STEM IE'Ecl YP...
2. Auto choke unit resistance • Disconnect the auto choke unit coupler from the wireharness. • Connect the pocket tester ( ~ x l ) to the auto choke unit coupler lead. Tester (+) l e a d . B l a c k terminal (~ Tester (-) lead->Black terminal (~ Auto choke unit resistance: 8~12~ at 20°C (68°F)
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OUT OF SPECIFICATION
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I Replace the auto choke unit.
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SPECIFICATION 3. Wiring connection • Check the connection of the entire auto choke system. Refer to "CIRCUIT DIAGRAM" section.
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POOR CONNECTION
7-44
I Correct.
I
ITRBLI STARTnNG FAnLURE/HARD STARTnNG ISHTGI
?
II
TROUBLESHOOTING NOTE:
The f o l l o w i n g t r o u b l e s h o o t i n g does not cover all the possible causes of trouble. It should be helpful, however, as a guide to t r o u b l e s h o o t i n g . Refer to the relative procedure in this manual for inspection, a d j u s t m e n t and replacement of parts. STARTING FAILURE/HARD STARTING FUEL S Y S T E M
PROBABLE CAUSE
• Empty • Clogged fuel filter • Deteriorated fuel or fuel containing w a t e r or foreign material • Clogged fuel tank cap
Fuelcock
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Fueltank
• C l o g g e d fuel hose • Clogged fuel cock • Faulty fuel cock operation • Broken or disconnected fuel cock
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A u t o choke
• Deteriorated fuel, fuel c o n t a i n i n g w a t e r or foreign material • Clogged pilot jet • Clogged pilot air passage • Sucked-in air • Deformed float • G r o o v e - w o r n needle valve • I m p r o p e r l y sealed valve seat • I m p r o p e r l y adjusted fuel level • I m p r o p e r l y set pilot jet • Clogged starter jet
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Carburetor
/-
Starter plunger malfunction W a x malfunction Faulty t h e r m i s t e r • Clogged air filter
Air cleaner
8-1
S T A R T I N G FAILURE/HARD S T A R T I N G IGNITION SYSTEM
ITRBLI
ISHTGI
?
PROBABLE C A U S E
• • • • •
Spark plug
L
• Broken or shorted primary/secondary coil • Faulty spark plug lead • Broken body
CD I unit system
• Faulty CD I unit • Faulty source coil • Faulty pick-up coil
Switches and wiring
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Ignition coil
Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap
• Faulty main switch • Broken or shorted wiring
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PROBABLE C A U S E
.S
COMPRESSION SYSTEM
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Cylinder and cylinder head
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Piston and piston rings
D
Crankcase and crankshaft
Loose spark plug Loose cylinder head or cylinder Broken cylinder head gasket Broken cylinder gasket Worn, damaged or seized cylinder
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Reed valve
Improperly seated crankcase Improperly sealed crankcase (Damaged oil seal) Seized crankshaft • • • • •
8-2
Improperly installed piston ring Worn, fatigued or broken piston ring Seized piston ring Seized or damaged piston
Deformed reed valve stopper Improperly seated read valve Loose intake manifold Broken gasket Broken reed valve
II
PERFORMANCE ITRBLI ? I
POOR IDLE SPEED POOR IVIIDIUIVI A N D HIGH SPEED P E R F O R M A N C E
ISHTGI
POOR IDLE SPEED P E R F O R M A N C E P O O R IDLE S P E E D P E R F O R M A N C E
PROBABLE CAUSE
Carburetor
• • • •
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• Starter plunger malfunction • Wax malfunction • Faulty thermister
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Auto choke
•
Improperly returned starter plunger Clogged or loose pilot jet Clogged pilot air jet Improperly adjusted idle speed (Throttle stop screw) Improper throttle cable play Flooded carburetor
• Clogged air cleaner
Ignition system
• • • • •
spark plug spark plug read C.D.I. unit source coil ignition coil
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Faulty Faulty Faulty Faulty Faulty
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Air cleaner
HIGH SPEED PERFOR-
PROBABLE CAUSE
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• Refer to starting failure/Hard starting item (Fuel system, Ignition system, compression system) • Clogged or loose main nozzle • Clogged or loose main jet • Improperly adjust fuel level • Sucked-in air
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Carburetor
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POOR MEDIUM MANCE
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POOR M I D I U M A N D HIGH SPEED PERFORMANCE
--
Air cleaner
• Clogged air filter
Muffler
• Clogged
8-3
POOR M I D I U M A N D HIGH SPEED P E R F O R M A N C E
ITRBLI '? ISHTGI
FULTY A U T O M A T I C ( V - B E L T TYPE) PROBABLE CAUSE
SCOOTER DOES NOT MOVE WHILE ENGINE IS O P E R A T I N G --
V-belt
• W o r n , d a m a g e d or s l i p p e d V - b e l t
--
Cam, slider
• Worn, damaged
--
Compression spring
• Damaged
--
Transmission
• Damaged
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C L U T C H O U T FAILURE Clutch w e i g h t spring
• Damaged
--
Clutch shoe
• Pealed l i n i n g
--
Primary sheave
• S e i z e d p r i m a r y s l i d i n g s h e a v e and c o l l a r
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CLIMBING
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START(LOW
PROBABLE CAUSE
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POOR STANDING ABILITY)
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• W o r n or s l i p p e d V - b e l t
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V-belt
• Improper operation • Damaged
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Primary sheave
Secondary sheave
• Damaged
/
Clutch shoe
• Plealed l i n i n g
P O O R A C C E L E R A T I O N ( P O O R H I G H SPEED) --
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• Improper operation • W o r n g u i d e pin
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--
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Compression spring
PROBABLE CAUSE
V-belt
/
• Worn • Greasy
Weight
/
• Worn • Improper operation • Worn
Primary/Secondary seave
8-4
I
OVER HEAT I POOR SPEED
ITRBLI ? I ISHTGI
OVER HEAT OVER HEAT
PROBABLE C A U S E
Ignition system
L
• I m p r o p e r plug gap • Improper spark plug heat range • Faulty C.D.I. unit
--
Fuel system
L
• I m p r o p e r carburetor setting • Clogged air filter
--
Compression system
• Carbon accumulation of cylinder head
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Muffler, Exhaust pipe
•
et
Brake
• Faulty oil pump • Faulty oil quality • Drag
Cooling system
• Fan damaged
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--
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Oil pimp
Clogged
.S
POOR SPEED POOR SPEED
Ignition system
• • • •
L
• Clogged fuel tank cap • Clogged air filter • Clogged carburetor
L
• • • • •
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PROBABLE C A U S E
Compression system
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Fuel system
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Faulty spark plug Improper spark plug heat range Faulty C.D.I. unit Faulty source coil
Worn cylinder Worn, fatigued or broken piston ring Broken cylinder head gasket Broken cylinder gasket Carbon accumulation of cylinder head
Muffler, Exhaust pipe
• Clogged
Clutch
• Refer to "FAULTY AUTOMATIC"
Brake
• Drag
8-5
ITRBLI ,MPROPER K,CK,NG ISHTGI
?
IMPROPER KICKING SLIPPING
PROBABLE C A U S E
Kick axle assembly
• • • • • •
Transmission oil
Low tension of kick clip Worn kick axle Worn or damaged kick gear Damaged kick clip Kick clip coming off Damaged kick clip stopper
• Improper quality (Low viscosity) • Deterioration
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H A R D KICKING
Kick axle assembly
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PROBABLE C A U S E
• High tension of kick clip • Seized kick gear
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- - C y l i n d e r , piston and piston r i n g - - L
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•Damaged or seized cylinder • Damaged or seized piston • Damaged or seized piston ring
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Kick axle assembly
PROBABLE C A U S E
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KICK C R A N K N O T R E T U R N I N G
• Improperly seated crankcase • I m p r o p e r l y seated crankshaft • Damaged or seized crankshaft • Damaged or seized crankshaft bearing
8-6
• • • •
Damaged kick return spring Kick return spring coming off Kick clip coming off Damaged kick return spring stopper
I
I
ITRBLI
FAULTY BRAKE I S H T G I
?
FAULTY BRAKE PROBABLE C A U S E
POOR B R A K I N G EFFECT
Worn brake shoe Worn or rusty brake drum Improperly adjusted brake free play Improper brake cam lever position Improper brake shoe position Fatigue/Damaged return spring Oily or greasy brake shoe Oily or greasy brake drum Broken brake cable
Disc b r a k e (Front)
• • • • • • • • • •
W o r n b r a k e pad W o r n b r a k e disc A i r in brake f l u i d Leaking brake fluid F a u l t y m a s t e r c y l i n d e r kit F a u l t y c a l i p e r seal kit Loose union bolt Broken brake hose O i l y o r g r e a s y b r a k e pad O i l y o r g r e a s y b r a k e disc
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• • • • • • • • •
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Drum brake
PROBABLE C A U S E
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MALFUNCTION
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• • • • • •
8-7
Bent, d e f o r m e d o r d a m a g e d i n n e r t u b e B e n t or d e f o r m e d o u t e r t u b e Damaged fork spring W o r n o r d a m a g e d slide m e t a l I m p r o p e r oil v i s c o s i t y I m p r o p e r oil level
I
I
ITRBLI INSTABLE HANDLING ISHTGI
?
INSTABLE H A N D L I N G PROBABLE CAUSE
INSTABLE HANDLING
• Improperly installed or bent
Handlebar --
• Improperly installed steering column (Improperly tightened ringnut) • Bent steering column • Damaged ball bearing or bearing race
Steering L
• Broken spring • B o n d e d front forks
Front forks
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L
L
• Uneven tire pressures on both sides •Incorrect tire pressure • Unevenly worn tires
L
• Damaged bearing • Bent or loose wheel axle • Excessive wheel run-out
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Tires
.S
Frame
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• Bent or damaged /
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Rear shock absorber
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• Twisted • D a m a g e d head pipe • Improperly installed bearing race
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~Wheels
8-8
• Fatigued spring • O i l leakage
II
FAULTY SIGNAL AND LIGHTING SYSTEM
ITRBLI ISHTGI ? I
FAULTY SIGNAL AND LIGHTING SYSTEM PROBABLE C A U S E
I
• • • • • • •
I m p r o p e r bulb Too m a n y electric accessories Hard charging (Broken charging coil) Incorrect c o n n e c t i o n Improperly grounded Poor contacts (main or light switch) Bulb life expires
- -
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• I m p r o p e r bulb •Improperly grounded • Faulty main and/or light switch • Bulb life expires
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PROBABLE C A U S E
BULB BURNT OUT
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HEADLIGHT DARK
PROBABLE C A U S E
FLASHER DOES NOT BLINK
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Improperly grounded Discharged battery Faulty flasher switch Faulty flasher relay Broken w i r e h a r n e s s Loosely connected c o u p l e r Bulb burnt out Faulty fuse
PROBABLE C A U S E
FLASHER KEEPS ON
D
- -
• • • • • • • •
• Faulty flasher relay • I n s u f f i c i e n t b a t t e r y c a p a c i t y ( n e a r l y discharged) • Bulb burnt out
L
8-9
FAULTY SIGNAL AND LIGHTING SYSTEM FLASHER BLINKS SLOWER
ITRBLI ISHTGI ? I
PROBABLE C A U S E
I
• Faulty flasher relay • Insufficient battery capacity (nearly discharged) • Improper bulb • Faulty main and/or flasher switch
FLASHER BLINKS QUICKER
PROBABLE C A U S E
I HORN DOES NOT S O U N D
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Faulty battery Faulty fuse Faulty main and/or horn switch I m p r o p e r l y adjusted horn Faulty horn Broken w i r e h a r n e s s
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PROBABLE C A U S E
8-10
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• Improper bulb • F a u l t y flasher relay
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OYAMAHA
Y A M A H A MOTOR TAIWAN CO., LTD
et e. n im er T co ot .S w w w m fro ad ed nl o ow D Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, ON M2H 3B4
