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It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology.
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EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters.
EAS00009 SYMBOLS SPEC INFO The following symbols are not relevant to every vehicle. INSP Symbols Q to I indicate the subject of each chapter. Q General information W Specifications CARB CHAS E Periodic checks and adjustments R Engine T Carburetor Y Chassis TRBL U Electrical system...
EAS00011 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND INSP ADJUSTMENTS ENGINE CARBURETOR CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
INFO CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ................ 1-1 VEHICULE IDENTIFICATION NUMBER ..........1-1 ENGINE NUMBER ................... 1-1 IMPORTANT INFORMATION ..............1-3 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-3 REPLACEMENT PARTS ................. 1-3 GASKETS, OIL SEALS, AND O-RINGS ..........1-3 LOCK WASHERS/PLATES AND COTTER PINS ........
INFO GENERAL INFORMATION EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the bottom of the frame as shown. NOTE: The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your state.
This will speed up assembly and allow for the correct installation of all parts. 5.Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS 1.Use only genuine Yamaha/MBK parts for all replacements. grease recommended by Yamaha/MBK for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
INFO IMPORTANT INFORMATION EAS00023 LOCK WASHERS / PLATES AND COTTER PINS 1.After removal, replace all lock washers / plates and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the...
INFO CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1.Disconnect: • lead • coupler • connector 2.Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...
INFO HOW TO USE THE CONVERSION TABLE HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULTIPLIER IMPERERIAL ** mm 0.03937...
INFO SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
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INFO SPECIAL TOOLS Tool N° Tool name/usage Illustration 90890-01337 Clutch spring holder. This tool is used for compressing the spring of the secondary sheave when removing the nut. Oil seal guide 90890-01409 90890-01410 Oil seal installer This tool is used to install the left side crankcase oil seal.
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YQ100 Dimensions: Overall length 1,762 mm Overall width 690 mm Overall height 1,151 mm Seat height 812 mm Wheelbase 1,272 mm Minimum ground clearance 157 mm Minimum turning radius 1,800 mm Basic weight: With oil and full fuel tank 95 kg Engine:...
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SPEC GENERAL SPECIFICATIONS Model YQ100 Spark plug: Type BR8HS Manufacturer 0.5 ~ 0.7 mm Clutch type: Dry, centrifugal automatic Transmission: Primary reduction system Helical gear Primary reduction ratio 47 / 15 (3.133) Secondary reduction system Spur gear Secondary reduction ratio 43 / 13 (3.308) Transmission V-belt...
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SPEC GENERAL SPECIFICATIONS Model YQ100 Wheel travel: Front 80 mm Rear 72 mm Electrical: Ignition system Charging system Flywheel magneto Battery type/model YT4L-BS Battery capacity 12V 3AH Headlight type: Bulb Bulb wattage x quantity: Headlight 12V 35W/35W x 1 Position light 12V 5W x 1 License light 12V 5W x 1...
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Standard Limit Cylinder head: Warp limit 0.02 mm * Lines indicate straight edge measurements. Cylinder: Bore size 52.002 ~ 52.012 mm Taper 0.05 mm Piston: Piston clearance 0.044 ~ 0.045 0.10 mm Piston size 51.958 ~ 51.967 mm Measuring point* 10 mm...
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SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Crankshaft: Crank width “A” 37.90 ~ 37.95 mm Runout limit “C” 0.03 mm Connecting rod length 79.9 ~ 80.1 mm Side clearance “D” 0.2 ~ 0.5 mm Small End Free Play 0.4 ~0.8 mm Automatic centrifugal clutch: Clutch shoe thickness 4.0 mm...
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SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Reed valve: Valve stopper height 6.0 ~ 6.4 mm Reed Valve Clearance Less than 0.2 mm Lubrication System Autolub Pump Plunger diameter 2.5 mm Autolub pump stroke/ Manufacturer PLB-D39 / Dell'orto Minimum output at 3000rpm 4.5 cc/h Maximum output at 3000rpm 16 cc/h...
SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Tightening Part to be tightened Part Thread Q'ty torque Remarks name size m.kg Spark plug Head cylinder Cylinder stud bolt Air shroud (3) Screw Screw Air shroud (1x3) Screw Oil pump assembly Screw Reed valve Bolt Air filter Screw...
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model Standard Limit Steering system: Steering bearing type Ball bearing Size of steel balls x qty: Upper ø4.75 mm x 15 Lower ø4.75 mm x 15 Lock to lock angle Left 45° Right 45° Front suspension: Front fork travel 80 mm Optional spring...
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SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Front disk brake: Type Single disc Diameter and thickness 190.0 x 3.5 mm Pad thickness 4.5 mm 2 mm Master cylinder inside diameter 11 mm Caliper cylinder inside diameter 30 mm Brake fluid type DOT #3 or DOT#4 Rear drum brake: Type...
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SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Battery : Specific gravity 1.280 Starter motor: Model / Type MORYAMA Output 0.14 kW 0.06 ~ 0.08 Ω at 20°C Armature coil resistance Brush length 3.9 mm 0.9 mm Brush spring pressure 563 ~ 844 g Commutator diameter 15.8 mm 14.8 mm...
SPEC GENERAL TORQUE SPECIFICATIONS EAS00029 GENERAL TIGHTENING TORQUE General torque (Nut) (Bolt) specifications SPECIFICATIONS m.kg This chart specifies tightening torques for stan- 10 mm 6 mm dard fasteners with a standard ISO thread pitch. 12 mm 8 mm Tightening torque specifications for special components or assemblies are provided for each 14 mm 10 mm...
SPEC LUBRICATION POINT AND GRADE OF LUBRICANT EAS00032 CHASSIS Lubrication point Lubricant type Front wheel oil seal (right/left) Rear wheel oil seal Steering bearing and bearing race (upper/lower) Throttle grip inner surface Lever pivots and cable end Oil seal lips (front wheel) Bearing (front wheel) Speedometer gear Center stand pivot...
SPEC CABLE ROUTING EAS00035 CABLE ROUTING Taillight Ignition coil assy' Rear left flasher light Starter motor Seat lock assy' Rear right flasher light Band switch Oil pump wire Clip Wire harness Starter relay Seat lock cable Fuse Fuel and sunction pipe Battery assy' 15 –...
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SPEC CABLE ROUTING A Untight the seat lock plate to give to the seat lock cable more free play. Tight the seat lock cable at 1 1/2 turn. B Fix on the footrest board. C Pass the wire harness through the footrest board. D Push the wire harness to the inside.
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SPEC CABLE ROUTING Q Fuel sender O Resistor W C.D.I. unit P Headlight E Band switch { Engine assy' R Oil level sender } Starter wire T Wire cylinder assy' q Throttle cable Y Rectifier / Regulator w Oil pump wire U Band switch cordon e Wire harness I Main switch...
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SPEC CABLE ROUTING A Fix the wire harness, starter motor wire and the flywheel wire all together. B Fix the wire harness. C Pass the wire harness between the regulator and the steering head pipe. D Secure the right position of the headlight protection. E Adjust the oil pump.
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SPEC CABLE ROUTING Resistor assy' A Install the front brake hose on the front fork assy' clip. Horn B Pass the speedometer cable through the front Band switch mudguard bracket. Frame Front brake hose Speedometer cable Gear unit assy' Front mudguard Front fork assy' 2-21...
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SPEC CABLE ROUTING Right hand grip Starter wire Master cylinder Stop switch wire Speedometer assy' Front brake hose Left hand grip Wire harness Rear brake lever Speedometer cable Rear brake cable Front brake lever 2-22...
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SPEC CABLE ROUTING A Fix the wire harness on the frame bracket. B Group all connection in this area. C Pass the starter cable through the hole. D Tight this bolt first. E Tight this bolt first. F Stop the cap on the handlebar end. Tight at 7 Nm (0.7 m.kg). G Stop the grip on the handlebar projection.
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SPEC CABLE ROUTING Speedometer cable A Secure the installation of the clip. Wire harness B Group all connections in this area. Front brake hose Rear brake cable Front handlebar cover Speedometer cover Speedometer Rear handlebar cover Handlebar switch wire Starter wire Master cylinder Throttle grip 1.5 ~ 3.0 mm...
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CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE AND LUBRICATION ........3-1 COVERS ......................3-3 SEAT AND SIDE COVERS ..............3-3 BOX, LOWER SIDE COVERS AND MUDGUARD ........3-4 FRAME REINFORCEMENT, FUEL TANK AND REAR UNDER COVER ..............3-5 FRONT COVERS ..................3-6 HANDLEBAR COVERS ................
INSP PERIODIC CHECKS AND ADJUSTMENTS EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
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• Correct if necessary. and switches • Adjust headlight beam if necessary. Items maked with an asterisk (*) require special tools, data and technical skills for servicing. Take the scooter to a Yamaha or MBK dealer when servicing these items. NOTE: •...
INSP COVERS SEAT AND SIDE COVERS 8 Nm (0,8 m.kg) 3 Nm (0,3 m.kg) 8 Nm (0,8 m.kg) 2 Nm (0,2 m.kg) Order Job/Part Q’ty Remarks Removing the seat and side covers Remove the parts in the order listed. Remove: Seat Fuel tank cap Rear seat screws and strap...
INSP COVERS BOX, LOWER SIDE COVERS AND MUDGUARD 8 Nm (0,8 m.kg) 3 Nm (0,3 m.kg) 2,5 Nm (0,25 m.kg) 6 Nm (0,6 m.kg) Order Job/Part Q’ty Remarks Removing the box, lower side covers Remove the parts in the order listed. and mudguard Remove: Glove compartment cover...
INSP COVERS FRAME REINFORCEMENT, FUEL TANK AND REAR UNDER COVER 13 Nm (1,3 m.kg) 6,5 Nm (0,65 m.kg) 3 Nm (0,3 m.kg) 6,5 Nm (0,65 m.kg) 2 Nm (0,2 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the frame reinforcement, fuel tank and rear under cover.
INSP COVERS FRONT COVERS 3 Nm (0,3 m.kg) 3 Nm (0,3 m.kg) 2 Nm (0,2 m.kg) 3 Nm (0,3 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the front covers Disconnect: Headlight lead Remove: Front cover and headlight Front fender Front inner panel CAUTION:...
INSP COVERS HANDLEBAR COVERS 3 Nm (0,3 m.kg) 3 Nm (0,3m.kg) 3 Nm (0,3 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the handlebar covers Untighten: Handlebar under cover Disconnect: Speedometer lead Wires and leads Remove: Handlebar cover (front) Handlebar cover (rear)
INSP COVERS BATTERY COVER AND LOWER COVER 3 Nm (0,3 m.kg) 3 Nm (0,3 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the battery cover and lower cover. Refer to “SEAT AND SIDE COVERS” section. Seat Refer to “BOX, SIDE COVERS AND MUD- Box and side covers...
INSP COVERS INNER PANEL AND FOOTREST BOARD 4 Nm (0,4 m.kg) 4 Nm (0,4 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the inner panel and footrest board. NOTE: Remove: To remove the main switch ring, turn it Inner panel counterclockwise.
INSP COVERS NOTE: Correct routing of cables and wires is essential for a safe operation of this scooter. Refer to the section “CABLE ROUTING” in Chapter 2. NOTE: Be careful not to pinch any wires with the covers. NOTE: When installing the covers, be careful to not damage the mounting clips. 3-10...
INSP ADJUSTING THE ENGINE IDLING SPEED EAS00054 ENGINE ADJUSTING THE ENGINE IDLING SPEED CAUTION: For safety reasons, place the scooter on the centerstand before starting the engine. 1.Start the engine and let it warm up for several minutes. 2.Attach: • engine tachometer (onto the spark plug lead) Engine tachometer 90890-03113...
INSP ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play (at the / flange of the throttle grip) @ 1.5 ~ 3.0 mm EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted.
ADJUSTING THE THROTTLE CABLE FREE PLAY / INSP CHECKING THE SPARK PLUG Handlebar side a.Loosen the locknut. b.Turn the adjusting nut in direction left or rught until the specified throttle cable free play is obtained. Direction left Throttle cable free play is increased.
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INSP CHECKING THE SPARK PLUG 5.Clean: •spark plug (with a spark plug cleaner or wire brush) 6.Measure: •spark plug gap (with a wire gauge or feeler gauge) Out of specification → Adjust. Spark plug gap 0.5 ~ 0.7 mm 7.Install: •spark plug Spark plug 20 Nm (2 m•kg)
AUTOLUBE PUMP AIR BLEEDING/ INSP CLEANING THE AIR FILTER ELEMENT 2.Bleed: •Pump housing and oil hose a.Place a rag under the pump. b.Remove the bleed screw c. Let oil run until there are no more air bubbles in it. d.When there are no more bubbles, tighten the bleed screw.
CLEANING THE AIR FILTER ELEMENT/ INSP CHECKING THE EXHAUST PIPE SYSTEM b. Squeeze excess solvent out of the element and let dry. CAUTION: Do not twist the element. c. Apply foam air filter oil or motor oil on the element. d.Squeeze out the excess oil.
ADJUSTING THE FRONT BRAKE/ INSP ADJUSTING THE REAR BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: •brake lever free play @ Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 10 ~ 20 mm WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake...
INSP CHECKING THE BRAKE FLUID LEVEL EAS00116 CHECKING THE BRAKE FLUID LEVEL 1.Stand the scooter on a level surface. NOTE: • Place the scooter on a suitable stand. • Make sure the scooter is upright. • In order to ensure a correct reading of the brake fluid level, make sure the top of the reservoir is horizontal.
CHECKING THE FRONT BRAKE PADS/ CHECKING THE BRAKE SHOES/ INSP BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00123 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1.Operate the brake. 2.Check: • brake pad Out of specification → Replace. NOTE: Replace the brake pad and spring as a set when replacing the brake pads.
BLEEDING THE HYDRAULIC BRAKE SYSTEM / INSP CHECKING AND ADJUSTING THE STEERING HEAD i. Repeat steps (e) to (h) until all air bubbles have been removed from the system. j. Add brake fluid to proper level. WARNING Check the operation of the brake after bleeding the brake system.
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INSP CHECKING AND ADJUSTING THE STEERING HEAD Steering nut wrench 90890-01403 Lower ring nut (initial tightening torque) 38 Nm (3.8 m•kg) c. Loosen the lower ring nut of 1/4 turn and then tighten it to specification with a steering nut wrench . CAUTION: Do not overtighten the lower ring nut.
CHECKING AND ADJUSTING THE STEERING HEAD / INSP CHECKING THE FRONT FORK 5.Install: •front cover Refer to "FRONT COVER" •Handlebar Refer to "HANDLEBAR" in chapter 6. Handlebar holder bolt 60 Nm (6.0 m•kg) EAS00151 CHECKING THE FRONT FORK 1.Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over.
INSP CHECKING THE TIRES EAS00165 CHECKING THE TIRES The following procedure applies to both of the tires. 1.Measure: •tire pressure Out of specification → Regulate. WARNING The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and...
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INSP CHECKING THE TIRES Minimum tire tread depth 0.8 mm Tire tread depth Side wall Wear indicator WARNING 3103 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using tube tires, be sure to install the correct tube.
CHECKING THE WHEELS/ INSP CHECKING AND LUBRICATING THE CABLES EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1.Check: • wheel Damage/out-of-round → Replace. WARNING Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.
LUBRICATING THE CENTERSTAND/ INSP LUBRICATING THE REAR SUSPENSION EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to- metal moving parts of the centerstand. Recommended lubricant Engine oil EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum disulfide grease 3-28...
INSP CHECKING THE BATTERY EAS00177 ELECTRICAL SYSTEM CHECKING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
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INSP CHECKING THE BATTERY 4.Check: •electrolyte level The electrolyte level should be between the UPPER minimum level mark and the maximum LOWER level mark Below the minimum level mark → Add distilled water to the proper level. CAUTION: Add only distilled water. Tap water contains minerals which are harmful to the battery.
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INSP CHECKING THE BATTERY • Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.
CHECKING THE BATTERY/ INSP CHECKING THE FUSE 10.Lubricate: •battery terminals Recommended lubricant Dielectric grease 11.Install: •battery cover Refer to "BATTERY COVER AND LOWER COVER". EAS00181 CHECKING THE FUSE The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to "OFF"...
CHECKING THE FUSE/ INSP REPLACING THE HEADLIGHT BULB 3.Replace: • blown fuse a.Set the main switch to “OFF”. b.Install a new fuse of the correct amperage. c. Set on the switches to verify if the electrical circuit is operational. d.If the fuse immediately blows again, check the electrical circuit.
REPLACING THE HEADLIGHT BULB/ INSP ADJUSTING THE HEADLIGHT BEAM 4.Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
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CHAPTER 4. OVERHAULING THE ENGINE ENGINE ......................4-1 LEADS AND HOSES ................4-1 EXHAUST PIPE ..................4-3 ENGINE ....................4-4 INSTALLING THE ENGINE ..............4-5 CYLINDER HEAD, CYLINDER AND PISTON ..........4-6 PISTON PIN AND PISTON REMOVAL ........... 4-7 CYLINDER HEAD INSPECTION ............. 4-7 CYLINDER AND PISTON INSPECTION ..........
OVERHAULING THE ENGINE EAS00188 OVERHAULING THE ENGINE ENGINE LEADS AND HOSES Order Job/Part Q’ty Remarks Removing the leads and hoses Remove the parts in the order listed. Seat Refer to "SEAT AND SIDE COVERS" Upper side covers in chapter 3. Glove compartment cover Oil cover Refer to "BOX, SIDE COVERS AND...
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OVERHAULING THE ENGINE Order Job/Part Q’ty Remarks Starter motor lead coupler Untighten : Rear wheel nut Note: Loosen the rear wheel nut. Remove : Rear brake adjuster Rear brake cable For installation, reverse the removal procedure.
OVERHAULING THE ENGINE EXHAUST PIPE 29 Nm (2,9 m.kg) 8.5 Nm (0,85 m.kg) Order Job/Part Q’ty Remarks Removing the exhaust pipe Remove the parts in the order listed. Lower cover Refer to "BATTERY COVER AND LOWER COVER" in chapter 3. Untighten: Bolt (from cylinder) Remove:...
OVERHAULING THE ENGINE EAS00192 ENGINE Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. Leads and hoses NOTE: Exhaust pipe Place a suitable stand under the frame and engine. Remove: • Rear shock absorber bolt (lower) •...
CYLINDER HEAD EAS00222 CYLINDER HEAD, CYLINDER AND PISTON 14 Nm (1,4 m.kg) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. and piston Lower cover Refer to "BATTERY COVER AND LOWER COVER" in chapter 3. Exhaust pipe Refer to "EXHAUST PIPE".
CYLINDER HEAD, CYLINDER, PISTON PISTON PIN AND PISTON REMOVAL 1. Remove: • Piston pin clip NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase. 2.
CYLINDER HEAD, CYLINDER, PISTON CYLINDER AND PISTON INSPECTION 1. Eliminate : • Carbon deposits Use a rounded scraper 2. Inspect : • Cylinder wall Wear/Scratches→Rebore or replace. 3. Eliminate : • Carbon deposits From the piston crown and ring grooves 4.
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CYLINDER HEAD, CYLINDER, PISTON Standard Wear limit Cylinder bore 52.002~52.012mm 52.10 mm “C” – 0.05 mm Taper “T” Out of round 0.03 mm – “R” C = Maximum D T=( Maximum D1 or D2 ) - ( Maximum D5 or D6 ) R=( Maximum D1 D3 or D5 ) - ( Maximum D2 D4 or D6 )
CYLINDER HEAD, CYLINDER, PISTON PISTON RINGS INSPECTION 1. Measure: • Side clearance Out of specification→Replace piston and /or rings. Use a feeler gauge Standard Limit Top ring 0.03 ~ 0.05 mm 0.10 mm 2nd ring 0.03 ~ 0.05 mm 0.10 mm 2.
CYLINDER HEAD, CYLINDER, PISTON 3. Install : • Small end bearing • Piston • Piston pin • Piston pin clip NOTE: • The arrow a on the piston to the exhaust side. • Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip material into the crankcase.
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CYLINDER HEAD, CYLINDER, PISTON 4. Install : • Cylinder head gasket (new gasket) 5. Install : • Cylinder head 14Nm(1.4m.kg) • Spark plug 20Nm(2.0m.kg) • Air shroud NOTE: Tighten the cylinder head holding nuts in stage, using a crisscross pattern. 4-13...
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE CRANKCASE COVER (LEFT) 12Nm(1.2kg.m) 9 Nm(0.9kg.m) 13 Nm(1.3kg.m) Order Job name/Part name Q’ty Remarks Crankcase cover (left) removal Remove the parts in order. Air cleaner assembly mounting screw Screw(Bind) Kick starter Crankcase (left) Gasket Reverse the removal procedure for installation.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE KICK STARTER Job name/Part name Remarks Order Q’ty Kick starter removal Remove the parts in order. Kickstarter pinion gear Kickstarter pinion gear clip Circlip/Plain washer Kick shaft Return spring Collar Reverse the removal procedure for installation. 4-15...
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 40Nm(4.0kg.m) 45Nm(4.5kg.m) Order Job name/Part name Q’ty Remarks V-belt, clutch and secondary/primary Remove the parts in order. sheave removal Lower rear cover Refer to “BATTERY COVER AND Air shroud 3 LOWER COVER”...
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE SECONDARY SHEAVE SECONDARY SHEAVE 50Nm(5.0kg.m) Job name/Part name Remarks Order Q’ty Secondary sheave disassembly Disassemble the parts in order. Clutch carrier Clutch shoe spring Refer to “SECONDARY SHEAVE Compression spring INSTALLATION” section. Spring seat Guide pin Secondary sliding sheave O-ring Refer to “SECONDARY SHEAVE...
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 3. Loosen : • Nut(Clutch carrier) NOTE: Install the secondary sheave to primary drive shaft as shown, and hold the secondary sheave by Universal Roter Holder to loosen the nut Flywheel holding tool : 90890-01235 CAUTION: Do not remove the clutch securing nut yet.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 2. Measure : • Clutch shoe thickness a Out of specification→Replace. Clutch shoe thickness : 4 mm < Wear limit> : 2.5 mm V-BELT INSPECTION 1. Inspect : • V-belt Crack→Replace. NOTE: Replace the V-belt smeared with a lot of oil or grease.
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE SECONDARY SHEAVE INSTALLATION When assembling the secondary sheave, re- verse the disassembly procedure. Note the following points. 1. Apply : • BEL-RAY assembly lube ® (to the inside of the sliding/fixed sheave) 2. Install : •...
STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR 13Nm(1.3kg.m) 8Nm(0.8kg.m) Job name/Part name Remarks Order Q’ty Starter clutch and starter motor Remove the parts in order. removal Left/Right lower side cover Left/right upper side cover Refer to “COVERS”...
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STARTER CLUTCH AND STARTER MOTOR 13Nm(1.3kg.m) 8Nm(0.8kg.m) Order Job name/Part name Q’ty Remarks Starter clutch Plain washer Starter wheel gear Collar Starter motor Starter motor connector Reverse the removal procedure for instalation 4-28...
C.D.I. MAGNETO C.D.I. MAGNETO C.D.I. MAGNETO 8Nm(0.8kg.m) 43Nm(4.3kg.m) 7Nm(0.7kg.m) Job name/Part name Remarks Order Q’ty C.D.I. magneto removal Remove the parts in order. Lower cover Refer to “BATTERY COVER AND LOWER COVER” section in chapter 3. Oil cover Air shroud 3 Fan /O-ring Magneto rotor Bind...
TRANSMISSION TRANSMISSION TRANSMISSION 18Nm(1.8kg.m) 12Nm(1.2kg.m) Job name/Part name Remarks Order Q’ty Transmission removal Remove the parts in order. Rear wheel Refer to “REAR WHEEL AND REAR BRAKE ” section in chapter 6. Secondary sheave Refer to “V-BELT, CLUTCH, SECONDARY/ PRIMARY SHEAVE” section Drain the transmission oil.
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TRANSMISSION TRANSMISSION TRANSMISSION 18Nm(1.8kg.m) 12Nm(1.2kg.m) Order Job name/Part name Q’ty Remarks Circlip Main axle Drive axle Reverse the removal procedure for installation. 4-35...
TRANSMISSION EAS00423 CHECKING THE TRANSMISSION 1.Measure: •main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle deflection limit 0.08 mm 319005(a) 2.Measure: •drive axle runout (with a centering device and dial gauge) Out of specification →...
CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE 9Nm(0.9kg.m) 12Nm(1.2kg.m) Job name/Part name Remarks Order Q’ty Crankcase and Reed valve removal Remove the parts in order. Engine removal Refer to “ENGINE REMOVAL” section. Cylinder head, cylinder, piston Refer to “CYLINDER HEAD CYLINDER AND PISTON”...
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CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE 9Nm(0.9kg.m) 12Nm(1.2kg.m) Order Job name/Part name Q’ty Remarks Intake manifold Reed valve Valve seat gasket Stopper Crankcase 2 Refer to “CRANCKCASE REMOVEL” and “CRANCKCASE INSTALLATION” Dowel pin Engine mount spacer Circlip Bearing Oil seal...
CRANKCASE AND REED VALVE CRANKCASE (RIGHT) INSTALLATION 1. Install : • Dowel pins • Engine mount spacer 2. Apply : • Yamaha Bond No.1215 To the mating surfaces of both case helves. Yamaha bond No.1215: 90890-85505 3. Attach : • Crankshaft installing tools...
CRANKSHAFT CRANKSHAFT CRANKSHAFT Job name/Part name Remarks Order Q’ty Crankshaft removal Remove the parts in order. Right crankcase removal Refer to “CRANKCASE AND REED VALVE” section. Crankshaft Bearing Oil seal Crankcase cover (left) Reverse the removal procedure for installation. 4-42...
CRANKSHAFT CRANKSHAFT INSTALLATION 1. Attach : • Crankshaft Installing Tool Crankshaft installing tool: 90890-01274 90890-01275 90890-01277 90890-01288 2. Install : • Crankshaft (to the crankcase 3. Install : • Oil seal • Apply lithium soap base grease onto the oil seal lip. Use the guide and seal driver to install...
CARB CARBURETOR EAS00480 CARBURETOR CARBURETOR 9Nm(0.9kg.m) Remarks Order Job/Part Q'ty Remove the parts in the order listed. Removing the carburetor Air filter box Fuel hose Vacuum hose Oil delivery hose Choke cable Air filter joint Unhook Throttle cable Carburetor For installation, reverse the removal procedure.
CARB CARBURETOR EAS000483 TEIKEI CARBURETOR DISASSEMBLY Remarks Order Job/Part Q'ty Carburetor disassembly Remove the parts in the order listed. Carburetor top Gasket Throttle valve spring Needle set Throttle valve Starter retaining plate Starter top cover Starter plunger O'ring Starter plunger spring Starter plunger Air screw set Throttle stop screw...
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CARB CARBURETOR EAS000483 TEIKEI CARBURETOR DISASSEMBLY Remarks Order Job name/Part name Q'ty Float chamber Float chamber gasket Float pin Float / Needle valve Main jet Main nozzle Pilot jet Carburetor body For installation, reverse the removal procedure.
CARB CARBURETOR EAS00485 CHECKING THE CARBURETOR 1.Check : • carburetor body • float chamber • jet housing • fuel passages Durt/Obstruction → Clean Cracks/damage → Replace. 322006 a.Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution.
CARB CARBURETOR 6.Check : •Throttle valve free movement Unsmooth/Stickiness → Replace. Insert the throttle valve into the carburetor body and check for smooth movement. 322015 7.Check : •throttle stop screw •air screw •needle •starter plunger Damage/Wear → Replace. 322016 NOTE: The float height is factory-adjusted.
CARB CARBURETOR 2.Install : • throttle valve • starter plunger NOTE: Align the groove of the throttle valve with the projection of the carburetor. 322019 3.Install : • Carburetor NOTE: Align projection with projection 322020 EAS00492 INSTALLING THE CARBURETOR 1. Adjust: •...
CARB FUEL COCK FUEL COCK INSPECTING THE FUEL COCK 1.Stop the engine. 2.Remove: • Side covers Refer to "COVERS" in Chapter 3. 3.Inspect: •Fuel cock ******************************************************* Fuel cock inspection steps: • Disconnect the fuel hose • Place the receptacle under the fuel hose end. •...
CARB REED VALVE REED VALVE 11 Nm (1.1 m.kg) Remarks Order Job/Part Q'ty Removing the reed valve Remove the parts in the order listed. Carburetor Refer to "CARBURETOR" section. Carburetor joint Reed valve assembly For installation, reverse the removal procedure.
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CHAS CHAPTER 6. CHASSIS FRONT WHEEL AND BRAKE DISC ............. 6-1 FRONT WHEEL AND BARKE DISC ............6-1 FRONT WHEEL ..................6-2 REMOVING THE FRONT WHEEL ............6-3 DISASSEMBLING THE FRONT WHEEL ..........6-3 CHECKING THE FRONT WHEEL ............6-4 CHECKING THE BRAKE DISC ...............
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CHAS FRONT FORK ....................6-30 REMOVING THE FRONT FORK LEGS ..........6-32 DISASSEMBLING THE FRONT FORK LEGS ........6-32 CHECKING THE FRONT FORK LEGS ..........6-33 ASSEMBLING THE FRONT FORK LEGS ..........6-34 HANDLEBAR ....................6-37 REMOVING THE HANDLEBAR ............6-39 CHECKING THE HANDLEBAR .............
CHAS FRONT WHEEL AND BRAKE DISC EAS00513 CHASSIS FRONT WHEEL AND BRAKE DISC FRONT WHEEL AND BRAKE DISC 23 Nm (2,3 m.kg) 35 Nm (3,5 m.kg) Order Job/Part Q'ty Remarks Removing the front wheel and brake Remove the parts in the order listed. disc WARNING Securely support the scooter so there is...
CHAS FRONT WHEEL AND BRAKE DISC EAS00518 FRONT WHEEL Order Job/Part Q'ty Remarks Disassembling the front wheel Remove the parts in the order listed. Remove: Oil seal Refer to "DISASSEMBLING/ASSEM- Bearing BLING THE FRONT WHEEL" section. Collar For assembly, reverse the disassembly procedure.
CHAS FRONT WHEEL AND BRAKE DISC EAS00520 REMOVING THE FRONT WHEEL 1.Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
CHAS FRONT WHEEL AND BRAKE DISC a.Clean the outside of the front wheel hub. b.Remove the oil seal with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface. c. Remove the wheel bearings with a general bearing puller 2.Remove:...
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CHAS FRONT WHEEL AND BRAKE DISC 4.Check: • Wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. • Oil seals Damage/wear → Replace. 5.Replace: • Wheel bearings • Oil seals a.Clean the outside of the front wheel hub. b.Remove the oil seals with a flat-head screwdriver.
CHAS FRONT WHEEL AND BRAKE DISC EAS00528 CHECKING THE BRAKE DISC 1.Check: • Brake disc Damage/galling → Replace. 2.Measure: • Brake disc deflection Out of specification → Inspect wheel runout. If wheel runout is in good condition, correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.2 mm...
CHAS FRONT WHEEL AND BRAKE DISC Brake disc bolt 23 Nm (2.3 m • kg) d.Measure the brake disc deflection. e.If out of specification, repeat the adjustment steps until the brake disc deflection is within 23 Nm (2,3 m.kg) specification. f.
CHAS FRONT WHEEL AND BRAKE DISC 5.Tighten: • Wheel axle • Brake caliper bolts Wheel axle 35 Nm (3.5 m • kg) Brake caliper bolt 23 Nm (2.3 m • kg) WARNING Make sure the brake hose is routed properly. CAUTION: Before tightening the axle nut, stroke the front fork several times to check for proper...
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CHAS FRONT WHEEL AND BRAKE DISC 3.Adjust: • Front wheel static balance a.Install a balancing weight onto the rim exactly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b.Turn the front wheel 90° so that the heavy spot is positioned as shown.
CHAS REAR WHEEL AND BRAKE EAS00555 REAR WHEEL AND BRAKE 9.75 Nm (0,98 m.kg) 125 Nm (12,5 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the rear wheel and the rear brake Refer to "BATTERY COVER AND LOWER Lower cover COVER"...
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CHAS REAR WHEEL AND BRAKE 9.75 Nm (0,98 m.kg) 125 Nm (12,5 m.kg) Q'ty Remarks Order Job/Part Camshaft lever Refer to "INSTALLING THE REAR Wear indicator BRAKE" section. Brake camshaft For installation, reverse the removal pro- cedure. 6-12...
CHAS REAR WHEEL AND BRAKE 3.Measure: • Brake drum inside diameter a Out of specification → Replace the wheel. Brake drum inside diameter limit (maximum) 130.5 mm 4.Check: 346008 • Brake drum inner surface Oil deposits → Clean. Remove the oil with a rag soaked in lacquer thin- ner or solvent.
CHAS REAR WHEEL AND BRAKE 3.Install: • Wear indicator • Camshaft lever a.Align the projection on the wear indicator with the camshaft notch and install. b.Align the punch marks c. Check the proper position of the brake shoe. 346011(a) 4.Install: •...
CHAS FRONT BRAKE EAS00576 FRONT BRAKE FRONT BRAKE PADS 6 Nm (0.6 m.kg) 31 Nm (3.1 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the front brake pads Remove: Plastic cap Refer to "BRAKE PAD REPLACE- Retaining clip MENT"...
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CHAS FRONT BRAKE EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
CHAS FRONT BRAKE BRAKE PADS REPLACEMENT NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1.Remove: • Brake pads NOTE: • Do not depress the brake lever when the wheel is off the scooter otherwise the brake pads will be forced shut.
CHAS FRONT BRAKE EAS00584 FRONT BRAKE MASTER CYLINDER 8.5 Nm (0.85 m.kg) 6 Nm (0.6 m.kg) 23 Nm (2.3 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the front brake master cylinder Drain the brake fluid Refer to “HANDLEBAR COVERS”...
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CHAS FRONT BRAKE EAS00585 1.2 Nm (0.12 m.kg) Q'ty Remarks Order Job/Part Disassembling the master cylinder Remove the parts in the order listed. NOTE: Drain completely before removing the master cylinder. Remove: Master cylinder cap Diaphragm Remove: Dust boot Actuator Actuator spring Master cylinder piston Piston return spring...
CHAS FRONT BRAKE EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: • Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. • To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.
CHAS FRONT BRAKE EAS00596 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. Recommended brake fluid DOT #3 or DOT #4 1.Install: •...
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CHAS FRONT BRAKE 4.Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT #3 or DOT #4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
CHAS FRONT BRAKE EAS00612 FRONT BRAKE CALIPER 23 Nm (2.3 m.kg) 31 Nm (3.1 m.kg) Q'ty Remarks Order Job name/Part name Remove the parts in the order listed. Removing the front brake caliper Drain the brake fluid Remove: Union bolt Copper washer Brake hose Copper washer...
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CHAS FRONT BRAKE EAS00614 6 Nm (0.6 m.kg) 23 Nm (2.3 m.kg) 23 Nm (2.3 m.kg) Q'ty Remarks Order Job/Part Caliper disassembly Remove the parts in the order listed. Brake pads Refer to "REMOVING THE FRONT BRAKE PADS". Remove: Caliper O-ring Refer to "DISASSEMBLING THE FRONT Caliper piston...
CHAS FRONT BRAKE EAS00620 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1.Remove: • Union bolt • Copper washers • Brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
CHAS FRONT BRAKE EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommanded brake component replacement schedule: Brake pads If necessary Brake hose Every two years Brake fluid Every two years or when- ever the brake is disas- sembled 1.Check: • brake caliper pistons Rust/scratches/wear →...
CHAS FRONT BRAKE EAS00635 INSTALLING THE FRONT BRAKE CALIPER WARNING Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Recommended brake fluid DOT #3 or DOT #4 1.Install: • brake caliper (temporarily) •...
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CHAS FRONT BRAKE 4.Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT #3 or DOT #4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
CHAS FRONT FORK EAS00646 FRONT FORK FRONT FORK 3 Nm (0,3 m.kg) 30 Nm (3,0 m.kg) 31 Nm (3,1 m.kg) Q'ty Remarks Order Job/Part Removing the front fork Remove the parts in the order listed. Front wheel Refer to "FRONT WHEEL AND BRAKE DISC".
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CHAS FRONT FORK EAS00648 23 Nm (2,3 m.kg) Q'ty Remarks Order Job/Part Disassembling the front fork Remove the parts in the order listed. Remove: Spring seat clip Spring seat O-ring Fork spring Remove: Refer to "ASSEMBLING THE FRONT Dust seal FORK LEGS".
CHAS FRONT FORK REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1.Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
CHAS FRONT FORK 4.Remove: • damper rod assembly bolt NOTE: While holding the damper rod assembly with the damper rod holder and T-handle , loosen the damper rod assembly bolt Damper rod holder 342010 90890-01294 T-Handle 90890-01326 5.Remove: • inner tube a.Hold the front fork leg horizontally.
CHAS FRONT FORK 3.Check: • damper rod Damage/wear → Replace. Obstruction → Blow out all of the oil passages with compressed air. • oil flow stopper Damage → Replace. EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
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CHAS FRONT FORK Damper rod holder 90890-01294 T-handle 90890-01326 4.Install: • oil seal (with the fork seal driver weight and fork seal driver attachment Fork seal driver weight 90890-01367 Fork seal driver attachment 90890-01400 CAUTION: Make sure the numbered side of the oil seal faces up.
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CHAS FRONT FORK NOTE: • While filling the front fork leg, keep it upright. • After filling, slowly pump the front fork leg up and down to distribute the fork oil. 8. Install: • spring • o-ring • spring seat •...
CHAS HANDLEBAR HANDLEBAR 60 Nm (6,0 m.kg) Q'ty Remarks Order Job/Part Removing the handlebar Remove the parts in the order listed. Handlebar covers Refer to "COVERS" in Chapter 3. Disconnect: Stop switch Handlebar switch Remove: Rear view mirror Stop switch Front master cylinder Refer to "MASTER CYLINDER".
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CHAS HANDLEBAR 60 Nm (6,0 m.kg) Order Job/Part Q'ty Remarks Handlebar switch (left) Rear brake cable Refer to "INSTALLING THE HANDLE- Starter cable BAR". Left grip Handlebar For installation, reverse the removal pro- cedure. 6-38...
CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1.Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: • handlebar grip NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
CHAS HANDLEBAR EAS00673 INSTALLING THE HANDLEBAR 1.Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2.Install: • handlebar NOTE: Install the handlebar onto the steering shaft notch. CAUTION: •...
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CHAS HANDLEBAR 7.Install: • right handlebar switch WARNING Make sure the throttle grip operates smoothly. NOTE: Align the projection on the right handlebar switch with the hole in the handlebar. 8.Adjust: • throttle cable free play Refer to "ADJUSTING THE THROTTLE CABLE FREE PLAY"...
CHAS STEERING HEAD EAS00675 STEERING HEAD 75 Nm (7.5 m.kg) Fisrt step: 38 Nm (3.8 m.kg) step: Loosen the ring nut 1/4 turn. step: 22 Nm (2.2 m.kg) Q'ty Remarks Order Job/Part Removing the lower bracket Remove the parts in the order listed. WARNING Securely support the scooter so that there is no danger of it falling over.
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CHAS STEERING HEAD 75 Nm (7.5 m.kg) Fisrt step: 38 Nm (3.8 m.kg) step: Loosen the ring nut 1/4 turn. step: 22 Nm (2.2 m.kg) Order Job/Part Q'ty Remarks Ball race (upper) Lower bracket Refer to "REMOVING THE LOWER Ball BRACKET".
CHAS STEERING HEAD EAS00680 REMOVING THE LOWER BRACKET 1.Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2.Remove: • upper ring nut • lock washer 3.Remove: • center ring nut •...
CHAS STEERING HEAD 3.Replace: • bearing balls • bearing races a.Remove the bearing races from the steering head pipe with a long rod and hammer. 354007 b.Remove the bearing race from the lower bracket with a floor chisel and hammer. c.
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 31.5 Nm (3,15 m.kg) 17.5 Nm (1,75 m.kg) Q'ty Remarks Order Job/Part Removing the rear shock absorber Remove the parts in the order listed. assembly Rear covers Refer to "COVERS" in chapter 3. Remove: Rear under cover Remove:...
ELEC CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR GW BR BR GW WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W 12V 5W 12V10W...
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ELEC CIRCUIT DIAGRAM Q CDI magneto w Front flasher light (left) W CDI unit e Front flasher light (right) E Ignition coil r Rear flasher light (left) R Spark plug t Rear flasher light (right) T Main switch y Tail / "STOP" light Y Fuse u Horn U Battery...
ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS Q Wire harness U Battery W Fuel sender I Resistance E Starter relay R Ignition coil T CDI unit Y Oil sender...
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ELEC ELECTRICAL COMPONENTS Q Main switch W Flasher relay E Horn R Rectifier/Regulator...
ELEC SWITCH INSPECTION SWITCH INSPECTION "0" SWITCH INSPECTION "∞" Use a pocket tester to check the terminals for continuity. If the continuity is faulty as any point, "Ω x 1" replace the switch. Pocket tester: 90890-03112 NOTE: • Set the pocket tester to "O" before starting the test.
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ELEC SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Before checking a switch refer to the checking switches as shown in the page 7-5 and check for the correct terminal connections (closed cir- cuit) according to color combinations shown in the chart. Poor connection, fault → Repair or replace. Dimmer switch Start switch LW B...
ELEC IGNITION AND STARTING SYSTEM IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR BR GW GW BR WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W...
ELEC IGNITION AND STARTING SYSTEM TROUBLESHOOTING THE STARTING SYSTEM DOES NOT WORK (NO SPARK OR IRREGULAR SPARKS) Procedure: Check: 1. Fuse (main) 6. Ignition coil resistance 2. Battery 7. Pickup coil resistance 3. Spark plug 8. Source coil resistance 4. Spark check 9.
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ELEC IGNITION AND STARTING SYSTEM 4.Spark check • Remove the spark plug cap. • Connect the ignition checker Ground a Spark plug gap • Turn the main switch to "ON". • Start the engine. MEETS SPECIFICATION • Check the length of the spark gap. •...
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ELEC IGNITION AND STARTER SYSTEM Ω x 1 6.Ignition coil resistance • Disconnect the ignition coil leads. • Connect the pocket tester (Ωx1) to the igni- tion coil. Pocket tester (+) lead → → → → → Orange Pocket tester (-) lead → → → → → Black •...
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ELEC IGNITION AND STARTING SYSTEM MEETS SPECIFICATION 8.Source coil resistance • Disconnect the source coil coupler from the wire harness. BR GW • Connect the pocket tester (Ωx100) to the WR WL source coil. Pocket tester (+) lead → → → → → Black/Red Pocket tester (-) lead →...
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ELEC IGNITION AND STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT WORK Procedure Check: 5. Main switch 1. Fuse (main) 6. Starter motor switch 2. Battery 7. Connections 3. Starter motor 4. Starter relay NOTE: • Remove the following parts before proceed- ing with the troubleshooting: 1) Side covers (right and left) 2) Footrest board/Leg shields...
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ELEC IGNITION AND STARTER SYSTEM DOES NOT WORK • Check the starter motor operation WORKS Starter defect → Repair or replace 4.Starter relay • Disconnect Blue/White lead from the wire harness. • Connect the (-) terminal of the battery to the Blue/White lead.
ELEC STARTER MOTOR STARTER MOTOR 13 Nm (1.3 m.kg) Order Job name/Part name Remarks Q'ty Starter motor removal Refer to "STARTER CLUTCH AND GENERATOR" in Chapter 4. Stater motor disassembly Disassemble the parts in the order below O-ring Front bracket Rubber seal Brush holder assembly Armature...
ELEC STARTER MOTOR INSPECTION 1.Check: • Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: • Commutator diameter @ Out of specification → Replace starter motor Commutator wear limit: 14.8 mm 3.Measure: • Mica undercut @ Out of specification → Scrape the mica to proper value using a hacksaw blade can be ground to fit.
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ELEC STARTER MOTOR 5.Measure: • Brush length @ Out of specification → Replace. Brush length limit @: 0.9 mm 6.Measure: • Brush spring force Fatigue/Out of specification → Replace as a set. Brush spring force: 563 ~ 844 g 7-16...
ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR GW BR BR GW WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W 12V 5W 12V10W...
ELEC CHARGING SYSTEM TROUBLESHOOTING THE BATTERY IS NOT CHARGED Procedure Check: 1. Fuse (main) 2. Battery 3. Charging voltage 4. Charging coil resistance 5. Connections NOTE: • Remove the following parts before proceed- ing with the troubleshooting: 1) Battery cover 2) Side covers (right and left) •...
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ELEC CHARGING SYSTEM 3. Charging voltage • Connect the engine tachometer to the spark plug lead. • Connect the pocket tester (DC20V) to the battery terminals. Pocket tester (+) lead → → → → → Battery (+) terminals Pocket tester (-) lead → → → → → Battery (-) terminals •...
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ELEC CHARGING SYSTEM 4. Charging coil resistance BR GW WR WL • Disconnect the CDI magneto coupler from the wire harness. • Connect the pocket tester (Ω x 1) to the charging coil. Pocket tester (+) lead → → → → → White Pocket tester (-) lead →...
ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR GW BR BR GW WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W 12V 5W 12V10W...
ELEC LIGHTING SYSTEM TROUBLESHOOTING THE HEADLIGHT, HEADLIGHT INDICATOR, POSITION LIGHT, METER LIGHT, LICENSE LIGHT AND/OR TAILLIGHT DO NOT WORK Procedure Check: 1. "LIGHTS" switch 2. Lighting coil resistance 3. "HI/LO" switch 4. Connections NOTE: • Remove the following parts before proceed- ing with the troubleshooting: 1) Side covers 2) Handlebar covers...
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ELEC LIGHTING SYSTEM YP802018 NO CONTINUITY 1."LIGHTS" switch Refer to "SWITCH INSPECTION" section. Replace the right handlebar switch. CONTINUITY 2.Lighting coil resistance • Disconnect the lighting coil coupler from the BR GW wire harness. WR WL • Connect the pocket tester (Ω x 0,1) to the lighting coil.
ELEC LIGHTING SYSTEM LIGHTING SYSTEM CHECK 1.Headlight and high beam indicator light do not work. NO CONTINUITY 1.Bulb and socket. Refer to "SWITCH INSPECTION". Replace the bulb or socket. CONTINUITY 2.Voltage • Connect the pocket tester (AC20V) to the headlight and the high beam indicator light 35W / 35W couplers.
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ELEC LIGHTING SYSTEM 2.Voltage • Connect the pocket tester (AC 20 V) to the front position light connectors. 12V 5W Pocket tester (+) lead → → → → → Blue/Red Pocket tester (-) lead → → → → → Black Pocket tester (+) lead →...
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ELEC LIGHTING SYSTEM 4.The taillight does not work. 1.Bulb and socket. NO CONTINUITY Refer to " SWITCH INSPECTION " section. CONTINUITY Replace bulb or socket. 2.Voltage • Connect the pocket tester (AC 20 V) to the taillight connectors. 21W / 5W Pocket tester (+) lead →...
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ELEC LIGHTING SYSTEM 2.Voltage • Connect the pocket tester (AC 20 V) to the license light coupler. 12V 5W Pocket tester (+) lead → → → → → Blue/Red Pocket tester (-) lead → → → → → Black • Set the main switch to "ON". •...
ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR GW BR BR GW WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W 12V 5W 12V10W...
ELEC SIGNAL SYSTEM TROUBLESHOOTING FLASHER LIGHTS, TAIL/BRAKE LIGHT, "OIL" WARNING LIGHT DO NOT WORK. HORN DOES NOT SOUND, FUEL METER DOES NOT WORK. Procedure Check: 1. Fuse (main) 2. Battery 3. Main switch 4. Connections NOTE: • Remove the following parts before proceeding with the troubleshooting: 1) Side covers and footrest board 2) Handlebar covers...
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ELEC SIGNAL SYSTEM 4.Connections POOR CONNECTIONS • Check all connections in the signal system. Refer to "WIRE DIAGRAM". Repair. CONTINUITY Check the condition of each circuit of the signal system. Refer to "SIGNAL SYSTEM CHECK". 7-30...
ELEC SIGNAL SYSTEM SIGNAL SYSTEM CHECK 1. Horn does not sound. 1."HORN" switch NO CONTINUITY Refer to "SWITCH INSPECTION". Replace the horn switch. CONTINUITY 2.Voltage • Connect the pocket tester (DV20 V ) to the horn lead. Pocket tester (+) lead → → → → → Brown Pocket tester (-) lead →...
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ELEC SIGNAL SYSTEM 2. The brake light does not work. NO CONTINUITY 1.Bulb and socket. Refer to "SWITCH INSPECTION". Replace bulb or socket. CONTINUITY NO CONTINUITY 2.Brake switch Refer to "SWITCH INSPECTION". Brake switch is defect → Replace. CONTINUITY 3.Voltage •...
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ELEC SIGNAL SYSTEM 3.Flashers and flasher indicator do not work. NO CONTINUITY 1.Bulb and socket Refer to "SWITCH INSPECTION". Replace buld and/or socket. CONTINUITY NO CONTINUITY 2.Flasher switch Refer to "SWITCH INSPECTION". Replace the left handlebar switch. CONTINUITY 3.Voltage • Connect the pocket tester (DC 20 V ) to the flasher relay.
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ELEC SIGNAL SYSTEM 5.Voltage • Connect the pocket tester (DC 20 V) to the flasher coupler. 12V10W 12V10W Left flasher bulb Pocket tester (+) lead → → → → → Chocolate Pocket tester (-) lead → → → → → Black Right flasher bulb Pocket tester (+) lead →...
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ELEC SIGNAL SYSTEM 12V 1.2W 3. Voltage 12V 1.2W • Connect the pocket tester (DC20V) to the 12V 1.2W bulb socket connector Pocket tester (+) lead → → → → → Grey Pocket tester (-) lead → → → → → Black •...
TRBL SHTG STARTING FAILURE/HARD STARTING TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank...
TRBL POOR MEDIUM AND HIGH SPEED PERFORMANCE/ FAULTY AUTOMATIC SHTG POOR MEDIUM AND HIGH SPEED PERFORMANCE FUEL SYSTEM Fuel tank Carburetor • Clogged fuel filter • Deteriorated fuel, fuel containing water or • Deteriorated fuel or fuel containing water or foreign material foreign material •...
FRONT FORK OIL LEAKAGE AND FRONT FORK TRBL MALFUNCTION/ SHTG INSTABLE HANDLING FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE MALFUNCTION • Bent, damaged or rusty inner tube • Bent, deformed or damaged inner tube • Damaged or cracked outer tube •...
TRBL SHTG FAULTY SIGNAL AND LIGHTING SYSTEM FAULTY SIGNAL AND LIGHTING SYSTEM Headlight dark Flasher does not light • Improper bulb • Improperly grounded • Too many electric accessories • Discharged battery • Hard charging (broken charging coil) • Faulty flasher switch •...
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Q C.D.I. magneto YQ100 WIRING DIAGRAM Br R W C.D.I. unit Gy B E Ignition coil R Spark plug T Main switch LOCK Y Fuse MAIN HARNESS STARTER MOTOR U Battery CHECK I Rectifier / regulator O Starter relay P Starter motor R W B YR { Right handle switch Starter switch...