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Yamaha YW125Y 2009 Service Manual

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2009
MOTORCYCLE
SERVICE MANUAL
Model : YW125Y_
32SF819770E0
*32SF819770E0*

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Summary of Contents for Yamaha YW125Y 2009

  • Page 1 2009 MOTORCYCLE SERVICE MANUAL Model : YW125Y_ 32SF819770E0 *32SF819770E0*...

  • Page 2: Spark Plug

    0.16 ~ 0.20mm (0.006 ~ 0.008in) EAS00000 YW125Y 2009 SERVICE MANUAL ©2008 by Yamaha Motor Taiwan Co., Ltd. First edition, July 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd.
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    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. 1 The manual is divided into chapters.

  • Page 5: General Information

    EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Fuel injection system 8 Electrical system...

  • Page 6: Table Of Contents

    EAS00011 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE FUEL INJECTION SYSTEM ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 7: Gen Info

    INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL LABEL .................. 1-1 FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM ............1-2 FI SYSTEM ..................1-3 sensor .................... 1-4 IMPORTANT INFORMATION ..............1-5 PREPARATION FOR REMOVAL AND DISASSEMBLY ....1-5 REPLACEMENT PARTS ..............

  • Page 8: General Information

    SCOOTER IDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL LABEL The model label 1 is affixed to the frame under the seat. This information will be needed to or- der spare parts.

  • Page 9: Features

    FEATURES INFO EAS00896 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 10: Fi System

    FEATURES INFO EAS00897 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kgf/cm , 35.6 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 11: O 2 Sensor

    FEATURES INFO sensor The O sensor has been adopted to enable the catalyst to function at a high degree of efficiency by maintaining the air-fuel mixture near the stoichiometric ratio (14.7:1). This sensor, which is a zirconia type, utilizes the oxygen ion conductivity of the solid electrolyte for detecting the oxygen concentra- tion levels.

  • Page 12: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but infe- rior in quality.

  • Page 13: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the...

  • Page 14: Equipment Preparation

    IMPORTANT INFORMATION INFO EAS00021 EQUIPMENT PREPARATION Turn Rivet (Turn type) Assembly status of the turn rivet(turn type). Dissembling 1. Press center pin1 inward to release the lock. 2. Remove the push rivet main body2. Assembling 1. Restore the center pin, replace the turn rivet main body.

  • Page 15: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector 2. Check: 8 lead 8 coupler 8 connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times.
  • Page 16 SPECIAL TOOLS INFO 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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.

  • Page 17: Special Tools

    SPECIAL TOOLS INFO Tool NO. Tool name / Function Illustration 90890-01189 Flywheel puller YM-01189 This tool is used for removing the AC mag- neto rotor. Fork seal driver weight 1 90890-01367 Fork seal driver attachment (Ø33mm) 2 YM-A9409-7 90890-01368 YM-A9409-4 These tools are used when installing the fork seal.
  • Page 18 SPECIAL TOOLS INFO Tool NO. Tool name / Function Illustration 90890-03141 Timing light YU-03141 This tool is used to check the ignition tim- ing. 90890-04101 Valve lapper This tool is needed to remove and install the valve lifters. 90890-04019 Valve spring compressor YM-04019 Compressor adapter (Ø19mm) 90890-04108...
  • Page 19 SPECIAL TOOLS INFO Tool NO. Tool name / Function Illustration 90890-85505 Yamaha bond NO.1215 ® ACC-11001-05-01 Sealant (Quick Gasket This sealant (bond) is used to apply on crankcase mating surfaces. 1-12...

  • Page 20: Spec

    SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS ..............2-2 CHASSIS SPECIFICATIONS ..............2-12 ELECTRICAL SPECIFICATIONS ............2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS ....... 2-18 TIGHTENING TORQUES................ 2-19 ENGINE .................... 2-19 CHASSIS ..................2-21 LUBRICATION POINTS AND LUBRICANT TYPES ......2-23 ENGINE ....................

  • Page 21: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model Code 32S1 (USA) … 32S2 (CAN) … Dimensions Overall length 1910mm (75.2in) … Overall width 765mm (30.1in) … Overall height 1110mm (43.7in) … Seat height 780mm (30.7in) … Wheelbase 1290mm (50.8in) …...

  • Page 22: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Standard Limit Item Engine Engine type Air-cooled, 4-stroke, SOHC … Displacement 0.125L (125cm , 7.63cu-in) … Cylinder arrangement Forward inclined … single cylinder Bore × stroke 52.4 × 57.9mm (2.06 × 2.28in) … Compression ratio 10:1 …...
  • Page 23 SPEC ENGINE SPECIFICATIONS Standard Limit Item Oil filter Oil filter type Wire mesh … Oil pump Oil pump type Trochoid … Inner rotor to outer rotor tip clearance 0.15mm (0.006in) or less 0.23mm (0.009in) Outer rotor to pump housing clearance 0.07 ~ 0.12mm 0.19mm (0.003 ~ 0.005in)
  • Page 24 SPEC ENGINE SPECIFICATIONS Standard Limit Item Camshaft Drive system Chain drive (left) … Intake camshaft lobe dimensions Measurement A 25.267 ~ 25.367mm 25.167mm (0.995 ~ 0.999in) (0.991in) Measurement B 21.069 ~ 21.169mm 20.969mm (0.829 ~ 0.833in) (0.826in) Exhaust camshaft lobe dimensions Measurement A 25.275 ~ 25.375mm 25.175mm...
  • Page 25 SPEC ENGINE SPECIFICATIONS Standard Limit Item Timing chain Model/number of links Morse 92RH2005/94 … Tensioning system Automatic … Valve, valve seats, valve guides Valve clearance (cold) Intake 0.10 ~ 0.14mm … (0.004 ~ 0.006in) Exhaust 0.16 ~ 0.20mm … (0.006 ~ 0.008in) Valve dimensions Head Diameter Face Width...
  • Page 26 SPEC ENGINE SPECIFICATIONS Standard Limit Item Valve stem to valve guide clearance Intake 0.015 ~ 0.042mm 0.08mm (0.0006 ~ 0.0017in) (0.0031in) Exhaust 0.030 ~ 0.057mm 0.1mm (0.0012 ~ 0.0022in) (0.0039in) Valve stem runout … 0.01mm (0.0004 in) Valve seat width Intake 0.9 ~ 1.1mm (0.035 ~ 0.043in) 1.6mm (0.063in)
  • Page 27 SPEC ENGINE SPECIFICATIONS Standard Limit Item Valve springs Free length Intake 41.88mm (1.649in) 39.786mm (1.566in) Exhaust 41.88mm (1.649in) 39.786mm (1.566in) Installed length (valve closed) Intake 30mm (1.18in) … Exhaust 30mm (1.18in) … Compressed spring force (installed) Intake 137 ~ 157N/mm …...
  • Page 28 SPEC ENGINE SPECIFICATIONS Standard Limit Item Piston Piston-to-cylinder clearance 0.010 ~ 0.035mm 0.15mm (0.0004 ~ 0.0014in) (0.0059in) Diameter D 52.375 ~ 52.390mm … (2.0620 ~ 2.0626in) Height H 7.0mm (0.28in) … Piston pin bore (in the piston) Diameter 15.002 ~ 15.013mm 15.043mm (0.5906 ~ 0.5911in) (0.5922in)
  • Page 29 SPEC ENGINE SPECIFICATIONS Standard Limit Item Oil ring Dimensions (B × T) 2.0 × 2.5mm … (0.0787 × 0.0984in) End gap (installed) 0.2 ~ 0.7mm … (0.0079 ~ 0.0276in) Ring side clearance 0.04 ~ 0.12mm … (0.0016 ~ 0.0047in)
  • Page 30 SPEC ENGINE SPECIFICATIONS Standard Limit Item Rocker arm/rocker arm shaft Rocker arm inside diameter 10.000 ~ 10.015mm … (0.3937 ~ 0.3943in) Rocker arm shaft outside diameter 9.981 ~ 9.991mm … (0.3930 ~ 0.3933in) Arm-to-shaft clearance 0.009 ~ 0.034mm … (0.0004 ~ 0.0013in) Connecting rod Connecting rod length 93.45 ~ 93.55mm...
  • Page 31 SPEC ENGINE SPECIFICATIONS Standard Limit Item Transmission Transmission type V-belt automatic … Primary reduction system Helical gear … Primary reduction ratio 40/15 (2.667) … Secondary reduction system Spur gear … Secondary reduction ratio 44/11 (4.0) … Single speed automatic 2.398 ~ 0.823:1 …...

  • Page 32: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Standard Limit Item Frame Frame type Steel tube underbone … Caster angle 27° … Trail 90mm (3.54in) … Front wheel Wheel type Cast wheel … Size J12 × MT2.75 … Material Aluminum … Wheel travel 78mm (3.07in) …...
  • Page 33 SPEC CHASSIS SPECIFICATIONS Standard Limit Item Rear tire Tire type Tubeless … Size 130/70-12 56L … Model (manufacturer) K761 (KENDA) … Tire pressure (cold) 0 ~ 90kg (0 ~ 198lb) 200kPa (2.0kgf/cm², 29psi) … 90kg (198lb)~ maximum load 225kPa (2.25kgf/cm², 33psi) …...
  • Page 34 SPEC CHASSIS SPECIFICATIONS Standard Limit Item Front suspension Suspension type Telescopic … Front fork type Coil spring/oil damper … Front fork travel 90mm (3.54in) … Spring Free length 252.1mm (9.93in) 247mm (9.72in) Installed length 230.9mm (9.09in) … Spring rate (K1) 7.1N/mm (0.72kgf/mm, …...

  • Page 35: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Standard Limit Item System voltage … Ignition system Ignition system type Transistorized coil ignition … Ignition timing 5° BTDC at 1800r/min … Advancer type Digital … Pickup coil resistance/color 248 ~ 372Ω at 20°C (68°F) …...
  • Page 36 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Electric starting system System type Constant mesh … Starter motor Model (manufacturer) 5S9 00 (T-MORIC) … Suction voltage … Power output 0.35kW … Brushes Overall length 10.0mm (0.39in) 3.5mm (0.14in) Quantity … Spring force 5.52 ~ 8.28N/mm …...
  • Page 37 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Fuel sender Model (manufacturer) 5S9 (AISAN) … Sender unit resistance-full 4 ~ 10Ω … Sender unit resistance-empty 90 ~ 100Ω … Fuel level gauge Gauge type (manufacture) Analog (CHAOLONG) … Starting circuit cut-off relay Model (manufacturer) 4HC1 (MATSU SHITA) …...

  • Page 38: General Tightening Torque Specifications

    SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

  • Page 39: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE Tightening Thread Part to be tightened ’ Part name torque Remarks size Nm m•kgf ft•lbf 15.9 Cylinder head and cylinder Spark plug Cylinder head (timing chain side) Bolt Exhaust pipe stud bolt Breather Bolt Valve cover Bolt Stopper plate (camshaft)
  • Page 40 SPEC TIGHTENING TORQUES Tightening Thread ’ Part to be tightened Part name torque Remarks Remarks size Nm m•kgf ft•lbf Plate (V-belt guide) Bolt Idle gear plate Bolt Plate Bolt Clutch housing 43.4 Primary fixed sheave 32.5 Starter motor Bolt AC magneto rotor 50.6 Stator coil Screw...

  • Page 41: Chassis

    SPEC TIGHTENING TORQUES CHASSIS Tightening Thread Part to be tightened torque Remarks size Nm m•kgf ft•lbf 23.1 Frame and engine bracket 2 Engine bracket 2, compression rod and engine 23.1 23.1 Compression rod and frame Sidestand (bolt and stand) Sidestand (bolt and nut) 28.9 16.6 Centerstand...
  • Page 42 SPEC TIGHTENING TORQUES 1. First, tighten the ring nut (lower) approximately 38Nm (3.8m • kgf, 27.5ft • lbf) by using the torque wrench, then loosen the ring nut 1/4 turn. 2. Second, tighten the ring nut (lower) approximately 14Nm (1.4m • kgf, 10.1ft • lbf) by using the torque wrench.
  • Page 43 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant Oil seal lips Bearings O-rings (except V-belt drive unit) O-rings (fuel injector) Cylinder head tightening nut mounting surface Cylinder head stud bolt thread Cylinder head nut Cylinder head gasket dowel pin Crankshaft pin outside surface Crankshaft journals...

  • Page 44: Lubrication Points And Lubricant Types

    Lubricant Main and drive axle serration (sprocket) Drive axle taper rollor bearing Transmission bearing Secondary fixed sheave inner surface ® BEL-RAY asembly lube ® Secondary sliding sheave torque cam ditch BEL-RAY asembly lube Crankcase mating surfaces Yamaha bond NO.1215 2-24...

  • Page 45: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Lubricant Engine mounting bolt Steering bearing and bearing races (upper and lower) Throttle grip inner surface and throttle cables Rear brake lever pivoting point and metal-to-metal moving parts Rear brake cable and brake lock lever (cable connection area) Front wheel oil seal Front wheel axle Speedometer gear unit...

  • Page 46: Cable Routing

    SPEC CABLE ROUTING i Engine temperature sensor lead EAS00035 CABLE ROUTING o Positive wire lead 1 Connector cover p Starter relay lead 2 Horn a Clamp (90464-25803) 3 Front bracket s Air shroud cylinder 2 4 Starting circuit cut-off relay d Rectifier/regulator 5 Turn signal relay f Body earth lead...
  • Page 47 SPEC CABLE ROUTING E Headlight relay lead passes by the right side R Turn signal relay lead passes under of the of inner fender rib. front bracket. F Start relay sub lead to forward. S After connecting, put the front signal light G Orientation: white tape.
  • Page 48 SPEC CABLE ROUTING 1 Rectifier/regulator B Brake hose passes through the left hole of 2 Body earth lead inner fender. 3 Horn C Locate the end of gasoline overflow pipe at 4 ECU between frame and air duct. 5 Headlight lead D Rear brake holder 2 holds the rear brake 6 Turn signal relay cable and covers the ultrasonic weld mark...
  • Page 49 SPEC CABLE ROUTING 1 Plain washer u Fuel hose 2 Lean angle cut-off switch i Ignition coil 3 Lean angle cut-off switch lead o Battery 4 FI diagnostic tool p Battery band 5 Hight tension cord a Clamp (90464-12812) 6 Fuel pump lead A Fasten the sidestand switch lead to the 7 Engine temperature sensor lead frame with a plastic locking tie, point the band...
  • Page 50 SPEC CABLE ROUTING F Ignition coil lead passes under the cross N After combining the couplers, insert them tube. into the sockets at tail/brake light. G Pass the throttle cable assembly through O Yellow mark to up of pipe 11. P Assembly range of starter motor negative wire guide.
  • Page 51 SPEC CABLE ROUTING 1 Rear brake cable u Rear brake light switch lead 2 Speedometer i Left lever holder lead 3 Front master cylinder o Turn signal light lead (left) 4 Brush guard (right) p Brake hose 5 Turn signal light (right) A Fasten the right handlebar switch lead, front 6 Throttle cable assembly brake light switch lead and right turn signal...

  • Page 52: Chk Adj

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..................3-1 PERIODIC MAINTENANCE AND ADJUSTMENT ......... 3-1 Periodic maintenance chart for the emission control system ... 3-1 Genela maintenance and lublication chart ........3-2 COVER AND PANEL ................3-4 SEAT AND TRUNK ................3-4 FOOTREST BOARD................
  • Page 53 CHECKING THE TIRES ..............3-43 CHECKING THE WHEELS.............. 3-46 CHECKING AND LUBRICATING THE CABLES ......3-46 LUBRICATING THE LEVERS ............3-47 LUBRICATING THE SIDESTAND ........... 3-47 LUBRICATING THE CENTERSTAND ..........3-47 LUBRICATING THE REAR SUSPENSION ........3-47 ELECTRICAL SYSTEM ................. 3-48 CHECKING AND CHARGING THE BATTERY.......

  • Page 54: Periodic Checks And Adjustments

    Fuel injection • Check engine idle speed. • Check for leakage. Exhaust system • Tighten if necessary. • Replace gasket(s) if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

  • Page 55: Genela Maintenance And Lublication Chart

    Every 18000 km (12000 mi) Front and rear brake • Check operation. switches Control and meter • Apply Yamaha chain and cable cables lube or engine oil thoroughly. • Check operation and free play. • Adjust the throttle cable free play if Throttle grip housing necessary.
  • Page 56 PERIODIC MAINTENANCE AND ADJUSTMENT * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 19000 km (12000 mi) or 36 months, repeat the maintenance intervals starting from 7000 km (4000 mi) or 12 months.

  • Page 57: Cover And Panel

    COVER AND PANEL EAS00038 COVER AND PANEL SEAT AND TRUNK 7Nm (0.7 m•kgf, 5.1 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks Removing the seat and trunk Remove the parts in the order listed. Seat Fuel tank cap cover Seat hinge Upper cover Trunk...

  • Page 58: Footrest Board

    COVER AND PANEL FOOTREST BOARD 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks Removing the footrest board Remove the parts in the order listed. Battery box cover Front cover Band Battery negative lead NOTICE Battery positive lead First, disconnect the negative battery Battery lead, and then the positive battery lead.
  • Page 59 COVER AND PANEL 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks Footrest board While installing, the fuse box should be installed to the correct position. For installation, reverse the removal pro- cedure.

  • Page 60: Leg Shield 1 Assembly And Leg Shield 2

    COVER AND PANEL LEG SHIELD 1 ASSEMBLY AND LEG SHIELD 2 7Nm (0.7 m•kgf, 5.1 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 9Nm (0.9 m•kgf, 6.5 ft•lbf) 23Nm (2.3 m•kgf, 16.6 ft•lbf) 14Nm (1.4 m•kgf, 10.1 ft•lbf) Order Job/Part Q’ty Remarks Removing the leg shield 1 assembly Remove the parts in the order listed.
  • Page 61 COVER AND PANEL 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks Disassembling the leg shield 1 as- Remove the parts in the order listed. sembly Panel Headlight cover Headlight assembly Panel (leg shield 1) Leg shield 1 For assembly, reverse the disassembly procedure.

  • Page 62: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. 8 Valve clearance adjustment should be made on a cold engine, at room temperature. 8 When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 63 ADJUSTING THE VALVE CLEARANCE c. Align the TDC mark c on the AC magneto rotor with the stationary pointer d on the crankcase. d. Measure the valve clearance with a thick- ness gauge. Out of specification Adjust. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Adjust: 8 valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 64 ADJUSTING THE VALVE CLEARANCE e. Measure the valve clearance again. f. If the valve clearance is still out of specifi- cation, repeat all of the valve clearance ad- justment steps until the specified clearance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: 8 breather 7Nm (0.7m •...

  • Page 65: Checking The Engine Idling Speed

    CHECKING THE ENGINE IDLING SPEED EAS00054 CHECKING THE ENGINE IDLING SPEED Prior to checking the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes.

  • Page 66: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY Prior to adjusting the throttle cable free play, the engine idling speed should be checked properly. 1. Check: 8 throttle cable free play a Out of specification Adjust.

  • Page 67: Adjusting The Seat Spring Force

    ADJUSTING THE SEAT SPRING FORCE ADJUSTING THE SEAT SPRING FORCE When open the seat and seat will not fold up automatically, adjust the spring force. 1. Remove: 8 seat 8 upper cover 2. Adjust: 8 screw 1 Direction a Spring force is increased. Direction b Spring force is decreased.

  • Page 68: Checking The Spark Plug

    CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Remove: 8 battery box cover 8 front cover Refer to “COVER AND PANEL”. 2. Disconnect: 8 spark plug cap WARNING Remove the spark plug cap, the engine is extremely hot. 3.
  • Page 69 CHECKING THE SPARK PLUG 8. Install: 8 spark plug 13Nm(1.3m • kgf, 9.4ft • lbf) Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: 8 spark plug cap 10. Install: 8 front cover 8 battery box cover Refer to “COVER AND PANEL”.

  • Page 70: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING EAS00062 CHECKING THE IGNITION TIMING Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: 8 battery box cover 8 front cover Refer to “COVER AND PANEL”.
  • Page 71 CHECKING THE IGNITION TIMING Engine idling speed 1700 ~ 1900r/min b. Check that the mark a on the AC magneto rotor is within the firing range b on the crankcase. Incorrect firing range Check the ignition system. The ignition timing is not adjustable. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 72: Measuring The Compression Pressure

    MEASURING THE COMPRESSION PRESSURE EAS00067 MEASURING THE COMPRESSION PRES- SURE Insufficient compression pressure will result in a loss of performance. 1. Measure: 8 valve clearance Out of specification Adjust Refer to “ADJUSTING THE VALVE CLEARANCE”. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 73 MEASURING THE COMPRESSION PRESSURE 7. Measure: 8 compression pressure Out of specification Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1175kPa(11.8kgf/cm , 167psi) at 1800r/min Standard 1350kPa(13.5kgf/cm , 192psi) at 1800r/min Maximum 1512kPa(15.1kgf/cm , 215psi) at 1800r/min ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 74 MEASURING THE COMPRESSION PRESSURE 8. Remove: 8 compression gauge 9. Install: 8 spark plug 13Nm(1.3m • kgf, 9.4ft • lbf) 10. Connect: 8 spark plug cap 11. Install: 8 front cover 8 battery box cover Refer to “COVER AND PANEL”. 3-21...

  • Page 75: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the scooter on a level surface. 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.

  • Page 76: Changing The Engine Oil

    CHANGING THE ENGINE OIL EAS00076 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: 8 engine oil filler cap 1 8 engine oil drain bolt 2 (along with the gasket) 4.
  • Page 77 CHANGING THE ENGINE OIL Quantity Total amount 0.85 ~ 0.95L (0.9 ~ 1.0 US qt, 0.75 ~ 0.84 Imp. qt) Periodic oil change 0.80 ~ 0.90L (0.87 ~ 0.98 US qt, 0.74 ~ 0.83 Imp. qt) 8. Install: 8 engine oil filler cap 9.

  • Page 78: Changing The Transmission Oil

    CHANGING THE TRANSMISSION OIL CHANGING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. 8 Stand the scooter on a suitable stand. 8 Make sure that the scooter upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.

  • Page 79: Measuring The Engine Oil Pressure

    MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: 8 engine oil level Below the minimum level mark Add the recommended engine oil to the proper level. Refer to”CHECKING THE ENGINE OIL LEVEL”. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 80 MEASURING THE ENGINE OIL PRESSURE c. Start the engine after solving the problem(s) and check the engine oil pressure again. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Tighten: 8 engine temperature sensor 18Nm(1.8m • kgf, 13.0ft • lbf) 8. Connect: 8 engine temperature sensor coupler 9.

  • Page 81: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: 8 air filter case cover 1 8 air filter element 2 2. Clean: 8 air filter element 1 Apply compressed air to the outer sur- face of the air filter element. 3.

  • Page 82: Cleaning The V-Belt Case Air Filter Element

    CLEANING THE V-BELT CASE AIR FILTER ELEMENT EAS00090 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: 8 V-belt case cover 8 V-belt case air filter guide 1 8 V-belt case air filter element 2 2. Clean: 8 V-belt case air filter element (with solvent) After cleaning, carefully pat the V-belt case air filter element on a clean cloth to remove the ex-...

  • Page 83: Checking The Throttle Body Joint And Intake Manifold

    CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD/CHECKING THE FUEL HOSE EAS00094 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 1. Remove: 8 seat 8 trunk 8 battery box cover 8 front cover Refer to “COVER AND PANEL”. 2. Remove: 8 fuel tank Refer to “REMOVING THE FUEL TANK”...

  • Page 84: Checking The Breather Hoses

    CHECKING THE FUEL HOSE/CHECKING THE BREATHER HOSES 2. Check: 8 fuel hose 1 Cracks/damage Replace. Loose connection Connect properly. 3. Install: 8 front cover 8 battery box cover 8 trunk 8 seat Refer to “COVER AND PANEL”. EAS00098 CHECKING THE BREATHER HOSES 1.

  • Page 85: Checking The Exhaust System

    CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler and gasket. 1. Remove: sensor coupler 8 muffler Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM” in chapter 4. 2. Check: 8 muffler 1 Crack/damage Replace.

  • Page 86: Checking The Canister And Roll Over Valve

    CHECKING THE CANISTER AND ROLL OVER VALVE CHECKING THE CANISTER AND ROLL OVER VALVE The following procedure applies to all of the can- ister and roll over valve. 1. Remove: 8 seat 8 trunk Refer to “COVER AND PANEL”. 2. Check: 8 hose (to throttle body) 1 8 hose (to roll over valve) 2 Cracks/damage...
  • Page 87 CHECKING THE CANISTER AND ROLL OVER VALVE 7. Check: 8 roll over valve ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the roll over valve. b. Put roll over valve with the vertical angle. c. Connect the hose to direction a and blow air in the hose. Unobstructed Normal.

  • Page 88: Chassis

    CHECKING THE FRONT BRAKE/ADJUSTING THE REAR BRAKE EAS00108 CHASSIS CHECKING THE FRONT BRAKE The brake lever free play is not adjustable. WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system.

  • Page 89: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVEL EAS00116 CHECKING THE BRAKE FLUID LEVEL 1. Stand the scooter on a level surface. 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Check: 8 brake fluid level Below the minimum level mark a the recommended brake fluid to the proper level.

  • Page 90: Checking The Front Brake Pads

    CHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKE SHOES/CHECKING THE FRONT BRAKE HOSE EAS00117 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: 8 front brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as a set.

  • Page 91: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00133 BLEEDING THE HYDRAULIC BRAKE SYS- WARNING Bleed the hydraulic brake system whenever: 8 8 8 8 8 the system is disassembled. 8 8 8 8 8 a brake hose is loosened, disconnected or replaced. 8 8 8 8 8 the brake fluid level is very low.
  • Page 92 BLEEDING THE HYDRAULIC BRAKE SYSTEM Loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle grip. h. Tighten the bleed screw and then release the brake lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.

  • Page 93: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD EAS00148 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. Place the scooter on a suitable stand so that the front wheel is elevated.
  • Page 94 CHECKING AND ADJUSTING THE STEERING HEAD Lower ring nut (initial tightening torque) 38Nm (3.8m • kgf, 27.5ft • lbf) c. Losen the lower ring nut completely and then tighten it to specification with a steering nut wrench. WARNING Do not over tighten the lower ring nut. Lower ring nut (final tightening torque) 14Nm (1.4m •...

  • Page 95: Checking The Front Fork

    CHECKING THE FRONT FORK EAS00151 CHECKING THE FRONT FORK 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Check: 8 inner tube Damage/scratches Replace. 8 oil seal Oil leakage Replace.

  • Page 96: Checking The Tires

    CHECKING THE TIRES EAS00163 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 8 tire pressure Out of specification Regulate. WARNING 8 8 8 8 8 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air tem- perature.
  • Page 97 The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one ap- proved by Yamaha is used on this scooter. 3-44...
  • Page 98 CHECKING THE TIRES Front tire Manufacturer Model Size KENDA K761 120/70-12 51L Rear tire Manufacturer Model Size KENDA K761 130/70-12 56L WARNING New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.

  • Page 99: Checking The Wheels

    CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: 8 wheel Damage/out-of-round Replace. WARNING Never attempt to make any repairs to the wheel. After a tire or wheel has been changed or re- placed, always balance the wheel.

  • Page 100: Lubricating The Levers

    LUBRICATING THE LEVERS/LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTERSTAND/LUBRICATING THE REAR SUSPENSION EAS00171 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant Lithium-soap-based grease EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand.

  • Page 101: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00179 ELECTRICAL SYSTEM CHECKING AND CHARGING 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: 8 8 8 8 8 Wear protective eye gear when handling or working near batteries.
  • Page 102 CHECKING AND CHARGING THE BATTERY Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the bat- tery terminals.
  • Page 103 CHECKING AND CHARGING THE BATTERY 8 No charging is necessary when the open- Relationship between the open-circuit voltage 13.0 and the charging time at 20˚C circuit voltage equals or exceeds 12.8 V. 12.5 b. Check the charge of the battery, as shown 12.0 in the charts and the following example.
  • Page 104 CHECKING AND CHARGING THE BATTERY 8 8 8 8 8 Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. 8 8 8 8 8 Make sure the battery charger lead clips are in full contact with the battery termi- nal and that they are not shorted.
  • Page 105 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Measure the open-circuit Ammeter Leave the battery unused for more voltage prior to charging. than 30 minutes before measuring its opencircuit voltage. Connect a charger and am- meter to the battery and Set the charging voltage to 16-17 V.
  • Page 106 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. Connect a charger and am- meter to the battery and start charging.
  • Page 107 CHECKING AND CHARGING THE BATTERY 6. Install: 8 battery 8 band 7. Connect: 8 battery leads (to the battery terminals) NOTICE First, connect the positive battery lead 1 1 1 1 1 , and then the negative battery lead 2 2 2 2 2 . 8.

  • Page 108: Checking The Fuses

    CHECKING THE FUSES EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. NOTICE To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: 8 battery box cover Refer to “COVER AND PANEL”.
  • Page 109 CHECKING THE FUSES Fuses Amperage rating Q’ty Main Headlight Signaling system Ignition Fuel injection sys- Reserve WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

  • Page 110: Replacing The Headlight Bulbs

    REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: 8 safeguard 8 leg shield 1 Refer to “COVER AND PANEL”. 2. Disconnect: 8 headlight coupler 3. Remove: 8 dust boot 8 headlight bulb holder 1 8 headlight bulb 2 WARNING...

  • Page 111: Adjusting The Headlight Beams

    ADJUSTING THE HEADLIGHT BEAMS EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: 8 headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the low beam light adjusting screw 1 in direction a or b. Direction a Headlight beam is raised.

  • Page 112: Chas

    CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC ............4-1 FRONT WHEEL ................. 4-2 REMOVING THE FRONT WHEEL ............ 4-3 CHECKING THE FRONT WHEEL ............ 4-4 CHECKING THE BRAKE DISC ............4-6 CHECKING THE SPEEDOMETER GEAR UNIT ......4-7 ASSEMBLING THE FRONT WHEEL ..........
  • Page 113 CHAS HANDLEBAR ..................4-49 REMOVING THE HANDLEBAR ............4-51 CHECKING THE HANDLEBAR ............4-52 INSTALLING THE HANDLEBAR............. 4-53 STEERING HEAD ................... 4-55 HANDLEBAR BRACKET AND FRONT BRACKET ....... 4-55 LOWER BRACKET ................4-56 REMOVING THE LOWER BRACKET ..........4-58 CHECKING THE STEERING HEAD ..........4-59 INSTALLING THE STEERING HEAD ..........

  • Page 114: Front Wheel And Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC EAS00513 CHASSIS FRONT WHEEL AND BRAKE DISC 4Nm (0.4 m•kgf, 2.9 ft•lbf) 70Nm (7.0 m•kgf, 50.6 ft•lbf) 23Nm (2.3 m•kgf, 16.6 ft•lbf) Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. disc Place the scooter on a suitable stand so that the front wheel is elevated.

  • Page 115: Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISK EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly procedure.

  • Page 116: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISK EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. Place the scooter on a suitable stand so that the front wheel is elevated.

  • Page 117: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISK EAS00525 CHECKING THE FRONT WHEEL 1. Check: 8 wheel axle Roll the wheel axle on a flat surface. Bends Replace. Wheel axle bending limit 0.25mm (0.01in) WARNING Do not attempt to straighten a bent wheel axle.
  • Page 118 CHAS FRONT WHEEL AND BRAKE DISK 5. Replace: 8 wheel bearings 8 oil seal ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver. To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface.

  • Page 119: Checking The Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISK EAS00528 CHECKING THE BRAKE DISC 1. Check: 8 brake disc Damage/galling Replace. 2. Measure: 8 brake disc deflection a Out of specification Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maxi- mum) 0.15mm (0.006in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 120: Checking The Speedometer Gear Unit

    CHAS FRONT WHEEL AND BRAKE DISK Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 23Nm (2.3m • kgf, 16.6ft • lbf) ® LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.

  • Page 121: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISK EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: 8 wheel axle 8 wheel bearings 8 oil seal lip 8 speedometer gear unit Recommended lubricant Lithium-soap-based grease 2. Install: 8 speedometer gear unit 1 Make sure the speedometer gear unit and the wheel hub are installed with the two projections 2 meshed into the speedmeter clutch 3 re- spectively.

  • Page 122: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISK EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE 8 After replacing the tire, wheel or both, the front wheel static balance should be ad- justed. 8 Adjust the front wheel static balance with the brake disc installed. 1.
  • Page 123 CHAS FRONT WHEEL AND BRAKE DISK 3. Adjust: 8 front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. Start with the lightest weight. b. Turn the front wheel 90° so that the heavy spot is positioned as shown.

  • Page 124: Rear Wheel And Rear Brake

    CHAS REAR WHEEL AND REAR BRAKE EAS00555 REAR WHEEL AND REAR BRAKE 10Nm (1.0 m•kgf, 7.2 ft•lbf) Order Job/Part Q’ty Remarks Removing the rear wheel and rear Remove the parts in the order listed. brake Place the scooter on a suitable stand so that the front wheel is elevated.
  • Page 125 CHAS REAR WHEEL AND REAR BRAKE 10Nm (1.0 m•kgf, 7.2 ft•lbf) Order Job/Part Q’ty Remarks Collar For installation, reverse the removal pro- cedure. 4-12...

  • Page 126: Removing The Rear Wheel

    CHAS REAR WHEEL AND REAR BRAKE EAS00564 REMOVING THE REAR WHEEL 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 127: Checking The Rear Wheel

    CHAS REAR WHEEL AND REAR BRAKE EAS00565 CHECKING THE REAR WHEEL 1. Check: 8tire 8rear wheel Damage/wear Replace. Refer to”CHECKING THE TIRES ”and” CHECKING THE WHEELS” in chapter 3. 2. Measure: 8radial wheel runout 8lateral wheel runout Refer to”CHECKING THE FRONT WHEEL”.

  • Page 128: Assembling The Brake Shoes

    CHAS REAR WHEEL AND REAR BRAKE 2. Measure: 8 brake shoe lining thickness a Out of specification Replace. Brake shoe lining thickness limit (minimum) 1.0mm (0.04in) WARNING Do not allow oil or grease to contact the brake shoes. Replace the brake shoes as a set, if either is worn to the wear limit.
  • Page 129 CHAS REAR WHEEL AND REAR BRAKE Lubricate the brake camshaft and O-rings with lithium-soap-based grease. WARNING After installing the brake camshaft and O- rings, remove any excess grease. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the brake camshaft so its punch mark a is positioned as shown. b.

  • Page 130: Installing The Rear Wheel

    CHAS REAR WHEEL AND REAR BRAKE EAS00574 INSTALLING THE REAR WHEEL 1. Lubricate: 8 wheel axle Recommended lubricant Lithium-soap-based grease 2. Install: 8 rear wheel 3. Install: 8 swingarm 8 wheel axle nut 1 8 muffler Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM”.

  • Page 131: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL AND REAR BRAKE EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE 8 After replacing the tire, wheel or both, the rear wheel static balance should be ad- justed. 8 Adjust the rear wheel static balance with the rear wheel drive hub installed. 1.

  • Page 132: Front Brake

    CHAS FRONT BRAKE EAS00576 FRONT BRAKE FRONT BRAKE PADS 49Nm (4.9 m•kgf, 35.4 ft•lbf) 13Nm (1.3 m•kgf, 9.4 ft•lbf) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Brake caliper Disconnect. Refer to “REPLACING Circlip THE FRONT BRAKE Brake pad retaining bolt...
  • Page 133 CHAS FRONT BRAKE EAS00579 NOTICE Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: 8 8 8 8 8 Never disassemble brake components unless absolutely necessary. 8 8 8 8 8 If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after...

  • Page 134: Replacing The Front Brake Pads

    CHAS FRONT BRAKE EAS00581 REPLACING THE FRONT BRAKE PADS When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Loosen: 8 brake pad retaining bolt 1 2. Remove: 8 brake caliper 2 3.
  • Page 135 CHAS FRONT BRAKE 6. Lubricate: 8 brake pad retaining bolt Recommended lubricant Silicone grease NOTICE 8 8 8 8 8 Do not allow grease to contact the brake pads. 8 8 8 8 8 Remove any excess grease. 7. Install: 8 brake pad retaining bolt 13Nm (1.3m •...

  • Page 136: Front Brake Master Cylinder

    CHAS FRONT BRAKE EAS00584 FRONT BRAKE MASTER CYLINDER 9Nm (0.9 m•kgf, 6.5 ft•lbf) 1.6Nm (0.16 m•kgf, 1.5 ft•lbf) 26Nm (2.6 m•kgf, 18.8 ft•lbf) Order Job/Part Q’ty Remarks Removing the front brake master cyl- Remove the parts in the order listed. inder Brush guard (right) Refer to “HANDLEBAR”.
  • Page 137 CHAS FRONT BRAKE EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Washer Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure. 4-24...

  • Page 138: Disassembling The Front Brake Master Cylinder

    CHAS FRONT BRAKE EAS00588 DISASSEMBLING THE FRONT BRAKE MAS- TER CYLINDER Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: 8 brush guard (right) Refer to “HANDLEBAR”. 2. Remove: 8 brake lever/compress spring 8 front brake light switch 8 union bolt 1 8 copper washers 2...

  • Page 139: Checking The Front Brake Master Cylinder

    CHAS FRONT BRAKE EAS00590 CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: 8 brake master cylinder 1 Damage/scratches/wear Replace. 8 brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air. 2. Check: 8 brake master cylinder kit 1 Damage/scratches/wear Replace.

  • Page 140: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT BRAKE EAS00597 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING 8 8 8 8 8 Before installation, all internal brake components should be cleaned and lu- bricated with clean or new brake fluid. 8 8 8 8 8 Never use solvents on internal brake components.
  • Page 141 CHAS FRONT BRAKE 3. Install: 8 copper washers 1 8 brake hose 2 8 union bolt 3 26Nm (2.6m • kgf, 18.8ft • lbf) NOTICE When installing the brake hose onto the brake master cylinder, make sure the brake hose touch the projection a a a a a on the brake master cylinder.
  • Page 142 CHAS FRONT BRAKE NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: 8 brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 6. Check: 8 brake fluid level Below the minimum level mark a the recommended brake fluid to the proper level.

  • Page 143: Front Brake Caliper

    CHAS FRONT BRAKE EAS00612 FRONT BRAKE CALIPER 26Nm (2.6 m•kgf, 18.8 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 49Nm (4.9 m•kgf, 35.4 ft•lbf) Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed. Brake fluid Drain.
  • Page 144 CHAS FRONT BRAKE EAS00614 Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. Brake pad Refer to “REPLACING THE FRONT Brake pad spring BRAKE PADS”. Brake caliper bracket Brake caliper piston Refer to “DISASSEMBLING THE Brake caliper dust seal FRONT BRAKE CALIPER”...

  • Page 145: Disassembling The Front Brake Caliper

    CHAS FRONT BRAKE EAS00619 DISASSEMBLING THE FRONT BRAKE CALIPER Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: 8 union bolt 1 8 copper washers 2 8 brake hose 3 Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 146: Checking The Front Brake Caliper

    CHAS FRONT BRAKE EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every two years Brake hose Every four years Brake fluid Every two years and whenever the brake is disassembled 1. Check: 8 brake caliper piston 1 Rust/scratches/wear Replace the...

  • Page 147: Assembling And Installing The Front Brake Caliper

    CHAS FRONT BRAKE EAS00637 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER WARNING 8 8 8 8 8 Before installation, all internal brake components should be cleaned and lu- bricated with clean or new brake fluid. 8 8 8 8 8 Never use solvents on internal brake components as they will cause the pis- ton seal to swell and distort.
  • Page 148 CHAS FRONT BRAKE 5. Install: 8 brake caliper 1 (temporarily) 8 copper washers 2 8 brake hose 3 8 union bolt 4 26Nm (2.6m • kgf, 18.8ft • lbf) 8 brake hose holder 1 7Nm (0.7m • kgf, 5.1ft • lbf) WARNING Proper brake hose routing is essential to insure safe scooter operation.
  • Page 149 CHAS FRONT BRAKE 8. Fill: 8 brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING 8 8 8 8 8 Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leakage and poor brake performance.
  • Page 150 CHAS FRONT BRAKE 11. Check: 8 brake lever operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4-37...

  • Page 151: Front Fork

    CHAS FRONT FORK EAS00646 FRONT FORK 26Nm (2.6 m•kgf, 18.8 ft•lbf) 5Nm (0.5 m•kgf, 3.6 ft•lbf) Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Leg shield 1 Refer to “COVER AND PANEL”...
  • Page 152 CHAS FRONT FORK EAS00648 20Nm (2.0 m•kgf, 14.5 ft•lbf) Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Clamp/boot Stopper ring Collar/O-ring Refer to “DISASSEMBLING THE Fork spring FRONT FORK LEGS”...
  • Page 153 CHAS FRONT FORK 20Nm (2.0 m•kgf, 14.5 ft•lbf) Order Job/Part Q’ty Remarks For assembly, reverse the disassembly procedure. 4-40...

  • Page 154: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00651 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. Place the scooter on a suitable stand so that the front wheel is elevated.

  • Page 155: Disassembling The Front Fork Legs

    CHAS FRONT FORK EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: 8clamp/boot 2. Remove: 8 cap 8stopper ring 8collar/O-ring 8fork spring 1 NOTICE The collar/O-ring and fork spring jump out after removing stopper ring.
  • Page 156 CHAS FRONT FORK Damper rod holder 90890-01294 (YM-01300-1) T-handle 90890-01326 (YM-01326) 5. Remove: 8 damper rod 1 8 rebound spring 8 inner tube 2 6. Remove: 8 oil seal clip 1 (with a flat-head screwdriver) NOTICE Do not scratch the inner tube. 7.

  • Page 157: Checking The Front Fork Legs

    CHAS FRONT FORK EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 8 inner tube 1 8 outer tube 2 Bends/damage/scratches Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

  • Page 158: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING 8 8 8 8 8 Make sure the oil levels in both front fork legs are equal. 8 8 8 8 8 Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 159 CHAS FRONT FORK While holding the damper rod assembly with the damper rod holder 2 and T-handle 3, tighten the damper rod assembly bolt. Damper rod holder 90890-01294 (YM-01300-1) T-handle 90890-01326 (YM-01326) 4. Install: 8 oil seal 1 (with the fork seal driver weight 2 and adapter 3) Fork seal driver weight 90890-01367 (YM-A9409-7)
  • Page 160 CHAS FRONT FORK 5. Install: 8 oil seal clip 1 Adjust the oil seal clip so that it fits into the outer tube’s groove. 6. Fill: 8 front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.104L (0.11 US qt, 0.09 Imp.

  • Page 161: Installing The Front Fork Legs

    CHAS FRONT FORK 8 Install the spring with the smaller pitch fac- ing down. 8 Before installing the collar, lubricate its O- ring with grease. 8 Press down the collar/O-ring, adjust the stopper ring so that it fits into the inner tube’s groove.

  • Page 162: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR 28Nm (2.8 m•kgf, 20.3 ft•lbf) 5Nm (0.5 m•kgf, 3.6 ft•lbf) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Leg shield 1 Refer to “COVER AND PANEL” in chap- Leg shield 2 ter 3.
  • Page 163 CHAS HANDLEBAR 28Nm (2.8 m•kgf, 20.3 ft•lbf) 5Nm (0.5 m•kgf, 3.6 ft•lbf) Order Job/Part Q’ty Remarks Upper handlebar holder Handlebar For installation, reverse the removal pro- cedure. 4-50...

  • Page 164: Removing The Handlebar

    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: 8 leg shield 1 8 leg shield 2 Refer to “COVER AND PANEL” in chap- ter 3.

  • Page 165: Checking The Handlebar

    CHAS HANDLEBAR EAS00668 CHECKING THE HANDLEBAR 1. Check: 8handlebar 1 Bends/cracks/damage Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken 4-52...

  • Page 166: Installing 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: 8 handlebar 1 8 upper handlebar holders 2 28Nm(2.8m • kgf, 20.3ft • lbf) NOTICE First, tighten the bolts on the front side of the handlebar holders, and then on the rear...
  • Page 167 CHAS HANDLEBAR 5. Install: 8 throttle grip assembly 1 8 throttle cable assembly 2 8 right handlebar switch 3 8 Lubricate the inside of the throttle grip as- sembly with a thin coat of lithium-soap- based grease and install it onto the handle- bar 4.

  • Page 168: Steering Head

    CHAS STEERING HEAD EAS00675 STEERING HEAD HANDLEBAR BRACKET AND FRONT BRACKET 4Nm (0.4 m•kgf, 2.9 ft•lbf) 4Nm (0.4 m•kgf, 2.9 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 48Nm (4.8 m•kgf, 34.7 ft•lbf) 60Nm (6.0 m•kgf, 43.4 ft•lbf) 9Nm (0.9 m•kgf, 6.5 ft•lbf) 16Nm (1.6 m•kgf, 11.6 ft•lbf) 4Nm (0.4 m•kgf, 2.9 ft•lbf) Order...

  • Page 169: Lower Bracket

    CHAS STEERING HEAD LOWER BRACKET 75Nm (7.5 m•kgf, 54.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 1st 38Nm (3.8 m•kgf, 27.5 ft•lbf) 2nd 14Nm (1.4 m•kgf, 10.1 ft•lbf) Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Leg shield 1 Refer to “COVER AND PANEL”...
  • Page 170 CHAS STEERING HEAD 75Nm (7.5 m•kgf, 54.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 1st 38Nm (3.8 m•kgf, 27.5 ft•lbf) 2nd 14Nm (1.4 m•kgf, 10.1 ft•lbf) Order Job/Part Q’ty Remarks Lower bearing Upper bearing outer race Lower bearing outer race Lower bearing inner race Dust seal For installation, reverse the removal pro- cedure.

  • Page 171: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00678 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: 8brake hose holder 2 8handlebar bracket 1 Remove the handlebar bracket by loosening the ring nut 2 gradually.

  • Page 172: Checking The Steering Head

    CHAS STEERING HEAD EAS00682 CHECKING THE STEERING HEAD 1. Wash: 8bearings 8bearing races Recommended cleaning solvent Kerosene 2. Check: 8bearings 1 8bearing races 2 Damage/pitting Replace. 3. Replace: 8bearings 8bearing races 8dust seal ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races from the steer- ing head pipe with a long rod 1 and ham- mer.

  • Page 173: Installing The Steering Head

    CHAS STEERING HEAD EAS00684 INSTALLING THE STEERING HEAD 1. Lubricate: 8 bearings 1 8 bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 8 lower ring nut 1 8 rubber washer 2 8 center ring nut 3 8 lock washer 4 8 upper ring nut 5 Refer to “CHECKING THE STEERING HEAD”...

  • Page 174: Rear Shock Absorber Assemblies And Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS00685 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 30Nm (3.0 m•kgf, 21.7 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 31Nm (3.1 m•kgf, 22.4 ft•lbf) 44Nm (4.4 m•kgf, 31.8 ft•lbf) 13Nm (1.3 m•kgf, 9.4 ft•lbf) 11 9 53Nm (5.3 m•kgf, 38.3 ft•lbf) 18Nm (1.8 m•kgf, 13.0 ft•lbf) 105Nm (10.5 m•kgf, 75.9 ft•lbf)

  • Page 175: Removing The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS00693 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 176: Installing The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS00699 INSTALLING THE REAR SHOCK AB- SORBER ASSEMBLIES 1. Install: 8 rear shock absorber assembly upper nuts 30Nm (3.0m • kgf, 21.7ft • lbf) 8 rear shock absorber assembly lower bolts 18Nm (1.8m • kgf, 13.0ft • lbf) EAS00702 REMOVING THE SWINGARM 1.

  • Page 177: Checking The Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS00708 CHECKING THE SWINGARM 1. Check: 8 swingarm Bends/cracks/damage Replace. 2. Check: 8 spacer 1 8 collar 2 8 oil seals 3 8 bearing 4 Damage/wear Replace. EAS00711 INSTALLING THE SWINGARM 1. Lubricate: 8 bearing 8 oil seal lips 8 rear wheel axle splines...
  • Page 178 REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM 4. Tighten: 8 exhaust pipe nut 13Nm (1.3m • kgf, 9.4ft • lbf) 8 muffler and swingarm bolt 31Nm (3.1m • kgf, 22.4ft • lbf) 8 muffler and swingarm bolt 53Nm (5.3m • kgf, 38.3ft • lbf) 5.

  • Page 179: Eng

    CHAPTER 5 ENGINE ENGINE REMOVAL .................. 5-1 LEADS AND HOSES ................. 5-1 ENGINE ....................5-3 INSTALLING THE ENGINE ............... 5-4 CYLINDER HEAD ..................5-5 REMOVING THE CYLINDER HEAD..........5-7 CHECKING THE CYLINDER HEAD ..........5-9 INSTALLING THE CYLINDER HEAD ..........5-10 THE ROCKER ARMS AND CAMSHAFT ..........
  • Page 180 CHECKING THE V-BELT ..............5-45 CHECKING THE PRIMARY SHEAVE ..........5-46 CHECKING THE PRIMARY SHEAVE WEIGHTS ......5-46 CHECKING THE SLIDER ..............5-47 CHECKING THE SECONDARY SHEAVE ........5-47 ASSEMBLING THE PRIMARY SHEAVE ........5-48 ASSEMBLING THE SECONDARY SHEAVE ......... 5-49 INSTALLING THE SECONDARY SHEAVE, V-BELT AND PRIMARY SHEAVE ..................

  • Page 181: Engine Removal

    ENGINE REMOVAL EAS00188 ENGINE ENGINE REMOVAL LEADS AND HOSES 3Nm (0.3 m•kgf, 2.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks Removing the leads and hoses Remove the parts in the order listed. Seat/trunk Battery box cover/front cover Refer to “COVER AND PANEL”...
  • Page 182 ENGINE REMOVAL 3Nm (0.3 m•kgf, 2.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks TEM” in chapter 7. Rear brake cable holder Spark plug cap Disconnect. Engine temperature sensor coupler Disconnect. Air filter/breather hose For installation, reverse the removal pro- cedure.
  • Page 183 ENGINE REMOVAL EAS00191 ENGINE 18Nm (1.8 m•kgf, 13.0 ft•lbf) 32Nm (3.2 m•kgf, 23.1 ft•lbf) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. Place a suitable stand under the frame and engine. Rear fender Rear shock absorber assembly lower bolt Engine mounting nut/washer Refer to “INSTALLING THE ENGINE”.

  • Page 184: Installing The Engine

    ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: 8 engine 1 8 engine mounting bolt 2 8 engine mounting nut 3 8 Apply lithium-soap-based grease to the unthreaded portion of the engine mounting bolt shaft. 8 Do not fully tighten the engine mounting bolt..

  • Page 185: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD 8Nm (0.8 m•kgf, 5.8 ft•lbf) 9Nm (0.9 m•kgf, 6.5 ft•lbf) 10Nm (1.0 m•kgf, 7.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 13Nm (1.3 m•kgf, 9.4 ft•lbf) 18Nm (1.8 m•kgf, 13.0 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 12Nm (1.2 m•kgf, 8.7 ft•lbf) 30Nm (3.0 m•kgf, 21.7 ft•lbf) 22Nm (2.2 m•kgf, 15.9 ft•lbf)
  • Page 186 CYLINDER HEAD 8Nm (0.8 m•kgf, 5.8 ft•lbf) 9Nm (0.9 m•kgf, 6.5 ft•lbf) 10Nm (1.0 m•kgf, 7.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 13Nm (1.3 m•kgf, 9.4 ft•lbf) 18Nm (1.8 m•kgf, 13.0 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 12Nm (1.2 m•kgf, 8.7 ft•lbf) 30Nm (3.0 m•kgf, 21.7 ft•lbf) 22Nm (2.2 m•kgf, 15.9 ft•lbf) Order...

  • Page 187: Removing The Cylinder Head

    CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Remove : 8 air guide 8 air shroud cylinder 3 Refer to “STARTER CLUTCH AND AC MAGNETO”. 8 V-belt case Refer to “BELT DRIVE”. 8 muffler Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM” in chapter 4.
  • Page 188 CYLINDER HEAD 6. Remove: 8 timing chain tensioner (along with the gasket) 8 camshaft sprocket bolt 1 8 camshaft sprocket plate 2 8 camshaft sprocket 3 8 timing chain 4 To prevent the timing chain from falling into the crankcase, fasten it with a wire. 7.

  • Page 189: Checking The Cylinder Head

    CYLINDER HEAD EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: 8 combustion chamber carbon deposits (with a rounded scraper) Do not use a sharp instrument to avoid damag- ing or scratching: 8 spark plug bore thread 8 valve seats 2. Check: 8 cylinder head Damage/scratches Replace.

  • Page 190: Installing The Cylinder Head

    CYLINDER HEAD EAS00231 INSTALLING THE CYLINDER HEAD 1. Install: 8 gasket 8 dowel pins 2. Install: 8 cylinder head 3. Tighten: 8 cylinder head nuts 22 Nm (2.2 m • kgf, 15.9 ft • lbf) 8 cylinder head bolts 12 Nm (1.2 m • kgf, 8.7 ft • lbf) 8 Lubricate the cylinder head nuts with en- gine oil.
  • Page 191 CYLINDER HEAD 8 When installing the camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side. 8 Align the slot on the camshaft with the tab in the camshaft sprocket. NOTICE Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing.
  • Page 192 CYLINDER HEAD Cap bolt 8 Nm (0.8 m • kgf, 5.8 ft • lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Turn: 8crankshaft (several turns counterclockwise) 8. Check: 8“I” mark a Align the “I” mark on the AC magneto ro- tor with the stationary pointer b on the crankcase.

  • Page 193: The Rocker Arms And Camshaft

    THE ROCKER ARMS AND CAMSHAFT THE ROCKER ARMS AND CAMSHAFT 7Nm (0.7 m•kgf, 5.1 ft•lbf) 12Nm (1.2 m•kgf, 8.7 ft•lbf) Order Job/Part Q’ty Remarks Removing the rocker arms and cam- Remove the parts in the order listed. shaft Cylinder head Refer to “CYLINDER HEAD”.

  • Page 194: Removing The Rocker Arms And Camshaft

    THE ROCKER ARMS AND CAMSHAFT EAS00202 REMOVING THE ROCKER ARMS AND CAM- SHAFT 1. Remove: 8 locknut 1 8 stopper plate 2 2. Remove: 8 intake rocker arm shaft 8 exhaust rocker arm shaft 8 intake rocker arm 8 exhaust rocker arm Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2 .

  • Page 195: Checking The Camshaft

    THE ROCKER ARMS AND CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: 8camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft. 2. Measure: 8camshaft lobe dimensions a and b Out of specification Replace the cam- shaft. Camshaft lobe dimension limit Intake a a a a a 25.267 ~ 25.367mm (0.995 ~0.999in) <Limit>:25.167mm (0.991in) b b b b b 21.069 ~ 21.169mm (0.829...

  • Page 196: Checking The Rocker Arms And Rocker Arm Shafts

    THE ROCKER ARMS AND CAMSHAFT EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: 8rocker arm (camshaft touch surface)1 8rocker arm (valve touch surface)2 Damage/wear Replace.

  • Page 197: Checking The Timing Chain, Camshaft Sprocket And Timing Chain Guides

    THE ROCKER ARMS AND CAMSHAFT Above 0.034mm (0.0013in) Replace the de- fective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.034mm (0.0004 ~ 0.0013in) EAS00207 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES The following procedure applies to all of the cam- shaft sprocket and timing chain guides.

  • Page 198: Checking The Timing Chain Tensioner

    THE ROCKER ARMS AND CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: 8 timing chain tensioner Cracks/damage Replace. 2. Check: 8 one-way cam operation Rough movement Replace the timing chain tensioner. 3. Check: 8 cap bolt 8 O-ring 8 spring 8 one-way cam 8 gasket 8 timing chain tensioner rod...

  • Page 199: Installing The Camshaft And Rocker Arms

    THE ROCKER ARMS AND CAMSHAFT EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 8 camshaft 1 Recommended lubricant Camshaft Engine oil Camshaft bearing Engine oil 2. Lubricate: 8 rocker arms 8 rocker arm shafts Recommended lubricant Molybdenum disulfide oil 3.
  • Page 200 THE ROCKER ARMS AND CAMSHAFT 5. Install: 8 stopper plate 1 8 locknut 2 12Nm (1.2m • kgf, 8.7ft • lbf) 5-20...

  • Page 201: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Rocker arms Refer to “REMOVING THE ROCKER Rocker arm shafts ARMS AND CAMSHAFT”...
  • Page 202 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks For installation, reverse the removal pro- cedure. 5-22...

  • Page 203: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.

  • Page 204: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 3 . Remove: 8 valve spring retainer 1 8 valve spring 2 8 valve stem seal 3 8 valve 4 Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES...
  • Page 205 VALVES AND VALVE SPRINGS 2. Replace: 8 valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100°C (212°F) in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover 1.
  • Page 206 VALVES AND VALVE SPRINGS 5. Measure: 8 valve margin thickness a Out of specification Replace the valve. Valve margin thickness (intake) 0.7mm (0.028in) Valve margin thickness (exhaust) 1.0mm (0.039in) 6. Measure: 8 valve stem runout Out of specification Replace the valve. 8 When installing a new valve, always replace the valve guide.

  • Page 207: Checking The Valve Seats

    VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: 8 carbon deposits (from the valve face and valve seat) 2. Check: 8 valve seat Pitting/wear Replace the cylinder head. 3.
  • Page 208 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound a to the valve face. NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem.

  • Page 209: Checking The Valve Springs

    VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: 8 valve spring free length a Out of specification Replace the valve spring. Valve spring free length 41.88mm (1.649in) <Limit>: 39.786mm (1.566in) 2.

  • Page 210: Installing The Valves

    VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 8 valve stem end (with an oil stone) 2. Lubricate: 8 valve stem 1 8 valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...
  • Page 211 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 (YM-04019) Valve spring compressor attach- ment 90890-04108 (YM-04108) 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. NOTICE Hitting the valve tip with excessive force could damage the valve.

  • Page 212: Cylinder And Piston

    CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Timing chain guide (exhaust side) Cylinder Dowel pin Cylinder gasket Piston pin clip Refer to “REMOVING THE CYLINDER Piston pin AND PISTON”...

  • Page 213: Removing The Cylinder And Piston

    CYLINDER AND PISTON EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 3 NOTICE Do not use a hammer to drive the piston pin out. 8 Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.

  • Page 214: Checking The Cylinder And Piston

    CYLINDER AND PISTON EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: 8 piston wall 8 cylinder wall Vertical scratches Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: 8 piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
  • Page 215 CYLINDER AND PISTON e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” - Piston skirt diameter “P” Piston-to-cylinder clearance 0.010 ~ 0.035mm (0.0004 ~0.0014in) <Limit>: 0.15mm (0.0059in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

  • Page 216: Checking The Piston Rings

    CYLINDER AND PISTON EAS00263 CHECKING THE PISTON RINGS 1. Measure: 8 piston ring side clearance Out of specification Replace the pis- ton and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 217: Checking The Piston Pin

    CYLINDER AND PISTON EAS00265 CHECKING THE PISTON PIN 1. Check: 8 piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system. 2. Measure: 8 piston pin outside diameter a Out of specification Replace the pis- ton pin. Piston pin outside diameter 14.995 ~ 15.000mm (0.5904 ~0.5906in)

  • Page 218: Checking The Timing Chain Guide (Exhaust Side)

    CYLINDER AND PISTON CHECKING THE TIMING CHAIN GUIDE (EX- HAUST SIDE) 1. Check: 8 timing chain guide (exhaust side) Damage/wear Replace EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: 8 oil ring expander 8 oil ring rail 8 2nd ring 8 top ring Be sure to install the piston rings so that the manufacturer’s marks or numbers a face up.
  • Page 219 CYLINDER AND PISTON 3. Install: 8 gasket 8 dowel pins 4. Lubricate: 8 piston 8 piston rings 8 cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: 8 piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Exhaust side...

  • Page 220: Belt Drive

    BELT DRIVE EAS00316 BELT DRIVE V-BELT CASE 7Nm (0.7 m•kgf, 5.1 ft•lbf) 11Nm (1.1 m•kgf, 8.0 ft•lbf) (x8) 10Nm (1.0 m•kgf, 7.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks Removing the V-belt case Remove the parts in the order listed.

  • Page 221: V-Belt Case

    BELT DRIVE V-BELT AND PRIMARY/SECONDARY SHEAVE 60Nm (6.0 m•kgf, 43.2 ft•lbf) 45Nm (4.5 m•kgf, 32.5 ft•lbf) Order Job/Part Q’ty Remarks Removing the V-belt and primary/sec- Remove the parts in the order listed. ondary sheave V-belt case Refer to “V-BELT CASE”. Primary fixed sheave nut/plate washer Refer to “REMOVING THE PRIMARY Oneway clutch...

  • Page 222: Secondary Sheave

    BELT DRIVE SECONDARY SHEAVE 90Nm (9.0 m•kgf, 7.2 ft•lbf) Order Job/Part Q’ty Remarks Disassembling the secondary Disassemble the parts in the order listed. sheave Clutch carrier nut Clip Plate Clutch shoe spring Clutch shoe Damper Clutch carrier Compression spring Spring seat Guide pin Secondary sliding sheave O-ring...

  • Page 223: Removing The Primary Sheave

    BELT DRIVE EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: 8 V-belt case 8 Refer to “V-BELT CASE”. 2. Remove: 8 primary fixed sheave nut 1 8 plate washer 8 oneway clutch 8 primary fixed sheave 2 While holding the primary fixed sheave with the rotor holding tool 3, loosen the primary fixed sheave nut.

  • Page 224: Disassembling The Secondary Sheave

    BELT DRIVE While holding the clutch carrier with the rotor holding tool 2, loosen the clutch carrier nut one full turn with the locknut wrench 3. Rotor holding tool 90890-01235 (YU-01235) Locknut wrench 90890-01348 (YM-01348) 3. Remove: 8 secondary sheave 1 8 V-belt 2 Remove the V-belt and secondary sheave from the primary sheave side.

  • Page 225: Checking The V-Belt

    BELT DRIVE After sanding the glazed areas, clean the clutch with a cloth. 2. Measure: 8 clutch shoe thickness Out of specification Replace the clutch shoes and springs as a set. Clutch shoe thickness 3.2 ~ 3.5mm (0.13 ~ 0.14in) <Limit>: 2.0mm (0.079in) 8 Inspect clutch shoes a.

  • Page 226: Checking The Primary Sheave

    BELT DRIVE CHECKING THE PRIMARY SHEAVE 1. Check: 8 primary sliding sheave 1 8 primary fixed sheave 2 Cracks/damage/wear Replace the pri- mary sliding sheave, primary fixed sheave and V-belt. 2. Check: 8free movement Stick or excessive play Replace the primary sliding sheave, collar or both.

  • Page 227: Checking The Slider

    BELT DRIVE CHECKING THE SLIDER 1. Check: 8 slider 1 Damage/wear Replace EAS00322 CHECKING THE SECONDARY SHEAVE 1. Check: 8secondary fixed sheave 8secondary sliding sheave Cracks/damage/wear Replace the sec- ondary fixed and sliding sheaves as a set. 2. Check: 8torque cam groove 1 Damage/wear Replace the secondary fixed and sliding sheaves as a set.

  • Page 228: Assembling The Primary Sheave

    BELT DRIVE EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 Use thinner to clean up grease, dirt on the pri- mary sliding sheave cam side 5. 2. Install: 8primary sheave weights 1 8collar 2 3.

  • Page 229: Assembling The Secondary Sheave

    BELT DRIVE EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: 8 secondary fixed sheave’s inner surface 8 secondary sliding sheave’s inner surface 8 oil seals 8 bearings (with the recommended lubricant) Recommended lubricant ® BEL-RAY assembly lube 2. Install: 8 secondary sliding sheave 1 Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide Oil seal guide...

  • Page 230: Installing The Secondary Sheave, V-Belt And Primary Sheave

    BELT DRIVE 5. Install: 8 secondary sheave 1 8 spring 8 clutch carrier 2 Attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch carrier nut 5. Clutch spring holder 90890-01337 (YM-33285) EAS00325...
  • Page 231 BELT DRIVE Rotor holding tool 90890-01235 (YU-01235) Locknut wrench 90890-01348 (YM-01348) 3. Install: 8 clutch housing 1 8 secondary sheave nut 2 60Nm(6.0m • kgf, 43.4ft • lbf) Tighten the secondary sheave nut with the sheave holder 3. Sheave holder 90890-01701 (YS-01880-A) 4.
  • Page 232 BELT DRIVE 5. Position: 8 V-belt 1 Position the V-belt in the primary sheave 2 (when the pulley is at its widest position) and in the secondary sheave 3 (when the pulley is at its narrowest position), and make sure the V- belt is tight.

  • Page 233: Starter Clutch And Ac Magneto

    STARTER CLUTCH AND AC MAGNETO EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY 7Nm (0.7 m•kgf, 5.1 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 10Nm (1.0 m•kgf, 7.2 ft•lbf) 70Nm (7.0 m•kgf, 50.6 ft•lbf) 9Nm (0.9 m•kgf, 6.5 ft•lbf) Order Job/Part Q’ty Remarks...

  • Page 234: Starter Clutch

    STARTER CLUTCH AND AC MAGNETO EAS00342 STARTER CLUTCH 10Nm (1.0 m•kgf, 7.2 ft•lbf) 10Nm (1.0 m•kgf, 7.2 ft•lbf) Order Job/Part Q’ty Remarks Removing the starter clutch Remove the parts in the order listed. Refer to “V-BELT CASE”. V-belt case Primary fixed sheave Refer to “V-BELT AND PRIMARY/SEC- Primary sliding sheave ONDARY SHEAVE”.

  • Page 235: Removing The Ac Magneto

    STARTER CLUTCH AND AC MAGNETO EAS00347 REMOVING THE AC MAGNETO 1. Remove: 8 air guide 8 air shroud cylinder 3 2. Remove: 8 fan 8 AC magneto rotor nut 1 8 washer While holding the AC magneto rotor 3 with the rotor holding tool 2, loosen the AC magneto ro- tor nut.

  • Page 236: Checking The Starter Clutch

    STARTER CLUTCH AND AC MAGNETO EAS00351 CHECKING THE STARTER CLUTCH 1. Check: 8starter clutch roller Damage/wear Replace. 2. Check: 8starter clutch idle gear 8starter wheel gear Burrs/chips/roughness/wear Replace the defective part(s). 3. Check: 8starter wheel gear’s contacting surfaces Damage/pitting/wear Replace the starter wheel gear.

  • Page 237: Installing The Ac Magneto

    STARTER CLUTCH AND AC MAGNETO EAS00354 INSTALLING THE AC MAGNETO 1. Install: 8 stator coil assembly 8 crankshaft position sensor 8 woodruff key 8 AC magneto rotor 8 washer 8 AC magneto rotor nut 8 Clean the tapered portion of the crankshaft and the AC magneto rotor hub.

  • Page 238: Oil Pump

    OIL PUMP EAS00360 OIL PUMP 13Nm (1.3 m•kgf, 9.4 ft•lbf) 4Nm (0.4 m•kgf, 2.9 ft•lbf) 13Nm (1.3 m•kgf, 9.4 ft•lbf) Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed. AC magneto rotor Refer to “STARTER CLUTCH AND AC Stator coil assembly MAGNETO”.

  • Page 239: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: 8 oil pump drive gear 8 oil pump driven gear 1 8 oil pump housing 8 oil pump housing cover Cracks/damage/wear Replace the defective part(s). 2. Measure: 8 inner-rotor-to-outer-rotor-tip clearance a 8 outer-rotor-to-oil-pump-housing clearance Out of specification Replace the oil...

  • Page 240: Assembling The Oil Pump

    OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: 8 inner rotor 8 outer rotor 8 oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 8 oil pump shaft 1 (to the oil pump housing 2) 8 pin 3 8 inner rotor 4 8 outer rotor 5...

  • Page 241: Transmission

    TRANSMISSION EAS00419 TRANSMISSION 10Nm (1.0 m•kgf, 7.2 ft•lbf) Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Transmission oil Drain. Muffler Refer to “REAR SHOCK ABSORBER Swingarm ASSEMBLIES AND SWINGARM” in chapter 4. Rear wheel Refer to “REAR WHEEL AND REAR BRAKE”...

  • Page 242: Checking The Transmission

    TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Measure: 8 main axle runout (with a centering device and dial gauge ) Out of specification Replace the main axle. Main axle runout limit 0.04mm (0.002in) 2. Measure: 8 drive axle runout (with a centering device and dial gauge ) Out of specification Replace the drive axle.

  • Page 243: Crankshaft

    CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 13Nm (1.3 m•kgf, 9.4 ft•lbf) (x7) (x2) 20Nm (2.0 m•kgf, 14.5 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 23Nm (2.3 m•kgf, 16.6 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed.
  • Page 244 CRANKSHAFT 13Nm (1.3 m•kgf, 9.4 ft•lbf) (x7) (x2) 20Nm (2.0 m•kgf, 14.5 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 23Nm (2.3 m•kgf, 16.6 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks Timing chain guide (intake side) Crankcase (right) Oil seal Crankshaft assembly Timing chain Oil seal...

  • Page 245: Disassembling The Crankcase

    CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 8 centerstand 2. Remove: 8 crankcase bolts 1 Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 3.

  • Page 246: Removing The Crankshaft Assembly

    CRANKSHAFT EAS00389 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: 8 crankshaft assembly 1 8 timing chain 2 8 Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. 8 The crankshaft assembly cannot be re- moved if the timing chain is attached onto the crankshaft sprocket.

  • Page 247: Checking The Crankcase

    CRANKSHAFT 3. Measure: 8 crankshaft width Out of specification Replace the crank- shaft. Crankshaft width 45.45 ~ 45.50mm (1.789 ~ 1.791in) 4. Check: 8crankshaft sprocket 1 Damage/wear Replace the crankshaft. 8bearing 2 Cracks/damage/wear Replace the crankshaft. 8oil pump drive gear 3 Damage/wear Replace the crankshaft.

  • Page 248: Checking The Timing Chain And Timing Chain Guide(Intake Side)

    CRANKSHAFT EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE(INTAKE SIDE) 1. Check: 8 timing chain Damage/stiffness Replace the timing chain and camshaft sprocket as a set. 2. Check: 8 timing chain guide (intake side) Damage/wear Replace. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1.

  • Page 249: Installing The Crankshaft Assembly

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: 8 sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (ACC-11001-05-01) Do not allow any sealant to come into contact with the oil gallery. 5-69...
  • Page 250 CRANKSHAFT 3. Install: 8 dowel pins 8 right crankcase 1 Tap lightly on the right crankcase with a soft- face hammer. 4. Tighten: 8crankcase bolts 13Nm(1.3m • kgf, 9.4ft • lbf) Tighten the crankcase bolts in stages and in a crisscross pattern.
  • Page 251 CHAPTER 6 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ..............6-1 WIRING DIAGRAM ................6-2 ECU’S SELF-DIAGNOSTIC FUNCTION .......... 6-4 CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB ................... 6-5 SELF-DIAGNOSTIC FANCTION TABLE........... 6-5 TROUBLESHOOTING CHART ............6-7 DIAGNOSTIC MODE ................. 6-8 TROUBLESHOOTING DETAILS.............

  • Page 252: Fuel Injection System

    FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 ECU q Air filter case 2 Engine trouble warning light w Catalytic converter 3 Lean angle cut-off switch e Crankshaft position sensor 4 Fuel hose r Engine temperature sensor 5 Ignition coil t Spark plug 6 Fuel injector...

  • Page 253: Wiring Diagram

    FUEL INJECTION SYSTEM WIRING DIAGRAM...
  • Page 254 FUEL INJECTION SYSTEM 1 Crankshaft position sensor 4 Main fuse 5 Fuel injection system fuse 6 Battery q Main switch w Sidestand switch t Engine stop switch y Ignition fuse u Signaling system fuse s Engine trouble warning light d Speed sensor , Ignition coil .

  • Page 255: Ecu's Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 256: Checking For A Defective Engine Trouble Warning Light Bulb

    FUEL INJECTION SYSTEM EAS00901 CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB The engine trouble warning light comes on for 2 seconds after the main switch has been turned “ON” and when the start switch is being pushed. If the warning light does not come on under these condi- tions, the warning light bulb may be defective.
  • Page 257 FUEL INJECTION SYSTEM Fault Engine Vehicle Item Symptom code No. startability driveability Fuel injector Fuel injector open or short circuit is de- Unable Unable tected. Lean angle cut-off switch The vehicle has overturned. Unable Unable (latch up detected) (open or Lean angle cut-off switch-open or short cir- short circuit) cuit is detected.

  • Page 258: Troubleshooting Chart

    FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. *Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. The engine trouble warning light does not come on.

  • Page 259: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators with con- necting the Fl diagnostic tool to the normal mode or the diagnostic monitoring mode. Fl diagnostic tool 90890-03182 (YU-03182) Setting the normal mode The engine speed, engine temperature, and fault...
  • Page 260 FUEL INJECTION SYSTEM Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the self diag signal connector 1, and then connect the Fl diagnostic-tool 2 as shown. 3. While press the “MODE” button, turn the main switch to “ON”. 8 ”DIAG”...
  • Page 261 FUEL INJECTION SYSTEM Fault code table Fault Symptom Probable cause of malfunction Diagnostic code codeNo. No normal signals are received from • Open or short circuit in wiring harness. the crankshaft position sensor. • Defective crankshaft position sensor. • Malfunction in pickup rotor. •...
  • Page 262 FUEL INJECTION SYSTEM EAS00907 Diagnostic mode table 8 Check the intake air temperature and engine temprature as close as possible to the intake air temperature sensor and the engine temperature sensor respectively. 8 If it is not possible to check the intake air temperature, use the ambient temperature as refer- ence.
  • Page 263 FUEL INJECTION SYSTEM Communication error with the FI diagnostic tool LCD Display Sympton Probable cause of malfunction Waiting for connec- No signals are received from the • Improper installed lead connector in the coupler. tion... ECU. • The main switch is OFF position. •...
  • Page 264 FUEL INJECTION SYSTEM Symptom No normal signals are received from the crankshaft position sensor. Fault code No. Used diagnostic code No. -- Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Installed condition of sensor. Check the installed area for looseness or Reinstated by crank- pinching.
  • Page 265 FUEL INJECTION SYSTEM Symptom Intake air pressure sensor-open or short circuit detected. Fault code No. Used diagnostic code No. D03 (intake air pressure sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, reper it and connect Reinstated by turn- nector...
  • Page 266 FUEL INJECTION SYSTEM Intake air pressure sensor system malfunction Fault code No. Symptom Intake air pressure- sensor hose system malfunction (clogged or de- (clogged or detached). tached hose). Used diagnostic code No. D03 (intake air pressure sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure...
  • Page 267 FUEL INJECTION SYSTEM Symptom Stuck throttle position sensor detected. Fault code No. Used diagnostic code No. D01 (throttle position sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Installed condition of throttle Check the installed area for looseness or Reinstated by start- position sensor.
  • Page 268 FUEL INJECTION SYSTEM Symptom Intake air temperature sensor open or short circuit is detected. Fault code No. Used diagnostic code No. D05 (intake air temperature sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Installed condition of sensor Check the installed area for looseness or Reinstated by turn- pinching.
  • Page 269 FUEL INJECTION SYSTEM Symptom No normal signal is received from the O sensor. Fault code No. Used diagnostic code No. -- Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Defective O sensor. Replace if defective. Reinstated by start- ing the engine, oper- Open or short circuit in wiring...
  • Page 270 FUEL INJECTION SYSTEM Symptom The vehicle has overturned. Fault code No. Used diagnostic code No. D08 (lean angle cut-off switch) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method The vehicle has overturned. Raise the vehicle upright. Reinstated by turn- ing the main switch Installed condition of the lean...
  • Page 271 FUEL INJECTION SYSTEM Symptom Open circuit detected in the primary lead of the ignition coil. Fault codeNo. Used diagnostic code No. D30 Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect Reinstated by start- nector it securely.
  • Page 272 FUEL INJECTION SYSTEM Symptom Fuel injector open or short circuit is detected. Fault code No. Used diagnostic code No. D36 (fuel injector) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect Reinstated by start- nector it securely.
  • Page 273 FUEL INJECTION SYSTEM Symptom No normal signals are received from the speed sensor. Fault code No. Used diagnostic code No. D07 (speed sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of speed- If there is a malfunction, repair it and connect Reinstated by input- ometer connector...
  • Page 274 FUEL INJECTION SYSTEM Power supply to the fuel injector, fuel pump and ignistion coil are not Symptom Fault code No. normal. Used diagnostic code No. D09 (fuel system voltage) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect...
  • Page 275 FUEL INJECTION SYSTEM Symptom Power supply to FI system is not normal. (red lead) Fault code No. Used diagnostic code No. -- Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect Reinstated by start- nector it securely.
  • Page 276 FUEL INJECTION SYSTEM Symptom ISC (idle speed control) valve open or short circuit is detected. Fault code No. Used diagnostic code No. D54 (ISC (idle speed control)valve) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect Reinstated by set-...

  • Page 277: Throttle Body And Fuel Injector

    THROTTLE BODY AND FUEL INJECTOR EAS00909 THROTTLE BODY AND FUEL INJECTOR FUEL TANK 10Nm (1.0 m•kgf, 7.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 4Nm (0.4 m•kgf, 2.9 ft•lbf) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Place the scooter on a suitable stand.

  • Page 278: Fuel Tank

    THROTTLE BODY AND FUEL INJECTOR 10Nm (1.0 m•kgf, 7.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 4Nm (0.4 m•kgf, 2.9 ft•lbf) Order Job/Part Q’ty Remarks Fuel pump Refer to “REMOVING THE FUEL PUMP” and “INSTALLING THE FUEL PUMP”. Fuel tank Refer to “REMOVING THE FUEL TANK” and “INSTALLING THE FUEL TANK AND FUEL HOSE”.

  • Page 279: Fuel Injector And Fuel Hose

    THROTTLE BODY AND FUEL INJECTOR FUEL INJECTOR AND FUEL HOSE 12Nm (1.2 m•kgf, 8.7 ft•lbf) 10Nm (1.0 m•kgf, 7.2 ft•lbf) 7Nm (0.7m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty Remarks Removing the fuel injector and fuel Remove the parts in the order listed. hose Fuel tank Refer to “REMOVING THE FUEL TANK”.

  • Page 280: Throttle Body

    THROTTLE BODY AND FUEL INJECTOR THROTTLE BODY 5Nm (0.5 m•kgf, 3.6 ft•lbf) 3Nm (0.3 m•kgf, 2.2 ft•lbf) Order Job/Part Q’ty Remarks Removing the throttle body Remove the parts in the order listed. Air filter/breather hose Refer to “ENGINE REMOVAL” in chap- ter 5.

  • Page 281: Removing The Fuel Tank

    THROTTLE BODY AND FUEL INJECTOR REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove : 8 fuel return hose 8 fuel hose 1 NOTICE 8 8 8 8 8 Be sure to disconnect the fuel hose by hand.

  • Page 282: Removing The Fuel Pump

    THROTTLE BODY AND FUEL INJECTOR REMOVING THE FUEL PUMP 1. Remove: 8 fuel tank Refer to “REMOVING THE FUEL TANK”. 2. Remove: 8fuel pump NOTICE 8 8 8 8 8 Do not drop the fuel pump or give it a strong shock.

  • Page 283: Checking The Fuel Injector

    THROTTLE BODY AND FUEL INJECTOR EAS00912 CHECKING THE FUEL INJECTOR 1. Check: 8 fuel injector Damage Replace. EAS00913 CHECKING THE THROTTLE BODY 1. Check: 8 throttle body Cracks/damage Replace the throttle body. 2. Check: 8 butterfly valve Damage/scratches/wear Replace. NOTICE 8 8 8 8 8 Do not adjust the stop screw 1 1 1 1 1 .

  • Page 284: Installing The Fuel Pump

    THROTTLE BODY AND FUEL INJECTOR INSTALLING THE FUEL PUMP 1. Install : 8 fuel pump 4Nm (0.4m • kgf, 2.9ft • lbf) 8 Do not damage the installion surface of the fuel tank when installing the fuel pump. 8 Always use a new fuel pump gasket. 8 Align the projection a on the fuel pump with the alignment mark b on the fuel tank.

  • Page 285: Checking The Fuel Pump And Pressure Regulator Operation

    THROTTLE BODY AND FUEL INJECTOR EAS00915 CHECKING THE FUEL PUMP AND PRES- SURE REGULATOR OPERATION 1. Check: 8 pressure regulator operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the battery box cover and front cover. Refer to “COVER AND PANEL” in chapter b. Remove the fuel hose 1 from the fuel pump. NOTICE Although the fuel has been removed from the fuel tank, be careful when removing the...

  • Page 286: Checking The Throttle Position Sensor

    THROTTLE BODY AND FUEL INJECTOR EAS0091 6 CHECKING THE THROTTLE POSITION SEN- 1. Check: P/W Br/W 8 throttle position sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester to the ter- minals of the throttle position sensor. blue terminal 1 1 1 1 1 Positive tester probe Negative tester probe black/blue...

  • Page 287: Checking The Isc (Idle Speed Control) Valve

    THROTTLE BODY AND FUEL INJECTOR EAS00916 CHECKING THE ISC (IDLE SPEED CON- TROL) VALVE Do not remove the ISC (idle speed control) valve unit completely from the throttle body assembly. 1. Check: 8 ISC (idle speed control) valve ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ISC (idle speed control) valve coupler from the ISC (idle speed con- trol) valve.

  • Page 288: Elec

    ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ..............7-1 WIRING DIAGRAM ................... 7-2 CHECKING SWITCH CONTINUITY ............7-4 CHECKING THE SWITCHES ..............7-5 CHECKING THE BULBS AND BULB SOCKETS ........7-6 TYPES OF BULBS ................7-6 CHECKING THE CONDITION OF THE BULBS ....... 7-6 CHECKING THE CONDITION OF THE BULB SOCKETS ....

  • Page 289: Electrical System

    ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Main switch q Spark plug cap 2 Front brake light switch w Fuel pump 3 Rectifier/regulator e Starter relay 4 Rear brake light switch r Horn 5 Sidestand switch t Turn signal relay 6 Battery y Starting circuit cut-off relay 7 Main fuse...

  • Page 290: Wiring Diagram

    ELEC WIRING DIAGRAM WIRING DIAGRAM...
  • Page 291 ELEC WIRING DIAGRAM 1 AC magneto Color Code 2 Rectifier/regulator B ....Black 3 Body earth Br ....Brown 4 Main fuse Ch ....Chocolate 5 Fuel injection system fuse Dg ....Dark green 6 Battery G ....Green 7 Wire lead Gy ....

  • Page 292: Checking Switch Continuity

    ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. NOTICE Never insert the tester probes into the coupler terminal slots a a a a a .

  • Page 293: Checking The Switches

    ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.

  • Page 294: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly con- nect.

  • Page 295: Checking The Condition Of The Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS NOTICE 8 8 8 8 8 Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the ter- minal in the coupler. 8 8 8 8 8 Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass,...
  • Page 296 ELEC CHECKING THE BULBS AND BULB SOCKETS Pocket tester 90890-03112 (YU-03112-C) Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. b.

  • Page 297: Ignition System

    ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 1 Crankshaft position sen- 4 Main fuse 6 Battery q Main switch w Sidestand switch t Engine stop switch y Ignition fuse , Ignition coil . Spark plug @ ECU # Lean angle cut-off switch...

  • Page 298: Troubleshooting

    ELEC IGNITION SYSTEM EAS00736 EAS00738 TROUBLESHOOTING 1.Main and ignition fuses 8 Check the main and ignition fuses for conti- The ignition system fails to operate (no nuity. spark or intermittent spark). Refer to “CHECKING THE FUSES” in chap- ter 3. Check: 8 Are the main and ignition fuses OK? main and ignition fuses...
  • Page 299 ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance 8 Disconnect the spark plug cap from the spark 8 Remove the spark plug cap from the spark plug. plug lead. 8 Connect the pocket tester (“Ω × 1k” range) 8 Connect the ignition checker 1 as shown.
  • Page 300 ELEC IGNITION SYSTEM EAS00748 7. Crankshaft position sensor resistance 8 Disconnect the crankshaft position sensor coupler from the wire harness. 8 Connect the pocket tester (Ω × 100) to the crankshaft position sensor coupler as shown. white/red 1 1 1 1 1 Positive tester probe white/blue 2 2 2 2 2 Negative tester probe...
  • Page 301 ELEC IGNITION SYSTEM EAS00749 11. Lean angle cut-off switch 8. Main switch 8 Remove the lean angle cut-off switch. 8 Check the main switch for continuity. 8 Connect the pocket tester (Ω × 1) to the Refer to “CHECKING THE SWITCHES”. lean angle cut-off switch terminals as shown.
  • Page 302 ELEC IGNITION SYSTEM EAS00754 12. Wiring 8 Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. 8 Is the ignition system’s wiring properly con- nected and without defects? Replace the ECU. Properly connect or repair the ignition system’s wiring. 7-14...

  • Page 303: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 4 Main fuse 6 Battery 7 Wire lead 8 Starter relay 9 Starter motor 0 Starting circuit cut-off relay q Main switch w Sidestand switch r Start switch t Engine stop switch y Ignition fuse u Signaling system fuse j Front brake light switch...

  • Page 304: Starting Circuit Cut-Off System Operation

    ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OP- ERATION If the engine stop switch is set to “#” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: 8 The brake lever (front or rear) is pulled to the handlebar (the brake light switch is...

  • Page 305: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00738 TROUBLESHOOTING 1.Main, signal and ignition fuses 8 Check the main, signal and ignition fuses for The starter motor fails to turn. continuity. Refer to “CHECKING THE FUSES” in chap- Check: ter 3. main, signal and ignition fuses 8 Are the main, signal and ignition fuses OK? battery starter motor...
  • Page 306 ELEC ELECTRIC STARTING SYSTEM EAS00758 EAS00759 3. Starter motor 4. Starting circuit cut-off relay 8 Connect the positive battery terminal 1 and 8 Disconnect the starting circuit cut-off relay starter motor lead 2 with a jumper lead 3. coupler from the wire harness. 8 Connect the pocket tester (Ω...
  • Page 307 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 5. Starter relay 7. Engine stop switch 8 Disconnect the starter relay coupler from the 8 Check the engine stop switch for continuity. coupler. Refer to “CHECKING THE SWITCHES”. 8 Connect the pocket tester (Ω × 1) and bat- 8 Is the engine stop switch OK? tery (12 V) to the starter relay coupler as shown.
  • Page 308 ELEC ELECTRIC STARTING SYSTEM EAS00764 10. Start switch 8 Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the start switch OK? Replace the right handlebar switch. EAS00766 11. Wiring 8 Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”.
  • Page 309 ELEC ELECTRIC STARTING SYSTEM EAS00767 STARTER MOTOR 7Nm (0.7 m•kgf, 5.1 ft•lbf) 4Nm (0.4 m•kgf, 2.9 ft•lbf) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Seat/trunk Refer to “COVER AND PANEL” in chap- ter 3.
  • Page 310 ELEC ELECTRIC STARTING SYSTEM 7Nm (0.7 m•kgf, 5.1 ft•lbf) 4Nm (0.4 m•kgf, 2.9 ft•lbf) Order Job/Part Q’ty Remarks For assembly, reverse the disassembly procedure. 7-22...

  • Page 311: Checking The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Check: 8 commutator Dirt Clean with 600-grit sandpaper. 2. Measure: 8 commutator diameter a Out of specification Replace the starter motor. Commutator wear limit 21 mm (0.83in) 3. Measure: 8 mica undercut b Out of specification Scrape the mica to the proper measurement with a hack-...
  • Page 312 ELEC ELECTRIC STARTING SYSTEM 5. Measure: 8 brush length a Out of specification Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14in) 6. Measure: 8 brush spring force Out of specification Replace the brush springs as a set. Brush spring force 5.52 ~ 8.28 N/mm (0.56 ~ 0.84kgf/ mm, 1.24 ~ 1.86lbf/in)

  • Page 313: Assembling The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: 8 brush spring 8 brush 1 2. Install: 8 armature 8 starter motor front cover 1 8 O-ing 2 8 stator 3 8 O-ing 4 8 starter motor rear cover 5 3.

  • Page 314: Charging System

    ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 1 AC magneto 2 Rectifier/regulator 3 Body earth 4 Main fuse 6 Battery 7-26...

  • Page 315: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. The battery is not being charged. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: main fuse Minimum open-circuit voltage battery 12.8 V or more at 20°C (68°F) charging voltage stator coil resistance 8 Is the battery OK?
  • Page 316 ELEC CHARGING SYSTEM EAS00779 5. Wiring Make sure the battery is fully charged. 8 Check the wiring connections of the entire charging system. 8Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”. 8 Is the charging system’s wiring properly con- nected and without defects? The charging circuit is Replace the rectifier/...

  • Page 317: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 4 Main fuse 6 Battery q Main switch e Headlight relay i Headlight fuse p Speedometer light a High beam indica- tor light ; Dimmer switch x Headlight m Tail/brake light @ ECU 7-29...

  • Page 318: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. Any of the following fail to light: headlight, Refer to “CHECKING AND CHARGING high beam indicator light, taillight or meter THE BATTERY” in chapter 3. light.

  • Page 319: Checking The Lighting System

    ELEC LIGHTING SYSTEM EAS00788 5. Headlight relay CHECKING THE LIGHTING SYSTEM 8 Disconnect the headlight relay coupler from 1. The headlight and the high beam indicator the wire harness. light fail to come on. 8 Connect the pocket tester (Ω × 1) and bat- tery (12 V) to the headlight relay coupler as 1.
  • Page 320 ELEC LIGHTING SYSTEM 3. Voltage 8 Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light cou- The wiring circuit from This circuit is OK. plers as shown. the main switch to the headlight coupler or AWhen the dimmer switch is set to “%”...
  • Page 321 ELEC LIGHTING SYSTEM EAS00789 2. Voltage 2. The meter light fails to come on. 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as 1. Meter light bulb and socket shown. 8 Check the meter light bulb and socket for continuity.
  • Page 322 ELEC LIGHTING SYSTEM EAS00790 3. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket 8 Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Are the tail/brake light bulb and socket OK? Replace the tail/brake light bulb, socket or both.

  • Page 323: Signaling System

    ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 4 Main fuse 6 Battery q Main switch u Signaling system fuse o Fuel level gauge f Turn signal indicator light g Horn h Turn signal relay j Front brake light switch k Rear brake light switch l Horn switch z Turn signal switch...

  • Page 324: Troubleshooting

    ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. 8 8 8 8 8 Any of the following fail to light: turn sig- Refer to “CHECKING AND CHARGING nal light, brake light or an indicator light. THE BATTERY”...

  • Page 325: Checking The Signaling System

    ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 8 Disconnect the pink connector at the horn 1. The horn fails to sound. terminal. 8 Connect a jumper lead 1 to the horn termi- 1. Horn switch nal and ground the jumper lead. 8 Check the horn switch for continuity.
  • Page 326 ELEC SIGNALING SYSTEM EAS00798 3. Voltage 2. The tail/brake light fails to come on. 8 Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) 1. Tail/brake light bulb and socket as shown. 8 Check the tail/brake light bulb and socket for continuity.
  • Page 327 ELEC SIGNALING SYSTEM EAS00799 4. Voltage 3. The turn signal light, turn signal indicator light 8 Connect the pocket tester (DC 20 V) to the or both fail to blink. turn signal relay coupler (wire harness side) as shown. 1. Turn signal indicator light bulb and socket 8 Check the turn signal indicator light bulb and brown 1 1 1 1 1 Positive tester probe...
  • Page 328 ELEC SIGNALING SYSTEM 5. Voltage 6. Voltage 8 Connect the pocket tester (DC 20 V) to the 8 Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) turn signal light coupler or meter assembly as shown.
  • Page 329 ELEC SIGNALING SYSTEM EAS00804 2. Voltage 4. The fuel level gauge fails to operate. 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as 1. Fuel sender shown. 8 Remove the fuel pump from the fuel tank. 8 Connect the pocket tester (Ω...
  • Page 330 ELEC SIGNALING SYSTEM 3. Fuel level gauge 8 Set the main switch to “ON”. 8 Move the float up 1 or down 2. 8 Check that the fuel level gauge needle moves to “F” or “E”. Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes.

  • Page 331: Trbl Shtg

    TRBL SHTG CHAPTER 8 TROUBLE SHOOTING STARTING FAILURE/HARD STARTING..........8-1 ENGINE ....................8-1 FUEL SYSTEM .................. 8-1 ELECTRICAL SYSTEMS ..............8-1 INCORRECT ENGINE IDLING SPEED ........... 8-2 ENGINE ....................8-2 FUEL SYSTEM .................. 8-2 ELECTRICAL SYSTEMS ..............8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......8-2 ENGINE ....................

  • Page 332: Troubleshooting

    TRBL STARTING FAILURE/HARD STARTING SHTG EAS00844 TROUBLESHOOTING The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.

  • Page 333: Incorrect Engine Idling Speed

    TRBL INCORRECT ENGINE IDLING SPEED/POOR MEDIUM- SHTG AND-HIGH-SPEED PERFORMANCE EAS00847 EAS00848 INCORRECT ENGINE IDLING POOR MEDIUM-AND-HIGH- SPEED SPEED PERFORMANCE ENGINE Refer to “STARTING FAILURE/HARD START- Cylinder and cylinder head ING”. 8 Incorrect valve clearance 8 Damaged valve train components ENGINE Air filter 8 Clogged air filter element Air filter...

  • Page 334: Faulty Clutch

    TRBL FAULTY CLUTCH/OVERHEATING SHTG 8 Worn primary pulley weight EAS00853 FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL Primary fixed sheave NOT MOVE 8 Worn primary fixed sheave V-belt Primary sliding sheave 8 Bent, damaged or worn V-belt 8 Worn primary sliding sheave 8 Slipping V-belt Secondary fixed sheave Primary pulley cam and primary pulley slider...

  • Page 335: Poor Braking Performance

    POOR BRAKING PERFORMANCE/FAULTY FRONT TRBL FORK LEGS/UNSTABLE HANDLING SHTG EAS00859 EAS00862 POOR BRAKING PERFORMANCE UNSTABLE HANDLING Disc brake Handlebar 8 Worn brake pad 8 Bent or improperly installed handlebar 8 Worn brake disc 8 Air in hydraulic brake system Steering head components 8 Leaking brake fluid 8 Improperly installed handlebar bracket 8 Faulty brake caliper kit...

  • Page 336: Faulty Lighting Or Signaling System

    TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 TURN SIGNAL REMAINS LIT FAULTY LIGHTING OR SIGNALING 8 Faulty turn signal relay 8 Burnt-out turn signal bulb SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL BLINKS QUICKLY 8 Wrong headlight bulb 8 Incorrect turn signal bulb 8 Too many electrical accessories 8 Faulty turn signal relay...
  • Page 337 YW125Y WIRING DIAGRAM 1 AC magneto 2 Rectifier/regulator 3 Body earth 4 Main fuse 5 Fuel injection system fuse 6 Battery 7 Wire lead 8 Starter relay 9 Starter motor 0 Starting circuit cut-off relay q Main switch w Sidestand switch e Headlight relay r Start switch t Engine stop switch...
  • Page 338 Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, ON M2H 3B4...

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