EAS00002 NOTICE This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
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EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
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EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. Symbols 1 to 9 indicate the subject of each chapter. i g l General information CHAS (3^3^) Specifications ADJ I ^ < \ Periodic checks and adjustments Chassis Engine Cooling system COOL j K...
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EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO 0 » SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM ELECTRICAL SYSTEM ELEC TROUBLESHOOTING SHTG...
j y * INFO \<^® CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER MODEL LABEL FEATURES OUTLINE OF THE FI SYSTEM FI SYSTEM IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS EQUIPMENT PREPARATION...
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 trunk. This information will be needed to order spare parts.
FEATURES 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.
FEATURES 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 kg/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.
IMPORTANT INFORMATION EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISAS- SEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together.
IMPORTANT INFORMATION 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...
IMPORTANT INFORMATION INFO EAS00021 EQUIPMENT PREPARATION Push Rivet (Push type) Assembly status of the push rivet(push type). Dissembling 1. Press center p i n 1 inward to release the lock. <D 2. Remove the push rivet main body2. Assembling 1. Restore the center pin, replace the push rivet main body.
CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8lead 8coupler 8connector 2. Check: • lead • coupler • connector Moisture -» Dry with an air blower. Rust/stains -» Connect and disconnect several times.
SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
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SPECIAL TOOLS Tool NO. Tool name / Function Illustration 90890-01384 Oil seal guide YM-33299 This tool is used for protecting the oil seal lip when installing the secondary sliding sheave. 90890-01403 Steering nut wrench YU-A9472 This tool is used to loosen and tighten the steering ring nut.
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SPECIAL TOOLS Tool NO. Tool name / Function Illustration 90890-03141 Timing light YU-03141 This tool is used to check the ignition tim- ing. 90890-03182 FI diagnostic tool YU-03182 Execute CO adjustment, confirm fault Code, self diagnosis tool 90890-04101 Valve lapper This tool is needed to remove and install the valve lifters.
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SPEC ENGINE SPECIFICATIONS Standard Limit Item Piston Piston-to-cylinder clearance 0.010~0.035mm 0.150mm (0.0004~0.0014in) (0.0059in) Diameter D 37.975~37.990mm … (1.4951~1.4957in) "X. -D— Height H 5.0mm(0.1969in) … Piston pin bore(in the piston) Diameter 10.002~10.013mm 10.043mm (0.3938~0.3942in) (0.3954in) 0.35~0.65mm … Offset (0.0138~0.0256in) Intake side Offset direction …...
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SPEC ENGINE SPECIFICATIONS Standard Limit Item Oil ring Dimensions(B×T) 1.5×1.6mm … (0.0591×0.0630in) End gap(installed) 0.2~0.7mm … (0.0079~0.0276in) Ring side clearance 0.03~0.15mm … (0.0012~0.0059in)
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SPEC ENGINE SPECIFICATIONS Standard Limit Item Rocker arm/rocker arm shaft 10.000~10.015mm 10.030mm Rocker arm inside diameter (0.3937~0.3943in) (0.3949in) 9.981~9.991mm 9.950mm Rocker arm shaft outside diameter (0.3930~0.3933in) (0.3917in) 0.009~0.034mm … Arm-to-shaft clearance (0.0004~0.0013in) Connecting rod Connecting rod length 79.95~80.05mm … (3.1476~3.1516in) Small end inside diameter 10.015~10.028mm …...
SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Standard Limit Item System voltage … Ignition system Ignition system type Transistorized coil ignition … Ignition timing 5° BTDC at 2000~2200r/min … Advancer type Digita … Crankshaft position sensor resistance/color 248~372 at 20°C(68°F)/ … white/red-white/blue Ignition coil Model(manufacturer) 3B3 00(T-MORIC)
CONVERTION TABLE / GENERAL TIGHTENING SPEC TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE Tightening Thread Thread ’ ’ Part to be tightened Part to be tightened Part name Part name torque Remarks Remarks size size m»kg ft»lb Exhaust pipe stud bolt Oil check bolt Cylinder head cover Bolt Cylinder head and cylinder —4\\4jl...
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SPEC TIGHTENING TORQUES Tightening Thread Thread ’ ’ Part to be tightened Part to be tightened Part name Part name torque Remarks Remarks size size m»kg ft»lb Drain bolt(engine oil) 2.3 16.6 Centerstand spring Hook Starter clutch 9.0 65.1 Left-hand thread Kickstarter Bolt Primary fixed sheave...
SPEC 0*" TIGHTENING TORQUES CHASSIS Tightening Thread Thread Part to be tightened Part to be tightened torque Remarks Remarks size size m»kg ft»lb Frame and engine bracket3 33.1 Engine bracket3 and engine 42.0 Handlebar bracket and steering shaft 43.4 Rear shock absorber and frame 21.7 Rear shock absorber and engine 11.6...
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SPEC TIGHTENING TORQUES NOTE : 1. First,tighten the upper bearing inner race approximately 7Nm(0.7m»kg, 5.1ft»lb) by using the torque wrench and check turn steering shaft smoothly. 2. Second,hold the upper bearing inner race and tighten the ring nut 30Nm(3.0m»kg, 21.7ft»lb) by using the torque wrench.
SPEC 0*" LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Lubricant ^^LSp^L Front wheel oil seal lips ^^LSp^L Steering bearing and bearing races(upper and lower) Frame head pipe dust seal lips(lower) ^ ^ T L S ^ ^ ^ L Tube guide(throttle grip) inner surface ^ L S ^ ^ A ^^LSpn...
SPEC COOLING SYSTEM DIAGRAMS EAS00033 Insert until contacting with the latch of ra- COOLING SYSTEM DIAGRAMS diator tank. Raidator cap Install white paint marck of pipe 3 toward Coolant reservoir hose the direction of radiator cover. Radiator inlet hose Install clip for the turning knob to face for- Air bleed bolt ward.
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SPEC COOLING SYSTEM DIAGRAMS Radiator Install clip for the turning knob to face down- Radiator inlet hose ward. Radiator outlet hose Thermostat Water pump outlet hose 2-27...
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SPEC COOLING SYSTEM DIAGRAMS Thermostat assembly inlet breather hose Install the paint mark of hose facing up. Breather hose Install clip for the turning knob to face down- Water pump outlet hose ward. Radiator outlet hose Make sure that hose is inserted to the bot- Water pump tom.
SPEC CABLE ROUTING EAS00035 Battery positive lead hole of down tube 1 . CABLE ROUTING Wire lead cover Fix connector cover on the Assemble cramp on the T- head light stay. Hose3 stud at the right of back Install the protruding part of stay.
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SPEC CABLE ROUTING Speedometer After wiring the cover, Install the horn of coupler Rectifier/Regulator cover the coupler. accotding to the direction Turn signal relay Enter tail/brake light. shown in the drawing, and Throttle cable Ass’y After fixing the rear brake make sure that it is not Holder cable, fix crank case 1 .
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SPEC CABLE ROUTING Fuel pump Rear fender Put the idle speed control FI diagnostic tool connec- Fuel injector lead lead and wire sub lead in, Sub-wire harness lead and then close the cramp. Fuse box ISC(idle speed control) Wire the starting device of Battery negative lead valve lead the rear fender of rear mo-...
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SPEC CABLE ROUTING Speedometer Penetrate the rear brake Penetrate the main switch Rectifier/Regulator cable and throttle cable Comp. Lead into the con- Horn through the left side of car nector cover. Turn signal relay body. Penetrate horn cable Front brake cable Make sure to install the through the connector Rear brake cable...
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SPEC CABLE ROUTING Let the left and right flasher lights, meter, and right lead wire of handle bar switch to face upward, let the main switch, front and rear brake switchand left lead wire of handle bar switch to face downward, connect to the coupler, and then store in the connector cover.
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SPEC CABLE ROUTING Turn signal light lead(right) Penetrate the rear brake Enter rectifier and regulator Handlebar switch cable and throttle cable Ass’y. lead(right) through the left side of car First, tighting the backward Front brake light switch body. screw and tighting the for- lead Make sure to install the ward screw.
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< & CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE CHART FOR THE EMISSION CON- TROL SYSTEM GENERAL MAINTENANCE AND LUBRICATION CHART COVER AND PANEL SIDE COVERS AND TAIL/BRAKE LIGHT SINGLE SEAT AND TRUNK LEG SHIELD1,2 FOOTREST BOARD AND INNER FENDER ENGINE...
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< & CHECKING THE WHEELS 3-48 CHECKING AND LUBRICATING THE CABLES 3-48 LUBRICATING THE LEVERS AND PEDALS 3-49 LUBRICATING THE CENTERSTAND 3-49 ELECTRICAL SYSTEM 3-50 CHECKING AND CHARGING THE BATTERY 3-50 CHECKING THE FUSE 3-56 REPLACING THE HEADLIGHT BULB 3-58 ADJUSTING THE HEADLIGHT BEAM 3-59...
INTRODUCTION < & EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INITIAL ODOMETER READING 600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi 10,000 mi (1,000 km) (4,000 km) (7,000 km) (10,000 km) (13,000 km) (16,000 km) ITEM...
PERIODIC MAINTENANCE AND MINOR REPAIR < & GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READING 600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi 10,000 mi (1,000 km) (4,000 km) (7,000 km) (10,000 km) (13,000 km) (16,000 km) ITEM ROUTINE month months...
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PERIODIC MAINTENANCE AND MINOR REPAIR < & Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 12000mi(19000km) or 36 months, repeat the maintenance intervals starting from 4000mi(7000km) or 12 months. EAU17680 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
COVER AND PANEL < & EAS00038 COVER AND PANEL SIDE COVERS AND TAIL/BRAKE LIGHT Order Job/Part Remarks Q’ty Removing the side covers and tail/ Remove the parts in the order listed. brake light Front cover Side cover(left) Side cover(right) Tail/brake and rear turn signal light(left and right) Battery cover Battery negative lead...
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COVER AND PANEL < & Order Job/Part Remarks Q’ty control system. For installation, reverse the removal pro- cedure.
COVER AND PANEL < & SINGLE SEAT AND TRUNK \y10Nm(1.0m • kg, 7.2 ft • lb) \ l 12Nm(1.2m« kg, 8.7 ft* lb) [s& 7Nm(0.7m• kg, 5.1 ft• lb) "10 '/* *£® / Order Job/Part Remarks Q’ty Removing the single seat and trunk Remove the parts in the order listed.
COVER AND PANEL < & LEG SHIELD1,2 Order Job/Part Remarks Q’ty Removing the leg shield1,2 Removing the leg shield1,2 Remove the parts in the order listed. Front fork upper cover Front fork upper cover Reflector(left) Reflector(left) Caution, do not damage the claw while Front fork cover(left) Front fork cover(left) removing.
COVER AND PANEL < & FOOTREST BOARD AND INNER FENDER Order Job/Part Remarks Q’ty Removing the footrest board and in- Removing the footrest board and in- Remove the parts in the order listed. ner fender ner fender Single seat/trunk Single seat/trunk Refer to “SINGLE SEAT AND TRUNK “.
ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
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ADJUSTING THE VALVE CLEARANCE < & ••••••••••••••••••••••• a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align the punch mark a in the camshaft sprocket with the stationary b on the plate. c.
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ADJUSTING THE VALVE CLEARANCE < & Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number =148(thickness =1.48mm(0.0583in)) Rounded value =150 g. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.
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ADJUSTING THE VALVE CLEARANCE < & n. Install the timing chain tensioner spring and cap bolt . 8Nm(0.8m kg, 5.8ft o. Measure the valve clearance again. p. 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.
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ADJUSTING THE VALVE CLEARANCE < & 8. Install: 8all removed parts NOTE: For installation, reverse the removal procedure. 9. Fill: 8cooling system (with the specified amount of the recom- mended coolant) Refer to”CHANGING THE COOLANT”. 3-15...
CHECKING THE ENGINE IDLING SPEED < & EAS00054 CHECKING THE ENGINE IDLING SPEED NOTE: Prior to adjusting 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.
ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check: • throttle cable free play a Out of specification ^Adjust. Throttle cable free play (at the flange of the throttle grip) 1.5~3.5mm (0.06~0.14in)
CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Remove: 8 panel Refer to”FOOTREST BOARD AND IN- NER FENDER”. 2. Disconnect: 8 spark plug cap Remove the spark plug cap, the engine is extremely hot. 3. Remove: 8 spark plug Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling...
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CHECKING THE SPARK PLUG < & 8. Install: • spark plug 13Nm(1.3m kg, 9.4ft NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • spark plug cap 10. Install: • panel Refer to”FOOTREST BOARD AND IN- NER FENDER”.
CHECKING THE IGNITION TIMING < & EAS00062 CHECKING THE IGNITION TIMING NOTE: 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: 8front cover 8side cover(left and right) 8battery /battery cover 8single seat/trunk...
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CHECKING THE IGNITION TIMING < & 5. Check: 8ignition timing • • • • • • • • • • • • • • • • • • • • • • • a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed.
MEASURING THE COMPRESSION PRESSURE < & EAS00067 MEASURING THE COMPRESSION PRES- SURE NOTE: 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.
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MEASURING THE COMPRESSION PRESSURE ••••••••••••••••••••••• a. Set the main switch to “ON”. b. With the throttle wide open, crank the en- gine until the reading on the compression gauge stabilizes. FflWUzWIgM To prevent sparking, ground the spark plug lead before cranking the engine. c.
CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the scooter on a level surface. NOTE: 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.
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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: 8engine oil filler cap 1 8engine oil drain bolt 2 (along with the gasket) 4.
CHANGING THE ENGINE OIL Install: 8engine oil filler cap Start the engine, warm it up for several min- utes, and then turn it off. 10.Check: 8engine (for engine oil leaks) 11.Check: 8engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”.
CHANGING THE TRANSMISSION OIL < & CHANGING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. NOTE: • Stand the scooter on a suitable stand. • Make sure that the scooter upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.
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.
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MEASURING THE ENGINE OIL PRESSURE < & 6. Install: 8oil gallery bolt 7Nm(0.7m kg, 5.1ft 7. Install: • panel Refer to”FOOTREST BOARD AND IN- NER FENDER”. 3-29...
CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD/CHECKING THE FUEL HOSE EAS00094 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 1. Remove: 8front cover 8side cover(left and right) 8single seat/trunk Refer to”COVER AND PANEL”. 2. Check: • throttle body joint •...
CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler assembly and gasket. 1. Remove: 8muffler assembly Refer to”ENGINE REMOVAL”in chapter 2. Check: • muffler assembly Crack/damage -» Replace. • gasket Exhaust gas leak -»...
CHECKING THE COOLANT LEVEL EAS00103 CHECKING THE COOLANT LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Check: 8 coolant level The coolant level should be between the maximum level mark a and minimum level mark b .
CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: 8front cover 8side cover(right) 8coolant reservoir cap cover Refer to”COVER AND PANEL”. 8radiator cover Refer to”RADIATOR”in chapter 6. Disconnect: 8coolant reservoir hose 1 Drain: 8coolant (from the coolant reservoir) 8coolant (from the radiator under drain bolt) Remove: 8radiator cap 8coolant reservoir cap...
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CHANGING THE COOLANT 7. Fill: 8cooling system (with the specified amount of the recom- mended coolant) «0 Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion inhibi- tors for aluminum engines Mixing ratio 4:6(antifreeze:water) Quantity Total amount 0.50L(0.46 Imp qt, 0.53 US qt) Coolant reservoir capacity 0.26L(0.23 Imp qt, 0.28 US qt) Up to the maximum level mark...
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CHANGING THE COOLANT < & 9. Fill: 8coolant reservoir (with the recommended coolant to the maximum level mark 1 ) 10.Install: 8coolant reservoir cap 11.Start the engine, warm it up for several min- utes, and then stop it. 12.Check: 8coolant level Refer to “CHECKING THE COOLANT LEVEL”.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE < & EAS00109 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: 8 brake lever free play a Out of specification -» Adjust. Brake lever free play (at the end of the brake lever) 10~20mm(0.39~0.79in) 2.
CHECKING THE FRONT AND REAR BRAKE SHOES < & EAS00127 CHECKING THE FRONT AND REAR BRAKE SHOES Operate the brake. Check: • wear indicator Reaches the wear limit line (2) -» Replace the brake shoes as a set. Refer to “FRONT WHEEL AND BRAKE” and “REAR WHEEL AND BRAKE”...
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CHECKING AND ADJUSTING THE STEERING HEAD < & EAS00148 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
CHECKING AND ADJUSTING THE STEERING HEAD b. Loosen the upper bearing inner race2 com- pletely and then tighten it to specification with a steering nut wrench3 . Steering nut wrench 90890-01444 YM-A9409-7 Do not overtighten the upper bearing inner race. Upper bearing inner race(final tight- ening torque) 7Nm(0.7m...
CHECKING THE FRONT FORK < & EAS00151 CHECKING THE FRONT FORK 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. 2. Check: •inner tube Damage/scratches -» Replace. •oil seal Oil leakage -»...
CHECKING THE TIRES EAS00163 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification -> Regulate. rr\w«:»iwei • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air tem- perature.
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CHECKING THE TIRES 2. Check: • tire surfaces Damage/wear -» Replace the tire. Minimum tire tread depth 0.8mm(0.03in) Tire tread depth Sidewall Wear indicator Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation.
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CHECKING THE TIRES < & 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. NOTE: For tires with a direction of rotation mark 1 : 8 Install the tire with the mark pointing in the direction of wheel rotation.
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CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES < & EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: • wheel Damage/out-of-round -»Replace. FflWUzWIgM Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or re- placed, always balance the wheel.
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LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE CENTERSTAND < & EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.
CHECKING AND CHARGING THE BATTERY EAS00179 ELECTRICAL SYSTEM BATTERY INSTRUCTION This is a sealed lype 12 volt battery. No liquid level inspection is ever needed and no refilling water will be required. CHECKING AND CHARGING THE BATTERY IMPORTANT: • Never interfere with the sealed state of the battery. •Check the charging condition with a voltmeter (Normal charging voltage should be above 12.8V) •This battery may be installed in an vehicle only If it replaces a similar sealed type battery.
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CHECKING AND CHARGING THE BATTERY NOTE: 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.
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CHECKING AND CHARGING THE BATTERY < & b. Check the charge of the battery, as shown Relationship between the open-circuit voltage 13.0 and the charging time at 20 C in the charts and the following example. 12.5 Example 12.0 Open-circuit voltage = 12.0 V 11.5 11.5 Charging time = 6.5 hours...
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CHECKING AND CHARGING THE BATTERY < & Make sure the battery charger lead clips are in full contact with the battery termi- nal and that they are not shorted. A cor- roded battery charger lead clip may gen- erate heat in the contact area and a weak clip spring may cause sparks.
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CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Charger Measure the open-circuit Ammeter Leave the battery unused for more voltage prior to charging. than 30 minutes before measuring its opencircuit voltage. Set the charging voltage to 16-17 V. (If the charging voltage is lower charg- ing will be insufficient, if it is higher, the battery will be over-charged.)
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CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: 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.
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CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSE < & Install: 8battery Connect: 8battery leads (to the battery terminals) First, connect the positive battery lead 1, and then the negative battery lead 2. 8 After installing the battery, be sure to turn the main switch from “ON”...
CHECKING THE FUSE 2. Check: 8fuse • • • • • • • • • • • • • • • • • • • • • • • a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “...
REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: 8headlight unit Disconnect: 8headlight lead coupler Remove: 8dust b o o t 1 8headlight bulb holder2 8headlight bulb3 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
ADJUSTING THE HEADLIGHT BEAM < & EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: headlight beam (vertically) • • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting screw 1 in direction a or b .
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CHAS (3^3^) CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE FRONT WHEEL FRONT BRAKE SHOE PLATE REMOVING THE FRONT WHEEL DISASSEMBLING THE BRAKE SHOE PLATE CHECKING THE FRONT WHEEL CHECKING THE SPEEDOMETER GEAR UNIT CHECKING THE BRAKE ASSEMBLING THE BRAKE SHOE PLATE ASSEMBLING THE FRONT WHEEL INSTALLING THE FRONT WHEEL 4-10...
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CHAS (3^3^) REAR SHOCK ABSORBER ASSEMBLY 4-37 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-38 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-38 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-39...
CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00517 CHASSIS FRONT WHEEL AND BRAKE Order Job/Part Remarks Q’ty Removing the front wheel and brake Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. Stop ring Speedometer cable Brake adjuster...
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CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00518 FRONT WHEEL Order Job/Part Remarks Q’ty Disassembling the front wheel Remove the parts in the order listed. Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly procedure.
CHAS (3^3^) FRONT WHEEL AND BRAKE FRONT BRAKE SHOE PLATE Order Job/Part Remarks Q’ty Disassembling the front brake shoe Remove the parts in the order listed. plate Brake shoe kit Tension spring Camshaft lever Brake shoe wear indicator Return spring Brake camshaft/O-ring Oil seal Refer...
CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
FRONT WHEEL AND BRAKE EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends -» Replace. Do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel Damage/wear -»...
CHAS (3^3^) FRONT WHEEL AND BRAKE • • • • • • • • • • • • • • • • • • • • • • • a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver.
CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00536 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: •—Q7\__ • brake shoe lining Glazed areas -» Repair. Sand the glazed areas with course sand- paper. • "...
FRONT WHEEL AND BRAKE 4. Check: • brake drum inner surface Oil deposits -»Clean. Remove the oil with a rag soaked in lac- quer thinner or solvent. Scratches -» Repair. Lightly and evenly polish the scratches with an emery cloth. 5.
CHAS (3^5^) FRONT WHEEL AND BRAKE 3. Install: 8 camshaft lever 8Nm(0.8m • kg, 5.8ft • • • • • • • • • • • • • • • • • • • • • • • • a. Align the camshaft punch mark a and cam- shaft lever punch mark b is positioned as shown.
CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00540 INSTALLING THE FRONT WHEEL 1. Lubricate: 8wheel axle 8wheel bearings 8oil seal lips 8speedometer drive gear 8speedometer driven gear Recommended lubricant Lithium-soap-based grease 2. Install: 8front wheel1 NOTE: Make sure the slot® in the brake shoe plate fits over the stopper®...
FRONT WHEEL AND BRAKE EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: 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 .
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CHAS (3^% FRONT WHEEL AND BRAKE 3. Adjust: 8front wheel static balance • • • • • • • • • • • • • • • • • • • • • • • a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”.
CHAS (3^3^) REAR WHEEL AND BRAKE EAS00555 REAR WHEEL AND BRAKE Order Job/Part Remarks Q’ty Removing the rear wheel and brake Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. Muffler Refer to”ENGINE REMOVAL”in chapter Self lock nut/Plate washer...
CHAS (3^3^) REAR WHEEL AND BRAKE EAS00564 REMOVING THE REAR WHEEL 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.
CHAS (3^3^) REAR WHEEL AND BRAKE EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: • rear wheel drive hub Cracks/damage -» Replace. EAS00569 CHECKING THE BRAKE /)> The following procedure applies to all of the brake shoes. ~~~G77\-__ 1. Check: •...
CHAS (3^3^) REAR WHEEL AND BRAKE 3. Measure: • brake drum inside diameter b Out of specification -» Replace the wheel. Brake drum inside diameter limit (maximum) 110.5 mm(4.35 in) 4. Check: • brake drum inner surface Oil deposits -» Clean.
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CHAS (3^3^) REAR WHEEL AND BRAKE 3. Install: 8brake shoe k i t 1 8tension springs Do not put lubricating oil on the brake lining. Change the tension spring at the same time of changing the brake shoe. Refer to the direction in the illustration when assembling the brake shoe and spring.
CHAS (3^3^) FRONT FORK EAS00646 FRONT FORK S & 45Nm(4.5m • kg, 32.5 ft • lb) g R 30Nm(3.0m • kg, 21.7 ft • lb) Order Job/Part Remarks Q’ty Removing the front fork legs Remove the parts in the order listed. Front fork upper cover Reflector Refer to”LEG SHIELD1,2 “...
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FRONT FORK C H A S (3^3^) EAS00648 3 R 23Nm(2.3m • kg, 16.6 ft < lb) Order Job/Part Remarks Q’ty Disassembling the front fork legs Remove the parts in the order listed. Fork oil Drain. Fork spring Damper rod bolt/Copper washer Damper rod Rebound spring Inner tube...
CHAS (3^3^) 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. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
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FRONT FORK 2. Drain: 8fork oil 3. Remove: 8damper rod assembly b o l t 1 NOTE: While holding the damper rod with the damper rod holder 2 and T-handle3, loosen the damper rod assembly bolt. Damper rod holder 90890-01294(YM-01300-1) •...
CHAS (3^% FRONT FORK 6. Remove: 8oil s e a l 1 Never reuse the oil seal. 8 R a g 2 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 8 inner tube®...
FRONT FORK EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: 8 When assembling the front fork leg, be sure to replace the following parts: - oil seal - dust seal 8 Before assembling the front fork leg, make sure all of the components are clean.
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CHAS (3^3^) FRONT FORK 4. Install: 8oil seal 1New (with the fork seal driver weight 2 and adapter 3 ) Fork seal driver weight 90890-01367(YM-A9409-7) Adapter 90890-01400(YM-A9409-3 ) Make sure the numbered side of the oil seal faces up. NOTE: 8 Before installing the oil seal, lubricate its lips with lithium soap base grease.
CHAS (3^3^) FRONT FORK NOTE: 8 While filling the front fork leg, keep it up- right. 8 After filling, slowly pump the front fork leg up and down to distribute the fork oil. 7. Install: 8fork spring 1 NOTE: 8 Install the spring with the smaller pitch fac- ing down .
CHAS (3^3^) HANDLEBAR EAS00664 HANDLEBAR -10^ Order Job/Part Remarks Q’ty Removing the handlebar Remove the parts in the order listed. Front fork upper cover Front fork cover(left and right) Refer to”LEG SHIELD1,2"in chapter 3. Leg shield1,2 Rear view mirror(left and right) Band Front brake cable Disconnect.
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CHAS (3^3^) HANDLEBAR -10^ Order Job/Part Remarks Q’ty Front turn signal light(left) Front turn signal light bracket(left) Handlebar switch(left) Handlebar grip Handlebar upper holder Handlebar assembly For installation, reverse the removal pro- cedure. 4-28...
CHAS (3^3^) HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. 2. Remove: 8handlebar switch(right)1 8throttle grip assembly2 NOTE: While removing the handlebar holder assembly (right), pull back the rubber cover.
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HANDLEBAR 5. Install: 8 throttle grip assembly1 8 right handlebar switch2 8 throttle cables 3 NOTE: 8 Align the projectiona on the right handlebar switch with the hole b on the handlebar. 8 Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar4.
LOWER BRACKET LOWER BRACKET r V 30Nm(3.0m • kg, 21.7 ft • lb)f Order Job/Part Remarks Q’ty Removing the lower bracket Remove the parts in the order listed. Front fork upper cover Front fork cover(left and right) Refer to”LEG SHIELD1,2"in chapter 3. Leg shield1,2 Front wheel Refer to”FRONT WHEEL AND BRAKE”.
CHAS (3^3^) STEERING HEAD EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. 2 . Remove: 8handlebar bracket1 NOTE: Remove the handlebar bracket by loosening the ring n u t 2 gradually.
CHAS (3^3^) STEERING HEAD EAS00684 INSTALLING THE STEERING HEAD 1. Lubricate: 8bearing balls 1 8bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 8lower bracket 1 8upper bearing inner r a c e 2 (with the steering nut wrench3) Upper bearing inner race 7Nm(0.7m •...
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CHAS (3^3^) REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY Order Job/Part Remarks Q’ty Removing the rear shock absorber Remove the parts in the order listed. assembly Front cover Refer to”SIDE COVERS AND TAIL/ Side cover(left) BRAKE LIGHT”in chapter 3. Rear shock absorber assembly upper Rear shock absorber assembly upper bolt...
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REAR SHOCK ABSORBER ASSEMBLY EAS00692 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.
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CHAPTER 5 ENGINE ENGINE REMOVAL LEADS, HOSES AND MUFFLER ENGINE INSTALLING THE ENGINE CYLINDER HEAD REMOVING THE CYLINDER HEAD CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER HEAD 5-10 THE ROCKER ARMS AND CAMSHAFT 5-13 REMOVING THE ROCKER ARMS AND CAMSHAFT 5-14 CHECKING THE CAMSHAFT 5-15...
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REMOVING THE SECONDARY SHEAVE AND V-BELT 5-44 DISASSEMBLING THE SECONDARY SHEAVE 5-45 CHECKING THE CLUTCH SHOES 5-45 CHECKING THE V-BELT 5-46 CHECKING THE PRIMARY SHEAVE 5-46 CHECKING THE PRIMARY SHEAVE WEIGHTS 5-47 CHECKING THE SLIDER 5-47 CHECKING THE SECONDARY SHEAVE 5-47 ASSEMBLING THE PRIMARY SHEAVE 5-48...
ENGINE REMOVAL EAS00188 ENGINE ENGINE REMOVAL LEADS, HOSES AND MUFFLER r V 10Nm(1.0m • kg, 7.2 ft* lb) r V 10Nm(1.0m • kg, 7.2 ft* lb) Order Job/Part Remarks Q’ty Removing the leads, hoses and muf- Remove the parts in the order listed. fler Front cover/Single seat/Trunk Battery cover/Battery...
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ENGINE REMOVAL r^10Nm(1.0m • kg, 7.2 ft* lb) 1 * 10Nm(1.0m • kg, 7.2 ft • lb) Order Job/Part Remarks Q’ty Crankshaft position sensor/Stator as- Disconnect. sembly coupler Ignition primary coil coupler Disconnect. Air filter assembly/Breather hose Bracket Muffler Gasket For installation, reverse the removal pro- cedure.
ENGINE REMOVAL EAS00191 ENGINE Order Job/Part Remarks Q’ty Removing the engine Removing the engine Remove the parts in the order listed. Place a suitable stand under the frame and engine. Rear shock absorber assembly lower Rear shock absorber assembly lower bolt bolt Engine mounting nut...
ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: 8engine1 8engine mounting b o l t 2 8engine mounting n u t 3 NOTE: 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..
CYLINDER HEAD EAS00221 CYLINDER HEAD P^9Nm(0.9m • kg, 6.5 ft • lb) P|^j8Nm(0.8m • kg, 5.8 ft • lb) n^10Nm(1.0m« kg, 7.2 ft* lb) . i ^ \ [ \ 30Nm(3.0m • kg, 21.7 ft • lb) «13Nm(1.3m • kg, 9.4 ft • lb) Order Job/Part Remarks...
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CYLINDER HEAD P^9Nm(0.9m • kg, 6.5 ft • lb) «13Nm(1.3m • kg, 9.4 ft • lb) Order Job/Part Remarks Q’ty Timing chain tensioner gasket Camshaft sprocket Refer to”REMOVING THE CYLINDER Bolt HEAD” and “INSTALLING THE CYLIN- DER HEAD”. Plate Cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal pro-...
CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Remove : 8V-belt case cover 8Refer to “BELT DRIVE”. 8cylinder head cover 2. Align: 8“I” mark a on the AC magneto rotor (with the stationary pointer b on the crankcase cover) • • • • • • • • • • • • • • • • • • • • • • • a.
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CYLINDER HEAD 4. Remove: 8timing chain tensioner (along with the gasket) 8camshaft sprocket 1 8timing chain 2 NOTE: 8 To prevent the timing chain from falling into the crankcase, fasten it with a wire. 5. Remove: 8cylinder head NOTE: 8 Loosen the nuts in the proper sequence as shown.
CYLINDER HEAD EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: 8combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore thread • valve seats 2. Check: •...
CYLINDER HEAD EAS00231 INSTALLING THE CYLINDER HEAD 1. Install: • gasket • dowel pins 2. Install: • cylinder head 3. Tighten: • cylinder head nuts 10 Nm (1.0 m kg, 7.2 ft • cylinder head bolts 10 Nm (1.0 m kg, 7.2 ft NOTE: •...
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CYLINDER HEAD Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. e. While holding the camshaft, temporarily tighten the camshaft sprocket bolt. f. Remove the wire from the timing chain. • • • • • • • • • • • • • • • • • • • • • • • 5.
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CYLINDER HEAD 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 cover. 8“I” mark c Align the “I” mark on the camshaft sprocket with the stationary pointer d on the plate.
THE ROCKER ARMS AND CAMSHAFT THE ROCKER ARMS AND CAMSHAFT Order Job/Part Remarks Q’ty Removing the rocker arms and cam- Remove the parts in the order listed. shaft Cylinder head Refer to “CYLINDER HEAD”. Camshaft Rocker arm shaft(intake) Rocker arm shaft(exhaust) Rocker arm(intake) Rocker arm(exhaust) Collar...
THE ROCKER ARMS AND CAMSHAFT EAS00202 REMOVING THE ROCKER ARMS AND CAM- SHAFT 1. Remove: 8intake rocker arm shaft 8exhaust rocker arm shaft 8intake rocker arm 8exhaust rocker arm 8collar NOTE: Remove the rocker arm shafts with the clip plier. 2.
THE ROCKER ARMS AND CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: •camshaft bushings Damage/wear -» Replace. 2. Check: •camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft. 3. Measure: ® •camshaft lobe dimensions a and b Out of specification Replace the cam- m§>...
THE ROCKER ARMS AND CAMSHAFT 5. Measure: • rocker arm shaft outside diameter a Out of specification -» Replace. Rocker arm shaft outside diameter 9.981 ~ 9.991 mm (0.3930 ~ 0.3933 <Limit>:9.950mm (0.3917 in) 6. Calculate: •rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.
VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Remarks Q’ty 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”...
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VALVES AND VALVE SPRINGS Order Job/Part Remarks Q’ty For installation, reverse the removal pro- cedure. 5-21...
VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
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VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach- ment 90890-04148 YM-04148 4 . Remove: 8valve spring retainer 1 8valve spring 2 8valve stem seal 3 8valve spring seat 4 8valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
VALVES AND VALVE SPRINGS EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1 . Measure: 8valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a - Valve stem diameter b Out of specification Replace the valve guide.
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VALVES AND VALVE SPRINGS 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face Pitting/wear Grind the valve face. • valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve.
VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbon deposits (from the valve face and valve seat) 2. Check: • valve seat Pitting/wear Replace the cylinder head. 3.
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VALVES AND VALVE SPRINGS • • • • • • • • • • • • • • • • • • • • • • • a. Apply a coarse lapping compound a to the valve face. X"7 Do not let the lapping compound enter the gap between the valve stem and the valve guide.
VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a Out of specification -» Replace the valve spring. Valve spring free length Intake valve spring 39.35 mm (1.5492 in) <Limit>: 37.38 mm (1.4717 in) Exhaust valve spring...
VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 8valve stem end (with an oil stone) 2. Lubricate: 8valve stem 1 8valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3.
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VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019(YM-04019) Valve spring compressor attach- ment 90890-04148(YM-04148) 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. Hitting the valve tip with excessive force could damage the valve.
CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON Order Job/Part Remarks Q’ty 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”...
CYLINDER AND PISTON EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: 8piston pin clip 1 8piston pin 2 8piston 3 Do not use a hammer to drive the piston pin out. NOTE: 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.
CYLINDER AND PISTON EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: • piston wall • cylinder wall Vertical scratches Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: piston-to-cylinder clearance • • • • • • • • • • • • • • • • • • • • • • • a.
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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.
CYLINDER AND PISTON EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification -» Replace the pis- ton and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.
CYLINDER AND PISTON EAS00265 CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification Replace the pis- ton pin. Piston pin outside diameter 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in)
CYLINDER AND PISTON CHECKING THE TIMING CHAIN GUIDE 1. Check: 8 timing chain guide (exhaust side) Damage/wear -» Replace EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: 8oil ring expander 1 8oil ring rail 2 82nd ring 3 8top ring 4 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
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CYLINDER AND PISTON 3. Install: N e w 8gasket 8dowel pins 4. Lubricate: 8piston 8piston rings 8cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: 8piston ring end gaps a Top ring Lower oil ring rail Upper oil ring rail d 2nd ring A Exhaust side 6.
BELT DRIVE EAS00316 BELT DRIVE V-BELT CASE COVER %. 10Nm(1.0m • kg, 7.2 ft • lb) P|« 12Nm(1.2m • kg, 8.7 ft* lb) Order Job/Part Remarks Q’ty Removing the V-belt case cover Remove the parts in the order listed. Kickstarter Cover V-belt case cover V-belt case cover gasket...
BELT DRIVE EAS00338 KICKSTARTER Order Job/Part Remarks Q’ty Disassembling the kickstarter Remove the parts in the order listed. V-belt case cover Refer to”V-BELT CASE COVER“. Kick pinion gear Kick pinion gear clip Circlip/Plate washer Refer to”INSTALLING THE KICKSTARTER”. Kickstarter shaft Torsion spring Solid bush For assembly, reverse the disassembly...
BELT DRIVE EAS00340 INSTALLING THE KICKSTARTER 1. Install: 8solid b u s h 1 8kick shaft assembly2 8torsion spring3 2. Hook: 8torsion spring NOTE: Hook the spring e n d a on the kickstarter shaft b as shown, and hook the other end c on the projectiond .
BELT DRIVE V-BELT AND PRIMARY/SECONDARY SHEAVE 40Nm (4.0 m«kg, 28.9 fHb) 30Nm (3.0 m«kg, 21.7 fHb) Order Job/Part Remarks Q’ty Removing the V-belt and primary/sec- Remove the parts in the order listed. ondary sheave Primary sheave nut/Plate washer Refer to”REMOVING THE PRIMARY Oneway clutch SHEAVE”...
BELT DRIVE SECONDARY SHEAVE Order Job/Part Remarks Q’ty Disassembling secondary Disassemble the parts in the order listed. sheave Clutch carrier nut Refer to”DISASSEMBLING THE SEC- Clutch carrier ONDARY SHEAVE” and “ASSEMBLING THE SECONDARY SHEAVE”. Clutch shoe spring Compression spring Secondary spring seat Refer to”ASSEMBLING THE SECOND- Guide pin ARY SHEAVE”...
BELT DRIVE Clutch shoe thickness 3.7mm(0.146in) <Limit>:2.0mm(0.079in) NOTE: 8 Inspect clutch shoesa. 8 After removing the clutch shoe spring, do not use them again. 8 Replace the all three as a set. EAS00320 CHECKING THE V-BELT 1. Check: j^ia • V-belt® Cracks/damage/wear -»...
BELT DRIVE EAS00321 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • primary sheave weight Cracks/damage/wear Replace. 2. Measure: • primary sheave weight outside diameter Out of specification Replace. Primary sheave weight outside di- ameter 15 mm (0.591 in)
BELT DRIVE EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 NOTE: Use thinner to clean up grease, dirt on the pri- mary sliding sheave cam side 5 . 2.
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BELT DRIVE 5. Position: 8V-belt 1 NOTE: 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.
STARTER CLUTCH AND AC MAGNETO EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY Order Job/Part Remarks Q’ty Removing the stator coil assembly Remove the parts in the order listed. Coolant Drain. Refer to”CHANGING THE COOLANT”in chapter 3. Single seat/Trunk Front cover Side cover(left and right) Refer to”COVER AND PANEL”in chap-...
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STARTER CLUTCH AND AC MAGNETO Order Job/Part Remarks Q’ty Lock plate Crankshaft position sensor Stator coil assembly For installation, reverse the removal pro- cedure. 5-54...
STARTER CLUTCH AND AC MAGNETO EAS00342 STARTER CLUTCH Order Job/Part Remarks Q’ty Removing the starter clutch Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL”in chapter 3. AC magneto rotor Refer to”REMOVING THE AC MAG- Stator coil assembly NETO”...
STARTER CLUTCH AND AC MAGNETO EAS00347 REMOVING THE AC MAGNETO 1. Remove: 8AC magneto rotor n u t 1 8washer NOTE: 8 While holding the AC magneto rotor 2 with the sheave holder 3 , loosen the AC mag- neto rotor nut. 8 Do not allow the sheave holder to touch the projection on the AC magneto rotor.
STARTER CLUTCH AND AC MAGNETO EAS00344 REMOVING THE STARTER CLUTCH 1. Remove: 8crankcase cover (right)1 NOTE: 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. 2.
STARTER CLUTCH AND AC MAGNETO EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: • idle gear • starter clutch • collar • roller • starter wheel gear • washer • starter clutch nut® 90 Nm (9.0 m kg, 65.1 ft NOTE: The starter clutch nut is left-hand thread.
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STARTER CLUTCH AND AC MAGNETO 2. Tighten: •AC magneto rotor nut 43 Nm (4.3 m kg, 31.1 ft NOTE: • While holding the AC magneto rotor (2)with the sheave holder®, tighten the AC mag- neto rotor nut. • Do not allow the sheave holder to touch the projection on the AC magneto rotor.
OIL PUMP EAS00360 OIL PUMP 4Nm (0.4 m«kg, 2.9 fHb) Order Job/Part Remarks Q’ty Removing the oil pump Remove the parts in the order listed. Radiator Refer to”RADIATOR”in chapter 6. AC magneto Refer to”STARTER CLUTCH AND AC Refer to”STARTER CLUTCH AND AC Starter clutch MAGNETO”...
TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Remarks Q’ty Removing the transmission Remove the parts in the order listed. Transmission oil Drain. Refer to”CHANGING THE TRANSMIS- SION OIL” in chapter 3. Muffler/Bracket Refer to”ENGINE REMOVAL”. Rear wheel Refer to”REAR WHEEL AND BRAKE” in chapter 4.
TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Measure: • main axle runout (with a centering device and dial gauge ) Out of specification -» Replace the main axle. Main axle runout limit 0.04 mm (0.002 in) 2. Measure: • drive axle runout (with a centering device and dial gauge ) Out of specification -»...
CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 7Nm (0.7 m»kg, 5.1 fHb) 7Nm (0.7 m»kg, 5.1 fHb) Order Job/Part Remarks Q’ty Removing the crankshaft assembly Remove the parts in the order listed. Engine Refer to”ENGINE REMOVAL” . Cylinder head Refer to”CYLINDER HEAD”. Cylinder and piston Refer to”CYLINDER AND PISTON”.
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CRANKSHAFT 7Nm (0.7 m»kg, 5.1 fHb) 7Nm (0.7 m»kg, 5.1 fHb) Order Job/Part Remarks Q’ty Hook Drain plug Oil strainer Compression spring O-ring Crankcase(right) Refer to”DISASSEMBLING CRANKCASE” and “ASSEMBLING THE CRANKCASE”. Spacer Dowel pin Guide Crankshaft Refer to”REMOVING THE CRANK- SHAFT ASSEMBLY”...
CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 8centerstand assembly 2. Remove: 8crankcase bolts1 NOTE: 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.
CRANKSHAFT EAS00389 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: 8crankshaft assembly1 8timing chain2 8timing chain guide(intake side) NOTE: 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.
CRANKSHAFT EAS00408 INSTALLING THE CRANKSHAFT 1. Install: 8timing chain guide (intake side) 8timing chain1 8crankshaft assembly2 NOTE: Install the timing chain so it is not visible through the opening in the left crankcase 3 . To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.
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CRANKSHAFT 3. Install: 8dowel pins 8spacer 8right crankcase1 NOTE: Tap lightly on the right crankcase with a soft- face hammer. 4. Tighten: •crankcase bolts 10Nm(1.0m kg, 7.2ft NOTE: Tighten the crankcase bolts in stages and in a crisscross pattern. 5. Apply: •engine oil (onto the crankshaft pin, bearing and oil delivery hole)
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COOL J C CHAPTER 6 COOLING SYSTEM RADIATOR CHECKING THE RADIATOR INSTALLING THE RADIATOR THERMOSTAT CHECKING THE THERMOSTAT INSTALLING THE THERMOSTAT WATER PUMP DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP ASSEMBLING THE WATER PUMP 6-10 INSTALLING THE WATER PUMP 6-11...
COOL J C RADIATOR EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Remarks Q’ty Remove the parts in the order listed. Removing the radiator Front cover Side cover(left and right) Refer to”COVER AND PANEL”in chap- Single seat/Trunk ter 3. Footrest board Coolant Drain.
RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction -» Clean. Apply compressed air to the rear of the radiator. Damage -» Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator inlet hose •...
COOL J C THERMOSTAT EAS00460 THERMOSTAT 10Nm (1.0 m«kg, 7.2 fHb) 10Nm (1.0 m«kg, 7.2 fHb) Order Job/Part Remarks Q’ty Removing the thermostat Remove the parts in the order listed. Front cover Side cover(left and right) Refer to”COVER AND PANEL”in chap- Single seat/Trunk ter 3.
COOL J C WATER PUMP EAS00468 WATER PUMP lyJ2|10 4 i , / 10Nm(1.0m« kg, 7.2 ft* lb) d r ^ ® Order Job/Part Remarks Q’ty Removing the water pump Remove the parts in the order listed. Front cover Side cover(left and right) Refer to”COVER AND PANEL”in chap- Single seat/Trunk ter 3.
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COOL J C WATER PUMP 10Nm(1.0m • kg, 7.2 ft* lb) ® ^ ^ ® Order Job/Part Remarks Q’ty Oil seal Bearing Gasket For installation, reverse the removal pro- cedure.
COOL J C WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: 8water pump housing c o v e r 1 8dowel pin 8gasket 2. Remove: 8plate 2 8impeller shaft 8gasket 8oil seal (with a thin, flat-head screwdriver) 8bearing NOTE: 8 Remove the oil seal from the inside of the water pump housing.
COOL J C WATER PUMP EAS00475 ASSEMBLING THE WATER PUMP 1. Install: 8bearing1 NOTE: 8 Before installing the oil seal, apply tap wa- ter or coolant onto its out surface. 8 Install the oil seal with a socket that matches its outside diameter. 2.
COOL J C WATER PUMP 5. Install: 8gasket 8water pump housing c o v e r 1 EAS00478 INSTALLING THE WATER PUMP M§ 1. Install: • water pump assembly 10Nm(1.0m kg, 7.2ft NOTE: \ \Ji—- \ \Ji—- Align the slit a on the impeller shaft with the projection b on the camshaft sprocket bolt.
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.
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.
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.
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 does not come on. The engine trouble warning light comes on.
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 <P 90890-03182 YU-03182...
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FUEL INJECTION SYSTEM Setting the diagnostic mode 1. Turn the main switch to “OFF” and the en- gine stop switch to “RUN”.. 2. Disconnect the self diag signal connector 1 , and then connect the Fl diagnostic-tool 2 as shown. 3.
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. •...
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FUEL INJECTION SYSTEM EAS00907 Diagnostic mode table NOTE: 8 Check the intake air temperature and coolant temprature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively. 8 If it is not possible to check the intake air temperature, use the ambient temperature as refer- ence.
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. •...
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FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No. -- Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Check the installed area for looseness or Reinstated by crank- Reinstated by crank- Reinstated by crank-...
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FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor-open or short circuit detected. 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...
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FUEL INJECTION SYSTEM Intake air pressure sensor-hose system malfunction Fault code No. Symptom (clogged or detached hose). tached hose). Used diagnostic code No. D03 (intake air pressure sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected state of connector Check the coupler for any pins that may have...
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FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. 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- Reinstated by start- position sensor.
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FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor open or short circuit is detected. Used diagnostic code No. D06 (coolant 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- Reinstated by turn-...
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FUEL INJECTION SYSTEM Fault code No. Symptom Intake temperature sensor open or short circuit is detected. 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.
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FUEL INJECTION SYSTEM Fault code No. Symptom The vehicle has overturned. 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...
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FUEL INJECTION SYSTEM Fault codeNo. Symptom Open circuit detected in the primary lead of the ignition coil. 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- Reinstated by start- Reinstated by start-...
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FUEL INJECTION SYSTEM Fault code No. Symptom Fuel injector open or short circuit is detected. 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- Reinstated by start- Reinstated by start-...
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FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the speed sensor. 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...
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FUEL INJECTION SYSTEM Power supply to the fuel injector, fuel pump and ignistion coil are not Fault code No. Symptom 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...
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FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to FI system is not normal. (red lead) 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- Reinstated by start- Reinstated by start-...
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FUEL INJECTION SYSTEM Fault code No. Symptom ISC (idle speed control) valve open or short circuit is detected. 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 set- Reinstated by set-...
THROTTLE BODY AND FUEL INJECTOR EAS00909 THROTTLE BODY AND FUEL INJECTOR THROTTLE BODY Order Job/Part Remarks Q’ty Removing the throttle body Remove the parts in the order listed. Side cover(left and right) Refer to “COVER AND PANEL”in chap- Single seat/Trunk ter 3.
THROTTLE BODYAND FUEL INJECTOR FUEL INJECTOR AND FUEL HOSE Order Job/Part Remarks Q’ty Removing the fuel injector and fuel Remove the parts in the order listed. hose Footrest board Refer to”COVER AND PANEL”in chap- ter 3. Fuel pump coupler Disconnect. Fuel hose connector cover Fuel hose connector Fuel hose holder(to frame)
THROTTLE BODYAND FUEL INJECTOR FUEL TANK «& 4Nm(0.4m • kg, 2.9 ft • lb) Order Job/Part Remarks Q’ty Removing the fuel tank Remove the parts in the order listed. Place the scooter on a suitable stand. Fuel hose Refer to “FUEL INJECTOR AND FUEL HOSE”.
THROTTLE BODY AND FUEL INJECTOR REMOVING THE FUEL HOSE 1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove: 8fuel hose connector cover 1 3. Disconnect: 8fuel hose 2 8 Be sure to disconnect the fuel hose by hand.
THROTTLE BODY AND FUEL INJECTOR INSTALLING THE FUEL PUMP 1. Install: 8 fuel pump 4Nm(0.4m»kg, 2.9ft*Ib) NOTE: 8 Do not damage the installation surfaces 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.
THROTTLE BODY AND FUEL INJECTOR EAS00915 CHECKING THE FUEL PUMP AND PRES- SURE REGULATOR OPERATION 1. Check: 8 pressure regulator operation • • • • • • • • • • • • • • • • • • • • • • • a.
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THROTTLE BODY AND FUEL INJECTOR Positive tester probe -> blue terminal ® Negative tester probe -» black/blue terminal Digital circuit tester 90890-03174 b. Measure the throttle position sensor volt- age. Out of specification -» Replace or repair the wire harness. Throttle position sensor voltage (blue-black/blue) c.
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THROTTLE BODY AND FUEL INJECTOR EAS00916 CHECKING THE ISC (IDLE SPEED CON- TROL) VALVE NOTE: Do not remove the ISC (idle speed control) valve unit completely from the throttle body assembly. 1. Check: 8ISC (idle speed control) valve • • • • • • • • • • • • • • • • • • • • • • • a.
AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust pipe reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS Air induction system hose Air filter case Air induction system hose (air filter case to air cut-off valve) Air cut-off valve Air induction system hose (air cut-off valve to exhaust pipe) 7-36...
AIR INDUCTION SYSTEM AIR CUT-OFF VALVE AND AIR FILTER CASE PV 7Nm(0.7m • kg, 5.1 ft • lb) 3R 7Nm(0.7m • kg, 5.1 ft • lb) Order Job/Part Remarks Q’ty Removing the air cut-off valve and Remove the parts in the order listed. air filter case Front cover Refer to”COVER AND PANEL”in chap-...
AIR INDUCTION SYSTEM EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection -» Connect properly. Cracks/damage -» Replace. 2. Check: • reed valve • reed valve stopper • reed valve seat Cracks/damage -» Replace the reed valve. 3.
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ELEC CHAPTER 8 ELECTORICAL ELECTRICAL COMPONENTS WIRING DIAGRAM CHECKING SWITCH CONTINUITY CHECKING THE SWITCHES CHECKING THE BULBS AND BULB SOCKETS TYPES OF BULBS CHECKING THE CONDITION OF THE BULBS CHECKING THE CONDITION OF THE BULB SOCKETS IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING 8-10 ELECTRIC STARTING SYSTEM...
WIRING DIAGRAM AC magneto COLOR CODE Rectifier/regulator Black Main fuse Brown Battery Chocolate Starter relay Dark green Starter motor Green Start switch Gray Engine stop switch Blue Light green Main switch Orange Intake air pressure sensor Pink Intake air temperature sensor Throttle position sensor Sky blue Lean angle cut-off switch...
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. Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
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 -»...
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 -»...
CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 8bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Be sure to hold the socket firmly when removing the bulb.
CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. Check: • bulb socket (for continuity) (with the pocket tester) No continuity -» Replace. Pocket tester 90890-03112 (YU-03112-C) NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section;...
IGNITION SYSTEM EAS00736 EAS00738 TROUBLESHOOTING 1. Main Fuse • Check the fuse for continuity. The ignition system fails to operate (no Refer to “CHECKING THE FUSE” in chap- spark or intermittent spark). ter 3. Is the fuse OK? Check: 1. main fuse 2.
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IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance Disconnect the spark plug cap from the spark • Remove the spark plug cap from the spark plug. plug lead. Connect the ignition checker 1 as shown. •...
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IGNITION SYSTEM EAS00748 7. Crankshaft position sensor resistance • Disconnect the crankshaft position sensor coupler from the wire harness. • Connect the pocket tester (£2 x100) to the crankshaft position sensor coupler shown. Positive tester probe g white/red 1 Negative tester probe g white/blue2 •...
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ELEC IGNITION SYSTEM EAS00750 9. Engine stop switch • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? Replace right handlebar switch. EAS00752 10. Sidestand switch(optional) Replace the lean angle •...
ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main fuse Battery Starter relay Starter motor Start switch Engine stop switch Main switch 8-14...
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...
ELECTRIC STARTING SYSTEM EAS00757 EAS00738 TROUBLESHOOTING 1. Main Fuse • Check the fuse for continuity. The starter motor fails to turn. Refer to “CHECKING THE FUSE” in chap- ter 3. Check: Is the fuse OK? 1. main fuse 2. battery 3.
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+1 I ELEC ELECTRIC STARTING SYSTEM EAS00758 EAS00759 4. Starting circuit cut-off relay • Remove the starting circuit cut-off relay. • Connect the pocket tester x1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown. Positive battery terminal -»...
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ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00751 5. Starter relay 7. Brake light switch(front and rear) • Remove the starter relay . • Check the brake light switches for continu- • Connect the pocket tester x1) and bat- ity. tery (12 V) to the starter relay coupler as Refer to “CHECKING THE SWITCHES”.
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ELECTRIC STARTING SYSTEM EAS00766 11. Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly con- nected and without defects? The starting system Properly connect or re- circuit is OK. pair starting system’s wiring.
ELEC ELECTRIC STARTING SYSTEM EAS00767 STARTER MOTOR ® ® Order Job/Part Remarks Q’ty Removing the starter motor Remove the parts in the order listed. Front cover Refer to “COVER AND PANEL”in chap- Single seat/Trunk ter 3. Air filter assembly Refer to“ENGINE REMOVAL”in chapter Starter motor lead coupler Disconnect.
ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt -» Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification -» Replace the starter motor. Commutator wear limit 16.6 mm (0.65 in) Measure: •...
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ELEC ELECTRIC STARTING SYSTEM b. If any resistance is out of specification, re- place the starter motor. • • • • • • • • • • • • • • • • • • • • • • • 5.
ELEC ELECTRIC STARTING SYSTEM EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: 8brush seat 1 2. Install: 8washer1 8armature coil 2 8o-ing 8stator assembly4 3 . Install: • bracket • bolts 5 Nm (0.5 m kg, 3.6 ft NOTE: Align the match marks a on the starter motor yoke with the match marks b on the bracket.
ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The battery is not being charged. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1 . main fuse Minimum open-circuit voltage 2. battery 12.8 V or more at 20°C (68°F) 3.
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ELEC CHARGING SYSTEM EAS00779 NOTE: 5. Wiring Make sure the battery is fully charged. • Check the wiring connections of the entire charging system. • Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly con- nected and without defects? The charging circuit is Replace the recti-...
LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Any of the following fail to light: headlight, Refer to “CHECKING AND CHARGING high beam indicator light, taillight, license THE BATTERY” in chapter 3. plate light or meter light. Minimum open-circuit voltage Check: 12.8 V or more at 20°C (68°F)
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LIGHTING SYSTEM EAS00787 5. Wiring • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly con- nected and without defects? Properly connect or re- Check the condition pair the lighting system’s of each of the light- wiring.
ELEC LIGHTING SYSTEM EAS00788 3. Voltage CHECKING THE LIGHTING SYSTEM • Connect the pocket tester (DC 20 V) to the 1. The headlight and the high beam indicator headlight and high beam indicator light cou- light fail to come on. plers as shown.
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ELEC LIGHTING SYSTEM EAS00789 2. The meter light fails to come on. 1. Meter light bulb and socket The wiring circuit from • Check the meter light bulb and socket for This circuit is OK. the main switch to the continuity.
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ELEC LIGHTING SYSTEM EAS00790 3. Voltage The tail/brake light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket ECU coupler (wire harness side) as shown. • Check the tail/brake light bulb and socket for continuity.
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LIGHTING SYSTEM EAS00792 4. The license plate light fails to come on. 1. License plate light bulb and socket • Check the license plate light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the license plate light bulb and socket Replace the license plate light bulb, socket or both.
SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • Any of the following fail to light: turn sig- Refer to “CHECKING AND CHARGING nal light, brake light or an indicator light. THE BATTERY” in chapter 3. •...
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ELEC SIGNALING SYSTEM EAS00798 3. Voltage The tail/brake light fails to come on. • 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. • Check the tail/brake light bulb and socket for continuity.
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ELEC SIGNALING SYSTEM EAS00799 4. Voltage 3. The turn signal light, turn signal indicator light • 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 •...
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SIGNALING SYSTEM 5. Voltage 6. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) turn signal light connector or meter assem- as shown.
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ELEC SIGNALING SYSTEM EAS00804 2. Voltage 4. The fuel level meter fails to operate. • Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as 1. Fuel sender shown. • Remove the fuel pump from the fuel tank. •...
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ELEC SIGNALING SYSTEM 3. Fuel level meter • Set the main switch to “ON”. • Move the float u p ® or down (2). • Check that the fuel level meter needle moves to “F” or “E”. NOTE: Before reading the fuel level meter, leave the float in one position (either up or down) for at least three minutes.
ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • The coolant temperature indicator light Refer to “CHECKING AND CHARGING fails to indicate. THE BATTERY” in chapter 3. • The coolant temperature indicator light fails to indicate when the engine is warm.
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+1 I ELEC COOLING SYSTEM EAS00812 Coolant temperature sensor 4. Coolant temperature sensor 22 Nm (2.2 m • kg, 15.9 ft • Remove the coolant temperature sensor from the cylinder head. • Does the coolant temperature sensor oper- Connect the pocket tester ( ×...
COOLING SYSTEM CHECKING THE COOLING SYSTEM 3. Voltage • Connect the pocket tester (DC 20 V) to the The coolant temperature indicator light fails meter light coupler (wire harness side) as to come on. shown. 1. Coolant temperature indicator light bulb and socket Positive tester probe ->...
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ELEC COOLING SYSTEM 4. Coolant temperature indicator light • Disconnect the coolant temperature sensor coupler at the coolant temperature sensor. • Connect the green/red® black/blue® with a jumper lead®. • Set the main switch to “ON”. • Is the coolant temperature indicator light OK? Replace the coolant This circuit is OK.
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TRBL SHTGl • CHAPTER 9 TROUBLE SHOOTING STARTING FAILURE/HARD STARTING ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING SPEED ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY CLUTCH ENGINE FUEL SYSTEM FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL NOT MOVE CLUTCH SLIPS POOR STARTING PERFORMANCE POOR SPEED PERFORMANCE...
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TRBL SHTGl • TURN SIGNAL DOES NOT COME ON TURN SIGNAL BLINKS SLOWLY TURN SIGNAL REMAINS LIT TURN SIGNAL BLINKS QUICKLY HORN DOES NOT SOUND...
TRBL STARTING FAILURE/HARD STARTING SHTGl • EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTGl • EAS00866 TURN SIGNAL REMAINS LIT FAULTY LIGHTING OR SIGNALING 8 F a u l t y t u r n signal relay SYSTEM 8Burnt-out turn signal bulb TURN SIGNAL BLINKS QUICKLY HEADLIGHT DOES NOT COME ON 8Incorrect turn signal bulb 8Wrong headlight bulb 8Faulty turn signal relay...