Yamaha 2004 YP400 Service Manual
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Yamaha 2004 YP400 Service Manual

Yamaha yp400(s) scooter service manual
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2004
YP400(S)
5RU1-AE1
SERVICE MANUAL

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  • Page 1 2004 YP400(S) 5RU1-AE1 SERVICE MANUAL...
  • Page 3 EAS00000 YP400(S) 2004 SERVICE MANUAL ©2003 by Yamaha Motor Co., Ltd. First edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers 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.
  • Page 5 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 6: General Information

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

  • Page 7: Table Of Contents

    EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 9 INFO...
  • Page 10 INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF FI SYSTEM ................. 1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTION ............... 1-4 IMPORTANT INFORMATION ............... 1-10 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-10 REPLACEMENT PARTS.................1-10 GASKETS, OIL SEALS AND O-RINGS ..........
  • Page 11 INFO...

  • Page 12: 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 inside the storage box. Record the information on this label in the space provided.

  • Page 13: 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 14: 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 kg/cm , 35.6 psi). Accord- ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 15: Instrument Function

    FEATURES INFO INSTRUMENT FUNCTIONS Multifunction display WARNING Be sure to stop the vehicle before making any setting changes to the multifunction display. 1 Clock/ambient temperature display 2 Coolant temperature meter 3 Fuel meter 4 Odometer/tripmeters 5 “SELECT” button 6 “RESET” button 1 V-belt replacement indicator “V-BELT”...
  • Page 16 FEATURES INFO Odometer and tripmeter modes Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the tripmeter modes “TRIP” in the follow- ing order: ODO → TRIP (top) → TRIP (bottom) → ODO When approximately 2.8 L (0.62 Imp gal, 0.74 US gal) of fuel remains in the fuel tank, the bottom segment of the fuel meter and fuel level warning symbol will start flashing, and the...
  • Page 17 FEATURES INFO Coolant temperature meter With the key in the “ON” position, the coolant temperature meter indicates the temperature of the coolant. The coolant temperature varies with changes in the weather and engine load. If the top segment and coolant temperature symbol flash, stop the vehicle and let the engine cool.
  • Page 18 FEATURES INFO To reset the oil change indicator 1. Turn the key to “ON”. 2. Hold the reset button pushed for two to eight seconds. 1 Reset button “OIL CHANGE” 3. Release the reset button, and the oil change indicator will go off. NOTE: If the engine oil is changed before the oil change indicator comes on (i.e.
  • Page 19 FEATURES INFO Self-diagnosis device This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the multi- function display will indicate a two-digit error code (e.g., 12, 13, 14). If the multifunction display indicates an error code, note the code number, and then check the vehicle.
  • Page 20 FEATURES INFO Clock mode To set the clock: 1. Push the “SELECT” button and “RESET” button together for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button, and the minute digits will start flashing.

  • Page 21: Important Information

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

  • Page 22: 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 manu-...

  • Page 23: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 24: Special Tools

    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 25 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Flywheel puller Flywheel puller Flywheel puller attachment 90890-01362 Flywheel puller attachment 90890-04089 This tool is used to remove the generator YM-33282 rotor. Fork seal driver weight Fork seal driver weight 90890-01367 Fork seal driver attachment (41 mm) YM-A9409-7 Fork seal driver These tools are used to install the oil...
  • Page 26 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Timing light 90890-03141 YU-03141 This tool is used to check the ignition tim- ing. Pressure gauge 90890-03153 YU-03153 This tool is used to measure fuel pres- sure. Adapter 90890-03181 This tool is used to measure fuel pres- sure.
  • Page 27 This tool is used to install or remove the crankshaft journal bearings. Ignition checker 90890-06754 YM-34487 This tool is used to check the ignition sys- tem components. Yamaha bond No. 1215 ® Sealant (Quick Gasket Bond 90890-85505 Sealant ACC-11001-05-01 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces).
  • Page 28 SPEC...
  • Page 29 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-10 ELECTRICAL SPECIFICATIONS ..............2-14 CONVERSION TABLE .................. 2-17 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-17 TIGHTENING TORQUES ................2-18 ENGINE TIGHTENING TORQUES............2-18 CHASSIS TIGHTENING TORQUES............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ....
  • Page 30 SPEC...

  • Page 31: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5RU1 (EUR) ---- 5RU3 (AUS) ---- Dimensions Overall length 2,230 mm (87.8 in) ---- Overall width 780 mm (30.7 in) ---- Overall height 1,380 mm (54.3 in) ---- Seat height 750 mm (29.5 in) ---- Wheelbase...

  • Page 32: Engine

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 394.9 cm (24.10 cu.in) ---- Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 83.0 × 73.0 mm (3.27 × 2.87 in) ---- Compression ratio 10.6 : 1 ---- Engine idling speed...

  • Page 33: Spec

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clear- 0.07 mm 0.15 mm ance (0.0028 in) (0.0059 in) Outer-rotor-to-oil-pump-housing 0.013 ~ 0.036 mm 0.106 mm clearance (0.0005 ~ 0.0014 in) (0.0042 in) Oil-pump-housing-to-inner-and-outer 0.040 ~ 0.096 mm 0.166 mm rotor clearance (0.0016 ~ 0.0038 in)
  • Page 34 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) ---- Camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ---- Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) ---- Camshaft-journal-to-camshaft-cap 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) 0.08 mm clearance (0.0031 in)
  • Page 35 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links SCR-0409 SDH/136 ---- Tensioning system Automatic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) ---- Exhaust 0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in) ---- Valve dimensions Head Diameter...
  • Page 36 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem runout ---- 0.01 mm (0.0004 in) Valve seat width Intake 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm (0.06 in) Exhaust 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm (0.06 in) Valve springs Free length...
  • Page 37 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinder Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 83.0 × 73.0 mm (3.27 × 2.87 in) ---- Compression ratio 10.6 : 1 ---- Bore 83.000 ~ 83.010 mm (3.2677 ~ 3.2681 in) ---- Maximum taper ----...
  • Page 38 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper ---- Dimensions (B × T) 1.00 × 3.10 mm (0.04 × 0.12 in) ---- End gap (installed) 0.40 ~ 0.55 mm (0.0157 ~ 0.0217 in) 0.80 mm (0.0315 in) Ring side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.100 mm...
  • Page 39 SPEC ENGINE SPECIFICATIONS Item Standard Limit Automatic centrifugal clutch Clutch shoe thickness 4.0 mm (0.16 in) 2.5 mm (0.10 in) Clutch shoe spring free length 34.7 mm (1.37 in) ---- Clutch housing inside diameter 160 mm (6.30 in) 160.5 mm (6.30 in) Compression spring free length 103.5 mm (4.075 in)

  • Page 40: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Aluminum die-cast and steel tube back- ---- bone Caster angle 27° ---- Trail 100.0 mm (3.94 in) ---- Front wheel Wheel type Cast wheel ---- 14 M/C × MT3.00 Size ---- Material...
  • Page 41 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 150/70-13M/C 64S ---- Model (manufacturer) MB 67 (IRC) ---- D305L (DUNLOP) ---- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.50 kgf/cm , 36 psi) ---- 90 ~ 198 kg (198 ~ 437 lb)
  • Page 42 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear brake Brake type Single-disc brake ---- Operation Left-hand operation ---- Recommended fluid DOT 4 ---- Brake discs Diameter × thickness 267 × 5 mm (10.51 × 0.20 in) ---- Minimum thickness ---- 4.5 mm (0.18 in) Maximum deflection ----...
  • Page 43 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular and taper roller bearings ---- Lock-to-lock angle (left) 40° ---- Lock-to-lock angle (right) 40° ---- Rear suspension Suspension type Unit swing ---- Rear shock absorber assembly type Coil spring/oil damper ---- Rear shock absorber assembly travel 130 mm (5.12 in) ----...

  • Page 44: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 5° BTDC at 1,400 r/min ---- Advancer type Digital ---- 248 ~ 372 Ω at 20 °C (68 °F)/red–white Crankshaft position sensor resis- ---- tance/color...
  • Page 45 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Indicator light (voltage/wattage × quantity) 12 V 1.4 W × 1 High beam indicator light ---- 12 V 1.4 W × 2 Turn signal indicator light ---- 12 V 1.4 W × 1 Engine trouble warning light ---- LED ×...
  • Page 46 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage × quantity) 40 A × 1 Main fuse ---- 10 A × 1 Fuel injection system fuse ---- 25 A × 1 Headlight fuse ---- 10 A × 1 Signaling system fuse ---- 10 A ×...

  • Page 47: Conversion Table

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS 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.

  • Page 48: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size Nm m · kg ft · lb Camshaft cap Bolt Exhaust pipe stud bolt — Spark plug — Cylinder head and cylinder Bolt Cylinder head and cylinder Cylinder head and cylinder Cap nut Cylinder head cover and cylinder...
  • Page 49 SPEC TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size Nm m · kg ft · lb Exhaust pipe Air induction system pipe Bolt Air induction system pipe stay Bolt Air cut-off valve Bolt Muffler mount Bolt V-belt case air duct 1 and 2 Bolt Crankcase Bolt...
  • Page 50 SPEC TIGHTENING TORQUES Camshaft cap tightening sequence: Cylinder head tightening sequence: 2 - 20...

  • Page 51: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks Nm m · kg ft · lb Bottom cover and sub-frame Radiator cover and frame Front cowling and front cowling stay Footrest board and footrest board stay Footrest board and sub-frame Reflector and reflector bracket Storage compartment and frame Rear fender and frame...
  • Page 52 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks Nm m · kg ft · lb Rear brake master cylinder and rear brake mas- ter cylinder holder Grip end Right handlebar switch Rear brake lock lever and left handlebar switch Storage box and frame Rider seat and bottom plate Seat lock assembly and frame...

  • Page 53: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips Bearings O-rings Cylinder head nut Camshaft cap and camshaft cap bolts Crankshaft pin Connecting rod big end thrust surface Balancer drive gear inner surface Crankshaft thrust surface Crankshaft journals...
  • Page 54 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Water pump seal lip Crankcase breather pipe Transmission case breather pipe Yamaha bond Cylinder head cover (guide stopper mating surface) No. 1215 Yamaha bond Crankcase mating surface No. 1215 Yamaha bond Generator rotor cover (grommet mating surface) No.

  • Page 55: Chassis Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Symbol Engine mounting bolt Swingarm, oil seal Steering bearings and oil seal Throttle grip inner surface and throttle cables Brake lever pivoting point and metal-to-metal moving parts (left and right) Rear brake lock lever cable and rear brake lock lever (cable connection area) Front wheel oil seal...

  • Page 56: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Radiator outlet hose 2 Radiator 3 Radiator cap 4 Coolant reservoir hose 5 Radiator filler hose 6 Radiator inlet hose 7 Radiator pipe assembly 2 - 26...
  • Page 57 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator pipe assembly B Water jacket inlet pipe 2 Oil cooler outlet hose C Oil cooler pipe 3 Oil cooler cover 4 Water pump outlet hose 5 Water pump cover 6 Water pump inlet hose 7 Thermostat inlet hose 8 Cooling system air bleed hose 9 Thermostat outlet hose...

  • Page 58: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Rear brake lock lever cable È Route the handlebar switch leads to the left of 2 Rear brake hose the cable guide (lower handlebar holder). 3 Cable guide (lower handlebar holder) É Route the throttle cables in front of the handle- 4 Throttle cable (accelerator cable) bar.
  • Page 59 SPEC CABLE ROUTING Ë Fasten the left handlebar switch lead to the han- Ï Install the grommet on the front brake hose in dlebar with a plastic locking tie. the hole in the lower handlebar cover before Ì Route the rear brake lock lever cable in front of connecting the hose.
  • Page 60 SPEC CABLE ROUTING 1 Meter assembly B Rectifier/regulator 2 Handlebar switch leads C Speed sensor lead 3 Throttle cable (accelerator cable) D Front turn signal light lead (right) 4 Throttle cable (decelerator cable) E Front turn signal light lead (left) 5 Front brake hose F Front turn signal light lead coupler (right) 6 Rear brake lock lever cable...
  • Page 61 SPEC CABLE ROUTING M Fuel injection system relay È After connecting the meter assembly coupler, N Headlight relay 1 install the cover to the meter assembly. O Meter assembly lead É Fasten the wire harness to the frame with a plas- P Lean angle cut-off switch tic locking tie.
  • Page 62 SPEC CABLE ROUTING Ë Pass the rear brake lock lever cable and rear Ð Route the handlebar switch leads in front of the brake hose through the hole in the frame so that front brake hose. Ñ Route the rear brake hose and rear brake lock the rear brake lock lever cable is to the outside of the rear brake hose.
  • Page 63 SPEC CABLE ROUTING Ó Pass the radiator fan motor lead through the cut- Ö Fasten the wire harness to the front cowling stay out in the left side of the bottom cover. with a plastic band. The end of the plastic band Ô...
  • Page 64 SPEC CABLE ROUTING 1 Sidestand switch lead B Starter motor 2 Crankshaft position sensor lead coupler C Fuel hose 3 Sub-wire harness D Spark plug lead 4 Crankshaft position sensor/stator coil lead E Sidestand switch 5 Storage box light switch lead F Stator coil lead 6 Storage box light G Wire harness...
  • Page 65 SPEC CABLE ROUTING M Battery band Ë Route the tail/brake light lead and rear turn sig- N Positive battery lead nal light/license plate light lead below the O V-belt replacement indicator reset coupler lead bracket on the frame. Ì Fasten the wire harness, starter motor lead, and È...
  • Page 66 SPEC CABLE ROUTING Î Connect the orange lead to the upper terminal of Ò Fasten the sub-wire harness at the white tape the ignition coil and connect the red/black lead to and the crankshaft position sensor/stator coil the lower terminal. lead to the engine bracket with a plastic locking Ï...
  • Page 67 SPEC CABLE ROUTING Ô Fasten the wire harness, starter motor lead, and Ø Route the positive battery lead between the negative battery lead to the frame with a plastic leads and the battery. Ù Install the cover over the positive battery termi- locking tie.
  • Page 68 SPEC CABLE ROUTING Ý Route the starter motor lead and negative bat- tery lead below the boss on the left engine bracket as shown. Þ Install the battery band with its projection in the recess in the top of the battery case. Ê...
  • Page 69 SPEC CABLE ROUTING 1 Rear brake lock lever cable È Route the seat lock cable through the cable 2 Rear brake hose cover. 3 Throttle cable (accelerator cable) É Pass the throttle cables through the hole in the 4 Throttle cable (decelerator cable) frame.
  • Page 70 SPEC CABLE ROUTING Ì After connecting the main switch lead, immobi- Ð Hook the end of the cable cover in the hole in lizer unit lead, and speed sensor lead, put the the frame. Ñ Fasten a plastic band around the middle of the cover on the couplers.
  • Page 71 SPEC CABLE ROUTING 1 Seat lock cable È Fasten the rear brake hose with the brake hose 2 Rear brake lock lever cable holder and route the rear brake lock lever cable 3 Rear brake hose through the guide. 4 Fuel overflow hose É...
  • Page 72 SPEC CABLE ROUTING Ì Route the fuel overflow hose to the outside of the hose guide. Í Fasten the coolant reservoir breather hose with the two holders on the bottom cover. Î Route the coolant reservoir breather hose to the outside of the hose guide.
  • Page 73 SPEC CABLE ROUTING 1 Seat lock cable È Route the throttle cables above the seat lock 2 Throttle cable (decelerator cable) cable guide. 3 Throttle cable (accelerator cable) É Route the section of the wire harness shown and 4 Rear brake lock lever cable the throttle cables through the cutout in the rub- 5 Rear brake hose ber sheet and then below the frame cross mem-...
  • Page 74 SPEC CABLE ROUTING Í Route the throttle cable (decelerator cable) above the throttle cable (accelerator cable). Î Route the throttle cables above the rear brake hose and rear brake lock lever cable. Ï Pass the seat lock cable through the space between the storage compartment and seat lock cable guide.
  • Page 75 SPEC CABLE ROUTING 1 Spark plug cap B Fuel injector lead 2 Seat lock cable C Storage box light switch lead 3 Seat lock assembly D Storage box light switch 4 ISC (idle speed control) valve lead E Sub-wire harness 5 Rear brake lock lever cable F Crankshaft position sensor/stator coil lead 6 Rear brake hose...
  • Page 76 SPEC CABLE ROUTING È Do not pinch any hoses, leads, etc., when Ë Route the starter motor lead and negative bat- installing the storage box. tery lead between the two projections on the É After connecting the positive battery lead, starter frame.
  • Page 78 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ......3-1 COWLING AND COVERS................3-3 PASSENGER SEAT AND SIDE COVERS..........3-3 RIDER SEAT AND STORAGE BOX ............3-4 SIDE COVER MOULDINGS AND FOOTREST BOARDS ......3-6 FRONT COWLING ..................3-7 AIR FILTER CASES ..................3-9 ENGINE ......................3-10 ADJUSTING THE VALVE CLEARANCE ..........
  • Page 79 CHASSIS ....................... 3-36 ADJUSTING THE REAR BRAKE LOCK LEVER CABLE .......3-36 CHECKING THE BRAKE FLUID LEVEL..........3-37 CHECKING THE FRONT AND REAR BRAKE PADS ......3-38 CHECKING THE FRONT AND REAR BRAKE HOSES......3-38 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........3-39 CHECKING AND ADJUSTING THE STEERING HEAD ......

  • Page 80: Periodic Checks And Adjustments

    • From 50,000 km, repeat the maintenance intervals starting from 10,000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1,000 km)
  • Page 81 PERIODIC MAINTENANCE AND LUBRICATION CHART ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Sidestand, center- • Check operation. √ √ √ √ √ stand • Lubricate. (See page 3-47.) Sidestand switch √ √ √ √ √ √...

  • Page 82: Cowling And Covers

    COWLING AND COVERS COWLING AND COVERS PASSENGER SEAT AND SIDE COVERS 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the passenger seat and Remove the parts in the order listed. side covers Upper rear cover Lower rear cover...

  • Page 83: Rider Seat And Storage Box

    COWLING AND COVERS RIDER SEAT AND STORAGE BOX 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 84 COWLING AND COVERS 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks...

  • Page 85: Side Cover Mouldings And Footrest Boards

    COWLING AND COVERS EAS00040 SIDE COVER MOULDINGS AND FOOTREST BOARDS 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the side cover mouldings Remove the parts in the order listed. and footrest boards Storage box Refer to “RIDER SEAT AND STORAGE BOX”.

  • Page 86: Front Cowling

    COWLING AND COVERS EAS00042 FRONT COWLING 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • •...
  • Page 87 COWLING AND COVERS 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • Order Job/Part Q’ty Remarks...

  • Page 88: Air Filter Cases

    AIR FILTER CASES AIR FILTER CASES 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the air filter cases Remove the parts in the order listed. Storage box Refer to “RIDER SEAT AND STORAGE BOX”.

  • Page 89: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00048 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.
  • Page 90 ADJUSTING THE VALVE CLEARANCE NOTE: • TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. • In order to be sure that the piston is at TDC, the punch marks c on the intake camshaft sprocket and the punch mark d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in...
  • Page 91 ADJUSTING THE VALVE CLEARANCE b. Select the proper valve pad from the follow- ing table. Valve pad thick- Available valve ness range pads 1.20 ~ 25 thicknesses in Nos. 2.40 mm 0.05 mm (0.002 in) 120 ~ 240 (0.0472 ~ increments 0.0945 in) NOTE:...
  • Page 92 ADJUSTING THE VALVE CLEARANCE NOTE: • Lubricate the valve pad with molybdenum disulfide grease. • Lubricate the valve lifter with molybdenum disulfide oil. • The valve lifter must turn smoothly when rotated by hand. • Install the valve lifter and the valve pad in the correct place.
  • Page 93 ADJUSTING THE VALVE CLEARANCE INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.10 ~ 0.14...

  • Page 94: Adjusting The Exhaust Gas Volume

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE EXHAUST GAS VOLUME 7. Install: • all removed parts Refer to “CYLINDER HEAD” in chapter 5. NOTE: For installation, reverse the removal proce- dure. Note the following points. EAS00869 ADJUSTING THE EXHAUST GAS VOLUME NOTE: Be sure to set the CO density level to stan- dard, and then adjust the exhaust gas volume.

  • Page 95: Checking The Engine Idling Speed

    ADJUSTING THE EXHAUST GAS VOLUME/ CHECKING THE ENGINE IDLING SPEED 5. Check that “C1” appears on the odometer LCD, and then simultaneously press the “SELECT” and “RESET” buttons for 2 sec- onds or more. 6. Change the CO adjustment volume by pressing the “SELECT”...

  • Page 96: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY 1. Check: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 2.
  • Page 97 CHECKING THE SPARK PLUG 3. Remove: • spark plug CAUTION: Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from fall- ing into the cylinder. 4. Check: • spark plug type Incorrect →...

  • Page 98: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING EAS00064 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition sys- tem. Make sure all connections are tight and free of corrosion. 1. Remove: • storage box lower plate Refer to “RIDER SEAT AND STORAGE BOX”.

  • Page 99: Measuring The Compression Pressure

    MEASURING THE COMPRESSION PRESSURE EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Remove: • storage box lower plate Refer to “RIDER SEAT AND STORAGE BOX”. 2. Measure: • valve clearance Out of specification → Adjust. Refer “ADJUSTING VALVE...
  • Page 100 MEASURING THE COMPRESSION PRESSURE 7. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,218 kPa (12.18 kg/cm , 173.2 psi) Standard 1,400 kPa (14.00 kg/cm , 199.1 psi) Maximum 1,568 kPa (15.68 kg/cm...

  • Page 101: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 8. Install: • spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb) 9. Connect: • spark plug cap 10.Install: • storage box lower plate Refer to “RIDER SEAT AND STORAGE BOX”.

  • Page 102: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5.
  • Page 103 CHANGING THE ENGINE OIL 6. If the oil filter element is also to be replaced, perform the following procedure. M MMM M MMM M MMM M MMM M MMM a. Remove the oil filter element cover 1 and oil filter element 2. b.
  • Page 104 CHANGING THE ENGINE OIL 10.Fill: • crankcase (with the specified amount of the recom- mended engine oil) Quantity Total amount 1.7 L (1.50 Imp qt, 1.80 US qt) Without oil filter element replacement 1.5 L (1.32 Imp qt, 1.59 US qt) With oil filter element replace- ment 1.7 L (1.50 Imp qt, 1.80 US qt)

  • Page 105: Changing The Transmission Oil

    CHANGING THE ENGINE OIL/ CHANGING THE TRANSMISSION OIL 16.Reset: • engine oil change indicator M MMM M MMM M MMM M MMM M MMM a. Turn the key to “ON”. b. Hold the reset button 1 pushed for two to eight seconds.

  • Page 106: Replacing The Air Filter Elements

    CHANGING THE TRANSMISSION OIL/ REPLACING THE AIR FILTER ELEMENTS 7. Fill: • transmission case (with the specified amount of the recom- mended transmission oil) Recommended oil SAE 10W30 type SE motor oil Quantity 0.25 L (0.22 Imp qt, 0.26 US qt) 8.

  • Page 107: Cleaning The V-Belt Case Air Filter Element

    REPLACING THE AIR FILTER ELEMENTS/ CLEANING THE V-BELT CASE AIR FILTER ELEMENT 3. Install: • air filter element • air filter case cover (along with the gasket) CAUTION: Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.

  • Page 108: Checking The Throttle Body Joint And Intake Manifold

    CLEANING THE V-BELT CASE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD/ CHECKING THE FUEL HOSE 6. Install: • footrest board (left) Refer to “RIDER SEAT AND STORAGE BOX”. EAS00094 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 1.

  • Page 109: Checking The Breather Hoses

    CHECKING THE BREATHER HOSES EAS00098 CHECKING THE BREATHER HOSES 1. Remove: • storage box Refer to “RIDER SEAT AND STORAGE BOX”. 2. Check: • crankcase breather hose 1 • transmission case breather hose 2 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: Make sure the breather hoses are routed correctly.

  • Page 110: Checking The Exhaust System

    CHECKING THE EXHAUST SYSTEM/ CHECKING THE COOLANT LEVEL EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • footrest board (right) Refer to “SIDE COVER MOULDINGS AND FOOTREST BOARDS”. 2. Check: •...

  • Page 111: Checking The Cooling System

    CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. •...

  • Page 112: Changing The Coolant

    CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT 3. Install: • footrest boards (left and right) Refer to “SIDE COVER MOULDINGS AND FOOTREST BOARDS”. EAS00105 CHANGING THE COOLANT 1. Remove: • storage box • footrest board (right) Refer to “SIDE COVER MOULDINGS AND FOOTREST BOARDS”.
  • Page 113 CHANGING THE COOLANT 7. Install: • copper washer • coolant drain bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) 8. Connect: • coolant reservoir hose 9. Remove: • air bleed bolt (coolant) 1 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze...
  • Page 114 CHANGING THE COOLANT CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.

  • Page 115: Chassis

    ADJUSTING THE REAR BRAKE LOCK LEVER CABLE EAS00116 CHASSIS ADJUSTING THE REAR BRAKE LOCK LEVER CABLE NOTE: • Place the scooter on a suitable stand. • Before adjusting the rear brake lock lever, check the rear brake fluid level. 1. Measure: •...

  • Page 116: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVEL CHECKING THE BRAKE FLUID LEVEL È 1. Stand the scooter on a level surface. NOTE: • Place the scooter on a suitable stand. • Make sure the scooter is upright. 2. Check: • brake fluid level Below the minimum level mark a →...

  • Page 117: Checking The Front And Rear Brake Pads

    CHECKING THE FRONT AND REAR BRAKE PADS/ CHECKING THE FRONT AND REAR BRAKE HOSES EAS00118 È CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad Wear indicator groove a almost disap- peared →...

  • Page 118: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. •...

  • Page 119: Checking And Adjusting The Steering Head

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHECKING AND ADJUSTING THE STEERING HEAD g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake levers to contact the handlebar. h. Tighten the bleed screw and then release the brake lever.
  • Page 120 CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: • lower handlebar holder Refer to “STEERING HEAD” in chapter 4. 4. Adjust: • steering head M MMM M MMM M MMM M MMM M MMM a. Remove the upper steering ring nut 1, the lock washer 2, the center steering ring nut 3 and the rubber washer.

  • Page 121: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK g. Finger tighten the center steering ring nut, and then align the slots of both ring nuts. If necessary, hold the lower steering ring nut and tighten the center steering ring nut until their slots are aligned.

  • Page 122: Checking The Tires

    CHECKING THE FRONT FORK/ CHECKING THE TIRES 4. Check: • front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to “FRONT FORK” in chapter 4. EAS00165 CHECKING THE TIRES The following procedure applies to both of the...
  • Page 123 Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.
  • Page 124 CHECKING THE TIRES Front tire Manufacturer Size Model 120/80- DUNLOP 14M/C D305FL 120/80- 14M/C MB 67 Rear tire Manufacturer Size Model 150/70- DUNLOP 13M/C D305L 150/70- 13M/C MB 67 WARNING • New tires have a relatively low grip on the road surface until they have been slightly worn.

  • Page 125: 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: • wheel Damage/out-of-round → Replace. WARNING Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.

  • Page 126: Lubricating The Levers

    LUBRICATING THE LEVERS/LUBRICATING THE SIDESTAND/LUBRICATING THE CENTERSTAND 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. Recommended lubricant Lithium-soap-based grease EAS00173...

  • Page 127: Chk Adj

    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: • Wear protective eye gear when handling or working near batteries.
  • Page 128 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 129 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20 °C (68 °F) • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. • Never remove the MF battery sealing caps.
  • Page 130 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger NOTE: Ammeter Leave the battery unused for more than 30 minutes before Measure the open-circuit measuring its open-circuit voltage. voltage prior to charging. NOTE: Set the charging voltage to Connect a charger and 16 ~ 17 V.
  • Page 131 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

  • Page 132: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals Dirt →...
  • Page 133 CHECKING THE FUSES 2. Check: • fuse M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112, YU-03112-C b.

  • Page 134: Replacing The Headlight Bulbs

    CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULBS WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
  • Page 135 REPLACING THE HEADLIGHT BULBS 5. Remove: • headlight bulb 1 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 6. Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder.

  • Page 136: Adjusting The Headlight Beams

    ADJUSTING THE HEADLIGHT BEAMS EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b.

  • Page 138: Chas

    CHAS...
  • Page 139 CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC............... 4-1 REMOVING THE FRONT WHEEL............4-3 CHECKING THE FRONT WHEEL ............4-3 CHECKING THE BRAKE DISCS .............. 4-4 INSTALLING THE FRONT WHEEL ............4-6 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-7 REAR WHEEL AND BRAKE DISC..............4-9 REMOVING THE REAR WHEEL ............
  • Page 140 CHAS STEERING HEAD..................4-60 LOWER BRACKET ................. 4-60 REMOVING THE LOWER BRACKET.............4-62 CHECKING THE STEERING HEAD ............4-63 INSTALLING THE STEERING HEAD .............4-64 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM....4-65 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ....4-67 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES....4-67 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES....

  • Page 141: Front Wheel And Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC EAS00513 CHASSIS FRONT WHEEL AND BRAKE DISC 20 Nm (2.0 m kg, 14 ft 55 Nm (5.5 m kg, 40 ft • • • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty...
  • Page 142 CHAS FRONT WHEEL AND BRAKE DISC EAS00518 Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal Bearing Collar For assembly, reverse the disassembly procedure. 4 - 2...

  • Page 143: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC 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. 2. Elevate: • front wheel NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.

  • Page 144: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISC 4. Check: • wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. • oil seals Damage/wear → Replace. 5. Replace: • wheel bearings • oil seal M MMM M MMM M MMM M MMM M MMM...
  • Page 145 CHAS FRONT WHEEL AND BRAKE DISC 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maxi- mum) Front: 0.15 mm (0.006 in) Rear: 0.15 mm (0.006 in) M MMM M MMM M MMM...

  • Page 146: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC 4. Adjust: • brake disc deflection M MMM M MMM M MMM M MMM M MMM a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.

  • Page 147: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISC 2. Install: • spacer • speed sensor • front wheel NOTE: • Make sure that the projections on the speed sensor are installed in the slots on the wheel hub. • Make sure that the slot a in the speed sen- sor fits over the stopper b on the outer tube.
  • Page 148 CHAS FRONT WHEEL AND BRAKE DISC 2. Find: • front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. M MMM M MMM M MMM M MMM M MMM a. Spin the front wheel. b. When the front wheel stops, put an “X ”...

  • Page 149: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC EAS00552 REAR WHEEL AND BRAKE DISC 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the rear wheel and brake Remove the parts in the order listed. disc NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 150: Removing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00561 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. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 151: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Front brake caliper retaining bolt Front brake caliper Brake pad Refer to “REPLACING THE FRONT...

  • Page 152: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Air filter case (right) Refer to “AIR FILTER CASES” in chapter Rear brake caliper retaining bolt Rear brake caliper Refer to “REPLACING THE REAR...

  • Page 153: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 154 CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4. Install: • brake pad shims 1 • brake pads 2 •...

  • Page 155: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES 6. Install: • front brake caliper 1 • front brake caliper retaining bolts 2 27 Nm (2.7 m · kg, 19 ft · lb) 7. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
  • Page 156 CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4. Install: • brake pad springs 1 • brake pads 2 •...
  • Page 157 CHAS FRONT AND REAR BRAKES d. Install new brake pads, new pad springs, and the rear brake caliper. NOTE: È Align the projection c on the piston side of the brake pad with the lower recess in the brake caliper piston. È...

  • Page 158: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Upper handlebar cover Refer to “HANDLEBAR”. Brake fluid Drain. Brake master cylinder reservoir cap Brake master cylinder reservoir dia- phragm holder Brake master cylinder reservoir dia-...
  • Page 159 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake master cylinder holder Refer to “ASSEMBLING AND INSTALL- ING THE FRONT BRAKE MASTER Brake master cylinder CYLINDER”. Front brake light switch For installation, reverse the removal pro- cedure. 4 - 19...
  • Page 160 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure.

  • Page 161: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder Upper handlebar cover Refer to “HANDLEBAR”. Brake fluid Drain. Brake master cylinder reservoir cap Brake master cylinder reservoir dia- phragm holder Brake master cylinder reservoir dia-...
  • Page 162 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake master cylinder holder Refer to “ASSEMBLING AND INSTALL- ING THE REAR BRAKE MASTER CYL- Brake master cylinder INDER”. Rear brake light switch For installation, reverse the removal pro- cedure. 4 - 22...

  • Page 163: Disassembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure.
  • Page 164 CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hoses 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the...

  • Page 165: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS00592 È CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction →...

  • Page 166: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00596 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components.
  • Page 167 CHAS FRONT AND REAR BRAKES NOTE: • While holding the brake hose, tighten the union bolt as shown. • Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads).

  • Page 168: Assembling And Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: • brake lever operation Soft or spongy feeling →...
  • Page 169 CHAS FRONT AND REAR BRAKES 2. Install: • brake master cylinder 1 • brake master cylinder holder 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Make sure to install the brake master cylin- der holder that has the “L” mark. •...
  • Page 170 CHAS FRONT AND REAR BRAKES 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 171: Front Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00612 FRONT BRAKE CALIPER Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Refer to “DISASSEMBLING THE FRONT BRAKE CALIPER” and Copper washer “ASSEMBLING AND INSTALLING THE Brake hose FRONT BRAKE CALIPER”.
  • Page 172 CHAS FRONT AND REAR BRAKES EAS00614 Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. Brake caliper retaining bolt Brake caliper bracket Bleed screw Brake pad Brake pad shim Brake pad spring Brake pad spring Brake caliper piston Refer to “DISASSEMBLING THE FRONT BRAKE CALIPER”...

  • Page 173: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed.
  • Page 174 CHAS FRONT AND REAR BRAKES 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Rear brake caliper retaining bolt Rear brake caliper Brake caliper bracket bolt Refer to “ASSEMBLING AND INSTALL-...

  • Page 175: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 m kg, 4.3 ft • • 22 Nm (2.2 m kg, 16 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Brake caliper piston Refer to “DISASSEMBLING THE REAR BRAKE CALIPER”...
  • Page 176 CHAS FRONT AND REAR BRAKES EAS00619 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 177: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: • brake caliper piston 1 •...
  • Page 178 CHAS FRONT AND REAR BRAKES 1. Check: È • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper pistons. • brake caliper cylinders 2 Scratches/wear → Replace the brake cali- per assembly. • brake caliper body 3 Cracks/damage → Replace the brake cali- per assembly.

  • Page 179: Assembling And Installing The Front Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00635 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort.
  • Page 180 CHAS FRONT AND REAR BRAKES 4. Remove: • brake caliper 5. Install: • brake pad springs • brake pads • brake caliper retaining bolts 27 Nm (2.7 m · kg, 19 ft · lb) Refer “REPLACING FRONT BRAKE PADS”. 6. Fill: •...

  • Page 181: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 8. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 9. Check: • brake lever operation Soft or spongy feeling →...
  • Page 182 CHAS FRONT AND REAR BRAKES 2. Install: • brake caliper piston 1 Turn the brake caliper piston clockwise until section a of the brake caliper piston is level with the surface of the brake caliper body. NOTE: Align the recesses b in the brake caliper pis- ton with the brake caliper body as shown in the illustration.
  • Page 183 CHAS FRONT AND REAR BRAKES Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.

  • Page 184: Front Fork

    CHAS FRONT FORK EAS00646 FRONT FORK 30 Nm (3.0 m kg, 22 ft 70 Nm (7.0 m kg, 50 ft • • • • 7 Nm (0.7 m kg, 5.1 ft • • 40 Nm (4.0 m kg, 29 ft •...
  • Page 185 CHAS FRONT FORK 30 Nm (3.0 m kg, 22 ft 70 Nm (7.0 m kg, 50 ft • • • • 7 Nm (0.7 m kg, 5.1 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks...
  • Page 186 CHAS FRONT FORK EAS00648 30 Nm (3.0 m kg, 22 ft • • 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. Fork spring seat Fork spring Dust seal...
  • Page 187 CHAS FRONT FORK 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Washer Refer to “DISASSEMBLING THE Outer tube bushing FRONT FORK LEGS” and “ASSEM- BLING THE FRONT FORK LEGS”. Outer tube For assembly, reverse the disassembly procedure.

  • Page 188: 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. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
  • Page 189 CHAS FRONT FORK 3. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 4. Remove: • damper rod bolt 1 NOTE: While holding the damper rod with the damper rod holder 2 and T-handle 3, loosen the damper rod bolt.

  • Page 190: 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: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
  • Page 191 CHAS FRONT FORK NOTE: • When assembling the front fork leg, be sure to replace the following parts: - inner tube bushing - outer tube bushing - oil seal - dust seal - cap bolt O-ring • Before assembling the front fork leg, make sure all of the components are clean.
  • Page 192 CHAS FRONT FORK 4. Install: • outer tube bushing 1 • washer 2 (with the fork seal driver weight 3 and fork seal driver attachment 4) Fork seal driver weight 90890-01367, YM-A9409-7 Fork seal driver attachment (41 mm) 90890-01381, YM-A5142-2 5.

  • Page 193: Installing The Front Fork Legs

    Quantity (each front fork leg) 0.298 L (0.262 Imp qt, 0.315 US qt) Recommended oil Yamaha fork and shock oil 10 W or equivalent Front fork leg oil level a (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) 88 mm (3.46 in)

  • Page 194: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR 23 Nm (2.3 m kg, 17 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft • • 6 Nm (0.6 m kg, 4.3 ft •...
  • Page 195 CHAS HANDLEBAR 23 Nm (2.3 m kg, 17 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft • • 6 Nm (0.6 m kg, 4.3 ft •...

  • Page 196: 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: • handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
  • Page 197 CHAS HANDLEBAR 2. Install: • handlebar 1 • upper handlebar holders 2 23 Nm (2.3 m · kg, 17 ft · lb) CAUTION: First, tighten the bolts on the front side of the handlebar holders, and then on the rear side.
  • Page 198 CHAS HANDLEBAR 5. Install: • rear brake lock lever cable 1 NOTE: Lubricate the inside of the rear brake lock lever cable and rear brake lock lever with a thin coat of lithium-soap-based grease. 6. Install: • left handlebar switch 1 6 Nm (0.6 m ·...
  • Page 199 CHAS HANDLEBAR 9. Install: • right handlebar switch 1 WARNING Make sure the throttle grip operates smoothly. NOTE: Align the projection a on the right handlebar switch with the hole b in the handlebar. 10.Install: • grip end (left) NOTE: There should be 1 ~ 3 mm (0.04 ~ 0.12 in) of clearance a between the throttle grip and the grip end.

  • Page 200: Steering Head

    CHAS STEERING HEAD EAS00675 STEERING HEAD LOWER BRACKET 140 Nm (14.0 m kg, 100 ft • • 90 Nm (9.0 m kg, 65 ft • • 1st 36 Nm (3.6 m kg, 25 ft • • 2nd 24 Nm (2.4 m kg, 17 ft •...
  • Page 201 CHAS STEERING HEAD 140 Nm (14.0 m kg, 100 ft • • 90 Nm (9.0 m kg, 65 ft • • 1st 36 Nm (3.6 m kg, 25 ft • • 2nd 24 Nm (2.4 m kg, 17 ft • •...

  • Page 202: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00680 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: • handlebar lower holder 1 • woodruff key 2 NOTE: Remove the handlebar lower holder by loosen- ing the upper steering ring nut 3 gradually.

  • Page 203: Checking The Steering Head

    CHAS STEERING HEAD EAS00681 CHECKING THE STEERING HEAD 1. Wash: • bearings • bearing races Recommended cleaning solvent Kerosene 2. Check: • bearings 1 • bearing races 2 Damage/pitting → Replace. 3. Replace: • bearings • bearing races M MMM M MMM M MMM M MMM...

  • Page 204: Installing The Steering Head

    CHAS STEERING HEAD EAS00684 INSTALLING THE STEERING HEAD 1. Lubricate: • upper bearing • lower bearing • bearing races Recommended lubricant Lithium-soap-based grease 2. Clean: • lower bracket • steering ring nuts • lower handlebar holder NOTE: Clean the area a of the lower bracket indi- cated in the illustration and the inner surfaces of the lower handlebar holder and steering ring nuts.

  • Page 205: Rear Shock Absorber Assemblies And Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS00685 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 135 Nm (13.5 m kg, 98 ft • • 40 Nm (4.0 m kg, 29 ft • •...
  • Page 206 REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 135 Nm (13.5 m kg, 98 ft • • 40 Nm (4.0 m kg, 29 ft • • 46 Nm (4.6 m kg, 33 ft •...

  • Page 207: Removing The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS00693 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 208: Removing The Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS00702 REMOVING THE SWINGARM 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 209: Installing The Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS00711 INSTALLING THE SWINGARM 1. Lubricate: • bearing • oil seal lips • drive axle splines Recommended lubricant Lithium-soap-based grease 2. Install: • swingarm 1 46 Nm (4.6 m · kg, 33 ft · lb) •...
  • Page 212 CHAPTER 5 ENGINE ENGINE REMOVAL ..................5-1 LEADS, HOSES, EXHAUST PIPE AND MUFFLER .........5-1 ENGINE..................... 5-3 INSTALLING THE ENGINE............... 5-5 CAMSHAFTS....................5-6 CYLINDER HEAD COVER................ 5-6 CAMSHAFTS .................... 5-7 REMOVING THE CAMSHAFTS..............5-9 CHECKING THE CAMSHAFTS ..............5-10 CHECKING THE CAMSHAFT SPROCKETS .........5-12 CHECKING THE DECOMPRESSION SYSTEM........5-12 CHECKING THE TIMING CHAIN TENSIONER........
  • Page 213 BELT DRIVE....................5-37 V-BELT CASE COVER ................5-37 V-BELT AND PRIMARY/SECONDARY SHEAVE........5-38 SECONDARY SHEAVE ................5-40 REMOVING THE PRIMARY SHEAVE............5-42 REMOVING THE SECONDARY SHEAVE AND V-BELT .......5-42 DISASSEMBLING THE SECONDARY SHEAVE........5-43 CHECKING THE V-BELT................5-44 CHECKING THE V-BELT CASE AIR DUCTS.........5-44 CHECKING THE PRIMARY SHEAVE ............5-44 CHECKING THE PRIMARY SHEAVE WEIGHTS........

  • Page 214: Engine

    ENGINE REMOVAL EAS00188 ENGINE ENGINE REMOVAL LEADS, HOSES, EXHAUST PIPE AND MUFFLER 53 Nm (5.3 m kg, 38 ft • • 20 Nm (2.0 m kg, 14 ft • • 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks...
  • Page 215 ENGINE REMOVAL 53 Nm (5.3 m kg, 38 ft • • 20 Nm (2.0 m kg, 14 ft • • 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Starter motor Refer to “STARTER MOTOR” in chapter Thermostat cover and thermostat Refer to “THERMOSTAT”...

  • Page 216: Engine

    ENGINE REMOVAL EAS00191 ENGINE 56 Nm (5.6 m kg, 40 ft 65 Nm (6.5 m kg, 47 ft • • • • 59 Nm (5.9 m kg, 43 ft • • 29 Nm (2.9 m kg, 21 ft • • 45 Nm (4.5 m kg, 32 ft •...
  • Page 217 ENGINE REMOVAL 56 Nm (5.6 m kg, 40 ft 65 Nm (6.5 m kg, 47 ft • • • • 59 Nm (5.9 m kg, 43 ft • • 29 Nm (2.9 m kg, 21 ft • • 45 Nm (4.5 m kg, 32 ft •...

  • Page 218: Installing The Engine

    ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: • right engine bracket 1 • center engine bracket 2 • left engine bracket 3 • engine mounting bolt/nut 4 • engine bracket bolts 5 NOTE: • Apply lithium-soap-based grease to the unthreaded portion of the engine mounting bolt shaft.

  • Page 219: Camshafts

    CAMSHAFTS EAS00194 CAMSHAFTS CYLINDER HEAD COVER 10 Nm (1.0 m kg, 7.2 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Storage box and rubber sheet Refer to “COWLING AND COVERS”...

  • Page 220: Camshafts

    CAMSHAFTS EAS00196 CAMSHAFTS 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 221 CAMSHAFTS 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 222: Removing The Camshafts

    CAMSHAFTS EAS00198 REMOVING THE CAMSHAFTS 1. Remove: • timing plug • V-belt case air filter cover 1 • V-belt case air filter element 2. Align: • TDC mark on the generator rotor (with the stationary pointer on the generator rotor cover) M MMM M MMM M MMM...

  • Page 223: Checking The Camshafts

    CAMSHAFTS 6. Remove: • camshaft cap 1 • dowel pins NOTE: • Loosen the camshaft cap bolts in the descending order of the embossed numbers on the camshaft cap. • Loosen each camshaft cap bolt 1/2 of a turn at a time. After all of the camshaft cap bolts are fully loosened, remove them.
  • Page 224 CAMSHAFTS 3. Measure: • camshaft runout Out of specification → Replace. Camshaft runout limit 0.03 mm (0.0012 in) 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance Out of specification → Measure the cam- shaft journal diameter. Camshaft-journal-to-camshaft- cap clearance limit 0.08 mm (0.0031 in) M MMM M MMM M MMM...

  • Page 225: Checking The Camshaft Sprockets

    CAMSHAFTS 5. Measure: • camshaft journal diameter a Out of specification → Replace the cam- shaft. Within specification → Replace the cylinder head and the camshaft cap as a set. Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) CHECKING THE CAMSHAFT SPROCKETS 1.

  • Page 226: Checking The Timing Chain Tensioner

    CAMSHAFTS EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage/rough movement → Replace. M MMM M MMM M MMM M MMM M MMM a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1.
  • Page 227 CAMSHAFTS 3. Install: • intake camshaft 1 • exhaust camshaft 2 M MMM M MMM M MMM M MMM M MMM a. Turn the primary sheave nut on the left side of the crankshaft counterclockwise to turn the crankshaft. b. When piston is at TDC on the compression stroke, align the “I”...
  • Page 228 CAMSHAFTS CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft cap, and camshafts will result. 6. Install: • timing chain tensioner M MMM M MMM M MMM M MMM M MMM a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1.
  • Page 229 CAMSHAFTS 8. Turn: • crankshaft (turn the primary sheave nut on the left side of the crankshaft several turns counter- clockwise) 9. Check: • “I” mark Make sure the “I” mark on the generator rotor is aligned with the stationary pointer on the generator rotor cover.

  • Page 230: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 18 Nm (1.8 m kg, 13 ft • • 12 Nm (1.2 m kg, 8.7 ft • •...
  • Page 231 CYLINDER HEAD 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 18 Nm (1.8 m kg, 13 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 52 Nm (5.2 m kg, 37 ft •...

  • Page 232: Removing The Cylinder Head

    CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: • cylinder head nuts NOTE: • Loosen the cylinder head nuts in the proper sequence as shown. • Loosen each cylinder head nut 1/2 of a turn at a time. After all of the cylinder head nuts are fully loosened, remove them.

  • Page 233: Checking The Timing Chain Guide (Exhaust Side)

    CYLINDER HEAD CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) 1. Check: • timing chain guide (exhaust side) Damage/wear → Replace. EAS00232 INSTALLING THE CYLINDER HEAD 1. Install: • timing chain guide (exhaust side) • cylinder head gasket • dowel pins 2.

  • Page 234: 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”. Valve lifter Adjusting pad Valve cotter Upper valve spring seat Valve spring Refer to “REMOVING THE VALVES”...

  • Page 235: Removing The Valves

    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.

  • Page 236: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 4. Remove: • upper spring seat 1 • valve spring 2 • valve stem seal 3 • lower spring seat 4 • valve 5 NOTE: 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 237 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: 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. M MMM M MMM M MMM M MMM M MMM a.

  • Page 238: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.01 mm (0.0004 in) EAS00240...
  • Page 239 VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. L LLL L LLL L LLL L LLL L LLL 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

  • Page 240: Checking The Valve Springs

    VALVES AND VALVE SPRINGS j. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. L LLL L LLL L LLL L LLL L LLL EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.

  • Page 241: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Measure: • valve spring tilt a Out of specification → Replace the valve spring. Spring tilt limit 2.0 mm (0.08 in) EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1.
  • Page 242 VALVES AND VALVE SPRINGS NOTE: Install the valve spring with the larger pitch a facing up. b Smaller pitch 4. Install: • valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attach- ment 3.

  • Page 243: Cylinder And Piston

    CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed.

  • Page 244: Removing The Piston

    CYLINDER AND PISTON EAS00253 REMOVING THE PISTON 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to pre- vent the piston pin clip from falling into the crankcase.
  • Page 245 CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance M MMM M MMM M MMM M MMM M MMM a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder.

  • Page 246: Checking The Piston Rings

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

  • Page 247: Checking The Piston Pin

    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 piston pin.
  • Page 248 CYLINDER AND PISTON NOTE: Be sure to install the top and 2nd rings so that the manufacturer’s marks or numbers face up. 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 NOTE: • Apply engine oil onto the piston pin. •...
  • Page 249 CYLINDER AND PISTON 6. Install: • dowel pins • cylinder gasket • cylinder • cylinder bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • While compressing the piston rings with one hand, install the cylinder with the other hand. •...

  • Page 250: Belt Drive

    BELT DRIVE EAS00316 BELT DRIVE V-BELT CASE COVER 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 251: V-Belt And Primary/Secondary Sheave

    BELT DRIVE V-BELT AND PRIMARY/SECONDARY SHEAVE ® Apply Shell BT grease 3 (YAMAHA grease G 90890-40010) ® Apply BEL-RAY assembly lube Order Job/Part Q’ty Remarks Removing the V-belt and primary/ Remove the parts in the order listed. secondary sheave Primary sheave nut/collar Refer to “REMOVING THE PRIMARY...
  • Page 252 BELT DRIVE ® Apply Shell BT grease 3 (YAMAHA grease G 90890-40010) ® Apply BEL-RAY assembly lube Order Job/Part Q’ty Remarks Weight Slider Spacer O-ring For installation, reverse the removal procedure. 5 - 39...
  • Page 253 BELT DRIVE SECONDARY SHEAVE ® Apply BEL-RAY assembly lube Order Job/Part Q’ty Remarks Disassembling the secondary Remove the parts in the order listed. sheave Clutch shoe assembly nut Refer to “DISASSEMBLING THE SEC- ONDARY SHEAVE” and “ASSEMBLING Clutch shoe assembly THE SECONDARY SHEAVE”.
  • Page 254 BELT DRIVE ® Apply BEL-RAY assembly lube Order Job/Part Q’ty Remarks Circlip Bearing For assembly, reverse the disassembly procedure. 5 - 41...

  • Page 255: Removing The Primary Sheave

    BELT DRIVE EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: • primary sheave nut 1 • collar • primary fixed sheave 2 NOTE: While holding the primary fixed sheave with the rotor holding tool 3, loosen the primary sheave nut. Rotor holding tool 90890-01235, YU-01235 EAS00318 REMOVING THE SECONDARY SHEAVE...

  • Page 256: Disassembling The Secondary Sheave

    BELT DRIVE 2. Loosen: • clutch shoe assembly nut 1 CAUTION: Do not remove the clutch shoe assembly nut at this stage. NOTE: While holding the clutch shoe assembly with the rotor holding tool 2, loosen the clutch shoe assembly nut one full turn with the lock- nut wrench 3.

  • Page 257: Checking The V-Belt

    BELT DRIVE EAS00320 CHECKING THE V-BELT 1. Check: • V-belt 1 Cracks/damage/wear → Replace. Grease/oil → Clean the primary and sec- ondary sheaves. 2. Measure: • V-belt width 2 Out of specification → Replace. V-belt width 30 mm (1.18 in) <Limit>: 27 mm (1.06 in) CHECKING THE V-BELT CASE AIR DUCTS 1.

  • Page 258: Checking The Secondary Sheave

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

  • Page 259: Assembling The Primary Sheave

    BELT DRIVE EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: • primary fixed sheave 1 • primary sliding sheave 2 • collar 3 • primary sheave weights 4 • cam 2. Lubricate: • collar’s inner and outer surface Recommended lubricant BEL-RAY assembly lube 3.

  • Page 260: Installing The Secondary Sheave, V-Belt And Primary Sheave

    BELT DRIVE 3. Install: • guide pin 1 4. Lubricate: • guide pin groove 2 • O-ring 3 (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube 5. Install: • spring seat • compression spring • clutch shoe assembly • clutch shoe assembly nut 1 NOTE: Attach the sheave spring compressor 2 and sheave fixed block 3 onto the secondary...
  • Page 261 BELT DRIVE 2. Tighten: • clutch shoe assembly nut 1 90 Nm (9.0 m · kg, 65 ft · lb) NOTE: While holding the clutch shoe assembly with the rotor holding tool 2, tighten the clutch shoe assembly nut with the locknut wrench 3. Rotor holding tool 90890-01235, YU-01235 Locknut wrench...

  • Page 262: Starter Clutch And Generator

    STARTER CLUTCH AND GENERATOR EAS00341 STARTER CLUTCH AND GENERATOR GENERATOR ROTOR COVER AND STATOR COIL Order Job/Part Q’ty Remarks Removing the generator rotor cover Remove the parts in the order listed. and stator coil Side cover (right) Refer to “COWLING AND COVERS” in chapter 3.
  • Page 263 STARTER CLUTCH AND GENERATOR Order Job/Part Q’ty Remarks Water pump inlet hose Disconnect. Oil cooler outlet hose Disconnect. Crankshaft position sensor/stator Disconnect. assembly coupler Generator rotor cover Refer to “INSTALLING THE GENERA- TOR”. Gasket Dowel pin Stator coil Refer to “INSTALLING THE GENERA- TOR”.
  • Page 264 STARTER CLUTCH AND GENERATOR EAS00343 STARTER CLUTCH AND GENERATOR Order Job/Part Q’ty Remarks Removing the starter clutch and Remove the parts in the order listed. generator Generator rotor Refer to “REMOVING THE GENERA- Starter clutch TOR”, “INSTALLING THE STARTER Woodruff key CLUTCH”...

  • Page 265: Removing The Generator

    STARTER CLUTCH AND GENERATOR EAS00347 REMOVING THE GENERATOR 1. Remove: • generator rotor cover bolts • generator rotor cover 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.

  • Page 266: Checking The Starter Clutch

    STARTER CLUTCH AND GENERATOR Flywheel puller 90890-01362 Flywheel puller attachment 90890-04089, YM-33282 4. Remove: • starter clutch bolts • starter clutch EAS00351 CHECKING THE STARTER CLUTCH 1. Check: • starter clutch rollers 1 Damage/wear → Replace. 2. Check: • starter clutch idle gear •...

  • Page 267: Installing The Starter Clutch

    STARTER CLUTCH AND GENERATOR EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: • starter clutch bolts 1 30 Nm (3.0 m · kg, 22 ft · lb) NOTE: • While holding the generator rotor 2 with the sheave holder 3, tighten the starter clutch bolts.
  • Page 268 STARTER CLUTCH AND GENERATOR 3. Apply: • sealant (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 90890-85505 ® Sealant (Quick Gasket ACC-11001-05-01 4. Install: • generator rotor cover • generator rotor cover bolts 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: •...

  • Page 269: Oil Pump

    OIL PUMP EAS00356 OIL PUMP Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Generator rotor Refer to “STARTER CLUTCH AND GEN- ERATOR”. Oil pump assembly Refer to “ASSEMBLING THE OIL PUMP” and “INSTALLING THE OIL PUMP”. Oil pump gasket Refer to “INSTALLING THE OIL PUMP”.

  • Page 270: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump drive sprocket • oil pump driven sprocket • oil pump housing • oil pump housing cover Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a •...

  • Page 271: Assembling The Oil Pump

    OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: • oil pump shaft 1 (to the oil pump cover 2) •...

  • Page 272: Crankshaft

    CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ASSEMBLY 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 273 CRANKSHAFT 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • Order Job/Part Q’ty Remarks Dowel pin O-ring...

  • Page 274: Crankcase Bearings

    CRANKSHAFT CRANKCASE BEARINGS Order Job/Part Q’ty Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft journal bearing Refer to “REMOVING THE CRANK- SHAFT JOURNAL BEARINGS” and “INSTALLING THE CRANKSHAFT JOURNAL BEARINGS”. Bearing Oil seal For installation, reverse the removal pro- cedure.

  • Page 275: Disassembling The Crankcase

    CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase bolts 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. Remove: •...

  • Page 276: Checking The Crankshaft And Connecting Rod

    CRANKSHAFT EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: • crankshaft runout Out of specification → Replace the crank- shaft, bearing or both. NOTE: Turn the crankshaft slowly. Maximum crankshaft runout 0.030 mm (0.0012 in) 2. Check: • crankshaft journal surfaces Scratches/wear →...
  • Page 277 CRANKSHAFT NOTE: If either the left or right journal bearing is worn or scratched, replace both bearings as a set. c. Measure the crankshaft journal outside diameter a in two places. If it is out of spec- ification, replace the crankshaft. d.
  • Page 278 CRANKSHAFT M MMM M MMM M MMM M MMM M MMM Select the crankshaft journal bearings from the following table according to the number stamped on the inside of the crankcase. BEARING COLOR BEARING THICKNESS CODE 1.981 ~ 1.991 mm white (0.0780 ~ 0.0784 in) 1.977 ~ 1.987 mm...

  • Page 279: Checking The Balancer Shaft Assembly

    CRANKSHAFT CHECKING THE BALANCER SHAFT ASSEMBLY 1. Check: • balancer shaft assembly Cracks/damage → Replace. EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3.

  • Page 280: Checking The Oil Pump Gears And Shafts

    CRANKSHAFT CHECKING THE OIL PUMP GEARS AND SHAFTS 1. Check: • oil pump drive gear • oil pump driven gear • oil pump drive gear shaft • oil pump driven gear shaft Cracks/damage/wear → Replace the defec- tive part(s). EAS00365 CHECKING THE RELIEF VALVE 1.

  • Page 281: Installing The Crankshaft Journal Bearings

    CRANKSHAFT INSTALLING THE CRANKSHAFT JOURNAL BEARINGS 1. Attach: • crankshaft journal bearings 1 NOTE: Attach the crankshaft journal bearing to the installer 2. Plane bearing installer/remover 90890-04146 2. Install: • crankshaft journal bearings NOTE: • Install each crankshaft journal bearing from the inside of the crankcase with the notch a facing inward.

  • Page 282: Assembling The Crankcase

    ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 ® Sealant (Quick Gasket ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery.

  • Page 283: Transmission

    TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Rear wheel Refer to “REAR WHEEL AND BRAKE DISC” in chapter 4. Transmission oil Drain. Refer to “CHANGING THE TRANSMIS- SION OIL” in chapter 3. Secondary sheave assembly Refer to “BELT DRIVE”.
  • Page 284 TRANSMISSION Order Job/Part Q’ty Remarks Drive axle Main axle Washer Primary driven gear Washer For installation, reverse the removal procedure. 5 - 71...

  • Page 285: Checking The Transmission

    TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Check: • transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). 2. Check: • transmission gear movement Rough movement → Replace the defective part(s).

  • Page 286: Cool

    COOL...
  • Page 287 COOL CHAPTER 6 COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR..............6-3 THERMOSTAT ....................6-4 CHECKING THE THERMOSTAT.............. 6-5 INSTALLING THE THERMOSTAT............6-6 WATER PUMP AND OIL COOLER ..............6-7 CHECKING THE WATER PUMP .............. 6-9 CHECKING THE OIL COOLER ..............6-9 ASSEMBLING THE WATER PUMP............
  • Page 288 COOL...

  • Page 289: Cooling System

    COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Radiator cover Refer to “COWLING AND COVERS”...

  • Page 290: Checking The Radiator

    COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.

  • Page 291: Installing The Radiator

    COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. M MMM M MMM M MMM...

  • Page 292: Thermostat

    COOL THERMOSTAT EAS00460 THERMOSTAT 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Storage box Refer to “COWLING AND COVERS” in chapter 3.

  • Page 293: Checking The Thermostat

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 70.5 ~ 73.5 °C (158.9 ~ 164.3 °F) → Replace. M MMM M MMM M MMM M MMM M MMM a. Suspend the thermostat in a container filled with water.

  • Page 294: Installing The Thermostat

    COOL THERMOSTAT EAS00467 INSTALLING THE THERMOSTAT 1. Install: • thermostat 1 • thermostat cover 10 Nm (1.0 m · kg, 7.2 ft · lb) 2. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3.

  • Page 295: Water Pump And Oil Cooler

    COOL WATER PUMP AND OIL COOLER EAS00469 WATER PUMP AND OIL COOLER 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 296 COOL WATER PUMP AND OIL COOLER 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 297: Checking The Water Pump

    COOL WATER PUMP AND OIL COOLER EAS00473 CHECKING THE WATER PUMP 1. Check: • water pump cover • impeller shaft • water pump seal Cracks/damage/wear → Replace. 2. Check: • bearing Rough movement → Replace. 3. Check: • water pump inlet hose •...

  • Page 298: Assembling The Water Pump

    COOL WATER PUMP AND OIL COOLER EAS00475 ASSEMBLING THE WATER PUMP 1. Install: • bearing • circlip • water pump seal 1 (into the generator rotor cover 2) NOTE: Install the water pump seal with the special tools. Mechanical seal installer 90890-04145 3 Middle driven shaft bearing driver 90890-04058, YM-04058 4...
  • Page 300 CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM................7-1 WIRING DIAGRAM ................... 7-2 ECU’S SELF-DIAGNOSTIC FUNCTION........... 7-3 ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) ................7-4 FAIL-SAFE ACTIONS TABLE ..............7-4 TROUBLESHOOTING CHART ..............7-6 DIAGNOSTIC MODE ................7-7 TROUBLESHOOTING DETAILS ............7-12 THROTTLE BODY AND FUEL INJECTOR ..........7-25 THROTTLE BODY AND FUEL INJECTOR..........

  • Page 302: Fuel Injection System

    FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 ECU 8 Intake air pressure sensor E Crankshaft position sensor 2 Fuel injection system relay 9 Throttle position sensor F Coolant temperature sensor 3 Engine trouble warning light 0 ISC (idle speed control) valve G Spark plug 4 Lean angle cut-off switch A Intake air temperature sensor...

  • Page 303: Wiring Diagram

    FUEL INJECTION SYSTEM WIRING DIAGRAM 7 - 2...

  • Page 304: 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 oper- ates 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 305: Alternate Instructions Operation Control (Fail-Safe Action)

    FUEL INJECTION SYSTEM EAS00901 Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1.4 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 conditions, the warning light bulb may be defective.
  • Page 306 FUEL INJECTION SYSTEM Fault Engine start- Vehicle drive- Item Symptom Fail-safe action code No. ability ability ISC (idle speed con- Engine speed is high when the trol) valve (stuck fully engine is idling. Able Able open) Fuel injector Fuel injector open or short cir- Unable Unable cuit is detected.

  • Page 307: 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 308: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode.
  • Page 309 FUEL INJECTION SYSTEM 7. Verify the operation of the sensor or actua- tor. • Sensor operation The data representing the operating condi- tions of the sensor appears on the trip LCD. • Actuator operation Set the engine stop switch to “ON” to oper- ate the actuator.
  • Page 310 FUEL INJECTION SYSTEM Fault code table Fault Symptom Probable cause of malfunction Diagnostic code Code No. 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 311 FUEL INJECTION SYSTEM Fault Symptom Probable cause of malfunction Diagnostic code Code No. An error is detected while reading or • Malfunction in ECU. (The CO adjustment value, code re- writing on EEPROM. registering key code, and throttle valve fully closed notifi- cation value are not properly written on or read from the internal memory.) Power supply to the FI system is not...
  • Page 312 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Fuel system voltage Displays the fuel system voltage (battery voltage). 0 ~ 18.7 V (battery voltage) Engine stop switch is on. Normally, approximately 12.0 V Sidestand switch Displays that the switch is ON or OFF.

  • Page 313: Troubleshooting Details

    FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Malfunction history code • Displays the codes of the history of the self-diag- 12 ~ 61 display nosis malfunctions (i.e., a code of a malfunction (00) Displays when there is no mal- that occurred once and which has been corrected).
  • Page 314 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No. – – Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Installed condition of sensor. Check the installed area for looseness or pinching.
  • Page 315 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor - open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by turn- Inspect the coupler for any pins...
  • Page 316 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor - hose system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Intake air pressure sensor hose Repair or replace the sensor hose.
  • Page 317 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Used diagnostic code No. 01 (throttle position sensor) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Installed condition of throttle posi- Check the installed area for looseness or pinching. Reinstated by tion sensor.
  • Page 318 FUEL INJECTION SYSTEM Fault code No. Symptom Intake temperature sensor open or short circuit is detected. Used diagnostic code No. 05 (intake air temperature sensor) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Installed condition of sensor Check the installed area for looseness or pinching.
  • Page 319 FUEL INJECTION SYSTEM Fault code No. Symptom The scooter has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method The scooter has overturned. Raise the scooter upright. Reinstated by turn- ing the main switch Installed condition of the lean...
  • Page 320 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Used diagnostic code No. 54 (ISC (idle speed control) valve) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Incorrect speed sensor signal Check the speed sensor.
  • Page 321 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle cut-off switch open or short circuit is detected. Used diagnostic code No. 08 (lean angle cut-off switch) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by turn- Inspect the coupler for any pins...
  • Page 322 FUEL INJECTION SYSTEM Fault code No. Symptom Supply power to the fuel injector and fuel pump is not normal. Used diagnostic code No. 09 (fuel system voltage) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by...
  • Page 323 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading from or writing on EEPROM (code re-registering key code and throttle valve fully closed notification value). Used diagnostic No. 60 (EEPROM improper cylinder indication) Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause...
  • Page 324 FUEL INJECTION SYSTEM Fault code No. Symptom Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.) Used diagnostic code No. – – Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method...
  • Page 325 FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signals are received from the ECU within the specified duration. Used diagnostic code No. – – Order Inspection operation item and Operation item and countermeasure Reinstatement probable cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated if nor- Inspect the coupler for any pins...

  • Page 326: Throttle Body And Fuel Injector

    THROTTLE BODY AND FUEL INJECTOR EAS00909 THROTTLE BODY AND FUEL INJECTOR THROTTLE BODY AND FUEL INJECTOR 10 Nm (1.0 m kg, 7.2 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Part Q’ty Remarks Removing the throttle body and fuel Remove the parts in the order listed.
  • Page 327 THROTTLE BODY AND FUEL INJECTOR 10 Nm (1.0 m kg, 7.2 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Part Q’ty Remarks Throttle position sensor Fuel injector coupler Disconnect. Fuel injector assembly For installation, reverse the removal pro- cedure.

  • Page 328: Fuel Hose

    THROTTLE BODY AND FUEL INJECTOR FUEL HOSE 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel hose Remove the parts in the order listed.

  • Page 329: Fuel Tank

    THROTTLE BODY AND FUEL INJECTOR FUEL TANK 54 Nm (5.4 m kg, 39 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
  • Page 330 THROTTLE BODY AND FUEL INJECTOR 54 Nm (5.4 m kg, 39 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • •...

  • Page 331: Removing The 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: • fuel hose connector cover 1 3. Disconnect: • fuel hose 2 CAUTION: •...

  • Page 332: Checking The Fuel Injector

    THROTTLE BODY AND FUEL INJECTOR EAS00912 CHECKING THE FUEL INJECTOR 1. Check: • fuel injector Damage → Replace. EAS00913 CHECKING THE THROTTLE BODY 1. Check: • throttle body Cracks/damage → Replace the throttle body. 2. Check: • piston valve 1 Damage/scratches/wear →...

  • Page 333: Installing The Fuel Pump

    THROTTLE BODY AND FUEL INJECTOR INSTALLING THE FUEL PUMP 1. Install: • fuel pump 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: • Do not damage the installation surfaces of È the fuel tank when installing the fuel pump. •...

  • Page 334: Installing The Fuel Hose

    THROTTLE BODY AND FUEL INJECTOR 4. Tighten: • sub-frame adjusting bolts 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: • Tighten the bolt on the left side of the scooter first. • Use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the sub-frame adjusting bolts.

  • Page 335: Checking The Fuel Pump And Pressure Regulator Operation

    THROTTLE BODY AND FUEL INJECTOR EAS00915 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • pressure regulator operation M MMM M MMM M MMM M MMM M MMM a. Remove the storage box. Refer to “COWLING AND COVERS” in chapter 3.
  • Page 336 THROTTLE BODY AND FUEL INJECTOR Positive tester probe → blue terminal 1 Negative tester probe → black/blue terminal 2 Y/L B/L Pocket tester 90890-03112, YU-03112-C b. Measure the throttle position sensor volt- age. Out of specification → Replace or repair the wire harness.

  • Page 337: Checking The Isc (Idle Speed Control) Valve

    THROTTLE BODY AND FUEL INJECTOR EAS00916 CHECKING THE ISC (IDLE SPEED CONTROL) VALVE NOTE: Do not remove the ISC (idle speed control) valve unit completely from the throttle body assembly. 1. Check: • ISC (idle speed control) valve M MMM M MMM M MMM M MMM...

  • Page 338: Air Induction System

    AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, 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.

  • Page 339: Air Induction System Diagrams

    AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air induction system hose (air filter case to air cut-off valve) 2 Air cut-off valve 3 Air induction system hose (air cut-off valve to cylinder head) 4 Air induction system pipe 5 Air filter case cover (right) 7 - 38...

  • Page 340: Air Cut-Off Valve And Air Induction System Hoses

    AIR INDUCTION SYSTEM AIR CUT-OFF VALVE AND AIR INDUCTION SYSTEM HOSES 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the air cut-off valve and Remove the parts in the order listed. air induction system hoses Air induction system hose (air filter Disconnect.

  • Page 341: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connections → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. Check: • reed valve • reed valve stopper • reed valve seat Cracks/damage → Replace the reed valve. 3.

  • Page 342: Elec

    – ELEC...
  • Page 343 – ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................ 8-1 CHECKING SWITCH CONTINUITY..............8-3 CHECKING THE SWITCHES................8-4 CHECKING THE BULBS AND BULB SOCKETS .......... 8-5 TYPES OF BULBS ..................8-5 CHECKING THE CONDITION OF THE BULBS ........8-6 CHECKING THE CONDITION OF THE BULB SOCKETS .......8-7 CHECKING THE LEDs................8-7 IGNITION SYSTEM ..................
  • Page 344 – ELEC IMMOBILIZER SYSTEM................8-49 SYSTEM DIAGRAM ................8-49 CIRCUIT DIAGRAM ................8-50 GENERAL INFORMATION ..............8-51 KEY CODE REGISTRATION ..............8-52 SELF-DIAGNOSIS MALFUNCTION CODES..........8-54 TROUBLESHOOTING ................8-56 CHECKING THE IMMOBILIZER SYSTEM ..........8-57 PART REPLACEMENT KEY REGISTRATION REQUIREMENTS..8-59...

  • Page 345: Electrical System

    – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Starting circuit cut-off relay 8 Rear brake light switch 2 Headlight relay 1 9 Storage box light switch 3 Turn signal relay 0 Starter relay 4 Radiator fan motor relay A Main fuse 5 Headlight relay 2 B Battery...
  • Page 346 – ELEC ELECTRICAL COMPONENTS E Stator coil F Sidestand switch G Ignition coil H Radiator fan motor I Rectifier/regulator J Horn K Thermistor L ECU M Wire harness 8 - 2...

  • Page 347: 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 incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots a.

  • Page 348: 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 ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...

  • Page 349: 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 con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.

  • Page 350: Checking The Condition Of The Bulbs

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 351: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112, YU-03112-C NOTE:...

  • Page 352: Ignition System

    – ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 8 - 8...

  • Page 353: Troubleshooting

    – ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses Minimum open-circuit voltage 2.
  • Page 354 – ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance • Disconnect the spark plug cap from the • Remove the spark plug cap from the spark spark plug. plug lead. • Connect the ignition checker 1 as shown. •...
  • Page 355 – ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Crankshaft position sensor resistance • Disconnect the ignition coil connectors • Disconnect the crankshaft position sensor from the ignition coil terminals. coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the •...
  • Page 356 – ELEC IGNITION SYSTEM EAS00750 EAS00753 9. Engine stop switch 11.Starting circuit cut-off relay • Check the engine stop switch for continu- • Remove the starting circuit cut-off relay. • Connect the pocket tester (Ω × 1) to the ity. Refer to “CHECKING THE SWITCHES”.
  • Page 357 – ELEC IGNITION SYSTEM EAS00754 12.Lean angle cut-off switch 13.Wiring • Remove the lean angle cut-off switch. • Connect the pocket tester (Ω × 1) to the • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. lean angle cut-off switch terminals as •...

  • Page 358: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8 - 14...

  • Page 359: Starting Circuit Cut-Off System Operation

    – ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 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 the following conditions are met: •...

  • Page 360: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition, and signaling system fuses 2.
  • Page 361 – ELEC ELECTRIC STARTING SYSTEM EAS00759 EAS00761 4. Starting circuit cut-off relay 5. Starter relay • Remove the starting circuit cut-off relay. • Remove the starter relay. • Connect the pocket tester (Ω × 1) and bat- • Connect the pocket tester (Ω × 1) and bat- tery (12 V) to the starting circuit cut-off tery (12 V) to the starter relay terminal as relay terminals as shown.
  • Page 362 – ELEC ELECTRIC STARTING SYSTEM EAS00750 EAS00766 7. Engine stop switch 11.Wiring • Check the engine stop switch for continu- • Check the entire starting system’s wiring. ity. Refer to “CIRCUIT DIAGRAM”. Refer to “CHECKING THE SWITCHES”. • Is the starting system’s wiring properly •...

  • Page 363: Starter Motor

    – ELEC STARTER MOTOR EAS00767 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Throttle body Refer to “THROTTLE BODY AND FUEL INJECTOR” in chapter 7. Starter motor lead Starter motor For installation, reverse the removal pro- cedure.
  • Page 364 – ELEC STARTER MOTOR Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Front bracket O-ring Shim Lock washer Rear bracket Refer to “ASSEMBLING THE STARTER MOTOR”. O-ring Shim Brush holder set Armature assembly Starter motor yoke For assembly, reverse the disassembly procedure.

  • Page 365: Checking The Starter Motor

    – ELEC STARTER MOTOR EAS00770 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 27 mm (1.06 in) 3.

  • Page 366: Assembling The Starter Motor

    – ELEC STARTER MOTOR 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 4.0 mm (0.16 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set.

  • Page 367: Charging System

    – ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 8 - 23...

  • Page 368: Troubleshooting

    – ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 3.
  • Page 369 – ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Stator coil resistance • Connect the pocket tester (DC 20 V) to the • Disconnect the stator coil coupler from the battery as shown. wire harness. • Connect the pocket tester (Ω × 1) to the Positive tester probe →...

  • Page 370: Lighting System

    – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8 - 26...

  • Page 371: Troubleshooting

    – ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: head- • Check the condition of the battery. lights, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING license plate light, storage box light, aux- THE BATTERY”...
  • Page 372 – ELEC LIGHTING SYSTEM EAS00786 7. Headlight relay 1 5. Pass switch • Remove the headlight relay 1. • Check the pass switch for continuity. • Connect the pocket tester (Ω × 1) and bat- Refer to “CHECKING THE SWITCHES”. tery (12 V) to the headlight relay 1 terminals •...
  • Page 373 – ELEC LIGHTING SYSTEM EAS00787 8. Headlight relay 2 9. Wiring • Remove the headlight relay 2. • Check the entire lighting system’s wiring. • Connect the pocket tester (Ω × 1) and bat- Refer to “CIRCUIT DIAGRAM”. tery (12 V) to the headlight relay 2 terminal •...

  • Page 374: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EAS00788 È When the dimmer switch is set to “ ” CHECKING THE LIGHTING SYSTEM É When the dimmer switch is set to “ ” 1. The headlights and the high beam indicator Headlight light fail to come on. Positive tester probe →...
  • Page 375 – ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light bulb and socket 1. Tail/brake light LEDs • Check the meter light bulb and socket for •...
  • Page 376 – ELEC LIGHTING SYSTEM EAS00791 EAS00792 4. The auxiliary lights fail to come on. 5. The license plate light fails to come on. 1. Auxiliary light bulb and socket 1. License plate light bulb and socket • Check the auxiliary light bulb and socket •...
  • Page 377 – ELEC LIGHTING SYSTEM EAS00792 6. The storage box light fails to come on. 1. Storage box light bulb and socket • Check the storage box light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. •...
  • Page 378 – ELEC LIGHTING SYSTEM 8 - 34...

  • Page 379: Signaling System

    – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 35...
  • Page 380 – ELEC SIGNALING SYSTEM 4 Main switch 8 Ignition fuse 9 Backup fuse (storage box light, immobilizer unit, and meter assembly) A Battery B Main fuse J Hazard switch K Front brake light switch R ECU X Speed sensor b Turn signal relay c Horn i Horn switch j Turn signal switch...

  • Page 381: Troubleshooting

    – ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn • Check the condition of the battery. signal light, brake light or an indicator Refer to “CHECKING AND CHARGING light. THE BATTERY” in chapter 3. •...

  • Page 382: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the horn coupler at the horn. • Connect a jumper lead 1 to the brown ter- 1. Horn switch minal in the horn coupler and the horn ter- •...
  • Page 383 – ELEC SIGNALING SYSTEM EAS00799 2. Brake light switches 3. The turn signal light, turn signal indicator light or both fail to blink. • Check the brake light switches for continu- ity. 1. Turn signal light bulb and socket Refer to “CHECKING THE SWITCHES”. •...
  • Page 384 – ELEC SIGNALING SYSTEM 6. Voltage 4. Hazard switch • Connect the pocket tester (DC 20 V) to the • Check the hazard switch for continuity. turn signal relay coupler (wire harness Refer to “CHECKING THE SWITCHES”. side) as shown. •...
  • Page 385 – ELEC SIGNALING SYSTEM 7. Voltage • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Connect the pocket tester (DC 20 V) to the • Measure the voltage (DC 12 V) of the turn signal light coupler or meter assembly chocolate 1 or dark green 2 at the turn coupler (wire harness side) as shown.
  • Page 386 – ELEC SIGNALING SYSTEM 2. V-belt replacement indicator reset coupler 3. Voltage • Connect the pocket tester (Ω × 1) to the V- • Connect the pocket tester (DC 20 V) to the belt replacement indicator reset coupler as meter assembly coupler (wire harness shown.
  • Page 387 – ELEC SIGNALING SYSTEM EAS00803 EAS00806 5. The engine oil change indicator fails to 6. The speedometer fails to operate. come on. 1. Speed sensor 1. Engine oil change indicator bulb and • Connect the pocket tester (DC 20 V) to the socket speed sensor coupler (wire harness side) •...
  • Page 388 – ELEC SIGNALING SYSTEM 2. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe → yellow/blue 1 Negative tester probe → black 2 Ch Dg R/W R/G G Y/L B/L Gy •...

  • Page 389: Cooling System

    – ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 8 - 45...

  • Page 390: Troubleshooting

    – ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • The radiator fan motor fails to turn. • Check the condition of the battery. • The coolant temperature meter (meter Refer to “CHECKING AND CHARGING assembly) fails to indicate. THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
  • Page 391 – ELEC COOLING SYSTEM EAS00809 5. Radiator fan motor relay 4. Radiator fan motor • Remove the radiator fan motor relay. • Disconnect the radiator fan motor coupler • Connect the pocket tester (Ω × 1) and bat- from the wire harness. tery (12 V) to the radiator fan motor terminal •...
  • Page 392 – ELEC COOLING SYSTEM EAS00812 6. Coolant temperature sensor • Remove the coolant temperature sensor. • Connect the pocket tester (Ω × 1k) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2. NOTE: Make sure the coolant temperature sensor terminals do not get wet.

  • Page 393: Immobilizer System

    – ELEC IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM SYSTEM DIAGRAM 1 ECU 2 Immobilizer system indicator light 3 Main switch and immobilizer unit Main switch Fuel injection system fuse R ..Red Br/L . . . Brown/Blue Br/L G/L .
  • Page 394 – ELEC IMMOBILIZER SYSTEM CIRCUIT DIAGRAM 8 - 50...

  • Page 395: General Information

    – ELEC IMMOBILIZER SYSTEM GENERAL INFORMATION This scooter is equipped with an immobilizer system to help prevent theft by registering codes in standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with black bows) that can be re-registered with new codes •...

  • Page 396: Key Code Registration

    – ELEC IMMOBILIZER SYSTEM KEY CODE REGISTRATION Code registration of the code re-registering key or standard keys may be required when parts are replaced or a standard key is lost. NOTE: Each standard key is registered during production, therefore, registering the keys at purchase is not necessary.
  • Page 397 – ELEC IMMOBILIZER SYSTEM 3. Insert the standard key to be registered into the main switch, and then turn the main switch to “ON” within 5 seconds to activate the key registration mode. NOTE: All existing standard key codes will be erased from the memory when the key registration mode is activated.

  • Page 398: Self-Diagnosis Malfunction Codes

    – ELEC IMMOBILIZER SYSTEM SELF-DIAGNOSIS MALFUNCTION CODES When a system malfunction occurs, the malfunction code number is displayed on the LCD display of the meter assembly and is indicated by the immobilizer system indicator light flash patterns. Malfunction Part Symptom Cause Action code...
  • Page 399 – ELEC IMMOBILIZER SYSTEM Immobilizer system indicator light malfunction code indication Units of 10: on for 1 second and off for 1.5 seconds. Units of 1: on for 0.5 second and off for 0.5 second. <Example> malfunction code 52 Light on Light off 8 - 55...

  • Page 400: Troubleshooting

    – ELEC IMMOBILIZER SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery When the main switch is turned “ON”, • Check the condition of the battery. the immobilizer system indicator light Refer to “CHECKING AND CHARGING does not come on or flash. THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.

  • Page 401: Checking The Immobilizer System

    – ELEC IMMOBILIZER SYSTEM EAS00788 3. Wiring CHECKING THE IMMOBILIZER SYSTEM 1. The immobilizer system indicator light does • Disconnect the meter coupler and immobi- not come on. lizer unit coupler. • Check the immobilizer system indicator 1. Immobilizer system indicator light (LED) light lead (green/blue) continuity.
  • Page 402 – ELEC IMMOBILIZER SYSTEM 3. When the main switch is turned to “ON”, the immobilizer system indicator light flashes. • Check if a metal object or other immobilizer system keys are placed near the immobilizer unit. If so, remove the object or keys, and then check the condition again. Turn the main switch to “ON”...

  • Page 403: Part Replacement Key Registration Requirements

    – ELEC IMMOBILIZER SYSTEM PART REPLACEMENT KEY REGISTRATION REQUIREMENTS Parts to be replaced Required key Accessory Main Standard registration lock Immobilizer switch unit Standard key is lost New standard key All keys have been lost Code re-registering (including code re-reg- key and standard keys istering key) ECU is defective...

  • Page 405: Trbl Shtg

    TRBL SHTG...
  • Page 406 TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURE/HARD STARTING ............9-1 ENGINE..................... 9-1 FUEL SYSTEM..................9-1 ELECTRICAL SYSTEMS ................9-2 INCORRECT ENGINE IDLING SPEED............9-2 ENGINE..................... 9-2 FUEL SYSTEM..................9-2 ELECTRICAL SYSTEMS ................9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .........9-3 ENGINE..................... 9-3 FUEL SYSTEM..................9-3 FAULTY CLUTCH ................... 9-3 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE......9-3 CLUTCH SLIPS..................
  • Page 407 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM..........9-6 HEADLIGHT DOES NOT COME ON ............9-6 HEADLIGHT BULB BURNT OUT.............. 9-6 TAIL/BRAKE LIGHT DOES NOT COME ON ..........9-6 TAIL/BRAKE LIGHT BULB BURNT OUT..........9-6 TURN SIGNAL DOES NOT COME ON ............ 9-6 TURN SIGNAL BLINKS SLOWLY............. 9-6 TURN SIGNAL REMAINS LIT..............9-6 TURN SIGNAL BLINKS QUICKLY............

  • Page 408: Troubleshooting

    TRBL STARTING FAILURE/HARD STARTING SHTG 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 man- ual for checks, adjustments, and replacement of parts.

  • Page 409: Electrical Systems

    STARTING FAILURE/HARD STARTING/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Battery Ignition system • Discharged battery • Faulty ECU • Faulty battery • Faulty crankshaft position sensor Fuse(s) • Broken generator rotor woodruff key • Blown, damaged or incorrect fuse Switches and wiring •...

  • Page 410: Poor Medium-And-High-Speed Performance

    POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY CLUTCH SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURE/HARD STARTING”. ENGINE FUEL SYSTEM Air filter Throttle body • Clogged air filter element • Faulty diaphragm Fuel pump • Faulty fuel pump EAS00853 FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL POOR STARTING PERFORMANCE NOT MOVE...

  • Page 411: Overheating

    OVERHEATING/ TRBL OVERCOOLING SHTG EAS00855 OVERHEATING ENGINE FUEL SYSTEM Clogged coolant passages Throttle body • Cylinder head and piston • Damaged or loose throttle body joint • Heavy carbon buildup Air filter Engine oil • Clogged air filter element • Incorrect oil level CHASSIS •...

  • Page 412: Poor Braking Performance

    POOR BRAKING PERFORMANCE/ TRBL FAULTY FRONT FORK LEGS/UNSTABLE HANDLING SHTG EAS00857 POOR BRAKING PERFORMANCE • Worn brake pad • Worn brake disc • Air in hydraulic brake system • Leaking brake fluid • Faulty brake caliper kit • Faulty brake caliper seal •...
  • Page 413 TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL DOES NOT COME ON • Wrong headlight bulb • Faulty turn signal switch • Too many electrical accessories • Faulty turn signal relay •...
  • Page 414 YP400(S) 2004 WIRING DIAGRAM 1 A.C. magneto m Rear turn signal light (left) COLOR CODE 2 Crankshaft position sensor n Rear turn signal light (right) B.... Black 3 Rectifier/regulator o License plate light Br ..Brown 4 Main switch p Tail/brake light Ch ..
  • Page 416 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 417 YP400(S) 2004 WIRING DIAGRAM P O/B R/L Y Y/L R/L O/B P Sb Gy Lg G/R G/R Lg Gy Sb Br/W L B/L P/W P/W B/L Br/W (GRAY) (GRAY) WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 3 W/L L/B Y/L B/W B G/Y R/Y Y W/R...

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