Yamaha YH50 19992006 EN

YH50 '99
5EU-AE2
SERVICE
MANUAL
EB000000
YH50
SERVICE MANUAL
© 1999 MBK INDUSTRIE
2nd Edition, January 1999
All rights reserved.
Any reprinting or unauthorized
use without the written
permission of MBK INDUSTRIE
is expressly prohibited.
EB001000
NOTICE
This manual was written by the MBK INDUSTRIE primarily for use by Yamaha and MBK dealers and
their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so
it is assumed that persons using this book to perform maintenance and repairs on Yamaha and MBK
scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter
repair technology. Without such knowledge, attempted repairs or service to this model may render it
unfit to use and/or unsafe.
MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and
significant changes in specifications or procedures will be forwarded to all Authorized Yamaha and
MBK dealers and will, where applicable, appear in future editions of this manual.
NOTE:
Designs and specifications are subject to change without notice.
TECHNICAL DOCUMENTATION
MBK INDUSTRIE
PARTICULARY IMPORTANT INFORMATION

This material is distinguished by the following notation :
The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or

death to the scooter operator, a bystander, or a person inspecting or
repairing the scooter.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid

damage to the scooter.
NOTE: A NOTE provides key information to make procedures easier or clearer.

YP002000
HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This manual constits of chapters for the main catogories of subjects.
(See "illustrated symbols")
1st title !: This is a chapter with its symbol on the upper right of each page.
2nd title ": This title indicates the section of the chapter and is only on the first page of each section
It appears on the upper of each page on the left of the chapter symbol.
3rd title #: This title indicates a sub-section which is following by step-by-step procedures with
corresponding illustrations.
EXPLODED DIAGRAM
To make the pieces identification easy and to make the procedures steps clear, exploded diagram
are before each removal and disassembly section.
1. Exploded diagram easy to read $ is provided for removal and disassembly operations.
2. Numbered marks % are indicated in the order of operations on the exploded diagram. A numeral
corresponds to a disassembly step.
3. Note and indication of special operations are illustrated by symbols & .
The signification of this symbols is next page.
4. A work instrutions diagram ' goes with the exploded diagram, indicating the orders of the
operations, the pieces name, notes concerning the work to do,etc.
5. For the operations which needs complementary informations, additionnal informations, step-by-
step, ( are provided to complete the exploded diagram and the work instructions diagram.
" ! $ #
CDI MAGNETO
ENG CDI MAGNETO
ENG
CDI MAGNETO REMOVAL
CDI MAGNETO, ROTOR, STATOR NOTE:
" It is not necessary to remove the engine for
removing the CDI magneto
!
1.Remove:
% T.R 37 Nm (3.7 m.kg) • Nut ! (rotor)

• Plate washer
NOTE:
Hold the rotor using ! flywheel holder " to
loosen the nut (
3
Flywheel holder:
4 90890-01235
5
&
6.5 Nm (0.65 m.kg)
LS
T.R
2.Remove:
• Rotor
• Woodruff key
9 Use the flywheel puller.
7
Flywheel puller:
90890-01189
8
• Stator assembly
1 • Gasket
2 T.R 8.5 Nm (0.85 m.kg)
' INSTALLATION
1.Install:
Order Job name/Part name Q'ty Remarks • Gasket
CDI magneto, Rotor, Startor removal Remove the parts in the order below
2.Apply
Seat cover !
• Lithium soap base grease
Side covers Refer to "COVERS" in Chapter 3. (to oil seal !)
Footrest board
LS
1 Fan cover 1
2 Fan 1
3 Nut 1 3.Pass the CDI magneto lead through the
4 Washer 1 crankcase
5 Magneto rotor 1 Refer to "CDI MAGNETO REMOVAL"
6 Woodruff key 1 section.
7 Stator assembly 1
8 Gasket 1
9 Oil seal 1
For installation, reverse the removal procedure
4 - 27 4 - 28
Q W ILLUSTRATED SYMBOLS
GEN SPEC
(REFER TO THE ILLUSTRATION)
INFO
Illustrated symbols Q to I are designed as
E R thumb tabs to indicate the chapter’s number and
content.
INSP ENG
REG Q General information
W Specifications
T Y E Periodic inspection and adjustment
R Engine
CARB CHAS T Carburetion
Y Chassis
U I U Electrical
I Troubleshooting
ELEC TRBL
SHTG
O P
Illustrated symbols O to r are used to identify

the specifications appearing in the text.
{ }
O Repair without removal the engine
0 Filling fluid
{ Lubricant
} Special tool
q w
q Tightening
w Wear limit, clearance
T.
R e Engine speed
r Ω, V, A
e r
t y u
Illustrated symbols t to ] in the exploded
diagram indicate grade of lubricant and location
of lubrication point.
i o p t Apply engine oil

y Apply gear oil
B LS M u Apply molybdenum disulfide oil
i Apply wheel bearing grease
[ ] o Apply lightweight lithium-soap
base grease
p Apply molybdenum disulfide grease
[ Apply locking agent
(THREADLOCK ®)
] Use new one
INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION
AND ADJUSTMENT INSP
REG 3
ENGINE OVERHAUL ENG
4
CARBURETION CARB
5
CHASSIS CHAS
6
ELECTRICAL ELEC
7
TROUBLESHOOTING TRBL
SHTG 8
GEN
INFO 1
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
SCOOTER IDENTIFICATION ........................................................................ 1-1

VEHICULE IDENTIFICATION NUMBER ................................................. 1-1
ENGINE SERIAL NUMBER ..................................................................... 1-1
IMPORTANT INFORMATION ...................................................................... 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ 1-2
ALL REPLACEMENT PARTS .................................................................. 1-2
GASKETS, OIL SEALS, AND O-RINGS ................................................. 1-2
LOCK WASHERS/PLATES AND COTTER PINS .................................... 1-3
BEARINGS AND OIL SEALS ................................................................... 1-3
CIRCLIPS ................................................................................................. 1-3
CHECKING OF CONNECTIONS .................................................................. 1-4
HOW TO USE THE CONVERSION TABLE .................................................. 1-5
SPECIAL TOOLS .......................................................................................... 1-6

GEN
GENERAL INFORMATION INFO
GENERAL INFORMATION
SCOOTER IDENTIFICATION
!
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number ! is stamped
into the frame.
NOTE:
The vehicle identification number is used to
identify your scooter and may be used to register
your scooter with the licensing authority in your
state.
ENGINE SERIAL NUMBER

The engine serial number ! is stamped into the
crankcase.
!
NOTE:
Designs and specifications are subject to change
without notice.
1-1
GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Removal all dirt, dust and foreign material before
removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the "SPECIAL TOOLS" section.
4. When disassembling the machine, always keep
mated parts together. This include gears, cylinders,
pistons and other parts that have been "mated"
through normal wear. Mated parts must always be
reused or remplaced as an assembly.
5. During machine disassembly, clean all parts and
place them in trays in order of disassembly. This
will speed up assembly and allow for the correct
installation of all parts.
6. Keep all parts away from any source of fire.
EB101010
ALL REPLACEMENT PARTS
1. Use only genuine parts for all replacements. Use
oil and /or grease recommended by MBK / Yamaha
for assembly and adjustment. Other brands may
be similar in function and appearance, but inferior
in quality.
EB101020
GASKETS ,OIL SEALS, AND O-RINGS
1. All gaskets, seals and o-rings should be replaced
when an engine is overhauled. All gaskets surfa-
ces, oil seal lips and o-rings must be cleaned.
2. Properly oil all mating parts and bearing during
reassembly. Apply grease to the oil seal lips.
1-2
GEN
IMPORTANT INFORMATION INFO
EB101030
LOCK WASHERS/PLATES AND COTTER
PINS
1.All lock washers/plates ! and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or nut
flat(s) after the bolt or nut has been properly
tightened.
EB101040
BEARING AND OIL SEALS
1.Install the bearing(s) ! and oil seal(s) " with
their manufacturer's marks or numbers facing
outward. ( In other words, the stamped letters
must be on the side exposed to view.) When
installing oil seal(s), apply a light coating of
lightweight lithium base grease to the seal
lip(s). Oil the bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
EB101050
CIRCLIPS
1.All circlips should be inspected carefully before
reassembly. Always replace piston pin clips
once they have been removed. Replace bent
circlips. When installing a circlips ! make
sure that sharp edge " is positioned opposite
to the thrust # it receives. See the sectional
view.
$ Shaft
1-3
GEN
CHECKING OF CONNECTIONS INFO
EB801000
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1.Disconnect:
• Connector
2.Dry each terminal with an air blower.
3.Connect and disconnect the connector two or

three times.
! 4.Pull the lead to check that it will not come off.
5.If the terminal comes off, bend up the pin !

and reinsert the terminal into the connector.
6.Connect:
• Connector
NOTE:
The two connectors "click" together.
- + 7.Check for continuity with a tester.
NOTE:
• If there is no continuity, clean the terminals.
• Be sure to perform the steps 1 to 7 listed above
when checking the wireharness.
• For a field remedy, use a contact revitalizer
available on the market.
• Use the tester on the connector as shown.
- +
1-4
GEN
HOW TO USE THE CONVERSION TABLE INFO
HOW TO USE THE CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex:
METRIC MULTIPLIER IMPERERIAL
** mm x 0.03937 = ** in
2 mm x 0.03937 = 0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit

Torque m·kg 7.233 ft.lb
m·kg 86.794 in.lb
cm·kg 0.0723 ft.lb
cm·kg 0.8679 in.lb
Weight kg 2.205 lb
g 0.03527 oz
Speed km/h 0.6214 mph
Distance km 0.6214 mi
m 3.281 ft
m 1.094 yd
cm 0.3937 in
mm 0.03937 in
Volume/ cc (cm3) 0.03527 oz(IMP liq.)
Capacity cc (cm3) 0.061102 cu.in
lit (litre) 0.8799 qt(IMP liq.)
lit (litre) 0.2199 gal(IMP liq.)
Miscella- kg/mm 55.997 lb/in
neous kg/cm2 14.2234 psi(lb/in2)
Centrigrade 9/5(°C)+32 Fahrenheit(°F)
1-5
GEN
SPECIAL TOOLS INFO
EB102000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up an assembly.
Use only the appropriate special tools; this will help prevent damage caused by the use of
inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool N° Tool name/usage Illustration
90890-01135 Crankcase separating tool
This tool is used to separate the crank-

case and remove the crankshaft.
90890-01189 Flywheel puller
This tool is used to remove the flywheel

magneto.
90890-01235 Rotor holding tool
This tool is used to remove the flywheel

magneto.
90890-01274 Crankshaft installer set.

90890-01275
90890-01277
90890-01411
These tools are used to install the crank-
shaft.
90890-11044 Locknut wrench
This tool is used when removing or

installing the secondary sheave nut.
90890-01701 Sheave holder
This tool is used to hold the secondary

sheave when removing or installing the
nut.
90890-01337 Clutch spring holder.
This tool is used for compressing the

spring of the secondary sheave when
removing the nut.
1-6
GEN
SPECIAL TOOLS INFO
Tool N° Tool name/usage Illustration
9079Q-02218 Ring nut wrench.
This tool is used to loosen and tighten the

steering ring nut.
90890-01184 Fork seal driver weight.
90890-01185 Fork seal driver attachment (ø28)
These tools are used when installing the

fork seals.
90890-03112 Pocket Tester
This instrument is invaluable for checking

the electrical system.
90890-03113 Engine tachometer.
This tool is needed for detecting the

engine rpm.
90890-06754 Ignition checker.
This instrument is necessary for checking

the ignition system components.
1-7
SPEC 2
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ...................................................................... 2-1
MAINTENANCE SPECIFICATIONS ............................................................. 2-4

ENGINE ................................................................................................... 2-4
TIGHTENING TORQUES (ENGINE) ....................................................... 2-7
CHASSIS ................................................................................................. 2-8
TIGHTENING TORQUES (CHASSIS) ................................................... 2-10
ELECTRICAL ......................................................................................... 2-11
GENERAL TORQUE SPECIFICATIONS ................................................... 2-13
LUBRICATION POINT AND GRADE OF LUBRICANT .............................. 2-14

ENGINE ................................................................................................. 2-14
CHASSIS ............................................................................................... 2-15
CABLE ROUTING ....................................................................................... 2-16

SPEC
GENERAL SPECIFICATIONS
SPECIFICATIONS
Model YH50
Dimensions:
Overall length 1,940 mm
Overall width 685 mm
Overall height 1,105 mm
Seat height 765 mm
Wheelbase 1,294 mm
Minimum ground clearance 125 mm
Minimum turning radius 1,800 mm
Basic weight:
With oil and full fuel tank 78 kg
Engine:
Type Air-cooled-2 stroke, gasoline torque induction.
Cylinder arrangement Single cylinder, horizontal
Displacement 49.2 cm3
Bore x stroke 40.0 x 39.2 mm
Compression ratio 7.25 : 1 (B)(E)(F)(GB)(I)(P)
7.9 (D)
7.65 (NL)
Starting system Electrical and Kick starter
Lubrication system: Separate lubrification
Oil type or grade:
Engine oil: SEMI-SYNTHETIC, in accordance with
API TC TS C3 STANDARD.
Transmission oil SAE 10W30 type SE motor oil
Oil capacity:
Engine oil: 1.3 L
Transmission oil:
Periodic oil change 0.11 L
Total amount 0.13 L
Air filter: Wet type element
Fuel:
Type Regular unleaded gasoline with a research
octane number of 91 or higher.
Tank capacity: 7.2 L
Carburetor:
Type/quantity PY 12 / 1
Manufacturer GURTNER
2-1
SPEC
Model YH50
Spark plug:
Type BR8HS
Manufacturer NGK
Gap 0.5 ~ 0.7 mm
Clutch type: Dry, centrifugal automatic
Transmission:
Primary reduction system Helical gear
Primary reduction ratio 52 / 13 (4.000)
Secondary reduction system Spur gear
Secondary reduction ratio 45 / 12 (3.750)
Transmission V-belt
Operation Automatic
Chassis:
Frame type Steel tube underbone
Caster angle 27°
Trail 90 mm
Tires:
Type With tube
Size Front 70 / 90 -16 42M
Rear 80 / 90 -16 46M
Manufacturer/Type MICHELIN/M 29 STT
Wear limit(Front/Rear) 0.8 mm
Tires pressure (Cold tire):
Front (single riding) 180 kPa (1.80 Kg/cm2, 1.80 bar)
Rear (single riding) 190 kPa (1.90 Kg/cm2, 1.90 bar)
Front (dual riding) 200 kPa (2.00 Kg/cm2, 2.00 bar)
Rear (dual riding) 220 kPa (2.20 Kg/cm2, 2.20 bar)
Brakes:
Front brake type Disk brake
Operation Right hand operation
Rear brake type Drum brake
Operation Left hand operation
Suspension:
Front Telescopic fork
Rear Unit swing
Shock absorber:
Front Coil spring/ Oil damper
Rear Coil spring/ Oil damper
2-2
SPEC
Model YH50
Wheel travel:
Front 71 mm
Rear 86 mm
Electrical:
Ignition system CDI
Charging system Flywheel magneto
Battery type/model GM4-3B, YB4L-B, FB4L-B
Battery capacity 12V 4AH
Headlight type: Bulb
Bulb wattage x quantity:
Headlight 12V 35W/35W x 1
Taillight / brake light 12V 5W /21W x 1
License light (Switzerland only) 12V 5Wx1
Flasher light Front 12V 10W x 2
Rear 12V 10W x 2
Meter light 12V 1.2W x 2
Warning lights wattage/quantity:
"OIL" 12V 1.2W x 1
"TURN" 12V 1.2W x 1
"HIGH BEAM" 12V 1.2W x 1
2-3
MAINTENANCE SPECIFICATIONS
SPEC
ENGINE
Model Standard Limit
Cylinder head:
Warp limit *** 0.02 mm
* Lines indicate straight edge
measurements.
Cylinder:
Bore size 39.993 ~ 40.012 mm ***
Taper *** 0.05 mm
Out-of-round *** 0.01 mm
Piston:
Piston size 39.952 ~ 39.972 mm ***
Measuring point* 5 mm ***
Piston clearance 0.034 ~ 0.047 mm 0.1 mm

Oversize: 1st 40.25 mm ***
2nd 40.50 mm ***
Piston rings:
Sectional sketch (BxT)/Type:
Top ring B 1.2 x 1.8 mm (B)(E)(F)(GB)(I)(P) ***

T 1.5 x 1.8 mm (D)(CH)(NL) ***
2nd ring 1.2 x 1.8 mm (B)(E)(F)(GB)(I)(P) ***
1.5 x 1.8 mm (D)(CH)(NL) ***
End gap (Installed):
Top ring 0.15 ~ 0.35 mm ***
2nd ring 0.15 ~ 0.35 mm ***
Side clearance (Installed):
Top ring 0.03 ~ 0.05 mm ***
2nd ring 0.03 ~ 0.05 mm ***
Piston pin:
Outside diameter 9.996 ~ 10.000 mm ***
Piston pin to piston clearance 0.004 ~ 0.019 mm ***
2-4
SPEC
Crankshaft:
Crank width “A” 37.90 ~ 37.95 mm ***

Runout limit “C” *** 0.03 mm
Connecting rod big end
side clearance “D” 0.2 ~ 0.5mm ***
Connecting rod length 79.9 ~80.1 mm ***
Automatic centrifugal clutch:
Clutch shoe thickness 2 mm 1 mm
Clutch shoe spring free length 29.9 mm ***
Clutch housing inside diameter 105 mm 105.4 mm
Clutch-in revolution 3850 ~ 4350 r/min ***
Clutch-stall revolution 6100 ~ 6900 r/min ***
V-belt:
Width 16.5 mm 14.85 mm
Transmission:
Main axle runout limit *** 0.08 mm
Drive axle runout limit *** 0.08 mm
Kick starter:
Type Ratchet type ***
Kick clip tension force 0.15 ~ 0.25 kg ***
Carburetor:
I.D. mark Gurtner 402 ***
Main jet (M.J.) # 74 (B)(E)(F)(GB)(I)(P) ***
# 68 (D)(NL) ***
Main air jet (M.A.J.) 2.0 ***
Jet needle (J.N.) B10A 2/3 (B)(E)(F)(GB)(I)(P) ***
B10A 1/3 (D)(NL) ***
Needle jet (N.J.) 2326 (B)(E)(F)(GB)(I)(P) ***
20608/8 (D)(NL) ***
Cutaway (C.A.) 3.0 ***
Pilot jet (P.J.) # 38 ***
Bypass 1 (B.P.1) *** ***
Air screw (A.S.) 1 - 1/8 (B)(E)(F)(GB)(I)(P) ***
1 - 1/2 (D) ***
1 - 3/4 (NL) ***
Valve seat size (V.S.) 1.4 ***
Starter jet (G.S.1) # 42 ***
Engine idle speed 1800 ± 200 r/min (B)(E)(F)(GB)(I)(P) ***
2000 ± 200 r/min (D)(NL) ***
2-5
SPEC
Reed valve:
Thickness 0.142 ~ 0.162 mm ***
Valve stopper height 6.0 ~ 6.4 mm ***
Valve bending limit 0.2 mm ***
Lubrication system: Autolube pump ***
Stroke 0.5 mm ***
2-6
SPEC
TIGHTENING TORQUES
ENGINE
Tightening
Part to be tightened Part Thread Q'ty torque Remarks
name size
Nm m.kg
Spark plug - M14 1 23 2.3
Head cylinder Nut M7 4 14 1.4
Cylinder stud bolt bolt stud M7 4 Fixed till end
Air shroud (fan cover) Screw M6 2 6.5 0.65
Fan Screw M6 3 6.5 0.65
Air shroud (cylinder cover) Screw 5.5x40 1 1.5 0.15
Oil pump assembly Screw M5 2 4 0.4
Reed valve Bolt M6 4 11 1.1
Air filter Screw M6 2 8.5 0.85
Carburetor top Bolt M5 1 2.5 0.25
Exaust pipe/cylinder Screw M6 2 7.0 0.7
Muffler Bolt M8 2 29 2.9
Muffler protector Screw M6 2 18.5 1.85
Crankcase Screw M6 6 13 1.3
Holder Bolt M6 1 8 0.8
Crankcase cover (right cover) Screw M6 2 10 1.0
Bolt M6 4 10 1.0
Crankcase cover (left cover) Screw M6 9 9 0.9
Bolt M6 3 9 0.9
Drain bolt Bolt M8 1 17 1.7
Plug oil Plug oil M14 1 - -
Plate idle gear Bolt M6 2 8 0.8
Self starting motor Bolt M6 2 8 0.8
Cluth housing Nut M10 2 40 4.0
Cluth one-way Nut M28 1 - -
Pin pivot Nut M10 1 12 1.2
Base magneto Screw M6 2 8.5 0.85
C.D.I. rotor Nut M10 2 37 3.7
2-7
SPEC
CHASSIS
Steering system:
Steering bearing type Ball bearing ***
No/Size of steel balls:
Upper ø4.77 mm x 15 ***
Lower ø4.77 mm x 15 ***
Front suspension:
Front fork travel 80 mm ***
Optional spring No
Oil quantity / tube 70 cc ***
Oil grade ISO 6743/4 LHV 46 or SAE 10 ***
Rear suspension:
Shock absorber travel 70 mm ***
Spring free length 235 mm ***
Spring fitting length 208 mm ***
Srping rate (K1) 23 N/mm ***
Stroke 0 ~ 75 mm ***
Optional spring No
Wheels:
Front wheel type Cast wheel
Rear wheel type Cast wheel
Front wheel size/Material MT 1.60 x16/Aluminium
Rear wheel size/Material MT 1.85 x 16/Aluminium
Rim runout limit:
Front Radial *** 1 mm
Lateral *** 1 mm
Rear Radial *** 1 mm
Lateral *** 1 mm
2-8
SPEC

Front disk brake:
Type Single disc ***
Diameter and thickness 220 x 4 mm ***
Pad thickness 4.5 mm 0.5 mm
Master cylinder inside diameter 11 mm ***
Caliper cylinder inside diameter 30 mm ***
Brake fluid type DOT #3 or DOT#4 ***
Rear drum brake:
Type Leading, trailing ***
Drum inside diameter 110 mm 110.5 mm
Lining thickness 4 mm 2 mm
Spring free length 50.5 mm ***
Brake lever freeplay:
Front brake lever free play 10 ~ 20 mm ***
Rear brake lever free play 10 ~ 20 mm ***
2-9
SPEC
TIGHTENING TORQUES
CHASSIS
Tightening
Part to be tightened Thread torque Remarks
size Nm m.kg
Frame with engine bracket M10 42 4.2
Engine bracket with engine M10 52 5.2
Rear schock absorber with frame (top) M10 31.5 3.15
Rear schock absorber with engine (bottom) M8 17.5 1.75
Handle with steering shaft M10 60 6.0
Steering nut (securing nut) M25 27.5 2.75
Front and rear flasher M6 1.5 0.15
Cover handle under/handle M8 4 0.4
Master cylinder/Handle M6 8.5 0.85
Seat lock M6 4 0.4
Box / Frame M6 7 0.7
Fuel tank / Fuel cock x 2.5 0.25
Carrier / Frame M6 4 0.4
Fuel tank M6 6.5 0.65
Front wheel axle M12 45 4.5
Rear wheel axle M14 103.5 10.35
Front disc brake M10 23 2.3
Front caliper M8 23 2.3
Rear brake camshaft lever M6 9.75 0.98
Rear brake pin pivot M10 12 1.2 Punch the nut.
Bolt union/Master cylinder M10 23 2.3
Bolt union/Caliper M10 23 2.3
Screws tapping in plastic Ø5 3.25 0.33
Screws tapping in clip Ø5 2.25 0.23
Board footrest / Frame M6 4 0.4
Inner pannel / Frame M6 4 0.4
Oil tank M6 5 0.5
Guard flap / Frame M6 7 0.7
Fender / Front fork M6 4 0.4
Inner fender / Frame M6 4 0.4
Bleed screw and caliper *** 6 0.6
2-10
SPEC
ELECTRICAL

Voltage: 12 V ***
Ignition system:
Ignition timing(B.T.D.C.) 14° at 5000 r/min ***
Ignition timing type Constant ***
CDI:
Model/Manufacturer 3KJ / MORYAMA
Pickup coil resistance (color) 400 ~ 600 Ω at 20°C (68°F)
(White/Red-Black)
Source coil resistance (color) 640 ~ 960 Ω at 20°C (68°F) ***
(Black/Red-Black)
Ignition coil:
Model/Manufacturer 2JN / MORYAMA ***
Minimum spark length *** 6 mm
Primary coil resistance 0.32 ~ 0.48 Ω at 20°C (68°F) ***
Secondary coil resistance 5.68 ~ 8.52 kΩ at 20°C (68°F) ***
Spark plug cap:
Type Resin
Resistance 5 kΩ at 20°C (68°F) ***
Charging system / Type Flywheel magneto
CDI Magneto:
Model/Manufacturer F2JA / MORYAMA ***
Charging coil resistance (color) 0,48 ~ 0,72 Ω at 20°C (68°F) ***
(White-Black)
Lighting coil resistance (color) 0,4 ~ 0,6 Ω at 20°C (68°F) ***
(Yellow/Red-Black)
Voltage Regulator/Rectifier:
Type Semi-conductor,
Short-circuit type
Model/Manufacturer DUCATI
No load regulated voltage 13 ~ 14 V ***
Capacity 8A ***
2-11
SPEC
Battery :
Specific gravity 1.280 ***
Starter motor:
Model / Type 3AA / YAMAHA
Output 0.14 kW ***
Armature coil resistance 0.06 ~ 0.08 Ω at 20°C (68°F) ***
Brush length 3.9 mm 0.9 mm
Brush spring pressure 563 ~ 844 g ***
Commutator diameter 15.8 mm 14.8 mm
Mica undercut (depth) 1.15 mm ***
Starter relay:
Amperage rating 20 A ***
Coil resistance 54 ~ 66 Ω at 20°C (68°F) ***
Horn:
Type/Quantity Plain type/1pc.
Model/Manufacturer TR9/TRANSVAL
Maximum amperage 2.5 A ***
Flasher relay:
Type Condenser type
Self cancelling device No
Flasher frequency 75 ~ 95 cycles/min ***
Wattage 10W x 2 + 3W ***
Circuit breaker:
Type Fuse
Amperage for individual
circuit x Quantity 7.5 A x 1 ***
Fuel sender unit:
Resistance (Full) 9.2 ~ 10.8 Ω at 20°C (68°F) ***
(Empty) 89.2 ~ 90.8 Ω at 20°C (68°F) ***
2-12
GENERAL TORQUE SPECIFICATIONS
SPEC
GENERAL TORQUE
A B General torque
SPECIFICATIONS (Nut) (Bolt) specifications
This chart specifies torque for standard fasteners Nm m.kg
with standard I.S.O. pitch threads. Torque 10 mm 6 mm 60 0.6
specifications for special components or
12 mm 8 mm 15 1.5
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten 14 mm 10 mm 30 3.0
multi-fastener assemblies in a crisscross 17 mm 12 mm 55 5.5
fashion, in progressive stages, until full torque 19 mm 14 mm 85 8.5
is reached. Unless otherwise specified, torque 22 mm 16 mm 130 13.0
specifications call for clean, dry threads.
Components should be at room temperature.
A B
A: Distance across flats.

B: Outside thread diameter.
2-13
LUBRICATION POINTS AND GRADE OF LUBRICANT SPEC
LUBRICATION POINTS AND GRADE OF LUBRICANT
ENGINE
Lubrication points Lubricant type

Oil seal lips LS
O-ring LS
Crankshaft bearings
Needle bearings (connecting rod)
Main axle bearings
Drive axle bearings LS
Secondary sheave axle bearing

Piston rings, piston pin and piston
Kick pinion gear LS
Kick shaft LS
Starter idle gear

starter clutch pin
Oil pump driven gear and drive gear LS
Secondary sliding sheave cam groove BEL-RAY® assembly lube

Secondary fixed sheave inside diameter BEL-RAY® assembly lube
Crankcase surface Yamaha N°1215
2-14
LUBRICATION POINTS AND GRADE OF LUBRICANT
SPEC
CHASSIS
Lubrication points Lubricant type

Front wheel oil seal (right/left) LS
Rear wheel oil seal LS
Steering bearing and bearing race (upper/lower) LS
Throttle grip inner surface LS
Lever pivots and cable end LS
Oil seal lips (front wheel) LS
Bearing (front wheel) LS
Speedometer gear LS
Center stand pivot LS
2-15
CABLE ROUTING
SPEC
CABLE ROUTING A Place the fuel sender wire on the rear-right side of the vehicul.
! Fuel sender B Pipes must pass above the engine bracket axle.
" Fuel tank C Insert the fuel cock completly without turning and tighten the hose
# Oil tank clamp assembly.
$ Overflow pipes D Place the fuel cock as specified.
% Box
& Fuel hose
' Sunction pipe
( Fuel cock
"
A C
B
"
( D
& '
!
45°
$ "
(
%
$
#
2-16
SPEC
CABLE ROUTING
! Wire throttle A Pass the speedometer cable through the fender guide.
" Rear brake cable B Clamp the brake hose to the clip.
# Front brake hose C Clamp all the cables and wires to the frame with a plastic band.
$ Band switch Place the plastic band on the seat lock cable mark.
% Wire harness D Install the wire harness with the mudguard plastic band.
& Speedometer cable E Attach the rear brake cable, the seat lock cable and the wire
' Seat lock cable harness all together on the frame.
( Right flasher connector
) Tail light connector
* Left flasher connector
+ Oil gauge
" 5~10 mm
% %
"
'
!
$ E
5~10 mm
5~10 mm
%
$ &
# % ' %
" "
!
"
+
B
" D
A & %
# !
* (
)
2-17
SPEC
CABLE ROUTING
! Wire harness A Put the fuse in place.
" C.D.I. magneto wire B Install the starter relay support into the box tongue.
# Starter lead C Clamp the C.D.I. magneto wire,the starter lead and the
$ Autochoke lead autochoke lead all together.
% Battery D Clamp all wires and cables to the frame on the right side only.
& Plastic band Place the plastic band on the wire harness mark.
' Seat lock cable E Clamp the wire harness to the frame, on the right side only.
( Rear brake cable
) Throttle cable
* Left flasher connector
+ Tail light connector
, Right flasher connector
- Breather pipe
. Starter relay
B
C
A
!
"
. #
$
%
5~7 mm
!
E * + ,
&
5~10 mm
& -
D
'
!
'
!
'
) ( !
2-18
SPEC
CABLE ROUTING
! Speedometer cable A Pass the seat lock cable on the right side of the front trunk.
" Seat lock cable B Fix the starter ground wire with the CHC screw as shown.
# Regulator/Rectifier
$ Resistor
% Flasher relay
& Wire harness
' Rear brake cable
( Throttle cable
) Front brake hose
* Fuel meter
+ Horn
' (
&
%
$ )
# 0¡ + 45¡
0
A
*
B
"
2-19
SPEC
CABLE ROUTING
! Spark plug lead A Clamp all the wires and cables to the frame, only on the right
" Wire harness side .
# Oil gauge Place the plastic band on the wire harness mark.
$ Ignition coil B Do not clamp the spark plug lead to the frame.
% C.D.I. Unit C Pass the rear brake cable in the guide fixed to the
& Throttle cable centerstand.
D Clamp the wire harness to the frame, on the right side only.
#
"
5~7 mm
!
$
D
&
%
B
! &
2-20
SPEC
CABLE ROUTING
! Stop switch A Install the left screw first and the right after.
" Clamp B Do not install screw at the front of the handlebar.
# Speedometer cable
$ Wire harness
% Throttle cable
& Rear brake cable
' Brake hose
( Right handle switch
) Front master cylinder
* Left handle switch
+ Grip
"
! '
&
# $ %
! )
*
+
(
'
&
2-21
SPEC
CABLE ROUTING
! Handlebar switch A Respect the position of the handlebar switch.
" Flasher B Respect the brake hose position.
# Master cylinder C Install the master cylinder close to the handlebar switch.
$ Brake hose Install the master cylinder bracket to be in accordance with
% Speedometer assembly the handlebar switch assembling line.
& Speedometer cable D Install the handlebar as shown.
' Headlight assembly
!
! 0–1
A C
B
'
$
25¡ &
"
D
2-22
CHK
ADJ 3
CHK
ADJ
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION ............................................................................................ 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................... 3-1
COVERS ........................................................................................................ 3-3

SIDE COVERS (SINGLE RIDING) .......................................................... 3-3
SIDE COVERS (DUAL RIDING) .............................................................. 3-4
BOX AND FUEL TANK ............................................................................ 3-5
HANDLEBAR COVERS ........................................................................... 3-6
FENDERS AND FRONT PANEL ............................................................. 3-7
INNER PANEL AND BOARD FOOTREST .............................................. 3-8
ENGINE ......................................................................................................... 3-9

ENGINE IDLE SPEED ADJUSTMENT .................................................... 3-9
THROTTLE CABLE FREE PLAY ADJUSTMENT ................................. 3-10
SPARK PLUG INSPECTION ................................................................. 3-11
AUTOLUBE PUMP AIR BLEEDING ...................................................... 3-12
ENGINE OIL LEVEL INSPECTION ....................................................... 3-13
TRANSMISSION OIL REPLACEMENT ................................................. 3-14
AIR CLEANER ELEMENT CLEANING .................................................. 3-15
EXHAUST SYSTEM INSPECTION ....................................................... 3-16
V-BELT INSPECTION ............................................................................ 3-16
CHASSIS ..................................................................................................... 3-17

FRONT BRAKE LEVER FREE PLAY ADJUSTMENT ........................... 3-17
BRAKE FLUID LEVEL INSPECTION .................................................... 3-17
BRAKE PADS INSPECTION ................................................................. 3-18
BRAKE HOSE INSPECTION ................................................................. 3-18
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ................................. 3-19
REAR BRAKE LEVER FREE PLAY ADJUSTMENT ............................. 3-20
BRAKE SHOE INSPECTION ................................................................. 3-20
STEERING HEAD ADJUSTMENT ......................................................... 3-20
TIRE INSPECTION ................................................................................ 3-21
WHEEL INSPECTION ........................................................................... 3-22
CABLE INSPECTION AND LUBRICATION ........................................... 3-22
LEVER LUBRICATION .......................................................................... 3-23
CENTERSTAND LUBRICATION ........................................................... 3-23
FRONT FORK INSPECTION ................................................................. 3-23
REAR SHOCK ABSORBER .................................................................. 3-23
ELECTRICAL .............................................................................................. 3-24

BATTERY INSPECTION ........................................................................ 3-24
FUSE INSPECTION ............................................................................... 3-25
HEADLIGHT BEAM ADJUSTMENT ...................................................... 3-26
HEADLIGHT LENS REPLACEMENT .................................................... 3-27
HEADLIGHT BULB REPLACEMENT .................................................... 3-27
INSP
PERIODIC INSPECTION AND ADJUSTMENT REG
PERIODIC INSPECTION AND ADJUSTMENT
EB300000
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as new vehicles that are being prepared for
sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
EVERY
BREAK-IN 3,000 km 6,000 km
ITEM REMARKS 1,000 km or or
6 months 12 months
1 Spark plug • Check condition.
• Clean or replace if necessary.
2 Air filter • Clean.
• Replace if necessary.
3 * Carburetor • Check idle speed/Choke operation.
• Adjust if necessary.
4 * Fuel line • Check fuel hose and vacuum pipe for cracks or damage.
• Replace if necessary..
• Check oil leakage.
5 * Transmission oil • Correct if necessary.
• Replace every 12.000 km or 24 months. REPLACE
(Warm engine before draining.)
• Check operation.
6 * Autolube-pump • Correct if necessary.
• Air bleeding.
• Check operation/Fluid leakage/See NOTE.
7 * Front brake (disc) • Correct if necessary.
8 * Rear brake (drum) • Correct if necessary.
• Check damage/run out, wheels tightening.
9 * Wheels • Replace/tighten if necessary.
• Check bearing assembly for looseness.
10 * Wheel bearings • Replace if damaged.
• Check bearing assembly for looseness.
11 * Steering bearings • Correct if necessary.
• Moderately repack every 12.000 km or 24 months.**
• Check operation/oil leakage.
12 * Rear shock absorber • Replace if necessary.
• Check damage and wear.
13 * V-belt • Replace if necessary.
• Check all chassis fittings and fasteners.
14 * Fittings/Fasteners • Correct if necessary.
15 * Centerstand • Repair if necessary.
• Check specific gravity.
16 * Battery • Check breather pipe for proper operation.
• Correct if necessary.
Items with an asterisk (*) require special tools, data and technical skills for servicing. Take the scooter to a Yamaha/MBK
dealer when servicing these items.
** : Medium weight wheel bearing grease.
3-1
INSP
PERIODIC INSPECTION AND ADJUSTMENT REG
NOTE:
Brake fluid replacement:
1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3.Replace the brake hoses every four years, or when cracked or damaged.
3-2
INSP
COVERS REG
COVERS
SIDE COVERS (SINGLE RIDING)
T.R 4 Nm (0.4 m.kg)
3
7 6
T.R 4 Nm (0.4 m.kg)

2
4 5
T.R 6 Nm (0.6 m.kg)
Order Job name/Part name Q'ty Remarks

Side covers removal Remove the parts in the order below.
1 Rear carrier 1
2 Taillight 1
3 Taillight lead 1 Disconnect.
4 Seat cover 1 NOTE:
5 Left side cover 1 Open the seat to remove the seat cover
6 Right side cover 1 and left and right side covers.
7 Seat 1
For installation, reverse the removal proce-

dure.
3-3
INSP
COVERS REG
SIDE COVERS (DUAL RIDING)
4 Nm (0.4 m.kg)
1
T.R
T.R 4 Nm (0.4 m.kg)
5
2
7
T.R 4 Nm (0.4 m.kg)
T.R 4 Nm (0.4 m.kg)

4
6 8
T.R 6 Nm (0.6 m.kg)

Remove the parts in the order below.
Side covers removal NOTE:
1 Rear seat 1 Open the seat to remove the rear seat and
2 Rear carrier 1 rear carrier.
3 Taillight 1
4 Taillight lead 1 Disconnect.
5 Seat 1
6 Seat cover 1
7 Left side cover 1
8 Right side cover 1

dure.
3-4
INSP
COVERS REG
BOX AND FUEL TANK
T.R 7 Nm (0.7 m.kg)

1
6
T.R 6.5 Nm (0.65 m.kg)
5
8
2
4
9
T.R 5 Nm (0.5 m.kg)

Box and fuel tank removal Remove the parts in the order below.
Rear carrier, tail light, side covers Refer to "SIDE COVERS" section.
and seat
1 Battery cover 1
2 Battery negative lead (-) 1
3 Battery positive lead (+) 1
4 Battery 1
5 Starter relay 1
6 Box 1
7 Box fixing bracket 1
8 Fuel tank 1
9 Oil tank 1

dure.
3-5
INSP
COVERS REG
HANDLEBAR COVERS
3 2
7
4
T.R 2.25 Nm (0.23 m.kg)

6
5
4 Nm (0.4 m.kg)
3.25 Nm (0.33 m.kg)
T.R
T.R

Handlebar covers removal Remove the parts in the order below.
1 Rim 1 CAUTION:
Remove the headlight lens with the rim.
2 Headlight lead 1 Disconnect

3 Upper handlebar cover/Headlight cover 1/1 NOTE:
Remove them together.
4 Meter cable 1
5 High beam indicator light connector 1
6 Turn indicator light connector 1
7 Meter light connector 1

dure.
3-6
INSP
COVERS REG
FENDERS AND FRONT PANEL
T.R 2.25Nm (0.23 m.kg)
T.R 4 Nm (0.4 m.kg)
1
2
T.R 2.25 Nm (0.23 m.kg) T.R 2.25 Nm (0.23 m.kg)

Fenders and front panel removal Remove the parts in the order below.
1 Front fender (front part) 1
2 Front fender (rear part) 1

3 Inner fender 1
4 Front panel 1
5 Front cover 1

dure.
3-7
INSP
COVERS REG
INNER PANEL AND BOARD FOOTREST
T.R 3.25 Nm (0.33 m.kg)
T.R 4 Nm (0,4 m.kg)
T.R 3,25 Nm (0,33 m.kg)

Inner panel and board footrest Remove the parts in the order below.
removal
Front panel Refer to "FENDERS AND FRONT PANEL"
section.
1 Horn 1
2 Fuel meter 1 NOTE:
Remove one screw to remove the inner
panel.
3 Lid 1
4 Board footrest 1
5 Inner panel 1

dure.
3-8
INSP
ENGINE IDLE SPEED ADJUSTMENT REG
ENGINE
YP303022
ENGINE IDLE SPEED ADJUSTMENT
1.Start the engine and let it warm up for several
minutes.
WARNING
For safety reasons, place the scooter on the
centerstand before starting the engine.
2.Attach:
• Inductive tachometer to the spark plug
lead.
Inductive tachometer:
90890-03113
3.Check:
• Engine idle speed
If out of specification → Adjust.
Engine idle speed

1800 ± 200 r/mn (B)(E)(F)(GB)(I)(P)
2000 ± 200 r/mn (D)(NL)
4.Adjust:
• Engine idle speed.
******************************************************
Adjustment steps:
• Turn the pilot air screw in until lightly seated.
• Turn the pilot air screw out as specified.
Pilot air screw:

1-1/8 turns out (B)(E)(F)(GB)(I)(P)
1-1/2 turns out (D)
1-3/4 turns out (NL)
• Turn the throttle stop screw in or out until

specified idling speed is obtained.
Turn right Idling speed increased

Turn left Idling speed decreased
******************************************************
5.Adjust:
• Throttle cable free play
Refer to the section "THROTTLE CABLE
FREE PLAY ADJUSTMENT".
3-9
INSP
THROTTLE CABLE FREE PLAY ADJUSTMENT REG
YP303032
THROTTLE CABLE FREE PLAY
ADJUSTMENT
NOTE:
Before adjusting the throttle cable free play, the
engine idle speed should be adjusted.
1.Check:
• Throttle cable free play @
If out of specification → Adjust.
Free play (throttle cable):

1.5 ~ 3.0 mm
2.Adjust:
@ • Throttle cable free play
*****************************************************
Adjustment steps:
• Loosen the locknut on the throttle cable.
• Turn the adjuster in or out until the specified
free play is obtained.
Turning left Free play increased.

Turning right Free play decreased.
• Tighten the locknut.
WARNING
After adjusting, turn the handlebar to the
right and left, making sure that the engine
idling speed does not change.
******************************************************
3-10
INSP
SPARK PLUG INSPECTION REG
EB303040
SPARK PLUG INSPECTION
1.Remove:
• Spark plug cap
• Spark plug
CAUTION:
Before completely removing the spark plug,
use compressed air to clean the cylinder
head cover areas to prevent dirt from falling
into the engine.
2.Check:
• Spark plug type
Incorrect → Replace.
Standard spark plug:

BR8HS (NGK)
3.Inspect:
• Electrode !
Wear/ Damage → Replace.
• Insulator "
Abnormal color → Replace.
(Normal color is medium-to-light tan color).
" ! 4.Clean:
• Spark plug
(with spark plug cleaner or wire brush).
5.Measure:
• Spark plug gap !
Use a wire gauge.
Out of specification → Adjust.
! Spark plug gap:

0.5 ~ 0.7 mm
6.Install:
• Spark plug
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
3-11
INSP
AUTOLUBE PUMP AIR BLEEDING REG
AUTOLUBE PUMP AIR BLEEDING.
1.Bleed:
• Pump housing and oil hose
*****************************************************
Pump bleeding steps:
• Place a rag under the pump.
• Remove the bleed screw.
• Let oil run until there are no more air bubbles
in it.
• When there are no more bubbles, tighten the
bleed screw.
NOTE:
Check the condition of the bleed screw gasket.
If it is damaged, replace it with a new one.
• Start the engine.

• Let the engine run two or three minutes at
2.000 rpm. This will force out any air in the
hose.
*****************************************************
3-12
INSP
ENGINE OIL LEVEL INSPECTION REG
ENGINE OIL LEVEL INSPECTION
1.Inspect:
• Oil level
Oil level low → Add oil to proper level as
follows.
Q "OIL" indicator light

!
OIL LEVEL AND GAUGE CHECK
Turn main switch

to "*"
"OIL" indicator "OIL" indicator

doesn't light. light.
Turn main switch

to "ON".
"OIL" indicator "OIL" indicator

goes stays on.
Inspect Faulty Engine oil level

Add oil.
electrical circuit, and electric circuit
Light bulb etc. are OK.
"OIL" indicator
stays on.
Recommended oil:
Semi-synthetic oil in accordance
! with APITC TSC3 STANDARD.
Capacity :
Total:
1.3 L
NOTE:
Install the oil tank filler cap ! and push it fully
into the filler.
CAUTION:
Always use the same type of engine oil;
mixing oils may result in a harmful chemical
reaction and lead to poor performance.
3-13
INSP
TRANSMISSION OIL REPLACEMENT REG
TRANSMISSION OIL REPLACEMENT
1.Remove:
• Drain plug "
!
• Oil filler plug !
Drain the transmission oil.
2.Check:
" • Gasket (drain plug)
• O-ring (oil filler plug)
Damaged → Replace.
3.Install:
! • Gasket !
• Drain plug " T.R 17 Nm (1.7 m•kg)
4.Fill:
• Transmission case
"
Transmission oil:
SAE 10W30 type SE motor oil.
Capacity:
Periodic replacement
0.11 L
Total amount
0.13 L
NOTE:
Wipe off any oil spilt on the crankcase, tire or
wheel.
5.Install:
• Oil filter plug
3-14
INSP
AIR CLEANER ELEMENT CLEANING REG
YP303123
AIR CLEANER ELEMENT CLEANING
1.Remove:
• Air cleaner element cleaning
2.Remove:
• Air filter element !
! CAUTION:
Never operate the engine with the air cleaner
element removed. Unfiltered air will cause
rapid wear of engine parts and possible engine
damage.
3.Inspect:
• Element !
Damaged → Replace.
4.Clean:
!
• Air filter element
*****************************************************
Cleaning steps:
• Wash the element gently but thoroughly in
! "
solvent.
WARNING
$ # Never use low flashpoint solvents such as
gasoline to clean the element. Such solvents
may lead to fire or explosion.
• Squeeze excess of solvent out of the element

and let dry.
CAUTION:
Do not twist the element.
• Apply specified oil on the air filter and squeeze

out the excess oil.
Recommanded oil:
SAE 10W30 type SE motor oil
NOTE:
The element should be wet but not dripping.
*****************************************************
5.Install:
• The air filter element
In the case cover.
3-15
EXHAUST SYSTEM INSPECTION/ INSP
V-BELT INSPECTION REG
EXHAUST SYSTEM INSPECTION
1.Inspect:
• Exhaust pipe assembly !
Cracks/Damage → Replace.
• Gasket
Exhaust gas leaks → Replace.
*****************************************************
Replacement steps:
• Remove the exhaust pipe assembly
!
• Install a new exhaust pipe.
Screw (exhaust pipe/cylinder):

T.
R 7.0 Nm (0.7 m•kg)
Bolt (muffler):
29 Nm (2.9 m•kg)
Screw (muffler protector)
18.5 Nm(0.19 m•kg)
*****************************************************
V-BELT INSPECTION
1.Remove:
• Air cleaner case
• Crankcase (left) and kick starter
2.Check:
• V-belt
Cracks/Scaling/Chipping → Replace.
Traces of oil/grease → Replace.
3.Measure:
• V-belt width a
Out of specification → Replace.
V-belt width:
Standard: 16.5 mm
Limit: 14.85 mm
312001
NOTE:
Measure the V-belt width on several points.
4.Install:
• Gasket (crankcase cover left)
• Crankcase cover (left)
9 Nm (9.0 m•kg)
T.R
• Air cleaner case T.R 8.5 Nm (8.5 m•kg)
3-16
FRONT BRAKE LEVER FREE PLAY ADJUSTMENT/ INSP
BRAKE FLUID LEVEL INSPECTION REG
CHASSIS
@ FRONT BRAKE LEVER FREE PLAY
ADJUSTMENT
1. Check:
• Front brake lever free play @
Out of specification → Check the brake system.
Free play :
10 ~ 20 mm
WARNING
A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake
system. This air must be removed by bleeding
the brake system before the scooter is
operated. Air in the system will reduce brake
performance and can result in loss of control
and an accident. Inspect and bleed the system
if necessary.
BRAKE FLUID LEVEL INSPECTION

NOTE:
Position the scooter straight up when inspecting
the fluid level, and make sure be turning the
handlebar that the top of the master cylinder is
horizontal.
1. Inspect:
MINI • Brake fluid level
Brake fluid level is under "LOWER" level line
→ Fill to proper level.
Recommended brake fluid :

DOT #3 or DOT # 4
CAUTION:
The brake fluid may corrode painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
3-17
BRAKE FLUID LEVEL INSPECTION/
BRAKE PADS INSPECTION/ INSP
BRAKE HOSE INSPECTION REG
WARNING
• Use only the designated quality fluid.
Otherwise, the rubber seals may deteriorate
causing leakage and poor brake
performance.
• Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical
reaction leading to poor brake performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
BRAKE PADS INSPECTION

1.Measure:
• Brake pads
NOTE:
Replace the brake pad and spring as a set when
replacing the brake pads.
Wear limit ! :
! 0.5 mm
BRAKE HOSE INSPECTION

1.Inspect:
• Brake hose
Cracks/Wear/Damage → Replace.
2.Check:
• Brake hose clamp
Loosen → Tighten.
3.Hold the scooter on upright position.
4.Check:
• Brake hose
Activate the brake lever several times.
Fluid leakage → Replace the hose.
Refer to the section "FRONT BRAKE" in
Chapter 6.
3-18
INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) REG
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
WARNING
Bleed the brake system if:
• The system has been disassembled.
• A brake hose has been loosened or
removed.
• The brake fluid has been very low.
• The brake operation has been faulty.
A loss of braking performance may occur if
the brake system is not properly bled.
1.Bleed:
!
• Brake fluid.
*****************************************************
Air bleeding steps :
a.Add proper brake fluid into the reservoir.
b.Install the diaphragm. Be careful not to spill
346002(a)
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic tube ! tightly to the
caliper bleed screw.
d.Place the other end of the tube into a container.
e.Slowly apply the brake lever several times.
f. Pull the lever as far as possible and hold it
there.
g.Loosen the bleed screw and pull the lever all
the way.
h.When the lever is completely pulled, tighten
the bleed screw, then release the lever.
T.R 6 Nm (0.6 m•kg)
i. Repeat steps (e) to (h) until all air bubbles
have been removed from the system.
NOTE:
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat the
bleeding procedure when the tiny bubbles in the
system has disappeared.
j. Add brake fluid to proper level.

Refer to the "BRAKE FLUID INSPECTION".
*****************************************************
WARNING
Check the operation of the brake after
bleeding the brake system.
3-19
REAR BRAKE LEVER FREE PLAY ADJUSTMENT/
BRAKE SHOE INSPECTION/ INSP
STEERING HEAD ADJUSTMENT REG
REAR BRAKE LEVER FREE PLAY
ADJUSTMENT
@ 1. Check:
• Rear brake lever free play @
Free play :
10 ~ 20 mm
*****************************************************
Rear brake lever free play adjustment
steps:
• Turn the adjuster ! in " or out $ until the
correct free play is obtained.
*****************************************************
"
!
$
BRAKE SHOE INSPECTION

1. Apply the rear brake lever.
2. Inspect :
• Wear indicator !
Indicator reaches the wear limit line "
! → Replace brake shoes.
Refer to the section "REAR WHEEL" in the
chapter 6.
"
STEERING HEAD ADJUSTMENT
1.Check:
• Steering assembly bearings
Grasp the bottom of the forks and gently rock
the fork assembly back and forth.
Looseness → Adjust steering head.
******************************************************
Steering head adjustment steps:
• Remove the front fender and the front panels.
Refer to "COVERS" section.
• Unscrew the securing nut !
• Tighten the ring nut "
Ring nut wrench :

9079Q - 02218
!
" WARNING
Do not overtighten.
3-20
STEERING HEAD ADJUSTMENT/ INSP
TIRE INSPECTION REG
• Check the steering head by turning it lock to
lock. If it binds, remove the steering stem
assembly and inspect the steering bearings.
• Install the steering shaft lock nut and tighten it
to the specified torque.
T.R 27.5 Nm (2.75 m•kg)
NOTE:
Tighten the steering shaft lock nut while holding
the ring nut with the ring nut wrench.
Ring nut wrench:

9079Q - 02218
*****************************************************
• Move the handlebar up and down and from
front to rear. If steering play is too important,
!
tighten the nut ! to the specified torque.
T.R 60 Nm (6.0 m•kg)
TIRE INSPECTION
1.Measure:
• Air pressure
WARNING
Proper loading of your scooter is important
(Single riding) for the handling, braking, and other
Tire pressure (cold) Front Rear performance and safety characteristics of
Up to 90 kg 180 kPa 190 kPa your scooter. Do not carry loosely packed
(1.80 kgf/cm2) (1.90 kgf/cm2) items that can shift. Securely pack your
90 kg ~ maximum 190 kPa 200 kPa heaviest items close to the center of the
load * (1.90 kgf/cm2) (2.00 kgf/cm2) scooter, and distribute the weight evenly
Maximum load : 182 kg from side to side. And check the condition
* Maximum load is the total weight of rider, accessories and pressure of your tires. NEVER
and luggage. OVERLOAD YOUR SCOOTER. Make sure the
total weight of the cargo, rider, and
(Dual riding) accessories (fairing, saddlebags, etc. if
Tire pressure (cold) Front Rear approved for this model) does not exceed the
Up to 90 kg 180 kPa 190 kPa maximum load of the scooter. Operation of
(1.80 kgf/cm2) (1.90 kgf/cm2) an overloaded scooter could cause tire
90 kg ~ maximum 200 kPa 220 kPa damage, an accident, or even injury.
load * (2.00 kgf/cm )
2
(2.20 kgf/cm2)
Maximum load : 182 kg
* Maximum load is the total weight of rider, accessories
and luggage.
3-21
TIRE INSPECTION/WHEEL INSPECTION/ INSP
CABLE INSPECTION AND LUBRICATION REG
2.Inspect:
• Tire surface
Wear/Damage/Cracks/Road hazards
→ Replace.
• Aluminum wheels
Damage/Bends → Replace.
Never attempt even small repairs to the wheel.
WARNING
Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.
• If the tire is removed with a tire lever, use a

suitable protection to prevent damaging the
rim.
• When installing the tire, make sure the arrow
points to the front.
3.Measure:
• Tire tread depth
Minimum tire tread depth

(front and rear) :
0,8 mm
! Tread depth
" Side wall
$ Wear indicator
WHEEL INSPECTION
1.Inspect:
• Wheels
Damage/Bends → Replace.
WARNING
Never attempt even small repairs to the wheel.
CABLE INSPECTION AND LUBRICATION

WARNING
A damaged cable sheath will rapidly corrode.
As a result, the cable cannot move smoothly
inside the sheath. Since this situation is
dangerous, replace a damaged cable
immediately.
1.Check:
• Cable sheath
• Cable end
Damage → Replace.
3-22
CABLE INSPECTION AND LUBRICATION/
FRONT FORK INSPECTION/ INSP
REAR SHOCK ABSORBER REG
2.Check:
• Cable movement
Stickiness → Lubricate.
Recommended lubricant :
Engine oil SAE 10W30
NOTE:
Hold the cable end up and pour a few drops of oil
into the sheath.
3.Lubricate the throttle cable end and the cable

guide notch on the throttle grip with grease !.
LS
Recommanded lubricant :
Lithium soap based grease
LEVER LUBRICATION
1.Lubricate rotating parts of the levers
CENTERSTAND LUBRICATION
1.Lubricate rotating parts
FRONT FORK INSPECTION

1.Check:
• Front fork
Bend/Damage → Replace fork assembly as a
set.
Excessive oil leakage → Replace fork
assembly as a set.
Unsmooth operation → Replace fork assembly.
3115(a).art
REAR SHOCK ABSORBER
1.Check:
• Rear shock absorber !
Oil leaks/Damage → Replace.
2.Check:
• Upper bolt tightening torque
T.R31.5 Nm (3.15 m•kg)
• Lower bolt tightening torque
!
T.R 17.5 Nm (1.75 m•kg)
3-23
INSP
BATTERY INSPECTION REG
ELECTRICAL
! BATTERY INSPECTION
1.Inspect:
UPPER
LOWER + • Battery fluid level
" Fluid level low → Add to proper level.
Fluid level should be between upper and lower
level marks.
! Upper level
" Lower level
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.
2.Inspect:
• Breather hose
Obstruction → Remove.
3.Inspect:
• Battery
*******************************************************
Replace the battery if :
• Battery voltage will not rise to a specific value
or bubbles fail to rise during charging.
• Sulfation of one or more cells occurs. (As
indicated by the plates turning white, or an
accumulation of material in the bottom of the
sell.)
• Specific gravity readings after a long, slow
charge indicate that one cell is lower than the
rest.
• Warpage or buckling of plates or insulators is
evident.
*********************************************************
4.Measure:
• Specific gravity
Less than 1.280 → Recharge battery.
Charging Current :
0.4 amps/10 hrs
Specific Gravity :
1.280 at 20°C (68° F)
3-24
BATTERY INSPECTION/ INSP
FUSE INSPECTION REG
CAUTION:
Always charge a new battery before using it
to ensure maximum performance.
WARNING
Battery electrolyte is dangerous. It contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolyte as it
can cause severe burns and permanent
eye injury.
• Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
• SKIN – Flush with water.
• EYES – Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg,
or vegetable oil. Get immediate medical
attention.
Batteries generate explosive hydrogen gas.
Always follow these preventive measures:
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
• DO NOT SMOKE when charging or handling
batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
FUSE INSPECTION
1.Remove the battery cover.
!
2.Inspect:
• Fuse !
Blown → Replace.
3-25
FUSE INSPECTION/ INSP
HEADLIGHT BEAM ADJUSTEMENT REG
******************************************************
Fuse replacement steps :
• Turn off the ignition.
• Install a new fuse of the right amperage.
• Turn on the switches to verify the operation of
the electric circuit.
• If the fuse immediately blows again, check the
electric circuit.
*****************************************************
WARNING
Never use a fuse with a rating higher than
specified. An improper fuse may cause
damage to the electrical circuit, and possibly
cause a fire.
Fuse :
Main circuit : 7.5A
HEADLIGHT BEAM ADJUSTMENT

1.Adjust :
• Headlight beam
Higher Turn screw in "

Lower Turn screw out !
" !
3-26
HEADLIGHT LENS REPLACEMENT INSP
HEADLIGHT BULB REPLACEMENT REG
HEADLIGHT LENS REPLACEMENT
!
1.Remove:
• Rim !
2.Remove:
• Headlight lens
(Pull out the pins)
3.Remove:
• Gasket
4.Install:
Reverse the “REMOVAL” procedure.
HEADLIGHT BULB REPLACEMENT

1. Remove:
------ • Front cover
--
---
2. Remove:
• Headlight bulb socket !
! (Turn one quart of a turn).
3. Remove:
• Headlight bulb
4. Install:
Reverse the “REMOVAL” procedure.
3-27
ENG 4
ENG
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL ...................................................................................... 4-1

CABLES, LEADS, HOSES, PIPES, ENGINE BOLTS
AND ENGINE ........................................................................................... 4-1
ENGINE REMOVAL ................................................................................. 4-1
CYLINDER HEAD .......................................................................................... 4-3

REMOVAL ................................................................................................ 4-4
INSPECTION ........................................................................................... 4-4
INSTALLATION ........................................................................................ 4-5
CYLINDER AND PISTON .............................................................................. 4-6

PISTON PIN AND PISTON REMOVAL ................................................... 4-7
CYLINDER INSPECTION ........................................................................ 4-7
PISTON INSPECTION ............................................................................. 4-8
PISTON PIN AND PISTON PIN BEARING INSPECTION ....................... 4-9
PISTON RINGS INSPECTION .............................................................. 4-10
INSTALLATION OF THE PISTON RINGS, THE PISTON
AND THE CYLINDER ............................................................................ 4-10
KICKSTATER .............................................................................................. 4-12

KICKSTARTER INSPECTION ............................................................... 4-13
PRIMARY SHEAVE AND SECONDARY SHEAVE .................................... 4-14

PRIMARY SHEAVE REMOVAL ............................................................. 4-16
PRIMARY SHEAVE INSPECTION ........................................................ 4-16
PRIMARY SHEAVE INSTALLATION ..................................................... 4-17
SECONDARY SHEAVE REMOVAL ...................................................... 4-18
SECONDARY SHEAVE INSPECTION .................................................. 4-19
SECONDARY SHEAVE INSTALLATION .............................................. 4-20
STARTER SYSTEM .................................................................................... 4-22

STARTER SYSTEM INSPECTION ........................................................ 4-23
STARTER SYSTEM INSTALLATION .................................................... 4-23
TRANSMISSION .......................................................................................... 4-24

TRANSMISSION REMOVAL ................................................................. 4-24
TRANSMISSION INSPECTION ............................................................. 4-25
TRANSMISSION INSTALLATION ......................................................... 4-25
C.D.I. MAGNETO ......................................................................................... 4-27

C.D.I. MAGNETO REMOVAL ................................................................ 4-28
C.D.I. MAGNETO INSTALLATION ........................................................ 4-28
ENG
AUTOLUBE PUMP ...................................................................................... 4-30

AUTOLUBE PUMP REMOVAL .............................................................. 4-31
AUTOLUBE PUMP INSPECTION ......................................................... 4-31
AUTOLUBE PUMP INSTALLATION ...................................................... 4-31
CRANKSHAFT AND CRANKCASE ........................................................... 4-32

CRANKSHAFT AND CRANKCASE REMOVAL .................................... 4-34
CRANKSHAFT AND CRANKCASE INSPECTION ................................ 4-35
CRANKSHAFT AND CRANKCASE INSTALLATION ............................ 4-35
ENGINE REMOVAL ENG
ENGINE OVERHAUL
ENGINE REMOVAL
CABLES, LEADS, HOSES, PIPES, ENGINE BOLTS AND ENGINE
2 T.R 31.5 Nm (3.15 m.kg)
13
T.R 42 Nm (4.2 m.kg)
T.R 17.5 Nm (1.75 m.kg)
1
14
T.R 52 Nm (5.2 m.kg)
3 6
7
9 5
11
10
8
T.R 6.5 Nm (0.65 m.kg)
12
4 15
Cables, leads, pipes engine bolts Remove the parts in the order below.
and removal
Seat cover and side covers
Footrest board Refer to "COVERS" in chapter 3.
Muffler assembly
1 Battery negative lead 1

2 Battery positive lead 1
3 Auto choke coupler 1
4 Spark plug cap 1
5 C.D.I. magneto wire 1
6 Starter motor lead 1
7 Fuel pipe 1
8 Fan cover 1
9 Air shroud 1
4-1
ENGINE REMOVAL ENG
2 T.R 31.5 Nm (3.15 m.kg)
13
T.R 42 Nm (4.2 m.kg)
T.R 17.5 Nm (1.75 m.kg)
1
14
T.R 52 Nm (5.2 m.kg)
3 6
9 7
5
11
10
8
T.R 6.5 Nm (0.65 m.kg)
12
4 15
10 Oil pump hose 1

11 Throttle cable 1
12 Rear brake cable
13 Rear shock absorber 1
14 Engine mounting bolt 1
15 Engine 1
For installation, reverse the removal procedure.
4-2
CYLINDER HEAD ENG
CYLINDER HEAD
T.R 10 Nm (1.0 m.kg)
3
2
1 T.R 23 Nm (2.3 m.kg)
Cylinder head removal Remove the parts in the order below.

Side covers
Seat cover Refer to "COVERS" in Chapter 3.
Footrest board
Fan cover and air shroud
1 Spark plug 1
2 Cylinder head nuts 4
3 Cylinder head 1
4 Cylinder head gasket 1
For installation reverse the removal

procedure
4-3
CYLINDER HEAD
ENG
WARNING
Securely support the scooter so there is no
danger of it falling over.
REMOVAL
• Spark plug !
• Cylinder head "
T.R 10 Nm (1,0 m.kg) • Cylinder head gasket #
" # NOTE:
• Before loosening the cylinder head nuts, loosen
the spark plug.
• Loosen the cylinder head nuts $ crosswise
! 1/4 of a turn each before removing them.
• It is not necessary to remove the engine for the
removal of the cylinder head.
INSPECTION
1.Eliminate:
• Carbon deposits
! Use a rounded scraper !.
NOTE:
Take care to avoid damaging the spark plug
threads. Do not use a sharp instrument. Avoid
scratching the aluminum.
2.Inspect:
• Cylinder head
Scratches/Damage → Replace.
3.Inspect:
• Cylinder head warpage
Out of specification → Re-surface.
Cylinder head warpage:

<Limite: 0.02 mm>
4-4
CYLINDER HEAD
ENG
******************************************************
! Warpage measurement and re-surfacement
steps:
" • Attach a straight edge ! and thickness gauge
" to the cylinder head.
• Measure the warpage limit.
• Place a 400 ~ 600 grit wet sandpaper on the
surface plate, and resurface the head using a
figure-eight sanding pattern.
NOTE:
Rotate the head several times to avoid removing
too much material from one side.
******************************************************
INSTALLATION
1.Install:
• Cylinder head gasket
• Cylinder head
2. Tighten:
• Cylinder head nuts
3. Install:
• Spark plug
NOTE:
• Apply Engine oil on the cylinder head nuts.
• Tighten the cylinder head holding nuts in
stages, and crisscross sequence.
3. Install:
• Air shrouds
4-5
CYLINDER AND PISTON
ENG
CYLINDER AND PISTON
6
5 7
8 E 4 E
Cylinder and piston removal Remove the parts in the order below.
Cylinder head Refer to "CYLINDER HEAD" section.
Muffler
1 Cylinder 1
2 Cylinder gasket 1
3 Stud bold 4
4 Piston pin circlips 2
5 Piston pin 1
Refer to "PISTON AND PISTON PIN"
6 Piston 1
section.
7 Piston pin bearing 1
8 Piston ring set (top and 2nd)

procedure
4-6
CYLINDER AND PISTON
ENG
YP401031
PISTON PIN AND PISTON REMOVAL
1. Remove:
$ • Piston pin clips !
! " • Piston pin "
• Piston #
!
• Piston pin bearing $
# NOTE:
Before removing the piston pin clip, cover the
crankcase with a clean rag, so that the clip
cannot accidentally fall into the crankcase.
! 2. Remove:
• Piston rings
NOTE:
To remove the piston rings, open by pushing the
two ends of each ring with your fingers and
remove it by pushing on he opposite side.
YP402100
CYLINDER INSPECTION
1. Eliminate:
• Carbon deposits
Use a rounded scraper.
NOTE:
Do not use a sharp instrument. Avoid scratching
the cylinder.
2.Measure:
• Cylinder bore
D1 Out of specification → Rebore or replace
D2
NOTE:
• Measure the cylinder bore with a cylinder bore
gauge.
D3 • Measure the cylinder bore in parallel to and at
D4
right angles to the crankshaft.Then, calculate
the average of the measurement.
D5
D6 Cylinder bore:
39.993 ~ 40.012 mm
<Limit: 40.5 mm>
<Taper limit: 0.05 mm>
<Out of round limit: 0.01 mm>
4-7
CYLINDER AND PISTON
ENG
YP402201
! PISTON INSPECTION
1.Eliminate:
• Carbon deposits
From the piston crown ! and ring grooves ".
• Score marks and lacquer deposits
From the sides of piston.
Use an emery cloth (600 ~ 800 grit).
NOTE:
• Sand in a crisscross pattern.
• Do not sand excessively.
2.Measure:
• The piston skirt diameter
Out of specification → Replace
a 5,0 mm from the piston bottom edge.
Piston skirt diameter:

39.952 ~ 39.972 mm
Oversize (1):
40.25 mm
Oversize (2):
40.50 mm
3.Calculate:
• Piston-to-cylinder clearance
Piston-to-cylinder clearance =
Cylinder bore - Piston skirt diameter
For the cylinder bore refer to "CYLINDER"

section.
Out of specification → Replace piston and
piston rings as a set.
Piston-to-cylinder clearance:
0.034 ~ 0.047 mm
4.Measure:
• Piston pin bore diameter
Use/Damage/Scratches → Replace the piston.
4-8
CYLINDER AND PISTON
ENG
YP402202
PISTON PIN AND PISTON PIN BEARING
INSPECTION
1.Inspect:
• Piston pin
Blue discoloration/Groove → Replace, then
inspect lubrication system.
2.Measure:
a • Outside diameter (piston pin)
Outside diameter (piston pin):

9.996 ~ 10.000 mm
307009
b 3.Measure:
• Piston pin-to-piston clearance
Out of specification → Replace piston.
Piston pin-to-piston clearance =

Bore (piston pin ) b -
Outside diameter (piston pin) a
307010
Piston pin-to-piston clearance :

0.004 ~ 0.019 mm
4.Inspect:
• Bearing (piston pin)
Pitting/ Damage → Replace.
4-9
CYLINDER AND PISTON
ENG
YP402111
PISTON RINGS INSPECTION
!
1.Measure:
• Side clearance
Out of specification → Replace piston and/or
rings
Use a feeler gauge.
NOTE:
Eliminate the carbon deposits from the piston
rings grooves and rings ! before measuring the
side clearance.
Side clearance:
Top ring:
! 0.03 ~ 0.05 mm
2nd ring:
0.03 ~ 0.05 mm
2.Position:
307007 • Piston rings
(into cylinder)
NOTE:
a Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
3.Measure:
• End gap
Out of spécification → Replace.
a 5 mm
End gap:
Top ring:
0.15 ~ 0.35 mm
2nd ring:
0.15 ~ 0.35 mm
EB404184
INSTALLATION OF THE PISTON RING, THE
PISTON AND THE CYLINDER
1.Install:
• Top ring
• 2nd ring
NOTE:
• Be sure to install rings so that the manu-
facturer's marks or numbers are located on
the upper side of the rings.
• Oil the piston and the rings liberally.
4-10
CYLINDER AND PISTON ENG
2.Install:
• Piston pin bearing
• Piston !
• Piston pin "
! • Clips # (piston pin)
NOTE:
#
$ " • Apply engine oil onto the piston pins.
• Be sure that the mark $ " → " on the piston
points to the exhaust side of the engine.
• Before installing the piston, cover the
crankcase with a clean rag to prevent the
piston from falling into the crankcase.
CAUTION:
You must use new piston pin clips.
3.Install:
! • Stud bolts
• Cylinder gasket
CAUTION:
Make sure the ring ends ! are properly fitted
around the ring locating pins in the piston
groove.
4.Install:
• Cylinder
NOTE:
Install the cylinder with one hand, while
compressing the piston rings with the other
hand.
4-11
ENG
KICKSTARTER
KICKSTARTER
KICKSTARTER REMOVAL
10
11
3
9 T.R 9 Nm (0.9 m.kg)
LS
6
5
150 ~ 250 g
2
4
7
T.R 10 Nm (1.0 m.kg)
Kickstarter removal Remove the parts in the order below.

Seat cover
Side covers Refer to "COVERS" in chapter 3.
Footrest board
1 Kick crank 1
2 Crankcase cover (left) 1
3 Crankcase gasket 1
4 Dowel pin 2
5 Ratchet 1
6 Clip 1
7 Circlip 1
8 Plain washer 1 NOTE:
9 Spacer 1 To remove the kick shaft, unlook the return
10 Kick shaft 1 spring first.
11 Return spring 1
For installation reverse the removal procedure
4-12
KICKSTARTER
ENG
INSPECTION
1.Inspect:
•Kick gear teeth !
•Kick pinion gear teeth "
Burrs/Chips/Roughness/Wear → Replace.
317005
2.Inspect:
•Mating dogs (kick pinion gear and one-way
cluth)
Rounded edges/Damage → Replace.
317006
3.Measure:
•Clip tension (kick pinion gear)
Use a spring balance.
Standard tension:
150 ~ 250 g.
317007
4-13
PRIMARY AND SECONDARY SHEAVE
ENG
15
LS
14
13
50 Nm (5.0 m.kg)
12
T.R
11 10
19
T.R 40 Nm (4.0 m.kg)
LS
20 16
18
17 LS
8
4
7 3
6 2
1 T.R 33 Nm (3.3 m.kg)
5
Primary and secondary sheave Remove the parts in the order below.
removal
Seat cover
Side covers Refer to "COVERS" in chapter 3.
Footrest board
Crankcase cover (left)
Refer to "CDI MAGNETO" section.
Crankcase cover gasket, Dowel pin
Fan, Fan cover
1 Nut 1
2 Conical washer 1
3 One way cluth 1
4 Special washer 1
5 Primary fixed sheave 1
6 Spacer 1
7 V-belt 1
8 Primary sliding sheave assembly 1
4-14
ENG
15
LS
14
13
50 Nm (5.0 m.kg)
12
T.R
11 10
19
T.R 40 Nm (4.0 m.kg)
LS
20 16
18
17 LS
8
4
7 3
6 2
1 T.R 33 Nm (3.3 m.kg)
5
Remove the parts in the order below.

9 Nut 1
10 Cluth housing 1
11 Nut 1
12 Cluth 1
13 Cluth spring 1
14 Spring seat 1
15 Oil seal 1
16 O-ring 2
17 Secondary sliding sheave 1
18 Oil seal 1
19 Guide pin 1
20 Secondary fixed sheave 1

procedure
4-15
ENG
PRIMARY SHEAVE REMOVAL
1.Remove:
• Fan
2.Remove:
• Nut (primary sheave)
NOTE:
To loosen the primary sheave nut hold the CDI
magneto with a flywheel holder ".
Flywheel holder:
90890-01235
3.Remove:
% • Washer !
• One-way cluth "
• Special washer #
$ # • Fixed primary sheave $
" • Washer %
!
• V-belt
4.Remove:
" • Spacer !
• Primary sliding sheave "
PRIMARY SHEAVE INSPECTION

1.Inspect:
• Primary sliding sheave !
• Primary fixed sheave "
Wear/Crack/Scratch/Damage → Replace
2.Check:
! • Free movement
"
Insert collar " into the primary sliding sheave
!, and check for free movement.
Stick or excessive play → Replace the sheave
and/or collar.
!
3.Measure:
"
• Outside diameter (weight)
Ouside diameter (weight):

15.0 mm
<Limit:14.5 mm>
4-16
ENG
% PRIMARY SHEAVE INSTALLATION

1.Clean:
• Primary sliding sheave face !
• Primary fixed sheave face "
• Collar #
• Weight $
• Primary sliding sheave cam surface %
! " # $
319024
2.Install:
• Weight !
!# "
• Cam "
• Slider #
! • Collar $
#
3.Check:
$ • Cam operation
Unsmooth operation → Repair.
! #
4.Install:
• Primary sheave assembly !
! • Collar "
5.Install:
• V-belt
Place the V-belt around the secondary sheave,
and compress the secondary sheave spring hard
so that the V-belt moves toward the clutch hub.
" NOTE:
• The arrow on the V-belt must point to the front.
• Make sure the V-belt is not stained with oil or
grease.
$ % 6.Install:
• Shim !
! • Primary fixed sheave "
• Washer #
#
" $ • One-way clutch $
% & • Washer %
• Nut &
7.Tighten:
• Nut T.R 33 Nm (3.3 m•kg)
NOTE:
When tightening the nut (primary sheave), hold the
magneto rotor using the flywheel holding tool.
Flywheel holding tool:

90890-01235
4-17
ENG
8.Adjust:
• V-belt
Tense the V-belt by turning the primary sheave
several times
9.Install:
• Fan ! T.R 6.5 Nm (0.65 m•kg)
SECONDARY SHEAVE REMOVAL

1.Remove:
" • Nut ! (secondary sheave)
NOTE:
Hold the secondary sheave with a sheave holder
" to loosen the nut.
! Sheave holder:
90890-01701
2.Remove:
• Clutch housing !
• Secondary sheave "
• Crankcase cover gasket
• Dowel pins
3.Attach:
"
• Sheave holder !
! • Nut wrench (41 mm)
Sheave holder:
90890-01701
" Nut wrench:
90890-01348
!
4.Loosen:
• Clutch securing nut
WARNING
Loosen the nut do not remove it yet.
! 5.Attach:
• Clutch spring holder !
NOTE:
Compresse the secondary sheave using the
clutch spring holder ! .
Clutch spring holder:

90890-01337
4-18
ENG
6.Remove:
$ & • Clutch securing nut.
%
7.Remove:
! • Clutch assembly !
• Clutch spring "
• Spring seat #
#
" • Guide pin $
• Secondary sliding sheave %
• Secondary fixed sheave &
SECONDARY SHEAVE INSPECTION
# " ! 1.Inspect:
• Secondary fixed sheave !
• Secondary sliding sheave "
Scratch/Crack/Damage → Replace as a set.
• Oil seal #
Damage → Replace.
2.Inspect:
•Torque cam groove !
# • Guide pin "
Wear/Damage → Replace as a set.
• O-rings #
Damage → Replace.
3.Measure:
" ! • Clutch spring free length
Clutch spring free length:

29.9 mm
4. Inspect:
• Clutch housing inner surface
Oil/Scratches → Remove.
Oil Use a rag soaked in lacquer

thinner or solvent.
Scratches Use an emerycloth (lightly and
evenly polishing).
5.Measure:
• Clutch housing inside diameter @
Clutch housing inside diameter:

105.0 mm
<Wear limit: 105.4 mm>
4-19
ENG
6.Inspect:
• Clutch shoes
Glazed parts → Sand with coarse sandpaper.
NOTE:
After using the sand paper, clean off the polished
particles with a cloth.
7. Measure:
• Cluth shoe thickness @
Clutch shoe thickness:

2.0 mm
<Wear limit : 1mm>
SECONDARY SHEAVE INSTALLATION

When assembling the secondary sheave, re-
verse the disassembly procedure. Note the
following points.
1.Apply:
• BEL-RAY Assembly lube ®
(to the sliding parts of the sheave)
2.Install:
• Sliding sheave !.
NOTE:
Wind adhesive tape around the end of the sheave
to avoid turning over the oil seal lips when
installing the sheave.
!
3.Install:
• Pin !
4.Apply:
• BEL-RAY Assembly lube ®
! (to the torque cam grooves and O-rings)
5.Check:
• Sliding sheave
Unsmooth operation → Repair
CAUTION:
Remove excessive grease.
4-20
ENG
! 6.Install:
Use the clutch spring holder !
Clutch spring holder:

90890-01337
7.Tighten:
"
T.R 50 Nm (5.0 m•kg)
!
Use sheave holder ! and the Locknut wrench "
Sheave holder:
90980-01701
Locknut wrench:
90980-01348
8.Install:
• Dowel pin
! • Gasket
• Secondary sheave assembly !
• Clutch housing "
"
9.Tighten:
• Nut ! (secondary sheave)
"
Use sheave holder "
Sheave holder:
90890-01701
4-21
STARTER SYSTEM
ENG
STARTER SYSTEM
10
11 M
T.R 13 Nm (1.3 m.kg) M 7 6
5
4 8
G T.R 8 Nm (0.8 m.kg)
2
1
LS
Starter system removal Remove the parts in the order below.

Primary and secondary sheave Refer to "PRIMARY AND SECONDARY
SHEAVE" section.
1 Starter motor 1
2 O-ring 1
3 Plate 1
4 Shaft 1
5 Washer 1
6 Idle gear 1
7 Washer 1
8 Starter clutch 1
9 Bearing 1
10 Starter wheel gear 1
11 Collar 1
4-22
STARTER SYSTEM
ENG
STARTER SYSTEM INSPECTION
1.Inspect:
• Starter cluth
Push the dowel pin in arrow direction.
Unsmooth operation → Replace starter cluth
assembly.
2.Inspect:
! • Starter wheel gear teeth !
• Idle gear teeth "
# Burrs/Chips/Roughness/Wear → Replace.
" • Bearing # (Starter wheel gear)
Pitting/Damage → Replace.
STARTER SYSTEM INSTALLATION

1.Install:
•Collar !
! # •Bearing "
$
" •Starter wheel gear #
•Starter cluth $
NOTE:
• Apply lithium soap base grease to the bearing
".
M
• Apply molybdenum bisulfide oil to the shaft $
M M (starter cluth).
2.Install:
•Plain washer !
•Idle gear "
! G
•Plain washer #
•Plate $ (idle gear)
"
# T.R 8 Nm (0.8 m•kg)
$ NOTE:
317012
Apply engine oil to the idle gear "
3.Install:
! •Starter motor !
Starter motor Screw:

LS T.
R 8 Nm (0.8 m.kg)
NOTE:
Apply lithium soap base grease to O-ring of the
starter motor.
317013
4-23
TRANSMISSION
ENG
TRANSMISSION
TRANSMISSION
LS
7
6
G G
LT
3
2
4 1
3 LS
T.R 10 Nm (1.0 m.kg)
Transmission removal Remove the parts in the order below.

Rear wheel Refer to "REAR WHEEL AND REAR
BRAKE" in chapter 6.
Secondary sheave, V-belt Refer to "PRIMARY AND SECONDARY
SHEAVE" section.
Drain the transmission oil Refer to "TRANSMISSION OIL REPLACE-
MENT" in chapter 3.
1 Transmission case 1
2 Gasket 1
3 Dowel pin 2 Refer to "TRANSMISSION INSTALLA-
4 Secondary sheave axle 1 TION" section.
5 Drive shaft 1
6 Main shaft 1
7 Oil seal 1
4-24
TRANSMISSION ENG
TRANSMISSION INSPECTION
1.Inspect:
• Drive axle !
• Main axle "
• Secondary sheave axle #
Burrs/Chips/Roughness/Wear → Replace
! " #
! 2. Inspect:
• Secondary sheave axle bearing !
• Main axle bearing "
• Drive axle bearing #
Spin the bearing inner race.
# Excessive play/Roughness → Replace.
Pitting/Damage → Replace
"
TRANSMISSION INSTALLATION
1.Apply:
• 10W30 Type SE Motor oil
(to transmission case cover bearing)
2.Install:
• Bearing !
3.Install:
" • Oil seal "
#
• Secondary sheave axle #
!
NOTE:
Apply lithium soap base grease onto the oil seal
lips.
4-25
TRANSMISSION
ENG
4.Check:
• Secondary sheave axle operation
5. Apply:
• 10W30 Type SE Motor oil
(to main axle bearing and drive axle bearing)
6.Install:
• Main axle !
" • Drive axle "
• Conical spring washer #
• Plain washer $
! NOTE:
#
$ • Apply lithium soap base grease onto the oil
seal lips.
• Always use a new gasket.
" 7.Install:
• Gasket !
• Dowel pins "
• Transmission case cover #
"
!
#
4-26
CDI MAGNETO
ENG
CDI MAGNETO
CDI MAGNETO, ROTOR, STATOR
T.R 37 Nm (3.7 m.kg)
3
4
6.5 Nm (0.65 m.kg)
LS
T.R
9
7
8
1
2 T.R 8.5 Nm (0.85 m.kg)
CDI magneto, Rotor, Startor removal Remove the parts in the order below
Seat cover
Side covers Refer to "COVERS" in Chapter 3.
Footrest board
1 Fan cover 1
2 Fan 1
3 Nut 1
4 Washer 1
5 Magneto rotor 1 Refer to "CDI MAGNETO REMOVAL"
6 Woodruff key 1 section.
7 Stator assembly 1
8 Gasket 1
9 Oil seal 1
4-27
CDI MAGNETO
ENG
REMOVAL
NOTE:
" It is not necessary to remove the engine for
removing the CDI magneto
!
1.Remove:
• Nut ! (rotor)
• Plate washer
NOTE:
Hold the rotor using ! flywheel holder " to
loosen the nut
Flywheel holder:
90890-01235
2.Remove:
• Rotor
• Woodruff key
Use the flywheel puller.
Flywheel puller:
90890-01189
• Stator assembly
• Gasket
INSTALLATION
1.Install:
• Gasket
2.Apply
!
(to oil seal !)
LS
3.Pass the CDI magneto lead through the

crankcase
4-28
CDI MAGNETO
ENG
4.Install:
" • Stator assembly
$
5. Install:
! • Woodruff key !
# • Magneto rotor "
• Plain washer #
• Nut $
NOTE:
When installing the magneto rotor, make sure
the woodruff key is properly seated in the key
way of the crankshaft. Apply a light coating of
lithium soap base grease to the tapered portion
of crankshaft end.
6.Tighten:
• Nut ! (magneto rotor)
Use the flywheel holding tool ".
Flywheel holding tool:

90890-01235
4-29
AUTOLUBE PUMP
ENG
AUTOLUBE PUMP
2 5
4
LS
T.R 4 Nm (0.4 m.kg)
Autolube pump removal Remove the parts in the order below.
Side covers
Refer to "COVERS" in Chapter 3.
Footrest board
CDI magneto Refer to "CDI MAGNETO" section.
1 Autolube oil pump 1

2 Circlip 1 Refer to "AUTOLUBE OIL PUMP
3 Pump drive gear 1 REMOVAL" and "AUTOLUBE OIL PUMP
4 Pin 1 INSTALLATION" sections.
5 Circlip 1
For installation reverse the removal procedure
4-30
AUTOLUBE PUMP
ENG
AUTOLUBE PUMP REMOVAL
1.Remove:
• Autolube oil pump
2.Remove:
• Circlips !
• Pump drive gear "
! • Pin #
• Circlip $
AUTOLUBE PUMP INSPECTION
Wear or an internal malfunction may cause the
" $ pump output to vary from the factory setting. This
#
situation is, however, extremely rare. If improper
output is suspected, inspect the following:
1.Inspect:
• Delivery line
Obstructions → Blow out.
• O-ring
Wear/Damage → Replace
2.Inspect:
! • Autolube pump drive gear teeth !
" • Autolube pump driven gear teeth "
Pitting/Wear/Damage → Replace
AUTOLUBE PUMP INSTALLATION

1.Iinstall:
• Circlip !
• Pin "
• Pump drive gear $
• Circlip %
!"
# $ 2.Apply:
(to O-ring)
3. Install:
! • Autolube pump
4. Apply:
" • Lithium soap base grease
(to autolube pump gear !, " )
4-31
CRANKCASE AND CRANKSHAFT
ENG
T.R 10 Nm (1.0 m.kg)
T.R 10 Nm (1.0 m.kg)
3
1 2
LS
7
6 5
E
T.R 17 Nm (1.7 m.kg)

E
LS
Crankcase and crankshaft removal Remove the parts in the order below.
Engine removal Refer to "ENGINE REMOVAL" section.
Cylinder head Refer to "CYLINDER HEAD" section.
Cylinder and piston Refer to "CYLINDER AND PISTON" section
Primary and secondary sheave Refer to "PRIMARY AND SECONDARY
SHEAVE" section.
Starter system Refer to "STARTER SYSTEM" section.
Transmission Refer to "TRANSMISSION" section.
CDI magneto Refer to "CDI MAGNETO" section.
Autolube oil pump Refer to "AUTOLUBE OIL PUMP" section.
Rear wheel Refer to "REAR WHEEL AND REAR
BRAKE" in Chapter 6.
Carburetor Refer to "CARBURETOR" in Chapter 5.
Reed valve assy. Refer to "REED VALVE" in Chapter 5.
4-32
ENG
T.R 10 Nm (1.0 m.kg)
T.R 10 Nm (1.0 m.kg)
3
1 2
LS
7
6 5
E
T.R 17 Nm (1.7 m.kg)

E
LS
1 Crankcase right 1
2 Dowel pin 2 Refer to "CRANKCASE AND
3 Oil seal 1 CRANKSHAFT REMOVAL AND INS-
4 Spacer 1 TALLATION" section.
5 Crankcase left 1
6 Oil seal 1
7 Crankshaft assembly

procedure
4-33
ENG
! CRANKCASE AND CRANKSHAFT REMOVAL
1.Remove:
• Oil seal stopper !
• Screws (crankcase)
NOTE:
Loosen each screw one quart of a turn before
10 Nm (1,0 m.kg)
T.R
beginning to remove them.
2. Attach:
• Crankcase separating tool !
Crankcase separating tool:

90890-01135
!
"
NOTE:
Fully tighten the tool holding bolts. Insure that
the tool body is parallel with the case. If necessary,
loosen one screw as much as required to level
the tool body.
3.Remove:
• Crankcase (right) "
As pressure is applied, keep tapping carefully
on the engine mounting bosses.
CAUTION:
Use a soft hammer to tap on the case. Tap
only on reinforced spots of the case. Never
tap on the gasket mating surfaces. Work
slowly and carefully. Make sure the cases
separate evenly. If one end "hand-up" take
the pressure off the push screw, realign the
cases and the tool and start again. If the
cases do not separate at all, check for a
remaining case screw or fitting. Do not force.
4. Attach:
• Crankcase separating tool !
Crankcase separating tool:

90890-01135
"
5. Remove:
• Crankshaft "
!
4-34
CRANKCASE AND CRANKSHAFT ENG
CRANKSHAFT INSPECTION
1.Measure:
• Crankshaft width "A"
• Runout limit "C"
• Connecting rod big end side clearance "D"
Use V-blocks, dial gauge and thickness gauge.
Crankshaft width "A":

37.90 ~ 37.95 mm
Runout limit "C":
0.03 mm
Connecting rod big end side
clearance "D":
0.2 ~ 0.5 mm
CRANKSHAFT AND CRANKCASE

INSTALLATION
CAUTION:
To protect the crankshaft against scratches
and to facilitate the engine assembly and
installation,apply grease to oil seal lips, and
engine oil to bearings.
1.Attach:
! #$ • Crankshaft installation tool !, ", #, $
Crankshaft installation tool:

! : 90890-01274
" : 90890-01275
" # : 90890-01277
$ : 90890-01411
2.Install:
• Crankshaft
(to left crankcase)
NOTE:
Hold the connecting rod at top dead center with
one hand while tightening the nut of the
installation tool with the other. Tighten the
installation tool until the crankshaft bottoms
against the bearing.
3.Install:
" • Dowel pins !
• Spacer "
4.Apply:
• HEATPROOF or Yamaha Bond N°.1215
To the mating surfaces of both case halves.
!
HEATPROOF or Yamaha Bond
N°.1215
4-35
ENG
5.Attach:
• Crankshaft installation tool !, ", #, $.
! Crankshaft installation tool:
! : 90890-01274
" : 90890-01275
# : 90890-01277
$ : 90890-01411
$ # "
NOTE:
Hold the connecting rod at top dead center with
one hand while tightening the nut of the
installation tool with the other. Tighten the
installation tool until the crankcase halves close
with one another.
6.Install:
• Right crankcase
7.Tighten:
• Crankcase holding screws.
T.R13 Nm (1.3 m•kg)
NOTE:
Tighten the crankcase holding screws in stages,
using a crisscross pattern.
8.Check:
• Crankshaft operation
CAUTION:
Never hit on the crankshaft.
9. Install:
• Oil seal stopper plate !
4-36
CARB 5
CARB
CHAPTER 5.
CARBURETOR
AUTO-CHOKE SYSTEM ............................................................................... 5-1

CONSTITUENTS ..................................................................................... 5-1
OPERATION ............................................................................................ 5-2
CARBURETOR .............................................................................................. 5-3

REMOVAL ................................................................................................ 5-3
DISASSEMBLY ........................................................................................ 5-4
INSPECTION ........................................................................................... 5-6
ASSEMBLY .............................................................................................. 5-8
AUTO CHOKE UNIT CHECK .................................................................. 5-8
FUEL COCK .................................................................................................. 5-9

INSPECTION ........................................................................................... 5-9
REED VALVE .............................................................................................. 5-10

REMOVAL .............................................................................................. 5-10
INSPECTION ......................................................................................... 5-11
INSTALLATION ...................................................................................... 5-11
AUTO CHOKE SYSTEM
CARB
! CARBURETION
AUTO CHOKE SYSTEM
CONSTITUENTS
" The electric auto-choke consists of a positive
# Temperature Coefficient (P.T.C.) thermistor, a
wax element and a starter plunger.
$ ! P.T.C. thermistor
" Wax element
# O-ring
$ Starter plunger
P.T.C. THERMISTOR
When electric current flows in this thermistor, it
heats up to a specified temperature, which it then
retains.
WAX ELEMENT
The volume of this wax element changes with
the temperature of the thermistor, thereby
operating the starter plunger.
STARTER PLUNGER
The starter plunger opens or closes the starter
passage according to the volume of the wax
element.
WIRING SCHEMATIC
! " Power source is provided by the C.D.I. magneto
lighting coil.
! C.D.I. magneto
# " Rectifier/Regulator
# Auto choke
5-1
AUTO CHOKE SYSTEM CARB
OPERATION
COLD ENGINE
When the engine is cold and the ambient
temperature low, the volume of the wax element
is reduced.
The starter plunger is then in its upper position,
thereby opening the starter plunger.
! : Air
" : Fuel
RUNNING ENGINE
When the engine is started, the P.T.C. thermistor
heats and expands the wax element, gradually
pushing the opening of the starter passage.
When the thermistor reaches its maximum
temperature, the wax element is at its maximum
volume, thereby fully closing the starter passage.
This will progressively reduce the engine r.p.m.
to the specified idle speed.
During the ride, the P.T.C. Thermistor keeps the
wax element expanded and the starter passage
fully closed.
! : Air
" : Fuel
RESTARTING AFTER ENGINE WARM-UP

1.Restarting after riding:
The wax element is fully expanded, so that the
starter plunger closes completely the starter
passage
2.Restarting after stopping the engine for some
time:
The volume of the wax element begins to
reduce depending on the ambient temperature,
thereby allowing the starter plunger to open
the passage to meet the engine fuel
requirement.
5-2
CARBURETOR CARB
CARBURETOR
CARBURETOR
2
7
4
5
Carburetor removal Remove the parts in the order below.

Seat cover
Sides covers Refer to "COVERS" in Chapter 3.
Footrest board
1 Fuel hose 1
2 Vacuum hose 1
3 Oil delivery hose 1
4 Auto choke unit lead coupler 1
5 Air filter joint 1
6 Throttle cable 1 Unhook
7 Carburetor 1
For installation, reverse the removal

procedure.
5-3
CARBURETOR CARB
CARBURETOR DISASSEMBLY
/ !
"
#
%
$
.
- &
'
, (
)
+
*
Carburetor disassembly Remove the parts in the order below.
1 Carburetor top 1
2 O-ring 1
3 Throttle valve spring 1
4 Needle set 1
5 Throttle valve 1
6 Throttle stop screw 1
7 Pilot air screw 1
8 Spring 2
9 Float chamber 1
0 Gasket 1
5-4
CARBURETOR CARB
/ !
"
#
%
$
.
- &
'
, (
)
+
*
{ Float pin stop screw 1

} Float pin 1
q Float 1
w Needle valve 1
e Main jet 1
r Main nozzle 1
t Auto choke 1

procedure.
5-5
CARBURETOR
CARB
YP600040
CARBURETOR INSPECTION
1.Inspect:
• Carburetor body !.
• Float chamber.
Contamination → Clean.
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with compressed
air.
2.Inspect:
• Float !
Damage → Replace.
• Gasket
Damage → Replace.
• Needle valve "
Wear/Contamination → Replace.
! 3.Inpect:
• Throttle valve !
Wear/Damage → Replace.
322014
4.Check:
• Free movement
Unsmooth → Replace.
! Insert the throttle valve ! into the carburetor
body ", and check for smooth movement.
"
322019(a)
5.Inspect:
• Main jet
• Main nozzle
5-6
CARB
CARBURETOR
6.Inspect:
" •Throttle stop screw !
! Wear/Damage → Replace.
•Pilot air screw "
#
•Jet needle #
Bends/Wear → Replace.
322016(a)
7.Inspect:
•Starter plunger
8.Measure:
•Float height !
Out of specification → Inspect needle valve,
float and valve seat.
!
Float height ! :
15.0 ~ 17.0 mm
322017 ***************************************************************
Float height measurement steps:
• Install the needle valve, float and float pin to
the carburetor body.
• Hold the carburetor in an upside down position.
• Measure the distance between the mating
surface of the float chamber (gasket removed)
and the top of the float, using a gauge.
NOTE:
The float arm should be resting on the needle
valve, but not compressing the needle valve.
• If the float height is not within specification,

inspect the needle valve, float and valve seat.
• If one of these parts is worn, replace it.

************************************************************
NOTE:
The float height is factory-adjusted. Never attempt
to adjust it.
5-7
CARBURETOR/
CARB
AUTO CHOKE UNIT CHECK
YP600042
ASSEMBLY
Reverse the disassembly procedures.
Note the following points:
CAUTION:
• Before reassembling, wash all parts in
clean gasoline.
• Always use new gaskets.
1.Install:
$ • Throttle valve !
# • Jet needle "
" • Clip #
• Spring seat $
!
Jet needle clip position:
2/3 (B)(E)(F)(GB)(I)(P)
1/3 (D)(NL)
322029(a)
2.Install:
• Throttle valve !
! NOTE:
Align the groove " of the throttle valve with the
"
# projection # of the carburetor body.
322019
3.Install:
! • Carburetor assembly.
NOTE:
Align the projection ! with the projections ".
" 322020
AUTO CHOKE UNIT CHECK

1.Remove:
• Auto choke unit
2.Measure:
• Starter plunger height
Plunger height will not change with the
temperature increase → Replace
5-8
FUEL COCK
CARB
FUEL COCK INSPECTION
1.Stop the engine.
2.Remove:
• Side covers
•Footrest board
3.Inspect:
•Fuel cock
*******************************************************
Fuel cock inspection steps:
• Disconnect the fuel hose.
• Place the receptacle under the fuel hose end.
• If fuel stops flowing out in a few seconds, the
fuel cock is in good condition.
If not, clean or replace the fuel cock.
• Disconnect the vaccum hose and breathe in
through the vaccum hose, for vaccum.
• If fuel flows out of the fuel hose under vaccum
and stops under non-vaccum, the fuel cock is
in good condition.
If not, clean or replace the vaccum hose, fuel
hose and fuel cock.
*******************************************************
5-9
REED VALVE CARB
REED VALVE REMOVAL
T.R 11 Nm (1.1 m.kg)
Reed valve removal Remove the parts in the order below.

Caburetor Refer to "CARBURETOR" section.
Oil tank Refer to "BOX AND FUEL TANK" section.
1 Carburetor joint 1
2 Reed valve assembly 1

procedure.
5-10
REED VALVE CARB
YP600051
REED VALVE INSPECTION
1.Inspect:
• Caburetor joint
Damage/Cracks → Replace.
• Reed valve
Fatigue/Cracks → Replace.
*****************************************************
Inspection steps:
• Visually inspect the reed valve.
NOTE:
Correct reed valve should fit flush or nearly flush
against valve seat.
• If in doubt as to sealing ability, apply suction to

carburetor side of assembly.
• Leakage should be slight to moderate.
*****************************************************
2.Measure:
! • Valve stopper height !
Out of specification → Replace valve stopper.
Valve stopper height !:

6.0 ~ 6.4 mm
322023
3.Measure:
• Reed valve clearance !
! Out of specification → Replace reed valve.
Reed valve clearance a:

Less than 0.2 mm
322024
INSTALLATION
Reserve the removal procedure.
Note the following points.
1. Install:
• Gasket
2.Tighten:
• Reed valve securing bolts
11Nm (1.1 m•kg)
T.R
NOTE:
Tighten the bolts gradually to avoid warping.
5-11
CHAS 6
CHAS
CHAPTER 6.
CHASSIS
FRONT WHEEL AND BRAKE DISC ............................................................. 6-1

REMOVAL ................................................................................................ 6-2
FRONT WHEEL INSPECTION ................................................................ 6-2
BRAKE DISC INSPECTION .................................................................... 6-4
ASSEMBLY .............................................................................................. 6-4
INSTALLATION ........................................................................................ 6-5
REAR WHEEL AND REAR BRAKE ............................................................. 6-6

REAR WHEEL INSPECTION .................................................................. 6-7
REAR BRAKE INSPECTION ................................................................... 6-7
REAR BRAKE INSTALLATION ............................................................... 6-8
REAR WHEEL INSTALLATION ............................................................... 6-9
FRONT BRAKE ........................................................................................... 6-10

FRONT BRAKE PADS ........................................................................... 6-10
BRAKE PADS REPLACEMENT ............................................................ 6-12
MASTER CYLINDER ............................................................................. 6-13
MASTER CYLINDER DISASSEMBLY ................................................... 6-14
MASTER CYLINDER INSPECTION ...................................................... 6-15
MASTER CYLINDER ASSEMBLY ......................................................... 6-15
MASTER CYLINDER INSTALLATION .................................................. 6-16
FRONT BRAKE CALIPER ..................................................................... 6-18
CALIPER DISASSEMBLY ..................................................................... 6-20
CALIPER INSPECTION ......................................................................... 6-20
CALIPER ASSEMBLY ........................................................................... 6-21
CALIPER INSTALLATION ..................................................................... 6-21
HANDLEBAR .............................................................................................. 6-23

REMOVAL .............................................................................................. 6-24
INSPECTION ......................................................................................... 6-24
INSTALLATION ...................................................................................... 6-24
STEERING HEAD ........................................................................................ 6-26

REMOVAL .............................................................................................. 6-27
INSPECTION ......................................................................................... 6-27
INSTALLATION ...................................................................................... 6-28
FRONT FORK .............................................................................................. 6-29

FRONT FORK DISASSEMBLY ............................................................. 6-30
REMOVAL .............................................................................................. 6-31
INSPECTION ......................................................................................... 6-31
ASSEMBLY ............................................................................................ 6-31
FRONT WHEEL AND BRAKE DISC
CHAS
CHASSIS
T.R 45 Nm (4.5 m.kg)
5 2
4 LS
LT
LS 8 LT
6
T.R 23 Nm (2.3 m.kg)
LT
7 LS
6
3
LT T.R 23 Nm (2.3 m.kg)

Front wheel and brake disc removal Remove the parts in the order below.
WARNING
Securely support the scooter so there is
no danger of it falling over.
1 Speedometer cable 1 Disconnect

2 Brake caliper 1
3 Nut (Nylstop) 1
4 Front wheel axle 1
5 Speedometer gear 1
6 Spacer 1
7 Wheel 1
8 Brake disc 1
dure.
6-1
CHAS
REMOVAL
1.Disconnect:
• Speedometer cable
2.Remove:
• Brake caliper
3.Loosen:
• Axle nut
4.Remove:
• Front wheel axle
• Speedometer gear
• Spacer
• Front wheel
• Brake disc
NOTE:
Never depress the brake lever when the wheel
is off the scooter. Otherwise the brake pads will
be forced out.
CAUTION:
Handle the wheel with care not to damage the
brake disc. If the brake disc is damaged,
replace.
FRONT WHEEL INSPECTION
1.Inspect:
• Front wheel axle runout
(Roll it on a flat surface.)
Bends → Replace.
WARNING
Never attempt to straighten a bent axle.
2.Inspect:
• Tire
Wear/Cracks/Warpage → Replace.
Refer to Chapter 3 "TIRE INSPECTION".
• Front wheel
Refer to Chapter 3 "TIRE INSPECTION".
6-2
CHAS
" 3.Measure:
! • Front wheel runout
Over the specified limits → Replace.
Rim runout limit:

Radial ! : 1.0 mm
Lateral " : 1.0 mm
4.Inspect:
• Wheel bearings
Bearings allow free play in the wheel hub or
wheel turns roughly → Replace.
• Oil seals
******************************************************
Wheel bearing replacement steps:
• Clean the outside of the wheel hub.
• Remove the oil seals using a flat-head screw
driver.
NOTE:
Place a rag on the outer edge to prevent damage.
• Remove the bearing using a general bearing

puller.
• Install the new bearing and oil seal by reversing
the previous steps.
@ NOTE:
Use a socket that matches the outside diameter
@ of the race of the bearing.
CAUTION:
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
******************************************************
5.Inspect:
• Collar
Wear/Damage → Replace collar and oil seal
as set.
6-3
FRONT WHEEL AND BRAKE DISC CHAS
BRAKE DISC INSPECTION
1.Measure:
• Brake disc deflection
Out of specification → Inspect wheel runout.
If wheel runout is in good condition, replace
the brake disc.
NOTE:
Remove the brake caliper before inspecting the
347001
brake disc deflection.
Maximum deflection:
0.1 mm
2.Measure:
• Brake disc thickness
Minimum thickness:
347002 3.5 mm
Measuring point 1 ~ 3 mm.
*****************************************************
Replacement steps:
• Remove the brake disc.
• Install the new brake disc.
Brake disc:
23 Nm (2.3 m.kg)
NOTE:
Tighten the bolts (brake disc) in stage using a
crisscross pattern.
*****************************************************
ASSEMBLY
Reverse the "DISASSEMBLY" procedure.
1.Lubricate:
• Bearings
• Oil seals (lips)
Recommanded lubricant:
Lithium soap base grease
6-4
CHAS
INSTALLATION
Reverse the "REMOVAL" procedure.
1.Lubricate:
• Front wheel axle
• Drive/Driven gear (speedometer)
Recommanded lubricant:
Lithium soap base grease
2.Install:
• Speedometer gear unit !
!
NOTE:
Be sure that two projections inside the wheel
hub mesh with the two slots in the gear unit
assembly.
340004
3.Install:
• Front wheel
• Front wheel axle T.R 45 Nm (4.5 m•kg)
NOTE:
Be sure that the projection (torque stopper) of
the gear unit housing is positioned correctly.
WARNING
Be sure to assemble the front wheel as shown.
Difference between A and B < 3 mm

A B
4.Install:
• Brake caliper T.R 23 Nm (2.3 m•kg)
6-5
REAR WHEEL AND REAR BRAKE
CHAS
1 T.R 103.5 Nm (10.35 m.kg)
11
T.R 9.75 Nm (0.98 m.kg)
LS
10
5
8
9
7
T.R 12 Nm (1.2 m.kg)

Rear wheel and rear brake removal Remove the parts in the order below.
1 Rear axle nut (Nylstop) 1 NOTE:
Pull the rear brake to loosen the axle nut.
2 Rear wheel 1
3 Brake shoe 1
4 Tension spring 1
5 Adjuster 1
6 Brake cable 1
7 Compression spring 1
8 Pin 1
9 Camshaft lever 1
10 Wear indicator 1
11 Brake camshaft 1
dure.
6-6
CHAS
REAR WHEEL INSPECTION
1.Inspect:
• Rear wheel axle
Refer to "FRONT WHEEL AND BRAKE DISC".
2.Inspect:
• Tire
Wear/Cracks/Warpage → Replace.
Refer to "TIRE INSPECTION" in Chapter 3.
• Rear wheel
Refer to "TIRE INSPECTION" in Chapter 3.
" 3.Measure:
! • Rear wheel runout
Refer to "FRONT WHEEL AND BRAKE DISC"
section.
Rim runout limit:

Radial !: 1 mm
Lateral ": 1 mm
4.Check:
• Wheel bearings
Refer to "FRONTWHEEL AND BRAKE DISC"
section.
REAR BRAKE INSPECTION

1.Check:
• Brake lining surface
Glazed areas → Polish.
Use coarse sand paper.
NOTE:
After polishing the brake lining, remove dust
particles from the brake shoe with a clean cloth.
2.Measure:
• Brake lining thickness
Brake lining thickness @:

4.0 mm
Wear limit:
2.0 mm
NOTE:
Replace the brake shoe as a set if either is worn
@
to the limit.
346007
6-7
CHAS
3.Inspect:
• Brake drum inner surface
Oil/Scratches → Repair.
Oil Use a rag soaked in lacquer

thinner or solvent.
Scratches Use an emery cloth lightly and
evenly polishing
4.Measure:
• Brake drum inside diameter @
Out of specification → Replace the wheel.
Brake drum inside diameter:

a Wear limit:
110.5 mm
5.Inspect:
• Camshaft face
346008 Wear → Replace.
WARNING
When inspecting the brake lining, do not spill
oil or grease on the brake lining.
REAR BRAKE INSTALLATION

Reverse the removal procedure.
1.Install:
• Brake camshaft !
NOTE:
Apply lithium soap base grease onto the brake
" camshaft ! and pin ".
LS
CAUTION:
After installing the brake camshaft, remove
! the excess of grease.
346009
2.Install:
• Tension springs "
• Brake shoes !
!
NOTE:
The arrow mark # must point outwards.
"
CAUTION:
When installing the springs and the brake
# shoes, take care not to damage the springs.
346010
6-8
REAR WHEEL AND REAR BRAKE CHAS
3.Install:
• Wear indicator !
! • Camshaft lever "
******************************************************
Installation steps:
A • Align the projection ! on the wear indicator
with the camshaft notch " A" and install.
# " • Align the punch marks ".
346011 • Check the proper position # of the brake shoe.
*****************************************************
4.Install:
• Plain washer !
• Pin
• Compression spring
• Brake cable
• Adjuster
!
346012
REAR WHEEL INSTALLATION
! 1.Clean:
" • Rear wheel axle
2.Install:
• Rear wheel
• Plain washer !
346013
• Axle nut " T.R 103.5 Nm (10.4 m•kg)
NOTE:
Make sure the splines on the wheel hub fit onto
the rear drive axle.
3.Install:
• Muffler
Bolt (exhaust pipe):

7 Nm (0.7 m • kg)
T.
R
Bolt (muffler):
26 Nm (2.6 m • kg)
4.Adjust:
• Rear brake lever free play
Refer to "REAR BRAKE LEVER FREE PLAY
ADJUSTMENT" in Chapter 3.
6-9
FRONT BRAKE CHAS
FRONT BRAKE
FRONT BRAKE PADS
T.R 6 Nm (0.6 m.kg) 6

4
T.R 23 Nm (2.3 m.kg)

Front brake pads removal Remove the parts in the order below.
1 Plastic cap 1
2 Retaining clip 1
3 Retaining pin 1 Refer to "BRAKE PAD REPLACE-
4 Pad spring 1 MENT" section.
5 Brake pad 2
6 Bleed screw 1

dure.
6-10
FRONT BRAKE
CHAS
CAUTION:
Disc brake components rarely require
disassembly. DO NOT:
• Disassemble components unless
absolutely necessary.
• Use solvents on internal brake components.
• Use contaminated brake fluid for cleaning.
Use only clean brake fluid.
• Allow brake fluid to come in contact with
the eyes, otherwise eye injury may occur.
• Allow brake fluid to contact painted surfaces
or plastic parts otherwise damage may
occur.
• Disconnect any hydraulic connection
otherwise the entire system must be
disassembled, drained, cleaned, and then
properly filled and bled after reassembly.
Recommanded brake component replacement

schedule:
Brake pads As required

Piston seal,
Every two years
Dust seal
Brake hose Every four years
Replace only when

Brake fluid
brakes are disassembled
WARNING
All internal parts should be cleaned in new
brake fluid only. Do not use solvents as they
will cause seals to swell and distort.
6-11
FRONT BRAKE CHAS
BRAKE PAD REPLACEMENT
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1.Remove:
• Brake pads
NOTE:
• Do not depress the brake lever when the
wheel is off the scooter otherwise the brake
pads will be forced shut.
• Install new brake pad springs when the brake
pads have to be replaced.
• Replace the pads as a set if either is found to
be worn to the wear limit @.
Wear limit @:
0.5 mm
2.Push the caliper piston into the brake caliper

by finger.
@
CAUTION:
When pushing the caliper piston into the
brake caliper, brake fluid level in reservoir
tank is increasing higher.
3.Install:
• Brake pads
• Pad spring
4.Inspect:
• Brake fluid level
Refer to "BRAKE FLUID LEVEL INSPECTION"
section in Chapter 3.
5.Check:
• Brake level inspection
Soft spongy feeling - Bleed the brake system.
Refer to "AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)" section in Chapter 3.
6-12
FRONT BRAKE CHAS
MASTER CYLINDER
3 4 T.R 8.5 Nm (0.85 m.kg)

7
2
8
T.R 7 Nm (0.7 m.kg)
1 5 T.R 23 Nm (2.3 m.kg)
5 T.R 23 Nm (2.3 m.kg)

Master cylinder removal Remove the parts in the order below.
Drain the brake fluid
1 Brake switch 1
2 Brake lever 1
3 Circlip 1
4 Actuator 1
5 Union bolt 1
6 Copper washer/Brake hose 2/1
7 Master cylinder bracket 1
8 Master cylinder 1

dure.
6-13
FRONT BRAKE CHAS
MASTER CYLINDER DISASSEMBLY
T.R 3 Nm (0.3 m.kg)
!
#
$
"
&
'

Master cylinder disassembly Remove the parts in the order below.
NOTE:
Drain completely before removing the
master cylinder.
Q Master cylinder cap 1

W Diaphragm 1
E Dust boot 1
R Actuator 1
T Piston/Lip seal 1/1
Y Piston return spring 1
U Plain washer 1

dure.
6-14
FRONT BRAKE CHAS
MASTER CYLINDER INSPECTION
1.Inspect:
• Master cylinder
Scratches/Wear/Damage → Replace the
master cylinder assembly.
• Diaphragm
347006
2.Inspect:
• Piston !
Scratches/Wear/Damage → Replace the
master cylinder assembly.
!
MASTER CYLINDER ASSEMBLY

WARNING
• All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
Recommanded brake fluid:

DOT #3 or DOT #4
• Replace the piston seals and dust seals

whenever a master cylinder is disassem-
bled.
1.Install:
' • Plain washer
• Piston return spring !
2.Install:
• Piston seal "
• Seal #
On the piston.
3.Install:
& • Piston $
In the master cylinder.
• Actuator %
# • Dust boot &
% " • Diaphragm '
!
$
6-15
FRONT BRAKE CHAS
MASTER CYLINDER INSTALLATION
"
1.Install:
! • Master cylinder !
• Master cylinder bracket "
# 8.5 Nm (0.85 m•kg)
T.R
CAUTION:
• Install the master cylinder holder with the
arrow mark pointing upwards.
'
• Tighten the upper bolt first, then the lower
bolt.
$
& Bolt (master cylinder holder):
T.
R 8.5 Nm (0.85 m • kg)
2.Install:
• Copper washer #
% • Brake hose $
• Copper washer %
• Union bolt &
• Brake switch '
WARNING
• Proper hose routing is essential to insure
safe operation. Refer to "CABLE ROUTING"
$ in Chapter 2.
• Always use new copper washers.
346014(a)
3.Install:
• Actuator
On the brake lever.
• Circlip
• Brake lever
4.Fill:
• Brake reservoir
in Chapter 3.

DOT #3 or DOT #4
CAUTION:
The brake fluid may corrode painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
6-16
FRONT BRAKE CHAS
WARNING
• Use only the designated quality fluid.
Otherwise, the rubber seals may deteriorate
causing leakage and poor brake
performance.
• Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical
reaction leading to poor brake performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
5.Air bleed:
• Brake system
BRAKE SYSTEM)" in Chapter 3.
6.Inspect:
in Chapter 3.
7.Check:
• Brake lever operation
A soft or spongy feeling → Bleed brake system.
6-17
FRONT BRAKE CHAS
FRONT BRAKE CALIPER
T.R 23 Nm (2.3 m.kg)
1
3 2
LT
LT
T.R 23 Nm (2.3 m.kg)

Caliper removal Remove the parts in the order below.
Drain the brake fluid
1 Union bolt 1
2 Copper washer 1
3 Brake hose 1
4 Copper washer 1
5 Brake caliper 1

dure.
6-18
FRONT BRAKE
CHAS
CALIPER DISASSEMBLY
& T.R 6 Nm (0.6 m.kg)
"
T.R 23 Nm (2.3 m.kg)
% !
$
#
T.R 23 Nm (2.3 m.kg)
#
$

Caliper disassembly Remove the parts in the order below.
Brake pads Refer to "FRONT BRAKE PADS
REMOVAL" section.
Q Caliper 1
W O-ring 1
Refer to "CALIPER DISASSEMBLY" and
E Caliper piston 2
R Dust seal 2 "CALIPER ASSEMBLY" section.
T Piston seal 2
Y Bleed screw 1

dure.
6-19
FRONT BRAKE
CHAS
CALIPER DISASSEMBLY
NOTE:
Before disassembling the front brake caliper,
drain all brake fluid from the brake hose, master
cylinder, brake caliper and tank.
1.Remove:
• Brake caliper piston
*****************************************************
Removal steps:
• Blow compressed air into the hose joint opening
to force out the piston from the caliper body.
WARNING
• Never try to pry out the piston.
• Cover the piston with a rag. Use care so
346004
that the piston does not cause injury as it
is expelled from the cylinder.
CAUTION:
Carefully remove the caliper piston ! to
prevent damage.
" # !
*****************************************************
2.Remove:
• Dust seal "
• Piston seal #
When removing, push the seals by your finger.
CAUTION:
• Do not use a sharp instrument. Remove
seals by your finger.
• Do not re-use removed parts.
CALIPER INSPECTION
1.Inspect:
• Caliper cylinder
• Caliper piston
Scratches/Wear → Replace caliper assembly.
6-20
FRONT BRAKE
CHAS
CALIPER ASSEMBLY
WARNING
• All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.

DOT #3 or DOT #4
• Replace the piston seals and dust seals

whenever a caliper is disassembled.
! "
1.Install:
• Piston seals !
• Dust seals
• O-ring
346015(a)
2.Install:
• Caliper piston "
Apply brake fluid to the outer surface and
install.
CAUTION:
• Do not force.
• Use care to prevent damage on caliper
piston.
3.Install:
• O-ring
!
CALIPER INSTALLATION
1.Install:
• Brake caliper !
• Caliper support bolt "
"
T.R 23 Nm (2.3 m•kg)
• Copper washer
• Brake hose
LT
• Copper washer
• Union bolt
T.R 23 Nm (2.3 m•kg)
LT
6-21
FRONT BRAKE
CHAS
2.Fill:
• Brake reservoir
in Chapter 3.

DOT #3 or DOT #4
5.Air bleed:
• Brake system
6.Inspect:
in Chapter 3.
7.Check:
• Brake lever operation
A soft or spongy feeling → Bleed brake system.
6-22
HANDLEBAR
CHAS
HANDLEBAR
4
3
T.R 60 Nm (6.0 m.kg)

Handlebar removal Remove the parts in the order below.
Handlebar covers
Front panel Refer to "COVERS" in Chapter 3.
Inner panel
Master cylinder Refer to "MASTER CYLINDER" section.
1 Stop switch coupler 2

2 Handlebar switch (left) 1
3 Rear brake cable 1
4 Grip (left) 1
5 Handlebar switch (right) 1
6 Throttle cable 1
7 Throttle grip 1

dure.
6-23
HANDLEBAR
CHAS
REMOVAL
1.Remove:
• Grip (left)
*****************************************************
Removal steps:
• Blow with compressed air between the
handlebar and adhesive side of the grip to
remove.
*****************************************************
INSPECTION
1.Inspect:
• Handlebar
Bends/Cracks/Damage → Replace.
WARNING
Do not attempt to straighten a bent handlebar
as this may dangerously weaken the
handlebar.
*****************************************************
Left handlebar replacement steps:
• Remove the handlebar grip.
• Apply a light coat of an adhesive for rubber on
the handlebar end.
• Install the handlebar grip.
NOTE:
Wipe off excess adhesive with a clean rag.
WARNING
Leave the handlebar intact until the adhesive
becomes dry enough to make the grip and
handlebar stuck securely.
INSTALLATION
1.Install:
• Handlebar !
• Bolt "
# • Nut # T.R60 Nm (6.0 m•kg)
!
NOTE:
• Install the handlebar onto the steering shaft
notch.
• Install the wire harness, the throttle cable, the
" speedometer cable and the rear brake cable.
6-24
HANDLEBAR
CHAS
CAUTION:
• Before installing the handlebar, wipe off
any trace of oil from the inserted section of
the shaft with solvent.
• Insert the bolt from the left as shown.
2.Install:
• Throttle grip (complete)
• Grip (left)
• Handlebar switches (right and left)
"
NOTE:
Align the projection on the handlebar switch with
the hole on the handlebar.
3.Install:
! • Master cylinder !
• Master cylinder bracket "
NOTE:
• Install the master cylinder close to the
handlebar switch.
• Install the master cylinder bracket to be in
accordance with the handlebar switch
assembling line.
CAUTION:
Tighten first the upper bolt, then the lower
bolt.
4.Install:
• Band
Refer to the section "CABLE ROUTING" in
Chapter 2.
6-25
STEERING HEAD
CHAS
STEERING HEAD
T.R 27.5 Nm (2.75 m.kg)
B 1
3
4
B

Steering head removal Remove the parts in the order below.
Front wheel Refer to "FRONT WHEEL AND BRAKE
DISC" section.
Front brake caliper Refer to "FRONT BRAKE CALIPER"
section.
Handlebar Refer to "HANDLEBAR" section.
1 Ring nut 1
2 Steering shaft 1
Refer to "STEERING HEAD ASSEMBLY
3 Bearing balls (upper/lower) 15/15
AND INSTALLATION" section.
4 Bearing race (upper/lower) 2
5 Bearing race (steering shaft) 2

dure.
6-26
STEERING HEAD CHAS
REMOVAL
WARNING
• Securely support the scooter so there is no
danger of it falling over.
! • Stand the scooter on a level surface.
1.Remove:
354001
• Ring nut !
Use the ring nut wrench.
Ring nut wrench:

9079Q-02218
INSPECTION
1.Wash the bearing balls and the bearing races
in solvent.
2.Check:
• Bearing races !
! • Bearing balls
NOTE:
Always replace the bearing balls and the upper
and lower bearing races as a set.
354006
*****************************************************
Bearing race replacement steps:
• Drive out the bearing race from the steering
tube by hitting on it several places.
!
• Remove the bearing race on the steering shaft
with a hammer and a chisel ! as shown.
• Drive in the new bearing race evenly by hitting
on them on several places.
CAUTION:
• Unless installed correctly, the bearing races
354007 will damage the frame or steering column.
• Never hit the bearing races on the ball race
surface.
*****************************************************
3.Check:
• Steering shaft
Bend/Damage → Replace.
WARNING
Never attempt to straighten a bent steering
354008
shaft.
6-27
STEERING HEAD
CHAS
INSTALLATION
WARNING
Proper cable and hose routing is essential to
insure safe scooter operation. Refer to
"CABLE ROUTING" in Chapter 2.
1.Install:
• Bearing balls
B
2.Apply:
• Bearing grease (onto upper and lower bearing
balls)
354010 (a)
3.Install:
• Steering shaft
• Ring nut
Ring nut wrench:

9079Q-02218
CAUTION:
Hold the steering shaft until it is securely
attached.
4.Install:
• Washer !
• Steering shaft lock nut "
T.R 27.5 Nm (2.75 m•kg)
" NOTE:
Tighten the steering shaft lock nut while holding
! the ring nut wrench.
354001(a)
Ring nut wrench:

9079Q-02218
6-28
FRONT FORK CHAS
FRONT FORK
FRONT FORK
T.R 27.5 Nm (2.75 m.kg)
B 1
2

Front fork removal Remove the parts in the order below.
Front wheel Refer to "FRONT WHEEL AND BRAKE
DISC" section.
Front brake caliper Refer to "FRONT BRAKE CALIPER"
section.
Handlebar Refer to "HANDLEBAR" section.
1 Ring nut 1
Refer to "FRONT FORK REMOVAL"
2 Bearing balls
section.
3 Front fork 1

dure.
6-29
FRONT FORK CHAS
FRONT FORK DISASSEMBLY
,
(
+ '
* &
- %
) "
#
$
.
/
2,5 Nm (0,25 m.kg)

Front fork disassembly Remove the parts in the order below.
Q Outer fork tube (left) 1/1
W Dust seal 2
E Oil seal circlip 2
R Oil seal 2
T Circlip 2
Y Spring (left tube) 1 Refer to "FRONT FORK ASSEMBLY"
U Piston (left tube) 1 section.
I Spring (left tube) 1
O Oil lock spacer (right tube) 1
P Collar (right tube) 1
{ Spring (right tube) 1
} Piston (right tube) 1
q Spring (right tube) 1
dure.
6-30
FRONT FORK CHAS
REMOVAL
WARNING
Securely support the scooter with a stand
under the engine.
!
1.Remove:
• Ring nut !
354001
Use the ring nut wrench.
Ring nut wrench:

9079Q-02218
INSPECTION
1.Check:
• Inner fork tube and fork components
• Outer fork tube
Wear/Scratches/Damage → Replace.
WARNING
Never attempt to straighten a bent fork tube
as this may dangerously weaken the tube.
!
2.Inspect:
• Fork spring !
Bends/damage → Replace.
342011
ASSEMBLY
Reverse the disassembly procedure.
NOTE:
• When reassembling the front fork, make sure
you use following new parts:
• Oil seals
• Circlips
• Make sure that all components are clean before
reassembling.
6-31
FRONT FORK CHAS
1.Install:
• Oil seal
Use the fork seal driver weight and adapter.
Fork seal driver weight:

90890-01184
∅28):
Fork seal driver attachment (∅
90890-01185
NOTE:
Before installing the oil seal, apply the lithium
soap base grease onto the oil seal lips.
CAUTION:
Be sure that the oil seal numbered side face
upward.
2.Install:
• Circlip !
• Dust seal "
" Use the fork seal driver weight.
Fork seal driver weight:

! 90890-01184
3.Fill:
• Fork oil
342018(a) Fork oil type:

ISO 6743/4-LHV 46 or SAE 10
Amount (per fork leg):
70 cc
4.Tighten:
• Outer fork tubes bolt
T.R 2.5 Nm (0.25 m•kg)
6-32
ELEC 7
ELEC
CHAPTER 7.
ELECTRICAL COMPONENTS
CIRCUIT DIAGRAM ...................................................................................... 7-1
ELECTRICAL COMPONENTS ...................................................................... 7-3
SWITCH INSPECTION .................................................................................. 7-4

SWITCH INSPECTION ............................................................................ 7-4
SWITCH CONTINUITY INSPECTION ............................................................ 7-4
IGNITION AND STARTING SYSTEM ........................................................... 7-6

CIRCUIT DIAGRAM ................................................................................. 7-6
TROUBLESHOOTING ............................................................................. 7-7
ELECTRIC STARTING SYSTEM ................................................................ 7-13

STARTER MOTOR ................................................................................ 7-13
CHARGING SYSTEM .................................................................................. 7-16

CIRCUIT DIAGRAM ............................................................................... 7-16
TROUBLESHOOTING ........................................................................... 7-17
LIGHTING SYSTEM .................................................................................... 7-20

CIRCUIT DIAGRAM ............................................................................... 7-20
LIGHTING SYSTEM INSPECTION ....................................................... 7-23
SIGNAL SYSTEM ........................................................................................ 7-26

CIRCUIT DIAGRAM ............................................................................... 7-26
SIGNAL SYSTEM CHECK ..................................................................... 7-29
AUTO CHOKE ............................................................................................. 7-34

CIRCUIT DIAGRAM ............................................................................... 7-34
ELEC
CIRCUIT DIAGRAM
ELECTRICAL
CIRCUIT DIAGRAM
2
Or
1 BW B R Br Gy
B } LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
5 9
YR 8
R
B
B
YB
q 0
7
YR YR YB L LW
OFF B
B
ON L B
LW B
GY OFF {
:
ON
B
L L
B
GY GY
L L L
r r a t
B B B B y u
Br Br Br Br
J E i D
6 F H
GB L Y B
HI Ch BrW Dg
P Gy
LOW L
G o
N
Y Gy
GB R
Y K Ch Dg
F
e [ p A
] S
w G
B B B B B B B B B
7-1
ELEC
CIRCUIT DIAGRAM
Q Spark plug u Rear brake switch
W Ignition coil i Flasher relay
E CDI magneto o Flasher switch
R CDI unit p Flasher indicator
T Rectifier/regulator [ Rear flasher light (left)
Y "HI/LO" switch ] Front flasher light (left)
U Starter motor A Front flasher light (right)
I Starter relay S Rear flasher light (right)
O Fuse D Horn
P Battery F Horn switch
{ Starter switch G Oil level indicator
} Main switch H Oil level gauge
q Lighting switch J Fuel meter
w High beam indicator K Sender (a resistance)
e Head light L Resistor
r Meter light : Auto choke
t Tail / "STOP" light a License light (Switzerland only)
y Front brake switch
COLOR CODE
B Black Y Yellow
Br Brown B/R Black/Red
Ch Chocolate B/W Black/White
Dg Dark green Br/W Brown/White
G Green Br/Y Brown/Yellow
Gy Grey G/B Green/Black
L Blue G/Y Green/Yellow
Or Orange L/W Blue/White
P Pink W/R White/Red
R Red Y/B Yellow/Black
Sb Sky blue Y/R Yellow/Red
W White
7-2
ELEC
Q Wire harness U Resistor
W Fuel sender I Rectifier/Regulator
E Oil sender O Horn
R Battery P CDI unit
T Main switch { Ignition coil
Y Flasher relay
!
&
%
#
$
( '
"
+ *
7-3
ELEC
SWITCH INSPECTION
"0"
SWITCH INSPECTION
"∞" SWITCH INSPECTION
Use a pocket tester to check the terminals for
continuity. If the continuity is faulty as any point,
"Ω x 1" replace the switch.
Pocket tester:
90890-03112
NOTE:
• Set the pocket tester to "O" before starting the
test.
• The pocket tester should be set to the "x1" Ω
range when testing the switch for continuity.
• Turn the switch on and off a few times when
checking it.
SWITCH CONTINUITY INSPECTION.

The terminal connections for switches (main
R Br B B/W
OFF
! switch, handlebar switch, engine stop switch,
ON
light switch,etc.) are shown in a chart similar to
the one on the left.
"
This chart shows the switch positions in the
B column and the switch lead colors in the top row.
Br For each switch position, " " indicates the
R
terminals with continuity.
The example chart shows that:

! There is continuity between the "Black" and
"Black/White" leads when the switch is set
to "OFF".
" There is continuity between the "Red" and
"Brown" leads when the switch is set to "ON".
7-4
ELEC
SWITCH INSPECTION
SWITCH CONTINUITY INSPECTION
Before checking a switch refer to the checking

switches as shown in the page 7-4 and check
for the correct terminal connections (closed cir-
cuit) according to color combinations shown in
the chart. Main switch
Poor connection, fault → Repair or replace. LOCK
BW B Gy R Br
OFF
CHECK
ON
Dimmer switch Gy B
G L Y Br R
HI
LOW
Horn switch
B P Ch L B Start switch
OFF Dg BrW P
LW B
ON
OFF
Flasher switch ON
B YB L
Ch BrW Dg
LW YR Lighting switch
L
N YB YR L
OFF
R
ON
Br Br
GY GY
Rear brake Front brake

switch switch
Fuse
7-5
ELEC
IGNITION AND STARTING SYSTEM
CIRCUIT DIAGRAM
2
Or
1 BW B R Br Gy
B } LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
5 9
YR 8
R
B
B
YB
q 0
7
YR YR YB L LW
OFF B
B
ON L B
LW B
GY OFF {
:
ON
B
L L
B
GY GY
L L L
r r a t
B B B B y u
Br Br Br Br
J E i D
6 F H
GB L Y B
HI Ch BrW Dg
P Gy
LOW L
G o
N
Y Gy
GB R
Y K Ch Dg
F
e [ p A
] S
w G
B B B B B B B B B
1 Spark plug 9 Fuse

2 Ignition coil 0 Battery
3 CDI magneto CDI { Starter switch
4 CDI unit } Main switch
7 Starter motor y Front brake switch
8 Starter relay u Rear brake switch
7-6
ELEC
TROUBLESHOOTING
THE STARTING SYSTEM DOES NOT
WORK (NO SPARK OR IRREGULAR
SPARKS)
Procedure:
Check:
1. Fuse (main) 6. Ignition coil resistance
2. Battery 7. Pickup coil resistance
3. Spark plug 8. Source coil resistance
4. Spark check 9. Main switch
5. Spark plug cap resistance 10. Connections
NOTE:
Remove the following parts before proceeding
with the troubleshooting:
1) Seat
2) Side covers
3) Fuel tank
For accurate troubleshooting use the following
special tools:
Ignition tester:
90890-06754
Pocket tester:
90890-03112
NO CONTINUITY
1.Fuse
Refer to "SWITCH INSPECTION" section.
Replace the fuse.
CONTINUITY
DOES NOT MEET SPECIFICATION
2.Battery
• Check the condition of the battery.
Refer to "BATTERY INSPECTION" in
• Clean battery terminals.
chapter 3.
• Charge or replace the battery.
CONTINUITY
3.Spark plug Spark plug standard:

BR8HS/NGK
• Check the spark plug type.
• Check the condition of the spark plug.
• Check the spark plug gap.
Refer to "SPARK PLUG INSPECTION" DOES NOT MEET SPECIFICATION
in Chapter 3.
Spark plug gap:
0.5 ~ 0.7 mm Adjust it or replace the spark plug.
7-7
ELEC
IGNITION AND STARTER SYSTEM
"
4.Spark check !
a
• Remove the spark plug cap.
• Connect the ignition checker !
" Ground
a Spark plug cap
• Turn the main switch to "ON".
MEETS SPECIFICATION
• Check the length of the spark gap.
• Increase the spark length until the engine
begins to misfire.
Ignition system in good condition.
Minimum spark gap:
6 mm
OUT OF
SPECIFICATION
OR NO SPARK
5.Spark plug cap resistance

• Disconnect the spark plug cap.
• Connect the pocket tester (Ωx1k) to the
ignition coil.
• Check the resistance of the spark plug cap.
Spark plug cap resistance: DOES NOT MEET SPECIFICATION

5kΩ (20°C)
CORRECT Replace the spark plug cap.
7-8
ELEC
Ωx1
6.Ignition coil resistance
• Disconnect the ignition coil leads.
• Connect the pocket tester (Ωx1) to the igni-
tion coil.
Pocket tester (+) lead → Orange
Pocket tester (-) lead → Black
• Check the primary coil resistance.
Primary coil resistance:
0.32 ~ 0.48 Ω (20°C) Ω x 1k
• Connect the pocket tester (Ωx1k) to the

ignition coil.
Pocket tester (+) lead → Ground
Pocket tester (-) lead → Spark plug lead
• Check the secondary coil resistance.
Secondary coil resistance: DOES NOT MEET SPECIFICATION

5,68 ~ 8,52 kΩ (20°C)
MEETS Defect. Replace the ignition coil.

SPECIFICATION
!
7.Pickup coil resistance
W YR -
• Disconnect the pickup coil coupler.
WR BR
• Connect the pocket tester (Ωx100) to the
pickup coil. "
CDI
MAGNETO
Pocket tester (+) lead → White/Red
Pocket tester (-) lead → Ground (Black)
• Check the pickup coil resistance.
Pickup coil resistance:
400 ~ 600 Ω at 20°C DOES NOT MEET SPECIFICATION
MEETS
SPECIFICATION
Replace the pickup coil.
7-9
ELEC
MEETS
SPECIFICATION
8.Source coil resistance " !

• Disconnect the source coil coupler from the W YR -
wire harness. WR BR
• Connect the pocket tester (Ωx100) to the
source coil.
CDI
MAGNETO
Pocket tester (+) lead → Black/Red !
Pocket tester (-) lead → White "
• Check the source coil resistance.
Source coil resistance:

640 ~ 960 Ω at 20°C
MEETS Replace the source coil.

SPECIFICATION
9.Main switch
Refer to "SWITCH INSPECTION" section. NO CONTINUITY
CONTINUITY
Replace the main switch.
10.Connections
• Check all connections in the ignition sys-
tem. POOR CONNECTIONS
Refer to "WIRING DIAGRAM".
GOOD
CONNECTIONS Repair
Replace the CDI unit.
7-10
IGNITION AND STARTER SYSTEM
ELEC
TROUBLESHOOTING
STARTER MOTOR DOES NOT WORK

Procedure
Check:
1. Fuse (main) 5. Main switch
2. Battery 6. Starter motor switch
3. Starter motor 7. Connections
4. Starter relay
NOTE:
• Remove the following parts before proceed-
ing with the troubleshooting:
1) Side covers
2) Handlebar cover
3) Footrest board/Leg shields
• For accurate troubleshooting use the fol-
lowing special tools:
Pocket tester:
90890-03112
NO CONTINUITY
1.Fuse.
Replace the fuse.
CONTINUITY

2.Battery
Refer to "BATTERY INSPECTION" in the • Clean battery terminals.
Chapter 3. • Charge or replace the battery.
MEETS CAUTION:
SPECIFICATIONS • If the gauge of the jumper lead is smaller
than that of the battery leads, the jumper
3.Starter motor lead might melt or burn.
• This test could cause sparks. Never perform
• Use a jumper lead # to connect the (+) !
it near a gas source or near flammable
terminal of the battery to the starter motor
products.
terminal ".
" # !
+ -
7-11
ELEC
DOE NOT WORK
• Check the starter motor operation
WORKS
Starter defect → Repair or replace

4.Starter relay
• Disconnect Blue/White lead from the wire
harness.
• Connect the (-) terminal of the battery to the
Blue/White lead.
• Check the starter motor operation.
DOES NOT WORK

+ -
LW Replace the starter relay.
WORK
5.Main switch. DOES NOT MEET SPECIFICATION

MEETS
SPECIFICATION Replace the main switch.
6.Starter motor switch. DOES NOT MEET SPECIFICATION

MEETS
SPECIFICATION Replace the right handlebar switch.
7.Connections.
POOR CONNECTIONS
• Check all connections in the starter system.
Refer to "WIRING DIAGRAM" section.
Repair.
7-12
ELECTRIC STARTING SYSTEM
ELEC
STARTER MOTOR
T.R 13 Nm (1.3 m.kg)
&
#
"
LS
Starter motor removal Refer to "STARTER MOTOR" in

Chapter 5.
Stater motor disassembly Disassemble the parts in the order below

! O-ring 1
" Front bracket 1
# Rubber seal 1
$ Brush holder assembly 1
% Armature 1
& Rubber seal 1
For the assembly, reverse the disassemble

procedure.
7-13
ELEC
INSPECTION
1.Check:
@ • Commutator
Dirty → Clean it with #600 grit sandpaper.
2.Measure:
• Commutator diameter @
Out of specification → Replace starter motor
Commutator wear limit:

14.8 mm
3.Measure:
• Mica undercut @
Out of specification → Scrape the mica to
@ proper value using a hacksaw blade can be
ground to fit.
Mica undercut @:
1.15 mm
N.B.:
The mica insulation of the commutator must be
undercut to ensure proper operation of
commutator.
4.Inspect:
• Armature coil (insulation/continuity)
Defects → Replace starter motor.
**********************************************************
Inspecting steps:
• Connect the pocket tester for continuity check
! and insulation check ".
• Measure the armature resistances.
Armature coil resistance:

Continuity check !:
0.06 ~ 0.08 Ω at 20°C (68°F)
! Insulation check ":
More than 1 MΩ
• If the resistance is incorrect, replace the starter

motor.
"
********************************************************
7-14
ELEC
5.Measure:
• Brush length @
Brush length limit @:

0.9 mm
6.Measure:
• Brush spring force
Fatigue/Out of specification → Replace as a
set.
Brush spring force:

563 ~ 844 g
7-15
CHARGING SYSTEM
ELEC
CHARGING SYSTEM
CIRCUIT DIAGRAM
2
Or
1 BW B R Br Gy
B } LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
5 9
YR 8
R
B
B
YB
q 0
7
YR YR YB L LW
OFF B
B
ON L B
LW B
GY OFF {
:
ON
B
L L
B
GY GY
L L L
r r a t
B B B B y u
Br Br Br Br
J E i D
6 F H
GB L Y B
HI Ch BrW Dg
P Gy
LOW L
G o
N
Y Gy
GB R
Y K Ch Dg
F
e [ p A
] S
w G
B B B B B B B B B
3 CDI magneto
5 Rectifier/Regulator
9 Fuse
0 Battery
7-16
ELEC
CHARGING SYSTEM
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED
Procedure
Check:
1. Fuse (main)
2. Battery
3. Charging voltage
4. Charging coil resistance
5. Connections
NOTE:
1) Side cover
2) Footrest board
3) Seat
• For accurate troubleshooting special tools:
Inductive tachometer:
90890-03113
Pocket tester:
90890-03112
NO CONTINUITY
1.Fuse.
Replace the fuse.
CONTINUITY
2.Battery
Refer to "BATTERY INSPECTION" in the • Clean battery terminals.
Chapter 3. • Charge or replace the battery.
MEETS
SPECIFICATION
7-17
ELEC
CHARGING SYSTEM
3. Charging voltage
• Connect the engine tachometer to the spark - +
plug lead.
• Connect the pocket tester(DC20V)to the
battery terminals.
Pocket tester (+) lead →

Battery (+) terminals
Pocket tester (-) lead →
Battery (-) terminals
• Start the engine and accelerate to about

5.000 rpm.
• Check the charging voltage.
MEETS SPECIFICATION
Charging voltage:
14 ~ 15V at 5.000 r/min
NOTE: Charging circuit is OK.
Use a fully charged battery.
OUT OF
SPECIFICATION
7-18
CHARGING SYSTEM
ELEC
!
W YR -
4. Charging coil resistance WR BR
• Disconnect the CDI magneto coupler from "

the wire harness. CDI
MAGNETO
• Connect the pocket tester (Ω x 1) to the
charging coil.
Pocket tester (+) lead → White !

Pocket tester (-) lead → Black "
• Check the charging coil resistance. OUT OF SPECIFICATION

Charging coil resistance:
0.48 ~ 0.72 Ω at 20°C
Charging coil defect → Replace.

MEETS
SPECIFICATION
5.Connections
POOR CONNECTIONS
• Check all connections in the charging sys-
tem.
Repair.
MEETS
SPECIFICATION
Replace the rectifier/regulator.
7-19
LIGHTING SYSTEM
ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM
2
Or
1 BW B R Br Gy
B } LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
5 9
YR 8
R
B
B
YB
q 7 0
YR YR YB L LW
OFF B
B
ON L B
LW B
GY OFF {
:
ON
B
L L
B
GY GY
L L L
r r a t
B B B B y u
Br Br Br Br
J E i D
6 F H
GB L Y B
HI Ch BrW Dg
P Gy
LOW L
G o
N
Y Gy
GB R
Y K Ch Dg
F
e [ p A
] S
w G
B B B B B B B B B
3 CDI magneto r Meter light

Y "HI/LO" switch t Taillight
q Lighting switch L Resistor
w High beam indicator light a License light (Switzerland only)
e Head light
7-20
LIGHTING SYSTEM
ELEC
TROUBLESHOOTING
THE HEADLIGHT, HEADLIGHT

INDICATOR, METER LIGHT, TAIL LIGHT,
OR LICENSE LIGHT DO NOT WORK
Procedure
Check:
1. "LIGHTS" switch
2. Lighting coil resistance
3. "HI/LO" switch
4. Connections
NOTE:
1) Side covers and footrest board
2) Handlebar covers
lowing special tools.
Pocket tester:
90890-03112
YP802018
NO CONTINUITY
1."LIGHTS" switch
Replace the right handlebar switch.

CONTINUITY
2.Lighting coil resistance !
• Disconnect the lighting coil coupler from the W YR -
wire harness. WR BR
• Connect the pocket tester (Ω x 0,1) to the "

lighting coil. CDI
MAGNETO
Pocket tester (+) lead → Yellow/Red !
Pocket tester (-) lead → Ground "
• Check the lighting coil resistance.

OUT OF SPECIFICATION
Lighting coil resistance:
0.4 ~ 0.6 Ω à 20°C
Lighting coil defect → Replace.

MEETS
SPECIFICATION
7-21
LIGHTING SYSTEM
ELEC
3."HI/LO" switch NO CONTINUITY
Refer to "SWITCH INSPECTION".
CONTINUITY Replace the "HI/LO" switch .
POOR CONNECTIONS
4.Connections
• Check all connections in the lighting sys-
tem. Repair.
Refer to "WIRING DIAGRAM"
CORRECT
Circuit is in good condition.
7-22
LIGHTING SYSTEM
ELEC
LIGHTING SYSTEM INSPECTION
1.Headlight and headlight indicator do not work.
1.Bulb and socket. NO CONTINUITY

CONTINUITY Replace the bulb or socket.
2.Voltage
• Connect the pocket tester (AC20V) to the
headlight coupler.
Headlight:
• "LO":
Pocket tester (+) lead → Green !
Pocket tester (-) lead → Black #
• "HI":
Pocket tester (+) lead → Yellow "
#
• Headlight indicator: $ Y
Pocket tester (+) lead → Yellow $ B B

Y B Y Y "
Pocket tester (-) lead → Black %
Y 187,5
G G
B
• Set the main switch to "ON". %

G
!
• Set the light switch to " ".
• Switch from "HI" to "LOW" and back.
• Check the voltage (12 V) between the head- OUT OF SPECIFICATION
light coupler leads.
MEETS
SPECIFICATION There is a defect in the wire harness between
the main switch and the headlight coupler
→ Repair.
2.The meter light does not work.
1.Bulb and socket.

NO CONTINUITY
Refer to " SWITCH INSPECTION " section.
Replace bulb or socket.

CONTINUITY
7-23
ELEC
LIGHTING SYSTEM
2.Voltage
B
• Connect the pocket tester (AC 20 V) to the L Ch Dg Dg Ch
Dg
meter light coupler. Ch
L B B L
Pocket tester (+) lead → Blue ! " !

• Set the main switch to "ON".

• Set the light switch to " ". OUT OF SPECIFICATION
• Check the voltage (12 V) between the meter
MEETS There is a defect in the wire harness between

SPECIFICATION the main switch and the meter light coupler
Circuit is in good condition. → Repair.
3.The taillight does not work.
1.Bulb and socket.

NO CONTINUITY
CONTINUITY Replace bulb or socket.
2.Voltage
!
• Connect the pocket tester (AC 20 V) to the
tail light coupler. L L
GY GY
Pocket tester (+) lead → Blue ! B B

"
• Check the voltage (12 V) between the head- OUT OF SPECIFICATION
MEETS
There is a defect in the wire harness between
SPECIFICATION
the main switch and the taillight coupler
→ Repair.
7-24
ELEC
LIGHTING SYSTEM
4.The license light does not work. (LICENSE
LIGHT ONLY FOR SWITZERLAND)
1.Bulb and socket. NO CONTINUITY

CONTINUITY Replace bulb or socket.
2.Voltage
• Connect the pocket tester (AC 20 V) to the !
license light coupler.
L
Pocket tester (+) lead → Blue ! B

"
• Check the voltage (12 V) between the head-
MEETS There is a defect in the wire harness between

SPECIFICATION the main switch and the license light coupler
→ Repair.
7-25
SIGNAL SYSTEM ELEC
SIGNAL SYSTEM
CIRCUIT DIAGRAM
2
Or
1 BW B R Br Gy
B } LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
5 9
YR 8
R
B
B
YB
q 7 0
YR YR YB L LW
OFF B
B
ON L B
LW B
GY OFF {
:
ON
B
L L
B
GY GY
L L L
r r a t
B B B B y u
Br Br Br Br
J E i D
6 F H
GB L Y B
HI Ch BrW Dg
P Gy
LOW L
G o
N
Y Gy
GB R
Y K Ch Dg
F
e p A
[ ] S
w G
B B B B B B B B B
9 Fuse ] Front flasher light (left)

0 Battery A Front flasher light (right)
} Main switch S Rear flasher light (right)
t Tail / "STOP" light D Horn
y Front brake switch F Horn switch
u Rear brake switch G Oil level indicator
i Flasher relay H Oil level gauge
o Flasher switch J Fuel meter
p Flasher indicator K Sender (a resistance)
[ Rear flasher light (left)
7-26
ELEC
SIGNAL SYSTEM
TROUBLESHOOTING
FLASHER LIGHTS, TAIL/BRAKE LIGHT,

"OIL" WARNING LIGHT DO NOT WORK.
HORN DOES NOT SOUND, FUEL METER
DOES NOT WORK.
Procedure
Check:
1. Fuse (main)
2. Battery
3. Main switch
4. Connections
NOTE:
• Remove the following parts before proceeding
with the troubleshooting:
1) Side covers and footrest board
2) Handlebar covers
3) Leg shields
• For accurate troubleshooting use the following
special tools:
Pocket tester:
90890-03112
1.Fuse.
NO CONTINUITY
CONTINUITY
Replace the fuse.
2.Battery
Refer "BATTERY INSPECTION" in the
Chapter 3.
Battery voltage: • Clean battery terminals.
12.8 or more at 20°C • Charge or replace the battery.
MEETS
SPECIFICATION
3.Main switch
NO CONTINUITY
Refer to "SWITCH INSPECTION" in the
Chapter 7.
CONTINUITY Replace the main switch.

7-27
ELEC
SIGNAL SYSTEM
4.Connections
POOR CONNECTIONS
• Check all connections in the signal system.
Refer to "WIRE DIAGRAM".
CONTINUITY Repair.
Check the condition of each circuit of the

signal system.
Refer to "SIGNAL SYSTEM CHECK".
7-28
ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM CHECK
1. Horn does not sound.
1."HORN" switch
NO CONTINUITY
CONTINUITY Replace the horn switch.
2.Voltage
! Br P
• Connect the pocket tester (DV20 V ) to the
horn lead.
Pocket tester (+) lead → Brown !

Pocket tester (-) lead → Ground " "

• Check for voltage (12 V) between "Brown"
and the ground.
MEETS
SPECIFICATION Defect in the wire harness between the main
switch and the horn → Repair.
3.Horn
HORN SOUNDS
• Disconnect the "Pink" lead at the horn ter-
minal.
• Ground the horn terminal with a jumper lead.
• Set the main switch to "ON". Horn is in good condition.
HORN DOES
NOT SOUND
4.Horn
• Connect the pocket tester (DC20 V) to the Br P !
horn lead.
Pocket tester (+) lead → Pink !

Pocket tester (-) lead → Ground

• Press the "HORN" switch.
• Check the voltage (12V) between "Pink" NO CONTINUITY
and ground.
MEETS
SPECIFICAITON
Replace Horn.
Adjust Horn.
7-29
ELEC
SIGNAL SYSTEM
2. The brake light does not work.

NO CONTINUITY
1.Bulb and socket.
Replace bulb or socket.
CONTINUITY
NO CONTINUITY
2.Brake switch
Brake switch is defect → Replace.
CONTINUITY
3.Voltage
• Connect the pocket tester (DC 20 V ) to the
socket.
Pocket tester (+) lead → Green/Yellow !
L L L
GY GY GY
B
B B
"
• Pull the brake lever.
• Check the voltage (12V) between Green/
Yellow and Black. 4.Connections
• There is a defect in the wire harness be-
MEETS
tween the main switch and the tail light
SPECIFICATION
socket → Repair.
Circuit is in good condition. Refer to "CIRCUIT DIAGRAM OF THE SIG-
NAL SYSTEM".
7-30
SIGNAL SYSTEM
ELEC
3.Flashers and flasher indicator do not work.

NO CONTINUITY
1.Bulb and socket
Replace buld and/or socket.
CONTINUITY
NO CONTINUITY
2.Flasher switch
Replace the left handlebar switch.
CONTINUITY
Br/W Br/W
3.Voltage Br Br
• Connect the pocket tester (DC 20 V ) to the !

flasher relay.
Pocket tester (+) lead → Brown ! "
• Check the voltage (12 V) between the
"Brown" lead and the Ground.
Defect in the wire harness between the main

MEETS switch and the flasher relay → Repair.
SPECIFICATION
!
4.Voltage
Br/W Br/W
• Connect the pocket tester (DC20 V) to the Br Br
flasher connector.
Pocket tester (+) lead → Brown/White ! "
• Check the voltage (12 V) between OUT OF SPECIFICATION
Brown/White and the ground.
MEETS
SPECIFICATION Flasher relay defect → Replace.
7-31
ELEC
SIGNAL SYSTEM
Ch B #
5.Voltage B Ch
B Ch
!
• Connect the pocket tester (DC 20 V) to the
B
flasher connector. Ch
Left flasher bulb

Pocket tester (+) lead → Chocolate !
Right flasher bulb Dg
B
Pocket tester (+) lead → Dark green "
Pocket tester (-) lead → Black # "
Dg B
• Turn the main switch "ON". Dg B

#
• Set the "TURN" switch to "L", then to "R". Dg B
• Check the voltage (12 V) between

"chocolate" and the ground, then "Dark OUT OF SPECIFICATION
green" and the ground.
MEETS
SPECIFICATION
6.Connections
This circuit is in good condition. • Defect in the wire harness between the
main switch and the flasher bulb socket
→ Repair.
4.The "Oil" indicator light does not work.

NO CONTINUITY
1.Bulb and socket
Replace buld and/or socket.
CONTINUITY
2.Oil level switch
Replace oil level switch is defect.
MEETS
SPECIFICATION
7-32
SIGNAL SYSTEM
ELEC
3. Voltage
• Connect the pocket tester (DC20V) to the
bulb socket connector
Pocket tester (+) lead → Grey
Pocket tester (-) lead → Ground
• Turn the main switch to "ON"
• Check the voltage (12V) between "Grey"
and the ground
MEETS 6.Connections
SPECIFICATION • Check all connections in the signal system.
This circuit is in good condition.
5.The fuel meter does not work.
1. Voltage
• Disconnect the fuel sender leads.
• Connect the pocket tester (Ω x 100) then
(Ωx10) to the fuel sender.
• Drain the fuel tank.
• Measure the resistance.
Sender unit resistance
(empty tank):
89.2 ~ 90.8 Ω at 20°C
• Fill the tank

• Measure the resistance.
Sender unit resistance DOES NOT MEET SPECIFICATION

(fuel tank):
9.2 ~ 10.8 Ω at 20°C
MEETS
Replace the fuel sender.
SPECIFICATION
This circuit is in good condition.
7-33
ELEC
AUTO CHOKE
AUTO CHOKE
CIRCUIT DIAGRAM
2
Or
1 BW B R Br Gy
B } LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
5 9
YR 8
R
B
B
YB
q 7 0
YR YR YB L LW
OFF B
B
ON L B
LW B
GY OFF {
:
ON
B
L L
B
GY GY
L L L
r r a t
B B B B y u
Br Br Br Br
J E i D
6 F H
GB L Y B
HI Ch BrW Dg
P Gy
LOW L
G o
N
Y Gy
GB R
Y K Ch Dg
F
e [ p A
] S
w G
B B B B B B B B B
3 C.D.I. magneto
: Auto choke
7-34
ELEC
AUTO CHOKE
TROUBLESHOOTING
AUTO CHOKE DOES NOT OPERATE.
Procedure
Check:
1. P.T.C. thermistor resistance
2. Lighting coil resistance
3. Voltage
4. Wiring connection
NOTE:
1) Seat and rear carrier
2) Side covers, lower side covers, oil tank
cover
lowing special tools.
Pocket tester:
90890-03112
1.P.T.C. thermistor resistance

• Disconnect the auto choke unit coupler.
• Connect the pocket tester (Ω x 1) to the auto
choke unit lead.
Pocket tester (+) lead → Yellow
Pocket tester (-) lead → Green
P.T.C. thermistor resistance: OUT OF SPECIFICATION

2 ~ 6 Ω at 20°C
MEETS
SPECIFICATION Replace the auto choke unit.
7-35
ELEC
AUTO CHOKE
2.Lighting coil resistance

• Disconnect the C.D.I. magneto coupler from
the wire harness.
• Connect the pocket tester (Ω x 1) to the
lighting coil lead.
Pocket tester (+) lead → Yellow/Red !
W YR -
WR BR
"
CDI
MAGNETO
Lighting coil resistance:

0.4 ~ 0.6 Ω at 20°C Replace the lighting coil.
MEETS
SPECIFICATION
3.Voltage
• Connect the pocket tester (AC20V) to the
auto choke lead.
Pocket tester (+) lead → Yellow/Red
Pocket tester (-) lead → Black
• Turn the main switch to "ON". OUT OF SPECIFICATION
• Start the engine and accelerate to about
3.000 r/min.
• Check the voltage.
4.Wiring connection
Voltage: • Check the connections in the entire auto
10 V or more at 3.000 r/min choke unit.
Refer to the "WIRING DIAGRAM"
MEETS
SPECIFICATION
Auto choke unit is good.
7-36
TRBL
SHTG 8
TRBL
SHTG
CHAPTER 8.
TROUBLESHOOTING
STARTING FAILURE/ HARD STARTING .................................................... 8-1

FUEL SYSTEM ........................................................................................ 8-1
ELECTRICAL SYSTEM ........................................................................... 8-1
COMPRESSION SYSTEM ...................................................................... 8-2
POOR IDLE SPEED PERFORMANCE ......................................................... 8-2

POOR IDLE SPEED PERFORMANCE ................................................... 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE ................................ 8-3

FUEL SYSTEM ........................................................................................ 8-3
ELECTRICAL SYSTEM ........................................................................... 8-3
COMPRESSION SYSTEM ...................................................................... 8-3
FAULTY AUTOMATIC (V-BELT TYPE) ........................................................ 8-3

MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING ... 8-3
CLUTCH -OUT FAILURE ......................................................................... 8-4
POOR STANDING START (LOW CLIMBING ABILITY) .......................... 8-4
POOR ACCELERATION (POOR HIGH SPEED) .................................... 8-4
OVER HEATING ............................................................................................ 8-4

OVER HEATING ...................................................................................... 8-4
IMPROPER KICKING .................................................................................... 8-5

SLIPPING ................................................................................................. 8-5
HARD KICKING ....................................................................................... 8-5
KICK CRANK NOT RETURNING ............................................................ 8-5
FAULTY BRAKE ........................................................................................... 8-5

POOR BRAKING EFFECT ...................................................................... 8-5
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION ......... 8-6
OIL LEAKAGE .......................................................................................... 8-6
MALFUNCTION ....................................................................................... 8-6
INSTABLE HANDLING ................................................................................. 8-6

INSTABLE HANDLING ............................................................................ 8-6
FAULTY SIGNAL AND LIGHTING SYSTEM ................................................ 8-7

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

FUEL SYSTEM
Fuel tank Carburetor
• Empty • Deteriorated fuel, fuel containing water or
• Clogged fuel filter foreign material
• Deteriorated fuel or fuel containing water or • Clogged pilot jet
foreign material • Clogged pilot air passage
• Clogged fuel tank cap • Sucked-in air
Fuel cock • Deformed float
• Clogged fuel hose • Groove-worn needle valve
• Clogged vacuum • Improperly sealed valve seat
• Faulty diaphragm • Improperly adjusted fuel level
Air cleaner • Improperly set pilot jet
• Clogged air filter • Clogged starter jet
• Starter plunger malfunction
• Improperly adjusted pilot air screw
ELECTRICAL SYSTEM
Spark plug CDI unit system
• Improper plug gap • Faulty CDI unit
• Worn electrodes • Faulty source coil
• Wire between terminals broken • Faulty pick-up coil
• Improper heat range Switches and wiring
• Faulty spark plug cap • Faulty main switch
Ignition coil • Broken or shorted wiring
• Broken or shorted primary/secondary coil • Faulty brake switch (front or rear)
• Faulty spark plug lead Auto choke
• Broken body • Broken or shorted wiring
Starter motor • Faulty auto choke unit
• Faulty starter motor
• Faulty starter relay
8-1
STARTING FAILURE/HARD STARTING/ TRBL
POOR IDLE SPEED PERFORMANCE SHTG
COMPRESSION SYSTEM
Cylinder and cylinder head Crankcase and crankshaft
• Loose spark plug • Improperly seated crankcase
• Loose cylinder head or cylinder • Improperly sealed crankcase
• Broken cylinder head gasket (damaged oil seal)
• Broken cylinder gasket • Seized crankshaft
• Worn, damaged or seized cylinder Reed valve
Piston and piston rings • Deformed reed valve stopper
• Improperly installed piston ring • Improperly seated reed valve
• Worn, fatigued or broken piston ring • Loose intake manifold
• Seized piston ring • Broken gasket
• Seized or damaged piston • Broken reed valve
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE
Carburetor
• Improperly returned starter plunger
• Clogged or loose pilot jet
• Clogged pilot air jet
• Improperly adjusted idle speed ( throttle stop screw)
• Improper throttle cable play
• Flooded carburetor
8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE/ TRBL
FAULTY AUTOMATIC SHTG
POOR MEDIUM AND HIGH SPEED PERFORMANCE
FUEL SYSTEM
Fuel tank Carburetor
• Clogged fuel filter • Deteriorated fuel, fuel containing water or
• Deteriorated fuel or fuel containing water or foreign material
foreign material • Sucked-in air
• Clogged fuel tank cap • Deformed float
Fuel cock • Groove-worn needle valve
• Clogged fuel hose • Improperly sealed valve seat
• Clogged vacuum hose • Improperly set clip position of jet needle
• Faulty diaphragm • Improperly adjusted fuel level
Air cleaner • Clogged or loose main jet
• Clogged air cleaner • Clogged or loose main nozzle
• Clogged main air passage
ELECTRICAL SYSTEM
Spark plug CDI unit system
• Improper plug gap • Faulty CDI unit
• Worn electrodes • Faulty source coil
• Wire between terminals broken • Faulty pick-up coil
• Improper heat range Auto choke
• Faulty spark plug cap • Broken or shorted wiring
• Faulty auto choke unit
COMPRESSION SYSTEM
Cylinder and cylinder head Crankcase and crankshaft
• Loose spark plug • Improperly seated crankcase
• Loose cylinder head or cylinder • Improperly sealed crankcase
• Broken cylinder head gasket (damaged oil seal)
• Broken cylinder gasket • Seized crankshaft
• Worn, damaged or seized cylinder
Piston and piston rings Reed valve
• Improperly installed piston ring • Deformed reed valve stopper
• Worn, fatigued or broken piston ring • Improperly adjusted reed valve stopper height
• Seized piston ring • Improperly sealing reed valve
• Seized or damaged piston • Loose intake manifold
• Broken gasket
• Broken reed valve
FAULTY AUTOMATIC (V-BELT TYPE)

MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING.
V-belt Secondary sheave
• Worn, damaged or slippery v-belt • Broken compression spring
Primary sheave • Pealed lining from clutch shoe
• Worn or damaged cam plate • Worn spline of clutch housing
• Worn or damaged slider bushing
8-3
FAULTY AUTOMATIC/ TRBL
OVER HEATING SHTG
CLUTCH-OUT FAILURE
Primary sheave Secondary sheave
• Seized primary sliding sheave and collar • Broken or fatigued clutch shoe spring
POOR STANDING START (LOW CLIMBING ABILITY)

V-belt Secondary sheave
• Worn, damaged or slippery v-belt • Fatigued compression spring
Primary sheave • Improper operation of secondary sliding sheave
• Worn or improper operation of weight
POOR ACCELERATION (POOR HIGH SPEED)

V-belt
• Worn or greasy V-belt
Secondary sheave
• Worn or greasy clutch shoe
• Improper operation of secondary sliding sheave
OVER HEATING
OVER HEATING
Ignition system Engine oil
• Improper spark plug gap • Improper engine oil quality (high viscosity)
• Improper spark plug heat range • Low engine oil quality
• Faulty ignitor unit
Brakes
Fuel system • Dragging brake
• Improper carburetor setting
• Improper fuel level adjustment Cooling fan
• Clogged air cleaner element • Damaged cooling fan
• Lean mixture (Air in the autolube pump) • Damaged air shrouds
Compression system
• Heavy carbon deposit build-up
8-4
IMPROPER KICKING/ TRBL
FAULTY BRAKE SHTG
IMPROPER KICKING
SLIPPING
Kick axle assembly Transmission oil
• Low tension of kick clip • Improper quality (low viscosity)
• Worn kick axle • Deterioration
• Worn or damaged kick gear
• Damaged kick clip
• Kick clip coming off
• Damaged kick clip stopper
HARD KICKING
Kick axle assembly Crankcase and crankshaft
• High tension of kick clip • Improperly seated crankcase
• Seized kick gear • Improperly seated crankshaft
• Damaged or seized crankshaft
Cylinder, piston and piston ring • Damaged or seized crankshaft bearing
• Damaged or seized cylinder
• Damaged or seized piston
• Damaged or seized piston ring
KICK CRANK NOT RETURNING

Kick axle assembly
• Damaged kick return spring
• Kick return spring coming off
• Kick clip coming off
• Damaged kick return spring stopper
FAULTY BRAKE
POOR BRAKING EFFECT
Front disc brake Rear drum brake
• Worn brake pads • Worn brake shoe
• Worn disc • Worn or rusty brake drum
• Air in brake fluid • Improperly adjuster brake play
• Leaking brake fluid • Improper brake cam lever
• Wrong brake fluid • Improper brake shoe position
• Seized main cylinder piston • Fatigue/damaged return spring
• Faulty caliper seal kit • Oily or greasy brake shoe
• Loose union bolt • Oily or greasy brake drum
• Broken brake hose • Broken brake cable
• Oily or greasy disc/brake pads
• Improper brake fluid level
• Excessive free play (brake lever)
8-5
FRONT FORK OIL LEAKAGE AND FRONT FORK
MALFUNCTION/ TRBL
INSTABLE HANDLING SHTG
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION
OIL LEAKAGE MALFUNCTION
• Bent, damaged or rusty inner tube • Bent, deformed or damaged inner tube
• Damaged or cracked outer tube • Bent or deformed outer tube
• Damaged oil seal lip • Damaged fork spring
• Improperly installed oil seal • Worn or damaged slide metal
• Improper oil level (too much) • Bent or damaged damper rod
• Loose damper rod holding bolt • Improper oil viscosity
• Broken cap bolt O-ring • Improper oil level
• Loose drain bolt or damaged drain bolt gasket
INSTABLE HANDLING
INSTABLE HANDLING
Handlebar Wheels
• Improperly installed or bent • Damaged bearing
• Bent or loose wheel axle
• Excessive wheel run-out
Steering Frame
• Improperly installed steering column • Twisted
(Improperly tightened ring nut) • Damaged head pipe
• Bent steering column • Improperly installed bearing race
• Damaged ball bearing or bearing race
Front forks Engine bracket

• Broken damper spring • Bent or damaged
• Bent or deformed suspension arm and pivots
• Oil level
Tires Rear shock absorber

• Incorrect tire pressure
• Uneven tire pressures on both sides • Fatigued spring
• Unevenly worn tires • Oil leakage
8-6
TRBL
FAULTY SIGNAL AND LIGHTING SYSTEM SHTG
FAULTY SIGNAL AND LIGHTING SYSTEM

Headlight dark Flasher does not light
• Improper bulb • Improperly grounded
• Too many electric accessories • Discharged battery
• Hard charging (broken charging coil) • Faulty flasher switch
• Incorrect connection • Faulty flasher relay
• Improperly grounded • Broken wire harness
• Poor contacts (main or light switch) • Loosely connected coupler
• Bulb life expired (high internal resistance) • Bulb burnt out
• Faulty fuse
Bulb burnt out Flasher keeps on

• Improper bulb • Faulty flasher relay
• Improperly grounded • Insufficient battery capacity
• Faulty main and/or light switch (nearly discharged)
• Bulb life expired
Flasher winks slower Horn is inoperative

• Faulty flasher relay • Faulty battery
• Insufficient battery capacity (nearly discharged) • Faulty fuse
• Improper bulb • Faulty main and/or horn switch
• Faulty main and/or flasher switch • Improperly adjusted horn
• Faulty horn
• Broken wire harness
Flasher winks quicker
• Improper bulb
• Faulty flasher relay
8-7
YH50 WIRING DIAGRAM (EXCEPT SWITZERLAND) Q
W
Handlebar switch (right)
"START" switch
E "LIGHT" switch
R Resistor
Q T Main switch
T
E I Y Ignition coil
W R BW B Gy R Br
Y
YB YR L LOCK
U O U Spark plug
OFF
LW B OFF
ON
OFF
CHECK P { I Rectifier / regulator
ON ON
- - - -
O Fuel sender
Gy B
BW
YR B W R
P Oil level gauge
(GREEN)
Br Br R G B
f B YB L
LW YR
YB B YR B W R
G B { Auto choke
GY Br
LW YR
Br R
Gy B Or G B
} Rear flasher (right)
q Tail / "STOP" light
(BLACK)
B YB L
B
Br GY Br B Gy R BW Dg
d GY
YR B L LW YB
Br Gy YR B
B } w Rear flasher (left)
Fuse
YR B
e
s r Starter motor
(BLACK)
Dg B
B
F Gy
G B G G B
B
G
Dg B
t Starter relay
B
Br
Br Gy Gy Br Br
Gy
Dg B y Battery
E B
CDI unit
L L
L
L u
a i CDI magneto
: L
Horn
L L
{
GY GY GY q o
L Y Y
B
B B p Handlebar switch (left)
H K B
L Ch Dg Dg Ch
L
B
[ Flasher switch
J
Dg
Ch
L B B L Ch
Dg
Ch B
] "HORN" switch
B Ch A "HI / LO" switch
B Ch
S Front flasher light (left)
G
Br/W Br/W
B
D Front flasher light (right)
Br Br
e Ch w F Head light
LW GY G Flasher relay
Y
H Speedometer
B B B BrW L Ch Dg B P BR WR BW
B B J Flasher indicator light
F 187,5 B Y Y Y B Or
R
G G G
Dg BrW P
W YR R R
K Meter light
P Br W YR - B Or
L "HIGH BEAM" indicator light
(BLACK)
G Ch L B R
W YR - B Or R
Fuel meter
(BLACK)
Ch L B LW GY
:
D Dg
B
B
Dg Dg
B B
Dg
Dg BrW P
WR BR BR WR BW B Or - + R R
a Meter light
G Y L B P Ch BrW Dg
s Oil warning indicator light
S
B
B B B
B d Rear brake switch
Ch
Ch Ch
u y t Front brake switch
Ch
o f
(GREEN)
i r
G L Y B P Ch BrW Dg
HI OFF L
LOW ON N
R
A ] [
p
COLOR CODE
B Black L Blue Y Yellow G/Y Green/Yellow
Br Brown Or Orange B/R Black/Red L/W Blue/White
Ch Chocolate P Pink B/W Black/White W/R White/Red
Dg Dark green R Red Br/W Brown/White Y/B Yellow/Black
G Green Sb Sky blue Br/Y Brown/Yellow Y/R Yellow/Red
Gy Grey W White G/B Green/Black
YH50 WIRING DIAGRAM (ONLY FOR SWITZERLAND) Q
W
Handlebar switch (right)
"START" switch
E "LIGHT" switch
R Resistor
T Main switch
Q Y Ignition coil
T U Spark plug
W E R Y I
YB YR L LOCK
BW B Gy R Br
U O I Rectifier / regulator
OFF
LW B OFF
ON
OFF
CHECK P { O Fuel sender
ON ON
P Oil level gauge
Auto choke
- - - -
Gy B
BW
YR B W R {
Rear flasher (right)
(GREEN)
Br
f B YB L YB B
Br R YR B W R
G
G
B
B
}
GY Br LW YR
LW YR
Br R q Tail / "STOP" light
Gy B Or G B
w Rear flasher (left)
(BLACK)
B YB L
B
Br GY Br B Gy R BW
d YR B L LW YB
Br Gy YR B Dg
B } e Fuse
GY
YR B
r Starter motor
s t Starter relay
(BLACK)
Dg B
F
B
Gy B Dg B y Battery
CDI unit
G B G G B G
B Br L u
Br
Br Gy Gy Br Dg B
g
E B
L L L
Gy
L
B
i CDI magneto
a o Horn
: L L L L L L
p Handlebar switch (left)
{
GY GY GY
GY GY GY q
B
B
B
B [ Flasher switch
L Y Y B B
L ] "HORN" switch
H K B
L B
"HI / LO" switch
Ch Dg Dg Ch
Dg Ch B A
J Ch
L B B L Ch
Dg
B Ch
S Front flasher light (left)
B Ch D Front flasher light (right)
G
Br/W Br/W F Head light
Flasher relay
B
Br Br
e Ch w G
LW GY
H Speedometer
Y J Flasher indicator light
B B B BrW L Ch Dg B P BR WR BW
B B
K Meter light
F 187,5 B Y
G
Y
G
Y
G
W YR
B Or
R
R R L "HIGH BEAM" indicator light
Fuel meter
Dg BrW P
P Br W YR - B Or :
(BLACK)
G Ch L B R
Meter light
W YR B Or R
-
a
(BLACK)
Ch L B LW GY
D Dg
B
B
Dg Dg
B B
Dg
Dg BrW P
WR BR BR WR BW B Or - + R R
s Oil warning indicator light
G Y L B P Ch BrW Dg d Rear brake switch
B
B B B f Front brake switch
S Ch
Ch Ch Ch u y t
B
g License light
o
(GREEN)
i r
G L Y B P Ch BrW Dg
HI OFF L
LOW ON N
R
A ] [
p
COLOR CODE
B Black L Blue Y Yellow G/Y Green/Yellow
Br Brown Or Orange B/R Black/Red L/W Blue/White
Ch Chocolate P Pink B/W Black/White W/R White/Red
Dg Dark green R Red Br/W Brown/White Y/B Yellow/Black
G Green Sb Sky blue Br/Y Brown/Yellow Y/R Yellow/Red
Gy Grey W White G/B Green/Black

Yamaha YH50 19992006 EN

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Yamaha YH50 19992006 EN

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Available Formats

YH50 '99

PARTICULARY IMPORTANT INFORMATION

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

WARNING Failure to follow WARNING instructions could result in severe injury or

CAUTION: A CAUTION indicates special precautions that must be taken to avoid

NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

% T.R 37 Nm (3.7 m.kg) • Nut ! (rotor)

Illustrated symbols O to r are used to identify

i o p t Apply engine oil

SCOOTER IDENTIFICATION ........................................................................ 1-1

IMPORTANT INFORMATION ...................................................................... 1-2

CHECKING OF CONNECTIONS .................................................................. 1-4

HOW TO USE THE CONVERSION TABLE .................................................. 1-5

SPECIAL TOOLS .......................................................................................... 1-6

ENGINE SERIAL NUMBER

2.Dry each terminal with an air blower.

3.Connect and disconnect the connector two or

! 4.Pull the lead to check that it will not come off.

5.If the terminal comes off, bend up the pin !

- + 7.Check for continuity with a tester.

Metric unit Multiplier Imperial unit

Tool N° Tool name/usage Illustration

90890-01135 Crankcase separating tool

This tool is used to separate the crank-

90890-01189 Flywheel puller

This tool is used to remove the flywheel

90890-01235 Rotor holding tool

This tool is used to remove the flywheel

90890-01274 Crankshaft installer set.

This tool is used when removing or

90890-01701 Sheave holder

This tool is used to hold the secondary

This tool is used for compressing the

Tool N° Tool name/usage Illustration

9079Q-02218 Ring nut wrench.

This tool is used to loosen and tighten the

These tools are used when installing the

This instrument is invaluable for checking

This tool is needed for detecting the

This instrument is necessary for checking

GENERAL SPECIFICATIONS ...................................................................... 2-1

MAINTENANCE SPECIFICATIONS ............................................................. 2-4

GENERAL TORQUE SPECIFICATIONS ................................................... 2-13

LUBRICATION POINT AND GRADE OF LUBRICANT .............................. 2-14

CABLE ROUTING ....................................................................................... 2-16

Measuring point* 5 mm ***

Piston clearance 0.034 ~ 0.047 mm 0.1 mm

Top ring B 1.2 x 1.8 mm (B)(E)(F)(GB)(I)(P) ***

Crank width “A” 37.90 ~ 37.95 mm ***

Model Standard Limit

Model Standard Limit

A: Distance across flats.

LUBRICATION POINTS AND GRADE OF LUBRICANT

Lubrication points Lubricant type

Secondary sheave axle bearing

Starter idle gear

Secondary sliding sheave cam groove BEL-RAY® assembly lube

Lubrication points Lubricant type

Rear wheel oil seal LS

Steering bearing and bearing race (upper/lower) LS

Throttle grip inner surface LS

Lever pivots and cable end LS