02-05 Zuma SM PDF

2002 - 2005
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MOTORCYCLE
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SERVICE MANUAL
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Model : YW50P, YW50R, YW50S, YW50T

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5PNF81972000 *5PNF81972000*
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EBO00000
YW50BP
SERVICE M A N U A L
©2001 by Yamaha M o t o r Taiwan Co,.Ltd.
First edition, November 2001
All rights reserved.
A n y reprinting or unauthorized use
w i t h o u t the w r i t t e n permission of
Yamaha M o t o r Taiwan Co,.Ltd.
is expressly prohibited.
EB001000
NOTICE
T h i s m a n u a l w a s p r o d u c e d b y t h e Y a m a h a M o t o r C o m p a n y , Ltd. p r i m a r i l y for use b y Y a m a h a deal-
ers and t h e i r q u a l i f i e d m e c h a n i c s . It is not p o s s i b l e to i n c l u d e all t h e k n o w l e d g e o f a m e c h a n i c in
one m a n u a l . Therefore, a n y o n e w h o uses t h i s b o o k to p e r f o r m m a i n t e n a n c e and repairs on Y a m a h a
v e h i c l e s s h o u l d have a basic u n d e r s t a n d i n g of m e c h a n i c s and the t e c h n i q u e s to repair these t y p e s
of vehicles. Repair and m a i n t e n a n c e w o r k a t t e m p t e d by a n y o n e w i t h o u t t h i s k n o w l e d g e is likely to
r e n d e r t h e v e h i c l e u n s a f e and unfit for use.
Y a m a h a M o t o r C o m p a n y , Ltd. is c o n t i n u a l l y s t r i v i n g to i m p r o v e all of its m o d e l s . M o d i f i c a t i o n s

and s i g n i f i c a n t c h a n g e s in s p e c i f i c a t i o n s or p r o c e d u r e s w i l l be f o r w a r d e d to all a u t h o r i z e d Y a m a h a
deal-ers and w i l l a p p e a r in f u t u r e e d i t i o n s of t h i s m a n u a l w h e r e applicable.
NOTE:
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D e s i g n s and s p e c i f i c a t i o n s are subject to c h a n g e w i t h o u t notice.
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IMPORTANT MANUAL INFORMATION

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P a r t i c u l a r l y i m p o r t a n t i n f o r m a t i o n is d i s t i n g u i s h e d in t h i s m a n u a l by the f o l l o w i n g .
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ZL The Safety Alert Symbol means ATTENTION! BECOME ALERT! Y O U R

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SAFETY IS INVOLVED!
Failure to f o l I o w W A R N I N G i n s t r u c t i o n s could result in severe i n j u r y or death

~'~,WARNING
to the s c o o t e r o p e r a t o r , a b y s t a n d e r or a p e r s o n c h e c k i n g or r e p a i r i n g the
scooter.
CAUTION: A C A U T I O N i n d i c a t e s special p r e c a u t i o n s t h a t m u s t be taken to a v o i d d a m -

age to the scooter.
NOTE: A NOTE p r o v i d e s key i n f o r m a t i o n to make p r o c e d u r e s easier or clearer.

HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. C o m p r e h e n s i v e
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
(~ The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter. Refer to " S Y M B O L S " .
(~ Each chapter is divided into sections. The current section title is shown at the top of each
page, except in Chapter 3 ("PERIODIC CHECKS A N D A D J U S T M E N T S " ) , w h e r e the sub-sec-
tion title(s) appears.
(~ Sub-section titles appear in smaller print than the section title.
(~ To help identify parts and clarify procedure steps, there are exploded d i a g r a m s at the start of
each removal and disassembly section.
(~ N u m b e r s are given in the order of the jobs in the exploded diagram. A circled n u m b e r indi-
cates a disassembly step.
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(~ S y m b o l s indicate parts to be lubricated or replaced. Refer to " S Y M B O L S " .
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(~) A job instruction chart accompanies the exploded diagram, providing the order of jobs, names
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of parts, notes in jobs, etc.
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(~ Jobs requiring more information (such as special tools and technical data) are described sequen-
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tially.
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CYLINDEB HEAD" CYF~:N::R: P ~ ~

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1. Remove:
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Begore removing tha piston pin celt,, cover the

' crankcase with a clean rag so y o u will not acci
ed
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• Piston pTn 1~
® • Piston ®
• Piston pin bearing ~
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GA~ON~
Donot use a h a m m e r t o d r i v e t h e piston pin
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CYUNDER HEAD INSPECTION

~. Elhxlin~te:
• Carbon deposits
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Use a rounded ~crapper
Q'ty Rurllark~ • Cylinder head war~3age

Out of specification >Re8ur'0ce.
Cvlinder head. Cylinder and piston Remove the pa~s Enthe order
removal Warpage measurement a n d re s u r f a c e m e n t
Engine Refer to the "ENGINE REMOVAL" sec-
1 Muffler/Gasket 1/1 tion • Attach a =traight e d g e ~ a n d a thickness
2 A i r ~hroud (cylTnder head) 1 g a u g e ( ~ on the cylinder head.
3 SparkIJlug 1 • M e a s u r e the w a r p a g e limit.
4 Cylinder head/Cylinder head gasket 1/1
Cylinder 1
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7
8
Piston pin clip
Piston p i n / B e a r i n g
Piston
2
1 • If the w a r p a g e is out of specification, reface
I
9 Pistonring set 1 t h e cylinder head.
10 CyITnder gasket 1 NOTE:
Reverse the r e m o v a l procedure f o r in Rotate the head severaT tTres t o a v o i d r e m o v -
stallatien. ing too m u c h moteriol f r o m o n e side.
4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - -
Q ® EAS00009
SYMBOLS
GEN
INFO SPEC The following symbols are not relevant to ev-
ery vehicle.
® ® Symbols (~to (~ are designed as thumb tabs
to indicate the chapter's number and content.
INSP
ENG ~)~ (~ General information
(~ Specifications
® ® (~ Periodic inspection and adjustment
Engine
CARB CHAS ( ~ ® (~) Carburetor(s)
(~ Chassis
(~ Electrical system
® (~ Troubleshooting
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ELEC TRBL w.~
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SHTG •
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® @ Symbols (~ to (~) indicate the following.
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® Serviceable with engine mounted
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@ Filling fluid
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@ Lubricant
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® @ @ Special tool
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@ Tightening torque
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@ Wear limit, clearance

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@ Engine speed
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@ @ Electrical data
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Symbols @to @ in the exploded diagrams in-

dicate the types of lubricants and lubrication
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(~ Engine oil
@ Gear oil
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® i i 1 (~) Molybdenum disulfide oil

(~ Wheel bearing grease
(~ Lithium soap base grease
® ® @ (~) Molybdenum disulfide grease
Symbols@ to @ in the exploded diagrams

indicate the following.
@ @ (~ Apply locking agent (LOCTITE ®)
(~ Replace the part
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INDEX
GENERAL INFORMATION
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SPECIFICATIONS
PERIODIC INSPECTION AND
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ADJUSTMENT
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ENGINE O V E R H A U L
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CARBURETION
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CHASSIS
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ELECTRICAL
TROUBLESHOOTING
CHAPTER 1.
GENERAL INFORMATION
SCOOTER INDENTIFICATION ........................................................................................................... 1-1

VEHICLE IDENTIFICATION NUMBER ........................................................................................... 1-1
MODEL CODE ................................................................................................................................ 1-1
IMPORTANT INFORMATION ............................................................................................................ 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY ................................................................ 1-2
REPLACEMENT PARTS ................................................................................................................. 1-2
GASKETS, OIL SEALS AND O-RINGS .......................................................................................... 1-2
LOCK WASHERS/PLATES AND COTTER P I N S ........................................................................... 1-2
BEARINGS AND OIL SEALS ......................................................................................................... 1-3
CIRCLIPS ........................................................................................................................................ 1-3
CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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H O W T O U S E THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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CONVERSION TABLE .................................................................................................................... 1-5
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SPECIAL TOOLS ................................................................................................................................ 1-6
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C H A P T E R 2.
SPECIFICATIONS
GENERAL SPECIFICATION ............................................................................................................... 2-1

MAINTENANCE SPECIFICATION ..................................................................................................... 2-4
ENGINE .......................................................................................................................................... 2-4
TIGHTENING TORQUES ............................................................................................................... 2-6

ENGINE .......................................................................................................................................... 2-6
CHASSIS ........................................................................................................................................ 2-7
TIGHTENING TORQUES ............................................................................................................... 2-8

CHASSIS ........................................................................................................................................ 2-8

ELECTRICAL ................................................................................................................................... 2-9
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GENERAL TORQUE SPECIFICATIONS ........................................................................................... 2-1 1
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LUBRICATION POINTS AND LUBRICATION TYPE ....................................................................... 2-12
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ENGINE ........................................................................................................................................ 2-12
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CHASSIS ...................................................................................................................................... 2-13
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CABLE ROUTING ............................................................................................................................. 2-14
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CHAPTER 3.
PERIODIC I N S P E C T I O N A N D A D J U S T M E N T S
INTRODUCTION ................................................................................................................................ 3-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ................................................................ 3-1
COVER AND PANEL .......................................................................................................................... 3-3
SIDECOVER AND SEAT ................................................................................................................ 3-3
LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 A N D FOOTREST BOARD ..................... 3-4
HANDLEBAR COVER(FRONT AND REAR) ................................................................................... 3-5
ENGINE ..............................................................................................................................................3 - 6
IDLE SPEED ADJUSTMENT .......................................................................................................... 3-6
THROTTLE CABLE FREE ADJUSTMENT ..................................................................................... 3-7
AUTOLUBE PUMP AIR BLEEDING ............................................................................................... 3-8
SPARK PLUG INSPECTION ........................................................................................................... 3-9
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ENGINE OIL LEVEL INSPECTION ............................................................................................... 3-10
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TRANSMISSION OIL REPLACEMENT ........................................................................................ 3-11
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AIR FILTER ELEMENT CLEANING .............................................................................................. 3-12
V-BELT INSPECTION ................................................................................................................... 3-14
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CHASSIS ..........................................................................................................................................3-15
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FRONT BRAKE LEVER FREE PLAY CHECK ................................................................................ 3-15
REAR BRAKE
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LEVER FREE PLAY CHECK ................................................................................... 3-15
BRAKE PAD INSPECTION ........................................................................................................... 3-15
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BRAKE SHOE INSPECTION ........................................................................................................ 3-16

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BRAKE FLUID LEVEL INSPECTION ............................................................................................ 3-16

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AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ........................................................................ 3-17

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STEERING ADJUSTMENT .......................................................................................................... 3-18

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TIRE INSPECTION ........................................................................................................................3-19

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WHEEL INSPECTION ................................................................................................................... 3-22

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FRONT FORK INSPECTION ......................................................................................................... 3-22

REAR SHOCK ABSORBER INSPECTION .................................................................................... 3-22
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SEAT LOCK CABLE ADJUSTMENT ........................................................................................... 3-22

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CABLE CHECKING AND LUBRICATING ..................................................................................... 3-23

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LEVERS LUBRICATING ............................................................................................................... 3-23

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CENTERSTAND LUBRICATING .................................................................................................. 3-23

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ELECTRICAL .....................................................................................................................................3-24
BATTERY INSPECTION ............................................................................................................... 3-24
FUSE INSPECTION ......................................................................................................................3-29
HEADLIGHT BEAM ADJUSTMENT ............................................................................................ 3-30
HEADLIGHT BULB REPLACEMENT ............................................................................................ 3-30
TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT ........................................................... 3-31
TAILLIGHT BULB REPLACEMENT .............................................................................................. 3-32
LICENSE LIGHT BULB REPLACEMENT ...................................................................................... 3-32
C H A P T E R 4.
ENGINE
E N G I N E O V E R H A U L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
WlREHARNESS AND CABLES ...................................................................................................... 4-1
C Y L I N D E R HEAD, C Y L I N D E R A N D P I S T O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
CYLINDER HEAD, CYLINDER AND PISTON ................................................................................ 4-3
PISTON PIN AND PISTON REMOVAL .......................................................................................... 4-4
CYLINDER HEAD INSPECTION ..................................................................................................... 4-4
CYLINDER AND PISTON INSPECTION ........................................................................................ 4-5
PISTON RINGS INSPECTION ........................................................................................................ 4-7
PISTON PIN AND PISTON PIN BEARING .................................................................................... 4-7
PISTON PIN AND PISTON INSTALLATION ................................................................................. 4-8
CYLINDER AND CYLINDER HEAD ................................................................................................ 4-9
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V-BELT, C L U T C H A N D S E C O N D A R Y / P R I M A R Y S H E A V E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1
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KICK STARTER AND CRANKCASE COVER(LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1
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KICK STARTER ............................................................................................................................. 4-12
KICK STARTER INSTALLATION ................................................................................................. 4-13
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V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................ 4-14
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SECONDARY SHEAVE ................................................................................................................ 4-15
PRIMARY SHEAVE REMOVAL
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.................................................................................................... 4-16
SECONDARY SHEAVE REMOVAL .............................................................................................. 4-16
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CLUTCH INSPECTION ................................................................................................................. 4-17

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V-BELT INSPECTION ................................................................................................................... 4-18

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PRIMARY SHEAVE INSPECTION ................................................................................................ 4-19

SECONDARY SHEAVE ................................................................................................................ 4-20
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SECONDARY SHEAVE INSTALLATION ..................................................................................... 4-21

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PRIMARY SHEAVE ...................................................................................................................... 4-22

STARTER CLUTCH A N D STARTER M O T O R ................................................................................. 4-24
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STARTER CLUTCH AND STARTER MOTOR .............................................................................. 4-24

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STARTER CLUTCH AND GEARS INSPECTION ......................................................................... 4-26

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C.D.I. MAGNET ................................................................................................................................ 4-27

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C.D.I. MAGNETO ......................................................................................................................... 4-27

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C.D.I. MAGNETO REMOVAL ....................................................................................................... 4-28

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C.D.I. MAGNETO INSTALLATION .............................................................................................. 4-28

A U T O L U B E P U M P ........................................................................................................................... 4-29
AUTOLUBE PUMP ....................................................................................................................... 4-29
AUTOLUBE PUMP INSTALLATION ........................................................................................... 4-30
T R A N S M I S S I O N .............................................................................................................................. 4-31
TRANSMISSION .......................................................................................................................... 4-31
C R A N K C A S E A N D REED V A L V E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 3
CRANKCASE AND REED VALVE ................................................................................................ 4-33
CRANKCASE(RIGHT) REMOVAL ................................................................................................ 4-35
CHECKING THE CRANKCASE .................................................................................................... 4-35
CHECKING THE BEARINGS AND OIL SEALS ............................................................................ 4-35
REED VALVE INSPECTION ......................................................................................................... 4-36
CRANKCASE (RIGHT) INSTALLATION ...................................................................................... 4-36
C R A N K S H A F T .................................................................................................................................. 4-38
CRANKSHAFT .............................................................................................................................. 4-38
CRANKSHAFT REMOVAL ........................................................................................................... 4-39
CRANKSHAFT INSPECTION ....................................................................................................... 4-39
CRANKSHAFT INSTALLATION ................................................................................................... 4-40
CHAPTER 5
CARBURETION
CARBURETION .................................................................................................................................. 5-1
CARBURETOR ................................................................................................................................ 5-1

CABURETOR DISASSEMBLY ....................................................................................................... 5-2
CABURETOR INSPECTION ........................................................................................................... 5-3
CARBURETOR ASSEMBLY ........................................................................................................... 5-5
FUEL LEVEL ADJUSTMENT ......................................................................................................... 5-6
AUTO CHOKE INSPECTION .......................................................................................................... 5-7
FUEL COCK INSPECTION ............................................................................................................. 5-8
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CHAPTER 6
CHASSIS
F R O N T W H E E L A N D B R A K E D I S C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
FRONT WHEEL AND BRAKE D I S C ............................................................................................... 6-1
FRONT WHEEL DISASSEMBLY .................................................................................................... 6-2
FRONT WHEEL DISASSEMBLY .................................................................................................... 6-3
FRONT WHEEL INSPECTION ........................................................................................................ 6-3
BRAKE DISC INSPECTION ............................................................................................................ 6-4
FRONT WHEEL ASSEMBLY .......................................................................................................... 6-4
FRONT WHEEL INSTALLATION ................................................................................................... 6-5
WHEEL STATIC BALANCE ADJUSTMENT .................................................................................. 6-6
F R O N T B R A K E ................................................................................................................................... 6-8
BRAKE P A D .................................................................................................................................... 6-8
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BRAKE PAD REPLACEMENT ........................................................................................................ 6-9
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MASTER CYLINDER ........................................................................................................................ 6-12
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MASTER CYLINDER DISASSEMBLY ............................................................................................. 6-13
MASTER CYLINDER INSPECTION .............................................................................................. 6-14
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MASTER CYLINDER ASSEMBLY ................................................................................................ 6-14
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MASTER CYLINDER INSTALLATION ......................................................................................... 6 - 1 5
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CALIPER ........................................................................................................................................... 6 - 1 7
CALIPER DISASSEMBLY ................................................................................................................. 6-18
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BRAKE CALIPER DISASSEMBLY ................................................................................................ 6-19

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CALIPER INSPECTION ................................................................................................................. 6 - 1 9

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BRAKE CALIPER ASSEMBLY ...................................................................................................... 6-20

BRAKE CALIPER INSTALLATION ............................................................................................... 6 - 2 0
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REAR W H E E L A N D REAR BRAKE .................................................................................................. 6-21

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REAR WHEEL ............................................................................................................................... 6-21

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R E A R B R A K E ................................................................................................................................ 6-22
REAR WHEEL INSPECTION ........................................................................................................ 6-23
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REAR BRAKE INSPECTION ......................................................................................................... 6-23

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REAR BRAKE INSTALLATION .................................................................................................... 6-24

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HANDLEBAR .................................................................................................................................... 6-25

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HANDLEBAR ................................................................................................................................ 6-25

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HAN DLE BAR INSTALLATIO N ..................................................................................................... 6-27

STEERING ........................................................................................................................................ 6-29
STEERING .................................................................................................................................... 6-29
STEERING REMOVAL ................................................................................................................. 6 - 3 0
STEERING INSPCTION ................................................................................................................ 6-31
STEERING INSTALLATION ......................................................................................................... 6-31
F R O N T FORK ................................................................................................................................... 6 - 3 4
FRONT FORK ............................................................................................................................... 6-34
FRONT FORK DISASSEMBLY ..................................................................................................... 6-35
FRONT FORK REMOVAL ............................................................................................................. 6-36
FRONT FORK DISASSEMBLY ..................................................................................................... 6-36
FRONT FORK INSPECTION ......................................................................................................... 6-37
FRONT FORK ASSEMBLY ........................................................................................................... 6-37
FRONT FORK INSTALLATION .................................................................................................... 6-39
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS ............................................................................................................ 7-1

ELECTRICAL COMPONENTS ........................................................................................................ 7-1
CIRCUIT DIAGRAM ........................................................................................................................ 7-2
CHECKING SWITCHES ...................................................................................................................... 7-4
CHECKING STEPS ......................................................................................................................... 7-4
SWITCH CONNECTION AS SHOWN IN THIS MANUAL ............................................................. 7-4
S W I T C H P O S I T I O N A N D T E R M I N A L C O N N E C T I O N ...................................................................... 7-5
C H E C K I N G T H E B L U B S A N D B U L B S O C K E T S ............................................................................... 7-5
CHECKING THE BULBS AND BULB SOCKETS ........................................................................... 7-6
TYPES OF BULBS .......................................................................................................................... 7-6
CHECKING THE CONDITION OF THE BULBS .............................................................................. 7-7
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CHECKING THE CONDITION OF THE BULB SOCKETS .............................................................. 7-8
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IGNITION SYSTEM ............................................................................................................................ 7-9
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CIRCUIT DIAGRAM ........................................................................................................................ 7-9
TROUBLESHOOTING .................................................................................................................. 7-10
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CHARGING SYSTEM ....................................................................................................................... 7-14
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CIRCUIT DIAGRAM ...................................................................................................................... 7-14
TROUBLESHOOTING
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.................................................................................................................. 7-15
ELECTRIC STARTING SYSTEM ...................................................................................................... 7-18
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CIRCUIT DIAGRAM ...................................................................................................................... 7-18

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STARTER MOTOR ....................................................................................................................... 7-22

STARTER MOTOR DISASSEMBLY ............................................................................................. 7-23
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INSPECTION AND REPAIR .......................................................................................................... 7-24

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LIGHTING SYSTEM ......................................................................................................................... 7-26

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CIRCUIT DIAGRAM ...................................................................................................................... 7-26

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LIGHTING SYSTEM CHECK ........................................................................................................ 7-29

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SIGNAL SYSTEM ............................................................................................................................. 7-33

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CIRCUIT DIAGRAM ...................................................................................................................... 7-33

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SIGNAL SYSTEM CHECK ............................................................................................................ 7-36

AUTO CHOKE SYSTEM .................................................................................................................. 7-42
CIRCUIT DIAGRAM ...................................................................................................................... 7-42
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD S T A R T I N G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

FUEL SYSTEM ............................................................................................................................... 8-1
IGNITION SYSTEM ........................................................................................................................ 8-2
COMPRESSION SYSTEM ............................................................................................................. 8-2
P O O R IDLE S P E E D P E R F O R M A N C E ................................................................................................ 8-3
POOR IDLE SPEED PERFORMANCE ............................................................................................ 8-3
POOR MIDIUM AND HIGH SPEED PERFORMANCE ....................................................................... 8-3
POOR MIDIUM AND HIGH SPEED PERFORMANCE ................................................................... 8-3
FULTY AUTOMATIC(V-BELT TYPE) ................................................................................................. 8-4
SCOOTER DOES NOT MOVE WHILE ENGINE IS O P E R A T I N G .................................................. 8-4
CLUTCH OUT FAILURE ................................................................................................................. 8-4
et
POOR STANDING START(LOW CLIMBING ABILITY) ................................................................. 8-4
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e.
POOR ACCELERATION(POOR HIGH SPEED) .............................................................................. 8-4
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O V E R H E A T ........................................................................................................................................ 8-5
OVERHEAT ..................................................................................................................................... 8-5
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P O O R S P E E D ..................................................................................................................................... 8-5
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POOR SPEED ................................................................................................................................. 8-5
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I M P R O P E R KICKING .......................................................................................................................... 8-6
SLIPPING ........................................................................................................................................ 8-6
.S
HARD KICKING .............................................................................................................................. 8-6

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KICK CRANK NOT RETURNING ................................................................................................... 8-6

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F A U L T Y BRAKE ................................................................................................................................. 8-7

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POOR BRAKING E F F E C T ............................................................................................................... 8-7

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MALFUNCTION ............................................................................................................................. 8-7

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INSTABLE HANDLING ...................................................................................................................... 8-8

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INSTABLE HANDLING .................................................................................................................. 8-8

FAULTY SIGNAL AND LIGHTING SYSTEM .................................................................................... 8-9
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HEADLIGHT D A R K ......................................................................................................................... 8-9

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BULB BURNT OUT ........................................................................................................................ 8-9

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FLASHER DOES NOT B L I N K ......................................................................................................... 8-9

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FLASHER K E E P S O N ..................................................................................................................... 8-9

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FLASHER BLINKS SLOWER ........................................................................................................ 8-10

FLASHER BLINKS QUICKER ....................................................................................................... 8-10
HORN DOES NOT SOUND ......................................................................................................... 8-10
SCOOTER INDENTIFICATION
I GEN
f
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE I D E N T I F I C A T I O N N U M B E R
The vehicle identification number (~) is stamped
into the frame.
f
EAS00018
M O D E L CODE
The model code label ~) is affixed to the loca-
tion s h o w n in the figure. Record the informa-
tion on this label in the space provided. This
et
information will be needed to order spare parts.
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1-1
IMPORTANT INFORMATION I GEN
EAS00020
IMPORTANT INFORMATION
P R E P A R A T I O N FOR R E M O V A L A N D D I S A S -
SEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
2. Use o n l y the proper tools and cleaning
equipment.
Refer to "SPECIAL TOOLS".
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have
been
" m a t e d " t h r o u g h normal wear. M a t e d
parts must always be reused or replaced
et
as an assembly.
n
4. During disassembly, clean all o f t h e parts
e.
and place them in trays in the order of dis-
im
assembly. This will speed up a s s e m b l y
and allow for the correct installation of all
T
parts.
er
300-008
5. Keep all parts a w a y from any source of
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co fire.
.S
EAS00021
R E P L A C E M E N T PARTS
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Use o n l y genuine Yamaha parts for all replace-

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ments. Use oil and grease recom-mended by

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Yamaha for all lubrication jobs.

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Other brands may be similar in function and

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appearance, but inferior in quality.

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300-016
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EAS00022
G A S K E T S , OIL SEALS A N D O - R I N G S
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1. When overhauling the engine, replace all

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gaskets, seals and O-rings. All gasket sur-

ow
faces, oil seal lips and O-rings must be

D
cleaned.
2. During reassembly, properly oil all mat-
ing parts and bearings and lubricate the
oil seal lips w i t h grease.
EAS00023
LOCK W A S H E R S / P L A T E S A N D C O T T E R PINS
After removal, replace all lock washers/plates
~ ) a n d cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat o f t h e bolt or nut.
1-2
IMPORTANT INFORMATION I ,NFOI
GEN I
EAS00024
~\\\\\\\\~1 BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu
facturer's marks or n u m b e r s are visible. W h e n
installing oil seals, lubricate the oil seal l i p s w i t h
a light coat of lithium soap base grease.
Oil bearings liberally w h e n installing, if appro
priate.
~) Oil seal
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
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(~ Bearing
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EAS00025
.S
CIRCLIPS
Before reassembly, check all circlips carefully
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and replace d a m a g e d or distorted circlips,

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A l w a y s replace piston pin clips after one use.

W h e n installing a circlip (~), make sure the
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s h a r p - e d g e d corner (~) is positioned o p p o s i t e

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the t h r u s t ~ that the circlip receives.

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(~ Shaft
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1-3
IMPORTANT INFORMATION I GEN
EB801000
CHECKING OF C O N N E C T I O N S
D e a l i n g w i t h stains, rust, m o i s t u r e , etc. on t h e
connector.
1. D i s c o n n e c t :
• Connector
2. D r y each t e r m i n a l w i t h an air b l o w e r .
3. C o n n e c t and d i s c o n n e c t t h e c o n n e c t o r t w o
or t h r e e .
4. Pull t h e read to c h e c k t h a t it w i l l not c o m e
et
off.
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5. If t h e t e r m i n a l c o m e s off, b e n d up t h e pin
e.
( ~ a n d r e i n s e r t t h e t e r m i n a l into t h e c o n -
im
Rector.
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er
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6.
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Connect:
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• Connector
NOTE:
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The two connectors "click" together.

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7. Check for continuity with a tester.

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NOTE:
ed
• If t h e r e is no c o n t i n u i t y , c l e a n t h e t e r m i -
ad
nals.
o
• Be s u r e to p e r f o r m t h e s t e p s 1 to 7 listed
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above when checking the wireharness.

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• For a field r e m e d y , use a c o n t a c t revitalizer

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a v a i l a b l e on t h e m a r k e t .
• Use t h e t e s t e r on t h e c o n n e c t o r as s h o w n .
1-4
H O W TO USE THE C O N V E R S I O N TABLE
I GEN
EB201000
H O W TO USE THE C O N V E R S I O N TABLE

All s p e c i f i c a t i o n data in t h i s m a n u a l are listed in SI and M E T R I C U N I T S .
Use t h i s t a b l e to c o n v e r t M E T R I C u n i t data t o I M P E R I A L u n i t data.
Ex.
METRIC MULTIPLIER IMP
** mm x 0.03937 = * * in
2 mm x 0.03937 = 0.083 in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result

m.kg 7.233 ft.lb
et
Torque m.kg 86.794 in.lb
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cm.kg 0.0723 ft.lb
e.
cm.kg 0.8679 in.lb
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Weight kg 2.205 Ib
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g 0.03527 oz
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km/h 0.6214 mph
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km 0.6214 co mi
Distance m 3.281 ft
.S
m 1.094 yd
ca 0.3937 in
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mm 0.03937 in
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Volume/ cc(cm 3) 0.03527 oz (IMP liq.)

Capacity cc(cm 3) 0.06102 cu.in
m
lit(liter) 0.8799 qt(IMP liq.)

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lit(liter) 0.2199 gal(IMP liq.)

Miscellaneous kg/mm 55.997 Ib/in
ed
kg/cm 2 14.2234 psi(Ib/in 2)

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Centigrade 9/5(°C)+32 Fahrenheit (°F)

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1-5
SPECIAL TOOLS I GEN
EEl02000
SPECIAL TOOLS
T h e f o l l o w i n g s p e c i a l t o o l s are n e c e s s a r y f o r c o m p l e t e and a c c u r a t e t u n e - u p and a s s e m b l y . Use
o n l y t h e a p p r o p r i a t e s p e c i a l t o o l s ; t h i s Will h e l p p r e v e n t d a m a g e c a u s e d b y t h e use o f i n a p p r o p r i -
ate t o o l s or i m p r o v i s e d t e c h n i q u e s .
W h e n p l a c i n g an o r d e r , r e f e r to t h e list p r o v i d e d b e l o w to a v o i d a n y m i s t a k e s .
Tool No. Tool name / Function Illustration
YU-01235 Rotor holding tool
This tool is used to hold the generator ro-

t o r w h e n removing or installing the genera-
tor rotor bolt.
et
YS-28891 Clutch spring holder
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e.
This tool is used to disassembly and assem-
im
bly the secondary pulley.
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YU -90050 Crankshaft Installation set (~
er
-90062 Adapter (~)
These tools are used to install the crank-
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u
shaft. co
Flywheel puller
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YU-01189
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This tool is used for removing the rotor.

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YU-01135-A Crankcase Separating tool

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This tool is used to remove the crankshaft

or separate the crankcase.
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YM-33299 Oil seal guide

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This tool is used for protecting the oil seal
0
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lip w h e n installing the secondary sliding

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sheave.
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YU-33975 Steering nut wrench

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This tool is used to loosen or tighten the

steering stem ring nut.
YU-01701 Sheave holder
This tool is used to hold the clutch hous-

ing w h e n removing or installing the clutch
housing nut.
YU-8036-A Inductive tachometer
This tool is used to check engine speed.
1-6
SPECIAL TOOLS I GEN ,.,o1 1
Tool No. Tool name / Function I llustratio n
YU-03112 Pocket tester
This tool is used to c h e c k t h e electrical sys-

tem.
YM-1409 Oil seal guide
This tool is used to install the left side crank-

case oil seal.
YM-1410 Oil seal d r i v e r
This tool is used to install the left side crank-

case oil seal.
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YM-34487 D y n a m i c spark tester
e.
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This i n s t r u m e n t is necessary for checking
the ignition s y s t e m c o m p o n e n t s .
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er
ACC-1100-15-01 Quick Gasket ®
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This sealant is used to seal to m a t i n g sur-
.S
faces (e.g., crankcase m a t i n g sur-faces).
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90890-01348 Lockn ut w r e n c h
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This tool is used to loosen and t i g h t e n the

c l u t c h c a r r i e r I o c k n u t of t h e s e c o n d a r y
m
sheave.
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YU-33963 Front fork seal d r i v e r

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-1400 Weight (~
A d a p t e r Q2~
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These tools are used w h e n installing the fork

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seal.
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T-handle ( ~ T-handle ( ~ ) / D a m p e r rod holder ( ~ ®

YM-01326
D
Holder T h e s e t o o l s are n e e d e d to l o o s e n and

dJ / ~//
YM-01300-1 ( ~ tighten the d a m p e r rod holding bolt.
YM-01312-A Fuel level gauge
This gauge is used to nleasure the fuel level

in the float chamber.
1-7
G E N E R A L SPECIFICATION
SPECIFICATION
IsPEcl.-I
GENERAL SPECIFICATION
Model YW50AP
Model code: 5P J1
Dimensions:
Overall length 1,890 mm(74.4 in)
Overall w i d t h 705 mm(27.8 in)
Overall height 1,110 mm(43.7 in)
Seat height 765 mm(30.1 in)
Wheelbase 1,275 mm(50.2 in)
M i n i m u m ground clearance 120 mm(4.7 in)
M i n i m u m turning radius 2,000 mm(78.7 in)
Basic weight:
et
With oil and full fuel tank 94 kg(207 Ib)
n
e.
Engine:
Engine type Air cooled 2 strcke, gasoline torque induction
im
Cylinder arrangement Forward- inclined single cylinder
T
Displacement 49cm 3 (2.99 cu.in)
er
Bore x stroke 40.0 x 39.2 mm(1.57 x 1.54 in)
ot
Compression ratio 7.2:1
Starting system
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Electric and kick starter
Lubrication system: Separate lubrication
.S
Oil Type or Grade:

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Engine Oil For Y A M A H A brand:

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Yamalube 2 or Air cooled 2-stroke engine oil (ISO

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EG-C, EG-D grade)

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Transmission Oil Yamalube 4 SAE 10W/30 SE or GL gear oil

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Oil Capacity:
Oil Tank (Engine Oil) 1.4 L (1.23 Imp°qt, 1.48 US qt)
ed
Transmission Oil:
Periodic Oil Change 0.11 L(0.096 Imp.qt, 0.12 US qt)
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Total A m o u n t 0.13 L(0.11 Imp.qt, 0.13 US qt)

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Air Filter: Wet type element

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Fuel:
Type Regular unleaded gasoline
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Tank Capacity 5.7 L (1.25 Imp.gal, 1.5 US gal)

Carburetor:
Type / Manufacturer Y14P/1/TEIKEI
2-1
G E N E R A L SPECIFICATION IsPEcl.-I
Model YW50A
Spark Plug:
Type/Manufacturer BPRTHS/NGK
Gap 0.6 ~ 0.7 mm(0.02 ~ 0.03 in)
Clutch Type Dry, Centrifugal automatic
Transmission:
Primary Reduction System Helical gear
Primary Reduction Ratio 4.000
Secondary Reduction System Supur gear
Secondary Reduction Ratio 3.666
Transmission Type V-belt
Operation Automatic
Chassis:
et
Frame type Steel tube underbone
Caster angle 26.5 °
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e.
Trail 93mm(3.7 in)
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Tire:
Type Tubeless
T
er
Size front 120/90-10
rear 130/90-10
ot
Manufacturer front CHENG SHIN
co
rear CHENG SHIN
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Type front 56J
rear 59J
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Maximum load* 143 kg(315 Ib)

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Cold tire Pressure:

Up to 90 kg
m
Front 200kpa(2.0 kg/crn 2, 29 psi)

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Rear 200kpa(2.0 kg/cm 2, 29 psi)

90 kg load~Maximum load*
ed
Front 200kpa(2.0 kg/cm 2, 29 psi)

Rear 200kpa(2.0 kg/cm 2, 29 psi)
ad
Brake:
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Front brake type Single disc brake

operation Right hand operation
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Rear brake type Drum brake

D
operation Left hand operation

Suspension:
Front suspension Telescopic fork
Rear suspension Unit swing
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel:
Front wheel travel 65 rnrn(2.56 in)
Rear wheel travel 60 mm(2.36 in)
Electrical:
Ignition system C.D.I
Generator system Flywheel Magneto
Battery type YTX5L-BS
Battery capacity 12V 4AH
2-2
G E N E R A L SPECIFICATION IsPEcl.-I
Model YW50A
Headlight type: Bulb
Bulb wattage x quantity:
Headlight 12V 35W/35Wx2
Tail/brake light 12 V 5W/21Wx1
Flasher light 10Wx4
Licence plate light 5Wx 1
Meter light 3.4Wxl/1.7Wxl
High beam indicator light 1.7Wx 1
Oil indicator light 1.7Wx 1
Turn indicator light 1.7Wx 1
n et
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T im
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2-3
MA...E°A.OE SPEO.F.OA-.O° ISPEcl I
M A I N T E N A N C E SPECIFICATION
ENGINE
Item Sta nda rd Limit
C y l i n d e r head:
Warp l i m i t "~ 0.03 m m
(0.0012 in)
*Lines indicate s t r a i g h t e d g e m e a s u r e m e n t
Cylinder:
et
Bore size 40.000~40.014mm 40.10 m m
n
(1.5748~1.5754 in) (1.5787 in)
e.
Taper l i m i t 0.05 m m
im
(0.0020 in)
T
Out of round Ih-nit 0.03 rnm
er
(0.0012 in)
ot
Piston: co
Piston to c y l i n d e r clearance 0.035~0.040 m m 0.10 m m
(0.0014~0.0016 in) (0.0039 in)
.S
Piston size " D " 39.958~39.972 m m

w
(1.5731~1.5737 in)
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M e a s u r i n g point " H " 5 mm(O.2 in)

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Piston pin bore inside d i a m e t e r 10.004~10.015 m m 10.045 m m

m
(0.3939~0.3943 in) (0.4 in)

Piston pin outside d i a m e t e r 9.996~10.000 rnrn 9.975 m m
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(0.3935~0.3937 in) (0.39 in)

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Piston Ring:
Sectional Sketch (B × T)/'l-ype
ad
Top Ring 1.2 × 1.6 m m / k e y s t o n e

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(0.05 × 0.06 in)

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2nd Ring 1.2 × 1.6 r a m / k e y s t o n e

ow
(0.05 × 0.06 in)

End Gap (Installed):
D
Top Ring 0.15~0.35 m m 0.6 mm(O.02 in)

(0.005~0.01 in)
2nd Ring I~ Yl 0.15~0.35 m m 0.6 mm(O.02 in)
(0.005~0.01 in)
Side Clearance ( Installed):
Top Ring 0.03~0.05 m m 0.1 mm(O.O039 in)
(0.0012~0.0020 in)
2nd Ring 0.03~0.05 m m 0.1 mm(O.O039 in)
(0.0012~0.0020 in)
2-4
MA..TE°A°OE SPEO.F.OAT.O° ISPEcl " I
Item Standard Limit
Crankshaft: F
Crank Width " A " - "--D 37.90~37.95 mm(1.49~1.49 in)

Run Out Limit " C " .q- .~p
0.03 mm(0.0012 in)
Connecting Rod Big End Side A
Clearance " D " 0.2~0.5 m m 1.0 mm(0.04 in)
(0.0029~0.020 in)
Small End Free Play " F " 0.4~0.8 m m
(0.016~0.031 in)
et
A u t o m a t i c centrifugal clutch:
n
e.
Clutch shoe thickness 4.0 mm(0.16 in) 2.5 mm(0.1 in)
Clutch housing inside d i a m e t e r 105 m m 105.5 m m
im
(4.13 in) (4.15 in)
T
Clutch shoe spring free length 94 mm(3.7 in) 91 mm(3.58 in)
er
Clutch - in r e v o l u t i o n 3,300~3,700 r/min
ot
Clutch - stall r e v o l u t i o n 5,500~6,500 r/rain
co
V-belt:
.S
V-belt w i d t h 16.6 mm(0.65 in) 14.6 mm(0.57 in)
w
Kick Starter:
w
Type Ratchet t y p e
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Kick Clip Tension 1.5~2.5 N (0.15~0.25 kgf)

(0.34~0.56 Ib)
m
fro
Carburetor:
I.D. Mark 5DA-01
ed
Main Jet (M.J.) #8O

Needle jet (N J) 2.085
ad
Jet Needle-clip Position (J.N.) 3N24-3/5

Main A i r Jet (M.A.J.) 2.0
o
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Cutaway (C.A.) 3.5

Pilot Jet (P.J.) #44
ow
Bypass 0.8
D
Valve Seat Size (V.S.) 1.8

Starter Jet (G.S.) #48
Float Height 15 ~17 ram(0.59 ~ 0.67 in)
Fuel level height 3.0~4.0 rnrn(0.12 ~0.16 in)
Engine Idling Speed 1,750~1,850 r/rain
Reed Valve:
Thickness 0.150~0.154 mm(0.059~0.0060 in)
Valve Stopper Height 6.0~6.4 mm(0.24~0.25 in)
Valve bending l i m i t 0.2 m m (0.0078)
2-5
M..°TE°..OE SPEO.F.C.T.O. ISPEcl "" I
TIGHTENING TORQUES
ENGINE
Tightening
Thread Q'ty torque
Part to be tightened Part name Remarks
size
Nm m°kg ft°lb
Spark plug m
M 14 1 20 2.0 14
Cylinder head and cylinder Nut M 7 4 14 1.4 10
Cylinder Stud bolt M 7 4 10 1.0 7
Air shroud 1 Screw M 6 3 7 0.7 5.1
Air shroud l x 2 Sc rew 6.0 1 2 0.2 1.4
Fan Screw M 6 3 7 0.7 5.1
Autolube pump Screw M 5 2 4 0.4 2.8
et
Reed valve Bolt M 6 4 11 1.1 8.0
n
e.
Air filter Sc rew M 6 2 9 0.9 6.5
im
Carburetor cap Screw M 4 2 2 0.2 1.4
Exhaust pipe Screw M 6 2 9 0.9 6.5
T
Muffler
er
Bolt M 8 2 26 2.6 18.2
Exhaust protector Bolt M 6 3 11 1.1 8.0
ot
Protector Screw M 6 1 9 0.9 6.5
co
Crankcase l x 2 Bolt M 6 6 12 1.2 8.4
.S
T r a n s m i s s i o n case cover Bolt M 6 6 12 1.2 8.4

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Crankcase cover 1(left) Bolt M 6 12 12 1.2 8.4

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Bolt(case2) Screw M 6 1 7 0.7 5.1

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Crankcase cover2(left) Bolt M 6 3 7 0.7 5.1

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Drain bolt Bolt M 8 1 18 1.8 13

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Oil plug Plug M 14 1 3 0.3 22

Idle gear plate Screw M 6 2 8 0.8 5.8
ed
Kick crank Bolt M 6 1 9 0.9 6.5

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Starter m o t o r Bolt M 6 2 13 1.3 9.4

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Clutch housing Nut M 10 1 40 4.0 29

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Clutch w e i g h t Nut M 10 1 30 3.0 22

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Magnet base Screw M 6 2 8 0.8 5.8

C.D.I. rotor Nut M 10 1 38 3.8 27
D
2-6
MA. A.OE SPEO.F.OAT.O. ISPEcl " I
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Ball and race bearing ...
No/size of steel balls: Upper 22 pcs ...
Lower 19 pcs ...
Front suspension:
Front fork travel 70 rnrn(2.8 in)
Fork spring free length 236.6 mm(9.31 in) 233.6 mm
Fork length (Installed) 212.1 mm(8.35 in)
Spring rate (K1) 15.68 Nm/mm(1.6 kg/mm,901b/in)
(K2) 23.5 Nm/mm(2.43 kg/mm,1361b/in)
Inner tube vend limit 0.2 mm
(0.008 in)
et
Rear suspension:
n
Shock absorber stroke 55 mm(2.2 in)
e.
Shock absorber free length (Installed) 281.8 rnrn(11.1 in)
im
Spring free length (Installed) 159.8 mm(6.29 in)
T
Spring rate (K1) 71.15 N/mm(7.26 kg/mm,4071b/in)
er
Front wheel:
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Type Cast wheel
co
Rim size MT3.50xl 0
Rim material Aluminum
.S
Rim runout limit radial 1 mm(0.04 in)

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lateral 1 ram(0.04 in)

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Rear wheel:
w
Type Cast wheel

m
Rim size MT3.50xl 0

fro
Rim material Aluminum

Rim runout limit radial 1 mm(0.04 in)
ed
lateral 1 mm(0.04 in)

ad
Front disc brake:

Type Single
o
Disc outside diameter x thickness 180x4.0mm 180x3.5 mm

nl
(7.1x0.16 in) (7.1x0.14in)

ow
Pad thickness 6 ram(0.24 in) 0.8 mm(0.03 in)

Master cylinder inside diameter 11 mm(0.4 in)
D
Caliper cylinder outside diameter 34.93 mm(1.38 in)

Brake fluid type DOT #4(or DOT #3)
Rear drum brake:
Type Leading, trailing
Drum inside diameter 130 mm(5.12 in) 131 mm(5.16 in)
Shoe thickness 4 ram(0.16 in) 2 ram(0.08 in)
Brake lever:
Brake lever free play (front at lever side) 2~5 mm(0.08~0.20 in)
Brake lever free play (rear) 10~20 mm(0.39~0.79 in)
Throttle cable free play 3~5 mm(0.12~0.20 in)
2-7
MA. A.OE SPEO.F.OAT.O. ISPEcl "" I
TIGHTENING TORQUES
CHASSIS
Tightening
Part to be t i g h t e n e d Th read torque Remarks
size
Nm m,kg ft°lb
Frame and e n g i n e bracket M 12 84 8.4 61

E n g i n e bracket, c o m p r e s s i o n rod and e n g i n e M 10 45 4.5 31
Rear carrier M 6 13 1.3 9.4
Rear s h o c k a b s o r b e r and f r a m e M 10 30 3.0 22
Rear s h o c k a b s o r b e r and e n g i n e M 8 16 1.6 12
S t e e r i n g ring nut M 25 22 2.2 16 See
Handle h o l d e r and s t e e r i n g shaft M 10 43 4.3 37 "page3-18"
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Brake hose and m a s t e r c y l i n d e r M 8 20 2.0 14
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Fuel t a n k M 6 10 1.0 7
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Fuel cock M 6 7 0.7 5.1
Fuel s e n d e r M 5 4 0.4 2.9
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Box M 6 7 0.7 5.1
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Seat lock a s s e m b l y M 6 7 0.7 5.1
Plastic parts & c o v e r
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M 5 2 0.2 1.4
Footrest board M 6 7 0.7 5.1
.S
Front w h e e l axle and nut M 10 70 7.0 51

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Rear w h e e l axle and n u t M 14 120 12.0 87

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Rear brake cam lever M 6 10 1.0 7.2

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Front brake caliper and f r o n t fork M 8 23 2.3 16.6 41~

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Brake disc and h u b MIO 20 2.0 14.5

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Brake hose and caliper M 8 23 2.3 16.6

Brake caliper and bleed s c r e w M 5 6 0.6 4.3
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2-8
ELECTRICAL
Item Standard limit
Ignition t i m i n g :
Ignition t i m i n g (B.T.D.C.) 14 ° at 5,000 r/min ...
Advanced type Fixed ...
C.D.I.:
Pickup coil resistance/color 248 ~ 372~ at 20°C (68°F)
(W/R-W/L)
Source coil resistance/color 640 ~ 960 ~ at 20°C (68°F)
(B/R-G/W)
C.D.I. unit m o d e l / m a n u f a c t u r e r 5PJ/TIIC
Ignition coil:
M o d e l / m a n ufacturer 4WX/TI IC
M i n i m u m spark gap 6 rnrn (0.24 in)
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P r i m a r y w i n d i n g resistance 0.32~0.48 ~ at 20°C (68°F)
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S e c o n d a r y w i n d i n g resistance 5.68~8.52k~ at 20°C (68°F)
e.
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Spark plug cap:
Type Resin ...
T
Resistance 5 kE2 ...
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Charging System/Type: Flywheel m a g n e t o ...
C.D.I. Magneto:
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M o d e l / M a n ufacturer 5PJ/TIIC
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Nominal output 12V 85W/5,000 rpm

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Charging current 0.6A at 3,000r/min

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1.2A at 8,000r/min
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Charging v o l t a g e 13~14V at 4,000 rpm

Charging Coil Resistance (Color) 0.48~0.72 ~ (White-Black)
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Lighting Coil Resistance (Color) 0.4~0.6 ~ (Yellow/Red- Black)

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Lighting Voltage 12~15V (3,000~8,000 rpm)

Rectifier:
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M o d e l / M a n ufactu rer 3GF/Taichung

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Capacity 8A
Withstand voltage 18V
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Battery:
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Specific g r a v i t y 1.320 ...

Electric starter system:
D
Type Constant mesh t y p e

Starter motor:
M o d e l / m a n ufactu rer/ID n u m b e r 4WX/shulin
Output 0.14 kw
A r m a t u r e coil resistance 0.0648 ~ 0.0792 E2 at 20°C (68°F)
Brush overall length 6.5 m m (0.26 in) 3 m m (0.12 in)
Spring force 5.49 ~ 8.24 N 400g
(360~540 g) (12.69~19.04 oz)
Commutator diameter 16.1 m m (0.63 in) 15.1 m m (0.59 in)
Mica undercut (depth) 1.05 m m (0.04 in)
Starter relay:
M o d e l / m a n ufacturer 4WX/Shulin
A m p e r a g e rating 20A
Coil resistance 54~66 E2
2-9
Item Standard limit
Horn:
M o d e l / m a n ufacturer 4KP/Asian
Maximum amperage 1.5A
Flasher relay:
Type Capacitor
Flasher f r e q u e n c y 60~ 120 C y c l e / m i n
Fuel gage:
M o d e l / m a n ufacturer 4VP/Sa n Chu
S e n d e r unit resistance - full 4~10 ~
- empty 90~100 ~
Oil level g a u g e :
M o d e l / m a n ufacturer 4VP/Lun Ping ...
et
Circuit breaker:
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Type Fuse ...
e.
MAIN 7 A x l pc . . . .
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2-10
OEOERA"TOROOESPEC,F,CAT,ONS ISPEcl " I
GENERAL TORQUE A B
General t o r q u e
specifications
SPECIFICATIONS (Nut) (Bolt)
Nm m°kg ft°lb
This chart specifies torque for standard fasten-
10 m m 6 mm 6 0.6 4.3
ers w i t h standard I.S.O. pitch threads. Torque
specifications for special c o m p o n e n t s or as- 12 m m 8 mm 15 1.5 11
semblies are included in the applicable sections 14 m m 10 m m 30 3.0 22
of this book. To avoid warpage, tighten multi- 17 m m 12 m m 55 5.5 40
fastener assemblies in a crisscross fashion, in 19 m m 14 m m 85 8.5 61
progressive stages, until full torque is reached. 22 m m 16 m m 130 13.0 94
Unless otherwise specified, t o r q u e specifica-
tions call for clean, dry threads. C o m p o n e n t s
should be at room temperature.
net
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F--
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Am
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A: Distance across flats

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B: Outside thread diameter

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2-11
LUB..OAT.O° PO.°TS A.O LUB..OAT.O° T'.PE ISPEcl "" I
L U B R I C A T I O N POINTS A N D L U B R I C A T I O N TYPE
ENGINE
Lubrication Point Lublicant Type
Oil seal lips
O-rings
Bearings --~11~
Piston surface --411~
Piston pin --411~
Cyl i n d e r --~11~
Transmission case (bearing) ---411~
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Autolube pump
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Starter wheel gear
T
Idle gear plate --~11~
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Secondary drive gear co ----II1~
Kickstarter pinion gear
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Drive axle ---~11~

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Pump drive gear

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Main axle --'qG

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Main axle (bearing) ---~11~

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2-12
• OB"'OAT'O" PO'°TS A"O'OB"'OAT'O° T PE ISPEcl " I
CHASSIS
Lubrication Point Lubricant Type

Oil seal lips
O-rings
Bearings
Speedometer drive gear
Front brake camshaft
Front brake cable
Throttle cable
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Tube guide (throttle grip) inner surface
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Upper steering stem ring nut
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Upper bearing outer race
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Lower bearing outer race
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Rear brake camshaft co
Centersta nd
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2-13
CAB'E.OOT,.O ISPEcl " I
CABLE R O U T I N G (~) Wire harness brand.
(~ Horn [ ] Pass the speedometer cable [ ] Clamp the wire harness.
(~ Rectifier regulator through the right hole of front [ ] Insert the seat cable through
(~ Main switch fender, then t h r o u g h the the frame tube.
(~ Headlight leads guide. [ ] C l a m p w i r e h a r n e s s , rear
(~) Speedometer cable [ ] Pass the wire harness through brake cable throttle cable 1,3.
(~ Ignition coil the inside of ignition coil. [ ] Position the cylinder between
(~ Throttle cable 1 [ ] Secure the ground lead and the s u p p o r t e r and main
(~ Throttle cable 3 the ignition coil base to the switch.
(~ Battery negative(-) ignition coil stay.
@ Wire brake [ ] Pass the wire harness through
(~) Fuel sender lead the inside of oil tank.
(~) Seat lock cable [ ] Pass the seat cable through
(~) Oil tank hose the inside of frame.
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@ C.D.I. unit [ ] Align the clip with the white
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2-14
OAB'E.OOT,°O ISPEcl " I
(~ Brake cable [ ] Pass the brake hose through the holder.
(~) Speedometer cable [ ] Insert the fuel overflowhose bottom.
(~ Fuel tank overflow hose [ ] Pass the fuel overflowhose through the rear
(~ Brake cable holder fender hole.
(~ Brake hose [ ] Pass the fuel o v e r f l o w h o s e t h r o u g h the
(~ Brake hose holder holder.
(~ License bracket [ ] Hold the fuel overflowhose with a clamp.
(~ Flasher relay [ ] Pass the brake cable through the holder.
(~ Fuel tank breather hose
@ Fuel hose
@ Breather hose
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2-15
CAB'E.OOT,°O IS"Eel " I
(~ Brake hose [ ] Pass the brake hose through the holder.
(~) Front fender
(~ Front fork assembly
(~ Nut
(~ Plate washer
(~ Brake hose holder
(~ Flange bolt
(~ Bolt
(~ Brake hose holder
@ Flange bolt
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2-16
C,B'E.OOT,°O IS"Eel " I
(~ Ignition coil @ Battery(+)lead and autolube hose on to carbure-
(~) Spark plug lead [ ] Pass battery leads through tor throttle cable.
(~ Starter relay leads the slot of footrestboard. [ ] Pass the battery leads over frame
(~ Auto choke leads [ ] Cover them after securing member.
(~ Starter relay starter relay leads. [ ] Put fuse box on to footrest board
(~ Bind [ ] Pass the seat lock cable holder.
(~ C.D.I. unit through the hole of bracket. [ ] Pass throttle cable1,3 wireharness,
(~ Autolube hose [ ] Pass the fuel tank breath autolube pump cable, brake cable
(~ Seat lock cable hose over seat lock cable. through the outside of battery box.
@ Bracket [ ] Clamp carburetor vacuum
@ Fuel tank breather hose hose, fuel hose and fuel
@ Bind 2 cock vacuum hose.
(~ Battery(-)lead []Clamp a u t o c h o k e leads
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~i~ ~~,~ ......... ~ ~ q ~ - ~ l
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..q-.~,J I I ~*~/'~ . . . . . . . I •
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@~.
2-17
CAB'E ROOT,OO ISPEcl " I
(~ Handlebar switch(right) [ ] Pass brake cable through the slot of bracket.
(~) Speedometer [ ] Avoid clamping front flasher leads when in-
(~ Wire brake stalling handlebar covers.
(~ Handlebar switch(left) [ ] P a s s throttle cable1,3 t h r o u g h between
(~ Wire harness handlebar and wireharness.
(~ Brake hose [ ] Hang the wireharness bind on to the bracket.
(~ Speedometer cable
(~ Throttle cable1
(~ Throttle cable 3
@ Front flasher leads
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2-18
INTRODUCTION/
PERIODICIVIAINTENANCE/LUBLICATION INTERVALS I INSP
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION
T h i s c h a p t e r i n c l u d e s all i n f o r m a t i o n necessary'to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if f o l l o w e d , will ensure more reliable vehicle
operation a n d a l o n g e r s e r v i c e life. T h e n e e d f o r costly" o v e r h a u l w o r k w i l l be g r e a t l y " r e d u c e d . T h i s
information a p p l i e s t o v e h i c l e s a l r e a d y ' in s e r v i c e as w e l l as t o n e w v e h i c l e s t h a t a r e b e i n g p r e -
pared for sale. All service technicians s h o u l d be f a m i l i a r w i t h t h i s e n t i r e c h a p t e r .
YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

BREAK-IN EVERY
3,000 km 6,000 km
NO. ITEM ROUTINE TYPE INITIAL (2,000 mi) (4,000 mi)
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1,000 km or or
(600 mi) 6 months 12months
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(whichever (wh]chever
e.
co mes first c o m e s fi rst
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• Check fuel hoses and v a c u u m hose
1 * Fuel line f o r cracks or d a m a g e . - 0 O
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• Replace if necessary.
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• Check c o n d i t i o n .
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Refer to SPARK
Spark p l u g • Clean, regap or replace if neces- PLUGINSPECTION co 0 0 O
sa ry.
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3 Air filter element • Clean or replace if necessary, s. . . . . . . ginooil 0 O

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• Check o p e r a t i o n , f l u i d e level and Brakefluid DOT4

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Front brake v e h i c l e f o r f l u i d leakage. Ior DOT3) 0 0 O

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4 *
• Replace brake pads.

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Whenever worn to the limit.

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• Check o p e r a t i o n .
5 * Rear brake • A d j u s t brake lever free play. - O O O
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• Replace brake shoes. Whenever worn to the limit.

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• Check balance, runout and for

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6 * Wheels damage. - O O
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• C h e c k t r e a d d e p t h and f o r d a m a g e .
7 * Tires - Replace if necesssary. - O O O
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• Check air pressure.

• Correct if necessary.
• Check Bearing for looseness or
8 ~ Wheel bearings damage. - O O
Steering bear- • Check b e a r i n g play and steering for 0 0 0

9 * ings roughness.
• L u b r i c a t e w i t h l i t h i u m soap base - Every 12,000 km(8,000 mi)or 24
greese, months(whichever occurs first).
1C * Chassis fasteners • M a k e sure t h a t all nuts, bolts and - 0 0

s c r e w s are p r o p e r l y t i g h t e n e d .
3-1
PERIODICINSPECTION AND ADJUSTMENTSI INSPDI I
BREAK-IN EVERY
3,000 km 6,000 km
NO. ITEM ROUTINE TYPE INITIAL (2,000 mi) (4,000 mi)
1,000 km or or
(600 mi) 6 months 12months
(whichever (wh ichever
comes first) comes fi rst
• Check operation.
11 Centerstand • Lubricate with lithium soap base Sarne as engine oil O O
greese (all purpose grease).
12" Front fork - Check operation and for oil leakage. - O O
- C h e c k o p e r a t i o n and shock ab-
13" Rear s h o c k absorber for oil leakage. - O O
sorberassembly - Replace shock absorber assembly
if necessary.
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14 * Carburetor • Check engine idling speed. - O O O
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• Adjust if necessary.
e.
• Check operation.
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15" A u t o l u b e pump - Correct if necessary. - O @ O
T
• Bleed if necessary.
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16" Final t r a n s m i s - - C h e c k o i l level and vehicle for oil - O O O
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sion oil leakage. co E v e r y 12,000 k m ( 8 , 0 0 0
• Replace. Yarnalubel
300WSE 4orSAEGL O mi)or 24 mont hs(whichever
.S
gear oil Occurs first).
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17 * V-belt o Replace. Every 9,000 kin(6,000 mi)

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I t e m s m a r k e d w i t h an a s t e r i s k (*) r e q u i r e s p e c i a l t o o l s , d a t a a n d t e c h n i c a l skills f o r s e r v i c i n g . T a k e
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t h e s c o o t e r to a Y a m a h a d e a l e r .
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NOTE:
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• T h e air f i l t e r n e e d s m o r e f r e q u e n t s e r v i c e if y o u are r i d i n g in u n u s u a l l y w e t or d u s t y areas.

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• Brake f l u i d r e p l a c e m e n t :
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1. R e p l a c e t h e b r a k e f l u i d a f t e r d i s a s s e m b l i n g t h e m a s t e r c y l i n d e r or c a l i p e r c y l i n d e r . C h e c k t h e
ow
b r a k e f l u i d level a n d a d d f l u i d as r e q u i r e d .
D
2. R e p l a c e t h e m a s t e r c y l i n d e r a n d c a l i p e r c y l i n d e r oil seals e v e r y t w o years.

3. R e p l a c e t h e b r a k e h o s e s e v e r y f o u r y e a r s , o r if c r a c k e d o r d a m a g e d .
NOTE:
F r o m 6,000 mi (9,000 k m ) - o r 18 m o n t h s , r e p e a t t h e m a i n t e n a n c e i n t e r v a l s s t a r t i n g 2,000 mi (3,000
mi) o r 6 m o n t h s .
3-2
INSP
COVER AND PANEL

COVER AND PANEL
I
SIDECOVER A N D SEAT
' i
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~,~/~ ~ m . k g , 9.4ft.lb)
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Order J o b name/Part n a m e Q'ty Remarks

D
Sidecover and seat removal Remove the parts in order.

. Battery box cover NOTF"
Insert the (-) s c r e w d r i v e r into the slot of
battery cover and pickup then remove.
. Seat
3. Seat hange
4. Rear carrier
5. Rear cover
6. Left side cover
7. Right side cover
8. Center cover
Reverse the removal procedure for instal-
lation.
3-3
INSP
COVER AND PANEL
I
LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 A N D FOOTREST BOARD
4
5
[~1 7Nm(0.7m.kg, 5.1ft.lb)
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Order Job n a m e / p a r t name Q'ty Remarks

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L o w e r c o w l i n g , u p p e r cover, leg Remove the parts in order.

shield 1,2 and f o o t r e s t board re-
moval
. Lower c o w l i n g 1
2. Upper cover 1
3. Leg shield 1 1
4. Main switch c o v e r / l e g shield 2 1/1
5. Battery 1
6. Footrest board 1
lation.
3-4
INSP
COVER AND PANEL
I
H A N D L E B A R C O V E R ( F R O N T A N D REAR)
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Order Job name/Part name Q'ty Remarks

H a n d l e b a r c o v e r ( F r o n t and Rear) re- R e m o v e t h e part in order.
moval.
1. Mirrors 2
2. Front h a n d l e b a r c o v e r 1
3. Rear h a n d l e b a r c o v e r 1
4. Flasher light(Left/Right) 1/1
Reverse the r e m o v a l p r o c e d u r e for instal-
lation.
3-5
ENGINE IDLE SPEED ADJUSTMENT I INSP
ENGINE
IDLE SPEED A D J U S T M E N T
1. Remove
• Battery box cover (~
2. Tighten:
• Pilot air screw (~)
Turn the pilot air screw in until lightly
seated.
3. Loosen:
• Pilot air screw
Back it out from its lightly seated posi-
tion.
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I Pilot air screw turn out: I
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load 1-1/4
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2. Start the engine and let it warm up.
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r!~VAVL,W--']~ I I~ [¢-!
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Before starting t h e engine, be sure to use t h e

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c e n t e r s t a n d for safety.
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. Attach:
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• Inductive tachometer (~
To the spark plug lead
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I<~1 Inductive tachometer:

YU-8036-A
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4. Check:
• Engine idle speed
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Out of specification-->Adjust.
I-~1 Engine idle speed

1,750~1,850 r/min
5. Adjust:
• Engine idle speed
Adjustment steps.
• Turn the throttle stop screw(~ in or out until
specified idle speed is obtained.
I Turn i:u t Idle speed becomes higher. I
Turn Idle speed becomes lower.
3-6
THROTTLE CABLE FREE A D J U S T M E N T I INSP
T H R O T T L E CABLE FREE A D J U S T M E N T
1. Check:
• Throttle cable free play (~
ree3 ~o5 mm(0.12 ~ 0.20 in)

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Throttle cable free play a d j u s t m e n t steps;

NOTE:
Before adjusting the throttle cable free play, the
engine idle speed should be adjusted.
et
• Remove the adjuster cover (~
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e.
• Loosen the Iocknut @~)on the throttle cable.
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• Turn the adjuster (~ in or out until the speci-
fied free play is obtained.
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er
I T u r n i n g in--~Free play is increased. I
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T u r n i n g out->Free play is decreased.
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• Tighten the Iocknuts.
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• Install the adjuster cover

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After adjusting the throttle cable free play, start

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the engine and turn the h a n d l e b a r to the right

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and to the left to ensure that this does not cause

the engine idling speed to change.
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3-7
A U T O L U B E P U M P AIR BLEEDING I INSP
A U T O L U B E P U M P AIR BLEEDING
1. Remove
• Lower cowling
• A i r shroud 1 (~
2. Air bleeding:
• Pump case and / or oil hose.
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
Air bleeding steps:

• Place a rag under the autolube p u m p t o catch
the oil.
• Remove the bleed screw (~.
• Keepthe oil running out until air bubbles dis-
appear.
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• When air bubbles are expelled completely,
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tighten the bleed screw.
e.
NOTE:
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Check the bleed screw gasket. If damaged, re-
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place w i t h a new one.
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Place a oil pan under the autolube p u m p to
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catch oil.
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3. Air bleeding:
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• Pump d i s t r i b u t o r and/or delivery hose

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Air bleeding steps:

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• Start the engine.

• Run the engine for 2-3 minutes at 2000 r / m i n .
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This will c o m p l e t e l y r e m o v e autolube p u m p

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system of air.
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3-8
SPARK PLUG INSPECTION I INSP
SPARK PLUG I N S P E C T I O N
1. Remove:
• Battery box cover
2. Inspect:
• Spark plug type
I nco rrect-->Replace.
I Standard spark plug: I

BPR7HS/NGK
3. Inspect:
• Electrode (~
Wea r/Da m ag e-->Re place.
• Insulator (~)
A b n o r m a l color->Replace.
et
Normal color is a medium-to-light tan
n
e.
color.
im
4. Clean the spark plug w i t h a spark plug
cleaner or wire brush.
T
er
5. Measure:
ot
• Plug gap (~
co Use a wire gauge or feeler gauge.
Out of specification-->Regap.
.S
I l'0ar'0u00ao I
w
w
0.6 ~ 0.7 m m (0.02 ~ 0.03 in)

w
m
6. Tighten:
fro
• Spark plug I~4~i20Nm(2"0m'kg'14ft'lb) I

7. Install:
ed
• Battery box cover.

ad
o
nl
ow
D
3-9
INSP
E N G I N E OIL LEVEL I N S P E C T I O N
I
E N G I N E OIL LEVEL I N S P E C T I O N
1. Inspect:
• Engine oil level Oil level Iow--~Add suf-
ficient oil by the f o l l o w i n g inspection
steps.
(~ "OIL" indicator light
Engine oil level visual inspection steps:
et
Turn main switch to " * "
n
position.
e.
im
t
T
|
"OIL" indicator light does I "OIL" indicator light
er
not comes on.
I comes on.
ot
co
.S
Turn main switch to
w
" O N " position.

w
w
t /
m
"OIL" indicator light does I _ "OIL" indicator light

C
fro
not come on. comes on.
1
ed
Inspect f a u l t y electrical Engine oil level and elec-

ad
S u p p l y engine oil.
circuit, light bulbs etc. trical circuit are OK.
o
nl
ow
"OIL" indicator light comes on.

D
Recommended oil:
©1 For Yamaha:
Yamalube 2 or 2-stroke engine oil
(ISO EG-C, EG-D grade)
Total:
1.4L(1.23 Imp.qt, 1.48 US.qt)
NOTE:
Install the oil tank filler cap (~ and push it fully
into the filler.
3-10
T R A N S M I S S I O N OIL R E P L A C E M E N T I INSP
TRANSMISSION OIL R E P L A C E M E N T
1. Warm up the engine for several minutes,
then stop the engine.
2. Place a container under the drain hole.
3. Remove:
• Oil filler plug (~
• Drain bolt (with gasket) ~)
NOTE:
Drain the t r a n s m i s s i o n oil completely.
While draining, slightly tilt the scooter to
the right and to the left.
4. Inspect:
et
• Gasket (drain bolt) (~
n
e.
• O-ring (oil filler plug) (~
im
Damage--~Replace.
T
er
ot
5.
co
Install:
.S
Drain bolt H 18 .m m,g. 13.,,)1
6. Fill:
w
w
• Transmission case
w
©1 Recommended oil:
m
Yamalube 4 SAE 10W 30SE or GL gear

fro
oil
Oil capacity:
ed
Total a m o u n t
ad
0.13 L (0.11 Imp.qt, 0.13 US.qt)

Periodic oil change
o
0.11 L(0.096 Imp.qt, 0.12 US qt)

nl
ow
CAUTION:
D
• A l w a y s use t h e s a m e t y p e of oil; m i x i n g
oils m a y r e s u l t in a h a r m f u l c h e m i c a l re-
action a n d lead t o p o o r p e r f o r m a n c e .
• Do n o t a l l o w f o r e i g n m a t e r i a l t o e n t e r s
t h e t r a n s m i s s i o n case.
7. Install:
• Oil filler plug (with O-ring)
8. Inspect:
• Oil leaks
• Oil level
NOTE:
Wipe off any oil spilt on the t r a n s m i s s i o n , tire
or wheel.
3-11
AIR FILTER E L E M E N T C L E A N I N G I INSP
AIR FILTER E L E M E N T C L E A N I N G
1. Remove:
• Battery b o x c o v e r
2. Remove:
• Caburetor jont clamp ~)
3. Remove:
• Screw
• A i r filter ( ~
n et
e.
T im
er
ot
4.
co Remove:
.S
• A i r filter case (~)
• A i r filter e l e m e n t
w
w
CAUTION:
w
N e v e r o p e r a t e t h e e n g i n e w i t h t h e air f i l t e r el-
m
e m e n t r e m o v e d . T h i s w i l l a l l o w u n f i l t e r e d air
fro
t o enter, c a u s i n g r a p i d w e a r and p o s s i b l e en-

gine damage. Additionally, operation without
ed
t h e c l e a n e r e l e m e n t w i l l affect c a r b u r e t o r jet-
ad
t i n g w i t h s u b s e q u e n t p o o r p e r f o r m a n c e and
o
possible engine overheating.

nl
Be careful n o t t o h a v e rags or t h e like b l o c k i n g

ow
t h e i n t a k e area of t h e air filter.

D
5. Inspect:
• Element (~
Da mage-->Replace.
6. Clean:
• A i r filter e l e m e n t
A i r filter e l e m e n t c l e a n i n g steps:
• W a s h the e l e m e n t g e n t l y , but t h o r o u g h l y in
solvent.
3-12
INSP
AIR FILTER E L E M E N T C L E A N I N G
AWARNING
I
N e v e r use l o w flash p o i n t s o l v e n t s such as
gasoline t o clean t h e e l e m e n t . Such s o l v e n t
m a y lead to a fire or explosion.
• S q u e e z e t h e e x c e s s s o l v e n t o u t of t h e ele-
m e n t a n d let dry.
CAUTION:
Do not t w i s t t h e e l e m e n t w h e n s q u e e z i n g t h e
element.
et
• A p p l y t h e f o a m -air f i l t e r oil or e n g i n e o i l .
n
e.
• S q u e e z e o u t t h e e x c e s s oil.
im
NOTE:
T
T h e e l e m e n t s h o u l d be w e t b u t n o t d r i p p i n g .
er
ot
co
7. Install:
.S
• Air filter
w

w
w
m
fro
ed
ad
o
nl
ow
D
3-13
V-BELT I N S P E C T I O N I INSP
V-BELT INSPECTION
1. Remove:
• Kick crank ( ~
• Screws (~
• Crankcase c o v e r 2(left) (~)
• S c r e w s ( A i r c l e a n e r and left crankcase
cover (~
• Crankcase c o v e r 1(left) ( ~
n et
e.
T im
er
ot
.
coInspect
• V-belt ( ~
.S
Cracks/Wea r/Da mage-->Replace.

w
Oil or grease a d h e r e to t h e
w
w
V-belt-->Check the p r i m a r y and s e c o n d -

ary sheaves.
m
Refer to "ENGINE OVERHAUL -INSPEC-

fro
TION A N D REPAIR" section in the CHAP-

ed
TER 4.
ad
. Measure:
o
• V-belt w i d t h ( ~
nl
Out of specification-->Replace.
ow
Refer to " E N G I N E O V E R H A U L " section

D
in the CHAPTER 4.
~ V-belt w i d t h "
16.6 m m (0.65 in)
< L i m i t > 14.6 m m (0.57 in)
NOTE:
M e a s u r e the V-belt w i d t h on several points.
4. Install:
• Crankcase c o v e r 1 (left)
I~%l 12Nm(1.2m.kg, 8.4 ft.lb) I
• A i r cleaner [ ~ l 9N m(0.9m.kg, 6.5 ft.lb) I
• Crankcase c o v e r 2 (left)
• Kick crank
3-14
F"O"T B"A"E'EVE" F"EE P'AY C"EC"'"EA" B"A"E I,.Sp I
LEVER FREE PLAY CHECK/BRAKE PAD INSPECTION A D J
I
CHASSIS
F R O N T BRAKE LEVER FREE PLAY CHECK
1. Check:
• Front brake lever free play
I ~ 1 2~5 mm(0.08~0.20 in) I
xkWARNING
A soft or s p o n g y feeling in the brake lever can
indicate the presence of air in the brake sys-
tem. This air must be removed by bleeding the
brake system before the motorcycle is oper-
et
ated. Air in the system will cause greatly di-
n
minished braking capability and can result in
e.
loss of control and an accident. Inspect and
im
bleed the system if necessary.
T
er
ot
co
REAR BRAKE LEVER FREE PLAY CHECK
1. Check:
.S
• Rear brake lever free play (~

w
w
w
I~110~20 mm,o3~0 79,n, I

m
fro
ed
ad
o
Rear brake lever free play adjustment steps:

nl
< • Turn the adjuster (~ in or out until the cor-

ow
rect free play is obtained.

X o
D
to
BRAKE PAD I N S P E C T I O N
1. Activate the brake lever.
j 2. Inspect:
• Brake pad
Wear i n d i c a t o r (~ nearly c o n t a c t i n g
brake disc-->Replace brake pads as a set.
Refer to the "BRAKE PAD REPLACE-
MENT" section in the CHAPTER 6.
(~ Brake disc
(~ Brake pads
3-15
B"AKES"OE'"SPECT'O°' I'"SP I
BRAKE FLUID LEVEL INSPECTION
I
\ BRAKE SHOE I N S P E C T I O N
1. Activate the brake lever.
2. Inspect:
• W e a r indicator (~
Indicator at w e a r limit line (~)-->Replace
brake shoes.
n et
e.
im
BRAKE FLUID LEVEL I N S P E C T I O N
T
NOTE:
er
Position the scooter straight up w h e n inspect-
ot
ing the fluid level.
co
.S
G-L
w
m
w
. Inspect:
w
• Fluid level is under " L O W E R " level line

m
(~-->Fill to proper level.

fro
Ii~l R e c o m m e n d e d fluid:
ed
DOT#4(or DOT#3)
ad
CAUTION:
o
nl
The fluid m a y corrode p a i n t e d surfaces or plas-

ow
tic parts. A l w a y s clean up spilled fluid i m m e -

D
diately.
~!~LvAv/±1-']~ II~ [¢!

e U s e o n l y t h e d e s i g n a t e d q u a l i t y fluid. Other-
w i s e ,the r u b b e r s e a l s m a y d e t e r i o r a t e caus-
ing leakage and p o o r brake p e r f o r m a n c e .
eRefill w i t h t h e s a m e t y p e of fluid. M i x i n g flu-
ids m a y result in a harmful chemical reaction
leading to p o o r brake p e r f o r m a n c e .
eBe careful t h a t w a t e r does n o t enter t h e mas-
ter cylinder w h e n refilling. W a t e r w i l l signifi-
cantly l o w e r t h e boiling p o i n t of t h e fluid and
m a y result in v a p o r lock.
3-16
AIR BLEEDING (HYDRAULIC BRAKE SYSTEIVI)I INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
1. Bleed:
• Brake f l u i d
Air bleeding steps:

a. A d d p r o p e r brake f l u i d to the reservoir.
b. Install the d i a p h r a g m . Be careful not to
spill a n y f l u i d or a l l o w t h e r e s e r v o i r to
overflow.
c. C o n n e c t t h e clear plastic tu be ( ~ t i g h t l y to
the caliper bleed screw.
d. Place the o t h e r end o f t h e t u b e into a con-
tainer.
et
e. S l o w l y a p p l y t h e brake lever several times.
n
f. Pull the lever in. Hold the lever in posi-
1
e.
tion.
im
g. Loosen the bleed s c r e w and a l l o w the le-
T
ver to t r a v e l t o w a r d s its limit.
er
h. T i g h t e n the bleed s c r e w w h e n the l i m i t
ot
cohas been reached, t h e n release the lever.
i. Repeat steps ( e ) t o (h) until the air b u b b l e s
.S
have been r e m o v e d f r o m t h e s y s t e m .
j. A d d brake f l u i d to p r o p e r level.
w
w
~!~LvAv/±1-'t ~ I I~ [¢-!
w
Check the operation of the brake after bleed-

m
ing the brake system.

fro
ed
ad
o
nl
ow
D
3-17
STEERING ADJUSTMENT I INSP
STEERING ADJUSTMENT
1. Check:
• Steering assembly bearings
Gap the bottom of the forks and gently
rock the fork assembly back and forth.
Loosen-->Adjust.
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
A d j u s t m e n t steps:
! • Remove u p p e r cover, l o w e r c o w l i n g , leg
shield 1,2. refer to "COVER AND PANEL" sec-
tion.
• Remove all ringnuts using ringnut wrench.
et
::~1 Ring nut wrench: I
YU-33975
n
e.
im
• Tighten the ring nut 3 (~ using nut wrench.
[~122 Nm(2.2 m.kg, 16 f-t.lb) I
T
er
ot
NOTE:
co
Set the torque wrench to the ring nut w r e n c h
so that they form a right angle.
.S
w
w
• Loosen the ring nut 3 (~ 1/4 turn.

w
• Install rubber ring (~) and ring nut 2 (~, then

m
tighten the ring nut 2 until it contacts w i t h

fro
rubber ring.
CAUTION:
ed
Aligning the slot of ring nut 2 w i t h the slot of

ad
ring nut 3. If not, slightly t i g h t e n ring nut 2 un-

o
til the slots a l i g n m e n t .

nl
ow
• Install special w a s h e r (~
D
NOTE:
Insert the projections of special w a s h e r into the
slots of ring nut 3, 2
• Install ring nut 1 ( ~ r~166Nm(6.6 m.kg, 478~.b> I

• Move the handlebar up and d o w n , and/or
back and forth. If handlebar play is excess,
remove the front fork assembly and check
the balls/ball races. Refer to chapter 6.
3-18
TIRE I N S P E C T I O N I INSP
FRONT TIRE I N S P E C T I O N
Manufacturec Size Type WARNING
CHENG SHIN 120/90-10 56J • The tire pressure should only be checked and
r e g u l a t e d w h e n t h e tire t e m p e r a t u r e equals
REAR
t h e a m b i e n t air t e m p e r a t u r e ,
Manufacturec Size Type • T h e tire pressure m u s t be adjusted accord-
CHENG SHIN 130/90-10 59J ing to t h e total w e i g h t (including cargo, rider
passenger and accessories) and t h e antici-
p a t e d riding speed,
• O p e r a t i o n of an o v e r l o a d e d scooter could
cause tire d a m a g e , an accident or an injury,
N E V E R O V E R L O A D THE SCOOTER,
n et
Basic weight
e.
( w i t h oil and a 9 4 k g ( 2 0 7 1 b )
im
full uel tank)
T
M a x i m u m load* 1 4 3 k g ( 3 1 5 1 b )
er
Front Rear
ot
Cold t i r e pres- 200 kpa
co 200 kpa
sure (2.0 kgf/cm 2, (2.0 kgf/cm<
.S
29 psi) 29 psi)
w
* Total of cargo, rider, passenger and acces-

w
sories.
w
•WARNING
m
It is d a n g e r o u s to ride w i t h a w o r n - o u t tire.
fro
When the tire tread reaches the w e a r limit, re-

ed
place the tire immediately.

ad
. Inspect:
o
• Tire surfaces
nl
>
Wea r/Da m age-->Re place.
ow
M i n i m u m tire tread depth (~

D
® (front and rear):

1.6 mm (0.06 in)
(~ Tread depth
(~) Side wall
(~) Wear indicator
3-19
CHECKING THE TmESl INSP I I
•WARNING
• Do not use a tubeless tire on a w h e e l de-
signed only for t u b e tires t o avoid tire fail-
ure and personal injury f r o m sudden defla-
tion.
• When using t u b e tires, be sure t o install t h e
correct tube.
• A l w a y s replace a n e w t u b e tire and a n e w
t u b e as a set.
• To avoid pinching the tube, make sure t h e
a__l BI
w h e e l rim band and t u b e are centered in t h e
w h e e l groove.
• Patching a p u n c t u r e d t u b e is n o t r e c o m -
et
mended. If it is a b s o l u t e l y necessary t o do
n
so, use great care and replace t h e t u b e as
e.
soon as possible w i t h a good quality replace-
im
ment.
T
[ ] Tire
er
IB] Wheel
ot
co
Tube wheel Tube tire o n l y
.S
w
Tubeless wheel Tube or tubeless tire

w
w
• After e x t e n s i v e tests, the tires listed b e l o w

m
have been a p p r o v e d by Y a m a h a M o t o r Co.,

fro
Ltd. for t h i s model. The f r o n t and rear tires

s h o u l d a l w a y s be by t h e same m a n u f a c t u r e r
ed
and of t h e same design. No guarantee con-

ad
c e r n i n g h a n - d l i n g c h a r a c t e r i s t i c s can be
given if a tire c o m b i n a t i o n o t h e r t h a n one
o
nl
approved by Yamaha is used on this scooter.

ow
D
3-20
CHECKING THE T I R E S / C H E C K I N G THE WHEELSI INSP
N e w tires have a relatively l o w grip on the road
surface until t h e y have been s l i g h t l y w o r n .
Therefore, a p p r o x i m a t e l y 100 km should be
t r a v e l e d at n o r m a l speed b e f o r e any high-
speed riding is done.
NOTE:
For tires w i t h a direction of rotation mark (~:
• Install the tire w i t h the mark pointing in the
direction of wheel rotation.
• Align the mark (~)with the valve installation
et
point.
n
e.
T im
er
ot
co
.S
w
w
w
m
fro
ed
ad
o
nl
ow
D
3-21
WHEEL INSPECTION/FRONT FORK INSPECTION INSP
REAR SHOCK ABSORBER INSPECTION/SEAT LOCK C A B L E A D J U S T M E N T
WHEEL INSPECTION
I
1. Inspect:
• wheels
Da mage/Bends-->Replace.
Never attempt to make any repairs to the wheel.
NOTE:
After a tire or wheel has been changed or re-
placed, always balance the wheel.
et
FRONT FORK INSPECTION
n
1. Inspect:
e.
• Front f o r k ~
im
Bends/Damage-->Replace inner t u b e
T
comp, fork ass'y.
er
Grease leakage--~Replace inner t u b e
ot
co comp. fork ass'y.
U n s m o o t h operation-->Replace f o r k
.S
ass'y.
w
w
REAR SHOCK ABSORBER INSPECTION

w
1. Inspection:
• Rear shock absorber(~)
m
Oil leaks/Da mage-->Re place.

fro
2. Check
ed
• Tightening torque
ad
% ~ Upper(nut) 30Nm (3.0 m.kg, 22ft.lb',

o
nl
Lower (bolt) 16 Nm(1.6 m.kg, 12ft.lb',

ow
SEAT LOCK CABLE A D J U S T M E N T

D
1. Remove:
• Upper cover
Refer to "COVER A N D PANEL" section.
2. Adjust:
• Seat cable
Seat cable adjustment steps:

• Loosen lock nut (~
• Turn adjuster (~ in or out to adjust the seat
lock cable.
• Tighten the lock nut.
3. Install:
• Upper cover
3-22
CABLE C°EOK.°O A ° O " U B . . O A T . ° O . "EVE.S "UB..OAT.°O "'"SP''"' '
C E N T E R S T A N D LUBRICATING
I ADJ
I~1
EAS00170
CABLE C H E C K I N G A N D L U B R I C A T I N G
The f o l l o w i n g procedure applies to all of the
cable sheaths and cables.
r!~VAVL, W--'t~ I I ~ [¢-!
D a m a g e d cable sheaths m a y cause the cable
to corrode and interfere w i t h its m o v e m e n t .
Replace d a m a g e d cable sheaths and cables as
soon as possible.
. Check:
• cable sheath
et
Damage --> Replace.
n
. Check:
e.
• cable operation
im
Rough m o v e m e n t --> Lubricate.
T
er
Recommended lubricant t
ot
Engine oil or a suitable cable lubri
ca nt
co
.S
NOTE:
w
Hold the cable end u p r i g h t and pour a f e w

w
drops of lubricant into the cable sheath or use

w
a suitable lubricating device.

m
fro
EAS00171
ed
LEVERS L U B R I C A T I N G
Lubricate the pivoting point and metal-to-metal
ad
m o v i n g parts of the levers.

o
nl
Recommended lubricant
ow
Lithium soap base grease

D
EAS00173
CENTERSTAND LUBRICATING
Lubricate the pivoting point and metal-to-metal
m o v i n g parts of the centerstand.
Recommended lubricant
Lithium soap base grease
3-23
BATTERY I N S P E C T I O N I INSP
ELECTRICAL
BATTERY INSPECTION
NOTE:
Since the MF battery is of a sealed-type con-
struction, it is impossible to measure the spe-
cific g r a v i t y of the electrolyte in order to check
the state of charge in the battery. Therefore, to
check the state of charge in the battery, volt-
age must be measured at the batteryterminals.
CAUTION:
CHARGING METHOD
et
• This b a t t e r y is sealed type. Never r e m o v e
n
sealing caps even w h e n charging. W i t h t h e
e.
sealing cap removed, t h i s balancing w i l l n o t
im
be m a i n t a i n e d , and b a t t e r y performance w i l l
T
l o w e r gradually.
er
• Never add w a t e r . If distilled w a t e r is added,
ot
chemical reaction in the b a t t e r y w i l l not pro-
co
ceed in the normal w a y , t h u s m a k i n g it im-
.S
possible for t h e b a t t e r y t o operate regularly.
w
• The c h a r g i n g t i m e , c h a r g i n g c u r r e n t and
w
charging v o l t a g e for t h e MF b a t t e r y is differ-

w
ent t h a n general t y p e batteries.

m
The MF b a t t e r y s h o u l d be c h a r g e d as in-
fro
structed in t h e " C h a r g i n g m e t h o d " . Should

the b a t t e r y be overcharged, t h e electrolyte
ed
level w i l l l o w e r e x t r e m e l y . Therefore, use

ad
special care w h e n charging t h e battery.

• A v o i d using any electrolyte other than speci-
o
nl
fied. The specific g r a v i t y of t h e MF b a t t e r y

ow
electrolyte is 1.32 at 20°C (68°F). (The spe-

cific g r a v i t y of the general t y p e b a t t e r y elec-
D
t r o l y t e is 1.28. ) If the electrolyte w h o s e spe-

cific g r a v i t y is less than 1.32, the sulfuric acid
w i l l decrease and t h u s l o w b a t t e r y perfor-
mance w i l l result.
Should any electrolyte, w h o s e specific grav-
ity is 1.32 or more, be used, the b a t t e r y plates
w i l l corrode and b a t t e r y life w i l l shorten.
1. Remove:
• Battery b o x cover
Refer to "COVER A N D PANEL" section.
2. Remove:
• Battery
NOTE:
Remove the (-) lead first.
3-24
INSP
BATTERY I N S P E C T I O N
I
Batteries g e n e r a t e e x p l o s i v e h y d r o g e n gas and
c o n t a i n e l e c t r o l y t e w h i c h is m a d e of p o i s o n -
o u s a n d h i g h l y c a u s t i c s u l f u r i c acid.
Therefore, always follow these preventive
measures:
// • W e a r p r o t e c t i v e eye gear w h e n h a n d l i n g or
w o r k i n g near b a t t e r i e s .
• C h a r g e b a t t e r i e s in a w e l l - v e n t i l a t e d area.
• Keep b a t t e r i e s a w a y f r o m fire, sparks or o p e n
f l a m e s (e.g., w e l d i n g e q u i p m e n t , l i g h t e d
cigarettes).
• DO NOT SMOKE w h e n c h a r g i n g or h a n - d l i n g
et
batteries.
n
• KEEP BATTERIES A N D ELECTROLYTE O U T
e.
OF REACH OF CHILDREN.
im
• A v o i d b o d i l y c o n t a c t w i t h e l e c t r o l y t e as it
T
can cause s e v e r e b u r n s or p e r m a n e n t eye
er
injury.
ot
FIRST AID IN CASE OF BODILY CONTACT:
co
EXTERNAL
.S
• Skin ~ Wash with water.
w
• Eyes - - Flush w i t h w a t e r for 15 m i n u t e s and

w
get immediate medical attention.

w
INTERNAL
m
• D r i n k large q u a n t i t i e s of w a t e r or m i l k fol
fro
l o w e d w i t h m i l k of m a g n e s i a , b e a t e n egg or
v e g e t a b l e oil. G e t i m m e d i a t e medical a t t e n -
ed
tion.
o ad
Volt meter 3. Check:

nl
• Battery c o n d i t i o n
ow
D
Battery c o n d i t i o n c h e c k i n g steps:
• Connect a digital v o l t m e t e r to the b a t t e r y t e r -
minals.
I Tester (+) lead Battery (+) t e r m i n a l . I

Tester (-) lead Battery (-) t e r m i n a l .
I
(v) Relationshipbetweenopen-circuit
13.0 8 ° C ) NOTE:
&
12.5 The state of a d i s c h a r g e d MF b a t t e r y can be
o
12.0 checked by m e a s u r i n g o p e n circuit v o l t a g e (the
~, 11.5 v o l t a g e m e a s u r e d w i t h the p o s i t i v e t e r m i n a l s
0
being d i s c o n n e c t e d ) .
i
5 6.5 ~0
Chargingtime(hours)
•Thisvariesdependingon the temperature,the stateof
chargein batteryplatesand the electrolytelevel.
3-25
BATTERYINSPECTION I INSP
~1(~1
14 Ambient Open circuit voltage Charging time
temperature
20°C 12.8 v or more No charging is necessary.
.~ 11 | |
|
• Check the b a t t e r y c o n d i t i o n u s i n g f i g u r e s .
I I
EXAMPLE:
B B
Open circuit v o l t a g e = 12.0v

100 75 50 30 25 20
C h a r g i n g t i m e = 6.5 h o u r s
Condition of charge in battel~J(%) C o n d i t i o n of c h a r g e in b a t t e r y = 20 ~ 30%
2. C h a r g i n g m e t h o d of MF b a t t e r y
CAUTION:
• If it is i m p o s s i b l e t o set t h e s t a n d a r d c h a r g -
et
ing c u r r e n t , be careful n o t t o o v e r c h a r g e .
n
e W h e n c h a r g i n g t h e b a t t e r y , be s u r e t o re-
e.
m o v e it f r o m t h e m o t o r c y c l e . (If c h a r g i n g has
im
t o be d o n e w i t h t h e b a t t e r y m o u n t e d on t h e
T
m o t o r c y c l e for s o m e reason, be s u r e t o dis-
er
c o n n e c t t h e w i r e at t h e n e g a t i v e t e r m i n a l . )
ot
• Never remove the sealing plug from the MF
co
Charging Ambient temperature
20oc battery.
.S
& • Use special care so t h a t c h a r g i n g clips are in

w
o a full c o n t a c t w i t h t h e t e r m i n a l and t h a t t h e y
\
w
2
are n o t s h o r t e d . (A c o r r o d e d c l i p of t h e
w
& c h a r g e r m a y cause t h e b a t t e r y t o g e n e r a t e
m
o heat at t h e c o n t a c t area. A w e a k clip s p r i n g

fro
Time(Minutes)
m a y cause sparks.)
~1~ Check the open circuit • Before r e m o v i n g t h e clips f r o m t h e b a t t e r y
ed
voltage
t e r m i n a l s , be s u r e t o t u r n off t h e p o w e r
ad
s w i t c h of t h e charger.
• C h a n g e in t h e o p e n - c i r c u i t v o l t a g e of t h e M F
o
nl
b a t t e r y after b e i n g c h a r g e d is s h o w n b e l o w .
ow
As s h o w n in t h e f i g u r e , t h e o p e n c i r c u i t v o l t -
age is s t a b i l i z e d 30 m i n u t e s after c h a r g i n g
D
has been c o m p l e t e d .
T h e r e f o r e , t o c h e c k t h e c o n d i t i o n of t h e bat-
t e r y , m e a s u r e t h e o p e n - c i r c u i t v o l t a g e 30
m i n u t e s after has b e e n c o m p l e t e d .
3-26
BATTERY INSPECTION I INSP
C h a r g i n g m e t h o d u s i n g a v a r i a b l e - c u r r e n t (voltage) t y p e c h a r g e r
Charger AMP
NOTE:
meter Measure the open-circuit volt- Voltage should be measured
age prier to c h a r g i n g . 30 minutes after the machine
is stopped.
t
NOTE:
C o n n e c t a c h a r g e r and A M P Set the c h a n g i n g v o l t a g e at
m e t e r to the b a t t e r y and start 16 17 V. (Ifthe setting is lower,
charging Will be insufficient.
charging. If t o o high, the battery Will be
+ over-charged.)
Make sure the c u r r e n t is h i g h e r

YES NO
than the standard charging
c u r r e n t w r i t t e n on the battery.
1
n et
e.
By t u r n i n g the c h a r g i n g v o l t a g e
im
a d j u s t dial, set the c h a r g i n g v o l t -
T
age at 20 - 25 V.
+
er
ot
A d j u s t the v o l t a g e so t h a t c u r r e n t 4 YES
co M o n i t o r t h e a m p e r a g e f o r 3-5
is at s t a n d a r d c h a r g i n g level. m i n u t e s to check if the s t a n d a r d
.S
c h a r g i n g c u r r e n t is reached.
w
1
w
NO
w
1
m
fro
Set the t i m e r a c c o r d i n g to the

ed
If c u r r e n t d o e s
c h a r g i n g t i m e s u i t a b l e for the
ad
not exceed stan-

o p e n - c i r c u i t v o l t a g e . Refer to
dard charging
o
"Battery condition checking

nl
current after 5
steps".
ow
m i n u t e s , replace
l
the battery.
D
In case t h a t c h a r g i n g r e q u i r e s m o r e t h a n 5 h o u r s , it is a d v i s a b l e to
check the c h a r g i n g c u r r e n t after a lapse of 5 h o u r s . If t h e r e is a n y
c h a n g e in the a m p e r a g e , r e a d j u s t the v o l t a g e to o b t a i n the s t a n d a r d
c h a r g i n g current.
I
M e a s u r e the b a t t e r y o p e n - c i r c u i t v o l t a g e after h a v i n g left t h e bat-

t e r y u n u s e d for m o r e t h a n 30 m i n u t e s .
12.8 V o r m o r e --- C h a r g i n g is c o m p l e t e .
12.7 V o r less --- R e c h a r g i n g is r e q u i r e d .
U n d e r 1 2 . 0 V --- Replace t h e battery.
3-27
BATTERY I N S P E C T I O N I INSP
Charging method using a constant-voltage type charger
NOTE:
Measure the open-circuit volt- V o l t a g e s h o u l d be m e a s u r e d 30 min-
Charger utes after the m a c h i n e is s t o p p e d .
age prier to charging.
AMP meter
Volt meter
II
~ Connect a c h a r g e r and A M P
et
meter to the battery, and start
n
I charging.
e.
im
T
er
Make sure the current is higher
ot
YES NO
than the standard charging
co
1 1
current w r i t t e n on the battery.
.S
w
w
w
Charge the battery until the

m
This type of battery charger Can

battery's charging voltage is 15
fro
not charge the MF b a t t e r y . A

volts.
variable voltage charger is rec-
ed
ommended.
NOTE:
ad
Set the c h a r g i n g t i m e at 20 h o u r s
(maximum).
o
nl
ow
D
Checkthe open-circuit voltage after hav-

ing left the battery for 30 minutes
after charging.
12.8 V or m o r e - - - Charging is complete.
12.7 V or less --- Recharging is neces-
sary.
Under 12 V --- Replace the battery.
Charging method using a constant current type charger

This t y p e if battery charger Can not charge the MF battery.
3-28
FUSE INSPECTION I INSP
4. Inspect:
• Battery terminal
D i r t y terminal-->Clean w i t h w i r e brush.
Poor co n nection-->Co rrect.
NOTE:
A f t e r cleaning t e r m i n a l s , a p p l y l i g h t l y to the
terminals.
. Install
• Battery
n et
e.
T im
er
ot
co
FUSE I N S P E C T I O N
1. R e m o v e :
.S

w
Refer to " C O V E R A N D P A N E L " section.

w
2. R e m o v e :
w
• Fuse ( ~
m
3. Inspect:
• Fuse ( ~
fro
defective--~Replace
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
ed
B l o w n fuse p r o c e d u r e steps:
ad
• T u r n off i g n i t i o n and the circuit.

• Install a n e w fuse of p r o p e r a m p e r a g e .
o
nl
• T u r n on s w i t c h e s to v e r i f y o p e r a t i o n of elec-
ow
trical device.
• If fuse b l o w s i m m e d i a t e l y again, check cir-
D
cuit in q u e s t i o n .
~!~Lvlv/±1:] ~11~[¢-!
Never use a fuse w i t h an a m p e r a g e rating other
t h a n t h a t specified. Improvising or using a fuse
w i t h t h e w r o n g a m p e r a g e rat-ing m a y cause
e x t e n s i v e d a m a g e t o t h e electrical s y s t e m ,
cause t h e lighting and ignition systems to mal-
f u n c t i o n and could possibly cause a fire.
Description Amperage Quantity

Main 7A 1
. Install:
• Fuse
3-29
HEADLIGHT BEAM A D J U S T M E N T I INSP
/HEADLIGHT BULB REPLACEIVIENT I
I
HEAD LIGHT BEAM A D J U S T M E N T

1. Adjust:
\ j) • Head l i g h t (vertically)
T u r n t h e a d j u s t i n g s c r e w ( ~ in or o u t to
a d j u s t h e a d l i g h t beam.
• Head l i g h t (Horizontal)
T u r n t h e a d j u s t i n g s c r e w ( ~ in or o u t to
a d j u s t h e a d l i g h t beam.
HEADLIGHT BULB REPLACEMENT

1. Remove:
• Upper cover
Refer to "COVER A N D P A N E L " section.
n et
e.
T im
er
ot
2.
co Disconnect:
• Headlight coupler (~
.S
3. Remove:
w
• Bulb h o l d e r c o v e r ( ~
w
w
m
fro
ed
ad
4. Remove:
o
• Headlight bulb holder (~

nl
T u r n the b u l b h o l d e r c o u n t e r c l o c k w i s e
ow
to r e m o v e it.
D
5. Remove:
• Bulb(defective) (~
W!~VAV/±I -'| ~ I I ~ [¢']1
Since the headlight bulb gets extremely hot,
keep f l a m m a b l e p r o d u c t s and y o u r hands
a w a y from the bulb until it has cooled down.
3-30
HEADLIGHT BULB / TURN SIGNAL BULB REPLACEMENT
6. Install:
i,.S.l l
ADJ
• Bulb(new)
CAUTION:
A v o i d t o u c h i n g t h e glass p a r t of t h e h e a d - l i g h t
b u l b t o keep it free f r o m oil, o t h e r w i s e t h e
t r a n s p a r e n c y of t h e glass, t h e life of t h e b u l b
a n d t h e l u m i n o u s f l u x w i l l be a d v e r s e l y af-
fected. If t h e h e a d l i g h t b u l b g e t s s o i l e d , t h o r -
o u g h l y clean it w i t h a c l o t h m o i s t e n e d w i t h
a l c o h o l or l a c q u e r t h i n n e r .
7. Install:
et
• Bulb h o l d e r
n
• T u r n the b u l b h o l d e r c l o c k w i s e to install
e.
it.
im
8. Install:
T
• Bulb h o l d e r c o v e r
er
9. Connect:
ot
• Headlight coupler
co
10. Install:
.S
• Upper cover
11. A d j u s t :
w
w
• H e a d l i g h t beam
w
Refer to " H E A D L I G H T BEAM

ADJ U S T M E N T " s e c t i o n
m
fro
ed
ad
TURN SIGNAL BULB REPLACEMENT

o
1. Remove:
nl
• Screw (~
ow
• Lens ( ~
D
2. Replace:
• Bulb ( d e f e c t i v e ) ( ~
3. Install:
• Lens (~)
• Screw (~
CAUTION:
/REAR
_
Do n o t o v e r - t i g h t e n t h e s c r e w s as t h e lens m a y
break.
3-31
TAILLIGHT BULB / LICENCE LIGHT BULB REPLACEMENT i,.s l l
ADJ
CAUTION:
A v o i d t o u c h i n g the glass part of t h e head-light
bulb t o keep it free f r o m oil, o t h e r w i s e t h e
t r a n s p a r e n c y of t h e glass, t h e life of t h e bulb
and t h e l u m i n o u s f l u x w i l l be a d v e r s e l y af-
fected. If t h e h e a d l i g h t bulb gets soiled, t h o r -
o u g h l y clean it w i t h a cloth m o i s t e n e d w i t h
alcohol or lacquer thinner.
T A I L L I G H T BULB R E P L A C E M E N T
1. Remove:
• Screws (~
et
• Lens (~
n
2. Replace:
e.
• Bulb (defective) (~
im
3. Install:
T
• Lens (~)
er
• Screws ~)
ot
co
LICENSE LIGHT BULB R E P L A C E M E N T
1. Remove:
.S
• Screws (~
w
• Lens (~)
w
w
2. Replace:
• Bulb (defective) (~
m
3. Install:
fro
• Lens (~)
ed
• Screws (~
ad
o
nl
ow
D
3-32
E.O..E.EMOVA" I E"O I o '1
EB400000
ENGINE OVERHAUL
ENGINE R E M O V A L
W l R E H A R N E S S A N D CABLES
~ 1 2 0 N m ( 1 2 . 0 m.kg, 87 ft.lb)
7
12 1~145Nm(4-5 m.kg, 31ft.lb) I
n et
e.
T im
er
ot
co
.S
w
w
w
m
fro
ed
o ad

nl
W i r e h a r n e s s and cables r e m o v a l Remove the parts in order.

ow
Rear carrier
D
Tail cover Refer to "COVER A N D PANEL" section

Left side panel in CHAPTER 3.
Right side panel
Battery b o x cover
Center c o w l i n g
Air filter case
Carburetor Refer to " C A R B U R E T O R " s e c t i o n in
CHAPTER 6.
1 Air shroud 1
2 A u t o l u b e delivery hose
4-1
ENGINE R E M O V A L mENG m~)~,mm
[~m120Nm(12.0 m.kg, 87 ft.lb)
\
12 [~q45Nm(4.5m.kg, 31ft.lb) I
~ 7
//
n et
e.
T im
er
ot
co
.S
w
w
w
m
fro
Order J o b name/Part name Q'ty Remarks

ed
Spark plug cap 1

Battery (-) lead 1
ad
C.D.I magneto leads coupler 1

o
Starter m o t o r leads coupler 1

nl
Rear wheel nut 1

ow
NOTF"
Loosen the rear wheel nut.
D
8 Rear brake adjuster

9 Rear brake cable
10 Pin
11 Bolt
12 Engine m o u n t bolt
13 Engine
Reverse the removal procesure for instal-
lation.
4-2
CYLINDER HEAD, CYLINDER A N D PISTON I ENG I~>]DI
CYLINDER HEAD, CYLINDER A N D PISTON
C Y L I N D E R HEAD, C Y L I N D E R A N D P I S T O N
~126Nm(2.6 m.kg, 18.2 ft.lb) I
10[]~ 1 ..~ ~ _ . ~
n et
e.
T im
er
ot
co
~ ~ 9N m(0.9 m
.S
w
w
w
' H1,Nm(1. m.kg, 10 ft.'bll

m
fro
2 9 l 7
ed
o ad
Order Job name/Part name Q'ty Rema rks

nl
Cylinder head, Cylinder and piston Remove the parts in the order.
ow
removal
D
Engine Refer to the "ENGINE REMOVAL" sec-

1 Muffler/Gasket 1/1 tion
2 Air shroud 2 1
3 Spark plug 1
4 Cylinder head/Cylinder head gasket 1/1
5 Cylinder 1
6 Piston pin clip 2
7 Piston pin/Bearing 1/1
8 Piston 1
9 Piston ring set 1
10 Cylinder gasket 1
Reverse the removal procedure for in-
stallation.
4-3
CV'..OE..EAO. OV'..OE.. P.STO. I E"O Io .1
P I S T O N PIN A N D P I S T O N R E M O V A L
1. Remove:
• Piston pin clip ( ~
NOTE:
Before r e m o v i n g the p i s t o n pin clip, c o v e r the
crankcase w i t h a clean rag so y o u w i l l not acci-
d e n t a l l y d r o p t h e clip into the crankcase.
2. Remove:
• Piston pin ( ~
• Piston ~ )
et
• Piston pin b e a r i n g ( ~
n
e.
CAUTION:
im
Do not use a h a m m e r t o d r i v e t h e p i s t o n pin
T
out.
er
ot
co
CYLINDER HEAD INSPECTION
.S
1. E l i m i n a t e :
w
• Carbon deposits
w
Use a r o u n d e d s c r a p p e r (~.
w
m
fro
ed
ad
2. Inspect:
o
• C y l i n d e r head w a r p a g e
nl
Out of specification-->Re-surface.
ow
W a r p a g e m e a s u r e m e n t and r e - s u r f a c e m e n t
D
steps:
• A t t a c h a s t r a i g h t e d g e ( ~ and a t h i c k n e s s
g a u g e ( ~ on the c y l i n d e r head.
• M e a s u r e the w a r p a g e limit.
I l aroaoe" 't" 0.03 m m ( 0 . 0 0 1 2 in) I

• If the w a r p a g e is o u t of s p e c i f i c a t i o n , reface
the c y l i n d e r head.
NOTE:
Rotate the head severai tires to a v o i d r e m o v -
ing t o o m u c h material f r o m one side.
4-4 ~ ~ ~ ~ ~ ~
CYLINDER AND PISTON INSPECTION I ENG I TDI
CYLINDER AND PISTON INSPECTION
1. E l i m i n a t e :
• Carbon deposits
Use a r o u n d e d scraper (~.
2. Inspect:
• Cylinder wall
Q Wear/Scratches-->Rebore or replace.
. Eliminate:
• Carbon d e p o s i t s ( ~
From the piston crown and ring
et
grooves.
n
e.
T im
er
ot
4.
co Remove:
.S
• Score markes and lacquer d e p o s i t s
From the sides of piston.
w
w
5. Inspect:
w
• Piston w a l l
Wea r/Scratches/Da m age-->Re place.
m
fro
ed
ad
6. Measure:
o
• Piston-to c y l i n d e r clearance
nl
ow
Piston to c y l i n d e r c l e a r a n c e m e a s u r e m e n t
D
steps: First step:

• M e a s u r e the c y l i n d e r bore " C " w i t h a c y l i n -
der bore g a u g e .
NOTE:
M e a s u r e the c y l i n d e r bore " C " in parallel to and
I~...~ / -----~ ~ at r i g h t a n g l e s to the crankshaft. Then, find the
a v e r a g e of the m e a s u r e m e n t s .
4-5
CYLINDER HEAD, CYLINDER A N D PISTON I ENG I
Standard Wear limit
C y l i n d e r bore 40.000~40.014mm 40.10 m m

IJCF, (1.5748~ 1.5754 in) (1.5787 in)
- 0.05 mm
Taper "T" (0.0020 in)
O u t of r o u n d - 0.03 mm
" R" (0.0012 in)
C = Maximum D
T=( M a x i m u m D1 o r D2 ) - ( M a x i m u m D5 or
D6 )
R=( M a x i m u m D1 D3 or D5 ) - ( M a x i m u m D2
et
D4 or D6 )
n
e.
• If o u t o f s p e c i f i c a t i o n , r e b o r e or r e p l a c e cyl-
im
inder, a n d r e p l a c e p i s t o n a n d p i s t o n r i n g s
T
as a set.
er
2 n d step:
ot
• M e a s u r e t h e p i s t o n skirt d i a m e t e r " p " w i t h
co
a micrometer.
.S
( ~ 10 m m f r o m t h e p i s t o n b o t t o m edge.
I l st°nsze I
w
w
3 9 . 9 5 8 ~ 3 9 . 9 7 2 m m ( 1 . 5 7 3 1 ~ 1 . 5 7 3 7 in)
w
®
m
• If o u t of s p e c i f i c a t i o n , replace p i s t o n a n d pis-
fro
t o n r i n g s as a set.
3rd step:
ed
• Calculate the piston-to cylinder clearance

ad
with following formula:

o
I
nl
I P i s t o n - t o c y l i n d e r c l e a r a n c e = C y l i n d e r bore I
ow
" C "- Piston skirt d i a m e t e r " p "

I
D
• If o u t of s p e c i f i c a t i o n , r e b o r e or r e p l a c e cyl-
i n d e r , a n d r e p l a c e p i s t o n a n d p i s t o n r i n g s as
a set.
Piston-to cylinder clearance:

0.035 - 0 . 0 4 0 m m (0.014 - 0.0016 in)
L i m i t : 0.10 m m (0.0039 in)
4-6
OV'.°OE..EAO. OV'..OE. A°O P.STO. I E"O I o =1
PISTON R I N G S I N S P E C T I O N
1. Measure:
• Side clearance
O u t of s p e c i f i c a t i o n - - > R e p l a c e piston
a n d / o r rings.
Use a feeler g a u g e ( ~
Standard Li m i t
T o p ring 0.03~0.05mm 0.1 m m

(0.0012 ~ 0.002 in) (0.0039 in)
2nd ring 0.03-0.05mm 0.1 m m
(0.0012 ~ 0.002 in) (0.0039 in)
et
2. Install:
n
e.
• Piston ring
im
Into the c y l i n d e r
T
Push t h e ring w i t h the piston c r o w n .
er
ot
.
co
Measure:
• End gap
.S
Out of specification-->Replace r i n g s as
w
a set.
w
w
Use a feeler g a u g e (~.

m
L Stand a rd Li m it
fro
ed
T o p ring 0 . 1 5 - 0.35 m m 0.6ram

(0.005 ~ 0.01 in) (0.02 in)
ad
2nd ring 0.15~0.35mm 0.6ram

o
(0.005 ~ 0.01 in) (0.02 in)

nl
ow
( ~ M e a s u r i n g Point 20 m m ( 0 . 7 9 in)
D
PISTON PIN A N D P I S T O N PIN B E A R I N G

1. Inspect:
• Piston pin
B l u e discoloration/Groove-->Replace,
t h e n inspect l u b r i c a t i o n s y s t e m .
4-7
CV'..OE..EAO CV'..OE. A.O P.STO. I E"O I o '1
. Measure:
f • Outside d i a m e t e r (~ (piston pin)
"2
ootsdedameter,0ston on' '
9.996~ 10.000 m m(0.3935~0.3937in t
. Measure:
• Piston pin-to-piston clearance
Out of specification-->Replace piston.
Piston pin-to-piston clearance =

Bore size (piston pin)
Outside d i a m e t e r (piston pin)
n et
Piston pin-to-piston clearance" I
e.
0.004-0.019 mm(0.0016-0.00075 in
1
im
<Limit: 0.07 mm>(0.003 in)
T
er
ot
co
4. Inspect:
.S
• Bearing(piston pin)
Pitting/Da m a g e ~ R e p l a c e .
w
w
w
m
fro
ed
ad
P I S T O N PIN A N D P I S T O N I N S T A L L A T I O N
o
1. Apply:
nl
• Engine oil
ow
(to the crankshaft bearing, connecting

D
rod big end bearing, small end bearing,

piston pin, piston ring g r o o v e s and pis-
ton skirt areas.)
. Install:
• Reed valve gasket
• Reed valve
• Carburetor joint (~ ~ l 11Nrn(1.1m.kg, 8ft.lb~
4-8
OV',.OE..EAO. CV',°OE. A.O ,,StO. I E"O I0 '1
3. Install:
• Small end bearing
• Piston (~
• Piston pin (~)
Q~ °-, J • Piston pin clip ~)
NOTE:
• The a r r o w (~ on the piston to the e x h a u s t
side.
• Before installing the piston pin clip, cover the
crankcase w i t h a clean towel or rag so you
will not accidentally drop the pin clip mate-
rial into the crankcase.
• A l w a y s use a n e w piston pin clip.
n et
e.
T im
er
ot
co
CYLINDER AND CYLINDER HEAD
.S
1. Install:
w
• Cylinder gasket (new gasket)

w
2. Check:
w
• Piston rings
m
(~ 1st ring
fro
(~ 2nd ring
ed
NOTE:
Make sure the ring ends (~ are properly fitted
ad
around the ring locating pins (~) in the piston

o
grooves.
nl
ow
D
3. Install:
• Cylinder (~
NOTE:
• r/ 0
Install the cylinder w i t h one hand w h i l e com-
pressing the piston rings w i t h the other hand.
4-9
O*'.°OE..EAO. C*'.°OE. A°O P.S*O. I' "0 I0 .1
4. Install:
• Cylinder head gasket (new gasket)
5. Install:
• Cylinder head (~ ~114Nm(1.4m.kg,10ft.lb)
• Spark plug (~) r~120Nm(2.0m.kg,14ft.lb)
• Air shroud
NOTE:
Tighten the cylinder head holding nuts in stage,
using a crisscross pattern.
n et
e.
T im
er
ot
co
.S
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w
w
m
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ed
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o
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ow
D
4-10
V-BELT, CLUTCH A N D
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE

KICK STARTER AND CRANKCASE COVER (LEFT)
12Nm(1.2m.kg, 8.4 ft.lb)~

4 ~
3
n et
e.
im
I ~ l 7Nm(0.Tm.kg, 5.1 ft.lb
//
T
er
ot
co
I~190Nm(0.9m.kg, 6.5 ft.lb) I
.S
w
w
w
m
fro
ed
ad

o
Kick starter and crankcase cover (left) Remove the parts in order.
nl
removal
ow
1 Kick starter
2 Crankcase cover 2 (left)
D
3 Crankcase cover 1 (left)

4 Gasket
5 Pin

stallation.
4-11
S E C O N D A R Y / P R I M A R Y SHEAVE I ENG
V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE
KICK STARTER
n et
e.
T im
er
ot
co
®
.S
w
w
w
m
fro
ed
ad

o
Kick starter r e m o v a l R e m o v e the parts in order.

nl
Crankcase c o v e r 1 (left) r e m o v a l
ow
(# Kickstarter p i n i o n gear 1
® Kickstarter p i n i o n gear clip 1
D
® Circlip/Plain w a s h e r 1/1
® Kickstarter s e g m e n t gear 1
® Return s p r i n g 1
® Collar 1
Reverse the r e m o v a l p r o c e d u r e for in-
stallation.
4-12
V-BELT, CLUTCH AND
SECONDARY/PRIIVIARY
SHEAVEI ENG I ~>= I
KICK S T A R T E R I N S T A L L A T I O N
1. Install:
Return spring
• Kickstarter segment gear (~
• Collar (~
• Plain w a s h e r (~
• Circlip (~
Installation steps:
a. Install return spring (~ and s e g m e n t gear
et
(~ as s h o w n .
n
b. Install clip (~.
e.
c. Hook the spring onto the crankcase pro-
im
jection (~.
T
d. Install the kick starter pinion gear (~ and
er
the kick starter.
ot
co
.S
w
w
w
m
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ed
ad
o
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ow
D
4-13
V-BELT" CLUTCH AND I I~)~1
SECONDARY/PRIMARY SHEAVE ENG
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE
3
2
et
t/~~/
n
e.
T im
er
ot
co 7
<i
.S
w
4 /
,~ ~QI40 N m(4.0 m.kg,29ft.lb)
w
w
m
~145Nm(4.5m.kg,33ft.lb)
10 8 ~ v
fro
ed
Order J o b name/Part name Remarks

ad
Q'ty
o
V-belt, clutch and s e c o n d a r y / p r i m a r y Remove the parts in order.

nl
sheave removal
ow
Lower cowling ]Refer to "COVER A N D PANEL" section

Air s h r o u d 3 in chapter 3.
D
Crankcase cover (left) Refer to "ENGINE R E M O V A L " section.

1 Clutch h o u s i n g 1 -I Refer to "SECONDARY SHEAVE A N D V-
2 S e c o n d a r y sheave a s s e m b l y 1 J BELT REMOVAL " section.
3 V-belt 1
4 Conical w a s h e r / O n e - w a y clutch 1/1 - Refer to " P R I M A R Y SHEAVE REMOVAL
5 Crow washer 1 ASSE M BLY" section.
6 Primary fixed sheave 1
7 Collar/Washer 1/1
8 Primary sliding sheave 1
9 Cam/Slider 1/3
10 Weight 6
stallation
4-14
V-BELT, C L U T C H A N D I
SECONDARY/PRIMARY SHEAVE I ENG
SECONDARY SHEAVE
n et
e.
T im
/
er
ot
co [~150Nm(5.0m.kg, 36ft.lb) I
.S
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w
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m
fro
""-4
ed
Order Job name/Part name Remarks

ad
Q'ty
o
Secondary sheave d i s a s s e m b l y Disassemble the parts in order.

nl
(# Nut 1
ow
® Refer to "SECONDARY SHEAVE DISAS-

Clutch carrier 1
® S E M B L Y " section.
Clutch shoe spring 2
D
® Refer to " S E C O N D A R Y SHEAVE IN-

Compression spring 1
® S T A L L A T I O N " section.
Spring seat 1
® Guide pin 2
@ Refer to " S E C O N D A R Y SHEAVE IN-
Secondary sliding sheave 1
® S T A L L A T I O N " section.
O-ring 2
® Oil seal 2
® Secondary fixed sheave 1
Reverse the d i s a s s e m b l y procedure for

assembly.
4-15
V-BE'T" O'UTC" A"O I ENG Io =1
S E C O N D A R Y / P R I M A R Y SHEAVE
/ PRIMARY SHEAVE REMOVAL
1. Remove:
i
• Fan
2. Remove:
• Nut (~ (primary sheave)
NOTE:
When loosening the nut (primary sheave), hold
the C.D.I. magneto using flywheel holding tool
® ®.
I ~ I Rotor
holdiyu_01235ngtool: I
et
3. Remove:
n
• Conical spring washer (~
e.
• One-way clutch ®
im
• Washer (~
T
• Primary fixed sheave (~
er
• Shim (~
ot
• V-Belt
co
4. Remove:
.S
• Collar (~
w
• Primary sheave assembly®

w
w
m
fro
ed
ad
SECONDARY SHEAVE REMOVAL

o
1. Remove:
nl
• Nut (~ (secondary sheave)

ow
NOTE:
D
Hold the secondary sheave using sheave holder

®.
I<~1 Sh eave holder: I

YU-01701
2. Remove:
• Clutch housing
• Secondary sheave assembly
• Dowel pins
4-16
S E C O N D A R Y / P R I M A R Y SHEAVE I ENG I{ =l
3. Loosen:
• Nut(Clutch carrier)(~
NOTE:
Install the secondary sheave to primary drive
shaft as shown, and hold the secondary sheave
by Universal Roter Holder(~to loosen the nut
(#.
~ Roter holding tool" ]
YU-01235
CAUTION:
Do not r e m o v e the clutch securing nut yet.
et
If the nut is r e m o v e d w i t h o u t c o m p r e s s i o n g
n
e.
the secondary sheave. It j u m p s and causes in-
im
jury.
T
er
ot
co
4. Attach:
• Clutch spring holder (~
.S
w
I<~l CI utch
holder:ys_28891
spring
w
w
m
5. Remove:
fro
• Clutch securing nut (~)

ed
ad
6. Remove:
o
• Clutch assembly (~
nl
• Clutch spring (~
ow
• Spring seat (~
• Guide pins
D
• Secondary sliding sheave

CLUTCH I N S P E C T I O N
1. Inspect:
• Clutch shoes
Glazed parts-->Sand with coarse sand-
paper.
NOTE:
After using the sand paper, clean of the pol-
ished particles with cloth.
4-17
S E C O N D A R Y / P R I M A R Y SHEAVE I ENG
. Measure:
• Clutch shoe thickness (~
Clutch shoe thickness:

4 mm (0.16 in)
< Wear limit>:
2.5 mm (0.1 in)
V-BELT I N S P E C T I O N
1. Inspect:
• V-belt(~
et
Crack->Replace.
n
NOTE:
e.
Replace the V-belt smeared w i t h a lot of oil or
im
grease.
T
er
. Measure:
ot
co • V-belt w i d t h (~
.S
w
~ 1 V-belt width"
16.6 mm(0.65 in)
w
w
<Wear limit>:
14.6 mm(0.57 in)
m
fro
ed
ad
o
nl
ow
D
4-18
SECONDARY/PRIMARY SHEAVE i ENG
PRIMARY SHEAVE INSPECTION
1. Inspect:
• Primary sliding sheave (~
• Primary fixed sheave (~)
Wea r/Cracks/Scratch/Da mage
-->Replace.
. Check:
• Free m o v e m e n t
Insert the collar (~into the p r i m a r y slid-
et
ing sheave(~, and check for free move-
n
ment.
e.
Stick or excessive p l a y - > R e p l a c e the
im
sheave or collar.
T
er
ot
.
co Measure:
.S
• Out side d i a m e t e r (~) (weight)
w
w
w
----~Out side d i a m e t e r (weight)

15.0 mm(0.59 in)
m
<Limit 14.5 mm>(0.57 in)

fro
ed
ad
o
nl
ow
D
4-19
SECONDARY SHEAVE
1. Inspect:
• S e c o n d a r y fixed s h e a v e ( ~
• Secondary sliding sheave (~
Scratch/Crack/Damage-->Replace as a
set.
• Oil seal ( ~
Da mage-->Replace
. Inspect:
• T o r q u e cam g r o v e ( ~
• G u i d e pin (~)
et
Wear/Damage-->Replace as a set.
n
• O - r i n g s (~)
e.
Damage-->Replace.
T im
er
ot
co
. Measure:
.S
• Clutch s p r i n g free l e n g t h
w
w
w
Clutch s p r i n g free length:

94 m m ( 3 . 7 in)
m
<Limit>:
fro
91 m m ( 3 . 5 8 in)
ed
ad
4. Inspect:
o
• Clutch h o u s i n g i n n e r surface
nl
Oil/Scratches--~Remove.
ow
Use a rag soaked in lacquer

D
Oil
t h i n n e r or s o l v e n t .
Use an e m e r y cloth ( l i g h t l y
Scratches
and e v e n l y p o l i s h i n g ) .
. Measure:
• Clutch h o u s i n g i n s i d e d i a m e t e r ( ~
Clutch h o u s i n g inside d i a m e t e r :
105 m m ( 4 . 1 3 in)
< W e a r limit>:
105.5 m m ( 4 . 1 5 in)
4-20
S E C O N D A R Y / P R I M A R Y SHEAVE I ENG I~=1
SECONDARY SHEAVE INSTALLATION
When assembling the secondary sheave, re-
verse the d i s a s s e m b l y procedure. Note the fol-
lowing points.
. Apply:
• Lithium soap base grease
(to the inside of the sliding/fixed sheave)
2. Install:
• Sliding sheave (~
NOTE:
et
Be careful so that the oil seal (~ lips are not
n
turned over w h e n installing the sheave.
e.
im
3. Apply:
T
er
(to the torque cam grooves and O-rings)
ot
4.
co Install:
• Guide pin (~
.S
5. Check:
w
• Sliding sheave
w
w
U n s m o o t h operation-->Repair.
m
fro
ed
ad
. Install:
o
• Clutch securing nut (~

nl
Use clutch spring holder (~

ow
c,utchs0r,n0ho,der
s288l I
D
. Tighten:
• Clutch securing nut (~
I%~%150Nm(5.0 m.kg, 36 ft.lb) I
Use Flywheel holding tool
otorho,d,n0too,o01`0 I
4-21
8. Install:
• Secondary sheave assembly
• Clutch h o u s i n g ( ~
• V-belt (~)
NOTE:
The V-belt m u s t be i n s t a l l e d w i t h t h e a r r o w
fro ntwa rd.
. Tighten:
• Nut ( ~ (secondary sheave)
1~140 Nm(4.0 m.kg, 29 ft.,b)I
et
Use s h e a v e h o l d e r ( ~
n
Sheaveho'der: I
e.
YU-01701
T im
er
ot
PRIMARY SHEAVE
co
1. Clean:
.S
• P r i m a r y s l i d i n g s h e a v e face ( ~
w
• P r i m a r y fixed s h e a v e face ( ~
w
• Collar ( ~
w
• Weight (~
m
• P r i m a r y s l i d i n g s h e a v e cam surface (~)

fro
ed
ad
. Install:
o
• Weight (~
@
nl
• Cam@
ow
• Slider (~
• Collar ( ~
D
. Check:
• Cam o p e r a t i o n
Not s m o o t h . R e p a i r .
4. Install:
• Primary sheave assembly (~
• Collar (~)
. Install:
• V-belt
4-22
S E C O N D A R Y / P R I M A R Y SHEAVE I ENG I%=I
. Install:
• Shim (~
/ • Primary fixed sheave ~)

• Washer (~
• One-way clutch (~
• Conical spring washer (~)
• Nut(~
J . Tighten:
• Nut (~ (primary sheave)
i
[%l 45 Nm(4.5 m.kg, 31ft.lb)
net
N O T E :
e.
When tightening the nut (primary sheave), hold
im
the C.D.I. magneto using Flywheel Holding Tool
T
®.
er
~l ~°t°r
t°°':¥~-01
h°'d~'n° I
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co
.S
w
w
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. Adjust:
o
• V-belt O
nl
Tense the V-belt by turning the primary

ow
sheave several times.

D
9. Install:
• Fan ~I 7 Nm (0.7 m.kg, 5.1 ~.,blI
4-23
S T A R T E R CLUTCH A N D STARTER M O T O R I ENG I~ll
S T A R T E R CLUTCH A N D STARTER M O T O R
~TARTER C L U T C H A N D S T A R T E R M O T O R
11
~, ,10
9.4 ft.lb
et
4 3
n
e.
T im
er
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co
.S
9 J
Ns,ml0 8mk0.58,t,b
w
6
w
w
m
fro
8
ed
ad

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S t a r t e r clutch and s t a r t e r m o t o r re- Remove the parts in order.

nl
moval
ow
Left/Right side cover

Center cover ] Refer to "COVERS A N D PANE L " section
in chapter 3.
D
Lower cowling
Air shroud 3 Refer to "C.D.I. M A G N E T O " section
Cooling fan
Rear wheel Refer to "REAR WHEEL" section in chap-
ter 6.
Crankcase cover (left)l,2 Refer to "KICKER STARTER " section.
Primary sheave Refer to "V-BELT, PRIMARY SHEAVE "

section.
1 Plate
2 Plain w a s h e r
3 Idle gear
4 Plain w a s h e r
5 Starter clutch
4-24
STARTERCLUTCH AND STARTERMOTOR I ENG I ~TDI
11
~. .10
9.4 ft.lb
et
4 3
n
e.
Tim
er
ot
co
.S
9
Ns.ml0.sm.k0.5.8 ft.,b
w
w
w
m
fro
8
ed
ad

o
6 Gear boss 1
nl
7 Bearing 1
ow
8 Starter wheel gear 1

9 Plate w a s h e r 1
D
10 Starter m o t o r 1
11 Starter m o t o r coupler 2
Reverse the removal procedure for
instalation
4-25
STARTERCLUTCHAND STARTERIVIOTORI ENG I {~ I
STARTER CLUTCH AND GEARS INSPECTION
1. Inspect:
• Starter c l u t c h
Push t h e d o w e l pin to a r r o w d i r e c t i o n .
U n s m o o t h operation-->Replace starter
clutch a s s e m b l y .
2. Inspect:
• Starter w h e e l gear teeth ( ~
• Idle gear teeth (~)
et
B u rrs/C h i ps/Ro u g h n ess/Wea r-->Re p la ce.
n
e.
T im
er
ot
co
3. Inspect:
c::C> F~
.S
• Starter clutch o p e r a t i o n
w
w
Clutch o p e r a t i o n c h e c k i n g steps:
w
• Install the starter w h e e l gear to the starter

clutch, and hold t h e starter clutch.
m
• W h e n t u r n i n g t h e w h e e l gear c l o c k w i s e [ ]
fro
the starter c l u t c h and the w h e e l gear s h o u l d

ed
be e n g a g e d .
If not the starter c l u t c h is faulty. Replace it.
ad
• W h e n t u r n i n g the w h e e l gear c o u n t e r clock-

o
w i s e [~], the w h e e l gear s h o u l d t u r n freely. If

nl
not, the starter c l u t c h is faulty. Replace it.

ow
D
4-26
C.O.'."'°"ETO I ENO I O '1
C.D.I. M A G N E T O
.'.D.I. M A G N E T O
5
. 4 7
,0i80
n et
e.
T im
er
m(3.8 m.kg, 27 ft.lb) I
ot
co
.S
w
17Nm(0.7m.kg,
w
[ ~ 1 7 N m ( 0 . 7 m . k g " 5.1ft.lb) i 5.1 ft.I ) I

w
1
m
fro
ed
ad
Order Job name/Part name Q'ty R e m a r ks

o
C.D.I. m a g n e t o r e m o v a l R e m o v e t h e parts in o r d e r .
nl
Rear c a r r i e r
ow
Tail c o v e r
Left side c o v e r Refer to " C O V E R A N D P A N E L " s e c t i o n
D
Right side cover in c h a p t e r 3.

Center cover
Lower cowling
1 Air shroud 1 1
2 Fan/O-ring 1/1
3 Magneto rotor 1
4 Bind 1
5 C o u p l e r s ( m a g n e t o leads) 1
6 S t a t o r coil 1
7 W o o d ruff key 1
8 Gasket ( M a g n e t o c o v e r ) 1
R e v e r s e t h e r e m o v a l p r o c e d u r e f o r in-
stallation.
4-27
co, MAo.ETol E"° I o --I
C.D.I. M A G N E T O REMOVAL
1. Remove:
• N ut (~(roto r)
• Plain washer
NOTE:
Hold the rotor to loosen the nut bythe flywheel
holding tool (~.
I<~l Rotor
holdiyu_01235ng tool: I
2. Remove:
• Rotor O
et
• Wood ruff key
n
Use the flywheel magneto puller (~.
e.
im
I<~l Flywheel puller: I
T
YU-01189
er
ot
co • Stator assembly
• Gasket
.S
C.D.I. M A G N E T O INSTALLATION
w
1. Install:
w
• Gasket (~
w
2. Apply:
m

fro
(to oil seal)

3. Pass the C.D.I. magneto lead through the
ed
crankcase hole.
ad
4. Install:
o
• Stator assembly[R e8 Nm(0.8 m.kg, 5.8 ft.lb) I

nl
5. Install:
ow
• Wood ruff key

• C.D.I. magneto Rotor (~
D
• Plain washer
• Nut ~~;~l 38Nm(3.S m.kg, 31.1ft.lb) I
NOTE:
• Clean the tapered portion of the crankshaft
and the magneto rotor hub.
• When installing the magneto rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
• Do not allow the rotor holding tool to touch
the projection on the magneto rotor.
4-28
AOTO'OBEPUMP I E"O I O '1
AUTOLUBEPUMPF ~
AUTOLUBE PUMP
JZ
net
e.
im
// \ '~ 1
T
er
ot
co
.S
w
w
2 ,~314Nm(0.4m.kg, 2.8ft.l~b)i / \ ' ~ ~

w
7
m
fro
ed

ad
Autolube pump removal Remove the parts in order.

o
nl
C.D.I. magneto Refer to "C.D.I. magneto" section.

ow
1 Air shroud 2. 1
2 Circlip 1
D
3 Pump drive gear 1

4 Pin 1
5 Oil hose 1
6 Oil delivery hose 1
7 Autolube pump ass'y 1 Refer to "Autolube pump installation"
section

stallation.
4-29
AUTOLUBE PUMP I ENG I{~]DI
AUTOLUBE PUMP INSTALLATION
CAUTION:
A f t e r installing a u t o l u b e p u m p , it m u s t be
bleeded.
1. Install
• Pin O
• P u m p d r i v e gear (~)
• Circlip ~
2. Apply:
• L i t h i u m soap base grease
(to O-ring)
et
3. Install:
n
• Autolube pump (~ [~J4 Nm(0.4m.kg, 2.8ft.lb~
e.
4. Apply:
im
• L i t h i u m soap base grease
T
(to a u t o l u b e p u m p gear (~,(~)
er
ot
co 15 cc (0.92 cu o in)
.S
w
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ed
ad
o
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ow
D
4-30
T.A.SM.SS.O. I E"O I o '1
TRANSMISSION
TRANSMISSION
net
e.
T im
/" 2
er
I
ot
/ 4 / ~ O co I~112N m(1.2 m.kg, 8.4ft.lb)
[~418Nm(1.8 m.kg, 13ft.lb I
.S
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w
m
fro
ed
Order Job name/Part name Q'ty Re m a r ks

o ad
Transmission removal Remove the parts in order.

nl
Rear wheel Refer to "REAR WHEEL/REAR BRAKE "

ow
section in chapter 7.
Secondary sheave Refer to "V-BELT, CLUTCH, SECOND-
D
ARY/ PRIMARY SHEAVE" section

Drain the transmission oil. Refer to " T R A N S M I S S I O N OIL RE-
PLACEMENT " section in chapter 3.
1 Transmission case cover 1
2 Gasket (transmission case cover) 1
3 Dowel pin 2
4 Primary drive gear 1
5 Drive gear 1
6 Circlip 1
7 Main axle 1
4-31
TRANSMISSIONI ENG I~>]DI
- 3
n et
e.
T im
er
/ 4/ I.~..~ ~ [~112Nm(1"2m'kg• 8"4ft'lb:
ot
co
[~'~11 8Nm(1.8 m.kg, 13ft.lb I
.S
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Q'ty
o
8 Drive axle 1
nl

ow
stallation.
D
4-32
C R A N K C A S E A N D REED V A L V E I ENG I TDI
C R A N K C A S E A N D REED V A L V E
C R A N K C A S E A N D REED V A L V E
~19Nm(0.9m.kg,6.5ft.lb)l ~112Nm(1.2m.kg,8.4ft.lb) I
n et
e.
im
1 1 N m ( 1 1 m kg,8ft Ib) I ~ ~
T
er
ot
co
.S
j - J
~ j 3 j,
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Order J o b name/Part n a m e Q'ty Re m a r ks

o
Crankcase a n d Reed valve r e m o v a l R e m o v e the parts in order.

nl
ow
Engine removal Refer to " E N G I N E R E M O V A L " section.

C y l i n d e r head, c y l i n d e r , p i s t o n Refer to "CYLINDER HEAD CYLINDER
D
A N D PISTON" section.
Crankcase c o v e r (left) Refer to " K I C K STARTER A N D CRANK-
CASE COVER (LEFT) " section.
V-belt, clutch, secondary/primary Refer to "V-BELT, CLUTCH A N D SEC-
sheave O N D A R Y / P R I M A R Y SHEAVE " section.
C.D.I. m a g n e t o Refer to "C.D.I. M A G N E T O " section.
Starter clutch, starter m o t o r Refer to "STARTOR CLUTCH AND
STARTOR M O T O R " section.
Autolube pump Refer to " A U T O L U B E P U M P " section.
Rear w h e e l Refer to " R E A R W H E E L A N D REAR
BRAKE" section in c h a p t e r 6.
Transmission Refer to " T R A N S M I S S I O N " section.
4-33
CRANKCASE AND REEDVALVE I ENG I >]DI
~19Nm(0.9m.kg,6.5ft.lb)l ~ 1 1 2 N m ( 1 . 2 m . k g , 8.4ft.lb) I
et
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e.
im
11Nm(1 l m kg,8ft Ib) I ~ ~
T
er
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j-J
.S
~ j 3 j.
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o
1 Intake manifold 1
nl
2 Reed valve 1
ow
3 Valve seat gasket 1

Stopper 1
D
4
5 Crankcase 2 1
6 Dowel pin 2
7 Engine m o u n t spacer 1
8 Circlip 1
9 Bearing 1
10 Oil seal 1
stallation.
4-34
O.A°KOASE A°O.EEOVA'VE I E"O Io =1
CRANKCASE(RIGHT) REMOVAL
1. Remove:
• Oil seal s t o p p e r (~
• Screws ( c r a n k c a s e ~ 19Nm(0.9 m.kg,6.5ft.lb !
NOTE:
=~r~ri Loosen each s c r e w 1/4turn, and remove t h e m
after all are loosened.
2. Attach:
• Crankcase separating tool (~
et
I<~l CrankcaSeyu_01135se
pa rating tool: I
n
e.
im
NOTE:
T
Fully tighten the tool holding bolts, but make
er
sure the tool b o d y is parallel w i t h the case. If
ot
n e c e s s a r y , o n e s c r e w m a y be b a c k e d o u t
co
slightly to level tool body.
.S
w
. Remove
w
• Crankcase (right)
w
As pressure is applied, alternately tap

m
on the engine m o u n t i n g bosses.

fro
ed
ad
C H E C K I N G THE C R A N K C A S E
o
1. T h o r o u g h l y w a s h the crankcase halves in

nl
a mild solvent.
ow
2. T h o r o u g h l y clean all the gasket surfaces

D
and crankcase mating surfaces.

3. Check:
• crankcase
Cracks/damage --> Replace.
• oil delivery passages
O b s t r u c t i o n --> B l o w o u t w i t h c o m -
pressed air.
C H E C K I N G THE B E A R I N G S A N D OIL SEALS
1. Check:
• bearings
Clean and lubricate the bearings, then
rotate the inner race w i t h y o u r finger.
Rough m o v e m e n t --> Replace.
2. Check:
• oil seals
D a m a g e / w e a r ~ Replace.
4-35
C R A N K C A S E A N D REED V A L V E I ENG I TDI
REED V A L V E I N S P E C T I O N
1. Measure:
• Valve stopper height (~
Out of specification-->Adjust stopper/Re-
place valve stopper.
I ~ l Valve stopper height (~

6.0~6.4 mm(0.24~0.25 in)
. Measure:
• Reed valve clearance @)
Out of specification-->Replace reed
va lye.
et
lReedvavecearance
I I
n
e.
Less than 0.2 mm(0.0079 in)
T im
er
ot
co
C R A N K C A S E (RIGHT) I N S T A L L A T I O N
1. Install:
.S
• Dowel pins (~
w
• Engine mount spacer (~

w
2. Apply:
w
• Sealant (~)
m
To the mating surfaces of both case

fro
helves.
ed
~ 1 Quick gasket®: I
ad
ACC-1100-15-01
o
nl
NOTE:
ow
Do not allow any sealant to come into contact

D
with the oil galley.
-ii -I;
" I
3. Attach:
• Crankshaft installing tool (~,~)
Crankshaft installation set (~

YU-90050
Crankshaft installer adapter
(M 10)~)
YU-90062
4-36
.OASE A.O.EEO VA'VE I E"O Io .1
4. Tighten:
• Crankcase holding screws
[ ~ l 12 Nm(1.2 m.kg,8.4 ft.lb) I
NOTE:
T i g h t e n t h e c r a n k c a s e h o l d i n g s c r e w s in stage,
using a crisscross pattern.
,4
5. Check:
• Crankshaft operation
Unsmnothoperation Repair.
6. Install:
• Oil seal ( r i g h t c r a n k case) ( ~
A p p l y g r e a s e on to oil seal lip.
n et
e.
T im
er
ot
.
coInstall:
• Oil seal s t o p p e r plate ( ~
.S
H 9 .ml09 m.kg, 6.5 ft.lb) I

w
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ad
. Install:
o
• Gasket
nl
• Reed v a l v e
ow
• Intake m a n i f o l d (~I~111 Nm(1.1 m.kg, 8 ft.lb) I

D
4-37
KS.AFT I ENO I O ,,I
CRANKSHAFT
CRANKSHAFT
et
~ 4
n
e.
T im
er
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co
2
.S
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ad

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Crankshaft removal R e m o v e the parts in order.

nl
Right crankcase r e m o v a l Refer to " C R A N K C A S E A N D REED

ow
V A L V E " section.
1 Crankshaft 1
D
2 Bearing 2
3 Oil seal 2
4 Crankcase c o v e r (left) 1
stal lation.
4-38
KS.AFT I E"O I o '1
CRANKSHAFT REMOVAL
1. Attach:
• Crankcase s e p a r a t i n g tool ( ~
~ l Crankcase s e p a r a t i n g t o o l :
YU-01135-A
2.
Remove:
• Crankshaft (~
NOTE:
Make sure the crankcase s e p a r a t i n g tool is cen-
tered o v e r t h e c r a n k s h a f t a s s e m b l y .
n et
e.
T im
er
ot
co
CRANKSHAFT INSPECTION
F
1. Measure:
.S
• Runout limit " C"

w
• C o n n e c t i n g rod big end side clearance

w
iJ g rr
w
• Small end free play l i m i t " F "

m
fro
Use V-blocks, dial g a u g e and t h i c k n e s s

--H ~-- D
ed
gauge.
ad
Runout limit "C":

o
0.03 m m ( 0 . 0 0 1 2 in)
nl
C o n n e c t i n g rod big end side clear-

ow
ance " D " :

0.2 ~ 0.5 m m ( 0 . 0 0 7 9 ~ 0.020 in)
D
Small end free play " F ' :

0.4 ~ 0.8 m m ( 0 . 0 1 6 ~ 0.031 in)
2. Inspect:
• B e a r i n g s (crankshaft)
Spin the b e a r i n g i n n e r race.
Excessive play/Ro ugh n ess-->Replace.
Pitting/Da mage--~Replace.
4-39
CRANKSHAFTI ENG I{ ll
CRANKSHAFT INSTALLATION
1. Attach:
• Crankshaft Installing Tool
Crankshaft installation set (~

Q YU-90050
Crankshaft installer adapter
(M10) ~)
YU-90062
2. Install:
• Crankshaft ®
(to the crankcase (~)
n et
CAUTION:
e.
im
To avoid scratching the crankshaft and to ease
T
the installation procedure, lubricate the oil seal
er
lips w i t h grease and each bear-ing w i t h engine
ot
oil.
co
.S
NOTE:
w
Hold the connecting rod at t o p dead center

w
(TDC) w i t h one hand w h i l e t u r n i n g the nut of

w
the crankshaft installing tool w i t h the other.

m
Turn the crankshaft installing tool until the

fro
crankshaft assembly b o t t o m s against the bear-

ing.
ed
ad
. Install:
o
• Oil seal (~
nl
• A p p l y lithium soap base grease onto

ow
i~ P
the oil seal lip.

D
Use the guide (~ and seal d r i v e r ~) to

install the oil seal
Oil seal driver

YM-1410
Oil seal guide
YM-1409
4-40
CARBURETION
CARBURETOR
n et
e.
im
/
T
er
ot
co
.S
w
w
2
w
m
fro
1 k l 9 N m l 0 . 9 m.kg, 6.5 ft.lb) I

ed
ad

o
Carbu retor removal Remove the parts in order.

nl
Battery b o x cover
ow
Grip
End cover Refer to "COVER A N D PANEL" section
D
Left/Right cover in CHAPTER 3.

Center cover
1 Air cleaner case a s s e m b l y
2 A u t o choke lead coupler
3 Fuel hose/vacuum hose
4 Oil delivery pipe a s s e m b l y
5 Carburetor
6 Throttle cable

lation.
5-1
CABURETOR DISASSEMBLY
• I
'
net
e.
T im
er
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co
.S
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~,_ .~'~
ed

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Carburetor d i s a s s e m b l y Disassemble the parts in order.

nl
O Throttle cable 1
ow
® Throttle valve 1
® Needle set 1
D
® Carburetor top cover/o-ring 1

® Throttle stop screw 1
® A u t o choke unit assembly 1
@ Float chamber/Seal ring 1/1
® Float pin 1
® Float/Needle valve 1
® Main jet 1
® Pilot jet 1
@ Main nozzle 1
@ Carburetor b o d y 1
stallation.
5-2
O'"'O"'TO" Ic""'l V I
CABURETOR INSPECTION
1. Check:
• Carburetor b o d y
• Float c h a m b e r
• Jet housing
Cracks/damage --> Replace.
2. Check:
• Fuel passages
Obstruction --~ Clean.
n et
a. Wash the carburetor in a petroleum-based
e.
solvent. Do not use any caustic carbure-
im
tor cleaning solution.
T
b. Blow out all of the passages and jets w i t h
er
compressed air.
ot
co
3. Check:
.S
• Float c h a m b e r b o d y
Q
Dirt --> Clean.
w
w
4. Check:
w
• Float c h a m b e r rubber gasket

Cracks/damage/wear --> Replace.
m
5. Check:
fro
• Float
ed
Damage --> Replace.

ad
. Check:
o
• Needle valve O
nl
D a m a g e / o b s t r u c t i o n / w e a r --~ Replace
ow
the needle valve.

D
. Check:
• Throttle valve ( ~
Damage/scratches/wear--> Replace.
5-3
OA"BO"ETO" ICA"BI V I
. Check:
• Jet n e e d l e kit ( ~
• M a i n nozzle ~ )
• M a i n jet ( ~
• Pilot jet ( ~
B e n d s / d a m a g e / w e a r --> Replace.
O b s t r u c t i o n --> Clean.
B l o w o u t the jets w i t h c o m p r e s s e d air.
9. Check:
• Throttle valve movement
Insert the t h r o t t l e v a l v e into t h e c a r b u -
et
retor
n
B o d y and m o v e it up and d o w n .
e.
T i g h t n e s s --> Replace the p i s t o n valve.
im
10. Check:
T
• V a c u u m hose
er
• Fuel hose
ot
co C r a c k s / d a m a g e / w e a r --> Replace.
O b s t r u c t i o n --> Clean.
.S
B l o w o u t t h e hoses w i t h c o m p r e s s e d air.
w
w
w
m
fro
ed
ad
11. M e a s u r e :
o
• Float h e i g h t (~)
nl
Out of specification-->lnspect needle

ow
v a l v e , float and v a l v e seat.

D
Feathe0ht
15 - 17 m m (0.59 ~ 0.67 in)
I
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
Float height measurement steps:

• Install the n e e d l e v a l v e , float and float pin to
the c a r b u r e t o r body.
• Hold the c a r b u r e t o r in an u p s i d e d o w n posi-
tion.
• M e a s u r e the d i s t a n c e b e t w e e n t h e m a t i n g
s u r f a c e o f t h e f l o a t c h a m b e r ( g a s k e t re-
m o v e d ) and t o p of t h e float u s i n g a g a u g e .
5-4
CARBURETOR Ic..,I • I
NOTE:
The float arm should be resting on the needle
valve, but not compressing the needle valve.
• If the float height is not w i t h i n specification,

inspect the needle valve, float and valve seat.
• If it is w o r n , replace it.
NOTE:
The float height is properly adjusted at the Yama ha
factory. Never attempt to adjust it.
et
CARBURETOR ASSEMBLY
n
To assemble the carburetor, reverse the disas-
e.
s e m b l y procedures.
im
Note the f o l l o w i n g points.
T
CAUTION:
er
ot
• Before r e a s s e m b l i n g , w a s h all parts in clean
co
gasoline.
• A l w a y s use a n e w gasket.
.S
w
w
w
m
fro
ed
ad
o
nl
ow
D
5-5
OA"BU"ETO"IOA"BI V I
1. Install:
• T h r o t t l e cable ( ~
2.Install:
• Carburetor assembly
NOTE:
et
A l i g n the p r o j e c t i o n ( ~ w i t h t h e p r o j e c t i o n s @ .
n
e.
T im
er
ot
co
FUEL LEVEL A D J U S T M E N T
1. Measure:
.S
• Fuel level ( ~
w
Out of specifications-->Adjust.
w
w
Fuel level (~:

m
3.0~4.0 m m ( 0 . 1 2 ~ 0 . 1 6 in)
fro
( B e l o w the float c h a m b e r line)

ed
ad
M e a s u r e m e n t steps:
o
• Place the s c o o t e r on a level surface.

nl
• Use a g a r a g e jack u n d e r the e n g i n e to en-

ow
sure that t h e c a r b u r e t o r is p o s i t i o n e d v e r t i -
cally.
D
• C o n n e c t the fuel level g a u g e ( ~ to the d r a i n

pipe (~.
Fuel level g a u g e :
YM-01312-A
I
• Loosen t h e d r a i n s c r e w ~).
• M e a s u r e the fuel level ( ~ w i t h the gauge.
• If the fuel level is incorrect, a d j u s t t h e fuel
level:
R e m o v e t h e f l o a t c h a m b e r f l o a t and t h e
needle v a l v e .
Inspect the needle valve.
If it is w o r n , replace it.
5-6
• Install the c a r b u r e t o r .
• Recheck the fuel level.
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
AUTO CHOKE INSPECTION

(Ambient temperature lower than 45°C)
1. Remove:
et
• Carburetor
n
2. Inspect:
e.
• Autochoke unit
im
C o n n e c t a s u i t a b l e hose ( ~ to t h e starter
T
(~, a n d b l o w it w i t h t h e m o u t h etc.
er
Possible--~Good c o n d i t i o n .
ot
coImpossible-->Replace auto choke unit.
3. Inspect:
.S
• A u t o choke unit (with battery)
w
B
w
I n s p e c t i o n and a d j u s t m e n t steps:
w
• C o n n e c t a u t o choke u n i t leads to t h e 12 V
b a t t e r y for 5 m i n u t e s .
m
Black terminal-->12 V b a t t e r y (+) ( ~

fro
Black terminal-->12 V b a t t e r y (-) ( ~

ed
• C o n n e c t a s u i t a b l e hose ( ~ to t h e starter (~),

and b l o w it w i t h the m o u t h etc.
ad
Possible-->Replace auto choke unit.

o
Im possible-->Good c o n d i t i o n .
nl
ow
D
5-7
CA"BO"ETO"IOA"BI V I
FUEL COCK INSPECTION
1. Stop the engine.
2. Remove:
• Rear c a r r i e r
• Tail c o v e r
• Left s i d e c o v e r
R e f e r to " C O V E R A N D P A N E L " s e c t i o n
in c h a p t e r 3.
3. Inspect:
• Fuel c o c k
Fuel cock inspection steps:
et
• D i s c o n n e c t t h e fuel h o s e (~.
n
• Place t h e r e c e p t a c l e u n d e r t h e fuel h o s e e n d .
e.
• If fuel s t o p s f l o w i n g o u t in a f e w s e c o n d s ,
im
t h e fuel cock is in g o o d c o n d i t i o n . If not, clean
T
or r e p l a c e t h e fuel cock.
er
• Disconnect the vacuum hose ~)and breathe
ot
in t h e v a c u u m h o s e w i t h t h e m o u t h etc. f o r
co
vacuum .
.S
• If f u e l f l o w s o u t o f t h e f u e l h o s e u n d e r
vacuum and stops under non-vacuum, the
w
w
fuel c o c k is in g o o d c o n d i t i o n .
w
If not, clean o r r e p l a c e t h e v a c u u m hose, fuel

h o s e a n d fuel cock.
m
* * * * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
fro
4. Install:
ed

• Left s i d e c o v e r
ad
• Tail c o v e r
o
• Rear c a r r i e r
nl
ow
D
5-8
F.O°T W.EEL A.O B.AKE O.SC IC"ASI oI
CHASSIS
F R O N T W H E E L A N D BRAKE DISC
4 _ _ ~--/~ /1 -'~'I~.~.~I7~N m (0.7 m.kg, 5. lft.i b) '
n et
: ,/ ~ " ' - ~ %~ZJ70 Nm(7 m.kg, 5 lft.I b)l
e.
T im
er
ot
co
.S
w
w
w
m
fro
~1-O" ( .0 . g, .5ft.lb) I ~
ed

o ad
Front wheel and brake disc removal Remove the parts in order.
nl
~WARNIN(
ow
S e c u r e l y s u p p o r t t h e s c o o t e r so t h e r e
D
is no d a n g e r of it falling over.
1 Speedometer cable 1
2 Front brake hose holder 1 -
3 Brake caliper 1 Refer to "FRONT WHEEL INSTALLA-
4 Wheel axle 1 TION" section.
5 Front wheel assembly 1
6 Gear unit assembly 1 -
7 Collar 1 Refer to "FRONT WHEEL ASSEMBLY"
8 Brake disc 1 section.
stallation.
6-1
FROOT W.EEL AO0 BRAKE O,SC IC"ASI oI
FRONT WHEEL DISASSEMBLY
net
e.
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er
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.S
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w
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ed

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Q'ty
o
Front wheel disassembly Remove the parts in order.

nl
(# Oil seal 1 m Refer to "FRONT WHEEL DISASSEM-

ow
® Bearing 1 BLY/ASSEMBLY" section.

® Collar
D
1
® Spacer 1
® Bearing 1 -
stallation.
6-2
F.OOT W.EE. AO0 B.A.E O.SC IC'ASI oI
YP ......
f f f - f
FRONT W H E E L D I S A S S E M B L Y
1. Remove:
• Bearing ( ~
• Spacer
Remove the bearing using a general
bearing p u l l e r (~).
CAUTION:
Handle the wheel w i t h care not to d a m a g e the
brake disc. If the brake disc is d a m a g e d , re-
place.
YP700020
et
FRONT W H E E L INSPECTION
n
e.
1. Inspect:
im
• Front w h e e l axle
(by r o l l i n g it on a flat surface)
T
er
Bends-->Replace.
ot
W!~VAV/±I -'| ~ I I ~ [¢']1
co
Do not a t t e m p t to straighten a bent wheel axle.
.S
I l heeaxe endn0
w
I
w
0.25 m m (0.0098 in)

w
m
2. Inspect:
fro
• Front tire
Wea r/da mag e--~ Re place.
ed
Refer to "TIRE INSPECTION" in CHAP-

ad
TER 3.
• Front w h e e l
o
nl
R e f e r t o " W H E E L I N S P E C T I O N " in
ow
CHAPTER 3.
3. Measure:
D
• Front w h e e l r u n o u t
O v e r the specified limits--~Replace.
Front w h e e l r u n o u t limits:
Radial (~: 1.0 m m (0.04 in)
Lateral ( ~ " 1.0 m m (0.04 in)
4. Inspect:
• Front w h e e l b e a r i n g s
B e a r i n g s a l l o w free p l a y in the w h e e l
hub or the wheel does not turn
s m o o t h l y - - > Replace.
• Oil seals
W e a r / damage-->Replace.
6-3
F.O°T W.EE. A°O B.A.E O.SO IC"ASI oI
4. Inspect:
• Collar
Grooved wear-->Replace the collar and
the oil seal as a set.
Ye .....
BRAKE DISC I N S P E C T I O N
1. Measure:
et
• Brake disc deflection(~
n
e.
I ~ 1 M a x i m u m deflection:
im
0.15 mm (0.0059 in)
T
er
ot
2.
co Measure:
• Brake disc thickness(~
.S
w
Brake disc thickness:

w
4.0 mm (0.16 in)

w
M i n i m u m thickness:
m
3.5 mm(0.14 in)

fro
ed
ad
Ye .....
FRONT WHEEL ASSEMBLY

o
1. Install:
nl
• Bearing (~
ow
• Collar @~)
D
• Spacer (~)
• Bearing (~
• Oil seal (~
NOTE:
• A p p l y the lithium soap base grease on the
bearing and oil seal lip w h e n installing.
• Use a socket that matches the outside diam-
eter of the race of the bearing.
• A l w a y s use a n e w oil seal.
• Install the oil seal w i t h its m a n u f a c t u r e r ' s
marks or numbers facing o u t w a r d .
CAUTION:
Do n o t strike t h e inner race of balls of t h e bear-
ing. C o n t a c t s h o u l d be m a d e only w i t h t h e
outer race.
6-4
F.O°T W . E E . . ° O B . . . E O.SO IC"ASI oI
2. Install:
• Brake disc O H 20 Nm~20 ~k~, 14 ft.lb) I
i
NOTE:
T i g h t e n the bolts (brake disc) in stage u s i n g a
c r i s s c r o s s pattern.
EB700030
FRONT WHEEL INSTALLATION

Reverse the " R E M O V A L " p r o c e d u r e .
et
Note t h e f o l l o w i n g points.
n
1. Lubricate:
e.
• Front w h e e l axle
im
• Bearings
T
• Oil seal (lips)
er
• D r i v e / d r i v e n gear ( s p e e d o m e t e r )
ot
co Recommended lubricant:
@
L i t h i u m soap base grease
.S
w
2. Install:
w
• S p e e d o m e t e r gear u n i t ( ~
w
NOTE:
m
Make sure t h a t t h e w h e e l h u b and the speed-

fro
o m e t e r gear unit are installed w i t h the t h r e e

ed
p r o j e c t i o n s m e s h e d into the t w o slots.

ad
3. Install:
o
• Front w h e e l
nl
NOTE:
ow
Make sure that the slot in the s p e e d o m e t e r gear

unit fits o v e r the s t o p p e r on the f r o n t f o r k o u t e r
D
tube.
4. Tighten:
• Front w h e e l axle ( ~
• A x l e nut (front w h e e l axle)
H 70 NmCT0 m.kg, 51 "'btl
CAUTION:
Before t i g h t e n i n g t h e axle nut, stroke t h e front
fork several t i m e s to check for proper fork op-
eration,
•WARNING
M a k e sure t h a t t h e brake hose is r o u t e d prop-
erly.
6-5
F.OOT W . E E . . O 0 B . . . E O.SO IONASI oI
YP700040
WHEEL STATIC BALANCE ADJUSTMENT

NOTE:
• After replacing the tire and/or rim, the wheel
static balance should be adjusted.
• A d j u s t the front wheel static balance with the
brake disc installed.
1. Remove:
• Balancing w e i g h t
2. Set:
• Wheel
(on a suitable stand)
et
3. Find:
n
e.
• Heavy spot
im
Procedure:
T
er
a. Spin the wheel and w a i t for it to rest.
b. Put an "X~" mark on the w h e e l ' s b o t t o m
ot
spot.
co
c. Turn the wheel so that the "X~" mark is
.S
90 ° up.
w
d. Release the wheel and wait for it to rest.

w
Put an " X 2 " mark on the w h e e l ' s b o t t o m

w
spot.
m
e. Repeat the above b., c., and d. several

fro
times until all marks come to the same

spot.
ed
f. This spot is the w h e e l ' s heavy spot " X " .

ad
o
/
4. Adjust:
nl
• Wheel static balance

ow
D
A d j u s t i n g steps:
• Instail a balancing w e i g h t (~ on the rim ex-
actly opposite to the heavy spot " X ' .
NOTE:
Start w i t h the smallest weight.
• Turn the wheel so that the heavy spot is 90 °

up.
• Check that the heavy spot is at rest there. If
not, try another w e i g h t until the wheel is bal-
anced.
6-6
F.OOT W.EE. AOO B.A.E O.SC IC"ASI oI
X 5. Check:
• W h e e l static balance
* * * * * * * * * * * * * * * * * * * * ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
Checking steps:
X X • T u r n the w h e e l so t h a t it c o m e s to each p o i n t
as s h o w n .
• C h e c k t h a t the w h e e l is at rest at each point.
If not, readjust the f r o n t w h e e l static balance.
n et
e.
T im
er
ot
co
.S
w
w
w
m
fro
ed
ad
o
nl
ow
D
6-7
F.O°T B.AKE IC"ASI oI
F R O N T BRAKE
BRAKE PAD
n et
e.
~ H23Nm(23.
im
m.kg, 16.6 ft.lb) I
T
er
ot
co
.S
w
w
w
~ ~ ~ [~423NmI2.3m.kg,16.6ft.lb)I
m
fro
ed
ad
Order J o b name/Part n a m e Q'ty R e m a r ks

o
Brake pad r e m o v a l R e m o v e the parts in order.

nl
1 Caliper s u p p o r t bolt 1 --I Refer to " BRAKE PAD R E P L A C E M E N T

ow
2 Caliper 1 J section .
"
3 Brake pad 2
D
4 Pad s p r i n g 2
stallation.
6-8
F.ONT B.A.E IC"ASI oI
CAUTION:
Disc b r a k e c o m p o n e n t s r a r e l y r e q u i r e disas-
s e m b l y . DO NOT:
• Disassembly components unless absolutely
necessary.
• Use s o l v e n t s in i n t e r n a l brake c o m p o n e n t .
• Use c o n t a m i n a t e d b r a k e f l u i d for c l e a n i n g .
• Use o n l y clean fluid.
• A l l o w brake f l u i d t o c o m e in c o n t a c t w i t h
t h e eyes o t h e r w i s e eye i n j u r y m a y occur.
• A l l o w brake f l u i d t o c o n t a c t p a i n t e d surfaces
or p l a s t i c p a r t s o t h e r w i s e d a m a g e m a y oc-
cur.
et
• Disconnect any hydraulic connection other-
n
w i s e t h e e n t i r e s y s t e m m u s t be disas-
e.
s e m b l e d , drained, cleaned, and then prop-
im
erly filled and bled after reassembly.
T
er
ot
co
BRAKE PAD R E P L A C E M E N T
NOTE:
.S
It is not n e c e s s a r y to d i s a s s e m b l e the brake

w
w
c a l i p e r and brake h o s e to replace t h e brake

w
pads.
m
fro
1.Loosen:
e o o
• Retaining bolt ( ~
ed
2. Remove:
ad
• Brake caliper (~)

• H o l d e r (brake hose) ( ~
o
nl
3. Remove:
ow
• Retaining bolt
• Pads ( ~
D
• Pad s p r i n g ( ~
NOTE:
• R e p l a c e t h e pad s p r i n g i f t h e pad r e p l a c e m e n t
is r e q u i r e d .
• Replace the pads as a set if e i t h e r is f o u n d to
be w o r n to t h e w e a r limit.
WearJmJt
0.8 m m (0.03 in)
I
®
6-9
,.o°T B.AKE Ic"AsI ol
4. Install:
• Pad springs
• Brake pads (new)
Installation steps:
• Connect a suitable hose (~ t i g h t l y to the cali-
per bleed screw (~. Then, place the other end
/ of this hose into an open container.
• Loosen the caliper bleed screw and push the
piston (~ into the caliper by y o u r finger.
• Tighten the capliper bleed screw.
H ~ ~ (0.~ ~.k~, 4.3 ~.'~ i
• Install the pad spring (new) and brake pad
et
(new) (~
n
• Tighten retaining bolt (~
e.
~ 1 2 3 Nm (2.3 m.kg, 16.6 ft.lb) I
im
• Install brake hose holder (~
/
T
l ~ l 7 Nm (0.7 m.k~, 5.15 ft.lb) I
er
i • Install caliper (~ [~23 Nm (2.3 m.kg, 16.6 ft.ib) I
ot
co
.S
w
w
w
m
fro
ed
o ad
nl
ow
I
D
5. Inspect:
• Brake fluid level
Refer to the "BRAKE FLUID INSPEC-
TION" section in the CHAPTER 3.
(~ "LOWER" level line
t
6-10
F.O.T B.A.E IC"ASI oI
. Check:
• Brake lever o p e r a t i o n
A s o f t y or s p o n g y feeling Bleed-->brake
system.
Refer to " AIR BLEEDING " section in
the CHAPTER 3.
n et
e.
T im
er
ot
co
.S
w
w
w
m
fro
ed
ad
o
nl
ow
D
6-11
MASTER CYLINDER
6 6
n et
e.
T im
er
ot
co
] 3
.S
l~120Nm(2.0m.kg, 14 ft.lb)
w
w
w
m
fro
ed
ad

o
Master cylinder removal R e m o v e the parts in order.

nl
Drain the brake f l u i d R e f e r t o " B R A K E F L U I D REPLACE-

ow
M E N T " section in CHAPTER 3.

1 Brake l e v e r / c o m p r e s s i o n s p r i n g 1/1
D
2 Brake s w i t c h 1
3 U n i o n bolt 1
4 Copper washer 2 Refer to " M A S T E R CYLINDER INSTAL-
5 Brake hose 1 L A T I O N " section.
6 M a s t e r c y l i n d e r bracket 1
7 Master cylinder 1
stallation.
6-12
M A S T E R CYLINDER D I S A S S E M B L Y
n et
e.
T im
er
ot
co
.S
w
w
w
m
fro
ed
ad

o
Master cylinder disassembly R e m o v e the parts in order.

nl
O Master cylinder boot 1 -

ow
® Circlip 1 Refer to " M A S T E R CYLINDER A S S E M -

® M a s t e r c y l i n d e r kit 1 B L Y " section.
D
® Spring 1 -
Reverse the d i s a s s e m b l y p r o c e d u r e for
assembly.
6-13
YP702040
MASTER CYLINDER INSPECTION

1. Inspect:
• Master cylinder kit O
Wear/scratches-->Replace the master
cylinder assembly.
• Master cylinder boot
Cracks/da m age-->Re pla ce.
. Inspect:
• Master cylinder O
• Scratches/wear/damage-->Replace the
et
master cylinder assembly.
n
e.
T im
er
ot
co
. Inspect:
• Diaphragm (~
.S
Wea r/da mag e-->Re place.

w
w
w
m
fro
Y P .....
MASTER CYLINDER A S S E M B L Y
ed
WARNING
ad
• All internal brake components should be

o
cleaned and lubricated with new brake fluid

nl
only before installation.

ow
16~)1 Recommended brake fluid:

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

whenever a master cylinder is disassembled.
1. Install:
• Cylinder cup (~
• Master cylinder piston (~
Install cylinder cup (~ by using cylinder
cup installer (~).
::~1 Cylinder cup installer set: I

90890-01996
6-14
. Install:
• Spring (~
Install the s p r i n g w i t h its s m a l l e r d i a m -
eter to the m a s t e r c y l i n d e r piston.
• M a s t e r c y l i n d e r kit ( ~
. Install:
• Circlip (~)
Install the circlip s e c u r e l y into the mas-
et
ter c y l i n d e r g r o o v e .
n
• M a s t e r c y l i n d e r boot ( ~
e.
T im
er
ot
Ye
co
.....
.S
MASTER CYLINDER INSTALLATION
1. Install:
w
w
• Master cylinder (~
w
• M a s t e r c y l i n d e r bracket ( ~
~ l 9 Nm (0.9 m.kg, 6.5 ft.lb) I
m
fro
CAUTION:
/ • Install the master cylinder bracket ( ~ w i t h
ed
the " U P " m a r k ~ facing u p w a r d .

ad
• Align the end of the holder w i t h the punch

o
m a r k b on the handle bar.

nl
ow
D
6-15
2. Air bleed:
• Brake s y s t e m
Refer to " A I R B L E E D I N G " s e c t i o n in
CHAPTER 3.
r!~vAvg_,W --']~ I I ~ [¢-]
• Use o n l y d e s i g n a t e d q u a l i t y brake fluid:
O t h e r w i s e , t h e r u b b e r seals m a y d e t e r i o r a t e ,
causing leakage and poor brake
perforrmance.
• Refill w i t h t h e s a m e t y p e of brake f l u i d :
M i x i n g f l u i d s m a y r e s u l t in a h a r m f u l c h e m i -
cal r e a c t i o n a n d lead t o p o o r p e r f o r r m a n c e .
• Be careful t h a t w a t e r d o e s n o t e n t e r t h e sig-
et
n i f i c a n t l y l o w e r t h e b o i l i n g p o i n t of t h e f l u i d
n
m a y r e s u l t in v a p o r lock.
e.
T im
3. Inspect:
er
• Brake o p e r a t i o n
ot
co
.S
w
w
w
m
fro
ed
ad
o
nl
ow
D
6-16
F.O.T..AKE IC"ASI oI
CALIPER
lh%123Nm(2.3 m.k,g, 16.6 ft.lb)l
........ i ....... 3
net
e.
T im
er
ot
co
.S
w
w
w
m
fro
ed

o ad
Caliper removal Remove the parts in order.

nl
Drain the brake fluid Refer t o " B R A K E F L U I D REPLACE-

ow
M E N T " section in CHAPTER 3.

1 Union bolt 1 -
D
2 Copper w a s h e r 2 Refer to "CALl PER INSTALLATION" sec-

3 Brake hose 1 tion.
4 Caliper s u p p o r t bolt 1
5 Caliper assembly 1
stallation.
6-17
CALIPER D I S A S S E M B L Y
~ ~ ~ j~J'~ ~ ~ ~ [~0"6m~ "4"3ft'lb) l
net
e.
im
T
er
ot
co
.S
w
w
w
m
fro
ed
Order Job name/Part name Q'ty Rem a r ks

ad
Caliper disassembly Remove the parts in order.

o
nl
(# Caliper bracket 1
ow
® Brake pad 2
® Pad spring 2 --I Refer to "BRAKE CALIPER DISASSEM-
D
® Caliper piston 1 BLY/ASSEMBLY" section.

® Dust seal 1 J
® Piston seal 1
@ Bleed screw 1
Reverse the disassembly procedure for
assembly.
6-18
YP702020
BRAKE CALIPER D I S A S S E M B L Y
NOTE:
Before disassembling either brake caliper, drain
the brake fluid from the brake hose, master
cylinder, brake caliper and reservoir tank.
1. Remove:
• Brake caliper piston
Removal steps:
• B l o w c o m p r e s s e d air into the hose joint
opening to force out the caliper piston from
et
the brake caliper body.
n
~!~LVAV/_'I-"] ~ I I ~ [¢']
e.
im
• N e v e r try to pry out the caliper piston.
T
• Cover the caliper piston w i t h a rag. Be care-
er
ful not to get injured w h e n the piston is ex-
ot
pelled from the m a s t e r cylinder.
co
.S
CAUTION:
w
Carefully r e m o v e the caliper piston to prevent

w
w
damage.
m
fro
ed
ad
2. Remove:
o
• Dust seal ~)
nl
• Piston seal ~)
ow
When removing, push the seals by your

D
finger.
CAUTION:
• Do not use a sharp instrument. R e m o v e seals
by your finger.
• Do not re-use r e m o v e d parts.
YP...
CALIPER I N S P E C T I O N
1. Inspect:
• Caliper cylinder
• Caliper piston ~)
Scratches, wear--~Replace caliper as-
sembly.
6-19
EB702050
BRAKE CALIPER ASSEMBLY

r!~vAvg_,1--'t~ I I ~ [¢-!
• All i n t e r n a l brake c o m p o n e n t s s h o u l d be
cleaned and lubricated w i t h n e w brake fluid
o n l y before installation.
DOT #4(or DOT #3)
• Replace the caliper piston seals w h e n e v e r a

brake caliper is disassembled.
1. Install:
et
• Piston seal (~
)
n
e.
• Dust seal (~
im
O( )
T
er
ot
2.
co Install:
• Caliper piston (~
.S
A p p l y brake fluid to the outer surface

w
and install.
w
w
CAUTION:
m
• Do n o t force.
fro
• Use care t o p r e v e n t damage on caliper pis-

ton.
ed
ad
Y P .....
o
BRAKE CALIPER INSTALLATION

nl
1. Install:
ow
• Caliper (~
D
• Caliper s u p p o r t bolt
P~123Nm(2.3m.kg, 16.6ft.lb) I
• Brake hose (~)
• Copper w a s h e r (~
• Union bolt (~ H 25Nm(2.5 m.kg,18ft.lb) I
CAUTION:
When installing the brake hose t o the caliper,
l i g h t l y t o u c h t h e brake hose w i t h t h e s t o p p e r
(~ on t h e caliper.
6-20
, E , , w.EE, A ° 0 , E , , =,,KE IC"A=I oI
REAR WHEEL AND REAR BRAKE
REAR W H E E L
n et
e.
T im
< .S
co
ot
er
w
2 [;;l~i~]((;16~i:18:8f.?liilb)~" 1
w
w
m
fro
ed

ad
Q'ty
o
Rear w h e e l and rear brake removal Remove the parts in order.

nl
NOTE"
ow
Place the scooter on a suitable atand so

D
that the rear wheel is elevated.
1 Muffler assem bly/Gasket 1/1

2 Nut/Plain w a s h e r 1
3 Rear w h e e l a s s e m b l y 1
4 Plain w a s h e r 1
Reverse the d i s a s s e m b l y procedure for
installation.
6-21
,E,, w,EE,,.o,EA, B,AKE IC"Asl
REAR BRAKE
kllONm(1.0 m.kg, 7.2 ft.lb) I
. /
n et
e.
T im
8
er
./
ot
co
.S
w
w
w
\ t3 -
m
fro
ed
ad

o
1 Adjuster 1
nl
2 Brake cable 1
ow
3 Pin 1
4 Return s p r i n g 1
D
5 Brake shoe 1
6 C a m s h a f t lever 1
7 Wear indicator 1
8 Brake c a m s h a f t 1
stallation.
6-22
.EA. W.EE" A.O .EA. B.A.E I C"Asl
EB701020
REAR W H E E L I N S P E C T I O N
1 Inspect:
• Rear w h e e l axle
• Rear w h e e l
• Rear w h e e l b e a r i n g s
• Oil seals
Refer to " F R O N T WHEEL".
2. Measure:
• Rear w h e e l r u n o u t
Refer to " F R O N T W H E E L " .
EB701021
REAR BRAKE I N S P E C T I O N
1. Inspect:
et
• Brake l i n i n g surface
n
e.
Glazed areas-->Polish.
im
Use coarse sand paper.
NOTE:
T
er
After p o l i s h i n g , w i p e the polished particles w i t h
ot
a cloth.
co
.S
2. Measure:
w
• Brake l i n i n g t h i c k n e s s ( ~
w
~ 1 Brake l i n i n g t h i c k n e s s ( ~ •
w
Standard:
m
4 m m (0.16 in)
fro
Limit:
2 m m (0.08 in)
ed
ad
Measuring points " t "

o
NOTE:
nl
ow
Replace the brake s h o e s as a set, if e i t h e r is

w o r n to the w e a r limit.
D
. Measure:
® • Brake d r u m i n s i d e d i a m e t e r ( ~
Out of specification-->Replace the w h e e l
Brake d r u m i n s i d e d i a m e t e r :
Standard:
130 m m (5.12 in)
Limit:
131 m m (5.16 in)
6-23
,EA, W.EE" A.O .E,, B.,,E I C"Asl
4. Inspect:
• Brake drum inner surface
• Oil/scratc hes-->Re pair.
• Oil
Use a rag soaked in lacquer t h i n n e r or
solvent.
• Scratches
Use an e m e r y cloth (lightly and e v e n l y
polishing)
5. Inspect:
• Cam shaft face.
Wea r-->Replace.
et
W h e n inspecting t h e brake lining, do not spill
n
oil or grease on t h e brake lining,
e.
T im
er
ot
Ye
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.....
.S
REAR BRAKE I N S T A L L A T I O N
1. Install:
w
w
• Camshaft (~
w
• Indicator plate (~
m
Installation steps:
fro
• Set the camshaft w i t h its punched mark (~

ed
facing the direction as shown.

• Align the projection @ on the indicator plate
ad
w i t h the camshaft notch and install.

o
• C h e c k t h e proper position of the brake shoe.

nl
ow
D
2.
Install:
• Camshaft l e v e r ( ~ r~ll0Nm(1.0 m.kg,7.2ft.lb~
NOTE:
Set the camshaft w i t h its punched m a r k ( ~ fac-
ing the direction on the cam shaft lever @.
6-24
.AOOLEBARIC"ASI oI
~ 1 9 N m ( 0 . 9 m.kg, 6.5 ft.lb) I
5
,)~D 1~143Nm(4.3 m.kg, 37 ftJb)l
. 8
et
10
n
e.
T im
er
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2
w
w
w
m
fro
ed

ad
Q'ty
o
10 Wire harness strap 1

nl
11 Brake hose 1
ow
12 Handlebar comp. 1
13 Left grip 1/1
D

stallation.
6-26
HAOOLE.,. IONASI oI
HANDLEBAR
HANDLEBAR
~;~19Nm(0.9 m.kg, 6.5 ft.lb) I
5
,) 1~143Nm(4.3 m.k 9, 37 ft.lb) I
. 8
et
10
n
e.
T im
er
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.S
2
w
w
w
m
fro
ed

ad
Q'ty
o
Handlebar removal Remove the parts in order.

nl
Left/Right bake m i r r o r
ow
Front protector bar Refer to " C O V E R S A N D P A N E L " IN

Upper cover CHAPTER 3.
D
Front/Rear handlebar cover

Left/Rig ht flasher
1 Brake master cylinder 1
2 Front brake switch 1
3 Handlebar switch (Right) 1
4 Throttle cable 1
5 Right grip 1/1
6 Brake cable 1
7 Rear brake switch 1
8 Handlebar switch (Left) 1
9 Bind 1
6-25
.,,O,EBA, IC"ASI oI
HANDLEBAR INSTALLATION
1. Clean:
• Steering shaft ®
~!~v~v/±1 --']~ I I~ [e-]l
® Proper cables and leads routing is essential to
issue safe scooter operation.
® 2. Install:
• Handlebar O
• Bolt (~)
et
• Nut I~143Nm(4.3 m.kg, 37ft.lb) I
n
NOTE:
e.
Match the bolt (~ on to the steering c o l u m n
im
dent (~.
®
T
er
ot
CAUTION:
co
There m u s t be a space b after t i g h t i n g bolt ~).
.S
w
3. Install:
w
• Ba nd
w
NOTE:
m
Clamp the w i r e harness.

fro
ed
4. Apply:
ad
• Lithium soap base grease (to t h r o t t l e

cable end and h a n d l e b a r right end).
o
nl
ow
D
5. Install:
• Handlebar switch (right) (~
NOTE:
Insert the projection (~ into the hole (~ on the
h a n d l e b a r comp.
6-27
.AOO,EBA. IC"ASI oI
Q 6. Install:
• Handlebar switch (left) (~
® NOTE:
Insert the projection (~ into the hole @ on the
handlebar comp.
7. Install:
• Master cylinder
NOTE:
et
Match the slot w i t h the punched mark @ on
n
the handlebar comp.
e.
T im
er
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co
.S
w
w
w
m
fro
ed
ad
o
nl
ow
D
6-28
STEE.,°O IC"ASI oI
STEERING
STEERING
~-766Nm(6.6 m.kg, 47.8 ft.lb)]
r~122Nm(2.2 m.kg, 16 ft.lb)
21
-J/
I
I 8
38Nm(3.8 m.kg, 27ft.lb)
et
n
i
e.
im
I
T
er
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-9
.S
8
w
w
5
w
40Nm(4.0 29 ft.lb)
m
fro
ed

ad
Q'ty
o
Steering removal Remove the parts in order

nl
Handlebar Refer to " H A N D L E B A R " section.

ow
Front wheel Refer to "FRONT WHEEL A N D BRAKE

DISC" section
D
1 Ring nut 1/Special w a s h e r 1/1 -

2 Ring nut 2 / R u b b e r w a s h e r 1/1Refer to "STEERING REMOVAL/INSTAL-
3 Ring nut 3 1 LATION" section.
4 Under bracket 1 -
5 Front fork (Left/Right) 1/1
6 Bearing cover 1
7 Ball race 1
8 Ball (Upper/Lower) 22/19
9 Ball race 3
stal lation.
6-29
STEE.,°O IC"ASI oI
STEERING REMOVAL
~WARNING
• S e c u r e l y s u p p o r t t h e s c o o t e r so t h a t t h e r e
is n o d a n g e r of it falling over.
• S t a n d t h e s c o o t e r on a level surface.
1. Removal:
• Ring nut 1 ~)
• Special w a s h e r (~
• Ring nut 2 (~)
• Rubber w a s h e r (~
• Ring nut 3 (~
et
• Bearing cover (~
n
• Ball race (~
e.
• Ball (~
im
• Front fork a s s e m b l y (~
T
NOTE:
er
• Remove the ring nuts by steering nut wrench.
ot
co
~:c~l Steering
YU-33975
nut w r e n c h (~ I
.S
w
• Hold the lower bracket by hand, then remove

w
by using the steering nut w r e n c h @.

w
• Do not loss the balls (Upper: 22 pcs, Lower:

m
19 pcs).
fro
2. Remove
ed
• Front fork a s s e m b l y
ad
Refer to "FRONT FORK" section.

o
3. Remove
nl
• Ball race
ow
Ball race r e p l a c e m e n t steps:

D
• Remove the ball races on the head pipe us-

ing long rod (~ and the h a r m m e r as s h o w n .
• Remove the ball races on the under bracket
using the floor chisel ( ~ a n d the h a r m m e r as
shown.
6-30
STEE.,°O IC"ASI oI
STEERING I N S P E C T I O N
1. W a s h t h e b e a r i n g races w i t h a s o l v e n t .
2. Inspect:
• Ball race
• Ball
P i t t i n g / D a mage--~Replace.
NOTE:
A l w a y s r e p l a c e b e a r i n g s a n d races as set.
3. Inspect:
• Under bracket (~
Crack/Bend/Damage-->Replace.
Q
et
W!~LVAV/±I-'] ~ I I ~ [¢']1
n
Do not attempt to straighten a bent under
e.
b r a c k e t as t h i s m a y d a n g e r o u s l y w e a k e n t h e
im
under bracket.
T
er
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co
STEERING I N S T A L L A T I O N
.S
1. Install:
• Ball <~
w
w
NOTE:
w
U p p e r ....... 22 pcs
m
L o w e r ...... 19 pcs
fro
2. Lubricate
ed
• Ball
ad
• Ball race
o
nl
L i t h i u m s o a p base g r e a s e
ow
D
6-31
STEE.,°O IC"ASI oI
3. Install:
• Front fork assembly (~
• Ball race (Upper) ~)
• Bearing cover (~
, \ ® • Ring nut 3 ~)
• Rubber washer {~)
• Ring nut 2 (~
• Special washer (~
• Ring nut 1 (~
NOTE:
Securely support the steering shaft so that
there is no danger of it falling down.
n et
e.
T im
er
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co
4. Tighten:
• Ring nuts
.S
w
Tighten steps:
w
• Tighten the ring nut 3 (~ using the ring nut

w
wrench (~ r~122 am {2.2 m.kg, 16 ft..b~ I

m
steor,no,utwrenoho_9 I
fro
ed
NOTE:
ad
Set the torque wrench (~ to ring nut wrench (~

o
.~...~~ ~ @@ ~ so that they form right angle.

nl
ow
D
, ~!~Lvlv/±~ --{ ~11 ~, [ ,¢-]1

Do not over-tightening.
• Loosen the ring nut 3 @) 1/4 turn.

/// / ~) • Checkthe front fork by turning it lock to lock.
If there is any binding, remove the front fork
, assembly and inspect the steering ball bear-
~ , ~ ~ ings and ball races.
• Install rubber washer (~ and ring nut 2 (~,
then turn the ring nut 2 until it contacts with
rubber washer.
6-32
STEE.,°O IC"ASI oI
CAUTION:
Slots on t h e ring n u t 2 and ring n u t 3 s h o u l d
be align. If not, t u r n t h e ring n u t 2 t o w a r d s
t i g h t e n direction until slots a l i g n m e n t .
• Install special w a s h e r (~)

NOTE:
Insert the projections of the special w a s h e r into
the slots.
• Install ring nut 1 (~ and tighten.

[~166Nm(6.6 m.kg, 47.8 ft.lb) I
n et
e.
T im
er
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.S
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w
w
m
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ed
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D
6-33
F.O.T FO.K IC"ASI oI
F R O N T FORK
FRONT FORK
n et
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T im
er
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.S
w
w
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m
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o
Front f o r k r e m o v a l R e m o v e t h e parts in order.

nl
Steering Refer to " S t e e r i n g " section.

ow
1 Under fender 1
2 S p e e d o m e t e r cable h o l d e r 1
D
3 Cap bolt 2 -
4
5
Pinch bolt
Front f o r k
2
l
Refer to " F R O N T FORK R E M O V A L / I N -
2 - S T A L L A T I O N " section.

stallation.
6-34
F.O°T FO.K IC"ASI oI
FRONT FORK D I S A S S E M B L Y
®
/
@
® c-~
net
®
e.
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er
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.S
Q
w
w
w
m
[~, 23N m (2.3 m ~ t ~ / '.

fro
ed

ad
Front fork disassembly Remove the parts in order.

o
nl
O Fork spring Refer to "FRONT FORK REMOVAL/IN-

ow
STALLATION" section.
® Band/Front fork boot 1
D
® Bolt/Copper washer 1/1 -

® Inner tube 1
® Damper rod 1/1 Refer to FRONT FORK DISASSEMBLY/
"
® Rebound spring 1 ASSEMBLY" section.

@ Oil lock piece 1/1
® Oil seal clip 1
® Oil seal 1
@ Outer tube 1 -
assembly.
6-35
F.O.T FO.K IC"ASI oI
Y P .....
f FRONT FORK R E M O V A L
~!~LvAv/_,l -"t ~ I I ~ [¢-]
• Securely support the scooter so there is no
danger of it falling over.
• Stand the scooter on a level surface.
• Stand the scooter on its centerstand.
1. Remove:
• Under fender (~
2. Remove:
• Cap bolt (~)
• Pinch bolt (~
et
W!~kvAv/±1 -'] ~ I I ~ [¢']1
n
Fork spring will j u m p out after removing cap
e.
bolt.
T im
er
3. Remove:
ot
co • Front fork (Left/Right) (~
.S
w
w
w
m
fro
ed
ad
YP703020
o
FRONT FORK D I S A S S E M B L Y
nl
1. Remove:
ow
• Bolt (damper rod) (~

D
Loosen the bolt (damper rod) (~ while

holding the damper rod with T-handle
~) and holder (~).
~ 1 T-handle
YM-1326
Holder
YM-01300-1
6-36
F.O.T FO.. IC"ASI oI
. Remove:
• Inner tube (~
O ® • Oil lock pice (~
• Damper rod ®
® • Rebound spring (~
®
3. Remove:
• Oil seal (~
"7 "°'" i~: CAUTION:
et
N e v e r reuse th e oil seal.
n
e.
im
~) Rag
T
er
ot
YP703030
co
F R O N T FORK I N S P E C T I O N
.S
1. Inspect:
w
• Inner tube bending

w
w
I ~ l Inner tube bending limit:

0.2 mm(0.008 in)
m
fro
Scratches/be nds/da m age-->Replace.

- U
W!~VAV/±I -'| ~ I I ~ [¢']1
ed
Do not a t t e m p t to straighten a bent inner t u b e

ad
as this m a y d a n g e r o u s l y w e a k e n th e tube.
o
nl
ow
D
YP.....
F R O N T FORK A S S E M B L Y
® Q Reverse the DISASSEMBLY" procedure.
"
Note the following points.

® 1. Install:
• Damper rod (~
® • Rebound spring (~
• Oil lock piece (~
• Inner tube L~
6-37
. Install:
• Inner tube (~
Into outer tube ~).
. Install:
• Plain w a s h e r (~
• Bolt ( d a m p e r rod) (~)
n et
e.
T im
er
ot
4. Tighten:
• Bolt ( d a m p e r rod) (~
co
\ A
~%O%123Nm(2.3m.kg, 16.6ft.lb) I
.S
NOTE:
w
Tighten the damper rod bolt ( ~ w h i l e holding the

w
damper rod with a T-handle(~ and holder ~).

w
m
~ T-handle
fro
YM-01326-A
Holder
ed
YM-01300-1
ad
5. Install:
o
• Oil seal (~
nl
• Retaining clip
ow
Use the fork seal driver w e i g h t ~) and

the a t t a c h m e n t (~).
D
NOTE:
• Before installing the oil seal (~, apply lithium
soap base grease onto the oil seal lips.
• A d j u s t the retaining clip so that it fits into the
outer tube groove.
CAUTION:
M a k e sure t h a t t h e oil seal n u m b e r e d side faces
upward.
~ Fork seal driver w e i g h t :

YM-33963
Attachment:
YM-01400
6-38
. Inspect:
• Inner tube operation
U n s m o o t h operation-->Disassembly and
recheck.
7. Fill:
• Fork oil ( ~
Oil q u a n t i t y :
©1
et
88 cc
n
R e c o m m e n d e d oil:
e.
Fork oil 10 W or e q u i v a l e n t
im
8. A f t e r f i l l i n g up, s l o w l y p u m p the f o r k up
T
er
and d o w n to d i s t r i b u t e the fork oil.
ot
9.
co
Install:
0; • Front f o r k s p r i n g O
.S
NOTE:
w
• Install the fork s p r i n g w i t h its s m a l l e r p i t c h ( ~

w
w
upward .
• Before i n s t a l l i n g the cap bolt, a p p l y grease
m
to the O-ring.
fro
• T e m p o r a r i l y t i g h t e n t h e cap bolt.
ed
ad
EB703050
o
FRONT FORK INSTALLATION

nl
Reverse the " R E M O V A L " p r o c e d u r e .

ow
Note t h e f o l l o w i n g points.
D
1. Install:
• Front f o r k ( ~
NOTE:
A p p l y grease o n t o cap bolt O-ring before in-
s t a l l i n g cap bolt.
. Tighten:
• Cap bolts (~) 38Nm(3.8 m.kg, 27 ft.lb) I
• Pinch bolts (~) ~1 I 40Nm(4.0 m.kg, 29 ft.lb)~
6-39
Cl.O°lT OlAO.A. IE'EC I I
CIRCUIT D I A G R A M
, 111L u i II ~ III~l~ ~ III~L

I I ~1~2- / I~ @
~ l ------I
/--/
__i, , I®
, I ~ ~4-4- ......
i® i~
:0
et
~ I B I ~-I~- " I1~ II
~ ®,,® ,,
n
__1
e.
I I
T im
- -i-I
er
:~ I ~ ~ '®
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.S
i
w
w
w
•~ - - - I - - 1
m
@
fro
_EB I I i-- i
ed
L .... J b__ _J
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L
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_E,2 ~ _ _ _ _
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I
I
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I ,
i@
I
D
I I
L
I I I
7-2
c..cu.T o..o..M I E'Ec I I
(~ Main switch (~ Head light(for low beam)
(~) Main fuse (~) Flasher relay
(~ Battery (~ Horn
(~ Starter relay @ Handlebar switch (left)
(~ Starter motor (~ Horn switch
(~ Rectifier regulator @ Dimmer switch
(~ Auto choke (~ Turn switch
(~ C.D.I. magneto @ Fuel sender
(~ C.D.I. unit @ Meter
@ Ignition coil @ Fuel gauge
@ Spark plug (~ Oil indicator light
@ Rear brake switch @ Meter light
(~ Front brake switch @ High beam indicator light
et
@ Tail/Brake light @ Turn indicator light
n
@ Rear flasher light(left) (~ Oil level gauge
e.
@ Rear flasher light(right) @ Handlebar switch (right)
im
(~ Licence light @ Starter switch
T
(~) Front flasher light(right) @ Engine stop switch
er
(~ Front flasher light(left)
ot
(~ Head light(for high beam) co
.S
COLOR CODE
w
B Black Gy G ray L/R Blue/Red

w
Br Brown Y Yellow R/B Red/Black

w
Ch Chocolate W White R/Y Red/Yel low

m
Dg Dark Green B/R Black/Red R/W Red/wh ite

fro
G Green Br/W Brown/White Y/R Yellow/White

ed
L Blue G/R G ree n/Red W/G White/Green

ad
Or Orange G/Y Green/Yellow G/W Green/White

o
Sb Sky blue L/B Blue/Black W/R White/Red

nl
P Pink L/Y Blue/Yellow L/G Blue/Green

ow
R Red L/W Blue/White

D
7-3
O.EOK.°OSW.TO.ESIE'EC I I
YP N
JJoo r, "O" CHECKING S W I T C H E S

C H E C K I N G STEPS
Using pocket tester, check switches for conti-
n u i t y b e t w e e n t h e i r t e r m i n a l s to d e t e r m i n e
"~xl " -- w h e t h e r t h e y are correctly connected.
Replace the switch c o m p o n e n t if any of the
c o m b i n a t i o n s does not produce the correct
reading.
I ~ 1 Pocket tester:
YU-03112
NOTE:
et
• Turn the switch to the " O N " , " O F F " positions
n
several times.
e.
• A d j u s t the pocket tester to correct " 0 " posi-
im
tion before checking switches.
T
• Set the pocket tester selector to " x l ' E 2 .
er
ot
S W I T C H C O N N E C T I O N A S S H O W N IN THIS
co
X",• Br R
MANUAL
.S
This manual contains connection charts, like

w
OFF the one s h o w n on the left, s h o w i n g the termi-

w
ON O - - O nal c o n n e c t i o n s of s w i t c h e s (e.g. the main

w
switch, handlebar switch, brake switch, light-

m
ing switch etc.)

fro
The column on the extreme left indicates the

ed
different switch positions, the top line ind icates

ad
the colors of the leads connected to the termi-

o
nals on the switch.

nl
ow
"0~0" indicates terminals between w h i c h

there is c o n t i n u i t y , i.e. a closed circuit, in the
D
given switch position.
In this chart:
" B r and R" have c o n t i n u i t y w i t h the switch in
the " O N " position.
7-4
O.EOK.°OSW.TO.ESIE'EC I I
S W I T C H POSITION A N D T E R M I N A L CONNECTION
Before c h e c k i n g a s w i t c h refer to the check- I-

Main switch
ing s w i t c h e s as s h o w n in the left page and I
check for t h e c o r r e c t t e r m i n a l c o n n e c t i o n s I Gy Br R B B/VV
LOCK
(closed circuit) a c c o r d i n g to the c o l o r c o m b i - ~ OPEN
n a t i o n s s h o w n in the chart. OFF
Poor c o n n e c t i o n , fault-->Repair or replace. C)---O
ON C ) - O 0 -O
I
7
I
Rear brake s w i t c h L J
n et
r Front brake s w i t c h
I
e.
T im
er
I
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I- I
co I
L
Horn s w i t c h
.S
--'~P B ~
Release
w
Push in O- 0 <
w
w
Dimmer switch I iI
I I",,t
m
~ G L Y ,,,,,,"~
-C> O-43
fro
gO 00
Start s w i t c h
L/W L/G
Turn switch
ed
Release
Ch Br/VV Dg Push in O - - O
ad
<~ O--O
o
~> O--O E n g i n e stop s w i t c h

nl
L
ow
J B/W B/W L/G B

OFF
D
RUN 0--0 0--0
<
/
/
F Fuse
7-5
c.Ec...o T.E Bo.Bs A.o BO.B SOO.ETS IE'EC I I
EAS00733
CHECKING THE BULBS A N D BULB

SOCKETS
Check each b u l b and b u l b socket for d a m a g e
or wear, p r o p e r c o n n e c t i o n s , and also for con
tinuity between the terminals.
D a m a g e / w e a r --~ Repair o r replace t h e bulb,
b u l b socket or both.
I m p r o p e r l y c o n n e c t e d --~ P r o p e r l y connect.
No c o n t i n u i t y --~ Repair o r replace the bulb,
b u l b socket or both.
n et
e.
T im
er
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@ TYPES OF BULBS
.S
The b u l b s used on t h i s s c o o t e r are s h o w n in

w
the i l l u s t r a t i o n on the left.

w
• Bulbs @ and ( ~ are used for the h e a d l i g h t s

w
and u s u a l l y use a b u l b h o l d e r t h a t m u s t be
m
detached before r e m o v i n g t h e bulb. The ma-

fro
j o r i t y of these t y p e s of b u l b s can be r e m o v e d
184 1 0 6 0 3
f r o m t h e i r respective socket b y t u r n i n g t h e m
ed
co u n t e r c l o c k w i s e .
ad
• Bulbs © are used for t u r n s i g n a l and tail/

©
o
brake l i g h t s and can be r e m o v e d f r o m t h e

nl
socket by p u s h i n g and t u r n i n g the bulb coun-

ow
te rcl ockwise.
• Bulbs ( ~ and ( ~ are used for m e t e r and indi-
D
cator l i g h t s and can be r e m o v e d f r o m t h e i r

respective socket by c a r e f u l l y p u l l i n g t h e m
out.
18410004
7-6
C.EOK..O T.E BO'BS..O BO'B SOCKETSIE'EC I I
C H E C K I N G THE C O N D I T I O N OF THE BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
Since the headlight bulb gets extremely hot,

keep f l a m m a b l e p r o d u c t s and y o u r h a n d s
a w a y from the bulb until it has cooled d o w n .
CAUTION:
• Be sure to hold the socket firmly w h e n re-
et
moving the bulb. Never pull the lead, other-
n
w i s e it may be pulled out of the ter-minal in
e.
the coupler.
im
• Avoid touching the glass part of the head-
T
light bulb to keep it free from oil, other-wise
er
the transparency of the glass, the life of the
ot
bulb, and the luminous flux will be adversely
co
affected. If the headlight bulb gets soiled,
.S
t h o r o u g h l y clean it w i t h a cloth moistened

w
w i t h alcohol or lacquer thinner.

w
w
. Check:
m
• bulb (for continuity)

fro
(with the pocket tester)

ed
No continuity --> Replace.

ad
~ 1 Pocket tester
o
YU-03112
nl
ow
NOTE:
D
Before checking for continuity, set the pocket

tester to " 0 " and to the "El x 1" range.
a. Connect the positive tester probe to termi-

nal (~ and the negative tester probe to ter-
minal (~, and check the continuity.
b. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal (~, and check the continuity.
c. If e i t h e r of t h e r e a d i n g s i n d i c a t e no
continu-ity, replace the bulb.
18410002
7-7
O.EOK.°O T.E BO'BS A.O BO'B SOCKETS IE'Ecl I
C H E C K I N G T H E C O N D I T I O N OF THE B U L B
SOCKETS
The f o l l o w i n g p r o c e d u r e a p p l i e s to all o f the
b u l b sockets.
1. Check:
• b u l b socket (for c o n t i n u i t y )
( w i t h the pocket tester)
No c o n t i n u i t y --> Replace.
P°ckettester
YU-03112
I
NOTE:
et
Check each b u l b socket for c o n t i n u i t y in the
n
same m a n n e r as d e s c r i b e d in the b u l b section;
e.
h o w e v e r , note t h e f o l l o w i n g .
T im
er
a. Install a g o o d b u l b into t h e b u l b socket.
ot
b. C o n n e c t t h e pocket tester p r o b e s to t h e
co
respective leads of t h e b u l b socket.
.S
c. Check the bulb socket for c o n t i n u i t y . If a n y
w
of the r e a d i n g s indicate no c o n t i n u i t y , re-

w
place the b u l b socket.

w
m
fro
ed
ad
o
nl
ow
D
7-8
IGNITION SYSTEM
IE'ECI I
CIRCUIT D I A G R A M
• .... ~-r~', ~
~~ ~L~J~ ~E~
I-- -- -------- . . . . I. . . . . . . . . I
,
I __ ~,BI
~ ,~w wa? ~or I
-- - B B I
I
-
I
~ ~-~_~
r s- ------7
'B~'
I I ~ I I
~,_ . . . . . . . . I. . . . . . . . . . I
I
I __~ I
et
---~L . . . . . ~®
n
',® I r ~ ® "
e.
; ..... __~___J
T im
er
I I I
ot
co
@.___~ ____~ ....... 2~___]
.S
', ; - - t * ~ ~B
w
]~- -v- " v

w
I
®I Io I
w
I
I ,
~ F--- --- .... I
m
L_ _ _ j L . . . . J
B S S
fro
l
ed
F ~ -~ ~ ~ _ _ _ _
ad
I@l b
o
nl
L . . . . . . . . . . I
,,',#~
-
ow
r . . . . --q ~ --I ~ _ _ _ _
',
D
I I . . . . I I
L_ ~ '
(~) Main switch

(~ C.D.I. magneto
(~) C.D.I. unit
@ Ignition coil
(~) Spark plug
(~3 Engine stop switch
7-9
.o..T.o° SVSTEMI':":C I I
TROUBLESHOOTING
IF I G N I T I O N S Y S T E M S H O U L D B E C O M E I N O P E R A T I V E
(NO S P A R K OR I N T E R M I T T E N T SPARK)
NOTE:
• Remove the following parts before troubleshooting.
1) Battery box cover 4) Tail cover
2) Center cowling 5) Side cover (right)
3) Rear carrier 6) Handlebar cover (front)
• Use the following special tools in this troubleshooting.
~ 1 Dynamic
tester:YM-34487
spark I ~ 1 Pocket
tester:Yu-03112
n et
e.
im
1. Spark plug Standard spark plug:
T
• Check the spark plug condition. BPR7HS (NGK)
er
• Check the spark plug type.
ot
Spark plug gap:
• Checkthe spark plug gap. co 0.6~0.7 mm(0.02~0.03 in)
Refer to the "SPARK PLUG INSPECTION"
.S
section in the CHAPTER 3. INCORRECT
w
w
~ CORRECT
w
m
fro
I Spark plug is faulty, replace it or repair plug

gap.
ed
ad
2. Ignition spark gap

• Disconnect the spark plug cap from spark
o
nl
plug.
ow
• Connect the dynamic spark tester (~ as

shown.
D
(~ Spark plug cap

• Checkthe ignition spark gap (~.
• Start engine, and increase spark gap until
misfire occurs. lgll0201
~ Minimum spark gap: MEETS SPECIFICATION

6.0 mm (0.24 in)
I OUT OF SPECIFI-
CATION OR NO
SPARK
* I Ignition system is good.
7-10
E.EOT..OA. OO=,O=E°T= I E'EC I I
ELECTRICAL
ELECTRICAL C O M P O N E N T S
(~ Main switch (~ Battery
(~) Flasher relay (~ Ignition coil
(~) Oil level gauge @ Rectifier/Regulator
(~ C.D.I. UNIT (~) Horn
(~ Fuel level gauge
(~ Starter relay
(~ Fuse
et
®
n
®
e.
T im
er
ot
co
.S
w
w
@
w
, ®
m
fro
0
ed
o ad
nl
ow
D
Y
®
7-1
IGNITION SYSTEM ELEC +'
*
l
3. Spark plug cap resistance
• Remove the spark plug cap.
• Connect the pocket tester (~Q x lk) to the
spark plug cap.
• Check the spark plug cap for specificated
resistance. • J
[~ Spark plug cap resistance:
5k£Q at 20°C (68°F)
et
OUT OF SPECIFICATION
n
MEETS
e.
SPECIFICATION
T im
4. Ignition coil resistance
er
• Disconnect the ignition coil leads from the Replace spark plug cap.
ot
ignition coil. co
• Connect the pocket tester (~ x 1) to the
.S
ignition coil.
w
Ignition coil:
w
w
Tester (+) lead->Terminal (~

Tester (-) lead->Coil base (~)
m
fro
• Check the p r i m a r y coil for specification

resistance.
ed
Primary coil resistance:

ad
0.32~0.48 E2 at 20°C (68°F)

o
///"
nl
• Connect the pocket tester (£Q x 1 k) to the

ow
ignition coil. © ©
D
Tester (+) lead--~Spark plug lead (~

Tester (-) lead->Coil base (~)
• Check the s e c o n d a r y coil for specificated

resistance.
S e c o n d a r y coil resistance: OUT OF SPECIFICATION

5.68 ~ 8.52 k ~ at 20°C (68°F)
(Spark plug lead - Coil base)
B O T H MEET
SPECIFICATIONS
I Ignition coil is faulty, replace it.
7-11
,ON,T,OOS STEM IE'EC I I
5. Pickup coil resistance

• Disconnect the pickup coil coupler from
the wireharness.
• Connect the pocket tester (~ × 100) to the
pickup coil terminal.
Tester (+) lead->White/Red lead (~

Tester (-) l e a d , W h i t e / B l u e (~)
• Check the pickup coil for specificated re-
et
sistance. OUT OF SPECIFICATION
n
-~ Pickupcoilresistance:
e.
im
248~ 372 ~Q at 20°C (68°F)
(Wh ite/Red-Wh ite/Blu e)
T
er
I Pickup coil is faulty, replace it.
~N7 SPECIFICATION
MEET
ot
co
.S
6. Source resistance
w
• Disconnect the source coil coupler from

w
the wireharness.
w
• Connect the pocket tester (~ × 100) to the

m
source coil terminal.

fro
Tester (+) lead->Black/Red lead (~

ed
Tester (-) l e a d , G r e e n / W h i t e (~
ad
• Check the source coil for specificated re- OUT OF SPECIFICATION

o
sistance.
nl
-~ Sourcecoilresistance:
ow
640 ~ 960 E2 at 20°C (68°F)

D
(Black/Red - Green/White )
I Source coil is faulty, replace it.
~ 7 SPECIFICATION
MEET
NO CONTINUITY
7. Main switch
Refer to "CHECKING SWlTCHS" section.
CONTINUITY
I Main switch is faulty, replace it.
7-12
.O..Z.O° SVSTEM IE'EC I I
NO CONTINUITY
8. Engine stop switch
CONTINUITY I Engine stop switch is faulty, replace it. I
POOR CONNECTION
9. Wiring connection
Check the entire ignition system for conneo
et
tions.
n
Refer to the "WIRING DIAGRAM" section.
e.
I Correct. I
im
~ CORRECT
T
er
I Replace CDI unit.
ot
co
.S
w
w
w
m
fro
ed
oad
nl
ow
D
7-13
O,.OSYSTE. IE'Ecl
CHARGING SYSTEM
CIRCUIT DIAGRAM
[- . . . . ~ ~ : I
L--~ ______i ~ i. . . . . . i
,'........ ~,rm'
....... 78-',r~
i ~ , ~$~ I I I o,d-E-~--~ - I
~,R_, ( ® ~ ~ I ~ ~ ' ,
_ J R,~.
I I
,~ ~R
r
I ~_~_~_~
-~ ------1
' - C 1"]
I
,BI, I
I
I
I
L ....... I. . . . . . . . . .
I
i
,~'- -'
,eeL-' ~r ~
et
---4- ........ ~-
,,® ® ,,
n
e.
,, ~,,1~
im
II . . . . . . . . £~rq . . . .
T
er
iI _t _ll
ot
l ...... l i [ ~ I [ ~
co
i<~ ~_li~ ~------~ .... ~ ___
.S
w
i
w
,'--@, ,'TE --,,

~ ~-~T~,~ --1---: ~
w
,', ~',~ ,' B',~

m
L_ _] L__ _J
I
fro
[___
i- ~ -~
ed
I
I
14~ IHb i
ad
L ..... i
o
i
i
nl
L_____
ow
,' ® ~ ~',D
'[_~' B,,~ ,,' ~ i ~
D
', I J - - ~ I I
(~) Main fuse

(~ Battery
(~ Rectifier Regulator
(~ CDI magnet
7-14
O,.OSYSTEMIE'ECI
TROUBLESHOOTING
THE B A T T E R Y IS N O T C H A R G E D .
NOTE:
1) Front protector bar 4) Tail cover
2) Upper cover 5) Right side cover
3) Rear carrier
• Use the following special tool (s) in this trobleshooting.
Pocket tester:
1~1 Inductive
YU-8036-A
tach°meter: I 1 ~ 1
YU-03112
net
e.
1. Fuse (main) NO CONTINUITY
im
• Remove the fuse.
• Connect the pocket tester (£1 x 1) to the
T
er
fuse.
ot
• Check the fuse for continuity. co
I Fuse is faulty, replace it.
.S
~ CONTINUITY
w
w
2. Battery INCORRECT
w
• Check the battery condition

m
Refer to the "BATTERY INSPECTION" sec-

fro
tion in the CHAPTER 3.

ed
[~ Open circuit voltage:

12.8V or more at 20°C (68°F) I o Clean battery terminals.
ad
• Recharge or replace battery.

o
nl
7 CORRECT
ow
*
D
/ J
J/
7-15
O,NOS,STEMIE'ECI
3. Charging voltage
Connect the inductive tachometer to the
spark plug lead.
Connect the pocket tester (DC20V) to the
battery.
Tester (+) lead- >Battery (+) terminal

Tester (-) lead- >Battery (-) terminal
• Start the engine and accelerate to about
et
5,000 r/min.
n
• Check charging voltage.
e.
~ Chargingvoltage:
im
13 ~ 14 V at 4,000 r/min
T
er
NOTE:
MEETS SPECIFICATION
ot
Use a full charged battery. co
.S
l
OUT OF
w
SPECIFICATION
w
I Charging circuit is good.

w
4. Charging coil and lighting coil resistance

m
J
• Disconnect the charging coil coupler from ~ z
fro
the wireharness.
• Connect the pocket tester " ~ x 1" to the
ed
charging coils.
ad
• Measurethe charging coil and lighting coil

resistance.
o
nl
Charging coil resistance:

ow
Tester (+) lead->White lead (~

D
Tester (-) lead->Earth
Lighting coil resistance:

Tester (+) lead->Yellow/Red (~
Tester (-) lead->Earth OUT OF SPECIFICATION
-~ Chargingcoilresistance:
0.48~0.72 ~ at 20°C (68°F)
Lighting coil resistance:
0.4-0.6 ~, at 20°C (68°F)
I Charging coil is faulty, replace it.
~=, MEET
SPECIFICATION
*
7-16
O,OOS
STEMIE'ECI
Se
5. Wiring connection i
Check the entire ignition system for con-
nections.
Refer to the "WIRING D I A G R A M " section.
] POOR CONNECTION
.~o~ I Correct.
Replace rectifier regulator.
et
n
e.
im
T
er
ot
co
.S
w
w
w
m
fro
ed
o ad
nl
ow
D
7-17
E.EOT..O ST..T.°O S STE. I E'EC I I
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
IIII
CI~~
cl-
....
__
ON~,IIC~--~______I
,',
...... -~',B
,
.....Y--
f--~, ~ ~ .... I I
~-',,B
, o,d-Z-~S4~ -'
B ~/a
i ---,® [r -~ ---1
L . . . . .
'-# 71 , ~~I ~ I~ ITZ:~=~

~,,@,
I I I
o~_ .,,~
' - -
,,
,@~ ......
I ' ' ®,,® ,

I
L . . . . . . . I. . . . . . . . . . I
,,~~~',~
et
--i-" "~-~ °
n
e.
L ___J
T im
er
i
'~ -~-' ~
I!Io,,o ...... " ot
co
.S
1
w
~)r----- I a
w
I
,'--G I ,'~3- --',
w
. . . . I
I ,"
L_ B,,(
_J ,'L__ B,,~
_J
m
S
I___
fro
ed
, @ ',
ad
L~__ I
I
o
I
nl
L I
ow
r . . . . --~' ~--I s
' ®~',D ' fl -~' I ®l
I
0B8
D
I
I
,L_ ~ L I
,t_B_j
(~ Main switch (~) Front brake switch

(~ Main fuse (~ Engine stop switch
(~ Battery (~) Starter switch
(~ Starter relay
(~ Starter motor
(~ Rear brake sv~
switch
7-18
E.EO*..O STA.*.OO S*S*EM I E'EC I I
TROUBLESHOOTING
J S T A R T E R M O T O R DOES N O T OPERATE.
NOTE:
1)Battery box cover 4)Side covers (left and right)
2)Rear carrier 5)Trunk
3)Tail cover 6)Handlebar cover (front)
• Use the following special tool in this troubleshooting.
Pocket tester:
YU-03112
I
n et
1. Fuse
e.
• Remove the fuse. NO CONTINUITY
im
• Connect the pocket tester (~ x 1 ) to the
T
fuse.
er
• Check the fuse for continuity.
ot
co
S CONTINUITY I Fuse is faulty, replace it.
.S
w
2. Battery
w
• Check the battery condition.

w
Refer to the "BATTERY INSPECTION" sec- INCORRECT

m
tion in the CHAPTER 3.

fro
Open circuit voltage:

ed
12.8 V or more at 20°C (68°F)

ad
l e Clean battery terminals.

S CORRECT • Recharge or replace battery.
o
nl
3. Startermotor
ow
~WARNING
• Connect the battery@positive terminal
D
and starter motor cable ~) using a jumper • A w i r e for t h e j u m p e r lead m u s t have t h e

lead (~ * e q u i v a l e n t capacity as t h a t of t h e b a t t e r y
lead or more, o t h e r w i s e it m a y cause t h e
j u m p e r lead t o be burned.
• This check is likely t o p r o d u c e sparks, so be
sure t h a t no f l a m m a b l e gas or fluid is in t h e
vicinity.
t DOES NOT MOVE

J
• Check the starter motor for operation.

I
S MOVES I Starter motor is faulty, repair or replace it. I
* 7-19
E.EOT..O STA.T.OO S STEM I E'EC I I
4. Starter relay
• Disconnect the relay unit coupler from the
wire harness.
• Connect the pocket t e s t e r ( ~ x 1)and
battery(12V) to the relay unit coupler ter-
minals.
Battery(+)lead-->
Blue/White terminal (~
Battery(-)lead--~
et
Green/Yellow terminal (~)
n
e.
• Check the starter relay for continuity.
im
NO CONTINUITY
T
Tester (+) lead--> (~ terminal
er
Tester ( - ) l e a d ~ (~ terminal
ot
co
, ~ CONTINUITY
.S
J Replace the starter relay.

w
w
5. Main switch NO CONTINUITY

w
Refer to "CHECKING SWITCHS" section.

m
fro
, ~ CONTINUITY
ed
J Main switch is faulty, replace it.

oad
6. "START" switch NO CONTINUITY

nl

ow
~ 1
D
!;7 CONTINUITY
"START" switch is faulty, replace handlebar

7. Engine stop switch switch (right).
CONTINUITY
9$ J Engine stop switch is faulty, replace it.
7-20
E'EOT..C S*A.*.°O S*S*EM I E'EC I I
CONTINUITY
8. Brake s w i t c h e s (front and rear)

Disco n nect the brake switch leads from the
w i r e harness.
Connect the pocket tester (~ × 1 )to the
brake switch leads.
/f \\\
et
n
e.
im
T
er
Check the brake switch for c o n t i n u i t y
ot
Switch Good co
Bad condition
Position condition
.S
Brake is
w
applied 0
w
w
Brake is X
m
not applied
fro
O:Continuity X
ed
I Replace brake switch(es)•

GOOD
ad
CONDITION
o
nl
9• Wiring connection
ow
C h e c k t h e entire electrical starting system POOR CONNECTION

D
for connections•
Refer to "WIRING D I A G R A M " section.
I Correct•
7-21
E'ECT..O STA.T.OO S STEM I E'EC I I
STARTER M O T O R
n et
._._' .
e.
im
~- [~113 N m(1"3 m "kg' 9"4 ft'l b)~
T
er
ot
~. ( ~ co ~ ~ 1
.S
w
w
w
m
fro
ed
Remarks
ad
Order J o b name/Part name Q'ty

o
Starter m o t o r removal Remove the parts in order.

nl
Rear carrier
ow
Tail cover Refer to "COVER P A N E L " section in

Battery box cover CHAPTER 3.
D
Left/Right side cover

Center c o w l i n g
Muffler m
]Refer to " R E A R W H E E L A N D REAR

Rear w h e e l BRAKE" section in CHAPTER 6.
Air s h r o u d 3 Refer to "ENGINE R E M O V A L " section
chapter 4.
1 Starter m o t o r c o u p l e r
2 Starter m o t o r
stallation.
7-22
E,ECTR,OSTART,OOSVSTEM I E'EC I I
STARTER M O T O R D I S A S S E M B L Y
<C_
n et
e.
im
k~ ry~,113Nm(1.3 m.kg, 9.4 ft.lb)l
T
er
ot
<. ( ~ . . ~ ~ co ~ ~ = ~ 1
.S
w
w
w
m
fro
ed
Order Job name/Part name Q'ty Re marks

o ad
Starter motor disassembly Disassembly the parts in order.

nl
Cb O-ring 1 m
ow
® Rear bracket 1
® Armature ass'y 1 Refer to "Starter motor assembly"
D
® Ring 1
® Brush holder set 1-
assembly.
7-23
E.EOT..C STA.T..O S STEM I E'EC I I
YP803034
I N S P E C T I O N A N D REPAIR
® 1. Inspect:
• Commutator
Dirt-->Clean it w i t h #600 grit s a n d p a p e r .
2. Measure:
• Commutator diameter (~
Commutatorwearit
15.1 m m (0.59 in)
I
Out of specification-->Replace the starter
motor
. Measure:
• Mica u n d e r c u t ( ~
et
Ilocaun'ercut I
n
e.
1.05 m m (0.04 in)
im
Out of s p e c i f i c a t i o n ~ S c r a p e the mica to
T
er
the p r o p e r v a l u e (a h a c k s a w blade can
be g r o u n d to fit).
NOTE:
ot
co
The mica i n s u l a t i o n of the c o m m u t a t o r m u s t
.S
be u n d e r c u t to ensure proper o p e r a t i o n of c o m -
w
mutator.
w
w
m
fro
ed
ad
4. Inspect:
o
• A r m a t u r e coil resistances ( i n s t a l l a t i o n /
nl
continuity)
ow
Defects-->Replace the starter m o t o r .

D
If c o m m u t a t o r is dirty, clean it w i t h sand-

® paper.
(~ m 4-(
J Good Bad c o n d i t i o n
condition
[] © 0 x x
[] × 0 x 0
O: C o n t i n u i t y
x: No c o n t i n u i t y
Bad condition-->Replace.
7-24
E.EOT.,O STA.T,°O SVSTEM I E'EC I I
. Measure:
• Brush length (~
I ~ 1 Brush length wear limit
3.0 mm (0.012 in)
. Measure:
• Brush spring force
Fatigue/out of specification-->Replace as
a set.
n et
e.
T im
er
ot
co
.S
w
w
w
m
fro
ed
ad
o
nl
ow
D
7-25
..o.T.oo s sTEM IE'EC I I
LIGHTING SYSTEM
CIRCUIT DIAGRAM
[- . . . . ~ ~ : I
iI........ 4~lrml
....... ~-',r~
L--~ ______1 ~ I...... I i I'UL~- ~ I~L~r ®
~,R_, ( ® ~ ~ I ~ ~ l l
_ J R,~.
I I
~ ~ R
r
I
~
-~ ------1
'-C 1"]
I
,BI I
I
I
I
I
L ....... I.......... I
,~'
et
- -' ---4- ........ ~-
,,® ® ,,
n
e.
,, 4~ ,,1~
im
II . . . . . . . . £~rq . . . .
T
er
ot
i I _t _ll l ...... l i [ ~ I [ ~
co
I<~ ~_Ii~ ~------~ .... ~ ___
.S
w
I
w
,'--@, ,'TE --,,

w
,', ~',~ ,' B',~

m
L_ _J L__ _J
I
fro
I___
i- ~ -~
ed
I
I
14~ IHb I
ad
L ..... I
o
I
I
nl
L_____
ow
,' ® ~ ~',D
'[_~' B,,~ ~i~
D
', I J - - ~ I I
(~)Main switch (~ Head light(for high beam)

(~ Fuse (~ Head light(for low beam)
(~ Battery (~ Light dimmer switch
(~ C.D.I. magneto (~) Meter light
@ Tail light (~) High beam indicator light
(~ Licence light
7-26
..o.T.°o s,,sTE , I':":c I I
YP805010
TROUBLESHOOTING
IF THE H E A D L I G H T , HIGH B E A M I N D I C A T O R LIGHT. T A I L L I G H T

A N D / O R M E T E R L I G H T FAIL T O C O M E ON.
Procedure
Check:
1. Lights switch
2. D i m m e r switch
3. Wiring connection (entire lighting system)
NOTE:
• Remove the f o l l o w i n g parts before t r o u b l e s h o o t i n g .
1) Front h a n d l e b a r cover
et
2) Rear carrier
n
3) Right side cover
e.
• Use the special tools specified in the t r o u b l e s h o o t i n g section.
im
°ckettester I
T
er
YU-03112
ot
co
NO CONTINUITY
.S
YP .....
1.Fuse
sectionlIII
w
Referto "CHECKING SWITCHES"

w
w
m
CONTINUITY I Replace the fuse.

fro
YP .....
2. Battery IN CORRECT
ed

ad
Refer to "BATTERY INSPECTION" sectior

o
in CHAPTER 3.
nl
ow
~ CORRECT
D
o Clean battery terminals.
D

YP .....
3. Main switch I NOCONTINUlTY

Refer to "CHECKING SWITCHES" section
~ CONTINUITY
i
* i Replace the main switch.

I
7-27
Se
IE'ECI I
YP .....
NO CONTINUITY
4. D i m m e r switch
Refer to "CHECKING SWITCHES" section.
~ CONTINUITY i l
Replace the left handlebar switch.
5. Lighting coil resistance
• Disconnect the lighting coil coupler from
the wireharness.
• Connect the pocket tester " ~ x 1 " to the
et
lighting coils.
n
e.
• Measure the lighting coil resistances.
im
Tester (+) lead->Yellow/Red lead (~
T
Tester (-) l e a d , E a r t h
er
- - ~ Lightingcoilresistance:
ot
0.4 ~ 0.6 ~ at 20°C (68°F) OUT OF SPECIFICATION
co
~
.S
MEET
w
SPECIFICATION
w
w
*
I Lighting coil is faulty, replace it.
m
fro
ed
ad
o
nl
ow
D
7-28
..o.T.°o svsTEMIE'ECI I
Se
YP .....
6. Wiring connection POOR CONNECTIONS

Check the connections of the entire light-
ing system.
Refer to "WIRING DIAGRAM".
,~OK I Correct. I
Check the condition of each of the lighting

system's circuits.
Refer to "LIGHTING SYSTEM CHECK"
n et
e.
YP805020
im
L I G H T I N G S Y S T E M CHECK
1. If the headlight and the high beam indi-
T
er
cator light fail to come on.
ot
1. Bulb and bulb socket
co
I Refer to "CHECKING SWITCHES" section.
NO CONTINUITY
.S
w
7 CONTINUITY
w
w
2. V o l t a g e I Replace the bulb and/or bulb socket.

m
• Connect the pocket tester (DC20V) to the

fro
headlight and high beam indicator light m ~ ~ ~ \ n
couplers.
ed
h
ad
[~]When the dimmer switch is on low beam.

IBIWhen dimmer switch is on high beam.
o
nl
Headlight(low beam):
ow
--®
Tester (+) l e a d , G r e e n O lead
D
Tester (-) lead->Black (~) lead

Headlight(high beam):
Tester (+) lead-->Yellow (~ lead
~i:,i,~i,~ ~
Tester (-) l e a d , B l a c k (~ lead
High beam indicator light:

Tester (+) lead->Yellow ~ lead G/~ :]]
Tester (-) lead->Black (~ lead B
7-29
..o.T.°o s sTEM IE'EC I I
• Turn the main switch to on. OUT OF SPECIFICATION

• Start the engine.
• Turn the dimmer switch to low beam or
high beam.
• Checkfor voltage (12V) on the lead at bulb
socket connectors. I The wiring circuit from the main switch to
,• MEETS
SPECIFICATION
bulb socket connector is faulty. Repair.
et
I This circuit is not faulty.
n
e.
im
YP805021
T
2. If t h e m e t e r light f a i l s t o c o m e o n .
er
l. Bulb and bulb socket I NO CONTINUITY
l Refer to "CHECKING SWITCHES" section. co
ot
1
.S
7 CONTINUITY
w
w
2. V o l t a g e I Replace the bulb and/or bulb socket.

w
• C o n n e c t t h e p o c k e t t e s t e r (DC20V) t o t h e
m
bulb socket coupler.

fro
Tester (+) lead-->

ed
Blue terminal (~
Tester (-) lead-->
ad
Black terminal (~)

o
nl
ow
%
D
- - L
G_~y
,B
• Turn the main switch to on.

• Start the engine. OUT OF SPECIFICATION
• Check the voltage (12V) of the leads on
the bulb socket connector.
g MEETS
SPECIFICATION The wiring circuit from main switch to bulb
I This circuit is not faulty. I socket is faulty. Repair.
7-30
..o.T.°o svsTEMIE'ECI I
Se
3. Licence light does not come on.
1. Bulb and bulb socket NO CONTINUITY

• Checkthe bulb and bulb socket for conti-
nuity
~ CONTINUITY
I Bulb and/or bulb socket are faulty, replace. I
2. Voltage
et
• Connect the pocket tester (DC20V)to the
n
e.
bulb socket connector.
im
Tester (+) lead --> Brown @ lead.
T
Tester (-) lead --> Black (~ lead.
er
ot
co
.S
w
w
w
m
fro
ed
• Check the voltage (12V) on the " B r o w n "

l
ad
lead at the bulb socket connector.

~ MEETS
o
nl
SPECIFICATION I W i r i n g circuit f r o m main s w i t c h to bulb

ow
(12V) socket connector is faulty. Repair.

D
7-31
L.O.T..O SYSTEMIE'EC I I
YP805022
3. T h e t a i l l i g h t fails t o c o m e o n .
NO CONTINUITY
I Refer to "CHECKING SWITCHES" section.
7 CONTINUITY
I Replace the bulb and/or bulb socket.
2. V o l t a g e
• C o n n e c t t h e p o c k e t t e s t e r (DC20V) t o t h e
Tester (+) lead-->

Brown terminal (~
et
Tester (-) lead-->
n
Black terminal (~)
e.
T im
er
GH Br
ot
,B co
Ch Dg
.S
w
w
w

m
Checkthe voltage (12V) on the bulb socket

fro
connector.
,•
I
I The wiring circuit from main switch to bulb I
MEETS
connector is faulty. Repair.
I
ed
SPECIFICATION
ad

o
nl
ow
D
7-32
S.O...SVSTE. IE'Ecl I
SIGNAL SYSTEM
CIRCUIT DIAGRAM
C ON
I ~,
IIII ~IIC
_.... ~ ~-~___I
,',
...... -~',B
,
.....Y--
f--~, ~ .... I I
~-',,B
, ° ' ~ - '
B ~/a
i ---,® [r -~ ---1
b . . . . .
,-C?] , ~~I ~ I~ IT~=~
I I I o~_ .,,~
' - - ,,
,~I.~ ......
I ' ' ®,,® ,

I
b . . . . . . . I. . . . . . . . . . I
et
--i -= ,~_~ °
n
e.
L ___J
T im
er
i
ot
'~ -@-'
T!I~IIB ' T l_a~1 co
.S
1
w
~)r----- I
w
I
,'- -G I ,'~3- I
w
. . . . I
I
L_S _J L__ _J
m
I___
fro
ed
, @ ',
ad
L~___I
I
o
I
nl
b I
. . . . -->'~--I
ow
LI_B_j~
r
[ 1 -@ ,-
I ~ ) ~ I~IIB ®l
,' 0B8
D
'
I
• _ _I__Bj I
~ L I
(~ Main switch (~ Rear flasher light(left) (~ Turn switch

(~ Main fuse (~) Front flasher light(right) @ Fuel sender
(~) Battery @) Front flasher light(left) (~ Fuel meter
@ Rear brake switch @ Flasher relay (~) Oil indicator light
@ Front brake switch (~ Horn @ Turn indicator light
@ Brake light (~ Handlebar switch (Left) (~ Oil level gauge
(~) Rear flasher light(right) (~) Horn switch
7-33
S,O.ALSVSTEMIE'ECI I
YP806010
TROUBLESHOOTING
IF T H E F L A S H E R L I G H T , B R A K E L I G H T A N D / O R I N D I C A T O R LIGHT
FAIL T O C O M E O N . IF T H E H O R N F A I L S T O S O U N D .
Procedure
Check:
1. Fuse (Main) 3.Main switch
2. Battery 4.Wiring connection (entire signal system)
NOTE:
1 ) Battery box cover 5) Tail cover
et
2) Front protector bar 6) Side covers(Left/Right)
n
3) Upper cover 7) Center cover
e.
4) Rear carrier
im
• Use the special tools in the troubleshooting section.
T
P°ckettester: I
er
ot
YU-03112 co
.S
¥P . . . . . NO CONTINUITY
1. Fuse
I
w
w

w
~ CONTINUITY
m
fro
I Replace the fuse.

YP .....
ed
2. Battery IN CORRECT
ad
Refer to "BATTERY INSPECTION" section

o
in CHAPTER 3.
nl
ow
~ CORRECT l e Clean battery terminals.

D

YP .....
3. Main switch NO CONTINUITY

CONTINUITY
.-X- I Replace the main switch.
7-34
S,O°A. SVSTEMIE'ECI I
Se
YP ......
4. Wireharness
• Check the connections of the entire sig- POOR CONNECTION
nal system.
Refer to "CIRCUIT SYSTEM WIRING DIA-
GRAM" section.
~ CONTINUITY I Correct. I
Check condition of each of the signal

system's circuits.
et
Refer to "SIGNAL SYSTEM CHECK" sec-
n
e.
tion.
Tim
er
ot
co
.S
w
w
w
m
fro
ed
oad
nl
ow
D
7-35
SIGNAL SYSTEM ELEC '- *'
YP806020
SIGNAL SYSTEM CHECK

1. If the horn fails to sound.
NO CONTINUITY
l
l. HORN switch
I Replace the left h a n d l e b a r switch.

CONTINUITY
2. Voltage
LoLI
et
horn lead.
n
e.
Tester (+) l e a d - > B r o w n terminal (~.
im
Tester (-) lead->Frame g r o u n d _L
T
i
er
• Check for voltage (12V) on the " B r o w n " OUT OF SPECIFICATION
ot
lead at the horn terminal. co
.S
,•
w
n
w
MEETS I The w i r i n g circuit from the main switch to the e

w
SPECIFICATION horn is faulty. Repair.

I
m
fro
1- "Y
ed
3. Horn
ad

o
horn at the " P i n k " terminal.

nl
Tester (+) lead->Pink (~ terminal.

ow
Tester (-) lead->Frame g r o u n d

_L
D

• Check for voltage on the " P i n k " lead at
NO CONTINUITY
the horn terminal.
@ CONTINUITY
i A d j u s t or replace horn.
I Replace the horn.
7-36
YP806022
S,O.A,S*S*EMIE'Ecl I
2. If t h e b r a k e l i g h t f a i l s t o c o m e o n :
NO CONTINUITY
J l. Bulb and bulb socket
~7 CONTINUITY J Replace the bulb and/or bulb socket.
NO CONTINUITY
J2. Brake switch (Front/Rear)

Refer to "CHECKING SWI
SWITCHES" section.
I 1
et
, ~ CONTINUITY J Replace brake switch.
n
e.
im
3. Voltage
T
er
ot
Tester (+) lead~>Green/Yellow terminal (~
co
Tester (-) lead~>Black terminal (~
.S
w
w
w
m
- -
fro
ed
ad
/ %'
o

nl
• T h e b r a k e l e v e r is p u l l e d in.
ow
• C h e c k f o r v o l t a g e (12V) o f t h e " G r e e n / Y e l -
D
low" lead on the bulb socket connector.
~ MEETS
SPECIFICATION
Wiring circuit from the main switch to the
bulb socket connector is faulty. Repair.
JThis circuit is not faulty. Refer to "SIGNAL SYSTEM WIRING DIA-
GRAM "
7-37
S,ONA, SVSTEM IE'Ecl I
YP806023
3. If the flasher light and/or turn indicator

light fails to blink.
NO CONTINUITY
J l. Bulb and bulb socket
, ~ CONTINUITY J Replace the bulb and/or bulb socket.
NO CONTINUITY
J2. Turn switch

I 1
n et
~ CONTINUITY J Replace the left handlebar switch.
e.
T im
er
3. Voltage
ot
• Connect the pocket tester (DC20V) to the co
flasher relay coupler.
.S
Tester (+) lead->Brown lead (~.

w
Tester (-) lead->Black lead(~)

w
w

m
• Check for voltage (12V) of the "Brown" OUT OF SPECIFICATION

fro
lead at the flasher relay terminal.

ed
ad
,• MEETS The wiring circuit from main switch to flasher

o
nl
SPECIFICATION relay connector is faulty. Repair.

ow
D
G
4. Voltage
flasher relay coupler.
Tester (+) lead->Brown/White lead (~.
Tester (-) lead->Black lead(~)
• Check for voltage (12V) on the "Brown/ OUT OF SPECIFICATION
White" lead at the flasher relay terminal.
~7 MEETS
SPECIFICATION
* J The flasher relay is faulty. Replace.
7-38
S,OOA,SVSTEMIE'Ecl I
5. Voltage
At flasher light (left)

Tester (+) lead->Chocolate lead (~
Tester (-) lead->Black terminal (~)
At flasher light (right)

Tester (+) lead--~Dark green lead (~
Tester (-) lead->Black terminal (~
et
n
e.
• Turn the turn switch to left or right.
im
• Check for voltage (12V) on the " C h o c o -
T
late" lead and " D a r k g r e e n " at the flasher
er
light terminal. 6. Wiring connection
J ~ MEETS ot
• Wiring circuit from t h e t u r n switch to bulb
co
SPECIFICATION socket c o n n e c t o r is fault. Repair.
.S
Refer to "CIRCUIT D I A G R A M " .
w
w
w
4. "OIL" indicator light does not c o m e on. NO CONTINUITY

m

fro
• C h e c k t h e bulb and bulb socket for conti-

nuity.
l
ed
~ CONTINUITY
ad
I Replace bulb and/or bulb socket.

o
nl
2. Oil level switch

ow
• Remove the oil level switch from the oil

tank.
D
• Connect the Pocket Tester (~ x 1) to the

oil level switch.
Tester (+) Lead--~Brown (~ ~,2 .... "-

Tester (-) Lead->Gray (~
• Check the oil level gauge for continuity.

Good
Switch position Bad condition
condition BAD CONDITION
[ ] U p r i g h t position X © × ©
[]Upside down
position © x x ©
C): C o n t i n u i t y X : No c o n t i n u i t y
I Replace oil level switch.
GOODCONDITION
7-39
S,°°A,S,S,EM IE'Ecl I
3. Voltage
• Connect the Pocket Tester (DC20V) to the
g
Tester (+) Lead->Gray lead (~ b

Tester (-) Lead--~Black lead (~
,BI q~l L
• Turn the main switch to " * "
• Check for voltage (12V) on the "Gray" lead
at bulb socket connector.
,• MEETS
SPECIFICATION
(12V)
n et
I This circuit is good.
e.
im
• Checkthe entire signal system for connec-
T
tions.
er
Refer to the "WIRING DIAGRAM" section.
ot
YP806027
co
5. If t h e fuel g a u g e fails t o o p e r a t e .
.S
1. Fuel sender
w
w
Remove the fuel sender from the fuel tank.

w
Disconnect the fuel sender coupler from

the wireharness.
m
Connect the pocket tester (~ xl0) to the

fro
fuel sender coupler lead.

ed
Tester (+) lead->Green terminal (~

ad
Tester (-) lead--~Black terminal (~

o
nl
• Check the fuel sender for specificated re-

ow
sistance.
~Jl Float position Specificated
D
resista nce OUT OF SPECIFICATION

UP (~ 4~10~
DOWN (~ 90~100£~
~7 BOTH MEET
SPECIFICATION
I Replace the fuel sender.
7-40
S,O.A,SSTEMIE'Ecl I
2. Voltage ,/ \

fuel gauge coupler.
Tester (+) lead->Brown terminal (~

Tester (-) lead->Frame ground
II G I Ch II
• Turn the main switch to " O N " .

• Check for voltage (12V) of the " B r o w n "
lead on the fuel sender lead.
,• MEETS
SPECIFICATION l
n et
Checkthe connection of the entire signal sys-
e.
tem.
im
3. Fuel gauge
Refer to " C H E C K I N G OF CONNECTIONS".
• Connect the fuel sender to wireharness.
T
Refer to "CIRCUIT D I A G R A M " .
er
• M o v e the float to " U P " ( ~ or " D O W N " (~.
ot
NOTE:
co
I Before reading the meter, stay put the float
.S
for more than three minutes respectively at

w
" U P " or " D O W N " .

w
w
m
fro
• Turn the main switch to " O N " .

ed
• Check the fuel gauge needle moves " F " DOES NOT MOVE
ad
or " E "
o
nl
Float position Needle moves

ow
Float " U P " (~ "F"

D
Float " DOWN " ( ~ "E" I Replace the fuel gauge.
~7 MOVES
7-41
,UZO O.OKE S STE. IE'Ecl I
A U T O CHOKE S Y S T E M
CIRCUIT DIAGRAM
I[-CI~~
I__....
ON
II~,IIC~--~______I
c I. . . . . . . . I. . . . . . . I
,
' ¢]
,IB Y-- ~'
,B
B ~,a
~#~ / ~ ~ ~ I ,~o ~ ,
L
, H-~I ~ I~1
"~ I T. .~. .'. ,. ~
. . . . .
,%7~T]
• --,® [r -~ ---1 ~ l ~I ' ! I --~i_ -l~' - -
'~ ' '~ ~__~_8 L_~: ®Ira II
-o- L . . . . . . . I. . . . . . . . . . I
-i 1
et
-~- ~ - 6 -
n
-
e.
im
L ___~
T
er
I I
...... ,T _~ i
ot
co
.S
1
w
~)r----- I
w
I
,'- %71 ,'%- I
w
. . . . I
I
L_ _J L__
m
_J
s
fro
I___
ed
, e ',
ad
Lit_ - - I
o
I
nl
L I
ow
r . . . . -->' ~ - - I S
' ®~',D ' fl -~' I ®l
I
0B8
D
I
I
,L_ ~ L I
,t_B_j
(7) Auto choke

(~ C.D.I. magneto
7-42
AUTO O.O.E SYSTEM IE'Ecl I
"y'p .....
TROUBLESHOOTING
IF THE A U T O CHOKE FAILS TO OPERATE.
Procedure
Check:
2. Auto choke unit resistance
3. Wiring connection (entire auto choke system)
NOTE:
1. Battery box cover
et
2. Rear carrier
n
3. Tail cover
e.
4. Right side cover
im
• Use the special tools specified in the troubleshooting section.
T
er
~ 1 P°cket tester: I
ot
YU-03112 co
.S

w
• Disconnectthe CDI magneto couple from

w
w
wire harness.
• Connect the pocket tester (E2 x l ) to the
m
lighting coil coupler

fro
Tester (+) Lead->Yellow/Red (~ terminal

ed
Tester (-) Lead--~Frame earth

oad
nl
w
ow
Y/R
$
D
(~ C.D.I. magneto OUT OF SPECIFICATION

• Checkthe lighting coil for specificated re-
sistance
Lighting coil resistance
0.4~0.6 ~ 20°C (68°F)
I Replace the lighting coil
MEETS
SPECIFICATION
7-43
AUTO O.O.E S STEM IE'Ecl I
YP...
2. Auto choke unit resistance

• Disconnect the auto choke unit coupler
from the wireharness.
• Connect the pocket tester ( ~ x l ) to the auto
choke unit coupler lead.
Tester (+) l e a d . B l a c k terminal (~ OUT OF SPECIFICATION

Tester (-) lead->Black terminal (~
~_~ Auto choke unit resistance:
8~12~ at 20°C (68°F)
et
~ MEETS
n
e.
I Replace the auto choke unit.
SPECIFICATION
Tim
er
POOR CONNECTION
• Check the connection of the entire auto
ot
choke system. co
Refer to "CIRCUIT DIAGRAM" section.
.S
w
I Correct.
w
w
m
fro
ed
o ad
nl
ow
D
7-44
ITRBLI
STARTnNG FAnLURE/HARD STARTnNG ISHTGI ? II
TROUBLESHOOTING
NOTE:
The f o l l o w i n g t r o u b l e s h o o t i n g does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to t r o u b l e s h o o t i n g . Refer to the relative procedure in this manual for
inspection, a d j u s t m e n t and replacement of parts.
STARTING FAILURE/HARD STARTING
FUEL S Y S T E M PROBABLE CAUSE
Fueltank • Empty
• Clogged fuel filter
et
• Deteriorated fuel or fuel containing w a t e r or
n
foreign material
e.
• Clogged fuel tank cap
T im
Fuelcock L • C l o g g e d fuel hose
er
• Clogged fuel cock
ot
• Faulty fuel cock operation
co
• Broken or disconnected fuel cock
.S
Carburetor • Deteriorated fuel, fuel c o n t a i n i n g w a t e r or

w
foreign material
w
w
• Clogged pilot jet

• Clogged pilot air passage
m
• Sucked-in air
fro
• Deformed float
ed
• G r o o v e - w o r n needle valve
• I m p r o p e r l y sealed valve seat
ad
• I m p r o p e r l y adjusted fuel level

o
• I m p r o p e r l y set pilot jet

nl
• Clogged starter jet

ow
D
A u t o choke
/- Starter plunger malfunction
W a x malfunction
Faulty t h e r m i s t e r
Air cleaner • Clogged air filter
8-1
S T A R T I N G FAILURE/HARD S T A R T I N G
ITRBLI
ISHTGI ? II
IGNITION SYSTEM PROBABLE C A U S E
Spark plug • Improper plug gap

• Worn electrodes
• Wire between terminals broken
• Improper heat range
• Faulty spark plug cap
Ignition coil L • Broken or shorted primary/secondary coil

• Faulty spark plug lead
• Broken body
CD I unit system • Faulty CD I unit
et
L • Faulty source coil
n
• Faulty pick-up coil
e.
im
Switches and wiring / • Faulty main switch
T
L • Broken or shorted wiring
er
ot
COMPRESSION SYSTEM
co
PROBABLE C A U S E
.S
Cylinder and cylinder head Loose spark plug

w
L"
Loose cylinder head or cylinder
w
w
Broken cylinder head gasket

Broken cylinder gasket
m
Worn, damaged or seized cylinder

fro
ed
Piston and piston rings Improperly installed piston ring
L Worn, fatigued or broken piston ring

ad
Seized piston ring

o
•
Seized or damaged piston
nl
ow
Crankcase and crankshaft

/" Improperly seated crankcase
D
Improperly sealed crankcase (Damaged oil

seal)
Seized crankshaft
Reed valve • Deformed reed valve stopper

• Improperly seated read valve
• Loose intake manifold
• Broken gasket
• Broken reed valve
8-2
POOR IDLE SPEED PERFORMANCE
ITRBLI ? I
POOR IVIIDIUIVI A N D HIGH SPEED P E R F O R M A N C E ISHTGI
POOR IDLE SPEED P E R F O R M A N C E
P O O R IDLE S P E E D P E R F O R M A N C E PROBABLE CAUSE
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
m •
Flooded carburetor
Auto choke L • Starter plunger malfunction

• Wax malfunction
et
• Faulty thermister
n
e.
Air cleaner • Clogged air cleaner
Tim
Ignition system • Faulty spark plug
er
• Faulty spark plug read
ot
• Faulty
co C.D.I. unit
• Faulty source coil
.S
• Faulty ignition coil
w
w
POOR M I D I U M A N D HIGH SPEED

w
PERFORMANCE
m
POOR MEDIUM AND HIGH SPEED PERFOR- PROBABLE CAUSE

fro
MANCE • Refer to starting failure/Hard starting item

(Fuel system, Ignition system, compression
ed
system)
ad
Carburetor
/ • Clogged or loose main nozzle

o
• Clogged or loose main jet

nl
• Improperly adjust fuel level

ow
• Sucked-in air
D
-- Air cleaner • Clogged air filter
Muffler • Clogged
8-3
POOR M I D I U M A N D HIGH SPEED P E R F O R M A N C E
ITRBLI '?
ISHTGI I
FULTY A U T O M A T I C ( V - B E L T TYPE)
SCOOTER DOES NOT MOVE WHILE ENGINE PROBABLE CAUSE
IS O P E R A T I N G
-- V-belt • W o r n , d a m a g e d or s l i p p e d V - b e l t
-- Cam, slider • Worn, damaged
-- Compression spring • Damaged
-- Transmission • Damaged
C L U T C H O U T FAILURE
n et
-- Clutch w e i g h t spring • Damaged
e.
im
-- Clutch shoe • Pealed l i n i n g
T
er
-- Primary sheave • S e i z e d p r i m a r y s l i d i n g s h e a v e and c o l l a r
ot
co
.S
POOR STANDING START(LOW CLIMBING
ABILITY)
w
PROBABLE CAUSE
w
w
V-belt • W o r n or s l i p p e d V - b e l t
m
fro
Primary sheave • Improper operation

• Damaged
ed
Compression spring
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• Damaged
o
-- Secondary sheave /
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• Improper operation
ow
• W o r n g u i d e pin
D
Clutch shoe • Plealed l i n i n g
P O O R A C C E L E R A T I O N ( P O O R H I G H SPEED) PROBABLE CAUSE
-- V-belt
/ • Worn
• Greasy
Weight
/ • Worn
• Improper operation
m Primary/Secondary seave • Worn
8-4
OVER HEAT I POOR SPEED
ITRBLI ? I
ISHTGI
OVER HEAT
OVER HEAT PROBABLE C A U S E
Ignition system L • I m p r o p e r plug gap

• Improper spark plug heat range
• Faulty C.D.I. unit
-- Fuel system L • I m p r o p e r carburetor setting

• Clogged air filter
-- Compression system • Carbon accumulation of cylinder head
m Muffler, Exhaust pipe • Clogged
n et
Oil pimp / • Faulty oil pump
e.
• Faulty oil quality
im
Brake • Drag
T
er
-- Cooling system • Fan damaged
ot
POOR SPEED
co
.S
POOR SPEED PROBABLE C A U S E
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-- Ignition system L • Faulty spark plug

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• Improper spark plug heat range

m
• Faulty C.D.I. unit

fro
• Faulty source coil

ed
Fuel system L • Clogged fuel tank cap

• Clogged air filter
ad
• Clogged carburetor
o
nl
ow
-- Compression system L • Worn cylinder

• Worn, fatigued or broken piston ring
D
• Broken cylinder head gasket

• Broken cylinder gasket
• Carbon accumulation of cylinder head
Muffler, Exhaust pipe • Clogged
Clutch • Refer to "FAULTY AUTOMATIC"
m Brake • Drag
8-5
ITRBLI
,MPROPER K,CK,NG ISHTGI ? I
I
IMPROPER KICKING
SLIPPING PROBABLE C A U S E
Kick axle assembly • Low tension of kick clip

• Worn kick axle
• Worn or damaged kick gear
• Damaged kick clip
• Kick clip coming off
• Damaged kick clip stopper
Transmission oil • Improper quality (Low viscosity)

L • Deterioration
net
H A R D KICKING PROBABLE C A U S E
e.
im
Kick axle assembly j~ • High tension of kick clip
T
• Seized kick gear
er
ot
- - C y l i n d e r , piston and piston r i n g - - L •Damaged or seized cylinder
co
• Damaged or seized piston
.S
• Damaged or seized piston ring
w
w
m Crankcase and crankshaft • Improperly seated crankcase

w
L • I m p r o p e r l y seated crankshaft
m
• Damaged or seized crankshaft

fro
• Damaged or seized crankshaft bearing

ed
ad
KICK C R A N K N O T R E T U R N I N G PROBABLE C A U S E
o
nl
L Kick axle assembly L • Damaged kick return spring

ow
• Kick return spring coming off

• Kick clip coming off
D
• Damaged kick return spring stopper
8-6
FAULTY BRAKE I S H T G I
ITRBLI ? I
I
FAULTY BRAKE
POOR B R A K I N G EFFECT PROBABLE C A U S E
Drum brake • Worn brake shoe

• Worn or rusty brake drum
• Improperly adjusted brake free play
• Improper brake cam lever position
• Improper brake shoe position
• Fatigue/Damaged return spring
• Oily or greasy brake shoe
• Oily or greasy brake drum
• Broken brake cable
et
m Disc b r a k e • W o r n b r a k e pad
n
(Front) • W o r n b r a k e disc
e.
• A i r in brake f l u i d
im
• Leaking brake fluid
T
• F a u l t y m a s t e r c y l i n d e r kit
er
• F a u l t y c a l i p e r seal kit
ot
• Loose union bolt
co
• Broken brake hose
.S
• O i l y o r g r e a s y b r a k e pad
w
• O i l y o r g r e a s y b r a k e disc
w
w
MALFUNCTION PROBABLE C A U S E
m
fro
• Bent, d e f o r m e d o r d a m a g e d i n n e r t u b e
• B e n t or d e f o r m e d o u t e r t u b e
ed
• Damaged fork spring

ad
• W o r n o r d a m a g e d slide m e t a l
• I m p r o p e r oil v i s c o s i t y
o
nl
• I m p r o p e r oil level
ow
D
8-7
ITRBLI
INSTABLE HANDLING ISHTGI ? II
INSTABLE H A N D L I N G
INSTABLE HANDLING PROBABLE CAUSE
Handlebar • Improperly installed or bent
-- Steering • Improperly installed steering column

L (Improperly tightened ringnut)
• Bent steering column
• Damaged ball bearing or bearing race
Front forks • Broken spring

L • B o n d e d front forks
et
Tires • Uneven tire pressures on both sides
n
L •Incorrect tire pressure
e.
• Unevenly worn tires
T im
~Wheels • Damaged bearing
er
L • Bent or loose wheel axle
ot
• Excessive wheel run-out
co
.S
-- Frame • Twisted
w
L • D a m a g e d head pipe
w
• Improperly installed bearing race

w
m
m Engine bracket • Bent or damaged

fro
Rear shock absorber / • Fatigued spring

ed
L • O i l leakage
ad
o
nl
ow
D
8-8
FAULTY SIGNAL AND LIGHTING SYSTEM
ITRBLI
ISHTGI ? I
FAULTY SIGNAL AND LIGHTING
SYSTEM
HEADLIGHT DARK PROBABLE C A U S E
I • I m p r o p e r bulb
• Too m a n y electric accessories
• Hard charging (Broken charging coil)
• Incorrect c o n n e c t i o n
• Improperly grounded
• Poor contacts (main or light switch)
• Bulb life expires
BULB BURNT OUT PROBABLE C A U S E
et
I
n
• I m p r o p e r bulb
e.
L_ •Improperly grounded
im
• Faulty main and/or light switch
T
• Bulb life expires
er
ot
- - FLASHER DOES NOT BLINK PROBABLE C A U S E
co
I
.S
• Improperly grounded
w
• Discharged battery
w
• Faulty flasher switch

w
• Faulty flasher relay

m
• Broken w i r e h a r n e s s
fro
• Loosely connected c o u p l e r
• Bulb burnt out
ed
• Faulty fuse
ad
PROBABLE C A U S E
o
- - FLASHER KEEPS ON
nl
I
ow
• Faulty flasher relay

L • I n s u f f i c i e n t b a t t e r y c a p a c i t y ( n e a r l y dis-
D
charged)
• Bulb burnt out
8-9
FAULTY SIGNAL AND LIGHTING SYSTEM
ITRBLI
ISHTGI ? I
FLASHER BLINKS SLOWER PROBABLE C A U S E
I • Faulty flasher relay

• Insufficient battery capacity
(nearly discharged)
• Improper bulb
• Faulty main and/or flasher switch
FLASHER BLINKS QUICKER PROBABLE C A U S E
I • Improper bulb
L • F a u l t y flasher relay
et
HORN DOES NOT S O U N D PROBABLE C A U S E
n
I
e.
• Faulty battery
im
• Faulty fuse
T
• Faulty main and/or horn switch
er
• I m p r o p e r l y adjusted horn
ot
• Faulty horn
co
• Broken w i r e h a r n e s s
.S
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D
OYAMAHA
Y A M A H A MOTOR TAIWAN CO., LTD
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Yamaha Motor Canada Ltd.

480 Gordon Baker Road
Toronto, ON M2H 3B4

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2002 - 2005

Model : YW50P, YW50R, YW50S, YW50T

Y a m a h a M o t o r C o m p a n y , Ltd. is c o n t i n u a l l y s t r i v i n g to i m p r o v e all of its m o d e l s . M o d i f i c a t i o n s

IMPORTANT MANUAL INFORMATION

ZL The Safety Alert Symbol means ATTENTION! BECOME ALERT! Y O U R

Failure to f o l I o w W A R N I N G i n s t r u c t i o n s could result in severe i n j u r y or death

CAUTION: A C A U T I O N i n d i c a t e s special p r e c a u t i o n s t h a t m u s t be taken to a v o i d d a m -

NOTE: A NOTE p r o v i d e s key i n f o r m a t i o n to make p r o c e d u r e s easier or clearer.

CYLINDEB HEAD" CYF~:N::R: P ~ ~

Begore removing tha piston pin celt,, cover the

CYUNDER HEAD INSPECTION

Use a rounded ~crapper

Q'ty Rurllark~ • Cylinder head war~3age

@ Wear limit, clearance

Symbols @to @ in the exploded diagrams in-

® i i 1 (~) Molybdenum disulfide oil

Symbols@ to @ in the exploded diagrams

PERIODIC INSPECTION AND

SCOOTER INDENTIFICATION ........................................................................................................... 1-1

GENERAL SPECIFICATION ............................................................................................................... 2-1

TIGHTENING TORQUES ............................................................................................................... 2-6

MAINTENANCE SPECIFICATION ..................................................................................................... 2-7

CHASSIS ........................................................................................................................................ 2-7

TIGHTENING TORQUES ............................................................................................................... 2-8

MAINTENANCE SPECIFICATION ..................................................................................................... 2-9

INTRODUCTION ................................................................................................................................ 3-1

BRAKE SHOE INSPECTION ........................................................................................................ 3-16

BRAKE FLUID LEVEL INSPECTION ............................................................................................ 3-16

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ........................................................................ 3-17

STEERING ADJUSTMENT .......................................................................................................... 3-18

TIRE INSPECTION ........................................................................................................................3-19

WHEEL INSPECTION ................................................................................................................... 3-22

FRONT FORK INSPECTION ......................................................................................................... 3-22

SEAT LOCK CABLE ADJUSTMENT ........................................................................................... 3-22

CABLE CHECKING AND LUBRICATING ..................................................................................... 3-23

LEVERS LUBRICATING ............................................................................................................... 3-23

CENTERSTAND LUBRICATING .................................................................................................. 3-23

CLUTCH INSPECTION ................................................................................................................. 4-17

V-BELT INSPECTION ................................................................................................................... 4-18

PRIMARY SHEAVE INSPECTION ................................................................................................ 4-19

SECONDARY SHEAVE INSTALLATION ..................................................................................... 4-21

PRIMARY SHEAVE ...................................................................................................................... 4-22

STARTER CLUTCH AND STARTER MOTOR .............................................................................. 4-24

STARTER CLUTCH AND GEARS INSPECTION ......................................................................... 4-26

C.D.I. MAGNET ................................................................................................................................ 4-27

C.D.I. MAGNETO ......................................................................................................................... 4-27

C.D.I. MAGNETO REMOVAL ....................................................................................................... 4-28

C.D.I. MAGNETO INSTALLATION .............................................................................................. 4-28

CARBURETION .................................................................................................................................. 5-1

CARBURETOR ................................................................................................................................ 5-1

BRAKE CALIPER DISASSEMBLY ................................................................................................ 6-19

CALIPER INSPECTION ................................................................................................................. 6 - 1 9

BRAKE CALIPER ASSEMBLY ...................................................................................................... 6-20

REAR W H E E L A N D REAR BRAKE .................................................................................................. 6-21

REAR WHEEL ............................................................................................................................... 6-21

REAR BRAKE INSPECTION ......................................................................................................... 6-23

REAR BRAKE INSTALLATION .................................................................................................... 6-24

HANDLEBAR .................................................................................................................................... 6-25

HANDLEBAR ................................................................................................................................ 6-25

HAN DLE BAR INSTALLATIO N ..................................................................................................... 6-27

ELECTRICAL COMPONENTS ............................................................................................................ 7-1

CIRCUIT DIAGRAM ...................................................................................................................... 7-18

TROUBLESHOOTING .................................................................................................................. 7-19