Service Manual BWS NG 1998

CW50RS '98
5FX-AE1
SERVICE
MANUAL
CW50RS
SERVICE MANUAL
© 1998 by MBK INDUSTRIE
1st Edition, July 1998
All rights reserved. Any
reprinting or unauthorized use
without the written
permission of MBK INDUSTRIE
is expressly prohibited.
NOTICE
This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers
and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and
MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in
scooter repair technology. Without such knowledge, attempted repairs or service to this model may
render it unfit to use and/or unsafe.
MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and
significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and
MBK dealers and will, where applicable, appear in future editions of this manual.
DOCUMENTATION TECHNIQUE
MBK INDUSTRIE
PARTICULARY IMPORTANT INFORMATION

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

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

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

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

HOW TO USE THIS MANUAL
CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See «illustrated symbols).
1st title 1 This is a chapter with its symbol on the upper right of each page.
2nd title 2 This title appears on the upper of each page on the left of the chapter symbol.
(For the chapter «Periodic inspection and adjustment» the 3rd title appears.)
3rd title 3 This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particulary important procedure 4 is placed between a line of asterisks " * " with each step
preceded by " • ".
IMPORTANT FEATURES
• Data and a special tools are framed in a box preceded by a relevant symbol 5.
• An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data for an
alignement mark 7, the others being indicated by an alphabetical letter in a box 8.
• A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams are before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
Q W ILLUSTRATED SYMBOLS
GEN (REFER TO THE ILLUSTRATION)
SPEC
INFO
Illustrated symbols Q to W are designed as
E R thumb tabs to indicate the chapter’s number and
content.
INSP ENG
ADJ Q General information
W Specifications
T Y E Periodic inspection and adjustment
R Engine
CARB CHAS T Carburetion
Y Chassis
U I U Electrical
I Troubleshooting
TRBL
ELEC
SHTG
O P
Illustrated symbols O to e are used to identify
the specifications appearing in the text.
O Filling fluid
{ } P Lubricant
{ Special tool
T.
R
} Tightening
q Wear limit, clearance
w Engine speed
q w
e Ω, V, A
e Illustrated symbols r to [ in the exploded

diagram indicate grade of lubricant and location
of lubrication point.
r t y r Apply engine oil

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

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

ALL REPLACEMENT PARTS ................................................................. 1-2
GASKETS, OIL SEALS, AND O-RINGS .................................................. 1-2
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-2
BEARINGS AND OIL SEALS ................................................................... 1-2
CIRCLIPS ................................................................................................. 1-3
SPECIAL TOOLS ........................................................................................... 1-3

FOR TUNE UP ......................................................................................... 1-3
FOR ENGINE SERVICE .......................................................................... 1-4
FOR CHASSIS SERVICE ........................................................................ 1-5
FOR ELECTRICAL COMPONENTS ........................................................ 1-5
GEN
SCOOTER IDENTIFICATION INFO
GENERAL
햲
INFORMATION
SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number Q is stamped
into the frame.
NOTE:
The vehicle identification number is used to
identify your scooter and may be used to register
your scooter with the licensing authority in your
state.
ENGINE SERIAL NUMBER

The engine serial number Q is stamped into the
crankcase.
NOTE:
Designs and specifications are subject to change
without notice.
햲
1-1
GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1.Use only genuine parts for all replacements.
Use oil and/or grease recommended by MBK/
YAMAHA for assembly and adjustment. Other
brands may be similar in function and
appearance, but inferior in quality.
GASKETS, OIL SEALS, AND O-RINGS

1.All gaskets, seals and O-rings should be
replaced when an engine is overhauled. All
gaskets surfaces, oil seal lips and O-rings
must be cleaned.
2.Properly oil all mating parts and bearing during
reassembly. Apply grease to the oil seal lips.
LOCK WASHERS/PLATES AND COTTER

PINS
1.All lock washers/plates Q and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or nut
flat(s) after the bolt or nut has been properly
tightened.
BEARINGS AND OIL SEALS

1.Install the bearing(s) Q and oil seal(s) W with
their manufacturer’s marks or numbers facing
outward. (In other words, the stamped letters
must be on the side exposed to view.) When
installing oil seal(s), apply a light coating of
lightweight lithium base grease to the seal
lip(s). Oil the bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
1-2
GEN
IMPORTANT INFORMATION/SPECIAL TOOLS INFO
CIRCLIPS
1.All circlips should be inspected carefully before
reassembly. Always replace piston pin clips
once they have been removed. Replace bent
circlips. When installing a circlip Q make sure
that the sharp edge W is positioned opposite
to the thrust E it receives. See the sectional
view.
R Shaft
SPECIAL TOOLS
The proper special tools are necessary for
complete and accurate tune-up and assembly.
Using the correct special tool will help prevent
damage caused by the use of improper tools or
improvised techniques.
Inductive tachometer
90890-03113
FOR TUNE UP
Ignition checker
90890-06754
1-3
GEN
SPECIAL TOOLS INFO
Flywheel magneto puller
90890-01189
FOR ENGINE SERVICE
Crankcase separating tool Flywheel holding tool

90890-01135 90890-01235
Crankshaft installing tool set Clutch serving nut wrench

90890-01274 Q 90890-01348
90890-01275 W
90890-01277 E
90890-01411 R
Sheave holder Clutch spring holder

90890-01701 90890-01337 Q
90890-01016 W
1-4
GEN
SPECIAL TOOLS INFO
Steering Head wrench
9079Q-02218
FOR CHASSIS SERVICE
T-HANDLE Damper rod holder

90890-01326 90890-01294
Oil seal guide Oil seal guide adapter

90890-01367 90890-01400
30
Pocket Tester
90890-03112
FOR ELECTRICAL
COMPONENT
1-5
SPEC 2
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
MAINTENANCE SPECIFICATIONS .............................................................. 2-4

ENGINE ................................................................................................... 2-4
CHASSIS ................................................................................................. 2-7
ELECTRICAL ........................................................................................... 2-8
CABLE ROUTING ........................................................................................ 2-10

SPEC
GENERAL SPECIFICATIONS
SPECIFICATIONS
Model CW50RS
Dimensions:
Overall length 1.746 mm (0.07 in)
Overall width 675 mm (26.5 in)
Overall height 1.120 mm (0.04in)
Seat height 803 mm (31.61 in)
Wheelbase 1.206 mm (0.05 in)
Minimum ground clearance 153 mm (6.02 in)
Basic weight:
With oil and full fuel tank 83 kg (183 lbs)
Minimum turning radius : 1.800 mm (0.07 in)
Engine:
Type Air-cooled 2-stroke, gasoline torque induction.
Cylinder arrangement Single cylinder, Vertical
Displacement 49,2 cm3
Bore x stroke 40 x 39.2 mm (1.57 x 1.54 in)
Compression ratio 7.22 : 1
Starting system Electric and kick starter
Lubrication system: Separate lubrication (Yamaha Autolube )
Oil type or grade:
Engine oil: SEMI-SYNTHETIC, in accordance with
API TC TSC 3 STANDARD.
Transmission oil SAE 10W30 type SE motor oil
Oil capacity:
Transmission oil:
Periodic oil change 0.11 L (0.10 Imp qt, 0.12 US qt)
Total amount 0.13 L (0.11 Imp qt, 0.13 US qt)
Air filter: Wet type element
Fuel:
Type Regular unleaded gasoline with a reserch octane
number of 91 or higher.
Tank capacity 6.5 L (1.42 Imp gal, 1.71 US gal)
2-1
SPEC
Model CW50RS
Carburetor:
Type/Manufacturer 5FX / TEIKEI
PHBN12 HS / DELL'ORTO
Spark plug:
Type/Manufacturer BR8HS/NGK
Gap 0.5 ~ 0.7 mm (0.19 ~ 0.27 in)
Clutch type: Dry, centrifugal automatic
Transmission:
Primary reduction system Helical gear
Primary reduction ratio 52/13 (4.000)
Secondary reduction system Spur gear
Secondary reduction ratio 42/13 (3.323)
Transmission V-belt
Operation Automatic
Chassis:
Frame type Steel tube underbone
Caster angle 27°
Trail 90 mm (3.54 in)
Tire:
Type Front Tubeless
Rear Tubeless
Size Front 120/90-10
Rear 130/90-10
Manufacturer Front MICHELIN (REGGAE)
Rear MICHELIN (REGGAE)
Tire pressure (cold tire):

Up to 90 kg Front 150 kPa (1.50 kg/cm2, 21.3 psi)
Rear 150 kPa (1.50 kg/cm2, 21.3 psi)
90 kg ~ maximum load Front 150 kPa (1.50 kg/cm2, 21.3 psi)
Rear 160 kPa (1.60 kg/cm2, 22.7 psi)
Brake:
Front brake type Disc brake
Operation Right hand operation
Rear brake type Drum brake
Operation Left hand operation
Suspension:
Front Telescopic fork
Rear Unit swing
Shock absorber:
Front Coil spring/Oil damper
Rear Coil spring/Oil damper
Wheel travel:
Front wheel travel 80 mm (3.14 in)
Rear wheel travel 60 mm (2.36 in)
2-2
SPEC
Model CW50RS
Electrical:
Ignition system CDI
Charging system Flywheel magneto
Battery type/model GM4-3B, YB4L-B, FB4L-B
Battery capacity 12V 4AH
Headlight type Bulb
Bulb wattage / quantity:
Headlight 12V 35W/35W x 1
Auxiliary light 12V 5W x 1
Taillight/brake light 12V 5W/21W x 1
Flasher light Front 12V 10W x 2
Rear 12V 10W x 2
Meter light 12V 1.2W x 2
Warning lights wattage / quantity:
“OIL” 12V 1.2W x 1
“HIGH BEAM” 12V 1.2W x 1
“TURN” 12V 1.2W x 1
2-3
MAINTENANCE SPECIFICATIONS
SPEC
ENGINE
Model CW50RS
Cylinder head:
Warp limit 0,02 mm (0.0008 in)
* Lines indicate straight edge measurements.
Cylinder:
Bore size 39.993 ~ 40.012 mm (1.576 ~ 1.575 in)
Taper limit 0.05 mm (0,0002 in)
Piston:
Piston size 39.952 ~ 39.972 mm (1.576 ~ 1.574 in)
Measuring point * 5 mm (0.19 in)
Piston clearance 0.034 ~ 0.047 mm (0.001 ~ 0.002 in)

<Limit> <0.1 mm (0.004 in)>
Oversize 1st 40.25 (1.58 in)
Oversize 2nd 40.50 (1.59 in)
Piston pin bore size 10.004 ~ 10.019 mm (0.394 ~ 0.395 in)
Piston pin:
Outside diameter 9.996 ~ 10.000 mm (0.393 ~ 0.394 in)
Piston ring:
Sectional sketch (BxT)/Type:
Top ring 1.2 ∼ 1.8 mm (0.05 ~ 0.07 in)
2nd ring 1.2 ∼ 1.8 mm (0.05 ~ 0.07 in)
End gap (installed):
Top ring 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
2nd ring 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
Side clearance (installed):
Top ring 0.03 ~ 0.05 mm (0.001 ~ 0.002 in)
2nd ring 0.03 ~ 0.05 mm (0.001 ~ 0.002 in)
2-4
SPEC
Model CW50RS
Crankshaft:
Crank width “A” 37.90 ~ 37.95 mm (1.492 ~ 1.494 in)

Runout limit “C” 0.03 mm (0.001 in)
Connecting rod big end 0.2 ~ 0.5 mm (0.007 ~ 0.019 in)
side clearance “D”
Automatic centrifugal clutch:
Shoe thickness 2.0 mm (0.08 in)
<Wear limit> <1.0 mm (0.039 in)>
Clutch shoe spring free length 29.9 mm (1.177 in)
Clutch-in revolution 3.250 ~ 3.750 r.p.m.
Clutch-stall revolution 6.100 ~ 6.900 r.p.m.
V-belt:
Width 16.5 mm (0.64 in)
Transmission:
Main axle runout limit 0.08 mm (0.003 in)
Drive axle runout limit 0.08 mm (0.003 in)
Kick starter:
Type Ratchet type
Kick clip tension 0.15 ~ 0.25 kg (0.33 ~ 0.55 lbs)
Reed valve:
Valve stopper height 4.0 ~ 4.4 mm (0.15 ~ 0.17 in)
Reed valve clearance 0.2 mm (0.007 in)
Lubrication system: Autolube pump
Stroke 2.62 mm (0.103 in)
Bore 0.5 mm (0.019 in)
2-5
SPEC
Carburetor: DELL’ORTO TEIKEI
I.D. mark PHBN12 HS 5FX
Main jet (M.J.) #90 #88
Main air jet (M.A.J.) 1.5 2.0
Jet needle (J.N.) 211 GA 3/5 3S12-3/5
Needle jet (N.J.) 2.110 GA 2,085
Cutaway (C.A.) 4.0 3.0
Pilot jet (P.J.) #36 #50
Bypass (B.P.1) 0.80 0.80
Pilot air screw (A.S.) 1+3/8 ±1/8 out 1+1/2 ±1/4 out
Valve seat size (V.S.) 1 1.2
Starter jet (G.S.1) #40 #46
Engine idle speed 2000 ± 200 rpm 2000 ± 200 rpm
2-6
SPEC
CHASSIS
Model CW50RS
Steering system:
Steering bearing type Ball bearing
No/Size of steel balls:
Upper 15 pcs (4.77 mm)
Lower 15 pcs (4.77 mm)
Front suspension:
Front fork travel 80 mm (3.14 in)
Spring rate (K1) 5.7 Nmm (0.57 kg/mm, 31.92 lb/in)
Stroke (K1) 0 ~ 80 mm (0 ~ 3.14 in)
Optional spring No
Rear suspension:
Shock absorber travel 70 mm (2.75 in)
Spring free length 165 mm (6.49 in)
Spring fitting length 151.5 mm (5.96 in)
Spring rate (K1) 26 Nmm (2.6 kg/mm, 145.61 lb/in)
Stroke (K1) 0 ~ 40 mm (0 ~ 1.57 in)
Spring rate (K2) 36 Nmm (3.6 kg/mm, 201.62 lb/in)
Stroke (K2) 40 ~ 70 mm (1.57 ~ 2.75 in)
Optional spring No
Wheels:
Front wheel type Cast wheel
Rear wheel type Cast wheel
Front wheel size/Material MT 3.00 x10 / Aluminium
Rear wheel size/Material MT 3.50 x10 / Aluminium
Rim runout limit:
Radial 1.0 mm (0.039 in)
Lateral 1.0 mm (0.039 in)
Front disc brake:
Type Single disc
Diameter and thickness 190 x 3.5 mm (7.48 x 3.5 in)
Pad thickness 3.75 mm (0.15 in)
<Wear limit> <0.5 mm (0.0019 in)>
Master cylinder inside diameter 11 mm (0.43 in)
Caliper cylinder inside diameter 30 mm (1.18 in)
Brake fluid type DOT# 3 or DOT# 4
Rear drum brake:
Type Leading, trailing
Drum inside diameter 110 mm (4.33 in)
<Wear limit> <110.5 mm (4.35 in)>
Lining thickness 4.0 mm (0.15 in)
Spring free length 54 mm (2.12 in)
Front brake lever freeplay: 10 ~ 20 mm (0.39 ~ 0.78 in)
Rear brake lever freeplay: 10 ~ 20 mm (0.39 ~ 0.78 in)
2-7
SPEC
ELECTRICAL
Model CW50RS
Voltage: 12 V
Ignition system:
Ignition timing (B.T.D.C.) 14° at 5.000 r/min
CDI:
Pickup coil resistance (color) 400 ~ 600 Ω at 20°C (68°F) (White/Red-Black)
Source coil resistance (color) 640 ~ 960 Ω at 20°C (68°F) (Black/Red-Black)
Ignition coil:
Minimum spark length 6 mm (0.23 in)
Primary coil resistance 0.32 ~ 0.48 Ω at 20°C (68°F)
Secondary coil resistance 5.68 ~ 8.52 Ωk at 20°C (68°F)
Spark plug cap:
Resistance 5 kΩ at 20°C (68°F)
CDI Magneto:
Lighting coil resistance 0.32 ~ 0.48 Ω at 20°C (68°F)(Yellow/Red-Black)
Charging coil resistance 0.48 ~ 0.72 Ω at 20°C (68°F)(White-Black)
Voltage regulator/Rectifier:
Type Semi-conductor, short-circuit type
No load regulated voltage 13 ~ 14 V
Capacity 8A
2-8
SPEC
Model CW50RS
Battery:
Capacity 12V, 4 Ah
Specific gravity 1.280
Starter motor:
Output 0.14 kW
Armature coil resistance 0.06 ~ 0 08 Ω a 20°C (68°F)
Brush length 3.9 mm (0.15 in)
Brush spring pressure 563 ~ 844 gr (19.85 ~ 29.76 oz)
Commutator diameter 15.8 mm (0.62 in)
Mica undercut 1.15 mm (0.045 in)
Starter relay:
Amperage rating 20 A
Coil resistance 54 ~ 66 Ω at 20°C (68°F)
Horn:
Type/Quantity Plain type/1 pc.
Model/Manufacturer TR9/TRANSVAL
Maximum amperage 2.5 A
Flasher relay:
Type Condenser type
Self cancelling device No
Flasher frequency 65 - 95 cycle/min
Wattage 2x(10+3)W
Circuit breaker:
Type Fuse
Amperage for individual circuit x Quantity:
Main 7Ax1
Fuel sender unit:
Resistance (full) 7.4 ~ 9.0 Ω at 20°C (68°F)
(empty) 82 ~ 98 Ω at 20°C (68°F)
2-9
SPEC
CABLE ROUTING
CABLE ROUTING A Pass the wire harness under the frame.
Q Rectifier/regulator O Ignition coil B Attach on the mole fender (only on the left Side).
W Battery P Oil level gauge C Attach the wire harness with a plastic band.
E Fuse holder { Mudguard D Attach all the wire.
R Oil tank } Starter motor E Cut the end of each plastic clip only after the
T Fuel level sender q CDI magneto tightening.
Y Brake hose guide w Brake wire F Attach all the wires and the mud guard.
U Head light e Under cover G Pass the wire under the frame dropout.
I Speedometer cable H Clamp the throttle cables and the starter cable all
together.
I The oil level switch connector must be slightly
inclined (0° to 30°).
I
A 6
6
6
6
6 6
2221 2221 6

6
6 6 6 6 6
6 6
2221
6
2221 6 6
2221
6
2221 6
6 6
6 6 22216 3
2221 6
2221
6 6 6 3 3
3 6

3
1 2 5 1 2 5
3
1 1 1 6 3
5 1
2 1
2 1 1
5 2 1 3 3 3 6 6
1 1
2 1 1 1
0 5 2 3 3 1 6
2 3 1
0 0 2 2 3
8 3 1
5 2 2 6
0 0 5
2
2 1
4 2 6
5 8 3 2 1
5 1
0 0 4
5 5 4 2
0 0 2
5 6
5 5 5
3 5 5
4 8 6
6 5 5 5 5 5
3 5 5
5 5
4 5
3
8 6
4 6
6 9
6 6
6

6
6
B
+5
10 0

E

5
5
5
5
5
5
6
6 0

0
6 2221
2
1
6
5 2221
2
6 1
5
0 2221
6
1
6 5
2221
02 1
6
6 5
0 6
2221
6
6 6 6
2
0 6
5
1
2221 6
6
F
0
C
6 2 6
1 2221
0
6 2
0 6
5
6
1
0
2 6
2221 6
0 2
1 6
0 2221
2
5
6

1
2 6
1
1 2
6
2221
0 1
6
6 1 2
0 1
2221 5
D
6
2
6
2
0
2 1 2 1
1
2
2
2221 6 1
0
2 2
1
5
6 6 2
0
2
1
5 6
8
2221 2
0
1 1
6 8
6
6 8
3
0 2
3 3
1
6
5 4
2221
1 3
3
4
1
0 2
6 5 2 6
3 4
1
5 6 3
6 4 6 3
8 1
2
3
3 4
5 2
3 3 3
1 6
6 3
3 8 3
3
5 2 8 4
3 1
1 6 2
4
5 1 3
6 6
4
5 1 1 2
2 1 3
1 2
5 4
1 1 2 4
6 2
5 1 6
3
6 4
6
5
5 5 5 5 5 5 3
5
3
3
5
5
5
5
5 5 5 5
5
5
5
4 3 6
2
3
1
H
30–10
2-10
SPEC
CABLE ROUTING
Q Grip assembly (right) } Brake hose [ Upper race ball
W Handle switch (right) q Handle cover ] Steering balls
E Front stop switch w Speedometer assembly A Lower race ball
R Front master cylinder e Handle cover S Frame
T Plain washer r Speedometer cable D Front fork assembly
Y Union bolt t Wire harness
U Flasher relay y Plastic clip
I Handle switch (left) u Nut flange
O Grip assembly (left) i Bolt flange
P Rear brake lever o Fitting nut
{ Starter cable p Washer
1 MINI
2 8
5–1
A
3 4
1 2 3 4 56 7 8 9
0
6
{
6
w
B 6
q
C
D }
t e
o y
E
p
[ r
]
A
S
A RIGHT
] FRONT
D u
F LEFT
2-11
CABLE ROUTING
SPEC
A Install the handlebar switch before the master cylinder.
B Install all connectors under the handlebar and the speedometer assembly.
C Attach the wire harness holder on the frame dropout.
D Do not clamp the speedometer cable and the brake wire.
E Apply grease.
F Install in the correct position.
1 MINI
2 8
5–1
A
3 4
1 2 3 4 56 7 8 9
0
6
{
6
w
B 6
q
C
D }
t e
o y
E
p
[ r
]
A
S
A RIGHT
] FRONT
D u
F LEFT
2-12
SPEC
CABLE ROUTING
Q Rear brake cable I Front brake hose A Install the cable end stop on the brake lever
W Rear stop switch O Starter cable holder.
E Handlebar switch (left) P Throttle cable B Adjust the grip mark with the seal surface.
R Handlebar switch (right) { Rear brake cable C Install the boot after the adjustment.
T Throttle cable } Wire harnness D Apply grease on the throttle cable end and on
Y Grip 5FX q Speedometer cable the cable holder.
U Master cylinder E Install the front brake wire as shown.

B

FRONT
C
1.5 ~ 3 mm
D

5¡
–
9 0¡
E

6
5 mm
10¡

2-13
CHK
ADJ 3
CHK
ADJ
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION ............................................................................................ 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............................ 3-1
COVERS ........................................................................................................ 3-3

REMOVAL ................................................................................................ 3-3
INSTALLATION ........................................................................................ 3-6
HANDLEBAR COVERS ................................................................................. 3-7

REMOVAL ................................................................................................ 3-7
INSTALLATION ........................................................................................ 3-7
ENGINE ......................................................................................................... 3-9

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

FRONT BRAKE LEVER FREE PLAY ADJUSTMENT ........................... 3-16
REAR BRAKE LEVER FREE PLAY ADJUSTMENT ............................. 3-16
BRAKE PADS INSPECTION ................................................................. 3-16
BRAKE SHOE INSPECTION ................................................................. 3-17
BRAKE FLUID LEVEL INSPECTION .................................................... 3-17
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)- ................................ 3-18
STEERING HEAD ADJUSTMENT ......................................................... 3-18
TIRE INSPECTION ................................................................................ 3-19
WHEEL INSPECTION ........................................................................... 3-20
CABLE INSPECTION AND LUBRICATION ........................................... 3-20
LEVER LUBRICATION .......................................................................... 3-21
CENTERSTAND LUBRICATION ........................................................... 3-21
FRONT FORK INSPECTION ................................................................. 3-21
REAR SHOCK ABSORBER .................................................................. 3-22
ELECTRICAL ............................................................................................... 3-23

BATTERY INSPECTION ........................................................................ 3-23
FUSE INSPECTION ............................................................................... 3-24
HEADLIGHT BEAM ADJUSTMENT ...................................................... 3-25
HEADLIGHT LENS REPLACEMENT .................................................... 3-26
HEADLIGHT BULB REPLACEMENT .................................................... 3-26
INTRODUCTION/PERIODIC MAINTENANCE/ INSP
LUBRICATION INTERVALS ADJ
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as new vehicles that are being prepared for
sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Km(miles)
EVERY
BREAK-IN
1,000 3,000(2,000) 6,000(4,000)
ITEM REMARKS or or
(600) 6 Months 12 Months
Spark plug* Check condition. Clean or replace if necessary.
Air filter Clean. Replace if necessary.
Carburetor* Check idle speed/starter operation. Adjust if neces-

sary.
Fuel line* Check fuel hose and vacuum hose for cracks or
damage. Replace if necessary.
Transmission oil* Check oil leakage. Correct if necessary. RE-

Replace every 12,000 (8,000) or 24 months (warm PLACE
engine before draining).
Autolube pump * Check operation.
Front brake* See NOTE. Correct if necessary. Air bleeding.

Check operation/fluid leakage. Correct if necessary.
Rear brake* Check operation. Adjust if necessary.
Wheels* Check balance/runout. Repair if necessary.
Wheel bearings* Check bearing assembly for looseness /damage.

Replace if damaged.
Steering bearings* Check bearing assembly for looseness. Correct if

necessary. Moderately repack every 12,000 (8,000)
or 24 months.**
Rear shock absorber* Check operation/oil leakage. Repair if necessary.
V-belt* Check damage and wear. Replace if necessary.
Fittings/Fasteners* Check all chassis fittings and fasteners.
Centerstand* Correct if necessary. Check operation. Repair if

necessary.
Battery * Check specific gravity. Check breather hose for

proper operation. Correct if necessary.
*: It is recommended that these items be serviced by a MBK or a Yamaha dealer.

**: Medium weight wheel bearing grease.
3-1
INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
NOTE:
Brake fluid replacement:
1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3.Replace the brake hoses every four years, or when cracked or damaged.
3-2
INSP
COVERS ADJ
COVERS
햲
REMOVAL
1. Remove:
• Seat Q
353001
2. Remove:
햲 • Rear cover Q
햲 3. Remove:
• Side cover (left and right) Q
4. Remove:
햲 • Battery cover Q
CAUTION:
When removing the cover, be careful not to
damage the mounting clips.
5. Remove:
• Seat cover Q
햲
3-3
INSP
COVERS ADJ
6. Disconnect:
햲 • Battery terminals Q
햳
7. Remove:
• Battery W
367001
8. Remove:
• Footrest board Q
햲 9. Remove:
• Front cover Q
CAUTION:
10. Remove:
• Headlight socket Q
Turn the headlight socket clockwise, then
remove it.
햲
11 . Remove:
• Main switch ring Q
Turn the ring clockwise to remove it.
3-4
INSP
COVERS ADJ
12. Remove:
• Inner panel Q
13. Remove:
• Lower cover Q
14. Remove:
• Front wheel Q
햲 Refer to the section “ FRONT WHEEL - RE-
MOVAL” in Chapter 6.
15. Disconnect:
• Flasher light couplers (left and right) Q
16. Remove:
• Front fender Q
햲
3-5
INSP
COVERS ADJ
INSTALLATION:
Reverse the “REMOVAL” procedure. Note the
following points.
NOTE:
Correct routing of cables and wires is essential
for a safe operation of this scooter. Refer to the
section “CABLE ROUTING” in Chapter 2.
NOTE:
Be careful not to pinch any wires with the covers.
NOTE:
When installing the covers, be careful not to
3-6
INSP
HANDLEBAR COVERS ADJ
햲 HANDLEBAR COVERS
REMOVAL
1. Remove:
• Handlebar cover (front) Q
CAUTION:
2. Remove:
햲
• Auxiliary light socket Q
3. Remove:
햲 • Rear handlebar cover screws
• Rear handlebar cover Q
4. Remove:
• Meter coupler Q
햳
• Speedometer cable W
햲
INSTALLATION
Reverse the “REMOVAL” procedure. Note the
following points:
1. Connect:
• Speedometer cable
• Meter connector
3-7
INSP
HANDLEBAR COVERS ADJ
2. Install:
• Rear handlebar cover
• Rear handlebar cover screws
• Auxiliary light socket
3. Install:
• Front brake hose
(into the slot in the front fender)
4. Install:
• Front handlebar cover
5. Install:
• Front handlebar cover screws
NOTE:
When installing the handlebar covers, be careful
not to damage any cables. Refer to the section
“CABLE ROUTING” in Chapter 2 for proper
routing of wires.
3-8
INSP
ENGINE IDLE SPEED ADJUSTMENT ADJ
ENGINE
ENGINE IDLE SPEED ADJUSTMENT
1. Tighten:
• Pilot air screw Q
햲 Turn the pilot air screw in until lightly seated.
2. Loosen:
• Pilot air screw
322025 Back out from the lightly seated position.
Pilot air screw position:

DELL'ORTO
1+3/8 turns out ± 1/8
TEIKEI
1+1/2 turns out ± 1/4
3. Start the engine and let it warm up for several

minutes.
WARNING
For safety reasons, place the scooter on the
center stand before starting the engine.
4. Attach:
• Inductive tachometer Q
햲 (to the spark plug lead)
Inductive tachometer:
90890-03113
5. Check:
• Engine idle speed
Out of specification ➔ Adjust.
Engine idle speed:
2000 ± 200 r/min
3-9
ENGINE IDLE SPEED ADJUSTMENT/ INSP
THROTTLE CABLE FREE PLAY ADJUSTEMENT ADJ
6. Adjust:
********************************************************
Adjustment steps:
• Turn the throttle stop screw Q in or out until
햲
specified idling speed is obtained.
Turning left Idling speed increased.

322025
Turning right Idling speed decreased.
*******************************************************
THROTTLE CABLE FREE PLAY
ADJUSTMENT
1 Check:
• Throttle cable free play
Out of specification ➞ Adjust.
Free play:
1.5 ~ 3 mm (0.06 ~ 0,12 in)
*******************************************************
Throttle cable free play adjustment steps:
NOTE:
Before adjusting the throttle cable free play, the
engine idle speed should be adjusted.
First step:
• Loosen the locknut on the throttle cable.
• Turn the adjuster in or out until the specified
free play is obtained.
Turning left Idling speed increased.
Turning right Idling speed decreased.
• Tighten the locknuts.
WARNING
After adjusting, turn the handlebar to the
right and left, making sure that the engine
idling speed does not change.
*******************************************************
3-10
INSP
SPARK PLUG INSPECTION ADJ
SPARK PLUG INSPECTION
1. Remove:
• Spark plug
2. Inspect:
• Electrode Q
Wear/Damage ➞ Replace.
• Insulator W
Abnormal color ➞ Replace.
Standard spark plug:

BR8HS (NGK)
3. Measure:
• Plug gap @
Use a wire gauge or feeler gauge.
Spark plug gap @:

0,5 ~ 0,7 mm (0.020 ~ 0.028 in)
4. Tighten:
• Spark plug
Before installing the spark plug, clean the gasket
surface and plug surface.
NOTE:
First tighten by hand, then torque to specifica-
tion.
Spark plug:
20 Nm (2.0 m • kg, 14ft • lb)
3-11
INSP
AUTOLUBE PUMP AIR BLEEDING ADJ
AUTOLUBE PUMP AIR BLEEDING
1. Remove:
• Fan cover Q
2. Bleed:
• Pump housing and oil hose
*******************************************************
Pump bleeding steps:
햲 ● Place a rag under the pump.
● Remove the bleed screw Q.
● Let oil run until there are no more air bubbles
in it.
● When there are no more bubbles, tighten the
bleed screw.
NOTE:
Check the condition of the bleed screw gasket.
If it is damaged, replace it with a new one.
● Start the engine.

● Let the engine run two or three minutes at 2000
rpm. This will force out any air in the hose.
*******************************************************
3-12
INSP
ENGINE OIL LEVEL INSPECTION ADJ
ENGINE OIL LEVEL INSPECTION
1. Inspect:
• Oil level
Oil level low ➞ Add oil to proper level as
follows.
Q “OIL” indicator light
OIL LEVEL AND GAUGE CHECK
Turn main switch

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

doesn't light. light.
Turn main switch

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

stays on.
Inspect Faulty Engine oil level

Add oil.
electrical circuit, and electric circuit
Light bulb etc. are OK.
"OIL" indicator
stays on.
Recommended oil:
햲 Semi-synthetic oil in accordance
with APITC TSC3 STANDARD.
Capacity:
Total:
1.3 L (1.14 Imp qt, 1.37 US qt)
NOTE:
Install the oil tank filler cap Q and push it fully
into the filler.
CAUTION:
Always use the same type of engine oil;
mixing oils may result in a harmful chemical
reaction and lead to poor performance.
3-13
INSP
TRANSMISSION OIL REPLACEMENT ADJ
TRANSMISSION OIL REPLACEMENT
1. Remove:
• Drain plug Q
• Oil filler plug W
Drain the transmission oil.
2. Check:
햲 • Gasket (drain plug)
• O-ring (oil filler plug)
Damaged ➞ Replace.
햳
3. Install:
• Gasket
• Drain plug
Drain plug:
T.
R 18 Nm (1.8 m • kg, 13 ft • lb)
4. Fill:
• Transmission case
Transmission oil:
SAE 10W30 type SE motor oil.
Capacity:
Periodic replacement
0.11 L
(0.096 Imp qt, 0.116 US qt)
Total amount
0.13 L
(0.114 Imp qt, 0.137 US qt)
NOTE:
Wipe off any oil spilt on the crankcase, tire or
wheel.
5 Install:
• Oil filler plug
3-14
INSP
AIR CLEANER ELEMENT CLEANING ADJ
AIR CLEANER ELEMENT CLEANING
1. Remove:
햲 • Air cleaner case cover Q
2. Remove:
• Air filter element
CAUTION:
Never operate the engine with the air cleaner
element removed. Unfiltered air will cause
rapid wear of engine parts and possible
engine damage.
3.Inspect:
햲
• Element Q
• Damage ➞ replace.
4.Clean:
• Air filter element
*******************************************************
Cleaning steps:
• Wash the element gently but thoroughly in
solvent.
WARNING
Never use low flashpoint solvents such as
gasoline to clean the element. Such solvents
may lead to fire or explosion.
• Squeeze excess solvent out of the element and

let dry.
CAUTION:
Do not twist the element.
• Apply foam air filter oil or SAE 10W30 typ SE

oil on the element.
• Sqeeze out the excess oil.
*******************************************************
NOTE:
The element should be wet but not dripping.
3-15
FRONT BRAKE LEVER FREE PLAY ADJUSTEMENT/
REAR BRAKE LEVER FREE PLAY ADJUSTEMENT/ INSP
BRAKE PADS INSPECTION ADJ
CHASSIS
FRONT BRAKE LEVER FREE PLAY
a
ADJUSTMENT
1. Check:
• Front brake lever free play @
Free play:
10 ~ 20 mm (0.40 ~ 0.80 in)
WARNING
A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake
system. This air must be removed by bleeding
the brake system before the scooter is
operated. Air in the system will reduce brake
performance and can result in loss of control
and an accident. Inspect and bleed the system
if necessary.
REAR BRAKE LEVER FREE PLAY

a ADJUSTMENT
1. Check:
• Rear brake lever free play @
Free play:
10 ~ 20 mm (0.40 ~ 0.80 in)
*******************************************************
Adjustment steps:
• Turn the adjuster Q in W or out E until the
specified free play is obtained.
********************************************************
햳
햲 햴
BRAKE PADS INSPECTION
1.Measure:
• Brake pads
Out of specification ➞ Replace.
NOTE:
Replace the brake pad and spring as a set when
replacing the brake pads.
Wear limit @:
347003 0.5 mm (0.02 in)
3-16
BRAKE SHOE INSPECTION/ INSP
BRAKE FLUID LEVEL INSPECTION ADJ
BRAKE SHOE INSPECTION
1. Apply the rear brake lever.
2. Inspect:
• Wear indicator Q
Indicator reaches the wear limit line W ➞
Replace brake shoes.
BRAKE FLUID LEVEL INSPECTION

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

DOT # 3 or DOT # 4
CAUTION:
The brake fluid may corrode painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
WARNING
• Use only the designated quality fluid.
Otherwise, the rubber seals may deteriorate
causing leakage and poor brake
performance.
• Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical re-
action leading to poor brake performance.
• Be careful that water does no enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
3-17
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP
STEERING HEAD ADJUSTEMENT ADJ
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
1. Bleed:
• Brake fluid.
*******************************************************
Air bleeding steps:
a. Add proper brake fluid into the reservoir.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic tube Q tightly to the
caliper bleed screw.
d. Place the other end of the tube into a con-
tainer.
햲 e. Slowly apply the brake lever several times.
f. Pull the lever as far as possible and hold it
there.
g. Loosen the bleed screw and pull the lever all
the way.
h. When the lever is completely pulled, tighten
346002
the bleed screw, then release the lever.
i. Repeat steps (e) to (h) until all air bubbles have
been removed from the system.
j. Add brake fluid to proper level.
WARNING
Check the operation of the brake after
bleeding the brake system.
*******************************************************
STEERING HEAD ADJUSTMENT

1 Check:
• Steering assembly bearings
Grasp the bottom of the forks and gently rock the
fork assembly back and forth.
Looseness ➞ Adjust steering head.
*******************************************************
Steering head adjustment steps:
● Remove the front fender and the front panels.
Refer to “COVERS REMOVAL”.
● Unscrew the securing nut Q
● Tighten the nut W
햲
Stearing head wrench:
햳 9079Q - 02218
WARNING
354002 Do not overtighten.
3-18
STEERING HEAD ADJUSTEMENT/ INSP
TIRE INSPECTION ADJ
● Check the steering head by turning it lock to
lock. If it binds, remove the steering stem
assembly and inspect the steering bearings.
● Install the steering shaft lock nut and tighten it
to the specified torque.
NOTE:
Tighten the steering shaft lock nut while holding
the ring nut with the ring nut wrench.
Stearing head wrench:

9079Q - 02218
Security nut:
27.5Nm (2.75 m.kg, 19.89 ft.lb)
● Move the handlebar up and down and from

front to rear. If steering play is too important,
354001 tighten the nut to the specified torque.
Stearing head nut:

60 Nm (6.0 m • kg, 43.3 ft • lb)
*******************************************************
TIRE INSPECTION
1. Measure:
• Air pressure
WARNING
Tire pressure (cold) Front Rear
Up to 90 kg 150 kPa 150 kPa Proper loading of your scooter is important
(1.50 kgf/cm2) (1.50 kgf/cm2) for the handling, braking, and other perform-
90 kg ~ maximum 150 kPa 160 kPa ance and safety characteristics of your
load * (1.50 kgf/cm2) (1.60 kgf/cm2) scooter. Do not carry loosely packed items
Maximum load: 182 kg that can shift.
Securely pack your heaviest items close to
* Maximum load is the total weight of rider, passenger, the center of the scooter, and distribute the
accessories and luggage. weight evenly from side to side. And check
the condition and pressure of your tires.
NEVER OVERLOAD YOUR SCOOTER.
Make sure the total weight of the cargo, rider,
passenger, and accessories (fairing,
saddlebags, etc. if approved for this model)
does not exceed the maximum load of the
scooter. Operation of an overloaded scooter
could cause tire damage, an accident, or
even injury.
3-19
TIRE INSPECTION/WHEEL INSPECTION/ INSP
CABLE INSPECTION AND LUBRICATION ADJ
2 Inspect:
• Tire surface
Wear/Damage/Cracks/Road hazards ➞ Re-
place.
• Aluminum wheels
Damage/Bends ➞ Replace.
Never attempt even small repairs to the wheel.
WARNING
Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.
• If the tire is removed with a tire lever, use a

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

(front and rear):
0,8mm (0.03 in)
Q Tread depth
W Side wall
E Wear indicator
WHEEL INSPECTION
1.Inspect:
• Wheels
Damage/Bends ➞ Replace.
WARNING
Never attempt even small repairs to the wheel.
CABLE INSPECTION AND LUBRICATION

WARNING
A damaged cable sheath will rapidly corrode.
As a result, the cable cannot move smoothly
inside the sheath. Since this situation is
dangerous, replace a damaged cable
immediately.
1. Check:
• Cable sheath
• Cable end
Damage ➞ Replace.
3-20
CABLE INSPECTION AND LUBRICATION/
CENTERSTAND LUBRICATION/ INSP
FRONT FORK INSPECTION ADJ
2. Check:
• Cable movement
Stickiness ➞ Lubricate.
Recommended lubricant:
Engine oil SAE 10W30
NOTE:
Hold the cable end up and pour a few drops of oil
into the sheath.
3. Lubricate the throttle cable end and the cable

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

1.Check:
• Front fork
Bend/Damage ➞ Replace fork assembly as a
set.
Excessive oil leakage ➞ Replace fork assem-
bly as a set.
Unsmooth operation ➞ Replace fork assem-
bly.
3-21
INSP
REAR SHOCK ABSORBER ADJ
REAR SHOCK ABSORBER
1.Check:
햲
• Rear shock absorber Q
Oil leaks/Damage ➞ Replace.
2.Check:
• Tightening torque
Upper bolt:
T.
R 31 Nm (3.1 m • kg, 22.4 ft • lb)
Lower bolt:
17 Nm (1.7 m • kg, 12.2 ft • lb)
3-22
INSP
BATTERY INSPECTION ADJ
ELECTRICAL
햲 BATTERY INSPECTION
1. Inspect:
UPPER
LOWER + • Battery fluid level
햳 Fluid level low ➞ Add to proper level.
Fluid level should be between upper and lower
level marks.
Q Upper level
W Lower level
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.
2. Inspect:
• Breather hose
Obstruction ➞ Remove.
3. Inspect:
• Battery
*******************************************************
Replace the battery if:
● Battery voltage will not rise to a specific value
or bubbles fail to rise during charging.
● Sulfation of one or more cells occurs. (As
indicated by the plates turning white, or an
accumulation of material in the bottom of the
sell.)
● Specific gravity readings after a long, slow
charge indicate that one cell is lower than the
rest.
● Warpage or buckling of plates or insulators is
evident.
*********************************************************
4. Measure:
• Specific gravity
Less than 1.280 ➞ Recharge battery.
Charging Current:
0.4 amps/10 hrs
Specific Gravity:
1.280 at 20°C (68° F)
3-23
BATTERY INSPECTION/ INSP
FUSE INSPECTION ADJ
CAUTION:
Always charge a new battery before using
it to ensure maximum performance.
WARNING
Battery electrolyte is dangerous. It contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolyte as it
can cause severe burns and permanent
eye injury.
• Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
• SKIN – Flush with water.
• EYES – Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg,
or vegetable oil. Get immediate medical
attention.
Batteries generate explosive hydrogen gas.
Always follow these preventive measures:
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
• DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
FUSE INSPECTION
1. Remove the battery cover.
2. Inspect:
• Fuse
Blown ➞ Replace.
3-24
FUSE INSPECTION/ INSP
HEADLIGHT BEAM ADJUSTEMENT ADJ
******************************************************
Fuse replacement steps:
● Turn off the ignition.
● Install a new fuse of the right amperage.
● Turn on the switches to verify the operation of
the electric circuit.
● If the fuse immediately blows again, check the
electric circuit.
*******************************************************
WARNING
Never use a fuse with a rating higher than
specified. An improper fuse may cause
damage to the electrical circuit, and possibly
cause a fire.
Fuse:
Main circuit: 7A
3 Install:
햳 • Battery cover
FUSE CAUTION:
When installing the battery cover, pay par-
ticular attention to the following points:
• No cable or wire should cross the area
햵 햴 marked “NO”.
햲 • The (+) terminal cover should be properly
installed.
• Cables and wires should be routed as
shown in the illustration, within the appro-
priate area.
Q. “NO” zone
W. “+”-terminal
E. Wiring
R. Battery vent
HEADLIGHT BEAM ADJUSTMENT

1. Adjust:
• Headlight beam
햲
Higher Turn out screw Q
Lower Turn in screw Q
3-25
HEADLIGHT LENS REPLACEMENT INSP
HEADLIGHT BULB REPLACEMENT ADJ
HEADLIGHT LENS REPLACEMENT
햲
1. Remove:
• Front cover Q
2. Remove:
• Headlight lens
(Pull out the cotter pins)
3. Remove:
• Gasket
4. Install:
Reverse the “REMOVAL” procedure.
HEADLIGHT BULB REPLACEMENT

1. Remove:
• Front cover
햲 2. Remove:
• Headlight bulb socket Q
(Turn one quart of a turn).
3. Remove:
• Headlight bulb
4. Install:
3-26
ENG 4
ENG
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL ....................................................................................... 4-1

COVER REMOVAL .................................................................................. 4-1
CARBURETOR ........................................................................................ 4-1
CABLES, LEADS AND HOSES ............................................................... 4-2
ENGINE REMOVAL ................................................................................. 4-3
ENGINE DISASSEMBLY ............................................................................... 4-4

REAR WHEEL ......................................................................................... 4-4
CENTER STAND ..................................................................................... 4-4
CYLINDER HEAD AND CYLINDER ........................................................ 4-4
PISTON PIN AND PISTON ...................................................................... 4-4
KICK STARTER ....................................................................................... 4-5
PRIMARY SHEAVE ................................................................................. 4-6
SECONDARY SHEAVE ........................................................................... 4-6
STARTER SYSTEM ................................................................................. 4-7
TRANSMISSION ...................................................................................... 4-8
CDI MAGNETO ........................................................................................ 4-8
AUTOLUBE OIL PUMP ............................................................................ 4-9
CRANKCASE AND CRANKSHAFT ......................................................... 4-9
INSPECTION AND REPAIR ........................................................................ 4-11

CYLINDER HEAD .................................................................................. 4-11
CYLINDER AND PISTON ...................................................................... 4-11
PISTON RINGS ..................................................................................... 4-13
PISTON PIN AND PISTON PIN BEARING ............................................ 4-14
KICK STARTER ..................................................................................... 4-15
TRANSMISSION .................................................................................... 4-15
AUTOLUBE PUMP ................................................................................ 4-16
CRANKSHAFT ....................................................................................... 4-16
PRIMARY SHEAVE ............................................................................... 4-16
SECONDARY SHEAVE ......................................................................... 4-17
V-BELT ................................................................................................... 4-18
STARTER CLUTCH AND GEARS ......................................................... 4-19
ENGINE ASSEMBLY AND ADJUSTMENT ................................................. 4-20

CRANKSHAFT AND CRANKCASE ....................................................... 4-21
AUTOLUBE PUMP ................................................................................ 4-23
CDI MAGNETO ...................................................................................... 4-24
TRANSMISSION .................................................................................... 4-26
STARTER SYSTEM ............................................................................... 4-28
PRIMARY SHEAVE ............................................................................... 4-30
SECONDARY SHEAVE ......................................................................... 4-31
KICK STARTER ..................................................................................... 4-35
PISTON PIN AND PISTON .................................................................... 4-36
CYLINDER AND CYLINDER HEAD ...................................................... 4-37
ENGINE REMOUNTING ........................................................................ 4-39
ENGINE REMOVAL
ENG
ENGINE OVERHAUL
ENGINE REMOVAL
COVER REMOVAL
1. Remove:
• Covers
See “CHAPTER 3 - COVERS AND HANDLE-
BAR COVER”.
CARBURETOR
1. Remove:
햲 • Air cleaner case assembly Q
2. Disconnect:
햲 • Carburetor cover
• Hoses
• Carburetor top
3.Remove:
• Carburetor Q
322032
4. Remove:
• Air shroud Q
햲 • Muffler assembly W
햳
320000
5. Loosen:
햲 • Rear axle nut Q
NOTE:
Apply the rear brake while loosening the rear
axle nut.
340002
4-1
ENGINE REMOVAL
ENG
CABLES, LEADS AND HOSES
1. Remove:
• Oil hose Q on the oil pump side
햲
NOTE:
Plug the hose to prevent oil spillage.
321000
2. Disconnect:
• CDI unit lead pump side
• Spark plug cap
• Starter motor lead
385000
3. Remove:
• Rear brake cable Q
햲
324000
4-2
ENGINE REMOVAL
ENG
ENGINE REMOVAL
햳 1. Place a suitable stand under the frame.
2. Remove:
• Rear shock absorber bolt (lower) Q
• Engine mounting bolt W
햲
320001(a)
3. Remove:
• Engine
NOTE:
Lift up the frame and remove the engine.
4. Place the frame on a suitable stand.
4-3
ENGINE DISASSEMBLY
ENG
ENGINE DISASSEMBLY
햳 REAR WHEEL
1. Remove:
• Rear wheel
• Brake shoes Q
• Plate washer W
햲
346001
CENTERSTAND
1. Remove:
• Spring Q
햶 • Clip W
햳 햲 • Rubber washer E
햵
햴 • Axle R
• Clamp T
햷
• Center stand Y
358001
CYLINDER HEAD AND CYLINDER

햲 1. Remove:
• Air shroud
• Cylinder head Q
• Cylinder head gasket
NOTE:
• Before loosening the cylinder head nuts, loosen
301005
the spark plug.
• Loosen the cylinder head nuts crosswise 1/4 of
a turn each before removing them.
햲
햳 2. Remove:
Cylinder Q
Cylinder gasket W
304002
PISTON PIN AND PISTON

1. Remove:
• Piston pin clip Q
햲
NOTE:
Before removing the piston pin clip, cover the
crankcase with a clean rag, so that the clip
cannot accidentally fall into the crankcase.
307001
4-4
ENGINE DISASSEMBLY
ENG
2. Remove:
• Piston pin Q
햴 • Piston W
• Piston pin bearing E
햲
CAUTION:
햳 Do not use a hammer to drive out the
piston pin.
307002
KICKSTARTER
1. Remove:
• Transmission cover Q (left)
313001
2. Remove:
• Kick pinion gear Q
NOTE:
To remove the kick pinion gear, push down the
kick crank.
3 Unhook:
• Kick return spring W
317001
4. Remove:
• Kick crank
• Circlips Q
• Plate washer W
• Kick shaft E
317002
4-5
ENGINE DISASSEMBLY
ENG
PRIMARY SHEAVE
1. Remove:
• Fan
2. Remove:
• Nut Q (primary sheave)
햳 NOTE:
To loosen the primary sheave nut hold the CDI
magneto with a flywheel holder W.
햲 319035
Flywheel holder:
90890-01235
3. Remove:
• Washer Q
• Ratchet W
햶 • Washer E
• Fixed primary sheave R
• Washer T
햵 햴 • V-belt
햳
햲
319001
4. Remove:
햳 • Spacer Q
• Primary sliding sheave W
햲
319002
SECONDARY SHEAVE
1. Remove:
햳 • Nut Q (secondary sheave)
NOTE:
Hold the secondary sheave with a sheave holder
W to loosen the nut.
Sheave holder:
햲 90890-01701
319003
4-6
ENGINE DISASSEMBLY
ENG
2. Remove:
• Clutch housing Q
• Secondary sheave W
• Crankcase cover gasket
• Dowel pins
3. Attach:
햳 • Sheave holder Q
햲 • Nut wrench (39 mm)
319004
Sheave holder:
90890-01701
4. Loosen:
햲 • Clutch securing nut
WARNING
Loosen the nut but do not remove it yet.
319031
5. Attach:
햲
• Clutch spring holder Q
NOTE:
Compress the secondary sheave using the clutch
spring holder Q.
Clutch spring holder:

90890-01337
311001
6. Remove:
햵 햷
햶 • Clutch securing nut
7. Remove:
햲
• Clutch assembly Q
• Clutch spring W
햴 • Spring seat E
햳 • Guide pin R
311002 • Secondary sliding sheave T
• Secondary fixed sheave Y
STARTER SYSTEM
1. Remove:
• Starter clutch assembly Q
• Plate W (idle gear)
• Idle gear E
• Starter wheel gear R
• Spacer T
• Bearing Y
317003 • Washer U
4-7
ENGINE DISASSEMBLY
ENG
2. Remove:
• Spacer Q
• Bearing W
• Washer E
• Starter motor
317004
TRANSMISSION
1. Remove:
• Transmission case Q
• Gasket
• Dowel pins
햲
319036
햲 2. Remove:
• Drive shaft Q
• Main shaft W
• Plate washer E
• Conical spring washer R
햳
햴
햵
319037
3. Remove:
• Oil seal Q
햲 • Secondary sheave axle W
햳
319032
CDI MAGNETO
1. Remove:
• Nut Q (rotor)
• Plate washer
햲 햳
NOTE:
Hold the rotor using a flywheel holder W to
loosen the nut.
Flywheel holder:
321004
90890-01235
4-8
ENGINE DISASSEMBLY
ENG
2. Remove:
햲 • Rotor Q
• Woodruff key
Use the flywheel puller W
햳 Flywheel puller:
90890-01189
• Stator assembly
321005
• Gasket
AUTOLUBE OIL PUMP
1. Remove:
• Autolube oil pump Q
314001
2. Remove:
• Circlips Q
• Pump drive gear W
• Pin E
• Circlip R
314002
CRANKCASE AND CRANKSHAFT

1. Remove:
• Oil seal stopper Q
• Screws (crankcase)
햲
NOTE:
Loosen each screw one quart of a turn before
beginning to remove them.
313009
2. Attach:
• Crankcase separating tool Q
Crankcase separating tool:

햲 90890-01135
NOTE:
Fully tighten the tool holding bolts. Insure that
313002 the tool body is parallel with the case. If necessary,
4-9
ENGINE DISASSEMBLY
ENG
loosen one screw as much as required to level
the tool body.
3. Remove:
• Crankcase (right)
As pressure is applied, keep tapping carefully on
the engine mounting bosses.
CAUTION:
Use a soft hammer to tap on the case. Tap
only on reinforced spots of the case. Never
tap on the gasket mating surfaces. Work
slowly and carefully. Make sure the cases
separate evenly. If one end “hangs up” take
the pressure off the push screw, realign the
cases and the tool and start again. If the
cases do not separate at all, check for a
remaining case screw or fitting. Do not force.
4. Attach:
• Crankcase separating tool Q
Crankcase separating tool:

90890-01135
5. Remove:
햳 • Crankshaft W
햲
313004
4-10
INSPECTION AND REPAIR
ENG
CYLINDER HEAD
1. Eliminate:
햲
• Carbon deposits
Use a rounded scraper Q
NOTE:
Take care to avoid damaging the spark plug
301001 threads. Do not use a sharp instrument. Avoid
scratching the aluminum.
햲 2. Inspect:
• Cylinder head warpage
햳
Out of specification ➞ Re-surface.
*******************************************************
Warpage measurement and re-surfacement
steps :
● Attach a straight edge Q and a thickness
301002 gauge W to the cylinder head.
● Measure the warpage limit.
Warpage limit:
0.02 mm (0.001 in)
● If the warpage is out of specification, re-surface

the cylinder head.
NOTE:
Rotate the head several times to avoid removing
301003 too much material from one side.
*******************************************************
CYLINDER AND PISTON
1. Eliminate:
• Carbon deposits
Use a rounded scraper Q
2. Inspect:
• Cylinder wall
햲
Wear/Scratches ➞ Replace.
304001
햲 햳 3. Eliminate:
• Carbon deposits
From the piston crown Q and ring grooves W.
4. Remove:
• Score marks and lacquer deposits
From the sides of piston.
307003
4-11
ENG
NOTE:
Sand in a crisscross pattern. Do not sand
excessively.
5. Inspect:
• Piston wall
Wear/Scratches/Damage ➞ Replace.
307004
6. Measure:
• Piston to cylinder clearance
********************************************************
Piston to cylinder clearance measurement
D1 steps :
D2
First step :
● Measure the cylinder bore “C” with a cylinder
bore gauge.
D3 NOTE:
D4
Measure the cylinder bore “C” in parallel to and
at right angles to the crankshaft. Then, calculate
the average of the measurements.
D5
D6
Standard Wear limit
Cylinder 39.99 ~ 40.01mm 40.10 mm

307005
Bore “C” (1.574 ~ 1.575 in) (1.579 in)
Taper _ 0,05mm
"T" (0.002 in)
C = Maximum D
T = (Maximum D1,D3 or D5) -
(Maximum D2,D4 or D6 )
● If out of specification, replace cylinder, piston

and piston rings as a set.
2nd step:
● Measure the piston skirt diameter “P” with a
micrometer.
@ 5 mm (0.20 in) from the piston bottom edge.
@
Piston Size:
Standard:
39.952 ~ 39.972 mm
(1.57 ~ 1.57 in)
307006
4-12
ENG
● If out of specification, replace piston and piston
rings as a set.
3rd step:
● Calculate the piston-to-cylinder clearance with
following formula:
Piston-to cylinder clearance =

Cylinder Bore “C” –
Piston Skirt Diameter “P”
● If out of specification, replace cylinder, piston

and piston rings as a set.
Piston-to-cylinder clearance:
0.034 ~ 0.047 mm
(0.0013 ~ 0.0018 in)
<Wear limit : 0.1 mm (0.004 in)>
*******************************************************
PISTON RINGS
1. Measure:
• Side clearance
Out of specification ➞ Replace piston and/or
햲 rings.
Use a Feeler Gauge Q
Standard Limit
307007
Top 0.03 ~ 0.05 mm 0.10 mm

ring (0.0012 ~ 0.0020 in) (0.004 in)
2nd 0.03 ~ 0.05 mm 0.10 mm

ring (0.0012 ~ 0.0020 in) (0.004 in)
2. Install:
햲 • Piston ring
a
• Into the cylinder
Push the ring with the piston crown.
3. Measure:
• End gap
Out of specification ➞ Replace rings as a set.
307008
Use a Feeler Gauge Q
4-13
ENG
Standard Limit
Top 0.15 ~ 0.30 mm 0.70 mm

ring (0.005 ~ 0.011 in) (0.028 in)
2nd 0.15 ~ 0.30 mm 0.70 mm

ring (0.005 ~ 0.011 in) (0.028 in)
@ Measuring Point 20 mm (0.8 in)
PISTON PIN AND PISTON PIN BEARING

1. Inspect:
• Piston pin
Blue discoloration/Groove ➞ Replace, then
inspect lubrication system.
a 2. Measure:
• Outside diameter (piston pin)
Outside diameter (piston pin):
9.996 ~ 10.000 mm
(0.3935 ~ 0.3937 in)
307009
b 3. Measure:
• Piston pin-to-piston clearance
Out of specification ➞ Replace piston.
Piston pin-to-piston clearance =

Bore (piston pin) b -
Outside diameter (piston pin) a
307010
Piston pin-to-piston clearance:
0.004 ~ 0.023 mm
(0.0002 ~ 0.0009 in)
<Limit : 0.07 mm (0.028 in)>
4. Inspect:
• Bearing (piston pin)
Pitting/Damage ➞ Replace
307011
4-14
ENG
KICK STARTER
1. Inspect:
• Kick gear teeth Q
• Kick pinion gear teeth W
Burrs/Chips/Roughness/Wear ➞ Replace.
317005
2. Inspect:
• Mating dogs (kick pinion gear and one-way
clutch)
Rounded edges/Damage ➞ Replace.
317006
3. Measure:
• Clip tension (kick pinion gear) Q
Use a spring balance W.
Standard tension:
150 ~ 250 g (5.3 ~ 8.8 oz.)
317007
TRANSMISSION
1. Inspect:
• Drive axle Q
• Main axle W
• Secondary sheave axle E
햲 햳 햴
319005
2. Inspect:
• Secondary sheave axle bearing Q
• Main axle bearing W
• Drive axle bearing E
Spin the bearing inner race.
Excessive play/Roughness ➞ Replace.
햴
Pitting/Damage ➞ Replace.
햳
햲 319038
4-15
ENG
AUTOLUBE PUMP
Wear or an internal malfunction may cause the
pump output to vary from the factory setting.
This situation is, however, extremely rare. If
improper output is suspected, inspect the
following:
1. Inspect:
• Delivery line
Obstructions ➞ Blow out.
• O-ring
2. Inspect:
• Autolube pump drive gear teeth Q
• Autolube pump driven gear teeth W
Pitting/Wear/Damage ➞ Replace.
314003
CRANKSHAFT
1. Measure:
• Crankshaft width "A"
• Runout limit “C”
• Connecting rod big end side clearance “D”
Use V-blocks, dial gauge and thickness gauge.
Crankshaft width "A":

37.90 ~ 37.95 mm
308001
(1.492 ~ 1.494 in)
Runout limit “C”:
0.03 mm (0.0012 in)
Connecting rod big end side
clearance “D”:
0.2 ~ 0.5 mm (0.008 ~ 0.02 in)
PRIMARY SHEAVE
1. Inspect:
• Primary sliding sheave Q
• Primary fixed sheave W
Wear/Cracks/Scratch/Damage ➞ Replace.
햲
햳
319006
4-16
ENG
2. Check:
• Free movement
햲
Insert the collar W into the primary sliding sheave
Q, and check for free movement.
햳
Stick or excessive play ➞ Replace the sheave
and/or collar.
319007
3. Measure:
• Outside diameter Q (weight)
Outside diameter (weight):

15.0 mm (0.59 in)
<Limit 14.5 mm (0.57 in)>
햲
319008
SECONDARY SHEAVE
1. Inspect:
햴 햳 햲 • Secondary fixed sheave Q
• Secondary sliding sheave W
Scratch/Crack/Damage ➞ Replace as a set.
• Oil seal E
Damage ➞ Replace.
319009
2. Inspect:
• Torque cam groove Q
햴 • Guide pin W
Wear/Damage ➞ Replace as a set.
• O-rings E
Damage ➞ Replace.
햳 햲 319010
3. Measure:
• Clutch spring free length
Clutch spring free length:

121.7 mm
<Limit>
106.7 mm
319011
4-17
ENG
4. Inspect:
• Clutch housing inner surface
Oil/Scratches ➞ Remove.
Use a rag soaked in lacquer

Oil
thinner or solvent.
Use an emery cloth (lightly

Scratches and evenly polishing).
319030
5. Measure:
• Clutch housing inside diameter @
@ Clutch housing inside diameter:

107.0 mm ( 4.21 in)
<Wear Limit>:
107.4 mm ( 4.22 in)
319012
6. Inspect:
• Clutch shoes
Glazed parts ➞ Sand with coarse sandpaper.
NOTE:
After using the sand paper, clean off the polished
particles with a cloth.
7. Measure:
• Clutch shoe thickness @
@
Clutch shoe thickness:
2.0 mm (0.08 in)
<Wear Limit> :
1 mm (0.039 in)
319013
V-BELT
1. Inspect:
• V-belt
Crack/Wear ➞ Replace.
NOTE:
Replace the V-belt if it is greasy or oily.
4-18
ENG
2. Measure:
• V-belt width @
V-Belt width:
16,5 mm (0.65 in)
<Wear Limit>:
15,7 mm (0.62 in)
312001
STARTER CLUTCH AND GEARS

1. Inspect:
• Starter clutch
Push the dowel pin in arrow direction.
Unsmooth operation ➞ Replace starter clutch
assembly.
317008
2. Inspect:
• Starter wheel gear teeth Q
• Idle gear teeth W
• Bearing E (starter wheel gear)
317009
4-19
ENGINE ASSEMBLY AND ADJUSTMENT
ENG
Q Oil seal I Crankshaft pin
W Oil seal holder O Connecting rod
E Crankcase (right) P Crankshaft (left)
R Dowel pin { Bearing
T Bearing } Engine mount shaft
Y Crankshaft (right) q Crankcase (left)
U Bearing w Oil seal
9 Nm (0.9 m.kg, 6.5 ft.lb) 13 Nm (1.3 m.kg, 9.4 ft.lb)

A CRANKSHAFT:
Crank width:
햳 햴
37,90 ~ 37,95 mm
(1.49 ~ 1.50 in)
Runout limit:
햲
< 0,03 mm>
햵 햶 < 0,002 in>
Big end side clearance:
0,2 ~ 0,5 mm
(0,008 ~ 0,020 in)
햷
햸
햹 햺
햻
햿
햾 햽
313008
4-20
ENG
CRANKSHAFT AND CRANKCASE
CAUTION:
To protect the crankshaft against scratches
and to facilitate the engine assembly and
installation, apply grease to oil seal lips, and
engine oil to bearings.
1. Attach:
• Crankshaft installation tool Q, W, E, R
햲 햴햵
Crankshaft installation tool:
Q : 90890-01274
W : 90890-01275
E : 90890-01277
햳 R : 90890-01411
2. Install:
• Crankshaft
(to left crankcase)
NOTE:
Hold the connecting rod at top dead center with
one hand while tightening the nut of the
installation tool with the other. Tighten the
installation tool until the crankshaft bottoms
against the bearing.
3. Install:
햲 • Dowel pins Q
• Spacer W
햳 햳
313005
4. Apply:
• HEATPROOF or Yamaha Bond No.1215
To the mating surfaces of both case halves.
HEATPROOF or Yamaha Bond

No.1215
313006
4-21
ENG
5. Attach:
• Crankshaft installation tool Q, W, E, R
햲 Crankshaft installation tool:

Q : 90890-01274
W : 90890-01275
E : 90890-01277
햴 R : 90890-01411
햵 햳
NOTE:
Hold the connecting rod at top dead center with
one hand while tightening the nut of the installa-
tion tool with the other. Tighten the installation
tool until the crankcase halves close with one
another.
6. Install:
• Right crankcase
7. Tighten:
• Crankcase holding screws
NOTE:
Tighten the crankcase holding screws in stages,
using a crisscross pattern.
Crankcase holding screw:

T.
R 9 Nm (0.9 m • kg,( 6.5 ft • lb)
313009
8. Check:
• Crankshaft operation
Unsmooth operation ➞ Repair.
CAUTION:
Never hit on the crankshaft.
308003
9. Install:
• Oil seal stopper plate Q
햲 Screw (oil seal stopper plate):

T.
R 9 Nm (0.9 m • kg,( 6.5 ft • lb)
313009
4-22
ENG
AUTOLUBE PUMP AND CDI MAGNETO
Q Fan O Gasket
W Plain washer P Oil hose
E Rotor assembly { Oil delivery hose
R Lighting coil } Clip
T Charge coil q Autolube pump
Y Pick up coil w O-ring
U Stator assembly e Circlip
I Oil seal r Oil pump drive gear
햻
햽
4 Nm (0.4 m.kg, 2.9 ft.lb)
햿
헀
6.5 Nm (0.65 m.kg, 4.7 ft.lb)
37.5 Nm (3.75 m.kg, 27.1 ft.lb)
햶
햲
햳
햹 햺
헁
8 Nm (0.8 m.kg, 5.8 ft.lb)
헂
헁
314007
4-23
ENG
AUTOLUBE PUMP
1. Install:
• Circlip Q
• Pin W
• Pump drive gear E
• Circlip R
314004
2. Apply:
• Lithium soap base grease
(to O-ring Q)
햳 3. Instal:
햲 • Autolube pump W
Screw (autolube pump):

314005
T.
R 4 Nm (0.4 m • kg, 2.9 ft • lb)
4. Apply:
• Lithium soap base grease
(to autolube pump gear Q, W)
Lithium soap base grease:

15 cc (0.92 cu • in)
햳
햲
314006
CDI MAGNETO
1. Install:
• Gasket
2. Apply:
햲 • Lithium soap base grease
(to oil seal Q)
321001
3. Pass the CDI magneto lead through the

crankcase hole.
4. Install:
• Stator assembly
Screw (stator assembly):

T.
R 8 Nm (0.8 m • kg, 5.8 ft • lb)
4-24
ENG
5. Install:
햵 햳 • Woodruff key Q
• Magneto rotor W
햲 • Plain washer E
햴 • Nut R
NOTE:
When installing the magneto rotor, make sure
the woodruff key is properly seated in the key
321002
way of the crankshaft. Apply a light coating of
lithium soap base grease to the tapered portion
of the crankshaft end.
6. Tighten:
• Nut Q (magneto rotor)
햲 햳 Use the flywheel holding tool W.
Flywheel holding tool:

90890-01235
Nut (Flywheel magneto):

T.
R 37.5 Nm (3.75 m • kg, 27.1 ft • lb)
321004
4-25
ENG
TRANSMISSION
Q Circlip O Bearing
W Bearing P Secondary sheave axle
E Oil seal { Bearing
R Drive axle } Dowel pin
T Bearing q Gasket
Y Main axle w Transmission case cover
U Conical spring washer e Oil seal
I Plain washer
햳
햴
햺
햷
햻 햸
햾 햹
12 Nm (1.2 m.kg, 8.7 ft.lb)
햾
햿
헁
319033
4-26
ENG
TRANSMISSION
1. Apply:
• 10W30 Type SE Motor oil
(to transmission case cover bearing)
2. Install:
• Bearing Q
3. Install:
• Oil seal W
• Secondary sheave axle E
햳 NOTE:
햴 Apply lithium soap base grease onto the oil seal
햲 lips.
4. Check:
319014
• Secondary sheave axle operation
5. Apply:
• 10W30 type SE Motor oil
햳 (to main axle bearing and drive axle bearing)
6. Install:
• Main axle Q
햲 • Drive axle W
햴 • Conical spring washer E
햵
319016 • Plain washer R
NOTE:
• Apply lithium soap base grease onto the oil seal
lips.
• Always use a new gasket.
7. Install:
• Gasket
햳 • Dowel pins
• Transmission case cover
햳 Screw (case cover):

T.
R 9 Nm (0.9 m • kg, 6.5 ft • lb)
햲
햴 319017
4-27
ENG
STARTER SYSTEM
Q Collar U Plate
W Washer I Shaft
E Bearing O Plain washer
R Starter wheel gear P Idle gear
T Collar { O-ring
Y Starter clutch } Starter motor
햶
햲
햷
햺
햻
13 Nm (1.3 m.kg, 9.4 ft.lb) 햺
햹
햸
햾
8 Nm (0.8 m.kg, 5.8 ft.lb)
317017
4-28
ENG
STARTER SYSTEM
1. Install:
• Collar Q
• Washer W
• Bearing E
• Starter wheel gear R
• Starter clutch T
NOTE:
317010
• Apply lithium soap base grease to the bearing.
• Apply molybdenum disulfide oil to the shaft
(starter clutch).
317011
2. Install:
• Plain washer Q
햲 • Idle gear W
• Plain washer E
햳 • Plate R (idle gear)
햴
Screw (idle gear plate):
T.
R 8 Nm (0.8 m • kg, 5.8 ft • lb)
햵
317012
NOTE:
Apply engine oil to the idle gear W.
햲
3. Install:
• Starter motor Q
Screw (starter motor):

T.
R 13 Nm (1.3 m • kg, 9.4 ft • lb)
317013
NOTE:
Apply lithium soap base grease to the O-ring of
the starter motor.
4-29
ENG
PRIMARY AND SECONDARY SHEAVE
Q Clutch housing } Conical spring washer *Apply BEL-RAY Assembly Lube ®
W Clutch q One-way clutch
E Clutch shoe spring w Washer
R Clutch spring e Primary fixed sheave
T Spring seat r Plate washer
Y Gasket t Spacer
U O-rings y Primary sliding sheave
I Secondary sliding sheave u Clutch weights
O V-belt i Slider
P Guide pin o Cam
{ Secondary fixed sheave
50 Nm (5.0 m.kg, 36.2 ft.lb)
40 Nm (4.0 m.kg, 28.9 ft.lb)
A Spring (secondary sheave)

free lenght limit: 106.7 mm
(4.20 in)
B Clutch housing weare limit:
107.4 mm (4.22 in)
C Clutch shoes wear limit: 30 Nm (3.0 m.kg, 21.7 ft.lb)
1 mm (0.039 in)
D V-belt wear limit:
15.7 mm (0.62 mm)
E Weight outside diameter
limit : 14.5 mm (0.57 in)
319034
4-30
ENG
KICK STARTER
Q Kick shaft U Dowel pin

W Return spring I Transmission case
E Collar O Kick crank
R Plain washer P Kick pinion gear
T Circlip { Kick pinion gear clip
Y Gasket
햲 A KICK CLIP FRICTION FORCE : 0,15 ~ 0,25

kg
햴
햵
햶 햷
햳 햹
햻
햽
150 ~ 250 g
12 Nm (1,2 m.kg, 8.7 ft.lb)
10 Nm (1,0 m.kg, 7.2 ft.lb)
317018(a)
4-31
ENG
SECONDARY SHEAVE
When assembling the secondary sheave, reverse
the disassembly procedure. Note the following
points.
1. Apply:
• BEL-RAY Assembly Lube ®
(to the sliding parts of the sheave)
319018
2. Install:
• Sliding sheave Q
NOTE:
Wind adhesive tape around the end of the sheave
햲 to avoid turning over the oil seal lips when
installing the sheave.
319019
3. Install:
햲 • Pin Q
4. Apply:
• BEL-RAY Assembly Lube ®
(to the torque cam grooves and O-rings)
5. Check:
319020 • Sliding sheave
햲 CAUTION:
Remove excessive grease.
6. Install:
• Clutch securing nut
Use the clutch spring holder Q
Clutch spring holder:

319021
90890-01337
7. Tighten:
• Clutch securing nut
Use sheave holder Q (39 mm).
햲
Sheave holder:
90890-01701
Clutch securing nut:

319031
T.
R
50 Nm (5.0 m • kg, 36 ft • lb)
4-32
ENG
8. Install:
• Dowel pin
햲 • Gasket
• Secondary sheave assembly Q
• Clutch housing W
햳
319022
9. Tighten:
햳 • Nut Q (secondary sheave)
Use sheave holder W
Sheave holder:
P/N. 90890-01701
Nut (secondary sheave):

햲 T.
R 40 Nm (4.0 m • kg, 29 ft • lb)
319023
PRIMARY SHEAVE
햶
1. Clean:
• Primary sliding sheave face Q
• Primary fixed sheave face W
• Collar E
• Weight R
• Primary sliding sheave cam surface T
햲 햳 햴 햵
319024
2. Install:
햲햴 햳 • Weight Q
• Cam W
햲 • Slider E
햴 • Collar R
햵 3.Check:
• Cam operation
햲 햴 Unsmooth operation ➞ Repair.
319025
4. Install:
햲 • Primary sheave assembly Q
• Collar W
햳
319026
4-33
ENG
5. Install:
• V-belt
Place the V-belt around the secondary sheave,
and compress the secondary sheave spring
hard so that the V-belt moves toward the clutch
hub.
NOTE:
• The arrow on the V-belt must point to the front.
• Make sure the V-belt is not stained with oil or
grease.
6. Install:
햵 햶 • Shim Q
• Primary fixed sheave W
• Washer E
햲
• One-way clutch R
햴 • Washer T
햳 햵 햶
햷 • Nut Y
319027
7. Tighten:
Nut Q (primary sheave)
Nut (primary sheave):

T.
R
30 Nm (3.0 m • kg, 21.7 ft • lb)
햳 NOTE:
When tightening the nut (primary sheave), hold
햲 319035 the magneto rotor using the flywheel holding tool
W.
Flywheel holding tool:

90890-01235
8. Adjust:
• V-belt
Tense the V-belt by turning the primary sheave
several times.
319028
4-34
ENG
9. Install:
• Fan Q
Screw (fan):
T.
R 7 Nm (0.7 m • kg, 5.1 ft • lb)
320000
KICK STARTER
1. Install:
• Return spring Q
햴 • Kick shaft W
햵
햳 햶 • Collar E
햲 • Washer R
• Circlip T
317014
2. Hook:
• Return spring
(to the kick gear and boss)
3. Install:
• Kick pinion gear Q
NOTE:
Install the clamp as shown.
317015
4. Install:
• Transmission case Q
Screw (Transmission case):

햲 T.
R 9 Nm (0.9 m • kg, 6.5 ft • lb)
319029
5. Install:
햲 • Kick crank Q
Bolt (kick crank):

T.
R 9 Nm (0.9 m • kg, 6.5 ft • lb)
317016(a)
4-35
ENG
PISTON, CYLINDER AND CYLINDER HEAD
Q Carburetor joint U Cylinder gasket

W Reed valve I Piston ring
E Gasket O Piston
R Cylinder head P Piston pin
T Cylinder head gasket { Piston pin clip
Y Cylinder } Bearing
20 Nm (2.0 m.kg, 14.0 ft.lb) 10 Nm (1.0 m.kg, 7.2 ft.lb)
햴 햳
햷
햺 A Piston clearance :
0.034 ~ 0.047 mm (0.0013 ~ 0.0017 in)
햽
햻 B Piston rings end gap :
0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
C Piston rings side clearance :
0.03 ~ 0.05 mm (0.0012 ~ 0.0019 in)
햽 D Spark plug :
Type : BR8HS
Manufacturer : NGK
햾
304003
4-36
ENG
PISTON PIN AND PISTON
햲 1. Apply:
• Engine oil Q
(to crankshaft bearing, connecting rod big end
bearing, small end bearing, piston pin, piston
ring grooves and piston skirt .)
308004
2. Install:
• Small end bearing
• Piston Q
• Piston pin E
햲 • Piston pin clip R
NOTE:
햵
햳 햴 • The arrow W on the piston must point to the
exhaust side.
307012
• Before installing the piston pin clip, cover the
crankcase with a clean towel or rag so you will
not accidentally drop the pin clip and material
into the crankcase.
WARNING
• The ends of the piston pin clip must not
come together at the slot in the piston
groove.
• Always use a new piston pin clip.
햲 CYLINDER AND CYLINDER HEAD

1. Install:
• Cylinder gasket (new gasket)
2. Check:
• Piston rings
NOTE:
• Make sure the ring ends Q are properly fitted
around the ring locating pins in the piston grooves.
307013
• Be sure to check the manufacturer’s marks or
numbers stamped on the rings are on the top
side of the rings.
4-37
ENG
3. Install:
햲 • Cylinder Q
햲
NOTE:
햳
Install the cylinder with one hand, while com-
pressing the piston rings with the other hand.
304002
4. Install:
햳
햲 • Cylinder head gasket (new gasket)
5. Install:
• Cylinder head Q
햴
• Spark plug W
NOTE:
• Tighten the cylinder head holding nuts in stages,
301004
and crisscross sequence.
• The arrow E on the cylinder head must point to
the front.
Nut (cylinder head):

T.
R
10 Nm (1.0 m • kg, 7.2 ft • lb)
Spark plug:
20 Nm (2.0 m • kg, 14 ft • lb)
6. Install:
• Center stand Q
• Shaft W
햴 • Clamp E
햶 햷 • Rubber washer R
햳
햵 • Clip T
햲 • Spring Y
358002
7. Install:
• Brake shoe plate Q
햳 • Plain washer W
• Rear wheel
햲
346001
4-38
ENG
8. Install:
• Air shroud
• Oil hose
• Oil delivery hose
9. Air bleeding:
• Autolube pump
Refer to the section “CHAPTER 3 – AUTOLUBE
PUMP AIR BLEEDING”.
ENGINE REMOUNTING
햲
Reverse the removal procedure.
Note the following points.
1. Install:
• Engine mounting bolt Q
• Rear shock absorber bolt W (lower)
햳 These bolts should be temporarily secured.
2. Tighten:
320001
• Engine mounting bolt
• Rear shock absorber bolt (lower)
Engine mounting bolt:

햲 T.
84 Nm (8.4 m • kg, 61 ft • lb)
햳
R
Rear shock absorber bolt (lower):

햴 16 Nm (1.6 m • kg, 12 ft • lb)
3. Install:
• Carburetor top together with throttle valve Q
• Fuel hose W/Vacuum hose E
• Brake cable/plug cap
322032
NOTE:
When installing the throttle valve into the
carburetor, align the groove of the throttle valve
with the projection of the carburetor.
4. Connect:
• Starter motor
• CDI magneto lead
• Earth
385000
4-39
ENG
5. Tighten:
햲 • Rear wheel axle nut Q
NOTE:
When tightening the rear wheel axle nut, apply
the rear brake.
Rear wheel axle nut:

T.
R 105 Nm (10,5 m • kg, 76 ft • lb)
340002
6. Install:
• Muffler assembly Q
• Fan cover W.
햳
Bolt (muffler):
T.
R
26 Nm (2.6 m • kg, 19 ft • lb)
Bolt (exhaust pipe):
9 Nm (0.9 m • kg, 6.5 ft • lb)
햲 7. Fill:
320000
• Transmission oil
Refer to “CHAPTER 3 – TRANSMISSION OIL
REPLACEMENT” section.
8. Adjust:
• Brake lever free play
Refer to “CHAPTER 3 – FRONT/REAR BRAKE
LEVER FREE PLAY ADJUSTMENT” section.
Refer to “THROTTLE CABLE FREE PLAY
ADJUSTMENT” and “ENGINE IDLE SPEED
ADJUSTMENT”.
4-40
CARB 5
CARB
CHAPTER 5.
CARBURETION
CARBURETOR .............................................................................................. 5-1

TEIKEI CARBURETOR ............................................................................ 5-1
DELL'ORTO CARBURETOR ................................................................... 5-3
REMOVAL ................................................................................................ 5-5
DISASSEMBLY ........................................................................................ 5-5
INSPECTION ........................................................................................... 5-7
ASSEMBLY .............................................................................................. 5-9
INSTALLATION ...................................................................................... 5-10
FUEL COCK ................................................................................................. 5-11

INSPECTION .........................................................................................5-11
FUEL FILTER CLEANING ..................................................................... 5-11
REED VALVE ............................................................................................... 5-11

REMOVAL .............................................................................................. 5-11
INSPECTION .........................................................................................5-12
INSTALLATION ...................................................................................... 5-13
CARBURETOR CARB
TEIKEI CARBURETOR
Q Carburetor top P Pilot jet
W Gasket { Needle jet
E Throttle valve spring } Needle valve
R Needle set q Main jet
T Throttle valve w Float pin
Y Starter plunger spring e Float
U Starter plunger r Float chamber gasket
I Air screw t Float chamber
O Throttle stop screw y Drain screw
햷 햵
햸
햶
햺 햾
햻 햿
햽
헀
헂
헃
322033
5-1
CARBURETOR CARB
Main jet (M.J.) #90 #88
Jet needle (J.N.) 211 GA 3/5 3S12-3/5
Bypass (B.P.1) 0.80 0.80
5-2
CARBURETOR CARB
DELL'ORTO CARBURETOR
Q Carburetor top P Pilot jet
W Gasket { Needle jet
E Throttle valve spring } Needle valve
R Needle set q Main jet
T Throttle valve w Float pin
Y Starter plunger spring e Float
U Starter plunger r Float chamber gasket
I Air screw t Float chamber
O Throttle stop screw y Drain screw
햲
햳
햴 햷
햶 햸
햵
햺
햹
햽
햿
햻
헁 햾
헀
헂
헃
헄
322034
5-3
CARBURETOR CARB
Main jet (M.J.) #90 #88
Jet needle (J.N.) 211 GA 3/5 3S12-3/5
Bypass (B.P.1) 0.80 0.80
5-4
CARBURETOR CARB
REMOVAL
1. Remove:
• Side covers and footrest board
Refer to the section “SIDE COVERS AND
FOOTREST BOARD” in Chapter 3.
• Air filter case assembly
2. Disconnect:
햳 햲 • Fuel hose Q
• Oil hose W
TEIKEI CARBURETOR
3. Remove:
• Carburetor top
• Throttle valve
322030
• Starter plunger
• Carburetor
DELL’ORTO CARBURETOR
3. Remove:
• Carburetor top
• Throttle valve
• Starter plunger top
• Starter plunger
• Carburetor
DISASSEMBLY (TEIKEI CARBURETOR)

1. Remove:
• Float chamber Q
322001
2. Remove:
햶
• Float pin screw Q
햲
• Float pin W
햳 • Float E
• Needle valve R
햴 • Gasket T
햵
322002
5-5
CARBURETOR CARB
햲 3. Remove:
• Main jet Q
햴
• Needle jet W
햳 • Pilot jet E
322003
4. Remove:
• Throttle stop screw Q
• Spring (throttle stop screw)
햲 • Air screw W
햳 • Spring (air screw)
322004
5. Remove:
• Needle clip Q
• Jet needle W
햲 • Throttle valve E
햴
322005
DISASSEMBLY (DELL’ORTO
CARBURETOR)
1. Remove:
햲 • Float chamber Q
322007
햴 2. Remove:
햳
햲 • Float pin Q
• Float W
• Needle valve E
322026
5-6
CARBURETOR CARB
3. Remove:
햲 햳
• Pilot jet Q
• Main jet W
햴 • Needle jet E
• Starter jet R
햵
322027
4. Remove:
햳
• Spring (throttle stop screw)
햲
• Air screw W
• Spring (air screw)
322028(a)
5. Remove:
햲 • Needle clip Q
햳 • Jet needle W
• Throttle valve E
햴
322029
INSPECTION
1. Check:
• Carburetor body Q
햲
Dirt ➞ Clean.
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with compressed
air.
322006
2. Inspect:
• Main jet Q
• Needle jet W
• Pilot jet E
햳 • Starter jet (DELL’ORTO)
햲 햴 Contamination ➞ Clean.
322012
5-7
CARBURETOR CARB
3. Check:
• Needle valve Q
Wear/Contamination ➞ Replace.
• Float W
Damage ➞ Replace.
햳 • Gasket
Damage ➞ Replace.
햲
322013
4. Check:
햲 • Throttle valve Q
322014
5. Check:
• Throttle valve free movement
햲 Unsmooth/stickiness ➞ Replace.
햳 Insert the throttle valve Q into the carburetor
body W and check for smooth movement.
322015
6. Check:
햲 햳
• Air screw W
• Needle E
햴 햵 • Starter plunger R
322016
7. Measure:
• Needle valve
• Valve seat
NOTE:
The float height is factory-adjusted. Never try to
adjust it yourself.
5-8
CARBURETOR CARB
ASSEMBLY
Reverse the “DISASSEMBLY” procedures. Note
the following points.
CAUTION:
• Before reassembling the carburetor wash
all its components in clean gasoline.
• Always use new gaskets.
1. Install:
• Needle W
햳 • Clip E
햵 • Throttle valve Q
햴 • Spring seat R
햴 • Spring
햳
Jet needle clip position:
3/5
햲
322018
2. Install:
• Throttle valve Q
• Starter plunger
햲
햳 NOTE:
햴 Align the groove W of the throttle valve with the
projection E of the carburetor body.
322019
3. Install:
햲 • Carburetor
NOTE:
Align projection Q with projection W.
햳 322020
5-9
CARBURETOR CARB
INSTALLATION
To install the carburetor reverse the “REMOVAL”
햲 procedures. Note the following points.
1. Install:
• Carburetor cover Q
햳 • Air hose W
Pass the air hose through the hole E in the
carburetor cover.
햴 322021
2. Adjust:
Refer to the section “THROTTLE CABLE FREE
PLAY ADJUSTMENT” in Chapter 3.
3. Install:
• Air filter case
5-10
FUEL COCK/
REED VALVE CARB
FUEL COCK
INSPECTION
1. Stop the engine.
2. Remove:
• Side covers
3. Check:
햲 • Fuel cock
********************************************************
Fuel cock inspection steps :
● Disconnect the fuel hose Q.
● Place a receptacle under the fuel hose end.
● If fuel stops flowing within a few seconds, the
fuel cock is in good condition. If not clean or
322031 replace the fuel cock.
● Disconnect the vacuum hose and breathe in
through the hose to create a vacuum in the fuel
cock.
If fuel flows out of the fuel hose when vacuum is
applied and stops flowing when vacuum stops,
the fuel cock is in good condition.
If not, clean or replace the vacuum hose, the fuel
hose and the fuel cock.
********************************************************
FUEL FILTER CLEANING

The fuel filter Q is fitted inside the fuel tank. It is
accessible when the fuel hose (between the fuel
tank and the fuel cock) is disconnected.
햲
352001
REED VALVE
REMOVAL
1. Remove:
• Side covers
2. Remove:
• Carburetor
Refer to section “CARBURETOR REMOVAL”.
5-11
REED VALVE CARB
3. Remove :
• Carburetor joint
• Reed valve assembly
322022
INSPECTION
1. Check :
• Carburetor joint
Damage/Cracks ➞ Replace.
• Reed valve
Wear/Cracks/Damage ➞ Replace.
*********************************************************
Reed valve inspection steps :
● Visually inspect the reed valve.
NOTE:
A reed valve in good condition should be com-
pletely or at least nearly flush with the valve seat.
● If in doubt, apply suction to the carburetor side

of the assembly.
● Leakage should be minimal to moderate.
*********************************************************
2. Measure:
• Valve stopper height Q
햲 Out of specification ➞ Replace valve stopper.
Valve stopper height:

4.0 ~ 4.4 mm (0.157 ~ 0.173 in)
322023
3. Measure:
• Reed valve clearance Q
Out of specification ➞ Replace reed valve.
햲
Reed valve clearance:
Less than 0.2 mm (0.008 in)
322024
5-12
REED VALVE CARB
INSTALLATION
To install the reed valve reverse the “REM-
OVAL” procedure. Note the following points.
1. Install:
• Gasket (new)
2. Tighten:
• Reed valve assembly bolts
Reed valve assembly bolts:

T.
R 9 Nm (0.9 m.kg, 6.5 ft.lb)
NOTE:
Tighten the screws crosswise in several steps to
prevent warpage of the read valve assembly and
the carburetor joint.
5-13
CHAS 6
CHAS
CHAPTER 6.
CHASSIS
FRONT WHEEL ............................................................................................. 6-1

REMOVAL ................................................................................................ 6-2
INSPECTION ........................................................................................... 6-2
INSTALLATION ....................................................................................... 6-3
FRONT BRAKE .............................................................................................. 6-4

BRAKE PAD REPLACEMENT ................................................................. 6-6
CALIPER DISASSEMBLY ....................................................................... 6-7
MASTER CYLINDER DISASSEMBLY ..................................................... 6-8
INSPECTION AND REPAIR .................................................................... 6-9
CALIPER ASSEMBLY ........................................................................... 6-10
MASTER CYLINDER ASSEMBLY ......................................................... 6-11
REAR WHEEL ............................................................................................. 6-13

REMOVAL .............................................................................................. 6-14
INSPECTION .........................................................................................6-14
ASSEMBLY ............................................................................................ 6-15
INSTALLATION ...................................................................................... 6-16
FRONT FORK .............................................................................................. 6-18

REMOVAL .............................................................................................. 6-19
DISASSEMBLY ...................................................................................... 6-20
INSPECTION .........................................................................................6-21
ASSEMBLY ............................................................................................ 6-21
INSTALLATION ...................................................................................... 6-22
STEERING HEAD AND HANDLEBAR ........................................................ 6-23

REMOVAL .............................................................................................. 6-24
INSPECTION .........................................................................................6-25
ASSEMBLY AND INSTALLATION ......................................................... 6-26
FRONT WHEEL
CHAS
CHASSIS
FRONT WHEEL
Q Axle Y Oil seal

W Speedometer gear U Collar
E Bearing I Axle nut
R Collar O Tire
T Valve P Front wheel
TIRE SIZE:
A
120/90-10
RIM RUNOUT
LIMIT:
B VERTICAL:
1,0 mm (0.040in)
LATERAL:
1,0 mm (0.040in)

LS

LS
340001(a)
6-1
FRONT WHEEL
CHAS
REMOVAL
1. Remove:
• Front caliper fixing bolts
• Front caliper
• Speedometer cable Q
• Axle W
• Front wheel
NOTE:
340003
Never depress the brake lever when the wheel
is off the scooter. Otherwise the brake pads will
be forced shut.
INSPECTION
1. Inspect:
• Front axle runout
Axle runout limit:

340006
0.25 mm (0.01 in)
WARNING
Do not attempt to straighten a bent axle.
2. Measure:
• Wheel runout
Rim runout limit:

Radial: 1.0 mm (0.040 in)
340007
Lateral: 1.0 mm (0.040 in)
3. Inspect:
• Tire
Wear/Cracks/Warpage ➞ Replace.
4. Inspect:
• Wheel bearings
Bearings allow play in the wheel hub or
wheel turns roughly ➞ Replace.
340008
5. Check:
• Speedometer gear Q
340004
6-2
FRONT WHEEL
CHAS
INSTALLATION
Reverse the “Removal” procedure.
1.Lubricate:
• Front wheel axle
• Bearings
• Oil seal (lips)
• Drive/driven gear (speedometer)
Lithium soap base grease
2. Install:
• Speedometer gear unit Q
NOTE:
Be sure that the two projections at the gear unit
mesh with the two slots on the wheel hub.
340004
3. Install:
• Front wheel Q

• Front caliper W
NOTE:
Be sure that the slot (torque stopper) of the gear
unit housing is positioned correctly.
346005
4.Tighten:
• Front wheel axle
• Front caliper mounting bolts
Front wheel axle:

T.
R 35 Nm (3.5 m • kg, 25.3 ft • lb)
Front caliper mounting bolts:
23 Nm (2.3 m • kg, 16.6 ft • lb)
WARNING
Make sure that the brake hoses are routed
properly.
6-3
FRONT BRAKE
CHAS
FRONT BRAKE
NOTE:
Q Brake disc U Pad spring Be sure to install the pads correctly.
W Bolt I Pad retainer
E Caliper O Brake pads
A PAD WEAR LIMIT:
R Piston P O. ring
B DISC WEAR LIMIT:
T Piston seals { Bolt
Y Air bleed screw } Mounting bolt
A 0,5 mm (0.02 in)

6 Nm (0,6 m.kg; 4 ft.lb)
B 3.2 mm (0.12 in)
21,5 Nm (2,15 m.kg; 16 ft.lb)

LT
23 Nm ( 2,3 m.kg; 17 ft.lb)

23 Nm ( 2,3 m.kg; 17 ft.lb)

LT
347009(a)
6-4
FRONT BRAKE
CHAS
MASTER CYLINDER DISASSEMBLY
NOTE:
Q Master cylinder U Bolt
Drain completely before removing the master
W Master cylinder piston ass'y I Brake hose
cylinder.
E Diaphragm O Bolt
R Master cylinder cap P Bolt
T Screw { Copper washer
Y Master cylinder bracket
3 Nm ( 0,3 m.kg; 2,17 ft.lb)

10,8 Nm (1,08 m.kg; 8 ft.lb)

BRAKE FLUID
A
DOT# 3 or DOT# 4
23 Nm (2,3 m.kg; 17 ft.lb)
23 Nm (2,3 m.kg; 17 ft.lb)

347007
6-5
FRONT BRAKE
CHAS
WARNING
• Disc brake components rarely require
disassembly. Do not disassemble
components unless absolutely necessary.
If any hydraulic connection is disconnected,
the entire system must be disassembled,
drained, cleaned, and then properly filled
and bled after reassembly. Do not use
solvents on internal brake component.
• Solvents will cause seals to swell and
distort. Use only clean brake fluid for
cleaning. Use care with brake fluid. Never
allow brake fluid to come in contact with
the eyes. Brake fluid can damage painted
surfaces and plastic parts.
BRAKE PAD REPLACEMENT

It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1. Remove:
• Pin Q
• Axle W

346005 2. Remove:
• Pad spring E
• Brake pads R
NOTE:
Replace the brake pads as a set when either one
is worn to the limit.
3.Measure:
• Brake pads
NOTE:
Replace the brake pad and spring as a set when
replacing the brake pads.
Wear limit @:
347003 0.5 mm (0.020 in)
6-6
FRONT BRAKE
CHAS
4. Install:
• Brake pads
• Pad spring
• Axle
• Pin
NOTE:
Be careful to install the brake pads correctly.
5.Lubricate:
• Mounting bolt (caliper body)
Lithium soap base grease
6.Install:
• Wheel axle
• Mounting bolt
Wheel axle:
T.
R 35 Nm (3.5 m • kg, 25.3 ft • lb)
Mounting bolt:
23 Nm (2.3 m • kg, 17 ft • lb)
LOCTITE ®
CALIPER DISASSEMBLY
NOTE:
Before disassembling the front brake caliper,
drain all brake fluid from the brake hose, master
cylinder, brake caliper and tank.
1.Remove:
• Union bolt Q
• Copper washers W
346005
NOTE:
Place the open end of the drain hose into a
container and pump out the remaining brake
fluid carefully.
2.Remove:
• Caliper body
• Caliper bracket
3. Remove:
• Piston
347004 • Piston seals Q
6-7
FRONT BRAKE
CHAS
*******************************************************
Removal steps :
● Blow compressed air into the hose joint opening
to force out the piston from the caliper body.
WARNING
• Never try to pry out the piston.
• Cover the piston with a rag. Use care so
346004 that the piston does not cause injury as it is
expelled from the cylinder.
● Remove the piston seals.

********************************************************
MASTER CYLINDER DISASSEMBLY

NOTE:
Before disassembling the front brake master
cylinder, drain all brake fluid from the brake
hose, master cylinder, brake caliper and reser-
voir tank.
1. Remove:
• Upper handlebar cover
2. Remove:
• Brake switch
• Brake lever
• Union bolt
NOTE:
Release the brake switch by pushing with a
screw driver into the hole on the lower side of the
brake lever and pull out the brake switch.
3. Remove:
• Master cylinder holder
• Master cylinder
6-8
FRONT BRAKE
CHAS
4. Remove:
• Master cylinder dust boot Q
• Master cylinder kit W

347008

Recommended brake component replacement
schedule:
Brake pads As required
Piston seal,
Every two years
Dust seal
Brake hoses Every four years
Brake fluid Replace only when

brakes are disassembled
WARNING
All internal parts should be cleaned in new
brake fluid only. Do not use solvents as they
will cause seals to swell and distort.
1. Inspect:
• Caliper piston Q
Scratches/Rust/Wear ➞ Replace caliper
assembly.
• Caliper body W
Wear/Scratches/Cracks/Damage ➞ Replace
caliper assembly.

WARNING
Replace the piston seals whenever the caliper
is disassembled.
347005
2. Inspect:
• Master cylinder
Wear/Scratches ➞ Replace the master
cylinder assembly.
• Master cylinder body/Diaphragm
Cracks/Damage ➞ Replace.
• Master cylinder kit
Scratches/Wear/Damage ➞ Replace as a set.
347006
6-9
FRONT BRAKE
CHAS
3. Check:
• Brake hose Q
Cracks/Wear/Damage ➞ Replace.

346014
4. Measure:
• Brake disc deflection
Out of specification ➞ Inspect wheel runout.
If wheel runout is good, replace the brake disc(s).
Maximum deflection:
0.25 mm (0.01 in)
347001
• Brake disc thickness
Minimum thickness:
3,2 mm (0.12 in)
Bolt (brake disc):

T.
R 23 Nm (2.3 m • kg, 17 ft • lb)
LOCTITE®
347002
CALIPER ASSEMBLY
WARNING
• All internal parts should be cleaned in new
brake fluid only.
• Internal parts should be lubricated with
clean brake fluid when installed.
DOT #3 or DOT #4
• Replace the piston seals whenever a caliper

is disassembled.

1. Install:
• Piston seals Q
• Caliper piston W
WARNING
346015 Always use new piston seals.
6-10
FRONT BRAKE
CHAS
2. Install:
• Brake caliper
Bolt (brake caliper):

T.
R 23 Nm (2.3 m • kg, 17 ft • lb)
3. Install:
• Caliper body Q
4. Install:
• Brake hose W
• Copper washers E
• Union bolt R

Union bolt:
T.
R 23 Nm (2.3 m • kg, 17 ft • lb)

346005
CAUTION:
When installing the brake hose to the caliper,
turn the brake pipe against the projection on
the caliper.
WARNING
• Proper hose routing is essential to insure
safe operation. Refer to “CABLE ROUTING”.
• Always use new copper washers.
MASTER CYLINDER ASSEMBLY
WARNING
• All internal parts should be cleaned in new
brake fluid only.
• Internal parts should be lubricated with
clean brake fluid when installed.

DOT #3 or DOT #5
6-11
FRONT BRAKE
CHAS
1. Install:
• Master cylinder Q

CAUTION:
• Tighten the upper bolt first, then the lower
bolt.
Bolt (master cylinder holder):

T.
9 Nm (0.9 m • kg, 6.5 ft • lb)

R
2. Install:
• Brake lever 2

NOTE:
Apply lithium soap base grease to the brake
lever pivot.
3. Install:
• Brake hose 3
• Copper washers 4
• Union bolts 5
• Brake switch 6
Union bolt:
T.
R 23 Nm (2.3 m • kg, 17 ft • lb)
WARNING
• Proper hose routing is essential to insure
safe operation. Refer to “CABLE ROUTING”
in CHAPTER 2.
• Always use new copper washers.
4. Check that the brake hose does not touch

other parts (throttle cable, wire harness, etc.)
when the handlebar is turned to the left or right.
Repair if necessary.
6-12
REAR WHEEL
CHAS
REAR WHEEL
Q Rear wheel ass’y U Brake shoe q Washer

W Tire I Spring w Nut
E Valve O Brake camshaft e Washer
R Axle P Brake camshaft lever
T Nut { Wear indicator
Y O-ring } Bolt
A TIRE SIZE:
105 Nm (10,5 Kg.m ; 76 ft.lb) 130/90-10
B DRUM BRAKE WEAR LIMIT:

110,5 mm (4.40 in)

C BRAKE LINING WEAR LIMIT:
2 mm (0.08 in)

D RIM RUNOUT LIMIT:
VERTICAL : 1,0 mm (0.04in)
LATERAL : 1,0 mm (0.04in)
E REPLACE BRAKE LININGS
AND SPRINGS AS A SET

LS
13 Nm (1,3 Kg.m ; 9.4 ft.lb)

12 Nm (1,2 Kg.m ; 8.67 ft.lb)
340005(a)
6-13
REAR WHEEL
CHAS
REMOVAL
1. Remove:
• Muffler ass’y
2. Loosen:
• Rear axle nut
NOTE:
Pull the rear brake to loosen the axle nut.
3. Remove:
• Rear wheel
4. Remove:
• Brake cable
• Brake shoes Q
• Plain washer W
346006
INSPECTION
1. Check:
• Rear wheel
Refer to the section “FRONT WHEEL
INSPECTION”.
2.Measure :
• Wheel runout
INSPECTION”.
Rim runout limits:

Radial : 1.0 mm (0.04 in)
Lateral : 1.0 mm (0.04 in)
340007
6-14
REAR WHEEL
CHAS
3. Check:
• Wheel bearings
INSPECTION”.
4. Check:
• Brake lining surface
Glazed spots ➞ Eliminate with sandpaper.
340008
NOTE:
After sanding the brake lining remove dust par-
ticles from the brake shoe with a clean cloth.
5. Measure:
• Brake lining thickness
a Out of specification ➞ Replace
Brake lining thickness:
4.0 mm (0.16 in)
Wear limit:
346007
2.0 mm (0.08 in)
6. Check:
• Brake drum inner surface
Oil/Scratches ➞ Repair.
a
7. Measure:
• Brake drum inside diameter @
Brake drum inside diameter:
110 mm ( 4.33 in)
346008
Wear limit:
110.5 mm (4.35 in)
ASSEMBLY

1. Install:
• Brake camshaft Q
NOTE:

346009 Apply lithium soap base grease onto the brake
camshaft Q and pin W.
CAUTION:
After installing the brake camshaft, remove
the excess of grease.
6-15
REAR WHEEL
CHAS
2. Install:
• Brake shoes Q
• Return spring W
NOTE:
The arrow mark E must point outwards.
CAUTION:
When installing the springs and the brake
346010
shoes, take care not to damage the springs
3. Install:
• Wear indicator Q
• Camshaft lever W

NOTE:
• Align the wear indicator tip Q with the line “A”
A as shown.
• Align the punch marks E.

346011
Bolt (camshaft lever):

T.
R 10 Nm (1.0 m • kg, 7.23 ft • lb)
4. Install:
• Plain washer Q
• Brake cable

346012
INSTALLATION
Reverse the REMOVAL procedure.
1. Clean:
• Rear wheel axle
2. Install:
• Rear wheel
• Plain washer Q

• Nut W
NOTE:
Make sure the splines on the wheel hub fit onto
the rear drive axle.
346013
6-16
REAR WHEEL
CHAS
Nut (rear wheel axle):

T.
R 105 Nm (10.5 m • kg, 76 ft • lb)
3. Install:
• Muffler
Bolt (exhaust pipe):

T.
R 9 Nm (0.9 m • kg, 6.5 ft • lb)
Bolt (muffler):
26 Nm (2.6 m • kg, 19 ft • lb)
4. Adjust:
• Rear brake lever free play.
Refer to the section “REAR BRAKE LEVER
FREE PLAY ADJUSTMENT” in CHAPTER 3.
6-17
FRONT FORK
CHAS
FRONT FORK
Q Steering bracket P Piston
W Bolt { Spring
E Circlip } Stopper
R Rubber cap q Washer
T Circlip w Bolt
Y Spring seat e Dust boot
U Circlip r Circlip
I Inner tube t Oil seal
O Spring y Outer fork tube
A FRONT FORK TUBE CAPACITY: T.R 22.5 Nm (2.25 m.kg)

75 cc ( 2.53 oz)
T.R 30 Nm (0.3 m.kg)
B FRONT FORK OIL GRADE:
ISO 6743 / 4-LHV 46

T.R 23 Nm (2,3 m.kg)
342012(a)
6-18
FRONT FORK
CHAS
REMOVAL
WARNING
Securely support the scooter with a stand
under the engine.
1. Place the scooter on an even surface.

2. Disconnect:
• Speedometer cable
3. Remove:
• Front wheel
Refer to section “FRONT WHEEL” in Chapter 6.
4. Remove:
• Front fender
Refer to section “COVERS - REMOVAL AND
INSTALLATION” in Chapter 3.
5. Remove:
• Steering head
Refer to section “STEERING HEAD AND
HANDLEBAR” in Chapter 6.
6. Remove:
• Nut Q
• Washer W

• Ring nut E

NOTE:
• Loosen the ring nut with the ring nut wrench R.

Ring nut wrench:
354003
T.
R 9079Q-02218
• Support the steering shaft to prevent it from

falling.
7. Remove:
• Front fork assembly
• Bearing balls
342000(a)

8. Remove:
• Circlips
9 Loosen
• Bolt W
10. Remove:
• Fork leg (complete)
342001
6-19
FRONT FORK
CHAS
DISASSEMBLY
1. Remove:
• Rubber plug Q
• Circlip W
• Spring seat E
• Spring 4
342014
2. Remove:
• Bolt Q
• Copper washer
NOTE:
To remove the drain bolt Q, use the T-handle W
and the holder E.
342010
T-handle for front fork:
90890-01326
Holder:
90890-01294
3. Remove:
• Inner fork tube Q
• Piston W
• Spring E
• Stopper 4

342015(a)
4. Remove:
• Dust boot Q
• Circlip W
• Oil seal E

342016
6-20
FRONT FORK
CHAS
INSPECTION
1. Check:
• Inner fork tube and fork components
• Outer fork tube
Wear/Scratches/Damage ➞ Replace.
WARNING
Never attempt to straighten a bent fork tube
as this may dangerously weaken the tube.
ASSEMBLY
Reverse the “DISASSEMBLY” procedure.
NOTE:
• When reassembling the front fork, make sure
you use following new parts:
• Oil seals
• Circlips and retainers
• Make sure that all components are clean be-
fore reassembling.
1. Install:
• Stopper
• Inner fork tube
• Spring
• Piston
NOTE:
Before installing the oil seal, apply lithium soap
grease onto the oil seal lips.
2. Install:
• Oil seal
• Circlip
• Dust boot
6-21
FRONT FORK
CHAS
3. Install:
• Copper washer
• Bolt
NOTE:
Tighten the drain bolt Q while holding the piston
with the T-handle W and holder E.
T-handle for front fork:

342010
90890-01326
Holder:
90890-01294
4. Fill:
• Fork oil
Fork oil type:

ISO 6743/4-LHV 46
Amount (per fork tube):
75 cc
5. Install:
• Spring
• Spring seat
• Circlip
• Rubber plug
INSTALLATION
1. Install:
• Left and right fork tube into the steering crown.
2.Install:
• Circlips 1
3. Install:
• Pinch bolts 2
Pinch bolt:
T.
R 30 Nm (3.0 m • kg; 21.7 ft • lb)

342001
6-22
STEERING HEAD AND HANDLEBAR
CHAS
Q Handlebar
W Nut
E Bolt
R Grip
T Throttle grip
Y Throttle cable
U Screw
I Brake cable
O Starter cable

354004(a)
6-23
CHAS
STEERING HEAD AND
HANDLEBAR
REMOVAL
WARNING
Securely support the scooter so there is no
danger of it falling over.
1. Place the scooter on an even surface.
2. Remove:
• Front fender
• Inner panels
• Upper handlebar cover
Refer to section “REMOVAL AND INSTALLATI-
ON OF COVERS” in Chapter 3.
3. Drain:
• Front brake system
Refer to section “FRONT BRAKE” in Chapter 6.
4. Remove:
• Front brake master cylinder
5. Remove:
• Front brake caliper mounting bolts
6. Remove:
• Front wheel
7. Remove:
• Rear brake cable
• Throttle grip
8. Disconnect:
• Ground wire
• All couplers
• Wire harness band
• Clamp
9. Remove:
• Nut Q
• Bolt
• Handlebar
354001 10. Remove:
• Ring nut
• Washer
6-24
CHAS
11. Remove:
• Upper bearing race Q
Steering head nut wrench:

9079Q-02218
• Steering shaft
• Bearing balls
354005
INSPECTION
1. Check:
• Handlebar Q
Bends/Cracks/Damage ➞ Replace.
2. Wash the bearing balls in solvent.

3. Check:
• Bearing races Q
• Bearing balls
354006
NOTE:
Always replace the bearing balls and the upper
and lower bearing races as a set.
*******************************************************
Bearing race replacement steps :

● Drive out the bearing race from the steering
tube by hitting on it in several places.
● Remove the bearing race on the steering shaft
with a hammer and a chisel Q as shown.
● Drive in the new bearing races evenly by
hitting on them in several places.
354007
6-25
CHAS
CAUTION:
• Unless installed correctly, the bearing races
will damage the frame.
• Never hit the bearing races on the ball
race surface.
*********************************************************
354008
4. Check:
• Steering shaft
Bend/Damage ➞ Replace.
WARNING
Never attempt to straighten a bent steering
shaft.
354009
ASSEMBLY AND INSTALLATION

Reverse the “REMOVAL” and “DISASSEMBLY”
procedure.
WARNING
Proper cable and hose routing is essential to
insure safe scooter operation. Refer to section
“CABLE ROUTING” in Chapter 2.
1. Install:
• Bearing balls
2. Apply:
• Bearing grease (onto upper and lower bearing
balls)
354010
3. Install:
• Steering shaft
• Bearing race (upper) Q

9079Q-02218
354003
6-26
CHAS
CAUTION:
Hold the steering shaft until it is securely
attached.

4. Install:
• Washer Q
• Steering shaft lock nut W
354002
NOTE:
Tighten the steering shaft lock nut with the Steer-
ing head nut wrench. Set the torque wrench to the
ring nut wrench so that they form a right angle.

9079Q-02218
Steering shaft ring nut:

T.
R 27.5 Nm (2.75 m.kg, 19.9 ft.lb)
5. Install:
• Handlebar Q
• Bolt W (new)
• Nut E (new)
NOTE:
• Install the handlebar onto the steering shaft
notch.
• Install the wire harness, the throttle cable, the
speedometer cable and the rear brake cable.

354011
6. Install:
• Throttle grip (complete)
• Master cylinder
• Brake hose (into the clip)
CAUTION:
• Before installing the handlebar, wipe off any
trace of oil from the inserted section of the
shaft with solvent.
• Insert the bolt from the left as shown.
Bolt (handlebar):
T.
R 60 Nm (6.0 m.kg, 43.3 ft.lb)
7. Install:
• Band
Refer to section “CABLE ROUTING” in Chapter 2.
6-27
ELEC 7
ELEC
CHAPTER 7.
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS ...................................................................... 7-1
CIRCUIT DIAGRAM ....................................................................................... 7-3
IGNITION AND STARTING SYSTEM ............................................................ 7-5

CIRCUIT DIAGRAM ................................................................................. 7-5
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM .................... 7-6
TROUBLESHOOTING ............................................................................. 7-7
CHARGING SYSTEM .................................................................................. 7-13

CIRCUIT DIAGRAM ............................................................................... 7-13
TROUBLESHOOTING ........................................................................... 7-14
LIGHTING SYSTEM .................................................................................... 7-16

CIRCUIT DIAGRAM ............................................................................... 7-16
SIGNAL SYSTEM ........................................................................................ 7-21

WIRING DIAGRAM ................................................................................ 7-21
ELEC
ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS BATTERY:
Q Wire harness SPECIFIC GRAVITY: 1.280
W Fuel sender IGNITION COIL
E Ignition coil Primary coil resistance:
R Starter relay 0.32 ~ 0.48 Ω at 20°C (68°F)
T Battery Secondary coil resistance:
Y CDI unit 5.68 ~ 8.52 Ω at 20°C (68°F)
U Oil sender
햵
햳
383002
7-1
ELEC
Q Main switch Starter motor coil resistance:
W Rectifier / Regulator 0.06 - 0.08 Ω at 20°C (68°F)
E Horn Brush wear limit:
R Flasher relay 0.9 mm (0.035 in)
Commutator diameter wear limit:
14.8 mm (0.582 in)
Commutator mica undercut:
1.15 mm (0.045 in)
햲
햵
383001
7-2
ELEC
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
2
O
1
0 BW B R Br Gy
B LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
YR
7 9
B
B R
5
} YR L G Y
OFF 6
8
LOW B
HI B LW
G {
Y
GY B
L L L
t
q w r
B B B B
A S
Br Br Br Br
J H
D
y
i
B
Ch BrW Dg
Gy
L
K G N
G Y P Gy
R
F
Ch Dg
e L o p u [ ] G
B B B B B B B B B
7-3
ELEC
CIRCUIT DIAGRAM
Q Spark plug y Flasher relay
W Ignition coil u Flasher indicator
E CDI magneto i "TURN" switch
R CDI unit o Rear flasher light (left)
T Rectifier/regulator p Front flasher light (left)
Y Starter motor [ Rear flasher light (right)
U Starter relay ] Front flasher light (right)
I Battery A Front stop switch
O Fuse S Rear stop switch
P Main switch D Horn
{ Starter switch F Horn switch
} "LIGHTS" switch G Oil level indicator
q Meter light H Oil level gauge
w Meter light J Fuel meter
e Headlight K Sender
r Position light L High beam indicator
t Tail/Stop light
COLOR CODE
B Black Y Yellow
Br Brown B/R Black/Red
Ch Chocolate B/W Black/White
Dg Dark green Br/W Brown/White
G Green Br/Y Brown/Yellow
Gy Grey G/B Green/Black
L Blue G/Y Green/Yellow
O Orange L/W Blue/White
P Pink W/R White/Red
R Red Y/B Yellow/Black
Sb Sky blue Y/R Yellow/Red
W White
7-4
ELEC
IGNITION AND STARTING SYSTEM
2
O
1
0 BW B R Br Gy
B LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
YR
7 9
B
R
B 5
} YR L G Y
OFF 6
8
LOW B
HI B LW
G {
Y
GY B
L L L
t
q w r
B B B B
A S
Br Br Br Br
J H
D
y
i
B
Ch BrW Dg
Gy
L
K G N
G Y P Gy
R
F
Ch Dg
e L o p u [ ] G
B B B B B B B B B
Q Spark plug R CDI unit I Battery { Starter switch
W Ignition coil Y Starter motor O Fuse A Front brake switch
E CDI Magneto U Starter Relay P Main switch S Rear brake switch
7-5
ELEC
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM
Q Spark plug } Main switch a Source coil
W Ignition coil t Front brake switch b Pickup coil
R CDI unit y Rear brake switch c Wave-shape shaping circuit
U Starter Motor d Condenser
I Starter relay e Diode
O Fuse f SCR
P Battery g To oil level switch
{ Starter switch
햵
O B/R
a
햳 d e
e e
f
c W/R b
e
d
B
햲 B B
햾 B/W
BW B R Br Gy
LOCK
OFF
CHECK
ON
햹 햺 B
R g
R
햸
M 햻
B
B
L/W
헃
Br
햽
G/Y 헄
B
: Current flow in ignition control circuit

: Current flow in starter motor control circuit
374001
7-6
ELEC
TROUBLESHOOTING
THE STARTING SYSTEM DOES NOT WORK

(NO SPARK OR IRREGULAR SPARKS).
NOTE:
• Remove the following parts before proceeding with the troubleshooting:
1) Side covers (left and right)
• For accurate troubleshooting use the following special tools:
Ignition checker: Pocket tester:

90890-06754 90890-03112
1.Spark plug
• Check the spark plug type.

• Check the condition of the spark plug.
• Check the spark plug gap.
Refer to “SPARK PLUG INSPECTION” in
Chapter 3. INCORRECT
BR8HS (NGK)
Spark plug gap: The spark plug is defective. Replace it or

0.5 ~ 0.7 mm (0.019 ~ 0.028 in) adjust the spark plug gap.
CORRECT
2.Spark check
• Remove the spark plug cap.

• Connect the ignition checker Q. 햲
햴
W Spark plug cap
E Spark
• Check the length of the spark gap.
• Start the engine and increase the spark 햳
length until the engine begins to misfire. 372000
Minimum spark gap:

6.0 mm (0.24 in) MEETS SPECIFICATION
OUT OF
SPECIFICATION
OR NO SPARK Ignition system in good condition.
7-7
ELEC
3.Spark plug cap resistance
• Disconnect the spark plug cap.

• Connect the pocket tester (Ω x 1 k) to the
spark plug cap.
• Check the resistance of the spark plug cap.
Spark plug cap resistance:

5kΩ at 20°C (68°F)
DOES NOT MEET

SPECIFICATION
372001
Replace the spark plug cap
MEETS
SPECIFICATION
4.Ignition coil resistance
• Disconnect the ignition coil leads.

• Connect the pocket tester (Ω x 1) to the
ignition coil.
Ignition coil :
Pocket tester (+) lead ➞ Orange
Pocket tester (-) lead ➞ Ground
372002
• Check the primary coil resistance.
Primary coil resistance:

0.32 ~ 0.48 Ω at 20°C (68°F)
• Connect the pocket tester (Ω x 1k) to the
ignition coil.
Pocket tester (+) lead ➞ Ground
Pocket tester (-) lead ➞ Spark plug lead
• Check the secondary coil resistance.
372003
Secondary coil resistance:
5.68 ~ 8.52 Ω at 20°C (68°F) DOES NOT MEET
SPECIFICATION
MEETS
SPECIFICATION
Defect. Replace the ignition coil.
7-8
ELEC
5.Pickup coil resistance

CDI
• Disconnect the pickup coil coupler.
MAGNETO
pickup coil. 햳
Pocket tester (+) lead Q ➞ White / Red
x Y/R w W/R B/R
Pocket tester (-) lead W ➞ Ground
• Check the pickup coil resistance. 햲
372004
Pickup coil resistance: DOES NOT MEET

400 ~ 600 Ω at 20°C (68°F) SPECIFICATION
MEETS
SPECIFICATION Pickup coil defect ➞ Replace.
6.Source coil resistance
• Disconnect the source coil coupler from the

CDI
wire harness. MAGNETO
source coil. 햳
Pocket tester (+) lead Q ➞ Black / Red x Y/R w W/R B/R
• Check the source coil resistance. 햲
372005
DOES NOT MEET

Source coil resistance:
MEETS
SPECIFICATION
Source coil defect ➞ Replace.
POOR CONNECTIONS
7.Connections
• Check all connections in the ignition sys-

tem.
Refer to “WIRING DIAGRAM”. Repair.
GOOD
CONNECTIONS
Replace the CDI unit.
7-9
ELEC
TROUBLESHOOTING
STARTER MOTOR DOES NOT WORK
NOTE:
2) Footrest boards
3) Front panel
4) Handlebar cover
Pocket tester:
90890-03112
1.Fuse
NO CONTINUITY
• Remove the fuse.
• Connect the pocket tester (Ω x 1) to the fuse.
• Check the fuse for continuity.
Defect ➞ Replace fuse.
CONTINUITY
2.Battery DOES NOT MEET

• Check the condition of the battery. SPECIFICATION
Refer to “BATTERY INSPECTION” in
CHAPTER 3.
Open circuit voltage: • Clean battery terminals.

12.8 V or more at à 20°C (68°F) • Charge or replace the battery.
MEETS
*
SPECIFICATION CAUTION:
• If the gauge of the jumper lead is smaller
3.Starter motor than that of the battery leads, the jumper
• Use a jumper lead E * to connect the (+) Q lead might melt or burn.
terminal of the battery to the starter motor • This test could cause sparks. Never
terminal W. perform it near a gas source or near
flammable products.
햴
햲
햳
DOES NOT WORK

M + -
372006
Starter defect ➞ Repair or replace.
• Check the starter motor operation.
WORKS
7-10
ELEC
4. Starter relay
• Disconnect the Blue/White lead from the

wire harness.
• Connect the (-) Q terminal of the battery to
the Blue/White lead.
M + -
DOES NOT WORK
햲
L/W Starter relay defect ➞ Replace.
372007
WORKS
5. Main switch
• Disconnect the main switch from the wire

harness.
• Check for continuity between Red Q and
Brown W.
BW B R Br Gy
LOCK
DOES NOT MEET
OFF SPECIFICATION
CHECK
ON
R B/W
Main switch defect ➞ Replace.
R Br Gy B
햲 햳 372008
MEETS
SPECIFICATION
6.Starter switch
• Disconnect the right handlebar switch cou-

pler from the wire harness.
• Check for continuity between Blue / White
Q and Black W.
7-11
ELEC
LW B
OFF DOES NOT MEET
ON
SPECIFICATION
햳 B YB L
LW YR LR
햲
Starter switch defect ➞ Replace right handle-
372009A 372009B bar switch.
MEETS
SPECIFICATION
POOR CONNECTIONS
7.Connections
Check all connections in the starter system.

Refer to “WIRING DIAGRAM”.
Repair.
7-12
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
WIRING DIAGRAM
2
O
1
0 BW B R Br Gy
B LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
YR
B 7 9
B R
5
} YR L G Y
OFF 6
LOW 8
B
HI B LW
G {
Y
GY B
L L L
t
q w r
B B B B
A S
Br Br Br Br
J H
D
y
i
B
Ch BrW Dg
Gy
L
K G N
G Y P Gy
R
F
Ch Dg
e L o p u [ ] G
B B B B B B B B B
E CDI magneto I Battery

T Rectifier / regulator O Fuse
7-13
ELEC
CHARGING SYSTEM
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED

NOTE:
1) Side covers (left and right) and foot rest board.
Inductive tachometer: Pocket tester:

90890-03113 90890-03112
1.Fuse (Main)

NO CONTINUITY
CONTINUITY
2.Battery
Fuse defect ➞ Replace.
• Check the condition of the battery.
CHAPTER 3.
DOES NOT MEET
Open circuit voltage: SPECIFICATION
12,8 V or more at 20°C (68°F)
• Clean battery terminals.

3.Charging voltage
• Charge or replace the battery.
• Connect the engine tachometer to the spark
plug lead.
• Connect the pocket tester (DC20V) to the
battery terminals.
Pocket tester (+) lead ➞ Battery (+) terminal
Pocket tester (-) lead ➞ Battery (-) terminal
• Start the engine and accelerate to about
5000 rpm. - +
• Check the charging voltage.
Charging voltage : 367001 372010
14 ~ 15 V at 5.000 tr/mn
NOTE: MEETS SPECIFICATION
Use a fully charged battery.
OUT OF
SPECIFICATION Charging circuit is OK.
7-14
ELEC
CHARGING SYSTEM
4.Charging coil resistance
• Disconnect the CDI magneto coupler from CDI

MAGNETO
the wire harness.
• Connect the pocket tester (Ω x 1) to the 햳
charging coil.
• Check the charging coil resistance x Y/R w W/R B/R
Tester (+) lead ➞ White Q 햲

Tester (–) lead ➞ Ground W 372015
OUT OF SPECIFICATION
Charging coil resistance:
0.48 ~ 0.72 Ω at 20°C (68°F)
MEETS
Charging coil defect ➞ Replace.
SPECIFICATION
POOR CONNECTIONS
5.Connections
Check all connections in the charging system.

Repair.
MEETS
SPECIFICATION
Replace the rectifier/regulator.
7-15
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM
2
O
1
0 BW B R Br Gy
B LOCK
OFF
CHECK
WR ON
4
BW
B
BR
B
W R R
3
YR
B 7 9
B R
5
} YR L G Y
OFF 6
LOW 8
B
HI B LW
G {
Y
GY B
L L L
t
q w r
B B B B
A S
Br Br Br Br
J H
D
y
i
B
Ch BrW Dg
Gy
L
K G N
G Y P Gy
R
F
Ch Dg
e L o p u [ ] G
B B B B B B B B B
E CDI magneto q Meter light e Headlight t Tail/Stop light

} “LIGHTS” switch w Meter light r Position light L “HIGH BEAM“ indicator light
7-16
ELEC
LIGHTING SYSTEM
TROUBLESHOOTING
THE AUXILIARY LIGHT, HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT,

TAILLIGHT OR METER LIGHT DO NOT WORK
NOTE:
Remove the following parts before proceeding with the troubleshooting:
• Handlebar covers
For accurate troubleshooting use the following special tools:
Pocket tester:
90890-03112
1. “LIGHTS” switch
YR L G Y
• Disconnect the right handlebar switch cou- OFF
pler from the wire harness. P0

ON
• Set the switch to “ ” .
• Check for continuity between
햴 햲
G YR LW
Yellow / Red Q and Blue W L Y B
Yellow / Red Q and Green 3 햳햵 372013(a)

372009A
• Then set the switch to “ ”.
• Check for continuity between: NO CONTINUITY
Yellow / Red Q and Blue W
Yellow / Red Q and Yellow 4
"Light" switch defect ➞ Replace.
CONTINUITY
7-17
ELEC
LIGHTING SYSTEM
2. Lighting coil resistance

CDI
• Disconnect the lighting coil coupler from the
MAGNETO
wire harness.
lighting coil.
• Check the lighting coil resistance x Y/R w W/R B/R
Tester (+) lead ➞ Yellow / Red Q 햲

Tester (-) lead ➞ Ground W 372036
Lighting coil resistance:
0.32 ~ 0.48Ω at 20°C (68°F)
MEETS
SPECIFICATION Lighting coil defect ➞ Replace.
3. Connections
• Check all connections in the lighting system. POOR CONNECTIONS

MEETS
SPECIFICATION Repair.
Circuit is in good condition.
7-18
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM INSPECTION
1. Headlight and headlight indicator do not work.
1. Bulb and socket

NO CONTINUITY
• Check the bulb and socket for continuity.
CONTINUITY Replace bulb or socket.
2. Voltage
• Connect the pocket tester (AC20V) to the

headlight coupler. 햲
햴
Headlight:
• “LO”: 햳
Pocket tester (+) lead ➞ Green Q
Pocket tester (-) lead ➞ Black E
• “HI”:
Pocket tester (+) lead ➞ Yellow W
• Headlight indicator: 햶
Pocket tester (+) lead ➞ Yellow R B B
Pocket tester (-) lead ➞ Black T Y Y 햵
• Set the main switch to “ON”.
• Start the engine.
• Switch from “HI” to “LO” and back.
372017(a)
• Check the voltage (12V) between the head-
light coupler leads. OUT OF SPECIFICATION
MEETS
SPECIFICATION
There is a defect in the wire harness between
Circuit is in good condition. the main switch and the headlight coupler
and/or between the main switch and the
2. The meter light does not work. headlight indicator coupler
➞ Repair.
1. Bulb and socket NO CONTINUITY
CONTINUITY
Replace bulb or socket.
7-19
ELEC
LIGHTING SYSTEM
2. Voltage
L Br Br L
• Connect the pocket tester (AC20V) to the Dg G G Dg 햲
Ch Gy Gy Ch
meter light coupler.
Pocket tester (+) lead ➞ Blue Q 햳
Pocket tester (-) lead ➞ Black W B B
• Set the main switch to “ON”. Y Y
372037(a)
light coupler leads “Blue” and “Black”. OUT OF SPECIFICATION
MEETS
SPECIFICATION
Circuit is in good condition. the main switch and the meter light coupler
➞ Repair.
3. The taillight does not work.

NO CONTINUITY
1. Bulb and socket

CONTINUITY
2. Voltage Dg 110
B 110
햲
• Connect the pocket tester (AC20V) to the L
250
taillight coupler.
GYL L GY L
GY GY 250
Pocket tester (+) lead ➞ Blue Q - B B - Dg

Ch
250
B
Pocket tester (-) lead ➞ Black W 햳 Ch Dg Dg Ch
B
• Set the main switch to “ON”. B

Ch
• Start the engine. 372019(a)
light coupler leads “Blue” and “Black”. OUT OF SPECIFICATION
MEETS
SPECIFICATION There is a defect in the wire harness between
the main switch and the taillight coupler ➞
Repair.
7-20
ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM
WIRING DIAGRAM
2
O
1
0 BW B R Br Gy
B LOCK
OFF
CHECK
WR ON
4
BW
BR B
B
W R R
3
YR
B 7 9
R
B 5
} YR L G Y
OFF 6
LOW 8
B
HI B LW
G {
Y
GY B
L L L
t
q w r
B B B B
A S
Br Br Br Br
J H
D
y
i
B
Ch BrW Dg
Gy
L
K G N
G Y P Gy
R
F
Ch Dg
e L o p u [ ] G
B B B B B B B B B
I Battery u Flasher indicator ] Front flasher light (right) G Oil level indicator
O Fuse i "TURN" switch A Front stop switch H Oil level gauge
0 Main switch o Rear flasher light (left) S Rear stop switch J Fuel meter
t Tail / Stop light p Front flasher light (left) D Horn K Sender
y Flasher relay [ Rear flasher light (right) F "HORN" switch
7-21
ELEC
SIGNAL SYSTEM
TROUBLESHOOTING
FLASHER LIGHTS, BRAKE LIGHT, “OIL” WARNING LIGHT DO NOT WORK

HORN DOES NOT SOUND
NOTE:
• Handlebar cover
Pocket tester:
90890-03112
1. Fuse
NO CONTINUITY
Refer to “FUSE INSPECTION” in Chapter 3. Fuse defect ➞ Replace.
CONTINUITY
2. Battery
DOES NOT MEET SPECIFICATION
CHAPTER 3.
Battery voltage: • Charge or replace the battery.
12.8 V or more at 20°C (68°F)
MEETS
SPECIFICATION
3. Main switch BW B R Br Gy
LOCK
• Disconnect the main switch from the wire OFF
harness. CHECK
• Turn the main switch to “✱”. ON
• Check for continuity between:

R B/W
Red Q and Grey E R Br Gy B
• Turn the main switch to “ON”. 햲 햳 햴 372040

Red Q and Brown W
MEETS
SPECIFICATION Main switch defect ➞ Replace.
7-22
ELEC
SIGNAL SYSTEM
4. Connections
POOR CONNECTIONS
• Check all connections in the signal system.
GOOD Repair.
CONNECTIONS
Check the condition of each circuit of the
signal system.
Refer to the section “SIGNAL SYSTEM
CHECK”.
SIGNAL SYSTEM CHECK

1. Horn does not sound
1. “HORN” switch
• Disconnect the handlebar switch (left) from

the wire harness.
Black Q and Pink W.
B P
OFF
ON
햳 NO CONTINUITY
Ch - P
B BrW Dg
햲
Horn switch is defect ➞ Replace.
372029(a)
CONTINUITY
2. Voltage

horn lead.
Pocket tester (+) lead ➞ Brown Q
Pocket tester (-) lead ➞ Ground W
• Turn the main switch to ON.
• Check for voltage (12V) between “Brown”
and the ground.
7-23
ELEC
SIGNAL SYSTEM
햲 Br P
Defect in the wire harness between the main

372025 switch and the horn ➞ Repair.
MEETS
SPECIFICATION
3. Horn
• Disconnect the “Pink” lead at the horn terminal.

• Ground the horn terminal Q with a jumper
lead.
• Set the main switch to ON.
Br
햲
HORN SOUNDS
372026 Horn in good condition.

HORN DOES
NOT SOUND
4. Voltage
Br P 햲
“Pink” lead.
Pocket tester (+) lead ➞ Pink Q
• Press the “HORN” switch. 372027
• Check the voltage (12V) between “Pink” and
ground. DOES NOT MEET SPECIFICATION
MEETS
SPECIFICATION
Horn is defect ➞ Replace.
Adjust the horn.
7-24
ELEC
SIGNAL SYSTEM
2. The brake light does not work.
1. Bulb and socket

NO CONTINUITY
CONTINUITY
2. Brake switch
• Disconnect the brake switch leads from the

wire harness.
Brown Q and Green / Yellow W
Br G/Y
ON (Pull in)
OFF (Free) NO CONTINUITY
Br G/Y
햲 햳 Brake switch is defect ➞ Replace.
372030
CONTINUITY
3. Voltage

socket.
Pocket tester (+) lead ➞ Green / Yellow Q
Pocket tester (-) lead ➞ Black W
• Turn the main switch to “ON”.
• Pull the brake lever.
• Check the voltage (12V) between “ Green /
Yellow” Q and “Black” W.
Dg 110
B 110
햲 L OUT OF SPECIFICATION
250
GY L L GY L
GY GY 250
- B B - Dg
Ch
250
B
햳 Ch Dg Dg Ch
B
B the main switch and the brake light socket
➞ Repair.
Ch
372019(a)
MEETS
SPECIFICATION
7-25
ELEC
SIGNAL SYSTEM
3. Flasher does not work
NO CONTINUITY
1. Bulb and socket
2. “TURN” switch

the wire harness.
• Check for continuity between :
Left side : Brown / White Q and Chocolate W
Right side : Brown / White Q and Dark green E
Ch BrW Dg
L
NO CONTINUITY
N
R
햳 Ch - P
햴 Left handlebar switch is defect ➞ Replace.
B BrW Dg
햲 372032(a)
CONTINUITY
3. Voltage

flasher relay.
• Check the voltage (12V) between the “Brown”
lead and the ground.
- Br/W Defect in the wire harness between the main

- Br
햲 switch and the flasher relay ➞ Repair.
372033
MEETS
SPECIFICATION
7-26
ELEC
SIGNAL SYSTEM
4. Voltage

flasher relay.
Pocket tester (+) lead ➞ Brown / White Q
• Check the voltage (12V) between Brown /
White and the ground.
- Br/W
Br
햲
-
Flasher relay defect ➞ Replace.
372034
MEETS
SPECIFICATION
5. Voltage

flasher connector.
Left flasher bulb:
Pocket tester (+) lead ➞ Chocolate Q
Right flasher bulb:
Pocket tester (+) lead ➞ Dark green W
• Set the “TURN” switch to “L”, then to “R”.
• Check the voltage (12V) between “Choco-
late” and the ground, then “Dark green “ and
the ground.
Dg 110 DOES NOT MEET SPECIFICATION

B 110
L
250
GY L L GY L
GY GY 250
- B B - Dg
Ch Defect in the wire harness between the main
250
B
Ch Dg Dg Ch
B switch and the flasher bulb socket ➞ Re-
햲 햳 B
pair.
Ch
372038(a)
MEETS
SPECIFICATION 7-27
ELEC
SIGNAL SYSTEM
This circuit is in good condition.
4. The “OIL” indicator light does not work.

CONTINUITY
2. Oil level switch
• Disconnect the oil level switch from the oil

tank.
• Connect the pocket tester (Ω x 1) to the oil
level switch.
Pocket tester (+) lead ➞ Terminal Q
Pocket tester (-) lead ➞ Terminal Q
• Check the switch for continuity.
Float Good Bad
position condition condition
HIGH X O X O
LOW O X X O
O : Continuity X : No continuity
햲 햳
B Replace oil level switch is defect.

372035
MEETS
SPECIFICATION
7-28
ELEC
SIGNAL SYSTEM
3. Voltage

bulb socket connector.
Pocket tester (+) lead ➞ Grey Q
• Check the voltage (12V) between “Grey” and
the ground.

L Br
Dg G
Ch Gy
햲
4. Connections
372039(a) • Check all connections in the signal system.

MEET
SPECIFICATION
7-29
TRBL
SHTG 8
TRBL
SHTG
CHAPTER 8.
TROUBLESHOOTING
STARTING FAILURE/ HARD STARTING ..................................................... 8-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

• Faulty flasher relay • Faulty battery
• Insufficient battery capacity (nearly discharged) • Faulty fuse
• Improper bulb • Faulty main and/or horn switch
• Faulty main and/or flasher switch • Improperly adjusted horn
• Faulty horn
• Broken wire harness
Flasher winks quicker
• Improper bulb
• Faulty flasher relay
8-7
CW50RS WIRING DIAGRAM Q Handlebar switch (right)
W "START" switch
E "LIGHT" switch
R Main switch
a T Ignition coil
Br 1 5
7 Y Spark plug
* 6
GY Br
3 4 U Rectifier / regulator
2 BW B Gy R Br 8 9
YR L G Y I Fuel lever sender
Br
* GY LW B OFF LOCK
OFF
GY
OFF
ON
LOW
HI CHECK YR B WR O Oil level gauge
ON
: B G P Rear flasher light (right)
B B B Dg BW
L Dg Dg Dg B
L Y B
YR B W R
B G { Tail /Stop light
R
G YR LW Br Gy B
Br Gy B
Or B
BG Br Gy
} Rear flasher light (left)
B G YR LW R Dg
K L L Y B
B
110
110
0 q Starter motor
Y
Br B Gy R BW
w Starter switch
J Y G B L LW YR
B
B
e Battery
H Gy (BLACK)
G
Dg
L Br Br L
L r Fuse
Ch Gy
t CDI unit
250
Dg G G Dg G
Ch Gy Gy Ch Br
Br L L L y CDI magneto
F G
B B
Y GY GYL L GY GY GY 250 {
B
Y Y
Dg
Ch
Dg
Ch
- B B -
Ch Dg Dg Ch
Dg
Ch
u Horn
250
D B
L
(GREEN)
B B B
i Handle switch (left)
S B
L
B
o "TURN" switch
p "HORN" switch
187.8 Y
A B [ Flasher relay
r B
G
Ch
} ] Front flasher light (left)
B B B B
BrW Dg B Ch P BR
LW GY
A Head light
] Ch Ch Ch Ch P Br W YR WR BR B Or BW
S Meter light
B BrW P WR R
Ch - Dg
Ch - P B Or
B R R B D Meter light
R B
BrW Br
B BrW Dg W YR
W YR B Or
LW
GY
R
R
F Fuel meter
Br BrW
B P Ch
BrW
Dg G Flasher indicator
u WR
12V 4AH
H Oil caution indicator
B P Ch BrW Dg
[ BR
OFF L
N
J "HIGH BEAM" indicator light
ON
R t e w q K Position light
p y
o
L Front flasher light (right)
i : Rear stop switch
a Front stop switch
COLORS CODE
B Black L Blue Y Yellow G/Y Green/Yellow
Br Brown O Orange B/R Black/Red L/W Blue/White
Ch Chocolate P Pink B/W Black/White W/R White/Red
Dg Dark green R red Br/W Brown/White Y/R Yellow/White
G Green Sb Sky blue Br/Y Brown/Yellow Y/R Yellow/Red
Gy Grey W White G/B Green/Black
CW50RS '00
5FX-ME2
SUPPLEMENTARY
SERVICE MANUAL
FOREWORD
This supplementary service manual has been prepared to introduce new service and data for the
CW50RS ('00). For complete service information procedures it is necessary to use this supplementary
service manual together with the following manual.
CW50RS ('99) SERVICE MANUAL : 5FX-ME1
CW50RS ('00)
SUPPLEMENTARY
SERVICE MANUAL
© 1999 by MBK INDUSTRIE
1st Edition, September 1999
All rights reserved. Any
reprinting or unauthorized use
without the written
permission of MBK INDUSTRIE
is expressly prohibited.
NOTICE
This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers
and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and
MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in
scooter repair technology. Without such knowledge, attempted repairs or service to this model may
render it unfit to use and/or unsafe.
MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and
significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and
MBK dealers and will, where applicable, appear in future editions of this manual.
DOCUMENTATION TECHNIQUE
MBK INDUSTRIE
PARTICULARY IMPORTANT INFORMATION

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

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

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

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

HOW TO USE THIS MANUAL
CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See «illustrated symbols).
1st title 1 This is a chapter with its symbol on the upper right of each page.
2nd title 2 This title appears on the upper of each page on the left of the chapter symbol.
(For the chapter «Periodic inspection and adjustment» the 3rd title appears.)
3rd title 3 This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particulary important procedure 4 is placed between a line of asterisks " * " with each step
preceded by " • ".
IMPORTANT FEATURES
• Data and a special tools are framed in a box preceded by a relevant symbol 5.
• An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data for an
alignement mark 7, the others being indicated by an alphabetical letter in a box 8.
• A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams are before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
Q W ILLUSTRATED SYMBOLS
GEN (REFER TO THE ILLUSTRATION)
SPEC
INFO
Illustrated symbols Q to W are designed as
E R thumb tabs to indicate the chapter’s number and
content.
INSP ENG
ADJ Q General information
W Specifications
T Y E Periodic inspection and adjustment
R Engine
CARB CHAS T Carburetion
Y Chassis
U I U Electrical
I Troubleshooting
TRBL
ELEC
SHTG
O P
Illustrated symbols O to e are used to identify
the specifications appearing in the text.
O Filling fluid
{ } P Lubricant
{ Special tool
T.
R
} Tightening
q Wear limit, clearance
w Engine speed
q w
e Ω, V, A
e Illustrated symbols r to [ in the exploded

diagram indicate grade of lubricant and location
of lubrication point.
r t y r Apply engine oil

t Apply gear oil
y Apply molybdenum disulfide oil
u Apply wheel bearing grease
i Apply lightweight lithium-soap base
u i o grease
o Apply molybdenum disulfide grease
p Apply locking agent (THREADLOCK ®)
[ Use new one
p [
CONTENTS
ELECTRICAL COMPONENTS ......................................................................... 1
CIRCUIT DIAGRAM .......................................................................................... 3
IGNITION AND STARTING SYSTEM ............................................................... 5

CIRCUIT DIAGRAM .................................................................................... 5
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM ....................... 6
TROUBLESHOOTING ................................................................................ 7
CHARGING SYSTEM ..................................................................................... 13

CIRCUIT DIAGRAM .................................................................................. 13
TROUBLESHOOTING .............................................................................. 14
LIGHTING SYSTEM ....................................................................................... 16

CIRCUIT DIAGRAM .................................................................................. 16
SIGNAL SYSTEM ........................................................................................... 21

WIRING DIAGRAM ................................................................................... 21
ELEC
ELECTRICAL COMPONENTS BATTERY:
Q Wire harness SPECIFIC GRAVITY: 1.280
W Fuel sender IGNITION COIL
E Ignition coil Primary coil resistance:
R Starter relay 0.32 ~ 0.48 Ω at 20°C (68°F)
T Battery Secondary coil resistance:
Y CDI unit 5.68 ~ 8.52 Ω at 20°C (68°F)
U Oil sender
햵
햳
383002
-1-
ELEC
Q Main switch Starter motor coil resistance:
W Rectifier / Regulator 0.06 - 0.08 Ω at 20°C (68°F)
E Horn Brush wear limit:
R Flasher relay 0.9 mm (0.035 in)
Commutator diameter wear limit:
14.8 mm (0.582 in)
Commutator mica undercut:
1.15 mm (0.045 in)
햲
햵
383001
-2-
ELEC
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R R
T Br Gy B B B
Gy Br R B BW
LOCK
OFF MAIN HARNESS STARTER MOTOR
CHECK R R
ON
BW BW BW
B Or
W YR -
Gy
Br
R
B
W YR -
B Or
BW
R R W B YR
LW GY R
W W BR BR
W E
R
I YR Q WR WR Or
Y
YR
O B
R
GY
RAR
R
R
LW B
Br R
M B
P
BAB
o U
Gy B
LW { YR
A B L
LW B YR LR LR/L L L LR
OFF OFF YR _ _ YR
ON ON LW B B LW
B L LR
Br
Br
Br
12V10W
y BrW
(BLACK) ]
t Br
Ch Gy (GREEN)
u i
Gy
Br
Dg G Y
[ L Br B P
BrW
B
}
L Br B
Dg G Y C D E
Ch BrW Dg
Ch Gy B P G LR Y Y Dg LR LR Dg Y
L
12V 1.2W
12V 1.2W
HI -
12V 1.2W
OFF -
N N
B BrW BrW B
12V 1.2W
ON LOW
K Dg R G Ch P P Ch G
GY
L
Ch
Dg
12V 1.2W
J B
M Ch r
Y
GY
Ch Dg
G
L
Y
Ch Dg Dg Ch
B B _ B
(GREEN) B _
G B
B G
12V
q Ch Dg
H
GY L L GY
35W / 35W B B F G
G B 12V
12V10W 12V10W 21W / 5W
p 12V10W 12V10W
w e
B
B B B B
-3-
ELEC
CIRCUIT DIAGRAM
Q C.D.I. magneto e Right front flasher
W C.D.I. unit r Taillight assembly
E Ignition coil F Left rear flasher
R Spark plug G Right rear flasher
T Main switch H Tail / Stop light
Y Fuse t Horn
U Battery y Flasher relay
I Rectifier / regulator u Front stop switch
O Starter relay i Rear stop switch
P Starter motor o Oil level gauge
{ Right handle switch p Fuel sender
A Starter switch [ Meter assembly
B Lighting switch J Meter light
} Left handle switch K Oil warning light
C "HORN" switch L Flasher indicator light
D "Hi / Lo" switch M High beam indicator light
E Flasher switch N Fuel meter
q Head light ] Position light
w Left front flasher
COLOR CODE
B Black Y Yellow
Br Brown B/R Black/Red
Ch Chocolate B/W Black/White
Dg Dark green Br/W Brown/White
G Green Br/Y Brown/Yellow
Gy Grey G/B Green/Black
L Blue G/Y Green/Yellow
O Orange L/R Blue/Red
P Pink L/W Blue/White
R Red W/R White/Red
Sb Sky blue Y/B Yellow/Black
W White Y/R Yellow/Red
-4-
ELEC
CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R R
T Br Gy B B B
Gy Br R B BW
LOCK
CHECK R R
ON
BW BW BW
B Or
W YR
Gy
Br
R
B
W YR -
B Or
BW
R R W B YR
LW GY R
W W BR BR
W E
R
I YR Q WR WR Or
YR
O B
R
GY
RAR
R
R
LW B
Br R
M B
P
BAB
o U
Gy B
LW { YR
A B L
OFF OFF YR YR
ON ON LW B B LW
B L LR
Br
Br
Br
12V10W
y BrW
(BLACK) ]
t Br
Ch Gy (GREEN)
u i
Gy
Br
Dg G Y
[ L Br B P
BrW
B
}
L Br B
Dg G Y C D E
Ch BrW Dg
L
12V 1.2W
12V 1.2W
HI -
12V 1.2W
OFF -
N N
B BrW BrW B
12V 1.2W
ON LOW
GY
L
Ch
Dg
12V 1.2W
J B
M Ch r
Y
GY
Ch Dg
G
L
Y
Ch Dg Dg Ch
B B _ B
(GREEN) B _
G B
B G
12V
q Ch Dg
H
GY L L GY
35W / 35W B B F G
G B 12V
12V10W 12V10W 21W / 5W
p 12V10W 12V10W
w e
B
B B B B
Q C.D.I. magneto Y Fuse { Right handle switch

W C.D.I. unit U Battery A Starter switch
E Ignition coil O Starter relay u Front stop switch
R Spark plug P Starter motor i Rear stop switch
T Main switch
-5-
ELEC
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM
Q Spark plug } Main switch a Source coil
W Ignition coil t Front brake switch b Pickup coil
R CDI unit y Rear brake switch c Wave-shape shaping circuit
U Starter Motor d Condenser
I Starter relay e Diode
O Fuse f SCR
P Battery g To oil level switch
{ Starter switch
햵
O B/R
a
햳 d e
e e
f
c W/R b
e
d
B
햲 B B
햾 B/W
BW B R Br Gy
LOCK
OFF
CHECK
ON
햹 햺 B
R g
R
햸
M 햻
B
B
L/W
헃
Br
햽
G/Y 헄
B
: Current flow in ignition control circuit

: Current flow in starter motor control circuit
374001
-6-
ELEC
TROUBLESHOOTING
THE STARTING SYSTEM DOES NOT WORK

(NO SPARK OR IRREGULAR SPARKS).
NOTE:
Ignition checker: Pocket tester:

90890-06754 90890-03112
1.Spark plug
• Check the spark plug type.

• Check the condition of the spark plug.
• Check the spark plug gap.
Refer to “SPARK PLUG INSPECTION” in
Chapter 3. INCORRECT
BR8HS (NGK)
Spark plug gap: The spark plug is defective. Replace it or

0.5 ~ 0.7 mm (0.019 ~ 0.028 in) adjust the spark plug gap.
CORRECT
2.Spark check
• Remove the spark plug cap.

• Connect the ignition checker Q. 햲
햴
W Spark plug cap
E Spark
• Check the length of the spark gap.
• Start the engine and increase the spark 햳
length until the engine begins to misfire. 372000
Minimum spark gap:

6.0 mm (0.24 in) MEETS SPECIFICATION
OUT OF
SPECIFICATION
OR NO SPARK Ignition system in good condition.
-7-
ELEC
3.Spark plug cap resistance
• Disconnect the spark plug cap.

• Connect the pocket tester (Ω x 1 k) to the
spark plug cap.
• Check the resistance of the spark plug cap.
Spark plug cap resistance:

5kΩ at 20°C (68°F)
DOES NOT MEET

SPECIFICATION
372001
Replace the spark plug cap
MEETS
SPECIFICATION
4.Ignition coil resistance
• Disconnect the ignition coil leads.

ignition coil.
Ignition coil :
Pocket tester (+) lead ➞ Orange
372002
• Check the primary coil resistance.
Primary coil resistance:

0.32 ~ 0.48 Ω at 20°C (68°F)
• Connect the pocket tester (Ω x 1k) to the
ignition coil.
Pocket tester (+) lead ➞ Ground
Pocket tester (-) lead ➞ Spark plug lead
• Check the secondary coil resistance.
372003
Secondary coil resistance:
5.68 ~ 8.52 Ω at 20°C (68°F) DOES NOT MEET
SPECIFICATION
MEETS
SPECIFICATION
Defect. Replace the ignition coil.
-8-
ELEC
5.Pickup coil resistance

CDI
• Disconnect the pickup coil coupler.
MAGNETO
pickup coil. 햳
Pocket tester (+) lead Q ➞ White / Red
x Y/R w W/R B/R
• Check the pickup coil resistance. 햲
372004
Pickup coil resistance: DOES NOT MEET

MEETS
SPECIFICATION Pickup coil defect ➞ Replace.
6.Source coil resistance
• Disconnect the source coil coupler from the

CDI
wire harness. MAGNETO
source coil. 햳
Pocket tester (+) lead Q ➞ Black / Red x Y/R w W/R B/R
• Check the source coil resistance. 햲
372005
DOES NOT MEET

Source coil resistance:
MEETS
SPECIFICATION
Source coil defect ➞ Replace.
POOR CONNECTIONS
7.Connections
• Check all connections in the ignition sys-

tem.
Refer to “WIRING DIAGRAM”. Repair.
GOOD
CONNECTIONS
Replace the CDI unit.
-9-
ELEC
TROUBLESHOOTING
STARTER MOTOR DOES NOT WORK
NOTE:
2) Footrest board
3) Front panel
4) Handlebar cover
Pocket tester:
90890-03112
1.Fuse
NO CONTINUITY
Defect ➞ Replace fuse.
CONTINUITY
2.Battery DOES NOT MEET

• Check the condition of the battery. SPECIFICATION
CHAPTER 3.
Open circuit voltage: • Clean battery terminals.

12.8 V or more at à 20°C (68°F) • Charge or replace the battery.
MEETS
*
SPECIFICATION CAUTION:
• If the gauge of the jumper lead is smaller
3.Starter motor than that of the battery leads, the jumper
• Use a jumper lead E * to connect the (+) Q lead might melt or burn.
terminal of the battery to the starter motor • This test could cause sparks. Never
terminal W. perform it near a gas source or near
flammable products.
햴
햲
햳
DOES NOT WORK

M + -
372006
Starter defect ➞ Repair or replace.
WORKS
-10-
ELEC
4. Starter relay
• Disconnect the Blue/White lead from the

wire harness.
• Connect the (-) Q terminal of the battery to
the Blue/White lead.
M + -
DOES NOT WORK
햲
L/W Starter relay defect ➞ Replace.
372007
WORKS
5. Main switch
• Disconnect the main switch from the wire

harness.
• Check for continuity between Red Q and
Brown W.
BW B R Br Gy
LOCK
DOES NOT MEET
OFF SPECIFICATION
CHECK
ON
R B/W
Main switch defect ➞ Replace.
R Br Gy B
햲 햳 372008
MEETS
SPECIFICATION
6.Starter switch
• Disconnect the right handlebar switch cou-

pler from the wire harness.
• Check for continuity between Blue / White
Q and Black W.
-11-
ELEC
LW B
OFF DOES NOT MEET
ON
SPECIFICATION
햳 B YB L
LW YR LR
햲
Starter switch defect ➞ Replace right handle-
372009A 372009B bar switch.
MEETS
SPECIFICATION
POOR CONNECTIONS
7.Connections
Check all connections in the starter system.

Repair.
-12-
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R R
T Br Gy B B B
Gy Br R B BW
LOCK
CHECK R R
ON
BW BW BW
B Or
W YR
Gy
Br
R
B
W YR -
B Or
BW
R R W B YR
LW GY R
W W BR BR
W E
R
I YR Q WR WR Or
YR
O B
R
GY
RAR
R
R
LW B
Br R
M B
P
BAB
o U
Gy B
LW { YR
A B L
OFF OFF YR YR
ON ON LW B B LW
B L LR
Br
Br
Br
12V10W
y BrW
(BLACK) ]
t Br
Ch Gy (GREEN)
u i
Gy
Br
Dg G Y
[ L Br B P
BrW
B
}
L Br B
Dg G Y C D E
Ch BrW Dg
L
12V 1.2W
12V 1.2W
HI -
12V 1.2W
OFF -
N N
B BrW BrW B
12V 1.2W
ON LOW
GY
L
Ch
Dg
12V 1.2W
J B
M Ch r
Y
GY
Ch Dg
G
L
Y
Ch Dg Dg Ch
B B _ B
(GREEN) B _
G B
B G
12V
q Ch Dg
H
GY L L GY
35W / 35W B B F G
G B 12V
12V10W 12V10W 21W / 5W
p 12V10W 12V10W
w e
B
B B B B
Q C.D.I. magneto
Y Fuse
U Battery
I Rectifier / regulator
-13-
ELEC
CHARGING SYSTEM
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED

NOTE:
1) Side covers (left and right) and footrest board.
Inductive tachometer: Pocket tester:

90890-03113 90890-03112
1.Fuse (Main)

NO CONTINUITY
CONTINUITY
2.Battery
Fuse defect ➞ Replace.
CHAPTER 3.
DOES NOT MEET
Open circuit voltage: SPECIFICATION
12,8 V or more at 20°C (68°F)

3.Charging voltage
• Charge or replace the battery.
• Connect the engine tachometer to the spark
plug lead.
battery terminals.
Pocket tester (+) lead ➞ Battery (+) terminal
Pocket tester (-) lead ➞ Battery (-) terminal
• Start the engine and accelerate to about
5000 rpm. - +
• Check the charging voltage.
Charging voltage : 367001 372010
14 ~ 15 V at 5.000 tr/mn
NOTE: MEETS SPECIFICATION
Use a fully charged battery.
OUT OF
SPECIFICATION Charging circuit is OK.
-14-
ELEC
CHARGING SYSTEM
4.Charging coil resistance
• Disconnect the CDI magneto coupler from CDI

MAGNETO
the wire harness.
charging coil.
• Check the charging coil resistance x Y/R w W/R B/R
Tester (+) lead ➞ White Q 햲

Tester (–) lead ➞ Ground W 372015
Charging coil resistance:
0.48 ~ 0.72 Ω at 20°C (68°F)
MEETS
Charging coil defect ➞ Replace.
SPECIFICATION
POOR CONNECTIONS
5.Connections
Check all connections in the charging system.

Repair.
MEETS
SPECIFICATION
Replace the rectifier/regulator.
-15-
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R R
T Br Gy B B B
Gy Br R B BW
LOCK
CHECK R R
ON
BW BW BW
B Or
W YR
Gy
Br
R
B
W YR -
B Or
BW
R R W B YR
LW GY R
W W BR BR
W E
R
I YR Q WR WR Or
YR
O B
R
GY
RAR
R
R
LW B
Br R
M B
P
BAB
o U
Gy B
LW { YR
A B L
OFF OFF YR YR
ON ON LW B B LW
B L LR
Br
Br
Br
12V10W
y BrW
(BLACK) ]
t Br
Ch Gy (GREEN)
u i
Gy
Br
Dg G Y
[ L Br B P
BrW
B
}
L Br B
Dg G Y C D E
Ch BrW Dg
L
12V 1.2W
12V 1.2W
HI -
12V 1.2W
OFF -
N N
B BrW BrW B
12V 1.2W
ON LOW
GY
L
Ch
Dg
12V 1.2W
J B
M Ch r
Y
GY
Ch Dg
G
L
Y
Ch Dg Dg Ch
B B _ B
(GREEN) B _
G B
B G
12V
q Ch Dg
H
GY L L GY
35W / 35W B B F G
G B 12V
12V10W 12V10W 21W / 5W
p 12V10W 12V10W
w e
B
B B B B
Q C.D.I. magneto r Taillight assembly

{ Right handle switch H Tail / Stop light
B Lighting switch [ Meter assembly
} Left handle switch J Meter light
D "Hi / Lo" switch M High beam indicator light
q Head light ] Position light
-16-
ELEC
LIGHTING SYSTEM
TROUBLESHOOTING
THE AUXILIARY LIGHT, HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT,

TAILLIGHT OR METER LIGHT DO NOT WORK
NOTE:
• Handlebar covers
Pocket tester:
90890-03112
YR LR
OFF
ON
1. “LIGHTS” switch
햳
L LR
• Disconnect the right handlebar switch cou- _ YR
pler from the wire harness. 햲
B LW
• Set the switch to “ ”.
372009A
• Check for continuity between
NO CONTINUITY
Yellow / Red Q and Blue / Red W
"Light" switch defect ➞ Replace.

CONTINUITY
G LR Y
2. “HI / LO” switch HI
• Disconnect the “HI / LO” switch coupler (left) LOW
from the wire harness.

• Set the switch to " ". 햲 햴
LR Dg Y
• Check for continuity between BrW - B
Blue / Red Q and Green W

P Ch G
햳
372009A
• Then set the switch to “ ”.
• Check for continuity between: NO CONTINUITY
Blue / Red Q and Yellow E
"HI / LO" switch defect ➞ Replace.

CONTINUITY
-17-
ELEC
LIGHTING SYSTEM
2. Lighting coil resistance

CDI
• Disconnect the lighting coil coupler from the
MAGNETO
wire harness.
lighting coil.
• Check the lighting coil resistance x Y/R w W/R B/R
Tester (+) lead ➞ Yellow / Red Q 햲

Tester (-) lead ➞ Ground W 372036
Lighting coil resistance:
0.32 ~ 0.48Ω at 20°C (68°F)
MEETS
SPECIFICATION Lighting coil defect ➞ Replace.
3. Connections
• Check all connections in the lighting system. POOR CONNECTIONS

MEETS
SPECIFICATION Repair.
-18-
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM INSPECTION
1. Headlight and headlight indicator do not work.
1. Bulb and socket

NO CONTINUITY
2. Voltage

headlight coupler. 햲
햴
Headlight:
• “LO”: 햳
Pocket tester (+) lead ➞ Green Q
• “HI”:
Pocket tester (+) lead ➞ Yellow W
• Headlight indicator: 햶
Pocket tester (+) lead ➞ Yellow R B B
Pocket tester (-) lead ➞ Black T Y Y 햵
• Set the main switch to "ON".
• Set the light switch to " ".
372017(a)
• Switch from "HI" to "LO" and back.
light coupler leads.
MEETS
the main switch and the headlight coupler
Circuit is in good condition. and/or between the main switch and the
headlight indicator coupler
➞ Repair.
2. The meter light does not work.
CONTINUITY
-19-
ELEC
LIGHTING SYSTEM
2. Voltage
L Br Br L
• Connect the pocket tester (AC20V) to the Dg G G Dg 햲
Ch Gy Gy Ch
meter light coupler.
Pocket tester (+) lead ➞ Blue Q 햳
Pocket tester (-) lead ➞ Black W B B
• Set the main switch to "ON". Y Y
372037(a)
• Check the voltage (12V) between the head- OUT OF SPECIFICATION
light coupler leads “Blue” and “Black”.
MEETS
the main switch and the meter light coupler
➞ Repair.
3. The taillight does not work.

NO CONTINUITY
1. Bulb and socket

CONTINUITY
2. Voltage 햲
GY

L
Ch Dg Dg Ch
_ B B _
taillight coupler. GY L L GY
Pocket tester (+) lead ➞ Blue Q 12V

21W / 5W
12V10W 12V10W
• Set the main switch to “ON”.
• Start the engine. 햳
B

• Check the voltage (12V) between the head- OUT OF SPECIFICATION
light coupler leads “Blue” and “Black”.
MEETS
SPECIFICATION
the main switch and the taillight coupler ➞
Circuit is in good condition. Repair.
-20-
ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM
A
(BLACK)
Br Gy B
R R
T Br Gy B B B
Gy Br R B BW
LOCK
CHECK R R
ON
BW BW BW
B Or
W YR
Gy
Br
R
B
W YR -
B Or
BW
R R W B YR
LW GY R
W W BR BR
W E
R
I YR Q WR WR Or
YR
O B
R
GY
RAR
R
R
LW B
Br R
M B
P
BAB
o U
Gy B
LW { YR
A B L
OFF OFF YR YR
ON ON LW B B LW
B L LR
Br
Br
Br
12V10W
y BrW
(BLACK) ]
t Br
Ch Gy (GREEN)
u i
Gy
Br
Dg G Y
[ L Br B P
BrW
B
}
L Br B
Dg G Y C D E
Ch BrW Dg
L
12V 1.2W
12V 1.2W
HI -
12V 1.2W
OFF -
N N
B BrW BrW B
12V 1.2W
ON LOW
GY
L
Ch
Dg
12V 1.2W
J B
M Ch r
Y
GY
Ch Dg
G
L
Y
Ch Dg Dg Ch
B B _ B
(GREEN) B _
G B
B G
12V
q Ch Dg
H
GY L L GY
35W / 35W B B F G
G B 12V
12V10W 12V10W 21W / 5W
p 12V10W 12V10W
w e
B
B B B B
T Main switch r Taillight assembly o Oil level gauge

Y Fuse F Left rear flasher p Fuel sender
U Battery G Right rear flasher [ Meter assembly
} Left handle switch H Tail / Stop light K Oil warning light
C "HORN" switch t Horn L Flasher indicator light
E Flasher switch y Flasher relay N Fuel meter
w Left front flasher u Front stop switch
e Right front flasher i Rear stop switch
-21-
ELEC
SIGNAL SYSTEM
TROUBLESHOOTING
FLASHER LIGHTS, BRAKE LIGHT, “OIL” WARNING LIGHT DO NOT WORK

HORN DOES NOT SOUND
NOTE:
• Handlebar cover
Pocket tester:
90890-03112
1. Fuse
NO CONTINUITY
Refer to “FUSE INSPECTION” in Chapter 3. Fuse defect ➞ Replace.
CONTINUITY
2. Battery
CHAPTER 3.
Battery voltage: • Charge or replace the battery.
12.8 V or more at 20°C (68°F)
MEETS
SPECIFICATION
3. Main switch BW B R Br Gy
LOCK
• Disconnect the main switch from the wire OFF
harness. CHECK
• Turn the main switch to “✱”. ON

R B/W
Red Q and Grey E R Br Gy B
• Turn the main switch to “ON”. 햲 햳 햴 372040

Red Q and Brown W
MEETS
SPECIFICATION Main switch defect ➞ Replace.
-22-
ELEC
SIGNAL SYSTEM
4. Connections
POOR CONNECTIONS
GOOD Repair.
CONNECTIONS
Check the condition of each circuit of the
signal system.
Refer to the section “SIGNAL SYSTEM
CHECK”.
SIGNAL SYSTEM CHECK

1. Horn does not sound
1. “HORN” switch

the wire harness.
Black Q and Pink W.
B P
OFF
ON
NO CONTINUITY
LR Dg Y
BrW - B
햲
P Ch G Horn switch is defect ➞ Replace.
햳
CONTINUITY
2. Voltage

horn lead.
• Check for voltage (12V) between “Brown”
and the ground.
-23-
ELEC
SIGNAL SYSTEM
햲 Br P
Defect in the wire harness between the main

372025 switch and the horn ➞ Repair.
MEETS
SPECIFICATION
3. Horn
• Disconnect the “Pink” lead at the horn terminal.

• Ground the horn terminal Q with a jumper
lead.
• Set the main switch to ON.
Br
햲
HORN SOUNDS
372026 Horn is in good condition.

HORN DOES
NOT SOUND
4. Voltage
Br P 햲
“Pink” lead.
Pocket tester (+) lead ➞ Pink Q
• Press the “HORN” switch. 372027
• Check the voltage (12V) between “Pink” and
ground. DOES NOT MEET SPECIFICATION
MEETS
SPECIFICATION
Horn is defect ➞ Replace.
Adjust the horn.
-24-
ELEC
SIGNAL SYSTEM
2. The brake light does not work.
1. Bulb and socket

NO CONTINUITY
CONTINUITY
2. Brake switch
• Disconnect the brake switch leads from the

wire harness.
Brown Q and Green / Yellow W
Br G/Y
ON (Pull in)
OFF (Free) NO CONTINUITY
Br G/Y
햲 햳 Brake switch is defect ➞ Replace.
372030
CONTINUITY
3. Voltage

socket.
Pocket tester (+) lead ➞ Green / Yellow Q
• Pull the brake lever.
• Check the voltage (12V) between “ Green /
Yellow” Q and “Black” W.
햲
GY
L
Ch Dg Dg Ch
_ B B _
GY L L GY
12V
12V10W 12V10W 21W / 5W

the main switch and the brake light socket
B
햳 ➞ Repair.
MEETS
SPECIFICATION
-25-
ELEC
SIGNAL SYSTEM
3. Flasher does not work
NO CONTINUITY
1. Bulb and socket
2. “TURN” switch

the wire harness.
• Check for continuity between :
Left side : Brown / White Q and Chocolate W
Right side : Brown / White Q and Dark green E
Ch BrW Dg
L
N
NO CONTINUITY
R
햴
햲
LR Dg Y
BrW - B Left handlebar switch is defect ➞ Replace.
P Ch G
CONTINUITY
3. Voltage

flasher relay.
• Check the voltage (12V) between the “Brown”
lead and the ground.
- Br/W Defect in the wire harness between the main

- Br
햲 switch and the flasher relay ➞ Repair.
372033
MEETS
SPECIFICATION
-26-
ELEC
SIGNAL SYSTEM
4. Voltage

flasher relay.
Pocket tester (+) lead ➞ Brown / White Q
• Check the voltage (12V) between Brown /
White and the ground.
- Br/W
Br
햲
-
Flasher relay defect ➞ Replace.
372034
MEETS
SPECIFICATION
5. Voltage
flasher connector.
Left flasher bulb:
Pocket tester (+) lead ➞ Chocolate Q
Pocket tester (-) lead ➞ Black W FRONT: 햲 햴
Ch Dg
Right flasher bulb: Ch Dg
햳 B
햵 B
Pocket tester (+) lead ➞ Dark green E
Pocket tester (-) lead ➞ Black R Ch Dg
B B
• Turn the main switch to "ON".

12V10W 12V10W
• Set the "TURN" switch to the left, then to the
right.
• Check the voltage (12V) between "Choco- B B
late" and "Black", then "Dark green" and

"Black".
REAR: 햴
Ch Dg
GY
L
Ch Dg Dg Ch
_ B B _
GY L L GY
햲 REAR: Defect in the wire harness between
12V10W 12V10W
12V
21W / 5W the main switch and the flasher bulb socket
햳 ➞ Repair.
FRONT: Defect in the wire harness be-
햵
B tween the main switch and the flasher bulb
coupler ➞ Repair.
MEETS
SPECIFICATION -27-
ELEC
SIGNAL SYSTEM
4. The “OIL” indicator light does not work.

CONTINUITY
2. Oil level switch
• Disconnect the oil level switch from the oil

tank.
• Connect the pocket tester (Ω x 1) to the oil
level switch.
Pocket tester (+) lead ➞ Terminal W
Pocket tester (-) lead ➞ Terminal Q
• Check the switch for continuity.
Float Good Bad
position condition condition
HIGH X O X O
LOW O X X O
O : Continuity X : No continuity
햲 햳
B Replace oil level switch is defect.

372035
MEETS
SPECIFICATION
-28-
ELEC
SIGNAL SYSTEM
3. Voltage

bulb socket connector.
Pocket tester (+) lead ➞ Grey Q
• Turn the main switch to "ON".
• Check the voltage (12V) between "Grey"
and "Black".
햲
(BLACK)
Ch Gy
(GREEN)
Dg G Y
Gy Br L
L Br B
햳
L Br B
Dg G Y
12V 1.2W
12V 1.2W
12V 1.2W
Ch Gy
12V 1.2W
Dg
4. Connections
12V 1.2W
Ch
Y
B
MEET
SPECIFICATION
-29-
Q C.D.I. magneto
CW50RS WIRING DIAGRAM (BLACK)
A
W C.D.I. unit
Br Gy B
R R E Ignition coil
T Br Gy B B B
R Spark plug
Gy Br R B BW
T Main switch
LOCK Y Fuse
R
U Battery
CHECK R
ON I Rectifier / regulator
BW BW BW O Starter relay
B Or
W YR - P Starter motor
Gy
Br
R
B
W YR - { Right handle switch
B Or
A Starter switch
BW
R R W B YR
B "Light" switch
LW GY R
W W BR BR
W E } Left handle switch
R
I YR Q WR WR Or
C "HORN" switch
Y
YR
O B D "Hi / Lo" switch
R
GY
RAR
R E Flasher switch
R
Br
LW
R B
q Head light
M w Left front flasher
B
e Right front flasher
P
BAB
o U r Taillight assembly
F Left rear flasher
G Right rear flasher
Gy B
H Tail / Stop light
LW { YR t Horn
y Flasher relay
A B L
u Front stop switch
OFF OFF YR _ _ YR i Rear stop switch
ON ON LW B B LW o Oil level gauge
p Fuel sender
B L LR
COLOR CODE [ Meter assembly
Br J Meter light
B Black
K Oil warning light
Br
Br Brown
Br
L Flasher indicator light
Ch Chocolate M High beam indicator light
Dg Dark green
12V10W
y BrW
(BLACK) ] N Fuel meter
G Green t Br
] Position light
Ch Gy (GREEN)
u i
Gy
Br
Gy Grey
L
Dg G Y
L Blue [ L Br B P
BrW
B
Or Orange
}
L Br B
P Pink Dg G Y C D E
Ch BrW Dg
Ch Gy
R Red B P G LR Y
L Y Dg LR LR Dg Y
12V 1.2W
12V 1.2W
HI -
12V 1.2W
OFF -
W White N N
B BrW BrW B
12V 1.2W
ON LOW
GY
Y Yellow L
Ch
Dg
B/R Black/Red
12V 1.2W
J B
B/W Black/White M Ch r
Y
Br/W Brown/White
GY
Ch Dg
G
L
Y
Ch Dg Dg Ch
G/Y Green/Yellow (GREEN) B B _ B B _
L/R Blue/Red B G
G B
q Ch Dg
GY L L GY
L/W Blue/White 12V

35W / 35W B B F G H
G B 12V
W/R White/Red 12V10W 12V10W 21W / 5W
Y/R Yellow/Red p 12V10W 12V10W
w e
B
B B B B

Service Manual BWS NG 1998

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual BWS NG 1998

Uploaded by

Copyright:

Available Formats

CW50RS '98

PARTICULARY IMPORTANT INFORMATION

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

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

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

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

e Illustrated symbols r to [ in the exploded

r t y r Apply engine oil

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

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

SPECIAL TOOLS ........................................................................................... 1-3

ENGINE SERIAL NUMBER

GASKETS, OIL SEALS, AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

FOR ENGINE SERVICE

Crankcase separating tool Flywheel holding tool

Crankshaft installing tool set Clutch serving nut wrench

Sheave holder Clutch spring holder

FOR CHASSIS SERVICE

T-HANDLE Damper rod holder

Oil seal guide Oil seal guide adapter

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

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

CABLE ROUTING ........................................................................................ 2-10

Tire pressure (cold tire):

Piston clearance 0.034 ~ 0.047 mm (0.001 ~ 0.002 in)

Crank width “A” 37.90 ~ 37.95 mm (1.492 ~ 1.494 in)

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

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............................ 3-1

COVERS ........................................................................................................ 3-3

HANDLEBAR COVERS ................................................................................. 3-7

ENGINE ......................................................................................................... 3-9

CHASSIS ..................................................................................................... 3-16

ELECTRICAL ............................................................................................... 3-23

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Spark plug* Check condition. Clean or replace if necessary.

Air filter Clean. Replace if necessary.

Carburetor* Check idle speed/starter operation. Adjust if neces-

Transmission oil* Check oil leakage. Correct if necessary. RE-

Autolube pump * Check operation.

Front brake* See NOTE. Correct if necessary. Air bleeding.

Rear brake* Check operation. Adjust if necessary.

Wheels* Check balance/runout. Repair if necessary.

Wheel bearings* Check bearing assembly for looseness /damage.

Steering bearings* Check bearing assembly for looseness. Correct if

Rear shock absorber* Check operation/oil leakage. Repair if necessary.

V-belt* Check damage and wear. Replace if necessary.

Fittings/Fasteners* Check all chassis fittings and fasteners.

Centerstand* Correct if necessary. Check operation. Repair if

Battery * Check specific gravity. Check breather hose for

*: It is recommended that these items be serviced by a MBK or a Yamaha dealer.

Pilot air screw position:

3. Start the engine and let it warm up for several

Turning left Idling speed increased.

Turning left Idling speed increased.

Turning right Idling speed decreased.

• Tighten the locknuts.

Standard spark plug:

Spark plug gap @:

● Start the engine.

Q “OIL” indicator light

OIL LEVEL AND GAUGE CHECK

Turn main switch