Yamaha XF50W Service Manual
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Yamaha XF50W Service Manual

Yamaha xf50w scooter service manual
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©YAMAHA
XF50W

SERVICE MANUAL

LIT-11616-20-58
3B3-F8197-10

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Summary of Contents for Yamaha XF50W

  • Page 1: Service Manual

    ©YAMAHA XF50W SERVICE MANUAL LIT-11616-20-58 3B3-F8197-10...
  • Page 2 EAS00000 XF50W 2006 SERVICE MANUAL ©2006 by Yamaha Motor Taiwan Co., Ltd. First edition, September 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd. is expressly prohibited. Printed in U.S.A.

  • Page 3: Info

    EAS00002 NOTICE This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4 EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 5 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. Symbols 1 to 9 indicate the subject of each chapter. i g l General information CHAS (3^3^) Specifications ADJ I ^ < \ Periodic checks and adjustments Chassis Engine Cooling system COOL j K...
  • Page 6 EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO 0 » SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM ELECTRICAL SYSTEM ELEC TROUBLESHOOTING SHTG...

  • Page 7: Table Of Contents

    j y * INFO \<^® CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER MODEL LABEL FEATURES OUTLINE OF THE FI SYSTEM FI SYSTEM IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS EQUIPMENT PREPARATION...

  • Page 8: Scooter Identification

    SCOOTER IDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL LABEL The model label 1 is affixed to the frame trunk. This information will be needed to order spare parts.

  • Page 9: Features

    FEATURES EAS00896 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 10: Fi System

    FEATURES EAS00897 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kg/cm , 35.6 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 11: Important Information

    IMPORTANT INFORMATION EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISAS- SEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together.

  • Page 12: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the...

  • Page 13: Equipment Preparation

    IMPORTANT INFORMATION INFO EAS00021 EQUIPMENT PREPARATION Push Rivet (Push type) Assembly status of the push rivet(push type). Dissembling 1. Press center p i n 1 inward to release the lock. <D 2. Remove the push rivet main body2. Assembling 1. Restore the center pin, replace the push rivet main body.

  • Page 14: Checking The Connections

    CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8lead 8coupler 8connector 2. Check: • lead • coupler • connector Moisture -» Dry with an air blower. Rust/stains -» Connect and disconnect several times.

  • Page 15: Special Tools

    SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 16 SPECIAL TOOLS Tool NO. Tool name / Function Illustration 90890-01384 Oil seal guide YM-33299 This tool is used for protecting the oil seal lip when installing the secondary sliding sheave. 90890-01403 Steering nut wrench YU-A9472 This tool is used to loosen and tighten the steering ring nut.
  • Page 17 SPECIAL TOOLS Tool NO. Tool name / Function Illustration 90890-03141 Timing light YU-03141 This tool is used to check the ignition tim- ing. 90890-03182 FI diagnostic tool YU-03182 Execute CO adjustment, confirm fault Code, self diagnosis tool 90890-04101 Valve lapper This tool is needed to remove and install the valve lifters.
  • Page 18 SPECIAL TOOLS INFO Tool NO. Tool name / Function Illustration 90890-01326 T-handle1 YM-01326 Damper rid holder2 These tools are used to hold the damper rod 90890-01294 when removing or installing the damper rod. YM-01300-1 © 90890-03153 Pressure gauge YU-03153 This tool is used to measure fuel pressure. Fuel pressure adapter 90890-03181 This tool is used to measure fuel pressure.
  • Page 19 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS CHASSIS SPECIFICATIONS 2-12 ELECTRICAL SPECIFICATIONS 2-15 CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICA- TIONS 2-18 TIGHTENING TORQUES 2-19 ENGINE 2-19 CHASSIS 2-21 LUBRICATION POINTS AND LUBRICANT TYPES 2-23 ENGINE 2-23 CHASSIS 2-25 COOLING SYSTEM DIAGRAMS 2-26 CABLE ROUTING...

  • Page 20: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 3B32(USA) … 3B33(CAN) … Dimensions Overall length 1905mm(75.00in) … Overall width 685mm(26.97in) … … Overall height 1045mm(41.14in) … Seat height 735mm(28.94in) Wheelbase 1280mm(50.39in) … Minimum ground clearance 115mm(4.53in) … …...

  • Page 21: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Standard Limit Item Engine Engine type Liquid-cooled, 4-stroke, SOHC … Displacement 0.049L(49cm³, 2.99cu-in) … Cylinder arrangement Forward inclined single cylinder … 38.0×43.5mm(1.496×1.713in) … Bore×stroke Compression ratio 12:1 … Engine idle speed 2000~2200r/min … Vacuum pressure at engine idle speed 34.7kPa(260mmHg,10.24inHg) …...
  • Page 22 SPEC ENGINE SPECIFICATIONS Standard Limit Item Oil pump Oil pump type Trochoid … Inner rotor to outer rotor tip clearance 0.15mm(0.006in) or less 0.23mm (0.009in) Outer rotor to pump housing clearance 0.13~0.18mm(0.005~0.007in) 0.25mm (0.010in) Oil pump housing to inner rotor and 0.07~0.12mm(0.003~0.005in) 0.19mm outer rotor clearance...
  • Page 23 SPEC ENGINE SPECIFICATIONS Standard Limit Item Camshaft Drive system Chain drive(left) … Intake camshaft lobe dimensions Measurement A 30.158~30.258mm 30.058mm (1.1873~1.1913in) (1.1834in) Measurement B 25.082~25.182mm 24.982mm (0.9875~0.9914in) (0.9835in) Exhaust camshaft lobe dimensions •^ • Measurement A 30.158~30.258mm 30.058mm (1.1873~1.1913in) (1.1834in) Measurement B 25.020~25.120mm 24.920mm...
  • Page 24 SPEC ENGINE SPECIFICATIONS Standard Limit Item Timing chain Model/number of links Morse 92RH2005/82 … Tensioning system Automatic … Valve, valve seats, valve guides Valve clearance(cold) Intake 0.10~0.16mm … (0.0039~0.0063in) Exhaust 0.18~0.24mm … (0.0071~0.0094in) Valve dimensions \ . \ . C Head Diameter Face Width Seat Width...
  • Page 25 SPEC ENGINE SPECIFICATIONS Standard Limit Item Valve stem to valve guide clearance Intake 0.010~0.037mm 0.080mm (0.0004~0.0015in) (0.0031in) Exhaust 0.025~0.052mm 0.100mm (0.0010~0.0020in) (0.0039in) 0.010mm Valve stem runout … (0.0004in) / / / / / / / / / / / / / / / / / / / / / Valve seat width Intake 0.9~1.1mm...
  • Page 26 SPEC ENGINE SPECIFICATIONS Standard Limit Item Valve springs Free length Intake 39.35mm(1.5492in) 37.38mm (1.4717in) Exhaust 41.57mm(1.6366in) 39.49mm (1.5547in) Installed length(valve closed) Intake 28.0mm(1.1024in) … Exhaust 30.0mm(1.1811in) … Compressed spring force(installed) Intake 91.1~104.9N … (9.3~10.7kg, 20.48~23.58lb) Exhaust 107.9~124.1N … (11.0~12.7kg, 24.26~27.90lb) Spring tilt —...
  • Page 27 SPEC ENGINE SPECIFICATIONS Standard Limit Item Piston Piston-to-cylinder clearance 0.010~0.035mm 0.150mm (0.0004~0.0014in) (0.0059in) Diameter D 37.975~37.990mm … (1.4951~1.4957in) "X. -D— Height H 5.0mm(0.1969in) … Piston pin bore(in the piston) Diameter 10.002~10.013mm 10.043mm (0.3938~0.3942in) (0.3954in) 0.35~0.65mm … Offset (0.0138~0.0256in) Intake side Offset direction …...
  • Page 28 SPEC ENGINE SPECIFICATIONS Standard Limit Item Oil ring Dimensions(B×T) 1.5×1.6mm … (0.0591×0.0630in) End gap(installed) 0.2~0.7mm … (0.0079~0.0276in) Ring side clearance 0.03~0.15mm … (0.0012~0.0059in)
  • Page 29 SPEC ENGINE SPECIFICATIONS Standard Limit Item Rocker arm/rocker arm shaft 10.000~10.015mm 10.030mm Rocker arm inside diameter (0.3937~0.3943in) (0.3949in) 9.981~9.991mm 9.950mm Rocker arm shaft outside diameter (0.3930~0.3933in) (0.3917in) 0.009~0.034mm … Arm-to-shaft clearance (0.0004~0.0013in) Connecting rod Connecting rod length 79.95~80.05mm … (3.1476~3.1516in) Small end inside diameter 10.015~10.028mm …...
  • Page 30 SPEC ENGINE SPECIFICATIONS Standard Limit Item Clutch Clutch type Automatic centrifugal … Clutch shoe thickness 3.7mm(0.146in) 2.0mm (0.079in) Clutch shoe spring free length 30.1mm(1.185in) … Clutch housing inside diameter 107mm(4.213in) 107.5mm (4.232in) Compression spring free length 76.4mm(3.008in) … Weight outside diameter 15.0mm(0.591in) 14.5mm (0.571in)

  • Page 31: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Standard Item Limit Frame Frame type Steel tube backbone … Caster angle … 26° Trail … 84mm(3.31in) Front wheel Wheel type Cast wheel … Size … J10×MT3.00 Material Aluminum … Wheel travel 58mm(2.28in) … Wheel runout Maximum radial wheel runout …...
  • Page 32 SPEC CHASSIS SPECIFICATIONS Standard Limit Item Rear tire Tire type Tubeless … Size 120/90-10 57J … Model(manufacturer) C-6022(CHENG SHIN) … Tire pressure(cold) 0~175kg(0~386lb) 175kPa(1.75kgf/cm², 25psi) … Minimum tire tread depth … 0.8mm (0.03in) Front brake Brake type Drum brake … Operation Right-hand operation …...
  • Page 33 SPEC CHASSIS SPECIFICATIONS Standard Limit Item Steering system Steering bearing type Angular bearing … Lock-to-lock angle(left) … 46° Lock-to-lock angle(right) … 46° Rear suspension Suspension type Unit swing … Rear shock absorber assembly type Coil spring … Rear shock absorber assembly travel 45mm(1.77in) …...

  • Page 34: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Standard Limit Item System voltage … Ignition system Ignition system type Transistorized coil ignition … Ignition timing 5° BTDC at 2000~2200r/min … Advancer type Digita … Crankshaft position sensor resistance/color 248~372 at 20°C(68°F)/ … white/red-white/blue Ignition coil Model(manufacturer) 3B3 00(T-MORIC)
  • Page 35 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Bulbs(voltage/wattage×quantity) Headlight 12V 35/35W×1 … Tail/brake light 12V 5/21W×1 … 12V 10W×2 … Front turn signal light 12V 10W×2 … Rear turn signal light License plate light 12V 5W×1 … Speedometer light 12V 1.7W×1 …...
  • Page 36 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Fuse(amperage×quantity) Main fuse 15A×1 … Fuel gauge Model(manufacturer) 3B3(AISAN) … Sender unit resistance-full 4~10Q … Sender unit resistance-empty 90~100£2 … Starting circuit cut-off relay Model(manufacturer) 4HC1(MATSU SHITA) … Coil resistance 72~88 … Diode … Radiator fan Model(manufacturer) 5ST1(LUNTAI)

  • Page 37: Torque Specifications

    CONVERTION TABLE / GENERAL TIGHTENING SPEC TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.

  • Page 38: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE Tightening Thread Thread ’ ’ Part to be tightened Part to be tightened Part name Part name torque Remarks Remarks size size m»kg ft»lb Exhaust pipe stud bolt Oil check bolt Cylinder head cover Bolt Cylinder head and cylinder —4\\4jl...
  • Page 39 SPEC TIGHTENING TORQUES Tightening Thread Thread ’ ’ Part to be tightened Part to be tightened Part name Part name torque Remarks Remarks size size m»kg ft»lb Drain bolt(engine oil) 2.3 16.6 Centerstand spring Hook Starter clutch 9.0 65.1 Left-hand thread Kickstarter Bolt Primary fixed sheave...

  • Page 40: Chassis

    SPEC 0*" TIGHTENING TORQUES CHASSIS Tightening Thread Thread Part to be tightened Part to be tightened torque Remarks Remarks size size m»kg ft»lb Frame and engine bracket3 33.1 Engine bracket3 and engine 42.0 Handlebar bracket and steering shaft 43.4 Rear shock absorber and frame 21.7 Rear shock absorber and engine 11.6...
  • Page 41 SPEC TIGHTENING TORQUES NOTE : 1. First,tighten the upper bearing inner race approximately 7Nm(0.7m»kg, 5.1ft»lb) by using the torque wrench and check turn steering shaft smoothly. 2. Second,hold the upper bearing inner race and tighten the ring nut 30Nm(3.0m»kg, 21.7ft»lb) by using the torque wrench.

  • Page 42: Lubrication Points And Lubricant Types

    SPEC 0 * LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant ^^TLS^P^L Oil seal lips O-rings(except V-belt drive unit) ^ ^ L S ^ ^ A O-ring(fuel injector assembly) ~~^\4Jl Cylinder head tightening nut mounting surface ~~^%4Jl Cylinder head stud bolt thread ~ ^ l 4...
  • Page 43 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Lubricant Drive axle taper rollor bearing —HI^GJ ^HICGJ Transmission bearings ® Secondary fixed sheave inner surface BEL-RAY asembly lube ® Secondary sliding sheave torque cam ditch BEL-RAY asembly lube Crankcase mating surfaces Sealant 2-24...

  • Page 44: Chassis

    SPEC 0*" LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Lubricant ^^LSp^L Front wheel oil seal lips ^^LSp^L Steering bearing and bearing races(upper and lower) Frame head pipe dust seal lips(lower) ^ ^ T L S ^ ^ ^ L Tube guide(throttle grip) inner surface ^ L S ^ ^ A ^^LSpn...

  • Page 45: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS EAS00033 Insert until contacting with the latch of ra- COOLING SYSTEM DIAGRAMS diator tank. Raidator cap Install white paint marck of pipe 3 toward Coolant reservoir hose the direction of radiator cover. Radiator inlet hose Install clip for the turning knob to face for- Air bleed bolt ward.
  • Page 46 SPEC COOLING SYSTEM DIAGRAMS Radiator Install clip for the turning knob to face down- Radiator inlet hose ward. Radiator outlet hose Thermostat Water pump outlet hose 2-27...
  • Page 47 SPEC COOLING SYSTEM DIAGRAMS Thermostat assembly inlet breather hose Install the paint mark of hose facing up. Breather hose Install clip for the turning knob to face down- Water pump outlet hose ward. Radiator outlet hose Make sure that hose is inserted to the bot- Water pump tom.

  • Page 48: Cable Routing

    SPEC CABLE ROUTING EAS00035 Battery positive lead hole of down tube 1 . CABLE ROUTING Wire lead cover Fix connector cover on the Assemble cramp on the T- head light stay. Hose3 stud at the right of back Install the protruding part of stay.
  • Page 49 SPEC CABLE ROUTING Speedometer After wiring the cover, Install the horn of coupler Rectifier/Regulator cover the coupler. accotding to the direction Turn signal relay Enter tail/brake light. shown in the drawing, and Throttle cable Ass’y After fixing the rear brake make sure that it is not Holder cable, fix crank case 1 .
  • Page 50 SPEC CABLE ROUTING Fuel pump Rear fender Put the idle speed control FI diagnostic tool connec- Fuel injector lead lead and wire sub lead in, Sub-wire harness lead and then close the cramp. Fuse box ISC(idle speed control) Wire the starting device of Battery negative lead valve lead the rear fender of rear mo-...
  • Page 51 SPEC CABLE ROUTING Speedometer Penetrate the rear brake Penetrate the main switch Rectifier/Regulator cable and throttle cable Comp. Lead into the con- Horn through the left side of car nector cover. Turn signal relay body. Penetrate horn cable Front brake cable Make sure to install the through the connector Rear brake cable...
  • Page 52 SPEC CABLE ROUTING Let the left and right flasher lights, meter, and right lead wire of handle bar switch to face upward, let the main switch, front and rear brake switchand left lead wire of handle bar switch to face downward, connect to the coupler, and then store in the connector cover.
  • Page 53 SPEC CABLE ROUTING Turn signal light lead(right) Penetrate the rear brake Enter rectifier and regulator Handlebar switch cable and throttle cable Ass’y. lead(right) through the left side of car First, tighting the backward Front brake light switch body. screw and tighting the for- lead Make sure to install the ward screw.
  • Page 54 < & CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE CHART FOR THE EMISSION CON- TROL SYSTEM GENERAL MAINTENANCE AND LUBRICATION CHART COVER AND PANEL SIDE COVERS AND TAIL/BRAKE LIGHT SINGLE SEAT AND TRUNK LEG SHIELD1,2 FOOTREST BOARD AND INNER FENDER ENGINE...
  • Page 55 < & CHECKING THE WHEELS 3-48 CHECKING AND LUBRICATING THE CABLES 3-48 LUBRICATING THE LEVERS AND PEDALS 3-49 LUBRICATING THE CENTERSTAND 3-49 ELECTRICAL SYSTEM 3-50 CHECKING AND CHARGING THE BATTERY 3-50 CHECKING THE FUSE 3-56 REPLACING THE HEADLIGHT BULB 3-58 ADJUSTING THE HEADLIGHT BEAM 3-59...

  • Page 56: Introduction

    INTRODUCTION < & EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.

  • Page 57: Periodic Maintenance And Minor Repair

    PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INITIAL ODOMETER READING 600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi 10,000 mi (1,000 km) (4,000 km) (7,000 km) (10,000 km) (13,000 km) (16,000 km) ITEM...

  • Page 58: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE AND MINOR REPAIR < & GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READING 600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi 10,000 mi (1,000 km) (4,000 km) (7,000 km) (10,000 km) (13,000 km) (16,000 km) ITEM ROUTINE month months...
  • Page 59 PERIODIC MAINTENANCE AND MINOR REPAIR < & Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 12000mi(19000km) or 36 months, repeat the maintenance intervals starting from 4000mi(7000km) or 12 months. EAU17680 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 60: Cover And Panel

    COVER AND PANEL < & EAS00038 COVER AND PANEL SIDE COVERS AND TAIL/BRAKE LIGHT Order Job/Part Remarks Q’ty Removing the side covers and tail/ Remove the parts in the order listed. brake light Front cover Side cover(left) Side cover(right) Tail/brake and rear turn signal light(left and right) Battery cover Battery negative lead...
  • Page 61 COVER AND PANEL < & Order Job/Part Remarks Q’ty control system. For installation, reverse the removal pro- cedure.

  • Page 62: Single Seat And Trunk

    COVER AND PANEL < & SINGLE SEAT AND TRUNK \y10Nm(1.0m • kg, 7.2 ft • lb) \ l 12Nm(1.2m« kg, 8.7 ft* lb) [s& 7Nm(0.7m• kg, 5.1 ft• lb) "10 '/* *£® / Order Job/Part Remarks Q’ty Removing the single seat and trunk Remove the parts in the order listed.

  • Page 63: Leg Shield1,2

    COVER AND PANEL < & LEG SHIELD1,2 Order Job/Part Remarks Q’ty Removing the leg shield1,2 Removing the leg shield1,2 Remove the parts in the order listed. Front fork upper cover Front fork upper cover Reflector(left) Reflector(left) Caution, do not damage the claw while Front fork cover(left) Front fork cover(left) removing.

  • Page 64: Footrest Board And Inner Fender

    COVER AND PANEL < & FOOTREST BOARD AND INNER FENDER Order Job/Part Remarks Q’ty Removing the footrest board and in- Removing the footrest board and in- Remove the parts in the order listed. ner fender ner fender Single seat/trunk Single seat/trunk Refer to “SINGLE SEAT AND TRUNK “.

  • Page 65: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 66 ADJUSTING THE VALVE CLEARANCE < & ••••••••••••••••••••••• a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align the punch mark a in the camshaft sprocket with the stationary b on the plate. c.
  • Page 67 ADJUSTING THE VALVE CLEARANCE < & Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number =148(thickness =1.48mm(0.0583in)) Rounded value =150 g. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.
  • Page 68 ADJUSTING THE VALVE CLEARANCE < & n. Install the timing chain tensioner spring and cap bolt . 8Nm(0.8m kg, 5.8ft o. Measure the valve clearance again. p. If the valve clearance is still out of specifi- cation, repeat all of the valve clearance ad- justment steps until the specified clearance is obtained.
  • Page 69 ADJUSTING THE VALVE CLEARANCE INTAKE MEASURED MEASURED ORIGINAL VALVE PAD NUMBER • CLEARANCE CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00~0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0.05~0.09...
  • Page 70 ADJUSTING THE VALVE CLEARANCE < & 8. Install: 8all removed parts NOTE: For installation, reverse the removal procedure. 9. Fill: 8cooling system (with the specified amount of the recom- mended coolant) Refer to”CHANGING THE COOLANT”. 3-15...

  • Page 71: Checking The Engine Idling Speed

    CHECKING THE ENGINE IDLING SPEED < & EAS00054 CHECKING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes.

  • Page 72: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check: • throttle cable free play a Out of specification ^Adjust. Throttle cable free play (at the flange of the throttle grip) 1.5~3.5mm (0.06~0.14in)

  • Page 73: Checking The Spark Plug

    CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Remove: 8 panel Refer to”FOOTREST BOARD AND IN- NER FENDER”. 2. Disconnect: 8 spark plug cap Remove the spark plug cap, the engine is extremely hot. 3. Remove: 8 spark plug Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling...
  • Page 74 CHECKING THE SPARK PLUG < & 8. Install: • spark plug 13Nm(1.3m kg, 9.4ft NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • spark plug cap 10. Install: • panel Refer to”FOOTREST BOARD AND IN- NER FENDER”.

  • Page 75: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING < & EAS00062 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: 8front cover 8side cover(left and right) 8battery /battery cover 8single seat/trunk...
  • Page 76 CHECKING THE IGNITION TIMING < & 5. Check: 8ignition timing • • • • • • • • • • • • • • • • • • • • • • • a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed.

  • Page 77: Measuring The Compression Pressure

    MEASURING THE COMPRESSION PRESSURE < & EAS00067 MEASURING THE COMPRESSION PRES- SURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: 8 valve clearance Out of specification -» Adjust Refer to “ADJUSTING THE VALVE CLEARANCE”. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 78 MEASURING THE COMPRESSION PRESSURE ••••••••••••••••••••••• a. Set the main switch to “ON”. b. With the throttle wide open, crank the en- gine until the reading on the compression gauge stabilizes. FflWUzWIgM To prevent sparking, ground the spark plug lead before cranking the engine. c.

  • Page 79: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 80 CHANGING THE ENGINE OIL < & EAS00076 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: 8engine oil filler cap 1 8engine oil drain bolt 2 (along with the gasket) 4.

  • Page 81: Changing The Engine Oil

    CHANGING THE ENGINE OIL Install: 8engine oil filler cap Start the engine, warm it up for several min- utes, and then turn it off. 10.Check: 8engine (for engine oil leaks) 11.Check: 8engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”.

  • Page 82: Changing The Transmission Oil

    CHANGING THE TRANSMISSION OIL < & CHANGING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. NOTE: • Stand the scooter on a suitable stand. • Make sure that the scooter upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.

  • Page 83: Measuring The Engine Oil Pressure

    MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: 8 engine oil level Below the minimum level mark -»Add the recommended engine oil to the proper level. Refer to”CHECKING THE ENGINE OIL LEVEL”. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 84 MEASURING THE ENGINE OIL PRESSURE < & 6. Install: 8oil gallery bolt 7Nm(0.7m kg, 5.1ft 7. Install: • panel Refer to”FOOTREST BOARD AND IN- NER FENDER”. 3-29...

  • Page 85: Replacing The Air Filter Element

    REPLACING THE AIR FILTER ELEMENT EAS00086 REPLACING THE AIR FILTER ELEMENT 1. Remove: 8front cover 8side cover(left) Refer to”SIDE COVERS AND TAIL/ BRAKE LIGHT”. 2. Remove: 8air filter case c o v e r 1 8air filter element 3. Check: 8 air filter element©...
  • Page 86 REPLACING THE AIR FILTER ELEMENT < & 5. Install: 8side cover(left) 8front cover Refer to”SIDE COVERS AND TAIL/ BRAKE LIGHT”. 3-31...

  • Page 87: Checking The Throttle Body Joint And Intake Manifold

    CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD/CHECKING THE FUEL HOSE EAS00094 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 1. Remove: 8front cover 8side cover(left and right) 8single seat/trunk Refer to”COVER AND PANEL”. 2. Check: • throttle body joint •...

  • Page 88: Checking The Breather Hoses

    CHECKING THE BREATHER HOSES < & EAS00098 CHECKING THE BREATHER HOSES 1. Remove: 8front cover 8side cover(left and right) 8single seat/trunk Refer to”COVER AND PANEL”. 2. Check: 8 breather hose 8 transmission case breather hose Cracks/damage -» Replace. Loose connection -»...

  • Page 89: Checking The Exhaust System

    CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler assembly and gasket. 1. Remove: 8muffler assembly Refer to”ENGINE REMOVAL”in chapter 2. Check: • muffler assembly Crack/damage -» Replace. • gasket Exhaust gas leak -»...

  • Page 90: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL EAS00103 CHECKING THE COOLANT LEVEL 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Check: 8 coolant level The coolant level should be between the maximum level mark a and minimum level mark b .

  • Page 91: Checking The Cooling System

    CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: 8front cover 8side cover(left and right) 8battery /battery cover 8single seat/trunk 8footrest board Refer to”COVER AND PANEL”. 8radiator cover Refer to”RADIATOR”in chapter 6. 2. Check: ^ ^ v \ / -/C-^y J l "...

  • Page 92: Changing The Coolant

    CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: 8front cover 8side cover(right) 8coolant reservoir cap cover Refer to”COVER AND PANEL”. 8radiator cover Refer to”RADIATOR”in chapter 6. Disconnect: 8coolant reservoir hose 1 Drain: 8coolant (from the coolant reservoir) 8coolant (from the radiator under drain bolt) Remove: 8radiator cap 8coolant reservoir cap...
  • Page 93 CHANGING THE COOLANT 7. Fill: 8cooling system (with the specified amount of the recom- mended coolant) «0 Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion inhibi- tors for aluminum engines Mixing ratio 4:6(antifreeze:water) Quantity Total amount 0.50L(0.46 Imp qt, 0.53 US qt) Coolant reservoir capacity 0.26L(0.23 Imp qt, 0.28 US qt) Up to the maximum level mark...
  • Page 94 CHANGING THE COOLANT < & 9. Fill: 8coolant reservoir (with the recommended coolant to the maximum level mark 1 ) 10.Install: 8coolant reservoir cap 11.Start the engine, warm it up for several min- utes, and then stop it. 12.Check: 8coolant level Refer to “CHECKING THE COOLANT LEVEL”.

  • Page 95: Chassis

    ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE < & EAS00109 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: 8 brake lever free play a Out of specification -» Adjust. Brake lever free play (at the end of the brake lever) 10~20mm(0.39~0.79in) 2.

  • Page 96: Checking The Front And Rear Brake Shoes

    CHECKING THE FRONT AND REAR BRAKE SHOES < & EAS00127 CHECKING THE FRONT AND REAR BRAKE SHOES Operate the brake. Check: • wear indicator Reaches the wear limit line (2) -» Replace the brake shoes as a set. Refer to “FRONT WHEEL AND BRAKE” and “REAR WHEEL AND BRAKE”...
  • Page 97 CHECKING AND ADJUSTING THE STEERING HEAD < & EAS00148 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.

  • Page 98: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD b. Loosen the upper bearing inner race2 com- pletely and then tighten it to specification with a steering nut wrench3 . Steering nut wrench 90890-01444 YM-A9409-7 Do not overtighten the upper bearing inner race. Upper bearing inner race(final tight- ening torque) 7Nm(0.7m...

  • Page 99: Checking The Front Fork

    CHECKING THE FRONT FORK < & EAS00151 CHECKING THE FRONT FORK 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. 2. Check: •inner tube Damage/scratches -» Replace. •oil seal Oil leakage -»...

  • Page 100: Checking The Tires

    CHECKING THE TIRES EAS00163 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification -> Regulate. rr\w«:»iwei • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air tem- perature.
  • Page 101 CHECKING THE TIRES 2. Check: • tire surfaces Damage/wear -» Replace the tire. Minimum tire tread depth 0.8mm(0.03in) Tire tread depth Sidewall Wear indicator Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation.
  • Page 102 CHECKING THE TIRES < & New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a direction of rotation mark 1 : 8 Install the tire with the mark pointing in the direction of wheel rotation.
  • Page 103 CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES < & EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: • wheel Damage/out-of-round -»Replace. FflWUzWIgM Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or re- placed, always balance the wheel.
  • Page 104 LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE CENTERSTAND < & EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.

  • Page 105: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00179 ELECTRICAL SYSTEM BATTERY INSTRUCTION This is a sealed lype 12 volt battery. No liquid level inspection is ever needed and no refilling water will be required. CHECKING AND CHARGING THE BATTERY IMPORTANT: • Never interfere with the sealed state of the battery. •Check the charging condition with a voltmeter (Normal charging voltage should be above 12.8V) •This battery may be installed in an vehicle only If it replaces a similar sealed type battery.
  • Page 106 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the bat- tery terminals.
  • Page 107 CHECKING AND CHARGING THE BATTERY < & b. Check the charge of the battery, as shown Relationship between the open-circuit voltage 13.0 and the charging time at 20 C in the charts and the following example. 12.5 Example 12.0 Open-circuit voltage = 12.0 V 11.5 11.5 Charging time = 6.5 hours...
  • Page 108 CHECKING AND CHARGING THE BATTERY < & Make sure the battery charger lead clips are in full contact with the battery termi- nal and that they are not shorted. A cor- roded battery charger lead clip may gen- erate heat in the contact area and a weak clip spring may cause sparks.
  • Page 109 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Charger Measure the open-circuit Ammeter Leave the battery unused for more voltage prior to charging. than 30 minutes before measuring its opencircuit voltage. Set the charging voltage to 16-17 V. (If the charging voltage is lower charg- ing will be insufficient, if it is higher, the battery will be over-charged.)
  • Page 110 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. Connect a charger and am- meter to the battery and start charging.
  • Page 111 CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSE < & Install: 8battery Connect: 8battery leads (to the battery terminals) First, connect the positive battery lead 1, and then the negative battery lead 2. 8 After installing the battery, be sure to turn the main switch from “ON”...

  • Page 112: Checking The Fuse

    CHECKING THE FUSE 2. Check: 8fuse • • • • • • • • • • • • • • • • • • • • • • • a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “...

  • Page 113: Replacing The Headlight Bulb

    REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: 8headlight unit Disconnect: 8headlight lead coupler Remove: 8dust b o o t 1 8headlight bulb holder2 8headlight bulb3 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 114: Adjusting The Headlight Beam

    ADJUSTING THE HEADLIGHT BEAM < & EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: headlight beam (vertically) • • • • • • • • • • • • • • • • • • • • • • • a. Turn the adjusting screw 1 in direction a or b .
  • Page 115 CHAS (3^3^) CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE FRONT WHEEL FRONT BRAKE SHOE PLATE REMOVING THE FRONT WHEEL DISASSEMBLING THE BRAKE SHOE PLATE CHECKING THE FRONT WHEEL CHECKING THE SPEEDOMETER GEAR UNIT CHECKING THE BRAKE ASSEMBLING THE BRAKE SHOE PLATE ASSEMBLING THE FRONT WHEEL INSTALLING THE FRONT WHEEL 4-10...
  • Page 116 CHAS (3^3^) REAR SHOCK ABSORBER ASSEMBLY 4-37 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-38 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-38 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-39...

  • Page 117: Front Wheel And Brake

    CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00517 CHASSIS FRONT WHEEL AND BRAKE Order Job/Part Remarks Q’ty Removing the front wheel and brake Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. Stop ring Speedometer cable Brake adjuster...
  • Page 118 CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00518 FRONT WHEEL Order Job/Part Remarks Q’ty Disassembling the front wheel Remove the parts in the order listed. Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly procedure.

  • Page 119: Front Brake Shoe Plate

    CHAS (3^3^) FRONT WHEEL AND BRAKE FRONT BRAKE SHOE PLATE Order Job/Part Remarks Q’ty Disassembling the front brake shoe Remove the parts in the order listed. plate Brake shoe kit Tension spring Camshaft lever Brake shoe wear indicator Return spring Brake camshaft/O-ring Oil seal Refer...

  • Page 120: Removing The Front Wheel

    CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.

  • Page 121: Checking The Front Wheel

    FRONT WHEEL AND BRAKE EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends -» Replace. Do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel Damage/wear -»...

  • Page 122: Checking The Speedometer Gear Unit

    CHAS (3^3^) FRONT WHEEL AND BRAKE • • • • • • • • • • • • • • • • • • • • • • • a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver.

  • Page 123: Checking The Brake

    CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00536 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: •—Q7\__ • brake shoe lining Glazed areas -» Repair. Sand the glazed areas with course sand- paper. • "...

  • Page 124: Assembling The Brake Shoe Plate

    FRONT WHEEL AND BRAKE 4. Check: • brake drum inner surface Oil deposits -»Clean. Remove the oil with a rag soaked in lac- quer thinner or solvent. Scratches -» Repair. Lightly and evenly polish the scratches with an emery cloth. 5.

  • Page 125: Assembling The Front Wheel

    CHAS (3^5^) FRONT WHEEL AND BRAKE 3. Install: 8 camshaft lever 8Nm(0.8m • kg, 5.8ft • • • • • • • • • • • • • • • • • • • • • • • • a. Align the camshaft punch mark a and cam- shaft lever punch mark b is positioned as shown.

  • Page 126: Installing The Front Wheel

    CHAS (3^3^) FRONT WHEEL AND BRAKE EAS00540 INSTALLING THE FRONT WHEEL 1. Lubricate: 8wheel axle 8wheel bearings 8oil seal lips 8speedometer drive gear 8speedometer driven gear Recommended lubricant Lithium-soap-based grease 2. Install: 8front wheel1 NOTE: Make sure the slot® in the brake shoe plate fits over the stopper®...

  • Page 127: Adjusting The Front Wheel Static Balance

    FRONT WHEEL AND BRAKE EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: 8 After replacing the tire, wheel or both, the front wheel static balance should be ad- justed. 8 Adjust the front wheel static balance with the brake disc installed. 1 .
  • Page 128 CHAS (3^% FRONT WHEEL AND BRAKE 3. Adjust: 8front wheel static balance • • • • • • • • • • • • • • • • • • • • • • • a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”.

  • Page 129: Rear Wheel And Brake

    CHAS (3^3^) REAR WHEEL AND BRAKE EAS00555 REAR WHEEL AND BRAKE Order Job/Part Remarks Q’ty Removing the rear wheel and brake Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. Muffler Refer to”ENGINE REMOVAL”in chapter Self lock nut/Plate washer...

  • Page 130: Removing The Rear Wheel

    CHAS (3^3^) REAR WHEEL AND BRAKE EAS00564 REMOVING THE REAR WHEEL 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.

  • Page 131: Checking The Rear Wheel Drive Hub

    CHAS (3^3^) REAR WHEEL AND BRAKE EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: • rear wheel drive hub Cracks/damage -» Replace. EAS00569 CHECKING THE BRAKE /)> The following procedure applies to all of the brake shoes. ~~~G77\-__ 1. Check: •...

  • Page 132: Assembling The Brake Shoe Plate

    CHAS (3^3^) REAR WHEEL AND BRAKE 3. Measure: • brake drum inside diameter b Out of specification -» Replace the wheel. Brake drum inside diameter limit (maximum) 110.5 mm(4.35 in) 4. Check: • brake drum inner surface Oil deposits -» Clean.
  • Page 133 CHAS (3^3^) REAR WHEEL AND BRAKE 3. Install: 8brake shoe k i t 1 8tension springs Do not put lubricating oil on the brake lining. Change the tension spring at the same time of changing the brake shoe. Refer to the direction in the illustration when assembling the brake shoe and spring.

  • Page 134: Installing The Rear Wheel

    CHAS (3^3^) REAR WHEEL AND BRAKE EAS00574 INSTALLING THE REAR WHEEL 1. Lubricate: 8wheel axle Recommended lubricant Lithium-soap-based grease 2. Install: • rear wheel 3. Tighten: • plate washer • wheel axle nut© 120Nm(12.0m 86.8ft* 4. Install: • muffler Refer to”ENGINE REMOVAL”in chapter 5.

  • Page 135: Front Fork

    CHAS (3^3^) FRONT FORK EAS00646 FRONT FORK S & 45Nm(4.5m • kg, 32.5 ft • lb) g R 30Nm(3.0m • kg, 21.7 ft • lb) Order Job/Part Remarks Q’ty Removing the front fork legs Remove the parts in the order listed. Front fork upper cover Reflector Refer to”LEG SHIELD1,2 “...
  • Page 136 FRONT FORK C H A S (3^3^) EAS00648 3 R 23Nm(2.3m • kg, 16.6 ft < lb) Order Job/Part Remarks Q’ty Disassembling the front fork legs Remove the parts in the order listed. Fork oil Drain. Fork spring Damper rod bolt/Copper washer Damper rod Rebound spring Inner tube...

  • Page 137: Removing The Front Fork Legs

    CHAS (3^3^) FRONT FORK EAS00651 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
  • Page 138 FRONT FORK 2. Drain: 8fork oil 3. Remove: 8damper rod assembly b o l t 1 NOTE: While holding the damper rod with the damper rod holder 2 and T-handle3, loosen the damper rod assembly bolt. Damper rod holder 90890-01294(YM-01300-1) •...

  • Page 139: Checking The Front Fork Legs

    CHAS (3^% FRONT FORK 6. Remove: 8oil s e a l 1 Never reuse the oil seal. 8 R a g 2 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 8 inner tube®...

  • Page 140: Assembling The Front Fork Legs

    FRONT FORK EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: 8 When assembling the front fork leg, be sure to replace the following parts: - oil seal - dust seal 8 Before assembling the front fork leg, make sure all of the components are clean.
  • Page 141 CHAS (3^3^) FRONT FORK 4. Install: 8oil seal 1New (with the fork seal driver weight 2 and adapter 3 ) Fork seal driver weight 90890-01367(YM-A9409-7) Adapter 90890-01400(YM-A9409-3 ) Make sure the numbered side of the oil seal faces up. NOTE: 8 Before installing the oil seal, lubricate its lips with lithium soap base grease.

  • Page 142: Installing The Front Fork Legs

    CHAS (3^3^) FRONT FORK NOTE: 8 While filling the front fork leg, keep it up- right. 8 After filling, slowly pump the front fork leg up and down to distribute the fork oil. 7. Install: 8fork spring 1 NOTE: 8 Install the spring with the smaller pitch fac- ing down .

  • Page 143: Handlebar

    CHAS (3^3^) HANDLEBAR EAS00664 HANDLEBAR -10^ Order Job/Part Remarks Q’ty Removing the handlebar Remove the parts in the order listed. Front fork upper cover Front fork cover(left and right) Refer to”LEG SHIELD1,2"in chapter 3. Leg shield1,2 Rear view mirror(left and right) Band Front brake cable Disconnect.
  • Page 144 CHAS (3^3^) HANDLEBAR -10^ Order Job/Part Remarks Q’ty Front turn signal light(left) Front turn signal light bracket(left) Handlebar switch(left) Handlebar grip Handlebar upper holder Handlebar assembly For installation, reverse the removal pro- cedure. 4-28...

  • Page 145: Removing The Handlebar

    CHAS (3^3^) HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. 2. Remove: 8handlebar switch(right)1 8throttle grip assembly2 NOTE: While removing the handlebar holder assembly (right), pull back the rubber cover.

  • Page 146: Installing The Handlebar

    HANDLEBAR EAS00673 INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. 2. Install: handlebar© 8 handlebar upper holders 28Nm(2.8m kg, 20.3ft First, tighten the bolts on the front side of the handlebar holders, and then on the rear side.
  • Page 147 HANDLEBAR 5. Install: 8 throttle grip assembly1 8 right handlebar switch2 8 throttle cables 3 NOTE: 8 Align the projectiona on the right handlebar switch with the hole b on the handlebar. 8 Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar4.

  • Page 148: Steering Head

    CHAS (3^3^) STEERING HEAD EAS00675 STEERING HEAD HANDLEBAR BRACKET AND HEADLIGHT STAY BRACKET ®~. 48Nm(4.8m • kg, 34.7 ft • lb) > S^60Nm(6.0m • kg, 43.4 ft • lb) P^23Nm(2.3m kg, 16.6 ft lb) al4Nm(0.4m • kg, 2.9 ft • lb) Order Job/Part Remarks...

  • Page 149: Lower Bracket

    LOWER BRACKET LOWER BRACKET r V 30Nm(3.0m • kg, 21.7 ft • lb)f Order Job/Part Remarks Q’ty Removing the lower bracket Remove the parts in the order listed. Front fork upper cover Front fork cover(left and right) Refer to”LEG SHIELD1,2"in chapter 3. Leg shield1,2 Front wheel Refer to”FRONT WHEEL AND BRAKE”.

  • Page 150: Removing The Lower Bracket

    CHAS (3^3^) STEERING HEAD EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. 2 . Remove: 8handlebar bracket1 NOTE: Remove the handlebar bracket by loosening the ring n u t 2 gradually.

  • Page 151: Checking The Steering Head

    CHAS (3^3^) STEERING HEAD EAS00682 CHECKING THE STEERING HEAD 1. Wash: 8bearing balls 8bearing races Recommended cleaning solvent Kerosene 2. Check: 8bearing balls 8bearing races Damage/pitting -» Replace. 3. Replace: 8bearing balls 8bearing races • • • • • • • • • • • • • • • • • • • • • • • a.

  • Page 152: Installing The Steering Head

    CHAS (3^3^) STEERING HEAD EAS00684 INSTALLING THE STEERING HEAD 1. Lubricate: 8bearing balls 1 8bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 8lower bracket 1 8upper bearing inner r a c e 2 (with the steering nut wrench3) Upper bearing inner race 7Nm(0.7m •...
  • Page 153 CHAS (3^3^) REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY Order Job/Part Remarks Q’ty Removing the rear shock absorber Remove the parts in the order listed. assembly Front cover Refer to”SIDE COVERS AND TAIL/ Side cover(left) BRAKE LIGHT”in chapter 3. Rear shock absorber assembly upper Rear shock absorber assembly upper bolt...
  • Page 154 REAR SHOCK ABSORBER ASSEMBLY EAS00692 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the scooter on a level surface. Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.
  • Page 155 CHAS (3^3^) REAR SHOCK ABSORBER ASSEMBLY EAS00698 INSTALLING THE REAR SHOCK AB- SORBER ASSEMBLY 1. Install: • rear shock absorber assembly 2. Tighten: • rear shock absorber assembly upper nut 30Nm(3.0m kg, 21.7ft • rear shock absorber assembly lower bolt 16Nm(1.6m kg, 11.6ft 3.
  • Page 156 CHAPTER 5 ENGINE ENGINE REMOVAL LEADS, HOSES AND MUFFLER ENGINE INSTALLING THE ENGINE CYLINDER HEAD REMOVING THE CYLINDER HEAD CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER HEAD 5-10 THE ROCKER ARMS AND CAMSHAFT 5-13 REMOVING THE ROCKER ARMS AND CAMSHAFT 5-14 CHECKING THE CAMSHAFT 5-15...
  • Page 157 REMOVING THE SECONDARY SHEAVE AND V-BELT 5-44 DISASSEMBLING THE SECONDARY SHEAVE 5-45 CHECKING THE CLUTCH SHOES 5-45 CHECKING THE V-BELT 5-46 CHECKING THE PRIMARY SHEAVE 5-46 CHECKING THE PRIMARY SHEAVE WEIGHTS 5-47 CHECKING THE SLIDER 5-47 CHECKING THE SECONDARY SHEAVE 5-47 ASSEMBLING THE PRIMARY SHEAVE 5-48...

  • Page 158: Engine Removal

    ENGINE REMOVAL EAS00188 ENGINE ENGINE REMOVAL LEADS, HOSES AND MUFFLER r V 10Nm(1.0m • kg, 7.2 ft* lb) r V 10Nm(1.0m • kg, 7.2 ft* lb) Order Job/Part Remarks Q’ty Removing the leads, hoses and muf- Remove the parts in the order listed. fler Front cover/Single seat/Trunk Battery cover/Battery...
  • Page 159 ENGINE REMOVAL r^10Nm(1.0m • kg, 7.2 ft* lb) 1 * 10Nm(1.0m • kg, 7.2 ft • lb) Order Job/Part Remarks Q’ty Crankshaft position sensor/Stator as- Disconnect. sembly coupler Ignition primary coil coupler Disconnect. Air filter assembly/Breather hose Bracket Muffler Gasket For installation, reverse the removal pro- cedure.

  • Page 160: Engine

    ENGINE REMOVAL EAS00191 ENGINE Order Job/Part Remarks Q’ty Removing the engine Removing the engine Remove the parts in the order listed. Place a suitable stand under the frame and engine. Rear shock absorber assembly lower Rear shock absorber assembly lower bolt bolt Engine mounting nut...

  • Page 161: Installing The Engine

    ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: 8engine1 8engine mounting b o l t 2 8engine mounting n u t 3 NOTE: 8 Apply lithium-soap-based grease to the unthreaded portion of the engine mounting bolt shaft. 8 Do not fully tighten the engine mounting bolt..

  • Page 162: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD P^9Nm(0.9m • kg, 6.5 ft • lb) P|^j8Nm(0.8m • kg, 5.8 ft • lb) n^10Nm(1.0m« kg, 7.2 ft* lb) . i ^ \ [ \ 30Nm(3.0m • kg, 21.7 ft • lb) «13Nm(1.3m • kg, 9.4 ft • lb) Order Job/Part Remarks...
  • Page 163 CYLINDER HEAD P^9Nm(0.9m • kg, 6.5 ft • lb) «13Nm(1.3m • kg, 9.4 ft • lb) Order Job/Part Remarks Q’ty Timing chain tensioner gasket Camshaft sprocket Refer to”REMOVING THE CYLINDER Bolt HEAD” and “INSTALLING THE CYLIN- DER HEAD”. Plate Cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal pro-...

  • Page 164: Removing The Cylinder Head

    CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Remove : 8V-belt case cover 8Refer to “BELT DRIVE”. 8cylinder head cover 2. Align: 8“I” mark a on the AC magneto rotor (with the stationary pointer b on the crankcase cover) • • • • • • • • • • • • • • • • • • • • • • • a.
  • Page 165 CYLINDER HEAD 4. Remove: 8timing chain tensioner (along with the gasket) 8camshaft sprocket 1 8timing chain 2 NOTE: 8 To prevent the timing chain from falling into the crankcase, fasten it with a wire. 5. Remove: 8cylinder head NOTE: 8 Loosen the nuts in the proper sequence as shown.

  • Page 166: Checking The Cylinder Head

    CYLINDER HEAD EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: 8combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore thread • valve seats 2. Check: •...

  • Page 167: Installing The Cylinder Head

    CYLINDER HEAD EAS00231 INSTALLING THE CYLINDER HEAD 1. Install: • gasket • dowel pins 2. Install: • cylinder head 3. Tighten: • cylinder head nuts 10 Nm (1.0 m kg, 7.2 ft • cylinder head bolts 10 Nm (1.0 m kg, 7.2 ft NOTE: •...
  • Page 168 CYLINDER HEAD Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. e. While holding the camshaft, temporarily tighten the camshaft sprocket bolt. f. Remove the wire from the timing chain. • • • • • • • • • • • • • • • • • • • • • • • 5.
  • Page 169 CYLINDER HEAD 7. Turn: 8crankshaft (several turns counterclockwise) 8. Check: 8“I” mark a Align the “I” mark on the AC magneto ro- tor with the stationary pointer b on the crankcase cover. 8“I” mark c Align the “I” mark on the camshaft sprocket with the stationary pointer d on the plate.

  • Page 170: The Rocker Arms And Camshaft

    THE ROCKER ARMS AND CAMSHAFT THE ROCKER ARMS AND CAMSHAFT Order Job/Part Remarks Q’ty Removing the rocker arms and cam- Remove the parts in the order listed. shaft Cylinder head Refer to “CYLINDER HEAD”. Camshaft Rocker arm shaft(intake) Rocker arm shaft(exhaust) Rocker arm(intake) Rocker arm(exhaust) Collar...

  • Page 171: Removing The Rocker Arms And Camshaft

    THE ROCKER ARMS AND CAMSHAFT EAS00202 REMOVING THE ROCKER ARMS AND CAM- SHAFT 1. Remove: 8intake rocker arm shaft 8exhaust rocker arm shaft 8intake rocker arm 8exhaust rocker arm 8collar NOTE: Remove the rocker arm shafts with the clip plier. 2.

  • Page 172: Checking The Camshaft

    THE ROCKER ARMS AND CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: •camshaft bushings Damage/wear -» Replace. 2. Check: •camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft. 3. Measure: ® •camshaft lobe dimensions a and b Out of specification Replace the cam- m§>...

  • Page 173: Checking The Rocker Arms And Rocker Arm Shafts

    THE ROCKER ARMS AND CAMSHAFT EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: • rocker arm (camshaft touch surface©) • rocker arm (valve touch surface®) Damage/wear -»...

  • Page 174: Checking The Timing Chain, Camshaft Sprocket, And Timing Chain Guides

    THE ROCKER ARMS AND CAMSHAFT 5. Measure: • rocker arm shaft outside diameter a Out of specification -» Replace. Rocker arm shaft outside diameter 9.981 ~ 9.991 mm (0.3930 ~ 0.3933 <Limit>:9.950mm (0.3917 in) 6. Calculate: •rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.

  • Page 175: Checking The Timing Chain Tensioner

    THE ROCKER ARMS AND CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage -» Replace. 2. Check: • one-way cam operation Rough movement -» Replace the timing chain tensioner. 3. Check: • cap bolt • o-ring •...

  • Page 176: Installing The Camshaft And Rocker Arms

    THE ROCKER ARMS AND CAMSHAFT EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 8camshaft 1 Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2. Lubricate: 8rocker arm shafts Recommended lubricant Molybdenum disulfide oil 3. Install: 8exhaust rocker arm 1 8collar2 8exhaust rocker arm shaft NOTE:...

  • Page 177: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Remarks Q’ty Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to”CYLINDER HEAD”. Rocker arms Refer to”REMOVING THE ROCKER Rocker arm shafts ARMS AND CAMSHAFT”...
  • Page 178 VALVES AND VALVE SPRINGS Order Job/Part Remarks Q’ty For installation, reverse the removal pro- cedure. 5-21...

  • Page 179: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 180 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach- ment 90890-04148 YM-04148 4 . Remove: 8valve spring retainer 1 8valve spring 2 8valve stem seal 3 8valve spring seat 4 8valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.

  • Page 181: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1 . Measure: 8valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a - Valve stem diameter b Out of specification Replace the valve guide.
  • Page 182 VALVES AND VALVE SPRINGS 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face Pitting/wear Grind the valve face. • valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve.

  • Page 183: Checking The Valve Seats

    VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbon deposits (from the valve face and valve seat) 2. Check: • valve seat Pitting/wear Replace the cylinder head. 3.
  • Page 184 VALVES AND VALVE SPRINGS • • • • • • • • • • • • • • • • • • • • • • • a. Apply a coarse lapping compound a to the valve face. X"7 Do not let the lapping compound enter the gap between the valve stem and the valve guide.

  • Page 185: Checking The Valve Springs

    VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a Out of specification -» Replace the valve spring. Valve spring free length Intake valve spring 39.35 mm (1.5492 in) <Limit>: 37.38 mm (1.4717 in) Exhaust valve spring...

  • Page 186: Installing The Valves

    VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 8valve stem end (with an oil stone) 2. Lubricate: 8valve stem 1 8valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3.
  • Page 187 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019(YM-04019) Valve spring compressor attach- ment 90890-04148(YM-04148) 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. Hitting the valve tip with excessive force could damage the valve.

  • Page 188: Cylinder And Piston

    CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON Order Job/Part Remarks Q’ty Removing the cylinder and piston Remove the parts in the order listed. Cylinder head Refer to”CYLINDER HEAD”. Timing chain guide(exhaust side) Cylinder Dowel pin Cylinder gasket Piston pin clip Refer to”REMOVING THE CYLINDER Piston pin AND PISTON”...

  • Page 189: Removing The Cylinder And Piston

    CYLINDER AND PISTON EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: 8piston pin clip 1 8piston pin 2 8piston 3 Do not use a hammer to drive the piston pin out. NOTE: 8 Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.

  • Page 190: Checking The Cylinder And Piston

    CYLINDER AND PISTON EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: • piston wall • cylinder wall Vertical scratches Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: piston-to-cylinder clearance • • • • • • • • • • • • • • • • • • • • • • • a.
  • Page 191 CYLINDER AND PISTON e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” - Piston skirt diameter “P” Piston-to-cylinder clearance 0.010 ~ 0.035mm(0.0004 ~ 0.0014in) <Limit>:0.15mm(0.0059in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

  • Page 192: Checking The Piston Rings

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

  • Page 193: Checking The Piston Pin

    CYLINDER AND PISTON EAS00265 CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification Replace the pis- ton pin. Piston pin outside diameter 9.996 ~ 10.000 mm (0.3935 ~ 0.3937 in)

  • Page 194: Checking The Timing Chain Guide

    CYLINDER AND PISTON CHECKING THE TIMING CHAIN GUIDE 1. Check: 8 timing chain guide (exhaust side) Damage/wear -» Replace EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: 8oil ring expander 1 8oil ring rail 2 82nd ring 3 8top ring 4 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
  • Page 195 CYLINDER AND PISTON 3. Install: N e w 8gasket 8dowel pins 4. Lubricate: 8piston 8piston rings 8cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: 8piston ring end gaps a Top ring Lower oil ring rail Upper oil ring rail d 2nd ring A Exhaust side 6.

  • Page 196: Belt Drive

    BELT DRIVE EAS00316 BELT DRIVE V-BELT CASE COVER %. 10Nm(1.0m • kg, 7.2 ft • lb) P|« 12Nm(1.2m • kg, 8.7 ft* lb) Order Job/Part Remarks Q’ty Removing the V-belt case cover Remove the parts in the order listed. Kickstarter Cover V-belt case cover V-belt case cover gasket...

  • Page 197: Kickstarter

    BELT DRIVE EAS00338 KICKSTARTER Order Job/Part Remarks Q’ty Disassembling the kickstarter Remove the parts in the order listed. V-belt case cover Refer to”V-BELT CASE COVER“. Kick pinion gear Kick pinion gear clip Circlip/Plate washer Refer to”INSTALLING THE KICKSTARTER”. Kickstarter shaft Torsion spring Solid bush For assembly, reverse the disassembly...

  • Page 198: Installing The Kickstarter

    BELT DRIVE EAS00340 INSTALLING THE KICKSTARTER 1. Install: 8solid b u s h 1 8kick shaft assembly2 8torsion spring3 2. Hook: 8torsion spring NOTE: Hook the spring e n d a on the kickstarter shaft b as shown, and hook the other end c on the projectiond .

  • Page 199: V-Belt And Primary/Secondary Sheave

    BELT DRIVE V-BELT AND PRIMARY/SECONDARY SHEAVE 40Nm (4.0 m«kg, 28.9 fHb) 30Nm (3.0 m«kg, 21.7 fHb) Order Job/Part Remarks Q’ty Removing the V-belt and primary/sec- Remove the parts in the order listed. ondary sheave Primary sheave nut/Plate washer Refer to”REMOVING THE PRIMARY Oneway clutch SHEAVE”...

  • Page 200: Secondary Sheave

    BELT DRIVE SECONDARY SHEAVE Order Job/Part Remarks Q’ty Disassembling secondary Disassemble the parts in the order listed. sheave Clutch carrier nut Refer to”DISASSEMBLING THE SEC- Clutch carrier ONDARY SHEAVE” and “ASSEMBLING THE SECONDARY SHEAVE”. Clutch shoe spring Compression spring Secondary spring seat Refer to”ASSEMBLING THE SECOND- Guide pin ARY SHEAVE”...

  • Page 201: Removing The Primary Sheave

    BELT DRIVE EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: 8primary sheave nut 1 8plate washer 8oneway clutch 8primary fixed sheave 2 NOTE: While holding the primary fixed sheave with the rotor holding tool 3 , loosen the primary fixed sheave nut. Rotor holding tool 90890-01235 (YU-01235) EAS00318...

  • Page 202: Disassembling The Secondary Sheave

    BELT DRIVE 3. Remove: 8secondary sheave 1 8V-belt 2 NOTE: Remove the V-belt and secondary sheave from the primary sheave side. EAS00319 %-© DISASSEMBLING SECONDARY SHEAVE 1. Remove: 8clutch carrier nut 1 1 // / /Py*—\ 1 NOTE: Install the clutch spring holder 2 and clutch spring holder arm 3 onto the secondary sheave as shown.

  • Page 203: Checking The V-Belt

    BELT DRIVE Clutch shoe thickness 3.7mm(0.146in) <Limit>:2.0mm(0.079in) NOTE: 8 Inspect clutch shoesa. 8 After removing the clutch shoe spring, do not use them again. 8 Replace the all three as a set. EAS00320 CHECKING THE V-BELT 1. Check: j^ia • V-belt® Cracks/damage/wear -»...

  • Page 204: Checking The Primary Sheave Weights

    BELT DRIVE EAS00321 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • primary sheave weight Cracks/damage/wear Replace. 2. Measure: • primary sheave weight outside diameter Out of specification Replace. Primary sheave weight outside di- ameter 15 mm (0.591 in)

  • Page 205: Assembling The Primary Sheave

    BELT DRIVE EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 NOTE: Use thinner to clean up grease, dirt on the pri- mary sliding sheave cam side 5 . 2.

  • Page 206: Assembling The Secondary Sheave

    BELT DRIVE 1&m\ EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: 8secondary fixed sheave’s inner surface 8secondary sliding sheave’s inner surface 8oil seals 8bearings (with the recommended lubricant) Recommended lubricant ® BEL-RAY assembly lube 2. Install: 8secondary sliding sheave 1 NOTE: Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide Oil seal guide...

  • Page 207: Installing The Secondary Sheave, V-Belt And Primary Sheave

    BELT DRIVE 5. Install: 8secondary sheave 1 8spring 8clutch carrier 2 I f ' / /F^r~\\ NOTE: ® Attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave © as shown. Then, compress the spring, and tighten the clutch carrier nut 5 .
  • Page 208 BELT DRIVE Rotor holding tool 90890-01235 YU-01235 Socket wrench(39mm) 90890-01493 3. Install: • clutch housing • secondary sheave nut® 40Nm(4.0m kg, 28.9ft NOTE: Tighten the secondary sheave nut with the sheave holder®. Sheave holder 90890-01701 YS-01880-A 4. Install: • primary fixed sheave©...
  • Page 209 BELT DRIVE 5. Position: 8V-belt 1 NOTE: Position the V-belt in the primary sheave 2 (when the pulley is at its widest position) and in the secondary sheave 3 (when the pulley is at its narrowest position), and make sure the V- belt is tight.

  • Page 210: Starter Clutch And Ac Magneto

    STARTER CLUTCH AND AC MAGNETO EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY Order Job/Part Remarks Q’ty Removing the stator coil assembly Remove the parts in the order listed. Coolant Drain. Refer to”CHANGING THE COOLANT”in chapter 3. Single seat/Trunk Front cover Side cover(left and right) Refer to”COVER AND PANEL”in chap-...
  • Page 211 STARTER CLUTCH AND AC MAGNETO Order Job/Part Remarks Q’ty Lock plate Crankshaft position sensor Stator coil assembly For installation, reverse the removal pro- cedure. 5-54...

  • Page 212: Starter Clutch

    STARTER CLUTCH AND AC MAGNETO EAS00342 STARTER CLUTCH Order Job/Part Remarks Q’ty Removing the starter clutch Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL”in chapter 3. AC magneto rotor Refer to”REMOVING THE AC MAG- Stator coil assembly NETO”...

  • Page 213: Removing The Ac Magneto

    STARTER CLUTCH AND AC MAGNETO EAS00347 REMOVING THE AC MAGNETO 1. Remove: 8AC magneto rotor n u t 1 8washer NOTE: 8 While holding the AC magneto rotor 2 with the sheave holder 3 , loosen the AC mag- neto rotor nut. 8 Do not allow the sheave holder to touch the projection on the AC magneto rotor.

  • Page 214: Removing The Starter Clutch

    STARTER CLUTCH AND AC MAGNETO EAS00344 REMOVING THE STARTER CLUTCH 1. Remove: 8crankcase cover (right)1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

  • Page 215: Checking The Starter Clutch

    STARTER CLUTCH AND AC MAGNETO EAS00351 CHECKING THE STARTER CLUTCH 1. Check: •starter clutch roller Damage/wear -» Replace. 2. Check: •starter clutch idle gear •starter wheel gear Burrs/chips/roughness/wear -» Replace the defective part(s). 3. Check: •starter wheel gear’s contacting surfaces Damage/pitting/wear -»...

  • Page 216: Installing The Starter Clutch

    STARTER CLUTCH AND AC MAGNETO EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: • idle gear • starter clutch • collar • roller • starter wheel gear • washer • starter clutch nut® 90 Nm (9.0 m kg, 65.1 ft NOTE: The starter clutch nut is left-hand thread.
  • Page 217 STARTER CLUTCH AND AC MAGNETO 2. Tighten: •AC magneto rotor nut 43 Nm (4.3 m kg, 31.1 ft NOTE: • While holding the AC magneto rotor (2)with the sheave holder®, tighten the AC mag- neto rotor nut. • Do not allow the sheave holder to touch the projection on the AC magneto rotor.

  • Page 218: Oil Pump

    OIL PUMP EAS00360 OIL PUMP 4Nm (0.4 m«kg, 2.9 fHb) Order Job/Part Remarks Q’ty Removing the oil pump Remove the parts in the order listed. Radiator Refer to”RADIATOR”in chapter 6. AC magneto Refer to”STARTER CLUTCH AND AC Refer to”STARTER CLUTCH AND AC Starter clutch MAGNETO”...

  • Page 219: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear© • oil pump housing • oil pump housing cover Cracks/damage/wear -» Replace the defective part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance A •...

  • Page 220: Assembling The Oil Pump

    OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: 8inner rotor 8outer rotor 8oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 8 oil pump shaft (to the oil pump housing®) 8 pin 8 inner rotor® 8 outer rotor©...

  • Page 221: Transmission

    TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Remarks Q’ty Removing the transmission Remove the parts in the order listed. Transmission oil Drain. Refer to”CHANGING THE TRANSMIS- SION OIL” in chapter 3. Muffler/Bracket Refer to”ENGINE REMOVAL”. Rear wheel Refer to”REAR WHEEL AND BRAKE” in chapter 4.

  • Page 222: Checking The Transmission

    TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Measure: • main axle runout (with a centering device and dial gauge ) Out of specification -» Replace the main axle. Main axle runout limit 0.04 mm (0.002 in) 2. Measure: • drive axle runout (with a centering device and dial gauge ) Out of specification -»...

  • Page 223: Crankshaft

    CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 7Nm (0.7 m»kg, 5.1 fHb) 7Nm (0.7 m»kg, 5.1 fHb) Order Job/Part Remarks Q’ty Removing the crankshaft assembly Remove the parts in the order listed. Engine Refer to”ENGINE REMOVAL” . Cylinder head Refer to”CYLINDER HEAD”. Cylinder and piston Refer to”CYLINDER AND PISTON”.
  • Page 224 CRANKSHAFT 7Nm (0.7 m»kg, 5.1 fHb) 7Nm (0.7 m»kg, 5.1 fHb) Order Job/Part Remarks Q’ty Hook Drain plug Oil strainer Compression spring O-ring Crankcase(right) Refer to”DISASSEMBLING CRANKCASE” and “ASSEMBLING THE CRANKCASE”. Spacer Dowel pin Guide Crankshaft Refer to”REMOVING THE CRANK- SHAFT ASSEMBLY”...

  • Page 225: Disassembling The Crankcase

    CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 8centerstand assembly 2. Remove: 8crankcase bolts1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 3.

  • Page 226: Removing The Crankshaft Assembly

    CRANKSHAFT EAS00389 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: 8crankshaft assembly1 8timing chain2 8timing chain guide(intake side) NOTE: 8 Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. 8 The crankshaft assembly cannot be re- moved if the timing chain is attached onto the crankshaft sprocket.

  • Page 227: Checking The Crankcase

    CRANKSHAFT 3. Measure: • crankshaft width Out of specification -»Replace the crank- shaft. Crankshaft width 42.45~42.50mm(1.671~1.673in) 4. Check: ^ ^ ^ •crankshaft sprocket y>^ y& Damage/wear -»Replace the crankshaft. •bearing Cracks/damage/wear -» Replace the crankshaft. •oil pump drive gear ^ ^ L Damage/wear -»...

  • Page 228: Checking The Timing Chain And Timing Chain Guide(Intake Side)

    CRANKSHAFT EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE(INTAKE SIDE) 1. Check: • timing chain Damage/stiffness -> Replace the timing chain and camshaft sprocket as a set. 2. Check: • timing chain guide (intake side) Damage/wear -> Replace. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1.

  • Page 229: Installing The Crankshaft

    CRANKSHAFT EAS00408 INSTALLING THE CRANKSHAFT 1. Install: 8timing chain guide (intake side) 8timing chain1 8crankshaft assembly2 NOTE: Install the timing chain so it is not visible through the opening in the left crankcase 3 . To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.
  • Page 230 CRANKSHAFT 3. Install: 8dowel pins 8spacer 8right crankcase1 NOTE: Tap lightly on the right crankcase with a soft- face hammer. 4. Tighten: •crankcase bolts 10Nm(1.0m kg, 7.2ft NOTE: Tighten the crankcase bolts in stages and in a crisscross pattern. 5. Apply: •engine oil (onto the crankshaft pin, bearing and oil delivery hole)
  • Page 231 COOL J C CHAPTER 6 COOLING SYSTEM RADIATOR CHECKING THE RADIATOR INSTALLING THE RADIATOR THERMOSTAT CHECKING THE THERMOSTAT INSTALLING THE THERMOSTAT WATER PUMP DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP ASSEMBLING THE WATER PUMP 6-10 INSTALLING THE WATER PUMP 6-11...

  • Page 232: Radiator

    COOL J C RADIATOR EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Remarks Q’ty Remove the parts in the order listed. Removing the radiator Front cover Side cover(left and right) Refer to”COVER AND PANEL”in chap- Single seat/Trunk ter 3. Footrest board Coolant Drain.

  • Page 233: Checking The Radiator

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

  • Page 234: Installing The Radiator

    RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: 8cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks -» Repair or replace any faulty part. 3 © ^ ^ C •...

  • Page 235: Thermostat

    COOL J C THERMOSTAT EAS00460 THERMOSTAT 10Nm (1.0 m«kg, 7.2 fHb) 10Nm (1.0 m«kg, 7.2 fHb) Order Job/Part Remarks Q’ty Removing the thermostat Remove the parts in the order listed. Front cover Side cover(left and right) Refer to”COVER AND PANEL”in chap- Single seat/Trunk ter 3.

  • Page 236: Checking The Thermostat

    THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat Does not open at 85 ~100°C (185 ~212°F) -» Replace. • • • • • • • • • • • • • • • • • • • • • • • a.

  • Page 237: Installing The Thermostat

    COOL J C THERMOSTAT EAS00466 INSTALLING THE THERMOSTAT 1. Install: • thermostat© • thermostat cover 10Nm(1.0m kg, 7.2ft NOTE: Align the breather a of thermostat to mark b of thermosat before installation. 2. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT”...

  • Page 238: Water Pump

    COOL J C WATER PUMP EAS00468 WATER PUMP lyJ2|10 4 i , / 10Nm(1.0m« kg, 7.2 ft* lb) d r ^ ® Order Job/Part Remarks Q’ty Removing the water pump Remove the parts in the order listed. Front cover Side cover(left and right) Refer to”COVER AND PANEL”in chap- Single seat/Trunk ter 3.
  • Page 239 COOL J C WATER PUMP 10Nm(1.0m • kg, 7.2 ft* lb) ® ^ ^ ® Order Job/Part Remarks Q’ty Oil seal Bearing Gasket For installation, reverse the removal pro- cedure.

  • Page 240: Disassembling The Water Pump

    COOL J C WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: 8water pump housing c o v e r 1 8dowel pin 8gasket 2. Remove: 8plate 2 8impeller shaft 8gasket 8oil seal (with a thin, flat-head screwdriver) 8bearing NOTE: 8 Remove the oil seal from the inside of the water pump housing.

  • Page 241: Assembling The Water Pump

    COOL J C WATER PUMP EAS00475 ASSEMBLING THE WATER PUMP 1. Install: 8bearing1 NOTE: 8 Before installing the oil seal, apply tap wa- ter or coolant onto its out surface. 8 Install the oil seal with a socket that matches its outside diameter. 2.

  • Page 242: Installing The Water Pump

    COOL J C WATER PUMP 5. Install: 8gasket 8water pump housing c o v e r 1 EAS00478 INSTALLING THE WATER PUMP M§ 1. Install: • water pump assembly 10Nm(1.0m kg, 7.2ft NOTE: \ \Ji—- \ \Ji—- Align the slit a on the impeller shaft with the projection b on the camshaft sprocket bolt.

  • Page 243: Fuel Injection System Fi

    CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM WIRING DIAGRAM ECU’S SELF-DIAGNOSTIC FUNCTION CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB SELF-DIAGNOSTIC FANCTION TABLE Self-diagnostic fanction table TROUBLESHOOTING CHART DIAGNOSTIC MODE TROUBLESHOOTING DETAILS 7-12 THROTTLE BODY AND FUEL INJECTOR 7-26 THROTTLE BODY 7-26...

  • Page 244: Fuel Injection System

    FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM Air filter case Engine trouble warning light Catalytic converter Lean angle cut-off switch Crankshaft position sensor Fuel hose Coolant temperature sensor Ignition coil Spark plug Fuel injector Fuel tank Intake air pressure sensor Fuel pump ISC(idle speed control) valve Throttle position sensor...

  • Page 245: Wiring Diagram

    FUEL INJECTION SYSTEM WIRING DIAGRAM < Br/W © © © © © © © © © © Br/W < -Hi,® H k J — © — t H i- — 1 L / G " O...
  • Page 246 FUEL INJECTION SYSTEM AC magneto Main fuse Battery Engine stop switch Main switch Intake air pressure sensor Intake air temperature sensor Throttle position sensor Lean angle cut-off switch Coolant temperature sensor Ignition coil Spark plug Fuel injector Fuel pump ISC (idle speed control) valve Dimmer switch Headlight High beam indicator light...

  • Page 247: Ecu's Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 248: Checking For A Defective Engine Trouble Warning Light Bulb

    FUEL INJECTION SYSTEM EAS00901 CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB The engine trouble warning light comes on for 2 seconds after the main switch has been turned “ON” and when the start switch is being pushed. If the warning light does not come on under these condi- tions, the warning light bulb may be defective.

  • Page 249: Fuel Injection System

    FUEL INJECTION SYSTEM Fault Engine Vehicle Item Symptom code No. startability driveability Fuel injector Fuel injector open or short circuit is de- Unable Unable tected. Lean angle cut-off switch The vehicle has overturned. Unable Unable (latch up detected) (open or Lean angle cut-off switch-open or short cir- short circuit) cuit is detected.

  • Page 250: Troubleshooting Chart

    FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. *Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light does not come on. The engine trouble warning light comes on.

  • Page 251: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators with con- necting the Fl diagnostic tool to the normal mode or the diagnostic monitoring mode. Fl diagnostic tool <P 90890-03182 YU-03182...
  • Page 252 FUEL INJECTION SYSTEM Setting the diagnostic mode 1. Turn the main switch to “OFF” and the en- gine stop switch to “RUN”.. 2. Disconnect the self diag signal connector 1 , and then connect the Fl diagnostic-tool 2 as shown. 3.

  • Page 253: Fuel Injection System Fi

    FUEL INJECTION SYSTEM Fault code table Fault Symptom Probable cause of malfunction Diagnostic code codeNo. No normal signals are received from • Open or short circuit in wiring harness. the crankshaft position sensor. • Defective crankshaft position sensor. • Malfunction in pickup rotor. •...
  • Page 254 FUEL INJECTION SYSTEM EAS00907 Diagnostic mode table NOTE: 8 Check the intake air temperature and coolant temprature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively. 8 If it is not possible to check the intake air temperature, use the ambient temperature as refer- ence.

  • Page 255: Troubleshooting Details

    FUEL INJECTION SYSTEM Communication error with the FI diagnostic tool LCD Display Sympton Probable cause of malfunction Waiting for connec- No signals are received from the • Improper installed lead connector in the coupler. tion... ECU. • The main switch is OFF position. •...
  • Page 256 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No. -- Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Check the installed area for looseness or Reinstated by crank- Reinstated by crank- Reinstated by crank-...
  • Page 257 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor-open or short circuit detected. Used diagnostic code No. D03 (intake air pressure sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, reper it and connect Reinstated by turn- nector...
  • Page 258 FUEL INJECTION SYSTEM Intake air pressure sensor-hose system malfunction Fault code No. Symptom (clogged or detached hose). tached hose). Used diagnostic code No. D03 (intake air pressure sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected state of connector Check the coupler for any pins that may have...
  • Page 259 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Used diagnostic code No. D01 (throttle position sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Installed condition of throttle Check the installed area for looseness or Reinstated by start- Reinstated by start- position sensor.
  • Page 260 FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor open or short circuit is detected. Used diagnostic code No. D06 (coolant temperature sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Installed condition of sensor Check the installed area for looseness or Reinstated by turn- Reinstated by turn-...
  • Page 261 FUEL INJECTION SYSTEM Fault code No. Symptom Intake temperature sensor open or short circuit is detected. Used diagnostic code No. D05 (intake air temperature sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Installed condition of sensor Check the installed area for looseness or Reinstated by turn- pinching.
  • Page 262 FUEL INJECTION SYSTEM Fault code No. Symptom The vehicle has overturned. Used diagnostic code No. D08 (lean angle cut-off switch) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method The vehicle has overturned. Raise the vehicle upright. Reinstated by turn- ing the main switch Installed condition of the lean...
  • Page 263 FUEL INJECTION SYSTEM Fault codeNo. Symptom Open circuit detected in the primary lead of the ignition coil. Used diagnostic code No. D30 Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect Reinstated by start- Reinstated by start- Reinstated by start-...
  • Page 264 FUEL INJECTION SYSTEM Fault code No. Symptom Fuel injector open or short circuit is detected. Used diagnostic code No. D36 (fuel injector) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect Reinstated by start- Reinstated by start- Reinstated by start-...
  • Page 265 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the speed sensor. Used diagnostic code No. D07 (speed sensor) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of speed- If there is a malfunction, repair it and connect Reinstated by input- ometer connector...
  • Page 266 FUEL INJECTION SYSTEM Power supply to the fuel injector, fuel pump and ignistion coil are not Fault code No. Symptom normal. Used diagnostic code No. D09 (fuel system voltage) Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect...
  • Page 267 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to FI system is not normal. (red lead) Used diagnostic code No. -- Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect Reinstated by start- Reinstated by start- Reinstated by start-...
  • Page 268 FUEL INJECTION SYSTEM Fault code No. Symptom ISC (idle speed control) valve open or short circuit is detected. Used diagnostic code No. -- Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con- If there is a malfunction, repair it and connect Reinstated by set- Reinstated by set-...

  • Page 269: Throttle Body And Fuel Injector

    THROTTLE BODY AND FUEL INJECTOR EAS00909 THROTTLE BODY AND FUEL INJECTOR THROTTLE BODY Order Job/Part Remarks Q’ty Removing the throttle body Remove the parts in the order listed. Side cover(left and right) Refer to “COVER AND PANEL”in chap- Single seat/Trunk ter 3.

  • Page 270: Fuel Injector And Fuel Hose

    THROTTLE BODYAND FUEL INJECTOR FUEL INJECTOR AND FUEL HOSE Order Job/Part Remarks Q’ty Removing the fuel injector and fuel Remove the parts in the order listed. hose Footrest board Refer to”COVER AND PANEL”in chap- ter 3. Fuel pump coupler Disconnect. Fuel hose connector cover Fuel hose connector Fuel hose holder(to frame)

  • Page 271: Fuel Tank

    THROTTLE BODYAND FUEL INJECTOR FUEL TANK «& 4Nm(0.4m • kg, 2.9 ft • lb) Order Job/Part Remarks Q’ty Removing the fuel tank Remove the parts in the order listed. Place the scooter on a suitable stand. Fuel hose Refer to “FUEL INJECTOR AND FUEL HOSE”.

  • Page 272: Removing The Fuel Hose

    THROTTLE BODY AND FUEL INJECTOR REMOVING THE FUEL HOSE 1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove: 8fuel hose connector cover 1 3. Disconnect: 8fuel hose 2 8 Be sure to disconnect the fuel hose by hand.

  • Page 273: Checking The Throttle Body

    THROTTLE BODY AND FUEL INJECTOR EAS00912 CHECKING THE FUEL INJECTOR 1. Check: 8 fuel injector Damage -» Replace. EAS00913 CHECKING THE THROTTLE BODY 1. Check: 8 throttle body Cracks/damage -» Replace the throttle body. 2. Check: 8 butterfly valve Damage/scratches/wear -»...

  • Page 274: Installing The Fuel Pump

    THROTTLE BODY AND FUEL INJECTOR INSTALLING THE FUEL PUMP 1. Install: 8 fuel pump 4Nm(0.4m»kg, 2.9ft*Ib) NOTE: 8 Do not damage the installation surfaces of the fuel tank when installing the fuel pump. 8 Always use a new fuel pump gasket. 8 Align the projection a on the fuel pump with the alignment mark b on the fuel tank.

  • Page 275: Checking The Fuel Pump And Pressure Regulator Op- Eration

    THROTTLE BODY AND FUEL INJECTOR EAS00915 CHECKING THE FUEL PUMP AND PRES- SURE REGULATOR OPERATION 1. Check: 8 pressure regulator operation • • • • • • • • • • • • • • • • • • • • • • • a.
  • Page 276 THROTTLE BODY AND FUEL INJECTOR Positive tester probe -> blue terminal ® Negative tester probe -» black/blue terminal Digital circuit tester 90890-03174 b. Measure the throttle position sensor volt- age. Out of specification -» Replace or repair the wire harness. Throttle position sensor voltage (blue-black/blue) c.
  • Page 277 THROTTLE BODY AND FUEL INJECTOR EAS00916 CHECKING THE ISC (IDLE SPEED CON- TROL) VALVE NOTE: Do not remove the ISC (idle speed control) valve unit completely from the throttle body assembly. 1. Check: 8ISC (idle speed control) valve • • • • • • • • • • • • • • • • • • • • • • • a.

  • Page 278: Air Induction System

    AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust pipe reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.

  • Page 279: Air Induction System Diagrams

    AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS Air induction system hose Air filter case Air induction system hose (air filter case to air cut-off valve) Air cut-off valve Air induction system hose (air cut-off valve to exhaust pipe) 7-36...

  • Page 280: Air Cut-Off Valve And Air Filter Case

    AIR INDUCTION SYSTEM AIR CUT-OFF VALVE AND AIR FILTER CASE PV 7Nm(0.7m • kg, 5.1 ft • lb) 3R 7Nm(0.7m • kg, 5.1 ft • lb) Order Job/Part Remarks Q’ty Removing the air cut-off valve and Remove the parts in the order listed. air filter case Front cover Refer to”COVER AND PANEL”in chap-...

  • Page 281: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection -» Connect properly. Cracks/damage -» Replace. 2. Check: • reed valve • reed valve stopper • reed valve seat Cracks/damage -» Replace the reed valve. 3.
  • Page 282 ELEC CHAPTER 8 ELECTORICAL ELECTRICAL COMPONENTS WIRING DIAGRAM CHECKING SWITCH CONTINUITY CHECKING THE SWITCHES CHECKING THE BULBS AND BULB SOCKETS TYPES OF BULBS CHECKING THE CONDITION OF THE BULBS CHECKING THE CONDITION OF THE BULB SOCKETS IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING 8-10 ELECTRIC STARTING SYSTEM...

  • Page 283: Electrical Components

    ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS Main switch Spark plug cap Front brake light switch Fuel pump Rectifier/regulator Starter relay Rear brake light switch Horn Battery Turn signal relay Main fuse Starting circuit cut-off relay Stator coil Coolant temperature sensor Wire harness Ignition coil...
  • Page 284 ELEC WIRING DIAGRAM WIRING DIAGRAM Br/W © © © © © © © © © © < — Br/W < rHi' /R~f| < > ' BrT ) j — Br/W r-rrriTTT—rr L / B...

  • Page 285: Wiring Diagram

    WIRING DIAGRAM AC magneto COLOR CODE Rectifier/regulator Black Main fuse Brown Battery Chocolate Starter relay Dark green Starter motor Green Start switch Gray Engine stop switch Blue Light green Main switch Orange Intake air pressure sensor Pink Intake air temperature sensor Throttle position sensor Sky blue Lean angle cut-off switch...

  • Page 286: Checking Switch Continuity

    CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 287: Checking The Switches

    ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear -» Repair or replace. Improperly connected -» Properly connect. Incorrect continuity reading -»...

  • Page 288: Checking The Bulbs And Bulb Sockets

    CHECKING THE BULBS AND BULB SOCKETS EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear -» Repair or replace the bulb, bulb socket or both. Improperly connected -»...

  • Page 289: Checking The Condition Of The Bulbs

    CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 8bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Be sure to hold the socket firmly when removing the bulb.

  • Page 290: Checking The Condition Of The Bulb Sockets

    CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. Check: • bulb socket (for continuity) (with the pocket tester) No continuity -» Replace. Pocket tester 90890-03112 (YU-03112-C) NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section;...

  • Page 291: Ignition System

    ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM -•- 1,®...

  • Page 292: Troubleshooting

    IGNITION SYSTEM EAS00736 EAS00738 TROUBLESHOOTING 1. Main Fuse • Check the fuse for continuity. The ignition system fails to operate (no Refer to “CHECKING THE FUSE” in chap- spark or intermittent spark). ter 3. Is the fuse OK? Check: 1. main fuse 2.
  • Page 293 IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance Disconnect the spark plug cap from the spark • Remove the spark plug cap from the spark plug. plug lead. Connect the ignition checker 1 as shown. •...
  • Page 294 IGNITION SYSTEM EAS00748 7. Crankshaft position sensor resistance • Disconnect the crankshaft position sensor coupler from the wire harness. • Connect the pocket tester (£2 x100) to the crankshaft position sensor coupler shown. Positive tester probe g white/red 1 Negative tester probe g white/blue2 •...
  • Page 295 ELEC IGNITION SYSTEM EAS00750 9. Engine stop switch • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? Replace right handlebar switch. EAS00752 10. Sidestand switch(optional) Replace the lean angle •...

  • Page 296: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main fuse Battery Starter relay Starter motor Start switch Engine stop switch Main switch 8-14...

  • Page 297: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OP- ERATION If the engine stop switch is set to “ # ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: 8 The brake lever(front or rear) is pulled to the handlebar(the brake light switch is...

  • Page 298: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS00757 EAS00738 TROUBLESHOOTING 1. Main Fuse • Check the fuse for continuity. The starter motor fails to turn. Refer to “CHECKING THE FUSE” in chap- ter 3. Check: Is the fuse OK? 1. main fuse 2. battery 3.
  • Page 299 +1 I ELEC ELECTRIC STARTING SYSTEM EAS00758 EAS00759 4. Starting circuit cut-off relay • Remove the starting circuit cut-off relay. • Connect the pocket tester x1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown. Positive battery terminal -»...
  • Page 300 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00751 5. Starter relay 7. Brake light switch(front and rear) • Remove the starter relay . • Check the brake light switches for continu- • Connect the pocket tester x1) and bat- ity. tery (12 V) to the starter relay coupler as Refer to “CHECKING THE SWITCHES”.
  • Page 301 ELECTRIC STARTING SYSTEM EAS00766 11. Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly con- nected and without defects? The starting system Properly connect or re- circuit is OK. pair starting system’s wiring.

  • Page 302: Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00767 STARTER MOTOR ® ® Order Job/Part Remarks Q’ty Removing the starter motor Remove the parts in the order listed. Front cover Refer to “COVER AND PANEL”in chap- Single seat/Trunk ter 3. Air filter assembly Refer to“ENGINE REMOVAL”in chapter Starter motor lead coupler Disconnect.

  • Page 303: Checking The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt -» Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification -» Replace the starter motor. Commutator wear limit 16.6 mm (0.65 in) Measure: •...
  • Page 304 ELEC ELECTRIC STARTING SYSTEM b. If any resistance is out of specification, re- place the starter motor. • • • • • • • • • • • • • • • • • • • • • • • 5.

  • Page 305: Assembling The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: 8brush seat 1 2. Install: 8washer1 8armature coil 2 8o-ing 8stator assembly4 3 . Install: • bracket • bolts 5 Nm (0.5 m kg, 3.6 ft NOTE: Align the match marks a on the starter motor yoke with the match marks b on the bracket.

  • Page 306: Charging System

    ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM © AC magneto © Rectifier/regulator Main fuse -vJHHL/-' —111 i« Battery © 1 C r y J £1 -rfrffr-rr —LIUL U - l — 0 @ ©@© 12V10W L i " j LVlAr 12V10W [J -=r...

  • Page 307: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The battery is not being charged. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1 . main fuse Minimum open-circuit voltage 2. battery 12.8 V or more at 20°C (68°F) 3.
  • Page 308 ELEC CHARGING SYSTEM EAS00779 NOTE: 5. Wiring Make sure the battery is fully charged. • Check the wiring connections of the entire charging system. • Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly con- nected and without defects? The charging circuit is Replace the recti-...

  • Page 309: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM Br/W © © © © © © © © © © < I ! -H • 8-27...

  • Page 310: Troubleshooting

    LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Any of the following fail to light: headlight, Refer to “CHECKING AND CHARGING high beam indicator light, taillight, license THE BATTERY” in chapter 3. plate light or meter light. Minimum open-circuit voltage Check: 12.8 V or more at 20°C (68°F)
  • Page 311 LIGHTING SYSTEM EAS00787 5. Wiring • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly con- nected and without defects? Properly connect or re- Check the condition pair the lighting system’s of each of the light- wiring.

  • Page 312: Checking The Lighting System

    ELEC LIGHTING SYSTEM EAS00788 3. Voltage CHECKING THE LIGHTING SYSTEM • Connect the pocket tester (DC 20 V) to the 1. The headlight and the high beam indicator headlight and high beam indicator light cou- light fail to come on. plers as shown.
  • Page 313 ELEC LIGHTING SYSTEM EAS00789 2. The meter light fails to come on. 1. Meter light bulb and socket The wiring circuit from • Check the meter light bulb and socket for This circuit is OK. the main switch to the continuity.
  • Page 314 ELEC LIGHTING SYSTEM EAS00790 3. Voltage The tail/brake light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket ECU coupler (wire harness side) as shown. • Check the tail/brake light bulb and socket for continuity.
  • Page 315 LIGHTING SYSTEM EAS00792 4. The license plate light fails to come on. 1. License plate light bulb and socket • Check the license plate light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the license plate light bulb and socket Replace the license plate light bulb, socket or both.

  • Page 316: Signaling System

    ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM - H " ^<^ Or/B Main fuse Battery © Main switch Fuel pump Horn switch Turn signal switch Tail/brake light Front brake light switch Rear brake light switch © © Horn © Turn signal relay ©...

  • Page 317: Troubleshooting

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

  • Page 318: Checking The Signaling System

    ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM • Disconnect the pink connector at the horn terminal. The horn fails to sound. • Connect a jumper lead © to the horn termi- nal and ground the jumper lead. 1.
  • Page 319 ELEC SIGNALING SYSTEM EAS00798 3. Voltage The tail/brake light fails to come on. • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) 1. Tail/brake light bulb and socket as shown. • Check the tail/brake light bulb and socket for continuity.
  • Page 320 ELEC SIGNALING SYSTEM EAS00799 4. Voltage 3. The turn signal light, turn signal indicator light • Connect the pocket tester (DC 20 V) to the or both fail to blink. turn signal relay coupler (wire harness side) as shown. 1. Turn signal indicator light bulb and socket •...
  • Page 321 SIGNALING SYSTEM 5. Voltage 6. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) turn signal light connector or meter assem- as shown.
  • Page 322 ELEC SIGNALING SYSTEM EAS00804 2. Voltage 4. The fuel level meter fails to operate. • Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as 1. Fuel sender shown. • Remove the fuel pump from the fuel tank. •...
  • Page 323 ELEC SIGNALING SYSTEM 3. Fuel level meter • Set the main switch to “ON”. • Move the float u p ® or down (2). • Check that the fuel level meter needle moves to “F” or “E”. NOTE: Before reading the fuel level meter, leave the float in one position (either up or down) for at least three minutes.

  • Page 324: Cooling System

    ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Br/W © © © © © © © © © © < I ! -H • 8-42...

  • Page 325: Troubleshooting

    ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • The coolant temperature indicator light Refer to “CHECKING AND CHARGING fails to indicate. THE BATTERY” in chapter 3. • The coolant temperature indicator light fails to indicate when the engine is warm.
  • Page 326 +1 I ELEC COOLING SYSTEM EAS00812 Coolant temperature sensor 4. Coolant temperature sensor 22 Nm (2.2 m • kg, 15.9 ft • Remove the coolant temperature sensor from the cylinder head. • Does the coolant temperature sensor oper- Connect the pocket tester ( ×...

  • Page 327: Checking The Cooling System

    COOLING SYSTEM CHECKING THE COOLING SYSTEM 3. Voltage • Connect the pocket tester (DC 20 V) to the The coolant temperature indicator light fails meter light coupler (wire harness side) as to come on. shown. 1. Coolant temperature indicator light bulb and socket Positive tester probe ->...
  • Page 328 ELEC COOLING SYSTEM 4. Coolant temperature indicator light • Disconnect the coolant temperature sensor coupler at the coolant temperature sensor. • Connect the green/red® black/blue® with a jumper lead®. • Set the main switch to “ON”. • Is the coolant temperature indicator light OK? Replace the coolant This circuit is OK.
  • Page 329 TRBL SHTGl • CHAPTER 9 TROUBLE SHOOTING STARTING FAILURE/HARD STARTING ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING SPEED ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY CLUTCH ENGINE FUEL SYSTEM FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL NOT MOVE CLUTCH SLIPS POOR STARTING PERFORMANCE POOR SPEED PERFORMANCE...
  • Page 330 TRBL SHTGl • TURN SIGNAL DOES NOT COME ON TURN SIGNAL BLINKS SLOWLY TURN SIGNAL REMAINS LIT TURN SIGNAL BLINKS QUICKLY HORN DOES NOT SOUND...

  • Page 331: Starting Failure/Hard Starting

    TRBL STARTING FAILURE/HARD STARTING SHTGl • EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.

  • Page 332: Speed

    TRBL STARTING FAILURES/HARD STARTING/ INCORRECT ENGINE IDLING SPEED SHTGl • EAS00847 Starting system INCORRECT ENGINE IDLING 8Faulty starter motor SPEED 8Faulty starter relay 8Faulty starting circuit cut-off relay ENGINE 8Faulty starter clutch Cylinder and cylinder head 8Incorrect valve clearance 8Damaged valve train components Air filter 8Clogged air filter element FUEL SYSTEM...

  • Page 333: Poor Medium-And-High-Speed Performance/Faulty Clutch

    TRBL POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY CLUTCH SHTGl • EAS00848 EAS00853 POOR MEDIUM-AND-HIGH- FAULTY CLUTCH SPEED PERFORMANCE ENGINE OPERATES BUT SCOOTER WILL NOT MOVE Refer to “STARTING FAILURE/HARD START- ING”. V-belt ENGINE 8Bent, damaged or worn V-belt Air filter 8Slipping V-belt 8Clogged air filter element Primary pulley cam and primary pulley slider FUEL SYSTEM...

  • Page 334: Poor Speed Performance

    TRBL FAULTY CLUTCH/OVERHEATING/OVERCOOLING SHTGl • POOR SPEED PERFORMANCE Hose(s) and pipe(s) V-belt 8Damaged hose 8Worn V-belt 8Improperly connected hose 8Oil or grease on the V-belt 8Damaged pipe 8Improperly connected pipe Primary pulley weight(s) 8Faulty operation FUEL SYSTEM 8Worn primary pulley weight Throttle body 8Damaged or loose throttle body joint Primary fixed sheave...

  • Page 335: Poor Braking Performance/Faulty Front Fork Legs/Un- Stable Handling

    TRBL POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING SHTGl • EAS00859 EAS00862 POOR BRAKING PERFORMANCE UNSTABLE HANDLING Drum brake Handlebar 8Worn brake shoe 8Bent or improperly installed handlebar 8Worn or rusty brake drum 8Incorrect brake lever position Steering head components 8Incorrect brake lever free play 8Improperly installed handlebar bracket 8Incorrect brake camshaft lever position...

  • Page 336: Faulty Lighting Or Signaling System

    TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTGl • EAS00866 TURN SIGNAL REMAINS LIT FAULTY LIGHTING OR SIGNALING 8 F a u l t y t u r n signal relay SYSTEM 8Burnt-out turn signal bulb TURN SIGNAL BLINKS QUICKLY HEADLIGHT DOES NOT COME ON 8Incorrect turn signal bulb 8Wrong headlight bulb 8Faulty turn signal relay...
  • Page 337 ©YAMAHA YAMAHA MOTOR TAIWAN CO., LTD...
  • Page 338 XF50W WIRING DIAGRAM —^ •q= » • • © XK • c • • » MARK EXPLANATION R, Br, BrW... COLOR C O D E CONNECTING WITH G R D . WIRE GRD. • CONNECTOR MARK (BETWEEN MAIN & SUB HARNESS)

This manual is also suitable for:

2006 xf50w

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