Page 1: Service Manual
XC50V SERVICE MANUAL LIT-11616-19-49 3D1-F8197-10...
Page 2 EAS00000 XC50V 2005 SERVICE MANUAL ©2005 by Yamaha Motor Taiwan Co., Ltd. First edition, July 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd. is expressly prohibited. LIT-11616-19-49...
Page 3 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 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: General Information
EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Carburetor(s) 8 Electrical system...
Page 6: Table Of Contents
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING COOL CARBURETOR CARB ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
Page 7: Gen Info
INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL LABEL .................. 1-1 IMPORTANT INFORMATION ..............1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ....1-2 REPLACEMENT PARTS ..............1-2 GASKETS, OIL SEALS AND O-RINGS ..........1-2 LOCK WASHERS/PLATES AND COTTER PINS ......
Page 8: General Information
SCOOTER IDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the trunk. This information will be needed to order spare parts.
Page 9: Important Information
5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but infe- rior in quality.
Page 10: Lock Washers/Plates And Cotter Pins
IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the...
Page 11: Notes 3 On Equipment Preparation
IMPORTANT INFORMATION INFO JAS00021 Notes 3 on equipment preparation Push Rivet (Push type) Assembly status of the Push Rivet (Push type) Dissembling 1. Press Center Pin 1 inward to release the Lock. 2. Remove the Push Rivet main body 2. Assembling 1.
Page 12: Checking The Connections
CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector 2. Check: 8 lead 8 coupler 8 connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times.
Page 13: Special Tools
SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
Page 14 SPECIAL TOOLS INFO Tool NO. Tool name / Function Illustration 90890-01367 Fork seal driver weight1 YM-A9409-7 90890-01400 Fork seal driver attachment(Ø30mm)2 YM-A9409-3 This tool is used when installing the fork seal. 90890-01384 Oil seal guide YM-33299 This tool is used for protecting the oil seal lip when installing the secondary sliding sheave.
Page 15 YM-04113 This tool is used to rebore the new valve guides. 90890-06754 Ignition checker YM-34487 This instrument is necessary for checking the ignition system components. 90890-85505 Yamaha bond NO.1215 ACC-11001-05-01 This sealant (bond) is used on crankcase mating surfaces, etc.
Page 16: Spec
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS ..............2-2 CHASSIS SPECIFICATIONS ..............2-10 ELECTRICAL SPECIFICATIONS ............2-12 CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICA- TIONS ....................2-15 TIGHTENING TORQUES................ 2-16 ENGINE .................... 2-16 CHASSIS ..................2-18 LUBRICATION POINTS AND LUBRICANT TYPES ......2-19 ENGINE ....................
Page 17: General Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 3D11 (for USA) … 3D12 (for CAN) … Dimensions Overall length 1665 mm( 65.6in ) … Overall width 630 mm( 24.8in ) … Overall height 1005 mm( 39.6in ) …...
Page 18: Engine Specifications
Wet sump … Recommended oil SAE10W40 … -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚ Yamaha 4-cycle oil EFERO X,Z,BX SAE 10W-30 SAE 10W-40 SAE 20W-40 SAE 20W-50 Quantity Periodic oil change 0.73~0.83 L (0.67~0.76 Imp qt, … 0.80~0.90 US qt) Total amount 0.8~0.9L (0.74~0.83 Imp qt,...
Page 19 SPEC ENGINE SPECIFICATIONS Standard Limit Item Oil filter Oil filter type Wire mesh … Oil pump Oil pump type Trochoid … Inner rotor to outer rotor tip clearance 0.15 mm or less 0.23mm Outer rotor to pump housing clearance 0.13-0.18 mm 0.25mm Oil pump housing to inner rotor and outer 0.07-0.12 mm...
Page 20 SPEC ENGINE SPECIFICATIONS Standard Limit Item Camshaft Drive system Chain drive (left) … Intake camshaft lobe dimensions Measurement A 30.158~30.258 mm 30.058 mm Measurement B 25.082~25.182 mm 24.982 mm Measurement C 5.2077mm … Exhaust camshaft lobe dimensions Measurement A 30.158~30.258 mm 30.058 mm Measurement B 25.020~25.120 mm...
Page 21 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 0.10~0.16 mm … Exhaust 0.18~0.24 mm … Valve dimensions Head Diameter Face Width Seat Width Margin Thickness...
Page 22 SPEC ENGINE SPECIFICATIONS Standard Limit Item Valve springs Free length Intake 39.35 mm 37.38 mm Exhaust 41.57 mm 39.49 mm Installed length (valve closed) Intake 28.0mm … Exhaust 30.0mm … Compressed spring force (installed) Intake 91.1~104.9N(9.3~10.7kg) … Exhaust 107.9~124.1N … (11.0~12.7kg) Spring tilt Intake...
Page 23 SPEC ENGINE SPECIFICATIONS Standard Limit Item Piston Piston-to-cylinder clearance 0.010~0.035 mm 0.150mm Diameter D 37.975~37.990 mm … Height H 5.0 mm … Piston pin bore (in the piston) Diameter 10.002~10.013 mm 10.043 mm Offset 0.35~0.65mm … Offset direction Intake side …...
Page 24 SPEC ENGINE SPECIFICATIONS Standard Limit Item Rocker arm/rocker arm shaft Rocker arm inside diameter 10.000~10.015mm … Rocker arm shaft outside diameter 9.981~9.991 mm … Arm-to-shaft clearance 0.009~0.034 mm … Connecting rod Connecting rod length 79.95~80.05 mm … Small end inside diameter 10.015~10.028mm …...
Page 25 SPEC ENGINE SPECIFICATIONS Standard Limit Item Clutch Clutch type Automatic centrifugal … Clutch shoe thickness 3.7 mm 2.0mm Clutch shoe spring free length 30.1±0.4mm … Clutch housing inside diameter 107 mm … Compression spring free length 76.4 mm … Weight outside diameter 15.0 mm 14.5 mm Clutch-in revolution...
Page 26: Chassis Specifications
SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Standard Limit Item Frame Frame type Steel tube underbone … Caster angle 24 ° … Trail 70 mm … Front wheel Wheel type Cast wheel … Size J10 × MT2.15 … Material Aluminum … Wheel travel 59mm …...
Page 27 SPEC CHASSIS SPECIFICATIONS Standard Limit Item Front brake Brake type Drum brake … Operation Right-hand operation … Brake lever free play (at lever end) 10~20mm … Brake drum inside diameter 110 mm 110.5mm Lining thickness 4.0mm 2.0mm Rear brake Brake type Drum brake …...
Page 28: Electrical Specifications
SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Standard Limit Item System voltage … Ignition system Ignition system type C.D.I. … Ignition timing 13 ° B.T.D.C. at … 2000~2400 r/min Advancer type Digital … 248~372 Ω / WR-WL Pickup coil resistance /color … C.D.I.
Page 29 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Bulbs (voltage/wattage × quantity) Headlight 12 V 35W/35W × 1 … Tail/brake light 12 V 5W/21 W × 1 … Front turn signal light 12 V 10 W × 2 … Rear turn signal light 12 V 10 W ×...
Page 30 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Throttle position sensor Output voltage (throttle opens) 2.8~3.4V … Output voltage (throttle closes) 0.625~0.775V … Radiator fan Model (manufacturer) 5ST-00 (LUNTAI) … Running rpm 10000 r/min … Thermostat switch Model (manufacturer) 5ST (NIPPON THERMOSTAT) … Thermo unit Model (manufacturer) 5JJ (NIPPON THERMOSTAT) …...
Page 31: Convertion Table / General Tightening Torque Specifica- Tions
CONVERTION TABLE / GENERAL TIGHTENING SPEC TORQUE SPECIFICATIONS EB201000 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
Page 32: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE Tightening Thread Part to be tightened ’ Part name torque Remarks size Nm m•kg ft•lb Cylinder head and cylinder Spark plug 12.5 1.25 Cylinder head(timing chain side) Bolt Exhaust pipe stud bolt 12.5 1.25 Cylinder head cover Oil check bolt Water pump housing cover...
Page 33 SPEC TIGHTENING TORQUES Tightening Thread ’ Part to be tightened Part name torque Remarks size Nm m•kg ft•lb Clutch housing 28.9 Ignition coil Bolt Thermo unit PT1/8 Primary fixed sheave 21.7 Starter motor assembly Bolt AC magneto rotor 31.1 Stator coil Bolt Pickup coil Screw...
Page 34: Chassis
SPEC TIGHTENING TORQUES CHASSIS Tightening Thread Part to be tightened torque Remarks size m•kg ft•lb Frame and engine bracket 3 33.1 Engine bracket 3 and engine 42.0 Handlebar and steering shaft 43.4 Front fork and lower bracket 21.7 Seat lock assembly Rear carrier(front) Rear carrier(rear) 16.6...
Page 35: Lubrication Points And Lubricant Types
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant Oil seal lips O-rings (Except V-belt drive unit) Cylinder head tightening nut mounting surface Cylinder head stud bolt thread Cylinder head gasket dowel pin Crankshaft pin outside surface Connecting rod Piston outside and ring groove...
Page 36 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Lubricant ® Secondary fixed sheave inner surface BEL-RAY asembly lube Secondary sliding sheave torque cam ditch ® BEL-RAY asembly lube Crankcase mating surfaces Sealant 2-20...
Page 37: Chassis
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Lubricant Front wheel oil seal lips Steering bearing and bearing races (upper and lower) Frame head pipe dust seal lips ( lower) Tube guide (throttle grip) inner surface Brake lever and lever holder bolt sliding surface Centerstand pivoting point and sliding surface Rear shock absorber backward, bush inner surface and spacer sliding surface Seat lock cable and rear wheel lock cable inner surface...
Page 38: Cooling System Diagrams
SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Raidator cap 2 Coolant reservoir 3 Radiator inlet hose 4 Radiator outlet hose 5 Thermo switch 6 Conduit hose 2-22...
Page 39 SPEC COOLING SYSTEM DIAGRAMS 1 Outlet hose(to cylinder) 2 Radiator inlet hose 3 Radiator outlet hose 4 Thermostat 5 Thermostat housing 2-23...
Page 40 SPEC COOLING SYSTEM DIAGRAMS 1 Breather hose 2 Outlet hose(to cylinder) 3 Radiator outlet hose 4 Water pump 2-24...
Page 41 SPEC COOLING SYSTEM DIAGRAMS 1 Thermostat housing 2 Thermostat assembly inlet breather hose 3 Water pump 4 Breather hose 2-25...
Page 42: Oil Flow Diagrams
SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Oil filter 2 Oil pump 3 To cylinder head 4 Oil strainer 5 Oil nozzle 6 Camshaft 2-26...
Page 43 SPEC OIL FLOW DIAGRAMS 1 Crankshaft pin 2 Connecting rod big end bearing 3 Oil nozzle 4 Camshaft Rocker arm shaft Cylinder wall and rocler arm Connecting rod Camshaft big end bearing Crankshaft pin Oil nozzle Centrifugal oil filter Oil pump Oil filter Crankcase sump 2-27...
Page 44: Cable Routing
SPEC CABLE ROUTING A Insert the wire harness plate G Clamp the seat lock cable EAS00035 CABLE ROUTING holder to the T-stud of down and wire harness to the frame tube . of cover , install upward of the 1 Fuel sender lead B Insert the seat lock cable into seat lock cable .
Page 45 SPEC CABLE ROUTING 1 Turn signal relay A Fasten the throttle cable kit and Rear wheel lock cable 2 Horn and rear brake cable to the through upward of the frame. 3 Head light relay I Route the rear brake cable frame and cut the end to be 4 Speedometer cable shorter than 5mm, point the...
Page 46 SPEC CABLE ROUTING M Assemble the horn lead to the best forward of connec- tor cover, do not through back side of the other leads. N Route the turn signal relay lead and front turn signal light lead(left) through backward of the steering head pipe.
Page 47 SPEC CABLE ROUTING 1 Battery negative - lead E Route the starter motor lead L Route the throttle cable kit 2 Battery positive + lead through upward of the en- through upward of the 3 Fuse box gine bracket and through left breather pipe.
Page 48 SPEC CABLE ROUTING 1 Front brake cable A After locking the right side tightening torque 2 Front brake switch lead switch of control lever, con- 3Nm(0.3m.kg,2.2ft.lb). 3 Speedometer assembly E Route the lever holder firm the driving status of 4 Speedometer cable holder.
Page 49 SPEC CABLE ROUTING H After spread with adhesion N Install the speedometer as- R Route the throttle cable agent on the inner side, push sembly to the handlebar through upper of handlebar the grip into the handlebar bracket, and tightening torque guide and handlebar upper assembly.
Page 50: Chk Adj
CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..................3-1 PERIODIC MAINTENANCE AND MINOR REPAIR ........ 3-2 Periodic maintenance chart for the emission control system ... 3-2 General maintenance and lubrication chart........3-3 COVER AND PANEL ................3-5 SEAT AND TRUNK ................3-5 SIDE COVER (LEFT AND RIGHT) ...........
Page 51 CHECKING THE TIRES ..............3-44 CHECKING THE WHEELS.............. 3-47 CHECKING AND LUBRICATING THE CABLES ......3-47 LUBRICATING THE LEVERS AND PEDALS ......... 3-48 LUBRICATING THE CENTERSTAND ..........3-48 ELECTRICAL SYSTEM ................. 3-49 CHECKING AND CHARGING THE BATTERY....... 3-49 CHECKING THE FUSE ..............3-55 REPLACING THE HEADLIGHT BULB ...........
Page 52: Introduction
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 30,000 km, repeat the maintenance intervals starting from 6,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 53: Periodic Maintenance And Minor Repair
• Check the air cut-off valve, reed √ √ √ √ √ Air induction system valve, and hose for damage. • Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Page 54: General Maintenance And Lubrication Chart
Every 6250 mi (10000 km) Front and rear brake √ √ √ √ √ √ • Check operation. switches • Apply Yamaha chain and cable Control and meter √ √ √ √ √ √ lube or engine oil 10W-30 cables thoroughly.
Page 55 PERIODIC MAINTENANCE AND MINOR REPAIR * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 12000 mi ( 19000 km) or 36 months, repeat the maintenance intervals starting from 4000 mi (7000 km) or 12 months.
Page 56: Cover And Panel
COVER AND PANEL COVER AND PANEL SEAT AND TRUNK 12Nm (1.2 m•kg, 8.7 ft•lb) 12Nm (1.2 m•kg, 8.7 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 23Nm (2.3 m•kg, 16.6 ft•lb) Order Job/Part Q’ty Remarks Removing the seat and trunk Remove the parts in the order listed. Seat Damper Rubber cap...
Page 57: Side Cover (Left And Right)
COVER AND PANEL SIDE COVER (LEFT AND RIGHT) Order Job/Part Q’ty Remarks Removing the side cover(left and Remove the parts in the order listed. right) Seat/Trunk Refer to “SEAT AND TRUNK”. Tail / brake and rear turn signal (left, Disconnect. right) light lead Front cover Side cover(left)
Page 58: Footrest Board And Footrest Board Side Cover Mole
COVER AND PANEL FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE 4Nm (0.4 m•kg, 2.9 ft•lb) Order Job/Part Q’ty Remarks Removing the footrest board and Remove the parts in the order listed. footrest board side cover mole Side cover(left and right) Refer to “SIDE COVER(LEFT AND RIGHT)”.
Page 59: Leg Shield 1 , 2
COVER AND PANEL LEG SHIELD 1 , 2 Order Job/Part Q’ty Remarks Removing the leg shield 1,2 Remove the parts in the order listed. Footrest board Refer to “FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE”. Headlight cover Head and front turn signal (left, right) light Disconnect.
Page 60: Engine
ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: 8 Valve clearance adjustment should be made on a cold engine, at room temperature. 8 When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 61 ADJUSTING THE VALVE CLEARANCE d. Measure the valve clearance with a thick- ness gauge 1. Out of specification Adjust. ***************************************************** 6. Adjust: 8valve clearance ***************************************************** a. Remove the valve pad 2 with a magnetic bar 1. NOTE: 8 Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.
Page 62 ADJUSTING THE VALVE CLEARANCE Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table.
Page 63 ADJUSTING THE VALVE CLEARANCE INTAKE ORIGINAL VALVE PAD NUMBER MEASURED 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 0.05∼0.09 STANDARD CLEARANCE 0.10∼0.16 0.17∼0.21 0.22∼0.26...
Page 64 ADJUSTING THE VALVE CLEARANCE 7. Install: 8all removed parts NOTE: For installation, reverse the removal procedure. 8. Fill: 8cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT”. 3-13...
Page 65: Adjusting The Engine Idling Speed
ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING 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 66: Checking The Exhaust Gas At Idle
CHECKING THE EXHAUST GAS AT IDLE CHECKING THE EXHAUST GAS AT IDLE ( Measuring the exhaust gas at idle(when air in- duction system is operation)) 1. Stand the scooter on a level surface. NOTE: 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright.
Page 67 CHECKING THE EXHAUST GAS AT IDLE NOTE: 8 Since it is necessary to insert the sampling probe 600mm into the exhaust pipe, be sure to use a heat-resisant rubber tube as shown in the illustration. 8 Be sure to set the heat-resistant rubber tube so that exhaust gas does not leak out.
Page 68: Adjusting The Throttle Cable Free Play
ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00057 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: 8 throttle cable free play a Out of specification Adjust.
Page 69: Checking The Spark Plug
CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Remove: 8 battery cover 8 battery holder Refer to “COVER AND PANEL”. 2. Disconnect: 8 spark plug cap 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 into the cylinder.
Page 70: 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. Drain: 8coolant (completely from the radiator ) 2.
Page 71 CHECKING THE IGNITION TIMING NOTE: The ignition timing is not adjustable. ***************************************************** 5. Remove: 8timing light 8engine tachometer 6. Install: 8fan case 8radiator 8radiator cover Refer to “RADIATOR”in chapter 6. 7. Fill: 8cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT”.
Page 72: 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: 8valve 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 73 MEASURING THE COMPRESSION PRESSURE Compression pressure (at sea level) Minimum 1262 kPa (12.6 kgf/cm , 700r/min) Standard 1450 kPa (14.5 kgf/cm , 700r/min) Maximum 1624 kPa (16.2 kgf/cm , 700r/min) ***************************************************** Set the main switch to “ON”. With the throttle wide open, crank the en- gine until the reading on the compression gauge stabilizes.
Page 74: 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 75: Changing The Engine Oil
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: 8 engine oil filler cap 1 8 engine oil drain bolt 2 (along with the gasket) 4.
Page 76 CHANGING THE ENGINE OIL 8. Install: 8engine oil filler cap 9. 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 77: Changing The Transmission Oil
CHANGING THE TRANSMISSION OIL CHANGING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. NOTE: 8 Stand the scooter on a suitable stand. 8 Make sure that the scooter up right. 2. Start the engine, warm it up for several min- utes, and then turn it off.
Page 78: 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 79 MEASURING THE ENGINE OIL PRESSURE 6. Install: 8 gallery bolt 7 Nm (0.7 m • kg, 5.1 ft • lb) 7. Install: 8 front cover 8 battery cover 8 seat/trunk Refer to “COVER AND PANEL”. 3-28...
Page 80: Checking The Air Filter Element
CHECKING THE AIR FILTER ELEMENT EAS00086 CHECKING THE AIR FILTER ELEMENT 1. Remove: 8 air filter case cover 1 8 air filter element 2. Check: 8 air filter element Damage/dirty Replace. 3. Install: 8air filter element 8air filter case cover 10 Nm (1.0 m •...
Page 81: Checking The Carburetor Joint And Intake Manifold
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/CHECKING THE FUEL AND VACUUM HOSES EAS00094 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Remove: 8 seat/trunk 8 rear carrier 8 battery cover 8 front cover 8 side cover (left and right) 8 rear cover Refer to “COVER AND PANEL”.
Page 82: Checking The Fuel Hoses And Fuel Filter
CHECKING THE FUEL HOSES AND FUEL FILTER EAS00097 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. 1. Remove: 8battery cover 8seat/trunk 8rear carrier 8front cover 8side cover (left and right) 8rear cover Refer to “COVER AND PANEL”.
Page 83: Checking The Crankcase Breather Hose
CHECKING THE CRANKCASE BREATHER HOSE EAS00098 CHECKING THE CRANKCASE BREATHER HOSE Remove: 8seat/trunk Refer to “COVER AND PANEL”. Check: 8crankcase breather hose 1 Cracks/damage Replace. Loose connection Connect properly. Make sure the crankcase breather hose is routed correctly. Install: 8seat/trunk Refer to “COVER AND PANEL”.
Page 84: Checking The Exhaust System
CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler assembly and gaskets. 1. Remove: 8 muffler assembly Refer to “MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY” in chapter 5. 2 . Check: 8 muffler assembly 1 Cracks/damage Replace.
Page 85: 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. Remove: 8 mat 8 battery cover Refer to “COVER AND PANEL”. Check: 8 coolant level The coolant level should be between the...
Page 86: Checking The Cooling System
CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM Remove: 8 seat/trunk 8 battery cover 8 front cover 8 battery holder/ battery 8 footrest board side cover mole( left and right) 8 mat/footrest board Refer to “COVER AND PANEL”. 8 radiator cover Refer to “COOLING SYSTEM”in chap- ter 6.
Page 87: Changing The Coolant
CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: 8 mat 8 battery cover 8 footrest board side cover mole (right) Refer to “COVER AND PANEL”. 8 radiator cover Refer to “COOLING SYSTEM”in chap- ter 6. 2. Disconnect: 8 coolant reservoir hose 1 3.
Page 88 CHANGING THE COOLANT 7. Fill: 8 cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion inhibi- tors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 0.52 L (0.48 Imp qt, 0.57 US qt) Coolant reservoir capacity 0.26 L (0.24 Imp qt, 0.28 US qt) From minimum to maximum level...
Page 89 CHANGING THE COOLANT 9. Fill: 8 coolant reservoir (with the recommended coolant to the maximum level mark a) 10.Install: 8 coolant reservoir cap 11.Start the engine, warm it up for several min- utes, and then stop it. 12.Check: 8 coolant level Refer to “CHECKING THE COOLANT LEVEL”.
Page 90: 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 ~ 20 mm (0.394 ~ 0.787 in) Adjust: 8 brake lever free play *****************************************************...
Page 91: Checking The Front And Rear Brake Shoes
CHECKING THE FRONT AND REAR BRAKE SHOES EAS00127 CHECKING THE FRONT AND REAR BRAKE SHOES 1. Operate the brake. 2. Check: 8 wear indicator 1 Reaches the wear limit line 2 Replace the brake shoes as a set. Refer to “FRONT WHEEL AND FRONT BRAKE”...
Page 92: Checking And Adjusting The Steering Head
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 93 CHECKING AND ADJUSTING THE STEERING HEAD Do not overtighten the upper bearing inner race. Upper bearing inner race(final tight- ening torque) 7 Nm (0.7 m • kg, 5.1 ft • lb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions.
Page 94: 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: 8inner tube Damage/scratches Replace. 8dust seal Damage/scratches Replace.
Page 95: Checking The Tires
CHECKING THE TIRES EAS00163 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 8tire pressure Out of specification Regulate. 8 8 8 8 8 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air tem- perature.
Page 96 The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one ap- proved by Yamaha is used on this scooter. Front tire Manufacturer Model...
Page 97 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 98: Checking The Wheels
CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. Check: 8wheel Damage/out-of-round Replace. Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or re- placed, always balance the wheel.
Page 99: Lubricating The Levers And Pedals
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 100: Electrical System
CHECKING AND CHARGING THE BATTERY EAS00179 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 8 8 8 8 8 Wear protective eye gear when handling or working near batteries.
Page 101 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 102 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 c. Open-circuit voltage = 12.0 V 11.5 d.
Page 103 CHECKING AND CHARGING THE BATTERY 8 8 8 8 8 Make sure the battery charger lead clips are in full contact with the battery ter- minal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.
Page 104 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. Connect a charger and am- NOTE: meter to the battery and Set the charging voltage to 16-17 V.
Page 105 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 106: Checking The Fuse
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSE 6. Install: 8 battery 7. Connect: 8 battery leads (to the battery terminals) First, connect the positive battery lead 1 1 1 1 1 , and then the negative battery lead 2 2 2 2 2 . 8.
Page 107 CHECKING THE FUSE 2. Check: 8 fuse ***************************************************** a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03132 (YU-03112-C) b. If the pocket tester indicates “∞”, replace the fuse.
Page 108: Replacing The Headlight Bulb
REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: 8 headlight cover 2. Disconnect: 8 headlight coupler 3. Remove: 8 headlight bulb holder rubber1 8 headlight bulb holder 8 headlight bulb 2 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
Page 109: Adjusting The Headlight Beam
ADJUSTING THE HEADLIGHT BEAM EAS00184 ADJUSTING THE HEADLIGHT BEAM Adjust: 8headlight beam (vertically) ***************************************************** Turn the adjusting screw 1 in direction a or b . Direction a Headlight beam is raised. Direction b Headlight beam is lowered. ***************************************************** Adjust: 8 headlight beam (horizontally) ***************************************************** Turn the adjusting knob 2 in direction a or Direction a...
Page 110: Chas
CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE ..............4-1 FRONT WHEEL ................. 4-2 FRONT BRAKE SHOE PLATE ............4-3 REMOVING THE FRONT WHEEL ............ 4-4 DISASSEMBLING THE BRAKE SHOE PLATE ........ 4-4 CHECKING THE FRONT WHEEL ............ 4-5 CHECKING THE SPEEDOMETER GEAR UNIT ......4-6 CHECKING THE BRAKE ..............
Page 111 CHAS REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ..4-35 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ..4-35 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ..4-36 4-38...
Page 112: Front Wheel And Brake
CHAS FRONT WHEEL AND BRAKE EAS00517 CHASSIS FRONT WHEEL AND BRAKE 48Nm (4.8 m•kg, 34.7 ft•lb) Order Job/Part Q’ty Remarks 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.
Page 113: Front Wheel
CHAS FRONT WHEEL AND BRAKE EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal Bearing Spacer Bearing Refer to”REMOVING THE FRONT WHEEL” and “INSTALLING THE FRONT WHEEL” For assembly, reverse the disassembly procedure.
Page 114: Front Brake Shoe Plate
CHAS FRONT WHEEL AND BRAKE FRONT BRAKE SHOE PLATE 8Nm (0.8 m•kg ,5.8 ft•lb) Order Job/Part Q’ty Remarks Disassembling the front brake shoe Remove the parts in the order listed. plate Brake shoe kit Refer to”DISASSEMBLING Tension spring BRAKE SHOE PLATE” and “ASSEM- Comshaft lever BLING THE BRAKE SHOE PLATE”.
Page 115: Removing The Front Wheel
CHAS 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 116: Checking The Front Wheel
CHAS FRONT WHEEL AND BRAKE EAS00525 CHECKING THE FRONT WHEEL 1. Check: 8 wheel axle Roll the wheel axle on a flat surface. Bends Replace. Do not attempt to straighten a bent wheel axle. 2. Check: 8 tire 8 front wheel Damage/wear Replace.
Page 117: Checking The Speedometer Gear Unit
CHAS FRONT WHEEL AND BRAKE a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. c.
Page 118: Checking The Brake
CHAS FRONT WHEEL AND BRAKE EAS00536 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: 8 brake shoe lining Glazed areas Repair. Sand the glazed areas with course sand- paper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth.
Page 119: Assembling The Brake Shoe Plate
CHAS FRONT WHEEL AND BRAKE 4. Check: 8 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 120: Assembling The Front Wheel
CHAS FRONT WHEEL AND BRAKE EAS00538 ASSEMBLING THE FRONT WHEEL 1. Install: 8 wheel bearing(right)1 8 oil seal 8 spacer 8 wheel bearing(left) ***************************************************** a. Install the new wheel bearings and oil seal in the reverse order of disassembly. Do not contact the wheel bearing inner race 1 1 1 1 1 or balls 2 2 2 2 2 .
Page 121: Installing The Front Wheel
CHAS FRONT WHEEL AND BRAKE EAS00540 INSTALLING THE FRONT WHEEL Lubricate: 8 wheel axle 8 wheel bearings 8 oil seal lips 8 speedometer drive gear 8 speedometer gear Recommended lubricant Lithium-soap-based grease Install: 8front wheel1 NOTE: Make sure the slot2 in the brake shoe plate fits over the stopper3 on the outer tube.
Page 122: Adjusting The Front Wheel Static Balance
CHAS 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 123 CHAS FRONT WHEEL AND BRAKE 3. Adjust: 8 front wheel static balance ***************************************************** a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. NOTE: Start with the lightest weight. Turn the front wheel 90° so that the heavy spot is positioned as shown.
Page 124: Rear Wheel And Brake
CHAS REAR WHEEL AND BRAKE EAS00555 REAR WHEEL AND BRAKE 7Nm (0.7 m•kg, 5.1 ft•lb) 104Nm (10.4 m•kg, 75.2 ft•lb) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
Page 125: Removing The Rear Wheel
CHAS REAR WHEEL AND BRAKE EAS00564 REMOVING THE REAR WHEEL 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 126: Checking The Rear Wheel
CHAS REAR WHEEL AND BRAKE EAS00565 CHECKING THE REAR WHEEL 1. Check: 8 tire 8 rear wheel Damage/wear Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 2. Measure: 8 radial wheel runout 8 lateral wheel runout Refer to “CHECKING THE FRONT WHEEL”.
Page 127: Checking The Brake
CHAS REAR WHEEL AND BRAKE EAS00569 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: 8 brake shoe lining Glazed areas Repair. Sand the glazed areas with course sand- paper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth.
Page 128: Assembling The Brake Shoe Plate
CHAS REAR WHEEL AND BRAKE EAS00570 ASSEMBLING THE BRAKE SHOE PLATE Install: 8 brake camshaft 1 7 Nm (0.7 m • kg, 5.1 ft • lb) 8 return spring 2 8 brake shoe wear indicator 3 ***************************************************** Install the brake camshaft 1 so its punch mark a is positioned as shown.
Page 129: Installing The Rear Wheel
CHAS REAR WHEEL AND BRAKE EAS00574 INSTALLING THE REAR WHEEL 1. Lubricate: 8 wheel axle Recommended lubricant Lithium-soap-based grease 2. Install: 8 rear wheel 3. Tighten: 8 wheel axle nut1 104 Nm (10.4 m • kg, 75.2 ft • lb) 4.
Page 130: Front Fork
CHAS FRONT FORK EAS00646 FRONT FORK 30Nm (3.0 m•kg, 21.7 ft•lb) Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE”. Handlebar Refer to “HANDLE BAR”. Front fork assembly Refer to “STEERING HEAD”.
Page 131 CHAS FRONT FORK EAS00648 Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. Band Boot Dust seal Circlip Refer to “DISASSEMBLING AND IN- Spring guide STALLING THE FRONT FORK LEGS “ Rebound spring Inner tube Damper rubber Fork spring...
Page 132: Removing The Front Fork Legs
CHAS FRONT FORK EAS00651 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 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 133: Checking The Front Fork Legs
CHAS FRONT FORK Remove: 8 damper rubber 1 8 fork spring 2 8 outer tube 3 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Check: 8 inner tube 8 outer tube Bends/damage/scratches Replace.
Page 134: Assembling The Front Fork Legs
CHAS 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: - dust seal - circlip 8 Before assembling the front fork leg, make sure all of the components are clean.
Page 135: Installing The Front Fork Legs
CHAS FRONT FORK EAS00663 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Install: 8front fork leg 1 8snap ring 2 8inner tube plug 8lower bracket pinch bolt 3 NOTE: Pull up the inner tube until it stops, then install the snap ring to groove.
Page 136 CHAS HANDLEBAR EAS00664 HANDLEBAR 60Nm (6.0 m•kg, 43.4 ft•lb) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Headlight cover Refer to “COVER AND PANEL” in chap- Leg shield 1 ter 3. Clamp Speedometer cable Speedometer assembly Rear view mirror(left and right) Front brake cable...
Page 137: Handlebar
CHAS HANDLEBAR 60Nm (6.0 m•kg, 43.4 ft•lb) Order Job/Part Q’ty Remarks Handlebar grip Handlebar upper cover Handlebar assembly For installation, reverse the removal pro- cedure. 4-26...
Page 138: Removing The Handlebar
CHAS 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 holder assembly (right)1 8throttle grip assembly 2 NOTE: While removing the handlebar holder assembly (right), pull back the rubber cover.
Page 139: Installing The Handlebar
CHAS 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: 8handlebar 1 RIGHT FORWARD NOTE: Align the slot a on the handlebar with the steer- ing shaft 2 surface.
Page 140 CHAS HANDLEBAR NOTE: 8 Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar4. 8 Align the projectiona on the right handle- bar holder assembly with the hole b on the handlebar.
Page 141: Steering Head
CHAS STEERING HEAD EAS00675 STEERING HEAD 7Nm (0.7 m•kg, 5.1 ft•lb) 30Nm (3.0 m•kg, 21.7 ft•lb) Order Job/Part Q’ty Remarks Removing the front fork assembly Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE”. Leg shield 1 Refer to “COVER AND PANEL”...
Page 142: Removing The Front Fork Assembly
CHAS STEERING HEAD EAS00678 REMOVING THE FRONT FORK 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 front wheel is elevated.
Page 143: Checking The Steering Head
CHAS STEERING HEAD EAS00682 CHECKING THE STEERING HEAD 1. Wash: 8bearing balls 8bearing races Recommended cleaning solvent Kerosene 2. Check: 8bearing balls 1 8bearing races 2 Damage/pitting Replace. 3. Replace: 8bearing balls 8bearing races ***************************************************** a. Remove the bearing races from the steer- ing head pipe with a long rod 1 and ham- mer.
Page 144: Installing The Steering Head
CHAS STEERING HEAD EAS00684 INSTALLING THE STEERING HEAD Lubricate: 8 bearing balls 1 8 bearing races Recommended lubricant Lithium-soap-based grease Install: 8 front fork assembly 1 8 upper bearing inner race 2 7 Nm (0.7 m • kg, 5.1 ft • lb) (with the ring nut wrench 3) Install: 8 ring nut 1...
Page 145: Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 30Nm (3.0 m•kg, 21.7 ft•lb) 16Nm (1.6 m•kg, 11.6 ft•lb) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Rear shock absorber assembly upper Rear shock absorber assembly upper bolt Rear shock absorber assembly lower...
Page 146 CHAS 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 147 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: 8 spacer 8 bush Recommended lubricant Molybdenum disulfide grease 2. Install: 8 rear shock absorber assembly 3. Tighten: 8 rear shock absorber assembly upper nut 30 Nm (3.0 m • kg, 21.7 ft • lb) 8 rear shock absorber assembly lower bolt 16 Nm (1.6 m •...
Page 148: Eng
CHAPTER 5 ENGINE ENGINE ..................... 5-1 LEADS, HOSES AND REAR BRAKE ..........5-1 MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY ....5-3 INSTALLING THE ENGINE ............... 5-4 CYLINDER HEAD ..................5-5 REMOVING THE CYLINDER HEAD..........5-6 CHECKING THE CYLINDER HEAD ..........5-8 INSTALLING THE CYLINDER HEAD ..........
Page 149 CHECKING THE V-BELT ..............5-40 CHECKING THE PRIMARY SHEAVE ..........5-40 CHECKING THE PRIMARY SHEAVE WEIGHTS ......5-41 CHECKING THE SLIDER ..............5-41 CHECKING THE SECONDARY SHEAVE ........5-41 ASSEMBLING THE PRIMARY SHEAVE ........5-42 ASSEMBLING THE SECONDARY SHEAVE ......... 5-43 INSTALLING THE BELT DRIVE ............
Page 150: Leads, Hoses And Rear Brake
ENGINE EAS00188 ENGINE ENGINE LEADS, HOSES AND REAR BRAKE 46Nm (4.6 m•kg, 33.3 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 12Nm (1.2 m•kg, 8.7 ft•lb) 16Nm (1.6 m•kg, 11.6 ft•lb) Order Job/Part Q’ty Remarks Removing the leads, hoses and rear Remove the parts in the order listed. brake Seat/Trunk/Rear carrier Battery cover/Battery holder...
Page 151 ENGINE 46Nm (4.6 m•kg, 33.3 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 12Nm (1.2 m•kg, 8.7 ft•lb) 16Nm (1.6 m•kg, 11.6 ft•lb) Order Job/Part Q’ty Remarks Refer to “STARTER CLUTCH AND AC AC magneto lead MAGNETO”. Disconnect. Starting motor lead/Earth lead Disconnect.
Page 152: Manifold, Air Filter And Muffler Assembly
ENGINE MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY 31Nm (3.1 m•kg, 22.4 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 13Nm (1.3 m•kg, 9.4 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 8Nm (0.8 m•kg, 5.8 ft•lb) Order Job/Part Q’ty Remarks Removing the manifold, air filter and Remove the parts in the order listed.
Page 153: Installing The Engine
ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: 8engine 1 8engine mounting bolt 2 8self lock nut3 NOTE: Do not fully tighten the bolts. 2. Tighten: 8self lock nut 46Nm(4.6 m • kg, 33.3 ft • lb) 3. Tighten: 8rear shock absorber assembly lower bolt1 16 Nm (1.6 m •...
Page 154: Cylinder Head
CYLINDER HEAD EAS00221 CYLINDER HEAD 8Nm (0.8 m•kg, 5.8 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 9Nm (0.9 m•kg, 6.5 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) 12.5Nm (1.25 m•kg, 9.0 ft•lb) 8Nm (0.8 m•kg, 5.8 ft•lb) 30Nm (3.0 m•kg, 21.7 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part...
Page 155: Removing The Cylinder Head
CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Remove : 8 crankcase cover (left) Refer to “ BELT DRIVE”. 8 cylinder head cover 2. Align: 8 “I” mark a on the magneto rotor (with the stationary pointer b on the crankcase cover) ***************************************************** Turn the primary fixed sheave counterclock-...
Page 156 CYLINDER HEAD 4. Remove: 8 timing chain tensioner (along with the gasket) 8 camshaft sprocket 1 8 timing chain 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire. 5. Remove: 8 cylinder head NOTE: 8 Loosen the nuts in the proper sequence as shown.
Page 157: Checking The Cylinder Head
CYLINDER HEAD EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: 8 combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: 8 spark plug bore thread 8 valve seats 2. Check: 8 cylinder head Damage/scratches Replace.
Page 158: Installing The Cylinder Head
CYLINDER HEAD EAS00231 INSTALLING THE CYLINDER HEAD 1. Install: 8 gasket 8 dowel pins 2. Install: 8 cylinder head 3. Tighten: 8 cylinder head nuts 10 Nm (1.0 m • kg, 7.2 ft • lb) 8 cylinder head bolts 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: 8 Lubricate the cylinder head nuts with en- gine oil.
Page 159 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. Install 8camshaft sprocket bolt 1 6.
Page 160 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 161: The Rocker Arms And Camshaft
THE ROCKER ARMS AND CAMSHAFT THE ROCKER ARMS AND CAMSHAFT Order Job/Part Q’ty Remarks 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) Spring...
Page 162: Removing The Rocker Arms And Camshaft
THE ROCKER ARMS AND CAMSHAFT EAS00202 REMOVING THE ROCKER ARMS AND CAM- SHAFT 1. Remove: 8camshaft 1 2. Remove: 8intake rocker arm shaft 8exhaust rocker arm shaft 8intake rocker arm 8exhaust rocker arm NOTE: Remove the rocker arm shafts with the clip plier1 .
Page 163 THE ROCKER ARMS AND CAMSHAFT Camshaft lobe dimension limit Intake a a a a a 30.158~30.258 mm (1.187~1.191 <Limit>:30.058mm b b b b b 25.082~25.182 mm (0.987~0.991 <Limit>:24.982mm Exhaust a a a a a 30.158~30.258 mm (1.187~1.191 <Limit>:30.058mm b b b b b 25.020~25.120 mm (0.985~0.989 <Limit>:24.920mm 4.
Page 164 THE ROCKER ARMS AND CAMSHAFT 4. Measure: 8rocker arm inside diameter a Out of specification Replace. Rocker arm inside diameter 10 ~ 10.015 mm (0.393 ~ 0.394 in) 5. Measure: 8rocker arm shaft outside diameter a Out of specification Replace. Rocker arm shaft outside diameter 9.981 ~ 9.991 mm (0.392 ~ 0.393 6.
Page 165: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides
THE ROCKER ARMS AND CAMSHAFT EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the cam- shaft sprockets and timing chain guides. 1. Check: 8 timing chain Damage/stiffness Replace the timing chain and camshaft sprockets as a set.
Page 166: Installing The Camshaft And Rocker Arms
THE ROCKER ARMS AND CAMSHAFT EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 8 camshaft 1 Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2. Lubricate: 8 rocker arm shafts Recommended lubricant Molybdenum disulfide oil 3. Install: 8 exhaust rocker arm 1 8 spring 2 8 exhaust rocker arm shaft 3...
Page 167: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Rocker arm and rocker arm shaft Refer to “THE ROCKER ARMS AND CANSHAFT”.
Page 168: 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 169: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS 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. EAS00239 CHECKING THE VALVES AND VALVE GUIDES...
Page 170 VALVES AND VALVE SPRINGS NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (4.0 mm) 90890-04111(YM-04111) Valve guide installer (4.0 mm) 90890-04112(YM-04112) Valve guide reamer (4.0 mm) 90890-04113(YM-04113) ***************************************************** 3. Eliminate: 8 carbon deposits (from the valve face and valve seat) 4.
Page 171: 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: 8 carbon deposits (from the valve face and valve seat) 2. Check: 8 valve seat Pitting/wear Replace the cylinder head. 3.
Page 172 VALVES AND VALVE SPRINGS a. Apply a coarse lapping compound a to the valve face. Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem. c.
Page 173: 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: 8 valve spring free length a Out of specification Replace the valve spring. Valve spring free length Intake valve spring 39.35 mm (1.549 in) <Limit>: 37.38 mm (1.472 in) Exhaust valve spring...
Page 174: 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 Install:...
Page 175 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04109(YM-04109) 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 176: Cylinder And Piston
CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Timing chain guide(exhaust side) Cylinder Case cap Reed valve assembly Dowel pin Cylinder gasket...
Page 177: Removing The Cylinder And Piston
CYLINDER AND PISTON EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 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 178: Checking The Cylinder And Piston
CYLINDER AND PISTON EAS00261 CHECKING THE CYLINDER AND PISTON Check: 8 piston wall 8 cylinder wall Vertical scratches Replace the cylin- der, and the piston and piston rings as a set. Measure: 8piston-to-cylinder clearance ***************************************************** a. Please carry out the following inspections: 8 cylinder Measure the piston pin in both of its hori- zontal axis direction a and its right angle...
Page 179: Checking The Piston Rings
CYLINDER AND PISTON EAS00263 CHECKING THE PISTON RINGS 1. Measure: 8 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 180: Checking The Piston Pin
CYLINDER AND PISTON EAS00265 CHECKING THE PISTON PIN 1. Check: 8 piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system. 2. Measure: 8 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 181: Checking The Timing Chain Guide
CYLINDER AND PISTON CHECKING THE TIMING CHAIN GUIDE Check: 8 timing chain guide (exhaust side) Damage/wear Replace EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: 8 oil ring expander 1 8 oil ring rail 2 8 2nd ring 3 8 top ring 4 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
Page 182 CYLINDER AND PISTON 3. Install: 8 gasket 8 dowel pins 4. Lubricate: 8 piston 8 piston rings 8 cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: 8 piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Exhaust side...
Page 183: Belt Drive
BELT DRIVE EAS00316 BELT DRIVE CRANKCASE COVER (LEFT) 10Nm (1.0 m•kg, 7.2 ft•lb) 15Nm (1.5 m•kg, 10.9 ft•lb) Order Job/Part Q’ty Remarks Removing the crankcase cover (left) Remove the parts in the order listed. Kickstarter Rear wheel lock cable cover Refer to “...
Page 184: Installing The Kickstarter
BELT DRIVE EAS00340 INSTALLING THE KICKSTARTER 1. Install: 8 solid bush1 8 kick shaft assembly2 8 torsion spring3 2. Hook: 8 kickstarter spring NOTE: Hook the spring enda on the kickstarter shaft b as shown, and hook the other end c on the projectiond .
Page 185: V-Belt, Clutch, Primary And Secondary Sheave
BELT DRIVE V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE 40Nm (4.0 m•kg, 28.9 ft•lb) 30Nm (3.0 m•kg, 21.7 ft•lb) Order Job/Part Q’ty Remarks Removing the V-belt, clutch, primary Remove the parts in the order listed. and secondary sheave Primary sheave nut/Plate washer Oneway clutch Refer to “...
Page 186 BELT DRIVE 55Nm (5.5 m•kg, 39.8 ft•lb) Order Job/Part Q’ty Remarks Disassembling the secondary Disassemble the parts in the order listed. sheave assembly Clutch carrier nut Clutch carrier Clutch shoe spring Compression spring Secondary spring seat Refer to “ REMOVING AND INSTALL- Guide pin ING THE SECONDARY SHEAVE “...
Page 187: Removing The Primary Sheave
BELT DRIVE EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: 8primary sheave nut 1 8plate washer2 8oneway clutch3 8primary fixed sheave 4 NOTE: While holding the primary fixed sheave with the rotor holding tool 5, loosen the primary fixed sheave nut. Rotor holding tool: 90890-01235 (YU-01235) EAS00318...
Page 188: Disassembling The Secondary Sheave
BELT DRIVE 3. Remove: 8 secondary sheave assembly 1 8 V-belt 2 NOTE: Remove the V-belt and clutch assembly from the primary sheave side. EAS00319 DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: 8 clutch carrier nut 1 NOTE: Install the clutch spring holder 2 and clutch spring holder arm 3 onto the secondary sheave as shown.
Page 189: Checking The V-Belt
BELT DRIVE EAS00320 CHECKING THE V-BELT 1. Check: 8 V-belt 1 Cracks/damage/wear Replace. Grease/oil Clean the primary and sec- ondary sheave. 2. Measure: 8 V-belt width a Out of specification Replace. V-belt width 16.8 mm (0.0661 in) <Limit>: 15.8 mm (0.622 in) CHECKING THE PRIMARY SHEAVE Check: 8 primary sliding sheave1...
Page 190: 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: 8 primary sheave weight Cracks/damage/wear Replace. 2. Measure: 8 primary sheave weight outside diameter Out of specification Replace. Primary sheave weight outside di- ameter 15 mm (0.591 in)
Page 191: 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 192: Assembling The Secondary Sheave
BELT DRIVE EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: 8 secondary fixed sheave’s inner surface 8 secondary sliding sheave’s inner surface 8 oil seals 8 bearings (with the recommended lubricant) Recommended lubricant ® BEL-RAY assembly lube 2. Install: 8 secondary sliding sheave 1 NOTE: Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide...
Page 193: Installing The Belt Drive
BELT DRIVE 5. Install: 8 secondary sheave 1 8 spring 8 clutch carrier 2 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. Clutch spring holder 90890-01337 (YM-33285) ( YM-33285-6)
Page 194 BELT DRIVE 3. Install: 8 clutch housing 1 8 secondary sheave nut2 40 Nm (4.0 m • kg, 28.9 ft • lb) NOTE: Tighten the secondary sheave nut with the sheave holder 3. Sheave holder 90890-01701 (YS-01880-A) 4. Install: 8primary fixed sheave 1 8primary sheave nut 2 30 Nm (3.0 m•...
Page 195: Starter Clutch And Ac Magneto
STARTER CLUTCH AND AC MAGNETO EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY 4Nm (0.4 m•kg, 2.9 ft•lb) 9Nm (0.9 m•kg, 6.5 ft•lb) 7Nm (0.7 m•kg, 5.1 ft•lb) 7Nm (0.7 m•kg, 5.1 ft•lb) 43Nm (4.3 m•kg, 31.1 ft•lb) Order Job/Part Q’ty Remarks...
Page 196 STARTER CLUTCH AND AC MAGNETO 4Nm (0.4 m•kg, 2.9 ft•lb) 9Nm (0.9 m•kg, 6.5 ft•lb) 7Nm (0.7 m•kg, 5.1 ft•lb) 7Nm (0.7 m•kg, 5.1 ft•lb) 43Nm (4.3 m•kg, 31.1 ft•lb) Order Job/Part Q’ty Remarks Lock plate Pick up coil Stator coil assembly For installation, reverse the removal pro- cedure.
Page 197: Starter Clutch
STARTER CLUTCH AND AC MAGNETO EAS00342 STARTER CLUTCH image 10Nm (1.0 m•kg, 7.2 ft•lb) 90Nm (9.0 m•kg, 65.1 ft•lb) Order Job/Part Q’ty Remarks Removing the starter clutch Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL”in chapter 3.
Page 198: Removing The Ac Magneto
STARTER CLUTCH AND AC MAGNETO EAS00347 REMOVING THE AC MAGNETO Remove: 8 AC magneto rotor nut1 8 washer 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 199: Removing The Starter Clutch
STARTER CLUTCH AND AC MAGNETO EAS00344 REMOVING THE STARTER CLUTCH 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. Remove: 8starter clutch nut1 8washer...
Page 200: Checking The Starter Clutch
STARTER CLUTCH AND AC MAGNETO EAS00351 CHECKING THE STARTER CLUTCH 1. Check: 8starter clutch roller 1 Damage/wear Replace. 2. Check: 8starter clutch idle gear 8starter wheel gear Burrs/chips/roughness/wear Replace the defective part(s). 3. Check: 8starter wheel gear’s contacting surfaces Damage/pitting/wear Replace the starter clutch gear.
Page 201: Installing The Starter Clutch
STARTER CLUTCH AND AC MAGNETO EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: 8 idle gear 8 starter clutch 8 collar 8 roller 8 starter wheel gear 8 washer 8 starter clutch nut1 90 Nm (9.0 m • kg, 65.1 ft • lb) NOTE: The starter clutch nut is left-hand thread.
Page 202 STARTER CLUTCH AND AC MAGNETO Tighten: 8AC magneto rotor nut 1 43 Nm (4.3 m • kg, 31.1 ft • lb) NOTE: 8 While holding the AC magneto rotor 3with the sheave holder 2, tighten the AC mag- neto rotor nut. 8 Do not allow the sheave holder to touch the projection on the AC magneto rotor.
Page 203: Oil Pump
OIL PUMP EAS00360 OIL PUMP 4Nm (0.4 m•kg, 2.9 ft•lb) 1Nm (0.1 m•kg, 0.7 ft•lb) Order Job/Part Q’ty Remarks Disassembling 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 Starter clutch MAGNETO “...
Page 204: Checking The Oil Pump
OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: 8 oil pump drive gear 8 oil pump driven gear 1 8 oil pump housing 8 oil pump housing cover Cracks/damage/wear Replace the defective part(s). 2. Measure: 8 inner-rotor-to-outer-rotor-tip clearance A 8 outer-rotor-to-oil-pump-housing clear- ance B 8 oil-pump-housing-to-inner-rotor-and-...
Page 205: Assembling The Oil Pump
OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: 8 inner rotor 8 outer rotor 8 oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 8 oil pump shaft 1 (to the oil pump housing2) 8 pin 3 8 inner rotor 4 8 outer rotor5 8 oil pump housing cover6...
Page 206: Transmission
TRANSMISSION EAS00419 TRANSMISSION 13Nm (1.3 m•kg, 9.34 ft•lb) Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Transmission oil Drain. Refer to “CHANGING THE TRANSMIS- SION OIL “ in chapter 3. Muffler assembly Refer to “MANIFOLD, AIR FILTER AND Rear fender MUFFLER ASSEMBLY “.
Page 207: Checking The Transmission
TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Measure: 8 main axle runout (with a centering device and dial gauge ) Out of specification Replace the main axle. Main axle runout limit 0.04 mm (0.0002 in) 2. Measure: 8 drive axle runout (with a centering device and dial gauge ) Out of specification Replace the drive...
Page 208: Crankshaft
CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 10Nm (1.0 m•kg, 7.2 ft•lb) 32Nm (3.2 m•kg, 23.1 ft•lb) Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Engine Refer to “ ENGINE “ . Cylinder head Refer to “CYLINDER HEAD “. Cylinder piston Refer to “CYLINDER AND PISTON “.
Page 209 CRANKSHAFT 10Nm (1.0 m•kg, 7.2 ft•lb) 32Nm (3.2 m•kg, 23.1 ft•lb) Order Job/Part Q’ty Remarks Hook Drain plug Oil strainer Compression spring O-ring Crankcase (right ) Spacer Dowel pin Guide Crankshaft Refer to “DISASSEMBLING THE CRANKCASE “ Timing chain Crankcase ( left ) Refer to “INSTALLING THE CRANK- SHAFT “...
Page 210: Disassembling The Crankcase
CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 8 centerstand assembly 2. Remove: 8 crankcase 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 211: Checking The Timing Chain And Timing Chain Guide
CRANKSHAFT EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE Check: 8 timing chain Damage/stiffness Replace the timing chain. 2. Check: 8 timing chain guide (intake side) Damage/wear Replace. 5-62...
Page 212: Checking The Crankshaft And Connecting Rod
CRANKSHAFT EAS00394 CHECKING THE CRANKSHAFT AND CON- NECTING ROD 1. Measure: 8 crankshaft runout Out of specification Replace the crank- shaft, bearing or both. NOTE: Turn the crankshaft slowly. Maximum crankshaft runout 0.03 mm ( 0.001 in ) 2. Measure: 8 big end side clearance Out of specification Replace the big end...
Page 213: Checking The Crankcase
CRANKSHAFT 5. Check: 8 crankshaft journal Scratches/wear Replace the crank- shaft. 8 crankshaft journal oil passage Obstruction Blow out with compressed air. EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces.
Page 214: Installing The Crankshaft
1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: 8 sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery.
Page 215: Cool
COOL CHAPTER 6 RADIATOR RADIATOR ....................6-1 CHECKING THE RADIATOR ............6-2 INSTALLING THE RADIATOR ............6-3 THERMOSTAT ASSEMBLY ..............6-4 CHECKING THE THERMOSTAT ............6-6 INSTALLING THE THERMOSTAT ASSEMBLY ........ 6-7 WATER PUMP ..................6-8 DISASSEMBLING THE WATER PUMP .......... 6-10 CHECKING THE WATER PUMP .............
Page 216: Radiator
COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Seat/Trunk Battery cover/Battery holder Battery/Front cover Refer to “COVER AND PANEL”in chap- Footrest board side cover mole ( left ter 3.
Page 217: Checking The Radiator
COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: 8 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: 8 radiator hoses Radiator inlet hose1 8 radiator pipes Radiator outlet hose2 Cracks/damage Replace.
Page 218: Installing The Radiator
COOL RADIATOR 4. Check: 8 radiator fan Damage Replace. Malfunction Check and repair. 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: 8cooling system Leaks Repair or replace any faulty part.
Page 219: Thermostat Assembly
COOL THERMOSTAT ASSEMBLY EAS00460 THERMOSTAT ASSEMBLY 10Nm (1.0 m•kg, 7.2 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Seat/Trunk/Rear carrier Battery cover/Battery holder Battery/Front cover Refer to “COVER AND PANEL”in chap- Side cover (left and right)/Rear cover ter 3.
Page 220 COOL THERMOSTAT ASSEMBLY 10Nm (1.0 m•kg, 7.2 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Thermostat assembly For installation, reverse the removal pro- cedure.
Page 221: Checking The Thermostat
COOL THERMOSTAT ASSEMBLY EAS00462 CHECKING THE THERMOSTAT 1. Check: 8 thermostat 1 Does not open at 65 ~ 80°C Replace. ***************************************************** a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.
Page 222: Installing The Thermostat Assembly
COOL THERMOSTAT ASSEMBLY EAS00466 INSTALLING THE THERMOSTAT ASSEMBLY Install: 8thermostat1 8thermostat housing 8thermostat assembly inlet breather hose. 8thermostat assembly outlet breather hose. 2. Fill: 8cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3.
Page 223: Water Pump
COOL WATER PUMP EAS00468 WATER PUMP 10Nm (1.0 m•kg, 7.2 ft•lb) 7Nm (0.7 m•kg, 5.1 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. Seat/Trunk/Rear carrier Battery cover/Battery holder Refer to “COVER AND PANEL”in chap- Battery/Front cover ter 3.
Page 224 COOL WATER PUMP 10Nm (1.0 m•kg, 7.2 ft•lb) 7Nm (0.7 m•kg, 5.1 ft•lb) 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Water pump housing Dowel pin Plate Impeller shaft Oil seal Bearing Gasket For installation, reverse the removal pro- cedure.
Page 225: Disassembling The Water Pump
COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: 8water pump housing cover1 8dowel pin 8gasket 2. Remove: 8plate 2 8impeller shaft 3 8gasket 8oil seal (with a thin, flat-head screwdriver) 8bearing NOTE: Remove the oil seal from the inside of the water pump housing.
Page 226: Assembling The Water Pump
COOL WATER PUMP EAS00475 ASSEMBLING THE WATER PUMP 1. Install: 8oil seal (into the water pump housing 3) 8bearing 2 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.
Page 227: Installing The Water Pump
COOL WATER PUMP EAS00478 INSTALLING THE WATER PUMP 1. Install: 8gasket 8water pump assembly 1 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Align the slit a on the impeller shaft with the projection b on the camshaft sprocket bolt. 2.
Page 228: Carb
CARB CHAPTER 7 CARBRETOR CARBURETOR ..................7-1 CHECKING THE CARBURETOR ............. 7-4 ASSEMBLING THE CARBURETOR..........7-6 INSTALLING THE CARBURETOR ........... 7-7 MEASURING AND ADJUSTING THE FUEL LEVEL ....... 7-8 CHECKING THE AUTOCHOKE UNIT ..........7-9 CHECKING THE FUEL COCK ............7-10 CHECKING THE THROTTLE POSITION SENSOR ......
Page 229 CARB CARBURETOR EAS00480 CARBURETOR CARBURETOR Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Mat/Seat/Trunk Refer to “COVER AND PANEL”in chap- Battery cover/Front cover ter 3. Hose(to cylinder head) Auto choke lead Disconnect. Throttle position sensor lead Disconnect.
Page 230 CARB CARBURETOR EAS00483 Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. Auto choke cap Auto choke unit Auto choke holder Auto choke seat Before leaving the factory, throttle Throttle stop screw kit position sensor should be measured Bracket and adjusted with a precision Vacuum chamber cover/Piston valve...
Page 231 CARB CARBURETOR Order Job/Part Q’ty Remarks Main nozzle Nedle jet Slow air jet Slow jet Throttle position sensor For assembly, reverse the disassembly procedure.
Page 232: Carburetor
CARB CARBURETOR EAS00485 CHECKING THE CARBURETOR 1. Check: 8 carburetor body 8 float chamber Cracks/damage Replace. 2. Check: 8 fuel passages Obstruction Clean. ***************************************************** a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b.
Page 233 CARB CARBURETOR 6. Check: 8 needle valve Damage/obstruction/wear Replace. 7. Check: 8 piston valve 1 Damage/scratches/wear Replace. 8 piston valve diaphragm 2 Cracks/tears Replace. 8. Check: 8 vacuum chamber cover 1 8 piston valve spring 2 Cracks/damage Replace. 9. Check: 8jet needle 1 8main jet 2 8main nozzle 3...
Page 234: Assembling The Carburetor
CARB CARBURETOR EAS00487 ASSEMBLING THE CARBURETOR 8 8 8 8 8 Before assembling the carburetor, wash all of the parts in a petroleum-based sol- vent. 8 8 8 8 8 Always use a new gasket. 1. Install: 8 needle jet 1 8 main nozzle2 8 main jet 3 8 slow air jet 4...
Page 235: Installing The Carburetor
CARB CARBURETOR 7. Install: 8piston valve spring 8vacuum chamber cover 8. Install: 8bracket 8auto choke unit 8throttle position sensor EAS00492 INSTALLING THE CARBURETOR 1. Adjust: 8 engine idling speed Engine idling speed 2,000 ~ 2,400r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED”...
Page 236: Measuring And Adjusting The Fuel Level
CARB CARBURETOR EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: 8 fuel level a Out of specification Adjust. Fuel level (below the float chamber mating surface) 6.6~7.6 mm (0.26~0.30 in) ***************************************************** a. Stand the motorcycle on a level surface. b.
Page 237: Checking The Autochoke Unit
CARB CARBURETOR EAS00503 CHECKING THE AUTOCHOKE UNIT NOTE: When checking the autochoke unit, the ambient temperature must be lower than 45°C. 1. Remove: 8carburetor 2. Check: 8autochoke unit ***************************************************** a. Connect a 3.3-mm hose 2 to the starter air passage 1 and blow into the hose. NOTE: When the starter plunger is open, air should come out of the other side of the starter air pas-...
Page 238: Checking The Fuel Cock
CARB CARBURETOR EAS00504 CHECKING THE FUEL COCK 1. Remove: 8 seat/trunk 8 battery cover 8 front cover Refer to “COVER AND PANEL”in chap- ter 3. 2. Check: 8fuel cock1 ***************************************************** a. Disconnect the fuel cock to carburetor fuel hose2from the carburetor . b.
Page 239: Checking The Throttle Position Sensor
CARB CARBURETOR CHECKING THE THROTTLE POSITION SEN- NOTE: B/L Y/L Before checking the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: 8throttle position sensor ***************************************************** a. Turn the main switch to “ON”. b. Connect the pocket tester (DC 20V) to the throttle position sensor.
Page 240: Air Induction System
CARB AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 10Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Removing the air induction system Remove the parts in the order listed. Seat/Trunk Refer to “COVER AND PANEL”in chap- ter 3. Hose(from AI air filter ) Vacuum hose(from mainfold ) Hose(to cylinder head ) Air cut-off valve assembly...
Page 241: Checking The Air Induction System
CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: 8 hoses Loose connection Connect properly. Cracks/damage Replace. 8 pipe Cracks/damage Replace. 2. Check: 8 air cut-off valve Cracks/damage Replace. NOTE: When the negative pressure is applied to the part 1, check that the continuity in the direction of arrow mark is completely lost.
Page 242: Elec
ELEC CHAPTER 8 ELECTORICAL ELECTRICAL COMPONENTS ..............8-1 WIRING DIAGRAM ................... 8-2 CHECKING SWITCH CONTINUITY ............8-4 CHECKING THE SWITCHES ..............8-5 CHECKING THE BULBS AND BULB SOCKETS ........8-6 TYPES OF BULBS ................8-6 CHECKING THE CONDITION OF THE BULBS ....... 8-7 CHECKING THE CONDITION OF THE BULB SOCKETS ....
Page 243: Electrical Components
ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Rear brake light switch 0 Battery 2 Front brake light switch q Main fuse 3 Main switch w Turn signal relay 4 Starter relay e Horn 5 Thermo unit r Rectifier/Regulator 6 Fuel sender t Thermo switch 7 C.D.I.
Page 244: Wiring Diagram
ELEC WIRING DIAGRAM WIRING DIAGRAM 12V21W/5W 12V10W 12V10W 12V10W 12V10W 12V35W/35W TURN R TURN L HI BEAM ILLUMI ILLUMI TEMP 7.5A...
Page 245 ELEC WIRING DIAGRAM 1 Main switch Color Code 2 AC magneto Black 3 Rectifier/Regulator Green 4 Battery Blue 5 Main fuse Pink 6 Starter relay 7 Starter motor White 8 C.D.I. unit Yellow 9 Ignition coil Brown 0 Auto choke unit Chocolate q Front brake light switch Dark green...
Page 246: Checking Switch Continuity
ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the coupler terminal slots.
Page 247: 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 Replace the switch.
Page 248: Checking The Bulbs And Bulb Sockets
ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly con- nect.
Page 249 ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 8 bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 8 8 8 8 8 Be sure to hold the socket firmly when removing the bulb.
Page 250: Checking The Condition Of The Bulbs
ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. Check: 8 bulb socket (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03132 (YU-03112-C) NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section;...
Page 251: Ignition System
ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 1 Main switch 2 Pickup coil 4 Battery 5 Main fuse 8 C.D.I. unit 9 Ignition coil r Engine stop switch 12V21W/5W 12V10W 12V10W 12V10W 12V10W 12V35W/35W TURN R TURN L HI BEAM ILLUMI ILLUMI TEMP...
Page 252: Troubleshooting
ELEC IGNITION SYSTEM EAS00736 EAS00738 TROUBLESHOOTING 1. Main Fuse 8 Check the fuse for continuity. The ignition system fails to operate (no spark Refer to “CHECKING THE FUSE” in or intermittent spark). chapter 3. 8 Is the fuse OK? Check: 1.
Page 253 ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance 8 Disconnect the spark plug cap from the 8 Remove the spark plug cap from the spark plug. spark plug lead. 8 Connect the pocket tester (“Ω × 1k” 8 Connect the ignition checker 1 as shown.
Page 254 ELEC IGNITION SYSTEM EAS00748 7. Pickup coil resistance 8 Disconnect the pickup coil coupler from the wire harness. 8 Connect the pocket tester (Ω × 100) to the pickup coil terminal as shown. white/red 1 1 1 1 1 Positive tester probe white/blue2 2 2 2 2 Negative tester probe 8 Measure the primary coil resistance.
Page 255 ELEC IGNITION SYSTEM EAS00750 9. Engine stop switch 8 Check the engine stop switch for conti- nuity. Refer to “CHECKING THE SWITCHES”. 8 Is the engine stop switch OK? Replace the right handlebar switch. EAS00754 10.Wiring 8 Check the entire ignition system’s wir- ing.
Page 256: Electric Starting System
ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 12V21W/5W 12V10W 12V10W 1 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor q Front brake light switch w Rear brake light switch e Start switch 12V10W r Engine stop switch 12V10W...
Page 257: Starting Circuit Cut-Off System Operation
ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OP- ERATION If the main switch is set to “ON” (switch is 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 closed).
Page 258: Troubleshooting
ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00738 TROUBLESHOOTING 1. Main fuse 8 Check the fuse for continuity. The starter motor fails to turn. Refer to “CHECKING THE FUSE” in chapter 3. 8 Is the fuse OK? Check: 1. mainfuse 2. battery 3.
Page 259 ELEC ELECTRIC STARTING SYSTEM EAS00758 EAS00761 3. Starter motor 4. Starter relay 8 Connect the positive battery terminal 1 8 Disconnect the starter relay coupler from and starter motor lead 2 with a jumper the coupler. 8 Connect the pocket tester (Ω × 1) and lead3.
Page 260 ELEC ELECTRIC STARTING SYSTEM EAS00751 6. Brake light switch(front and rear) 8 Check the brake light switch for continu- ity. Refer to “CHECKING THE SWITCHES”. 8 Is the brake light switch OK? Replace the brake light switch. EAS00750 7. Engine stop switch 8 Check the engine stop switch for conti- nuity.
Page 261: Starter Motor
ELEC ELECTRIC STARTING SYSTEM EAS00767 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Seat/Trunk Front cover Refer to “COVER AND PANEL”in chap- ter 3. Battery cover Air filter assembly Refer to“MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLY”in chapter 5.
Page 262: Checking The Starter Motor
ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Check: 8 commutator Dirt Clean with 600-grit sandpaper. 2. Measure: 8 commutator diameter a Out of specification Replace the starter motor. Commutator wear limit 16.6 mm (0.654 in) Measure: 8 mica undercut a Out of specification Scrape the mica to the proper measurement with a hack-...
Page 263 ELEC ELECTRIC STARTING SYSTEM 5. Measure: 8 brush length a Out of specification Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: 8 brush spring force Out of specification Replace the brush springs as a set. Brush spring force 3.92 ~ 5.88 N 7.
Page 264: Assembling The Starter Motor
ELEC ELECTRIC STARTING SYSTEM EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: 8 brush seat 1 2. Install: 8 washer1 8 armature coil 2 8 o-ing 8 stator assembly4 3 . Install: 8 bolts 1 5 Nm (0.5 m • kg, 3.6 ft • lb) NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and...
Page 265: Charging System
ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 2 Stator coil 3 Rectifier/regulator 4 Battery 5 Main fuse 12V21W/5W 12V10W 12V10W 12V10W 12V10W 12V35W/35W TURN R TURN L HI BEAM ILLUMI ILLUMI TEMP 7.5A 8-23...
Page 266: Troubleshooting
ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery 8Check 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 3.
Page 267 ELEC CHARGING SYSTEM EAS00754 NOTE: 5. Wiring Make sure the battery is fully charged. 8Check the entire charging system’s wir- ing. 8Is the charging voltage within specifica- Refer to “CIRCUIT DIAGRAM”. tion? 8Is the charging system’s wiring properly connected and without defects? The charging circuit is OK.
Page 268: Lighting System
ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 1 Main switch Lighting coil 4 Battery 5 Main fuse t Headlight relay a Dimmer switch d Speedometer light f High beam indicator light k Headlight 12V21W/5W 12V10W 12V10W 12V10W 12V10W 12V35W/35W TURN R TURN L HI BEAM...
Page 269: Troubleshooting
ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. Any of the following fail to light: headlight, Refer to “CHECKING AND CHARGING high beam indicator light or meter light. THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
Page 270 ELEC LIGHTING SYSTEM EAS00749 EAS00787 4. Main switch 7. Wiring 8 Check the main switch for continuity. 8 Check the entire lighting system’s wir- Refer to “CHECKING THE SWITCHES”. ing. 8 Is the main switch OK? Refer to “CIRCUIT DIAGRAM”. 8 Is the lighting system’s wiring properly connected and without defects? Replace the main switch.
Page 271: Checking The Lighting System
ELEC LIGHTING SYSTEM EAS00788 3. Voltage CHECKING THE LIGHTING SYSTEM 8 Connect the pocket tester (DC 20 V) to 1. The headlight and the high beam indicator the headlight and high beam indicator light fail to come on. light couplers as shown. When the dimmer switch is set to “%”...
Page 272 ELEC LIGHTING SYSTEM EAS00789 2. The meter light fails to come on. 1. Meter light bulb and socket 8 Check the meter light bulb and socket The wiring circuit from the This circuit is OK. for continuity. main switch to the headlight Refer to “CHECKING THE BULBS AND and hight beam indicator BULB SOCKETS”...
Page 273 ELEC LIGHTING SYSTEM EAS00754 4. Wiring 8 Check the entire lighting system’s wir- ing. Refer to “CIRCUIT DIAGRAM”. 8 Is the lighting system’s wiring properly connected and without defects? Properly connect or Check the condi- repair the lighting tion of each of the system’s wiring.
Page 274: Signaling System
ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 1 Main switch 4 Battery 5 Main fuse q Front brake light switch w Rear brake light switch y Horn u Horn switch i Turn signal switch o Turn signal relay p Tail/brake light g Left turn signal indicator light 12V21W/5W 12V10W...
Page 275: Troubleshooting
ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. 8 8 8 8 8 Any of the following fail to light: turn Refer to “CHECKING AND CHARGING signal light, brake light or an indica- THE BATTERY”...
Page 276: Checking The Signaling System
ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 8 Disconnect the pink connector at the horn terminal. The horn fails to sound. 8 Connect a jumper lead 1 to the horn ter- minal and ground the jumper lead. 1.
Page 277 ELEC SIGNALING SYSTEM EAS00798 3. Voltage The tail/brake light fails to come on. 8 Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness 1. Tail/brake light bulb and socket side) as shown. 8 Check the tail/brake light bulb and socket green/ yellow 1 1 1 1 1 Positive tester probe for continuity.
Page 278 ELEC SIGNALING SYSTEM EAS00799 3. Voltage 3. The turn signal light, turn signal indicator 8 Connect the pocket tester (DC 20 V) to light or both fail to blink. the turn signal relay coupler (wire har- ness side) as shown. 1.
Page 279 ELEC SIGNALING SYSTEM 4. Voltage 5. Voltage 8Connect the pocket tester (DC 20 V) to 8Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire har- the turn signal light connector or meter ness side) as shown. assembly coupler (wire harness side) as brown/white 1 1 1 1 1 Positive tester probe...
Page 280 ELEC SIGNALING SYSTEM EAS00804 2. Voltage 4. The fuel level meter fails to operate. 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness 1. Fuel sender side) as shown. 8 Remove the fuel sender from the fuel brown 1 1 1 1 1 Positive tester probe tank.
Page 281 ELEC SIGNALING SYSTEM 3. Fuel level meter 8 Set the main switch to “ON”. 8 Move the float up 1 or down 2. 8 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 282: Cooling System
ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 1 Main switch 4 Battery 5 Main fuse 8 C.D.I. unit s Water temperature indicator 12V21W/5W 12V10W light 12V10W c Thermo switch v Thermo unit 12V10W 12V10W 12V35W/35W TURN R TURN L HI BEAM ILLUMI ILLUMI...
Page 283 ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. The cooling system fails to operate. 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 3.
Page 284 ELEC COOLING SYSTEM EAS00811 A Cooling phase 4. Thermo switch B Heating phase 8 Remove the thermo switch from the ther- mostat housing. 8 Connect the pocket tester (Ω × 1) to the thermo switch 1 as shown. 8 Immerse the thermo switch in a container filled with coolant2.
Page 285 ELEC COOLING SYSTEM EAS00812 2. Voltage 5. The water temperature indicator light fails 8 Connect the pocket tester (DC 20 V) to to operate. the meter light coupler (wire harness 1. Thermo unit side) as shown. 8 Remove the thermo unit from the cylin- green/red 1 1 1 1 1 Positive tester probe der head.
Page 286 ELEC COOLING SYSTEM 3. Water temperature indicator light 8 Remove the thermo unit coupler . 8 Set the main switch to “ON”. 8 Connect the green/red1 and black/ blue2 with a jumper lead3. G/R B/L 8 Is the water temperature indicator light Replace the water This circuit is OK.
Page 287: Circuit Diagram
ELEC AUTO CHOKE SYSTEM AUTO CHOKE SYSTEM CIRCUIT DIAGRAM 4 Battery 5 Main fuse 8 C.D.I. unit 0 Auto choke unit c Thermo switch 12V21W/5W 12V10W 12V10W 12V10W 12V10W 12V35W/35W TURN R TURN L HI BEAM ILLUMI ILLUMI TEMP 7.5A 8-45...
Page 288: Troubleshooting
ELEC AUTO CHOKE SYSTEM EAS00821 EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. The auto choke system fails to operate. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse Minimum open-circuit voltage 2.
Page 289 ELEC AUTO CHOKE SYSTEM EAS00811 A Cooling phase 3. Thermo switch B Heating phase 8 Remove the thermo switch from the thermostat housing. 8 Connect the pocket tester (Ω × 1) to the thermo switch 1 as shown. 8 Immerse the thermo switch in a con- tainer filled with coolant2.
Page 290: Circuit Diagram
ELEC AUTO CHOKE SYSTEM 4. Auto choke unit 8 Disconnect the auto choke unit coupler from wire harness. 8 Connect the pocket tester(Ω × 1) to the Auto choke unit coupler as shown. green/black 1 1 1 1 1 Positive tester probe yellow 2 2 2 2 2 Negative tester probe 8Measure the auto choke unit resistance.
Page 291: Trbl Shtg
TRBL SHTG CHAPTER 9 TROUBLE SHOOTING STARTING FAILURE/HARD STARTING..........9-1 ENGINE ....................9-1 FUEL SYSTEM .................. 9-1 ELECTRICAL SYSTEMS ..............9-1 INCORRECT ENGINE IDLING SPEED ........... 9-2 ENGINE ....................9-2 FUEL SYSTEM .................. 9-2 ELECTRICAL SYSTEMS ..............9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-3 ENGINE ....................
Page 292: Starting Failure/Hard Starting
TRBL STARTING FAILURE/HARD STARTING SHTG EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
Page 293: Incorrect Engine Idling Speed
STARTING FAILURES/HARD STARTING/ TRBL INCORRECT ENGINE IDLING SPEED SHTG EAS00847 Ignition system INCORRECT ENGINE IDLING 8Faulty C.D.I.unit 8Faulty pickup coil SPEED 8Broken AC magneto rotor woodruff key ENGINE Cylinder and cylinder head 8Incorrect valve clearance Switches and wiring 8Damaged valve train components 8Faulty main switch 8Faulty engine stop switch Air filter...
Page 294: Poor Medium-And-High-Speed Performance
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY CLUTCH SHTG EAS00849 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 Air intake system 8Damaged or worn primary pulley cam...
Page 295: Overheating
TRBL FAULTY CLUTCH/OVERHEATING/OVERCOOLING SHTG POOR SPEED PERFORMANCE Hose(s) and pipe(s) 8Damaged hose V-belt 8Oil or grease on the V-belt 8Improperly connected hose 8Damaged pipe 8Improperly connected pipe Primary pulley weight(s) 8Faulty operation 8Worn primary pulley weight FUEL SYSTEM Carburetor 8Incorrect main jet setting Primary fixed sheave 8Worn primary fixed sheave 8Incorrect fuel level...
Page 296: Poor Braking Performance
POOR BRAKING PERFORMANCE/FAULTY FRONT TRBL FORK LEGS/UNSTABLE HANDLING SHTG 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 lower bracket 8Incorrect brake camshaft lever position (improperly tightened ring nut)
Page 297: Faulty Lighting Or Signaling System
TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 TURN SIGNAL REMAINS LIT FAULTY LIGHTING OR SIGNALING 8Faulty turn signal relay 8Burnt-out turn signal bulb SYSTEM TURN SIGNAL BLINKS QUICKLY HEADLIGHT DOES NOT COME ON 8Incorrect turn signal bulb 8Wrong headlight bulb 8Faulty turn signal relay 8Faulty headlight relay 8Burnt-out turn signal bulb...
Page 298 YAMAHA MOTOR TAIWAN CO., LTD...

Yamaha XC50V Service Manual

Table of Contents

Spec

Chk Adj

Chas

Eng

Cool

Carb

Elec

Trbl Shtg

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SERVICE MANUAL

Chapters

Troubleshooting

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Summary of Contents for Yamaha XC50V