Yamaha XP500 2001 Service Manual
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Yamaha XP500 2001 Service Manual

Yamaha xp500(n) 2001 scooter service manual
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  • Page 3 EAS00000 XP500 (N) SERVICE MANUAL 2000 by Yamaha Motor Co.Ltd. First edition, September 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

  • Page 4: Important Information

    EAS00002 NOTICE This manual was produced by the Yamaha Motor 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 manu- al. 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 5: Periodic Checks And

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.

  • Page 6: 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 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Carburetor(-s) COOL 8 Electrical system...

  • Page 7: Table Of Contents

    EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL CARBURETORS CARB ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 10: Gen

    INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ........VEHICLE IDENTIFICATION NUMBER .
  • Page 11 INFO...

  • Page 12: General Information

    SCOOTER IDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame. EAS00018 MODEL CODE The model code label 2 is affixed to the lug- gage Box. This information will be needed to or- der spare parts.

  • Page 13: Features

    FEATURES INFO FEATURES CRANKSHAFT AND BALANCER SHAFT An integrated crankshaft of a new design is used Horizontally opposed reciprocating balancers are used. Layout free from primary inertial force, secondary inertial force, and a couple of force, and signifi- cant vibration reduction are implemented. CHAIN DRIVE The chain drive is newly designed.

  • Page 14: Swingarm And Rear Suspension

    FEATURES INFO SWINGARM AND REAR SUSPENSION A newly designed swingarm is used. A pull-type monocross suspension is used. These components are located out under the engine.

  • Page 15: 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 inferior in quality.

  • Page 16: Lock Washers/Plates And Cotterpins

    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 washer tabs and the cotter pin ends along a flat of the bolt or nut.

  • Page 17: Checking The Connections

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

  • Page 18: 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 inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 19 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve guide remover (4 mm) 90890-04111 This tool is used to remove or install the valve guides. Valve guide installer 90890-04112 This tool is used to install the valve guides. Valve guide reamer 90890-04113 This tool is used to rebore the new valve guides.
  • Page 20 This tool is needed to loosen or tighten the oil filter cartridge. Engine tachometer 90890-03113 This tool is used to check engine speed. Yamaha bond No. 1215 90890-85505 This sealant is used to seal two mating surfaces (e.g., crankcase mating surfaces). Oil pressure...
  • Page 21 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Clutch spring compressor 90890-01482 This tool is used to remove or install the nut. 1-10...

  • Page 23: Spec

    SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .
  • Page 24 SPEC...

  • Page 25: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code XP500 (N) : 5GJ1 (EUR) 5GJ2 (GBR) 5GJ3 (OCE) Dimensions Overall length 2235 mm Overall width 775 mm Overall height 1410 mm Seat height 795 mm Wheelbase 1575 mm Minimum ground clearance 130 mm Minimum turning radius...

  • Page 26: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine tipe Liquid-cooled, 4-stroke, DOHC Displacement 499 cm Cylinder arrangement Bore stroke 73 mm Compression ratio 10.1 1150 X 1250 r/min Engine idling speed Vacuum pressure at engine idling 35 kPa (3.5 kg/cm speed Standard compression pressure 1450 kPa (14.5 kg/cm...
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) 80 X 120 kPa (0.8 X 1.2 kgf/cm Bypass valve opening pressure Oil pump Oil pump type Trochoidal 0.04 X 0.12 mm Inner-rotor-to-outer-rotor-tip 0.20 mm clearance 0.045 X 0.085 mm Outer-rotor-to-oil-pump-housing 0.15 mm clearance...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (left) 23.000 X 23.021 mm Camshaft cap inside diameter 22.967 X 22.980 mm Camshaft journal diameter 0.020 X 0.054 mm Camshaft-journal-to-camshaftcap 0.08 mm clearance Intake camshaft lobe dimensions 33.252 X 33.352 mm Measurement A 33.152 mm 24.956 X 25.056 mm...
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links SCR-0409SDH/132 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) 0.15 X 0.20 mm Intake 0.25 X 0.30 mm Exhaust Valve dimensions Head Diameter Face Width Seat Width Margin Thickness Valve head diameter A 24.9 X 25.1 mm...
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake 35.59 mm 33.81 mm Exhaust 35.59 mm 33.81 mm Installed length (valve closed) Intake 30.39 mm Exhaust 30.39 mm Compressed spring force (installed) 91.1 X 104.9 N (9.3 X 10.7 kgf) at 30.4 mm Intake 91.1 X 104.9 N (9.3 X 10.7 kgf) at 30.4 mm Exhaust...
  • Page 31 SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons 0.020 X 0.045 mm Piston-to-cylinder clearance 0.15 mm 65.965 X 65.980 mm Diameter D Height H 9 mm Piston pin bore (in the piston) 16.002 X 16.013 mm Diameter Offset 0.5 mm Offset direction Intake side Piston pins 15.991 X 16.000 mm...
  • Page 32 SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.026 X 0.050 mm Crankshaft-pin-to-big-end-bearing clearance Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green Crankshaft 118.55 X 118.60 mm Width B Max. runout C 0.03 mm 0.160 X 0.262 mm Big end side clearance D 0.026 X 0.050 mm...
  • Page 33 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Primary reduction system Spur gear/helical gear Primary reduction ratio 52/32 36/22 (2.659) Secondary reduction system Chain drive Secondary reduction ratio 41/25 40/29 (2.262) Max. main axle runout 0.08 mm Max. drive axle runout 0.08 mm Air filter type Dry element...

  • Page 34: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond Caster angle Trail 95 mm Front wheel Wheel type Cast wheel Size MT3.50 Material Aluminum Wheel travel 120 mm Wheel runout Max. radial wheel runout 1 mm Max. lateral wheel runout 0.5 mm Rear wheel Wheel type...
  • Page 35 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless Size 150/70-14 Model (manufacturer) BRIDGESTONE HOOP B02 DUNLOP D305 Tire pressure (cold) 0 X 90 kg 225 kPa (2.25 kg/cm , 2.25 bar) 90 X 197 kg 250 kPa (2.50 kg/cm , 2.50 bar) High-speed riding 250 kPa (2.5 kg/cm...
  • Page 36 SPEC CHASSIS SPECIFICATION Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil spring/oil damper Front fork travel 120 mm Spring Free length 428.5 mm 419.9 mm Spacer length 129.6 mm Installed length 419.5 mm Spring rate (K1) 11.8 N/mm (1.2 kgf/mm) Spring rate (K2) 15.7 N/mm (1.6kgf/mm)
  • Page 37 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type T.C.I. Ignition timing 10_ BTDC at 1200 r/min Advancer type Digital 189 X 231 Ω/Gy-B Pickup coil resistance/color Transistorized coil ignition unit model J4T120 (MITSUBISHI) (manufacturer) Ignition coils...

  • Page 38: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit License plate light 12 V 5 W Meter light 12 V 1.7 W High beam indicator light 12 V 1.7 W Oil level indicator light 12 V 1.7 W Turn signal indicator light 12 V 3.4 W Electric starting system System type Constant mesh...
  • Page 39 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Temperature sender 69 Ω at 80_C Resistance 22 Ω at 120_C Fuses (amperage quantity) Main fuse 30 A Headlight fuse 15 A Signaling system fuse 15 A Ignition fuse 10 A Radiator fan fuse 15 A Backup fuse (odometer) 10 A...

  • Page 40: Conversion Table

    SPEC CONVERSION TABLE/TIGHTENING TORQUES EB202001 EB201000 CONVERSION TABLE TIGHTENING TORQUES All specification data in this manual are GENERAL TIGHTENING TORQUES listed in SI and METRIC UNITS. This chart specifies tightening torques for standard Use this table to convert METRIC unit data fasteners with a standard ISO thread pitch.

  • Page 41: Engine Tightening Torques

    SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening Thread torque Item Part name Q’ty Remarks size size mSkg Spark plug – 12.5 1.25 Cylinder head cover Bolt Camshaft cap Bolt Cylinder head and cylinder body Cylinder head and cylinder body Cylinder head and cylinder body Bolt Cylinder head (exhaust pipe) Stud bolt...
  • Page 42 SPEC TIGHTENING TORQUES Tightening Thread torque Item Part name Q’ty Remarks size size mSkg Muffler Muffler protector Bolt A.I.System pipe A.I.System reed valve assembly Bolt Air cut valve assembly Bolt Crankcase Bolt Crankcase Bolt Engine oil drain bolt Bolt Engine oil sub tank cover Bolt Stator coil base Screw...
  • Page 43 SPEC TIGHTENING TORQUES Tightening Thread torque Item Part name Q’ty Remarks size size mSkg Primary bearing cover plate Screw Secondary bearing cover plate Screw Stator coil assembly Bolt Pickup coil Bolt Starter motor Bolt Thermo switch – Thermo unit – PT 1/8 Ignitor unit Screw...
  • Page 44 SPEC TIGHTENING TORQUES Crankcase tightening sequence: M8 Bolt 9 X 21 M6 Bolt Cylinder head tightening sequence: 2-20...

  • Page 45: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks mSkg Upper bracket pinch bolt Steering stem nut 11.0 Lower ring nut See NOTE Front fork cap bolt Handlebar upper holder Brake hose union bolt Brake master cylinder holder Master cylinder reservoir cap Handlebar grip end Engine mounting...
  • Page 46 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks mSkg Fuel tank Fuel sender Grab bar Seat lock Cover and panel Cover and panel Windshield 0.04 Coolant reservoir tank Mainstand bracket Mainstand Sidestand (bolt and frame) Sidestand (bolt and nut) Rear footrest NOTE: 1.

  • Page 47: Lubrication Points And Lubricant Types

    Shell BT grease 3 Primary sheave nut Shell BT grease 3 Secondary sheave nut BEL-RAY Secondary sheave assembly lube Swingarm pivot shaft bearing Belt drive cover bearing YAMAHA bond Crankcase mating surface No.1215 YAMAHA bond A.C. magneto lead No.1215 2-23...

  • Page 48: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS Oil pump Intake camshaft Oil tank Oil pipe Oil strainer Oil delivery pipe Relief valve Oil cooler Oil filter Exhaust camshaft 2-24...
  • Page 49 SPEC OIL FLOW DIAGRAMS Oil pan Oil strainer Crankshaft 2-25...
  • Page 50 SPEC OIL FLOW DIAGRAMS Clutch Right main journal bearing Main gallery bolt 2-26...
  • Page 51 SPEC OIL FLOW DIAGRAMS Exhaust camshaft Intake camshaft Piston cooler Crankshaft Oil filter Oil tank Oil cooler Relief valve Check valve Strainer Flush oil pump Suction oil pump Oil pan Strainer 2-27...

  • Page 52: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS Coolant reservoir tank Thermostat Radiator Water pump Cooling fan Radiator cap 2-28...

  • Page 53: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Headlight lead F Connect the brake light switch from the handlebar Horn (H mark on the back of the horn). switch side wiring. G Route the throttle cables through the hole of the A Attach the wireharness clamp (protector handle under cover.
  • Page 54 SPEC CABLE ROUTING J Connect the taped headlight lead coupler to the headlight’s white marked side (left side: high beam side). (For UK, the right side is the high beam side.) K Fasten the headlight sub-harness. L Connect the turn signal light. M Securely fasten the wire strap to the front cowling hook to prevent it from being pulled out by the headlight assembly.
  • Page 55 SPEC CABLE ROUTING Rectifier/ regulator A The wireharness pass-through is change. Starting circuit cut-off relay B Fasten the starter motor lead, battery negative lead Pump relay and seat lock cable (right side) to the frame with a Flasher relay plastic clamp. Fuel pump C Fasten the starter motor lead and battery negative Main switch...
  • Page 56 SPEC CABLE ROUTING D Fasten the starter motor lead, battery negative H Use the clamp on the back of the frame to hold the lead, V-belt reset coupler, and seat lock cable to side stand switch lead and fan motor lead. the frame with a plastic band.
  • Page 57 SPEC CABLE ROUTING N Fasten the headlight sub harness with a plastic T Through the wireharness to the frame wireharness clamp. holder. O Fasten the igniter lead to the stay with a plastic U Route the wireharness and regulator lead through clamp.
  • Page 58 SPEC CABLE ROUTING AA After connecting the left headlight sub-harness and wireharness (by matching the coupler colors), fold back the lead facing to the right and insert it into the air filter case rib. AB Fasten the coolant reservoir hose to the stay with a plastic clamp.
  • Page 59 SPEC CABLE ROUTING Air vent hose A Route the wireharness through the frame guide. Vacuum hose At this time, place the protector (for the handle A.C. magneto lead cover inner side) on the bottom side. Sidestand switch B Fasten the rear brake hose and vacuum hose with Fan motor lead a plastic clamp.
  • Page 60 SPEC CABLE ROUTING D Fasten the wireharness to the frame with a K Use this as a reference when adjusting the throttle plastic clamp. cable. E Fasten the wireharness to the frame with a L After adjusting the throttle cables, make sure the plastic clamp.
  • Page 61 SPEC CABLE ROUTING Fuel hose A Route the wireharness against the stay wire guide. Battery negative lead B Fasten the wireharness branch wiring to the frame Seat lock with a plastic clamp. Starter motor lead C Fasten the wireharness to the frame with a plastic Fuse box clamp.
  • Page 62 SPEC CABLE ROUTING H Install the box light to the box 1. N Route the wireharness through the guide. I Fasten the auto choke leads (left and right) and O Place the speed sensor lead between the ribs of throttle position sensor lead to the frame with a the air filter case.
  • Page 63 SPEC CABLE ROUTING U Align the plastic clamp with the white tape on the AA Pass the speed sensor lead under the stay and wireharness and fasten the wireharness to the cross pipe and then over the brake hose guide. frame.
  • Page 64 SPEC CABLE ROUTING Vacuum hose A Route the throttle cable through the cable holder. Rear brake hose B Into the handle cover. Switch assembly lead C Route the main switch lead through over the seat Auto choke lead lock cable. Throttle position sensor lead D Fasten the sidestand switch lead and thermo Fan motor lead...
  • Page 65 SPEC CABLE ROUTING H Fasten the rear end of the carburetor air vent M Route the left carburetor drain hose through the hose to the frame with a plastic clamp. (The outside of the left high tension cable. distance from the end of clamp to the frame must range from 0 to 5 mm.) I Bundle the auto choke leads (left and right) and the throttle position sensor lead with a plastic...
  • Page 68 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..........PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .
  • Page 69 LUBRICATING THE LEVELS ....... . . 3-48 LUBRICATING THE CENTERSTAND .

  • Page 70: Chk Adj

    INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 71 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING ( 1,000 km) ANNUAL ITEM ITEM CHECK OR MAINTENANCE JOB CHECK OR MAINTENANCE JOB CHECK 4,000 km after initial 1,000 km Engine oil Engine oil S Change. When the oil change indicator light comes on (See page 3-23) (every 5,000 km) Engine oil filter...

  • Page 72: Seat

    SEAT AND FUEL LID SEAT SEAT AND FUEL LID Order Job/Part Q’ty Remarks Removing the seat and fuel lid Removing the parts in the order listed. Seat Fuel lid For installation, reverse the removal procedure.

  • Page 73: Cover And Panel

    FRONT COWLING COVER AND PANEL FRONT COWLING Order Job/Part Q’ty Remarks Removing the front cowling Refer to parts in the order listed. Front side cover mole Rear view mirror Front cowling upper cover Windshield Front cowling inner panel Front cowling For installation, reverse the removal procedure.

  • Page 74: Side Cover Moles

    SIDE COVER MOLES SIDE COVER MOLES Order Job/Part Q’ty Remarks Removing the side cover moles Removing the parts in the order listed. Mat (left and right) Upper side cover mole (left and right) Lower side cover mole (left and right) Center cover Hinge cover Side cover (left and right)

  • Page 75: Rear Covers And Taillight

    REAR COVERS AND TAILLIGHT REAR COVERS AND TAILLIGHT 15 Nm (1.5 mSkg) Order Job/Part Q’ty Remarks Removing the rear covers and Removing the parts in the order listed. taillight Grab bar Rear cover Rear side cover (left and right) Taillight assembly For installation, reverse the removal procedure.

  • Page 76: Fuel Tank

    FUEL TANK FUEL TANK 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Battery Fuse box coupler Disconnect. Battery positive lead Disconnect. Luggage box mat Luggage box Hinge and domper Fuel tank cover Fuel tank...

  • Page 77: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 78 ADJUSTING THE VALVE CLEARANCE a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the generator rotor with the mark b on the gen- erator cover. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
  • Page 79 ADJUSTING THE VALVE CLEARANCE S Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place. b. Select the proper valve pad from the follow- ing table. Valve pad Available valve thickness range...
  • Page 80 ADJUSTING THE VALVE CLEARANCE NOTE: S Apply molybdenum disulfide to the valve pad. S Lubricate the valve lifter with molybdenum dis- ulfide oil. S The valve lifter must turn smoothly when ro- tated by hand. S Install the valve lifter and the valve pad in the correct place.
  • Page 81 ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE ORIGINAL VALVE PAD NUMBER MEASURED 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 VALVE CLEARANCE 0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 X 0.07...

  • Page 82: Synchronizing The Carburetors

    ADJSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS 8. Install: S all removed parts NOTE: For installation, reverse the removal procedure. EAS00051 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked.
  • Page 83 SYNCHRONIZING THE CARBURETORS 5. Start the engine and let it warm up for several minutes. 6. Check: S engine idling speed Out of specification ! Adjust. Refer to “ADJUSTING THE ENGINE IDLING SPEED”. Engine idling speed 1150 X 1250 r/min 7.

  • Page 84: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00052 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes.

  • Page 85: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY c. Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained. Engine idling speed is in- Direction creased. Engine idling speed is Direction decreased.
  • Page 86 ADJUSTING THE THROTTLE CABLE FREE PLAY Carburetor side a. Loosen the locknut 1 on the decelerator cable. b. Turn the adjusting nut 2 in direction a or b to take up any slack on the decelerator cable. c. Loosen the locknut 3 on the accelerator cable.

  • Page 87: Checking The Spark Plugs

    CHECKING THE SPARK PLUGS CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: S center cover S side cover (left and right) Refer to “COVER AND PANEL”. 2. Disconnect: S spark plug cap 3.

  • Page 88: Checking The Ignition Timing

    CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: S spark plug cap 10. Install: S center cover S side cover (left and right) Refer to “COVER AND PANEL”. EAS00062 CHECKING THE IGNITION TIMING NOTE:...

  • Page 89: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 4. Check: S ignition timing a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed. Engine idling speed 1150 X 1250 r/min b.
  • Page 90 MEASURING THE COMPRESSION PRESSURE 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Disconnect: S spark plug cap 5. Remove: S spark plug CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders.

  • Page 91: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits. d. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again.

  • Page 92: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL Recommended oil SAE10W30 or SAE 10W40 API standard SE, SF, SG or higher grade (Non-Friction modified) CAUTION: S Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage.
  • Page 93 CHANGING THE ENGINE OIL c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 mSkg) 6. Check: S engine oil drain bolt washer Damage ! Replace. 7. Install: S engine oil drain bolt 43 Nm (4.3 mSkg) 8.

  • Page 94: Measuring The Engine Oil Pressure

    MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: S engine oil level Below the minimum level mark ! Add the recommended engine oil to the proper level. 2. Remove: S lower side cover mole Refer to “COVER AND PANEL”. 3.
  • Page 95 MEASURING THE ENGINE OIL PRESSURE Engine oil pressure Possible causes Faulty oil pump Clogged oil filter Below specification Leaking oil passage Broken or damaged oil seal Leaking oil passage Above specification Faulty oil filter Oil viscosity too high 7. Install: S main gallery bolt 1 20 Nm (2.0 mSkg) 3-26...

  • Page 96: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT CLEANING THE AIR FILTER ELEMENT 1. Remove: S front cowling upper cover S windshield S front cowling inner panel Refer to “COVER AND PANEL”. 2. Remove: S air filter case cover 1 S air filter element 3.

  • Page 97: Cleaning The V-Belt Case Air Filter Element

    CLEANING THE V-BELT CASE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: S upper side cover mole (left) S footrest board (left) Refer to “COVER AND PANEL”. 2. Remove: S V-velt case air filter element 1 and 2 3.

  • Page 98: Checking The Fuel Hoses And Fuel Filter

    CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS/CHECKING THE FUEL HOSES AND FUEL FILTER 2. Check: S carburetor joints 1 Cracks/damage ! Replace. Refer to “CARBURETOR” in chapter 7. 3. Install: S legshield EAS00097 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses.

  • Page 99: Checking The Crankcase Breather Hose

    CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: S legshield Refer to “COVER AND PANEL”. 2. Check: S crankcase breather hose 1 Cracks/damage ! Replace. Loose connection ! Connect properly. CAUTION: Make sure that the crankcase breather hose is routed correctly.

  • Page 100: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL EAS00103 CHECKING THE COOLANT LEVEL 1. Stand the scooter on a level surface. NOTE: S Place the scooter on a suitable stand. S Make sure that the scooter is upright. 2. Remove: S lower side cover mole (right) 3.

  • Page 101: Checking The Cooling System

    CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT CHECKING THE COOLING SYSTEM 1. Remove: S footrest board (left and right) S legshield Refer to “COVER AND PANEL”. 2. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler inlet hose 4 S oil cooler outlet hose 5 Cracks/damage ! Replace.
  • Page 102 CHANGING THE COOLANT 3. Drain: S coolant (from the coolant reservoir) 4. Install: S coolant reservoir bolts 5. Remove: S front side cover mole (right) Refer to “COVER AND PANEL”. S radiator cap 1 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot.
  • Page 103 CHANGING THE COOLANT 10. Fill: S 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 Mix ratio 50% antifreeze/50% water Quantity Total amount 1.5 L Coolant reservoir capacity 0.6 L Handling notes for coolant...
  • Page 104 CHANGING THE COOLANT 12. Fill: S coolant reservoir (with the recommended coolant to the maxi- mum level mark a ) 13. Install: S coolant reservoir cap 14. Start the engine, warm it up for several min- utes, and then turn it off. 15.

  • Page 105: Chassis

    CHECKING THE BRAKE FLUID LEVEL CHASSIS EAS00116 CHECKING THE BRAKE FLUID LEVEL 1. Stand the scooter on a level surface. NOTE: S Place the scooter on a suitable stand. S Make sure that the scooter is upright. 2. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

  • Page 106: Checking The Brake Pads

    CHECKING THE BRAKE PADS/ CHECKING THE BRAKE HOSES EB304032 CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: S front brake pad S rear brake pad Brake pad wear limit a Wear limit reached ! Replace the brake pads as a set.

  • Page 107: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00135 BLEEDING THE HYDRAULIC BRAKE SYS- WARNING Bleed the hydraulic brake system whenev- S the system was disassembled, S a brake hose was loosened or removed, S the brake fluid level is very low, S brake operation is faulty. NOTE: S Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow.

  • Page 108: Checking The Chain Drive Oil Level

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHECKING THE CHAIN DRIVE OIL LEVEL Bleed screw 6 Nm (0.6 mSkg) k. Fill the reservoir to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. WARNING After bleeding the hydraulic brake system, check the brake operation . CHECKING THE CHAIN DRIVE OIL LEVEL 1.

  • Page 109: Changing The Chain Drive Oil

    CHANGING THE CHAIN DRIVE OIL/ CHECKING AND ADJUSTING THE STEERING HEAD CHANGING THE CHAIN DRIVE OIL 1. Place a container under the chain drive. 2. Remove: S chain drive oil drain bolt 1 S chain drive oil filler cap Completely drain the chain drive of its oil. 3.
  • Page 110 CHECKING AND ADJUSTING THE STEERING HEAD 2. Check: S steering head Grasp the bottom of the front fork legs and gently rock the front fork. Looseness or binding ! Adjust the steering head. 3. Remove: S handlebar Refer to “HANDLEBAR” in chapter 4. 4.
  • Page 111 CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut 4 completely, then tighten it to specification. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 19 Nm (1.9 mSkg) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions.

  • Page 112: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK 9. Measure: S steering head tension (with the motorcycle still on the stand) NOTE: Make sure that all of the cables and wires are properly routed. a. Point the front wheel straight ahead. b.
  • Page 113 CHECKING THE FRONT FORK 2. Check: S inner tube Damage/scratches ! Replace. S oil seal Oil leakage ! Replace. 3. Hold the motorcycle upright and apply the front brake. 4. Check: S operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly.

  • Page 114: Checking The Tires

    CHECKING THE TIRES EB304170 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: S tire pressure Out of specification ! Regulate. WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 115 No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one ap- proved by Yamaha is used on this scooter. Front tire Manufacturer Size...

  • Page 116: Checking The Wheels

    CHECKING THE TIRES/CHECKING THE WHEELS Rear tire Manufacturer Size Model 150/70-14 HOOP BRIDGESTONE M/C 66S 150/70-14 DUNLOP D305 M/C 66S WARNING After mounting a new tire, ride conservative- ly for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim.

  • Page 117: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES /LUBRICATING THE LEVERS LUBRICATING THE CENTERSTAND/ LUBRICATING THE SIDESTAND EAS00170 CHECKING LUBRICATING CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its move- ment.
  • Page 118 LUBRICATING THE REAR SUSPENSION EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum disulfide grease 3-49...
  • Page 119 CHECKING AND CHARGING THE BATTERY EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
  • Page 120 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 battery terminals.
  • Page 121 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20_C S battery (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. CAUTION: Time (minutes) Check the open-circuit voltage. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger since it forces a high-amperage current Ambient...
  • Page 122 CHECKING AND CHARGING THE BATTERY Charging method using a variable-voltage charger Charger Measure the open-circuit NOTE: Ammeter voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Connect a charger and am- NOTE: meter to the battery and Set the charging voltage to 16 X 17 V.
  • Page 123 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 open- circuit voltage. Connect a charger and am- meter to the battery and start charging.
  • Page 124 CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: S battery 7. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 8. Check: S battery terminals Dirt ! Clean with a wire brush.
  • Page 125 CHECKING THE FUSES 3. Replace: S blown fuse a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage. c. Set the main switch to “ON” and verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit.
  • Page 126 REPLACING THE HEADLIGHT BULBS EB305051 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: S headlight coupler 1 S headlight bulb holder cover 2 2. Detach: S headlight bulb holder 1 3. Remove: S headlight bulb 2 WARNING Since the headlight bulb gets extremely hot,...
  • Page 127 ADJUSTING THE HEADLIGHT BEAM EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or Direction Headlight beam is raised. Direction Headlight beam is lowered. 2. Adjust: S headlight beam (horizontally) a.

  • Page 129: Chas

    CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC ......REMOVING THE FRONT WHEEL .
  • Page 130 CHAS HANDLEBAR ..........4-56 REMOVING THE HANDLEBAR .

  • Page 131: Chassis

    CHAS FRONT WHEEL AND BRAKE DISC CHASSIS FRONT WHEEL AND BRAKE DISC 59 Nm (5.9 mSkg) 40 Nm (4.0 mSkg) 20 Nm (2.0 mSkg) 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. NOTE: disc Place the scooter on a suitable stand...
  • Page 132 CHAS FRONT WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Dust seal Oil seal Bearing Collar For assembly, reverse the disassembly procedure.

  • Page 133: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. WARNING Securely support the so that there is no dan- ger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

  • Page 134: Checking The Front Wheel

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

  • Page 135: Checking The Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC c. Remove the wheel bearings 3 with a gener- al bearing puller. d. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing center race 4 or balls 5 .
  • Page 136 CHAS FRONT WHEEL AND BRAKE DISC 3. Measure: S brake disc thickness a Measure the brake disc thickness at a few different locations. Out of specification ! Replace. Min. brake disc thickness Front: 4.5 mm Rear: 3.5 mm 4. Adjust: S brake disc deflection a.

  • Page 137: Assembling The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EB700711 ASSEMBLING THE FRONT WHEEL 1. Install: S wheel bearings a. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing center race 1 or balls 2 .
  • Page 138 CHAS FRONT WHEEL AND BRAKE DISC 3. Install: S brake disc 18 Nm (1.8 mSkg) NOTE: S Apply LOCTITE 648 to the threads of the brake disc bolts. S Tighten the brake disc bolts in stages and in a crisscross pattern. 4.

  • Page 139: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISC EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the front wheel static balance should be adjusted. S Adjust the front wheel static balance with the brake disc installed. 1.
  • Page 140 CHAS FRONT WHEEL AND BRAKE DISC 4. Check: S front wheel static balance a. Turn the front wheel and make sure that it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it. 4-10...

  • Page 141: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL AND BRAKE DISC REAR WHEEL 17 Nm (1.7 mSkg) 7 Nm (0.7 mSkg) 104 Nm (10.4 mSkg) 40 Nm (4.0 mSkg) 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 rear wheel is elevated.
  • Page 142 CHAS REAR WHEEL AND BRAKE DISC 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Brake disc Rear wheel drive hub O-ring Dust seal Oil seal Bearing For assembly, reverse the disassembly procedure.

  • Page 143: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00565 CHECKING THE REAR WHEEL 1. Check: S wheel axle S rear wheel S wheel bearings S oil seals Refer to “FRONT WHEEL”. 2. Check: S tire S rear wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS”...

  • Page 144: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the fornt brake pads Remove the parts in the order listed. Front brake caliper bolt Brake caliper Brake pad Brake pad spring For installation, reverse the removal procedure.

  • Page 145: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Rear brake caliper bolt Brake caliper Brake pad Brake pad shim Brake pad spring For installation, reverse the removal procedure.

  • Page 146: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
  • Page 147 CHAS FRONT AND REAR BRAKES 3. Measure: S brake pad thickness a Out of specification ! Replace the brake pads as a set. Minimum brake pad thickness 0.8 mm 4. Install: S brake pad spring 1 S brake pads 2 NOTE: Always install new brake pads and a new brake pad shim as a set.

  • Page 148: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES 6. Install: S brake caliper 1 S brake caliper bolts 2 40 Nm (4.0 mSkg) 7. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
  • Page 149 CHAS FRONT AND REAR BRAKES 3. Measure: S brake pad thickness a Out of specification ! Replace the brake pads as a set. Minimum brake pad thickness 0.8 mm 4. Install: S brake pads 1 S brake pad spring 2 S brake pad shim 3 NOTE: Always install new brake pads and a brake pad...
  • Page 150 CHAS FRONT AND REAR BRAKES 6. Install: S brake caliper S brake caliper bolt 40 Nm (4.0 mSkg) 7. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 151: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER 1 Nm (0.1 mSkg) 30 Nm (3.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
  • Page 152 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure. 4-22...

  • Page 153: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES REAR BRAKE MSTER CYLINDER 30 Nm (3.0 mSkg) 10 Nm (1.0 mSkg) 1 Nm (0.1 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
  • Page 154 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure. 4-24...

  • Page 155: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MAS- TER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: S front brake light switch connector (from the brake light switch) 2.

  • Page 156: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: S brake master cylinder 1 Damage/scratches/wear ! Replace. S brake fluid delivery passages (brake master cylinder body) Obstruction ! Blow out with compressed air.

  • Page 157: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 5. Check: S brake hoses 1 Cracks/damage/wear ! Replace. EAS00596 ASSEMBLING INSTALLING FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents.
  • Page 158 CHAS FRONT AND REAR BRAKES 4. Install: S brake master cylinder 1 S brake master cylinder holder 2 S holder bolts 10 Nm (1.0 mSkg) NOTE: S Install the brake master cylinder holder with the “UP” mark facing up a . S Align the end of the brake master cylinder hold- er with the punch mark b in the handlebar.
  • Page 159 CHAS FRONT AND REAR BRAKES 6. Connect: S front brake light switch connector 7. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 160: Assembling And Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00600 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents.
  • Page 161 CHAS FRONT AND REAR BRAKES 4. Install: S brake master cylinder 1 S brake master cylinder holder 2 S holder bolts 10 Nm (1.0 mSkg) NOTE: S Install the brake master cylinder holder with the “UP” mark facing up a . S Align the end of the brake master cylinder hold- er with the punch mark b on the handlebar.
  • Page 162 CHAS FRONT AND REAR BRAKES 6. Connect: S rear brake light switch connector 7. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 163: Front Brake Caliper

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPER 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper bolt Brake caliper For installation, reverse the removal...
  • Page 164 CHAS FRONT AND REAR BRAKES 6 Nm (0.6 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. caliper Brake caliper bolt Brake caliper bracket Bleed screw Brake pad Brake pad spring Brake pad crip Brake caliper piston Dust seal...

  • Page 165: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper bolt Brake caliper For installation, reverse the removal...
  • Page 166 CHAS FRONT AND REAR BRAKES 6 Nm (0.6 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear brake Disassemble the parts in the order listed. caliper Brake caliper bolt Brake caliper bracket Bleed screw Brake pad Brake pad spring Brake pad shim Brake caliper piston Dust seal...

  • Page 167: Disassembling The Front Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00619 DISASSEMBLING THE FRONT BRAKE CAL- IPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 168: Checking The Front And Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: S brake caliper piston 1 S brake caliper piston seals 2 a.
  • Page 169 CHAS FRONT AND REAR BRAKES 1. Check: S brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper. S brake caliper cylinders 2 Scratches/wear ! Replace the brake cali- per. S brake caliper body 3 Cracks/damage ! Replace the brake cali- per.

  • Page 170: Assembling And Installilng The Front Brake Calilper

    CHAS FRONT AND REAR BRAKES EAS00635 ASSEMBLING INSTALLING FRONT BRAKE CALIPER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 171 CHAS FRONT AND REAR BRAKES 3. Install: S brake caliper S brake caliper bolt 40 Nm (4.0 mSkg) 4. Install: S brake hose 1 S copper washers 2 S union bolt 3 30 Nm (3.0 mSkg) WARNING Proper brake hose routing is essential to in- sure safe scooter operation.

  • Page 172: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 6. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 7. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
  • Page 173 CHAS FRONT AND REAR BRAKES 2. Install: S brake pad shim 1 S brake pad spring 2 S brake pad 3 NOTE: Install the brake pad with the attached brake pad shim. 3. Install: S brake caliper S brake caliper bolt 40 Nm (4.0 mSkg) 4.
  • Page 174 CHAS FRONT AND REAR BRAKES 5. Fill: S brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 175: Front Fork

    CHAS FRONT FORK FRONT FORK 30 Nm (3.0 mSkg) 45 Nm (4.5 mSkg) 30 Nm (3.0 mSkg) 27 Nm (2.7 mSkg) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed. The following procedure applies to both of the front fork legs.
  • Page 176 CHAS FRONT FORK 30 Nm (3.0 mSkg) 45 Nm (4.5 mSkg) 30 Nm (3.0 mSkg) 27 Nm (2.7 mSkg) Order Job/Part Q’ty Remarks Brake hose holder Speed sensor holder Cap bolt Loosen. Upper bracket pinch bolt Loosen. Lower bracket pinch bolt Loosen.
  • Page 177 CHAS FRONT FORK 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the front fork leg Disassemble the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Fork spring seat Fork spring Damper rod assembly bolt Copper washer...
  • Page 178 CHAS FRONT FORK 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Inner tube bushing Dust seal Oil seal clip Oil seal Washer Outer tube bushing For assembly, reverse the disassembly procedure. 4-48...

  • Page 179: 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. 1. Stand the scooter on a level surface. WARNING 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 180: Disassemblilng The Front Fork Legs

    CHAS FRONT FORK EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: S dust seal 1 S oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 2.

  • Page 181: Checking The Front Fork Legs

    CHAS FRONT FORK EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

  • Page 182: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Make sure that the oil levels in both front fork legs are equal. S Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 183 CHAS FRONT FORK 5. Tighten: S damper rod bolt 1 20 Nm (2.0 mSkg) NOTE: S Apply the locking agent (LOCTITE 204) to the threads of the damper rod bolt. S While holding the damper rod with the damper rod holder 2 and T-handle 3 , tighten the damper rod bolt.
  • Page 184 135 mm Recommended oil Yamaha fork shock oil 5 WT or equivalent NOTE: S While filling the front fork leg, keep it upright. S After filling, slowly pump the front fork leg up and down to distribute the fork oil.

  • Page 185: 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. 1. Install: S front fork leg NOTE: Pull up the inner tube until it stops. 2. Tighten: S cap bolt 1 45 Nm (4.5 mSkg) S lower bracket pinch bolt 3 30 Nm (3.0 mSkg)

  • Page 186: Handlebar

    CHAS HANDLEBAR HANDLEBAR 26 Nm (2.6 mSkg) 23 Nm (2.3 mSkg) 10 Nm (1.0 mSkg) 26 Nm (2.6 mSkg) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Handle cover (upper) Handle cover (lower) Band Front brake light switch connecter Disconnect.
  • Page 187 CHAS HANDLEBAR 26 Nm (2.6 mSkg) 23 Nm (2.3 mSkg) 10 Nm (1.0 mSkg) 26 Nm (2.6 mSkg) Order Job/Part Q’ty Remarks Handlebar upper holder Grip end Handlebar For installation, reverse the removal procedure. 4-57...

  • Page 188: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: S right handlebar switch 1 S throttle cable S throttle grip 2 S front brake master cylinder 3 S grip end 4 3.

  • Page 189: Installing The Handlebar

    CHAS HANDLEBAR EAS00671 INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Install: S handlebar 1 S handlebar upper holders 2 23 Nm (2.3 mSkg) WARNING S First, tighten the bolts on the front side of the handlebar holder, then on the rear side.
  • Page 190 CHAS HANDLEBAR S First, tighten the upper bolt, then the lower bolt. 4. Install: S throttle cable S throttle grip S grip end 5. Install: S right handlebar switch 1 NOTE: Align the projection a on the right handlebar switch with the hole b in the handlebar. 6.
  • Page 191 CHAS HANDLEBAR 9. Install: S left handlebar grip S grip end a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.

  • Page 192: Lower Bracket

    CHAS STEERING HEAD STEERING HEAD LOWER BRACKET 52 Nm (5.2 mSkg) 19 Nm (1.9 mSkg) Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front cowling Refer to “COVER AND PANEL” in chapter 3. Front wheel Refer to “FRONT WHEEL AND BRAKE DISC”.
  • Page 193 CHAS STEERING HEAD 52 Nm (5.2 mSkg) 19 Nm (1.9 mSkg) Order Job/Part Q’ty Remarks Lower ring nut Bearing cover Bearing inner race Upper bearing Bearing outer race Bearing inner race Lower bearing Bearing outer race Oil seal Lower bracket For installation, reverse the removal procedure.

  • Page 194: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Remove: S upper bracket 3. Remove: S lock washer 1 S upper ring nut 2 S rubber washer 3 S lower ring nut 4...

  • Page 195: Installing The Steering Head

    CHAS STEERING HEAD 3. Replace: S bearings S bearing races a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c.
  • Page 196 CHAS STEERING HEAD 4. Install: S upper bearing S bearing cover 5. Install: S lower ring nut 1 S rubber washer 2 S upper ring nut 3 S lock washer 4 Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3. 6.

  • Page 197: Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER REAR SHOCK ABSORBER 52 Nm (5.2 mSkg) 67 Nm (6.7 mSkg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Muffler Refer to “MUFFLER ASSEMBLY” in chapter 5. Lock washer Bolt Bolt/nut...

  • Page 198: Handling The Rear Shock Absorber And

    CHAS REAR SHOCK ABSORBER EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand following information.

  • Page 199: Removing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER EAS00693 REMOVING THE REAR SHOCK ABSORBER 1. Stand the scooter on a level surface. WARNING 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 200: Installing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER INSTALLING THE REAR SHOCK ABSORB- 1. Lubricate: S spacer S bearings Recommended lubricant Molybdenum disulfide grease 2. Install: S bush 1 S washer 2 S bearings 3 S spacer 4 3. Install: S rear shock absorber 1 S bolt (rear side) 2 52 Nm (5.2 mSkg) 4.

  • Page 202: Eng

    CHAPTER 5 OVERHAULING THE ENGINE ENGINE ............MUFFLER ASSEMBLY .
  • Page 203 CHECKING THE CLUTCH BOSS ......5-43 CHECKING THE PRESSURE PLATE ......5-43 CHECKING THE WEIGHT .

  • Page 204: Overhauling The Engine

    ENGINE OVERHAULING THE ENGINE ENGINE MUFFLER ASSEMBLY 48 Nm (4.8 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Removing the muffler assembly Remove the parts in the order listed. Lower side cover mole (right) Muffler assembly For installation, reverse the removal procedure.
  • Page 205 ENGINE LEADS AND HOSES Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Legshield Refer to “COVER AND PANEL” in Footrest board chapter 3. Muffler assembly Refer to “MUFFLER ASSEMBLY”. Rear shock absorber Refer to “REAR SHOCK ABSORBER”...
  • Page 206 ENGINE Order Job/Part Q’ty Remarks A.C. magneto lead Hose Air induction system Refer to “AIR INDUCTION SYSTEM” in chapter 7. For installation, reverse the removal procedure.

  • Page 207: Engine

    ENGINE ENGINE 87 Nm (8.7 mSkg) 87 Nm (8.7 mSkg) 48 Nm (4.8 mSkg) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. Upper mounting bolt/nut Lower mounting bolts/washers Collar Rear mounting bolt/nut For installation, reverse the removal procedure.

  • Page 208: Installing The Engine

    ENGINE INSTALLING THE ENGINE 1. Install: S front mounting bolt/nut 1 S front mounting bolts (lower) 2 S collar 3 S rear mounting bolt/nut 4 NOTE: Do not fully tighten the bolts. 2. Tighten: S front mounting nut (upper) 1 87 Nm (8.7 mSkg) S front mounting bolts (lower) 2 48 Nm (4.8 mSkg)

  • Page 209: Camshafts

    CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER 12.5 Nm (1.25 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Carburetor assembly Refer to “CARBURETOR” in chapter 7. Coolant Drain. Radiator assembly Refer to “RADIATOR AND OIL COOLER”...

  • Page 210: Camshafts

    CAMSHAFTS CAMSHAFTS 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Timing chain tensioner Timing chain tensioner gasket Camshaft caps Dowel pins NOTE: During removal, the dowel pins may still be connected to the camshaft cap.

  • Page 211: Removing The Camshafts

    CAMSHAFTS REMOVING THE CAMSHAFTS 1. Remove: S timing plug 1 2. Align: S “I” mark a (with the stationary pointer b ) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the stationary pointer b .

  • Page 212: Checking The Camshafts

    CAMSHAFTS 5. Remove: S intake camshaft 1 S exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, faster it with a wire 3 . 6. Remove: S timing chain guide (exhaust side) EAS00204 CHECKING THE CAMSHAFTS 1.
  • Page 213 CAMSHAFTS 4. Measure: S camshaft-journal-to-camshaft-cap clear- ance Out of specification ³ Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.020 X 0.054 mm a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position a strip of Plastigauge 1 onto the camshaft journal as shown.

  • Page 214: Checking The Camshaft Sprockets, And Timing Chain Guides

    CAMSHAFTS CHECKING THE CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: S camshaft sprocket More than 1/4 tooth wear a ! Replace the camshaft sprockets and the timing chain as a set.

  • Page 215: Installing The Camshafts

    CAMSHAFTS INSTALLING THE CAMSHAFTS 1. Install: S timing chain guide (exhaust side) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the stationary pointer b . 2.
  • Page 216 CAMSHAFTS 4. Install: S chair guide (exhaust side) S timing chain tensioner gasket S timing chain tensioner a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. b. While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until if stops.
  • Page 217 CAMSHAFTS 8. Install: S cylinder head cover gasket S cylinder head cover NOTE: Tighten the cylinder head cover bolts in stages and in a crisscross pattern. 5-14...

  • Page 218: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD 46 Nm (4.6 mSkg) 10 Nm (1.0 mSkg) 35 Nm (3.5 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Legshield Footrest board Refer to “COVER AND PANEL” in chapter 3.

  • Page 219: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD 1. Remove: S cylinder head bolts 1 S cylinder head nuts 2 NOTE: S Loosen the nuts in the proper sequence as shown. S Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

  • Page 220: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD 1. Install: S dowel pins S gasket 2. Install: S cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: S cylinder head nuts 1 35 Nm (3.5 mSkg) S cylinder head nuts 2 46 Nm (4.6 mSkg) S cylinder head bolts 3 10 Nm (1.0 mSkg)

  • Page 221: Valves And Valve Springs

    VALVES AND VALVE SPRINGS 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”. Valve lifter Valve pad Valve cotter Valve retainer Valve spring Intake valve stem seal Exhaust valve stem seal Valve spring seat...

  • Page 222: 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 that the valves properly seal. 1.

  • Page 223: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS Valve spring compressor 90890-04109 Attachment 90890-04114 4. Remove: S valve retainer 1 S valve spring 2 S oil seal 3 S valve spring seat 4 S valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
  • Page 224 VALVES AND VALVE SPRINGS 2. Replace: S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_ in an oven. a. Remove the valve guide with a valve guide remover 1 .

  • Page 225: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: S valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide. S If the valve is removed or replaced, always re- place the oil seal. Valve stem runout 0.04 mm EAS00240...
  • Page 226 VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been re- moved. 4. Lap: S valve face S valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

  • Page 227: Checking The Valve Springs

    VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g.

  • Page 228: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS Compressed spring force Intake valve spring 9.3 X 10.7 kg at 30.4 mm Exhaust valve spring 9.3 X 10.7 kg at 30.4 mm 3. Measure: S valve spring tilt a Out of specification ! Replace the valve spring.
  • Page 229 VALVES AND VALVE SPRINGS 3. Install: S valve 1 S valve spring seat 2 S oil seal 3 S valve spring 4 S valve retainer 5 (into the cylinder head) NOTE: S Make sure that each valve is installed in its original place.
  • Page 230 VALVES AND VALVE SPRINGS 6. Lubricate: S valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 7. Install: S valve pad S valve lifter CAUTION: After making sure that the valve pads are ful- ly inserted, install the valve lifter taking care so that the pads do not fall.

  • Page 231: Starter Clutch And Generator

    STARTER CLUTCH AND GENERATOR STARTER CLUTCH AND GENERATOR 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) 60 Nm (6.0 mSkg) + 120_ 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the starter clutch and Remove the parts in the order listed. generator Side panel (left) Lower cover...
  • Page 232 STARTER CLUTCH AND GENERATOR 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) 60 Nm (6.0 mSkg) + 120_ 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Starter coil assembly Spacer Generator rotor Starter clutch Idler gear shaft Idler gear Starter clutch gear Washer...

  • Page 233: Removing The Generator

    STARTER CLUTCH AND GENERATOR REMOVING THE GENERATOR 1. Remove: S generator rotor cover 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 loosend, remove them.

  • Page 234: Checking The Starter Clutch

    STARTER CLUTCH AND GENERATOR CHECKING THE STARTER CLUTCH 1. Check: S starter clutch Damage/wear ! Replace. 2. Check: S idle gear S idle gear shaft S starter clutch gear Pitting/burrs/chips/roughness/wear ! Re- place the defective parts. 3. Check: S starter clutch operation a.
  • Page 235 S After tightening the generator rotor nut, to the specified torque, turn the connecting rod nut another + 120_. 3. Apply: S sealant (onto the stator coil assembly lead grommet) Yamaha bond No1215 90890-85505 4. Install: S stator coil 5. Install: S generator rotor cover...

  • Page 236: Oil Pump

    OIL PUMP OIL PUMP 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the oil pump Removing the parts in the order listed. Side panel (left) Lower cover Footrest board Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Engine oil Drain.
  • Page 237 OIL PUMP 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks O-ring Oil pipe Oil pipe Relief valve assembly For installation, reverse the removal procedure. 5-34...
  • Page 238 OIL PUMP Order Job/Part Q’ty Remarks Disassembling the oil pump Disassemble the parts in the order listed. Oil pump housing Oil pump outer rotor Oil pump inner rotor Dowel pin Oil pump housing center Oil pump cover Oil pump driven gear For assembly, reverse the disassembly procedure.

  • Page 239: Checking The Oil Pump

    OIL PUMP CHECKING THE OIL PUMP 1. Check: S oil pump driven gear 1 S oil pump housing 2 S oil pump cover 3 Cracks/damage/wear ! Replace the de- fective part(-s). 2. Measure: S inner-rotor-to-outer-rotor-tip clearance a S outer-rotor-to-oil-pump-housing clearance Out of specification ! Replace the oil pump.

  • Page 240: Checking The Oil Delivery Pipes

    OIL PUMP EAS00367 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1. Check: S oil delivery pipe 1 Damage ! Replace. Obstruction ! Wash and blow out with com- pressed air. EAS00368 CHECKING THE OIL STRAINER 1.

  • Page 241: Clutch

    CLUTCH CLUTCH 65 Nm (6.5 mSkg) Order Job/Part Q’ty Remarks Removing the clutch assembly Remove the parts in the order listed. Generator cover Refer to “STARTER CLUTCH AND GENERATOR”. Clutch assembly For installation, reverse the removal procedure. 5-38...
  • Page 242 CLUTCH 90 Nm (9.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the clutch Disassemble the parts in the order listed. Primary drive gear Rollar bearing Circlip Bearing Collar Clutch boss Circlip Spring plate stopper Clutch spring 2 Pressure plate Clutch plate 2 Friction plate Clutch plate 1 Clutch spring...
  • Page 243 CLUTCH 90 Nm (9.0 mSkg) Order Job/Part Q’ty Remarks Spring Thrust plate Weight Clutch housing For assembly, reverse the disassembly procedure. 5-40...

  • Page 244: Removing The Clutch

    CLUTCH REMOVING THE CLUTCH 1. Remove: S generator cover 1 Refer to “STARTER CLUTCH AND GENER- ATOR”. 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.

  • Page 245: Checking The Friction Plates

    CLUTCH EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: S friction plate Damage/wear ! Replace the friction plates as a set. 2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set.

  • Page 246: Checking The Clutch Housing

    CLUTCH 3. Measure: S clutch spring 2 c Out of specification ! Replace the clutch spring 2 Clutch spring 2 limit 4.4 mm EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: S clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause er- ratic clutch operation.

  • Page 247: Belt Drive

    BELT DRIVE BELT DRIVE BELT DRIVE COVER 7 Nm (0.7 mSkg) 24 Nm (2.4 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the belt drive cover Remove the parts in the order listed. Side panel (right) Lower cover Footrest board Protector cover 1 Protector cover 2...

  • Page 248: Belt Drive

    BELT DRIVE BELT DRIVE : Shell BT grease 3 24 Nm (2.4 mSkg) 90 Nm (9.0 mSkg) 160 Nm (16.0 mSkg) Order Job/Part Q’ty Remarks Removing the belt drive Remove the parts in the order listed. Primary sheave nut Spacer O-ring Primary sheave assembly Primary fixed sheave...

  • Page 249: Disassembly The Primary Sheave

    BELT DRIVE : Shell BT grease 3 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the primary sheave Dissassemble the parts in the order listed. Stopper Slider Weight Primary sliding sheave Collar O ring For assembly, reverse the disassembly procedure.

  • Page 250: Disassembly The Secondary Sheave

    BELT DRIVE : BEL-RAY assembly lube 90 Nm (9.0 mSkg) Order Job/Part Q’ty Remarks Disassembly the secondary sheave Disassemble the parts in the order listed. Upper spring seat Compression spring Spring seat Secondary sliding sheave Oil seal Guide pin Secondary fixed sheave Collar For assembly, reverse the disassembly procedure.
  • Page 251 BELT DRIVE REMOVING THE PRIMARY SHEAVE AS- SEMBLY, SECONDARY SHEAVE SEMBLY AND V-BELT 1. Remove: S primary sheave nut 1 S secondary sheave nut 2 NOTE: While holding the primary and secondary sheave with the sheave holder, loosen the nut. Sheave holder 90890-01481 2.

  • Page 252: Checking The V-Belt

    BELT DRIVE DISASSEMBLING THE PRIMARY SHEAVE 1. Remove: S cam 1 S slider 2 S weight 3 DISASSEMBLING SECONDARY SHEAVE 1. Remove: S secondary sheave nut 1 NOTE: Install the sheave spring compresser 2 onto the secondary sheave as shown. Then, com- press the spring, and remove the secondary pulley nut 1 with locknut wrench 3 .

  • Page 253: Checking The Primary Sheave

    BELT DRIVE CHECKING THE PRIMARY SHEAVE 1. Check: S primary sliding sheave 1 S primary fixed sheave 2 Cracks/damage/wear ! Replace the pri- mary sliding sheave and primary fixed sheave as a set. CHECKING THE WEIGHT 1. Check: S weight 1 Cracks/wear/scaling/chipping ! Replace.

  • Page 254: Assembling The Primary Sheave

    BELT DRIVE ASSEMBLING THE PRIMARY SHEAVE 1. Clean: S primary fixed sheave S primary sliding sheave S collar S weight S slider S cam S stopper NOTE: Remove any excess grease. 2. Install: S weight 1 S slider 2 S cam 3 NOTE: S Before installing the weights, lubricate the in- side and outside of each weight with Shell BT...

  • Page 255: Assembling The Secondary Sheave

    BELT DRIVE EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: S secondary fixed sheave’s outer and inner surface 1 S secondary sliding sheave’s outer and inner surface 2 S grease nipple groove S oil seals S bearings (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube 2.

  • Page 256: Installing The Belt Drive

    BELT DRIVE Sheave spring compresser 2 90890-04134 Locknut wrench 3 90890-01348 Sheave fixed block 4 90890-04135 6. Tighten: S nut 90 Nm (9.0 mSkg) INSTALLING THE BELT DRIVE 1. Install: S primary fixed sheave 1 S V-belt 2 S secondary sheave assembly 3 CAUTION: Do not allow grease to contact the V-belt and secondary pulley...
  • Page 257 BELT DRIVE 4. Tighten: S primary sheave nut 1 160 Nm (16.0 mSkg) CAUTION: S Before tightening the nut to remount the primary sheave, make sure that the serra- tion of the cam brinells deeply into the serration of the crankshaft. Also, fully tighten the nut as far as the clepths while holding down the cam so as not to allow the serration to disengage.

  • Page 258: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON 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 Cylinder gasket Dowel pin Circlip Piston pin Piston Piston ring set For installation, reverse the removal...

  • Page 259: Removing The Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON The following procedure applies to all of the pis- tons. 1. Remove: S piston pin clip 1 S piston pin 2 S piston 3 CAUTION: Do not use a hammer to drive the piston pin out.

  • Page 260: Checking The Cylinder And Piston

    CYLILNDER AND PISTON EAS00261 CHECKING THE CYLINDER AND PISTON 1. Check: S piston wall S cylinder wall Vertical scratches ! Replace the cylinder, and the piston and piston rings as a set. 2. Measure: S piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge.

  • Page 261: Checking The Piston Rings

    CYLILNDER AND PISTON e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.020 X 0.045 mm <Limit>: 0.15 mm f. If out of specification, replace the cylinder, and the piston and piston rings as a set.

  • Page 262: Checking The Piston Pins

    CYLINDER AND PISTON 3. Measure: S piston ring end gap Out of specification ! Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring end gap Top ring 0.15 X 0.25 mm...

  • Page 263: Installing The Pistons And Cylinders

    CYLINDER AND PISTON 4. Calculate: S piston-pin-to-piston-pin-bore clearance Out of specification ! Replace the piston pin. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter (in the piston) – Piston pin outside diameter Piston-pin-to-piston-pin-bore clearance 0.002 X 0.022 mm <Limit>: 0.072 mm EAS00271 INSTALLING THE PISTONS AND CYL- INDERS...
  • Page 264 CYLINDER AND PISTON 3. Lubricate: S piston S piston pin Recommended lubricant Engine oil 4. Install: S piston 3 S piston pin 2 S piston pin clip NOTE: S Apply engine oil onto the piston pin. S Make sure that the arrow mark a on the piston points towards the exhaust side of the cylinder.

  • Page 265: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT CRANKSHAFT ASSEMBLY 58 Nm (5.8 mSkg) 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) 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”.
  • Page 266 CRANKCASE AND CRANKSHAFT 58 Nm (5.8 mSkg) 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) Order Job/Part Q’ty Remarks Crankcase (left) Crankshaft Cylinder (barancer) Main journal bearing For installation, reverse the removal procedure. 5-63...

  • Page 267: Connecting Rod

    CRANKCASE AND CRANKSHAFT CONNECTING ROD 16 Nm (1.6 mSkg) + 90_ 16 Nm (1.6 mSkg) + 90_ 60 Nm (6.0 mSkg) Order Job/Part Q’ty Remarks Removing the connecting rod Remove the parts in the order listed. Connecting rod Connecting rod (balancer) Crankshaft Connecting rod cap Circlip...

  • Page 268: Disassembling The Crankcase

    CRANKCASE AND CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: S crankcase bolts NOTE: S 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. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).

  • Page 269: Removing The Crankshaft Journal Bearing

    CRANKCASE AND CRANKSHAFT EAS00387 REMOVING THE CRANKSHAFT JOURNAL BEARING 1. Remove: S crankshaft assembly S crankshaft main journal bearings 1 NOTE: Remove the main journal bearing by the plane bearing installer/remover 2 . Plane bearing installer/remover 90890-01439 NOTE: Identify the position of each crankshaft main journal bearing so that it can be reinstalled in its original place.
  • Page 270 CRANKCASE AND CRANKSHAFT Crankshaft-pin-to-big-end-bearing clearance 0.040 X 0.082 mm The following procedure applies to all of the connecting rods. CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions.
  • Page 271 CRANKCASE AND CRANKSHAFT CAUTION: S When tightening the connecting rod nuts, be sure to use an F-type torque wrench. S After tightening the connecting rod nut to the specified torque, turn the connecting rod nut another+90_. Refer to “INSTALLING THE CONNECTING RODS”.
  • Page 272 CRANKCASE AND CRANKSHAFT BEARING COLOR CODE blue black brown green 5. Measure: S crankshaft-journal-to-crankshaft-journal- bearing clearance. Out of specification ! Replace the crank- shaft journal bearings. Crankshaft-journal-to-crankshaft- journal-bearing clearance 0.04 X 0.082 mm The following procedure applies to all of the journal bearing.
  • Page 273 CRANKCASE AND CRANKSHAFT e. If journal bearing inside diameter is “45.03” and crankshaft journal outside diameter is “44.98”, then the main journal oil clearance Main journal oil clearance: Journal bearing inside diameter – Main journal outside diameter = 45.03 – 44.98 = 0.05 mm If the oil clearance is out of specification, se- lect a replacement bearings.

  • Page 274: Installing The Crankshaft Journal Bearing

    CRANKCASE AND CRANKSHAFT INSTALLING THE CRANKSHAFT JOURNAL BEARING 1. Attach: S crankshaft journal bearings NOTE: S Attach the crankshaft journal bearing to the in- staller 1 . Plane bearing installer/remover 90890-01439 2. Install: S crankshaft journal bearings 2 NOTE: S align the projection a on the bearing with the projection b on the crankcase.
  • Page 275 CRANKCASE AND CRANKSHAFT 3. Install: S Connecting rod cap 1 NOTE: Be sure that the characters on the side of the cap and connecting rod are aligned. Tighten: S nuts (connecting rod cap) 16 Nm (1.6 mSkg)+90_ NOTE: Apply molybdenum disulfide grease to the rod cap bolt threads and nut surfaces.

  • Page 276: Assembling The Crankcase

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: S sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery.

  • Page 277: Transmission

    TRANSMISSION TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Crankcase (left) Refer to “CRANKCASE AND CRANKSHAFT”. Secondary shaft Main axle Primary driven gear First pinion gear Washer Drive axle First wheel gear Circlip Bearing Oil seal For installation, reverse the removal...

  • Page 278: Removing The Transmission

    TRANSMISSION REMOVING THE TRANSMISSION 1. Remove: S crankcase (left) Refer to “CRANKCASE AND CRANK- SHAFT”. 2. Remove: S secondary shaft 1 S main axle 2 S drive axle 3 S primary driven gear 4 S first pinion gear 5 S first wheel gear 6 EAS00425 CHECKING THE TRANSMISSION 1.

  • Page 279: Assembling The Crankcase

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: S sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery.

  • Page 280: Chain Drive

    CHAIN DRIVE CHAIN DRIVE 30 Nm (3.0 mSkg) 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) 100 Nm (10.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the chain drive assembly Remove the parts in the order listed. Chain drive oil Drain.
  • Page 281 CHAIN DRIVE 30 Nm (3.0 mSkg) 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) 100 Nm (10.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Collar Oil seal Bearing Chain drive assembly Holder O ring For installation, reverse the removal procedure.
  • Page 282 CHAIN DRIVE 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the chain drive Disassemble the parts in the order listed. assembly Chain drive case (outer) Secondary drive chain Secondary drive gear Secondary driven gear Primary drive chain Primary drive gear Primary driven gear Bearing Oil seal...

  • Page 283: Checking The Swingarm

    TRANSFER CHECKING THE SWINGARM 1. Check: S swingarm 1 Damage/wear ! Replace. 2. Check: S pivot shaft 1 S collar S bearing S oil seal Damage/wear ! Replace. CHECKING THE CHAIN DRIVE ASSEMBLY 1. Check: S primary drive chain 1 S secondary drive chain 2 Damage/stiffness ! Replace the drive chain and its respective gears as a set.

  • Page 284: Installing The Chain Drive

    CHAIN DRIVE INSTALLING THE CHAIN DRIVE 1. Install: S chain drive assembly S swingarm 2. Tighten: S swingarm bolt 40 Nm (4.0 mSkg) 3. Adjust: S pivot shaft NOTE: S With your fingers, screw in the pivot shaft until it touches the collar and then tighten the pivot shaft to the tightening torque.

  • Page 287: Cool

    COOL CHAPTER 6 COOLING SYSTEM RADIATOR ........... . RADIATOR AND OIL COOLER .
  • Page 288 COOL...

  • Page 289: Cooling System

    COOL RADIATOR COOLING SYSTEM RADIATOR RADIATOR AND OIL COOLER 63 Nm (6.3 mSkg) 17 Nm (1.7 mSkg) Order Job/Part Q’ty Remarks Removing the radiator and oil cooler Remove the parts in the order listed. Footrest board Lower cover Refer to “COVER AND PANEL” in Side panel chapter 3.
  • Page 290 COOL RADIATOR 63 Nm (6.3 mSkg) 17 Nm (1.7 mSkg) Order Job/Part Q’ty Remarks Radiator Radiator fan coupler Radiator fan Oil cooler inlet hose Oil cooler outlet hose Oil filter Bolt Oil cooler O-ring For installation, reverse the removal procedure.

  • Page 291: Checking The Radiator

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

  • Page 292: Installilng The Radiator

    COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: S cooling system Leaks ! Repair or replace any faulty part. 3.
  • Page 293 COOL RADIATOR 3. Bend the lock washer tab along a flat side of the bolt. 4. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. S crankcase (with the specified amount of the recom- mended engine oil) Refer to “CHANGING THE ENGINE OIL”...

  • Page 294: Thermostat

    COOL THERMOSTAT THERMOSTAT 10 Nm (1.0 mSkg) 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Footrest board Leg shield Refer to “COVER AND PANEL” in Side panel chapter 3. Lower cover Coolant Drain.

  • Page 295: Checking The Thermostat

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 80 X 84_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 296 COOL THERMOSTAT 2. Install S thermostat cover 10 Nm (1.0 mSkg) NOTE: Befor installing the thermostat cover to the cylin- der head, lubricate the O-ring with a thin coat of litium soap base grease. 3. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT”...

  • Page 297: Water Pump

    COOL WATER PUMP WATER PUMP 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. Footrest board Lower cover Side panel (left) Leg shield Coolant Drain. Pipe 1 O-ring Water pump Pipe 2 For installation, reverse the removal procedure.
  • Page 298 COOL WATER PUMP Order Job/Part Q’ty Remarks Disassembling the water pump Disassemble the parts in the order listed. NOTE: It is not necessary to remove the impeller shaft, unless the coolant level is extremely low or coolant contains to engine oil. Water pump cover Cir clip Impeller shaft...

  • Page 299: Checking The Water Pump

    COOL WATER PUMP EAS00474 CHECKING THE WATER PUMP 1. Check: S water pump housing cover 1 S water pump housing 2 S impeller shaft 3 S water pump seal 4 S oil seal 5 Cracks/damage/wear ! Replace. 2. Check: S water pump seal 1 S oil seal Cracks/damage/wear ! Replace.
  • Page 300 NOTE: S Install the water pump seal with the water pump seal installers. S Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3 . Water pump seal installer 90890-04078 4 90890-04058 5 Yamaha bond No.1215...

  • Page 302: Carb

    CARB CHAPTER 7 CARBURETORS CARBURETORS ..........CHECKING THE CARBURETORS .
  • Page 303 CARB...

  • Page 304: Carburetors

    CARB CARBURETORS CARBURETORS CARBURETORS 10 Nm (1.0 mSkg) 85 Nm (8.5 mSkg) Order Job/Part Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Footrest board Leg shield Refer to “COVER AND PANEL” in Center cover chapter 3. Silencer Fuel hose Throttle position sensor coupler...
  • Page 305 CARB CARBURETORS Order Job/Part Q’ty Remarks Separating the carburetors Remove the parts in the order listed. Bracket Throttle stop screw Throttle stop screw bracket Spring Pipe Hose joint Float chamber air vent hose Throttle position sensor For installation, reverse the removal procedure.
  • Page 306 CARB CARBURETORS Order Job/Part Q’ty Remarks Disassembling the carburetor Disassembly the parts in the order listed. NOTE: The following procedure applies to all of the carburetors. Starter plunger Vacuum chamber cover Piston valve spring Jet needle kit Piston valve Screw plug Pilot screw Fuel drain bolt Float chamber cover...
  • Page 307 CARB CARBURETORS Order Job/Part Q’ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet For assembly, reverse the disassembly procedure.

  • Page 308: Checking The Carburetors

    CARB CARBURETORS EB600031 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check: S carburetor body S float chamber Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleumbased solvent.
  • Page 309 CARB CARBURETORS 8. Check: S piston valve 1 Damage/scratches/wear ! Replace. S piston valve diaphragm 2 Cracks/tears ! Replace. 9. Check: S vacuum chamber cover 1 S piston valve spring 2 Cracks/damage ! Replace. 10. Check: S jet needle 1 S main jet 2 S main jet holder 3 S pilot jet 4...

  • Page 310: Assembling The Carburetors

    CARB CARBURETORS 13. Check: S fuel hoses Cracks/damage/wear ! Replace. Obstruction ! Clean. Blow out the hoses with compressed air. EAS00488 ASSEMBLING THE CARBURETORS The following procedure applies to all of the car- buretors. CAUTION: S Before assembling the carburetors, wash all of the parts in a petroleum-based sol- vent.

  • Page 311: Installilng The Carburetors

    CARB CARBURETORS 3. Install: S pipe S fuel feed pipes S spring S float chamber air vent hoses S hose joint S copper washer S throttle stop screw NOTE: S Install the throttle valve lever 1 onto carbure- tors #1, and #2 between the spring 2 and syn- chronizing screw 3 .

  • Page 312: Measuring And Adjusting The Fuel Level

    CARB CARBURETORS EAS00496 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: S fuel level a Out of specification ! Adjust Fuel level (below the float chamber mating surface) 5.5 X 6.5 mm a. Stand the motorcycle on a level surface. b.

  • Page 313: Checking And Adjusting The Throttle Position Sensor

    CARB CARBURETORS EB600071 CHECKING ADJUSTING THROTTLE POSITION SENSOR NOTE: S Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: S throttle position sensor a. Disconnect the throttle position sensor cou- pler. b. Connect the pocket tester (Ω 1k) to the throttle position sensor.
  • Page 314 CARB CARBURETORS Closed-throttle resistance 0.56 X 0.84 kΩ at 20 C (yellow – black) c. Tighten the throttle position sensor screws. NOTE: Remove the pocket tester leads and connect the throttle position sensor coupler. 7-11...

  • Page 315: Checking The Fuel Pump

    CARB CARBURETORS CHECKING THE FUEL PUMP 1. Check: S fuel pump 1 a. Disconnect the fuel pump to carburetor fuel hose 2 from the carburetor. b. Place a container under the end of the fuel hose. c. Start the engine and check if fuel folws from the fuel hose 2 .

  • Page 316: Air Induction System

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

  • Page 317: Air Induction System Diagrams

    CARB AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 10 Nm (1.0 mSkg) 1 Reed valve 2 Air filter 3 Air cutoff valve 7-14...

  • Page 318: Checking The Air Induction System

    CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S reed valve 1 S reed valve stopper S reed valve seat Cracks/damage ! Replace the reed valve.

  • Page 321: Elec

    ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS ........ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS .
  • Page 322 ELEC FUEL PUMP SYSTEM ......... . 8-50 CIRCUIT DIAGRAM .

  • Page 323: Electrical

    ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS Front brake light switch Pickup coil Rear brake light switch Stator coil Thermo unit Thermo switch Fuel sender Radiator fan Starting circuit cut-off relay Speed sensor Fuel pump relay Horn Flasher relay Throttle position sensor Battery Ignition coil Fuse box...

  • Page 324: Arrangement Of The Electrical Components And Couplers

    ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS Headlight couplers Handlebar switch couplers Lean angle cut-off switch Meter Horns Speed sensor...
  • Page 325 ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS Main switch Starting circuit cut-off relay Ignition coils Turn signal relay Fuel sender Pump relay Fuel pump Rectifier/ regulator Reset coupler Radiator fan motor Throttle position sensor Thermo switch (fan motor) Thermo unit Sidestand switch Pickup coil Auto chokes...
  • Page 326 ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS Fuse box Box light Battery negative lead Battery positive lead Tail/ brake light coupler Starter relay...

  • Page 327: Instrument Functions Indicator Lights

    ELEC INSTRUMENT FUNCTIONS INSTRUMENT FUNCTIONS INDICATOR LIGHTS Engine oil change indicator light (display functions based on the oil indicator) The display functions based on the engine oil change indicator can be divided into three major types: 1. Bulbs disconnections confirmation (light ON) by main switch ON.
  • Page 328 ELEC INSTRUMENT FUNCTIONS S Detection of the second and subsequent re- set switch on operations with the indicator light off when 2 X 5 second reset switch on is cletected, the indicator will light on for 1.4 se- conds and then after it has gone off, cumula- tive distance data will be reset.
  • Page 329 ELEC INSTRUMENT FUNCTIONS V-belt indicator light Indicates V-belt change timing every 20,000 km (the V-belt indicator light reset connecter is lo- cated in the side cover at right). When change the V-belt, temporarily discon- nect the short connector of the double-pole for about 2 X 5 seconds and then reconnect the connecter to complete the resetting operation.

  • Page 330: Switches

    ELEC SWITCHES EAS00730 SWITCHES 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. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1 .

  • Page 331: 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 termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.

  • Page 332: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING BULBS 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 connect.
  • Page 333 ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: S Be sure to hold the socket firmly when re- moving the bulb.

  • Page 334: Checking The Condition Of The Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the...

  • Page 335: Ignition System

    ELEC IGNITION SYSTEM DAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM Pickup coil Main switch Battery Main fuse Igniter unit Ignition coil Spark plug Lean angle cut-off switch Engine stop switch Ignition fuse 8-13...

  • Page 336: Troubleshooting

    ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING THE BATTERY” in spark or intermittent spark). CHAPTER 3. Check: Open-circuit voltage 1. Main and ignition fuses 12.8 V or more at 20_C 2.
  • Page 337 ELEC IGNITION SYSTEM EAS00743 Spark plug cap resistance 4. Ignition spark gap 10 kΩ at 20_C S The following procedure applies to all of the S Is the spark plug cap OK? spark plugs. S Disconnect the spark plug cap from the spark plug.
  • Page 338 ELEC IGNITION SYSTEM EAS00750 Secondary coil resistance 9. Engine stop switch 12 X 18 kΩ at 20_C S Check the engine stop switch for continuity. S Is the ignition coil OK? Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? Replace the ignition coil.

  • Page 339: Electrical Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8-17...
  • Page 340 ELEC ELECTORIC STARTING SYSTEM Main switch Battery Main fuse Starter relay Starter motor Diode Starting circuit cut-off relay Sidestand switch Start switch Engine stop switch Front brake light switch Rear brake light switch Signal fuse Ignition fuse 8-18...

  • Page 341: Starting Circuit Cut Off System Operation

    ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUTOFF SYSTEM OP- ERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can operate S The brake light switch lever is pulled to the handlebar (the brake light switch switch is closed) and the sidestand is up (the sidestand switch is closed).

  • Page 342: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING THE BATTERY” in Check: CHAPTER 3. 1. Main, signal and ignition fuses Open-circuit voltage 2. Battery 12.8 V or more at 20_C 3.
  • Page 343 ELEC ELECTRIC STARTING SYSTEM EAS00759 S Does the starter relay have continuity be- 4. Starting circuit cut-off relay tween red and black? S Disconnect the starting circuit cut-off relay coupler from the wireharness. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the starting circuit cut-off relay Replace the starter coupler as shown.
  • Page 344 ELEC ELECTRIC STARTING SYSTEM EAS00752 9. Sidestand switch S Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the sidestand switch OK? Replace the sidestand switch. EAS00764 10. Start switch S Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”.

  • Page 345: Starter Motor

    ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Fuel tank Refer to “FUEL TANK” in chapter 3. Battery negative lead Starter motor lead Starter motor For installation, reverse the removal procedure.
  • Page 346 ELEC ELECTRIC STARTING SYSTEM Order Job/Part Q’ty Remarks Disassembling the starter motor Disassemble the parts in the order listed. Front bracket Bearing Oil seal Wahser kit Starter motor yoke Armature assembly Washer kit Brush holder Rear bracket For assembly reverse the disassembly procedure.

  • Page 347: Checking The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00770 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit 27 mm 3. Measure: S mica (insulation) undercut a Out of specification ! Scrape the mica (in- sulation) to the proper measurement with a...
  • Page 348 ELEC ELECTRIC STARTING SYSTEM 5. Measure: S brush length a Out of specification ! Replace the brushes as a set. Brush length wear limit 4.0 mm 6. Measure: S brush spring force Fatigue/out of specification ! Replace the brush springs as a set. Brush spring force 7.65 X 10.01 N 7.
  • Page 349 ELEC ELECTRIC STARTING SYSTEM 3. Install: S o-ring 1 S washers 2 S front bracket 3 S o-ring 4 NOTE: Align the match marks a on the yoke with the match marks b on the brackets. 4. Install: S bolts 1 7 Nm (0.7 mSkg) 8-27...

  • Page 350: Charging System

    ELEC CHARGING SYSTEM YP80400 CHARGING SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifire/ regulator Battery Main fuse 8-28...

  • Page 351: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 EAS00775 TROUBLESHOOTING 3. Charging voltage S Connect the engine tachometer to the spark The battery is not being charged. plug lead of cylinder #1. S Connect the pocket tester (20 V DC) to the Check: battery as shown. 1.
  • Page 352 ELEC CHARGING SYSTEM S Measure the stator coil resistances. Stator coil resistance 0.338 X 0.413 Ω at 20_C S Is the stator coil OK? Replace the stator coil assembly. EAS00779 5. Wiring S Check the wiring connections of the entire charging system.

  • Page 353: Lighting System

    ELEC LIGHTING SYSTEM EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM Box light switch Headlight (Hi) Box light Headlight (Lo) Main switch Auxiliary light Battery Tail / brake light Main fuse Licence plate ligtht Light switch Hi beam indicator light Pass swtich Meter light Dimmer switch Headlight fuse 8-31...

  • Page 354: Troubleshooting

    ELEC LIGHTING SYSTEM EB805010 EB802401 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Any of the following fail to light: headlight, Refer to “CHECKING AND CHARGING THE high beam indicator light, taillight, auxilia- BATTERY” in chapter 3. ry light or meter light. Open-circuit voltage Check: 12.8 V or more at 20_C...
  • Page 355 ELEC LIGHTING SYSTEM EB805401 5. Dimmer switch S Check the dimmer switch for continuity. Check the condition Properly connect or Refer to “CHECKING THE SWITCHES”. S Is the dimmer switch OK? of each of the lighting repair the lighting system’s circuits. system’s wiring.

  • Page 356: Checking The Lighting System

    ELEC LIGHTING SYSTEM EB805410 CHECKING THE LIGHTING SYSTEM Headlight 1. The headlight and the high beam indicator Tester positive probe ! light fail to come on. yellow or green Tester negative probe ! black 1. Headlight bulb and socket High beam indicator light S Check the headlight bulb and socket for con- Tester positive probe ! yellow Tester negative probe ! black...
  • Page 357 ELEC LIGHTING SYSTEM 2. Voltage 2. Voltage S Connect the pocket tester (20 V) to the meter S Connect the pocket tester (DC 20 V) to the assembly coupler (wireharness side) as tail/brake light coupler (wireharness side) as shown. shown. Tester positive probe ! blue Tester positive probe ! blue/red Tester negative probe ! black...
  • Page 358 ELEC LIGHTING SYSTEM 2. Voltage 2. Voltage S Connect the pocket tester (DC 20 V) to the S Connect the pocket tester (20 V) to the li- auxiliary light couplers (wireharness side) as cence plate light coupler (wireharness side) shown. as shown.

  • Page 359: Signal System

    ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 8-37...
  • Page 360 ELEC SIGNAL SYSTEM Main switch Battery Main fuse Igniter unit Reset coupler Speed sensor Front brake light switch Horn switch Turn signal switch Rear brake light switch Horn Flasher relay Front turn signal light (Left) Front turn signal light (Right) Rear turn signal light (Left) Rear turn signal light (Right) Tail/ brake light...

  • Page 361: Troubleshooting

    ELEC SIGNAL SYSTEM EAS00794 EAS00749 TROUBLESHOOTING 3. Main switch S Any of the following fail to come on: turn S Check the main switch for continuity. signal light, brake light or indicator light. Refer to “CHECKING THE SWITCHES”. S The horn fails to sound. S Is the main switch OK? Check: 1.
  • Page 362 ELEC SIGNAL SYSTEM Tester positive probe ! brown Tester positive probe ! pink Tester negative probe ! ground Tester negative probe ! ground S Set the main switch to “ON”. S Set the main switch to “ON”. S Measure the voltage (12 V) of the brown S Measure the voltage (12 V) of pink at the connecter at the horn terminal.
  • Page 363 ELEC SIGNAL SYSTEM Tester positive probe ! green/yellow 3. Voltage Tester negative probe ! black S Connect the pocket tester (20 V DC) to the flasher relay coupler (flasher relay side) as shown. Tester positive probe ! brown Tester negative probe ! ground S Set the main switch to “ON”.
  • Page 364 ELEC SIGNAL SYSTEM S Set the main switch to “ON”. 6. Voltage S Measure the voltage (12 V) on brown/white S Connect the pocket tester (20 VDC) to the at the flasher relay coupler (wireharness meter assembly coupler (wireharness side) side).
  • Page 365 ELEC SIGNAL SYSTEM 4. The V-belt indicator light fails to come on. 5. Fuel gauge fails to operate 1. V-belt indicator light bulb and socket 1. Fuel sender S Check the V-belt indicator light bulb and S Remove the fuel sender from the fuel tank. S Disconnect the fuel sender coupler from the socket for continuity.
  • Page 366 ELEC SIGNAL SYSTEM 6. Water temperature gauge fails to operate S Set the main switch to “ON”. S Measure the voltage (12 V) of brown 1. Thermo unit the meter assembly coupler. S Remove the thermo unit from the cylinder (wireharness side) head.
  • Page 367 ELEC SIGNAL SYSTEM The wiring circuit from the signal fuse to the meter assembly coupler (wireharness side) is faulty and must be repaired. 3. Water temperature gauge S Disconnect the thermo unit connecter. S Set the main switch to “ON”. S Connect the thermo unit connecter lead green/red and ground with a jumper lead...

  • Page 368: Cooling System

    ELEC COOLING SYSTEM EB807000 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Battery Main fuse Thermo switch Fan motor Water temperature gauge Thermo unit Signal fuse Radiator fan fuse 8-46...

  • Page 369: Troubleshooting

    ELEC COOLING SYSTEM EB807010 S Is the battery OK? TROUBLESHOOTING S The radiator fan motor fails to turn. Check: S Clean the battery 1. Main, and radiator fan motor fuses terminals. 2. Battery S Recharge or 3. Main switch replace the battery. 4.
  • Page 370 ELEC COOLING SYSTEM EB807400 Coolant temperature Test 5. Radiator fan motor (test 2) Continuity step Thermo switch S Disconnect the thermo switch coupler. 0 X 92 S Set the main switch to “ON”. S Connect the brown/red and blue termi- More than 98 nals with a jumper lead as shown.
  • Page 371 ELEC COOLING SYSTEM 3 _C 3 _C S Does the thermo switch operate properly as described above? Replace the thermo switch. EB807403 7. Wiring S Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the cooling system’s wiring properly con- nected and without defects? This circuit is OK.

  • Page 372: Circuit Diagram

    ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Battery Main fuse Fuel pump relay Fuel pump Ignitor unit Engine stop switch Ignition fuse 8-50...

  • Page 373: Fuel Pump Circuit Operation

    ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION Battery The fuel pump circuit consists of the fuel pump Main fuse relay, fuel pump, engine stop switch and ignitor Main switch unit. Ignition fuse The ignitor unit includes the control unit for the Engine stop switch fuel pump.

  • Page 374: Troubleshooting

    ELEC FUEL PUMP SYSTEM EAS00816 EAS00749 TROUBLESHOOTING 3. Main switch If the fuel pump fails to operate: S Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Check: S Is the main switch OK? 1. Main and ignition fuses 2.
  • Page 375 ELEC FUEL PUMP SYSTEM EAS00817 6. Fuel pump resistance S Disconnect the fuel pump coupler from the wireharness. S Connect the pocket tester (Ω 1) to the fuel pump coupler as shown. Tester positive probe ! black/blue Tester negative probe ! black S Measure the fuel pump resistance.

  • Page 376: Checking The Fuel Pump

    ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: S Stop the engine before refuelling. S Do not smoke and keep away from open flames, sparks, or any other source of fire.

  • Page 377: Auto Choke System

    ELEC AUTO CHOKE SYSTEM AUTO CHOKE SYSTEM CIRCUIT DIAGRAM Battery Main fuse Thermo switch Auto choke 1 Auto choke 2 Igniter Backup fuse 8-55...

  • Page 378: Troubleshooting

    ELEC AUTO CHOKE SYSTEM EAS00821 3. Thermo switch TROUBLESHOOTING S Remove the thermo switch from the thermo- The auto choke system fails to operate. stat housing. S Connect the pocket tester (Ω 1) to the ther- Check: mo switch as shown. 1.
  • Page 379 ELEC AUTO CHOKE SYSTEM WARNING S Handle the thermo switch with special care. S Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. Thermo switch 23 Nm (2.3 mSkg) S Measure the auto choke unit resistance. Three bond sealock 10 Auto choke resistance COOL DOWN...

  • Page 380: Self-Diagnosis

    ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The XP500 features a self-diagnosing system for following circuit (-s). 1. Throttle position sensor (TPS) 2. Speed sensor 3. Lean angle cut-off switch 1. ENGINE TROUBLE INDICATOR LIGHT When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the engine oil change indicator light (irrespective of whether the engine is running or not).
  • Page 381 ELEC SELF-DIAGNOSIS Display order on the engine warning light When one item being monitored Repetition Repetition Repetition 0.5 seconds Light on 0.5 seconds 3 seconds Light off When more than one item is being monitored Light on (seconds) ..0.5 seconds Light off (seconds) .
  • Page 382 ELEC SELF-DIAGNOSIS EAS00835 1. Wire harness TROUBLESHOOTING S Check the wire harness for continuity. The tachometer starts to display the self- Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? diagnosis sequence. Check: 1. Throttle position sensor 2. Speed sensor Repair or replace the 3.
  • Page 383 ELEC SELF-DIAGNOSIS EB812401 2. Speed sensor 2. Speedometer CIRCUIT DIAGRAM S Check the speedometer operation. S Is the speedometer OK? Replace the igniter Replace the speed unit. sensor. 3. Lean angle cut-off switch CIRCUIT DIAGRAM Igniter unit Lean angle cut-off suitch 1.
  • Page 384 ELEC SELF-DIAGNOSIS EB812401 2. Lean angle cut-off switch S Replace with a lean angle cut-off switch that is operating correctly, and if the diagnosis generates a lean angle cut-off switch condi- tion code again, replace the lean angle cut- off switch. S Is the leam angle cut-off switch OK? Replace the igniter Replace the lean...

  • Page 386: Trbl Shtg

    TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING PROBLEMS ........ENGINE .
  • Page 387 TRBL SHTG...

  • Page 388: Engine

    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 inspection, adjustment, and replacement of parts.

  • Page 389: Incorrect Engine Idling Speed

    INCORRECT ENGINE IDLING SPEED/ POOR TRBL MEDIUM-AND-HIGH-SPEED PERFORMANCE SHTG Switches and wiring Starting system S Faulty main switch S Faulty starter motor S Faulty engine stop switch S Faulty starter relay S Broken or shorted wiring S Faulty starting circuit cut-off relay S Faulty front, rear or both brake switches S Faulty starter clutch S Faulty start switch...

  • Page 390: Faulty Clutch

    FAULTY CLUTCH/OVERHEATING/ TRBL OVERCOOLING SHTG EAS00853 FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL POOR STARTING PERFORMANCE NOT MOVE V-belt S V-belt slips V-belt S Bent, damaged or worn V-belt S Oil or grease on the V-belt S Slipping V-belt Primary sliding sheave S Faulty operation Primary pulley cam and primary pulley slid- S Worn pin groove...

  • Page 391: Poor Braking Performance

    POOR BRAKING PERFORMANCE/FAULTY TRBL FRONT FORK LEGS/UNSTABLE HANDLING SHTG EAS00857 EAS00861 POOR BRAKING PERFORMANCE FAULTY FRONT FORK LEGS Disc brake LEAKING OIL S Worn brake pad S Bent, damaged or rusty inner tube S Worn brake disc S Cracked or damaged outer tube S Air in hydraulic brake system S Improperly installed oil seal.

  • Page 392: Faulty Signaling System

    TRBL FAULTY SIGNALING SYSTEM SHTG EAS00866 FAULTY SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT S Wrong headlight bulb S Too many electrical accessories S Hard charging S Incorrect connection S Incorrect ground S Poor contacts (main or light switch) S Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT S Wrong headlight bulb S Faulty battery...
  • Page 394 XP500 WIRING DIAGRAM (for EUR) 1 Pickup coil 38 Left handlebar switch 2 A.C.magneto 39 Pass switch 3 Rectifier / regulator 40 Dimmer switch 4 Box light switch 41 Horn switch 5 Box light 42 Turn signal switch 6 Main switch 43 Rear brake light switch 7 Battery 44 Horn...
  • Page 395 XP500 WIRING DIAGRAM (for OCE) 1 Pickup coil 38 Left handlebar switch 2 A.C.magneto 39 Pass switch 3 Rectifier / regulator 40 Dimmer switch 4 Box light switch 41 Horn switch 5 Box light 42 Turn signal switch 6 Main switch 43 Rear brake light switch 7 Battery 44 Horn...

This manual is also suitable for:

Xp500n 2001

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