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Yamaha MBK YQ100 Service Manual

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YQ100
5ME1-AE1
SERVICE
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Summary of Contents for Yamaha MBK YQ100

  • Page 1 YQ100 5ME1-AE1 SERVICE MANUAL...
  • Page 2 YQ100 SERVICE MANUAL © 2000 by MBK INDUSTRIE 1st Edition, February 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited.
  • Page 3 It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology.
  • Page 4 EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters.

  • Page 5: Info

    EAS00009 SYMBOLS SPEC INFO The following symbols are not relevant to every vehicle. INSP Symbols Q to I indicate the subject of each chapter. Q General information W Specifications CARB CHAS E Periodic checks and adjustments R Engine T Carburetor Y Chassis TRBL U Electrical system...

  • Page 6: Table Of Contents

    EAS00011 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND INSP ADJUSTMENTS ENGINE CARBURETOR CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 INFO...

  • Page 8: General Information

    INFO CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ................ 1-1 VEHICULE IDENTIFICATION NUMBER ..........1-1 ENGINE NUMBER ................... 1-1 IMPORTANT INFORMATION ..............1-3 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-3 REPLACEMENT PARTS ................. 1-3 GASKETS, OIL SEALS, AND O-RINGS ..........1-3 LOCK WASHERS/PLATES AND COTTER PINS ........

  • Page 9: Scooter Identification

    INFO GENERAL INFORMATION EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the bottom of the frame as shown. NOTE: The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your state.

  • Page 10: Important Information

    This will speed up assembly and allow for the correct installation of all parts. 5.Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS 1.Use only genuine Yamaha/MBK parts for all replacements. grease recommended by Yamaha/MBK for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 11: Lock Washers/Plates And Cotter Pins

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

  • Page 12: Checking The Connections

    INFO CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1.Disconnect: • lead • coupler • connector 2.Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 13: How To Use The Conversion Table

    INFO HOW TO USE THE CONVERSION TABLE HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULTIPLIER IMPERERIAL ** mm 0.03937...

  • Page 14: Special Tools

    INFO SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 15 INFO SPECIAL TOOLS Tool N° Tool name/usage Illustration 90890-01337 Clutch spring holder. This tool is used for compressing the spring of the secondary sheave when removing the nut. Oil seal guide 90890-01409 90890-01410 Oil seal installer This tool is used to install the left side crankcase oil seal.
  • Page 16 SPEC...

  • Page 17: Specifications

    SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 MAINTENANCE SPECIFICATIONS ............. 2-4 ENGINE ....................2-4 TIGHTENING TORQUES (ENGINE) ............2-7 CHASSIS ....................2-9 TIGHTENING TORQUES (CHASSIS) ........... 2-11 ELECTRICAL ..................2-13 GENERAL TORQUE SPECIFICATIONS ........... 2-15 LUBRICATION POINTS AND LUBRICANT TYPES ........2-16 ENGINE ....................

  • Page 18: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YQ100 Dimensions: Overall length 1,762 mm Overall width 690 mm Overall height 1,151 mm Seat height 812 mm Wheelbase 1,272 mm Minimum ground clearance 157 mm Minimum turning radius 1,800 mm Basic weight: With oil and full fuel tank 95 kg Engine:...
  • Page 19 SPEC GENERAL SPECIFICATIONS Model YQ100 Spark plug: Type BR8HS Manufacturer 0.5 ~ 0.7 mm Clutch type: Dry, centrifugal automatic Transmission: Primary reduction system Helical gear Primary reduction ratio 47 / 15 (3.133) Secondary reduction system Spur gear Secondary reduction ratio 43 / 13 (3.308) Transmission V-belt...
  • Page 20 SPEC GENERAL SPECIFICATIONS Model YQ100 Wheel travel: Front 80 mm Rear 72 mm Electrical: Ignition system Charging system Flywheel magneto Battery type/model YT4L-BS Battery capacity 12V 3AH Headlight type: Bulb Bulb wattage x quantity: Headlight 12V 35W/35W x 1 Position light 12V 5W x 1 License light 12V 5W x 1...

  • Page 21: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Standard Limit Cylinder head: Warp limit 0.02 mm * Lines indicate straight edge measurements. Cylinder: Bore size 52.002 ~ 52.012 mm Taper 0.05 mm Piston: Piston clearance 0.044 ~ 0.045 0.10 mm Piston size 51.958 ~ 51.967 mm Measuring point* 10 mm...
  • Page 22 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Crankshaft: Crank width “A” 37.90 ~ 37.95 mm Runout limit “C” 0.03 mm Connecting rod length 79.9 ~ 80.1 mm Side clearance “D” 0.2 ~ 0.5 mm Small End Free Play 0.4 ~0.8 mm Automatic centrifugal clutch: Clutch shoe thickness 4.0 mm...
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Reed valve: Valve stopper height 6.0 ~ 6.4 mm Reed Valve Clearance Less than 0.2 mm Lubrication System Autolub Pump Plunger diameter 2.5 mm Autolub pump stroke/ Manufacturer PLB-D39 / Dell'orto Minimum output at 3000rpm 4.5 cc/h Maximum output at 3000rpm 16 cc/h...

  • Page 24: Tightening Torques Engine

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Tightening Part to be tightened Part Thread Q'ty torque Remarks name size m.kg Spark plug Head cylinder Cylinder stud bolt Air shroud (3) Screw Screw Air shroud (1x3) Screw Oil pump assembly Screw Reed valve Bolt Air filter Screw...

  • Page 25: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model Standard Limit Steering system: Steering bearing type Ball bearing Size of steel balls x qty: Upper ø4.75 mm x 15 Lower ø4.75 mm x 15 Lock to lock angle Left 45° Right 45° Front suspension: Front fork travel 80 mm Optional spring...
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Front disk brake: Type Single disc Diameter and thickness 190.0 x 3.5 mm Pad thickness 4.5 mm 2 mm Master cylinder inside diameter 11 mm Caliper cylinder inside diameter 30 mm Brake fluid type DOT #3 or DOT#4 Rear drum brake: Type...

  • Page 27: Tightening Torques (Chassis)

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Tightening Part to be tightened Thread torque Remarks size m.kg Frame with engine bracket Engine bracket with engine Reinforcement tail 12.5 1.25 Rear schock absorber with frame (top) 31.5 3.15 Rear schock absorber with engine (bottom) 17.5 1.75 Handle with steering shaft...
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Tightening Part to be tightened Thread torque Remarks size m.kg Screws tapping in plastic Ø5 0.32 Screws tapping in clip Ø5 0.22 2-11...

  • Page 29: Electrical

    Ignition system: Ignition timing(B.T.D.C.) 14° at 5000 r/min Ignition timing type Constant CDI: Model/Manufacturer 4VP / YAMAHA 400 ~ 600 Ω at 20°C (WR/WL) Pickup coil resistance (color) (White/Red-Black) 640 ~ 960 Ω at 20°C (BR/GW) Source coil resistance (color) (Black/Red-Black)
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Battery : Specific gravity 1.280 Starter motor: Model / Type MORYAMA Output 0.14 kW 0.06 ~ 0.08 Ω at 20°C Armature coil resistance Brush length 3.9 mm 0.9 mm Brush spring pressure 563 ~ 844 g Commutator diameter 15.8 mm 14.8 mm...

  • Page 31: General Torque Specifications

    SPEC GENERAL TORQUE SPECIFICATIONS EAS00029 GENERAL TIGHTENING TORQUE General torque (Nut) (Bolt) specifications SPECIFICATIONS m.kg This chart specifies tightening torques for stan- 10 mm 6 mm dard fasteners with a standard ISO thread pitch. 12 mm 8 mm Tightening torque specifications for special components or assemblies are provided for each 14 mm 10 mm...

  • Page 32: Lubrication Points And Lubricant Types

    Kick pinion gear Kick shaft Starter idle gear Starter clutch pin Oil pump driven gear and drive gear ® Secondary sliding sheave cam groove BEL-RAY assembly lube Secondary fixed sheave inside diameter BEL-RAY ® assembly lube Crankcase surface Yamaha N°1215 2-15...

  • Page 33: Chassis

    SPEC LUBRICATION POINT AND GRADE OF LUBRICANT EAS00032 CHASSIS Lubrication point Lubricant type Front wheel oil seal (right/left) Rear wheel oil seal Steering bearing and bearing race (upper/lower) Throttle grip inner surface Lever pivots and cable end Oil seal lips (front wheel) Bearing (front wheel) Speedometer gear Center stand pivot...

  • Page 34: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING Taillight Ignition coil assy' Rear left flasher light Starter motor Seat lock assy' Rear right flasher light Band switch Oil pump wire Clip Wire harness Starter relay Seat lock cable Fuse Fuel and sunction pipe Battery assy' 15 –...
  • Page 35 SPEC CABLE ROUTING A Untight the seat lock plate to give to the seat lock cable more free play. Tight the seat lock cable at 1 1/2 turn. B Fix on the footrest board. C Pass the wire harness through the footrest board. D Push the wire harness to the inside.
  • Page 36 SPEC CABLE ROUTING Q Fuel sender O Resistor W C.D.I. unit P Headlight E Band switch { Engine assy' R Oil level sender } Starter wire T Wire cylinder assy' q Throttle cable Y Rectifier / Regulator w Oil pump wire U Band switch cordon e Wire harness I Main switch...
  • Page 37 SPEC CABLE ROUTING A Fix the wire harness, starter motor wire and the flywheel wire all together. B Fix the wire harness. C Pass the wire harness between the regulator and the steering head pipe. D Secure the right position of the headlight protection. E Adjust the oil pump.
  • Page 38 SPEC CABLE ROUTING Resistor assy' A Install the front brake hose on the front fork assy' clip. Horn B Pass the speedometer cable through the front Band switch mudguard bracket. Frame Front brake hose Speedometer cable Gear unit assy' Front mudguard Front fork assy' 2-21...
  • Page 39 SPEC CABLE ROUTING Right hand grip Starter wire Master cylinder Stop switch wire Speedometer assy' Front brake hose Left hand grip Wire harness Rear brake lever Speedometer cable Rear brake cable Front brake lever 2-22...
  • Page 40 SPEC CABLE ROUTING A Fix the wire harness on the frame bracket. B Group all connection in this area. C Pass the starter cable through the hole. D Tight this bolt first. E Tight this bolt first. F Stop the cap on the handlebar end. Tight at 7 Nm (0.7 m.kg). G Stop the grip on the handlebar projection.
  • Page 41 SPEC CABLE ROUTING Speedometer cable A Secure the installation of the clip. Wire harness B Group all connections in this area. Front brake hose Rear brake cable Front handlebar cover Speedometer cover Speedometer Rear handlebar cover Handlebar switch wire Starter wire Master cylinder Throttle grip 1.5 ~ 3.0 mm...
  • Page 43 CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE AND LUBRICATION ........3-1 COVERS ......................3-3 SEAT AND SIDE COVERS ..............3-3 BOX, LOWER SIDE COVERS AND MUDGUARD ........3-4 FRAME REINFORCEMENT, FUEL TANK AND REAR UNDER COVER ..............3-5 FRONT COVERS ..................3-6 HANDLEBAR COVERS ................

  • Page 44: Periodic Checks And Adjustments

    INSP PERIODIC CHECKS AND ADJUSTMENTS 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 45 • Correct if necessary. and switches • Adjust headlight beam if necessary. Items maked with an asterisk (*) require special tools, data and technical skills for servicing. Take the scooter to a Yamaha or MBK dealer when servicing these items. NOTE: •...

  • Page 46: Covers

    INSP COVERS SEAT AND SIDE COVERS 8 Nm (0,8 m.kg) 3 Nm (0,3 m.kg) 8 Nm (0,8 m.kg) 2 Nm (0,2 m.kg) Order Job/Part Q’ty Remarks Removing the seat and side covers Remove the parts in the order listed. Remove: Seat Fuel tank cap Rear seat screws and strap...

  • Page 47: Box, Lower Side Covers And Mudguard

    INSP COVERS BOX, LOWER SIDE COVERS AND MUDGUARD 8 Nm (0,8 m.kg) 3 Nm (0,3 m.kg) 2,5 Nm (0,25 m.kg) 6 Nm (0,6 m.kg) Order Job/Part Q’ty Remarks Removing the box, lower side covers Remove the parts in the order listed. and mudguard Remove: Glove compartment cover...

  • Page 48: Frame Reinforcement, Fuel Tank And Rear Under Cover

    INSP COVERS FRAME REINFORCEMENT, FUEL TANK AND REAR UNDER COVER 13 Nm (1,3 m.kg) 6,5 Nm (0,65 m.kg) 3 Nm (0,3 m.kg) 6,5 Nm (0,65 m.kg) 2 Nm (0,2 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the frame reinforcement, fuel tank and rear under cover.

  • Page 49: Front Covers

    INSP COVERS FRONT COVERS 3 Nm (0,3 m.kg) 3 Nm (0,3 m.kg) 2 Nm (0,2 m.kg) 3 Nm (0,3 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the front covers Disconnect: Headlight lead Remove: Front cover and headlight Front fender Front inner panel CAUTION:...

  • Page 50: Handlebar Covers

    INSP COVERS HANDLEBAR COVERS 3 Nm (0,3 m.kg) 3 Nm (0,3m.kg) 3 Nm (0,3 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the handlebar covers Untighten: Handlebar under cover Disconnect: Speedometer lead Wires and leads Remove: Handlebar cover (front) Handlebar cover (rear)

  • Page 51: Battery Cover And Lower Cover

    INSP COVERS BATTERY COVER AND LOWER COVER 3 Nm (0,3 m.kg) 3 Nm (0,3 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the battery cover and lower cover. Refer to “SEAT AND SIDE COVERS” section. Seat Refer to “BOX, SIDE COVERS AND MUD- Box and side covers...

  • Page 52: Inner Panel And Footrest Board

    INSP COVERS INNER PANEL AND FOOTREST BOARD 4 Nm (0,4 m.kg) 4 Nm (0,4 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the inner panel and footrest board. NOTE: Remove: To remove the main switch ring, turn it Inner panel counterclockwise.

  • Page 53: Insp

    INSP COVERS NOTE: Correct routing of cables and wires is essential for a safe operation of this scooter. Refer to the section “CABLE ROUTING” in Chapter 2. NOTE: Be careful not to pinch any wires with the covers. NOTE: When installing the covers, be careful to not damage the mounting clips. 3-10...

  • Page 54: Engine

    INSP ADJUSTING THE ENGINE IDLING SPEED EAS00054 ENGINE ADJUSTING THE ENGINE IDLING SPEED CAUTION: For safety reasons, place the scooter on the centerstand before starting the engine. 1.Start the engine and let it warm up for several minutes. 2.Attach: • engine tachometer (onto the spark plug lead) Engine tachometer 90890-03113...

  • Page 55: Adjusting The Throttle Cable Free Play

    INSP ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play (at the / flange of the throttle grip) @ 1.5 ~ 3.0 mm EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted.

  • Page 56: Checking The Spark Plug

    ADJUSTING THE THROTTLE CABLE FREE PLAY / INSP CHECKING THE SPARK PLUG Handlebar side a.Loosen the locknut. b.Turn the adjusting nut in direction left or rught until the specified throttle cable free play is obtained. Direction left Throttle cable free play is increased.
  • Page 57 INSP CHECKING THE SPARK PLUG 5.Clean: •spark plug (with a spark plug cleaner or wire brush) 6.Measure: •spark plug gap (with a wire gauge or feeler gauge) Out of specification → Adjust. Spark plug gap 0.5 ~ 0.7 mm 7.Install: •spark plug Spark plug 20 Nm (2 m•kg)

  • Page 58: Checking The Engine Oil Level

    INSP CHECKING THE ENGINE OIL LEVEL EAS00070 CHECKING THE ENGINE OIL LEVEL 1.Inspect: •oil level Oil level low → Add oil to proper level as follows. "OIL" indicator light. OIL LEVEL AND GAUGE CHECK Turn main switch to " "OIL" indicator "OIL"...

  • Page 59: Changing The Transmission Oil

    CHANGING THE TRANSMISSION OIL/ INSP AUTOLUBE PUMP AIR BLEEDING CHANGING THE TRANSMISSION OIL 1.Remove: •drain plug •oil filler plug Drain the transmission oil. 2.Check: •gasket (drain plug) •O-ring (oil filler plug) Damage → Replace. 3.Install: •gasket •drain plug Drain plug: 18 Nm (1.8 m•kg) 4.Fill: •transmision case...

  • Page 60: Cleaning The Air Filter Element

    AUTOLUBE PUMP AIR BLEEDING/ INSP CLEANING THE AIR FILTER ELEMENT 2.Bleed: •Pump housing and oil hose a.Place a rag under the pump. b.Remove the bleed screw c. Let oil run until there are no more air bubbles in it. d.When there are no more bubbles, tighten the bleed screw.

  • Page 61: Checking The Exhaust System

    CLEANING THE AIR FILTER ELEMENT/ INSP CHECKING THE EXHAUST PIPE SYSTEM b. Squeeze excess solvent out of the element and let dry. CAUTION: Do not twist the element. c. Apply foam air filter oil or motor oil on the element. d.Squeeze out the excess oil.

  • Page 62: Chassis

    ADJUSTING THE FRONT BRAKE/ INSP ADJUSTING THE REAR BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: •brake lever free play @ Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 10 ~ 20 mm WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake...

  • Page 63: Checking The Brake Fluid Level

    INSP CHECKING THE BRAKE FLUID LEVEL EAS00116 CHECKING THE BRAKE FLUID LEVEL 1.Stand the scooter on a level surface. NOTE: • Place the scooter on a suitable stand. • Make sure the scooter is upright. • In order to ensure a correct reading of the brake fluid level, make sure the top of the reservoir is horizontal.

  • Page 64: Checking The Front Brake Pads

    CHECKING THE FRONT BRAKE PADS/ CHECKING THE BRAKE SHOES/ INSP BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00123 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1.Operate the brake. 2.Check: • brake pad Out of specification → Replace. NOTE: Replace the brake pad and spring as a set when replacing the brake pads.

  • Page 65: Checking And Adjusting The Steering Head

    BLEEDING THE HYDRAULIC BRAKE SYSTEM / INSP CHECKING AND ADJUSTING THE STEERING HEAD i. Repeat steps (e) to (h) until all air bubbles have been removed from the system. j. Add brake fluid to proper level. WARNING Check the operation of the brake after bleeding the brake system.
  • Page 66 INSP CHECKING AND ADJUSTING THE STEERING HEAD Steering nut wrench 90890-01403 Lower ring nut (initial tightening torque) 38 Nm (3.8 m•kg) c. Loosen the lower ring nut of 1/4 turn and then tighten it to specification with a steering nut wrench . CAUTION: Do not overtighten the lower ring nut.

  • Page 67: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD / INSP CHECKING THE FRONT FORK 5.Install: •front cover Refer to "FRONT COVER" •Handlebar Refer to "HANDLEBAR" in chapter 6. Handlebar holder bolt 60 Nm (6.0 m•kg) EAS00151 CHECKING THE FRONT FORK 1.Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over.

  • Page 68: Checking The Tires

    INSP CHECKING THE TIRES EAS00165 CHECKING THE TIRES The following procedure applies to both of the tires. 1.Measure: •tire pressure Out of specification → Regulate. WARNING The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and...
  • Page 69 INSP CHECKING THE TIRES Minimum tire tread depth 0.8 mm Tire tread depth Side wall Wear indicator WARNING 3103 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using tube tires, be sure to install the correct tube.

  • Page 70: Checking The Wheels

    CHECKING THE WHEELS/ INSP CHECKING AND LUBRICATING THE CABLES EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1.Check: • wheel Damage/out-of-round → Replace. WARNING Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.

  • Page 71: Lubricating The Centerstand

    LUBRICATING THE CENTERSTAND/ INSP LUBRICATING THE REAR SUSPENSION EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to- metal moving parts of the centerstand. Recommended lubricant Engine oil EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum disulfide grease 3-28...

  • Page 72: Electrical System

    INSP CHECKING THE BATTERY EAS00177 ELECTRICAL SYSTEM CHECKING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 73 INSP CHECKING THE BATTERY 4.Check: •electrolyte level The electrolyte level should be between the UPPER minimum level mark and the maximum LOWER level mark Below the minimum level mark → Add distilled water to the proper level. CAUTION: Add only distilled water. Tap water contains minerals which are harmful to the battery.
  • Page 74 INSP CHECKING THE BATTERY • Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.

  • Page 75: Checking The Fuse

    CHECKING THE BATTERY/ INSP CHECKING THE FUSE 10.Lubricate: •battery terminals Recommended lubricant Dielectric grease 11.Install: •battery cover Refer to "BATTERY COVER AND LOWER COVER". EAS00181 CHECKING THE FUSE The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to "OFF"...

  • Page 76: Replacing The Headlight Bulb

    CHECKING THE FUSE/ INSP REPLACING THE HEADLIGHT BULB 3.Replace: • blown fuse a.Set the main switch to “OFF”. b.Install a new fuse of the correct amperage. c. Set on the switches to verify if the electrical circuit is operational. d.If the fuse immediately blows again, check the electrical circuit.

  • Page 77: Adjusting The Headlight Beam

    REPLACING THE HEADLIGHT BULB/ INSP ADJUSTING THE HEADLIGHT BEAM 4.Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 79 CHAPTER 4. OVERHAULING THE ENGINE ENGINE ......................4-1 LEADS AND HOSES ................4-1 EXHAUST PIPE ..................4-3 ENGINE ....................4-4 INSTALLING THE ENGINE ..............4-5 CYLINDER HEAD, CYLINDER AND PISTON ..........4-6 PISTON PIN AND PISTON REMOVAL ........... 4-7 CYLINDER HEAD INSPECTION ............. 4-7 CYLINDER AND PISTON INSPECTION ..........
  • Page 80 CRANKCASE AND REED VALVE ............. 4-37 CRANKCASE (RIGHT) REMOVAL ............4-39 CRANKCASE (RIGHT) INSTALLATION ..........4-40 CRANKSHAFT .................... 4-42 CRANKSHAFT REMOVAL ..............4-43 CRANKSHAFT INSPECTION ..............4-43 CRANKSHAFT INSTALLATION ............4-44...

  • Page 81: Chapter 4. Overhauling The Engine

    OVERHAULING THE ENGINE EAS00188 OVERHAULING THE ENGINE ENGINE LEADS AND HOSES Order Job/Part Q’ty Remarks Removing the leads and hoses Remove the parts in the order listed. Seat Refer to "SEAT AND SIDE COVERS" Upper side covers in chapter 3. Glove compartment cover Oil cover Refer to "BOX, SIDE COVERS AND...
  • Page 82 OVERHAULING THE ENGINE Order Job/Part Q’ty Remarks Starter motor lead coupler Untighten : Rear wheel nut Note: Loosen the rear wheel nut. Remove : Rear brake adjuster Rear brake cable For installation, reverse the removal procedure.

  • Page 83: Exhaust Pipe

    OVERHAULING THE ENGINE EXHAUST PIPE 29 Nm (2,9 m.kg) 8.5 Nm (0,85 m.kg) Order Job/Part Q’ty Remarks Removing the exhaust pipe Remove the parts in the order listed. Lower cover Refer to "BATTERY COVER AND LOWER COVER" in chapter 3. Untighten: Bolt (from cylinder) Remove:...

  • Page 84: Engine

    OVERHAULING THE ENGINE EAS00192 ENGINE Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. Leads and hoses NOTE: Exhaust pipe Place a suitable stand under the frame and engine. Remove: • Rear shock absorber bolt (lower) •...

  • Page 85: Installing The Engine

    EAS00192 INSTALLING THE ENGINE 17.5 Nm (1,75 m.kg) 50 Nm (5,0 m.kg) Order Job/Part Q’ty Remarks Install: Engine mounting bolt Rear shock absorber bolt (lower) NOTE: Do not fully tighten the bolts. Tighten the bolts in the following order. Rear shock absorber bolt 17.5 Nm (1.75 m•kg) Engine mounting bolt 50 Nm (5.0 m•kg)

  • Page 86: Cylinder Head, Cylinder And Piston

    CYLINDER HEAD EAS00222 CYLINDER HEAD, CYLINDER AND PISTON 14 Nm (1,4 m.kg) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. and piston Lower cover Refer to "BATTERY COVER AND LOWER COVER" in chapter 3. Exhaust pipe Refer to "EXHAUST PIPE".

  • Page 87: Piston Pin And Piston Removal

    CYLINDER HEAD, CYLINDER, PISTON PISTON PIN AND PISTON REMOVAL 1. Remove: • Piston pin clip NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase. 2.

  • Page 88: Cylinder And Piston Inspection

    CYLINDER HEAD, CYLINDER, PISTON CYLINDER AND PISTON INSPECTION 1. Eliminate : • Carbon deposits Use a rounded scraper 2. Inspect : • Cylinder wall Wear/Scratches→Rebore or replace. 3. Eliminate : • Carbon deposits From the piston crown and ring grooves 4.
  • Page 89 CYLINDER HEAD, CYLINDER, PISTON Standard Wear limit Cylinder bore 52.002~52.012mm 52.10 mm “C” – 0.05 mm Taper “T” Out of round 0.03 mm – “R” C = Maximum D T=( Maximum D1 or D2 ) - ( Maximum D5 or D6 ) R=( Maximum D1 D3 or D5 ) - ( Maximum D2 D4 or D6 )

  • Page 90: Piston Rings Inspection

    CYLINDER HEAD, CYLINDER, PISTON PISTON RINGS INSPECTION 1. Measure: • Side clearance Out of specification→Replace piston and /or rings. Use a feeler gauge Standard Limit Top ring 0.03 ~ 0.05 mm 0.10 mm 2nd ring 0.03 ~ 0.05 mm 0.10 mm 2.

  • Page 91: Piston Pin And Piston Installation

    CYLINDER HEAD, CYLINDER, PISTON 2. Measure : • Outside diameter @ (piston pin) Out of specification→Replace. Outside diameter (piston pin) : 13.996~14.000 mm 3. Measure: • Piston pin-to-piston clearance Out of specification→Replace piston. Piston pin-to-piston clearance = Bore size (piston pin) Outside diameter (piston pin) Piston pin-to-piston clearance : 0.004~0.019 mm...

  • Page 92: Cylinder And Cylinder Head

    CYLINDER HEAD, CYLINDER, PISTON 3. Install : • Small end bearing • Piston • Piston pin • Piston pin clip NOTE: • The arrow a on the piston to the exhaust side. • Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip material into the crankcase.
  • Page 93 CYLINDER HEAD, CYLINDER, PISTON 4. Install : • Cylinder head gasket (new gasket) 5. Install : • Cylinder head 14Nm(1.4m.kg) • Spark plug 20Nm(2.0m.kg) • Air shroud NOTE: Tighten the cylinder head holding nuts in stage, using a crisscross pattern. 4-13...

  • Page 94: V-Belt, Clutch And Secondary/Primary Sheave

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE CRANKCASE COVER (LEFT) 12Nm(1.2kg.m) 9 Nm(0.9kg.m) 13 Nm(1.3kg.m) Order Job name/Part name Q’ty Remarks Crankcase cover (left) removal Remove the parts in order. Air cleaner assembly mounting screw Screw(Bind) Kick starter Crankcase (left) Gasket Reverse the removal procedure for installation.

  • Page 95: Kick Starter

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE KICK STARTER Job name/Part name Remarks Order Q’ty Kick starter removal Remove the parts in order. Kickstarter pinion gear Kickstarter pinion gear clip Circlip/Plain washer Kick shaft Return spring Collar Reverse the removal procedure for installation. 4-15...

  • Page 96: Kick Starter Installation

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE KICK STARTER INSTALLATION 1. Install : • Return spring • Kick shaft • Collar • Plain washer • Circlip ****************************************************** Installation steps : a. Install return spring and kick shaft shown. b. Install collar, plain washer and clip c.

  • Page 97: V-Belt, Clutch And Secondary/Primary Sheave

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 40Nm(4.0kg.m) 45Nm(4.5kg.m) Order Job name/Part name Q’ty Remarks V-belt, clutch and secondary/primary Remove the parts in order. sheave removal Lower rear cover Refer to “BATTERY COVER AND Air shroud 3 LOWER COVER”...

  • Page 98: Secondary Sheave

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE SECONDARY SHEAVE SECONDARY SHEAVE 50Nm(5.0kg.m) Job name/Part name Remarks Order Q’ty Secondary sheave disassembly Disassemble the parts in order. Clutch carrier Clutch shoe spring Refer to “SECONDARY SHEAVE Compression spring INSTALLATION” section. Spring seat Guide pin Secondary sliding sheave O-ring Refer to “SECONDARY SHEAVE...

  • Page 99: Primary Sheave Removal

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE PRIMARY SHEAVE REMOVAL 1. Remove : • Fan 2. Remove : • Nut (primary sheave) NOTE: When loosening the nut (primary sheave), hold the C.D.I. magneto using flywheel holding tool Flywheel holding tool : 90890-01235 3.

  • Page 100: Clutch Inspection

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 3. Loosen : • Nut(Clutch carrier) NOTE: Install the secondary sheave to primary drive shaft as shown, and hold the secondary sheave by Universal Roter Holder to loosen the nut Flywheel holding tool : 90890-01235 CAUTION: Do not remove the clutch securing nut yet.

  • Page 101: V-Belt Inspection

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 2. Measure : • Clutch shoe thickness a Out of specification→Replace. Clutch shoe thickness : 4 mm < Wear limit> : 2.5 mm V-BELT INSPECTION 1. Inspect : • V-belt Crack→Replace. NOTE: Replace the V-belt smeared with a lot of oil or grease.

  • Page 102: Primary Sheave Inspection

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE PRIMARY SHEAVE INSPECTION 1. Inspect : • Primary sliding sheave • Primary fixed sheave Wear/Cracks/Scratch/Damage →Replace. 2. Check : • Free movement Insert the collar into the primary sliding sheave , and check for free movement. Stick or excessive play →...

  • Page 103: Secondary Sheave Inspection

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE SECONDARY SHEAVE INSPECTION 1. Inspect : • Secondary fixed sheave • Secondary sliding sheave Scratch/Crack/Damage→Replace as a set. • Oil seal Damage→Replace 2. Inspect : • Torque cam grove • Guide pin Wear/Damage→Replace as a set. •...

  • Page 104: Secondary Sheave Installation

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE SECONDARY SHEAVE INSTALLATION When assembling the secondary sheave, re- verse the disassembly procedure. Note the following points. 1. Apply : • BEL-RAY assembly lube ® (to the inside of the sliding/fixed sheave) 2. Install : •...

  • Page 105: Primary Sheave Installation

    V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 8. Install : • Secondary sheave assembly • Clutch housing • V-belt NOTE: The V-belt must be installed with the arrow frontward. 9. Tighten : • Nut (secondary sheave) 40 Nm(4.0 m.kg) Use sheave holder Sheave holder : 90890-01701 PRIMARY SHEAVE INSTALLATION...
  • Page 106 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 6. Install : • Shim • Primary fixed sheave • Crow washer • One-way clutch • Conical spring washer • Nut 7. Tighten : • Nut (primary sheave) 45 Nm(4.5 kg.m) NOTE: When tightening the nut (primary sheave), hold the C.D.I.

  • Page 107: Starter Clutch And Starter Motor

    STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR 13Nm(1.3kg.m) 8Nm(0.8kg.m) Job name/Part name Remarks Order Q’ty Starter clutch and starter motor Remove the parts in order. removal Left/Right lower side cover Left/right upper side cover Refer to “COVERS”...
  • Page 108 STARTER CLUTCH AND STARTER MOTOR 13Nm(1.3kg.m) 8Nm(0.8kg.m) Order Job name/Part name Q’ty Remarks Starter clutch Plain washer Starter wheel gear Collar Starter motor Starter motor connector Reverse the removal procedure for instalation 4-28...

  • Page 109: Starter Clutch And Gears

    INSPECTION AND REPAIR STARTER CLUTCH AND GEARS 1. Inspect : • Starter clutch Push the dowel pin to arrow direction. Unsmooth operation→Replace starter clutch assembly. 2. Inspect : • Starter wheel gear teeth • Idle gear teeth Burrs/Chips/Roughness/Wear→Replace. 3. Inspect : •...

  • Page 110: C.d.i. Magneto

    C.D.I. MAGNETO C.D.I. MAGNETO C.D.I. MAGNETO 8Nm(0.8kg.m) 43Nm(4.3kg.m) 7Nm(0.7kg.m) Job name/Part name Remarks Order Q’ty C.D.I. magneto removal Remove the parts in order. Lower cover Refer to “BATTERY COVER AND LOWER COVER” section in chapter 3. Oil cover Air shroud 3 Fan /O-ring Magneto rotor Bind...

  • Page 111: C.d.i. Magneto Removal

    ENGINE DISASSEMBLY C.D.I. MAGNETO REMOVAL 1. Remove : • Nut (rotor) • Plain washer NOTE: Hold the rotor to loosen the nut by the flywheel holding tool Flywheel holding tool : 90890-01235 2. Remove : • Rotor • Woodruff key Use the flywheel magneto puller Flywheel magneto puller : 90890-01189...

  • Page 112: Autolube Pump

    AUTOLUBE PUMP AUTOLUBE PUMP AUTOLUBE PUMP 4Nm(0.4kg.m) Job name/Part name Remarks Q’ty Order Autolube pump removal Remove the parts in order. C.D.I. magneto Refer to “C.D.I. MAGNETO” section. Air shroud 2. Circlip Pump drive gear Oil hose Oil delivery hose Autolube pump cable Refer to “AUTOLUBE PUMP INSTALLA- Autolube pump ass’y...

  • Page 113: Autolube Pump Installation

    AUTOLUBE PUMP AUTOLUBE PUMP INSTALLATION CAUTION: After installing autolube pump, it must be bleeded. 1. Install : • Pin • Pump drive gear • Circlip 2. Apply : • Lithium soap base grease (to O-ring) 3. Install : • Autolube pump 4 Nm(0.4m.kg) 4.

  • Page 114: Transmission

    TRANSMISSION TRANSMISSION TRANSMISSION 18Nm(1.8kg.m) 12Nm(1.2kg.m) Job name/Part name Remarks Order Q’ty Transmission removal Remove the parts in order. Rear wheel Refer to “REAR WHEEL AND REAR BRAKE ” section in chapter 6. Secondary sheave Refer to “V-BELT, CLUTCH, SECONDARY/ PRIMARY SHEAVE” section Drain the transmission oil.
  • Page 115 TRANSMISSION TRANSMISSION TRANSMISSION 18Nm(1.8kg.m) 12Nm(1.2kg.m) Order Job name/Part name Q’ty Remarks Circlip Main axle Drive axle Reverse the removal procedure for installation. 4-35...

  • Page 116: Checking The Transmission

    TRANSMISSION EAS00423 CHECKING THE TRANSMISSION 1.Measure: •main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle deflection limit 0.08 mm 319005(a) 2.Measure: •drive axle runout (with a centering device and dial gauge) Out of specification →...

  • Page 117: Crankcase And Reed Valve

    CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE 9Nm(0.9kg.m) 12Nm(1.2kg.m) Job name/Part name Remarks Order Q’ty Crankcase and Reed valve removal Remove the parts in order. Engine removal Refer to “ENGINE REMOVAL” section. Cylinder head, cylinder, piston Refer to “CYLINDER HEAD CYLINDER AND PISTON”...
  • Page 118 CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE CRANKCASE AND REED VALVE 9Nm(0.9kg.m) 12Nm(1.2kg.m) Order Job name/Part name Q’ty Remarks Intake manifold Reed valve Valve seat gasket Stopper Crankcase 2 Refer to “CRANCKCASE REMOVEL” and “CRANCKCASE INSTALLATION” Dowel pin Engine mount spacer Circlip Bearing Oil seal...

  • Page 119: Crankcase (Right) Removal

    CRANKCASE AND REED VALVE CRANKCASE (RIGHT) REMOVAL 1. Remove : • Oil seal stopper • Screws (crankcase) 9Nm(0.9 kg.m) NOTE: Loosen each screw 1/4 turn, and remove them after all are loosened. 2. Attach : • Crankcase separating tool Crankcase separating tool : 90890-01135 NOTE: Fully tighten the tool holding bolts, but make...

  • Page 120: Crankcase (Right) Installation

    CRANKCASE AND REED VALVE CRANKCASE (RIGHT) INSTALLATION 1. Install : • Dowel pins • Engine mount spacer 2. Apply : • Yamaha Bond No.1215 To the mating surfaces of both case helves. Yamaha bond No.1215: 90890-85505 3. Attach : • Crankshaft installing tools...
  • Page 121 CRANKCASE AND REED VALVE 8. Install : • Gasket • Reed valve 11 Nm(1.1 kg.m) 4-41...

  • Page 122: Crankshaft

    CRANKSHAFT CRANKSHAFT CRANKSHAFT Job name/Part name Remarks Order Q’ty Crankshaft removal Remove the parts in order. Right crankcase removal Refer to “CRANKCASE AND REED VALVE” section. Crankshaft Bearing Oil seal Crankcase cover (left) Reverse the removal procedure for installation. 4-42...

  • Page 123: Crankshaft Removal

    CRANKSHAFT CRANKSHAFT REMOVAL 1. Attach : • Crankcase separating tool Crankcase separating tool : 90890-01135 2. Remove : • Crankshaft CRANKSHAFT INSPECTION 1. Measure : • Runout limit “ C” • Connecting rod big end side clearance “D” • Small end free play limit “F” Out of specification→Replace.

  • Page 124: Crankshaft Installation

    CRANKSHAFT CRANKSHAFT INSTALLATION 1. Attach : • Crankshaft Installing Tool Crankshaft installing tool: 90890-01274 90890-01275 90890-01277 90890-01288 2. Install : • Crankshaft (to the crankcase 3. Install : • Oil seal • Apply lithium soap base grease onto the oil seal lip. Use the guide and seal driver to install...
  • Page 125 CARB...

  • Page 126: Carburetor

    CARB CHAPTER 5. CARBURETOR CARBURETOR ....................5-1 CARBURETOR ..................5-1 TEIKEI CARBURETOR DISASSEMBLY ..........5-2 CHECKING THE CARBURETOR ............5-4 ASSEMBLING THE CARBURETOR ............5-5 INSTALLING THE CARBURETOR ............5-6 FUEL COCK ....................5-7 INSPECTING THE FUEL COCK ............. 5-7 CLEANING THE FUEL FILTER ...............

  • Page 127: Carburetor

    CARB CARBURETOR EAS00480 CARBURETOR CARBURETOR 9Nm(0.9kg.m) Remarks Order Job/Part Q'ty Remove the parts in the order listed. Removing the carburetor Air filter box Fuel hose Vacuum hose Oil delivery hose Choke cable Air filter joint Unhook Throttle cable Carburetor For installation, reverse the removal procedure.

  • Page 128: Teikei Carburetor Disassembly

    CARB CARBURETOR EAS000483 TEIKEI CARBURETOR DISASSEMBLY Remarks Order Job/Part Q'ty Carburetor disassembly Remove the parts in the order listed. Carburetor top Gasket Throttle valve spring Needle set Throttle valve Starter retaining plate Starter top cover Starter plunger O'ring Starter plunger spring Starter plunger Air screw set Throttle stop screw...
  • Page 129 CARB CARBURETOR EAS000483 TEIKEI CARBURETOR DISASSEMBLY Remarks Order Job name/Part name Q'ty Float chamber Float chamber gasket Float pin Float / Needle valve Main jet Main nozzle Pilot jet Carburetor body For installation, reverse the removal procedure.

  • Page 130: Checking The Carburetor

    CARB CARBURETOR EAS00485 CHECKING THE CARBURETOR 1.Check : • carburetor body • float chamber • jet housing • fuel passages Durt/Obstruction → Clean Cracks/damage → Replace. 322006 a.Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution.

  • Page 131: Assembling The Carburetor

    CARB CARBURETOR 6.Check : •Throttle valve free movement Unsmooth/Stickiness → Replace. Insert the throttle valve into the carburetor body and check for smooth movement. 322015 7.Check : •throttle stop screw •air screw •needle •starter plunger Damage/Wear → Replace. 322016 NOTE: The float height is factory-adjusted.

  • Page 132: Installing The Carburetor

    CARB CARBURETOR 2.Install : • throttle valve • starter plunger NOTE: Align the groove of the throttle valve with the projection of the carburetor. 322019 3.Install : • Carburetor NOTE: Align projection with projection 322020 EAS00492 INSTALLING THE CARBURETOR 1. Adjust: •...

  • Page 133: Fuel Cock

    CARB FUEL COCK FUEL COCK INSPECTING THE FUEL COCK 1.Stop the engine. 2.Remove: • Side covers Refer to "COVERS" in Chapter 3. 3.Inspect: •Fuel cock ******************************************************* Fuel cock inspection steps: • Disconnect the fuel hose • Place the receptacle under the fuel hose end. •...

  • Page 134: Reed Valve

    CARB REED VALVE REED VALVE 11 Nm (1.1 m.kg) Remarks Order Job/Part Q'ty Removing the reed valve Remove the parts in the order listed. Carburetor Refer to "CARBURETOR" section. Carburetor joint Reed valve assembly For installation, reverse the removal procedure.

  • Page 135: Checking The Reed Valve

    CARB REED VALVE YP600051 CHECKING THE REED VALVE 1.Inspect : • Caburetor joint Damage/Cracks → Replace. • Reed valve Fatigue/Cracks → Replace. ***************************************************** Inspection steps : • Visually inspect the reed valve. NOTE: Correct reed valve should fit flush or nearly flush against valve seat.
  • Page 136 CHAS...
  • Page 137 CHAS CHAPTER 6. CHASSIS FRONT WHEEL AND BRAKE DISC ............. 6-1 FRONT WHEEL AND BARKE DISC ............6-1 FRONT WHEEL ..................6-2 REMOVING THE FRONT WHEEL ............6-3 DISASSEMBLING THE FRONT WHEEL ..........6-3 CHECKING THE FRONT WHEEL ............6-4 CHECKING THE BRAKE DISC ...............
  • Page 138 CHAS FRONT FORK ....................6-30 REMOVING THE FRONT FORK LEGS ..........6-32 DISASSEMBLING THE FRONT FORK LEGS ........6-32 CHECKING THE FRONT FORK LEGS ..........6-33 ASSEMBLING THE FRONT FORK LEGS ..........6-34 HANDLEBAR ....................6-37 REMOVING THE HANDLEBAR ............6-39 CHECKING THE HANDLEBAR .............

  • Page 139: Chapter 6. Chassis

    CHAS FRONT WHEEL AND BRAKE DISC EAS00513 CHASSIS FRONT WHEEL AND BRAKE DISC FRONT WHEEL AND BRAKE DISC 23 Nm (2,3 m.kg) 35 Nm (3,5 m.kg) Order Job/Part Q'ty Remarks Removing the front wheel and brake Remove the parts in the order listed. disc WARNING Securely support the scooter so there is...

  • Page 140: Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00518 FRONT WHEEL Order Job/Part Q'ty Remarks Disassembling the front wheel Remove the parts in the order listed. Remove: Oil seal Refer to "DISASSEMBLING/ASSEM- Bearing BLING THE FRONT WHEEL" section. Collar For assembly, reverse the disassembly procedure.

  • Page 141: Removing The Front Wheel

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

  • Page 142: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC a.Clean the outside of the front wheel hub. b.Remove the oil seal with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface. c. Remove the wheel bearings with a general bearing puller 2.Remove:...
  • Page 143 CHAS FRONT WHEEL AND BRAKE DISC 4.Check: • Wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. • Oil seals Damage/wear → Replace. 5.Replace: • Wheel bearings • Oil seals a.Clean the outside of the front wheel hub. b.Remove the oil seals with a flat-head screwdriver.

  • Page 144: Checking The Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC EAS00528 CHECKING THE BRAKE DISC 1.Check: • Brake disc Damage/galling → Replace. 2.Measure: • Brake disc deflection Out of specification → Inspect wheel runout. If wheel runout is in good condition, correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.2 mm...

  • Page 145: Checking The Speedometer Gear Unit

    CHAS FRONT WHEEL AND BRAKE DISC Brake disc bolt 23 Nm (2.3 m • kg) d.Measure the brake disc deflection. e.If out of specification, repeat the adjustment steps until the brake disc deflection is within 23 Nm (2,3 m.kg) specification. f.

  • Page 146: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00542* INSTALLING THE FRONT WHEEL 1.Lubricate: • Wheel axle • Wheel bearings • Oil seal lips • Speedometer drive gear • Speedometer driven gear Recommended lubricant Lithium soap base grease 2.Install: • Brake disc Brake disc bolt 23 Nm (2.3 m •...

  • Page 147: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISC 5.Tighten: • Wheel axle • Brake caliper bolts Wheel axle 35 Nm (3.5 m • kg) Brake caliper bolt 23 Nm (2.3 m • kg) WARNING Make sure the brake hose is routed properly. CAUTION: Before tightening the axle nut, stroke the front fork several times to check for proper...
  • Page 148 CHAS FRONT WHEEL AND BRAKE DISC 3.Adjust: • Front wheel static balance a.Install a balancing weight onto the rim exactly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b.Turn the front wheel 90° so that the heavy spot is positioned as shown.

  • Page 149: Rear Wheel And Brake

    CHAS REAR WHEEL AND BRAKE EAS00555 REAR WHEEL AND BRAKE 9.75 Nm (0,98 m.kg) 125 Nm (12,5 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the rear wheel and the rear brake Refer to "BATTERY COVER AND LOWER Lower cover COVER"...
  • Page 150 CHAS REAR WHEEL AND BRAKE 9.75 Nm (0,98 m.kg) 125 Nm (12,5 m.kg) Q'ty Remarks Order Job/Part Camshaft lever Refer to "INSTALLING THE REAR Wear indicator BRAKE" section. Brake camshaft For installation, reverse the removal pro- cedure. 6-12...

  • Page 151: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE EAS00565 CHECKING THE REAR WHEEL 1.Check: • Wheel axle • Rear wheel Refer to "FRONT WHEEL". 2.Check: • Tire • Rear wheel Damage/wear → Replace. Refer to "CHECKING THE TIRES" and "CHECKING THE WHEELS" in chapter 3. 3.Measure: •...

  • Page 152: Installing The Rear Brake

    CHAS REAR WHEEL AND BRAKE 3.Measure: • Brake drum inside diameter a Out of specification → Replace the wheel. Brake drum inside diameter limit (maximum) 130.5 mm 4.Check: 346008 • Brake drum inner surface Oil deposits → Clean. Remove the oil with a rag soaked in lacquer thin- ner or solvent.

  • Page 153: Installing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE 3.Install: • Wear indicator • Camshaft lever a.Align the projection on the wear indicator with the camshaft notch and install. b.Align the punch marks c. Check the proper position of the brake shoe. 346011(a) 4.Install: •...

  • Page 154: Front Brake

    CHAS FRONT BRAKE EAS00576 FRONT BRAKE FRONT BRAKE PADS 6 Nm (0.6 m.kg) 31 Nm (3.1 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the front brake pads Remove: Plastic cap Refer to "BRAKE PAD REPLACE- Retaining clip MENT"...
  • Page 155 CHAS FRONT BRAKE EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.

  • Page 156: Brake Pads Replacement

    CHAS FRONT BRAKE BRAKE PADS REPLACEMENT NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1.Remove: • Brake pads NOTE: • Do not depress the brake lever when the wheel is off the scooter otherwise the brake pads will be forced shut.

  • Page 157: Front Brake Master Cylinder

    CHAS FRONT BRAKE EAS00584 FRONT BRAKE MASTER CYLINDER 8.5 Nm (0.85 m.kg) 6 Nm (0.6 m.kg) 23 Nm (2.3 m.kg) Q'ty Remarks Order Job/Part Remove the parts in the order listed. Removing the front brake master cylinder Drain the brake fluid Refer to “HANDLEBAR COVERS”...
  • Page 158 CHAS FRONT BRAKE EAS00585 1.2 Nm (0.12 m.kg) Q'ty Remarks Order Job/Part Disassembling the master cylinder Remove the parts in the order listed. NOTE: Drain completely before removing the master cylinder. Remove: Master cylinder cap Diaphragm Remove: Dust boot Actuator Actuator spring Master cylinder piston Piston return spring...

  • Page 159: Disassembling The Front Brake Master Cylinder

    CHAS FRONT BRAKE EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: • Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. • To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

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

    CHAS FRONT BRAKE EAS00596 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. Recommended brake fluid DOT #3 or DOT #4 1.Install: •...
  • Page 161 CHAS FRONT BRAKE 4.Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT #3 or DOT #4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 162: Front Brake Caliper

    CHAS FRONT BRAKE EAS00612 FRONT BRAKE CALIPER 23 Nm (2.3 m.kg) 31 Nm (3.1 m.kg) Q'ty Remarks Order Job name/Part name Remove the parts in the order listed. Removing the front brake caliper Drain the brake fluid Remove: Union bolt Copper washer Brake hose Copper washer...
  • Page 163 CHAS FRONT BRAKE EAS00614 6 Nm (0.6 m.kg) 23 Nm (2.3 m.kg) 23 Nm (2.3 m.kg) Q'ty Remarks Order Job/Part Caliper disassembly Remove the parts in the order listed. Brake pads Refer to "REMOVING THE FRONT BRAKE PADS". Remove: Caliper O-ring Refer to "DISASSEMBLING THE FRONT Caliper piston...

  • Page 164: Disassembling The Front Brake Caliper

    CHAS FRONT BRAKE EAS00620 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1.Remove: • Union bolt • Copper washers • Brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 165: Checking The Front Brake Caliper

    CHAS FRONT BRAKE EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommanded brake component replacement schedule: Brake pads If necessary Brake hose Every two years Brake fluid Every two years or when- ever the brake is disas- sembled 1.Check: • brake caliper pistons Rust/scratches/wear →...

  • Page 166: Installing The Front Brake Caliper

    CHAS FRONT BRAKE EAS00635 INSTALLING THE FRONT BRAKE CALIPER WARNING Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Recommended brake fluid DOT #3 or DOT #4 1.Install: • brake caliper (temporarily) •...
  • Page 167 CHAS FRONT BRAKE 4.Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT #3 or DOT #4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 168: Front Fork

    CHAS FRONT FORK EAS00646 FRONT FORK FRONT FORK 3 Nm (0,3 m.kg) 30 Nm (3,0 m.kg) 31 Nm (3,1 m.kg) Q'ty Remarks Order Job/Part Removing the front fork Remove the parts in the order listed. Front wheel Refer to "FRONT WHEEL AND BRAKE DISC".
  • Page 169 CHAS FRONT FORK EAS00648 23 Nm (2,3 m.kg) Q'ty Remarks Order Job/Part Disassembling the front fork Remove the parts in the order listed. Remove: Spring seat clip Spring seat O-ring Fork spring Remove: Refer to "ASSEMBLING THE FRONT Dust seal FORK LEGS".

  • Page 170: Removing The Front Fork Legs

    CHAS FRONT FORK 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 171: Checking The Front Fork Legs

    CHAS FRONT FORK 4.Remove: • damper rod assembly bolt NOTE: While holding the damper rod assembly with the damper rod holder and T-handle , loosen the damper rod assembly bolt Damper rod holder 342010 90890-01294 T-Handle 90890-01326 5.Remove: • inner tube a.Hold the front fork leg horizontally.

  • Page 172: Assembling The Front Fork Legs

    CHAS FRONT FORK 3.Check: • damper rod Damage/wear → Replace. Obstruction → Blow out all of the oil passages with compressed air. • oil flow stopper Damage → Replace. EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
  • Page 173 CHAS FRONT FORK Damper rod holder 90890-01294 T-handle 90890-01326 4.Install: • oil seal (with the fork seal driver weight and fork seal driver attachment Fork seal driver weight 90890-01367 Fork seal driver attachment 90890-01400 CAUTION: Make sure the numbered side of the oil seal faces up.
  • Page 174 CHAS FRONT FORK NOTE: • While filling the front fork leg, keep it upright. • After filling, slowly pump the front fork leg up and down to distribute the fork oil. 8. Install: • spring • o-ring • spring seat •...

  • Page 175: Handlebar

    CHAS HANDLEBAR HANDLEBAR 60 Nm (6,0 m.kg) Q'ty Remarks Order Job/Part Removing the handlebar Remove the parts in the order listed. Handlebar covers Refer to "COVERS" in Chapter 3. Disconnect: Stop switch Handlebar switch Remove: Rear view mirror Stop switch Front master cylinder Refer to "MASTER CYLINDER".
  • Page 176 CHAS HANDLEBAR 60 Nm (6,0 m.kg) Order Job/Part Q'ty Remarks Handlebar switch (left) Rear brake cable Refer to "INSTALLING THE HANDLE- Starter cable BAR". Left grip Handlebar For installation, reverse the removal pro- cedure. 6-38...

  • Page 177: 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: • handlebar grip NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

  • Page 178: Installing The Handlebar

    CHAS HANDLEBAR EAS00673 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: • handlebar NOTE: Install the handlebar onto the steering shaft notch. CAUTION: •...
  • Page 179 CHAS HANDLEBAR 7.Install: • right handlebar switch WARNING Make sure the throttle grip operates smoothly. NOTE: Align the projection on the right handlebar switch with the hole in the handlebar. 8.Adjust: • throttle cable free play Refer to "ADJUSTING THE THROTTLE CABLE FREE PLAY"...

  • Page 180: Steering Head

    CHAS STEERING HEAD EAS00675 STEERING HEAD 75 Nm (7.5 m.kg) Fisrt step: 38 Nm (3.8 m.kg) step: Loosen the ring nut 1/4 turn. step: 22 Nm (2.2 m.kg) Q'ty Remarks Order Job/Part Removing the lower bracket Remove the parts in the order listed. WARNING Securely support the scooter so that there is no danger of it falling over.
  • Page 181 CHAS STEERING HEAD 75 Nm (7.5 m.kg) Fisrt step: 38 Nm (3.8 m.kg) step: Loosen the ring nut 1/4 turn. step: 22 Nm (2.2 m.kg) Order Job/Part Q'ty Remarks Ball race (upper) Lower bracket Refer to "REMOVING THE LOWER Ball BRACKET".

  • Page 182: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00680 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: • upper ring nut • lock washer 3.Remove: • center ring nut •...

  • Page 183: Installing The Steering Head

    CHAS STEERING HEAD 3.Replace: • bearing balls • bearing races a.Remove the bearing races from the steering head pipe with a long rod and hammer. 354007 b.Remove the bearing race from the lower bracket with a floor chisel and hammer. c.

  • Page 184: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 31.5 Nm (3,15 m.kg) 17.5 Nm (1,75 m.kg) Q'ty Remarks Order Job/Part Removing the rear shock absorber Remove the parts in the order listed. assembly Rear covers Refer to "COVERS" in chapter 3. Remove: Rear under cover Remove:...

  • Page 185: Checking The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Oil leaks → Replace the rear shock absorber assembly. •...
  • Page 186 ELEC...
  • Page 187 ELEC CHAPTER 7. ELECTRICAL CIRCUIT DIAGRAM ..................7-1 ELECTRICAL COMPONENTS ..............7-3 SWITCH INSPECTION .................. 7-5 SWITCH INSPECTION ................7-5 SWITCH CONTINUITY INSPECTION ............7-5 IGNITION AND STARTING SYSTEM ............7-7 CIRCUIT DIAGRAM ................. 7-7 TROUBLESHOOTING ................7-8 STARTER MOTOR ..................7-14 INSPECTION ..................7-15 CHARGING SYSTEM ..................

  • Page 188: Chapter 7. Electrical

    ELEC CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR GW BR BR GW WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W 12V 5W 12V10W...
  • Page 189 ELEC CIRCUIT DIAGRAM Q CDI magneto w Front flasher light (left) W CDI unit e Front flasher light (right) E Ignition coil r Rear flasher light (left) R Spark plug t Rear flasher light (right) T Main switch y Tail / "STOP" light Y Fuse u Horn U Battery...

  • Page 190: Electrical Components

    ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS Q Wire harness U Battery W Fuel sender I Resistance E Starter relay R Ignition coil T CDI unit Y Oil sender...
  • Page 191 ELEC ELECTRICAL COMPONENTS Q Main switch W Flasher relay E Horn R Rectifier/Regulator...

  • Page 192: Switch Inspection

    ELEC SWITCH INSPECTION SWITCH INSPECTION "0" SWITCH INSPECTION "∞" Use a pocket tester to check the terminals for continuity. If the continuity is faulty as any point, "Ω x 1" replace the switch. Pocket tester: 90890-03112 NOTE: • Set the pocket tester to "O" before starting the test.
  • Page 193 ELEC SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Before checking a switch refer to the checking switches as shown in the page 7-5 and check for the correct terminal connections (closed cir- cuit) according to color combinations shown in the chart. Poor connection, fault → Repair or replace. Dimmer switch Start switch LW B...

  • Page 194: Ignition And Starting System

    ELEC IGNITION AND STARTING SYSTEM IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR BR GW GW BR WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W...

  • Page 195: Elec

    ELEC IGNITION AND STARTING SYSTEM TROUBLESHOOTING THE STARTING SYSTEM DOES NOT WORK (NO SPARK OR IRREGULAR SPARKS) Procedure: Check: 1. Fuse (main) 6. Ignition coil resistance 2. Battery 7. Pickup coil resistance 3. Spark plug 8. Source coil resistance 4. Spark check 9.
  • Page 196 ELEC IGNITION AND STARTING SYSTEM 4.Spark check • Remove the spark plug cap. • Connect the ignition checker Ground a Spark plug gap • Turn the main switch to "ON". • Start the engine. MEETS SPECIFICATION • Check the length of the spark gap. •...
  • Page 197 ELEC IGNITION AND STARTER SYSTEM Ω x 1 6.Ignition coil resistance • Disconnect the ignition coil leads. • Connect the pocket tester (Ωx1) to the igni- tion coil. Pocket tester (+) lead → → → → → Orange Pocket tester (-) lead → → → → → Black •...
  • Page 198 ELEC IGNITION AND STARTING SYSTEM MEETS SPECIFICATION 8.Source coil resistance • Disconnect the source coil coupler from the wire harness. BR GW • Connect the pocket tester (Ωx100) to the WR WL source coil. Pocket tester (+) lead → → → → → Black/Red Pocket tester (-) lead →...
  • Page 199 ELEC IGNITION AND STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT WORK Procedure Check: 5. Main switch 1. Fuse (main) 6. Starter motor switch 2. Battery 7. Connections 3. Starter motor 4. Starter relay NOTE: • Remove the following parts before proceed- ing with the troubleshooting: 1) Side covers (right and left) 2) Footrest board/Leg shields...
  • Page 200 ELEC IGNITION AND STARTER SYSTEM DOES NOT WORK • Check the starter motor operation WORKS Starter defect → Repair or replace 4.Starter relay • Disconnect Blue/White lead from the wire harness. • Connect the (-) terminal of the battery to the Blue/White lead.

  • Page 201: Starter Motor

    ELEC STARTER MOTOR STARTER MOTOR 13 Nm (1.3 m.kg) Order Job name/Part name Remarks Q'ty Starter motor removal Refer to "STARTER CLUTCH AND GENERATOR" in Chapter 4. Stater motor disassembly Disassemble the parts in the order below O-ring Front bracket Rubber seal Brush holder assembly Armature...

  • Page 202: Inspection

    ELEC STARTER MOTOR INSPECTION 1.Check: • Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: • Commutator diameter @ Out of specification → Replace starter motor Commutator wear limit: 14.8 mm 3.Measure: • Mica undercut @ Out of specification → Scrape the mica to proper value using a hacksaw blade can be ground to fit.
  • Page 203 ELEC STARTER MOTOR 5.Measure: • Brush length @ Out of specification → Replace. Brush length limit @: 0.9 mm 6.Measure: • Brush spring force Fatigue/Out of specification → Replace as a set. Brush spring force: 563 ~ 844 g 7-16...

  • Page 204: Charging System

    ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR GW BR BR GW WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W 12V 5W 12V10W...

  • Page 205: Troubleshooting

    ELEC CHARGING SYSTEM TROUBLESHOOTING THE BATTERY IS NOT CHARGED Procedure Check: 1. Fuse (main) 2. Battery 3. Charging voltage 4. Charging coil resistance 5. Connections NOTE: • Remove the following parts before proceed- ing with the troubleshooting: 1) Battery cover 2) Side covers (right and left) •...
  • Page 206 ELEC CHARGING SYSTEM 3. Charging voltage • Connect the engine tachometer to the spark plug lead. • Connect the pocket tester (DC20V) to the battery terminals. Pocket tester (+) lead → → → → → Battery (+) terminals Pocket tester (-) lead → → → → → Battery (-) terminals •...
  • Page 207 ELEC CHARGING SYSTEM 4. Charging coil resistance BR GW WR WL • Disconnect the CDI magneto coupler from the wire harness. • Connect the pocket tester (Ω x 1) to the charging coil. Pocket tester (+) lead → → → → → White Pocket tester (-) lead →...

  • Page 208: Lighting System

    ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR GW BR BR GW WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W 12V 5W 12V10W...

  • Page 209: Troubleshooting

    ELEC LIGHTING SYSTEM TROUBLESHOOTING THE HEADLIGHT, HEADLIGHT INDICATOR, POSITION LIGHT, METER LIGHT, LICENSE LIGHT AND/OR TAILLIGHT DO NOT WORK Procedure Check: 1. "LIGHTS" switch 2. Lighting coil resistance 3. "HI/LO" switch 4. Connections NOTE: • Remove the following parts before proceed- ing with the troubleshooting: 1) Side covers 2) Handlebar covers...
  • Page 210 ELEC LIGHTING SYSTEM YP802018 NO CONTINUITY 1."LIGHTS" switch Refer to "SWITCH INSPECTION" section. Replace the right handlebar switch. CONTINUITY 2.Lighting coil resistance • Disconnect the lighting coil coupler from the BR GW wire harness. WR WL • Connect the pocket tester (Ω x 0,1) to the lighting coil.

  • Page 211: Lighting System Check

    ELEC LIGHTING SYSTEM LIGHTING SYSTEM CHECK 1.Headlight and high beam indicator light do not work. NO CONTINUITY 1.Bulb and socket. Refer to "SWITCH INSPECTION". Replace the bulb or socket. CONTINUITY 2.Voltage • Connect the pocket tester (AC20V) to the headlight and the high beam indicator light 35W / 35W couplers.
  • Page 212 ELEC LIGHTING SYSTEM 2.Voltage • Connect the pocket tester (AC 20 V) to the front position light connectors. 12V 5W Pocket tester (+) lead → → → → → Blue/Red Pocket tester (-) lead → → → → → Black Pocket tester (+) lead →...
  • Page 213 ELEC LIGHTING SYSTEM 4.The taillight does not work. 1.Bulb and socket. NO CONTINUITY Refer to " SWITCH INSPECTION " section. CONTINUITY Replace bulb or socket. 2.Voltage • Connect the pocket tester (AC 20 V) to the taillight connectors. 21W / 5W Pocket tester (+) lead →...
  • Page 214 ELEC LIGHTING SYSTEM 2.Voltage • Connect the pocket tester (AC 20 V) to the license light coupler. 12V 5W Pocket tester (+) lead → → → → → Blue/Red Pocket tester (-) lead → → → → → Black • Set the main switch to "ON". •...

  • Page 215: Signal System

    ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM Br R Gy B LOCK MAIN HARNESS STARTER MOTOR CHECK R W B YR GW BR BR GW WR WL LW B LW YR LW YR 12V 5W 12V 1.2W 12V 1.2W 12V 1.2W 21W / 5W 12V 5W 12V10W...

  • Page 216: Troubleshooting

    ELEC SIGNAL SYSTEM TROUBLESHOOTING FLASHER LIGHTS, TAIL/BRAKE LIGHT, "OIL" WARNING LIGHT DO NOT WORK. HORN DOES NOT SOUND, FUEL METER DOES NOT WORK. Procedure Check: 1. Fuse (main) 2. Battery 3. Main switch 4. Connections NOTE: • Remove the following parts before proceeding with the troubleshooting: 1) Side covers and footrest board 2) Handlebar covers...
  • Page 217 ELEC SIGNAL SYSTEM 4.Connections POOR CONNECTIONS • Check all connections in the signal system. Refer to "WIRE DIAGRAM". Repair. CONTINUITY Check the condition of each circuit of the signal system. Refer to "SIGNAL SYSTEM CHECK". 7-30...

  • Page 218: Signal System Check

    ELEC SIGNAL SYSTEM SIGNAL SYSTEM CHECK 1. Horn does not sound. 1."HORN" switch NO CONTINUITY Refer to "SWITCH INSPECTION". Replace the horn switch. CONTINUITY 2.Voltage • Connect the pocket tester (DV20 V ) to the horn lead. Pocket tester (+) lead → → → → → Brown Pocket tester (-) lead →...
  • Page 219 ELEC SIGNAL SYSTEM 2. The brake light does not work. NO CONTINUITY 1.Bulb and socket. Refer to "SWITCH INSPECTION". Replace bulb or socket. CONTINUITY NO CONTINUITY 2.Brake switch Refer to "SWITCH INSPECTION". Brake switch is defect → Replace. CONTINUITY 3.Voltage •...
  • Page 220 ELEC SIGNAL SYSTEM 3.Flashers and flasher indicator do not work. NO CONTINUITY 1.Bulb and socket Refer to "SWITCH INSPECTION". Replace buld and/or socket. CONTINUITY NO CONTINUITY 2.Flasher switch Refer to "SWITCH INSPECTION". Replace the left handlebar switch. CONTINUITY 3.Voltage • Connect the pocket tester (DC 20 V ) to the flasher relay.
  • Page 221 ELEC SIGNAL SYSTEM 5.Voltage • Connect the pocket tester (DC 20 V) to the flasher coupler. 12V10W 12V10W Left flasher bulb Pocket tester (+) lead → → → → → Chocolate Pocket tester (-) lead → → → → → Black Right flasher bulb Pocket tester (+) lead →...
  • Page 222 ELEC SIGNAL SYSTEM 12V 1.2W 3. Voltage 12V 1.2W • Connect the pocket tester (DC20V) to the 12V 1.2W bulb socket connector Pocket tester (+) lead → → → → → Grey Pocket tester (-) lead → → → → → Black •...

  • Page 223: Trbl Shtg

    TRBL SHTG...
  • Page 224 TRBL SHTG CHAPTER 8. TROUBLESHOOTING STARTING FAILURE/ HARD STARTING ............ 8-1 FUEL SYSTEM ..................8-1 ELECTRICAL SYSTEM ................8-1 COMPRESSION SYSTEM ..............8-2 POOR IDLE SPEED PERFORMANCE ............8-2 POOR IDLE SPEED PERFORMANCE ........... 8-2 POOR MEDIUM AND HIGH SPEED PERFORMANCE ........ 8-3 FUEL SYSTEM ..................

  • Page 225: Chapter 8. Troubleshooting

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

  • Page 226: Compression System

    TRBL STARTING FAILURE/HARD STARTING/ POOR IDLE SPEED PERFORMANCE SHTG COMPRESSION SYSTEM Cylinder and cylinder head Crankcase and crankshaft • Loose spark plug • Improperly seated crankcase • Loose cylinder head or cylinder • Improperly sealed crankcase • Broken cylinder head gasket (damaged oil seal) •...

  • Page 227: Poor Medium And High Speed Performance

    TRBL POOR MEDIUM AND HIGH SPEED PERFORMANCE/ FAULTY AUTOMATIC SHTG POOR MEDIUM AND HIGH SPEED PERFORMANCE FUEL SYSTEM Fuel tank Carburetor • Clogged fuel filter • Deteriorated fuel, fuel containing water or • Deteriorated fuel or fuel containing water or foreign material foreign material •...

  • Page 228: Clutch-Out Failure

    TRBL FAULTY AUTOMATIC/ SHTG OVER HEATING CLUTCH-OUT FAILURE Primary pulley Secondary pulley • Seized primary sliding pulley and collar • Broken or fatigued clutch shoe spring POOR STANDING START (LOW CLIMBING ABILITY) V-belt Secondary pulley • Worn, damaged or slippery v-belt •...

  • Page 229: Improper Kicking

    TRBL IMPROPER KICKING/ SHTG FAULTY BRAKE IMPROPER KICKING SLIPPING Kick axle assembly Transmission oil • Low tension of kick clip • Improper quality (low viscosity) • Worn kick axle • Deterioration • Worn or damaged kick gear • Damaged kick clip •...

  • Page 230: Front Fork Oil Leakage And Front Fork Malfunction

    FRONT FORK OIL LEAKAGE AND FRONT FORK TRBL MALFUNCTION/ SHTG INSTABLE HANDLING FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE MALFUNCTION • Bent, damaged or rusty inner tube • Bent, deformed or damaged inner tube • Damaged or cracked outer tube •...

  • Page 231: Faulty Signal And Lighting System

    TRBL SHTG FAULTY SIGNAL AND LIGHTING SYSTEM FAULTY SIGNAL AND LIGHTING SYSTEM Headlight dark Flasher does not light • Improper bulb • Improperly grounded • Too many electric accessories • Discharged battery • Hard charging (broken charging coil) • Faulty flasher switch •...
  • Page 232 Q C.D.I. magneto YQ100 WIRING DIAGRAM Br R W C.D.I. unit Gy B E Ignition coil R Spark plug T Main switch LOCK Y Fuse MAIN HARNESS STARTER MOTOR U Battery CHECK I Rectifier / regulator O Starter relay P Starter motor R W B YR { Right handle switch Starter switch...

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