Yamaha XN125 2000 Service Manual
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Yamaha XN125 2000 Service Manual

Yamaha XN125 2000 Service Manual

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XN125
2000
5MF1-AE2
XN150
SERVICE MANUAL

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Summary of Contents for Yamaha XN125 2000

  • Page 1 XN125 2000 5MF1-AE2 XN150 SERVICE MANUAL...
  • Page 2 EASM0000 XN125 / XN150 SERVICE MANUAL © 2000 by MBK Industrie 2nd edition, April 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.
  • Page 3 EASM0001 NOTICE This manual was produced by the MBK Industrie primarily for use by Yamaha and MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 4: How To Use This Manual

    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: General Information

    EAS00008 SYMBOLS The following symbols are not relevant to every SPEC INFO vehicle. Symbols indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Engine Cooling system Carburetor COOL CARB Chassis Electrical system Troubleshooting CHAS ELEC Symbols indicate the following.

  • Page 6: Table Of Contents

    EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM COOL CARBURETOR CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 INFO...
  • Page 8 INFO CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ................ 1-1 VEHICLE IDENTIFICATION NUMBER ............ 1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 OIL INDICATOR LIGHT ................1-2 ODOMETER/TRIPMETER READING MODE ......... 1-2 BATTERY VOLTAGE/FUEL GAUGE ............1-2 THE CLOCK ..................... 1-3 AUTO-CHOKE SYSTEM .................

  • Page 9: Chapter 1. General Information

    INFO SCOOTER IDENTIFICATION EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EASM0002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the frame. ZAUM0071 EASM0003 MODEL LABEL The model label is affixed under the seat. This information will be needed to order spare parts.

  • Page 10: Features

    INFO FEATURES EASM0004 FEATURES OIL INDICATOR LIGHT • FUNCTION Pulses (travel distance signals) from the speedometer are counted and cause the oil indicator light to come on at 500 km for the first time and thereafter every 3,000 km. In this way, the light indicates the time for oil change.

  • Page 11: The Clock

    INFO FEATURES THE CLOCK • Setting the clock To set the clock: 1) Make sure that the key is turned to “OFF”. 2) Press the “TRIP” button for two seconds and the hour display will flash. 3) Press the “TRIP” button to set the hours. 4) Press the “TRIP”...

  • Page 12: Important Information

    5.Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS 1.Use only genuine Yamaha and MBK parts for all replacements. Use oil and grease recom- mended by Yamaha or MBK for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 13: 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 manu-...

  • Page 14: 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 15: 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 16 INFO SPECIAL TOOLS Tool No. Tool name/usage Illustration 90890-01367 Fork seal driver weight 90890-01368 Frok seal driver attachment These tools are used when installing the fork seal. 90890-01701 Sheave holder This tool is used to hold the secondary sheave when removing or installing the nut.
  • Page 17 This tool is used to rebore the valve guide. 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. 90890-85505 Yamaha bond No. 1215 This sealant (bond) is used for crankcase mating surface, etc. 90890-03081 Compression gauge This gauge is used to measure the engine...
  • Page 18 SPEC...
  • Page 19 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 MAINTENANCE SPECIFICATIONS ............. 2-4 ENGINE ....................2-4 CHASSIS ....................2-8 ELECTRICAL ..................2-10 CONVERSION TABLE ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-13 TIGHTENING TORQUES ................2-14 TIGHTENING TORQUES (ENGINE) ............. 2-14 TIGHTENING TORQUES (CHASSIS) ...........

  • Page 20: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item XN125 [XN150] Dimensions Overall length 1.868 mm Overall width 740 mm Overall height 1.096 mm Seat height 777 mm Wheelbase 1.315 mm Minimum ground clearance 105 mm Minimum turning radius 1.800 mm Weight Wet (with oil and a full fuel tank) 123 kg Dry (without oil and fuel)
  • Page 21 SPEC GENERAL SPECIFICATIONS Item XN125 [XN150] Carburator TK 5DS/1 [TK 5KD/1] Type/quantity Manufacturer TEIKEI Spark plug Type CR8E Manufacturer Spark plug gap 0.5~0.7 mm Dry, centrifugal automatic Clutch type Transmission Helical gear Primary reduction system Primary reduction ratio 40/15 (2.666) Spur gear Secondary reduction system Secondary reduction ratio...
  • Page 22 SPEC GENERAL SPECIFICATIONS Item XN125 [XN150] Brake Front brake type Single disc brake Front brake operation Right hand operation Rear brake type Drum brake Rear brake operation Left hand operation Suspension Front suspension Telescopic fork Rear suspension Unit swing Shock absorber Front fork type Coil spring/oil damper Rear shock absorber assembly type...

  • Page 23: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE *[XN150] Item Standard Limit Cylinder head Warp limit ••• 0.03 mm Cylinder Bore size 53.700 ~ 53.705 mm [59.500 ~ 59.505mm]* ••• Out of round limit ••• 0.05 mm Camshaft Drive system Chain drive (left) •••...
  • Page 24 SPEC MAINTENANCE SPECIFICATIONS *[XN150] Item Standard Limit Valve spring Inner spring Free length IN/EX 41.94 mm 39.84 mm Set length (valve closed) IN/EX 37.5 mm ••• Compressed pressure IN/EX 45.1 ~ 50.9 N ••• Tilt limit IN/EX 2.5° / 1.9 mm •••...

  • Page 25: Carburetor

    SPEC MAINTENANCE SPECIFICATIONS *[XN150] Item Standard Limit Carburetor Type TK 5DS [TK 5KD]* I.D mark ••• ••• Main jet (M.J) #116 [#114]* ••• Main air jet (M.A.J) ø1.0 [ø1.4]* ••• Jet needle (J.N) 4E31 (3/5) [4E32 (3/5)]* ••• Pilot air jet (P.A.J.1) ø1.30 •••...
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS Item Size Crankshaft oil seal (left) 22 x 32 x 7 Crankshaft oil seal (right) 19 x 30 x 8 (Reinforced) Crankshaft oil seal (right) 19 x 30 x 8 (Double lips) Camshaft bearing (left) 20 x 42 x 12 Camshaft bearing (right) 15 x 32 x 9 Starter clutch bearing...

  • Page 27: Chassis

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system Steering bearing type Ball bearing ••• No./size of steel balls Upper 15 pcs 4.75 mm ••• Lower 15 pcs 4.75 mm ••• Front suspension Front fork travel 90 mm •••...
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Brake lever Brake lever free play (front) 10 ~ 20 mm ••• Brake lever free play (rear) 10 ~ 20 mm ••• Throttle cable free play 1.5 ~ 3.0 mm •••...

  • Page 29: Electrical

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Ignition timing Ignition timing (B.T.D.C) 10° at 1.700 rpm ••• Advanced timing (B.T.D.C) 32° at 5.000 rpm ••• Advanced type Digital ••• T.C.I 248 ~ 372 Ω at 20°C / Pickup coil resistance/color •••...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Horn Model/manufacturer YF-12 / NIKKO ••• Maximum amperage ••• Flasher relay Flasher frequency 80 ~ 160 cycle/min ••• Fuel gauge Model/manufacturer 25.33.06/MAXIMA ••• 4 ~ 10 Ω Sender unit resistance - full ••• 90 ~ 100 Ω - empty •••...

  • Page 31: Conversion Table

    SPEC CONVERSION TABLE AS00028 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 ** in 2 mm 0.03937 0.08 in CONVERSION TABLE...

  • Page 32: General Tightening Torque Specifications

    SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00029 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

  • Page 33: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE Tightening Thread torque Item Fastener Q'ty Remarks size m•kg Oil check bolt Bolt Spark plug Cylinder, water drain bolt Bolt Cylinder head and cylinder Cylinder head and cylinder Bolt Cylinder and crankcase Bolt Camshaft bearing stopper Bolt Camchain guide Bolt...
  • Page 34 SPEC TIGHTENING TORQUES Tightening Thread torque Item Fastener Q'ty Remarks size m•kg Rear brake shoes pin pivot 12.0 Thermo unit Pt 1/8 Coolant drain bolt on cylinder Bolt Starter motor Bolt Rotor 22.5 22.5 Stator Bolt 2-15...

  • Page 35: Tightening Torques Chassis

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES CHASSIS Tightening Thread torque Item Fastener Q'ty Remarks size m•kg Frame with engine bracket Bolt Engine bracket 2 with 3 Bolt E/G bracket with E/G (with main stand) Bolt Reinforcement tail Bolt 0.65 Rear cushion with frame Rear cushion with engine See chapter 7 Steering shaft...

  • Page 36: Lubrication Points And Lubricant Types

    Idle gear 1 thrust surfaces Shaft 1 Idle gear 2 thrust surfaces Idle gear 2 inner surface Main axle thrust surfaces Crankcase mating surfaces Yamaha bond No. 1215 Crankcase breather plug Stator grommet Yamaha bond No. 1215 Suction pipe 2-17...

  • Page 37: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left/right) Steering head pipe bearing (upper/lower) Tube guide (throttle grip) inner surface Brake cable (brake lever) Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft...

  • Page 38: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS A Pass the hose under inlet manifold. Radiator cap Radiator Radiator fan Thermo switch Coolant tank Water pump Cylinder Inlet manifold 2-19...
  • Page 39 SPEC COOLING SYSTEM DIAGRAMS EAS00033(bis) COOLING SYSTEM DIAGRAMS Radiator A Pass the hose between radiator and radiator Radiator fan filler hose. Radiator cap Coolant tank Water pump Thermostat 2-20...

  • Page 40: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1Lubrication of the cylinder head Cylinder head Cylinder Crankcase 2Lubrication of the crankshaft Crankshaft 2-21...
  • Page 41 SPEC LUBRICATION DIAGRAMS EAS00034(bis) LUBRICATION DIAGRAMS 1Oil flow Cylinder head Cylinder Oil pump 2Lubrication table Oil pressure flow Oil return flow Camshaft Crankshaft Cylinder head Rocker arm Oil pump Connecting rod Oil strainer Crankcase 2-22...

  • Page 42: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING Thermo switch wire Wire harness Seat lock cable Horn Speedometer wire Horn wire Main switch wire Rear brake cable Seat lock cable adjuster Throttle cable Radiator Band switch Headlight and front flasher connector Make the wire harness getting out here. Front fork assembly Place the speedometer wire as shown.
  • Page 43 SPEC CABLE ROUTING Starter motor Seat lock assembly CDI unit Fuel tank rectifier/Regulator Wire lead CDI magneto wire Mud guard Ignition coil assembly Fuel cock Footrest board Starter relay Place the wire as shown. Battery ground Place the sidestand wire as shown (option). Wire harness C Apply grease on stater motor connector/ terminal.
  • Page 44 SPEC CABLE ROUTING Rear left flasher Battery Rear brake cable adjuster Starter relay Rear brake cable Frame Fuel overflowed pipe Fuses box Relay Radiator Sender Main switch Fuel pipe Sidestand wire (option) Engine air breather Fueal gauge wire Fuel cock Rear right flasher Seat lock assembly Taillight...
  • Page 45 SPEC CABLE ROUTING Right handlebar switches Glue the handlebar grip. Inner handlebar cover Install the handlebar switch as shown. Left handlebar switches Rear brake lever Front handlebar cover Master cylinder Front brake lever B - B A - A C - C view D 30¡...
  • Page 46 SPEC CABLE ROUTING Master cylinder Pass wires behind the turn signal relay bracket Inner handlebar cover Clip all wires and cables all together Speedometer assembly Install the wire harness behind the turn signal Rear brake cable relay bracket. Throttle cable Front brake hose Wire harness Handlebar...
  • Page 48 CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION .................... 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ....3-1 COVER AND PANEL ..................3-3 SIDE COVERS AND SEAT ..............3-3 FRONT COVER, INNER PANEL AND INNER FRONT COVER ..... 3-5 FOOTREST BOARD AND UNDER COVER ..........3-6 HANDLEBAR COVERS ................
  • Page 49 ELECTRICAL SYSTEM ................3-37 CHECKING THE BATTERY ..............3-37 CHECKING THE FUSES ............... 3-40 REPLACING THE HEADLIGHT BULBS AND THE FRONT TURN SIGNAL LIGHT BULBS ................3-41 REPLACING THE REAR TURN SIGNAL LIGHT BULBS ...... 3-42 REPLACING THE TAIL/BRAKE LIGHT BULBS ........3-43 ADJUSTING THE HEADLIGHT BEAMS ..........

  • Page 50: Chapter 3. Periodic Checks And Adjustments

    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 51 • Adjust headlight beam. * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha or MBK dealer. NOTE: • The air filters need more frequent service if you are riding in unusually wet or dusty areas.

  • Page 52: Cover And Panel

    COVER AND PANEL EASM0005 COVER AND PANEL SIDE COVERS AND SEAT 8 Nm (0.8 m¥kg) 18.5 Nm (1.85 m¥kg) 7 Nm (0.7 m¥kg) 7 Nm (0.7 m¥kg) Order Job/Part Q’ty Remarks Removing the side covers Remove the parts in the order listed. Remove: Battery cover NOTE:...
  • Page 53 COVER AND PANEL 8 Nm (0.8 m¥kg) 18.5 Nm (1.85 m¥kg) 7 Nm (0.7 m¥kg) 7 Nm (0.7 m¥kg) Order Job/Part Q’ty Remarks Remove: Side cover (right) Side cover (left) For installation, reverse the removal procedure.

  • Page 54: Front Cover, Inner Panel And Inner Front Cover

    COVER AND PANEL EASM0007 FRONT COVER, INNER PANEL AND INNER FRONT COVER 7 Nm (0.7 m 7 Nm (0.7 m © © 7 Nm (0.7 m © 7 Nm (0.7 m © 7 Nm (0.7 m © Order Job/Part Q’ty Remarks Removing the front cover, inner Remove the parts in the order listed.

  • Page 55: Footrest Board And Under Cover

    COVER AND PANEL EASM0008 FOOTREST BOARD AND UNDER COVER 7 Nm (0.7 m © 4 Nm (0.4 m © 13.5 Nm (1.35 m © 7 Nm (0.7 m © Order Job/Part Q’ty Remarks Removing the footrest board Remove the parts in the order listed. and under cover Remove: Side covers...

  • Page 56: Handlebar Covers

    COVER AND PANEL EASM0009 HANDLEBAR COVERS 7 Nm (0.7 m © 4.5 Nm (0.45 m © 4.5 Nm (0.45 m © Order Job/Part Q’ty Remarks Removing the handlebar covers Remove the parts in the order listed. Remove: Front handlebar cover Disconnect: Speedometer assy’...

  • Page 57: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.

  • Page 58: Adjusting The Engine Idling Speed

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED 3. Adjust: • valve clearance a. Loosen the locknut b. Insert a thickness gauge between the end of the adjusting screw and the valve tip. c. Turn the adjusting screw in or out until the specified valve clearance is obtained.

  • Page 59: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 2. Attach: • engine tachometer (onto the spark plug lead of the cylinder) Engine tachometer 90890-03113 3. Measure: • engine idling speed Out of specification → Adjust. Engine idling speed 1,400 ~ 1,800 r / min 4.

  • Page 60: Checking The Spark Plug

    ADJUSTING THE THROTTLE CABLE FREE PLAY / CHECKING THE SPARK PLUG 1. Check: • throttle cable free play Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3 mm 2. Adjust: ZAUM0051 •...

  • Page 61: Checking The Ignition Timing

    CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 4. Check: • electrodes Damage/wear → Replace the spark plug. • insulator Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6.

  • Page 62: Transmission Oil Replacement

    CHECKING THE IGNITION TIMING/ TRANSMISSION OIL REPLACEMENT 2. Check: • ignition timing a. Start the engine, warm it up for several minu- tes, and then let it run at the specified engine idling speed. Engine idling speed 1,400 ~ 1,800 r/min b.

  • Page 63: Measuring The Compression Pressure

    MEASURING THE COMPRESSION PRESSURE EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance Out of specification → Adjust Refer to “ADJUSTING THE VALVE CLEA- RANCE” section. 2. Start the engine, warm it up for several minu- tes, and then turn it off.

  • Page 64: 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. Carbon deposits → Remove. d. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again.

  • Page 65: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL Recommended oil -20° -10° 0° 10° 20° 30° 40° 50°C Refer to the chart for the engine oil grade which is best suited for SAE 10W/30 certain atmospheric temperatures. SAE 10W/40 API standard SE or higher grade SAE 15W/40...

  • Page 66: Measuring The Engine Oil Pressure

    CHECKING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE/ 7. Reset: • engine oil warning circuit a. Press the “TRIP” button while turning the key to “ON” b. Release the “TRIP” button and oil indicator light will go off NOTE: •...

  • Page 67: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT/ CLEANING THE V-BELT CASE AIR FILTER ELEMENT EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: • air filter case cover 2. Clean: • air filter element Apply compressed air to the outer surface of the air filter element. 3.

  • Page 68: Checking The Fuel And Vacuum Hoses

    CHECKING THE FUEL AND VACUUM HOSES/ EXHAUST SYSTEM INSPECTION EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses. 1. Remove: • Seat • Box Refer to “SIDE COVERS AND SEAT” section. 2.

  • Page 69: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL EAS00103 CHECKING THE COOLANT LEVEL 1. Stand the scooter on a level surface. NOTE: Place the scooter on a suitable stand. Make sure the scooter is upright. 2. Remove: • Coolant tank cover Refer to “FRONT COVER, INNER PANEL AND INNER FRONT COVER”...

  • Page 70: Changing The Coolant

    CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: • Side covers • Seat • Rear carrier • Box Refer to “SIDE COVERS AND SEAT” sec- tion. • Front cover • Inner panel Refer to “FRONT COVER, INNER PANEL AND INNER FRONT PANEL” section. 2.
  • Page 71 CHANGING THE COOLANT 7. Check: • copper washer (coolant drain bolt-engine ) • copper washer (coolant drain bolt-water pump) Damage → Replace. 8. Install: • coolant drain bolt (engine) 10 Nm (1.0m•kg) • coolant drain bolt (water pump) 10 Nm (1.0m•kg) 9.
  • Page 72 CHANGING THE COOLANT CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concen- tration of the coolant. • Use only distilled water. However, if distilled water is not available, soft water may be used.

  • Page 73: Inspecting The Coolant System

    INSPECTING THE COOLANT SYSTEM EASM0015 INSPECTING THE COOLANT SYSTEM 1. Inspect: • Radiator • Filler hose (radiator) • Outlet hose (radiator) • Pipe • Outlet hose (radiator) Cracks/Damage → Replace Refer to “COOLING SYSTEM” section in chapter 5. 3-24...

  • Page 74: Chassis

    CHECKING THE FRONT BRAKE LEVER FREE PLAY/ ADJUSTING THE REAR BRAKE EASM0016 CHASSIS CHECKING THE FRONT BRAKE LEVER FREE PLAY 1. Check: • brake lever free play Out of specification → check the front brake system. Refer to “FRONT BRAKE” section in chapter ZAUM0055 Brake lever free play (at the end of the brake lever)

  • Page 75: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CAUTION: After adjusting the brake lever free play, make sure there is no brake drag. EAS00116 CHECKING THE BRAKE FLUID LEVEL 1. Stand the scooter on a level surface. NOTE: • Place the scooter on a suitable stand. •...

  • Page 76: Checking The Brake Pads

    CHECKING THE BRAKE PADS/CHECKING THE BRAKE SHOES/ CHECKING THE BRAKE HOSES EASM0017 CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • brake pad thickness Less than specification → Replace the brake pads as a set.

  • Page 77: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00133 BLEEDING THE HYDRAULIC BRAKE SY- STEM WARNING Bleed the hydraulic brake system whenever: • the system is disassembled, • a brake hose is loosened, disconnected or replaced, • the brake fluid level is very low, •...

  • Page 78: Checking And Adjusting The Steering Head

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHECKING AND ADJUSTING THE STEERING HEAD i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 m•kg) k.
  • Page 79 CHECKING AND ADJUSTING THE STEERING HEAD a. Remove the lock washer , the upper ring , the center ring nut and the rubber washer. b. Loosen the lower ring nut and then tighten it to specification with the ring nut wrench NOTE: Set the torque wrench at a right angle to the ring nut wrench.

  • Page 80: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK Ring nut wrench 90890-01268 Upper ring nut 75 Nm (7.5 m•kg) 5. Install: • Handlebar Refer to “HANDLEBAR” section in chapter 7. • Handlebar cover Refer to “HANDLEBAR COVERS” section. EAS00151 CHECKING THE FRONT FORK 1.

  • Page 81: Inspecting The Rear Shock Absorber

    INSPECTING THE REAR SHOCK ABSORBER/ CHECKING THE TYRES EASM0018 INSPECTING THE REAR SHOCK ABSOR- 1. Remove: • Side covers Refer to “SIDE COVERS AND SEAT” sec- tion. 2. Check • Rear shock absorber mount Looseness → Tighten 31.5 Nm (3.15m•kg) Bolt (upper) 17.5 Nm (1.75m•kg) Bolt (lower)
  • Page 82 CHECKING THE TYRES WARNING It is dangerous to ride with a worn-out tyre. When the tyre tread reaches the wear limit, replace the tyre immediately. 2. Check: • tyre surfaces Damage/wear → Replace the tyre. 3101 Minimum tyre tread depth 0.8 mm Tyre tread depth Side wall...
  • Page 83 CHECKING THE TYRES Front tyre Manufacturer METZELER Model ME-7 TEEN Size 120/70-12 Rear tyre Manufacturer METZELER Model ME-7 TEEN Size 120/70-12 WARNING • New tyres have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.

  • Page 84: Checking The Wheels

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

  • Page 85: Lubricating The Levers And Pedals

    LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE CENTERSTAND EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Engine oil ZAUM0061 EAS00172 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.

  • Page 86: Electrical System

    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 sulphuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 87 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 88 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 89: Checking The Fuses

    CHECKING THE BATTERY/ CHECKING THE FUSES 11. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead and then the negative battery lead 12. Lubricate: om913(b) • battery terminals Recommended lubricant Dielectric grease 13. Install: •...

  • Page 90: Replacing The Headlight Bulbs And The Front Turn Signal Light Bulbs

    CHECKING THE FUSES / REPLACING THE HEADLIGHT BULBS AND THE FRONT TURN SIGNAL LIGHT BULBS 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.

  • Page 91: Replacing The Rear Turn Signal Light Bulbs

    REPLACING THE REAR TURN SIGNAL LIGHT BULBS 5. 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 92: Replacing The Tail/Brake Light Bulbs

    REPLACING THE TAIL/BRAKE LIGHT BULB CAUTION: Do not overtighten the screw, otherwise the lensmay break. 4. Install: • Turn signal light lens EAS00183 REPLACING THE TAIL/BRAKE LIGHT BULB 1. Remove: • Tail/brake light lens 2. Remove: • Tail/brake bulb (push and turn it counterclockwise) WARNING Since the tail/brake bulb gets extremely hot,...

  • Page 93: Chk Adj

    ADJUSTING THE HEADLIGHT BEAMS/ ADJUSTING THE DIGITAL CLOCK EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) a. Turn the adjusting screw in or out. → Headlight beam is raised. Turning in Turning out →...
  • Page 95 CHAPTER 4. OVERHAULING THE ENGINE ENGINE ......................4-1 WIRING HARNESS, CABLE ..............4-1 HOSES, AIR FILTER, ENGINE MOUNTING BOLT AND ENGINE ..4-3 CAMSHAFT ....................4-4 REMOVING THE ROCKER ARMS AND THE CAMSHAFT ....4-5 CHECKING THE CAMSHAFT ..............4-5 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..
  • Page 96 CLUTCH ...................... 4-28 CRANKCASE COVER ................4-28 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ....4-29 SECONDARY SHEAVE ................. 4-30 REMOVING THE PRIMARY SHEAVE ..........4-31 REMOVING THE SECONDARY SHEAVE AND V-BELT ...... 4-31 DISASSEMBLING THE SECONDARY SHEAVE ........4-32 CHECKING THE CLUTCH ..............4-32 CHECKING THE CLUTCH HOUSING ...........

  • Page 97: Chapter 4. Overhauling The Engine

    ENGINE EASM0020 (bis) OVERHAULING THE ENGINE ENGINE WIRING HARNESS, CABLE 10 Nm (1.0 m¥kg) Order Job/Part Q’ty Remarks Removing the wire harness and Remove the parts in the order listed. cables Side covers Refer to “SIDE COVERS AND SEAT” Seat section in chapter 3.
  • Page 98 ENGINE 10 Nm (1.0 m¥kg) Order Job/Part Q’ty Remarks Earth lead Adjuster Rear brake cable Rear brake cable pin Rear brake cable compression spring Cable holder For installation, reverse the removal procedure.

  • Page 99: Hoses, Air Filter, Engine Mounting Bolt And Engine

    ENGINE EASM0021 HOSES, AIR FILTER, ENGINE MOUNTING BOLT AND ENGINE 17.5 Nm (1,75 m¥kg) 43 Nm (4,3 m¥kg) Order Job/Part Q’ty Remarks Removing the hoses, air filter, Remove the parts in the order listed. engine mounting bolt and engine Crankcase breather hose Pump inlet hose Cylinder head outlet hose Air filter case assembly...

  • Page 100: Camshaft

    CAMSHAFT EASM0023 CAMSHAFT 6,5 Nm (0,65 m¥kg) 10 Nm (1,0 m¥kg) 6,5 Nm (0,65 m¥kg) 12 Nm (1,2 m¥kg) Order Job/Part Q’ty Remarks Removing the camshaft Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD” section. Plate bolt Plate Rocker arm shaft (intake)

  • Page 101: Removing The Rocker Arms And The Camshaft

    CAMSHAFT EAS00197 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Align: • “T” mark on the generator rotor (with the mark on the generator rotor cover) a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align the “T”...

  • Page 102: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFT 3. Measure: • camshaft lobe dimensions a and b . Out of specification → Replace the camshaft. Camshaft lobe dimension limit Intake a 30.711mm b 25.045 mm Exhaust a 30.711 mm b 25.052 mm 4. Check: • camshaft oil passage Obstruction →...

  • Page 103: Checking The Timing Chain, Camshaft Sprocket And Timing Chain Guides

    CAMSHAFT 6. Calculate: • rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.037 mm EAS00207 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES 1.

  • Page 104: Checking The Tappet Covers And Camshaft Sprocket Cover

    CAMSHAFT EAS00212 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER The following procedure applies to both of the tappet covers and O-rings. 1. Check: • tappet covers • O-rings Damage/wear → Replace the defective part(s). INSTALLING THE CAMSHAFT AND ROCKER ARMS 1.
  • Page 105 CAMSHAFT CAUTION: Make sure the threaded part of the rocker arm shaft and O-rings faces outwards. 6. Install: • rocker arm shaft clamp and bolt. 10 Nm (1.0m•kg) 7. Install: • timing chain (onto the camshaft sprocket) • camshaft sprocket (onto the camshaft) NOTE: •...

  • Page 106: Cylinder Head

    CYLINDER HEAD EASM0020 CYLINDER HEAD 8 Nm (0.8 m¥kg) 10 Nm (1.0 m¥kg) 22 Nm (2.2 m¥kg) 12 Nm (1.2 m¥kg) 30 Nm (3.0 m¥kg) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Side covers Refer to “SIDE COVERS AND SEAT”...
  • Page 107 CYLINDER HEAD 8 Nm (0.8 m¥kg) 10 Nm (1.0 m¥kg) 22 Nm (2.2 m¥kg) 12 Nm (1.2 m¥kg) 30 Nm (3.0 m¥kg) Order Job/Part Q’ty Remarks Crankcase breather hose WARNING Water pump Follow the arrows Timing chain tensioner Camshaft sprocket NOTE: Lock the flywheel with the special tool.

  • Page 108: Removing The Cylinder Head

    CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Remove: • camshaft and rocker arms Refer to “REMOVING THE ROCKER ARMS AND CAMSHAFT” section. NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire. 2. Remove: •...

  • Page 109: Installing The Cylinder Head

    CYLINDER HEAD d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. EAS00232 INSTALLING THE CYLINDER HEAD 1.

  • Page 110: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EASM0024 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valves Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD” section Rocker arm, rocker arm shaft Refer to “CAMSHAFT” section. Valve cotters Spring retainer Valve spring...

  • Page 111: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.

  • Page 112: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: • valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter b - Valve stem diameter a Out of specification →...

  • Page 113: Checking The Valve Seats

    VALVES AND VALVE SPRINGS c. After installing the valve guide, bore the valve guide with the valve guide reamer to obtain the proper valve-stem-to-valve-guide clea- rance. NOTE: After replacing the valve guide, reface the valve seat . Valve guide remover (4.5 mm) 90890-04116 Valve guide installer (4.5 mm) 90890-04117...
  • Page 114 VALVES AND VALVE SPRINGS 3. Measure: • valve seat width a Out of specification → Replace the cylinder head. Valve seat width Intake 0.9 ~ 1.1 mm <limit>: 1.6 mm Exhaust 0.9 ~ 1.1 <limit>: 1.6 mm) a. Apply Mechanic’s blueing dye (Dykem) onto the valve face b.

  • Page 115: Checking The Valve Springs

    VALVES AND VALVE SPRINGS c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

  • Page 116: Installing The Valves

    VALVES AND VALVE SPRINGS Spring compressed pressure (intake and exhaust) 45.1 ~ 50.9 N 3. Measure: • valve spring tilt a Out of specification → Replace the valve spring. Spring tilt limit Intake and exhaust valve spring ° / 1.9 mm EAS00245 INSTALLING THE VALVES The following procedure applies to all of the...
  • Page 117 VALVES AND VALVE SPRINGS 4. Install: • valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor and attachment. Valve spring compressor 90890-04019 Attachment 90890-04108 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

  • Page 118: Cylinder And Piston

    CYLINDER AND PISTON EASM0025 CYLINDER AND PISTON 12 Nm (1.2 m¥kg) Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD” section. Cylinder bolts Timing chain guide (lower) Cylinder Dowel pin Cylinder gasket...

  • Page 119: Removing The Cylinder And Piston

    CYLINDER AND PISTON EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clip • piston pin • piston CAUTION: Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.
  • Page 120 CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. Cylinder XN 125 53.700 ~ 53.705 mm bore “C”...

  • Page 121: Checking The Piston Rings

    CYLINDER AND PISTON EAS00264 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, remove any carbon deposits from the piston ring grooves and piston rings.

  • Page 122: Checking The Piston Pin

    CYLINDER AND PISTON EAS00265 CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration / grooves → Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 14.991 ~ 15.000 mm 3.
  • Page 123 CYLINDER AND PISTON 2. Install: • piston • piston pin • piston pin clip NOTE: • Lubricate the piston pin with engine oil. • Make sure the arrow mark a on the piston points towards the exhaust side of the cylinder. •...

  • Page 124: Clutch

    CLUTCH EASM0026 CLUTCH CRANKCASE COVER 9 Nm (0.9 m¥kg) 10 Nm (1.0 m¥kg) 10 Nm (1.0 m¥kg) Order Job/Part Q’ty Remarks Removing the crankcase cover Remove the parts in the order listed. Side covers Refer SIDE COVERS AND SEAT” section in chapter 3. Air filter crankcase cover Air filter crankcase cover gasket Air filter crankcase element...
  • Page 125 V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE EASM0027 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 60 Nm (6.0 m¥kg) 55 Nm (5.5 m¥kg) Order Job/Part Q’ty Remarks Removing the V-belt, clutch and Remove the parts in the order listed. secondary/primary sheave Nut/plain washer/washer 1/1/1 Refer to “REMOVING THE PRIMARY Primary fixed sheave...
  • Page 126 V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE EASM0028 SECONDARY SHEAVE Apply BEL-RAY assembly lube ® 90 Nm (9.0 m¥kg) Order Job/Part Q’ty Remarks Disassembling the secondary Disassemble the parts in the order listed. sheave Refer to “DISASSEMBLING THE Clutch carrier SECONDARY SHEAVE”...

  • Page 127: V-Belt, Clutch And Secondary/Primary Sheave

    V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE REMOVING THE PRIMARY SHEAVE 1. Remove: • nut (primary sheave) • plate washer • primary fixed sheave NOTE: Loosen the nut (primary fixed sheave) while holding the primary fixed sheave with the rotor holder Rotor holder 90890-01235...

  • Page 128: Disassembling The Secondary Sheave

    V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE 3. Remove: • clutch assembly • V-belt NOTE: Remove the V-belt from the primary sheave side with clutch assembly. DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: • nut (secondary sheave) NOTE: Loosen the nut while attaching the clutch spring compressor and clutch spring holder...

  • Page 129: Checking The Clutch Housing

    V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE EAS00290 CHECKING THE CLUTCH HOUSING 1. Check: • clutch housing Damage/wearr → Replace. 2. Measure: • clutch housing inside diameter a Out of specification → Replace the clutch housing. Clutch housing inside diameter XN125: 120 mm XN150: 135 mm <Limit XN125>: 120.5 mm...

  • Page 130: Checking The Weights

    V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE CHECKING THE WEIGHTS 1. Check: • weight minimum outside diameter Cracks/wear/scaling/chipping → Replace. Out of specification → Replace. Weight out side diameter 20.0 mm <Limit>: 19.5 mm CHECKING THE SECONDARY SHEAVE 1. Check: •...

  • Page 131: Installing The Secondary Sheave

    V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE INSTALLING THE SECONDARY SHEAVE 1. Apply: • BEL-RAY assembly lube ® (to the secondary sliding sheave inner sur- face, grease nipple groove, and oil seals) • BEL-RAY assembly lube ® (to the bearings, oil seals and inner surface of the secondary fixed sheave) 2.
  • Page 132 V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE 6. Install: • V-belt • clutch assembly NOTE: Install the V-belt with the clutch assembly to the primary sheave side. CAUTION: Never smear grease to the V-belt, secondary sheave and clutch. 7. Install: •...

  • Page 133: Starter Clutch And Generator

    STARTER CLUTCH AND GENERATOR EASM0029 STARTER CLUTCH AND GENERATOR MAGNETO COVER AND STATOR COIL 7 Nm (0,7 m•kg) 70 Nm (7,0 m•kg) 7 Nm (0,7 m•kg) Order Job/Part Q’ty Remarks Removing the magneto cover and Remove the parts in the order listed. stator coil Side cover Refer to “SIDE COVERS AND SEAT”...

  • Page 134: Starter Cluth

    STARTER CLUTCH AND GENERATOR EASM0030 STARTER CLUTH 65 Nm (6,5 m•kg) 7 Nm (0,7 m•kg) Order Job/Part Q’ty Remarks Removing the starter clutch Remove the parts in the order listed. Gear retainer plane Washer Idle gear Washer Starter one way cluth Collar Starter wheel gear For installation, reverse the removal...

  • Page 135: Checking The Starter Clutch

    STARTER CLUTCH AND GENERATOR EAS00348 CHECKING THE STARTER CLUTCH 1. Check: • starter clutch idle gear • starter clutch wheel gear • starter one way clutch Chips/pitting/roughness/wear → Replace the defective part(s). 2. Check: • starter clutch operation a. Install the starter clutch drive gear onto the starter clutch and hold the starter clutch.

  • Page 136: Oil Pump

    OIL PUMP EASM0031 OIL PUMP 7 Nm (0,7 m•kg) 65 Nm (6,5 m•kg) Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Drain Engine oil Refer to “CHANGING THE ENGINE OIL” section in chapter 3. Flywheel Refer to “STARTER CLUTCH AND GENERATOR”...

  • Page 137: Checking The Oil Pump

    OIL PUMP EAS00363 CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear • oil pump housing • oil pump housing cover Cracks/damage/wear → Replace the defective part(-s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance A •...

  • Page 138: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT EASM0032 CRANKCASE AND CRANKSHAFT 9 Nm (0.9 m¥kg) 9 Nm (0.9 m¥kg) Order Job/Part Q’ty Remarks Removing the crankcase and Remove the parts in the order listed. crankshaft Engine Refer to “ENGINE” section. Cylinder head Refer to “CYLINDER HEAD” section. Cylinder and piston Refer to “CYLINDER AND PISTON”...
  • Page 139 CRANKCASE AND CRANKSHAFT 9 Nm (0.9 m¥kg) 9 Nm (0.9 m¥kg) Order Job/Part Q’ty Remarks Bolt Timing chain guide Screws Crankcase (right) Refer to “INSTALLING THE CRANK- SHAFT AND STARTER CLUTCH” section. Dowel pin Crankshaft assembly Timing chain Crankcase (left) For installation, reverse the removal procedure.

  • Page 140: Disassembling The Crankcase

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

  • Page 141: Checking The Crankshaft And Connecting Rod

    CRANKCASE AND CRANKSHAFT EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: • crankshaft runout Out of specification → Replace the crankshaft, bearing or both. NOTE: Turn the crankshaft slowly. Maximum crankshaft runout 0.03 mm 2. Measure: • big end side clearance Out of specification →...

  • Page 142: Checking The Crankcase

    CRANKCASE AND CRANKSHAFT EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase Cracks/damage → Replace. • oil delivery passages Obstruction → Blow out with compressed air. EAS00401 CHECKING THE BEARINGS AND OIL SEALS...

  • Page 143: Assembling The Crankcase

    CRANKCASE AND CRANKSHAFT EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: • 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. 2. Install: • dowel pins 3.

  • Page 144: Transmission

    TRANSMISSION EASM0033 TRANSMISSION 6.5 Nm (0,65 m•kg) Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Rear wheel Refer to “REAR WHEEL AND BRAKE” section in chapter 7. Crankcase cover (left) Refer to “V-BELT, CLUTH AND SECONDARY/PRIMARY SHEAVE”...
  • Page 145 TRANSMISSION 6.5 Nm (0,65 m•kg) Order Job/Part Q’ty Remarks Idle gear Main axle For installation, reverse the removal procedure. 4-49...

  • Page 146: Cool

    COOL...
  • Page 147 COOL CHAPTER 5. COOLING SYSTEM RADIATOR ....................5-1 CHECKING THE RADIATOR ..............5-3 INSTALLING THE RADIATOR ..............5-3 THERMOSTAT ....................5-4 CHECKING THE THERMOSTAT ............5-5 INSTALLING THE THERMOSTAT ............5-5 WATER PUMP ....................5-6 CHECKING THE WATER PUMP ............. 5-7 INSTALLING THE WATER PUMP ............

  • Page 148: Chapter 5. Cooling System

    COOL RADIATOR EASM0034 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Remarks Drain coolant Refer to “CHANGING THE COOLANT” section in chapter 3. Front cover Refer to “FRONT COVER, INNER PANEL AND INNER FRONT COVER” section in chapter 3. Footrest board Refer to “FOOTREST BOARD AND UNDER COVER”...
  • Page 149 COOL RADIATOR Order Job/Part Q’ty Remarks Remove: NOTE: Radiator Avoid the radiator of falling Radiator fan For installation, reverse the removal procedure.

  • Page 150: Checking The Radiator

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

  • Page 151: Thermostat

    COOL THERMOSTAT EASM0036 THERMOSTAT 9 Nm (0,9 m•kg) Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Drain coolant Refer to “CHANGING COOLANT” section in chapter 3. Refer to “SIDE COVERS AND SEAT” section in chapter 3. Hose Cylinder head outlet hose Thermostat cover fixing screws...

  • Page 152: Checking The Thermostat

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat Does not open at 80.5 ~ 83.5°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 153: Water Pump

    COOL WATER PUMP EASM0035 WATER PUMP 7 Nm (0.7m¥kg) 10 Nm (1.0m¥kg) 7 Nm (0.7m¥kg) Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. Drain coolant Refer to “CHANGING THE COOLANT” section in chapter 3. Pump inlet hose Pump outlet hose NOTE:...

  • Page 154: Checking The Water Pump

    COOL WATER PUMP EAS00472 CHECKING THE WATER PUMP 1. Check: • O-ring Damage/wear → Replace. • oil seal Damage/wear → Replace the water pump housing assembly. NOTE: The mark “water side” on the oil seal should be installed outward. 2. Check: •...
  • Page 155 COOL WATER PUMP 3. Install: • dowel pin • gasket • water pump housing cover • screws 7 Nm (0.7m•kg) • copper washer • bleed screw 7 Nm (0.7m•kg) NOTE: Do not forget to install the copper washer on the bleed screw.

  • Page 156: Carb

    CARB...
  • Page 157 CARB CHAPTER 6. CARBURETOR CARBURETOR ....................6-1 CARBURETOR REMOVAL ..............6-1 CARBURETOR DISASSEMBLY .............. 6-2 CHECKING THE CARBURETOR ............6-3 ASSEMBLING THE CARBURETOR ............6-5 MEASURING AND ADJUSTING THE FUEL LEVEL ....... 6-6 CHECKING THE AUTOCHOKE UNIT ............. 6-6 CHECKING THE FUEL COOK ..............6-7...
  • Page 158 CARB CARBURETOR EASM0038 CARBURETOR CARBURETOR Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Side cover Refer to “SIDE COVERS AND SEAT” Fuel tank in chapter section 3. Disconnect: Auto choke coupler Carburetor heater connectors Unplug: Fuel hose Remove:...
  • Page 159 CARB CARBURETOR Order Job/Part Q’ty Remarks Carburetor disassembly Remove the parts in the order listed. Auto choke unit Throttle stop screw set Pilot screw set Diaphragm cover/spring Throttle valve Needle set Accelerating pump lever NOTE: Float chamber/gasket Remove the float pin from the side of the Float axle arrow.
  • Page 160 CARB CARBURETOR EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber • jet housing Cracks/damage → Replace. 2. Check: • fuel passages 322006 Obstruction → Clean. a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution.
  • Page 161 CARB CARBURETOR 9. Check: • vacuum chamber cover • piston valve spring • jet needle holder Cracks/damage → Replace. 10. Check: • jet needle kit • main jet • needle jet • pilot jet • pilot screw Bends/damage/wear → Replace. Obstruction →...
  • Page 162 CARB CARBURETOR EAS00487 ASSEMBLING THE CARBURETOR CAUTION: • Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. • Always use a new gasket. 1. Install: • main jet holder • main jet • pilot jet 2. Install: •...
  • Page 163 CARB CARBURETOR EAS00499 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust Fuel level (below the float chamber mating surface) 5 ~ 6 mm a. Stand the scooter on a level surface. b.
  • Page 164 CARB CARBURETOR 2. Check: • autochoke unit a. Connect ø 3.3 mm hose to the starter air passage and blow into the hose. NOTE: When the starter plunger is open, air should come out of the other side of the starter air passage.

  • Page 165: Chas

    CHAS...
  • Page 166 CHAS CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISC ............. 7-1 REMOVING THE FRONT WHEEL ............7-2 CHECKING THE FRONT WHEEL ............7-3 CHECKING THE BRAKE DISC ............... 7-4 CHECKING THE SPEEDOMETER GEAR UNIT ........7-5 ASSEMBLING THE FRONT WHEEL ............7-5 INSTALLING THE FRONT WHEEL ............
  • Page 167 CHAS HANDLEBAR ....................7-31 CHECKING THE HANDLEBAR ............. 7-32 INSTALLING THE HANDLEBAR ............7-32 STEERING HEAD ..................7-34 REMOVING THE LOWER BRACKET ........... 7-35 CHECKING THE STEERING HEAD ............7-35 INSTALLING THE STEERING HEAD ............ 7-36 REAR SHOCK ABSORBER AND EXHAUST PIPE ........7-37 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....

  • Page 168: Chapter 7. Chassis

    CHAS FRONT WHEEL AND BRAKE DISC EASM0040 CHASSIS FRONT WHEEL AND BRAKE DISC FRONT WHEEL AND BRAKE DISC 23 Nm (2,3 m¥kg) 70 Nm (7,0 m¥kg) 23 Nm (2,3 m¥kg) Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed.

  • Page 169: 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 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 170: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00525 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bent → Replace. WARNING Do not attempt to straighten a bent wheel axle. 2. Check: • tyre •...

  • Page 171: Checking The Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC c. Remove the wheel bearings with a general bearing puller d. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing inner race or balls .

  • Page 172: Checking The Speedometer Gear Unit

    CHAS FRONT WHEEL AND BRAKE DISC 4. Adjust: • brake disc deflection a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. 23 Nm (2.3m•kg) NOTE: • Tighten the brake disc bolts in stages and in a crisscross pattern.

  • Page 173: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00540 INSTALLING THE FRONT WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips • speedometer gear unit • collar Recommended lubricant Lithium soap base grease 2. Install: • speedometer gear unit NOTE: Make sure that the speedometer gear unit and the wheel hub are installed with the projection...
  • Page 174 CHAS FRONT WHEEL AND BRAKE DISC 1. Remove: • balancing weight(s) 2. Find: • front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel.

  • Page 175: Rear Wheel And Brake

    CHAS REAR WHEEL AND BRAKE EASM0041 REAR WHEEL AND BRAKE 13.5 Nm (1.35 m•kg) 103.5 Nm (10.35 m•kg) Order Job/Part Q’ty Remarks Removing the rear wheel and brake Remove the parts in the order listed. Exhaust pipe (cylinder) Exhaust pipe (bracket holder) Rear brake adjuster Rear brake cable/spring Rear wheel axle nut...

  • Page 176: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE EAS00565 CHECKING THE REAR WHEEL 1. Check: • wheel axle • rear wheel • wheel bearings • oil seals Refer to “FRONT WHEEL AND BRAKE DISC” section. 2. Check: • tyre • rear wheel Damage/wear → Replace. Refer to “CHECKING THE TYRES”...

  • Page 177: Assembling The Brake Shoe Plate

    CHAS REAR WHEEL AND BRAKE NOTE: Replace the brake shoes as a set, if either is worn to the wear limit. 3. Measure: • brake drum inside diameter b Out of specification → Replace the wheel. Brake drum inside diameter limit 346008 (maximum) 130.5 mm...

  • Page 178: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL AND BRAKE NOTE: • Align the punch mark in the brake camshaft with the mark on the brake camshaft lever. • Lubricate the brake camshaft and pin with lithium soap base grease. WARNING After installing the rear brake camshaft, 346009 remove any excess grease.

  • Page 179: Front Brake

    CHAS FRONT BRAKE EASM0042 FRONT BRAKE FRONT BRAKE PADS 22Nm (2,2 m¥kg) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Front caliper Refer to “REMOVING THE FRONT WHEEL” section. Caliper fixing bolt Retaining clip Retaining pin Pad spring...

  • Page 180: Replacing The Front Brake Pads

    CHAS FRONT BRAKE EAS00579 CAUTION: Disc brake components rarely require disassembly. 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 181 CHAS FRONT BRAKE 4. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm 5. Install: • brake pad spring • brake pads NOTE: • Always install new brake pads and a new brake pad spring as a set.

  • Page 182: Front Brake Master Cylinder

    CHAS FRONT BRAKE EASM0043 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 m¥kg) 8.5 Nm (0.85 m¥kg) 23 Nm (2.3 m¥kg) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Drain brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...

  • Page 183: Master Cylinder

    CHAS FRONT BRAKE EASM0044 MASTER CYLINDER Order Job/Part Q’ty Remarks Disassembling the master cylinder Disassemble the parts in the order listed. Master cylinder Refer to “FRONT BRAKE MASTER CYLINDER” section. Master cylinder kit Master cylinder spring seat Spring For assembly, reverse the removal procedure.

  • Page 184: 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. 1. Disconnect: • brake switch coupler (from the brake switch) 2. Remove: • union bolt •...

  • Page 185: Assembling And Installing The Front Brake Master Cylinder- Warning

    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. WARNING Never use solvents on internal brake components. Recommended brake fluid DOT#3 or DOT#4 1.

  • Page 186: Disassembling The Front Brake Caliper

    CHAS FRONT BRAKE • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake master cylinder reservoir.

  • Page 187: Checking The Front Brake Caliper

    CHAS FRONT BRAKE a. Blow compressed air into the brake hose joint opening to force out the piston from the brake caliper. WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper.

  • Page 188: Assembling And Installing The Front Brake Caliper

    CHAS FRONT BRAKE EAS00635 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 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 as they will cause the piston seals to swell and distort.
  • Page 189 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 190: Front Fork

    CHAS FRONT BRAKE EASM0045 FRONT FORK FRONT FORK 45 Nm (4.5 m•kg) 33 Nm (3.3m•kg) 23 Nm (2.3 m•kg) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE” section.

  • Page 191: Front Fork Disassembly

    CHAS FRONT FORK EASM0046 FRONT FORK DISASSEMBLY 45 Nm (4.5 m•kg) 33 Nm (3.3m•kg) 23 Nm (2.3 m•kg) Order Job/Part Q’ty Remarks Disassembling the front fork Disassemble the parts in the order listed. Cap bolt O-ring Fork spring Dust seal Retaining clip Oil seal Bolt (damper rod)/Gasket...

  • Page 192: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00649 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 193: Checking The Front Fork Legs

    CHAS FRONT FORK Damper rod holder 90890-01294 T-handle 90890-01326 5. Remove: • inner tube a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vice with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully.

  • Page 194: Assembling The Front Fork Legs

    CHAS FRONT FORK CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.
  • Page 195 CHAS FRONT FORK 2. Lubricate: • inner tube’s outer surface Recommended lubricant Yamaha fork and fork oil SAE 10 or equivalent 3. Tighten: • damper rod assembly bolt 23 Nm (2.3m•kg) NOTE: While holding the damper rod assembly with the damper rod holder , tighten the damper rod assembly bolt.
  • Page 196 (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.125 L Recommended oil Yamaha fork and fork oil SAE 20 or equivalent CAUTION: • Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.

  • Page 197: Installing The Front Fork Legs

    CHAS FRONT FORK NOTE: Be sure to bleed the front fork leg of any residual air. 13. Measure: • front fork leg oil level a Out of specification → Correct. Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed, and without the spring) 80 mm...

  • Page 198: Handlebar

    CHAS FRONT FORK EASM0047 HANDLEBAR 10 Nm (1.0 m•kg) 10 Nm (1.0 m•kg) 10 Nm (1.0 m•kg) 10 Nm (1.0 m•kg) 60 Nm (6.0 m•kg) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Handlebar covers Refer to “HANDLEBAR COVERS”...

  • Page 199: Checking The Handlebar

    CHAS HANDLEBAR EAS00668 CHECKING 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. Check: • handlebar Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
  • Page 200 CHAS HANDLEBAR NOTE: Align the projection on the left handlebar switch with the hole in the handlebar. 6. Install: • brake lever holder NOTE: Align the mating surfaces of the brake lever holder with the punch mark a in the handlebar. 7.

  • Page 201: Steering Head

    CHAS STEERING HEAD EASM0048 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 Removing the steering head Remove the parts in the order listed. Front covers Refer to “FRONT COVERS”...

  • Page 202: 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: • ring nut (upper) • lock washer •...

  • Page 203: Installing The Steering Head

    CHAS STEERING HEAD CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: • Always replace the bearings and bearing races as a set. • Whenever the steering head is disassembled, replace the rubber seal. 354008 4.

  • Page 204: Rear Shock Absorber And Exhaust Pipe

    CHAS REAR SHOCK ABSORBER AND EXHAUST PIPE EASM0049 REAR SHOCK ABSORBER AND EXHAUST PIPE 4,5 Nm (0,45 m¥kg) 31,5 Nm (3,15 m¥kg) 27 Nm (2,7 m¥kg) 27 Nm (2,7 m¥kg) 11Nm (1,1 m¥kg) 17,5 Nm (1,75 m¥kg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.

  • Page 205: Checking The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER AND EXHAUST PIPE 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 206: Elec

    ELEC...
  • Page 207 ELEC CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS ..............8-1 SWITCHES ....................8-2 CHECKING SWITCH CONTINUITY ............8-2 CHECKING THE SWITCHES ................ 8-3 CHECKING THE BULBS AND BULB SOCKETS ........8-4 TYPES OF BULBS ................... 8-4 CHECKING THE CONDITION OF THE BULBS ........8-4 CHECKING THE CONDITION OF THE BULB SOCKETS ......

  • Page 208: Electrical Components

    ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS Wire harness Starter motor Battery Thermo switch Ignition unit (CDI) Flasher relay Main switch Horn Ignition coil Fuses Spark plug cap Relays Rectifier/Regulator Coolant thermo switch Fuel sender Carburator heater thermo switch Starter relay...

  • Page 209: 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 a.

  • Page 210: Checking The Switches

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

  • Page 211: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 212 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: • Be sure to hold the socket firmly when removing the bulb.

  • Page 213: 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: 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 214: Ignition System

    ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) LOCK OPEN (BLUE) (BLUE) CHECK GW BR Br Or B R - W W (BLACK) (RED) (RED) (BLACK) BW L ANTI-THEFT HANDLE SWITCH 2 ALARM (OPTION) L LB START...

  • Page 215: Troubleshooting

    ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery THE IGNITION SYSTEM FAILS TO • Check the condition of the battery. OPERATE (NO SPARK OR Refer to “CHECKING THE BATTERY” in INTERMITTENT SPARK). chapter 3. Check: Minimum open-circuit voltage 1. Main fuse °...
  • Page 216 ELEC IGNITION SYSTEM EAS00742 EAS00746 4.Ignition spark gap 6. Ignition coil resistance • Disconnect the spark plug cap from the spark • Disconnect the ignition coil connectors from plug. the ignition coil terminals. • Connect the ignition checker/dynamic spark • Connect the pocket tester (Ω X 1) to the tester as shown.
  • Page 217 ELEC IGNITION SYSTEM EAS00749 7.Main switch 9. Source coil resistance • Check the main switch for continuity. • Disconnect the source coil coupler from the Refer to “CHECKING THE SWITCHES”. wire harness. • Is the main switch OK? • Connect the pocket tester (Ω X 100) to the charging coil terminal as shown.

  • Page 218: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) LOCK OPEN (BLUE) (BLUE) CHECK GW BR Br Or B R - W W (RED) (BLACK) (RED) (BLACK) BW L ANTI-THEFT HANDLE SWITCH 2 ALARM (OPTION) L LB...

  • Page 219: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery THE STARTER MOTOR FAILS TO TURN. • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in Check: chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 3. starter motor °...
  • Page 220 ELEC ELECTRIC STARTING SYSTEM EAS00761 EASM0050 4.Starter relay 6. Front and Rear brake switch • Disconnect the starter relay coupler from the • Check the front and rear switches for conti- coupler. nuity. • Connect the pocket tester (Ω X 1) and battery Refer to “CHECKING THE SWITCHES”.

  • Page 221: Starter Motor

    ELEC STARTER MOTOR EASM0051 STARTER MOTOR 5 Nm (0.5 m.kg) 65 Nm (6.5 m.kg) Order Job/Part Q’ty Remarks Removing the starter motor Remove/disassemble the parts in the order listed. Side covers Refer to “SIDE COVERS AND SEAT” Box and seat section in chapter 3.
  • Page 222 ELEC STARTER MOTOR 5 Nm (0.5 m.kg) 65 Nm (6.5 m.kg) Order Job/Part Q’ty Remarks Brushes/Springs Brush holder/washer O-ring Starter motor front cover/O-ring For installation/assembly, reverse the removal/disassembly procedure. 8-15...

  • Page 223: Checking The Starter Motor

    ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator diameter 22 mm <Limit>: 21 mm 3.

  • Page 224: Assembling The Starter Motor

    ELEC STARTER MOTOR 5. Measure: • brush length a . Out of specification → Replace the brushes as a set. Brush length 10 mm <Limit>: 3.5 mm 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set.
  • Page 225 ELEC STARTER MOTOR 3. Install: • O-rings • washers • starter motor mounting bolts 5 Nm (0.5m•kg) • stater motor fixing bolts 65 Nm (6.5m•kg) 8-18...

  • Page 226: Charging System

    ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) LOCK OPEN (BLUE) (BLUE) CHECK GW BR Br Or B R - W W (RED) (BLACK) (RED) (BLACK) BW L ANTI-THEFT HANDLE SWITCH 2 ALARM (OPTION) L LB START...

  • Page 227: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery THE BATTERY IS NOT BEING CHARGED. • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in Check: chapter 3. 1. main fuse Minimum open-circuit voltage 2. battery ° 12.8 V or more at 20 3.
  • Page 228 ELEC CHARGING SYSTEM EAS00779 NOTE: 5. Wiring connections Make sure the battery is fully charged. • Check the wiring connections of the entire • Is the charging voltage within specification? charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly con- nected and without defects? The charging circuit is OK.

  • Page 229: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) LOCK OPEN (BLUE) (BLUE) CHECK GW BR Br Or B R - W W (RED) (BLACK) (RED) (BLACK) BW L ANTI-THEFT HANDLE SWITCH 2 ALARM (OPTION) L LB START...

  • Page 230: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. ANY OF THE FOLLOWING FAIL TO Refer to “CHECKING THE BATTERY” in LIGHT: HEADLIGHT, HIGH BEAM chapter 3. INDICATOR LIGHT, TAILLIGHT, AUXILIARY LIGHT OR INSTRUMENT Minimum open-circuit voltage LIGHT .

  • Page 231: Checking The Lighting System

    ELEC LIGHTING SYSTEM EAS00784 EAS00788 CHECKING THE LIGHTING SYSTEM 5.Hi/Lo beam switch 1. The headlight and the high beam indicator • Check the Hi/Lo beam switch for continuity. light fail to come on. Refer to “CHECKING THE SWITCHES”. 1. Headlight bulb and socket •...
  • Page 232 ELEC LIGHTING SYSTEM EAS00789 • Meter light coupler (wire harness side) 2. The meter light fails to come on. • Set the main switch to “ON”. 1. Meter light bulb and socket • Set the light switch to “ ”. •...
  • Page 233 ELEC LIGHTING SYSTEM EAS00790 EAS00791 3. The tail/brake light fails to come on. 4. The front postion light fails to come on. 1.Tail/brake light bulb and socket 1. Auxiliary light bulb and socket • Check the tail/brake light bulb and socket for •...

  • Page 234: Signaling System

    ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) LOCK OPEN (BLUE) (BLUE) CHECK GW BR Br Or B R - W W (RED) (BLACK) (RED) (BLACK) BW L ANTI-THEFT HANDLE SWITCH 2 ALARM (OPTION) L LB START...
  • Page 235 ELEC SIGNALING SYSTEM Main switch Fuse (main) Battery Horn switch Turn signal switch Left front flasher Right front flasher Left rear flasher Right rear flasher Tail/stop light Horn Flasher relay Coolant thermo indicator light 22 P Fuel sender indicator Clock and odometer Flasher light indicator Flasher light indicator Sender...

  • Page 236: Troubleshooting

    ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. ANY OF THE FOLLOWING FAIL TO Refer to “CHECKING THE BATTERY” in LIGHT: FLASHER LIGHT, BRAKE LIGHT chapter 3. OR AN INDICATOR LIGHT. THE HORN FAILS TO SOUND. Minimum open-circuit voltage °...

  • Page 237: Checking The Signaling System

    ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM • Disconnect the pink connector at the horn 1. The horn fails to sound. terminal. • Connect a jumper lead to the horn terminal 1.Horn switch and ground the jumper lead. •...
  • Page 238 ELEC SIGNALING SYSTEM EAS00798 • Set the main switch to “ON”. 2. The tail/brake light fails to come on. • Pull in the brake levers. 1.Tail/brake light bulb and socket • Measure the voltage (12 V) of yellow the tail/brake light coupler (wire harness side). •...
  • Page 239 ELEC SIGNALING SYSTEM 3. Voltage • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Connect the pocket tester (DC V 20) to the • Measure the voltage (12 V) on brown/white flasher relay coupler (wire harness side) as at the turn signal relay coupler (wire har- shown.
  • Page 240 ELEC SIGNALING SYSTEM EASM0052 EAS00804 4. The Coolant temperature warning light fails 5. The fuel level gauge fails to operate. to come on. 1. Fuel sender 1.Coolant temperature warning light bulb and • Remove the fuel sender from the fuel tank. socket •...
  • Page 241 ELEC SIGNALING SYSTEM 2.Voltage 4. Wiring • Connect the pocket tester (DC V 20) to the • Check the entire signal system’s wiring. meter light coupler (wire harness side) . Refer to “CIRCUIT DIAGRAM”. Positive tester probe → brown • Is the signalling system’s wiring properly Negative tester probe →...
  • Page 242 ELEC SIGNALING SYSTEM EAS00805 6. The clock/odometer fails to come on. 1.Voltage • Connect the pocket tester (DC V 20) to the clock/odometer coupler (wire harness side) as shown. Positive tester probe → red Negative tester probe → ground • Set the main switch to “ON”. •...

  • Page 243: Cooling System

    ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) LOCK OPEN (BLUE) (BLUE) CHECK GW BR Br Or B R - W W (RED) (BLACK) (RED) (BLACK) BW L ANTI-THEFT HANDLE SWITCH 2 ALARM (OPTION) L LB START...

  • Page 244: Troubleshooting

    ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • The radiator fan motor fails to turn. • Check the condition of the battery. • The water temperature warning light Refer to “CHECKING THE BATTERY” in fails to light up when the engine is warm. chapter 3.
  • Page 245 ELEC COOLING SYSTEM • Does the radiator fan motor turn? A Thermo switch circuit “ON” B Thermo switch circuit “OFF” The radiator fan motor is faulty and must be replaced. EAS00811 6.Thermo switch • Remove the thermo switch from the radiator. •...
  • Page 246 ELEC COOLING SYSTEM EAS00739 Temperature sender resistance ° Ω 2. Battery C: 47.5 ~ 56.8 ° Ω C: 26.2 ~ 29.3 • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in WARNING chapter 3. • Handle the temperature sender with Minimum open-circuit voltage special care.

  • Page 247: Carburetor Heating System

    ELEC CARBURETOR HEATING SYSTEM EAS00820 CARBURETOR HEATING SYSTEM CIRCUIT DIAGRAM WIRE LEAD sur SIDE STAND (OPTION) (BLUE) LOCK OPEN (BLUE) (BLUE) CHECK GW BR Br Or B R - W W (RED) (BLACK) (RED) (BLACK) BW L ANTI-THEFT HANDLE SWITCH 2 ALARM (OPTION) L LB...
  • Page 248 ELEC CARBURETOR HEATING SYSTEM EAS00821 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The carburetor heating system fails to Refer to “CHECKING THE BATTERY” in operate. chapter 3. Check: Minimum open-circuit voltage 1. Main fuse ° 12.8 V or more at 20 2.
  • Page 249 ELEC CARBURETOR HEATING SYSTEM EAS00823 EAS00824 4. Thermo switch 5. Carburetor heater • Disconnect the thermo switch from the wire • Remove the carburetor heating element from harness. the carburetor. • Connect the pocket tester (Ω x 1) to the •...

  • Page 250: Trbl Shtg

    TRBL SHTG...

  • Page 251: Troubleshooting

    TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/ HARD STARTING ............ 9-1 ENGINE ....................9-1 FUEL SYSTEM ..................9-1 ELECTRICAL SYSTEMS ................. 9-2 INCORRECT ENGINE IDLING SPEED ............9-2 ENGINE ....................9-2 FUEL SYSTEM ..................9-2 ELECTRICAL SYSTEMS ................. 9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ....... 9-2 ENGINE ....................
  • Page 252 TRBL SHTG UNSTABLE HANDLING ................9-5 FAULTY LIGHTING OR SIGNALING SYSTEM ..........9-5 HEADLIGHT DOES NOT LIGHT ............. 9-5 HEADLIGHT BULB BURNT OUT ............9-5 TAIL/BRAKE LIGHT DOES NOT LIGHT ..........9-5 TAIL/BRAKE LIGHT BULB BURNT OUT ..........9-5 TURN SIGNAL DOES NOT LIGHT ............9-5 TURN SIGNAL BLINKS SLOWLY ............

  • Page 253: Starting Failure/Hard Starting

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

  • Page 254: Electrical Systems

    STARTING FAILURE/HARD STARTING/ TRBL INCORRECT ENGINE IDLING SPEED/ SHTG POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ELECTRICAL SYSTEMS Ignition system Battery • Improperly charged battery • Faulty ignition unit • Faulty pickup coil • Faulty battery • Broken generator rotor woodruff key/slipped Fuse(s) timing •...

  • Page 255: Faulty Clutch

    TRBL FAULTY CLUTCH/ SHTG OVERHEATING EAS00853 FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL POOR STARTING PERFORMANCE NOT MOVE V-belt V-belt • V-belt slips • Bent, damaged or worn V-belt • Oil or grease on the V-belt • Slipping V-belt Primary sliding sheave Primary pulley cam and primary pulley slider •...

  • Page 256: Overcooling

    OVERCOOLING/ TRBL POOR BRAKING/ SHTG FAULTY FRONT FORK LEGS EAS00856 OVERCOOLING COOLING SYSTEM • Thermostat • Thermostat stays open EAS00859 POOR BRAKING Disc brake Drum brake • Worn brake pad • Worn brake shoe • Worn brake disc • Worn or rusty brake drum •...

  • Page 257: Unstable Handling

    TRBL UNSTABLE HANDLING/ SHTG FAULTY LIGHTING OR SIGNALING SYSTEM EAS00862 UNSTABLE HANDLING Handlebar Rear shock absorber assembly • Faulty rear shock absorber spring • Bent or improperly installed handlebar • Leaking oil or gas Steering head components • Improperly installed lower bracket Tyres •...
  • Page 258 TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG TURN SIGNAL REMAINS LIT HORN DOES NOT SOUND • Faulty turn signal relay • Improperly adjusted horn • Burnt-out turn signal bulb • Damaged or faulty horn • Faulty main switch TURN SIGNAL BLINKS QUICKLY •...
  • Page 259 XN125-150 WIRING DIAGRAM COLOR CODE B ..... black Sb ... sky blue G / R ..green / red R / L ..red / blue Br .... brown W .... white G / W ..green / white R / W ..red / white Ch ...

This manual is also suitable for:

Xn150 2000

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