Yamaha Zuma Scooter Repair And Maintenance Manual i373m

(0.003 in)

1

4.

Inspect: • Bearing(piston pin) Pitting/Da m a g e ~ R e p l a c e .

P I S T O N PIN A N D P I S T O N I N S T A L L A T I O N

1.

.

4-8

Apply: • Engine oil (to the crankshaft bearing, connecting rod big end bearing, small end bearing, piston pin, piston ring g r o o v e s and piston skirt areas.)

Install: • Reed valve gasket • Reed valve • Carburetor t (~ ~ l 11Nrn(1.1m.kg,

8ft.lb~

OV',.OE..EAO. CV',°OE. A.O ,,StO. I E"O I0 '1 3.

Q~

°-, J

Install: • Small end bearing • Piston (~ • Piston pin (~)

• Piston pin clip ~) NOTE: • The a r r o w (~ on the piston to the e x h a u s t side. • Before installing the piston pin clip, cover the crankcase w i t h a clean towel or rag so you will not accidentally drop the pin clip material into the crankcase. • A l w a y s use a n e w piston pin clip.

CYLINDER AND CYLINDER HEAD 1. Install: • Cylinder gasket (new gasket) 2. Check: • Piston rings (~ 1st ring (~ 2nd ring NOTE:

Make sure the ring ends (~ are properly fitted around the ring locating pins (~) in the piston grooves.

3.

•

r/

Install: • Cylinder (~ NOTE:

0

Install the cylinder w i t h one hand w h i l e compressing the piston rings w i t h the other hand.

4-9

O*'.°OE..EAO. C*'.°OE. A°O P.S*O. I' "0 I0 .1 4.

Install: • Cylinder head gasket (new gasket) 5. Install: • Cylinder head (~ ~114Nm(1.4m.kg,10ft.lb) • Spark plug (~) r~120Nm(2.0m.kg,14ft.lb) • Air shroud NOTE: Tighten the cylinder head holding nuts in stage, using a crisscross pattern.

4-10

V-BELT, CLUTCH A N D V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE KICK STARTER AND CRANKCASE COVER (LEFT)

12Nm(1.2m.kg, 8.4 ft.lb)~

4 ~ 3

I ~ l 7Nm(0.Tm.kg, 5.1 ft.lb

//

I~190Nm(0.9m.kg, 6.5 ft.lb) I

Order

1 2 3 4 5

Job name/Part name

Q'ty

Kick starter and crankcase cover (left) removal Kick starter Crankcase cover 2 (left) Crankcase cover 1 (left) Gasket Pin

Remarks Remove the parts in order.

Reverse the removal procedure for installation.

4-11

V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE

I ENG

V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE KICK STARTER

®

Order

(# ® ® ® ® ®

J o b name/Part n a m e

Q'ty

Remarks R e m o v e the parts in order.

Kick starter r e m o v a l Crankcase c o v e r 1 (left) r e m o v a l Kickstarter p i n i o n gear Kickstarter p i n i o n gear clip Circlip/Plain w a s h e r Kickstarter s e g m e n t gear Return s p r i n g Collar

1 1 1/1 1 1 1 Reverse the r e m o v a l p r o c e d u r e for installation.

4-12

V-BELT, CLUTCH AND

SECONDARY/PRIIVIARY SHEAVEI ENG I ~>= I KICK S T A R T E R I N S T A L L A T I O N 1. Install: Return spring • Kickstarter segment gear (~ • Collar (~ • Plain w a s h e r (~ • Circlip (~

Installation steps: a. Install return spring (~ and s e g m e n t gear (~ as s h o w n . b. Install clip (~. c. Hook the spring onto the crankcase projection (~. d. Install the kick starter pinion gear (~ and the kick starter.

4-13

V-BELT" CLUTCH AND I I~)~1 ENG SECONDARY/PRIMARY SHEAVE V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

3 2

t/~~ /

7

,~

10 Order

8 ~

~145Nm(4.5m.kg,33ft.lb)

v

J o b name/Part name

Remarks

Q'ty

V-belt, clutch and s e c o n d a r y / p r i m a r y sheave removal Lower cowling Air s h r o u d 3

1 2 3 4 5 6 7 8 9 10

/

~QI40 N m(4.0 m.kg,29ft.lb)

Crankcase cover (left) Clutch h o u s i n g S e c o n d a r y sheave a s s e m b l y V-belt Conical w a s h e r / O n e - w a y clutch Crow washer Primary fixed sheave Collar/Washer Primary sliding sheave Cam/Slider Weight

Remove the parts in order. ]Refer to "COVER A N D " section in chapter 3.

1 1 1 1/1 1

Refer to "ENGINE R E M O V A L " section. -I Refer to "SECONDARY SHEAVE A N D VJ BELT REMOVAL " section. -

Refer to " P R I M A R Y SHEAVE REMOVAL ASSE M BLY" section.

1 1/1 1 1/3 6 Reverse the removal procedure for installation 4-14

V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE

I

I ENG

SECONDARY SHEAVE

/

[~150Nm(5.0m.kg,

""-4 Order

(# ® ® ® ® ® @ ® ® ®

Job name/Part name

Q'ty

Secondary sheave d i s a s s e m b l y Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave

Remarks Disassemble the parts in order.

1 1 2 1 1 2 1 2 2 1

Refer to "SECONDARY SHEAVE DISASS E M B L Y " section. Refer to " S E C O N D A R Y SHEAVE INS T A L L A T I O N " section. Refer to " S E C O N D A R Y S T A L L A T I O N " section.

SHEAVE IN-

Reverse the d i s a s s e m b l y procedure for assembly.

4-15

36ft.lb)

V-BE'T" O'UTC" A"O I ENG Io =1

S E C O N D A R Y / P R I M A R Y SHEAVE /

i

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

®

®. I ~

I Rotor holdiyu_01235ngtool:

I

3. Remove: • Conical spring washer (~ • One-way clutch ® • Washer (~ • Primary fixed sheave (~ • Shim (~ • V-Belt 4. Remove: • Collar (~ • Primary sheave assembly®

SECONDARY SHEAVE REMOVAL 1. Remove: • Nut (~ (secondary sheave)

NOTE: Hold the secondary sheave using sheave holder

®. I<~1

Sh eave holder: YU-01701

2. Remove: • Clutch housing • Secondary sheave assembly • Dowel pins

4-16

I

V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE 3.

I ENG I{ =l

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

(#. ~

Roter holding tool" YU-01235

]

CAUTION: Do not r e m o v e the clutch securing nut yet. If the nut is r e m o v e d w i t h o u t c o m p r e s s i o n g the secondary sheave. It j u m p s and causes injury.

4. Attach: • Clutch spring holder (~ I<~l

CI utch holder:ys_28891 spring

5.

Remove: • Clutch securing nut (~)

6.

Remove: • Clutch assembly (~ • Clutch spring (~ • Spring seat (~ • Guide pins • Secondary sliding sheave

CLUTCH I N S P E C T I O N

1. Inspect: • Clutch shoes Glazed parts-->Sand with coarse sandpaper. NOTE:

After using the sand paper, clean of the polished particles with cloth.

4-17

V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE .

I ENG

Measure: • Clutch shoe thickness (~ Out of specification-->Replace. Clutch shoe thickness: 4 mm (0.16 in) < Wear limit>: 2.5 mm (0.1 in)

V-BELT I N S P E C T I O N 1. Inspect: • V-belt(~ Crack->Replace. NOTE:

Replace the V-belt smeared w i t h a lot of oil or grease. .

~ 1

4-18

Measure: • V-belt w i d t h (~ Out of specification-->Replace. V-belt width" 16.6 mm(0.65 in) <Wear limit>: 14.6 mm(0.57 in)

V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE

I

i ENG

PRIMARY SHEAVE INSPECTION

1.

Inspect: • Primary sliding sheave (~ • Primary fixed sheave (~) Wea r/Cracks/Scratch/Da mage -->Replace.

.

Check: • Free m o v e m e n t Insert the collar (~into the p r i m a r y sliding sheave(~, and check for free movement. Stick or excessive p l a y - > R e p l a c e the sheave or collar.

.

Measure: • Out side d i a m e t e r (~) (weight) Out of specification-->Replace.

----~Out

4-19

side d i a m e t e r (weight) 15.0 mm(0.59 in) (0.57 in)

V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE SECONDARY

1.

I

I ENG

SHEAVE

Inspect: • S e c o n d a r y fixed s h e a v e ( ~ • Secondary sliding sheave (~

Scratch/Crack/Damage-->Replace

as a

set. • Oil seal ( ~ Da mage-->Replace

.

Inspect: • T o r q u e cam g r o v e ( ~ • G u i d e pin (~) Wear/Damage-->Replace as a set. • O - r i n g s (~) Damage-->Replace.

.

Measure: • Clutch s p r i n g free l e n g t h Out of specification-->Replace. Clutch s p r i n g free length: 94 m m ( 3 . 7 in) : 91 m m ( 3 . 5 8 in)

4.

Inspect: • Clutch h o u s i n g i n n e r surface Oil/Scratches--~Remove. Oil

Scratches

.

Use a rag soaked in lacquer t h i n n e r or s o l v e n t . Use an e m e r y cloth ( l i g h t l y and e v e n l y p o l i s h i n g ) .

Measure: • Clutch h o u s i n g i n s i d e d i a m e t e r ( ~ Out of specification-->Replace. Clutch h o u s i n g inside d i a m e t e r : 105 m m ( 4 . 1 3 in) < W e a r limit>: 105.5 m m ( 4 . 1 5 in)

4-20

V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE SECONDARY

SHEAVE

I ENG I~=1

INSTALLATION

When assembling the secondary sheave, reverse the d i s a s s e m b l y procedure. Note the following points. . Apply: • Lithium soap base grease (to the inside of the sliding/fixed sheave)

2.

Install: • Sliding sheave (~

NOTE:

Be careful so that the oil seal (~ lips are not turned over w h e n installing the sheave. 3.

Apply: • Lithium soap base grease (to the torque cam grooves and O-rings)

4.

Install: • Guide pin (~ Check: • Sliding sheave U n s m o o t h operation-->Repair.

5.

.

Install: • Clutch securing nut (~ Use clutch spring holder (~

c,utchs0r,n0ho,der s288l I .

Tighten: • Clutch securing nut (~ I%~%150Nm(5.0 m.kg, 36 ft.lb) Use Flywheel holding tool

otorho,d,n0too,o01`0

4-21

I

I

V-BELT, C L U T C H A N D SECONDARY/PRIMARY SHEAVE 8.

I

I ENG

Install: • Secondary sheave assembly • Clutch h o u s i n g ( ~ • V-belt (~)

NOTE:

The V-belt m u s t be i n s t a l l e d w i t h t h e a r r o w fro ntwa rd.

.

Tighten: • Nut ( ~ (secondary sheave)

1~140 Nm(4.0 m.kg, 29 ft.,b)I Use s h e a v e h o l d e r ( ~

Sheaveho'der: YU-01701

PRIMARY

1.

.

Install: • Weight (~ • Cam@ • Slider (~ • Collar ( ~

.

Check: • Cam o p e r a t i o n Not s m o o t h . R e p a i r .

@

4.

.

4-22

SHEAVE

Clean: • P r i m a r y s l i d i n g s h e a v e face ( ~ • P r i m a r y fixed s h e a v e face ( ~ • Collar ( ~ • Weight (~ • P r i m a r y s l i d i n g s h e a v e cam surface (~)

Install: • Primary sheave assembly (~ • Collar (~) Install: • V-belt

I

V-BELT, CLUTCH A N D S E C O N D A R Y / P R I M A R Y SHEAVE .

/

I ENG I%=I

Install: • Shim (~ • Primary fixed sheave ~) • Washer (~ • One-way clutch (~ • Conical spring washer (~) • Nut(~

. Tighten: • Nut (~ (primary sheave) [%l 45 Nm(4.5 m.kg, 31ft.lb)

J

i

N O T E :

When tightening the nut (primary sheave), hold the C.D.I. magneto using Flywheel Holding Tool

®.

~l

.

9.

4-23

~°t°r t°°':¥~-01 h°'~d'n°

I

Adjust: • V-belt O Tense the V-belt by turning the primary sheave several times. Install: • Fan

~I

7 Nm

(0.7 m.kg, 5.1

~.,blI

S T A R T E R CLUTCH A N D STARTER M O T O R

I ENG I~ll

S T A R T E R CLUTCH A N D STARTER M O T O R ~TARTER C L U T C H A N D S T A R T E R M O T O R 11

~,

,10

9.4 ft.lb 4

9

J

3

Ns,ml0 8mk0.58,t,b 6

8

Order

Job name/Part name S t a r t e r clutch and s t a r t e r m o t o r removal Left/Right side cover Center cover Lower cowling Air shroud 3 Cooling fan Rear wheel Crankcase cover (left)l,2 Primary sheave

1 2 3 4 5

Remarks

Q'ty

Remove the parts in order.

]

Refer to "COVERS A N D PANE L " section in chapter 3. Refer to "C.D.I. M A G N E T O

"

section

Refer to "REAR WHEEL" section in chapter 6. Refer to "KICKER STARTER " section. Refer to "V-BELT, PRIMARY SHEAVE " section.

Plate Plain w a s h e r Idle gear Plain w a s h e r Starter clutch 4-24

STARTERCLUTCH AND STARTERMOTOR I ENG I ~TDI 11

~.

.10

9.4 ft.lb 4

3

Ns.ml0.sm.k0.5.8 ft.,b

9

8

Order 6 7 8 9 10 11

Job name/Part name

Q'ty

Remarks

1 1 1 1 1 2

Gear boss Bearing Starter wheel gear Plate w a s h e r Starter m o t o r Starter m o t o r coupler

Reverse the removal instalation

4-25

procedure for

STARTERCLUTCHAND STARTERIVIOTORI ENG I {~

I

STARTER CLUTCH AND GEARS INSPECTION 1. Inspect: • Starter c l u t c h Push t h e d o w e l pin to a r r o w d i r e c t i o n . U n s m o o t h operation-->Replace starter clutch a s s e m b l y .

2. Inspect: • Starter w h e e l gear teeth ( ~ • Idle gear teeth (~) B rrs/C u h ps/Ro i u g ess/Wea h n r-->Re la ce. p

3. Inspect: • Starter clutch o p e r a t i o n

c::C> F~

Clutch o p e r a t i o n c h e c k i n g steps: • Install the starter w h e e l gear to the starter clutch, and hold t h e starter clutch. • W h e n t u r n i n g t h e w h e e l gear c l o c k w i s e [ ] the starter c l u t c h and the w h e e l gear s h o u l d be e n g a g e d . If not the starter c l u t c h is faulty. Replace it. • W h e n t u r n i n g the w h e e l gear c o u n t e r clockw i s e [~], the w h e e l gear s h o u l d t u r n freely. If not, the starter c l u t c h is faulty. Replace it.

4-26

C.O.'."'°"ETO ENO I O '1 I C.D.I. M A G N E T O .'.D.I. M A G N E T O

5

.

4

7

,0i80 m(3.8 m.kg, 27 ft.lb) I

[ ~ 1 7 N m ( 0 . 7 m . k g " 5.1ft.lb) i

17Nm(0.7m.kg,

5.1 ft.I ) I

1

Order

1 2 3 4 5 6 7 8

Q'ty

Job name/Part name

R e mks a r R e m o v e t h e parts in o r d e r .

C.D.I. m a g n e t o r e m o v a l Rear c a r r i e r Tail c o v e r Left side c o v e r Right side cover Center cover Lower cowling Air shroud 1 Fan/O-ring Magneto rotor Bind C o u p l e r s ( m a g n e t o leads) S t a t o r coil W o o d ruff key Gasket ( M a g n e t o c o v e r )

Refer to " C O V E R A N D P A N E L " s e c t i o n in c h a p t e r 3.

1 1/1 1 1 1 1 1 1 R e v e r s e t h e r e m o v a l p r o c e d u r e f o r installation.

4-27

co, MAo.ETol E"° I o --I C.D.I. M A G N E T O

1.

REMOVAL

Remove: Nut (~(roto r) • Plain washer •

NOTE:

Hold the rotor to loosen the nut bythe flywheel holding tool (~. I<~l 2.

Rotor holdiyu_01235ng tool:

I

Remove: • Rotor O • Wood ruff key Use the flywheel magneto puller (~.

I<~l

Flywheel puller: YU-01189

I

• Stator assembly • Gasket C.D.I. M A G N E T O

1. 2.

3. 4. 5.

INSTALLATION

Install: • Gasket (~ Apply: • Lithium soap base grease (to oil seal) the C.D.I. magneto lead through the crankcase hole. Install: • Stator assembly[R e Nm(0.8 8 m.kg, 5.8 ft.lb) I Install: • Wood ruff key • C.D.I. magneto Rotor (~ • Plain washer • Nut ~~;~l 38Nm(3.S m.kg, 31.1ft.lb) I

NOTE:

• Clean the tapered portion of the crankshaft and the magneto rotor hub. • When installing the magneto rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft. • Do not allow the rotor holding tool to touch the projection on the magneto rotor.

4-28

AOTO'OBEPUMP I E"O I O '1 AUTOLUBEPUMPF ~ AUTOLUBE PUMP

5

JZ

// \

2

,~314Nm(0.4m.kg, 2.8ft.l~b)i /\ ' ~

'~

1

~

7

Order

1 2 3 4 5 6 7

Job name/Part name

Q'ty

Remarks Remove the parts in order. Refer to "C.D.I. magneto" section.

Autolube pump removal C.D.I. magneto Air shroud 2. Circlip Pump drive gear Pin Oil hose Oil delivery hose Autolube pump ass'y

1 1 1 1 1 1 1

Refer to "Autolube pump installation" section Reverse the removal procedure for installation.

4-29

AUTOLUBE PUMP

I ENG I{~]DI

AUTOLUBE PUMP INSTALLATION

CAUTION: A f t e r installing a u t o l u b e p u m p , it m u s t be bleeded.

1.

2.

3. 4.

Install • Pin O • P u m p d r i v e gear (~) • Circlip ~ Apply: • L i t h i u m soap base (to O-ring) Install: • Autolube pump (~ Apply: • L i t h i u m soap base (to a u t o l u b e p u m p

grease

[~J4 Nm(0.4m.kg, 2.8ft.lb~ grease gear (~,(~)

15 cc (0.92 cu o in)

4-30

T.A.SM.SS.O. I E"O I o '1 TRANSMISSION TRANSMISSION

I

/

4

[~418Nm(1.8

Order

/

~

O

m.kg,

13ft.lb

Job name/Part name

I

Q'ty

6

7

a r ks

"

Drain the transmission oil.

4

R e m

Remove the parts in order. Refer to "REAR WHEEL/REAR BRAKE section in chapter 7. Refer to "V-BELT, CLUTCH, SECONDARY/ PRIMARY SHEAVE" section Refer to " T R A N S M I S S I O N OIL REPLACEMENT " section in chapter 3.

Secondary sheave

5

2 I~112N m(1.2 m.kg, 8.4ft.lb)

Transmission removal Rear wheel

1 2 3

/"

Transmission case cover Gasket (transmission case cover) Dowel pin Primary drive gear Drive gear Circlip Main axle

1 1 2 1 1 1 1

4-31

TRANSMISSIONI ENGI~>]DI -

3

5

/

4/

I.~..~ ~

[~112Nm(1"2m'kg• 8"4ft'lb:

[~'~11 8Nm(1.8 m.kg, 13ft.lb I

Order 8


Q'ty

Drive axle

Remarks

1 Reverse the r e m o v a l p r o c e d u r e for installation.

4-32

C R A N K C A S E A N D REED V A L V E

I ENG I TDI

C R A N K C A S E A N D REED V A L V E C R A N K C A S E A N D REED V A L V E

~19Nm(0.9m.kg,6.5ft.lb)l ~112Nm(1.2m.kg,8.4ft.lb) I

4

1 1 N m ( 1 1 m kg,8ft Ib) I

~ Order

j

3

j,

~

~

j - J

J"


Q'ty

R e mks a r

Crankcase a n d Reed valve r e m o v a l

R e m o v e the parts in order.

Engine removal C y l i n d e r head, c y l i n d e r , p i s t o n

Refer to " E N G I N E R E M O V A L " section. Refer to "CYLINDER HEAD CYLINDER A N D PISTON" section. Refer to " K I C K STARTER A N D CRANKCASE COVER (LEFT) " section. Refer to "V-BELT, CLUTCH A N D SECO N D A R Y / P R I M A R Y SHEAVE " section. Refer to "C.D.I. M A G N E T O " section. Refer to "STARTOR CLUTCH AND STARTOR M O T O R " section. Refer to " A U T O L U B E P U M P " section. Refer to " R E A R W H E E L A N D REAR BRAKE" section in c h a p t e r 6. Refer to " T R A N S M I S S I O N " section.

Crankcase c o v e r (left) V-belt, clutch, secondary/primary sheave C.D.I. m a g n e t o Starter clutch, starter m o t o r Autolube pump Rear w h e e l Transmission

4-33

CRANKCASE AND REEDVALVE

~19Nm(0.9m.kg,6.5ft.lb)l

I ENG I >]DI

~ 1 1 2 N m ( 1 . 2 m . k g , 8.4ft.lb) I

4

11Nm(1 l m kg,8ft Ib) I

~ Order 1 2 3 4

5 6

7 8 9

10

j

3

j.

~

~

j-J

J"

Job name/Part name

Q'ty

Intake manifold Reed valve Valve seat gasket Stopper Crankcase 2 Dowel pin Engine m o u n t spacer Circlip Bearing Oil seal

Remarks

1 1 1 1 1 2 1 1 1 1 Reverse the removal procedure for installation.

4-34

O.A°KOASEA°O.EEOVA'VE I E"O Io =1 CRANKCASE(RIGHT) REMOVAL

1.

Remove: • Oil seal s t o p p e r (~ • Screws ( c r a n k c a s e ~ 19Nm(0.9 m.kg,6.5ft.lb ! NOTE: Loosen each s c r e w 1/4turn, and remove t h e m after all are loosened.

=~r~ri

2.

Attach: • Crankcase separating tool (~

I<~l

CrankcaSeyu_01135se pa rating tool:

I

NOTE:

Fully tighten the tool holding bolts, but make sure the tool b o d y is parallel w i t h the case. If n e c e s s a r y , o n e s c r e w m a y be b a c k e d o u t slightly to level tool body. .

Remove • Crankcase (right) As pressure is applied, alternately tap on the engine m o u n t i n g bosses.

C H E C K I N G THE C R A N K C A S E

1.

4-35

T h o r o u g h l y w a s h the crankcase halves in a mild solvent. 2. T h o r o u g h l y clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase Cracks/damage --> Replace. • oil delivery ages O b s t r u c t i o n --> B l o w o u t w i t h c o m pressed air. C H E C K I N G THE B E A R I N G S A N D OIL SEALS 1. Check: • bearings Clean and lubricate the bearings, then rotate the inner race w i t h y o u r finger. Rough m o v e m e n t --> Replace. 2. Check: • oil seals D a m a g e / w e a r ~ Replace.

C R A N K C A S E A N D REED V A L V E

I ENG I TDI

REED V A L V E I N S P E C T I O N

1.

Measure: • Valve stopper height (~ Out of specification-->Adjust stopper/Replace valve stopper.

I ~ l

Valve stopper height (~ 6.0~6.4 mm(0.24~0.25 in)

. Measure: • Reed valve clearance @) Out of specification-->Replace va lye.

reed

lReedvavecearance I I Less than 0.2 mm(0.0079 in)

C R A N K C A S E (RIGHT) I N S T A L L A T I O N

1.

Install: • Dowel pins (~ • Engine mount spacer (~ 2. Apply: • Sealant (~) To the mating surfaces of both case helves. ~ 1

Quick gasket®: ACC-1100-15-01

NOTE:

Do not allow any sealant to come into with the oil galley.

-ii -I; "

I

3. Attach: • Crankshaft installing tool (~,~) Crankshaft installation set (~ YU-90050 Crankshaft installer adapter (M 10)~) YU-90062

4-36

I

.OASE A.O.EEO VA'VE I E"O Io .1 4.

Tighten: • Crankcase holding screws [ ~ l 12 Nm(1.2 m.kg,8.4 ft.lb)

I

NOTE:

T i g h t e n t h e c r a n k c a s e h o l d i n g s c r e w s in stage, using a crisscross pattern. ,4

5.

6.

Check: • Crankshaft operation Unsmnothoperation Install:

Repair.

• Oil seal ( r i g h t c r a n k case) ( ~ A p p l y g r e a s e on to oil seal lip.

.

Install: • Oil seal s t o p p e r plate ( ~

H

.

4-37

.ml09 9

m.kg, 6.5

Install: • Gasket • Reed v a l v e • Intake m a n i f o l d (~I~111 Nm(1.1

ft.lb)

m.kg,

I

8 ft.lb)

I

KS.AFT I ENO I O ,,I CRANKSHAFT CRANKSHAFT

~

4

2

Order

Job name/Part name

Q'ty

Crankshaft removal Right crankcase r e m o v a l 1 2 3 4

R e mks a r R e m o v e the parts in order. Refer to " C R A N K C A S E A N D V A L V E " section.

Crankshaft Bearing Oil seal Crankcase c o v e r (left)

REED

1 2 2 1 Reverse the r e m o v a l p r o c e d u r e for instal lation.

4-38

KS.AFT I E"O I o '1 CRANKSHAFT REMOVAL 1. Attach: • Crankcase s e p a r a t i n g tool ( ~ ~

l

Crankcase s e p a r a t i n g t o o l : YU-01135-A

2.

Remove: • Crankshaft (~ NOTE: Make sure the crankcase s e p a r a t i n g tool is centered o v e r t h e c r a n k s h a f t a s s e m b l y .

CRANKSHAFT INSPECTION 1. Measure: • Runout limit " C" • C o n n e c t i n g rod big end side clearance

F

iJ g rr

• Small end free play l i m i t " F " Out of specification-->Replace. Use V-blocks, dial g a u g e and t h i c k n e s s gauge.

--H ~-- D

Runout limit "C": 0.03 m m ( 0 . 0 0 1 2 in) C o n n e c t i n g rod big end side clearance " D " : 0.2 ~ 0.5 m m ( 0 . 0 0 7 9 ~ 0.020 in) Small end free play " F ' : 0.4 ~ 0.8 m m ( 0 . 0 1 6 ~ 0.031 in) 2. Inspect: • B e a r i n g s (crankshaft) Spin the b e a r i n g i n n e r race. Excessive play/Ro ugh n ess-->Replace. Pitting/Da mage--~Replace.

4-39

CRANKSHAFTI ENGI{ ll CRANKSHAFT INSTALLATION 1. Attach: • Crankshaft Installing Tool Crankshaft installation set (~ YU-90050 Crankshaft installer adapter (M10) ~) YU-90062

Q

2. Install: • Crankshaft ® (to the crankcase (~)

CAUTION: To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips w i t h grease and each bear-ing w i t h engine oil. NOTE: Hold the connecting rod at t o p dead center (TDC) w i t h one hand w h i l e t u r n i n g the nut of the crankshaft installing tool w i t h the other. Turn the crankshaft installing tool until the crankshaft assembly b o t t o m s against the bearing. . i ~

P

Install: • Oil seal (~ • A p p l y lithium soap base grease onto the oil seal lip. Use the guide (~ and seal d r i v e r ~) to install the oil seal Oil seal driver YM-1410 Oil seal guide YM-1409

J

4-40

CARBURETION CARBURETOR

4

/

/

2

1 Order

1 2 3 4 5 6

Q'ty

Job name/Part name

k l 9 N m l 0 . 9 m.kg, 6.5 ft.lb) I R e m ks a r

Remove the parts in order.

Carbu retor removal Battery b o x cover Grip End cover Left/Right cover Center cover Air cleaner case a s s e m b l y A u t o choke lead coupler Fuel hose/vacuum hose Oil delivery pipe a s s e m b l y Carburetor Throttle cable

Refer to "COVER A N D " section in CHAPTER 3.


5-1

• CABURETOR DISASSEMBLY

'

~,_ .~'~ Order

O ® ® ® ® ® @ ® ® ® ® @ @

Job name/Part name

Q'ty

Carburetor d i s a s s e m b l y Throttle cable Throttle valve Needle set Carburetor top cover/o-ring Throttle stop screw A u t o choke unit assembly Float chamber/Seal ring Float pin Float/Needle valve Main jet Pilot jet Main nozzle Carburetor b o d y

Remarks Disassemble the parts in order.

1 1 1 1 1 1 1/1 1 1 1 1 1 1 Reverse the removal procedure for installation.

5-2

I

O'"'O"'TO" Ic""'l V CABURETOR

INSPECTION

1.

Check: • Carburetor b o d y • Float c h a m b e r • Jet housing Cracks/damage --> Replace.

2.

Check: • Fuel ages Obstruction --~ Clean.

a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the ages and jets w i t h compressed air. 3. Q 4.

5.

5-3

Check: • Float c h a m b e r b o d y Dirt --> Clean. Check: • Float c h a m b e r rubber gasket Cracks/damage/wear --> Replace. Check: • Float Damage --> Replace.

.

Check: • Needle valve O D a m a g e / o b s t r u c t i o n / w e a r --~ Replace the needle valve.

.

Check: • Throttle valve ( ~ Damage/scratches/wear--> Replace.

I

OA"BO"ETO" ICA"BI

V

Check: • Jet n e e d l e kit ( ~ • M a i n nozzle ~ ) • M a i n jet ( ~ • Pilot jet ( ~ B e n d s / d a m a g e / w e a r --> Replace. O b s t r u c t i o n --> Clean. B l o w o u t the jets w i t h c o m p r e s s e d air.

.

9.

Check: • Throttle valve movement Insert the t h r o t t l e v a l v e into t h e c a r b u retor B o d y and m o v e it up and d o w n . T i g h t n e s s --> Replace the p i s t o n valve. 10. Check: • V a c u u m hose • Fuel hose C r a c k s / d a m a g e / w e a r --> Replace. O b s t r u c t i o n --> Clean. B l o w o u t t h e hoses w i t h c o m p r e s s e d air.

11. M e a s u r e : • Float h e i g h t (~) Out of specification-->lnspect needle v a l v e , float and v a l v e seat.

Feathe0ht

I

15 - 17 m m (0.59 ~ 0.67 in)

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

Float height measurement

*

*

*

*

*

~

~

~

~

~

steps:

• Install the n e e d l e v a l v e , float and float pin to the c a r b u r e t o r body. • Hold the c a r b u r e t o r in an u p s i d e d o w n position. • M e a s u r e the d i s t a n c e b e t w e e n t h e m a t i n g s u r f a c e o f t h e f l o a t c h a m b e r ( g a s k e t rem o v e d ) and t o p of t h e float u s i n g a g a u g e .

5-4

~

~

~

~

CARBURETOR

Ic..,I •

NOTE:

The float arm should be resting on the needle valve, but not compressing the needle valve. • If the float height is not w i t h i n specification, inspect the needle valve, float and valve seat. • If it is w o r n , replace it. NOTE:

The float height is properly adjusted at the Yama ha factory. Never attempt to adjust it. CARBURETOR ASSEMBLY

To assemble the carburetor, reverse the disass e m b l y procedures. Note the f o l l o w i n g points.

CAUTION: • Before r e a s s e m b l i n g , w a s h all parts in clean gasoline. • A l w a y s use a n e w gasket.

5-5

I

OA"BU"ETO"IOA"BI V 1.

I

Install: • T h r o t t l e cable ( ~

2.

Install: • Carburetor assembly NOTE: A l i g n the p r o j e c t i o n ( ~ w i t h t h e p r o j e c t i o n s @ .

FUEL LEVEL A D J U S T M E N T 1. Measure: • Fuel level ( ~ Out of specifications-->Adjust. Fuel level (~: 3.0~4.0 m m ( 0 . 1 2 ~ 0 . 1 6 in) ( B e l o w the float c h a m b e r line)

M e a s u r e m e n t steps: • Place the s c o o t e r on a level surface. • Use a g a r a g e jack u n d e r the e n g i n e to ensure that t h e c a r b u r e t o r is p o s i t i o n e d v e r t i cally. • C o n n e c t the fuel level g a u g e ( ~ to the d r a i n pipe (~. Fuel level g a u g e : YM-01312-A • Loosen t h e d r a i n s c r e w ~). • M e a s u r e the fuel level ( ~ w i t h the gauge. • If the fuel level is incorrect, a d j u s t t h e fuel level: R e m o v e t h e f l o a t c h a m b e r f l o a t and t h e needle v a l v e . Inspect the needle valve. If it is w o r n , replace it. 5-6

I

• Install the c a r b u r e t o r . • Recheck the fuel level. *

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

~

~

~

~

~

AUTO CHOKE INSPECTION (Ambient temperature lower than 45°C) 1. Remove: • Carburetor 2. Inspect: • Autochoke unit C o n n e c t a s u i t a b l e hose ( ~ to t h e starter (~, a n d b l o w it w i t h t h e m o u t h etc. Possible--~Good c o n d i t i o n . Impossible-->Replace auto choke unit. 3. Inspect: • A u t o choke unit (with battery)

B

I n s p e c t i o n and a d j u s t m e n t steps: • C o n n e c t a u t o choke u n i t leads to t h e 12 V b a t t e r y for 5 m i n u t e s . Black terminal-->12 V b a t t e r y (+) ( ~ Black terminal-->12 V b a t t e r y (-) ( ~ • C o n n e c t a s u i t a b l e hose ( ~ to t h e starter (~), and b l o w it w i t h the m o u t h etc. Possible-->Replace auto choke unit. Im possible-->Good c o n d i t i o n .

5-7

~

~

~

~

~

~

~

~

~

CA"BO"ETO"IOA"BI V

I

FUEL COCK INSPECTION 1. 2.

Stop the engine. Remove: • Rear c a r r i e r • Tail c o v e r • Left s i d e c o v e r • Battery box cover R e f e r to " C O V E R A N D P A N E L " s e c t i o n in c h a p t e r 3. Inspect: • Fuel c o c k

3.

Fuel cock inspection steps: • D i s c o n n e c t t h e fuel h o s e (~. • Place t h e r e c e p t a c l e u n d e r t h e fuel h o s e e n d . • If fuel s t o p s f l o w i n g o u t in a f e w s e c o n d s , t h e fuel cock is in g o o d c o n d i t i o n . If not, clean or r e p l a c e t h e fuel cock. • Disconnect the vacuum hose ~)and breathe in t h e v a c u u m h o s e w i t h t h e m o u t h etc. f o r vacuum . • If f u e l f l o w s o u t o f t h e f u e l h o s e u n d e r vacuum and stops under non-vacuum, the fuel c o c k is in g o o d c o n d i t i o n . If not, clean o r r e p l a c e t h e v a c u u m hose, fuel h o s e a n d fuel cock. *

*

4.

5-8

*

*

*

*

*

*

*

*

*

*

*

*

Install: • Battery box cover • Left s i d e c o v e r • Tail c o v e r • Rear c a r r i e r

*

*

*

*

*

*

*

*

~

~

~

~

~

~

~

F.O°T W.EEL A.O B.AKE O.SC IC"ASI

oI

CHASSIS F R O N T W H E E L A N D BRAKE DISC

4 _ _

~--/~

:

/1

,/

m (0.7 m.kg, 5. lft.i b) '

~ " ' - ~ %~ZJ70 Nm(7 m.kg,

~1-O" Order

-'~'I~.~.~I7~N

(

.0

g,.

.5ft.lb) I Q'ty

Job name/Part name

b)l5 lft.I

~ R e mks a r Remove the parts in order.

Front wheel and brake disc removal

~WARNIN( S e c u r e l y s u p p o r t t h e s c o o t e r so t h e r e is no d a n g e r of it falling over.

1 2 3 4

5 6

7 8

Speedometer cable Front brake hose holder Brake caliper Wheel axle Front wheel assembly Gear unit assembly Collar Brake disc

1 1 1 1 1 1 1 1

6-1

Refer to "FRONT WHEEL INSTALLATION" section. Refer to "FRONT WHEEL ASSEMBLY" section. Reverse the removal procedure for installation.

FROOT W.EEL AO0 BRAKE O,SC IC"ASI

oI

FRONT WHEEL DISASSEMBLY

Order

(# ® ® ® ®

Job name/Part name

Remarks

Q'ty

Front wheel disassembly Oil seal Bearing Collar Spacer Bearing

1

m

1

Remove the parts in order. Refer to "FRONT WHEEL DISASSEMBLY/ASSEMBLY" section.

1 1 1

-


6-2

F.OOT W.EE. AO0 B.A.E O.SC IC'ASI f

f

f

oI

YP ...... -

f

FRONT W H E E L D I S A S S E M B L Y 1. Remove: • Bearing ( ~ • Spacer Remove the bearing using a general bearing p u l l e r (~).

CAUTION: Handle the wheel w i t h care not to d a m a g e the brake disc. If the brake disc is d a m a g e d , replace.

YP700020

FRONT W H E E L INSPECTION 1. Inspect: • Front w h e e l axle (by r o l l i n g it on a flat surface) Bends-->Replace. W!~VAV/±I -'| ~ I [¢']1 I ~ Do not a t t e m p t to straighten a bent wheel axle.

I l heeaxe endn0

0.25 m m (0.0098 in)

2.

3.

Inspect: • Front tire Wea r/da mag e--~ Re place. Refer to "TIRE INSPECTION" in CHAPTER 3. • Front w h e e l R e f e r t o " W H E E L I N S P E C T I O N " in CHAPTER 3. Measure: • Front w h e e l r u n o u t O v e r the specified limits--~Replace. Front w h e e l r u n o u t limits: Radial (~: 1.0 m m (0.04 in) Lateral ( ~ " 1.0 m m (0.04 in)

4.

6-3

I

Inspect: • Front w h e e l b e a r i n g s B e a r i n g s a l l o w free p l a y in the w h e e l hub or the wheel does not turn s m o o t h l y - - > Replace. • Oil seals W e a r / damage-->Replace.

F.O°T W.EE. A°O B.A.E O.SO IC"ASI 4.

Ye

oI

Inspect: • Collar Grooved wear-->Replace the collar and the oil seal as a set.

.....

BRAKE DISC I N S P E C T I O N 1. Measure: • Brake disc deflection(~

I ~ 1

M a x i m u m deflection: 0.15 mm (0.0059 in) Out of specification-->Replace.

2.

Measure: • Brake disc thickness(~ Brake disc thickness: 4.0 mm (0.16 in) M i n i m u m thickness: 3.5 mm(0.14 in) Out of specification-->Replace.

Ye

.....

FRONT WHEEL ASSEMBLY 1. Install: • Bearing (~ • Collar @~) • Spacer (~) • Bearing (~ • Oil seal (~ NOTE:

• A p p l y the lithium soap base grease on the bearing and oil seal lip w h e n installing. • Use a socket that matches the outside diameter of the race of the bearing. • A l w a y s use a n e w oil seal. • Install the oil seal w i t h its m a n u f a c t u r e r ' s marks or numbers facing o u t w a r d .

CAUTION:

6-4

Do n o t strike t h e inner race of balls of t h e bearing. C o n t a c t s h o u l d be m a d e only w i t h t h e outer race.

F.O°T W . E E . . ° O 2.

i

B . . . E O.SO IC"ASI Install: • Brake disc O H

20 Nm~20 ~k~,

oI 14

ft.lb)

I

NOTE: T i g h t e n the bolts (brake disc) in stage u s i n g a c r i s s c r o s s pattern.

EB700030

FRONT WHEEL INSTALLATION Reverse the " R E M O V A L " p r o c e d u r e . Note t h e f o l l o w i n g points. 1. Lubricate: • Front w h e e l axle • Bearings • Oil seal (lips) • D r i v e / d r i v e n gear ( s p e e d o m e t e r ) Recommended lubricant: L i t h i u m soap base grease

@ 2.

Install: • S p e e d o m e t e r gear u n i t ( ~ NOTE: Make sure t h a t t h e w h e e l h u b and the speedo m e t e r gear unit are installed w i t h the t h r e e p r o j e c t i o n s m e s h e d into the t w o slots. 3.

Install: • Front w h e e l NOTE: Make sure that the slot in the s p e e d o m e t e r gear unit fits o v e r the s t o p p e r on the f r o n t f o r k o u t e r tube. 4.

Tighten: • Front w h e e l axle ( ~ • A x l e nut (front w h e e l axle)

H

70

NmCT0 51 "'btlm.kg,

CAUTION: Before t i g h t e n i n g t h e axle nut, stroke t h e front fork several t i m e s to check for proper fork operation,

•WARNING M a k e sure t h a t t h e brake hose is r o u t e d properly. 6-5

F.OOT W . E E . . O 0 B . . . E O.SO IONASI

oI

YP700040

WHEEL STATIC BALANCE ADJUSTMENT NOTE: • After replacing the tire and/or rim, the wheel static balance should be adjusted. • A d j u s t the front wheel static balance with the brake disc installed. 1. 2.

3.

Remove: • Balancing w e i g h t Set: • Wheel (on a suitable stand) Find: • Heavy spot

Procedure: a. Spin the wheel and w a i t for it to rest. b. Put an "X~" mark on the w h e e l ' s b o t t o m spot. c. Turn the wheel so that the "X~" mark is 90 ° up. d. Release the wheel and wait for it to rest. Put an " X 2 " mark on the w h e e l ' s b o t t o m spot. e. Repeat the above b., c., and d. several times until all marks come to the same spot. f. This spot is the w h e e l ' s heavy spot " X " .

/

4.

Adjust: • Wheel static balance

A d j u s t i n g steps: • Instail a balancing w e i g h t (~ on the rim exactly opposite to the heavy spot " X ' . NOTE: Start w i t h the smallest weight. • Turn the wheel so that the heavy spot is 90 ° up. • Check that the heavy spot is at rest there. If not, try another w e i g h t until the wheel is balanced.

6-6

F.OOT W.EE. AOO B.A.E O.SC IC"ASI 5.

X *

X

*

oI

Check: • W h e e l static balance *

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

~

~

~

~

~

Checking steps: • T u r n the w h e e l so t h a t it c o m e s to each p o i n t as s h o w n . • C h e c k t h a t the w h e e l is at rest at each point. If not, readjust the f r o n t w h e e l static balance.

X

6-7

~

~

~

~

~

~

~

~

~

F.O°T B.AKE IC"ASI

oI

F R O N T BRAKE BRAKE PAD

~

H23Nm(23.

m.kg, 16.6 ft.lb) I

~ Order 1 2 3 4

~ ~


[~423NmI2.3m.kg,16.6ft.lb)I

Q'ty

Brake pad r e m o v a l Caliper s u p p o r t bolt Caliper Brake pad Pad s p r i n g

R e mks a r

R e m o v e the parts in order. BRAKE PAD R E P L A C E M E N T 1 --I Refer to 1 J section . 2 2 Reverse the r e m o v a l p r o c e d u r e for installation. "

"

6-8

F.ONT B.A.E IC"ASI

oI

CAUTION: Disc b r a k e c o m p o n e n t s r a r e l y r e q u i r e disass e m b l y . DO NOT: • Disassembly components unless absolutely necessary. • Use s o l v e n t s in i n t e r n a l brake c o m p o n e n t . • Use c o n t a m i n a t e d b r a k e f l u i d for c l e a n i n g . • Use o n l y clean fluid. • A l l o w brake f l u i d t o c o m e in c o n t a c t w i t h t h e eyes o t h e r w i s e eye i n j u r y m a y occur. • A l l o w brake f l u i d t o c o n t a c t p a i n t e d surfaces or p l a s t i c p a r t s o t h e r w i s e d a m a g e m a y occur. • Disconnect any hydraulic connection otherw i s e t h e e n t i r e s y s t e m m u s t be disass e m b l e d , drained, cleaned, and then properly filled and bled after reassembly.

BRAKE PAD R E P L A C E M E N T NOTE: It is not n e c e s s a r y to d i s a s s e m b l e the brake c a l i p e r and brake h o s e to replace t h e brake pads. 1.

e

o

Loosen: • Retaining bolt ( ~ 2. Remove: • Brake caliper (~) • H o l d e r (brake hose) ( ~ 3. Remove: • Retaining bolt • Pads ( ~ • Pad s p r i n g ( ~ NOTE:

o

• R e p l a c e t h e pad s p r i n g i f t h e pad r e p l a c e m e n t is r e q u i r e d . • Replace the pads as a set if e i t h e r is f o u n d to be w o r n to t h e w e a r limit.

Wear JmJt 0.8 m m (0.03 in)

®

6-9

I

,.o°T B.AKE Ic"AsI 4.

ol

Install: • Pad springs • Brake pads (new)

Installation steps: • Connect a suitable hose (~ t i g h t l y to the caliper bleed screw (~. Then, place the other end of this hose into an open container. • Loosen the caliper bleed screw and push the piston (~ into the caliper by y o u r finger. • Tighten the capliper bleed screw.

/

H ~~ (0.~ ~.k~, 4.3 ~.'~ i • Install the pad spring (new) and brake pad (new) (~ • Tighten retaining bolt (~ ~ 1 2 3 Nm (2.3 m.kg, 16.6 ft.lb) I • Install brake hose holder (~ l ~ l 7 Nm (0.7 m.k~, 5.15 ft.lb) I • Install caliper (~ [~23 Nm (2.3 m.kg, 16.6 ft.ib)

/ i

I

5. Inspect: • Brake fluid level Refer to the "BRAKE FLUID INSPECTION" section in the CHAPTER 3. (~ "LOWER" level line

t 6-10

I

F.O.T B.A.E IC"ASI .

Check: • Brake lever o p e r a t i o n A s o f t y or s p o n g y feeling Bleed-->brake system. AIR BLEEDING " section in Refer to the CHAPTER 3. "

6-11

oI

F.O°T B.AKE IC"ASI

oI

MASTER CYLINDER

6

]

6

3

l~120Nm(2.0m.kg, 14 ft.lb)

Order


Q'ty

R e m o v e the parts in order. R e f e r t o " B R A K E F L U I D REPLACEM E N T " section in CHAPTER 3.

Master cylinder removal Drain the brake f l u i d 1 2 3 4 5 6 7

Remarks

Brake l e v e r / c o m p r e s s i o n s p r i n g Brake s w i t c h U n i o n bolt Copper washer Brake hose M a s t e r c y l i n d e r bracket Master cylinder

1/1 1 1 2 1 1 1

Refer to " M A S T E R CYLINDER INSTALL A T I O N " section.

Reverse the r e m o v a l p r o c e d u r e for installation.

6-12

F.O°T B.AKE IC"ASI

oI

M A S T E R CYLINDER D I S A S S E M B L Y

Order

O ® ® ®

Job name/Part name

Q'ty

Master cylinder disassembly Master cylinder boot Circlip M a s t e r c y l i n d e r kit Spring

R e mks a r R e m o v e the parts in order.

1 1 1 1

Refer to " M A S T E R CYLINDER A S S E M B L Y " section. Reverse the d i s a s s e m b l y p r o c e d u r e for assembly.

6-13

F.ONT B.A.E IC"ASI

oI

YP702040

MASTER CYLINDER INSPECTION 1. Inspect: • Master cylinder kit O Wear/scratches-->Replace the master cylinder assembly. • Master cylinder boot Cracks/da m age-->Re pla ce.

. Inspect: • Master cylinder O • Scratches/wear/damage-->Replace the master cylinder assembly.

. Inspect: • Diaphragm (~ Wea r/da mag e-->Re place.

Y P .....

MASTER CYLINDER A S S E M B L Y

WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. 16~)1

Recommended brake fluid: DOT #4(or DOT #3)

• Replace the piston seals and dust seals whenever a master cylinder is disassembled. 1.

Install: • Cylinder cup (~ • Master cylinder piston (~ Install cylinder cup (~ by using cylinder cup installer (~). ::~1 Cylinder cup installer set: 90890-01996

6-14

I

F.O.T B.A.E IC"ASI

Ye

oI

.

Install: • Spring (~ Install the s p r i n g w i t h its s m a l l e r d i a m eter to the m a s t e r c y l i n d e r piston. • M a s t e r c y l i n d e r kit ( ~

.

Install: • Circlip (~) Install the circlip s e c u r e l y into the master c y l i n d e r g r o o v e . • M a s t e r c y l i n d e r boot ( ~

.....

MASTER CYLINDER INSTALLATION 1. Install: • Master cylinder (~ • M a s t e r c y l i n d e r bracket ( ~ ~ l 9 Nm (0.9

m.kg, 6.5 ft.lb)

CAUTION:

/

• Install the master cylinder bracket ( ~ w i t h the " U P " m a r k ~ facing u p w a r d . • Align the end of the holder w i t h the punch m a r k b on the handle bar.

6-15

I

F.O.T B.A.E IC"ASI 2.

oI

Air bleed: • Brake s y s t e m Refer to " A I R B L E E D I N G " s e c t i o n in CHAPTER 3.

r!~vAvg_,W --']~ I [¢-] I ~ • Use o n l y d e s i g n a t e d q u a l i t y brake fluid: O t h e r w i s e , t h e r u b b e r seals m a y d e t e r i o r a t e , causing leakage and poor brake perforrmance. • Refill w i t h t h e s a m e t y p e of brake f l u i d : M i x i n g f l u i d s m a y r e s u l t in a h a r m f u l c h e m i cal r e a c t i o n a n d lead t o p o o r p e r f o r r m a n c e . • Be careful t h a t w a t e r d o e s n o t e n t e r t h e sign i f i c a n t l y l o w e r t h e b o i l i n g p o i n t of t h e f l u i d m a y r e s u l t in v a p o r lock. 3.

6-16

Inspect: • Brake o p e r a t i o n

F.O.T..AKE IC"ASI oI CALIPER lh%123Nm(2.3 m.k,g, 16.6

........

Order

Job name/Part name

i .......

Q'ty

3

Remarks

Caliper removal Drain the brake fluid 1 2 3 4 5

ft.lb)l

Remove the parts in order. Refer t o " B R A K E F L U I D REPLACEM E N T " section in CHAPTER 3.

Union bolt Copper w a s h e r Brake hose Caliper s u p p o r t bolt Caliper assembly

1 2 1 1 1

Refer to "CALl PER INSTALLATION" section.


6-17

F.O°T B.AKE IC"ASI

oI

CALIPER D I S A S S E M B L Y

~ ~ ~ j~J'~

Order

(# ® ® ® ® ® @

~

Job name/Part name

~

~

[~0"6m~

Q'ty

"4"3ft'lb) l

R e m ks a r Remove the parts in order.

Caliper disassembly Caliper bracket Brake pad Pad spring Caliper piston Dust seal Piston seal Bleed screw

1 2 2 1 1 1 1

Refer to "BRAKE CALIPER --I BLY/ASSEMBLY" section.

J

Reverse the disassembly procedure for assembly.

6-18

DIS

F.ONT B.A.E IC"ASI

oI

YP702020

BRAKE CALIPER D I S A S S E M B L Y NOTE:

Before disassembling either brake caliper, drain the brake fluid from the brake hose, master cylinder, brake caliper and reservoir tank. 1.

Remove: • Brake caliper piston

Removal steps: • B l o w c o m p r e s s e d air into the hose t opening to force out the caliper piston from the brake caliper body. ~!~LVAV/_'I-"] ~ I [¢'] I ~ • N e v e r try to pry out the caliper piston. • Cover the caliper piston w i t h a rag. Be careful not to get injured w h e n the piston is expelled from the m a s t e r cylinder.

CAUTION: Carefully r e m o v e the caliper piston to prevent damage.

2.

Remove: • Dust seal ~) • Piston seal ~) When removing, push the seals by your finger.

CAUTION: • Do not use a sharp instrument. R e m o v e seals by your finger. • Do not re-use r e m o v e d parts.

YP...

CALIPER I N S P E C T I O N 1. Inspect: • Caliper cylinder • Caliper piston ~) Scratches, wear--~Replace caliper assembly.

6-19

F.O.T B.A.E IC"ASI

oI

EB702050

BRAKE CALIPER ASSEMBLY

r!~vAvg_,1--'t~ I [¢-! I ~ • All i n t e r n a l brake c o m p o n e n t s s h o u l d be cleaned and lubricated w i t h n e w brake fluid o n l y before installation.

DOT #4(or DOT #3) • Replace the caliper piston seals w h e n e v e r a

brake caliper is disassembled. 1.

Install: • Piston seal (~ • Dust seal (~

2.

Install: • Caliper piston (~ A p p l y brake fluid to the outer surface and install.

)

O( ) CAUTION: • Do n o t force. • Use care t o p r e v e n t damage on caliper piston.

Y P .....

BRAKE CALIPER INSTALLATION

1. Install: • Caliper (~ • Caliper s u p p o r t bolt

P~123Nm(2.3m.kg, 16.6ft.lb) I • Brake hose (~) • Copper w a s h e r (~ • Union bolt (~ H

25Nm(2.5 m.kg,18ft.lb) I

CAUTION: When installing the brake hose t o the caliper, l i g h t l y t o u c h t h e brake hose w i t h t h e s t o p p e r (~ on t h e caliper.

6-20

, E , , w.EE, A ° 0 , E , ,

=,,KE IC"A=I

oI

REAR WHEEL AND REAR BRAKE REAR W H E E L

< 2 [;;l~i~]((;16~i:18:8f.?liilb)~"

Order

1


Q'ty

Remarks Remove the parts in order. NOTE"

Rear w h e e l and rear brake removal

Place the scooter on a suitable atand so that the rear wheel is elevated. 1 2 3 4

Muffler assem bly/Gasket Nut/Plain w a s h e r Rear w h e e l a s s e m b l y Plain w a s h e r

1/1 1 1 1 Reverse the d i s a s s e m b l y procedure for installation.

6-21

,E,, w,EE,,.o,EA,

B,AKE IC"Asl

REAR BRAKE

kllONm(1.0

m.kg,

7.2 ft.lb) I

.

/

J

8

\

Order 1 2 3 4 5 6 7 8

t3

./

-

Job name/Part name

Q'ty

Adjuster Brake cable Pin Return s p r i n g Brake shoe C a m s h a f t lever Wear indicator Brake c a m s h a f t

Remarks

1 1 1 1 1 1 1 1 Reverse the r e m o v a l p r o c e d u r e for installation.

6-22

.EA. W.EE" A.O .EA. B.A.E I C"Asl EB701020

REAR W H E E L I N S P E C T I O N 1 Inspect: • Rear w h e e l axle • Rear w h e e l • Rear w h e e l b e a r i n g s • Oil seals Refer to " F R O N T WHEEL". 2. Measure: • Rear w h e e l r u n o u t Refer to " F R O N T W H E E L " . EB701021

REAR BRAKE I N S P E C T I O N 1. Inspect: • Brake l i n i n g surface Glazed areas-->Polish. Use coarse sand paper. NOTE: After p o l i s h i n g , w i p e the polished particles w i t h a cloth. 2.

~ 1

Measure: • Brake l i n i n g t h i c k n e s s ( ~ Brake l i n i n g t h i c k n e s s ( ~ • Standard: 4 m m (0.16 in) Limit: 2 m m (0.08 in)

Out of specification-->Replace. Measuring points " t " NOTE: Replace the brake s h o e s as a set, if e i t h e r is w o r n to the w e a r limit.

.

®

Measure: • Brake d r u m i n s i d e d i a m e t e r ( ~ Out of specification-->Replace the w h e e l Brake d r u m i n s i d e d i a m e t e r : Standard: 130 m m (5.12 in) Limit: 131 m m (5.16 in)

6-23

,EA, W.EE" A.O .E,, B.,,E I C"Asl 4.

5.

Inspect: • Brake drum inner surface • Oil/scratc hes-->Re pair. • Oil Use a rag soaked in lacquer t h i n n e r or solvent. • Scratches Use an e m e r y cloth (lightly and e v e n l y polishing) Inspect: • Cam shaft face. Wea r-->Replace.

W h e n inspecting t h e brake lining, do not spill oil or grease on t h e brake lining,

Ye

.....

REAR BRAKE I N S T A L L A T I O N 1. Install: • Camshaft (~ • Indicator plate (~

Installation steps: • Set the camshaft w i t h its punched mark (~ facing the direction as shown. • Align the projection @ on the indicator plate w i t h the camshaft notch and install. • C h e c k t h e proper position of the brake shoe.

2.

Install: • Camshaft l e v e r ( ~ NOTE:

r~ll0Nm(1.0 m.kg,7.2ft.lb~

Set the camshaft w i t h its punched m a r k ( ~ facing the direction on the cam shaft lever @.

6-24

HAOOLE.,. IONASI oI HANDLEBAR HANDLEBAR

~;~19Nm(0.9 m.kg, 6.5

ft.lb) I

5 ,)

1~143Nm(4.3 m.k 9, 37 ft.lb) I .

8

10

t-,,.,

2

Order

1 2 3 4 5 6 7 8 9

Job name/Part name

Q'ty


Handlebar removal Left/Right bake m i r r o r Front protector bar Upper cover Front/Rear handlebar cover Left/Rig ht flasher Brake master cylinder Front brake switch Handlebar switch (Right) Throttle cable Right grip Brake cable Rear brake switch Handlebar switch (Left) Bind

Refer to " C O V E R S A N D P A N E L " IN CHAPTER 3.

1 1 1 1 1/1 1 1 1 1

6-25

.AOOLEBARIC"ASI oI

~ 1 9 N m ( 0 . 9 m.kg, 6.5 5

,)~D

1~143Nm(4.3 m.kg, 37 .

ft.lb) I

ftJb)l 8

10

p-..

2

Order 10

11 12 13

Job name/Part name

Q'ty

Remarks

1 1 1 1/1

Wire harness strap Brake hose Handlebar comp. Left grip


6-26

.,,O,EBA, IC"ASI oI HANDLEBAR INSTALLATION

1.

Clean: • Steering shaft ®

~!~v~v/±1 --']~ I I ~ [e-]l Proper cables and leads routing is essential to issue safe scooter operation.

®

2.

Install: • Handlebar O • Bolt (~) • Nut NOTE:

®

I~143Nm(4.3 m.kg,

37ft.lb)

Match the bolt (~ on to the steering c o l u m n dent (~.

®

CAUTION: There m u s t be a space b after t i g h t i n g bolt ~).

3.

Install:

• Ba nd NOTE:

Clamp the w i r e harness. 4.

Apply: • Lithium soap base grease (to t h r o t t l e cable end and h a n d l e b a r right end).

5.

Install: • Handlebar switch (right) (~ NOTE: Insert the projection (~ into the hole (~ on the h a n d l e b a r comp.

6-27

I

.AOO,EBA. IC"ASI oI 6.

Install: • Handlebar switch (left) (~ NOTE:

Q ®

Insert the projection (~ into the hole @ on the handlebar comp.

7.

Install: • Master cylinder NOTE: Match the slot w i t h the punched mark @ on the handlebar comp.

6-28

STEE.,°OIC"ASI oI STEERING STEERING

~-766Nm(6.6 m.kg, 47.8 ft.lb)] r~122Nm(2.2 m.kg, 16 ft.lb) 21

-J/ I

8

I

38Nm(3.8 m.kg, 27ft.lb) i

I

I

-9 8

5 40Nm(4.0

Order

29 ft.lb)

Job name/Part name

Q'ty

Remove the parts in order Refer to " H A N D L E B A R " section. Refer to "FRONT WHEEL A N D BRAKE DISC" section

Steering removal Handlebar Front wheel 1 2 3 4

5 6

7 8 9

Ring nut 1/Special w a s h e r Ring nut 2 / R u b b e r w a s h e r Ring nut 3 Under bracket Front fork (Left/Right) Bearing cover Ball race Ball (Upper/Lower) Ball race

Remarks

1/1 -

Refer to "STEERING REMOVAL/INSTAL1 LATION" section. 1 1/1 1 1 22/19 3 Reverse the removal procedure for instal lation. 1/1

6-29

STEE.,°O IC"ASI oI STEERING REMOVAL

~WARNING • S e c u r e l y s u p p o r t t h e s c o o t e r so t h a t t h e r e is n o d a n g e r of it falling over. • S t a n d t h e s c o o t e r on a level surface.

1.

Removal: • Ring nut 1 ~) • Special w a s h e r (~ • Ring nut 2 (~) • Rubber w a s h e r (~ • Ring nut 3 (~ • Bearing cover (~ • Ball race (~ • Ball (~ • Front fork a s s e m b l y (~

NOTE:

• Remove the ring nuts by steering nut wrench. ~:c~l

Steering YU-33975 nut w r e n c h (~

I

• Hold the lower bracket by hand, then remove by using the steering nut w r e n c h @. • Do not loss the balls (Upper: 22 pcs, Lower: 19 pcs). 2.

3.

Remove • Front fork a s s e m b l y Refer to "FRONT FORK" section. Remove • Ball race

Ball race r e p l a c e m e n t steps: • Remove the ball races on the head pipe using long rod (~ and the h a r m m e r as s h o w n . • Remove the ball races on the under bracket using the floor chisel ( ~ a n d the h a r m m e r as shown.

6-30

STEE.,°OIC"ASI oI STEERING I N S P E C T I O N 1. W a s h t h e b e a r i n g races w i t h a s o l v e n t . 2. Inspect: • Ball race • Ball P i t t i n g / D a mage--~Replace. NOTE: A l w a y s r e p l a c e b e a r i n g s a n d races as set.

3.

Inspect: • Under bracket (~

Crack/Bend/Damage-->Replace.

Q

W!~LVAV/±I-'] ~ I I ~ [¢']1 Do not attempt to straighten a bent under b r a c k e t as t h i s m a y d a n g e r o u s l y w e a k e n t h e under bracket.

STEERING I N S T A L L A T I O N 1. Install: • Ball <~ NOTE: U p p e r ....... 22 pcs L o w e r ...... 19 pcs 2.

Lubricate • Ball

• Ball race L i t h i u m s o a p base g r e a s e

6-31

STEE.,°O IC"ASI oI ,

\

3. Install: • Frontfork assembly (~ • Ball race (Upper) ~) • Bearingcover (~ • Ring nut 3 ~) • Rubberwasher {~) • Ring nut 2 (~ • Specialwasher (~ • Ring nut 1 (~

®

NOTE:

Securely the steering shaft so that there is no danger of it falling down.

4. Tighten: • Ring nuts Tighten steps: • Tightenthe ring nut 3 (~ using the ring nut wrench (~ r~122 am {2.2 m.kg, 16 ft..b~

steor,no,utwrenoho_9 I

NOTE:

.~...~~

~

@@

Set the torque wrench (~ to ring nut wrench (~ so that they form right angle.

~

~!~Lvlv/±~ --{ ~11 ~, [ ,¢-]1

,

Do not over-tightening.

///

/

• Loosen the ring nut 3 @) 1/4 turn. • Checkthe front fork by turning it lock to lock. If there is any binding, remove the front fork assembly and inspect the steering ball bearings ball and races. • Install rubber washer (~ and ring nut 2 (~, then turn the ring nut 2 until it s with rubber washer.

~)

, ~ , ~

~

6-32

I

STEE.,°OIC"ASI oI CAUTION: Slots on t h e ring n u t 2 and ring n u t 3 s h o u l d be align. If not, t u r n t h e ring n u t 2 t o w a r d s t i g h t e n direction until slots a l i g n m e n t . • Install special w a s h e r (~) NOTE: Insert the projections of the special w a s h e r into the slots. • Install ring nut 1 (~ and tighten. [~166Nm(6.6

6-33

47.8 ft.lb)m.kg, I

F.O.T FO.K IC"ASI

oI

F R O N T FORK FRONT FORK 8

Order

1 2 3 4 5

Q'ty

Job name/Part name

Remarks R e m o v e t h e parts in order. Refer to " S t e e r i n g " section.

Front f o r k r e m o v a l Steering Under fender S p e e d o m e t e r cable h o l d e r Cap bolt Pinch bolt Front f o r k

1 1 2 2 2

-

l

Refer to " F R O N T FORK R E M O V A L / I N - S T A L L A T I O N " section. Reverse the r e m o v a l p r o c e d u r e for installation.

6-34

F.O°T FO.K IC"ASI

oI

FRONT FORK D I S A S S E M B L Y

/

® ®

@ ®

c-~ ®

Q

[~, 23N m m (2.3 ~ Order

t

~

O

Job name/Part Front fork disassembly Fork spring

® ® ® ® ® @ ® ® @

Band/Front fork boot Bolt/Copper washer Inner tube Damper rod Rebound spring Oil lock piece Oil seal clip Oil seal Outer tube

/ '. name Q'ty

Remarks Remove the parts in Refer to "FRONT FORK STALLATION"

order. REMOVAL/INsection.

1 1/1 1 1/1 Refer to FRONT FORK DISASSEMBLY/ 1 ASSEMBLY" section. 1/1 1 1 1 Reverse the disassembly procedure for assembly. "

6-35

F.O.T FO.K IC"ASI

oI

Y P .....

f

FRONT FORK R E M O V A L

~!~LvAv/_,l -"t ~ I [¢-] I ~ • Securely the scooter so there is no danger of it falling over. • Stand the scooter on a level surface. • Stand the scooter on its centerstand. 1. Remove: • Under fender (~ 2.

Remove: • Cap bolt (~) • Pinch bolt (~

W!~kvAv/±1 -'] ~ I I ~ [¢']1 Fork spring will j u m p out after removing cap bolt. 3.

Remove: • Front fork (Left/Right) (~

YP703020

FRONT FORK D I S A S S E M B L Y 1. Remove: • Bolt (damper rod) (~ Loosen the bolt (damper rod) (~ while holding the damper rod with T-handle ~) and holder (~).

~ 1

6-36

T-handle YM-1326 Holder YM-01300-1

F.O.T FO.. IC"ASI .

®

O

®

oI

Remove: • Inner tube (~ • Oil lock pice (~ • Damper rod ® • Rebound spring (~

®

3.

Remove: • Oil seal (~

CAUTION:

"7 "°'" i~:

N e v e r reuse th e oil seal.

~) Rag

YP703030 F R O N T FORK I N S P E C T I O N 1. Inspect: • Inner tube bending

I ~ l

Inner tube bending limit: 0.2 mm(0.008 in) Scratches/be nds/da m age-->Replace.

-

U

W!~VAV/±I -'| ~ I I ~ [¢']1 Do not a t t e m p t to straighten a bent inner t u b e as this m a y d a n g e r o u s l y w e a k e n th e tube.

YP..... ®

F R O N T FORK A S S E M B L Y Reverse the DISASSEMBLY" procedure. Note the following points. 1. Install: • Damper rod (~ • Rebound spring (~ • Oil lock piece (~ • Inner tube L~

Q

"

® ®

6-37

F.O.T FO.. IC"ASI

\

.

Install: • Inner tube (~ Into outer tube ~).

.

Install: • Plain w a s h e r (~ • Bolt ( d a m p e r rod) (~)

4.

Tighten: • Bolt ( d a m p e r rod) (~

A

oI

~%O%123Nm(2.3m.kg, 16.6ft.lb) NOTE:

Tighten the damper rod bolt ( ~ w h i l e holding the damper rod with a T-handle(~ and holder ~). ~

5.

T-handle YM-01326-A Holder YM-01300-1 Install:

• Oil seal (~ • Retaining clip Use the fork seal driver w e i g h t ~) and the a t t a c h m e n t (~). NOTE: • Before installing the oil seal (~, apply lithium soap base grease onto the oil seal lips. • A d j u s t the retaining clip so that it fits into the outer tube groove.

CAUTION: M a k e sure t h a t t h e oil seal n u m b e r e d side faces upward.

~ 6-38

Fork seal driver w e i g h t : YM-33963 Attachment: YM-01400

I

F.O.T FO.. IC"ASI .

7.

oI

Inspect: • Inner tube operation U n s m o o t h operation-->Disassembly and recheck.

Fill: • Fork oil ( ~

©1

Oil q u a n t i t y : 88 cc R e c o m m e n d e d oil: Fork oil 10 W or e q u i v a l e n t

0;

8.

A f t e r f i l l i n g up, s l o w l y p u m p the f o r k up and d o w n to d i s t r i b u t e the fork oil.

9.

Install: • Front f o r k s p r i n g O

NOTE:

• Install the fork s p r i n g w i t h its s m a l l e r p i t c h ( ~ upward . • Before i n s t a l l i n g the cap bolt, a p p l y grease to the O-ring. • T e m p o r a r i l y t i g h t e n t h e cap bolt.

EB703050

FRONT

FORK INSTALLATION

Reverse the " R E M O V A L " p r o c e d u r e . Note t h e f o l l o w i n g points. 1. Install: • Front f o r k ( ~ NOTE:

A p p l y grease o n t o cap bolt O-ring before ins t a l l i n g cap bolt. .

6-39

Tighten: • Cap bolts (~) • Pinch bolts (~)

~1

38Nm(3.8 m.kg, 27 ft.lb) I I 40Nm(4.0 m.kg, 29 ft.lb)~

E.EOT..OA. OO=,O=E°T= I E'EC I ELECTRICAL ELECTRICAL C O M P O N E N T S

(~ (~) (~) (~ (~ (~ (~

Main switch Flasher relay Oil level gauge C.D.I. UNIT Fuel level gauge Starter relay Fuse

(~ (~ @ (~)

Battery Ignition coil Rectifier/Regulator Horn

® ® ®

@

,

®

0 Y ® F

7-1

I

Cl.O°lTOlAO.A. IE'EC I

I

CIRCUIT D I A G R A M

,

111L

u

II

i

I II~l~ I ~1~2- /

~

I

~ l

------I

__i,

/--/

i ®

~ I B I

__1

~

~-I~-

~

"

~4-4-

I1~

II

I

I

®,,®

,,

~ '® i

•~ - - - I - -

@

1

_EB

I

L ....

I

i--

J

b__

L

i

_J o

_E,2 ~ _ _ _ _ I I I

,

i@ I I

L

I

7-2

@

I® I

- -i-I

:~ I ~

III~L I ~

, ,

:0

i~

~

I

I

I

......

c..cu.T o..o..M I E'Ec I (~ (~) (~ (~ (~ (~ (~ (~ (~ @ @ @ (~ @ @ @ (~ (~) (~ (~

(~ (~) (~ @ (~ @ (~ @ @ @ (~ @ @ @ (~ @ @ @

Main switch Main fuse Battery Starter relay Starter motor Rectifier regulator Auto choke C.D.I. magneto C.D.I. unit Ignition coil Spark plug Rear switch brake Front brake switch Tail/Brake light Rear flasher light(left) Rear flasher light(right) Licence light Front flasher light(right) Front flasher light(left) Head light(for high beam)

Head light(for low beam) Flasher relay Horn Handlebar switch (left) Horn switch Dimmer switch Turn switch Fuel sender Meter Fuel gauge Oil indicator light Meter light High beam indicator light Turn indicator light Oil level gauge Handlebar switch (right) Starter switch Engine stop switch

COLOR CODE

B Br Ch

Black Brown Chocolate

Dg G

Dark Green

L

Blue

Or

Orange

Sb P R

Sky blue Pink Red

Gy Y W

Green

G ray

Yellow White B/R Black/Red Br/W Brown/White n/Red G/R G ree G/Y Green/Yellow L/B L/Y L/W

Blue/Black Blue/Yellow Blue/White

7-3

L/R R/B

Blue/Red Red/Black

R/Y R/W

Red/Yel low Red/wh

Y/R

Yellow/White

W/G

White/Green

G/W Green/White W/R White/Red L/G Blue/Green

ite

I

O.EOK.°OSW.TO.ESIE'EC I YP N JJoo r,

"~xl

CHECKING S W I T C H E S

"O"

C H E C K I N G STEPS Using pocket tester, check switches for contin u i t y b e t w e e n t h e i r t e r m i n a l s to d e t e r m i n e w h e t h e r t h e y are correctly connected. Replace the switch c o m p o n e n t if any of the c o m b i n a t i o n s does not produce the correct reading.

" --

I ~ 1

Pocket tester: YU-03112

NOTE:

• Turn the switch to the " O N " , " O F F " positions several times. • A d j u s t the pocket tester to correct " 0 " position before checking switches. • Set the pocket tester selector to " x l ' E 2 . S W I T C H C O N N E C T I O N A S S H O W N IN THIS MANUAL This manual contains connection charts, like the one s h o w n on the left, s h o w i n g the terminal c o n n e c t i o n s of s w i t c h e s (e.g. the main switch, handlebar switch, brake switch, lighting switch etc.)

X",•

Br R

OFF ON O - - O

The column on the extreme left indicates the different switch positions, the top line ind icates the colors of the leads connected to the terminals on the switch. "0~0" indicates terminals between w h i c h there is c o n t i n u i t y , i.e. a closed circuit, in the given switch position.

In this chart: " B r and R" have c o n t i n u i t y w i t h the switch in the " O N " position.

7-4

I

O.EOK.°OSW.TO.ESIE'EC I S W I T C H POSITION A N D T E R M I N A L

CONNECTION I-

Before c h e c k i n g a s w i t c h refer to the checking s w i t c h e s as s h o w n in the left page and check for t h e c o r r e c t t e r m i n a l c o n n e c t i o n s (closed circuit) a c c o r d i n g to the c o l o r c o m b i n a t i o n s s h o w n in the chart. Poor c o n n e c t i o n , fault-->Repair or replace.

Rear brake s w i t c h

I

I I

Main switch Gy Br R

~

C)---O C ) - O 0 -O

ON

L

J

r Front brake s w i t c h

I

I-

I I

I

Horn s w i t c h

--'~P

B

~ G

L

< I

Ch

~>

iI

I I",,t ,,,,,,"~

Y

-C> O-43 gO 00 Turn switch <~

L

~

Release Push in O- 0 Dimmer switch

Start s w i t c h L/W L/G Release Push in O - - O

Br/VV Dg

O--O O--O

L

E n g i n e stop s w i t c h J

B/W B/W L/G OFF RUN

0--0

L

< / /

F

\

\

7-5

B/VV

OPEN OFF

I I

7

B

LOCK

Fuse

0--0

B

c.Ec...o T.E Bo.Bs A.o BO.B SOO.ETS IE'EC I EAS00733

CHECKING THE BULBS A N D BULB SOCKETS Check each b u l b and b u l b socket for d a m a g e or wear, p r o p e r c o n n e c t i o n s , and also for con tinuity between the terminals. D a m a g e / w e a r --~ Repair o r replace t h e bulb, b u l b socket or both. I m p r o p e r l y c o n n e c t e d --~ P r o p e r l y connect. No c o n t i n u i t y --~ Repair o r replace the bulb, b u l b socket or both.

@

TYPES OF BULBS The b u l b s used on t h i s s c o o t e r are s h o w n in the i l l u s t r a t i o n on the left. • Bulbs @ and ( ~ are used for the h e a d l i g h t s and u s u a l l y use a b u l b h o l d e r t h a t m u s t be detached before r e m o v i n g t h e bulb. The maj o r i t y of these t y p e s of b u l b s can be r e m o v e d f r o m t h e i r respective socket b y t u r n i n g t h e m co u n t e r c l o c k w i s e . • Bulbs © are used for t u r n s i g n a l and tail/ brake l i g h t s and can be r e m o v e d f r o m t h e socket by p u s h i n g and t u r n i n g the bulb counte rcl ockwise. • Bulbs ( ~ and ( ~ are used for m e t e r and indicator l i g h t s and can be r e m o v e d f r o m t h e i r respective socket by c a r e f u l l y p u l l i n g t h e m out.

18410603

©

18410004

7-6

I

C.EOK..O T.E BO'BS..O BO'B SOCKETSIE'EC I C H E C K I N G THE C O N D I T I O N OF THE BULBS

The following procedure applies to all of the bulbs. 1. Remove: • bulb Since the headlight bulb gets extremely hot, keep f l a m m a b l e p r o d u c t s and y o u r h a n d s a w a y from the bulb until it has cooled d o w n .

CAUTION: • Be sure to hold the socket firmly w h e n removing the bulb. Never pull the lead, otherw i s e it may be pulled out of the ter-minal in the coupler. • Avoid touching the glass part of the headlight bulb to keep it free from oil, other-wise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled, t h o r o u g h l y clean it w i t h a cloth moistened w i t h alcohol or lacquer thinner. . Check: • bulb (for continuity) (with the pocket tester) No continuity --> Replace. ~ 1

Pocket tester YU-03112

NOTE:

Before checking for continuity, set the pocket tester to " 0 " and to the "El x 1" range.

a. Connect the positive tester probe to terminal (~ and the negative tester probe to terminal (~, and check the continuity. b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal (~, and check the continuity. c. If e i t h e r of t h e r e a d i n g s i n d i c a t e no continu-ity, replace the bulb. 18410002

7-7

I

O.EOK.°O T.E BO'BS A.O BO'B SOCKETS IE'Ecl

I

C H E C K I N G T H E C O N D I T I O N OF THE B U L B SOCKETS The f o l l o w i n g p r o c e d u r e a p p l i e s to all o f the b u l b sockets. 1. Check: • b u l b socket (for c o n t i n u i t y ) ( w i t h the pocket tester) No c o n t i n u i t y --> Replace.

P°ckettester YU-03112

I

NOTE: Check each b u l b socket for c o n t i n u i t y in the same m a n n e r as d e s c r i b e d in the b u l b section; h o w e v e r , note t h e f o l l o w i n g .

a. Install a g o o d b u l b into t h e b u l b socket. b. C o n n e c t t h e pocket tester p r o b e s to t h e respective leads of t h e b u l b socket. c. Check the bulb socket for c o n t i n u i t y . If a n y of the r e a d i n g s indicate no c o n t i n u i t y , replace the b u l b socket.

7-8

IE'ECI I IGNITION SYSTEM CIRCUIT D I A G R A M • ....

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Main switch C.D.I. magneto C.D.I. unit Ignition coil Spark plug Engine stop switch 7-9

_ _ _

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.o..T.o° SVSTEMI':":C I

I

TROUBLESHOOTING IF I G N I T I O N S Y S T E M S H O U L D B E C O M E I N O P E R A T I V E (NO S P A R K OR I N T E R M I T T E N T SPARK) NOTE:

•

Removethe following parts before troubleshooting. 1) Battery box cover 4) Tail cover 2) Center cowling 5) Side cover 3) Rear carrier 6) Handlebar • Use the following special tools in this troubleshooting. ~ 1

1. • • •

Dynamic tester:YM-34487 spark

I

~ 1

Spark plug Check the spark plug condition. Check the spark plug type. Checkthe spark plug gap. Refer to the "SPARK PLUG INSPECTION" section in the CHAPTER 3. ~

(right) cover

Pocket tester:Yu-03112

Standard spark BPR7HS (NGK)

plug:

Spark plug gap: 0.6~0.7 mm(0.02~0.03 in) INCORRECT

CORRECT I Spark gap.

is faulty, plug replace it or repair plug

2. Ignition spark gap • Disconnectthe spark cap plugfrom spark plug. • Connectthe dynamic spark tester (~ as shown. (~ Spark cap plug • Checkthe ignition spark (~.gap • Start engine, and increase gap until spark misfire occurs. ~

(front)

Minimum spark 6.0 mm (0.24 in) I

gap:

lgll0201

MEETS SPECIFICATION

OUTOF SPECIFICATION OR NO SPARK

I Ignition system is good.

*

7-10

IGNITION SYSTEM

ELEC

+'

*

l 3. Spark plug cap resistance • Remove the spark plug cap. • Connect the pocket tester (~Q x lk) to the spark plug cap. • Check the spark plug cap for specificated resistance. [~

•

J

Spark plug cap resistance: 5k£Q at 20°C (68°F) OUT OF SPECIFICATION MEETS SPECIFICATION

4. Ignition coil resistance • Disconnect the ignition coil leads from the ignition coil. • Connect the pocket tester (~ x 1)to the ignition coil.

Replace spark plug cap.

Ignition coil: Tester (+) lead->Terminal (~ Tester (-) lead->Coil base (~) • Check the p r i m a r y coil for specification resistance. Primary coil resistance: 0.32~0.48 E2 at 20°C (68°F) • Connect the pocket tester (£Q x ignition coil.

///"

1k) to the ©

Tester (+) lead--~Spark plug lead (~ Tester (-) lead->Coil base (~) • Check the s e c o n d a r y coil for specificated resistance. S e c o n d a r y coil resistance: 5.68 ~ 8.52 k ~at 20°C (68°F) (Spark plug lead - Coil base)

OUT OF SPECIFICATION

B O T H MEET SPECIFICATIONS

I Ignition coil is faulty, replace it.

7-11

©

,ON,T,OOS STEM IE'EC I 5. Pickup coil resistance • Disconnect the pickup coil coupler from the wireharness. • Connect the pocket tester (~ × 100) to the pickup coil terminal. Tester (+) lead->White/Red lead (~ Tester (-) l e a d , W h i t e / B l u e (~) • Check the pickup coil for specificated resistance.

-~


Pickupcoilresistance:

248~ 372 ~Q at 20°C (68°F) (Wh ite/Red-Wh ite/Blu e) I Pickup coil is faulty, replace it.

~N7 SPECIFICATION MEET 6. Source resistance • Disconnect the source coil coupler from the wireharness. • Connect the pocket tester (~ × 100) to the source coil terminal. Tester (+) lead->Black/Red lead (~ Tester (-) l e a d , G r e e n / W h i t e (~ • Check the source coil for specificated resistance.

-~


Sourcecoilresistance:

640 ~ 960 E2 at 20°C (68°F) (Black/Red - Green/White ) I Source coil is faulty, replace it.

~ 7 SPECIFICATION MEET

NO CONTINUITY 7. Main switch

Refer to "CHECKING SWlTCHS" section. CONTINUITY I Main switch is faulty, replace it.

7-12

I

.O..Z.O° SVSTEM IE'EC I

I

NO CONTINUITY Engine stop switch Refer to "CHECKING SWlTCHS" section.

8.

I Engine stop switch is faulty, replace it.

CONTINUITY

I

POOR CONNECTION 9. Wiring connection Check the entire ignition system for conneo tions. Refer to the "WIRING DIAGRAM" section. I Correct.

~ CORRECT I Replace CDI unit.

7-13

I

O,.OSYSTE. IE'Ecl CHARGING CIRCUIT

SYSTEM DIAGRAM

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Main fuse Battery Rectifier Regulator CDI magnet

7-14

I

i i

o,d-E-~--~ - I

~ ~ ' ,

O,.OSYSTEMIE'ECI TROUBLESHOOTING THE B A T T E R Y IS N O T C H A R G E D . NOTE:

• Remove the following parts before troubleshooting. 1) Front protector bar 4) Tail cover 2) Upper cover 5) Right side cover 3) Rear carrier • Usethe following special tool (s) in this trobleshooting. 1~1

Inductive YU-8036-A tach°meter:

Pocket tester: YU-03112

I 1 ~ 1

1. Fuse (main) • Remove the fuse. • Connect the pocket tester (£1 x 1) to the fuse. • Checkthe fuse for continuity.

NO CONTINUITY

I Fuse is faulty, replace ~

CONTINUITY

2. Battery • Checkthe battery condition Refer to the "BATTERY INSPECTION" tion in the CHAPTER 3. [~

it.

Open circuit voltage: 12.8V or more at 20°C 7

INCORRECT sec-

battery terminals. (68°F) I o Clean • Rechargeor replace battery.

CORRECT

* / J

J/

7-15

O,NOS,STEMIE'ECI 3. Charging voltage Connect the inductive tachometer to the spark plug lead. Connect the pocket tester (DC20V) to the battery. Tester (+) lead- >Battery (+) terminal Tester (-) lead- >Battery (-) terminal • Start the engine and accelerate to about 5,000 r/min. • Check charging voltage.

~

Chargingvoltage: 13 ~

14 at V 4,000 r/min

NOTE:

MEETS SPECIFICATION

Use a full charged battery.

l

OUT OF SPECIFICATION I Charging circuit is good.

4. Charging coil and lighting coil resistance • Disconnect the charging coil coupler from the wireharness. • Connect the pocket tester " ~ x 1" to the charging coils. • Measurethe charging coil and lighting coil resistance.

~

z

J

Charging coil resistance: Tester (+) lead->White lead (~ Tester (-) lead->Earth Lighting coil resistance: Tester (+) lead->Yellow/Red (~ Tester (-) lead->Earth

-~


Chargingcoilresistance:

0.48~0.72 ~ at 20°C (68°F) Lighting coil resistance: 0.4-0.6 ~, at 20°C (68°F) I Charging coil is faulty, replace it. ~=,

MEET SPECIFICATION

*

7-16

O,OOS STEMIE'ECI Se

]

5. Wiring connection i Check the entire ignition system for connections. Refer to the "WIRING D I A G R A M " section.

.~o~

POOR CONNECTION

I Correct.

Replace rectifier regulator.

7-17

E.EOT..O ST..T.°O S STE. I E'EC I ELECTRIC

STARTING

SYSTEM

CIRCUIT DIAGRAM

IIII clCI~~ .... __ ON~,IIC~--~______I

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(~) Front brake switch Main switch (~ Engine stop switch Main fuse (~) Starter switch Battery Starter relay Starter motor Rear brake sv~ switch 7-18

I I I I

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E.EO*..O

STA.*.OO E'EC I S*S*EM I

TROUBLESHOOTING J

S T A R T E R M O T O R DOES N O T OPERATE.

NOTE:

• Remove the following parts before troubleshooting. 1)Battery box cover 4)Side covers (left and right) 2)Rear carrier 5)Trunk 3)Tail cover 6)Handlebar cover (front) • Use the following special tool in this troubleshooting.

I

Pocket tester: YU-03112 1. Fuse • Remove the fuse. • Connect the pocket tester (~ x fuse. • Check the fuse for continuity. S

NO CONTINUITY 1 to ) the

I Fuse is faulty, replace it.

CONTINUITY

2. Battery • Check the battery condition. Refer to the "BATTERY INSPECTION" section in the CHAPTER 3.

INCORRECT

Open circuit voltage: 12.8 V or more at 20°C (68°F)

S

l eClean battery terminals. • Recharge or replace battery.

CORRECT

3. Startermotor

~WARNING

• Connect the battery@positive terminal and starter motor cable ~) using a jumper lead (~ *

•

Aw i r e for t h e j u m p e r lead m u s t have t h e e q u i v a l e n t capacity as t h a t of t h e b a t t e r y lead or more, o t h e r w i s e it m a y cause t h e j u m p e r lead t o be burned. • This check is likely t o p r o d u c e sparks, so be sure t h a t no f l a m m a b l e gas or fluid is in t h e vicinity.

DOES NOT MOVE

t J

• Check the starter motor for operation. S

MOVES *

I Starter motor is faulty, repair or replace it. 7-19

I

I

E.EOT..O STA.T.OO S STEM I E'EC I

4. Starter relay • Disconnect the relay unit coupler from the wire harness. • Connect the pocket t e s t e r ( ~ x 1)and battery(12V) to the relay unit coupler terminals. Battery(+)lead--> Blue/White terminal (~ Battery(-)lead--~ Green/Yellow terminal (~) • Check the starter relay for continuity. NO CONTINUITY

Tester (+) lead--> (~ terminal Tester ( - ) l e a d ~ (~ terminal , ~

CONTINUITY J Replace the starter relay. NO CONTINUITY

5. Main switch Refer to "CHECKING SWITCHS" section.

, ~

CONTINUITY J Main switch is faulty, replace it. NO CONTINUITY

6. "START" switch Refer to "CHECKING SWlTCHS" section.

~

1

!;7 CONTINUITY

"START" switch is faulty, replace handlebar switch (right).

7. Engine stop switch Refer to "CHECKING SWlTCHS" section. CONTINUITY

J Engine stop switch is faulty, replace it.

9$

7-20

I

E'EOT..C S*A.*.°O S*S*EM E'EC I I CONTINUITY 8. Brake s w i t c h e s (front and rear) Disco n nect the brake switch leads from the w i r e harness. Connect the pocket tester (~ × 1)to the brake switch leads.

/f

\\\

Check the brake switch for c o n t i n u i t y Switch Position Brake is applied Brake is not applied O:Continuity

Good condition

Bad condition

0 X X I Replace brake switch(es)•

GOOD CONDITION 9• Wiring connection C h e c k t h e entire electrical starting system for connections• Refer to "WIRING D I A G R A M " section.

POOR CONNECTION

I Correct•

7-21

I

E'ECT..O STA.T.OO S STEM I E'EC I STARTER M O T O R

._._' . ~~. (

Order


~

Q'ty

~

1


Starter m o t o r removal Rear carrier Tail cover Battery box cover Left/Right side cover Center c o w l i n g Muffler Rear w h e e l Air s h r o u d 3 1 2

~

[~113 N m(1"3 m "kg' 9"4 ft'l b)~

Refer to "COVER P A N E L " section in CHAPTER 3.

m

]Refer to " R E A R W H E E L A N D REAR BRAKE" section in CHAPTER 6. Refer to "ENGINE R E M O V A L " section chapter 4.

Starter m o t o r c o u p l e r Starter m o t o r Reverse the removal procedure for installation.

7-22

I

E,ECTR,OSTART,OOSVSTEM I E'EC I

I

STARTER M O T O R D I S A S S E M B L Y

Order

Cb ® ® ® ®

Job name/Part name

Q'ty

ry~,113Nm(1.3 ~

~

=

~

1

Re marks Disassembly the parts

Starter motor disassembly O-ring Rear bracket Armature ass'y Ring Brush holder set

1

1 1 1 1-

9.4 m.kg, ft.lb)l

order. in

m

Refer to "Starter motor assembly"

Reverse the disassembly procedure for assembly.

7-23

E.EOT..C STA.T..O S STEM I E'EC I

I

YP803034

I N S P E C T I O N A N D REPAIR 1. Inspect: • Commutator Dirt-->Clean it w i t h #600 grit s a n d p a p e r . 2. Measure: • Commutator diameter (~

®

Commutatorwearit

I

15.1 m m (0.59 in)

.

Out of specification-->Replace the starter motor Measure: • Mica u n d e r c u t ( ~

Ilocaun'ercut

I

1.05 m m (0.04 in)

Out of s p e c i f i c a t i o n ~ S c r a p e the mica to the p r o p e r v a l u e (a h a c k s a w blade can be g r o u n d to fit).

NOTE: The mica i n s u l a t i o n of the c o m m u t a t o r m u s t be u n d e r c u t to ensure proper o p e r a t i o n of c o m mutator.

4.

Inspect: • A r m a t u r e coil resistances ( i n s t a l l a t i o n / continuity) Defects-->Replace the starter m o t o r . If c o m m u t a t o r is dirty, clean it w i t h sandpaper.

® (~

m

4-(

Bad c o n d i t i o n

Good condition

J

[]

©

0

x

x

[]

×

0

x

0

O: C o n t i n u i t y x: No c o n t i n u i t y Bad condition-->Replace.

7-24

E.EOT.,O STA.T,°O SVSTEM I E'EC I .

Measure: • Brush length (~ Out of specification-->Replace.

I ~ 1

.

7-25

Brush length wear limit 3.0 mm (0.012 in)

Measure: • Brush spring force Fatigue/out of specification-->Replace as a set.

I

..o.T.oo s sTEM IE'EC I LIGHTING CIRCUIT

SYSTEM DIAGRAM

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I

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~

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Main switch Fuse Battery C.D.I. magneto @ Tail light (~ Licence light

(~ (~ (~ (~) (~)

I

~i~ I

J - - ~

Head light(for high beam) Head light(for low beam) Light dimmer switch Meter light High beam indicator light

7-26

~ ~ l l

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..o.T.°o s,,sTE , I':":c I YP805010

TROUBLESHOOTING IF THE H E A D L I G H T , HIGH B E A M I N D I C A T O R LIGHT. T A I L L I G H T A N D / O R M E T E R L I G H T FAIL T O C O M E ON.

Procedure Check: 1. Lights switch 2. D i m m e r switch 3. Wiring connection (entire lighting system) NOTE: • Remove the f o l l o w i n g parts before t r o u b l e s h o o t i n g . 1) Front h a n d l e b a r cover 2) Rear carrier 3) Right side cover • Use the special tools specified in the t r o u b l e s h o o t i n g section.

°ckettester

I

YU-03112

YP

NO CONTINUITY

.....

1.Fuse Referto "CHECKING SWITCHES"

sectionlIII

CONTINUITY YP

I Replace the fuse.

.....

2. Battery • Check the battery condition. Refer to "BATTERY INSPECTION" sectior in CHAPTER 3.

~ YP

IN CORRECT

CORRECT

D

o Clean battery terminals. • Recharge or replace battery.

.....

3. Main switch I Refer to "CHECKING SWITCHES" section

~

NOCONTINUlTY

CONTINUITY i

*

i Replace the main switch. I

7-27

I

IE'ECI I Se

YP

NO CONTINUITY

.....

4. D i m m e r switch Refer to "CHECKING SWITCHES" section.

~

CONTINUITY

i

l Replace the left handlebar switch.

5. Lighting coil resistance • Disconnect the lighting coil coupler from the wireharness. • Connect the pocket tester " ~ x 1 to " the lighting coils. • Measure the lighting coil resistances. Tester (+) lead->Yellow/Red lead (~ Tester (-) l e a d , E a r t h

- - ~ Lightingcoilresistance:


0.4 ~ 0.6 ~ at 20°C (68°F)

~

MEET SPECIFICATION

*

I Lighting coil is faulty, replace it.

7-28

..o.T.°osvsTEMIE'ECI

I

Se

YP .....

6. Wiring connection Check the connections of the entire lighting system. Refer to "WIRING DIAGRAM".

POOR CONNECTIONS

,~OK

I Correct.

I

Check the condition of each of the lighting system's circuits. Refer to "LIGHTING SYSTEM CHECK" YP805020

L I G H T I N G S Y S T E M CHECK

1.

I

If the headlight and the high beam indicator light fail to come on.

1. Bulb and bulb socket Refer to "CHECKING SWITCHES" section. 7

NO CONTINUITY

CONTINUITY

2. V o l t a g e

I Replace the bulb and/or bulb socket.

• Connect the pocket tester (DC20V) to the headlight and high beam indicator light couplers.

m

~

~

~

\

n

h

[~]When the dimmer switch is on low beam. IBIWhen dimmer switch is on high beam. Headlight(low beam): Tester (+) l e a d , G r e e n O lead Tester (-) lead->Black (~) lead Headlight(high beam): Tester (+) lead-->Yellow (~ lead Tester (-) l e a d , B l a c k (~ lead

--®

~i:,i,~i,~

High beam indicator light: Tester (+) lead->Yellow ~ lead Tester (-) lead->Black (~ lead

~

G/~ :]] B

g 7-29

..o.T.°o s sTEM IE'EC I • Turn the main switch to on. • Start the engine. • Turn the dimmer switch to low beam or high beam. • Checkfor voltage (12V) on the lead at bulb socket connectors.

,•


I The wiring circuit from the main switch to bulb socket connector is faulty. Repair.

MEETS SPECIFICATION

I This circuit is not faulty. YP805021

2. If t h e m e t e r light f a i l s t o c o m e o n .

l

I l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section. 7

NO CONTINUITY

1

CONTINUITY

I Replace the bulb and/or bulb socket.

2. V o l t a g e • C o n n e c t t h e p o c k e t t e s t e r (DC20V) t o t h e bulb socket coupler.

Tester (+) lead--> Blue terminal (~ Tester (-) lead--> Black terminal (~)

% -

-

L

G_~y ,B

• Turn the main switch to on. • Start the engine. • Check the voltage (12V) of the leads on the bulb socket connector. g


MEETS SPECIFICATION

I

I This circuit is not faulty. 7-30

The wiring circuit from main switch to bulb socket is faulty. Repair.

I

..o.T.°osvsTEMIE'ECI

I

Se

3. Licence light does not come on. 1. Bulb and bulb socket • Checkthe bulb and bulb socket for continuity

~

NO CONTINUITY

CONTINUITY

I Bulb and/or bulb socket are faulty, replace.

2. Voltage • Connect the pocket tester (DC20V)to the bulb socket connector. Tester (+) lead --> Brown @ lead. Tester (-) lead --> Black (~ lead.

OUT OF SPECIFICATION • Turn the main switch to on. • Check the voltage (12V) on the " B r o w n " lead at the bulb socket connector.

~

l

MEETS

I W i r i n g circuit f r o m main s w i t c h to bulb socket connector is faulty. Repair.

SPECIFICATION (12V) I This circuit is not faulty.

7-31

I

L.O.T..O SYSTEMIE'EC

I

YP805022

3. T h e t a i l l i g h t fails t o c o m e o n .

NO CONTINUITY

I

1. Bulb and bulb socket Refer to "CHECKING SWITCHES" section. 7

CONTINUITY

I Replace the bulb and/or bulb socket. 2. V o l t a g e • C o n n e c t t h e p o c k e t t e s t e r (DC20V) t o t h e bulb socket connector.

Tester (+) lead--> Brown terminal (~ Tester (-) lead--> Black terminal (~)

GH Br ,B Ch Dg

OUT OF SPECIFICATION • Turn the main switch to on. Checkthe voltage (12V) on the bulb socket connector. MEETS SPECIFICATION

,•

I

I The wiring circuit from main switch to bulb I connector is faulty. Repair.

I

I This circuit is not faulty.

7-32

S.O...SVSTE. IE'Ecl SIGNAL

SYSTEM

CIRCUIT DIAGRAM

C IIII _.... ON I ~, ~IIC ~ ~-~___I

,', ...... -~',B .....Y-, B b

i

---,®

f--~,

.

.

.

.

, ~~I

,-C?]

.

[r -~ ---1

I

I

I

'

,~_~

o~_

I

.... I

~-',,B I

,° ' ~ - '

.

.

.

.

.

~ I~ ' .,,~

-

.

.

I.

.

.

IT~=~ ,,

-

,~I.~

®,,®

' b

--i -=

~

~/a

, I .

.

.

.

.

.

.

I

°

L

___J i

'~ -@-'

T!I~IIB

'

T l_a~1 1

I

~)r-----

,'- -G I

I . . . .

,'~3-

I

I

L_S _J L__ _J

I

I___ ,

@

',

L~___I I

I b

. . . . -->'~--I I I~ ) ~ I~IIB r

' I

•

(~ (~ (~) @ @ @ (~)

_

_I__Bj

Main switch Main fuse Battery Rear brake switch Front brake switch Brake light Rear flasher light(right)

I

~

(~ (~) @) @ (~ (~ (~)

LI_B_j~ [ 1 -@

,-

,'

L

®l

0B8 I

Rear flasher light(left) Front flasher light(right) Front flasher light(left) Flasher relay Horn Handlebar switch (Left) Horn switch 7-33

I

(~ @ (~ (~) @ (~

Turn switch Fuel sender Fuel meter Oil indicator light Turn indicator light Oil level gauge

......

I

S,O.ALSVSTEMIE'ECI I YP806010

TROUBLESHOOTING IF T H E F L A S H E R L I G H T , B R A K E L I G H T A N D / O R I N D I C A T O R FAIL T O C O M E O N . IF T H E H O R N F A I L S T O S O U N D .

Procedure Check: 1. Fuse (Main) 2. Battery

LIGHT

3.Main switch 4.Wiring connection (entire signal system)

NOTE:

• Remove the following parts before troubleshooting. 1 Battery ) box cover 5) Tail cover 2) Front protector bar 6) Side covers(Left/Right) 3) Upper cover 7) Center cover 4) Rear carrier • Use the special tools in the troubleshooting section.

P°ckettester:

I

YU-03112

NO CONTINUITY

¥P

. . . . .

I

1. Fuse

Refer to "CHECKING SWITCHES" section.

~ CONTINUITY I Replace the fuse.

YP

.....

2. Battery • Check the battery condition. Refer to "BATTERY INSPECTION" section in CHAPTER 3.

IN CORRECT

~ CORRECT

l eClean battery terminals. • Recharge or replace battery.

YP .....

3. Main switch Refer to "CHECKING SWITCHES" section.

NO CONTINUITY

CONTINUITY .-X-

I Replace the main switch.

7-34

S,O°A.SVSTEMIE'ECI

I

Se

YP

......

4. Wireharness • Checkthe connections of the entire signal system. Refer to "CIRCUIT SYSTEM WIRING GRAM" section. ~

POOR CONNECTION DIAI Correct.

CONTINUITY

Check condition of each of the signal system's circuits. Refer to "SIGNAL SYSTEM CHECK" tion.

7-35

sec-

I

SIGNAL SYSTEM

ELEC

'-

*'

YP806020

SIGNAL SYSTEM CHECK

1.

l

If the horn fails to sound.

NO CONTINUITY

l. HORN switch Refer to "CHECKING SWITCHES" section.

I Replace the left h a n d l e b a r switch. CONTINUITY

2. Voltage • Connect the pocket tester (DC20V) to the horn lead. Tester (+) l e a d - > B r o w n terminal (~. Tester (-) lead->Frame g r o u n d

i

• Turn the main switch to on. • Check for voltage (12V) on the " B r o w n " lead at the horn terminal.

,•

LoLI

_L


n

I The w i r i n g circuit from the main switch to the e horn is faulty. Repair.

MEETS

I

SPECIFICATION

1-

"Y

3. Horn • Connect the pocket tester (DC20V) to the horn at the " P i n k " terminal. Tester (+) lead->Pink (~ terminal. Tester (-) lead->Frame g r o u n d

_L

• Turn the main switch to on. • Check for voltage on the " P i n k " lead at the horn terminal.

NO CONTINUITY

@ CONTINUITY i A d j u s t or replace horn.

I Replace the horn.

7-36

S,O.A,S*S*EMIE'Ecl YP806022

2.

If t h e b r a k e l i g h t f a i l s t o c o m e o n :

NO CONTINUITY

J l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.

~7

CONTINUITY

J Replace the bulb and/or bulb socket. NO CONTINUITY

J

2. Brake switch (Front/Rear) Refer to "CHECKING SWI SWITCHES" section.

, ~

I

CONTINUITY

1 J Replace brake switch.

3. Voltage • Connect the pocket tester (DC20V) to the bulb socket connector. Tester (+) lead~>Green/Yellow terminal (~ Tester (-) lead~>Black terminal (~

-

/ • • •

-

%' Turn the main switch to on. T h e b r a k e l e v e r is p u l l e d in. C h e c k f o r v o l t a g e (12V) o f t h e " G r e e n / Y e l low" lead on the bulb socket connector.

~


MEETS SPECIFICATION

4. Wiring connection Wiring circuit from the main switch to the bulb socket connector is faulty. Repair. Refer to "SIGNAL SYSTEM WIRING DIAGRAM

JThis circuit is not faulty.

"

7-37

I

S,ONA, SVSTEM IE'Ecl YP806023

3.

If the flasher light and/or turn indicator light fails to blink.

NO CONTINUITY

J l. Bulb and bulb socket Refer to "CHECKING SWITCHES" section.

, ~

CONTINUITY

J Replace the bulb and/or bulb socket. NO CONTINUITY

J

2. Turn switch Refer to "CHECKING SWITCHES" section.

~

I

CONTINUITY

1 J Replace the left handlebar switch.

3. Voltage • Connect the pocket tester (DC20V) to the flasher relay coupler. Tester (+) lead->Brown lead (~. Tester (-) lead->Black lead(~) • Turn the main switch to on. • Check for voltage (12V) of the "Brown" lead at the flasher relay terminal.

,•


The wiring circuit from main switch to flasher relay connector is faulty. Repair.

MEETS SPECIFICATION

G

4. Voltage • Connect the pocket tester (DC20V) to the flasher relay coupler. Tester (+) lead->Brown/White lead (~. Tester (-) lead->Black lead(~) • Turn the main switch to on. • Check for voltage (12V) on the "Brown/ White" lead at the flasher relay terminal. ~7


MEETS SPECIFICATION

J The flasher relay is faulty. Replace.

* 7-38

I

S,OOA,SVSTEMIE'Ecl 5. Voltage • Connect the pocket tester (DC20V) to the bulb socket connector. At flasher light (left) Tester (+) lead->Chocolate lead (~ Tester (-) lead->Black terminal (~) At flasher light (right) Tester (+) lead--~Dark green lead (~ Tester (-) lead->Black terminal (~ OUT OF SPECIFICATION

• Turn the main switch to on. • Turn the turn switch to left or right. • Check for voltage (12V) on the " C h o c o late" lead and " D a r k g r e e n " at the flasher light terminal.

6. Wiring connection • Wiring circuit from t h e t u r n switch to bulb socket c o n n e c t o r is fault. Repair. Refer to "CIRCUIT D I A G R A M " .

J ~MEETS

SPECIFICATION

I This circuit is not faulty. 4.

"OIL" indicator light does not c o m e on.

NO CONTINUITY

1. Bulb and bulb socket • C h e c k t h e bulb and bulb socket for continuity.

l

~ CONTINUITY 2. Oil level • Remove tank. • Connect oil level

I Replace bulb and/or bulb socket.

switch the oil level switch from the oil the Pocket Tester (~ x switch.

1)to the

Tester (+) Lead--~Brown (~ Tester (-) Lead->Gray (~

~,2

....

"-

• Check the oil level gauge for continuity. Good Bad condition condition BAD CONDITION © × © [ ] U p r i g h t position X []Upside down © x x © position Switch position

C): C o n t i n u i t y

X : No c o n t i n u i t y I Replace oil level switch. GOODCONDITION 7-39

I

S,°°A,S,S,EM IE'Ecl 3. Voltage • Connect the Pocket Tester (DC20V) to the bulb socket connector.

g

Tester (+) Lead->Gray lead (~ Tester (-) Lead--~Black lead (~ • Turn the main switch to " * " • Check for voltage (12V) on the "Gray" lead at bulb socket connector.

,•

MEETS SPECIFICATION (12V)

I b ,BI q~l L


I This circuit is good. 4. Wiring connection • Checkthe entire signal system for connections. Refer to the "WIRING DIAGRAM" section. YP806027

5.

If t h e fuel g a u g e fails t o o p e r a t e .

1. Fuel sender Remove the fuel sender from the fuel tank. Disconnect the fuel sender coupler from the wireharness. Connect the pocket tester (~ xl0) to the fuel sender coupler lead. Tester (+) lead->Green terminal (~ Tester (-) lead--~Black terminal (~ • Check the fuel sender for specificated resistance. ~Jl

Float position UP (~ DOWN (~ ~7

Specificated resista nce 4~10~ 90~100£~


BOTH MEET SPECIFICATION

I Replace the fuel sender.

7-40

S,O.A,SSTEMIE'Ecl 2. Voltage • Connect the pocket tester (DC20V) to the fuel gauge coupler.

,/

I

\

Tester (+) lead->Brown terminal (~ Tester (-) lead->Frame ground

II G • Turn the main switch to " O N " . • Check for voltage (12V) of the " B r o w n " lead on the fuel sender lead.

,•

Ch I II


l

MEETS SPECIFICATION

Checkthe connection of the entire signal system. Refer to " C H E C K I N G OF CONNECTIONS". Refer to "CIRCUIT D I A G R A M " .

3. Fuel gauge • Connect the fuel sender to wireharness. • M o v e the float to " U P " ( ~ or " D O W N " (~.

NOTE:

Before reading the meter, stay put the float for more than three minutes respectively at " U P " or " D O W N " .

I

• Turn the main switch to " O N " . • Check the fuel gauge needle moves " F " or " E " Float position

DOES NOT MOVE

Needle moves

Float " U P " (~

"F"

Float " DOWN " ( ~

"E"

I Replace the fuel gauge.

~7 MOVES I This circuit is not faulty.

7-41

,UZO O.OKE S STE. IE'Ecl A U T O CHOKE S Y S T E M CIRCUIT

DIAGRAM

IION CI~~ IIIICc

[-__ .... ~, ~--~______I I. . . . . . . . '

I. . . . . . .

, B

'~

• --,®

'~

'

~#~ /

~,a

L

.

.

.

.

.

~ l ~I ' !

~__~_8

--~i_

I

-i 1

-~- ~ - 6

L I

I

~

-l~'

L . . . . . . .

I

,T

I

I

i

1

I

~)r----I . . . .

I

I

,'- %71

,'%-

L_

L__

_J

I

s

I___

,

e

',

I

Lit_ - - I I L

r . . . .

'

L_

,

-->' ~ - - I

S

®~',D

' fl ~

-~'

L ,t_B_j

(7) Auto choke (~ C.D.I. magneto

7-42

I I I I

®l

0B8

I

"~ I T. .~. .'. ,. ~ I

I. . . . . . . . . .

-

_~

,~o ~ ,

~ I~1

- -

___~

......

,B

~'

®Ira

L_~: -o-

-

~

, H-~I

,%7~T]

[r -~ ---1

~

I

,IB Y--

¢]

I

_J

I

AUTO O.O.E SYSTEM IE'Ecl "y'p .....

TROUBLESHOOTING IF THE A U T O CHOKE FAILS TO OPERATE.

Procedure Check: 1. Lighting coil resistance 2. Auto choke unit resistance 3. Wiring connection (entire auto choke system) NOTE:

• Remove the following parts before troubleshooting. 1. Battery box cover 2. Rear carrier 3. Tail cover 4. Right side cover • Use the special tools specified in the troubleshooting section. ~ 1

P°cket tester: YU-03112

I

1. Lighting coil resistance • Disconnectthe CDI magneto couple from wire harness. • Connect the pocket tester (E2 x l ) to the lighting coil coupler Tester (+) Lead->Yellow/Red (~ terminal Tester (-) Lead--~Frame earth

w

Y/R

$

(~ C.D.I. magneto • Checkthe lighting coil for specificated resistance


Lighting coil resistance 0.4~0.6 ~ 20°C (68°F) I Replace the lighting coil MEETS SPECIFICATION

7-43

I

AUTO O.O.E S STEM IE'Ecl YP...

2. Auto choke unit resistance • Disconnect the auto choke unit coupler from the wireharness. • Connect the pocket tester ( ~ x l ) to the auto choke unit coupler lead. Tester (+) l e a d . B l a c k terminal (~ Tester (-) lead->Black terminal (~ ~_~


Auto choke unit resistance: 8~12~ at 20°C (68°F)

~ MEETS

I Replace the auto choke unit.

SPECIFICATION

3. Wiring connection • Check the connection of the entire auto choke system. Refer to "CIRCUIT DIAGRAM" section.

POOR CONNECTION

I Correct.

7-44

I

STARTnNG FAnLURE/HARD

?

ITRBLI I ISHTGI STARTnNGI

TROUBLESHOOTING NOTE:

The f o l l o w i n g t r o u b l e s h o o t i n g does not cover all the possible causes of trouble. It should be helpful, however, as a guide to t r o u b l e s h o o t i n g . Refer to the relative procedure in this manual for inspection, a d j u s t m e n t and replacement of parts. STARTING FAILURE/HARD STARTING FUEL S Y S T E M

PROBABLE CAUSE

Fueltank

Fuelcock

• Empty • Clogged fuel filter • Deteriorated fuel or fuel containing w a t e r or foreign material • Clogged fuel tank cap L

• Deteriorated fuel, fuel c o n t a i n i n g w a t e r or foreign material • Clogged pilot jet • Clogged pilot air age • Sucked-in air • Deformed float • G r o o v e - w o r n needle valve • I m p r o p e r l y sealed valve seat • I m p r o p e r l y adjusted fuel level • I m p r o p e r l y set pilot jet • Clogged starter jet

Carburetor

A u t o choke

• C l o g g e d fuel hose • Clogged fuel cock • Faulty fuel cock operation • Broken or disconnected fuel cock

/-

Starter plunger malfunction W a x malfunction Faulty t h e r m i s t e r • Clogged air filter

Air cleaner

8-1

S T A R T I N G FAILURE/HARD S T A R T I N G IGNITION SYSTEM

• • • • • L

?

Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap

•Broken or shorted primary/secondary coil • Faulty spark plug lead • Broken body

CD I unit system L

Switches and wiring

ISHTGI

PROBABLE C A U S E

Spark plug

Ignition coil

ITRBLI

• Faulty CD I unit •Faulty source coil • Faulty pick-up coil • Faulty main switch •Broken or shorted wiring

/

L

COMPRESSION SYSTEM

PROBABLE C A U S E

Cylinder and cylinder head

Loose spark plug Loose cylinder head or cylinder Broken cylinder head gasket Broken cylinder gasket Worn, damaged or seized cylinder

L" Piston and piston rings

Crankcase and crankshaft

L

•

/"

Reed valve

Improperly seated crankcase Improperly sealed crankcase (Damaged oil seal) Seized crankshaft • • • • •

8-2

Improperly installed piston ring Worn, fatigued or broken piston ring Seized piston ring Seized or damaged piston

Deformed reed valve stopper Improperly seated read valve Loose intake manifold Broken gasket Broken reed valve

II

PERFORMANCE ITRBLI ?

POOR IDLE SPEED POOR IVIIDIUIVI A N D HIGH SPEED P E R F O R M A N C E

ISHTGI

POOR IDLE SPEED P E R F O R M A N C E P O O R IDLE S P E E D P E R F O R M A N C E

PROBABLE CAUSE

Carburetor

• • • •

m

•

L

Auto choke

Improperly returned starter plunger Clogged or loose pilot jet Clogged pilot air jet Improperly adjusted idle speed (Throttle stop screw) Improper throttle cable play Flooded carburetor

•Starter plunger malfunction • Wax malfunction • Faulty thermister

Air cleaner

• Clogged air cleaner

Ignition system

• • • • •

Faulty Faulty Faulty Faulty Faulty

spark plug spark plug read C.D.I. unit source coil ignition coil

POOR M I D I U M A N D HIGH SPEED PERFORMANCE POOR MEDIUM MANCE

AND

HIGH SPEED PERFOR-

Carburetor

--

PROBABLE CAUSE

• Refer to starting failure/Hard starting item (Fuel system, Ignition system, compression system) • Clogged or loose main nozzle • Clogged or loose main jet • Improperly adjust fuel level • Sucked-in air

/

Air cleaner

• Clogged air filter

Muffler

• Clogged

8-3

I

POOR M I D I U M A N D HIGH SPEED P E R F O R M A N C E

ITRBLI ISHTGI '? I

FULTY A U T O M A T I C ( V - B E L T TYPE) PROBABLE CAUSE

SCOOTER DOES NOT MOVE WHILE ENGINE IS O P E R A T I N G --

V-belt

• W o r n , d a m a g e d or s l i p p e d V - b e l t

--

Cam, slider

• Worn, damaged

--

Compression spring

• Damaged

--

Transmission

• Damaged

C L U T C H O U T FAILURE --

Clutch w e i g h t spring

• Damaged

--

Clutch shoe

• Pealed l i n i n g

--

Primary sheave

• S e i z e d p r i m a r y s l i d i n g s h e a v e and c o l l a r

POOR STANDING ABILITY)

--

START(LOW

CLIMBING PROBABLE CAUSE

V-belt

• W o r n or s l i p p e d V - b e l t

Primary sheave

• Improper operation • Damaged

Compression spring

• Damaged

Secondary sheave

/

• Improper operation • W o r n g u i d e pin

Clutch shoe

• Plealed l i n i n g

P O O R A C C E L E R A T I O N ( P O O R H I G H SPEED) --

m

PROBABLE CAUSE

V-belt

/

• Worn • Greasy

Weight

/

• Worn • Improper operation • Worn

Primary/Secondary seave

8-4

OVER HEAT I POOR SPEED

ITRBLI ISHTGI ? I

OVER HEAT OVER HEAT

PROBABLE C A U S E

Ignition system

L

• I m p r o p e r plug gap • Improper spark plug heat range • Faulty C.D.I. unit

--

Fuel system

L

• I m p r o p e r carburetor setting • Clogged air filter

--

Compression system

• Carbon accumulation of cylinder head

m

Muffler, Exhaust pipe

•

Oil pimp

--

Clogged

Brake

• Faulty oil pump • Faulty oil quality • Drag

Cooling system

•

/

Fandamaged

POOR SPEED POOR SPEED

--

--

m

PROBABLE C A U S E

Ignition system

L

•Faulty spark plug • Improper spark plug heat range • Faulty C.D.I. unit • Faulty source coil

Fuel system

L

•Clogged fuel tank cap • Clogged air filter • Clogged carburetor

Compression system

L

• • • •

•Worn cylinder Worn, fatigued or broken piston ring Broken cylinder head gasket Broken cylinder gasket Carbon accumulation of cylinder head

Muffler, Exhaust pipe

• Clogged

Clutch

• Refer to "FAULTY AUTOMATIC"

Brake

• Drag

8-5

,MPROPER

ITRBLI NG ISHTGI K,CK,

?

IMPROPER KICKING SLIPPING

PROBABLE C A U S E

Kick axle assembly

• • • • • •

Transmission oil L

H A R D KICKING

Kick axle assembly

Low tension of kick clip Worn kick axle Worn or damaged kick gear Damaged kick clip Kick clip coming off Damaged kick clip stopper

• Improper quality (Low viscosity) •Deterioration

PROBABLE C A U S E

j~

• High tension of kick clip • Seized kick gear

- - C y l i n d e r , piston and piston r i n g - - L

•Damaged or seized cylinder • Damaged or seized piston • Damaged or seized piston ring

m Crankcase and crankshaft

• Improperly seated crankcase • I m p r o p e r l y seated crankshaft • Damaged or seized crankshaft • Damaged or seized crankshaft bearing

L

KICK C R A N K N O T R E T U R N I N G

L

Kick axle assembly

PROBABLE C A U S E

L

8-6

•Damaged kick return spring • Kick return spring coming off • Kick clip coming off • Damaged kick return spring stopper

I

I

ITRBLI

FAULTY BRAKE I S H T G I

?

FAULTY BRAKE PROBABLE C A U S E

POOR B R A K I N G EFFECT Drum brake

m

Disc b r a k e (Front)

• • • •

Worn brake shoe Worn or rusty brake drum Improperly adjusted brake free play Improper brake cam lever position

• • • • •

Improper brake shoe position Fatigue/Damaged return spring Oily or greasy brake shoe Oily or greasy brake drum Broken brake cable

• • • • • • • • • •

W o r n b r a k e pad W o r n b r a k e disc A i r in brake f l u i d Leaking brake fluid F a u l t y m a s t e r c y l i n d e r kit F a u l t y c a l i p e r seal kit Loose union bolt Broken brake hose O i l y o r g r e a s y b r a k e pad O i l y o r g r e a s y b r a k e disc

PROBABLE C A U S E

MALFUNCTION

• • • • • •

8-7

Bent, d e f o r m e d o r d a m a g e d i n n e r t u b e B e n t or d e f o r m e d o u t e r t u b e Damaged fork spring W o r n o r d a m a g e d slide m e t a l I m p r o p e r oil v i s c o s i t y I m p r o p e r oil level

I

I

ITRBLI INSTABLE HANDLING ISHTGI

?

INSTABLE H A N D L I N G PROBABLE CAUSE

INSTABLE HANDLING

• Improperly installed or bent

Handlebar --

Steering L

Front forks L

• Uneven tire pressures on both sides •Incorrect tire pressure • Unevenly worn tires

L

• Damaged bearing •Bent or loose wheel axle • Excessive wheel run-out

L

• Twisted • D a m a g e d head pipe • Improperly installed bearing race

~Wheels

Frame

• Bent or damaged

m Engine bracket Rear shock absorber

• Broken spring • B o n d e d front forks

L

Tires

--

• Improperly installed steering column (Improperly tightened ringnut) • Bent steering column • Damaged ball bearing or bearing race

/

L

8-8

• Fatigued spring • O i l leakage

II

FAULTY SIGNAL AND LIGHTING SYSTEM

ITRBLI ISHTGI ? I

FAULTY SIGNAL AND LIGHTING SYSTEM PROBABLE C A U S E

HEADLIGHT DARK

I

• • • • • • •

PROBABLE C A U S E

BULB BURNT OUT

I L_

- -

• I m p r o p e r bulb •Improperly grounded • Faulty main and/or light switch • Bulb life expires PROBABLE C A U S E

FLASHER DOES NOT BLINK

I

- -

I m p r o p e r bulb Too m a n y electric accessories Hard charging (Broken charging coil) Incorrect c o n n e c t i o n Improperly grounded Poor s (main or light switch) Bulb life expires

• • • • • • • •

Improperly grounded Discharged battery Faulty flasher switch Faulty flasher relay Broken w i r e h a r n e s s Loosely connected c o u p l e r Bulb burnt out Faulty fuse

PROBABLE C A U S E

FLASHER KEEPS ON

I

• Faulty flasher relay • I n s u f f i c i e n t b a t t e r y c a p a c i t y ( n e a r l y discharged) • Bulb burnt out

L

8-9

FAULTY SIGNAL AND LIGHTING SYSTEM FLASHER BLINKS SLOWER

ITRBLI ISHTGI ? I

PROBABLE C A U S E

I

• Faulty flasher relay • Insufficient battery capacity (nearly discharged) • Improper bulb • Faulty main and/or flasher switch

FLASHER BLINKS QUICKER

PROBABLE C A U S E

I L HORN DOES NOT S O U N D

• Improper bulb • F a u l t y flasher relay PROBABLE C A U S E

I

• • • • • •

8-10

Faulty battery Faulty fuse Faulty main and/or horn switch I m p r o p e r l y adjusted horn Faulty horn Broken w i r e h a r n e s s

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Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, ON M2H 3B4

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