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Yamaha XF50 Service Manual - Absolutely Scooters & Supply

1. 3 36 CHANGING THE 3 37 CHASSIS nee ee 3 40 ADJUSTING THE FRONT BRAKE 3 40 ADJUSTING THE REAR 3 40 CHECKING THE FRONT AND REAR BRAKE SHOES 3 41 CHECKING AND ADJUSTING THE STEERING HEAD 3 42 CHECKING THE FRONT 3 44 CHK INTRODUCTION PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments If followed these preventive maintenance procedures will ensure more reliable vehicle operation a longer service life and reduce the need for costly overhaul work This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter 500036 NOTE The annual checks must be performed every year except if a kilometer based maintenance Is performed instead From 30 000 km repeat the maintenance intervals starting from 6 000 km Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills tools data technical 50000 o 3 1 CHK Q PERIODIC MAINTENANCE AND MINOR REPAIR ADJ PERIODIC MAINTENANCE AND MINOR REPAIR PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INITIAL ODOMETER READING i 2 000 mi 4 000 mi
2. installing the oil seal lubricate its lips with lithi soap base grease Hid e Lubricatethe outer surface of the inner tube wit oil e re installing the oil seal cover the top the front fork leg with a plastic bag 4 to protect the oil seal during installation 5 Install seal Adjust the oil seal clip so that it fits into the outer tube s groove 6 Fill e front fork leg with the specified amount of the recom mended fork oil Quantity each front fork leg 0 042 L 0 038 Imp qt 0 046 US qt Recommended oil Fork oil 10W or equivalent 4 25 FRONT FORK CHAS NOTE LLL e While filling the front fork leg keep it up right e After filling slowly pump the front fork leg up and down to distribute the fork oil 7 Install e fork spring 1 e Install the spring smaller pitch fac ing down 500663 ING THE FORK LEGS ollowing procedure applies to both of the A fork legs 1 Install e front fork leg e o ring 0271 e cap bolt LLL Pull up the inner tube until it stops then install AN the cap bolt O 2 Tighten lt ecap bolt 1 45 Nm 4 5 32 5 ft Ib e lower bracket pinch bolt 30Nm 3 0m kg 21 7ft Ib 4 26 EASO0664 HANDLEBAR gt ON Front fork upper cover Front fork cover left and right Leg shield1 2 Hear view mirror lef
3. enne Qo C 2 29 9 S S GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model code 3B32 U 3B33 C Dimensions Overall length 1905mm 75 00in Overall width 685 26 97 Overall height 1045mm 41 14in Seat height 735mm 28 94 in Wheelbase 1280mm 50 39in Minimum ground clearance 115mm 4 53in Minimum turning radius 2000mm 78 74in Weight NN Wet without oil and a full fuel tank 9Okg 198lb Dry without and fuel 85kg Maximun load total of cargo rider enn passenger and accessories 2 1 ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Engine Engine type Displacement Cylinder arrangement Borexstroke Compression ratio Engine idle speed Vacuum pressure at engine idle speed Standard compression pressure at sea level Fuel Hecommended fuel Fuel tank capacity Total Engine oil Lubrication system Hecommended oil Quantity Periodic oil change Total amount Final gear oil Hecommended o Periodic oil change Total amount Liquid cooled 4 stroke SOHC 0 0491 49cms 2 99cu in Forward inclined single cylinder 38 0 43 5 1 496 1 713 12 1 2000 2200r min 34 7kPa 260mmHg 10 24inHg 1450kPa 14 5kg cm at 700r min line Unleaded gasoline gSA API service SG type or higher JASO stand MA 0 73 0 83L 0 67 0 76 Imp qt 0 80 0 90 US qt 0 80 0 90L 0 74 0 83 Imp qt 0 87 0 98 US qt SAE1
4. 1 5 BEARINGS AND OIL 1 5 21 1 5 EQUIPMENT PREPARATION oM 1 6 CHECKING THE CONNECTIONS 1 7 SPECIAL 1 lt c MEM 1 8 9 S S SCOOTER IDENTIFICATION GEN fes 500015 GENERAL INFORMATION SCOOTER IDENTIFICATION 500017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame 500018 MODEL LABEL The model label is affixed to the frame trunk This information will be needed to order spare parts QN S AS 2 W 500896 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti mum air fuel ratio in accordance with the engine operating conditions and the atmospheric tempera ture In the conventional carburetor system the air fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor Despite the same volume of intake air the fuel volume requirement varies by the engine operating conditions such as acceleration deceleration or operation under a heavy load Carburetors that meter the fuel through the use of jets have been provided with various
5. Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal A AAAAAAAAAAAAAAAAAAAAA 2 Install brake shoe plate Align the tab on the speedometer clutch with the slot in the wheel hub 4 9 FRONT WHEEL AND BRAKE CHAS 500540 INSTALLING THE FRONT WHEEL 1 Lubricate wheel axle e wheel bearings seal lips e speedometer drive gear e speedometer driven gear Recommended lubricant Lithium soap based grease 2 Install efront wheel 1 NOTE Make sure the slot 2 if Wie brake shoe plate fits over the the outer tube 3 Tighten e wh le nut 5 748 Nm 4 8 34 7 ft Ib Make sure the brake cable is routed properly Ss CAUTION SS Before tightening the wheel axle nut push 2 down hard on the handlebar several times and check if the front fork rebounds O smoothly 4 10 FRONT WHEEL AND BRAKE CHAS 12010101 4 11 500548 ADJUSTING THE WHEEL STATIC BALANCE NOIRES R e After replacing the tire wheel or both the front wheel static balance should be ad justed e Adjust the front wheel static balance with the brake disc installed 1 Remove e balancing weight s 2 C front wheel s heavy spot IBN LI L A a Place the front wheel on a suitable balancing stand
6. oil level Q e incorrect oil viscosity e nferior oil quality 92 COOLING SYSTEM S Coolant e ow coolant level Radiator eDamaged or leaking radiator radiator cap eBent or damaged radiator fan Water pump eDamaged or faulty water pump Thermostat e hermostat stays closed Oil cooler eClogged or damaged oil cooler COOLING SYSTEM Thermostat e hermostat stays open POOR BRAKING PERFORMANCE FAULTY FRONT TRBL FORK LEGS UNSTABLE HANDLING SHTG 500859 500862 POOR BRAKING PERFORMANCE UNSTABLE HANDLING Drum brake Handlebar eWorn brake shoe eBent or improperly installed handlebar eWorn or rusty brake drum e ncorrect brake lever position Steering head components brake lever free play eimproperly installed handlebar bracket brake camshaft lever position eimproperly installed lower bracket e ncorrect brake shoe position improperly tightened ring nut eDamaged or fatigued brake shoe spring eBent steering stem or grease on the brake shoe eDamaged ball bearing or bearing race or grease on the brake drum Front fork leg s eUneven oil levels Roth front fork legs eUnevenly tension O fork spring both front 0 fork legs 4 FAULTY FRONT FORK LEGS eBroken forkspting LEAKING OIL eBent o aged inner tube eBent damaged or rusty inner tube ee outer tube eCracked or damaged outer tube installed oil seal Rear E absorber assembly
7. Replace if necessary AN Check bearing assemblies for looseness Moderately repack with lithium soap based grease every 8000 mi 13000 km or 24 months Check all chassis fitting and m Chassis fasteners fasteners y y V Correct if necessary v Front and rear brake Apply lithium soap based grease y Y J lever pivot all purpose grease lightly Check N AA NC Check and for Front fork leakage 4 if necessary amp heckabsorBor Check operation and ES leakage assembly Replace if necessa Change warm ep draining Check oil gem Engine oil strainer Cooling system A 7 Every 3 years Final transmission NN vehicle for oil leakage oil Change Front and rear brake Check operation Check operation switches Apply Yamaha chain and cable Control and meter lube or engine oil 10W 30 cables thoroughly Check operation and free play Adjust the throttle cable free play if necessary y y y Lubricate the throttle grip housing and cable Lights signals and Check operation y switches Adjust headlight beam Steering bearings 7 Throttle grip housing and cable 3 3 CHK
8. Spin the front wheel b When the front wheel stops put an X mark at the bottom of the wheel Turnthe front wheel 90 so that the X mark is positioned as shown d Release the front wheel e When the wheel stops put an X mark at the bottom of the wheel f Repeat steps d through f several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X AAAAAAAAAAAAAAAAAAAAAAA FRONT WHEEL AND BRAKE CHAS Adjust e front wheel static balance WWVVVVVVVVVVVVVVVVVYVYVYVY a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X NOTE Start with the lightest weight 12010103 b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced AAAAAAAAA 2 AS XO X 4 ront wheel static balance JGAvvvvVYYYVYYYYYYYYYYYYY Turn the front wheel and make sure it stays X 2 X at each position shown amp b If the front wheel does not remain station O ary at all of the positions rebalance it SS AAAAAAAAAAAAAAAAAAAAAAA 2 12010106 dl SM 4 12 REAR WHEEL AND BRAKE CHAS 500555 REAR WHEEL AND BRAKE 120Nm 12 0m kg 86 8 ft Ib Job Part C P Hemarks Removing the rea
9. efuel hose e fuel hose connector cover 557 CAUTION Be sure to connect the fuel hose securely and install the fuel hose connector cover in the correct position otherwise the fuel hose will not be properly installed 5552 0 e Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose After installing the fuel hose connector cover 1 make sure that it is installed se curely THROTTLE BODY AND FUEL INJECTOR 500915 CHECKING THE FUEL PUMP AND PRES SURE REGULATOR OPERATION 1 Check e pressure regulator operation a Remove the footrest board Refer to COVER AND PANEL in chapter 3 b Remove the fuel hose connector cover 1 and disconnect the fuel hose 2 from the fuel pump GALITION Although the fuel has been removed from the fuel tank be carefulwhen removing the fuel hose since there Qo be fuel remaining In it T Before remoting the hose place a few rags the area r where it will be removed C pressure gauge 3 and adapter onto the fuel hose Pressure gauge 90890 03153 YU 03153 Adapter 90890 03181 d Start the engine e Measure the fuel pressure Fuel pressure 246 254 kPa 2 46 2 54 kg cm 35 0 36 1 psi Faulty gt Replace the fuel pump
10. 4 37 S REAR SHOCK ABSORBER ASSEMBLY CHAS 500692 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the scooter on a level surface Securely support the scooter so that there is no danger of it falling over NOTE 2L Place the scooter on a suitable stand so that the rear wheel is elevated 2 Remove e front cover e side cover left Refer to SIDE ERS AND TAIL BRAKE LIGHTS chapter 3 3 Remove e rear 570 bsorber nut upper e rear M k absorber bolt upper cg ock absorber bolt lower 500695 CHECKING THE SHOCK ABSORBER ASSEMBLY 1 Check erear shock absorber rod Bend damage gt Replace the rear shock absorber assembly erear shock absorber Oil leak Replace the rear shock ab sorber assembly espring Damage wear gt Replace the rear shock absorber assembly ebushing Damage wear gt Replace edust seal Damage wear gt Replace ebolts Bends damage wear gt Replace 4 38 REAR SHOCK ABSORBER ASSEMBLY CHAS 500698 INSTALLING THE REAR SHOCK AB SORBER ASSEMBLY 1 Install e rear shock absorber assembly 2 Tighten e rear shock absorber assembly upper nut 30Nm 3 0m kg 21 7ft Ib rear shock absorber assembly lower bolt 16Nm 1 6m 11 6ft Ib 3 Install e side cover left QN e front cover Refer to SIE COVERS AND TAIL BRAKE chapter 3 O 4 39 CHAPTER 5 ENGINE ENGINE REMOVAL sssssss
11. radiator cover lt Refer to HADIATOR in chapter 6 8 Fill 9 e cooling system with the specified amount of the recom ee mended coolant Refer to CHANGING THE COOLANT NO 9 Install SN e single seat trunk O e battery battery cover 49 e side cover left and right e front cover Refer to COVER AND PANEL 3 21 CHK Q MEASURING THE COMPRESSION PRESSURE ADJ EAS00067 MEASURING THE COMPRESSION PRES SURE 2 Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of specification gt Adjust Hefer to ADJUSTING THE VALVE CLEARANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Remove e panel A Refer to FOOT T BOARD AND IN NER FENDER 4 Disconne RNING Remoye e spark plug cap the engine is exe ely hot SS Hemove EN e spark plug CAUTION Before removing the spark plug use compressed air to blow away any dirt ee accumulated in the spark plug well to prevent it from falling into the cylinder 6 Install e compression gauge 1 Compression gauge 90890 03081 YU 33223 7 Measure compression pressure Out of specification gt Refer to steps and d Compression pressure at sea level Minimum 1262kPa 12 62kg cm 179 7psi Standard 1450kPa 14 5kg cm 206 5psi Maximum 1624kPa 16 24kg cm 231 3psi 3 22 CHK Q MEASURING THE COM
12. 5 36 CHECKING THE TIMING CHAIN GUIDE eee 5 37 INSTALLING THE PISTON AND CYLINDER 5 37 BELT DRIVE Q sssssssssssssssssssssesssssssesssessseesssesssesssssssnessneesssesssessseessnessnessneen 5 39 V BELT CASE COVER 5 39 KICKSTARTER 404 40 0000 5 40 INSTALLING THE KICKSTARTER u c 5 41 V BELT AND PRIMARY SECONDARY SHEAVE 5 42 SECONDARY SHEAVE 0 cscsscsssesssesssessssesssesssecssesssesssessseesseesaseeaee 5 43 REMOVING THE PRIMARY 5 44 REMOVING THE SECONDARY SHEAVE AND V BELT DISASSEMBLING THE SECONDARY SHEAVE CHECKING THE CLUTCH SHOES cene CHECKING THE CHECKING THE PRIMARY 5 CHECKING THE PRIMARY SHEAVE WEIGHTS CHECKING THE SLIDER eene CHECKING THE SECONDARY SHEAVE ASSEMBLING THE PRIMARY SHEAVE ASSEMBLING THE SECONDARY SHEAVE INSTALLING THE SECONDARY SHEAVE V BELT AND PRIMARY 5 50 STARTER CLUTCH AND ee 5 53 STATOR COIL ASSEMBLY cem tese 5 53 STARTER CLUTCH eee AS 5 55 REMOVING
13. ECU S SELF DIAGNOSTIC FUNCTION The ECU is equipped with a self diagnostic function in order to ensure that the engine control sys tem is operating normally If this function detects a malfunction in the system it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system Once a malfunction has been detected a fault code is stored in the memory of the ECU e inform the rider that the fuel injection sys tem is not functioning correctly the engine trouble warning light flashes when the start switch is being pushed to start the engine e f a malfunction is detected in the system by the self diagnostic function this mode provides an appropriate substitute charac teristic operation and alerts the rider of the detected malfunctio illuminating the en gine trouble warnigg fight e Afterthe been stopped the low D Engine trouble warning light est fault umber appears on the en gine rod arning light or displayed on the FJ diagnostic tool It remains stored in the Memory of the ECU until it is deleted ce e Engine trouble warning light fault code indicata i Digit of 10 Cycles of 1 see ON and 1 5 sec OR Digit of 1 Cycles of 0 5 sec ON and 0 5 sec Example 42 Light ON Light OFF 1 15 1 5 1 15 1 1 5 0505 05 3 500900 Engine trouble warnin
14. Is the main switch OK in YES NO Heplace the main Switch 8 12 500750 9 Engine stop switch e Check the engine stop switch for continuity Refer to CHECKING THE SWITCHES 15 the engine stop switch OK 1 YES 4 NO Heplace the right handlebar switch 500 52 10 Sidestand switch optional Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK j YES 4 NO Heplace the sidestand switch 11 Lean angle cut off switch Remove the lean angle cut off switch Connect the pocket tester Q x1 to there angle cut off switch terminals as shewn Positive tester probe blue Negative tester probe gt yelOW green Lean angle cut off switch voltage Less than 65 gt 0 4 1 4V More than 65 b 23 7 4 4V 8 13 IGNITION system ELEC YES Replace the ECU Properly connect or re pair the ignition system s wiring ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main fuse Battery Starter relay Starter motor Start switch Engine stop switch Main switc Front bralg tight switch Rear b ake light switch 51 switch optional 2 ing circuit cut off relay 22699090000 ELECTRIC STARTING SYSTEM ELEC 8 15 Ly 500756 STARTING CIRCUIT CUT OFF SYSTEM OP ERATION If the en
15. 9 Fill e cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT 3 15 CHK Q CHECKING THE ENGINE IDLING SPEED ADJ 500054 CHECKING THE ENGINE IDLING SPEED NOTE LLL Prior to adjusting the engine idling speed the air filter element should be clean and the engine should have adequate compression 1 Start the engine and let it warm up for sev eral minutes 2 Hemove e panel Refer to FOOTREST BOARD AND IN NER FENDER 3 Connect e digital circuit tes onto the spark Qg lead of cylinder Digital circuit tester 90890 06760 y 4 shgine idling speed Out of specification gt Replace the throttle A body assembly A CS Engine idling speed amp 2000 2200r min SS 5 Install Q e panel Refer to FOOTREST BOARD AND IN O NER FENDER 3 16 3 17 CHK Q ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE eeSsSsSsSsSsSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS Prior to adjusting the throttle cable free play the engine idling speed should be adjusted properly 1 Check throttle cable free play Out of specification Adjust gt play at the flange of the throttl grip 2 Adjust S e cable free play v YPrvvvvYYYYYYYYYYYYYY ebar side Loosen the locknut 1 b Turn the adjusting nut 2 in direction or b until the
16. YAMAHA SERVICE MANUAL LIT 11616 20 58 3B3 F8197 10 500000 XF50W 2006 SERVICE MANUAL 2006 by Yamaha Motor Taiwan Co Ltd First edition September 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co Ltd Is expressly prohibited Printed in U S A LIT 11616 20 58 500002 This manual was produced by the Yamaha Motor Taiwan Company Ltd primarily for use by Yamaha dealers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one manual Therefore anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use Yamaha Motor Taiwan Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice 500005 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the lowing AN O The Safety Alert Symbol mea scAPTENTION BECOME ALERT Y
17. on the camshaft sprocket the stationary pointer d on the pl lignment Correct R fer to the installation steps above ce 9 Tighten ecamshaft sprocket bolt CAUTION Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 10 Measure evalve clearance Out of specification Adjust Hefer to ADJUSTING THE VALVE CLEARANCE in chapter 3 5 12 THE ROCKER ARMS AND CAMSHAFT ENG THE ROCKER ARMS AND CAMSHAFT Job Part C Hemarks Removing the rockstar ms and cam Remove the parts in the order listed shaft NS Cylinder head 2 Refer to CYLINDER HEAD Camshaft Rocker ain shaft intake Rocker arm shaft exhaust Rocker arm intake Rocker arm exhaust Collar For installation reverse the removal pro cedure 5 13 THE ROCKER ARMS AND CAMSHAFT ENG OD 5 14 EAS00202 REMOVING THE ROCKER ARMS AND CAM SHAFT 1 Remove intake rocker arm shaft e exhaust rocker arm shaft intake rocker arm e exhaust rocker arm e collar NOTE Remove the rocker arm shafts with the clip plier 2 ue amshaft 1 hore Remove the camshaft with the slide hammer bolt Slide hammer bolt 90890 01085 YU 01083 2 Weight 90890 01084 YU 01083 3 THE ROCKER ARMS CAMSHAFT ENG EAS00205 CHECKING THE CAMSHAFT 1 Check ecamshaft bushings Damage wear
18. HEADLIGHT BULB BURNT OUT eWrong headlight bulb Faulty battery eFaulty rectifier regulator eimproperly grounded circuit eFaulty main switch AS e Headlight bulb life expired x O TAIL BRAKE LIGHT DOES NOT COME c9 eWrong tail brake light bulb C eToo many electrical accessories AM connection A eBurnt out tail brake light bulb TAIL BRAKE LIGHT BULB BURNT S eWrong tail brake light bulb SS Faulty battery e Jail brake light bulb life gis TURN SIGNAL DOES ON eFaulty turn signal ch Faulty turn si lay eBurnt out turn signal bulb eincorrect connection eDamaged or faulty wire harness grounded circuit battery eBlown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY turn signal relay eFaulty main switch eFaulty turn signal switch e ncorrect turn signal bulb Faulty battery 9 6 YAMAHA YAMAHA MOTOR TAIWAN CO LTD XF50W WIRING DIAGRAM EE 1 mmm 1 1 NEP 1 1 mmm p 1 0 1 ee nm D iu EE orn n W MM STARTI EG STOP F mL M eil sarioa RUN OR A o 2 4 a ABL O
19. Primary weight outside di ameter 15 Ko in Lifaits 14 5 mm 0 571 in CHE THE SLIDER 1 eck SAM slider 1 Damage wear Replace CHECKING THE SECONDARY SHEAVE 1 Check esecondary fixed sheave esecondary sliding sheave Cracks damage wear gt Replace the sec ondary fixed and sliding sheaves as a set 2 Check etorque cam groove 1 Damage wear gt Replace the secondary fixed and sliding sheaves as a set 3 Check eguide pin 2 Damage wear gt Replace the secondary fixed and sliding sheaves as a set 5 47 y ASSEMBLING THE PRIMARY SHEAVE 1 Clean eprimary fixed sheave 1 eprimary sliding sheave 2 ecollar 3 eprimary sheave weights 4 2 222 Use thinner to clean up grease dirt on the pri mary sliding sheave cam side 5 2 Install eprimary sliding sheave 1 eprimary sheave 2 ecollar 3 Qr 5 48 BELT DRIVE ENG OD ASSEMBLING THE SECONDARY SHEAVE 1 Lubricate e secondary fixed sheave s inner surface CD secondary sliding sheave s inner surface 2 oil seals bearings with the recommended lubricant Recommended lubricant BEL RAY assembly lube 2 Il secondary sliding sheave 1 Sore Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide Oil seal quide 4 90890 01384 YM 33299 3 Install e guide pi
20. e Before troubleshooting remove the follow ing part s battery cover front cover side cover right front fork upper cover front fork cover left and right leg shield e Troubleshoot with the following special tool s op Digital tachometer 90890 06760 Pocket tester 90890 03112 YU 03112 C 500 38 Inuity THE FUSE in chap 4 Refer to CHECKIN ter 3 the fuse OK 1 5 Heplace the fuse CHARGING system ELEC EAS00739 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 1 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is battery OK ves Clean the battery ter inals or replace the battery ib Wa digital tachometer to the spark plug ad of cylinder cR ct the pocket tester DC 20 V to the tery as shown Positive tester probe positive battery terminal Negative tester probe negative battery terminal Start the engine and let it run at approxi mately 5 000 r min e Measure the charging voltage Charging voltage 14 V at 5000r min CHARGING system ELEC EAS00779 _ 5 Wiring Make sure the battery is fully charged Check the wiring connections of the entire charging system 15 the charging voltage within specification Refer to CIRCUIT DIA
21. iu 47 indicate the following iceable with engine mounted Ku illing fluid Lubricant WH Special tool 44 Tightening torque Wear limit clearance Engine speed Electrical data Symbols 19 to 3 in the exploded diagrams indi cate the types of lubricants and lubrication points Engine oil Gear oil Molybdenum disulfide oil 0 Wheel bearing grease 2 Lithium soap based grease 0 Molybdenum disulfide grease Symbols Q3 to 05 the exploded diagrams indi cate the following Apply locking agent LOCTITE Q5 Replace the part TABLE OF CONTENTS SPECIFICATIONS 7 PERIODIC CHECKS AND 4 ADJUSTMENTS eS 3 5 CHASSIS E D NN 6 2 EL 38 COOLING SYSTEM coo COOL FUEL INJECTION SYSTEM m ELECTRICAL SYSTEM m CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ssssssssssssssssessssssssessseesseerssessseesseessneesseessnss 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 MODEL 1 1 FEATURES MEM 1 2 OUTLINE OF THE 1 2 FI SYSTEM 440 tette tetti 1 3 IMPORTANT 1 4 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 4 REPLACEMENT PARTS 1 4 GASKETS OIL SEALS AND 5 ee NM 1 4 LOCK WASHERS PLATES AND COTTER 9 2
22. 0 006 0 01 8in 0 0394in Big end radial clearance E 0 0 010 0 0 0004 2 10 ENGINE SPECIFICATIONS SPEC Clutch Clutch type Automatic centrifugal Clutch shoe thickness 3 7mm 0 146in 2 0mm 0 079in Clutch shoe spring free length 30 1mm 1 185in Clutch housing inside diameter 107mm 4 213in 107 5mm 4 232in Compression spring free length 76 4mm 3 008in Weight outside diameter 15 0mm 0 591 in 14 5mm 0 571in Clutch in revolution 3050 3450r min Clutch stall revolution 5000 6000r min V belt V belt width 17 9mm 0 705in 16 1mm 0 634in Transmission amp Transmission type V belt autos f iic Primary reduction system Helical Primary reduction ratio 50 46 Secondary reduction system elical gear Secondary reduction ratio 3 12 3 583 Single speed automatic 087 0 945 1 Maximum main axle runout T 0 04mm 0 002 in Maximum drive axle runout 0 04mm 0 002in Air filter type Fuel pump Pump type Electrical vine goin x 3B3 AISAN Output pressure 250kPa 2 5kg cm 35 6psi Throttle body Throttle cable free play at the flange of the throttle grip 1 5 3 5mm 0 06 0 14in ID mark 3B31 00 2 11 CHASSIS SPECIFICATIONS SPEC v CHASSIS SPECIFICATIONS Frame Frame type Caster angle Trail Front wheel Wheel type Him Size Material Wheel travel Wheel runout Maximum radial wheel runout Maximum lateral wheel runout Wheel axle bending limit Rear wh
23. Battery Battery type manufacturer Battery voltage capacity Specific gravity Ten hour rate amperage Headlight type Halogen bulb Indicator light voltage wattagexquantity Turn signal indicator light High beam indicator light Engine trouble warning light Water temperature indicator light M AV 130W 5000r min Standard Limit Transistorized coil ignition 5 BTDC at 2000 2200r min Digita 248 372Q at 20 C 68 F white red white blue 3B3 00 T MORIC 6mm 0 24in 2 16 2 640 at 20 C 68eF 8 64 12 96kQ at 205 68 F 4 6 at 20 C 68 F magneto 0 28 0 42Q at 20 C 68 F white white Semiconductor short circuit SH745 AA SHINDENGEN 13 0 14 0V 24A 200V GTX5L BS GS 12V 4AH 1 330 14V 3 0Wx1 12V 1 7Wx1 12V 1 7Wx1 14V 1 7Wx1 2 15 ELECTRICAL SPECIFICATIONS SPEC Bulbs voltage wattagexquantity Headlight Tail brake light Front turn signal light Hear turn signal light License plate light Speedometer light 12V 35 35Wx1 12V 5 21Wx1 12V 10Wx2 12V 10Wx2 12V 5Wx1 12V 1 7Wx1 Electric starting system System type Starter motor Constant mesh Model manufacturer Suction voltage Power output Brushes Overall length Quantity Spring force Commutator diameter Commutator resistance Mica undercut depth Starter relay Model manufacturer Coil resistance Suction voltage Horn A Horn type Q Model manufac
24. Open or short it in wiring harness Defective int emperature sensor ImproperlyNnstalled sensor lead connector in the coupler 80 The vehicle has overtumed Oveyturhed condition Open circuit is detected in Ope circuit in wiring harness mary lead of the ignition coil 008 D30 unction in ignition coil properly installed primary lead connector in the Malfunction in throttle body Malfunction in throttle cables D54 ISC idle speed control valve is stuck fully open Open or short circuit in wiring harness Defective fuel injector D36 Improperly installed lead connector in the coupler Open or short circuit in wiring harness Defective lean angle cut off switch 008 Improperly installed lead connector in the coupler Open or short circuit in wiring harness Defective speed sensor 007 Improperly installead lead connector in the coupler Open or short circuit in wiring harness J detected A Lean angle fi4witch open short circuit ted No normal signals are received from the speed sensor I 42 Power supply to the fuel injector fuel pump and ignition coil are not nor mal An error is detected while reading Malfunction in ECU The CO adjustment value code or writing on 2 reregistering key code and throttle valve fully closed notification value are not properly w
25. cess tensioner rod to the cam chain e SN N KS d S nsioner housing Installing the spring and cap bolt Loosen the front end of cam chain tensioner slowly Make sure to return to the front end of cam chain tensioner AA4A4AAAAAAAAAAAAAAAAAAAA Hough movement Replace the timing chain tensioner THE ROCKER ARMS AND CAMSHAFT ENG OD 5 19 EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Lubricate e camshaft 1 Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2 Lubricate e rocker arm shafts Molybdenufim disulfide oil exhaust rocker arm 1 ecollar2 e exhaust rocker arm shaft 3 22 222 LLL Make sure the exhaust rocker arm shaft is com pletely pushed into the cylinder head 4 Install eintake rocker arm 1 ecollar2 eintake rocker arm shaft 3 NOTE LLL Make sure the intake rocker arm shaft is com pletely pushed into the cylinder head VALVES AND VALVE SPRINGS ENG EAS00236 VALVES AND VALVE SPRINGS Job Part Removing the valves and valve Remove the parts in the order listed springs Cylinder head Refer to CYLINDER HEAD Rocker arms Refer 10 REMOVING THE ROCKER Rocker arm shafts ARMS AND CAMSHAFT and INSTALL Camshaft ING THE CAMSHAFT AND ROCKER ARMS Valve pad Valve cotter Valve spring retainer Valve spring Valve intake Valve exhaust Valve stem
26. e plate washer e primary sheave nut 30Nm 3 0m kg 21 7ft Ib eeeeSSsSSSSsSsSSSessSSsSSSSSSSSsSSsSSSSSSSSSS While holding the primary fixed sheave with the rotor holding tool 3 tighten the primary fixed sheave nut 5 51 2 o C uo 2 NA 5 52 BELT DRIVE ENG 5 Position e V belt 1 NOTE LLL Position the V belt in the primary sheave 2 when the pulley is at its widest position and in the secondary sheave 3 when the pulley is at its narrowest position and make sure the V belt is tight STARTER CLUTCH AND AC MAGNETO ENG STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY war 2 SOS mg 29 feb EM S ye Sa M a M TIN mS 43Nm 4 3 mekg 31 1 ftelb Q Job Part Removing the stator coil assembly Remove the parts in the order listed Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Single seat Trunk Front cover Side cover left and right Refer to COVERH AND PANEL In chap Battery cover Battery ter 3 Footrest board Radiator Refer to RADIATOR in chapter 6 Crankshaft position sensor coupler Sta 1 1 Disconnect tor coil assembly coupler Fan Nut Plate washer AC magneto rotor Woodruff key 5 53 Remarks Lock plate Cranksh ition sensor Stator coil assembly For installation reverse the removal pro cedure 5 54 EASO0342 STARTER CLUTCH
27. warming up the eng 3 Remove 7 6 H o FOOTREST BOARD AND IN FENDER 4 Lossen oil gallery bolt 1 The engine muffler and engine oil are extremely hot 5 Check e engine oil pressure Start the engine and keep it idling until en gine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize b Check the engine oil passages the oil filter and oil pump for damage or leakage Refer to OIL PUMP in chapter 5 c Start the engine after solving the problem s and check the engine oil pressure again AAAAAAAAAAAAAAAAAAAAAAA CHK Q MEASURING THE ENGINE OIL PRESSURE ADJ 6 Install oil gallery bolt 7Nm 0 7m kg 5 1ft Ib 7 Install e panel Refer to FOOTREST BOARD AND IN NER FENDER 3 29 CHK Q REPLACING THE AIR FILTER ELEMENT ADJ 500086 REPLACING THE AIR FILTER ELEMENT 1 Remove e front cover e side cover left Refer to SIDE COVERS AND TAIL BRAKE LIGHT 2 Remove e air filter case cover 1 e air filter element 3 k ir filter element 1 SN Damage dirty gt Replace RNY e the air filter element every 4000km 2000mi e The air filter needs more frequent service if you are riding in unusually wet or dusty ar eas 4 nstall e air filter element e air filter case cover CAUTION Never operate the engin
28. Hefer to CHECKING THE COOLANT LEVEL Before checking the coolant level wait few minutes until the a settled 13 Install e radiator c inel jS IATOR in chapter 6 servoir cap cover e sida 6over right cover efer to COVER AND PANEL AM ADJUSTING THE FRONT BRAKE CHK Q ADJUSTING THE REAR BRAKE ADJ CHASSIS ADJUSTING THE FRONT BRAKE 1 Check brake lever free play Out of specification gt Adjust Brake lever free play at the end of the brake lever 10 20mm 0 39 0 79in 2 Adjust brake lever free play a Turn the adjusting nut 1 in direction or until the specifi ake lever free play is obtained Direction R play is increased Brake lever free play is decreased the brake lever free play sure there is no brake drag A A AAAAAAAAAAAAAAAAAAAA EASO0114 SS ADJUSTING THE REAR BRAKE 1 Check e brake lever free play a Out of specification Adjust Brake lever free play 10 20mm 0 39 0 79in 2 Adjust e brake lever free play Turn the adjusting nut 1 in direction 8 or b until the specified brake lever free play is obtained Brake lever free play is increased Brake lever free play is decreased CAUTION After adjusting the brake lever free play ma
29. Lower bracket BRACKET and INSTALLING THE Lower bearing STEERING HEAD Upper bearing outer race Lower bearing outer race Lower bearing inner race For installation reverse the removal cedure 4 34 STEERING HEAD CHAS EAS00678 REMOVING THE LOWER BRACKET 1 Stand the scooter on a level surface Securely support the scooter so that there is no danger of it falling over 2 Remove ehandlebar bracket 1 NOTE Hemove the handlebar bracket by loosening the ring nut 2 gradually ing nut 1 AM with the ring nut wrench S Ring nut wrench 90890 01268 YU 01268 4 Remove eupper bearing inner race 1 with the steering nut wrench 2 Steering nut wrench 90890 01444 YM A9409 7 Securely support the lower bracket 3 so that there is no danger of it falling STEERING HEAD CHAS 500682 CHECKING THE STEERING HEAD 1 Wash ebearing balls ebearing races Recommended cleaning solvent Kerosene 2 Check ebearing balls 1 ebearing races 2 Damage pitting gt Replace 3 earing balls ebearing races a Remove the bearing races from the steer ing head pipe with a long rod 1 and ham mer b Remove the bearing race from the front fork assembly with a floor chisel 2 and ham mer c Install a new bearing races CAUTION If the bearing race
30. MAAAAAAAAAAAAAAAAAAAAAA EASO091 6 CHECKING THE THROTTLE POSITION SEN SOR 1 Check throttle position sensor a Connect the digital circuit tester to the ter minals of the throttle position sensor 7 32 THROTTLE BODY AND FUEL INJECTOR Positive tester probe blue terminal 1 Negative tester probe black blue terminal 2 Digital circuit tester 90890 03174 b Measure the throttle position sensor volt age Out of specification gt Replace or repair the wire harness Throttle position sensor voltage 5V blue black bl blu lue c Connect tester to the ter minals of th ttle position sensor Positive t ster probed gt AC yellow terminal 3 Negative tester probe gt black blue terminal Wa While slowly opening the throttle check that the throttle position sensor voltage is in creased Ss Voltage does not change or it changes w abruptly gt Replace the throttle body Out of specification closed position gt Re ee place the throttle body Throttle position sensor voltage SN closed position Q 0 63 0 73 V 49 yellow black blue AA4AAAAAAAAAAAAAAAAAAAAA 7 34 THROTTLE BODY AND FUEL INJECTOR 500916 CHECKING THE ISC IDLE SPEED CON TROL VALVE 5 0 0 Do not remove the ISC idle speed control valve unit completely from the throttle body assembly 1 Check ISC idle speed control val
31. Sidestand switch signal input line of main switch coupler blue green blue green rue INJECTION system Fault code No 21 Symptom Coolant temperature sensor open or short circuit is detected Used diagnostic code No D06 coolant temperature sensor Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Installed condition of sensor Check the installed area for looseness or Reinstated by turn pinching ing the main switch Connected condition of con If there is a malfunction repair it and connect ON nector it securely Inspect the coupler for any Coolant temperature sensor coupler pins that may have pulled Main wiring harness ECU coupler out Check the locking condition of the coupler Open or short circuit in wiring Repair or replace if there is an open or short harness circuit Between sensor coupler and ECU coupler black blue black blue green red green red S Defective coolant temperature Execute the diagnostic modo 006 sensor Heplace if defective Refer to COOLING SY in chapter 8 FUEL INJECTION SYSTEM code No 22 Symptom Intake temperature sensor open or short circuit is detected Used diagnostic code No 005 intake air temperature sensor Inspection operation item and Reinstatement Operation item and countermeasure probable cause method Installed condition of sensor Check
32. WS SS Cylinder head tightening sequence 1092232422256 2 20 TIGHTENING TORQUES v CHASSIS Tightening Part to be tightened eon torque Hemarks Frame and engine bracket3 M10 46 4 6 33 1 Engine bracket3 and engine M10 58 5 8 42 0 Handlebar bracket and steering shaft M10 60 6 0 43 4 Rear shock absorber and frame 10 30 3 0 21 7 Rear shock absorber and engine M8 16 1 6 11 6 Steering shaft and upper bearing inner race BC1 7 0 7 5 1 See NOTE Steering shaft and ring nut 1 30 3 0 217 See NOTE Front fork and lower bracket M10 30 3 0 21 7 Handlebar bracket and handlebar lower holder M10 48 4 8 Handlebar lower holder and handlebar upper holder M8 28 2 8 20 3 Throttle cable and holder lever2 M5 4 v 2 9 Throttle cable and throttle body M5 Da X 3 6 Front reflector M5 0 7 5 1 Fuel tank M6 1 0 72 Fuel pump M5 54 0 4 2 9 Single seat lock assembly 50 12 1 2 87 Trunk 12 1 2 8 7 Bottom plate and single seat lock bracket wie 7 0 7 5 1 Bottom plate and frame single seat AS M6 10 1 0 7 2 Single seat and frame single seat M6 10 101 72 Single seat lock assembly and trunk 6 7 0 7 5 1 Resin part and resin cover AbutM5 2 0 21 1 5 Footrest board M6 7 0 7 5 1 License bracket ee M6 7 O7 5 1 Rear turn signal light for M6 4 04 29 License light AbutM5 2 0 2 15 Front wheel shaft M10 48 48 347 Front brake cams ver M6 8 0 8 5 8 Hear wheel
33. XV 30 058mm 1 1873 1 1913 1 1834in Measurement B 25 082 25 18 24 982mm 0 9875 0 993 in 0 9835in Exhaust camshaft lobe dimensions Measurement eo 30 158 30 258mm 30 058mm NO 1 1873 1 1913in 1 1834in Measurement B SN 25 020 25 120 24 920 O 0 9850 0 9890in 0 9811in lt 0 03 Maximum camshaft runout 0 0012in 2 4 ENGINE SPECIFICATIONS SPEC Timing chain Morse 92RH2005 82 Automatic Model number of links Tensioning system Valve valve seats valve guides Valve clearance cold Intake 0 10 0 16 0 0039 0 0063 Exhaust 0 18 0 24mm 0 0071 0 0094in Valve dimensions A m Ae Head Diameter Face Width Seat Width Margin Valve head diameter Intake 15 4 15 ae 0 60 CA Exhaust a 6mm Q96457 0 6535in Valve face width B Intake 1 48 2 19mm amp 0 0583 0 0862in Exhaust 9 1 48 2 19mm 0 0583 0 0862in Valve seat width C ee Intake 0 9 1 1mm 1 6mm N 0 0354 0 0433in 0 0630in Exhaust AS 0 9 1 1mm 1 6mm 0 0354 0 0433in 0 0630in Valve margin D Intake 0 70mm 0 0276in Exhaust 0 70mm 0 0276in Valve stem diameter Intake 3 975 3 990 3 945 0 1565 0 1571in 0 1553in Exhaust 3 9 5 3 990mm 3 930mm 0 1565 0 1571in 0 1547 Valve guide inside diameter Intake 4 000 4 012mm 4 050mm 0 1575 0 1580in 0 1594in Exhaust 4 000 4 012mm 4 050mm 0 1575 0 158
34. eerte ten 7 35 AIR INDUCTION SYSTEM DIAGRAMS 7 36 AIR CUT OFF VALVE AND AIR FILTER CASE 7 37 CHECKING THE AIR INDUCTION 38 rue INJECTION system EASO0894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 ECU D Air filter case 2 Engine trouble warning light 2 Catalytic converter 3 Lean angle cut off switch 43 Crankshaft position sensor 4 Fuel hose Coolant temperature sensor 5 Ignition coil b Spark plug 6 Fuel injector Fuel tank 7 Intake air pressure sensor 7 Fuel pump ISC idle speed control valve Throttle position sensor 9 Intake air temperature sensor Battery 7 1 FUEL INJECTION SYSTEM WIRING DIAGRAM amp amp 6 amp 9 t9 3 CO magneto Main fuse Battery Engine stop switch ECU Main switch Intake air pressure sensor Intake air temperature sensor Throttle position sensor Lean angle cut off switch Coolant temperature sensor Ignition coil Spark plug Fuel injector Fuel pump ISC idle speed control valve Dimmer switch Headlight High beam indicator light Engine trouble warning light Coolant temperature indicator light Speed sensor diagnostic tool optional Sidestand switch optional c FUEL INJECTION system Fl 7 3 rue INJECTION system
35. leads Pocket tester 90890 03132 1VU 03112 C NOTE e Before checking for continuity set the pockett ester to 0 and to the Q 1 range e Wh ecking for continuity switch back orth between the switch positions a times A terminal connections for switches e g main switch engine stop switch are shown in an il lustration similar to the one on the left The switch positions 8 are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE 5 indicates a continuity of electricity be tween switch terminals i e a closed circuit at the respective switch position The example illustration on the left shows that There is continuity between black and black white when the switch is set to OFF There is continuity between red and brown when the switch is set to ON CHECKING THE SWITCHES ELEC 500731 CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the terminals Refer to CHECKING SWITCH CONTINUITY Damage wear gt Repair or replace Improperly connected gt Properly connect Incorrect continuity reading gt Replace the switch BLACK lg L T A aoo ee Se q x RED Hear brake light switch Main fuse 9 Front brake light switch Dimmer switch Start switch Sidest
36. mark 8 is positioned as shown b Align the projection b on the brake shoe wear indicator with the notch in the brake shoe camshaft c Check that the brake shoes are properly positioned 2 Tighten e brake camshaft bolt 10Nm 1 0m 7 2ft 16 REAR WHEEL AND BRAKE CHAS 3 Install e brake shoe e tension springs CAUTION e Do not put lubricating oil on the brake lining e Change the tension spring at the same time of changing the brake shoe e Refer to the direction in the illustration when assembling the brake shoe and spring Refer to the illustration with regards to the assembly direction of tension spring and do not let th ing hook and coil to be damaged Hythe pliers 4 17 REAR WHEEL AND BRAKE CHAS 500574 INSTALLING THE REAR WHEEL 1 Lubricate wheel axle Recommended lubricant Lithium soap based grease 2 Install e rear wheel 3 Tighten e plate washer wheel axle nut 1 S 4 Install e muffler Refer 40 GINE REMOVAL In chapter 5 xO 5 Adjust ke lever free play Refer to ADJUSTING THE REAR BRAKE in chapter 3 SS NO EASO0575 lt ADJUSTING THE REAR WHEEL cS BALANCE Q NOTE e After replacing the tire wheel or both the rear wheel static balance should be ad justed e Adjust the rear wheel static balance with the rear w
37. 2 Check e lead e coupler e connector Moisture gt Dry wittwan air blower Rust stains Connect and disconnect several times connections SN Loose connection gt Connect properly OTE If the pin D on the terminal is flattened bend it up 4 Connect e lead e coupler e connector NOTE Make sure all connections are tight 5 Check e continuity with the pocket tester Pocket tester 90890 03112 YU 03112 C 2222 e fthere is no continuity clean the terminals e When checking the wire harness perform steps 1 to 3 e Asaquick remedy use a contact revitalizer available at most part stores EASO0027 SPECIAL TOOLS INFO R5 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune up and assembly Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri ate tools or improvised techniques Special tools part numbers or both may differ depending on the country When placing an order refer to the list provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YU or ACC For others use part number starting with 90890 Tool NO Tool name Function Illustration 90890 01052 Meter gear bush tool This tool is used when removing or install ing the meter gear 90890 01085 Slide hammer bolt 8mm YU 01083 2 Weight 2 90890 01084 YU 01
38. 202 2mm 7 96in 188 2mm 7 41in 10 1N mm 1 03kg mm 0 65mm 0 2 56in No Fork oil 10W or equivalent 0 042L 0 038Imp qt 0 046 US qt 26mmY 1 02in 2 13 CHASSIS SPECIFICATIONS SPEC v 110 5mm 4 35in 2 0mm 0 08in 110 5mm 4 35in 2 0mm 0 08in 198 2mm 7 80in Steering system Steering bearing type Lock to lock angle left Lock to lock angle right Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate K1 Spring rate K2 Spring stroke K1 Spring stroke K2 Optional spring available CHASSIS SPECIFICATIONS SPEC v Angular bearing 46 46 Unit swing Coil spring 45mm 1 77in 176 5mm 6 95in 162 5mm 6 40in 28 03N mm x 2 85kg mm NN 42 18N mm 4 30kg mm 240 In A 0 17mm 0 0 17 4 9 1 77 2 14 ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Ignition system Ignition system type Ignition timing Advancer type Crankshaft position sensor resistance color Ignition coil Model manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug cap Material Hesistance Charging system System type Model manufacturer Nominal output Stator coil resistance color Rectifier regulator Hegulator type Model manufacturer No load regulated voltage O Hectifier capacity SN Withstand voltage _
39. 6 000 mi 8 000 mi 10 000 mi ITEM ROUTINE E ip months entis Check fuel and vacuum hoses for Fuel line cracks or damage Replace if necessary Check condition Adjust gap and clean Spark plug Replace at 4000 mi 7000 km or Replace Replace 12 months and thereafter every 4000 mi 6000 km or 12 months Valve clearance Check and adjust valve clearance Every 6000 mi 10000 km when engine is cold Cvankesse breather 2 hose for cracks or system ger Replace if necessary Check for leakage Exhaust system Tighten if necessary Replace gasket s if necessary Check the air cut off valve reed Air induction system valve and hose for damage Replace any damaged parts Since these items require special tools data andt skills have a Yamaha dealer perform the service AM S lt O 3 2 CHK 4o PERIODIC MAINTENANCE AND MINOR REPAIR ADJ GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READING ITEM ROUTINE Check operation Front brake Adjust cable and replace brake shoes if necessary Check operation Rear brake Adjust cable and replace brake shoes if necessary Check runout and for damage Replace if necessary Checktread depth and for damage Replace if necessary Tires Check air pressure Correct if necessary Check bearings for smooth Wheel bearings operation y y Pat N
40. AA4A4AAAAAAAAAAAAAAAAAAAA 6 Install e engine oil drain bolt along with the gasket 23Nm 2 3m kg 16 6ft Ib fs 3 2b Fill ecrankcase with the specified amount of the recom mended engine oil Quantity Total amount 0 8 0 9L 0 74 0 83 Imp qt 0 87 0 98 US qt Periodic oil change 0 73 0 83L 0 67 0 76 0 80 0 90 US Imp qt CHK CHANGING THE ENGINE OIL 8 Install e engine oil filler cap 9 Start the engine warm it up for several min utes and then turn it off 10 Check e engine for engine oil leaks 11 Check e engine oil level Refer to CHECKING THE ENGINE OIL LEVEL 12 Check engine oil pressure WWVVVVVVVVVVVVVVVVVVVVY a Slightly loosen the dr d bolt HN 1 b Start the engine ep it idling until en gine oil starts t ep from the oil gallery bolt If no oil comes out after one minute T e engine off so that it will not seize C engine oil passages the oil filter caido and the oil pump for damage or leakage Refer to OIL PUMP in chapter 5 d Start the engine after solving the problem s S and check the engine oil pressure again e Tighten the oil gallery bolt to specification amp N Oil gallery bolt 9 7Nm 0 7m 5 1ft Ib ee AA4AAAAAAAAAAAAAAAAAAAAA 3 26 CHK CHANGING THE TRANSMISSION AD Q CHANGING THE TRANSMISSION OIL 1 Stand the scooter on a level surface NOTE e Stand the scooter on a suitable stand e Make sure that th
41. AIR INDUCTION SYSTEM AIR CUT OFF VALVE AND AIR FILTER CASE 7 Nm 0 7m kg 5 1 ft Ib Remarks Removing cut off valve and Remove the parts in the order listed air filter SS Front cove Refer to COVER AND PANEL in chap Side cover right ter 3 Hose to air filter case Air filter case Hose air cut off valve to air filter case Hose air cut off valve assembly to ex haust pipe Air cut off valve For installation reverse the removal pro cedure 7 37 AIR INDUCTION SYSTEM EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1 Check ehoses Loose connection gt Connect properly Cracks damage gt Replace 2 Check e reed valve reed valve stopper e reed valve seat Cracks damage gt the reed valve 3 Check e air cut off valve Cracks damage Replace Re Qy AS 7 38 CHAPTER 8 ELECTORICAL ELECTRICAL COMPONENTS nene ett 8 1 WIRING DIAGRAM uicccsccssecececsssssssecsscsssusscsueusussseususeesususecsusususeeeususeeansesees 8 2 CHECKING SWITCH CONTINUITY 8 4 CHECKING THE SWITCHES ener 8 5 CHECKING THE BULBS AND BULB SOCKETS ener 8 6 TYPES OF BULBS eec 8 6 CHECKING THE CONDITION OF THE 9 8 7 CHECKING THE CONDITION OF THE BULB SOCKETS 8 8 IGNITION SYSTEM entren 8 9 CIRCUIT DIAGRAM ou cccccccccccecccccscececcesceseecescecesseseeeee ce VEMM 8 9 TROU
42. COVERS AND TAIL BRAKE LIGHT CHK REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1 Remove e headlight unit 2 Disconnect e headlight lead coupler 3 Hemove e dust boot 1 e headlight bulb holder e headlight bulb A WARNING Since the headhight bulb gets extremely hot keep flamnrable products and your hands away fr e bulb until it has cooled down tall 3 7 headlight bulb RNY Secure the new headlight bulb with the headlight bulb holder K CAUTION Avoid touching the glass part of the Q headlight bulb to keep it free from oil otherwise the transparency of the glass the NO life of the bulb and the luminous flux will be ON adversely affected If the headlight bulb gets SM soiled thoroughly clean it with a cloth SX moistened with alcohol or lacquer thinner 5 Install e headlight bulb holder 6 Install e dust boot 7 Connect e headlight lead coupler 8 Install e headlight unit 3 58 CHK 22 HEADLIGHT BEAM ADs 500184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically VVVVVVVVVVVVVVVVVVVVVVY a Turn the adjusting screw 1 in direction a or b Headlight beam is raised Headlight beam is lowered AA4AAAAAAAAAAAAAAAAAAAAA S Q AS 2 st adlight beam horizontally VVVVVVVVVVVVVVVVVVVYV RNY a Turn the adjusting screw in direction 8 or b Headlight
43. Heplace AS 2 VN 3 Vre ylinder head warpage AM Out of specification gt Resurface the cyl inder head Maximum cylinder head warpage 0 05 mm 0 0020 in Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the oylin der head using a figure eight sanding pat tern NOTE To ensure an even surface rotate the cylinder head several times AA4AAAAAAAAAAAAAAAAAAAAA 5 9 CYLINDER HEAD ENG 500231 INSTALLING THE CYLINDER HEAD 1 Install e gasket e dowel pins 2 Install e cylinder head 3 Tighten e cylinder head nuts 3 110 Nm 1 0 7 2 ft Ib e cylinder head bolts 10 Nm 1 0 m kg 7 2 ft Ib NOTE NN e lubricate the c liqder head nuts with en gine oil e lightent inder head nuts in the proper tightening equence as shown and torque them4f two stages der head tightening sequence 2228242225260 4 Install e camshaft sprocket e timing chain WVVVVVVVVVVVVVVVVVVVVVYV a Turn the primary pulley counterclockwise b Align the I mark on the AC magneto rotor with the stationary pointer b on the crankcase cover c Align the 4 mark on the camshaft sprock
44. No 15 Symptom Throttle position sensor open or short circuit detected Used diagnostic code 001 throttle position sensor oO Inspection operation item and Reinstatement dui it e countermeasure probable cause method Check th Stalled area for looseness or Reinstated by turn ing the main switch Installed condition of throttle position sensor Connected condition of nector Q Inspect the coup N any pins that may AN pulled out Check aA condition of the coupler Open or short circuit in wiring harness and or sub lead Defective throttle position sen sor pinchin Che hat it is installed in the specified po efer to THROTTLE BODY AND FUEL IN If there is a malfunction repair it and connect it securely Throttle position sensor coupler Main wiring harness ECU coupler Sub wire harness coupler Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler black blue black blue yellow yellow blue blue Execute the diagnostic mode code No 001 Replace the throttle body NOTE Do not remove the sensor assembly MAQS Refer to THROTTLE BODY AND FUEL IN JECTOR ON rue system Fault code No 16 Symptom Stuck throttle position sensor detected Used diagnostic code No D01 throttle position sensor Inspection operation item and Reinstatement Order Operation item and countermeasure probable caus
45. Q PERIODIC MAINTENANCE AND MINOR REPAIR ADJ Since these items require special tools data and technical skills have a Yamaha dealer perform the service NOTE _ _ From 12000mi 19000km or 36 months repeat the maintenance intervals starting from 4000mi 7000km or 12 months EAU17680 NOTE 5222 The air filter needs more frequent service if you are riding in unusually wet or dusty areas 3 4 CHK COVER AND PANEL 500038 COVER AND PANEL SIDE COVERS AND TAIL BRAKE LIGHT BiNm 0 2m kg 1 5 ft Ib V Removing the side covers and tail Hemove the parts in the order listed brake light Front cover Side cover left Side cover right Tail brake and rear turn signal light left and right Battery cover Battery negative lead CAUTION Battery positive lead eFirst disconnect the negative Battery battery lead and then the positive battery lead eAfter installing the battery be sure to turn the main switch from ON to OFF three times in 3 seconds intervals to initialize the idle speed 2Nm 0 2m kg 1 5 ft Ib control system For installation reverse the removal pro cedure 3 6 CHK COVER AND PANEL 2 kg 7 2 fte Ib SINGLE SEAT AND TRUNK CyJob Part Hemarks Removing t e single seat and trunk Remove the parts in the order listed Side cover left and right Refer to SIDE COVERS AND TAIL BRAKE LIGHT Single
46. Repair or replace if there is an ope circuit Between sensor coupler and black blue black blue pink white pink whte 57 blue blue Execute the diagn s ode code No Replace the throttle body NOTE Do not re the sensor assembly MAQS ct the digital circuit tester to the in air pressure sensor coupler as shown 2 Set the main switch to ON 3 Measure the intake air pressure sensor out put voltage Intake air pressure sensor output voltage 3 9 4 1V 4 Isthe intake air pressure sensor OK rue system Intake air pressure sensor hose system malfunction Fault code No 14 clogged detached hose Symptom Used diagnostic code No 003 intake air pressure sensor Inspection operation item and Heinstatement Order Operation item and countermeasure probable cause method Connected state of connector Check the coupler for any pins that have Reinstated by start Intake air pressure sensor cou pulled out ing the engine and pler Check that the coupler is connected securely operating it at idle Main wirring harness ECU cou If there is a malfunction repair it and connect pler it securely Sub wire harness coupler Defective intake air pressure sensor Execute the diagnostic mode code No Replace the throttle body NOTE Do not remove the sensor assembly Refer to Fault code No 13 code
47. THE OIL PUMP 1 Install eoil pump drive gear 1 egasket eoil pump 2 eoil pump bolt CAUTION After tightening the bolts make sure the oil pump turns smoothly 5 63 TRANSMISSION ENG TRANSMISSION O Job Parsc Removing the trans Hission Remove the parts in the order listed Transmission oi QN Drain Refer to CHANGING THE TRANSMIS lt SION OIL in chapter 3 Muffler Bracket Refer t ENGINE REMOVAL Rear wheel Refer to REAR WHEEL AND BRAKE in chapter 4 V belt case cover Refer to BELT DRIVE Secondary sheave 1 Transmission cover 1 2 Transmission cover gasket 1 3 Dowel pin 2 4 Main axle 1 9 Drive axle 1 6 1 Primary drive gear For installation reverse the removal pro cedure 5 64 TRANSMISSION ENG EAS00425 CHECKING THE TRANSMISSION 1 Measure e main axle runout with a centering device and dial gauge Out of specification gt Replace the main axle Main axle runout limit 0 04 mm 0 002 in 2 Measure e drive axle runout with a centering device and dial gauge Out of specification gt Replace the drive axle Q Primary drive gear shaft runout limit 0 04 mim 0 002 in 2 9 ransmission gears Blue discoloration pitting wear gt Replace the defective gear s RN etransmission gear dogs amp Cracks damage rounded edges gt Re place the defective gear s gt 4 Check Q etransmission
48. Troubleshoot with the following special tool s Pocket tester 90890 03112 YU 03112 C THE FUSE in chap Refer to CHECKING ter 3 Is the fuse OK 1 YES 4 the fuse SIGNALING system ELEC EAS00739 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F e Clean the battery ter nals Hecharge or replace the battery 500749 A 3 Main swatch Replace the main switch 500795 Check the entire signal system s wiring Refer to CIRCUIT DIAGRAM sthe signaling system s wiring properly con nected and without defects Check the condi tion of each of the pair the signaling system s circuits Refer to CHECK ING THE SIG NALING SYS TEM Properly connect or re signaling system s wiring 500796 CHECKING THE SIGNALING SYSTEM 1 The horn fails to sound 1 Horn switch Check the horn switch for continuity Refer to CHECKING THE SWITCHES Is the horn switch OK n YES 4 NO Replace the left handlebar switch 2 Voltage Connect the pocket tester DC 20 V to the horn connector at the horn terminal as shown Positive tester probe brown 1 Negative tester probe ground Set the main to ON Push the horn switch Measure the voltage DC 12 V of brown at the
49. YS 01880 A Sheave holder RNY This tool is used the secondary sheave Thickness 59469 This is used to measure the valve 90890 03079 YM 34483 90890 03081 YU 33223 This too is used to measure the engine com pression Pocket tester 90890 03112 YU 03112 C This instrument is invaluable for checking the electrical system Digital circuit tester 90890 03174 90890 03141 YU 03141 This instrument is invaluable for checking the electrical system 1 9 SPECIAL roots INEO EPO Tool NO Tool name Function Illustration 90890 03141 YU 03141 90890 03182 YU 03182 90890 04101 90890 04058 YM 04058 90890 04145 90890 04019 YM 04019 90890 04148 YM 04148 90890 06760 90890 06754 YM 34487 90890 04111 04111 90890 04112 04112 90890 04113 04113 Timing light This tool is used to check the ignition tim ing diagnostic tool Execute CO adjustment confirm fault Code self diagnosis tool Valve lapper This tool is needed to remove and install the valve lifters Middle driven shaft bearing Mechanical seal installer 2 There tools are used to install the water pump seal Valve spring compressor Compressor adapter O16 5mm This tool is used to remove or install the valve quides Valve guide installer 4 0mm This tool is used to install the valve guides Valve guide remover 4 0
50. all of the fuse CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Hemove e battery cover Refer to SIDE COVERS AND TAIL BRAKE LIGHT CHK CHECKING THE FUSE 2 Check efuse Connect the pocket tester the fuse and check the continuity NOTE Set the pocket tester selector to Q x 1 Pocket tester 90890 03112 YU 03112 C b If the pocket tester indicates oo replace the fuse AAAAAAAAAAA AAAAAAAAA 3 Replace e plown fuse Q VYYYYYVHEY Y YYYYY Y YYYYYY a Set the switch to OFF D fuse of the correct amperage rating c Seton the switches to verify if the electrical Circuit is operational MY If the fuse immediately blows again check S the electrical circuit amp Amperage rating Q ty O 15A 29 Never use fuse with amperage rating AS other than that specified Improvising or O using a fuse with the wrong amperage Q rating may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire CAUTION After removing and installing the main fuse be sure to turn the main switch from ON to OFF three times in 3 seconds intervals to initialize the idle speed control system AAAAAAAAAAAAAAAAAAAAAAA 4 Install e battery cover Refer to SIDE
51. and INSTALLING THE PISTON AND CYLINDER For installation reverse the removal pro cedure CYLINDER AND PISTON ENG OWD EAS00253 REMOVING THE CYLINDER AND PISTON 1 Remove e piston pin clip 1 e piston pin 2 e piston 3 CAUTION o Do not use a hammer to drive the piston pin out NOTE LL e Before removing the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase e e Before removing Qiiston pin deburr the piston pin clip s gr e ve and the piston s pin bore area ted areas are deburred and the is still difficult to remove re move the piston pin puller set 4 O Vo Piston pin puller set 90890 01304 YU 01304 2 Remove etop ring 2nd ring e oil ring NOTE SSeS When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown 5 32 CYLINDER AND PISTON ENG OD 500255 CHECKING THE CYLINDER AND PISTON 1 Check e piston wall e cylinder wall Vertical scratches gt Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge Q NOTE 4 Measure oylin re C by taking side to side and front to Ra measurements of the cylinder T
52. auxiliary devices so that an optimum air fuel ratio can be achieved to accommodate the constant changes in the operating con ditions of the engine As the requirements for the engine to deliver more performance and cleaner exhaust gases in crease it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accommodate this need this model has adopted an electronical Controlled fuel injection Fl system in place of the conventional carburetor system This Sy SIGN an achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injec tion volume according to the engine operating conditions det by various sensors The adoption of the Fl system has resulted in a hig cise fuel supply improved engine re sponse better fuel economy and reduced exhaust ions Oo 1 ECU Battery 2 Engine trouble warning light 17 Air filter case 3 Lean angle cut off switch 2 Catalytic converter 4 Fuel hose 43 Crankshaft position sensor 5 Ignition coil Coolant temperature sensor 6 Fuel injector 5 Spark plug 7 Intake air pressure sensor Fuel tank ISC idle speed control valve 4 Fuel pump 9 Intake air temperature sensor Throttle position sensor 1 2 500897 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter The pressure regulator maintains the fuel pressure that is ap
53. beam moves to the right Headlight beam moves to the left AA4A4AAAAAAAAAAAAAAAAAAAA 3 59 CHAPTER 4 CHASSIS FRONT WHEEL AND nnn 4 1 FRONT WREE 4 2 FRONT BRAKE SHOE LATE canes 4 3 REMOVING THE FRONT WHEEL 2 4 4 DISASSEMBLING THE BRAKE SHOE PLATE 4 4 CHECKING THE FRONT 4 5 CHECKING THE SPEEDOMETER GEAR UNIT 4 6 CHECKING THE BRAKE 4 7 ASSEMBLING THE BRAKE SHOE PLATE 4 8 ASSEMBLING THE FRONT WHEEL ce 4 9 INSTALLING THE FRONT WHEEL 4 10 ADJUSTING THE FRONT WHEEL STATIC BA NCE ooi 4 11 REAR WHEEL AND BRAKE oP 4 13 REMOVING THE REAR WHEEL A 4 14 CHECKING THE REAR WHEEL 4 14 CHECKING THE REAR WHEEL DRIVE HUB 4 15 CHECKING THE BRAKE S 4 15 ASSEMBLING THE BRAKE SHOE 4 16 INSTALLING THE REAR HEEL 4 18 ADJUSTING THE REARKWHEEL STATIC BALANCE 4 18 FRONT FORK s 4 19 REMOVING THE F c 4 21 DISASSEMBLIN E FRONT FORK LEGS 4 21 CHECKING CE I 4 23 ASSEMBLING THE
54. e oil pump drive gear pump driven gear 1 e oil pump housing e oil pump housing cover Cracks damage wear gt Replace the defective part s 2 Measure e inner rotor to outer rotor tip clearance e outer rotor to oil pump housing clear ance e oil pump housi to inner rotor and outer rotor Out of specifi ation gt Replace the oil 4 1 In tor 2 er rotor Oi pump housing Inner rotor to outer rotor tip clear ance 0 15 mm 0 006 in or less Limit 0 23 mm 0 009 in Outer rotor to oil pump housing clearance 0 13 0 18 mm 0 005 0 007 in Limit 0 25mm 0 010 in Oil pump housing to inner rotor and outer rotor clearance 0 07 0 12 mm 0 003 0 005 in Limit 0 19 mm 0 008 in 3 Check e oil pump operation Rough movement gt Repeat steps 1 and 2 or replace the defective part s OIL PUMP ENG ASSEMBLING THE OIL PUMP 1 Lubricate rotor outer rotor oil pump shaft with the recommended lubricant Recommended lubricant Engine oil 2 Install e oil pump shaft 1 to the oil pump housing 2 e pin 3 e inner rotor 4 QN eouter rotos e oil pump h ig cover 6 e oil pum Sing Screw 2 9 ft lb 2 ween installing the inner rotor align the pin in oil pump shaft with the groove a in the inner SN rotor 4 3 Check e oil pump operation Hefer to CHECKING THE OIL PUMP EAS00376 INSTALLING
55. gear engagement each pinion gear to its respective wheel Nd gear i QC Incorrect gt Reassemble the transmission AS axle assemblies SX 5 Check etransmission gear movement Hough movement gt Replace the defec tive part s 6 Check circlip Bends damage looseness gt Replace 5 65 CRANKSHAFT CRANKSHAFT ASSEMBLY 7 C 05 OP Remarks Removing th crankshaft assembly Remove the parts in the order listed Engine Refer to ENGINE REMOVAL Cylinder head Refer to CYLINDER HEAD Cylinder and piston Refer 10 AND PISTON V belt case cover 7 Refer to BELT DRIVE V belt and primary secondary sheave Radiator 7 Refer to COOLING SYSTEM in chapter Water pump 6 Starter clutch Refer 10 5 CLUTCH AND AC AC magneto MAGNETO Oil pump Refer to OIL PUMP Transmission Refer to TRANSMISSION Rear wheel Refer to REAR WHEEL AND BRAKE in chapter 4 Tension spring Circlip Plate washer Pin Centerstand CRANKSHAFT ENG 10Nm 1 0 mekg 7 2 ftelb 2 Q 2 ea A Job Pars Hemarks O Hook Q Drain plug S Oil strainer N Compres pring O ring Crankcase right Refer to DISASSEMBLING THE CRANKCASE and ASSEMBLING THE CRANKCASE Spacer Dowel pin Guide Crankshaft Refer to REMOVING THE CRANK SHAFT ASSEMBLY and INSTALLING THE C
56. gt Replace 2 Check ecamshaft lobes Blue discoloration pitting scratches Replace the camshaft 3 Measure ecamshaft lobe dimensions a and b Out of specification gt Replace the cam shaft R Camshaft lob dimension limit Intake OS 30 258mm wu 1 1913 in it gt 30 058mm 1 1834 in umi 0 9875 0 9914 in lt Limit gt 24 982mm 0 9835 Exhaust 8 30 158 30 258mm 1 1873 1 1913 Limit 30 058mm 1 1834 5 25 020 25 120 0 9850 0 9890 in lt Limit gt 24 920mm 0 9811 ecamshaft oil passage Obstruction gt Blow out with compressed air 5 15 THE ROCKER ARMS AND CAMSHAFT ENG OD EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check erocker arm camshaft touch surface erocker arm valve touch surface 2 Damage wear gt Replace 2 Check erocker arm shaft Blue discoloration excessive wear pitting scratches gt Replace or check the lubri cation system 3 Check lobe 5 Excessive wea the camshaft O 4 M asure ocker arm inside diameter a AM Out of specification gt Replace Rocker arm inside diameter 10 10 015 mm 0 3937 0 3943 In lt Limit gt 10 030mm 0 3949 in 5 16 5 Measure erocker arm shaft outside diameter a Out of specification Replace Rocker arm
57. hose Remove fuel pump CAUTION Do not drop the fuel pump or give ita strong shock Donottouch the base section of the fuel sender CAUTION The fuel pump should not be disassembled 7 29 THROTTLE BODY AND FUEL INJECTOR 500912 CHECKING THE FUEL INJECTOR 1 Check e fuel injector Damage gt Replace 500913 CHECKING THE THROTTLE BODY 1 Check ethrottle body Cracks damage gt the throttle body lt 2 Check e e butterfly Damafje scratches wear gt Replace A CAU N e ot adjust the stop screw 1 not clean the throttle body using car buretor cleaner or compressed air SN e Whenreplace the throttle body the main switch is operated three times turn ON amp and OFF position 9 ON position 3 seconds more OFF po o sition 3seconds more And then start the engine and keep idling at 10 minutes oe more NO v 7 30 THROTTLE BODY AND FUEL INJECTOR INSTALLING THE FUEL PUMP S 1 Install e fuel pump 1 4Nm 0 4mekg 2 9ftelb NOTE Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Align the projection 8 on the fuel pump with the alignment mark b on the fuel tank Tighten the fuel pump bolts in the proper tightening sequence as shown and torque them in two stages Forward Qv x INSTALLING THE FUEL HOSE 1 tall
58. install the cylinder with the other hand e Pass the timing chain and timing chain guide exhaust side through the timing chain cavity 5 38 BELT DRIVE ENG BELT DRIVE V BELT CASE COVER ON of CN KC j o Ny T2Nm 1 2m 8 7 ft Ib Removing theWrbelt case cover Remove the parts in the order listed Kickstarter Cover Q V belt case cover V belt case cover gasket Dowel pin For installation reverse the removal pro cedure 5 39 500338 KICKSTARTER 6 6 5 9 OS Disassembli V belt case over Kick piniorgear Kick pinion gear clip Circlip Plate washer Kickstarter shaft Torsion spring Solid bush 5 40 BELT DRIVE ENG Remarks Remove the parts in the order listed Refer to V BELT CASE COVER Heferto INSTALLING THE KICKSTARTER For assembly reverse the disassembly procedure BELT DRIVE ENG EAS00340 INSTALLING THE KICKSTARTER 1 Install e solid bush 1 kick shaft assembly etorsion spring 3 2 Hook etorsion spring NOTE Hook the spring end he kickstarter shaft b as shown and ho e other end C on the projection Qr ES S 3 Il plain washer 53 ecirclip X A 4 Install ekick pinion gear 1 ekick pinion gear clip 2 2 e Lubricate the kick pinion gear clip and shaft with molybdenum disulfide oil e Install the kick pinion gear clip a
59. oo f st D L ciu clearance va lt 92 a Remove the timing chain tensioner and cam shaft sprocket b Remove the head nuts bolts and plate c Hemove the rocker arm shaft rocker arm and collar d Remove the valve pad 2 with a magnetic 2222 0 e Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase e Make a note of the position of each valve pad so that they can be installed in the cor rect place e Selectthe proper valve pad from the follow ing table Valve pad thickness range Available valve pads Nos 1 20 0 0472in 25 thicknesses in 120 240 2 40 mm 0 05 mm 0 002 in 0 0945 in increments f Round off the original valve pad number ac cording to the following table 9 3 12 Q ADJUSTING THE VALVE CLEARANCE ADJ Roundedvalus 88 EXAMPLE Original valve pad number 148 thickness 1 48mm 0 0583in Rounded value 150 g Locate the rounded number of the original valve pad and the measured valve clear ance in the valve pad selection table The point where the column and row intersect is the new valve pad The new AM number is only an approxi mation The clearance must be measured again bove steps should be repeated if the ment is still incorrect the new valve OTE e Lubricat
60. procedure applies to all of the valves 22 e Valve clearance adjustment should be made on a cold engine at room temperature e Whenthe valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove e front cover e side cover left andyight e battery battery es e single seat trurik efootrest bo e Refer RS ER AND PANEL 2 Drain X e co pletely from the radiator 3 Remove E radiator cover 1 e radiator efan case Refer to HADIATOR in chapter 6 4 Remove e spark plug e spark plug e ignition coil e cylinder head cover 5 Remove water pump Refer to WATER PUMP in chapter 6 6 Measure e valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 10 0 16mm 0 0039 0 0063in Exhaust valve 0 18 0 24mm 0 0071 0 0094in CHK Q ADJUSTING THE VALVE CLEARANCE ADJ a the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align the punch mark a in the camshaft sprocket with the stationary b on the plate c Align the TDC mark C on the AC magneto rotor with the stationary pointer d on the crankcase cover d Measure the valve clearance with a thick ness gauge 1 Out of specification Adjust oe oS
61. remover 4 0 mm 90890 04111 YM 04111 Valve quide installer 4 0 mm 90890 04112 YM 041 12 Valve guide reamer 4 0 mm 90890 04113 YM 04113 A A AAAAAAAAAAAAAAAAAAAA VALVES AND VALVE SPRINGS ENG 4 3 Eliminate e carbon deposits from the valve face and valve seat 4 Check valve face Pitting wear gt Grind the valve face valve stem end Mushroom shape or diameter larger than the body of the valve stem gt Replace the valve S AS XO eL ure alve margin thickness a MM Out of specification Replace the valve Valve margin thickness 0 9 1 1mm 0 0354 0 0433in 6 Measure valve stem runout Out of specification Replace the valve NOTES LR B H n e valve is removed or replaced always replace the oil seal Valve stem runout 0 01 mm 0 0004 in 5 25 VALVES AND VALVE SPRINGS ENG OD 500240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wear gt Replace the cylinder head Measure valve seat width Out of specification Replace the cylin der head 1 1 mm 0 0354 it 1 6 mm 0 063 in ust 0 9 1 1 mm 0 0354 0 0433 in O lt gt 1 6 mm 0 063 11171604 Apply Mechanic s blueing dye Dykem
62. resis tances with the pocket tester lt lt Pocket tester gt 90890 03112 YU 03112 C Armature coil Commutator resistance 1 0 0378 0 0462 at 20 C 68 F Insulation resistance 2 Above 1 MQ at 20 C 68 F ELECTRIC STARTING SYSTEM ELEC b If any resistance is out of specification re place the starter motor AA4A4AAAAAAAAAAAAAAAAAAAA 5 Measure e brush length 8 Out of specification gt Replace the brushes as a set 6 re rush spring force NS Out of specification gt Replace the brush springs as a set Brush spring force 3 92 5 88N 400 600gf 14 11 21 160z Check e gear teeth Damage wear gt Replace the gear Check e bearing oil seal e bush 3 Damage wear Heplace 8 22 ELECTRIC STARTING SYSTEM ELEC 500772 ASSEMBLING THE STARTER MOTOR 1 Install e brush seat 1 2 Install e washer 1 e armature coil 2 e o ing e stator assembh racket e bolts 1 5 Nm 0 5 m kg 3 6 Ib NOTE Align the match marks 8 on the starter motor yoke with the match marks b on the bracket 8 23 CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM AC magneto Rectifier regulator Main fuse Battery 500774 TROUBLESHOOTING The battery is not being charged Check main fuse battery charging voltage stator coil resistance wiring connections of the entire charging system NOTE
63. seal Valve stem seat Valve guide Refer to REMOVING THE VALVES and INSTALLING THE VALVES OMAN OAR WN WOW gt POCO CO 5 20 VALVES AND VALVE SPRINGS ENG For installation reverse the removal pro cedure 5 21 VALVES AND VALVE SPRINGS ENG O 500237 REMOVING THE VALVES The following procedure applies to all of the valves and related components MUNERE f Before removing the internal parts of the cylin der head e g valves valve springs valve seats make sure the valves properly seal 1 Remove e valve pad 1 le ER Make a note of the of each valve pad so that they can in their original place 2 AN 3 aling age at the valve seat Check the Ive face valve seat and valve seat width 57 Refer to CHECKING THE VALVE SEATS a Pour a clean solvent into the intake and exhaust ports b Check that the valves properly seal o e NO There should be no leakage at the valve seat S QD lt A A AAAAAAAAAAAAAAAAAAAA 3 Hemove valve cotters 1 eM Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment VALVES AND VALVE SPRINGS ENG Valve spring compressor 90890 04019 YM 04019 Valve spring com
64. shaft M14 120 12 0 86 8 Hear brake camshaft lever M6 10 1 0 7 2 Rear brake pin pivot M8 16 1 6 11 6 Speedometer cable M12 5 0 5 3 6 Main switch and headlight stay bracket M6 7 0 7 5 1 Headlight body and headlight unit M5 4 0 4 2 9 Headlight stay bracket and headlight body M6 10 1 0 72 Lower bracket and headlight stay bracket M8 23 2 3 16 6 Handlebar bracket and headlight stay bracket M8 23 2 3 16 6 ECU and trunk M6 7 0 7 5 1 Hear reflector and license bracket M5 2 0 2 1 5 Taillight underside M6 2 0 2 1 5 2 21 TIGHTENING TORQUES v NOTE 1 First tighten the upper bearing inner race approximately 7Nm 0 7mekg 5 1ftelb by using the torque wrench and check turn steering shaft smoothly 2 Second hold the upper bearing inner race and tighten the ring nut 30Nm 3 0mekg 21 7ftelb by using the torque wrench 3 Final operate the steering shaft together with the steering stem nut now 1 Upper bearing inner race 2 Ring nut S AS e S Q 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 500031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point L ubricant Cil seal lips O rings except V belt drive unit O ring fuel injector assembly Cylinder head tightening nut mounting surface Cylinder head stud bolt thread Cylinder head gasket dowel pin Crankshaft pin outside surface Connecting rod Piston outside and ring groove 4 Pisto
65. shaft outside diameter 9 981 9 991 mm 0 3930 0 3933 in Limit 9 950mm 0 3917 in 6 Calculate erocker arm to rocker arm shaft clearance NOEL a Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Above 0 034 mm 0 9688 in gt Replace the de fective part s Hocker arm to rocker arm shaft ance 009 0 034 mm 0 0004 0 0013 im 500207 CHECKING THE TIMING CHAIN CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES 1 Check e timing chain Damage stiffness gt Replace the timing chain and camshaft sprocket as a set 2 Check e camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket and the timing chain as a set 1 4 tooth Correct CD Timing chain roller Camshaft sprocket 3 Check e timing chain guide exhaust side e timing chain guide intake side Damage wear gt Replace the defective part s THE ROCKER ARMS AND CAMSHAFT ENG EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1 Check 2 3 4 etiming chain tensioner Cracks damage gt Replace Check one way cam operation Hough movement gt Replace the timing chain tensioner Check e cap bolt e o ring e spring e one way cam e gasket e timing chain one rod ae ae Replace the defective part s wvvvVVV VVVVVVYVYVYYVYYYYYY a Re g the spring and cap bolt D H cam chain tensioner one way cam
66. specified throttle cable free play is obtained Throttle cable free play is increased Throttle cable free play is de creased c Tighten the locknut After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change AA4AAAAAAAAAAAAAAAAAAAAA CHK CHECKING THE SPARK PLUG 500060 CHECKING THE SPARK PLUG 1 Remove e panel Refer to FOOTREST BOARD AND IN NEH FENDER 2 Disconnect e spark plug cap A WARNING Remove the spark plug cap the engine is extremely hot 3 Remove spark plug CAUTION Before removing agb plug blow away any dirt accumul in the spark plug well with compres r to prevent it from falling into the 4 t Spark plug type C ncorrect gt Change 9 Spark plug type manufacturer CR7E NGK 5 Check electrode 1 Damage wear Replace the spark plug insulator 2 Abnormal color gt Replace the spark plug Normal color is medium to light tan 6 Clean e spark plug with spark plug cleaner or wire brush 7 Measure e spark plug gap with a wire Thickness gauge Out of specification gt Regap Spark plug gap 0 7 0 8mm 0 028 0 031in IBUETDUTE 3 18 CHK CHECKING THE SPARK PLUG 8 Install e spark plug 13Nm 1 3m kg 9 4ft e Ib NOTE Before installing the spark plug clean the spark p
67. spring s eDamaged autc Sn Transmission eDamag Q ansmission gear E jos MS oe springs chp amaged loose or worn clutch shoe spring liten shoes SN eDamaged or worn clutch shoe Primary sliding sheave eSeized primary sliding sheave POOR STARTING PERFORMANCE V belt e V belt slips e Oil or grease on the V belt Primary sliding sheave Faulty operation eWorn pin groove eWorn pin Clutch shoes eBent damaged or worn clutch shoe dE FAULTY CLUTCH OVERHEATING OVERCOOLING SHTG POOR SPEED PERFORMANCE V belt eWorn V belt or grease on the V belt Primary pulley weight s Faulty operation eWorn primary pulley weight Primary fixed sheave eWorn primary fixed sheave Primary sliding sheave eWorn primary sliding sheave Secondary fixed sheave eWorn secondary fixed sheave Secondary sliding sheave eWorn secondary sliding sheave 500855 Hose s and pipe s eDamaged hose eimproperly connected hose eDamaged pipe eimproperly connected pipe FUEL SYSTEM Throttle body eDamaged or loose throttle body joint Air filter eClogged air filter element CHASSIS Brake s X eDragging brake ELECTRICAL Systems Spark plug x eincorr ct spark plug gap spark plug heat range IN system Faulty coolant temperature sensor e ENGINE S Faulty ECU Clogged coolant passages 59 eHeavy carbon buildup amp 500856 O OVERCOOLING Engine oil SS
68. start charging Is the amperage higher than the standard charging am perage written on the bat tery is type of battery charger cannot charge MF battery Charge the battery until tne charging variablevoltage charger is recom voltage reaches 15 V mended NOTE Set the charging time of 20 hours lt N w Leave the battery unus r more than 30 minutes before suring its open circuit voltage 12 8 V I ET complete Ammeter 12 0 12 7 V XRecharging is re Voltmeter quired Under 12 0 V Replace the battery Charger CAUTION Constant amperage chargers are not suitable for charging MF batteries CHECKING AND CHARGING THE CHECKING THE FUSE ADJ 3 56 6 Install battery 7 Connect battery leads to the battery terminals CAUTION First connect the positive battery lead 1 and then the negative battery lead 2 After installing the battery be sure to turn the main switch from ON to OFF three times in 3 seconds intervals to ini tialize the idle speed control system 8 Check e battery terminals X Dirt Clean wire brush Loose connegye gt Connect properly 9 Lubricate SY aneri inals FK commended lubricant Dielectric grease 3 Install e battery cover Refer to SIDE COVERS AND TAIL BRAKE LIGHT EASO0181 CHECKING THE FUSE The following procedure applies to
69. the installed area for looseness or Reinstated by turn pinching ing the main switch 2 Connected condition of con If there is a malfunction repair it and connect ON nector it securely Inspect the coupler for any Intake air temperature sensor coupler pins that may have pulled Main wiring harness ECU coupler out Sub wire harness coupler Check the locking condition of the coupler 3 Open or short circuit in wireing Repair or replace if there is an open or sho harness and or sub lead circuit Between sensor coupler and ECU coupler black blue black blue brown white brown white amp 4 Defective intake air tempera Execute the diagnostic Oe No 005 ture sensor Replace the throttle body xX NOTE Do not remove the se 1 Connect the equa circuit tester to the in take air t rature sensor terminal as shown e tester probe brown white 1 sgative tester probe black blue 2 2 Measure the intake air temperature sensor resistance Intake air temperature sensor resis tance 2 4 2 9 at 20 C 68 F AWARNING e Handle the intake air temperature sen sor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it Is the intake air temperature sensor OK 7 18 rue INJECTION system Fault code No 30 Symptom The vehicle has overturned Used diagnostic code No 008 l
70. voltage DC 12 V of blue 1 on the license plate light coupler license plate light side s the voltage within specification 1 YES 4 This circuit is OK The wiring circuit from the main switch to the li cense plate light coupler is faulty and must be re paired Refer to CIRCUIT DIA GRAM 8 33 SIGNALING SYSTEM CIRCUIT DIAGRAM ER 1 KERKEE E de ere SERRE i Main fuse Battery ECU Main switch Fuel pump Horn switch Turn signal switch Tail brake light Front brake light switch Rear brake light switch Horn Turn signal relay Front turn signal light left Front turn signal Fuel level meter Engine trouble wafning light Coolant tempe ature indicator light IS Speed senstr Turn signal indicator light FI diagnostic tool optional Rear turn signal light left Rear turn signal light right 669699 500794 TROUBLESHOOTING Any of the following fail to light turn sig nal light brake light or an indicator light The horn fails to sound Check 1 main fuse 2 battery 3 main switch 4 wiring connections of the entire signaling system 5 e Before troubleshooting remove the follow ing part s battery cover front cover side cover left and right front fork upper cover front fork cover left and right leg shield1 2 footrest board e
71. 083 3 These tools are needed to remove the cam shaft 90890 01235 Rotor holding tool YU 01235 This tool is used to hold the sheave and secondary sheayk 90890 01268 Ring nut wrench amp YU 01268 O This tool is used ty loosen and tighten the 90890 01304 YU 01304 90890 01337 Clutch spring holder YM 33285 YM 33285 6 These tool are used for removing the nut with holding the compression spring 90890 01325 Radiator cap tester YU 24460 01 Radiator cap tester adapter 90890 01352 YU 33984 This tester and its adapter are needed for checking the cooling system 90890 01367 Fork seal driver weight YM A9409 7 Fork seal driver attachment 90890 01400 YM A9409 3 This tool is used when installing the fork seal 1 8 SPECIAL roots INEO R5 Tool NO Tool name Function Illustration 90890 01384 Oil seal guide YM 33299 This tool is used for protecting the oil seal lip when installing the secondary sliding sheave 90890 01403 Steering nut wrench YU A9472 This tool is used to loosen and tighten the steering ring nut 90890 01444 Steering nut wrench 45mm YM A9409 7 This tool is used to loosen and tighten the upper bearing inner race Flywheel puller set 90890 01468 YU 33270 B This tool is used to remove the AC magneto rotor 90890 01493 Socket wrench 39mm 4 O This tool is used when removing Qui ing the secondary sheave nut 90890 01701
72. 0W30 hypoid gear oil 0 09 0 11L 0 08 0 10 Imp qt 0 10 0 12 US qt 0 11 0 13L 0 10 0 12 Imp at 0 12 0 14 US qt ENGINE SPECIFICATIONS SPEC Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 15mm 0 006in or less 0 23mm 0 009 Outer rotor to pump housing clearance 0 13 0 18mm 0 005 0 007in 0 25mm 0 010in Oil pump housing to inner rotor and 0 07 0 12mm 0 003 0 005in 0 19mm outer rotor clearance 0 008in Cooling system Radiator capacity 0 26L 0 23 Imp gal 0 28 US gal Hadiator cap opening pressure 107 9 137 3kPa 1 1 1 4kg cm 15 6 19 e Valve relief pressure 1 1kPa 0 01 ae 0 1 Radiator core Width 127 4mm 5 01 Height 8 mm 3 4251 Depth 16mm 0 E Coolant reservoir Capacity up to the maximum level mark 0 25L Imp gal 0 27 US gal From low to full level om Imp gal 0 16 US gal Water pump Water pump type NSingle suction centrifugal Max impeller shaft tilt 0 15mm 0 0059in Starting system type Electric and kick starter MEE Electric fuel injection KS Type NO 3B3 Manufacturer 5 AISAN Spark plug Q Kodel manalaci CH7E NGK x1 Spark plug gap 0 7 0 8mm 0 028 0 031 in Cylinder head Volume 3 1 3 5 0 19 0 21 Maximum warpage bus 0 05mm 0 0020in 11110304 2 3 ENGINE SPECIFICATIONS Item Standard Camshaft Drive system Chain drive left Intake camshaft lobe dimensions Measurement A 30 158 30 258
73. 0in 0 1594in 2 5 ENGINE SPECIFICATIONS SPEC Valve stem to valve guide clearance Intake 0 010 0 037 0 080mm 0 0004 0 0015in 0 003 1in Exhaust 0 025 0 052mm 0 100mm 0 0010 0 0020 0 0039in 0 010mm Valve stem runout 0 0004in e Valve seat width Intake 0 9 1 1mm S 1 6mm 0 0354 0 04 0 0630 Exhaust 9 1 N 1 6mm 33in 0 0630 2 6 ENGINE SPECIFICATIONS SPEC Valve springs Free length Intake 39 35mm 1 5492 in 3 38mm 1 4717in Exhaust 41 57 1 636 39 49mm 1 5547in Installed length valve closed Intake 28 0mm 1 1024in Exhaust 30 0mm 1 1811in Compressed spring force installed Intake 91 1 104 9N 9 3 10 7 20 48 23 58lb Exhaust 107 9 124 1N 11 0 12 7kg 24 26 2590 Spring tilt Intake 2 5 1 mm 2 5 0 0669in Exhaust ET 2 5 1 8mm 2 5 0 0709in Winding direction top view Intake Clockwise Exhaust Clockwise Valve seat reformed Cylinder Cylinder arrangement Forward inclined single cylinder Borexstroke 38 0 43 5 1 496 1 713 Compression ratio 12 1 Bore 38 000 38 010mm 1 496 1 497in Maximum taper 0 05mm 0 0020in Maximum out of round 0 05mm 0 0020in 2 7 ENGINE SPECIFICATIONS SPEC Piston Piston to cylinder clearance 0 010 0 035mm 0 150mm 0 0004 0 001 4in 0 0059in Diameter D 3 975 37 990mm 1 4951 1 4957in Height H 5 Omm 0 1969in Piston pin bore in the piston Diam
74. 1200 208 2301215 220 225 23012351240 037 041 145 155 160 165 70 175 180 190 1951 2105 220 225 230 295 240 0 42 0 46 150 155 160 165 170 175 180 185 190 195 200 240 704 051 tes eo tes 17017 ao 185 180 195 200 aos eto ets zen os o0 0 52 0 56 195 200 205 1210 22123101030 5 0 61 165 170 175 180 185 190 195 1200 205 210 215 220 225 230 235 240 62 171751610 se nn ae ev 215 eau os e s 67 0 71 175 1180 1185 1190 195 200 205 210 215 12201225 230 235 240 0 72 0 76 inc ts 200 zoo os i 206 240 N 0 77 0 81 185 t90 195 200 205 210 215 220 225 230 235 240 0 82 0 86 ino ros pon 2100272 2207276 030 238 240 0 87 0 91 19512001205 210 215 220 225 230 235 240 0 92 0 96 210 2151220 225 230 235 240 4 XS m 097 101 1205210 215 220 225 230 235 240 0 16mm 0 0039 0 0063in 102 106 210215220 225 230 235 240 TR RAS pint repealed 1 07 1 11 215 220 225 230 235 240 Q Measured clearance is 0 24mm 0 0084in 1 12 1 16 240 S Heplace pad 175 with pad 185 7117 i 55 240 Q Pad number example 122 126 230 e35 240 No 175 1 75mm 0 0688in 1337 131 235 C Pad No 185 1 85mm 0 0728in 1 32 1 36 240 EXHAUST Y MEASURED ORIGINAL VALVE PAD NUMBER CLEARANCE 120 125 130 140 45 159 RMGO 16511701 175180 188 199 195 200 205 210 15 2201225 200 20
75. 54040 0 18 0 24 ae a D 23 0 29 0 35 0 39 STETERUNT MUI 2 M 0 40 0 44 vao ro ies 70 iz ro ras 1e tos 265 20 215 zo zz 20 ss 5 240 0 45 0 49 146 150 866 160 165 170 175 180 185 1901195 200 205 210 215 220 225 230 235 240 0 50 0 54 a5 169 165170175 80 tas ro 66 200 2210275 20 p25 ao os 240 0 55 0 59 155 160 165 1170 175 180 185 190 195 200 205 2 10215 220 228 230 235 240 0 60 0 Ta 160 18 200 111 0 65 0 69 1651176175 180 185 190 195 200 205 210 215 220 225 230 235 240 070 074 Tro 178 180 186 150 T95 200 205 210 216 220 225 230 235 240 0 75 0 79 176 180 185 90 res oo 205 2 10 218 z2d 28 230 23s 240 080 034 SOINS 0 85 0 89 185 190 195 200 205 210 215 220 225 230 235 240 0 90 0 94 90 95 200 205 210215 20 225 z30 23s 240 0 95 0 99 195 200 205 210 215 220 225 1230 2351240 VALVE CLEARANCE ecold 1 00 1 04 512102152026 em 2 peeled 215 220 225 230 235 5 39 240 Measured clearance 15 0 32mm 0 0126in 240 Replace pad 175 with pad 185 225 230 238 51940 Pad number example Pad No 175 1 75mm 0 0689in Pad No 185 1 85mm 0 0728in 3 14 CHK Q ADJUSTING THE VALVE CLEARANCE ADJ 8 Install e all removed parts NOTE LLL For installation reverse the removal procedure
76. 74 Positive tester probe positive battery terminal Negative tester probe negative battery terminal e he charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive ter minal is disconnected e No charging is necessary when the open circuit voltage equals or exceeds 12 8 V CHK Q CHECKING AND CHARGING THE BATTERY ADJ Relationship between the open circuit voltage b Check the charge of the battery as shown and the charging time at 20 C 4 in the charts and the following example Example c Open circuit voltage 12 0 V d Charging time 6 5 hours e Charge of the battery 20 30 QUE AN A A AAAAAAAAAAAAAAAAAAAA These values vary with the temperature the condition of the battery plates and the electrolyte level Open circuilt voltage V Ambient 2 temperature 5 20 S x e amp 2 Q SA refer to the appropriate charging method illustration A WARNING Do not quick charge a battery CAUTION Never remove the MF battery sealing caps Do not use a high rate battery charger since it forces a high amperage current into the battery quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charg ing current on the battery charger be careful not to overcharge the battery When charging a battery be sure to re move it fr
77. AL e Drink large quantities of water or milk ee followed with milk of magnesia beaten QY egg or vegetable oil Get immediate medical attention CAUTION Q This is a sealed battery Never remove the sealing caps because the balance be tween cells will not be maintained and battery performance will deteriorate e Charging time charging amperage and charging voltage for an MF battery are different from those of conventional bat teries The MF battery should be charged as explained in the charging method il lustrations If the battery is overcharged the electrolyte level will drop consider ably Therefore take special care when charging the battery 3 50 CHK Q CHECKING AND CHARGING THE BATTERY ADJ NOTE Since MF batteries are sealed it is not possible to check the charge state of the battery by mea suring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the bat tery terminals 1 Remove e battery cover Refer to SIDE COVERS AND TAIL BRAKE LIGHT 2 Di amp oonnect attery leads the battery terminals First disconnect the negative battery lead 1 and then the positive battery lead 3 Hemove e battery 4 Check e battery charge a digital circuit tester to the battery terminals Digital circuit tester 90890 031
78. BLESHOOTING e ess 8 10 ELECTRIC STARTING lt 8 14 CIRCUIT DIAGRAM ee RN ecce 8 14 STARTING CIRCUIT CUT OFF 2572 ERATION 8 15 TROUBLESHOOTING es 8 16 STARTER MOTOR ME S S 95 8 20 CHECKING THE STARTER 8 21 ASSEMBLING THE STARTEN OTOR 8 23 CHARGING SYSTEM 8 24 CIRCUIT DIAGRAM amp CMM 8 24 TROUBLESHOOTING ce 8 25 LIGHTING SYSTEM J esee tte teta 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHQ QTING s ec 8 28 CHECKIN E LIGHTING SYSTEM ee 8 30 SIGNALING SYSTEM eene aa 8 34 CIRCUIT DIAGRAM Y eee ccce 8 34 TROUBLESHOOTING cce 8 35 CHECKING THE SIGNALING 8 36 COOLING SYSTEM cecccccccesessecscsssecesscseseveusessvevecseseueusesevevsuseseveusesevsusueees 8 42 TROUBLESHOOTING ecce 8 43 CHECKING THE COOLING SYSTEM eene 8 45 ELECTRICAL COMPONENTS ELEC 500729 ELECTRICAL ELECTRICAL COMPONENTS D Main switch Spark plug cap 2 Front brake light switch 4 Fuel pump 3 Rectifier regulator 2 Starter relay 4 Rear brake light switch 43 Horn 5 Battery Turn signal relay 6 Main fuse 45 Starting circuit cut off relay 7 ECU Stator coil Coolant temperature sensor 67 Wire h
79. DER HEAD 1 Remove e V belt case cover e Refer to BELT DRIVE e cylinder head cover 2 Align e mark on the AC magneto rotor with the stationary pointer b on the crankcase cover Va hh lh a Turn the primary fixed sheave counterclock wise t b When is at DC on compres sion stroke align the 4 mark on the cam WU re with the mark on the plate AAA AAAAAAAAAAAAAAAAA 3 Loosen e timing chain tensioner cap bolt e camshaft sprocket bolt 1 While holding the crank bolt with a wrench 2 remove the camshaft sprocket bolt Rotor holding tool 90890 01235 YU 01235 5 7 CYLINDER HEAD ENG 4 Remove timing chain tensioner along with the gasket e camshaft sprocket 1 timing chain 2 NOTE LLL e To prevent the timing chain from falling into the crankcase fasten it with a wire 5 Remove VAN JI e cylinder head NOTE Loosen the nuts in ipe proper sequence as shown Loosen each 1 2 of a turn at a time ter all of QS S are fully loosened remove them 52 c9 MM 5 8 CYLINDER HEAD ENG EAS00227 CHECKING THE CYLINDER HEAD 1 Eliminate e combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching e spark plug bore thread valve seats 2 Check e cylinder head Damage scratches e
80. ELEC Job Part 0 69 69 6 65 9 C Removing the start Front cover Single seat Tug Air filter assembly Starter motor lead coupler Starter motor Disassembling the starter motor O ring Gasket Stator assembly O ring Armature coil Brush Plate washer Bracket 8 20 2 o Remove the parts in the order listed Refer to COVER AND PANEL In chap ter 3 Refer to ENGINE REMOVAL in chapter 5 Disconnect For installation reverse the removal pro cedure Disassemble the parts in the order listed Refer to ASSEMBLING THE STARTER MOTOR For assembly reverse the disassembly procedure ELECTRIC STARTING SYSTEM ELEC 500769 CHECKING THE STARTER MOTOR 1 Check e commutator Dirt gt Clean with 600 grit sandpaper 2 Measure e commutator diameter Out of specification gt Replace the starter motor Commutator wear limit 16 6 mm 0 65 in 3 Measure e mica undercut 8 b Out of specificatie N gt Scrape the mica to the proper measurement with hack saw blade has been grounded to fit the co or undercut R 35 mm 0 05 in e mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure e armature assembly resistances commu tator and insulation Out of specification gt Replace the starter motor VVVVVVVVVVVVVVVVVVVVVVYV a Measure the armature assembly
81. F Touch the ISC idle speed control valve unit with your hand and check if it is vibrating to confirm if the ISC idle speed control valve is operating NOTE Do not remove the ISC idle speed control valve unit ISC idle speed control valve Execute the diagnostic mode code No D54 not moving correctly After the ISC idle speed control valve is fully closed it opens until it is at the standby open ing position when the engine is started This operation takes approximately 3 seconds un til it is completed Start the engine If the er ror recurs replace the throttle body assem bly rue system code No 39 Symptom Fuel injector open or short circuit is detected Used diagnostic code No D36 fuel injector Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method Connected condition of con If there is a malfunction repair it and connect Reinstated by start nector it securely ing the engine Inspect the coupler for any Fuel injector coupler orange black pins that may have pulled Main wiring harness ECU coupler out Check the locking condition of the coupler Open or short circuit in lead Repair or replace if there is an open or short wire circuit Between fuel injector coupler and ECU co pler main harness orange black orange black 3 Defective fuel injector Execute the diagnostic mode cod
82. FRONT FORK LEGS 4 24 INSTALLING THE FRONT FORK 5 2 0 4 26 HANDLE BA 4 27 REMOVING THE HANDLEBAR eere 4 29 CHECKING THE HANDLEBAR 4 29 INSTALLING THE 2 4 30 STEERING HEAD 4 32 HANDLEBAR BRACKET AND HEADLIGHT STAY BRACKET 4 32 EOWER BRAOKE Re 4 33 REMOVING THE LOWER BRACKET eee 4 34 CHECKING THE STEERING HEAD eese 4 35 INSTALLING THE STEERING HEAD esee 4 36 REAR SHOCK ABSORBER 4 37 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 38 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 38 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 39 FRONT WHEEL AND BRAKE CHAS CHASSIS FRONT WHEEL AND BRAKE d Order _ 4 JopPat Remaks Remove the parts in the order listed 5 Place the scooter a suitable stand so that the front wheel is elevated Removing the front wheel and brake Stop ring Speedometer cable Brake adjuster Front brake cable Adjusting pin Wheel axle nut Wheel axle Collar Front brake shoe plate Front wheel Hefer to REMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL ooo xooesomv For installation
83. G HEAD ADJ b Loosen the upper bearing inner race 2 com pletely and then tighten it to specification with a steering nut wrench 3 Steering nut wrench 90890 01444 YM A9409 7 Do not overtighten the upper bearing inner race Upper bearing inner race final tight ening torque c Check ne sb head for looseness or binding b i ning the front fork all the way in bothesirections If any binding is felt re mo h lower bracket and check the bear to STEERING HEAD chapter 4 S d Hold the upper bearing inner race with a steering nut wrench and tighten the steer ing nut 1 with a steering nut wrench lt lt Steering nut wrench 90890 01403 YU A9472 Steering nut 30Nm 3 0m 21 7ft Ib AAAAAAAAAAAAAAAAAAAAAAA 5 Install eheadlight stay bracket Refer to HANDLE BRACKET AND HEADLIGHT STAY chap ter 4 eleg shield1 2 e ront fork cover left right front fork upper cover Refer to LEG SHIELD1 2 3 43 CHK CHECKING THE FRONT FORK 500151 CHECKING THE FRONT FORK 1 Stand the scooter on a level surface Securely support the scooter so that there is no danger of it falling over 2 Check einner tube Damage scratches gt Replace seal Oil leakage gt Replace 3 Hold the scooter upright and apply the front ebrake 2 ront fork operation Push down hard on the handlebar sev eral times and check if th
84. GRAM Is the charging system s wiring properly con 4 NO YES nected and without defects The charging circuit is j WES OK Heplacethe recti Properly connect or re fier regulator pair the charging system s wiring 500 76 4 Stator coil resistance Disconnect the starter coil coupler from wireharness Connect the pocket tester Q x 1 to the sta tor coil as shown Positive tester probe white 1 Negative tester probe white 2 Measure the stator coil pesstances Stator coil lt istance 0 28 0 at 20 C 68 F the stator coil OK Replace the crank shaft position sensor stator coil assembly 8 26 LIGHTING SYSTEM 800780 LIGHTING SYSTEM CIRCUIT DIAGRAM BE L ji TE lly 1 n 1 LIE x h 4 T val a j i E wid a z i i i ur j 1672 J E d et 21 I 1 1 UEM b 4 T Fi 1 i 1 3 1 7 4 i d 1 FETE TEMNA Main fuse Battery ECU Main switch Dimmer switch Headlight Tail brake light High beam indicator light Speedometer light License plate light 4 9 LIGHTING 5 ELEC 500781 500739 TROUBLES
85. HOOTING 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Any of the following fail to light headlight high beam indicator light taillight license plate light or meter light Minimum open circuit voltage 12 8 V more at 20 C 68 F main fuse 2 battery s the battery OK 3 main switch 4 dimmer switch YES 4 NO 5 Wiring connections of the entire lighting system Clean the battery ter LLL inals e Before troubleshooting remove the follow echarge or replace ing part s the battery 1 battery cover front cover 2 side cover right 3 front fork upper cover 4 front fork cover left and right main switch for continuity 5 leg shield1 to CHECKING THE SWITCHES e Troubleshoot with the following special he main switch OK Pocket tester 90890 03112 Heplace the main YU 03112 C switch ee 92 EAS00784 Eis SS Check the dimmer switch for continuity Refer to CHECKING THE SWITCHES 1 Main fuse Check the fuse ley continuity Refer to CHECKING THE FUSE in chap the dimmer switch OK ter 3 Is the fuse OK YES NO 4 The dimmer switch is faulty Replace the left Heplace the fuse handlebar switch 8 28 LIGHTING system ELEC 500787 Check the entire lighting system s wiring Hefer to CIRCUIT DIAGRAM s the lighti
86. ING THE STARTER CLUTCH CO OD 1 Remove aw Q ecrankcase cover right 1 mX 2 D and in a crisscross pattern After all of the bolts are fully loosened remove them p 7 Q Loosen each bolt 1 4 of a turn at a time in stages op 6 2 Remove estarter clutch nut 1 e washer estarter wheel gear eroller ecollar lt estarter clut RN seg oth nut is left hand thread 5 57 STARTER CLUTCH AND AC MAGNETO ENG 4 500351 CHECKING THE STARTER CLUTCH 1 Check estarter clutch roller Damage wear gt Replace 2 Check estarter clutch idle gear estarter wheel gear Burrs chips roughness wear gt Replace the defective part s 3 Check estarter wheel gear s contacting surfaces Damage pitting wear gt Replace the starter clutch gear 4 29d clutch operation B evereerevererrnvers a Install the starter wheel gear onto the starter clutch 2 and hold the starter clutch b When turning the starter wheel gear clock wise A the starter clutch and the starter wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear coun terclockwise B it should turn freely other wise the starter clutch is faulty and must be replaced AAAAAAAAAAAAAAAAAAAAAAA STARTER CLUTCH AND AC MAGNETO ENG EAS00355 INSTALLING THE STARTER CLUTCH 1 Install e idle g
87. LANT LEVEL ADI EAS00103 CHECKING THE COOLANT LEVEL 1 Stand the scooter on a level surface NOTE e Place the scooter on a suitable stand e Make sure the scooter is upright 2 Check e coolant level The coolant level should be between the maximum level mark 8 and minimum level mark b Below the level mark Add the recommen oolant to the proper level CAUTIONx S e Addingwater instead of coolant lowers the content of the coolant If Is used instead of coolant check c n If necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis AM tilled water is not available soft water may be used 3 Startthe engine warm it up for several min utes and then turn it off ee 4 Check e coolant level NO NOTE o o SN Before checking the coolant level wait a few minutes until it settles CHK CHECKNG THE cooune system ADJ Q 500104 CHECKING THE COOLING SYSTEM 1 3 36 3 Hemove e front cover e side cover left and right e battery battery cover e single seat trunk footrest board Refer 10 AND PANEL e radiator cover Refer to HADIATOR in chapter 6 adiator 1 eradiator inlet hose 2 e radiator outlet hose 3 Cracks damage Replace Refer to COOLING SYSTEM in chap ter 6 Install e radiator cover Refer to HADIATOR in chapter 6 efootrest board e single sea
88. MBLING THE BRAKE SHOE PLATE front brake shoe kit e camshaft lever e brake shoe wear indicator e return spring e brake camshaft Hemove e circlip e plate washer e speedometer clutch e speedometer drive gear e plate washer Hemove e bushing with the special tool e speedometer driven gear e plate washer Meter gear bush tool 90890 01052 Remove the bushing from the brake shoe plate with the meter gear bush tool 4 4 FRONT WHEEL AND BRAKE CHAS 500525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace A WARNING Do not attempt to straighten a bent wheel axle 2 Check e tire e front wheel Damage wear 2 Replace Refer to CHECKING THE TIRES and CHECKING T HEELS in chapter 3 Qr 3 Vre adial wheel runout 1 KS lateral wheel runout Over the specified limits gt Replace Radial wheel runout limit 1 0 mm 0 04 in Lateral wheel runout limit 1 0 mm 0 04 in 4 Check wheel bearings Front wheel turns roughly or is loose gt Heplace the wheel bearings E seal Damage wear gt Replace B 5 Replace e wheel bearings 340 012 oil seal 4 5 FRONT WHEEL AND BRAKE a Clean the outside of the front wheel hub b Remove the oil seal 1 with a flat head screwdriver NOTE 2 222 To prevent damaging the wheel
89. ODUCTION eren tenete to tete tassa 3 1 PERIODIC MAINTENANCE AND MINOR REPAIR 3 2 PERIODIC MAINTENANCE CHART FOR THE EMISSION CON TROL 3 2 GENERAL MAINTENANCE AND LUBRICATION CHART 3 3 COVER AND PANEL rennen rennen nnne rtn inta tea 3 5 SIDE COVERS AND TAIL BRAKE LIGHT 3 5 SINGLE SEAT AND TRUNK 3 7 LEG 5 1 2200 E 3 8 FOOTREST BOARD AND INNER FENDER c NM 3 9 ENGINE RM 3 10 ADJUSTING THE VALVE CLEARANCE SS O 3 10 CHECKING THE ENGINE IDLING SPEED 3 16 ADJUSTING THE THROTTLE CABLE F PLAY MR 3 17 CHECKING THE SPARK PLUG 3 18 CHECKING THE IGNITION TIMING amp 2 0 3 20 MEASURING THE COMPRESSION PRESSURE 3 22 CHECKING THE ENGINE 3 24 CHANGING THE ENGINE 3 25 CHANGING THE TRANSMISSION OIL 3 27 MEASURING THE E E OIL 3 28 REPLACING THE FILTER ELEMENT 3 30 CHECKING BODY JOINT AND INTAKE MANIFOLD 3 32 erae E FUEL 3 32 CHECKINGYTHE BREATHER sse 3 33 CHECKING THE EXHAUST 3 34 CHECKING THE COOLANT LEVEL 3 35 CHECKING THE COOLING
90. OUR SAFETY IS INVOLVED e e Failure to follow could result in severe injury or death AWARNING to the scooter pene bystander or a person checking or repairing the scooter e A CAUTION i gt es special precautions that must be taken to avoid dam pr Tauron A NOT ovides key information to make procedures easier or clearer lt gt 500007 HOW USE THIS MANUAL This manual is intended as a handy easy to read reference book for the mechanic Comprehensive explanations of all installation removal disassembly assembly repair and check procedures are laid out with the individual steps in sequential order D The manual is divided into chapters An abbreviation and symbol in the upper right corner of each page indicate the current chapter Refer to SYMBOLS 2 Each chapter is divided into sections The current section title is shown at the top of each page except in Chapter PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are explode Rams at the start of each removal and disassembly section Q 5 Numbers are given in the order of the jobs in the exploded A circled number indicates a disassembly step xo 6 Symbols indicate parts to be lubricated or replaced ie to SYMBOLS 7 Aj
91. PRESSION PRESSURE ADJ a Set the main switch to ON b With the throttle wide open crank the en gine until the reading on the compression gauge stabilizes To prevent sparking ground the spark plug lead before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits gt d If the compressi essure is below the minimum speci pour a teaspoonful engine of the spark plug bore and measur n Hefer ge following table W stebsion pressure with oil applied into the cylinder igher than without oil Piston ring s wear damage gt Repair Same as without oil Piston ring s valves cylinder head gasket or piston possibly defec tive gt Repair ee AAAAAAAAAAAAAAAAAAAAAAA 8 Remove compression gauge SN 9 Install SX e spark plug 13Nm 1 3m kg9 4ft 10 Connect e spark plug 11 Install e panel Refer 10 BOARD AND IN NER FENDER 3 23 CHK CHECKING THE ENGINE on LEVEL ADs 500069 CHECKING THE ENGINE LEVEL 1 Stand the scooter on a level surface NOTE e Place the scooter on a suitable stand e Make sure the scooter is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check e engine oil
92. RANKSHAFT ASSEMBLY Timing chain Crankcase left Oil seal Bolt O ring Timing chain guide intake side For installation reverse the removal pro cedure CRANKSHAFT ENG 500385 DISASSEMBLING THE CRANKCASE 1 Remove e centerstand assembly 2 Hemove crankcase bolts 1 Loosen each 1 4 of adum at a time in stages and in a crisscross After all of the bolts are fully loosened ove them 3 ove ight crankcase AM e spacer X CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly CRANKSHAFT ENG 4 500389 REMOVING THE CRANKSHAFT ASSEMBLY 1 Remove e crankshaft assembly 1 etiming chain 2 e timing chain guide intake side sSsSsSsSssssSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS e Before removing the crankshaft assembly remove the timing chain from the crankshaft sprocket e The crankshaft assembly cannot be re moved if the timing chain is attached onto the crankshaft sprocket EAS00394 O CHES ING THE CRANKSHAFT AND CON ECTING ROD aX Measure e crankshaft runout Out of specification gt Replace the crank shaft bearing or both NOTE Turn the crankshaft slowly Maximum crankshaft runout 0 03mm 0 0012in 2 Measure e big end side clearance Out
93. Remarks Removing the chatter clutch Remove the parts in the order listed Engine oil Cy Drain Hefer to CHANGING THE ENGINE chapter AC magneto rotor Refer to REMOVING THE AC MAG Stator coil assembly NETO and INSTALLING THE AC MAG 1 Crankcase cover right 1 NETO 2 Starter clutch nut 1 CAUTION 4 Washer 1 The starter clutch nut is left hand 4 Starter wheel gear 1 Thread 5 Roller 1 E Oa Refer 19 REMOVING THE STARTER ME CLUTCH and INSTALLING THE 8 Idle gear 1 T STARTER CLUTCH For installation reverse the removal pro cedure 5 55 STARTER CLUTCH AND AC MAGNETO ENG 4 500347 REMOVING THE AC MAGNETO 1 Remove AC magneto rotor nut 1 e washer 22 e While holding the AC magneto rotor 2 with the sheave holder 3 loosen the AC mag neto rotor nut e Donotallow the sheave holder to touch the projection on the AC magneto rotor 3 Sheave holder AA 90890 01701 YS 01880 A C magneto rotor 1 with the flywheel puller set ewoodruff key _CAUTION To protect the end of the crankshaft place an appropriate sized socket between the flywheel puller set s center bolt and the crankshaft Make sure the flywheel puller is centered over the AC magneto rotor Flywheel puller set 90890 01468 YU 33270 B 5 56 STARTER CLUTCH AND AC MAGNETO ENG 4 EAS00344 z EX K REMOV
94. SAN 4 100 90 1000 4HC1 MATSU SHITA 72 880 YES 5ST1 LUNTAI 10000r min or less 4BA1 NPPONgNERMOSTAN 83 87 C 100C 3 5m Q 5 7 6 3kQ at 20 C 68 F brown white black blue DC 4 8V or more DC 0 6V or less 5V blue black blue 0 63 0 73V yellow black blue 18 220 at 20 C 68 F pink green yellow or gray sky blue 2 17 CONVERTION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METHIC unit data to IMPERIAL unit data MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO IMPERIAL Multiplier Imperial unit 2 205 cc cm cc cm It liter It liter kg mm kg cm 2 18 SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan dard fasteners with a standard ISO thread pitch Tightening torque specifications for spe cial components or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at TOR Temper A Width across flats B Thread diameter TIGHTENING TORQUES ENGINE Part to be tightened Exhaust
95. STALLING THE RADIATOR 1 Fill e cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check e cooling system Leaks gt Repair or replace any faulty part N vyvvvvvvvvv vvvvvvvvvv a Attach the radi amp fer cap tester 1 to the ra diator NN adiator cap tester adapter 90890 01352 YU 33984 A b Apply 100 kPa 1 0 14 22 psi of ES pressure c Measure the indicated pressure with the 9 gauge MAAAAAAAAAAAAAAAAAAAAAA Q 3 Measure eo e radiator cap opening pressure Below the specified pressure gt Replace the radiator cap AN Refer to CHECKING THE RADIATOR 6 3 THERMOSTAT coo 98 THERMOSTAT 0 4 Me Remarks Removing thexttiermostat Remove the parts in the order listed Front cover Side and right Refer 10 AND PANEL in chap Single seat Trunk ter 3 Footrest board Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Clip Thermostat inlet hose Disconnect Clip Thermostat outlet hose Disconnect Thermostat cover Thermostat For installation reverse the removal pro cedure 6 4 THERMOSTAT coo 500462 CHECKING THE THERMOSTAT 1 Check ethermostat 1 Does not open at 85 100 C 185 212 F 2 Replace a Suspend the thermostat a container filled with water b Slow
96. THE AC MAGNETO i a 5 56 REMOVING THE STARTER CLUTCH 5 57 CHECKING THE STARTER CLUTC cO A 5 58 INSTALLING THE STARTER ee 5 59 INSTALLING THE AC MAGNETQSS 5 59 OIL PUMP m 5 61 CHECKING THE OIL 5 62 ASSEMBLING THE OIL RM 5 63 INSTALLING THE 5 63 TRANSMISSION Queen 5 64 CHECKING THR TN 22 44044 5 65 CRANKSHAFT 5 66 CRANKS 5 66 DISASSEMBLING THE CRANKCASE 5 68 REMOVING THE CRANKSHAFT 5 69 CHECKING THE CRANKSHAFT AND CONNECTING 5 69 CHECKING THE CRANKCASE een 5 70 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE INTAKE SIDE 5 71 CHECKING THE BEARINGS AND OIL 5 5 71 CHECKING THE CIRCLIPS AND 5 71 INSTALLING THE CRANKSHAFT ccccccscccccsceecceccesececesseseeseeseeeeee 5 72 ASSEMBLING THE CRANKCASE 5 2 ENGINE REMOVAL ENG ENGINE EAS00188 ENGINE REMOVAL LEADS HOSES AND MUFFLER w 1 1 kg 22 4 ft Ib iw CG AO Job Part Removing the leads hoses and muf Remove the parts in the order listed fler Front cover Single seat Trunk Battery cover Battery Refer
97. VE ENG REMOVING THE PRIMARY SHEAVE 1 Remove eprimary sheave nut 1 eplate washer eoneway clutch eprimary fixed sheave 2 NOTE While holding the primary fixed sheave with the rotor holding tool loosen the primary fixed sheave nut Remove e secondary sheave nut 1 e clutch housing 2 NOTE While holding the clutch housing with the sheave holder 3 loosen the secondary sheave nut v 2 Loosen e clutch carrier nut CAUTION Do not remove the clutch carrier nut at this stage While holding the clutch carrier with the rotor holding tool D loosen the clutch carrier nut one full turn with the socket wrench 2 Rotor holding tool 90890 01235 YU 01235 Socket wrench 39mm 90890 01493 5 45 2 2 BELT DRIVE ENG CD 3 Remove e secondary sheave V belt 2 NOTE Hemove the V belt and secondary sheave from the primary sheave side 500319 DISASSEMBLING THE SECONDARY SHEAVE 1 Remove e clutch carrier nut Install the holder 2 and clutch spring holder onto the secondary sheave as shown n compress the spring and re move th tch carrier nut 1 Clutch spring holder 90890 01337 YM 33285 YM 33285 6 CHECKING THE CLUTCH SHOES Thefollowing procedure applies to all of the clutch shoes 1 Check e clutch shoe Damage wear gt Replace the clutch shoes and springs as a set Glazed areas San
98. a 9 5 LEAKING 9 5 MALFUNCTION D 9 5 UNSTABLE HANDLING nnne nnne ena 9 5 FAULTY LIGHTING OR SIGNALING SYSTEM rennes 9 6 HEADLIGHT DOES NOT COME ON 9 6 HEADLIGHT BULB BURNT ns 9 6 TAIL BRAKE LIGHT DOES NOT COME 9 6 TAIL BRAKE LIGHT BULB BURNT OUT essere 9 6 TURN SIGNAL DOES NOT COME 2 9 6 TURN SIGNAL BLINKS 9 6 TURN SIGNAL REMAINS LIT eese mmm 9 6 TURN SIGNAL BLINKS QUICKLY 9 6 HORN DOES NOT SOUND 9 6 ge S lt AN Q lt C 9 co SM TRBL STARTING FAILURE HARD STARTING SHTG EASO0845 TROUBLESHOOTING NOTE The following guide for troubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative procedure in this manual for checks adjustments and replacement of parts STARTING FAILURE HARD STARTING ENGINE Cylinder and cylinder head e oose spark plug e oose cylinder head or cylinder eDamaged cylinder head gasket eDamaged cylinder gasket eWorn or damaged oylinder valve clearance eimproperly sealed valve e ncorrect valve to valve seat contact valve timing eFaulty valve spring eSeized valve Piston and piston ring eimproperly installed piston ring eDa
99. able Fault Item Symptom Engine Vehicle ode No M startability driveability 12 Crankshaft position 5536 No normal signals received from the Unable Unable crankshaft position sensor 13 Intake air pressure sensor Intake air pressure sensor open or short open or SX cuit pipe circuit detected Able Able system Faulty intake air pressure sensor pipe sys tem Throttle position sensor Throttle position sensor open or short cir open or short circuit stuck cuit detected A stuck throttle position sensor is de tected Broken or disconnected blue Open circuit in the input line blue yellow Unable Unable yellow lead of the ECU lead of the ECU is detected Coolant temperature sensor Coolant temperature sensor open or short Able Able circuit is detected 22 Intake temperature sensor Intake temperature sensor open or short Able Able circuit is detected bp Faulty ignition Open circuit detected in the primary lead Unable Unable of the ignition coil b ISC idle speed control valve Engine speed is high when the engine is Able Able stuck fully open 7 5 19 21 37 rue INJECTION system F Fault ltem Symptom Engine Vehicle ode No startability driveability Fuel injector Fuel injector open or short circuit is de Unable Unable tected Lean angle cut off switch The vehicle has overturned Unable Unable latch up detected open or Lean angle
100. ad Crankcase2 Enter slant angle of sensor Enter tail brake light Fix throttle cable Ass y In stall the protruding part of cramp on the hole of fuel tank bracket Fix throttle cable Ass y In stall the protruding part of cramp on the hole of foot rest bracket 6 ci 7 77 d l E Put the idle speed control lead and wire sub lead in and then close the cramp Wire the starting device of the rear fender of rear mo tor lead and crank case 2 Do not clip the lead in 9 we i LS e EV NUS 1 ND NAN STO Pq WI N Er 9 C 6 6 5 3 t9 CO Speedometer Rectifier Regulator Horn Turn signal relay Front brake cable Rear brake cable Throttle cable Ass y Speedometer cable Rectifier Regulator lead Wiring harness Main switch lead Horn lead CABLE ROUTING SPEC v Penetrate the rear brake cable and throttle cable through the left side of car body Make sure to install the cramp on the head light Stay Install the protruding part of cable strap of electrical wire harmess Ass y on the hole of head light stay i C 3 ag RES D Penetrate the main switch Comp Lead into the con nector cover Penetrate horn cable through the connector
101. ammer 4 Tighten ecrankcase bolts 10Nm 1 0m kg 7 2ft 16 NOTE Tighten the crankcase in stages and in crisscross pattern _ 5 Apply RS eenginetol e crankshaft pin bearing oil ery hole ce ck crankshaft operation Hough movement Repair CHAPTER 6 COOLING SYSTEM 6 1 CHECKING THE RADIATOMH 4 5 5 6 2 INSTALLING THE 4 4 5 5 55 0 6 3 THERMOSTAT o o n 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE 5 4 4 0 00 7 4 6 6 WATER PUMP 6 7 DISASSEMBLING THE 4 4 4 4 6 9 CHECKING THE WATER 6 9 ASSEMBLING THE WATER ce A 6 10 INSTALLING THE WATER Queue 6 11 AS XS 9 ee E AS x RADIATOR COOL EASO0454 COOLING SYSTEM RADIATOR Remove the parts in the order listed Fron
102. and switch optional Horn switch Engine stop switch Turn signal switch Main switch 8 5 CHECKING THE BULBS AND BULB SOCKETS ELEC EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear proper connections and also for continu ity between the terminals Damage wear gt Repair or replace the bulb bulb socket or both Improperly connected Properly con nect No continuity gt Repair or replace the bulb bulb socket or both BULBS bs used this scooter are shown in the illustration on the left e Bulbs A and B are used for the head lights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise e Bulbs C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise e Bulbs D and are used for meter and indicator lights and can be removed from their respective socket by carefully pull ing them out 8 6 CHECKING THE BULBS AND BULB Sockers ELEC CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs 1 Remove e bulb Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION Be sure to hold the socket fi
103. arness 9 Ignition coil 8 1 ELEC WIRING DIAGRAM WIRING DIAGRAM SSSNYVH ans NIV N33M139 HOLO3NNOO 099 JHM SNILO3NNOO 3900 40109 4931 ans SS3NHYH NIYIN a B G pe E EL n E uoa Kumos o zs 2 umorg eo 5 5 lods 1 1 502 B sl 190 1459 19 a 3 s 1 E ig 1 l 5 TURN peg EE be E 4015 93 8 2 amp amp 69 amp C2 6 amp 6 OOS amp OOOO 6 6 6 amp 2 C 6 69 6 639 6 9 AC magneto Hectifier regulator Main fuse Battery Starter relay Starter motor Start switch Engine stop switch ECU Main switch Intake air pressure sensor Intake air temperature sensor Throttle position sensor Lean angle cut off switch Coolant temperature sensor Ignition coil Spark plug Fuel injector Fuel pump ISC idle speed control valve Horn switch Dimmer switch Turn signal switch Headlight Tail brake light Front brake light switch Hear brake light switch Horn Turn signal relay Front turn signal light left Fr
104. ase EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand CHK Q CHECKING AND CHARGING THE BATTERY ADJ EAS00179 BATTERY INSTRUCTION ELECTRICAL SYSTEM MORTAN 12 volt battery No liquid level inspection is ever needed and no refilling water will be required CHECKING AND CHARGING THE BATTERY Never interfere wi e se d state of the battery Raed idees eth AWARNING m Batteries generate explosive hydrogen gas FLAMMABLES Eves E OUT Ce THE llega rt and contain electrolyte which IS made of AUDIO poisonous and highly caustic sulfuric acid This 12V battery is only for starting engine Do not apply for other uses RE AN spr NAH CUM M Therefore always follow these preventive measures Wear protective eye gear when handling or working near batteries Charge batteries in a well ventilated area e Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes e DO NOT SMO hen charging or han dling batteri e KEEP RIES AND ELECTROLYTE OUT REACH OF CHILDREN Avoid bodily contact with electrolyte as e cause severe burns or permanent e injury T AID IN CASE OF BODILY CONTACT TERNAL S e Skin Wash with water lt Eyes Flush with water for 15 minutes O and get immediate medical attention AN INTERN
105. ature sen sor Wiring harness Throttle cable kit Rear brake cable AC magneto lead 5 Starter motor lead 1 amp Vals MG d Ay i i CABLE ROUTING v Battery positive lead Wire lead cover Assemble cramp on the stud at the right of back Stay Install the protruding part of cable strap of electrical wire harmess Ass y on the hole of box bracket 1 Install crap on the hols of stay 1 Penetrate thermo unit lead through the rear of hose 3 Install the protruding part of cable strap of electrical wire harmess Ass y on the ONE T NS To EAR RERI uu A CO EM Gu EN D PA PN VC ES cee og 1 AN SH l hole of down tube 1 Fix connector cover on the head light stay Install the protruding part of cable strap of electrical wire harmess Ass y on the hole of fuel tank bracket 2 Connect AC magnet lead on the cramp of fan case 1 C 6 6 3 9 CO Speedometer Rectifier Regulator Turn signal relay Throttle cable Ass y Holder Cable holder Rear brake cable Speedometer cable Front brake cable Headlight Horn Starting circuit cut off relay gt CABLE ROUTING After wiring the cover cover the coupler Enter tail brake light Af
106. b onto the valve face S Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear impres sion Measure the valve seat width RS NOTE Where the valve seat and valve face contacted Q one another the blueing will have been removed SS 117 H0 AAAAAAAAAAAAAAAAAAAAAAA 4 Lap e valve face valve seat After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped 5 26 VALVES AND VALVE SPRINGS ENG 5 27 WVWVVVVVVVVVVVVVVVVVYVYVYVVYV a Apply a coarse lapping compound 3 to the valve face CAUTION Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound NOTE Sad ULT Cn For the best lappingesults lightly tap the valve seat while rotati e valve back and forth be tween your e lapping compound to the valve fa 8 and repeat the above steps f er every lapping procedure be sure to QS clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder hea
107. ble to monitor the sensor output data or check the activation of actuators with con necting the Fl diagnostic tool to the normal mode orthe diagnostic monitoring mode FI diagnostic tool 90890 03182 YU 03182 Setting the normal mode a The engine speed engine temperature and fault code if detected can be displayed on the LCD of the Fl diagnostic to en the tool is con nected to the vhicle 15 set to the normal mode 1 Turn theath switch to OFF and the en gine s switch to RUN 2 Di nect the self diag signal connector nd then connect the FI diagnostic tool shown Diagnostic Tool lt Turn the main switch to and start the NOTE e Engine temperature and engine revolution appears on the LCD of the Fl diagnostic tool e POWER LED Green comes on e f a malfunction is detected in the system WARNING LED Orange comes on How ever the fault code is not appears on the LCD of FI diagnostic tool 4 Stop the engine NOTES If a malfunction is detected in the system the fault code appears on the LCD of the FI diag nostic tool And also WARNING LED Orange comes on 5 Turn the main switch to OFF to cancel the normal mode 6 Disconnect the FI diagnostic tool and con nect the self diag signal connector 7 8 1 2 3 4 7 9 NOTE FUEL INJECTION SYSTEM Setting the diagnostic mode Turn the main switc
108. board Refer to COVEH AND PANEL 2 Check efuel hose 1 Cracks damage Replace Loose connection gt Connect properly 3 Install efootrest board esingle seat trunk eside cover left and right efront cover Refer to COVER AND PANEL 3 32 CHK CHECKING BREATHER noses ADI Q 500098 CHECKING THE BREATHER HOSES 1 Remove e front cover e side cover left and right e single seat trunk Refer to COVERH AND PANEL 2 V 2 Check By 2 e breather hose 1 ze etransmission case breather hose 2 SVE Cracks damage Replace Loose connectio Connect properly Make sure the yates hoses are routed correctly NS 3 Inst gitigle seat trunk cse cover left and right front cover S Refer to COVER AND PANEL 3 33 CHK CHECKING THE EXHAUST SYSTEM ADI 500099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler assembly and gasket 1 Remove muffler assembly Refer to ENGINE REMOVAL in chapter 5 2 Check muffler assembly 1 Crack damage gt Replace e gasket 2 Exhaust gas leak place 3 Check c e tightening torque Exhaust pipe nut 3 S m 1 3m 9 4ft Ib fiu fler and rear arm bolt 4 31Nm 3 1m 22 411 16 4 Install muffler assembly d Refer to ENGINE REMOVAL in chapter 5 9 3 34 CHK CHECKING THE COO
109. bulb section however note the a Install 265 ulb into the bulb socket pocket tester probes to spegil eads of the bulb socket c C the bulb socket for continuity If any readings indicate no continuity re the bulb socket SEA AAAAAAAAAAA AAA AAA AAA S 8 8 500734 IGNITION SYSTEM CIRCUIT DIAGRAM 4 T UE Los sor Main fuse Battery Engine stop switch ECU Main switch Lean angle cut off switch Ignition coil Spark plug Sidestand switch op tional 7 IU 1 500736 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check main fuse battery Spark plug ignition spark gap spark plug cap resistance ignition coil resistance crankshaft position sensor resistance main switch engine stop switch 10 sidestand switch optional 11 lean angle cut off switch 12 wiring connections of the entire ignition system e ing part s Battery cover Front cover Side cover right Troubleshoot with the following sp errr tool s lt O Ignition checker 90890 06754 YM 34487 Pocket tester 90890 03 YU 03112 Before troubleshooting remove the follow 8 10 IGNITION system ELEC EAS00738 Ma
110. ce with your finger Rough movement gt Replace 2 Check e seals Damage wear gt Replace 500402 CHECKING THE CIRCLIPS AND WASHERS 1 Check ecirclips Bends damage looseness gt Replace e washers Bends damage gt Replace 5 71 CRANKSHAFT ENG EAS00408 INSTALLING THE CRANKSHAFT 1 Install timing chain guide intake side timing chain 1 e crankshaft assembly NOTE s Install the timing chain so it is not visible through the opening in the left crankcase 3 CAUTION To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithiumzsoap based grease and each bearing oil NOTE Put the timin in parallel into the crank case then u amp e hands to place the crankshaft assemblysto the crankcase Manually rotate the cr aft to check whether it is tightly en g ith the timing chain if not install again EAS00418 ASSEMBLING THE CRANKCASE 1 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 2 Apply e sealant onto the crankcase mating surfaces Yamaha bond No 1215 90890 85505 Sealant Quick Gasket ACC 11001 05 01 NOTE LLL Do not allow any sealant to come into contact with the oil gallery 5 73 CRANKSHAFT ENG 3 Install e dowel pins spacer e right crankcase 1 2 Tap lightly on the right crankcase with a soft face h
111. cover without sticking out horn cable Enter rectifier and regulator ASS y 2 32 CABLE ROUTING SPEC v Letthe left and right flasher lights meter and right lead wire of handle bar switch to face upward let the main switch front and rear brake switchand left lead wire of handle bar switch to face downward connect to the coupler and then store in the connector cover 2 33 WO Turn signal light lead right Handlebar switch lead right Front brake light switch lead Turn signal light lead left Handlebar switch lead left Rear brake light switch Throttle cable Ass y Front brake cable Rear brake cable Backward screw Forward screw CABLE ROUTING v Penetrate the rear brake cable and throttle cable through the left side of car body Make sure to install the cramp on the head light Stay Install the protruding part of cable strap of electrical wire harmess Ass y on the hole of head light stay Penetrate the main switch Comp Lead into the con nector cover Penetrate horn cable through the connector cover without sticking out horn cable Enter rectifier and regulator ASS y First tighting the backward screw and tighting the for ward screw CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTR
112. ction operation item and TP Heinstatement Order Operation item and countermeasure probable cause method Connected condition of con If there is a malfunction repair it and connect Reinstated by start nector it securely ing the engine and Inspect the coupler for any Ignition coil primary side coupler orange operating it at idle pins that may have pulled Main wiring harness ECU coupler out Check the locking condition of the coupler Open or short circuit in lead Hepair or replace if there is an open or short circuit Between ignition coil coupler and ECU co pler main harness orange orange Defective ignition coil test the primary and secondary coils for Replace if defective continuity Refer to IGNITION SYSTEM code No 37 Symptom Engine speed is high when the engine is idling Used diagnostic code No D54 ISC idle speed control o Inspection operation item and Heinstatement Order and countermeasure probable cause method speed sensor Reinstated if the en e speed sensor leads gine idle speed is the speed sensor coupler within specification after starting the engine FUEL INJECTOR ASSEMBLY Check the throttle cables Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 ISC idle sp Sed control valve The ISC idle speed control valve is stuck stuck fully open fully open if it does not operate when the main switch is set to OF
113. cut off switch open or short cir short circuit cuit is detected Speed sensor No normal signals are received from the idi s speed sensor Fuel system voltage moni Power supply to the fuel injector fuel pump EN E toring voltage and ignition coil are not normal Error in reading from or writ An error is delected while reading from or ing on E2PROM writing on E2PROM CO adjustment Able Able value Vehicle system power sup Power supply to Fl system is not normal 10 Able Able ply monitoring voltage red lead ECU internal malfunction Faulty ECU memory When this malfe e memory check error tion is detected the code num ght Unable Unable arning tool Start unable warning Helay is not activated even if the crank Engine trouble warning light signal is inputa amp Rile the start switch is Unable Unable flashes when the start pushed Q switch is turned ON K 7 6 FUEL INJECTION SYSTEM EASO0904 TROUBLESHOOTING CHART Engine operation is not normal orthe engine trouble warning light is on Engine trouble warning light may not come on even if the engine operation is not normal The engine trouble warning light does not come on Check the operation of following sensors and ac tuators in the diagnostic mode Refer to Diagnos tic mode table 33 Ignition coil 39 Fuel injector The engine trouble warning light comes on Check the fault code number displaye
114. d i Pressthe valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width again If the valve seat width is out of specification reface and lap the valve seat AAAAAAAAAAAAAAAAAAAAAAA VALVES AND VALVE SPRINGS ENG 4 500241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure valve spring free length a Out of specification Replace the valve spring Valve spring free length Intake valve spring 39 35 mm 1 5492 in Limit 37 38 mm 1 4717 in Exhaust valve spring 41 57 mm 1 6366 in am 1 5547 in ompressed valve spring force 8 AM Out of specification Replace the valve spring b Installed length Compressed valve spring force in stalled Intake valve spring 91 1 104 9N 9 3 10 7kg 20 48 23 58lb at 28mm 1 1024in Exhaust valve spring 107 9 124 1N 11 0 12 7kg 24 26 27 90lb at 30mm 1 1811in 3 Measure valve spring tilt Out of specification Replace the valve spring Spring tilt limit Intake valve spring 1 7 mm 0 0669 in 2 5 Exhaust valve spring 1 8 mm 0 0709 in 2 5 VALVES AND VALVE SPRINGS ENG OD 5 29 EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr evalve stem end with an oil stone 2 Lubricate evalve stem 1 evalve stem seal 2 with the recomm
115. d is the spark gap within specification 500746 6 lgnition coil resistance Disconnect the ignition coil connectors from the ignition coil terminals Connect the pocket tester Q x1 to the igni tion coil as shown Positive tester probe gt orange 1 Negative tester probe gt red black 2 8 11 IGNITION system FLEC 500748 7 Crankshaft position sensor resistance Disconnect the crankshaft position sensor coupler from the wire harness Connect the pocket tester Q x100 to the crankshaft position sensor coupler as shown Positive tester probe g white red 1 Negative tester probe g white blue 2 D Measure the primary coil resistance Primary coil resistance 2 16 2 64 Q at 20 C 68 F Connect the pocket tester Q x1k to the ig nition coil as shown Negative tester probe g orange 2 Positive tester probe ark plu Kad RPM Measur amp dhe crankshaft position sensor re sistagce g lead 1 e Lax ni Crankshaft position sensor resis LO tance 248 372Q at 20 C 68 F between white red and white blue 5 the crankshaft position sensor OK Replace the crankshaft position sensor stator assembly PAS Measure the secondary coil Sistance YES NO 500749 n 4 8 Main switch a Check the main switch for continuity Replace the ignition coil Hefer to CHECKING THE SWITCHES
116. d on the FI diagnostic tool Identify the system with the malfunction Refer to FAIL SAFE ACTIONS TABLE Identify the probable cause of malfunction Refer to Fault code table Check and repair the probable cause of malfunc tion Faultcode No YES Check and repair Hefer to TROUBLE SHOOTING DE Check and repairthe TAILS corresponding sen Monitor the operation Ref o Chapter 5 sor or actuator of the sensors and actuators in the diag nostic mode Refer to Diagnostic mode table Defective sensor or actuator malfunction Faultcode No NO Check and repair Refer to FAIL SAFE ACTIONS TABLE Check and repair the Check the efrgtne condition ECU reinstatement action Refer to Rein statement method in TROUBLESHOOTING DE TAILS Fault code number displayed OK Turn the main switch to OFF turn the main switch back to ON and then check if the fault code num ber is still displayed Fault code number not displayed Repairs completed Erasing the malfunction history The malfunction history is stored even if the main switch is turned OFF The malfunction history must be erased in the diagnostic mode Referto Diagnostic mode table Diagnostic code No 62 Operated when the engine trouble warning light is on 7 7 FUEL INJECTION svsrew F EASCDOSOS DIAGNOSTIC MODE It is possi
117. d with coarse sand paper oo After sanding the glazed areas clean the clutch with a cloth 2 Measure e clutch shoe thickness Out of specification gt Replace the clutch shoes and springs as a set e BELT DRIVE ENG Clutch shoe thickness 3 7mm 0 146in lt Limit gt 2 0mm 0 079in NOTE e Inspect clutch e After removing the clutch shoe spring do not use them again e Replace the all three as a set 500320 CHECKING THE V BELT 1 Check e V belt 1 Cracks damage 2 Replace Grease oil gt primary and ondary 2 M asure belt width AM Out of specification gt Replace V belt width 17 9 mm 0 705 in Limit 16 1 mm 0 634 in CHECKING THE PRIMARY SHEAVE 1 Check e primary sliding sheave 1 e primary fixed sheave Cracks damage wear gt Replace the pri mary sliding sheave primary fixed sheave and V belt 2 Check e ree movement Stick or excessive play gt Replace the primary sliding sheave or collar NOTE LLL Insert the collar into the primary sliding sheave and check for free movement 5 46 BELT DRIVE ENG OD CHECKINGTHE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri mary sheave weights 1 Check primary sheave weight Cracks damage wear gt Replace 2 Measure primary sheave weight outside diameter Out of specification Replace
118. e Fault codeNo Symptom Probable cause of malfunction Diagnostic code No normal signals are received from Open or short circuit in wiring harness the crankshaft position sensor Defective crankshaft position sensor e Malfunction in pickup rotor Improperly installed sensor lead connector in the coupler Intake air pressure sensor open or Open or short circuit in wiring sub lead short circuit detected Open orshort circuit in wiring harness Defective intake air pressure sensor DO3 Improperly installed sendor lead connector in the coupler 4 Faulty intake air pressure sensor Intake air pressure sensor is disconnected or DO3 pipe system clogged Throttle position sensor open or Open or short circuit in wiring sub lead short circuit detected Open or short circuit in wiring harness Defective throttle position sensor DO 1 Improperly installed throttle position sensor lead nector in the coupler 6 Stuck throttle position sensor DO1 detected Defective throttle position sensor A Open circuit in the input line blue yellow lead of ECU is detected D20 when the start switch is pressed Coolant temperature sensor open Open or short circuit in wirinOsftef or short circuit detected ure sensor NO coupler Intake air temperature sensor open Open or short cirguit4 wire sub lead or short circuit detected
119. e s D36 Replace if defective Fault code No 41 Symptom Lean angle cut off switch open or short circuit is detected Used diagnostic code No 008 lean angle cut off switch Inspection operation item and Heinstatement Order Operatio and countermeasure probable cause method Connected condition of con If there is malfunction repair it and connect Reinstated by turn nector it sec ing the main switch Inspect the coupler for any ue angle cut off switch coupler ON pins that may have pulled ain wiring harness ECU coupler out Checkthe locking condition of the coupler Ao Open or short circul iN Wiring Hepair or replace if there is an open or short harness circuit O Between switch coupler and ECU coupler lt black blue black blue yellow green yellow green blue blue Defective lean angle cut off Execute the diagnostic mode code No 008 switch Replace if defective Refer to Fault code No 30 rue INJECTION system Fault code No 42 Symptom No normal signals are received from the speed sensor Used diagnostic code No 007 speed sensor Inspection operation item and TP Heinstatement Order Operation item and countermeasure probable cause method 1 Connected condition of speed ometer connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler 2 Open or short circuit in speed ometer lead 3 Breakage s
120. e battery OK 4 front fork cover left and right A 5 leg shield1 6 air filter assembly 4 YES 4 NO e Troubleshoot with the followi Social tool s Clean the battery ter minals loy e Recharge or replace the battery Pocket tester 90890 03112 0 03112 C 8 16 ELECTRIC STARTING system FLEC 500759 3 Starter motor 4 Starting circuit cut off relay Connect the positive battery terminal 1 and Remove the starting circuit cut off relay starter motor lead 2 with a jumper lead 3 Connect the pocket tester x1 and bat tery 12 V to the starting circuit cut off relay coupler as shown Positive battery terminal red white 1 Negative battery terminal light green 2 Positive tester probe gt green yellow Negative tester probe gt green yellow AWARNING A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure nothing flammable is in the vicinity Does the starter motor turn Repair or re the starter m wwe 8 17 ELECTRIC STARTING SYSTEM ELEC 500761 5 Starter relay e Remove the starter relay Connect the pocket tester Q x1 and bat tery 12 V to the starter relay coupler as shown Positive battery terminal 2green yellow 1 Negative battery terminal gt blue whi
121. e coupler for any ECU coupler operating it at idle pins that may have pulled out Check the locking condition of the coupler Faulty battery Heplace or charge the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 3 Malfunction in rectifier regula Replace if defective Q tor Refer to CHARGING SYSTEM in cha N harness circuit Between battery and ECU red red Faulty ECU memory when this malfunction is detected in the ECU the Fault code No 50 Symptom fault code number might not appear on the meter Used diagnostic code No Inspection operation item and Reinstatement Order tion item and countermeasure probable cause method Malfunction in ECU E ECU Heinstated by turn ing the main switch ON rue INJECTION system Fault code No 61 Symptom ISC idle speed control valve open or short circuit is detected Used diagnostic code No Inspection operation item and TP Heinstatement Order Operation item and countermeasure probable cause method Connected condition of con Ifthereis a malfunction repair it and connect Reinstated by set nector it securely ting the main switch Inspect the coupler for any ISC idle speed control valve coupler to ON The ISC idle pins that may have pulled Main wiring harness ECU coupler speed control valve Out fully closes and Checkthe locking condition then it opens until it of the coupler is at the standby Open or s
122. e free play at the flange of the throttle grip 1 5 3 5mm 0 06 0 14in 500675 STEERING HEAD CHAS STEERING HEAD HANDLEBAR BRACKET AND HEADLIGHT STAY BRACKET er SM BNm 4 8m kg 34 7 ft Ib 1 0 kg 7 2 ft Ib Remarks Removing the handlebar bracket and Remove the parts in the order listed headligh y bracket Front fork upper cover Front fork cover left and right Refer to LEG SHIELD1 2 in chapter 3 Leg shield1 2 Handlebar assembly Refer to HANDLEBAR Speedometer cable Speedometer Headlight unit Headlight body Main switch Horn Rectifier regulator Turn signal relay Starting circuit cut off relay Headlight stay bracket Handlebar lower holder Handlebar bracket Disconnect Disconnect A For installation reverse the removal pro cedure LOWER BRACKET v LOWER BRACKET Removing the love Remove the parts in the order listed Front fork upper Cever Front fork co ft and right Refer to LEG SHIELD1 2 in chapter Leg shiel Front whee Refer to FRONT WHEEL AND BRAKE Front fork legs Refer to FRONT FORK Handlebar assembly Refer to HANDLEBAR Headlight stay bracket Refer 10 HANDLEBAR BRACKET AND Handlebar bracket HEADLIGHT STAY BRACKET Front fender Ring nut Upper bearing inner race Upper bearing Refer to REMOVING THE LOWER
123. e front fork re bounds smoothly Hough movement gt Repair Refer to FRONT FORK in chapter 4 3 44 CHK CHECKING THE TIRES 500163 CHECKING THE TIRES The following procedure applies to both of the tires 1 Check etire pressure Out of specification gt Regulate A WARNING e The tire pressure should only be checked and regulated when the tire temperature equals the ambient air tem perature e The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passen ger and accesso nd the anticipated riding speed Operatio overloaded scooter could c ire damage an accident or an NEVER OVERLOAD THE SCOOTER e NEV NEVER OVERLOAD THE SCOOTER THE SCOOTER 90 kg 198 Ib 175 kg 386 Ib load pressure Up to 55 kg 175 kPa 1 75 175 kPa 1 75 kgf cm 25 psi kgf cm M psi 175 kPa 1 75 1175 kPa 1 75 55 kg 175 kg kgf cm 25 psi kgf cm 25 psi Total weight of rider passenger cargo and ac cessories A WARNING It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately CHK CHECKING THE TIRES 2 Check etire surfaces Damage wear gt Replace the tire Minimum tire tread depth 0 8mm 0 03in Tire tread depth 2 Sidewall 3 Wear indicator Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire fai
124. e method Installed condition of throttle Check the installed area for looseness or Reinstated by start position sensor pinching ing the engine oper Check that it is installed in the specified posi ating it at idle and tion then racing it Refer to THROTTLE BODY AND FUEL IN Defective throttle position sen Execute the diagnostic mode code No 01 sor Replace the throttle body NOTE J Do not remove the sensor assembly C Refer to THROTTLE BODY AND FUEN JECTOR 3 When fault code No 15 has Refer to Fault code No 15 AN Refer to Fault code been detected No 15 code No 19 Symptom Open circuit in the input line of ECU blue yellow lead detected Used diagnostic code No D20 sidestand switch ere Inspection operation item and Heinstatement Order and countermeasure probable cause method Connected state of connector diagnostic mode code No 020 Reinstated by recon Main wiring harness ECU cou e coupler for any pins that may have necting the wiring pler n out and retracting the blue yellow connector Sheck the locking condition of the coupler sidestand lt If there is a malfunction repair it and connect it securely Open or short circuit ring Repair or replace if there is an open circuit harness and or sos Between main switch coupler and ECU cou pler 49 blue yellow blue yellow
125. e scooter upright 2 Start the engine warm it up for several min utes and then turn it off 3 Place a container under the transmission oil drain bolt 4 Remove transmission oil fill bolt along with the gasket transmission oil drain bolt 1 5 Drain transmission completely ft rh the transmission case 6 Install e ransrSsion oil drain bolt etransmission case with the specified amount of the recom Q mended transmission oil Recommended oil SAE10W30 hypoid gear oil Total amount 0 11 0 13L 0 10 0 12 Imp qt 92 0 12 0 14 US qt ON Periodic oil change RN 0 09 0 11L 0 08 0 10 Imp qt Q 0 10 0 12 US qt 8 Install transmission oil fill along with the gasket 23Nm 2 3m kg 16 6ft Ib 9 Startthe engine for several minutes to warm it up and check for the oil leakage 10 Check etransmission case for transmission oil leaks 3 28 CHK Q MEASURING THE ENGINE OIL PRESSURE ADJ EAS00077 MEASURING THE ENGINE OIL PRESSURE 1 Check e engine oil level Below the minimum level mark gt Add the recommended engine oil to the proper level Refer to CHECKING THE ENGINE OIL LEVEL 2 Start the engine warm it up for several min utes and then turn it off CAUTION When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engl abi pressure after
126. e seat Trunk ter 3 Footrest board Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Disconnect Disconnect Disconnect Breather hose Thermostat inlet hose Water pump outlet hose Radiator outlet hose Water pump housing cover Gasket Water pump housing Plate Impeller shaft OTA 2 6 7 WATER Pump COOL v a Job Par lt Remarks 10 Oil seal gt 1 11 Bearing S 1 12 Gasket 1 Q For installation reverse the removal pro cedure WATER Pump COOL EAS0047 1 DISASSEMBLING THE WATER PUMP 1 Remove ewater pump housing cover 1 edowel pin e gasket 2 Remove eplate 2 eimpeller shaft 3 egasket seal with a thin flat jead screwdriver ebearing e NOTE M Rema he oil seal from the inside of the wat p pump housing ove the bearing from the inside of the Cwater pump housing EASO0474 CHECKING THE WATER PUMP 1 Check ewater pump housing cover ewater pump housing eimpeller 1 Cracks damage wear gt Replace 2 Check ewater pump seal 1 Cracks damage wear gt Replace 3 Check ebearing Hough movement gt Replace 4 Check eradiator outlet hose Cracks damage wear gt Replace 6 9 WATER PUMP 9 500475 ASSEMBLING THE WATER PUMP 1 Install bearing 1 NOTE e Before installing the oil seal apply tap wa ter or coolant ont
127. e the valve pad with molybdenum disulfide oil e Install the valve pad in the correct place i Install the rocker arm collar and rocker arm shaft j Install the plate and cylinder head nuts 10Nm 1 0m kg 7 2ft Ib k Install the cylinder head bolts 10Nm 1 0m kg 7 2ft Ib l Install the camshaft sprocket 30Nm 3 0m 21 7ft Ib m Install the timing chain tensioner and gas ket 9Nm 0 9m kg 6 5ft Ib CHK Q ADJUSTING THE VALVE CLEARANCE ADJ n Install the timing chain tensioner spring and cap bolt 8Nm 0 8m kg 5 8ft Ib o Measure the valve clearance again p If the valve clearance is still out of specifi cation repeat all of the valve clearance ad justment steps until the specified clearance is obtained AAAAAAAAAAAAAAAAAAAAAAA 3 13 ADJUSTING THE VALVE CLEARANCE INTAKE MEASURED ORIGINAL VALVE PAD NUMBER CLEARANCE 201125120 136 140146 1551 160165 1701761 160 tae 190 196 aoo oe 210 216 220 225 290 za 249 3 E poles aero pone e Lee tse A Ro eE 0 17 021 125 130 135 140 145 150 1551160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 022 026 ro ras nas e Iro ron e on 19 poo ons faro 215 o ze o rs 210 0 27 0 31 195 140 145 1501155 160 155 170 175 180 185 1901188 200 205 210 215 220 225 120 225 240 0 32 0 36 340 145 150 155 160 165 170 175180 186 190 195
128. e without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the throttle body tuning leading to poor engine performance possible overheating NOTE When installing the air filter element into the air filter case cover make sure their sealing sur faces are aligned to prevent any air leaks 3 30 CHK Q REPLACING THE AIR FILTER ELEMENT ADJ 5 Install e side cover left e front cover Refer to SIDE COVERS AND TAIL BRAKE LIGHT Ko AS 2 XS C s amp S ee S AS 3 31 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD CHECKING THE FUEL HOSE ADJ CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 1 Remove e front cover e side cover left and right e single seat trunk Refer to COVER AND PANEL RY 2 2 Check SN throttle body joint 1 EN gt intake manifold 2 NN Cracks damage Replace 5 Refer to FUEL INJECTION SYSTEM in WSs chapter 7 A COS 2 A 3 Install Q esingle spem 50 AN left and right co 10 AND PANEL MM SN SU ee 92 500096 ON CHECKING THE FUEL HOSE The following procedure applies to all of the fuel lt 1 Remove front cover eside cover left and right esingle seat trunk efootrest
129. eDamaged oil seal lip Faulty rear shock absorber spring eincorrect oil level high e eaking oil e oose damper rod assembly bolt eDamaged damper rod assembly bolt cop Tire s per washer eUneven tire pressures front and rear eCracked or damaged cap bolt O ring tire pressure eUneven tire wear MALFUNCTION eBent or damaged inner tub Wheel s or damaged outer me eincorrect wheel balance eDamaged fork sprin NO eDeformed cast wheel eWorn or damaged r tube bushing eDamaged wheel bearing eBent or dama V UR rod eBent or loose wheel axle e ncorrect oil wheel runout oil level Frame eBent frame eDamaged steering head pipe installed bearing race 9 5 TRBL FAULTY LIGHTING OR SIGNALING SYSTEM 500866 TURN SIGNAL REMAINS LIT FAULTY LIGHTING OR SIGNALING eFaulty turn signal relay SYSTEM eBurnt out turn signal bulb TURN SIGNAL BLINKS QUICKLY e ncorrect turn signal bulb eFaulty turn signal relay eBurnt out turn signal bulb HEADLIGHT DOES NOT COME ON eWrong headlight bulb e Too many electrical accessories eHard charging eincorrect connection eimproperly grounded circuit ePoor contacts main or light switch eBurnt out headlight bulb HORN DOES NOT SOUND eimproperly adjusted horn eDamaged or faulty horne Faulty main switch horn switch eFaulty battery eBlown damaged Gh correct fuse eFaulty wire harness
130. ean angle cut off switch Inspection operation item and Reinstatement Order Operation item and countermeasure probable cause method lt a The vehicle has overturned Raise the vehicle upright Reinstated by turn Installed condition of the lean Check the installed area for looseness or Ing the main switch angle cut off switch pinching ON however the Connected condition of con If there is a malfunction repair it and connect Engine Cannone restarted unless the nector it securely main switch is first Inspect the coupler for any Lean angle cut off switch coupler turned OFF pins that may have pulled Main wiring harness ECU coupler out Check the locking condition of the coupler 4 Defective lean angle cut off Execute the diagnostic mode code No D os switch Replace if defective A 1 Remove the lean angle cutoff the vehicle 2 Connect the lean angle cuti witch cou pler to the wire harness 3 Connect the digital ci tester to the lean angle cut off switc inals as shown Positive probe bleu 1 Negative tester probe gt yellow green 2 CERES 4 Whenturning the lean angle cut off switch Q approximately 65 the voltage reading 49 change from 0 4 V to 4 4 V 5 s the lean angle cut off switch OK rue system 33 Symptom Open circuit detected in the primary lead of the ignition coil Used diagnostic code No D30 Inspe
131. ear e starter clutch e collar e roller e starter wheel gear e washer e starter clutch nut 1 90 Nm 9 0 m kg 65 1 ft Ib NOTE The starter clutch nut is left hand thread ecrankcase cover right 1 10 Nm 1 0 m ka 7 2 ft Ib 7 4 KL 500354 INSTALLING THE MAGNETO 1 Install estator coil assembly 1 ecrankshaft position sensor 2 ewoodruff key eAC magneto rotor ewasher eAC magneto rotor nut 2 0 e Clean the tapered portion of the crankshaft and the AC magneto rotor hub e Wheninstalling the AC magneto rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 5 59 STARTER CLUTCH AND AC MAGNETO ENG OD 5 60 2 Tighten eAC magneto rotor nut 1 43 Nm 4 3 m kg 31 1 ft Ib NOTE e While holding the AC magneto rotor with the sheave holder 3 tighten the AC mag neto rotor nut e Donotallow the sheave holder to touch the projection on the AC magneto rotor kc Sheave holder 90890 01701 OIL PUMP ENG OIL PUMP Remarks Remove the parts in the order listed Radiator O Refer to RADIATOR in chapter 6 AC magneto Refer 10 5 CLUTCH AND AC Starter clutch MAGNETO Drive gear Circlip Plate washer Oil pump driven gear Dowel pin Oil pump For installation reverse the removal pro cedure 5 61 5 62 OIL PUMP ENG CHECKING THE OIL PUMP 1 Check
132. ecification Replace the pis ton pin and piston as a set Piston pin to piston pin bore clearance Piston pin bore diameter 6 Piston pin outside diameter a Piston pin to piston clearance 0 002 0 017 mm 0 0001 0 0007 in 5 36 e CYLINDER AND PISTON ENG CHECKING THE TIMING CHAIN GUIDE 1 Check e timing chain guide exhaust side Damage wear gt Replace 500267 INSTALLING THE PISTON AND CYLINDER 1 Install ring expander 1 oil ring rail 2 xX e2nd ring 3 etop ring 4 N Be sure ggjeta the piston rings so that the rs marks or numbers face up 2 Install e piston 1 e piston pin 2 e piston pin clip IEA 3 NOTE e Apply engineoil the piston pin e Make sure the arrow mark 8 on the piston points towards the exhaust side of the cyl inder e Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the clip from falling into the crank case 5 37 e CYLINDER AND PISTON ENG 3 Install e gasket e dowel pins 4 Lubricate e piston e piston rings e cylinder with the recep ended lubricant A ended lubricant t Co ring end gaps SS Topring b Lower oil ring rail Upper oil ring rail d 2ndring Exhaust side 6 Install ecylinder 1 etiming chain guide exhaust side NOTE e While compressing the piston rings with one hand
133. ect nector it securely Inspect the coupler for any Crankshaft position sensor coupler pins that may have pulled Main wiring harness ECU coupler out Check that the coupler is connected securely NOTE oet the main switch to OFF before connecting or discon necting the connector Open or short circuit in wiring Repair or replace if there is AY en or short harness circuit between the main wirl g harnesses Between sensor coupler MECU coupler white red black blue 4 Defective crankshaft position Replace if defe e sensor Refer to IGNHION SYSTEM in chapter 8 code No 13 Symptom Used diagnostic code No 003 intake air pressure sensor Inspection operation item and Reinstatement Operation item and countermeasure probable cause method Connected condition of con nector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler NOTE oet the main switch to OFF before connecting or discon necting the connector Open or short circuit in wiring harnes and or sub lead Defective intake air pressure sensor FUEL INJECTION SYSTEM Intake air pressure sensor open or short circuit detected Heinstated by turn ing the main switch ON If there is a malfunction reper it and connect it securely Intake air pressure sensor coupler Main wiring harness ECU coupler Sub wire harness coupler
134. ee minutes Does the fuel level meter e move ap propriately Yes SJ NO This circuit is OK Replace the speedo meter COOLING SYSTEM CIRCUIT DIAGRAM 4 45 Main fuse Battery ECU Main switch Coolant temperature sensor Coolant temperature indicas tor light COOLING SYSTEM COOLING SYSTEM 500808 TROUBLESHOOTING The coolant temperature indicator light fails to indicate The coolant temperature indicator light fails to indicate when the engine is warm Check VT main fuse battery main switch coolant temperature sensor wiring connections the entire cooling system e Before troubleshooting remove the follow ogmom e Troubleshoot with the following special AM ing part s battery cover front cover side cover right front fork upper cover front fork cover left and right leg shield1 2 footrest board X tool s Pocket tester 90890 03112 YU 03112 C Refer to CHECKING THE FUSE in chap ter 3 Is the fuse OK j YES 4 the fuse 8 43 500739 ELEC 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery ter nals Hec
135. eel Wheel type Him Size NS Material 9 Wheel travel Wheel runout Maximum radial wheel UN Maximum lateral wh nout Front tire Tire type Size Model manufacturer Tire pressure cold 0 175 0 386 Minimum tire tread depth Steel tube backbone 26 84mm 3 31in Cast wheel J10xMT3 00 Aluminum 58mm 2 28in 1 0mm 0 04in 1 0mm 0 04in 0 25mm 0 01in NG ast wheel J10xMT3 00 Aluminum 56mm 2 20in 1 0mm 0 04in 1 0mm 0 04in Tubeless 120 90 10 57J C 6022 CHENG SHIN 175kPa 1 75kgf cm 25psi 2 12 Rear tire Tire type Size Model manufacturer Tire pressure cold 0 175kg 0 386lb Minimum tire tread depth Front brake Brake type Operation Brake lever free play at lever end Brake drum inside diameter Lining thickness Rear brake Brake type Operation Brake lever free play at lever end Brake drum inside diameter Lining thickness Front suspension Suspension type Front fork type Front fork travel Spring SN Free length O Installed length Spring rate K1 Spring stroke K1 Optional spring available Fork oil Recommended oil Quantity each front fork leg Inner tube outer diameter Inner tube bending limit Tubeless 120 90 10 57J C 6022 CHENG SHIN 175kPa 1 75kgf cm 25psi Drum brake Right hand operation 10 20mm 0 39 0 79in x 110mm 4 33in 4 0mm 0 1 PS uu eration m 0 39 0 79in Telescopic fork Coil spring 65mm 2 56in
136. ended lubricant wy Recommend d tubricant disulfide oil 1 AM evalve spring seat 2 evalve stem seal evalve spring 4 evalve spring retainer 5 into the cylinder head NOTE Install the valve spring with the larger pitch facing up b Smaller pitch 4 Install evalve cotters 1 Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 VALVES AND VALVE SPRINGS ENG Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 04148 YM 04148 5 o secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION Hitting the valve wit excessive force could damage alve A NO Y 6 Save pad 1 E S Lubricate the valve pad with engine oil e Valve pad must be reinstalled in its original position 5 30 500251 CYLINDER AND PISTON CYLINDER AND PISTON ENG 4 2 wW Removing the cylinder and piston Cylinder head Timing chain guide exhaust side Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set st NH 5 31 Remove the parts in the order listed Refer to CYLINDER HEAD Refer to REMOVING THE CYLINDER AND PISTON
137. erature Displays the coolant temperature value displayed on the in te in Vehicle speed pulse Displays the accumulation of the vehicle pulses 0 9997 5 to 0 after 999 007 that are generated when the tire is spun qve numbers appear on the Fl diag AgStic tool 008 Lean angle cut off Displays the lean angle cut off switch values pright 0 4 1 4 V switch 2 Overturned 3 7 4 4V Fuel system voltage Displays the fuel system voltage batte o 0 187 V battery voltage age Normally approximately 12 0 V D20 Sidestand switch Op Displays that the switch is ON or EC Stand retracted ON tion Stand extended OFF Ignition coil When the MODE button is pressed the ignition Check that spark is generated 5 times D30 coil is actuated five times pei Second and the with the MODE button press Fuel injector 1 Is pressed the fuel Check the operating sound of the fuel in D36 times per second and the jector five times with MODE button nge comes on press Headlight button is pressed the head Check the headlight operating 5 times with D52 light is acp five times every 5 seconds and the MODE button is pressed the engi uble warning light comes on ON 2 OFF 3 seconds ISC idle speed con iet The ISC idle speed control valve unit trol valve speed control valve fully closes and then it vibrates when the ISC idle speed Opens until it is at the standby open
138. ery Adjust the voltage to obtain the standard charging amperage Set the timer to the charging time determined by the opencircuit voltage Hefer to CHECKING CHARGING THE BAT Measure the open circuit voltage prior to charging NOTE _ Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage mm Set the charging voltage to 16 17 It the charging voltage is lower charg ing will be insufficient if it is higher Monitor the amperage for 3 5 minutes Is the standard charg ing amperage exceeded If the amperage does not ex ceed the standard charging am perage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the am perage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery the battery will be over charged CHK Q CHECKING AND CHARGING THE BATTERY ADJ Charging method using a constant voltage charger Measure the open circuit NOTE voltage prior to charging Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage Connect a charger and am meter to the battery and
139. et with the stationary pointer d on the plate d Install the timing chain onto the camshaft sprocket and then install the camshaft sprocket onto the camshaft NOTE SSS e When installing the camshaft sprocket be sure to keep the timing chain as tight as possible on the exhaust side e Align the slot on the camshaft with the tab in the camshaft sprocket CYLINDER HEAD ENG CAUTION Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing e While holding the camshaft temporarily tighten the camshaft sprocket bolt f Remove the wire from the timing chain AA4AAAAAAAAAAAAAAAAAAAAA 5 Install ecamshaft sprocket bolt 1 6 Il Aiming chain tensioner gasket etiming chain tensioner VVVVVVVVVVVVVVVVVVVVVVY a Remove the cap bolt 1 and spring 2 b Release the timing chain tensioner one way cam 3 and push the timing chain tensioner rod 4 all the way into the timing chain tensioner housing c Install the timing chain tensioner and gas ket 5 onto the cylinder d Install the springs 2 and cap bolt 1 Cap bolt 8Nm 0 8 m 5 8 ft Ib AA4AAAAAAAAAAAAAAAAAAAAA CYLINDER HEAD ENG 7 ecrankshaft several turns counterclockwise 8 Check e mark a Align the I mark on the AC magneto ro tor with the stationary pointer b on the crankcase covero e mark C Align the
140. eter 10 002 10 013mm Q 10 043mm 0 3938 0 3942 0 3954in Offset 0 35 0 65mm amp ay 0 0138 0 0256 Offset direction Intake side Q 22 Piston Outside diameter 9 996 Domm 9 976mm 03059 aos 0 3928in Piston rings M Top ring S Hing type Barrel Dimensions BxT 0 8x1 65mm 0 0315x0 0650in End gap installed 0 05 0 15mm 0 40mm KS 0 0020 0 0059in 0 0157 Ring side clearance 0 038 0 07mm 0 12mm 0 0012 0 0028in 0 004 7in 2nd ring Hing type Taper Dimensions BxT 0 8x1 5mm 0 0315 0 0591 End gap installed 0 05 0 17mm 0 52mm 0 0020 0 0067in 0 0205in Ring side clearance 0 02 0 06mm 0 12mm 0 0008 0 0024in 0 004 7in 2 8 ENGINE SPECIFICATIONS SPEC Oil ring Dimensions BxT 1 5x1 6mm 0 0591 x0 0630in End gap installed 0 2 0 7mm 0 0079 0 0276in Ring side clearance 0 03 0 15mm 0 0012 0 0059in 2 9 ENGINE SPECIFICATIONS SPEC Rocker arm rocker arm shaft Hocker arm inside diameter 10 000 10 015mm 10 080mm 0 3937 0 3943in 0 3949in Hocker arm shaft outside diameter 9 981 9 991 9 950mm 0 3930 0 3933 0 391 7in Arm to shaft clearance 0 009 0 034mm 0 0004 0 001 3in Connecting rod Connecting rod length 79 95 80 05mm 3 1476 3 1516in Small end inside diameter 10 015 10 028mm 0 3943 0 3948 Crankshaft Width A 671 1 673 Maximum runout C 0 08mm 0 0012in Big end side clearance D 0 15 0 45mm 1 00mm
141. eze water Quantity Total amount 0 50L 0 46 Imp qt 0 53 US qt Coolant reservoir capacity 0 261 0 23 t 0 28 US qt iaximum level mark The specified amount of coolant is a standard amount e cooling system with coolant un til cool omes out of the air bleed bolt hole Gang notes for coolant olant is potentially harmful and should be RNY handled with special care AN O e f coolant splashes in your eyes thor oughly wash them with water and con sult a doctor ee e If coolant splashes on your clothes QY quickly wash it away with water and then with soap and water AS e If coolant is swallowed induce vomiting SX and get immediate medical attention CAUTION e Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used e If coolant comes into contact with painted surfaces immediately wash them with water e Do not mix different types of antifreeze 8 Install e radiator cap 3 38 S S 3 39 CHK CHANGING THE COOLANT 9 Fill e coolant reservoir with the recommended coolant to the maximum level mark 1 10 Install e coolant reservoir cap 11 Start the engine warm it up for several min utes and then stop it 12 Check e coolant level
142. f pipe 3 toward 2 Coolant reservoir hose the direction of radiator cover 3 Radiator inlet hose Install clip for the turning knob to face for 4 Air bleed bolt ward 5 Radiator outlet hose D Hand and fix the claw of fan case 1 on the 6 Fan case radiator cover 7 Damper Insert to the bent part of radiator pipe Raidator cover Make sure that hose is inserted to the bot tom Install clip for the turning knob to face down ward 2 26 5 9 9 C COOLING SYSTEM DIAGRAMS SPEC ve Radiator Install clip for the turning knob to face down Radiator inlet hose ward Radiator outlet hose Thermostat Water pump outlet hose COOLING SYSTEM DIAGRAMS SPEC v 5 9 C Thermostat assembly inlet breather hose Breather hose Water pump outlet hose Radiator outlet hose Water pump 2 28 we Install the paint mark of hose facing up Install clip for the turning knob to face down ward Make sure that hose is inserted to the bot tom Align the paint mark of pipe 7 to the stopper of water pump Ass y Insert until contacting with the stopper 500035 CABLE ROUTING e 9GG Hose3 ECU Ignition coil Sidestand switch lead Main switch Hose Coolant temper
143. g light indication and Fl system operating condition Engine condition Warning light Fl operation Vehicle operation indication Flashing Operation stopped Operate Hemains ON Operated with substitute char Able cranking with electric acteristics in accordance with starter the description of the mal function Flashing indicate the fault code 7 4 FUEL INJECTION system EASDOBO CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB The engine trouble warning light comes on for 2 seconds after the main switch has been turned ON and when the start switch is being pushed If the warning light does not come on under these condi tions the warning light bulb may be defective Main switch Main switch OFF ON Engine trouble Light Light ON for warning light OFF 12 seconds Intialize eo 00802 QN SELF DIAGNOSTIC FANCTION TABLE If the ECU detects an abnormal signal from a sensorwhile the being driven the ECU illuminates the engine trouble warning light and provides the engine h alternate operating instruc tions that are appropriate for the type of malfunction s 2 When abnormal signal is received from a sensor the ocesses the specified values that are programmed for each sensor in order to provide the e with alternate operating instructions that enable the engine to continue to operate or stop ogpfating depending on the conditions EY Self diagnostic fanction t
144. gerously weaken it HANDLEBAR CHAS INSTALLING THE HANDLEBAR 1 Stand the scooter on a level surface A WARNING Securely support the scooter so that there is no danger of it falling over 2 Install e handlebar 1 e handlebar upper holders 2 28Nm 2 8m kg 2Q3ft Ib CAUTION ol First tightenct ts on the front side of the olders and then on the rear side X O eL CARPETA RUE SERRE OH 7 he upper handlebar holders should be in RS Stalled with the arrow marks facing for ward e Align the match marks b on the handlebar with the upper surface of the handlebar lower holder 3 Install e handlebar grip NOTELIIIIIIIIIII Before installing the handlebar grip apply the bond 4 Install e left handlebar switch 1 NOTE Align the projection a on the left handlebar switch with the hole b on the handlebar 4 30 4 31 HANDLEBAR CHAS 5 Install e throttle grip assembly 1 e right handlebar switch 2 e throttle cables 3 NOTE 22 e Align the projection on the right handlebar switch with the hole b on the handlebar e Lubricate the inside of the throttle grip with a thin coat of lithium soap based grease and install it onto the handlebar 4 A WARNING Make sure the grip operates smoothly 6 Adjust SM e free play Hef ADJUSTING THE THROTTLE C FREE PLAY in chapter 3 Throttle cabl
145. gine stop switch is set to and the main switch is set to ON both switches are closed the starter motor can only operate if at least one of the following conditions is met e he brake lever front or rear is pulled to the handlebar the brake light switch is closed and the sidestand optional is up the sidestand switch optional is closed Battery Main fuse Main switch gt Front brake light Qon Hear brake li witch Engine st een Starting cut off relay switch optional St itch er relay arter motor 9 6 9 6 ELECTRIC STARTING ELEC 500757 EASO0738 TROUBLESHOOTING Main Fuse Check the fuse for continuity Hefer to CHECKING THE FUSE in chap ter 3 Check Is the fuse OK 1 main fuse 2 battery n YES 4 3 starter motor 4 starting circuit cut off relay 5 starter relay 6 main switch 7 brake light switch front and rear 8 engine stop switch 9 sidestand switch optional 10 start switch QN 11 wiring connections 500739 of the entire starting system 2 Battery Check the cand Hefer to AND CHARGING SsssSSSsSsSsssFFFFSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS THE RY in chapter 3 e Before troubleshooting remove the follow ing part s inimum open circuit voltage 1 battery cover front cover MAN 12 8 or more at 20 C 68 F 2 side cover left and right N 3 front fork upper cover Is th
146. gth 202 2mm 7 96in lt Limit gt 198 2mm 7 80in 12311708 3 Check e damper rod 1 KS Damage wear gt Replace 1 Obstruction gt Blow out all of the oil pas sages with compressed air 4 23 FRONT FORK CHAS ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs e When assembling the front fork leg be sure to replace the following parts 01 seal dust seal e Before assembling the front fork leg make sure all of the components are clean 1 Install e damper rod assemblyq e rebound spring 2 lt CAUTION Allow the danger rod assembly to slide slowly do e inner tube until it protrudes the bottom of the inner tube Be care ot to damage the inner tube ache ricate EN einner tube s outer surface sS 3 Tighten e Copper washer 371 e damper rod assembly bolt 1 S 23 Nm 2 3 m kg 16 6 ft Ib Q NOTE While holding the damper rod assembly with the damper rod holder 2 and T handle 3 tighten the damper rod assembly bolt Damper rod holder 90890 01294 YM 01300 1 T handle 90890 01326 01326 4 24 FRONT FORK CHAS 4 Install seal with the fork seal driver weight 2 and adapter 3 Fork seal driver weight 90890 01367 YM A9409 7 Adapter 90890 01400 YM A9409 3 CAUTION OZ OOOO O oO Make sure the numbered side of the oil seal faces up 6 lt NOTE
147. h to OFF and the en gine stop switch to RUN Disconnect the self diag signal connector 1 and then connect the Fl diagnostic tool 2 as shown While press the MODE button turn the main switch to ON NOTE DIAG appears the LCD of the FI diag nostic tool POWER LED Green comes on Press the UP button to select the CO ad justment mode CO the diagnostic mode DIAG After selecting qe press the MODE button Select the diagnostic code number that ap plies to item that was verified with the fault number by pressing the UP and Li N buttons he diagnostic code number appears on the LCD 001 070 To decrease the selected diagnostic code number press the DOWN button Press the DOWN button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the UP button Press the UP button for 1 second or longer to auto matically increase the diagnostic code num bers Verify the operation of the sensor or actua tor e Sensor operation The data representing the operating con ditions of the sensor appears on the LCD e Actuator operation Press the MODE button to operate the actuator Turn the main switch to OFF to cancel the diagnostic mode Disconnect the Fl diagnostic tool and con nect the self diag signal connector FUEL INJECTION SYSTEM Fault code tabl
148. harge or replace the battery the main Heplace switch COOLING system ELEC Ny Coolant temperature sensor 22 Nm 2 2 m kg 15 9 ft Ib Does the coolant temperature sensor oper ate properly EASO08 12 4 Coolant temperature sensor Remove the coolant temperature sensor from the cylinder head Connect the pocket tester x 1k to the coolant temperature sensor 1 as shown Immerse the coolant temperature sensor in a container filled with coolant 2 SS M Make sure the coolant temperature sensor ter minals do not get wet Place a thermometer in the coolant Slowly heat the coolant and then let it cool to the specified temperature indicated in the table Check the thermo switch for continuity at the temperatures indicated below 5 Wiring Check the entire casling system s wiring Refer to CIR DIAGRAM Is the cook stem s wiring properly con d without defects Properly connect or re pair the cooling system s wiring Coolant tance 20 C 68 F 2 32 2 59k 80 C 176 F 0 310 0 326k Q A WARNING Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 8 44 COOLING SYSTEM ELEC 7 CHECKING THE COOLING SYSTEM 3 Voltage Connect the pocket tester DC 20 V to the meter light couple
149. heel drive hub installed 1 Adjust e rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 18 FRONT FORK CHAS 500646 FRONT FORK Giob Part Removingt e front fork legs Remove the parts in the order listed Front fork upper cover Reflector Refer to LEG SHIELD1 2 chapter Front fork cover left and right Front wheel Refer to FRONT WHEEL AND BRAKE Cable guide Cap bolt Refer to REMOVING THE FRONT O ring FORK LEGS and INSTALLING THE Lower bracket pinch bolt FRONT FORK LEGS Front fork leg For installation reverse the removal pro cedure 4 19 FRONT FORK CHAS 500648 23Nm 2 3m kg 16 6 ft ei Disasserfibling the front fork legs Remove the parts in the order listed Fork oil Drain Fork spring Damper rod washer Damper rod Hebound spring Inner tube Refer to DISASSEMBLING THE Dust seal FRONT FORK LEGS and ASSEM Oil seal clip BLING THE FRONT FORK LEGS Oil seal Outer tube DOWOOQOGOHVO For assembly reverse the disassembly procedure 4 20 FRONT FORK CHAS 500651 REMOVING THE FORK LEGS The following procedure applies to both of the front fork legs 1 Stand the scooter on a level surface Securely support the scooter so that there is no danger of it falling over LLL Place the scooter on a suitable stand so that the front wheel is e
150. hen finde average of the measurements 38 000 38 010mm 1 4961 1 4965in T Out of round 0 05mm 0 0020in C maximum of D D T maximum of D or D maximum of D or D R maximum of D D or D minimum of D D or D ee b If out of specification rebore or replace the cylinder and replace the piston and piston NO rings as a set SN c Measure piston skirt diameter P with the micrometer a 5mm 0 1969in from the bottom edge of the piston Pisonsze P Standard 37 975 37 990mm 1 4951 1 4957in d If out of specification replace the piston and piston rings as a set 5 33 CYLINDER AND 5 ENG e Calculate the piston to cylinder clearance with the following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 010 0 035mm 0 0004 0 0014in lt Limit gt 0 15mm 0 0059in f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set AAAAAAAAAA AAAAAAAAAA 5 34 e CYLINDER AND PISTON ENG EAS00263 CHECKING THE PISTON RINGS 1 Measure e piston ring side clearance j Out of specification Replace the pis ton and piston rings as a set NOTE e o Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring g
151. horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is faulty and must be repaired Refer to CIRCUIT DIA GRAM SIGNALING system e Disconnect the pink connector at the horn terminal Connect a jumper lead 1 to the horn termi nal and ground the jumper lead Set the main switch to ON Push the horn switch Does the horn sound O The horn is OK Voltage Connect the pocket tester DC 20 V to the horn connector at the pink terminal as shown Positive tester probe pink 1 Negative tester probe gt ground Set the main switch to ON Measure the voltage DC 12 V of pink at the horn terminal 15 the voltage within specification i YES 4 NO Repair or replace Replace the horn the horn SIGNALING 3 Voltage Connect the pocket tester DC 20 V to the 1 Tail brake light bulb and socket tail brake light coupler wire harness side e Check the tail brake light bulb and socket for as shown continuity 7 Refer to CHECKING THE BULBS AND Positive tester probe gt green yellow 1 BULB SOCKETS Negative tester probe gt black Are the tail brake light bulb and socket OK 1 YES 4 NO Heplace the tail brake light bulb socket or both 2 Brake light switches e Check the brake light switches for continu Set the Switch to ON ity e Pull in the rake
152. hort circuit in lead Repair or replace if there is an open or short Opening position circuit when the engine is Between ISC idle speed control valve and Started ECU coupler main harness pink pink green yellow green yellow 2 gray gray S Sky blue sky blue A Detective ISC idle speed con Execute diagnostic mode esae No D54 trol valve Replace the throttle bod NOTE Do not remove th idle speed control valve S A Hefer to WTE BODY AND FUEL IN THROTTLE BODY AND FUEL INJECTOR EASO0909 THROTTLE BODY AND FUEL INJECTOR THROTTLE BODY Remarks Removing the throttle body Remove the parts in the order listed Side cover left and right Refer to COVER AND PANEL in chap Single seat Trunk ter Air filter assembly Refer to ENGINE REMOVAL in chap ter 5 Throttle body clamp screw Lossen MAQS modulated air quantity sensor Disconnect coupler ISC idle speed control valve coupler Disconnect Throttle cable Disconnect Throttle body Sub wire harness For installation reverse the removal pro cedure 7 26 THROTTLE BODYAND FUEL INJECTOR FUEL INJECTOR AND FUEL HOSE e T Nm 0 7m kg 5 1 ft Ib NS O Job Part V Removing the fuel injector and fuel hose Footrest board Remarks Remove the parts in the order listed Refer 10 COVER AND PANEL In chap ter 3 Fuel pump coupler Disconnect Fuel hose connector cover Fuel hose connector Fue
153. in Fl diagnostic tool Malfunction in ECU ERROR 4 Commands from the Fl diagnostic Turn the main switch to OFF once and then turn it back to CO tool are not accepted by the ECU adjustment mode or diagnostic mode Vehicle battery is insufficiently charged Malfunction in Fl diagnostic tool Malfunction in ECU 500908 TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the Fl diagnostic tool Check and service the items or components that are the probable cage of the malfunction following the order given After the check and service of the malfunctioned part has been compl ted reset the FI diagnostic tool display according to the Reinstatement method Fault code No Fault code number displayed on the FI diagnostic tool r2 engine failed to work normally Refer to Fault code table Diagnostic code No Diagnostic code number to be used when the A mode is operated Refer to DIAG NOSTIC S SN SF rue INJECTION system Fault code No 12 Symptom No normal signals are received from the crankshaft position sensor Used diagnostic code No Inspection operation item and TP Heinstatement Order Operation item and countermeasure probable cause method 1 Installed condition of sensor Check the installed area for looseness or Reinstated by crank pinching ing the engine Connected condition of con If there is a malfunction repair it and conn
154. in Fuse Check the fuse for continuity Refer to CHECKING THE FUSE in chap ter 3 i YES 4 EASO0739 Check the condition of the battery Refer to CHECKING AND CHARGING Is the fuse OK Heplace the fuse 2 Battery THE BATTERY in chapter Clean the battery ter minals Recharge or replace the battery 500740 3 Spark plug Check the condition of the spark plug Check the spark plug type Measure the spark plug gap Refer to CHECKING THE SPARK PLUG in chapter 3 Standard spark plug CR7E NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in 5 the spark plug in good condition is it of the correct type and is its gap within speci fication Il YES He gap or replace the spark plug IGNITION svsrEM ELEC 500742 500744 4 Ignition spark gap 5 Spark plug cap resistance Disconnect the spark plug cap from the spark Remove the spark plug cap from the spark plug plug lead Connect the ignition checker 1 as shown Connect the pocket tester Q x1k range 2 Spark plug cap to the spark plug cap as shown Set the main switch to ON Measure the spark plug cap resistance Measure the ignition spark gap 8 Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs zi SPICER cap resistance 4 at 20 C 68 F Is plug cap OK s there a spark an
155. ing position trol valve operates when the engine is started This operation takes approximately 3 seconds until it is completed Transmits the abnormal portion of the data in 01 CO adjustment value is detected display the E2PROM that has been detected as a fault 00 Displays when there is no malfunc code 44 tion If multiple malfunctions have been detected different codes are displayed at 2 second in tervals and this process is repeated Malfunction history Displays the codes of the history of the self 12 61 code display diagnosis malfunctions i e a code of a mal 00 Displays when there is no malfunc function that occurred once and which has been tion corrected If multiple malfunctions have been detected different codes are displayed at 2 second in tervals and this process is repeated Malfunction history Displays the total number of codes that are 00 18 code erasure being detected through self diagnosis and the 00 Dispiays when there is no malfunc fault codes in the past history tion Erases only the history codes when the MODE button is pressed Control number Displays the program control number 00 254 rue INJECTION system Communication error with the FI diagnostic tool LCD Display Probable cause of malfunction Waiting for connec No signals are received from the Improper installed lead connector in the coupler tion ECU The main switch is OFF position Malfunction
156. is not installed properly the steering head pipe could be damaged NOTES III I Always replace the balls and bearing races as a set AA4AAAAAAAAAAAAAAAAAAAAA 4 Check elower bracket along with the steering stem Bends cracks damage gt Replace STEERING HEAD CHAS 500684 INSTALLING THE STEERING HEAD 1 Lubricate bearing balls 1 e bearing races Recommended lubricant Lithium soap based grease 2 Install elower bracket 1 eupper bearing inner 2 with the steering Upper bearing inner race 7 0 7 1 kg 5 1ft Ib NE YM A9409 7 3 Install e ring nut 1 with the steering nut wrench 2 Ring nut 30Nm 3 0m kg 21 7ft Ib Steering nut wrench 90890 01403 YU A9472 4 Install e handlebar bracket 1 NOTE Align the handlebar bracket across rod a on the lower bracket concave 5 Tighten ehandlebar bracket nut 60Nm 6 0m kg 43 4ft Ib 4 36 REAR SHOCK ABSORBER ASSEMBLY CHAS 500685 REAR SHOCK ABSORBER ASSEMBLY Removing the Wear shock absorber Remove the parts in the order listed Front cover Refer to 5IDE COVERS AND TAIL Side cover left BRAKE LIGHT in chapter 3 Rear shock absorber assembly upper nut Rear shock absorber assembly upper bolt Rear shock absorber assembly lower bolt Rear shock absorber assembly For installation reverse the removal pro cedure
157. ke sure there is no brake drag AAAAAAAAAAAAAAAAAAAAAAA 3 40 CHK Q CHECKING THE FRONT AND REAR BRAKE SHOES ADJ EAS00127 CHECKING THE FRONT AND REAR BRAKE SHOES 1 Operate the brake 2 Check wear indicator 1 Reaches the wear limit line gt Replace the brake shoes as a set Refer to FRONT WHEEL AND BRAKE and REAR WHEEL AND BRAKE in chapter 4 Front brake Rear brake 3 41 CHK Q CHECKING AND ADJUSTING THE STEERING HEAD ADJ EAS00148 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the scooter on a level surface Securely support the scooter so that there is no danger of it falling over LLL Place the scooter on a suitable stand so that the front wheel is elevated 2 Check e steering head Grasp the botto front fork legs and gently rock the front fork Binding lo ss 2 Adjust the steering head AN 3 ON e fro rk upper cover e fork cover left right css shield1 2 Refer to LEG SHIELD1 2 S e headlight stay bracket Refer HANDLE BRACKET AND HEADLIGHT STAY chap ter 4 4 Adjust e steering head Loosen the steering nut 1 and then tighten it to specification with the ring nut wrench NOTE Set the torque wrench at a right angle to the steering nut wrench Ring nut wrench 90890 01268 YU 01268 3 42 CHK Q CHECKING AND ADJUSTING THE STEERIN
158. l hose holder to frame Fuel hose holder to intake manifold Clamp Fuel injector coupler Fuel injector Open lock Disconnect For installation reverse the removal pro cedure Il 9 et 7 27 THROTTLE BODYAND FUEL INJECTOR FUEL TANK CC o MAR VATER M 2 wIob Part Hemarks Removing e fuel tank Remove the parts in the order listed NOTE Place the scooter on a suitable stand Fuel hose Refer to FUEL INJECTOR AND FUEL HOSE Fuel tank Refer to REMOVING THE FUEL HOSE Fuel pump Refer to REMOVING THE FUEL PUMP and INSTALLING THE FUEL PUMP For installation reverse the removal pro cedure 7 28 N SN lt S Q ee th KJ Remove THROTTLE BODY AND FUEL INJECTOR REMOVING THE FUEL HOSE t Extract the fuel in the fuel tank through the fuel tank filler hole with a pump 2 Hemove e fuel hose connector cover 1 3 Disconnect e fuel hose CAUTION e Be sure to disconnect the fuel hose by hand Do not forcefully disconnect the hose with tools Although the fuel has been removed from the fuel tank be careful when re moving the fuel h Se since there may be fuel remaini it Do not disconnect the fuel hose from the fuel hose c ctor Disconnect the con nector ffam the fuel pump a under where it will be removed e fuel tank REMOVING THE FUEL PUMP 1 Disconnect e fuel pump coupler e fuel
159. l relay coupler is faulty and must be re light bulb 50 ket or both paired Refer to CIRCUIT DIA GRAM Check the turn signal switch for continuity Refer to CHECKING THE SWITCHES s the turn signal switch OK Heplace the left handle bar switch 8 38 5 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler wire harness side as shown Positive tester probe brown white 1 Negative tester probe gt ground Set the main switch to ON Measure the voltage DC 12 V on brown white 1 at the turn signal relay coupler wire harness side Is the voltage within specification The turn signal reja faulty and musky placed 8 39 This circuit is OK SIGNALING 6 Voltage Connect the pocket tester DC 20 V to the turn signal light connector or meter assem bly coupler wire harness side as shown A Left turn signal light front and rear B Right turn signal light front and rear C Turn signal indicator light Left turn signal light Positive tester probe gt chocolate 1 Negative tester probe gt ground Right turn signal light Positive tester probe gt dark green 2 Negative tester prob 5S ground Set the main switch to ON Set the turn signal switch to lt or oy Measure the voltage DC 12 V of the choco late 1 or dark green 2 at the turn signal light connector wire harness side Is the v
160. levated 2 Hemove efront fork upper cover efront fork cover rind right Refer to LEG SHIELD1 2 in chapter whee Refer ta NT WHEEL AND BRAKE N xe O 3 en ower bracket pinch bolt 1 gt Remove RNY ecap bolt 2 with a 10 mm hexagonal wrench Before loosening the lower bracket pinch bolt support the front fork leg 5 Remove front fork leg EASO0653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove e fork spring 1 4 21 FRONT FORK CHAS 2 Drain e fork oil 12311405 3 Remove e damper rod assembly bolt 1 NOTE While holding the dam er d with the damper rod holder and T har dle 3 loosen the damper rod assembly 4 Remove e damper e spring e inner tube 2 5 Hemove e dust seal oil seal clip 1 with a flat head screwdriver CAUTION Do not scratch the inner tube 4 22 FRONT Fonk C HAS 6 Remove oil seal 1 CAUTION Never reuse the oil seal e Rag 2 EASOO6S6 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check x e inner tube 1 lt outer tube ends cR e scratches gt Replace A WARNING Do tempt to straighten a bent inner tu his may dangerously weaken it 2 Measure e spring free length 8 Out of specification Replace Spring free len
161. level The engine oil level should be between the minimum level mark 8 and maximum level mark b Below the minimum level mark gt Add the recommended engine oil to the proper level c E20W40 ecommended engine oil grade API service SG type or higher JASO standard MA E CAUTION e Do not allow foreign materials to enter the crankcase ee Before checking engine oil level wait a few NO minutes until the oil has settled cS 4 Startthe engine warm it up for several min 49 utes and then turn it off 5 Check the engine oil level again NOTE Before checking the engine oil level wait a few minutes until the oil has settled CHK CHANGING THE ENGINE OIL e omo 0O 9 52 cleaned perform the following procedure a D C 500076 CHANGING THE ENGINE OIL Start the engine warm it up for several min utes and then turn it off Place a container under the engine oil drain bolt Remove e engine oil filler cap 1 e engine oil drain bolt 2 along with the gasket Drain e engine oil completely from the crankcase A 2 9 oil filter element is also to be replaced WWWVVVVVVVVVVVVVVVVY Remove the oil strainer cover spring and oil filter element 4 Replace the O ring Install the new or clean oil filter element and the oil strainer cover Oil strainer cover 32Nm 3 2m kg 23 1ft Ib
162. levers Refer to CHECKING THE SWITCHES Mea the voltage DC 12 V of green 15 the brake light switch OK on the tail brake light coupler wire ess side 15 the voltage within specification 500798 2 Thetail brake light fails to come on Heplace the brake switch es v The wiring circuit from the main switch to the tail brake light coupler is faulty and must be re paired Refer to CIRCUIT DIA GRAM SIGNALING 500799 The turn signal light turn signal indicator light Ode or both fail to blink Connect the pocket tester DC 20 V to the turn signal relay coupler wire harness side 1 Turn signal indicator light bulb and socket as shown ie indicator light bulb and Positive tester probe gt brown I y Refer to CHECKING THE BULBS AND Negative tester probe gt ground BULB SOCKETS e Are the turn signal indicator light bulb and socket OK Replace the turn signal indicator light bulb socket or both Set the m switch to ON 2 Turn signal light bulb and socket Meas oe voltage DC 12 V on brown e Check the turn signal light bulb and socket Dal 9 turn signal relay coupler wire har for continuity Ie E Refer to CHECKING THE BULBS AND voltage within specification BULB SOCKETS Are the turn signal light bulb and socket OK The wiring circuit from the main switch to the turn signa
163. lug and gasket surface 9 Connect e spark plug 10 Install e panel Refer to FOOTREST BOARD AND IN NER FENDER x 3 19 CHK checkin THE enmon AD 500062 CHECKING THE IGNITION TIMING NOTE LL Prior to checking the ignition timing check the wiring connections of the entire ignition system Make sure all connections are tight and free of corrosion 1 Remove front cover e side cover left and right e battery battery cover e single seat trunk Refer to COVER AND PANEL 2 Drain e coolant completely the radiator Remove 9 ever uem se to RADIATOR in chapter 6 4 Attach e timing light 1 e digital circuit tester onto the spark plug lead of cylinder Timing light 90890 03141 YU 03141 Digital circuit tester 90890 06760 3 20 CHK 22 03 5 Check eignition timing WWVVVVVVVVVVVVVVVVVVVVY a Startthe engine warm it up for several min utes and then let it run at the specified en gine idling speed Engine idling speed 2000 2200r min b Check that the mark a on the AC magneto rotor is within the firing range b on the right crankcase cover Incorrect firing range gt Check the ignition system MAAAAAAAAAA AAAAAAAAA NOTE The ignition timings 6 Hemov KS et circuit tester rf Sian case S e radiator
164. lure and from sudden deflation e When using tube vires be sure to install the correst e Always ce a new tube tire and a new tube set e To d pinching the tube make sure wheel rim band and tube are cen ed the wheel groove Patching a punctured tube is not recom WAX LOAD 230 kg 507 175 KP TUBEL ES PSU Las a ELESS 5 Cou RNY mended If it is absolutely necessary to SUITTABLE FOR aS do so use great care and replace the tube as soon as possible with a good quality replacement Tire Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire e After extensive tests the tires listed below have been approved by Yamaha Motor Taiwan Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this scooter wle Front tire Manufacturer Mode Size CHENG SHIN C6022 120 90 10 57 Rear tire Manufacturer Mode Size CHENG SHIN C6022 120 90 10 57 3 46 CHK CHECKING THE TIRES A WARNING New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rota
165. ly heat the water c Place a thermometer in the water d While stirring the water observe the ther mostat and thermometers indicated tem perature E NIU Q 1 ostat ntainer hermometer Water SA Fully closed Fully open If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause seri ous overheating or overcooling 2 Check e thermostat cover Cracks damage Replace 3 5mm 0 141n 3 Check ethermostat inlet hose e thermostat outlet hose 85 2 C Cracks damage gt Replace 185 3 6 6 THERMOSTAT coo 98 500466 INSTALLING THE THERMOSTAT 1 Install ethermostat 1 ethermostat cover 10Nm 1 0m kg 7 2ft NOTE LLL Align the breather a of thermostat to mark b of thermosat before installation 2 Fill N e cooling system with the s ied amount of the recom menos M THE COOLANT 3 3 C oling system C Leaks gt Repair or replace any faulty part Measure RNY e radiator cap opening pressure S Below the specified pressure gt Replace amp the radiator cap Q Refer to CHECKING THE RADIATOR 6 6 WATER PUMP coo 98 WATER PUMP Pw TONm 1 0m kg 7 2 ft Ib ob Part Hemarks Removin Remove the parts in the order listed Front cover Side cover left and right Refer to gt COVER AND PANEFP in chap Singl
166. maged worn or fatigued piston dod eSeized piston ring N eSeized or damaged piston Air filter installed ai r eClogged air filter leg Crankcase and cr aft eimproperly assembled crankcase eSeized crankshaft FUEL SYSTEM Fuel tank eEmpty fuel tank eClogged fuel tank cap breather hole eDeteriorated or contaminated fuel eClogged or damaged fuel hose Fuel pump eFaulty fuel pump routed hose Throttle body eDeteriorated or contaminated fuel eSucked in air ELECTRICAL SYSTEMS Battery c eDischarged battery Faulty Fuse QN BlQwn damaged or incorrect fuse properly installed fuse Spark plug RS spark plug gap spark plug heat range Fouled spark plug eWorn or damaged electrode eWorn or damaged insulator eFaulty spark plug Ignition coil eCracked or broken ignition coil body eBroken or shorted primary or secondary Coil eFaulty spark plug lead Ignition system eFaulty ECU eFaulty crankshaft position sensor eBroken AC magneto rotor woodruff key Switches and wiring main switch eFaulty engine stop switch eBroken or shorted wiring eFaulty front rear or both brake light switches eFaulty start switch eFaulty sidestand switch optional eimproperly grounded circuit e oose connections 9 1 INCORRECT ENGINE IDLING SPEED SHTG STARTING FAILURES HARD STARTING Starting system eFaulty starte
167. mm This tool is used to rebore the new valve guides speciat TooLs INFO 2465 Tool NO Tool name Function 90890 01326 T handle t YM 01326 Damper rid holder 2 90890 01294 These tools are used to hold the damper rod YM 01300 1 when removing or installing the damper rod 90890 03153 Pressure gauge YU 03153 This tool is used to measure fuel pressure 90890 03181 Fuel pressure adapter This tool is used to measure fuel pressure 90890 85505 Yamaha bond NO 1215 ACC 11001 05 01 Sealant Quick Gasket This sealamt bond is used on crankcase mating surfaces e g crankcase mating sur faces CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 42 rnnt nnn nennen 2 1 ENGINE SPECIFICATIONS eren rennen nnn nnntnt rani 2 2 CHASSIS SPECIFICATIONS ssssssssssssssssssssesssssssssssssssseessesssessnesseesses 2 12 ELECTRICAL SPECIFICATIONS sssssssssssssssssssssssessssssesssessssssesseesses 2 15 CONVERTION TABLE GENERAL TIGHTENING TORQUE SPECIFICA TONS 2 18 TIGHTENING TORQUEG csssssssssessssssesssssesssessssssssessuesssessesseesseessesess 2 19 ENGINE sccsscssccssccsscssecsscesecsssesecssessscstessecessesscesecsscesecsneasecsneeseeesense 2 19 CHASSIS dem 2 21 LUBRICATION POINTS AND LUBRICANT TYPES c 2 23 reete 2 23 CHASSIS AS 2 25 COOLING SYSTEM DIAGRAMS 2 26 CABLE ROUTING
168. n 1 4 Lubricate e guide pin groove 2 s o ring 2 with the recommended lubricant Recommended lubricant BEL RAY assembly lube 5 49 BELT DRIVE ENG 5 Install e secondary sheave 1 e spring e clutch carrier 2 NOTE Attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave as shown Then compress the spring and tighten the clutch carrier nut 5 Vz Clutch spring holder 90890 01337 YM 33285 500325 ge ING THE SECONDARY SHEAVE V AND PRIMARY SHEAVE M Install V belt 1 e secondary sheave 2 CAUTION Do not allow grease to contact the V belt secondary sheave assembly e Install the V belt onto the primary sheave side e Install the V belt with printed arrow mark on the V belt facing in the direction shown in the illustration 2 lighten e clutch carrier nut 55Nm 5 5m kg 39 8ft Ib NOTE While holding the clutch carrier with the rotor holding tool 7 tighten the clutch carrier nut with the socket wrench 2 5 50 BELT DRIVE ENG Rotor holding tool 90890 01235 0 01235 Socket wrench 39mm 90890 01493 3 Install e clutch housing 1 e secondary sheave nut 2 40Nm 4 0m kg 29398 Ib Tighten the dary sheave nut with the sheave oe N 90890 01701 YS 01880 A 4 Install e primary fixed sheave 1 e oneway clutch
169. n pin outside surface surface and bolt thread Q Crankshaft journal Piston balancer outside surface Piston pin balancer outside surface Camshaft lobe Camshaft profile journal Valve stems intake and exhaus n Valve stem seals intake a Ix xhaust Valve pads intake an aust i Valve stem ends i and exhaust Oil pump assembly inside surface Oil pipe union bolt thread and surface Starter clutch pin and weight Kick pinion gear and kick pinion gear clip thrust surface Idle gear 1 thrust surface 1111141 VW AAAAAABAAAAAAAA 6 2 0 Idle gear2 Main and drive axle serration sprocket 2 23 LUBRICATION POINTS AND LUBRICANT TYPES SPEC v BEL RAY asembly lube BEL RAY asembly lube 2 24 LUBRICATION POINTS AND LUBRICANT TYPES 500032 CHASSIS SPEC Lubrication Point Front wheel oil seal lips Steering bearing and bearing races upper and lower Frame head pipe dust seal lips lower Tube guide throttle grip inner surface Brake lever and lever holder bolt sliding surface Centerstand pivoting point and sliding surface Single seat lock cable inner surface Engine bracket and engine mound bolt sliding surface 2 25 i COOLING SYSTEM DIAGRAMS v EASO0033 Insert until contacting with the latch of ra COOLING SYSTEM DIAGRAMS diator tank 1 Raidator cap Install white paint marck o
170. ng bolt shaft e Do not fully engine mounting bolt c N xo ear shock absorber assembly lower NY bota OTE Do not fully tighten the bolt 3 Tighten e engine mounting bolt 58Nm 5 8m kg 42 0ft 10 e rear shock absorber assembly lower bolt 16Nm 1 6m kg 11 6ft Ib 5 4 500221 CYLINDER HEAD Ny 13Nm 1 3m kg 9 4 ft Ib N y Ww 10 1 kg 7 2 ft Ib ne A Ss SS 1 1 t 2 i CYLINDER HEAD ENG 80Nm 3 0m kg 21 7 ft Ib Job Part 1 2 3 4 5 6 7 8 9 Removing the cylinder head Hadiator Thermostat Water pump Muffler Bracket Intake manifold O ring Joint O ring Spark plug cap Ignition coil Spark plug Coolant temperature sensor Cylinder head cover O ring Timing chain tensioner Remove the parts in the order listed Refer to COOLING SYSTEM in chapter 6 Refer to ENGINE REMOVAL CYLINDER HEAD ENG ToNm 1 0m kg 7 2 ft Ib m 11 2 10 1 0 kg 7 2 fio g Ny 13Nm 1 3m kg 9 4 ft Ib Timing chain tensioner gasket Camshaft sprocket Bolt Nut Plate Cylinder head Cylinder head gasket Dowel pin Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD For installation reverse the removal pro cedure pastes 5 6 CYLINDER HEAD ENG EAS00225 REMOVING THE CYLIN
171. ng system s wiring properly con nected and without defects 1 YES 4 NO Check the condition Properly connect or re of each of the light pair the lighting system s ing system s cir WirIng cuits Refer to CHECK x ING THE LIGHT ING SYSTEM S 2 AS X 8 29 LIGHTING system CHECKING THE LIGHTING SYSTEM Voltage 1 The headlight and the high beam indicator Connect the pocket tester DC 20 V to the light fail to come on headlight and high beam indicator light cou plers as shown 1 Headlight bulb and socket Check the headlight bulb and socket for con tinuity the dimmer switch is set to 2 B When the dimmer switch is set to Refer to CHECKING THE BULBS AND BULB SOCKETS e Are the headlight bulb and socket OK Headlight Positive tester probe yellow 1 or green 2 YES J NO Negative tester probe gt black green Headlight coupler Replace the headlight bulb socket or both QN 2 High beam indicator light bulb and socket Check the high beam indicator light bulb and Socket for continuity Hefer to CHECKING THE BULBS AND BULB SOCKETS Are the high beam indicator light bulb d Socket OK Set the main switch to ON Start the engine Set the dimmer switch to O or ZD Measure the voltage DC 12 V of yellow tX green 2 on the headlight coupler and yellow on the meter assembl
172. nut has been tightened to specification bend the lock tabs along a flat of the bolt or nut EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturers marks or numbers are visible When installing oil sealsXlubricate the oil seal lips with a light co lithium soap based SS grease bearingsliberally when installing if Riga appropriate L N 1 Oil se 50 O C YAON Dowot spin the bearing with compressed because this will damage the bearing surfaces D Bearing EASO0025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives 4 Shaft IMPORTANT INFORMATION GEN fes 500021 EQUIPMENT PREPARATION Push Rivet Push type Assembly status of the push rivet push type Dissembling 1 Press center pin 1 inward to release the lock 2 Remove the push rivet main body 2 Ass vM 1 store the center pin replace the push AM rivet main body 2 Push in the center pin until leveling off with the surface position of the push rivet main body CHECKING THE CONNECTIONS o 500026 CHECKING THE CONNECTIONS Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect e lead e coupler e connector
173. o its out surface e Install the oil seal with a socket that matches its outside diameter 2 Install water pump seal into the water pump housing CAUTION 2 Never lubricate thew ter pump seal surface with oil or Inst e water pump seal with the special cess in depth of water pump and oil seal S 215 5 5 6 0mm 4 Mechanical seal installer 90890 04145 Middle driven shaft bearing driver 90890 04058 YM 04058 3 Measure e impeller shaft tilt Out of specification gt Replace the impeller shaft Impeller shaft tilt limit 0 15mm 0 0059in 1 Straightedge 2 Impeller 4 Install impeller shat plate 2 CAUTION After installation check that the impeller shaft rotates smoothly 6 10 SS 6 11 5 WATER Pump COOL Install egasket Tm ewater pump housing cover 1 EASO0478 INSTALLING THE WATER PUMP 1 Install water pump assembly 1 1ONm 1 0m kg Hane Ib Qy itt a on the impeller shaft with ction b on the camshaft sprocket NOTE tall breather hose e thermostat inlet hose e water pump outlet hose e radiator outlet hose Fill e cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 Check e cooling system Leaks gt Repair or replace the faulty part Measure e radiator cap opening pressure Below the specified pressu
174. ob instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc NS Jobs requiring more information such ecial tools and technical data are described se quentially 9 CYLINDER AND PISTON ENG EAS00e53 REMOVING THE CYLINDER AND PISTON 1 Remove e piston pin dip D episton pin 2 episton 3 CAUTION Do not use a hammer to drive the piston pin out NOTE Before removing the piston pin clip cover e crankcase opening with a clean rag to prevent the piston pin clip from falling e crankcase into Remarks Removing the cylinder and piston Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD Timing chain guide exhaust side nder Cylind 2 a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown Refer to REMOVING THE CYLINDER AND PISTON and INSTALLING THE PISTON AND CYLINDER Qo Amb wm wp HA For installation reverse the removal pro cedure 500008 SYMBOLS The following symbols are not relevant to every vehicle Symbols 1 to 9 indicate the subject of each chapter General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting QN
175. ocket OK 4 the tail brake light bulb socket or both Positive tester probe black green 1 Negative tester probe gt black white 2 Set the main switch to ON e Measure the voltage DC 12 V of black socket tester DC 20 V to the green 1 on the ECU coupler wire harness oig t coupler wire harness side side 1 the voltage within specification n YES This circuit is OK The wiring circuit fro the main switch t ECU coupler SS Ity and must be repaired X DIA SX Set the main switch to ON Measure the voltage DC 12 V of blue 1 on the tail brake light coupler tail brake light side 15 the voltage within specification i YES This circuit is OK Wiring circuit from the main switch to the tail brake light coupler is faulty and must be re paired Refer to CIRCUIT DIA GRAM 8 32 LIGHTING 5 ELEC 500792 4 The license plate light fails to come on 1 License plate light bulb and socket Check the license plate light bulb and socket for continuity Hefer to CHECKING THE BULBS AND BULB SOCKETS Are the license plate light bulb and socket OK 2 Voltage Connect the pocket tester DC 20 V to the license plate light coupler license plate light side as shown Positive tester probe blue 1 Negative tester probe gt black 0 Set the main NT ON Measure the
176. of specification gt Replace the big end bearing crankshaft pin or connecting rod Big end side clearance 0 15 0 45 0 006 0 018 5 69 CRANKSHAFT ENG 3 Measure e crankshaft width Out of specification gt Replace the crank shaft Crankshaft width 42 45 42 50mm 1 671 1 673in 4 Check ecrankshaft sprocket 1 Damage wear gt Replace the crankshaft ebearing 2 Cracks damage gt Replace the crankshaft pump driv gear r 2 Replace crankshaft 5 Check amp craakghaft journal fatches wear gt Replace the crank aft Cs crankshaft journal oil passage Obstruction gt Blow out with compressed ar O NO 500399 ON CHECKING THE CRANKCASE cS 1 Thoroughly wash the crankcase halves in 49 a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check ecrankcase Cracks damage Replace eoil delivery passages Obstruction gt Blow out with compressed air 5 70 CRANKSHAFT ENG OD 500207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE INTAKE SIDE 1 Check e timing chain Damagge stiffness gt Replace the timing chain and camshaft sprocket as a set 2 Check e timing chain guide intake side 22 Damage wear gt Replace 500401 CHECKING THE BEARINGS AND OIL DE NS Check ES ebearings Clean and lubricate the bearings then ro tate the inner ra
177. oltage within specification i YES The wiring circuit from the turn signal switch to the turn signal light con nector is faulty and must be repaired SIGNALING 4 The fuel level meter fails to operate 2 Voltage Connect the pocket tester DC 20 V to the Fuel sender meter light coupler wire harness side as Remove the fuel pump from the fuel tank SON Connect the pocket tester x1 to the fuel sender coupler wire harness side as tester probe gt brown 0 hem Negative tester probe black 2 Positive tester probe green 1 Negative tester probe gt black 0 Set the Switch to ON voltage DC 12 V of brown 1 on theymeter light coupler wire harness s voltage within specification Fuel sender resistance up position PPQ 1 4 10Q at 20 C 68 F Fuel sender resistance down Check the wiring con tion E Q x 10 nections of the entire 90 100 Q at 20 C 68 F A signaling system Refer to CIRCUIT DIA s the fuel sender OK GRAM NO 0 3 cg Heplace the fuel pump 8 40 SIGNALING 3 Fuellevel meter Set the main switch to Move the float up 1 or down 2 Check that the fuel level meter needle moves RN to E Or E Q NOTE Before reading the fuel level meter lea e float in one position either up or do der at least thr
178. om the scooter If charging has to be done with the battery mounted on the scooter disconnect the negative bat tery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the bat tery charger leads are connected to the battery e Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger 3 52 CHK Q CHECKING AND CHARGING THE BATTERY ADJ Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may gen erate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery stabilizes about 30 minutes after charg ing has been completed Therefore wait 30 minutes after ging is completed before measuring the open circuit volt age Q S 3 53 2 CHK Q CHECKING AND CHARGING THE BATTERY ADJ Charging method using a variable current voltage charger Charger Ammeter Connect a charger and am meter to the battery and start charging Is the amperage higher than the standard charging am perage written on the bat t
179. ont turn signal ight righ yo Fuel level meter High beam indicator ght Speedometer Engine trouble warning light Coolant temperature indicator Speed sensor Turn signal indicator light diagnostic tool optional Sidestand switch optional Rear turn signal light left Hear turn signal light right License plate light Starting circuit cut off relay Connector S lt O light WIRING DIAGRAM ELEC COLOR CODE Black Br Brown errr Green cae Gray ere Blue PRINS Light green OF Orange a Pink NT Hed OD uis Sky blue White x Yellow White B W las B Y giri G R reen Red Gs Green Yellow PM Green White E m Blue Black Blue Green LAN Blue White Vs Blue Yellow Or B Orange Black PAN Pink White R B Red Black R L Red Blue R W Red White W L White Blue WIR White Red Y Q san Yellow Green Br W Brown White Br L Brown Blue 1 12 8 4 CHECKING SWITCH ELEC EASO0730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester If the continuity reading is incorrect check the wiring connections and if necessary replace the switch CAUTION Never insert the tester probes into the coupler terminal slots Always insert the probes from the opposite end of the coupler taking care not to loosen or damage the
180. or short circuit in wiring Execute the diagnostic mode code No 0 9j harness Qr When the leads are a volt age check by the code No DO ossable Repair or replace if open or short circuit e Between attona ain switch red red e Between maitfSwitch and handlebar switch engine witch brown n e Be n handlebar switch engine stop and white red black Fault code No 44 Svmptom Error is detected while reading from or writing on EEROM code re ympr registering key code and throttle valve fully closed notification valve Used diagnostic code No 60 EEPROM improper cylinder indication ofer item and Heinstatement Order Operation item and countermeasure ion of e cause method 1 Malfunction in ECU Execute the diagnostic mode code No D60 Reinstated by turn 01 is displayed on meter ing the main switch Readjust the CO of the displayed cylin ON der Refer to ADJUSTING THE EXHAUST GAS VOLUME in chapter 3 Heplace ECU if defective rue system code No 46 Symptom Power supply to Fl system is not normal red lead Used diagnostic code No Inspection operation item and TP Heinstatement Order Operation item and countermeasure probable cause method Connected condition of con If there is a malfunction repair it and connect Reinstated by start nector it securely ing the engine and Inspect th
181. peedometer cable or speedometer gear unit 4 Defective speed sensor If there is a malfunction repair it and connect it securely Speedometer coupler Main wiring harness ECU coupler Repair or replace if there is an open or short circuit Between speedometer coupler and ECU co pler white white black blue black blue Execute the diagnostic mode 564 Checking the speedometer and loose connection Qy Checking the movement gihe speedometer gear unit 1 Checking the of the speedometer clutch Maa and speedometer gear unit slots b breakage Execute the diagnostic mode code No 007 Replace the meter assembly Heinstated by input ting the vehicle speed signals by turning the front wheel rue system Power supply to the fuel injector fuel pump and ignistion coil are not Fault code No 43 Symptom normal Used diagnostic code No 009 fuel system voltage Inspection operation item and Heinstatement Operation item and countermeasure probable cause method Connected condition of con If there is a malfunction repair it and connect Reinstated by start nector it securely ing the engine and Inspect the coupler for any ECU coupler operating it at idle pins that may have pulled out Check the locking condition of the coupler Faulty battery Heplace or charge the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open
182. pipe stud bolt Oil check bolt Cylinder head cover Cylinder head and cylinder Cylinder head timing chain side Spark plug Camshaft sprocket Timing chain tensioner body Guide stopper2 Timing chain tensioner plug Water pump assembly Thermostat cover air bleed bolt Thermostat cover Fan case Fan Radiator drain bolt Radiator cover Oil pump assembly Engine oil drain plug Intake manifold Air filter assembly Injector Intake manifold side band Air filter assembly side pany Protector SN Exhaust pipe e Stay fender lt Muffler Heed valve and holder Al filter case Oil guide Crankcase left and right Cylinder stud bolt Drain bolt transmission oil fill bolt V belt case cover Drain bolt transmission oil Transmission case Transmission case Covert starter clutch Hold lead plate bolt TIGHTENING TORQUES v Part name 2 19 Thread size Tightening Qty torque 13 13 9 4 N00 0 5 When fastened apply screw retaining com pound TIGHTENING TORQUES SPEC v Tightening Part to be tightened Part name beg Qty Hemarks M8 23 2 3 Drain bolt engine oil Centerstand spring Hook Starter clutch Nut Left handthread Kickstarter Bolt Primary fixed sheave Nut Clutch housing Nut Stator coil Bolt Pulser coil Screw AC magneto rotor Nut Starter motor assembly Bolt Ignition coil Bolt Coolant temperature sensor 1 NO
183. place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 4 with a gen eral bearing puller 3 d Install the new wheel bearings and oil seal in the reverse order of disassembly AAAAAAAAAALAG AAAAAAAAA 500535 CHECKING THE SPEEDOMETER GEAR M Check e speedometer clutch Bends damage wear gt Replace 2 Check e speedometer drive gear 1 e speedometer driven gear 2 Damage wear Heplace 4 6 FRONT WHEEL AND BRAKE CHAS 500536 CHECKING THE BRAKE The following procedure applies to all of the brake shoes 1 Check e brake shoe lining Glazed areas gt Repair Sand the glazed areas with course sand paper After sanding the glazed areas clean the brake shoe with a cloth AS 2 2 re rake shoe lining thickness Out of specification Replace Brake shoe lining thickness limit minimum 2 0 mm 0 08 in Do not allow oil or grease to contact the brake shoes NOTE SOF Replace the brake shoes as a set if either is worn to the wear limit 3 Measure e brake drum inside diameter b Out of specification Replace the wheel Brake drum inside diameter limit maximum 110 5 mm 4 35 in FRONT WHEEL AND BRAKE CHAS 4 Check e brake drum inner surface Oil deposits gt Clean Remove the oil with a rag soaked in lac quer thinner or solvent Scratches gt Repair Lightly and evenly poli
184. plied to the fuel injector at only 250 kPa 2 5 kg cm 35 6 psi Accordingly when the energizing signal from the ECU energizes the fuel injector the fuel passage opens caus ing the fuel to be injected into the intake manifold only during the time the passage remains open Therefore the longer the length of time the fuel injector is energized injection duration the greater the volume of fuel that is supplied Conversely the shorter the length of time the fuel injector is energized injection duration the lesser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU Signals that are input from the crankshaft position sensor intake air pressure sensor intake temperature sensor and engine temperature sensor enable the ECU to determine the injection duration The injection timing is deter mined through the signals from the crankshaft position sensor As a result the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions HEC REG Illustration is for reference only D 2 4 5 6 0 9 Fuel pump 1 Air filter case Fuel injector 2 ISC idle speed control valve Ignition coil 3 Throttle position sensor ECU Fuel system Catalytic converter Air system Coolant temperature sensor Control system Crankshaft position sensor Intake air pressure sensor Throttle body assembly Intake air temperature
185. pressor attach ment 90890 04148 YM 04148 4 Remove e valve spring retainer 1 e valve spring 2 e valve stem seal 3 e valve spring seat e valve 5 Qr NOTE Identify t sition of each part very carefully SO n be reinstalled in its original place 5 23 VALVES AND VALVE SPRINGS ENG 11170641 5 24 500239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Out of specification gt Replace the valve guide Valve stem to valve guide clearance Intake 0 010 0 p3 mmi0 0004 0 00 5in 08 mm 0 0031 in Limit 0 025 0 052 mm 0 001 0 002 in mit 0 10 mm 0 0039 in 2 alve guide EIS aG To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven WWYVVVVVVVVVVVVVVVVVVVVYV a Hemove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover D c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOMBRE RED After replacing the valve guide reface the valve seat Valve guide
186. r wire harness side as shown socket Positive tester probe green red 1 e Check the coolant temperature indicator light Negative tester probe2 ground bulb and socket for continuity Hefer to CHECKING THE BULBS AND BULB SOCKETS Are the coolant temperature indicator light bulb and socket OK 1 Thecoolant temperature indicator light fails to come on Heplace the coolant temperature indicator light bulb socket or both Set the m in Switch to ON Measure voltage DC 12V of green 2 Voltage redayg the coolant temperature sensor e Connect the pocket tester DC 20 V to the harness meter light coupler wire harness side as lt a e voltage with in specification shown Positive tester probe brown 1 Negative tester probe2green white 2 AS The wiring circuit from the main switch to the coolant temperature sensor coupler is faulty and must be repaired Refer to CIRCUIT DIA GRAM Set the main switch to ON Measure the voltage DC 12 V of brown 1 on the meter light coupler wire harness side s the voltage within specification The wiring circuit from the main switch to the meter light coupler is faulty and must be re paired COOLING SYSTEM ELEC 7 4 Coolant temperature indicator light e Disconnect the coolant temperature sensor coupler at the coolant temperature sensor Connect the green red 1 and black blue with a jumper lead Set
187. r Wheel and brake Remove the parts in the order listed Q NOTE SN Place the scooter on a suitable stand so that the front wheel is elevated Muffler Refer to ENGINE REMOVAL in chapter 5 AD ll ol l Self lock nut Plate washer Brake adjuster Spring Rear brake cable Adjusting pin Rear wheel Brake shoe kit Tension spring Plate washer Camshaft lever Indicator plate Brake camshaft O ring Disconnect COON OAR WN C For installation reverse the removal pro cedure 4 13 REAR WHEEL AND BRAKE CHAS EAS00564 REMOVING THE REAR WHEEL 1 Stand the scooter on a level surface Securely support the scooter so that there is no danger of it falling over 2L Place the scooter on a suitable stand so that the rear wheel is elevated 2 Remove muffler Refer to ENGINE REMOVALDL in chapter 5 3 Loosen QN ebrake adjuster x O ove heel axle nut 1 eplate washer erear wheel 5000565 SN CHECKING THE REAR WHEEL 1 Check SX erear wheel Damage wear gt Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 2 Measure eradial wheel runout elateral wheel runout Refer THE FRONT WHEEL 4 14 REAR WHEEL AND BRAKE CHAS 500567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check erear wheel drive hub C
188. r motor eFaulty starter relay eFaulty starting circuit cut off relay starter clutch plug S lt O EAS00847 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder and cylinder head valve clearance eDamaged valve train components Air filter eClogged air filter element FUEL SYSTEM Throttle body eDamaged or loose throttle body joint eimproperly control valve throttl e free play eFlooded throttle body Faulty air i tion system N CLECTRIGAL SYSTEMS Battery 2 Discharged battery battery spark plug gap spark plug heat range eFouled spark plug eWorn or damaged electrode eWorn or damaged insulator eFaulty spark plug Ignition coil eFaulty spark plug lead Ignition system eFaulty ECU eFaulty crankshaft position sensor 9 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 500848 MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURE HARD START ING ENGINE Air filter eClogged air filter element FUEL SYSTEM Throttle body eFaulty diaphragm Fuel pump eFaulty fuel pump S lt O FAULTY CLUTCH SHTG 500853 FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL NOT MOVE V belt eBent damaged or worn V belt eSlipping V belt Primary pulley cam and primary pulley slider eDamaged or worn primary pulley cam eDamaged or worn primary pulley slider Clutch
189. racks damage gt Replace 500569 CHECKING THE BRAKE The following procedure applies to all of the brake shoes 1 Check X e brake shoe ining Glazed areagy gt epair Sand the ed areas with course sand paper NOTE di ing the glazed areas clean the brake S ith a cloth 2 Measure e brake shoe lining thickness Out of specification gt Replace Brake shoe lining thickness limit minimum 2 0 mm 0 08 in Do not allow oil or grease to contact the brake shoes NOTE LLL Heplace the brake shoes as a set if either is worn to the wear limit 4 15 REAR WHEEL AND BRAKE CHAS 3 Measure e brake drum inside diameter b Out of specification gt Replace the wheel Brake drum inside diameter limit maximum 110 5 mm 4 35 in 4 Check e brake drum inner surface Oil deposits gt Clean Remove the oil with a rag soaked in lac quer thinner or solvent Scratches gt Repair Lightly and evenly polish the scratches with an emery 5 Check brake cam Damag wear gt Replace XO O 500570 ASSEMBLING THE BRAKE SHOE PLATE 1 4nstall S e brake camshaft 1 eo rings TR e brake shoe wear indicator 2 55 22 Lubricate the brake camshaft and o rings with lithium soap based grease After installing the brake camshaft and o rings remove any excess grease Install the brake camshaft 1 so its punch
190. re gt Replace the radiator cap Refer to CHECKING THE RADIATOR CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM nnne tenente neni 7 1 WIRING DIAGRAM eet tette 7 2 ECU S SELF DIAGNOSTIC FUNCTION ree 7 4 CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT 7 5 SELF DIAGNOSTIC FANCTION TABLE ee 7 5 oself diagnostic fanction 7 5 TROUBLESHOOTING CHART seen 7 7 DIAGNOSTIC MODE ccccccecesesessecesesececesererseseeesesecece E 7 8 TROUBLESHOOTING amp 522 7 12 THROTTLE BODY AND FUEL INJECTOR oa 7 26 THROTTLE BODY oain Aen 7 26 FUEL INJECTOR AND FUEL HOSE A 7 27 FUEL 7 28 REMOVING THE FUEL HOSE A ME 7 29 REMOVING THE FUEL 9 7 29 CHECKING THE THROTTLE 7 30 INSTALLING THE FUEL 20022 222140 7 31 INSTALLING THE FUEL HOSE sss 7 31 CHECKING THE FUEL P AND PRESSURE REGULATOR OP ERATION S retten 7 32 CHECKING THE THBOTTLE POSITION SENSOR 7 32 CHECKING THAG IDLE SPEED CONTROL VALVE 7 34 AIR INDUCTION E 7 35 AIR INJECHION 22 7 35 AIR CUT OFF VALVE
191. reverse the removal pro cedure ll 4 1 FRONT WHEEL AND BRAKE CHAS 500518 FRONT WHEEL ex Order Remarks Disassengbifng the front wheel Remove the parts in the order listed Oil seal Bearing Spacer Bearing For assembly reverse the disassembly procedure 4 2 FRONT WHEEL AND BRAKE CHAS FRONT BRAKE SHOE PLATE Disassembling the f plate Brake shoe kit S Tension sprin S Camshaf Brake shoeWwear indicator Heturn spring Brake camshaft O ring Oil seal Oil seal Circlip Plate washer Speedometer clutch Speedometer drive gear Plate washer Bushing Oil seal Speedometer driven gear Plate washer Refer to DISASSEMBLING THE BRAKE SHOE PLATE and ASSEM BLING THE BRAKE SHOE PLATE c cL I I cL c N 6 6 9 C9 6 9 6 6 9 For assembly reverse the disassembly procedure 4 3 FRONT WHEEL AND BRAKE CHAS EAS00520 REMOVING THE FRONT WHEEL 1 Stand the scooter on a level surface Securely support the scooter so that there is no danger of it falling over 2L Place the scooter on a suitable stand so that the front wheel is elevated 1 2 3 Hemove e speedometer cable 1 e front brake cable e front wheel axle nur e front wheel ME 0 e collar front egeo front b hoe plate 6 O EAS00524 DISASSE
192. ritten on or read from the internal memory Power supply to Fl system is not Malfunction in charging system normal red lead Faulty ECU memory When this Malfunction ECU The program and data are not malfunction is detected the code properly written on or read from the internal memory Oo number might not appear on the meter 61 ISC idle speed control valve open Open or short circuit in wiring harness D54 or short circuit is detected Improperly installed lead connector in the coupler FUEL INJECTION SYSTEM 500907 Diagnostic mode table NOTE e Check the intake air temperature and coolant temprature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively e f it is not possible to check the intake air temperature use the ambient temperature as refer ence Diag Data displayed on FI diagnostic tool nostic Description of action reference value code Throttle angle Displays the throttle angle 0 125 degrees Check with throttle fully closed Fully closed position 14 20 Check with throttle fully open Fully open position 97 107 Intake air pressure Displays the intake air pressure Compare it to the value displayed on the Intake air temperature Displays the intake air temperature Compare it to the value displayed on the eS v Geek tho temperature m manitold diagnose Coolant temp
193. rmly when removing the bulb Never pull the lead otherwise it may lled out of the ter minal in the coufter Avoid touchifig the glass part of the headlig 1 to keep it free from oil otherwi e transparency of the glass the li the bulb and the luminous flux will be adversely affected If the head bulb gets soiled thoroughly clean with a cloth moistened with alcohol or lacquer thinner SS Check e bulb for continuity O with the pocket tester No continuity gt Replace gt Pocket tester 90890 03112 YU 03112 C SN NOTE Q Before checking for continuity set the pocket tester to 0 and to the Q x 1 range WVVVVVVVVVVVVVVVVVVVVVVY a Connect the positive tester probe to termi nal 1 and the negative tester probe to ter minal 2 and check the continuity b Connect the positive tester probe to termi nal 1 and the negative tester probe to ter minal 3 and check the continuity If either of the readings indicate no continu ity replace the bulb AA4AAAAAAAAAAAAAAAAAAAAA 8 7 CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets 1 Check bulb socket for continuity with the pocket tester No continuity gt Replace Pocket tester 90890 03112 YU 03112 C NOTE 0 Check each bulb socket for continuity in the same manner as described in the
194. rooves and piston rings Piston ring side clearance Top ring 0 03 0 07 mpm 0 0012 0 0028 Limit 0 m 0 0047 in 2nd ring 06 mm 0 0008 0 0024 in lt Lin nw 0 12 mm 0 0047 in 2 lI piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown 8 10 mm 0 3937 in 3 Measure e piston ring end gap Out of specification Replace the pis ton ring NOTE The oil ring expander spacers end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 05 0 15 mm 0 0020 0 0059 in Limit 0 40 mm 0 0157 in 2nd ring 0 05 0 17 mm 0 0020 0 0067 in Limit 0 52 mm 0 0205 in Oil ring 0 20 0 70 mm 0 0079 0 0276 in 5 35 CYLINDER AND PISTON ENG 4 500265 CHECKING THE PISTON 1 Check piston pin Blue discoloration grooves gt Replace the piston pin and then check the lubrication system 2 Measure piston pin outside diameter Out of specification Replace the pis ton pin oN O 3 M asure piston pin bore diameter b specification Replace the piston J LA EXC N 4 I Piston pin bore diameter 10 002 10 013 0 3938 0 3942 lt Limit gt 10 043 mm 0 3954 in 4 Calculate piston pin to piston pin bore clearance Out of sp
195. seat Single seat upper cover Bottom plate Frame single seat ECU Starter relay Main fuse Single seat lock assembly Helmet holder Trunk Disconnect Disconnect Disconnect Oe 1 2 3 4 5 6 7 8 9 10 For installation reverse removal pro cedure 3 7 CHK COVER AND PANEL LEG SHIELD1 2 7Nm 0 7m kg 5 1 ft Ib g Order Remarks 0 leg shield1 2 Remove the parts in the order listed Front fork Reflector left Front fork cover left Reflector right Front fork cover right Leg shield1 Main switch cover Leg shield2 NOTE Caution do not damage the claw while removing er cover CONOR ON 2 a camelis For installation reverse the removal pro cedure 3 8 CHK COVER AND PANEL FOOTREST BOARD AND INNER FENDER Removin the ootrest board and in Remove the parts in the order listed ner fend Single seat trunk Refer to SINGLE SEAT AND TRUNK Fuel tank cap cover Fuel tank cap NOTE Coolant reservoir cap cover When installing the fuel tank cap align it Panel cap end and the mark on the car body Footrest board z QNEM Coolant reservoir Disconnect Inner fender For installation reverse the removal pro cedure 3 9 m AUV 3 10 CHK Q ADJUSTING THE VALVE CLEARANCE ADJ 500049 ADJUSTING THE VALVE CLEARANCE The following
196. sensor 1 3 IMPORTANT INFORMATION GEN des 500020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISAS SEMBLY 1 Before removal and disassembly remove all dirt mud dust and foreign material 2 Use only the proper tools and cleaning equipment Refer to the SPECIAL TOOLS 3 When disassembling always keep mated parts together Thisdhcludes gears cylin ders pistons and fh r parts that have been mated througfrriormal wear Mated parts MS reused or replaced as an must alw assem 4 Duri isassembly clean all of the parts si them in trays in the order of dis mbly This will speed up assembly and ow for the correct installation of all parts Keep all parts away from any source of fire 500021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but infe rior in quality 500022 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket sur faces oil seal lips and O rings must be cleaned 2 During reassembly properly oil all mating parts and bearings and lubricate the oil seal lips with grease 1 4 IMPORTANT INFORMATION GEN des EASO0023 LOCK WASHERS PLATES AND COTTER PINS After removal replace all lock washers plates 1 and cotter pins After the bolt or
197. sh the scratches with an emery cloth 5 Check ebrake camshaft Damage wear gt Replace S Q AS EAS00537 ASSEMBLING THE BRAKE SHOE PLATE 1 Cubricate e brake camshaft Recommended lubricant Lithium soap based grease 2 Install e brake camshaft 1 e spring brake shoe wear indicator 2 a Install the brake camshaft so its punch mark a is positioned as shown b Align the projection b on the brake shoe wear indicator with the notch in the brake camshaft c Check that the brake shoes are properly positioned 4 8 FRONT WHEEL AND BRAKE 3 Install e camshaft lever 1 8Nm 0 8m kg 5 8ft Ib a Align the camshaft punch mark cam shaft lever punch mark b is positioned as shown A AAAAAAAAAAAAAAAAAAAAA 4 Install e plate washer e speedometer driven gear e bushing with the special tool 500638 ASSEMBLING THE FRONT WHEEL AY nstall wheel bearing right O1 spacer e wheel bearing left seal 9 VVVVVVVVVVVVVVYVVVYVVVYVYY a Install the new wheel bearings and oil seal in the reverse order of disassembly CAUTION Do not contact the wheel bearing inner race D or balls Contact should be made only with the outer race 3
198. sssssssssesssesssesssesssesssesssesssessssersserssersnersneesneesssen 5 1 LEADS HOSES AND MUFFLER 20200 5 1 LN 5 3 INSTALLING THE ENGINE nnn 5 4 CYLINDER HEAD ccssssssssssssssssssssssssessnesssessneessessscesssersserssersseesseesseesseens 5 5 REMOVING THE CYLINDER 202 5 7 CHECKING THE CYLINDER HEAD 5 9 INSTALLING THE CYLINDER HEAD 5 10 THE ROCKER ARMS AND 5 13 REMOVING THE ROCKER ARMS AND CAMSHAK 5 14 CHECKING THE 5 15 CHECKING THE ROCKER ARMS AND RO ARM SHAFTS 5 16 CHECKING THE TIMING CHAIN CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES 5 17 CHECKING THE TIMING CHAIN TENSIONER 5 18 INSTALLING THE CAMSHAFT rca ARMS 5 19 VALVES AND VALVE SPRINGS 2SS cscsssssssssssssesssesssesssesssessteessessseesssen 5 20 REMOVING THE VALVES 4 5 22 CHECKING THE VALVESSAND VALVE GUIDES 5 24 CHECKING THE VA VALY SEATS mM 5 26 CHECKING TH SPRINGS 5 28 INSTALLING THYALVES 5 29 CYLINDER AND 8 5 31 ME RAM AND PISTON 5 32 CHECKING THE CYLINDER AND 5 33 CHECKING THE PISTON RINGS 5 35 CHECKING THE PISTON PIN
199. t and right Band Front brake cable Brake lever right Front brake switch Front turn signal light right Front turn signal light bracket right Handlebar switch right Throttle cable Throttle grip assembly Rear brake cable Brake lever left Rear brake switch 4 27 o sl HANDLEBAR CHAS Hemarks Remove the parts in the order listed Refer to LEG SHIELD1 2 in chapter 3 Disconnect Disconnect Disconnect HANDLEBAR CHAS Remarks Front turn signal as Front turn signa t bracket left Handlebar s left Handleb Cap Q Handlebar upper holder Handlebar assembly For installation reverse the removal pro cedure 4 28 4 29 HANDLEBAR CHAS REMOVING THE HANDLEBAR 1 Stand the scooter on a level surface Securely support the scooter so that there is no danger of it falling over 2 Remove ehandlebar switch right 1 ethrottle grip assembly 2 NOTE V While removing the holder assembly right pull back th ubber cover 3 ove andlebar switch left RN ehandlebar 1 S handlebar upper holder 52222 0 Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar 500668 CHECKING THE HANDLEBAR 1 Check ehandlebar 1 Bends cracks damage gt Replace Do not attempt to straighten a bent handlebar as this may dan
200. t cov Side coveNeft and right Refer to COVEH AND PANEL in chap Single seat Trunk ter 3 Footrest board Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Radiator cover Radiator cap Conduit hose Disconnect Radiator inlet hose Disconnect Radiator outlet hose Disconnect Radiator Fan case For installation reverse the removal pro cedure 6 1 RADIATOR coo 9 CHECKING THE RADIATOR 1 Check e radiator fins Obstruction Clean Apply compressed air to the rear of the radiator Damage gt Repair or replace _ __ _ __ __ _ _ _ ___ Straighten any flattened fins with a thin flat head screwdriver 2 Check e radiator inlet hose e radiator outlet ho e conduit hose S ne sd 2 Replace AN 3 M asure adiator cap opening pressure AM Below the specified pressure gt Replace the radiator cap Radiator cap opening pressure 107 9 137 3kPa 1 1 1 4kg cm 15 6 19 9psi Install the radiator cap tester 1 and radia tor cap tester adapter 2 to the radiator cap Radiator cap tester 90890 01325 YU 24460 01 Radiator cap tester adapter 90890 01352 YU 33984 b Apply the specified pressure for ten sec onds and make sure there is no drop in pres sure AAAAAAAAAAAAAAAAAAAAAAA 4 Check e radiator fan Damage gt Replace Malfunction Check and repair 6 2 RADIATOR coo 9 IN
201. t the posi tion shown 5 41 J Removing the and primary sec ondary Primary sheave nut Plate washer Oneway clutch Primary fixed sheave Secondary sheave nut Clutch housing Secondary sheave V belt Plate washer Collar Primary sliding sheave Cam Weight Slider Plate washer 5 42 BELT DRIVE ENG V BELT AND PRIMARY SECONDARY SHEAVE 40Nm 4 0 mekg 28 9 ftelb Remove the parts in the order listed Hefer to REMOVING THE PRIMARY SHEAVE and INSTALLING THE SEC ONDARY SHEAVE V BELT AND PHI MARY SHEAVE Refer to REMOVING THE SECOND ARY SHEAVE AND V BELT and IN STALLING THE SECONDARY SHEAVE V BELT AND PRIMARY SHEAVE For installation reverse the removal pro cedure SECONDARY SHEAVE D D 6 e awy Remarks Disassembling ihe secondary sheave Clutch t Clutch Clutch shoe spring Compression spring Secondary spring seat Guide pin Secondary sliding sheave O ring Oil seal Secondary fixed sheave WO NO HO C 5 43 BELT DRIVE ENG Disassemble the parts in the order listed Refer to DISASSEMBLING THE SEC ONDARY SHEAVE and ASSEMBLING THE SECONDARY Refer to ASSEMBLING THE SECOND ARY SHEAVE For assembly reverse the disassembly procedure BELT DRI
202. t trunk e battery battery cover e side cover left and right e front cover Refer to COVER AND PANEL CHK CHANGING THE COOLANT 500105 CHANGING THE COOLANT 1 Remove front cover eside cover right ecoolant reservoir cap cover Refer 10 AND PANEL eradiator cover Refer to HADIATOR in chapter 6 2 Disconnect ecoolant reservoir hose 1 3 Drain ecoolant from the coolant 66 ecoolant from the under drain bolt 4 Remove NN eradiatcy bap eco reservoir cap LL sposi Is under pressure Therefore ot remove the radiator cap when the NS gine is hot Scalding hot fluid and steam AM may be blown out which could cause serious injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap ee counterclockwise toward the detent to allow gt any residual pressure to escape When the NO hissing sound has stopped press down on SN the radiator cap and turn it counterclockwise S to remove 5 Connect ecoolant reservoir hose 6 Install eradiator under drain bolt 1Nm 0 1m kg 0 7ft CHK CHANGING THE COOLANT 7 Fill ecooling system with the specified amount of the recom mended coolant Recommended antifreeze High quality ethylene glycol anti freeze containing corrosion inhibi tors for aluminum engines Mixing ratio 4 6 antifre
203. te Positive tester probe gt red 3 Negative tester probe red 4 500749 6 Main switch Check the main switcbsfor continuity Refer to CHECKI E SWITCHES 2 4 NO Heplace Switch the main swit the main 500751 7 Brake light switch front and rear Check the brake light switches for continu ity Refer to CHECKING THE SWITCHES 15 each brake light switch OK n YES 4 NO Heplace the brake light switch es 500750 _ 8 Engine stop switch Check the enginestop switch for continuity Hefer to THE SWITCHES N op switch OK Heplace right handlebar switch 5 engi Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES e Is the sidestand switch OK Replace the sidestand switch 500764 10 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES the start switch OK i YES 4 Heplace the right handlebar switch ELECTRIC STARTING SYSTEM ELEC 500766 11 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM e s the starting system s wiring properly con nected and without defects n YES 4 The starting system connect re circuit is OK pair the starting system s wiring 8 19 500767 STARTER MOTOR ELECTRIC STARTING SYSTEM
204. ter fixing the rear brake cable fix crank case 1 When locking make sure that the stopper at the front of holder touches the posi tion of crank case 1 After fixing the rear brake cable install the protruding part of cramp on the hole of under cover 6 gt 4 f Bem Val nj 1 ET 27 Install the horn of coupler accotding to the direction shown in the drawing and make sure that it is not loosen easily Penetrate through the speed meter cable m CQ eO TNT TSS RW lt lt ag 9 OF e ORS 4 lad 5 Eae 10 DL IZ 4 f 2 b fd M u x J D gt p 249 vnd 1 4 DT d Ri 6 9 6 WO Fuel pump Fl diagnostic tool connec tor Fuse box Battery negative lead ECU lead Battery positive lead Starter relay AC magneto lead Tail brake light lead Starter motor lead Holder Cable holder Lean angle cut off switch Ignition coil Throttle cable Ass y Hear brake cable Wiring harness 0269 260606 fT 22 2 er Uf Ov 4 2 amp ys bes e AUN Y LFS N SAR e CABLE ROUTING v Hear fender Fuel injector lead Sub wire harness lead ISC idle speed control valve le
205. the main switch to ON sthe coolant temperature indicator light OK YES NO 9 5 This circuit is OK bicis temperature indicator 8 46 CHAPTER 9 TROUBLE SHOOTING STARTING FAILURE HARD STARTING eren 9 1 ENGINE eere emere rre e rer en 9 1 FUEL 5 9 1 ELECTRICAL SYSTEMS 02 0 9 1 STARTING FAILURES HARD STARTING INCORRECT ENGINE IDLING SPEED MM 9 2 ENGINE eene emere rre een 9 2 FUEL SYSTEM ees 9 2 ELECTRICAL 9 2 POOR MEDIUM AND HIGH SPEED PERFORMANCEIFAULTY CLUTCH 9 3 ENGINE eee AS 9 3 FUEL 5 5 2 600 0060 02 5 9 3 FAULTY A pcenas teta seno ga 9 3 ENGINE OPERATES BUT SCOOTER ILL NOT MOVE 9 3 CLUTCH SLIPS e Dee eee 9 3 POOR STARTING PERFORMANCE 9 3 POOR SPEED 9 4 OVERHEATING er eee nnne 9 4 2 4 eel 9 4 COOLING 5 5 00 9 4 FUEL SYSTEM QE esset tcc 9 4 CHASSIS QU ee 9 4 ELECTRICAL SYSTEMS s 9 4 COOLING 9 4 POOR BRAKING PERFORMANCE FAULTY FRONT FORK LEGS UN STABLE HANDLING nnnm nnne nena 9 5 FAULTY FRONT FORK 1 665 0 000 2 nen
206. tion mark 1 e Install the tire with the mark pointing in the direction of wheel rotation e Align the mark 2 with the valve installation point S AS e 3 47 CHECKING THE WHEELS CHK Q CHECKING AND LUBRICATING THE CABLES ADJ CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check wheel Damage out of round gt Replace Never attempt to make any repairs to the wheel After a tire or wheel has been changed or re placed always balance the wheel 500170 CuSO ING AND LUBRICATING THE ABLES e following procedure applies to all of the in RN ner and outer cables Ma O Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 e outer cable SX Damage gt Replace 2 Check e cable operation Hough movement gt Lubricate Recommended lubricant Engine oil or a suitable cable lubricant NOTE LLL Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device 3 48 3 49 LUBRICATING THE LEVERS AND PEDALS CHK Q LUBRICATING THE CENTERSTAND ADJ EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Lithium soap based gre
207. to COVEH AND PANEFL in chap Side cover left and right ter 3 Footrest board Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Hear brake cable Adjuster Pin Refer WHEEL AND BRAKE in chapter 4 Throttle body and fuel injector Refer to THROTTLE BODY AND FUEL INJECTOR in chapter 7 Starter motor Refer 5 chapter 8 Conduit hose Disconnect Coolant temperature sensor coupler Disconnect ENGINE REMOVAL ENG e Job PargS 3 Crankshaft positiarcse sor Stator as 1 1 Disconnect sembly coupler ON Ignition prim il coupler 1 Disconnect Air filter bly Breather hose 1 1 Bracket 1 1 1 Muffler Gasket For installation reverse removal cedure 5 2 ENGINE REMOVAL ENG 500191 58Nm 5 8m kg 42 0 ft Ib C Removing the engine Remove the parts in the order listed NOTE Place a suitable stand under the frame and engine Hear shock absorber assembly lower bolt Engine mounting nut Refer to INSTALLING THE ENGINE Engine mounting bolt Engine Hear fender For installation reverse the removal pro cedure 5 3 ENGINE REMOVAL ENG EAS00192 INSTALLING THE ENGINE 1 Install e engined e engine mounting bolt 2 e engine mounting nut 3 e Apply lithium soap based grease to the unthreaded portion of the engine mounti
208. ttx r Maximum amperage Performance Coil resistance Turn signal relay Relay type Model manufacturer Self cancelling device built in Turn signal blinking frequency Wattage O 3B3 00 T MORIC 12V 0 25kW 7 0mm 0 28in gf 14 11 21 1602 0 69in 16 6mm 0 65in 30 0378 0 0462Q at 20 C 68 F 1 35 0 5WC 50A 90 1100 More than DC10V Plane GF 127 NIKKO 1 0A 95 115dB 2m 3 96 4 10W at 20 C 68 F Condenser FZ222SD DENSO NO 75 95cycles minute 10Wx24 3 4W 2 16 ELECTRICAL SPECIFICATIONS SPEC om Fuse amperagexquantity Main fuse 15Ax1 Fuel gauge Model manufacturer Sender unit resistance full Sender unit resistance empty Starting circuit cut off relay Model manufacturer Coil resistance Diode Radiator fan Model manufacturer Running rpm Thermostat Type manufacture Valve opening temperature Valve full open temperature Valve lift full open Coolant temperature sensor Model manufacturer Coil resistance at 20 C 68 F Coil resistance at 80 C 1 76 F Intake air pressure sensor Output voltage Intake air temperature d Coil resistance color Speed sensor 5 Output voltage When sensor 59 When sensor is Throttle position sensor Voltage color Output voltage closed position color ISC idle speed control valve Hesistance color Lean angle cut off switch Voltage Less than 65 More than 65 3B3 AI
209. u T umm n COLOR CODE ck 1 L Bla ck CONNECTING WITH GRD WIRE I lt 1 CONNECTOR MARK Black Black eg a BETWEEN MAIN amp SUB HARNESS m aia 1 ee ee ee NN ee E DE DE SE DE
210. ve a Disconnect the ISC idle speed control valve coupler from the ISC idle speed con trol valve b Connect the digital circuit tester to the ter minals of the ISC idle speed control valve Positive tester prole pink terminal 1 Negative tester robe gt green yellow c Measure the ISC idle speed control valve resistance Out of specification Replace the throttle body ISC idle speed control valve resis tance 18 22 at 20 C 68 F AA4AAAAAAAAAAAAAAAAAAAAA AIR INDUCTION SYSTEM 500507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex haust gases by injecting fresh air secondary air into the exhaust pipe reducing the emission of hydrocarbons When there is negative pressure at the exhaust port the reed valve opens allowing secondary air to flow into the exhaust port The resuired temperature for burning the unburned exhaust gases is approximately 600 to 700 C 1 112 to 1 292 F 500917 VALVE ae cut off valve prevents air backflow from haus pipe to the air filter From the air filter To the exhaust pipe ass y 7 35 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM DIAGRAMS Air induction system hose Air filter case Air induction system hose air filter case to air cut off valve Air cut off valve Air induction system hose air cut off valve to exhaust pipe 9 OD 1 36
211. y coupler wire harness side Is the voltage within specification 8 30 n YES This circuit is OK 4 The wiring circuit from the main switch to the headlight coupler or meter assembly coupler is faulty and must be re paired Refer to CIRCUIT DIA GRAM LIGHTING SYSTEM EAS00789 2 he meter light fails to come 1 Meter light bulb and socket Check the meter light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the meter light bulb and socket OK i YES 4 the meter light bulb socket or both 2 Voltage e Connect the pocket tester DC 20 V to the meter ligh er wire harness side as N ester probe brown 1 e tester probe black 2 Positi Nec Set the main switch to ON Measure the voltage DC 12 V of brown 1 on the meter light coupler wire harness side Is the voltage within specification YES This circuit is OK The wiring circuit from the main switch to the meter light coupler is faulty and must be re paired Hefer to CIRCUIT DIA GRAM LIGHTING ELEC 3 Voltage 2 The tail brake light fails to come Connect the pocket tester DC 20 V to the 1 Tail brake light bulb and socket Checkthe tail brake light bulb and socket for continuity Hefer to CHECKING THE BULBS AND BULB SOCKETS Are the tail brake light bulb and s

Yamaha XF50 Service Manual - Absolutely Scooters & Supply

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Yamaha XF50 Service Manual - Absolutely Scooters &amp; Supply

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Yamaha XF50 Service Manual - Absolutely Scooters & Supply