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Yamaha 2009 YW125Y Service Manual

Other manuals for 2009 YW125Y: Owner's Manual

Summary of 2009 YW125Y

  • Page 1

    2009 motorcycle service manual model : yw125y_ 32sf819770e0 *32sf819770e0*.

  • Page 2: Valve Clearance (Cold)

    Eas00000 yw125y 2009 service manual ©2008 by yamaha motor taiwan co., ltd. First edition, july 2008 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor taiwan co., ltd. Is expressly prohibited. 0.10 ~ 0.14mm (0.004 ~ 0.006in) 0.16 ~ 0.20mm (0.006 ...

  • Page 3

    Eas20070 important 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...

  • Page 4: How To Use This Manual

    Eas00007 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 the manual is di...

  • Page 5: Gen

    Gen info spec chk adj eng trbl shtg chas - + elec 4 m b ls new m g cool 1 2 3 4 5 6 7 8 9 0 q w e r i s h j eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic checks and adju...

  • Page 6: Table of Contents

    Eas00011 table of contents general information specifications periodic checks and adjustments chassis engine fuel injection system electrical system troubleshooting - + gen info spec chk adj chas eng fi elec trbl shtg 1 2 3 4 5 6 7 8.

  • Page 7: Gen

    1-13 gen info chapter 1 general information scooter identification ................................................................... 1-1 vehicle identification number ............................................. 1-1 model label ........................................................................

  • Page 8: Gen

    1-1 gen info scooter identification eas00015 general information scooter identification eas00017 vehicle identification number the vehicle identification number 1 is stamped into the frame. Eas00018 model label the model label 1 is affixed to the frame under the seat. This information will be needed...

  • Page 9: Gen

    1-2 gen info eas00896 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, ...

  • Page 10: Gen

    1-3 gen info features eas00897 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kpa (2.5 kgf/cm 2 , 35.6 psi). Accordingly, when the energizing signal from the ecu energ...

  • Page 11: Gen

    1-4 gen info features o 2 sensor the o 2 sensor has been adopted to enable the catalyst to function at a high degree of efficiency by maintaining the air-fuel mixture near the stoichiometric ratio (14.7:1). This sensor, which is a zirconia type, utilizes the oxygen ion conductivity of the solid elec...

  • Page 12: Gen

    1-5 gen info important information eas00020 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, al...

  • Page 13: Gen

    1-6 gen info important information eas00023 lock washers/plates and cotter pins after removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Eas00024 bearings and oil seals install bea...

  • Page 14: Gen

    1-7 gen info important information eas00021 equipment preparation turn rivet (turn type) assembly status of the turn rivet(turn type). Dissembling 1. Press center pin1 inward to release the lock. 2. Remove the push rivet main body2. Assembling 1. Restore the center pin, replace the turn rivet main b...

  • Page 15: Gen

    1-8 gen info checking the connections eas00026 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector 2. Check: 8 lead 8 coupler 8 connector moisture j dry with an air blower. Rust/stains j connect and disconnec...

  • Page 16: Gen

    1-9 gen info tool no. Tool name / function illustration 90890-01085 (m8) yu-01083-2 90890-01084 yu-01083-3 90890-01235 yu-01235 90890-01268 yu-01268 90890-01304 yu-01304 90890-01337 ym-33285 90890-01311 ym-08035-a 90890-01326 ym-01326 90890-01294 ym-01300-1 90890-01348 ym-01348 slide hammer bolt (8m...

  • Page 17: Gen

    1-10 gen info tool no. Tool name / function illustration special tools 90890-01189 ym-01189 90890-01367 ym-a9409-7 90890-01368 ym-a9409-4 90890-01384 ym-33299 90890-01403 yu-a9472 90890-01701 ys-01880-a 90890-03079 ym-34483 90890-03081 yu-33223 90890-03112 yu-03112-c 90890-03174 90890-06760 flywheel...

  • Page 18: Gen

    1-11 gen info tool no. Tool name / function illustration special tools 90890-03141 yu-03141 90890-04101 90890-04019 ym-04019 90890-04108 ym-04108 90890-04116 ym-04116 90890-04117 ym-04117 90890-04118 ym-04118 90890-06754 ym-34487 90890-03182 yu-03182 90890-03153 yu-03153 90890-03186 timing light thi...

  • Page 19: Gen

    1-12 gen info special tools tool no. Tool name / function illustration 90890-85505 acc-11001-05-01 yamaha bond no.1215 sealant (quick gasket ® ) this sealant (bond) is used to apply on crankcase mating surfaces..

  • Page 20: Spec

    2-32 spec chapter 2 specifications general specifications ................................................................. 2-1 engine specifications ..................................................................... 2-2 chassis specifications ........................................................

  • Page 21: Spec

    2-1 spec specifications general specifications item standard limit general specifications model code 32s1 (usa) … 32s2 (can) … dimensions overall length 1910mm (75.2in) … overall width 765mm (30.1in) … overall height 1110mm (43.7in) … seat height 780mm (30.7in) … wheelbase 1290mm (50.8in) … minimum ...

  • Page 22: Spec

    2-2 spec engine specifications item standard limit engine specifications engine engine type air-cooled, 4-stroke, sohc … displacement 0.125l (125cm 3 , 7.63cu-in) … cylinder arrangement forward inclined … single cylinder bore × stroke 52.4 × 57.9mm (2.06 × 2.28in) … compression ratio 10:1 … engine i...

  • Page 23: Spec

    2-3 spec item standard limit engine specifications oil filter oil filter type wire mesh … oil pump oil pump type trochoid … inner rotor to outer rotor tip clearance 0.15mm (0.006in) or less 0.23mm (0.009in) outer rotor to pump housing clearance 0.07 ~ 0.12mm 0.19mm (0.003 ~ 0.005in) (0.008in) starti...

  • Page 24: Spec

    2-4 spec item standard limit engine specifications a b a b camshaft drive system chain drive (left) … intake camshaft lobe dimensions measurement a 25.267 ~ 25.367mm 25.167mm (0.995 ~ 0.999in) (0.991in) measurement b 21.069 ~ 21.169mm 20.969mm (0.829 ~ 0.833in) (0.826in) exhaust camshaft lobe dimens...

  • Page 25: Spec

    2-5 spec item standard limit b c d a head diameter face width seat width margin thickness engine specifications timing chain model/number of links morse 92rh2005/94 … tensioning system automatic … valve, valve seats, valve guides valve clearance (cold) intake 0.10 ~ 0.14mm … (0.004 ~ 0.006in) exhaus...

  • Page 26: Spec

    2-6 spec engine specifications item standard limit valve stem to valve guide clearance intake 0.015 ~ 0.042mm 0.08mm (0.0006 ~ 0.0017in) (0.0031in) exhaust 0.030 ~ 0.057mm 0.1mm (0.0012 ~ 0.0022in) (0.0039in) valve stem runout … 0.01mm (0.0004 in) valve seat width intake 0.9 ~ 1.1mm (0.035 ~ 0.043in...

  • Page 27: Spec

    2-7 spec item standard limit engine specifications valve springs free length intake 41.88mm (1.649in) 39.786mm (1.566in) exhaust 41.88mm (1.649in) 39.786mm (1.566in) installed length (valve closed) intake 30mm (1.18in) … exhaust 30mm (1.18in) … compressed spring force (installed) intake 137 ~ 157n/m...

  • Page 28: Spec

    2-8 spec item standard limit h d engine specifications t b b t piston piston-to-cylinder clearance 0.010 ~ 0.035mm 0.15mm (0.0004 ~ 0.0014in) (0.0059in) diameter d 52.375 ~ 52.390mm … (2.0620 ~ 2.0626in) height h 7.0mm (0.28in) … piston pin bore (in the piston) diameter 15.002 ~ 15.013mm 15.043mm (0...

  • Page 29: Spec

    2-9 spec engine specifications item standard limit b t oil ring dimensions (b × t) 2.0 × 2.5mm … (0.0787 × 0.0984in) end gap (installed) 0.2 ~ 0.7mm … (0.0079 ~ 0.0276in) ring side clearance 0.04 ~ 0.12mm … (0.0016 ~ 0.0047in).

  • Page 30: Spec

    2-10 spec item standard limit engine specifications rocker arm/rocker arm shaft rocker arm inside diameter 10.000 ~ 10.015mm … (0.3937 ~ 0.3943in) rocker arm shaft outside diameter 9.981 ~ 9.991mm … (0.3930 ~ 0.3933in) arm-to-shaft clearance 0.009 ~ 0.034mm … (0.0004 ~ 0.0013in) connecting rod conne...

  • Page 31: Spec

    2-11 spec item standard limit engine specifications transmission transmission type v-belt automatic … primary reduction system helical gear … primary reduction ratio 40/15 (2.667) … secondary reduction system spur gear … secondary reduction ratio 44/11 (4.0) … single speed automatic 2.398 ~ 0.823:1 ...

  • Page 32: Spec

    2-12 spec chassis specifications chassis specifications item standard limit frame frame type steel tube underbone … caster angle 27° … trail 90mm (3.54in) … front wheel wheel type cast wheel … rim size j12 × mt2.75 … material aluminum … wheel travel 78mm (3.07in) … wheel runout maximum radial wheel ...

  • Page 33: Spec

    2-13 spec item standard limit chassis specifications rear tire tire type tubeless … size 130/70-12 56l … model (manufacturer) k761 (kenda) … tire pressure (cold) 0 ~ 90kg (0 ~ 198lb) 200kpa (2.0kgf/cm², 29psi) … 90kg (198lb)~ maximum load 225kpa (2.25kgf/cm², 33psi) … minimum tire tread depth … 0.8m...

  • Page 34: Spec

    2-14 spec chassis specifications item standard limit front suspension suspension type telescopic … front fork type coil spring/oil damper … front fork travel 90mm (3.54in) … spring free length 252.1mm (9.93in) 247mm (9.72in) installed length 230.9mm (9.09in) … spring rate (k1) 7.1n/mm (0.72kgf/mm, …...

  • Page 35: Spec

    2-15 spec item standard limit electrical specifications electrical specifications system voltage 12v … ignition system ignition system type transistorized coil ignition … ignition timing 5° btdc at 1800r/min … advancer type digital … pickup coil resistance/color 248 ~ 372 Ω at 20°c (68°f) … /white/r...

  • Page 36: Spec

    2-16 spec electrical specifications item standard limit electric starting system system type constant mesh … starter motor model (manufacturer) 5s9 00 (t-moric) … suction voltage 12v … power output 0.35kw … brushes overall length 10.0mm (0.39in) 3.5mm (0.14in) quantity 2 … spring force 5.52 ~ 8.28n/...

  • Page 37: Spec

    2-17 spec electrical specifications item standard limit fuel sender model (manufacturer) 5s9 (aisan) … sender unit resistance-full 4 ~ 10 Ω … sender unit resistance-empty 90 ~ 100 Ω … fuel level gauge gauge type (manufacture) analog (chaolong) … starting circuit cut-off relay model (manufacturer) 4h...

  • Page 38: Spec

    2-18 spec eas00030 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, tight...

  • Page 39: Spec

    2-19 spec part to be tightened part name thread size q ’ ty tightening torque remarks tightening torques 4 tightening torques engine crankcase (left and right) together tightening. Cylinder head and cylinder spark plug cylinder head (timing chain side) exhaust pipe stud bolt breather valve cover sto...

  • Page 40: Spec

    2-20 spec tightening torques remarks cylinder head tightening sequence plate (v-belt guide) idle gear plate plate clutch housing primary fixed sheave starter motor ac magneto rotor stator coil crankshaft position sensor ignition coil o 2 sensor engine temperature sensor clamp holder bolt bolt bolt n...

  • Page 41: Spec

    2-21 spec part to be tightened thread size tightening torque remarks tightening torques chassis lt ft•lbf nm m•kgf frame and engine bracket 2 engine bracket 2, compression rod and engine compression rod and frame sidestand (bolt and stand) sidestand (bolt and nut) centerstand swingarm rear shock abs...

  • Page 42: Spec

    2-22 spec tightening torques tip 1. First, tighten the ring nut (lower) approximately 38nm (3.8m • kgf, 27.5ft • lbf) by using the torque wrench, then loosen the ring nut 1/4 turn. 2. Second, tighten the ring nut (lower) approximately 14nm (1.4m • kgf, 10.1ft • lbf) by using the torque wrench. 3. In...

  • Page 43: Spec

    2-23 spec lubrication point lubricant ls ls m 4 4 4 4 4 4 4 4 4 4 m lubrication points and lubricant types eas00031 lubrication points and lubricant types engine m 4 4 oil seal lips bearings o-rings (except v-belt drive unit) o-rings (fuel injector) cylinder head tightening nut mounting surface cyli...

  • Page 44: Spec

    2-24 spec bel-ray asembly lube ® bel-ray asembly lube ® yamaha bond no.1215 lubrication point lubricant lubrication points and lubricant types g g main and drive axle serration (sprocket) drive axle taper rollor bearing transmission bearing secondary fixed sheave inner surface secondary sliding shea...

  • Page 45: Spec

    2-25 spec lubrication points and lubricant types lubrication point lubricant ls ls ls ls ls ls ls eas00032 chassis ls engine mounting bolt steering bearing and bearing races (upper and lower) throttle grip inner surface and throttle cables rear brake lever pivoting point and metal-to-metal moving pa...

  • Page 46: Spec

    2-26 spec cable routing eas00035 cable routing 1 connector cover 2 horn 3 front bracket 4 starting circuit cut-off relay 5 turn signal relay 6 headlight relay 7 ecu lead 8 turn signal relay lead 9 main switch 0 horn lead q main switch lead w rectifier/regulator lead e wire harness r throttle cable a...

  • Page 47: Spec

    2-27 spec cable routing e headlight relay lead passes by the right side of inner fender rib. F start relay sub lead to forward. G orientation: white tape. H totally cover the terminal after locking. I torque: 4nm (0.4m • kgf, 2.9ft • lbf). J starter relay inserts into holder certainly. K after conne...

  • Page 48: Spec

    2-28 spec cable routing 1 rectifier/regulator 2 body earth lead 3 horn 4 ecu 5 headlight lead 6 turn signal relay 7 horn lead 8 rectifier/regulator lead 9 brake hose holder 3 0 brake hose holder 1 q fuel hose w pipe 3 e roll over valve r pipe 4 t rear brake cable y sidestand switch a rear brake cabl...

  • Page 49: Spec

    2-29 spec cable routing 1 plain washer 2 lean angle cut-off switch 3 lean angle cut-off switch lead 4 fi diagnostic tool 5 hight tension cord 6 fuel pump lead 7 engine temperature sensor lead 8 fuel injector lead 9 clamp (90464-13800) 0 starter motor positive lead q starter motor negative lead w sta...

  • Page 50: Spec

    2-30 spec cable routing f ignition coil lead passes under the cross tube. G pass the throttle cable assembly through wire guide. H locate the white tape of wire harness in the holder. I clamp (90464-10800) the o 2 sensor lead. J clamp (90464-25803) the starter motor lead, ac magneto lead, isc (idle ...

  • Page 51: Spec

    2-31 spec cable routing 1 rear brake cable 2 speedometer 3 front master cylinder 4 brush guard (right) 5 turn signal light (right) 6 throttle cable assembly 7 speedometer cable 8 turn signal light (left) 9 brush guard (left) 0 handlebar bracket q clamp (90464-12812) w bracket e turn signal light lea...

  • Page 52: Chk

    3-59 chk adj chapter 3 periodic checks and adjustments introduction ....................................................................................... 3-1 periodic maintenance and adjustment ................................. 3-1 periodic maintenance chart for the emission control system ..........

  • Page 53: Chk

    3-60 chk adj checking the tires .................................................................. 3-43 checking the wheels.............................................................. 3-46 checking and lubricating the cables ............................ 3-46 lubricating the levers ...................

  • Page 54: Chk

    3-1 chk adj eas00036 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need...

  • Page 55: Chk

    3-2 chk adj periodic maintenance and adjustment no. Item routine initial odometer reading 1000 km (600 mi) or 1 month 4000 km (2000 mi) or 6 months 7000 km (4000 mi) or 12 months 10000 km (6000 mi) or 18 months 13000 km (8000 mi) or 24 months 16,000 km (10,000 mi) or 30 months 1 air filter element •...

  • Page 56: Chk

    3-3 chk adj eaut2710 tip 8 air filter and v-belt filter • this model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • the air filter element needs to be replaced and v-belt filter needs to be serviced more fre-...

  • Page 57: Chk

    3-4 chk adj eas00038 cover and panel seat and trunk remarks order job/part q’ty 1 2 3 4 5 6 7 1 1 1 1 1 1 1 remove the parts in the order listed. For installation, reverse the removal pro- cedure. Cover and panel removing the seat and trunk seat fuel tank cap cover seat hinge upper cover trunk side ...

  • Page 58: Chk

    3-5 chk adj cover and panel footrest board remarks order job/part q’ty 1 2 3 4 5 6 7 1 1 1 1 1 4 remove the parts in the order listed. Notice first, disconnect the negative battery lead, and then the positive battery lead. After installing the battery be sure to turn the main switch from “on” to “of...

  • Page 59: Chk

    3-6 chk adj cover and panel remarks order job/part q’ty tip while installing, the fuse box should be installed to the correct position. For installation, reverse the removal pro- cedure. 8 footrest board 1 1 5 4 6 3 7 2 8 7nm (0.7 m•kgf, 5.1 ft•lbf).

  • Page 60: Chk

    3-7 chk adj 1 23nm (2.3 m•kgf, 16.6 ft•lbf) 4 5 2 3 9nm (0.9 m•kgf, 6.5 ft•lbf) 14nm (1.4 m•kgf, 10.1 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) leg shield 1 assembly and leg shield 2 remarks order job/part q’ty cover and panel removing the leg shield 1 assembly and leg shield 2...

  • Page 61: Chk

    3-8 chk adj cover and panel remarks order job/part q’ty disassembling the leg shield 1 as- sembly panel headlight cover headlight assembly panel (leg shield 1) leg shield 1 1 2 3 4 5 1 1 1 1 1 remove the parts in the order listed. For assembly, reverse the disassembly procedure. 5 4 7nm (0.7 m•kgf, ...

  • Page 62: Chk

    3-9 chk adj adjusting the valve clearance eas00049 engine adjusting the valve clearance the following procedure applies to all of the valves. Tip 8 valve clearance adjustment should be made on a cold engine, at room temperature. 8 when the valve clearance is to be measured or adjusted, the piston mu...

  • Page 63: Chk

    3-10 chk adj 3 2 1 adjusting the valve clearance c. Align the tdc mark c on the ac magneto rotor with the stationary pointer d on the crankcase. D. Measure the valve clearance with a thick- ness gauge. Out of specification j adjust. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Adjust: 8 valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 64: Chk

    3-11 chk adj adjusting the valve clearance e. Measure the valve clearance again. F. 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: 8 breather 7nm (0.7m • kgf, ...

  • Page 65: Chk

    3-12 chk adj 1 checking the engine idling speed eas00054 checking the engine idling speed tip prior to checking 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. Remove: 8...

  • Page 66: Chk

    3-13 chk adj a 1 2 b a adjusting the throttle cable free play eas00056 adjusting the throttle cable free play tip prior to adjusting the throttle cable free play, the engine idling speed should be checked properly. 1. Check: 8 throttle cable free play a out of specification jadjust. Throttle cable f...

  • Page 67: Chk

    3-14 chk adj 1 a b adjusting the seat spring force adjusting the seat spring force tip when open the seat and seat will not fold up automatically, adjust the spring force. 1. Remove: 8 seat 8 upper cover 2. Adjust: 8 screw 1 direction a spring force is increased. Direction b spring force is decrease...

  • Page 68: Chk

    3-15 chk adj checking the spark plug eas00060 checking the spark plug 1. Remove: 8 battery box cover 8 front cover refer to “cover and panel”. 2. Disconnect: 8 spark plug cap warning remove the spark plug cap, the engine is extremely hot. 3. Remove: 8 spark plug notice before removing the spark plug...

  • Page 69: Chk

    3-16 chk adj checking the spark plug 8. Install: 8 spark plug 13nm(1.3m • kgf, 9.4ft • lbf) tip before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: 8 spark plug cap 10. Install: 8 front cover 8 battery box cover refer to “cover and panel”. T r . ..

  • Page 70: Chk

    3-17 chk adj 2 1 checking the ignition timing eas00062 checking the ignition timing tip 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: 8 battery box cover 8 front cover refer to ...

  • Page 71: Chk

    3-18 chk adj checking the ignition timing engine idling speed 1700 ~ 1900r/min b. Check that the mark a on the ac magneto rotor is within the firing range b on the crankcase. Incorrect firing range j check the ignition system. Tip the ignition timing is not adjustable. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Rem...

  • Page 72: Chk

    3-19 chk adj 1 measuring the compression pressure eas00067 measuring the compression pres- sure tip insufficient compression pressure will result in a loss of performance. 1. Measure: 8 valve clearance out of specification j adjust refer to “adjusting the valve clearance”. 2. Start the engine, warm ...

  • Page 73: Chk

    3-20 chk adj measuring the compression pressure compression pressure (with oil applied into the cylinder) reading higher than without oil same as without oil diagnosis piston ring(s) wear or damage j repair. Piston, valves, cylinder head gasket or piston possibly defective j repair. 7. Measure: 8 co...

  • Page 74: Chk

    3-21 chk adj measuring the compression pressure t r . . 8. Remove: 8 compression gauge 9. Install: 8 spark plug 13nm(1.3m • kgf, 9.4ft • lbf) 10. Connect: 8 spark plug cap 11. Install: 8 front cover 8 battery box cover refer to “cover and panel”..

  • Page 75: Chk

    3-22 chk adj 3. Check: 8 engine oil level the engine oil level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark j add the recommended engine oil to the proper level. Recommended engine oil type sae20w-40 or sae10w-30 recommended engine oil grade api s...

  • Page 76: Chk

    3-23 chk adj 1 2 1 4 3 2 1 changing the engine oil t r . . T r . . Eas00076 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: 8 engine oil filler cap 1 8 engine oil drain bolt 2 (along...

  • Page 77: Chk

    3-24 chk adj 1 changing the engine oil quantity total amount 0.85 ~ 0.95l (0.9 ~ 1.0 us qt, 0.75 ~ 0.84 imp. Qt) periodic oil change 0.80 ~ 0.90l (0.87 ~ 0.98 us qt, 0.74 ~ 0.83 imp. Qt) 8. Install: 8 engine oil filler cap 9. Start the engine, warm it up for several min- utes, and then turn it off. ...

  • Page 78: Chk

    3-25 chk adj 1 2 1 changing the transmission oil t r . . Changing the transmission oil 1. Stand the scooter on a level surface. Tip 8 stand the scooter on a suitable stand. 8 make sure that the scooter upright. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place a c...

  • Page 79: Chk

    3-26 chk adj measuring the engine oil pressure eas00077 measuring the engine oil pressure 1. Check: 8 engine oil level below the minimum level mark j 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, an...

  • Page 80: Chk

    3-27 chk adj measuring the engine oil pressure t r . . C. Start the engine after solving the problem(s) and check the engine oil pressure again. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Tighten: 8 engine temperature sensor 18nm(1.8m • kgf, 13.0ft • lbf) 8. Connect: 8 engine temperature sensor coupler 9. Install: ...

  • Page 81: Chk

    3-28 chk adj 1 2 1 cleaning the air filter element eas00086 cleaning the air filter element 1. Remove: 8 air filter case cover 1 8 air filter element 2 2. Clean: 8 air filter element 1 apply compressed air to the outer sur- face of the air filter element. 3. Check: 8 air filter element damage j repl...

  • Page 82: Chk

    3-29 chk adj 1 2 eas00090 cleaning the v-belt case air filter element 1. Remove: 8 v-belt case cover 8 v-belt case air filter guide 1 8 v-belt case air filter element 2 2. Clean: 8 v-belt case air filter element (with solvent) tip after cleaning, carefully pat the v-belt case air filter element on a...

  • Page 83: Chk

    3-30 chk adj 2 1 checking the throttle body joint and intake manifold/checking the fuel hose eas00094 checking the throttle body joint and intake manifold 1. Remove: 8 seat 8 trunk 8 battery box cover 8 front cover refer to “cover and panel”. 2. Remove: 8 fuel tank refer to “removing the fuel tank” ...

  • Page 84: Chk

    3-31 chk adj 1 1 2 eas00098 checking the breather hoses 1. Remove: 8 seat 8 trunk 8 battery box cover 8 front cover refer to “cover and panel”. 2. Check: 8 crankcase breather hose 1 8 transmission case breather hose 2 cracks/damage j replace. Loose connection j connect properly. Notice make sure the...

  • Page 85: Chk

    3-32 chk adj 2 1 3 4 5 checking the exhaust system eas00099 checking the exhaust system the following procedure applies to all of the muffler and gasket. 1. Remove: 8 o 2 sensor coupler 8 muffler refer to “rear shock absorber assemblies and swingarm” in chapter 4. 2. Check: 8 muffler 1 crack/damage ...

  • Page 86: Chk

    3-33 chk adj 1 2 1 1 checking the canister and roll over valve checking the canister and roll over valve the following procedure applies to all of the can- ister and roll over valve. 1. Remove: 8 seat 8 trunk refer to “cover and panel”. 2. Check: 8 hose (to throttle body) 1 8 hose (to roll over valv...

  • Page 87: Chk

    3-34 chk adj checking the canister and roll over valve 7. Check: 8 roll over valve ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the roll over valve. B. Put roll over valve with the vertical angle. C. Connect the hose to direction a and blow air in the hose. Unobstructed j normal. Obstruction j replace. D. Put ...

  • Page 88: Chk

    3-35 chk adj 1 checking the front brake/adjusting the rear brake eas00114 adjusting the rear brake 1. Check: 8 brake lever free play a out of specification j adjust. Brake lever free play 10 ~ 20mm (0.39 ~ 0.79in) eas00108 chassis checking the front brake tip the brake lever free play is not adjusta...

  • Page 89: Chk

    3-36 chk adj eas00116 checking the brake fluid level 1. Stand the scooter on a level surface. Tip 8 place the scooter on a suitable stand. 8 make sure the scooter is upright. Checking the brake fluid level 2. Check: 8 brake fluid level below the minimum level mark a j add the recommended brake fluid...

  • Page 90: Chk

    3-37 chk adj 1 1 1 2 checking the front brake pads/checking the rear brake shoes/checking the front brake hose eas00117 checking the front brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: 8 front brake pad wear indicators 1 almost touch the brake d...

  • Page 91: Chk

    3-38 chk adj 1 2 eas00133 bleeding the hydraulic brake sys- tem warning bleed the hydraulic brake system whenever: 8 8 8 8 8 the system is disassembled. 8 8 8 8 8 a brake hose is loosened, disconnected or replaced. 8 8 8 8 8 the brake fluid level is very low. 8 8 8 8 8 brake operation is faulty. 1. ...

  • Page 92: Chk

    3-39 chk adj bleeding the hydraulic brake system tip loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle grip. H. Tighten the bleed screw and then release the brake lever. I. Repeat steps (e) to (h) until all of the air bubbles have disappeared fro...

  • Page 93: Chk

    3-40 chk adj 5 checking and adjusting the steering head eas00148 checking and adjusting the steer- ing head 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. Tip place the scooter on a suitable stand so that the front wheel i...

  • Page 94: Chk

    3-41 chk adj 6 checking and adjusting the steering head t r . . Lower ring nut (initial tightening torque) 38nm (3.8m • kgf, 27.5ft • lbf) c. Losen the lower ring nut completely and then tighten it to specification with a steering nut wrench. Warning do not over tighten the lower ring nut. Lower rin...

  • Page 95: Chk

    3-42 chk adj checking the front fork eas00151 checking the front fork 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. 2. Check: 8 inner tube damage/scratches j replace. 8 oil seal oil leakage j replace. 3. Hold the scooter ...

  • Page 96: Chk

    3-43 chk adj checking the tires eas00163 checking the tires the following procedure applies to both of the tires. 1. Check: 8 tire pressure out of specification j regulate. Warning 8 8 8 8 8 the tire pressure should only be checked and regulated when the tire temperature equals the ambient air tem- ...

  • Page 97: Chk

    3-44 chk adj checking the tires 2. Check: 8 tire surfaces damage/wear j replace the tire. Minimum tire tread depth 0.8mm (0.03in) 1 tire tread depth 2 sidewall 3 wear indicator warning 8 8 8 8 8 do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal inj...

  • Page 98: Chk

    3-45 chk adj checking the tires front tire manufacturer model size kenda k761 120/70-12 51l rear tire manufacturer model size kenda k761 130/70-12 56l warning new tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be travel...

  • Page 99: Chk

    3-46 chk adj eas00170 checking and lubricating the cables the following procedure applies to all of the in- ner and outer cables. Warning 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. Check: 8 ...

  • Page 100: Chk

    3-47 chk adj lubricating the levers/lubricating the sidestand/ lubricating the centerstand/lubricating the rear suspension eas00171 lubricating the levers lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant lithium-soap-based grease eas00172 lubricating ...

  • Page 101: Chk

    3-48 chk adj checking and charging the battery eas00179 electrical system checking and charging the battery warning batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 8 8 8...

  • Page 102: Chk

    3-49 chk adj 2 1 checking and charging the battery tip 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 t...

  • Page 103: Chk

    3-50 chk adj checking and charging the battery 8 no charging is necessary when the open- circuit voltage equals or exceeds 12.8 v. B. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 v d. Charging time = 6.5 hours e. Charge of ...

  • Page 104: Chk

    3-51 chk adj checking and charging the battery 8 8 8 8 8 before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. 8 8 8 8 8 make sure the battery charger lead clips are in full contact with the battery termi- nal and that they are not shorte...

  • Page 105: Chk

    3-52 chk adj charger ammeter measure the open-circuit voltage prior to charging. 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- tery? Charging method using a variable-current (voltage) charger tip le...

  • Page 106: Chk

    3-53 chk adj this type of battery charger cannot charge an mf batter y. A variablevoltage charger is recom- mended. Yes no charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Connect a charger and am- meter to the battery and start charging. Is the am...

  • Page 107: Chk

    3-54 chk adj 1 2 checking and charging the battery 6. Install: 8 battery 8 band 7. Connect: 8 battery leads (to the battery terminals) notice first, connect the positive battery lead 1 1 1 1 1, and then the negative battery lead 2 2 2 2 2. 8. Check: 8 battery terminals dirt j clean with a wire brush...

  • Page 108: Chk

    3-55 chk adj eas00181 checking the fuses the following procedure applies to all of the fuses. Notice to avoid a short circuit, always set the main switch to “off” when checking or replacing a fuse. 1. Remove: 8 battery box cover refer to “cover and panel”. Checking the fuses 2. Check: 8 fuse ▼▼▼▼▼▼▼...

  • Page 109: Chk

    3-56 chk adj checking the fuses fuses main headlight signaling system ignition fuel injection sys- tem reserve q’ty 1 1 1 1 1 1 1 1 amperage rating 20a 10a 15a 10a 10a 20a 15a 10a warning never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong a...

  • Page 110: Chk

    3-57 chk adj 1 2 replacing the headlight bulbs eas00183 replacing the headlight bulbs the following procedure applies to both of the headlight bulbs. 1. Remove: 8 safeguard 8 leg shield 1 refer to “cover and panel”. 2. Disconnect: 8 headlight coupler 3. Remove: 8 dust boot 8 headlight bulb holder 1 ...

  • Page 111: Chk

    3-58 chk adj 1 b a c d 2 b 1 a c d 2 adjusting the headlight beams eas00185 adjusting the headlight beams the following procedure applies to both of the headlights. 1. Adjust: 8 headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the low beam light adjusting screw 1 in direction a or b. Dire...

  • Page 112: Chas

    Chas 4-66 chapter 4 chassis front wheel and brake disc ....................................................... 4-1 front wheel ................................................................................. 4-2 removing the front wheel .................................................... 4-3 check...

  • Page 113: Chas

    Chas 4-67 handlebar .......................................................................................... 4-49 removing the handlebar ...................................................... 4-51 checking the handlebar ...................................................... 4-52 installing the han...

  • Page 114: Chas

    Chas 4-1 remarks order job/part q’ty front wheel and brake disc removing the front wheel and brake disc speedometer cable wheel axle nut wheel axle front wheel collar speedometer gear unit front brake disc 1 2 3 4 5 6 7 1 1 1 1 1 1 1 remove the parts in the order listed. Tip place the scooter on a s...

  • Page 115: Chas

    Chas 4-2 remarks order job/part q’ty 1 1 1 1 eas00518 front wheel front wheel and brake disk disassembling the front wheel oil seal bearing spacer bearing 1 2 3 4 remove the parts in the order listed. For assembly, reverse the disassembly procedure. 2 1 4 3.

  • Page 116: Chas

    Chas 4-3 front wheel and brake disk eas00520 removing the front wheel 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. Tip place the scooter on a suitable stand so that the front wheel is elevated. 2. Remove: 8 speedometer c...

  • Page 117: Chas

    Chas 4-4 2. Check: 8 tire 8 front wheel damage/wear replace. Refer to “checking the tires” and “checking the wheels” in chapter 3. Front wheel and brake disk eas00525 checking the front wheel 1. Check: 8 wheel axle roll the wheel axle on a flat surface. Bends replace. Wheel axle bending limit 0.25mm...

  • Page 118: Chas

    Chas 4-5 1 2 4 3 5. Replace: 8 wheel bearings new 8 oil seal new ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. B. Remove the oil seal 1 with a flat-head screwdriver. Tip to prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. C. Remove the w...

  • Page 119: Chas

    Chas 4-6 front wheel and brake disk eas00528 checking the brake disc 1. Check: 8 brake disc damage/galling replace. 2. Measure: 8 brake disc deflection a out of specification correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maxi- mum) 0.15mm (0.006in) ▼▼▼▼▼▼▼...

  • Page 120: Chas

    Chas 4-7 front wheel and brake disk tip tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 23nm (2.3m • kgf, 16.6ft • lbf) loctite ® d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is withi...

  • Page 121: Chas

    Chas 4-8 1 2 3 1 2 front wheel and brake disk eas00542 installing the front wheel 1. Lubricate: 8 wheel axle 8 wheel bearings 8 oil seal lip 8 speedometer gear unit recommended lubricant lithium-soap-based grease 2. Install: 8 speedometer gear unit 1 tip make sure the speedometer gear unit and the w...

  • Page 122: Chas

    Chas 4-9 front wheel and brake disk eas00548 adjusting the front wheel static balance tip 8 after replacing the tire, wheel or both, the front wheel static balance should be ad- justed. 8 adjust the front wheel static balance with the brake disc installed. 1. Remove: 8 balancing weight(s) 2. Find: 8...

  • Page 123: Chas

    Chas 4-10 front wheel and brake disk 3. Adjust: 8 front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “x”. Tip start with the lightest weight. B. Turn the front wheel 90° so that the heavy spot is positioned as shown. C. If ...

  • Page 124: Chas

    Chas 4-11 2 3 1 9 10 4 6 5 8 12 12 11 7 10nm (1.0 m•kgf, 7.2 ft•lbf) remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 11 1 1 1 1 1 1 2 1 1 1 1/2 removing the rear wheel and rear brake o 2 sensor coupler muffler swingarm brake adjuster brake cable compression spring pin rear wheel brake shoe kit tens...

  • Page 125: Chas

    Chas 4-12 remarks order job/part q’ty for installation, reverse the removal pro- cedure. Rear wheel and rear brake 2 3 1 9 10 4 6 5 8 12 12 11 7 10nm (1.0 m•kgf, 7.2 ft•lbf) 12 collar 1.

  • Page 126: Chas

    Chas 4-13 1 eas00564 removing the rear wheel 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. Tip place the scooter on a suitable stand so that the rear wheel is elevated. 2. Disconnect: 8o 2 sensor coupler 3. Remove: 8muffl...

  • Page 127: Chas

    Chas 4-14 rear wheel and rear brake eas00567 checking the rear wheel drive hub 1. Check: 8rear wheel drive hub cracks/damage replace the rear wheel. Eas00569 checking the brake the following procedure applies to all of the brake shoes. 1. Check: 8 brake shoe lining glazed areas repair. Sand the glaz...

  • Page 128: Chas

    Chas 4-15 2 1 a a a a 2. Measure: 8 brake shoe lining thickness a out of specification replace. Brake shoe lining thickness limit (minimum) 1.0mm (0.04in) warning do not allow oil or grease to contact the brake shoes. Tip replace the brake shoes as a set, if either is worn to the wear limit. Rear wh...

  • Page 129: Chas

    Chas 4-16 1 t r . . Rear wheel and rear brake tip lubricate the brake camshaft and o-rings with lithium-soap-based grease. Warning after installing the brake camshaft and o- rings, remove any excess grease. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the brake camshaft so its punch mark a is positioned as sh...

  • Page 130: Chas

    Chas 4-17 rear wheel and rear brake eas00574 installing the rear wheel 1. Lubricate: 8 wheel axle recommended lubricant lithium-soap-based grease 2. Install: 8 rear wheel 3. Install: 8 swingarm 8 wheel axle nut 1 8 muffler refer to “rear shock absorber assemblies and swingarm”. 1 4. Connect: 8 o 2 s...

  • Page 131: Chas

    Chas 4-18 eas00575 adjusting the rear wheel static balance tip 8 after replacing the tire, wheel or both, the rear wheel static balance should be ad- justed. 8 adjust the rear wheel static balance with the rear wheel drive hub installed. 1. Adjust: 8 rear wheel static balance refer to “adjusting the...

  • Page 132: Chas

    Chas 4-19 remarks order job/part q’ty 1 2 3 4 5 1 1 1 2 2 removing the front brake pads brake caliper circlip brake pad retaining bolt brake pad brake pad spring remove the parts in the order listed. Disconnect. For installation, reverse the removal pro- cedure. Front brake eas00576 front brake fron...

  • Page 133: Chas

    Chas 4-20 front brake eas00579 notice disc brake components rarely require disassembly. Therefore, always follow these preventive measures: 8 8 8 8 8 never disassemble brake components unless absolutely necessary. 8 8 8 8 8 if any connection on the hydraulic brake system is disconnected, the entire ...

  • Page 134: Chas

    Chas 4-21 1 2 front brake eas00581 replacing the front brake pads tip when replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Loosen: 8 brake pad retaining bolt 1 2. Remove: 8 brake caliper 2 3. Remove: 8 circlip 8 brake pad retaining ...

  • Page 135: Chas

    Chas 4-22 front brake 6. Lubricate: 8 brake pad retaining bolt recommended lubricant silicone grease notice 8 8 8 8 8 do not allow grease to contact the brake pads. 8 8 8 8 8 remove any excess grease. 7. Install: 8 brake pad retaining bolt 13nm (1.3m • kgf, 9.4ft • lbf) 8 circlip 8 brake caliper 49n...

  • Page 136: Chas

    Chas 4-23 1 2 3 9 4 7 8 7 6 10 5 1.6nm (0.16 m•kgf, 1.5 ft•lbf) 26nm (2.6 m•kgf, 18.8 ft•lbf) 9nm (0.9 m•kgf, 6.5 ft•lbf) front brake eas00584 front brake master cylinder remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 1 1 1 1/1 1 1 2 1 1 1 removing the front brake master cyl- inder brush guard (ri...

  • Page 137: Chas

    Chas 4-24 front brake remarks order job/part q’ty 1 2 3 4 5 1 1 1 1 1 disassembling the front brake mas- ter cylinder dust boot circlip washer brake master cylinder kit brake master cylinder body remove the parts in the order listed. For assembly, reverse the disassembly procedure. Eas00585 1 2 3 4 ...

  • Page 138: Chas

    Chas 4-25 1 3 2 front brake eas00588 disassembling the front brake mas- ter cylinder tip before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: 8 brush guard (right) refer to “handlebar”. 2. Remove: 8 brake lever/compress spring 8 front b...

  • Page 139: Chas

    Chas 4-26 1 1 1 front brake eas00590 checking the front brake master cylinder 1. Check: 8 brake master cylinder 1 damage/scratches/wear replace. 8 brake fluid delivery passages (brake master cylinder body) obstruction blow out with compressed air. 2. Check: 8 brake master cylinder kit 1 damage/scrat...

  • Page 140: Chas

    Chas 4-27 2 1 a front brake eas00597 assembling and installing the front brake master cylinder warning 8 8 8 8 8 before installation, all internal brake components should be cleaned and lu- bricated with clean or new brake fluid. 8 8 8 8 8 never use solvents on internal brake components. Recommended...

  • Page 141: Chas

    Chas 4-28 2 1 3 front brake 3. Install: 8 copper washers 1 new 8 brake hose 2 8 union bolt 3 26nm (2.6m • kgf, 18.8ft • lbf) notice when installing the brake hose onto the brake master cylinder, make sure the brake hose touch the projection a a a a a on the brake master cylinder. Warning proper brak...

  • Page 142: Chas

    Chas 4-29 front brake notice brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: 8 brake system refer to “bleeding the hydraulic brake system” in chapter 3. 6. Check: 8 brake fluid level below the minimum level mark a add...

  • Page 143: Chas

    Chas 4-30 remarks order job/part q’ty 1 2 3 4 5 1 1 2 1 1 removing the front brake caliper brake fluid brake hose holder 1 union bolt copper washer brake hose brake caliper remove the parts in the order listed. Drain. Disconnect. For installation, reverse the removal pro- cedure. Eas00612 front brak...

  • Page 144: Chas

    Chas 4-31 front brake remarks order job/part q’ty 1 2 3 4 5 6 7 8 1 1 1 1 1 1 1/1 1 disassembling the front brake cali- per brake pad brake pad spring brake caliper bracket brake caliper piston brake caliper dust seal brake caliper piston seal spring spring seat bleed screw/cap brake caliper body re...

  • Page 145: Chas

    Chas 4-32 2 1 3 a front brake eas00619 disassembling the front brake caliper tip before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: 8 union bolt 1 8 copper washers 2 8 brake hose 3 tip put the end of the brake hose into a container and pump out the...

  • Page 146: Chas

    Chas 4-33 1 2 3 front brake eas00631 checking the front brake caliper recommended brake component replacement schedule brake pads piston seal brake hose brake fluid if necessary every two years every four years every two years and whenever the brake is disassembled 1. Check: 8 brake caliper piston 1...

  • Page 147: Chas

    Chas 4-34 2 1 3 front brake eas00637 assembling and installing the front brake caliper warning 8 8 8 8 8 before installation, all internal brake components should be cleaned and lu- bricated with clean or new brake fluid. 8 8 8 8 8 never use solvents on internal brake components as they will cause t...

  • Page 148: Chas

    Chas 4-35 3 2 4 1 1 front brake 5. Install: 8 brake caliper 1 (temporarily) 8 copper washers 2 new 8 brake hose 3 8 union bolt 4 26nm (2.6m • kgf, 18.8ft • lbf) 8 brake hose holder 1 7nm (0.7m • kgf, 5.1ft • lbf) warning proper brake hose routing is essential to insure safe scooter operation. Refer ...

  • Page 149: Chas

    Chas 4-36 front brake 8. Fill: 8 brake fluid reservoir (with the specified amount of the recom- mended brake fluid) recommended brake fluid dot 4 warning 8 8 8 8 8 use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leakage and poor brake perf...

  • Page 150: Chas

    Chas 4-37 front brake 11. Check: 8 brake lever operation soft or spongy feeling bleed the brake system. Refer to “bleeding the hydraulic brake system” in chapter 3..

  • Page 151: Chas

    Chas 4-38 front fork remarks order job/part q’ty 1 2 3 4 1 2 1 1 removing the front fork legs leg shield 1 front wheel brake hose holder 1 brake caliper front fender lower bracket pinch bolt stopper ring front fork leg remove the parts in the order listed. The following procedure applies to both of ...

  • Page 152: Chas

    Chas 4-39 front fork remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 0 q w 1/1 1 1 1/1 1 1/1 1 1 1 1 1 1 disassembling the front fork legs clamp/boot cap stopper ring collar/o-ring fork spring damper rod bolt/copper washer damper rod rebound spring inner tube oil seal clip oil seal outer tube remove t...

  • Page 153: Chas

    Chas 4-40 front fork remarks order job/part q’ty for assembly, reverse the disassembly procedure. 2 3 4 5 7 8 9 1 6 6 q 0 4 w 20nm (2.0 m•kgf, 14.5 ft•lbf).

  • Page 154: Chas

    Chas 4-41 2 1 front fork eas00651 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. Tip place the scooter on a suitable stand so tha...

  • Page 155: Chas

    Chas 4-42 front fork eas00653 disassembling the front fork legs the following procedure applies to both of the front fork legs. 1. Remove: 8clamp/boot 2. Remove: 8 cap 8stopper ring 8collar/o-ring 8fork spring 1 notice the collar/o-ring and fork spring jump out after removing stopper ring. 3. Drain:...

  • Page 156: Chas

    Chas 4-43 front fork 5. Remove: 8 damper rod 1 8 rebound spring 8 inner tube 2 6. Remove: 8 oil seal clip 1 (with a flat-head screwdriver) notice do not scratch the inner tube. 7. Remove: 8 oil seal 1 notice never reuse the oil seal. 8 rag 2 1 2 1 1 2 damper rod holder 90890-01294 (ym-01300-1) t-han...

  • Page 157: Chas

    Chas 4-44 front fork eas00656 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: 8 inner tube 1 8 outer tube 2 bends/damage/scratches replace. Warning do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: 8 s...

  • Page 158: Chas

    Chas 4-45 front fork 1 2 3 eas00658 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning 8 8 8 8 8 make sure the oil levels in both front fork legs are equal. 8 8 8 8 8 uneven oil levels can result in poor han- dling and a loss of stability. Tip 8 wh...

  • Page 159: Chas

    Chas 4-46 front fork tip 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 (ym-01326) 4. Install: 8 oil seal 1 new (with the fork seal driver weight 2 and adapter 3)...

  • Page 160: Chas

    Chas 4-47 5. Install: 8 oil seal clip 1 tip adjust the oil seal clip so that it fits into the outer tube’s groove. Front fork 6. Fill: 8 front fork leg (with the specified amount of the recom- mended fork oil) quantity (each front fork leg) 0.104l (0.11 us qt, 0.09 imp. Qt) recommended oil fork oil ...

  • Page 161: Chas

    Chas 4-48 1 2 front fork t r . . Tip 8 install the spring with the smaller pitch fac- ing down. 8 before installing the collar, lubricate its o- ring with grease. 8 press down the collar/o-ring, adjust the stopper ring so that it fits into the inner tube’s groove. 8. Install: 8 clamp/boot eas00663 i...

  • Page 162: Chas

    Chas 4-49 28nm (2.8 m•kgf, 20.3 ft•lbf) 1 8 12 10 2 11 9 3 14 3 13 5 7 1 4 2 6 5nm (0.5 m•kgf, 3.6 ft•lbf) remove the parts in the order listed. Refer to “cover and panel” in chap- ter 3. Disconnect. Refer to “front brake”. Cut. Disconnect. Disconnect. Remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 1...

  • Page 163: Chas

    Chas 4-50 28nm (2.8 m•kgf, 20.3 ft•lbf) 1 8 12 10 2 11 9 3 14 3 13 5 7 1 4 2 6 5nm (0.5 m•kgf, 3.6 ft•lbf) handlebar remarks order job/part q’ty 13 14 upper handlebar holder handlebar 2 1 for installation, reverse the removal pro- cedure..

  • Page 164: Chas

    Chas 4-51 1 3 2 handlebar 1 eas00666 removing the handlebar 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. 2. Remove: 8 leg shield 1 8 leg shield 2 refer to “cover and panel” in chap- ter 3. 8 rear view mirror (left and ri...

  • Page 165: Chas

    Chas 4-52 eas00668 checking the handlebar 1. Check: 8handlebar 1 bends/cracks/damage replace. Warning do not attempt to straighten a bent handlebar as this may dangerously weaken it. Handlebar 1.

  • Page 166: Chas

    Chas 4-53 1 2 1 handlebar t r . . Eas00673 installing the handlebar 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. 2. Install: 8 handlebar 1 8 upper handlebar holders 2 28nm(2.8m • kgf, 20.3ft • lbf) notice first, tighten ...

  • Page 167: Chas

    Chas 4-54 1 2 3 a b handlebar 5. Install: 8 throttle grip assembly 1 8 throttle cable assembly 2 8 right handlebar switch 3 tip 8 lubricate the inside of the throttle grip as- sembly with a thin coat of lithium-soap- based grease and install it onto the handle- bar 4. 8 align the projection a on the...

  • Page 168: Chas

    Chas 4-55 8 16nm (1.6 m•kgf, 11.6 ft•lbf) 4 6 3 1 2 13 12 10 9 5 11 7 4nm (0.4 m•kgf, 2.9 ft•lbf) 4nm (0.4 m•kgf, 2.9 ft•lbf) 48nm (4.8 m•kgf, 34.7 ft•lbf) 60nm (6.0 m•kgf, 43.4 ft•lbf) 4nm (0.4 m•kgf, 2.9 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 9nm (0.9 m•kgf, 6.5 ft•lbf) remarks order job/part q’ty st...

  • Page 169: Chas

    Chas 4-56 remarks order job/part q’ty lower bracket steering head removing the lower bracket leg shield 1 leg shield 2 front wheel brake caliper front fork legs handlebar handlebar bracket brake hose holder 2 upper ring nut lock washer center ring nut rubber washer lower ring nut bearing race cover ...

  • Page 170: Chas

    Chas 4-57 remarks order job/part q’ty steering head 11 12 13 14 15 lower bearing upper bearing outer race lower bearing outer race lower bearing inner race dust seal 1 1 1 1 1 for installation, reverse the removal pro- cedure. 7nm (0.7 m•kgf, 5.1 ft•lbf) 2 9 3 4 5 6 10 12 7 8 13 11 14 15 1 75nm (7.5...

  • Page 171: Chas

    Chas 4-58 1 2 1 2 2 1 steering head eas00678 removing the lower bracket 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. 2 . Remove: 8brake hose holder 2 8handlebar bracket 1 tip remove the handlebar bracket by loosening the...

  • Page 172: Chas

    Chas 4-59 1 steering head eas00682 checking the steering head 1. Wash: 8bearings 8bearing races recommended cleaning solvent kerosene 2. Check: 8bearings 1 8bearing races 2 damage/pitting replace. 3. Replace: 8bearings 8bearing races 8dust seal ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races fro...

  • Page 173: Chas

    Chas 4-60 1 4 2 5 3 1 3 2 steering head eas00684 installing the steering head 1. Lubricate: 8 bearings 1 8 bearing races recommended lubricant lithium-soap-based grease 2. Install: 8 lower ring nut 1 8 rubber washer 2 8 center ring nut 3 8 lock washer 4 8 upper ring nut 5 refer to “checking the stee...

  • Page 174: Chas

    Chas 4-61 11 9 10 8 4 7 6 5 2 2 1 3 44nm (4.4 m•kgf, 31.8 ft•lbf) 31nm (3.1 m•kgf, 22.4 ft•lbf) 53nm (5.3 m•kgf, 38.3 ft•lbf) 105nm (10.5 m•kgf, 75.9 ft•lbf) 18nm (1.8 m•kgf, 13.0 ft•lbf) 30nm (3.0 m•kgf, 21.7 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 13nm (1.3 m•kgf, 9.4 ft•lbf) 31nm (3.1 m•kgf, 22.4 ft•...

  • Page 175: Chas

    Chas 4-62 1 eas00693 removing the rear shock absorber assemblies 1. Stand the scooter on a level surface. Warning securely support the scooter so that there is no danger of it falling over. Tip place the scooter on a suitable stand so that the rear wheel is elevated. Eas00695 checking the rear shock...

  • Page 176: Chas

    Chas 4-63 2 1 1 2 t r . . T r . . Eas00699 installing the rear shock ab- sorber assemblies 1. Install: 8 rear shock absorber assembly upper nuts 1 30nm (3.0m • kgf, 21.7ft • lbf) 8 rear shock absorber assembly lower bolts 2 18nm (1.8m • kgf, 13.0ft • lbf) rear shock absorber assemblies and swingarm ...

  • Page 177: Chas

    Chas 4-64 2 4 3 1 3 1 2 eas00708 checking the swingarm 1. Check: 8 swingarm bends/cracks/damage replace. 2. Check: 8 spacer 1 8 collar 2 8 oil seals 3 8 bearing 4 damage/wear replace. Rear shock absorber assemblies and swingarm eas00711 installing the swingarm 1. Lubricate: 8 bearing 8 oil seal lips...

  • Page 178: Chas

    Chas 4-65 rear shock absorber assemblies and swingarm 4. Tighten: 8 exhaust pipe nut 13nm (1.3m • kgf, 9.4ft • lbf) 8 muffler and swingarm bolt 31nm (3.1m • kgf, 22.4ft • lbf) 8 muffler and swingarm bolt 53nm (5.3m • kgf, 38.3ft • lbf) 5. Connect: 8 o 2 sensor coupler t r . . T r . . T r . ..

  • Page 179: Eng

    Eng 5-71 chapter 5 engine engine removal .................................................................................. 5-1 leads and hoses ......................................................................... 5-1 engine ..........................................................................

  • Page 180: Eng

    Eng 5-72 checking the v-belt ................................................................. 5-45 checking the primary sheave ............................................ 5-46 checking the primary sheave weights .......................... 5-46 checking the slider .....................................

  • Page 181: Eng

    5-1 eng 7nm (0.7 m•kgf, 5.1 ft•lbf) 1 4 4 3 2 3nm (0.3 m•kgf, 2.2 ft•lbf) remarks order job/part q’ty eas00188 engine engine removal leads and hoses engine removal removing the leads and hoses seat/trunk battery box cover/front cover side cover (left and right) battery/footrest board rear brake cabl...

  • Page 182: Eng

    5-2 eng 7nm (0.7 m•kgf, 5.1 ft•lbf) 1 4 4 3 2 3nm (0.3 m•kgf, 2.2 ft•lbf) engine removal remarks order job/part q’ty 1 2 3 4 rear brake cable holder spark plug cap engine temperature sensor coupler air filter/breather hose 1 1 1 1/1 tem” in chapter 7. Disconnect. Disconnect. For installation, revers...

  • Page 183: Eng

    5-3 eng 1 7 18nm (1.8 m•kgf, 13.0 ft•lbf) 5 3 7 4 6 2 32nm (3.2 m•kgf, 23.1 ft•lbf) remarks order job/part q’ty eas00191 engine engine removal removing the engine rear fender rear shock absorber assembly lower bolt engine mounting nut/washer engine mounting bolt engine washer collar 1 2 3 4 5 6 7 1 ...

  • Page 184: Eng

    Eng 5-4 engine removal t r . . T r . . Eas00192 installing the engine 1. Install: 8 engine 1 8 engine mounting bolt 2 8 engine mounting nut 3 tip 8 apply lithium-soap-based grease to the unthreaded portion of the engine mounting bolt shaft. 8 do not fully tighten the engine mounting bolt.. 2. Instal...

  • Page 185: Eng

    5-5 eng 6 1 2 3 3 2 13 4 7 12 11 5 5 14 15 8 9 10 6 10nm (1.0 m•kgf, 7.2 ft•lbf) 8nm (0.8 m•kgf, 5.8 ft•lbf) 9nm (0.9 m•kgf, 6.5 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 13nm (1.3 m•kgf, 9.4 ft•lbf) 18nm (1.8 m•kgf, 13.0 ft•lbf) 22nm (2.2 m•kgf, 15.9 ft•lbf) 12nm (1.2 m•kgf, 8.7 ft•lbf) 30nm (3.0 m•kgf, ...

  • Page 186: Eng

    5-6 eng 6 1 2 3 3 2 13 4 7 12 11 5 5 14 15 8 9 10 6 10nm (1.0 m•kgf, 7.2 ft•lbf) 8nm (0.8 m•kgf, 5.8 ft•lbf) 9nm (0.9 m•kgf, 6.5 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 13nm (1.3 m•kgf, 9.4 ft•lbf) 18nm (1.8 m•kgf, 13.0 ft•lbf) 22nm (2.2 m•kgf, 15.9 ft•lbf) 12nm (1.2 m•kgf, 8.7 ft•lbf) 30nm (3.0 m•kgf, ...

  • Page 187: Eng

    Eng 5-7 cylinder head eas00225 removing the cylinder head 1. Remove : 8 air guide 8 air shroud cylinder 3 refer to “starter clutch and ac magneto”. 8 v-belt case refer to “belt drive”. 8 muffler refer to “rear shock absorber assemblies and swingarm” in chapter 4. 2. Remove : 8breather/o-ring 8 valve...

  • Page 188: Eng

    Eng 5-8 1 2 1 2 3 6 5 4 cylinder head 6. Remove: 8 timing chain tensioner (along with the gasket) 8 camshaft sprocket bolt 1 8 camshaft sprocket plate 2 8 camshaft sprocket 3 8 timing chain 4 tip to prevent the timing chain from falling into the crankcase, fasten it with a wire. 7. Remove: 8 cylinde...

  • Page 189: Eng

    Eng 5-9 1 2 cylinder head eas00227 checking the cylinder head 1. Eliminate: 8 combustion chamber carbon deposits (with a rounded scraper) tip do not use a sharp instrument to avoid damag- ing or scratching: 8 spark plug bore thread 8 valve seats 2. Check: 8 cylinder head damage/scratches j replace. ...

  • Page 190: Eng

    Eng 5-10 6 1 4 3 2 5 eas00231 installing the cylinder head 1. Install: 8 gasket new 8 dowel pins 2. Install: 8 cylinder head 3. Tighten: 8 cylinder head nuts 22 nm (2.2 m • kgf, 15.9 ft • lbf) 8 cylinder head bolts 12 nm (1.2 m • kgf, 8.7 ft • lbf) tip 8 lubricate the cylinder head nuts with en- gin...

  • Page 191: Eng

    Eng 5-11 1 2 3 4 5 tip 8 when installing the camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side. 8 align the slot on the camshaft with the tab in the camshaft sprocket. Notice do not turn the crankshaft when installing the camshaft to avoid damage or imprope...

  • Page 192: Eng

    Eng 5-12 8. Check: 8“i” mark a align the “i” mark on the ac magneto ro- tor with the stationary pointer b on the crankcase. 8“i” mark c align the “i” mark on the camshaft sprocket with the stationary pointer d on the cylinder head. Out of alignment j correct. Refer to the installation steps above. 9...

  • Page 193: Eng

    5-13 eng 5 2 3 3 4 1 8 6 3 3 2 7 7nm (0.7 m•kgf, 5.1 ft•lbf) 12nm (1.2 m•kgf, 8.7 ft•lbf) remarks order job/part q’ty 1 2 3 4 5 6 7 8 the rocker arms and camshaft 1 4 4 1 1 1 1 1 remove the parts in the order listed. Refer to “cylinder head”. Refer to “removing the rocker arms and camshaft” and “ins...

  • Page 194: Eng

    Eng 5-14 1 2 1 2 the rocker arms and camshaft eas00202 removing the rocker arms and cam- shaft 1. Remove: 8 locknut 1 8 stopper plate 2 2. Remove: 8 intake rocker arm shaft 8 exhaust rocker arm shaft 8 intake rocker arm 8 exhaust rocker arm tip remove the rocker arm shafts with the slide hammer bolt...

  • Page 195: Eng

    Eng 5-15 the rocker arms and camshaft eas00205 checking the camshaft 1. Check: 8camshaft lobes blue discoloration/pitting/scratches j replace the camshaft. 2. Measure: 8camshaft lobe dimensions a and b out of specification j replace the cam- shaft. Camshaft lobe dimension limit intake a a a a a 25.2...

  • Page 196: Eng

    Eng 5-16 the rocker arms and camshaft 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: 8rocker arm (camshaft touch surface)1 8rocker arm (valve touch surface)2 damage/wear j replace. 2. Check: 8rocker a...

  • Page 197: Eng

    Eng 5-17 the rocker arms and camshaft above 0.034mm (0.0013in) j replace the de- fective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.034mm (0.0004 ~ 0.0013in) eas00207 checking the timing chain, camshaft sprocket and timing chain guides the following procedure applies to all of the c...

  • Page 198: Eng

    Eng 5-18 the rocker arms and camshaft eas00210 checking the timing chain tensioner 1. Check: 8 timing chain tensioner cracks/damage j replace. 2. Check: 8 one-way cam operation rough movement j replace the timing chain tensioner. 3. Check: 8 cap bolt 8 o-ring new 8 spring 8 one-way cam 8 gasket new ...

  • Page 199: Eng

    Eng 5-19 1 1 2 1 2 eas00220 installing the camshaft and rocker arms 1. Lubricate: 8 camshaft 1 recommended lubricant camshaft engine oil camshaft bearing engine oil 2. Lubricate: 8 rocker arms 8 rocker arm shafts recommended lubricant molybdenum disulfide oil the rocker arms and camshaft 3. Install:...

  • Page 200: Eng

    Eng 5-20 the rocker arms and camshaft 5. Install: 8 stopper plate 1 8 locknut 2 12nm (1.2m • kgf, 8.7ft • lbf) t r . ..

  • Page 201: Eng

    5-21 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 8 4 4 2 2 4 4 8 eas00236 valves and valve springs removing the valves and valve springs cylinder head rocker arms rocker arm shafts camshaft valve cotter valve spring retainer valve spring valve (intake) valve (exhaust) valve stem seal valve stem ...

  • Page 202: Eng

    5-22 eng valves and valve springs remarks order job/part q’ty for installation, reverse the removal pro- cedure. 1 2 3 6 8 7 8 1 2 8 3 6 8 7 4 5.

  • Page 203: Eng

    Eng 5-23 1 2 3 valves and valve springs eas00237 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 2 . Remove: ...

  • Page 204: Eng

    Eng 5-24 valves and valve springs 3 . Remove: 8 valve spring retainer 1 8 valve spring 2 8 valve stem seal 3 8 valve 4 tip identify the position of each part very carefully so that it can be reinstalled in its original place. Eas00239 checking the valves and valv e guides the following procedure app...

  • Page 205: Eng

    Eng 5-25 valves and valve springs 2. Replace: 8 valve guide tip 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. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover 1. B. Install the new valv...

  • Page 206: Eng

    Eng 5-26 5. Measure: 8 valve margin thickness a out of specification j replace the valve. Valve margin thickness (intake) 0.7mm (0.028in) valve margin thickness (exhaust) 1.0mm (0.039in) valves and valve springs 6. Measure: 8 valve stem runout out of specification j replace the valve. Tip 8 when ins...

  • Page 207: Eng

    Eng 5-27 eas00240 checking the valve seats the following procedure applies to all of the valves and valve seats. 1. Eliminate: 8 carbon deposits (from the valve face and valve seat) 2. Check: 8 valve seat pitting/wear j replace the cylinder head. 3. Measure: 8 valve seat width a out of specification...

  • Page 208: Eng

    Eng 5-28 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound a to the valve face. Notice 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 va...

  • Page 209: Eng

    Eng 5-29 a eas00241 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: 8 valve spring free length a out of specification j replace the valve spring. Valve spring free length 41.88mm (1.649in) : 39.786mm (1.566in) valves and valve springs 2. Measure: 8...

  • Page 210: Eng

    Eng 5-30 1 2 3 eas00245 installing the valves the following procedure applies to all of the valves and related components. 1. Deburr: 8 valve stem end (with an oil stone) 2. Lubricate: 8 valve stem 1 8 valve stem seal 2 (with the recommended lubricant) recommended lubricant molybdenum disulfide oil ...

  • Page 211: Eng

    Eng 5-31 valve spring compressor 90890-04019 (ym-04019) valve spring compressor attach- ment 90890-04108 (ym-04108) valves and valve springs 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. Notice hitting the valve tip with excessive force could...

  • Page 212: Eng

    5-32 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 eas00251 cylinder and piston 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 remove the parts in the order listed. Refer to “cyli...

  • Page 213: Eng

    Eng 5-33 3 2 1 eas00253 removing the cylinder and piston 1. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 3 notice do not use a hammer to drive the piston pin out. Tip 8 before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from fallin...

  • Page 214: Eng

    Eng 5-34 cylinder and piston eas00255 checking the cylinder and piston 1. Check: 8 piston wall 8 cylinder wall vertical scratches j rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: 8 piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder...

  • Page 215: Eng

    Eng 5-35 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) : 0.15mm (0.0059in) f. If out of specification, rebore or replace the cylind...

  • Page 216: Eng

    Eng 5-36 eas00263 checking the piston rings 1. Measure: 8 piston ring side clearance out of specification j replace the pis- ton and piston rings as a set. Tip before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring si...

  • Page 217: Eng

    Eng 5-37 4. Calculate: 8 piston-pin-to-piston-pin-bore clearance out of specification j replace the pis- ton pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = piston pin bore diameter b - piston pin outside diameter a piston-pin-to-piston clearance 0.002 ~ 0.018mm (0.00008 ~ 0.0007i...

  • Page 218: Eng

    Eng 5-38 2 3 1 cylinder and piston eas00267 installing the piston and cylinder 1. Install: 8 oil ring expander 8 oil ring rail 8 2nd ring 8 top ring tip be sure to install the piston rings so that the manufacturer’s marks or numbers a face up. Checking the timing chain guide (ex- haust side) 1. Chec...

  • Page 219: Eng

    Eng 5-39 1 a b a c d cylinder and piston 3. Install: 8 gasket new 8 dowel pins 4. Lubricate: 8 piston 8 piston rings 8 cylinder (with the recommended lubricant) recommended lubricant engine oil 5. Offset: 8 piston ring end gaps a top ring b lower oil ring rail c upper oil ring rail d 2nd ring a exha...

  • Page 220: Eng

    5-40 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 eas00316 belt drive v-belt case removing the v-belt case air duct v-belt case cover v-belt case filter guide v-belt case filter element o-ring gasket (v-belt case) plate gasket (plate) v-belt case remove the parts in the order ...

  • Page 221: Eng

    5-41 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 11 12 1/1 1 1 1 1 1 1 1 1/3 6 2 1 remove the parts in the order listed. Refer to “v-belt case”. Refer to “removing the primary sheave” and “installing the sec- ondary sheave, v-belt and pri- mary sheave”. Refer to “removing the second- ary sh...

  • Page 222: Eng

    5-42 eng 8 2 4 3 5 6 7 1 e 0 q w e 9 r 90nm (9.0 m•kgf, 7.2 ft•lbf) remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 0 q w e r 1 3 1 3 3 3 1 1 1 3 1 2 2 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. Disassembling the secondary sheave clutch carrier nut cl...

  • Page 223: Eng

    Eng 5-43 2 1 3 1 2 3 1 2 3 belt drive eas00318 removing the secondary sheave and v-belt 1. Remove: 8 secondary sheave nut 1 8 clutch housing 2 tip while holding the clutch housing with the sheave holder 3, loosen the secondary sheave nut. Sheave holder 90890-01701 (ys-01880-a) eas00317 removing the ...

  • Page 224: Eng

    Eng 5-44 1 2 belt drive tip while holding the clutch carrier with the rotor holding tool 2, loosen the clutch carrier nut one full turn with the locknut wrench 3. Rotor holding tool 90890-01235 (yu-01235) locknut wrench 90890-01348 (ym-01348) 3. Remove: 8 secondary sheave 1 8 v-belt 2 tip remove the...

  • Page 225: Eng

    Eng 5-45 2. Measure: 8 clutch shoe thickness out of specification j replace the clutch shoes and springs as a set. Clutch shoe thickness 3.2 ~ 3.5mm (0.13 ~ 0.14in) : 2.0mm (0.079in) tip 8 inspect clutch shoes a. 8 after removing the clutch shoe spring, do not use them again. 8 replace the all three...

  • Page 226: Eng

    Eng 5-46 2 1 belt drive checking the primary sheave 1. Check: 8 primary sliding sheave 1 8 primary fixed sheave 2 cracks/damage/wear j replace the pri- mary sliding sheave, primary fixed sheave and v-belt. 2. Check: 8free movement stick or excessive play j replace the primary sliding sheave, collar ...

  • Page 227: Eng

    Eng 5-47 belt drive checking the slider 1. Check: 8 slider 1 damage/wear j replace eas00322 checking the secondary sheave 1. Check: 8secondary fixed sheave 8secondary sliding sheave cracks/damage/wear j replace the sec- ondary fixed and sliding sheaves as a set. 2. Check: 8torque cam groove 1 damage...

  • Page 228: Eng

    Eng 5-48 1 2 3 4 4 5 belt drive eas00323 assembling the primary sheave 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 tip use thinner to clean up grease, dirt on the pri- mary sliding sheave cam side 5. 2. Install: 8primary sheave weights 1 8collar 2 ...

  • Page 229: Eng

    Eng 5-49 2 1 3 eas00324 assembling the secondary sheave 1. Lubricate: 8 secondary fixed sheave’s inner surface 1 8 secondary sliding sheave’s inner surface 2 8 oil seals 8 bearings (with the recommended lubricant) recommended lubricant bel-ray assembly lube ® 2. Install: 8 secondary sliding sheave 1...

  • Page 230: Eng

    Eng 5-50 2 1 3 2 1 5. Install: 8 secondary sheave 1 8 spring 8 clutch carrier 2 tip 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. Clutch spring holder 90890-01337 (ym-33285) belt d...

  • Page 231: Eng

    Eng 5-51 2 1 3 2 1 3 belt drive rotor holding tool 90890-01235 (yu-01235) locknut wrench 90890-01348 (ym-01348) 3. Install: 8 clutch housing 1 8 secondary sheave nut 2 60nm(6.0m • kgf, 43.4ft • lbf) tip tighten the secondary sheave nut with the sheave holder 3. Sheave holder 90890-01701 (ys-01880-a)...

  • Page 232: Eng

    Eng 5-52 1 2 3 belt drive 5. Position: 8 v-belt 1 tip 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. 6. Install: 8 v-belt case refer to “v-belt c...

  • Page 233: Eng

    5-53 eng 9 1 2 3 4 5 6 7 8 7nm (0.7 m•kgf, 5.1 ft•lbf) 10nm (1.0 m•kgf, 7.2 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 70nm (7.0 m•kgf, 50.6 ft•lbf) 9nm (0.9 m•kgf, 6.5 ft•lbf) remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 1 1 1/1 1 1 1 1 1 1 remove the parts in the order listed. Disconnect. For installati...

  • Page 234: Eng

    5-54 eng 7 6 5 4 2 3 2 1 10nm (1.0 m•kgf, 7.2 ft•lbf) 10nm (1.0 m•kgf, 7.2 ft•lbf) remarks order job/part q’ty 1 2 3 4 5 6 7 1 2 1 1 1 1 1 eas00342 starter clutch removing the starter clutch v-belt case primary fixed sheave primary sliding sheave idle gear plate plate washer idle gear starter clutch...

  • Page 235: Eng

    Eng 5-55 1 2 3 1 2 eas00347 removing the ac magneto 1. Remove: 8 air guide 8 air shroud cylinder 3 2. Remove: 8 fan 8 ac magneto rotor nut 1 8 washer tip while holding the ac magneto rotor 3 with the rotor holding tool 2, loosen the ac magneto ro- tor nut. Rotor holding tool 90890-01235 (yu-01235) 3...

  • Page 236: Eng

    Eng 5-56 eas00351 checking the starter clutch 1. Check: 8starter clutch roller damage/wear j replace. 2. Check: 8starter clutch idle gear 8starter wheel gear burrs/chips/roughness/wear j replace the defective part(s). 3. Check: 8starter wheel gear’s contacting surfaces damage/pitting/wear j replace ...

  • Page 237: Eng

    Eng 5-57 2 3 1 starter clutch and ac magneto eas00354 installing the ac magneto 1. Install: 8 stator coil assembly 8 crankshaft position sensor 8 woodruff key 8 ac magneto rotor 8 washer 8 ac magneto rotor nut tip 8 clean the tapered portion of the crankshaft and the ac magneto rotor hub. 8 when ins...

  • Page 238: Eng

    5-58 eng 1 2 3 4 5 7 6 8 9 1 13nm (1.3 m•kgf, 9.4 ft•lbf) 13nm (1.3 m•kgf, 9.4 ft•lbf) 4nm (0.4 m•kgf, 2.9 ft•lbf) eas00360 oil pump remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 1/1 1 1 1 1/1 1 1 1 1 removing the oil pump ac magneto rotor stator coil assembly cover/o-ring gasket oil seal dowel pin ...

  • Page 239: Eng

    Eng 5-59 eas00364 checking the oil pump 1. Check: 8 oil pump drive gear 8 oil pump driven gear 1 8 oil pump housing 8 oil pump housing cover cracks/damage/wear j replace the defective part(s). 2. Measure: 8 inner-rotor-to-outer-rotor-tip clearance a 8 outer-rotor-to-oil-pump-housing clearance b. Out...

  • Page 240: Eng

    Eng 5-60 1 2 3 4 5 6 1 oil pump eas00375 assembling the oil pump 1. Lubricate: 8 inner rotor 8 outer rotor 8 oil pump shaft (with the recommended lubricant) recommended lubricant engine oil eas00376 installing the oil pump 1. Install: 8 gasket new 8 oil pump 1 4 nm (0.4 m • kgf, 2.9 ft • lbf) notice...

  • Page 241: Eng

    5-61 eng remarks order job/part q’ty 1 2 3 4 5 6 1 1 2 1 1 1 removing the transmission transmission oil muffler swingarm rear wheel v-belt case v-belt secondary sheave right crankcase cover right crankcase cover gasket dowel pin primary drive gear shaft main axle drive axle remove the parts in the o...

  • Page 242: Eng

    Eng 5-62 transmission eas00425 checking the transmission 1. Measure: 8 main axle runout (with a centering device and dial gauge ) out of specification j replace the main axle. Main axle runout limit 0.04mm (0.002in) 2. Measure: 8 drive axle runout (with a centering device and dial gauge ) out of spe...

  • Page 243: Eng

    5-63 eng (x7) (x2) 1 2 3 3 3 4 4 10 5 6 7 8 9 12 12 13 11 20nm (2.0 m•kgf, 14.5 ft•lbf) 23nm (2.3 m•kgf, 16.6 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 13nm (1.3 m•kgf, 9.4 ft•lbf) remarks order job/part q’ty 1 2 3 4 2 1 1/2 1/1 remove the parts in the order listed. Refer to “e...

  • Page 244: Eng

    5-64 eng (x7) (x2) 1 2 3 3 3 4 4 10 5 6 7 8 9 12 12 13 11 20nm (2.0 m•kgf, 14.5 ft•lbf) 23nm (2.3 m•kgf, 16.6 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) 13nm (1.3 m•kgf, 9.4 ft•lbf) crankshaft remarks order job/part q’ty 5 6 7 8 9 10 11 12 13 timing chain guide (intake side) cra...

  • Page 245: Eng

    Eng 5-65 1 1 2 eas00385 disassembling the crankcase 1. Remove: 8 centerstand 2. Remove: 8 crankcase bolts 1 tip loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 3. Remove: 8 right crankcase 1 notice tap on one si...

  • Page 246: Eng

    Eng 5-66 1 2 crankshaft eas00389 removing the crankshaft assembly 1. Remove: 8 crankshaft assembly 1 8 timing chain 2 tip 8 before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. 8 the crankshaft assembly cannot be re- moved if the timing chain is attached ont...

  • Page 247: Eng

    Eng 5-67 3. Measure: 8 crankshaft width out of specification jreplace the crank- shaft. Crankshaft width 45.45 ~ 45.50mm (1.789 ~ 1.791in) 4. Check: 8crankshaft sprocket 1 damage/wear jreplace the crankshaft. 8bearing 2 cracks/damage/wear j replace the crankshaft. 8oil pump drive gear 3 damage/wear ...

  • Page 248: Eng

    Eng 5-68 eas00207 checking the timing chain and timing chain guide(intake side) 1. Check: 8 timing chain damage/stiffness j replace the timing chain and camshaft sprocket as a set. 2. Check: 8 timing chain guide (intake side) damage/wear j replace. Eas00401 checking the bearings and oil seals 1. Che...

  • Page 249: Eng

    Eng 5-69 1 2 crankshaft eas00418 assembling the crankcase 1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: 8 sealant (onto the crankcase mating surfaces) yamaha bond no. 1215 90890-85505 (acc-11001-05-01) tip do not allow any sealant to come into contact ...

  • Page 250: Eng

    Eng 5-70 1 crankshaft 3. Install: 8 dowel pins 8 right crankcase 1 tip tap lightly on the right crankcase with a soft- face hammer. T r . . 4. Tighten: 8crankcase bolts 13nm(1.3m • kgf, 9.4ft • lbf) tip tighten the crankcase bolts in stages and in a crisscross pattern. 5. Apply: 8engine oil (onto th...

  • Page 251

    6-37 fi chapter 6 fuel injection system fuel injection system .................................................................... 6-1 wiring diagram ............................................................................ 6-2 ecu’s self-diagnostic function .........................................

  • Page 252: Fuel Injection System

    6-1 fi eas00894 fuel injection system fuel injection system 1 ecu 2 engine trouble warning light 3 lean angle cut-off switch 4 fuel hose 5 ignition coil 6 fuel injector 7 intake air pressure sensor 8 isc (idle speed control) valve 9 intake air temperature sensor 0 battery q air filter case w catalyt...

  • Page 253

    6-2 fi wiring diagram fuel injection system l/y b/l r w/r b/l w/r w/l w w w ww w w/r b/l w w w w w w w w w r b b r r r r r b r r r b l/w r/w l/w r/w l/w r/w (bla ck) (bla ck) b r b br br br r/b br br/l r br b/w (red) (red) 10a 15a 10a main lock off on 20a off push horn hi lo l n r dimmer flasher 10a...

  • Page 254

    6-3 fi fuel injection system 1 crankshaft position sensor 4 main fuse 5 fuel injection system fuse 6 battery q main switch w sidestand switch t engine stop switch y ignition fuse u signaling system fuse s engine trouble warning light d speed sensor , ignition coil . Spark plug / fuel injector ! Fuel...

  • Page 255

    6-4 fi 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 illuminat...

  • Page 256

    6-5 fi eas00902 self-diagnostic fanction table if the ecu detects an abnormal signal from a sensorwhile the vehicle is being driven, the ecu illuminates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction. ...

  • Page 257

    6-6 fi fault code no. Item symptom engine startability vehicle driveability 39 30 41 42 43 44 46 50 61 _ fuel injector lean angle cut-off switch (latch up detected) (open or short circuit) speed sensor fuel system voltage (moni- toring voltage) error in reading from or writ- ing on eeprom vehicle sy...

  • Page 258

    6-7 fi fuel injection system eas00904 troubleshooting chart 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 wh...

  • Page 259

    6-8 fi eas00905 diagnostic mode it is possible to monitor the sensor output data or check the activation of actuators with con- necting the fl diagnostic tool to the normal mode or the diagnostic monitoring mode. Fl diagnostic tool 90890-03182 (yu-03182) setting the normal mode tip the engine speed,...

  • Page 260

    6-9 fi setting the diagnostic mode 1. Turn the main switch to “off”. 2. Disconnect the self diag signal connector 1, and then connect the fl diagnostic-tool 2 as shown. 3. While press the “mode” button, turn the main switch to “on”. Tip 8 ”diag” appears on the lcd of the fl diag- nostic tool. 8 ”pow...

  • Page 261

    6-10 fi fault codeno. Symptom diagnostic code 12 13 14 15 16 19 22 24 28 30 33 37 39 41 42 43 44 46 50 61 no normal signals are received from the crankshaft position sensor. Intake air pressure sensor-open or short circuit detected. Faulty intake air pressure sensor system throttle position sensor-o...

  • Page 262

    6-11 fi diag- nostic code item data displayed on fi diagnostic tool (reference value) description of action eas00907 diagnostic mode table tip 8 check the intake air temperature and engine temprature as close as possible to the intake air temperature sensor and the engine temperature sensor respecti...

  • Page 263

    6-12 fi fuel injection system lcd display probable cause of malfunction sympton communication error with the fi diagnostic tool eas00908 troubleshooting details this section describes the countermeasures per fault code number displayed on the fl diagnostic tool. Check and service the items or compon...

  • Page 264

    6-13 fi no normal signals are received from the crankshaft position sensor. 1 2 3 4 installed condition of sensor. Connected condition of con- nector. Inspect the coupler for any pins that may have pulled out. Check that the coupler is connected securely. Tip set the main switch to off before connec...

  • Page 265

    6-14 fi fuel injection system intake air pressure sensor-open or short circuit detected. 1 2 3 connected condition of con- nector inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Tip set the main switch to off before connecting or discon- necting...

  • Page 266

    6-15 fi intake air pressure- sensor hose system malfunction (clogged or de- tached hose). 1 2 connected state of connector intake air pressure sensor cou- pler main wirring harness ecu cou- pler defective intake air pressure sensor. Check the coupler for any pins that may have pulled out. Check that...

  • Page 267

    6-16 fi stuck throttle position sensor detected. 1 2 3 fault code no. 16 symptom used diagnostic code no. D01 (throttle position sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method fuel injection system reinstated by start- ing the engine...

  • Page 268

    6-17 fi 1 2 b/l y l p/w br/w fuel injection system intake air temperature sensor open or short circuit is detected. 1 2 3 4 fault code no. 22 symptom used diagnostic code no. D05 (intake air temperature sensor) order inspection operation item and probable cause operation item and countermeasure rein...

  • Page 269

    6-18 fi engine temperature sensor open or short circuit is detected. 1 2 3 4 fault code no. 28 symptom used diagnostic code no. D11 (engine temperature sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method reinstated by turn- ing the main s...

  • Page 270

    6-19 fi 2 1 l y/g b/l 45˚ 45˚ b/r the vehicle has overturned. 1 2 3 4 fault code no. 30 symptom used diagnostic code no. D08 (lean angle cut-off switch) order inspection operation item and probable cause operation item and countermeasure reinstatement method reinstated by turn- ing the main switch o...

  • Page 271

    6-20 fi fuel injection system open circuit detected in the primary lead of the ignition coil. 1 2 3 fault codeno. 33 symptom used diagnostic code no. D30 order inspection operation item and probable cause operation item and countermeasure reinstatement method reinstated by start- ing the engine and ...

  • Page 272

    6-21 fi fuel injection system fuel injector open or short circuit is detected. 1 2 3 fault code no. 39 symptom used diagnostic code no. D36 (fuel injector) order inspection operation item and probable cause operation item and countermeasure reinstatement method reinstated by start- ing the engine. C...

  • Page 273

    6-22 fi fuel injection system no normal signals are received from the speed sensor. 1 2 3 4 fault code no. 42 symptom used diagnostic code no. D07 (speed sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method reinstated by input- ting the ve...

  • Page 274

    6-23 fi fuel injection system an error is delected while reading from or writing on eeprom (co adjustment value, code re-registering key code, and throttle valve fully closed notification value). 1 fault code no. 44 symptom used diagnostic code no. D60 (eeprom improper cylinder indication) order ins...

  • Page 275

    6-24 fi fuel injection system 1 used diagnostic code no. -- order inspection operation item and probable cause operation item and countermeasure reinstatement method reinstated by turn- ing the main switch on. Malfunction in ecu replace the ecu. Faulty ecu memory. (when this malfunction is detected ...

  • Page 276

    6-25 fi isc (idle speed control) valve open or short circuit is detected. 1 2 3 fault code no. 61 symptom used diagnostic code no. D54 (isc (idle speed control)valve) order inspection operation item and probable cause operation item and countermeasure reinstatement method reinstated by set- ting the...

  • Page 277

    6-26 fi 3 7 4 5 6 1 2 10nm (1.0 m•kgf, 7.2 ft•lbf) 4nm (0.4 m•kgf, 2.9 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) remarks order job/part q’ty eas00909 throttle body and fuel injector fuel tank throttle body and fuel injector removing the fuel tank seat/trunk battery box cover/front cover side cover (left a...

  • Page 278

    6-27 fi 3 7 4 5 6 1 2 10nm (1.0 m•kgf, 7.2 ft•lbf) 4nm (0.4 m•kgf, 2.9 ft•lbf) 7nm (0.7 m•kgf, 5.1 ft•lbf) remarks order job/part q’ty throttle body and fuel injector 6 7 fuel pump fuel tank 1 1 refer to “removing the fuel pump” and “installing the fuel pump”. Refer to “removing the fuel tank” and “...

  • Page 279

    6-28 fi remarks order job/part q’ty fuel injector and fuel hose throttle body and fuel injector removing the fuel injector and fuel hose fuel tank fuel hose holder (to frame) fuel hose holder (to intake manifold) clamp fuel injector coupler fuel injector and fuel hose 1 2 3 4 5 remove the parts in t...

  • Page 280

    6-29 fi throttle body and fuel injector remarks order job/part q’ty throttle body removing the throttle body air filter/breather hose fuel tank fuel pipe (to throttle body) throttle body clamp screw sensor module coupler isc (idle speed control) valve coupler throttle cable assembly throttle body 1 ...

  • Page 281

    6-30 fi 1 throttle body and fuel injector removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove : 8 fuel return hose 8 fuel hose 1 notice 8 8 8 8 8 be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. 8 ...

  • Page 282

    6-31 fi throttle body and fuel injector removing the fuel pump 1. Remove: 8 fuel tank refer to “removing the fuel tank”. 2. Remove: 8fuel pump notice 8 8 8 8 8 do not drop the fuel pump or give it a strong shock. 8 8 8 8 8 do not touch the base section of the fuel sender. Eas00911 notice the fuel pu...

  • Page 283

    6-32 fi eas00912 checking the fuel injector 1. Check: 8 fuel injector damage j replace. Eas00913 checking the throttle body 1. Check: 8 throttle body cracks/damage j replace the throttle body. 2. Check: 8 butterfly valve damage/scratches/wear j replace. Notice 8 8 8 8 8 do not adjust the stop screw ...

  • Page 284

    6-33 fi 1 throttle body and fuel injector installing the fuel pump 1. Install : 8 fuel pump 4nm (0.4m • kgf, 2.9ft • lbf) tip 8 do not damage the installion surface of the fuel tank when installing the fuel pump. 8 always use a new fuel pump gasket. 8 align the projection a on the fuel pump with the...

  • Page 285

    6-34 fi 1 2 3 eas00915 checking the fuel pump and pres- sure regulator operation 1. Check: 8 pressure regulator operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the battery box cover and front cover. Refer to “cover and panel” in chapter 3. B. Remove the fuel hose 1 from the fuel pump. Notice although th...

  • Page 286

    6-35 fi throttle body and fuel injector 3 2 1 b/l y l p/w br/w eas0091 6 checking the throttle position sen- sor 1. Check: 8 throttle position sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester to the ter- minals of the throttle position sensor. Positive tester probe j j j j j blue...

  • Page 287

    6-36 fi eas00916 checking the isc (idle speed con- trol) valve tip do not remove the isc (idle speed control) valve unit completely from the throttle body assembly. 1. Check: 8 isc (idle speed control) valve ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the isc (idle speed control) valve coupler from the is...

  • Page 288: Elec

    7-43 - + elec chapter 7 electrical system electrical components ................................................................ 7-1 wiring diagram ................................................................................... 7-2 checking switch continuity ........................................

  • Page 289: Elec

    7-1 - + elec eas00729 electrical system electrical components 1 main switch 2 front brake light switch 3 rectifier/regulator 4 rear brake light switch 5 sidestand switch 6 battery 7 main fuse 8 ecu 9 fuse box 0 ignition coil q spark plug cap w fuel pump e starter relay r horn t turn signal relay y s...

  • Page 290: Elec

    7-2 - + elec wiring diagram wiring diagram l/y b/l r w/r b/l w/r w/l w w w ww w w/r b/l w w w w w w w w w r b b r r r r r b r r r b l/w r/w l/w r/w l/w r/w (bla ck) (bla ck) b r b br br br r/b br br/l r br b/w (red) (red) 10a 15a 10a main lock off on 20a off push horn hi lo l n r dimmer flasher 10a ...

  • Page 291: Elec

    7-3 - + elec wiring diagram 1 ac magneto 2 rectifier/regulator 3 body earth 4 main fuse 5 fuel injection system fuse 6 battery 7 wire lead 8 starter relay 9 starter motor 0 starting circuit cut-off relay q main switch w sidestand switch e headlight relay r start switch t engine stop switch y ignitio...

  • Page 292: Elec

    7-4 - + elec eas00730 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. Notice never insert the tester probes into the coupler terminal slots a a a a a. Always...

  • Page 293: Elec

    7-5 - + elec eas00731 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “checking switch continuity”. Damage/wear j repair or replace. Improperly connected j properly connect. Incorrect continuity reading j replace...

  • Page 294: Elec

    7-6 - + 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 j repair or replace the bulb, bulb socket or both. Improperly connected j properly con- nect. No continuity j...

  • Page 295: Elec

    7-7 - + elec notice 8 8 8 8 8 be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the ter- minal in the coupler. 8 8 8 8 8 avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glas...

  • Page 296: Elec

    7-8 - + elec pocket tester 90890-03112 (yu-03112-c) tip check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. B. Connect the pocket tester probes to the re- spective...

  • Page 297: Elec

    7-9 - + elec eas00734 ignition system circuit diagram ignition system l/y b/l r w/r b/l w/r w/l w w w ww w w/r b/l w w w w w w w w w r b b r r r r r b r r r b l/w r/w l/w r/w l/w r/w (bla ck) (bla ck) b r b br br br r/b br br/l r br b/w (red) (red) 10a 15a 10a main lock off on 20a off push horn hi l...

  • Page 298: Elec

    7-10 - + elec eas00736 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Check: 1. Main and ignition fuses 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Crankshaft position sensor resistance 8. Main swi...

  • Page 299: Elec

    7-11 - + elec eas00742 4. Ignition spark gap 8 disconnect the spark plug cap from the spark plug. 8 connect the ignition checker 1 as shown. 2 spark plug cap 8 set the main switch to “on”. 8 measure the ignition spark gap a. 8 crank the engine by pushing the starter switch and gradually increase the...

  • Page 300: Elec

    7-12 - + elec 8 measure the primary coil resistance. Primary coil resistance 2.16 ~ 2.64 Ω Ω Ω Ω Ω at 20°c (68°f) 8 connect the pocket tester ( Ω × 1k) to the ignition coil as shown. Negative tester probe j j j j j orange 2 2 2 2 2 positive tester probe j j j j j spark plug lead 1 1 1 1 1 8 measure ...

  • Page 301: Elec

    7-13 - + elec ignition system eas00749 8. Main switch 8 check the main switch for continuity. Refer to “checking the switches”. 8 is the main switch ok? Yes no replace the main switch. Eas00750 9. Engine stop switch 8 check the engine stop switch for continuity. Refer to “checking the switches”. 8 i...

  • Page 302: Elec

    7-14 - + elec ignition system eas00754 12. Wiring 8 check the entire ignition system’s wiring. Refer to “circuit diagram”. 8 is the ignition system’s wiring properly con- nected and without defects? Yes no properly connect or repair the ignition system’s wiring. Replace the ecu..

  • Page 303: Elec

    7-15 - + elec eas00755 electric starting system circuit diagram electric starting system l/y b/l r w/r b/l w/r w/l w w w ww w w/r b/l w w w w w w w w w r b b r r r r r b r r r b l/w r/w l/w r/w l/w r/w (bla ck) (bla ck) b r b br br br r/b br br/l r br b/w (red) (red) 10a 15a 10a main lock off on 20a...

  • Page 304: Elec

    7-16 - + elec eas00756 starting circuit cut-off system op- eration if the engine stop switch is set to “#” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: 8 the brake lever (front or rear) is pulled...

  • Page 305: Elec

    7-17 - + elec eas00757 troubleshooting the starter motor fails to turn. Check: 1. Main, signal and ignition fuses 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starter relay 6. Main switch 7. Engine stop switch 8. Brake light switch (front and rear) 9. Sidestand switch 10. Start s...

  • Page 306: Elec

    7-18 - + elec eas00758 3. Starter motor 8 connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3. Warning 8 8 8 8 8 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. 8 8 8 ...

  • Page 307: Elec

    7-19 - + elec electric starting system eas00761 5. Starter relay 8 disconnect the starter relay coupler from the coupler. 8 connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starter relay coupler as shown. Positive battery terminal j j j j j red/white 1 1 1 1 1 negative battery terminal...

  • Page 308: Elec

    7-20 - + elec eas00764 10. Start switch 8 check the start switch for continuity. Refer to “checking the switches”. 8 is the start switch ok? Yes no replace the right handlebar switch. Eas00766 11. Wiring 8 check the entire starting system’s wiring. Refer to “circuit diagram”. 8 is the starting syste...

  • Page 309: Elec

    7-21 - + elec eas00767 starter motor remarks order job/part q’ty removing the starter motor seat/trunk air filter/breather hose starter motor lead/earth lead starter motor disassembling the starter motor o-ring starter motor front cover o-ring brush brush spring circlip armature stator o-ring starte...

  • Page 310: Elec

    7-22 - + elec electric starting system remarks order job/part q’ty for assembly, reverse the disassembly procedure. 1 2 7nm (0.7 m•kgf, 5.1 ft•lbf) 4nm (0.4 m•kgf, 2.9 ft•lbf).

  • Page 311: Elec

    7-23 - + elec 1 2 eas00769 checking the starter motor 1. Check: 8 commutator dirt j clean with 600-grit sandpaper. 2. Measure: 8 commutator diameter a out of specification j replace the starter motor. Commutator wear limit 21 mm (0.83in) 3. Measure: 8 mica undercut b out of specification j scrape th...

  • Page 312: Elec

    7-24 - + elec 5. Measure: 8 brush length a out of specification j replace the brushes as a set. Brush length wear limit 3.5 mm (0.14in) 6. Measure: 8 brush spring force out of specification j replace the brush springs as a set. Brush spring force 5.52 ~ 8.28 n/mm (0.56 ~ 0.84kgf/ mm, 1.24 ~ 1.86lbf/...

  • Page 313: Elec

    7-25 - + elec electric starting system 3. Install: 8 o-rings new 8 bolts 1 4nm (0.4m • kgf, 2.9ft • lbf) tip align the match marks a on the stator with the match marks b on the front and starter motor rear covers. Eas00772 assembling the starter motor 1. Install: 8 brush spring 8 brush 1 2. Install:...

  • Page 314: Elec

    7-26 - + elec eas00773 charging system circuit diagram charging system l/y b/l r w/r b/l w/r w/l w w w ww w w/r b/l w w w w w w w w w r b b r r r r r b r r r b l/w r/w l/w r/w l/w r/w (bla ck) (bla ck) b r b br br br r/b br br/l r br b/w (red) (red) 10a 15a 10a main lock off on 20a off push horn hi ...

  • Page 315: Elec

    7-27 - + elec eas00774 troubleshooting the battery is not being charged. Check: 1. Main fuse 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connections (of the entire charging system) tip 8 before troubleshooting, remove the follow- ing part(s): 1. Battery box cover 2. Front cove...

  • Page 316: Elec

    7-28 - + elec the charging circuit is ok. Eas00776 4. Stator coil resistance 8 disconnect the starter coil coupler from the wire harness. 8 connect the pocket tester ( Ω ×1) to the sta- tor coil as shown. Positive tester probe j j j j j white 1 1 1 1 1 negative tester probe j j j j j white 2 2 2 2 2...

  • Page 317: Elec

    7-29 - + elec eas00780 lighting system circuit diagram lighting system r r b r l/y b/l r w/r b/l w/r w/l w w w ww w w/r b/l w w w w w w w w w r b b r r r r r b r r r b l/w r/w l/w r/w l/w r/w (bla ck) (bla ck) b r b br br br r/b br br/l r br b/w (red) (red) 10a 15a 10a main lock off on 20a off push ...

  • Page 318: Elec

    7-30 - + elec eas00781 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight or meter light. Check: 1. Main and headlight fuses 2. Battery 3. Main switch 4. Dimmer switch 5 headlight relay 6 wiring connections (of the entire lighting system) tip 8 before...

  • Page 319: Elec

    7-31 - + elec eas00787 6. Wiring 8 check the entire lighting system’s wiring. Refer to “circuit diagram”. 8 is the lighting system’s wiring properly con- nected and without defects? Yes no properly connect or repair the lighting system’s wiring. Check the condition of each of the lighting system’s c...

  • Page 320: Elec

    7-32 - + elec the wiring circuit from the main switch to the headlight coupler or meter assembly cou- pler is faulty and must be repaired. Refer to “circuit diagram”. This circuit is ok. Yes no lighting system 3. Voltage 8 connect the pocket tester (dc 20 v) to the headlight and high beam indicator ...

  • Page 321: Elec

    7-33 - + elec lighting system 2. Voltage 8 connect the pocket tester (dc 20 v) to the meter light coupler (wire harness side) as shown. Positive tester probe j j j j j blue 1 1 1 1 1 negative tester probe j j j j j black 2 2 2 2 2 8 set the main switch to “on”. 8 measure the voltage (dc 12 v) of blu...

  • Page 322: Elec

    7-34 - + elec eas00790 3. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket 8 check the tail/brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” 8 are the tail/brake light bulb and socket ok? Yes no replace the tail/brake light bulb, so...

  • Page 323: Elec

    7-35 - + elec eas00793 signaling system circuit diagram signaling system r r b r l/y b/l r w/r b/l w/r w/l w w w ww w w/r b/l w w w w w w w w w r b b r r r r r b r r r b l/w r/w l/w r/w l/w r/w (bla ck) (bla ck) b r b br br br r/b br br/l r br b/w (red) (red) 10a 15a 10a main lock off on 20a off pus...

  • Page 324: Elec

    7-36 - + elec eas00794 troubleshooting 8 8 8 8 8 any of the following fail to light: turn sig- nal light, brake light or an indicator light. 8 8 8 8 8 the horn fails to sound. Check: 1. Main and signaling fuses 2. Battery 3. Main switch 4. Wiring connections (of the entire signaling system) tip 8 be...

  • Page 325: Elec

    7-37 - + elec 4. Voltage 8 connect the pocket tester (dc 20 v) to the horn connector at the pink terminal as shown. Positive tester probe j j j j j pink 1 1 1 1 1 negative tester probe j j j j j ground 8 set the main switch to “on”. 8 measure the voltage (dc 12 v) of pink 1 at the horn terminal. 8 i...

  • Page 326: Elec

    7-38 - + elec 2. Brake light switches 8 check the brake light switches for continu- ity. Refer to “checking the switches”. 8 is the brake light switch ok? Yes no replace the brake light switch. Signaling system eas00798 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket 8 ...

  • Page 327: Elec

    7-39 - + elec eas00799 3. The turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal indicator light bulb and socket 8 check the turn signal indicator light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” 8 are the turn signal indicator li...

  • Page 328: Elec

    7-40 - + elec 5. Voltage 8 connect the pocket tester (dc 20 v) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe j j j j j brown/white 1 1 1 1 1 negative tester probe j j j j j ground 8 set the main switch to “on”. 8 measure the voltage (dc 12 v) on brown/ white 1 ...

  • Page 329: Elec

    7-41 - + elec eas00804 4. The fuel level gauge fails to operate. 1. Fuel sender 8 remove the fuel pump from the fuel tank. 8 connect the pocket tester ( Ω × 1) to the fuel sender coupler (wire harness side) as shown. Positive tester probe j j j j j green 1 1 1 1 1 negative tester probe j j j j j bla...

  • Page 330: Elec

    7-42 - + elec 3. Fuel level gauge 8 set the main switch to “on”. 8 move the float up 1 or down 2. 8 check that the fuel level gauge needle moves to “f” or “e”. Tip before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes. 8 does the fuel lev...

  • Page 331: Trbl

    8-6 trbl shtg chapter 8 trouble shooting starting failure/hard starting................................................. 8-1 engine .............................................................................................. 8-1 fuel system ............................................................

  • Page 332: Trbl

    8-1 trbl shtg eas00844 troubleshooting tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts. ...

  • Page 333: Trbl

    8-2 trbl shtg incorrect engine idling speed/poor medium- and-high-speed performance eas00847 incorrect engine idling speed engine cylinder and cylinder head 8 incorrect valve clearance 8 damaged valve train components air filter 8 clogged air filter element fuel system throttle body 8 damaged or loo...

  • Page 334: Trbl

    8-3 trbl shtg faulty clutch/overheating eas00853 faulty clutch engine operates but scooter will not move v-belt 8 bent, damaged or worn v-belt 8 slipping v-belt primary pulley cam and primary pulley slider 8 damaged or worn primary pulley cam 8 damaged or worn primary pulley slider clutch spring(s) ...

  • Page 335: Trbl

    8-4 trbl shtg poor braking performance/faulty front fork legs/unstable handling eas00859 poor braking performance disc brake 8 worn brake pad 8 worn brake disc 8 air in hydraulic brake system 8 leaking brake fluid 8 faulty brake caliper kit 8 faulty brake caliper seal 8 loose union bolt 8 damaged br...

  • Page 336: Trbl

    8-5 trbl shtg faulty lighting or signaling system eas00866 faulty lighting or signaling system headlight does not come on 8 wrong headlight bulb 8 too many electrical accessories 8 hard charging 8 incorrect connection 8 improperly grounded circuit 8 poor contacts (main switch) 8 burnt-out headlight ...

  • Page 337: Yw125Y Wiring Diagram

    (black) (black) (red) (red) 10a 15a 10a main lock off on 20a off push horn hi lo l n r dimmer flasher 10a (black) (black) off on off run start e/g stop b (brown) (brown) (green) (green) (black) (black) (black) (black) (black) (black) (black) (black) (black) (black) (black) 4 6 7 8 9 q r t y u i # $ ...

  • Page 338

    Yamaha motor canada ltd. 480 gordon baker road toronto, on m2h 3b4.