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Yamaha VINO XC50V Service Manual

Other manuals for VINO XC50V: Owner's Manual

Summary of VINO XC50V

  • Page 1

    Xc50v service manual lit-11616-19-49 3d1-f8197-10

  • Page 2

    Eas00000 xc50v 2005 service manual ©2005 by yamaha motor taiwan co., ltd. First edition, july 2005 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor taiwan co., ltd. Is expressly prohibited. Lit-11616-19-49.

  • Page 3: Notice

    Eas00002 notice this manual was produced by the yamaha motor taiwan company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on...

  • Page 4

    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 divided int...

  • Page 5: Gen

    Gen info spec chk adj eng trbl shtg carb 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 o p a s d f g 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 ch...

  • Page 6: Table of Contents

    Eas00010 table of contents general information specifications periodic checks and adjustments chassis engine cooling carburetor electrical system troubleshooting - + gen info spec chk adj chas eng carb elec trbl shtg cool 1 2 3 4 5 6 5 7 8 9.

  • Page 7: Gen

    1-9 gen info chapter 1 general information scooter identification ................................................................... 1-1 vehicle identification number ............................................. 1-1 model label .........................................................................

  • Page 8: Gen

    1-1 gen info eas00015 general information scooter identification eas00017 vehicle identification number the vehicle identification number 1 is stamped into the steering head pipe. Eas00018 model label the model label 1 is affixed to the trunk. This information will be needed to order spare parts. Sc...

  • Page 9: Gen

    1-2 gen info 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, always keep mated parts ...

  • Page 10: Gen

    1-3 gen info 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 bearings and oil seals so...

  • Page 11: Gen

    1-4 gen info jas00021 notes 3 on equipment preparation push rivet (push type) assembly status of the push rivet (push type) dissembling 1. Press center pin 1 inward to release the lock. 2. Remove the push rivet main body 2. Assembling 1. Restore the center pin, replace the push rivet main body. 2. P...

  • Page 12: Gen

    1-5 gen info 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 disconnect several times. 3. Check...

  • Page 13: Gen

    1-6 gen info 41 46 eas00027 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers...

  • Page 14: Gen

    1-7 gen info tool no. Tool name / function illustration special tools 90890-01367 ym-a9409-7 90890-01400 ym-a9409-3 90890-01384 ym-33299 90890-01403 yu-a9472 90890-01701 ys-01880-a 90890-03079 ym-34483 90890-03081 yu-33223 90890-03132 yu-03112-c 90890-03113 yu-08036-c 90890-03141 yu-03141 fork seal ...

  • Page 15: Gen

    1-8 gen info tool no. Tool name / function illustration special tools 90890-04109 ym-04109 90890-04148 ym-04148 90890-04111 ym-04111 90890-04112 ym-04112 90890-04113 ym-04113 90890-06754 ym-34487 90890-85505 acc-11001-05-01 valve spring compressor compressor adapter(Ø16.5mm) these tools are used whe...

  • Page 16: Spec

    2-34 spec chapter 2 specifications general specifications ................................................................. 2-1 engine specifications ..................................................................... 2-2 chassis specifications ........................................................

  • Page 17: Spec

    2-1 spec specifications general specifications item standard limit general specifications model code 3d11 (for usa) … 3d12 (for can) … dimensions overall length 1665 mm( 65.6in ) … overall width 630 mm( 24.8in ) … overall height 1005 mm( 39.6in ) … seat height 715 mm( 28.2in ) … wheelbase 1160 mm( 4...

  • Page 18: Spec

    2-2 spec engine specifications item standard limit engine specifications -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚ sae 10w-30 sae 10w-40 sae 20w-40 sae 20w-50 engine engine type liquid-cooled, 4-stroke, sohc … displacement 0.049l(49cm 3 ) … cylinder arrangement forward inclined single cylinder … bore × strok...

  • Page 19: 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 0.15 mm or less 0.23mm outer rotor to pump housing clearance 0.13-0.18 mm 0.25mm oil pump housing to inner rotor and outer 0.07-0.12 mm...

  • Page 20: Spec

    2-4 spec item standard limit c a b c a b engine specifications camshaft drive system chain drive (left) … intake camshaft lobe dimensions measurement a 30.158~30.258 mm 30.058 mm measurement b 25.082~25.182 mm 24.982 mm measurement c 5.2077mm … exhaust camshaft lobe dimensions measurement a 30.158~3...

  • Page 21: 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 / 82 … tensioning system automatic … valve, valve seats, valve guides valve clearance (cold) intake 0.10~0.16 mm … exhaust 0.18~0.24 mm … ...

  • Page 22: Spec

    2-6 spec item standard limit engine specifications valve springs free length intake 39.35 mm 37.38 mm exhaust 41.57 mm 39.49 mm installed length (valve closed) intake 28.0mm … exhaust 30.0mm … compressed spring force (installed) intake 91.1~104.9n(9.3~10.7kg) … exhaust 107.9~124.1n … (11.0~12.7kg) s...

  • Page 23: Spec

    2-7 spec item standard limit h d t b b t engine specifications b t piston piston-to-cylinder clearance 0.010~0.035 mm 0.150mm diameter d 37.975~37.990 mm … height h 5.0 mm … piston pin bore (in the piston) diameter 10.002~10.013 mm 10.043 mm offset 0.35~0.65mm … offset direction intake side … piston...

  • Page 24: Spec

    2-8 spec item standard limit engine specifications rocker arm/rocker arm shaft rocker arm inside diameter 10.000~10.015mm … rocker arm shaft outside diameter 9.981~9.991 mm … arm-to-shaft clearance 0.009~0.034 mm … connecting rod connecting rod length 79.95~80.05 mm … small end inside diameter 10.01...

  • Page 25: Spec

    2-9 spec item standard limit engine specifications clutch clutch type automatic centrifugal … clutch shoe thickness 3.7 mm 2.0mm clutch shoe spring free length 30.1±0.4mm … clutch housing inside diameter 107 mm … compression spring free length 76.4 mm … weight outside diameter 15.0 mm 14.5 mm clutch...

  • Page 26: Spec

    2-10 spec chassis specifications chassis specifications item standard limit frame frame type steel tube underbone … caster angle 24 ° … trail 70 mm … front wheel wheel type cast wheel … rim size j10 × mt2.15 … material aluminum … wheel travel 59mm … wheel runout max. Radial wheel runout … 1.0 mm max...

  • Page 27: Spec

    2-11 spec item standard limit chassis specifications front brake brake type drum brake … operation right-hand operation … brake lever free play (at lever end) 10~20mm … brake drum inside diameter 110 mm 110.5mm lining thickness 4.0mm 2.0mm rear brake brake type drum brake … operation left-hand opera...

  • Page 28: Spec

    2-12 spec item standard limit electrical specifications electrical specifications system voltage 12v … ignition system ignition system type c.D.I. … ignition timing 13 ° b.T.D.C. At … 2000~2400 r/min advancer type digital … pickup coil resistance /color 248~372 Ω / wr-wl … c.D.I. Unit model (manufac...

  • Page 29: Spec

    2-13 spec electrical specifications item standard limit bulbs (voltage/wattage × quantity) headlight 12 v 35w/35w × 1 … tail/brake light 12 v 5w/21 w × 1 … front turn signal light 12 v 10 w × 2 … rear turn signal light 12 v 10 w × 2 … speedometer lighting 12 v 1.7 w × 2 … electric starting system sy...

  • Page 30: Spec

    2-14 spec item standard limit electrical specifications throttle position sensor output voltage (throttle opens) 2.8~3.4v … output voltage (throttle closes) 0.625~0.775v … radiator fan model (manufacturer) 5st-00 (luntai) … running rpm 10000 r/min … thermostat switch model (manufacturer) 5st (nippon...

  • Page 31: Spec

    2-15 spec eb201000 conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Conversion table eas00030 general tightening torque specifications this chart specifies tightening torques for stan- dard fas...

  • Page 32: Spec

    2-16 spec part to be tightened part name thread size q ’ ty tightening torque nm m•kg ft•lb remarks tightening torques nut - bolt - nut - bolt bolt bolt - bolt bolt plug bolt bolt bolt bolt - bolt bolt - bolt bolt nult nut screw bolt bolt bolt bolt bolt - - - - bolt bolt bolt bolt nut m6 m10 m6 m8 m...

  • Page 33: Spec

    2-17 spec cylinder head tightening sequence tightening torques part to be tightened part name thread size q ’ ty tightening torque nm m•kg ft•lb remarks clutch housing ignition coil thermo unit primary fixed sheave starter motor assembly ac magneto rotor stator coil pickup coil nut bolt - nut bolt n...

  • Page 34: Spec

    2-18 spec part to be tightened thread size tightening torque nm m•kg ft•lb remarks tightening torques chassis m10 m10 m10 m10 m6 m6 m8 bc bc1 m6 m6 m5 about m5 m6 m6 m6 m10 m14 m6 m8 m12 m10 m8 46 58 60 30 12 10 23 7 30 12 4 3 1.5 2 7 8 48 104 7 16 3 30 16 4.6 5.8 6.0 3.0 1.2 1.0 2.3 0.7 3.0 1.2 0.4...

  • Page 35: Spec

    2-19 spec lubrication point lubricant ls ls 4 m 4 4 4 4 4 4 4 4 4 4 4 m m m 4 lubrication points and lubricant types oil seal lips o-rings (except v-belt drive unit) cylinder head tightening nut mounting surface cylinder head stud bolt thread cylinder head gasket dowel pin crankshaft pin outside sur...

  • Page 36: Spec

    2-20 spec bel-ray asembly lube ® bel-ray asembly lube ® sealant lubrication point lubricant lubrication points and lubricant types secondary fixed sheave inner surface secondary sliding sheave torque cam ditch crankcase mating surfaces.

  • Page 37: Spec

    2-21 spec lubrication points and lubricant types lubrication point lubricant ls ls ls ls ls ls m ls eas00032 chassis front wheel oil seal lips steering bearing and bearing races (upper and lower) frame head pipe dust seal lips ( lower) tube guide (throttle grip) inner surface brake lever and lever h...

  • Page 38: Spec

    2-22 spec cooling system diagrams eas00033 cooling system diagrams 1 raidator cap 2 coolant reservoir 3 radiator inlet hose 4 radiator outlet hose 5 thermo switch 6 conduit hose 2 5 3 6 1 4.

  • Page 39: Spec

    2-23 spec 1 outlet hose(to cylinder) 2 radiator inlet hose 3 radiator outlet hose 4 thermostat 5 thermostat housing cooling system diagrams 2 5 4 3 1.

  • Page 40: Spec

    2-24 spec cooling system diagrams 1 breather hose 2 outlet hose(to cylinder) 3 radiator outlet hose 4 water pump 1 4 3 2.

  • Page 41: Spec

    2-25 spec cooling system diagrams 1 thermostat housing 2 thermostat assembly inlet breather hose 3 water pump 4 breather hose 1 2 3 4.

  • Page 42: Spec

    2-26 spec oil flow diagrams oil flow diagrams 1 oil filter 2 oil pump 3 to cylinder head 4 oil strainer 5 oil nozzle 6 camshaft.

  • Page 43: Spec

    2-27 spec 1 crankshaft pin 2 connecting rod big end bearing 3 oil nozzle 4 camshaft cylinder wall connecting rod big end bearing crankshaft pin crankcase sump oil filter oil pump oil nozzle camshaft rocker arm shaft and rocler arm centrifugal oil filter oil flow diagrams.

  • Page 44: Spec

    2-28 spec cable routing eas00035 cable routing 1 fuel sender lead 2 c.D.I. Unit 3 ai filter 4 starter motor lead 5 main switch 6 rectifier/regulator 7 overflow pipe 8 thermo unit 9 rear wheel lock cable 0 rear brake cable q throttle cable kit w seat lock cable e wire harness r hose t bend hose y vac...

  • Page 45: Spec

    2-29 spec cable routing 1 turn signal relay 2 horn 3 head light relay 4 speedometer cable 5 front brake cable 6 starter relay 7 ignition coil 8 throttle cable kit 9 rear wheel lock cable 0 air cut-off valve assembly q ai filter w holder e rectifier/regulator r clamp t frame y rear brake cable a fast...

  • Page 46: Spec

    2-30 spec cable routing m assemble the horn lead to the best forward of connec- tor cover, do not through back side of the other leads. N route the turn signal relay lead and front turn signal light lead(left) through backward of the steering head pipe. 1 3 2 4 5 6 7 8 w 9 0 q a b i h g f e d c 2 r ...

  • Page 47: Spec

    2-31 spec cable routing 1 battery negative - lead 2 battery positive + lead 3 fuse box 4 starter motor lead 5 ac magneto lead 6 fuel sender a insert the wire harness cable strap into the footrest bracket of hole. B route the wire harness through concave of the re- covery tank and clamp it. C insert ...

  • Page 48: Spec

    2-32 spec cable routing 1 front brake cable 2 front brake switch lead 3 speedometer assembly 4 speedometer cable 5 rear brake cable 6 rear brake switch lead 7 lever holder lead(left) 8 handlebar 9 lever holder lead(right) 0 lever holder(left) q grip(left) w throttle cable kit e speedometer assembly ...

  • Page 49: Spec

    2-33 spec cable routing h after spread with adhesion agent on the inner side, push the grip into the handlebar assembly. I allow the gain position to ar- rive at this range. J install the handlebar cover to the handlebar bracket, and tightening torque 4nm(0.4m•kg,2.9ft•lb). K to the headlight. L ins...

  • Page 50: Chk

    3-59 chk adj chapter 3 periodic checks and adjustments introduction ....................................................................................... 3-1 periodic maintenance and minor repair ................................ 3-2 periodic maintenance chart for the emission control system .........

  • Page 51: Chk

    3-60 chk adj checking the tires .................................................................. 3-44 checking the wheels.............................................................. 3-47 checking and lubricating the cables ............................ 3-47 lubricating the levers and pedals ........

  • Page 52: 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 53: Chk

    3-2 chk adj periodic maintenance and minor repair eau17560* periodic maintenance and minor repair periodic maintenance chart for the emission control system * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. No. Item routine initial odomet...

  • Page 54: Chk

    3-3 chk adj periodic maintenance and minor repair general maintenance and lubrication chart maintenance and lubrication, periodic no. Item routine initial odometer reading 600 mi (1,000 km) or 1 month 2,000 mi (4,000 km) or 6 months 4,000 mi (7,000 km) or 12 months 6,000 mi (10,000 km) or 18 months ...

  • Page 55: Chk

    3-4 chk adj periodic maintenance and minor repair * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Note: from 12000 mi ( 19000 km) or 36 months, repeat the maintenance intervals starting from 4000 mi (7000 km) or 12 months. Eau17680 note...

  • Page 56: Chk

    3-5 chk adj 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 damper rubber cap trunk rear carrier mat battery cover 23nm (2....

  • Page 57: Chk

    3-6 chk adj remarks order job/part q’ty 1 2 3 4 5 6 1 1 1 1 1 1 side cover (left and right) removing the side cover(left and right) seat/trunk tail / brake and rear turn signal (left, right) light lead front cover side cover(left) side cover(right) tail/brake light rear cover remove the parts in the...

  • Page 58: Chk

    3-7 chk adj footrest board and footrest board side cover mole remarks order job/part q’ty 1 2 3 4 5 6 7 1 1 1 1 1 1 1 removing the footrest board and footrest board side cover mole side cover(left and right) battery holder battery negative - lead battery positive + lead battery footrest board side c...

  • Page 59: Chk

    3-8 chk adj leg shield 1 , 2 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 1 1 removing the leg shield 1,2 footrest board cap headlight cover head and front turn signal (left, right) light lead leg shield 1 turn signal relay headlight relay rear wheel lock clip hook leg ...

  • Page 60: Chk

    3-9 chk adj adjusting the valve clearance eas00049 engine adjusting the valve clearance the following procedure applies to all of the valves. Note: 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 ...

  • Page 61: Chk

    3-10 chk adj adjusting the valve clearance d. Measure the valve clearance with a thick- ness gauge 1. Out of specification j adjust. ***************************************************** 6. Adjust: 8valve clearance ***************************************************** a. Remove the valve pad 2 with ...

  • Page 62: Chk

    3-11 chk adj adjusting the valve clearance example: original valve pad number = 148 (thickness =1.48 mm (0.058 in)) rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table. The point where the column and row inter...

  • Page 63: Chk

    3-12 chk adj adjusting the valve clearance valve clearance (cold) 0.10 ∼ 0.16 mm rounded value 175 measured valve clearance is 0.24 mm replace pad 175 with pad 185 pad no. 175 = 1.75 mm pad no. 185 = 1.85 mm always install the valve pad with the number facing down. Measured clearance original valve ...

  • Page 64: Chk

    3-13 chk adj adjusting the valve clearance 7. Install: 8all removed parts note: for installation, reverse the removal procedure. 8. Fill: 8cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant”..

  • Page 65: Chk

    3-14 chk adj adjusting the engine idling speed eas00054 adjusting the engine idling speed note: prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes. 2. Connec...

  • Page 66: Chk

    3-15 chk adj checking the exhaust gas at idle checking the exhaust gas at idle ( measuring the exhaust gas at idle(when air in- duction system is operation)) 1. Stand the scooter on a level surface. Note: 8 place the scooter on a suitable stand. 8 make sure the scooter is upright. 2. Install: 8pocke...

  • Page 67: Chk

    3-16 chk adj checking the exhaust gas at idle note: 8 since it is necessary to insert the sampling probe 600mm into the exhaust pipe, be sure to use a heat-resisant rubber tube as shown in the illustration. 8 be sure to set the heat-resistant rubber tube so that exhaust gas does not leak out. 8 befo...

  • Page 68: Chk

    3-17 chk adj adjusting the throttle cable free play eas00057 adjusting the throttle cable free play note: prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check: 8 throttle cable free play a out of specification j adjust. Throttle cable free pl...

  • Page 69: Chk

    3-18 chk adj checking the spark plug t r . . Eas00060 checking the spark plug 1. Remove: 8 battery cover 8 battery holder refer to “cover and panel”. 2. Disconnect: 8 spark plug cap 3. Remove: 8 spark plug c c before removing the spark plug, blow away any dirt accumulated in the spark plug well with...

  • Page 70: Chk

    3-19 chk adj checking the ignition timing eas00062 checking the ignition timing note: 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. Drain: 8coolant (completely from the radiator ) 2. Re...

  • Page 71: Chk

    3-20 chk adj checking the ignition timing note: the ignition timing is not adjustable. ***************************************************** 5. Remove: 8timing light 8engine tachometer 6. Install: 8fan case 8radiator 8radiator cover refer to “radiator”in chapter 6. 7. Fill: 8cooling system (with the...

  • Page 72: Chk

    3-21 chk adj measuring the compression pressure eas00067 measuring the compression pres- sure note: insufficient compression pressure will result in a loss of performance. 1. Measure: 8valve clearance out of specification j adjust refer to “adjusting the valve clearance”. 2. Start the engine, warm i...

  • Page 73: Chk

    3-22 chk adj measuring the compression pressure t r . . Compression pressure (at sea level) minimum 1262 kpa (12.6 kgf/cm 2 , 700r/min) standard 1450 kpa (14.5 kgf/cm 2 , 700r/min) maximum 1624 kpa (16.2 kgf/cm 2 , 700r/min) ***************************************************** a. Set the main switc...

  • Page 74: Chk

    3-23 chk adj checking the engine oil level eas00069 checking the engine oil level 1. Stand the scooter on a level surface. Note: 8 place the scooter on a suitable stand. 8 make sure the scooter is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Check: 8 engin...

  • Page 75: Chk

    3-24 chk adj changing the engine oil 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 with the gasket) 4. Drain: 8 ...

  • Page 76: Chk

    3-25 chk adj changing the engine oil 8. Install: 8engine oil filler cap 9. Start the engine, warm it up for several min- utes, and then turn it off. 10. Check: 8engine (for engine oil leaks) 11. Check: 8engine oil level refer to “checking the engine oil level”. 12. Check: 8engine oil pressure refer ...

  • Page 77: Chk

    3-26 chk adj changing the transmission oil 1. Stand the scooter on a level surface. Note: 8 stand the scooter on a suitable stand. 8 make sure that the scooter up right. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place a container under the transmission. Changing...

  • Page 78: Chk

    3-27 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, a...

  • Page 79: Chk

    3-28 chk adj measuring the engine oil pressure 6. Install: 8 gallery bolt 7 nm (0.7 m • kg, 5.1 ft • lb) 7. Install: 8 front cover 8 battery cover 8 seat/trunk refer to “cover and panel”. T r . ..

  • Page 80: Chk

    3-29 chk adj checking the air filter element eas00086 checking the air filter element 1. Remove: 8 air filter case cover 1 8 air filter element 2. Check: 8 air filter element damage/dirty j replace. 3. Install: 8air filter element 8air filter case cover 10 nm (1.0 m • kg, 7.2 ft • lb) c c never oper...

  • Page 81: Chk

    3-30 chk adj eas00094 checking the carburetor joint and intake manifold 1. Remove: 8 seat/trunk 8 rear carrier 8 battery cover 8 front cover 8 side cover (left and right) 8 rear cover refer to “cover and panel”. 2. Check: 8 carburetor joint 1 8 intake manifold 2 cracks/damage j replace. Refer to “ca...

  • Page 82: Chk

    3-31 chk adj checking the fuel hoses and fuel filter eas00097 checking the fuel hoses and fuel filter the following procedure applies to all of the fuel hoses. 1. Remove: 8battery cover 8seat/trunk 8rear carrier 8front cover 8side cover (left and right) 8rear cover refer to “cover and panel”. 2. Che...

  • Page 83: Chk

    3-32 chk adj eas00098 checking the crankcase breather hose 1. Remove: 8seat/trunk refer to “cover and panel”. Checking the crankcase breather hose 2. Check: 8crankcase breather hose 1 cracks/damage j replace. Loose connection j connect properly. C c make sure the crankcase breather hose is routed co...

  • Page 84: Chk

    3-33 chk adj checking the exhaust system t r . . Eas00099 checking the exhaust system the following procedure applies to all of the muffler assembly and gaskets. 1. Remove: 8 muffler assembly refer to “manifold, air filter and muffler assembly” in chapter 5. 2 . Check: 8 muffler assembly 1 cracks/da...

  • Page 85: Chk

    3-34 chk adj eas00103 checking the coolant level 1. Stand the scooter on a level surface. Note: 8 place the scooter on a suitable stand. 8 make sure the scooter is upright. 2. Remove: 8 mat 8 battery cover refer to “cover and panel”. 3. Check: 8 coolant level the coolant level should be between the ...

  • Page 86: Chk

    3-35 chk adj eas00104 checking the cooling system 1. Remove: 8 seat/trunk 8 battery cover 8 front cover 8 battery holder/ battery 8 footrest board side cover mole( left and right) 8 mat/footrest board refer to “cover and panel”. 8 radiator cover refer to “cooling system”in chap- ter 6. Checking the ...

  • Page 87: Chk

    3-36 chk adj eas00105 changing the coolant 1. Remove: 8 mat 8 battery cover 8 footrest board side cover mole (right) refer to “cover and panel”. 8 radiator cover refer to “cooling system”in chap- ter 6. 2. Disconnect: 8 coolant reservoir hose 1 3. Drain: 8 coolant (from the coolant reservoir) 8 cool...

  • Page 88: Chk

    3-37 chk adj changing the coolant 7. Fill: 8 cooling system (with the specified amount of the recom- mended coolant) recommended antifreeze high-quality ethylene glycol anti- freeze containing corrosion inhibi- tors for aluminum engines mixing ratio 1:1 (antifreeze:water) quantity total amount 0.52 ...

  • Page 89: Chk

    3-38 chk adj 9. Fill: 8 coolant reservoir (with the recommended coolant to the maximum level mark a) 10.Install: 8 coolant reservoir cap 11.Start the engine, warm it up for several min- utes, and then stop it. 12.Check: 8 coolant level refer to “checking the coolant level”. Note: before checking the...

  • Page 90: Chk

    3-39 chk adj adjusting the front brake/ adjusting the rear brake eas00109 chassis adjusting the front brake 1. Check: 8 brake lever free play a out of specification j adjust. Brake lever free play (at the end of the brake lever) 10 ~ 20 mm (0.394 ~ 0.787 in) 2. Adjust: 8 brake lever free play ******...

  • Page 91: Chk

    3-40 chk adj eas00127 checking the front and rear brake shoes 1. Operate the brake. 2. Check: 8 wear indicator 1 reaches the wear limit line 2 j replace the brake shoes as a set. Refer to “front wheel and front brake” and “rear wheel and rear brake” in chapter 4. A front brake b rear brake checking ...

  • Page 92: Chk

    3-41 chk adj checking and adjusting the steering head eas00148 checking and adjusting the steer- ing head 1. Stand the scooter on a level surface. W securely support the scooter so that there is no danger of it falling over. Note: place the scooter on a suitable stand so that the front wheel is elev...

  • Page 93: Chk

    3-42 chk adj checking and adjusting the steering head t r . . T r . . W do not overtighten the upper bearing inner race. Upper bearing inner race(final tight- ening torque) 7 nm (0.7 m • kg, 5.1 ft • lb) d. Check the steering head for looseness or binding by turning the front fork all the way in bot...

  • Page 94: Chk

    3-43 chk adj checking the front fork eas00151 checking the front fork 1. Stand the scooter on a level surface. W securely support the scooter so that there is no danger of it falling over. 2. Check: 8inner tube damage/scratches j replace. 8dust seal damage/scratches j replace. 3. Hold the scooter up...

  • Page 95: Chk

    3-44 chk adj basic weight (with oil and a full fuel tank) maximum load* cold tire pressure front rear up to 55 kg 55 kg ~ 158 kg 81 kg (179 lb) 158 kg (348 lb) 150 kpa (1.5 kgf/cm 2 , 22 psi) 150 kpa (1.5 kgf/cm 2 , 22 psi) 175 kpa (1.75 kgf/cm 2 , 25 psi) 175 kpa (1.75 kgf/cm 2 , 25 psi) checking t...

  • Page 96: Chk

    3-45 chk adj checking the tires 2. Check: 8tire surfaces damage/wear j replace the tire. Minimum tire tread depth 0.8 mm (0.032 in) 1 tire tread depth 2 sidewall 3 wear indicator w 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 injury ...

  • Page 97: Chk

    3-46 chk adj checking the tires w new tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. Note: for tires with a direction of rotation mark 1: 8 install the t...

  • Page 98: Chk

    3-47 chk adj checking the wheels/ checking and lubricating the cables eas00168 checking the wheels the following procedure applies to both of the wheels. 1. Check: 8wheel damage/out-of-round j replace. W never attempt to make any repairs to the wheel. Note: after a tire or wheel has been changed or ...

  • Page 99: Chk

    3-48 chk adj eas00171 lubricating the levers and pedals lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant lithium-soap-based grease lubricating the levers and pedals/ lubricating the centerstand eas00173 lubricating the centerstand lubricate...

  • Page 100: Chk

    3-49 chk adj checking and charging the battery eas00179 electrical system checking and charging the battery w 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 8 8 w...

  • Page 101: Chk

    3-50 chk adj note: since mf batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the bat- tery terminals. 1. Remove: 8 mat 8 battery...

  • Page 102: Chk

    3-51 chk adj 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 the battery = 20 ~ 30% ***************************************************** 5. Charge: 8 battery (refer to the approp...

  • Page 103: Chk

    3-52 chk adj 8 8 8 8 8 make sure the battery charger lead clips are in full contact with the battery ter- minal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. 8 8 8 8 8 if the battery becomes hot to t...

  • Page 104: Chk

    3-53 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 note: ...

  • Page 105: Chk

    3-54 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 106: Chk

    3-55 chk adj 6. Install: 8 battery 7. Connect: 8 battery leads (to the battery terminals) c c 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. Loose connection j connect properly. 9. Lubric...

  • Page 107: Chk

    3-56 chk adj checking the fuse 2. Check: 8 fuse ***************************************************** a. Connect the pocket tester to the fuse and check the continuity. Note: set the pocket tester selector to “ Ω × 1”. Pocket tester 90890-03132 (yu-03112-c) b. If the pocket tester indicates “ ∞”, re...

  • Page 108: Chk

    3-57 chk adj replacing the headlight bulb eas00182 replacing the headlight bulb 1. Remove: 8 headlight cover 2. Disconnect: 8 headlight coupler 3. Remove: 8 headlight bulb holder rubber1 8 headlight bulb holder 8 headlight bulb 2 w since the headlight bulb gets extremely hot, keep flammable products...

  • Page 109: Chk

    3-58 chk adj adjusting the headlight beam eas00184 adjusting the headlight beam 1. Adjust: 8headlight beam (vertically) ***************************************************** a. Turn the adjusting screw 1 in direction a or b . Direction a headlight beam is raised. Direction b headlight beam is lowere...

  • Page 110: Chas

    Chas 4-37 chapter 4 chassis front wheel and brake ................................................................. 4-1 front wheel ................................................................................. 4-2 front brake shoe plate ......................................................... 4...

  • Page 111: Chas

    Chas 4-38 removing the rear shock absorber assembly .......... 4-35 checking the rear shock absorber assembly .......... 4-35 installing the rear shock absorber assembly ........ 4-36.

  • Page 112: Chas

    Chas 4-1 remarks order job/part q’ty front wheel and brake removing the front wheel and brake stop ring speedometer cable adjuster front brake cable pin wheel axle nut wheel axle front brake shoe plate collar front wheel 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 1 1 1 remove the parts in the order listed. ...

  • Page 113: Chas

    Chas 4-2 remarks order job/part q’ty 1 1 1 1 eas00518 front wheel front wheel and brake disassembling the front wheel oil seal bearing spacer bearing 1 2 3 4 remove the parts in the order listed. Refer to”removing the front wheel” and “installing the front wheel” for assembly, reverse the disassembl...

  • Page 114: Chas

    Chas 4-3 remarks order job/part q’ty 1 2 1 1 1 1/1 1 1 1 1 1 1 1 1 1 1 1 front brake shoe plate front wheel and brake disassembling the front brake shoe plate brake shoe kit tension spring comshaft lever indicator plate return spring brake camshaft / o-ring oil seal oil seal circlip plate washer spe...

  • Page 115: Chas

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

  • Page 116: Chas

    Chas 4-5 front wheel and brake eas00525 checking the front wheel 1. Check: 8 wheel axle roll the wheel axle on a flat surface. Bends j replace. W do not attempt to straighten a bent wheel axle. 2. Check: 8 tire 8 front wheel damage/wear j replace. Refer to “checking the tires” and “checking the whee...

  • Page 117: Chas

    Chas 4-6 a. Clean the outside of the front wheel hub. B. Remove the oil seal 1 with a flat-head screwdriver. Note: to prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. C. Remove the wheel bearings 4 with a gen- eral bearing puller3. D. Install the new wheel bea...

  • Page 118: Chas

    Chas 4-7 eas00536 checking the brake the following procedure applies to all of the brake shoes. 1. Check: 8 brake shoe lining glazed areas j repair. Sand the glazed areas with course sand- paper. Note: after sanding the glazed areas, clean the brake shoe with a cloth. 2. Measure: 8 brake shoe lining...

  • Page 119: Chas

    Chas 4-8 4. Check: 8 brake drum inner surface oil deposits j clean. Remove the oil with a rag soaked in lac- quer thinner or solvent. Scratches j repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: 8brake camshaft damage/wear j replace. Eas00537 assembling the brake shoe p...

  • Page 120: Chas

    Chas 4-9 front wheel and brake eas00538 assembling the front wheel 1. Install: 8 wheel bearing(right)1 new 8 oil seal new 8 spacer 8 wheel bearing(left) new ***************************************************** a. Install the new wheel bearings and oil seal in the reverse order of disassembly. C c d...

  • Page 121: Chas

    Chas 4-10 front wheel and brake t r . . Eas00540 installing the front wheel 1. Lubricate: 8 wheel axle 8 wheel bearings 8 oil seal lips 8 speedometer drive gear 8 speedometer gear recommended lubricant lithium-soap-based grease 2. Install: 8front wheel1 note: make sure the slot2 in the brake shoe pl...

  • Page 122: Chas

    Chas 4-11 x 1 x 2 front wheel and brake eas00548 adjusting the front wheel static balance note: 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. F...

  • Page 123: Chas

    Chas 4-12 front wheel and brake 3. Adjust: 8 front wheel static balance ***************************************************** a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “x”. Note: start with the lightest weight. B. Turn the front wheel 90° so that the heavy spot is ...

  • Page 124: Chas

    Chas 4-13 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 2 1 1 1 1 1/2 removing the rear wheel muffler assembly self lock nut/plate washer brake adjuster rear brake cable pin rear wheel brake shoe kit tension spring plate washer camshaft lever indicator plate return spring brak...

  • Page 125: Chas

    Chas 4-14 eas00564 removing the rear wheel 1. Stand the scooter on a level surface. W securely support the scooter so that there is no danger of it falling over. Note: place the scooter on a suitable stand so that the rear wheel is elevated. 2. Remove: 8brake adjuster 3. Remove: 8muffler assembly 8w...

  • Page 126: Chas

    Chas 4-15 rear wheel and brake eas00565 checking the rear wheel 1. Check: 8 tire 8 rear wheel damage/wear j replace. Refer to “checking the tires” and “checking the wheels” in chapter 3. 2. Measure: 8 radial wheel runout 8 lateral wheel runout refer to “checking the front wheel”. Eas00567 checking t...

  • Page 127: Chas

    Chas 4-16 rear wheel and brake eas00569 checking the brake the following procedure applies to all of the brake shoes. 1. Check: 8 brake shoe lining glazed areas j repair. Sand the glazed areas with course sand- paper. Note: after sanding the glazed areas, clean the brake shoe with a cloth. 2. Measur...

  • Page 128: Chas

    Chas 4-17 rear wheel and brake eas00570 assembling the brake shoe plate 1. Install: 8 brake camshaft 1 7 nm (0.7 m • kg, 5.1 ft • lb) 8 return spring 2 8 brake shoe wear indicator 3 ***************************************************** a. Install the brake camshaft 1 so its punch mark a is positione...

  • Page 129: Chas

    Chas 4-18 rear wheel and brake eas00574 installing the rear wheel 1. Lubricate: 8 wheel axle recommended lubricant lithium-soap-based grease 2. Install: 8 rear wheel eas00575 adjusting the rear wheel static balance note: 8 after replacing the tire, wheel or both, the rear wheel static balance should...

  • Page 130: Chas

    Chas 4-19 remarks order job/part q’ty 1 2 3 4 1 1 1 1 removing the front fork legs front wheel handlebar front fork assembly headlight cover leg shield 1 lower bracket pinch bolt snap ring inner tube plug front fork leg remove the parts in the order listed. Refer to “front wheel and brake”. Refer to...

  • Page 131: Chas

    Chas 4-20 remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 0 1 1 1 1 1 1 1 1 1 1 disassembling the front fork legs band boot dust seal circlip spring guide rebound spring inner tube damper rubber fork spring outer tube remove the parts in the order listed. Refer to “disassembling and in- stalling the f...

  • Page 132: Chas

    Chas 4-21 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. W securely support the scooter so that there is no danger of it falling over. Note: place the scooter on a suitable stand so that the fr...

  • Page 133: Chas

    Chas 4-22 front fork 3. Remove: 8 damper rubber 1 8 fork spring 2 8 outer tube 3 eas00656 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: 8 inner tube 8 outer tube bends/damage/scratches j replace. W do not attempt to straighten a bent inner tub...

  • Page 134: Chas

    Chas 4-23 front fork eas00658 assembling the front fork legs the following procedure applies to both of the front fork legs. Note: 8 when assembling the front fork leg, be sure to replace the following parts: - dust seal - circlip 8 before assembling the front fork leg, make sure all of the componen...

  • Page 135: Chas

    Chas 4-24 front fork t r . . Eas00663 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: 8front fork leg 1 8snap ring 2 new 8inner tube plug 8lower bracket pinch bolt 3 note: pull up the inner tube until it stops, then install the snap ring to ...

  • Page 136: Chas

    Chas 4-25 remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 1 1 1/1 1 1 1 1 1 1 1 1 1 1 eas00664 handlebar removing the handlebar headlight cover leg shield 1 clamp speedometer cable speedometer assembly rear view mirror(left and right) front brake cable front brake switch brake lever (...

  • Page 137: Chas

    Chas 4-26 handlebar for installation, reverse the removal pro- cedure. Remarks order job/part q’ty 2 9 5 6 7 10 17 4 12 11 13 15 14 4 16 3 8 1 60nm (6.0 m•kg, 43.4 ft•lb) ls ls ls ls 1 1 1 handlebar grip handlebar upper cover handlebar assembly 15 16 17.

  • Page 138: Chas

    Chas 4-27 handlebar eas00666 removing the handlebar 1. Stand the scooter on a level surface. W securely support the scooter so that there is no danger of it falling over. 2. Remove: 8handlebar holder assembly (right)1 8throttle grip assembly 2 note: while removing the handlebar holder assembly (righ...

  • Page 139: Chas

    Chas 4-28 handlebar t r . . Eas00673 installing the handlebar 1. Stand the scooter on a level surface. W securely support the scooter so that there is no danger of it falling over. 2. Install: 8handlebar 1 note: align the slot a on the handlebar with the steer- ing shaft 2 surface. 3. Tighten: 8hand...

  • Page 140: Chas

    Chas 4-29 handlebar note: 8 lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar4. 8 align the projectiona on the right handle- bar holder assembly with the hole b on the handlebar. W make sure the throttle grip operates smoothly. ...

  • Page 141: Chas

    Chas 4-30 remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 11 12 removing the front fork assembly front wheel leg shield 1 handlebar assembly front fender inner fender cable holder ball race cover ring nut upper bearing inner race front fork assembly upper bearing lower bearing upper bearing outer r...

  • Page 142: Chas

    Chas 4-31 steering head eas00678 removing the front fork assembly 1. Stand the scooter on a level surface. W securely support the scooter so that there is no danger of it falling over. Note: place the scooter on a suitable stand so that the front wheel is elevated. 2 . Remove: 8ball race cover 8ring...

  • Page 143: Chas

    Chas 4-32 steering head eas00682 checking the steering head 1. Wash: 8bearing balls 8bearing races recommended cleaning solvent kerosene 2. Check: 8bearing balls 1 8bearing races 2 damage/pitting j replace. 3. Replace: 8bearing balls 8bearing races ***************************************************...

  • Page 144: Chas

    Chas 4-33 steering head eas00684 installing the steering head 1. Lubricate: 8 bearing balls 1 8 bearing races recommended lubricant lithium-soap-based grease 2. Install: 8 front fork assembly 1 8 upper bearing inner race 2 7 nm (0.7 m • kg, 5.1 ft • lb) (with the ring nut wrench 3) t r . . 3. Instal...

  • Page 145: Chas

    Chas 4-34 remarks order job/part q’ty 1 2 3 4 1 1 1 1 eas00685 rear shock absorber assembly removing the rear shock absorber assembly rear shock absorber assembly upper nut rear shock absorber assembly upper bolt rear shock absorber assembly lower bolt rear shock absorber assembly remove the parts i...

  • Page 146: Chas

    Chas 4-35 eas00692 removing the rear shock absorber assembly 1. Stand the scooter on a level surface. W securely support the scooter so that there is no danger of it falling over. Note: place the scooter on a suitable stand so that the rear wheel is elevated. 2. Remove: 8 rear shock absorber nut (up...

  • Page 147: Chas

    Chas 4-36 eas00698 installing the rear shock absorber assembly 1. Lubricate: 8 spacer 8 bush recommended lubricant molybdenum disulfide grease 2. Install: 8 rear shock absorber assembly 3. Tighten: 8 rear shock absorber assembly upper nut 30 nm (3.0 m • kg, 21.7 ft • lb) 8 rear shock absorber assemb...

  • Page 148: Eng

    Eng 5-66 chapter 5 engine engine ..................................................................................................... 5-1 leads, hoses and rear brake ............................................... 5-1 manifold, air filter and muffler assembly ................... 5-3 installing the ...

  • Page 149: Eng

    Eng 5-67 checking the v-belt ................................................................. 5-40 checking the primary sheave ............................................ 5-40 checking the primary sheave weights .......................... 5-41 checking the slider .....................................

  • Page 150: Eng

    5-1 eng removing the leads, hoses and rear brake seat/trunk/rear carrier battery cover/battery holder battery/front cover side cover(left and right)/rear cover footrest board side cover mole (left and right) mat/footrest board coolant radiator thermostat housing water pump assembly carburetor thermo...

  • Page 151: Eng

    5-2 eng engine remarks order job/part q’ty ac magneto lead starting motor lead/earth lead ignition primary coil lead vacuum hose(to air cut-off valve) hose(to air cut-off valve) vacuum hose(to fuel cock) rear brake cable/adjuster/pin kickstarter rear wheel lock cable cover rear wheel lock cable rear...

  • Page 152: Eng

    5-3 eng remarks order job/part q’ty 1 2 3 4 5 6 7 1/1 1 1 1/1 1 1 1/1 manifold, air filter and muffler assembly removing the manifold, air filter and muffler assembly rear brake cable(adjuster/pin) rear wheel lock cable hose(to air cut-off valve) vacuum hose(to air cut-off valve) vacuum hose(to fuel...

  • Page 153: Eng

    Eng 5-4 engine t r . . Eas00192 installing the engine 1. Install: 8engine 1 8engine mounting bolt 2 8self lock nut3 note: do not fully tighten the bolts. 2. Tighten: 8self lock nut 46nm(4.6 m • kg, 33.3 ft • lb) 1 2 3 1 t r . . 3. Tighten: 8rear shock absorber assembly lower bolt1 16 nm (1.6 m • kg,...

  • Page 154: Eng

    5-5 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 1 1 1 1 2 4 1 1 1 2 removing the cylinder head muffler assembly air filter assembly/breather hose manifold/o-ring thermostat unit spark plug cylinder head cover o-ring timing chain tensioner assembly timing chain tensioner gaske...

  • Page 155: Eng

    Eng 5-6 cylinder head eas00225 removing the cylinder head 1. Remove : 8 crankcase cover (left) refer to “ belt drive”. 8 cylinder head cover 2. Align: 8 “i” mark a on the magneto rotor (with the stationary pointer b on the crankcase cover) ***************************************************** a. Tur...

  • Page 156: Eng

    Eng 5-7 cylinder head 4. Remove: 8 timing chain tensioner (along with the gasket) 8 camshaft sprocket 1 8 timing chain 2 note: to prevent the timing chain from falling into the crankcase, fasten it with a wire. 5. Remove: 8 cylinder head note: 8 loosen the nuts in the proper sequence as shown. 8 loo...

  • Page 157: Eng

    Eng 5-8 cylinder head eas00227 checking the cylinder head 1. Eliminate: 8 combustion chamber carbon deposits (with a rounded scraper) note: 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. 3....

  • Page 158: Eng

    Eng 5-9 eas00231 installing the cylinder head 1. Install: 8 gasket new 8 dowel pins 2. Install: 8 cylinder head 3. Tighten: 8 cylinder head nuts 10 nm (1.0 m • kg, 7.2 ft • lb) 8 cylinder head bolts 10 nm (1.0 m • kg, 7.2 ft • lb) note: 8 lubricate the cylinder head nuts with en- gine oil. 8 tighten...

  • Page 159: Eng

    Eng 5-10 c c do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. E. While holding the camshaft, temporarily tighten the camshaft sprocket bolt. F. Remove the wire from the timing chain. ***************************************************** 5. Install 8ca...

  • Page 160: Eng

    Eng 5-11 7. Turn: 8crankshaft (several turns counterclockwise) 8. Check: 8“i” mark a align the “i” mark on the ac magneto ro- tor with the stationary pointer b on the crankcase cover. 8“i” mark c align the “i” mark on the camshaft sprocket with the stationary pointer d on the plate. Out of alignment...

  • Page 161: Eng

    5-12 eng remarks order job/part q’ty 1 2 3 4 5 6 the rocker arms and camshaft removing the rocker arms and cam- shaft cylinder head camshaft rocker arm shaft(intake) rocker arm shaft(exhaust) rocker arm(intake) rocker arm(exhaust) spring 1 1 1 1 1 2 remove the parts in the order listed. Refer to “cy...

  • Page 162: Eng

    Eng 5-13 the rocker arms and camshaft eas00202 removing the rocker arms and cam- shaft 1. Remove: 8camshaft 1 2. Remove: 8intake rocker arm shaft 8exhaust rocker arm shaft 8intake rocker arm 8exhaust rocker arm note: remove the rocker arm shafts with the clip plier1 . Eas00205 checking the camshaft ...

  • Page 163: Eng

    Eng 5-14 the rocker arms and camshaft camshaft lobe dimension limit intake a a a a a 30.158~30.258 mm (1.187~1.191 in) :30.058mm b b b b b 25.082~25.182 mm (0.987~0.991 in) :24.982mm exhaust a a a a a 30.158~30.258 mm (1.187~1.191 in) :30.058mm b b b b b 25.020~25.120 mm (0.985~0.989 in) :24.920mm 4...

  • Page 164: Eng

    Eng 5-15 the rocker arms and camshaft 4. Measure: 8rocker arm inside diameter a out of specification j replace. Rocker arm inside diameter 10 ~ 10.015 mm (0.393 ~ 0.394 in) 5. Measure: 8rocker arm shaft outside diameter a out of specification j replace. Rocker arm shaft outside diameter 9.981 ~ 9.99...

  • Page 165: Eng

    Eng 5-16 eas00208 checking the timing chain, camshaft sprockets, and timing chain guides the following procedure applies to all of the cam- shaft sprockets and timing chain guides. 1. Check: 8 timing chain damage/stiffness j replace the timing chain and camshaft sprockets as a set. 2. Check: 8 camsh...

  • Page 166: Eng

    Eng 5-17 eas00220 installing the camshaft and rocker arms 1. Lubricate: 8 camshaft 1 recommended lubricant camshaft molybdenum disulfide oil camshaft bearing engine oil 2. Lubricate: 8 rocker arm shafts recommended lubricant molybdenum disulfide oil 3. Install: 8 exhaust rocker arm 1 8 spring 2 8 ex...

  • Page 167: Eng

    5-18 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 3 6 3 3 2 1 3 3 3 eas00236 valves and valve springs removing the valves and valve springs cylinder head rocker arm and rocker arm shaft valve pad valve cotter valve spring retainer valve spring valve(intake) valve(exhaust) valve stem seal valve ...

  • Page 168: Eng

    Eng 5-19 eas00237 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: 8 valve sealing leakage at the ...

  • Page 169: Eng

    Eng 5-20 4. Remove: 8valve spring retainer 1 8valve spring 2 8valve stem seal 3 8valve spring seat 4 8valve 5 note: identify the position of each part very carefully so that it can be reinstalled in its original place. Valves and valve springs eas00239 checking the valves and valv e guides the follo...

  • Page 170: Eng

    Eng 5-21 valves and valve springs note: after replacing the valve guide, reface the valve seat. Valve guide remover (4.0 mm) 90890-04111(ym-04111) valve guide installer (4.0 mm) 90890-04112(ym-04112) valve guide reamer (4.0 mm) 90890-04113(ym-04113) **************************************************...

  • Page 171: Eng

    Eng 5-22 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 172: Eng

    Eng 5-23 a. Apply a coarse lapping compound a to the valve face. C c do not let the lapping compound enter the gap between the valve stem and the valve guide. B. Apply molybdenum disulfide oil onto the valve stem. C. Install the valve into the cylinder head. D. Turn the valve until the valve face an...

  • Page 173: Eng

    Eng 5-24 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 intake valve spring 39.35 mm (1.549 in) : 37.38 mm (1.472 in) exhaust valve spr...

  • Page 174: Eng

    Eng 5-25 eas00245 installing the valves the following procedure applies to all of the valves and related components. 1. Deburr: 8valve stem end (with an oil stone) 2. Lubricate: 8valve stem 1 8valve stem seal 2 (with the recommended lubricant) recommended lubricant molybdenum disulfide oil 3. Instal...

  • Page 175: Eng

    Eng 5-26 valve spring compressor 90890-04109(ym-04109) valve spring compressor attach- ment 90890-04148(ym-04148) 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. C c hitting the valve tip with excessive force could damage the valve. Valves and ...

  • Page 176: Eng

    5-27 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 eas00251 cylinder and piston removing the cylinder and piston cylinder head timing chain guide(exhaust side) cylinder case cap reed valve assembly dowel pin cylinder gasket piston pin clip piston pin piston piston ring set remove the parts in...

  • Page 177: Eng

    Eng 5-28 eas00253 removing the cylinder and piston 1. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 3 c c do not use a hammer to drive the piston pin out. Note: 8 before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into ...

  • Page 178: Eng

    Eng 5-29 cylinder and piston eas00261 checking the cylinder and piston 1. Check: 8 piston wall 8 cylinder wall vertical scratches j replace the cylin- der, and the piston and piston rings as a set. 2. Measure: 8piston-to-cylinder clearance ***************************************************** a. Ple...

  • Page 179: Eng

    Eng 5-30 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. Note: before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring ...

  • Page 180: Eng

    Eng 5-31 eas00265 checking the piston pin 1. Check: 8 piston pin blue discoloration/grooves j replace the piston pin and then check the lubrication system. 2. Measure: 8 piston pin outside diameter a out of specification j replace the pis- ton pin. Piston pin outside diameter 9.996 ~ 10.000 mm (0.39...

  • Page 181: Eng

    Eng 5-32 cylinder and piston eas00267 installing the piston and cylinder 1. Install: 8 oil ring expander 1 8 oil ring rail 2 8 2nd ring 3 8 top ring 4 note: be sure to install the piston rings so that the manufacturer’s marks or numbers face up. 2. Install: 8 piston 1 8 piston pin 2 8 piston pin cli...

  • Page 182: Eng

    Eng 5-33 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 exhaust side 6. ...

  • Page 183: Eng

    5-34 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 11 12 1 1 2 1 1 1/1 1 1 1 1 1 1 eas00316 belt drive crankcase cover (left) removing the crankcase cover (left) kickstarter rear wheel lock cable cover rear wheel lock cable crankcase cover(left) crankcase cover gasket(left) dowel pin kick pin...

  • Page 184: Eng

    Eng 5-35 belt drive eas00340 installing the kickstarter 1. Install: 8 solid bush1 8 kick shaft assembly2 8 torsion spring3 2. Hook: 8 kickstarter spring note: hook the spring end a on the kickstarter shaft b as shown, and hook the other end c on the projection d . 3. Install: 8 plain washer 8 circli...

  • Page 185: Eng

    5-36 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 1/6 3 1 remove the parts in the order listed. Refer to “ removing and install- ing the secondary sheave “ refer to “ removing and install- ing the primary sheave “ for installation, reverse the removal pro- cedure. R...

  • Page 186: Eng

    5-37 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 0 1 1 2 1 1 2 1 2 2 1 disassemble the parts in the order listed. Refer to “ removing and install- ing the secondary sheave “ . For installation, reverse the removal pro- cedure. Disassembling the secondary sheave assembly clutch carrier nut clut...

  • Page 187: Eng

    Eng 5-38 belt drive eas00318 removing the secondary sheave and v-belt 1. Remove: 8 secondary sheave nut 1 8 clutch housing 2 note: while holding the clutch housing with the sheave holder 3, loosen the secondary sheave nut. Sheave holder: 90890-01701 (ys-01880-a) 2. Loosen: 8 clutch carrier nut 1 c c...

  • Page 188: Eng

    Eng 5-39 belt drive eas00319 disassembling the secondary sheave 1. Remove: 8 clutch carrier nut 1 note: install the clutch spring holder 2 and clutch spring holder arm 3 onto the secondary sheave as shown. Then, compress the spring, and re- move the clutch carrier nut 1. Clutch spring holder 90890-0...

  • Page 189: Eng

    Eng 5-40 belt drive eas00320 checking the v-belt 1. Check: 8 v-belt 1 cracks/damage/wear j replace. Grease/oil j clean the primary and sec- ondary sheave. 2. Measure: 8 v-belt width a out of specification j replace. V-belt width 16.8 mm (0.0661 in) : 15.8 mm (0.622 in) checking the primary sheave 1....

  • Page 190: Eng

    Eng 5-41 eas00321 checking the primary sheave weights the following procedure applies to all of the pri- mary sheave weights. 1. Check: 8 primary sheave weight cracks/damage/wear j replace. 2. Measure: 8 primary sheave weight outside diameter a out of specification j replace. Primary sheave weight o...

  • Page 191: Eng

    Eng 5-42 belt drive eas00323 assembling the primary sheave 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 note: use thinner to clean up grease, dirt on the pri- mary sliding sheave cam side 5. 2. Install: 8primary sliding sheave 1 8primary sheave weig...

  • Page 192: Eng

    Eng 5-43 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 note:...

  • Page 193: Eng

    Eng 5-44 5. Install: 8 secondary sheave 1 8 spring 8 clutch carrier 2 note: attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch carrier nut 5. Clutch spring holder 90890-01337 (ym-33285) ( ym-33285-6) ...

  • Page 194: Eng

    Eng 5-45 belt drive t r . . 3. Install: 8 clutch housing 1 8 secondary sheave nut2 40 nm (4.0 m • kg, 28.9 ft • lb) note: tighten the secondary sheave nut with the sheave holder 3. Sheave holder 90890-01701 (ys-01880-a) 4. Install: 8primary fixed sheave 1 8primary sheave nut 2 30 nm (3.0 m• kg, 21.7...

  • Page 195: Eng

    5-46 eng remarks order job/part q’ty 1 2 3 4 5 1 1/1 1/1 1 1 remove the parts in the order listed. Drain. Refer to “changing the coolant”in chapter 3. Refer to “radiator”in chapter 6. Refer to “cover and panel”in chap- ter 3. Disconnect. Removing the stator coil assembly coolant radiator seat/trunk/...

  • Page 196: Eng

    5-47 eng remarks order job/part q’ty for installation, reverse the removal pro- cedure. Starter clutch and ac magneto 43nm (4.3 m•kg, 31.1 ft•lb) 3 4 6 8 7 1 5 7nm (0.7 m•kg, 5.1 ft•lb) 7nm (0.7 m•kg, 5.1 ft•lb) 9nm (0.9 m•kg, 6.5 ft•lb) 4nm (0.4 m•kg, 2.9 ft•lb) lt 2 6 7 8 lock plate pick up coil s...

  • Page 197: Eng

    5-48 eng remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 11 1 1 2 1 1 1 1 1 1 1 1 new image eas00342 starter clutch removing the starter clutch engine oil ac magneto rotor stator coil assembly crankcase cover(right) gasket dowel pin starter clutch nut washer starter wheel gear roller collar starter...

  • Page 198: Eng

    Eng 5-49 eas00347 removing the ac magneto 1. Remove: 8 ac magneto rotor nut1 8 washer note: 8 while holding the ac magneto rotor 2 with the sheave holder 3, loosen the ac mag- neto rotor nut. 8 do not allow the sheave holder to touch the projection on the ac magneto rotor. Sheave holder 90890-01701 ...

  • Page 199: Eng

    Eng 5-50 eas00344 removing the starter clutch 1. Remove: 8crankcase cover (right)1 note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: 8starter clutch nut1 8washer 8starter wheel gear 8roller 8colla...

  • Page 200: Eng

    Eng 5-51 eas00351 checking the starter clutch 1. Check: 8starter clutch roller 1 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 replac...

  • Page 201: Eng

    Eng 5-52 starter clutch and ac magneto 2. Install: 8 gasket new 8 crankcase cover (right)1 10 nm (1.0 m • kg, 7.2 ft • lb) t r . . T r . . Eas00354 installing the ac magneto 1. Install: 8stator coil assembly1 8pick up coil2 8woodruff key3 8ac magneto rotor 8washer 8ac magneto rotor nut note: 8 clean...

  • Page 202: Eng

    Eng 5-53 2. Tighten: 8ac magneto rotor nut 1 43 nm (4.3 m • kg, 31.1 ft • lb) note: 8 while holding the ac magneto rotor 3with the sheave holder 2, tighten the ac mag- neto rotor nut. 8 do not allow the sheave holder to touch the projection on the ac magneto rotor. Sheave holder 90890-01701 ys-01880...

  • Page 203: Eng

    5-54 eng eas00360 oil pump remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 1 1/1 1 2 1 1 1 1 1 1 disassembling the oil pump radiator ac magneto starter clutch drive gear circlip/plate washer oil pump driven gear dowel pin oil pump housing oil pump shaft inner rotor outer rotor oil pump housing cove...

  • Page 204: Eng

    Eng 5-55 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 clear- ance b 8 ...

  • Page 205: Eng

    Eng 5-56 oil pump t r . . 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 2. Install: 8 oil pump shaft 1 (to the oil pump housing2) 8 pin 3 8 inner rotor 4 8 outer rotor5 8 oil pump housing ...

  • Page 206: Eng

    5-57 eng remarks order job/part q’ty 1 2 3 4 5 6 7 1 1 1 2 1 1 1 removing the transmission transmission oil muffler assembly rear fender rear wheel crankcase cover(left) belt drive secondary sheave circlip transmission cover transmission cover gasket dowel pin main axle drive axle primary drive gear...

  • Page 207: Eng

    Eng 5-58 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 0.04 mm (0.0002 in) 2. Measure: 8 drive axle runout (with a centering device and dial gauge ) out of specification...

  • Page 208: Eng

    5-59 eng remarks order job/part q’ty 1 2 3 4 1 1/1 1 1 remove the parts in the order listed. Refer to “ engine “ . Refer to “cylinder head “. Refer to “cylinder and piston “. Refer to “v-belt,clutch ,primary and secondary sheave “. Refer to “cooling system”in chap- ter 6. Refer to “starter clutch an...

  • Page 209: Eng

    5-60 eng remarks order job/part q’ty 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 hook drain plug oil strainer compression spring o-ring crankcase (right ) spacer dowel pin guide crankshaft timing chain crankcase ( left ) oil seal bolt/o-ring timing chain guide 1 1 1 1 1 1 1 2 1 1 1 1 1 1/1 1 refer to “d...

  • Page 210: Eng

    Eng 5-61 eas00385 disassembling the crankcase 1. Remove: 8 centerstand assembly 2. Remove: 8 crankcase bolts1 note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 3. Remove: 8 right crankcase1 8 spacer c c tap ...

  • Page 211: Eng

    Eng 5-62 eas00207 checking the timing chain and timing chain guide 1. Check: 8 timing chain damage/stiffness j replace the timing chain. 2. Check: 8 timing chain guide (intake side) damage/wear j replace. Crankshaft.

  • Page 212: Eng

    Eng 5-63 eas00394 checking the crankshaft and con- necting rod 1. Measure: 8 crankshaft runout out of specification j replace the crank- shaft, bearing or both. Note: turn the crankshaft slowly. Maximum crankshaft runout 0.03 mm ( 0.001 in ) 2. Measure: 8 big end side clearance out of specification ...

  • Page 213: Eng

    Eng 5-64 5. Check: 8 crankshaft journal scratches/wear j replace the crank- shaft. 8 crankshaft journal oil passage obstruction j blow out with compressed air. Eas00399 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and c...

  • Page 214: Eng

    Eng 5-65 eas00408 installing the crankshaft 1. Install: 8 timing chain guide (intake side) 8 timing chain1 8 crankshaft assembly2 note: install the timing chain so it is not visible through the opening in the left crankcase 3. C c to avoid scratching the crankshaft and to ease the installation proce...

  • Page 215: Cool

    6-13 cool chapter 6 radiator radiator ................................................................................................ 6-1 checking the radiator ............................................................ 6-2 installing the radiator .....................................................

  • Page 216: Cool

    6-1 cool remarks order job/part q’ty 1 1 1 1 1 1 1 1 2 3 4 5 6 7 removing the radiator seat/trunk battery cover/battery holder battery/front cover footrest board side cover mole ( left and right ) mat/footrest board coolant radiator cover radiator cap conduit hose radiator inlet hose radiator outlet...

  • Page 217: Cool

    6-2 cool radiator eas00455 checking the radiator 1. Check: 8 radiator fins obstruction j clean. Apply compressed air to the rear of the radiator. Damage j repair or replace. Note: straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: 8 radiator hoses radiator inlet hose1 8 radi...

  • Page 218: Cool

    6-3 cool eas00456 installing the radiator 1. Fill: 8cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2. Check: 8cooling system leaks j repair or replace any faulty part. 3. Measure: 8radiator cap opening pressure below the specifie...

  • Page 219: Cool

    6-4 cool remarks order job/part q’ty 1 1 1 1/1 1 1 2 3 4 5 removing the thermostat assembly seat/trunk/rear carrier battery cover/battery holder battery/front cover side cover (left and right)/rear cover footrest board side cover mole ( left and right ) mat/footrest board coolant radiator inlet hose...

  • Page 220: Cool

    6-5 cool remarks order job/part q’ty for installation, reverse the removal pro- cedure. A a 10nm (1.0 m•kg, 7.2 ft•lb) 6 3 2 5 4 1 10nm (1.0 m•kg, 7.2 ft•lb) 4 thermostat assembly 6 thermostat assembly 1.

  • Page 221: Cool

    6-6 cool eas00462 checking the thermostat 1. Check: 8 thermostat 1 does not open at 65 ~ 80°c j replace. ***************************************************** a. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in the water. D. While stirring ...

  • Page 222: Cool

    6-7 cool eas00466 installing the thermostat assembly 1. Install: 8thermostat1 8thermostat housing 8thermostat assembly inlet breather hose. 8thermostat assembly outlet breather hose. 2. Fill: 8cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in ...

  • Page 223: Cool

    6-8 cool eas00468 water pump remarks order job/part q’ty 1 1 1 1 1 2 3 4 removing the water pump seat/trunk/rear carrier battery cover/battery holder battery/front cover side cover (left and right)/rear cover footrest board side cover mole ( left and right ) mat/footrest board coolant thermostat ass...

  • Page 224: Cool

    6-9 cool remarks order job/part q’ty 5 6 7 8 9 10 11 water pump housing dowel pin plate impeller shaft oil seal bearing gasket 1 2 1 1 1 1 1 for installation, reverse the removal pro- cedure. Water pump 10nm (1.0 m•kg, 7.2 ft•lb) 1 7 5 4 9 8 11 10 6 3 10nm (1.0 m•kg, 7.2 ft•lb) 7nm (0.7 m•kg, 5.1 ft...

  • Page 225: Cool

    6-10 cool eas00471 disassembling the water pump 1. Remove: 8water pump housing cover1 8dowel pin 8gasket eas00474 checking the water pump 1. Check: 8water pump housing cover 8water pump housing 8impeller 1 cracks/damage/wear j replace. 2. Remove: 8plate 2 8impeller shaft 3 8gasket 8oil seal (with a ...

  • Page 226: Cool

    6-11 cool eas00475 assembling the water pump 1. Install: 8oil seal new 1 (into the water pump housing 3) 8bearing 2 note: 8 before installing the oil seal, apply tap wa- ter or coolant onto its out surface. 8 install the oil seal with a socket that matches its outside diameter. C c never lubricate t...

  • Page 227: Cool

    6-12 cool eas00478 installing the water pump 1. Install: 8gasket new 8water pump assembly 1 10 nm (1.0 m • kg, 7.2 ft • lb) note: align the slit a on the impeller shaft with the projection b on the camshaft sprocket bolt. 2. Fill: 8cooling system (with the specified amount of the recom- mended coola...

  • Page 228: Carb

    7-14 carb chapter 7 carbretor carburetor ......................................................................................... 7-1 checking the carburetor ..................................................... 7-4 assembling the carburetor................................................. 7-6 inst...

  • Page 229: Carb

    7-1 carb remarks order job/part q’ty 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 removing the carburetor mat/seat/trunk battery cover/front cover hose(to cylinder head) auto choke lead throttle position sensor lead fuel hose compensator hose thermostat assembly inlet breather hose throttle cable kit ...

  • Page 230: Carb

    7-2 carb remarks order job/part q’ty carburetor disassembling the carburetor auto choke cap auto choke unit auto choke holder auto choke seat throttle stop screw kit bracket vacuum chamber cover/piston valve spring piston valve jet needle kit float chamber float chamber rubber gasket accelerator pum...

  • Page 231: Carb

    7-3 carb remarks order job/part q’ty u i o p a main nozzle nedle jet slow air jet slow jet throttle position sensor 1 1 1 1 1 for assembly, reverse the disassembly procedure. Carburetor 8 7 9 1 2 3 4 t e u r y o 0 q w 6 5 p i a.

  • Page 232: Carb

    7-4 carb eas00485 checking the carburetor 1. Check: 8 carburetor body 8 float chamber cracks/damage j replace. Carburetor 2. Check: 8 fuel passages obstruction j clean. ***************************************************** a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic c...

  • Page 233: Carb

    7-5 carb 6. Check: 8 needle valve damage/obstruction/wear j replace. 7. Check: 8 piston valve 1 damage/scratches/wear j replace. 8 piston valve diaphragm 2 cracks/tears j replace. Carburetor 10. Check: 8 piston valve movement insert the piston valve into the carburetor body and move it up and down. ...

  • Page 234: Carb

    7-6 carb eas00487 assembling the carburetor c c 8 8 8 8 8 before assembling the carburetor, wash all of the parts in a petroleum-based sol- vent. 8 8 8 8 8 always use a new gasket. 1. Install: 8 needle jet 1 8 main nozzle2 8 main jet 3 8 slow air jet 4 2. Install: 8 float 1 8 needle valve 2 8 float ...

  • Page 235: Carb

    7-7 carb eas00492 installing the carburetor 1. Adjust: 8 engine idling speed engine idling speed 2,000 ~ 2,400r/min refer to “adjusting the engine idling speed” in chapter 3. 2. Adjust: 8 throttle cable free play throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.5 mm (0.059 ~ 0.1...

  • Page 236: Carb

    7-8 carb eas00498 measuring and adjusting the fuel level 1. Measure: 8 fuel level a out of specification j adjust. Fuel level (below the float chamber mating surface) 6.6~7.6 mm (0.26~0.30 in) ***************************************************** a. Stand the motorcycle on a level surface. B. Place ...

  • Page 237: Carb

    7-9 carb carburetor eas00503 checking the autochoke unit note: when checking the autochoke unit, the ambient temperature must be lower than 45°c. 1. Remove: 8carburetor 2. Check: 8autochoke unit ***************************************************** a. Connect a 3.3-mm hose 2 to the starter air passa...

  • Page 238: Carb

    7-10 carb carburetor eas00504 checking the fuel cock 1. Remove: 8 seat/trunk 8 battery cover 8 front cover refer to “cover and panel”in chap- ter 3. 2. Check: 8fuel cock1 ***************************************************** a. Disconnect the fuel cock to carburetor fuel hose2from the carburetor . B...

  • Page 239: Carb

    7-11 carb checking the throttle position sen- sor note: before checking the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: 8throttle position sensor ***************************************************** a. Turn the main switch to “on”. B. Connect the pocket ...

  • Page 240: Carb

    7-12 carb remarks order job/part q’ty air induction system removing the air induction system seat/trunk hose(from ai air filter ) vacuum hose(from mainfold ) hose(to cylinder head ) air cut-off valve assembly 1 2 3 4 1 1 1 1 remove the parts in the order listed. Refer to “cover and panel”in chap- te...

  • Page 241: Carb

    7-13 carb eas00510 checking the air induction system 1. Check: 8 hoses loose connection j connect properly. Cracks/damage j replace. 8 pipe cracks/damage j replace. 2. Check: 8 air cut-off valve cracks/damage j replace. Note: when the negative pressure is applied to the part 1, check that the contin...

  • Page 242: Elec

    8-49 - + elec chapter 8 electorical electrical components ................................................................ 8-1 wiring diagram ................................................................................... 8-2 checking switch continuity ..............................................

  • Page 243: Elec

    8-1 - + elec eas00729 electrical electrical components electrical components 1 rear brake light switch 2 front brake light switch 3 main switch 4 starter relay 5 thermo unit 6 fuel sender 7 c.D.I. Unit 8 ignition coil 9 spark plug cap 0 battery q main fuse w turn signal relay e horn r rectifier/regu...

  • Page 244: Elec

    8-2 - + elec wiring diagram wiring diagram off check on off start off push l n r hi lo off run gw ll y y r yl gr br bl wl b or yr w wr wl yr w wr wl r yb r yr bl l yl w r b yr r br rr gy lw lw gy l yr b r b r lw ly b b ly lw gb y yr b g b br g gw b gw b br g l y dg ch dg ch l y gr bl b brw br y g l ...

  • Page 245: Elec

    8-3 - + elec wiring diagram color code b black g green l blue p pink r red w white y yellow br brown ch chocolate dg dark green or orange b/l black/blue g/b green/black g/r green/red g/y green/yellow g/w green/white l/w blue/white l/y blue/yellow w/l white/blue w/r white/red y/b yellow/black y/l yel...

  • Page 246: Elec

    8-4 - + 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. C c never insert the tester probes into the coupler terminal slots. Always insert the p...

  • Page 247: Elec

    8-5 - + 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 248: Elec

    8-6 - + 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 249: Elec

    8-7 - + elec checking the condition of the bulbs the following procedure applies to all of the bulbs. 1. Remove: 8 bulb w since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. C c 8 8 8 8 8 be sure to hold the socket firmly w...

  • Page 250: Elec

    8-8 - + elec checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: 8 bulb socket (for continuity) (with the pocket tester) no continuity j replace. Pocket tester 90890-03132 (yu-03112-c) note: check each bulb socket for continuity in the sam...

  • Page 251: Elec

    8-9 - + elec off check on off start off push l n r hi lo off run gw ll y y r yl gr br bl wl b or yr w wr wl yr w wr wl r yb r yr bl l yl w r b yr r br rr gy lw lw gy l yr b r b r lw ly b b ly lw gb y yr b g b br g gw b gw b br g l y dg ch dg ch l y gr bl b brw br y g l p b ch brw dg ch brw dg l p b ...

  • Page 252: Elec

    8-10 - + elec eas00738 1. Main fuse 8 check the fuse for continuity. Refer to “checking the fuse” in chapter 3. 8 is the fuse ok? Yes no replace the fuse. Eas00739 2. Battery 8 check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Minimum open-circuit voltage...

  • Page 253: Elec

    8-11 - + 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 254: Elec

    8-12 - + elec 8 measure the primary coil resistance. Primary coil resistance 0.168 ~ 0.252 Ω Ω Ω Ω Ω at 20°c 8 connect the pocket tester ( Ω × 1k) to the ignition coil as shown. Negative tester probe j j j j j spark plug lead 2 2 2 2 2 positive tester probe j j j j j spark plug lead 1 1 1 1 1 8 meas...

  • Page 255: Elec

    8-13 - + elec ignition system eas00750 9. Engine stop switch 8 check the engine stop switch for conti- nuity. Refer to “checking the switches”. 8 is the engine stop switch ok? Yes no replace the right handlebar switch. Eas00754 10.Wiring 8 check the entire ignition system’s wir- ing. Refer to “circu...

  • Page 256: Elec

    8-14 - + elec b off check on off start off push l n r hi lo off run gw ll y y r yl gr br bl wl b or yr w wr wl yr w wr wl r yb r yr bl l yl w r b yr r br rr gy lw lw gy l yr b r b r lw ly b b ly lw gb y yr b g b br g gw b gw b br g l y dg ch dg ch l y gr bl b brw br y g l p b ch brw dg ch brw dg l p...

  • Page 257: Elec

    8-15 - + elec electric starting system eas00756 starting circuit cut-off system op- eration if the main switch is set to “on” (switch is 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 to the handlebar (the ...

  • Page 258: Elec

    8-16 - + elec eas00757 troubleshooting the starter motor fails to turn. Check: 1. Mainfuse 2. Battery 3. Starter motor 4 starter relay 5 main switch 6 brake light switch (front, rear) 7 engine stop switch 8 start switch 9 wiring connections (of the entire starting system) note: 8 before troubleshoot...

  • Page 259: Elec

    8-17 - + elec eas00758 3. Starter motor 8 connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead3. W 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 8 8 thi...

  • Page 260: Elec

    8-18 - + elec eas00751 6. Brake light switch(front and rear) 8 check the brake light switch for continu- ity. Refer to “checking the switches”. 8 is the brake light switch ok? Yes no replace the brake light switch. Electric starting system eas00750 7. Engine stop switch 8 check the engine stop switc...

  • Page 261: Elec

    8-19 - + elec remarks order job/part q’ty removing the starter motor seat/trunk front cover battery cover air filter assembly starter motor lead starter motor disassembling the starter motor o-ring gasket stator assembly o-ring armature coil brush plate washer 1 2 1 2 3 4 5 6 7 1 1 1 1 1 1 1 2 1 rem...

  • Page 262: Elec

    8-20 - + elec 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 16.6 mm (0.654 in) 3. Measure: 8 mica undercut a out of specification j scrape th...

  • Page 263: Elec

    8-21 - + elec 5. Measure: 8 brush length a out of specification j replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: 8 brush spring force out of specification j replace the brush springs as a set. Brush spring force 3.92 ~ 5.88 n 7. Check: 8 gear teeth damage/wear j r...

  • Page 264: Elec

    8-22 - + elec electric starting system t r . . Eas00772 assembling the starter motor 1. Install: 8 brush seat 1 2. Install: 8 washer1 8 armature coil 2 8 o-ing new 3 8 stator assembly4 3 . Install: 8 bolts 1 5 nm (0.5 m • kg, 3.6 ft • lb) note: align the match marks a on the starter motor yoke with ...

  • Page 265: Elec

    8-23 - + elec b off check on off start off push l n r hi lo off run gw ll y y r yl gr br bl wl b or yr w wr wl yr w wr wl r yb r yr bl l yl w r b yr r br rr gy lw lw gy l yr b r b r lw ly b b ly lw gb y yr b g b br g gw b gw b br g l y dg ch dg ch l y gr bl b brw br y g l p b ch brw dg ch brw dg l p...

  • Page 266: Elec

    8-24 - + 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) note: 8 before troubleshooting, remove the follow- ing part(s): 1. Seat/trunk 2. Battery cover 3...

  • Page 267: Elec

    8-25 - + elec the charging circuit is ok. Note: make sure the battery is fully charged. 8is the charging voltage within specifica- tion? No yes eas00776 4. Stator coil resistance 8 remove the starter coil couplers from wireharness. 8connect the pocket tester ( Ω × 1) to the stator coils as shown. Po...

  • Page 268: Elec

    8-26 - + elec b off check on off start off push l n r hi lo off run gw ll y y r yl gr br bl wl b or yr w wr wl yr w wr wl r yb r yr bl l yl w r b yr r br rr gy lw lw gy l yr b r b r lw ly b b ly lw gb y yr b g b br g gw b gw b br g l y dg ch dg ch l y gr bl b brw br y g l p b ch brw dg ch brw dg l p...

  • Page 269: Elec

    8-27 - + elec eas00781 troubleshooting any of the following fail to light: headlight, high beam indicator light or meter light. Check: 1. Main fuse 2. Battery 3. Lighting coil resistance. 4. Main switch 5. Dimmer switch 6. Headlight relay 7. Wiring connections (of the entire lighting system) note: 8...

  • Page 270: Elec

    8-28 - + elec lighting system eas00749 4. 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. Eas00784 5. Dimmer switch 8 check the dimmer switch for continuity. Refer to “checking the switches”. 8 is the dimm...

  • Page 271: Elec

    8-29 - + elec eas00788 checking the lighting system 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb and socket 8 check the headlight bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” 8 are the headlight bulb and socket ok? Yes no 2. ...

  • Page 272: Elec

    8-30 - + elec the wiring circuit from the main switch to the headlight and hight beam indicator light coupler are faulty and must be repaired. This circuit is ok. Yes no lighting system 2. Voltage 8 connect the pocket tester (dc 20 v) to the meter light coupler (wire harness side) as shown. Positive...

  • Page 273: Elec

    8-31 - + elec lighting system eas00754 4. Wiring 8 check the entire lighting system’s wir- ing. Refer to “circuit diagram”. 8 is the lighting system’s wiring properly connected and without defects? Yes no properly connect or repair the lighting system’s wiring. Check the condi- tion of each of the l...

  • Page 274: Elec

    8-32 - + elec b off check on off start off push l n r hi lo off run gw ll y y r yl gr br bl wl b or yr w wr wl yr w wr wl r yb r yr bl l yl w r b yr r br rr gy lw lw gy l yr b r b r lw ly b b ly lw gb y yr b g b br g gw b gw b br g l y dg ch dg ch l y gr bl b brw br y g l p b ch brw dg ch brw dg l p...

  • Page 275: Elec

    8-33 - + elec eas00794 troubleshooting 8 8 8 8 8 any of the following fail to light: turn signal light, brake light or an indica- tor light. 8 8 8 8 8 the horn fails to sound. Check: 1. Main fuse 2. Battery 3. Main switch 4. Wiring connections (of the entire signaling system) note: 8 before troubles...

  • Page 276: Elec

    8-34 - + 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 277: Elec

    8-35 - + elec eas00798 2. 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 278: Elec

    8-36 - + elec eas00799 3. The turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal light and turn signal indicator light bulbs and sockets 8 check the turn signal light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” 8 check the turn sig...

  • Page 279: Elec

    8-37 - + elec 4. Voltage 8connect the pocket tester (dc 20 v) to the turn signal relay coupler (wire har- ness 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 8set the main switch to “on”. 8set the turn signal switch to “4” or “6”. 8measur...

  • Page 280: Elec

    8-38 - + elec eas00804 4. The fuel level meter fails to operate. 1. Fuel sender 8 remove the fuel sender 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 b...

  • Page 281: Elec

    8-39 - + elec 3. Fuel level meter 8 set the main switch to “on”. 8 move the float up 1 or down 2. 8 check that the fuel level meter needle moves to “f” or “e”. Note: before reading the fuel level meter, leave the float in one position (either up or down) for at least three minutes. 8 does the fuel l...

  • Page 282: Elec

    8-40 - + elec b off check on off start off push l n r hi lo off run gw ll y y r yl gr br bl wl b or yr w wr wl yr w wr wl r yb r yr bl l yl w r b yr r br rr gy lw lw gy l yr b r b r lw ly b b ly lw gb y yr b g b br g gw b gw b br g l y dg ch dg ch l y gr bl b brw br y g l p b ch brw dg ch brw dg l p...

  • Page 283: Elec

    8-41 - + elec cooling system eas00808 troubleshooting the cooling system fails to operate. Check: 1. Main fuse 2. Battery 3. Main switch 4. Thermo switch 5. Water temperature indicator light 6. Wiring connections (the entire cooling system) note: 8 before troubleshooting, remove the follow- ing part...

  • Page 284: Elec

    8-42 - + elec eas00811 4. Thermo switch 8 remove the thermo switch from the ther- mostat housing. 8 connect the pocket tester ( Ω × 1) to the thermo switch 1 as shown. 8 immerse the thermo switch in a container filled with coolant2. 8 place a thermometer3 in the coolant. 8 slowly heat the coolant, t...

  • Page 285: Elec

    8-43 - + elec eas00812 5. The water temperature indicator light fails to operate. 1. Thermo unit 8 remove the thermo unit from the cylin- der head. 8 connect the pocket tester ( Ω × 1k) to the thermo unit as shown. Positive tester probe j j j j j black/blue 1 1 1 1 1 negative tester probe j j j j j ...

  • Page 286: Elec

    8-44 - + elec eas00813 6. Wiring 8 check the entire cooling system’s wiring. Refer to “circuit diagram”. 8 is the cooling system’s wiring properly connected and without defects? Yes no 3. Water temperature indicator light 8 remove the thermo unit coupler . 8 set the main switch to “on”. 8 connect th...

  • Page 287: Elec

    8-45 - + elec b off check on off start off push l n r hi lo off run gw ll y y r yl gr br bl wl b or yr w wr wl yr w wr wl r yb r yr bl l yl w r b yr r br rr gy lw lw gy l yr b r b r lw ly b b ly lw gb y yr b g b br g gw b gw b br g l y dg ch dg ch l y gr bl b brw br y g l p b ch brw dg ch brw dg l p...

  • Page 288: Elec

    8-46 - + elec eas00821 troubleshooting the auto choke system fails to operate. Check: 1. Main fuse 2. Battery 3. Thermo switch 4. Auto choke unit 5. Wiring connections (of the entire autochoke system) note: 8 before troubleshooting, remove the follow- ing part(s): 1. Seat/trunk 2. Battery cover 3. F...

  • Page 289: Elec

    8-47 - + elec eas00811 3. Thermo switch 8 remove the thermo switch from the thermostat housing. 8 connect the pocket tester ( Ω × 1) to the thermo switch 1 as shown. 8 immerse the thermo switch in a con- tainer filled with coolant2. 8 place a thermometer3 in the coolant. 8 slowly heat the coolant, t...

  • Page 290: Elec

    8-48 - + elec 4. Auto choke unit 8 disconnect the auto choke unit coupler from wire harness. 8 connect the pocket tester( Ω × 1) to the auto choke unit coupler as shown. Positive tester probe jj jj jj jj jjgreen/black 1 1 1 1 1 negative tester probe j j j j jyellow 2 2 2 2 2 8measure the auto choke ...

  • Page 291: Trbl

    9-7 trbl shtg chapter 9 trouble shooting starting failure/hard starting................................................. 9-1 engine .............................................................................................. 9-1 fuel system ............................................................

  • Page 292: Trbl

    9-1 trbl shtg eas00845 troubleshooting note: the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts...

  • Page 293: Trbl

    9-2 trbl shtg starting failures/hard starting/ incorrect engine idling speed ignition system 8faulty c.D.I.Unit 8faulty pickup coil 8broken ac magneto rotor woodruff key switches and wiring 8faulty main switch 8faulty engine stop switch 8broken or shorted wiring 8faulty front, rear or both brake lig...

  • Page 294: Trbl

    9-3 trbl shtg poor medium-and-high-speed performance/ faulty clutch eas00849 poor medium-and-high- speed performance refer to “starting failure/hard start- ing”. Engine air filter 8clogged air filter element air intake system 8bent, clogged or disconnected carbure- tor air vent hose 8clogged or leak...

  • Page 295: Trbl

    9-4 trbl shtg poor speed performance v-belt 8oil or grease on the v-belt primary pulley weight(s) 8faulty operation 8worn primary pulley weight primary fixed sheave 8worn primary fixed sheave primary sliding sheave 8worn primary sliding sheave secondary fixed sheave 8worn secondary fixed sheave seco...

  • Page 296: Trbl

    9-5 trbl shtg poor braking performance/faulty front fork legs/unstable handling eas00859 poor braking performance drum brake 8worn brake shoe 8worn or rusty brake drum 8incorrect brake lever position 8incorrect brake lever free play 8incorrect brake camshaft lever position 8incorrect brake shoe posi...

  • Page 297: Trbl

    9-6 trbl shtg faulty lighting or signaling system eas00866 faulty lighting or signaling system headlight does not come on 8wrong headlight bulb 8faulty headlight relay 8too many electrical accessories 8hard charging 8incorrect connection 8improperly grounded circuit 8poor contacts (main or light swi...

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