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Yamaha YP400T Service Manual

Other manuals for YP400T: Owner's Manual, Service Manual
Manual is about: 2005-2007 years

Summary of YP400T

  • Page 1

    2005 - 2007 motorcycle service manual model : yp400t, yp400v, yp400w 5ru281972000 *5ru281972000* downloaded from www.Scootertime.Net.

  • Page 2

    Eas00000 yp400t service manual ©2004 by yamaha motor co., ltd. First edition, june 2004 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Downloaded from www.Scootertime.Net.

  • Page 3: Notice

    Eas00002 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers 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 yama...

  • Page 4: How to Use This Manual

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

  • Page 5: Gen

    Eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic checks and adjustments 4 chassis 5 engine 6 cooling system 7 fuel injection system 8 electrical system 9 troubleshooting sy...

  • Page 6: Gen

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

  • Page 7: Gen

    1 - 1 gen info eas00015 general information scooter identification eas00017 vehicle identification number the vehicle identification number 1 is stamped into the frame. 1 eas00018 model label the model label 1 is affixed inside the storage box. Record the information on this label in the space provi...

  • Page 8: Gen

    1 - 2 gen info features eas00896 features outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburet...

  • Page 9: Gen

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

  • Page 10: Gen

    1 - 4 gen info features instrument functions multifunction display warning be sure to stop the vehicle before making any setting changes to the multifunction display. 1 clock/ambient temperature display 2 coolant temperature meter 3 fuel meter 4 odometer/tripmeters 5 “select” button 6 “reset” button...

  • Page 11: Gen

    1 - 5 gen info features odometer and tripmeter modes pushing the “select” button switches the display between the odometer mode “odo” and the tripmeter modes “trip” in the follow- ing order: odo → trip (top) → trip (bottom) → odo when approximately 2.8 l (0.62 imp gal, 0.74 us gal) of fuel remains i...

  • Page 12: Gen

    1 - 6 gen info features coolant temperature meter with the key in the “on” position, the coolant temperature meter indicates the temperature of the coolant. The coolant temperature varies with changes in the weather and engine load. If the top segment and coolant temperature symbol flash, stop the v...

  • Page 13: Gen

    1 - 7 gen info features to reset the oil change indicator 1. Turn the key to “on”. 2. Hold the reset button pushed for two to eight seconds. 1 reset button “oil change” 3. Release the reset button, and the oil change indicator will go off. Note: if the engine oil is changed before the oil change ind...

  • Page 14: Gen

    1 - 8 gen info features self-diagnosis device this model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the multi- function display will indicate a two-digit error code (e.G., 12, 13, 14). If the multifunction display indicates an er...

  • Page 15: Gen

    1 - 9 gen info features ambient temperature display this display shows the ambient temperature from –10 °c to 50 °c in 1 °c increments. The temperature displayed may vary from the ambient temperature. Pushing the “reset” button for at least two seconds switches the ambient temperature display to the...

  • Page 16: Gen

    1 - 10 gen info important information eas00020 important information preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “special tools”. 3. When disassembling, alway...

  • Page 17: Gen

    1 - 11 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...

  • Page 18: Gen

    1 - 12 gen info checking the connections eas00026 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and discon...

  • Page 19: Gen

    1 - 13 gen info special tools eas00027 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, p...

  • Page 20: Gen

    1 - 14 gen info special tools flywheel puller 90890-01362 flywheel puller attachment 90890-04089 ym-33282 flywheel puller flywheel puller attachment this tool is used to remove the generator rotor. Fork seal driver weight 90890-01367 ym-a9409-7 fork seal driver attachment 90890-01381 ym-a5142-2 fork...

  • Page 21: Gen

    1 - 15 gen info special tools 90890-03141 yu-03141 timing light this tool is used to check the ignition tim- ing. 90890-03153 yu-03153 pressure gauge this tool is used to measure fuel pres- sure. 90890-03181 ym-03181 adapter this tool is used to measure fuel pres- sure. Valve spring compres- sor 908...

  • Page 22: Gen

    1 - 16 gen info special tools 90890-04101 valve lapper this tool is needed to remove and install the valve lifters. Sheave spring com- pressor 90890-04134 ym-04134 sheave fixed block 90890-04135 ym-04135 sheave spring compressor sheave fixed block this tool is used to hold the compression spring whe...

  • Page 23: Spec

    Spec chapter 2 specifications general specifications ........................................................................ 2-1 engine specifications ........................................................................... 2-2 chassis specifications ................................................

  • Page 24: Spec

    2 - 1 spec general specifications specifications general specifications item standard limit model code 5ru4 (usa) 5ruc (cdn) ---- ---- dimensions overall length 2,230 mm (87.8 in) ---- overall width 780 mm (30.7 in) ---- overall height 1,380 mm (54.3 in) ---- seat height 750 mm (29.5 in) ---- wheelb...

  • Page 25: Spec

    2 - 2 spec engine specifications engine specifications item standard limit engine engine type liquid-cooled, 4-stroke, dohc ---- displacement 394.9 cm 3 (24.10 cu.In) ---- cylinder arrangement forward-inclined single cylinder ---- bore × stroke 83.0 × 73.0 mm (3.27 × 2.87 in) ---- compression ratio ...

  • Page 26: Spec

    2 - 3 spec engine specifications oil pump oil pump type trochoid ---- inner-rotor-to-outer-rotor-tip clear- ance 0.07 mm (0.0028 in) 0.15 mm (0.0059 in) outer-rotor-to-oil-pump-housing clearance 0.013 ~ 0.036 mm (0.0005 ~ 0.0014 in) 0.106 mm (0.0042 in) oil-pump-housing-to-inner-and-outer rotor clea...

  • Page 27: Spec

    2 - 4 spec engine specifications camshafts drive system chain drive (right) ---- camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ---- camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) ---- camshaft-journal-to-camshaft-cap clearance 0.028 ~ 0.062 mm (0.0011 ~ 0.00...

  • Page 28: Spec

    2 - 5 spec engine specifications timing chain model/number of links did scr-0409 sv/136le ---- tensioning system automatic ---- valves, valve seats, valve guides valve clearance (cold) intake 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) ---- exhaust 0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in) ---- valve dimensions v...

  • Page 29: Spec

    2 - 6 spec engine specifications valve stem runout ---- 0.01 mm (0.0004 in) valve seat width intake 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm (0.06 in) exhaust 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm (0.06 in) valve springs free length intake 46.45 mm (1.83 in) 44.13 mm (1.74 in) exhaust 46.45 mm (1...

  • Page 30: Spec

    2 - 7 spec engine specifications winding direction (top view) intake clockwise ---- exhaust clockwise ---- cylinder cylinder arrangement forward-inclined single cylinder ---- bore × stroke 83.0 × 73.0 mm (3.27 × 2.87 in) ---- compression ratio 10.6 : 1 ---- bore 83.000 ~ 83.010 mm (3.2677 ~ 3.2681 i...

  • Page 31: Spec

    2 - 8 spec engine specifications 2nd ring ring type taper ---- dimensions (b × t) 1.00 × 3.10 mm (0.04 × 0.12 in) ---- end gap (installed) 0.40 ~ 0.55 mm (0.0157 ~ 0.0217 in) 0.80 mm (0.0315 in) ring side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.100 mm (0.0039 in) oil ring dimensions (b × t...

  • Page 32: Spec

    2 - 9 spec engine specifications automatic centrifugal clutch clutch shoe thickness 4.0 mm (0.16 in) 2.5 mm (0.10 in) clutch shoe spring free length 34.7 mm (1.37 in) ---- clutch housing inside diameter 160 mm (6.30 in) 160.5 mm (6.32 in) compression spring free length 103.5 mm (4.075 in) 91 mm (3.5...

  • Page 33: Spec

    2 - 10 spec chassis specifications chassis specifications item standard limit frame frame type aluminum die-cast and steel tube back- bone ---- caster angle 27° ---- trail 100.0 mm (3.94 in) ---- front wheel wheel type cast wheel ---- rim size 14 m/c × mt3.00 ---- material aluminum ---- wheel travel...

  • Page 34: Spec

    2 - 11 spec chassis specifications rear tire tire type tubeless ---- size 150/70-13m/c 64s ---- model (manufacturer) mb 67 (irc) ---- d305l (dunlop) ---- tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kpa (2.50 kgf/cm 2 , 36 psi) ---- 90 ~ 196 kg (198 ~ 432 lb) 250 kpa (2.50 kgf/cm 2 , 36 psi) ----...

  • Page 35: Spec

    2 - 12 spec chassis specifications rear brake brake type single-disc brake ---- operation left-hand operation ---- recommended fluid dot 4 ---- brake discs diameter × thickness 267 × 5 mm (10.51 × 0.20 in) ---- minimum thickness ---- 4.5 mm (0.18 in) maximum deflection ---- 0.15 mm (0.006 in) brake ...

  • Page 36: Spec

    2 - 13 spec chassis specifications steering steering bearing type angular and taper roller bearings ---- lock-to-lock angle (left) 40° ---- lock-to-lock angle (right) 40° ---- rear suspension suspension type unit swing ---- rear shock absorber assembly type coil spring/oil damper ---- rear shock abs...

  • Page 37: Spec

    2 - 14 spec electrical specifications electrical specifications item standard limit system voltage 12 v ---- ignition system ignition system type transistorized coil ignition (digital) ---- ignition timing 5° btdc at 1,400 r/min ---- advancer type digital ---- crankshaft position sensor resis- tance...

  • Page 38: Spec

    2 - 15 spec electrical specifications bulbs (voltage/wattage × quantity) headlight 12 v 60/55 w × 2 ---- tail/brake light led × 1 ---- front turn signal/position light 12 v 21 w/5 w × 2 ---- rear turn signal light 12 v 21 w × 2 ---- licence plate light 12 v 5 w × 1 ---- meter light 12 v 2.0 w × 3 --...

  • Page 39: Spec

    2 - 16 spec electrical specifications fuses (amperage × quantity) main fuse 40 a × 1 ---- fuel injection system fuse 10 a × 1 ---- headlight fuse 20 a × 1 ---- signaling system fuse 10 a × 1 ---- ignition fuse 10 a × 1 ---- radiator fan motor fuse 10 a × 1 ---- backup fuse (storage box light and met...

  • Page 40: Spec

    2 - 17 spec conversion table/ general tightening torque specifications eas00028 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 specificatio...

  • Page 41: Spec

    2 - 18 spec tightening torques tightening torques engine tightening torques item fastener thread size q’ty tightening torque remarks nm m · kg ft · lb camshaft cap bolt m6 8 10 1.0 7.2 exhaust pipe stud bolt — m8 2 13 1.3 9.4 spark plug — m10 1 13 1.3 9.4 cylinder head and cylinder bolt m6 2 10 1.0 ...

  • Page 42: Spec

    2 - 19 spec tightening torques exhaust pipe nut m8 2 20 2.0 14 air induction system pipe bolt m6 2 12 1.2 8.7 air induction system pipe stay bolt m6 1 7 0.7 5.1 air cut-off valve bolt m6 2 10 1.0 7.2 muffler mount bolt m10 3 53 5.3 38 v-belt case air duct 1 and 2 bolt m6 4 7 0.7 5.1 crankcase bolt m...

  • Page 43: Spec

    2 - 20 spec camshaft cap tightening sequence: cylinder head tightening sequence: tightening torques downloaded from www.Scootertime.Net.

  • Page 44: Spec

    2 - 21 spec tightening torques chassis tightening torques item thread size tightening torque remarks nm m · kg ft · lb bottom cover and sub-frame m6 7 0.7 5.1 radiator cover and frame m6 7 0.7 5.1 front cowling and front cowling stay m6 7 0.7 5.1 footrest board and footrest board stay m6 7 0.7 5.1 f...

  • Page 45: Spec

    2 - 22 spec tightening torques note: 1. Tighten the lower steering ring nut 36 nm (3.6 m · kg, 25 ft · lb) with a torque wrench and the steering nut wrench, and then loosen the nut 1/4 turn. 2. Tighten the lower steering ring nut 24 nm (2.4 m · kg, 17 ft · lb) with a torque wrench and the steering n...

  • Page 46: Spec

    2 - 23 spec lubrication points and lubricant types eas00031 lubrication points and lubricant types engine lubrication points and lubricant types lubrication point lubricant oil seal lips ls bearings e o-rings ls cylinder head nut e camshaft cap and camshaft cap bolts e crankshaft pin e connecting ro...

  • Page 47: Spec

    2 - 24 spec lubrication points and lubricant types water pump seal lip ls crankcase breather pipe lt transmission case breather pipe lt cylinder head cover (guide stopper mating surface) yamaha bond no. 1215 crankcase mating surface yamaha bond no. 1215 generator rotor cover (grommet mating surface)...

  • Page 48: Spec

    2 - 25 spec lubrication points and lubricant types eas00032 chassis lubrication points and lubricant types lubrication point symbol engine mounting bolt ls swingarm, oil seal ls steering bearings and oil seal ls throttle grip inner surface and throttle cables ls brake lever pivoting point and metal-...

  • Page 49: Spec

    2 - 26 spec cooling system diagrams eas00033 cooling system diagrams 1 radiator outlet hose 2 radiator 3 radiator cap 4 coolant reservoir hose 5 radiator filler hose 6 radiator inlet hose 7 radiator pipe assembly 1 2 3 5 6 7 6 2 1 7 4 downloaded from www.Scootertime.Net.

  • Page 50: Spec

    2 - 27 spec cooling system diagrams 1 radiator pipe assembly 2 oil cooler outlet hose 3 oil cooler cover 4 water pump outlet hose 5 water pump cover 6 water pump inlet hose 7 thermostat inlet hose 8 cooling system air bleed hose 9 thermostat outlet hose 0 thermostat a thermostat cover b water jacket...

  • Page 51: Spec

    2 - 28 spec cable routing eas00035 cable routing 1 rear brake lock lever cable 2 rear brake hose 3 cable guide (lower handlebar holder) 4 throttle cable (accelerator cable) 5 throttle cable (decelerator cable) 6 front brake hose 7 handlebar switch leads È route the handlebar switch leads to the left...

  • Page 52: Spec

    2 - 29 spec cable routing Ë fasten the left handlebar switch lead to the han- dlebar with a plastic locking tie. Ì route the rear brake lock lever cable in front of the handlebar. Í route the throttle cables under the rear brake hose, rear brake lock lever cable, and front brake hose, and then to th...

  • Page 53: Spec

    2 - 30 spec cable routing 1 meter assembly 2 handlebar switch leads 3 throttle cable (accelerator cable) 4 throttle cable (decelerator cable) 5 front brake hose 6 rear brake lock lever cable 7 rear brake hose 8 wire harness 9 fuel overflow hose 0 radiator fan motor lead a radiator b rectifier/regula...

  • Page 54: Spec

    2 - 31 spec cable routing l radiator fan motor relay m fuel injection system relay n headlight relay 1 o meter assembly lead p lean angle cut-off switch q horn r ecu s right handlebar switch lead t left handlebar switch lead u rectifier/regulator lead È after connecting the meter assembly coupler, i...

  • Page 55: Spec

    2 - 32 spec cable routing Ë pass the rear brake lock lever cable and rear brake hose through the hole in the frame so that the rear brake lock lever cable is to the outside of the rear brake hose. Ì route the throttle cable (decelerator cable) above the throttle cable (accelerator cable). Í connect ...

  • Page 56: Spec

    2 - 33 spec cable routing Ó pass the radiator fan motor lead through the cut- out in the left side of the bottom cover. Ô face the end of the plastic locking tie away from the scooter. Õ fasten the headlight lead, front turn signal/posi- tion light lead (left), and front turn signal/position light l...

  • Page 57: Spec

    2 - 34 spec cable routing 1 sidestand switch lead 2 crankshaft position sensor lead coupler 3 sub-wire harness 4 crankshaft position sensor/stator coil lead 5 storage box light switch lead 6 storage box light 7 negative battery lead 8 starter motor lead 9 fuse box 0 tail/brake light lead a rear turn...

  • Page 58: Spec

    2 - 35 spec cable routing m battery band n positive battery lead o v-belt replacement indicator reset coupler lead È after connecting the stator coil lead coupler, slide the cover over the coupler. É route the storage box light lead through the two guides in the storage box. Ê route the wire harness...

  • Page 59: Spec

    2 - 36 spec cable routing Î connect the orange lead to the upper terminal of the ignition coil and connect the red/black lead to the lower terminal. Ï fasten the throttle cables, sidestand switch lead, and wire harness with a plastic holder as shown. ³ fasten the sub-wire harness, stator coil lead c...

  • Page 60: Spec

    2 - 37 spec cable routing Ô route the rear brake hose and rear brake lock lever cable through the two engine bracket guides so that the rear brake lock lever cable is towards the outside of the scooter. Õ align the paint mark on the rear brake lock lever cable with the engine bracket guide. Ö fasten...

  • Page 61: Spec

    2 - 38 spec cable routing Ü route the starter motor lead, wire harness, and positive battery lead over the boss of the upper rear cover. Ý route the negative battery lead between the leads and the battery. Þ fasten the v-belt replacement indicator reset coupler with the battery band. ß install the n...

  • Page 62: Spec

    2 - 39 spec cable routing 1 rear brake lock lever cable 2 rear brake hose 3 throttle cable (accelerator cable) 4 throttle cable (decelerator cable) 5 seat lock cable 6 main switch 7 thermistor lead coupler 8 front brake hose 9 speed sensor lead 0 coolant reservoir a front cowling stay È route the se...

  • Page 63: Spec

    2 - 40 spec cable routing Ì route the speed sensor lead as shown. Í route the front brake hose and speed sensor lead through the guide on the front cowling stay so that the speed sensor lead is towards the out- side of the scooter. Î hook the end of the cable cover in the hole in the frame. Ï attach...

  • Page 64: Spec

    2 - 41 spec cable routing 1 seat lock cable 2 rear brake lock lever cable 3 rear brake hose 4 fuel overflow hose 5 coolant reservoir breather hose È fasten the rear brake hose with the brake hose holder and route the rear brake lock lever cable through the guide. É fasten the rear brake hose with th...

  • Page 65: Spec

    2 - 42 spec cable routing Ì route the fuel overflow hose to the outside of the hose guide. Í fasten the coolant reservoir breather hose with the two holders on the bottom cover. Î route the coolant reservoir breather hose to the outside of the hose guide. Ï the end of the coolant reservoir breather ...

  • Page 66: Spec

    2 - 43 spec cable routing 1 seat lock cable 2 throttle cable (decelerator cable) 3 throttle cable (accelerator cable) 4 rear brake lock lever cable 5 rear brake hose 6 wire harness 7 thermistor 8 thermistor lead È route the throttle cables above the seat lock cable guide. É route the seat lock cable...

  • Page 67: Spec

    2 - 44 spec cable routing Ì route the throttle cables below the gas spring assembly. Í route the throttle cable (decelerator cable) above the throttle cable (accelerator cable). Î route the throttle cables above the rear brake hose and rear brake lock lever cable. Ï pass the seat lock cable through ...

  • Page 68: Spec

    2 - 45 spec cable routing 1 spark plug cap 2 seat lock cable 3 seat lock assembly 4 isc (idle speed control) valve lead 5 rear brake lock lever cable 6 rear brake hose 7 wire harness 8 starter motor lead 9 positive battery lead 0 negative battery leads a intake air temperature sensor b fuel injector...

  • Page 69: Spec

    2 - 46 spec cable routing È do not pinch any hoses, leads, etc., when installing the storage box. É after connecting the positive battery lead, starter motor lead, and wire harness, install the starter relay cover. Ê 30° connect the positive battery lead to the starter relay within the angle shown. ...

  • Page 70: Spec

    2 - 47 spec cable routing canister 1 canister 2 fuel overflow hose 3 rollover valve to canister hose 4 rollover valve 5 fuel tank to rollover valve hose 6 fuel tank 7 throttle body 8 canister to throttle body hose 9 plastic holder 0 fuel hose a plastic clip b guide downloaded from www.Scootertime.Ne...

  • Page 71: Spec

    2 - 48 spec cable routing È install the rollover valve to canister hose with the paint mark facing up. É install the fuel tank to rollover valve hose with the paint mark facing to the left. Ê fasten the canister to throttle body hose with the plastic holder between the stoppers on the hose. Ë align ...

  • Page 72: Chk

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

  • Page 73: Chk

    Chk adj chassis ....................................................................................................... 3-37 adjusting the rear brake lock lever cable ....................... 3-37 checking the brake fluid level................................................. 3-38 checking the front ...

  • Page 74: 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 ne...

  • Page 75: Chk

    3 - 2 chk adj periodic maintenance chart for the emission control system general maintenance and lubrication chart no. Item routine initial odometer readings 1000 km (600 mi) or 1 month 7000 km (4000 mi) or 6 months 13000 km (8000 mi) or 12 months 19000 km (12000 mi) or 18 months 25000 km (16000 mi)...

  • Page 76: Chk

    3 - 3 chk adj 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. Note: from 37000 km (24000 mi) or 36 months, repeat the maintenance intervals starting from 13000 km (8000 mi) or 1...

  • Page 77: Chk

    3 - 4 chk adj cowling and covers cowling and covers passenger seat and side covers 3 4 5 7 1 2 7 6 6 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) order job/part q’ty remarks removing the passenger seat and side covers remove the parts in the order listed. 1 upper rea...

  • Page 78: Chk

    3 - 5 chk adj cowling and covers rider seat and storage box t r . . 30 nm (3.0 m • kg, 22 ft • ib) 8 15 11 10 9 3 4 7 5 6 13 12 14 2 1 8 (4) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) order job/part q’ty remarks removing the ...

  • Page 79: Chk

    3 - 6 chk adj cowling and covers t r . . 30 nm (3.0 m • kg, 22 ft • ib) 8 15 11 10 9 3 4 7 5 6 13 12 14 2 1 8 (4) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) order job/part q’ty remarks 7 bottom plate 1 8 grab bar bracket 2 9 ...

  • Page 80: Chk

    3 - 7 chk adj cowling and covers eas00040 side cover mouldings and footrest boards 1 2 4 3 5 5 3 1 2 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the side cover mouldings and footrest boards remove the parts in the order listed. Storage box refer to “rider seat and sto...

  • Page 81: Chk

    3 - 8 chk adj cowling and covers eas00042 front cowling 10 6 3 1 13 5 5 2 11 12 7 8 4 9 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the front cowling r...

  • Page 82: Chk

    3 - 9 chk adj cowling and covers 10 6 3 1 13 5 5 2 11 12 7 8 4 9 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks 11 main switch cover 1 12 storage compartment 1 13 ...

  • Page 83: Chk

    3 - 10 chk adj air filter cases air filter cases t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 4 2 5 5 1 3 6 7 order job/part q’ty remarks removing the air filter cases remove the parts in the order listed. Storage box refer to “rider seat and storage box”. 1 crankcas...

  • Page 84: Chk

    3 - 11 chk adj adjusting the valve clearance eas00048 engine adjusting the valve clearance the following procedure applies to all of the valves. Note: _ • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the pi...

  • Page 85: Chk

    3 - 12 chk adj adjusting the valve clearance note: _ • tdc on the compression stroke can be found when the camshaft lobes are turned away from each other. • in order to be sure that the piston is at tdc, the punch marks c on the intake camshaft sprocket and the punch mark d on the exhaust camshaft s...

  • Page 86: Chk

    3 - 13 chk adj adjusting the valve clearance b. Select the proper valve pad from the follow- ing table. Note: _ • the thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. • since valve pads of various sizes are origi- nally installed, the va...

  • Page 87: Chk

    3 - 14 chk adj adjusting the valve clearance note: _ • lubricate the valve pad with molybdenum disulfide grease. • lubricate the valve lifter with molybdenum disulfide oil. • the valve lifter must turn smoothly when rotated by hand. • install the valve lifter and the valve pad in the correct place. ...

  • Page 88: Chk

    3 - 15 chk adj adjusting the valve clearance intake exhaust measured clearance installed pad number 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 ...

  • Page 89: Chk

    3 - 16 chk adj adjusting the valve clearance/ adjusting the exhaust gas volume 7. Install: • all removed parts refer to “cylinder head” in chapter 5. Note: _ for installation, reverse the removal proce- dure. Note the following points. Eas00869 adjusting the exhaust gas volume note: _ be sure to set...

  • Page 90: Chk

    3 - 17 chk adj adjusting the exhaust gas volume/ checking the engine idling speed 5. Check that “c1” appears on the odometer lcd, and then simultaneously press the “select” and “reset” buttons for 2 sec- onds or more. 6. Change the co adjustment volume by pressing the “select” and “reset” but- tons....

  • Page 91: Chk

    3 - 18 chk adj adjusting the throttle cable free play/ checking the spark plug eas00056 adjusting the throttle cable free play 1. Check: • throttle cable free play a out of specification → adjust. 2. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the l...

  • Page 92: Chk

    3 - 19 chk adj checking the spark plug 3. Remove: • spark plug caution: _ before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from fall- ing into the cylinder. 4. Check: • spark plug type incorrect → change. 5. Check: • electrode 1 ...

  • Page 93: Chk

    3 - 20 chk adj checking the ignition timing eas00064 checking the ignition timing note: _ prior to checking the ignition timing, check the wiring connections of the entire ignition sys- tem. Make sure all connections are tight and free of corrosion. 1. Remove: • storage box lower plate refer to “rid...

  • Page 94: Chk

    3 - 21 chk adj measuring the compression pressure eas00067 measuring the compression pressure note: _ insufficient compression pressure will result in a loss of performance. 1. Remove: • storage box lower plate refer to “rider seat and storage box”. 2. Measure: • valve clearance out of specification...

  • Page 95: Chk

    3 - 22 chk adj measuring the compression pressure 7. Measure: • compression pressure out of specification → refer to steps (c) and (d). ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compress...

  • Page 96: Chk

    3 - 23 chk adj measuring the compression pressure/ checking the engine oil level 8. Install: • spark plug 9. Connect: • spark plug cap 10.Install: • storage box lower plate refer to “rider seat and storage box”. T r . . 13 nm (1.3 m · kg, 9.4 ft · lb) eas00072 checking the engine oil level 1. Stand ...

  • Page 97: Chk

    3 - 24 chk adj checking the engine oil level/ changing the engine oil note: _ • api service “se”, “sf” and “sg” type or equivalent (e.G., “sf-se”, “sf-se-cc”, “sf- se-sd”) • before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for severa...

  • Page 98: Chk

    3 - 25 chk adj changing the engine oil 6. If the oil filter element is also to be replaced, perform the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the oil filter element cover 1 and oil filter element 2. B. Install new o-rings 3. C. Install the new oil filter el...

  • Page 99: Chk

    3 - 26 chk adj changing the engine oil 10.Fill: • crankcase (with the specified amount of the recom- mended engine oil) 11.Install: • engine oil filler cap 12.Start the engine, warm it up for several min- utes, and then turn it off. 13.Check: • engine (for engine oil leaks) 14.Check: • engine oil le...

  • Page 100: Chk

    3 - 27 chk adj changing the engine oil/ changing the transmission oil 16.Reset: • engine oil change indicator ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the key to “on”. B. Hold the reset button 1 pushed for two to eight seconds. C. Release the reset button and the engine oil change i...

  • Page 101: Chk

    3 - 28 chk adj changing the transmission oil/ replacing the air filter elements 7. Fill: • transmission case (with the specified amount of the recom- mended transmission oil) 8. Install: • transmission oil filler plug 1 • o-ring 2 9. Start the engine, warm it up for several min- utes, and then turn ...

  • Page 102: Chk

    3 - 29 chk adj replacing the air filter elements/ cleaning the v-belt case air filter element 3. Install: • air filter element • air filter case cover (along with the gasket) caution: _ never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engin...

  • Page 103: Chk

    3 - 30 chk adj cleaning the v-belt case air filter element/ checking the throttle body joint and intake manifold/ checking the fuel hose 6. Install: • footrest board (left) refer to “rider seat and storage box”. Eas00094 checking the throttle body joint and intake manifold 1. Remove: • storage box r...

  • Page 104: Chk

    3 - 31 chk adj checking the breather hoses eas00098 checking the breather hoses 1. Remove: • storage box refer to “rider seat and storage box”. 2. Check: • crankcase breather hose 1 • transmission case breather hose 2 cracks/damage → replace. Loose connection → connect properly. Caution: _ make sure...

  • Page 105: Chk

    3 - 32 chk adj checking the exhaust system/ checking the coolant level eas00099 checking the exhaust system the following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • footrest board (right) refer to “side cover mouldings and footrest boards”. 2. Check: • exhaust pipe 1 • m...

  • Page 106: Chk

    3 - 33 chk adj checking the coolant level/ checking the cooling system caution: _ • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • use only distilled wat...

  • Page 107: Chk

    3 - 34 chk adj checking the cooling system/ changing the coolant 3. Install: • footrest boards (left and right) refer to “side cover mouldings and footrest boards”. Eas00105 changing the coolant 1. Remove: • storage box • footrest board (right) refer to “side cover mouldings and footrest boards”. 2....

  • Page 108: Chk

    3 - 35 chk adj changing the coolant 7. Install: • copper washer • coolant drain bolt 8. Connect: • coolant reservoir hose 9. Remove: • air bleed bolt (coolant) 1 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) note: the specified amount of coolant is a standard amo...

  • Page 109: Chk

    3 - 36 chk adj changing the coolant caution: _ • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • use only distilled water. However, if dis- tilled water i...

  • Page 110: Chk

    3 - 37 chk adj adjusting the rear brake lock lever cable eas00116 chassis adjusting the rear brake lock lever cable note: • place the scooter on a suitable stand. • before adjusting the rear brake lock lever, check the rear brake fluid level. 1. Measure: • rear brake lock lever cable length a out of...

  • Page 111: Chk

    3 - 38 chk adj checking the brake fluid level checking the brake fluid level 1. Stand the scooter on a level surface. Note: _ • place the scooter on a suitable stand. • make sure the scooter is upright. 2. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to...

  • Page 112: Chk

    3 - 39 chk adj checking the front and rear brake pads/ checking the front and rear brake hoses eas00118 checking the front and rear brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad wear indicator groove a almost disap- peared → re...

  • Page 113: Chk

    3 - 40 chk adj bleeding the hydraulic brake system eas00134 bleeding the hydraulic brake system warning _ bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty....

  • Page 114: Chk

    3 - 41 chk adj bleeding the hydraulic brake system/ checking and adjusting the steering head g. Loosen the bleed screw. Note: _ loosening the bleed screw will release the pressure and cause the brake levers to contact the handlebar. H. Tighten the bleed screw and then release the brake lever. I. Rep...

  • Page 115: Chk

    3 - 42 chk adj checking and adjusting the steering head 3. Remove: • lower handlebar holder refer to “steering head” in chapter 4. 4. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the upper steering ring nut 1, the lock washer 2, the center steering ring nut 3 a...

  • Page 116: Chk

    3 - 43 chk adj checking and adjusting the steering head/ checking the front fork g. Finger tighten the center steering ring nut, and then align the slots of both ring nuts. If necessary, hold the lower steering ring nut and tighten the center steering ring nut until their slots are aligned. H. Insta...

  • Page 117: Chk

    3 - 44 chk adj checking the front fork/ checking the tires 4. Check: • front fork operation push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → repair. Refer to “front fork” in chapter 4. Eas00165 checking the tires the following procedure ap...

  • Page 118: Chk

    3 - 45 chk adj checking the tires warning _ it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: • tire surfaces damage/wear → replace the tire. 1 tire tread depth 2 sidewall 3 wear indicator warning _ • do not use a tubele...

  • Page 119: Chk

    3 - 46 chk adj checking the tires front tire rear tire manufacturer size model dunlop 120/80- 14m/c 58s d305fl irc 120/80- 14m/c 58s mb 67 manufacturer size model dunlop 150/70- 13m/c 64s d305l irc 150/70- 13m/c 64s mb 67 warning _ • new tires have a relatively low grip on the road surface until the...

  • Page 120: 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: • wheel damage/out-of-round → replace. Warning _ never attempt to make any repairs to the wheel. Note: _ after a tire or wheel has bee...

  • Page 121: Chk

    3 - 48 chk adj lubricating the levers/lubricating the sidestand/lubricating the centerstand eas00171 lubricating the levers lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant lithium-soap-based grease eas00172 lubricating the sidestand lubricate the piv...

  • Page 122: Chk

    3 - 49 chk adj checking and charging the battery eas00179 electrical system checking and charging the battery warning _ batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: •...

  • Page 123: Chk

    3 - 50 chk adj checking and charging the battery note: _ since mf batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery...

  • Page 124: Chk

    3 - 51 chk adj checking and charging the battery 5. Charge: • battery (refer to the appropriate charging method illustration) warning _ do not quick charge a battery. Caution: _ • never remove the mf battery sealing caps. • do not use a high-rate battery charger since it forces a high-amperage curre...

  • Page 125: Chk

    3 - 52 chk adj checking and charging the battery charging method using a variable-current (voltage) charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the b...

  • Page 126: Chk

    3 - 53 chk adj checking and charging the battery charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. No yes is the amperage higher than the standard charging amperage written on the batt...

  • Page 127: Chk

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

  • Page 128: Chk

    3 - 55 chk adj checking the fuses 2. Check: • fuse ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. Note: _ set the pocket tester selector to “ Ω × 1”. B. If the pocket tester indicates “ ∞”, replace the fuse. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ...

  • Page 129: Chk

    3 - 56 chk adj checking the fuses/ replacing the headlight bulbs warning _ never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to ...

  • Page 130: Chk

    3 - 57 chk adj replacing the headlight bulbs 5. Remove: • headlight bulb 1 warning _ since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 6. Install: • headlight bulb secure the new headlight bulb with the headlight bulb hol...

  • Page 131: Chk

    3 - 58 chk adj adjusting the headlight beams eas00185 adjusting the headlight beams the following procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw 1 in direction a or b. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 132: Chas

    Chas chapter 4 chassis front wheel and brake disc............................................................... 4-1 removing the front wheel............................................................ 4-3 checking the front wheel ............................................................ 4-3 chec...

  • Page 133: Chas

    Chas steering head.......................................................................................... 4-60 lower bracket ................................................................................. 4-60 removing the lower bracket..................................................... 4-62 ...

  • Page 134: Chas

    4 - 1 chas eas00513 chassis front wheel and brake disc 1 4 7 5 2 6 3 lt lt t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) order job/part q’ty remarks removing the front wheel and brake disc remove the parts in the order listed. No...

  • Page 135: Chas

    4 - 2 chas front wheel and brake disc eas00518 3 2 1 2 ls order job/part q’ty remarks disassembling the front wheel remove the parts in the order listed. 1 oil seal 1 2 bearing 2 3 collar 1 for assembly, reverse the disassembly procedure. Downloaded from www.Scootertime.Net.

  • Page 136: Chas

    4 - 3 chas front wheel and brake disc eas00520 removing the front wheel 1. Stand the scooter on a level surface. Warning _ securely support the scooter so that there is no danger of it falling over. 2. Elevate: • front wheel note: _ place the scooter on a suitable stand so that the front wheel is el...

  • Page 137: Chas

    4 - 4 chas front wheel and brake disc 4. Check: • wheel bearings front wheel turns roughly or is loose → replace the wheel bearings. • oil seals damage/wear → replace. 5. Replace: • wheel bearings • oil seal ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the outside of the front wheel hu...

  • Page 138: Chas

    4 - 5 chas front wheel and brake disc 2. Measure: • brake disc deflection out of specification → correct the brake disc deflection or replace the brake disc. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place the scooter on a suitable stand so that the wheel is elevated. B. Before measuring ...

  • Page 139: Chas

    4 - 6 chas front wheel and brake disc 4. Adjust: • brake disc deflection ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the brake disc. B. Rotate the brake disc by one bolt hole. C. Install the brake disc. Note: _ tighten the brake disc bolts in stages and in a crisscross pattern. D. Me...

  • Page 140: Chas

    4 - 7 chas front wheel and brake disc 2. Install: • spacer • speed sensor • front wheel note: _ • make sure that the projections on the speed sensor are installed in the slots on the wheel hub. • make sure that the slot a in the speed sen- sor fits over the stopper b on the outer tube. 3. Tighten: •...

  • Page 141: Chas

    4 - 8 chas front wheel and brake disc 2. Find: • front wheel’s heavy spot note: _ place the front wheel on a suitable balancing stand. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Spin the front wheel. B. When the front wheel stops, put an “x 1 ” mark at the bottom of the wheel. C. Turn the ...

  • Page 142: Chas

    4 - 9 chas rear wheel and brake disc eas00552 rear wheel and brake disc lt lt 1 2 t r . . 23 nm (2.3 m • kg, 17 ft • ib) ls order job/part q’ty remarks removing the rear wheel and brake disc remove the parts in the order listed. Note: _ place the scooter on a suitable stand so that the rear wheel is...

  • Page 143: Chas

    4 - 10 chas rear wheel and brake disc eas00561 removing the rear wheel 1. Stand the scooter on a level surface. Warning _ securely support the scooter so that there is no danger of it falling over. Note: _ place the scooter on a suitable stand so that the rear wheel is elevated. Eas00565 checking th...

  • Page 144: Chas

    4 - 11 chas front and rear brakes eas00577 front and rear brakes front brake pads t r . . 27 nm (2.7 m • kg, 19 ft • ib) 2 1 6 3 4 5 6 order job/part q’ty remarks removing the front brake pads remove the parts in the order listed. 1 front brake caliper retaining bolt 2 refer to “replacing the front ...

  • Page 145: Chas

    4 - 12 chas rear brake pads ls ls t r . . 27 nm (2.7 m • kg, 19 ft • ib) 1 2 3 4 4 order job/part q’ty remarks removing the rear brake pads remove the parts in the order listed. Air filter case (right) refer to “air filter cases” in chapter 3. 1 rear brake caliper retaining bolt 2 refer to “replacin...

  • Page 146: Chas

    4 - 13 chas front and rear brakes eas00579 caution: _ disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the entir...

  • Page 147: Chas

    4 - 14 chas front and rear brakes 3. Measure: • brake pad wear limit a out of specification → replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4. Install: • brake pad shims 1 • brake pads 2 • brake pad springs 3 note: _ always install new brake pads, new brake pad shims, and a ...

  • Page 148: Chas

    4 - 15 chas front and rear brakes 6. Install: • front brake caliper 1 • front brake caliper retaining bolts 2 1 2 t r . . 27 nm (2.7 m · kg, 19 ft · lb) 7. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fl...

  • Page 149: Chas

    4 - 16 chas front and rear brakes 3. Measure: • brake pad wear limit a out of specification → replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4. Install: • brake pad springs 1 • brake pads 2 • rear brake caliper note: always install new brake pads, and new brake pad springs as...

  • Page 150: Chas

    4 - 17 chas d. Install new brake pads, new pad springs, and the rear brake caliper. Note: align the projection c on the piston side of the brake pad with the lower recess in the brake caliper piston. È up É down ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Lubricate: • rear brake caliper ret...

  • Page 151: Chas

    4 - 18 chas front and rear brakes eas00584 front brake master cylinder order job/part q’ty remarks removing the front brake master cylinder remove the parts in the order listed. Upper handlebar cover refer to “handlebar”. Brake fluid drain. 1 brake master cylinder reservoir cap 1 2 brake master cyli...

  • Page 152: Chas

    4 - 19 chas order job/part q’ty remarks 9 brake master cylinder holder 1 refer to “assembling and install- ing the front brake master cylinder”. 10 brake master cylinder 1 11 front brake light switch 1 for installation, reverse the removal pro- cedure. Front and rear brakes downloaded from www.Scoot...

  • Page 153: Chas

    4 - 20 chas front and rear brakes eas00585 order job/part q’ty remarks disassembling the front brake mas- ter cylinder remove the parts in the order listed. 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 brake master cylinder body 1 for assembly, reverse the disassembly procedure. Downloa...

  • Page 154: Chas

    4 - 21 chas front and rear brakes eas00586 rear brake master cylinder order job/part q’ty remarks removing the rear brake master cyl- inder remove the parts in the order listed. Upper handlebar cover refer to “handlebar”. Brake fluid drain. 1 brake master cylinder reservoir cap 1 2 brake master cyli...

  • Page 155: Chas

    4 - 22 chas order job/part q’ty remarks 9 brake master cylinder holder 1 refer to “assembling and install- ing the rear brake master cyl- inder”. 10 brake master cylinder 1 11 rear brake light switch 1 for installation, reverse the removal pro- cedure. Front and rear brakes downloaded from www.Scoot...

  • Page 156: Chas

    4 - 23 chas front and rear brakes eas00587 order job/part q’ty remarks disassembling the rear brake mas- ter cylinder remove the parts in the order listed. 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 brake master cylinder body 1 for assembly, reverse the disassembly procedure. Download...

  • Page 157: Chas

    4 - 24 chas front and rear brakes eas00588 disassembling the front brake master cylinder note: _ before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hoses 3 note: _ to collect any remaining bra...

  • Page 158: Chas

    4 - 25 chas front and rear brakes eas00592 checking the front and rear brake master cylinders the following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder 1 damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) o...

  • Page 159: Chas

    4 - 26 chas front and rear brakes eas00596 assembling and installing the front brake master cylinder warning _ • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake components. 1. Install: • brake...

  • Page 160: Chas

    4 - 27 chas front and rear brakes note: _ • while holding the brake hose, tighten the union bolt as shown. • turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.G., wire harness, cables, leads). Correct if necessary. Caution: when installing the brake h...

  • Page 161: Chas

    4 - 28 chas front and rear brakes 6. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 7. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “b...

  • Page 162: Chas

    4 - 29 chas front and rear brakes 2. Install: • brake master cylinder 1 • brake master cylinder holder 2 note: • make sure to install the brake master cylin- der holder that has the “l” mark. • install the brake master cylinder holder with the “up” mark facing up. • align the end of the brake master...

  • Page 163: Chas

    4 - 30 chas front and rear brakes 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning _ • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refil...

  • Page 164: Chas

    4 - 31 chas front and rear brakes eas00612 front brake caliper order job/part q’ty remarks removing the front brake caliper remove the parts in the order listed. Brake fluid drain. 1 union bolt 1 refer to “disassembling the front brake caliper” and “assembling and installing the front brake caliper”...

  • Page 165: Chas

    4 - 32 chas eas00614 order job/part q’ty remarks disassembling the front brake cali- per remove the parts in the order listed. 1 brake caliper retaining bolt 2 2 brake caliper bracket 1 3 bleed screw 1 4 brake pad 2 5 brake pad shim 2 6 brake pad spring 1 7 brake pad spring 2 8 brake caliper piston ...

  • Page 166: Chas

    4 - 33 chas front and rear brakes eas00616 rear brake caliper t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 5 6 7 10 2 13 12 13 11 8 9 8 1 3 4 new ls order job/part q’ty remarks removing the rear brake caliper remove the parts in...

  • Page 167: Chas

    4 - 34 chas front and rear brakes t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 5 6 7 10 2 13 12 13 11 8 9 8 1 3 4 new ls order job/part q’ty remarks 8 rear brake caliper retaining bolt 2 refer to “assembling and install- ing the...

  • Page 168: Chas

    4 - 35 chas front and rear brakes eas00617 new t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) 4 1 3 2 new t r . . 22 nm (2.2 m • kg, 16 ft • ib) 5 6 order job/part q’ty remarks disassembling the rear brake cali- per remove the parts in the order listed. 1 brake caliper piston 1 refer to “disassembling the r...

  • Page 169: Chas

    4 - 36 chas front and rear brakes eas00619 disassembling the front brake caliper note: _ before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 note: _ put the end of the brake hose into a container and ...

  • Page 170: Chas

    4 - 37 chas front and rear brakes 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 note: _ put the end of the brake hose into a container and pump out the brake fluid carefully. 2 3 1 2. Remove: • brake caliper piston 1 • dust seal 2 • brake caliper piston seal 3 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 171: Chas

    4 - 38 chas front and rear brakes 1. Check: • brake caliper pistons 1 rust/scratches/wear → replace the brake caliper pistons. • brake caliper cylinders 2 scratches/wear → replace the brake cali- per assembly. • brake caliper body 3 cracks/damage → replace the brake cali- per assembly. • brake fluid...

  • Page 172: Chas

    4 - 39 chas front and rear brakes eas00635 assembling and installing the front brake caliper warning _ • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake components as they will cause the pisto...

  • Page 173: Chas

    4 - 40 chas front and rear brakes 4. Remove: • brake caliper 5. Install: • brake pad springs • brake pads • brake caliper retaining bolts refer to “replacing the front brake pads”. 6. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning _ • use...

  • Page 174: Chas

    4 - 41 chas front and rear brakes 8. Check: • brake fluid level below the minimum level mark a → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 9. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “b...

  • Page 175: Chas

    4 - 42 chas front and rear brakes 2. Install: • brake caliper piston 1 turn the brake caliper piston clockwise until section a of the brake caliper piston is level with the surface of the brake caliper body. Note: align the recesses b in the brake caliper pis- ton with the brake caliper body as show...

  • Page 176: Chas

    4 - 43 chas front and rear brakes warning _ • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a h...

  • Page 177: Chas

    4 - 44 chas front fork eas00646 front fork t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 70 nm (7.0 m • kg, 50 ft • lb) 7 8 5 6 4 6 4 9 10 2 1 3 new order job/part q’ty remarks remov...

  • Page 178: Chas

    4 - 45 chas t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 70 nm (7.0 m • kg, 50 ft • lb) 7 8 5 6 4 6 4 9 10 2 1 3 new order job/part q’ty remarks 7 cap bolt 1 refer to “removing the ...

  • Page 179: Chas

    4 - 46 chas front fork eas00648 1 2 7 8 0 a 3 4 b c d 9 e 6 5 t r . . 30 nm (3.0 m • kg, 22 ft • ib) new new new new lt order job/part q’ty remarks disassembling the front fork legs remove the parts in the order listed. The following procedure applies to both of the front fork legs. 1 fork spring se...

  • Page 180: Chas

    4 - 47 chas 1 2 7 8 0 a 3 4 b c d 9 e 6 5 t r . . 30 nm (3.0 m • kg, 22 ft • ib) new new new new lt order job/part q’ty remarks c washer 1 refer to “disassembling the front fork legs” and “assem- bling the front fork legs”. D outer tube bushing 1 e outer tube 1 for assembly, reverse the disassembly ...

  • Page 181: Chas

    4 - 48 chas front fork eas00651 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface. Warning _ securely support the scooter so that there is no danger of it falling over. Note: _ place the scooter on a suitable stand so...

  • Page 182: Chas

    4 - 49 chas front fork 3. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) caution: _ do not scratch the inner tube. 4. Remove: • damper rod bolt 1 note: _ while holding the damper rod with the damper rod holder 2 and t-handle 3, loosen the damper rod bolt. Damper rod holder 90...

  • Page 183: Chas

    4 - 50 chas front fork eas00656 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 bends/damage/scratches → replace. Warning _ do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measur...

  • Page 184: Chas

    4 - 51 chas front fork note: _ • when assembling the front fork leg, be sure to replace the following parts: - inner tube bushing - outer tube bushing - oil seal - dust seal - cap bolt o-ring • before assembling the front fork leg, make sure all of the components are clean. 1. Install: • damper rod ...

  • Page 185: Chas

    4 - 52 chas front fork 4. Install: • outer tube bushing 1 • washer 2 (with the fork seal driver weight 3 and fork seal driver attachment 4) 5. Install: • oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachment 3) caution: _ make sure the numbered side of the oil seal faces up....

  • Page 186: Chas

    4 - 53 chas front fork 8. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) note: _ • while filling the front fork leg, keep it upright. • after filling, slowly pump the front fork leg up and down to distribute the fork oil. 9. Install: • fork spring 1 • fork spring se...

  • Page 187: Chas

    4 - 54 chas handlebar eas00664 handlebar t r . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) 19 1 4 3 2 11 12 2 10 11...

  • Page 188: Chas

    4 - 55 chas t r . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) 19 1 4 3 2 11 12 2 10 11 5 17 18 3 9 5 6 7 14 8 13 16...

  • Page 189: Chas

    4 - 56 chas handlebar eas00666 removing the handlebar 1. Stand the scooter on a level surface. Warning _ securely support the scooter so that there is no danger of it falling over. 2. Remove: • handlebar grip 1 note: _ blow compressed air between the handlebar and the handlebar grip, and gradually p...

  • Page 190: Chas

    4 - 57 chas handlebar 2. Install: • handlebar 1 • upper handlebar holders 2 caution: _ first, tighten the bolts on the front side of the handlebar holders, and then on the rear side. Note: _ • the upper handlebar holders should be installed with the arrow marks a facing for- ward È. • align the matc...

  • Page 191: Chas

    4 - 58 chas handlebar 5. Install: • rear brake lock lever cable 1 note: lubricate the inside of the rear brake lock lever cable and rear brake lock lever with a thin coat of lithium-soap-based grease. 1 ls 6. Install: • left handlebar switch 1 note: align the projection a on the left handlebar switc...

  • Page 192: Chas

    4 - 59 chas 9. Install: • right handlebar switch 1 warning _ make sure the throttle grip operates smoothly. Note: _ align the projection a on the right handlebar switch with the hole b in the handlebar. 1 b a 10.Install: • grip end (left) note: there should be 1 ~ 3 mm (0.04 ~ 0.12 in) of clearance ...

  • Page 193: Chas

    4 - 60 chas steering head eas00675 steering head lower bracket 17 14 13 12 4 6 7 8 9 10 3 2 11 18 5 1 16 15 ls ls t r . . 1st 36 nm (3.6 m • kg, 25 ft • lb) 2nd 24 nm (2.4 m • kg, 17 ft • lb) t r . . 90 nm (9.0 m • kg, 65 ft • ib) t r . . 140 nm (14.0 m • kg, 100 ft • lb) t r . . 7 nm (0.7 m • kg, 5...

  • Page 194: Chas

    4 - 61 chas steering head 17 14 13 12 4 6 7 8 9 10 3 2 11 18 5 1 16 15 ls ls t r . . 1st 36 nm (3.6 m • kg, 25 ft • lb) 2nd 24 nm (2.4 m • kg, 17 ft • lb) t r . . 90 nm (9.0 m • kg, 65 ft • ib) t r . . 140 nm (14.0 m • kg, 100 ft • lb) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remar...

  • Page 195: Chas

    4 - 62 chas steering head eas00680 removing the lower bracket 1. Stand the scooter on a level surface. Warning _ securely support the scooter so that there is no danger of it falling over. 2. Remove: • handlebar lower holder 1 • woodruff key 2 note: remove the handlebar lower holder by loosen- ing t...

  • Page 196: Chas

    4 - 63 chas steering head eas00681 checking the steering head 1. Wash: • bearings • bearing races recommended cleaning solvent kerosene 2. Check: • bearings 1 • bearing races 2 damage/pitting → replace. 3. Replace: • bearings • bearing races ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov...

  • Page 197: Chas

    4 - 64 chas steering head eas00684 installing the steering head 1. Lubricate: • upper bearing • lower bearing • bearing races recommended lubricant lithium-soap-based grease 2. Clean: • lower bracket • lower handlebar holder note: clean the area a of the lower bracket indi- cated in the illustration...

  • Page 198: Chas

    4 - 65 chas rear shock absorber assemblies and swingarm eas00685 rear shock absorber assemblies and swingarm 4 4 1 6 8 9 10 7 11 5 2 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 135 nm (13.5 m • kg, 98 ft • lb) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 46 nm (4.6 m • kg, 33 ft • ib) ls ls 3 ...

  • Page 199: Chas

    4 - 66 chas rear shock absorber assemblies and swingarm 4 4 1 6 8 9 10 7 11 5 2 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 135 nm (13.5 m • kg, 98 ft • lb) t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 46 nm (4.6 m • kg, 33 ft • ib) ls ls 3 t r . . 34 nm (3.4 m • kg, 24 ft • ib) t r . . 29 nm ...

  • Page 200: Chas

    4 - 67 chas rear shock absorber assemblies and swingarm eas00693 removing the rear shock absorber assemblies 1. Stand the scooter on a level surface. Warning _ securely support the scooter so that there is no danger of it falling over. Note: _ place the scooter on a suitable stand so that the rear w...

  • Page 201: Chas

    4 - 68 chas rear shock absorber assemblies and swingarm eas00702 removing the swingarm 1. Stand the scooter on a level surface. Warning _ securely support the scooter so that there is no danger of it falling over. Note: _ place the scooter on a suitable stand so that the rear wheel is elevated. 2. R...

  • Page 202: Chas

    4 - 69 chas rear shock absorber assemblies and swingarm eas00711 installing the swingarm 1. Lubricate: • bearing • oil seal lips • drive axle splines recommended lubricant lithium-soap-based grease 2. Install: • swingarm 1 • rear shock absorber assembly lower bolt (right) 2 • brake hose holder 3 • r...

  • Page 203: Eng

    Eng chapter 5 engine engine removal ........................................................................................ 5-1 leads, hoses, exhaust pipe and muffler ................................. 5-1 engine...........................................................................................

  • Page 204: Eng

    Eng belt drive.................................................................................................. 5-37 v-belt case cover ........................................................................... 5-37 v-belt and primary/secondary sheave................................... 5-38 seconda...

  • Page 205: Eng

    5 - 1 eng eas00188 engine engine removal leads, hoses, exhaust pipe and muffler 3 1 2 5 6 7 t r . . 53 nm (5.3 m • kg, 38 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) new 4 order job/part q’ty remarks removing the leads, hoses, exhaust pipe and muffler remov...

  • Page 206: Eng

    5 - 2 eng 3 1 2 5 6 7 t r . . 53 nm (5.3 m • kg, 38 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) new 4 order job/part q’ty remarks starter motor refer to “starter motor” in chapter 8. Thermostat cover and thermostat refer to “thermostat” in chapter 6. Rear b...

  • Page 207: Eng

    5 - 3 eng eas00191 engine t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) t r . . 29 nm (2.9 m • kg, 21 ft • ib) t r . . 65 nm (6.5 m • kg, 47 ft • ib) t r . . 56 nm (5.6 m • kg, 40 ft • ib) ls 2 2 5 3 4 5 9 8 7 11 10 6 6 5 1 5 ls lt lt 4 3 lt lt ls 7 order job/part q’t...

  • Page 208: Eng

    5 - 4 eng t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) t r . . 29 nm (2.9 m • kg, 21 ft • ib) t r . . 65 nm (6.5 m • kg, 47 ft • ib) t r . . 56 nm (5.6 m • kg, 40 ft • ib) ls 2 2 5 3 4 5 9 8 7 11 10 6 6 5 1 5 ls lt lt 4 3 lt lt ls 7 order job/part q’ty remarks 10 rig...

  • Page 209: Eng

    5 - 5 eng engine removal eas00192 installing the engine 1. Install: • right engine bracket 1 • center engine bracket 2 • left engine bracket 3 • engine mounting bolt/nut 4 • engine bracket bolts 5 note: _ • apply lithium-soap-based grease to the unthreaded portion of the engine mounting bolt shaft. ...

  • Page 210: Eng

    5 - 6 eng eas00194 camshafts cylinder head cover new t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) (9) 1 2 3 4 5 5 order job/part q’ty remarks removing the cylinder head cover remove the parts in the order listed. Storage box and rubber sheet refer to “cowling and c...

  • Page 211: Eng

    5 - 7 eng camshafts eas00196 camshafts t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) 1 new ls (8) e m e m 5 6 4 12 13 10 14 7 8 8 3 2 (4) (4) 4 11 9 ...

  • Page 212: Eng

    5 - 8 eng t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) 1 new ls (8) e m e m 5 6 4 12 13 10 14 7 8 8 3 2 (4) (4) 4 11 9 order job/part q’ty remarks 1...

  • Page 213: Eng

    5 - 9 eng camshafts eas00198 removing the camshafts 1. Remove: • timing plug • v-belt case air filter cover 1 • v-belt case air filter element 2. Align: • tdc mark on the generator rotor (with the stationary pointer on the generator rotor cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T...

  • Page 214: Eng

    5 - 10 eng camshafts 6. Remove: • camshaft cap 1 • dowel pins note: _ • loosen the camshaft cap bolts in the descending order of the embossed numbers on the camshaft cap. • loosen each camshaft cap bolt 1/2 of a turn at a time. After all of the camshaft cap bolts are fully loosened, remove them. 7. ...

  • Page 215: Eng

    5 - 11 eng 3. Measure: • camshaft runout out of specification → replace. Camshaft runout limit 0.03 mm (0.0012 in) 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance out of specification → measure the cam- shaft journal diameter. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install t...

  • Page 216: Eng

    5 - 12 eng camshafts 5. Measure: • camshaft journal diameter a out of specification → replace the cam- shaft. Within specification → replace the cylinder head and the camshaft cap as a set. Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) checking the camshaft sprockets 1. Check: • ...

  • Page 217: Eng

    5 - 13 eng camshafts eas00210 checking the timing chain tensioner 1. Check: • timing chain tensioner cracks/damage/rough movement → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise wi...

  • Page 218: Eng

    5 - 14 eng camshafts 3. Install: • intake camshaft 1 • exhaust camshaft 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the primary sheave nut on the left side of the crankshaft counterclockwise to turn the crankshaft. B. When piston is at tdc on the compression stroke, align the “i” mar...

  • Page 219: Eng

    5 - 15 eng camshafts caution: _ the camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft cap, and camshafts will result. 6. Install: • timing chain tensioner ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While lightly pressing the timing chain ten- sioner rod b...

  • Page 220: Eng

    5 - 16 eng camshafts 8. Turn: • crankshaft (turn the primary sheave nut on the left side of the crankshaft several turns counter- clockwise) 9. Check: • “i” mark make sure the “i” mark on the generator rotor is aligned with the stationary pointer on the generator rotor cover. • camshaft sprocket pun...

  • Page 221: Eng

    5 - 17 eng eas00221 cylinder head t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 52 nm (5.2 m • kg, 37 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) 8 9 9 7 6 5 4 1 10 3 2 e e ne...

  • Page 222: Eng

    5 - 18 eng t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 52 nm (5.2 m • kg, 37 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) 8 9 9 7 6 5 4 1 10 3 2 e e new new order job/part q’...

  • Page 223: Eng

    5 - 19 eng cylinder head eas00222 removing the cylinder head 1. Remove: • cylinder head nuts note: _ • loosen the cylinder head nuts in the proper sequence as shown. • loosen each cylinder head nut 1/2 of a turn at a time. After all of the cylinder head nuts are fully loosened, remove them. Eas00229...

  • Page 224: Eng

    5 - 20 eng cylinder head checking the timing chain guide (exhaust side) 1. Check: • timing chain guide (exhaust side) damage/wear → replace. Eas00232 installing the cylinder head 1. Install: • timing chain guide (exhaust side) • cylinder head gasket • dowel pins 2. Install: • cylinder head note: _ p...

  • Page 225: Eng

    5 - 21 eng valves and valve springs eas00236 valves and valve springs m m new e 1 1 2 3 3 4 5 6 7 2 3 3 4 5 6 7 9 8 new m m m e m 10 10 order job/part q’ty remarks removing the valves and valve springs remove the parts in the order listed. Cylinder head refer to “cylinder head”. 1 valve lifter 4 ref...

  • Page 226: Eng

    5 - 22 eng valves and valve springs 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. Remove: •...

  • Page 227: Eng

    5 - 23 eng valves and valve springs 4. Remove: • upper spring seat 1 • valve spring 2 • valve stem seal 3 • lower spring seat 4 • valve 5 note: _ identify the position of each part very carefully so that it can be reinstalled in its original place. Eas00239 checking the valves and valve guides the f...

  • Page 228: Eng

    5 - 24 eng valves and valve springs 2. Replace: • valve guide note: _ to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide with the valve guide ...

  • Page 229: Eng

    5 - 25 eng valves and valve springs 6. Measure: • valve stem runout out of specification → replace the valve. Note: _ • when installing a new valve, always replace the valve guide. • if the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.01 mm (0.0004 in) eas00240 chec...

  • Page 230: Eng

    5 - 26 eng valves and valve springs note: _ where the valve seat and valve face contacted one another, the blueing will have been removed. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Lap: • valve face • valve seat note: _ after replacing the cylinder head or replacing the valve and valve gu...

  • Page 231: Eng

    5 - 27 eng valves and valve springs j. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas00241 checking the valve springs the following procedure applies to all of the valve springs...

  • Page 232: Eng

    5 - 28 eng 3. Measure: • valve spring tilt a out of specification → replace the valve spring. Spring tilt limit 2.0 mm (0.08 in) eas00242 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: • valve lifter damage/scratches → replace the valve lift- ers an...

  • Page 233: Eng

    5 - 29 eng valves and valve springs note: _ install the valve spring with the larger pitch a facing up. B smaller pitch 4. Install: • valve cotters 1 note: _ install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attach- ment 3. V...

  • Page 234: Eng

    5 - 30 eng cylinder and piston eas00251 cylinder and piston new new new new e e ls t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 4 5 7 8 7 3 6 6 1 2 9 10 order job/part q’ty remarks removing the cylinder and piston remove the p...

  • Page 235: Eng

    5 - 31 eng cylinder and piston eas00253 removing the piston 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 caution: _ do not use a hammer to drive the piston pin out. Note: _ • before removing the piston pin clip, cover the crankcase opening with a clean rag to pre- vent the piston pin cli...

  • Page 236: Eng

    5 - 32 eng cylinder and piston 2. Measure: • piston-to-cylinder clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore “c” with the cylinder bore gauge. Note: _ measure cylinder bore “c” by taking side-to- side and front-to-back measurements of the cylinder. Then, find ...

  • Page 237: Eng

    5 - 33 eng cylinder and piston eas00263 checking the piston rings 1. Measure: • piston ring side clearance out of specification → replace the piston and piston rings as a set. Note: _ before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and pi...

  • Page 238: Eng

    5 - 34 eng cylinder and piston eas00265 checking the piston pin 1. Check: • piston pin blue discoloration/grooves → replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a out of specification → replace the piston pin. 3. Measure: • piston pin bore d...

  • Page 239: Eng

    5 - 35 eng note: _ be sure to install the top and 2nd rings so that the manufacturer’s marks or numbers face up. 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 note: _ • apply engine oil onto the piston pin. • make sure the arrow mark a on the piston points towards the exhaust side of th...

  • Page 240: Eng

    5 - 36 eng cylinder and piston 6. Install: • dowel pins • cylinder gasket • cylinder • cylinder bolt note: _ • while compressing the piston rings with one hand, install the cylinder with the other hand. • pass the timing chain and timing chain guide (exhaust side) through the timing chain cav- ity. ...

  • Page 241: Eng

    5 - 37 eng belt drive eas00316 belt drive v-belt case cover t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 22 nm (2.2 m • kg, 16 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 1 (4...

  • Page 242: Eng

    5 - 38 eng v-belt and primary/secondary sheave * apply shell bt grease 3 ® (yamaha grease g 90890-40010) ** apply bel-ray assembly lube ® order job/part q’ty remarks removing the v-belt and primary/ secondary sheave remove the parts in the order listed. 1 primary sheave nut/collar 1/1 refer to “remo...

  • Page 243: Eng

    5 - 39 eng * apply shell bt grease 3 ® (yamaha grease g 90890-40010) ** apply bel-ray assembly lube ® order job/part q’ty remarks 11 weight 8 12 slider 4 13 spacer 1 14 o-ring 1 for installation, reverse the removal procedure. Belt drive downloaded from www.Scootertime.Net.

  • Page 244: Eng

    5 - 40 eng secondary sheave ** apply bel-ray assembly lube ® order job/part q’ty remarks disassembling the secondary sheave remove the parts in the order listed. 1 clutch shoe assembly nut 1 refer to “disassembling the sec- ondary sheave” and “assembling the secondary sheave”. 2 clutch shoe assembly...

  • Page 245: Eng

    5 - 41 eng ** apply bel-ray assembly lube ® order job/part q’ty remarks b circlip 1 c bearing 1 for assembly, reverse the disassembly procedure. Belt drive downloaded from www.Scootertime.Net.

  • Page 246: Eng

    5 - 42 eng belt drive eas00317 removing the primary sheave 1. Remove: • primary sheave nut 1 • collar • primary fixed sheave 2 note: _ while holding the primary fixed sheave with the rotor holding tool 3, loosen the primary sheave nut. Rotor holding tool 90890-01235, yu-01235 1 3 2 eas00318 removing...

  • Page 247: Eng

    5 - 43 eng belt drive 2. Loosen: • clutch shoe assembly nut 1 caution: _ do not remove the clutch shoe assembly nut at this stage. Note: _ while holding the clutch shoe assembly with the rotor holding tool 2, loosen the clutch shoe assembly nut one full turn with the lock- nut wrench 3. Rotor holdin...

  • Page 248: Eng

    5 - 44 eng belt drive eas00320 checking the v-belt 1. Check: • v-belt 1 cracks/damage/wear → replace. Grease/oil → clean the primary and sec- ondary sheaves. 2. Measure: • v-belt width 2 out of specification → replace. Checking the v-belt case air ducts 1. Check: • v-belt case air ducts cracks/damag...

  • Page 249: Eng

    5 - 45 eng belt drive eas00322 checking the secondary sheave 1. Check: • secondary fixed sheave • secondary sliding sheave cracks/damage/wear → replace the sec- ondary fixed and sliding sheaves as a set. 2. Check: • torque cam groove 1 damage/wear → replace the secondary fixed and sliding sheaves as...

  • Page 250: Eng

    5 - 46 eng belt drive eas00323 assembling the primary sheave 1. Clean: • primary fixed sheave 1 • primary sliding sheave 2 • collar 3 • primary sheave weights 4 • cam 2. Lubricate: • collar’s inner and outer surface 3. Install: • primary sheave weights • collar 4. Install: • sliders • cam recommende...

  • Page 251: Eng

    5 - 47 eng belt drive 3. Install: • guide pin 1 4. Lubricate: • guide pin groove 2 • o-ring 3 (with the recommended lubricant) 5. Install: • spring seat • compression spring • clutch shoe assembly • clutch shoe assembly nut 1 note: _ attach the sheave spring compressor 2 and sheave fixed block 3 ont...

  • Page 252: Eng

    5 - 48 eng belt drive 2. Tighten: • clutch shoe assembly nut 1 note: _ while holding the clutch shoe assembly with the rotor holding tool 2, tighten the clutch shoe assembly nut with the locknut wrench 3. 3. Install: • clutch housing 1 • collar • secondary sheave nut 2 note: while holding the clutch...

  • Page 253: Eng

    5 - 49 eng starter clutch and generator eas00341 starter clutch and generator generator rotor cover and stator coil order job/part q’ty remarks removing the generator rotor cover and stator coil remove the parts in the order listed. Side cover (right) refer to “cowling and covers” in chapter 3. Engi...

  • Page 254: Eng

    5 - 50 eng starter clutch and generator order job/part q’ty remarks 3 water pump inlet hose 1 disconnect. 4 oil cooler outlet hose 1 disconnect. 5 crankshaft position sensor/stator assembly coupler 2 disconnect. 6 generator rotor cover 1 refer to “installing the genera- tor”. 7 gasket 1 8 dowel pin ...

  • Page 255: Eng

    5 - 51 eng starter clutch and generator eas00343 starter clutch and generator order job/part q’ty remarks removing the starter clutch and generator remove the parts in the order listed. 1 generator rotor 1 refer to “removing the genera- tor”, “installing the starter clutch” and “installing the gen- ...

  • Page 256: Eng

    5 - 52 eng starter clutch and generator eas00347 removing the generator 1. Remove: • generator rotor cover bolts • generator rotor cover 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: • generat...

  • Page 257: Eng

    5 - 53 eng starter clutch and generator 4. Remove: • starter clutch bolts • starter clutch flywheel puller 90890-01362 flywheel puller attachment 90890-04089, ym-33282 eas00351 checking the starter clutch 1. Check: • starter clutch rollers 1 damage/wear → replace. 2. Check: • starter clutch idle gea...

  • Page 258: Eng

    5 - 54 eng starter clutch and generator eas00355 installing the starter clutch 1. Install: • starter clutch bolts 1 note: _ • while holding the generator rotor 2 with the sheave holder 3, tighten the starter clutch bolts. • do not allow the sheave holder to touch the projection on the generator roto...

  • Page 259: Eng

    5 - 55 eng starter clutch and generator 3. Apply: • sealant (onto the crankshaft position sensor/stator assembly lead grommet) 4. Install: • generator rotor cover • generator rotor cover bolts note: • align the projection a on the impeller shaft with the slit b on the balancer shaft. • tighten the g...

  • Page 260: Eng

    5 - 56 eng oil pump eas00356 oil pump order job/part q’ty remarks removing the oil pump remove the parts in the order listed. Generator rotor refer to “starter clutch and gen- erator”. 1 oil pump assembly 1 refer to “assembling the oil pump” and “installing the oil pump”. 2 oil pump gasket 1 refer t...

  • Page 261: Eng

    5 - 57 eng oil pump eas00364 checking the oil pump 1. Check: • oil pump drive sprocket • oil pump driven sprocket • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-housi...

  • Page 262: Eng

    5 - 58 eng oil pump eas00375 assembling the oil pump 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) 2. Install: • oil pump shaft 1 (to the oil pump cover 2) • pin 3 • inner rotor 4 • outer rotor 5 • oil pump housing 6 • screw note: _ when installing the i...

  • Page 263: Eng

    5 - 59 eng crankshaft eas00381 crankshaft crankshaft assembly and balancer shaft assembly t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) new new new (7) (3) t r . . 30 nm (3.0 m • kg, 22 ft • ib) new 10 8 6 7 4 5 8 2 1 3 9 11 12...

  • Page 264: Eng

    5 - 60 eng crankshaft t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) new new new (7) (3) t r . . 30 nm (3.0 m • kg, 22 ft • ib) new 10 8 6 7 4 5 8 2 1 3 9 11 12 14 13 e e e lt lt e order job/part q’ty remarks 6 dowel pin 1 7 o-r...

  • Page 265: Eng

    5 - 61 eng crankshaft crankcase bearings 4 2 1 3 3 new e e ls order job/part q’ty remarks removing the crankcase bearings remove the parts in the order listed. 1 left crankshaft journal bearing 1 refer to “removing the crank- shaft journal bearings” and “installing the crankshaft journal bearings”. ...

  • Page 266: Eng

    5 - 62 eng crankshaft eas00385 disassembling the crankcase 1. Remove: • crankcase bolts note: _ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • right crankcase caution: _ tap on one side of the cran...

  • Page 267: Eng

    5 - 63 eng crankshaft eas00394 checking the crankshaft and connecting rod 1. Measure: • crankshaft runout out of specification → replace the crank- shaft, bearing or both. Note: _ turn the crankshaft slowly. 2. Check: • crankshaft journal surfaces scratches/wear → replace the crankshaft. Maximum cra...

  • Page 268: Eng

    5 - 64 eng crankshaft note: if either the left or right journal bearing is worn or scratched, replace both bearings as a set. C. Measure the crankshaft journal outside diameter a in two places. If it is out of spec- ification, replace the crankshaft. D. Measure the journal bearing inside diame- ter ...

  • Page 269: Eng

    5 - 65 eng crankshaft ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ select the crankshaft journal bearings from the following table according to the number stamped on the inside of the crankcase. Left crankshaft journal bearing: right crankshaft journal bearing: after replacing the crankshaft jo...

  • Page 270: Eng

    5 - 66 eng crankshaft 7. Check: • crankshaft sprocket 1 damage/wear → replace the crankshaft. • balancer drive gear 2 damage/wear → replace the crankshaft. 2 1 8. Check: • crankshaft journal scratches/wear → replace the crankshaft. • crankshaft journal oil passage obstruction → blow out with compres...

  • Page 271: Eng

    5 - 67 eng crankshaft eas00207 checking the timing chain and timing chain guide (intake side) 1. Check: • timing chain damage/stiffness → replace the timing chain and camshaft sprockets as a set. 2. Check: • timing chain guide (intake side) damage/wear → replace. Checking the oil pump gears and shaf...

  • Page 272: Eng

    5 - 68 eng crankshaft eas00402 checking the circlips and washers 1. Check: • circlips bends/damage/looseness → replace. • washers bends/damage → replace. Installing the crankshaft journal bearings 1. Attach: • crankshaft journal bearings 1 note: attach the crankshaft journal bearing to the installer...

  • Page 273: Eng

    5 - 69 eng crankshaft eas00410 installing the crankshaft assembly and balancer shaft assembly 1. Install: • crankshaft assembly • balancer shaft assembly note: _ align the punch mark a in the balancer drive gear with the punch mark b in the balancer driven gear. A b eas00418 assembling the crankcase...

  • Page 274: Eng

    5 - 70 eng 3. Tighten: • crankcase bolts note: tighten the crankcase bolts in stages and in a crisscross pattern. • m8 × 100 mm (3.94 in) bolt: 1 • m8 × 90 mm (3.54 in) bolt: 2 • m8 × 80 mm (3.15 in) bolt: 3 • m8 × 60 mm (2.36 in) bolts: 4 • m6 × 70 mm (2.76 in) bolts: 5 t r . . Crankcase bolt bolt ...

  • Page 275: Eng

    5 - 71 eng transmission eas00419 transmission order job/part q’ty remarks removing the transmission remove the parts in the order listed. Rear wheel refer to “rear wheel and brake disc” in chapter 4. Transmission oil drain. Refer to “changing the transmis- sion oil” in chapter 3. Secondary sheave as...

  • Page 276: Eng

    5 - 72 eng order job/part q’ty remarks 8 drive axle 1 9 main axle 1 10 washer 1 11 primary driven gear 1 12 washer 1 for installation, reverse the removal procedure. Transmission downloaded from www.Scootertime.Net.

  • Page 277: Eng

    5 - 73 eng transmission eas00425 checking the transmission 1. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cracks/damage/rounded edges → replace the defective gear(s). 2. Check: • transmission gear movement rough movement → rep...

  • Page 278: Cool

    Cool chapter 6 cooling system radiator ...................................................................................................... 6-1 checking the radiator.................................................................... 6-2 installing the radiator........................................

  • Page 279: Cool

    6 - 1 cool eas00454 cooling system radiator 3 8 6 1 2 7 4 5 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the radiator remove the parts in the order listed. Radiator cover refer to “cowling and covers” in chapter 3. Coolant drain. ...

  • Page 280: Cool

    6 - 2 cool radiator eas00455 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radi- ator. Damage → repair or replace. Note: _ straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: • radiator inlet hose • radiator outl...

  • Page 281: Cool

    6 - 3 cool radiator eas00456 installing the radiator 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2. Check: • cooling system leaks → repair or replace any faulty part. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼...

  • Page 282: Cool

    6 - 4 cool thermostat eas00460 thermostat 1 3 2 5 4 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) order job/part q’ty remarks removing the thermostat remove the parts in the order listed. Storage box refer to “cowling and covers” in chapter 3. Rubber sheet coolant dr...

  • Page 283: Cool

    6 - 5 cool thermostat eas00462 checking the thermostat 1. Check: • thermostat 1 does not open at 70.5 ~ 73.5 °c (158.9 ~ 164.3 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer...

  • Page 284: Cool

    6 - 6 cool thermostat eas00467 installing the thermostat 1. Install: • thermostat 1 • thermostat cover 2. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 3. Check: • cooling system leaks → repair or replace any faulty part...

  • Page 285: Cool

    6 - 7 cool water pump and oil cooler eas00469 water pump and oil cooler 7 8 10 11 12 13 3 4 5 2 1 6 9 new new new new new new new t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) ls lt lt lt...

  • Page 286: Cool

    6 - 8 cool water pump and oil cooler 7 8 10 11 12 13 3 4 5 2 1 6 9 new new new new new new new t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) ls lt lt lt e order job/part q’ty remarks 11 w...

  • Page 287: Cool

    6 - 9 cool water pump and oil cooler eas00473 checking the water pump 1. Check: • water pump cover • impeller shaft • water pump seal cracks/damage/wear → replace. 2. Check: • bearing rough movement → replace. 3. Check: • water pump inlet hose • water pump outlet hose • thermostat inlet hose cracks/...

  • Page 288: Cool

    6 - 10 cool water pump and oil cooler eas00475 assembling the water pump 1. Install: • bearing • circlip • water pump seal 1 (into the generator rotor cover 2) note: _ install the water pump seal with the special tools. È push down. Mechanical seal installer 90890-04145, ym-04145 3 middle driven sha...

  • Page 289: Chapter  7

    Fi chapter 7 fuel injection system fuel injection system............................................................................ 7-1 wiring diagram ................................................................................... 7-2 ecu’s self-diagnostic function.................................

  • Page 290: Fuel Injection System

    7 - 1 fi fuel injection system eas00894 fuel injection system fuel injection system 1 ecu 2 fuel injection system relay 3 engine trouble warning light 4 lean angle cut-off switch 5 fuel hose 6 ignition coil 7 fuel injector 8 intake air pressure sensor 9 throttle position sensor 0 isc (idle speed con...

  • Page 291

    7 - 2 fi fuel injection system wiring diagram b b sub-wire harness 1 wire harness a g b y g b y ( blue ) l /y b ( blue ) b b b lc h l bc h b ld g l bd g (black) (black) dg ch g /b br /w bb r r /y p g /y r /y g /y p br /w br b g /b dg ch r l/ g rw l/ gr /g w /lw /r o /br /l ly (black) (black) dg br c...

  • Page 292

    7 - 3 fi fuel injection system ecu’s self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute cha...

  • Page 293

    7 - 4 fi fuel injection system eas00901 checking for a defective engine trouble warning light bulb the engine trouble warning light comes on for 1.4 seconds after the main switch has been turned “on” and when the start switch is being pushed. If the warning light does not come on under these conditi...

  • Page 294

    7 - 5 fi fuel injection system communication error with the meter 37 isc (idle speed con- trol) valve (stuck fully open) engine speed is high when the engine is idling. -- able able 39 fuel injector fuel injector open or short cir- cuit is detected. -- unable unable 30 41 lean angle cut-off switch (...

  • Page 295

    7 - 6 fi eas00904 troubleshooting chart engine operation is not normal or the engine trouble warning light is on. * engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. Check the fault code number displayed on the meter. ...

  • Page 296

    7 - 7 fi fuel injection system eas00905 diagnostic mode it is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diag...

  • Page 297

    7 - 8 fi fuel injection system 7. Verify the operation of the sensor or actua- tor. • sensor operation the data representing the operating condi- tions of the sensor appears on the trip lcd. • actuator operation set the engine stop switch to “on” to oper- ate the actuator. * if the engine stop switc...

  • Page 298

    7 - 9 fi fuel injection system fault code table fault code no. Symptom probable cause of malfunction diagnostic code 12 no normal signals are received from the crankshaft position sensor. • open or short circuit in wiring harness. • defective crankshaft position sensor. • malfunction in pickup rotor...

  • Page 299

    7 - 10 fi fuel injection system eas00907 diagnostic mode table switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “diagnostic mode”. Note: _ • check the intake air temperature and coolant temperature as close as possible to the intake air temperatu...

  • Page 300

    7 - 11 fi fuel injection system 09 fuel system voltage (battery voltage) displays the fuel system voltage (battery voltage). Engine stop switch is on. 0 ~ 18.7 v normally, approximately 12.0 v 20 sidestand switch displays that the switch is on or off. Stand retracted: on stand extended: off 30 ignit...

  • Page 301

    7 - 12 fi fuel injection system eas00908 troubleshooting details this section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of...

  • Page 302

    7 - 13 fi fuel injection system fault code no. 12 symptom no normal signals are received from the crankshaft position sensor. Used diagnostic code no. – – order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 installed condition of sensor. Check ...

  • Page 303

    7 - 14 fi fuel injection system fault code no. 13 symptom intake air pressure sensor - open or short circuit detected. Used diagnostic code no. 03 (intake air pressure sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 connected condit...

  • Page 304

    7 - 15 fi fuel injection system fault code no. 14 symptom intake air pressure sensor - hose system malfunction (clogged or detached hose). Used diagnostic code no. 03 (intake air pressure sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement metho...

  • Page 305

    7 - 16 fi fuel injection system fault code no. 16 symptom stuck throttle position sensor detected. Used diagnostic code no. 01 (throttle position sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 installed condition of throttle posi- ...

  • Page 306

    7 - 17 fi fuel injection system fault code no. 22 symptom intake temperature sensor open or short circuit is detected. Used diagnostic code no. 05 (intake air temperature sensor) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 installed con...

  • Page 307

    7 - 18 fi fuel injection system fault code no. 30 symptom the scooter has overturned. Used diagnostic code no. 08 (lean angle cut-off switch) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 the scooter has overturned. Raise the scooter upri...

  • Page 308

    7 - 19 fi fuel injection system fault code no. 37 symptom engine speed is high when the engine is idling. Used diagnostic code no. 54 (isc (idle speed control) valve) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 incorrect speed sensor si...

  • Page 309

    7 - 20 fi fuel injection system fault code no. 41 symptom lean angle cut-off switch open or short circuit is detected. Used diagnostic code no. 08 (lean angle cut-off switch) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 connected conditi...

  • Page 310

    7 - 21 fi fuel injection system fault code no. 43 symptom supply power to the fuel injector and fuel pump is not normal. Used diagnostic code no. 09 (fuel system voltage) order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 connected condition o...

  • Page 311

    7 - 22 fi fuel injection system fault code no. 44 symptom error is detected while reading from or writing on eeprom (code re-registering key code and throttle valve fully closed notification value). Used diagnostic no. 60 (eeprom improper cylinder indication) order inspection operation item and prob...

  • Page 312

    7 - 23 fi fuel injection system fault code no. 50 symptom faulty ecu memory. (when this malfunction is detected in the ecu, the fault code number might not appear on the meter.) used diagnostic code no. – – order inspection operation item and probable cause operation item and countermeasure reinstat...

  • Page 313

    7 - 24 fi fuel injection system fault code no. Er-2 symptom no signals are received from the ecu within the specified duration. Used diagnostic code no. – – order inspection operation item and probable cause operation item and countermeasure reinstatement method 1 connected condition of connector in...

  • Page 314

    7 - 25 fi throttle body and fuel injector eas00909 throttle body and fuel injector throttle body and fuel injector new 13 12 3 5 8 7 6 10 4 9 2 1 11 lt lt t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the throttle body and fuel i...

  • Page 315

    7 - 26 fi throttle body and fuel injector new 13 12 3 5 8 7 6 10 4 9 2 1 11 lt lt t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks 11 throttle position sensor 1 12 fuel injector coupler 1 disconnect. 13 fuel injector assembly 1 for installat...

  • Page 316

    7 - 27 fi fuel hose 1 4 11 2 3 3 5 6 7 8 9 10 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) order job/part q’ty remarks removing the fuel hose remove the parts in the order listed. Radiator refer to “radiator” in chapter 6. 1 pla...

  • Page 317

    7 - 28 fi fuel tank (6) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 54 nm (5.4 m • kg, 39 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) 10 9 8 5 5 6 1 2 7 4 3 2 1 1 7 4 3 6 t r . . 54 nm (5.4 m • kg, 39 ft • ib) lt lt lt lt new order job/part q’ty remarks...

  • Page 318

    7 - 29 fi (6) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 54 nm (5.4 m • kg, 39 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) 10 9 8 5 5 6 1 2 7 4 3 2 1 1 7 4 3 6 t r . . 54 nm (5.4 m • kg, 39 ft • ib) lt lt lt lt new order job/part q’ty remarks 7 sub-fra...

  • Page 319

    7 - 30 fi throttle body and fuel injector removing the fuel hose 1. Extract the fuel in the fuel tank through the fuel tank filler hole with a pump. 2. Remove: • fuel hose connector cover 1 3. Disconnect: • fuel hose 2 caution: • be sure to disconnect the fuel hose by hand. Do not forcefully disconn...

  • Page 320

    7 - 31 fi throttle body and fuel injector eas00912 checking the fuel injector 1. Check: • fuel injector damage → replace. Eas00913 checking the throttle body 1. Check: • throttle body cracks/damage → replace the throttle body. 2. Check: • piston valve 1 damage/scratches/wear → replace. • piston valv...

  • Page 321

    7 - 32 fi throttle body and fuel injector installing the fuel pump 1. Install: • fuel pump note: • do not damage the installation surfaces of the fuel tank when installing the fuel pump. • always use a new fuel pump gasket. • align the projection a on the fuel pump with the alignment mark b on the f...

  • Page 322

    7 - 33 fi throttle body and fuel injector 4. Tighten: • sub-frame adjusting bolts note: • tighten the bolt on the left side of the scooter first. • use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the sub-frame adjusting bolts. • when tightening the sub-frame adjusting bolts,...

  • Page 323

    7 - 34 fi throttle body and fuel injector eas00915 checking the fuel pump and pressure regulator operation 1. Check: • pressure regulator operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the storage box. Refer to “cowling and covers” in chapter 3. B. Remove the fuel hose connect...

  • Page 324

    7 - 35 fi throttle body and fuel injector b. Measure the throttle position sensor volt- age. Out of specification → replace or repair the wire harness. C. Connect the pocket tester (dc 20 v) to the terminals of the throttle position sensor. D. While slowly opening the throttle, check that the thrott...

  • Page 325

    7 - 36 fi throttle body and fuel injector eas00916 checking the isc (idle speed control) valve note: do not remove the isc (idle speed control) valve unit completely from the throttle body assembly. 1. Check: • isc (idle speed control) valve ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disco...

  • Page 326

    7 - 37 fi air induction system eas00507 air induction system air injection the air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve ...

  • Page 327

    7 - 38 fi air induction system eas00509 air induction system diagrams 1 air induction system hose (air filter case to air cut-off valve) 2 air cut-off valve 3 air induction system hose (air cut-off valve to cylinder head) 4 air induction system pipe 5 air filter case cover (right) b b a 1 a 1 3 2 2 ...

  • Page 328

    7 - 39 fi air induction system air cut-off valve and air induction system hoses 1 3 2 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the air cut-off valve and air induction system hoses remove the parts in the order listed. 1 air induction system hose (air filter case t...

  • Page 329

    7 - 40 fi air induction system eas00918 checking the air induction system 1. Check: • hoses loose connections → connect properly. Cracks/damage → replace. • pipes cracks/damage → replace. 2. Check: • reed valve • reed valve stopper • reed valve seat cracks/damage → replace the reed valve. 3. Check: ...

  • Page 330

    7 - 41 fi canister t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 1 5 3 2 4 order job/part q’ty remarks removing the canister remove the parts in the order listed. 1 canister 1 2 rollover valve 1 3 fuel tank to rollover valve hose 1 4 rollover valve to canister hose 1 5 canister to throttle body hose 1 for ...

  • Page 331: Elec

    – + elec chapter 8 electrical system electrical components........................................................................ 8-1 checking switch continuity................................................................ 8-3 checking the switches....................................................

  • Page 332: Elec

    8 - 1 – + elec eas00729 electrical system electrical components 1 starting circuit cut-off relay 2 headlight relay 1 3 turn signal relay 4 radiator fan motor relay 5 headlight relay 2 6 main switch 7 front brake light switch 8 rear brake light switch 9 storage box light switch 0 starter relay a main...

  • Page 333: Elec

    8 - 2 – + elec electrical components e stator coil f sidestand switch g ignition coil h radiator fan motor i rectifier/regulator j horn k thermistor l ecu m wire harness 1 2 3 4 5 7 8 0 a 6 b c d e f g h i j k l 9 m downloaded from www.Scootertime.Net.

  • Page 334: Elec

    8 - 3 – + elec checking switch continuity eas00730 checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. Caution: _ never insert the tester probes into the cou...

  • Page 335: Elec

    8 - 4 – + elec checking the switches eas00731 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “checking switch continuity”. Damage/wear → repair or replace. Improperly connected → properly connect. Incorrect co...

  • Page 336: Elec

    8 - 5 – + elec checking the bulbs and bulb sockets eas00733 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected...

  • Page 337: Elec

    8 - 6 – + elec checking the bulbs and bulb sockets checking the condition of the bulbs the following procedure applies to all of the bulbs. 1. Remove: • bulb warning _ since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Cau...

  • Page 338: Elec

    8 - 7 – + elec checking the bulbs and bulb sockets checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: _ check each bulb socket for continuity in the sa...

  • Page 339: Elec

    8 - 8 – + elec ignition system eas00734 ignition system circuit diagram b b sub-wire harness 1 wire harness a g b y g b y ( blue ) l /y b ( blue ) b b b lc h l bc h b ld g l bd g (black) (black) dg ch g /b br /w bb r r /y p g /y r /y g /y p br /w br b g /b dg ch r l/ g rw l/ gr /g w /lw /r o /br /l ...

  • Page 340: Elec

    8 - 9 – + elec ignition system eas00736 troubleshooting check: 1. Main and ignition fuses 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Crankshaft position sensor resistance 8. Main switch 9. Engine stop switch 10.Sidestand switch 11.Start...

  • Page 341: Elec

    8 - 10 – + elec ignition system eas00742 yes no eas00744 yes no 4. Ignition spark gap • disconnect the spark plug cap from the spark plug. • connect the ignition checker 1 as shown. 2 spark plug cap • set the main switch to “on”. • measure the ignition spark gap a. • crank the engine by pushing the ...

  • Page 342: Elec

    8 - 11 – + elec ignition system eas00746 yes no eas00748 yes no eas00749 yes no 6. Ignition coil resistance • disconnect the ignition coil connectors from the ignition coil terminals. • connect the pocket tester ( Ω × 1) to the ignition coil as shown. Positive tester probe → red/black negative teste...

  • Page 343: Elec

    8 - 12 – + elec ignition system eas00750 yes no eas00752 yes no eas00753 yes no 9. Engine stop switch • check the engine stop switch for continu- ity. Refer to “checking the switches”. • is the engine stop switch ok? Replace the right handlebar switch. 10.Sidestand switch • check the sidestand switc...

  • Page 344: Elec

    8 - 13 – + elec ignition system yes no eas00754 yes no 12.Lean angle cut-off switch • remove the lean angle cut-off switch. • connect the pocket tester ( Ω × 1) to the lean angle cut-off switch terminals as shown. Positive tester probe → blue 1 negative tester probe → yellow/green 2 lean angle cut-o...

  • Page 345: Elec

    8 - 14 – + elec eas00755 electric starting system circuit diagram b b sub-wire harness 1 wire harness a ( blue ) l /y b ( blue ) b b dg ch g /b br /w bb r r /y p g /y r /y g /y p br /w br b g /b dg ch r l/ g rw l/ gr /g w /lw /r ly (black) ( b b gy b r /y g /l r /yw /b g /l y g /b g (black) b br l r...

  • Page 346: Elec

    8 - 15 – + elec electric starting system eas00756 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if the following conditions are met: • a brake lever is pulled to the ...

  • Page 347: Elec

    8 - 16 – + elec electric starting system eas00757 troubleshooting check: 1. Main, ignition, and signaling system fuses 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starter relay 6. Main switch 7. Engine stop switch 8. Brake light switch (front and rear) 9. Sidestand switch 10.Sta...

  • Page 348: Elec

    8 - 17 – + elec electric starting system eas00759 yes no eas00761 yes no eas00749 yes no 4. Starting circuit cut-off relay • remove the starting circuit cut-off relay. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starting circuit cut-off relay terminals as shown. Positive battery...

  • Page 349: Elec

    8 - 18 – + elec electric starting system eas00750 yes no eas00751 yes no eas00752 yes no eas00764 yes no eas00766 yes no 7. Engine stop switch • check the engine stop switch for continu- ity. Refer to “checking the switches”. • is the engine stop switch ok? Replace the right handlebar switch. 8. Bra...

  • Page 350: Elec

    8 - 19 – + elec starter motor eas00767 starter motor order job/part q’ty remarks removing the starter motor remove the parts in the order listed. Throttle body refer to “throttle body and fuel injector” in chapter 7. 1 starter motor lead 1 2 starter motor 1 for installation, reverse the removal pro-...

  • Page 351: Elec

    8 - 20 – + elec order job/part q’ty remarks disassembling the starter motor remove the parts in the order listed. 1 front bracket 1 refer to “assembling the starter motor”. 2 o-ring 1 3 shim 1 4 lock washer 1 5 rear bracket 1 6 o-ring 1 7 shim 1 8 brush holder set 1 9 armature assembly 1 0 starter m...

  • Page 352: Elec

    8 - 21 – + elec starter motor eas00770 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter a out of specification → replace the starter motor. 3. Measure: • mica undercut a out of specification → scrape the mica to the proper meas...

  • Page 353: Elec

    8 - 22 – + elec starter motor 5. Measure: • brush length a out of specification → replace the brushes as a set. 6. Measure: • brush spring force out of specification → replace the brush springs as a set. 7. Check: • gear teeth damage/wear → replace the gear. Brush length wear limit 4.0 mm (0.16 in) ...

  • Page 354: Elec

    8 - 23 – + elec charging system eas00773 charging system circuit diagram b b ( blue ) l /y b ( blue ) b b r l/ g rw l/ gr /g w /lw /r r /y g /l r /yw /b g /y r r l/ w br w ww (black) off on g /w r /b l /y g /y (bla ck) (green) b /lp /w l r br /l r br /l g /y (black) l/ w br /wb /l lb /l (gra y) y /l...

  • Page 355: Elec

    8 - 24 – + elec charging system eas00774 troubleshooting check: 1. Main fuse 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connections (of the entire charging system) note: _ • before troubleshooting, remove the following part(s): 1. Footrest board (left) • troubleshoot with the...

  • Page 356: Elec

    8 - 25 – + elec charging system eas00775 no yes eas00776 yes no eas00779 yes no 3. Charging voltage • connect the pocket tester (dc 20 v) to the battery as shown. Positive tester probe → positive battery terminal negative tester probe → negative battery terminal • start the engine and let it run at ...

  • Page 357: Elec

    8 - 26 – + elec lighting system eas00780 lighting system circuit diagram b /r b /r b /r b /r b b sub-wire harness 1 wire harness a g b y g b y ( blue ) l /y b ( blue ) b b b lc h l bc h b ld g l bd g (black) (black) dg ch g /b br /w bb r r /y p g /y r /y g /y p br /w br b g /b dg ch r l/ g rw l/ gr ...

  • Page 358: Elec

    8 - 27 – + elec lighting system eas00781 troubleshooting check: 1. Main, headlight, signaling system, turn sig- nal/position light, and backup fuses 2. Battery 3. Main switch 4. Dimmer switch 5. Storage box light switch 6. Headlight relay 1 7. Headlight relay 2 8. Wiring connections (of the entire l...

  • Page 359: Elec

    8 - 28 – + elec lighting system yes no yes no yes no 5. Storage box light switch • check the storage box light switch for con- tinuity. Refer to “checking the switches”. • is the storage box light switch ok? The storage box light switch is faulty. Replace the storage box light switch. 6. Headlight r...

  • Page 360: Elec

    8 - 29 – + elec lighting system eas00787 yes no eas00788 checking the lighting system 1. The headlights and the high beam indicator light fail to come on. Yes no yes no 8. Wiring • check the entire lighting system’s wiring. Refer to “circuit diagram”. • is the lighting system’s wiring properly conne...

  • Page 361: Elec

    8 - 30 – + elec lighting system yes no eas00789 2. The meter light fails to come on. Yes no 3. Voltage • connect the pocket tester (dc 20 v) to the headlight and meter assembly couplers as shown. È when the dimmer switch is set to “ ” É when the dimmer switch is set to “ ” headlight positive tester ...

  • Page 362: Elec

    8 - 31 – + elec lighting system yes no eas00790 3. The tail/brake light fails to come on. Yes no yes no eas00791 4. The front turn signal/position lights fail to come on. Yes no 2. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. Positive test...

  • Page 363: Elec

    8 - 32 – + elec lighting system yes no eas00792 5. The license plate light fails to come on. Yes no yes no 2. Voltage • connect the pocket tester (dc 20 v) to the front turn signal/position light coupler (wire harness side) as shown. È front turn signal/position light (left) É front turn signal/posi...

  • Page 364: Elec

    8 - 33 – + elec eas00792 6. The storage box light fails to come on. Yes no yes no 1. Storage box light bulb and socket • check the storage box light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the storage box light bulb and socket ok? Replace the storage box...

  • Page 365: Elec

    8 - 34 – + elec lighting system downloaded from www.Scootertime.Net.

  • Page 366: Elec

    8 - 35 – + elec signaling system eas00793 signaling system circuit diagram b /r b /r b /r b /r b b sub-wire harness 1 wire harness a g b y g b y ( blue ) l /y b ( blue ) b b b lc h l bc h b ld g l bd g (black) (black) dg ch g /b br /w bb r r /y p g /y r /y g /y p br /w br b g /b dg ch r l/ g rw l/ g...

  • Page 367: Elec

    8 - 36 – + elec signaling system 4 main switch 7 ignition fuse 8 backup fuse (storage box light and meter assembly) 0 battery a main fuse i front brake light switch p ecu v speed sensor _ turn signal relay a horn f horn switch g turn signal switch h rear brake light switch j rear turn signal light (...

  • Page 368: Elec

    8 - 37 – + elec signaling system eas00794 troubleshooting check: 1. Main, ignition, signaling system, turn signal/ position light, and backup fuses 2. Battery 3. Main switch 4. Wiring connections (of the entire signaling system) note: _ • before troubleshooting, remove the following part(s): 1. Stor...

  • Page 369: Elec

    8 - 38 – + elec signaling system eas00796 checking the signaling system 1. The horn fails to sound. Yes no yes no no yes eas00798 2. The tail/brake light fails to come on. Yes no 1. Horn switch • check the horn switch for continuity. Refer to “checking the switches”. • is the horn switch ok? Replace...

  • Page 370: Elec

    8 - 39 – + elec signaling system yes no yes no eas00799 3. The turn signal light, turn signal indicator light or both fail to blink. Yes no yes no yes no 2. Brake light switches • check the brake light switches for continu- ity. Refer to “checking the switches”. • is the brake light switch ok? Repla...

  • Page 371: Elec

    8 - 40 – + elec signaling system yes no yes no 4. Voltage • connect the pocket tester (dc 20 v) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe → brown 1 negative tester probe → ground • set the main switch to “on”. • measure the voltage (dc 12 v) on brown 1 at t...

  • Page 372: Elec

    8 - 41 – + elec signaling system yes no 4. The v-belt replacement indicator fails to come on. Yes no 6. Voltage • connect the pocket tester (dc 20 v) to the front turn signal/position light coupler, rear turn signal/license plate light coupler or meter assembly coupler (wire harness side) as shown. ...

  • Page 373: Elec

    8 - 42 – + elec signaling system yes no yes no 2. V-belt replacement indicator reset coupler • connect the pocket tester ( Ω × 1) to the v- belt replacement indicator reset coupler as shown. • check the v-belt replacement indicator reset coupler for continuity. Positive tester probe → black 1 negati...

  • Page 374: Elec

    8 - 43 – + elec signaling system eas00803 5. The engine oil change indicator fails to come on. Yes no eas00806 6. The speedometer fails to operate. Yes no 1. Engine oil change indicator bulb and socket • check the engine oil change indicator bulb and socket for continuity. Refer to “checking the bul...

  • Page 375: Elec

    8 - 44 – + elec signaling system yes no 2. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. Positive tester probe → yellow/blue 1 negative tester probe → black 2 • set the main switch to “on”. • measure the voltage (dc 12 v) of yellow/ blue 1 ...

  • Page 376: Elec

    8 - 45 – + elec cooling system eas00807 cooling system circuit diagram b /r b /r b /r b b sub-wire harness 1 wire harness a g b y g b y ( blue ) l /y b ( blue ) b b b lc h l bc h b ld g l bd g (black) (black) dg ch g /b br /w bb r r /y p g /y r /y g /y p br /w br b g /b dg ch r l/ g rw l/ gr /g w /l...

  • Page 377: Elec

    8 - 46 – + elec cooling system eas00808 troubleshooting check: 1. Main, ignition, and radiator fan motor fuses 2. Battery 3. Main switch 4. Radiator fan motor 5. Radiator fan motor relay 6. Coolant temperature sensor 7. Wiring connections (the entire cooling system) note: _ • before troubleshooting,...

  • Page 378: Elec

    8 - 47 – + elec cooling system eas00809 yes no yes no 4. Radiator fan motor • disconnect the radiator fan motor coupler from the wire harness. • connect the battery (dc 12 v) as shown. Positive battery lead → blue 1 negative battery lead → black 2 • does the radiator fan motor turn? The radiator fan...

  • Page 379: Elec

    8 - 48 – + elec cooling system eas00812 yes no eas00813 yes no 6. Coolant temperature sensor • remove the coolant temperature sensor. • connect the pocket tester ( Ω × 1k) to the coolant temperature sensor 1 as shown. • immerse the coolant temperature sensor in a container filled with coolant 2. Not...

  • Page 380: Trbl

    Trbl shtg chapter 9 troubleshooting starting failure/hard starting ....................................................... 9-1 engine..................................................................................................... 9-1 fuel system.....................................................

  • Page 381: Trbl

    Trbl shtg faulty lighting or signaling system.............................................. 9-6 headlight does not come on ........................................................ 9-6 headlight bulb burnt out.............................................................. 9-6 tail/brake light does not...

  • Page 382: 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 man- ual for checks, adjustments, and replacement of...

  • Page 383: Trbl

    9 - 2 trbl shtg starting failure/hard starting/ incorrect engine idling speed electrical systems battery • discharged battery • faulty battery fuse(s) • blown, damaged or incorrect fuse • improperly installed fuse spark plug • incorrect spark plug gap • incorrect spark plug heat range • fouled spark...

  • Page 384: Trbl

    9 - 3 trbl shtg poor medium-and-high-speed performance/ faulty clutch eas00848 poor medium-and-high-speed performance refer to “starting failure/hard starting”. Engine air filter • clogged air filter element fuel system throttle body • faulty diaphragm fuel pump • faulty fuel pump eas00853 faulty cl...

  • Page 385: Trbl

    9 - 4 trbl shtg overheating/ overcooling eas00855 overheating engine clogged coolant passages • cylinder head and piston • heavy carbon buildup engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality cooling system coolant • low coolant level radiator • damaged or leaking r...

  • Page 386: Trbl

    9 - 5 trbl shtg poor braking performance/ faulty front fork legs/unstable handling eas00857 poor braking performance • worn brake pad • worn brake disc • air in hydraulic brake system • leaking brake fluid • faulty brake caliper kit • faulty brake caliper seal • loose union bolt • damaged brake hose...

  • Page 387: Trbl

    9 - 6 trbl shtg faulty lighting or signaling system eas00866 faulty lighting or signaling system headlight does not come on • wrong headlight bulb • too many electrical accessories • hard charging • incorrect connection • improperly grounded circuit • poor contacts (main switch) • burnt-out headligh...

  • Page 388: Yp400T Wiring Diagram

    Yp400t wiring diagram 1 a.C. Magneto 2 crankshaft position sensor 3 rectifier/regulator 4 main switch 5 storage box light switch 6 storage box light 7 ignition fuse 8 backup fuse (storage box light and meter assembly) 9 fuel injection system fuse 0 battery a main fuse b starter relay c starter motor...

  • Page 389

    Yp400t wiring diagram b b sub-wire harness 1 wire harness a g b y g b y (blue) l/y b (blue) b b b l ch l b ch b l dg l b dg (black) (black) dg ch g/b br/w b br r/y p g/y r/y g/y p br/w br b g/b dg ch r l/g r w l/g r/g w/l w/r o/b r/l l y (black) (black) dg br ch b l/r dg b ch b b gy b r r/l r/b r/y ...

  • Page 390

    Yamaha motor canada ltd. 480 gordon baker road toronto, on m2h 3b4 downloaded from www.Scootertime.Net.