Yamaha YP250 manual

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EB000000 YP250 SERVICE MANUAL  1996 by Y amaha Motor Co., Ltd. 1st Edition, January 1996 All rights reserved. Any reprinting or unauthorized use without the written permission of Y amaha Motor Co., Ltd. is expressly prohibited.[...]

NOTE: CAUTION: EB001000 NOTICE This manual was produced by the Y amaha Motor Company primarily for use by Y amaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Y amaha scooter has a basic unders[...]

1 2 4 3 5 6 7 6 8 YP002000 HOW T O USE THIS MANUAL MANUAL ORGANIZA TION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol on the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only ap[...]

1 3 5 7 9 11 13 15 18 2 4 8 10 12 14 16 6 21 24 25 17 19 20 22 23 EB003000 ILLUSTRA TED SYMBOLS Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter ’s number and content. 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 T roublesh[...]

GENERAL INFORMA TION SPECIFICA TIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 INDEX[...]

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CHAPTER 1 GENERAL INFORMA TION SCOOTER IDENTIFICA TION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICA TION NUMBER (for E) 1-1 . . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER 1-1 . . . . . . . . . .[...]

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1-1 SCOOTER IDENTIFICA TION GEN INFO NOTE: NOTE: YP100000 GENERAL INFORMA TION SCOOTER IDENTIFICA TION YP100010 VEHICLE IDENTIFICA TION NUMBER (for E) The vehicle identification number 1 is stamped into the right side of the frame. The vehicle identification number is used to identify your scooter and may be used to regis- ter your scooter with the[...]

1-2 FEA TURES GEN INFO Engine stop switch Main switch Oil indicator light Fuse Battery Meter Reset button I gnitor unit C.P .U Oil indicator light Reset button NOTE: FEA TURES OIL INDICA TOR LIGHT  Function Pulses (travel distance signals) from the speedometer are counted and cause the oil indicator light to come on at 1,000 km for the first tim[...]

1-3 FEA TURES GEN INFO Main switch Fuse Battery Thermo switch Auto-choke Igniter unit C.P .U Ignition Main switch Engine stop switch Brake switch Fuse Starter relay Relay Ignitor unit Battery Starter motor Start switch Brake light Sidestand switch AUTO-CHOKE SYSTEM This system is the parallel connection of the ignitor unit circuit and the thermo sw[...]

1-4 IMPORT ANT INFORMA TION GEN INFO EB101000 IMPORT ANT INFORMA TION PREP ARA TION FOR REMOV AL PROCE- DURES 1. Remove all dirt, mud, dust and foreign ma- terial before removal and disassembly . 2. Use proper tools and cleaning equipment. 3. Refer to the “SPECIAL TOOLS” section. 4. When disassembling the machine, always keep mated parts togeth[...]

1-5 IMPORT ANT INFORMA TION GEN INFO OR CAUTION: EB101030 LOCK W ASHERS / PLA TES AND COTTER PINS 1. Replace all lock washers / plates and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufac[...]

1-6 IMPORT ANT INFORMA TION GEN INFO NOTE: NOTE: EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector . 1. Disconnect: S Connector 2. Dry each terminal with an air blower . 3. Connect and disconnect the connector two or three. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, b[...]

1-7 HOW T O USE THE CONVERSION T ABLE GEN INFO EB201000 HOW TO USE THE CONVERSION T ABLE 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. Ex. METRIC MUL TIPLIER IMP **mm  0.03937 = ** in 2 mm  0.03937 = 0.08 in CONVERSION T ABLE METRIC TO IMP Known Multi[...]

1-8 SPECIAL TOOLS GEN INFO EB102000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly . Use only the appropriate special tools; this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. When placing an order , refer to the list provided below to avoid any [...]

1-9 SPECIAL TOOLS GEN INFO T ool No. T ool name / Usage Illustration 90890-01362 Flywheel puller This tool is used for removing the rotor . 90890-01367 -01368 Fork seal driver weight Fork seal driver attachment (ø33) This tool is used when installing the fork seal. 90890-01384 Oil seal guide This tool is used for protecting the oil seal lip when i[...]

1-10 SPECIAL TOOLS GEN INFO T ool No. T ool name / Usage Illustration 90890-03141 T iming light This tool is needed for detecting ignition timing. 90890-04101 V alve lapper This tool is used for removing and installing the lifter and for lapping the valve. 90890-04019 -04108 V alve spring compressor Attachment These tools are used when removing or [...]

CHAPTER 2. SPECIFICA TIONS GENERAL SPECIFICA TIONS 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICA TIONS 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-10 . . . .[...]

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2-1 GENERAL SPECIFICA TIONS SPEC SPECIFICA TIONS GENERAL SPECIFICA TIONS Model YP250 Model code: 4UC 1 (except for CH, A) 4UD1 (for CH, A) Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,1 10 mm , 750 mm 1,330 mm , 700 mm 1,500 mm , 1 15 mm 2,600 mm Basic weight: With o[...]

2-2 GENERAL SPECIFICA TIONS SPEC Model YP250 Carburetor: T ype / quantity Manufacturer Y28V -1A / 1 TEIKEI Spark plug: T ype Manufacturer Spark plug gap DR8EA NGK 0.6 X 0.7 mm Clutch type: Dry , centrifugal automatic T ransmission: Primary reduction system Primary reduction ratio Secondary reduction sytem Secondary reduction ratio T ransmission typ[...]

2-3 GENERAL SPECIFICA TIONS SPEC Model YP250 Brake: Front brake type operation Rear brake type operation Single disc brake Right hand operation Drum brake Left hand operation Suspension: Front suspension Rear suspension T elescopic fork Unit swing Shock absorber: Front shock absorber Rear shock absorber Coil spring / Oil damper Coil spring / Oil da[...]

2-4 MAINTENANCE SPECIFICA TIONS SPEC Face Width Seat Width Margin Thickness MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Cylinder head: W arp limit SSS 0.03 mm Cylinder: Bore size Out of round limit 69.000 X 69.005 mm SSS 69.1 mm 0.03 mm Camshaft: Cam dimensions Intake “A” “B” “C” Exhaust “A” “B” “C” Camshaft runou[...]

2-5 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Stem-to-guide clearance IN EX Stem runout limit V alve seat width IN EX 0.010 X 0.037 mm 0.025 X 0.052 mm SSS 0.9 X 1.1 mm 0.9 X 1.1 mm 0.08 mm 0.1 mm 0.01 mm 1.6 mm 1.6 mm V alve spring: Free length (Inner) IN / EX Free length (Outer) IN / EX Set length (valve closed) (Inner) IN / EX Set len[...]

2-6 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Automatic centrifugal clutch: Clutch shoe thickness Clutch housing inside diameter Clutch shoe spring free length Weight outside diameter Clutch – in revolution Clutch – stall revolution 3.0 mm 135 mm 28.1 mm 20 mm 2,100 X 2,700 r / min 3,700 X 4,700 r / min 2.0 mm 135.5 mm SSS 19.5 mm SS[...]

2-7 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Radiator: T ype Width / height / thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Cooling fin with electric fan 140 / 238 / 24 mm 1 10 X 140 kPa (1.1 X 1.4 kg / cm 2 , 1.1 X 1.4 bar) 1.4 L 0.35 L SSS SSS SSS SSS SSS Thermostatic valve: T ype / manufacturer V a[...]

2-8 MAINTENANCE SPECIFICA TIONS SPEC TIGHTENING TORQUES ENGINE Part to be tightened Part name Thread size Q’ty T ightening torque Remarks g size y Nm m S kg Oil check bolt Exhaust pipe stud bolt Spark plug Cam sprocket cover Cylinder head and cylinder Cylinder head and cylinder (Cam chain side) V alve cover Rotor V alve adjuster locknut Cam shaft[...]

2-9 MAINTENANCE SPECIFICA TIONS SPEC Part to be tightened Part name Thread size Q’ty T ightening torque Remarks g size y Nm m S kg Cover (oil pump) T iming check plug One way clutch Clutch housing Grease stopper (Primary sheave) Primary fixed sheave Clutch carrier assembly Stator Pick up coil Starter motor Thermo switch Thermo unit Bolt Plug — [...]

2-10 MAINTENANCE SPECIFICA TIONS SPEC CHASSIS Item Standard Limit Steering system: Steering bearing type Ball bearing SSS Front suspension: Front fork travel Fork spring free length Spring rate (K1) Stroke (K1) Oil capacity Oil level Oil grade Inner tube vend limit 100 mm 265.8 mm 5.7 N / mm (0.57 kg / mm) 0 X 100 mm 0.142 L (142 cm 3 ) 80 mm Fork [...]

2-1 1 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Rear drum brake: T ype Drum inside diameter Shoe thickness Leading, trailing 160 mm 4 mm SSS 161 mm 2 mm Brake lever: Brake lever free play (front at lever side) Brake lever free play (rear) Throttle cable free play 2 X 5 mm 10 X 20 mm 3 X 5 mm SSS SSS SSS Item Size Bearings and oil seals: [...]

2-12 MAINTENANCE SPECIFICA TIONS SPEC TIGHTENING TORQUES CHASSIS Part to be tightened Thread size Tightening torque Remarks Nm m S kg Frame and engine bracket Engine bracket, compression rod and engine Compression rod and frame Sidestand (bolt and frame) Sidestand (bolt and nut) Rear footrest bracket Swingarm Rear shock absorber and frame Rear shoc[...]

2-13 MAINTENANCE SPECIFICA TIONS SPEC NOTE: 1. First, tighten the ring nut (lower) approximately 38 Nm (3.8 m S kg) by using the torque wrench, then loosen the ring nut 1 / 4 turn. 2. Second, tighten the ring nut (lower) approximately 22 Nm (2.2 m S kg) by using the torque wrench, then finger tighten the ring nut (center). Align the slots both ring[...]

2-14 MAINTENANCE SPECIFICA TIONS SPEC ELECTRICAL Item Standard limit Ignition timing: Ignition timing (B.T .D.C.) Advanced timing (B.T .D.C.) Advanced type 10 _ at 1,500 r / min 32 _ at 5,000 r / min Electrical type SSS SSS SSS T .C.I.: Pickup coil resistance / color T .C.I. unit model / manufacturer 168 X 252 Ω at 20 _ C/ Y ellow – Black J4T06[...]

2-15 MAINTENANCE SPECIFICA TIONS SPEC Item Standard limit Starter relay: Model / manufacturer Amperage rating Coil winding resistance 4FL / JIDECO 100 A 4.2 X 4.6 Ω at 20 _ C SSS SSS SSS Horn: Model / manufacturer Maximum amperage YF-12 / NIKKO 2.5 A SSS SSS Flasher relay: T ype Model / manufacturer Flasher frequency Full transistor type 4MY / NI[...]

2-16 GENERAL T ORQUE SPECIFICA TIONS SPEC GENERAL TORQUE SPECIFICA TIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. T orque specifications for special components or as- semblies are included in the applicable sections of this book. T o avoid warpage, tighten multi- fastener assemblies in a crisscross fa[...]

2-17 LUBRICA TION POINT AND GRADE OF LUBRICANT SPEC LUBRICA TION POINT AND GRADE OF LUBRICANT ENGINE Lubrication Point Symbol Oil seal lips O-ring (Except V -belt drive unit) Cylinder head tightening nut mounting surface Crankshaft pin outside Connecting rod big end thrust surface Rotary filter inner surface Drive gear inner surface Cam chain outsi[...]

2-18 LUBRICA TION POINT AND GRADE OF LUBRICANT SPEC CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left / right) Swingarm oil seal lips (left / right) Steering head pipe bearing (upper / lower) Steering head pipe dust seal lips (upper / lower) T ube guide (throttle grip) inner surface Brake cable (brake lever) Brake lever and lever hol[...]

2-19 CABLE ROUTING SPEC 1 Rectifier regulator 2 Fuel sender 3 Fuse (fan) 4 Roll over valve 5 Ignition coil 6 Seat lock cable 7 Handlebar switch 3 lead (right) 8 Front brake switch lead 9 Brake hose 10 Speedometer cable 11 Radiator overflow hose 12 Starter relay / Fuse (main) 13 Battery 14 Battery positive (+) lead 15 Battery negative (–) lead 16 [...]

2-20 E Pass the overflow hose from the reservoir tank through the clamp inside the frame. F Clamp the mainharness, battery (+) lead and (–) lead to clamp of the frame. G Clamp the fuel sender lead to the pipe. H The mainharness connecting to the taillight assembly to the frame. I Connect the taillight assembly lead to the mainharness over the mud[...]

2-21 CABLE ROUTING SPEC 1 Seat lock 2 Air filter case 3 Breather hose 4 Fuel hose 5 V acuum hose 6 Sidestand switch lead 7 Thermo switch lead 8 Fan motor lead , 9 Breather hose 10 Overflow hose (fuel tank) 11 Relay 12 Auto choke lead 13 A.C. magneto lead 14 Starter motor lead 15 Engine earth lead 16 Protector (pipe) 17 Seat lock cable A Clamp the m[...]

2-22 CABLE ROUTING SPEC 1 Front flasher light (right) 2 Front flasher light (left) 3 Handlebar switch (right) lead 4 Front brake switch lead 5 Seat lock cable 6 Throttle cable 7 Brake hose 8 Handlebar switch (left) lead 9 Rear brake switch lead 10 Handlebar under cover 11 Brake cable 2 12 Speedometer cable 13 Stay 1 14 Horn 15 Brake hose stopper 16[...]

2-23 CABLE ROUTING SPEC G Pass the brake hose through the hose holder and clamp. H Clamp the headlight lead and horn lead from mainharness to the stay 1. I Install the brake hose with its marking facing to the stopper side.[...]

2-24 CABLE ROUTING SPEC 1 Fuel overflow hose (filler neck) 2 Throttle cable 1 (nut white) 3 Throttle cable 2 (nut black) 4 Air vent hose (carburetor) 5 Coolant drain hose (carburetor) 6 Fuel drain hose (carburetor) 7 Fuel overflow hose (fuel tank) A Pass the brake cable 2 though the holder and clamp to the crankcase. B Pass the air vent hose, coola[...]

2-25 CABLE ROUTING SPEC 1 Steering head pipe 2 Brake cable 2 3 Mainharness 4 Downtube 5 Throttle cable 6 Radiator 7 Stay 1 A Pass the brake cable 2 though the clamp on the handlebar holder . B Band the brake cable 2 to the steering head pipe, noting the band direction. (view A) C Band the throttle cable and the right mainharness to the downtube, no[...]

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CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE / LUBRICA TION INTER V ALS 3-1 . . . . . . . . . . . COVER AND P ANEL 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T AIL COVER AND FU[...]

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3-1 INTRODUCTION / PERIODIC MAINTENANCE / LUBRICA TION INTERV ALS INSP ADJ EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera- tion and a longer s[...]

3-2 PERIODIC MAINTENANCE / LUBRICA TION INTER V ALS INSP ADJ NOTE: BREAK-IN EVERY NO. ITEM ROUTINE TYPE 1,000 km 6,000 km or 6 months 12,000 km or 12 month 15 Centerstand and sidestand pivot  Check operation and lubricate. Same as engine oil   16 * Sidestand switch  Check and clean or replace if necessary . —    17 * Front fo[...]

3-3 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Side panel and seat removal Rear panel Side panel (left) Side panel (right) Rivet Front panel Clip Damper assembly Seat 1 1 1 2 1 2 1 1 Remove the parts in order . Install the damper assembly to the body with its rod side backward and labels up- ward. Reverse the removal procedure for in[...]

3-4 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 T ail cover and fuel tank removal Grab bar Seat lock bracket Screw T ail cover Fuel tank cap Fuel overflow hose Cover Fuel tank cover Coupler (fuel sender lead) Fuel overflow hose Fuel hose 1 1 2 1 1 1 1 1 1 1 1 Remove the parts in order . T ail cover Fuel tank Disconnect the cou[...]

3-5 COVER AND P ANEL INSP ADJ Order Job name / Part name Q’ty Remarks 12 13 14 V acuum hose Bracket Fuel tank 1 1 1 Reverse the removal procedure for installation. Fuel tank 10 Nm (1.0 m  kg) 7 Nm (0.7 m  kg) 7 Nm (0.7 m  kg)[...]

3-6 Order Job name / Part name Q’ ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 Footrest board and lower cover removal Mat (footrest board) (left / right) Cover 2 Battery negative (-) lead Battery positive (+) lead Battery Flasher relay Starter relay Reservoir tank Footrest Lid Box Lower cover Footrest board 1/1 1 1 1 1 1 1 1 2 1 1 1 1 Remove the part[...]

3-7 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Cowling removal Upper cover Wind screen Inner panel Cowling body Coupler (headlight lead) Coupler (front flasher light lead (left)) Coupler (front flasher light lead (right)) 1 1 1 1 1 1 Remove the parts in order . Reverse the removal procedure for installation. Disconnect the couplers. NO[...]

3-8 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Handle cover , meter assembly and legshield removal Handle cover Coupler (meter lead) Meter cable Meter assembly Main switch cover Cover Legshield 1 1 1 2 1 2 1 Remove the parts in order . Disconnect the couplers. Reverse the removal procedure for installation. NOTE: COVER AND P ANEL INSP [...]

3-9 V AL VE CLEARANCE ADJUSTMENT INSP ADJ NOTE: ***************************************************** ***************************************************** YP303004 ENGINE V AL VE CLEARANCE ADJUSTMENT V alve clearance adjustment should be made with the engine cool, at room temperature. When the valve clearance is to be measured or adjusted, the pis[...]

3-10 V AL VE CLEARANCE ADJUSTMENT / IDLING SPEED ADJUSTMENT INSP ADJ ***************************************************** ***************************************************** 14 Nm (1.4 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) 18 Nm (1.8 m S kg) 7 Nm (0.7 m S kg) 6. Adjust: D V alve clearance Adjustment steps: D Loosen the locknut 1 . D T ur[...]

3-1 1 IDLING SPEED ADJUSTMENT / THROTTLE CABLE ADJUSTMENT INSP ADJ ***************************************************** ***************************************************** NOTE: ************************************* NOTE: 3. Check:  Engine idling speed Out of specification  Adjust. Engine idling speed: 1,450  1,550 r / min 4. Adjust: ?[...]

3-12 THROTTLE CABLE ADJUSTMENT / SP ARK PLUG INSPECTION INSP ADJ ***************************************************** CAUTION:  Loosen the locknut 1 on the throttle cable.  T urn the adjuster 2 in or out until specified free play is obtained. T urning in  Free play is increased. T urning out  Free play is decreased.  T ighten the lo[...]

3-13 SP ARK PLUG INSPECTION / IGNITION TIMING CHECK INSP ADJ 18 Nm (1.8 m S kg) NOTE: NOTE: ***************************************************** ***************************************************** Spark plug gap: 0.6  0.7 mm 6. Install: D Spark plug Before installing a spark plug, clean the gasket surface and plug surface. YP303052 IGNITION T[...]

3-14 IGNITION TIMING CHECK / COMPRESSION PRESSURE MEASUREMENT INSP ADJ NOTE: NOTE: CAUTION: Ignition timing is not adjustable. 3. Install:  T iming check plug YP303060 COMPRESSION PRESSURE MEASUREMENT Insufficient compression pressure will result in performance loss. 1. Remove:  Side panels Refer to “COVER AND P ANEL” section. 2. Check: ?[...]

3-15 COMPRESSION PRESSURE MEASUREMENT / ENGINE OIL REPLACEMENT INSP ADJ ***************************************************** ***************************************************** 18 Nm (1.8 m S kg) NOTE: Compression pressure pp (With oil applied into cylinder) Reading Diagnosis Higher than without oil Worn or damaged pistons Same as without oil Po[...]

3-16 ENGINE OIL LEVEL INSPECTION / ENGINE OIL REPLACEMENT INSP ADJ CAUTION: NOTE: 32 Nm (3.2 m S kg) NOTE: RECOMMENDED ENGINE OIL Refer to the chart for selection of the oils suited to the atomosperic temperature. API ST ANDARD: API SE or higher grade D Do not put in any chemical sdditives or use oils with a grade of CD a or higher . D Be sure not [...]

3-17 ENGINE OIL REPLACEMENT / ENGINE OIL PRESSURE INSPECTION INSP ADJ ************************************* ***************************************************** NOTE: ***************************************************** 5. Fill:  Crankcase Oil quantity: 1.4L 6. Check:  Engine oil level Refer to “ENGINE OIL LEVEL INSPEC- TION” section. 7[...]

3-18 ENGINE OIL PRESSURE INSPECTION / TRANSMISSION OIL REPLACEMENT INSP ADJ 10 Nm (1.0 m S kg) CAUTION: ***************************************************** NOTE: NOTE: 22 Nm (2.2 m S kg) CAUTION: D Start the engine after solving the problem(s), and recheck the oil pressure. D T ighten the oil check bolt to specification. D Start the engine and ch[...]

3-19 TRANSMISSION OIL REPLACEMENT / EXHAUST SYSTEM INSPECTION / AIR FIL TER CLEANING INSP ADJ 20 Nm (2.0 m S kg) 53 Nm (5.3 m S kg) 20 Nm (2.0 m S kg) CAUTION: 7. Install: D Oil filler cap 1 D O-ring 2 8. Start the engine for several minutes to warm it up and check for the oil leakage. YP***** EXHAUST SYSTEM INSPECTION 1. Remove: D Side panels Refe[...]

3-20 AIR FIL TER CLEANING / CRANKCASE FIL TER CLEANING INSP ADJ NOTE: CAUTION: 7 Nm (0.7 m S kg) NOTE: 3. Inspect: D Air filter element Damaged  Replace. 4. Clean: D Air filter element 1 Use solvent to clean the element After cleaning, remove the remaining solvent by squeezing the element. Do not twist the element when squeezing the element. 5. [...]

3-21 CRANKCASE FIL TER CLEANING / COOLANT LEVEL INSPECTION INSP ADJ CAUTION: 7 Nm (0.7 m S kg) NOTE: CAUTION: NOTE: This element is a dry type. Be careful not to stain with grease or water . 3. Clean: D Crankcase filter element 1 Blow out the dust in the element from the outer surface using compressed air . 4. Install: D Crankcase filter element D [...]

3-22 COOLANT REPLACEMENT INSP ADJ NOTE: YP303180 COOLANT REPLACEMENT 1. Remove:  Side panels  Fuel tank Refer to the “COVERS AND P ANEL” section. 2. Remove:  Hose 1 (reservoir tank) Drain the reservoir tank of its coolant. 3. Remove:  Drain bolt 1  Radiator cap Open the front trunk, remove the cover , slowly loosen to remove the [...]

3-23 COOLANT REPLACEMENT INSP ADJ 10 Nm (1.0 m S kg) ***************************************************** 5. Install: D Gasket 1 D Drain bolt 2 6. Loosen: D Screw 1 (carburetor bleed) 7. Connect: D Hose (reservoir tank) 8. Fill: D Radiator (to specified level 1 ) Fill the coolant slowly , until the coolant comes out from the carburetor drain pipe.[...]

3-24 COOLANT REPLACEMENT INSP ADJ ***************************************************** CAUTION: NOTE:  If coolant splashes in your eyes: thoroughly wash your eyes with water and consult a doctor .  If coolant splashes on your clothes: quickly wash it away with water and then with soap and water .  If coolant is swallowed: quickly make the[...]

3-25 COOLING SYSTEM INSPECTION INSP ADJ YP303190 COOLING SYSTEM INSPECTION 1. Inspect:  Radiator 1  Filler hose (radiator) 2  Outlet hose (radiator) 3  Pipe  Outlet hose (radiator) 4 Cracks / Damage  Replace. Refer to “COOLING SYSTEM” section in chapter 5.[...]

3-26 FRONT BRAKE ADJUSTMENT INSP ADJ ***** ********************************************** ***************************************************** CAUTION: EB304002 CHASSIS FRONT BRAKE ADJUSTMENT 1. Check:  Brake lever free play a Out of specification  Adjust. Free play (brake lever): 2  5 mm (at brake lever end) 2. Adjust:  Brake lever fr[...]

3-27 BRAKE FLUID LEVEL INSPECTION INSP ADJ NOTE: NOTE: CAUTION: YP304020 BRAKE FLUID LEVEL INSPECTION 1. Stand the scooter on a level surface. Make sure the scooter is upright when inspect- ing the brake fluid level. 2. Stand the scooter on its centerstand. 3. Inspect:  Brake fluid level Brake fluid level is below the “LOWER” level line a ?[...]

3-28 BRAKE P AD INSPECTION / AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP ADJ ***************************************************** YP304030 BRAKE P AD INSPECTION 1. Operate the brake lever . 2. Inspect:  Brake pad (front) Wear indicators 1 almost touch the brake disc  Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKE” in CHAP[...]

3-29 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) / REAR BRAKE ADJUSTMENT INSP ADJ NOTE: 6 Nm (0.6 m S kg) NOTE: ***************************************************** ***************************************************** When bleeding the brake system, make sure that there is always enough brake fluid in the brake fluid reservoir before applying the brake[...]

3-30 REAR BRAKE ADJUSTMENT / BRAKE SHOE INSPECTION / STEERING HEAD INSPECTION INSP ADJ CAUTION: ***************************************************** NOTE:  T ighten the locknut (s). Rear wheel side:  T urn the adjuster 3 in or out until the speci- fied free play is obtained. T urning in  Free play is decreased. T urning out  Free play [...]

3-31 STEERING HEAD INSPECTION INSP ADJ ***************************************************** 38 Nm (3.8 m S kg) NOTE: 22 Nm (2.2 m S kg) 5. Remove: D Handlebar lower holder D Woodruf f key Refer to “STEERING” section in chapter 7. 6. Adjust: D Steering head Adjustment steps: D Remove the ring nut (upper) 1 , lock washer 2 , the ring nut (center[...]

3-32 STEERING HEAD INSPECTION / FRONT FORK INSPECTION INSP ADJ NOTE: 75 Nm (7.5 m S kg) ***************************************************** D Install the lock washer 1 . Make sure the lock washer tabs sit correctly in the ring nut slots. D Hold the ring nut (under and center), using the exhaust and ring nut wrench, and tighten the ring nut (upper[...]

3-33 SWINGARM INSPECTION / REAR SHOCK ABSORBER INSPECTION / REAR SHOCK ABSORBER ADJUSTMENT INSP ADJ 40 Nm (4.0 m S kg) 16 Nm (1.6 m S kg) NOTE: YP***** SWINGARM INSPECTION Securely support the scooter so there is no danger of it falling over . 1. Place the scooter on the level place. 2. Check: D Operation Grasp the end of the swingarm and gent- ly [...]

3-34 REAR SHOCK ABSORBER ADJUSTMENT / TIRE INSPECTION INSP ADJ ***************************************************** b a CAUTION: ***************************************************** Adjustment steps:  T urn the adjuster ring in or out. T urning toward  Spring preload is increased. T urning toward  Spring preload is decreased. Hard Standa[...]

3-35 TIRE INSPECTION INSP ADJ Basic weight: With oil and full fuel tank 158 kg Maximum load* 197 kg Cold tire pressure Front Rear Up to 90 kg load* 175 kPa (1.75 kg / cm 2 , 1.75 bar) 200 kPa (2.0 kg / cm 2 , 2.0 bar) 90 kg  maximum. load* 200 kPa (2.0 kg / cm 2 , 2.0 bar) 225 kPa (2.25 kg / cm 2 , 2.25 bar) High speed riding 200 kPa (2.0 kg / c[...]

3-36 TIRE INSPECTION / WHEEL INSPECTION INSP ADJ NOTE: FRONT : Manufacture Size T ype IRC 1 10 / 90-12 64J MB61 CHENG SHIN 1 10 / 90-12 64J C922 REAR: Manufacture Size T ype IRC 130 / 70-12 62L MB61 CHENG SHIN 130 / 70-12 62L C940 After mounting a tire, ride conservatively for a while to give the tire time to seat itself properly in the rim. Failur[...]

3-37 BA TTER Y INSPECTION INSP ADJ NOTE: CAUTION: YP305000 ELECTRICAL BA TTERY INSPECTION Since the MF battery is a sealed type battery , it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery . Therefore the charge of the bat- tery has to be checked by measuring the volt- age at the [...]

3-38 V olt meter Relationship between open-circuit voltage and charging time at 20 _ C (68 _ F) *This varies depending on the temperature, the state of charge in battery plates and the electrolyte level. Charging time Hours Open-circuit voltage BA TTER Y INSPECTION INSP ADJ CAUTION: ***************************************************** NOTE: D Batt[...]

3-39 BA TTER Y INSPECTION INSP ADJ Open-circuit voltage (V) Condition of charge in battery (%) Ambient temperature 20 _ C (68 _ F) Open-circuit voltage (V) Charging Ambient temperature 20 _ C (68 _ F) Check the Open-circuit voltage Time (Minutes) ***************************************************** CAUTION: D Check the condition of the battery usi[...]

3-40 Measure the open-circuit voltage prior to charging. Connect a charger and AMP meter to the battery , and start charging. Make sure the current is higher than the standard charging current written on the battery . By turning the charging voltage adjust dial, set the charging voltage at 20  25 V . Adjust the voltage so that cur- rent is at st[...]

3-41 Measure the open-circuit voltage prior to charging. Connect a charger and AMP meter to the battery , and start charging. NOTE: V oltage should be measured 30 min- utes after the machine is stopped. Make sure the current is higher than the standard charging current written on the battery . Charge the battery until the battery’s charging volta[...]

3-42 BA TTER Y INSPECTION / FUSE INSPECTION INSP ADJ NOTE: CAUTION: CAUTION: ***************************************************** ***************************************************** NOTE: 6. Inspect:  Battery terminals Dirty terminal  Clean with wire brush. Poor connection  Correct. After cleaning the terminals, grease them light- ly . [...]

3-43 FUSE INSPECTION / HEADLIGHT BEAM ADJUSTMENT INSP ADJ ***************************************************** ***************************************************** 3. Replace:  Blown fuse Replacement steps:  T urn off the main switch.  Install a new fuse with the proper current rat- ing.  T urn on switches to verify operation of relat[...]

INSP ADJ[...]

CHAPTER 4. ENGINE ENGINE OVERHAUL 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIREHARNESS AND CABLE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOSES, AIR FIL TER CASE, ENGINE MOUNTING BOL T AND ENGINE 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OIL PUMP 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP INSPECTION 4-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION 4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE AND CRANKSHAF[...]

4-1 ENGINE REMOV AL ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Wireharness and cables removal Side panel Footrest board Fuel tank Drain the coolant. Carburetor Spark plug cap Thermo unit lead Startor coil / Pick up coil lead Starting motor lead Earth lead Adjuster Brake cable 1 1 1/1 1 1 1 1 Remove the parts in order . Refer to “[...]

4-2 ENGINE REMOV AL ENG Order Job name / Part name Q’ty Remarks 8 9 10 11 Pin Compression spring Cable holder Cable holder 1 1 1 1 Reverse the removal procedure for installation. 7 Nm (0.7 m  kg) 10 Nm (1.0 m  kg)[...]

4-3 ENGINE REMOV AL ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Hoses, air filter , engine mounting bolt and engine removal V acuum hose Crankcase breather hose Inlet hose (water pump) Outlet hose (cylinder head) Air filter case assembly Bolt Self locknut / Plane washer Bolt Bolt / Plane washer / Rod assembly Engine 1 1 1 1 1[...]

4-4 ENGINE REMOV AL ENG NOTE: 64 Nm (6.4 m  kg) 32 Nm (3.2 m  kg) YP****** ENGINE REMOUNTING When remounting the engine, reverse the re- moval procedure in job instruction chart. Note the following points: 1. Install:  Engine 1  Plane washer 2  Rod 3 T emporarily install the rod and engine, and then tighten the bolts and nuts to spec[...]

4-5 CYLINDER HEAD ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Cylinder head removal Drain the coolant. Side panel Footrest board Fuel tank Carburetor Thermo unit lead Plug cap Crankcase breather hose Outlet hose (cylinder head) V acuum hose Breather hose (crankcase) Carburetor joint Joint O-ring 1 1 2 1 1 1 1 1 2 Remove the part[...]

4-6 Order Job name / Part name Q’ty Remarks 10 11 12 13 14 15 16 17 18 19 20 21 Crankcase filter cover / seal / element Plug / O-ring Cam sprocket cover / O-ring V alve cover (intake side) / O-ring V alve cover (exhaust side) / O-ring T iming chain tensioner assembly T iming chain tensioner gasket Breather plate Cam sprocket / T iming chain Cylin[...]

4-7 CYLINDER HEAD ENG NOTE: NOTE: NOTE: NOTE: YP401030 CYLINDER HEAD REMOV AL 1. Align: S “I” mark a on the rotor (with stationary pointer b on the crank case cover) T urn the primary sheave counterclockwise with a wrench and align the “I” mark c with the cylin- der head match mark d when the piston is at TDC on the compression stroke. 2. L[...]

4-8 CYLINDER HEAD ENG ***************************************************** ***************************************************** NOTE: NOTE: 22 Nm (2.2 m S kg) 10 Nm (1.0 m S kg) 2. Inspect: S Cylinder head Scratches / damage  Replace. 3. Measure: S Cylinder head warpage Out of specification  Resurface. Cylinder head warpage: Less than 0.03 [...]

4-9 CYLINDER HEAD ENG ***************************************************** ***************************************************** NOTE: CAUTION: 3. Install: S Cam sprocket 1 S T iming chain 2 Installing steps: D T urn the primary sheave counterclockwise until the TDC mark a matches the stationary pointer b . D Align the “I” mark c on the cam sp[...]

4-10 CYLINDER HEAD ENG ***************************************************** ***************************************************** 10 Nm (1.0 m S kg) 8 Nm (0.8 m S kg) 60 Nm (6.0 m S kg) 5. Install: S T iming chain tensioner Installation steps: D Remove the tensioner cap bolt 1 and springs 2 . D Release the timing chain tensioner one-way cam 3 and [...]

4-1 1 CAMSHAFT AND ROCKER ARMS ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Camshaft and rocker arms removal Cylinder head Lock washer Plate Rocker arm shaft (intake) Rocker arm shaft (exhaust) Rocker arm Camshaft Locknut Adjuster O-ring 1 1 1 1 2 1 2 2 1 Remove the parts in order . Refer to “CYLINDER HEAD” section. Refer to [...]

4-12 CAMSHAFT AND ROCKER ARMS ENG NOTE: YP****** ROCKER ARM AND ROCKER ARM SHAFT REMOV AL 1. Remove:  Rocker arm shaft (intake)  Rocker arm shaft (exhaust) Attach a rocker arm shaft puller bolt 1 and weight 2 to the rocker arm shaft and slide out the shaft. Rocker arm shaft puller bolt: 90890-01085 Weight: 90890-01084 YP402052 CAMSHAFT INSPEC[...]

4-13 CAMSHAFT AND ROCKER ARMS ENG ***************************************************** ***************************************************** YP402060 ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 1. Inspect: S Cam lobe contact surface 1 S Adjuster surface 2 Wear / Pitting / Scratches / Blue discolor- ation  Replace. Inspection steps: D Inspect t[...]

4-14 CAMSHAFT AND ROCKER ARMS ENG 8 Nm (0.8 m  kg) NOTE: NOTE: NOTE: CAUTION: 2. Install:  Plate 1  Look washer 2  Bolt 3 Bend the lock washer tabs along the bolt 3 flats. 3. Apply:  Molybdenum disulfide oil (onto the rocker arm and rocker arm shaft) Molybdenum disulfide oil 4. Install:  Rocker arm 1  Rocker arm shaft 2 (exhaus[...]

4-15 V AL VES AND V AL VE SPRINGS ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 V alves and valve springs removal Cylinder head Rocker arm, rocker arm shaft V alve cotters Spring retainer V alve spring (inner) V alve spring (outer) V alve (intake) V alve (exhaust) V alve guide Spring seat 4 2 2 2 1 1 2 2 Remove the parts in order . [...]

4-16 V AL VES AND V AL VE SPRINGS ENG NOTE: CAUTION: YP401 150 V AL VES AND V AL VE SPRINGS REMOV AL 1. Remove:  V alve cotters 1 Attach a valve spring compressor and attach- ment 2 between the valve spring retainer and cylinder head to remove the valve cotters. Do not compress so much as to avoid dam- age to the valve spring. V alve spring comp[...]

4-17 V AL VES AND V AL VE SPRINGS ENG YP402030 4. Measure: S Spring tilt Out of specification  Replace. Spring tilt limit: 1.7 mm (2.5 _ ) 5. Inspect: S Spring contact face Wear / Pitting / Scratches  Replace. 6. Measure: S V alve guide inside diameter Out of specification  Replace. V alve guide inside diameter: Intake: 6.000  6.012 mm [...]

4-18 V AL VES AND V AL VE SPRINGS ENG ***************************************************** ***************************************************** NOTE: ***************************************************** CAUTION: 3. Measure: S V alve seat width a Out of specification  Reface the valve seat. V alve seat width: Intake: 0.9  1.1 mm <Limit: [...]

4-19 V AL VES AND V AL VE SPRINGS ENG NOTE: NOTE: ***************************************************** NOTE: D T urn the valve until the valve face and valve seat are evenly polished, then clean off all compound. For best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hand. D Apply a fine lapping[...]

4-20 V AL VES AND V AL VE SPRINGS ENG NOTE: CAUTION: 4. Install:  V alve cotters 1 Install the valve cotters while compressing the valve spring with a valve spring compressor and attachment 2 . V alve spring compressor: 90890-04019 Attachment: 90890-04108 5. Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood. Do[...]

4-21 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 Cylinder and piston removal Cylinder head Joint O-ring T iming chain guide (exhaust side) Cylinder Dowel pin Cylinder gasket Piston pin circlip Piston pin Piston Piston ring (top) Piston ring (2nd) Side rail / Spacer 1 2 1 1 2 1 2 1 1 1 1 2/1 Remove the parts in order . Refer[...]

4-22 CYLINDER AND PIST ON ENG NOTE: NOTE: NOTE: YP****** PISTON AND PIST ON RINGS REMOV AL 1. Remove: S Piston pin circlip 1 S Piston pin 2 S Piston 3 Before removing the piston pin circlip, cover the crankcase opening with a clean towel or rag to prevent the circlip from falling into the crank- case cavity . 2. Remove: S T op ring S 2nd ring S Oil[...]

4-23 CYLINDER AND PIST ON ENG YP****** PISTON AND PIST ON PIN INSPECTION 1. Measure:  Piston skirt diameter Out of specification  Replace. a 5.0 mm from the piston bottom edge Piston skirt diameter: 68.965  68.980 mm Oversize (2) 69.5 mm Oversize (4) 70.0 mm 2. Calculate:  Piston-to-cylinder clearance Piston-to-cylinder clearance = Cyli[...]

4-24 CYLINDER AND PIST ON ENG NOTE: NOTE: NOTE: YP4021 1 1 PISTON RINGS INSPECTION 1. Measure:  Side clearance Out of specification  Replace the piston and the piston rings as a set. Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance. Side clearance (piston ring): T op ring: 0.04  0.08 [...]

4-25 CYLINDER AND PIST ON ENG NOTE: NOTE: EB404184 PISTON RINGS, PIST ON AND CYLINDER INST ALLA TION 1. Install: S T op ring 1 S 2nd ring 2 S Side rails (oil ring) 3 S Expander spacer (oil ring) 4 D Make sure to install the piston rings so that the manufactuer ’s marks or numbers are lo- cated on the upper side of the rings. D Lubricate pistons a[...]

4-26 CYLINDER AND PIST ON ENG NOTE: NOTE: 4. Position: S Piston rings Offset the piston ring end gaps as shown. a T op ring end b Oil ring end (lower) c Oil ring end (upper) d 2nd ring end 5. Lubricate: S Piston outer surface S Piston ring S Cylinder inner surface Engine oil 6. Install: S Cylinder D Install the cylinder with one hand while com- pre[...]

4-27 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Crankcase filter cover and crankcase cover (left)removal Side panel Crankcase filter cover Crankcase filter cover seal Crankcase filter element Crankcase cover protector Crankcase cover (left) Crankcase cover gasket 1 1 1 1 1 1 Remove the parts in order . Refer to “COVER AND P ANEL” sec[...]

4-28 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 V -belt, clutch and secondary / primary sheave removal Nut / Plain washer Primary fixed sheave Nut Clutch housing Clutch assembly V -belt Primary sliding sheave Collar Primary sheave cap 1/1 1 1 1 1 1 1 1 1 Remove the parts in or[...]

4-29 Order Job name / Part name Q’ty Remarks 10 11 12 13 14 Cam Weight Slider Spacer Oil seal 1 8 4 4 1 Refer to “PRIMARY SHEA VE ASSEMBL Y” section. Reverse the removal procedure for installation. 60 Nm (6.0 m  kg) 60 Nm (6.0 m  kg) 3 Nm (0.3 m  kg) V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG *Shell BT grease No. 3 (9089[...]

4-30 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Secondary sheave disassembly Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave 1 1 3 1 1 4 1 2 2 1 Disassemble the parts in order . R[...]

4-31 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG NOTE: NOTE: CAUTION: NOTE: YP****** PRIMAR Y SHEA VE REMOV AL 1. Remove:  Nut 1 (primary sheave)  Plate washer  Primary fixed sheave 2 Loosen the nut (primary fixed sheave) while holding the primary fixed sheave with the rotor holder 3 . Rotor holder: 90890-01235 YP****** SECONDA[...]

4-32 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG NOTE: NOTE: CAUTION: NOTE: 3. Remove: S Clutch assembly 1 S V -belt 2 Remove the V -belt from the primary sheave side with clutch assembly . YP****** SECONDAR Y SHEA VE DISASSEMBL Y 1. Remove: S Nut 1 (secondary sheave) Loosen the nut 1 while attaching the clutch spring compressor 2 and c[...]

4-33 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG YP****** V -BEL T INSPECTION 1. Inspect:  V -belt 1 Cracks / Wear / Scaling / Chipping  Re- place. Oil / Grease  Check primary sheave and secondary sheave. 2. Measure:  V -belt width 2 Out of specification  Replace V -belt width: 22.6 mm <Limit: 21.0 mm> YP****** WEIG[...]

4-34 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG NOTE: NOTE: 3 Nm (0.3 m S kg) NOTE: YP****** PRIMAR Y SHEA VE ASSEMBL Y 1. Clean: S Primary sliding sheave face 1 S Primary fixed sheave face 2 S Collar 3 S Weight 4 S Primary sliding sheave cam face 5 Remove any excess grease. 2. Install: S Weight 1 S Collar 2 D Apply Shell BT grease No.[...]

4-35 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG NOTE: CAUTION: NOTE: CAUTION: 3. Install:  Guide pin 1 4. Apply:  BEL-RA Y assembly lube  (to the guide pin sliding groove 1 , and and oil seal 2 ) 5. Install:  Secondary sheave complete 1  Compression spring  Clutch carrier 2 T emporarily tighten the nut 5 while attachi[...]

4-36 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG 90 Nm (9.0 m  kg) NOTE: NOTE: NOTE: 7. Install:  Nut 1 (clutch carrier) T ighten the nut (clutch carrier), using the lock- nut wrench 3 while holding the clutch carrier with the rotor holder 2 . Rotor holder: 90890-01235 Locknut wrench: 90890-01348 8. Install:  Clutch housing 1 ?[...]

4-37 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Magneto cover and startor coil removal Drain the engine oil. Side panels Couplers (A.C. magneto lead) Exhaust pipe Exhaust pipe gasket Magneto cover Gasket (magneto cover) Dowel pins Startor coil Pick up coil 2 1 1 2 1 2 1 1 Remove the parts in order . NOTE: Refer to “ENGINE OIL REPLA[...]

4-38 A.C. MAGNETO AND ST ARTER CLUTCH ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 A.C. magneto and starter clutch removal Rotor Shaft (idle gear) Idler gear Starter one way clutch assembly Woodruf f key Starter wheel gear 1 1 1 1 1 1 Remove the parts in order . Refer to “A.C. MAGNETO ROT OR REMOV AL / INST ALLA TION” section. Refe[...]

4-39 A.C. MAGNETO AND ST ARTER CLUTCH ENG NOTE: NOTE: CAUTION: YP401081 A.C. MAGNETO ROT OR REMOV AL 1. Remove: S Nut 1 (rotor) S Plain washer 2 D Loosen the nut (rotor) 1 while holding the ro- tor with a sheave holder 3 . D Do not allow the sheave holder to touch the projection on the rotor . Sheave holder: 90890-01701 2. Remove: S Rotor 1 S Woodr[...]

4-40 A.C. MAGNETO AND ST ARTER CLUTCH ENG ***************************************************** ***************************************************** NOTE: NOTE: YP402163 ST ARTER DRIVE GEAR INSPECTION 1. Inspect: S Starter idle gear teeth S Starter drive gear teeth S Starter wheel gear teeth Burrs / chips / roughness / wear  Re- place. 2. Check[...]

4-41 A.C. MAGNETO AND ST ARTER CLUTCH ENG 80 Nm (8.0 m  kg) NOTE: 3. T ighten:  Nut (rotor) 1 T ighten the nut (rotor) 1 while holding the mag- neto rotor 2 with a sheave holder 3 . Sheave holder: 90890-01701[...]

4-42 OIL PUMP ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Oil pump removal A.C. magneto Cover Pump driven gear Dowel pin Oil pump assembly Gasket Impeller shaft gear Dowel pin Shaft 1 1 1 1 1 1 1 1 Remove the parts in order . Refer to the “A.C. MAGNETO AND ST ARTER CLUTCH” section. Reverse the removal procedure for installatio[...]

4-43 OIL PUMP ENG EB402140 OIL PUMP INSPECTION 1. Inspect:  Drive gear (oil pump)  Driven gear (oil pump) 1  Pump housing  Pump housing cover Wear / cracks / damage  Replace 2. Measure:  T ip clearance A (between the inner rotor 1 and the outer rotor 2 )  Side clearance B (between the outer rotor 2 and the pump housing 3 ) Out [...]

4-44 TRANSMISSION ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 T ransmission removal Rear wheel Crankcase cover (left) Drain the transmission oil. T ransmission case cover Gasket (transmission case cover) Dowel pin Primary drive gear Plain washer Plain washer 1st wheel gear 1 1 2 1 1 1 1 Remove the parts in order . Refer to “REAR W[...]

4-45 Order Job name / Part name Q’ty Remarks 8 9 10 11 Drive axle Main axle Primary driven gear Plain washer 1 1 1 1 Reverse the removal procedure for installation. 16 Nm (1.6 m  kg) TRANSMISSION ENG[...]

4-46 CRANKCASE AND CRANKSHAFT ENG Order Job name / Part name Q’ty Remarks 1 2 Crankcase and crankshaft removal Engine removal Cylinder head Cylinder , piston V -belt, clutch, secondary / primary sheave A.C. magneto, starter clutch Oil pump W ater pump Rear wheel Bolt O-ring 1 1 Remove the parts in the order . Refer to “ENGINE REMOV AL” sectio[...]

4-47 Order Job name / Part name Q’ty Remarks 3 4 5 6 7 8 9 T iming chain guide (intake) Crankcase (right) Dowel pin Crankshaft assembly T iming chain Crankcase (left) Oil seal 1 1 2 1 1 1 1 Refer to “CRANKSHAFT INST ALLA TION” section. Refer to “CRANKSHAFT REMOV AL / INST ALLA TION” section. Reverse the removal procedure for installation.[...]

4-48 CRANKCASE AND CRANKSHAFT ENG NOTE: NOTE: YP****** CRANKSHAFT REMOV AL 1. Remove:  Crankshaft assembly  T iming chain 1  Before removing the crankshaft assembly , remove the timing chain from the crank shaft sprocket.  If the timing chain hooks to the crankshaft sprocket, the crankshaft cannot be removed. YP****** CRANKSHAFT INSPECT[...]

4-49 CRANKCASE AND CRANKSHAFT ENG NOTE: NOTE: 4. Inspect:  Crankshaft sprocket 1 Wear / Damage  Replace crankshaft.  Bearing 2 Wear / Crack / Damage  Replace crank- shaft.  Pump drive gear 3 Wear / Damage  Replace crankshaft. 5. Inspect:  Crankshaft journal Clogged  Blow out the journal with com- pressed air . YP404073 CRANK[...]

ENG[...]

CHAPTER 5. COOLING SYSTEM RADIA TOR 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W A TER PUMP 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

[...]

5-1 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Radiator removal Drain the coolant. Fuel tank Footrest board, under cover Cowling body , leg shield Fan motor leads Thermo switch leads Filler hose (radiator) Outlet hose (radiator) Inlet hose (radiator) Radiator 1 2 1 1 1 1 Remove the parts in order . Refer to “COOLANT REPLACEMENT” sect[...]

5-2 RADIA T OR COOL CAUTION: ***************************************************** ***************************************************** YP500030 INSPECTION 1. Inspect: D Radiator 1 Obstruction  Blow out with com- pressed air through the rear of the radia- tor . Flattened fins  Repair or replace. If flattened over the 20 % of radiator fin, re[...]

5-3 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 W ater pump removal Drain the coolant. Impeller shaft gear Dowel pin / plain washer Shaft Inlet hose (water pump) Holder Housing cover Housing cover gasket W ater pump housing 1 1/1 1 1 1 1 1 1 Remove the parts in order . Refer to “COOLANT REPLACEMENT” section in CHAPTER 3. Refer to [...]

5-4 Order Job name / Part name Q’ty Remarks 9 10 11 Impeller shaft O-ring O-ring 1 1 1 Refer to “W A TER PUMP INST ALLA TION” section. Reverse the removal procedure for installation. 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) Oil pump side W A TER PUMP COOL[...]

5-5 W A TER PUMP COOL NOTE: ***************************************************** ***************************************************** YP****** D It is not necessary to disassemble the water pump, unless there is no abnormality such as excessive change in coolant temperature and / or level, discoloration of coolant, or milky transmission oil. D If[...]

5-6 W A TER PUMP COOL NOTE: ***************************************************** ***************************************************** NOTE: 10 Nm (1.0 m S kg) 2. Install: D Mechanical seal 1 Apply coolant to the outside of the me- chanical seal before installing. Do not smear any oils grease on to the ring side of the mechanical seal. 3. Inspect:[...]

5-7 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Thermostat removal Drain the coolant Side panel Fuel tank Clip Outlet hose (carburetor) Hose clamp Outlet hose (thermostat) Thermostatic cover Thermostatic valve 1 1 1 1 1 1 Remove the parts in order . Refer to “COOLANT REPLACEMENT” section in CHAPTER 3. Refer to “COVER AND P ANEL” s[...]

5-8 3mm 95 _ C 82”1.5 _ C THERMOST A T COOL ***************************************************** ***************************************************** NOTE: EB502010 INSPECTION 1. Inspect: D Thermostatic valve V alve does not open at 80.5  83.5 _ C  Replace. Inspection steps: D Suspend the thermostatic valve in a vessel. D Place a reliable[...]

CHAPTER 6. CARBURETION CARBURETION 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR DISASSEMBL Y 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBL Y 6-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LEVEL ADJUSTME[...]

[...]

6-1 Do not bend the air filter joint clamp when installing the carburetor . Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Carburetor removal Side panel Fuel tank Drain the coolant Auto choke lead coupler Inlet / Outlet hose (carburetor) Fuel hose Throttle cable Air filter joint Nut Carburetor ass’y 1 1/1 1 2 1 2 1 Remove the parts in or[...]

6-2 Refer to “CARBURETOR ASSEMBL Y” section. Refer to “CARBURETOR ASSEMBL Y” section. Order Job name / Part name Q’ty Remarks Carburetor disassembly Auto choke unit Throttle stop screw set Pilot screw set Cover / Diaphragm spring Piston valve Jet needle ass’y Coasting enricher Accererating pump Float chamber Float pin 1 1 1 1/1 1 1 1 1 [...]

6-3 Order Job name / Part name Q’ty Remarks Float Needle valve Main jet Pilot jet Main nozzle 1 1 1 1 1 Refer to “CARBURETOR ASSEMBL Y” section. Reverse the disassembly procedure for assembly . 11 12 13 14 15 CARBURET OR CARB[...]

6-4 CARBURET OR CARB CAUTION: ***************************************************** NOTE: YP600041 ASSEMBL Y Reverse the “DISASSEMBL Y” procedure. Note the following points. D Before assembling, wash all parts in clean petroleum based solvent. D Always use a new gasket. 1. Install: D Main nozzle 1 D Main jet 2 D Pilot jet 3 2. Install: D V alve[...]

6-5 CARBURET OR CARB ***************************************************** NOTE: ***************************************************** Float height (F .H.): 27 mm Out of specification  Replace. 5. Install: D Diaphragm 1 Align the tab a on the diaphragm with the slot b on the carburetor body . 6. Install: D Compression spring 1 D Cover 2 YP600060[...]

6-6 CARBURET OR CARB ***************************************************** ***************************************************** ***************************************************** D Put a garage jack under the engine to ensure that the carburetors are positioned vertically . D Connect the fuel level gauge 1 to the drain pipe 2 . Fuel level gauge[...]

6-7 CARBURET OR CARB ***************************************************** ***************************************************** YP****** FUEL PUMP INSPECTION 1. Remove: D Side panels Refer to “COVER AND P ANEL” section in CHAPTER 3. 2. Inspect: D Fuel pump Inspection steps: D Place the receptacle under the fuel pipe end. D Start engine, and in[...]

CARB[...]

CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISC 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL AND BRAKE DISC 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL DISASSEMBL Y 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL DISASSEMBL Y 7-3 . . . . . . . . . . . . . . . . . . . .[...]

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7-1 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Front wheel and brake disc removal Speedometer cable Axle nut Wheel axle Front wheel assembly Gear unit assembly Collar Brake disc 1 1 1 1 1 1 1 Remove the parts in order . Securely support the scooter so there is no danger of it falling over . Refer to “FRONT WHEEL ASSEMBL Y” section.[...]

7-2 1 2 3 4 Order Job name / Part name Q’ty Remarks Front wheel disassembly Oil seal Bearing Spacer Bearing 1 1 1 1 Remove the parts in order . Reverse the removal procedure for installation. Refer to “FRONT WHEEL DISASSEMBL Y / ASSEMBL Y” section. FRONT WHEEL AND BRAKE DISC CHAS FRONT WHEEL DISASSEMBL Y[...]

7-3 FRONT WHEEL AND BRAKE DISC CHAS CAUTION: YP****** FRONT WHEEL DISASSEMBL Y 1. Remove:  Bearing 1  Spacer Remove the bearing using a general bear- ing puller 2 . Handle the wheel with care not to damage the brake disc. If the brake disc is damaged, replace. YP700020 FRONT WHEEL INSPECTION 1. Inspect:  Front wheel axle (by rolling it on [...]

7-4 FRONT WHEEL AND BRAKE DISC CHAS NOTE: CAUTION: 5. Inspect: S Collar Grooved wear  Replace the collar and the oil seal as a set. YP****** BRAKE DISC INSPECTION 1. Measure: S Brake disc deflection Maximum deflection: 0.15 mm Out of specification  Replace. 2. Measure: S Brake disc thickness Brake disc thickness: 4.0 mm Minimum thickness: 3.5[...]

7-5 FRONT WHEEL AND BRAKE DISC CHAS 23 Nm (2.3 m  kg) NOTE: NOTE: NOTE: CAUTION: 2. Install:  Brake disc 1 T ighten the bolts (brake disc) in stage using a crisscross pattern. EB700030 FRONT WHEEL INST ALLA TION Reverse the “REMOV AL” procedure. Note the following points. 1. Lubricate:  Front wheel axle  Bearings  Oil seal (lips)[...]

7-6 FRONT WHEEL AND BRAKE DISC CHAS NOTE: ***************************************************** ***************************************************** ***************************************************** ***************************************************** NOTE: YP700040 WHEEL ST A TIC BALANCE ADJUSTMENT D After replacing the tire and / or rim, th[...]

7-7 FRONT WHEEL AND BRAKE DISC CHAS ***************************************************** ***************************************************** 5. Check: S Wheel static balance Checking steps: D T urn the wheel so that it comes to each point as shown. D Check that the wheel is at rest at each point. If not, readjust the front wheel static balance.[...]

7-8 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Rear wheel and rear brake removal Swingarm Adjuster Brake cable Compression spring Pin Rear wheel assembly Brake lining T ension spring Plate washer Camshaft lever Indicator plate Camshaft 1 1 1 1 1 2 2 1 1 1 1 Remove the part in order . Refer to “REAR SHOCK ABSORBER AND SWINGA[...]

7-9 REAR WHEEL AND REAR BRAKE CHAS Order Job name / Part name Q’ty Remarks 12 13 Camshaft shim Camshaft seal 1 1 Reverse the removal procedure for installation. 10 Nm (1.0 m  kg)[...]

7-10 REAR WHEEL AND REAR BRAKE CHAS NOTE: NOTE: EB701020 REAR WHEEL INSPECTION 1. Inspect:  Rear wheel axle  Rear wheel  Rear wheel bearings  Oil seals Refer to “FRONT WHEEL”. 2. Measure:  Rear wheel runout Refer to “FRONT WHEEL”. EB701021 REAR BRAKE INSPECTION 1. Inspect:  Brake lining surface Glazed areas  Polish. Use[...]

7-1 1 REAR WHEEL AND REAR BRAKE CHAS ***************************************************** ***************************************************** 4. Inspect: S Brake drum inner surface S Oil / scratches  Repair . S Oil Use a rag soaked in lacquer thinner or sol- vent. S Scratches Use an emery cloth (lightly and evenly polishing) 5. Inspect: S Cam[...]

7-12 FRONT BRAKE CHAS Order Job name / Part name Q’ty Remarks 1 2 3 Brake pad removal Caliper support bolt Brake pad Pad support 1 2 1 Remove the parts in order . Refer to “BRAKE P AD REPLACEMENT” section. Reverse the removal procedure for installation. 23 Nm (2.3 m  kg) FRONT BRAKE BRAKE P AD[...]

7-13 FRONT BRAKE CHAS NOTE: NOTE: CAUTION: 23 Nm (2.3 m S kg) YP702010 BRAKE P AD REPLACEMENT It is not necessary to disassemble the brake cal- iper and brake hose to replace the brake pads. 1. Remove: S Bolt (caliper support bolt) 1 Move the direction brake caliper to the ar- row mark. 2. Remove: S Brake pads D Install new brake pad springs when t[...]

7-14 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Master cylinder removal Drain the brake fluid Rear view mirror (right) Brake lever / compression spring Brake switch Union bolt Plain washer Brake hose Master cylinder bracket Master cylinder 1 1/1 1 1 2 1 1 1 Remove the parts in order . Refer to “BRAKE FLUID REPLACE- MENT” section [...]

7-15 Order Job name / Part name Q’ty Remarks 1 2 3 4 Master cylinder disassembly Master cylinder boot Circlip Master cylinder assembly Spring 1 1 1 1 Remove the parts in order . Refer to “MASTER CYLINDER ASSEMBL Y” section. Reverse the disassembly procedure for assembly . FRONT BRAKE CHAS MASTER CYLINDER DISASSEMBL Y[...]

7-16 FRONT BRAKE CHAS YP702040 MASTER CYLINDER INSPECTION 1. Inspect: S Master cylinder 1 Wear / scratches  Replace the master cylinder assembly . S Master cylinder cup 2 S Cracks / damage  Replace. 2. Inspect: S Master cylinder S Scratches / wear / damage  Replace the master cylinder assembly . 3. Inspect: S Diaphragm Wear / damage  Re[...]

7-17 FRONT BRAKE CHAS 10 Nm (1.0 m  kg) CAUTION: 26 Nm (2.6 m  kg) CAUTION: 2. Install:  Spring 1 Install the spring with its smaller diameter to the master cylinder piston.  Master cylinder kit 2 3. Install:  Circlip 1 Install the circlip securely into the master cylinder groove.  Master cylinder boot 2 YP****** MASTER CYLINDER I[...]

7-18 FRONT BRAKE CHAS 3. Air bleed: S Brake system Refer to “AIR BLEEDING” section in CHAPTER 3. D Use only designated quality brake fluid: Otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance. D Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to p[...]

7-19 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Caliper removal Drain the brake fluid Brake hose holder Union bolt Plain washer Brake hose Caliper support bolt Caliper assembly 1 1 2 1 1 1 Remove the parts in order . Refer to “BRAKE FLUID REPLACE- MENT” section in CHAPTER 3. Refer to “CALIPER INST ALLA TION” section. Reverse the [...]

7-20 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Caliper disassembly Brake pad Pad support Caliper piston Dust seal Piston seal Bleed screw / Cap 2 1 2 2 2 1/1 Remove the parts in order . Refer to “BRAKE CALIPER DIS- ASSEMBL Y / ASSEMBL Y” section. Reverse the disassembly procedure for assembly . 6 Nm (0.6 m  kg) FRONT BRAKE CHAS C[...]

7-21 FRONT BRAKE CHAS NOTE: ***************************************************** ***************************************************** CAUTION: CAUTION: YP702020 BRAKE CALIPER DISASSEMBL Y Before disassembling either brake caliper , drain the brake fluid from the brake hose, mas- ter cylinder , brake caliper and reservoir tank. 1. Remove: S Brake [...]

7-22 FRONT BRAKE CHAS CAUTION: 23 Nm (2.3 m S kg) 26 Nm (2.6 m S kg) CAUTION: EB702050 BRAKE CALIPER ASSEMBL Y D All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid: DOT #4 D Replace the caliper piston seals whenev- er a brake caliper is disassembled. 1. Install: S Pi[...]

7-23 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Front fork removal Front wheel Caliper assembly Front fender Inner fender Bolt (under bracket upper) Cap bolt / O-ring Bolt (under bracket lower) Front fork (left / right) 1 1 1 2 2/2 2 1/1 Remove the parts in order . Refer to “FRONT WHEEL” section. Refer to “FRONT FORK REMOV AL / I[...]

7-24 FRONT FORK CHAS Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Front fork disassembly Cap bolt O-ring Fork spring Dust seal Retaining clip Oil seal Bolt (Damper rod) / Gasket Inner tube Oil lock piece Damper rod Rebound spring 1 1 1 1 1 1 1/1 1 1 1 1 Remove the parts in order . Refer to “FRONT FORK REMOV AL / INST ALLA TIO[...]

7-25 FRONT FORK CHAS NOTE: NOTE: YP****** FRONT FORK REMOV AL D Securely support the scooter so there is no danger of it falling over . D Stand the scooter on a level surface. D Stand the scooter on its centerstand. 1. Loosen: S Bolt (lower bracket upper) 1 Loosen only the upper bolt. 2. Remove: S Cap bolt 1 Use 17 mm width hexagonal wrench for rem[...]

7-26 FRONT FORK CHAS CAUTION: 2. Remove:  Inner tube  Oil lock pice 3. Remove:  Oil seal 1 Never reuse the oil seal. 2 Rag YP703030 FRONT FORK INSPECTION 1. Inspect:  Inner tube bending Inner tube bending limit: 0.2 mm Scratches / bends / damage  Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken t[...]

7-27 FRONT FORK CHAS 23 Nm (2.3 m S kg) NOTE: NOTE: CAUTION: 2. Install: S Inner tube 1 Into outer tube 2 . 3. Install: S Plain washer 1 S Bolt (damper rod) 2 4. T ighten: S Bolt (damper rod) 1 T ighten damper rod bolt 1 while holding the damper rod with a T -handle 2 and a damper rod holder 3 . Damper rod holder: 90890-04084 T -handle 90890-01326 [...]

7-28 FRONT FORK CHAS NOTE: NOTE: 7. Inspect: S Inner tube operation Unsmooth operation  Disassembly and recheck. 8. Fill: S Fork oil Oil quantity: 0.142 L Recommended oil: Fork oil 15 WT or equivalent 9. After filling up, slowly pump the fork up and down to distribute the fork oil. 10. Measure: S Oil level a Out of specification  Adjust. Oil [...]

7-29 FRONT FORK CHAS NOTE: 45 Nm (4.5 m  kg) 23 Nm (2.3 m  kg) EB703050 FRONT FORK INST ALLA TION Reverse the “REMOV AL“ procedure. Note the following points. 1. Install:  Front fork 1 T emporary tighten the pinch bolts. Pull up the inner tube until its end flushes the top of the under bracket 2 , then temporarily tighten the bolt (und[...]

7-30 HANDLEBAR CHAS Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Handlebar removal Handlebar upper cover Rear view mirror (right) Rear view mirror (left) Master cylinder bracket Master cylinder Grip end (right) Handlebar switch (right) Throttle cable Grip assembly Brake cable Lever holder (left) 1 1 1 1 1 1 2 1 1 1 Remove the part[...]

7-31 HANDLEBAR CHAS Order Job name / Part name Q’ty Remarks 11 12 13 14 15 Handlebar switch (left) Grip end (left) Grip Upper handlebar holder Handlebar 1 1 1 2 1 Refer to “HANDLEBAR INST ALLA TION” section. Refer to “HANDLEBAR REMOV AL” section. Refer to “HANDLEBAR INST ALLA TION” section. Reverse the removal procedure for installati[...]

7-32 HANDLEBAR CHAS ***************************************************** ***************************************************** NOTE: 23 Nm (2.3 m S kg) NOTE: NOTE: YP****** HANDLEBAR REMOV AL 1. Remove: S Grip (Left) Removal steps: D Remove the grip end (left). D Blow with compressed air between the han- dlebar and adhesive side of the grip to re-[...]

7-33 HANDLEBAR CHAS NOTE: NOTE: NOTE: ***************************************************** ***************************************************** 4. Install: S Handlebar switch (left) 1 Align the handlebar switch mating surface with the punched mark a on the handlebar . 5. Install: S Lever holder (left) 1 Align the lever holder mating surface with [...]

7-34 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Steering removal Handlebar upper cover Front fork Handlebar Nut Handlebar lower holder Woodruf f key Ring nut (upper) Lock washer Ring nut (center) Rubber washer Ring nut (lower) Ball race cover Ball race 1 Lower bracket 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in order . Refer to[...]

7-35 STEERING CHAS Order Job name / Part name Q’ty Remarks 12 13 14 15 Ball bearing Ball bearing Ball race 1 Ball race 2 22 19 1 1 Refer to “STEERING INST ALLA TION” section. Reverse the removal procedure for installation. 139 Nm (13.9 m  kg) 75 Nm (7.5 m  kg) 1st step: 38 Nm (3.8 m  kg) 2nd step: Loosen the ring nut 1 / 4 turn. 3rd [...]

7-36 STEERING CHAS NOTE: NOTE: YP704010 STEERING REMOV AL D Securely support the scooter so that there is no danger of it falling over . D Stand the scooter on a level surface. 1. Remove: S Handlebar lower holder 1 S Woodruf f key 2 Remove the handlebar lower holder by loosen- ing the ring nut (upper) 3 gradually . 2. Remove: S Ring nut (upper) S L[...]

7-37 STEERING CHAS ***************************************************** ***************************************************** NOTE: CAUTION: 139 Nm (13.9 m S kg) NOTE: Bearing race replacement steps: D Remove the bearing races on the head pipe using long rod 1 and the hammer as shown. D Remove the bearing race on the under brack- et using the floo[...]

7-38 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Rear shock absorber and swingarm removal Side panels Box Nut Muffler assembly Axle nut Rear shock absorber Swingarm Collar Oil seal Bearing 1 2 1 1 1 1 1 1 1 Remove the parts in order . Refer to “COVER AND P ANEL” section in CHAPTER 3. Loosen. Remove with the rear brake applied. R[...]

CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCHES 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING STEPS 8-4 . . . . . .[...]

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8-1 ELECTRICAL COMPONENTS ELEC 1 Main switch 2 Ignition coil 3 Spark plug cap 4 Fuel sender 5 Rectifier / Regulator 6 Starting circuit cut-off relay 7 Wireharness 8 Thermo unit 9 Ignitor unit 10 Sidestand switch 11 Battery 12 Starter relay 13 Flasher relay 14 Horn EB800000 ELECTRICAL ELECTRICAL COMPONENTS[...]

8-2 CIRCUIT DIAGRAM ELEC CIRCUIT DIAGRAM[...]

8-3 CIRCUIT DIAGRAM ELEC 1 A.C. magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Thermo switch (auto choke) 9 Auto choke 10 Ignitor unit 11 Ignition coil 12 Spark plug 13 Pickup coil 14 Sidestand switch 15 Starting circuit cut-off relay 16 Lights switch 17 Starter switch 18 Engine stop switch 19 Ha[...]

8-4 CHECKING SWITCHES ELEC NOTE: YP-N CHECKING SWITCHES CHECKING STEPS Using pocket tester , check switches for continu- ity between their terminals to determine wheth- er they are correctly connected. Repalce the switch component if any of the combinations does not produce the correct reading. Pocket tester: 90890-031 12  T urn the switch to th[...]

8-5 Before checking a switch refer to the checking switches as shown in the left page and check for the correct terminal connections (closed circuit) according to the color combinations shown in the chart. Poor connection, fault  Repair or replace. * Indicates coupler positions. CHECKING SWITCHES ELEC YP****** SWITCH POSITION AND TERMINAL CONNEC[...]

8-6 IGNITION SYSTEM ELEC 3 Main switch 4 Battery 5 Main fuse 10 Ignitor unit 11 Ignition coil 12 Spark plug 13 Pickup coil 14 Sidestand switch 18 Engine stop switch EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM[...]

8-7 IGNITION SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section in CHAPTER 8. Replace the fuse. NO CONTINUITY CONTINUITY YP****** 2. Battery  Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3.  Clean battery terminals.  Recharge or replace the battery . INCORRECT CORRECT YP****** [...]

8-8 IGNITION SYSTEM ELEC YP****** 4. Ignition spark gap S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker as shown. Spark plug S T urn the main switch to “ON”. S Check the ignition spark gap . S Check the spark by pushing the starter switch, and increase the spark gap until a misfire occurs. MEETS SPECIFICA TIO[...]

8-9 IGNITION SYSTEM ELEC YP****** 6. Ignition coil resistance S Disconnect the ignition coil connector from the wireharness. S Connect the pocket tester ( Ω 1) to the ignition coil. S Check if the primary coil has the specified re- sistance. S Connect the pocket tester ( Ω 1 k) to the ignition coil. S Check the secondary has the specified re- s[...]

8-10 IGNITION SYSTEM ELEC YP****** 7. Pickup coil resistance S Disconnect the pickup coil coupler from the wireharness. S Connect the pocket tester ( Ω 100) to the pickup coil coupler . : Pickup coil resistance: 168 X 252 Ω (20 _ C) YP****** 8. Main switch Refer to “CHECKING SWITCHES” section in the CHAPTER 8. NO CONTINUITY Replace the main[...]

8-1 1 CHARGING SYSTEM ELEC 1 A.C. magneto 2 Rectifier regulator 4 Battery 5 Main fuse YP804000 CHARGING SYSTEM CIRCUIT DIAGRAM[...]

8-12 CHARGING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Replace the fuse. NO CONTINUITY CONTINUITY YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals. S Recharge or replace the battery . INCORRECT CORRECT : YP804010 TROUBLESHOOTING [...]

8-13 YP****** 3. Charging voltage S Connect the engine tachometer to the spark plug lead . S Connect the pocket tester (DC20 V) to the battery . S Measure the battery terminal voltage. S Start the engine and accelerate to about 5,000 r / min. S Check the terminal voltage. OUT OF SPECIFICA TION The charging circuit is not faulty . Replace the batter[...]

8-14 CHARGING SYSTEM ELEC YP****** 4. Starter coil resistance S Remove the A.C. magneto coupler from wireharness. S Connect the pocket tester ( Ω 1) to the sta- tor coil. S Measure the stator coil resistance. Replace the stator coil. OUT OF SPECIFICA TION T ester (+) lead  white terminal T ester (–) lead  White terminal : Stator coil resi[...]

8-15 ELECTRIC ST ARTING SYSTEM ELEC 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 14 Sidestand switch 15 Starting circuit cut-off relay 17 Starter switch 18 Engine stop switch 23 Rear brake switch 24 Front brake switch EB80300 ELECTRIC ST ARTING SYSTEM CIRCUIT DIAGRAM[...]

8-16 ELECTRICAL ST ARTING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section in CHAPTER 8. Replace the fuse. NO CONTINUITY CONTINUITY YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean the battery terminals. S Recharge or replace battery . INCORRECT CORRECT : [...]

8-17 ELECTRICAL ST ARTING SYSTEM ELEC YP****** 3. Starter motor S Connect the battery positive terminal and starter motor cable using a jumper lead. S Check the starter motor operation. CONTINUITY Repair or replace the starter motor . DOES NOT MOVE : : YP****** 4. Starter relay S Disconnect the relay unit coupler from the wireharness. S Connect the[...]

8-18 : YP****** 6. Main switch Refer to “CHECKING SWITCHES” section. NO CONTINUITY Replace the main switch. CONTINUITY YP****** 7. Engine stop switch Refer to “CHECKING SWITCHES” section. NO CONTINUITY Replace the right handlebar switch. CONTINUITY YP****** 8. Sidestand switch Refer to “CHECKING SWITCHES” section. NO CONTINUITY Replace [...]

8-19 ELECTRICAL ST ARTING SYSTEM ELEC Order Job name / Part name Q’ty Remarks 1 Starter motor removal Air cleaner case Starter motor 1 Remove the parts in order . Refer to “ENGINE REMOV AL AND INST ALLA TION” section in CHAPTER 4. Reverse the removal procedure for instal- lation. 7 Nm (0.7 m S kg) 7 Nm (0.7 m S kg) 10 Nm (1.0 m S kg) 5 Nm (0.[...]

8-20 ELECTRICAL ST ARTING SYSTEM ELEC NOTE: Good condition Bad condition A B f  f  f   f YP803034 Inspection and repair 1. Inspect: S Commutator Dirt  Clean it with #600 grit sandpaper . 2. Measure: S Commutator diameter a Commutator wear limit: 27 mm Out of specification  Replace the starter motor 3. Measure: S Mica undercut a Mi[...]

8-21 ELECTRICAL ST ARTING SYSTEM ELEC NOTE: 5 Nm (0.5 m  kg) NOTE: Brush spring force: 570 X 920 g 7. Inspect:  Bearing  Oil seal Wear / damage  Repalce. YP****** Assembly Reverse the “Removal” procedure. Note the following points. 1. Install:  Brush holder 1 Align the projection a on the brush seat with the slot b on the housing[...]

8-22 3 Main switch 4 Battery 5 Main fuse 16 Lights switch 29 Dimmer switch 30 Pass switch 32 T ail / Brake light 33 Licence light 36 Head light 39 Auxiliary light 40 Meter lights LIGHTING SYSTEM ELEC EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM[...]

8-23 LIGHTING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Repalce the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals. S Recharge or replace battery . INCORRECT CORRECT YP****** 3. Main switch Refer[...]

8-24 YP****** 5. Dimmer switch / Pass switch Refer to “CHECKING SWITCHES” section. Replace the left handlebar switch. NO CONTINUITY : YP****** 6. Wiring connection S Check the connections of the entire lighting system. Refer to “WIRING DIAGRAM”. Correct. POOR CONNECTIONS Check the condition of each of the lighting system’s circuits. Refer[...]

8-25 LIGHTING SYSTEM ELEC YP805021 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and / or bulb socket. NO CONTINUITY : 2. V oltage S Connect the pocket tester (DC20 V) to the bulb socket coupler . T ester (+) lead  Blue terminal T ester (–) lead  Black terminal S T urn the main switch to on. S T urn the [...]

8-26 LIGHTING SYSTEM ELEC 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and / or bulb socket. NO CONTINUITY 2. V oltage S Connect the pocket tester (DC20 V) to the bulb socket connector . T ester (+) lead  Blue terminal T ester (–) lead  Black terminal S T urn the main switch to on. S T urn the lights sw[...]

8-27 LIGHTING SYSTEM ELEC 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and / or bulb socket. NO CONTINUITY 2. V oltage S Connect the pocket tester (DC20 V) to the bulb socket connector . T ester (+) lead  Blue terminal T ester (–) lead  Black terminal S T urn the main switch to on. S T urn the lights sw[...]

8-28 SIGNAL SYSTEM ELEC 3 Main switch 4 Battery 5 Main fuse 23 Rear brake switch 24 Front brake switch 25 Flasher relay 26 Horn 27 T urn switch 28 Horn switch 33 T ail / Brake light 34 Rear flasher lights 35 Front flasher lights 38 T urn indicator lights 43 Fuel gauge 49 Fuel sender EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM[...]

8-29 SIGNAL SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Replace the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals. S Recharge or replace battery . INCORRECT CORRECT YP****** 3. Main switch Refer t[...]

8-30 SIGNAL SYSTEM ELEC YP****** 4. Wireharness S Check the connections of the entire signal system. Refer to “CIRCUIT SYSTEM WIRING DIA- GRAM” section. Correct. POOR CONNECTION : Check condition of each of the signal sys- tem’s circuits. Refer to “SIGNAL SYSTEM CHECK” section. CONTINUITY[...]

8-31 SIGNAL SYSTEM ELEC 1. HORN switch Refer to “CHECKING SWITCHES” section. CONTINUITY Replace the left handlebar switch. NO CONTINUITY 2. V oltage S Connect the pocket tester (DC20 V) to the horn lead. T ester (+) lead  Brown terminal . T ester (–) lead  Frame ground 1 MEETS SPECIFICA TION S T urn the main switch to on. S Check for vo[...]

8-32 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and / or bulb socket. NO CONTINUITY 3. V oltage S Connect the pocket tester (DC20 V) to the bulb socket connector . T ester (+) lead  Blue terminal T ester (–) lead  Black terminal S T urn the main switch to on. S The brake lever is pulled in. S Check fo[...]

8-33 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. MEETS SPECIFICA TION Replace the bulb and / or bulb socket. NO CONTINUITY 3. V oltage S Connect the pocket tester (DC20 V) to the flasher relay coupler . T ester (+) lead  Brown terminal . T ester (–) lead  Frame ground 1 MEETS SPECIFICA TION S T urn the main switch to o[...]

8-34 6. Wiring connection S Wiring circuit from the turn switch to bulb socket connector is fault. Repair . Refer to “CIRCUIT DIAGRAM”. 5. V oltage S Connect the pocket tester (DC20 V) to the bulb socket connector . At flasher light (left) T ester (+) lead  Chocolate lead T ester (–) lead  Black terminal S T urn the main switch to on. S[...]

8-35 SIGNAL SYSTEM ELEC Float position Specificated resistance UP 4 X 10 Ω 90 X 100 Ω DOWN 1. Fuel sender S Remove the fuel sender from the fuel tank. S Disconnect the fuel sender coupler from the wireharness. Connect the pocket tester ( Ω 10) to the fuel sender coupler lead. 2. V oltage S Connect the pocket tester (DC20 V) to the fuel gauge [...]

8-36 Float “UP” “F” “E” Float “DOWN” 3. Fuel gauge S Connect the fuel sender to wireharness. S Move the float to “UP” or “DOWN” . 1 S T urn the main switch to “ON”. S Check the fuel gauge needle moves “F” or “E”. Replace the fuel gauge. DOES NOT MOVE 2 MOVES : Float position Needle moves This circuit is not fault[...]

8-37 3 Main switch 4 Battery 5 Main fuse 20 Fuse (fan) 21 Thermo switch 22 Fan motor 46 Thermo meter 50 Thermo unit COOLING SYSTEM ELEC YP80700 COOLING SYSTEM CIRCUIT DIAGRAM[...]

8-38 COOLING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Replace the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals. S Recharge or replace battery . INCORRET CORRECT YP****** 3. Main switch Refer t[...]

8-39 COOLING SYSTEM ELEC 4. Fan motor (inspection 1)  Disconnect the fan motor couplers.  Cconnect the battery as shown. Battery (+) lead  Blue terminal Battery (–) lead  Black terminal 1 MOVES  Check the fan motor operation. Replace fan motor . DOES NOT MOVE 5. Fan motor (inspection 2)  T urn the main switch to on.  Remove t[...]

8-40 COOLING SYSTEM ELEC S Handle the thermo switch with special care. Never subject it to strong shocks or allow it to be dropped. Should it be dropped, it must be replaced. S Do not touch the thermo switch to the bottom of the heated vessel. 7. Wiring connection S Check the connection of the entire cooling system. Refer to “CIRCUIT DIAGRAM” s[...]

8-41 COOLING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Replace the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals. S Recharge or replace battery . INCORRET CORRECT YP****** 3. Main switch Refer t[...]

8-42 D Handle the thermo unit with special care. Never subject it to strong shocks or al- low it to be dropped. Should it be dropped, it must be replaced. D Do not touch the thermo unit to the bot- tom of the heated vessel. 80 _ C 47.5 X 56.8 Ω 26.2 X 29.3 Ω 100 _ C 4. Thermo unit S Drain the coolant, and remove the thermo unit from the radiato[...]

8-43 YP****** 6. Wiring connection S Check the connections of the entire cooling system. Refer to “CIRCUIT DIAGRAM” section. Correct. POOR CONNECTION : Replace the temperature gauge. CORRECT COOLING SYSTEM ELEC[...]

8-44 3 Main switch 4 Battery 5 Main fuse 8 Thermo switch (auto choke) 9 Auto choke 10 Ignitor unit 18 Engine stop switch AUT O CHOKE SYSTEM ELEC YP****** AUT O CHOKE SYSTEM CIRCUIT DIAGRAM[...]

8-45 AUT O CHOKE SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Repalce the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals. S Recharge or replace battery . INCORRECT CORRECT YP****** 3. Main switch Re[...]

8-46 AUT O CHOKE SYSTEM ELEC S Disconnect the thermo switch from the ra- diator . S Connect the pocket tester ( Ω 1) to the thermo switch . S Immerse the thermo switch in the coolant . S Check the thermo switch for continuity . Note temperatures while heating the water with the temperature gauge . S Handle the thermo switch with special care. Nev[...]

8-47 YP****** 6. Auto choke unit resistance S Disconnect the auto choke unit coupler from the wireharness. S Connect the pocket tester ( Ω 1) to the auto choke unit coupler lead. : Auto choke unit resistance: 16 X 24 Ω (20 _ C) T ester (+) lead  Black terminal T ester (–) lead  Black terminal 1 2 Replace the auto choke unit. OUT OF SPEC[...]

ELEC[...]

CHAPTER 9. TROUBLESHOOTING ST ARTING F AILURE / HARD ST ARTING 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION SYSTEM 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEM 9-2 . . . . . . [...]

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9-1 ST ARTING F AILURE / HARD ST ARTING TRBL SHTG NOTE: EB90000 TROUBLESHOOTING The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however , as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. YP90000 ST ARTING F AILURE[...]

9-2 POOR IDLE SPEED PERFORMANCE TRBL SHTG IGNITION SYSTEM Battery  Improperly charged battery  Faulty battery Fuse  Burnt out, improper connection Spark plug  Improper plug gap  Worn electrodes  Wire between terminals broken  Improper heat range  Worn electrodes  Faulty spark plug cap Ignition coil  Broken or shorted p[...]

9-3 POOR MEDIUM AND HIGH SPEED PERFORMANCE TRBL SHTG EB902000 POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to “ST ARTING F AILURE / HARD ST AR TING” section. (Fuel system, electrical system, compres- sion system and valve train) Carburetor  Improperly adjusted fuel level  Clogged main nozzle  Clog[...]

9-4 F AUL TY CLUTCH TRBL SHTG YP****** F AUL TY CLUTCH WHEN ENGINE IS RUN, SCOOTER DOES NOT RUN V belt  Worn / bent / slipping Cam, slider  Worn / damaged Compression spring  Damage Gears  Damage YP904000 CLUTCH SLIPPING Clutch weight spring  Worn / loose Clutch shoe  Worn / damaged Primary sliding sheave  Seized YP****** POOR [...]

9-5 OVERHEA TING OR OVER COOLING TRBL SHTG YP905000 OVERHEA TING OR OVER COOLING OVERHEA TING Ignition system  Improper spark plug gap  Improper spark plug heat range  Faulty ignitor unit Fuel system  Improper carburetor setting  Improper fuel level adjustment  Clogged air cleaner element Compression system  Heavy carbon deposi[...]

9-6 F AUL TY BRAKE / FRONT FORK MALFUNCTION TRBL SHTG YP906000 F AUL TY BRAKE POOR BRAKING EFFECT Front brake  Worn brake pad  Worn brake disc  Air in brake fluid  Leaking brake fluid  Faulty master cylinder kit  Faulty caliper seal kit  Loose union bolt  Broken brake hose  Oily or greasy brake pad  Oily or greasy brak[...]

9-7 INST ABLE HANDLING / ST ARTER MOTOR DOES NOT OPERA TE TRBL SHTG YP908000 INST ABLE HANDLING INST ABLE HANDLING Handlebars  Loose handlebar tightening bolt Steering  Loose or overtightening steering nut  Bent under bracket  Damaged bearing or ball race Front forks  Uneven oil levels on both sides  Broken front fork spring  T[...]

9-8 F AUL TY SIGNAL AND LIGHTING SYSTEM TRBL SHTG YP909000 F AUL TY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DARK  Improper bulb  T oo many electric accesories  Hard charging  Faulty rectifier / regulator  Faulty battery  Improperly connected coupler , connector , wireharness  Improperly grounded  Faulty main switch or Lights (d[...]

1. A.C. magneto 2. Rectifier / regulator 3. Main switch 4. Main fuse 5. Battery 6. Starter relay 7 Starter motor 8 Thermo switch (auto choke) 9. Auto choke 10. Ignitor unit 1 1. Ignition coil 12. Spark plug 13. Pickup coil 14. Sidestand switch 15. Starting circuit cut-off relay 16. Lights switch 17. Starter switch 18. Engine stop switch 19. Handleb[...]