User's Manual

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2009

MOTORCYCLE

SERVICE MANUAL

Model : YW125Y_

32SF819770E0

*32SF819770E0*

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Summary of content (338 pages)

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im .S co ot er T MOTORCYCLE e.
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ne t e. Ti m er ot .S co w w w fro m d oa de ow nl D EAS00000 YW125Y 2009 SERVICE MANUAL ©2008 by Yamaha Motor Taiwan Co., Ltd. First edition, July 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd. is expressly prohibited.
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EAS20070 Ti m e. ne t IMPORTANT This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
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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 divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter.] Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
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EAS00008 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 2 3 4 5 6 7 8 9 CHAS 5 6 ENG COOL 8 FI - er 0 e r w w ow nl u D y R. t T. oa de d fro m w q w .S co TRBL SHTG i o 4 p G d s Symbols 0 to u indicate the following.
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EAS00011 TABLE OF CONTENTS GENERAL INFORMATION SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 FI 6 e. Ti m ot er PERIODIC CHECKS AND ADJUSTMENTS 1 ne t SPECIFICATIONS GEN INFO w w w .
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GEN INFO CHAPTER 1 GENERAL INFORMATION D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t SCOOTER IDENTIFICATION ................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ............................................. 1-1 MODEL LABEL .................................................................................. 1-1 FEATURES ...............................................................................................
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SCOOTER IDENTIFICATION GEN INFO EAS00015 GENERAL INFORMATION 1 SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL LABEL The model label 1 is affixed to the frame under the seat. This information will be needed to order spare parts. D ow nl oa de d fro m w w w .S co ot er Ti m e.
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FEATURES GEN INFO EAS00896 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
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FEATURES GEN INFO EAS00897 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kgf/cm2, 35.6 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
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FEATURES GEN INFO D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t O2 sensor The O2 sensor has been adopted to enable the catalyst to function at a high degree of efficiency by maintaining the air-fuel mixture near the stoichiometric ratio (14.7:1). This sensor, which is a zirconia type, utilizes the oxygen ion conductivity of the solid electrolyte for detecting the oxygen concentration levels.
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IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. oa de d fro m w w w .S co ot er Ti m e. ne t 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear.
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IMPORTANT INFORMATION 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 .S co ot er 1 Oil seal Ti m e. ne t BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible.
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IMPORTANT INFORMATION GEN INFO EAS00021 EQUIPMENT PREPARATION Turn Rivet (Turn type) Assembly status of the turn rivet(turn type). ot er Ti m e. ne t Dissembling 1. Press center pin1 inward to release the lock. 2. Remove the push rivet main body2. oa de d fro m w w w .S co Assembling 1. Restore the center pin, replace the turn rivet main body. D ow nl 2. Turn in the center pin until leveling off with the surface position of the turn rivet main body.
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CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector ot er Ti m e. ne t 2. Check: 8 lead 8 coupler 8 connector Moisture J Dry with an air blower. Rust/stains J Connect and disconnect several times. TIP If the pin 1 on the terminal is flattened, bend it up. oa de d fro m w w w .S co 3. Check: 8 all connections Loose connection J Connect properly.
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SPECIAL TOOLS GEN INFO 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 inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. TIP 8 For U.S.A.
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SPECIAL TOOLS Tool NO. This tool is used to loosen and tighten the steering ring nut. Sheave holder fro m w w This tool is used for holding the secondary sheave. Thickness gauge This tool is used to measure the valve cleanance. Compression gauge ow nl 90890-03081 YU-33223 oa de d 90890-03079 YM-34483 This tool is used to measure the engine compression. Pocket tester D 90890-03112 YU-03112-C e.
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SPECIAL TOOLS Tool NO. e. This tool is used to remove or install the valve guides. Valve guide installer (4.5mm) w w This tool is used to install the valve guides. Valve guide reamer (4.5mm) fro m 90890-04118 YM-04118 90890-03153 YU-03153 90890-03186 d oa de This tool is used to check the ignition system components. FI diagnostic tool ow nl 90890-03182 YU-03182 This tool is used to rebore the new valve guides.
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SPECIAL TOOLS Tool NO. Illustration Yamaha bond NO.1215 Sealant (Quick Gasket®) ow nl oa de d fro m w w w .S co ot er Ti m e. ne t This sealant (bond) is used to apply on crankcase mating surfaces.
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SPEC CHAPTER 2 SPECIFICATIONS D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t GENERAL SPECIFICATIONS ................................................................. 2-1 ENGINE SPECIFICATIONS ..................................................................... 2-2 CHASSIS SPECIFICATIONS ................................................................. 2-12 ELECTRICAL SPECIFICATIONS ..........................................................
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GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Standard Item 1910mm (75.2in) 765mm (30.1in) 1110mm (43.7in) 780mm (30.7in) 1290mm (50.8in) 125mm (4.9in) 1900mm (74.8in) … … … … … … … ne t … … Ti m Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 32S1 (USA) 32S2 (CAN) e.
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ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Standard Item Engine Engine type Displacement Cylinder arrangement Limit Air-cooled, 4-stroke, SOHC 0.125L (125cm3, 7.63cu-in) Forward inclined single cylinder 52.4 × 57.9mm (2.06 × 2.28in) 10:1 1700 ~ 1900r/min 37 ~ 47kPa (281 ~ 357mmHg, 11.06 ~ 14.05inHg) at 1800r/min 1350kPa (13.5kgf/cm2, 192psi) at 1800r/min … … … … e. ne t Bore × stroke Compression ratio Engine idle speed Vacuum pressure at engine idle speed … … … ot Fuel Recommended fuel .
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ENGINE SPECIFICATIONS SPEC Standard Item Limit Oil filter Oil filter type Wire mesh … Oil pump Oil pump type Inner rotor to outer rotor tip clearance Trochoid 0.15mm (0.006in) or less 0.07 ~ 0.12mm (0.003 ~ 0.005in) … 0.23mm (0.009in) 0.19mm (0.008in) Starting system type Electric starter … Spark plug Model (manufacturer) × quantity Spark plug gap U22ESR-N (DENSO) × 1 … 0.7 ~ 0.8mm (0.028 ~ 0.031in) … Cylinder head Volume Ti m 11.4 ~ 12.0cm³ (0.70 ~ 0.73cu-in) … e.
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ENGINE SPECIFICATIONS SPEC Standard Item Camshaft Drive system Intake camshaft lobe dimensions Limit Chain drive (left) … 25.267 ~ 25.367mm (0.995 ~ 0.999in) 21.069 ~ 21.169mm (0.829 ~ 0.833in) 25.167mm (0.991in) 20.969mm (0.826in) A e. Measurement A ne t B Ti m Measurement B w w .S co ot er Exhaust camshaft lobe dimensions fro m w A oa de d B D Measurement B ow nl Measurement A Maximum camshaft runout 25.275 ~ 25.375mm (0.995 ~ 0.999in) 21.069 ~ 21.169mm (0.829 ~ 0.
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ENGINE SPECIFICATIONS SPEC Standard Item Timing chain Model/number of links Tensioning system Valve, valve seats, valve guides Valve clearance (cold) Intake Exhaust Limit Morse 92RH2005/94 Automatic … … 0.10 ~ 0.14mm (0.004 ~ 0.006in) 0.16 ~ 0.20mm (0.006 ~ 0.008in) … … B D e. C Head Diameter Ti m A Face Width Seat Width er Valve head diameter A Intake .S co ot 18.9 ~ 19.1mm (0.744 ~ 0.752in) 16.9 ~ 17.1mm (0.665 ~ 0.
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ENGINE SPECIFICATIONS SPEC Standard Item Valve stem to valve guide clearance Intake Limit 0.015 ~ 0.042mm (0.0006 ~ 0.0017in) 0.030 ~ 0.057mm (0.0012 ~ 0.0022in) … Exhaust ne t Valve stem runout 0.08mm (0.0031in) 0.1mm (0.0039in) 0.01mm (0.0004 in) e. Valve seat width Intake Ti m 0.9 ~ 1.1mm (0.035 ~ 0.043in) 1.6mm (0.063in) 0.9 ~ 1.1mm (0.035 ~ 0.043in) 1.6mm (0.063in) D ow nl oa de d fro m w w w .
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ENGINE SPECIFICATIONS SPEC Standard Item Valve springs Free length Intake Limit 41.88mm (1.649in) Exhaust 39.786mm (1.566in) 39.786mm (1.566in) 41.88mm (1.649in) 30mm (1.18in) 30mm (1.18in) … … 137 ~ 157N/mm (13.97 ~ 16.01kgf/mm, 30.83 ~ 35.33lbf/in) 137 ~ 157N/mm (13.97 ~ 16.01kgf/mm, 30.83 ~ 35.33lbf/in) … ne t Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake … Ti m e. Exhaust w w w .
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ENGINE SPECIFICATIONS Standard Limit 0.010 ~ 0.035mm (0.0004 ~ 0.0014in) 52.375 ~ 52.390mm (2.0620 ~ 2.0626in) 0.15mm (0.0059in) … 7.0mm (0.28in) … 15.002 ~ 15.013mm (0.5906 ~ 0.5911in) 0.35 ~ 0.65mm (0.0138 ~ 0.0256in) Intake side 15.043mm (0.5922in) … Item Piston Piston-to-cylinder clearance Diameter D SPEC H e. Height H Piston pin bore (in the piston) Diameter ne t D Ti m Offset ot er Offset direction Piston pin Outside diameter .S co 14.995 ~ 15.000mm (0.5904 ~ 0.5906in) 14.
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ENGINE SPECIFICATIONS SPEC Standard Item Limit Oil ring B T Dimensions (B × T) 2.0 × 2.5mm (0.0787 × 0.0984in) 0.2 ~ 0.7mm (0.0079 ~ 0.0276in) 0.04 ~ 0.12mm (0.0016 ~ 0.0047in) End gap (installed) … … D ow nl oa de d fro m w w w .S co ot er Ti m e.
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ENGINE SPECIFICATIONS SPEC Standard Item Rocker arm/rocker arm shaft Rocker arm inside diameter Limit 10.000 ~ 10.015mm (0.3937 ~ 0.3943in) 9.981 ~ 9.991mm (0.3930 ~ 0.3933in) 0.009 ~ 0.034mm (0.0004 ~ 0.0013in) Rocker arm shaft outside diameter Arm-to-shaft clearance Connecting rod Connecting rod length … … … 93.45 ~ 93.55mm (36.791 ~ 36.831in) 15.015 ~ 15.028mm (0.591 ~ 0.592in) … ne t Small end inside diameter … w .S co ot er Ti m e.
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ENGINE SPECIFICATIONS SPEC Standard Item Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Single speed automatic Maximum main axle runout Limit V-belt automatic Helical gear 40/15 (2.667) Spur gear 44/11 (4.0) 2.398 ~ 0.823:1 … Maximum drive axle runout … … … … … … 0.04mm (0.002in) 0.04mm (0.
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CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Standard Item … … … Cast wheel … J12 × MT2.75 Aluminum 78mm (3.07in) … … … ot w … J12 × MT3.00 Aluminum 71mm (2.80in) … … … … 1.0mm (0.04in) 1.0mm (0.04in) w fro m d oa de ow nl Cast wheel … D Maximum lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 ~ 90kg (0 ~ 198lb) 90kg (198lb) ~ maximum load Minimum tire tread depth 1.0mm (0.04in) 1.0mm (0.04in) 0.25mm (0.01in) w .
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CHASSIS SPECIFICATIONS SPEC Standard Item … … … 200kPa (2.0kgf/cm², 29psi) 225kPa (2.25kgf/cm², 33psi) … … … 0.8mm (0.03in) Single-disc brake Right-hand operation DOT 4 … … … e. Front brake Brake type Operation Recommended fluid Brake disc Diameter × thickness Tubeless 130/70-12 56L K761 (KENDA) ne t Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 ~ 90kg (0 ~ 198lb) 90kg (198lb)~ maximum load Minimum tire tread depth Limit Ti m 220 × 4.0mm (8.66 × 0.
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CHASSIS SPECIFICATIONS Standard Item Front suspension Suspension type Front fork type Front fork travel Spring Free length Installed length Spring rate (K1) Limit Telescopic Coil spring/oil damper 90mm (3.54in) … … … 252.1mm (9.93in) 247mm (9.72in) … … 230.9mm (9.09in) 7.1N/mm (0.72kgf/mm, 1.60lbf/in) 15.4N/mm (1.57kgf/mm, 3.47lbf/in) 0 ~ 66.7mm (0 ~ 2.63in) 66.7 ~ 90mm (2.63 ~ 3.54in) No Spring rate (K2) Ti m e.
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ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Standard System voltage Limit 12V … Transistorized coil ignition 5° BTDC at 1800r/min Digital 248 ~ 372Ω at 20°C (68°F) /white/red - white/blue … … … … Ignition coil Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance e. Item 2JN (T-MORIC) 6mm (0.24in) 2.16 ~ 2.64Ω at 20°C (68°F) 8.64~12.96Ω at 20°C (68°F) … … … … Spark plug cap Material Resistance Resin 8 ~ 12kΩ at 20°C (68°F) … … .
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ELECTRICAL SPECIFICATIONS SPEC Standard Item Quantity Spring force Constant mesh … 5S9 00 (T-MORIC) 12V 0.35kW … … … 10.0mm (0.39in) 3.5mm (0.14in) … … 2 5.52 ~ 8.28N/mm (0.56 ~ 0.84kgf/mm, 1.24 ~ 1.86lbf/in) 22mm (0.87in) Ti m e. Commutator diameter ne t Electric starting system System type Starter motor Model (manufacturer) Suction voltage Power output Brushes Overall length Limit Mica undercut (depth) 0.0252 ~ 0.0308Ω at 20°C (68°F) 1.5mm (0.
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ELECTRICAL SPECIFICATIONS SPEC Standard Limit 5S9 (AISAN) 4 ~ 10Ω 90 ~ 100Ω … … … Fuel level gauge Gauge type (manufacture) Analog (CHAOLONG) … Starting circuit cut-off relay Model (manufacturer) Coil resistance Diode 4HC1 (MATSU SHITA) 72 ~ 88Ω YES … … … Headlight relay Model (manufacturer) Coil resistance Diode 4HM-20 (OMRON) 90 ~ 110Ω YES … … … Engine temperature sensor Model (manufacturer) Coil resistance at 100°C (212°F) 4P91 (PANASONIC) 0.210 ~ 0.
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GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS w w .S co ot er Ti m e. ne t This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
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TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE w w w fro m d oa de ow nl D 2-19 22 13 12 13 7 7 12 7 7 30 9 8 2 2 7 9 2 4 20 10 7 12 3 3 10 13 53 31 13 13 11 10 13 13 7 7 13 23 20 7 2.2 1.3 1.2 1.3 0.7 0.7 1.2 0.7 0.7 3.0 0.9 0.8 0.2 0.2 0.7 0.9 0.2 0.4 2.0 1.0 0.7 1.2 0.3 0.3 1.0 1.3 5.3 3.1 1.3 1.3 1.1 1.0 1.3 1.3 0.7 0.7 1.3 2.3 2.0 0.7 ne t 4 1 2 2 2 6 1 1 4 1 2 1 5 1 3 4 3 2 1 2 2 1 1 1 4 2 1 2 8 1 8 6 2 1 3 2 4 1 1 1 e. M8 M10 M6 M8 M6 M6 M6 M6 M5 M8 M6 M8 6.0 6.0 M6 M6 6.
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TIGHTENING TORQUES Part to be tightened Part name SPEC Tightening torque Thread ’ Q ty size Remarks Nm m•kgf ft•lbf D ow nl oa de d fro m w w w .S co ot Cylinder head tightening sequence 2-20 1.0 1.0 1.0 6.0 4.5 0.7 7.0 0.7 0.7 0.7 4.4 1.8 1.0 ne t 10 10 10 60 45 7 70 7 7 7 44 18 10 e.
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TIGHTENING TORQUES SPEC CHASSIS Tightening torque Thread size Nm D 2-21 M6 M6 M6 M12 M14 M6 M10 M10 M8 M10 M7 m•kgf ft•lbf 23.1 23.1 23.1 6.5 28.9 16.6 22.4 21.7 13.0 3.2 3.2 3.2 0.9 4.0 2.3 3.1 3.0 1.8 60 26 4 4 48 28 60 9 10 7 7 7 4 1.5 5 7 7 70 105 10 32 49 23 26 6 6.0 43.4 2.6 18.8 0.4 2.9 0.4 2.9 4.8 34.7 2.8 20.3 6.0 43.4 0.9 6.5 1.0 7.2 0.7 5.1 0.7 5.1 0.7 5.1 0.4 2.9 0.15 1.1 0.5 3.6 0.7 5.1 0.7 5.1 7.0 50.6 10.5 75.9 1.0 7.2 3.2 23.1 4.9 35.4 2.3 16.6 2.6 18.8 0.6 4.
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TIGHTENING TORQUES SPEC Lower ring nut Rubber washer Center ring nut Lock washer Upper ring nut D ow nl oa de d fro m w w w .S co 1 2 3 4 5 ot er Ti m e. ne t TIP 1. First, tighten the ring nut (lower) approximately 38Nm (3.8m • kgf, 27.5ft • lbf) by using the torque wrench, then loosen the ring nut 1/4 turn. 2. Second, tighten the ring nut (lower) approximately 14Nm (1.4m • kgf, 10.1ft • lbf) by using the torque wrench. 3. Installing the rubber washer. 4.
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LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant LS Oil seal lips Bearings 4 O-rings (except V-belt drive unit) LS 4 Cylinder head tightening nut mounting surface 4 Cylinder head stud bolt thread 4 Cylinder head nut 4 ne t O-rings (fuel injector) 4 Ti m e. Cylinder head gasket dowel pin Crankshaft pin outside surface er Crankshaft journals 4 ot 4 4 .
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LUBRICATION POINTS AND LUBRICANT TYPES SPEC Lubrication Point Lubricant G Main and drive axle serration (sprocket) Drive axle taper rollor bearing G Transmission bearing G Secondary fixed sheave inner surface BEL-RAY asembly lube® Secondary sliding sheave torque cam ditch BEL-RAY asembly lube® Crankcase mating surfaces D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t Yamaha bond NO.
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LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS Lubrication Point Lubricant Engine mounting bolt LS Steering bearing and bearing races (upper and lower) LS Throttle grip inner surface and throttle cables LS Rear brake lever pivoting point and metal-to-metal moving parts LS Rear brake cable and brake lock lever (cable connection area) LS LS Front wheel axle LS ne t Front wheel oil seal e.
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CABLE ROUTING i o p a s d f g h j A EAS00035 Engine temperature sensor lead Positive wire lead Starter relay lead Clamp (90464-25803) Air shroud cylinder 2 Rectifier/regulator Body earth lead ECU Speedometer lead Left lever holder lead After connect the headlight coupler, lead do not touch horn. B Speedometer cable passes through the right hole of inner fender. C Five couplers of speedometer lead and lever holder. D ECU lead passes by the right side of the inner fender rib. CABLE ROUTING .
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CABLE ROUTING SPEC R Turn signal relay lead passes under of the front bracket. S After connecting, put the front signal light coupler (left and right), brake light switch coupler (front and rear) and right handlebar switch lead coupler in the connector cover. Connector cover hold to leg shield 2 rib. T Band the speedometer cable stopper in the top and white tape range of left lever holder lead. .S co ot er Ti m e. ne t E Headlight relay lead passes by the right side of inner fender rib.
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CABLE ROUTING B Brake hose passes through the left hole of inner fender. C Locate the end of gasoline overflow pipe at between frame and air duct. D Rear brake holder 2 holds the rear brake cable and covers the ultrasonic weld mark at the PVC protector. E Locate at between compression rod and air duct. F Rear brake cable passes through the wire guide. G Tightening the body earth terminal and rectifier/regulator. G 2 1 3 7 d 4 5 fro m w w w .S co ot er Ti m e.
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SPEC CABLE ROUTING u i o p a A Plain washer Lean angle cut-off switch Lean angle cut-off switch lead FI diagnostic tool Hight tension cord Fuel pump lead Engine temperature sensor lead Fuel injector lead Clamp (90464-13800) Starter motor positive lead Starter motor negative lead Starter motor Pipe 4 Roll over valve Pipe 3 Canister Fuel hose Ignition coil Battery Battery band Clamp (90464-12812) Fasten the sidestand switch lead to the frame with a plastic locking tie, point the band tip to down of car bod
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SPEC CABLE ROUTING e. Ti m er ot .S co D 5 F fro m w w E T a I 8 J 0 ow nl o Q H 9 V oa de R 6 7 d Sp A G w 23 A B C U1 4 N After combining the couplers, insert them into the sockets at tail/brake light. O Yellow mark to up of pipe 11. P Assembly range of starter motor negative lead terminal. Q Torque: 7Nm (0.7m • kgf, 5.1ft • lbf). R The terminal of battery negative pole (black lead) shall tough the left surface of battery box at least.
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CABLE ROUTING u i o p A Rear brake cable Speedometer Front master cylinder Brush guard (right) Turn signal light (right) Throttle cable assembly Speedometer cable Turn signal light (left) Brush guard (left) Handlebar bracket Clamp (90464-12812) Bracket Turn signal light lead (right) Right handlebar switch lead Front brake light switch lead Speedometer lead B C D Rear brake light switch lead Left lever holder lead Turn signal light lead (left) Brake hose Fasten the right handlebar switch lead, front brake
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CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t INTRODUCTION ....................................................................................... 3-1 PERIODIC MAINTENANCE AND ADJUSTMENT ................................. 3-1 Periodic maintenance chart for the emission control system ........... 3-1 Genela maintenance and lublication chart ....................................... 3-2 COVER AND PANEL .......................................
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CHK ADJ D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t CHECKING THE TIRES .................................................................. 3-43 CHECKING THE WHEELS.............................................................. 3-46 CHECKING AND LUBRICATING THE CABLES ............................ 3-46 LUBRICATING THE LEVERS ......................................................... 3-47 LUBRICATING THE SIDESTAND ...................................................
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INTRODUCTION/ PERIODIC MAINTENANCE AND ADJUSTMENT CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
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PERIODIC MAINTENANCE AND ADJUSTMENT CHK ADJ EAU32115 Genela maintenance and lublication chart INITIAL NO. ITEM 1000 km (600 mi) or 1 month ROUTINE ODOMETER READING 4000 km (2000 mi) or 6 months 7000 km (4000 mi) or 12 months 10000 km (6000 mi) or 18 months 13000 km (8000 mi) or 24 months 16,000 km (10,000 mi) or 30 months 1 Air filter element • Replace. 2 V-belt case air filter element • Clean 3 * Front brake • Check operation, fluid level, and for fluid leakage.
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PERIODIC MAINTENANCE AND ADJUSTMENT * CHK ADJ Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. TIP From 19000 km (12000 mi) or 36 months, repeat the maintenance intervals starting from 7000 km (4000 mi) or 12 months. EAUT2710 D ow nl oa de d fro m w w w .S co ot er Ti m e.
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COVER AND PANEL CHK ADJ EAS00038 COVER AND PANEL SEAT AND TRUNK 7Nm (0.7 m•kgf, 5.1 ft•lbf) 4 7 2 Ti m e. ne t 5 .S co ot er 1 w w w 3 oa de d fro m 6 Order ow nl 7Nm (0.7 m•kgf, 5.1 ft•lbf) Q’ty 1 2 3 4 5 6 7 Removing the seat and trunk Seat Fuel tank cap cover Seat hinge Upper cover Trunk Side cover (left) Side cover (right) 1 1 1 1 1 1 1 D Job/Part Remarks Remove the parts in the order listed. For installation, reverse the removal procedure.
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COVER AND PANEL CHK ADJ FOOTREST BOARD 2 1 5 3 4 ne t 6 w .S co ot er Ti m e. 7 fro m w w 8 ow nl oa de d 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Job/Part Q’ty 1 2 3 4 5 6 Removing the footrest board Battery box cover Front cover Band Battery negative lead Battery positive lead Battery 1 1 1 1 1 7 Cap 4 Remarks D Remove the parts in the order listed. 3-5 NOTICE First, disconnect the negative battery lead, and then the positive battery lead.
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COVER AND PANEL 1 5 CHK ADJ 2 3 4 6 .S co ot er Ti m e. ne t 7 w w 8 Order Job/Part ow nl Footrest board Q’ty Remarks 1 TIP While installing, the fuse box should be installed to the correct position. D 8 oa de d fro m w 7Nm (0.7 m•kgf, 5.1 ft•lbf) For installation, reverse the removal procedure.
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COVER AND PANEL CHK ADJ LEG SHIELD 1 ASSEMBLY AND LEG SHIELD 2 7Nm (0.7 m•kgf, 5.1 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 4 3 1 Ti m e. ne t 5 .S co ot er 2 w w Job/Part Q’ty Removing the leg shield 1 assembly and leg shield 2 Footrest board Safeguard Headlight coupler Leg shield 1 assembly Main switch cover Leg shield 2 1 2 3 4 5 Remarks Remove the parts in the order listed. Refer to “FOOTREST BOARD”. D Order ow nl oa de d 14Nm (1.4 m•kgf, 10.1 ft•lbf) fro m 23Nm (2.3 m•kgf, 16.
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COVER AND PANEL CHK ADJ 5 4 w w .S co ot er Ti m e. ne t 1 fro m w 2 3 1 2 3 4 5 Q’ty ow nl Job/Part Disassembling the leg shield 1 assembly Panel Headlight cover Headlight assembly Panel (leg shield 1) Leg shield 1 D Order oa de d 7Nm (0.7 m•kgf, 5.1 ft•lbf) Remarks Remove the parts in the order listed. 1 1 1 1 1 For assembly, reverse the disassembly procedure.
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ADJUSTING THE VALVE CLEARANCE CHK ADJ EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. TIP 8 Valve clearance adjustment should be made on a cold engine, at room temperature. 8 When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. ot er Ti m e. ne t 1. Remove: 8battery box cover 8front cover Refer to “COVER AND PANEL”. oa de d fro m w w w .S co 2.
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ADJUSTING THE VALVE CLEARANCE CHK ADJ ot er Ti m e. ne t c. Align the TDC mark c on the AC magneto rotor with the stationary pointer d on the crankcase. d. Measure the valve clearance with a thickness gauge. Out of specification J Adjust. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ .S co 4. Adjust: 8 valve clearance 3 fro m w w w 2 oa de d 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a Loosen the locknut 1. b. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip. c.
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ADJUSTING THE VALVE CLEARANCE CHK ADJ e. Measure the valve clearance again. f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: 8 breather T. R. 7Nm (0.7m • kgf, 5.1ft • lbf) 8 valve cover (intake and exhaust) R. T. 7Nm (0.7m • kgf, 5.1ft • lbf) er R. Ti m e. 8ignition coil ne t T. 7Nm (0.7m • kgf, 5.1ft • lbf) T. .S co ot 8spark plug R. 6.
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CHECKING THE ENGINE IDLING SPEED CHK ADJ EAS00054 CHECKING THE ENGINE IDLING SPEED TIP Prior to checking the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. ot er Ti m e. ne t 1. Start the engine and let it warm up for several minutes. 2. Remove: 8 battery box cover 8 front cover Refer to “COVER AND PANEL”. Digital tachometer 90890-06760 1 4. Check: 8 engine idling speed Out of specification J Replace the throttle body.
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ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY TIP Prior to adjusting the throttle cable free play, the engine idling speed should be checked properly. a 1. Check: 8 throttle cable free play a Out of specification JAdjust. ot er Ti m e. ne t Throttle cable free play (at the flange of the throttle grip) 3 ~5mm (0.12 ~ 0.20in) fro m w w w .S co 2. Adjust: 8 throttle cable free play b2 1 oa de d a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
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ADJUSTING THE SEAT SPRING FORCE CHK ADJ ADJUSTING THE SEAT SPRING FORCE TIP When open the seat and seat will not fold up automatically, adjust the spring force. b a 1 1. Remove: 8 seat 8 upper cover 2. Adjust: 8 screw 1 Direction a Direction b D ow nl oa de d fro m w w w .S co ot er Ti m e. 3. Install: 8 upper cover 8 seat ne t Spring force is increased. Spring force is decreased.
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CHECKING THE SPARK PLUG CHK ADJ EAS00060 CHECKING THE SPARK PLUG 1. Remove: 8 battery box cover 8 front cover Refer to “COVER AND PANEL”. 2. Disconnect: 8 spark plug cap WARNING Remove the spark plug cap, the engine is extremely hot. ne t 3. Remove: 8 spark plug e. NOTICE .S co ot er Ti m Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder.
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CHECKING THE SPARK PLUG CHK ADJ 8. Install: 8 spark plug T. R. 13Nm(1.3m • kgf, 9.4ft • lbf) TIP Before installing the spark plug, clean the spark plug and gasket surface. D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 9. Connect: 8 spark plug cap 10. Install: 8 front cover 8 battery box cover Refer to “COVER AND PANEL”.
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CHECKING THE IGNITION TIMING CHK ADJ EAS00062 CHECKING THE IGNITION TIMING TIP Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. ot er Ti m e. ne t 1. Remove: 8 battery box cover 8 front cover Refer to “COVER AND PANEL”. 1 Timing light 90890-03141 (YU-03141) Digital tachometer 90890-06760 D ow nl oa de d fro m w w w .S co 2.
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CHECKING THE IGNITION TIMING CHK ADJ Engine idling speed 1700 ~ 1900r/min b. Check that the mark a on the AC magneto rotor is within the firing range b on the crankcase. Incorrect firing range J Check the ignition system. TIP The ignition timing is not adjustable. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 4. Remove: 8 timing light 8 digital tachometer 5. Install: 8 front cover 8 battery box cover Refer to”COVER AND PANEL”.
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MEASURING THE COMPRESSION PRESSURE CHK ADJ EAS00067 MEASURING THE COMPRESSION PRESSURE TIP Insufficient compression pressure will result in a loss of performance. .S co ot er Ti m e. ne t 1. Measure: 8 valve clearance Out of specification J Adjust Refer to “ADJUSTING THE VALVE CLEARANCE”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Remove: 8 battery box cover 8 front cover Refer to “COVER AND PANEL”. 4.
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MEASURING THE COMPRESSION PRESSURE CHK ADJ 7. Measure: 8 compression pressure Out of specification J Refer to steps (c) and (d). ne t Compression pressure (at sea level) Minimum 1175kPa(11.8kgf/cm2, 167psi) at 1800r/min Standard 1350kPa(13.5kgf/cm2, 192psi) at 1800r/min Maximum 1512kPa(15.1kgf/cm2, 215psi) at 1800r/min .S co ot er Ti m e. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.
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MEASURING THE COMPRESSION PRESSURE CHK ADJ 8. Remove: 8 compression gauge 9. Install: 8 spark plug T. R. 13Nm(1.3m • kgf, 9.4ft • lbf) D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 10. Connect: 8 spark plug cap 11. Install: 8 front cover 8 battery box cover Refer to “COVER AND PANEL”.
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CHECKING THE ENGINE OIL LEVEL CHK ADJ EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the scooter on a level surface. TIP 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. er Ti m e. ne t 3. Check: 8 engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark J Add the recommended engine oil to the proper level.
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CHANGING THE ENGINE OIL CHK ADJ EAS00076 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 1 Ti m e. ne t 3. Remove: 8 engine oil filler cap 1 8 engine oil drain bolt 2 (along with the gasket) 4. Drain: 8 engine oil (completely from the crankcase) ot er 2 3 2 d 4 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil strainer cover 1,spring 3 and oil filter element 4. b. Replace the new O-ring 2. c.
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CHANGING THE ENGINE OIL CHK ADJ Quantity Total amount 0.85 ~ 0.95L (0.9 ~ 1.0 US qt, 0.75 ~ 0.84 Imp. qt) Periodic oil change 0.80 ~ 0.90L (0.87 ~ 0.98 US qt, 0.74 ~ 0.83 Imp. qt) ot er Ti m e. ne t 8. Install: 8 engine oil filler cap 9. Start the engine, warm it up for several minutes, and then turn it off. 10.Check: 8 engine (for engine oil leaks) 11.Check: 8 engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. .S co 12.
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CHANGING THE TRANSMISSION OIL CHK ADJ CHANGING THE TRANSMISSION OIL 1. Stand the scooter on a level surface. TIP 8 Stand the scooter on a suitable stand. 8 Make sure that the scooter upright. e. ne t 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place a container under the transmission oil drain bolt. 4 Remove: 8 transmission oil fill cap 8 transmission oil drain bolt 1 5. Drain: 8 transmission oil (completely from the transmission case) 6.
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MEASURING THE ENGINE OIL PRESSURE CHK ADJ EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: 8 engine oil level Below the minimum level mark J Add the recommended engine oil to the proper level. Refer to”CHECKING THE ENGINE OIL LEVEL”. 2. Start the engine, warm it up for several minutes, and then turn it off. NOTICE Ti m e. ne t When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase.
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MEASURING THE ENGINE OIL PRESSURE CHK ADJ c. Start the engine after solving the problem(s) and check the engine oil pressure again. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Tighten: 8 engine temperature sensor T. R. 18Nm(1.8m • kgf, 13.0ft • lbf) D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 8. Connect: 8 engine temperature sensor coupler 9. Install: 8 front cover 8 battery box cover Refer to “COVER AND PANEL”.
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CLEANING THE AIR FILTER ELEMENT CHK ADJ EAS00086 2 CLEANING THE AIR FILTER ELEMENT 1. Remove: 8 air filter case cover 1 8 air filter element 2 1 e. ne t 2. Clean: 8 air filter element 1 Apply compressed air to the outer surface of the air filter element. 3. Check: 8 air filter element Damage J Replace. ot er Ti m 1 fro m w w w .S co TIP 8 Replace the air filter element every 6000km (3500mi). 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
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CLEANING THE V-BELT CASE AIR FILTER ELEMENT CHK ADJ EAS00090 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: 8 V-belt case cover 8 V-belt case air filter guide 1 8 V-belt case air filter element 2 2. Clean: 8 V-belt case air filter element (with solvent) 1 2 ne t TIP After cleaning, carefully pat the V-belt case air filter element on a clean cloth to remove the excess solvent. ot er Ti m e. 3. Check: 8 V-belt case air filter element Damage J Replace. fro m w w w .S co 4.
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CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD/CHECKING THE FUEL HOSE CHK ADJ EAS00094 CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD 1. Remove: 8 seat 8 trunk 8 battery box cover 8 front cover Refer to “COVER AND PANEL”. ot er Ti m e. ne t 2. Remove: 8 fuel tank Refer to “REMOVING THE FUEL TANK” in chapter 6. .S co 3. Check: 8 throttle body joint 1 8 intake manifold 2 Cracks/damage J Replace. Refer to “CYLINDER HEAD” in chapter 5. 4.
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CHECKING THE FUEL HOSE/CHECKING THE BREATHER HOSES CHK ADJ 2. Check: 8 fuel hose 1 Cracks/damage J Replace. Loose connection J Connect properly. 3. Install: 8 front cover 8 battery box cover 8 trunk 8 seat Refer to “COVER AND PANEL”. .S co EAS00098 ot er Ti m e. ne t 1 oa de d fro m w w w CHECKING THE BREATHER HOSES 1. Remove: 8 seat 8 trunk 8 battery box cover 8 front cover Refer to “COVER AND PANEL”. D ow nl 2.
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CHECKING THE EXHAUST SYSTEM CHK ADJ EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the muffler and gasket. 1. Remove: 8 O2 sensor coupler 8 muffler Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM” in chapter 4. 2. Check: 8 muffler 1 Crack/damage J Replace. 8 gasket 2 Exhaust gas leak J Replace. 3. Check: 8 tightening torque 2 5 ne t 3 Ti m e. 1 D ow nl oa de d fro m w w w .S co ot R. Exhaust pipe nut 3 13Nm (1.3m • kgf, 9.
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CHECKING THE CANISTER AND ROLL OVER VALVE CHK ADJ CHECKING THE CANISTER AND ROLL OVER VALVE The following procedure applies to all of the canister and roll over valve. 1. Remove: 8 seat 8 trunk Refer to “COVER AND PANEL”. 2. Check: 8 hose (to throttle body) 1 8 hose (to roll over valve) 2 Cracks/damage J Replace. Loose connection J Connect properly. Ti m e. ne t 1 ot er 2 .S co 3. Remove: 8 canister 1 4. Check: 8 canister Cracks/damage J Replace. Obstruction J Blow out with compressed air. 5.
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CHECKING THE CANISTER AND ROLL OVER VALVE CHK ADJ 7. Check: 8 roll over valve ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the roll over valve. b. Put roll over valve with the vertical angle. c. Connect the hose to direction a and blow air in the hose. Unobstructed J Normal. Obstruction J Replace. ne t d. Put roll over valve with the horizontal angle. e. Connect the hose to direction a and blow air in the hose. Ti m e. Unobstructed J Replace. Obstruction J Normal. er ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ .S co ot 8.
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CHECKING THE FRONT BRAKE/ADJUSTING THE REAR BRAKE CHK ADJ EAS00108 CHASSIS CHECKING THE FRONT BRAKE TIP The brake lever free play is not adjustable. WARNING .S co EAS00114 ot er Ti m e. ne t A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system.
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CHECKING THE BRAKE FLUID LEVEL CHK ADJ EAS00116 CHECKING THE BRAKE FLUID LEVEL 1. Stand the scooter on a level surface. TIP 8 Place the scooter on a suitable stand. 8 Make sure the scooter is upright. ne t 2. Check: 8 brake fluid level Below the minimum level mark a J Add the recommended brake fluid to the proper level. Ti m e. Recommended brake fluid DOT 4 er WARNING D ow nl oa de d fro m w w w .S co ot 8 Use only the designated brake fluid.
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CHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKE SHOES/CHECKING THE FRONT BRAKE HOSE CHK ADJ EAS00117 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: 8 front brake pad Wear indicators 1 almost touch the brake disc J Replace the brake pads as a set. Refer to “REPLACING THE FRONT BRAKE PADS” in chapter 4. .S co EAS00126 ot er Ti m e. ne t 1 CHECKING THE REAR BRAKE SHOES 1. Operate the brake. 2.
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BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenever: 8 the system is disassembled. 8 a brake hose is loosened, disconnected or replaced. 8 the brake fluid level is very low. 8 brake operation is faulty. ne t 1. Remove: 8 brake master cylinder reservoir cap 2. Bleed: 8 hydraulic brake system 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b.
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BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ TIP Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip. h. Tighten the bleed screw and then release the brake lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. T. ne t R. Bleed screw 6Nm (0.6m • kgf, 4.3ft • lbf) er Ti m e. k.
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CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ EAS00148 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. TIP Place the scooter on a suitable stand so that the front wheel is elevated. ot er Ti m e. ne t 2. Check: 8 steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness J Adjust the steering head. oa de d fro m w w w .S co 3.
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CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ T. R. Lower ring nut (initial tightening torque) 38Nm (3.8m • kgf, 27.5ft • lbf) c. Losen the lower ring nut completely and then tighten it to specification with a steering nut wrench. 6 WARNING Do not over tighten the lower ring nut. T. e. ne t R. Lower ring nut (final tightening torque) 14Nm (1.4m • kgf, 10.1ft • lbf) oa de d fro m w w w .S co ot er Ti m d.
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CHECKING THE FRONT FORK CHK ADJ EAS00151 CHECKING THE FRONT FORK 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. ot er Ti m e. ne t 2. Check: 8 inner tube Damage/scratches J Replace. 8 oil seal Oil leakage J Replace. 3. Hold the scooter upright and apply the front brake. D ow nl oa de d fro m w w w .S co 4.
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CHECKING THE TIRES CHK ADJ EAS00163 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 8 tire pressure Out of specification J Regulate. WARNING .S co ot er Ti m e. ne t 8 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. 8 The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
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CHECKING THE TIRES CHK ADJ 2. Check: 8 tire surfaces Damage/wear J Replace the tire. Minimum tire tread depth 0.8mm (0.03in) 1 Tire tread depth 2 Sidewall 3 Wear indicator WARNING oa de d fro m w w w .S co ot er Ti m e. ne t 8 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. 8 When using tube tires, be sure to install the correct tube. 8 Always replace a new tube tire and a new tube as a set.
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CHECKING THE TIRES CHK ADJ Front tire Manufacturer KENDA Model K761 Size 120/70-12 51L Rear tire Manufacturer KENDA Model K761 Size 130/70-12 56L WARNING ne t New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. D ow nl oa de d fro m w w w .S co ot er Ti m e.
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CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES CHK ADJ EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: 8 wheel Damage/out-of-round J Replace. WARNING Never attempt to make any repairs to the wheel. .S co EAS00170 ot er Ti m e. ne t TIP After a tire or wheel has been changed or replaced, always balance the wheel. fro m w w w CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables.
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LUBRICATING THE LEVERS/LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTERSTAND/LUBRICATING THE REAR SUSPENSION CHK ADJ EAS00171 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant Lithium-soap-based grease EAS00172 ne t LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. .S co EAS00173 ot er Ti m e.
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CHECKING AND CHARGING THE BATTERY CHK ADJ EAS00179 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 8 Wear protective eye gear when handling or working near batteries. 8 Charge batteries in a well-ventilated area.
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CHECKING AND CHARGING THE BATTERY CHK ADJ TIP Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. ot er Ti m e. ne t 1. Remove: 8 battery box cover Refer to “COVER AND PANEL”. .S co 2.
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Open-circuit voltage (V) CHECKING AND CHARGING THE BATTERY 13.0 CHK ADJ 8 No charging is necessary when the opencircuit voltage equals or exceeds 12.8 V. Relationship between the open-circuit voltage and the charging time at 20˚C 12.5 b. Check the charge of the battery, as shown in the charts and the following example. 12.0 11.5 Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5 6.
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CHECKING AND CHARGING THE BATTERY CHK ADJ D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 8 Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. 8 Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.
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CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a variable-current (voltage) charger Charger Ammeter TIP Measure the open-circuit voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. Connect a charger and ammeter to the battery and start charging. TIP Set the charging voltage to 16-17 V. (If the charging voltage is lower charging will be insufficient, if it is higher, the battery will be over-charged.
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CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. TIP Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? ne t NO .S co ot er Ti m e. YES w w w Charge the battery until the charging voltage reaches 15 V.
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CHECKING AND CHARGING THE BATTERY 6. Install: 8 battery 8 band 7. Connect: 8 battery leads (to the battery terminals) 2 1 CHK ADJ NOTICE First, connect the positive battery lead 1, and then the negative battery lead 2. Ti m e. ne t 8. Check: 8 battery terminals Dirt J Clean with a wire brush. Loose connection J Connect properly. 9. Lubricate: 8 battery terminals ot er Recommended lubricant Dielectric grease D ow nl oa de d fro m w w w .S co 10.
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CHECKING THE FUSES CHK ADJ EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. NOTICE To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. ot er Ti m e. ne t 1. Remove: 8 battery box cover Refer to “COVER AND PANEL”. fro m w w w .S co 2. Check: 8 fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. oa de d TIP Set the pocket tester selector to “Ω × 1”.
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CHECKING THE FUSES Fuses Main Headlight Signaling system Ignition Fuel injection system Reserve CHK ADJ Amperage rating 20A 10A 15A 10A 10A Q’ty 1 1 1 1 1 20A 15A 10A 1 1 1 WARNING er Ti m e. ne t Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. .
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REPLACING THE HEADLIGHT BULBS CHK ADJ EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: 8 safeguard 8 leg shield 1 Refer to “COVER AND PANEL”. 2. Disconnect: 8 headlight coupler e. WARNING ne t 3. Remove: 8 dust boot 8 headlight bulb holder 1 8 headlight bulb 2 1 Ti m Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
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ADJUSTING THE HEADLIGHT BEAMS CHK ADJ EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: 8 headlight beam (vertically) 1 b ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the low beam light adjusting screw 1 in direction a or b. a Direction a Direction b 2 Headlight beam is raised. Headlight beam is lowered. c Direction c Direction d Headlight beam is raised. Headlight beam is lowered. ot er d Ti m e. ne t b.
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CHAS CHAPTER 4 CHASSIS D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t FRONT WHEEL AND BRAKE DISC ....................................................... 4-1 FRONT WHEEL ................................................................................. 4-2 REMOVING THE FRONT WHEEL .................................................... 4-3 CHECKING THE FRONT WHEEL .................................................... 4-4 CHECKING THE BRAKE DISC ................................................
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CHAS D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t HANDLEBAR .......................................................................................... 4-49 REMOVING THE HANDLEBAR ...................................................... 4-51 CHECKING THE HANDLEBAR ...................................................... 4-52 INSTALLING THE HANDLEBAR..................................................... 4-53 STEERING HEAD ......................................................................
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FRONT WHEEL AND BRAKE DISC CHAS EAS00513 CHASSIS FRONT WHEEL AND BRAKE DISC 3 ne t 4Nm (0.4 m•kgf, 2.9 ft•lbf) 2 Ti m e. 1 70Nm (7.0 m•kgf, 50.6 ft•lbf) fro m w w w .S co ot er 6 D Order 7 23Nm (2.3 m•kgf, 16.6 ft•lbf) ow nl oa de d 4 5 Job/Part Q’ty Removing the front wheel and brake disc Remarks Remove the parts in the order listed. TIP Place the scooter on a suitable stand so that the front wheel is elevated.
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FRONT WHEEL AND BRAKE DISK CHAS EAS00518 FRONT WHEEL 3 2 w w .S co ot er Ti m e. ne t 4 1 2 3 4 Job/Part Q’ty Disassembling the front wheel Oil seal Bearing Spacer Bearing Remarks Remove the parts in the order listed. D Order ow nl oa de d fro m w 1 1 1 1 1 For assembly, reverse the disassembly procedure.
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FRONT WHEEL AND BRAKE DISK CHAS EAS00520 REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. TIP Place the scooter on a suitable stand so that the front wheel is elevated. er Ti m e. ne t 2. Remove: 8 speedometer cable 8 front wheel axle nut 8 front wheel axle 8 front wheel 8 collar 8 speedometer gear unit D ow nl oa de d fro m w w w .
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FRONT WHEEL AND BRAKE DISK CHAS EAS00525 CHECKING THE FRONT WHEEL 1. Check: 8 wheel axle Roll the wheel axle on a flat surface. Bends Replace. Wheel axle bending limit 0.25mm (0.01in) WARNING ot er Ti m e. ne t Do not attempt to straighten a bent wheel axle. oa de d fro m w w w .S co 2. Check: 8 tire 8 front wheel Damage/wear Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. ow nl 3.
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FRONT WHEEL AND BRAKE DISK 2 CHAS 5. Replace: 8 wheel bearings New 8 oil seal New 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seal 1 with a flat-head screwdriver. TIP To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. 4 c. Remove the wheel bearings 3 with a general bearing puller 4. d. Install the new wheel bearings and oil seal in the reverse order of disassembly.
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FRONT WHEEL AND BRAKE DISK CHAS EAS00528 CHECKING THE BRAKE DISC 1. Check: 8 brake disc Damage/galling Replace. 2. Measure: 8 brake disc deflection a Out of specification Correct the brake disc deflection or replace the brake disc. b Brake disc deflection limit (maximum) 0.15mm (0.006in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place the scooter on a suitable stand so that the front wheel is elevated. b.
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FRONT WHEEL AND BRAKE DISK CHAS TIP Tighten the brake disc bolts in stages and in a crisscross pattern. T. R. Brake disc bolt 23Nm (2.3m • kgf, 16.6ft • lbf) LOCTITE® .S co EAS00535 ot er Ti m e. ne t d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.
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FRONT WHEEL AND BRAKE DISK CHAS EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: 8 wheel axle 8 wheel bearings 8 oil seal lip 8 speedometer gear unit Recommended lubricant Lithium-soap-based grease 2. Install: 8 speedometer gear unit 1 1 TIP Make sure the speedometer gear unit and the wheel hub are installed with the two projections 2 meshed into the speedmeter clutch 3 respectively. Ti m e. ne t 2 ot er 3 .S co 3.
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FRONT WHEEL AND BRAKE DISK CHAS EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP 8 After replacing the tire, wheel or both, the front wheel static balance should be adjusted. 8 Adjust the front wheel static balance with the brake disc installed. .S co ot er Ti m e. ne t 1. Remove: 8 balancing weight(s) fro m w w w 2. Find: 8 front wheel’s heavy spot TIP Place the front wheel on a suitable balancing stand. D ow nl oa de d ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Spin the front wheel. b.
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FRONT WHEEL AND BRAKE DISK CHAS 3. Adjust: 8 front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. TIP Start with the lightest weight. ot er Ti m e. ne t b. Turn the front wheel 90° so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced.
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REAR WHEEL AND REAR BRAKE CHAS EAS00555 REAR WHEEL AND REAR BRAKE 8 12 2 ne t 7 12 e. 11 Ti m 6 er 10Nm (1.0 m•kgf, 7.2 ft•lbf) ot 9 .S co 10 3 w w 4 fro m w 1 oa de d 5 Order Job/Part Q’ty Remove the parts in the order listed. ow nl Removing the rear wheel and rear brake TIP Place the scooter on a suitable stand so that the front wheel is elevated.
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REAR WHEEL AND REAR BRAKE CHAS 8 12 2 7 12 ne t 11 e. 6 Ti m 10Nm (1.0 m•kgf, 7.2 ft•lbf) 9 er 10 ot 3 .S co 4 w w 1 Remarks 1 For installation, reverse the removal procedure.
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REAR WHEEL AND REAR BRAKE CHAS EAS00564 REMOVING THE REAR WHEEL 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. TIP Place the scooter on a suitable stand so that the rear wheel is elevated. ot er Ti m e. ne t 2. Disconnect: 8O2 sensor coupler .S co 3. Remove: 8muffler 8wheel axle nut 1 8swingarm Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM”. oa de d fro m w w w 1 D ow nl 4. Loosen: 8brake adjuster 5.
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REAR WHEEL AND REAR BRAKE CHAS EAS00565 .S co EAS00567 ot er Ti m e. ne t CHECKING THE REAR WHEEL 1. Check: 8tire 8rear wheel Damage/wear Replace. Refer to”CHECKING THE TIRES ”and” CHECKING THE WHEELS” in chapter 3. 2. Measure: 8radial wheel runout 8lateral wheel runout Refer to”CHECKING THE FRONT WHEEL”. oa de d fro m w w w CHECKING THE REAR WHEEL DRIVE HUB 1. Check: 8rear wheel drive hub Cracks/damage Replace the rear wheel.
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REAR WHEEL AND REAR BRAKE 2. Measure: 8 brake shoe lining thickness a Out of specification Replace. a Brake shoe lining thickness limit (minimum) 1.0mm (0.04in) a WARNING Do not allow oil or grease to contact the brake shoes. ot er Ti m e. ne t TIP Replace the brake shoes as a set, if either is worn to the wear limit. w w .S co 3. Measure: 8 brake drum inside diameter b Out of specification Replace the wheel. fro m w Brake drum inside diameter limit (maximum) 151mm (5.94in) oa de d 4.
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REAR WHEEL AND REAR BRAKE CHAS TIP Lubricate the brake camshaft and O-rings with lithium-soap-based grease. WARNING After installing the brake camshaft and Orings, remove any excess grease. Ti m e. ne t ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the brake camshaft so its punch mark a is positioned as shown. b. Align the projection b on the brake camshaft lever with the notch in the brake shoe camshaft. c. Check that the brake shoes are properly positioned. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ot er 2.
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REAR WHEEL AND REAR BRAKE CHAS EAS00574 ne t INSTALLING THE REAR WHEEL 1. Lubricate: 8 wheel axle Ti m e. Recommended lubricant Lithium-soap-based grease 3. Install: 8 swingarm 8 wheel axle nut 1 8 muffler Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM”. 1 D ow nl oa de d fro m w w w .S co ot er 2. Install: 8 rear wheel 4. Connect: 8 O2 sensor coupler 5. Adjust: 8 brake lever free play Refer to “ADJUSTING THE REAR BRAKE” in chapter 3.
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REAR WHEEL AND REAR BRAKE CHAS EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP 8 After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. 8 Adjust the rear wheel static balance with the rear wheel drive hub installed. D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 1. Adjust: 8 rear wheel static balance Refer to “ADJUSTING THE FRONT WHEEL STATIC BALANCE”.
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FRONT BRAKE CHAS EAS00576 FRONT BRAKE FRONT BRAKE PADS er Ti m e. ne t 49Nm (4.9 m•kgf, 35.4 ft•lbf) w w .S co ot 5 w 3 fro m 4 1 Job/Part 2 4 13Nm (1.3 m•kgf, 9.4 ft•lbf) Q’ty D Order ow nl oa de d 5 1 2 3 4 5 Removing the front brake pads Brake caliper Circlip Brake pad retaining bolt Brake pad Brake pad spring 1 1 1 2 2 Remarks Remove the parts in the order listed. Disconnect. Refer to “REPLACING THE FRONT BRAKE PADS”. For installation, reverse the removal procedure.
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FRONT BRAKE CHAS EAS00579 NOTICE D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: 8 Never disassemble brake components unless absolutely necessary. 8 If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. 8 Never use solvents on internal brake components.
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FRONT BRAKE CHAS EAS00581 REPLACING THE FRONT BRAKE PADS TIP When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 2 1 ot er Ti m e. ne t 1. Loosen: 8 brake pad retaining bolt 1 2. Remove: 8 brake caliper 2 3. Remove: 8 circlip 8 brake pad retaining bolt 8 brake pads 8 brake pad springs Brake pad wear limit 0.8mm (0.03in) oa de d fro m w w w .S co 4.
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FRONT BRAKE CHAS 6. Lubricate: 8 brake pad retaining bolt Recommended lubricant Silicone grease NOTICE 8 Do not allow grease to contact the brake pads. 8 Remove any excess grease. 7. Install: 8 brake pad retaining bolt R. Ti m e. 8 circlip 8 brake caliper ne t T. 13Nm (1.3m • kgf, 9.4ft • lbf) oa de d fro m w w w .S co ot R. er T. 49Nm (4.9m • kgf, 35.4ft • lbf) D ow nl 8. Check: 8 brake fluid level Below the level mark a Add the recommended brake fluid to the proper level.
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FRONT BRAKE CHAS EAS00584 FRONT BRAKE MASTER CYLINDER 9Nm (0.9 m•kgf, 6.5 ft•lbf) 9 Ti m e. ne t 1.6Nm (0.16 m•kgf, 1.5 ft•lbf) ot er 1 w .S co 4 7 3 5 oa de d 6 7 w w 10 fro m 8 2 Job/Part Q’ty D Order ow nl 26Nm (2.6 m•kgf, 18.
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FRONT BRAKE CHAS EAS00585 1 ne t 2 e. 5 w w w .S co ot er Ti m 3 Job/Part Q’ty Disassembling the front brake master cylinder Dust boot Circlip Washer Brake master cylinder kit Brake master cylinder body 1 2 3 4 5 Remarks Remove the parts in the order listed. D Order ow nl oa de d fro m 4 1 1 1 1 1 For assembly, reverse the disassembly procedure.
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FRONT BRAKE CHAS EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER TIP Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. ot er Ti m e. ne t 1. Remove: 8 brush guard (right) Refer to “HANDLEBAR”. .S co 2.
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FRONT BRAKE CHAS EAS00590 CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: 8 brake master cylinder 1 Damage/scratches/wear Replace. 8 brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air. 1 Ti m e. ne t 2. Check: 8 brake master cylinder kit 1 Damage/scratches/wear Replace. ot er 1 w w w .S co 3. Check: 8 brake master cylinder reservoir Cracks/damage Replace. brake master cylinder reservoir diaphragm 1 Damage/wear Replace. 4.
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FRONT BRAKE CHAS EAS00597 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING 8 Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. 8 Never use solvents on internal brake components. ot er Ti m e. ne t Recommended brake fluid DOT 4 w 3 fro m w w 2 oa de ow nl 2. Install: 8 brake master cylinder 1 8 brake master cylinder holder 2 D a d 1 1 1.
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FRONT BRAKE CHAS 3. Install: 8 copper washers 1 New 8 brake hose 2 8 union bolt 3 1 2 T. R. 3 26Nm (2.6m • kgf, 18.8ft • lbf) NOTICE When installing the brake hose onto the brake master cylinder, make sure the brake hose touch the projection a on the brake master cylinder. ne t WARNING Ti m e. Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING” in chapter 2. fro m w w w .
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FRONT BRAKE CHAS NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. ot er Ti m e. ne t 5. Bleed: 8 brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. D ow nl oa de d fro m w w w .S co 6. Check: 8 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.
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FRONT BRAKE CHAS EAS00612 FRONT BRAKE CALIPER 26Nm (2.6 m•kgf, 18.8 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) Ti m e. ne t 1 ot er 2 3 w w .S co 3 4 fro m w 5 Job/Part Q’ty D Order ow nl oa de d 49Nm (4.9 m•kgf, 35.4 ft•lbf) 1 2 3 4 5 Removing the front brake caliper Brake fluid Brake hose holder 1 Union bolt Copper washer Brake hose Brake caliper Remarks Remove the parts in the order listed. Drain. 1 1 2 1 1 Disconnect. For installation, reverse the removal procedure.
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FRONT BRAKE CHAS EAS00614 5 1 3 ne t 4 .S co ot er Ti m e. 2 7 w w w 6 Job/Part Q’ty Disassembling the front brake caliper Brake pad Brake pad spring Brake caliper bracket Brake caliper piston Brake caliper dust seal Brake caliper piston seal Spring Spring seat Bleed screw/cap Brake caliper body 1 2 3 4 5 6 7 8 Remarks Remove the parts in the order listed. D Order ow nl oa de d fro m 8 Refer to “REPLACING THE FRONT BRAKE PADS”.
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FRONT BRAKE CHAS EAS00619 DISASSEMBLING THE FRONT BRAKE CALIPER TIP Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: 8 union bolt 1 8 copper washers 2 8 brake hose 3 3 ne t 1 Ti m e. TIP Put the end of the brake hose into a container and pump out the brake fluid carefully. ot er 2 .S co 2.
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FRONT BRAKE CHAS EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads Piston seal Brake hose Brake fluid ot er Ti m e. ne t If necessary Every two years Every four years Every two years and whenever the brake is disassembled 1. Check: 8 brake caliper piston 1 Rust/scratches/wear Replace the brake caliper piston. 8 brake caliper cylinder 2 Scratches/wear Replace the brake caliper assembly.
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FRONT BRAKE CHAS EAS00637 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER WARNING ne t 8 Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. 8 Never use solvents on internal brake components as they will cause the piston seal to swell and distort. 8 Whenever a brake caliper is disassembled, replace the brake caliper piston seal and dust seal. ot er Ti m e. Recommended brake fluid DOT 4 .S co 1.
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FRONT BRAKE CHAS 5. Install: 8 brake caliper 1 (temporarily) 8 copper washers 2 New 8 brake hose 3 8 union bolt 4 3 4 2 T. R. 26Nm (2.6m • kgf, 18.8ft • lbf) 1 8 brake hose holder 1 T. R. 7Nm (0.7m • kgf, 5.1ft • lbf) WARNING .S co ot er Ti m e. ne t Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING” in chapter 2.
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FRONT BRAKE CHAS 8. Fill: 8 brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING d fro m w w w .S co ot er Ti m e. ne t 8 Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. 8 Refill with the same type of brake fluid that is already in the system.
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FRONT BRAKE CHAS D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 11. Check: 8 brake lever operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
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FRONT FORK CHAS EAS00646 FRONT FORK 3 er Ti m e. ne t 1 w .S co ot 2 fro m w w 26Nm (2.6 m•kgf, 18.8 ft•lbf) 5Nm (0.5 m•kgf, 3.6 ft•lbf) Job/Part Q’ty D Order ow nl oa de d 4 Removing the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Refer to “COVER AND PANEL” in chapter 3. Refer to “FRONT WHEEL AND BRAKE DISC”.
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FRONT FORK CHAS EAS00648 1 2 3 4 4 0 q ne t 7 5 Ti m e. 8 .S co ot er w w w w 9 fro m 6 6 Order ow nl oa de d 20Nm (2.0 m•kgf, 14.5 ft•lbf) Q’ty Clamp/boot Cap Stopper ring Collar/O-ring Fork spring Damper rod bolt/copper washer Damper rod Rebound spring Inner tube Oil seal clip Oil seal Outer tube 1/1 1 1 1/1 1 1/1 1 1 1 1 1 1 Job/Part Remove the parts in the order listed. The following procedure applies to both of the front fork legs.
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FRONT FORK CHAS 1 2 3 4 4 0 q 7 8 e. ne t 5 .S co ot er Ti m w w w 9 fro m w 6 6 ow nl Job/Part Q’ty Remarks For assembly, reverse the disassembly procedure. D Order oa de d 20Nm (2.0 m•kgf, 14.
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FRONT FORK CHAS EAS00651 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. TIP Place the scooter on a suitable stand so that the front wheel is elevated. oa de d fro m w w w .S co ot er Ti m e. ne t 2. Remove: 8 leg shield 1 Refer to “COVER AND PANEL” in chapter 3. 8 brake hose holder 1 8 brake caliper Refer to “FRONT BRAKE”.
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FRONT FORK CHAS EAS00653 NOTICE Ti m 1 e. 2. Remove: 8 cap 8stopper ring 8collar/O-ring 8fork spring 1 ne t DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: 8clamp/boot oa de d fro m w w w .S co ot er The collar/O-ring and fork spring jump out after removing stopper ring. ow nl 3. Drain: 8 fork oil D TIP Stoke the outer tube several times while draining the fork oil. 4.
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FRONT FORK CHAS Damper rod holder 90890-01294 (YM-01300-1) T-handle 90890-01326 (YM-01326) Ti m e. ne t 5. Remove: 8 damper rod 1 8 rebound spring 8 inner tube 2 2 ot er 1 w w w .S co 6. Remove: 8 oil seal clip 1 (with a flat-head screwdriver) fro m ow nl oa de d 1 NOTICE Do not scratch the inner tube. 7. Remove: 8 oil seal 1 D 2 NOTICE Never reuse the oil seal.
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FRONT FORK CHAS EAS00656 2 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 8 inner tube 1 8 outer tube 2 Bends/damage/scratches Replace. 1 WARNING ot er Ti m e. ne t Do not attempt to straighten a bent inner tube as this may dangerously weaken it. Replace. Spring free length 252.1mm (9.93in) :247mm (9.72in) oa de d fro m w w w .S co 2. Measure: 8 spring free length a Out of specification D ow nl 3.
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FRONT FORK CHAS EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING 8 Make sure the oil levels in both front fork legs are equal. 8 Uneven oil levels can result in poor handling and a loss of stability. ot er Ti m e. ne t TIP 8 When assembling the front fork leg, be sure to replace the following parts: - oil seal 8 Before assembling the front fork leg, make sure all of the components are clean. .
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FRONT FORK CHAS TIP While holding the damper rod assembly with the damper rod holder 2 and T-handle 3, tighten the damper rod assembly bolt. ot er Ti m e. ne t Damper rod holder 90890-01294 (YM-01300-1) T-handle 90890-01326 (YM-01326) 8 oil seal 1 New (with the fork seal driver weight 2 and adapter 3) w w w .S co 4.
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FRONT FORK CHAS 5. Install: 8 oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube’s groove. ne t 6. Fill: 8 front fork leg (with the specified amount of the recommended fork oil) .S co ot er Ti m e. Quantity (each front fork leg) 0.104L (0.11 US qt, 0.09 Imp. qt) Recommended oil Fork oil 10W or equivalent D ow nl oa de d fro m w w w TIP 8 While filling the front fork leg, keep it upright.
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FRONT FORK CHAS TIP 8 Install the spring with the smaller pitch facing down. 8 Before installing the collar, lubricate its Oring with grease. 8 Press down the collar/O-ring, adjust the stopper ring so that it fits into the inner tube’s groove. .S co EAS00663 ot er Ti m e. ne t 8. Install: 8 clamp/boot fro m w w w INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1.
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HANDLEBAR CHAS EAS00664 HANDLEBAR 7 1 5 28Nm (2.8 m•kgf, 20.3 ft•lbf) 1 3 ne t 3 13 6 e. 14 8 9 11 .S co ot er Ti m 4 w 2 w 12 w 5Nm (0.5 m•kgf, 3.
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HANDLEBAR 7 1 CHAS 5 28Nm (2.8 m•kgf, 20.3 ft•lbf) 1 3 3 13 6 14 ne t 4 8 Ti m e. 9 er 11 ot 2 .S co 12 10 fro m w w w 5Nm (0.5 m•kgf, 3.6 ft•lbf) ow nl Job/Part Upper handlebar holder Handlebar Q’ty 2 1 Remarks For installation, reverse the removal procedure.
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HANDLEBAR CHAS 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. ot er Ti m e. ne t 2. Remove: 8 leg shield 1 8 leg shield 2 Refer to “COVER AND PANEL” in chapter 3. 8 rear view mirror (left and right) 8brush guard (left and right) 8band 3. Disconnect: 8brake master cylinder Refer to “FRONT BRAKE”. .S co TIP While removing the right handlebar switch, pull back the rubber cover.
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HANDLEBAR CHAS EAS00668 CHECKING THE HANDLEBAR 1. Check: 8handlebar 1 Bends/cracks/damage Replace. 1 WARNING D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
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HANDLEBAR 2 CHAS EAS00673 1 INSTALLING THE HANDLEBAR 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2. Install: 8 handlebar 1 8 upper handlebar holders 2 T. R. 28Nm(2.8m • kgf, 20.3ft • lbf) ne t NOTICE Ti m e. First, tighten the bolts on the front side of the handlebar holders, and then on the rear side. oa de d fro m w w w .
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HANDLEBAR CHAS 5. Install: 8 throttle grip assembly 1 8 throttle cable assembly 2 8 right handlebar switch 3 2 1 a TIP 8 Lubricate the inside of the throttle grip assembly with a thin coat of lithium-soapbased grease and install it onto the handlebar 4. 8 Align the projection a on the right handlebar switch with the hole b in the handlebar. b 3 3 4 ne t WARNING 1 Ti m e. Make sure the throttle grip operates smoothly. ot er 2 D ow nl oa de d fro m w w w .S co 6.
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STEERING HEAD CHAS EAS00675 STEERING HEAD HANDLEBAR BRACKET AND FRONT BRACKET 4Nm (0.4 m•kgf, 2.9 ft•lbf) 4Nm (0.4 m•kgf, 2.9 ft•lbf) 4 1 2 7Nm (0.7 m•kgf, 5.1 ft•lbf) 8 13 48Nm (4.8 m•kgf, 34.7 ft•lbf) ne t 6 e. 3 60Nm (6.0 m•kgf, 43.4 ft•lbf) Ti m 10 er 5 9 ot 12 w w w .S co 9Nm (0.9 m•kgf, 6.5 ft•lbf) fro m 11 oa de 4Nm (0.4 m•kgf, 2.
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STEERING HEAD CHAS LOWER BRACKET 7 8 75Nm (7.5 m•kgf, 54.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 10 Ti m e. ne t 12 2 3 4 5 6 1st 38Nm (3.8 m•kgf, 27.5 ft•lbf) 2nd 14Nm (1.4 m•kgf, 10.1 ft•lbf) .S co ot er 1 oa de d fro m w w 11 14 15 w 13 9 Order Job/Part Q’ty Remove the parts in the order listed. Refer to “COVER AND PANEL” in chapter 3. Refer to “FRONT WHEEL AND BRAKE DISC”. Refer to “FRONT BRAKE”. Refer to “FRONT FORK”. Refer to “HANDLEBAR”.
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STEERING HEAD CHAS 7 8 75Nm (7.5 m•kgf, 54.2 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 10 e. ne t 12 2 3 4 5 6 Ti m 1st 38Nm (3.8 m•kgf, 27.5 ft•lbf) 2nd 14Nm (1.4 m•kgf, 10.1 ft•lbf) .S co ot er 1 d Q’ty Remarks 1 1 1 1 1 ow nl Lower bearing Upper bearing outer race Lower bearing outer race Lower bearing inner race Dust seal D 11 12 13 14 15 Job/Part oa de Order fro m w w 11 14 15 w 13 9 For installation, reverse the removal procedure.
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STEERING HEAD CHAS EAS00678 REMOVING THE LOWER BRACKET 1. Stand the scooter on a level surface. WARNING Securely support the scooter so that there is no danger of it falling over. 2 . Remove: 8brake hose holder 2 8handlebar bracket 1 ne t TIP Remove the handlebar bracket by loosening the ring nut 2 gradually. Ti m e. 1 ot er 2 .S co w w 1 fro m w 2 oa de d Ring nut wrench 90890-01268 (YU-01268) 4 . Remove: 8lower ring nut 1 (with the ring nut wrench 2) ow nl D 3.
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STEERING HEAD CHAS EAS00682 CHECKING THE STEERING HEAD 1. Wash: 8bearings 8bearing races Recommended cleaning solvent Kerosene 2. Check: 8bearings 1 8bearing races 2 Damage/pitting Replace. 3. Replace: 8bearings 8bearing races 8dust seal 2 ot er Ti m e. ne t 1 .S co ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c.
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STEERING HEAD CHAS EAS00684 INSTALLING THE STEERING HEAD 1. Lubricate: 8 bearings 1 8 bearing races LS 1 Recommended lubricant Lithium-soap-based grease 2. Install: 8 lower ring nut 1 8 rubber washer 2 8 center ring nut 3 8 lock washer 4 8 upper ring nut 5 Refer to “CHECKING THE STEERING HEAD” in chapter 3. 4 2 1 e. ne t 5 ot er Ti m 3 w fro m 1 60Nm(6.0m • kgf, 43.4ft • lbf) TIP Align the handlebar bracket across rod 2 on the lower bracket concave 3 . oa de d 2 R. 3 T. w w .
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM CHAS EAS00685 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 30Nm (3.0 m•kgf, 21.7 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 1 31Nm (3.1 m•kgf, 22.4 ft•lbf) 44Nm (4.4 m•kgf, 31.8 ft•lbf) 2 ne t 3 Ti m 13Nm (1.3 m•kgf, 9.4 ft•lbf) 10 53Nm (5.3 m•kgf, 38.3 ft•lbf) 7 5 w d fro m 105Nm (10.5 m•kgf, 75.9 ft•lbf) w w 18Nm (1.8 m•kgf, 13.0 ft•lbf) 8 2 .S co 6 ot er 11 9 e.
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM CHAS 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. ot er Ti m e. ne t TIP Place the scooter on a suitable stand so that the rear wheel is elevated. .S co 2.
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM CHAS EAS00699 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Install: 8 rear shock absorber assembly upper nuts 1 1 2 T. R. 30Nm (3.0m • kgf, 21.7ft • lbf) 8 rear shock absorber assembly lower bolts 2 T. .S co EAS00702 ot er Ti m e. ne t R. 18Nm (1.8m • kgf, 13.0ft • lbf) fro m w w w REMOVING THE SWINGARM 1. Stand the scooter on a level surface. WARNING oa de d Securely support the scooter so that there is no danger of it falling over.
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM CHAS EAS00708 2 3 CHECKING THE SWINGARM 1. Check: 8 swingarm Bends/cracks/damage Replace. 2. Check: 8 spacer 1 8 collar 2 8 oil seals 3 8 bearing 4 Damage/wear Replace. 4 .S co EAS00711 ot er Ti m e. ne t 3 1 fro m w w w INSTALLING THE SWINGARM 1. Lubricate: 8 bearing 8 oil seal lips 8 rear wheel axle splines 2. Install: 8 swingarm 1 T. D ow nl oa de d Recommended lubricant Lithium-soap-based grease R. 31Nm (3.1m • kgf, 22.
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM CHAS 4. Tighten: 8 exhaust pipe nut T. R. 13Nm (1.3m • kgf, 9.4ft • lbf) 8 muffler and swingarm bolt T. R. 31Nm (3.1m • kgf, 22.4ft • lbf) 8 muffler and swingarm bolt T. R. 53Nm (5.3m • kgf, 38.3ft • lbf) D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 5.
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ENG CHAPTER 5 ENGINE D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t ENGINE REMOVAL .................................................................................. 5-1 LEADS AND HOSES ......................................................................... 5-1 ENGINE .............................................................................................. 5-3 INSTALLING THE ENGINE ............................................................... 5-4 CYLINDER HEAD .................
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ENG D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t CHECKING THE V-BELT ................................................................. 5-45 CHECKING THE PRIMARY SHEAVE ............................................ 5-46 CHECKING THE PRIMARY SHEAVE WEIGHTS .......................... 5-46 CHECKING THE SLIDER ................................................................ 5-47 CHECKING THE SECONDARY SHEAVE ...................................... 5-47 ASSEMBLING THE PRIMARY SHEAVE .........
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ENGINE REMOVAL ENG EAS00188 ENGINE ENGINE REMOVAL ne t LEADS AND HOSES er Ti m e. 3 3Nm (0.3 m•kgf, 2.2 ft•lbf) fro m w w w .S co ot 2 4 1 oa de d 4 ow nl Job/Part Q’ty D Order 7Nm (0.7 m•kgf, 5.1 ft•lbf) Removing the leads and hoses Seat/trunk Battery box cover/front cover Side cover (left and right) Battery/footrest board Rear brake cable/adjuster/spring/pin Remarks Remove the parts in the order listed. Refer to “COVER AND PANEL” in chapter 3.
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ENGINE REMOVAL ENG ne t 3 3Nm (0.3 m•kgf, 2.2 ft•lbf) 4 w 4 fro m w 1 w .S co ot er Ti m e. 2 oa de d 7Nm (0.7 m•kgf, 5.1 ft•lbf) Order Q’ty Remarks TEM” in chapter 7. 1 1 1 1/1 ow nl Rear brake cable holder Spark plug cap Engine temperature sensor coupler Air filter/breather hose D 1 2 3 4 Job/Part Disconnect. Disconnect. For installation, reverse the removal procedure.
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ENG ENGINE REMOVAL EAS00191 ENGINE 18Nm (1.8 m•kgf, 13.0 ft•lbf) Ti m e. ne t 1 2 .S co ot er 6 5 7 fro m w w w 4 3 oa de d 7 ow nl D Order 32Nm (3.2 m•kgf, 23.1 ft•lbf) Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the engine TIP Place a suitable stand under the frame and engine.
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ENGINE REMOVAL ENG EAS00192 INSTALLING THE ENGINE 1. Install: 8 engine 1 8 engine mounting bolt 2 8 engine mounting nut 3 3 1 2 ot er Ti m e. ne t TIP 8 Apply lithium-soap-based grease to the unthreaded portion of the engine mounting bolt shaft. 8 Do not fully tighten the engine mounting bolt.. fro m w w w .S co 2. Install: 8 rear shock absorber assembly lower bolts 1 ow nl oa de d 1 TIP Do not fully tighten the bolts. D 3. Tighten: 8 engine mounting bolt T. R. 32Nm(3.2m • kgf, 23.
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CYLINDER HEAD ENG EAS00221 CYLINDER HEAD 8Nm (0.8 m•kgf, 5.8 ft•lbf) 9Nm (0.9 m•kgf, 6.5 ft•lbf) 10 8 10Nm (1.0 m•kgf, 7.2 ft•lbf) 9 7Nm (0.7 m•kgf, 5.1 ft•lbf) 2 13Nm (1.3 m•kgf, 9.4 ft•lbf) 1 er Ti m 18Nm (1.8 m•kgf, 13.0 ft•lbf) 15 e. 6 6 ne t 2 3 3 .S co ot 13 14 w 4 7 oa de d 7 11 fro m w w 12 12Nm (1.2 m•kgf, 8.7 ft•lbf) 7Nm (0.7 m•kgf, 5.1 ft•lbf) 30Nm (3.0 m•kgf, 21.7 ft•lbf) D ow nl 22Nm (2.2 m•kgf, 15.
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CYLINDER HEAD ENG 8Nm (0.8 m•kgf, 5.8 ft•lbf) 9Nm (0.9 m•kgf, 6.5 ft•lbf) 10 8 10Nm (1.0 m•kgf, 7.2 ft•lbf) 9 7Nm (0.7 m•kgf, 5.1 ft•lbf) 2 13Nm (1.3 m•kgf, 9.4 ft•lbf) 1 Ti m 18Nm (1.8 m•kgf, 13.0 ft•lbf) 15 e. 6 6 ne t 2 3 3 12 .S co 14 4 ot er 13 w w w 11 7 fro m 7 7Nm (0.7 m•kgf, 5.1 ft•lbf) oa de d 12Nm (1.2 m•kgf, 8.7 ft•lbf) 5 5 9 10 11 12 13 14 15 D Order 30Nm (3.0 m•kgf, 21.7 ft•lbf) ow nl 22Nm (2.2 m•kgf, 15.
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CYLINDER HEAD ENG EAS00225 ot er Ti m e. ne t REMOVING THE CYLINDER HEAD 1. Remove : 8 air guide 8 air shroud cylinder 3 Refer to “STARTER CLUTCH AND AC MAGNETO”. 8 V-belt case Refer to “BELT DRIVE”. 8 muffler Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM” in chapter 4. 2. Remove : 8breather/O-ring 8 valve cover (intake)/O-ring 8 valve cover (exhaust)/O-ring D ow nl oa de d fro m w w w .S co 3.
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CYLINDER HEAD ENG 2 6. Remove: 8 timing chain tensioner (along with the gasket) 8 camshaft sprocket bolt 1 8 camshaft sprocket plate 2 8 camshaft sprocket 3 8 timing chain 4 2 4 Ti m e. ne t 1 3 4 3 1 6 2 D 5 ow nl oa de d fro m w w w .S co ot er TIP To prevent the timing chain from falling into the crankcase, fasten it with a wire. 7. Remove: 8 cylinder head TIP 8 Loosen the nuts in the proper sequence as shown. 8 Loosen each nut 1/2 of a turn at a time.
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CYLINDER HEAD ENG EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: 8 combustion chamber carbon deposits (with a rounded scraper) TIP Do not use a sharp instrument to avoid damaging or scratching: 8 spark plug bore thread 8 valve seats ot er Ti m e. ne t 2. Check: 8 cylinder head Damage/scratches J Replace. fro m w w w .S co 3. Measure: 8 cylinder head warpage Out of specification J Resurface the cylinder head. ow nl oa de d ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
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CYLINDER HEAD ENG EAS00231 INSTALLING THE CYLINDER HEAD 1. Install: 3 1 5 2 4 6 8 gasket New 8 dowel pins 2. Install: 8 cylinder head 3. Tighten: 8 cylinder head nuts T. R. 22 Nm (2.2 m • kgf, 15.9 ft • lbf) 8 cylinder head bolts T. ne t R. 12 Nm (1.2 m • kgf, 8.7 ft • lbf) 4. Install: 8 camshaft sprocket 1 8 timing chain 2 1 D ow nl oa de d fro m w w w .S co ot er Ti m e. TIP 8 Lubricate the cylinder head nuts with engine oil.
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CYLINDER HEAD ENG TIP 8 When installing the camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side. 8 Align the slot on the camshaft with the tab in the camshaft sprocket. NOTICE Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. e. Remove the wire from the timing chain. ot er Ti m e. ne t ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ .S co 5. Install 8 camshaft sprocket plate 1 8 camshaft sprocket bolt 2 fro m w w w 1 1 2 6.
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CYLINDER HEAD ENG T. R. Cap bolt 8 Nm (0.8 m • kgf, 5.8 ft • lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Turn: 8crankshaft (several turns counterclockwise) T. 30 Nm (3.0 m • kgf, 21.7 ft • lbf) fro m w R. w w .S co ot er Ti m e. ne t 8. Check: 8“I” mark a Align the “I” mark on the AC magneto rotor with the stationary pointer b on the crankcase. 8“I” mark c Align the “I” mark on the camshaft sprocket with the stationary pointer d on the cylinder head. Out of alignment J Correct.
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THE ROCKER ARMS AND CAMSHAFT ENG THE ROCKER ARMS AND CAMSHAFT 2 7Nm (0.7 m•kgf, 5.1 ft•lbf) 3 2 3 5 3 7 e. ne t 3 4 1 6 fro m w w w .S co ot er Ti m 12Nm (1.2 m•kgf, 8.7 ft•lbf) oa de d 8 Job/Part Q’ty 1 2 3 4 5 6 7 8 Removing the rocker arms and camshaft Cylinder head Stopper plate Locknut Adjusting screw Rocker arm shaft (intake) Rocker arm (intake) Rocker arm shaft (exhaust) Rocker arm (exhaust) Camshaft D Remarks Remove the parts in the order listed.
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THE ROCKER ARMS AND CAMSHAFT ENG EAS00202 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Remove: 8 locknut 1 8 stopper plate 2 2. Remove: 8 intake rocker arm shaft 8 exhaust rocker arm shaft 8 intake rocker arm 8 exhaust rocker arm e. ne t 1 Ti m TIP Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2 . Slide hammer bolt 90890-01085 (YU-01083-2) Weight 90890-01084 (YU-01083-3) oa de d fro m w w w .S co ot er 2 ow nl 3.
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THE ROCKER ARMS AND CAMSHAFT ENG EAS00205 CHECKING THE CAMSHAFT 1. Check: 8camshaft lobes Blue discoloration/pitting/scratches J Replace the camshaft. ne t 2. Measure: 8camshaft lobe dimensions a and b Out of specification J Replace the camshaft. oa de d fro m w w w .S co ot er Ti m e. Camshaft lobe dimension limit Intake a 25.267 ~ 25.367mm (0.995 ~0.999in) :25.167mm (0.991in) b 21.069 ~ 21.169mm (0.829 ~0.833in) :20.969mm (0.826in) Exhaust a 25.275 ~ 25.375mm (0.995 ~0.
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THE ROCKER ARMS AND CAMSHAFT ENG EAS00206 1 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: 8rocker arm (camshaft touch surface)1 8rocker arm (valve touch surface)2 Damage/wear J Replace. 2. Check: 8rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches J Replace or check the lubrication system. 3. Check: 8camshaft lobe Excessive wear J Replace the camshaft. 1 2 ot er Ti m e. ne t 2 w .
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THE ROCKER ARMS AND CAMSHAFT ENG Above 0.034mm (0.0013in) J Replace the defective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.034mm (0.0004 ~ 0.0013in) EAS00207 1 a b D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 2 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprocket and timing chain guides. 1.
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THE ROCKER ARMS AND CAMSHAFT ENG EAS00210 Ti m e. ne t CHECKING THE TIMING CHAIN TENSIONER 1. Check: 8 timing chain tensioner Cracks/damage J Replace. 2. Check: 8 one-way cam operation Rough movement J Replace the timing chain tensioner. 3. Check: 8 cap bolt 8 O-ring New 8 spring 8 one-way cam 8 gasket New 8 timing chain tensioner rod Damage/wear J Replace the defective part(s). D ow nl oa de d fro m w w w .S co ot er ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Removing the spring and cap bolt. b.
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THE ROCKER ARMS AND CAMSHAFT ENG EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: 8 camshaft 1 Recommended lubricant Camshaft Engine oil Camshaft bearing Engine oil 1 ne t 2. Lubricate: 8 rocker arms 8 rocker arm shafts ot er Ti m e. Recommended lubricant Molybdenum disulfide oil .S co 3. Install: 8 exhaust rocker arm 1 8 exhaust rocker arm shaft 2 1 TIP Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head. 4.
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THE ROCKER ARMS AND CAMSHAFT ENG 5. Install: 8 stopper plate 1 8 locknut 2 T. D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t R. 12Nm (1.2m • kgf, 8.
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VALVES AND VALVE SPRINGS ENG EAS00236 VALVES AND VALVE SPRINGS 1 2 2 1 3 3 6 6 8 7 ne t 8 e. 7 8 fro m w w w .S co ot er Ti m 8 4 D Order ow nl oa de d 5 Job/Part Q’ty Removing the valves and valve springs Cylinder head Rocker arms Rocker arm shafts Camshaft 1 2 3 4 5 6 7 8 Valve cotter Valve spring retainer Valve spring Valve (intake) Valve (exhaust) Valve stem seal Valve stem seat/valve guide O-ring Remove the parts in the order listed. Refer to “CYLINDER HEAD”.
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VALVES AND VALVE SPRINGS ENG 1 2 2 1 3 3 6 6 8 7 8 7 8 w w .S co ot er Ti m e. ne t 8 4 ow nl Job/Part Q’ty Remarks For installation, reverse the removal procedure.
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VALVES AND VALVE SPRINGS ENG EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. TIP Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. ne t 1. Check: 8 valve sealing Leakage at the valve seat J Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS”. a Ti m e. 1 .S co ot er ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
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VALVES AND VALVE SPRINGS ENG 3 . Remove: 8 valve spring retainer 1 8 valve spring 2 8 valve stem seal 3 8 valve 4 4 3 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place. 2 .S co EAS00239 ot er Ti m e. ne t 1 fro m w w w CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1.
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VALVES AND VALVE SPRINGS ENG 2. Replace: 8 valve guide TIP To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100°C (212°F) in an oven. ot er Ti m e. ne t ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover 1. b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. c.
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VALVES AND VALVE SPRINGS ENG 5. Measure: 8 valve margin thickness a Out of specification J Replace the valve. Valve margin thickness (intake) 0.7mm (0.028in) Valve margin thickness (exhaust) 1.0mm (0.039in) 6. Measure: 8 valve stem runout Out of specification J Replace the valve. .S co ot er Ti m e. ne t TIP 8 When installing a new valve, always replace the valve guide. 8 If the valve is removed or replaced, always replace the oil seal.. D ow nl oa de d fro m w w w Valve stem runout 0.
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VALVES AND VALVE SPRINGS ENG EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: 8 carbon deposits (from the valve face and valve seat) 2. Check: 8 valve seat Pitting/wear J Replace the cylinder head. ne t 3. Measure: 8 valve seat width a Out of specification J Replace the cylinder head. .S co ot er Ti m e. Valve seat width Intake: 0.9 ~ 1.1mm (0.035 ~ 0.043in) : 1.6mm (0.063in) Exhaust: 0.9 ~1.1mm (0.035 ~ 0.
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VALVES AND VALVE SPRINGS ENG ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound a to the valve face. a NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide. ne t b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. ot er Ti m e.
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VALVES AND VALVE SPRINGS ENG EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: 8 valve spring free length a Out of specification J Replace the valve spring. a ot er Ti m e. ne t Valve spring free length 41.88mm (1.649in) : 39.786mm (1.566in) .S co fro m w w w b Compressed valve spring force (installed) 137 ~ 157N/mm (13.97 ~ 16.01kgf/ mm, 30.83 ~ 35.33lbf/in) at 30mm (1.18in) D ow nl oa de d a 2.
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VALVES AND VALVE SPRINGS ENG EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 8 valve stem end (with an oil stone) 2. Lubricate: 8 valve stem 1 8 valve stem seal 2 (with the recommended lubricant) 2 ne t 1 ot er Ti m e. Recommended lubricant Molybdenum disulfide oil fro m 2 3 oa de ow nl b Smaller pitch D a TIP Install the valve spring with the larger pitch a facing up. d 4 w 1 w w .S co 3.
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VALVES AND VALVE SPRINGS ENG Valve spring compressor 90890-04019 (YM-04019) Valve spring compressor attachment 90890-04108 (YM-04108) ne t 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer. NOTICE D ow nl oa de d fro m w w w .S co ot er Ti m e. Hitting the valve tip with excessive force could damage the valve.
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CYLINDER AND PISTON ENG EAS00251 CYLINDER AND PISTON 5 8 7 6 5 Ti m e. ne t 3 .S co ot er 3 w w 4 1 Job/Part Q’ty Removing the cylinder and piston Cylinder head Timing chain guide (exhaust side) Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set 1 2 3 4 5 6 7 8 Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”.
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CYLINDER AND PISTON ENG EAS00253 3 REMOVING THE CYLINDER AND PISTON 1. Remove: 8 piston pin clip 1 8 piston pin 2 8 piston 3 2 1 NOTICE Do not use a hammer to drive the piston pin out. 3 TIP 8 Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. 8 Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area.
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CYLINDER AND PISTON ENG EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: 8 piston wall 8 cylinder wall Vertical scratches J Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: 8 piston-to-cylinder clearance Ti m e. ne t ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. .S co ot er TIP Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder.
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CYLINDER AND PISTON ENG e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” Piston skirt diameter “P” Piston-to-cylinder clearance 0.010 ~ 0.035mm (0.0004 ~0.0014in) : 0.15mm (0.0059in) D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.
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CYLINDER AND PISTON ENG EAS00263 CHECKING THE PISTON RINGS 1. Measure: 8 piston ring side clearance Out of specification J Replace the piston and piston rings as a set. TIP Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. ot er Ti m e. ne t Piston ring side clearance Top ring 0.02 ~ 0.08mm (0.0008 ~ 0.0031in) : 0.13mm (0.0051in) 2nd ring 0.02 ~ 0.06mm (0.0008 ~ 0.0024in) :0.12mm (0.0047in) w w .S co 2.
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CYLINDER AND PISTON ENG EAS00265 CHECKING THE PISTON PIN 1. Check: 8 piston pin Blue discoloration/grooves J Replace the piston pin and then check the lubrication system. ne t 2. Measure: 8 piston pin outside diameter a Out of specification J Replace the piston pin. ot er Ti m e. Piston pin outside diameter 14.995 ~ 15.000mm (0.5904 ~0.5906in) :14.975mm (0.5896in) Piston pin bore diameter 15.002 ~ 15.013mm (0.5906 ~ 0.5911in) :15.043mm (0.5922in) oa de d fro m w w w .S co 3.
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CYLINDER AND PISTON ENG CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) 1. Check: 8 timing chain guide (exhaust side) Damage/wear J Replace EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: 8 oil ring expander 8 oil ring rail 8 2nd ring 8 top ring Ti m e. ne t UP ow nl 2. Install: 8 piston 1 8 piston pin 2 8 piston pin clip 3 New D 1 oa de d fro m w w w .S co ot er TIP Be sure to install the piston rings so that the manufacturer’s marks or numbers a face up.
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CYLINDER AND PISTON ENG 3. Install: 8 gasket New 8 dowel pins e. ne t 4. Lubricate: 8 piston 8 piston rings 8 cylinder (with the recommended lubricant) ot er Ti m Recommended lubricant Engine oil .S co 5. Offset: 8 piston ring end gaps b d Top ring Lower oil ring rail Upper oil ring rail 2nd ring Exhaust side 6. Install: 8 cylinder 1 ow nl A oa de c a b c d A d fro m w w w a D TIP 8 While compressing the piston rings with one hand, install the cylinder with the other hand.
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BELT DRIVE ENG EAS00316 BELT DRIVE V-BELT CASE 7Nm (0.7 m•kgf, 5.1 ft•lbf) 11Nm (1.1 m•kgf, 8.0 ft•lbf) 6 9 (x8) ne t 4 Ti m e. 3 2 er 5 ot 7 w w .S co 8 oa de d fro m w 1 10Nm (1.0 m•kgf, 7.2 ft•lbf) Q’ty Removing the V-belt case Air duct V-belt case cover V-belt case filter guide V-belt case filter element O-ring Gasket (V-belt case) Plate Gasket (plate) V-belt case Remarks Remove the parts in the order listed.
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ENG BELT DRIVE V-BELT AND PRIMARY/SECONDARY SHEAVE 60Nm (6.0 m•kgf, 43.2 ft•lbf) Ti m e. ne t 4 er 6 7 .S co ot 8 5 2 w 1 11 w w 9 3 fro m 9 11 oa de d 10 12 45Nm (4.5 m•kgf, 32.5 ft•lbf) Job/Part Q’ty 1 2 3 Removing the V-belt and primary/secondary sheave V-belt case Primary fixed sheave nut/plate washer Oneway clutch Primary fixed sheave 1/1 1 1 Refer to “V-BELT CASE”. Refer to “REMOVING THE PRIMARY SHEAVE” and “INSTALLING THE SECONDARY SHEAVE, V-BELT AND PRIMARY SHEAVE”.
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BELT DRIVE ENG SECONDARY SHEAVE 8 2 4 5 6 3 ne t 7 e Ti m e. r er q ot 1 w w .S co w 9 90Nm (9.0 m•kgf, 7.2 ft•lbf) Job/Part Q’ty Disassembling the secondary sheave Clutch carrier nut Clip Plate Clutch shoe spring Clutch shoe Damper Clutch carrier Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave Remarks Disassemble the parts in the order listed.
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BELT DRIVE ENG EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: 8 V-belt case 8 Refer to “V-BELT CASE”. 2. Remove: 8 primary fixed sheave nut 1 8 plate washer 8 oneway clutch 8 primary fixed sheave 2 1 2 3 ne t TIP While holding the primary fixed sheave with the rotor holding tool 3, loosen the primary fixed sheave nut. .S co EAS00318 ot er Ti m e. Rotor holding tool 90890-01235 (YU-01235) REMOVING THE SECONDARY SHEAVE AND V-BELT 1.
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BELT DRIVE ENG TIP While holding the clutch carrier with the rotor holding tool 2, loosen the clutch carrier nut one full turn with the locknut wrench 3. Rotor holding tool 90890-01235 (YU-01235) Locknut wrench 90890-01348 (YM-01348) ne t 3. Remove: 8 secondary sheave 1 8 V-belt 2 Ti m e. TIP Remove the V-belt and secondary sheave from the primary sheave side. 1 .S co EAS00319 ot er 2 SECONDARY fro m w w w DISASSEMBLING THE SHEAVE 1.
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BELT DRIVE ENG TIP After sanding the glazed areas, clean the clutch with a cloth. 2. Measure: 8 clutch shoe thickness Out of specification J Replace the clutch shoes and springs as a set. ne t a e. Clutch shoe thickness 3.2 ~ 3.5mm (0.13 ~ 0.14in) : 2.0mm (0.079in) Ti m a er a oa de d fro m w w w .S co ot TIP 8 Inspect clutch shoes a. 8 After removing the clutch shoe spring, do not use them again. 8 Replace the all three as a set. ow nl CHECKING THE V-BELT 1.
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BELT DRIVE CHECKING THE PRIMARY SHEAVE 1. Check: 8 primary sliding sheave 1 8 primary fixed sheave 2 Cracks/damage/wear J Replace the primary sliding sheave, primary fixed sheave and V-belt. 1 2 ENG ne t 2. Check: 8free movement Stick or excessive play J Replace the primary sliding sheave, collar or both. .S co EAS00321 ot er Ti m e. TIP Insert the collar 2 into the primary sliding sheave 1, and check for free movement.
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BELT DRIVE ENG CHECKING THE SLIDER 1. Check: 8 slider 1 Damage/wearJ Replace EAS00322 ot er Ti m e. ne t CHECKING THE SECONDARY SHEAVE 1. Check: 8secondary fixed sheave 8secondary sliding sheave Cracks/damage/wear J Replace the secondary fixed and sliding sheaves as a set. .S co 2. Check: 8torque cam groove 1 Damage/wear J Replace the secondary fixed and sliding sheaves as a set. 3. Check: 8guide pin 2 Damage/wear J Replace the secondary fixed and sliding sheaves as a set.
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BELT DRIVE ENG EAS00323 4 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: 8primary fixed sheave 1 8primary sliding sheave 2 8collar 3 8primary sheave weights 4 3 1 2 TIP Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5. ot er Ti m e. ne t 5 .S co 2. Install: 8primary sheave weights 1 8collar 2 fro m w w w 2 3.
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BELT DRIVE ENG EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: 8 secondary fixed sheave’s inner surface 1 8 secondary sliding sheave’s inner surface 2 8 oil seals 8 bearings (with the recommended lubricant) 1 2 .S co ot er Ti m e. ne t Recommended lubricant BEL-RAY assembly lube® 2. Install: 8 secondary sliding sheave 1 3 w w w 1 oa de d fro m 2 TIP Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3.
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BELT DRIVE 5. Install: 8 secondary sheave 1 8 spring 8 clutch carrier 2 4 2 TIP Attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch carrier nut 5. 5 3 ENG 1 .S co EAS00325 ot er Ti m e. ne t Clutch spring holder 90890-01337 (YM-33285) fro m w w w INSTALLING THE SECONDARY SHEAVE, VBELT AND PRIMARY SHEAVE 1.
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BELT DRIVE ENG Rotor holding tool 90890-01235 (YU-01235) Locknut wrench 90890-01348 (YM-01348) 3. Install: 8 clutch housing 1 8 secondary sheave nut 2 3 T. e. R. 60Nm(6.0m • kgf, 43.4ft • lbf) ne t 2 Ti m TIP Tighten the secondary sheave nut with the sheave holder 3. .S co ot er 1 1 D ow nl oa de d fro m w w w Sheave holder 90890-01701 (YS-01880-A) 4. Install: 8 primary fixed sheave 1 8 oneway clutch 8 plate washer 8 primary fixed sheave nut 2 2 T. R. 3 45Nm(4.5m • kgf, 32.
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BELT DRIVE ENG 5. Position: 8 V-belt 1 TIP Position the V-belt in the primary sheave 2 (when the pulley is at its widest position) and in the secondary sheave 3 (when the pulley is at its narrowest position), and make sure the Vbelt is tight. 3 1 2 D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t 6. Install: 8 V-belt case Refer to “V-BELT CASE”.
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STARTER CLUTCH AND AC MAGNETO ENG EAS00341 STARTER CLUTCH AND AC MAGNETO STATOR COIL ASSEMBLY 7Nm (0.7 m•kgf, 5.1 ft•lbf) 3 1 6 ne t 2 7 .S co 9 ot er Ti m e. 8 w w w 5 fro m 7Nm (0.7 m•kgf, 5.1 ft•lbf) 1 2 3 4 5 6 7 8 9 9Nm (0.9 m•kgf, 6.
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STARTER CLUTCH AND AC MAGNETO ENG EAS00342 STARTER CLUTCH 3 Ti m e. 2 ne t 10Nm (1.0 m•kgf, 7.2 ft•lbf) 1 .S co ot er 5 2 4 10Nm (1.0 m•kgf, 7.2 ft•lbf) w w w 7 oa de d fro m 6 Job/Part Q’ty ow nl Order Remove the parts in the order listed. Refer to “V-BELT CASE”. Refer to “V-BELT AND PRIMARY/SECONDARY SHEAVE”.
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STARTER CLUTCH AND AC MAGNETO ENG EAS00347 REMOVING THE AC MAGNETO 1. Remove: 8 air guide 8 air shroud cylinder 3 2. Remove: 8 fan 8 AC magneto rotor nut 1 8 washer 1 3 2 ne t TIP While holding the AC magneto rotor 3 with the rotor holding tool 2, loosen the AC magneto rotor nut. ot er Ti m e. Rotor holding tool 90890-01235 (YU-01235) .
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STARTER CLUTCH AND AC MAGNETO ENG EAS00351 CHECKING THE STARTER CLUTCH 1. Check: 8starter clutch roller Damage/wear J Replace. 2. Check: 8starter clutch idle gear 8starter wheel gear Burrs/chips/roughness/wear J Replace the defective part(s). ot er Ti m e. ne t 3. Check: 8starter wheel gear’s contacting surfaces Damage/pitting/wear J Replace the starter wheel gear. D ow nl oa de d fro m w w w .S co 4. Check: 8starter clutch operation 5-56 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
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STARTER CLUTCH AND AC MAGNETO ENG EAS00354 INSTALLING THE AC MAGNETO 1. Install: 8 stator coil assembly 8 crankshaft position sensor 8 woodruff key 8 AC magneto rotor 8 washer 8 AC magneto rotor nut ot er Ti m e. ne t TIP 8 Clean the tapered portion of the crankshaft and the AC magneto rotor hub. 8 When installing the AC magneto rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft. .S co 2. Tighten: 8 AC magneto rotor nut 2 w fro m d 70 Nm (7.0 m • kgf, 50.
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OIL PUMP ENG EAS00360 OIL PUMP 13Nm (1.3 m•kgf, 9.4 ft•lbf) e. ne t 2 Ti m 3 ot er 4Nm (0.4 m•kgf, 2.9 ft•lbf) 4 1 1 ow nl Job/Part 5 7 6 13Nm (1.3 m•kgf, 9.4 ft•lbf) Q’ty Removing the oil pump AC magneto rotor Stator coil assembly Cover/O-ring Gasket Oil seal Dowel pin Circlip/plate washer Oil pump driven gear Dowel pin Oil pump Gasket 1 2 3 4 5 6 7 8 9 Remarks Remove the parts in the order listed. Refer to “STARTER CLUTCH AND AC MAGNETO”. D Order oa de d 8 fro m w w w .
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OIL PUMP ENG EAS00364 CHECKING THE OIL PUMP 1. Check: 8 oil pump drive gear 8 oil pump driven gear 1 8 oil pump housing 8 oil pump housing cover Cracks/damage/wear J Replace the defective part(s). 1 e. ne t 2. Measure: 8 inner-rotor-to-outer-rotor-tip clearance a 8 outer-rotor-to-oil-pump-housing clearance b. Out of specification J Replace the oil pump. Inner-rotor-to-outer-rotor-tip clearance 0.15mm (0.006in) or less : 0.23mm (0.009in) Outer-rotor-to-oil-pump-housing clearance 0.07 ~ 0.
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OIL PUMP ENG EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: 8 inner rotor 8 outer rotor 8 oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 8 oil pump shaft 1 (to the oil pump housing 2) 8 pin 3 8 inner rotor 4 8 outer rotor 5 8 oil pump housing cover 6 8 oil pump housing screw 6 5 4 1 Ti m e. ne t 2 er 3 3. Check: 8 oil pump operation Refer to “CHECKING THE OIL PUMP”. oa de d fro m w w w .
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TRANSMISSION ENG EAS00419 TRANSMISSION G G 6 e. ne t 5 Ti m 3 er 4 ot 3 .S co G G w w 2 fro m w 1 oa de d 10Nm (1.0 m•kgf, 7.2 ft•lbf) Order Job/Part Q’ty Remove the parts in the order listed. Drain. Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM” in chapter 4. Refer to “REAR WHEEL AND REAR BRAKE” in chapter 4.
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TRANSMISSION ENG EAS00425 CHECKING THE TRANSMISSION 1. Measure: 8 main axle runout (with a centering device and dial gauge ) Out of specification J Replace the main axle. Main axle runout limit 0.04mm (0.002in) e. ne t 2. Measure: 8 drive axle runout (with a centering device and dial gauge ) Out of specification J Replace the drive axle. .S co ot er Ti m Drive axle runout limit 0.04mm (0.002in) D ow nl oa de d fro m w w w 3 .
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CRANKSHAFT ENG EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 13Nm (1.3 m•kgf, 9.4 ft•lbf) 7 13 8 (x7) 6 (x2) e. ne t 5 er Ti m 12 3 .S co 9 4 4 10 3 ot 3 11 12 7Nm (0.7 m•kgf, 5.1 ft•lbf) w w 20Nm (2.0 m•kgf, 14.5 ft•lbf) fro m w 23Nm (2.3 m•kgf, 16.6 ft•lbf) 1 Order ow nl oa de d 2 7Nm (0.7 m•kgf, 5.1 ft•lbf) Job/Part Q’ty Remove the parts in the order listed. Refer to “ENGINE REMOVEL”. Refer to “CYLINDER HEAD”. Refer to “CYLINDER AND PISTON”.
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CRANKSHAFT ENG 13Nm (1.3 m•kgf, 9.4 ft•lbf) 7 13 8 (x7) 6 (x2) 5 11 ne t 12 4 4 e. 10 3 3 9 12 7Nm (0.7 m•kgf, 5.1 ft•lbf) .S co ot 20Nm (2.0 m•kgf, 14.5 ft•lbf) er Ti m 3 fro m 2 1 w w w 23Nm (2.3 m•kgf, 16.6 ft•lbf) oa de d 7Nm (0.7 m•kgf, 5.
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CRANKSHAFT ENG EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: 8 centerstand 2. Remove: 8 crankcase bolts 1 e. ne t TIP Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. ot er Ti m 1 .S co 3. Remove: 8 right crankcase 1 w D ow nl oa de d fro m 2 w w 1 5-65 NOTICE Tap on one side of the crankcase with a softface hammer 2 .
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CRANKSHAFT ENG EAS00389 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: 8 crankshaft assembly 1 8 timing chain 2 1 TIP 8 Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. 8 The crankshaft assembly cannot be removed if the timing chain is attached onto the crankshaft sprocket. .S co EAS00394 ot er Ti m e. ne t 2 fro m w w w CHECKING THE CRANKSHAFT AND CONNECTING ROD 1.
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CRANKSHAFT ENG 3. Measure: 8 crankshaft width Out of specification JReplace the crankshaft. Crankshaft width 45.45 ~ 45.50mm (1.789 ~ 1.791in) 4. Check: 8crankshaft sprocket 1 Damage/wear JReplace the crankshaft. 8bearing 2 Cracks/damage/wear J Replace the crankshaft. 8oil pump drive gear 3 Damage/wear J Replace the crankshaft. 2 1 ne t 3 ot er Ti m e. 2 oa de d fro m w w w .S co 5. Check: 8crankshaft journal Scratches/wear J Replace the crankshaft.
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CRANKSHAFT ENG EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE(INTAKE SIDE) 1. Check: 8 timing chain Damage/stiffness J Replace the timing chain and camshaft sprocket as a set. .S co EAS00401 ot er Ti m e. ne t 2. Check: 8 timing chain guide (intake side) Damage/wear J Replace. D ow nl oa de d fro m w w w CHECKING THE BEARINGS AND OIL SEALS 1. Check: 8bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement J Replace. 2.
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CRANKSHAFT ENG EAS00408 INSTALLING THE CRANKSHAFT ASSEMBLY 1. Install: 8 timing chain 1 8 crankshaft assembly 2 1 TIP Install the timing chain so it is not visible through the opening in the left crankcase. NOTICE To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. e. ne t 2 oa de d fro m w w w .
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CRANKSHAFT ENG 3. Install: 8 dowel pins 8 right crankcase 1 1 TIP Tap lightly on the right crankcase with a softface hammer. 4. Tighten: 8crankcase bolts T. ne t R. 13Nm(1.3m • kgf, 9.4ft • lbf) er Ti m e. TIP Tighten the crankcase bolts in stages and in a crisscross pattern. D ow nl oa de d fro m w w w .S co ot 5. Apply: 8engine oil (onto the crankshaft pin, bearing and oil delivery hole) 6. Check: 8crankshaft operation Rough movementJRepair.
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FI CHAPTER 6 FUEL INJECTION SYSTEM D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t FUEL INJECTION SYSTEM .................................................................... 6-1 WIRING DIAGRAM ............................................................................ 6-2 ECU’S SELF-DIAGNOSTIC FUNCTION .......................................... 6-4 CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB .................................................................................
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FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM q w e r t y u i o Air filter case Catalytic converter Crankshaft position sensor Engine temperature sensor Spark plug Fuel tank Fuel pump Throttle position sensor O2 sensor .S co ot er Ti m e.
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Br Br Br Br B/L W W B/L (BLACK) Br B Br/L Br (BLACK) G Lg L G o Br q L/Y R/B Ch Y Dg G Lg L 10A 15A 10A R Ch Y Dg Br B i u y B/W LOCK OFF ON MAIN (BLACK) (BLACK) 1 R B W W W W W W Ch e p B L B Lg B/L Dg a s d f Y B Y L/B W/B Br/L1 l B G x B Y B G P B OFF PUSH HORN P g Br (BLACK) Br/L1 Br/L W/B L/B B/W Y B G B HI LO DIMMER ; B R R 7 B L/W R/W G L/B B Y B/W B Ch B c (BROWN) Ch B (BROWN) L N R FLASHER (BLACK) z (B
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FUEL INJECTION SYSTEM ow nl oa de d fro m w w w .S co ot er Ti m e.
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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 system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU.
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FI FUEL INJECTION SYSTEM EAS00901 CHECKING FOR A DEFECTIVE ENGINE TROUBLE WARNING LIGHT BULB The engine trouble warning light comes on for 2 seconds after the main switch has been turned “ON” and when the start switch is being pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective. Main switch OFF Engine trouble warning light Main switch ON Light OFF Light OFF Light ON for 2 seconds ne t Intialize EAS00902 fro m w w w .
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FI FUEL INJECTION SYSTEM Fault code No. 39 Fuel injector 30 41 Lean angle cut-off switch (latch up detected) (open or short circuit) Speed sensor 42 43 Engine startability Vehicle driveability Fuel injector open or short circuit is detected. The vehicle has overturned. Lean angle cut-off switch-open or short circuit is detected. No normal signals are received from the speed sensor. Power supply to fuel injector, fuel pump and ignition coil are not normal.
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FI FUEL INJECTION SYSTEM 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. The engine trouble warning light does not come on. Check the fault code number displayed on the Fl diagnostic tool. Check the operation of following sensors and actuators in the diagnostic mode. Refer to “Diagnostic mode table”.
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FUEL INJECTION SYSTEM FI EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators with connecting the Fl diagnostic tool to the normal mode or the diagnostic monitoring mode. Fl diagnostic tool 90890-03182 (YU-03182) Setting the normal mode ne t TIP The engine speed, engine temperature, and fault code, if detected, can be displayed on the LCD of the Fl diagnostic tool when the tool is connected to the vhicle and is set to the normal mode. Ti m e.
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FUEL INJECTION SYSTEM FI Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the self diag signal connector 1, and then connect the Fl diagnostic-tool 2 as shown. 3. While press the “MODE” button, turn the main switch to “ON”. 2 1 TIP 8 ”DIAG” appears on the LCD of the Fl diagnostic tool. 8 ”POWER” LED (Green) comes on. .S co ot er Ti m e. ne t 4. Press the “UP” button to select the CO adjustment mode “CO” or the diagnostic mode “DIAG”. 5.
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FUEL INJECTION SYSTEM FI Fault code table Probable cause of malfunction Symptom 19 22 24 28 No normal signal is received from the O2 sensor. • • • • • • • • • • Engine temperature sensor-open or short circuit detected. 37 The ISC (idle speed control) valve is stuck fully open. 39 Fuel injector open or short circuit is detected. 41 Lean angle cut-off switch-open or short circuit detected. 42 No normal signals are received from the speed sensor.
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FUEL INJECTION SYSTEM FI EAS00907 Diagnostic mode table TIP 8 Check the intake air temperature and engine temprature as close as possible to the intake air temperature sensor and the engine temperature sensor respectively. 8 If it is not possible to check the intake air temperature, use the ambient temperature as reference.
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FUEL INJECTION SYSTEM FI Communication error with the FI diagnostic tool LCD Display Sympton Probable cause of malfunction Waiting for connection... No signals are received from the ECU. ERROR 4 Commands from the Fl diagnostic tool are not accepted by the ECU. • • • • • Improper installed lead connector in the coupler. The main switch is OFF position. Malfunction in Fl diagnostic tool. Malfunction in ECU.
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FUEL INJECTION SYSTEM Fault code No. 12 Symptom FI No normal signals are received from the crankshaft position sensor. Used diagnostic code No. -Inspection operation item and probable cause 1 Installed condition of sensor. 2 Connected condition of connector. Inspect the coupler for any pins that may have pulled out. Check that the coupler is connected securely. Operation item and countermeasure Check the installed area for looseness or pinching.
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FUEL INJECTION SYSTEM Fault code No. 13 Symptom FI Intake air pressure sensor-open or short circuit detected. Used diagnostic code No. D03 (intake air pressure sensor) Order 1 Inspection operation item and probable cause Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Operation item and countermeasure If there is a malfunction, reper it and connect it securely.
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FUEL INJECTION SYSTEM FI Intake air pressure sensor system malfunction Intake air pressure- sensor hoseor system malfunction (clogged or de(clogged detached). tached hose). Used diagnostic code No. D03 (intake air pressure sensor) Fault code No. Order 1 2 14 Symptom Inspection operation item and probable cause Operation item and countermeasure Connected state of connector Intake air pressure sensor coupler Main wirring harness ECU coupler Defective intake air pressure sensor.
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FUEL INJECTION SYSTEM Fault code No. 16 Symptom FI Stuck throttle position sensor detected. Used diagnostic code No. D01 (throttle position sensor) Order Inspection operation item and probable cause 1 Installed condition of throttle position sensor. 2 Defective throttle position sensor Operation item and countermeasure Check the installed area for looseness or pinching. Check that it is installed in the specified position. Refer to “THROTTLE BODY AND FUEL INJECTOR ”.
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FUEL INJECTION SYSTEM Fault code No. 22 Symptom FI Intake air temperature sensor open or short circuit is detected. Used diagnostic code No. D05 (intake air temperature sensor) Inspection operation item and probable cause 1 Installed condition of sensor 2 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in wireing harness. Check the installed area for looseness or pinching.
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FUEL INJECTION SYSTEM Fault code No. 24 Symptom FI No normal signal is received from the O2 sensor. Used diagnostic code No. -Inspection operation item and probable cause Installed state of O2 sensor. 4 Connected state of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Check fuel pressure Refer to “CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION. Engine temperature sensor open or short circuit is detected.
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FUEL INJECTION SYSTEM Fault code No. 30 Symptom FI The vehicle has overturned. Used diagnostic code No. D08 (lean angle cut-off switch) Raise the vehicle upright. Check the installed area for looseness or pinching. If there is a malfunction, repair it and connect it securely. Lean angle cut-off switch coupler Main wiring harness ECU coupler Reinstated by turning the main switch ON (however, the engine cannot be restarted unless the main switch is first turned OFF). ne t Reinstatement method .
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FUEL INJECTION SYSTEM Fault codeNo. 33 FI Open circuit detected in the primary lead of the ignition coil. Symptom Used diagnostic code No. D30 Order 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in lead. Operation item and countermeasure If there is a malfunction, repair it and connect it securely.
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FUEL INJECTION SYSTEM Fault code No. 39 FI Fuel injector open or short circuit is detected. Symptom Used diagnostic code No. D36 (fuel injector) Order 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in lead wire. Operation item and countermeasure If there is a malfunction, repair it and connect it securely.
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FUEL INJECTION SYSTEM Fault code No. 42 Symptom FI No normal signals are received from the speed sensor. Used diagnostic code No. D07 (speed sensor) Order 1 Connected condition of speedometer connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in speedometer lead. Operation item and countermeasure Reinstatement method If there is a malfunction, repair it and connect it securely.
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FUEL INJECTION SYSTEM Fault code No. 43 Symptom FI Power supply to the fuel injector, fuel pump and ignistion coil are not normal. Used diagnostic code No. D09 (fuel system voltage) 2 3 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Faulty battery Open or short circuit in wiring harness. Operation item and countermeasure Reinstatement method If there is a malfunction, repair it and connect it securely.
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FUEL INJECTION SYSTEM Fault code No. 46 FI Power supply to FI system is not normal. (red lead) Symptom Used diagnostic code No. -- 3 If there is a malfunction, repair it and connect it securely. ECU coupler Reinstated by starting the engine and operating it at idle. Replace or charge the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Replace if defective. Refer to “CHARGING SYSTEM” in chapter 7. Repair or replace if there is an open or short circuit.
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FUEL INJECTION SYSTEM Fault code No. 61 Symptom FI ISC (idle speed control) valve open or short circuit is detected. Used diagnostic code No. D54 (ISC (idle speed control)valve) Order 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Open or short circuit in lead. Operation item and countermeasure If there is a malfunction, repair it and connect it securely.
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THROTTLE BODY AND FUEL INJECTOR FI EAS00909 THROTTLE BODY AND FUEL INJECTOR FUEL TANK 3 10Nm (1.0 m•kgf, 7.2 ft•lbf) Ti m e. ne t 7 w 6 w w 5 7Nm (0.7 m•kgf, 5.1 ft•lbf) .S co ot er 4 oa de d 2 fro m 1 Order D ow nl 4Nm (0.4 m•kgf, 2.9 ft•lbf) Job/Part Q’ty Removing the fuel tank Remarks Remove the parts in the order listed. TIP Place the scooter on a suitable stand.
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THROTTLE BODY AND FUEL INJECTOR FI 3 10Nm (1.0 m•kgf, 7.2 ft•lbf) 7 ot er 6 .S co 5 7Nm (0.7 m•kgf, 5.1 ft•lbf) Ti m e. ne t 4 w w 1 fro m w 2 oa de d 4Nm (0.4 m•kgf, 2.9 ft•lbf) Job/Part ow nl Order Fuel pump 7 Fuel tank Remarks 1 Refer to “REMOVING THE FUEL PUMP” and “INSTALLING THE FUEL PUMP”. Refer to “REMOVING THE FUEL TANK” and “INSTALLING THE FUEL TANK AND FUEL HOSE”. For installation, reverse the removal procedure.
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THROTTLE BODY AND FUEL INJECTOR FI FUEL INJECTOR AND FUEL HOSE 12Nm (1.2 m•kgf, 8.7 ft•lbf) 10Nm (1.0 m•kgf, 7.2 ft•lbf) 3 2 4 e. ne t 7Nm (0.7m•kgf, 5.1 ft•lbf) Ti m 1 Job/Part Q’ty D Order ow nl oa de d fro m w w w .S co ot er 5 1 2 3 4 5 Removing the fuel injector and fuel hose Fuel tank Fuel hose holder (to frame) Fuel hose holder (to intake manifold) Clamp Fuel injector coupler Fuel injector and fuel hose Remarks Remove the parts in the order listed.
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THROTTLE BODY AND FUEL INJECTOR FI THROTTLE BODY 1 6 5 e. ne t 5Nm (0.5 m•kgf, 3.6 ft•lbf) Ti m 3 .S co ot er 2 w w w 4 Job/Part Q’ty D Order ow nl oa de d fro m 3Nm (0.3 m•kgf, 2.2 ft•lbf) Removing the throttle body Air filter/breather hose 1 2 3 4 5 6 Fuel tank Fuel pipe (to throttle body) Throttle body clamp screw Sensor module coupler ISC (idle speed control) valve coupler Throttle cable assembly Throttle body 1 1 1 1 1 1 Remarks Remove the parts in the order listed.
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THROTTLE BODY AND FUEL INJECTOR FI REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove : 8 fuel return hose 8 fuel hose 1 1 NOTICE ot er Ti m e. ne t 8 Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. 8 Although the fuel has been removed from the fuel tank be careful when removing the fuel hose, since there may be fuel remaining in it. 8 Do not disconnect the fuel hose from the fuel hose connector.
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THROTTLE BODY AND FUEL INJECTOR FI REMOVING THE FUEL PUMP 1. Remove: 8 fuel tank Refer to “REMOVING THE FUEL TANK”. 2. Remove: 8fuel pump NOTICE 8 Do not drop the fuel pump or give it a strong shock. 8 Do not touch the base section of the fuel sender. ne t EAS00911 NOTICE D ow nl oa de d fro m w w w .S co ot er Ti m e. The fuel pump should not be disassembled.
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THROTTLE BODY AND FUEL INJECTOR FI EAS00912 CHECKING THE FUEL INJECTOR 1. Check: 8 fuel injector Damage J Replace. EAS00913 e. ne t CHECKING THE THROTTLE BODY 1. Check: 8 throttle body Cracks/damage J Replace the throttle body. 2. Check: 8 butterfly valve Damage/scratches/wear J Replace. ot er Ti m 1 D ow nl oa de d fro m w w w .S co NOTICE 6-32 8 Do not adjust the stop screw 1. 8 Do not clean the throttle body ass’y using carburetor cleaner or compressed air.
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THROTTLE BODY AND FUEL INJECTOR FI INSTALLING THE FUEL PUMP 1. Install : 8 fuel pump T. R. 4Nm (0.4m • kgf, 2.9ft • lbf) e. ot er Ti m A Forward ne t TIP 8 Do not damage the installion surface of the fuel tank when installing the fuel pump. 8 Always use a new fuel pump gasket. 8 Align the projection a on the fuel pump with the alignment mark b on the fuel tank. 8 Tighten the fuel pump bolts in the proper tightening sequence as shown and torque them in two stages. T. fro m w w w .
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THROTTLE BODY AND FUEL INJECTOR FI EAS00915 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: 8 pressure regulator operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the battery box cover and front cover. Refer to “COVER AND PANEL” in chapter 3. b. Remove the fuel hose 1 from the fuel pump. 1 NOTICE Ti m e. ne t Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose, since there may be fuel remaining in it. .
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THROTTLE BODY AND FUEL INJECTOR FI EAS0091 6 L P/W Br/W 1 3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester to the terminals of the throttle position sensor. Positive tester probe J blue terminal 1 Negative tester probe J black/blue terminal 2 e. ne t Digital circuit tester 90890-03174 fro m w w w .S co ot er Ti m b. Measure the throttle position sensor voltage. Out of specification J Replace or repair the wire harness.
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THROTTLE BODY AND FUEL INJECTOR FI EAS00916 CHECKING THE ISC (IDLE SPEED CONTROL) VALVE P 1 G/Y 2 Sb Gy TIP Do not remove the ISC (idle speed control) valve unit completely from the throttle body assembly. 4 3 1. Check: 8 ISC (idle speed control) valve e. ne t ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ISC (idle speed control) valve coupler from the ISC (idle speed control) valve. b. Connect the digital circuit tester to the terminals of the ISC (idle speed control) valve.
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ELEC - + CHAPTER 7 ELECTRICAL SYSTEM D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t ELECTRICAL COMPONENTS ................................................................ 7-1 WIRING DIAGRAM ................................................................................... 7-2 CHECKING SWITCH CONTINUITY ........................................................ 7-4 CHECKING THE SWITCHES ...................................................................
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ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS q w e r t y u i o Spark plug cap Fuel pump Starter relay Horn Turn signal relay Starting circuit cut-off relay Headlight relay Stator coil Wire harness ne t Main switch Front brake light switch Rectifier/regulator Rear brake light switch Sidestand switch Battery Main fuse ECU Fuse box Ignition coil e 2 e. 4 w .
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Br Br Br Br B/L W W B/L (BLACK) Br B Br/L Br (BLACK) G Lg L G o Br q L/Y R/B Ch Y Dg G Lg L 10A 15A 10A R Ch Y Dg Br B i u y B/W LOCK OFF ON MAIN (BLACK) (BLACK) 1 W W R B W W W W W W W W Ch e B L B p L/Y Lg B/L Dg a s d f Y B Y L/B W/B Br/L1 l B G x B Y B G P B OFF PUSH HORN P g Br (BLACK) Br/L1 Br/L W/B L/B B/W Y B G B HI LO DIMMER ; B R R 7 B L/W R/W G L/B B Y B/W B c (BROWN) Ch B (BROWN) Ch B L N R FLASHER
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WIRING DIAGRAM .S co ot er Ti m e. ne t Color Code B .................. Black Br ................Brown Ch ............... Chocolate Dg ............... Dark green G ................. Green Gy ............... Gray L .................. Blue Lg ................Light green Or ................Orange P .................. Pink R ................. Red Sb ................Sky blue W ................. White Y .................. Yellow B/L ............... Black/Blue B/G .............. Black/Green B/R ............
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CHECKING SWITCH CONTINUITY ELEC - + EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. NOTICE ne t Never insert the tester probes into the coupler terminal slots a. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads. Ti m e.
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- ELEC CHECKING THE SWITCHES + EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear J Repair or replace. Improperly connected J Properly connect. Incorrect continuity reading J Replace the switch. 1 9 B B B B (BLACK) ne t (BLACK) L / B Y HI LO er Y G OFF ON 8 .
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CHECKING THE BULBS AND BULB SOCKETS ELEC - + EAS00733 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear J Repair or replace the bulb, bulb socket or both. Improperly connected J Properly connect. No continuity J Repair or replace the bulb, bulb socket or both. B TYPES OF BULBS The bulbs used on this scooter are shown in the illustration on the left.
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CHECKING THE BULBS AND BULB SOCKETS ELEC - + NOTICE 8 Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler. 8 Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
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CHECKING THE BULBS AND BULB SOCKETS ELEC - + Pocket tester 90890-03112 (YU-03112-C) TIP Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. b. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity.
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Br Br Br Br W B/L B/L W Br B Br/L Br (BLACK) G Lg L G o Br q L/Y R/B (BLACK) 10A 15A 10A Ch Y Dg G Lg L i u y B/W LOCK OFF ON R 1 Ch Y Dg Br B (BLACK) (BLACK) MAIN W R B W W W W W W Ch e p B L B a s d f Y Y L/B W/B Br/L1 l P g Br (BLACK) Br/L1 Br/L W/B L/B P B ; B R R B/W 7 B L/W R/W G L/B B Y B/W B FLASHER (BLACK) z (BLACK) B1 B w L/W R/W L/W Br/W h Br R/W Br/W B Lg B/L Dg B B G x Y B G B OFF PUSH HORN Y B
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IGNITION SYSTEM EAS00736 ELEC - + EAS00738 TROUBLESHOOTING 1.Main and ignition fuses 8 Check the main and ignition fuses for continuity. Refer to “CHECKING THE FUSES” in chapter 3. 8 Are the main and ignition fuses OK? The ignition system fails to operate (no spark or intermittent spark). Check: 1. main and ignition fuses 2. battery 3. spark plug 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. crankshaft position sensor resistance 8. main switch 9.
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IGNITION SYSTEM EAS00742 ELEC - + EAS00744 5. Spark plug cap resistance 8 Remove the spark plug cap from the spark plug lead. 8 Connect the pocket tester (“Ω × 1k” range) to the spark plug cap as shown. 8 Measure the spark plug cap resistance. e. ne t 4. Ignition spark gap 8 Disconnect the spark plug cap from the spark plug. 8 Connect the ignition checker 1 as shown. 2 Spark plug cap 8 Set the main switch to “ON”. 8 Measure the ignition spark gap a.
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IGNITION SYSTEM ELEC - + EAS00748 7. Crankshaft position sensor resistance 8 Disconnect the crankshaft position sensor coupler from the wire harness. 8 Connect the pocket tester (Ω × 100) to the crankshaft position sensor coupler as shown. Positive tester probe J white/red 1 Negative tester probe J white/blue 2 8 Measure the primary coil resistance. Primary coil resistance 2.16 ~ 2.64 Ω at 20°C (68°F) 1 2 Ti m e. ne t 8 Connect the pocket tester (Ω × 1k) to the ignition coil as shown.
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IGNITION SYSTEM EAS00749 - + 11. Lean angle cut-off switch 8 Remove the lean angle cut-off switch. 8 Connect the pocket tester (Ω × 1) to the lean angle cut-off switch terminals as shown. 8. Main switch 8 Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the main switch OK? YES ELEC Positive tester probe J blue 1 Negative tester probe J yellow/green 2 NO 1 Replace the main switch. 2 EAS00750 e. Ti m Lean angle cut-off switch voltage Less than 45° a J 0.
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IGNITION SYSTEM ELEC EAS00754 12. Wiring 8 Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. 8 Is the ignition system’s wiring properly connected and without defects? YES NO Properly connect or repair the ignition system’s wiring. D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t Replace the ECU.
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Br Br Br Br W B/L B/L W Br B Br/L Br (BLACK) G Lg L G o Br q L/Y R/B (BLACK) 10A 15A 10A Ch Y Dg G Lg L i u y B/W LOCK OFF ON R 1 Ch Y Dg Br B (BLACK) (BLACK) MAIN W W B/L R B W W W W W W W W W W Ch e p B L B Lg B/L Dg a s d f Y B Y L/B W/B Br/L1 l B G x B Y B G P B OFF PUSH HORN P g Br (BLACK) Br/L1 Br/L W/B L/B B/W Y B G B HI LO DIMMER ; B R R 7 B L/W R/W G L/B B Y B/W B Ch B c (BROWN) Ch B (BROWN) L N R FLA
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ELECTRIC STARTING SYSTEM ELEC - + EAS00756 r 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 at least one of the following conditions is met: 8 The brake lever (front or rear) is pulled to the handlebar (the brake light switch is closed) and the sidestand is up (the sidestand switch is closed). 3 9 fro m w 0 w w q 5 d 7 D ow nl oa de 6 ne t .
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ELECTRIC STARTING SYSTEM EAS00757 - + EAS00738 TROUBLESHOOTING 1.Main, signal and ignition fuses 8 Check the main, signal and ignition fuses for continuity. Refer to “CHECKING THE FUSES” in chapter 3. 8 Are the main, signal and ignition fuses OK? The starter motor fails to turn. Check: 1. main, signal and ignition fuses 2. battery 3. starter motor 4. starting circuit cut-off relay 5. starter relay 6. main switch 7. engine stop switch 8. brake light switch (front and rear) 9. sidestand switch 10.
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ELECTRIC STARTING SYSTEM EAS00758 - ELEC + EAS00759 3. Starter motor 8 Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3. 4. Starting circuit cut-off relay 8 Disconnect the starting circuit cut-off relay coupler from the wire harness. 8 Connect the pocket tester (Ω × 1 ) and battery (12 V) to the starting circuit cut-off relay coupler as shown.
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ELECTRIC STARTING SYSTEM EAS00761 ELEC - + EAS00750 5. Starter relay 8 Disconnect the starter relay coupler from the coupler. 8 Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay coupler as shown. 7. Engine stop switch 8 Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the engine stop switch OK? YES NO Positive battery terminal J red/white 1 Negative battery terminal J blue/white 2 Replace the right handlebar switch.
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ELECTRIC STARTING SYSTEM ELEC EAS00764 10. Start switch 8 Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the start switch OK? YES NO Replace the right handlebar switch. EAS00766 e. Ti m NO ot er YES ne t 11. Wiring 8 Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. 8 Is the starting system’s wiring properly connected and without defects? D ow nl oa de d fro m w w w .
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ELECTRIC STARTING SYSTEM ELEC - + EAS00767 STARTER MOTOR 1 7Nm (0.7 m•kgf, 5.1 ft•lbf) Job/Part fro m oa de Order d 4Nm (0.4 m•kgf, 2.9 ft•lbf) w w w .S co ot er Ti m e. ne t 2 Q’ty ow nl Removing the starter motor Seat/trunk D Air filter/breather hose 1 2 1 2 3 4 5 6 7 8 9 0 1/1 1 Starter motor lead/earth lead Starter motor Remarks Remove the parts in the order listed. Refer to “COVER AND PANEL” in chapter 3. Refer to “ENGINE REMOVEL” in chapter 5. Disconnect.
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ELECTRIC STARTING SYSTEM ELEC - + 1 7Nm (0.7 m•kgf, 5.1 ft•lbf) .S co ot er Ti m e. ne t 2 Job/Part Q’ty Remarks For assembly, reverse the disassembly procedure. D ow nl oa de d Order fro m w w w 4Nm (0.4 m•kgf, 2.
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ELECTRIC STARTING SYSTEM ELEC - + EAS00769 CHECKING THE STARTER MOTOR 1. Check: 8 commutator Dirt J Clean with 600-grit sandpaper. 2. Measure: 8 commutator diameter a Out of specification J Replace the starter motor. Commutator wear limit 21 mm (0.83in) er Ti m e. ne t 3. Measure: 8 mica undercut b Out of specification J Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. .S co ot Mica undercut 1.5 mm (0.
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ELECTRIC STARTING SYSTEM ELEC - + 5. Measure: 8 brush length a Out of specification J Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14in) a 6. Measure: 8 brush spring force Out of specification J Replace the brush springs as a set. e. ne t Brush spring force 5.52 ~ 8.28 N/mm (0.56 ~ 0.84kgf/ mm, 1.24 ~ 1.86lbf/in) ot er Ti m 7. Check: 8 gear teeth Damage/wear J Replace the gear. D ow nl oa de d fro m w w w .S co 8.
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ELECTRIC STARTING SYSTEM ELEC - + EAS00772 1 ASSEMBLING THE STARTER MOTOR 1. Install: 8 brush spring 8 brush 1 2. Install: 8 armature 8 starter motor front cover 1 8 O-ing 2 New 8 stator 3 8 O-ing 4 New 8 starter motor rear cover 5 2 1 ot er Ti m e. 4 .S co 3. Install: 8 O-rings New 8 bolts 1 R. fro m T. w w w 1 4Nm (0.4m • kgf, 2.9ft • lbf) ow nl oa de d TIP Align the match marks a on the stator with the match marks b on the front and starter motor rear covers.
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Br Br Br Br W B/L B/L W Br B Br/L Br (BLACK) G Lg L G o Br q L/Y R/B (BLACK) 10A 15A 10A Ch Y Dg G Lg L i u y B/W LOCK OFF ON R 1 Ch Y Dg Br B (BLACK) (BLACK) MAIN W R B W W W W W W Ch e p B L B Lg B/L Dg a s d f Y B Y L/B W/B Br/L1 l B G x B Y B G P B OFF PUSH HORN P g Br (BLACK) Br/L1 Br/L W/B L/B B/W Y B G B HI LO DIMMER ; B R R 7 B L/W R/W G L/B B Y B/W B Ch B c (BROWN) Ch B (BROWN) L N R FLASHER (BLACK) z
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CHARGING SYSTEM EAS00774 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The battery is not being charged. Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil resistance 5. wiring connections (of the entire charging system) Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) 8 Is the battery OK? YES 8 Clean the battery terminals. 8 Recharge or replace the battery. Ti m e.
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CHARGING SYSTEM NO The charging circuit is OK. YES e. ne t 4. Stator coil resistance 8 Disconnect the starter coil coupler from the wire harness. 8 Connect the pocket tester (Ω ×1) to the stator coil as shown. er Ti m Positive tester probe J white 1 Negative tester probe J white 2 .
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Br Br Br Br B/L W W B/L (BLACK) Br B Br/L Br (BLACK) G Lg L G o Br q L/Y R/B Ch Y Dg G Lg L 10A 15A 10A R Ch Y Dg Br B i u y B/W LOCK OFF ON MAIN (BLACK) (BLACK) 1 R B W W W W W W Ch e p B L B Lg B/L Dg a s d f Y B Y L/B W/B Br/L1 l B G x B Y B G P B OFF PUSH HORN P g Br (BLACK) Br/L1 Br/L W/B L/B B/W Y B G B HI LO DIMMER ; B R R 7 B L/W R/W G L/B B Y B/W B Ch B c (BROWN) Ch B (BROWN) L N R FLASHER (BLACK) z (B
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LIGHTING SYSTEM EAS00781 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Any of the following fail to light: headlight, high beam indicator light, taillight or meter light. Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) Check: 1. main and headlight fuses 2. battery 3. main switch 4.
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LIGHTING SYSTEM - + EAS00788 5. Headlight relay 8 Disconnect the headlight relay coupler from the wire harness. 8 Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay coupler as shown. CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb and socket 8 Check the headlight bulb and socket for continuity.
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LIGHTING SYSTEM YES 3. Voltage 8 Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown. ne t Headlight coupler Ti m 3 G B er B e. A Y B 4 w w oa de d Meter assembly coupler fro m High beam indicator light Positive tester probe J yellow 5 Negative tester probe J black 6 w .S co ot 2 6 DC20V B Lg Br G Dg Y Ch 5 D ow nl L 8 8 8 8 8 Set the main switch to “ON”. Set the engine stop switch to “#”. Start the engine.
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LIGHTING SYSTEM EAS00789 - + 2. Voltage 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. 2. The meter light fails to come on. 1. Meter light bulb and socket 8 Check the meter light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Are the meter light bulb and socket OK? YES ELEC Positive tester probe J blue 1 Negative tester probe J black 2 NO Replace the meter light bulb, socket or both.
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LIGHTING SYSTEM ELEC EAS00790 3. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket 8 Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Are the tail/brake light bulb and socket OK? YES NO e. ne t Replace the tail/brake light bulb, socket or both. .S co ot er Ti m 2. Voltage 8 Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown.
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Br Br Br Br W B/L B/L W Br B Br/L Br (BLACK) G Lg L G o Br q L/Y R/B (BLACK) 10A 15A 10A Ch Y Dg G Lg L i u y B/W LOCK OFF ON R 1 Ch Y Dg Br B (BLACK) (BLACK) MAIN W W B/L R B W W W W W W W W W W Ch e p B L B Lg B/L Dg a s d f Y B Y L/B W/B Br/L1 l B G x B Y B G P B OFF PUSH HORN P g Br (BLACK) Br/L1 Br/L W/B L/B B/W Y B G B HI LO DIMMER ; B R R 7 B L/W R/W G L/B B Y B/W B Ch B c (BROWN) Ch B (BROWN) L N R FLA
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SIGNALING SYSTEM EAS00794 ELEC - + EAS00739 TROUBLESHOOTING 2. Battery 8 Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. 8 Any of the following fail to light: turn signal light, brake light or an indicator light. 8 The horn fails to sound. Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) Check: 1. main and signaling fuses 2. battery 3. main switch 4.
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SIGNALING SYSTEM EAS00796 - + 3. Horn 8 Disconnect the pink connector at the horn terminal. 8 Connect a jumper lead 1 to the horn terminal and ground the jumper lead. 8 Set the main switch to “ON”. 8 Push the horn switch. 8 Does the horn sound? CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. 1. Horn switch 8 Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. 8 Is the horn switch OK? YES ELEC NO Br P Replace the left handlebar switch. e. ne t 1 Ti m 2.
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SIGNALING SYSTEM EAS00798 1. Tail/brake light bulb and socket 8 Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” 8 Are the tail/brake light bulb and socket OK? + Positive tester probe J green/yellow 1 Negative tester probe J black 2 NO 1 DC20V G/Y L B Ch Dg G/Y B Dg Ch L 2 e. ne t Replace the tail/brake light bulb, socket or both. 8 Set the main switch to “ON”. 8 Pull in the brake levers.
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SIGNALING SYSTEM EAS00799 - + 4. Voltage 8 Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. 3. The turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal indicator light bulb and socket 8 Check the turn signal indicator light bulb and socket for continuity.
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SIGNALING SYSTEM ELEC - + 5. Voltage 8 Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. 6. Voltage 8 Connect the pocket tester (DC 20 V) to the turn signal light coupler or meter assembly coupler (wire harness side) as shown.
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SIGNALING SYSTEM EAS00804 ELEC - + 2. Voltage 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. 4. The fuel level gauge fails to operate. 1. Fuel sender 8 Remove the fuel pump from the fuel tank. 8 Connect the pocket tester (Ω × 1) to the fuel sender coupler (wire harness side) as shown. Positive tester probe J brown 1 Negative tester probe J black 2 Positive tester probe J green 1 Negative tester probe J black 2 G Lg L Br B - e.
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SIGNALING SYSTEM ELEC 3. Fuel level gauge 8 Set the main switch to “ON”. 8 Move the float up 1 or down 2. 1 w w w 8 Check that the fuel level gauge needle moves to “F” or “E”. .S co ot er Ti m e. ne t 2 oa de d fro m TIP Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes. ow nl 8 Does the fuel level gauge needle move appropriately? NO D YES This circuit is OK. Replace the speedometer. 4.
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TRBL SHTG CHAPTER 8 TROUBLE SHOOTING D ow nl oa de d fro m w w w .S co ot er Ti m e. ne t STARTING FAILURE/HARD STARTING................................................. 8-1 ENGINE .............................................................................................. 8-1 FUEL SYSTEM .................................................................................. 8-1 ELECTRICAL SYSTEMS ..................................................................
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STARTING FAILURE/HARD STARTING TRBL SHTG EAS00844 TROUBLESHOOTING TIP The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
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INCORRECT ENGINE IDLING SPEED/POOR MEDIUMAND-HIGH-SPEED PERFORMANCE TRBL SHTG EAS00847 EAS00848 INCORRECT ENGINE IDLING SPEED POOR MEDIUM-AND-HIGHSPEED PERFORMANCE ENGINE Cylinder and cylinder head 8 Incorrect valve clearance 8 Damaged valve train components Refer to “STARTING FAILURE/HARD STARTING”.
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FAULTY CLUTCH/OVERHEATING TRBL SHTG 8 Worn primary pulley weight EAS00853 FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL NOT MOVE Primary fixed sheave 8 Worn primary fixed sheave V-belt 8 Bent, damaged or worn V-belt 8 Slipping V-belt Primary sliding sheave 8 Worn primary sliding sheave Secondary fixed sheave 8 Worn secondary fixed sheave Primary pulley cam and primary pulley slider 8 Damaged or worn primary pulley cam 8 Damaged or worn primary pulley slider Secondary sliding sheave 8 Worn secondar
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POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING TRBL SHTG EAS00859 EAS00862 POOR BRAKING PERFORMANCE UNSTABLE HANDLING Disc brake 8 Worn brake pad 8 Worn brake disc 8 Air in hydraulic brake system 8 Leaking brake fluid 8 Faulty brake caliper kit 8 Faulty brake caliper seal 8 Loose union bolt 8 Damaged brake hose 8 Oil or grease on the brake disc 8 Oil or grease on the brake pad 8 Incorrect brake fluid level Handlebar 8 Bent or improperly installed handlebar Steering head components
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FAULTY LIGHTING OR SIGNALING SYSTEM EAS00866 TRBL SHTG TURN SIGNAL REMAINS LIT 8 Faulty turn signal relay 8 Burnt-out turn signal bulb FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON 8 Wrong headlight bulb 8 Too many electrical accessories 8 Hard charging 8 Incorrect connection 8 Improperly grounded circuit 8 Poor contacts (main switch) 8 Burnt-out headlight bulb 8 Faulty headlight relay TURN SIGNAL BLINKS QUICKLY 8 Incorrect turn signal bulb 8 Faulty turn signal relay 8 Burnt-out turn si
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YW125Y WIRING DIAGRAM (BLACK) (BLACK) (BLACK) (BLACK) 2 1 10A , 20A et 4 5 7 8 rT im 6 # q LOCK OFF ON 9 (BLACK) (RED) (RED) .S co ot e MAIN . e.
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et e. n im er T co ot .S w w w m fro ad ed nl o ow D Yamaha Motor Canada Ltd.