MAXTER 125 Service Manual

XQ125 XQ150
5HT1-AE2
2001
SERVICE MANUAL
EASM0000
XQ125 / XQ150 SERVICE MANUAL 2001 by MBK Industrie 2nd edition, April 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.
EASM0001
NOTICE
This manual was produced by the MBK Industrie primarily for use by Yamaha and MBK 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 and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. MBK Industrie is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. TECHNICAL DOCUMENTATION MBK INDUSTRIE
EAS00005
IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander or a person checking or repairing the scooter.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the scooter. A NOTE provides key information to make procedures easier or clearer.
NOTE:
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. 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". Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears. Sub-section titles appear in smaller print than the section title. To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS". A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. Jobs requiring more information (such as special tools and technical data) are described sequentially.
CYLINDER AND PISTON

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ENG
CYLINDER AND PISTON

EAS00253
ENG
CYLINDER AND PISTON
REMOVING THE CYLINDER AND PISTON 1. Remove: piston pin clip piston pin piston
CAUTION: Do not use a hammer to drive the piston pin out.
6 4 5 3
NOTE: 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. Before removing the piston pin, deburr the piston pin clips groove and the pistons pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller. Piston pin puller 90890-01304
10
11
7 2. Remove: top ring 2nd ring oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.
T.R
12 Nm (1.2 mkg)
FW
Order
Job/Part Removing the cylinder and piston Cylinder head Cylinder bolt Timing chain guide (exhaust side) Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring (top) Piston ring (2nd) Oil ring
Qty
Remarks Remove the parts in the order listed. Refer to CYLINDER HEAD section.
1 2 3 4 5 6 7 8 9 10 11
2 1 1 2 1 2 1 1 1 1 1 For installation, reverse the removal procedure.
EAS00255
CHECKING THE CYLINDER AND PISTON 1. Check: piston wall cylinder wall Vertical scratches Rebore or replace the cylinder, and replace the piston and piston rings as a set.
4 - 23
4 - 24
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SYMBOLS GEN INFO SPEC

The following symbols are not relevant to every vehicle. to indicate the subject of each Symbols chapter. General information Specifications Periodic checks and adjustments Engine Cooling system Carburetor Chassis Electrical system Troubleshooting
CHK ADJ
ENG
COOL
CARB
CHAS
ELEC
Symbols to indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data
TRBL SHTG
T.
k 21
k 22
k 23
Symbols to k in the exploded diagrams indicate 23 the types of lubricants and lubrication points. Engine oil Gear oil Molybdenum disulfide oil k Wheel bearing grease 21 k Lithium soap base grease 22 k Molybdenum disulfide grease 23 Symbols k to k in the exploded diagrams 24 25 indicate the following. k Apply locking agent (LOCTITE) 24 k Use a new one 25
k 24
k 25
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TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM CARBURETOR CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING
GEN INFO
1 2 3 4 5 6 7 8 9
SPEC
CHK ADJ
ENG
COOL
CARB
CHAS
ELEC
TRBL SHTG
GEN INFO
GEN INFO
CHAPTER 1. GENERAL INFORMATION
SCOOTER IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................... 1-1 MODEL LABEL ........................................................................................ 1-1 FEATURES ................................................................................................... 1-2 OIL INDICATOR LIGHT ........................................................................... 1-2 ODOMETER/TRIPMETER READING MODE ......................................... 1-2 BATTERY VOLTAGE/FUEL GAUGE ...................................................... 1-2 THE CLOCK ............................................................................................. 1-3 AUTO-CHOKE SYSTEM ......................................................................... 1-3 IMPORTANT INFORMATION ...................................................................... PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ REPLACEMENT PARTS ........................................................................ GASKETS, OIL SEALS AND O-RINGS .................................................. LOCK WASHERS/PLATES AND COTTER PINS ................................... BEARINGS AND OIL SEALS .................................................................. CIRCLIPS ................................................................................................ 1-4 1-4 1-4 1-4 1-5 1-5 1-5
CHECKING THE CONNECTIONS ............................................................... 1-6 SPECIAL TOOLS .......................................................................................... 1-7
SCOOTER IDENTIFICATION
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GEN INFO
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EASM0002
VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the frame.
ZAUM0113
EASM0003
MODEL LABEL The model label is affixed under the seat. This information will be needed to order spare parts.
ZAUM0114
1-1
FEATURES
EASM0004
GEN INFO
FEATURES
OIL INDICATOR LIGHT FUNCTION Pulses (travel distance signals) from the speedometer are counted and cause the oil indicator light to come on at 500 km for the first time and thereafter every 3,000 km. In this way, the light indicates the time for oil change. RESETTING PROCEDURE To reset the oil change indicator light 1) Press the TRIP button while turning the key to ON. 2) Release the button and the oil change indicator light will go off. NOTE: To reset the oil change indicator light before the periodic oil change interval has been reached, follow the above procedure. ODOMETER/TRIPMETER READING MODE The odometer and tripmeter can be set to count in either miles or kilometers according to the following procedure. 1) Turn the key to ON. 2) Press the TRIP button until the current mode appears in the dispaly: CONT (continental) for kilometer mode and EnGL (English) for the mile mode. 3) Press the TRIP button to switch mode. 4) Press the TRIP button for two seconds to confirm the setting. NOTE: The odometer/tripmeter reading mode can be changed any number of times while the odometer reading is below 10, but it cannot changed anymore after the reading has reached 10. Switching between the mile and the kilometer mode does not change or convert the current odometer/ tripmeter reading. BATTERY VOLTAGE/FUEL GAUGE When the key is turned to OFF, the voltage/fuel gauge indicates the battery voltage. NOTE: If the battery voltage drops to 10V, refer to CHECKING THE BATTERY section in chapter 3. When the key is turned to ON, the voltage/fuel gauge indicates the amount of fuel in the fuel tank after indicating the battery voltage for two seconds.
1-2
FEATURES
GEN INFO
THE CLOCK Setting the clock To set the clock: 1) Make sure that the key is turned to OFF. 2) Press the TRIP button for two seconds and the hour display will flash. 3) Press the TRIP button to set the hours. 4) Press the TRIP button for two seconds, and the first minute digit will flash. 5) Press the TRIP button to set the first minute digit. 6) Press the TRIP button for two more seconds, and the second minute digit will flash. 7) Press the TRIP button to set the second minute digit. 8) Press the TRIP button for two seconds to set the clock. AUTO-CHOKE SYSTEM This system is the parallel connection of the ignitor unit circuit and the thermo switch as shown, detecting the engine temperature, and facilitates the restarting with the warm engine. Circuit diagram
Main switch Ignitor unit
Fuse Battery
Thermo switch
Ignition C.P.U
Auto-choke
Auto-choke operation Engine condition Start with the cold engine Thermo switch OFF Ignitor unit circuit OFF Auto-choke Activates Crank with the cold engine OFF ON Activates Crank with the warm engine ON ON Not activate Restart with the warm engine ON OFF Not activate
1-3
IMPORTANT INFORMATION
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GEN INFO
PREPARATION FOR REMOVAL AND DISASSEMBLY 1.Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2.Use only the proper tools and cleaning equipment. Refer to 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. Mated parts must always be reused or replaced as an assembly. 4.During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5.Keep all parts away from any source of fire.
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REPLACEMENT PARTS 1.Use only genuine Yamaha and MBK parts for all replacements. Use oil and grease recommended by Yamaha or MBK for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
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GASKETS, OIL SEALS AND O-RINGS 1.When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2.During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.
1-4
EAS00023
GEN INFO
LOCK WASHERS / PLATES AND COTTER PINS 1.After removal, replace all lock washers / plates and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturers marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium soap base grease. Oil bearings liberally when installing, if appropriate. Oil seal
CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces.
Bearing
EAS00025
CIRCLIPS 1.Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip , make sure the sharp-edged corner is positioned opposite the thrust that the circlip receives. Shaft
1-5
CHECKING THE CONNECTIONS

EAS00026
GEN INFO
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1.Disconnect: lead coupler connector
2.Check: lead coupler connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times.
3.Check: all connections Loose connection Connect properly. NOTE: If the pin up. on the terminal is flattened, bend it
4.Connect: lead coupler connector
NOTE: Make sure all connections are tight. 5.Check: continuity (with the pocket tester) Pocket tester 90890-03112 NOTE: If there is no continuity, clean the terminals. When checking the wire harness, perform steps 1 to 3. As a quick remedy, use a contact revitalizer available at most part stores.
1-6
SPECIAL TOOLS
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GEN INFO
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.
Tool No. 90890-01083 90890-01084
Tool name/usage Slide hammer bolt (M6) Weight These tools are used to remove or installing the rocker arms shafts.
Illustration
90890-01235
Rotor holding tool This tool is used to remove the flywheel magneto.
90890-01268 90890-01403
Ring nut wrench Steering nut wrench These tools are used to loosen and tighten the steering ring nuts.
90890-01294 90890-01326
Damper rod holder T-handle These tools are used for disassembling or assembling the front fork.
90890-01304
Piston pin puller This tool is used to remove the piston pins.
90890-01312
Fuel level gauge This tool is used to measure the fuel level in the float chamber.
90890-01337 90890-01464
Clutch spring holder Clutch spring holder arm These tools are used for removing the nut with holding the compression spring.
1-7
SPECIAL TOOLS
Tool No. 90890-01367 90890-01368 Tool name/usage Fork seal driver weight Frok seal driver attachment These tools are used when installing the fork seal. 90890-01701 Sheave holder This tool is used to hold the secondary sheave when removing or installing the nut. 90890-03111 Valve adjusting tool This tool is necessary for adjusting valve clearance. 90890-03112 Pocket Tester This instrument is invaluable for checking the electrical system. 90890-03113 Engine tachometer This tool is needed for detecting the engine rpm. 90890-03141 Timing light This tool is needed for detecting ignition timing. 90890-04019 90890-04108 Valve spring compressor Attachment These tools are used when removing or installing the valve and the valve spring. 90890-04116 Valve guide remover This tool is used to remove the valve guide.
GEN INFO
Illustration
1-8
SPECIAL TOOLS
Tool No. 90890-04117 Tool name/usage Valve guide installer This tool is needed to install the valve guide spring. 90890-04118 Valve guide reamer This tool is used to rebore the valve guide. 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. 90890-85505 Yamaha bond No. 1215 This sealant (bond) is used for crankcase mating surface, etc. 90890-03081 Compression gauge This gauge is used to measure the engine compression.
GEN INFO
Illustration
1-9
SPEC
SPEC
CHAPTER 2. SPECIFICATIONS
GENERAL SPECIFICATIONS ...................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................. 2-4 ENGINE ................................................................................................... 2-4 CHASSIS ................................................................................................. 2-8 ELECTRICAL .........................................................................................2-10 CONVERSION TABLE ................................................................................ 2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS ............................ 2-13 TIGHTENING TORQUES ........................................................................... 2-14 TIGHTENING TORQUES (ENGINE) ..................................................... 2-14 TIGHTENING TORQUES (CHASSIS) ................................................... 2-16 LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-17 ENGINE ................................................................................................. 2-17 CHASSIS ............................................................................................... 2-18 COOLING SYSTEM DIAGRAMS ............................................................... 2-19 LUBRICATION DIAGRAMS ....................................................................... 2-21 CABLE ROUTING ....................................................................................... 2-23
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
Item Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Engine Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Standard compression pressure (at sea level) Starting system type Lubrication system Oil capacity Engine oil
-20 -10 Temp. 0 10 20 30
XQ125 [XQ150] 1.920 mm 750 mm 1.180 mm 824 mm 1.400 mm 118 mm 2.050 mm 130 kg 124 kg Liquid cooled 4-stroke, SOHC Forward inclined single cylinder 124 cm3 [152 cm3] 53.7 x 54.8 mm [59.5 x 54.8 mm] 11: 1 1.400kPa/500r/min (14kgf/cm2/500r/min) Electric starter Wet sump
40
10W/30 10W/40 20W/40 20W/50
API STANDARD: SE, SF, SG Type or higher grade
Periodic oil change Total amount Final gear case oil Total amount Coolant system Radiator capacity (including all routes) Coolant reservoir capacity <from low to full level> Air filter type Fuel Recommended fuel Fuel tank capacity
1.2 L 1.4 L 0.15 L 1.25 L 0.35 L <0.15 L> Dry element Regular unleaded gasoline 7.5 L
2-1
Item Carburetor Type/quantity Manufacturer Spark plug Type Manufacturer Spark plug gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Chassis Frame type Caster angle Trail Tyre Tyre type Size (front) Size (rear) Manufacturer (front) Manufacturer (rear) Type (front) Type (rear)
SPEC
XQ125 [XQ150] TK 5DS/1 [TK 5KD/1] TEIKEI CR8E NGK 0.5~0.7 mm Dry, centrifugal automatic Helical gear 40/15 (2.666) Spur gear 44/12 (3.666) [42/14 (3)] V-belt automatic Centrifugal automatic type Steel tube backbone 25 81.3 mm Tubeless 130/60-13 140/60-13 PIRELLI / CHENG SHIN PIRELLI / CHENG SHIN SL36 / MAXXIS SL36 / MAXXIS
Tyre pressure (cold) 187 kg Maximum load*-except motorcycle Up to 90 kg load* 190 kPa (1.90 kgf/cm2) Front 200 kPa (2.00 kgf/cm2) Rear 90 kg load* ~ Maximum load* 200 kPa (2.00 kgf/cm2) Front 220 kPa (2.20 kgf/cm2) Rear * Load is total weight of cargo, rider, passenger and accessories except motorcycle Front wheel Wheel type Rim size Rear wheel Wheel type Rim size Cast wheel 13 x MT3.00 Cast wheel 13 x MT3.50
2-2
Item Brake Front brake type Front brake operation Rear brake type Rear brake operation Suspension Front suspension Rear suspension Shock absorber Front fork type Rear shock absorber assembly type Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system type Charging system type Battery type Battery voltage/capacity Headlight type Bulbs (voltage/wattage x quantity) Headlight Auxiliary light Brake/taillight Turn signal light Meter light High beam indicator light Turn indicator light Coolant temperature warning light Amperage for fuses Main fuse Radiator fan fuse
SPEC
XQ125 [XQ150] Single disc brake Right hand operation Single disc brake Left hand operation Telescopic fork Unit swing Coil spring/oil damper Coil spring/oil damper 103 mm 95 mm C.D.I Flywheel magneto CB7L-B2 or YB7L-B2 12V 8Ah Bulb 12V 35W/35W x 2 12V 5W x 2 12V 21W/5W x 1 12V 10W x 4 12V 1.2W x 2 12V 1.2W x 1 12V 1.2W x 2 12V 1.2W x 1 20 A 7.5 A
2-3
MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS

ENGINE Item Cylinder head Warp limit Cylinder Bore size Out of round limit Camshaft Drive system Cam dimensions Intake A B C Exhaust A B C Camshaft runout limit Standard
SPEC
* [XQ 150] Limit 0.03 mm
53.700~53.705 mm [59.500~59.505 mm]* 0.05 mm Chain drive (left)

C A
30.711 mm 25.045 mm 30.711 mm 25.052 mm 0.03 mm 12.030mm 11.950 mm
30.811 ~ 30.911 mm 25.145 ~ 25.245 mm 5.666 m 30.811 ~ 30.911 mm 25.152 ~ 25.252 mm 5.659 m 82 RH2005/94 12.000 ~ 12.018 mm 11.981 ~ 11.991 mm 0.10 ~ 0.14 mm 0.16 ~ 0.20 mm
Cam chain Cam chain type/No. of links Rocker arm/rocker armshaft Rocker arm inside diameter Rocker shaft outside diameter Valve,valve seat, valve guide Valve clearance (cold) IN EX Valve dimensions
Face width
Seat width
A head diameter
IN EX B face width IN EX C seat width IN EX Stem outside diameter IN EX Guide inside diameter IN EX Stem-to-guide clearence IN EX Stem runout limit Valve seat width IN EX
26.9 ~ 27.1 mm 22.9 ~ 23.1 mm 2.687 ~ 3.252 mm 2.687 ~ 3.252 mm 0.9 ~ 1.1 mm 0.9 ~ 1.1 mm 4.475 ~ 4.490 mm 4.460 ~ 4.475 mm 4.500 ~ 4.512 mm 4.500 ~ 4.512 mm 0.01 ~ 0.037 mm 0.025 ~ 0.052 0.9 ~ 1.1 mm 0.9 ~ 1.1 mm
1.6 mm 4.445 mm 4.430 mm 4.542 mm 4.542 mm 0.08 mm 0.10 mm 0.01 mm 1.6 mm 1.6 mm
2-4
MAINTENANCE SPECIFICATIONS
Item Valve spring Free length Set length (valve closed) Compressed pressure Tilt limit IN/EX IN/EX IN/EX IN/EX 41.94 mm 37.5 mm 45.1 ~ 50.9 N 2.5 / 1.9 mm 0.025 ~ 0.035 mm
H
SPEC
* [XQ 150] Limit 39.84 mm 0.15 mm 15.045 mm 14.975 mm
Standard
Piston Piston to cylinder clearence Piston size D D Measuring point H Piston pin bore inside diameter Piston pin outside diameter Piston rings Top ring: Type End gap (installed) Side clearance (installed) 2 nd ring: Type End gap (installed) Side clearence (installed) Oil ring: End gap (installed) Crankshaft
53.670~53.687 mm [59.470~59.487mm]* 4.5 mm 15.002~15.013 mm 14.991~15.000 mm
Barrel 0.15 ~ 0.25 mm 0.03 ~ 0.07 mm Taper 0.15 ~ 0.30 mm 0.02 ~ 0.06 mm 0.2 ~ 0.7 mm
0.50 mm 0.12 mm 0.65 mm 0.12 mm
Crank width A Runout limit C Big end side clearance D Automatic centrifugal clutch Clutch shoe thickness Clutch housing inside diameter Weight outside diameter Clutch-in revolution Clutch-stall revolution V-Belt V-belt width
47.950 ~ 48.000 mm 0.15 ~ 0.45 mm 2.0 mm 120 mm [135 mm]* 20.0 mm 3,550 ~ 4,050 rpm [3,250 ~ 3,750 rpm]* 5,900 ~ 6900 rpm [5,600 ~ 6,400 rpm]* 22 mm
0.03 mm 1.0 mm 120.5 [135.5]* 19.5 mm 19 mm
2-5
Item Carburetor Type I.D mark Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N) Pilot air jet (P.A.J.1) Needle jet (N.J) Pilot jet (P.J) Pilot screw (P.S) Valve seat size (V.S) Starter jet 1 (G.S.1) Float height (F.L) Engine idle speed Oil pump Type Tip clearence Side clearance Housing and rotor clearence Radiator Type Width/height thickness Radiator cap opening pressure Reservoir tank capacity Thermostatic valve Manufacturer Valve opening temperature Valve full open temperature Standard TK 5DS [TK 5KD]* #116 [#114] 1.0 [1.4] 4E31 (3/5) [4E32 (3/5)]* 1.30 2.590 #38 [#36] 2 1/4 ~ 2 3/4 [2 ~ 4]* 2.00 #45 5 ~ 6 mm 1.600 ~ 1.800 rpm Trochoid Cooling fin with electric fan 170 / 282 / 23 mm 100 ~ 120 kPa 0.35 L ANGLI 82 C 95 C
SPEC
* [XQ 150] Limit
0.15 mm 0.15 mm 0.17 mm
2-6
Item Crankshaft oil seal (left) Crankshaft oil seal (right) Crankshaft oil seal (right) Camshaft bearing (left) Camshaft bearing (right) Starter clutch bearing Primary drive gear bearing (left) Primary drive gear bearing (right) Primary drive gear oil seal Main axle bearing (left) Main axle bearing (right) Drive axle bearing (left) Drive axle bearing (right) Drive axle oil seal Size
SPEC
22 x 32 x 7 19 x 30 x 8 (Reinforced) 19 x 30 x 8 (Double lips) 20 x 42 x 12 15 x 32 x 9 17 x 35 x 10 25 x 52 x 15 17 x 40 x 12 25 x 42 x 6 (Double lips) 15 x 25 x 12 (Needle bearing) 12 x 37 x 12 17 x 47 x 14 (Sphere) 22 x 50 x 14 (Sphere) 32 x 52 x 7
2-7

CHASSIS Item Steering system Steering bearing type Front suspension Front fork travel Spring rate Stroke Ball bearing 103 mm 6.1 N/mm 7.8 N/mm 0 ~ 11 mm 11 ~ 87 mm 120 cm3 SAE20 33 mm No 95 mm 294 mm 8 N/mm 12 N/mm 18 N/mm 0 ~ 70 mm 70 ~ 100 mm 100 ~ 130 mm 1 1 4 Cast wheel MT 3.00 x 13 Aluminium Cast wheel MT 3.50 x 13 Aluminium Standard
SPEC
Limit 1 mm 0.5 mm 1 mm 0.5 mm
(K1) (K2) (K1) (K2)
Oil capacity Oil grade Inner tube outer diameter Optional spring Rear suspension Shock absorber travel Fitting length Spring rate (K1) (K2) (K3) Stroke (K1) (K2) (K3) Spring preload adjusting position Minimum Standard Maximum Front wheel Type Rim size Rim material Rim runout limit Radial Lateral Rear wheel Type Rim size Rim material Rim runout limit Radial Lateral
2-8
Item Front disc brake Type Disc outside diameter x thickness Min. thickness Max deflection Pad thickness Master cylinder inside diameter Caliper cylinder outside diameter Brake fluid type Rear brake Type Disc outside diameter x thickness Min. thickness Max deflection Pad thickness Master cylinder inside diameter Caliper cylinder outside diameter Brake fluid type Brake lever Brake lever free play (front) Brake lever free play (rear) Throttle cable free play Standard Single disc brake 245 x 4.7 mm 4 mm 13 mm 28 mm DOT #3 or DOT #4 Single disc brake 220 x 4.5 mm 4 mm 12 mm 32 mm DOT #3 or #4 10 ~ 20 mm 10 ~ 20 mm 1.5 ~ 3.0 mm
SPEC
Limit 4.2 mm 0.15 mm 0.8 mm 4.0 mm 0.15 mm 0.8 mm
2-9

ELECTRICAL Item Ignition timing Ignition timing (B.T.D.C) Advanced timing (B.T.D.C) Advancer type Ignition system Pickup coil resistance Source coil resistance Ignition coil Manufacturer Minimum spark gap Primary coil resistance Secondary coil resistance Spark plug cap Type Resistance Charging system Type Normal output Stator coil resistance Rectifier/regulator Model/manufacturer No load regulated voltage Capacity Withstand voltage Battery Specific gravity Electric starting system Type Starter motor: Operation voltage Output Armature coil resistance Brush overall length Brush quantity Spring force Commutator diameter Mica undercut (depth) Starter relay Model/manufacturer Amperage rating Coil winding resistance Standard 10 at 1.700 rpm 26 at 4.500 rpm Digital 248 ~ 372 at 20C 720 ~ 1080 at 20C MORIYAMA 0.5 mm 0.32 ~ 0.48 at 20C 5.7 ~ 8.5 k at 20C Resin type 10 k Flywheel magneto 14 V 170W at 5.000 rpm 0.6 ~ 0.9 at 20C 04012001 / FACOMSA 14.5 V 25 A 200 V 1.280 Constant mesh type 12 V 0.3 kW 0.0306 ~ 0.0374 at 20C 10 mm 2 5.6 ~ 8.3 N 22 mm 1.5 mm 9768054 / JIDECO 100 A 4.2 ~ 4.6 at 20C
SPEC
Limit
3.5 mm 21 mm
2-10
Item Horn Model/manufacturer Maximum amperage Turn signal relay Model/Manufacturer Turn signal blinking frequency Fuel gauge Model/manufacturer Sender unit resistance - full - empty Circuit breaker Main Radiator fan fuse Standard YF-12 / NIKKO 3A
SPEC
Limit
800 TRANSVAL / 01.2320.01 GUILERA 65 ~ 95 cycles/min. / 70 ~ 90 cycles/min. 25.33.07 / MAXIMA 4 ~ 10 90 ~ 100 20 A x 1 pcs 7.5 A x 1 pcs
2-11
CONVERSION TABLE
AS00028
SPEC
CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER IMPERERIAL ** mm x 0.03937 = ** in 2 mm x 0.03937 = 0.08 in CONVERSION TABLE METRIC TO IMPERIAL Metric unit Multiplier Torque mkg mkg cmkg cmkg kg g km/h km m m cm mm cc (cm3) cc (cm3) L (liter) L (liter) kg/mm kg/cm2 Centigrade (C) 7.233 86.794 0.0723 0.8679 2.205 0.03527 0.6214 0.6214 3.281 1.094 0.3937 0.03937 0.03527 0.06102 0.8799 0.2199 55.997 14.2234 9/5+32 ftlb inlb ftlb inlb lb oz mph mi ft yd in in oz(IMP liq.) cuin qt(IMP liq.) gal(IMP liq.) lb/in psi(lb/in2) Fahrenheit (F) Imperial unit
Weight Speed
Distance
Volume/ Capacity
Misc.
2-12
GENERAL TIGHTENING TORQUE SPECIFICATIONS

EAS00029
SPEC
GENERAL TIGHTENING TORQUE SPECIFICATIONS

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. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature. A (nut) B (bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General tightening torques Nm mkg 6 0.6 15 30 55 85 130 1.5 3.0 5.5 8.5 13.0
B
10 mm 12 mm 14 mm 17 mm 19 mm 22 mm
A: Width across flats B: Thread diameter
2-13
TIGHTENING TORQUES
TIGHTENING TORQUES ENGINE Thread size M6 M10 M6 M8 M6 M6 M6 M6 M5 M8 M6 M6 M6 M6 M6 M6 M6 M6 M35 M6 M6 M6 M6 M6 M6 M6 M6 M6 M8 M8 M8 M6 M6 M14 M36 M12
SPEC
Item Oil check bolt Spark plug Cylinder, water drain bolt Cylinder head and cylinder Cylinder head and cylinder Cylinder and crankcase Camshaft bearing stopper Camchain guide Valve adjuster nut Camshaft pinion bolt Camshaft tensionner Rocker shaft securing plate Thermostatic valve cover Water pump housing cover Water pump housing Water pump housing Thermostatic valve cover Oil pump Engine drain plug Inlet manifold on cylinder head Air filter cover V-belt air filter cover Crankcase (left) Cover, crankcase 1 Cover, crankcase 2 Cover, oil pump Duct, air Cover, magneto Cylinder head stud bolt Transmission oil drain plug Engine oil drain plug Cover, crankcase 3 Starter idle gear plate Primary fixed sheave Clutch carrier assembly Clutch housing
Fastener Bolt Bolt Nut Bolt Bolt Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Stud Plug Plug Bolt Bolt Nut Nut Nut
Q'ty 1 1 1 4 2 1 1 1 2 1 2 1 1 4 2 1 2 3 1 2 4 4 8 11 6 3 3 3 4 1 1 2 2 1 1 1
Tightening torque Nm 9 13 8 22 12 12 12 6.5 6.5 30 10 10 9 10 7 7 9 65 32 10 6.5 6.5 9 10 10 6.5 7 7 13 22 22 6.5 7 60 90 55 mkg 0.9 1.3 0.8 2.2 1.2 1.2 1.2 0.65 0.65 0.3 1.0 1.0 0.9 1.0 0.7 0.7 0.9 6.5 3.2 1.0 0.65 0.65 0.9 1.0 1.0 0.65 0.7 0.7 1.3 2.2 2.2 0.65 0.7 6.0 9.0 5.5
Remarks
2-14
TIGHTENING TORQUES
Item Thermo unit Coolant drain bolt on cylinder Starter motor Rotor Fastener Bolt Bolt Nut Thread size Pt 1/8 M6 M6 M12 M16 M16 M6 Q'ty 1 1 2 1 1 1 3
SPEC
Remarks
Tightening torque Nm 75 8 65 70 225 225 70 mkg 7.5 0.8 6.5 7.0 22.5 22.5 7.0
Stator
Bolt
2-15
TIGHTENING TORQUES
TIGHTENING TORQUES CHASSIS Thread size M10 M10 M10 M6 M8 M8 M6 M8 M10 M8 M25 M10 M6 M6 M6 M6 M6 5 5 M6 M6 M5 M10 M12 M14 M8 M8 M8 M8 M10 M10
SPEC
Item Frame with engine bracket Engine bracket 2 with 3 E/G bracket with E/G (with main stand) Exhaust pipe stud bolt on cylinder Muffler on rear arm Rear arm on crankcase Muffler protector Seat rail with frame Rear cushion with frame Rear cushion with engine Steering shaft Handle with steering shaft Master cylinder with handle Seat lock Box with seat rail Fuel cock with tank Handle seat with frame Box with fuel tank Screw tapping in plastic Screw tapping in clip Footrest board with frame Fender on front fork Cover handle with handle Mainstand Front wheel axle Rear wheel axle Front caliper on front fork Rear caliper on rear arm Front brake disc on wheel Rear brake disc on wheel Union bolt with caliper Union bolt with master cylinder
Fastener Bolt Bolt Bolt Nut Bolt Bolt Bolt Bolt Nut Nut Nut Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Nut Nut Bolt Bolt Bolt Bolt Bolt Bolt
Q'ty 1 2 2 2 3 2 2 8 1 1 3 1 2 2 2 4 2
Tightening torque Nm 42 55 42 11 27 27 4.5 26 32 18 60 8.5 4 8 2.5 4 4 3.25 2.25 4 4 4.5 42 70 104 23 23 23 23 23 23 mkg 4.2 5.5 4.2 1.1 2.7 2.7 0.45 2.6 3.2 1.8 6.0 0.85 0.4 0.8 0.25 0.4 0.4 0.33 0.23 0.4 0.4 0.45 4.2 7.0 10.4 2.3 2.3 2.3 2.3 2.3 2.3
Remarks
See chapter 7 STEERING HEAD
3 3 2 2 1 1 2 2 6 5 1 1
LT
2-16
LUBRICATION POINTS AND LUBRICANT TYPES

EAS00031
SPEC

ENGINE Lubrication Point Oil seal lips O-ring (Except V-belt drive unit) Cylinder head tightening nut mounting surface Crankshaft pin outside Connecting rod big end thrust surface Rotary filter inner surface Drive gear inner surface Cam chain outside sprocket inner surface Piston pin Piston outside and ring groove Camshaft cam profile Valve stem (IN, EX) Valve stem end (IN, EX) Rocker shaft Valve rocker arm inner surface Shaft Shaft (Oil pump assembly) Gasket (Oil pump assembly) Holder Idle gear 1 thrust surfaces Shaft 1 Idle gear 2 thrust surfaces Idle gear 2 inner surface Main axle thrust surfaces Crankcase mating surfaces Crankcase breather plug Stator grommet Suction pipe Yamaha bond No. 1215 Yamaha bond No. 1215 Symbol
2-17

EAS00032
SPEC
CHASSIS Lubrication Point Front wheel oil seal lips (left/right) Steering head pipe bearing (upper/lower) Tube guide (throttle grip) inner surface Brake cable (brake lever) Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft Symbol
2-18
COOLING SYSTEM DIAGRAMS

EAS00033
SPEC

Radiator cap Coolant tank cap Coolant hose (cylinder head outlet) Frame Coolant tank Coolant tank breather hose Clip Drain bolt Thermo switch cover Clip Hose Coolant hose (pump inlet) Clamp A Keep the smaller diameter for fixing on the frame ( 22). B Keep the larger diameter for fixing the hose ( 24).
2-19

EAS00033(bis)
SPEC

Radiator cap Coolant tank Coolant upper level mark Coolant lower level mark Coolant tank breather hose Battery box Drain bolt (on water pump) Under cover Thermo switch (on radiator) Radiator Grommet Coolant hose (pump inlet) A Pass the hose under the seat rail fixation. B Pass the hose under the frame down tube. C Pass the hose through the under cover.
FRONT
REAR
l B
2-20
LUBRICATION DIAGRAMS
EAS00034
SPEC
1 Lubrication of the cylinder head Cylinder head Cylinder Crankcase 2 Lubrication of the crankshaft Crankshaft
2-21
EAS00034(bis)
SPEC
1 Oil flow Cylinder head Cylinder Oil pump 2 Lubrication table A Oil pressure flow B Oil return flow
2
Camshaft Cylinder head Rocker arm
A B Crankshaft Oil pump Oil strainer Crankcase Connecting rod
2-22
CABLE ROUTING
EAS00035
SPEC
CABLE ROUTING
Speedometer sensor cable Front brake hose Wire harness Main switch Throttle cable Rectifier / Regulator Under cover Fan motor coupler Fan motor Thermo switch unit (on radiator) Horn Radiator Front brake caliper A Clamp the fan motor coupler with the wire harness. B Pass the battery breather pipe throught the left hole of the under cover. C Do pass the front brake hose ahead of the wire harness. D Put the grommet between bracket and front fork. Push bracket to minimise free play between the bracket hose and under bracket.
2-23
CABLE ROUTING
Fuel cock suction pipe Fuel cock pipe Fuel tank License plate light Rear shock absorber Carburetor wire holder Ignition coil assembly Carburetor overflow pipe Engine bracket Fuel tank overflow pipe Band switch License light lead Side cover Air filter assembly V-belt air filter assembly
SPEC
A Don't pinch the taillight and rear flasher wires during the rear fender installation. B Pass the engine oil hose throught the crankcase cover shape. C Pass the carburetor pipe throught the engine bracket. D Don't make the fuel hose touch the side cover.
5~10 mm C
E-E
A-A
A
View C
D
C View B B A A D E D D D D-D
E
2-24
CABLE ROUTING
Q Sensor unit coupler W Main switch coupler E Turn signal relay R Relay T CDI / Wire harness coupler Y Rectifier / Regulator coupler U Starter relay connector I Starter relay O Earth coupler P Battery { Fuse holder } Spark plug cap q Auto-chocke lead w Carburetor heater lead
SPEC
e CDI magneto lead r Clip t Fuel sender y Alarm coupler u Rear right turn signal coupler (green) i License light coupler o Rear left turn signal coupler (brown) p Band [ Pipe ] Wire lead A Clamp S Left headlight and turn signal light coupler (Black) D Right headlight and turn signal light coupler (White)
Q S E
D W R
A-A
D U O {
D T Y I P } [ e ]
r B t y C
q w e
5~10 mm
B-B
Bottom view
o i
2-25
CABLE ROUTING
A B C D
SPEC
Don't mix water temperature sensor (Grey) and carburetor heater connector (Black). Apply grease on screw and contact. Position the drain hole toward bottom for left and right turn signal light cover. Keep those areas free of wires and hoses.
Q S E
D W R
A-A
D U O {
D T Y I P } [ e ]
r B t y C
q w e
5~10 mm
B-B
Bottom view
o i
2-26
CABLE ROUTING
Rectifier / Regulator Band switch Main switch Rear brake hose Thermo switch Radiator Side stand coupler Clamp Brake hose holder Front fork Front brake hose Thermo switch wire Seat lock wire Throttle cable Wire harness
5~10 mm
SPEC
A Clamp the sensor unit wire on the white mark. B Pass the front brake hose behind the rear brake hose. C Pass the rear brake hose ahead wire harness. D Pass wires under the clamp. E Don't stretch out this wire.
5~10 mm
E-E
D-D
B D
E D
E
A
A-A
View C C A A
2-27
CABLE ROUTING
Wire harness White repere on the wire harness Ignition coil assembly Rear brake hose Engine breather hose Band switch Mudguard A B C D CDI magneto lead Wire lead Clamp Overflow pipe Wire lead Protector Rear fender
SPEC
Pass the air breather pipe between the air filter joint and the air filter cover. Clamp the wire harness on the white mark. Clamp the rear brake hose on the mark. Pass the CDI magneto and the Stator motor wires into the protector. Fit them into the engine wire holder.
5 ~10 mm
5 ~10 mm
5 ~10 mm
A-A
B-B
B
D-D
A
A
E-E
A B
B F C G D E E D
F C G
45
C-C
F-F
2-28
5 ~10 mm
G-G
CABLE ROUTING
Right handle switch Front brake hose Light switch coupler Start switch coupler Turn signal switch coupler Dimmer switch coupler Rear brake hose Left handle switch Rear brake lever Speedometer coupler Under handlebar cover
SPEC
Upper handlebar cover Front brake lever Speedometer cover Handlebar assembly Master cylinder Band switch (wire harness on handlebar)
A-A
7.5 0.5 mm
B-B
C-C
E-E D-D
B
B B C
7.5 0.5 mm
D E D E
C
A A J J I H
F
J I H
G G
F F
J-J
I-I
H-H
G-G
F-F
21.6
1.5 ~ 3 mm
2-29
CABLE ROUTING
A B C D E F G
SPEC
Keep 2 mm freeplay between the master cylinder and upper handlebar cover. Don't screw anything in the inner side of the handlebar. Glue the handlebar grip. Position the right and left lever as shown. Install the handlebar switch (left and right) on the handlebar as shown. Pass the throttle cable ahead the wire harness. Don't pinch the wire harness between the handlebar and the handlebar under cover.
A-A
7.5 0.5 mm
B-B
C-C
E-E D-D
B
B B C
7.5 0.5 mm
D E D E
C
A A J J I H
F
J I H
G G
F F
J-J
I-I
H-H
G-G
F-F
21.6
1.5 ~ 3 mm
2-30
CABLE ROUTING
Right handle switch Speedometer cover Front brake master cylinder Rear brake master cylinder Left handle switch Rear brake lever Upper handlebar cover Under handlebar cover Clamp Rear brake hose Front brake hose Wire harness Trottle cable Front brake lever Clamp Speedometer coupler
SPEC
A Make sure that the handlebar is in place before tightening the under handlebar cover. B Fix the wire harness attach on the handlebar bracket before installing the under handlebar cover. C Pass the throttle cable through the under handlebar cover. D Make sure that clamp is facing forward to avoid the wear of brake hoses. E Don't tight too hard, the clamp is only to keep cables all together.
A
D C
A B
5 ~ 10 mm
33
25
A-A
RIGHT
B A
FRONT
B-B
LEFT
2-31
CABLE ROUTING
Frame Bracket stopper Engine bracket 1 Bolt Self-locking nut Engine bracket 2
SPEC
A Check the existence of a free play in area "a" and "b", after installation of the engine bracket 1. B Tight the right side bolt first to assure clearance "C".
C=
13
A B
A-A
2-32
CHK ADJ
CHK ADJ
CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION ............................................................................................ 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .................. 3-1 COVER AND PANEL .................................................................................... 3-3 BOX AND SEAT ....................................................................................... 3-3 SIDE COVERS ......................................................................................... 3-4 FRONT COVER, INNER FRONT COVER AND FRONT SIDE COVERS ................................................................... 3-6 HANDLEBAR COVERS ........................................................................... 3-7 ENGINE ......................................................................................................... 3-8 ADJUSTING THE VALVE CLEARANCE ................................................. 3-8 ADJUSTING THE ENGINE IDLING SPEED ............................................ 3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY ............................. 3-10 CHECKING THE SPARK PLUG ............................................................ 3-11 CHECKING THE IGNITION TIMING ..................................................... 3-12 TRANSMISSION OIL REPLACEMENT ................................................. 3-13 MEASURING THE COMPRESSION PRESSURE ................................ 3-14 CHECKING THE ENGINE OIL LEVEL .................................................. 3-15 CHANGING THE ENGINE OIL .............................................................. 3-16 MEASURING THE ENGINE OIL PRESSURE ....................................... 3-17 CLEANING THE AIR FILTER ELEMENT .............................................. 3-18 CLEANING THE V-BELT CASE AIR FILTER ELEMENT ...................... 3-18 CHECKING THE FUEL AND VACUUM HOSES ................................... 3-19 EXHAUST SYSTEM INSPECTION ....................................................... 3-19 CHECKING THE COOLANT LEVEL ..................................................... 3-20 CHANGING THE COOLANT ................................................................. 3-21 INSPECTING THE COOLANT SYSTEM ............................................... 3-24 CHASSIS ..................................................................................................... 3-25 CHECKING THE FRONT AND REAR BRAKE LEVER FREE PLAY .... 3-25 CHECKING THE FRONT AND REAR BRAKE FLUID LEVEL .............. 3-26 CHECKING THE FRONT AND REAR BRAKE PADS ........................... 3-27 CHECKING THE FRONT AND REAR BRAKE HOSES ........................ 3-27 BLEEDING THE HYDRAULIC BRAKE SYSTEM .................................. 3-28 CHECKING AND ADJUSTING THE STEERING HEAD ........................ 3-29 CHECKING THE FRONT FORK ............................................................ 3-31 INSPECTING THE REAR SHOCK ABSORBER ................................... 3-32 CHECKING THE TYRES ....................................................................... 3-32 CHECKING THE WHEELS .................................................................... 3-35 CHECKING AND LUBRICATING THE CABLES ................................... 3-35 LUBRICATING THE LEVERS ................................................................ 3-36 LUBRICATING THE CENTERSTAND ................................................... 3-36
CHK ADJ
ELECTRICAL SYSTEM ............................................................................... 3-37 CHECKING THE BATTERY .................................................................. 3-37 CHECKING THE FUSES ....................................................................... 3-40 REPLACING THE HEADLIGHT BULBS ................................................ 3-41 REPLACING THE TURN SIGNAL LIGHT BULBS ................................. 3-42 REPLACING THE TAIL/BRAKE LIGHT BULB ...................................... 3-43 REPLACING THE LICENCE PLATE LIGHT BULB ............................... 3-44 ADJUSTING THE HEADLIGHT BEAMS ............................................... 3-44 ADJUSTING THE DIGITAL CLOCK ...................................................... 3-44
PERIODIC CHECKS AND ADJUSTMENTS

EAS00036
CHK ADJ

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. All service technicians should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

No. 1 * Fuel line ITEM CHECK, MAINTENANCE AND LUBRICATION Check fuel hoses and vacuum hose for cracks or damage. Check condition. Clean, regap. Replace. Check valve clearance. Adjust. Clean. Replace. Clean. Check electrolyte level and specific gravity. Make sure that the breather hose is properly routed. Check operation, fluid level and vehicle for fluid leakage.(See NOTE on page 3-2) Replace brake pads. Check operation, fluid level and vehicle for fluid leakage.(See NOTE on page 3-2) Replace brake pads. Check for cracks or damage. Replace. Check runout and for damage. Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. Checks bearing for looseness or damage. Check bearing play and steering for roughness. Lubricate with lithium soap base grease. Make sure that all nuts, bolts and screws are properly tightened. Check operation. Lubricate. ODMETER READING (x1,000km) 0.5 6 12 18 24 Annual check
Spark plug
3 * Valves 4 5 Air filter element V-belt air filter element
6 * Battery
7 * Front brake (disc)
Whenever worn to the limit
8 * Rear brake (disc)
Whenever worn to the limit Every 4 years.
9 * Brake hose 10 * Wheels
11 * Tires
12 * Wheel bearings 13 * Steering bearings 14 15 Chassis fasteners Centerstand
Every 24,000 kms.
3-1

No. ITEM CHECK, MAINTENANCE AND LUBRICATION -Check operation and for oil leakage. Check operation and shock absorber for oil leakage. Check engine idling speed and starter operation. Change. Clean. Check vehicle for oil leakage Change. Check coolant level and vehicle for coolant leakage. Change. Check wear and damage. Replace. Check operation. Lubricate. Check operation. Adjust headlight beam. 0.5 6
CHK ADJ
12 18 24 Annual check
ODMETER READING (x1,000km)
16 * Front fork 17 * Rear shock absorber assembly 18 * Carburetor 19 * Engine oil 20 * Engine oil filter strainer 21 * Final gear oil
Every 3,000 km.
22 * Coolant system
Every 3 years. Every 18,000 km.
23 * V-belt 24 * Front and rear brake switches 25 Moving parts and cables 26 * Light, signals and switches
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha or MBK dealer. NOTE: The air filters need more frequent service if you are riding in unusually wet or dusty areas. Brake fluid replacement: 1. Replace the brake fluid after disassembling the master cylinder or caliper cylinder. 2. Check the brake fluid level and add fluid as required. 3. Replace the brake hoses every four years or if cracked or damaged.
3-2
COVER AND PANEL

EASM0005
CHK ADJ
COVER AND PANEL

BOX AND SEAT
T.R
2.3 Nm (0.23 m kg)
T.R
4 Nm (0.4 m kg)
7 5
3
T.R
2.3 Nm (0.23 m kg)
D FW
T.R
8 Nm (0.8 m kg)
Order I 1 2 II 3
Job/Part Removing the box and seat Remove : Coolant tank cover Battery cover Disconnect : Battery leads
Qty
Remarks Remove the parts in the order listed.
1 1 2
NOTE: Open the seat to remove it.

CAUTION:
III 4 IV 5 V 6 7
Remove : Passenger seat Disconnect : Seat lock cable Remove : Seat and box assy Passanger handle (grip bar)
First, disconnect the negative battery lead, and then the positive battery lead. 1 1 1 1 NOTE: Pull the passenger seat to the back to remove it
For installation, reverse the removal procedure.
3-3
COVER AND PANEL

SIDE COVERS
CHK ADJ
T.R
2.3 Nm (0.23 m kg)
10
12 13
T.R
4 Nm (0.4 m kg)
11
T.R
5
2.3 Nm (0.23 m kg)
10
4 Nm (0.4 m kg)
T.R
FW
Order I 1 2 3 4 5 II 6 7 8 9 III 10 11
Job/Part Removing the side covers Remove : Left footrest board Right footrest board Left under cover Right under cover Rear mudguard Disconnect : Rear left flasher Rear right flasher Licence plate light Taillight wire Remove Passenger footrest covers Left side cover
Qty
1 1 1 1 1 1 1 1 1 2 1
NOTE: Pull it to the back.
NOTE: Pull it to the back.
3-4
COVER AND PANEL

SIDE COVERS
CHK ADJ
T.R
2.3 Nm (0.23 m kg)
10
12 13
T.R
4 Nm (0.4 m kg)
11
T.R
5
2.3 Nm (0.23 m kg)
10
4 Nm (0.4 m kg)
T.R
FW
Order 12 13
Job/Part right side cover / taillight Taillight
Qty 1 1
Remarks
3-5
COVER AND PANEL

FRONT COVER, INNER FRONT COVER AND FRONT SIDE COVERS
CHK ADJ
5
IP L/ TR TA TO
T.R
3.3 Nm (0.33 m kg)
2
T.R
2,3 Nm (0.23 m kg)
3 5
D FW
Order Job/Part Removing the front cover,the inner front cover and the front side covers Remove: Main switch cap Inner front cover Front cover Flasher relay / relay Disconnect Headlight / flashers connectors Remove: Left front side cover Right front side cover Under cover
T.R
2.3 Nm (0.23 m kg)
Qty
I 1 2 3 4 II 5 III 6 7 8
1 1 1 1/1 4 1 1 1 For installation, reverse the removal procedure.
3-6
COVER AND PANEL

HANDLEBAR COVERS
CHK ADJ
T.R
3,3 Nm (0.33 m kg)
R A T O T L /T
IP
2 FW D
T.R
4,5 Nm (0.45 m kg)
T.R
3,3 Nm (0.33 m kg)
Order I 1 II 2 III 3
Job/Part Removing the handlebar covers Remove: Upper handlebar cover Disconnect: Speedometer assy couplers Remove: Speedometer cover
Qty
1 1 1
3-7
ADJUSTING THE VALVE CLEARANCE

EAS00049
CHK ADJ
ENGINE
ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1.Remove: Battery cover Box and seat assembly Refer to BOX AND SEAT section. Side covers Refer to SIDE COVERS section. Spark plug Plug on magneto cover Valve cover inlet Valve cover exhaust 2.Measure: valve clearance Out of specification Adjust.
a
ZAUM0140
Valve clearance (cold) Intake valve 0.10 ~ 0.14 mm Exhaust valve 0.16 ~ 0.20 mm
a.Turn the crankshaft counterclockwise. b.When the piston is at TDC on the compression stroke, align the mark a on the generator rotor with the stationary pointer b on the crankcase. c. Measure the valve clearance with a thickness gauge . Out of specification Adjust.
3-8
ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED

3.Adjust: valve clearance
CHK ADJ
a.Loosen the locknut . b.Insert a thickness gauge between the end of the adjusting screw and the valve tip. c. Turn the adjusting screw in or out until the specified valve clearance is obtained. Valve clearance is decreased. Turning out Valve clearance is increased. Turning in Valve adjusting tool 90890-01311 Hold the adjusting screw to prevent it from moving and tighten the locknut to specification. Locknut 6.5 Nm (0.65 mkg)
T. R
d.Measure the valve clearance again. e.If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 4.Install: Side covers Refer to SIDE COVERS section Box and seat assembly Battery cover Refer to BOX AND SEAT section.
EASM0010
ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1.Start the engine and let it warm up for several minutes.
3-9
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK ADJ
2.Attach: engine tachometer (onto the spark plug lead of the cylinder) Engine tachometer 90890-03113 3.Measure: engine idling speed Out of specification Adjust. Engine idling speed 1,600 ~ 1,800 r / min 4.Adjust: engine idling speed a.Turn the pilot screw in until it is lightly seated. b.Turn the pilot screw out the specified number of turns. Pilot screw setting XQ 125: 2 1/4 ~ 2 3/4 XQ 150: 2 ~ 4 c. Turn the throttle stop screw in or out until the specified engine idling speed is obtained.
Engine idling speed is increased. Turning out Engine idling speed is decreased. Turning in 5.Adjust: throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3 mm
EASM0011
ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted.
3-10
ADJUSTING THE THROTTLE CABLE FREE PLAY / CHECKING THE SPARK PLUG
CHK ADJ
1.Check: throttle cable free play Out of specification Adjust. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3 mm 2.Adjust: throttle cable free play NOTE: When the throttle is opened, the accelerator cable is pulled. a.Turn the adjusting nut in or out until the specified throttle cable free play is obtained. Turning in Throttle cable free play is increased. Turning out Throttle cable free play is decreased.
ZAUM0051
WARNING
After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.
EAS00060
CHECKING THE SPARK PLUG 1.Disconnect: spark plug cap 2.Remove: spark plug
CAUTION:
ZAUM0035
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. 3.Check: spark plug type Incorrect Change. Spark plug type (manufacturer) CR8E (NGK)
3-11
CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING
CHK ADJ
4. Check: electrodes Damage/wear Replace the spark plug. insulator Abnormal color Replace the spark plug. Normal color is medium-to-light tan.
5.Clean: spark plug (with a spark plug cleaner or wire brush) 6.Measure: spark plug gap (with a wire gauge) Out of specification Regap.
ZAUM0037
Spark plug gap 0.5 ~ 0.7 mm 7.Install: spark plug
T.R
13 Nm (1.3mkg)
NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8.Connect: spark plug cap
EAS00061
CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion.
1.Attach: timing light engine tachometer (onto the spark plug lead of the cylinder) Timing light 90890-03141 Engine tachometer 90890-03113
3-12
CHECKING THE IGNITION TIMING/ TRANSMISSION OIL REPLACEMENT

2.Check: ignition timing
CHK ADJ
a.Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 1,600 ~ 1,800 r/min b.Check that the mark a is within the required firing range b on the timing plate. Incorrect firing range Check the ignition system. NOTE: The ignition timing is not adjustable.
b
ZAUM0140
TRANSMISSION OIL REPLACEMENT NOTE: Make sure the scooter is upright when replacing the oil. 1.Stand the scooter on a level surface. 2.Start the engine for several minutes to warm it up and then stop. 3.Place an oil pan under the crankcase. 4.Remove: oil filler cap drain bolt Drain the oil. 5.Tighten: 22 Nm (2.2mkg) drain bolt 6.Fill: crankcase
T.R
T.R
22 Nm (2.2 m kg)
ZAUM0131
Recommended oil: SAE 10W40 motor oil (API, SE) Oil quantity: 0.15L
CAUTION: Wipe any spilled oil off the tire or the wheel.
New
ZAUM0130
7.Install: oil filler cap O-ring 8.Start the engine for several minutes to warm it up and check for the oil leakage.
3-13
MEASURING THE COMPRESSION PRESSURE

EAS00067
CHK ADJ
MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1.Remove: under side cover Refer to SIDE COVERSsection 2.Measure: valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE section. 3.Start the engine, warm it up for several minutes, and then turn it off. 4.Disconnect: spark plug cap 5.Remove: spark plug
CAUTION:
Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder. 6.Install: compression gauge Compression gauge 90890-03081 7.Measure: compression pressure Out of specification Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,120 kPa (11.20 kg/cm2) Standard 1,400 kPa (14.00 kg/cm2)
a.Set the main switch to ON. b.With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.
3-14
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL
CHK ADJ
WARNING To prevent sparking, ground the spark plug lead before cranking the engine.
c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits. Carbon deposits Remove. d.If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than Piston wear or damage without oil Repair. Piston ring(s), valves, Same as cylinder head gasket or without oil piston possibly defective Repair. 7.Install: 13 Nm (1.3mkg) spark plug 8.Connect: spark plug cap
T.R
ZAUM0035
EAS00070
CHECKING THE ENGINE OIL LEVEL 1.Stand the scooter on a level surface. NOTE: Place the scooter on a suitable stand. Make sure the scooter is upright. 2.Start the engine, warm it up for several minutes, and then turn it off. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. Do not screw the dipstick in when inspecting the oil level.
ZAUM0134
3-15
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL
CHK ADJ
3.Check: engine oil level The engine oil level should be between the minimum level mark and maximum level mark . Below the minimum level mark Add the recommended engine oil to the proper level.
ZAUM0141
-20 -10
10
20
30
40
50C
SAE 10W/30 SAE 10W/40 SAE 15W/40 SAE 20W/40 SAE 20W/50
Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard SE or higher grade (Non-friction modified)
CAUTION: Do not allow foreign materials to enter the crankcase.

4.Start the engine, warm it up for several minutes, and then turn it off. 5.Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
EASM0012
ZAUM0040
T.R
32 Nm (3.2mkg)
CHANGING THE ENGINE OIL 1.Start the engine and let it warm up for several minutes. 2.Turn off the engine and place an oil pan under the engine. 3.Remove: Oil filler plug Drain plug Compression spring Oil strainer O-ring Drain the crankcase of its oil. 4.Install: O-ring Compression spring Oil strainer Drain plug 32 Nm (3.2mkg) Oil filler plug
T.R
ZAUM0040
3-16
CHECKING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE/

5.Fill: Crankcase Oil quantity: 1.2 L
CHK ADJ
6.Check: Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL section. 7.Reset: engine oil warning circuit a. Press the Trip button while turning the key to ON b. Release the Trip button and oil indicator light will go off NOTE: If the oil is changed before the oil change indicator light comes on (i.e. before the periodic oil change interval has been reached), the indicator light must be reset after the oil change for the next periodic oil change to be indicated at the correct time.To reset the oil change indicator light before the periodic oil change interval has been reached, follow the above procedure.
EASM0013
TOTAL
TOTAL/TRIP
ZAUM0100
T.R
10 Nm (1.0 m kg)
MEASURING THE ENGINE OIL PRESSURE 1.Remove: side covers Refer to SIDE COVERS section. 2.Inspect: oil pressure a.Slightly loosen the oil check bolt . b. Start the engine and keep it idling until the oil begins to seep from the oil check bolt. If no oil comes out after one minute, turn the engine off so it will not seize. c. Check oil passages and oil pump for damage or leakage. d.Start the engine after solving the problem(s), and recheck the oil pressure. e.Tighten the oil check bolt to specification. Oil check bolt 10 Nm (1.0mkg)
T.
3-17
CLEANING THE AIR FILTER ELEMENT/ CLEANING THE V-BELT CASE AIR FILTER ELEMENT
CAUTION:
CHK ADJ
Start the engine and check the oil pressure with the oil check bolt loosened. Do not apply at high speeds more than specified when checking the pressure. NOTE: Wipe any spilled oil off the engine.
EAS00086
ZAUM0125
CLEANING THE AIR FILTER ELEMENT 1.Remove: v-belt air filter cover air filter cover air filter case cover 2.Clean: air filter element Apply compressed air to the outer surface of the air filter element. 3.Check: air filter element Damage Replace. 4.Install: air filter element air filter case cover air filter cover v-belt air filter cover
ZAUM0021
CAUTION: Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating.
NOTE: When installing the air filter element into the air filter case cover, make sure their sealing surfaces are aligned to prevent any air leaks.
EAS00091
CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1.Remove: V-belt air filter cover V-belt air filter inner cover V-belt case air filter element
ZAUM0091
3-18
CHECKING THE FUEL AND VACUUM HOSES/ EXHAUST SYSTEM INSPECTION
CHK ADJ
2.Clean: V-belt case air filter element Apply compressed air to the outer surface of the primary fixed sheave air filter element. 3.Check: V-belt case air filter element Damage Replace.
ZAUM0050
CAUTION: Since the V-belt case air filter element is a dry type, do not let grease or water contact it.
4.Install: V-belt case air filter element 7 Nm (0.7mkg) V-belt air filter inner cover V-belt air filter cover
T.R
EAS00096
CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses. 1.Remove: Box and seat assembly Refer to BOX AND SEAT section. 2.Check: vacuum hose fuel hose Cracks/damage Replace. Loose connection Connect properly. 3.Install: Box and seat assembly Refer to BOX AND SEAT section.
EASM0014
EXHAUST SYSTEM INSPECTION 1. Remove: Side covers Refer to SIDE COVERS section. 2. Inspect: 11 Nm (1.1mkg) Nut (exhaust pipe) Loose/Damage Tighten/Replace. Gasket (exhaust pipe) Exhaust gas leaks Tighten/Replace
T.R
3-19
CHECKING THE COOLANT LEVEL

T.R
CHK ADJ
3. Inspect: 27 Nm (2.7 mkg) Bolt (mufler) Loose/Damage Tighten/Replace 4. Inspect: 19 Nm (1.9 mkg) Bolt (mufler/exhaust pipe) Loose/Damage Tighten/Replace
T.R
ZAUM0133
EAS00103
CHECKING THE COOLANT LEVEL 1.Stand the scooter on a level surface. NOTE: Place the scooter on a suitable stand. Make sure the scooter is upright. 2.Remove: coolant tank cover Refer to BOX AND SEATsection 3.Check: coolant level The coolant level should be between the maximum level mark and minimum level mark . Below the minimum level mark Add the recommended coolant to the proper level.
CAUTION: Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, if distilled water is not available, soft water may be used.
ZAUM0094
ZAUM0101
ZAUM0102
4.Start the engine, warm it up for several minutes, and then turn it off. 5.Check: coolant level NOTE: Before checking the coolant level, wait a few minutes until it settles.
3-20
CHANGING THE COOLANT

EAS00105
CHK ADJ
CHANGING THE COOLANT 1.Remove: Seat and box assembly Refer to BOX AND SEAT section. Side covers Refer to SIDE COVERS section. Inner front cover Under cover Refer to FRONT COVER, INNER FRONT COVER AND FRONT SIDE COVERS section. 2.Disconnect: coolant reservoir hose 3.Drain: coolant (from the coolant reservoir) 4.Remove: radiator cap
WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.
The following procedure applies to all of the coolant drain bolts and copper washers. 5. Remove: coolant drain bolt (water pump) (along with the copper washer) coolant drain bolt (engine) (along with the copper washer) 6. Drain: coolant (from the engine and radiator) 7.Disconnect: pump inlet hose
3-21
CHK ADJ
8. Drain: coolant (from the water pump and radiator) 9.Check: copper washer (coolant drain bolt-engine ) copper washer (coolant drain bolt-water pump) hoses Damage Replace. 10.Connect: pump inlet hose 11.Install: coolant drain bolt (engine)
T.R
10 Nm (1.0mkg) 10 Nm (1.0mkg)
coolant drain bolt (water pump)

T.R
12.Connect: coolant reservoir hose 13.Fill: cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 1.25 L Coolant reservoir capacity 0.35 L Handling notes for coolant Coolant is potentially harmful and should be handled with special care.
WARNING If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. If coolant is swallowed, induce vomiting and get immediate medical attention.
3-22
CHK ADJ
CAUTION: Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, if distilled water is not available, soft water may be used. If coolant comes into contact with painted surfaces, immediately wash them with water. Do not mix different types of antifreeze.
14. Install: radiator cap
ZAUM0101
15. Fill: coolant reservoir (with the recommended coolant to the maximum level mark ) 16. Install: coolant reservoir cap 17. Start the engine, warm it up for several minutes, and then stop it. 18. Check: coolant level Refer to CHECKING THE COOLANT LEVEL section. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. 19. Install: Under cover Inner front cover Refer to FRONT COVER, INNER FRONT COVER AND FRONT SIDE COVERS section. Side covers Refer to SIDE COVERS section. Seat and box assy Refer to BOX AND SEAT section.
3-23
INSPECTING THE COOLANT SYSTEM

EASM0015
CHK ADJ
INSPECTING THE COOLANT SYSTEM 1.Inspect: Radiator Filler hose Radiator inlet hose Radiator outlet hose Cracks/Damage Replace Refer to COOLING SYSTEM section in chapter 5.
3-24
CHECKING THE FRONT AND REAR BRAKE LEVER FREE PLAY

EASM0016
CHK ADJ
FRONT
CHASSIS
CHECKING THE FRONT AND REAR BRAKE LEVER FREE PLAY 1.Check: brake lever free play Out of specification check the brake system. Refer to FRONT BRAKE section in chapter 7.
ZAUM0107
REAR
Brake lever free play (at the end of the brake lever) 10 ~ 20 mm
WARNING
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. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if necessary, bleed the brake system.
3-25
CHECKING THE FRONT AND REAR BRAKE FLUID LEVEL

FRONT
EAS00116
CHK ADJ
CHECKING THE FRONT AND REAR BRAKE FLUID LEVEL 1.Stand the scooter on a level surface. NOTE: Place the scooter on a suitable stand. Make sure the scooter is upright.
ZAUM0110
REAR
2.Check: brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. Recommended brake fluid DOT#3 or DOT#4 Front brake minimum level mark Rear brake minimum level mark
ZAUM0111
WARNING
Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the reservoir is horizontal.
3-26
CHECKING THE FRONT AND REAR BRAKE PADS CHECKING THE FRONT AND REAR BRAKE HOSES
FRONT
EASM0017
CHK ADJ
ZAUM0095
REAR
CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1.Operate the brake. 2.Check: brake pad thickness Less than specification Replace the brake pads as a set. Refer to FRONT BRAKE section in chapter 7. Brake pad thickness wear limit 0,8 mm
ZAUM0096
EASM0017
CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1.Check: brake hose Cracks/damage/wear Replace 2.Check: brake hose clamp Loose Tighten the clamp bolt 3.Hold the scooter upright and apply the brake several times. 4.Check: brake hose Activate the brake several times. Brake fluid leakage Replace the damaged hose. Refer to FRONT WHEEL AND BRAKE DISC and REAR WHEEL AND BRAKE DISC section in chapter 7.
3-27
BLEEDING THE HYDRAULIC BRAKE SYSTEM

EAS00133
CHK ADJ
BLEEDING THE HYDRAULIC BRAKE SYSTEM

WARNING Bleed the hydraulic brake system whenever: the system is disassembled, a brake hose is loosened, disconnected or replaced, the brake fluid level is very low, brake operation is faulty.
FRONT
NOTE: Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow. When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. 1.Bleed: hydraulic brake system a.Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b.Install the brake master cylinder reservoir diaphragm. c. Connect a clear plastic hose tightly to the bleed screw . d.Place the other end of the hose into a container. e.Slowly squeeze the brake lever several times. f. Fully squeeze the brake lever without releasing it. g.Loosen the bleed screw. NOTE: 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.
ZAUM0136
REAR
ZAUM0137
3-28
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHECKING AND ADJUSTING THE STEERING HEAD
CHK ADJ
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. Bleed screw 6 Nm (0.6 mkg)
T. R
k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to CHECKING THE FRONT AND REAR BRAKE FLUID LEVEL section.
WARNING
After bleeding the hydraulic brake system, check the brake operation .
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.
NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2.Check: steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness Adjust the steering head. 3.Remove: Handlebar cover Refer to HANDLEBAR COVERS section. Handlebar Refer to HANDLEBAR section in chapter 7. 4.Adjust: steering head
3-29
CHECKING AND ADJUSTING THE STEERING HEAD
CHK ADJ
a.Remove the lock washer , the upper ring nut , the center ring nut and the rubber washer. b.Loosen the lower ring nut and then tighten it to specification with the ring nut wrench . NOTE: Set the torque wrench at a right angle to the ring nut wrench. Steering nut wrench 90890-01403 Lower ring nut (initial tightening torque) 38 Nm (3.8 mkg)
T.
c. Loosen the lower ring nut completely and then tighten it to specification with a ring nut wrench .
WARNING
Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 22 Nm (2.2 mkg)
T.
d.Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to STEERING HEAD section in chapter 7. e.Install the rubber washer. f. Install the centre ring nut . g.Finger tighten the centre ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the centre ring nut until their slots are aligned. h.Install the lock washer . NOTE: Make sure the lock washer tabs sit correctly in the ring nut slots. i. Hold the lower and centre ring nuts with a exhaust and ring nut wrench and tighten the upper ring nut with a ring nut wrench.
3-30
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK
Ring nut wrench 90890-01268
CHK ADJ
T.
Upper ring nut 75 Nm (7.5 mkg)
5.Install: Handlebar Refer to HANDLEBAR section in chapter 7. Handlebar cover Refer to HANDLEBAR COVERS section.
EAS00151
CHECKING THE FRONT FORK 1.Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is no danger of it falling over. 2.Check: inner tube Damage/scratches Replace. oil seal Oil leakage Replace. 3.Hold the scooter upright and apply the front brake. 4.Check: front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement Repair. Refer to FRONT FORK section in chapter 7.
3115
3-31
INSPECTING THE REAR SHOCK ABSORBER/ CHECKING THE TYRES

EASM0018
CHK ADJ
INSPECTING THE REAR SHOCK ABSORBER 1.Remove: Mudguard Refer to SIDE COVERS section. 2.Check Rear shock absorber mount Looseness Tighten 31.5 Nm (3.15mkg) Bolt (upper) 18 Nm (1.8mkg) Bolt (lower)
T.R
T.R
Refer to REAR SHOCK ABSORBER AND EXHAUST PIPE section in chapter 7.
EAS00167
CHECKING THE TYRES The following procedure applies to both of the tyres. 1.Measure: tyre pressure Out of specification Regulate.
WARNING The tyre pressure should only be checked and regulated when the tyre temperature equals the ambient air temperature. The tyre pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. Operation of an overloaded scooter could cause tyre damage, an accident or an injury. NEVER OVERLOAD THE SCOOTER.
Basic weight (with oil and a full fuel tank) Maximum load* Cold tyre pressure Up to 90 kg load* 90 kg ~ maximum load* High-speed riding
124 kg 187 kg Front 190 kPa

(1.9 kgf/cm2)
Rear 200 kPa

(2.0 kgf/cm2)
200 kPa
(2.0 kgf/cm )
2
220 kPa
(2.2 kgf/cm2)
200 kPa
(2.0 kgf/cm )
2
220 kPa
(2.2 kgf/cm2)
* total of cargo, rider, passenger and accessories (except the motorcycle).
3-32
CHECKING THE TYRES
CHK ADJ
WARNING It is dangerous to ride with a worn-out tyre. When the tyre tread reaches the wear limit, replace the tyre immediately.
3101
2.Check: tyre surfaces Damage/wear Replace the tyre. Minimum tyre tread depth 1.6 mm Tyre tread depth Side wall Wear indicator
WARNING Do not use a tubeless tyre on a wheel designed only for tube tyres to avoid tyre failure and personal injury from sudden deflation. When using tube tyres, be sure to install the correct tube. Always replace a new tube tyre and a new tube as a set. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement.
3103
Tube wheel Tube tyre only Tubeless wheel Tube or tubeless tyre After extensive tests, the tyres listed below have been approved by MBK Industrie for this model. The front and rear tyres should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tyre combination other than one approved by MBK Industrie is used on this scooter.
3-33
CHECKING THE TYRES
CHK ADJ
PIRELLI SL36 130/60-13
Front tyre Manufacturer CHENG-SHIN Model MAXXIS Size 130/60-13 Rear tyre Manufacturer Model Size
CHENG-SHIN MAXXIS 140/60-13
PIRELLI SL36 140/60-13
WARNING
New tyres 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. After a tyre has been repaired or replaced, be sure to tighten the tyre air valve stem locknut to specification. NOTE: For tyres with a direction of rotation mark: Install the tyre with the mark pointing in the direction of wheel rotation. Align the mark with the valve installation point.
3-34
CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES

EAS00168
CHK ADJ
CHECKING THE WHEELS The following procedure applies to both of the wheels. 1.Check: wheel Damage/out-of-round Replace.
WARNING
Never attempt to make any repairs to the wheel. NOTE: After a tyre or wheel has been changed or replaced, always balance the wheel.
EAS00170
CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables.
WARNING
Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible. 1.Check: cable sheath Damage Replace. 2.Check: cable operation Rough movement Lubricate. Recommended lubricant Engine oil or a suitable cable lubricant NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device.
3-35
LUBRICATING THE LEVERS/ LUBRICATING THE CENTERSTAND

EAS00171
CHK ADJ
LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant Engine oil
ZAUM0061
EAS00172
LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant Engine oil
ZAUM0062
3-36
CHECKING THE BATTERY

EAS00177
CHK ADJ
ELECTRICAL SYSTEM
WARNING
Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulphuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries. Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL Skin - Wash with water. Eyes - Flush with water for 15 minutes and get immediate medical attention. INTERNAL Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention. 1.Remove: Battery cover Refer to BOX AND SEAT section. 2.Disconnect: battery leads (from the battery terminals)
CAUTION: First, disconnect the negative battery lead , and then the positive battery lead .
ZAUM0138
3.Remove: battery
om913(b)
3-37
CHK ADJ
UPPER LOWER
4.Check: electrolyte level The electrolyte level should be between the minimum level mark and the maximum level mark . Below the minimum level mark Add distilled water to the proper level.
CAUTION: Add only distilled water. Tap water contains minerals which are harmful to the battery.
5.Check: specific gravity Less than 1.280 Recharge the battery. Specific gravity 1.280 at 20C 6.Charge: battery
WARNING Do not quick charge a battery. CAUTION: Loosen the battery sealing caps. Make sure the battery breather hose and battery vent are free of obstructions. To ensure maximum performance, always charge a new battery before using it. Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. When charging a battery, be sure to remove it from the scooter. (If charging has to be done with the battery mounted on the scooter, disconnect the negative battery lead from the battery terminal.) To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. Before removing the battery charger lead
3-38
CHK ADJ
clips from the battery terminals, be sure to turn off the battery charger. 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. If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! NOTE: Replace the battery whenever: battery voltage does not rise to specification or bubbles fail to rise during charging, sulphation of one or more battery cells occurs (as indicated by the battery plates turning white or material accumulating in the bottom of the battery cell), specific gravity readings after a long, slow charge indicate that one battery cells charge is lower than the rest, warpage or buckling of the battery plates or insulators is evident. 7.Check: battery breather hose and battery vent Obstruction Clean. Damage Replace. 8.Install: battery 9. Connect: battery breather hose
CAUTION:
om913(a)
When checking the battery, make sure the battery breather hose is properly installed and routed correctly. If the battery breather hose is positioned so as to allow electrolyte or hydrogen gas from the battery to contact the frame, the scooter and its finish may be damaged. 10. Check: battery terminals DirtClean with a wire brush. Loose connectionConnect properly.
3-39
CHECKING THE BATTERY/ CHECKING THE FUSES

11. Connect: battery leads (to the battery terminals)
CHK ADJ
CAUTION: First, connect the positive battery lead and then the negative battery lead .
om913(b)
12. Lubricate: battery terminals Recommended lubricant Dielectric grease 13. Install: Battery cover Refer to BOX AND SEAT section.
EAS00181
CHECKING THE FUSES The following procedure applies to all of the fuses.
CAUTION: To avoid a short circuit, always set the main switch to OFF when checking or replacing a fuse.
1.Remove: Battery cover Refer to BOX AND SEAT section. 2.Check: continuity a.Connect the pocket tester to the fuse and check the continuity.
ZAUM0139
NOTE: Set the pocket tester selector to x 1. Pocket tester 90890-03112 b.If the pocket tester indicates , replace the fuse.
3-40
CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULBS

3.Replace: blown fuse
CHK ADJ
a.Set the main switch to OFF. b.Install a new fuse of the correct amperage. c. Set on the switches to verify if the electrical circuit is operational. d.If the fuse immediately blows again, check the electrical circuit. Items Main fuse Fan fuse
WARNING
Amperage 20A 7.5A
Qty 1 1
ZAUM0109
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. 4.Install: Battery cover Refer to BOX AND SEAT section.
EAS00183
ZAUM0112
REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1.Remove: Inner front cover Refer to FRONT COVER, INNER FRONT COVER AND FRONT SIDE COVER section. 2.Detach: headlight bulb holder 3.Remove: headlight bulb
WARNING
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
3-41
REPLACING THE HEADLIGHT BULBS/ REPLACING THE TURN SIGNAL LIGHT BULBS
CHK ADJ
4.Install: headlight bulb Secure the new headlight bulb with the headlight bulb holder.
CAUTION: 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.
5.Attach: headlight bulb holder 6.Install: Inner front cover Refer to FRONT COVER, INNER FRONT COVER AND FRONT SIDE COVER section.
EAS00183
ZAUM0115
REPLACING THE TURN SIGNAL LIGHT BULBS The following procedure applies to both of the turn signal light bulbs. 1.Remove: Turn signal light lens 2.Remove: headlight bulb (push and turn it counterclockwise)
WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
3.Install: Turn signal light bulb clockwise until it stops)
CAUTION:
(push and turn it
ZAUM0116
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
3-42
REPLACING THE FLASHER LIGHT BULBS/ REPLACING TAIL/BRAKE LIGHT BULB

CAUTION:
CHK ADJ
moistened with alcohol or lacquer thinner.
Do not overtighten the screw, otherwise the lensmay break. 4.Install: Flasher light lens
EAS00183
ZAUM0117
REPLACING THE TAIL/BRAKE LIGHT BULB 1.Remove: Passanger seat Refer to BOX AND SEAT section 2.Remove: Bulb holder (turn it counterclockwise) 3.Remove: Taill/brake light bulb (push and turn it counterclockwise)
WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
4.Install: Tail/brake light bulb clockwise until it stops)

CAUTION:
(push and turn it
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. 5.Install: Bulb holder (turn it clockwise) 6.Install: Passanger seat Refer to BOX AND SEAT section
3-43
REPLACING THE LICENCE PLATE LIGHT BULB/ ADJUSTING THE HEADLIGHT BEAMS/ADJUSTING THE DIGITAL CLOCK
EAS00183
CHK ADJ
REPLACING THE LICENCE PLATE LIGHT BULB 1.Remove: Licence plate light 2.Remove: Socket assembly (pull it ) 3.Remove: Plate light bulb (pull it)
ZAUM0118
WARNING
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4.Install: Plate light bulb
CAUTION:
(push it)
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. 5.Install: Socket assembly (push it) 6.Install: Licence plate light
EAS00185
ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1.Adjust: headlight beam (vertically) a.Turn the adjusting screw
ZAUM0115
in or out.
Turning in Headlight beam is raised. Turning out Headlight beam is lowered.
EASM0019
ADJUSTING THE DIGITAL CLOCK To adjuste the digital clock, refer to FEATURES section in chapter 1.
3-44
ENG
ENG
CHAPTER 4. OVERHAULING THE ENGINE
ENGINE ......................................................................................................... 4-1 WIRING HARNESS, CABLE .................................................................... 4-1 HOSES, ENGINE MOUNTING BOLT AND ENGINE .............................. 4-3 CAMSHAFT ................................................................................................... 4-4 REMOVING THE ROCKER ARMS AND THE CAMSHAFT .................... 4-5 CHECKING THE CAMSHAFT ................................................................. 4-5 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ......... 4-6 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES ................................................................. 4-7 CHECKING THE TIMING CHAIN TENSIONER ...................................... 4-7 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER .................................................................................................... 4-8 INSTALLING THE CAMSHAFT AND ROCKER ARMS ........................... 4-8 CYLINDER HEAD ........................................................................................ 4-10 REMOVING THE CYLINDER HEAD ..................................................... 4-12 CHECKING THE CYLINDER HEAD ...................................................... 4-12 INSTALLING THE CYLINDER HEAD .................................................... 4-13 VALVES AND VALVE SPRINGS ................................................................ 4-14 REMOVING THE VALVES .................................................................... 4-15 CHECKING THE VALVES AND VALVE GUIDES ................................. 4-16 CHECKING THE VALVE SEATS ........................................................... 4-17 CHECKING THE VALVE SPRINGS ...................................................... 4-19 INSTALLING THE VALVES ................................................................... 4-20 CYLINDER AND PISTON ............................................................................ 4-22 REMOVING THE CYLINDER AND PISTON ......................................... 4-23 CHECKING THE CYLINDER AND PISTON .......................................... 4-23 CHECKING THE PISTON RINGS ......................................................... 4-25 CHECKING THE PISTON PIN ............................................................... 4-26 INSTALLING THE PISTON AND CYLINDER ........................................ 4-26
ENG
CLUTCH ...................................................................................................... 4-28 CRANKCASE COVER ........................................................................... 4-28 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ................. 4-29 SECONDARY SHEAVE ......................................................................... 4-30 REMOVING THE PRIMARY SHEAVE .................................................. 4-31 REMOVING THE SECONDARY SHEAVE AND V-BELT ...................... 4-31 DISASSEMBLING THE SECONDARY SHEAVE .................................. 4-32 CHECKING THE CLUTCH .................................................................... 4-32 CHECKING THE CLUTCH HOUSING ................................................... 4-33 CHECKING THE CLUTCH SPRINGS ................................................... 4-33 CHECKING THE V-BELT ...................................................................... 4-33 CHECKING THE WEIGHTS .................................................................. 4-33 CHECKING THE SECONDARY SHEAVE ............................................. 4-34 ASSEMBLING THE PRIMARY SHEAVE ............................................... 4-34 INSTALLING THE SECONDARY SHEAVE ........................................... 4-35 STARTER CLUTCH AND GENERATOR .................................................... 4-37 MAGNETO COVER AND STATOR COIL .............................................. 4-37 STARTER CLUTH ................................................................................. 4-38 CHECKING THE STARTER CLUTCH ................................................... 4-39 INSTALLING THE GENERATOR .......................................................... 4-39 OIL PUMP .................................................................................................... 4-40 CHECKING THE OIL PUMP .................................................................. 4-41 CRANKCASE AND CRANKSHAFT ........................................................... 4-42 DISASSEMBLING THE CRANKCASE .................................................. 4-44 REMOVING THE CRANKSHAFT ASSEMBLY ...................................... 4-44 CHECKING THE CRANKSHAFT AND CONNECTING ROD ................ 4-45 CHECKING THE CRANKCASE ............................................................. 4-46 CHECKING THE BEARINGS AND OIL SEALS .................................... 4-46 CHECKING THE CIRCLIPS AND WASHERS ....................................... 4-46 INSTALLING THE CRANKSHAFT ......................................................... 4-46 ASSEMBLING THE CRANKCASE ........................................................ 4-47 TRANSMISSION .......................................................................................... 4-48
ENGINE
EASM0020 (bis)
ENG
OVERHAULING THE ENGINE

ENGINE
WIRING HARNESS AND CABLE
6 7 2 5 1 8
3 4
FW
Order
Job/Part Removing the wire harness and cables Seat Box Side covers Drain coolant
Qty
Remarks Remove the parts in the order listed. Refer to BOX AND SEAT section in chapter 3. Refer to SIDE COVERS section in chapter 3. Refer to CHANGING THE COOLANT section in chapter 3.
I 1 2 3 4 5 6
Disconnect: Spark plug cap Thermo switch connector Carburetor heater connector Autochoke coupler Flywheel magneto couplers Starter motor connector
1 1 2 1 2 1
4-1
ENGINE
ENG
6 7 2 5 1 8
3 4
FW
Order 7 8 Earth lead Throttle cable
Job/Part
Qty 1 1
Remarks
4-2
ENGINE
EASM0021
ENG
HOSES, ENGINE MOUNTING BOLT AND ENGINE
6
T.R
18 Nm (1.8 mkg)
T.R
28 Nm (2.8 mkg)
1 8 4 5
T.R
55 Nm (5.5 mkg)
9 11 10 2 7
Order
Job/Part Removing the hoses, engine mounting bolt and engine Wire and cable
Qty
Remarks Remove the parts in the order listed. Refer to WIRING HARNESS AND CABLES section in chapter 1
1 2 3 4 5 6 7 8 9 10 11
Crankcase breather hose Inlet hose (water pump) Outlet hose (cylinder head) Fuel suction hose Fuel tank pipe Rear brake caliper Engine bracket covers (left and right) Rear shock absorbers bolt (lower) Self locknut Engine axle Engine
1 1 1 1 1 1 2 2 1 1 1
Place the scooter on a suitable stand so that the rear wheel is elevated.
4-3
CAMSHAFT
EASM0023
ENG
CAMSHAFT
10 11
T.R
6,5 Nm (0,65 m kg)
1
LS
2 3
T.R
9
E
5 4
10 Nm (1,0 m kg)
3
6
LS
12 8
M
LS
2
E
11 10
T.R
6,5 Nm (0,65 m kg)
T.R
12 Nm (1,2 m kg)
Order
Job/Part Removing the camshaft Cylinder head Valve cap (intake and exhaust) O-ring Plate bolt Plate Rocker arm shaft (intake) Rocker arm shaft (exhaust) Camshaft retaining plate Camshaft Rocker arms (intake and exhaust) Locknut Adjuster O-ring
Qty
1 2 3 4 5 6 7 8 9 10 11 12
2 1 3 1 1 1 1 1 2 2 2 2
Slide hammer bolt: 90890-01083 Weight: 90890-01084
4-4
CAMSHAFT
EAS00197
ENG
REMOVING THE ROCKER ARMS AND CAMSHAFT 1.Align: T mark on the generator rotor (with the mark on the generator rotor cover)
a
a.Turn the crankshaft counterclockwise. b.When the piston is at TDC on the compression stroke, align the T mark a on the generator rotor with the mark b on the crankcase. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. 2.Loosen: locknuts adjusting screws 3.Remove: timing chain tensioner assembly NOTE: Remove the timing chain tensioner adjusting screw and spring to release the spring tension and then remove the timing chain tensioner body. 4.Remove: bolt camshaft sprocket Rocker arms shaft 5.Remove: camshaft retaining plate and bolt camshaft Slide hammer bolt 90890-01083 (M6) Weight 90890-01084 6.Remove: rocker arms
EAS00205
CHECKING THE CAMSHAFT 1.Check: camshaft bearings Damage/wear Replace. 2.Check: camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft.
4-5
CAMSHAFT
ENG
3.Measure: camshaft lobe dimensions a and b . Out of specification Replace the camshaft. Camshaft lobe dimension limit Intake a 30.711mm b 25.045 mm Exhaust a 30.711 mm b 25.052 mm 4.Check: camshaft oil passage Obstruction Blow out with compressed air.
EAS00206
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1.Check: rocker arm Damage/wear Replace. 2.Check: rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches Replace or check the lubrication system. 3.Check: camshaft lobe Excessive wear Replace the camshaft. 4.Measure: rocker arm inside diameter Out of specification Replace. Rocker arm inside diameter 12.000 ~ 12.018 mm <Limit>:12.030mm 5.Measure: rocker arm shaft outside diameter Out of specification Replace. Rocker arm shaft outside diameter 11.981 ~ 11.991 mm <Limit>:11.950 mm
4-6
CAMSHAFT
ENG
6.Calculate: rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.037 mm
EAS00207
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES 1.Check: timing chain Damage/stiffness Replace the timing chain and camshaft sprocket as a set. 2.Check: camshaft sprocket More than 1/4 tooth a wear Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct Timing chain roller Camshaft sprocket 3.Check: timing chain guide (upper) timing chain guide (lower) Damage/wear Replace the defective part(s).
EAS00210
CHECKING THE TIMING CHAIN TENSIONER 1.Check: timing chain tensioner Cracks/damage Replace. 2.Check: one-way cam operation Rough movement Replace the timing chain tensioner housing. 3.Check: cap bolt O-ring spring one-way cam gasket timing chain tensioner rod Damage/wear Replace the defective part (-s).
4-7
CAMSHAFT
EAS00212
ENG
CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER The following procedure applies to both of the tappet covers and O-rings. 1.Check: tappet covers O-rings Damage/wear Replace the defective part(s). INSTALLING THE CAMSHAFT AND ROCKER ARMS 1.Lubricate: rocker arms and shafts (intake and exhaust) Recommended lubricant Molybdenum disulfide oil 2.Install: exhaust rocker arm intake rocker arm 3.Lubricate: camshaft Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 4.Align: T mark on the generator rotor (with the mark on the generator rotor cover) a.Turn the crankshaft counterclockwise. b.When the piston is at TDC on the compression stroke, align the T mark a on the generator rotor with the mark b on the generator rotor cover. NOTE: Be sure to keep the timing chain as tight as possible. 5. Install: camshaft camshaft retaining plate 12 Nm (1.2mkg) bolt O-rings (onto the intake and exhaust rocker arm shafts) exhaust rocker arm shaft intake rocker arm shaft
T.R
a
ZAUM0140
4-8
CAMSHAFT
CAUTION:
ENG
Make sure the threaded part of the rocker arm shaft and O-rings faces outwards. 6.Install: rocker arm shaft clamp and bolt.
T.R
10 Nm (1.0mkg)
7.Install: timing chain (onto the camshaft sprocket) camshaft sprocket (onto the camshaft) NOTE: The notch on the camshaft should face towards the intake side of the engine. Align the camshaft mark c with the edge of the cylinder head d as shown.
CAUTION:
Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. 8.Install: camshaft sprocket bolt
T.R
30 Nm (3.0mkg)
9.Adjust: valves clearance Refer to ADJUSTING THE VALVES CLEARANCE section in chapter 3. 10. Lubricate: cylinder head components Recommended lubricant Engine oil 11. Turn: crankshaft NOTE: Turn the crankshaft several full turns to make sure the camshaft is properly timed.
4-9
CYLINDER HEAD
EASM0020
ENG
CYLINDER HEAD
T.R
8 Nm (0.8 m kg)
8
T.R
10 Nm (1.0 m kg)
T.R
22 Nm (2.2 m kg)
14
12 2
5 1
15 13
E
10 7
12 Nm (1.2 m kg)
6 11
T.R
D FW
4
T.R
30 Nm (3.0 m kg)
Order
Job/Part Removing the cylinder head Seat Box Battery box Side covers Caburetor Exhaust pipe Drain coolant
Qty
Remarks Remove the parts in the order listed. Refer to SIDE COVERS and BOX AND SEAT section in chapter 3. Refer to CARBURETOR section in chapter 6. Refer to REAR SHOCKS ABSORBER AND EXHAUST PIPE section in chapter 7 Refer to CHANGING THE COOLANT section in chapter 3.
I 1 2 3 4
Remove: Spark plug Thermo switch connector Pump inlet hose Pump outlet hose
1 1 1 1
4-10
CYLINDER HEAD
ENG
T.R
8 Nm (0.8 m kg)
8
T.R
10 Nm (1.0 m kg)
T.R
22 Nm (2.2 m kg)
14
12 2
5 1
15 13
E
10 7
12 Nm (1.2 m kg)
6 11
T.R
WD
4
T.R
30 Nm (3.0 m kg)
Order 5 6 7 8 9 10 11 12 13 14 15
Job/Part Cylinder head outlet hose Crankcase breather hose Water pump Timing chain tensioner Camshaft sprocket Timing chain Cylinder head bolts Cylinder head nuts Cylinder head Dowel pin Cylinder head gasket
Qty 1 1 1 1 1 1 2 4 1 2 1
Remarks
WARNING Follow the arrows

NOTE: Lock the flywheel with the special tool.
NOTE: Avoid the dowel pin falling in the cylinder. For installation, reverse the removal procedure.
4-11
CYLINDER HEAD
EAS00225
ENG
REMOVING THE CYLINDER HEAD 1.Remove: camshaft and rocker arms Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT section. NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire. 2.Remove: cylinder head NOTE: Loosen the nuts in the proper sequence. Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
EAS00229
CHECKING THE CYLINDER HEAD 1.Remove: combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: spark plug bore threads valve seats 2.Check: cylinder head Damage/scratches Replace. cylinder head water jacket Mineral deposits/rust Remove. 3.Measure: cylinder head warpage Out of specification Resurface the cylinder head. Maximum cylinder head warpage 0.03mm
a.Place a straightedge and a thickness gauge across the cylinder head. b.Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows.
4-12
CYLINDER HEAD
ENG
d.Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times.
EAS00232
INSTALLING THE CYLINDER HEAD 1.Install: cylinder head gasket dowel pins 2.Install: cylinder head copper washers 22 Nm (2.2mkg) cylinder head nuts 12 Nm (1.2mkg) cylinder head bolts
T.R T.R
NOTE: Lubricate the cylinder head nuts with engine oil. Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages. 3.Install: camshaft rocker arms Refer to INSTALLING THE CAMSHAFTS AND ROCKER ARMS section.
4-13
VALVES AND VALVE SPRINGS

EASM0024
ENG
2 3 6 7
M
7 6 3 2 1
M
Order
Job/Part Removing the valves and valves springs Cylinder head Rocker arm, rocker arm shaft Valve cotters Spring retainers Valve spring Valve (intake) valve (exhaust) Valve guide (oil seals) Spring seat
Qty
Remarks Remove the parts in the order listed. Refer to CYLINDER HEAD section. Refer to CAMSHAFT section.
1 2 3 4 5 6 7
4 2 2 1 1 2 2
Valve spring compressor: 90890-04019 Attachment: 90890-04108
NOTE: After installation, refer to "Adjusting valve" section in chapter 3. For installation, reverse the removal procedure.
4-14

EAS00238
ENG
REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.Check: valve (for leakage) Leakage at the valve seat Check the valve face, valve seat, and valve seat width. Refer to CHECKING THE VALVE SEATS section.
b
a.Pour a clean solvent a into the intake and exhaust ports. b.Check that the valves properly seal. NOTE: There should be no leakage at the valve seat b . 2.Remove: valve cotters NOTE: Remove the valve cotters by compressing the valve springs with the valve spring compressor and attachment . Valve spring compressor 90890-04019 Attachment 90890-04108
3.Remove: spring retainer valve springs oil seal spring seat valve NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
4-15

EAS00239
ENG
CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1.Measure: valve-stem-to-valve-guide clearance b Valve-stem-to-valve-guide clearance = Valve guide inside diameter b Valve stem diameter a Out of specification Replace the valve guide.
a
Valve guide inside diameter: Intake 4.500 ~ 4.512 mm <Limit>: 4.542 mm Exhaust 4.500 ~4.512 mm <limit>: 4.542 mm Valve stem diameter: Intake 4.475 ~ 4.490 mm <limit>: 4.445 mm Exhaust 4.460 ~ 4.475 mm <limit>: 4.430 mm Valve-stem-to-valve-guide clearance Intake 0.01~0.037mm <Limit>: 0.08 mm Exhaust 0.025~0.052 mm <Limit>: 0.10mm 2.Replace: valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100C in an oven.
a.Remove the valve guide with the valve guide remover . b.Install the new valve guide with the valve guide installer and valve guide remover .
4-16
ENG
c. After installing the valve guide, bore the valve guide with the valve guide reamer to obtain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat . Valve guide remover (4.5 mm) 90890-04116 Valve guide installer (4.5 mm) 90890-04117 Valve guide reamer (4.5 mm) 90890-04118 3.Remove: carbon deposits (from the valve face and valve seat) 4.Check: valve face Pitting/wear Grind the valve face. valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve. 5.Measure: valve margin thickness a Out of specification Replace the valve. 6.Measure: valve stem runout Out of specification Replace the valve. NOTE: When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.01 mm
EAS00240
CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1.Remove: carbon deposits (from the valve face and valve seat) 2.Check: valve seat Pitting/wear Replace the cylinder head.
4-17
ENG
3.Measure: valve seat width a Out of specification Replace the cylinder head. Valve seat width Intake 0.9 ~ 1.1 mm <limit>: 1.6 mm Exhaust 0.9 ~ 1.1 <limit>: 1.6 mm)
a.Apply Mechanics blueing dye (Dykem) onto the valve face . b.Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make clear impression. d.Measure the valve seat width. a NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed.
4.Lap: valve face valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. a.Apply a coarse lapping compound a to the valve face.
CAUTION:
Do not let the lapping compound enter the gap between the valve stem and the valve guide. b.Apply molybdenum disulfide oil onto the valve stem.
4-18
ENG
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. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. e.Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g.Apply Mechanics blueing dye (Dykem) onto the valve face. h.Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impression. j. Measure the valve seat width k again. If the c valve seat width is out of specification, reface and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1.Measure: valve spring free length a Out of specification Replace the valve spring. Valve spring free length (intake and exhaust) Valve spring 41.94 mm <Limit>: 39.84mm 2.Measure: compressed valve spring force a Out of specification Replace the valve spring. b Installed length
4-19

a
ENG
Spring compressed pressure (intake and exhaust) 45.1 ~ 50.9 N 3.Measure: valve spring tilt a Out of specification Replace the valve spring. Spring tilt limit Intake and exhaust valve spring 2.5 / 1.9 mm
EAS00245
INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1.Deburr: valve stem end (with an oil stone) 2.Lubricate: valve stem oil seal (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil
a b
3.Install: valve spring seat valve stem seal valve valve spring spring retainer (into the cylinder head) NOTE: Install the valve spring with the larger pitch a facing up.
b Smaller pitch
4-20

4.Install: valve cotters
ENG
NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor and attachment. Valve spring compressor 90890-04019 Attachment 90890-04108 5.To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Hitting the valve tip with excessive force could damage the valve.
4-21
CYLINDER AND PISTON

EASM0025
ENG
CYLINDER AND PISTON
5 4 3
10
11
T.R
12 Nm (1.2 m kg)
D FW
Order
Job/Part Removing the cylinder and piston Cylinder head Cylinder bolts Timing chain guide (lower) Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring (top) Piston ring (2nd) Oil ring
Qty
1 2 3 4 5 6 7 8 9 10 11
2 1 1 2 1 2 1 1 1 1 1 For installation, reverse the removal procedure.
4-22
CYLINDER AND PISTON

EAS00253
ENG
REMOVING THE CYLINDER AND PISTON 1.Remove: piston pin clip piston pin piston Do not use a hammer to drive the piston pin out. NOTE: Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. Before removing the piston pin, deburr the piston pin clips groove and the pistons pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller. Piston pin puller 90890-01304 2.Remove: top ring 2nd ring oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.
EAS00255
CHECKING THE CYLINDER AND PISTON 1.Check: piston wall cylinder wall Vertical scratches Rebore or replace the cylinder, and replace the piston and piston rings as a set.
4-23
CYLINDER AND PISTON
ENG
2.Measure: piston-to-cylinder clearance a.Measure cylinder bore C with the cylinder bore gauge. NOTE: Measure cylinder bore C by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. Cylinder XQ 125 bore C XQ 150 Taper limit T Out-of-round R
D2
D1
53.700 ~ 53.705 mm 59.500 ~ 59.505 mm 0.05 mm 0.05 mm
D3
D4
C = maximum of D1 ~ D2 T = maximum of D1 or D2 - maximum of D5 or D6 R = maximum of D1, D3 or D5 - minimum of D2, D4 or D6 b.If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter P with the micrometer. Piston size P XQ 125 53.670 ~ 53.687 mm Standard XQ 150 59.470 ~ 59.487 mm XQ 125 53.92 mm Oversize 2 XQ 150 59.72 mm XQ 125 54.17 mm Oversize 4 XQ 150 59.97 mm d.If out of specification, replace the piston and piston rings as a set. 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 0.025 ~ 0.035 mm <Limit>: 0.15mm f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.
D5
D6
4-24
CYLINDER AND PISTON

EAS00264
ENG
CHECKING THE PISTON RINGS 1.Measure: piston ring side clearance Out of specification Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, remove any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.03 ~ 0.07 mm <Limit>: 0.12 mm 2nd ring 0.02 ~ 0.06 <Limit>: 0.12 mm 2.Install: piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown.
a 0.5 mm
3.Measure: piston ring end gap Out of specification Replace the piston ring. NOTE: The oil ring expander spacers end gap cannot be measured. If the oil ring rails gap is excessive, replace all three piston rings. Piston ring end gap Top ring 0.15 ~ 0.25 mm <Limit>: 0.50 mm 2nd ring 0.15 ~ 0.30 mm <Limit>: 0.65 mm Oil ring 0.20 ~ 0.70 mm
4-25
CYLINDER AND PISTON

EAS00265
ENG
CHECKING THE PISTON PIN 1.Check: piston pin Blue discoloration / grooves Replace the piston pin and then check the lubrication system. 2.Measure: piston pin outside diameter a Out of specification Replace the piston pin. Piston pin outside diameter 14.991~15.000 mm
3.Calculate: piston-pin-to-piston clearance Out of specification Replace the piston pin and piston as a set. Piston-pin-to-piston clearance = Piston pin bore size b Piston pin outside diameter a Piston-pin-to-piston clearance 0.002~0.022 mm
EAS00267
INSTALLING THE PISTON AND CYLINDER 1.Install: top ring 2nd ring lower oil ring rail upper oil ring rail oil ring expander NOTE: Be sure to install the piston rings so that the manufacturers marks or numbers face up.
4-26
CYLINDER AND PISTON

2.Install: piston piston pin piston pin clip
ENG
NOTE: Lubricate the piston pin with engine oil. Make sure the arrow mark a on the piston points towards the exhaust side of the cylinder. Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase. 3.Install: gasket dowel pins 4.Lubricate: piston piston rings cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5.Offset: piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring 6.Install: cylinder NOTE: While compressing the piston rings with one hand, install the cylinder with the other hand. Pass the timing chain and timing chain guide (lower) through the timing chain cavity.
4-27
CLUTCH
EASM0026
ENG
CLUTCH
CRANKCASE COVER
T.R
9 Nm (0,9 m kg)
4
T.R
10 Nm (1,0 m kg)
5
3
T.R
10 Nm (1,0 m kg)
Order 1 2 3 4 5 6 7
Job/Part Removing the crankcase cover V-belt air filter cover Air filter assembly V-belt air filter inner cover Crankcase air breather V-belt air filter element Crankcase cover Crankcase cover gasket
Qty 1 1 1 1 1 1 1
4-28
V-BELT, CLUTCH AND SECONDARY / PRIMARY SHEAVE

EASM0027
ENG
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE
12
6 5
T.R
55 Nm (5.5 m kg)
4 10 11 13 8 13 9 7
T.R
60 Nm (6.0 m kg)
FW
Order
Job/Part Removing the V-belt, clutch and secondary/primary sheave Nut/plain washer/washer Primary fixed sheave Nut Clutch housing Clutch assembly V-belt Washer Primary sliding sheave Collar Cam Weight Slider Oil seal
Qty
1 2 3 4 5 6 7 8 9 10 11 12 13
1/1/1 1 1 1 1 1 1 1 1 1 6 3 2
Refer to REMOVING THE PRIMARY SHEAVE section. Refer to REMOVING THE SECONDARY SHEAVE AND V-BELT section. Refer to INSTALLING THE SECONDARY SHEAVE section.
Refer to ASSEMBLING THE PRIMARY SHEAVE section.
4-29
EASM0028
ENG
SECONDARY SHEAVE
** Apply BEL-RAY assembly lube
T.R
90 Nm (9.0 m kg)
LS
** ** **
D FW
**
Order
Job/Part Disassembling the secondary sheave Nut Clutch carrier Clutch shoe springs Compression spring Spring seat Guide pins Secondary sliding sheave O-rings Oil seals Secondary fixed sheave
Qty
Remarks Disassemble the parts in the order listed.
1 1 3 1 1 3 1 2 2 1
Refer to DISASSEMBLING THE SECONDARY SHEAVE section. Refer to INSTALLING THE SECONDARY SHEAVE section.
Refer to INSTALLING THE SECONDARY SHEAVE section. For assembly, reverse the disassembly procedure.
4-30
ENG
REMOVING THE PRIMARY SHEAVE 1.Remove: nut (primary sheave) plate washer primary fixed sheave NOTE: Loosen the nut (primary fixed sheave) while holding the primary fixed sheave with the rotor holder . Rotor holder 90890-01235
REMOVING THE SECONDARY SHEAVE AND V-BELT 1.Remove: nut (secondary sheave) clutch housing NOTE: Loosen the nut (secondary sheave) while holding the clutch housing with the sheave holder . Sheave holder 90890-01701 2.Remove: nut (clutch carrier) Do not remove the nut (clutch carrier) yet. NOTE: Loosen the nut (clutch carrier) one turn using the locknut wrench while holding the clutch carrier with the rotor holder . Rotor holder 90890-01235
4-31

3.Remove: clutch assembly V-belt
ENG
NOTE: Remove the V-belt from the primary sheave side with clutch assembly.
DISASSEMBLING THE SECONDARY SHEAVE 1.Remove: nut (secondary sheave) NOTE: Loosen the nut while attaching the clutch spring compressor and clutch spring holder arm and release the compressed spring after removing the nut.
Use the spacer
( 40 mm, thickness:2~3 mm).
Clutch spring holder 90890-01337 Clutch spring holder arm 90890-01464 CHECKING THE CLUTCH 1.Measure: clutch shoe thickness. Scratches Glaze using coarse sandpaper. Wear/damage Replace. Clutch shoe thickness 2.0 mm <Limit>: 1.0 mm NOTE: After using the sandpaper, clean off the polished particles. Inspect the other clutch shoes. Replace the all three as a set.
4-32

EAS00290
ENG
CHECKING THE CLUTCH HOUSING 1.Check: clutch housing Damage/wear Replace. 2.Measure: clutch housing inside diameter a Out of specification Replace the clutch housing. Clutch housing inside diameter XQ125: 120 mm XQ150: 135 mm <Limit XQ125>: <120.5 mm> <Limit XQ150>: <135.5 mm>
EAS00282
CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: clutch spring Damage Replace the clutch springs as a set. 2. Measure: clutch spring free length Out of specification Replace the clutch springs as a set. Clutch spring free length XQ125: 28.5 mm XQ150: 31.3 mm CHECKING THE V-BELT 1.Check: V-belt Cracks/wear/scaling/chipping Replace. Oil/grease Check the secondary sheave. 2.Measure: V-belt width Out of specification Replace. V-belt width 22 mm <Limit>: <19 mm>
4-33
ENG
CHECKING THE WEIGHTS 1.Check: weight minimum outside diameter Cracks/wear/scaling/chipping Replace. Out of specification Replace. Weight out side diameter 20.0mm <Limit>: <19.5 mm> CHECKING THE SECONDARY SHEAVE 1.Check: secondary fixed sheave smooth operation secondary sliding sheave smooth operation Scratches/damage Replace as a set. 2.Check: Torque cam groove Wear/damage Replace. 3.Check: Guide pin Wear/damage Replace. ASSEMBLING THE PRIMARY SHEAVE 1.Clean: primary sliding sheave face primary fixed sheave face collar weight primary sliding sheave cam face 2.Install: weight collar
3.Install: slider cam
4-34

E
ENG
INSTALLING THE SECONDARY SHEAVE 1.Apply: BEL-RAY assembly lube (to the secondary sliding sheave inner surface, grease nipple groove, and oil seals) BEL-RAY assembly lube (to the bearings, oil seals and inner surface of the secondary fixed sheave ) 2.Install: secondary sliding sheave 3.Install: guide pin
4.Apply: BEL-RAY assembly lube (to the guide pin sliding groove and oil seal )
5.Install: secondary sheave complete compression spring clutch carrier NOTE: Temporarily tighten the nut while attaching the clutch spring holder and clutch spring holder arm and compress the spring.
Use the spacer
( 40 mm, thickness: 2~3 mm).
Clutch spring holder 90890-01337 Clutch spring holder arm 90890-01464
4-35

6.Install: V-belt clutch assembly
ENG
NOTE: Install the V-belt with the clutch assembly to the primary sheave side.
Never smear grease to the V-belt, secondary sheave and clutch. 7.Install: nut (clutch carrier)
T.R
90 Nm (9.0mkg)
NOTE: Tighten the nut (clutch carrier), using the locknut wrench while holding the clutch carrier with the rotor holder . Rotor holder 90890-01235 8. Install: clutch housing nut (clutch housing)
T.R
55 Nm (5.5mkg)
NOTE: Tighten the nut (clutch housing), using the sheave holder . Sheave holder 90890-01701
9.Set: V-belt NOTE: Move the V-belt to minimum diameter of the primary sheave , maximum diameter of the secondary sheave and make the V-belt tense.
4-36
STARTER CLUTCH AND GENERATOR

EASM0029
ENG

MAGNETO COVER AND STATOR COIL
9 3 4 7
T.R
7 Nm (0,7 m kg)
10
5 6
T.R
70 Nm (7,0 m kg)
T.R
7 Nm (0,7 m kg)
D FW
Order
Job/Part Removing the magneto cover and stator coil Side cover
Qty
Remarks Remove the parts in the order listed. Refer to SIDE COVERS AND SEAT section in chapter 3.
1 2 3 4 5 6 7 8 9 10
Flywheel lead couplers Flywheel cover Nut Washers Rotor Stator fixing screws Woodruf key Stator Pick up coil screws Pick up coil
2 1 1 2 1 3 1 1 2 1 For installation, reverse the removal procedure.
4-27

EASM0030
ENG
STARTER CLUTH
T.R
65 Nm (6.5 m kg)
LT
T.R
7 Nm (0.7 m kg)
3 2 1
WD
6 5
Order 1 2 3 4 5 6 7
Job/Part Removing the starter clutch Gear retainer plane Washer Idle gear Washer Starter one way cluth Collar Starter wheel gear
Qty 1 1 1 1 1 1 1
4-38

EAS00348
ENG
CHECKING THE STARTER CLUTCH 1.Check: starter clutch idle gear starter clutch wheel gear starter one way clutch Chips/pitting/roughness/wear Replace the defective part(s). 2.Check: starter clutch operation a.Install the starter clutch drive gear onto the starter clutch and hold the starter clutch. b.When turning the starter clutch drive gear counter-clockwise, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear clockwise, it should turn freely, otherwise the starter clutch is faulty and must be replaced.
EAS00354
INSTALLING THE GENERATOR 1.Install: woodruff key generator rotor washers generator rotor nut NOTE: Clean the tapered portion of the crankshaft and the generator rotor hub. When installing the generator rotor, make sure the woodruff key is properly seated in the key way of the crankshaft. 2.Tighten: generator rotor nut
T.R
70 Nm (7.0mkg)
NOTE: While holding the generator rotor with the rotor holder , tighten the generator rotor bolt. Rotor holder 90890-01235
321050
4-39
OIL PUMP
EASM0031
ENG
OIL PUMP
T.R
7 Nm (0.7 m kg)
3 4 5 6 8 2
T.R
65 Nm (6.5 m kg)
D FW
Order
Job/Part Removing the oil pump Drain Engine oil Flywheel
Qty
Remarks Remove the parts in the order listed. Refer to CHANGING THE ENGINE OIL section in chapter 3. Refer to STARTER CLUTCH AND GENERATOR section.
1 2 3 4 5 6 7 8
Oil pump cover fixing screws Oil pump cover Oil pump clip Washer Oil pump gear Oil pump gear dowel pin Oil pump fixing screws Oil pump assembly
3 1 1 1 1 1 2 1 For installation, reverse the removal procedure.
4-40
OIL PUMP
EAS00363
ENG
CHECKING THE OIL PUMP 1.Check: oil pump drive gear oil pump driven gear oil pump housing oil pump housing cover Cracks/damage/wear Replace the defective part(-s). 2.Measure: inner-rotor-to-outer-rotor-tip clearance A outer-rotor-to-oil-pump-housing clearance B Pump housing-to-rotors clearance C Out of specification Replace the oil pump. Inner rotor Outer rotor Oil pump housing Inner-rotor-to-outer-rotor-tip clearance limit: 0.15 mm Outer-rotor-to-oil-pump-housing clearance limit: 0.15 mm Pump housing-to-rotors clearance limit: 0.17 mm 3.Check: oil pump operation Rough movement Repeat steps (1) and (2) or replace the defective part(s).
B C
4-41
CRANKCASE AND CRANKSHAFT

EASM0032
ENG
T.R
9 Nm (0.9 m kg)
4 5
8
E
1
9 Nm (0.9 m kg)
D FW
T.R
Order
Job/Part Removing the crankcase and crankshaft Engine Cylinder head Cylinder and piston V-belt, clutch, secondary/primary sheave CDI magneto Oil pump Water pump Rear wheel
Qty
Remarks Remove the parts in the order listed. Refer to ENGINE section. Refer to CYLINDER HEAD section. Refer to CYLINDER AND PISTON section. Refer to V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE section. Refer to STARTER CLUTCH AND GENERATOR section. Refer to OIL PUMP section. Refer to WATER PUMP section in chapter 5. Refer to REAR WHEEL AND BRAKE section in chapter 7.
4-42
ENG
T.R
9 Nm (0.9 m kg)
4 5
8
E
1
9 Nm (0.9 m kg)
FW
D
T.R
Order 1 2 3 4 5 6 7 8
Job/Part Bolt Timing chain guide (upper) Screws Crankcase (right) Dowel pin Crankshaft assembly Timing chain Crankcase (left)
Qty 1 1 8 1 2 1 1 1
Remarks
Refer to INSTALLING THE CRANKSHAFT AND STARTER CLUTCH section.
4-43

EAS00385
ENG
DISASSEMBLING THE CRANKCASE 1.Remove: crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.Remove: right crankcase Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly. 3.Remove: timing chain from crankshaft sprocket
EAS00388
REMOVING THE CRANKSHAFT ASSEMBLY 1.Remove: crankshaft assembly
Tap on one side of the crankshaft with a softface hammer. Work slowly and carefully and make sure the crankshaft separate evenly from the crankcase.
4-44

EAS00394
ENG
CHECKING THE CRANKSHAFT AND CONNECTING ROD 1.Measure: crankshaft runout Out of specification Replace the crankshaft, bearing or both. NOTE: Turn the crankshaft slowly. Maximum crankshaft runout 0.03 mm 2.Measure: big end side clearance Out of specification Replace the crankshaft. Big end side clearance 0.15 ~ 0.45 mm 3.Measure: crankshaft width Out of specification Replace the crankshaft. Crankshaft width 47.95 ~ 48.00 mm
4.Check: crankshaft sprocket Damage/wear Replace the crankshaft. bearing Cracks/damage/wear Replace the crankshaft. oil pump drive gear Damage/wear Replace the crankshaft.
5.Check: crankshaft journal Scratches/wear Replace the crankshaft. crankshaft journal oil passage Obstruction Blow out with compressed air.
4-45

EAS00399
ENG
CHECKING THE CRANKCASE 1.Thoroughly wash the crankcase halves in a mild solvent. 2.Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3.Check: crankcase Cracks/damage Replace. oil delivery passages Obstruction Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL SEALS 1.Check: bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement Replace. 2.Check: oil seals Damage/wear Replace.
EAS00402
CHECKING THE CIRCLIPS AND WASHERS 1.Check: circlips Bends/damage/looseness Replace. washers Bends/damage Replace.
EAS00408
INSTALLING THE CRANKSHAFT 1.Install: crankshaft assembly timing chain
To avoid scratching the crankshaft and to ease the installation procedure, apply arease onto the oil seal lips and apply engine oil onto each bearing.
4-46

EAS00416
ENG
ASSEMBLING THE CRANKCASE 1.Apply: sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery. 2.Install: dowel pins 3.Install: crankshaft 4.Install: timing chain 5.Install: left crankcase (onto the right crankcase) NOTE: Tap lightly on the left crankcase with a soft-face hammer. 6.Install: 9 Nm (0.9mkg) crankcase bolts 7.Apply: engine oil (onto the crankshaft bearings, conrod and crank pin)
T.R
8.Check: crankshaft operation Rough movement Repair. timing chain position
4-47
TRANSMISSION
EASM0033
ENG
TRANSMISSION
LS
6 8 4
E E E G
5
E
D FW
3 2 1
T.R
6.5 Nm (0.65 m kg)
Order
Job/Part Removing the transmission Rear wheel Crankcase cover (left)
Qty
Remarks Remove the parts in the order listed. Refer to REAR WHEEL AND BRAKE section in chapter 7. Refer to V-BELT, CLUTH AND SECONDARY/PRIMARY SHEAVE section. Refer to TRANSMISSON OIL REPLACEMENT section in chapter 3.
Drain the transmission oil 1 2 3 4 5 6 7 Transmission cover screws Transmission case cover Gasket Dowel pins Primary drive gear Plain washer Secondary drive gear axle 6 1 1 2 1 1 1
Refer to INSTALLING THE CRANKSHAFT AND STARTER CLUTCH section.
4-48
TRANSMISSION
ENG
E
LS
6 8 4
E E E G
5
E
D FW
3 2 1
T.R
6.5 Nm (0.65 m kg)
Order 8 9 Idle gear Main axle
Job/Part
Qty 1 1
Remarks
4-49
COOL
COOL
CHAPTER 5. COOLING SYSTEM
RADIATOR .................................................................................................... 5-1 CHECKING THE RADIATOR .................................................................. 5-3 INSTALLING THE RADIATOR ................................................................ 5-3 THERMOSTAT .............................................................................................. 5-4 CHECKING THE THERMOSTAT ............................................................ 5-5 INSTALLING THE THERMOSTAT .......................................................... 5-5 WATER PUMP ............................................................................................... 5-6 CHECKING THE WATER PUMP ............................................................. 5-7 INSTALLING THE WATER PUMP ........................................................... 5-7
RADIATOR
EASM0034
COOL
COOLING SYSTEM
RADIATOR
6 4 9 2
10 7 2 3
Order
Job/Part Removing the radiator Drain coolant Front under cover
Qty
Remarks Remove the parts in the order listed. Refer to CHANGING THE COOLANT section in chapter 3. Refer to FRONT COVER section in chapter 3.
I 1 2 II 3 4 5 6 III 7
Disconnet: Fan motor coupler Thermo switch connectors Unplug: Radiator outlet hose Radiator inlet hose Radiator filler hose Expansion tank hose Untight: Radiator bracket bolts (frame)
1 4 1 1 1 1 2
5-1
RADIATOR
COOL
6 4 9 2
10 7 2 3
Order IV 8 9 10
Job/Part Remove: Radiator bracket (frame) Radiator Radiator fan
Qty 1 1 1
Remarks NOTE: Avoid the radiator of falling
5-2
RADIATOR
EAS00455
COOL
CHECKING THE RADIATOR 1.Check: radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator. Damage Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2.Check: radiator hoses Crack/damage Replace. 3.Check: radiator cap Crack/damage Replace. 4.Check: radiator fan Damage Replace. Malfunction Check and repair. Refer to COOLING SYSTEM section in chapter 8.
EAS00456
INSTALLING THE RADIATOR 1.Fill: cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT section in chapter 3. 2.Check: cooling system Leaks Repair or replace any faulty part.
5-3
THERMOSTAT
EASM0036
COOL
THERMOSTAT
T.R
9 Nm (0.9 mkg)
3 1 4
T.R
9 Nm (0.9 mkg)
Order
Job/Part Removing the thermostat Drain coolant Seat Box Hose Cylinder head outlet hose Thermostat cover fixing screws Thermostat cover Thermostat
Qty
Remarks Remove the parts in the order listed. Refer to CHANGING COOLANT section in chapter 3. Refer to BOX AND SEAT section in chapter 3.
1 2 3 4 5
1 1 2 1 1 For installation, reverse the removal procedure.
5-4
THERMOSTAT
EAS00462
COOL
CHECKING THE THERMOSTAT 1.Check: thermostat Does not open at 79 ~ 85C Replace. a.Suspend the thermostat in a container filled with water. b.Slowly heat the water. c. Place a thermometer in the water. d.While stiring the water, observe the thermostat and thermometers indicated temperature.
Thermometer Water Thermostat Container A Fully closed B Fully open

B
3mm
NOTE: If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.
A 82 95
2.Check: thermostat housing cover thermostat housing Cracks/damage Replace.
EASM0037
INSTALLING THE THERMOSTAT 1.Install: thermostat thermostat cover hoses
5-5
WATER PUMP
EASM0035
COOL
WATER PUMP
T.R
7 Nm (0.7mkg)
LS
T.R
10 Nm (1.0mkg)
3 3 3 1 3 2
T.R
7 Nm (0.7mkg)
Order
Job/Part Removing the water pump Drain coolant
Qty
Remarks Remove the parts in the order listed. Refer to CHANGING THE COOLANT section in chapter 3.
1 2 3 4
Pump inlet hose Pump outlet hose Water pump fixing screws Water pump assembly Disassembling water pump Water pump mounting screws Bleed screw with copper washer Water pump inner cover O-ring Water pump cover/gasket Impeller shaft Dowel pin
1 1 3 1 4 1/1 1 1 1/1 1 1
NOTE: Follow the arrows
5-6
WATER PUMP
EAS00472
COOL
CHECKING THE WATER PUMP 1.Check: O-ring Damage/wear Replace. oil seal Damage/wear Replace the water pump housing assembly. NOTE: The mark water side on the oil seal should be installed outward. 2.Check: impeller Cracks/damage/wear Replace the water pump housing assembly. water pump housing Cracks/damage Replace the water pump housing assembly.
EAS00477
INSTALLING THE WATER PUMP NOTE: Always replace the entire water pump assembly. 1.Install: impeller water pump inner cover 7 Nm (0.7mkg) screw
T.R
LS
NOTE: After installation, check that the impeller shaft rotates smoothly. 2.Install: O-ring NOTE: Lubricate the O-ring with a thin coat of lithium soap base grease.
5-7
WATER PUMP
COOL
3.Install: dowel pin gasket water pump housing cover 7 Nm (0.7mkg) screws copper washer 7 Nm (0.7mkg) bleed screw
T.R
T.R
NOTE: Do not forget to install the copper washer on the bleed screw.
5-8
CARB
CARB
CHAPTER 6. CARBURETOR
CARBURETOR .............................................................................................. 6-1 CARBURETOR REMOVAL ..................................................................... 6-1 CARBURETOR DISASSEMBLY .............................................................. 6-2 CHECKING THE CARBURETOR ............................................................ 6-3 ASSEMBLING THE CARBURETOR ....................................................... 6-5 MEASURING AND ADJUSTING THE FUEL LEVEL ............................... 6-6 CHECKING THE AUTOCHOKE UNIT ..................................................... 6-6 CHECKING THE FUEL COCK ................................................................ 6-7
CARBURETOR
EAM0038
CARB
CARBURETOR
CARBURETOR
6 5
2
4
Order
Job/Part Carburetor removal Box Side covers
Q'ty
Remarks Remove the parts in the order listed. Refer to BOX AND SEAT section in chapter 3. Refer to SIDE COVERS section in chapter3.
I 1 2 II 3 III 4 5 6 7
Disconnect: Auto choke coupler Carburetor heater connectors Unplug: Fuel hose Remove: Throttle cable Fixing clip Duct air Carburetor assembly
1 2 1 1 2 1 1
CAUTION: Do not bend the air filter joint clamp when installing the carburetor.
6-1
CARBURETOR
EASM0039
CARB
CARBURETOR
e E
R Y T U
q w W P } O
Order
Job/Part Carburetor disassembly Auto choke unit Throttle stop screw set Pilot screw set Diaphragm cover/spring Throttle valve Needle set Accelerating pump lever Float chamber/Gasket Float axle Float Needle jet Main jet Pilot jet Main nozzle Heater assembly
Q'ty
Q W E R T Y U I O P { } q w e
1 1 1 1/1 1 1 1 1 1 1 1 1 1 1 NOTE: For installation, place the float axle from the side opposite the arrow
6-2
CARBURETOR
EAS00485
CARB
322006
CHECKING THE CARBURETOR 1.Check: carburetor body float chamber jet housing Cracks/damage Replace. 2.Check: Fuel passages Obstruction Clean.
MMMMMMMMMMMMMMMMMMMMMMMMM
a.Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b.Blow out all of the passages and jets with compressed air.
LLLLLLLLLLLLLLLLLLLLLLLLLLLL
3.Check: float chamber body Dirt Clean 4.Check: float chamber rubben gasket Cracks/damage/wear Replace. 5.Check: float Damage Replace. 6.Check: needle valve needle valve seat Damage/Obstruction/Wear Replace the needle valve, needle valve seat and o-ring as a set.
7.Check: o-ring Damage/Wear Replace the needle valve, needle valve seat and o-ring as a set. 8.Check: piston valve Damage/Scratches/Wear Replace. piston valve diaphragm Cracks/Tears Replace.
6-3
CARBURETOR
CARB
9.Check: vacuum chamber cover piston valve spring jet needle holder Cracks/Damage Replace.
10. Check: jet needle kit main jet needle jet pilot jet pilot screw Bends/Damage/Wear Replace. Obstruction Clean.
322012
322015
11. Check: piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness Replace the piston valve. 12. Check: starter plunger starter plunger spring Bends/Cracks/Damage Replace. 13. Check: hose joints Cracks/Damage Replace. 14. Check: vacuum hoses fuel hoses Cracks/Damage/Wear Replace. Obstruction Clean. Blow out the hoses with compressed air.
6-4
CARBURETOR
EAS00487
CARB
ASSEMBLING THE CARBURETOR CAUTION: Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. Always use a new gasket. 1.Install: main jet holder main jet pilot jet 2.Install: needle valve seat 3.Check: float needle valve float axle baffle plate NOTE: Install the float axle from the side opposite the arrow 4.Install: float chamber gasket pilot screw 5.Install: o-ring accelerator pump diaphragm accelerator pump spring accelerator pump cover 6.Install: starter plunger kit 7.Install: piston valve jet needle holder jet needle 8.Install: throttle cable lever arm 9.Install: vaccum chamber cover 10. Install: carburetor on engine. Refer to CARBURETOR REMOVAL section.
2 1
W 1
6-5
CARBURETOR
EAS00499
CARB
MEASURING AND ADJUSTING THE FUEL LEVEL 1.Measure: fuel level a Out of specification Adjust Fuel level (below the float chamber mating surface) 5 ~ 6 mm
MMMMMMMMMMMMMMMMMMMMMMMMMM
a.Stand the scooter on level surface. b.Place the scooter on a suitable stand to ensure that the scooter is standing straight up. c. Install the fuel level gauge onto the fuel drain pipe . Fuel level gauge 90890-01312 d.Loosen the drain fuel screw . e.Hold the fuel level gauge vertically next to the float chamber. f. Measure the fuel level a .
LLLLLLLLLLLLLLLLLLLLLLLLLL
2.Adjust: fuel level

a.Remove the carburetor. b.Check the needle valve seat and needle valve. c. If either is worm, replace them as a set. d.If both are fine, adjust the float level by slightly bending the float tang. e.Install the carburetor. f. Measure the fuel level again. g.Repeat steps (a) to (f) until the fuel level is within specification.
EAS00503
CHECKING THE AUTOCHOKE UNIT NOTE: When checking the autochoke unit, the ambient temperature must be lower than 45C. 1.Remove: Carburetor Refer to CARBURETOR REMOVAL section.
6-6
CARBURETOR
2.Check: autochoke unit
CARB
a.Connect 3.3 mm hose to the strater air passage and blow into the hose. NOTE: When the starter plunger is open, air should come out of the other side of the starter air passage. Starter plunger opens Perform step. Starter plunger closes Replace the autochoke unit.
3.Check: autochoke unit

a.Connect that autochoke unit leads to a 12.0V battery to five minutes. Positive battery lead Black.
Negative battery lead Black. b.Connect 3.3 mm hose to the starter air passage and blow into the hose. Starter plunger opens Replace the autochoke unit. Starter plunger closes Autochoke unit is OK.
EAS00505
CHECKING THE FUEL COCK 1.Check: fuel cock Cracks/Damage/Wear Replace. 2.Check: fuel cock strainer (with compressed air) Dirt/Obstruction Clean. Damage Replace.
6-7
CHAS
CHAS
CHAPTER 7. CHASSIS
FRONT WHEEL AND BRAKE DISC ............................................................. 7-1 REMOVING THE FRONT WHEEL .......................................................... 7-2 CHECKING THE FRONT WHEEL ........................................................... 7-3 CHECKING THE BRAKE DISC ............................................................... 7-4 CHECKING THE SPEEDOMETER GEAR UNIT ..................................... 7-5 ASSEMBLING THE FRONT WHEEL ...................................................... 7-5 INSTALLING THE FRONT WHEEL ......................................................... 7-6 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......................... 7-6 REAR WHEEL AND BRAKE ........................................................................ 7-8 CHECKING THE REAR WHEEL ............................................................. 7-9 CHECKING THE BRAKE DISC ............................................................... 7-9 INSTALLING THE REAR WHEEL ......................................................... 7-10 ADJUSTING THE REAR WHEEL STATIC BALANCE .......................... 7-11 FRONT BRAKE ........................................................................................... 7-12 FRONT BRAKE PADS ........................................................................... 7-12 REPLACING THE FRONT BRAKE PADS ............................................. 7-13 REAR BRAKE ............................................................................................. 7-15 REAR BRAKE PADS ............................................................................. 7-15 REPLACING THE REAR BRAKE PADS ............................................... 7-16 FRONT BRAKE MASTER CYLINDER ....................................................... 7-19 MASTER CYLINDER ............................................................................. 7-20 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............ 7-21 CHECKING THE FRONT BRAKE MASTER CYLINDER ...................... 7-21 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER ............................................................................................. 7-22 FRONT BRAKE CALIPER .......................................................................... 7-23 CHECKING THE FRONT BRAKE CALIPER ......................................... 7-23 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER ...... 7-24 REAR BRAKE MASTER CYLINDER .......................................................... 7-27 MASTER CYLINDER ............................................................................. 7-28 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER .............. 7-29 CHECKING THE REAR BRAKE MASTER CYLINDER ......................... 7-29 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER ............................................................................................. 7-30
CHAS
REAR BRAKE CALIPER ............................................................................ 7-31 CHECKING THE REAR BRAKE CALIPER ........................................... 7-31 ASSEMBLINGAND INSTALLING THE REAR BRAKE CALIPER ......... 7-32 FRONT FORK .............................................................................................. 7-35 FRONT FORK DISASSEMBLY ............................................................. 7-36 REMOVING THE FRONT FORK LEGS ................................................ 7-37 DISASSEMBLING THE FRONT FORK LEGS ....................................... 7-37 CHECKING THE FRONT FORK LEGS ................................................. 7-38 ASSEMBLING THE FRONT FORK LEGS ............................................. 7-39 INSTALLING THE FRONT FORK LEGS ............................................... 7-42 HANDLEBAR .............................................................................................. 7-43 CHECKING THE HANDLEBAR ............................................................. 7-44 INSTALLING THE HANDLEBAR ........................................................... 7-44 STEERING HEAD ........................................................................................ 7-46 REMOVING THE LOWER BRACKET ................................................... 7-47 CHECKING THE STEERING HEAD ...................................................... 7-47 INSTALLING THE STEERING HEAD .................................................... 7-48 REAR SHOCK ABSORBERS AND EXHAUST PIPE ................................. 7-49 CHECKING THE REAR SHOCK ABSORBERS ASSEMBLY ............... 7-51
FRONT WHEEL AND BRAKE DISC

EASM0040
CHAS
CHASSIS
4
T.R
LS
70 Nm (7.0 mkg)
T.R
23 Nm (2.3 mkg)
3 6 9 8
LT
1 2
LT
5
T.R
23 Nm (2.3 mkg)
FW
Order
Job/Part Removing the front wheel and brake disc Front caliper mounting bolt Front caliper Front wheel axle nut
Qty
1 2 3
2 1 1 NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
4 5 6 7 8 9
Front wheel axle Front wheel collar Speedometer sensor Front wheel Front brake disc mounting screws Front brake disc
1 1 1 1 6 1
7-1

EAS00520
CHAS
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. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2.Remove: brake caliper NOTE: Do not squeeze the brake lever when removing the brake caliper. 3.Elevate: front wheel NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
7-2

EAS00525
CHAS
CHECKING THE FRONT WHEEL 1.Check: wheel axle Roll the wheel axle on a flat surface. Bent Replace.
WARNING Do not attempt to straighten a bent wheel axle.
2.Check: tyre front wheel Damage/wear Replace. Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3.
3.Measure: radial wheel runout lateral wheel runout Over the specified limits Replace. Radial wheel runout limit 1.0 mm Lateral wheel runout limit 0.5 mm
4.Check: wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings. oil seals Damage/wear Replace. 5.Replace: wheel bearings oil seals a.Clean the outside of the front wheel hub. b.Remove the oil seals with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface.
7-3
CHAS
c. Remove the wheel bearings with a general bearing puller . d.Install the new wheel bearings and oil seals in the reverse order of disassembly.
CAUTION: Do not contact the wheel bearing inner race or balls . Contact should be made only with the outer race .
NOTE: Use a socket that matches the diameter of the wheel bearing outer race and oil seal.
EAS00528
CHECKING THE BRAKE DISC 1.Check: brake disc Damaged/galling Replace. 2.Measure: brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.15 mm a.Place the scooter on a suitable stand so that the front wheel is elevated. b.Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary. c. Remove the brake caliper. d.Hold the dial gauge at a right angle against the brake disc surface. e.Measure the deflection 2 ~ 3 mm below the edge of the brake disc. 3.Measure: brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification Replace. Brake disc thickness limit (minimum) 4.7 mm
347001
347002
7-4

4.Adjust: brake disc deflection
CHAS
a.Remove the brake disc. b.Rotate the brake disc by one bolt hole. c. Install the brake disc. 23 Nm (2.3mkg)
T.R
NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Apply Loctite to the brake disc bolts. 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.
LT
T.R
23 Nm (2.3 m kg)
EAS00535
CHECKING THE SPEEDOMETER GEAR UNIT 1.Check: speedometer gear unit Bends/damage/wear Replace.
EAS00539
ASSEMBLING THE FRONT WHEEL 1.Install: wheel bearings oil seals a.Install the new wheel bearings and oil seals in the reverse order of disassembly. (refer to CHECKING THE FRONT WHEEL section)
7-5

EAS00540
CHAS
INSTALLING THE FRONT WHEEL 1.Lubricate: wheel axle wheel bearings oil seal lips speedometer gear unit collar Recommended lubricant Lithium soap base grease 2.Install: speedometer gear unit NOTE: Make sure that the speedometer gear unit and the wheel hub are installed with the projection meshed. 3.Install: collar front wheel front wheel axle
WARNING
Be sure to assemble the front wheel as shown on page 7-1. 4.Tighten: wheel axle nut
WARNING
70 Nm (7.0mkg)
T.R
Make sure the brake hose is routed properly.
CAUTION: Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.
EAS00548
ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: After replacing the tyre, wheel or both, the front wheel static balance should be adjusted. Adjust the front wheel static balance with the brake disc installed.
7-6
CHAS
1.Remove: balancing weight(s) 2.Find: front wheels heavy spot NOTE: Place the front wheel on a suitable balancing stand.
X1
X1
X2
a.Spin the front wheel. b.When the front wheel stops, put an X1 mark at the bottom of the wheel. c. Turn the front wheel 90 so that the X1 mark is positioned as shown. d.Release the front wheel. e.When the wheel stops, put an X2 mark at the bottom of the wheel. f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot. g.The spot where all the marks come to rest is the front wheels heavy spot X. 3.Adjust: front wheel static balance a.Install a balancing weight onto the rim exactly opposite the heavy spot X.
NOTE: Start with the lightest weight. b.Turn the front wheel 90 so that the heavy spot is 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. 4.Check: front wheel static balance
a.Turn the front wheel and make sure it stays at each position shown. b.If the front wheel does not remain stationary at all of the positions, rebalance it.
X
7-7
REAR WHEEL AND BRAKE

EASM0041
CHAS

T.R
104 Nm (10.4 m kg)

T.R
23 Nm (2.3 m kg)
T.R
7 Nm (0.7 m kg)
4
LT
5 7 9
LT
3 12
18 Nm (1.8 m kg)
T.R
8
T.R
42 Nm (4.2 m kg)
6 13 11
LT
10
D FW
Order I 1 2 3 II 4 III 5 6 7 8 9 10 11 12 13
Job/Part Removing the rear wheel and brake Remove: Muffler (bracket side) Exhaust pipe (cylinder side) Mudguard Untight: Rear wheel axle nut Remove: Spacer Rear right shock absorber bolt Rear brake caliper Rear arm Collar Rear wheel Washer Rear brake disc mounting bolt Rear brake disc
Qty
1 1 NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.
1 1 1 1 1 1 1 5 1 For installation, reverse the removal procedure.
7-8

EAS00565
CHAS
CHECKING THE REAR WHEEL 1.Check: wheel axle rear wheel wheel bearings oil seals Refer to FRONT WHEEL AND BRAKE DISC section. 2.Check: tyre rear wheel Damage/wear Replace. Refer to CHECKING THE TYRES and CHECKING THE WHEELS in chapter 3. 3.Measure: radial wheel runout lateral wheel runout Refer to FRONT WHEEL AND BRAKE DISC section. Radial wheel runout limit 1.0 mm Lateral wheel runout limit 0.5 mm 4.Check: wheel bearing Refer to FRONT WHEEL AND BRAKE DISC section
EAS00528
CHECKING THE BRAKE DISC 1.Check: brake disc Damaged/galling Replace. 2.Measure: brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.15 mm a.Place the scooter on a suitable stand so that the rear wheel is elevated. b.Remove the brake caliper. c. Hold the dial gauge at a right angle against the brake disc surface. d.Measure the deflection 2 ~ 3 mm below the edge of the brake disc.
347001
7-9
CHAS
3.Measure: brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification Replace. Brake disc thickness limit (minimum) 4 mm
347002
4.Adjust: brake disc deflection a.Remove the brake disc. b.Rotate the brake disc by one bolt hole. c. Install the brake disc. 23 Nm (2.3mkg)
T.R
NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Apply Loctite to the brake disc bolts. 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.
EAS00573
T.R
104 Nm (10.4 m.kg)
INSTALLING THE REAR WHEEL 1.Install: washer rear wheel collar rear arm spacer 104 Nm (10.4 mkg) rear wheel nut rear caliper
T.R
WARNING
Be sure to assemble the rear wheel as shown on page 7-8.
WARNING
Make sure the brake hose is routed properly.
7-10

EAS00575
CHAS
ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1.Adjust: rear wheel static balance Refer to FRONT WHEEL AND BRAKE DISC section.
7-11
FRONT BRAKE
EASM0042
CHAS
FRONT BRAKE
FRONT BRAKE PADS
4 2
5 6
LS
LT
LT
23 Nm (2.3 m kg)
Order
Job/Part Removing the front brake pads Front caliper
Qty
Remarks Remove the parts in the order listed. Refer to REMOVING THE FRONT WHEEL section.
1 2 3 4 5 6
Caliper fixing bolts Retaining clips Retaining pin Pad spring Brake pads Bleed screw
2 2 1 1 2 1 For installation, reverse the removal procedure.
7-12
FRONT BRAKE
EAS00579
CHAS
CAUTION:
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bleed after reassembly. Never use solvents on internal brake components. Use only clean or new brake fluid for cleaning brake components. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. Avoid brake fluid coming into contact with the eyes as it can cause serious injury. FIRST AID FOR BRAKE FLUID ENTERING THE EYES: Flush with water for 15 minutes and get immediate medical attention.
EAS00581
REPLACING THE FRONT BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1.Remove: caliper fixing bolts 2.Remove: brake caliper 3.Remove: retaining clips retaining pin brake pad spring brake pads
7-13
FRONT BRAKE
CHAS
4.Measure: brake pad wear limit a Out of specification Replace the brake pads as a set.
a
Brake pad wear limit 0.8 mm
5.Install: brake pad spring brake pads NOTE: Always install new brake pads and a new brake pad spring as a set. Make sure the brake pad spring is installed correctly. 6.Push the caliper piston into the brake caliper by finger.
CAUTION:
When pushing the caliper piston into the brake caliper, brake fluid level in the reservoir tank is increasing higher.
LS
7.Install: retaining pin retaining clips

CAUTION:
Do not allow grease to contact the brake pads. 8.Install: brake caliper brake caliper fixing bolts
T.R
23 Nm (2.3mkg)
ZAUM0110(*)
9.Check: brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL section in chapter 3. 10. Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM section in chapter 3.
7-14
REAR BRAKE
EASM??
CHAS
REAR BRAKE
REAR BRAKE PADS
T.R
23 Nm (2.3 m kg)
LT
6 3 5
D FW
Order
Job/Part Removing the rear brake pads Rear caliper
Qty
Remarks Remove the parts in the order listed. Refer to REMOVING THE REAR WHEEL section.
1 2 3 4 5 6
Caliper fixing bolts Retaining clip Retaining pin Pad spring Brake pads Bleed screw
2 1 1 1 2 1 For installation, reverse the removal procedure.
7-15
REAR BRAKE
EAS00579
CHAS
CAUTION: Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. 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. Never use solvents on internal brake components. Use only clean or new brake fluid for cleaning brake components. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. Avoid brake fluid coming into contact with the eyes as it can cause serious injury. FIRST AID FOR BRAKE FLUID ENTERING THE EYES: Flush with water for 15 minutes and get immediate medical attention.
EAS00581
REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1.Remove: caliper fixing bolts brake caliper retaining clip retaining pin brake pad spring brake pads
7-16
REAR BRAKE
CHAS
2.Measure: brake pad wear limit a Out of specification Replace the brake pads as a set.
a
Brake pad wear limit 0.8 mm
3.Install: brake pad spring brake pads NOTE: Always install new brake pads and a new brake pad spring as a set. Make sure the brake pad spring is installed correctly. 4.Push the caliper piston into the brake caliper by finger.
CAUTION:
LT
When pushing the caliper piston into the brake caliper, brake fluid level in the reservoir tank is increasing higher. 5.Install: retaining pin retaining clip
CAUTION:
T.R
23 Nm (2.3 m kg)
LT
Do not allow grease to contact the brake pads. 6.Install: brake caliper brake caliper fixing bolts
T.R
LT
23 Nm (2.3mkg)
7.Check: brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL section in chapter 3.
ZAUM0111(a)
7-17
REAR BRAKE
CHAS
8. Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM section in chapter 3.
7-18
FRONT BRAKE
EASM0043
CHAS
FRONT BRAKE MASTER CYLINDER

10 Nm (1.0 m kg)
T.R
LS
T.R
8.5 Nm (0.85 m kg)
6 1 5
T.R
23 Nm (2.3 m kg)
4 3
Order
Job/Part Removing the front brake master cylinder Drain brake fluid Handlebar covers
Qty
Remarks Remove the parts in the order listed. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM section in chapter 3. Refer to HANDLEBAR COVERS section in chapter 3.
1 2 3 4 5 6
Front brake lever Front brake switch Hose union bolt Plain washers/hose Master cylinder bracket Master cylinder
1 1 1 2/1 1 1 For installation, reverse the removal procedure.
7-19
FRONT BRAKE
EASM0044
CHAS
MASTER CYLINDER
Order
Job/Part Disassembling the master cylinder Master cylinder Master cylinder kit Master cylinder spring seat Spring
Qty
Remarks Disassemble the parts in the order listed. Refer to FRONT BRAKE MASTER CYLINDER section.
1 1 1 For assembly, reverse the removal procedure.
7-20
FRONT BRAKE
EAS00588
CHAS
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1.Disconnect: brake switch connectors (from the brake switch) 2.Remove: union bolt copper washers brake hose NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.
EAS00590
CHECKING THE FRONT BRAKE MASTER CYLINDER 1.Check: brake master cylinder Damage/scratches/wear Replace. brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air. 2.Check: brake master cylinder kit Damage/scratches/wear Replace.
3.Check: brake master cylinder reservoir Cracks/damage Replace. brake master cylinder reservoir diaphragm Damage/wear Replace. 4.Check: brake hoses Cracks/damage/wear Replace.
7-21
FRONT BRAKE
EAS00596
CHAS
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER

WARNING Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. WARNING Never use solvents on internal brake components.
Recommended brake fluid DOT#3 or DOT#4 1.Install: copper washers brake hose union bolt 23 Nm (2.3mkg)
T.R
WARNING Proper brake hose routing is essential to insure safe scooter operation. Refer to CABLE ROUTING.
NOTE: While holding the brake hose, tighten the union bolt as shown. Turn the handlebar to the left and to the right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. 3.Fill: brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT#3 or DOT#4
25
WARNING Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
7-22
FRONT BRAKE
CHAS
When refilling, be careful that water does not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
ZAUM0110(*)
4.Bleed: brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3. 5.Check: brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3. 6.Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
EAS00631
CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Brake fluid Every two years and whenever the brake is disassembled 1.Check: brake caliper pistons Rust/scratches/wear Replace the brake caliper. brake caliper cylinders Scratches/wear Replace the brake caliper. brake caliper body Cracks/damage Replace the brake caliper.
7-23
FRONT BRAKE
CHAS
brake fluid delivery passages (brake caliper body) Obstruction Blow out with compressed air.
WARNING Whenever a brake caliper is disassembled, replace the piston seals.
2.Check: brake caliper bracket Cracks/damage Replace.
EAS00635
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER

WARNING Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components as they will cause the piston seals to swell and distort. Whenever a brake caliper is disassembled, replace the brake caliper piston seals.
Recommended brake fluid DOT#3 or DOT#4
1.Install: brake caliper (temporarily) copper washers brake hose 23 Nm (2.3mkg) union bolt
T.R
WARNING
T.R
23 Nm (2.3 m kg)
Proper brake hose routing is essential to insure safe scooter operation. Refer to CABLE ROUTING.
7-24
FRONT BRAKE
CHAS
CAUTION: When installing the brake hose on to the brake caliper , make sure the brake pipe touches the projection on the brake caliper.
2.Remove: brake caliper 3.Install: brake pads brake pad springs brake caliper retaining bolts brake caliper brake hose holder Refer to REPLACING THE FRONT BRAKE PADS section. 4.Fill: brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT#3 or DOT#4
WARNING
Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
5.Bleed: brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
7-25
FRONT BRAKE
CHAS
ZAUM0110(*)
6.Check: brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3. 7.Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
7-26
REAR BRAKE
EASM0043
CHAS
REAR BRAKE MASTER CYLINDER
T.R
10 Nm (1.0 m kg)
T.R
8.5 Nm (0.85 m kg)
LS
T.R
23 Nm (2.3 m kg)
1 3
Order
Job/Part Removing the rear brake master cylinder Drain brake fluid Handlebar covers
Qty
Remarks Remove the parts in the order listed. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM section in chapter 3. Refer to HANDLEBAR COVERS section in chapter 3.
1 2 3 4 5 6
Rear brake lever Rear brake switch Hose union bolt Plain washers/hose Master cylinder bracket Master cylinder
1 1 1 2/1 1 1 For installation, reverse the removal procedure.
7-27
REAR BRAKE
EASM0044
CHAS
MASTER CYLINDER
Order
Job/Part Disassembling the master cylinder Master cylinder Master cylinder kit Master cylinder spring seat Spring
Qty
Remarks Disassemble the parts in the order listed. Refer to REAR BRAKE MASTER CYLINDER section.
1 1 1 For assembly, reverse the removal procedure.
7-28
REAR BRAKE
EAS00588(*)
CHAS
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER NOTE: Before disassembling the rear brake master cylinder, drain the brake fluid from the entire brake system. 1.Disconnect: brake switch connectors (from the brake switch) 2.Remove: union bolt copper washers brake hose NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.
EAS00590(*)
CHECKING THE REAR BRAKE MASTER CYLINDER 1.Check: brake master cylinder Damage/scratches/wear Replace. brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air. 2.Check: brake master cylinder kit Damage/scratches/wear Replace.
3.Check: brake master cylinder reservoir Cracks/damage Replace. brake master cylinder reservoir diaphragm Damage/wear Replace. 4.Check: brake hoses Cracks/damage/wear Replace.
7-29
REAR BRAKE
EAS00596(*)
CHAS
ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER
WARNING
Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid.
WARNING Never use solvents on internal brake components.
Recommended brake fluid DOT#3 or DOT#4 1.Install: copper washers brake hose union bolt
T.R
23 Nm (2.3mkg)
NOTE: While holding the brake hose, tighten the union bolt as shown. Turn the handlebar to the left and to the right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. 3.Fill: brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT#3 or DOT#4
WARNING Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
33
7-30
REAR BRAKE
CHAS
When refilling, be careful that water does not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4.Bleed: brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3. 5.Check: brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3. 6.Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
ZAUM0111(a)
EAS00631(*)
CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Brake fluid Every two years and whenever the brake is disassembled 1.Check: brake caliper pistons Rust/scratches/wear Replace the brake caliper. brake caliper cylinders Scratches/wear Replace the brake caliper. brake caliper body Cracks/damage Replace the brake caliper.
7-31
REAR BRAKE
CHAS
brake fluid delivery passages (brake caliper body) Obstruction Blow out with compressed air.
WARNING Whenever a brake caliper is disassembled, replace the piston seals.
2.Check: brake caliper bracket Cracks/damage Replace.
EAS00635(*)
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER

WARNING Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components as they will cause the piston seals to swell and distort. Whenever a brake caliper is disassembled, replace the brake caliper piston seals.
Recommended brake fluid DOT#3 or DOT#4
1.Install: brake caliper (temporarily) copper washers brake hose union bolt 23 Nm (2.3mkg)
T.R
T.R
23 Nm (2.3 m kg)
7-32
REAR BRAKE
CHAS
CAUTION: When installing the brake hose onto the brake caliper , make sure the brake pipe touches the projection on the brake caliper.
2.Remove: brake caliper 3.Install: brake pads brake pad spring brake caliper retaining bolts brake caliper brake hose holder Refer to REPLACING THE REAR BRAKE PADS section. 4.Fill: brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT#3 or DOT#4
WARNING Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
5.Bleed: brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
7-33
REAR BRAKE
CHAS
ZAUM0111(a)
6.Check: brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3. 7.Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
7-34
FRONT BRAKE
EASM0045
CHAS
FRONT FORK
FRONT FORK
3
T.R
33 Nm (3.3m kg) 2
T.R
23 Nm (2.3 m kg)
Order
Job/Part Removing the front fork Front wheel
Qty
Remarks Remove the parts in the order listed. Refer to FRONT WHEEL AND BRAKE section. NOTE: Disconnect the speedometer sensor coupler to remove the front mudguard.
I 1 II 2 III 3 4
Remove: Front mudguard Untight: Bolt (under bracket upper and lower) Remove: Circlip Front fork legs (right and left)
2 1 2
For installation, reverse the removal procedure
7-35
FRONT FORK
EASM0046
CHAS
FRONT FORK DISASSEMBLY

3
T.R
33 Nm (3.3m kg) 2
T.R
23 Nm (2.3 m kg)
Remarks
Order I
Job/Part Disassembling the front fork Remove: Front fork legs caps Circlips Spring stopper / o-ring Drain: Front fork legs Remove: Spring Drain bolt Piston Piston spring Inner tube Dust seal Circlip Oil seal Spring seat
Qty
Disassemble the parts in the order listed. 1 1 1/1 2 1 1 1 1 1 1 1 1 1 NOTE: To remove the circlip, push the spring stopper.
II III
Damper rod holder 90890-01294 T-handle 90890-01326
For assembly, reverse the disassembly procedure.
7-36
FRONT FORK
EAS00649
CHAS
REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1.Stand the scooter on a level surface.
NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2.Remove the front wheel Refer to REMOVING THE FRONT WHEEL section. 3.Loosen: upper bracket pinch bolt lower bracket pinch bolt
WARNING
Before loosening the upper and lower bracket pinch bolts, support the front fork leg. 4.Remove: circlip front fork leg
EAS00653(*)
DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1.Remove: front fork legs caps 2.Push: spring stopper (as shown) 3.Remove: circlip spring stopper O-ring 4.Drain: fork oil 5.Remove: damper rod assembly bolt damper rod assembly NOTE: While holding the damper rod with the damper rod holder , loosen the damper rod assembly bolt.
342010
7-37
FRONT FORK
CHAS
Damper rod holder 90890-01294 T-handle 90890-01326
6.Remove: inner tube

342010
a.Hold the front fork leg horizontally. b.Securely clamp the brake caliper bracket in a vice with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully.
CAUTION: Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced. Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged.
7.Remove: Dust seal Retaining clip Oil seal
CAUTION: Do not scratch the inner tube.
EAS00657
CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1.Check: inner tube outer tube Bends/damage/scratches Replace.
WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
2.Check: oil seal Dust seal Damage Replace.
7-38
FRONT FORK
CHAS
CAUTION: The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.
3.Check: cap bolt O-ring Damage/wear Replace.
EAS00661
ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
WARNING Make sure the oil levels in both front fork legs are equal. Uneven oil levels can result in poor handling and a loss of stability.
NOTE: When assembling the front fork leg, be sure to replace the following parts: oil seal dust seal Before assembling the front fork leg, make sure all of the components are clean. 1.Install: piston
WARNING Always use new copper washers.
CAUTION: Allow the piston to slide slowly down the inner tube until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube.
7-39
FRONT FORK
CHAS
2.Lubricate: inner tubes outer surface Recommended lubricant Yamaha fork and fork oil SAE 10 or equivalent 3.Tighten: damper rod assembly bolt
T.R
23 Nm (2.3mkg)
NOTE: While holding the damper rod assembly with the damper rod holder , tighten the damper rod assembly bolt. Damper rod holder 90890-01294 T-handle 90890-01326
342010
4.Install: outer tube bushing (with the fork seal driver weight )
and adapter
Fork seal driver weight 90890-01367 Fork seal driver attachment 90890-01368 5.Install: washer oil seal (with the fork seal driver weight and adapter)
CAUTION: Make sure the numbered side of the oil seal faces up.
NOTE: Before installing the oil seal, lubricate its lips with lithium soap base grease. Lubricate the outer surface of the inner tube with fork oil. Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation.
7-40
FRONT FORK
6.Install: oil seal clip
CHAS
NOTE: Adjust the oil seal clip so that it fits into the groove of the outer tube. 7.Install: dust seal (with the fork seal driver weight) 8.Fully compress the front fork leg. 9.Fill: front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.120 L Recommended oil Yamaha fork and fork oil SAE 20 or equivalent
CAUTION: Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.
10. After filling the front fork leg, slowly stroke the damper rod up and down (at least ten times) to distribute the fork oil. NOTE: Be sure to stroke the damper rod slowly because the fork oil may spurt out. 11. Slowly stroke the inner tube up and down to distribute the fork oil once more (1 stroke = about 150 mm). NOTE: Be careful not to stroke the inner tube over 150 mm as this will cause air to enter. If the inner tube is stroked more than 150 mm, repeat steps (12) and (13). 12. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
7-41
FRONT FORK
CHAS
NOTE: Be sure to bleed the front fork leg of any residual air. 13. Measure: front fork leg oil level a Out of specification Correct. Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed, and without the spring) 80 mm 14. Install: spring NOTE: Install the spring with its denser of pitch to upper side. O-ring 15. Install: spring stopper circlip front fork legs caps
EAS00663
INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1.Install: front fork leg NOTE: Pull up the inner tube until it stops, then tight the lower bracket pinch bolt. 2.Tight: lower bracket pinch bolt upper bracket pinch bolt 3.Install: circlip 4.Tighten: lower bracket pinch bolt upper bracket pinch bolt
T.R
33 Nm (3.3mkg) 33 Nm (3.3mkg)
T.R
7-42
FRONT FORK
EASM0047
CHAS
HANDLEBAR
9 2 3 3 2
T.R
10 Nm (1.0 m kg)
11
4 6 10
T.R
10 Nm (1.0 m kg)
LS
T.R
60 Nm (6.0 m kg)
Order
Job/Part Removing the handlebar Handlebar covers
Qty
Remarks Remove the parts in the order listed. Refer to HANDLEBAR COVERS section in chapter 3.
1 2 3 4 5 6 7 8 9 10 11
Rear view mirrors (right and left) Master cylinder boots (right and left) Master cylinders (right and left) Handlebar switch (right) Throttle cable Grip assembly Handlebar switch (left) Brake lever holder (left) Brake lever holder (right) Bolt/nut Handlebar
2 2 2 1 1 1 1 1 1 1/1 1
Refer to MASTER CYLINDER section.
7-43
HANDLEBAR
EAS00668
CHAS
CHECKING 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.Check: handlebar Bends/cracks/damage Replace.
WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
3.Install: handlebar grip a.Apply a thin coat of rubber adhesive onto the left end of the handlebar. b.Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried.
EAS00673
INSTALLING THE HANDLEBAR 1.Stand the scooter on a level surface.

WARNING
Securely support the scooter so that there is no danger of it falling over. 2.Install: handlebar NOTE: Align the slot in the handlebar with the steering shaft surface. 3.Tighten: 60 Nm (6.0mkg) nut 4.Fasten: wire harness 5.Install: left handlebar switch
T.R
T.R
60 Nm (6.0 m kg)
7-44
HANDLEBAR
CHAS
NOTE: Align the projection on the left handlebar switch with the hole in the handlebar. 6.Install: brake lever holder NOTE: Align the mating surfaces of the brake lever holder with the punch mark a in the handlebar. 7.Install: throttle cable throttle grip NOTE: Lubricate the inside of the throttle grip with a thin coat of lithium soap base grease and install it onto the handlebar. 8.Install: right handlebar switch
WARNING Make sure the throttle grip operates smoothly.
NOTE: Align the projection on the right handlebar switch with the hole a in the handlebar. There should be 2.5 mm of clearance between the throttle grip and the right grip end . 9.Adjust: throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3. Throttle cable free play (at the flange of the throttle grip) 1.5 ~ 3.0 mm
ZAUM0051
7-45
STEERING HEAD
EASM0048
CHAS
STEERING HEAD
1 2 3 4 5 6 7 9
LS
T.R
75 Nm (7.5 m kg)
T.R
Fisrt step: 38 Nm (3.8 m kg) 2nd step: Loosen the ring nut 1/4 turn. 3rd step: 22 Nm (2.2 m kg)
11
10 12 13
LS
Order
Job/Part Removing the steering head Front covers Front wheel Front fork legs Handlebar Ring nut Lock washer Ring nut (middle) Rubber washer Ring nut (lower) Ball race cover Ball race (upper) Lower bracket Ball bearing Bearing Ball races (in lower bracket) Ball race (lower) Steering oil seal
Qty
Remarks Remove the parts in the order listed. Refer to FRONT COVERS section in chapter 3. Refer to FRONT WHEEL section. Refer to FRONT FORK section. Refer to HANDLEBAR section.
1 2 3 4 5 6 7 8 9 10 11 12 13
1 1 1 1 1 1 1 1 22 1 2 1 1
7-46
STEERING HEAD
EAS00678
CHAS
REMOVING THE LOWER BRACKET 1.Stand the scooter on a level surface.
2.Remove: ring nut (upper) lock washer ring nut (center) rubber washer 3.Remove: ring nut (lower) NOTE: Hold the lower bracket by hand, then remove by using the exhaust ring and steering nut wrench . Ring nut wrench 90890-01268
WARNING
Securely support the steering shaft so that there is no danger of it falling down.
EAS00681
CHECKING THE STEERING HEAD 1.Wash: bearings bearing races Recommended cleaning solvent Kerosene 2.Check: bearings bearing races Damage/pitting Replace. 3.Replace: bearings bearing races a.Remove the bearing races from the steering head pipe with a long rod and hammer. b.Remove the bearing race from the lower bracket with a floor chisel and hammer. c. Install a new rubber seal and new bearing races.
354007
7-47
STEERING HEAD
CHAS
CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged.
NOTE: Always replace the bearings and bearing races as a set. Whenever the steering head is disassembled, replace the rubber seal. 4.Check: lower bracket (along with the steering stem) Bends/cracks/damage Replace.
354008
354009
EAS00684
LS
INSTALLING THE STEERING HEAD 1.Lubricate: upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2.Install: lower ring nut rubber washer ring nut lock washer upper ring nut Refer to CHECKING AND ADJUSTING THE STEERING HEAD section in chapter 3. 3.Install: handlebar bolt 60 Nm (6.0mkg) nut
T.R
7-48
REAR SHOCK ABSORBERS AND EXHAUST PIPE

EASM0049
CHAS
REAR SHOCK ABSORBER AND EXHAUST PIPE

T.R
4.5 Nm (0.45 m kg)
T.R
32 Nm (3.2 m kg)
4 2 8 1 27 Nm (2.7 m kg)
T.R T.R
18 Nm (1.8 m kg)
T.R
32 Nm (3.2 m kg)
5 3
T.R
11 Nm (1.1 m kg)
FW
D
T.R
18 Nm (1.8 m kg)
Order
Job/Part Removing the rear shock absorbers and exhaust pipe
Qty
Remarks Remove the parts in the order listed. WARNING Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the rear wheel is elevated.
Box and seat Side covers I 1 II 2 3 4 Untight: Band silencer Remove: Muffler bolts Exhaust pipe nuts Muffler
Refer to BOX AND SEAT section in chapter 3. Refer to SIDE COVERS AND SEAT section in chapter 3. 1 3 2 1
T.R
27 Nm (2.7 mkg) 11 Nm (1.1 mkg)
T.R
7-49
CHAS
T.R
4.5 Nm (0.45 m kg)
T.R
32 Nm (3.2 m kg)
4 2 8 1 27 Nm (2.7 m kg)
T.R T.R
18 Nm (1.8 m kg)
T.R
32 Nm (3.2 m kg)
5 3
T.R
11 Nm (1.1 m kg)
FW
D
T.R
18 Nm (1.8 m kg)
Order 5 6 7 8 9
Job/Part Exhaust pipe Rear left shock absorber bolt (engine) Rear left shock absorber bolt (frame) Rear right shock absorber bolt (engine) Rear right shock absorber bolt (frame)
Qty 1 1 1 1 1
Remarks
18 Nm (1.8 mkg) 32 Nm (3.2 mkg) 18 Nm (1.8 mkg) 32 Nm (3.2 mkg)
T.R
T.R
T.R
T.R
7-50

EAS00695(*)
CHAS
CHECKING THE REAR SHOCK ABSORBERS ASSEMBLY 1.Check: rear shock absorber rod Bends/damage Replace the rear shock absorber assembly. rear shock absorbers Oil leaks Replace the rear shock absorber assembly. spring Damage/wear Replace the rear shock absorber assembly. bushings Damage/wear Replace. dust seals Damage/wear Replace. bolts Bends/damage/wear Replace.
7-51
ELEC
ELEC
CHAPTER 8. ELECTRICAL
ELECTRICAL COMPONENTS ...................................................................... 8-1 SWITCHES .................................................................................................... 8-2 CHECKING SWITCH CONTINUITY ........................................................ 8-2 CHECKING THE SWITCHES ........................................................................ 8-3 CHECKING THE BULBS AND BULB SOCKETS ........................................ 8-4 TYPES OF BULBS ................................................................................... 8-4 CHECKING THE CONDITION OF THE BULBS ...................................... 8-4 CHECKING THE CONDITION OF THE BULB SOCKETS ...................... 8-6 IGNITION SYSTEM ....................................................................................... 8-7 CIRCUIT DIAGRAM ................................................................................. 8-7 TROUBLE SHOOTING ............................................................................ 8-8 ELECTRIC STARTING SYSTEM ................................................................ 8-11 CIRCUIT DIAGRAM ............................................................................... 8-11 TROUBLESHOOTING ........................................................................... 8-12 STARTER MOTOR ...................................................................................... 8-14 CHECKING THE STARTER MOTOR .................................................... 8-16 ASSEMBLING THE STARTER MOTOR ............................................... 8-17 CHARGING SYSTEM .................................................................................. 8-19 CIRCUIT DIAGRAM ............................................................................... 8-19 TROUBLESHOOTING ........................................................................... 8-20 LIGHTING SYSTEM .................................................................................... 8-22 CIRCUIT DIAGRAM ............................................................................... 8-22 TROUBLESHOOTING ........................................................................... 8-23 CHECKING THE LIGHTING SYSTEM .................................................. 8-24 SIGNALING SYSTEM ................................................................................. 8-28 CIRCUIT DIAGRAM ............................................................................... 8-28 TROUBLESHOOTING ........................................................................... 8-30 CHECKING THE SIGNALING SYSTEM ................................................ 8-31 COOLING SYSTEM ..................................................................................... 8-37 CIRCUIT DIAGRAM ............................................................................... 8-37 TROUBLESHOOTING ........................................................................... 8-38 CARBURETOR HEATING SYSTEM ........................................................... 8-41 CIRCUIT DIAGRAM ............................................................................... 8-41 TROUBLESHOOTING ........................................................................... 8-42
ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS

Wire harness Battery Ignition unit (CDI) Main switch Ignition coil Spark plug cap Rectifier/Regulator Fuel sender Starter relay
ELEC
Starter motor Thermo switch Flasher relay Horn Fuses Relay Coolant thermo switch Carburator heater thermo switch
8-1
SWITCHES
EAS00730
ELEC
SWITCHES
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.
CAUTION: Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester 90890-03112
x 1
NOTE: Before checking for continuity, set the pocket tester to 0 and to the x 1 range. When checking for continuity, switch back and forth between the switch positions a few times. The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions are shown in the far left column and the switch lead colors are shown in the top row in the switch illustration. NOTE: indicates a continuity of electricity be tween switch terminals (i.e., a closed circuit at the respective switch position). The example illustration on the left shows that: There is continuity between black and black/white when the switch is set to OFF. There is continuity between red and brown when the switch is set to ON.
Br
B/W
OFF ON
B Br R
8-2
CHECKING THE SWITCHES

EAS00731
ELEC
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to CHECKING SWITCH CONTINUITY section. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. Horn switch Light switch Dimmer switch Start switch Turn signal switch Fuses Main switch Rear brake switch Front brake switch
GY
Br
Y G LB B
P Dg Ch BrW LB Br L
GY
GY
Br
OFF OFF START

GY Br
Br L LB
POS ON
Ch BrW Dg
OFF PUSH
Y LB G HI LO
L N R
Br
R GR B BW
LOCK OPEN OFF CHECK ON
GyR B Br R
LY
(BLUE) B B B B (OPTION) B LY B B (BLUE) (BLUE) B
(option)
Indicates coupler position
8-3
CHECKING THE BULBS AND BULB SOCKETS

EAS00733
ELEC

Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. No continuity Repair or replace the bulb, bulb socket or both.
TYPES OF BULBS The bulbs used on this scooter are shown in the illustration on the left. Bulbs A and B are used for the headlights and usually use a bulb holder which must be detached before removing the bulb. The majority of these types of bulbs can be removed from their respective socket by pulling them out. Bulb C is used for turn signal and tail/brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by pushing and turning the bulb counterclockwise for D and carefully pulling them out for E .
CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1.Remove: bulb
8-4

WARNING
ELEC
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
CAUTION:
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. 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. 2.Check: bulb (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112 NOTE: Before checking for continuity, set the pocket tester to 0 and to the x 1 range. a.Connect the positive tester probe to terminal and the negative tester probe to terminal , and check the continuity. b.Connect the positive tester probe to terminal and the negative tester probe to terminal , and check the continuity. c. If either of the readings indicate no continuity, replace the bulb.
8-5
ELEC
CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1.Check: bulb socket (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. a.Install a good bulb into the bulb socket. b.Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket.
8-6
IGNITION SYSTEM
EAS00734
ELEC
IGNITION SYSTEM
CIRCUIT DIAGRAM
WIRE LEAD sur SIDE STAND

Br R GR B BW
LY
(OPTION)
(BLUE)

Gy B
5
GR Br B R B R GR Br
B B
B B
36
LY
B B (BLUE) (BLUE) B LY LY
BW
BW
Br B R R R - W W W W W W W W W W W W W W W
BR GW WR WL
GW BR WL WR
Or Br B YB Or Br
Br Or YB B Or YB B B Or B
3 4
(1)
R Br B R LW LW
BR GW
BR GW WR WL
(4)
LY LY (RED) Dg Ch (BLACK)
6
B R LW
WR WL
YB B
27
Br B
LW LW
LY LY (RED)
Dg Ch (BLACK)
LY
L BW
7 9
B
LW RW LW B
BW L
LY YR LY R LW
LY LY R LW LW Br Dg Ch L R B
34
11
LB Br LB Br L
GY
HANDLE SWITCH 2
LW L
LW Br Dg
LW
R B B B B
OFF START
GY
Br
POS ON
YR
OFF
Br L LB
Ch
L
ANTI-THEFT ALARM (OPTION)
23
GY Y
26
B B YR B
LW RW
GY
A
GY
Br
10
Br
LB
GY
B WIRE LEAD sur ANTI-THEFT 1 et 4 For LW/LW and LY/LY

LW LW
Br
Br
Br
Br
Br
RW
LW
Br
Br
GR
Br
GR BrW
LW LW
19
LB B Y G Y G LB B
LB
24
METER ASSY. Y Dg
20 12
HANDLE SWITCH 1
Br
31
Ch BrW P Dg P Dg Ch BrW LY
(NATURAL) LY
BrW
R Br
32
33
Br Br
THERMO. MOTOR
28
R LW LW Dg
NO-CONNECTION
CLOCK ODOMETER
FUEL METER
HI BEAM
Ch
TURN R
TURN L
ILLUMI
ILLUMI
GY
Ch
BrW
Dg
GY
C
OFF PUSH HI LO
D
Y LB G
E L N R
Ch L Dg L B
22
21
B LR L
NO-CONNECTION
Ch Br B
NO-CONNECTION NO-CONNECTION NO-CONNECTION
R
RW LW
K
R L
O
B B
L
G
Br
L Y
Dg Y Ch GR
P Sb
Y Dg Ch
29
B
Gy
Gy
G L B Sb B P
Y G
Y G
13
HEAD LIGHT ASSY. L
Ch
13
HEAD LIGHT ASSY. R
Dg
P Sb
Y B L
GY B L
30 25 37
B
Ch
Ch
B
Dg
B
Dg
14
15
18
35
Ch
16
Y G Ch G Ch L B B Y Y G Dg L G Dg L B Y
17
B (BLACK) B B B
k 21 k 22 k 23
CDI magneto CDI unit Ignition coil Spark plug Main switch Fuse (main) Battery Rectifier/regulator Front brake stop switch Rear brake stop switch Relay
8-7
Dg
B
IGNITION SYSTEM
EAS00736 EAS00739
ELEC
TROUBLESHOOTING THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK). Check: 1.Main fuse 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance 7.Main switch 8.Pickup coil resistance 9.Wiring (of the entire ignition system) NOTE: Before troubleshooting, remove the following part(s): 1) Box and seat 2) Footrest board (left and right) 3) Side covers Troubleshoot with the following special tool(s). Ignition checker 90890-06754 Pocket tester 90890-03112
2.Battery Check the condition of the battery. Refer to CHECKING THE BATTERY in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C Is the battery OK? YES NO Clean the battery terminals. Recharge or replace the battery.
EAS00740
3.Spark plug Check the condition of the spark plug. Check the spark plug type. Measure the spark plug gap. Refer to CHECKING THE SPARK PLUG in chapter 3. Standard spark plug CR8E (NGK) Spark plug gap 0.5 ~ 0.7 mm Is the spark plug in good condition, is it of the correct type, and is its gap within specification? YES NO Re-gap or replace the spark plug.
EAS00738
1.Main fuse Check the main fuse for continuity. Refer to CHECKING THE FUSES in chapter 3. Is the main fuse OK? YES NO
Replace the fuse.
8-8
IGNITION SYSTEM
EAS00742 EAS00746
ELEC
4.Ignition spark gap Disconnect the spark plug cap from the spark plug. Connect the ignition checker/dynamic spark tester as shown. Spark plug cap Set the main switch to ON. Measure the ignition spark gap a . Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.
6.Ignition coil resistance Disconnect the ignition coil connectors from the ignition coil terminals. Connect the pocket tester ( X 1) to the ignition coil as shown. Measure primary coil resistance. Positive tester probe black Negative tester probe orange
x1
Measure the primary coil resistance.
a
Ignition spark gap 5 ~ 7 mm Is there a spark and is the spark gap within specification? NO YES The ignition system is OK.
EAS00744
Primary coil resistance 0.32 ~ 0.48 at 20C Connect the pocket tester ( X 1k) to the ignition coil as shown. Measure the secondary coil resistance. Negative tester probe black Positive tester probe spark plug lead
x 1k
5.Spark plug cap resistance Remove the spark plug cap from the spark plug lead. Connect the pocket tester ( X 1k range) to the spark plug cap. Measure the spark plug cap resistance. Spark plug cap resistance 10 x k at 20C Is the spark plug cap OK? YES NO Replace the ignition coil. Replace the spark plug cap.
Measure the secondary coil resistance. Secondary coil resistance 5.7 ~ 8.5 k at 20C Is the ignition coil OK? YES NO
8-9
IGNITION SYSTEM
EAS00749
ELEC
7.Main switch Check the main switch for continuity. Refer to CHECKING THE SWITCHES. Is the main switch OK? YES NO Replace the main switch.
9. Source coil resistance Disconnect the source coil coupler from the wire harness. Connect the pocket tester ( X 100) to the charging coil terminal as shown. Positive tester probe black/red Negative tester probe green/white
EAS00748
WL GW WR BR
8.Pickup coil resistance Disconnect the pickup coil coupler from the wire harness. Connect the pocket tester ( X 100) to the pickup coil terminal as shown. Positive tester probe white/red Negative tester probe white/blue
BR GW WR WL
Measure the source coil resistance. Source coil resistance 720 ~ 1080 at 20C (between black/red and green/white) Is the source coil OK?
BR GW WR WL
YES
NO Replace the stator.
Measure the pickup coil resistance. Pickup coil resistance 248 ~ 372 at 20C (between white/red and white/blue) Is the pickup coil OK? YES NO Replace the stator.
EAS00754
10. Wiring (of the entire ignition system) Check the entire ignition systems wiring. Refer to CIRCUIT DIAGRAM. Is the ignition systems wiring properly connected and without defects? NO Properly connect or repair the ignition systems wiring. YES Replace the ignition unit. (CDI unit)
8-10
ELECTRIC STARTING SYSTEM

EAS00755
ELEC

CIRCUIT DIAGRAM

Br R GR B BW
LY
(BLUE)
(OPTION) B B

Gy B
R
5
GR Br B R B R GR Br
B B
36
LY
BW
BW
BR GW WR WL
GW BR WL WR
Or Br B YB Or Br
3 4
(1)
R Br B R LW LW
BR GW
BR GW WR WL
(4)
6
B R LW
WR WL
YB B
27
Br B
LW LW
LY LY (RED)
Dg Ch (BLACK)
LY
L BW
7 9
B
LW RW LW B
BW L
L
LY YR LY R LW
34
11
LB Br LB Br L
GY
HANDLE SWITCH 2
LW L
LW Br Dg
LW
R B B B B
OFF START
GY Br
POS ON
Br
YR
OFF
Br L LB
Ch
L
23
GY Y
GY
26
B B YR B
LW RW
10
L
GY
A
GY
Br
LB

LW LW
Br
Br
Br
Br GR
Br
GR
Br Br
RW
LW
Br
BrW
LB
LW LW
24
METER R ASSY. Br
THERMO. MOTOR L
19
LB B Y G Y G LB B
20 12
HANDLE SWITCH 1
Br
31
Y Dg
HI BEAM
(NATURAL) LY LY
Ch BrW P Dg P Dg Ch BrW
BrW
32
33
Br Br
28
R LW LW Dg
NO-CONNECTION
CLOCK ODOMETER
FUEL METER
Ch
TURN R TURN L
ILLUMI
ILLUMI
GY
Ch BrW Dg
GY
C
OFF PUSH
B
D
Y LB G HI LO
G Y
E L N R
Ch L Dg L B
22
21
B LR L
NO-CONNECTION
Ch Br B
R
RW LW
K
R L
O
B B
L
G
Br
L Y
Dg Y Ch GR
P Sb
Y Dg Ch
29
B
Gy
Gy
B
Ch
G L B Sb B P
Y G
Y G
13
HEAD LIGHT ASSY. L
13
HEAD LIGHT ASSY. R
Dg
P Sb
Y B L
GY B L
30 25 37
B
Ch
Ch
B
Dg
B
Dg
14
15
18
35
Ch
16
17
B (BLACK) B B B
Main switch Fuse (main) Battery Starter relay Starter motor k Starter switch A Front brake stop switch k 21 Rear brake stop switch k 22 Relay k 23 Anti-theft alarm (option) k 34
8-11
Dg

EAS00757 EAS00739
ELEC
TROUBLESHOOTING THE STARTER MOTOR FAILS TO TURN. Check: 1.main fuse 2.battery 3.starter motor 4.starter relay 5.main switch 6.front/rear brake switch 7.starter switch 8.wiring (entire starting system) NOTE: Before troubleshooting, remove the following part(-s) 1) Box and seat 2) Side covers Troubleshoot with the following special tool(-s).
EAS00758

EAS00738
3.Starter motor Connect the positive battery terminal and starter motor lead with a jumper lead .
1.Main fuse Check the main fuse for continuity. Refer to CHECKING THE FUSES in chapter 3. Is the main fuse OK? YES NO Replace the fuse.
WARNING A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn. This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity.
Does the starter motor turn? YES NO
Repair or replace the starter motor.
8-12

EAS00761 EASM0050
ELEC
4.Starter relay Disconnect the starter relay coupler from the coupler. Connect the pocket tester ( X 1) and battery (12 V) to the starter relay coupler as shown. Positive battery terminal red/white Negative battery terminal blue/white Positive tester probe red Negative tester probe red
6.Front and Rear brake switch Check the front and rear switches for continuity. Refer to CHECKING THE SWITCHES. Is the front and rear switches OK? YES NO Replace the front or rear brake switch.
EAS00764
R LW LW RW R B
7.Starter switch Check the starter switch for continuity. Refer to CHECKING THE SWITCHES. Is the starter switch OK? YES NO Replace the right handlebar switch.
Does the starter relay have continuity between red and black when it clicks? YES NO
EAS00766
Replace the starter relay.
8.Wiring (of the entire starting system) Check the entire starting systems wiring. Refer to CIRCUIT DIAGRAM. Is the starting systems wiring properly connected and without defects? NO YES The starting system circuit is OK.
EAS00749
Properly connect or repair the starting systems wiring.
8-13
STARTER MOTOR
EASM0051
ELEC
STARTER MOTOR
T.R
5 Nm (0.5 m.kg)
3
T.R
65 Nm (6.5 m.kg)
Order
Job/Part Removing the starter motor Rear mudguard
Qty
Remarks Remove/disassemble the parts in the order listed. Refer to REAR WHEEL AND BRAKE section in chapter 7
1 2 3
Starter connectors and couplers Starter motor fixing bolts/Washer Starter motor Disassembling the starter motor Starter motor mounting bolts Washers/o-rings Starter motor rear cover O-ring
1/1 2/2 1
2 2/2 1 1
8-14
STARTER MOTOR
ELEC
T.R
5 Nm (0.5 m.kg)
3
T.R
65 Nm (6.5 m.kg)
Order
Job/Part Stator assembly Armature assembly Brushes/Springs Brush holder/washer O-ring Starter motor front cover/O-ring
Qty 1 1 2/2 1/1 1 1/1
Remarks
For installation/assembly, reverse the removal/disassembly procedure.
8-15
STARTER MOTOR
EAS00770
ELEC
CHECKING THE STARTER MOTOR 1.Check: commutator Dirt Clean with 600 grit sandpaper. 2.Measure: commutator diameter a Out of specification Replace the starter motor. Commutator diameter 22 mm <Limit>: 21 mm
3.Measure: mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade which has been ground to fit the commutator. Mica undercut 1.5 mm NOTE: The mica of the commutator must be undercut to ensure proper operation of the commutator.
4.Measure: armature assembly resistances (commutator and insulation) Out of specification Replace the starter motor. a.Measure the armature assembly resistances with the pocket tester. Pocket tester 90890-03112 Armature coil Commutator resistance 0.0306~0.0374 at 20C Insulation resistance Above 1 M at 20C b.If any resistance is out of specification, replace the starter motor.
8-16
STARTER MOTOR
ELEC
5.Measure: brush length a . Out of specification Replace the brushes as a set. Brush length 10 mm <Limit>: 3.5 mm
a
6.Measure: brush spring force Out of specification Replace the brush springs as a set. Brush spring force 5.60 ~ 8.30 N 7.Check: gear teeth Damage/wear Replace the gear. 8.Check: bearing oil seal Damage/wear Replace the defective part(-s).
EAS00772
ASSEMBLING THE STARTER MOTOR 1.Install: Washer Brush Brush seat NOTE: Align the tab on the brush seat with the slot in the starter motor rear cover. 2.Install: armature assembly stator assembly starter motor front cover starter motor rear cover a b NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers.
8-17
STARTER MOTOR
ELEC
3.Install: O-rings washers starter motor mounting bolts starter motor fixing bolts
T.R
5 Nm (0.5mkg) 65 Nm (6.5mkg)
T.R
8-18
CHARGING SYSTEM
EAS00773
ELEC
CHARGING SYSTEM
CIRCUIT DIAGRAM

Br R GR B BW
LY
(BLUE)
(OPTION) B B

Gy B
R
5
GR Br B R B R GR Br
B B
36
LY
BW
BW
BR GW WR WL
GW BR WL WR
Or Br B YB Or Br
3 4
(1)
R Br B R LW LW
BR GW
BR GW WR WL
(4)
6
B R LW
WR WL
YB B
27
Br B
LW LW
LY LY (RED)
Dg Ch (BLACK)
LY
L BW
7 9
B
LW RW LW B
BW L
L
LY YR LY R LW
34
11
LB Br LB Br L
GY
HANDLE SWITCH 2
LW L
LW Br Dg
LW
R B B B B
OFF START
GY
Br
Br
POS ON
YR
OFF
Br L LB
Ch
L
23
GY Y
GY
26
B B YR B
LW RW
10
L
GY
A
GY
Br
LB

LW LW
Br
Br
Br
Br GR
Br
GR
Br Br
RW
LW
Br
BrW
LB
LW LW
24
METER ASSY. Y Dg
HI BEAM
19
LB B Y G Y G LB B
20 12
HANDLE SWITCH 1
Br
31
Ch BrW P Dg P Dg Ch BrW LY
BrW
(NATURAL) LY
R Br
THERMO. MOTOR
32
33
Br Br
28
R LW LW Dg
NO-CONNECTION
CLOCK ODOMETER
FUEL METER
Ch
TURN R TURN L
ILLUMI
ILLUMI
GY
Ch
BrW
Dg
GY
C
OFF PUSH
B
D
Y LB G HI LO
G Y
E L N R
Ch L Dg L B
22
21
B LR L
NO-CONNECTION
Ch Br B
R
RW LW
K
R L
O
B B
L
G
Br
L Y
Dg Y Ch GR
P Sb
Y Dg Ch
29
B
Gy
Gy
G L B Sb B P
Y G
Y G
13
HEAD LIGHT ASSY. L
Ch
13
HEAD LIGHT ASSY. R
Dg
P Sb
Y B L
GY B L
30 25 37
B
Ch
Ch
B
Dg
B
Dg
14
15
18
35
Ch
16
17
B (BLACK) B B B
CDI magneto Fuse (main) Battery Rectifier/regulator
8-19
Dg
CHARGING SYSTEM
EAS00774 EAS00739
ELEC
TROUBLESHOOTING THE BATTERY IS NOT BEING CHARGED. Check: 1.main fuse 2.battery 3.charging voltage 4.stator coil resistance 5.wiring (of the entire charging system) NOTE: Before troubleshooting, remove the following part(s): 1) Box and seat 2) Side covers Troubleshoot with the following special tool(s). Engine tachometer 90890-03113 Pocket tester 90890-03112
EAS00738
EAS00775
3.Charging voltage Connect the engine tachometer to the spark plug lead of the cylinder. Connect the pocket tester (DC V 20) to the battery as shown. Positive tester probe positive battery terminal Negative tester probe negative battery terminal
Replace the fuse.
Start the engine and let it run at approximately 5,000 r/min. Measure the charging voltage. Charging voltage measured voltage - terminal 14 V at 5,000 r/min
8-20
CHARGING SYSTEM
EAS00779
ELEC
5.Wiring (of the entire charging system) NOTE: Make sure the battery is fully charged. Is the charging voltage within specification? NO YES The charging circuit is OK.
EAS00776
Check the wiring connections of the entire charging system. Refer to CIRCUIT DIAGRAM. Is the charging systems wiring properly connected and without defects? NO Properly connect or repair the charging systems wiring. YES Replace the rectifier/ regulator.
4.Stator coil resistance Disconnect the stator coil coupler from the wire harness. Connect the pocket tester ( x 1) to the stator coils assembly coupler as shown. Positive tester probe white Negative tester probe white Positive tester probe white Negative tester probe white
1
W W W
Measure the stator coil resistances. Stator coil resistance 0.6 ~ 0.9 at 20C Is the stator coil OK? YES NO
Replace the stator coil assembly.
8-21
LIGHTING SYSTEM
EAS00780
ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM

Br R GR B BW
LY
(BLUE)
(OPTION) B B

Gy B
R
5
GR Br B R B R GR Br
B B
36
LY
BW
BW
BR GW WR WL
GW BR WL WR
Or Br B YB Or Br
3 4
(1)
R Br B R LW LW
BR GW
BR GW WR WL
(4)
6
B R LW
WR WL
YB B
27
Br B
LW LW
LY LY (RED)
Dg Ch (BLACK)
LY
L BW
7 9
B
LW RW LW B
BW L
L
LY YR LY R LW
34
11
LB Br LB Br L
GY
HANDLE SWITCH 2
LW L
LW Br Dg
LW
R B B B B
OFF START
GY
Br
Br
POS ON
YR
OFF
Br L LB
Ch
L
23
GY Y
GY
26
B B YR B
LW RW
10
L
GY
A
GY
Br
LB

LW LW
Br
Br
Br
Br GR
Br
GR
Br Br
RW
LW
Br
BrW
LB
LW LW
24
METER R ASSY. Br
THERMO. MOTOR L
19
LB B Y G Y G LB B
20 12
HANDLE SWITCH 1
Br
31
Y Dg
HI BEAM
(NATURAL) LY LY
BrW
32
33
Br Br
28
R LW LW Dg
NO-CONNECTION
CLOCK ODOMETER
FUEL METER
Ch
TURN R TURN L
ILLUMI
ILLUMI
GY
Ch BrW Dg
GY
C
OFF PUSH
B
D
Y LB G HI LO
G Y
E L N R
Ch L Dg L B
22
21
B LR L
NO-CONNECTION
Ch Br B
R
RW LW
K
R L
O
B B
L
G
Br
L Y
Dg Y Ch GR
P Sb
Y Dg Ch
29
B
Gy
Gy
G L B Sb B P
Y G
Y G
13
HEAD LIGHT ASSY. L
Ch
13
HEAD LIGHT ASSY. R
Dg
P Sb
Y B L
GY B L
30 25 37
B
Ch
Ch
B
Dg
B
Dg
14
15
18
35
Ch
16
17
B (BLACK) B B B
Tail/stop light Main switch k k Meter light Fuse (main) 24 K k Hi Beam indicator light Battery O License plate light k k Light switch B 35 k Dimmer switch D k Headlight (Left/Right) F k Position light (Left/Right) G
8-22
Dg
LIGHTING SYSTEM
EAS00781 EAS00739
ELEC
TROUBLESHOOTING ANY OF THE FOLLOWING FAIL TO LIGHT: HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT,LICENCE PLATE LIGHT, AUXILIARY LIGHT OR INSTRUMENT LIGHT . Check: 1.main fuse 2.battery 3.main switch 4.lighting switch 5.dimmer switch 6.wiring (of the entire lighting system) NOTE: Before troubleshooting, remove the following part(s): 1) Box and seat 2) Side covers 3) Front cover and handlebar covers Troubleshoot with the following special tool(s). Pocket tester 90890-03112
EAS00749
EAS00738
1.Main fuse Check the main fuse for continuity. Refer to CHECKING THE FUSES in chapter 3. Is the main fuse OK? YES NO Replace the fuse. The lighting switch is faulty. Replace the right handlebar switch.
EAS00783
4.Lighting switch Check the lighting switch for continuity. Refer to CHECKING THE SWITCHES. Is the lighting switch OK? YES NO
8-23
LIGHTING SYSTEM
EAS00784 EAS00788
ELEC
5.Dimmer switch Check the Dimmer switch for continuity. Refer to CHECKING THE SWITCHES. Is the Hi/Lo beam switch OK? YES NO The Dimmer switch is faulty. Replace the left handlebar switch.
CHECKING THE LIGHTING SYSTEM 1.The headlight and the high beam indicator light fail to come on. 1.Headlight bulb and socket Check the headlight bulb and socket for continuity. Are the headlight bulb and socket OK?
YES
NO
Replace the headlight bulb, socket or both.
EAS00787
6.Wiring (of the entire lighting system) Check the entire lighting systems wiring. Refer to CIRCUIT DIAGRAM. Is the lighting systems wiring properly connected and without defects? NO Properly connect or repair the lighting systems wiring. YES Check the condition of each of the lighting systems circuits. Refer to CHECKING THE LIGHTING SYSTEM.
2.Voltage Connect the pocket tester (DC V 20) to the headlight and high beam indicator light couplers as shown. A When the dimmer switch is set to B When the dimmer switch is set to Headlight coupler (wire harness side) Headlight Positive tester probe yellow or green Negative tester probe black High beam indicator light Positive tester probe yellow Negative tester probe black
Y G
A
G Ch L B Y
Br L
Y Dg Ch
A
G Dg L B Y
B
Br B G B
8-24
LIGHTING SYSTEM
EAS00789
ELEC
2.The meter light fails to come on. Meter light coupler (wire harness side) Set the main switch to ON. . Set the light switch to Set the dimmer switch to or . Measure the voltage (12 V) of green on the headlight coupler (wire harness side). Is the voltage within specification? NO YES 1.Meter light bulb and socket Check the meter light bulb and socket for continuity. Are the meter light bulb and socket OK? YES NO
The wiring circuit from the main switch to the headlight coupler is faulty and must be repaired.
This circuit is OK. 2.Voltage
Replace the meter light bulb, socket or both.
Connect the pocket tester (20 V) to the meter light coupler (wire harness side) as shown. Positive tester probe blue Negative tester probe black
METER ASSY.
Br
Y Dg Ch
R
Dg Y Ch GR
B B
G
Br P Sb
Set the main switch to ON. Set the light switch to or . Measure the voltage (12 V) of blue on the meter light coupler (wire harness side). Is the voltage within specification?
NO
YES
The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired.
This circuit is OK.
8-25
LIGHTING SYSTEM
EAS00790 EAS00790
ELEC
3.The tail/brake light fails to come on. 1.Tail/brake light bulb and socket Check the tail/brake light bulb and socket for continuity. Are the tail/brake light bulb and socket OK? YES NO
4.The license plate light fails to come on. 1.License plate light bulb and socket Check the licence plate light bulb and socket for continuity. Are the license plate bulb and socket OK? YES NO
Replace the tail/brake light bulb, socket or both. 2.Voltage Connect the pocket tester (DC V 20) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe blue Negative tester probe black
GY B L
Replace the license plate light bulb, socket or both. 2.Voltage Connect the pocket tester (DC V 20) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe blue Negative tester probe black
L
Set the main switch to ON. Set the light switch to or . Measure the voltage (12 V) of blue on the tail/brake light coupler (tail/brake light side). Is the voltage within specification? NO YES
Set the main switch to ON. Set the light switch to or . Measure the voltage (12 V) of blue on the license plate light coupler (license plate light side). Is the voltage within specification? NO YES
The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.
This circuit is OK.
The wiring circuit from the main switch to the license plate light coupler is faulty and must be repaired.
This circuit is OK.
8-26
LIGHTING SYSTEM
EAS00791
ELEC
5.The front position light fails to come on. 1.Auxiliary light bulb and socket Check the auxiliary light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKET. Are the auxiliary light bulb and socket OK? YES NO Replace the auxiliary light bulb, socket or both.
2.Voltage Connect the pocket tester (DC V 20) to the auxiliary light coupler (wire harness side) as shown. Positive tester probe blue Negative tester probe black
L
Set the main switch to ON. . Set the light switch to or Measure the voltage (12 V) of blue on the auxiliary light coupler (wire harness side). Is the voltage within specification? YES The wiring circuit from the main switch to the auxiliary light conectors is faulty and must be repaired. NO
This circuit is OK.
8-27
SIGNALING SYSTEM
EAS00793
ELEC
SIGNALING SYSTEM
CIRCUIT DIAGRAM

Br R GR B BW
LY
(OPTION)
(BLUE)

Gy B
5
GR Br B R B R GR Br
B B
B B
36
LY
BW
BW
BR GW WR WL
GW BR WL WR
Or Br B YB Or Br
3 4
(1)
R Br B R LW LW
BR GW
BR GW WR WL
(4)
6
B R LW
WR WL
YB B
27
Br B
LW LW
LY LY (RED)
Dg Ch (BLACK)
LY
L BW
7 9
B
LW RW LW B
BW L
LY YR LY R LW
34
11
LB Br LB Br L
GY
HANDLE SWITCH 2
LW L
LW Br Dg
LW
R B B B B
OFF START
GY
Br
POS ON
YR
OFF
Br L LB
Ch
L
23
GY Y
26
B B YR B
LW RW
GY
A
GY
Br
10
Br
LB
GY

LW LW
Br
Br
Br
Br
Br
RW
LW
Br
Br
GR
Br
GR BrW
LW LW
19
LB B Y G Y G LB B
LB
24
METER R ASSY. Br
20 12
HANDLE SWITCH 1
Br
31
Y Dg Ch BrW P Dg P Dg Ch BrW LY
(NATURAL) LY
BrW
32
33
Br Br
THERMO. MOTOR
28
R LW LW Dg
NO-CONNECTION
CLOCK ODOMETER
FUEL METER
HI BEAM
Ch
TURN R
TURN L
ILLUMI
ILLUMI
GY
Ch BrW Dg
GY
C
OFF PUSH HI LO
D
Y LB G
E L N R
Ch L Dg L B
22
21
B LR L
NO-CONNECTION
Ch Br B
R
RW LW
K
R L
O
B B
L
G
Br
L Y
Dg Y Ch GR
P Sb
Y Dg Ch
29
B
Gy
Gy
G L B Sb B P
Y G
Y G
13
HEAD LIGHT ASSY. L
Ch
13
HEAD LIGHT ASSY. R
Dg
P Sb
Y B L
GY B L
30 25 37
B
Ch
Ch
B
Dg
B
Dg
14
15
18
35
Ch
16
17
B (BLACK) B B B
8-28
Dg
B
SIGNALING SYSTEM
Main switch Fuse (main) Battery k Horn switch C k Turn signal switch E k Front position light (left and light) G Left front flasher Right front flasher Left rear flasher Right rear flasher Tail/stop light Horn Flasher relay k k Coolant themperature warning light 24 P k Fuel sender indicator N k Clock and odometer R k Meter light K k Turn signal indicator light L k Turn signal indicator light M k Sender 25
ELEC
8-29
SIGNALING SYSTEM
EAS00794 EAS00739
ELEC
TROUBLESHOOTING ANY OF THE FOLLOWING FAIL TO LIGHT: TURN SIGNAL LIGHT, BRAKE LIGHT OR AN INDICATOR LIGHT. THE HORN FAILS TO SOUND. Check: 1.main fuse 2.battery 3.main switch 4.wiring (of the entire signaling system) NOTE: Before troubleshooting, remove the following part(s): 1) Battery cover 2) Box and seat 3) Side covers Troubleshoot with the following special tool(s). Pocket tester 90890-03112
EAS00738
EAS00749
EAS00795
4.Wiring (of the entire signaling system) Check the entire signal systems wiring. Refer to CIRCUIT DIAGRAM. Is the signalling systems wiring properly connected and without defects? NO Properly connect or repair the signaling systems wiring. YES Check the condition of each of the signaling systems circuits. Refer to CHECKING THE SIGNALING SYSTEM.
Replace the fuse.
8-30
SIGNALING SYSTEM
EAS00796
ELEC
CHECKING THE SIGNALING SYSTEM 1.The horn fails to sound. 1.Horn switch Check the horn switch for continuity. Refer to CHECKING THE SWITCHES. Is the horn switch OK? YES NO
3.Horn Disconnect the pink connector at the horn terminal. Connect a jumper lead to the horn terminal and ground the jumper lead. Set the main switch to ON. Does the horn sound? NO YES The horn is OK.
Replace the left handlebar switch. 4.Voltage 2.Voltage Connect the pocket tester (DC V 20) to the horn connector at the horn terminal as shown. Positive tester probe pink Negative tester probe ground
Br P
Connect the pocket tester (DC V 20) to the horn connector at the brown terminal as shown. Positive tester probe brown Negative tester probe ground
Br
Set the main switch to ON. Push the horn switch. Measure the voltage (12 V) of pink at the horn terminal. Is the voltage within specification? YES NO The wiring circuit from the main switch to the horn connector is faulty and must be repaired.
Set the main switch to ON. Measure the voltage (12 V) of brown horn terminal. Is the voltage within specification? NO Replace the horn.
at the
YES Repair or replace the horn.
8-31
SIGNALING SYSTEM
EAS00798
ELEC
2.The tail/brake light fails to come on. 1.Tail/brake light bulb and socket Check the tail/brake light bulb and socket for continuity. Are the tail/brake light bulb and socket OK? YES NO NO Replace the tail/brake light bulb, socket or both. 2.Brake light switches Check the brake light switches for continuity. Refer to CHECKING THE SWITCHES. Is the brake light switch OK? YES NO Replace the brake light switch. The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.
EAS00799
Set the main switch to ON. Pull in the brake levers. Measure the voltage (12 V) of yellow on the tail/brake light coupler (wire harness side). Is the voltage within specification? YES This circuit is OK.
3.The turn signal light, turn signal indicator light or both fail to blink. 1.Turn signal indicator light bulb and socket Check the turn signal light bulb and socket for continuity. Are the turn signal light bulb and socket OK? YES NO Replace the turn signal light bulb, socket or both. 2.Turn signal switch Check the turn signal switch for continuity. Refer to CHECKING THE SWITCHES. Is the turn signal switch OK? YES NO Replace the left handlebar switch.
3.Voltage Connect the pocket tester (DC V 20) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe yellow Negative tester probe black
Y B L
8-32
SIGNALING SYSTEM
3.Voltage Connect the pocket tester (DC V 20) to the flasher relay coupler (wire harness side) as shown. Positive tester probe brown Negative tester probe ground
ELEC
Set the main switch to ON. Set the turn signal switch to or . Measure the voltage (12 V) on brown/white at the turn signal relay coupler (wire harness side). Is the voltage within specification? YES NO The turn signal relay is faulty and must be replaced. 5.Voltage
Br
BrW Br
BrW
Set the main switch to ON. Measure the voltage (12 V) on brown at the turn signal relay coupler (wire harness side). Is the voltage within specification? YES NO The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be repaired. 4.Voltage Connect the pocket tester (DC V 20) to the flasher relay coupler (wire harness side) as shown. Positive tester probe brown/white Negative tester probe ground
Connect the pocket tester (DC V 20) to the turn signal light connector as shown. Left turn signal light Positive tester probe chocolate Negative tester probe ground Right turn signal light Positive tester probe dark green Negative tester probe ground
Set the main switch to ON. Set the turn signal switch to or . Measure the voltage (12 V) of the chocolate or dark green at the turn signal light connector (wire harness side). Is the voltage within specification? NO YES This circuit is OK.
Br
BrW Br
The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.
BrW
8-33
SIGNALING SYSTEM
EASM0052 EAS00804
ELEC
4.The Coolant temperature warning light fails to come on. 1.Coolant temperature warning light bulb and socket Check the coolant temperature warning light bulb and socket for continuity. Are coolant temperature warning light bulb and socket OK? YES NO Replace the coolant temperature warning light bulb, socket or both.
5.The fuel level gauge fails to operate. 1.Fuel sender Remove the fuel sender from the fuel tank. Connect the pocket tester to the fuel sender coupler (wire harness side) as shown. Positive tester probe green Negative tester probe black
Measure the fuel sender resistances. Fuel sender resistance (up position) ( x 1) 4 ~ 10 at 20C Fuel sender resistance (down position) ( x 10) 90 ~ 100 at 20C Is the fuel sender OK? YES NO Replace the fuel sender.
8-34
SIGNALING SYSTEM
2.Voltage Connect the pocket tester (DC V 20) to the meter light coupler (wire harness side) . Positive tester probe brown Negative tester probe black Set the main switch to ON. Measure the voltage (12 V) of brown on the meter light coupler (wire harness side). Is the voltage within specification? YES NO Check the wiring connections of the entire signaling system. 4.Wiring
ELEC
Check the entire signal systems wiring. Refer to CIRCUIT DIAGRAM. Is the signaling systems wiring properly connected and without defects? NO Properly connect or repair the signaling systems wiring. YES Check the condition of each of the signaling systems circuits. Refer to CHECKING THE SIGNALING SYSTEM.
3.Fuel level gauge Set the main switch to ON. Move the float up or down. Check that the fuel level gauge needle moves to up or down. NOTE: Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes. Does the fuel level gauge needle move appropriately? YES NO Replace the speedometer unit.
8-35
SIGNALING SYSTEM
EAS00805
ELEC
6.The clock/odometer fails to come on. 1.Voltage Connect the pocket tester (DC V 20) to the clock/odometer coupler (wire harness side) as shown. Positive tester probe red Negative tester probe ground
Br
L
Y Dg Ch
R
Dg Y Ch GR
B B
G
Br P Sb
Set the main switch to ON. Measure the voltage (12 V). Is the voltage within specification? YES NO The wiring circuit from the main switch to the clock coupler is faulty and must be repaired. 2.Clock Check that the clock is operating properly. When setting the clock after its power source has been disconnected (e.g., when the battery is removed), first set the clock to 1:00 AM and then to the correct time. Is the clock operating properly? NO Replace the clock/ odometer. YES This circuit is OK.
8-36
COOLING SYSTEM
EAS00807
ELEC
COOLING SYSTEM
CIRCUIT DIAGRAM

Br R GR B BW
LY
(OPTION)
(BLUE)

Gy B
5
GR Br B R B R GR Br
B B
B B
36
LY
BW
BW
BR GW WR WL
GW BR WL WR
Or Br B YB Or Br
3 4
(1)
R Br B R LW LW
BR GW
BR GW WR WL
(4)
6
B R LW
WR WL
YB B
27
Br B
LW LW
LY LY (RED)
Dg Ch (BLACK)
LY
L BW
7 9
B
LW RW LW B
BW L L
LY YR LY R LW
34
11
LB Br LB Br L
GY
HANDLE SWITCH 2
LW L
LW Br Dg
LW
R B B B B
OFF START
GY Br
POS ON
YR
OFF
Br L LB
Ch
L
23
GY Y GY
26
B B YR B
LW RW
GY
A
GY
Br
10
Br
LB

LW LW
Br
Br
Br
Br
Br
Br
RW
LW
Br
GR
Br
GR BrW
LW LW
19
LB B Y G Y G LB B
LB
24
METER R ASSY. Br
20 12
HANDLE SWITCH 1
Br
31
Y Dg Ch BrW P Dg P Dg Ch BrW LY
(NATURAL) LY
BrW
32
33
Br Br
THERMO. MOTOR
28
R LW LW Dg
NO-CONNECTION
CLOCK ODOMETER
FUEL METER
HI BEAM
Ch
TURN R
TURN L
ILLUMI
ILLUMI
GY
Ch BrW Dg
GY
C
OFF PUSH HI LO
D
Y LB G
E L N R
Ch L Dg L B
22
21
B LR L
NO-CONNECTION
Ch Br B
R
RW LW
K
R L
O
B B
L
G
Br
L Y
Dg Y Ch GR
P Sb
Y Dg Ch
29
B
Gy
Gy
Ch
G L B Sb B P
Y G
Y G
13
HEAD LIGHT ASSY. L
13
HEAD LIGHT ASSY. R
Dg
P Sb
Y B L
GY B L
30 25 37
B
Ch
Ch
B
Dg
B
Dg
14
15
18
35
Ch
16
17
B (BLACK) B B B
k 24 k 28 k 29 k 30 k 31
Main switch Fuse (main) Battery P Coolant temperature warning light Thermo fan switch Fan Coolant thermo switch Fan Fuse
8-37
Dg
B
COOLING SYSTEM
EAS00808 EAS00739
ELEC
TROUBLESHOOTING The radiator fan motor fails to turn. The coolant temperature warning light fails to light up when the engine is warm. Check: 1.main and radiator fan motor fuses 2.battery 3.main switch 4.radiator fan motor 5.thermo switch 6.wiring connections (the entire cooling system) NOTE: Before troubleshooting, remove the following part(-s): 1) Battery cover 2) Box and seat 3) Side covers 4) Front cover Troubleshoot with the following special tool (s). Pocket tester 90890-03112
EAS00749
EASM0053
1.The radiator fan motor fails to turn. 1.Main and radiator fan motor fuses Check the fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. Are the fuses OK? YES NO Replace the fuses.
EAS00809
4.Radiator fan motor Disconnect the radiator fan motor coupler from the wire harness. Connect the battery (12 V) as shown. Positive battery lead blue Negative battery lead black
L B
8-38
COOLING SYSTEM
Does the radiator fan motor turn? YES NO The radiator fan motor is faulty and must be replaced.
EAS00811
ELEC
A Thermo switch circuit ON B Thermo switch circuit OFF
5.Thermo switch Remove the thermo switch from the radiator. Connect the pocket tester ( x 1) to the thermo switch as shown. Immerse the thermo switch in a container filled with coolant. Place a thermometer in the coolant. Slowly heat the coolant, then let it cool down to the specified temperature. Check the thermo switch for continuity at the temperatures indicated below. Does the thermo switch operate properly as described above? YES NO Replace the thermo switch.
EAS00813
6.Wiring (of the entire cooling system) Check the entire cooling systems wiring. Refer to CIRCUIT DIAGRAM. Is the cooling systems wiring properly connected and without defects? NO Properly connect or repair the cooling systems wiring.
EASM0053
YES This circuit is OK.
2.The water temperature warning light fails to light up when the engine is warm. 1.Main fuse Check the fuse for continuity. Refer to CHECKING THE FUSES in chapter 3. is the fuse OK? YES NO Replace the fuse.
WARNING
Handle the thermo switch with special care. Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it.
8-39
COOLING SYSTEM
EAS00739
ELEC
EAS00749
Temperature sender resistance 80C: 47.5 ~ 56.8 100C: 26.2 ~ 29.3

WARNING
Handle the temperature sender with special care. Never subject the temperature sender to strong shocks. If the temperature sender is dropped, replace it. A Thermo switch circuit is open and the temperature warning light is OFF B Thermo switch circuit is closed and the temperature warning light is ON Does the temperature sender operate properly? YES NO Replace the temperature sender.
EAS00813
EAS00812
5.Wiring (of the entire cooling system) Check the entire cooling systems wiring. Refer to CIRCUIT DIAGRAM. Is the cooling systems wiring properly connected and without defects? NO Properly connect or repair the cooling systems wiring. YES This circuit is OK.
4.Temperature sender Remove the temperature sender from the radiator. Connect the pocket tester ( x 10) to the temperature sender. Immerse the temperature sender in a container filled with coolant. NOTE: Make sure the thermo switch terminals do not get wet. Place a thermometer in the coolant. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. Check the thermo switch for continuity at the temperatures indicated in the table.
8-40
CARBURETOR HEATING SYSTEM

EAS00820
ELEC

CIRCUIT DIAGRAM

Br R GR B BW
LY
(BLUE)
(OPTION) B B

Gy B
R
5
GR Br B R B R GR Br
B B
36
LY
BW
BW
BR GW WR WL
GW BR WL WR
Or Br B YB Or Br
3 4
(1)
R Br B R LW LW
BR GW
BR GW WR WL
(4)
6
B R LW
WR WL
YB B
27
Br B
LW LW
LY LY (RED)
Dg Ch (BLACK)
LY
L BW
7 9
B
LW RW LW B
BW L
L
LY YR LY R LW
34
11
LB Br LB Br L
GY
HANDLE SWITCH 2
LW L
LW Br Dg
LW
R B B B B
OFF START
GY Br
POS ON
Br
YR
OFF
Br L LB
Ch
L
23
GY Y
GY
26
B B YR B
LW RW
10
L
GY
A
GY
Br
LB

LW LW
Br
Br
Br
Br GR
Br
GR
Br Br
RW
LW
Br
BrW
LB
LW LW
24
METER R ASSY. Br
THERMO. MOTOR L
19
LB B Y G Y G LB B
20 12
HANDLE SWITCH 1
Br
31
Y Dg
HI BEAM
(NATURAL) LY LY
BrW
32
33
Br Br
28
R LW LW Dg
NO-CONNECTION
CLOCK ODOMETER
FUEL METER
Ch
TURN R TURN L
ILLUMI
ILLUMI
GY
Ch
BrW
Dg
GY
C
OFF PUSH
B
D
Y LB G HI LO
G Y
E L N R
Ch L Dg L B
22
21
B LR L
NO-CONNECTION
Ch Br B
R
RW LW
K
R L
O
B B
L
G
Br
L Y
Dg Y Ch GR
P Sb
Y Dg Ch
29
B
Gy
Gy
G L B Sb B P
Y G
Y G
13
HEAD LIGHT ASSY. L
Ch
13
HEAD LIGHT ASSY. R
Dg
P Sb
Y B L
GY B L
30 25 37
B
Ch
Ch
B
Dg
B
Dg
14
15
18
35
Ch
16
17
B (BLACK) B B B
Main switch Fuse (main) Battery k Carburetor heater switch 32 k Carburetor heater 33
8-41
Dg

EAS00821 EAS00739
ELEC
TROUBLESHOOTING The carburetor heating system fails to operate. Check: 1.Main fuse 2.Battery 3.Main switch 4.Thermo switch 5.Carburetor heater 6.Wiring (of the entire carburetor heating system) NOTE: Before troubleshooting, remove the following part(s): 1) Side covers 2) Box and seat 3) Battery cover Troubleshoot with the following special tool(s).
EAS00749

EAS00738
1.Main fuse Check the main fuse for continuity. Refer to CHECKING THE FUSES in chapter 3. Is the main fuse OK? YES NO Replace the fuse.
8-42

EAS00823 EAS00824
ELEC
4. Thermo switch Disconnect the thermo switch from the wire harness. Connect the pocket tester ( x 1) to the thermo switch lead. Positive tester probe black Negative tester probe black
5.Carburetor heater Remove the carburetor heating element from the carburetor. Connect the pocket tester ( x 1) to the carburetor heating element. Positive tester probe heating element Negative tester probe heating element body
Measure the carburetor heater resistance. Carburetor heating element resistance: 6 ~ 12 at 20C Is the carburetor heating element OK? YES NO Replace the carburetor heating element.
Check the thermo switch for continuity at the temperatures indicated below.
A COOL DOWN B HEAT UP Does the thermo switch operated properly ? YES NO Replace the thermo switch.
EAS00826
6. Wiring (of the entire carburetor heating system) Check the entire carburetor heating systems wiring Refer to CIRCUIT DIAGRAM Is the carburetor heating system properly connected and without defects? NO Properly connect or repair the carburetor heating systems wiring. YES This circuit is OK.
8-43
TRBL SHTG
TRBL SHTG
CHAPTER 9. TROUBLESHOOTING
STARTING FAILURE/ HARD STARTING .................................................... 9-1 ENGINE ................................................................................................... 9-1 FUEL SYSTEM ........................................................................................ 9-1 ELECTRICAL SYSTEMS ......................................................................... 9-2 INCORRECT ENGINE IDLING SPEED ......................................................... 9-2 ENGINE ................................................................................................... 9-2 FUEL SYSTEM ........................................................................................ 9-2 ELECTRICAL SYSTEMS ......................................................................... 9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ............................... 9-2 ENGINE ................................................................................................... 9-2 FUEL SYSTEM ........................................................................................ 9-2 FAULTY CLUTCH ......................................................................................... 9-3 ENGINE OPERATES BUT SCOOTER WILL NOT MOVE ...................... 9-3 CLUTCH SLIPS ....................................................................................... 9-3 POOR STARTING PERFORMANCE ...................................................... 9-3 POOR SPEED PERFORMANCE ............................................................ 9-3 OVER HEATING ............................................................................................ 9-3 ENGINE ................................................................................................... 9-3 COOLING SYSTEM ................................................................................. 9-3 FUEL SYSTEM ........................................................................................ 9-3 CHASSIS ................................................................................................. 9-3 ELECTRICAL SYSTEMS ......................................................................... 9-3 OVERCOOLING ............................................................................................ 9-4 COOLING SYSTEM ................................................................................. 9-4 POOR BRAKING ........................................................................................... 9-4 FAULTY FRONT FORK LEGS ...................................................................... 9-4 LEAKING OIL ........................................................................................... 9-4 MALFUNCTION ....................................................................................... 9-4 UNSTABLE HANDLING ................................................................................ 9-5
TRBL SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM ............................................ 9-5 HEADLIGHT DOES NOT LIGHT ............................................................. 9-5 HEADLIGHT BULB BURNT OUT ............................................................ 9-5 TAIL/BRAKE LIGHT DOES NOT LIGHT ................................................. 9-5 TAIL/BRAKE LIGHT BULB BURNT OUT ................................................ 9-5 TURN SIGNAL DOES NOT LIGHT .......................................................... 9-5 TURN SIGNAL BLINKS SLOWLY ........................................................... 9-5 TURN SIGNAL REMAINS LIT ................................................................. 9-6 TURN SIGNAL BLINKS QUICKLY .......................................................... 9-6 HORN DOES NOT SOUND ..................................................................... 9-6
STARTING FAILURE/HARD STARTING

EAS00845
TRBL SHTG
TROUBLESHOOTING
NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING FAILURE/HARD STARTING

ENGINE Cylinder and cylinder head Loose spark plug Loose cylinder head or cylinder Damaged cylinder head gasket Damaged cylinder base gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timing Faulty valve spring Seized valve Piston and piston ring(s) Improperly installed piston ring Damaged, worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel tank cap breather hole Deteriorated or contaminated fuel Clogged or damaged fuel hose Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked-in air Damaged float Worn needle valve Improperly installed needle valve seat Incorrect fuel level Improperly adjusted pilot air screw Improperly installed pilot jet Clogged starter jet Clogged emulsion tube Autochoke unit Faulty starter plunger Faulty ignitor unit Faulty thermo switch
9-1
STARTING FAILURE/HARD STARTING/ INCORRECT ENGINE IDLING SPEED/ POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
ELECTRICAL SYSTEMS Battery Improperly charged battery Faulty battery Fuse(s) Blown, damaged or incorrect fuse Improperly installed fuse Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap Ignition coil Broken or shorted primary or secondary coils Faulty spark plug lead Cracked or broken ignition coil body
EAS00847
TRBL SHTG
Ignition system Faulty ignition unit Faulty pickup coil Broken generator rotor woodruff key/slipped timing Switches and wiring Faulty main switch Broken or shorted wiring Faulty front, rear or both brake switches Faulty start switch Improperly grounded circuit Loose connections Starting system Faulty starter motor Faulty starter relay Faulty starter clutch
INCORRECT ENGINE IDLING SPEED

ENGINE Cylinder and cylinder head Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Carburetor Faulty starter plunger Loose or clogged pilot jet Loose or clogged pilot air jet Damaged or loose carburetor joint Improperly adjusted engine idling speed (throttle stop screw) Improper throttle cable free play Flooded carburetor Autochoke unit Faulty starter plunger Faulty ignitor unit ELECTRICAL SYSTEMS Battery Discharged battery Faulty battery Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap Ignition coil Faulty spark plug lead Ignition system Faulty ignitor unit Faulty pickup coil
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Refer to STARTING FAILURE/HARD STARTING section. ENGINE FUEL SYSTEM Air filter Carburetor Clogged air filter element Faulty diaphragm Incorrect fuel level Loose or clogged main jet
9-2
FAULTY CLUTCH/ OVERHEATING

EAS00853
TRBL SHTG
FAULTY CLUTCH
ENGINE OPERATES BUT SCOOTER WILL NOT MOVE V-belt Bent, damaged or worn V-belt Slipping V-belt Primary pulley cam and primary pulley slider Damaged or worn primary pulley cam Damaged or worn primary pulley slider Clutch spring(s) Damaged clutch spring Transmission gear(s) Damaged transmission gear CLUTCH SLIPS Clutch shoe spring(s) Damaged, loose or worn clutch shoe spring Clutch shoe(s) Damaged or worn clutch shoe Primary sliding sheave Seized primary sliding sheave POOR STARTING PERFORMANCE V-belt V-belt slips Oil or grease on the V-belt Primary sliding sheave Faulty operation Worn pin groove Worn pin Clutch shoe(s) Bent, damaged or worn clutch shoe POOR SPEED PERFORMANCE V-belt Oil or grease on the V-belt Primary pulley weight(s) Faulty operation Worn primary pulley weight Primary fixed sheave Worn primary fixed sheave Primary sliding sheave Worn primary sliding sheave Secondary fixed sheave Worn secondary fixed sheave Secondary sliding sheave Worn secondary sliding sheave
EAS00855
OVERHEATING
ENGINE Clogged coolant passages Cylinder head and piston Heavy carbon buildup Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality COOLING SYSTEM Coolant Low coolant level Radiator Leaking coolant system Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin Water pump Damaged or faulty water pump Thermostat Thermostat stays closed FUEL SYSTEM Carburetor Incorrect main jet setting Incorrect fuel level Damaged or loose carburetor joint Air filter Clogged air filter element CHASSIS Brake(s) Dragging brake ELECTRICAL SYSTEMS Spark plug Incorrect spark plug gap Incorrect spark plug heat range Ignition system Faulty ignition unit
9-3
OVER COOLING/ POOR BRAKING/ FAULTY FRONT FORK LEGS

EAS00856
TRBL SHTG
OVERCOOLING
COOLING SYSTEM Thermostat Thermostat stays open
EAS00859
POOR BRAKING
Disc brake Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level
EAS00860
FAULTY FRONT FORK LEGS

LEAKING OIL Bent, damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level (high) Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O-ring Loose drain bolt Damaged drain bolt gasket MALFUNCTION Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level
9-4
UNSTABLE HANDLING/ FAULTY LIGHTING OR SIGNALING SYSTEM

EAS00862
TRBL SHTG
UNSTABLE HANDLING
Handlebar Bent or improperly installed handlebar Steering head components Improperly installed lower bracket (improperly tightened ring nut) Bent steering stem Damaged ball bearing or bearing rac Front fork leg(s) Uneven oil levels (both front fork legs) Unevenly tensioned fork spring (both front fork legs) Broken fork spring Bent or damaged inner tube Bent or damaged outer tube Swingarm Worn bearing or bushing Bent or damaged swingarm Rear shock absorber assembly Faulty rear shock absorber spring Leaking oil or gas Tyres Uneven tyre pressures (front and rear) Incorrect tyre pressure Uneven tyre wear Wheels Incorrect wheel balance Deformed cast wheel Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout Frame Bent frame Damaged steering head pipe Improperly installed bearing race
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM

HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts (main or light switch) Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT Wrong headlight bulb Faulty battery Faulty rectifier/regulator Improperly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired TAIL/BRAKE LIGHT DOES NOT LIGHT Wrong tail/brake light bulb Too many electrical accessories Incorrect connection Burnt-out tail/brake light bulb TAIL/BRAKE LIGHT BULB BURNT OUT Wrong tail/brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail/brake light bulb life expired TURN SIGNAL DOES NOT LIGHT Faulty turn signal switch Faulty turn signal relay Burnt-out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown, damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Faulty charging circuit
9-5
FAULTY LIGHTING OR SIGNALING SYSTEM

TURN SIGNAL REMAINS LIT Faulty turn signal relay Burnt-out turn signal bulb TURN SIGNAL BLINKS QUICKLY Incorrect turn signal bulb Faulty turn signal relay Burnt-out turn signal bulb
TRBL SHTG
HORN DOES NOT SOUND Improperly adjusted horn Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery Blown, damaged or incorrect fuse Faulty wire harness
9-6
XQ125/XQ150 WIRING DIAGRAM

Br R GR B BW
COLOR CODE
B ............. black Br ............ brown Ch ........... chocolate Dg ........... dark green G ............ green Gy ........... gray L ............. blue O ............ orange P ............. pink R ............. red
BW LY LY
(BLUE)
(OPTION) B B

Gy B R
5
GR Br B R B R GR Br
B B
36
LY
B B (BLUE) (BLUE) B
Sb ........... sky blue W ............ white Y ............. yellow B / L ........ brack / blue B / R ....... brack / red B / W ...... black / white B / Y ....... black / yellow Br / L ...... brown / blue Br / R ...... brown / red Br / W ..... brown / white
G / R ....... green / red G / W ...... green / white G / Y ....... green / yellow L / B ........ blue / black L / R ........ blue / red L / W ....... blue / white L / Y ........ blue / yellow O / R ....... orange / red R / B ....... red / black R / G ....... red / green
R / L ....... red / blue R / W ...... red / white R / Y ....... red / yellow W / B ...... white / black W / G ...... white / green W / Y ...... white / yellow Y / B ....... yellow / black Y / L ........ yellow / blue
BW
LY
BR GW WR WL
GW BR WL WR
Or Br B YB Or Br
3 4
(1)
R Br B R LW LW
BR GW
BR GW WR WL
(4)
6
B R LW
WR WL
YB B
27
Br B
LW LW
LY LY (RED)
Dg Ch (BLACK)
LY
L BW
7 9
B
LW RW LW B
BW L L
LY YR LY R LW
Q W E R T Y U I O P { A B } C D E q F G w e r t y u i o p [ ] K L M N O P R A S D F G H J K L : a s d
34
11
LB Br LB Br L
GY
HANDLE SWITCH 2
LW L
LW Br Dg
LW
R B B B B
OFF START
GY
Br Br
POS ON
YR
OFF
Br L LB
Ch
L
23
GY Y GY
26
B B YR B
LW RW
10
L
GY
A
GY

LW LW
Br
Br Br
Br GR Br GR Br Br BrW LB
LW LW
24
METER ASSY. Y Dg HI BEAM Ch TURN R TURN L
19
LB B Y G Y G LB B
20 12
HANDLE SWITCH 1
Br
31
Ch BrW P Dg P Dg Ch BrW LY BrW
(NATURAL) LY
R Br THERMO. MOTOR
32
33
Br Br
28
R LW LW Dg
CLOCK ODOMETER
FUEL METER
ILLUMI
ILLUMI
NO-CONNECTION
GY
Ch BrW Dg
GY
C
OFF PUSH B HI LO
D
Y LB G
E L N R
Ch L Dg L B
22
21
B LR L
NO-CONNECTION
Ch Br B
R
RW LW
K
R L
O
B B
L
G
Br
L Y
Dg Y Ch GR
P Sb
Y Dg Ch
29
B
Gy
B Ch
G L B Sb B P
Y G
Y G
13
HEAD LIGHT ASSY. L
Dg
P Sb
13
HEAD LIGHT ASSY. R
Y B L
GY B L
30 25 37
B
Ch
B
Dg
B
Dg
14
15
18
35
Ch
16
17
B (BLACK) B B B
CDI MAGNETO CDI UNIT IGNITION COIL SPARK PLUG MAIN SWITCH ASSY FUSE (MAIN) BATTERY RECTIFIER/REGULATOR STARTER RELAY STARTER MOTOR HANDLE SWITCH (2) STARTER SWITCH LIGHTING SWITCH HANDLE SWITCH (1) HORN SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HEADLIGHT ASSY (LEFT AND RIGHT) HEADLIGHT (2X12V-35X35W) POSITION LIGHT (2X12V-5W) LEFT FRONT TURN SIGNAL (12V-21W) REAR FRONT TURN SIGNAL (12V-21W) LEFT REAR TURN SIGNAL (12V-10W) RIGHT REAR TURN SIGNAL (12V-10W) TAIL/STOP LIGHT (12V-5/21W) HORN TURN SIGNAL RELAY FRONT STOP SWITCH REAR STOP SWITCH RELAY METER ASSY METER LIGHT (2X12V-1.2W) RIGHT TURN SIGNAL INDICATOR LIGHT (12V-1.2W) LEFT TURN SIGNAL INDICATOR LIGHT (12V-1.2W) FUEL METER HIGH BEAM INDICATOR (12V-1.2W) COOLANT TEMPERATURE WARNING LIGHT CLOCK AND ODOMETER SENDER AUTO CHOKE AUTO CHOKE THERMO SWITCH FAN THERMO SWITCH FAN COOLANT THERMO SWITCH FAN FUSE CARBURETOR HEATER THERMO SWITCH CARBURETOR HEATER ANTI THEFT UNIT (OPTION) LICENSE LIGHT (12V-5W) SIDE STAND SWITCH (OPTION) SPEEDOMETER GEAR SENSOR
Br
RW
LW
Br
LB
Gy
Y L
Ch
Dg

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What are the different symbols used in the manual and what do they indicate?

What information is provided in an exploded diagram?

What information is provided in an exploded diagram?

XQ125 XQ150

HOW TO USE THIS MANUAL

CYLINDER AND PISTON

CYLINDER AND PISTON

CYLINDER AND PISTON

2 1 1 2 1 2 1 1 1 1 1 For installation, reverse the removal procedure.

SYMBOLS GEN INFO SPEC

CHECKING THE CONNECTIONS ............................................................... 1-6 SPECIAL TOOLS .......................................................................................... 1-7

CHECKING THE CONNECTIONS

CHECKING THE CONNECTIONS

4.Connect: lead coupler connector

Tool No. 90890-01083 90890-01084

10W/30 10W/40 20W/40 20W/50

API STANDARD: SE, SF, SG Type or higher grade

MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS

53.700~53.705 mm [59.500~59.505 mm]* 0.05 mm Chain drive (left)

30.711 mm 25.045 mm 30.711 mm 25.052 mm 0.03 mm 12.030mm 11.950 mm

53.670~53.687 mm [59.470~59.487mm]* 4.5 mm 15.002~15.013 mm 14.991~15.000 mm

0.50 mm 0.12 mm 0.65 mm 0.12 mm

0.03 mm 1.0 mm 120.5 [135.5]* 19.5 mm 19 mm

0.15 mm 0.15 mm 0.17 mm

22 x 32 x 7 19 x 30 x 8 (Reinforced) 19 x 30 x 8 (Double lips) 20 x 42 x 12 15 x 32 x 9 17 x 35 x 10 25 x 52 x 15 17 x 40 x 12 25 x 42 x 6 (Double lips) 15 x 25 x 12 (Needle bearing) 12 x 37 x 12 17 x 47 x 14 (Sphere) 22 x 50 x 14 (Sphere) 32 x 52 x 7

MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS

Limit 1 mm 0.5 mm 1 mm 0.5 mm

(K1) (K2) (K1) (K2)

MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS

GENERAL TIGHTENING TORQUE SPECIFICATIONS

GENERAL TIGHTENING TORQUE SPECIFICATIONS

A: Width across flats B: Thread diameter

See chapter 7 STEERING HEAD

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

COOLING SYSTEM DIAGRAMS

COOLING SYSTEM DIAGRAMS

COOLING SYSTEM DIAGRAMS

COOLING SYSTEM DIAGRAMS

A B Crankshaft Oil pump Oil strainer Crankcase Connecting rod

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

3 * Valves 4 5 Air filter element V-belt air filter element

7 * Front brake (disc)

Whenever worn to the limit

8 * Rear brake (disc)

Whenever worn to the limit Every 4 years.

9 * Brake hose 10 * Wheels

12 * Wheel bearings 13 * Steering bearings 14 15 Chassis fasteners Centerstand

Every 24,000 kms.

PERIODIC CHECKS AND ADJUSTMENTS

ODMETER READING (x1,000km)

Every 3,000 km.

Every 3 years. Every 18,000 km.

COVER AND PANEL

COVER AND PANEL