Yamaha VINO XC50V Service Manual

XC50VSERVICE MANUALLIT-11616-19-49 3D1-F8197-10

1-3GENINFOEAS00023LOCK WASHERS/PLATES AND COTTERPINSAfter removal, replace all lock washers/plates1 and cotter pins. After the bolt or nut has beentig

3-49CHKADJCHECKING AND CHARGING THE BATTERYEAS00179ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERYwBatteries generate explosive hydrogen gasand con

3-50CHKADJNOTE:Since MF batteries are sealed, it is not possibleto check the charge state of the battery by mea-suring the specific gravity of the ele

3-51CHKADJb. Check the charge of the battery, as shownin the charts and the following example.Examplec. Open-circuit voltage = 12.0 Vd. Charging time

3-52CHKADJ88888 Make sure the battery charger lead clipsare in full contact with the battery ter-minal and that they are not shorted. Acorroded batter

3-53CHKADJChargerAmmeterMeasure the open-circuitvoltage prior to charging.Connect a charger and am-meter to the battery andstart charging.Is the amper

3-54CHKADJThis type of battery charger cannotcharge an MF battery. Avariablevoltage charger is recom-mended.YESNOCharging method using a constant volt

3-55CHKADJ6. Install:8battery7. Connect:8battery leads(to the battery terminals)cCFirst, connect the positive battery lead 11111,and then the negative

3-56CHKADJCHECKING THE FUSE2. Check:8fuse*****************************************************a. Connect the pocket tester to the fuse andcheck the co

3-57CHKADJREPLACING THE HEADLIGHT BULBEAS00182REPLACING THE HEADLIGHT BULB1. Remove:8headlight cover2. Disconnect:8headlight coupler3. Remove:8headlig

3-58CHKADJADJUSTING THE HEADLIGHT BEAMEAS00184ADJUSTING THE HEADLIGHT BEAM1. Adjust:8headlight beam (vertically)**************************************

1-4GENINFOJAS00021Notes 3 on equipment preparationPush Rivet (Push type)Assembly status of the Push Rivet (Push type)Dissembling1. Press Center Pin 1

CHAS4-37CHAPTER 4CHASSISFRONT WHEEL AND BRAKE ... 4-1FRONT WHEEL ...

CHAS4-38REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ... 4-35CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ... 4-35INSTALLING THE REAR SHOCK AB

CHAS4-1RemarksOrder Job/Part Q’tyFRONT WHEEL AND BRAKERemoving the front wheel and brakeStop ringSpeedometer cableAdjusterFront brake cablePinWheel ax

CHAS4-2RemarksOrder Job/Part Q’ty1111EAS00518FRONT WHEELFRONT WHEEL AND BRAKEDisassembling the front wheelOil sealBearingSpacerBearing1234Remove the p

CHAS4-3RemarksOrder Job/Part Q’ty121111/111111111111FRONT BRAKE SHOE PLATEFRONT WHEEL AND BRAKEDisassembling the front brake shoeplateBrake shoe kitTe

CHAS4-4FRONT WHEEL AND BRAKEEAS00520REMOVING THE FRONT WHEEL1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no d

CHAS4-5FRONT WHEEL AND BRAKEEAS00525CHECKING THE FRONT WHEEL1. Check:8wheel axleRoll the wheel axle on a flat surface.Bends J Replace.wDo not attempt

CHAS4-6a. Clean the outside of the front wheel hub.b. Remove the oil seal 1 with a flat-headscrewdriver.NOTE:To prevent damaging the wheel, place a ra

CHAS4-7EAS00536CHECKING THE BRAKEThe following procedure applies to all of the brakeshoes.1. Check:8brake shoe liningGlazed areas J Repair.Sand the gl

CHAS4-84. Check:8brake drum inner surfaceOil deposits J Clean.Remove the oil with a rag soaked in lac-quer thinner or solvent.Scratches J Repair.Light

1-5GENINFOEAS00026CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect:8lead8coupler8connect

CHAS4-9FRONT WHEEL AND BRAKEEAS00538ASSEMBLING THE FRONT WHEEL1. Install:8wheel bearing(right)1 New8oil seal New8spacer8wheel bearing(left) New*******

CHAS4-10FRONT WHEEL AND BRAKET R..EAS00540INSTALLING THE FRONT WHEEL1. Lubricate:8wheel axle8wheel bearings8oil seal lips8speedometer drive gear8speed

CHAS4-11X1X2FRONT WHEEL AND BRAKEEAS00548ADJUSTING THE FRONT WHEEL STATICBALANCENOTE:8 After replacing the tire, wheel or both, thefront wheel static

CHAS4-12FRONT WHEEL AND BRAKE3. Adjust:8front wheel static balance*****************************************************a. Install a balancing weight 1

CHAS4-13RemarksOrder Job/Part Q’ty1234567891011121/111111211111/2Removing the rear wheelMuffler assemblySelf lock nut/Plate washerBrake adjusterRear b

CHAS4-14EAS00564REMOVING THE REAR WHEEL1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no danger of it falling o

CHAS4-15REAR WHEEL AND BRAKEEAS00565CHECKING THE REAR WHEEL 1. Check:8tire8rear wheelDamage/wear J Replace.Refer to “CHECKING THE TIRES” and“CHECKING

CHAS4-16REAR WHEEL AND BRAKEEAS00569CHECKING THE BRAKEThe following procedure applies to all of thebrake shoes.1. Check:8brake shoe liningGlazed areas

CHAS4-17REAR WHEEL AND BRAKEEAS00570ASSEMBLING THE BRAKE SHOE PLATE1. Install:8brake camshaft 17 Nm (0.7 m • kg, 5.1 ft • lb)8return spring 28brake sh

CHAS4-18REAR WHEEL AND BRAKEEAS00574INSTALLING THE REAR WHEEL 1. Lubricate:8wheel axleRecommended lubricantLithium-soap-based grease 2. Install:8rear

1-6GENINFO4146EAS00027SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the appropriate s

CHAS4-19RemarksOrder Job/Part Q’ty12341111Removing the front fork legsFront wheelHandlebarFront fork assemblyHeadlight coverLeg shield 1Lower bracket

CHAS4-20RemarksOrder Job/Part Q’ty12345678901111111111Disassembling the front fork legsBandBootDust sealCirclipSpring guideRebound springInner tubeDam

CHAS4-21FRONT FORKEAS00651REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the scooter on a level su

CHAS4-22FRONT FORK3. Remove:8damper rubber 18fork spring 28outer tube 3EAS00656CHECKING THE FRONT FORK LEGSThe following procedure applies to both of

CHAS4-23FRONT FORKEAS00658ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.NOTE:8 When assembling the front

CHAS4-24FRONT FORKT R..EAS00663INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install:8front fork leg

CHAS4-25RemarksOrder Job/Part Q’ty12345678910111213141111/11111111111EAS00664HANDLEBARRemoving the handlebarHeadlight coverLeg shield 1ClampSpeedomete

CHAS4-26HANDLEBARFor installation, reverse the removal pro-cedure.RemarksOrder Job/Part Q’ty2956710174121113151441638160Nm (6.0 m•kg, 43.4 ft•lb) LSLS

CHAS4-27HANDLEBAREAS00666REMOVING THE HANDLEBAR1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no danger of it f

CHAS4-28HANDLEBART R..EAS00673INSTALLING THE HANDLEBAR1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no danger

1-7GENINFOTool NO.Tool name / Function IllustrationSPECIAL TOOLS90890-01367YM-A9409-790890-01400YM-A9409-390890-01384YM-3329990890-01403YU-A947290890-

CHAS4-29HANDLEBARNOTE:8 Lubricate the inside of the throttle grip witha thin coat of lithium-soap-based grease andinstall it onto the handlebar4.8 Ali

CHAS4-30RemarksOrder Job/Part Q’ty123456789101112Removing the front fork assemblyFront wheelLeg shield 1Handlebar assemblyFront fenderInner fenderCabl

CHAS4-31STEERING HEADEAS00678REMOVING THE FRONT FORK ASSEMBLY1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no

CHAS4-32STEERING HEADEAS00682CHECKING THE STEERING HEAD1. Wash:8bearing balls8bearing racesRecommended cleaning solventKerosene2. Check:8bearing balls

CHAS4-33STEERING HEADEAS00684INSTALLING THE STEERING HEAD1. Lubricate:8bearing balls 18bearing racesRecommended lubricantLithium-soap-based grease2. I

CHAS4-34RemarksOrder Job/Part Q’ty12341111EAS00685REAR SHOCK ABSORBER ASSEMBLYRemoving the rear shock absorberassemblyRear shock absorber assembly upp

CHAS4-35EAS00692REMOVING THE REAR SHOCK ABSORBERASSEMBLY1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no dange

CHAS4-36EAS00698INSTALLING THE REAR SHOCK ABSORBERASSEMBLY1. Lubricate:8spacer8bushRecommended lubricantMolybdenum disulfide grease2. Install:8rear sh

ENG5-66CHAPTER 5ENGINEENGINE ... 5-1LEADS, HOSES AND

ENG5-67CHECKING THE V-BELT ... 5-40CHECKING THE PRIMARY SHEAVE ...

1-8GENINFOTool NO.Tool name / Function IllustrationSPECIAL TOOLS90890-04109YM-0410990890-04148YM-0414890890-04111YM-0411190890-04112YM-0411290890-0411

5-1ENGRemoving the leads, hoses and rearbrakeSeat/Trunk/Rear carrierBattery cover/Battery holderBattery/Front coverSide cover(left and right)/Rear co

5-2ENGENGINERemarksOrder Job/Part Q’tyAC magneto leadStarting motor lead/Earth leadIgnition primary coil leadVacuum hose(to air cut-off valve)Hose(to

5-3ENGRemarksOrder Job/Part Q’ty12345671/1111/1111/1MANIFOLD, AIR FILTER AND MUFFLER ASSEMBLYRemoving the manifold, air filter andmuffler assemblyRear

ENG5-4ENGINET R..EAS00192INSTALLING THE ENGINE1. Install:8engine 18engine mounting bolt 28self lock nut3NOTE:Do not fully tighten the bolts.2. Tighten

5-5ENGRemarksOrder Job/Part Q’ty123456789101112131111111241112Removing the cylinder headMuffler assemblyAir filter assembly/Breather hoseManifold/O-ri

ENG5-6CYLINDER HEADEAS00225REMOVING THE CYLINDER HEAD1. Remove :8crankcase cover (left)Refer to “ BELT DRIVE”.8cylinder head cover 2. Align:8“I” mark

ENG5-7CYLINDER HEAD 4. Remove:8timing chain tensioner(along with the gasket)8camshaft sprocket 18timing chain 2NOTE:To prevent the timing chain from f

ENG5-8CYLINDER HEADEAS00227CHECKING THE CYLINDER HEAD1. Eliminate:8combustion chamber carbon deposits(with a rounded scraper)NOTE:Do not use a sharp i

ENG5-9EAS00231INSTALLING THE CYLINDER HEAD1. Install:8gasket New8dowel pins2. Install:8cylinder head3. Tighten:8cylinder head nuts10 Nm (1.0 m • kg, 7

ENG5-10cCDo not turn the crankshaft when installingthe camshaft to avoid damage or impropervalve timing.e. While holding the camshaft, temporarilytigh

2-34SPECCHAPTER 2SPECIFICATIONSGENERAL SPECIFICATIONS ... 2-1ENGINE SPECIFICATIONS ...

ENG5-117. Turn:8crankshaft(several turns counterclockwise)8. Check:8“I” mark aAlign the “I” mark on the AC magneto ro-tor with the stationary pointer

5-12ENGRemarksOrder Job/Part Q’ty123456THE ROCKER ARMS AND CAMSHAFTRemoving the rocker arms and cam-shaftCylinder headCamshaftRocker arm shaft(intake)

ENG5-13THE ROCKER ARMS AND CAMSHAFTEAS00202REMOVING THE ROCKER ARMS AND CAM-SHAFT1. Remove:8camshaft 1 2. Remove:8intake rocker arm shaft8exhaust roc

ENG5-14THE ROCKER ARMS AND CAMSHAFTCamshaft lobe dimension limit Intakeaaaaa 30.158~30.258 mm (1.187~1.191in)<Limit>:30.058mmbbbbb 25.082~25.182

ENG5-15THE ROCKER ARMS AND CAMSHAFT4. Measure:8rocker arm inside diameter aOut of specification J Replace.Rocker arm inside diameter10 ~ 10.015 mm (0.

ENG5-16EAS00208CHECKING THE TIMING CHAIN, CAMSHAFTSPROCKETS, AND TIMING CHAIN GUIDESThe following procedure applies to all of the cam-shaft sprockets

ENG5-17EAS00220INSTALLING THE CAMSHAFT AND ROCKERARMS1. Lubricate:8camshaft 1Recommended lubricantCamshaftMolybdenum disulfide oilCamshaft bearingEngi

5-18ENGRemarksOrder Job/Part Q’ty123456789363321333EAS00236VALVES AND VALVE SPRINGSRemoving the valves and valvespringsCylinder headRocker arm and ro

ENG5-19EAS00237REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.NOTE:Before removing the internal parts o

ENG5-20 4. Remove:8valve spring retainer 18valve spring 28valve stem seal 38valve spring seat 48valve 5NOTE:Identify the position of each part very ca

2-1SPECSPECIFICATIONSGENERAL SPECIFICATIONSItemStandard LimitGENERAL SPECIFICATIONSModel code 3D11 (for USA) …3D12 (for CAN) …DimensionsOverall length

ENG5-21VALVES AND VALVE SPRINGSNOTE:After replacing the valve guide, reface the valveseat.Valve guide remover (4.0 mm)90890-04111(YM-04111)Valve guide

ENG5-22EAS00240CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Eliminate:8carbon deposits(from the val

ENG5-23a. Apply a coarse lapping compound a to thevalve face.cCDo not let the lapping compound enter thegap between the valve stem and the valveguide.

ENG5-24EAS00241CHECKING THE VALVE SPRINGSThe following procedure applies to all of the valvesprings.1. Measure:8valve spring free length aOut of spec

ENG5-25EAS00245INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:8valve stem end(with an oil s

ENG5-26Valve spring compressor90890-04109(YM-04109)Valve spring compressor attach-ment90890-04148(YM-04148)5. To secure the valve cotters onto the val

5-27ENGRemarksOrder Job/Part Q’ty12345678910EAS00251CYLINDER AND PISTONRemoving the cylinder and pistonCylinder headTiming chain guide(exhaust side)Cy

ENG5-28EAS00253REMOVING THE CYLINDER AND PISTON1. Remove:8piston pin clip 18piston pin 28piston 3cCDo not use a hammer to drive the piston pinout.NOTE

ENG5-29CYLINDER AND PISTONEAS00261CHECKING THE CYLINDER AND PISTON1. Check:8piston wall8cylinder wallVertical scratches J Replace the cylin-der, and t

ENG5-30EAS00263CHECKING THE PISTON RINGS1. Measure:8piston ring side clearanceOut of specification J Replace the pis-ton and piston rings as a set.NOT

2-2SPECENGINE SPECIFICATIONSItemStandard LimitENGINE SPECIFICATIONS-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚SAE 10W-30SAE 10W-40SAE 20W-40SAE

ENG5-31EAS00265CHECKING THE PISTON PIN1. Check:8piston pinBlue discoloration/grooves J Replace thepiston pin and then check the lubricationsystem.2. M

ENG5-32CYLINDER AND PISTONEAS00267INSTALLING THE PISTON AND CYLINDER1. Install:8oil ring expander 18oil ring rail 282nd ring 38top ring 4NOTE:Be sure

ENG5-33CYLINDER AND PISTON3. Install:8gasket New8dowel pins4. Lubricate:8piston8piston rings8cylinder(with the recommended lubricant)Recommended lubri

5-34ENGRemarksOrder Job/Part Q’ty123456789101112112111/1111111EAS00316BELT DRIVECRANKCASE COVER (LEFT)Removing the crankcase cover (left)KickstarterRe

ENG5-35BELT DRIVEEAS00340INSTALLING THE KICKSTARTER1. Install:8solid bush18kick shaft assembly28torsion spring32. Hook:8kickstarter springNOTE:Hook th

5-36ENGRemarksOrder Job/Part Q’ty1234567891011121/1111111111/631Remove the parts in the order listed.Refer to “ REMOVING AND INSTALL-ING THE SECONDARY

5-37ENGRemarksOrder Job/Part Q’ty12345678901121121221Disassemble the parts in the order listed.Refer to “ REMOVING AND INSTALL-ING THE SECONDARY SHEAV

ENG5-38BELT DRIVEEAS00318REMOVING THE SECONDARY SHEAVE ANDV-BELT1. Remove:8secondary sheave nut 18clutch housing 2NOTE:While holding the clutch hou

ENG5-39BELT DRIVEEAS00319DISASSEMBLING THE SECONDARY SHEAVE1. Remove:8clutch carrier nut 1NOTE:Install the clutch spring holder 2 and clutchspring hol

ENG5-40BELT DRIVEEAS00320CHECKING THE V-BELT1. Check:8V-belt 1Cracks/damage/wear J Replace.Grease/oil J Clean the primary and sec-ondary sheave.2. Mea

2-3SPECItemStandardLimitENGINE SPECIFICATIONSOil filter Oil filter type Wire mesh …Oil pumpOil pump type Trochoid …Inner rotor to outer rotor tip cl

ENG5-41EAS00321CHECKING THE PRIMARY SHEAVE WEIGHTSThe following procedure applies to all of the pri-mary sheave weights.1. Check:8primary sheave weig

ENG5-42BELT DRIVEEAS00323ASSEMBLING THE PRIMARY SHEAVE1. Clean:8primary fixed sheave 18primary sliding sheave 28collar 38primary sheave weights 4NOTE:

ENG5-43EAS00324ASSEMBLING THE SECONDARY SHEAVE1. Lubricate:8secondary fixed sheave’s inner surface18secondary sliding sheave’s inner surface28oil seal

ENG5-445. Install:8secondary sheave 18spring8clutch carrier 2NOTE:Attach the clutch spring holder 3 and clutchspring holder arm 4 onto the secondary s

ENG5-45BELT DRIVET R..3. Install:8clutch housing 18secondary sheave nut240 Nm (4.0 m • kg, 28.9 ft • lb)NOTE:Tighten the secondary sheave nut with the

5-46ENGRemarksOrder Job/Part Q’ty1234511/11/111Remove the parts in the order listed.Drain.Refer to “CHANGING THE COOLANT”inchapter 3.Refer to “RADIATO

5-47ENGRemarksOrder Job/Part Q’tyFor installation, reverse the removal pro-cedure.STARTER CLUTCH AND AC MAGNETO43Nm (4.3 m•kg, 31.1 ft•lb) 34687157Nm

5-48ENGRemarksOrder Job/Part Q’ty123456789101111211111111NEWimageEAS00342STARTER CLUTCHRemoving the starter clutchEngine oilAC magneto rotorStator coi

ENG5-49EAS00347REMOVING THE AC MAGNETO1. Remove:8AC magneto rotor nut18washerNOTE:8 While holding the AC magneto rotor 2 withthe sheave holder 3, loos

ENG5-50EAS00344REMOVING THE STARTER CLUTCH1. Remove:8crankcase cover (right)1NOTE:Loosen each bolt 1/4 of a turn at a time, in stagesand in a crisscro

EAS00000XC50V 2005SERVICE MANUAL©2005 by Yamaha Motor Taiwan Co., Ltd.First edition, July 2005All rights reserved.Any reproduction or unauthorized us

2-4SPECItemStandardLimitCABCABENGINE SPECIFICATIONSCamshaftDrive system Chain drive (left) …Intake camshaft lobe dimensionsMeasurement A 30.158~30.25

ENG5-51EAS00351CHECKING THE STARTER CLUTCH1. Check:8starter clutch roller 1Damage/wear J Replace.2. Check:8starter clutch idle gear8starter wheel gear

ENG5-52STARTER CLUTCH AND AC MAGNETO2. Install:8gasket New8crankcase cover (right)110 Nm (1.0 m • kg, 7.2 ft • lb)T R..T R..EAS00354INSTALLING THE AC

ENG5-532. Tighten:8AC magneto rotor nut 143 Nm (4.3 m • kg, 31.1 ft • lb)NOTE:8 While holding the AC magneto rotor 3withthe sheave holder 2, tighten t

5-54ENGEAS00360OIL PUMPRemarksOrder Job/Part Q’ty1234567891011/112111111Disassembling the oil pumpRadiatorAC magnetoStarter clutchDrive gearCirclip/Pl

ENG5-55EAS00364CHECKING THE OIL PUMP1. Check:8oil pump drive gear8oil pump driven gear 18oil pump housing8oil pump housing coverCracks/damage/wear J

ENG5-56OIL PUMPT R..EAS00375ASSEMBLING THE OIL PUMP1. Lubricate:8inner rotor8outer rotor8oil pump shaft(with the recommended lubricant)Recommended lub

5-57ENGRemarksOrder Job/Part Q’ty12345671112111Removing the transmissionTransmission oilMuffler assemblyRear fenderRear wheelCrankcase cover(left)Belt

ENG5-58EAS00425CHECKING THE TRANSMISSION1. Measure:8main axle runout(with a centering device and dial gauge )Out of specification J Replace the mainax

5-59ENGRemarksOrder Job/Part Q’ty123411/111Remove the parts in the order listed.Refer to “ ENGINE “ .Refer to “CYLINDER HEAD “.Refer to “CYLINDER AND

5-60ENGRemarksOrder Job/Part Q’ty5678910111213141516171819HookDrain plugOil strainerCompression springO-ringCrankcase (right )SpacerDowel pinGuideCran

2-5SPECItemStandardLimitBCDAHead Diameter Face Width Seat Width Margin ThicknessENGINE SPECIFICATIONSTiming chainModel/number of links Morse 92RH2005

ENG5-61EAS00385DISASSEMBLING THE CRANKCASE1. Remove:8centerstand assembly2. Remove:8crankcase bolts1NOTE:Loosen each bolt 1/4 of a turn at a time, in

ENG5-62EAS00207CHECKING THE TIMING CHAIN AND TIMINGCHAIN GUIDE1. Check:8timing chainDamage/stiffness J Replace the timingchain. 2. Check:8timing chai

ENG5-63EAS00394CHECKING THE CRANKSHAFT AND CON-NECTING ROD1. Measure:8crankshaft runoutOut of specification J Replace the crank-shaft, bearing or both

ENG5-645. Check:8crankshaft journalScratches/wear J Replace the crank-shaft.8crankshaft journal oil passageObstruction J Blow out with compressedair.

ENG5-65EAS00408INSTALLING THE CRANKSHAFT1. Install:8timing chain guide (intake side)8timing chain18crankshaft assembly2NOTE:Install the timing chain s

6-13COOLCHAPTER 6RADIATORRADIATOR ... 6-1CHECKING THE RAD

6-1COOLRemarksOrder Job/Part Q’ty11111111234567Removing the radiatorSeat/TrunkBattery cover/Battery holderBattery/Front coverFootrest board side cover

6-2COOLRADIATOREAS00455CHECKING THE RADIATOR1. Check:8radiator finsObstruction J Clean.Apply compressed air to the rear of theradiator.Damage J Repair

6-3COOLEAS00456INSTALLING THE RADIATOR1. Fill:8cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT”in

6-4COOLRemarksOrder Job/Part Q’ty1111/1112345Removing the thermostat assemblySeat/Trunk/Rear carrierBattery cover/Battery holderBattery/Front coverSid

2-6SPECItemStandardLimitENGINE SPECIFICATIONSValve springsFree lengthIntake 39.35 mm 37.38 mmExhaust 41.57 mm 39.49 mmInstalled length (valve closed)I

6-5COOLRemarksOrder Job/Part Q’tyFor installation, reverse the removal pro-cedure.AA10Nm (1.0 m•kg, 7.2 ft•lb) 63254110Nm (1.0 m•kg, 7.2 ft•lb) 4THERM

6-6COOLEAS00462CHECKING THE THERMOSTAT1. Check:8thermostat 1Does not open at 65 ~ 80°C J Replace.*****************************************************

6-7COOLEAS00466INSTALLING THE THERMOSTAT ASSEMBLY1. Install:8thermostat18thermostat housing8thermostat assembly inlet breather hose.8thermostat assemb

6-8COOLEAS00468WATER PUMPRemarksOrder Job/Part Q’ty11111234Removing the water pumpSeat/Trunk/Rear carrierBattery cover/Battery holderBattery/Front cov

6-9COOLRemarksOrder Job/Part Q’ty567891011Water pump housingDowel pinPlateImpeller shaftOil sealBearingGasket1211111For installation, reverse the remo

6-10COOLEAS00471DISASSEMBLING THE WATER PUMP1. Remove:8water pump housing cover18dowel pin8gasketEAS00474CHECKING THE WATER PUMP1. Check:8water pump

6-11COOLEAS00475ASSEMBLING THE WATER PUMP1. Install:8oil seal New 1(into the water pump housing 3)8bearing 2NOTE:8 Before installing the oil seal, ap

6-12COOLEAS00478INSTALLING THE WATER PUMP1. Install:8gasket New8water pump assembly 110 Nm (1.0 m • kg, 7.2 ft • lb)NOTE:Align the slit a on the impel

7-14CARBCHAPTER 7CARBRETORCARBURETOR ... 7-1CHECKING THE CARBURE

7-1CARBRemarksOrder Job/Part Q’ty1111111111112345678910Removing the carburetorMat/Seat/TrunkBattery cover/Front coverHose(to cylinder head)Auto choke

2-7SPECItemStandardLimitHDTBBTENGINE SPECIFICATIONSBTPistonPiston-to-cylinder clearance 0.010~0.035 mm 0.150mmDiameter D 37.975~37.990 mm …Height H 5.

7-2CARBRemarksOrder Job/Part Q’tyCARBURETORDisassembling the carburetorAuto choke capAuto choke unitAuto choke holderAuto choke seatThrottle stop scre

7-3CARBRemarksOrder Job/Part Q’tyuiopaMain nozzleNedle jetSlow air jetSlow jetThrottle position sensor11111For assembly, reverse the disassemblyproced

7-4CARBEAS00485CHECKING THE CARBURETOR1. Check:8carburetor body8float chamberCracks/damage J Replace.CARBURETOR2. Check:8fuel passagesObstruction J Cl

7-5CARB6. Check:8needle valveDamage/obstruction/wearJ Replace.7. Check:8piston valve 1Damage/scratches/wearJ Replace.8piston valve diaphragm 2Cracks/t

7-6CARBEAS00487ASSEMBLING THE CARBURETORcC88888 Before assembling the carburetor, washall of the parts in a petroleum-based sol-vent.88888 Always use

7-7CARBEAS00492INSTALLING THE CARBURETOR1. Adjust:8engine idling speedEngine idling speed2,000 ~ 2,400r/minRefer to “ADJUSTING THE ENGINEIDLING SPEED”

7-8CARBEAS00498MEASURING AND ADJUSTING THE FUELLEVEL1. Measure:8fuel level aOut of specification J Adjust.Fuel level (below the float chambermating su

7-9CARBCARBURETOREAS00503CHECKING THE AUTOCHOKE UNITNOTE:When checking the autochoke unit, the ambienttemperature must be lower than 45°C.1. Remove:8

7-10CARBCARBURETOREAS00504CHECKING THE FUEL COCK1. Remove:8seat/trunk8battery cover8front coverRefer to “COVER AND PANEL”in chap-ter 3.2. Check:8fuel

7-11CARBCHECKING THE THROTTLE POSITION SEN-SORNOTE:Before checking the throttle position sensor, theengine idling speed should be properly adjusted.1.

2-8SPECItemStandardLimitENGINE SPECIFICATIONSRocker arm/rocker arm shaftRocker arm inside diameter 10.000~10.015mm …Rocker arm shaft outside diameter

7-12CARBRemarksOrder Job/Part Q’tyAIR INDUCTION SYSTEMRemoving the air induction systemSeat/TrunkHose(from AI air filter )Vacuum hose(from mainfold )H

7-13CARBEAS00510CHECKING THE AIR INDUCTION SYSTEM1. Check:8hosesLoose connection J Connect properly.Cracks/damage J Replace.8pipeCracks/damage J Repla

8-49-+ELECCHAPTER 8ELECTORICALELECTRICAL COMPONENTS ... 8-1WIRING DIAGRAM ...

8-1-+ELECEAS00729ELECTRICALELECTRICAL COMPONENTSELECTRICAL COMPONENTS1 Rear brake light switch2 Front brake light switch3 Main switch4 Starter relay5

8-2-+ELECWIRING DIAGRAMWIRING DIAGRAMOFFCHECKONOFFSTARTOFFPUSHLNRHILOOFFRUNGWLLYYRYL GRBrBLWLBOrYRWWRWLYRWWRWLRYBRYRBLLYLWRBYRRBrRRGYLWLWGYLYRBRBRLWLY

8-3-+ELECWIRING DIAGRAMColor CodeB BlackG GreenL BlueP PinkR RedW WhiteY YellowBr BrownCh ChocolateDg Dark greenOr OrangeB/L Black/BlueG/B Green/Black

8-4-+ELECEAS00730CHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity reading is incorrect, checkthe wi

8-5-+ELECEAS00731CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between theterminals. Refer to

8-6-+ELECEAS00733CHECKING THE BULBS AND BULBSOCKETSCheck each bulb and bulb socket for damage orwear, proper connections, and also for continu-ity bet

8-7-+ELECCHECKING THE CONDITION OF THEBULBSThe following procedure applies to all of thebulbs.1. Remove:8bulbwSince the headlight bulb gets extremely

2-9SPECItemStandardLimitENGINE SPECIFICATIONSClutchClutch type Automatic centrifugal …Clutch shoe thickness 3.7 mm 2.0mmClutch shoe spring free lengt

8-8-+ELECCHECKING THE CONDITION OF THE BULBSOCKETSThe following procedure applies to all of the bulbsockets.1. Check:8bulb socket (for continuity)(wit

8-9-+ELECOFFCHECKONOFFSTARTOFFPUSHLNRHILOOFFRUNGWLLYYRYL GRBrBLWLBOrYRWWRWLYRWWRWLRYBRYRBLLYLWRBYRRBrRRGYLWLWGYLYRBRBRLWLYBBLYLWGBYYRBGBBrGGWBGWBBrGLY

8-10-+ELECEAS007381. Main Fuse8Check the fuse for continuity.Refer to “CHECKING THE FUSE” inchapter 3.8Is the fuse OK?YES NO Repl

8-11-+ELECEAS007424. Ignition spark gap8Disconnect the spark plug cap from thespark plug.8Connect the ignition checker 1 asshown. 2 Spark plug cap8Set

8-12-+ELEC8Measure the primary coil resistance.Primary coil resistance0.168 ~ 0.252 ΩΩΩΩΩ at 20°C8Connect the pocket tester (Ω × 1k) tothe ignition co

8-13-+ELECIGNITION SYSTEMEAS007509. Engine stop switch8Check the engine stop switch for conti-nuity.Refer to “CHECKING THE SWITCHES”.8Is the engine st

8-14-+ELECBOFFCHECKONOFFSTARTOFFPUSHLNRHILOOFFRUNGWLLYYRYL GRBrBLWLBOrYRWWRWLYRWWRWLRYBRYRBLLYLWRBYRRBrRRGYLWLWGYLYRBRBRLWLYBBLYLWGBYYRBGBBrGGWBGWBBrG

8-15-+ELECELECTRIC STARTING SYSTEMEAS00756STARTING CIRCUIT CUT-OFF SYSTEM OP-ERATIONIf the main switch is set to “ON” (switch isclosed), the starter m

8-16-+ELECEAS00757TROUBLESHOOTING The starter motor fails to turn.Check:1. mainfuse2. battery3. starter motor4 starter relay5 main switch6 brake light

8-17-+ELECEAS007583. Starter motor8Connect the positive battery terminal 1and starter motor lead 2 with a jumperlead3. w88888 A wire that is used as a

2-10SPECCHASSIS SPECIFICATIONSCHASSIS SPECIFICATIONSItemStandardLimitFrameFrame type Steel tube underbone …Caster angle 24 ° …Trail 70 mm …Front whee

8-18-+ELECEAS007516. Brake light switch(front and rear)8Check the brake light switch for continu-ity.Refer to “CHECKING THE SWITCHES”.8Is the brake li

8-19-+ELECRemarksOrder Job/Part Q’tyRemoving the starter motorSeat/TrunkFront coverBattery coverAir filter assemblyStarter motor leadStarter motorDisa

8-20-+ELECEAS00769CHECKING THE STARTER MOTOR1. Check:8commutatorDirt J Clean with 600-grit sandpaper.2. Measure:8commutator diameter aOut of specifica

8-21-+ELEC5. Measure:8brush length aOut of specification J Replace thebrushes as a set.Brush length wear limit3.5 mm (0.14 in)6. Measure:8brush sprin

8-22-+ELECELECTRIC STARTING SYSTEMT R..EAS00772ASSEMBLING THE STARTER MOTOR1. Install:8brush seat 12. Install:8washer18armature coil 28o-ing New38stat

8-23-+ELECBOFFCHECKONOFFSTARTOFFPUSHLNRHILOOFFRUNGWLLYYRYL GRBrBLWLBOrYRWWRWLYRWWRWLRYBRYRBLLYLWRBYRRBrRRGYLWLWGYLYRBRBRLWLYBBLYLWGBYYRBGBBrGGWBGWBBrG

8-24-+ELECEAS00774TROUBLESHOOTING The battery is not being charged.Check:1. main fuse2. battery3. charging voltage4. stator coil resistance5. wiring

8-25-+ELECThe charging circuit is OK. NOTE: Make sure the battery is fully charged.8Is the charging voltage within specifica-tion?NO YESEAS007764. Sta

8-26-+ELECBOFFCHECKONOFFSTARTOFFPUSHLNRHILOOFFRUNGWLLYYRYL GRBrBLWLBOrYRWWRWLYRWWRWLRYBRYRBLLYLWRBYRRBrRRGYLWLWGYLYRBRBRLWLYBBLYLWGBYYRBGBBrGGWBGWBBrG

8-27-+ELECEAS00781TROUBLESHOOTINGAny of the following fail to light: headlight,high beam indicator light or meter light.Check:1. main fuse2. battery3.

2-11SPECItemStandardLimitCHASSIS SPECIFICATIONSFront brakeBrake type Drum brake …Operation Right-hand operation …Brake lever free play (at lever end)

8-28-+ELECLIGHTING SYSTEMEAS007494. Main switch8Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.8Is the main switch OK?YES NORep

8-29-+ELECEAS00788CHECKING THE LIGHTING SYSTEM1. The headlight and the high beam indicatorlight fail to come on.1. Headlight bulb and socket8Check the

8-30-+ELECThe wiring circuit from themain switch to the headlightand hight beam indicatorlight coupler are faulty andmust be repaired.This circuit is

8-31-+ELECLIGHTING SYSTEMEAS007544. Wiring8Check the entire lighting system’s wir-ing.Refer to “CIRCUIT DIAGRAM”.8Is the lighting system’s wiring pro

8-32-+ELECBOFFCHECKONOFFSTARTOFFPUSHLNRHILOOFFRUNGWLLYYRYL GRBrBLWLBOrYRWWRWLYRWWRWLRYBRYRBLLYLWRBYRRBrRRGYLWLWGYLYRBRBRLWLYBBLYLWGBYYRBGBBrGGWBGWBBrG

8-33-+ELECEAS00794TROUBLESHOOTING88888Any of the following fail to light: turnsignal light, brake light or an indica-tor light.88888The horn fails to

8-34-+ELEC4. Voltage8Connect the pocket tester (DC 20 V) tothe horn connector at the pink terminalas shown. Positive tester probe JJJJJ pink 11111 N

8-35-+ELECEAS007982. The tail/brake light fails to come on.1. Tail/brake light bulb and socket8Check the tail/brake light bulb and socketfor continuit

8-36-+ELECEAS007993. The turn signal light, turn signal indicatorlight or both fail to blink.1. Turn signal light and turn signal indicatorlight bulbs

8-37-+ELEC4. Voltage8Connect the pocket tester (DC 20 V) tothe turn signal relay coupler (wire har-ness side) as shown. Positive tester probeJJJJJ br

2-12SPECItemStandardLimitELECTRICAL SPECIFICATIONSELECTRICAL SPECIFICATIONSSystem voltage 12V …Ignition systemIgnition system type C.D.I. …Ignition t

8-38-+ELECEAS008044. The fuel level meter fails to operate.1. Fuel sender8Remove the fuel sender from the fueltank.8Connect the pocket tester (Ω × 1)

8-39-+ELEC3. Fuel level meter8Set the main switch to “ON”.8Move the float up 1 or down 2.8Check that the fuel level meter needlemoves to “F” or “E”. N

8-40-+ELECBOFFCHECKONOFFSTARTOFFPUSHLNRHILOOFFRUNGWLLYYRYL GRBrBLWLBOrYRWWRWLYRWWRWLRYBRYRBLLYLWRBYRRBrRRGYLWLWGYLYRBRBRLWLYBBLYLWGBYYRBGBBrGGWBGWBBrG

8-41-+ELECCOOLING SYSTEMEAS00808TROUBLESHOOTINGThe cooling system fails to operate.Check:1. main fuse2. battery3. main switch4. thermo switch5. water

8-42-+ELECEAS008114. Thermo switch8Remove the thermo switch from the ther-mostat housing.8Connect the pocket tester (Ω × 1) to thethermo switch 1 as s

8-43-+ELECEAS008125. The water temperature indicator light failsto operate.1. Thermo unit8Remove the thermo unit from the cylin-der head.8Connect the

8-44-+ELECEAS008136. Wiring8Check the entire cooling system’s wiring.Refer to “CIRCUIT DIAGRAM”.8Is the cooling system’s wiring properlyconnected and

8-45-+ELECBOFFCHECKONOFFSTARTOFFPUSHLNRHILOOFFRUNGWLLYYRYL GRBrBLWLBOrYRWWRWLYRWWRWLRYBRYRBLLYLWRBYRRBrRRGYLWLWGYLYRBRBRLWLYBBLYLWGBYYRBGBBrGGWBGWBBrG

8-46-+ELECEAS00821TROUBLESHOOTINGThe auto choke system fails to operate.Check:1. main fuse2. battery3. thermo switch4. auto choke unit5. wiring connec

8-47-+ELECEAS008113. Thermo switch8Remove the thermo switch from thethermostat housing.8Connect the pocket tester (Ω × 1) tothe thermo switch 1 as sh

2-13SPECELECTRICAL SPECIFICATIONSItemStandardLimitBulbs (voltage/wattage × quantity)Headlight 12 V 35W/35W × 1 …Tail/brake light 12 V 5W/21 W × 1 …Fro

8-48-+ELEC4. Auto choke unit8Disconnect the auto choke unit couplerfrom wire harness.8Connect the pocket tester(Ω × 1) to theAuto choke unit coupler a

9-7TRBLSHTGCHAPTER 9TROUBLE SHOOTINGSTARTING FAILURE/HARD STARTING... 9-1ENGINE ...

9-1TRBLSHTGEAS00845TROUBLESHOOTINGNOTE:The following guide for troubleshooting does not cover all the possible causes of trouble. It should behelpful,

9-2TRBLSHTGSTARTING FAILURES/HARD STARTING/INCORRECT ENGINE IDLING SPEEDIgnition system8Faulty C.D.I.unit8Faulty pickup coil8Broken AC magneto rotor w

9-3TRBLSHTGPOOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY CLUTCHEAS00849POOR MEDIUM-AND-HIGH-SPEED PERFORMANCERefer to “STARTING FAILURE/HARD START-ING

9-4TRBLSHTGPOOR SPEED PERFORMANCEV-belt8Oil or grease on the V-beltPrimary pulley weight(s)8Faulty operation8Worn primary pulley weightPrimary fixed s

9-5TRBLSHTGPOOR BRAKING PERFORMANCE/FAULTY FRONTFORK LEGS/UNSTABLE HANDLINGEAS00859POOR BRAKING PERFORMANCEDrum brake8Worn brake shoe8Worn or rusty br

9-6TRBLSHTGFAULTY LIGHTING OR SIGNALING SYSTEMEAS00866FAULTY LIGHTING OR SIGNALINGSYSTEMHEADLIGHT DOES NOT COME ON8Wrong headlight bulb8Faulty headlig

YAMAHA MOTOR TAIWAN CO., LTD

EAS00002NOTICEThis manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamahadealers and their qualified mechanics. It i

2-14SPECItemStandardLimitELECTRICAL SPECIFICATIONSThrottle position sensorOutput voltage (throttle opens) 2.8~3.4V …Output voltage (throttle closes) 0

2-15SPECEB201000CONVERSION TABLEAll specification data in this manual are listedin SI and METRIC UNITS.Use this table to convert METRIC unit data toIM

2-16SPECPart to be tightenedPart nameThreadsizeQ’tyTighteningtorque Nm m•kg ft•lbRemarksTIGHTENING TORQUESNut-Bolt-Nut-BoltBoltBolt-BoltBoltplugBo

2-17SPECCylinder head tightening sequenceTIGHTENING TORQUESPart to be tightenedPart nameThreadsizeQ’tyTighteningtorque Nm m•kg ft•lbRemarksClutch

2-18SPECPart to be tightenedThreadsizeTighteningtorque Nm m•kg ft•lbRemarksTIGHTENING TORQUESCHASSISM10M10M10M10M6M6M8BCBC1M6M6M5About M5M6M

2-19SPECLubrication Point LubricantLSLS4M44444444444MMM4LUBRICATION POINTS AND LUBRICANT TYPESOil seal lipsO-rings (Except V-belt drive unit)Cylinder

2-20SPECBEL-RAY asembly lube®BEL-RAY asembly lube®SealantLubrication Point LubricantLUBRICATION POINTS AND LUBRICANT TYPESSecondary fixed sheave inner

2-21SPECLUBRICATION POINTS AND LUBRICANT TYPESLubrication Point LubricantLSLSLSLSLSLSMLSEAS00032CHASSISFront wheel oil seal lipsSteering bearing and b

2-22SPECCOOLING SYSTEM DIAGRAMSEAS00033COOLING SYSTEM DIAGRAMS1 Raidator cap2 Coolant reservoir3 Radiator inlet hose4 Radiator outlet hose5 Thermo swi

2-23SPEC1 Outlet hose(to cylinder)2 Radiator inlet hose3 Radiator outlet hose4 Thermostat5 Thermostat housingCOOLING SYSTEM DIAGRAMS25431

HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation,

2-24SPECCOOLING SYSTEM DIAGRAMS1 Breather hose2 Outlet hose(to cylinder)3 Radiator outlet hose4 Water pump1432

2-25SPECCOOLING SYSTEM DIAGRAMS1 Thermostat housing2 Thermostat assembly inlet breather hose3 Water pump4 Breather hose1234

2-26SPECOIL FLOW DIAGRAMSOIL FLOW DIAGRAMS1 Oil filter2 Oil pump3 To cylinder head4 Oil strainer5 Oil nozzle6 Camshaft

2-27SPEC1 Crankshaft pin2 Connecting rod big end bearing3 Oil nozzle4 CamshaftCylinder wallConnecting rod big end bearingCrankshaft pinCrankcase sump

2-28SPECCABLE ROUTINGEAS00035CABLE ROUTING1 Fuel sender lead2 C.D.I. unit3 AI filter4 Starter motor lead5 Main switch6 Rectifier/Regulator7 Overflow p

2-29SPECCABLE ROUTING1 Turn signal relay2 Horn3 Head light relay4 Speedometer cable5 Front brake cable6 Starter relay7 Ignition coil8 Throttle cable k

2-30SPECCABLE ROUTINGM Assemble the horn lead tothe best forward of connec-tor cover, do not throughback side of the other leads.N Route the turn sign

2-31SPECCABLE ROUTING1 Battery negative - lead2 Battery positive + lead3 Fuse box4 Starter motor lead5 AC magneto lead6 Fuel senderA Insert the wire

2-32SPECCABLE ROUTING1 Front brake cable2 Front brake switch lead3 Speedometer assembly4 Speedometer cable5 Rear brake cable6 Rear brake switch lead7

2-33SPECCABLE ROUTINGH After spread with adhesionagent on the inner side, pushthe grip into the handlebarassembly.I Allow the gain position to ar-rive

GENINFOSPECCHKADJENGTRBLSHTGCARBCHAS-+ELEC4MBLSNewMGCOOL1234567890qweriopasdfgEAS00008SYMBOLSThe following symbols are not relevant to everyvehicle.Sy

3-59CHKADJCHAPTER 3PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTION ...

3-60CHKADJCHECKING THE TIRES ... 3-44CHECKING THE WHEELS...

3-1CHKADJEAS00036PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustme

3-2CHKADJPERIODIC MAINTENANCE AND MINOR REPAIREAU17560*PERIODIC MAINTENANCE AND MINOR REPAIRPeriodic maintenance chart for the emission control system

3-3CHKADJPERIODIC MAINTENANCE AND MINOR REPAIRGeneral maintenance and lubrication chartMaintenance and lubrication, periodicNO. ITEM ROUTINEINITIAL OD

3-4CHKADJPERIODIC MAINTENANCE AND MINOR REPAIR* Since these items require special tools, data and technical skills, have a Yamaha dealer performthe se

3-5CHKADJCOVER AND PANELSEAT AND TRUNKRemarksOrder Job/Part Q’ty12345671111111Remove the parts in the order listed.For installation, reverse the remov

3-6CHKADJRemarksOrder Job/Part Q’ty123456111111SIDE COVER (LEFT AND RIGHT)Removing the side cover(left andright)Seat/TrunkTail / brake and rear turn s

3-7CHKADJFOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLERemarksOrder Job/Part Q’ty12345671111111Removing the footrest board andfootrest board side c

3-8CHKADJLEG SHIELD 1 , 2RemarksOrder Job/Part Q’ty123456789101112111111111111Removing the leg shield 1,2Footrest boardCapHeadlight coverHead and fron

EAS00010TABLE OF CONTENTSGENERAL INFORMATIONSPECIFICATIONSPERIODIC CHECKS ANDADJUSTMENTSCHASSISENGINECOOLINGCARBURETORELECTRICAL SYSTEMTROUBLESHOOTING

3-9CHKADJADJUSTING THE VALVE CLEARANCEEAS00049ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.NOTE:8 Valve clea

3-10CHKADJADJUSTING THE VALVE CLEARANCEd. Measure the valve clearance with a thick-ness gauge 1.Out of specification J Adjust.************************

3-11CHKADJADJUSTING THE VALVE CLEARANCEEXAMPLE:Original valve pad number = 148 (thickness=1.48 mm (0.058 in))Rounded value = 150d. Locate the rounded

3-12CHKADJADJUSTING THE VALVE CLEARANCEValve Clearance (cold)0.10∼0.16 mmRounded value 175Measured valve clearance is 0.24 mmReplace pad 175 with pad

3-13CHKADJADJUSTING THE VALVE CLEARANCE7. Install:8all removed partsNOTE:For installation, reverse the removal procedure.8. Fill:8cooling system(with

3-14CHKADJADJUSTING THE ENGINE IDLING SPEEDEAS00054ADJUSTING THE ENGINE IDLING SPEEDNOTE:Prior to adjusting the engine idling speed, the airfilter ele

3-15CHKADJCHECKING THE EXHAUST GAS AT IDLECHECKING THE EXHAUST GAS AT IDLE( Measuring the exhaust gas at idle(when air in-duction system is operation)

3-16CHKADJCHECKING THE EXHAUST GAS AT IDLENOTE:8 Since it is necessary to insert the samplingprobe 600mm into the exhaust pipe, be sureto use a heat-r

3-17CHKADJADJUSTING THE THROTTLE CABLE FREE PLAYEAS00057ADJUSTING THE THROTTLE CABLE FREEPLAYNOTE:Prior to adjusting the throttle cable free play, the

3-18CHKADJCHECKING THE SPARK PLUGT R..EAS00060CHECKING THE SPARK PLUG1. Remove:8 battery cover8 battery holderRefer to “COVER AND PANEL”.2. Disconnect

1-9GENINFOCHAPTER 1GENERAL INFORMATIONSCOOTER IDENTIFICATION ... 1-1VEHICLE IDENTIFIC

3-19CHKADJCHECKING THE IGNITION TIMINGEAS00062CHECKING THE IGNITION TIMINGNOTE:Prior to checking the ignition timing, check thewiring connections of t

3-20CHKADJCHECKING THE IGNITION TIMINGNOTE:The ignition timing is not adjustable.*****************************************************5. Remove:8timin

3-21CHKADJMEASURING THE COMPRESSION PRESSUREEAS00067MEASURING THE COMPRESSION PRES-SURENOTE:Insufficient compression pressure will result ina loss of

3-22CHKADJMEASURING THE COMPRESSION PRESSURET R..Compression pressure (at sea level)Minimum1262 kPa (12.6 kgf/cm2, 700r/min)Standard1450 kPa (14.5 kgf

3-23CHKADJCHECKING THE ENGINE OIL LEVELEAS00069CHECKING THE ENGINE OIL LEVEL1. Stand the scooter on a level surface.NOTE:8 Place the scooter on a suit

3-24CHKADJCHANGING THE ENGINE OILEAS00076CHANGING THE ENGINE OIL1. Start the engine, warm it up for several min-utes, and then turn it off.2. Place a

3-25CHKADJCHANGING THE ENGINE OIL 8. Install:8engine oil filler cap 9. Start the engine, warm it up for several min-utes, and then turn it off. 10. Ch

3-26CHKADJCHANGING THE TRANSMISSION OIL1. Stand the scooter on a level surface.NOTE:8 Stand the scooter on a suitable stand.8 Make sure that the scoot

3-27CHKADJMEASURING THE ENGINE OIL PRESSUREEAS00077MEASURING THE ENGINE OIL PRESSURE1. Check:8engine oil levelBelow the minimum level mark J Add there

3-28CHKADJMEASURING THE ENGINE OIL PRESSURE6. Install:8gallery bolt7 Nm (0.7 m • kg, 5.1 ft • lb)7. Install:8front cover8 battery cover8seat/trunkRefe

1-1GENINFOEAS00015GENERAL INFORMATIONSCOOTER IDENTIFICATIONEAS00017VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the

3-29CHKADJCHECKING THE AIR FILTER ELEMENTEAS00086CHECKING THE AIR FILTER ELEMENT1. Remove:8air filter case cover 18air filter element 2. Check:8air fi

3-30CHKADJEAS00094CHECKING THE CARBURETOR JOINT ANDINTAKE MANIFOLD1. Remove:8seat/trunk8rear carrier8battery cover8front cover8side cover (left and ri

3-31CHKADJCHECKING THE FUEL HOSES AND FUEL FILTEREAS00097CHECKING THE FUEL HOSES AND FUELFILTERThe following procedure applies to all of the fuelhoses

3-32CHKADJEAS00098CHECKING THE CRANKCASE BREATHERHOSE1. Remove:8seat/trunkRefer to “COVER AND PANEL”.CHECKING THE CRANKCASE BREATHER HOSE2. Check:8cra

3-33CHKADJCHECKING THE EXHAUST SYSTEMT R..EAS00099CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of themuffler assembly and gaskets

3-34CHKADJEAS00103CHECKING THE COOLANT LEVEL1. Stand the scooter on a level surface.NOTE:8 Place the scooter on a suitable stand.8 Make sure the scoot

3-35CHKADJEAS00104CHECKING THE COOLING SYSTEM1. Remove:8seat/trunk8battery cover8front cover8 battery holder/ battery8footrest board side cover mole(

3-36CHKADJEAS00105CHANGING THE COOLANT1. Remove:8mat8battery cover8footrest board side cover mole (right)Refer to “COVER AND PANEL”.8radiator coverRef

3-37CHKADJCHANGING THE COOLANT 7. Fill:8cooling system(with the specified amount of the recom-mended coolant)Recommended antifreezeHigh-quality ethyle

3-38CHKADJ9. Fill:8coolant reservoir(with the recommended coolant to themaximum level mark a)10.Install:8coolant reservoir cap11.Start the engine, war

1-2GENINFOEAS00020IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DISAS-SEMBLY1. Before removal and disassembly, removeall dirt, mud, dust and foreig

3-39CHKADJADJUSTING THE FRONT BRAKE/ADJUSTING THE REAR BRAKEEAS00109CHASSISADJUSTING THE FRONT BRAKE1. Check:8brake lever free play aOut of specificat

3-40CHKADJEAS00127CHECKING THE FRONT AND REAR BRAKESHOES1. Operate the brake.2. Check:8wear indicator 1Reaches the wear limit line 2 J Replacethe brak

3-41CHKADJCHECKING AND ADJUSTING THE STEERING HEADEAS00148CHECKING AND ADJUSTING THE STEER-ING HEAD1. Stand the scooter on a level surface.wSecurely s

3-42CHKADJCHECKING AND ADJUSTING THE STEERING HEADT R..T R..wDo not overtighten the upper bearing innerrace.Upper bearing inner race(final tight-ening

3-43CHKADJCHECKING THE FRONT FORKEAS00151CHECKING THE FRONT FORK1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis

3-44CHKADJBasic weight(with oiland a fullfuel tank)Maximumload*Cold tirepressureFront RearUp to 55 kg55 kg ~ 158 kg 81 kg (179 lb) 158 kg (348 lb)150

3-45CHKADJCHECKING THE TIRES2. Check:8tire surfacesDamage/wear J Replace the tire.Minimum tire tread depth0.8 mm (0.032 in)1 Tire tread depth2 Sidewal

3-46CHKADJCHECKING THE TIRESwNew tires have a relatively low grip on theroad surface until they have been slightlyworn. Therefore, approximately 100 k

3-47CHKADJCHECKING THE WHEELS/CHECKING AND LUBRICATING THE CABLESEAS00168CHECKING THE WHEELSThe following procedure applies to both of thewheels.1. Ch

3-48CHKADJEAS00171LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedals.Recommended lu