Yamaha VINO 125 Service Manual

YJ125SSERVICE MANUALLIT-11616-17-43 5YR-28197-10

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

3-52CHKADJ6. Install:8battery7. Connect:8battery leads(to the battery terminals)cCFirst, connect the positive battery lead 11111,and then the negative

3-53CHKADJCHECKING THE FUSES2. Check:8fuse*****************************************************a. Connect the pocket tester to the fuse andcheck the c

3-54CHKADJREPLACING THE HEADLIGHT BULBEAS00182REPLACING THE HEADLIGHT BULB1. Remove:8headlight cover2. Disconnect:8headlight coupler 13. Remove:8headl

3-55CHKADJEAS00185ADJUSTING THE HEADLIGHT BEAMSThe following procedure applies to both of theheadlight.1. Adjust:8headlight beam (vertically)a. Loosen

CHAS4-55CHAPTER 4CHASSISFRONT WHEEL AND BRAKE DISC ... 4-1FRONT WHEEL ...

CHAS4-56HANDLEBAR ... 4-43REMOVING THE HANDLEBAR ...

CHAS4-1RemarksOrder Job/Part Q’tyEAS00513CHASSISFRONT WHEEL AND BRAKE DISCFRONT WHEEL AND BRAKE DISCRemoving the front wheel and brakediscSpeedometer

CHAS4-2RemarksOrder Job/Part Q’ty1111EAS00518FRONT WHEELFRONT WHEEL AND BRAKE DISCDisassembling the front wheelOil sealBearingCollarBearing1234Remove

CHAS4-3FRONT WHEEL AND BRAKE DISCEAS00520REMOVING THE FRONT WHEEL1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis

CHAS4-4FRONT WHEEL AND BRAKE DISCEAS00525CHECKING THE FRONT WHEEL1. Check:8wheel axleRoll the wheel axle on a flat surface.Bends J Replace.wDo not att

1-4GENINFOEAS00026CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect:8lead8coupler8connect

CHAS4-5FRONT WHEEL AND BRAKE DISCa. Clean the outside of the front wheel hub.b. Remove the oil seals 1 with a flat-headscrewdriver.NOTE:To prevent dam

CHAS4-6FRONT WHEEL AND BRAKE DISC3. Measure:8brake disc thicknessbMeasure the brake disc thickness at a fewdifferent locations.Out of specification J

CHAS4-7FRONT WHEEL AND BRAKE DISCEAS00539ASSEMBLING THE FRONT WHEEL1. Install:8wheel bearings8oil seals New*******************************************

CHAS4-8EAS00542INSTALLING THE FRONT WHEEL1. Lubricate:8wheel axle8wheel bearings8oil seal lipsRecommended lubricantLithium-soap-based grease2. Install

CHAS4-9X1X2FRONT WHEEL AND BRAKE DISCEAS00548ADJUSTING THE FRONT WHEEL STATICBALANCENOTE:8 After replacing the tire, wheel or both, thefront wheel st

CHAS4-10FRONT WHEEL AND BRAKE DISC3. Adjust:8front wheel static balance*****************************************************a. Install a balancing wei

CHAS4-11RemarksOrder Job/Part Q’ty123456789101111111221111Removing the rear wheel and rearbrakeMuffler assemblyRear armBrake adjusterBrake cableCompre

CHAS4-12REAR WHEEL AND REAR BRAKEEAS00565CHECKING THE REAR WHEEL1. Check:8wheel axle8rear wheelRefer to “CHECKING THE FRONTWHEEL”.2. Check:8tire8rear

CHAS4-13aREAR WHEEL AND REAR BRAKEEAS00569CHECKING THE BRAKEThe following procedure applies to all of thebrake shoes.1. Check:8brake shoe liningGlazed

CHAS4-14EAS00575ADJUSTING THE REAR WHEEL STATIC BAL-ANCENOTE:8 After replacing the tire, wheel or both, therear wheel static balance should be ad-j

1-5GENINFOEAS00027SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the appropriate speci

CHAS4-15RemarksOrder Job/Part Q’ty12345672121211Removing the front brake padsCaliper brake bracket boltCaliper brake pad boltBrake padBrake pad plateB

CHAS4-16FRONT BRAKEEAS00579cCDisc brake components rarely requiredisassembly.Therefore, always follow these preventivemeasures:88888 Never disassemble

CHAS4-17aT R..FRONT BRAKE3. Remove:8brake pad bolt8brake pad spring 18brake pads 28brake pad plate 34. Measure:8brake pad wear limit aOut of specifica

CHAS4-186. Lubricate:8brake caliper guide barRecommended lubricantLithium-soap-based greasecC88888 Do not allow grease to contact the brakepads.88888

CHAS4-19RemarksOrder Job/Part Q’ty1234567Removing the front brake master cyl-inderBrake fluidBrake lever / Compress springFront brake light switchUnio

CHAS4-20RemarksOrder Job/Part Q’ty12345111/111EAS00585DISASSEMBING THE FRONT BRAKE MASTER CYLINDERDisassembling the front brake mas-ter cylinderReserv

CHAS4-21EAS00588DISASSEMBLING THE FRONT BRAKE MAS-TER CYLINDERNOTE:Before disassembling the front brake mastercylinder, drain the brake fluid from the

CHAS4-22FRONT BRAKE3. Check:8brake master cylinder reservoirCracks/damage J Replace.brake master cylinder reservoir diaphragm1Damage/wear J Replace.4.

CHAS4-23EAS00597ASSEMBLING AND INSTALLING THE FRONTBRAKE MASTER CYLINDERw88888 Before installation, all internal brakecomponents should be cleaned and

CHAS4-24FRONT BRAKE5. Install:8copper washers1 New8brake hose28union bolt326 Nm (2.6 m • kg, 18.8 ft • lb)wProper brake hose routing is essential toin

1-6GENINFOTool NO.Tool name / Function Illustration90890-01367YM-A9409-790890-01400YM-A9409-390890-01384YM-3329990890-01403YU-3397590890-01701YS-01880

CHAS4-25FRONT BRAKE7. Bleed:8brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.8. Check:8brake fluid levelBelow the MIN level mar

CHAS4-26RemarksOrder Job/Part Q’ty1234512121EAS00612FRONT BRAKE CALIPERRemoving the front brake caliperBrake fluidUnion boltCopper washerBrake hoseFro

CHAS4-27RemarksOrder Job/Part Q’ty123456789112121111/1EAS00614DISASSEMBING THE FRONT BRAKE CALIPERDisassembling the front brake cali-perCapCaliper bra

CHAS4-28FRONT BRAKEEAS00619DISASSEMBLING THE FRONT BRAKE CALI-PERNOTE:Before disassembling the brake caliper, drain thebrake fluid from the entire bra

CHAS4-29EAS00631CHECKING THE FRONT BRAKE CALIPER1. Check:8brake caliper piston 1Rust/scratches/wear J Replace thebrake caliper piston assembly.8brak

CHAS4-30EAS00637ASSEMBLING AND INSTALLING THE FRONTBRAKE CALIPERw88888 Before installation, all internal brakecomponents should be cleaned and lu-bric

CHAS4-31FRONT BRAKE8brake caliper pad bolt 322 Nm (2.2 m • kg, 15.9 ft • lb)8brake hose 48copper washers 5 New8union bolt 623 Nm (2.3 m • kg, 16.6 ft

CHAS4-32FRONT BRAKEter will significantly lower the boilingpoint of the brake fluid and could causevapor lock.cCBrake fluid may damage painted surface

CHAS4-33RemarksOrder Job/Part Q’ty12345671111111EAS00646FRONT FORKRemoving the front fork legsFront wheelLeg shield 1Front fork protect coverBrake hos

CHAS4-34RemarksOrder Job/Part Q’ty123456789011/11/11111111EAS00648DISASSEMBING THE FRONT FORK LEGSDisassembling the front fork legsFork oilFork spring

1-7GENINFOTool NO.Tool name / Function Illustration90890-06754YM-3448790890-85505ACC-11001-05-0180890-04116YM-0411690890-04117YM-0411790890-04099YM-04

CHAS4-35FRONT FORKEAS00651REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the scooter on a level su

CHAS4-3612FRONT FORKEAS00653DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Remove:8fork spring 12.

CHAS4-37FRONT FORK5. Remove:8oil seal clip 1(with a flat-head screwdriver)cCDo not scratch the inner tube.6. Remove:8oil seal 1cCNever reuse the oil s

CHAS4-38FRONT FORKEAS00656CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check:8inner tube 18outer tube

CHAS4-39T R..FRONT FORKEAS00658ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.w88888 Make sure the oil le

CHAS4-40Damper rod holder90890-01294(YM-01300-1)T-handle90890-01326(YM-01326)4. Install:8oil seal 1 New(with the fork seal driver weight 2 andadapter

CHAS4-41FRONT FORK6. Install:8fork boot 17. Fill:8front fork leg(with the specified amount of the recom-mended fork oil)Quantity (each front fork leg)

CHAS4-42EAS00663INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install:8front fork legNOTE:Pull up the

CHAS4-43RemarksOrder Job/Part Q’ty123456789101112132111212111421EAS00664HANDLEBARRemoving the handlebarRear view mirror ( left and right )Brake master

CHAS4-441HANDLEBAREAS00666REMOVING THE HANDLEBAR1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no danger of it

2-31SPECCHAPTER 2SPECIFICATIONSGENERAL SPECIFICATIONS ... 2-1ENGINE SPECIFICATIONS ...

CHAS4-45EAS00671INSTALLING THE HANDLEBAR1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no danger of it falling

CHAS4-464. Install:8left handlebar switch 1NOTE:Align the projection a on the left handlebarswitch with the hole b in the handlebar.5. Install:8thrott

CHAS4-47RemarksOrder Job/Part Q’ty123456789Removing the lower fender cover andhandlebar lower holderFront wheelLeg shield 1Front fork legsHandlebar as

CHAS4-48RemarksOrder Job/Part Q’ty1234567891011121314Removing the lower bracketFront wheelHandlebar lower holderHandlebar holder bracketUpper ring nut

CHAS4-49RemarksOrder Job/Part Q’ty15 Rubber washer 1For installation, reverse the removal pro-cedure.STEERING HEAD12108765432113111415960Nm(6.0m • kg,

CHAS4-50STEERING HEADEAS00678REMOVING THE LOWER BRACKET1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no danger

CHAS4-51122STEERING HEADEAS00682CHECKING THE STEERING HEAD1. Wash:8bearings8bearing racesRecommended cleaning solventKerosene2. Check:8bearings 18bear

CHAS4-52EAS00684INSTALLING THE STEERING HEAD1. Lubricate:8upper bearing8lower bearing8bearing racesRecommended lubricantLithium-soap-based grease2. In

CHAS4-53REAR SHOCK ABSORBEREAS00692REMOVING THE REAR SHOCK ABSORBERASSEMBLY1. Stand the scooter on a level surface.wSecurely support the scooter so th

CHAS4-54EAS00698INSTALLING THE REAR SHOCK ABSORBERASSEMBLY1. Lubricate:8spacer8bushRecommended lubricantMolybdenum disulfide grease2. Install:8rear sh

2-1SPECSPECIFICATIONSGENERAL SPECIFICATIONSItemStandard LimitModel code 5YR1 (for USA) …5YR2 (for CAN) …Dimensions Overall length 1755 mm (69.1 in) …

ENG5-65CHAPTER 5ENGINEENGINE ... 5-1LEADS, HOSES AND

ENG5-66BELT DRIVE... 5-35CRANKCASE COVER...

5-1ENGRemoving the leads, hoses and rearbrakeSeat/Rear carrierSide cover ( left / right )/Fuel tank capRear cover/Hook( left and right )Front cover/T

5-2ENGRemarksOrder Job/Part Q’tyFor installation, reverse the removal pro-cedure.ENGINE26510111234781413911542Nm(4.2m • kg, 30.4 ft • lb)LS18Nm(1.8m •

ENG5-3NOTE:Make sure to reset the oil change indicator whenthe oil is changed.ENGINET R..1EAS00192INSTALLING THE ENGINE1. Install:8engine bracket bolt

5-4ENGRemarksOrder Job/Part Q’tyMAINFOLD, AIR FILTER AND MUFFLER ASSEMBLYENGINERemoving the mainfold, air filter andmuffler assemblyStarting motor lea

5-5ENGRemarksOrder Job/Part Q’ty12345678910111213141516121/11111/11/11/11114/2111EAS00221CYLINDER HEADRemoving the cylinder headMuffler assemblyAir fi

5-6ENGRemarksOrder Job/Part Q’tyCYLINDER HEAD17 Dowel pin 2For installation, reverse the removal pro-cedure.8Nm(0.8m • kg, 5.8 ft • lb)10Nm(1.0m • kg,

ENG5-7CYLINDER HEADEAS00225REMOVING THE CYLINDER HEAD1. Remove :8oil delivery pipe8engine oil cap8valve cover8Air shroud 18Air shroud 28breather2. Ali

ENG5-8CYLINDER HEADNOTE:8 To prevent the timing chain from falling intothe crankcase, fasten it with a wire.8 While holding the C.D.I. magneto bolt wi

2-2SPECENGINE SPECIFICATIONSItemStandard LimitEngine Engine type Forced Air cooled 4-stroke, …SOHC Displacement 0.125L(125.0 cm3)… Cylinder arrangemen

ENG5-9EAS00227CHECKING THE CYLINDER HEAD1. Eliminate:8combustion chamber carbon deposits(with a rounded scraper)NOTE:Do not use a sharp instrument to

ENG5-10EAS00231INSTALLING THE CYLINDER HEAD1. Install:8gasket New8dowel pins2. Install:8cylinder head3. Tighten:8cylinder head nuts22 Nm (2.2 m • kg,

ENG5-11cCDo not turn the crankshaft when installingthe camshaft to avoid damage or impropervalve timing.e. While holding the camshaft, temporarilytigh

ENG5-127. Turn:8crankshaft(several turns counterclockwise)8. Check:8“I” mark aAlign the “I” mark on the C.D.I. magnetorotor with the stationary pointe

5-13ENGRemarksOrder Job/Part Q’ty1234567THE ROCKER ARMS AND CAMSHAFTRemoving the rocker arms and cam-shaftCylinder headStopper plateLocknutAdjusting

ENG5-14EAS00202REMOVING THE ROCKER ARMS AND CAM-SHAFT1. Remove:8locknut 18stopper plate 22. Remove:8intake rocker arm shaft8exhaust rocker arm shaft8i

ENG5-15EAS00206CHECKING THE ROCKER ARMS ANDROCKER ARM SHAFTSThe following procedure applies to all of therocker arms and rocker arm shafts.1. Check:8r

ENG5-16Rocker-arm-to-rocker-arm-shaftclearance0.009 ~ 0.034 mm(0.0004~0.001 in)THE ROCKER ARMS AND CAMSHAFTEAS00205CHECKING THE CAMSHAFT1. Check:8cams

ENG5-17EAS00208CHECKING THE TIMING CHAIN, CAMSHAFTSPROCKETS, AND TIMING CHAIN GUIDESThe following procedure applies to all of the cam-shaft sprockets

ENG5-18EAS00220INSTALLING THE CAMSHAFT AND ROCKERARMS1. Lubricate:8camshaft 1Recommended lubricantCamshaftMolybdenum disulfide oilCamshaft bearingEngi

2-3SPECItemStandardLimitOil filter Oil filter type Wire mesh …Oil pump Oil pump type Trochoid … Inner rotor to outer rotor tip clearance 0.15 mm

5-19ENGRemarksOrder Job/Part Q’ty12345674221122EAS00236VALVES AND VALVE SPRINGSRemoving the valves and valvespringsCylinder headRocker arm and rocker

ENG5-20321EAS00237REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.NOTE:Before removing the internal part

ENG5-213. Remove:8valve cotter 18valve spring retainer 28valve spring 38valve stem seal 48lower spring seat 58valve 6NOTE:Identify the position of eac

ENG5-22NOTE:After replacing the valve guide, reface the valveseat.Valve guide remover (4.5 mm)90890-04116 (YM-04116)Valve guide installer (4.5 mm)9089

ENG5-23EAS00240CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Eliminate:8carbon deposits(from the valv

ENG5-24a. Apply a coarse lapping compound a to thevalve face.cCDo not let the lapping compound enter thegap between the valve stem and the valveguide.

ENG5-25EAS00241CHECKING THE VALVE SPRINGSThe following procedure applies to all of the valvesprings.1. Measure:8valve spring free length aOut of speci

ENG5-26EAS00245INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:8valve stem end(with an oil s

ENG5-27Valve spring compressor90890-04109 (YM-04109)Valve spring compressor attach-ment90890-04108 (YM-04108)5. To secure the valve cotters onto the v

5-28ENGRemarksOrder Job/Part Q’ty1234567891011121314EAS00251CYLINDER AND PISTONRemoving the cylinder and pistonCylinder headClampPipeTiming chain guid

2-4SPECItemStandardLimitCamshaft Drive system Chain drive (left) … Intake camshaft lobe dimensions Measurement A 26.153~26.253 mm 26.053 mm

ENG5-29EAS00253REMOVING THE CYLINDER AND PISTON1. Remove:8piston pin clip 18piston pin 28piston 3cCDo not use a hammer to drive the piston pinout.NOTE

ENG5-30EAS00261*CHECKING THE CYLINDER AND PISTON1. Check:8piston wall8cylinder wallVertical scratches J Replace the cylin-der, and the piston and pist

ENG5-31EAS00263CHECKING THE PISTON RINGS1. Measure:8piston ring side clearanceOut of specification J Replace the pis-ton and piston rings as a set.NOT

ENG5-32EAS00265CHECKING THE PISTON PIN1. Check:8piston pinBlue discoloration/grooves J Replace thepiston pin and then check the lubricationsystem.2. M

ENG5-33CHECKING THE TIMING CHAIN GUIDE1. Check:8timing chain guide (exhaust side)Damage/wear J ReplaceCYLINDER AND PISTONEAS00267INSTALLING THE PISTON

ENG5-34aAbdcCYLINDER AND PISTON3. Install:8gasket New 18dowel pins 24. Lubricate:8piston8piston rings8cylinder(with the recommended lubricant)Recommen

5-35ENGRemarksOrder Job/Part Q’ty123456789111111111EAS00316BELT DRIVECRANKCASE COVERRemoving the belt driveKickstarterCrankcase cover - 3V-belt case a

5-36ENGRemarksOrder Job/Part Q’ty1234567811111/1111Remove the parts in the order listed.Refer to “CRANKCASE COVER “.Refer to “INSTALLING THE KICKSTART

ENG5-37BELT DRIVEEAS00340INSTALLING THE KICKSTARTER1. Install:8solid bush 18kickstarter shaft 28kickstarter spring 32. Hook:8kickstarter springNOTE:H

5-38ENGRemarksOrder Job/Part Q’ty123456789101112131/11111111/111/6321Remove the parts in the order listed.Refer to “ REMOVING AND INSTALLINGTHE SECOND

EAS00000YJ125S 2003SERVICE MANUAL©2003 by Yamaha Motor Taiwan Co., Ltd.First edition, November 2003All rights reserved.Any reproduction or unauthorize

2-5SPECItemStandardLimitTiming chain Model/number of links Morse 92RH2005 / 88 … Tensioning system Automatic …Valve, valve seats, valve guides V

5-39ENGRemarksOrder Job/Part Q’ty12345678901131131221Disassemble the parts in the order listed.Refer to “ REMOVING AND INSTALLINGTHE SECONDARY SHEAVE

ENG5-40EAS00317REMOVING THE PRIMARY SHEAVE1. Remove:8primary sheave nut 18plate washer8primary fixed sheave 2NOTE:While holding the primary fixed shea

ENG5-4112BELT DRIVEEAS00319DISASSEMBLING THE SECONDARY SHEAVE1. Remove:8clutch carrier nut 1NOTE:Install the clutch spring holder 2 and clutchspring

ENG5-42EAS00320CHECKING THE V-BELT1. Check:8V-belt 1Cracks/damage/wear J Replace.Grease/oil J Clean the primary and sec-ondary sheave.2. Measure:8V-be

ENG5-43CHECKING THE SLIDER1. Check: slider 1Damage/wearJ ReplaceEAS00322CHECKING THE SECONDARY SHEAVE1. Check:8secondary fixed sheave8secondary slidin

ENG5-443. Install:8slider 18primary sliding sheave 28cam 3321BELT DRIVE

ENG5-45EAS00324ASSEMBLING THE SECONDARY SHEAVE1. Lubricate:8secondary fixed sheave’s inner surface 18secondary sliding sheave’s inner surface28torque

ENG5-465. Install:8secondary sheave 18spring8clutch carrier 2NOTE:Attach the clutch spring holder 3 and clutchspring holder arm 4 onto the secondary s

ENG5-472. Install:8clutch carrier nut 190 Nm (9.0 m • kg, 65.1 ft • lb)NOTE:While holding the clutch carrier with the rotorholding tool 2, tighten the

5-48ENGSTARTER CLUTCH AND STARTER MOTORRemarksOrder Job/Part Q’ty123456789101112111111111Disassemble the parts in the order listed.Refer to “ REMOVING

2-6SPECItemStandardLimitValve springs Free length Intake 37.30 mm 35.40 mm Exhaust 37.30 mm 35.40 mm Installed length (valve closed)

ENG5-49CHECKING THE STARTER WHEEL GEAR1. Check:8starter wheel gear 18idle gear2Burrs/chips/roughness/wear J Replace2. Check:8starter clutch operation*

5-50ENGRemarksOrder Job/Part Q’ty12341111Disassemble the parts in the order listed.Refer to “CYLINDER HEAD”in chapter 3. cCDisconnect the C.D.I. magne

ENG5-51C.D.I. MAGNETOREMOVING THE C.D.I. MAGNETO1. Remove:8nut 18plate washerNOTE:8 While holding the C.D.I. magneto rotor withthe holding tool 2, loo

ENG5-52INSTALLING THE C.D.I. MAGNETO1. Install:8C.D.I. magneto rotor 1NOTE:8 Clean the tapered portion of the crankshaftand the magneto rotor hub.8 Wh

5-53ENGEAS00360OIL PUMPRemarksOrder Job/Part Q’ty1234567891011121314111111/111111111Disassembling the oil pumpC.D.I. magnetoCoverO-ringGasketOil sealD

ENG5-54EAS00364CHECKING THE OIL PUMP1. Check:8oil pump driven gear 1Cracks/damage/wear J Replace the de-fective part(s).2. Measure:8inner-rotor-to-out

ENG5-55EAS00376INSTALLING THE OIL PUMP1. Install:8gasket 1 New8oil pump assembly28oil pump bolt7 Nm (0.7 m • kg, 5.1 ft • lb)cCAfter tightening the bo

5-56ENGEAS00419TRANSMISSIONRemarksOrder Job/Part Q’ty12345671121111Removing the transmission, shiftdrum assembly, and shift forksTransmission oilRear

ENG5-57EAS00425CHECKING THE TRANSMISSION1. Measure:8main axle runout(with a centering device and dial gauge )Out of specification J Replace the mainax

5-58ENGEAS00381CRANKCASE AND CRANKSHAFTRemarksOrder Job/Part Q’ty123456789102221111111Remove the parts in the order listed.Refer to “ ENGINE “Refer to

2-7SPECItemStandardLimitPiston Piston-to-cylinder clearance 0.010~0.030 mm 0.150mm Diameter D 51.470~51.510 mm … Height H 3.5 mm … Piston pin

5-59ENGRemarksOrder Job/Part Q’tyCRANKCASE AND CRANKSHAFT111213141516171819Dowel pinCrankshaftTiming chainCrankcase ( left )BoltO-ringTiming chain gui

ENG5-60CRANKCASE AND CRANKSHAFTDISASSEMBLING THE CRANKCASE1. Remove:8centerstand assembly2. Remove:8crankcase bolts 1NOTE:Loosen each bolt 1/4 of a tu

ENG5-61EAS00389REMOVING THE CRANKSHAFT ASSEMBLY1. Remove:8crankshaft assembly 18timing chain 2NOTE:8 Before removing the crankshaft assembly,remove th

ENG5-62EAS00394CHECKING THE CRANKSHAFT AND CON-NECTING ROD1. Measure:8crankshaft runoutOut of specification J Replace the crank-shaft, bearing or both

ENG5-635. Check:8crankshaft journalScratches/wear J Replace the crank-shaft.8crankshaft journal oil passageObstruction J Blow out with compressedair.

ENG5-64EAS00418ASSEMBLING THE CRANKCASE1. Thoroughly clean all the gasket mating sur-faces and crankcase mating surfaces.2. Apply:8sealant(onto the cr

6-12CARBCHAPTER 6CARBRETORCARBURETOR ... 6-1CHECKING THE CARBURE

6-1CARBRemarksOrder Job/Part Q’ty111/1111/111111111111111234567890qwertyuioDisassembling the carburetorAuto choke unitAuto choke holderThrottle stop s

6-2CARBRemarksOrder Job/Part Q’typaCarburetor heaterGround terminal11For assembly, reverse the disassemblyprocedure.CARBURETOR56879rtyu0ewoq2ap143i

6-3CARBEAS00485CHECKING THE CARBURETOR1. Check:8carburetor body8float chamberCracks/damage J Replace.2. Check:8fuel passagesObstruction J Clean.******

2-8SPECItemStandardLimitRocker arm/rocker arm shaft Rocker arm inside diameter 10~10.015mm … Rocker arm shaft outside diameter 9.981~9.991 mm …

6-4CARB6. Check:8needle valve 18needle valve seat 2Damage/obstruction/wear J Replace theneedle valve, needle valve seat and O-ring as a set.7. Check:8

6-5CARBEAS00487ASSEMBLING THE CARBURETORcC88888 Before assembling the carburetor, washall of the parts in a petroleum-based sol-vent.88888 Always use

6-6CARBEAS00492INSTALLING THE CARBURETOR1. Adjust:8engine idling speedEngine idling speed1,600 ~ 1,700r/minRefer to “ADJUSTING THE ENGINEIDLING SPEED”

6-7CARBEAS00498MEASURING AND ADJUSTING THE FUELLEVEL1. Measure:8fuel level aOut of specification J Adjust.Fuel level (below the float chambermating su

6-8CARBCARBURETOREAS00505CHECKING THE FUEL COCK1. Check:8fuel cockCracks/damage/wear J Replace.2. Check:8fuel cock strainer 1obstruction J clean.Blow

6-9CARB3. Check:8autochoke unit*****************************************************a. Connect the autochoke unit leads to a 12.0-V battery for five m

6-10CARBRemarksOrder Job/Part Q’tyAIR INDUCTION SYSTEMRemoving the air induction systemHose (from AI air filter)Vacuum hose( from mainfold )Hose (to c

6-11CARBEAS00510CHECKING THE AIR INDUCTION SYSTEM1. Check:8hosesLoose connection J Connect properly.Cracks/damage J Replace.8pipeCracks/damage J Repla

7-48-+ELECCHAPTER 7ELECTRICALELECTRICAL COMPONENTS ... 7-1WIRING DIAGRAM ...

7-1-+ELECEAS00729ELECTRICALELECTRICAL COMPONENTS1 Wire harness2 Battery3 C.D.I. unit4 Carburetor heater5 Sidestand switch6 Horn7 Rectifier/Regulator8

2-9SPECItemStandardLimitClutch Clutch type Automatic centrifugal … Clutch shoe thickness 3.4 ± 0.1 mm 2.0mm Clutch shoe spring free length 28.0

7-2-+ELECWIRING DIAGRAMWIRING DIAGRAMRBBrRBBrLYBLGYBSbLYBWSbLYBWBBrWBrGYBBWLWBWBrBWBrBWLWDgChLBLBDgBBrGLBBrGLBGBGBChBChBDgBDgBBrGYBBBrGYBrGYBBYRBWYRWY

7-3-+ELECWIRING DIAGRAM1 Main switch2 C.D.I. magneto3 Rectifier/Regulator4 Battery5 Main fuse6 Battery (+) lead7 Battery (-) lead8 Wire lead9 Starter

7-4-+ELECEAS00730CHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity reading is incorrect, checkthe wi

7-5-+ELECEAS00731CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between theterminals. Refer to

7-6-+ELECEAS00733CHECKING THE BULBS AND BULBSOCKETSCheck each bulb and bulb socket for damage orwear, proper connections, and also for continu-ity bet

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

7-8-+ELECCHECKING THE CONDITION OF THE BULBSOCKETSThe following procedure applies to all of the bulbsockets.1. Check:8bulb socket (for continuity)(wit

7-9-+ELECIGNITION SYSTEMCIRCUIT DIAGRAMIGNITION SYSTEMRBBrRBBrLYBLGYBSbLYBWSbLYBWBBrWBrGYBBWLWBWBrBWBrBWLWDgChLBLBDgBBrGLBBrGLBGBGBChBChBDgBDgBBrGYBBB

7-10-+ELECEAS00736TROUBLESHOOTINGThe ignition system fails to operate (nospark or intermittent spark).Check:1. Main Fuse2. Battery3. Spark plug4. Igni

7-11-+ELECEAS007424. Ignition spark gap8Disconnect the spark plug cap from thespark plug.8Connect the ignition checker 1 asshown. 2 Spark plug cap8Set

2-10SPECItemStandardLimitThrottle bodys Model (manufacturer) × quantity 5YR (SAFETY CONTROL …CABLE) × 2 Intake vacuum pressure 30.0kpa (238.6mmH

7-12-+ELEC8Measure the primary coil resistance.Primary coil resistance0.184 ~ 0.276 ΩΩΩΩΩ at 20°C8Connect the pocket tester (Ω × 1k) tothe ignition co

7-13-+ELECEAS0074810.Pickup coil resistance8Disconnect the pickup coil coupler fromthe wire harness.8Connect the pocket tester (Ω × 100) tothe pickup

7-14-+ELECELECTRIC STARTING SYSTEMCIRCUIT DIAGRAMELECTRIC STARTING SYSTEMRBBrRBBrLYBLGYBSbLYBWSbLYBWBBrWBrGYBBWLWBWBrBWBrBWLWDgChLBLBDgBBrGLBBrGLBGBGB

7-15-+ELECEAS00756STARTING CIRCUIT CUT-OFF SYSTEM OP-ERATIONIf the main switch is set to “ON” (switchis closed),the starter motor can only operate if

7-16-+ELECEAS00757TROUBLESHOOTING The starter motor fails to turn.Check:1. Main fuse2. Battery3. Starter motor4. Starting circuit cut-off relay5. Star

7-17-+ELECEAS007583. Starter motor8Connect the positive battery terminal 1and starter motor lead 2 with a jumperlead3. w88888 A wire that is used as a

7-18-+ELECEAS007615. Starter relay8Disconnect the starter relay coupler fromthe coupler.8Connect the pocket tester (Ω × 1) andbattery (12 V) to the st

7-19-+ELECProperly connect orrepair the startingsystem’s wiring orreplace the C.D.I.unit.The starting sys-tem circuit is OK.EAS0076611. Wiring8Check t

7-20-+ELECSTARTER MOTORRemarksOrder Job/Part Q’tyStarter motor removalAir filter caseStarter motor leadStarter motorStarter motor disassemblyO-ringRea

7-21-+ELECEAS00769CHECKING THE STARTER MOTOR1. Check:8commutatorDirt J Clean with 600-grit sandpaper.2. Measure:8commutator diameter aOut of specifica

2-11SPECCHASSIS SPECIFICATIONSCHASSIS SPECIFICATIONSItemStandardLimitFrame Frame type Steel tube underbone … Caster angle 32 ° … Trail 75 mm …Fr

7-22-+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

7-23-+ELECEAS00772ASSEMBLING THE STARTER MOTOR1. Install:8brush spring 18brush 28armature coil2. Install:8gasket 18starter motor front bracket 28start

7-24-+ELECEAS00773CHARGING SYSTEMCIRCUIT DIAGRAMCHARGING SYSTEMRBBrRBBrLYBLGYBSbLYBWSbLYBWBBrWBrGYBBWLWBWBrBWBrBWLWDgChLBLBDgBBrGLBBrGLBGBGBChBChBDgBD

7-25-+ELECEAS00774TROUBLESHOOTING The battery is not being charged.Check:1. main fuse2. battery3. charging voltage4. stator coil resistance5. wiring

7-26-+ELECThe charging circuit is OK. NOTE: Make sure the battery is fully charged.8Is the charging voltage within specifica-tion?YES NOEAS007764. Sta

7-27-+ELECEAS00780LIGHTING SYSTEMCIRCUIT DIAGRAMLIGHTING SYSTEMRBBrRBBrLYBLGYBSbLYBWSbLYBWBBrWBrGYBBWLWBWBrBWBrBWLWDgChLBLBDgBBrGLBBrGLBGBGBChBChBDgBD

7-28-+ELECEAS00781TROUBLESHOOTINGAny of the following fail to light: headlight,high beam indicator light, fuel level meterlight or meter light.Check:1

7-29-+ELECEAS007875. Wiring8Check the entire lighting system’s wir-ing.Refer to “CIRCUIT DIAGRAM”.8Is the lighting system’s wiring properlyconnected a

7-30-+ELECThe wiring circuit from themain switch to the head-light coupler and hightbeam indicator light arefaulty and must be re-paired.This circuit

7-31-+ELECLIGHTING SYSTEM2. Voltage8Connect the pocket tester (DC 20 V) tothe meter light coupler (wire harnessside) as shown. Positive tester probe

2-12SPECItemStandardLimitFront disc brake Brake type Single disc brake … Operation Right-hand operation … Brake lever free play (at lever end) 3

7-32-+ELECEAS007484. Lighting coil resistance8Disconnect the lighting coil coupler fromthe wire harness.8Connect the pocket tester (Ω × 1) to thelight

7-33-+ELECSIGNALING SYSTEMEAS00793SIGNALING SYSTEMCIRCUIT DIAGRAMRBBrRBBrLYBLGYBSbLYBWSbLYBWBBrWBrGYBBWLWBWBrBWBrBWLWDgChLBLBDgBBrGLBBrGLBGBGBChBChBDg

7-34-+ELECEAS00794TROUBLESHOOTING88888Any of the following fail to light: turnsignal light, brake light or an indica-tor light.88888The horn fails to

7-35-+ELEC4. Voltage8Connect the pocket tester (DC 20 V) tothe horn connector at the pink terminalas shown. Positive tester probe JJJJJ pink 11111 N

7-36-+ELECEAS007982. The tail/brake light fails to come on.1. Tail/brake light bulb and socket8Check the tail/brake light bulb and socketfor continuit

7-37-+ELECEAS007993. The turn signal light, turn signal indicatorlight or both fail to blink.1. Turn signal light and turn signal indicatorlight bulbs

7-38-+ELEC4. Voltage8Connect the pocket tester (DC 20 V) tothe turn signal relay coupler (wire har-ness side) as shown. Positive tester probeJJJJJ br

7-39-+ELECEAS008044. The fuel level meter fails to operate.1. Fuel sender8Remove the fuel sender from the fueltank.8Connect the pocket tester (Ω × 1)

7-40-+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

7-41-+ELECEAS00820CARBURETOR HEATING SYSTEMCIRCUIT DIAGRAMCRABURETOR HEATING SYSTEMRBBrRBBrLYBLGYBSbLYBWSbLYBWBBrWBrGYBBWLWBWBrBWBrBWLWDgChLBLBDgBBrGL

2-13SPECItemStandardLimitRear drum brake Brake type Drum brake … Operation Left-hand operation … Brake lever free play (at lever end) 10~20mm …

7-42-+ELECEAS00821TROUBLESHOOTINGThe carburetor heating system fails tooperate.Check:1. Main fuse2. Battery3. Main switch4. Thermo switch5. Carburetor

7-43-+ELECEAS008234. Thermo switch8Remove the thermo switch from thethermo switch plate wire harness.8Connect the pocket tester to the (Ω × 1)to the t

7-44-+ELECEAS008266. Wiring8Check the entire carburetor heatingsystem’s wiring.Refer to “CIRCUIT DIAGRAM”.8Is the carburetor heating system’s wir-ing

7-45-+ELECAUTO CHOKE SYSTEMCIRCUIT DIAGRAMAUTO CHOKE SYSTEMRBBrRBBrLYBLGYBSbLYBWSbLYBWBBrWBrGYBBWLWBWBrBWBrBWLWDgChLBLBDgBBrGLBBrGLBGBGBChBChBDgBDgBBr

7-46-+ELECTROUBLESHOOTING The auto choke system fails to operate.Check:1. Lighting coil resistance2. Auto choke unit resistance3. Wiring connections(

7-47-+ELEC2. Auto choke unit resistance8Disconnect the auto choke unit couplerfrom wire harness.8Connect the Pocket tester(Ω × 1) to theAuto choke uni

8-7TRBLSHTGCHAPTER 8TROUBLE SHOOTINGSTARTING FAILURES ... 8-1ENGINE ...

8-8TRBLSHTGUNSTABLE HANDLING/FAULTY LIGHTING OR SIGNALINGSYSTEM ...

8-1TRBLSHTGEAS00844TROUBLESHOOTINGNOTE:The following guide for troubleshooting does not cover all the possible causes of trouble. It should behelpful,

8-2TRBLSHTGSTARTING FAILURES/INCORRECT ENGINE IDLING SPEEDIgnition system8Faulty C.D.I unit8Faulty pickup coil8Broken magneto rotor woodruff keySwitch

2-14SPECItemStandardLimitELECTRICAL SPECIFICATIONSELECTRICAL SPECIFICATIONSSystem voltage 12V …Ignition system Ignition system type C.D.I. … Ignit

8-3TRBLSHTGPOOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY CLUTCHEAS00849POOR MEDIUM-AND-HIGH-SPEEDPERFORMANCERefer to “STARTING FAILURES”.ENGINEAir fil

8-4TRBLSHTGOVERHEATING/POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGSPOOR SPEED PERFORMANCEV-belt8Oil or grease on the V-beltPrimary pulley weight(s)

8-5TRBLSHTGUNSTABLE HANDLING/FAULTY LIGHTING OR SIGNALING SYSTEMEAS00862UNSTABLE HANDLINGHandlebar8Bent or improperly installed handlebarSteering head

8-6TRBLSHTGFAULTY LIGHTING OR SIGNALING SYSTEMTURN SIGNAL REMAINS LIT8Faulty turn signal relay8Burnt-out turn signal bulbTURN SIGNAL BLINKS QUICKLY8In

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

2-15SPECELECTRICAL SPECIFICATIONSItemStandardLimitBulbs (voltage/wattage × quantity) Headlight 12 V 60 W/55 W × 1 … Tail/brake light 12 V 8W/27 W

2-16SPECItemStandardLimitELECTRICAL SPECIFICATIONSElectric starting system System type Constant mesh … Starter motor Model (manufacturer) 4TE1

2-17SPECItemStandardLimitELECTRICAL SPECIFICATIONSFuel lever meter Type( manufacturer ) Moving magneto (CHAO LONG) …Fuse (amperage × quantity) Mai

2-18SPECEB201000CONVERSION TABLEAll specification data in this manual are listedin SI and METRIC UNITS.Use this table to convert METRIC unit data toIM

2-19SPECENGINE TIGHTENING TORQUESPart to be tightenedPart nameThreadsizeQ’tyTighteningtorque Nm m•kgf ft•lbRemarksTIGHTENING TORQUESCylinder head a

2-20SPECCylinder head tightening sequenceTIGHTENING TORQUESPart to be tightenedPart nameThreadsizeQ’tyTighteningtorque Nm m•kgf ft•lbRemarksDrain b

2-21SPECPart to be tightenedThreadsizeTighteningtorque Nm m•kgf ft•lbRemarksTIGHTENING TORQUESCHASSIS TIGHTENING TORQUESLTFrame and engine brac

2-22SPECENGINE LUBRICATION POINTS AND LUBRICANT TYPESLubrication Point LubricantLSLS4MLS4LSLS4444444444MMM444LSLSLUBRICATION POINTS AND LUBRICANT TYPE

2-23SPECBEL-RAY asembly lubeBEL-RAY asembly lubeSealantSealantSealantSealantSealantLubrication Point LubricantLUBRICATION POINTS AND LUBRICANT TYPESLS

2-24SPECLUBRICATION POINTS AND LUBRICANT TYPESLubrication Point LubricantLSLSLSLSLSLSLSLSLSMEAS00032CHASSIS LUBRICATION POINTS AND LUBRICATION TYPESFr

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

2-25SPECOIL FLOW DIAGRAMS1 Oil strainer2 Oil pump3 Oil filter4 Oil delivery pipe5 Oil delivery pipe union boltOIL FLOW DIAGRAMS

2-26SPECOIL FLOW DIAGRAMS1 Connecting rod big end bearing

2-27SPECCABLE ROUTING1 Turn signal relay2 Main switch assembly3 Seat lock cable4 Horn5 Rectifier / regulator assem-bly6 Starter motor negative lead7 W

2-28SPECCABLE ROUTINGJ Fasten the C.D.I. unit leadand wire harness to theframe with a plastic lockingtie, point the band tip to up-per and the trunk s

2-29SPEC1 Lever holder assembly (leftside)2 Rear brake cable3 Throttle cable 1 (left turnside)4 Throttle cable2 (right turnside)5 Breather hose6 Carbu

2-30SPEC1 Seat lock cable2 Carburetor heater lead3 Carburetor autochoke lead4 Starter switch lead5 Starter motor positive lead6 Starter motor negative

3-56CHKADJCHAPTER 3PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTION ...

3-57CHKADJCLEANING THE AIR FILTER ELEMENT/CLEANING THE V-BELTCASE AIR FILTER ELEMENT ... 3

3-58CHKADJLUBRICATING THE SIDESTAND/LUBRICATING THECENTERSTAND ... 3

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

GENINFOSPECCHKADJENGTRBLSHTGCARBCHAS-+ELECEMBLSNewMGCOOL1234567890qweriopasdfgEAS00008SYMBOLSThe following symbols are not relevant to everyvehicle.Sy

3-2CHKADJPERIODIC MAINTENANCE CHART FOR THEEMISSION CONTROL SYSTEMEAU17560*Periodic maintenance chart for the emission control system* Since these ite

3-3CHKADJEAU32121General maintenance and lubrication chart* Since these items require special tools, data and technical skills, have a Yamaha dealer p

3-4CHKADJCOVER AND PANELSEAT AND SIDE COVERSRemarksOrder Job/Part Q’ty123456789101112131111111111111Removing the seat and side coversSeatRear carrierS

3-5CHKADJRemarksOrder Job/Part Q’ty1234567811111111FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLERemoving the footrest board andfootrest board side

3-6CHKADJLEG SHIELD 1 , 2RemarksOrder Job/Part Q’ty12345671111111Removing the leg shield 1,2Footrest boardHeadlight coverHeadlight assemblyFront turn

3-7CHKADJ1ADJUSTING THE VALVE CLEARANCEEAS00049ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.NOTE:8 Valve cl

3-8CHKADJADJUSTING THE VALVE CLEARANCE*****************************************************a. Turn the crankshaft counterclockwise.b. When the piston

3-9CHKADJADJUSTING THE VALVE CLEARANCE5. Install:8cap8spark plug12.5 Nm (1.25 m • kg, 9 ft • lb)8valve cover (exhaust )8engine oil cap6. Install:8spar

3-10CHKADJADJUSTING THE ENGINE IDLING SPEEDEAS00054ADJUSTING THE ENGINE IDLING SPEEDNOTE:Prior to adjusting the engine idling speed, theair filter ele

3-11CHKADJCHECKING THE EXHAUST GAS AT IDLECHECKING THE EXHAUST GAS AT IDLE(Measuring the exhaust gas at idle[when airinduction system is operation])1.

EAS00011TABLE OF CONTENTSGENERAL INFORMATIONSPECIFICATIONSPERIODIC CHECKS ANDADJUSTMENTSCHASSISENGINECARBURETORELECTRICAL SYSTEMTROUBLESHOOTING-+GEN I

3-12CHKADJCHECKING 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

3-13CHKADJEAS00057ADJUSTING THE THROTTLE CABLE FREEPLAYNOTE:Prior to adjusting the throttle cable free play, theengine idling speed should be adjusted

3-14CHKADJHandlebar sidea. Loosen the locknut 1.b. Turn the adjusting nut 2 in direction a orb until the specified throttle cable free playis obtained

3-15CHKADJEAS00060CHECKING THE SPARK PLUG1. Remove:8 coverRefer to “COVER AND PANEL”.2. Disconnect:8spark plug cap3. Remove:8spark plugcCBefore removi

3-16CHKADJ121CHECKING THE IGNITION TIMINGEAS00062CHECKING THE IGNITION TIMINGNOTE:Prior to checking the ignition timing, check thewiring connections o

3-17CHKADJ1MEASURING THE COMPRESSION PRESSUREEAS00067MEASURING THE COMPRESSION PRES-SURENOTE:Insufficient compression pressure will result ina loss of

3-18CHKADJMEASURING THE COMPRESSION PRESSURE7. Measure:8compression pressureOut of specification J Refer to steps (c)and (d).Compression pressure (at

3-19CHKADJ11. Install:8front cover8hook8side cover (right,left )8rear carrier8coverRefer to “COVER AND PANEL”.MEASURING THE COMPRESSION PRESSURE

3-20CHKADJ1baCHECKING THE ENGINE OIL LEVELEAS00069CHECKING THE ENGINE OIL LEVEL1. Stand the scooter on a level surface.NOTE:8 Place the scooter on a s

3-21CHKADJ1CHECKING THE ENGINE OILEAS00076CHANGING THE ENGINE OIL1. Start the engine, warm it up for several min-utes, and then turn it off.2. Place a

1-8GENINFOCHAPTER 1GENERAL INFORMATIONSCOOTER IDENTIFICATION ... 1-1VEHICLE IDENTIFIC

3-22CHKADJCHANGING THE ENGINE OIL FILTER ELEMENT11. Check:8engine oil levelRefer to “CHECKING THE ENGINE OILLEVEL”.12. Check:8engine oil pressureRefer

3-23CHKADJcCCheck it under the condition that a checkbolt is surely loosened because oil eruptswhen a check bolt is removed and an engineis started.5.

3-24CHKADJCHANGING 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

3-25CHKADJ1MEASURING THE ENGINE OIL PRESSUREEAS00077MEASURING THE ENGINE OIL PRESSURE1. Check:8engine oil levelBelow the minimum level mark J Add ther

3-26CHKADJCLEANING THE AIR FILTER ELEMENT/CLEANING THE V-BELT CASE AIR FILTER ELEMENTEAS00086CLEANING THE AIR FILTER ELEMENT1. Remove:8air filter case

3-27CHKADJCLEANING THE V-BELT CASE AIR FILTER ELEMENTNOTE:After cleaning, gently squeeze the V-beltcase air filter element to remove the excesssolvent

3-28CHKADJCHECKING THE CARBURETOR JOINTAND INTAKE MANIFOLDEAS00094CHECKING THE CARBURETOR JOINT ANDINTAKE MANIFOLD1. Remove:8cover8rear carrier8side c

3-29CHKADJCHECKING THE FUEL AND VACUUM HOSES/CHECKING THE CRANKCASE BREATHER HOSEEAS00096CHECKING THE FUEL AND VACUUMHOSESThe following procedure appl

3-30CHKADJCHECKING THE EXHAUST SYSTEMEAS00099CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of themuffler assembly and gaskets.1.

3-31CHKADJADJUSTING THE FRONT BRAKE/ADJUSTING THE REAR BRAKEEAS00108CHASSISADJUSTING THE FRONT BRAKE1. Check:8brake lever free play aBrake lever free

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

3-32CHKADJCHECKING THE BRAKE FLUID LEVELEAS00116CHECKING THE BRAKE FLUID LEVEL1. Stand the scooter on a level surface.NOTE:8 Place the scooter on a su

3-33CHKADJCHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKE SHOES/CHECKING THE FRONT BRAKE HOSEEAS00117CHECKING THE FRONT BRAKE PADSThe following

3-34CHKADJBRAKE FLUID CHANGEBRAKE FLUID CHANGEwShould you feel loose when pulling Brake, itis possibly due to leaking of Brake fluid ofmixing with air

3-35CHKADJe. Remove the reservoir diaphragm.f. Fill proper volume of designated brake fluidinto the reservoir of the master cylinder.Refer to “CHECKIN

3-36CHKADJBLEEDING THE HYDRAULIC BRAKE SYSTEMEAS00133BLEEDING THE HYDRAULIC BRAKE SYS-TEMwBleed the hydraulic brake system whenever:88888 the system i

3-37CHKADJBLEEDING THE HYDRAULIC BRAKE SYSTEMh. Tighten the bleed screw and then releasethe brake lever.i. Repeat steps (e) to (h) until all of the ai

3-38CHKADJEAS00148CHECKING AND ADJUSTING THE STEER-ING HEAD1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no da

3-39CHKADJCHECKING AND ADJUSTING THE STEERING HEADc. Loosen the lower ring nut completely andthen tighten it to specification with a steer-ing nut wre

3-40CHKADJEAS00151CHECKING THE FRONT FORK1. Stand the scooter on a level surface.wSecurely support the scooter so that thereis no danger of it falling

3-41CHKADJBasic weight(with oiland a fullfuel tank)Maximumload*Cold tirepressureFront RearUp to 90 kgload*90 kg ~ max- imum load*EAS00163CHECKING THE

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

3-42CHKADJCHECKING THE TIRES2. Check:8tire surfacesDamage/wear J Replace the tire.Minimum tire tread depth0.8 mm (0.03 in)1 Tire tread depth2 Sidewall

3-43CHKADJwNew tires have a relatively low grip on theroad surface until they have been slightlyworn. Therefore, approximately 100 kmshould be travele

3-44CHKADJEAS00168CHECKING THE WHEELSThe following procedure applies to both of thewheels.1. Check:8wheelDamage/out-of-round J Replace.wNever attempt

3-45CHKADJEAS00172LUBRICATING THE SIDESTANDLubricate the pivoting point and metal-to-metalmoving parts of the sidestand.Recommended lubricantLithium-

3-46CHKADJCHECKING AND CHARGING THE BATTERYEAS00179ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERYwBatteries generate explosive hydrogen gasand con

3-47CHKADJNOTE: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

3-48CHKADJb. Check the charge of the battery, as shownin the charts and the following example.Examplec. Open-circuit voltage = 12.0 Vd. Charging time

3-49CHKADJ88888 Make sure the battery charger lead clipsare in full contact with the battery ter-minal and that they are not shorted. Acorroded batter

3-50CHKADJChargerAmmeterMeasure the open-circuitvoltage prior to charging.Connect a charger and am-meter to the battery andstart charging.Is the amper

3-51CHKADJThis type of battery charger cannotcharge an MF battery. Avariablevoltage charger is recom-mended.YESNOCharging method using a constant volt