Yamaha Majesty YP250

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

EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha
scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Re-
pairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit for
use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to

the scooter operator, a bystander or a person inspecting or repairing the scoot-
er.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the scooter.
NOTE: A NOTE provides key information to make procedures easier or clearer.

YP002000
HOW TO USE THIS MANUAL

MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1 : This is the title of the chapter with its symbol on the upper right corner of each page.
2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To heps identify parts and clarify procedure steps, there are exploded diagrams at start of each remov-
al and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs.
2. Numbers 5 are given in the order of jobs in the exploded diagram. A number that is enclosed by a
circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6 . The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.
2 1 4 3
5
8
6
6

EB003000
1 2 ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are designed as
thumb tabs to indicate the chapter’s number
and content.
3 4
1 General information
2 Specifications
3 Periodic inspection and adjustment
4 Engine
5 6 5 Cooling system
6 Carburetion
7 Chassis
8 Electrical
9 Troubleshooting
7 8
9 10 Illustrated symbols 10 to 17 are used to identify

the specifications appearing in the text.
10 Possible to maintain with engine mounted
11 Filling fluid
11 12 12 Lubricant
13 Special tool
14 Tightening
15 Wear limit, clearance
16 Engine speed
13 14
17 Ω, V, A
15 16 17
Illustrated symbols 18 to 23 in the exploded dia-
grams indicate the types of lubricants and lu-
brication points.
18 19 20 18 Apply engine oil
19 Apply gear oil
20 Apply molybdenum disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium-soap base grease
21 22 23 23 Apply molybdenum disulfide grease
Illustrated symbols 24 to 25 in the exploded dia-
grams indicate the where to apply locking agent
24 and when to install new parts 25 .
24 25 24 Apply locking agent (LOCTITE)
25 Use new one

INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION AND
ADJUSTMENT INSP
ADJ 3
ENGINE OVERHAUL ENG
4
COOLING SYSTEM COOL
5
CARBURETION CARB
6
CHASSIS CHAS
7
ELECTRICAL ELEC
8
TROUBLESHOOTING TRBL
SHTG 9

CHAPTER 1
GENERAL INFORMATION
SCOOTER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
VEHICLE IDENTIFICATION NUMBER (for E) . . . . . . . . . . . . . . . . . . . 1-1
FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
OIL INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
AUTO CHOKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
IGNITION CIRCUIT CUT-OFF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1-3
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
PREPARATION FOR REMOVAL PROCEDURES . . . . . . . . . . . . . . . 1-4
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
GASKETS, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . 1-4
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . 1-5
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . 1-7
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

GEN
SCOOTER IDENTIFICATION INFO
YP100000
GENERAL INFORMATION
SCOOTER IDENTIFICATION
YP100010
VEHICLE IDENTIFICATION NUMBER (for E)

The vehicle identification number 1 is stamped
into the right side of the frame.
NOTE:
The vehicle identification number is used to
identify your scooter and may be used to regis-
ter your scooter with the licensing authority in
your country.
YP100020
FRAME SERIAL NUMBER (except for E)

The frame serial number 1 is stamped into the
right side of the frame.
EB100030
ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the
crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
MODEL LABEL
The model label 1 is affixed under the seat.
This information will be needed to order spare
parts.
1-1

GEN
FEATURES 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 1,000 km for the first time and thereafter every 3,000 km. In this way, this light indicates the
time for oil change.
Circuit diagram
Engine stop
Main
switch Ignitor unit
switch
Oil indicator light
Reset button
Fuse
Oil indicator light
Battery Meter Reset button
C.P.U
Resetting procedure
Travel distance can be reset if the reset button is held down for 2 to 5 seconds with the main switch
“ON”.
1) If the “resetting” is done while the oil light is on, the oil indicator light goes off for resetting con-
firmation.
2) If the “resetting” is done while the oil light is off, the oil indicator light comes on for 1.4 seconds
for resetting confirmation.
Failure diagnosis
1) Checking oil indicator light for breakage
This oil indicator light is kept on for 1.4 seconds immediately after the main switch is turned on,
thereby checking the bulb for breakage.
2) In case of meter pulse failure
If travel distance signals are not detected during running, the oil indicator light flashes and gives a
warning of meter signal failure.
NOTE:
This circuit may be activated if the engine is accelerated without load with the mainestand put up.
Battery tending to discharge.

If the starting motor is run with the battery tending to discharge, the oil indicator light may come on (for
1.4 seconds), but this is noting abnormal.
In this case recharge or replace battery.
This light comes on if battery charging becomes poor, thereby causing the engine to run
as low as about 200 rpm against 600 rpm or so,
1-2

GEN
FEATURES INFO
AUTO-CHOKE SYSTEM
This system is the parallel connection of the ignitor unit circuit and the thermo switch as shown, detect-
ing the engine temperature, and facilitates the restarting with the warm engine.
Circuit diagram Igniter unit
Main switch
Thermo
Fuse
switch Ignition
C.P.U
Battery
Auto-choke
Auto-choke operation
Start with the Crank with the Crank with the Restart with the
Engine condition
cold engine cold engine warm engine warm engine
Thermo switch OFF OFF ON ON
Ignitor unit circuit OFF ON ON OFF
Auto-choke Activates Activates Not activate Not activate
IGNITION CIRCUIT CUT-OFF SYSTEM

A sidestand circuit is added to the existing electric starting circuit, thereby controlling the starter motor
operation and the ignition system of the igniter unit.
Circuit diagram
Main switch Engine stop switch
Brake
switch
Fuse Ignitor unit
Starter relay
Relay
Battery Start Sidestand

Starter Brake light
switch switch
motor
Operating mode
Operation of brake Operation of starter Operation of igniter

Sidestand switch
light motor unit control
OFF ON Not operated Misfire
(Sidestand in use) OFF Not operated Misfire
ON ON Operated Ignited
(Sidestand folded in) OFF Not operated Ignited (ridden)
1-3

GEN
IMPORTANT INFORMATION INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCE-
DURES
1. Remove all dirt, mud, dust and foreign ma-
terial before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the “SPECIAL TOOLS” section.
4. When disassembling the machine, always

keep mated parts 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.
5. During machine disassembly, clean all
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.
6. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
1-4

GEN
EB101030
LOCK WASHERS/PLATES AND COTTER

PINS
1. Replace all lock washers/plates and cotter
OR pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating of
lightweight lithium base grease to the seal lips.
Oil bearings liberally when installing, if appropri-
ate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the bearings
dry. This will damage the bearing surfaces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reas-
sembly. Always replace piston pin clips af-
ter one use. Replace distorted circlips.
When installing a circlip 1 , make sure that
the sharp-edged corner 2 is positioned op-
posite the thrust 3 it receives. See section-
al view.
4 Shaft
1-5

GEN
EB801000
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
S Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two

or three.
4. Pull the lead to check that it will not come
off.
5. If the terminal comes off, bend up the pin 1
and reinsert the terminal into the connector.
6. Connect:
S Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.

NOTE:
D If there is no continuity, clean the terminals.
D Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
D For a field remedy, use a contact revitalizer
available on the market.
D Use the tester on the connector as shown.
1-6

GEN
HOW TO USE THE CONVERSION TABLE INFO
EB201000
HOW TO USE THE 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 IMP
**mm 0.03937 = ** in
2 mm 0.03937 = 0.08 in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
mSkg 7.233 ftSlb
mSkg 86.794 inSlb
Torque
cmSkg 0.0723 ftSlb
cmSkg 0.8679 inSlb
kg 2.205 lb
Weight
g 0.03527 oz
km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
Distance
m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume/ cc (cm3) 0.06102 cuSin
Capacity lit (liter) 0.8799 qt (IMP liq.)
lit (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Miscella-
kg/cm2 14.2234 psi (lb/in2)
neous
Centigrade 9/5(_C) + 32 Fahrenheit (_F)
1-7

GEN
SPECIAL TOOLS INFO
EB102000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools; this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Usage Illustration

90890-01084 Weight
-01085 Rocker arm shaft puller bolt
These tools are used when removing

or installing the rocker arm shafts.
90890-01235 Rotor holding tool
This tool is used to remove the

flywheel magneto.
90890-01268 Ringnut wrench
This tool is used to loosen and tighten

the exhaust and steering ringnut.
90890-01311 Valve adjusting tool
This tool is necessary for adjusting

valve clearance.
90890-01312 Fuel level gauge
This gauge is used to measure the fuel

level in the float chamber.
90890-01325 Radiator cap tester
-01352 Adaptor
These tools are used for checking the

cooling system.
90890-01326 T-handle
-04084 Damper rod holder
These tool are used for holding the

damper rod holder when removing or
installing the damper rod holder.
90890-01337 Clutch spring compressor
-01464 Clutch spring holder arm
These tools are used for removing the

nut with holding the compression spring.
90890-01348 Locknut wrench
This tool is used when removing or

installing the secondary sheave nut.
1-8

GEN
SPECIAL TOOLS INFO

90890-01362 Flywheel puller
This tool is used for removing the

rotor.
90890-01367 Fork seal driver weight
-01368 Fork seal driver attachment (ø33)
This tool is used when installing the

fork seal.
90890-01384 Oil seal guide
This tool is used for protecting the oil

seal lip when installing the secondary
sliding sheave.
90890-01403 Ring nut wrench
This tool is used to loosen and tighten

the steering ring nut.
90890-01701 Sheave holder
This tool is used for holding the

secondary sheave.
90890-01996 Cylinder cup installer set
This tool is used for installing the

cylinder cup to the master cylinder
piston.
90890-03079 Thickness gauge
This tool is used to measure the valve

clearance.
90890-03081 Compression gauge
These tools are used to measure the

engine compression.
90890-03112 Pocket tester
These instruments are invaluable for

checking the electrical system.
90890-03113 Engine tachometer
This tool is needed for detecting

engine rpm.
1-9

GEN
SPECIAL TOOLS INFO

90890-03141 Timing light
This tool is needed for detecting

ignition timing.
90890-04101 Valve lapper
This tool is used for removing and

installing the lifter and for lapping the
valve.
90890-04019 Valve spring compressor
-04108 Attachment
These tools are used when removing

or installing the valve and the valve
spring.
90890-04058 Middle shaft bearing driver
-04078 Mechanical seal installer
These tools are used for installing

mechanical seal.
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.
1-10

CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
LUBRICATION POINTS AND GRADE OF LUBRICANT . . . . . . . . . . . . 2-17
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YP250
Model code: 4UC 1 (except for CH, A)
4UD1 (for CH, A)
Dimensions:
Overall length 2,110 mm
Overall width ,750 mm
Overall height 1,330 mm
Seat height ,700 mm
Wheelbase 1,500 mm
Minimum ground clearance ,115 mm
Minimum turning radius 2,600 mm
Basic weight:
With oil and full fuel tank 158 kg
Engine:
Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 0.249L (249 cm3)
Bore stroke 69.0 66.8 mm
Compression ratio 10 : 1
Compression pressure (STD) 1,400 kPa (14 kg/cm2, 14 bar) at 500 r/min
Starting system Electric starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil
API STANDERD:
SE or higher grade
Periodic oil change 1.2 L

Total amount 1.4 L
Transmission oil
Total amount 0.25 L
Radiator capacity
Total amount (including all routes) 1.4 L
Air filter: Carburetor side Wet type element
Crankcase side Dry type element
Fuel:
Type Regular unleaded gasoline
Fuel tank capacity 11 L
2-1

Model YP250
Carburetor:
Type/quantity Y28V-1A/1
Manufacturer TEIKEI
Spark plug:
Type DR8EA
Manufacturer NGK
Spark plug gap 0.6 X 0.7 mm
Clutch type: Dry, centrifugal automatic
Transmission:
Primary reduction system Helical gear
Primary reduction ratio 40/15 (2.666)
Secondary reduction sytem Sper gear
Secondary reduction ratio 37/16 (2.312)
Transmission type Single speed automatic (V-belt type)
Operation Centrifugal automatic type
Single speed automatic 2.20 X 0.88:1
Chassis:
Frame type Steel tube underbone
Caster angle 28
Trail 103 mm
Tire:
Type Tubeless
Size front 110/90-12 64J
rear 130/70-12 62L
Manufacturer front IRC/CHENG SHIN
rear IRC/CHENG SHIN
Type front MB61/C922
rear MB61/C940
Tire pressure (cold tire):
Maximum load-except motorcycle 197 kg
Loading condition A* 0 X 90 kg
front 175 kPa (1.75 kg/cm2, 1.75 bar)
rear 200 kPa (2.0 kg/cm2, 2.0 bar)
Loading condition B* 90 X 205 kg
rear 225 kPa (2.25 kg/cm2, 2.25 bar)
High-speed riding
rear 250 kPa (2.5 kg/cm2, 2.5 bar)
*Load is the total weight of cargo, rider, passenger, and accessories.
2-2

Model YP250
Brake:
Front brake type Single disc brake
operation Right hand operation
Rear brake type Drum brake
operation Left hand operation
Suspension:
Front suspension Telescopic fork
Rear suspension Unit swing
Shock absorber:
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Oil damper
Wheel travel:
Front wheel travel 85 mm
Rear wheel travel 90 mm
Electrical:
Ignition system T.C.I. (Digital)
Generator system A.C. magneto
Battery type GT7B-5
Battery capacity 12 V 6 AH
Headlight type: Quartz bulb (Halogen)
Bulb wattage quantity:
Headlight 12V 60 W/55 W 1
Marker light 12V 4 W 1
Tail/brake light 12V 5 W/21 W 1
Flasher light 12V 21W 4
Meter light 12V 1.7W 4
High beam indicator light 12V 3.4 W 1
Oil indicator light 12V 1.7 W 1
Turn indicator light 12V 3.4 W 2
License light 12V 5 W 1
2-3

MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit

Cylinder head:
Warp limit SSS 0.03 mm
Cylinder:
Bore size 69.000 X 69.005 mm 69.1 mm
Out of round limit SSS 0.03 mm
Camshaft:
Cam dimensions
Intake “A” 36.545 X 36.645 mm 36.45 mm
“B” 30.021 X 30.121 mm 29.92 mm
“C” 6.524 mm SSS
Exhaust “A” 36.547 X 36.647 mm 36.45 mm
“B” 30.067 X 30.167 mm 29.97 mm
“C” 6.48 mm SSS
Camshaft runout limit SSS 0.03 mm
Cam chain:
Cam chain type/No. of links DID SCSA-0404A SDH/104 SSS
Rocker arm/rocker armshaft:
Rocker arm inside diameter 12.000 X 12.018 mm 12.03 mm
Rocker shaft outside diameter 11.981 X 11.991 mm 11.995 mm
Rocker arm-to-rocker armshaft
clearance 0.009 X 0.012 mm SSS
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.08 X 0.12 mm SSS
EX 0.16 X 0.20 mm SSS
Valve dimensions
Face Width Seat Width Margin Thickness
“A” head diameter IN 33.9 X 34.1 mm SSS

EX 28.4 X 28.6 mm SSS
“B” face width IN 3.394 X 3.960 mm SSS
EX 3.394 X 3.960 mm SSS
“C” seat width IN 0.9 X 1.1 mm SSS
EX 0.9 X 1.1 mm SSS
“D” margin thickness IN 0.8 X 1.2 mm SSS
EX 0.8 X 1.2 mm SSS
Stem outside diameter IN 5.975 X 5.990 mm 5.94 mm
EX 5.960 X 5.975 mm 5.92 mm
Guide inside diameter IN 6.000 X 6.012 mm 6.05 mm
EX 6.000 X 6.012 mm 6.05 mm
2-4

Item Standard Limit

Stem-to-guide clearance IN 0.010 X 0.037 mm 0.08 mm
EX 0.025 X 0.052 mm 0.1 mm
Stem runout limit SSS 0.01 mm
Valve seat width IN 0.9 X 1.1 mm 1.6 mm
EX 0.9 X 1.1 mm 1.6 mm
Valve spring:
Free length (Inner) IN/EX 38.1 mm 36.1 mm
Free length (Outer) IN/EX 36.93 mm 35.0 mm
Set length (valve closed) (Inner) IN/EX 30.1 mm SSS
Set length (valve closed) (Outer) IN/EX 31.6 mm SSS
Compressed pressure (Inner) IN/EX 7.8 X 9.0 kg SSS
(Outer) IN/EX 37.22 X 42.83 kg SSS
Tilt limit (Inner) IN/EX SSS 2.5_/1.7 mm
Tilt limit (Outer) IN/EX SSS 2.5_/1.7 mm
Piston:
Piston to cylinder 0.02 X 0.04 mm 0.15 mm
clearance
Piston size “D” 68.965 X 68.980 mm SSS
Measuring point “H” 5 mm SSS
Piston pin bore 17.004 X 17.015 mm 17.045 mm
inside diameter
Piston pin outside diameter 16.991 X 17.000 mm 16.975 mm
Piston rings:
Top ring:
Type Barrel SSS
End gap (installed) 0.15 X 0.30 mm 0.45 mm
Side clearance (installed) 0.04 X 0.08 mm 0.12 mm
2nd ring:
Type Taper SSS
End gap (installed) 0.30 X 0.45 mm 0.7 mm
Side clearance 0.03 X 0.07 mm 0.12 mm
Oil ring:
End gap (installed) 0.2 X 0.7 mm SSS
Crankshaft:
Crank width “A” 59.95 X 60.00 mm SSS

Runout limit “C” 0.03 mm SSS
Big end side clearance “D” 0.35 X 0.85 mm SSS
2-5

Item Standard Limit

Automatic centrifugal clutch:
Clutch shoe thickness 3.0 mm 2.0 mm
Clutch housing inside diameter 135 mm 135.5 mm
Clutch shoe spring free length 28.1 mm SSS
Weight outside diameter 20 mm 19.5 mm
Clutch – in revolution 2,100 X 2,700 r/min SSS
Clutch – stall revolution 3,700 X 4,700 r/min SSS
V-belt:
V-belt width 22.6 mm 21.0 mm
Carburetor:
Type Y28V-1B-1
I.D. mark 4UC 00 [4UD 00 (CH, A)] SSS
Ventuly outside diameter ø28 SSS
Main jet (M.J) #130 SSS
Main air jet (M.A.J) ø0.9 SSS
Jet needle (J.N) 5D32-3/5 SSS
Throttle valve size (Th.V) 11_ SSS
Pilot air jet (P.A.J.1) ø1.2 SSS
Needle jet (N.J) ø2.585 SSS
Pilot outlet (P.O) ø0.8 SSS
Pilot jet (P.J) #44 SSS
Bypass (B.P) 0.7 4 SSS
Pilot screw (P.S) 17/8 SSS
Valve seat size (V.S) 1.4 SSS
Starter jet 1 (G.S.1) ø0.45 SSS
Starter jet 2 (G.S.2) ø0.5 SSS
Float height (F.H) 27 mm SSS
Engine idle speed 1,450 X 1,550 r/min SSS
Intake vacuum 220 X 260 mmHg SSS
Oil temperature 65 X 75_C SSS
Cooling water temperature 80_C SSS
Fuel pump:
Type Vaccum type SSS
Model/manufacturer 4HC/MIKUNI SSS
Oil pump:
Type Trochoid type SSS
Tip clearance 0.1 X 0.34 mm 0.4 mm
Side clearance 0.013 X 0.036 mm 0.15 mm
Housing and rotor clearance 0.04 X 0.09 mm 0.15 mm
2-6

Item Standard Limit

Radiator:
Type Cooling fin with electric fan SSS
Width/height/thickness 140/238/24 mm SSS
Radiator cap opening pressure 110 X 140 kPa (1.1 X 1.4 kg/cm2,
1.1 X 1.4 bar) SSS
Radiator capacity 1.4 L SSS
Reservoir tank capacity 0.35 L SSS
Thermostatic valve:
Type/manufacturer 4HC/NIHON THERMOSTAT
Valve opening temperature 80.5 X 83.5_C
Valve full open temperature 95_C
Valve full open lift 3 mm
Item Size
Bearings and oil seals:
Big end bearing 32 40 20 (needle bearing)
Crankshaft bearing (left) 6306
Crankshaft bearing (right) 63/28
Crankshaft oil seal (left) SD-30-45-5
Crankshaft oil seal (right) S7-14-27-6
Water pump bearing 6000
Water pump oil seal S-10-21-5
Main axle bearing (left) 15NQ2815
Main axle bearing (right) 15NQ2815
Drive axle bearing (left) 6303
Drive axle bearing (right) 6272
Drive axle oil seal SD8-32-52-7
Camshaft bearing (left) 6005
Camshaft bearing (right) 6202Z
Primary drive gear bearing (left) 6205
Primary drive gear bearing (right) 6302
Primary drive gear oil seal SD8-32-52-7
2-7

TIGHTENING TORQUES
ENGINE
Tightening
Thread torque
g
Part to be tightened Part name Q’ty
y Remarks
size
Nm mSkg
Oil check bolt — M6 1 7 0.7
Exhaust pipe stud bolt — M8 2 13 1.3
Spark plug — M12 1 18 1.8
Cam sprocket cover Bolt M6 2 10 1.0
Cylinder head and cylinder Nut M8 4 22 2.2
Cylinder head and cylinder Bolt M6 2 10 1.0
(Cam chain side)
Valve cover Bolt M6 5 10 1.0
Rotor Nut M16 1 80 8.0
Valve adjuster locknut Nut M6 2 14 1.4
Cam shaft bearing stopper Bolt M6 2 8 0.8
Cam sprocket Bolt M10 1 60 6.0
Cam chain tensioner
(Body) Bolt M6 2 10 1.0
(Plug) Bolt M8 1 8 0.8
Guide stopper 2 Bolt M6 1 10 1.0
Water pump housing cover Bolt M6 3 10 1.0
Hose joint — M6 2 7 0.7
Thermostatic valve cover Bolt M6 2 10 1.0
Filler neck supporting Bolt M5 1 5 0.5
Oil pump Screw M6 2 7 0.7
Oil pump cover Bolt M3 1 1 0.1
Drain plug Bolt M35 1 32 3.2
Carburetor joint Bolt M6 2 10 1.0
Carburetor joint and carburetor Nut M6 2 10 1.0
Air filter assembly Bolt M6 2 7 0.7
Air filter cover Screw M5 5 1 0.1
Fuel pump — M6 2 10 1.0
Exhaust pipe assembly Nut M8 2 20 2.0
Muffler Bolt M10 3 53 5.3
Muffler and exhaust pipe Bolt M8 1 20 2.0
Protector (Muffler) Screw M6 3 10 1.0
Protector (Exhaust pipe) Screw M6 2 10 1.0
Crankcase (left and right) Bolt M6 9 10 1.0
Drain bolt Bolt M8 1 22 2.2
Oil filler Bolt M14 1 3 0.3
Transmission case cover Bolt M8 6 16 1.6
Crankcase cover (left) Bolt M6 11 10 1.0
Crankcase filter cover — M6 3 7 0.7
Crankcase cover protector Bolt M6 2 7 0.7
Magnet cover — M6 10 10 1.0
2-8

Tightening
Thread torque
Part to be tightened
g Part name Q’ty
y Remarks
size
Nm mSkg
Cover (oil pump) Bolt M6 2 12 1.2
Timing check plug Plug M16 1 8 0.8
One way clutch — M8 3 30 3.0
Clutch housing Bolt M14 1 60 6.0
Grease stopper (Primary sheave) — M4 4 3 0.3
Primary fixed sheave — M14 1 60 6.0
Clutch carrier assembly — M36 1 90 9.0
Stator — M5 3 7 0.7
Pick up coil — M5 2 7 0.7
Starter motor Bolt M6 2 10 1.0
Thermo switch — M16 2 23 2.3
Thermo unit — Pt 1/8 1 8 0.8
2-9

CHASSIS
Item Standard Limit

Steering system:
Steering bearing type Ball bearing SSS
Front suspension:
Front fork travel 100 mm SSS
Fork spring free length 265.8 mm 263.5 mm
Spring rate (K1) 5.7 N/mm (0.57 kg/mm) SSS
Stroke (K1) 0 X 100 mm SSS
Oil capacity 0.142 L (142 cm3) SSS
Oil level 80 mm SSS
Oil grade Fork oil 15 WT or equivalent SSS
Inner tube vend limit SSS 0.2 mm
Rear suspension:
Shock absorber stroke 106 mm SSS
Spring free length 265 mm 260 mm
Fitting length 317 mm SSS
Spring rate (K1) 7.7 N/mm (0.77 kg/mm) SSS
(K2) 10.9 N/mm (1.09 kg/mm) SSS
(K3) 17.6 N/mm (1.76 kg/mm) SSS
Stroke (K1) 0 X 40 mm SSS
(K2) 40 X 75 mm SSS
(K3) 75 X 106 mm SSS
Front wheel:
Type Cast wheel SSS
Rim size MT2.75 12 SSS
Rim material Aluminum SSS
Rim runout limit radial SSS 2 mm
Rim runout limit lateral SSS 2 mm
Rear wheel:
Type Cast wheel SSS
Rim size MT3.50 12 SSS
Rim material Aluminum SSS
Rim runout limit radial SSS 2 mm
Rim runout limit lateral SSS 2 mm
Front disc brake:
Type Single SSS
Disc outside diameter thickness 245 4 mm SSS
Pad thickness 5.4 mm 0.8 mm
Master cylinder inside diameter 12.7 mm SSS
Caliper cylinder outside diameter 25.4 + 30.1 mm SSS
Brake fluid type DOT #4 SSS
2-10

Item Standard Limit

Rear drum brake:
Type Leading, trailing SSS
Drum inside diameter 160 mm 161 mm
Shoe thickness 4 mm 2 mm
Brake lever:
Brake lever free play (front at lever side) 2 X 5 mm SSS
Brake lever free play (rear) 10 X 20 mm SSS
Throttle cable free play 3 X 5 mm SSS
Item Size
Bearings and oil seals:
Front wheel bearing (left) 6302RS
Front wheel bearing (right) 6302RS
Front wheel oil seal (left) SD-22-42-7-1
Meter gear oil seal (right) SDD-47-58-7
Rear wheel bearing (left) 6302RS
Rear wheel oil seal (inner) SDO-28-35-4
Rear wheel oil seal (outer) DD-26-42-8
2-11

TIGHTENING TORQUES
CHASSIS
Tightening
Part to be tightened Thread size torque Remarks
Nm mSkg
Frame and engine bracket M12 1.25 59 5.9
Engine bracket, compression rod and engine M10 1.25 32 3.2
Compression rod and frame M10 1.25 64 6.4
Sidestand (bolt and frame) M10 1.25 40 4.0
Sidestand (bolt and nut) M10 1.25 40 4.0
Rear footrest bracket M 6 1.0 7 0.7
Swingarm M 8 1.25 23 2.3
Rear shock absorber and frame M10 1.25 40 4.0
Rear shock absorber and engine M 8 1.25 19 1.9
Steering ring nut M25 1.0 22 2.2 See “NOTE”
Handle holder and steering shaft M20 1.5 139 13.9
Handle upper holder and lower holder M 8 1.25 23 2.3
Brake hose and master cylinder M10 1.25 26 2.6
Fuel tank
(font) M 6 1.0 10 1.0
(rear) M 6 1.0 7 0.7
Fuel cock M 6 1.0 7 0.7
Fuel sender M 5 0.8 3 0.3
Filter M 6 1.0 7 0.7
Roll over valve M 5 0.8 4 0.4
Box M 6 1.0 7 0.7
Handle seat M 6 1.0 10 1.0
Sheet lock assembly M 6 1.0 7 0.7
Plastic parts & cover M 5 1.0 2 0.2
Cowling stay M 8 1.25 16 1.6
Side cover 1 M 6 1.0 7 0.7
Cowling body M 6 1.0 7 0.7
Footrest board M 6 1.0 7 0.7
Headlight assembly M 6 1.0 7 0.7
Tail light assembly M 6 1.0 7 0.7
Front wheel axle and nut M14 1.5 70 7.0
Rear wheel axle and nut M14 1.5 135 13.5
Rear brake cam lever M 6 1.0 10 1.0
Rear pivot pin M10 1.25 32 3.2
Front brake caliper and front fork M10 1.25 49 4.9
Brake disc and hub M 8 1.25 23 2.3
Brake hose and caliper M10 1.25 26 2.6
Brake caliper and bleed screw M 7 1.0 6 0.6
Windscreen M 5 1.0 0.4 0.04
2-12

NOTE:
1. First, tighten the ring nut (lower) approximately 38 Nm (3.8 mSkg) by using the torque wrench, then
loosen the ring nut 1/4 turn.
2. Second, tighten the ring nut (lower) approximately 22 Nm (2.2 mSkg) by using the torque wrench,
then finger tighten the ring nut (center). Align the slots both ring nut and install the lock washer.
3. Final, hold the ring nuts (lower and center) and tighten the ring nut (upper) 75 Nm (7.5 mSkg) by
using the torque wrench.
2-13

ELECTRICAL
Item Standard limit
Ignition timing:
Ignition timing (B.T.D.C.) 10_ at 1,500 r/min SSS
Advanced timing (B.T.D.C.) 32_ at 5,000 r/min SSS
Advanced type Electrical type SSS
T.C.I.:
Pickup coil resistance/color 168 X 252 Ω at 20_C/ SSS
Yellow – Black
T.C.I. unit model/manufacturer J4T069/MITSUBISHI SSS
Ignition coil:
Model/manufacturer F6T507 /MITSUBISHI SSS
Minimum spark gap 6 mm SSS
Primary winding resistance 3.6 X 4.8 Ω at 20_C SSS
Secondary winding resistance 10.7 X 14.5 kΩ at 20_C SSS
Spark plug cap:
Type Resin type SSS
Resistance 5 kΩ SSS
Charging system:
Type A.C. magneto SSS
Model/manufacturer 4HC/MITSUBISHI SSS
Normal output 14 V 16 A at 5,000 r/min SSS
Stator coil resistance/color 0.8 X 1.0 Ω at 20_C/ SSS
White – White
Rectifire/regulator:
Model/manufacturer SH640D-12/SHINDENGEN SSS
No load regulated voltage 14.7 V SSS
Capacity 20 A SSS
Withstand voltage 200 V SSS
Battery:
Specific gravity 1.310 SSS
Electric starter system:
Type Constant mesh type
Starter motor:
Model/manufacturer /ID number SM-13/MITSUBA/SM-13454 SSS
Operation voltage 12 V SSS
Output 0.65 kW SSS
Armature coil resistance 0.0012 X 0.0022 Ω at 20_C SSS
Brush overall length 12.5 mm 4 mm
Brash quantity 2 pcs. SSS
Spring force 570 X 920 g 570 g
Commutator diameter 28 mm 27 mm
Mica undercut (depth) 0.7 mm SSS
2-14

Item Standard limit

Starter relay:
Model/manufacturer 4FL/JIDECO SSS
Amperage rating 100 A SSS
Coil winding resistance 4.2 X 4.6 Ω at 20_C SSS
Horn:
Model/manufacturer YF-12/NIKKO SSS
Maximum amperage 2.5 A SSS
Flasher relay:
Type Full transistor type SSS
Model/manufacturer 4MY/NIPPONDENSO SSS
Flasher frequency 75 X 95 cycle/min SSS
Fuel gage:
Model/manufacturer 4HC/NIPPON SEIKI SSS
Sender unit resistance – full 4 X 10 Ω SSS
Sender unit resistance – empty 90 X 100 Ω SSS
Starting circuit cut-off relay:
Model/manufacturer 4HC/MATSUSHITA SSS
Coil winding resistance 72 X 88 Ω SSS
Electric fan motor:
Model/manufacturer 4HC/MITSUBA SSS
Thermo switch (electric fan):
Model/manufacturer 3LN/NIHON THERMOSTAT SSS
Thermo switch (auto choke):
Model/manufacturer 4HC/NIHON THERMOSTAT SSS
Thermo unit:
Model/manufacturer 2YK/NIPPON SEIKI SSS
Circuit breaker:
Type Fuse SSS
MAIN 20 A 1 pc. SSS
FAN 3A 1 pc. SSS
Reserve 20 A 1 pc. SSS
3A 1 pc. SSS
2-15

GENERAL TORQUE SPECIFICATIONS SPEC
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for standard fasten- General torque
ers with standard I.S.O. pitch threads. Torque A B specifications
specifications for special components or as- (Nut) (Bolt)
Nm mSkg
semblies are included in the applicable sections
of this book. To avoid warpage, tighten multi- 10 mm 6 mm 6 0.6
fastener assemblies in a crisscross fashion, in 12 mm 8 mm 15 1.5
progressive stages, until full torque is reached. 14 mm 10 mm 30 3.0
Unless otherwise specified, torque specifica-
17 mm 12 mm 55 5.5
tions call for clean, dry threads. Components
should be at room temperature. 19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0
A: Distance across flats

B: Outside thread diameter
2-16

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC
LUBRICATION POINT AND GRADE OF LUBRICANT

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

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC
CHASSIS
Lubrication Point Symbol
Front wheel oil seal lips (left/right)
Swingarm oil seal lips (left/right)
Steering head pipe bearing (upper/lower)
Steering head pipe dust seal lips (upper/lower)
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
Brake cam pivot shaft and cam surface
2-18

CABLE ROUTING SPEC
CABLE ROUTING
1 Rectifier regulator 15 Battery negative (–) lead B Pass the seat lock cable
2 Fuel sender 16 Flasher relay through the protection pipe.
3 Fuse (fan) 17 Reservoir tank C Clamp the mainharness and
4 Roll over valve 18 Breather hose radiator over flow hose
5 Ignition coil 19 Air filter together to the frame.
6 Seat lock cable 20 Mainharness D Install the brake hose to the
7 Handlebar switch 3 lead 21 Link (engine bracket) brake caliper with its marking
(right) 22 A.C. magneto lead facing to the tire side.
8 Front brake switch lead 23 Starter motor lead
9 Brake hose 24 Engine earth lead
10 Speedometer cable 25 Mudguard
11 Radiator overflow hose
12 Starter relay / Fuse (main) A Clamp the fuel sender lead
13 Battery and auto choke lead to the
14 Battery positive (+) lead frame.
2-19

CABLE ROUTING SPEC
E Pass the overflow hose from J Keep the clamping clearance
the reservoir tank through the over 5 mm.
clamp inside the frame. (Bend the metal clamp to keep
F Clamp the mainharness, battery the clearance between the
(+) lead and (–) lead to clamp metal clamp and link over
of the frame. 5 mm.)
G Clamp the fuel sender lead to K Install the meter cable with
the pipe. its sheaved side facing to the
H The mainharness connecting meter gear.
to the taillight assembly to L Separate the thermo switch
the frame. lead and ather lead forward
I Connect the taillight inside the frame.
assembly lead to the
mainharness over the
mudguard.
2-20

CABLE ROUTING SPEC
1 Seat lock A Clamp the mainharness and H Clamp the mainharness, A.C.
2 Air filter case sidestand switch lead magneto lead, starter motor
3 Breather hose together the frame. lead and engine earth lead
4 Fuel hose B Clamp the sidestand switch together inside the frame.
5 Vacuum hose lead. I Clamp the A.C. magneto lead,
6 Sidestand switch lead C Install the positive (+) lead starter motor lead and engine
7 Thermo switch lead between the battery and the earth lead to the link.
8 Fan motor lead , starter relay to the starter relay J Pass the breather hose
9 Breather hose along the chassis. through the hole of the air
10 Overflow hose (fuel tank) D Clamp the seat lock cable to filter case.
11 Relay the the frame.
12 Auto choke lead E Clamp the thermo switch lead
13 A.C. magneto lead and fan motor lead the frame.
14 Starter motor lead F Clamp the overflow hose to
15 Engine earth lead the metal clamp on the frame.
16 Protector (pipe) G Put the coupler of the A.C.
17 Seat lock cable magneto lead and the auto
choke lead along the frame
pipe after connection.
2-21

CABLE ROUTING SPEC
1 Front flasher light (right) 15 Brake hose stopper D Do not interfere each other
2 Front flasher light (left) 16 Marking after installing the handlebar
3 Handlebar switch (right) lead upper cover.
4 Front brake switch lead A Clamp the speedometer lead E Pass the handlebar switch
5 Seat lock cable the stay 1. (left) lead and rear brake
6 Throttle cable B Pass the speedometer cable switch lead on the left of the
7 Brake hose and the brake hose through speedometer cable, then
8 Handlebar switch (left) lead the clamps on the frame. connect to the mainharness.
9 Rear brake switch lead (Front : Speedometer cable F Hook the left and right front
10 Handlebar under cover Rear : Brake hose) flasher light leads on the pipe
11 Brake cable 2 C Pass the handlebar switch of stay 1. (Put the leads down
12 Speedometer cable (right) lead and front brake inside of the cowling body
13 Stay 1 switch lead through the plastic after connection.)
14 Horn “U” clamp.
2-22

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

CABLE ROUTING SPEC
1 Fuel overflow hose (filler neck) hose through the “U” clamp H Band the throttle cable to the
2 Throttle cable 1 (nut white) on the holder. frame, noting the band
3 Throttle cable 2 (nut black) C Put the lock of the band to the direction.
4 Air vent hose (carburetor) center from the line “a”.
5 Coolant drain hose D Pass the drain hose through
(carburetor) the clamp (spring hook).
6 Fuel drain hose (carburetor) E Pass the overflow hoses from
7 Fuel overflow hose (fuel tank) the filler neck and the fuel tank
through the clamp.
A Pass the brake cable 2 though F Pass the brake cable 2 through
the holder and clamp to the the guide ring.
crankcase. G Pass the overflow hose from
B Pass the air vent hose, coolant the tank through the
drain hose, and fuel drain clamp inside the frame pipe.
2-24

CABLE ROUTING SPEC
1 Steering head pipe downtube, noting the band I Pass the brake cable through
2 Brake cable 2 direction. (view B) the guide ring.
3 Mainharness D Band the brake cable 2 to the J Pass the brake cable 2 through
4 Downtube frame at the upper part of the the guide on the frame.
5 Throttle cable radiator, noting the band K Clamp the brake cable 2 to the
6 Radiator direction. (view C) frame.
7 Stay 1 E Band the brake cable 2 at the (Up and down)
left front of the steering head Align the locating mark of the
A Pass the brake cable 2 though pipe and set the rest of the brake cable 2 with the under
the clamp on the handlebar band to the left. clamp.
holder. F Set the lock of the band in this
B Band the brake cable 2 to the range.
steering head pipe, noting the G Clamp the brake cable in front
band direction. (view A) of the pipe.
C Band the throttle cable and the H Put the rest of the band end to
right mainharness to the the side.
2-25

SPEC

CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 3-1
COVER AND PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
TAIL COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
FOOTREST BOARD AND LOWER COVER . . . . . . . . . . . . . . . . . . . . 3-6
COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
HANDLE COVER, METER ASSEMBLY AND LEGSHIELD . . . . . . . 3-8
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
IDLING SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . 3-14
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
RECOMMENDED ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
ENGINE OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 3-17
TRANSMISSION OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 3-18
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
CRANKCASE FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
COOLING SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) . . . . . . . . . . . . . . . 3-28
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
BRAKE SHOE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
SWINGARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
REAR SHOCK ABSORBER INSPECTION . . . . . . . . . . . . . . . . . . . . . 3-33
REAR SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 3-33
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

INTRODUCTION / INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-
tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-
tion 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.
YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
BREAK-IN EVERY
NO. ITEM ROUTINE TYPE 6,000 km 12,000 km

1,000 km or or
6 months 12 months
Check and adjust valve clearance
1 * Valve clearance — Every 12,000 km
when engine is coled
Check condition. Refer to
2 Spark plug SPARK PLUG
Adjust gap and clean. INSPECTION
Check fuel hose and vacuum pipe

3 * Fuel line —
for cracks or damage.
Check and adjust engine idle
4 * Idle speed speed. —
Adjust throttle cable free play.
5 * Engine oil Replace. Refer to ENGINE
OIL INSPECTION Replace Replace every 3,000 km.
6 Oil strainer Clean with solvent. — Clean Clean every 3,000 km.
7 Transmission oil Replace. Same as
engine oil Replace Replace every 10,000 km.
Clean with solvent and dampen Same as

8 Air filter engine oil

with oil.
9 Crankcase filter Clean with compressed air —
Check hose for cracks or damage.
—
10 Cooling system Replace if necessary.
Ethylene glycol
Replace coolant. antifreeze Replace every 24 months.
Adjust free play.
Front Check and replace if necessary. Brake fluid;
11 *
brake system Replace brake fluid every DOT 4
24,000km or 24 months.
Adjust lever free play.
Rear
12 * Check and replace shoes —
brake system
if necessary.
13 * Control cables Apply oil lightly. Same as
engine oil
14 Brake laver pivot Apply oil lightly. Same as
engine oil
3-1

INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
BREAK-IN EVERY
6,000 km 12,000 km
NO. ITEM ROUTINE TYPE
1,000 km or or
6 months 12 month
Centerstand and Same as
15 Check operation and lubricate.
sidestand pivot engine oil
Check and clean or replace
16 * Sidestand switch —
if necessary.
Check operation and for
17 * Front fork —
oil leakage.
Steering Check bearing assembly
18 * —
bearings for looseness.
19 * Wheel bearings Check bearing for smooth rotation —
Items marked with an asterisk (*) require special tools data and technical skills for servicing. Take the
scooter to a Yamaha dealer.
NOTE:
The air filter needs 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.
Check the brake fluid level and add fluid as required.
2. Replace the master cylinder and caliper cylinder oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
3-2

INSP
COVER AND PANEL ADJ
COVER AND PANEL
SIDE PANEL AND SEAT
Order Job name/Part name Q’ty Remarks

Side panel and seat removal Remove the parts in order.
1 Rear panel 1
2 Side panel (left) 1
3 Side panel (right) 1
4 Rivet 2
5 Front panel 1
6 Clip 2 NOTE:
7 Damper assembly 1 Install the damper assembly to the body
with its rod side backward and labels up-
ward.
8 Seat 1
Reverse the removal procedure for

installation.
3-3

INSP
COVER AND PANEL ADJ
TAIL COVER AND FUEL TANK
10 Nm (1.0 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)

Tail cover and fuel tank removal Remove the parts in order.
1 Grab bar 1
2 Seat lock bracket 1
Tail cover
3 Screw 2
4 Tail cover 1
5 Fuel tank cap 1
6 Fuel overflow hose 1
7 Cover 1 Fuel tank
8 Fuel tank cover 1 NOTE:
9 Coupler (fuel sender lead) 1 Disconnect the couplers.
10 Fuel overflow hose 1

11 Fuel hose 1
3-4

INSP
COVER AND PANEL ADJ
10 Nm (1.0 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)

12 Vacuum hose 1
13 Bracket 1 Fuel tank
14 Fuel tank 1
installation.
3-5

INSP
COVER AND PANEL ADJ
FOOTREST BOARD AND LOWER COVER
7 Nm (0.7 mkg)

Footrest board and lower cover Remove the parts in order.
removal
1 Mat (footrest board) (left/right) 1/1
2 Cover 2 1
3 Battery negative (-) lead 1
4 Battery positive (+) lead 1
5 Battery 1
6 Flasher relay 1
7 Starter relay 1
8 Reservoir tank 1
9 Footrest 2
10 Lid 1
11 Box 1
12 Lower cover 1
13 Footrest board 1 Reverse the removal procedure for
installation.
3-6

INSP
COVER AND PANEL ADJ
COWLING
7 Nm (0.7 mkg) 7 Nm (0.7 mkg)

Cowling removal Remove the parts in order.
1 Upper cover
2 Wind screen 1
3 Inner panel 1
4 Cowling body 1
5 Coupler (headlight lead) 1 NOTE:
6 Coupler (front flasher light lead (left)) 1 Disconnect the couplers.
7 Coupler (front flasher light lead (right)) 1
installation.
3-7

INSP
COVER AND PANEL ADJ
HANDLE COVER, METER ASSEMBLY AND LEGSHIELD

Handle cover, meter assembly and Remove the parts in order.
legshield removal
1 Handle cover 1 NOTE:
2 Coupler (meter lead) 1 Disconnect the couplers.
3 Meter cable 1
4 Meter assembly 2
5 Main switch cover 1
6 Cover 2
7 Legshield 1
installation.
3-8

INSP
VALVE CLEARANCE ADJUSTMENT ADJ
YP303004
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
Valve clearance adjustment should be made
with the engine cool, at room temperature.
When the valve clearance is to be measured or
adjusted, the piston must be at Top Dead Cen-
ter (T.D.C.) on the compression stroke.
1. Remove:
Side panels
Tail cover
Fuel tank
Refer to “COVER AND PANEL” section.
2. Remove:
Crankcase filter cover 1
Crankcase filter cover seal
Crankcase filter element 2
3. Remove:
Spark plug
Valve cover (intake side)
Valve cover (exhaust side)
4. Remove:
Timing check plug
5. Measure:
Valve clearance
Out of specification Adjust.
Valve clearance (cold):

Intake valve 0.08 0.12 mm
Exhaust valve 0.16 0.20 mm
*****************************************************
Measurement steps:
Rotate the primary fixed sheave counter-
clockwise to align the slit a on the rotor with
the stationary pointer b on the crankcover 1
when the piston is Top Dead Center (TDC).
Measure the valve clearance by using a feel-
er gauge.
Out of specification Adjust clearance.
*****************************************************
3-9

VALVE CLEARANCE ADJUSTMENT/ INSP
IDLING SPEED ADJUSTMENT ADJ
6. Adjust:
D Valve clearance
*****************************************************
Adjustment steps:
D Loosen the locknut 1 .
D Turn the adjuster 3 in or out with the valve
adjusting tool 2 until specified clearance is
obtained.
Turning in Valve clearance is

decreased.
Turning out Valve clearance is
increased.
Valve adjusting tool:

90890-01311
D Hold the adjuster to prevent it from moving

and tighten the locknut.
14 Nm (1.4 mSkg)
D Measure the valve clearance.

D If the clearance is incorrect, repeat above
steps until specified clearance is obtained.
*****************************************************
7. Install:
D Valve cover (intake side) 1 10 Nm (1.0 mSkg)
D O-ring 2
8. Install:
D Valve cover (exhaust side)
10 Nm (1.0 mSkg)
D O-ring
D Spark plug 18 Nm (1.8 mSkg)
D Timing check window screw

D Crankcase filter element
D Crankcase filter cover seal
D Crankcase filter cover 7 Nm (0.7 mSkg)
YP303022
IDLING SPEED ADJUSTMENT

1. Start the engine and let it warm up for sev-
eral minutes.
2. Attach:
D Inductive tachometer to the spark plug
lead.
Inductive tachometer:
90890-03113
3-10

IDLING SPEED ADJUSTMENT/ INSP
THROTTLE CABLE ADJUSTMENT ADJ
3. Check:
Engine idling speed
Engine idling speed:

1,450 1,550 r/min
4. Adjust:
Engine idle speed
*****************************************************
Adjustment steps:
Turn the pilot screw 1 until it is lightly seated.
Turn the pilot screw out by the specified num-
ber of turns.
Pilot screw:
1-7/8 turns out
Turn the throttle stop screw 2 in or out until

the specified idling speed is obtained.
Turning in Idling speed is increased.

Turning out Idling speed is decreased.
*****************************************************
5. Adjust:
Throttle cable free play
Refer to “THROTTLE CABLE FREE
PLAY ADJUSTMENT” section.
YP303032
THROTTLE CABLE ADJUSTMENT

NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted.
1. Check:
Throttle cable free play a
Free play (throttle cable):

3 5 mm at throttle grip flange
2. Adjust:
Throttle cable free play
*************************************
Adjustment steps:
NOTE:
Never accelerate the throttle when stopping the
engine.
3-11

THROTTLE CABLE ADJUSTMENT/ INSP
SPARK PLUG INSPECTION ADJ
Loosen the locknut 1 on the throttle cable.
Turn the adjuster 2 in or out until specified
free play is obtained.
Turning in Free play is increased.

Turning out Free play is decreased.
Tighten the locknut.
After adjusting, turn the handlebar to the

right and to the left to ensure that this does
not cause the engine idling speed to
change.
*****************************************************
EB303040
SPARK PLUG INSPECTION

1. Remove:
Spark plug cap
Spark plug
CAUTION:
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinder.
1. Check:
Spark plug type
Incorrect Replace.
Standard spark plug:

DR8EA (NGK)
2. Inspect:
Electrode 1
Wear/damage Replace.
Insulator 2
Abnormal color Replace.
Normal color is a medium-to-light tan col-
or.
2. Clean:
Spark plug
(with spark plug cleaner or wire brush)
3. Measure:
Spark plug gap a
(with a wire gauge)
Out of specification Adjust gap.
3-12

SPARK PLUG INSPECTION/ INSP
IGNITION TIMING CHECK ADJ
Spark plug gap:
0.6 0.7 mm
6. Install:
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
YP303052
IGNITION TIMING CHECK

NOTE:
Prior to checking the ignition timing, check all
electrical connections related to the ignition
system. Make sure all connections are tight and
free of corrosion and that all ground connec-
tions are tight.
1. Remove:
D Timing check plug
2. Attach:
D Timing light 1
Engine tachometer 2
(to the spark plug lead)
Timing light:
90890-03141
Engine tachometer:
90890-03113
3. Check:
D Ignition timing
*****************************************************
Checking steps:
D Start the engine and let it warm up for several
minutes. Let the engine run at the specified
speed.
Engine idling speed:

1,450 1,550 r/min
D Visually check the stationary pointer a to

verify it is within the required firing range b
indicated on the flywheel.
Incorrect firing range Check the ignition
system.
*****************************************************
3-13

IGNITION TIMING CHECK/ INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
NOTE:
Ignition timing is not adjustable.
3. Install:
Timing check plug
YP303060
COMPRESSION PRESSURE
MEASUREMENT
NOTE:
Insufficient compression pressure will result in
performance loss.
1. Remove:
Side panels
2. Check:
Valve clearance
Refer to “VALVE CLEARANCE AD-
JUSTMENT” section.
eral minutes.
4. Turn off the engine.
5. Remove:
Spark plug
CAUTION:
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug well to prevent it from
falling into the cylinder.
6. Attach:
Compression gauge 1
Compression gauge:
90890-03081
7. Measure:
Compression pressure
If it exceeds the maximum pressure al-
lowed Inspect the cylinder head, valve
surfaces and piston crown for carbon de-
posits.
If it is below the minimum pressure
Squirt a few drops of oil into the affected
cylinder and measure again.
Follow the table below.
3-14

COMPRESSION PRESSURE MEASUREMENT/ INSP
ENGINE OIL REPLACEMENT ADJ
p
Compression p
pressure
(With oil applied into cylinder)
Reading Diagnosis
Higher than
Worn or damaged pistons
without oil
Possible defective ring(s),
Same as valves,
without oil cylinder head gasket or
piston Repair.
Compression pressure (at sea level):

Standard:
1,400 kPa (14 kg/cm2, 14 bar)
Minimum:
1,120 kPa (11.2 kg/cm2, 11.2 bar)
*****************************************************
Measurement steps:
D Crank the engine with the throttle wideopen
until the reading on the compression gauge
stabilizes.
Before cranking the engine, ground all

spark plug leads to prevent sparking.
*****************************************************
8. Install:
9. Install:
D Side panels
YP303070
ENGINE OIL LEVEL INSPECTION

1. Stand the scooter on a level surface.
NOTE:
Make sure the scooter is upright when inspect-
ing the oil level.
2. Start the engine and let it warm up for a few

minutes.
4. Inspect:
D Engine oil level
Oil level should be between maximum 1
and minimum 2 marks.
Oil level is below the minimum mark
Add oil up to the proper level.
3-15

ENGINE OIL LEVEL INSPECTION/ INSP
ENGINE OIL REPLACEMENT ADJ
RECOMMENDED ENGINE OIL
Refer to the chart for selection of the oils suited
to the atomosperic temperature.
API STANDARD:
API SE or higher grade
CAUTION:
D Do not put in any chemical sdditives or
use oils with a grade of CD a or higher.
D Be sure not to use oils labeled “ENERGY
CONSERVING II” b or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
D Be sure no foreign material enters the
crankcase.
5. Start the engine and let it warm up for a few

minutes.
NOTE:
Wait a few minutes until the oil settles before in-
specting the oil level.
YP*****
ENGINE OIL REPLACEMENT

eral minutes.
2. Turn off the engine and place an oil pan un-
der the engine.
3. Remove:
D Oil filler plug
D Drain plug 1
D Compression spring 2
D Oil strainer 3
D O-ring
Drain the crankcase of its oil.
4. Install:
D O-ring 1
D Oil strainer 3
D Drain plug 4 32 Nm (3.2 mSkg)
D Oil filler plug

NOTE:
Check the O-ring (drain plug). If damaged, re-
place it with a new one.
3-16

ENGINE OIL REPLACEMENT/ INSP
ENGINE OIL PRESSURE INSPECTION ADJ
5. Fill:
Crankcase
Oil quantity:
1.4L
6. Check:
Engine oil level
Refer to “ENGINE OIL LEVEL INSPEC-
TION” section.
7. Reset:
Engine oil warning circuit
*****************************************************
Resetting steps:
Turn the main switch to on.
Push and hold in the reset button for 2 to 5
seconds.
Release the reset button 1 and the oil in-
dicator light will go off.
NOTE:
If the oil is changed before the oil indicator light
comes on (i.e. before the 3,000 km oil change
interval is reached), be sure to reset the oil indi-
cator light after changing the oil, so that it will
come on at the correct time to indicate the next
3,000 km oil replacement.
To reset the oil indicator light before it comes on:
Release the reset button and the oil indicator
light will come on for 1.4 seconds.
*************************************
YP*****
ENGINE OIL PRESSURE INSPECTION

1. Remove:
Side panels
Refer to the “COVER AND PANEL” sec-
tion.
2. Inspect:
Oil pressure
*****************************************************
Inspection steps:
Slightly loosen the oil check bolt 1 .
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.
Check oil passages and oil pump for damage
or leakage.
3-17

ENGINE OIL PRESSURE INSPECTION/ INSP
TRANSMISSION OIL REPLACEMENT ADJ
D Start the engine after solving the problem(s),
and recheck the oil pressure.
D Tighten the oil check bolt to specification.
10 Nm (1.0 mSkg)
CAUTION:
D Start the engine and check the oil pres-
sure with the oil check bolt loosened.
D Do not apply at high speeds more than
specified when checking the pressure.
NOTE:
Wipe any spilled oil off the engine.
*****************************************************
YP******
TRANSMISSION OIL REPLACEMENT

NOTE:
Make sure the scooter is upright when replacing
the oil.

2. Start the engine for several minutes to
warm it up and then stop.
3. Place an oil pan under the crankcase.
4. Remove:
D Oil filler cap
D Drain bolt 1
Drain the oil.
5. Tighten:
D Drain bolt 22 Nm (2.2 mSkg)
6. Fill:
D Crankcase
Recommended oil:
SAE 10W30 motor oil
Oil quantity:
0.25 L
CAUTION:
Wipe any spilled oil off the tire or the wheel.
3-18

TRANSMISSION OIL REPLACEMENT/ INSP
EXHAUST SYSTEM INSPECTION/AIR FILTER CLEANING ADJ
7. Install:
D Oil filler cap 1
D O-ring 2
8. Start the engine for several minutes to
warm it up and check for the oil leakage.
YP*****
EXHAUST SYSTEM INSPECTION

1. Remove:
D Side panels
2. Inspect:
D Nut 1 (exhaust pipe) 20 Nm (2.0 mSkg)
Loose/Damage Tighten/replace.
D Gasket (exhaust pipe)
Exhaust gas leaks Tighten/replace.
3. Inspect:
D Bolt 2 (muffler) 53 Nm (5.3 mSkg)
D Connecting bolt 3 (muffler)

20 Nm (2.0 mSkg)
Loose/Damage Tighten/replace.
YP303123
AIR FILTER CLEANING

1. Remove:
D Side panels
D Air filter case cover
2. Remove:
D Air filter element 1
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the filter element will also affect the
carburetor tuning, leading to poor engine
performance and possible overheating.
3-19

AIR FILTER CLEANING/ INSP
CRANKCASE FILTER CLEANING ADJ
3. Inspect:
D Air filter element
Damaged Replace.
4. Clean:
D Air filter element 1
Use solvent to clean the element
NOTE:
After cleaning, remove the remaining solvent by
squeezing the element.
CAUTION:
Do not twist the element when squeezing
the element.
5. Apply the recommended oil to the entire

surface of the filter and squeeze out the ex-
cess oil. The element should be wet but not
dripping.
Recommended oil:
Engine oil
Never use low flash point solvents such as

gasoline to clean the air filter element. Such
solvents may cause a fire or an explosion.
6. Install:
D Air filter element
D Air filter case cover 7 Nm (0.7 mSkg)
D Side panels
Refer to “ENGINE REMOVAL” section in
chapter 4.
YP******
CRANKCASE FILTER CLEANING

1. Remove:
D Crankcase filter cover 1
D Crankcase filter element 2
NOTE:
When installing the element in its case, besure
its sealing surface matches the sealing surface
of the case so there is no air leak.
2. Inspect:
Damaged Replace.
3-20

CRANKCASE FILTER CLEANING/ INSP
COOLANT LEVEL INSPECTION ADJ
CAUTION:
This element is a dry type.
Be careful not to stain with grease or water.
3. Clean:
D Crankcase filter element 1
Blow out the dust in the element from the
outer surface using compressed air.
4. Install:
D Crankcase filter cover 7 Nm (0.7 mSkg)
YP303170
COOLANT LEVEL INSPECTION

NOTE:
ing the coolant level.

2. Stand the scooter on its centerstand.
3. Inspect:
D Coolant level
Coolant level should be between the
maximum a and minimum b marks
Coolant level is below the “LOWER” level
line Add soft water (tap water) up to
the proper level.
CAUTION:
Hard water or salt water is harmful to engine
parts. Use only distilled water if soft water is
not available. If you use tap water, make sure
it is soft water.

eral minutes.
5. Turn off the engine and inspect the coolant
level again.
NOTE:
Wait a few minutes until the coolant settles be-
fore inspecting the coolant level.
3-21

INSP
COOLANT REPLACEMENT ADJ
YP303180
COOLANT REPLACEMENT
1. Remove:
Side panels
Fuel tank
Refer to the “COVERS AND PANEL”
section.
2. Remove:
Hose 1 (reservoir tank)
Drain the reservoir tank of its coolant.
3. Remove:
Drain bolt 1
Radiator cap
Open the front trunk, remove the cover,
slowly loosen to remove the radiator cap
and drain the coolant.
Do not remove the radiator cap when the en-

gine and radiator are hot. Scalding hot fluid
and steam may be blown out under pres-
sure, which could cause serious injury.
When the engine has cooled, open the radia-
tor cap as follows:
Place a thick rag or a towel over the radiator
cap. Slowly rotate the cap counterclockwise
toward the detent. This allows any residual
pressure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
NOTE:
Remove the radiator cap after removing the
drain bolt.
Place the scooter upright on a level surface
when draining the coolant completely.
4. Clean:
Radiator
Fill soft water into the filler neck support
1 (reservoir tank).
3-22

INSP
5. Install:
D Gasket 1
D Drain bolt 2 10 Nm (1.0 mSkg)
6. Loosen:
D Screw 1 (carburetor bleed)
7. Connect:
D Hose (reservoir tank)
8. Fill:
D Radiator
(to specified level 1 )
Fill the coolant slowly, until the coolant
comes out from the carburetor drain
pipe.
D Reservoir tank
(to maximum level a )
Recommended coolant:
High quality ethylene glycol
anti-freeze containing
corrosion inhibitors for
aluminium engine.
Coolant 2 and water 3 (soft

water):
Mixed ratio: 50%/50%
Total amount:
1.4 L
Reservoir tank capacity:
0.35 L
*****************************************************
Handling notes for coolant:
Coolant is potentially harmful and should be
handled with special care.
3-23

INSP
If coolant splashes in your eyes:

thoroughly wash your eyes with water
and consult a doctor.
If coolant splashes on your clothes:
quickly wash it away with water and then
with soap and water.
If coolant is swallowed:
quickly make the person who has swal-
lowed it vomit and then take him to a doc-
tor.
*****************************************************
CAUTION:
Hard water or salt water is harmful to en-
gine parts. Use only distilled water if soft
water is not available.
If you use tap water, make sure it is soft
water.
Do not use water containing impurities or
oil.
Take care that no coolant splashes onto
painted surfaces. If it does, wash them
straightaway with water.
Do not mix different types of ethylene gly-
col antifreeze containing corrosion inhib-
itors for aluminum engines.
9. Tighten:
Screw (carburetor bleed)
Fill the coolant slowly to the specified lev-
el.
10. Install:
Radiator cap
eral minutes.
12. Stop the engine and inspect the level.
Refer to “COOLANT LEVEL INSPECTION”
section.
NOTE:
Wait a few minutes until the coolant settles be-
fore inspecting the coolant level.
13. Install:
Fuel tank
Side panels
3-24

INSP
COOLING SYSTEM INSPECTION ADJ
YP303190
COOLING SYSTEM INSPECTION

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

INSP
FRONT BRAKE ADJUSTMENT ADJ
EB304002
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:
Brake lever free play a
Free play (brake lever):

2 5 mm (at brake lever end)
2. Adjust:
Brake lever free play
*****************************************************
Adjustment steps:
Loosen the locknut 2 .
Turn the adjuster 3 in or out until the speci-
fied free play is obtained.
Turning in Free play is decreased.

Turning out Free play is increased.
Tighten the locknut.

CAUTION:
Make sure that there is no brake drag after
adjusting the front brake lever free play.
A soft or spongy feeling in the brake lever

can indicate the presence of air in the brake
system. This air must be removed by bleed-
ing the brake system before the motorcycle
is operated. Air in the brake system will con-
siderably reduce braking performance and
could result in loss of control and possibly
an accident. Inspect and bleed the brake
system if necessary.
***************************************************
3-26

INSP
BRAKE FLUID LEVEL INSPECTION ADJ
YP304020
BRAKE FLUID LEVEL INSPECTION

NOTE:
ing the brake fluid level.
2. Stand the scooter on its centerstand.

3. Inspect:
Brake fluid level
Brake fluid level is below the “LOWER”
level line a Fill to proper level.
Recommended brake fluid:

DOT#4
NOTE:
For a correct reading of the brake fluid level,
make sure the top of the handlebar brake
fluid reservoir is horizontal.
If DOT#4 is not available, DOT#3 can be
used.
CAUTION:
Brake fluid may corrode painted surfaces or
plastic parts. Always clean up any split fluid im-
mediately.
Use only the designated brake fluid. Other

fluids may deteriorate the rubber seals,
causing leakage and poor brake perfor-
mance.
Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical
reaction leading to poor brake perfor-
mance.
Be careful that water does not enter the
brake fluid reservoir during refilling. Wa-
ter will significantly lower the boiling
point of the fluid and may cause vapor
lock.
3-27

BRAKE PAD INSPECTION/ INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ADJ
YP304030
BRAKE PAD INSPECTION

1. Operate the brake lever.
2. Inspect:
Brake pad (front)
Wear indicators 1 almost touch the
brake disc Replace the brake pads as
a set.
Refer to “FRONT AND REAR BRAKE” in
CHAPTER 7.
YP304070
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
Bleed the brake system whenever:

The system is disassembled
A brake hose is loosened or removed
The brake fluid level is very low
Brake operation is faulty
Loss of braking performance may occur if
the brake system is not properly bled.
1. Bleed:
Brake system
*****************************************************
Air bleeding steps:
a. Fill the reservoir with the proper brake fluid.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2 .
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.
i. Repeat steps (e) to (h) until all air bubbles
have disappeared from the brake fluid.
3-28

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP
REAR BRAKE ADJUSTMENT ADJ
NOTE:
When bleeding the brake system, make sure
that there is always enough brake fluid in the
brake fluid reservoir before applying the brake
lever. Ignoring this precaution could allow air to
enter the brake system, considerably lengthen-
ing the bleeding procedure.
j. Tighten the bleed screw.

D Bleed screw 6 Nm (0.6 mSkg)
NOTE:
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
brake system have disappeared.
k. Fill the brake fluid reservoir to the proper

level.
Refer to “BRAKE FLUID LEVEL IN-
SPECTION”.
Check brake operation after bleeding the brake

system.
*****************************************************
YP******
REAR BRAKE ADJUSTMENT

1. Check:
D Brake lever free play 1 (rear)
Free play:
10 20 mm
2. Adjust:
D Brake lever free play
*****************************************************
Adjustment steps:
Handlebar side:
D Loosen the locknut (s) 1 .
D Turn the adjuster (s) 2 in or out until the spe-
cified free play is obtained.
Turning in Free play is increased.

Turning out Free play is decreased.
3-29

REAR BRAKE ADJUSTMENT/ INSP
BRAKE SHOE INSPECTION/STEERING HEAD INSPECTION ADJ
Tighten the locknut (s).
Rear wheel side:
Turn the adjuster 3 in or out until the speci-
fied free play is obtained.
Turning in Free play is decreased.

Turning out Free play is increased.
CAUTION:
Make sure that the brake does not drag after
adjusting it.
*****************************************************
YP304040
BRAKE SHOE INSPECTION

1. Operate the brake lever.
2. Inspect:
Brake shoes
Wear indicator 1 reaches the wear limit
line 2 Replace the brake shoes as a
set.
Refer to “REAR WHEEL” in CHAPTER
6.
YP304130
STEERING HEAD INSPECTION
Securely support the scooter so that there is no

danger of it falling over.

NOTE:
Stand the scooter on its centerstand.
2. Elevate the front wheel by placing a suit-

able stand under the engine.
3. Check:
Steering assembly bearings
Grasp the bottom of the lower front fork
tubes and gently rock the fork assembly.
Looseness Adjust the steering head.
4. Remove:
Handlebar cover
Handlebar
Refer to “HANDLEBAR” section in chap-
ter 7.
3-30

INSP
STEERING HEAD INSPECTION ADJ
5. Remove:
D Handlebar lower holder
D Woodruff key
Refer to “STEERING” section in chapter
7.
6. Adjust:
D Steering head
*****************************************************
Adjustment steps:
D Remove the ring nut (upper) 1 , lock washer
2 , the ring nut (center) 3 and the rubber
washer.
D Loosen the ring nut 4 (lower).
D Tighten the ring nut (lower) using the ring nut
wrench 5 . 38 Nm (3.8 mSkg)
NOTE:
Set the torque wrench at right angles to the ring
nut wrench.
Ring nut wrench:

90890-01403
D Loosen the ring nut (lower) 4 completely,

then tighten it to specification.
22 Nm (2.2 mSkg)
Do not overtighten.
D Check the steering head for looseness or

binding by turning it all the way in both direc-
tions. If it binds, remove the steering stem as-
sembly and inspect the steering bearings.
Refer to “STEERING HEAD” in CHAPTER 7.
D Install the rubber washer.
D Install the ring nut (center) 2 .
D Finger tighten the ring nut (center), then align
the slots of both ring nuts. If necessary, hold
the ring nut (lower) 1 and tighten the ring nut
(center) 2 until their slots are aligned.
3-31

STEERING HEAD INSPECTION/ INSP
FRONT FORK INSPECTION ADJ
D Install the lock washer 1 .
NOTE:
Make sure the lock washer tabs sit correctly in
the ring nut slots.
D Hold the ring nut (under and center), using

the exhaust and ring nut wrench, and tighten
the ring nut (upper) using the ring nut wrench.
75 Nm (7.5 mSkg)
Exhaust and ring nut wrench:

90890-01268
*****************************************************
8. Install:
D Woodruff key
D Handlebar lower holder
Refer to “STEERING” section in CHAP-
TER 7.
D Handlebar
Refer to “HANDLEBER” section in
CHAPTER 7.
9. Install:
D Handlebar cover
YP304140
FRONT FORK INSPECTION
Securely support the scooter so that there is no


2. Check:
D Inner tube
Scratches/damage Replace.
D Oil seal
Excessive oil leakage Replace.
Hold the scooter upright and apply the
front brake.
3. Check:
D Operation
Push down hard on the handlebars sev-
eral times.
Unsmooth operation Repair.
Refer to “FRONT FORK” in CHAPTER 7.
3-32

SWINGARM INSPECTION/
REAR SHOCK ABSORBER INSPECTION/ INSP
REAR SHOCK ABSORBER ADJUSTMENT ADJ
YP*****
SWINGARM INSPECTION
Securely support the scooter so there is no

1. Place the scooter on the level place.

2. Check:
D Operation
Grasp the end of the swingarm and gent-
ly rock the swingarm assembly back and
forth.
Unsmooth operation Repair.
Refer to “REAR SHOCK ABSORBER
AND SWINGARM” section in CHAPTER
7.
YP******
REAR SHOCK ABSORBER INSPECTION

1. Remove:
D Side panel
D Fuel tank
D Box
2. Check:
D Rear shock absorber mount
Looseness Tighten.
Bolt (upper) 1 40 Nm (4.0 mSkg)
Bolt (lower) 2 16 Nm (1.6 mSkg)
Refer to “REAR SHOCK ABSORBER

AND SWINGARM” section in chapter 7.
YP304160
REAR SHOCK ABSORBER ADJUSTMENT
D Always adjust each rear shock absorber

preload to the same setting. Uneven ad-
justment can cause poor handling and
loss of stability.
D Securely support the scooter so there is
no danger of it falling over.
1. Adjust:
D Spring preload
Turn the adjuster ring 1 to direction a
or b .
NOTE:
Use the special wrench included in the owner’s
tool kit to adjust the spring preload.
3-33

REAR SHOCK ABSORBER ADJUSTMENT/ INSP
TIRE INSPECTION ADJ
*****************************************************
Adjustment steps:
Turn the adjuster ring in or out.
Turning toward a Spring preload is

increased.
Turning toward b Spring preload is
decreased.
Hard Standard Soft

Adjusting
5 4 3 2 1
position:
CAUTION:
Never turn the adjuster beyond the maximum
or minimum setting.
Always adjust each shock absorber to the
same setting.
*****************************************************
EB304171
TIRE INSPECTION
1. Measure:
Tire inflation pressure
Tire inflation pressure should only be

checked and adjusted when the tire tem-
perature equals the ambient air tempera-
ture. Tire inflation pressure and suspen-
sion must be adjusted according to the
total weight of the cargo, rider, passenger
and accessories (fairing, saddlebags, etc.
if approved for this model), and according
to whether the scooter will be operated at
high speed or not.
NEVER OVERLOAD THE SCOOTER.
Operation of an overloaded scooter could
cause tire damage, accident or injury.
3-34

INSP
TIRE INSPECTION ADJ
Basic weight:
With oil and 158 kg
full fuel tank
Maximum load* 197 kg
Cold tire pressure Front Rear
175 kPa 200 kPa
Up to 90 kg load*
(1.75 kg/cm2, 1.75 bar) (2.0 kg / cm2, 2.0 bar)
90 kg 200 kPa 225 kPa

maximum. load* (2.0 kg / cm2, 2.0 bar) (2.25 kg/cm2, 2.25 bar)
High speed 200 kPa 250 kPa

riding (2.0 kg / cm2, 2.0 bar) (2.50 kg/cm2, 2.50 bar)
* Load is the total weight of the cargo, rider,

passenger and accessories.
2. Inspect:
Tire surfaces
Minimum tire tread depth

(front and rear):
1.6 mm
1 Tread depth
2 Side wall
3 Wear indicator
It is dangerous to ride with a worn-out tire.

When the tire tread begins to show signs
of wear, replace the tire immediately.
Do not use tubeless tires on a wheel de-
signed for tube type tires only. Tire failure
and personal injury may result from sud-
den deflation.
Tube type wheel Tube type tire only
Tubeless type wheel Tube type or
tubeless tire.
Be sure to install the correct tube when
using tube type tires.
After extensive tests, the tires listed be-
low have been approved by Yamaha Mo-
tor Co., Ltd. for this model. No guarantee
concerning handling characteristics can
be given if a tire combination other than
one approved by Yamaha is used on this
scooter. The front and rear tires should
always be by the same manufacturer and
of the same design.
3-35

INSP
TIRE INSPECTION/WHEEL INSPECTION ADJ
FRONT:
Manufacture Size Type
IRC 110 / 90-12 64J MB61
CHENG SHIN 110 / 90-12 64J C922
REAR:
Manufacture Size Type
IRC 130 / 70-12 62L MB61
CHENG SHIN 130 / 70-12 62L C940
After mounting a tire, ride conservatively for

a while to give the tire time to seat itself
properly in the rim. Failure to do so could
lead to an accident with possible injury to
the rider or damage to the scooter.
2. After a tire repair or replacement, besure to

tighten the valve stem locknut 1 to specifi-
cation.
EB304180
WHEEL INSPECTION
1. Inspect:
Wheels
Damage/Bends Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
Never attempt to make any repairs to the

wheel.
3-36

INSP
BATTERY INSPECTION ADJ
YP305000
ELECTRICAL
BATTERY INSPECTION
NOTE:
Since the MF battery is a sealed type battery, it
is not possible to measure the specific gravity of
the electrolyte in order to check the charge state
of the battery. Therefore the charge of the bat-
tery has to be checked by measuring the volt-
age at the battery terminals.
CAUTION:
CHARGING METHOD
This is a sealed type battery. Never re-
move the sealing caps. If the sealing caps
have been removed, the balance will not
be maintained and battery performance
will deteriorate.
Charging time, charging current and
charging voltage for the MF battery are
different from those of batterie of general
type.
The MF battery should be charged as ex-
plained in “CHARGING METHOD”. if the
battery is overcharged, the electrolyte
level will drop considerably. Therefore,
take special care when charging the bat-
tery.
Battery electrolyte is dangerous; it contains

sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive mea-
sures:
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
SKIN-Flush with water.
EYES-Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
3-37

INSP
D Batteries generate explosive hydrogen
gas. Always follow the following preven-
tive measures:
D Charge batteries in a well-ventilated area.
D Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
D DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
1. Remove:
D Mat (right)
D Cover (battery case)
2. Disconnect:
D Battery leads
CAUTION:
Disconnect the negative lead 1 first and
then disconnect the positive lead 2 .
3. Remove:
D Battery
4. Check:
D Battery condition
*****************************************************
Battery condition checking steps:
D Connect a digital voltmeter to the battery ter-
Volt meter minals.
Tester (+) lead Battery (+) terminal
Tester (-) lead Battery (-) terminal
NOTE:
The charge state of an MF battery can be
checked by measuring the open-circuit voltage
(i.e. the voltage when the positive terminal is
disconnected).
Relationship between open-circuit
voltage and charging time at 20_C
(68_F)
Open-circuit voltage
Open circuit voltage Charging time

12.8 V or more No charging is neces-
sary.
Hours
Charging time
*This varies depending on the temperature, the state of
charge in battery plates and the electrolyte level.
3-38

INSP
Ambient
D Check the condition of the battery using the
temperature charts.
20_C (68_F)
Open-circuit voltage (V)
Example:
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge condition of the battery = 20 30%
*****************************************************
5. Charging method for MF batteries
Condition of charge in battery (%)
Charging Ambient temperature

CAUTION:
20_C (68_F)
D If it is impossible to set the standard
charging current, be careful not to over-
Open-circuit voltage (V)
charge.
D When charging the battery, be sure to re-
move it from the motorcycle. (If charging
has to be done with the battery mounted
Time (Minutes)
on the motorcycle, be sure to disconnect
Check the Open-circuit voltage the wire at the negative terminal.)
D Never remove the sealing caps of an MF
battery.
D Make sure that the charging clips are in
full contact with the terminal and that they
are not shorted together. (A corroded clip
on the charger may cause the battery to
generate heat in the contact area. A weak
clip spring may cause sparks.)
D Before removing the clips from the bat-
tery terminals, be sure to turn off the char-
ger’s power switch.
D The open-circuit voltage variation for the
MF battery after charging is shown below.
As shown in the figure, the open-circuit
voltage stabilizes about 30 minutes after
charging has been completed.
D Therefore, wait 30 minutes after charging
is completed before measuring the open-
circuit voltage.
3-39

INSP
Charging method using a variable-current (voltage) type charger
Measure the open-circuit NOTE:

Charger voltage prior to charging. Voltage should be measured 30 min-
AMP meter utes after the machine is stopped.
Connect a charger and NOTE:

AMP meter to the battery, Set the changing voltage at 16 17 V.
(If the setting is lower, charging will be
and start charging. insufficient. If too high, the battery will
be over-charged.)
Make sure the current is

YES higher than the standard NO
charging current written on
the battery.
By turning the charging voltage

adjust dial, set the charging
voltage at 20 25 V.
Adjust the voltage so that cur- Monitor the amperage for 3

YES
rent is at standard charging 5 minutes to check if the stan-
level. dard charging current is
reached.
NO
Set the timer according to the If current does not

charging time suitable for the exceed standard
open-circuit voltage. Refer to charging current
the “Battery condition check- after 5 minutes, re-
ing steps” section. place the battery.
In case that charging requires more than 5 hours, it is advisable to

check the charging current after a lapse of 5 hours. If there is any
change in the amperage, readjust the voltage to obtain the standard
charging current.
Measure the battery open-circuit voltage after having left the battery
unused for more than 30 minutes.
12.8 V or more-Charging is complete.
12.7 V or less-Recharging is required.
Under 12.0 V-Replace the battery.
3-40

INSP
Charging method using a constant-voltage type charger
Measure the open-circuit NOTE:

voltage prior to charging. Voltage should be measured 30 min-
utes after the machine is stopped.
Connect a charger and

AMP meter to the battery,
and start charging.
Make sure the current is

YES higher than the standard NO
charging current written on
the battery.
Charge the battery until the battery’s This type of battery charger cannot
charging voltage is 15 volts. charge the MF battery. A variable volt-
age charger is recommended.
NOTE:
Set the charging time at 20 hours (maxi-
mum).
Check the open-circuit voltage after

having left the battery for 30 minutes Charger
after charging.
12.8 V or more-Charging is com- AMP meter
plete. Voltmeter
12.7 V or less-Recharging is neces-
sary.
Under 12 V-Replace the battery.
Charging method using a constant-current type charger

This type charger cannot charge the MF battery.
3-41

INSP
BATTERY INSPECTION/FUSE INSPECTION ADJ
6. Inspect:
Battery terminals
Dirty terminal Clean with wire brush.
Poor connection Correct.
NOTE:
After cleaning the terminals, grease them light-
ly.
7. Install:
Battery
8. Connect:
Battery leads
CAUTION:
Connect the positive lead first and then connect
the negative lead.
9. Install:
Cover (battery case)
Mat (right)
YP305010
FUSE INSPECTION
CAUTION:
Always turn off the main switch when checking
or replacing the fuse. Otherwise, a short circuit
may occur.
1. Remove:
Mat (right)
Cover (battery case)
2. Inspect:
Fuse
*****************************************************
Inspection steps:
Connect the Pocket tester to the fuse and
check it for continuity.
NOTE:
Set the tester selector to “Ω 1” position.
Pocket tester:
90890-03112
If the tester is indicated at ∞. Replace the

fuse.
*****************************************************
3-42

INSP
FUSE INSPECTION/HEADLIGHT BEAM ADJUSTMENT ADJ
3. Replace:
Blown fuse
*****************************************************
Replacement steps:
Turn off the main switch.
Install a new fuse with the proper current rat-
ing.
Turn on switches to verify operation of related
electrical devices.
If the fuse blows again immediately, check
the electrical circuit.
Never use a fuse with a rating other than that

specified. Never use other materials in place
of a fuse. An improper fuse may cause ex-
tensive damage to the electrical system,
malfunction of lighting and ignition systems
and could possibly cause a fire.
*****************************************************
4. Install:
Side panel
Panels
EB305022
HEADLIGHT BEAM ADJUSTMENT

1. Adjust
Headlight beam (vertical)
Turn the adjuster 1 in or out.
Turning in Headlight beam moves

lower.
Turning out Headlight beam moves
higher.
2. Adjust:
Headlight beam (horizontal)
Turn the adjuster 2 in or out.
Turning in Headlight beam moves

right.
Turning out headlight beam moves
left.
3-43

INSP
ADJ

CHAPTER 4.
ENGINE
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
WIREHARNESS AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT
AND ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
ENGINE REMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
CAMSHAFT AND ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
CAMSHAFT AND ROCKER ARM SHAFT REMOVAL . . . . . . . . . . . . 4-12
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
CAMSHAFT AND ROCKER ARM SHAFT INSPECTION . . . . . . . . . 4-13
CAMSHAFT AND ROCKER ARM INSTALLATION . . . . . . . . . . . . . . 4-13
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
VALVES AND VALVE SPRINGS REMOVAL . . . . . . . . . . . . . . . . . . . . 4-16
VALVES AND VALVE SPRINGS INSPECTION . . . . . . . . . . . . . . . . . 4-16
VALVE SEAT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
VALVES AND VALVE SPRINGS INSTALLATION . . . . . . . . . . . . . . . . 4-19
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
PISTON AND PISTONRINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . 4-22
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
PISTON AND PISTON PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . 4-23
PISTON RINGS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
PISTON RINGS, PISTON AND CYLINDER INSTALLATION . . . . . . 4-25
V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE . . . . . . . . . 4-27
CRANKCASE FILTER COVER AND CRANKCASE
COVER (LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE . . . . . . . 4-28
SECONDARY SHEAVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
PRIMARY SHEAVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
SECONDARY SHEAVE AND V BELT REMOVAL . . . . . . . . . . . . . . . 4-31
SECONDARY SHEAVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 4-32
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
V BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
SECONDARY SHEAVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
PRIMARY SHEAVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
SECONDARY SHEAVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 4-34
A.C. MAGNETO AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-37
MAGNETO COVER AND STATOR COIL . . . . . . . . . . . . . . . . . . . . . . . 4-37
A.C. MAGNETO AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . 4-38
A.C. MAGNETO AND ROTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . 4-39
STARTER DRIVE GEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 4-40
A.C. MAGNETO AND ROTER INSTALLATION . . . . . . . . . . . . . . . . . 4-40

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
OIL PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
CRANKCASE AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

ENGINE REMOVAL ENG
EB400000
ENGINE OVERHAUL
ENGINE REMOVAL
WIREHARNESS, CABLE
10 Nm (1.0 mkg)
7 Nm (0.7 mkg)

Wireharness and cables Remove the parts in order.
removal
Side panel
Refer to “COVER AND PANEL”
Footrest board
section in CHAPTER 3.
Fuel tank
Drain the coolant. Refer to “COOLANT REPLACEMENT”
Carburetor Refer to “CARBURETOR” section in
CHAPTER 6.
1 Spark plug cap 1
2 Thermo unit lead 1
3 Startor coil/Pick up coil lead 1/1
4 Starting motor lead 1
5 Earth lead 1
6 Adjuster 1
7 Brake cable 1
4-1

ENGINE REMOVAL ENG
10 Nm (1.0 mkg)
7 Nm (0.7 mkg)

8 Pin 1
9 Compression spring 1
10 Cable holder 1
11 Cable holder 1
installation.
4-2

ENGINE REMOVAL ENG
HOSES, AIR FILTER CASE, ENGINE MOUNTING BOLT AND ENGINE
7 Nm (0.7 mkg)
32 Nm (3.2 mkg)
19 Nm (1.9 mkg)
64 Nm (6.4 mkg)

Hoses, air filter, engine mounting Remove the parts in order.
bolt and engine removal
1 Vacuum hose 1
2 Crankcase breather hose 1
3 Inlet hose (water pump) 1
4 Outlet hose (cylinder head) 1
5 Air filter case assembly 1
6 Bolt 2 (Rear shock absorber – lower)
7 Self locknut/Plane washer 1/1
8 Bolt 1 Refer to “ENGINE REMOUNTING”
9 Bolt/Plane washer/Rod assembly 1/2/1 section.
10 Engine 1
installation.
4-3

ENGINE REMOVAL ENG
YP******
ENGINE REMOUNTING
When remounting the engine, reverse the re-
moval procedure in job instruction chart.
Note the following points:
1. Install:
Engine 1
Plane washer 2
Rod 3
NOTE:
Temporarily install the rod and engine, and then
tighten the bolts and nuts to specifications.
2. Tighten:
Bolt 1 64 Nm (6.4 mkg)
Self locknut (engine and swingarm) 2

32 Nm (3.2 mkg)
4-4

CYLINDER HEAD ENG
CYLINDER HEAD
22 Nm (2.2 mkg) 10 Nm (1.0 mkg)
60 Nm (6.0 mkg)
8 Nm (0.8 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)

Cylinder head removal Remove the parts in the order.
Drain the coolant.
Side panel Refer to the “COVER AND PANELS”
Footrest board section in CHAPTER 3.
Fuel tank
Carburetor Refer to “CARBURETOR” section in
1 Thermo unit lead 1 CHAPTER 6.
2 Plug cap 1
3 Crankcase breather hose 2
4 Outlet hose (cylinder head) 1
5 Vacuum hose 1
6 Breather hose (crankcase) 1
7 Carburetor joint 1
8 Joint 1
9 O-ring 2
4-5

CYLINDER HEAD ENG
22 Nm (2.2 mkg) 10 Nm (1.0 mkg)
60 Nm (6.0 mkg)
8 Nm (0.8 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)

10 Crankcase filter cover/seal/element 1/1/1
11 Plug/O-ring 1/1
12 Cam sprocket cover/O-ring 1/1
13 Valve cover (intake side)/O-ring 1/1
14 Valve cover (exhaust side)/O-ring 1/1
15 Timing chain tensioner assembly 1
16 Timing chain tensioner gasket 1
17 Breather plate 1 Refer to “CYLINDER HEAD REMOVAL
AND INSTALLATION” section.
18 Cam sprocket/Timing chain 1/1
19 Cylinder head 1
20 Cylinder head gasket 1
21 Dowel pin 2
installation.
4-6

CYLINDER HEAD ENG
YP401030
CYLINDER HEAD REMOVAL

1. Align:
S “I” mark a on the rotor
(with stationary pointer b on the crank
case cover)
NOTE:
Turn the primary sheave counterclockwise with
a wrench and align the “I” mark c with the cylin-
der head match mark d when the piston is at
TDC on the compression stroke.
2. Loosen:
S Bolt 1
3. Remove:
S Timing chain tensioner assembly
S Timing chain tensioner gasket
4. Remove:
S Breather plate 2
S Cam sprocket 3
S Timing chain 4
NOTE:
D Fasten a safety wire to the timing chain to
prevent it from falling into the crankcase.
D Remove the bolt 1 while holding the rotor
mounting bolt with a wrench.
5. Remove:
S Cylinder head
NOTE:
D Loosen the nuts in their proper loosening se-
quence.
D Start by loosening each nut 1/2 turn until all
are loose.
YP402000
CYLINDER HEAD INSPECTION

1. Eliminate:
S Carbon deposits
(from combustion chambers)
Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
D Spark plug threads
D Valve seats
4-7

CYLINDER HEAD ENG
2. Inspect:
S Cylinder head
Scratches/damage Replace.
3. Measure:
S Cylinder head warpage
Out of specification Resurface.
Cylinder head warpage:

Less than 0.03 mm
*****************************************************
Warpage measurement and resurfacement
steps:
D Place a straightedge and a feeler gauge
across the cylinder head.
D Measure the warpage.
If the warpage is out of specification, resur-
face the cylinder head.
D Place a 400 600 grit wet abrasive paper on
the surface plate, and resurface the head us-
ing a figure-eight sanding pattern.
NOTE:
Rotate the cylinder head several times for an
even resurfacement.
*****************************************************
YP404190
CYLINDER HEAD INSTALLATION

1. Install:
S Gasket (cylinder head)
S Dowel pins
S Cylinder head
NOTE:
D Apply engine oil onto the nut threads.
D Tighten the nuts in a crisscross pattern.
2. Tighten:
S Nuts (cylinder head) 22 Nm (2.2 mSkg)
S Bolts (cylinder) 10 Nm (1.0 mSkg)
4-8

CYLINDER HEAD ENG
3. Install:
S Cam sprocket 1
S Timing chain 2
*****************************************************
Installing steps:
D Turn the primary sheave counterclockwise
until the TDC mark a matches the stationary
pointer b .
D Align the “I” mark c on the cam sprocket with
the stationary pointer d on the cylinder
head.
D Fit the timing chain onto cam sprocket and
install the cam sprocket on the camshaft.
NOTE:
D When installing the cam sprocket, keep the
timing chain as tense as possible on the ex-
haust side.
D Align the match mark c on the cam sprocket
with the stationary pointer d on the cylinder
head.
D Align the pin on the camshaft with the slot in
the cam sprocket.
CAUTION:
Do not turn the crankshaft during installa-
tion of the camshaft. Damage or improper
valve timing will result.
D While holding the camshaft, temporarily

tighten the bolts.
D Remove the safety wire from the timing
chain.
*****************************************************
4. Install:
S Breather plate 1
S Plane washer 2
4-9

CYLINDER HEAD ENG
5. Install:
S Timing chain tensioner
*****************************************************
Installation steps:
D Remove the tensioner cap bolt 1 and
springs 2 .
D Release the timing chain tensioner one-way
cam 3 and push the tensioner rod 4 all the
way in.
D Install the tensioner with a new gasket 5
onto the cylinder.
D Install the springs 2 and cap bolt 1 .
D Tighten the bolt (with gasket) to the specified
torque.
Bolt (chain tensioner) 10 Nm (1.0 mSkg)
Cap bolt (timing chain tensioner)

8 Nm (0.8 mSkg)
*****************************************************
6. Tighten:
S Bolt (cam sprocket) 60 Nm (6.0 mSkg)
7. Check:
S Valve timing
Out of alignment Adjust.
Refer to the above steps 3 5.
8. Check:
S Valve clearance
Refer to the “VALVE CLEARANCE AD-
JUSTMENT” section in CHAPTER 3.
4-10

CAMSHAFT AND ROCKER ARMS ENG
CAMSHAFT AND ROCKER ARMS
14 Nm (1.4 mkg)
8 Nm (0.8 mkg)
14 Nm (1.4 mkg)

Camshaft and rocker arms Remove the parts in order.
removal
Cylinder head Refer to “CYLINDER HEAD” section.
1 Lock washer 1
2 Plate 1
3 Rocker arm shaft (intake) 1 Refer to “ROCKER ARM AND
4 Rocker arm shaft (exhaust) 1 ROCKER SHAFT REMOVAL AND
5 Rocker arm 2 INSTALLATION” section.
6 Camshaft 1 Refer to “CAMSHAFT INSTALLATION”
7 Locknut 2 section.
8 Adjuster 2
9 O-ring 1
installation.
4-11

YP******
ROCKER ARM AND ROCKER ARM SHAFT

REMOVAL
1. Remove:
Rocker arm shaft (intake)
Rocker arm shaft (exhaust)
NOTE:
Attach a rocker arm shaft puller bolt 1 and
weight 2 to the rocker arm shaft and slide out
the shaft.
Rocker arm shaft puller bolt:

90890-01085
Weight:
90890-01084
YP402052
CAMSHAFT INSPECTION
1. Inspect:
Cam lobes
Pitting/Scratches/Blue discoloration
Replace.
2. Measure:
Cam lobes length a and b .
Out of specification Replace.
Cam lobes length:

Intake:
a 36.545 36.645 mm
<Limit: 36.45 mm>
b 30.021 30.121 mm
<Limit: 29.92 mm>
Exhaust:
a 36.547 36.647 mm
<Limit: 36.45 mm>
b 30.067 30.167 mm
<Limit: 29.17 mm>
3. Inspect:
Camshaft oil passage
Stuffed Blow out oil passage with com-
pressed the air.
4-12

YP402060
ROCKER ARMS AND ROCKER ARM

SHAFTS INSPECTION
1. Inspect:
S Cam lobe contact surface 1
S Adjuster surface 2
Wear/Pitting/Scratches/Blue discolor-
ation Replace.
*****************************************************
Inspection steps:
D Inspect the two contact areas on the rocker
arms for signs of unusual wear.
D Rocker arm shaft hole.
D Cam-lobe contact surface.
Excessive wear Replace.
D Inspect the surface condition of the rocker
arm shafts.
Pitting/scratches/blue discoloration Re-
place or check lubrication.
D Measure the inside diameter a of the rocker
arm holes.
Inside diameter (rocker arm):

12.000 12.018 mm
<Limit: 12.030 mm>
D Measure the outside diameter b of the rocker

arm shafts.
Outside diameter
(rocker arm shaft):
11.981 11.991 mm
<Limit: 11.995 mm>
*****************************************************
YP******
CAMSHAFT AND ROCKER ARM

INSTALLATION
1. Lubricate:
S Camshaft 1
Camshaft:
Molybdenum disulfide oil
Camshaft bearing:
Engine oil
4-13

2. Install:
Plate 1
Look washer 2
Bolt 3 8 Nm (0.8 mkg)
NOTE:
Bend the lock washer tabs along the bolt 3
flats.
3. Apply:
(onto the rocker arm and rocker arm shaft)
4. Install:
Rocker arm 1
Rocker arm shaft 2 (exhaust)
NOTE:
Exhaust:
Install the rocker arm shaft (exhaust) complete-
ly pushed in.
5. Install:
Rocker arm 1
Rocker arm shaft 2 (intake)
NOTE:
Intake:
Insert the guide shaft (8 mm) 3 into the stud
bolt hole on the cylinder head to the rocker arm
shaft (intake).
CAUTION:
Do not confuse the installation direction of
rocker arm shaft. Be sure to install the
threaded part facing outward.
4-14

VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS

Valves and valve springs removal Remove the parts in order.
Rocker arm, rocker arm shaft Refer to “ROCKER ARM SHAFT AND
ROCKER ARMS” section.
1 Valve cotters 4 Refer to “VALVES AND VALVE SPRINGS
REMOVAL/INSTALLATION” section
2 Spring retainer 2
3 Valve spring (inner) 2
4 Valve spring (outer) 2 Refer to “VALVES AND VALVE
5 Valve (intake) 1 SPRINGS INSTALLATION” section
6 Valve (exhaust) 1
7 Valve guide 2
8 Spring seat 2
installation.
4-15

YP401150
VALVES AND VALVE SPRINGS REMOVAL

1. Remove:
Valve cotters 1
NOTE:
Attach a valve spring compressor and attach-
ment 2 between the valve spring retainer and
cylinder head to remove the valve cotters.
CAUTION:
Do not compress so much as to avoid dam-
age to the valve spring.
Valve spring compressor:

90890-04019
Attachment:
90890-04108
YP******
VALVES AND VALVE SPRINGS INSPECTION

1. Measure:
Valve stem diameter
Valve stem diameter:

Intake:
5.975 5.990 mm
<Limit: 5.94 mm>
Exhaust:
5.960 5.975 mm
<Limit: 5.92 mm>
YP402010
2. Measure:
Runout (valve stem)
Runout limit:
0.01 mm
YP402030
3. Measure:
Free length (valve spring)
Valve spring free length:

Inner spring:
38.1 mm
<Limit: 36.1 mm>
Outer spring:
36.93 mm
<Limit: 35.0 mm>
4-16

YP402030
4. Measure:
S Spring tilt
Spring tilt limit:

1.7 mm (2.5_)
5. Inspect:
S Spring contact face
Wear/Pitting/Scratches Replace.
6. Measure:
S Valve guide inside diameter
Valve guide inside diameter:

Intake:
6.000 6.012 mm
<Limit: 6.05 mm>
Exhaust:
6.000 6.012 mm
<Limit: 6.05 mm>
YP402010
7. Measure:
Stem-to-guide clearance =
Valve guide inside diameter –
Valve stem diameter
Out of specification Replace the valve
guide.
Stem-to-guide clearance limit:

Intake:
0.08 mm
Exhaust:
0.10 mm
EB402020
VALVE SEATS INSPECTION

1. Eliminate:
S Carbon deposits
(from the valve face and valve seat)
2. Inspect:
S Valve seats
Pitting/wear Reface the valve seat.
4-17

3. Measure:
S Valve seat width a
Out of specification Reface the valve
seat.
Valve seat width:

Intake:
0.9 1.1 mm
<Limit: 1.6 mm>
Exhaust:
0.9 1.1 mm
<Limit: 1.6 mm>
*****************************************************
Measurement steps:
D Apply Mechanic’s blueing dye (Dykem) 1 to
the valve face.
D Install the valve into the cylinder head.
D Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
D Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
D If the valve seat is too wide, too narrow, or the
seat is not centered, the valve seat must be
replaced.
*****************************************************
EB402020
4. Lap:
S Valve face
S Valve seat
NOTE:
After replacing the valve seat, valve and valve
guide, the valve seat and valve face should be
lapped.
*****************************************************
Lapping steps:
D Apply a coarse lapping compound a to the
valve face.
CAUTION:
Do not let compound enter the gap between
the valve stem and the guide.
D Apply molybdenum disulfide oil to the valve

stem.
4-18

D Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hand.
D Apply a fine lapping compound to the valve

face and repeat the above steps.
NOTE:
Make sure to clean off all compound from the
valve face and valve seat after every lapping
operation.
D Apply Mechanic’s blueing dye (Dykem) b to

the valve face.
D Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
D Measure the valve seat width c again.
*****************************************************
EB404032
VALVES AND VALVE SPRINGS

INSTALLATION
1. Deburr:
S Valve stem end
Use an oil stone to smooth the stem end.
2. Apply:
S Molybdenum disulfide oil
(onto the valve stem 3 and oil seal 2 )
3. Install:
S Valve spring seat 1
S Valve stem seal 2
S Valve 3
(into the cylinder head)
S Valve spring (inner) 4
S Valve spring (outer) 5
S Spring retainer 6
NOTE:
Install the valve spring with the larger pitch a
facing upwards.
b Smaller pitch
4-19

4. Install:
Valve cotters 1
NOTE:
Install the valve cotters while compressing the
valve spring with a valve spring compressor and
attachment 2 .
Valve spring compressor:

90890-04019
Attachment:
90890-04108
5. Secure the valve cotters onto the valve

stem by tapping lightly with a piece of wood.
CAUTION:
Do not hit so much as to damage the valve.
4-20

CYLINDER AND PISTON ENG
CYLINDER AND PISTON

Cylinder and piston removal Remove the parts in order.
1 Joint 1
2 O-ring 2
3 Timing chain guide (exhaust side) 1
4 Cylinder 1 Refer to “PISTON RINGS, PISTON
AND CYLINDER INSTALLATION”
5 Dowel pin 2 section.
6 Cylinder gasket 1
7 Piston pin circlip 2
8 Piston pin 1 Refer to “PISTON AND PISTON
9 Piston 1 RINGS REMOVAL” section.
10 Piston ring (top) 1 Refer to “PISTON RINGS, PISTON
11 Piston ring (2nd) 1 AND CYLINDER INSTALLATION”
12 Side rail/Spacer 2/1 section.
installation.
4-21

YP******
PISTON AND PISTON RINGS REMOVAL

1. Remove:
S Piston pin circlip 1
S Piston pin 2
S Piston 3
NOTE:
Before removing the piston pin circlip, cover the
crankcase opening with a clean towel or rag to
prevent the circlip from falling into the crank-
case cavity.
2. Remove:
S Top ring
S 2nd ring
S Oil ring
NOTE:
When removing the piston ring, open the end
gap of the ring by fingers, and push up the other
side of the ring.
YP402100
CYLINDER INSPECTION
1. Measure:
S Cylinder bore
Out of specification Rebore or replace
NOTE:
D Measure the cylinder bore with a cylinder
bore gauge.
D Measure the cylinder bore in parallel to and at
right angles to the crankshaft. Then, find the
average of the measurements.
Cylinder bore:
69.000 69.005 mm
<Limit: 69.1 mm>
<Defferance limit between A, B
and C: 0.03 mm>
2. Measure:
S Warpage
Cylinder warpage limit:

0.03 mm
4-22

YP******
PISTON AND PISTON PIN INSPECTION

1. Measure:
Piston skirt diameter
a 5.0 mm from the piston bottom edge
Piston skirt diameter:

68.965 68.980 mm
Oversize (2)
69.5 mm
Oversize (4)
70.0 mm
2. Calculate:
Piston-to-cylinder clearance
Piston-to-cylinder clearance =
Cylinder bore – Piston skirt diameter
Refer to “CYLINDER” section for cylinder
bore measurement.
Out of specification Replace the piston
and piston rings as a set.
Piston-to-cylinder clearance:
0.02 X 0.04 mm
3. Measure:
Piston pin bore diameter
Piston pin bore diameter:

17.004 17.015 mm
<Limit: 17.045 mm>
4. Measure:
Piston pin outside diameter
Piston pin outside diameter:

16.991 17.000 mm
<Limit: 16.975 mm>
5. Inspect:
Piston pin
Blue discoloration/groove Clean or re-
place.
4-23

YP402111
PISTON RINGS INSPECTION

1. Measure:
Side clearance
Out of specification Replace the piston
and the piston rings as a set.
NOTE:
Eliminate the carbon deposits from the piston
ring grooves and rings before measuring the
side clearance.
Side clearance (piston ring):

Top ring:
0.04 0.08 mm
<Limit: 0.12 mm>
2nd ring:
0.03 0.07 mm
<Limit: 0.12 mm>
2. Position:
Piston ring
(into the cylinder)
NOTE:
Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
a 5.0 mm
3. Measure:
End gap
NOTE:
You cannot measure the end gap on the expan-
der spacer of the oil ring. If the oil ring rails show
excessive gap, replace all three rings.
End gap:
Top ring:
0.15 0.30 mm
<Limit: 0.45 mm>
2nd ring:
0.30 0.45 mm
<Limit: 0.70 mm>
Oil ring:
0.20 0.70 mm
4-24

EB404184
PISTON RINGS, PISTON AND CYLINDER

INSTALLATION
1. Install:
S Top ring 1
S 2nd ring 2
S Side rails (oil ring) 3
S Expander spacer (oil ring) 4
NOTE:
D Make sure to install the piston rings so that
the manufactuer’s marks or numbers are lo-
cated on the upper side of the rings.
D Lubricate pistons and piston rings liberally
with engine oil.
2. Install:
S Piston 1
S Piston pin 2
S Piston pin clip 3
NOTE:
D Apply engine oil onto the piston pins.
D The “” mark a on the piston must face the
exhaust side of the cylinder.
D Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre-
vent the piston pin clip from falling into the
crankcase.
D Make sure to install each piston in its respec-
tive cylinder.
3. Install:
S Gasket (cylinder)
S Dowel pins
4-25

4. Position:
S Piston rings
NOTE:
Offset the piston ring end gaps as shown.
a Top ring end

b Oil ring end (lower)
c Oil ring end (upper)
d 2nd ring end
5. Lubricate:
S Piston outer surface
S Piston ring
S Cylinder inner surface
Engine oil
6. Install:
S Cylinder
NOTE:
D Install the cylinder with one hand while com-
pressing the piston rings with the other hand.
D Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cav-
ity.
4-26

V-BELT, CLUTCH AND
SECONDARY/PRIMARY SHEAVE ENG
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

CRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT)
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)
7 Nm (0.7 mkg)

Crankcase filter cover and Remove the parts in order.
crankcase cover (left)removal
Side panel Refer to “COVER AND PANEL”
1 Crankcase filter cover 1
2 Crankcase filter cover seal 1
3 Crankcase filter element 1
4 Crankcase cover protector 1
5 Crankcase cover (left) 1
6 Crankcase cover gasket 1
installation.
4-27

V-BELT, CLUTCH AND
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE
*Shell BT grease No. 3 (90890-69927)
60 Nm (6.0 mkg)
3 Nm (0.3 mkg)
60 Nm (6.0 mkg)

V-belt, clutch and secondary/ Remove the parts in order.
primary sheave removal
1 Nut/Plain washer 1/1 Refer to “PRIMARY SHEAVE
2 Primary fixed sheave 1 REMOVAL” section.
3 Nut 1 Refer to “SECONDARY SHEAVE AND
4 Clutch housing 1 V-BELT REMOVAL” section.
5 Clutch assembly 1 Refer to “SECONDARY SHEAVE
6 V-belt 1 INSTALLATION” section.
7 Primary sliding sheave 1
Refer to “PRIMARY SHEAVE
8 Collar 1
ASSEMBLY” section.
9 Primary sheave cap 1
4-28

V-BELT, CLUTCH AND
*Shell BT grease No. 3 (90890-69927)
60 Nm (6.0 mkg)
3 Nm (0.3 mkg)
60 Nm (6.0 mkg)

10 Cam 1
11 Weight 8
Refer to “PRIMARY SHEAVE
12 Slider 4
ASSEMBLY” section.
13 Spacer 4
14 Oil seal 1
installation.
4-29

V-BELT, CLUTCH AND
SECONDARY SHEAVE
**Apply BEL-RAY assembly lube
90 Nm (9.0 mkg)

Secondary sheave disassembly Disassemble the parts in order.
1 Nut 1
2 Clutch carrier 1 Refer to “SECONDARY SHEAVE
DISASSEMBLY” section.
3 Clutch shoe spring 3
Refer to “SECONDARY SHEAVE
INSTALLATION” section.
5 Spring seat 1
6 Guide pin 4
7 Secondary sliding sheave 1
8 O-ring 2 Refer to “SECONDARY SHEAVE
9 Oil seal 2
10 Secondary fixed sheave 1
Reverse the disassembly procedure
for assembly.
4-30

V-BELT, CLUTCH AND
YP******
PRIMARY SHEAVE REMOVAL

1. Remove:
Nut 1 (primary sheave)
Plate washer
Primary fixed sheave 2
NOTE:
Loosen the nut (primary fixed sheave) while
holding the primary fixed sheave with the rotor
holder 3 .
Rotor holder:
90890-01235
YP******
SECONDARY SHEAVE AND V-BELT

REMOVAL
1. Remove:
Nut 1 (secondary sheave)
Clutch housing 2
NOTE:
Loosen the nut (secondary sheave) while hold-
ing the clutch housing with the sheave holder
3.
Sheave holder:
90890-01701
2. Remove:
Nut 1 (clutch carrier)
CAUTION:
Do not remove the nut (clutch carrier) yet.
NOTE:
Loosen the nut (clutch carrier) one turn using
the locknut wrench 3 while holding the clutch
carrier with the rotor holder 2 .
Rotor holder:
90890-01235
Locknut wrench:
90890-01348
4-31

V-BELT, CLUTCH AND
3. Remove:
S Clutch assembly 1
S V-belt 2
NOTE:
Remove the V-belt from the primary sheave
side with clutch assembly.
YP******
SECONDARY SHEAVE DISASSEMBLY

1. Remove:
S Nut 1 (secondary sheave)
NOTE:
Loosen the nut 1 while attaching the clutch
spring compressor 2 and clutch spring holder
arm 3 and release the compressed spring after
removing the nut.
CAUTION:
Use the spacer 4 (ø 30 mm, thickness: 2
3 mm).
Clutch spring holder:

90890-01337
Clutch spring holder arm:
90890-01464
YP******
CLUTCH INSPECTION
1. Measure:
S Clutch shoe thickness
Scratches Glaze using coarse sandpa-
per.
Wear/Damage Replace
Clutch shoe thickness:

3.0 mm
<Limit: 2.0 mm>
NOTE:
D After using the sandpaper, clean off the pol-
ished particles.
D Inspect the other clutch shoes.
D Replace the all three as a set.
4-32

V-BELT, CLUTCH AND
YP******
V-BELT INSPECTION
1. Inspect:
V-belt 1
Cracks/Wear/Scaling/Chipping Re-
place.
Oil/Grease Check primary sheave and
secondary sheave.
2. Measure:
V-belt width 2
Out of specification Replace
V-belt width:
22.6 mm
<Limit: 21.0 mm>
YP******
WEIGHT INSPECTION
1. Inspect:
Weight minimum outside diameter
Cracks/Wear/Scaling/Chipping Re-
place.
Weight out side diameter:

20.0 mm
<Limit: 19.5 mm>
SECONDARY SHEAVE INSPECTION

1. Inspect:
Secondary fixed sheave smooth opera-
tion
Secondary sliding sheave smooth opera-
tion
Scratches/Damage Replace as a set.
2. Inspect:
Torque cam groove 1
Wear/Damage Replace.
3. Inspect:
Guide pin 2
Wear/Damage Replace.
4-33

V-BELT, CLUTCH AND
YP******
PRIMARY SHEAVE ASSEMBLY

1. Clean:
S Primary sliding sheave face 1
S Primary fixed sheave face 2
S Collar 3
S Weight 4
S Primary sliding sheave cam face 5
NOTE:
Remove any excess grease.
2. Install:
S Weight 1
S Collar 2
NOTE:
D Apply Shell BT grease No. 3 (90890-69927)
to the all of the outside of the weight and
install.
D Apply Shell BT grease No. 3 (90890-69927)
to the inside of the collar.
3. Install:
S Spacer 1
S Slider 2
S Cam 3
S Primary sliding sheave cap.
3 Nm (0.3 mSkg)
SECONDARY SHEAVE INSTALLATION

1. Apply:
S BEL-RAY assembly lube
(to the secondary sliding sheave 1 inner
surface, grease nipple groove, and oil
seals)
S BEL-RAY assembly lube
(to the bearings, oil seals and inner sur-
face of the secondary fixed sheave 2 )
2. Install:
S Secondary sliding sheave 1
NOTE:
Install the secondary sliding sheave 1 using
the oil seal guide 2 to the secondary fixed
sheave 3 .
Oil seal guide:

90890-01384
4-34

V-BELT, CLUTCH AND
3. Install:
Guide pin 1
4. Apply:
BEL-RAY assembly lube
(to the guide pin sliding groove 1 , and
and oil seal 2 )
5. Install:
Secondary sheave complete 1
Compression spring
Clutch carrier 2
NOTE:
Temporarily tighten the nut 5 while attaching
the clutch spring holder 3 and clutch spring
holder arm 4 and compress the spring.
CAUTION:
Use the spacer 6 (ø 30 mm, thickness: 2
3 mm).
Clutch spring holder:

90890-01337
Clutch spring holder arm:
90890-01464
6. Install:
V-belt 1
Clutch assembly 2
NOTE:
Install the V-belt with the clutch assembly to the
primary sheave side.
CAUTION:
Never smear grease to the V-belt, secondary
sheave and clutch.
4-35

V-BELT, CLUTCH AND
7. Install:
Nut 1 (clutch carrier) 90 Nm (9.0 mkg)
NOTE:
Tighten the nut (clutch carrier), using the lock-
nut wrench 3 while holding the clutch carrier
with the rotor holder 2 .
Rotor holder:
90890-01235
Locknut wrench:
90890-01348
8. Install:
Clutch housing 1
Nut 2 (clutch housing)
NOTE:
Tighten the nut (clutch housing), using the
sheave holder 3 .
Sheave holder:
90890-01701
9. Set:
V-belt 1
NOTE:
Move the V-belt to minimum diameter of the pri-
mary sheave 1 , maximum diameter of the sec-
ondary sheave 2 and make the V-belt tense.
4-36

A.C. MAGNETO AND STARTER CLUTCH ENG
A.C. MAGNETO AND STARTER CLUTCH

MAGNETO COVER AND STARTOR COIL
7 Nm (0.7 mkg)
20 Nm (2.0 mkg)
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)

Magneto cover and startor coil Remove the parts in order.
removal
Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
Side panels Refer to “COVER AND PANEL” section
in CHAPTER 3.
NOTE:
1 Couplers (A.C. magneto lead) 2 Disconnect the couplers.
2 Exhaust pipe 1
3 Exhaust pipe gasket 1
4 Magneto cover 2
5 Gasket (magneto cover) 1
6 Dowel pins 2
7 Startor coil 1
8 Pick up coil 1
installation.
4-37

A.C. MAGNETO AND STARTER CLUTCH
10 Nm (1.0 mkg) 80 Nm (8.0 mkg)

A.C. magneto and starter clutch Remove the parts in order.
removal
1 Rotor 1 Refer to “A.C. MAGNETO ROTOR
REMOVAL/INSTALLATION” section.
2 Shaft (idle gear) 1
3 Idler gear 1
4 Starter one way clutch assembly 1
5 Woodruff key 1 Refer to “ROTOR INSTALLATION”
6 Starter wheel gear 1 section.
installation.
4-38

YP401081
A.C. MAGNETO ROTOR REMOVAL

1. Remove:
S Nut 1 (rotor)
S Plain washer 2
NOTE:
D Loosen the nut (rotor) 1 while holding the ro-
tor with a sheave holder 3 .
D Do not allow the sheave holder to touch the
projection on the rotor.
Sheave holder:
90890-01701
2. Remove:
S Rotor 1
S Woodruff key
NOTE:
D Remove the rotor 2 using the flywheel pull-
er.
D Center the flywheel puller over the rotor.
Make sure after installing the holding bolts
that the clearance between the flywheel pull-
er and the rotor is the same everywhere. If
necessary, one holding bolt maybe turned
out slightly to adjust the flywheel puller’s
position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller:
90890-01362
4-39

YP402163
STARTER DRIVE GEAR INSPECTION

1. Inspect:
S Starter idle gear teeth
S Starter drive gear teeth
S Starter wheel gear teeth
Burrs/chips/roughness/wear Re-
place.
2. Check:
S Starter clutch operation
Push the dowel pins to the arrow direction.
Unsmooth operation Replace.
*****************************************************
Checking steps:
D Hold the starter clutch.
D When turning the starter wheel gear clock-
wise A , the starter clutch and the starter
wheel gear should be engaged.
D If not, the starter clutch is faulty. Replace it.
D When turning the starter wheel gear counter-
clockwise, B , it should turn freely.
D If not, the starter clutch is faulty. Replace it.
*****************************************************
YP404131
A.C. MAGNETO ROTOR INSTALLATION

1. Install:
S Starter wheel gear 1
S Woodruff key 2
NOTE:
Install the starter wheel gear 1 , then install the
woodruff key 2 .
2. Install:
S Plain washer
S Rotor 1
NOTE:
D Clean the tapered portion of the crankshaft
and the rotor hub.
D When installing the magneto rotor, make
sure the woodruff key is properly seated in
the key way of the crankshaft.
4-40

3. Tighten:
Nut (rotor) 1 80 Nm (8.0 mkg)
NOTE:
Tighten the nut (rotor) 1 while holding the mag-
neto rotor 2 with a sheave holder 3 .
Sheave holder:
90890-01701
4-41

OIL PUMP ENG
OIL PUMP
7 Nm (0.7 mkg)
12 Nm (1.2 mkg)

Oil pump removal Remove the parts in order.
A.C. magneto Refer to the “A.C. MAGNETO AND
STARTER CLUTCH” section.
1 Cover 1
2 Pump driven gear 1
3 Dowel pin 1
4 Oil pump assembly 1
5 Gasket 1
6 Impeller shaft gear 1
7 Dowel pin 1
8 Shaft 1
installation.
4-42

OIL PUMP ENG
EB402140
OIL PUMP INSPECTION

1. Inspect:
Drive gear (oil pump)
Driven gear (oil pump) 1
Pump housing
Pump housing cover
Wear/cracks/damage Replace
2. Measure:
Tip clearance A
(between the inner rotor 1 and the outer
rotor 2 )
Side clearance B
(between the outer rotor 2 and the pump
housing 3 )
Out of specification Replace the oil
pump assembly.
Housing and rotor clearance C
(between the pump housing 3 and the ro-
tors 1 2 )
Out of specification Replace the oil
pump assembly.
Tip clearance A :
0.100.34 mm <Limit: 0.40 mm>
Side clearance B :
0.0130.036 mm
<Limit: 0.15 mm>
Housing and rotor clearance C :
0.040.09 mm <Limit: 0.15 mm>
4-43

TRANSMISSION ENG
TRANSMISSION
16 Nm (1.6 mkg)

Transmission removal Remove the parts in order.
Rear wheel Refer to “REAR WHEEL/REAR BRAKE”
Crankcase cover (left) Refer to “V-BELT, CLUTCH,
SECONDARY/PRIMARY SHEAVE”
section.
Drain the transmission oil. Refer to “TRANSMISSION OIL
REPLACEMENT” section in CHAPTER 3.
1 Transmission case cover 1
2 Gasket (transmission case cover) 1
3 Dowel pin 2
4 Primary drive gear 1
5 Plain washer 1
6 Plain washer 1
7 1st wheel gear 1
4-44

TRANSMISSION ENG
16 Nm (1.6 mkg)

8 Drive axle 1
9 Main axle 1
10 Primary driven gear 1
11 Plain washer 1
installation.
4-45

CRANKCASE AND CRANKSHAFT ENG
CRANKCASE AND CRANKSHAFT
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)

Crankcase and crankshaft Remove the parts in the order.
removal
Engine removal Refer to “ENGINE REMOVAL” section.
Cylinder, piston Refer to “CYLINDER AND PISTON” sec-
tion.
V-belt, clutch, secondary/primary Refer to “V-BELT, CLUTCH AND SEC-
sheave ONDARY/PRIMARY SHEAVE” section.
A.C. magneto, starter clutch Refer to “A.C. MAGNETO AND
STARTER CLUTCH” section.
Oil pump Refer to “OIL PUMP” section.
Water pump Refer to “WATER PUMP” section in
CHAPTER 5.
Rear wheel Refer to “REAR WHEEL AND REAR
BRAKE” section in CHAPTER 7.
1 Bolt 1
2 O-ring 1
4-46

10 Nm (1.0 mkg)
10 Nm (1.0 mkg)

3 Timing chain guide (intake) 1
4 Crankcase (right) 1 Refer to “CRANKSHAFT
5 Dowel pin 2
6 Crankshaft assembly 1 Refer to “CRANKSHAFT REMOVAL/
7 Timing chain 1 INSTALLATION” section.
8 Crankcase (left) 1
9 Oil seal 1
installation.
4-47

YP******
CRANKSHAFT REMOVAL
1. Remove:
Crankshaft assembly
Timing chain 1
NOTE:
Before removing the crankshaft assembly,
remove the timing chain from the crank shaft
sprocket.
If the timing chain hooks to the crankshaft
sprocket, the crankshaft cannot be removed.
YP******
CRANKSHAFT INSPECTION
1. Measure:
Crankshaft runout
Out of specification Replace crankshaft
and/or bearing.
NOTE:
Measure the crankshaft runout with the crank-
shaft assembly turning slowly.
Runout limit:
0.03 mm
2. Measure:
Big end side clearance
Out of specification Replace big end
bearing, crank pin and/or connecting rod.
Big end side clearance:

0.35 0.85 mm
3. Measure:
Crank width
Out of specification Replace crank-
shaft.
Crank width:
59.95 60.00 mm
4-48

4. Inspect:
Crankshaft sprocket 1
Wear/Damage Replace crankshaft.
Bearing 2
Wear/Crack/Damage Replace crank-
shaft.
Pump drive gear 3
Wear/Damage Replace crankshaft.
5. Inspect:
Crankshaft journal
Clogged Blow out the journal with com-
pressed air.
YP404073
CRANKCASE INSTALLATION
1. Clean all the gasket mating surface and
crankcase mating surface thoroughly.
2. Apply:
Sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
NOTE:
DO NOT ALLOW any sealant to come in con-
tact with the oil gallery.
3. Install:
Dowel pins
Timing chain 1
NOTE:
Install the timing chain not to be seen through
the the crankshaft hole a on the crankcase
(left) 2 .
4-49

ENG

CHAPTER 5.
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
WATER PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

RADIATOR COOL
YP500000
COOLING SYSTEM
RADIATOR
23 Nm (2.3 mkg)

Radiator removal Remove the parts in order.
Fuel tank
Refer to “COVER AND PANEL”
Footrest board, under cover
Cowling body, leg shield
1 Fan motor leads 1
2 Thermo switch leads 2
3 Filler hose (radiator) 1
4 Outlet hose (radiator) 1
5 Inlet hose (radiator) 1
6 Radiator 1
installation.
5-1

RADIATOR COOL
YP500030
INSPECTION
1. Inspect:
D Radiator 1
Obstruction Blow out with com-
pressed air through the rear of the radia-
tor.
Flattened fins Repair or replace.
If flattened over the 20 % of radiator fin,
repair or replace the radiator.
CAUTION:
Use only specified adhesive to repair the ra-
diator.
2. Inspect:
D Radiator hoses
D Radiator pipes
Cracks/damage Replace.
3. Measure:
D Radiator cap opening pressure
D Radiator cap opens at a pressure below
the specified pressure Replace.
Radiator cap opening pressure:

110140 kPa
(1.11.4 kg/cm2, 1.11.4 bar)
*****************************************************
Measurement steps:
D Attach the radiator cap tester 1 and adapter
2 to the radiator cap 3 .
Radiator cap tester:

90890-01325
Adapter:
90890-01352
D Apply the specified pressure for 10 seconds,

and make sure there is no pressure drop.
*****************************************************
4. Inspect:
D Fan motor assembly
Damage Replace.
Malfunction Check and repair.
Refer to “COOLING SYSTEM” in CHAP-
TER 8.
5. Inspect:
D Pipes
5-2

WATER PUMP COOL
WATER PUMP
Oil pump side
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)

Water pump removal Remove the parts in order.
Refer to “A.C. MAGNETO AND
A.C. magneto
STARTER CLUTCH” section in
CHAPTER 4.
1 Impeller shaft gear 1
2 Dowel pin/plain washer 1/1
3 Shaft 1 Refer to “WATER PUMP
4 Inlet hose (water pump) 1
5 Holder 1
6 Housing cover 1
7 Housing cover gasket 1
8 Water pump housing 1
5-3

WATER PUMP COOL
Oil pump side
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)

9 Impeller shaft 1
10 O-ring 1 Refer to “WATER PUMP
11 O-ring 1
installation.
5-4

WATER PUMP COOL
YP******
NOTE:
D It is not necessary to disassemble the water
pump, unless there is no abnormality such as
excessive change in coolant temperature
and/or level, discoloration of coolant, or
milky transmission oil.
D If necessary, replace water pump as an as-
sembly.
YP******
INSPECTION
1. Inspect:
D Impeller shaft
Fur deposits Clean.
2. Inspect:
D Impeller shaft gear
3. Inspect:
D Mechanical seal 1
Damage/worn/wear Replace.
YP******
WATER PUMP INSTALLATION

1. Install:
D Mechanical seal 1
*****************************************************
Installation steps:
D Apply the Yamaha bond 1215 to the outside
of the mechanical seal.
D Install the mechanical seal by using the me-
chanical seal installer 2 and middle shaft
bearing driver 3 .
*****************************************************
Mechanical seal installer:
90890-04078
Middle shaft bearing driver:
90890-04058
5-5

WATER PUMP COOL
2. Install:
D Mechanical seal 1
Apply coolant to the outside of the me-
chanical seal before installing.
NOTE:
Do not smear any oils grease on to the ring side
of the mechanical seal.
3. Inspect:
D Mechanical seal, slip ring side 1
Inspect the slip ring side of the mechani-
cal seal and the impeller 2 for level
installation.
Incorrect level Reinstall.
4. Install:
D Impeller shaft 1
D Circlip 2
*****************************************************
Installation steps:
D Apply a small amount of grease to the impel-
ler shaft tip.
D Install the impeller shaft while turning it.
Use care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.
NOTE:
After installing the impeller shaft, check it for
smooth rotation.
*****************************************************
5. Install:
D O-ring 1
6. Install:
D Water pump housing
D Housing cover 10 Nm (1.0 mSkg)
7. Install:
D Shaft 1
Align the slot on the impeller shaft with
the projection on the shaft when instal-
ling.
5-6

THERMOSTAT COOL
THERMOSTAT
10 Nm (1.0 mkg)

Thermostat removal Remove the parts in order.
Drain the coolant Refer to “COOLANT REPLACEMENT”
Fuel tank section in CHAPTER 3.
1 Clip 1
2 Outlet hose (carburetor) 1
3 Hose clamp 1
4 Outlet hose (thermostat) 1
5 Thermostatic cover 1 Refer to “THERMOSTAT
6 Thermostatic valve 1 INSTALLATION” section.
installation.
5-7

THERMOSTAT COOL
EB502010
INSPECTION
1. Inspect:
D Thermostatic valve
Valve does not open at 80.5 83.5_C
Replace.
*****************************************************
Inspection steps:
D Suspend the thermostatic valve in a vessel.
D Place a reliable thermometer in water.
D Observe the thermometer, while continually
stirring the water.
*****************************************************
1 Thermostatic valve
2 Vessel
3 Thermometer
4 Water
A CLOSE
B OPEN
NOTE:
The thermostatic valve is sealed and its setting
requires specialized work. If its accuracy is in
3mm doubt, replace it. A faulty unit could cause seri-
ous overheating or over-cooling.
2. Inspect:
82”1.5_C 95_C D Thermostatic cover
YP******
INSTALLATION
1. Install:
D Thermostatic valve 1
D Thermostatic cover
5-8

CHAPTER 6.
CARBURETION
CARBURETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CARBURETOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
FUEL LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
AUTO CHOKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
FUEL PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

CARBURETOR CARB
EB600000
CARBURETION
CARBURETOR
10 Nm (1.0 mkg)

Carburetor removal Remove the parts in order.
Fuel tank section in CHAPTER 3.
Drain the coolant Refer to “COOLANT REPLACEMENT”
1 Auto choke lead coupler 1
2 Inlet/Outlet hose (carburetor) 1/1
3 Fuel hose 1
4 Throttle cable 2
CAUTION:
5 Air filter joint 1 Do not bend the air filter joint clamp
when installing the carburetor.
6 Nut 2
7 Carburetor ass’y 1
installation.
6-1

CARBURETOR CARB
CARBURETOR DISASSEMBLY

Carburetor disassembly Disassemble the parts in order.
1 Auto choke unit 1
2 Throttle stop screw set 1
3 Pilot screw set 1
4 Cover/Diaphragm spring 1/1
5 Piston valve 1
6 Jet needle ass’y 1
7 Coasting enricher 1
8 Accererating pump 1 Refer to “CARBURETOR ASSEMBLY”
9 Float chamber 1 section.
10 Float pin 1 Refer to “CARBURETOR ASSEMBLY”
section.
6-2

CARBURETOR CARB

11 Float 1
12 Needle valve 1
Refer to “CARBURETOR ASSEMBLY”
13 Main jet 1
section.
14 Pilot jet 1
15 Main nozzle 1
for assembly.
6-3

CARBURETOR CARB
YP600041
ASSEMBLY
Reverse the “DISASSEMBLY” procedure.
Note the following points.
CAUTION:
D Before assembling, wash all parts in
clean petroleum based solvent.
D Always use a new gasket.
1. Install:
D Main nozzle 1
D Main jet 2
D Pilot jet 3
2. Install:
D Valve seat 1
D Float 2
D Needle valve 3
D Float pin 4
3. Inspect:
D Float height a
*****************************************************
Inspection and adjustment steps:
D Hold the carburetor in an upside down posi-
tion.
D Measure the distance from the mating sur-
face of the float chamber (gasket removed) to
the top of the float.
D If the float height is not within specification,
inspect the valve seat and valve needle.
D If either is worn, replace them both.
D If both are fine, adjust the float height by
bending the float tang 5 on the float.
D Check the float height again.
NOTE:
The float arm should be resting on the valve
needle without compressing it.
6-4

CARBURETOR CARB
Float height (F.H.):

27 mm

*****************************************************
5. Install:
D Diaphragm 1
NOTE:
Align the tab a on the diaphragm with the slot
b on the carburetor body.
6. Install:
D Cover 2
YP600060
FUEL LEVEL ADJUSTMENT
Gasoline (fuel) and its vapors are highly

flammable and explosive. Keep away from
sparks, cigarettes, flames or other sources
of ignition.
1. Measure:
D Fuel level a
Fuel level:
56 mm below the float
chamber line
*****************************************************
Measurement and adjustment steps:
D Place the scooter on a level surface.
6-5

CARBURETOR CARB
D Put a garage jack under the engine to ensure
that the carburetors are positioned vertically.
D Connect the fuel level gauge 1 to the drain
pipe 2 .
Fuel level gauge:

90890-01312
D Loosen the drain screw 3 .

D Hold the gauge vertically next to the float
chamber line.
D Measure the fuel level a with the gauge.
D If the fuel level is incorrect, adjust the fuel lev-
el.
D Remove the carburetor.
D Inspect the valve seat and needle valve.
D If either is worn, replace them both.
D If both are fine, adjust float level by bending
the float tang 4 slightly.
D Install the carburetor.
D Recheck the fuel level.
*****************************************************
YP******
AUTO CHOKE INSPECTION

(Ambient temperature lower than 45_C)
1. Remove:
D Carburetor
2. Inspect:
D Autochoke unit
Connect ø 3.3 mm pipe 2 to the starter
1 , and blow it with the mouth etc.
Possible Good condition.
Impossible Replace auto choke unit.
3. Inspect:
D Auto choke unit (with battery)
*****************************************************
Inspection and adjustment steps:
D Connect auto choke unit leads to the 12 V
battery for 5 minutes.
Black terminal 12 V battery (+) 1
Black terminal 12 V battery (–) 2
D Connect ø 3.3 mm pipe 4 to the starter 3 ,
and blow it with the mouth etc.
Possible Replace auto choke unit.
Impossible Good condition.
*****************************************************
6-6

CARBURETOR CARB
YP******
FUEL PUMP INSPECTION

1. Remove:
D Side panels
Refer to “COVER AND PANEL” section
in CHAPTER 3.
2. Inspect:
D Fuel pump
*****************************************************
Inspection steps:
D Place the receptacle under the fuel pipe end.
D Start engine, and inspect gasoline to flow out
from fuel pipe 1 .
Engine is running:
Gasoline flows out Good.
Engine is stopping:
Gasoline does not flow out Good.
*****************************************************
D Gasoline (fuel) and its vapors are highly

flammable and explosive. Keep away
from sparks, cigarettes, flames or other
sources of ignition.
D Failure to check for fuel leakage may re-
sult in fire or explosion.
3. Install:
D Side panels
Refer to “COVER AND PANEL” section
in CHAPTER 3.
6-7

CARB

CHAPTER 7.
CHASSIS
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
FRONT WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
FRONT WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
FRONT WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
FRONT WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
WHEEL STATIC BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 7-6
REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
REAR WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
REAR BRAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
REAR BRAKE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
MASTER CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
BRAKE CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
BRAKE CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
FRONT FORK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
FRONT FORK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
FRONT FORK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
FRONT FORK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
HANDLEBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
HANDLEBAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
STEERING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
STEERING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
REAR SHOCK ABSORBER AND SWING ARM . . . . . . . . . . . . . . . . . . . 7-38

FRONT WHEEL AND BRAKE DISC CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC
FRONT WHEEL AND BRAKE DISC
70 Nm (7.0 mkg)
23 Nm (2.3 mkg)

Front wheel and brake disc Remove the parts in order.
removal
Securely support the scooter so there

is no danger of it falling over.
1 Speedometer cable 1
2 Axle nut 1
3 Wheel axle 1
Refer to “FRONT WHEEL
4 Front wheel assembly 1
5 Gear unit assembly 1
6 Collar 1
7 Brake disc 1 Refer to “FRONT WHEEL ASSEMBLY”
section.
installation.
7-1

FRONT WHEEL DISASSEMBLY

Front wheel disassembly Remove the parts in order.
1 Oil seal 1 Refer to “FRONT WHEEL
2 Bearing 1 DISASSEMBLY /ASSEMBLY” section.
3 Spacer 1
4 Bearing 1
installation.
7-2

YP******
FRONT WHEEL DISASSEMBLY

1. Remove:
Bearing 1
Spacer
Remove the bearing using a general bear-
ing puller 2 .
CAUTION:
Handle the wheel with care not to damage
the brake disc. If the brake disc is damaged,
replace.
YP700020
FRONT WHEEL INSPECTION

1. Inspect:
Front wheel axle
(by rolling it on a flat surface)
Bends Replace.
Do not attempt to straighten a bent axle.
Wheel axle bending limit:

0.25 mm
2. Inspect:
Front tire
Wear/damage Replace:
Refer to “TIRE INSPECTION” in CHAP-
TER 3.
Front wheel
Refer to “WHEEL INSPECTION” in
CHAPTER 3.
3. Measure:
Front wheel runout
Over the specified limits Replace.
Front wheel runout limits:

Radial 1 : 2.0 mm
Lateral 2 : 2.0 mm
4. Inspect:
Front wheel bearings
Bearings allow free play in the wheel hub
or the wheel does not turn smoothly Re-
place.
Oil seals
7-3

5. Inspect:
S Collar
Grooved wear Replace the collar and
the oil seal as a set.
YP******
BRAKE DISC INSPECTION

1. Measure:
S Brake disc deflection
Maximum deflection:
0.15 mm
2. Measure:
S Brake disc thickness
Brake disc thickness:

4.0 mm
Minimum thickness:
3.5 mm

YP******
FRONT WHEEL ASSEMBLY

1. Install:
S Bearing 1
S Spacer 2
S Bearing 3
S Oil seal 4
NOTE:
D Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
D Use a socket that matches the outside diam-
eter of the race of the bearing.
D Always use a new oil seal.
D Install the oil seal with its manufacturer’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of balls of the
bearing. Contact should be made only with
the outer race.
7-4

2. Install:
Brake disc 1 23 Nm (2.3 mkg)
NOTE:
Tighten the bolts (brake disc) in stage using a
crisscross pattern.
EB700030
FRONT WHEEL INSTALLATION

Reverse the “REMOVAL” procedure.
1. Lubricate:
Front wheel axle
Bearings
Oil seal (lips)
Drive/driven gear (speedometer)
Recommended lubricant:
Lithium soap base grease
2. Install:
Speedometer gear unit 1
NOTE:
Make sure that the wheel hub and the
speedometer gear unit are installed with the
three projections 2 meshed into the three slots
3.
3. Install:
Front wheel
NOTE:
Make sure that the slot in the speedometer gear
unit fits over the stopper on the front fork outer
tube.
4. Tighten:
Front wheel axle
Axle nut (front wheel axle) 1
CAUTION:
Before tightening the axle nut, stroke the
front fork several times to check for proper
fork operation.
Make sure that the brake hose is routed

properly.
7-5

YP700040
WHEEL STATIC BALANCE ADJUSTMENT

NOTE:
D After replacing the tire and/or rim, the wheel
static balance should be adjusted.
D Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
S Balancing weight
2. Set:
S Wheel
(on a suitable stand)
3. Find:
S Heavy spot
*****************************************************
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X1” mark on the wheel’s bottom
spot.
c. Turn the wheel so that the “X1” mark is 90_
up.
d. Release the wheel and wait for it to rest.
Put an “X2” mark on the wheel’s bottom
spot.
e. Repeat the above b., c., and d. several
times until all marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
*****************************************************
4. Adjust:
S Wheel static balance
*****************************************************
Adjusting steps:
D Install a balancing weight 1 on the rim exact-
ly opposite to the heavy spot “X”.
NOTE:
Start with the smallest weight.
D Turn the wheel so that the heavy spot is 90_

up.
D Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
anced.
*****************************************************
7-6

5. Check:
S Wheel static balance
*****************************************************
Checking steps:
D Turn the wheel so that it comes to each point
as shown.
D Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
*****************************************************
7-7

REAR WHEEL AND REAR BRAKE CHAS
REAR WHEEL AND REAR BRAKE
10 Nm (1.0 mkg)

Rear wheel and rear brake removal Remove the part in order.
Swingarm Refer to “REAR SHOCK ABSORBER
AND SWINGARM” section.
1 Adjuster 1
2 Brake cable 1
4 Pin 1
5 Rear wheel assembly 1
6 Brake lining 2
7 Tension spring 2
8 Plate washer 1
9 Camshaft lever 1
Refer to “REAR BRAKE
10 Indicator plate 1
11 Camshaft 1
7-8

10 Nm (1.0 mkg)

12 Camshaft shim 1
13 Camshaft seal 1
installation.
7-9

EB701020
REAR WHEEL INSPECTION

1. Inspect:
Rear wheel axle
Rear wheel
Rear wheel bearings
Oil seals
Refer to “FRONT WHEEL”.
2. Measure:
Rear wheel runout
Refer to “FRONT WHEEL”.
EB701021
REAR BRAKE INSPECTION

1. Inspect:
Brake lining surface
Glazed areas Polish.
Use coarse sand paper.
NOTE:
After polishing, wipe the polished particles with
a cloth.
2. Measure:
Brake lining thickness
Brake lining thickness a :

Standard:
4 mm
Limit:
2 mm

Measuring points
NOTE:
Replace the brake shoes as a set if either is
worn to the limit.
3. Measure:
Brake drum inside diameter a
Out of specification Replace the wheel.
Brake drum inside diameter:

Standard:
160 mm
Limit:
161 mm
7-10

4. Inspect:
S Brake drum inner surface
S Oil/scratches Repair.
S Oil
Use a rag soaked in lacquer thinner or sol-
vent.
S Scratches
Use an emery cloth
(lightly and evenly polishing)
5. Inspect:
S Camshaft face.
Wear Replace.
When inspecting the brake lining, do not

spill oil or grease on the brake lining.
YP******
REAR BRAKE INSTALLATION

1. Install:
S Camshaft 1
S Indicator plate 2
*****************************************************
Installation steps:
D Set the camshaft with its punched mark a
facing the direction as shown.
D Align the projection b on the indicator plate
with th camshaft notch and install.
D Check the proper position of the brake shoe.
*****************************************************
2. Install:
S Camshaft lever 1
Install the camshaft lever with its slit and
the indicator plate at right angle as shown.
7-11

FRONT BRAKE CHAS
FRONT BRAKE
BRAKE PAD
23 Nm (2.3 mkg)

Brake pad removal Remove the parts in order.
1 Caliper support bolt 1
Refer to “BRAKE PAD
2 Brake pad 2
REPLACEMENT” section.
3 Pad support 1
installation.
7-12

FRONT BRAKE CHAS
YP702010
BRAKE PAD REPLACEMENT

NOTE:
It is not necessary to disassemble the brake cal-
iper and brake hose to replace the brake pads.
1. Remove:
S Bolt (caliper support bolt) 1
Move the direction brake caliper to the ar-
row mark.
2. Remove:
S Brake pads
NOTE:
D Install new brake pad springs when the brake
pads have to be replaced.
D Replace the brake pads as a set if either is
found to be worn to the wear limit.
3. Push the caliper piston into the brake cali-

per by finger.
CAUTION:
When pushing the caliper piston into the
brake caliper, brake fluid level in reservoir
tank is increasing higher.
4. Install:
S Brake pad 1
Install the brake pad, and move the brake
caliper to the allow mark direction.
5. Install:
S Bolt (caliper support bolt)
23 Nm (2.3 mSkg)
6. Inspect:
S Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section in CHAPTER 3.
7. Check:
S Brake lever operation
Soft spongy feeling Bleed the brake
system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)”in CHAPTER 3.
7-13

FRONT BRAKE CHAS
MASTER CYLINDER
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
26 Nm (2.6 mkg)

Master cylinder removal Remove the parts in order.
Drain the brake fluid Refer to “BRAKE FLUID REPLACE-
MENT” section in CHAPTER 3.
1 Rear view mirror (right) 1
2 Brake lever/compression spring 1/1
3 Brake switch 1
4 Union bolt 1
5 Plain washer 2
Refer to “MASTER CYLINDER
6 Brake hose 1
7 Master cylinder bracket 1
8 Master cylinder 1
installation.
7-14

FRONT BRAKE CHAS
MASTER CYLINDER DISASSEMBLY

Master cylinder disassembly Remove the parts in order.
1 Master cylinder boot 1
2 Circlip 1 Refer to “MASTER CYLINDER
3 Master cylinder assembly 1 ASSEMBLY” section.
4 Spring 1
for assembly.
7-15

FRONT BRAKE CHAS
YP702040
MASTER CYLINDER INSPECTION

1. Inspect:
S Master cylinder 1
Wear/scratches Replace the master
cylinder assembly.
S Master cylinder cup 2
S Cracks/damage Replace.
2. Inspect:
S Master cylinder
S Scratches/wear/damage Replace the
master cylinder assembly.
3. Inspect:
S Diaphragm
YP******
MASTER CYLINDER ASSEMBLY
D All internal brake components should be

cleaned and lubricated with new brake
fluid only before installation.

DOT #4
D Replace the piston seals and dust seals

whenever a master cylinder is disas-
sembled.
1. Install:
S Cylinder cup 1
S Master cylinder piston 2
Install cylinder cup 1 by using cylinder
cup installer 3 .
Cylinder cup installer set:

90890-01996
7-16

FRONT BRAKE CHAS
2. Install:
Spring 1
Install the spring with its smaller diameter
to the master cylinder piston.
Master cylinder kit 2
3. Install:
Circlip 1
Install the circlip securely into the master
cylinder groove.
Master cylinder boot 2
YP******
MASTER CYLINDER INSTALLATION

1. Install:
Master cylinder 1
Master cylinder bracket 2
10 Nm (1.0 mkg)
CAUTION:
Align the end of the master cylinder with the
punch mark on the handlebar, then install
the master cylinder bracket 2 with the “UP”
mark facing upward.
2. Install:
Plain washer 1
Brake hose 2
Plain washer 3
Union bolt 4
26 Nm (2.6 mkg)
CAUTION:
Align the plain washer notch and master cyl-
inder edge a for assembly.
7-17

FRONT BRAKE CHAS
3. Air bleed:
S Brake system
Refer to “AIR BLEEDING” section in
CHAPTER 3.
D Use only designated quality brake fluid:

Otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
D Refill with the same type of brake fluid:
mixing fluids may result in a harmful
chemical reaction and lead to poor perfor-
mance.
D Be careful that water does not enter the
significantly lower the boiling point of the
fluid may result in vapor lock.
4. Inspect:
S Brake operation
7-18

FRONT BRAKE CHAS
CALIPER
26 Nm (2.6 mkg)
23 Nm (2.3 mkg)

Caliper removal Remove the parts in order.
Drain the brake fluid Refer to “BRAKE FLUID REPLACE-
1 Brake hose holder 1 MENT” section in CHAPTER 3.
2 Union bolt 1
3 Plain washer 2
Refer to “CALIPER INSTALLATION”
4 Brake hose 1
section.
5 Caliper support bolt 1
6 Caliper assembly 1
installation.
7-19

FRONT BRAKE CHAS
CALIPER DISASSEMBLY
6 Nm (0.6 mkg)

Caliper disassembly Remove the parts in order.
1 Brake pad 2
2 Pad support 1
3 Caliper piston 2
Refer to “BRAKE CALIPER DIS-
4 Dust seal 2
ASSEMBLY /ASSEMBLY” section.
5 Piston seal 2
6 Bleed screw/Cap 1/1
for assembly.
7-20

FRONT BRAKE CHAS
YP702020
BRAKE CALIPER DISASSEMBLY

NOTE:
Before disassembling either brake caliper,
drain the brake fluid from the brake hose, mas-
ter cylinder, brake caliper and reservoir tank.
1. Remove:
S Brake caliper piston
*****************************************************
Removal steps:
S Blow compressed air into the hose joint
opening to force out the caliper piston
from the brake caliper body.
D Never try to pry out the caliper piston.

D Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.
CAUTION:
Carefully remove the caliper piston to pre-
vent damage.
*****************************************************
2. Remove:
S Dust seal 1
S Piston seal 2
When removing, push the seals by your
finger.
CAUTION:
D Do not use a sharp instrument. Remove
seals by your finger.
D Do not re-use removed parts.
YP******
CALIPER INSPECTION
1. Inspect:
S Caliper cylinder 1
S Caliper piston 2
Scratches, wear Replace caliper as-
sembly.
7-21

FRONT BRAKE CHAS
EB702050
BRAKE CALIPER ASSEMBLY
D All internal brake components should be

cleaned and lubricated with new brake
fluid only before installation.

DOT #4
D Replace the caliper piston seals whenev-

er a brake caliper is disassembled.
1. Install:
S Piston seals 1
S Dust seal 2
2. Install:
S Caliper piston 1
Apply brake fluid to the outer surface and
install.
CAUTION:
D Do not force.
D Use care to prevent damage on caliper
piston.
YP******
CALIPER INSTALLATION
1. Install:
S Caliper 1
S Caliper support bolt 2 23 Nm (2.3 mSkg)
S Brake hose 3
S Plain washer 4
S Union bolt 5 26 Nm (2.6 mS kg)
CAUTION:
When installing the brake hose to the cali-
per, lightly touch the brake hose with the
stopper a on the caliper.
7-22

FRONT FORK CHAS
FRONT FORK
FRONT FORK
45 Nm (4.5 mkg)
23 Nm (2.3 mkg)
23 Nm (2.3 m kg)
49 Nm (4.9 mkg)

Front fork removal Remove the parts in order.
Front wheel Refer to “FRONT WHEEL” section.
1 Caliper assembly 1
2 Front fender 1
3 Inner fender 1
4 Bolt (under bracket upper) 2
5 Cap bolt/O-ring 2/2 Refer to “FRONT FORK REMOVAL/
6 Bolt (under bracket lower) 2 INSTALLATION” section.
7 Front fork (left/right) 1/1
installation.
7-23

FRONT FORK CHAS
FRONT FORK DISASSEMBLY
45 Nm (4.5 mkg)
23 Nm (2.3 mkg)

Front fork disassembly Remove the parts in order.
1 Cap bolt 1 Refer to “FRONT FORK REMOVAL/
2 O-ring 1
3 Fork spring 1 Refer to “FRONT FORK ASSEMBLY”
4 Dust seal 1 section.
5 Retaining clip 1
6 Oil seal 1
Refer to “FRONT FORK DISASSEM-
7 Bolt (Damper rod)/Gasket 1/1
BLY/ASSEMBLY” section.
8 Inner tube 1
9 Oil lock piece 1
Refer to “FRONT FORK ASSEMBLY”
10 Damper rod 1
section.
11 Rebound spring 1
for assembly.
7-24

FRONT FORK CHAS
YP******
FRONT FORK REMOVAL
D Securely support the scooter so there is

no danger of it falling over.
D Stand the scooter on a level surface.
D Stand the scooter on its centerstand.
1. Loosen:
S Bolt (lower bracket upper) 1
NOTE:
Loosen only the upper bolt.
2. Remove:
S Cap bolt 1
NOTE:
Use 17 mm width hexagonal wrench for remov-
ing.
3. Loosen the bolt (under bracket lower) to re-

move the front forks.
Support the front fork before loosening the

pinch bolts.
YP703020
FRONT FORK DISASSEMBLY

1. Remove:
S Bolt (damper rod) 1
Loosen the bolt (damper rod) 1 while
holding the damper rod with T-handle 2
and holder 3 .
Damper rod holder:

90890-04084
T-handle
90890-01326
7-25

FRONT FORK CHAS
2. Remove:
Inner tube
Oil lock pice
3. Remove:
Oil seal 1
CAUTION:
Never reuse the oil seal.
2 Rag
YP703030
FRONT FORK INSPECTION

1. Inspect:
Inner tube bending
Inner tube bending limit:

0.2 mm
Scratches/bends/damage Replace.
Do not attempt to straighten a bent inner

tube as this may dangerously weaken the
tube.
2. Measure:
Fork spring a
Front fork spring free length:

268.5 mm
<Wear limit>
263.5 mm
Over the specified limit Replace.

YP******
FRONT FORK ASSEMBLY

Reverse the “DISASSEMBLY” procedure.
1. Install:
Damper rod 1
Rebound spring
Oil lock piece 2
Inner tube 3
7-26

FRONT FORK CHAS
2. Install:
S Inner tube 1
Into outer tube 2 .
3. Install:
S Plain washer 1
S Bolt (damper rod) 2
4. Tighten:
S Bolt (damper rod) 1 23 Nm (2.3 mSkg)
NOTE:
Tighten damper rod bolt 1 while holding the
damper rod with a T-handle 2 and a damper
rod holder 3 .
Damper rod holder:

90890-04084
T-handle
90890-01326
6. Install:
S Oil seal 1
S Retaining clip
S Dust seal
Use the fork seal driver weight 3 and the
attachment 2 .
NOTE:
D Before installing the oil seal 1 , apply lithium
soap base grease onto the oil seal lips.
D Adjust the retaining clip so that it fits into the
outer tube groove.
CAUTION:
Make sure that the oil seal numbered side
faces upward.
Fork seal driver weight:

90890-01367
Attachment:
90890-01374
7-27

FRONT FORK CHAS
7. Inspect:
S Inner tube operation
Unsmooth operation Disassembly and
recheck.
8. Fill:
S Fork oil
Oil quantity:
0.142 L
Recommended oil:
Fork oil 15 WT or equivalent
9. After filling up, slowly pump the fork up and

down to distribute the fork oil.
10. Measure:
S Oil level a
Oil level:
80 mm
(from the top of the inner tube
fully compressed and without
the fork spring)
NOTE:
Hold the fork in an upright position.
11. Install:
S Front fork spring 1
NOTE:
D Install the fork spring with its smaller pitch up-
ward.
D Before installing the cap bolt, apply grease to
the O-ring.
D Temporarily tighten the cap bolt.
7-28

FRONT FORK CHAS
EB703050
FRONT FORK INSTALLATION

Reverse the “REMOVAL“ procedure.
1. Install:
Front fork 1
Temporary tighten the pinch bolts.
NOTE:
Pull up the inner tube until its end flushes the top
of the under bracket 2 , then temporarily tighten
the bolt (under bracket lower) 3 .
2. Tighten:
Cap bolts 1 45 Nm (4.5 mkg)
Pinch bolts (under bracket upper/lower)

23 Nm (2.3 mkg)
7-29

HANDLEBAR CHAS
HANDLEBAR
23 Nm (2.3 mkg)
10 Nm (1.0 mkg)

Handlebar removal Remove the parts in order.
Handlebar upper cover Refer to ”COVER AND PANEL” section
in CHAPTER 3.
1 Rear view mirror (right) 1 Left-thread screw.
2 Rear view mirror (left) 1
3 Master cylinder bracket 1
4 Master cylinder 1
5 Grip end (right) 1
6 Handlebar switch (right) 1
7 Throttle cable 2 Refer to “HANDLEBAR
8 Grip assembly 1 INSTALLATION” section.
9 Brake cable 1
10 Lever holder (left) 1
Refer to “HANDLEBAR
7-30

HANDLEBAR CHAS
23 Nm (2.3 mkg)
10 Nm (1.0 mkg)

11 Handlebar switch (left) 1 Refer to “HANDLEBAR
12 Grip end (left) 1 INSTALLATION” section.
13 Grip 1 Refer to “HANDLEBAR REMOVAL”
section.
14 Upper handlebar holder 2 Refer to “HANDLEBAR
15 Handlebar 1 INSTALLATION” section.
installation.
7-31

HANDLEBAR CHAS
YP******
HANDLEBAR REMOVAL
1. Remove:
S Grip (Left)
*****************************************************
Removal steps:
D Remove the grip end (left).
D Blow with compressed air between the han-
dlebar and adhesive side of the grip to re-
move.
*****************************************************
YP704020
HANDLEBAR INSPECTION
1. Inspect:
S Handlebar
Bends/Cracks/Damage Replace.
Do not attempt to straighten a bent handle-

bar as this may dangerously weaken the
handlebar.
YP******
HANDLEBAR INSTALLATION
1. Install:
S Handlebar 1
NOTE:
D Apply a light coat of lithium soap base grease
onto the handlebar right end.
D Align the match marks a on the handlebar
with the lower handlebar holder upper sur-
face.
2. Install:
S Upper handlebar holder 1
23 Nm (2.3 mSkg)
NOTE:
The upper handlebar holders should be
installed with the arrow marks a facing forward
a.
3. Install:
S Grip 1
S Grip end (Left) 2
NOTE:
Provide a clearance a of 2.5 mm between the
handlebar grip and handlebar grip end.
7-32

HANDLEBAR CHAS
4. Install:
S Handlebar switch (left) 1
NOTE:
Align the handlebar switch mating surface with
the punched mark a on the handlebar.
5. Install:
S Lever holder (left) 1
NOTE:
Align the lever holder mating surface with the
punched mark a on the handlebar.
6. Install:
S Throttle cable 1
S Grip assembly 2
NOTE:
Apply a light coat of lithium soap base grease
onto the inside of the grip assembly and install it
to the handlebar.
7. Install:
S Grip end (right) 1
S Handlebar switch (right) 2
*****************************************************
Installation steps:
D Align the handlebar switch (right) mating sur-
face and punched mark a on the handlebar.
D Provide a clearance b of 2.5 mm between
the grip assembly 3 and handlebar grip.
Otherwise, the grip may not move.
Check the throttle grip for smooth opera-

tion.
*****************************************************
7-33

STEERING CHAS
STEERING
139 Nm (13.9 mkg)
1st step:
38 Nm (3.8 mkg)
2nd step:
Loosen the ring nut 1 / 4
turn.
3rd step:
22 Nm (2.2 mkg)
75 Nm (7.5 mkg)

Steering removal Remove the parts in order.
Handlebar upper cover Refer to “FRONT WHEEL, BRAKE
DISC” section.
Front fork Refer to “FRONT FORK” section.
Handlebar Refer to “HANDLEBAR” section.
1 Nut 1
2 Handlebar lower holder 1
3 Woodruff key 1
4 Ring nut (upper) 1 Refer to “STEERING REMOVAL/
5 Lock washer 1 INSTALLATION” section.
6 Ring nut (center) 1
7 Rubber washer 1
8 Ring nut (lower) 1
9 Ball race cover 1
10 Ball race 1 1
11 Lower bracket 1
7-34

STEERING CHAS
139 Nm (13.9 mkg)
1st step:
38 Nm (3.8 mkg)
2nd step:
Loosen the ring nut 1 / 4
turn.
3rd step:
22 Nm (2.2 mkg)
75 Nm (7.5 mkg)

12 Ball bearing 22
13 Ball bearing 19 Refer to “STEERING
14 Ball race 1 1 INSTALLATION” section.
15 Ball race 2 1
installation.
7-35

STEERING CHAS
YP704010
STEERING REMOVAL
D Securely support the scooter so that

there is no danger of it falling over.
D Stand the scooter on a level surface.
1. Remove:
S Handlebar lower holder 1
S Woodruff key 2
NOTE:
Remove the handlebar lower holder by loosen-
ing the ring nut (upper) 3 gradually.
2. Remove:
S Ring nut (upper)
S Lock washer 1
S Ring nut (center) 2
S Rubber washer
3. Remove:
S Ring nut (lower) 1
NOTE:
Hold the lower bracket by hand, then remove by
using the exhaust ring and steering nut wrench
2.
Exhaust and steering nut wrench:

90890-01268
Securely support the steering shaft so that there

is no danger of it falling down.
INSPECTION
1. Wash the bearing and bearing races with a
solvent.
2. Inspect:
S Bearings
S Bearing races
Pitting/Damage Replace.
7-36

STEERING CHAS
*****************************************************
Bearing race replacement steps:
D Remove the bearing races on the head pipe
using long rod 1 and the hammer as shown.
D Remove the bearing race on the under brack-
et using the floor chisel 2 and the hammer
as shown.
D Install the new dust seal and races.
*****************************************************
NOTE:
D Always replace bearings and races as a set.
D Replace the dust seal whenever a steering
head disassembled.
CAUTION:
If the bearing race is fitted not squarely, the
head pipe could be damaged.
EB704030
STEERING INSTALLATION
Reverse the “REMOVAL” procedure.
1. Lubricate:
S Bearings (upper and lower)
S Bearing races
Recommended lubricant:
Lithium-soap base grease
2. Install:
S Ring nut (lower)
S Rubber washer
S Ring nut (center)
S Lock washer
S Ring nut (upper)
Refer to “STEERING HEAD INSPEC-
TION” section in CHAPTER 3.
3. Install:
S Woodruff key 1
S Handlebar lower bracket 2
139 Nm (13.9 mSkg)
NOTE:
Align the woodruff key to key groove mark a on
the handlebar lower holder.
7-37

REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARM
40 Nm (4.0 mkg)
19 Nm (1.9 mkg)
7 Nm (0.7 mkg)
135 Nm (13.5 mkg)
20 Nm (2.0 mkg)
23 Nm (2.3 mkg)
20 Nm (2.0 mkg)
53 Nm (5.3 mkg)

Rear shock absorber and Remove the parts in order.
swingarm removal
Side panels Refer to “COVER AND PANEL” section
in CHAPTER 3.
1 Box 1 NOTE:
2 Nut 2 Loosen.
3 Muffler assembly 1
NOTE:
4 Axle nut 1 Remove with the rear brake applied.
5 Rear shock absorber 1
6 Swingarm 1
7 Collar 1
8 Oil seal 1
9 Bearing 1
installation.
7-38

CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
CHECKING SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CHECKING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
SWITCH CONNECTION AS SHOWN IN THIS MANUAL . . . . . . . . . 8-4
SWITCH POSITION AND TERMINAL CONNECTION . . . . . . . . . . . 8-5
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
SIGNAL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
AUTO CHOKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44

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

CIRCUIT DIAGRAM ELEC
CIRCUIT DIAGRAM
8-2

CIRCUIT DIAGRAM ELEC
1 A.C. magneto 27 Turn switch

2 Rectifier regulator 28 Horn switch
3 Main switch 29 Dimmer switch
4 Battery 30 Pass switch
5 Main fuse 31 Handlebar switches (left)
6 Starter relay 32 Tail / Brake light
7 Starter motor 33 Licence light
8 Thermo switch (auto choke) 34 Rear flasher lights
9 Auto choke 35 Front flasher lights
10 Ignitor unit 36 Head light
11 Ignition coil 37 Auxiliary light
12 Spark plug 38 Turn indicator lights
13 Pickup coil 39 High beam indicator light
14 Sidestand switch 40 Meter lights
15 Starting circuit cut-off relay 41 Oil indicator light
16 Lights switch 42 Reset switch
17 Starter switch 43 Fuel gauge
18 Engine stop switch 44 Read switch
19 Handlebar switches (right) 45 Clock
20 Fuse (fan) 46 Thermometer
21 Thermo switch 47 Speedometer
22 Fan motor 48 Meter assembly
23 Rear brake switch 49 Fuel sender
24 Front brake switch 50 Thermo unit
25 Flasher relay
26 Horn
NOTE:
Starter switch is closed while the button (switch) is pushed.
Sidestand switch is closed while the side stand is upped.
Brake switch is closed while the brake is applied.
COLOR CODE
B Black Y Yellow R/B Red/Black

Br Brown W White R/Y Red/Yellow
Ch Chocolate B/R Black/Red R/W Red/White
Dg Dark green Br/W Brown/White Y/R Yellow/White
G Green G/R Green/Red W/G White/Green
L Blue G/Y Green/Yellow
O Orange L/B Blue/Black
Sb Sky blue L/Y Blue/Yellow
P Pink L/W Blue/White
R Red L/R Blue/Red
8-3

CHECKING SWITCHES ELEC
YP-N
CHECKING SWITCHES
CHECKING STEPS
Using pocket tester, check switches for continu-
ity between their terminals to determine wheth-
er they are correctly connected.
Repalce the switch component if any of the
combinations does not produce the correct
reading.
Pocket tester:
90890-03112
NOTE:
Turn the switch to the “ON”, “OFF” positions
several times.
Adjust the pocket tester to correct “0” position
before checking switches.
Set the pocket tester selector to “ 1” Ω.
SWITCH CONNECTION AS SHOWN IN THIS

MANUAL
This manual contains connection charts, like
the one shown on the left, showing the terminal
connections of switches (e.g. the main switch,
handlebar switch, brake switch, lighting switch
etc.)
The column on the extreme left indicates the dif-

ferent switch positions, the top line indicates the
colors of the leads connected to the terminals
on the switch.
“ ” indicates terminals between which

there is continuity, i.e. a closed circuit, in the giv-
en switch position.
In this chart:
“Br and R” have continuity with the switch in the
“ON” position.
8-4

CHECKING SWITCHES ELEC
YP******
SWITCH POSITION AND TERMINAL CONNECTION
Before checking a switch refer to the checking

switches as shown in the left page and check for
the correct terminal connections (closed circuit)
according to the color combinations shown in
the chart.
Poor connection, fault Repair or replace.
* Indicates coupler positions.
8-5

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

YP802010
TROUBLESHOOTING
IF THE IGNITION SYSTEM

FAILS TO OPERATE.
(NO SPARK OR INTERMITTENT SPARK)
Procedure
Check:
1. Fuse (Main) 7. Pickup coil resistance
2. Battery 8. Main switch
3. Spark plug 9. Engine stop switch
4. Ignition spark gap 10. Sidestand switch
5. Spark plug cap resistance 11. Wiring connection
6. Ignition coil (entire ignition system)
NOTE:
D Remove the following parts before trouble-
shooting.
1) Footrest board
2) Cowling body
D Use the special tools specified in the trouble
shooting section.
Ignition checker
90890-06754
Pocket tester:
90890-03112
YP****** NO CONTINUITY
1. Fuse
Refer to “CHECKING SWITCHES” section in
CHAPTER 8. Replace the fuse.
CONTINUITY
YP******
INCORRECT
2. Battery
S Check the battery condition.
Refer to “BATTERY INSPECTION” section S Clean battery terminals.
in CHAPTER 3. S Recharge or replace the battery.
CORRECT
YP******
3. Spark plug Standard spark plug:

DR8EA/NGK
S Check the spark plug condition.
S Check the spark plug type.
S Check the spark plug gap. OUT OF SPECIFICATION
Refer to “SPARK PLUG INSPECTION” sec-
tion in CHAPTER 3.
Spark plug gap: Repair or replace the spark plug

0.6 X 0.7 mm
8-7

:
YP******
4. Ignition spark gap

S Disconnect the spark plug cap from the
spark plug.
S Connect the ignition checker 1 as shown.
2 Spark plug
S Turn the main switch to “ON”.
S Check the ignition spark gap .a
S Check the spark by pushing the starter MEETS SPECIFICATION
switch, and increase the spark gap until a
misfire occurs.
Minimum spark gap: The ignition system is not faulty.
6 mm (0.24 in)
OUT OF SPECIFI-
CATION OR NO
SPARK
YP******
5. Spark plug cap resistance Tester (+) lead

Spark plug side 1
S Remove the spark plug cap.
Tester (–) lead
S Connect the pocket tester (Ω 1 k) to the
High tension cord side 2
spark plug cap.
NOTE:
S When removing the spark plug cap, do not
pull the spark plug cap from high tension
cord.
S Remove Turning counterclockwise.
S Connect Turning clockwise.
S Check the high tension cord when connect-
ing the spark plug cap.
S When connecting the spark plug cap, cut
the high tension cord about 5 mm.
OUT OF SPECIFICATION
Spark plug cap resistance:
5 kΩ (20_C)
CORRECT Replace the spark plug cap.
8-8

:
YP******
6. Ignition coil resistance Tester (+) lead

Red/White Terminal 1
S Disconnect the ignition coil connector from
Tester (–) lead
the wireharness.
Orange Terminal 2
S Connect the pocket tester (Ω 1) to the
ignition coil.
S Check if the primary coil has the specified re-
sistance.
Primary coil resistance:
3.6 X 4.8 Ω (20_C)
Tester (+) lead

Spark plug lead 1
Tester (–) lead
Red/White Terminal 2
S Connect the pocket tester (Ω 1 k) to the

ignition coil.
S Check the secondary has the specified re-
sistance.
Secondary coil resistance:
10.7 X 14.5 kΩ (20_C)
BOTH MEET Replace the ignition coil.

SPECIFICATION
8-9

:
YP******
7. Pickup coil resistance

S Disconnect the pickup coil coupler from the
wireharness.
pickup coil coupler.
Tester (+) lead
Yellow Terminal 1
Tester (–) lead
Blue Terminal 2
S Check the pickup coil has the specified re-
sistance.
Pickup coil resistance:
168 X 252 Ω (20_C) Replace the pickup coil.
MEETS
SPECIFICATION
8. Main switch
the CHAPTER 8. Replace the main switch.
CONTINUITY
9. Engine stop switch
Refer to “CHECKING SWITCHES” section.
Replace the right handlebar switch.
CONTINUITY
10. Sidestand switch
Replace the sidestand switch.
CORRECT
YP******
11. Wiring connection

POOR CONNECTIONS
S Check the connection of the entire ignition
system.
Refer to “CIRCUIT DIAGRAM”.
Correct.
CORRECT
Replace the ignitor unit.
8-10

CHARGING SYSTEM ELEC
YP804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
1 A.C. magneto
2 Rectifier regulator
4 Battery
5 Main fuse
8-11

YP804010
TROUBLESHOOTING
IF THE BATTERY IS NOT CHARGED
Procedure
Check:
1. Fuse (Main) 4. Stator coil resistance
2. Battery 5. Wiring system (entire charging system)
3. Charging voltage
NOTE:
shooting.
1) Side panels
2) Tail cover
D Use the special tools specified in the trouble-
shooting section.
Engine tachometer
90890-03113
Pocket tester:
90890-03112
1. Fuse
Replace the fuse.
CONTINUITY
YP******
INCORRECT
2. Battery
in CHAPTER 3. S Recharge or replace the battery.
CORRECT
:
8-12

:
YP******
3. Charging voltage
S Connect the engine tachometer to the spark
plug lead 1 .
S Connect the pocket tester (DC20 V) to the
battery.
Tester (+) lead
Battery (+) terminal 1
Tester (–) lead
Battery (–) terminal 2
S Measure the battery terminal voltage.
S Start the engine and accelerate to about
5,000 r/min.
S Check the terminal voltage.
Charging voltage =
measured voltage – terminal
MEETS SPECIFICATION
voltage:
0.2 X 2.5 V up
NOTE:
The charging circuit is not faulty.
Use a fully charged battery. Replace the battery.
OUT OF
SPECIFICATION
:
8-13

:
YP******
4. Starter coil resistance

S Remove the A.C. magneto coupler from
wireharness.
S Connect the pocket tester (Ω 1) to the sta-
tor coil.
Tester (+) lead white terminal
Tester (–) lead White terminal
S Measure the stator coil resistance.
Stator coil resistance:
0.8 X 1.0 Ω (20_C) Replace the stator coil.
MEETS
SPECIFICATION
YP******
POOR CONNECTION
Check the entire charging system for connec-
tions. Correct.
Refer to “CIRCUIT DIAGRAM” section.
CORRECT
Replace the rectifier/regulator.
8-14

ELECTRIC STARTING SYSTEM ELEC
EB80300
ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM
3 Main switch
4 Battery
5 Main fuse
6 Starter relay
7 Starter motor
14 Sidestand switch
15 Starting circuit cut-off relay
17 Starter switch
23 Rear brake switch
24 Front brake switch
8-15

ELECTRICAL STARTING SYSTEM ELEC
YP803020
TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO

OPERATE.
Procedure
Check:
1. Fuse (Main) 7. Engine stop switch
2. Battery 8. Sidestand switch
3. Starter motor 9. Front/Rear brake switch
4. Starter relay 10. Starter switch
5. Starting circuit cut-off relay 11. Wiring connection (entire starting system)
6. Main switch
NOTE:
shooting.
1) Side panels
2) Tail cover
3) Box
shooting section.
Pocket tester:
90890-03112
1. Fuse
CHAPTER 8. Replace the fuse.
CONTINUITY
YP******
INCORRECT
2. Battery
Refer to “BATTERY INSPECTION” section S Clean the battery terminals.
in CHAPTER 3. S Recharge or replace battery.
CORRECT
8-16

:
YP******
3. Starter motor DOES NOT MOVE

S Connect the battery positive terminal and
starter motor cable using a jumper lead.
S Check the starter motor operation. Repair or replace the starter motor.
A wire used as a jumper lead must have the

MOVES equivalent capacity as that of the battery
lead or more, otherwise it may burn.
This check is likely to produce sparks, so be
sure that no flammable gas or fluid is in the
YP******
vicinity.
4. Starter relay
S Disconnect the relay unit coupler from the
wireharness.
S Connect the pocket tester (Ω 1) and bat-
tery (12 V) to the relay unit coupler terminals.
Battery (+) lead
Green/Yellow terminal 1
Battery (–) lead
Blue/White terminal 2
S Check the starter relay for continuity. NO CONTINUITY
Tester (+) lead 3 terminal
Tester (–) lead 4 terminal
CONTINUITY Replace the starter relay.

YP******
5. Starting circuit cut-off relay

S Disconnect the starting circuit cut-off relay
coupler from the wireharness.
S Connect the the pocket tester (Ω 1) and
battery (12 V) to the starting circuit cut-off
relay coupler terminals.
Battery (+) lead 2 terminal
Battery (–) lead 4 terminal
S Check the starting circuit cut-off relay for NO CONTINUITY
continuity.
Tester (+) lead 1 terminal
Tester (–) lead 3 terminal Replace the starting circuit cut-off relay.
CONTINUITY
:
8-17

:
6. Main switch
Replace the main switch.
CONTINUITY
CONTINUITY
8. Sidestand switch
Replace the sidestand switch.
CORRECT
9. Front/Rear brake switch
CHAPTER 8. Replace the brake switch.
CORRECT
10. Starter switch
CORRECT
YP****** POOR CONNECTION
S Check the connections of the entire starting
system. Correct.
Refer to “CIRCUIT DIAGRAM”.
8-18

STARTER MOTOR
7 Nm (0.7 mSkg)
7 Nm (0.7 mSkg)
10 Nm (1.0 mSkg)
5 Nm (0.5 mSkg)

Starter motor removal Remove the parts in order.
Air cleaner case Refer to “ENGINE REMOVAL AND
INSTALLATION” section in CHAPTER 4.
1 Starter motor 1
Reverse the removal procedure for instal-
lation.
Starter motor disassembly Disassembly the parts in order.
1 Front bracket 1
2 Ring 1
3 Shims 1
4 Rear bracket 1
5 Ring 1 Refer to “Starter motor assembly”
6 Shims 1
7 Brush holder set 1
8 Armature ass’y 1
9 Stator ass’y 1
Reverse the disassembly procedure for
assembly.
8-19

YP803034
Inspection and repair

1. Inspect:
S Commutator
Dirt Clean it with #600 grit sandpaper.
2. Measure:
S Commutator diameter a
Commutator wear limit:

27 mm
Out of specification Replace the starter

motor
3. Measure:
S Mica undercut a
Mica undercut:
0.7 mm
Out of specification Scrape the mica to

the proper value (a hacksaw blade can be
ground to fit).
NOTE:
The mica insulation of the commutator must be
undercut to ensure proper operation of commu-
tator.
4. Inspect:
S Armature coil resistances
(installation/continuity)
Defects Replace the starter motor.
If commutator is dirty, clean it with sandpa-
per.
Good
Bad condition
condition
A f f
B f f
f: Continuity
: No continuity
Bad condition Replace.
5. Measure:
S Brush length a
Brush length wear limit:

4.0 mm
6. Measure:
S Brush spring force
Fatigue/out of specification Replace as
a set.
8-20

Brush spring force:

570 X 920 g
7. Inspect:
S Bearing
S Oil seal
Wear/damage Repalce.
YP******
Assembly
Reverse the “Removal” procedure.
1. Install:
S Brush holder 1
NOTE:
Align the projection a on the brush seat with
the slot b on the housing.
2. Install:
S Shims 1
S Armature coil 2
3. Install:
S Ring 1
S Stator ass’y 2
S Shims 3
S Front bracket 4 5 Nm (0.5 mSkg)
NOTE:
D Apply molybdenum grease lightly on to the
bearings of the starter motor.
D Align the match marks on the yoke with the
match marks on the brackets.
8-21

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

YP805010
TROUBLESHOOTING
IF THE HEADLIGHT, HIGH BEAM

INDICATOR LIGHT, TAILLIGHT,
MARKER LIGHT AND/OR METER LIGHT
FAIL TO COME ON.
Procedure
Check:
1. Fuse (Main) 4. Lights switch
2. Battery 5. Dimmer switch and pass switch
3. Main switch 6. Wiring connection (entire lighting system)
NOTE:
shooting.
1) Tail cover
2) Cowling body
shooting section.
Pocket tester:
90890-03112
1. Fuse
Repalce the fuse.
CONTINUITY
YP******
INCORRECT
2. Battery
CORRECT
3. Main switch
CONTINUITY
YP******
NO CONTINUITY
4. Lights switch
CONTINUITY
:
8-23

:
5. Dimmer switch/Pass switch
Replace the left handlebar switch.
YP******
6. Wiring connection POOR CONNECTIONS

S Check the connections of the entire lighting
system.
Refer to “WIRING DIAGRAM”. Correct.
Check the condition of each of the lighting

system’s circuits.
Refer to “LIGHTING SYSTEM CHECK”
YP805020
LIGHTING SYSTEM CHECK

1. If the headlight and the high beam indicator light fail to come on.
1. Bulb and bulb socket NO CONTINUITY
CONTINUITY
Replace the bulb and/or bulb socket.
2. Voltage
headlight and high beam indicator light cou-
plers.
A When the dimmer switch is on low beam.
When dimmer switch is on high beam or
B the Pass switch is pushed.
Headlight:
Tester (+) lead Green 1 or Yellow 2
lead
Tester negative (–) lead Black 3
lead
High beam indicator light:
Tester (+) lead Yellow 4 lead
Tester (–) lead Black 5 lead
:
8-24

:
S Turn the main switch to on.

S Turn the light switch to on position. OUT OF SPECIFICATION
S Turn the dimmer switch to low beam or high
beam.
S Pass switch to push in. The wiring circuit from the main switch to
S Check for voltage (12 V) on the lead at bulb bulb socket connector is faulty. Repair.
socket connectors.
MEETS
SPECIFICATION
This circuit is not faulty.
YP805021
2. If the meter light fails to come on.

NO CONTINUITY
1. Bulb and bulb socket
CONTINUITY
2. Voltage
bulb socket coupler.
Tester (+) lead
Blue terminal 1
Tester (–) lead
Black terminal 2

S Turn the lights switch to on or pilot position.
S Check the voltage (12 V) of the leads on the OUT OF SPECIFICATION
bulb socket connector.
MEETS The wiring circuit from main switch to bulb

SPECIFICATION socket is faulty. Repair.
8-25

YP805022
3. The taillight fails to come on.

NO CONTINUITY
CONTINUITY
2. Voltage
Tester (+) lead
Blue terminal 1
Tester (–) lead
Black terminal 2

The wiring circuit from main switch to bulb
connector is faulty. Repair.
S Check the voltage (12 V) on the bulb socket
connector.
MEETS
SPECIFICATION
8-26

YP805023
4. If the auxiliary light fails to come on.

NO CONTINUITY
CONTINUITY
2. Voltage
Tester (+) lead Blue terminal 1
Tester (–) lead Black terminal 2

The wiring circuit from main switch to bulb
connector is faulty. Repair.
S Check the voltage (12 V) on the bulb socket
connector.
MEETS
SPECIFICATION
8-27

SIGNAL SYSTEM ELEC
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
3 Main switch 38 Turn indicator lights

4 Battery 43 Fuel gauge
5 Main fuse 49 Fuel sender
23 Rear brake switch
24 Front brake switch
25 Flasher relay
26 Horn
27 Turn switch
28 Horn switch
33 Tail/ Brake light
34 Rear flasher lights
35 Front flasher lights
8-28

SIGNAL SYSTEM ELEC
YP806010
TROUBLESHOOTING
IF THE FLASHER LIGHT, BRAKE

LIGHT AND/OR INDICATOR LIGHT
FAIL TO COME ON.
IF THE HORN FAILS TO SOUND.
Procedure
Check:
1. Fuse (Main) 3. Main switch
2. Battery 4. Wiring connection (entire signal system)
NOTE:
shooting.
1) Cowling body
2) Side panels
D Use the special tools in the troubleshooting
section.
Pocket tester:
90890-03112
1. Fuse
Replace the fuse.
CONTINUITY
YP******
INCORRECT
2. Battery
CORRECT
3. Main switch
CONTINUITY
:
8-29

SIGNAL SYSTEM ELEC
:
YP******
4. Wireharness
POOR CONNECTION
S Check the connections of the entire signal
system.
Refer to “CIRCUIT SYSTEM WIRING DIA-
GRAM” section. Correct.
CONTINUITY
Check condition of each of the signal sys-

tem’s circuits.
Refer to “SIGNAL SYSTEM CHECK” section.
8-30

SIGNAL SYSTEM ELEC
YP806020
SIGNAL SYSTEM CHECK

1. If the horn fails to sound. NO CONTINUITY
1. HORN switch
CONTINUITY
2. Voltage
horn lead.
Tester (+) lead Brown terminal 1 .
Tester (–) lead Frame ground
S Check for voltage (12 V) on the “Brown” lead OUT OF SPECIFICATION
at the horn terminal.
The wiring circuit from the main switch to the

horn is faulty. Repair.
MEETS
SPECIFICATION
3. Horn
horn at the “Pink” terminal.
Tester (+) lead Pink 1 terminal.
S Check for voltage on the “Pink” lead to frame NO CONTINUITY
ground.
CONTINUITY Replace the horn.
Adjust or replace horn.
8-31

SIGNAL SYSTEM ELEC
YP806022
2. If the brake light fails to come on:

NO CONTINUITY
CONTINUITY
NO CONTINUITY
2. Brake switch (Front/Rear)
Replace brake switch.
CONTINUITY
3. Voltage
Tester (+) lead Blue terminal 1
S Turn the main switch to on. OUT OF SPECIFICATION

S The brake lever is pulled in.
S Check for voltage (12 V) of the “Yellow” lead
on the bulb socket connector. 4. Wiring connection
MEETS S Wiring circuit from the main switch to the
SPECIFICATION bulb socket connector is faulty. Repair.
This circuit is not faulty. Refer to “SIGNAL SYSTEM WIRING DIA-
GRAM”.
8-32

SIGNAL SYSTEM ELEC
YP806023
3. If the flasher light and/or turn indicator light

fails to blink. NO CONTINUITY
CONTINUITY
NO CONTINUITY
2. Turn switch
CONTINUITY
3. Voltage
flasher relay coupler.
Tester (+) lead Brown terminal 1 .
S Check for voltage (12 V) of the “Brown” OUT OF SPECIFICATION
1 lead at the flasher relay terminal.
MEETS
The wiring circuit from main switch to flasher
SPECIFICATION
relay connector is faulty. Repair.
4. Voltage
flasher relay coupler.
Tester (+) lead
Brown/White terminal 1.
S Check for voltage (12 V) on the “Brown/ OUT OF SPECIFICATION
White” lead at the flasher relay terminal.
MEETS
The flasher relay is faulty. Replace.
SPECIFICATION
:
8-33

SIGNAL SYSTEM ELEC
:
5. Voltage
At flasher light (left)
Tester (+) lead Chocolate lead 1
At flasher light (right)
Tester (+) lead Dark green lead 2
S Turn the turn switch to left or right.
S Check for voltage (12 V) on the “Chocolate” OUT OF SPECIFICATION
lead and “Dark green” at the flasher light ter-
minal.
MEETS
SPECIFICATION S Wiring circuit from the turn switch to bulb
socket connector is fault. Repair.
This circuit is not faulty. Refer to “CIRCUIT DIAGRAM”.
8-34

SIGNAL SYSTEM ELEC
YP806027
4. If the fuel gauge fails to operate.
1. Fuel sender
S Remove the fuel sender from the fuel tank.
S Disconnect the fuel sender coupler from the
wireharness.
Connect the pocket tester (Ω 10) to the
fuel sender coupler lead.
Tester (+) lead Green terminal 1
S Check the fuel sender for specificated resis-
tance.
Specificated
Float position OUT OF SPECIFICATION
resistance
UP 3 4 X 10 Ω
DOWN 4 90 X 100 Ω
BOTH MEET Replace the fuel sender.
SPECIFICATION
2. Voltage
fuel gauge coupler.
Tester (+) lead
Brown terminal 1
Tester (–) lead
Frame ground
S Turn the main switch to “ON”. OUT OF SPECIFICATION

S Check for voltage (12 V) of the “Brown” lead
on the fuel sender lead.
Check the connection of the entire signal
MEETS system.
SPECIFICATION Refer to “CHECKING OF CONNECTIONS”.
: Refer to “CIRCUIT DIAGRAM”.
8-35

SIGNAL SYSTEM ELEC
3. Fuel gauge
S Connect the fuel sender to wireharness. NOTE:
S Move the float to “UP” 1 or “DOWN” 2. Before reading the meter, stay put the float for
more than three minutes respectively at “UP”
or “DOWN”.
S Turn the main switch to “ON”.

S Check the fuel gauge needle moves “F” or DOES NOT MOVE
“E”.
Float position Needle moves
Float “UP” 1 “F” Replace the fuel gauge.
Float “DOWN” 2 “E”
MOVES
8-36

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

COOLING SYSTEM ELEC
YP******
TROUBLESHOOTING
IF THE FAN MOTOR FAILS TO TURN.
Procedure
Check:
1. Fuse (Main, Fan) 4. Fan motor (inspection 2)
2. Battery 5. Thermo switch
3. Fan motor (inspection 1) 6. Wiring connection (entire cooling system)
NOTE:
shooting.
1) Side panels
2) Footrest board
3) Under cover
4) Drain the cooling water
shooting section.
Pocket tester:
90890-03112
1. Fuse
Replace the fuse.
CONTINUITY
YP******
INCORRET
2. Battery
CORRECT
3. Main switch
CONTINUITY
:
8-38

COOLING SYSTEM ELEC

YP******
4. Fan motor (inspection 1)

Disconnect the fan motor couplers.
Cconnect the battery as shown.
Battery (+) lead Blue terminal 1
Battery (–) lead Black terminal 2
DOES NOT MOVE
Check the fan motor operation.
Replace fan motor.
MOVES
YP******
5. Fan motor (inspection 2)

Remove the thermo switch lead from thermo
switch.
Connect jumper lead 1 to thermo switch
leads. DOES NOT MOVE
MOVES
The wiring circuit from battery to fan motor is
YP807012
faulty. Repair.
6. Thermo switch
Remove the thermo switch from the radiator.
Connect the pocket tester (Ω 1) to the
thermo switch 1 .
Immerse the thermo switch in the water
2.
Check the thermo switch for continuity.
NOTE:
Measure temperatures while heating the
coolant with the temperature gauge 3 .
8-39

COOLING SYSTEM ELEC
S Handle the thermo switch with special

care.
Never subject it to strong shocks or allow
it to be dropped. Should it be dropped, it
must be replaced.
S Do not touch the thermo switch to the
bottom of the heated vessel.
More than 98_C 105"3_C
A Thermo switch “ON”. Replace the thermo switch.

B Thermo switch “OFF”.
CORRECT
POOR CONNECTION
S Check the connection of the entire cooling
system.
Correct.
8-40

COOLING SYSTEM ELEC
YP807010
TROUBLESHOOTING
IF THE WATER TEMPERATURE

METER FAILS TO MOVE,
WHEN ENGINE IS WARM
Procedure
Check:
1. Fuse (Main, Fan) 4. Thermo unit
2. Battery 5. Voltage
3. Main switch 6. Wiring connection (entire cooling system)
NOTE:
shooting.
1) Fuel tank
2) Cowling body
shooting section.
Pocket tester:
90890-03112
1. Fuse
Replace the fuse.
CONTINUITY
YP******
INCORRET
2. Battery
CORRECT
3. Main switch
CONTINUITY
:
8-41

COOLING SYSTEM ELEC
YP******
4. Thermo unit
S Drain the coolant, and remove the thermo
unit from the radiator. D Handle the thermo unit with special care.
S Immerse the thermo unit 2 in the cool- Never subject it to strong shocks or al-
ant 3 . low it to be dropped. Should it be
1 Thermometer dropped, it must be replaced.
D Do not touch the thermo unit to the bot-
tom of the heated vessel.
Coolant temperature Resistance

80_C 47.5 X 56.8 Ω
Replace the thermo unit.
100_C 26.2 X 29.3 Ω
MEETS
SPECIFICATION
YP******
5. Voltage
temperature gauge coupler.
Tester (+) lead Green/Red terminal 1
S Turn the main switch to on. OUT OF SPECIFICATION
S Check for voltage (12 V) on the temperature
gauge lead.
The wiring circuit from main switch to tem-
CORRECT perature gauge is faulty. Repair.
:
8-42

COOLING SYSTEM ELEC
:
YP******
POOR CONNECTION
S Check the connections of the entire cooling
system.
Correct.
CORRECT
Replace the temperature gauge.
8-43

AUTO CHOKE SYSTEM ELEC
YP******
AUTO CHOKE SYSTEM

CIRCUIT DIAGRAM
3 Main switch
4 Battery
5 Main fuse
8 Thermo switch (auto choke)
9 Auto choke
10 Ignitor unit
8-44

YP******
TROUBLESHOOTING
IF THE AUTO CHOKE FAILS

TO OPERATE.
Procedure
Check:
1. Fuse (Main) 5. Thermo switch
2. Battery 6. Auto choke unit resistance
3. Main switch 7. Voltage
4. Engine stop switch 8. Wiring connection
NOTE: (entire auto choke system)
shooting.
1) Fuel tank
2) Footrest board
3) Cowling body
shooting section.
Pocket tester:
90890-03112
1. Fuse
Repalce the fuse.
CONTINUITY
YP******
INCORRECT
2. Battery
CORRECT
3. Main switch
CONTINUITY
YP******
NO CONTINUITY
CONTINUITY
:
8-45

:
YP******
5. Thermo switch
S Disconnect the thermo switch from the ra-
diator.
thermo switch 1 .
S Immerse the thermo switch in the coolant
2 .
S Check the thermo switch for continuity.
NOTE:
Note temperatures while heating the water
with the temperature gauge 3 .
S Handle the thermo switch with special

care.
Never subject it to strong shocks or allow
it to be dropped. Should it be dropped, it
must be replaced.
S Do not touch the thermo switch to bot-
tom of the heated vessel.
More than 68_C 75"3_C
A Thermo switch on. Replace the thermo switch.

B Thermo switch off.
CORRECT
8-46

:
YP******
6. Auto choke unit resistance

S Disconnect the auto choke unit coupler from
the wireharness.
auto choke unit coupler lead.
Tester (+) lead Black terminal 1
Auto choke unit resistance:
16 X 24 Ω (20_C)
Replace the auto choke unit.
MEETS
SPECIFICATION
YP******
7. Voltage (temperature under 68_C)

S Connect the pocket teser (DC20 V) to the ig-
nitor unit.
Tester (+) lead
Yellow/Red terminal 1 (1 terminal)
S Turn the main switch to on, and start the en-
gine.
S Check for voltage (12 V) on “Yellow/Red”
terminal at the ignitor unit. Replace the ignitor unit.
MEETS
SPECIFICATION
YP******
POOR CONNECTION
S Check the connection of the entire auto
choke system.
Correct.
8-47

ELEC

CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . 9-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE . . . . . . . . . . . . . 9-3
POOR MEDIUM AND HIGH SPEED PERFORMANCE . . . . . . . . . . 9-3
POOR SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
POOR SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
WHEN ENGINE IS RUN, SCOOTER DOES NOT RUN . . . . . . . . . . 9-4
POOR SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
POOR STARTING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
OVERHEATING OR OVER COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
OVER COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
POOR BRAKING EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
FRONT FORK MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
STARTER MOTOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . 9-7
STARTER MOTOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . 9-7
FAULTY SIGNAL AND LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 9-8
HEADLIGHT DARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
FLASHER DOES NOT BLINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
FLASHER KEEPS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
FLASHER BLINKS SLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
FLASHER BLINKS QUICKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
WIRING DIAGRAM

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

FUEL SYSTEM
Fuel tank Auto choke
Empty Starter plunger malfunction
Clogged fuel tank cap breather hole Wax malfunction
Deteriorated fuel or fuel containing water or P.T.C. thermister malfunction
foreign material Ignitor unit malfunction
Fuel pump Thermo switch malfunction
Clogged fuel hose Air cleaner
Clogged fuel pump Clogged air cleaner element
Broken vacuum hose or improperly hose set- Improper air cleaner setting
ting
Carburetor
Deteriorated fuel or fuel containing water or
foreign material
Clogged pilot jet
Clogged air passage
Improperly set pilot air screw
Clogged pilot air passage
Improperly sealed valve seat
Improperly adjusted fuel level
Clogged starter jet
Clogged emulsion (heated water) tube
Sucked-in air
COMPRESSION SYSTEM
Cylinder and cylinder head Valve system
Loose spark plug Improperly adjusted valve clearance
Loose cylinder head Improperly sealed valve
Broken cylilnder head gasket Improperly contacted valve and valve seat
Broken cylinder gasket Improper valve timing
Worn, damaged or seized cylinder Broken valve spring
Piston and piston ring Seized valve
Worn piston
Worn, fatigued or broken piston ring
Seized piston ring
Seized or damaged piston
9-1

TRBL
POOR IDLE SPEED PERFORMANCE SHTG
IGNITION SYSTEM
Battery Ignition system
Improperly charged battery Faulty ignitor unit
Faulty battery Faulty pick up coil
Fuse Broken magneto woodruff key
Burnt out, improper connection Switch
Spark plug Faulty main switch
Improper plug gap Faulty “ENGINE STOP” switch
Worn electrodes Faulty front and/or rear brake switch
Wire between terminals broken Faulty sidestand switch
Improper heat range Wiring
Worn electrodes Loose battery terminal
Faulty spark plug cap Loose coupler connection
Ignition coil Improperly grounded
Broken or shorted primary/secondary coil Broken wireharness
Faulty high tension cord
Broken ignitin coil body
YP901000
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE
Carburetor Air cleaner
Loose or clogged pilot jet Clogged air cleaner element
Damaged carburetor joint Ignition system
Improperly tightened carburetor joint clamp Faulty spark plug
hose Faulty high tension cord
Improperly adjusted idle speed Faulty ignitor unit
(Pilot screw), (Throttle stop screw), (CO test) Faulty pick up coil
Improperly adjusted throttle cable Faulty ignition coil
Flooded carburetor Valve system
Auto choke Improperly adjusted valve clearance
Faulty starter plunger
Improper wax operation
Faulty ignitor unit
Faulty P.T.C. thermister
9-2

TRBL
POOR MEDIUM AND HIGH SPEED PERFORMANCE SHTG
EB902000
POOR MEDIUM AND HIGH SPEED PERFORMANCE

POOR MEDIUM AND HIGH SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING” section. (Fuel system, electrical system, compres-
sion system and valve train)
Carburetor Air cleaner
Improperly adjusted fuel level Clogged air cleaner element
Clogged main nozzle
Clogged or loose pilot jet
YP******
POOR SPEED PERFORMANCE

POOR SPEED PERFORMANCE
Ignition system Compression system
Dirty spark plug Worn cylinder
Improper heat range Worn or seized piston ring
Faulty ignitor unit Cylinder head gasket broken
Faulty pick up coil Cylinder gasket broken
Fuel system Carbon deposit build-up
Clogged fuel tank cap breather hole Improperly adjusted valve clearance
Clogged air cleaner element Improperly contacted valve and valve seat
Clooged jet Faulty valve timing
Improperly adjusted fuel level Clutch
Improper carburetor air vent hose setting Refer to “CLUTCH SLIPPING/DRAGGING”
section
Engine oil
Improper oil level (low or over oil level)
Improper quality (Low oil viscosity)
Deterioration
Clogged oil passage
Brakes
Dragging brake
9-3

TRBL
FAULTY CLUTCH SHTG
YP******
FAULTY CLUTCH
WHEN ENGINE IS RUN, SCOOTER DOES NOT RUN
V belt POOR SPEED PERFORMANCE
Worn/bent/slipping V belt
Cam, slider Worn
Worn/damaged Oily V belt
Compression spring Roller weight
Damage Worn/improper operation
Gears Primary/secondary sheave
Damage Worn
YP904000
CLUTCH SLIPPING
Clutch weight spring
Worn/loose
Clutch shoe
Worn/damaged
Primary sliding sheave
Seized
YP******
POOR STARTING PERFORMANCE

V belt
Slipping/oily V belt
Primary sliding sheave
Improper operation
Damage
Compression spring
Worn/loose
Secondary sliding sheave
Improper operation
Worn guide pin groove
Worn guide pin
Clutch shoe
Worn/bent
9-4

TRBL
OVERHEATING OR OVER COOLING SHTG
YP905000
OVERHEATING OR OVER COOLING

OVERHEATING OVER COOLING
Ignition system Cooling system
Improper spark plug gap Faulty cooling fan
Improper spark plug heat range Faulty thermostat
Faulty ignitor unit Faulty thermo switch
Fuel system
Improper carburetor setting
Improper fuel level adjustment
Clogged air cleaner element
Compression system
Heavy carbon deposit build-up
Improperly adjusted valve timing
Improperly adjusted valve clearance
Engine oil
Incorrect engine oil level
Improper engine oil quality (High viscosity)
Low engine oil quality
Brakes
Dragging brake
Cooling system
Inoperative fan motor
Faulty thermostat
Faulty thermo switch
Incorrect coolant level (low coolant level)
Faulty radiator (Clogged, damage)
Faulty radiator cap
Impeller shaft gear malfunction (bent dowel
pin, gear)
Damaged impeller shaft
Disconnected fan motor connector
9-5

TRBL
FAULTY BRAKE/FRONT FORK MALFUNCTION SHTG
YP906000 YP907000
FAULTY BRAKE FRONT FORK MALFUNCTION

POOR BRAKING EFFECT OIL LEAKAGE
Front brake Bent, damaged or rusty inner tube
Worn brake pad Damaged or cracked outer tube
Worn brake disc Damaged oil seal lip
Air in brake fluid Loose hexagon bolt
Leaking brake fluid Damage cap bolt O-ring
Faulty master cylinder kit MALFUNCTION
Faulty caliper seal kit Bent inner tube
Loose union bolt Deformed outer tube
Broken brake hose Damaged fork spring
Oily or greasy brake pad Bent cylinder complete
Oily or greasy brake disc Improper oil viscosity (High viscosity)
Rear brake Improper oil level
Improper brake lever adjustment
Worn brake shoe
Improper brake shoe contact
Worn camshaft
Worn brake drum
Mud or water into brake drum inside
Oily or greasy brake lining
Faulty brake cable
Broken or fatigued tension spring
Faulty camshaft, cam lever
9-6

INSTABLE HANDLING/ TRBL
STARTER MOTOR DOES NOT OPERATE SHTG
YP908000 YP******
INSTABLE HANDLING STARTER MOTOR DOES NOT

INSTABLE HANDLING OPERATE
Handlebars STARTER MOTOR DOES NOT OPERATE
Loose handlebar tightening bolt Battery
Steering Insufficient battery capacity
Loose or overtightening steering nut Faulty battery
Bent under bracket Fuse
Damaged bearing or ball race Burnt out, improper connection
Front forks Switch
Uneven oil levels on both sides Faulty main switch
Broken front fork spring Faulty sidestand switch
Twisted front forks Faulty front and/or rear brake switch
Wheels Faulty starting circuit cut-off relay
Incorrect wheel balance Faulty starter relay
Deformed wheel rim Wireharness
Unevenly worn tires Loose battery terminal
Incorrect tire pressure Loosely connected coupler
Loose bearing Improperly grounded
Bent or loose wheel axle Broken wireharness
Frame Starter motor
Twisted Worn brush
Damaged head pipe bearings Faulty commutator
Rear arm Broken armature coil
Faulty bearings Engine
Bent rear arm Seized engine
Rear shock absorber
Fatigued spring
Improperly adjusted spring preload
Oil leakage
Cowling
Damage
Improper mounting
9-7

TRBL
FAULTY SIGNAL AND LIGHTING SYSTEM SHTG
YP909000
FAULTY SIGNAL AND LIGHTING SYSTEM

HEADLIGHT DARK FLASHER BLINKS SLOWER
Improper bulb Faulty flasher relay
Too many electric accesories Insufficient battery capacity
Hard charging (nearly discharged)
Faulty rectifier/regulator Improper bulb
Faulty battery Faulty main and/or turn switch
Improperly connected coupler, connector, FLASHER BLINKS QUICKER
wireharness Improper bulb
Improperly grounded Faulty flasher relay
Faulty main switch or Lights (dimmer) switch HORN DOES NOT SOUND
Bulb life expired Faulty battery
BULB BURNT OUT Faulty fuse
Improper bulb Faulty main and/or horn switch
Faulty battery Improper horn adjustment
Faulty rectifier/regulator Faulty horn (burnt coil, connector)
Improperly grounded Broken wireharness
Faulty main switch
Bulb life expired
FLASHER DOES NOT BLILNK
Improperly grounded
Insufficient battery capacity
Faulty fuse
Faulty turn switch
Faulty flasher relay
Broken wireharness, incorrect coupler con-
nection
Bulb burnt out
FLASHER KEEPS ON
Faulty flasher relay
Insufficient battery capacity
(nearly discharged)
Bulb burnt out (front or rear)
9-8

YP250 WIRING DIAGRAM
1. A.C. magneto
2. Rectifier / regulator
3. Main switch
4. Main fuse
5. Battery
6. Starter relay
7 Starter motor
8 Thermo switch (auto choke)
9. Auto choke
10. Ignitor unit
11. Ignition coil
12. Spark plug
13. Pickup coil
14. Sidestand switch
15. Starting circuit cut-off relay
16. Lights switch
17. Starter switch
19. Handlebar switches (right)
20. Fuse (fan)
21. Thermo switch
22. Fan motor
23. Rear brake switch
24. Front brake switch
25. Flasher relay
26. Horn
27. Turn switch
28. Horn switch
29. Dimmer switch
30. Pass switch
31. Handlebar switches (left)
32. Tail / Brake light
33. Licence light
34. Rear flasher lights
35. Front flasher lights
36. Head light
37. Auxiliary light
38. Turn indicator lights
39. High beam indicator light
40. Meter lights
41. Cil indicator light
42. Reset switch
43. Fuel gauge
44. Read switch
45. Clock
46. Thermometer
47. Speedometer
48. Meter assembly
49. Fuel sender
50. Thermo unit
COLOR CODE
B ........ Black Br / W . . . . . Brown / White
Br . . . . . . . Brown G/R . . . . . Green / Red
Ch . . . . . . Chocolate G / Y. . . . . . Green / Yellow
Dg . . . . . . Dark green L/B . . . . . . Blue / Black
G ....... Green L/Y . . . . . . Blue / Yellow
L ........ Blue L/W . . . . . Blue / White
O ....... Orange L/R . . . . . . Blue / Red
Sb . . . . . . . Sky blue R/B. . . . . . Red / Black
P ........ Pink R/Y. . . . . . Red / Yellow
R........ Red R/W . . . . . Red / White
Y ........ Yellow Y/W . . . . . Yellow / White
W ....... White W/G . . . . . White / Green
B/R. . . . . . Black / Red

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The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

Failure to follow WARNING instructions could result in severe injury or death to

NOTE: A NOTE provides key information to make procedures easier or clearer.

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HOW TO USE THIS MANUAL

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9 10 Illustrated symbols 10 to 17 are used to identify

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VEHICLE IDENTIFICATION NUMBER (for E)

FRAME SERIAL NUMBER (except for E)

ENGINE SERIAL NUMBER

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Oil indicator light

Battery tending to discharge.

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IGNITION CIRCUIT CUT-OFF SYSTEM

Battery Start Sidestand

Operation of brake Operation of starter Operation of igniter

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4. When disassembling the machine, always

GASKETS, OIL SEALS AND O-RINGS

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LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

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3. Connect and disconnect the connector two

7. Check for continuity with a tester.

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HOW TO USE THE CONVERSION TABLE

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Tool No. Tool name/Usage Illustration

These tools are used when removing

This tool is used to remove the

This tool is used to loosen and tighten

This tool is necessary for adjusting

This gauge is used to measure the fuel

These tools are used for checking the

These tool are used for holding the

These tools are used for removing the

This tool is used when removing or

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Tool No. Tool name/Usage Illustration

This tool is used for removing the

This tool is used when installing the

This tool is used for protecting the oil

This tool is used to loosen and tighten

This tool is used for holding the

This tool is used for installing the

This tool is used to measure the valve

These tools are used to measure the

These instruments are invaluable for

This tool is needed for detecting

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Tool No. Tool name/Usage Illustration