Yamaha 2XJ-AE3, Service Manual

Page 1: ...YFS200R2XJ AE3 SUPPLEMENTARY SERVICE MANUAL ...

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Page 3: ...rvice Manual together with the following manual YFS200U SERVICE MANUAL 2XJ ME1 YFS200A 90 SUPPLEMENTARY SERVICE MANUAL 2XJ AE1 YFS200 P 2002 SUPPLEMENTARY SERVICE MANUAL 2XJ AE2 YFS200R SUPPLEMENTARY SERVICE MANUAL 2002 by Yamaha Motor Co Ltd First edition July 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibite...

Page 4: ...fications and sig nificant 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 ...

Page 5: ...nic with an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particularly important procedure 4 is placed between a line of asterisks with each proce dure preceded by IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol 5 An encircled numeral 6 indicates a part name and an encir...

Page 6: ...rance D Engine speed E Ω V A Illustrated symbols F to L in the exploded diagrams indicate the types of lubricants and lubrication points F Apply engine oil G Apply gear oil H Apply molybdenum disulfide oil I Apply wheel bearing grease J Apply lightweight lithium soap based grease K Apply molybdenum disulfide grease L Apply silicon grease Illustrated symbols M to N in the exploded diagrams indicate...

Page 7: ... BRAKE SYSTEM 18 ELECTRICAL 20 ADJUSTING THE HEADLIGHT BEAM 20 REPLACING THE HEADLIGHT BULB 20 CHASSIS 23 FRONT AND REAR BRAKES 23 REPLACING THE BRAKE PADS 25 DISASSEMBLING THE BRAKE CALIPERS 30 DISASSEMBLING THE BRAKE MASTER CYLINDER 33 CHECKING THE BRAKE CALIPER AND BRAKE MASTER CYLINDER 36 ASSEMBLING THE BRAKE CALIPER 40 ASSEMBLING THE MASTER CYLINDER 46 STEERING SYSTEM 51 FRONT SHOCK ABSORBERS...

Page 8: ...TROUBLESHOOTING 64 STARTING FAILURE HARD STARTING 64 ELECTRICAL SYSTEM 64 FAULTY BRAKE 64 POOR BRAKING EFFECT 64 YFS200R WIRING DIAGRAM ...

Page 9: ... and full fuel tank 155 kg 342 lb Chassis Frame type Steel tube Caster angle 9 Camber angle 1 Kingpin angle 13 Kingpin offset 10 mm 0 39 in Trail 40 mm 1 57 in Tread STD rear 780 mm 30 7 in front 820 mm 32 3 in Toe in 0 10 mm 0 0 39 in Brake Front brake type Dual disc brake operation Right hand Rear brake type Single disc brake operation Right foot ...

Page 10: ...1 0 6305 in Limit 16 045 mm 0 6317 in Piston pin outside diameter 15 995 16 000 mm 0 6297 0 6299 in Limit 15 975 mm 0 6289 in Carburetor Type manufacture quantity VM26SS MIKUNI 1 I D mark 5VM1 00 Main jet M J 230 Main air jet M A J ø0 7 Jet needle clip position J N 5JFJ34 3 Needle jet N J P 6 345 Cutaway C A 2 0 Pilot outlet P O 0 6 Pilot jet P J 32 5 Bypass 1 B P 1 0 8 3 75 Pilot air screw P A S ...

Page 11: ...and handlebar holder M8 1 25 23 2 3 17 Front brake disc and wheel hub M8 1 25 28 2 8 20 LT Front brake caliper and steering knuckle M8 1 25 28 2 8 20 Bleed screw M8 1 25 6 0 6 4 3 Steering knuckle and tie rod M10 1 25 25 2 5 18 Tie rod locknut M10 1 25 15 1 5 11 Steering column and frame M10 1 25 35 3 5 25 Parking brake adjuster locknut M8 1 25 16 1 6 11 Rear brake hose union bolt M10 1 25 30 3 0 ...

Page 12: ...AL Model YFS200R C D I Magneto model manufacturer F2XJ YAMAHA Pickup coil resistance color 16 24 Ω at 20 C 68 F White Red Black Charging coil resistance color 192 288 Ω at 20 C 68 F Green White Black Red C D I unit model manufacturer 5VM YAMAHA ...

Page 13: ...ar switch lead left 0 Headlight lead A Wire harness B C D I unit lead C C D I unit D Voltage regulator E Ground lead F Main switch lead È Route each lead through the cable guide and in front of the clutch cable and parking brake as shown É Do not clamp the main switch lead Ê 40 60 mm 1 57 2 36 in Ë 50 70 mm 1 97 2 76 in 7 8 F E D C B A 9 1 4 É Ê Ë 1 9 7 8 9 1 2 3 4 5 6 7 8 B B A A A A B B A A É È ...

Page 14: ...lutch cable 4 Parking brake cable 5 Crankcase ventilation hose 6 Front brake pipe 7 Handlebar cover È Pass the crankcase ventilation hose between the parking brake cable and clutch cable and then fasten it with a band 1 2 6 4 3 7 1 5 È CABLE ROUTING ...

Page 15: ... breather hose 5 Crankcase ventilation hose 6 Wire harness 7 Front brake hose 8 Front brake pipe È Route the clutch cable and parking brake cable in front of the fender stay É 30 40 mm 1 18 1 57 in 1 2 8 5 6 7 8 1 2 3 4 5 6 B B A A B B È C É 5 D D C D D 5 CABLE ROUTING ...

Page 16: ... switch lead 7 Band 8 Clamp 9 Oil hose 0 Carburetor overflow hose A C D I magneto lead È To install the wire harness align the positioning tape with the wire holder É The leads should be clamped on the inward half of the frame pipe Ê Clamp the oil hose and rear brake light switch lead with the plastic clamp CABLE ROUTING ...

Page 17: ...lation hose 5 Rear brake light switch 6 Band 7 Tail brake light lead 8 Oil level gauge lead 9 Oil hose 0 Wire harness A Clamp B Throttle switch lead C Throttle cable D Ignition coil lead E Ignition coil F Ground lead G Rear brake light switch lead È 50 80 mm 1 97 3 15 in CABLE ROUTING ...

Page 18: ... 10 SPEC 1 Oil hose 2 Crankcase ventilation hose 3 Clutch cable 4 Parking brake cable 5 Cable guide È Route the parking brake cable in front of the fender stay CABLE ROUTING ...

Page 19: ... 11 SPEC 1 Rear brake hose 2 Parking brake cable 3 Rear brake light switch 1 2 3 1 2 1 2 1 2 1 A D D C C B B A D D C C B B CABLE ROUTING ...

Page 20: ...just if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or damage Replace if necessary Throttle operation Inspect and adjust free play if necessary Front and rear brake operation Check operation fluid leakage S...

Page 21: ... When disassembling the master cylinder or caliper cylinder replace the brake fluid Normally check the brake fluid level and add fluid as required 2 On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged ...

Page 22: ... the specified brake cable length is obtained Tighten the locknut 1 Slowly turn the adjusting bolt 4 clockwise until resistance is felt and then turn it 1 8 turn counterclockwise Tighten the locknut 3 CAUTION When tightening the locknut 3 hold the adjusting bolt with a wrench so that the adjusting bolt does not turn together with the locknut CAUTION Make sure that the parking brake does not drag a...

Page 23: ...knut 1 Adjust the rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH Manual No 2XJ AE2 WARNING After this adjustment is performed lift the front and rear wheels off the ground by placing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again Direction a Brake pedal is lowered Direction b Brak...

Page 24: ...pilled fluid immediately WARNING Use only the recommended brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid Mixing brake fluids may result in a harm ful chemical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significan...

Page 25: ...er to FRONT WHEEL AND FRONT BRAKE in CHAPTER 6 Manual No 2XJ ME1 Wear limit 1 0 mm 0 04 in 1 È 1 É CHECKING THE BRAKE HOSES 1 Remove Front panel Refer to REPLACING THE HEADLIGHT BULB 2 Check Brake hoses 1 Cracks wear damage Replace Fluid leakage Replace the hose Refer to FRONT AND REAR BRAKES NOTE Hold the machine in an upright position and apply the front or rear brake 3 Check Brake hose clamps L...

Page 26: ...Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic hose 1 tightly to the caliper bleed screw 2 È Front É Rear d Place the other end of the hose into a con tainer e Slowly operate the brake lever or pedal several times f Pull the lever in or push down on the pedal Hold the lever or pedal in...

Page 27: ...ry to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the system have disappeared k Add brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL WARNING Check the operation of the brake after bleeding the brake system T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb ...

Page 28: ...DLIGHT BEAM 1 Adjust Headlight beam vertical Turn the adjusting screw 1 in or out Turning in Headlight beam is raised Turning out Headlight beam is lowered 1 REPLACING THE HEADLIGHT BULB 1 Remove Screws 1 Front panel 2 1 1 2 2 Disconnect Headlight connectors 1 1 3 Remove Bolt 1 Headlight assembly 1 ...

Page 29: ...ammable products or your hands away from the bulb while it is on since it will be hot Do not touch the bulb until it cools down 1 6 Install Headlight bulb 1 to headlight unit assembly NOTE Make sure that the projection on the bulb is meshed with the slot on the headlight unit assembly 2 2 1 New New 7 Install Headlight bulb holder 1 Headlight bulb holder cover NOTE Make sure that the projections on...

Page 30: ...T BULB 8 Install Headlight unit assembly Screws Nut Spring Washer Headlight adjusting screw Headlight assembly 9 Connect Headlight connectors 10 Install Front panel 11 Adjust Headlight beam vertical Refer to ADJUSTING THE HEADLIGHT BEAM ...

Page 31: ...iper body E Brake pad shim F Brake pad G Brake pad spring H Brake caliper piston I Brake caliper piston seal J Brake caliper bracket K Brake disc guard inner L Bearing M Spacer N Oil seal O Wheel hub P Brake disc guard outer 1 2 4 5 3 7 6 9 P O M L L N N 0 K 8 7 8 5 6 5 6 B C D H E F G J I A 28 Nm 2 8 m kg 20 ft lb 7 Nm 0 7 m kg 5 1 ft lb 27 Nm 2 7 m kg 19 ft lb 27 Nm 2 7 m kg 19 ft lb 27 Nm 2 7 m...

Page 32: ...sting bolt N Union bolt O Copper washer P Brake hose Q Brake master cylinder R Brake master cylinder kit S Clevis pin T Cotter pin U Brake hose joint V Circlip W Brake fluid reservoir hose X Brake fluid reservoir Y Brake fluid reservoir diaphragm Z Brake fluid reservoir diaphragm holder Brake fluid reservoir cap T C S R V U B Q O 9 1 2 3 4 M L K J H G I O N P N O Z Y X B A 0 8 7 5 6 C D E F New Ne...

Page 33: ...inted surfaces or plastic parts as this may cause damage Disconnect any hydraulic connection as this would require the entire brake system to be disassembled drained cleaned and properly filled and bled after reassembly REPLACING THE BRAKE PADS NOTE When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake calipers Front brake 1 Remove Front wheel Re...

Page 34: ...ke pad Pad spring Brake pads Installation steps Connect a suitable hose 1 tightly to the cali per bleed screw 2 Put the end of this hose into an open container Loosen the caliper bleed screw using a fin ger push the caliper piston into the brake caliper Tighten the caliper bleed screw 2 Install the pad shim 3 onto the brake pad 4 NOTE The arrow mark a on the pad shim must point in the direction of...

Page 35: ... FLUID LEVEL 9 Check Brake lever operation A soft or spongy feeling Bleed brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM T R Retaining bolt 18 Nm 1 8 m kg 13 ft lb Bolt front brake caliper 28 Nm 2 8 m kg 20 ft lb Rear brake 1 Remove Rear wheel Refer to REAR WHEEL AND REAR AXLE in CHAPTER 6 Manual No 2XJ ME1 Rear brake caliper 1 1 2 Straighten the lock washer tabs 3 Remove Retaining bol...

Page 36: ...pads Installation steps Loosen the locknut 1 and parking brake adjuster 2 Connect a suitable hose 3 tightly to the cali per bleed screw 4 Put the other end of this hose into an open container Loosen the caliper bleed screw and push the piston into the caliper with a finger Tighten the caliper bleed screw 4 Install the pad shim 5 onto the brake pad 6 NOTE The arrow mark a on the pad shim must point...

Page 37: ...l Refer to REAR WHEEL AND REAR AXLE in CHAPTER 6 Manual No 2XJ ME1 10 Adjust Parking brake Refer to ADJUSTING THE PARKING BRAKE 11 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL 12 Check Brake pedal operation A soft or spongy feeling Bleed brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM T R Retaining bolt 18 Nm 1 8 m kg 13 ft lb T R Bolt rear brake caliper 28 Nm 2 8 m k...

Page 38: ...NT WHEEL AND FRONT BRAKE in CHAPTER 6 Manual No 2XJ ME1 2 Loosen Union bolt 3 Remove Front brake caliper Retaining bolts Brake pads with pad shim Pad spring Refer to REPLACING THE BRAKE PADS 4 Remove Union bolt 1 Copper washers 2 Brake hose 3 NOTE Place the open end of the hose into a con tainer and pump the brake fluid out carefully 3 1 2 5 Remove Caliper body 1 Caliper bracket 2 NOTE Before remo...

Page 39: ...s WARNING Never attempt to pry out the piston 3 1 2 a Rear brake caliper 1 Remove Rear wheel right Refer to REAR WHEEL AND REAR AXLE in CHAPTER 6 Manual No 2XJ ME1 2 Loosen Union bolt 3 Remove Rear brake caliper Retaining bolts Lock washer Brake pads with pad shim Pad spring Refer to REPLACING THE BRAKE PADS 4 Remove Parking brake cable 1 Union bolt 2 Copper washers Brake hose 3 NOTE Place the ope...

Page 40: ...3 Spring 4 1 2 3 4 6 Remove Parking brake assembly 1 Gasket 1 7 Remove Cover 1 Spring 2 Adjuster nut 3 Parking brake cam 4 2 3 4 1 8 Remove Caliper body 1 Caliper bracket 2 NOTE Before removing the caliper body from the bracket remove the dust boot from the guide shaft on the bracket 1 2 ...

Page 41: ... WARNING Never attempt to pry out the piston 1 2 3 4 a DISASSEMBLING THE BRAKE MASTER CYLINDER NOTE Before disassembling the front or rear brake master cylinders drain the brake fluid from the brake hoses brake pipe master cylinder brake caliper and brake fluid reservoir Front brake master cylinder 1 Remove Front brake light switch 1 NOTE Push the fastener when removing the front brake light switc...

Page 42: ...ove Brake master cylinder reservoir cap 1 Brake master cylinder reservoir diaphragm Brake master cylinder 2 1 2 4 Remove Brake master cylinder kit 1 Drain the excess fluid 1 Rear brake master cylinder 1 Remove Cotter pin 1 Washer Clevis pin 2 1 2 2 Remove Union bolt 1 Copper washer 2 Brake hoses 3 NOTE Hold a container under the brake master cylin der and under the hose ends to collect the remaini...

Page 43: ...Remove Brake master cylinder 1 1 4 Remove Brake master cylinder kit 1 1 5 Remove Brake fluid reservoir 1 from frame 1 6 Remove Brake fluid reservoir cap 1 Brake fluid reservoir diaphragm holder 2 Brake fluid reservoir diaphragm 3 1 2 3 ...

Page 44: ...st seal Every two years Brake hoses Every two years Brake fluid Replace only when brakes are disassembled Brake pipes Replace whenever brake pipes are disconnected 1 Check Caliper piston 1 Scratches rust wear Replace caliper assembly Caliper cylinder 2 Wear scratches Replace caliper assembly Caliper body 3 Cracks damage Replace Oil delivery passage caliper body Blow out with compressed air WARNING...

Page 45: ... Replace È Front É Rear 1 È 1 É 3 Check Brake master cylinder 1 Wear scratches Replace the master cylin der assembly Brake master cylinder body 2 Cracks damage Replace Oil delivery passage brake master cylinder body Blow out with compressed air È Front É Rear 2 1 È 2 1 É ...

Page 46: ...Rear 1 È 1 É 5 Check Brake master cylinder reservoir 1 Cracks damage Replace Brake master cylinder reservoir diaphragm 2 Brake fluid reservoir 3 Brake fluid reservoir diaphragm 4 Brake fluid reservoir diaphragm holder 5 Wear damage Replace È Front É Rear 2 1 5 4 3 È É 6 Check Brake hose 1 Cracks wear damage Replace 1 ...

Page 47: ...ct wheel runout If wheel runout is in good condition replace the brake discs 1 Dial gauge Brake disc thickness a Out of specification Replace NOTE Tighten the brake disc bolts in stages and in a crisscross pattern Maximum deflection Front 0 1 mm 0 004 in Rear 0 1 mm 0 004 in Maximum deflection Front 3 0 mm 0 12 in Rear 3 3 mm 0 13 in Bolt front brake disc 28 Nm 2 8 m kg 20 ft lb Bolt rear brake di...

Page 48: ...led Replace the piston seals and dust seals whenever a caliper is disassembled Recommended brake fluid DOT 4 Front brake caliper 1 Install Bleed screw 1 Piston seals 2 Piston 3 WARNING Always use new piston seals 1 3 2 New New 2 Install Caliper bracket 1 Caliper body 2 Retaining bolt 3 NOTE Apply lithium soap based grease to the retain ing bolt T R Retaining bolt 18 Nm 1 8 m kg 13 ft lb 2 1 3 ...

Page 49: ...hose routing is essential to ensure safe machine operation Refer to CABLE ROUTING Always use new copper washers 4 Remove Brake caliper 5 Install Pad spring Brake pads with pad shim Retaining bolts Front brake caliper Refer to REPLACING THE BRAKE PADS Front wheel Refer to FRONT WHEEL AND FRONT BAKE in CHAPTER 6 Manual No 2XJ ME1 T R Union bolt 27 Nm 2 7 m kg 19 ft lb T R Retaining bolt 18 Nm 1 8 m ...

Page 50: ... same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock Recommended brake fluid DOT 4 7 Air bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM 8 Check Brake...

Page 51: ... caliper guide shaft and retaining bolt 3 Install Parking brake cam 1 Adjuster nut 2 Spring 3 Cover 4 NOTE Mesh the parking brake cam tab a with the parking brake case slit b Apply wheel bearing grease to the parking brake cam 1 CAUTION Be sure to install the parking brake spring 3 in the direction shown in the illustration T R Retaining bolt 18 Nm 1 8 m kg 13 ft lb 2 1 3 3 2 1 4 b a 4 Install Gas...

Page 52: ...g down as shown 1 a b 2 6 Install Brake caliper 1 temporarily Copper washers Brake hose 2 Union bolt 3 Parking brake cable 4 CAUTION When installing the brake hose onto the caliper make sure that the brake pipe con tacts the projection a on the brake caliper WARNING Proper hose routing is essential to ensure safe machine operation Refer to CABLE ROUTING Always use new copper washers 7 Remove Brake...

Page 53: ...arts Always clean up spilled fluid immediately WARNING Use only the recommended brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling...

Page 54: ...only Internal parts should be lubricated with brake fluid when installed Front brake master cylinder 1 Install Master cylinder kit 1 Recommended brake fluid DOT 4 1 2 Install Master cylinder 1 CAUTION Install the master cylinder holder with the UP mark facing forward Engage the indentations a in the collar with the lobes b on the throttle lever assembly and master cylinder First tighten the upper ...

Page 55: ...uting is essential to ensure safe machine operation Refer to CABLE ROUTING Always use new copper washers 4 Install Front brake light switch T R Union bolt 27 Nm 2 7 m kg 19 ft lb New 3 2 1 5 Fill Brake master cylinder reservoir CAUTION Brake fluid may erode painted surfaces of plastic parts Always clean up spilled fluid immediately WARNING Use only the recommended brake fluid Other brake fluids ma...

Page 56: ...g point of the brake fluid and may result in vapor lock 6 Air bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM 7 Install Brake master cylinder reservoir diaphragm Brake master cylinder reservoir cap 1 1 8 Install Front brake light switch 1 9 Check Brake fluid level Fluid level is below the LOWER level line Add the recommended brake fluid to the proper level Refer to CHECKING THE BRA...

Page 57: ...bolt 2 CAUTION When installing the brake hose onto the master cylinder make sure that the brake pipe contacts the projection a as shown WARNING Proper hose routing is essential to ensure safe machine operation Refer to CABLE ROUTING Always use new copper washers T R Union bolt 30 Nm 3 0 m kg 22 ft lb a 2 1 New 5 Install Clevis pin 1 Washer Cotter pin 2 WARNING Always use a new cotter pin 2 1 New N...

Page 58: ...ype of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 7 Air bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM 8 Check Brake fluid level Fluid level is below the...

Page 59: ...NG SYSTEM 1 Handlebar holder 2 Bearing lower 3 Oil seal 4 Bearing upper 5 Collar 6 Cable holder 7 Lock washer 8 Steering stem 9 Cotter pin 0 Tie rod end A Locknut B Tie rod C Steering knuckle D Knuckle arm E Washer F Bushing G O ring ...

Page 60: ... SHOCK ABSORBERS AND FRONT ARMS FRONT SHOCK ABSORBERS AND FRONT ARMS 1 Thrust cover 2 Bushing 3 Front arm upper 4 Inner collar 5 Knuckle arm 6 Steering knuckle 7 Shock absorber assembly 8 Front arm lower 9 Cotter pin ...

Page 61: ...D SWINGARM 1 Rear shock absorber assembly 2 Bushing 3 Cotter pin 4 Swingarm pivot shaft 5 Thrust cover 6 Plate washer 7 Dust cover 8 Bearing 9 Bushing 0 Oil seal A Inner collar B Swingarm C Protector guide D Thrust cover protector E Chain guide F Under guard G Shim ...

Page 62: ...Y GRAY 7 B Y B Y B B GRAY GRAY 9 0 6 4 5 BLACK O B B W W R B R Y B G Y G W G Y B B B Y R B R W R G W B R W R G W B B W G Y G Y B O Y B B L O B B Y R B W Br Y Br Y B B B W B G Y G Y Y L L Br G G B B B Y B B Y B 3 CH PU COIL IGN PKG STOP TORS GND 2 1 1 C D I magneto 3 C D I unit 4 Ignition coil 5 Spark plug 6 Parking brake switch 7 Throttle switch 8 Carburetor switch A Main switch B Engine stop swit...

Page 63: ...tation direction detection coil resistance 12 Wiring connection the engine ignition system IF THE IGNITION SYSTEM FAILS TO OPERATE NO SPARK OR INTERMITTENT SPARK NOTE Remove the following parts before trouble shooting 1 Seat 2 Fuel tank cover 3 Front panel 4 Fuel tank Use the specified special tools for trouble shooting Dynamic spark tester P N YM 34487 Ignition checker P N 90890 06754 Pocket test...

Page 64: ...firing occurs Minimum spark gap 7 0 mm 0 28 in MEETS SPECIFICATION The ignition system is not faulty For Europe and Oceania OUT OF SPECIFICATION OR NO SPARK 2 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition checker 1 as shown 2 Spark plug cap Turn the main switch to ON Check the ignition spark gap a Kickstart the engine and increase the spark gap until a m...

Page 65: ...the ignition coil connector from the wire harness Connect the pocket tester Ω 1 to the ignition coil Tester lead Orange lead terminal Tester lead Ignition coil lead Measure the primary coil resistance Primary coil resistance 0 18 0 28 Ω at 20 C 68 F BOTH MEET SPECIFICATION Connect the pocket tester Ω 1k to the ignition coil Tester lead Orange lead terminal Tester lead Spark plug lead Measure the s...

Page 66: ...NG THE SWITCH Manual No 2XJ AE2 INCORRECT Replace the parking brake switch CORRECT 7 Throttle switch Refer to CHECKING THE SWITCH Manual No 2XJ AE2 INCORRECT Replace the throttle switch CORRECT 8 Carburetor switch Refer to CHECKING THE SWITCH Manual No 2XJ AE2 INCORRECT Replace the carburetor switch CORRECT 9 Main switch Refer to CHECKING THE SWITCH Manual No 2XJ AE2 INCORRECT Replace the main swi...

Page 67: ... Black Red OUT OF SPECIFICATION Replace the pickup coil stator assembly G W W R Y R B R B 2 1 CORRECT 12 Wiring connection Check the connections of the entire ignition system Refer to CIRCUIT DIAGRAM Replace the C D I unit POOR CONNECTION Properly connect the ignition system C0NTINUITY MEETS SPECIFICATION 10 Pickup coil resistance Disconnect the C D I magneto connectors from the wire harness Conne...

Page 68: ...Y B Y B B BLACK BLACK BLACK GRAY GRAY 7 B Y B Y B B GRAY GRAY 9 0 6 4 5 BLACK O B B W W R B R Y B G Y G W G Y B B B Y R B R W R G W B R W R G W B B W G Y G Y B O Y B B L O B B Y R B W Br Y Br Y B B B W B G Y G Y Y L L Br G G B B B Y B B Y B 2 1 CH PU COIL IGN PKG STOP TORS GND 3 1 C D I magneto 2 Voltage regulator C Light switch D Headlight E Tail brake light ...

Page 69: ...0 03112 1 Lighting coil resistance Disconnect the C D I magneto connectors from the wire harness Connect the pocket tester Ω 1 to the lighting coil terminal Tester lead Yellow Red lead 1 Tester lead Black lead 2 G W W R Y R B R B 2 1 MEETS SPECIFICATION Measure the lighting coil resistance Lighting coil for the specified resistance Lighting coil resistance 0 16 0 24 Ω at 20 C 68 F Yellow Red Black...

Page 70: ...rly connect the lighting system EB805020 LIGHTING SYSTEM CHECK 1 If the headlight fails to come on CONTINUITY 1 Bulb and bulb socket Check the bulb and bulb socket for continu ity NO CONTINUITY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC 20 V to the headlight connectors Tester lead Green terminal 1 or Yellow lead 2 Tester lead Black lead 3 È When the lights switch is...

Page 71: ... brake light fails to come on CONTINUITY 1 Bulb and bulb socket Check the bulb and bulb socket for continu ity NO CONTINUITY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester 20 V to the bulb socket connectors Tester lead Blue lead 1 Tester lead Black lead 2 Y L B Y L B 1 2 MEETS SPECIFICATION Turn the main switch to ON Kickstart the engine Check the voltage 12 V of the Blue ...

Page 72: ...re preventing normal operation ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body C D I system Faulty C D I unit Faulty pickup coil Broken woodruff key Switches and wiring Faulty main switch Faulty engine stop switch Broken or shor...

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Page 75: ... Y B G Y G W G Y B B B CH PU COIL IGN PKG STOP TORS GND 1 C D I magneto 2 Voltage regulator 3 C D I unit 4 Ignition coil 5 Spark plug 6 Parking brake switch 7 Throttle switch 8 Carburetor switch 9 Oil level warning light 0 Oil level gauge A Main switch B Engine stop switch C Light switch D Headlight E Tail brake light F Rear brake light switch G Front brake light switch COLOR CODE B Black Br Brown...