Yamaha VINO YJ50RAP, Service Manual

Page 1: ...2001 2005 MOTORCYCLE SERVICE MANUAL Model YJ50RAP YJ50RAR YJ50RAS YJ50RAT YJ50RN YJ50RP YJ50RR YJ50RS YJ50RT 5PP281972000 5PP281972000 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 2: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 3: ...aha Motor Co Ltd First edition December 2000 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited D o w n l o a d e d...

Page 4: ...ficant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE Designs and specifications ar...

Page 5: ...PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there ar...

Page 6: ...ening torque D Wear limit clearance E Engine speed F Electrical data Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points G Engine oil H Gear oil I Molybdenu...

Page 7: ...TION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 CARBURETION CARB 6 ELECTRICAL SYSTEM ELEC 7 TROUBLESHOOTING TRBL SHTG 8 D o w n l o a d e d...

Page 8: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 9: ...GEN INFO 1 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 10: ...IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 3 CIRCLIP...

Page 11: ...GEN INFO D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 12: ...on number 1 is stamped into the frame 1 EAS00018 MODEL CODE The model code label 1 is affixed to the loca tion shown in the figure Record the informa tion on this label in the space provided This info...

Page 13: ...all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs...

Page 14: ...lling if appro priate 1 Oil seal CAUTION Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips care...

Page 15: ...heck all connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE Make sure all connections are tight 5 Check conti...

Page 16: ...nstall oil seals YM 01411 Crankshaft installer spacer This tool is used to install the crank shaft YM 34487 Dynamic spark tester This tool is used to check the ignition system components YS 28891 Clut...

Page 17: ...6 A Inductive tachometer This tool is used to check engine speed Crankshaft installer tool set YU 90050 Crankshaft installer pot YU 90058 Crankshaft installer bolt YU 90060 Crankshaft installer tool s...

Page 18: ...100 15 01 Quick Gasket This sealant is used to seal to mating surfaces e g crankcase mating sur faces Tool No Tool name Function Illustration SPECIAL TOOLS D o w n l o a d e d f r o m w w w S c o o t...

Page 19: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 20: ...SPEC 2 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 21: ...PECIFICATIONS 2 9 CONVERSION TABLE 2 11 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 TIGHTENING TORQUES 2 12 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 13 LUBRICATION POINTS AND LUBR...

Page 22: ...SPEC D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 23: ...erall width 630 mm 24 8 in Overall height 1 030 mm 40 5 in Seat height 715 mm 28 1 in Wheelbase 1 150 mm 45 3 in Minimum ground clearance 85 mm 3 3 in Minimum turning radius 1 600 mm 63 in Weight Wet...

Page 24: ...ine oil Quantity Capacity 1 4 L 1 23 Imp qt 1 48 US qt Air filter oil grade Foam air filter oil or SAE 10W30SE Transmission Recommended oil Yamalube 4 10W30 or SAE 10W30 type SE motor oil Periodic oil...

Page 25: ...Piston pin to piston pin bore clear ance 0 004 0 019 mm 0 00016 0 00075 in 0 069 mm 0 0027 in Piston ring Top ring Ring type Keystone Dimensions B T 1 2 1 8 mm 0 05 0 07 in End gap installed 0 15 0 3...

Page 26: ...mm 0 157 in 1 0 mm 0 039 in Clutch shoe spring Free length 29 9 mm 1 18 in Kickstarter Kickstarter type Ratchet Kickstarter pinion gear clip force 0 15 0 25 kg 0 34 0 56 lb Transmission Transmission t...

Page 27: ...5 Pilot jet 46 Bypass 1 0 8 Pilot air screw turns out 1 5 8 Valve seat size 1 8 Starter jet 1 46 Float height 15 17 mm 0 59 0 67 in Reed valve Thickness 0 164 0 176 mm 0 0065 0 0069 in Valve stopper...

Page 28: ...aterial Steel Wheel travel 46 mm 1 81 in Wheel runout Max radial wheel runout 1 0 mm 0 04 in Max lateral wheel runout 1 0 mm 0 04 in Front tire Tire type Tubeless Size 80 90 10 34J Model manufacturer...

Page 29: ...10 mm 4 33 in 110 5 mm 4 35 in Lining thickness 4 mm 0 16 in 2 mm 0 08 in Front suspension Suspension type Bottom link fork Front fork type Coil spring oil damper Front fork travel 40 mm 1 57 in Sprin...

Page 30: ...Rear shock absorber assembly travel 45 mm 1 77 in Spring Free length 173 5 mm 6 83 in 170 0 mm 6 69 in Installed length 166 5 mm 6 56 in Spring rate K1 34 5 N mm 3 45 kgf mm 197 lb in Spring stroke K...

Page 31: ...ator Regulator type Semiconductor short circuit Model manufacturer SH671 12 SHINDENGEN No load regulated voltage DC 14 0 15 0 V No load regulated voltage AC 12 3 13 3 V Rectifier Model manufacturer SH...

Page 32: ...mperage 20 A Coil resistance 54 66 Horn Horn type Plane Model manufacturer quantity GF 12 NIKKO 1 Max amperage 1 5 A Performance 95 115 db 2 m Coil resistance 4 3 4 8 Turn signal relay Relay type Cond...

Page 33: ...cifications require clean dry threads Com ponents should be at room temperature A Width across flats B Thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERI...

Page 34: ...6 5 Bearing retainer right crankcase Screw M6 1 7 0 7 5 1 Transmission cover Screw M6 5 9 0 9 6 5 Sheave cover Screw M6 10 9 0 9 6 5 Air filter case Screw M6 2 9 0 9 6 5 Starter motor ground lead Scre...

Page 35: ...gnal light M12 7 0 7 5 1 Fuel tank upper M6 7 0 7 5 1 Fuel tank lower M6 10 1 0 7 2 Fuel sender and fuel tank M5 3 0 3 2 2 Seat lock assembly M6 7 0 7 5 1 Carrier upper M6 10 1 0 7 2 Carrier lower M8...

Page 36: ...earings E Piston surface E Piston pin E Cylinder E Transmission case bearing LT Right crankcase bearing retainer LT Autolube pump LS Starter wheel gear LS Idle gear plate M Secondary drive gear G Kick...

Page 37: ...S Speedometer drive gear LS Front brake camshaft LS Front brake cable LS Throttle cable LS Tube guide throttle grip inner surface LS Upper steering stem ring nut LS Upper bearing outer race LS Lower b...

Page 38: ...Speedometer cable Push the brake cable flange in until it contacts the lever holder Fasten the handlebar switch leads brake light switch leads meter light lead speedometer cable brake cables and throt...

Page 39: ...0 Rectifier regulator coupler A CDI unit lead coupler B Fuel overflow hose C Crankcase breather hose D Ground lead E Carburetor overflow hose F Rear brake cable G Throttle cable Fasten the turn signal...

Page 40: ...ch leads with a plastic band Pass the vacuum hose and fuel hose through the holder Be sure to pass the vacuum hose through the holder first Install the fuel tank so that the paint mark on the fuel hos...

Page 41: ...er motor coupler 6 AC magneto coupler 7 Auto choke coupler 8 Headlight coupler 9 Front turn signal leads 0 Horn lead A Main switch lead B Flasher relay lead C Ignition coil lead D Spark plug lead E Oi...

Page 42: ...in switch lead with a plastic lock ing tie Fasten the wire harness with a plastic locking tie Pass the wire harness on the inside of the seat bracket Pass one end of a plastic clip through the hole of...

Page 43: ...il level switch lead 7 AC magneto lead 8 Fuel sender lead 9 Tail brake light lead 0 Rear turn signal leads A CDI unit B Vacuum hose C Rectifier regulator D Fuel hose E Auto choke lead F Oil delivery h...

Page 44: ...spacer and then through the hole of the cover Fasten the wire harness with a plastic locking tie in front of the storage box bracket Fasten the auto choke lead with a plastic clip After connecting the...

Page 45: ...CHK ADJ 3 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 46: ...OR JOINT 3 17 CHECKING THE FUEL AND VACUUM HOSES 3 17 CHECKING THE CRANKCASE BREATHER HOSE 3 18 CHECKING THE EXHAUST SYSTEM 3 18 CHASSIS 3 19 ADJUSTING THE FRONT BRAKE 3 19 ADJUSTING THE REAR BRAKE 3...

Page 47: ...CHK ADJ D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 48: ...arburetor Check idle speed Adjust if necessary 4 Fuel line Check fuel hose and vacuum hose for cracks or damage Replace if necessary 5 Final gear oil Check oil leakage Correct if necessary Replace eve...

Page 49: ...you are riding in unusually wet or dusty areas EAU03903 NOTE From 9 000 km 6 000 mi or 18 months repeat the maintenance intervals starting from 3 000 km 2 000 mi or 6 months PERIODIC MAINTENANCE AND L...

Page 50: ...Nm 1 2 m kg 8 7 ft Ib 11 Order Job Part Q ty Remarks Removing the side covers and foot rest board Remove the parts in the order listed 1 Seat 1 2 Pin 1 3 Seat bracket 1 4 Carrier 1 5 Center cover 1 6...

Page 51: ...Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib 11 Order Job Part Q ty Remarks 12 Rear turn signal bracket 1 13 Rear turn signal left 1 14 Rear turn signal right 1 15 Tail brake light 1 16 Fuel tan...

Page 52: ...order listed Footrest board Refer to SIDE COVERS AND FOOT REST BOARD 1 Headlight cover 1 2 Headlight coupler 1 Disconnect 3 Front turn signal lead 4 Disconnect 4 Horn lead 2 Disconnect 5 Front turn si...

Page 53: ...HIELD 1 9 2 3 4 5 7 13 6 8 10 11 12 Order Job Part Q ty Remarks 11 Fuel level gauge 1 12 Main switch cover 1 13 Leg shield 1 For installation reverse the removal procedure D o w n l o a d e d f r o m...

Page 54: ...center cover Refer to SIDE COVERS AND FOOTREST BOARD 3 Attach inductive tachometer 1 onto the spark plug lead of cylinder 4 Measure engine idling speed Out of specification Adjust Inductive tachomete...

Page 55: ...pecification Adjust 2 Adjust throttle cable free play a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained c Tighten the lockn...

Page 56: ...Refer to SIDE COVERS AND FOOTREST BOARD air shroud Refer to GENERATOR in chapter 5 2 Check oil level Refer to CHECKING THE ENGINE OIL LEVEL 3 Fill oil tank 1 oil tank filler cap 2 Recommended oil Yam...

Page 57: ...SIDE COVERS AND FOOTREST BOARD EAS00060 CHECKING THE SPARK PLUG 1 Disconnect spark plug cap 2 Remove spark plug CAUTION Before removing the spark plug blow away any dirt accumulated in the spark plug...

Page 58: ...ark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 8 Connect spark plug cap Spark plug gap 0 6 0 7 mm 0 02 0 03 in T R 20 Nm 2 0 m kg 14 ft lb EAS00067 MEASURING TH...

Page 59: ...n switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes WARNING To prevent sparking ground the spark plug lead before cranking the engine c...

Page 60: ...il applied into the cylinder Reading Diagnosis Higher than with out oil Piston wear or damage Repair Same as without oil Piston ring s cyl inder head gasket or piston possibly defective Repair T R 20...

Page 61: ...oil REPLACING THE TRANSMISSION OIL 1 Stand the scooter on a level surface NOTE Place the scooter on a suitable stand Make sure the scooter is upright 2 Start the engine warm it up for several min utes...

Page 62: ...all gasket 1 transmission oil drain bolt 2 New 1 2 New T R 18 Nm 1 8 m kg 13 ft lb 9 Fill crankcase with the specified amount of the recom mended transmission oil Recommended oil SAE 10W30SE Total amo...

Page 63: ...w flash point solvents such as gasoline to clean the air filter element Such solvents may cause a fire or an explo sion NOTE After cleaning gently squeeze the air filter ele ment to remove the excess...

Page 64: ...e and possible overheat ing 7 Install footrest board Refer to SIDE COVERS AND FOOTREST BOARD EAS00094 CHECKING THE CARBURETOR JOINT 1 Remove center cover footrest board Refer to SIDE COVERS AND FOOTRE...

Page 65: ...eather hose 1 Cracks damage Replace Loose connection Connect properly CAUTION Make sure the crankcase breather hose is routed correctly EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure app...

Page 66: ...urn the adjusting nut 1 in direction a or b until the specified brake lever free play is obtained CAUTION After adjusting the brake lever free play make sure there is no brake drag Direction a Brake l...

Page 67: ...r free play is increased Direction b Brake lever free play is decreased EAS00127 CHECKING THE BRAKE SHOES 1 Operate the brake 2 Check wear indicator 1 Reaches the wear limit line 2 Replace the brake s...

Page 68: ...nut b Loosen the upper race 1 and then tighten it to specification with the steering nut wrench 45 mm 2 NOTE Set the torque wrench at a right angle to the steering stem ring nut wrench c Hold the uppe...

Page 69: ...e scooter on a level surface WARNING Securely support the scooter so that there is no danger of it falling over 2 Hold the scooter upright and apply the front brake 3 Check front shock absorber operat...

Page 70: ...dent or an injury NEVER OVERLOAD THE SCOOTER total of cargo rider and accessories WARNING It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immed...

Page 71: ...to do so use great care and replace the tube as soon as possible with a good quality replacement Tire Wheel After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for...

Page 72: ...ll the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point Manufacturer Model Size INOUE MB38 80 90 10 34J CHENG SHIN C 922 80 90 10 34J E...

Page 73: ...ck cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device Recommended lubricant Engine oi...

Page 74: ...F CHILDREN Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 min...

Page 75: ...onnect battery lead coupler 1 from the battery terminals NOTE Push down on the tab a and then remove the battery lead coupler 3 Remove battery 1 4 Measure battery charge a Connect a battery tester 1 t...

Page 76: ...t on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the scooter If charging has to be done with the battery mounted on the scooter disco...

Page 77: ...he battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been c...

Page 78: ...3 31 CHK ADJ Charging method using a variable voltage charger CHECKING AND CHARGING THE BATTERY D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 79: ...3 32 CHK ADJ Charging method using a constant voltage charger CHECKING AND CHARGING THE BATTERY D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 80: ...h a wire brush Loose connection Connect properly 9 Lubricate battery terminal 10 Install battery box Refer to ENGINE REMOVAL in chapter 5 center cover Refer to SIDE COVERS AND FOOTREST BOARD Recommend...

Page 81: ...et tester to the fuse and check the continuity NOTE Set the pocket tester selector to 1 b If the pocket tester indicates replace the fuse Pocket tester YU 03112 3 Replace blown fuse a Set the main swi...

Page 82: ...nstall battery Refer to ENGINE REMOVAL in chapter 4 center cover Refer to SIDE COVERS AND FOOTREST BOARD EAS00182 REPLACING THE HEADLIGHT BULB 1 Remove Headlight cover Refer to FRONT PANEL AND LEG SHI...

Page 83: ...headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Attach headlight bulb holder 8 Install headlight bulb holder cover 9 Connect headlight coupler 1...

Page 84: ...M 2 Adjust headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left D o w n l o a d e d f...

Page 85: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 86: ...CHAS 4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 87: ...WHEEL 4 14 FRONT SHOCK ABSORBER ASSEMBLIES 4 15 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES 4 16 INSTALLING THE RELAY ARM 4 16 HANDLEBAR 4 17 REMOVING THE HANDLEBAR 4 19 CHECKING THE HANDLEBAR 4 19 I...

Page 88: ...CHAS D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 89: ...e the parts in the order listed NOTE Place the scooter on a suitable stand so that the front wheel is elevated 1 Speedometer cable assembly 1 2 Adjusting nut 1 Refer to INSTALLING THE FRONT WHEEL 3 Fr...

Page 90: ...RAKE 6 9 7 3 4 2 8 1 5 T R 48 Nm 4 8 m kg 35 ft Ib Order Job Part Q ty Remarks 8 Front brake shoe plate 1 9 Spacer 1 For installation reverse the removal procedure D o w n l o a d e d f r o m w w w S...

Page 91: ...g the front wheel Remove the parts in the order listed 1 Oil seal 1 Refer to CHECKING THE FRONT WHEEL 2 Wheel bearing right 1 3 Spacer 1 4 Collar 1 5 Wheel bearing left 1 6 Dust seal 1 For assembly re...

Page 92: ...e parts in the order listed 1 Brake shoe 2 2 Brake shoe spring pin side 1 3 Brake shoe spring brake camshaft side 1 4 Bushing 1 5 Speedometer drive gear 1 6 Brake camshaft lever 1 7 Brake shoe wear in...

Page 93: ...r Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Measure radial wheel runout 1 lateral wheel runout 2 Over the specified limits Replace Radial wheel runout limit 1 0 mm 0 0...

Page 94: ...with a gen eral bearing puller d Install the new wheel bearings and oil seal in the reverse order of disassembly CAUTION Do not contact the wheel bearing inner race 4 or balls 5 Contact should be made...

Page 95: ...contact the brake shoes NOTE Replace the brake shoes as a set if either is worn to the wear limit Brake shoe lining thickness limit minimum 2 mm 0 08 in 3 Measure brake drum inside diameter a Out of s...

Page 96: ...es are properly positioned 2 Install speedometer drive gear bushing 3 1 2 EAS00540 INSTALLING THE FRONT WHEEL 1 Lubricate wheel axle wheel bearings oil seal lips speedometer drive gear Recommended lub...

Page 97: ...sure the brake cable is routed prop erly CAUTION Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly T R 48 Nm 4 8 m kg 35...

Page 98: ...er Job Part Q ty Remarks Removing the rear wheel and brake Remove the parts in the order listed NOTE Place the scooter on a suitable stand so that the rear wheel is elevated 1 Muffler 1 2 Gasket 1 3 A...

Page 99: ...e parts in the order listed 1 Adjusting nut 1 2 Rear brake cable 1 3 Pin 1 4 Brake shoe 2 5 Brake shoe spring pin side 1 6 Brake shoe spring brake camshaft side 1 7 Brake camshaft lever 1 8 Brake shoe...

Page 100: ...he following procedure applies to all of the brake shoes 1 Check brake shoe lining Glazed areas Repair Sand the glazed areas with course sandpa per NOTE After sanding the glazed areas clean the brake...

Page 101: ...oth 5 Check brake camshaft Damage wear Replace Brake drum inside diameter limit maximum 110 5 mm 4 35 in EAS00570 INSTALLING THE BRAKE SHOE PLATE 1 Install brake camshaft 1 spring brake shoe wear indi...

Page 102: ...talling the rear brake camshaft remove any excess grease 2 Install brake shoes NOTE Do not to damage the springs during installa tion 1 INSTALLING THE REAR WHEEL 1 Tighten wheel axle nut CAUTION Do no...

Page 103: ...ed The following procedure applies to both of the front shock absorbers Front panel Refer to FRONT PANEL AND LEG SHIELD in chapter 3 Front wheel Refer to FRONT WHEEL AND BRAKE 1 Relay arm cover 2 2 Fr...

Page 104: ...Bends damage Replace the front shock absorber assembly front shock absorber Oil leaks Replace the front shock absorber assembly spring Damage wear Replace the front shock absorber assembly bolt Bends...

Page 105: ...Remove the parts in the order listed Center cover Refer to SIDE COVERS AND FOOT REST BOARD in chapter 3 1 Rear view mirror left right 2 2 Front brake cable 1 3 Rear brake cable 1 4 Throttle cable hold...

Page 106: ...andlebar switch 1 Refer to INSTALLING THE HANDLE BAR 8 Upper handlebar holder 2 9 Handlebar 1 10 Handlebar grip 1 Refer to REMOVING THE HANDLE BAR For installation reverse the removal procedure D o w...

Page 107: ...ace WARNING Securely support the scooter so that there is no danger of it falling over 2 Check handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this ma...

Page 108: ...e front side of the handlebar holder and then on the rear side NOTE Install the upper handlebar holders with the grooves a facing inward Align the match marks b on the handlebar with the upper surface...

Page 109: ...r switch 1 WARNING Make sure the throttle grip operates smoothly NOTE Align the mating surfaces of the right handle bar switch with the punch mark a on the han dlebar 6 Adjust throttle cable free play...

Page 110: ...Refer to FRONT PANEL AND LEG SHIELD in chapter 3 Front shock absorber assemblies Refer to FRONT SHOCK ABSORBER ASSEMBLIES Handlebar Refer to HANDLEBAR 1 Meter light lead coupler 1 Disconnect 2 Speedom...

Page 111: ...n the order listed 1 Cover 1 2 Upper steering stem ring nut 1 3 Upper race 1 4 Fork 1 5 Upper bearing 1 6 Lower bearing 1 7 Upper bearing outer race 1 8 Lower bearing outer race 1 For installation rev...

Page 112: ...wrench 45 mm and then remove the upper steering stem ring nut with the steering nut wrench WARNING Securely support the lower bracket so that there is no danger of it falling Steering nut wrench YU 3...

Page 113: ...the steering head is disassem bled replace the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00684 INSTALLING THE STEERING HEAD 1 Lubrica...

Page 114: ...ft Ib 1 Order Job Part Q ty Remarks Removing the rear shock absorber assembly Remove the parts in the order listed Side cover left Refer to SIDE COVERS AND FOOT REST BOARD in chapter 3 1 Rear shock ab...

Page 115: ...k absorber rod Bends damage Replace the rear shock absorber assembly rear shock absorber Oil leaks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock absorber assembly...

Page 116: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 117: ...ENG 5 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 118: ...20 DISASSEMBLING THE SECONDARY PULLEY 5 20 CHECKING THE CLUTCH SHOES 5 20 CHECKING THE SECONDARY PULLEY 5 21 CHECKING THE V BELT 5 22 CHECKING THE PRIMARY PULLEY WEIGHTS 5 22 ASSEMBLING THE SECONDARY...

Page 119: ...9 CHECKING THE BEARINGS AND OIL SEALS 5 40 CHECKING THE REED VALVE 5 40 ASSEMBLING THE CRANKCASE 5 41 CRANKSHAFT 5 42 REMOVING THE CRANKSHAFT ASSEMBLY 5 43 CHECKING THE CRANKSHAFT 5 43 INSTALLING THE...

Page 120: ...emove the parts in the order listed Center cover side cover left right and footrest board Refer to SIDE COVERS AND FOOT REST BOARD in chapter 3 Carburetor Refer to CARBURETOR in chapter 6 1 Muffler 1...

Page 121: ...1 1 m kg 8 0 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib 1 New Order Job Part Q ty Remarks 10 Adjusting nut 1 11 Rear brake cable 1 12 Pin 1 13 Kickstarter crank 1 14 Bolt rear shock absorber lower 1 15 Engin...

Page 122: ...t rear shock absorber lower 2 2 Install kickstarter crank muffler bolts exhaust pipe bolts T R 84 Nm 8 4 m kg 61 ft lb T R 15 Nm 1 5 m kg 11 ft lb T R 11 Nm 1 1 m kg 8 0 ft lb T R 28 Nm 2 8 m kg 20 ft...

Page 123: ...Remarks Removing the cylinder head cylin der and piston Remove the parts in the order listed Center cover side cover left right and footrest board Refer to SIDE COVERS AND FOOT REST BOARD in chapter...

Page 124: ...Nm 2 0 m kg 14 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib New New New New New E E E Order Job Part Q ty Remarks 10 Bearing 1 11 Piston 1 12 Piston ring set 1 13 Cylinder gasket 1...

Page 125: ...g NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS00227 CHECKING THE CYLINDER HEAD 1 Eliminate combustion chamber carbo...

Page 126: ...Check piston wall cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with...

Page 127: ...rebore or replace the cylinder and replace the piston and piston rings as a set Piston size P Standard 39 952 39 969 mm 1 5729 1 5736 in Piston to cylinder clearance Cylinder bore C Piston skirt diam...

Page 128: ...ing end gap Out of specification Replace the piston ring NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston r...

Page 129: ...pin Piston pin bore diameter in the piston 10 004 10 015 mm 0 3939 0 3943 in Limit 10 045 mm 0 3955 in 4 Calculate piston pin to piston pin bore clearance Out of specification Replace the piston pin a...

Page 130: ...ing end gaps to the respective knock pins as shown 1 2 2 Install bearing piston 1 piston pin 2 piston pin clip 3 NOTE Lubricate the piston pin with engine oil Make sure the arrow mark a on the piston...

Page 131: ...ile compressing the piston rings with one hand install the cylinder with the other hand cylinder head gasket cylinder head Recommended lubricant Yamalube 2 cycle oil or 2 stroke engine oil T R Cylinde...

Page 132: ...the sheave cover Remove the parts in the order listed Air filter case assembly Refer to CARBURETOR in chapter 6 Transmission oil Drain 1 Kickstarter crank 1 2 Cover 1 3 Damper 1 4 Ground lead 1 5 She...

Page 133: ...ter shaft Remove the parts in the order listed 1 Kickstarter pinion gear 1 2 Kickstarter pinion gear clip 1 3 Circlip 1 4 Washer 1 5 Kickstarter shaft 1 6 Kickstarter spring 1 7 Spacer 1 For assembly...

Page 134: ...e the kick starter pinion gear clip Kickstarter pinion gear clip force 0 15 0 25 kg 0 34 0 56 lb EAS00340 INSTALLING THE KICKSTARTER 1 Install kickstarter shaft 1 kickstarter spring 2 spacer washer ci...

Page 135: ...y and secondary pulley Remove the parts in the order listed Sheaves cover Refer to KICK STARTER Air shroud fan Refer to GENERATOR AND AUTOL UBE PUMP 1 O ring 1 2 Clutch housing 1 3 Secondary pulley 1...

Page 136: ...kg 22 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib Order Job Part Q ty Remarks 11 Collar 1 12 Primary sliding sheave 1 13 Slider 1 14 Cam 1 15 Primary pulley weight 6 16 Gasket 1 For installation reverse the re...

Page 137: ...secondary pulley Remove the parts in the order listed 1 Clutch carrier nut 1 2 Clutch carrier 1 3 Clutch spring 2 4 Spring 1 5 Spring seat 1 6 Pin 2 7 Secondary sliding sheave 1 8 O ring 2 9 Oil seal...

Page 138: ...ley 1 V belt 2 NOTE Pull the secondary sliding sheave out as shown remove the V belt from the primary pulley and then remove the secondary pulley 1 along with the V belt 2 2 1 4 Loosen clutch carrier...

Page 139: ...Y PULLEY 1 Remove clutch carrier nut 1 NOTE Install the clutch spring holder 2 onto the sec ondary pulley as shown Then compress the spring and remove the clutch carrier nut 1 EAS00291 CHECKING THE CL...

Page 140: ...HECKING THE SECONDARY PULLEY 1 Check secondary fixed sheave secondary sliding sheave Cracks damage wear Replace the sec ondary fixed and sliding sheaves as a set 2 Check guide pin groove 1 Damage wear...

Page 141: ...65 in Limit 15 0 mm 0 59 in 1 EAS00321 CHECKING THE PRIMARY PULLEY WEIGHTS The following procedure applies to all of the primary pulley weights 1 Check primary pulley weight Cracks damage wear Replac...

Page 142: ...liding sheave 1 NOTE Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 Recommended lubricant Lithium soap base grease Oil seal guide YM 01409 LS LS 1 2 2...

Page 143: ...the spring and tighten the clutch carrier nut 5 Clutch spring holder YS 28891 4 3 5 1 2 EAS00323 INSTALLING THE PRIMARY PULLEY 1 Clean primary fixed sheave primary sliding sheave spacer primary pulley...

Page 144: ...rotor with the rotor holding tool tighten the primary sheave nut Rotor holding tool YU 01235 B A 0 9 8 7 0 A T R 30 Nm 3 0 m kg 22 ft lb EAS00325 INSTALLING THE BELT DRIVE 1 Install clutch carrier nut...

Page 145: ...elt 1 3 2 1 3 Install clutch housing 1 clutch housing nut 2 NOTE Tighten the clutch housing nut while holding the clutch housing with the sheave holder 3 Sheave holder YU 01701 2 3 1 T R 40 Nm 4 0 m k...

Page 146: ...h and starter motor Remove the parts in the order listed Sheaves cover Refer to KICKSTARTER Primary sliding sheave Refer to BELT DRIVE 1 Idle gear plate 1 2 Washer 2 3 Idle gear 1 4 Starter clutch ass...

Page 147: ...ration a Install the starter wheel gear onto the starter clutch and hold the starter clutch b When turning the starter wheel gear clock wise the starter clutch and the starter wheel gear should engage...

Page 148: ...STARTER MOTOR 2 Install starter wheel gear 1 starter clutch assembly 2 NOTE Install the starter clutch assembly 1 while turning the starter wheel gear 2 clockwise 2 1 D o w n l o a d e d f r o m w w w...

Page 149: ...ks Removing the transmission Remove the parts in the order listed Transmission oil Drain Rear wheel Refer to REAR WHEEL AND BRAKE in chapter 4 Secondary pulley Refer to BELT DRIVE 1 Transmission cover...

Page 150: ...ew G G LS LT LT New T R 9 Nm 0 9 m kg 6 5 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib 10 Order Job Part Q ty Remarks 9 Circlip 1 10 Bearing 1 11 Oil seal 1 For installation reverse the removal procedure D o w n...

Page 151: ...in axle secondary drive gear Damage wear Replace 2 Check bearing Rough movement Replace 3 Check secondary drive gear movement Rough movement Replace the defective part 4 Check circlips Bends damage lo...

Page 152: ...e the parts in the order listed Center cover side cover right and footrest board Refer to SIDE COVERS AND FOOT REST BOARD in chapter 3 1 Coupler cover 1 2 Air shroud 1 3 Fan 1 4 Generator rotor 1 5 St...

Page 153: ...ube pump Remove the parts in the order listed Stator coil assembly Refer to GENERATOR AND AUTOLUBE PUMP 1 Spark plug cap 1 2 Cylinder head cover 1 3 Circlip 2 4 Pump drive gear 1 5 Pin 1 6 Oil hose 1...

Page 154: ...flywheel puller set 2 woodruff key Flywheel puller set YU 90105 1 2 CHECKING THE AUTOLUBE PUMP 1 Check oil hose 1 Obstruction Blow out with compressed air 2 Check autolube pump 2 pump drive gear 3 Dam...

Page 155: ...is properly seated in the keyway of the crankshaft Do not allow the rotor holding tool to touch the projection on the generator rotor LS 1 New 2 2 Tighten generator rotor nut 1 NOTE While holding the...

Page 156: ...ne assembly Refer to ENGINE REMOVAL Cylinder head cylinder and piston Refer to CYLINDER HEAD CYLINDER AND PISTON Sheaves cover Refer to KICKSTARTER V belt and secondary pulley Refer to BELT DRIVE Star...

Page 157: ...ob Part Q ty Remarks 1 Cover 1 2 Intake manifold 1 3 Reed valve assembly 1 4 Valve seat gasket 1 5 Bearing retainer 1 6 Right crankcase 1 Refer to DISASSEMBLING THE CRANKCASE 7 Dowel pin 2 8 Engine mo...

Page 158: ...ons of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly NOTE Remove the crankcase separating tool 2 Crankcase separating...

Page 159: ...t Replace 2 Check oil seals Damage wear Replace CHECKING THE REED VALVE 1 Measure reed valve bending a Out of specification Replace 2 Measure valve stopper height b Out of specification Adjust stopper...

Page 160: ...stalling tool 4 Install crankcase screws NOTE Tighten each bolt 1 4 of a turn at a time in stages and in a crisscross pattern 5 Apply engine oil onto the crankshaft pins bearings and oil delivery hole...

Page 161: ...moving the crankshaft Remove the parts in the order listed Engine assembly Refer to ENGINE REMOVAL Crankcase Separate Refer to CRANKCASE 1 Crankshaft 1 2 Bearing 2 3 Oil seal 1 4 Crankcase 1 1 For ins...

Page 162: ...ankshaft runout 1 Out of specification Replace the crank shaft bearing s or both NOTE Turn the crankshaft slowly 2 Measure big end side clearance 2 Out of specification Replace the big end bearing cra...

Page 163: ...he oil seal lips with grease and each bear ing with engine oil NOTE Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installing tool with the other...

Page 164: ...CARB 6 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 165: ...CARBURETOR 6 4 ASSEMBLING THE CARBURETOR 6 5 INSTALLING THE CARBURETOR 6 6 MEASURING AND ADJUSTING THE FLOAT HEIGHT 6 7 CHECKING THE AUTOCHOKE ASSEMBLY 6 7 CHECKING THE FUEL COCK OPERATION 6 8 D o w n...

Page 166: ...CARB D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 167: ...fer to SIDE COVERS AND FOOT REST BOARD in chapter 3 1 Air filter case assembly 1 2 Clip 1 3 Auto choke coupler 1 Disconnect 4 Oil delivery hose 1 5 Clamp screw intake manifold 1 Loosen 6 Carburetor as...

Page 168: ...the carburetor make sure to note the number of times the pilot air screw is turned out from the seated position to its set position 1 Throttle cables 2 2 Throttle valve 1 3 Jet needle kit 1 4 Mixing...

Page 169: ...der Job Part Q ty Remarks 9 O ring 1 0 Float pivot pin 1 A Float 1 B Needle valve 1 C Main jet 1 D Needle jet 1 E Pilot jet 1 F Carburetor body 1 For assembly reverse the disassembly procedure D o w n...

Page 170: ...eplace 2 Check fuel passages Obstruction Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compr...

Page 171: ...ce the piston valve 10 Check vacuum hose fuel hose Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air EAS00487 ASSEMBLING THE CARBURETOR NOTE Before assembling the car...

Page 172: ...e valve with the projection of the carburetor body 6 Install throttle cable EAS00492 INSTALLING THE CARBURETOR 1 Adjust engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3 2 Ad...

Page 173: ...check the needle valve e If either is worn replace them as a set f Install the carburetor Float height 15 17 mm 0 59 0 67 in EAS00503 CHECKING THE AUTOCHOKE ASSEMBLY NOTE When checking the autochoke...

Page 174: ...tery lead 1 black Negative battery lead 2 black Starter plunger opens Replace the auto choke assembly Starter plunger closes Autochoke is OK 4 3 1 2 B B EAS00506 CHECKING THE FUEL COCK OPERATION NOTE...

Page 175: ...ELEC 7 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 176: ...C STARTING SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 TROUBLESHOOTING 7 14 STARTER MOTOR 7 17 CHECKING THE STARTER MOTOR 7 19 ASSEMBLING THE STARTER MOTOR 7 20 CHARGING SYSTEM 7 21 CIRCUIT DIAGRAM 7 21 TROUBLES...

Page 177: ...ELEC D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 178: ...lay 3 Fuel sender 4 Oil level switch 5 CDI unit 6 Rectifier regulator 7 Main fuse 8 Battery 9 Spark plug cap 0 Ignition coil A Wire harness B Turn signal relay C Horn 1 C B A 0 9 8 7 6 5 4 3 2 ELECTRI...

Page 179: ...for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one o...

Page 180: ...e or wear proper connections and also for continuity between the ter minals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity...

Page 181: ...S 1 Front brake light switch 2 Turn signal switch 3 Dimmer switch 4 Horn switch 5 Main switch 6 Rear brake light switch 7 Start switch 8 Engine stop switch 9 Main fuse D o w n l o a d e d f r o m w w...

Page 182: ...are shown in the illustration on the left Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs c...

Page 183: ...the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bul...

Page 184: ...Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to th...

Page 185: ...O L W Br B W L L Y E Br G Y Br G Y B B GREEN GREEN F H I G Br Br L G Y Gy B Gy B Gy G Y Br G Y B B Y G G Y GREEN GREEN Z Br B G B B B Gy Br W Br Y G B G Y T S X U V W Br B Br W Gy Y Br W Gy Br Y B L...

Page 186: ...er YU 03112 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSE in chap ter 3 Is the main fuse OK Replace the main fuse 2 Battery Check the condition of the battery Refer to CHEC...

Page 187: ...the spark gap until a misfire occurs Minimum ignition spark gap 6 mm 0 24 in Is there a spark and is the spark gap within specification The ignition system is OK 5 Spark plug cap resistance Remove the...

Page 188: ...stance Secondary coil resistance 6 32 9 48 k at 20 C 68 F Is the ignition coil OK Replace the ignition coil 2 1 1 2 7 Pickup coil resistance Disconnect the stator coil assembly cou pler from the wire...

Page 189: ...op switch OK Replace the right handlebar switch 10 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly connected and without defects Repl...

Page 190: ...E Br G Y Br G Y B B GREEN GREEN F H I G Br Br L G Y Gy B Gy B Gy G Y Br G Y B B Y G G Y GREEN GREEN Z Br B G B B B Gy Br W Br Y G B G Y T S X U V W Br B Br W Gy Y Br W Gy Br Y B L Y B G Y B L J Br W...

Page 191: ...efer to CHECKING THE FUSE in chap ter 3 Is the main fuse OK Replace the main fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circ...

Page 192: ...main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch 6 Engine stop switch Check the engine stop switch for continu ity Refer to CHECKING THE SWITCHES...

Page 193: ...OK Replace the rear brake light switch 10 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly connected and without defects The starting...

Page 194: ...the starter motor Remove the parts in the order listed Air shroud Refer to CYLINDER HEAD CYLINDER AND PISTON in chapter 5 1 Starter motor coupler 1 2 Starter motor assembly 1 For installation reverse...

Page 195: ...starter motor Remove the parts in the order listed 1 O ring 1 2 Starter motor yoke 1 3 Armature assembly 1 4 Gasket 2 5 Brush holder 1 6 Starter motor cover 1 For assembly reverse the disassembly pro...

Page 196: ...crape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator NOTE The mica must be undercut to ensure proper operation of the commutator 4 Measure armatur...

Page 197: ...rushes as a set 6 Measure brush spring force Out of specification Replace the brush springs as a set 7 Check gear teeth Damage wear Replace the gear Brush length wear limit 0 9 mm 0 04 in Brush spring...

Page 198: ...W L B W Y R W W L W R Y R A A BLACK 0 B A B B B Y R BLACK BLACK BLACK B O L W Br B W L L Y H I Br Gy B Gy B Gy Y G G Y G B B Gy Br W Br Y G Y T S U V W Br B Br W Gy Y Br W Gy Br Y B J Br W Br Gy B Gy...

Page 199: ...se OK Replace the main fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery...

Page 200: ...uit is OK 4 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring properly connected and without defects Replace the recti fier reg...

Page 201: ...G Y Br G Y B B GREEN GREEN F H I G Br Br L G Y Gy B Gy B Gy G Y Br G Y B B Y G G Y GREEN GREEN Z Br B G B B B Gy Br W Br Y G B G Y T S X U V W Br B Br W Gy Y Br W Gy Br Y B L Y B G Y B L J Br W Br Gy...

Page 202: ...fuse Check the main fuse for continuity Refer to CHECKING THE FUSE in chap ter 3 Is the main fuse OK Replace the main fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING...

Page 203: ...th 2 Voltage Connect the pocket tester DC 20 V to the headlight and high beam indicator light couplers as shown When the dimmer switch is set to When the dimmer switch is set to Headlight coupler wire...

Page 204: ...he meter light bulb and socket for continuity Are the meter light bulb and socket OK Replace the meter light bulb socket or both W R W L Y R W 1 3 2 2 Voltage Connect the pocket tester 20 V to the met...

Page 205: ...ck 2 Set the main switch to ON Measure the voltage 12 V of blue 1 on the tail brake light coupler tail brake light side Is the voltage within specification This circuit is OK The wiring circuit from t...

Page 206: ...A B B B Y R BLACK RED RED BLACK BLACK B O L W Br B W L L Y E Br G Y Br G Y B B GREEN GREEN F H I G Br Br L G Y Gy B Gy B Gy G Y Br G Y B B Y G G Y GREEN GREEN Z Br B G B B B Gy Br W Br Y G B G Y T S...

Page 207: ...Diode J Turn signal relay K Horn M Horn switch O Turn signal switch P Rear turn signal light Q Front turn signal light T Oil level warning light W Turn signal indicator light X Fuel gauge assembly Y...

Page 208: ...3 Is the main fuse OK Replace the main fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68...

Page 209: ...n 1 Negative tester probe ground Set the main switch to ON Push the horn switch Measure the voltage 12 V of brown at the horn terminal Is the voltage within specification The wiring circuit from the m...

Page 210: ...ke light bulb socket or both 2 Brake light switches Check the brake light switches for continu ity Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch 3 Voltage...

Page 211: ...nuity Refer to CHECKING THE SWITCHES Is the turn signal switch OK Replace the left han dlebar switch 3 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler wire harness side as s...

Page 212: ...hown Turn signal light Left turn signal light Positive tester probe chocolate 1 Negative tester probe ground Right turn signal light Positive tester probe dark green 2 Negative tester probe ground Tur...

Page 213: ...l switch for continuity Hold the oil level switch in an upright posi tion and let the float 3 go all the way down Is the oil level switch OK Replace the oil level switch 1 2 3 3 Diode Remove the diode...

Page 214: ...aired 1 Fuel level indicator light bulb and socket Check the fuel level indicator light bulb and socket for continuity Are the fuel level indicator light bulb and socket OK Replace the fuel level indi...

Page 215: ...e Connect the pocket tester DC 20 V to the fuel level gauge coupler wire harness side as shown Fuel level gauge Positive tester probe brown 1 Negative tester probe green 2 Fuel level indicator light P...

Page 216: ...IAGRAM O O B B Br B L W L Y W Y R Y R W L W L R W L B W Y R W W L W R Y R LACK 0 B A B B B Y R BLACK BLACK BLACK B O L W Br B W L L Y F Br Br Gy B B J Br Gy B Gy Br W 0 AC magneto A Auto choke D o w n...

Page 217: ...ster 1 to the auto choke coupler as shown Tester positive probe black 1 Tester negative probe black 2 Auto choke resistance 8 12 at 20 C 68 F Is the auto choke unit OK Replace the auto choke B B 2 1 2...

Page 218: ...be black 2 Set the main switch to ON Start the engine and accelerate to about 3 000 r min Check the voltage Voltage 12 8 V or more at 20 C 68 F This auto choke is OK Check the entire auto choke unit f...

Page 219: ...D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 220: ...TRBL SHTG 8 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 221: ...TARTING PERFORMANCE 8 2 POOR ACCELERATION PERFORMANCE 8 2 OVERHEATING 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 CHASSIS 8 3 ELECTRICAL SYSTEMS 8 3 POOR BRAKING PERFORMANCE 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTI...

Page 222: ...TRBL SHTG D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...

Page 223: ...Clogged pilot air passage Sucked in air Damaged float Worn needle valve Improperly installed needle valve seat Incorrect fuel level Improperly adjusted pilot air screw Improperly installed pilot jet C...

Page 224: ...t FUEL SYSTEM Carburetor Faulty diaphragm Incorrect fuel level Loose or clogged main jet EAS00853 FAULTY CLUTCH ENGINE OPERATES BUT SCOOTER WILL NOT MOVE V belt Bent damaged or worn V belt Slipping V...

Page 225: ...n Incorrect brake shoe position Damaged or fatigued brake shoe spring Oil or grease on the brake shoe Oil or grease on the brake drum Broken brake torque rod EAS00862 UNSTABLE HANDLING Handlebar Bent...

Page 226: ...brake light bulb Faulty battery Tail brake light bulb life expired TURN SIGNAL DOES NOT LIGHT Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged...

Page 227: ...D B R R R B B B B B Br B L W L Y Y R W Y R Y R W L W L R R R R G Y R L W 4 Y R W B R R L W R G Y R R R B R 5 6 7 8 9 L Y L W L W B L Y L W L W B L W B L W B Br G B G Br B W L B W Y R W W L W R Y R A...

Page 228: ...Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto ON M2H 3B4 D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t...