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CW50RS

SERVICE
MANUAL

'98
5FX-AE1

CW50RS
SERVICE MANUAL
1998 by MBK INDUSTRIE
1st Edition, July 1998
All rights reserved. Any
reprinting or unauthorized use
without the written
permission of MBK INDUSTRIE
is expressly prohibited.

NOTICE
This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers
and their qualified mechanics. It is not possible to put an entire mechanics education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and
MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in
scooter repair technology. Without such knowledge, attempted repairs or service to this model may
render it unfit to use and/or unsafe.
MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and
significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and
MBK dealers and will, where applicable, appear in future editions of this manual.
DOCUMENTATION TECHNIQUE
MBK INDUSTRIE

PARTICULARY IMPORTANT INFORMATION


This material is distinguished by the following notation :

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR


SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE :

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 scooter.

A CAUTION indicates special precautions that must be taken to avoid


damage to the scooter.

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

HOW TO USE THIS MANUAL


CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See illustrated symbols).
1st title
1
This is a chapter with its symbol on the upper right of each page.
2nd title
2
This title appears on the upper of each page on the left of the chapter symbol.
(For the chapter Periodic inspection and adjustment the 3rd title appears.)
3rd title
3
This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particulary important procedure 4 is placed between a line of asterisks " * " with each step
preceded by " ".
IMPORTANT FEATURES
Data and a special tools are framed in a box preceded by a relevant symbol 5.
An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data for an
alignement mark 7, the others being indicated by an alphabetical letter in a box 8.
A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams are before each disassembly section for ease in identifying
correct disassembly and assembly procedures.

ILLUSTRATED SYMBOLS

GEN
INFO

(REFER TO THE ILLUSTRATION)

SPEC

Illustrated symbols Q to W are designed as


thumb tabs to indicate the chapters number and
content.

INSP
ADJ

ENG

Q General information
W Specifications
E Periodic inspection and adjustment
R Engine
T Carburetion
Y Chassis
U Electrical
I Troubleshooting

CARB

CHAS

TRBL
SHTG

ELEC
O

Illustrated symbols O to e are used to identify


the specifications appearing in the text.

T.

Illustrated symbols r to [ in the exploded


diagram indicate grade of lubricant and location
of lubrication point.
r

O Filling fluid
P Lubricant
{ Special tool
} Tightening
q Wear limit, clearance
w Engine speed
e , V, A

r Apply engine oil


t Apply gear oil
y Apply molybdenum disulfide oil
u Apply wheel bearing grease
i Apply lightweight lithium-soap base
grease
o Apply molybdenum disulfide grease
p Apply locking agent (THREADLOCK )
[ Use new one

INDEX
GENERAL INFORMATION

GEN
INFO

SPECIFICATIONS

SPEC

PERIODIC INSPECTION
AND ADJUSTMENT

INSP
ADJ

ENGINE OVERHAUL

ENG

CARBURETION

CARB

CHASSIS

CHAS

ELECTRICAL

ELEC

TRBL
SHTG

TROUBLESHOOTING

GEN
INFO

GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
SCOOTER IDENTIFICATION ........................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER .................................................... 1-1
ENGINE SERIAL NUMBER ..................................................................... 1-1
IMPORTANT INFORMATION ....................................................................... 1-2
ALL REPLACEMENT PARTS ................................................................. 1-2
GASKETS, OIL SEALS, AND O-RINGS .................................................. 1-2
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-2
BEARINGS AND OIL SEALS ................................................................... 1-2
CIRCLIPS ................................................................................................. 1-3
SPECIAL TOOLS ........................................................................................... 1-3
FOR TUNE UP ......................................................................................... 1-3
FOR ENGINE SERVICE .......................................................................... 1-4
FOR CHASSIS SERVICE ........................................................................ 1-5
FOR ELECTRICAL COMPONENTS ........................................................ 1-5

SCOOTER IDENTIFICATION

GEN
INFO

GENERAL
INFORMATION

SCOOTER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number Q is stamped
into the frame.
NOTE:
The vehicle identification number is used to
identify your scooter and may be used to register
your scooter with the licensing authority in your
state.

ENGINE SERIAL NUMBER


The engine serial number Q is stamped into the
crankcase.
NOTE:
Designs and specifications are subject to change
without notice.

1-1

IMPORTANT INFORMATION

GEN
INFO

IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1.Use only genuine parts for all replacements.
Use oil and/or grease recommended by MBK/
YAMAHA for assembly and adjustment. Other
brands may be similar in function and
appearance, but inferior in quality.

GASKETS, OIL SEALS, AND O-RINGS


1.All gaskets, seals and O-rings should be
replaced when an engine is overhauled. All
gaskets surfaces, oil seal lips and O-rings
must be cleaned.
2.Properly oil all mating parts and bearing during
reassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTER


PINS
1.All lock washers/plates Q and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or nut
flat(s) after the bolt or nut has been properly
tightened.

BEARINGS AND OIL SEALS


1.Install the bearing(s) Q and oil seal(s) W with
their manufacturers marks or numbers facing
outward. (In other words, the stamped letters
must be on the side exposed to view.) When
installing oil seal(s), apply a light coating of
lightweight lithium base grease to the seal
lip(s). Oil the bearings liberally when installing.

CAUTION:

Do not use compressed air to spin the


bearings dry. This causes damage to the
bearing surfaces.

1-2

IMPORTANT INFORMATION/SPECIAL TOOLS

GEN
INFO

CIRCLIPS
1.All circlips should be inspected carefully before
reassembly. Always replace piston pin clips
once they have been removed. Replace bent
circlips. When installing a circlip Q make sure
that the sharp edge W is positioned opposite
to the thrust E it receives. See the sectional
view.
R Shaft

SPECIAL TOOLS
The proper special tools are necessary for
complete and accurate tune-up and assembly.
Using the correct special tool will help prevent
damage caused by the use of improper tools or
improvised techniques.

Inductive tachometer
90890-03113

FOR TUNE UP

Ignition checker
90890-06754

1-3

SPECIAL TOOLS

GEN
INFO

Flywheel magneto puller


90890-01189

FOR ENGINE SERVICE

Crankcase separating tool


90890-01135

Flywheel holding tool


90890-01235

Crankshaft installing tool set


90890-01274 Q
90890-01275 W
90890-01277 E
90890-01411 R

Clutch serving nut wrench


90890-01348

Sheave holder
90890-01701

Clutch spring holder


90890-01337 Q
90890-01016 W

1-4

SPECIAL TOOLS

GEN
INFO

Steering Head wrench


9079Q-02218

FOR CHASSIS SERVICE

T-HANDLE
90890-01326

Damper rod holder


90890-01294

Oil seal guide


90890-01367

Oil seal guide adapter


90890-01400

30

Pocket Tester
90890-03112

FOR ELECTRICAL
COMPONENT

1-5

SPEC

SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
MAINTENANCE SPECIFICATIONS .............................................................. 2-4
ENGINE ................................................................................................... 2-4
CHASSIS ................................................................................................. 2-7
ELECTRICAL ........................................................................................... 2-8
CABLE ROUTING ........................................................................................ 2-10

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model

CW50RS

Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance

1.746 mm (0.07 in)


675 mm (26.5 in)
1.120 mm (0.04in)
803 mm (31.61 in)
1.206 mm (0.05 in)
153 mm (6.02 in)

Basic weight:
With oil and full fuel tank

83 kg (183 lbs)

Minimum turning radius :

1.800 mm (0.07 in)

Engine:
Type
Cylinder arrangement
Displacement
Bore x stroke
Compression ratio
Starting system

Air-cooled 2-stroke, gasoline torque induction.


Single cylinder, Vertical
49,2 cm3
40 x 39.2 mm (1.57 x 1.54 in)
7.22 : 1
Electric and kick starter

Lubrication system:

Separate lubrication (Yamaha Autolube )

Oil type or grade:


Engine oil:
Transmission oil

SEMI-SYNTHETIC, in accordance with


API TC TSC 3 STANDARD.
SAE 10W30 type SE motor oil

Oil capacity:
Transmission oil:
Periodic oil change
Total amount

0.11 L (0.10 Imp qt, 0.12 US qt)


0.13 L (0.11 Imp qt, 0.13 US qt)

Air filter:

Wet type element

Fuel:
Type
Tank capacity

Regular unleaded gasoline with a reserch octane


number of 91 or higher.
6.5 L (1.42 Imp gal, 1.71 US gal)

2-1

GENERAL SPECIFICATIONS
Model

SPEC

CW50RS

Carburetor:
Type/Manufacturer

5FX / TEIKEI
PHBN12 HS / DELL'ORTO

Spark plug:
Type/Manufacturer
Gap

BR8HS/NGK
0.5 ~ 0.7 mm (0.19 ~ 0.27 in)

Clutch type:

Dry, centrifugal automatic

Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission
Operation

Helical gear
52/13 (4.000)
Spur gear
42/13 (3.323)
V-belt
Automatic

Chassis:
Frame type
Caster angle
Trail

Steel tube underbone


27
90 mm (3.54 in)

Tire:
Type
Size
Manufacturer

Tire pressure (cold tire):


Up to 90 kg
90 kg ~ maximum load

Front
Rear
Front
Rear
Front
Rear

Tubeless
Tubeless
120/90-10
130/90-10
MICHELIN (REGGAE)
MICHELIN (REGGAE)

Front
Rear
Front
Rear

150 kPa (1.50 kg/cm2, 21.3 psi)


150 kPa (1.50 kg/cm2, 21.3 psi)
150 kPa (1.50 kg/cm2, 21.3 psi)
160 kPa (1.60 kg/cm2, 22.7 psi)

Brake:
Front brake type
Operation
Rear brake type
Operation

Disc brake
Right hand operation
Drum brake
Left hand operation

Suspension:
Front
Rear

Telescopic fork
Unit swing

Shock absorber:
Front
Rear

Coil spring/Oil damper


Coil spring/Oil damper

Wheel travel:
Front wheel travel
Rear wheel travel

80 mm (3.14 in)
60 mm (2.36 in)

2-2

GENERAL SPECIFICATIONS
Model

CW50RS

Electrical:
Ignition system
Charging system
Battery type/model
Battery capacity

CDI
Flywheel magneto
GM4-3B, YB4L-B, FB4L-B
12V 4AH

Headlight type

Bulb

Bulb wattage / quantity:


Headlight
Auxiliary light
Taillight/brake light
Flasher light

SPEC

Front
Rear

Meter light
Warning lights wattage / quantity:
OIL
HIGH BEAM
TURN

12V 35W/35W x 1
12V 5W x 1
12V 5W/21W x 1
12V 10W x 2
12V 10W x 2
12V 1.2W x 2
12V 1.2W x 1
12V 1.2W x 1
12V 1.2W x 1

2-3

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Model
Cylinder head:
Warp limit

CW50RS
0,02 mm (0.0008 in)
Lines indicate straight edge measurements.

Cylinder:
Bore size
Taper limit

39.993 ~ 40.012 mm (1.576 ~ 1.575 in)


0.05 mm (0,0002 in)

Piston:
Piston size
Measuring point

39.952 ~ 39.972 mm (1.576 ~ 1.574 in)


5 mm (0.19 in)

Piston clearance
<Limit>
Oversize 1st
Oversize 2nd
Piston pin bore size
Piston pin:
Outside diameter
Piston ring:
Sectional sketch (BxT)/Type:
Top ring
2nd ring
End gap (installed):
Top ring
2nd ring
Side clearance (installed):
Top ring
2nd ring

0.034 ~ 0.047 mm (0.001 ~ 0.002 in)


<0.1 mm (0.004 in)>
40.25 (1.58 in)
40.50 (1.59 in)
10.004 ~ 10.019 mm (0.394 ~ 0.395 in)
9.996 ~ 10.000 mm (0.393 ~ 0.394 in)

1.2 1.8 mm (0.05 ~ 0.07 in)


1.2 1.8 mm (0.05 ~ 0.07 in)
0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
0.03 ~ 0.05 mm (0.001 ~ 0.002 in)
0.03 ~ 0.05 mm (0.001 ~ 0.002 in)

2-4

MAINTENANCE SPECIFICATIONS
Model

SPEC

CW50RS

Crankshaft:

Crank width A
Runout limit C
Connecting rod big end
side clearance D

37.90 ~ 37.95 mm (1.492 ~ 1.494 in)


0.03 mm (0.001 in)
0.2 ~ 0.5 mm (0.007 ~ 0.019 in)

Automatic centrifugal clutch:


Shoe thickness
<Wear limit>
Clutch shoe spring free length
Clutch-in revolution
Clutch-stall revolution

2.0 mm (0.08 in)


<1.0 mm (0.039 in)>
29.9 mm (1.177 in)
3.250 ~ 3.750 r.p.m.
6.100 ~ 6.900 r.p.m.

V-belt:
Width
<Wear limit>

16.5 mm (0.64 in)


<15.7 mm (0.61 in)>

Transmission:
Main axle runout limit
Drive axle runout limit

0.08 mm (0.003 in)


0.08 mm (0.003 in)

Kick starter:
Type
Kick clip tension

Ratchet type
0.15 ~ 0.25 kg (0.33 ~ 0.55 lbs)

Reed valve:
Valve stopper height
Reed valve clearance

4.0 ~ 4.4 mm (0.15 ~ 0.17 in)


0.2 mm (0.007 in)

Lubrication system:
Stroke
Bore

Autolube pump
2.62 mm (0.103 in)
0.5 mm (0.019 in)

2-5

MAINTENANCE SPECIFICATIONS

SPEC

Carburetor:

DELLORTO

TEIKEI

I.D. mark

PHBN12 HS

5FX
#88

Main jet

(M.J.)

#90

Main air jet

(M.A.J.)

1.5

2.0

Jet needle

(J.N.)

211 GA 3/5

3S12-3/5

Needle jet

(N.J.)

2.110 GA

2,085

Cutaway

(C.A.)

4.0

3.0

Pilot jet

(P.J.)

#36

#50

Bypass

(B.P.1)

0.80

0.80

Pilot air screw

(A.S.)

1+3/8 1/8 out

1+1/2 1/4 out

Valve seat size

(V.S.)

1.2

#40

#46

2000 200 rpm

2000 200 rpm

Starter jet
Engine idle speed

(G.S.1)

2-6

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS
Model
Steering system:
Steering bearing type
No/Size of steel balls:
Upper
Lower

CW50RS
Ball bearing
15 pcs (4.77 mm)
15 pcs (4.77 mm)

Front suspension:
Front fork travel
Spring rate (K1)
Stroke (K1)
Optional spring

80 mm (3.14 in)
5.7 Nmm (0.57 kg/mm, 31.92 lb/in)
0 ~ 80 mm (0 ~ 3.14 in)
No

Rear suspension:
Shock absorber travel
Spring free length
Spring fitting length
Spring rate (K1)
Stroke (K1)
Spring rate (K2)
Stroke (K2)
Optional spring

70 mm (2.75 in)
165 mm (6.49 in)
151.5 mm (5.96 in)
26 Nmm (2.6 kg/mm, 145.61 lb/in)
0 ~ 40 mm (0 ~ 1.57 in)
36 Nmm (3.6 kg/mm, 201.62 lb/in)
40 ~ 70 mm (1.57 ~ 2.75 in)
No

Wheels:
Front wheel type
Rear wheel type
Front wheel size/Material
Rear wheel size/Material

Cast wheel
Cast wheel
MT 3.00 x10 / Aluminium
MT 3.50 x10 / Aluminium

Rim runout limit:


Radial
Lateral

1.0 mm (0.039 in)


1.0 mm (0.039 in)

Front disc brake:


Type
Diameter and thickness
Pad thickness
<Wear limit>
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type

Single disc
190 x 3.5 mm (7.48 x 3.5 in)
3.75 mm (0.15 in)
<0.5 mm (0.0019 in)>
11 mm (0.43 in)
30 mm (1.18 in)
DOT# 3 or DOT# 4

Rear drum brake:


Type
Drum inside diameter
<Wear limit>
Lining thickness
<Wear limit>
Spring free length

Leading, trailing
110 mm (4.33 in)
<110.5 mm (4.35 in)>
4.0 mm (0.15 in)
<2.0 mm (0.07 in)>
54 mm (2.12 in)

Front brake lever freeplay:


Rear brake lever freeplay:

10 ~ 20 mm (0.39 ~ 0.78 in)


10 ~ 20 mm (0.39 ~ 0.78 in)

2-7

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL
Model

CW50RS

Voltage:

12 V

Ignition system:
Ignition timing (B.T.D.C.)

14 at 5.000 r/min

CDI:
Pickup coil resistance (color)
Source coil resistance (color)

400 ~ 600 at 20C (68F) (White/Red-Black)


640 ~ 960 at 20C (68F) (Black/Red-Black)

Ignition coil:
Minimum spark length
Primary coil resistance
Secondary coil resistance

6 mm (0.23 in)
0.32 ~ 0.48 at 20C (68F)
5.68 ~ 8.52 k at 20C (68F)

Spark plug cap:


Resistance

5 k at 20C (68F)

CDI Magneto:
Lighting coil resistance
Charging coil resistance

0.32 ~ 0.48 at 20C (68F)(Yellow/Red-Black)


0.48 ~ 0.72 at 20C (68F)(White-Black)

Voltage regulator/Rectifier:
Type
No load regulated voltage
Capacity

Semi-conductor, short-circuit type


13 ~ 14 V
8A

2-8

MAINTENANCE SPECIFICATIONS
Model

SPEC

CW50RS

Battery:
Capacity
Specific gravity

12V, 4 Ah
1.280

Starter motor:
Output
Armature coil resistance
Brush length
<Wear limit>
Brush spring pressure
Commutator diameter
<Wear limit>
Mica undercut

0.14 kW
0.06 ~ 0 08 a 20C (68F)
3.9 mm (0.15 in)
<0.9 mm (0.035 in)>
563 ~ 844 gr (19.85 ~ 29.76 oz)
15.8 mm (0.62 in)
<14.8 mm (0.58 in)>
1.15 mm (0.045 in)

Starter relay:
Amperage rating
Coil resistance

20 A
54 ~ 66 at 20C (68F)

Horn:
Type/Quantity
Model/Manufacturer
Maximum amperage

Plain type/1 pc.


TR9/TRANSVAL
2.5 A

Flasher relay:
Type
Self cancelling device
Flasher frequency
Wattage

Condenser type
No
65 - 95 cycle/min
2x(10+3)W

Circuit breaker:
Type
Amperage for individual circuit x Quantity:
Main
Fuel sender unit:
Resistance

(full)
(empty)

Fuse
7Ax1
7.4 ~ 9.0 at 20C (68F)
82 ~ 98 at 20C (68F)

2-9

SPEC

CABLE ROUTING
CABLE ROUTING
Q Rectifier/regulator
W Battery
E Fuse holder
R Oil tank
T Fuel level sender
Y Brake hose guide
U Head light
I Speedometer cable

O
P
{
}
q
w
e

A
B
C
D
E

Pass the wire harness under the frame.


Attach on the mole fender (only on the left Side).
Attach the wire harness with a plastic band.
Attach all the wire.
Cut the end of each plastic clip only after the
tightening.
F Attach all the wires and the mud guard.
G Pass the wire under the frame dropout.
H Clamp the throttle cables and the starter cable all
together.
I The oil level switch connector must be slightly
inclined (0 to 30).

Ignition coil
Oil level gauge
Mudguard
Starter motor
CDI magneto
Brake wire
Under cover



6
6
6
6

6
6
2221

2221

6
6

6
6

2221
6

2221

2221
2221
22216

6
6

6
6

2221

6
2221

1 2

1
2

1
3

6
1

1
4

6
2

0
0

5
1

5
3

4
3

6
6

+5

10 0

5
5
5
5

5
5
5

5
6

0
2221

6
2

2221

2
1

6
5

2221

6
1

2221

02 1

2221

6
6

5
1
2221

6
6

6 2
1

0
6

2221
2

5
6

2221 6

2221

5
6
1
2
1
1

2221

2221

6
2

0
2

2221

6
2

2
1

5
6

6
2

1
2

6
6

2
3

4
3

4
1
2

2221

2221

5
3

3
3

6
1

6
5

1
1

2
5

4
3

1
2

5
6

1
1

6
5
5

5
3

5
5
5
5

5
5

5
5

H
3010

2-10

CABLE ROUTING
Q
W
E
R
T
Y
U
I
O
P
{

}
q
w
e
r
t
y
u
i
o
p

Grip assembly (right)


Handle switch (right)
Front stop switch
Front master cylinder
Plain washer
Union bolt
Flasher relay
Handle switch (left)
Grip assembly (left)
Rear brake lever
Starter cable

[
]
A
S
D

Brake hose
Handle cover
Speedometer assembly
Handle cover
Speedometer cable
Wire harness
Plastic clip
Nut flange
Bolt flange
Fitting nut
Washer

1 MINI

SPEC

Upper race ball


Steering balls
Lower race ball
Frame
Front fork assembly

2
51

3 4

3 4 56

B
6

t
E

o
p
[
]
A
S
A
]
D
F

y
r

RIGHT
FRONT

u
LEFT

2-11

CABLE ROUTING
A
B
C
D
E
F

SPEC

Install the handlebar switch before the master cylinder.


Install all connectors under the handlebar and the speedometer assembly.
Attach the wire harness holder on the frame dropout.
Do not clamp the speedometer cable and the brake wire.
Apply grease.
Install in the correct position.

1 MINI

2
51

3 4

3 4 56

B
6

t
E

o
p
[
]
A
S
A
]
D
F

y
r

RIGHT
FRONT

u
LEFT

2-12

SPEC

CABLE ROUTING
Rear brake cable
I
Rear stop switch
O
Handlebar switch (left) P
Handlebar switch (right) {
Throttle cable
}
Grip 5FX
q
Master cylinder

Front brake hose


Starter cable
Throttle cable
Rear brake cable
Wire harnness
Speedometer cable

A Install the cable end stop on the brake lever


holder.
B Adjust the grip mark with the seal surface.
C Install the boot after the adjustment.
D Apply grease on the throttle cable end and on
the cable holder.
E Install the front brake wire as shown.


B


FRONT

1.5 ~ 3 mm

Q
W
E
R
T
Y
U

9 0

5 mm

10

2-13

CHK
ADJ

CHK
ADJ
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION ............................................................................................ 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............................ 3-1
COVERS ........................................................................................................ 3-3
REMOVAL ................................................................................................ 3-3
INSTALLATION ........................................................................................ 3-6
HANDLEBAR COVERS ................................................................................. 3-7
REMOVAL ................................................................................................ 3-7
INSTALLATION ........................................................................................ 3-7
ENGINE ......................................................................................................... 3-9
ENGINE IDLE SPEED ADJUSTMENT .................................................... 3-9
THROTTLE CABLE FREE PLAY ADJUSTMENT ................................. 3-10
SPARK PLUG INSPECTION ................................................................. 3-11
AUTOLUBE PUMP AIR BLEEDING ...................................................... 3-12
ENGINE OIL LEVEL INSPECTION ....................................................... 3-13
TRANSMISSION OIL REPLACEMENT ................................................. 3-14
AIR CLEANER ELEMENT CLEANING .................................................. 3-15
CHASSIS ..................................................................................................... 3-16
FRONT BRAKE LEVER FREE PLAY ADJUSTMENT ........................... 3-16
REAR BRAKE LEVER FREE PLAY ADJUSTMENT ............................. 3-16
BRAKE PADS INSPECTION ................................................................. 3-16
BRAKE SHOE INSPECTION ................................................................. 3-17
BRAKE FLUID LEVEL INSPECTION .................................................... 3-17
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)- ................................ 3-18
STEERING HEAD ADJUSTMENT ......................................................... 3-18
TIRE INSPECTION ................................................................................ 3-19
WHEEL INSPECTION ........................................................................... 3-20
CABLE INSPECTION AND LUBRICATION ........................................... 3-20
LEVER LUBRICATION .......................................................................... 3-21
CENTERSTAND LUBRICATION ........................................................... 3-21
FRONT FORK INSPECTION ................................................................. 3-21
REAR SHOCK ABSORBER .................................................................. 3-22
ELECTRICAL ............................................................................................... 3-23
BATTERY INSPECTION ........................................................................ 3-23
FUSE INSPECTION ............................................................................... 3-24
HEADLIGHT BEAM ADJUSTMENT ...................................................... 3-25
HEADLIGHT LENS REPLACEMENT .................................................... 3-26
HEADLIGHT BULB REPLACEMENT .................................................... 3-26

INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS

INSP
ADJ

PERIODIC INSPECTION AND ADJUSTMENT


INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as new vehicles that are being prepared for
sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

ITEM

REMARKS

BREAK-IN

EVERY

1,000

3,000(2,000) 6,000(4,000)
or
or
6 Months
12 Months

(600)

Spark plug*

Check condition. Clean or replace if necessary.

Air filter

Clean. Replace if necessary.

Carburetor*

Check idle speed/starter operation. Adjust if necessary.

Fuel line*

Check fuel hose and vacuum hose for cracks or


damage. Replace if necessary.

Transmission oil*

Check oil leakage. Correct if necessary.


REReplace every 12,000 (8,000) or 24 months (warm PLACE
engine before draining).

Autolube pump *

Check operation.

Front brake*

See NOTE. Correct if necessary. Air bleeding.


Check operation/fluid leakage. Correct if necessary.

Rear brake*

Check operation. Adjust if necessary.

Wheels*

Check balance/runout. Repair if necessary.

Wheel bearings*

Check bearing assembly for looseness /damage.


Replace if damaged.

Steering bearings*

Check bearing assembly for looseness. Correct if


necessary. Moderately repack every 12,000 (8,000)
or 24 months.**

Rear shock absorber*

Check operation/oil leakage. Repair if necessary.

V-belt*

Check damage and wear. Replace if necessary.

Fittings/Fasteners*

Check all chassis fittings and fasteners.

Centerstand*

Correct if necessary. Check operation. Repair if


necessary.

Battery *

Check specific gravity. Check breather hose for


proper operation. Correct if necessary.

*: It is recommended that these items be serviced by a MBK or a Yamaha dealer.


**: Medium weight wheel bearing grease.

3-1

Km(miles)

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INSP
ADJ

NOTE:
Brake fluid replacement:
1.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 when cracked or damaged.

3-2

COVERS

INSP
ADJ

COVERS

REMOVAL
1. Remove:
Seat Q

353001

2. Remove:
Rear cover Q

3. Remove:
Side cover (left and right) Q

4. Remove:
Battery cover Q

CAUTION:
When removing the cover, be careful not to
damage the mounting clips.

5. Remove:
Seat cover Q

3-3

COVERS

INSP
ADJ

6. Disconnect:
Battery terminals Q

7. Remove:
Battery W

367001

8. Remove:
Footrest board Q

9. Remove:
Front cover Q

CAUTION:
When removing the cover, be careful not to
damage the mounting clips.

10. Remove:
Headlight socket Q
Turn the headlight socket clockwise, then
remove it.

11 . Remove:
Main switch ring Q
Turn the ring clockwise to remove it.

3-4

COVERS

INSP
ADJ

12. Remove:
Inner panel Q

13. Remove:
Lower cover Q

14. Remove:
Front wheel Q
Refer to the section FRONT WHEEL - REMOVAL in Chapter 6.

15. Disconnect:
Flasher light couplers (left and right) Q

16. Remove:
Front fender Q

3-5

COVERS

INSP
ADJ

INSTALLATION:
Reverse the REMOVAL procedure. Note the
following points.
NOTE:
Correct routing of cables and wires is essential
for a safe operation of this scooter. Refer to the
section CABLE ROUTING in Chapter 2.

NOTE:
Be careful not to pinch any wires with the covers.

NOTE:
When installing the covers, be careful not to
damage the mounting clips.

3-6

HANDLEBAR COVERS

INSP
ADJ

HANDLEBAR COVERS

REMOVAL
1. Remove:
Handlebar cover (front) Q
CAUTION:
When removing the cover, be careful not to
damage the mounting clips.

2. Remove:
Auxiliary light socket Q

3. Remove:
Rear handlebar cover screws
Rear handlebar cover Q

4. Remove:
Meter coupler Q
Speedometer cable W

INSTALLATION
Reverse the REMOVAL procedure. Note the
following points:
1. Connect:
Speedometer cable
Meter connector

3-7

HANDLEBAR COVERS

INSP
ADJ

2. Install:
Rear handlebar cover
Rear handlebar cover screws
Auxiliary light socket
3. Install:
Front brake hose
(into the slot in the front fender)
4. Install:
Front handlebar cover
5. Install:
Front handlebar cover screws
NOTE:
When installing the handlebar covers, be careful
not to damage any cables. Refer to the section
CABLE ROUTING in Chapter 2 for proper
routing of wires.

3-8

ENGINE IDLE SPEED ADJUSTMENT

INSP
ADJ

ENGINE
ENGINE IDLE SPEED ADJUSTMENT
1. Tighten:
Pilot air screw Q
Turn the pilot air screw in until lightly seated.

2. Loosen:
Pilot air screw
Back out from the lightly seated position.

322025

Pilot air screw position:


DELL'ORTO
1+3/8 turns out 1/8
TEIKEI
1+1/2 turns out 1/4

3. Start the engine and let it warm up for several


minutes.
WARNING
For safety reasons, place the scooter on the
center stand before starting the engine.

4. Attach:
Inductive tachometer Q
(to the spark plug lead)

Inductive tachometer:
90890-03113

5. Check:
Engine idle speed
Out of specification Adjust.
Engine idle speed:
2000 200 r/min

3-9

ENGINE IDLE SPEED ADJUSTMENT/


THROTTLE CABLE FREE PLAY ADJUSTEMENT

INSP
ADJ

6. Adjust:
Engine idle speed
********************************************************
Adjustment steps:
Turn the throttle stop screw Q in or out until
specified idling speed is obtained.

322025

Turning left

Idling speed increased.

Turning right

Idling speed decreased.

*******************************************************
THROTTLE
CABLE
FREE
PLAY
ADJUSTMENT
1 Check:
Throttle cable free play
Out of specification Adjust.
Free play:
1.5 ~ 3 mm (0.06 ~ 0,12 in)
*******************************************************
Throttle cable free play adjustment steps:
NOTE:
Before adjusting the throttle cable free play, the
engine idle speed should be adjusted.
First step:
Loosen the locknut on the throttle cable.
Turn the adjuster in or out until the specified
free play is obtained.
Turning left

Idling speed increased.

Turning right

Idling speed decreased.

Tighten the locknuts.

WARNING
After adjusting, turn the handlebar to the
right and left, making sure that the engine
idling speed does not change.
*******************************************************

3-10

SPARK PLUG INSPECTION

INSP
ADJ

SPARK PLUG INSPECTION


1. Remove:
Spark plug
2. Inspect:
Electrode Q
Wear/Damage Replace.
Insulator W
Abnormal color Replace.
Standard spark plug:
BR8HS (NGK)
3. Measure:
Plug gap @
Out of specification Adjust.
Use a wire gauge or feeler gauge.
Spark plug gap @:
0,5 ~ 0,7 mm (0.020 ~ 0.028 in)
4. Tighten:
Spark plug
Before installing the spark plug, clean the gasket
surface and plug surface.
NOTE:
First tighten by hand, then torque to specification.

Spark plug:
20 Nm (2.0 m kg, 14ft lb)

3-11

AUTOLUBE PUMP AIR BLEEDING

INSP
ADJ

AUTOLUBE PUMP AIR BLEEDING


1. Remove:
Fan cover Q

2. Bleed:
Pump housing and oil hose
*******************************************************
Pump bleeding steps:
Place a rag under the pump.
Remove the bleed screw Q.
Let oil run until there are no more air bubbles
in it.
When there are no more bubbles, tighten the
bleed screw.
NOTE:
Check the condition of the bleed screw gasket.
If it is damaged, replace it with a new one.

Start the engine.

Let the engine run two or three minutes at 2000

rpm. This will force out any air in the hose.


*******************************************************

3-12

ENGINE OIL LEVEL INSPECTION

INSP
ADJ

ENGINE OIL LEVEL INSPECTION


1. Inspect:
Oil level
Oil level low Add oil to proper level as
follows.
Q OIL indicator light

OIL LEVEL AND GAUGE CHECK


Turn main switch
to "*'

"OIL" indicator
doesn't light.

"OIL" indicator
light.

Turn main switch


to "ON".

"OIL" indicator goes

Inspect Faulty
electrical circuit,
Light bulb etc.

Engine oil level


and electric circuit
are OK.

"OIL" indicator
stays on.

Add oil.

"OIL" indicator
stays on.

Recommended oil:
Semi-synthetic oil in accordance
with APITC TSC3 STANDARD.
Capacity:
Total:
1.3 L (1.14 Imp qt, 1.37 US qt)

NOTE:
Install the oil tank filler cap Q and push it fully
into the filler.
CAUTION:
Always use the same type of engine oil;
mixing oils may result in a harmful chemical
reaction and lead to poor performance.

3-13

TRANSMISSION OIL REPLACEMENT

INSP
ADJ

TRANSMISSION OIL REPLACEMENT


1. Remove:
Drain plug Q
Oil filler plug W
Drain the transmission oil.
2. Check:
Gasket (drain plug)
O-ring (oil filler plug)
Damaged Replace.

3. Install:
Gasket
Drain plug

T.

Drain plug:
18 Nm (1.8 m kg, 13 ft lb)

4. Fill:
Transmission case
Transmission oil:
SAE 10W30 type SE motor oil.
Capacity:
Periodic replacement
0.11 L
(0.096 Imp qt, 0.116 US qt)
Total amount
0.13 L
(0.114 Imp qt, 0.137 US qt)
NOTE:
Wipe off any oil spilt on the crankcase, tire or
wheel.
5 Install:
Oil filler plug

3-14

AIR CLEANER ELEMENT CLEANING

INSP
ADJ

AIR CLEANER ELEMENT CLEANING


1. Remove:
Air cleaner case cover Q
2. Remove:
Air filter element
CAUTION:
Never operate the engine with the air cleaner
element removed. Unfiltered air will cause
rapid wear of engine parts and possible
engine damage.

3.Inspect:
Element Q
Damage replace.
4.Clean:
Air filter element
*******************************************************
Cleaning steps:
Wash the element gently but thoroughly in
solvent.
WARNING
Never use low flashpoint solvents such as
gasoline to clean the element. Such solvents
may lead to fire or explosion.
Squeeze excess solvent out of the element and
let dry.
CAUTION:
Do not twist the element.

Apply foam air filter oil or SAE 10W30 typ SE


oil on the element.
Sqeeze out the excess oil.
*******************************************************
NOTE:
The element should be wet but not dripping.

3-15

FRONT BRAKE LEVER FREE PLAY ADJUSTEMENT/


REAR BRAKE LEVER FREE PLAY ADJUSTEMENT/
BRAKE PADS INSPECTION

INSP
ADJ

CHASSIS
a

FRONT BRAKE LEVER FREE PLAY


ADJUSTMENT
1. Check:
Front brake lever free play @
Out of specification Adjust.
Free play:
10 ~ 20 mm (0.40 ~ 0.80 in)

WARNING
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 bleeding
the brake system before the scooter is
operated. Air in the system will reduce brake
performance and can result in loss of control
and an accident. Inspect and bleed the system
if necessary.
REAR BRAKE LEVER FREE PLAY
ADJUSTMENT
1. Check:
Rear brake lever free play @
Out of specification Adjust.

Free play:
10 ~ 20 mm (0.40 ~ 0.80 in)

*******************************************************
Adjustment steps:
Turn the adjuster Q in W or out E until the
specified free play is obtained.
********************************************************

BRAKE PADS INSPECTION


1.Measure:
Brake pads
Out of specification Replace.
NOTE:
Replace the brake pad and spring as a set when
replacing the brake pads.
Wear limit @:
0.5 mm (0.02 in)

347003

3-16

BRAKE SHOE INSPECTION/


BRAKE FLUID LEVEL INSPECTION

INSP
ADJ

BRAKE SHOE INSPECTION


1. Apply the rear brake lever.
2. Inspect:
Wear indicator Q
Indicator reaches the wear limit line W
Replace brake shoes.

BRAKE FLUID LEVEL INSPECTION


NOTE:
Position the scooter straight up when inspecting
the fluid level, and make sure be turning the
handlebar that the top of the master cylinder is
horizontal.

1. Inspect:
Brake fluid level
Brake fluid level is under LOWER level line Q
Fill to proper level.
Recommended brake fluid:
DOT # 3 or DOT # 4

CAUTION:

The brake fluid may corrode painted surfaces


or plastic parts. Always clean up spilled fluid
immediately.

WARNING
Use only the designated quality fluid.
Otherwise, the rubber seals may deteriorate
causing leakage and poor brake
performance.
Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical reaction leading to poor brake performance.
Be careful that water does no enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.

3-17

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/


STEERING HEAD ADJUSTEMENT

346002

INSP
ADJ

AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
1. Bleed:
Brake fluid.
*******************************************************
Air bleeding steps:
a. Add proper brake fluid into the reservoir.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic tube Q tightly to the
caliper bleed screw.
d. Place the other end of the tube into a container.
e. Slowly apply the brake lever several times.
f. Pull the lever as far as possible and hold it
there.
g. Loosen the bleed screw and pull the lever all
the way.
h. When the lever is completely pulled, tighten
the bleed screw, then release the lever.
i. Repeat steps (e) to (h) until all air bubbles have
been removed from the system.
j. Add brake fluid to proper level.

WARNING
Check the operation of the brake after
bleeding the brake system.
*******************************************************

STEERING HEAD ADJUSTMENT


1 Check:
Steering assembly bearings
Grasp the bottom of the forks and gently rock the
fork assembly back and forth.
Looseness Adjust steering head.

*******************************************************
Steering head adjustment steps:
Remove the front fender and the front panels.
Refer to COVERS REMOVAL.
Unscrew the securing nut Q
Tighten the nut W

Stearing head wrench:


9079Q - 02218

WARNING
354002

Do not overtighten.

3-18

STEERING HEAD ADJUSTEMENT/


TIRE INSPECTION

INSP
ADJ

Check the steering head by turning it lock to


lock. If it binds, remove the steering stem
assembly and inspect the steering bearings.
Install the steering shaft lock nut and tighten it
to the specified torque.
NOTE:
Tighten the steering shaft lock nut while holding
the ring nut with the ring nut wrench.
Stearing head wrench:
9079Q - 02218
Security nut:
27.5Nm (2.75 m.kg, 19.89 ft.lb)

354001

Move the handlebar up and down and from


front to rear. If steering play is too important,
tighten the nut to the specified torque.
Stearing head nut:
60 Nm (6.0 m kg, 43.3 ft lb)

*******************************************************
TIRE INSPECTION
1. Measure:
Air pressure
Out of specification Adjust.
Tire pressure (cold)
Up to 90 kg
90 kg ~ maximum
load *
Maximum load:

WARNING

Front
Rear
150 kPa
150 kPa
(1.50 kgf/cm2) (1.50 kgf/cm2)
150 kPa
160 kPa
(1.50 kgf/cm2) (1.60 kgf/cm2)
182 kg

* Maximum load is the total weight of rider, passenger,

accessories and luggage.

Proper loading of your scooter is important


for the handling, braking, and other performance and safety characteristics of your
scooter. Do not carry loosely packed items
that can shift.
Securely pack your heaviest items close to
the center of the scooter, and distribute the
weight evenly from side to side. And check
the condition and pressure of your tires.
NEVER OVERLOAD YOUR SCOOTER.
Make sure the total weight of the cargo, rider,
passenger, and accessories (fairing,
saddlebags, etc. if approved for this model)
does not exceed the maximum load of the
scooter. Operation of an overloaded scooter
could cause tire damage, an accident, or
even injury.

3-19

TIRE INSPECTION/WHEEL INSPECTION/


CABLE INSPECTION AND LUBRICATION

INSP
ADJ

2 Inspect:
Tire surface
Wear/Damage/Cracks/Road hazards Replace.
Aluminum wheels
Damage/Bends Replace.
Never attempt even small repairs to the wheel.

WARNING

Ride conservatively after installing a tire to


allow it to seat itself properly on the rim.
If the tire is removed with a tire lever, use a
suitable protection to prevent damaging the rim.
When installing the tire, make sure the arrow
points to the front.
3.Measure:
Tire tread depth
Out of specification Replace.
Minimum tire tread depth
(front and rear):
0,8mm (0.03 in)

Q Tread depth
W Side wall
E Wear indicator
WHEEL INSPECTION
1.Inspect:
Wheels
Damage/Bends Replace.
WARNING
Never attempt even small repairs to the wheel.
CABLE INSPECTION AND LUBRICATION
WARNING
A damaged cable sheath will rapidly corrode.
As a result, the cable cannot move smoothly
inside the sheath. Since this situation is
dangerous, replace a damaged cable
immediately.
1. Check:
Cable sheath
Cable end
Damage Replace.

3-20

CABLE INSPECTION AND LUBRICATION/


CENTERSTAND LUBRICATION/
FRONT FORK INSPECTION

INSP
ADJ

2. Check:
Cable movement
Stickiness Lubricate.
Recommended lubricant:
Engine oil SAE 10W30
NOTE:
Hold the cable end up and pour a few drops of oil
into the sheath.
3. Lubricate the throttle cable end and the cable
guide notch on the throttle grip with grease Q.
Recommanded lubricant:
Lithium soap based grease
LEVER LUBRICATION
1. Lubricate rotating parts of the levers
Recommended lubricant:
Engine oil SAE 10W30
CENTERSTAND LUBRICATION
1. Lubricate rotating parts
Recommended lubricant:
Engine oil SAE 10W30

FRONT FORK INSPECTION


1.Check:
Front fork
Bend/Damage Replace fork assembly as a
set.
Excessive oil leakage Replace fork assembly as a set.
Unsmooth operation Replace fork assembly.

3-21

REAR SHOCK ABSORBER

INSP
ADJ

REAR SHOCK ABSORBER


1.Check:
Rear shock absorber Q
Oil leaks/Damage Replace.
2.Check:
Tightening torque

T.

3-22

Upper bolt:
31 Nm (3.1 m kg, 22.4 ft lb)
Lower bolt:
17 Nm (1.7 m kg, 12.2 ft lb)

BATTERY INSPECTION

INSP
ADJ

ELECTRICAL

UPPER
LOWER

BATTERY INSPECTION
1. Inspect:
Battery fluid level
Fluid level low Add to proper level.
Fluid level should be between upper and lower
level marks.
Q Upper level
W Lower level
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.

2. Inspect:
Breather hose
Obstruction Remove.
3. Inspect:
Battery
*******************************************************
Replace the battery if:
Battery voltage will not rise to a specific value
or bubbles fail to rise during charging.
Sulfation of one or more cells occurs. (As
indicated by the plates turning white, or an
accumulation of material in the bottom of the
sell.)
Specific gravity readings after a long, slow
charge indicate that one cell is lower than the
rest.
Warpage or buckling of plates or insulators is
evident.
*********************************************************
4. Measure:
Specific gravity
Less than 1.280 Recharge battery.
Charging Current:
0.4 amps/10 hrs
Specific Gravity:
1.280 at 20C (68 F)

3-23

BATTERY INSPECTION/
FUSE INSPECTION

INSP
ADJ

CAUTION:
Always charge a new battery before using
it to ensure maximum performance.

WARNING
Battery electrolyte is dangerous. It contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
Avoid bodily contact with electrolyte as it
can cause severe burns and 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.
Follow with milk of magnesia, beaten egg,
or vegetable oil. Get immediate medical
attention.
Batteries generate explosive hydrogen gas.
Always follow these preventive measures:
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
DO NOT SMOKE when charging or handling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.

FUSE INSPECTION
1. Remove the battery cover.
2. Inspect:
Fuse
Blown Replace.

3-24

FUSE INSPECTION/
HEADLIGHT BEAM ADJUSTEMENT

INSP
ADJ

******************************************************
Fuse replacement steps:
Turn off the ignition.
Install a new fuse of the right amperage.
Turn on the switches to verify the operation of
the electric circuit.
If the fuse immediately blows again, check the
electric circuit.
*******************************************************
WARNING
Never use a fuse with a rating higher than
specified. An improper fuse may cause
damage to the electrical circuit, and possibly
cause a fire.
Fuse:
Main circuit: 7A

3 Install:
Battery cover

FUSE

CAUTION:
When installing the battery cover, pay particular attention to the following points:
No cable or wire should cross the area
marked NO.
The (+) terminal cover should be properly
installed.
Cables and wires should be routed as
shown in the illustration, within the appropriate area.

Q. NO zone
W. +-terminal
E. Wiring
R. Battery vent

HEADLIGHT BEAM ADJUSTMENT


1. Adjust:
Headlight beam

3-25

Higher

Turn out screw Q

Lower

Turn in screw Q

HEADLIGHT LENS REPLACEMENT


HEADLIGHT BULB REPLACEMENT

INSP
ADJ

HEADLIGHT LENS REPLACEMENT


1. Remove:
Front cover Q

2. Remove:
Headlight lens
(Pull out the cotter pins)
3. Remove:
Gasket

4. Install:
Reverse the REMOVAL procedure.

HEADLIGHT BULB REPLACEMENT


1. Remove:
Front cover

2. Remove:
Headlight bulb socket Q
(Turn one quart of a turn).
3. Remove:
Headlight bulb
4. Install:
Reverse the REMOVAL procedure.

3-26

ENG

ENG
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL ....................................................................................... 4-1
COVER REMOVAL .................................................................................. 4-1
CARBURETOR ........................................................................................ 4-1
CABLES, LEADS AND HOSES ............................................................... 4-2
ENGINE REMOVAL ................................................................................. 4-3
ENGINE DISASSEMBLY ............................................................................... 4-4
REAR WHEEL ......................................................................................... 4-4
CENTER STAND ..................................................................................... 4-4
CYLINDER HEAD AND CYLINDER ........................................................ 4-4
PISTON PIN AND PISTON ...................................................................... 4-4
KICK STARTER ....................................................................................... 4-5
PRIMARY SHEAVE ................................................................................. 4-6
SECONDARY SHEAVE ........................................................................... 4-6
STARTER SYSTEM ................................................................................. 4-7
TRANSMISSION ...................................................................................... 4-8
CDI MAGNETO ........................................................................................ 4-8
AUTOLUBE OIL PUMP ............................................................................ 4-9
CRANKCASE AND CRANKSHAFT ......................................................... 4-9
INSPECTION AND REPAIR ........................................................................ 4-11
CYLINDER HEAD .................................................................................. 4-11
CYLINDER AND PISTON ...................................................................... 4-11
PISTON RINGS ..................................................................................... 4-13
PISTON PIN AND PISTON PIN BEARING ............................................ 4-14
KICK STARTER ..................................................................................... 4-15
TRANSMISSION .................................................................................... 4-15
AUTOLUBE PUMP ................................................................................ 4-16
CRANKSHAFT ....................................................................................... 4-16
PRIMARY SHEAVE ............................................................................... 4-16
SECONDARY SHEAVE ......................................................................... 4-17
V-BELT ................................................................................................... 4-18
STARTER CLUTCH AND GEARS ......................................................... 4-19
ENGINE ASSEMBLY AND ADJUSTMENT ................................................. 4-20
CRANKSHAFT AND CRANKCASE ....................................................... 4-21
AUTOLUBE PUMP ................................................................................ 4-23
CDI MAGNETO ...................................................................................... 4-24
TRANSMISSION .................................................................................... 4-26
STARTER SYSTEM ............................................................................... 4-28
PRIMARY SHEAVE ............................................................................... 4-30
SECONDARY SHEAVE ......................................................................... 4-31
KICK STARTER ..................................................................................... 4-35
PISTON PIN AND PISTON .................................................................... 4-36
CYLINDER AND CYLINDER HEAD ...................................................... 4-37
ENGINE REMOUNTING ........................................................................ 4-39

ENGINE REMOVAL

ENG

ENGINE OVERHAUL
ENGINE REMOVAL
COVER REMOVAL
1. Remove:
Covers
See CHAPTER 3 - COVERS AND HANDLEBAR COVER.

CARBURETOR
1. Remove:
Air cleaner case assembly Q

2. Disconnect:
Carburetor cover
Hoses
Carburetor top

3.Remove:
Carburetor Q
322032

4. Remove:
Air shroud Q
Muffler assembly W

320000

5. Loosen:
Rear axle nut Q

NOTE:
Apply the rear brake while loosening the rear
axle nut.

340002

4-1

ENGINE REMOVAL

ENG

CABLES, LEADS AND HOSES


1. Remove:
Oil hose Q on the oil pump side

NOTE:
Plug the hose to prevent oil spillage.

321000

2. Disconnect:
CDI unit lead pump side
Spark plug cap
Starter motor lead

385000

3. Remove:
Rear brake cable Q

324000

4-2

ENGINE REMOVAL

ENG

ENGINE REMOVAL
1. Place a suitable stand under the frame.

2. Remove:
Rear shock absorber bolt (lower) Q
Engine mounting bolt W

320001(a)

3. Remove:
Engine
NOTE:
Lift up the frame and remove the engine.
4. Place the frame on a suitable stand.

4-3

ENGINE DISASSEMBLY

ENG

ENGINE DISASSEMBLY

REAR WHEEL
1. Remove:
Rear wheel
Brake shoes Q
Plate washer W

346001

CENTERSTAND
1. Remove:
Spring Q
Clip W
Rubber washer E
Axle R
Clamp T
Center stand Y

358001

CYLINDER HEAD AND CYLINDER


1. Remove:
Air shroud
Cylinder head Q
Cylinder head gasket

NOTE:
Before loosening the cylinder head nuts, loosen
the spark plug.
Loosen the cylinder head nuts crosswise 1/4 of
a turn each before removing them.

301005

2. Remove:
Cylinder Q
Cylinder gasket W

304002

PISTON PIN AND PISTON


1. Remove:
Piston pin clip Q

NOTE:
Before removing the piston pin clip, cover the
crankcase with a clean rag, so that the clip
cannot accidentally fall into the crankcase.
307001

4-4

ENGINE DISASSEMBLY

ENG

2. Remove:
Piston pin Q
Piston W
Piston pin bearing E

CAUTION:
Do not use a hammer to drive out the
piston pin.

307002

KICKSTARTER
1. Remove:
Transmission cover Q (left)

313001

2. Remove:
Kick pinion gear Q
NOTE:
To remove the kick pinion gear, push down the
kick crank.
3 Unhook:
Kick return spring W

317001

4. Remove:
Kick crank
Circlips Q
Plate washer W
Kick shaft E

317002

4-5

ENGINE DISASSEMBLY

ENG

PRIMARY SHEAVE
1. Remove:
Fan
2. Remove:
Nut Q (primary sheave)

NOTE:
To loosen the primary sheave nut hold the CDI
magneto with a flywheel holder W.

319035

Flywheel holder:
90890-01235

3. Remove:
Washer Q
Ratchet W
Washer E
Fixed primary sheave R
Washer T
V-belt

319001

4. Remove:
Spacer Q
Primary sliding sheave W

319002

SECONDARY SHEAVE
1. Remove:
Nut Q (secondary sheave)

NOTE:
Hold the secondary sheave with a sheave holder
W to loosen the nut.

Sheave holder:
90890-01701
319003

4-6

ENGINE DISASSEMBLY

ENG

2. Remove:
Clutch housing Q
Secondary sheave W
Crankcase cover gasket
Dowel pins
3. Attach:
Sheave holder Q
Nut wrench (39 mm)

319004

Sheave holder:
90890-01701
4. Loosen:
Clutch securing nut

WARNING
Loosen the nut but do not remove it yet.
319031

5. Attach:
Clutch spring holder Q

NOTE:
Compress the secondary sheave using the clutch
spring holder Q.
Clutch spring holder:
90890-01337
311001

6. Remove:
Clutch securing nut

7. Remove:
Clutch assembly Q
Clutch spring W
Spring seat E
Guide pin R
Secondary sliding sheave T
Secondary fixed sheave Y

311002

STARTER SYSTEM
1. Remove:
Starter clutch assembly Q
Plate W (idle gear)
Idle gear E
Starter wheel gear R
Spacer T
Bearing Y
Washer U

317003

4-7

ENGINE DISASSEMBLY

ENG

2. Remove:
Spacer Q
Bearing W
Washer E
Starter motor

317004

TRANSMISSION
1. Remove:
Transmission case Q
Gasket
Dowel pins

319036

2. Remove:
Drive shaft Q
Main shaft W
Plate washer E
Conical spring washer R

319037

3. Remove:
Oil seal Q
Secondary sheave axle W

319032

CDI MAGNETO
1. Remove:
Nut Q (rotor)
Plate washer

NOTE:
Hold the rotor using a flywheel holder W to
loosen the nut.
Flywheel holder:
90890-01235

321004

4-8

ENGINE DISASSEMBLY

ENG

2. Remove:
Rotor Q
Woodruff key
Use the flywheel puller W

Flywheel puller:
90890-01189

Stator assembly
Gasket

321005

AUTOLUBE OIL PUMP


1. Remove:
Autolube oil pump Q

314001

2. Remove:
Circlips Q
Pump drive gear W
Pin E
Circlip R

314002

CRANKCASE AND CRANKSHAFT


1. Remove:
Oil seal stopper Q
Screws (crankcase)

NOTE:
Loosen each screw one quart of a turn before
beginning to remove them.

313009

2. Attach:
Crankcase separating tool Q
Crankcase separating tool:
90890-01135

NOTE:
Fully tighten the tool holding bolts. Insure that
the tool body is parallel with the case. If necessary,

313002

4-9

ENGINE DISASSEMBLY

ENG

loosen one screw as much as required to level


the tool body.
3. Remove:
Crankcase (right)
As pressure is applied, keep tapping carefully on
the engine mounting bosses.

CAUTION:
Use a soft hammer to tap on the case. Tap
only on reinforced spots of the case. Never
tap on the gasket mating surfaces. Work
slowly and carefully. Make sure the cases
separate evenly. If one end hangs up take
the pressure off the push screw, realign the
cases and the tool and start again. If the
cases do not separate at all, check for a
remaining case screw or fitting. Do not force.

4. Attach:
Crankcase separating tool Q
Crankcase separating tool:
90890-01135

5. Remove:
Crankshaft W

313004

4-10

INSPECTION AND REPAIR

ENG

INSPECTION AND REPAIR


CYLINDER HEAD
1. Eliminate:
Carbon deposits
Use a rounded scraper Q

301001

301002

NOTE:
Take care to avoid damaging the spark plug
threads. Do not use a sharp instrument. Avoid
scratching the aluminum.
2. Inspect:
Cylinder head warpage
Out of specification Re-surface.
*******************************************************
Warpage measurement and re-surfacement
steps :
Attach a straight edge Q and a thickness
gauge W to the cylinder head.
Measure the warpage limit.
Warpage limit:
0.02 mm (0.001 in)

If the warpage is out of specification, re-surface


the cylinder head.

301003

NOTE:
Rotate the head several times to avoid removing
too much material from one side.
*******************************************************
CYLINDER AND PISTON
1. Eliminate:
Carbon deposits
Use a rounded scraper Q
2. Inspect:
Cylinder wall
Wear/Scratches Replace.

304001

3. Eliminate:
Carbon deposits
From the piston crown Q and ring grooves W.
4. Remove:
Score marks and lacquer deposits
From the sides of piston.

307003

4-11

ENG

INSPECTION AND REPAIR

NOTE:
Sand in a crisscross pattern. Do not sand
excessively.
5. Inspect:
Piston wall
Wear/Scratches/Damage Replace.
307004

6. Measure:
Piston to cylinder clearance
********************************************************
Piston to cylinder clearance measurement
steps :
First step :
Measure the cylinder bore C with a cylinder
bore gauge.

D1
D2

D3

D5

NOTE:
Measure the cylinder bore C in parallel to and
at right angles to the crankshaft. Then, calculate
the average of the measurements.

D4

D6

Standard
Cylinder
Bore C

307005

Taper
"T"

Wear limit

39.99 ~ 40.01mm 40.10 mm


(1.574 ~ 1.575 in) (1.579 in)
_

0,05mm
(0.002 in)

C = Maximum D
T = (Maximum D1,D3 or D5) (Maximum D2,D4 or D6 )

If out of specification, replace cylinder, piston


and piston rings as a set.

2nd step:
Measure the piston skirt diameter P with a
micrometer.
@ 5 mm (0.20 in) from the piston bottom edge.

@
Piston Size:
Standard:
39.952 ~ 39.972 mm
(1.57 ~ 1.57 in)
307006

4-12

INSPECTION AND REPAIR

ENG

If out of specification, replace piston and piston


rings as a set.
3rd step:
Calculate the piston-to-cylinder clearance with
following formula:
Piston-to cylinder clearance =
Cylinder Bore C
Piston Skirt Diameter P
If out of specification, replace cylinder, piston
and piston rings as a set.

Piston-to-cylinder clearance:
0.034 ~ 0.047 mm
(0.0013 ~ 0.0018 in)
<Wear limit : 0.1 mm (0.004 in)>
*******************************************************
PISTON RINGS
1. Measure:
Side clearance
Out of specification Replace piston and/or
rings.
Use a Feeler Gauge Q

Standard

Limit

307007

Top
ring

0.03 ~ 0.05 mm
(0.0012 ~ 0.0020 in)

0.10 mm
(0.004 in)

2nd
ring

0.03 ~ 0.05 mm
(0.0012 ~ 0.0020 in)

0.10 mm
(0.004 in)

2. Install:
Piston ring
Into the cylinder
Push the ring with the piston crown.

307008

3. Measure:
End gap
Out of specification Replace rings as a set.
Use a Feeler Gauge Q

4-13

INSPECTION AND REPAIR

ENG

Standard

Limit

Top
ring

0.15 ~ 0.30 mm
(0.005 ~ 0.011 in)

0.70 mm
(0.028 in)

2nd
ring

0.15 ~ 0.30 mm
(0.005 ~ 0.011 in)

0.70 mm
(0.028 in)

@ Measuring Point 20 mm (0.8 in)


PISTON PIN AND PISTON PIN BEARING
1. Inspect:
Piston pin
Blue discoloration/Groove Replace, then
inspect lubrication system.

2. Measure:
Outside diameter (piston pin)
Out of specification Replace.

Outside diameter (piston pin):


9.996 ~ 10.000 mm
(0.3935 ~ 0.3937 in)

307009

3. Measure:
Piston pin-to-piston clearance
Out of specification Replace piston.

Piston pin-to-piston clearance =


Bore (piston pin) b Outside diameter (piston pin) a

307010

Piston pin-to-piston clearance:


0.004 ~ 0.023 mm
(0.0002 ~ 0.0009 in)
<Limit : 0.07 mm (0.028 in)>
4. Inspect:
Bearing (piston pin)
Pitting/Damage Replace

307011

4-14

INSPECTION AND REPAIR

ENG

KICK STARTER
1. Inspect:
Kick gear teeth Q
Kick pinion gear teeth W
Burrs/Chips/Roughness/Wear Replace.

317005

2. Inspect:
Mating dogs (kick pinion gear and one-way
clutch)
Rounded edges/Damage Replace.

317006

3. Measure:
Clip tension (kick pinion gear) Q
Out of specification Replace.
Use a spring balance W.
Standard tension:
150 ~ 250 g (5.3 ~ 8.8 oz.)
317007

TRANSMISSION
1. Inspect:
Drive axle Q
Main axle W
Secondary sheave axle E
Burrs/Chips/Roughness/Wear Replace.

319005

2. Inspect:
Secondary sheave axle bearing Q
Main axle bearing W
Drive axle bearing E
Spin the bearing inner race.
Excessive play/Roughness Replace.
Pitting/Damage Replace.

319038

4-15

INSPECTION AND REPAIR

ENG

AUTOLUBE PUMP
Wear or an internal malfunction may cause the
pump output to vary from the factory setting.
This situation is, however, extremely rare. If
improper output is suspected, inspect the
following:
1. Inspect:
Delivery line
Obstructions Blow out.
O-ring
Wear/Damage Replace.
2. Inspect:
Autolube pump drive gear teeth Q
Autolube pump driven gear teeth W
Pitting/Wear/Damage Replace.
314003

CRANKSHAFT
1. Measure:
Crankshaft width "A"
Runout limit C
Connecting rod big end side clearance D
Use V-blocks, dial gauge and thickness gauge.
Crankshaft width "A":
37.90 ~ 37.95 mm
(1.492 ~ 1.494 in)
Runout limit C:
0.03 mm (0.0012 in)
Connecting rod big end side
clearance D:
0.2 ~ 0.5 mm (0.008 ~ 0.02 in)

308001

PRIMARY SHEAVE
1. Inspect:
Primary sliding sheave Q
Primary fixed sheave W
Wear/Cracks/Scratch/Damage Replace.

319006

4-16

INSPECTION AND REPAIR

ENG

2. Check:
Free movement
Insert the collar W into the primary sliding sheave
Q, and check for free movement.
Stick or excessive play Replace the sheave
and/or collar.

319007

3. Measure:
Outside diameter Q (weight)
Out of specification Replace.
Outside diameter (weight):
15.0 mm (0.59 in)
<Limit 14.5 mm (0.57 in)>

319008

SECONDARY SHEAVE
1. Inspect:
Secondary fixed sheave Q
Secondary sliding sheave W
Scratch/Crack/Damage Replace as a set.
Oil seal E
Damage Replace.

319009

2. Inspect:
Torque cam groove Q
Guide pin W
Wear/Damage Replace as a set.
O-rings E
Damage Replace.

319010

3. Measure:
Clutch spring free length
Out of specification Replace.
Clutch spring free length:
121.7 mm
<Limit>
106.7 mm
319011

4-17

INSPECTION AND REPAIR

ENG

4. Inspect:
Clutch housing inner surface
Oil/Scratches Remove.
Oil

Use a rag soaked in lacquer


thinner or solvent.

Scratches

Use an emery cloth (lightly


and evenly polishing).

319030

5. Measure:
Clutch housing inside diameter @
Out of specification Replace.
Clutch housing inside diameter:
107.0 mm ( 4.21 in)
<Wear Limit>:
107.4 mm ( 4.22 in)

319012

6. Inspect:
Clutch shoes
Glazed parts Sand with coarse sandpaper.
NOTE:
After using the sand paper, clean off the polished
particles with a cloth.

7. Measure:
Clutch shoe thickness @
Out of specification Replace.

Clutch shoe thickness:


2.0 mm (0.08 in)
<Wear Limit> :
1 mm (0.039 in)
319013

V-BELT
1. Inspect:
V-belt
Crack/Wear Replace.
NOTE:
Replace the V-belt if it is greasy or oily.

4-18

INSPECTION AND REPAIR

ENG

2. Measure:
V-belt width @
Out of specification Replace.
V-Belt width:
16,5 mm (0.65 in)
<Wear Limit>:
15,7 mm (0.62 in)
312001

STARTER CLUTCH AND GEARS


1. Inspect:
Starter clutch
Push the dowel pin in arrow direction.
Unsmooth operation Replace starter clutch
assembly.

317008

2. Inspect:
Starter wheel gear teeth Q
Idle gear teeth W
Burrs/Chips/Roughness/Wear Replace.
Bearing E (starter wheel gear)
Pitting/Damage Replace.

317009

4-19

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

ENGINE ASSEMBLY AND ADJUSTMENT


Q
W
E
R
T
Y
U

I
O
P
{
}
q
w

Oil seal
Oil seal holder
Crankcase (right)
Dowel pin
Bearing
Crankshaft (right)
Bearing

9 Nm (0.9 m.kg, 6.5 ft.lb)

Crankshaft pin
Connecting rod
Crankshaft (left)
Bearing
Engine mount shaft
Crankcase (left)
Oil seal
13 Nm (1.3 m.kg, 9.4 ft.lb)

A CRANKSHAFT:
Crank width:
37,90 ~ 37,95 mm
(1.49 ~ 1.50 in)
Runout limit:
< 0,03 mm>
< 0,002 in>
Big end side clearance:
0,2 ~ 0,5 mm
(0,008 ~ 0,020 in)

313008

4-20

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

CRANKSHAFT AND CRANKCASE


CAUTION:
To protect the crankshaft against scratches
and to facilitate the engine assembly and
installation, apply grease to oil seal lips, and
engine oil to bearings.

1. Attach:
Crankshaft installation tool Q, W, E, R

Crankshaft installation tool:


Q : 90890-01274
W : 90890-01275
E : 90890-01277
R : 90890-01411

2. Install:
Crankshaft
(to left crankcase)
NOTE:
Hold the connecting rod at top dead center with
one hand while tightening the nut of the
installation tool with the other. Tighten the
installation tool until the crankshaft bottoms
against the bearing.

3. Install:
Dowel pins Q
Spacer W

313005

4. Apply:
HEATPROOF or Yamaha Bond No.1215
To the mating surfaces of both case halves.
HEATPROOF or Yamaha Bond
No.1215

313006

4-21

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

5. Attach:
Crankshaft installation tool Q, W, E, R

Crankshaft installation tool:


Q : 90890-01274
W : 90890-01275
E : 90890-01277
R : 90890-01411

NOTE:
Hold the connecting rod at top dead center with
one hand while tightening the nut of the installation tool with the other. Tighten the installation
tool until the crankcase halves close with one
another.
6. Install:
Right crankcase

7. Tighten:
Crankcase holding screws
NOTE:
Tighten the crankcase holding screws in stages,
using a crisscross pattern.

T.

Crankcase holding screw:


9 Nm (0.9 m kg,( 6.5 ft lb)

313009

8. Check:
Crankshaft operation
Unsmooth operation Repair.

CAUTION:
Never hit on the crankshaft.

308003

9. Install:
Oil seal stopper plate Q

T.

313009

4-22

Screw (oil seal stopper plate):


9 Nm (0.9 m kg,( 6.5 ft lb)

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

AUTOLUBE PUMP AND CDI MAGNETO


O Gasket
Q Fan
P Oil hose
W Plain washer
{ Oil delivery hose
E Rotor assembly
} Clip
R Lighting coil
q Autolube pump
T Charge coil
w O-ring
Y Pick up coil
e Circlip
U Stator assembly
r Oil pump drive gear
I Oil seal

4 Nm (0.4 m.kg, 2.9 ft.lb)

6.5 Nm (0.65 m.kg, 4.7 ft.lb)

37.5 Nm (3.75 m.kg, 27.1 ft.lb)

8 Nm (0.8 m.kg, 5.8 ft.lb)

314007

4-23

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

AUTOLUBE PUMP
1. Install:
Circlip Q
Pin W
Pump drive gear E
Circlip R

314004

2. Apply:
Lithium soap base grease
(to O-ring Q)

3. Instal:
Autolube pump W

T.
R

314005

Screw (autolube pump):


4 Nm (0.4 m kg, 2.9 ft lb)

4. Apply:
Lithium soap base grease
(to autolube pump gear Q, W)
Lithium soap base grease:
15 cc (0.92 cu in)

314006

CDI MAGNETO
1. Install:
Gasket
2. Apply:
Lithium soap base grease
(to oil seal Q)

321001

3. Pass the CDI magneto lead through the


crankcase hole.
4. Install:
Stator assembly

T.
R

4-24

Screw (stator assembly):


8 Nm (0.8 m kg, 5.8 ft lb)

ENGINE ASSEMBLY AND ADJUSTMENT

5. Install:
Woodruff key Q
Magneto rotor W
Plain washer E
Nut R

321002

ENG

NOTE:
When installing the magneto rotor, make sure
the woodruff key is properly seated in the key
way of the crankshaft. Apply a light coating of
lithium soap base grease to the tapered portion
of the crankshaft end.

6. Tighten:
Nut Q (magneto rotor)
Use the flywheel holding tool W.

Flywheel holding tool:


90890-01235

T.
R

321004

4-25

Nut (Flywheel magneto):


37.5 Nm (3.75 m kg, 27.1 ft lb)

ENGINE ASSEMBLY AND ADJUSTMENT


TRANSMISSION
Q Circlip
W Bearing
E Oil seal
R Drive axle
T Bearing
Y Main axle
U Conical spring washer
I Plain washer

ENG

O Bearing
P Secondary sheave axle
{ Bearing
} Dowel pin
q Gasket
w Transmission case cover
e Oil seal

12 Nm (1.2 m.kg, 8.7 ft.lb)

319033

4-26

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

TRANSMISSION
1. Apply:
10W30 Type SE Motor oil
(to transmission case cover bearing)
2. Install:
Bearing Q

3. Install:
Oil seal W
Secondary sheave axle E
NOTE:
Apply lithium soap base grease onto the oil seal
lips.

319014

4. Check:
Secondary sheave axle operation
Unsmooth operation Repair.

5. Apply:
10W30 type SE Motor oil
(to main axle bearing and drive axle bearing)

6. Install:
Main axle Q
Drive axle W
Conical spring washer E
Plain washer R

319016

NOTE:
Apply lithium soap base grease onto the oil seal
lips.
Always use a new gasket.

7. Install:
Gasket
Dowel pins
Transmission case cover

T.

319017

4-27

Screw (case cover):


9 Nm (0.9 m kg, 6.5 ft lb)

ENG

ENGINE ASSEMBLY AND ADJUSTMENT


STARTER SYSTEM
Q Collar
W Washer
E Bearing
R Starter wheel gear
T Collar
Y Starter clutch

U Plate
I Shaft
O Plain washer
P Idle gear
{ O-ring
} Starter motor

13 Nm (1.3 m.kg, 9.4 ft.lb)

8 Nm (0.8 m.kg, 5.8 ft.lb)

317017

4-28

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

STARTER SYSTEM
1. Install:
Collar Q
Washer W
Bearing E
Starter wheel gear R
Starter clutch T
317010

NOTE:
Apply lithium soap base grease to the bearing.
Apply molybdenum disulfide oil to the shaft
(starter clutch).

317011

2. Install:
Plain washer Q
Idle gear W
Plain washer E
Plate R (idle gear)

T.

Screw (idle gear plate):


8 Nm (0.8 m kg, 5.8 ft lb)

317012

NOTE:
Apply engine oil to the idle gear W.

3. Install:
Starter motor Q

T.

317013

Screw (starter motor):


13 Nm (1.3 m kg, 9.4 ft lb)

NOTE:
Apply lithium soap base grease to the O-ring of
the starter motor.

4-29

ENGINE ASSEMBLY AND ADJUSTMENT


PRIMARY AND SECONDARY SHEAVE
Q Clutch housing
} Conical spring washer
W Clutch
q One-way clutch
E Clutch shoe spring
w Washer
R Clutch spring
e Primary fixed sheave
T Spring seat
r Plate washer
Y Gasket
t Spacer
U O-rings
y Primary sliding sheave
I Secondary sliding sheave u Clutch weights
O V-belt
i Slider
P Guide pin
o Cam
{ Secondary fixed sheave

ENG

*Apply BEL-RAY Assembly Lube

50 Nm (5.0 m.kg, 36.2 ft.lb)

40 Nm (4.0 m.kg, 28.9 ft.lb)

A Spring (secondary sheave)


free lenght limit: 106.7 mm
(4.20 in)
B Clutch housing weare limit:
107.4 mm (4.22 in)
C Clutch shoes wear limit:
1 mm (0.039 in)
D V-belt wear limit:
15.7 mm (0.62 mm)
E Weight outside diameter
limit : 14.5 mm (0.57 in)

30 Nm (3.0 m.kg, 21.7 ft.lb)

319034

4-30

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

KICK STARTER
Q Kick shaft
W Return spring
E Collar
R Plain washer
T Circlip
Y Gasket

U Dowel pin
I Transmission case
O Kick crank
P Kick pinion gear
{ Kick pinion gear clip

A KICK CLIP FRICTION FORCE : 0,15 ~ 0,25


kg

150 ~ 250 g

12 Nm (1,2 m.kg, 8.7 ft.lb)

10 Nm (1,0 m.kg, 7.2 ft.lb)

317018(a)

4-31

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

SECONDARY SHEAVE
When assembling the secondary sheave, reverse
the disassembly procedure. Note the following
points.
1. Apply:
BEL-RAY Assembly Lube
(to the sliding parts of the sheave)
319018

2. Install:
Sliding sheave Q

NOTE:
Wind adhesive tape around the end of the sheave
to avoid turning over the oil seal lips when
installing the sheave.

319019

3. Install:
Pin Q

4. Apply:
BEL-RAY Assembly Lube
(to the torque cam grooves and O-rings)

319020

5. Check:
Sliding sheave
Unsmooth operation Repair.

CAUTION:
Remove excessive grease.
6. Install:
Clutch securing nut
Use the clutch spring holder Q
Clutch spring holder:
90890-01337

319021

7. Tighten:
Clutch securing nut
Use sheave holder Q (39 mm).

Sheave holder:
90890-01701

T.

319031

4-32

Clutch securing nut:


50 Nm (5.0 m kg, 36 ft lb)

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

8. Install:
Dowel pin
Gasket
Secondary sheave assembly Q
Clutch housing W

319022

9. Tighten:
Nut Q (secondary sheave)
Use sheave holder W

Sheave holder:
P/N. 90890-01701

Nut (secondary sheave):


40 Nm (4.0 m kg, 29 ft lb)

PRIMARY SHEAVE
1. Clean:
Primary sliding sheave face Q
Primary fixed sheave face W
Collar E
Weight R
Primary sliding sheave cam surface T

T.

319023

319024

319025

2. Install:
Weight Q
Cam W
Slider E
Collar R
3.Check:
Cam operation
Unsmooth operation Repair.
4. Install:
Primary sheave assembly Q
Collar W

319026

4-33

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

5. Install:
V-belt
Place the V-belt around the secondary sheave,
and compress the secondary sheave spring
hard so that the V-belt moves toward the clutch
hub.
NOTE:
The arrow on the V-belt must point to the front.
Make sure the V-belt is not stained with oil or
grease.

6. Install:
Shim Q
Primary fixed sheave W
Washer E
One-way clutch R
Washer T
Nut Y

319027

7. Tighten:
Nut Q (primary sheave)

T.

319035

Nut (primary sheave):


30 Nm (3.0 m kg, 21.7 ft lb)

NOTE:
When tightening the nut (primary sheave), hold
the magneto rotor using the flywheel holding tool
W.
Flywheel holding tool:
90890-01235

8. Adjust:
V-belt
Tense the V-belt by turning the primary sheave
several times.

319028

4-34

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

9. Install:
Fan Q

T.

Screw (fan):
7 Nm (0.7 m kg, 5.1 ft lb)

320000

KICK STARTER
1. Install:
Return spring Q
Kick shaft W
Collar E
Washer R
Circlip T

317014

2. Hook:
Return spring
(to the kick gear and boss)
3. Install:
Kick pinion gear Q
NOTE:
Install the clamp as shown.
317015

4. Install:
Transmission case Q

T.

Screw (Transmission case):


9 Nm (0.9 m kg, 6.5 ft lb)

319029

5. Install:
Kick crank Q

T.

317016(a)

4-35

Bolt (kick crank):


9 Nm (0.9 m kg, 6.5 ft lb)

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

PISTON, CYLINDER AND CYLINDER HEAD


Q Carburetor joint
W Reed valve
E Gasket
R Cylinder head
T Cylinder head gasket
Y Cylinder

U Cylinder gasket
I Piston ring
O Piston
P Piston pin
{ Piston pin clip
} Bearing

20 Nm (2.0 m.kg, 14.0 ft.lb)

10 Nm (1.0 m.kg, 7.2 ft.lb)

B
C

Piston clearance :
0.034 ~ 0.047 mm (0.0013 ~ 0.0017 in)
Piston rings end gap :
0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
Piston rings side clearance :
0.03 ~ 0.05 mm (0.0012 ~ 0.0019 in)
Spark plug :
Type : BR8HS
Manufacturer : NGK

304003

4-36

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

PISTON PIN AND PISTON


1. Apply:
Engine oil Q
(to crankshaft bearing, connecting rod big end
bearing, small end bearing, piston pin, piston
ring grooves and piston skirt .)

308004

2. Install:
Small end bearing
Piston Q
Piston pin E
Piston pin clip R

307012

NOTE:
The arrow W on the piston must point to the
exhaust side.
Before installing the piston pin clip, cover the
crankcase with a clean towel or rag so you will
not accidentally drop the pin clip and material
into the crankcase.
WARNING
The ends of the piston pin clip must not
come together at the slot in the piston
groove.
Always use a new piston pin clip.

CYLINDER AND CYLINDER HEAD


1. Install:
Cylinder gasket (new gasket)
2. Check:
Piston rings

307013

NOTE:
Make sure the ring ends Q are properly fitted
around the ring locating pins in the piston grooves.
Be sure to check the manufacturers marks or
numbers stamped on the rings are on the top
side of the rings.

4-37

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

3. Install:
Cylinder Q

NOTE:
Install the cylinder with one hand, while compressing the piston rings with the other hand.

304002

4. Install:
Cylinder head gasket (new gasket)

5. Install:
Cylinder head Q
Spark plug W

301004

NOTE:
Tighten the cylinder head holding nuts in stages,
and crisscross sequence.
The arrow E on the cylinder head must point to
the front.

T.

6. Install:
Center stand Q
Shaft W
Clamp E
Rubber washer R
Clip T
Spring Y

Nut (cylinder head):


10 Nm (1.0 m kg, 7.2 ft lb)
Spark plug:
20 Nm (2.0 m kg, 14 ft lb)

358002

7. Install:
Brake shoe plate Q
Plain washer W
Rear wheel

346001

4-38

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

8. Install:
Air shroud
Oil hose
Oil delivery hose

9. Air bleeding:
Autolube pump
Refer to the section CHAPTER 3 AUTOLUBE
PUMP AIR BLEEDING.

320001

ENGINE REMOUNTING
Reverse the removal procedure.
Note the following points.
1. Install:
Engine mounting bolt Q
Rear shock absorber bolt W (lower)
These bolts should be temporarily secured.
2. Tighten:
Engine mounting bolt
Rear shock absorber bolt (lower)

T.

Engine mounting bolt:


84 Nm (8.4 m kg, 61 ft lb)
Rear shock absorber bolt (lower):
16 Nm (1.6 m kg, 12 ft lb)

3. Install:
Carburetor top together with throttle valve Q
Fuel hose W/Vacuum hose E
Brake cable/plug cap
322032

NOTE:
When installing the throttle valve into the
carburetor, align the groove of the throttle valve
with the projection of the carburetor.
4. Connect:
Starter motor
CDI magneto lead
Earth
385000

4-39

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

5. Tighten:
Rear wheel axle nut Q

NOTE:
When tightening the rear wheel axle nut, apply
the rear brake.

T.
R

Rear wheel axle nut:


105 Nm (10,5 m kg, 76 ft lb)

340002

6. Install:
Muffler assembly Q
Fan cover W.
T.
R

320000

Bolt (muffler):
26 Nm (2.6 m kg, 19 ft lb)
Bolt (exhaust pipe):
9 Nm (0.9 m kg, 6.5 ft lb)

7. Fill:
Transmission oil
Refer to CHAPTER 3 TRANSMISSION OIL
REPLACEMENT section.
8. Adjust:
Brake lever free play
Refer to CHAPTER 3 FRONT/REAR BRAKE
LEVER FREE PLAY ADJUSTMENT section.
Engine idle speed
Throttle cable free play
Refer to THROTTLE CABLE FREE PLAY
ADJUSTMENT and ENGINE IDLE SPEED
ADJUSTMENT.

4-40

CARB

CARB
CHAPTER 5.
CARBURETION
CARBURETOR .............................................................................................. 5-1
TEIKEI CARBURETOR ............................................................................ 5-1
DELL'ORTO CARBURETOR ................................................................... 5-3
REMOVAL ................................................................................................ 5-5
DISASSEMBLY ........................................................................................ 5-5
INSPECTION ........................................................................................... 5-7
ASSEMBLY .............................................................................................. 5-9
INSTALLATION ...................................................................................... 5-10
FUEL COCK ................................................................................................. 5-11
INSPECTION .........................................................................................5-11
FUEL FILTER CLEANING ..................................................................... 5-11
REED VALVE ............................................................................................... 5-11
REMOVAL .............................................................................................. 5-11
INSPECTION .........................................................................................5-12
INSTALLATION ...................................................................................... 5-13

CARBURETOR
TEIKEI CARBURETOR
Q Carburetor top
W Gasket
E Throttle valve spring
R Needle set
T Throttle valve
Y Starter plunger spring
U Starter plunger
I Air screw
O Throttle stop screw

CARB

P Pilot jet
{ Needle jet
} Needle valve
q Main jet
w Float pin
e Float
r Float chamber gasket
t Float chamber
y Drain screw

322033

5-1

CARBURETOR

CARB

Carburetor:

DELLORTO

TEIKEI

I.D. mark

PHBN12 HS

5FX
#88

Main jet

(M.J.)

#90

Main air jet

(M.A.J.)

1.5

2.0

Jet needle

(J.N.)

211 GA 3/5

3S12-3/5

Needle jet

(N.J.)

2.110 GA

2,085

Cutaway

(C.A.)

4.0

3.0

Pilot jet

(P.J.)

#36

#50

Bypass

(B.P.1)

0.80

0.80

Pilot air screw

(A.S.)

1+3/8 1/8 out

1+1/2 1/4 out

Valve seat size

(V.S.)

1.2

#40

#46

2000 200 rpm

2000 200 rpm

Starter jet
Engine idle speed

(G.S.1)

5-2

CARBURETOR
DELL'ORTO CARBURETOR
Q Carburetor top
W Gasket
E Throttle valve spring
R Needle set
T Throttle valve
Y Starter plunger spring
U Starter plunger
I Air screw
O Throttle stop screw

CARB

P Pilot jet
{ Needle jet
} Needle valve
q Main jet
w Float pin
e Float
r Float chamber gasket
t Float chamber
y Drain screw

322034

5-3

CARBURETOR

CARB

Carburetor:

DELLORTO

TEIKEI

I.D. mark

PHBN12 HS

5FX
#88

Main jet

(M.J.)

#90

Main air jet

(M.A.J.)

1.5

2.0

Jet needle

(J.N.)

211 GA 3/5

3S12-3/5

Needle jet

(N.J.)

2.110 GA

2,085

Cutaway

(C.A.)

4.0

3.0

Pilot jet

(P.J.)

#36

#50

Bypass

(B.P.1)

0.80

0.80

Pilot air screw

(A.S.)

1+3/8 1/8 out

1+1/2 1/4 out

Valve seat size

(V.S.)

1.2

#40

#46

2000 200 rpm

2000 200 rpm

Starter jet
Engine idle speed

(G.S.1)

5-4

CARBURETOR

CARB

REMOVAL
1. Remove:
Side covers and footrest board
Refer to the section SIDE COVERS AND
FOOTREST BOARD in Chapter 3.
Air filter case assembly

2. Disconnect:
Fuel hose Q
Oil hose W

TEIKEI CARBURETOR
3. Remove:
Carburetor top
Throttle valve
Starter plunger
Carburetor

322030

DELLORTO CARBURETOR
3. Remove:
Carburetor top
Throttle valve
Starter plunger top
Starter plunger
Carburetor

DISASSEMBLY (TEIKEI CARBURETOR)


1. Remove:
Float chamber Q

322001

2. Remove:
Float pin screw Q
Float pin W
Float E
Needle valve R
Gasket T

322002

5-5

CARBURETOR

CARB

3. Remove:
Main jet Q
Needle jet W
Pilot jet E

322003

4. Remove:
Throttle stop screw Q
Spring (throttle stop screw)
Air screw W
Spring (air screw)

322004

5. Remove:
Needle clip Q
Jet needle W
Throttle valve E

322005

DISASSEMBLY (DELLORTO
CARBURETOR)
1. Remove:
Float chamber Q

322007

2. Remove:
Float pin Q
Float W
Needle valve E

322026

5-6

CARBURETOR
3. Remove:
Pilot jet Q
Main jet W
Needle jet E
Starter jet R

CARB

322027

4. Remove:
Throttle stop screw Q
Spring (throttle stop screw)
Air screw W
Spring (air screw)

322028(a)

5. Remove:
Needle clip Q
Jet needle W
Throttle valve E

322029

INSPECTION
1. Check:
Carburetor body Q
Dirt Clean.

NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with compressed
air.
322006

2. Inspect:
Main jet Q
Needle jet W
Pilot jet E
Starter jet (DELLORTO)
Contamination Clean.

322012

5-7

CARBURETOR

3. Check:
Needle valve Q
Wear/Contamination Replace.
Float W
Damage Replace.
Gasket
Damage Replace.

CARB

322013

4. Check:
Throttle valve Q
Wear/Damage Replace.

322014

5. Check:
Throttle valve free movement
Unsmooth/stickiness Replace.
Insert the throttle valve Q into the carburetor
body W and check for smooth movement.

322015

6. Check:
Throttle stop screw Q
Air screw W
Needle E
Starter plunger R
Wear/Damage Replace.

322016

7. Measure:
Needle valve
Valve seat
NOTE:
The float height is factory-adjusted. Never try to
adjust it yourself.

5-8

CARBURETOR

CARB

ASSEMBLY
Reverse the DISASSEMBLY procedures. Note
the following points.
CAUTION:
Before reassembling the carburetor wash
all its components in clean gasoline.

Always use new gaskets.

1. Install:
Needle W
Clip E
Throttle valve Q
Spring seat R
Spring

Jet needle clip position:


3/5

322018

2. Install:
Throttle valve Q
Starter plunger
NOTE:
Align the groove W of the throttle valve with the
projection E of the carburetor body.

322019

3. Install:
Carburetor

NOTE:
Align projection Q with projection W.

322020

5-9

CARBURETOR

INSTALLATION
To install the carburetor reverse the REMOVAL
procedures. Note the following points.
1. Install:
Carburetor cover Q
Air hose W
Pass the air hose through the hole E in the
carburetor cover.

CARB

322021

2. Adjust:
Throttle cable free play
Refer to the section THROTTLE CABLE FREE
PLAY ADJUSTMENT in Chapter 3.

3. Install:
Air filter case

5-10

FUEL COCK/
REED VALVE

CARB

FUEL COCK
INSPECTION
1. Stop the engine.
2. Remove:
Side covers
Refer to the section SIDE COVERS AND
FOOTREST BOARD in Chapter 3.
3. Check:
Fuel cock

322031

********************************************************
Fuel cock inspection steps :
Disconnect the fuel hose Q.
Place a receptacle under the fuel hose end.
If fuel stops flowing within a few seconds, the
fuel cock is in good condition. If not clean or
replace the fuel cock.
Disconnect the vacuum hose and breathe in
through the hose to create a vacuum in the fuel
cock.
If fuel flows out of the fuel hose when vacuum is
applied and stops flowing when vacuum stops,
the fuel cock is in good condition.
If not, clean or replace the vacuum hose, the fuel
hose and the fuel cock.
********************************************************

FUEL FILTER CLEANING


The fuel filter Q is fitted inside the fuel tank. It is
accessible when the fuel hose (between the fuel
tank and the fuel cock) is disconnected.

352001

REED VALVE
REMOVAL
1. Remove:
Side covers
Refer to the section SIDE COVERS AND
FOOTREST BOARD in Chapter 3.
2. Remove:
Carburetor
Refer to section CARBURETOR REMOVAL.

5-11

REED VALVE

CARB

3. Remove :
Carburetor joint
Reed valve assembly

322022

INSPECTION
1. Check :
Carburetor joint
Damage/Cracks Replace.
Reed valve
Wear/Cracks/Damage Replace.
*********************************************************
Reed valve inspection steps :
Visually inspect the reed valve.
NOTE:
A reed valve in good condition should be completely or at least nearly flush with the valve seat.
If in doubt, apply suction to the carburetor side

of the assembly.
Leakage should be minimal to moderate.
*********************************************************

2. Measure:
Valve stopper height Q
Out of specification Replace valve stopper.
Valve stopper height:
4.0 ~ 4.4 mm (0.157 ~ 0.173 in)

322023

3. Measure:
Reed valve clearance Q
Out of specification Replace reed valve.
Reed valve clearance:
Less than 0.2 mm (0.008 in)

322024

5-12

REED VALVE

CARB

INSTALLATION
To install the reed valve reverse the REMOVAL procedure. Note the following points.
1. Install:
Gasket (new)
2. Tighten:
Reed valve assembly bolts

T.
R

Reed valve assembly bolts:


9 Nm (0.9 m.kg, 6.5 ft.lb)

NOTE:
Tighten the screws crosswise in several steps to
prevent warpage of the read valve assembly and
the carburetor joint.

5-13

CHAS

CHAS
CHAPTER 6.
CHASSIS
FRONT WHEEL ............................................................................................. 6-1
REMOVAL ................................................................................................ 6-2
INSPECTION ........................................................................................... 6-2
INSTALLATION ....................................................................................... 6-3
FRONT BRAKE .............................................................................................. 6-4
BRAKE PAD REPLACEMENT ................................................................. 6-6
CALIPER DISASSEMBLY ....................................................................... 6-7
MASTER CYLINDER DISASSEMBLY ..................................................... 6-8
INSPECTION AND REPAIR .................................................................... 6-9
CALIPER ASSEMBLY ........................................................................... 6-10
MASTER CYLINDER ASSEMBLY ......................................................... 6-11
REAR WHEEL ............................................................................................. 6-13
REMOVAL .............................................................................................. 6-14
INSPECTION .........................................................................................6-14
ASSEMBLY ............................................................................................ 6-15
INSTALLATION ...................................................................................... 6-16
FRONT FORK .............................................................................................. 6-18
REMOVAL .............................................................................................. 6-19
DISASSEMBLY ...................................................................................... 6-20
INSPECTION .........................................................................................6-21
ASSEMBLY ............................................................................................ 6-21
INSTALLATION ...................................................................................... 6-22
STEERING HEAD AND HANDLEBAR ........................................................ 6-23
REMOVAL .............................................................................................. 6-24
INSPECTION .........................................................................................6-25
ASSEMBLY AND INSTALLATION ......................................................... 6-26

FRONT WHEEL

CHAS

CHASSIS
FRONT WHEEL
Q Axle
W Speedometer gear
E Bearing
R Collar
T Valve

Y Oil seal
U Collar
I Axle nut
O Tire
P Front wheel

TIRE SIZE:
120/90-10

RIM RUNOUT
LIMIT:
VERTICAL:
1,0 mm (0.040in)
LATERAL:
1,0 mm (0.040in)








LS

LS

340001(a)

6-1

FRONT WHEEL

CHAS

REMOVAL
1. Remove:
Front caliper fixing bolts
Front caliper
Speedometer cable Q
Axle W
Front wheel

NOTE:
Never depress the brake lever when the wheel
is off the scooter. Otherwise the brake pads will
be forced shut.

340003

INSPECTION
1. Inspect:
Front axle runout
Out of specification Replace.
Axle runout limit:
0.25 mm (0.01 in)

340006

WARNING

Do not attempt to straighten a bent axle.


2. Measure:
Wheel runout
Out of specification Replace.
Rim runout limit:
Radial: 1.0 mm (0.040 in)
Lateral: 1.0 mm (0.040 in)

340007

3. Inspect:
Tire
Wear/Cracks/Warpage Replace.
4. Inspect:
Wheel bearings
Bearings allow play in the wheel hub or
wheel turns roughly Replace.
340008

5. Check:
Speedometer gear Q
Wear/Damage Replace.

340004

6-2

FRONT WHEEL

CHAS

INSTALLATION
Reverse the Removal procedure.
Note the following points.
1.Lubricate:
Front wheel axle
Bearings
Oil seal (lips)
Drive/driven gear (speedometer)
Recommended lubricant:
Lithium soap base grease

2. Install:
Speedometer gear unit Q
NOTE:
Be sure that the two projections at the gear unit
mesh with the two slots on the wheel hub.
340004

3. Install:
Front wheel Q
Front caliper W

NOTE:
Be sure that the slot (torque stopper) of the gear
unit housing is positioned correctly.

346005

4.Tighten:
Front wheel axle
Front caliper mounting bolts

T.
R

Front wheel axle:


35 Nm (3.5 m kg, 25.3 ft lb)
Front caliper mounting bolts:
23 Nm (2.3 m kg, 16.6 ft lb)

WARNING

Make sure that the brake hoses are routed


properly.

6-3

CHAS

FRONT BRAKE
FRONT BRAKE
Q
W
E
R
T
Y

Brake disc
Bolt
Caliper
Piston
Piston seals
Air bleed screw

U
I
O
P
{
}

NOTE:
Be sure to install the pads correctly.

Pad spring
Pad retainer
Brake pads
O. ring
Bolt
Mounting bolt

A
B

PAD WEAR LIMIT:


DISC WEAR LIMIT:

A 0,5 mm (0.02 in)


B 3.2 mm (0.12 in)

6 Nm (0,6 m.kg; 4 ft.lb)


21,5 Nm (2,15 m.kg; 16 ft.lb)






LT

23 Nm ( 2,3 m.kg; 17 ft.lb)




23 Nm ( 2,3 m.kg; 17 ft.lb)


LT
347009(a)

6-4

FRONT BRAKE

CHAS

MASTER CYLINDER DISASSEMBLY


Q Master cylinder
W Master cylinder piston ass'y
E Diaphragm
R Master cylinder cap
T Screw
Y Master cylinder bracket

NOTE:
U Bolt
Drain completely before removing the master
I Brake hose
cylinder.
O Bolt
P Bolt
{ Copper washer

3 Nm ( 0,3 m.kg; 2,17 ft.lb)


10,8 Nm (1,08 m.kg; 8 ft.lb)








BRAKE FLUID
DOT# 3 or DOT# 4

23 Nm (2,3 m.kg; 17 ft.lb)


23 Nm (2,3 m.kg; 17 ft.lb)


347007

6-5

FRONT BRAKE

CHAS

WARNING
Disc brake components rarely require
disassembly. Do not disassemble
components unless absolutely necessary.
If any hydraulic connection is disconnected,
the entire system must be disassembled,
drained, cleaned, and then properly filled
and bled after reassembly. Do not use
solvents on internal brake component.
Solvents will cause seals to swell and
distort. Use only clean brake fluid for
cleaning. Use care with brake fluid. Never
allow brake fluid to come in contact with
the eyes. Brake fluid can damage painted
surfaces and plastic parts.

BRAKE PAD REPLACEMENT


It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1. Remove:
Pin Q
Axle W






2. Remove:
Pad spring E
Brake pads R

346005

NOTE:
Replace the brake pads as a set when either one
is worn to the limit.

3.Measure:
Brake pads
Out of specification Replace.
NOTE:
Replace the brake pad and spring as a set when
replacing the brake pads.
Wear limit @:
0.5 mm (0.020 in)

347003

6-6

FRONT BRAKE

CHAS

4. Install:
Brake pads
Pad spring
Axle
Pin
NOTE:
Be careful to install the brake pads correctly.

5.Lubricate:
Mounting bolt (caliper body)
Recommended lubricant:
Lithium soap base grease
6.Install:
Wheel axle
Mounting bolt
T.

Wheel axle:
35 Nm (3.5 m kg, 25.3 ft lb)
Mounting bolt:
23 Nm (2.3 m kg, 17 ft lb)

LOCTITE

CALIPER DISASSEMBLY
NOTE:
Before disassembling the front brake caliper,
drain all brake fluid from the brake hose, master
cylinder, brake caliper and tank.

1.Remove:
Union bolt Q
Copper washers W


346005

NOTE:
Place the open end of the drain hose into a
container and pump out the remaining brake
fluid carefully.

2.Remove:
Caliper body
Caliper bracket
3. Remove:
Piston
Piston seals Q

347004

6-7

FRONT BRAKE

CHAS

*******************************************************
Removal steps :
Blow compressed air into the hose joint opening
to force out the piston from the caliper body.

WARNING
Never try to pry out the piston.
Cover the piston with a rag. Use care so
that the piston does not cause injury as it is
expelled from the cylinder.

346004

Remove the piston seals.

********************************************************

MASTER CYLINDER DISASSEMBLY


NOTE:
Before disassembling the front brake master
cylinder, drain all brake fluid from the brake
hose, master cylinder, brake caliper and reservoir tank.
1. Remove:
Upper handlebar cover
2. Remove:
Brake switch
Brake lever
Union bolt
NOTE:
Release the brake switch by pushing with a
screw driver into the hole on the lower side of the
brake lever and pull out the brake switch.
3. Remove:
Master cylinder holder
Master cylinder

6-8

FRONT BRAKE

CHAS

4. Remove:
Master cylinder dust boot Q
Master cylinder kit W


347008

INSPECTION AND REPAIR


Recommended brake component replacement
schedule:
Brake pads

As required

Piston seal,
Dust seal

Every two years

Brake hoses

Every four years

Brake fluid

Replace only when


brakes are disassembled

WARNING
All internal parts should be cleaned in new
brake fluid only. Do not use solvents as they
will cause seals to swell and distort.

1. Inspect:
Caliper piston Q
Scratches/Rust/Wear Replace caliper
assembly.
Caliper body W
Wear/Scratches/Cracks/Damage Replace
caliper assembly.

WARNING

Replace the piston seals whenever the caliper


is disassembled.
347005

2. Inspect:
Master cylinder
Wear/Scratches Replace the master
cylinder assembly.
Master cylinder body/Diaphragm
Cracks/Damage Replace.
Master cylinder kit
Scratches/Wear/Damage Replace as a set.
347006

6-9

FRONT BRAKE

CHAS

3. Check:
Brake hose Q
Cracks/Wear/Damage Replace.


346014

4. Measure:
Brake disc deflection
Out of specification Inspect wheel runout.
If wheel runout is good, replace the brake disc(s).

Maximum deflection:
0.25 mm (0.01 in)
347001

Brake disc thickness


Out of specification Replace.
Minimum thickness:
3,2 mm (0.12 in)

T.
R

Bolt (brake disc):


23 Nm (2.3 m kg, 17 ft lb)
LOCTITE

347002

CALIPER ASSEMBLY
WARNING
All internal parts should be cleaned in new
brake fluid only.
Internal parts should be lubricated with
clean brake fluid when installed.

Recommended brake fluid:


DOT #3 or DOT #4

Replace the piston seals whenever a caliper


is disassembled.
1. Install:
Piston seals Q
Caliper piston W

WARNING
346015

Always use new piston seals.

6-10

FRONT BRAKE

CHAS

2. Install:
Brake caliper

T.
R

Bolt (brake caliper):


23 Nm (2.3 m kg, 17 ft lb)

3. Install:
Caliper body Q

4. Install:
Brake hose W
Copper washers E
Union bolt R


T.

Union bolt:
23 Nm (2.3 m kg, 17 ft lb)


346005

CAUTION:
When installing the brake hose to the caliper,
turn the brake pipe against the projection on
the caliper.

WARNING
Proper hose routing is essential to insure
safe operation. Refer to CABLE ROUTING.
Always use new copper washers.
MASTER CYLINDER ASSEMBLY
WARNING
All internal parts should be cleaned in new
brake fluid only.
Internal parts should be lubricated with
clean brake fluid when installed.

Recommended brake fluid:


DOT #3 or DOT #5

6-11

FRONT BRAKE

CHAS

1. Install:
Master cylinder Q




CAUTION:
Tighten the upper bolt first, then the lower
bolt.

T.
R




Bolt (master cylinder holder):


9 Nm (0.9 m kg, 6.5 ft lb)

2. Install:
Brake lever 2
NOTE:
Apply lithium soap base grease to the brake
lever pivot.


3. Install:
Brake hose 3
Copper washers 4
Union bolts 5
Brake switch 6

T.

Union bolt:
23 Nm (2.3 m kg, 17 ft lb)

WARNING
Proper hose routing is essential to insure
safe operation. Refer to CABLE ROUTING
in CHAPTER 2.
Always use new copper washers.

4. Check that the brake hose does not touch


other parts (throttle cable, wire harness, etc.)
when the handlebar is turned to the left or right.
Repair if necessary.

6-12

REAR WHEEL

CHAS

REAR WHEEL
Rear wheel assy
Tire
Valve
Axle
Nut
O-ring

U
I
O
P
{
}

q Washer
w Nut
e Washer

Brake shoe
Spring
Brake camshaft
Brake camshaft lever
Wear indicator
Bolt

TIRE SIZE:
130/90-10

DRUM BRAKE WEAR LIMIT:


110,5 mm (4.40 in)

105 Nm (10,5 Kg.m ; 76 ft.lb)





C BRAKE LINING WEAR LIMIT:


2 mm (0.08 in)
D RIM RUNOUT LIMIT:
VERTICAL : 1,0 mm (0.04in)
LATERAL : 1,0 mm (0.04in)

REPLACE BRAKE LININGS


AND SPRINGS AS A SET

LS

Q
W
E
R
T
Y

13 Nm (1,3 Kg.m ; 9.4 ft.lb)





12 Nm (1,2 Kg.m ; 8.67 ft.lb)
340005(a)

6-13

REAR WHEEL

CHAS

REMOVAL
1. Remove:
Muffler assy

2. Loosen:
Rear axle nut
NOTE:
Pull the rear brake to loosen the axle nut.
3. Remove:
Rear wheel

4. Remove:
Brake cable
Brake shoes Q
Plain washer W

346006

INSPECTION
1. Check:
Rear wheel
Refer to the section FRONT WHEEL
INSPECTION.
2.Measure :
Wheel runout
Refer to the section FRONT WHEEL
INSPECTION.
Rim runout limits:
Radial : 1.0 mm (0.04 in)
Lateral : 1.0 mm (0.04 in)

340007

6-14

REAR WHEEL

CHAS

3. Check:
Wheel bearings
Refer to the section FRONT WHEEL
INSPECTION.
4. Check:
Brake lining surface
Glazed spots Eliminate with sandpaper.
340008

NOTE:
After sanding the brake lining remove dust particles from the brake shoe with a clean cloth.
5. Measure:
Brake lining thickness
Out of specification Replace

Brake lining thickness:


4.0 mm (0.16 in)
Wear limit:
2.0 mm (0.08 in)

346007

6. Check:
Brake drum inner surface
Oil/Scratches Repair.
7. Measure:
Brake drum inside diameter @
Out of specification Replace.

Brake drum inside diameter:


110 mm ( 4.33 in)
Wear limit:

346008

110.5 mm (4.35 in)

ASSEMBLY
Reverse the REMOVAL procedure.
Note the following points.
1. Install:
Brake camshaft Q

346009

NOTE:
Apply lithium soap base grease onto the brake
camshaft Q and pin W.
CAUTION:
After installing the brake camshaft, remove
the excess of grease.

6-15

REAR WHEEL

CHAS

2. Install:
Brake shoes Q
Return spring W

NOTE:
The arrow mark E must point outwards.

346010

CAUTION:
When installing the springs and the brake
shoes, take care not to damage the springs

3. Install:
Wear indicator Q
Camshaft lever W


A

NOTE:
Align the wear indicator tip Q with the line A
as shown.
Align the punch marks E.

346011

T.
R

Bolt (camshaft lever):


10 Nm (1.0 m kg, 7.23 ft lb)

4. Install:
Plain washer Q
Brake cable


346012

INSTALLATION
Reverse the REMOVAL procedure.
Note the following points.
1. Clean:
Rear wheel axle

2. Install:
Rear wheel
Plain washer Q
Nut W

NOTE:
Make sure the splines on the wheel hub fit onto
the rear drive axle.
346013

6-16

REAR WHEEL
T.
R

CHAS

Nut (rear wheel axle):


105 Nm (10.5 m kg, 76 ft lb)

3. Install:
Muffler

T.

Bolt (exhaust pipe):


9 Nm (0.9 m kg, 6.5 ft lb)
Bolt (muffler):
26 Nm (2.6 m kg, 19 ft lb)

4. Adjust:
Rear brake lever free play.
Refer to the section REAR BRAKE LEVER
FREE PLAY ADJUSTMENT in CHAPTER 3.

6-17

CHAS

FRONT FORK
FRONT FORK
Q Steering bracket
W Bolt
E Circlip
R Rubber cap
T Circlip
Y Spring seat
U Circlip
I Inner tube
O Spring

P Piston
{ Spring
} Stopper
q Washer
w Bolt
e Dust boot
r Circlip
t Oil seal
y Outer fork tube

FRONT FORK TUBE CAPACITY:


75 cc ( 2.53 oz)

FRONT FORK OIL GRADE:


ISO 6743 / 4-LHV 46

22.5 Nm (2.25 m.kg)

T.R

T.R

30 Nm (0.3 m.kg)

























T.R

23 Nm (2,3 m.kg)



342012(a)

6-18

FRONT FORK

CHAS

REMOVAL
WARNING
Securely support the scooter with a stand
under the engine.
1. Place the scooter on an even surface.
2. Disconnect:
Speedometer cable
3. Remove:
Front wheel
Refer to section FRONT WHEEL in Chapter 6.
4. Remove:
Front fender
Refer to section COVERS - REMOVAL AND
INSTALLATION in Chapter 3.
5. Remove:
Steering head
Refer to section STEERING HEAD AND
HANDLEBAR in Chapter 6.
6. Remove:
Nut Q
Washer W
Ring nut E






NOTE:
Loosen the ring nut with the ring nut wrench R.

T.

354003

Ring nut wrench:


9079Q-02218

Support the steering shaft to prevent it from


falling.
7. Remove:
Front fork assembly
Bearing balls

342000(a)

8. Remove:
Circlips 
9 Loosen
Bolt W


342001

10. Remove:
Fork leg (complete)

6-19

FRONT FORK

CHAS

DISASSEMBLY
1. Remove:
Rubber plug Q
Circlip W
Spring seat E
Spring 4






342014

2. Remove:
Bolt Q
Copper washer

NOTE:
To remove the drain bolt Q, use the T-handle W
and the holder E.

T-handle for front fork:


90890-01326
Holder:
90890-01294

342010

3. Remove:
Inner fork tube Q
Piston W
Spring E
Stopper 4





342015(a)

4. Remove:
Dust boot Q
Circlip W
Oil seal E





342016

6-20

FRONT FORK

CHAS

INSPECTION
1. Check:
Inner fork tube and fork components
Outer fork tube
Wear/Scratches/Damage Replace.
WARNING

Never attempt to straighten a bent fork tube


as this may dangerously weaken the tube.

ASSEMBLY
Reverse the DISASSEMBLY procedure.
Note the following points.
NOTE:
When reassembling the front fork, make sure
you use following new parts:
Oil seals
Circlips and retainers
Make sure that all components are clean before reassembling.
1. Install:
Stopper
Inner fork tube
Spring
Piston
NOTE:
Before installing the oil seal, apply lithium soap
grease onto the oil seal lips.
2. Install:
Oil seal
Circlip
Dust boot

6-21

FRONT FORK
3. Install:
Copper washer
Bolt

NOTE:
Tighten the drain bolt Q while holding the piston
with the T-handle W and holder E.

CHAS

T-handle for front fork:


90890-01326
Holder:
90890-01294

342010

4. Fill:
Fork oil
Fork oil type:
ISO 6743/4-LHV 46
Amount (per fork tube):
75 cc
5. Install:
Spring
Spring seat
Circlip
Rubber plug

INSTALLATION
Reverse the REMOVAL procedure.
Note the following points.
1. Install:
Left and right fork tube into the steering crown.
2.Install:
Circlips 1

3. Install:
Pinch bolts 2

T.

342001

6-22

Pinch bolt:
30 Nm (3.0 m kg; 21.7 ft lb)

STEERING HEAD AND HANDLEBAR

CHAS

STEERING HEAD AND HANDLEBAR


Q Handlebar
W Nut
E Bolt
R Grip
T Throttle grip
Y Throttle cable
U Screw
I Brake cable
O Starter cable











354004(a)

6-23

STEERING HEAD AND HANDLEBAR

CHAS

STEERING HEAD AND


HANDLEBAR
REMOVAL

WARNING
Securely support the scooter so there is no
danger of it falling over.

354001

1. Place the scooter on an even surface.


2. Remove:
Front fender
Inner panels
Upper handlebar cover
Refer to section REMOVAL AND INSTALLATION OF COVERS in Chapter 3.
3. Drain:
Front brake system
Refer to section FRONT BRAKE in Chapter 6.
4. Remove:
Front brake master cylinder
Refer to section FRONT BRAKE in Chapter 6.
5. Remove:
Front brake caliper mounting bolts
6. Remove:
Front wheel
Refer to section FRONT BRAKE in Chapter 6.
7. Remove:
Rear brake cable
Throttle grip
8. Disconnect:
Ground wire
All couplers
Wire harness band
Clamp
9. Remove:
Nut Q
Bolt
Handlebar
10. Remove:
Ring nut
Washer

6-24

STEERING HEAD AND HANDLEBAR

CHAS

11. Remove:
Upper bearing race Q

Steering head nut wrench:


9079Q-02218


354005

Steering shaft
Bearing balls
INSPECTION
1. Check:
Handlebar Q
Bends/Cracks/Damage Replace.

2. Wash the bearing balls in solvent.

3. Check:
Bearing races Q
Pitting/Damage Replace.
Bearing balls
Pitting/Damage Replace.
354006

NOTE:
Always replace the bearing balls and the upper
and lower bearing races as a set.

*******************************************************
Bearing race replacement steps :
Drive out the bearing race from the steering
tube by hitting on it in several places.
Remove the bearing race on the steering shaft
with a hammer and a chisel Q as shown.
Drive in the new bearing races evenly by
hitting on them in several places.

354007

6-25

STEERING HEAD AND HANDLEBAR

CHAS

CAUTION:

Unless installed correctly, the bearing races


will damage the frame.
Never hit the bearing races on the ball
race surface.
*********************************************************
354008

4. Check:
Steering shaft
Bend/Damage Replace.

WARNING
Never attempt to straighten a bent steering
shaft.

354009

ASSEMBLY AND INSTALLATION


Reverse the REMOVAL and DISASSEMBLY
procedure.
Note the following points.
WARNING
Proper cable and hose routing is essential to
insure safe scooter operation. Refer to section
CABLE ROUTING in Chapter 2.

1. Install:
Bearing balls
2. Apply:
Bearing grease (onto upper and lower bearing
balls)

354010

3. Install:
Steering shaft
Bearing race (upper) Q
Steering head nut wrench:
9079Q-02218

354003

6-26

STEERING HEAD AND HANDLEBAR

CHAS

CAUTION:
Hold the steering shaft until it is securely
attached.

4. Install:
Washer Q
Steering shaft lock nut W


354002

NOTE:
Tighten the steering shaft lock nut with the Steering head nut wrench. Set the torque wrench to the
ring nut wrench so that they form a right angle.
Steering head nut wrench:
9079Q-02218

T.

Steering shaft ring nut:


27.5 Nm (2.75 m.kg, 19.9 ft.lb)

5. Install:
Handlebar Q
Bolt W (new)
Nut E (new)
NOTE:
Install the handlebar onto the steering shaft
notch.
Install the wire harness, the throttle cable, the
speedometer cable and the rear brake cable.





354011

6. Install:
Throttle grip (complete)
Master cylinder
Brake hose (into the clip)

CAUTION:
Before installing the handlebar, wipe off any
trace of oil from the inserted section of the
shaft with solvent.
Insert the bolt from the left as shown.

T.

Bolt (handlebar):
60 Nm (6.0 m.kg, 43.3 ft.lb)

7. Install:
Band
Refer to section CABLE ROUTING in Chapter 2.

6-27

ELEC

ELEC
CHAPTER 7.
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS ...................................................................... 7-1
CIRCUIT DIAGRAM ....................................................................................... 7-3
IGNITION AND STARTING SYSTEM ............................................................ 7-5
CIRCUIT DIAGRAM ................................................................................. 7-5
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM .................... 7-6
TROUBLESHOOTING ............................................................................. 7-7
CHARGING SYSTEM .................................................................................. 7-13
CIRCUIT DIAGRAM ............................................................................... 7-13
TROUBLESHOOTING ........................................................................... 7-14
LIGHTING SYSTEM .................................................................................... 7-16
CIRCUIT DIAGRAM ............................................................................... 7-16
TROUBLESHOOTING ........................................................................... 7-17
SIGNAL SYSTEM ........................................................................................ 7-21
WIRING DIAGRAM ................................................................................ 7-21
TROUBLESHOOTING ........................................................................... 7-22

ELECTRICAL COMPONENTS

ELEC

ELECTRICAL COMPONENTS
BATTERY:
SPECIFIC GRAVITY: 1.280
IGNITION COIL
Primary coil resistance:
0.32 ~ 0.48 at 20C (68F)
Secondary coil resistance:
5.68 ~ 8.52 at 20C (68F)

ELECTRICAL COMPONENTS
Q Wire harness
W Fuel sender
E Ignition coil
R Starter relay
T Battery
Y CDI unit
U Oil sender

383002

7-1

ELECTRICAL COMPONENTS
Q Main switch
W Rectifier / Regulator
E Horn
R Flasher relay

ELEC

Starter motor coil resistance:


0.06 - 0.08 at 20C (68F)
Brush wear limit:
0.9 mm (0.035 in)
Commutator diameter wear limit:
14.8 mm (0.582 in)
Commutator mica undercut:
1.15 mm (0.045 in)

383001

7-2

ELEC

CIRCUIT DIAGRAM
CIRCUIT DIAGRAM

2
O
1

0
B

WR

LOCK
OFF
CHECK
ON

BR

BW

YR
B

5
}

YR

L G Y

OFF
LOW
HI

8
B
LW

G
Y

{
GY

B R

BW

L
t

q
B

Br

i
Ch

BrW

L
B

o
B

Dg

Gy

L
N
R

P
F
p

7-3

Gy

Dg

Ch
e

Br
H

Br

Br

u
B

[
B

]
B

Br Gy

CIRCUIT DIAGRAM
Q Spark plug
W Ignition coil
E CDI magneto
R CDI unit
T Rectifier/regulator
Y Starter motor
U Starter relay
I Battery
O Fuse
P Main switch
{ Starter switch
} "LIGHTS" switch
q Meter light
w Meter light
e Headlight
r Position light
t Tail/Stop light

ELEC

y Flasher relay
u Flasher indicator
i "TURN" switch
o Rear flasher light (left)
p Front flasher light (left)
[ Rear flasher light (right)
] Front flasher light (right)
A Front stop switch
S Rear stop switch
D Horn
F Horn switch
G Oil level indicator
H Oil level gauge
J Fuel meter
K Sender
L High beam indicator

COLOR CODE
B
Black
Br
Brown
Ch
Chocolate
Dg
Dark green
G
Green
Gy
Grey
L
Blue
O
Orange
P
Pink
R
Red
Sb
Sky blue
W
White

Y
B/R
B/W
Br/W
Br/Y
G/B
G/Y
L/W
W/R
Y/B
Y/R

7-4

Yellow
Black/Red
Black/White
Brown/White
Brown/Yellow
Green/Black
Green/Yellow
Blue/White
White/Red
Yellow/Black
Yellow/Red

ELEC

IGNITION AND STARTING SYSTEM


IGNITION AND STARTING SYSTEM

2
O
1

0
B

WR

BR

BW

YR
B

5
}

YR

B R

BW

LOCK
OFF
CHECK
ON

L G Y

OFF

LOW

B
B

HI

LW

G
Y

{
GY

L
t

q
B

Br

i
Ch

BrW

L
B

Q Spark plug
W Ignition coil
E CDI Magneto

o
B

R CDI unit
Y Starter motor
U Starter Relay

Dg

Gy

L
N
R

P
F
p

u
B

[
B

I Battery
O Fuse
P Main switch

7-5

Gy

Dg

Ch
e

Br
H

Br

Br

]
B

{ Starter switch
A Front brake switch
S Rear brake switch

Br Gy

ELEC

IGNITION AND STARTING SYSTEM

IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM


} Main switch
Q Spark plug
a Source coil
t Front brake switch
W Ignition coil
b Pickup coil
y Rear brake switch
R CDI unit
c Wave-shape shaping circuit
U Starter Motor
d Condenser
I Starter relay
e Diode
O Fuse
f SCR
P Battery
g To oil level switch
{ Starter switch

B/R

e
W/R

e
d

B
B

B/W
BW B

Br Gy

LOCK
OFF
CHECK
ON

M
B

B
L/W

Br

G/Y

: Current flow in ignition control circuit


: Current flow in starter motor control circuit
374001

7-6

ELEC

IGNITION AND STARTING SYSTEM


TROUBLESHOOTING
THE STARTING SYSTEM DOES NOT WORK
(NO SPARK OR IRREGULAR SPARKS).
NOTE:
Remove the following parts before proceeding with the troubleshooting:
1) Side covers (left and right)
For accurate troubleshooting use the following special tools:

Ignition checker:
90890-06754

Pocket tester:
90890-03112

1.Spark plug
Check the spark plug type.
Check the condition of the spark plug.
Check the spark plug gap.
Refer to SPARK PLUG INSPECTION in
Chapter 3.

INCORRECT

Standard spark plug:


BR8HS (NGK)
The spark plug is defective. Replace it or
adjust the spark plug gap.

Spark plug gap:


0.5 ~ 0.7 mm (0.019 ~ 0.028 in)
CORRECT
2.Spark check
Remove the spark plug cap.
Connect the ignition checker Q.
W Spark plug cap
E Spark
Check the length of the spark gap.
Start the engine and increase the spark
length until the engine begins to misfire.

372000

Minimum spark gap:


6.0 mm (0.24 in)

MEETS SPECIFICATION

OUT OF
SPECIFICATION
OR NO SPARK

Ignition system in good condition.

7-7

IGNITION AND STARTING SYSTEM

ELEC

3.Spark plug cap resistance


Disconnect the spark plug cap.
Connect the pocket tester ( x 1 k) to the
spark plug cap.
Check the resistance of the spark plug cap.
Spark plug cap resistance:
5k at 20C (68F)

DOES NOT MEET


SPECIFICATION

372001

Replace the spark plug cap


MEETS
SPECIFICATION
4.Ignition coil resistance
Disconnect the ignition coil leads.
Connect the pocket tester ( x 1) to the
ignition coil.
Ignition coil :
Pocket tester (+) lead Orange
Pocket tester (-) lead Ground
372002

Check the primary coil resistance.


Primary coil resistance:
0.32 ~ 0.48 at 20C (68F)
Connect the pocket tester ( x 1k) to the
ignition coil.
Pocket tester (+) lead Ground
Pocket tester (-) lead Spark plug lead
Check the secondary coil resistance.

372003

Secondary coil resistance:


5.68 ~ 8.52 at 20C (68F)

DOES NOT MEET


SPECIFICATION

MEETS
SPECIFICATION
Defect. Replace the ignition coil.

7-8

IGNITION AND STARTING SYSTEM

ELEC

5.Pickup coil resistance


CDI
MAGNETO

Disconnect the pickup coil coupler.


Connect the pocket tester ( x 100) to the
pickup coil.

Pocket tester (+) lead Q White / Red


Pocket tester (-) lead W Ground

Y/R

W/R B/R

Check the pickup coil resistance.

372004

DOES NOT MEET


SPECIFICATION

Pickup coil resistance:


400 ~ 600 at 20C (68F)

MEETS
SPECIFICATION

Pickup coil defect Replace.

6.Source coil resistance


Disconnect the source coil coupler from the
wire harness.
Connect the pocket tester ( x 100) to the
source coil.

CDI
MAGNETO

Pocket tester (+) lead Q Black / Red


Pocket tester (-) lead W Ground

Y/R

W/R B/R

Check the source coil resistance.

372005

DOES NOT MEET


SPECIFICATION

Source coil resistance:


640 ~ 960 at 20C (68F)
MEETS
SPECIFICATION

Source coil defect Replace.


POOR CONNECTIONS

7.Connections
Check all connections in the ignition system.
Refer to WIRING DIAGRAM.

Repair.

GOOD
CONNECTIONS
Replace the CDI unit.

7-9

IGNITION AND STARTING SYSTEM

ELEC

TROUBLESHOOTING
STARTER MOTOR DOES NOT WORK
NOTE:
Remove the following parts before proceeding with the troubleshooting:
1) Side covers (left and right)
2) Footrest boards
3) Front panel
4) Handlebar cover
For accurate troubleshooting use the following special tools:
Pocket tester:
90890-03112

1.Fuse

NO CONTINUITY

Remove the fuse.


Connect the pocket tester ( x 1) to the fuse.
Check the fuse for continuity.

Defect Replace fuse.

CONTINUITY
2.Battery
Check the condition of the battery.
Refer to BATTERY INSPECTION in
CHAPTER 3.

DOES NOT MEET


SPECIFICATION

Open circuit voltage:


12.8 V or more at 20C (68F)

Clean battery terminals.


Charge or replace the battery.

MEETS
SPECIFICATION
3.Starter motor
Use a jumper lead E * to connect the (+) Q
terminal of the battery to the starter motor
terminal W.

CAUTION:
If the gauge of the jumper lead is smaller
than that of the battery leads, the jumper
lead might melt or burn.

This test could cause sparks. Never


perform it near a gas source or near
flammable products.

DOES NOT WORK

372006

Starter defect Repair or replace.

Check the starter motor operation.


WORKS

7-10

IGNITION AND STARTING SYSTEM

ELEC

4. Starter relay
Disconnect the Blue/White lead from the
wire harness.
Connect the (-) Q terminal of the battery to
the Blue/White lead.
Check the starter motor operation.

DOES NOT WORK

L/W

Starter relay defect Replace.

372007

WORKS
5. Main switch
Disconnect the main switch from the wire
harness.
Check for continuity between Red Q and
Brown W.
BW B

Br Gy

LOCK
OFF

DOES NOT MEET


SPECIFICATION

CHECK
ON

R
R

B/W

Main switch defect Replace.

Br Gy B

372008

MEETS
SPECIFICATION
6.Starter switch
Disconnect the right handlebar switch coupler from the wire harness.
Check for continuity between Blue / White
Q and Black W.

7-11

IGNITION AND STARTING SYSTEM

ELEC

LW B
OFF

DOES NOT MEET


SPECIFICATION

ON

372009A

B YB L
LW YR LR

372009B

Starter switch defect Replace right handlebar switch.

MEETS
SPECIFICATION
POOR CONNECTIONS
7.Connections
Check all connections in the starter system.
Refer to WIRING DIAGRAM.

7-12

Repair.

ELEC

CHARGING SYSTEM
CHARGING SYSTEM
WIRING DIAGRAM

2
O
1

0
B

WR

BR

BW

YR

B
B
YR

5
}

L G Y

OFF

LOW

LW

HI
G
Y

{
GY

B R

BW

LOCK
OFF
CHECK
ON

L
t

q
B

Br

i
Ch

BrW

L
B

E CDI magneto
T Rectifier / regulator

Dg

Gy

L
N
R

P
F
p

I Battery
O Fuse

7-13

Gy

Dg

Ch
e

Br
H

Br

Br

u
B

[
B

]
B

Br Gy

CHARGING SYSTEM

ELEC

TROUBLESHOOTING
THE BATTERY IS NOT CHARGED
NOTE:
Remove the following parts before proceeding with the troubleshooting:
1) Side covers (left and right) and foot rest board.
For accurate troubleshooting use the following special tools:

Inductive tachometer:
90890-03113

Pocket tester:
90890-03112

1.Fuse (Main)
Remove the fuse.
Connect the pocket tester ( x 1) to the fuse.
Check the fuse for continuity.

NO CONTINUITY

CONTINUITY
2.Battery

Fuse defect Replace.

Check the condition of the battery.


Refer to BATTERY INSPECTION in
CHAPTER 3.
Open circuit voltage:
12,8 V or more at 20C (68F)

DOES NOT MEET


SPECIFICATION

Clean battery terminals.


Charge or replace the battery.

3.Charging voltage
Connect the engine tachometer to the spark
plug lead.
Connect the pocket tester (DC20V) to the
battery terminals.
Pocket tester (+) lead Battery (+) terminal
Pocket tester (-) lead Battery (-) terminal
Start the engine and accelerate to about
5000 rpm.
Check the charging voltage.

Charging voltage :
14 ~ 15 V at 5.000 tr/mn

367001

MEETS SPECIFICATION

NOTE:
Use a fully charged battery.
OUT OF
SPECIFICATION

Charging circuit is OK.

7-14

372010

CHARGING SYSTEM

ELEC

4.Charging coil resistance


CDI
MAGNETO

Disconnect the CDI magneto coupler from


the wire harness.
Connect the pocket tester ( x 1) to the
charging coil.
Check the charging coil resistance

Tester (+) lead White Q


Tester () lead Ground W
Charging coil resistance:
0.48 ~ 0.72 at 20C (68F)

Y/R

OUT OF SPECIFICATION

MEETS
SPECIFICATION

Charging coil defect Replace.


POOR CONNECTIONS

5.Connections
Check all connections in the charging system.
Refer to WIRING DIAGRAM.

Repair.

MEETS
SPECIFICATION
Replace the rectifier/regulator.

7-15

W/R B/R

372015

ELEC

LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM

2
O
1

0
B

WR

BR

BW

YR

B
B
YR

5
}

B R

BW

LOCK
OFF
CHECK
ON

L G Y

OFF

LOW

LW

HI
G
Y

{
GY

L
t

q
B

Br

i
Ch

BrW

K G

L
B

E CDI magneto
} LIGHTS switch

q Meter light
w Meter light

Dg

Gy

L
N
R

P
F
p

u
B

e Headlight
r Position light

7-16

Gy

Dg

Ch
e

Br
H

Br

Br

[
B

]
B

t Tail/Stop light
L HIGH BEAM indicator light

Br Gy

LIGHTING SYSTEM

ELEC

TROUBLESHOOTING
THE AUXILIARY LIGHT, HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT,
TAILLIGHT OR METER LIGHT DO NOT WORK
NOTE:
Remove the following parts before proceeding with the troubleshooting:
Side covers and footrest board
Handlebar covers
For accurate troubleshooting use the following special tools:
Pocket tester:
90890-03112

1. LIGHTS switch
Disconnect the right handlebar switch coupler from the wire harness.
Set the switch to .
Check for continuity between

YR L G Y
OFF
P0
ON

G YR LW

Yellow / Red Q and Blue W

Yellow / Red Q and Green 3


Then set the switch to .
Check for continuity between:

372009A

NO CONTINUITY

Yellow / Red Q and Blue W


Yellow / Red Q and Yellow 4
"Light" switch defect Replace.
CONTINUITY

7-17

372013(a)

LIGHTING SYSTEM

ELEC

2. Lighting coil resistance


CDI
MAGNETO

Disconnect the lighting coil coupler from the


wire harness.
Connect the pocket tester ( x 1) to the
lighting coil.
Check the lighting coil resistance

Tester (+) lead Yellow / Red Q


Tester (-) lead Ground W
Lighting coil resistance:
0.32 ~ 0.48 at 20C (68F)

OUT OF SPECIFICATION

MEETS
SPECIFICATION

Lighting coil defect Replace.

3. Connections
Check all connections in the lighting system.
Refer to WIRING DIAGRAM.

Y/R

POOR CONNECTIONS

MEETS
SPECIFICATION

Repair.

Circuit is in good condition.

7-18

W/R B/R

372036

LIGHTING SYSTEM

ELEC

LIGHTING SYSTEM INSPECTION


1. Headlight and headlight indicator do not work.
1. Bulb and socket

NO CONTINUITY

Check the bulb and socket for continuity.


Replace bulb or socket.

CONTINUITY
2. Voltage
Connect the pocket tester (AC20V) to the
headlight coupler.

Headlight:
LO:
Pocket tester (+) lead Green Q
Pocket tester (-) lead Black E
HI:
Pocket tester (+) lead Yellow W
Pocket tester (-) lead Black E
Headlight indicator:
Pocket tester (+) lead Yellow R
Pocket tester (-) lead Black T
Set the main switch to ON.
Start the engine.
Switch from HI to LO and back.
Check the voltage (12V) between the headlight coupler leads.

B
Y

B
Y

372017(a)

OUT OF SPECIFICATION

MEETS
SPECIFICATION
There is a defect in the wire harness between
the main switch and the headlight coupler
and/or between the main switch and the
headlight indicator coupler
Repair.

Circuit is in good condition.


2. The meter light does not work.

NO CONTINUITY

1. Bulb and socket


Check the bulb and socket for continuity.
CONTINUITY

Replace bulb or socket.

7-19

ELEC

LIGHTING SYSTEM
2. Voltage

L Br
Dg G
Ch Gy

Connect the pocket tester (AC20V) to the


meter light coupler.
Pocket tester (+) lead Blue Q
Pocket tester (-) lead Black W
Set the main switch to ON.
Start the engine.
Check the voltage (12V) between the headlight coupler leads Blue and Black.

Br L
G Dg
Gy Ch

B
Y

B
Y
372037(a)

OUT OF SPECIFICATION

MEETS
SPECIFICATION
There is a defect in the wire harness between
the main switch and the meter light coupler
Repair.

Circuit is in good condition.

3. The taillight does not work.


NO CONTINUITY

1. Bulb and socket


Check the bulb and socket for continuity.

Replace bulb or socket.

CONTINUITY
2. Voltage

110
L

Ch Dg Dg Ch

L
GY
Dg
Ch
B

GY

250

250

L L GY
- B B -

GY

Pocket tester (+) lead Blue Q


Pocket tester (-) lead Black W
Set the main switch to ON.
Start the engine.
Check the voltage (12V) between the headlight coupler leads Blue and Black.

110

250

Connect the pocket tester (AC20V) to the


taillight coupler.

Dg

B
Ch

372019(a)

OUT OF SPECIFICATION

MEETS
SPECIFICATION

There is a defect in the wire harness between


the main switch and the taillight coupler
Repair.

Circuit is in good condition.

7-20

ELEC

SIGNAL SYSTEM
SIGNAL SYSTEM
WIRING DIAGRAM
2
O
1

0
B

WR

BR

BW

YR

B
B
YR

5
}

L G Y

OFF

LOW

HI

{
GY
L

q
B

t
r

BrW

o
B

u Flasher indicator
I Battery
i "TURN" switch
O Fuse
o Rear flasher light (left)
0 Main switch
t Tail / Stop light p Front flasher light (left)
y Flasher relay [ Rear flasher light (right)

Gy
P
F

Ch
L

Dg

L
N
R

K G

Br

i
Ch

Br

Br

Br

LW

G
Y

B R

BW

LOCK
OFF
CHECK
ON

p
B

Dg
u
B

[
B

]
B

] Front flasher light (right)


A Front stop switch
S Rear stop switch
D Horn
F "HORN" switch

7-21

Gy

G Oil level indicator


H Oil level gauge
J Fuel meter
K Sender

Br Gy

ELEC

SIGNAL SYSTEM
TROUBLESHOOTING

FLASHER LIGHTS, BRAKE LIGHT, OIL WARNING LIGHT DO NOT WORK


HORN DOES NOT SOUND
NOTE:
Remove the following parts before proceeding with the troubleshooting:
Side covers and footrest board
Handlebar cover
For accurate troubleshooting use the following special tools:
Pocket tester:
90890-03112

1. Fuse
Remove the fuse.
Connect the pocket tester ( x 1) to the fuse.
Check the fuse for continuity.
Refer to FUSE INSPECTION in Chapter 3.

NO CONTINUITY

Fuse defect Replace.

CONTINUITY
2. Battery

DOES NOT MEET SPECIFICATION

Check the condition of the battery.


Refer to BATTERY INSPECTION in
CHAPTER 3.
Clean battery terminals.
Charge or replace the battery.

Battery voltage:
12.8 V or more at 20C (68F)
MEETS
SPECIFICATION
3. Main switch

BW B

Disconnect the main switch from the wire


harness.
Turn the main switch to .
Check for continuity between:

OFF

ON

R
R

Red Q and Brown W

Br Gy

CHECK

Red Q and Grey E


Turn the main switch to ON.
Check for continuity between:

LOCK

B/W
Br Gy B

DOES NOT MEET SPECIFICATION

MEETS
SPECIFICATION

Main switch defect Replace.

7-22

372040

SIGNAL SYSTEM

4. Connections

ELEC

POOR CONNECTIONS

Check all connections in the signal system.


Refer to WIRING DIAGRAM.
GOOD
CONNECTIONS

Repair.

Check the condition of each circuit of the


signal system.
Refer to the section SIGNAL SYSTEM
CHECK.

SIGNAL SYSTEM CHECK


1. Horn does not sound
1. HORN switch
Disconnect the handlebar switch (left) from
the wire harness.
Check for continuity between:
Black Q and Pink W.
B

OFF
ON

NO CONTINUITY

Ch - P
B BrW Dg

Horn switch is defect Replace.


372029(a)

CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to the
horn lead.
Pocket tester (+) lead Brown Q
Pocket tester (-) lead Ground W
Turn the main switch to ON.
Check for voltage (12V) between Brown
and the ground.

7-23

SIGNAL SYSTEM

Br

ELEC

DOES NOT MEET SPECIFICATION

Defect in the wire harness between the main


switch and the horn Repair.

372025

MEETS
SPECIFICATION
3. Horn
Disconnect the Pink lead at the horn terminal.
Ground the horn terminal Q with a jumper
lead.
Set the main switch to ON.

Br

HORN SOUNDS

Horn in good condition.

372026

HORN DOES
NOT SOUND
4. Voltage
Br

Connect the pocket tester (DC20V) to the


Pink lead.

Pocket tester (+) lead Pink Q


Pocket tester (-) lead Ground
Turn the main switch to ON.
Press the HORN switch.
Check the voltage (12V) between Pink and
ground.

372027

DOES NOT MEET SPECIFICATION

MEETS
SPECIFICATION

Horn is defect Replace.

Adjust the horn.

7-24

SIGNAL SYSTEM

ELEC

2. The brake light does not work.


1. Bulb and socket
NO CONTINUITY

Check the bulb and socket for continuity.


CONTINUITY

Replace bulb or socket.


2. Brake switch
Disconnect the brake switch leads from the
wire harness.
Check for continuity between:
Brown Q and Green / Yellow W
Br G/Y
ON (Pull in)
OFF (Free)

NO CONTINUITY
Br G/Y

Brake switch is defect Replace.


372030

CONTINUITY
3. Voltage
Connect the pocket tester (DC20V) to the
socket.
Pocket tester (+) lead Green / Yellow Q
Pocket tester (-) lead Black W
Turn the main switch to ON.
Pull the brake lever.
Check the voltage (12V) between Green /
Yellow Q and Black W.

Dg

110

110

OUT OF SPECIFICATION
250

Ch Dg Dg Ch

L
GY
Dg
Ch
B

GY

250

250

L L GY
- B B -

GY

There is a defect in the wire harness between


the main switch and the brake light socket
Repair.

B
Ch

372019(a)

MEETS
SPECIFICATION
Circuit is in good condition.

7-25

SIGNAL SYSTEM

ELEC

3. Flasher does not work


NO CONTINUITY

1. Bulb and socket


Check the bulb and socket for continuity.

Replace bulb or socket.

CONTINUITY
2. TURN switch
Disconnect the handlebar switch (left) from
the wire harness.
Check for continuity between :
Left side : Brown / White Q and Chocolate W
Right side : Brown / White Q and Dark green E
Ch BrW Dg

L
N
R

NO CONTINUITY

Ch - P
B BrW Dg

Left handlebar switch is defect Replace.

372032(a)

CONTINUITY
3. Voltage
Connect the pocket tester (DC20V) to the
flasher relay.
Pocket tester (+) lead Brown Q
Pocket tester (-) lead Ground
Turn the main switch to ON.
Check the voltage (12V) between the Brown
lead and the ground.
DOES NOT MEET SPECIFICATION

Br/W

Br

Defect in the wire harness between the main


switch and the flasher relay Repair.

372033

MEETS
SPECIFICATION

7-26

SIGNAL SYSTEM

ELEC

4. Voltage
Connect the pocket tester (DC20V) to the
flasher relay.
Pocket tester (+) lead Brown / White Q
Pocket tester (-) lead Ground
Turn the main switch to ON.
Check the voltage (12V) between Brown /
White and the ground.

DOES NOT MEET SPECIFICATION


-

Br/W

Br

Flasher relay defect Replace.


372034

MEETS
SPECIFICATION
5. Voltage
Connect the pocket tester (DC20V) to the
flasher connector.
Left flasher bulb:
Pocket tester (+) lead Chocolate Q
Pocket tester (-) lead Ground
Right flasher bulb:
Pocket tester (+) lead Dark green W
Pocket tester (-) lead Ground
Turn the main switch to ON.
Set the TURN switch to L, then to R.
Check the voltage (12V) between Chocolate and the ground, then Dark green and
the ground.
Dg

110

110

DOES NOT MEET SPECIFICATION


250

Ch Dg Dg Ch

L
GY
Dg
Ch
B

GY

250

Defect in the wire harness between the main


switch and the flasher bulb socket Repair.

250

L L GY
- B B -

GY

B
Ch

372038(a)

MEETS
SPECIFICATION 7-27

SIGNAL SYSTEM

ELEC

This circuit is in good condition.


4. The OIL indicator light does not work.
1. Bulb and socket

NO CONTINUITY

Check the bulb and socket for continuity.


CONTINUITY

Replace bulb or socket.

2. Oil level switch


Disconnect the oil level switch from the oil
tank.
Connect the pocket tester ( x 1) to the oil
level switch.
Pocket tester (+) lead Terminal Q
Pocket tester (-) lead Terminal Q
Check the switch for continuity.
Float
position

Good
condition

Bad
condition

HIGH

LOW

O : Continuity X : No continuity

DOES NOT MEET SPECIFICATION

Replace oil level switch is defect.

B
372035

MEETS
SPECIFICATION

7-28

SIGNAL SYSTEM

ELEC

3. Voltage
Connect the pocket tester (DC20V) to the
bulb socket connector.
Pocket tester (+) lead Grey Q
Pocket tester (-) lead Ground
Turn the main switch to ON.
Check the voltage (12V) between Grey and
the ground.

DOES NOT MEET SPECIFICATION

L Br
Dg G
Ch Gy

4. Connections

372039(a)

MEET
SPECIFICATION
This circuit is in good condition.

7-29

Check all connections in the signal system.


Refer to WIRING DIAGRAM.

TRBL
SHTG

TRBL
SHTG
CHAPTER 8.
TROUBLESHOOTING
STARTING FAILURE/ HARD STARTING ..................................................... 8-1
FUEL SYSTEM ........................................................................................ 8-1
ELECTRICAL SYSTEM ........................................................................... 8-1
COMPRESSION SYSTEM ...................................................................... 8-2
POOR IDLE SPEED PERFORMANCE ......................................................... 8-2
POOR IDLE SPEED PERFORMANCE ................................................... 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE ................................ 8-3
FUEL SYSTEM ........................................................................................ 8-3
ELECTRICAL SYSTEM ........................................................................... 8-3
COMPRESSION SYSTEM ...................................................................... 8-3
FAULTY AUTOMATIC (V-BELT TYPE) ......................................................... 8-3
MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING ... 8-3
CLUTCH -OUT FAILURE ......................................................................... 8-4
POOR STANDING START (LOW CLIMBING ABILITY) .......................... 8-4
POOR ACCELERATION (POOR HIGH SPEED) .................................... 8-4
OVER HEATING ............................................................................................ 8-4
OVER HEATING ...................................................................................... 8-4
IMPROPER KICKING .................................................................................... 8-5
SLIPPING ................................................................................................. 8-5
HARD KICKING ....................................................................................... 8-5
KICK CRANK NOT RETURNING ............................................................ 8-5
FAULTY BRAKE ............................................................................................ 8-5
POOR BRAKING EFFECT ...................................................................... 8-5
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION ........... 8-6
OIL LEAKAGE .......................................................................................... 8-6
MALFUNCTION ....................................................................................... 8-6
INSTABLE HANDLING .................................................................................. 8-6
INSTABLE HANDLING ............................................................................ 8-6
FAULTY SIGNAL AND LIGHTING SYSTEM ................................................. 8-7

STARTING FAILURE/HARD STARTING

TRBL
SHTG

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.

STARTING FAILURE/HARD STARTING


FUEL SYSTEM
Fuel tank
Empty
Clogged fuel filter
Deteriorated fuel or fuel containing water or
foreign material
Clogged fuel tank cap
Fuel cock
Clogged fuel hose
Clogged vacuum
Faulty diaphragm
Air cleaner
Clogged air filter

Carburetor
Deteriorated fuel, fuel containing water or
foreign material
Clogged pilot jet
Clogged pilot air passage
Sucked-in air
Deformed float
Groove-worn needle valve
Improperly sealed valve seat
Improperly adjusted fuel level
Improperly set pilot jet
Clogged starter jet
Starter plunger malfunction
Improperly adjusted pilot air screw

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 coil
Faulty spark plug lead
Broken body
Starter motor
Faulty starter motor
Faulty starter relay

CDI unit system


Faulty CDI unit
Faulty source coil
Faulty pick-up coil
Switches and wiring
Faulty main switch
Broken or shorted wiring
Faulty brake switch (front or rear)

8-1

STARTING FAILURE/HARD STARTING/


POOR IDLE SPEED PERFORMANCE
COMPRESSION SYSTEM
Cylinder and cylinder head
Loose spark plug
Loose cylinder head or cylinder
Broken cylinder head gasket
Broken cylinder gasket
Worn, damaged or seized cylinder
Piston and piston rings
Improperly installed piston ring
Worn, fatigued or broken piston ring
Seized piston ring
Seized or damaged piston

TRBL
SHTG

Crankcase and crankshaft


Improperly seated crankcase
Improperly sealed crankcase
(damaged oil seal)
Seized crankshaft
Reed valve
Deformed reed valve stopper
Improperly seated reed valve
Loose intake manifold
Broken gasket
Broken reed valve

POOR IDLE SPEED PERFORMANCE


POOR IDLE SPEED PERFORMANCE
Carburetor
Improperly returned starter plunger
Clogged or loose pilot jet
Clogged pilot air jet
Improperly adjusted idle speed ( throttle stop screw)
Improper throttle cable play
Flooded carburetor

8-2

POOR MEDIUM AND HIGH SPEED PERFORMANCE/


FAULTY AUTOMATIC

TRBL
SHTG

POOR MEDIUM AND HIGH SPEED PERFORMANCE


FUEL SYSTEM
Fuel tank
Clogged fuel filter
Deteriorated fuel or fuel containing water or
foreign material
Clogged fuel tank cap
Fuel cock
Clogged fuel hose
Clogged vacuum hose
Faulty diaphragm
Air cleaner
Clogged air cleaner

Carburetor
Deteriorated fuel, fuel containing water or
foreign material
Sucked-in air
Deformed float
Groove-worn needle valve
Improperly sealed valve seat
Improperly set clip position of jet needle
Improperly adjusted fuel level
Clogged or loose main jet
Clogged or loose main nozzle
Clogged main air passage

ELECTRICAL SYSTEM
Spark plug
Improper plug gap
Worn electrodes
Wire between terminals broken
Improper heat range
Faulty spark plug cap

CDI unit system


Faulty CDI unit
Faulty source coil
Faulty pick-up coil

COMPRESSION SYSTEM
Cylinder and cylinder head
Loose spark plug
Loose cylinder head or cylinder
Broken cylinder head gasket
Broken cylinder gasket
Worn, damaged or seized cylinder
Piston and piston rings
Improperly installed piston ring
Worn, fatigued or broken piston ring
Seized piston ring
Seized or damaged piston

Crankcase and crankshaft


Improperly seated crankcase
Improperly sealed crankcase
(damaged oil seal)
Seized crankshaft
Reed valve
Deformed reed valve stopper
Improperly adjusted reed valve stopper height
Improperly sealing reed valve
Loose intake manifold
Broken gasket
Broken reed valve

FAULTY AUTOMATIC (V-BELT TYPE)


MOTORCYCLE DOES NOT MOVE WHILE ENGINE IS OPERATING.
V-belt
Secondary sheave
Worn, damaged or slippery v-belt
Broken compression spring
Primary sheave
Pealed lining from clutch shoe
Worn or damaged cam plate
Worn spline of clutch housing
Worn or damaged slider bushing

8-3

FAULTY AUTOMATIC/
OVER HEATING
CLUTCH-OUT FAILURE
Primary sheave
Seized primary sliding sheave and collar

TRBL
SHTG

Secondary sheave
Broken or fatigued clutch shoe spring

POOR STANDING START (LOW CLIMBING ABILITY)


V-belt
Secondary sheave
Worn, damaged or slippery v-belt
Fatigued compression spring
Primary sheave
Improper operation of secondary sliding sheave
Worn or improper operation of weight
POOR ACCELERATION (POOR HIGH SPEED)
V-belt
Worn or greasy V-belt
Secondary sheave
Worn or greasy clutch shoe
Improper operation of secondary sliding sheave

OVER HEATING
OVER HEATING
Ignition system
Improper spark plug gap
Improper spark plug heat range
Faulty ignitor unit

Engine oil
Improper engine oil quality (high viscosity)
Low engine oil quality
Brakes
Dragging brake

Fuel system
Improper carburetor setting
Improper fuel level adjustment
Clogged air cleaner element
Lean mixture (Air in the autolube pump)

Cooling fan
Damaged cooling fan
Damaged air shrouds

Compression system
Heavy carbon deposit build-up

8-4

IMPROPER KICKING/
FAULTY BRAKE

TRBL
SHTG

IMPROPER KICKING
SLIPPING
Kick axle assembly
Low tension of kick clip
Worn kick axle
Worn or damaged kick gear
Damaged kick clip
Kick clip coming off
Damaged kick clip stopper

Transmission oil
Improper quality (low viscosity)
Deterioration

HARD KICKING
Kick axle assembly
High tension of kick clip
Seized kick gear

Crankcase and crankshaft


Improperly seated crankcase
Improperly seated crankshaft
Damaged or seized crankshaft
Damaged or seized crankshaft bearing

Cylinder, piston and piston ring


Damaged or seized cylinder
Damaged or seized piston
Damaged or seized piston ring
KICK CRANK NOT RETURNING
Kick axle assembly
Damaged kick return spring
Kick return spring coming off
Kick clip coming off
Damaged kick return spring stopper

FAULTY BRAKE
POOR BRAKING EFFECT
Front disc brake
Worn brake pads
Worn disc
Air in brake fluid
Leaking brake fluid
Wrong brake fluid
Seized main cylinder piston
Faulty caliper seal kit
Loose union bolt
Broken brake hose
Oily or greasy disc/brake pads
Improper brake fluid level
Excessive free play (brake lever)

Rear drum brake


Worn brake shoe
Worn or rusty brake drum
Improperly adjuster brake play
Improper brake cam lever
Improper brake shoe position
Fatigue/damaged return spring
Oily or greasy brake shoe
Oily or greasy brake drum
Broken brake cable

8-5

FRONT FORK OIL LEAKAGE AND FRONT FORK


MALFUNCTION/
INSTABLE HANDLING

TRBL
SHTG

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION


OIL LEAKAGE
Bent, damaged or rusty inner tube
Damaged or cracked outer tube
Damaged oil seal lip
Improperly installed oil seal
Improper oil level (too much)
Loose damper rod holding bolt
Broken cap bolt O-ring
Loose drain bolt or damaged drain bolt gasket

MALFUNCTION
Bent, deformed or damaged inner tube
Bent or deformed outer tube
Damaged fork spring
Worn or damaged slide metal
Bent or damaged damper rod
Improper oil viscosity
Improper oil level

INSTABLE HANDLING
INSTABLE HANDLING
Handlebar
Improperly installed or bent

Wheels
Damaged bearing
Bent or loose wheel axle
Excessive wheel run-out

Steering
Improperly installed steering column
(Improperly tightened ring nut)
Bent steering column
Damaged ball bearing or bearing race

Frame
Twisted
Damaged head pipe
Improperly installed bearing race

Front forks
Broken damper spring
Bent or deformed suspension arm and pivots
Oil level

Engine bracket
Bent or damaged

Tires
Incorrect tire pressure
Uneven tire pressures on both sides
Unevenly worn tires

Rear shock absorber


Improper adjustment
Fatigued spring
Oil leakage

8-6

FAULTY SIGNAL AND LIGHTING SYSTEM

TRBL
SHTG

FAULTY SIGNAL AND LIGHTING SYSTEM


Headlight dark
Improper bulb
Too many electric accessories
Hard charging (broken charging coil)
Incorrect connection
Improperly grounded
Poor contacts (main or light switch)
Bulb life expired (high internal resistance)

Flasher does not light


Improperly grounded
Discharged battery
Faulty flasher switch
Faulty flasher relay
Broken wire harness
Loosely connected coupler
Bulb burnt out
Faulty fuse

Bulb burnt out


Improper bulb
Improperly grounded
Faulty main and/or light switch
Bulb life expired

Flasher keeps on
Faulty flasher relay
Insufficient battery capacity
(nearly discharged)

Flasher winks slower


Faulty flasher relay
Insufficient battery capacity (nearly discharged)
Improper bulb
Faulty main and/or flasher switch

Horn is inoperative
Faulty battery
Faulty fuse
Faulty main and/or horn switch
Improperly adjusted horn
Faulty horn
Broken wire harness

Flasher winks quicker


Improper bulb
Faulty flasher relay

8-7

CW50RS WIRING DIAGRAM

a
1

Br

GY

Br

GY

LW

OFF
ON

GY

YR

L G Y

B OFF
LOW
HI

:
Dg Dg

YR

BW
L Y B
G YR LW

Y
B
B
Gy
Dg
Ch

Or

BG

Gy

Br

Dg

110

110

B
Y

B
L
B
L

BW

Br L
G Dg
Gy Ch

B
Y

(GREEN)

L
Gy
G
Br
L
Y
Dg

L
GY
Dg
Ch
B

Ch

L L GY
- B B -

GY

Ch Dg Dg Ch

L
GY
Dg
Ch
B

GY

B
Ch

B
Ch

B B

Ch Ch

Ch

BrW Dg B Ch P
B

BrW

Br

Ch - P
B BrW Dg

BrW

Br

Br

BrW

B P Ch

BrW

W YR

WR BR

W YR
W YR

Blue
Orange
Pink
red
Sky blue
White

Y
B/R
B/W
Br/W
Br/Y
G/B

R B

R B
LW
GY

WR

Ch BrW Dg

R
R

Yellow
Black/Red
Black/White
Brown/White
Brown/Yellow
Green/Black

12V 4AH

BR

L
N
R

COLORS CODE

L
O
P
R
Sb
W

B Or

Black
Brown
Chocolate
Dark green
Green
Grey

BW

Dg

u
OFF
ON

B Or
WR
B Or

B P

LW GY

BR
P

Ch - Dg

B
Br
Ch
Dg
G
Gy

250

187.8

(BLACK)
L Br
Dg G
Ch Gy

D
S

Y G B L LW YR

Br
G
B

B G

250

H
G

YR B W R

Br B Gy

B WR

Br Gy B
Br Gy B

G YR LW
L Y B

B
L

R Br

LOCK
OFF
CHECK
ON

B G

Dg
B

B B

BW B Gy

250

B
Dg

2
Br

G/Y
L/W
W/R
Y/R
Y/R

Green/Yellow
Blue/White
White/Red
Yellow/White
Yellow/Red

Q
W
E
R
T
Y
U
I
O
P
{
}
q
w
e
r
t
y
u
i
o
p
[
]
A
S
D
F
G
H
J
K
L
:
a

Handlebar switch (right)


"START" switch
"LIGHT" switch
Main switch
Ignition coil
Spark plug
Rectifier / regulator
Fuel lever sender
Oil level gauge
Rear flasher light (right)
Tail /Stop light
Rear flasher light (left)
Starter motor
Starter switch
Battery
Fuse
CDI unit
CDI magneto
Horn
Handle switch (left)
"TURN" switch
"HORN" switch
Flasher relay
Front flasher light (left)
Head light
Meter light
Meter light
Fuel meter
Flasher indicator
Oil caution indicator
"HIGH BEAM" indicator light
Position light
Front flasher light (right)
Rear stop switch
Front stop switch

CW50RS

'00
5FX-ME2

SUPPLEMENTARY
SERVICE MANUAL

FOREWORD
This supplementary service manual has been prepared to introduce new service and data for the
CW50RS ('00). For complete service information procedures it is necessary to use this supplementary
service manual together with the following manual.

CW50RS ('99) SERVICE MANUAL : 5FX-ME1

CW50RS ('00)
SUPPLEMENTARY
SERVICE MANUAL
1999 by MBK INDUSTRIE
1st Edition, September 1999
All rights reserved. Any
reprinting or unauthorized use
without the written
permission of MBK INDUSTRIE
is expressly prohibited.

NOTICE
This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers
and their qualified mechanics. It is not possible to put an entire mechanics education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and
MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in
scooter repair technology. Without such knowledge, attempted repairs or service to this model may
render it unfit to use and/or unsafe.
MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and
significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and
MBK dealers and will, where applicable, appear in future editions of this manual.
DOCUMENTATION TECHNIQUE
MBK INDUSTRIE

PARTICULARY IMPORTANT INFORMATION


This material is distinguished by the following notation :

The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR


SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE :

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 scooter.

A CAUTION indicates special precautions that must be taken to avoid


damage to the scooter.

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

HOW TO USE THIS MANUAL


CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See illustrated symbols).
1st title
1
This is a chapter with its symbol on the upper right of each page.
2nd title
2
This title appears on the upper of each page on the left of the chapter symbol.
(For the chapter Periodic inspection and adjustment the 3rd title appears.)
3rd title
3
This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particulary important procedure 4 is placed between a line of asterisks " * " with each step
preceded by " ".
IMPORTANT FEATURES
Data and a special tools are framed in a box preceded by a relevant symbol 5.
An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data for an
alignement mark 7, the others being indicated by an alphabetical letter in a box 8.
A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams are before each disassembly section for ease in identifying
correct disassembly and assembly procedures.

ILLUSTRATED SYMBOLS

GEN
INFO

(REFER TO THE ILLUSTRATION)

SPEC

Illustrated symbols Q to W are designed as


thumb tabs to indicate the chapters number and
content.

INSP
ADJ

ENG

Q General information
W Specifications
E Periodic inspection and adjustment
R Engine
T Carburetion
Y Chassis
U Electrical
I Troubleshooting

CARB

CHAS

TRBL
SHTG

ELEC
O

Illustrated symbols O to e are used to identify


the specifications appearing in the text.

T.

Illustrated symbols r to [ in the exploded


diagram indicate grade of lubricant and location
of lubrication point.
r

O Filling fluid
P Lubricant
{ Special tool
} Tightening
q Wear limit, clearance
w Engine speed
e , V, A

r Apply engine oil


t Apply gear oil
y Apply molybdenum disulfide oil
u Apply wheel bearing grease
i Apply lightweight lithium-soap base
grease
o Apply molybdenum disulfide grease
p Apply locking agent (THREADLOCK )
[ Use new one

CONTENTS
ELECTRICAL COMPONENTS ......................................................................... 1
CIRCUIT DIAGRAM .......................................................................................... 3
IGNITION AND STARTING SYSTEM ............................................................... 5
CIRCUIT DIAGRAM .................................................................................... 5
IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM ....................... 6
TROUBLESHOOTING ................................................................................ 7
CHARGING SYSTEM ..................................................................................... 13
CIRCUIT DIAGRAM .................................................................................. 13
TROUBLESHOOTING .............................................................................. 14
LIGHTING SYSTEM ....................................................................................... 16
CIRCUIT DIAGRAM .................................................................................. 16
TROUBLESHOOTING .............................................................................. 17
SIGNAL SYSTEM ........................................................................................... 21
WIRING DIAGRAM ................................................................................... 21
TROUBLESHOOTING .............................................................................. 22

ELECTRICAL COMPONENTS

ELEC

ELECTRICAL COMPONENTS
BATTERY:
SPECIFIC GRAVITY: 1.280
IGNITION COIL
Primary coil resistance:
0.32 ~ 0.48 at 20C (68F)
Secondary coil resistance:
5.68 ~ 8.52 at 20C (68F)

ELECTRICAL COMPONENTS
Q Wire harness
W Fuel sender
E Ignition coil
R Starter relay
T Battery
Y CDI unit
U Oil sender

383002

-1-

ELECTRICAL COMPONENTS
Q Main switch
W Rectifier / Regulator
E Horn
R Flasher relay

ELEC

Starter motor coil resistance:


0.06 - 0.08 at 20C (68F)
Brush wear limit:
0.9 mm (0.035 in)
Commutator diameter wear limit:
14.8 mm (0.582 in)
Commutator mica undercut:
1.15 mm (0.045 in)

383001

-2-

ELEC

CIRCUIT DIAGRAM
CIRCUIT DIAGRAM

A
(BLACK)
Br Gy B

R
B

R
B

Br Gy B
Gy Br R B BW

LOCK
MAIN HARNESS STARTER MOTOR

OFF
R

CHECK

ON
BW

BW

B Or

W YR -

W YR R W B YR

R
LW

GY

BR

BR
WR

YR

WR

Or

YR

B Or

BW

Br

Gy

BW

RAR

GY
LW

Br

BAB

o
B

Gy

LW

YR

LW B

YR LR

OFF

OFF

LR/L L
YR _

L LR
_ YR

ON

ON

LW B

B LW

LR

Br

Br

Br

12V10W

]
B

L Br

Dg G

}
C

Dg

OFF

HI

ON

LOW

BrW

G Ch P

LR Dg Y
BrW

P Ch G

GY

G B

12V
35W / 35W

Ch

Dg

Ch

Dg

G B
12V10W

p
B

-3-

12V10W

12V10W

e
B

12V10W

GY

Ch
Y

(GREEN)
B

Y Dg LR

Ch

Ch BrW Dg

G LR Y

D
B P

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

Ch Gy

BrW

L Br

Br

(GREEN)

Dg G

BrW

Dg

Ch Gy

Br

Gy

(BLACK)

H
12V
21W / 5W

Ch Dg
_ B

Dg Ch
B _

GY L

L GY

CIRCUIT DIAGRAM

ELEC

e Right front flasher


r Taillight assembly
F Left rear flasher
G Right rear flasher
H Tail / Stop light
t Horn
y Flasher relay
u Front stop switch
i Rear stop switch
o Oil level gauge
p Fuel sender
[ Meter assembly
J Meter light
K Oil warning light
L Flasher indicator light
M High beam indicator light
N Fuel meter
] Position light

Q
W
E
R
T
Y
U
I
O
P
{

C.D.I. magneto
C.D.I. unit
Ignition coil
Spark plug
Main switch
Fuse
Battery
Rectifier / regulator
Starter relay
Starter motor
Right handle switch
A Starter switch
B Lighting switch
} Left handle switch
C "HORN" switch
D "Hi / Lo" switch
E Flasher switch
q Head light
w Left front flasher
COLOR CODE
Black
B
Brown
Br
Chocolate
Ch
Dark green
Dg
Green
G
Grey
Gy
Blue
L
Orange
O
Pink
P
Red
R
Sky blue
Sb
White
W

Y
B/R
B/W
Br/W
Br/Y
G/B
G/Y
L/R
L/W
W/R
Y/B
Y/R

-4-

Yellow
Black/Red
Black/White
Brown/White
Brown/Yellow
Green/Black
Green/Yellow
Blue/Red
Blue/White
White/Red
Yellow/Black
Yellow/Red

ELEC

IGNITION AND STARTING SYSTEM


IGNITION AND STARTING SYSTEM
CIRCUIT DIAGRAM

A
(BLACK)
Br Gy B

R
B

R
B

Br Gy B
Gy Br R B BW

LOCK
MAIN HARNESS STARTER MOTOR

OFF
R

CHECK

ON
B Or

W YR
R

W YR R W B YR

R
LW

GY

BR

BR
WR

YR

WR

Or

YR

B Or
BW

Br

Gy

BW

BW

BW

RAR

R
R

GY
LW

Br

M
BAB

Gy

LW

YR

LW B

YR LR
OFF

YR

ON

ON

LW B

YR
B LW

LR

L LR

LR/L L

OFF

Br

Br

Br

12V10W

]
Y

L Br

L Br

Dg G

}
C

Dg

OFF

HI

ON

LOW

BrW

G Ch P

LR Dg Y
BrW

P Ch G

GY

Ch
Y
Y

G B

12V
35W / 35W

Ch

Dg

Ch

Dg

12V10W

12V10W

G B

p
B

Q
W
E
R
T

C.D.I. magneto
C.D.I. unit
Ignition coil
Spark plug
Main switch

Y
U
O
P

Fuse
Battery
Starter relay
Starter motor

-5-

12V10W

12V10W

e
B

{ Right handle switch


A Starter switch
u Front stop switch
i Rear stop switch

GY

(GREEN)
B

Y Dg LR

Ch

Ch BrW Dg

G LR Y

D
B P

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

Ch Gy

Br

BrW

(GREEN)

Dg G

BrW

Dg

Ch Gy

Br

Gy

(BLACK)

H
12V
21W / 5W

Ch Dg
_ B

Dg Ch
B _

GY L

L GY

ELEC

IGNITION AND STARTING SYSTEM

IGNITION AND STARTING SYSTEM CIRCUIT DIAGRAM


} Main switch
Q Spark plug
a Source coil
t Front brake switch
W Ignition coil
b Pickup coil
y Rear brake switch
R CDI unit
c Wave-shape shaping circuit
U Starter Motor
d Condenser
I Starter relay
e Diode
O Fuse
f SCR
P Battery
g To oil level switch
{ Starter switch

B/R

e
W/R

e
d

B
B

B/W
BW B

Br Gy

LOCK
OFF
CHECK
ON

M
B

B
L/W

Br

G/Y

: Current flow in ignition control circuit


: Current flow in starter motor control circuit
374001

-6-

ELEC

IGNITION AND STARTING SYSTEM


TROUBLESHOOTING
THE STARTING SYSTEM DOES NOT WORK
(NO SPARK OR IRREGULAR SPARKS).
NOTE:
Remove the following parts before proceeding with the troubleshooting:
1) Side covers (left and right)
For accurate troubleshooting use the following special tools:

Ignition checker:
90890-06754

Pocket tester:
90890-03112

1.Spark plug
Check the spark plug type.
Check the condition of the spark plug.
Check the spark plug gap.
Refer to SPARK PLUG INSPECTION in
Chapter 3.

INCORRECT

Standard spark plug:


BR8HS (NGK)
The spark plug is defective. Replace it or
adjust the spark plug gap.

Spark plug gap:


0.5 ~ 0.7 mm (0.019 ~ 0.028 in)
CORRECT
2.Spark check
Remove the spark plug cap.
Connect the ignition checker Q.
W Spark plug cap
E Spark
Check the length of the spark gap.
Start the engine and increase the spark
length until the engine begins to misfire.

372000

Minimum spark gap:


6.0 mm (0.24 in)

MEETS SPECIFICATION

OUT OF
SPECIFICATION
OR NO SPARK

Ignition system in good condition.

-7-

IGNITION AND STARTING SYSTEM

ELEC

3.Spark plug cap resistance


Disconnect the spark plug cap.
Connect the pocket tester ( x 1 k) to the
spark plug cap.
Check the resistance of the spark plug cap.
Spark plug cap resistance:
5k at 20C (68F)

DOES NOT MEET


SPECIFICATION

372001

Replace the spark plug cap


MEETS
SPECIFICATION
4.Ignition coil resistance
Disconnect the ignition coil leads.
Connect the pocket tester ( x 1) to the
ignition coil.
Ignition coil :
Pocket tester (+) lead Orange
Pocket tester (-) lead Ground
372002

Check the primary coil resistance.


Primary coil resistance:
0.32 ~ 0.48 at 20C (68F)
Connect the pocket tester ( x 1k) to the
ignition coil.
Pocket tester (+) lead Ground
Pocket tester (-) lead Spark plug lead
Check the secondary coil resistance.

372003

Secondary coil resistance:


5.68 ~ 8.52 at 20C (68F)

DOES NOT MEET


SPECIFICATION

MEETS
SPECIFICATION
Defect. Replace the ignition coil.

-8-

IGNITION AND STARTING SYSTEM

ELEC

5.Pickup coil resistance


CDI
MAGNETO

Disconnect the pickup coil coupler.


Connect the pocket tester ( x 100) to the
pickup coil.

Pocket tester (+) lead Q White / Red


Pocket tester (-) lead W Ground

Y/R

W/R B/R

Check the pickup coil resistance.

372004

DOES NOT MEET


SPECIFICATION

Pickup coil resistance:


400 ~ 600 at 20C (68F)

MEETS
SPECIFICATION

Pickup coil defect Replace.

6.Source coil resistance


Disconnect the source coil coupler from the
wire harness.
Connect the pocket tester ( x 100) to the
source coil.

CDI
MAGNETO

Pocket tester (+) lead Q Black / Red


Pocket tester (-) lead W Ground

Y/R

W/R B/R

Check the source coil resistance.

372005

DOES NOT MEET


SPECIFICATION

Source coil resistance:


640 ~ 960 at 20C (68F)
MEETS
SPECIFICATION

Source coil defect Replace.


POOR CONNECTIONS

7.Connections
Check all connections in the ignition system.
Refer to WIRING DIAGRAM.

Repair.

GOOD
CONNECTIONS
Replace the CDI unit.

-9-

IGNITION AND STARTING SYSTEM

ELEC

TROUBLESHOOTING
STARTER MOTOR DOES NOT WORK
NOTE:
Remove the following parts before proceeding with the troubleshooting:
1) Side covers (left and right)
2) Footrest board
3) Front panel
4) Handlebar cover
For accurate troubleshooting use the following special tools:
Pocket tester:
90890-03112

1.Fuse

NO CONTINUITY

Remove the fuse.


Connect the pocket tester ( x 1) to the fuse.
Check the fuse for continuity.

Defect Replace fuse.

CONTINUITY
2.Battery
Check the condition of the battery.
Refer to BATTERY INSPECTION in
CHAPTER 3.

DOES NOT MEET


SPECIFICATION

Open circuit voltage:


12.8 V or more at 20C (68F)

Clean battery terminals.


Charge or replace the battery.

MEETS
SPECIFICATION
3.Starter motor
Use a jumper lead E * to connect the (+) Q
terminal of the battery to the starter motor
terminal W.

CAUTION:
If the gauge of the jumper lead is smaller
than that of the battery leads, the jumper
lead might melt or burn.

This test could cause sparks. Never


perform it near a gas source or near
flammable products.

DOES NOT WORK

372006

Starter defect Repair or replace.

Check the starter motor operation.


WORKS

-10-

IGNITION AND STARTING SYSTEM

ELEC

4. Starter relay
Disconnect the Blue/White lead from the
wire harness.
Connect the (-) Q terminal of the battery to
the Blue/White lead.
Check the starter motor operation.

DOES NOT WORK

L/W

Starter relay defect Replace.

372007

WORKS
5. Main switch
Disconnect the main switch from the wire
harness.
Check for continuity between Red Q and
Brown W.
BW B

Br Gy

DOES NOT MEET


SPECIFICATION

LOCK
OFF
CHECK
ON

R
R

B/W

Main switch defect Replace.

Br Gy B

372008

MEETS
SPECIFICATION
6.Starter switch
Disconnect the right handlebar switch coupler from the wire harness.
Check for continuity between Blue / White
Q and Black W.

-11-

IGNITION AND STARTING SYSTEM

ELEC

LW B
OFF

DOES NOT MEET


SPECIFICATION

ON

372009A

B YB L
LW YR LR

Starter switch defect Replace right handlebar switch.

372009B

MEETS
SPECIFICATION
POOR CONNECTIONS
7.Connections
Check all connections in the starter system.
Refer to WIRING DIAGRAM.

Repair.

-12-

ELEC

CHARGING SYSTEM
CHARGING SYSTEM
CIRCUIT DIAGRAM

A
(BLACK)
Br Gy B

R
B

R
B

Br Gy B
Gy Br R B BW

LOCK
MAIN HARNESS STARTER MOTOR

OFF
R

CHECK

ON
B Or

W YR
R

W YR R W B YR

R
LW

GY

BR

BR
WR

YR

WR

Or

YR

B Or
BW

Br

Gy

BW

BW

BW

RAR

R
R

GY
LW

Br

BAB

o
B

Gy

LW

YR

LW B

YR LR
OFF

YR

ON

ON

LW B

YR
B LW

LR

L LR

LR/L L

OFF

Br

Br

Br

12V10W

]
B

L Br

Dg G

}
C

Dg

OFF

HI

ON

LOW

BrW

G Ch P

LR Dg Y
BrW

P Ch G

GY

G B

12V
35W / 35W

Ch

Dg

Ch

Dg

G B
12V10W

p
B

Q
Y
U
I

C.D.I. magneto
Fuse
Battery
Rectifier / regulator

-13-

12V10W

12V10W

e
B

12V10W

GY

Ch
Y
L

(GREEN)
B

Y Dg LR

Ch

Ch BrW Dg

G LR Y

D
B P

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

Ch Gy

BrW

L Br

Br

(GREEN)

Dg G

BrW

Dg

Ch Gy

Br

Gy

(BLACK)

H
12V
21W / 5W

Ch Dg
_ B

Dg Ch
B _

GY L

L GY

CHARGING SYSTEM

ELEC

TROUBLESHOOTING
THE BATTERY IS NOT CHARGED
NOTE:
Remove the following parts before proceeding with the troubleshooting:
1) Side covers (left and right) and footrest board.
For accurate troubleshooting use the following special tools:

Inductive tachometer:
90890-03113

Pocket tester:
90890-03112

1.Fuse (Main)
Remove the fuse.
Connect the pocket tester ( x 1) to the fuse.
Check the fuse for continuity.

NO CONTINUITY

CONTINUITY
2.Battery

Fuse defect Replace.

Check the condition of the battery.


Refer to BATTERY INSPECTION in
CHAPTER 3.
DOES NOT MEET
SPECIFICATION

Open circuit voltage:


12,8 V or more at 20C (68F)

Clean battery terminals.


Charge or replace the battery.

3.Charging voltage
Connect the engine tachometer to the spark
plug lead.
Connect the pocket tester (DC20V) to the
battery terminals.
Pocket tester (+) lead Battery (+) terminal
Pocket tester (-) lead Battery (-) terminal
Start the engine and accelerate to about
5000 rpm.
Check the charging voltage.

Charging voltage :
14 ~ 15 V at 5.000 tr/mn

367001

MEETS SPECIFICATION

NOTE:
Use a fully charged battery.
OUT OF
SPECIFICATION

Charging circuit is OK.

-14-

372010

CHARGING SYSTEM

ELEC

4.Charging coil resistance


CDI
MAGNETO

Disconnect the CDI magneto coupler from


the wire harness.
Connect the pocket tester ( x 1) to the
charging coil.
Check the charging coil resistance

Tester (+) lead White Q


Tester () lead Ground W

Y/R

OUT OF SPECIFICATION

Charging coil resistance:


0.48 ~ 0.72 at 20C (68F)
MEETS
SPECIFICATION

Charging coil defect Replace.


POOR CONNECTIONS

5.Connections
Check all connections in the charging system.
Refer to WIRING DIAGRAM.

Repair.

MEETS
SPECIFICATION
Replace the rectifier/regulator.

-15-

W/R B/R

372015

ELEC

LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM

A
(BLACK)
Br Gy B

R
B

R
B

Br Gy B
Gy Br R B BW

LOCK
MAIN HARNESS STARTER MOTOR

OFF
R

CHECK

ON
B Or

W YR
R

W YR R W B YR

R
LW

GY

BR

BR
WR

YR

WR

Or

YR

B Or
BW

Br

Gy

BW

BW

BW

RAR

R
R

GY
LW

Br

BAB

U
B

Gy

LW

YR

LW B

YR LR

OFF

OFF

YR

ON

ON

LW B

YR
B LW

LR

L LR

LR/L L

Br

Br

Br

12V10W

L Br

L Br

Dg G

}
C

Dg

HI

ON

LOW

BrW

G Ch P

LR Dg Y
BrW

P Ch G

GY

Ch
Y

G B

12V
35W / 35W

Ch

Dg

Ch

Dg

(GREEN)
B

Y Dg LR

Ch

Ch BrW Dg

G LR Y

OFF

D
B P

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

Ch Gy

12V10W

12V10W

G B

p
B

Q C.D.I. magneto
{ Right handle switch
B Lighting switch
} Left handle switch
D "Hi / Lo" switch
q Head light

12V10W

12V10W

e
B

r Taillight assembly
H Tail / Stop light
[ Meter assembly
J Meter light
M High beam indicator light
] Position light

-16-

GY

Br

BrW

(GREEN)

Dg G

BrW

Dg

Ch Gy

Br

Gy

(BLACK)

H
12V
21W / 5W

Ch Dg
_ B

Dg Ch
B _

GY L

L GY

LIGHTING SYSTEM

ELEC

TROUBLESHOOTING
THE AUXILIARY LIGHT, HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT,
TAILLIGHT OR METER LIGHT DO NOT WORK
NOTE:
Remove the following parts before proceeding with the troubleshooting:
Side covers and footrest board
Handlebar covers
For accurate troubleshooting use the following special tools:
Pocket tester:
90890-03112

YR LR
OFF
ON

1. LIGHTS switch
Disconnect the right handlebar switch coupler from the wire harness.
Set the switch to
.
Check for continuity between

L LR
_ YR

B LW
372009A

NO CONTINUITY

Yellow / Red Q and Blue / Red W

"Light" switch defect Replace.


CONTINUITY

G LR Y

2. HI / LO switch
Disconnect the HI / LO switch coupler (left)
from the wire harness.
Set the switch to " ".
Check for continuity between

HI
LOW

LR Dg Y
BrW

P Ch G

Blue / Red Q and Green W


372009A

Then set the switch to .


Check for continuity between:

NO CONTINUITY

Blue / Red Q and Yellow E


"HI / LO" switch defect Replace.
CONTINUITY

-17-

LIGHTING SYSTEM

ELEC

2. Lighting coil resistance


CDI
MAGNETO

Disconnect the lighting coil coupler from the


wire harness.
Connect the pocket tester ( x 1) to the
lighting coil.
Check the lighting coil resistance

Tester (+) lead Yellow / Red Q


Tester (-) lead Ground W

Y/R

OUT OF SPECIFICATION

Lighting coil resistance:


0.32 ~ 0.48 at 20C (68F)
MEETS
SPECIFICATION

Lighting coil defect Replace.

3. Connections
POOR CONNECTIONS

Check all connections in the lighting system.


Refer to WIRING DIAGRAM.
MEETS
SPECIFICATION

Repair.

Circuit is in good condition.

-18-

W/R B/R

372036

LIGHTING SYSTEM

ELEC

LIGHTING SYSTEM INSPECTION


1. Headlight and headlight indicator do not work.
1. Bulb and socket

NO CONTINUITY

Check the bulb and socket for continuity.


Replace bulb or socket.

CONTINUITY
2. Voltage
Connect the pocket tester (AC20V) to the
headlight coupler.

Headlight:
LO:
Pocket tester (+) lead Green Q
Pocket tester (-) lead Black E
HI:
Pocket tester (+) lead Yellow W
Pocket tester (-) lead Black E
Headlight indicator:
Pocket tester (+) lead Yellow R
Pocket tester (-) lead Black T

B
Y

Set the main switch to "ON".


Start the engine.
Set the light switch to " ".
Switch from "HI" to "LO" and back.
Check the voltage (12V) between the headlight coupler leads.

B
Y

372017(a)

OUT OF SPECIFICATION

MEETS
SPECIFICATION

There is a defect in the wire harness between


the main switch and the headlight coupler
and/or between the main switch and the
headlight indicator coupler
Repair.

Circuit is in good condition.

2. The meter light does not work.


NO CONTINUITY

1. Bulb and socket


Check the bulb and socket for continuity.
CONTINUITY

Replace bulb or socket.

-19-

ELEC

LIGHTING SYSTEM
2. Voltage

L Br
Dg G
Ch Gy

Connect the pocket tester (AC20V) to the


meter light coupler.
Pocket tester (+) lead Blue Q
Pocket tester (-) lead Black W

Br L
G Dg
Gy Ch

B
Y

Set the main switch to "ON".


Start the engine.
Set the light switch to " ".
Check the voltage (12V) between the headlight coupler leads Blue and Black.

B
Y
372037(a)

OUT OF SPECIFICATION

MEETS
SPECIFICATION

There is a defect in the wire harness between


the main switch and the meter light coupler
Repair.

Circuit is in good condition.

3. The taillight does not work.


NO CONTINUITY

1. Bulb and socket


Check the bulb and socket for continuity.

Replace bulb or socket.

CONTINUITY

Connect the pocket tester (AC20V) to the


taillight coupler.
Pocket tester (+) lead Blue Q
Pocket tester (-) lead Black W

12V10W

Set the main switch to ON.


Start the engine.
Set the light switch to " ".
Check the voltage (12V) between the headlight coupler leads Blue and Black.

12V10W

GY

2. Voltage

Ch Dg
_ B

Dg Ch
B _

GY L

L GY

12V
21W / 5W

OUT OF SPECIFICATION

MEETS
SPECIFICATION

There is a defect in the wire harness between


the main switch and the taillight coupler
Repair.

Circuit is in good condition.

-20-

ELEC

SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM

A
(BLACK)
Br Gy B

R
B

R
B

Br Gy B
Gy Br R B BW

LOCK
MAIN HARNESS STARTER MOTOR

OFF
R

CHECK

ON
BW

BW

B Or

W YR
R

W YR R W B YR

R
LW

GY

BR

BR
WR

YR

WR

Or

YR

B Or
BW

Br

Gy

BW

RAR

R
R

GY
LW

Br

BAB

U
B

Gy

LW

YR

LW B

YR LR
OFF

YR

ON

ON

LW B

YR
B LW

LR

L LR

LR/L L

OFF

Br

Br

Br

12V10W

]
B

L Br

Dg G

}
C

Dg

HI

ON

LOW

BrW

G Ch P

LR Dg Y
BrW

P Ch G

GY

Ch

Dg

G B

12V
35W / 35W

Ch

Dg

G B
12V10W

p
B

T
Y
U
}

Main switch
Fuse
Battery
Left handle switch
C "HORN" switch
E Flasher switch
w Left front flasher
e Right front flasher

12V10W

12V10W

r Taillight assembly
F Left rear flasher
G Right rear flasher
H Tail / Stop light
t Horn
y Flasher relay
u Front stop switch
i Rear stop switch

-21-

12V10W

GY

Ch
Y
L

(GREEN)
B

Y Dg LR

Ch

Ch BrW Dg

G LR Y

OFF

D
B P

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

Ch Gy

BrW

L Br

Br

(GREEN)

Dg G

BrW

Dg

Ch Gy

Br

Gy

(BLACK)

Ch Dg
_ B

Dg Ch
B _

GY L

L GY

H
12V
21W / 5W

o Oil level gauge


p Fuel sender
[ Meter assembly
K Oil warning light
L Flasher indicator light
N Fuel meter

ELEC

SIGNAL SYSTEM
TROUBLESHOOTING

FLASHER LIGHTS, BRAKE LIGHT, OIL WARNING LIGHT DO NOT WORK


HORN DOES NOT SOUND
NOTE:
Remove the following parts before proceeding with the troubleshooting:
Side covers and footrest board
Handlebar cover
For accurate troubleshooting use the following special tools:
Pocket tester:
90890-03112

1. Fuse
NO CONTINUITY

Remove the fuse.


Connect the pocket tester ( x 1) to the fuse.
Check the fuse for continuity.
Refer to FUSE INSPECTION in Chapter 3.

Fuse defect Replace.

CONTINUITY
2. Battery

DOES NOT MEET SPECIFICATION

Check the condition of the battery.


Refer to BATTERY INSPECTION in
CHAPTER 3.
Clean battery terminals.
Charge or replace the battery.

Battery voltage:
12.8 V or more at 20C (68F)
MEETS
SPECIFICATION
3. Main switch

BW B

Br Gy

LOCK

Disconnect the main switch from the wire


harness.
Turn the main switch to .
Check for continuity between:

OFF
CHECK
ON

Red Q and Grey E

Turn the main switch to ON.


Check for continuity between:

B/W
Br Gy B

DOES NOT MEET SPECIFICATION

Red Q and Brown W


MEETS
SPECIFICATION

Main switch defect Replace.

-22-

372040

SIGNAL SYSTEM

4. Connections

ELEC

POOR CONNECTIONS

Check all connections in the signal system.


Refer to WIRING DIAGRAM.
GOOD
CONNECTIONS

Repair.

Check the condition of each circuit of the


signal system.
Refer to the section SIGNAL SYSTEM
CHECK.

SIGNAL SYSTEM CHECK


1. Horn does not sound
1. HORN switch
Disconnect the handlebar switch (left) from
the wire harness.
Check for continuity between:
Black Q and Pink W.
B P
OFF
ON

NO CONTINUITY

LR Dg Y
BrW

Horn switch is defect Replace.

P Ch G

CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to the
horn lead.
Pocket tester (+) lead Brown Q
Pocket tester (-) lead Ground
Turn the main switch to ON.
Check for voltage (12V) between Brown
and the ground.

-23-

SIGNAL SYSTEM

Br

ELEC

DOES NOT MEET SPECIFICATION

Defect in the wire harness between the main


switch and the horn Repair.

372025

MEETS
SPECIFICATION
3. Horn
Disconnect the Pink lead at the horn terminal.
Ground the horn terminal Q with a jumper
lead.
Set the main switch to ON.

Br

HORN SOUNDS

Horn is in good condition.

372026

HORN DOES
NOT SOUND
4. Voltage
Br

Connect the pocket tester (DC20V) to the


Pink lead.

Pocket tester (+) lead Pink Q


Pocket tester (-) lead Ground
Turn the main switch to ON.
Press the HORN switch.
Check the voltage (12V) between Pink and
ground.

372027

DOES NOT MEET SPECIFICATION

MEETS
SPECIFICATION

Horn is defect Replace.

Adjust the horn.

-24-

SIGNAL SYSTEM

ELEC

2. The brake light does not work.


1. Bulb and socket
NO CONTINUITY

Check the bulb and socket for continuity.


CONTINUITY

Replace bulb or socket.


2. Brake switch
Disconnect the brake switch leads from the
wire harness.
Check for continuity between:
Brown Q and Green / Yellow W
Br G/Y
ON (Pull in)
OFF (Free)

NO CONTINUITY
Br G/Y

Brake switch is defect Replace.


372030

CONTINUITY
3. Voltage
Connect the pocket tester (DC20V) to the
socket.
Pocket tester (+) lead Green / Yellow Q
Pocket tester (-) lead Black W
Turn the main switch to ON.
Pull the brake lever.
Check the voltage (12V) between Green /
Yellow Q and Black W.

L
12V10W

12V10W

GY

Ch Dg
_ B

Dg Ch
B _

GY L

L GY

OUT OF SPECIFICATION

12V
21W / 5W

There is a defect in the wire harness between


the main switch and the brake light socket
Repair.

MEETS
SPECIFICATION
Circuit is in good condition.

-25-

SIGNAL SYSTEM

ELEC

3. Flasher does not work


NO CONTINUITY

1. Bulb and socket


Check the bulb and socket for continuity.

Replace bulb or socket.

CONTINUITY
2. TURN switch
Disconnect the handlebar switch (left) from
the wire harness.
Check for continuity between :
Left side : Brown / White Q and Chocolate W
Right side : Brown / White Q and Dark green E
Ch BrW Dg
L

NO CONTINUITY

N
R

LR Dg Y
BrW

Left handlebar switch is defect Replace.

P Ch G

CONTINUITY
3. Voltage
Connect the pocket tester (DC20V) to the
flasher relay.
Pocket tester (+) lead Brown Q
Pocket tester (-) lead Ground
Turn the main switch to ON.
Check the voltage (12V) between the Brown
lead and the ground.
DOES NOT MEET SPECIFICATION

Br/W

Br

Defect in the wire harness between the main


switch and the flasher relay Repair.

372033

MEETS
SPECIFICATION

-26-

SIGNAL SYSTEM

ELEC

4. Voltage
Connect the pocket tester (DC20V) to the
flasher relay.
Pocket tester (+) lead Brown / White Q
Pocket tester (-) lead Ground
Turn the main switch to ON.
Check the voltage (12V) between Brown /
White and the ground.

DOES NOT MEET SPECIFICATION


-

Br/W

Br

Flasher relay defect Replace.


372034

MEETS
SPECIFICATION
5. Voltage
Connect the pocket tester (DC20V) to the
flasher connector.
Left flasher bulb:
Pocket tester (+) lead Chocolate Q
Pocket tester (-) lead Black W
Right flasher bulb:
Pocket tester (+) lead Dark green E
Pocket tester (-) lead Black R
Turn the main switch to "ON".
Set the "TURN" switch to the left, then to the
right.
Check the voltage (12V) between "Chocolate" and "Black", then "Dark green" and
"Black".
Dg

Ch

GY

REAR:

12V10W

12V10W

Ch Dg
_ B

Dg Ch
B _

GY L

L GY

12V
21W / 5W

MEETS
SPECIFICATION -27-

FRONT:
Ch

Ch

Dg

Dg

Ch

12V10W

Dg

12V10W

DOES NOT MEET SPECIFICATION

REAR: Defect in the wire harness between


the main switch and the flasher bulb socket
Repair.
FRONT: Defect in the wire harness between the main switch and the flasher bulb
coupler Repair.

SIGNAL SYSTEM

ELEC

This circuit is in good condition.


4. The OIL indicator light does not work.
1. Bulb and socket

NO CONTINUITY

Check the bulb and socket for continuity.


CONTINUITY

Replace bulb or socket.

2. Oil level switch


Disconnect the oil level switch from the oil
tank.
Connect the pocket tester ( x 1) to the oil
level switch.
Pocket tester (+) lead Terminal W
Pocket tester (-) lead Terminal Q
Check the switch for continuity.
Float
position

Good
condition

Bad
condition

HIGH

LOW

O : Continuity X : No continuity

DOES NOT MEET SPECIFICATION

Replace oil level switch is defect.

B
372035

MEETS
SPECIFICATION

-28-

SIGNAL SYSTEM

ELEC

3. Voltage
Connect the pocket tester (DC20V) to the
bulb socket connector.
Pocket tester (+) lead Grey Q
Pocket tester (-) lead Black W
Turn the main switch to "ON".
Check the voltage (12V) between "Grey"
and "Black".

L Br

Br

L Br

Dg G

Ch Gy

(GREEN)

DOES NOT MEET SPECIFICATION

Dg

4. Connections

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

Gy

12V 1.2W

Ch Gy
Dg G

(BLACK)

Ch
Y

Check all connections in the signal system.


Refer to WIRING DIAGRAM.

MEET
SPECIFICATION
This circuit is in good condition.

-29-

CW50RS WIRING DIAGRAM

Q
W
E
R
T
Y
U
I
O
P
{

A
(BLACK)
Br Gy B

R
B

R
B

Br Gy B
Gy Br R B BW

LOCK
MAIN HARNESS STARTER MOTOR

OFF
R

CHECK

ON
B Or

W YR R

W YR R W B YR

R
LW

GY

YR

BR

BR

WR

WR

RAR

R
R

GY
LW

Br

Gy

LW

LW B
OFF

OFF

ON

ON

LW B

L LR
_ YR
B LW

LR

Br

Br

Br

12V10W

]
B

L Br

Dg G

}
C

Dg

OFF

HI

ON

LOW

BrW

G Ch P

LR Dg Y
BrW

P Ch G

GY

G B

12V
35W / 35W

Ch

Dg

Ch

Dg

12V10W

12V10W

G B

p
B

12V10W

12V10W

e
B

GY

Ch
Y
L

(GREEN)
B

Y Dg LR

Ch

Ch BrW Dg

G LR Y

D
B P

12V 1.2W

12V 1.2W

12V 1.2W

12V 1.2W

Ch Gy

u
BrW

L Br

Br

(GREEN)

Dg G

BrW

Dg

Ch Gy

Br

Gy

(BLACK)

12V 1.2W

Black
Brown
Chocolate
Dark green
Green
Grey
Blue
Orange
Pink
Red
White
Yellow
Black/Red
Black/White
Brown/White
Green/Yellow
Blue/Red
Blue/White
White/Red
Yellow/Red

YR LR

LR/L L
YR _

COLOR CODE

t
y
u
i
o
p
[

YR

B
Br
Ch
Dg
G
Gy
L
Or
P
R
W
Y
B/R
B/W
Br/W
G/Y
L/R
L/W
W/R
Y/R

BAB

q
w
e
r

Or

YR

B Or
BW

Br

Gy

BW

BW

BW

H
12V
21W / 5W

Ch Dg
_ B

Dg Ch
B _

GY L

L GY

C.D.I. magneto
C.D.I. unit
Ignition coil
Spark plug
Main switch
Fuse
Battery
Rectifier / regulator
Starter relay
Starter motor
Right handle switch
A Starter switch
B "Light" switch
Left handle switch
C "HORN" switch
D "Hi / Lo" switch
E Flasher switch
Head light
Left front flasher
Right front flasher
Taillight assembly
F Left rear flasher
G Right rear flasher
H Tail / Stop light
Horn
Flasher relay
Front stop switch
Rear stop switch
Oil level gauge
Fuel sender
Meter assembly
J Meter light
K Oil warning light
L Flasher indicator light
M High beam indicator light
N Fuel meter
Position light