B Ws 100 Service

YW100
4VP-ME1
EB000000
YW100E
SERVICE MANUAL
1999 by Yamaha Motor TAIWAN Co., Ltd.
1st Edition, March 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Taiwan Co., Ltd.
is expressly prohibited.
YP002000
HOW TO USE THIS MANUAL

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

ADJUSTMENT
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
EB003000
ILLUSTRATED SYMBOLS
GEN
INFO
SPEC
Illustrated symbols 1 to 9 are designed as

thumb tabs to indicate the chapters number
and content.
1 General information
2 Specifications
3 Periodic inspection and adjustment
4 Engine
5 Cooling system
6 Carburetion
7 Chassis
8 Electrical
9 Troubleshooting
INSP
ADJ
ENG
COOL
CARB
CHAS
ELEC
Illustrated symbols 0 to u are used to identify the specifications appearing in the text.
0 Possible to maintain with engine mounted
q Filling fluid
w Lubricant
e Special tool
r Tightening
t Wear limit, clearance
y Engine speed
u , V, A
TRBL
SHTG
q
T.
R.
o
G
p
M
s
B
d
M
LS
g
LT
New
Illustrated symbols i to d in the exploded diagrams indicate the types of lubricants and lubrication points.
i Apply engine oil
o Apply gear oil
p Apply molybdenum disulfide oil
a Apply wheel bearing grease
s Apply lightweight lithium-soap base grease
d Apply molybdenum disulfide grease
Illustrated symbols f to g in the exploded
diagrams indicate the where to apply locking
agent f and when to install new parts g .
f Apply locking agent (LOCTITE )
g Use new one
EB001000
NOTICE
This manual was produced by the Yamaha Motor Taiwan Company primarily for use by Yamaha/
MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a
mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance
and repairs on Yamaha/MBK scooter has a basic understanding of the mechanical ideas and the
procedures of scooter repair. Repairs attempted by anyone without this knowledge are likely to
render the scooter unsafe and unfit for use.
Yamaha Motor Taiwan Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha/MBK dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOUR

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

to the scooter operator, a bystander or a person inspecting or repairing the
scooter.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
CHAPTER 1.
GENERAL INFORMATION
SCOOTER IDENTIFICATION ............................................................................................................. 1-1
FRAME SERIAL NUMBER ............................................................................................................. 1-1
ENGINE SERIAL NUMBER ............................................................................................................ 1-2
IMPORTANT INFORMATION ............................................................................................................ 1-3
PREPARATION FOR REMOVAL PROCEDURES ........................................................................... 1-3
REPLACEMENT PARTS ................................................................................................................. 1-3
GASKETS, OIL SEALS, AND O-RINGS ........................................................................................ 1-3
LOCK WASHERS/PLATES AND COTTER PINS ........................................................................... 1-3
BEARINGS AND OIL SEALS ......................................................................................................... 1-4
CIRCLIPS ........................................................................................................................................ 1-4
CHECKING OF CONNECTIONS ........................................................................................................ 1-5
HOW TO USE THE CONVERSION TABLE ....................................................................................... 1-6
SPECIAL TOOLS ................................................................................................................................ 1-7
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ............................................................................................................. 2-1
MAINTENANCE SPECIFICATIONS ................................................................................................... 2-4
ENGINE .......................................................................................................................................... 2-4
CHASSIS ........................................................................................................................................ 2-7
ELECTRICAL ................................................................................................................................... 2-9
GENERAL TORQUE SPECIFICATIONS ........................................................................................... 2-11
LUBRICATION POINTS AND LUBRICANT TYPE ........................................................................... 2-12
ENGINE ........................................................................................................................................ 2-12
CHASSIS ...................................................................................................................................... 2-12
CABLE ROUTING ............................................................................................................................. 2-13
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENTS
NTRODUCTION ................................................................................................................................. 3-1
PERIODIC MAINTENANCE/ LUBRICATION INTERVALS ............................................................... 3-1
SIDECOVER AND SEAT ................................................................................................................ 3-3
JOB INSTRUCTION CHART .......................................................................................................... 3-3
LOWER COWLING ,UPPER COVER, LEG SHIELD1,2 AND FOOTREST BOARD ....................... 3-4
HANDLEBAR COVER(FRONT AND REAR) ................................................................................... 3-5
ENGINE .............................................................................................................................................. 3-6
IDLING SPEED ADJUSTMENT ..................................................................................................... 3-6
THROTTLE CABLE FREE ADJUSTMENT ..................................................................................... 3-7
AUTOLUBE PUMP AIR BLEEDING ............................................................................................... 3-8
AUTOLUBE PUMP CABLE ADJUSTMENT .................................................................................. 3-8
SPARK PLUG INSPECTION ........................................................................................................... 3-9
ENGINE OIL LEVEL INSPECTION ............................................................................................... 3-10
TRANSMISSION OIL REPLACEMENT ........................................................................................ 3-11
AIR FILTER ELEMENT CLEANING .............................................................................................. 3-12
V-BELT INSPECTION ................................................................................................................... 3-14
CHASSIS .......................................................................................................................................... 3-15
FRONT BRAKE LEVER FREE PLAY CHECK ................................................................................ 3-15
REAR BRAKE LEVER FREE PLAY CHECK................................................................................... 3-15
BRAKE PAD INSPECTION ........................................................................................................... 3-15
BRAKE SHOE INSPECTION ........................................................................................................ 3-16
BRAKE FLUID LEVEL INSPECTION ............................................................................................ 3-16
AIR BLEEDING(HYDRAULIC BRAKE SYSTEM) ......................................................................... 3-17
STEERING ADJUSTMENT .......................................................................................................... 3-18
TIRE INSPECTION ........................................................................................................................ 3-19
WHEEL INSPECTION ................................................................................................................... 3-20
FRONT FORK INSPECTION ......................................................................................................... 3-20
REAR SHOCK ABSORBER INSPECTION .................................................................................... 3-20
SEAT LOCK CABLE ADJUSTMENT ........................................................................................... 3-20
ELECTRICAL ..................................................................................................................................... 3-21
BATTERY INSPECTION ............................................................................................................... 3-21
FUSE INSPECTION ...................................................................................................................... 3-26
HEADLIGHT BEAM ADJUSTMENT ............................................................................................ 3-27
HEADLIGHT BULB REPLACEMENT ............................................................................................ 3-27
TAILLIGHT BULB/REAR FLASHER BULB REPLACEMENT ....................................................... 3-28
TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT ........................................................... 3-28
LICENCE LIGHT BULB REPLACEMENT...................................................................................... 3-29
CHAPTER 4.
ENGINE
ENGINE OVERHAUL ......................................................................................................................... 4-1
WIREHARNESS AND CABLES ...................................................................................................... 4-1
CYLINDER HEAD, CYLINDER AND PISTON .................................................................................... 4-3
CYLINDER HEAD CYLINDER AND PISTON ................................................................................. 4-3
PISTON PIN AND PISTON REMOVAL .......................................................................................... 4-4
CYLINDER HEAD INSPECTION ..................................................................................................... 4-4
CYLINDER AND PISTON INSPECTION ........................................................................................ 4-5
PISTON RINGS INSPECTION ........................................................................................................ 4-7
PISTON PIN AND PISTON PIN BEARING .................................................................................... 4-7
PISTON PIN AND PISTON INSTALLATION ................................................................................. 4-8
CYLINDER AND CYLINDER HEAD ................................................................................................ 4-9
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHAVE ............................................................. 4-11
KICK STARTER AND CRANKCASE COVER(LEFT)..................................................................... 4-11
KICK STARTER ............................................................................................................................. 4-12
KICK STARTER INSTALLATION ................................................................................................. 4-13
V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................ 4-14
SECONDARY SHEAVE ................................................................................................................ 4-15
PRIMARY SHEAVE REMOVAL .................................................................................................... 4-16
SECONDARY SHEAVE REMOVAL.............................................................................................. 4-16
CLUTCH INSPECTION ................................................................................................................. 4-17
V-BELT INSPECTION ................................................................................................................... 4-18
PRIMARY SHEAVE INSPECTION ................................................................................................ 4-19
SECONDARY SHEAVE ................................................................................................................ 4-20
SECONDARY SHEAVE INSTALLATION ..................................................................................... 4-21
PRIMARY SHEAVE ...................................................................................................................... 4-22
STARTER CLUTCH AND STARTER MOTOR ................................................................................. 4-24
STARTER CLUTCH AND STARTER MOTOR.............................................................................. 4-24
STARTER CLUTCH AND GEARS ................................................................................................ 4-26
C.D.I. MAGNETO ............................................................................................................................. 4-27
C.D.I. MAGNETO ......................................................................................................................... 4-27
C.D.I. MAGNETO REMOVAL ....................................................................................................... 4-28
C.D.I. MAGNETO INSTALLATION .............................................................................................. 4-28
AUTOLUBE PUMP ........................................................................................................................... 4-29
AUTOLUBE PUMP ....................................................................................................................... 4-29
AUTOLUBE PUMP INSTALLATION ........................................................................................... 4-30
TRANSMISSION .............................................................................................................................. 4-31
TRANSMISSION .......................................................................................................................... 4-31
CRANKCASE AND REED VALUE ................................................................................................... 4-33
CRANKCASE AND REED VALUE ................................................................................................ 4-33
CRANKCASE(RIGHT)REMOVAL ................................................................................................. 4-35
REED VALVE INSPECTION ......................................................................................................... 4-35
CRANKCASE(RIGHT)INSTALLATION ........................................................................................ 4-36
CRANKSHAFT .................................................................................................................................. 4-38
CRANKSHAFT .............................................................................................................................. 4-38
CRANKSHAFT REMOVAL ........................................................................................................... 4-39
CRANKSHAFT INSPECTION ....................................................................................................... 4-39
CRANKSHAFT INSTLLATION ..................................................................................................... 4-40
CHAPTER 5
CARBURETION
CARBURETION .................................................................................................................................. 5-1
CARBURETOR ................................................................................................................................ 5-1
CARBURETOR DISASSEMBLY ..................................................................................................... 5-2
CARBURETOR INSPECTION ......................................................................................................... 5-3
CARBURETOR ASSEMBLY ........................................................................................................... 5-3
FUEL LEVEL ADJUSTMENT ......................................................................................................... 5-4
AUTO CHOKE INSPECTION .......................................................................................................... 5-5
FUEL COCK INSPECTION ............................................................................................................. 5-6
CHAPTER 6
CHASSIS
FRONT WHEEL AND BRAKE DISC ................................................................................................... 6-1
FRONT WHEEL AND BRAKE DISC ............................................................................................... 6-1
FRONT WHEEL DISASSEMBLY .................................................................................................... 6-2
FRONT WHEEL DISASSEMBLY .................................................................................................... 6-3
FRONT WHEEL INSPECTION ........................................................................................................ 6-3
BRAKE DISC INSPECTION ............................................................................................................ 6-4
FRONT WHEEL ASSEMBLY .......................................................................................................... 6-4
FRONT WHEEL INSTALLATION ................................................................................................... 6-5
WHEEL STATIC BALANCE ADJUSTMENT .................................................................................. 6-6
FRONT BRAKE ................................................................................................................................... 6-8
BRAKE PAD .................................................................................................................................... 6-8
BRAKE PAD REPLACEMENT ........................................................................................................ 6-9
MASTER CYLINDER ........................................................................................................................ 6-12
MASTER CYLINDER DISASSEMBLY ............................................................................................. 6-13
MASTER CYLINDER INSPECTION.............................................................................................. 6-14
MASTER CYLINDER ASSEMBLY................................................................................................ 6-14
MASTER CYLINDER INSTALLATION ......................................................................................... 6-15
CALIPER ........................................................................................................................................... 6-17
CALIPER DISASSEMBLY ................................................................................................................. 6-18
BRAKE CALIPER DISASSEMBLY ................................................................................................ 6-19
CALIPER INSPECTION ................................................................................................................. 6-19
BRAKE CALIPER ASSEMBLY ...................................................................................................... 6-20
CALIPER INSTALLATION ............................................................................................................ 6-20
REAR WHEEL AND REAR BRAKE .................................................................................................. 6-21
REAR WHEEL AND REAR BRAKE ............................................................................................... 6-21
REAR WHEEL ............................................................................................................................... 6-21
REAR BRAKE ................................................................................................................................ 6-22
REAR WHEEL INSPECTION ........................................................................................................ 6-23
REAR BRAKE INSPECTION ......................................................................................................... 6-23
REAR BRAKE INSTALLATION .................................................................................................... 6-24
HANDLEBAR .................................................................................................................................... 6-25
HANDLEBAR ................................................................................................................................ 6-25
HANDLEBAR INSTALLATION ..................................................................................................... 6-27
STEERING ........................................................................................................................................ 6-29
STEERING .................................................................................................................................... 6-29
STEERING REMOVAL ................................................................................................................. 6-30
STEERING INSPCTION ................................................................................................................ 6-31
STEERING INSTALLATION ......................................................................................................... 6-31
FRONT FORK ................................................................................................................................... 6-34
FRONT FORK ............................................................................................................................... 6-34
FRONT FORK DISASSEMBLY ......................................................................................................... 6-35
FRONT FORK REMOVAL ............................................................................................................. 6-36
FRONT FORK DISASSEMBLY ..................................................................................................... 6-36
FRONT FORK INSPECTION ......................................................................................................... 6-37
FRONT FORK ASSEMBLY ........................................................................................................... 6-37
FRONT FORK INSTALLATION .................................................................................................... 6-39
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS ........................................................................................................... 7-1
CIRCUIT DIAGRAM ....................................................................................................................... 7-2
CHECKING SWITCHES ..................................................................................................................... 7-4
CHECKING STEPS ........................................................................................................................ 7-4
SWITCH CONNECTION AS SHOWN IN THIS MANUAL ............................................................... 7-4
SWITCH POSITION AND TERMINAL CONNECTION ..................................................................... 7-5
IGNITION SYSTEM ........................................................................................................................... 7-6
CIRCUIT DIAGRAM ....................................................................................................................... 7-6
TROUBLESHOOTING ................................................................................................................... 7-7
CHARGING SYSTEM ...................................................................................................................... 7-10
CIRCUIT DIAGRAM ..................................................................................................................... 7-10
TROUBLE SHOOTING ................................................................................................................ 7-11
ELECTRIC STARTING SYSTEM ..................................................................................................... 7-14
CIRCUIT DIAGRAM ..................................................................................................................... 7-14
TROUBLE SHOOTING ................................................................................................................ 7-15
STARTER MOTOR .......................................................................................................................... 7-19
STARTER DISASSEMBLY .......................................................................................................... 7-20
JOB INSTRUCTION CHART ....................................................................................................... 7-20
INSPECTION AND REPAIR ......................................................................................................... 7-21
LIGHTING SYSTEM ........................................................................................................................ 7-23
CIRCUIT DIAGRAM ..................................................................................................................... 7-23
TROUBLESHOOTING ................................................................................................................. 7-24
SIGNAL SYSTEM ............................................................................................................................ 7-29
CIRCUIT DIAGRAM ..................................................................................................................... 7-29
SIGNAL SYSTEM CHECK ........................................................................................................... 7-32
AUTO CHOKE SYSTEM ................................................................................................................. 7-38
CIRCUIT DIAGRAM ..................................................................................................................... 7-38
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ........................................................................................... 8-1
FUEL SYSTEM ............................................................................................................................... 8-1
IGNITION SYSTEM ........................................................................................................................ 8-2
COMPRESSION SYSTEM ............................................................................................................. 8-2
POOR IDLE SPEED PERFORMANCE ................................................................................................ 8-3
POOR IDLE SPEED PERFORMANCE ............................................................................................ 8-3
POOR MEDIUM AND HIGH SPEED PERFORMANCE ...................................................................... 8-3
POOR MEDIUM AND HIGH SPEED PERFORMANCE .................................................................. 8-3
FAULTY AUTOMATIC(V-BELT TYPE) .............................................................................................. 8-4
SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING .................................................. 8-4
CLUTCH OUT FAILURE ................................................................................................................. 8-4
POOR STANDING START(LOW CLIMBING ABILITY) ................................................................. 8-4
POOR ACCELERATION(POOR HIGH SPEED) .............................................................................. 8-4
OVERHEAT/POOR SPEED ................................................................................................................ 8-5
OVERHEAT ..................................................................................................................................... 8-5
POOR SPEED ..................................................................................................................................... 8-5
POOR SPEED ................................................................................................................................. 8-5
IMPROPER KICKING .......................................................................................................................... 8-6
SLIPPING ........................................................................................................................................ 8-6
HARD KICKING .............................................................................................................................. 8-6
KICK CRANK NOT RETURNING ................................................................................................... 8-6
FAULTY BRAKE ................................................................................................................................. 8-7
POOR BRAKING EFFECT ............................................................................................................... 8-7
MALFUNCTION ............................................................................................................................. 8-7
INSATABLE HANDLING .................................................................................................................... 8-8
INSATABLE HANDLING ................................................................................................................ 8-8
FAULTY SIGNAL AND LIGHTING SYSTEM .................................................................................... 8-9
HEADLIGHT DARK ......................................................................................................................... 8-9
BULB BURNT OUT ........................................................................................................................ 8-9
FLASHER DOES NOT BLINK ......................................................................................................... 8-9
FLASHER KEEPS ON ..................................................................................................................... 8-9
FLASHER BLINKS SLOWER ........................................................................................................ 8-10
FLASHER BLINKS QUICKER ....................................................................................................... 8-10
HORN DOES NOT SOUND ......................................................................................................... 8-10
WIRING DIAGRAM
SCOOTER INDENTIFICATION
GEN
INFO
GENERAL INFORMATION
SCOOTER IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number 1 is stamped into the
plate on the frame.
Initial serial number:
YW100E1(I)
*LPRSB0210*
*00000101*
YW100E1(F)
*LPRSB0210*
*00000101*
YW100E2(I)
*LPRSB0220*
*00100101*
YW100E2(F)
*LPRSB0220*
*00100101*
YW100E3(G)
*LPRSB0210*
*00300101*
YW100E4(G)
*LPRSB0220*
*00400101*
YW100E5(P)
*LPRSB0210*
*00200101*
YW100E5(Es)
*LPRSB0210*
*00200101*
YW100E6(A)
*LPRSB0210*
*00500101*
YW100E7(Che)
*LPRSB0210*
*00600101*
YW100E8(Che)
*LPRSB0220*
*00700101*
1-1
SCOOTER INDENTIFICATION
GEN
INFO
ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into
the transmission case.
Initial serial number:

YW100E1(I,F):
B103E-000101
YW100E2(I,F):
B103E-100101
YW100E3(G):
B103E-300101
YW100E4(G):
B103E-400101
YW100E5(P,S):
B103E-200101
YW100E6(A):
B103E-500101
YW100E7(Che):
B103E-600101
YW100E8(Che):
B103E-700101
1-2
GEN
INFO
EB101000
PREPARATION FOR REMOVAL PROCEDURES
1. Remove all dirt, mud, dust and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the SPECIAL TOOLS section.
4. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts
that have been mated through normal
wear. Mated parts must always be reused
or replaced as an assembly.
5. During machine disassembly, clean all
parts and place them in trays in the order
of disassembly. This will speed up assembly and allow for the correct installation
of all parts.
6. Keep all parts away from any source of
fire.
300-008
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication
jobs. Other brands may be similar in function and appearance, but inferior in quality.
300-016
EB101020
GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the
oil seal lips.
1-3
GEN
INFO
EB101030
LOCK WASHERS/PLATES AND COTTER PINS

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

Install bearings and oil seals so that the
manufacturers marks or numbers are visible.
When installing oil seals, apply a light coating
of lightweight lithium base grease to the seal
lips. Oil bearings liberally when installing, if
appropriate.
1 Oil seal
cC
Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassembly. Always replace piston pin clips after
one use. Replace distorted circlips. When
installing a circlip 1 , make sure that the
sharp-edged corner 2 is positioned opposite the thrust 3 it receives. See sectional view.
4 Shaft
1-4
GEN
INFO
EB801000
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
8 Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two

or three.
4. Pull the read to check that it will not come
off.
5. If the terminal comes off, bend up the pin
1 and reinsert the terminal into the connector.
6. Connect:
8 Connector
NOTE:
The two connectors click together.
7. Check for continuity with a tester.
NOTE:
8
8
8
8
1-5
If there is no continuity, clean the terminals.

Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
For a field remedy, use a contact revitalizer
available on the market.
Use the tester on the connector as shown.
HOW TO USE THE CONVERSION TABLE
GEN
INFO
EB201000
HOW TO USE THE CONVERSION TABLE

All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC
MULTIPLIER
IMP
** mm
0.03937
=
** in
2 mm
0.03937
=
0.083 in
CONVERSION TABLE
METRIC TO IMP
Known
Multiplier
Result
m.kg
m.kg
cm.kg
cm.kg
7.233
86.794
0.0723
0.8679
ft.lb
in.lb
ft.lb
in.lb
kg
g
2.205
0.03527
lb
oz
km/h
km
m
m
cm
mm
0.6214
0.6214
3.281
1.094
0.3937
0.03937
mph
mi
ft
yd
in
in
Volume/
Capacity
cc(cm3)
cc(cm3)
lit(liter)
lit(liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu.in
qt(IMP liq.)
gal(IMP liq.)
Miscellaneous
kg/mm
kg/cm2
Centigrade
55.997
14.2234
9/5(C)+32
lb/in
psi(lb/in2)
Fahrenheit (F)
Torque
Weight
Distance
1-6
SPECIAL TOOLS
GEN
INFO
EE102000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this Will help prevent damage caused by the use of inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
90890-01235
Tool name / Usage

Rotor holding tool
This tool is used to remove the flywheel
magneto.
90890-01268
Ringnut wrench
This tool is used to loosen and tighten the
exhaust and steering ringnut.
90890-01337
Clutch spring compressor

These tools are used for removing the nut
with holding the compression spring.
90890 -01274
-01275
-01277
-01288
Crankshaft Installer pot 1

Crankshaft Installer bolt 2
Adapter 3 ,Spacer 4
These tools are used to install the crankshaft.
90890-01189
Flywheel puller
This tool is used for removing the rotor.

90890- 01135
Crankcase Separating tool

This tool is used to remove the crankshaft
or separate the crankcase.
90890-01384
Oil seal guide

This tool is used for protecting the oil seal
lip when installing the secondary sliding
sheave.
90890-01403
Ring nut wrench

steering ring nut.
90890-01701
Sheave holder
This tool is used for holding the secondary
sheave.
90890-03079
Thickness gauge
This tool is used to measure the clearance
1-7
Illustration
SPECIAL TOOLS
Tool No.
90890-03112
GEN
INFO
Illustration
Tool name / Usage

Pocket tester
These instruments are invaluable for checking the electrical system.
90890-03113
Engine tachometer
This tool is needed for detecting engine
rpm.
90890-01409
Oil seal guide

This tool is used to install the left side crankcase oil seal.
90890-01410
Oil seal installer

This tool is used to install the left side crankcase oil seal.
90890-06754
Ignition checker
This instrument is necessary for checking
the ignition system components.
90890-85505
Yamaha bond No. 1215
This sealant (bond) is used for crankcase

mating surface, etc.
90890-01348
Locknut wrench
clutch carrier locknut of the secondary
sheave.
90890-01367 1
-01400 2
Front fork seal driver

Weight 1
Adapter 2
These tools are used when installing the

fork seal.
1-8
GENERAL SPECIFICATION
SPEC
SPECIFICATION
Model
YW100E1/2/3/4/5/6/7/8
Model code:
4VPB/F/G/H/J/K/L/M
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
1,890mm
660mm
1,115mm
765mm
1,270mm
119mm
1,800mm
Basic weight:
With oil and full fuel tank
96kg
Engine:
Engine type
Cylinder arrangement
Displacement
Bore stroke
Compression ratio
Starting system
Lubrication system:
Air cooled 2 strcke, gasoline torque induction

Forward- inclined single cylinder
101cm3
52.0 47.6 mm
6.6:1
Electric and kick starter
Separate lubrication
Oil Type or Grade:

Engine Oil
Transmission Oil
Oil Capacity:
Oil Tank (Engine Oil)
Transmission Oil:
Periodic Oil Change
Total Amount
For YAMAHA brand:

Yamalube 2 or Air cooled 2-stroke engine oil (JASO
FC grade or ISO EG-C, EG-D grade)
For MBK brand:
Semi synthetic oil in accordance to the API TS3
standard
SAE 85W/140
1.4L
0.11L
0.13L
Air Filter:
Wet type element
Fuel:
Type
Tank Capacity
Regular unleaded gasoline

5.7L
Carburetor:
Type / Manufacturer
VM16SS/MIKUNI
2-1
Model
YW100E1/2/3/4/5/6/7/8
Spark Plug:
Type/Manufacturer
Gap
BPR7HS/NGK
0.9 ~ 1.0 mm
Clutch Type
Dry, Centrifugal automatic
Transmission:
Primary Reduction System
Primary Reduction Ratio
Secondary Reduction System
Secondary Reduction Ratio
Transmission Type
Operation
Herical gear
47/15 (3.133)
Spur gear
43/13 (3.308)
V-belt
Automatic
Chassis:
Frame type
Caster angle
Trail
Steel tube underbone

26
86mm
Tire:
Type
Size
front
rear
front
rear
front
rear
Manufacturer
Type
Maximum load*
Cold tire Pressure:
Up to 90 kg
Front
Rear
90 kg load~Maximum load*
Front
Rear
Brake:
Front brake
type
operation
Rear brake
type
operation
SPEC
Tubeless
120/90-10
130/90-10
CHENG SHIN
CHENG SHIN
56J
59J
160 kg
200kpa(2.0 kg/cm2, 2.0 bar)

200kpa(2.0 kg/cm2, 2.0 bar)
200kpa(2.0 kg/cm2, 2.0 bar)
200kpa(2.0 kg/cm2, 2.0 bar)
Single disc brake
Right hand operation
Drum brake
Left hand operation
Suspension:
Front suspension
Rear suspension
Telescopic fork
Unit swing
Shock absorber:
Front shock absorber
Rear shock absorber
Coil spring/oil damper

Coil spring/oil damper
Wheel travel:
Front wheel travel
Rear wheel travel
70 mm
55 mm
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
C.D.I
Flywheel Magneto
YTX5L-BS
12V 4AH
2-2
SPEC
YW100E1/2/3/4/5/6/7/8
Model
Headlight type:
Bulb S1
Bulb wattage x quantity:

Headlight
Tail/brake light
Flasher light
Auxiliary light
Licence plate light
Meter light
High beam indicator light
Oil indicator light
Turn indicator light
25W/25W2
5W/21W1
10W4
5W2
5W1
3.4W1/1.7W1
1.7W1
1.7W1
1.7W1
2-3
MAINTENANCE SPECIFICATION
SPEC
ENGINE
Item
Standard
Cylinder head:
Warp limit
Limit
...
0.05 mm
52.002~52.012
...
...
52.10 mm
0.05 mm
0.03 mm
0.044~0.045 mm
51.958~51.967 mm
10 mm
52.52 mm
52.50 mm
14.004~14.015 mm
0.10 mm
...
...
...
...
...
14.045 mm
13.996~14.000 mm
13.975 mm
*Lines indicate straightedge measurement

Cylinder:
Bore size
Taper limit
Out of round limit
Piston:
Piston to cylinder
clearance
Piston size D
Measuring point H
Oversize 1st
2nd
Piston pin bore
inside diameter
Piston pin outside diameter
H
D
Piston Ring:
Sectional Sketch (B T)/Type
Top Ring
2nd Ring
End Gap (Installed):
Top Ring
2nd Ring
Side Clearance ( Installed):
Top Ring
2nd Ring
1.2 2.05 mm/keystone

1.2 2.05 mm/keystone
0.15~0.35 mm
0.15~0.35 mm
0.10 mm
0.10 mm
0.03~0.05 mm
0.03~0.05 mm
0.60 mm
0.60 mm
37.90~37.95 mm
0.03 mm
...
...
0.2~0.5 mm
0.4~0.8 mm
1.0 mm
...
Crankshaft:
Crank Width A
Run Out Limit C
Connecting Rod Big End Side
Clearance D
Small End Free Play F
2-4
Item
Standard
SPEC
Limit
Automatic centrifugal clutch:

Clutch shoe thickness
Clutch housing inside diameter
Clutch shoe spring free length
Clutch - in revolution
Clutch - stall revolution
4.0 mm
112 mm
26.2 mm
2,800~3,400 r/min
4,500~5,500 r/min
2.5 mm
122.5 mm
...
...
...
V-belt:
V-belt width
17.7 mm
16.0 mm
Transmission:
Main Axle Runout Limit
Drive Axle Runout Limit
0.08 mm
0.08 mm
Kick Starter:
Type
Kick Clip Tension
Ratchet type
150~250 g
Carburetor: Carburador
I.D. Mark
Main Jet
Main nozzle
Jet Needle-clip Position
Main Air Jet
Cutaway
Pilot Jet
Pilot Air Screw
Valve Seat Size
Starter Jet
Float Height
Fuel level height
Engine Idling Speed
4VP-30 (4VPL/M:4VP-40)
#75
E-3
4DM7-3
0.7
3.5
#32.5
1and1/41/4
1.5
#30
16.5 mm
3.0~4.0 mm
1,750~1,850 r/min
(M .J .)
(NJ)
(J.N.)
( M .A .J .)
(C.A.)
(P.J.)
(A.S .)
(V.S.)
(G .S.)
Reed Valve:
Valve Stopper Height
Reed Valve Clearance
6.0~6.4 mm
Less than 0.2 mm
2-5
SPEC
TIGHTENING TORQUES
ENGINE
2-6
M 14
M7
M7
M6
6.0
M6
M5
M6
M6
M4
M6
M8
M6
M6
M6
M6
M6
M6
M6
M6
M8
M 14
M6
M6
M6
M 10
M 12
M6
M 12
1
4
4
3
1
3
2
4
1
2
2
2
3
3
5
6
6
12
2
2
1
1
2
1
2
1
1
2
1
Nm mkg
20
14
17
7
2
7
4
11
9
2
9
26
9
11
13
12
12
12
7
7
18
3
8
9
13
40
45
8
43
2.0
1.4
1.7
0.7
0.2
0.7
0.4
1.1
0.9
0.2
0.9
2.6
0.9
1.1
1.3
1.2
1.2
1.2
0.7
0.7
1.8
0.3
0.8
0.9
1.3
4.0
4.5
0.8
4.3
LT
Nut
Stud bolt
Screw
Screw
Screw
Screw
Bolt
Screw
Screw
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Screw
Screw
Bolt
Plug
Screw
Bolt
Bolt
Nut
Nut
Screw
Nut
Remarks
LT
Spark plug
Cylinder head and cylinder
Cylinder
Air shroud 3
Air shroud 13
Fan
Autolube pump
Reed valve
Air filter
Carburetor cap
Exhaust pipe
Muffler
Exhaust protector
Cap and pipe
Exhaust cover
Crankcase 12
Crankcase cover 2
Crankcase cover 1
Air duct
Crankcase holder
Drain bolt
Oil plug
Idle gear plate
Kick crank
Starter motor
Clutch housing
Primary sheeve
Magnet base
Magnet rotor
Tightening
torque
LT
Part to be tightened
Thread
Qty
Part name
size
SPEC
CHASSIS
Item
Steering system:
Steering bearing type
No /size of steel balls:
Standard
Limit
Ball bearing
22 pcs
19 pcs
...
...
...
Front suspension:
Front fork travel
Fork free length
Fork length (Installed)
Spring rate (K1)
(K2)
Oil capacity
Oil grade
Inner tube vend limit
70 mm
350.8 mm
212.1 mm
15.68 Nm/mm(1.6 kg/mm)
23.5 Nm/mm(2.43 kg/mm)
88 c.c
Fork oil 10W or equivalent
...
...
212.1 mm
...
...
...
...
Rear suspension:
Shock absorber stroke
Shock absorber free length (Installed)
Spring free length (Installed)
Spring rate (K1)
55 mm
281.8 mm
159.8 mm
71.15 N/mm(7.26 kg/mm)
...
...
...
...
radial
lateral
Cast wheel
MT3.5010
Aluminum
...
...
...
...
...
...
1 mm
1 mm
radial
lateral
Cast wheel
MT3.5010
Aluminum
...
...
...
...
...
1 mm
1 mm
Front disc brake:

Type
Disc outside diameter thickness
Pad thickness
Master cylinder inside diameter
Caliper cylinder outside diameter
Brake fluid type
Single
1804.0
6 mm
11 mm
34.93 mm
DOT #4
...
1803.5 mm
0.8 mm
...
...
...
Rear drum brake:

Type
Drum inside diameter
Shoe thickness
Leading, trailing
130 mm
4 mm
...
131 mm
2 mm
Brake lever:
Brake lever free play (front at lever side)
Brake lever free play (rear)
Throttle cable free play
2~5 mm
10~20 mm
3~5 mm
...
...
...
Front wheel:
Type
Rim size
Rim material
Rim runout limit
Rear wheel:
Type
Rim size
Rim material
Rim runout limit
Upper
Lower
2-7
0.2 mm
SPEC
TIGHTENING TORQUES
CHASSIS
Part to be tightened
Frame and engine bracket

Engine bracket, compression rod and engine
Protect bar
Rear grip
Sidestand
Rear shock absorber and frame
Rear shock absorber and engine
Steering ring nut
Handle holder and steering shaft
Brake hose and master cylinder
Fuel tank
Fuel cock
Fuel sender
Box
Seat lock assembly
Plastic parts & cover
Footrest board
Front wheel axle and nut
Rear wheel axle and nut
Rear brake cam lever
Front brake caliper and front fork
Brake disc and hub
Brake hose and front fork(lower)-bolt
Brake hose and front fork(lower)-nut
Brake hose and front fork(upper)-bolt
Brake caliper and bleed screw
M 12
M 10
M6
M6
M 10
M 10
M8
M 25
M 10
M8
M6
M6
M5
M6
M6
M5
M6
M 10
M 14
M6
M8
M10
M6
M6
M6
M5
2-8
Tightening
torque
Nm
mkg
84
45
10
13
55
30
16
22
43
20
10
7
4
4
7
2
7
70
120
10
23
20
5
11
7
6
8.4
4.5
1.0
1.3
5.5
3.0
1.6
2.2
4.3
2.0
1.0
0.7
0.4
0.7
0.7
0.2
0.7
7.0
12.0
1.0
2.3
2.0
0.5
1.1
0.7
0.6
Remarks
See
page6-29
LT
Thread
size
SPEC
ELECTRICAL
Item
Ignition timing:
Ignition timing (B.T.D.C.)
Advanced type
Standard
limit
14 at 5,000 r/min
Electrical type
...
...
400~600 at 20C/
(Black-White/Red)
640~960
(Black/ Red ,Black)
4VP/TIIC
...
...
...
...
...
Ignition coil:
Model/manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
4VP/TIIC
6 mm
0.32~0.48 at 20C
5.68~8.52k at 20C
...
...
...
...
Spark plug cap:

Type
Resistance
Resin type
5 k
...
...
Charging System/Type:
Flywheel magneto
...
4VP/TIIC
12V 85W/5,000 rpm
0.6A at 3,000r/min
1.2A at 8,000r/min
13~14V at 4,000 rpm
0.48~0.72 (White-Black)
0.4~0.6 (Yellow/Red- Black)
12~15V (3,000~8,000 rpm)
...
C.D.I.:
Pickup coil resistance/color
Source coil resistance/color
C.D.I. unit model/manufacturer
C.D.I. Magneto:
Model/Manufacturer
Nominal output
Charging current
Charging voltage
Charging Coil Resistance (Color)
Lighting Coil Resistance (Color)
Lighting Voltage
Rectifier:
Model/Manufacturer
Capacity
Withstand voltage
Battery:
Specific gravity
Electric starter system:
Type
Starter motor:
Model/manufacturer/ID number
Operation voltage
Output
Armature coil resistance
Brush overall length
Brash quantity
Spring force
Commutator diameter
Mica undercut (depth)
Starter relay:
Model/manufacturer
Amperage rating
Coil winding resistance
3GF/Taichung
8A
18V
...
...
...
...
...
...
...
...
...
...
1.320
...
Constant mesh type
...
4VP/TIIC
12V
0.2 kw
0.03~0.04 at 20C
7 mm
2 pcs
400~600g
17.6 mm
1.35 mm
...
...
...
...
3.5 mm
...
400g
16.6 mm
...
3 KW/Shulin
100A
3.87~4.73 at 20C
...
...
...
2-9
Item
SPEC
Standard
limit
Horn:
Model/manufacturer
Maximum amperage
4VP/Asian
1.5A
...
...
Flasher relay:
Type
Flasher frequency
Capacitor
60~120 Cycle/min
...
...
Fuel gage:
Model/manufacturer
Sender unit resistance - full
- empty
4VP/San Chu
4~10
90~100
...
...
...
Oil level gauge:

Model/manufacturer
4VP/Lun Ping
...
Circuit breaker:
Type
MAIN
Fuse
7Ax1pc.
...
...
2-10
GENERAL TORQUE SPECIFICATIONS

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

B: Outside thread diameter
2-11
SPEC
B
(Bolt)
LUBRICATION POINTS AND LUBRICATION TYPE
SPEC
LUBRICATION POINTS AND LUBRICATION TYPE

ENGINE
Lubrication Points (Part name)
Lublicant Type
Oil Seal Lip (All)
LS
O-ring (All)
LS
Small End Bearing
Big End Bearing
Starter Idle Bearing
Primary Drive Gear Bearing
Kick Axle Bearing
Drive Axle Bearing
Main Axle Bearing
Starter Clutch
Piston, Piston Ring Piston Pin and Cylinder
Oil Pump Drive and Driven Gear
LS
Sliding Surface (Secondary Sheave)
BEL-LAY Assembly Lube
Oil Seal and O-ring (Secondary Sheave)
Cam Groove (Secondary Sheave)
Crankcase Matching Surface
Yamaha Bond No. 1215
CHASSIS
Lubrication Points
Lubricant Type
Steering Shaft Bearing
Throttle Grip Inner Surface
LS
Brake Cables End
LS
Brake Cam Shaft and Pin
LS
Wheel Bearing
LS
Speedometer Drive and Driven Gear
LS
Wheel Axles
LS
2-12
CABLE ROUTING
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
q
w
e
Horn
Rectifier regulator
Main switch
Resistor
Headlight leads
Speedometer cable
Ignition coil
Throttle cable
Battery negative(-)
Autolube pump cable
Fuel sender lead
Seat lock cable
Oil tank hose
r
t
y
A
C.D.I. unit
Throttle cable 1
Wire harness
Pass the speedometer cable
through the right hole of front
fender, then through the
guide.
B Pass the wire harness
through the inside of ignition
coil.
C Secure the ground lead and
the ignition coil base to the
ignition coil stay.
D Pass the wire harness
through the inside of oil tank.
2-13
SPEC
E Pass the seat cable through

the inside of frame.
F Align the clip with the white
brand.
G Clamp the wire harness
H Insert the seat cable through
the frame tube.
I Clamp wireharness, autolube
pump cable, rear brake cable
throttle cable 2.
J Position the cylinder between
the supporter and main
switch.
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
q
SPEC
A Pass the brake hose through the holder.

B Insert the fuel overflowhose bottom.
C Pass the fuel overflowhose through the rear
fender hole.
D Pass the fuel overflowhose through the
holder.
E Hold the fuel overflowhose with a clamp.
F Pass the brake cable through the holder.
G Pass the brake cable through the hook.
Brake cable
Speedometer cable
Fuel tank overflow hose
Brake cable holder
Air induct pipe
Brake hose
Brake hose holder
License bracket
Flasher relay
Resistance
Fuel tank breather hose
9
3
B
1
2
C
D
E
7
8
5
F
2-14
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
SPEC
A Pass the brake hose through the holder.
Brake hose
Front fender
Front fork assembly
Nut
Plate washer
Brake hose holder
Flange bolt
Bolt
Brake hose holder
Flange bolt
7
5
1
9
A
0
8
2-15
3
7
5
6
5
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
q
w
e
Ignition coil
Spark plug lead
Starter relay leads
Auto choke leads
Starter relay
Bind
C.D.I. unit
Autolube hose
Seat lock cable
Bracket
Fuel tank breather hose
Bind 2
Cooling pipe
r Battery()lead
t Battery(+)lead
A Pass battery leads through
the slot of footrestboard.
B Cover them after securing
starter relay leads.
C Pass the seat lock cable
through the hole of bracket.
D Pass the fuel tank breath
hose over seat lock cable.
E Clamp carburetor vacuum
hose, fuel hose and fuel
cock vacuum hose.
B 4
6
5
SPEC
F Clamp autochoke leads and

autolube hose on to carburetor
throttle cable.
G Pass the battery leads over frame
member.
H Put fuse box on to footrest board
holder.
I Pass throttle cable2, wireharness,
autolube pump cable, brake cable
through the outside of battery
box.
9
0
C
D
q
t rG
e
F
2-16
wE
CABLE ROUTING
1
2
3
4
5
6
7
8
9
0
SPEC
A Pass brake cable through the slot of bracket.

B Avoid clamping front flasher leads when installing handlebar covers.
C Pass throttle cable1 through between
handlebar and wireharness.
D Hang the wireharness bind on to the bracket.
Flasher relay
Speedometer
Brake cable
Handlebar switch(left)
Front flasher leads
Speedometer cable
Wire harness
Brake hose
Handlebar switch(right)
Throttle cable1
2-17
INTRODUCTION/
PERIODICMAINTENANCE/LUBLICATION INTERVALS
INSP
ADJ
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS

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 to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

BREAK-IN
NO.
ROUTINE
TYPE
1 * Fuel line
Check fuel hoses and vacuum

hose for cracks or damage.
Replace if necessary.
2 * Spark plug
Check condition.
Clean, regap or replace if necessary.
Refer to SPARK
PLUG INSPECTION
3 * Air filter
Clean or replace if necessary.
Same as engine oil
ITEM
Front brake
Check operation, fluide level and

vehicle for fluid leakage.
Correct accordingly.
Replace brake pads if necessary.
Brake fluid DOT 4
EVERY
6,000 km
or
6 months
(whichever
comes first)
12,000 km
or
12months
(whichever
comes first)
INITIAL
(1,000
km)
5 * Rear brake
Check operation.
Adjust brake lever free play and
replace brake shoes if necessary.
6 * Wheels
Check balance, runout and for

damage.
Rebalance or replace if necessary.
7 * Tires
Check tread depth and for damage.

Replace if necesssary.
Check air pressure.
Correct if necessary.
8 * Wheel bearings
Check Bearing for looseness or

damage.
Check bearing play and steering

for roughness.
9 * Steering bearings Correct accordingly.
Lubricate with lithium soap base
greese every 24,000 km or 24
months (whichever comes first).
10 * Chassis fasteners
Make sure that all nuts, bolts and

screws are properly tightened.
Tighten if necessary.
3-1
PERIODICINSPECTION AND ADJUSTMENTS
INSP
ADJ
BREAK-IN
NO.
11 *
ITEM
Sidestand/
centerstand
12 * Sidestand switch
ROUTINE
TYPE
Check operation.
INITIAL
(1,000
km)
Same as engine oil
EVERY
6,000 km
or
6 months
(whichever
comes first)
12,000 km
or
12months
(whichever
comes first)
Check operation.
13 * Front fork
Check operation and for oil leakage.

Correct accordingly.
14 * Rear shock absorber assembly
Check operation and shock absorber for oil leakage.

Replace shock absorber assembly
if necessary.
15 * Carburetor
Check engine idling speed and

starter operation.
Adjust if necessary.
16 * Autolube pump
Check operation.
Correct if necessary.
Bleed if necessary.
17 * Final gear oil
Check oil level and vehicle for oil

leakage.
Change oil at initial 1,000 km and
thereafter every 24,000 km or 24
months.
18 * V-belt
Check for wear and damage.

SAE 85W 140
Items marked with an asterisk (*) require special tools, data and technical skills for servicing. Take
the scooter to a Yamaha/MBK dealer.
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Brake fluid replacement:
1. Replace the brake fluid after disassembling the master cylinder or caliper cylinder. Check the
brake fluid level and add fluid as required.
2. Replace the master cylinder and caliper cylinder oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
3-2
INSP
ADJ
COVER AND PANEL

COVER AND PANEL
SIDECOVER AND SEAT
T.
R.
13Nm(1.3 kg.m)
Order
1.
Job name/Part name

Sidecover and seat removal
Battery box cover
Qty
1
Remarks
Remove the parts in order.
NOTE:
Insert the (-) screwdriver into the slot of
battery cover and pickup then remove.
2.
3.
4.
5.
6.
7.
Seat
Seat hange
Rear carrier
Left side cover
Right side cover
Center cover
1
1
1
1
1
1
3-3
Reverse the removal procedure for installation.
COVER AND PANEL
INSP
ADJ
LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD
T.
R.
10Nm(1.0kg.m)
4
T.
R.
7Nm(0.7kg.m)
3
9
Order
Job name/ part name
1.
2.
3.
4.
5.
6.
7.
8.
9.
Lower cowling, upper cover, leg

shield 1,2 and footrest board removal
Lower cowling
Protector bar
Upper cover
Bolt
Leg shield 1
Main switch cover/ leg shield 2
Battery
Footrest board
Flap
Qty
Remarks
1
1
1
4
1
1/1
1
1
2
3-4
COVER AND PANEL
INSP
ADJ
HANDLEBAR COVER(FRONT AND REAR)

3
1
Order
Job name / Part name
1.
2.
3.
4.
Handlebar cover(Front and Rear) removal.

Mirrors
Front handlebar cover
Rear handlebar cover
Flasher light(Left/Right)
Qty
Remarks
Remove the part in order.
2
1
1
1/1
3-5
ENGINE IDLE SPEED ADJUSTMENT
INSP
ADJ
ENGINE
IDLE SPEED ADJUSTMENT
1. Remove
8 Battery box cover
2. Tighten:
8 Pilot air screw 1
Turn the pilot air screw in until lightly
seated.
3. Loosen:
8 Pilot air screw
Back it out from its lightly seated position.
Pilot air screw turns out:

1and1/41/4
3. Start the engine and let it warm up.
Before starting the engine, be sure to use the

centerstand for safety.
4. Attach:
8 Inductive tachometer 1
To the spark plug lead
Inductive tachometer:
90890-03113
5. Check:
8 Engine idle speed
Out of specificationAdjust.
Engine idle speed:
1,750~1,850 r/min
6. Adjust:
8 Engine idle speed
***************************************
Adjustment steps.
8 Turn the throttle stop screw 1 in or out until
specified idle speed is obtained.
Turn in
Idle speed becomes higher.
Turn out Idle speed becomes lower.
***************************************
3-6
THROTTLE CABLE FREE ADJUSTMENT
INSP
ADJ
THROTTLE CABLE FREE ADJUSTMENT

1. Check:
8 Throttle cable free play a
Free play:
3 ~ 5 mm
***************************************
Throttle cable free play adjustment steps;
NOTE:
Before adjusting the throttle cable free play, the
engine idle speed should be adjusted.
2
3
First step:
8 Remove the adjuster cover 1
8 Loosen the locknut 2 on the throttle cable.
8 Turn the adjuster 3 in or out until the specified free play is obtained.
Turning inFree play is increased.
Turning outFree play is decreased.
8 Tighten the locknuts.
8 Install the adjuster cover
NOTE:
If the free play cannot be adjusted here, adjust
it at the carburetor side of the cable. (second
step)
Second step:
8 Remove the left/right side covers and center
cover.
8 Remove the adjuster cover 1
8 Loosen the lockout 2
8 Turn the adjuster 3 in or out until the specified free play is obtained.
Free play:
1~2 mm
Turn in Free play is increased.
Turn out Free play is decreased.
8 Tighten the lockout.
8 Install the adjuster cover.
8 Install left/right side covers and center cover.
w
After adjusting, turn the handlebar to right and
left and make sure that the engine idling does
3-7 not run faster.
***************************************
AUTOLUBE PUMP AIR BLEEDING/

AUTOLUBE PUMP CABLE ADJUSTMENT
INSP
ADJ
AUTOLUBE PUMP AIR BLEEDING

1. Remove
8 Lower cowling
8 Air shroud 3 1
2. Air bleeding:
8 Pump case and / or oil hose.
***********************************
Air bleeding steps:
8 Place a rag under the autolube pump to catch
the oil.
8 Remove the bleed screw 1.
8 Keep the oil running out until air bubbles disappear.
8 When air bubbles are expelled completely,
tighten the bleed screw.
NOTE:
Check the bleed screw gasket. If damaged, replace with a new one.
*************************************
3. Air bleeding:
8 Pump distributor and/or delivery hose
*************************************
Air bleeding steps:
8 Start the engine.
8 Pull the pump cable 1 all the way out set the
pump stroke to a maximum.
8 Run the engine for 2-3 minutes at 2000 r/ min.
This will completely remove autolube pump
system of air.
*************************************
AUTOLUBE PUMP CABLE ADJUSTMENT
NOTE:
Engine idling speed and throttle cable free play

should be adjusted properly before adjusting
the autolube pump cable.
1. Close the throttle completely.

2. Check:
8 Alignment mark
Out of specificationAdjust autolube
pump Cable.
NOTE:
The mark Ia on the swing plate should be

aligned with the mark Ib on the autolube
pump body.
3-8
SPARK PLUG INSPECTION
3. Adjust:
8 Autolube pump cable
***************************************
Adjustment steps:
8 Remove the adjuster cover 1.
8 Loosen the locknut 3.
8 Turn the adjuster 2 in or out until the alignment mark is specified.
8 Tighten the locknut 3
8 Install the adjuster cover.
***************************************
SPARK PLUG INSPECTION
1. Remove:
8 Battery box cover
2. Inspect:
8 Spark plug type
IncorrectReplace.
INSP
ADJ
Standard spark plug:

BPR7HS/NGK
a
1
3. Inspect:
8 Electrode 1
Wear/DamageReplace.
8 Insulator 2
Abnormal colorReplace.
Normal color is a medium-to-light tan
color.
4. Clean the spark plug with a spark plug
cleaner or wire brush.
5. Measure:
8 Plug gap a
Use a wire gauge or feeler gauge.
Out of specificationRegap.
Spark plug gap:

0.9~1.0 mm
T.
6. Tighten:
20 Nm (2.0 m.kg)
8 Spark plug
7. Install:
8 Battery box cover.
R.
3-9
ENGINE OIL LEVEL INSPECTION
ENGINE OIL LEVEL INSPECTION

1. Inspect:
8 Engine oil level Oil level lowAdd sufficient oil by the following inspection
steps.
1
60
40
80
100
km/h
120
20
10
INSP
ADJ
140
000010
1 OIL indicator light
Engine oil level visual inspection steps:

Turn main switch to *
position.
OIL indicator light does

not comes on.
OIL indicator light

comes on.
Turn main switch to

ON position.
Inspect faulty electrical

circuit, light bulbs etc.
OIL indicator light does

not come on.
OIL indicator light

comes on.
Engine oil level and electrical circuit are OK.
Supply engine oil.
OIL indicator light comes on.
Recommended oil:
For Yamaha:
Yamalube 2 or 2-stroke engine oil
(JASO FC grade or ISO EG-C, EGD grade)
For MBK:
Semi synthetic oil in accordance
to the API TS C3 standard
Total:
1.4L
NOTE:
Install the oil tank filler cap 1 and push it fully
into the filler.
3-10
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
TRANSMISSION OIL REPLACEMENT

1. Warm up the engine for several minutes,
then stop the engine.
2. Place a container under the drain hole.
3. Remove:
8 Oil filler plug 1
8 Drain bolt (with gasket) 2
NOTE:
Drain the transmission oil completely.

While draining, slightly tilt the scooter to
the right and to the left.
New
4. Inspect:
8 Gasket (drain bolt) 4
New
8 O-ring (oil filler plug) 3

DamageReplace.
T.
5. Install:
18 Nm (1.8 m.kg)
8 Drain bolt
6. Fill:
8 Transmission case
R.
Recommended oil:
SAE 85W/140
Oil capacity:
0.13 L
cC
8 Always use the same type of oil; mixing oils
may result in a harmful chemical reaction and
lead to poor performance.
8 Do not allow foreign material to enters the
transmission case.
7. Install:
8 Oil filler plug (with O-ring)
8. Inspect:
8 Oil leaks
8 Oil level
NOTE:
Wipe off any oil spilt on the transmission, tire
or wheel.
3-11
AIR FILTER ELEMENT CLEANING
INSP
ADJ

1. Remove:
8 Battery box cover
2. Remove:
8 Caburetor jont clamp 1
3. Remove:
8 Screw 1
8 Screw(for clamp) 2
8 Air filter 3
1
2
4. Remove:
8 Air filter case 1
8 Air filter element
cC
Never operate the engine with the air filter element removed. This will allow unfiltered air
to enter, causing rapid wear and possible engine damage. Additionally, operation without
the cleaner element will affect carburetor jetting with subsequent poor performance and
possible engine overheating.
Be careful not to have rags or the like blocking
the intake area of the air filter.
5. Inspect:
8 Element 1
DamageReplace.
6. Clean:
8 Air filter element
*************************************
Air filter element cleaning steps:
8 Wash the element gently, but thoroughly in
solvent.
3-12
INSP
ADJ
w
Never use low flash point solvents such as
gasoline to clean the element. Such solvent
may lead to a fire or explosion.
8 Squeeze the excess solvent out of the element and let dry.
cC
Do not twist the element when squeezing the
element.
8 Apply the foam -air filter oil or engine oil .
8 Squeeze out the excess oil.
NOTE:
The element should be wet but not dripping.
7. Install:
8 Air filter
8 Battery box cover
3-13
V-BELT INSPECTION
INSP
ADJ
V-BELT INSPECTION
1. Remove:
8 Air cleaner joint clamp 1
8 Screws(left crankcase cover) 2
8 Crankcase cover(left) 3
1
2
3
2. Inspect
8 V-belt 1
Cracks/Wear/DamageReplace.
Oil or grease adhere to the
V-beltCheck the primary and secondary sheaves.
Refer to ENGINE OVERHAUL - INSPECTION AND REPAIR section in the CHAPTER 4.
3. Measure:
8 V-belt width a
Out of specificationReplace.
Refer to ENGINE OVERHAUL section
in the CHAPTER 4.
V-belt width:
17.7 mm
<Limit> 16.0 mm
NOTE:
Measure the V-belt width on several points.
R.
3-14
T.
4. Install:
8 Crankcase cover(left)
8 Air cleaner joint clamp
12Nm(1.2kg.m)
FRONT BRAKE LEVER FREE PLAY CHECK/REAR BRAKE

LEVER FREE PLAY CHECK/BRAKE PAD INSPECTION
INSP
ADJ
CHASSIS
FRONT BRAKE LEVER FREE PLAY CHECK
1. Check:
8 Front brake lever free play
2~5 mm
w
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 motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in
loss of control and an accident. Inspect and
bleed the system if necessary.
REAR BRAKE LEVER FREE PLAY CHECK

1. Check:
8 Rear brake lever free play a
10 ~ 20 mm
***************************************
Rear brake lever free play adjustment steps:
8 Turn the adjuster 1 in or out until the correct free play is obtained.
***************************************
2
3-15
BRAKE PAD INSPECTION

1. Activate the brake lever.
2. Inspect:
8 Brake pad
Wear indicator 1 nearly contacting
brake discReplace brake pads as a set.
Refer to the BRAKE PAD REPLACEMENT section in the CHAPTER 6.
2 Brake disc
3 Brake pads
BRAKE SHOE INSPECTION/

BRAKE FLUID LEVEL INSPECTION
INSP
ADJ
BRAKE SHOE INSPECTION

1. Activate the brake lever.
2. Inspect:
8 Wear indicator 1
Indicator at wear limit line 2Replace
brake shoes.
1
2
BRAKE FLUID LEVEL INSPECTION

NOTE:
Position the scooter straight up when inspecting the fluid level.
1. Inspect:
8 Fluid level is under LOWER level line
1Fill to proper level.
Recommended fluid:
DOT#4
cC
The fluid may corrode painted surfaces or plastic parts. Always clean up spilled fluid immediately.
w
8Use only the designated quality fluid. Otherwise ,the rubberseals may deteriorate causing leakage and poor brake performance.
8Refill with the same type of fluid. Mixing fluids may result in a harmful chemical reaction
leading to poor brake performance.
8Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and
may result in vapor lock.
3-16
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
INSP
ADJ
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

1. Bleed:
8 Brake fluid
***************************************
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic tube 1 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 in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever to travel towards its limit.
h. Tighten the bleed screw when the limit
has been reached, then release the lever.
i. Repeat steps (e) to (h) until the air bubbles
have been removed from the system.
j. Add brake fluid to proper level.
w
Check the operation of the brake after bleeding the brake system.
*************************************
3-17
INSP
ADJ
STEERING ADJUSTMENT
5
3
2
STEERING ADJUSTMENT
1. Check:
8 Steering assembly bearings
Gap the bottom of the forks and gently
rock the fork assembly back and forth.
LoosenAdjust.
***************************************
Adjustment steps:
8 Remove upper cover, lower cowling, leg
shield 1,2. refer to COVER AND PANEL section.
8 Remove all ringnuts using ringnut wrench.
Ring nut wrench:

90890-01403
8 Tighten the ring nut 3 1 using nut wrench.
T.
R.
28 Nm(2.8 kg.m)
NOTE:
Set the torque wrench to the ring nut wrench
so that they form a right angle.
8 Loosen the ring nut 3 1 1/4 turn.
8 Install rubber ring 2 and ring nut 2 3, then
tighten the ring nut 2 until it contacts with
rubber ring.
cC
Aligning the slot of ring nut 2 with the slot of
ring nut 3. If not, slightly tighten ring nut 2 until the slots alignment.
8 Install special washer 4
NOTE:
Insert the projections of special washer into the
slots of ring nut 3, 2
T.
8 Install ring nut 1 5

66Nm(6.6 kg.m)
8 Move the handlebar up and down, and/or
back and forth. If handlebar play is excess,
remove the front fork assembly and check
the balls/ball races. Refer to chapter 6.
***************************************
R.
3-18
TIRE INSPECTION
TIRE INSPECTION
FRONT
Manufacturec
CHENG SHIN
Size
120/90-10
Type
8 Do not attempt to use tubeless tires on a

wheel designed for tube type tires only.
Tire failure and personal injury may result
from sudden deflation.
56J
FRONT
Manufacturec
CHENG SHIN
INSP
ADJ
Size
130/90-10
Type
59J
Wheel
Tire
Tube type
Tube type only
Tubeless type
Tube type or
tubeless type
8 Be sure to install the correct tube when using tube type tires.
1. Measure:
8 Air pressure
Maximum load*
Cold tire pressure
Up to 90 kg
90 kg load~ Maximum
load
160 kg
Front
Rear
200 kpa(2.00 kg/cm 2,
2.00 bar)
* Load is the total weight of cargo, rider, passenger and accessories.

2. Inspect:
8 Tire surfaces
Wear/DamageReplace.
Minimum tire tread depth 1
(front and rear):
1.6 mm (0.06 in)
1 Tread depth
2 Side wall
3 Wear indicator
3-19
WHEEL INSPECTION/FRONT FORK INSPECTION

REAR SHOCK ABSORBER INSPECTION/SEAT LOCK CABLEADJUSTMENT
INSP
ADJ
WHEEL INSPECTION
1. Inspect:
8 wheels
Damage/BendsReplace.
w
Never attempt even small repairs to the wheel.
FRONT FORK INSPECTION

1. Inspect:
8 Front fork1
Bends/DamageReplace inner tube
comp, fork assy.
Grease leakageReplace inner tube
comp. fork assy.
Unsmooth operationReplace fork
assy.
REAR SHOCK ABSORBER INSPECTION

1. Inspection:
8 Rear shock absorber1
Oil leaks/DamageReplace.
2. Check
8 Tightening torque
Upper(nut)
T.
R.
30Nm (3.0 m.kg)
Lower (bolt) 16 Nm(1.6 m.kg)
SEAT LOCK CABLE ADJUSTMENT

1. Remove:
8 Protector bar
8 Upper cover
Refer to COVER AND PANEL section.
2. Adjust:
8 Seat cable
***************************************
Seat cable adjustment steps:
8 Loosen lock nut 1
8 Turn adjuster 2 in or out to adjust the seat
lock cable.
8 Tighten the lock nut.
***************************************
3. Install:
8 Upper cover
8 Protector bar
1
2
3-20
BATTERY INSPECTION
INSP
ADJ
ELECTRICAL
BATTERY INSPECTION
NOTE:
Since the MF battery is of a sealed-type construction, it is impossible to measure the specific gravity of the electrolyte in order to check
the state of charge in the battery. Therefore, to
check the state of charge in the battery, voltage must be measured at the battery terminals.
cC
CHARGING METHOD
8 This battery is sealed type. Never remove
sealing caps even when charging. With the
sealing cap removed, this balancing will not
be maintained, and battery performance will
lower gradually.
8 Never add water. If distilled water is added,
chemical reaction in the battery will not proceed in the normal way, thus making it impossible for the battery to operate regularly.
8 The charging time, charging current and
charging voltage for the MF battery is different than general type batteries.
The MF battery should be charged as instructed in the Charging method. Should
the battery be overcharged, the electrolyte
level will lower extremely. Therefore, use
special care when charging the battery.
8 Avoid using any electrolyte other than specified. The specific gravity of the MF battery
electrolyte is 1.32 at 20C (68F). (The specific gravity of the general type battery electrolyte is 1.28. ) If the electrolyte whose specific gravity is less than 1.32, the sulfuric acid
will decrease and thus low battery performance will result.
Should any electrolyte, whose specific gravity is 1.32 or more, be used, the battery plates
will corrode and battery life will shorten.
1. Remove:
8 Battery box cover
2. Remove:
8 Battery
NOTE:
3-21
Remove the () lead first.
BATTERY INSPECTION
INSP
ADJ
w
Battery electrolyte is dangerous; it contains
sulfuric acid and therefore is poisonous and
highly caustic.
Always follow these preventive measures:
8 Avoid bodily contact with electrolyte as it can
cause severe burns or permanent eye injury.
8 Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
8 SKIN-Flush with water.
8 EYES-Flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
8 Drink large quantities of water or milk follow with milk of magnesia, beaten egg, or
vegetable oil. Get immediate medical attention .
Batteries also generate explosive hydrogen
gas, therefore you should always follow
these preventive measures:
8 Charge batteries in a well-ventilated area.
8 Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
8 DO NOT SMOKE When charging or handling
batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
3. Check:
8 Battery condition
***************************************
Battery condition checking steps:
8 Connect a digital volt meter to the battery terminals.
Volt meter
12.8V
Tester (+) lead Battery (+) terminal.

Tester (-) lead Battery () terminal.
Open-circuit voltage
(v)
13.0
Relationship between open-circuit

voltage and charging time 20C(68C)
NOTE:
The state of a discharged MF battery can be
checked by measuring open circuit voltage (the
voltage measured with the positive terminals
being disconnected).
12.5
12.0
11.5
5 6.5
10
Charging time(hours)
This varies depending on the temperature, the state of
charge in battery plates and the electrolyte level.
3-22
BATTERY INSPECTION
Open circuit voltage Charging time
Ambient
temperature
20C
13
12.8 v or more
No charging is necessary.
12
8 Check the battery condition using figures.

EXAMPLE:
Open circuit voltage = 12.0v
Charging time = 6.5 hours
Condition of charge in battery = 20 ~ 30%
***************************************
2. Charging method of MF battery
11
10
100
75
50
30 25 20
Condition of charge in battery(%)
cC
8 If it is impossible to set the standard charging current, be careful not to overcharge.
8 When charging the battery, be sure to remove it from the motorcycle. (If charging has
to be done with the battery mounted on the
motorcycle for some reason, be sure to disconnect the wire at the negative terminal.)
8 Never remove the sealing plug from the MF
battery.
8 Use special care so that charging clips are in
a full contact with the terminal and that they
are not shorted. (A corroded clip of the
charger may cause the battery to generate
heat at the contact area. A weak clip spring
may cause sparks.)
8 Before removing the clips from the battery
terminals, be sure to turn off the power
switch of the charger.
8 Change in the open-circuit voltage of the MF
battery after being charged is shown below.
As shown in the figure, the open circuit voltage is stabilized 30 minutes after charging
has been completed.
Therefore, to check the condition of the battery, measure the open-circuit voltage 30
minutes after has been completed.
Ambient temperature
20C
Charging
Open-circuit voltage(v)
Open-circuit voltage(v)
14
INSP
ADJ
18
17
16
15
14
13
12
11
10
0
10
20
30
40
Time(Minutes)
Check the open-circuit
voltage
3-23
BATTERY INSPECTION
INSP
ADJ
Charging method using a variable-current (voltage) type charger

Charger
AMP
meter
Measure the open-circuit voltage prier to charging.

Connect a charger and AMP
meter to the battery and start
charging.
YES
NOTE:
Voltage should be measured
30 minutes after the machine
is stopped.
NOTE:
Set the changing voltage at
16-17 V. (If the setting is lower,
charging Will be insufficient.
If too high, the battery Will be
over-charged.)
Make sure the current is higher

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

adjust dial, set the charging voltage at 20 - 25 V.
Adjust the voltage so that current
is at standard charging level.
YES
Monitor the amperage for 3-5

minutes to check if the standard
charging current is reached.
NO
Set the timer according to the

charging time suitable for the
open-circuit voltage. Refer to
Battery condition checking
steps.
If current does
not exceed standard charging
current after 5
minutes, replace
the battery.
In case that charging requires more than 5 hours, it is advisable to

check the charging current after a lapse of 5 hours. If there is any
change in the amperage, readjust the voltage to obtain the standard
charging current.
Measure the battery open-circuit voltage after having left the battery unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under12.0 V --- Replace the battery.
3-24
BATTERY INSPECTION
INSP
ADJ
Charging method using a constant-voltage type charger
Charger
Measure the open-circuit voltage prier to charging.
NOTE:
Voltage should be measured 30 minutes after the machine is stopped.
AMP meter
Volt meter
Connect a charger and AMP

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

than the standard charging
current written on the battery.
Charge the battery until the

batterys charging voltage is 15
volts.
NO
This type of battery charger Can

not charge the MF battery. A
variable voltage charger is recommended.
NOTE:
Set the charging time at 20 hours
(maximum).
Check the open-circuit voltage after having left the battery for 30 minutes
after charging.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is necessary.
Under 12 V --- Replace the battery.
Charging method using a constant current type charger

This type if battery charger Can not charge the MF battery.
3-25
FUSE INSPECTION
INSP
ADJ
4. Inspect:
8 Battery terminal
Dirty terminalClean with wire brush.
Poor connectionCorrect.
NOTE:
After cleaning terminals, apply lightly to the
terminals.
5. Install
8 Battery
8 Battery box cover
FUSE INSPECTION
1. Remove:
8 Battery box cover
2. Remove:
8 Fuse 1
3. Inspect:
8 Fuse 1
defectiveReplace
***************************************
Blown fuse procedure steps:
8 Turn off ignition and the circuit.
8 Install a new fuse of proper amperage.
8 Turn on switches to verify operation of electrical device.
8 If fuse blows immediately again, check circuit in question.
***************************************
w
Do not use fuses of higher amperage rating
than recommended. Extensive electrical system damage and fire could result from substitution of a fuse of improper amperage.
Description
Main
Amperage
7A
4. Install:
8 Fuse
8 Battery box cover
3-26
Quantity
1
HEADLIGHT BEAM ADJUSTMENT

/HEADLIGHT BULB REPLACEMENT
INSP
ADJ
HEAD LIGHT BEAM ADJUSTMENT

1. Adjust:
8 Head light (vertically)
Turn the adjusting screw in or out to
adjust headlight beam.
HEADLIGHT BULB REPLACEMENT

1. Remove:
8 Protector bar
8 Upper cover
2. Remove:
8 Headlight leads coupler 1
3. Remove:
8 Bulb holder 1
Turn the bulb holder counterclockwise
to remove it.
4. Remove:
8 Bulb(defective)1
Push bulb in and turn it counterclockwise to remove it
w
Keep flamble products and your hand away
from the bulb while it is on, since it is very
hot. Do not touch the bulb until it cools down.
3-27
TAILLIGHT BULB / REAR FLASHER BULB REPLACEMENT

FRONT FLASHER BULB REPLACEMENT
INSP
ADJ
5. Install:
8 Bulb(new)
cC
Avoid touching the glass part of bulb. keep it
free from oil; oil could adversely and illuminous
flux. If oil gets on bulb, clean it with a cloth
thoroughly moistened with alcohol or lacquer
thinner.
6. Install:
8 Bulb holder
7. Connect:
8 Headlight leads coupler
8. Install:
8 Upper
8 Protector bar
9. Adjust:
8 Headlight beam
Refer to HEADLIGHT BEAM
ADJUSTMENTsection
TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT

1. Remove:
8 Lense 1
8 Bulb 2
2. Replace:
8 Bulb 2
3. Install:
8 Lense 1
2
1
1
2
3-28
TAILLIGHT BULB / REAR FLASHER BULB REPLACEMENT

FRONT FLASHER BULB REPLACEMENT
INSP
ADJ
cC
Do not over-tighten the screws as the lense
may break.
2
LICENSE LIGHT BULB REPLACEMENT

1. Remove:
8 Lense 1
8 Bulb 2
2. Replace:
8 Bulb (defective) 2
3. Install:
8 Lense 1
2
1
3-29
ENG
ENGINE REMOVAL
EB400000
ENGINE OVERHAUL
ENGINE REMOVAL
WIREHARNESS AND CABLES
T.
R.
120Nm(12.0kg.m)
9
T.
R.
14
45Nm(4.5kg.m)
13
10
11 12
2
4
5
7
15
Order
Job name/Part name
Qty
Wireharness and cables removal

Rear carrier
Tail cover
Left side panel
Right side panel
Battery box cover
Center cowling
Air filter case
Carburetor
1
2
3
4
Remarks
Refer to COVER AND PANEL section

in CHAPTER 3.
Refer to CARBURETOR section in

CHAPTER 6.
1
1
1
1
Air shroud 3
Rear fender screw
Autolube delivery hose
Autolube pump cable
4-1
ENG
ENGINE REMOVAL
T.
R.
120Nm(12.0kg.m)
9
T.
R.
14
45Nm(4.5kg.m)
13
10
11 12
2
4
5
7
15
Order
Job name/Part name
Qty
5
6
7
8
9
Spark plug cap

Battery (-) lead
C.D.I magneto leads coupler
Starter motor leads coupler
Rear wheel nut
1
1
1
1
1
10
11
12
13
14
15
Rear brake adjuster

Rear brake cable
Pin
Bolt
Engine mount bolt
Engine
1
1
1
1
1
1
Remarks
NOTE:
Loosen the rear wheel nut.
Reverse the removal procesure for installation.
4-2
CYLINDER HEAD, CYLINDER AND PISTON
ENG

T.
R.
26Nm(2.6kg.m)
10 New 1
5
New
3
6 New
T.
R.
12Nm(1.2kg.m)
T.
R.
14Nm(1.4kg.m)
8
9
E
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Qty
Cylinder head, Cylinder and piston

removal
Engine
Muffler/Gasket
Air shroud (cylinder head)
Spark plug
Cylinder head/Cylinder head gasket
Cylinder
Piston pin clip
Piston pin/ Bearing
Piston
Piston ring set
Cylinder gasket
Remarks
Remove the parts in the order.
1/1
1
1
1/1
1
2
1/1
1
1
1
Refer to the ENGINE REMOVAL section
4-3
CYLINDER HEAD, CYLINDER, PISTON
ENG
PISTON PIN AND PISTON REMOVAL

1. Remove:
8 Piston pin clip 1
NOTE:
Before removing the piston pin clip, cover the
crankcase with a clean rag so you will not accidentally drop the clip into the crankcase.
2. Remove:
8 Piston pin 1
8 Piston 2
8 Piston pin bearing 3
cC
Do not use a hammer to drive the piston pin
out.
CYLINDER HEAD INSPECTION

1. Eliminate:
8 Carbon deposits
Use a rounded scrapper 1.
1
2
2. Inspect:
8 Cylinder head warpage
Out of specificationRe-surface.
*************************************
Warpage measurement and re-surfacement
steps:
8 Attach a straight edge 1 and a thickness
gauge 2 on the cylinder head.
8 Measure the warpage limit.
Warpage limit:
0.05 mm
8 If the warpage is out of specification, reface
the cylinder head.
NOTE:
Rotate the head severai tires to avoid removing too much material from one side.
4-4 *************************************
CYLINDER AND PISTON INSPECTION
ENG
CYLINDER AND PISTON INSPECTION

1. Eliminate:
8 Carbon deposits
Use a rounded scraper 1.
2. Inspect:
8 Cylinder wall
Wear/ScratchesRebore or replace.
3. Eliminate:
8 Carbon deposits 1
From the piston crown and ring
grooves.
4. Remove:
8 Score markes and lacquer deposits
From the sides of piston.
5. Inspect:
8 Piston wall
Wear/Scratches/DamageReplace.
D1
D3
D5
6. Measure:
8 Piston-to cylinder clearance
*************************************
Piston to cylinder clearance measurement
steps: First step:
8 Measure the cylinder bore C with a cylinder bore gauge.
NOTE:
D2
Measure the cylinder bore C in parallel to and

at right angles to the crankshaft. Then, find the
average of the measurements.
D4
D6
4-5
ENG
Standard
Cylinder bore
C
Wear limit
52.002~52.012mm 52.10 mm
Taper T
Out of round
R
0.05 mm
0.03 mm
C = Maximum D
T=( Maximum D1 or D2 ) - ( Maximum D5 or
D6 )
R=( Maximum D1 D3 or D5 ) - ( Maximum D2
D4 or D6 )
8 If out of specification, rebore or replace cylinder, and replace piston and piston rings
as a set.
2nd step:
8 Measure the piston skirt diameter p with
a micrometer.
a 10 mm from the piston bottom edge.
Piston size P
a
Standard
Oversize 1
Oversize 2
51.958~51.967 mm
52.25 mm
52.50 mm
8 If out of specification, replace piston and piston rings as a set.

3rd step:
8 Calculate the piston-to cylinder clearance
with following formula:
Piston-to cylinder clearance = Cylinder bore
C - Piston skirt diameter p
8 If out of specification, rebore or replace cylinder, and replace piston and piston rings as
a set.
Piston-to cylinder clearance:
0.044~0.045mm
Limit : 0.1 mm
4-6
ENG
PISTON RINGS INSPECTION

1. Measure:
8 Side clearance
Out of specificationReplace piston
and/or rings.
Use a feeler gauge 1
Standard
Limit
Top ring 0.03 ~ 0.05 mm
0.60 mm
2nd ring
0.60 mm
0.03 ~ 0.05 mm
2. Install:
8 Piston ring
Into the cylinder
Push the ring with the piston crown.
3. Measure:
8 End gap
Out of specificationReplace rings as
a set.
Use a feeler gauge 1.
Standard
Limit
Top ring 0.15 ~ 0.35 mm
0.10 mm
2nd ring
0.10 mm
0.15 ~ 0.35 mm
a Measuring Point 20 mm
4. Oversize piston ring size:
Ring size is stamped on top of the ring.
Oversize piston ring
Oversize 1
25
Oversize 2
50
PISTON PIN AND PISTON PIN BEARING

1. Inspect:
8 Piston pin
Blue discoloration/GrooveReplace,
then inspect lubrication system.
4-7
ENG
2. Measure:
8 Outside diameter a (piston pin)
Out side diameter (piston pin):
13.996~14.000 mm
3. Measure:
8 Piston pin-to-piston clearance
Out of specificationReplace piston.
Piston pin-to-piston clearance =

Bore size (piston pin)
Outside diameter (piston pin)
Piston pin-to-piston clearance:
0.008~0.015 mm
<Limit: 0.07 mm>
4. Inspect:
8 Bearing(piston pin)
Pitting/DamageReplace.
PISTON PIN AND PISTON INSTALLATION

1. Apply:
8 Engine oil
(to the crankshaft bearing, connecting
rod big end bearing, small end bearing,
piston pin, piston ring grooves and piston skirt areas.)
R.
4-8
T.
2. Install:
8 Reed valve gasket
8 Reed valve
8 Carburetor joint 1
11Nm(1.1 m.kg)
ENG
3. Install:
8 Small end bearing
8 Piston 1
8 Piston pin 2
8 Piston pin clip 3 New
NOTE:
a
New
8 The arrow a on the piston to the exhaust

side.
8 Before installing the piston pin clip, cover the
crankcase with a clean towel or rag so you
will not accidentally drop the pin clip material into the crankcase.
8 Always use a new piston pin clip.
CYLINDER AND CYLINDER HEAD

1. Install:
8 Cylinder gasket (new gasket)
2. Check:
8 Piston rings
1 1st ring
2 2nd ring
NOTE:
Make sure the ring ends 1 are properly fitted
around the ring locating pins 3 in the piston
grooves.
3. Install:
8 Cylinder 1
NOTE:
Install the cylinder with one hand while compressing the piston rings with the other hand.
New
4-9
INSPECTION AND REPAIR
ENG
4. Install:
8 Cylinder head gasket (new gasket)
5. Install:
14Nm(1.4m.kg
8 Cylinder head 1
8 Spark plug 2
20Nm(2.0m.kg
8 Air shroud
NOTE:
T.
R.
T.
R.
Tighten the cylinder head holding nuts in stage,

using a crisscross pattern.
4-10
V-BELT, CLUTCH AND

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

KICK STARTER AND CRANKCASE COVER (LEFT)
5 New
4
T.
R.
T.
R.
12Nm(1.2kg.m)
90Nm(0.9kg.m)
T.
R.
90Nm(0.9kg.m)
Order
Job name/Part name
1
2
3
4
5
6
Kick starter and crankcase cover (left)

removal
Air cleaner assembly mounting screw
Screw(Bind)
Kick starter
Crankcase (left)
Gasket
Pin
Qty
Remarks
1
1
1
1
1
2
4-11
V-BELT, CLUTCH AND

ENG

KICK STARTER
4
5
2
1
B
6
3
New
Order
1
2
3
4
5
6
Job name/Part name
Qty
Kick starter removal

Kickstarter pinion gear
Kickstarter pinion gear clip
Circlip/Plain washer
Kickstarter segment gear
Return spring
Collar
Remarks
1
1
1/1
1
1
1
4-12
KICK STARTER
ENG
KICK STARTER INSTALLATION

1. Install:
8 Return spring 1
8 Kick starter segment gear 2
8 Collar 3
8 Plain washer 4
8 Circlip 5
2
1
5
3
4
***************************************
Installation steps:
a. Install return spring 6 and segment gear
7 as shown.
b. Install clip 5.
c. Hook the spring onto the crankcase projection 8.
d. Install the kick starter pinion gear 9 and
the kick starter.
***************************************
7
6
4-13
V-BELT, CLUTCH AND

ENG

3
2
6
1
5
4
T.
R.
1
2
3
4
5
6
7
8
9
10
R.
Order
T.
10
Job name/Part name
Qty
40Nm(4.0kg.m)
45Nm(4.5kg.m)
Remarks
V-belt, clutch and secondary/primary

sheave removal
Lower cowling
Air shroud 3
Crankcase (left)
Clutch housing
Secondary sheave assembly
V-belt
Conical washer/One-way clutch
Crow washer
Primary fixed sheave
Collar/Washer
Primary sliding sheave
Cam/ Slider
Weight
Refer to ENGINE REMOVAL section.

Refer to SECONDARY SHEAVE AND VBELT REMOVAL section.

in chapter 3.
1
1
1
1/1
1
1
1/1
1
1/3
6
Refer to PRIMARY SHEAVE REMOVAL

ASSEMBLY section.
Reverse the removal procedure for installation

4-14
V-BELT, CLUTCH AND

ENG
SECONDARY SHEAVE
SECONDARY SHEAVE
9
3 New
6
5
4
1
9
2
T.
R.
50Nm(5.0kg.m)
8
0
LS
LS
Order
1
2
3
4
5
6
7
8
9
0
Job name/Part name
Qty
Remarks
Disassemble the parts in order.
Secondary sheave disassembly

Nut
Clutch carrier
Clutch shoe spring
Compression spring
Spring seat
Guide pin
Secondary sliding sheave
O-ring
Oil seal
Secondary fixed sheave
1
1
3
1
1
2
1
2
2
1
Refer to SECONDARY SHEAVE DISASSEMBLY section.

Refer to SECONDARY SHEAVE INSTALLATION section.
Refer to SECONDARY SHEAVE INSTALLATION section.
Reverse the disassembly procedure for

assembly.
4-15
V-BELT, CLUTCH AND

ENG
PRIMARY SHEAVE REMOVAL

1. Remove:
8 Fan
2. Remove:
8 Nut 1 (primary sheave)
NOTE:
When loosening the nut (primary sheave), hold
the C.D.I. magneto using flywheel holding tool
2.
2
1
Flywheel holding tool:

90890-01235
3. Remove:
8 Conical spring washer 1
8 One-way clutch 2
8 Washer 3
8 Primary fixed sheave 4
8 Shim 5
8 V-Belt
4. Remove:
8 Collar 1
8 Primary sheave assembly 2
SECONDARY SHEAVE REMOVAL

1. Remove:
8 Nut 1 (secondary sheave)
NOTE:
1
2
Hold the secondary sheave using sheave holder

2.
Sheave holder:
90890-01701
2. Remove:
8 Clutch housing
8 Secondary sheave assembly
8 Dowel pins
4-16
V-BELT, CLUTCH AND

ENG
3. Loosen:
8 Nut(Clutch carrier)1
NOTE:
Install the secondary sheave to primary drive
shaft as shown, and hold the secondary sheave
by Universal Roter Holder 2 to loosen the nut
1.
Universal Roter Holder:
90890-01235
cC
Do not remove the clutch securing nut yet.
If the nut is removed without compressiong the
secondary sheave. It jumps and causes injury.
4. Attach:
8 Clutch spring holder 1
Clutch spring holder:
90890-01337
5. Remove:
8 Clutch securing nut 2
6. Remove:
8 Clutch assembly 1
8 Clutch spring 2
8 Spring seat 3
8 Guide pins
8 Secondary sliding sheave
Clutch Inspection
1. Inspect:
8 Clutch shoes
Glazed partsSand with coarse sandpaper.
NOTE:
After using the sand paper, clean of the polished particles with cloth.
4-17
V-BELT, CLUTCH AND

ENG
2. Measure:
8 Clutch shoe thickness a
Clutch shoe thickness:
4 mm
< Wear limit>:
2.5 mm
V-BELT INSPECTION
1. Inspect:
8 V-belt1
CrackReplace.
NOTE:
Replace the V-belt smeared with a lot of oil or

grease.
2. Measure:
8 V-belt width a
V-belt width:
17.7 mm
<Wear limit>:
16.0 mm
4-18
V-BELT, CLUTCH AND

ENG
PRIMARY SHEAVE INSPECTION

1. Inspect:
8 Primary sliding sheave 1
Wear/Cracks/Scratch/Damage
Replace.
2. Check:
8 Free movement
Insert the collar 1into the primary sliding sheave2, and check for free movement.
Stick or excessive playReplace the
sheave or collar.
3. Measure:
8 Out side diameter 1 (weight)
Out side diameter (weight)
15.0 mm
<Limit 14.5 mm>
1
4-19
V-BELT, CLUTCH AND

ENG
SECONDARY SHEAVE
1. Inspect:
8 Secondary fixed sheave 1
8 Secondary sliding sheave 2
Scratch/Crack/DamageReplace as a
set.
8 Oil seal 3
DamageReplace
2. Inspect:
8 Torque cam grove 1
8 Guide pin 2
Wear/DamageReplace as a set.
8 O-rings 3
DamageReplace.
3. Measure:
8 Clutch spring free length
Clutch spring free length:
81 mm
<Limit>:
73 mm
4. Inspect:
8 Clutch housing inner surface
Oil/ScratchesRemove.
Oil
Scratches
Use a rag soaked in lacquer

thinner or solvent.
Use an emery cloth (lightly
and evenly polishing).
5. Measure:
8 Clutch housing inside diameter a
Clutch housing inside diameter:
112.0 mm
<Wear limit>:
112.5 mm
4-20
V-BELT, CLUTCH AND

ENG
SECONDARY SHEAVE INSTALLATION

When assembling the secondary sheave, reverse the disassembly procedure. Note the following points.
1. Apply:
8 BEL-RAY assembly lube
(to the inside of the sliding/fixed sheave)
2. Install:
8 Sliding sheave 1
NOTE:
Be careful so that the oil seal 2 lips are not
turned over when installing the sheave.
3. Apply:
8 BEL-RAY assembly lube
(to the torque cam grooves and O-rings)
4. Install:
8 Guide pin 1
5. Check:
8 Sliding sheave
Unsmooth operationRepair.
6. Install:
Use clutch spring holder 2
Clutch spring holder:
90890-01337
T.
7. Tighten:
50 Nm(5.0 m.kg)
Use Flywheel holding tool 2
R.
Fly holding tool

90890-01235
4-21
V-BELT, CLUTCH AND

ENG
8. Install:
8 Secondary sheave assembly
8 Clutch housing 1
8 V-belt 2
NOTE:
1
2
The V-belt must be installed with the arrow

frontward.
R.
T.
9. Tighten:
8 Nut 1 (secondary sheave)
Use sheaveholder 2
40 Nm(4.0 m.kg)
Sheave holder:
90890-01701
PRIMARY SHEAVE
1. Clean:
8 Primary sliding sheave face 1
8 Primary fixed sheave face 2
8 Collar 3
8 Weight 4
8 Primary sliding sheave cam surface 5
2. Install:
8 Weight 1
8 Cam 2
8 Slider 3
8 Collar 4
3. Check:
8 Cam operation
Not smoothRepair.
4. Install:
8 Primary sheave assembly 1
8 Collar 2
5. Install:
8 V-belt
2
4-22
V-BELT, CLUTCH AND

ENG
6. Install:
8 Shim 1
8 Washer 3
8 One-way clutch 4
8 Conical spring washer 5
8 Nut 6
T.
7. Tighten:
8 Nut 1 (primary sheave)
45 Nm(4.5 kg.m)
R.
NOTE:
When tightening the nut (primary sheave), hold
the C.D.I. magneto using Flywheel Holding Tool
2.
2
1
Flywheel holding
90890-01235
8. Adjust:
8 V-belt 1
Tense the V-belt by turning the primary
sheave several times.
R.
4-23
T.
9. Install:
8 Fan
7 Nm (0.7 kg.m)
ENG
STARTER CLUTCH AND STARTER MOTOR

10
9
New
T.
R.
13Nm(1.3kg.m)
4
3
2
1
8
T.
R.
8Nm(0.8kg.m)
B
M
Order
Job name/Part name
Qty
Starter clutch and starter motor removal

Left/Right side cover
Center cover
Lower cowling
Air shroud 3
Cooling fan
Rear wheel
Refer to COVERS AND PANEL section

in chapter 3.
Refer to C.D.I. MAGNETO section
Refer to REAR WHEEL section in chapter 6.
Refer to KICKER STARTER section.
Crankcase cover (left)
Refer to V-BELT, PRIMARY SHEAVE

section.
Primary sheave
1
2
3
4
5
Remarks
Plate
Plain washer
Idle gear
Plain washer
Starter clutch
2
1
1
2
1
4-24
ENG
10
9
New
T.
R.
13Nm(1.3kg.m)
4
3
2
1
8
T.
R.
8Nm(0.8kg.m)
B
M
Order
6
7
8
9
10
Job name/Part name
Qty
Remarks
2
1
1
1
2
Plain washer
Starter wheel gear
Collar
Starter motor
Starter motor coupler
Reverse the removal procedure for

instalation
4-25
ENG
STARTER CLUTCH AND GEARS

1. Inspect:
8 Starter clutch
Push the dowel pin to arrow direction.
Unsmooth operationReplace starter
clutch assembly.
2. Inspect:
8 Starter wheel gear teeth 1
8 Idle gear teeth 2
Burrs/Chips/Roughness/WearReplace.
3. Inspect:
8 Starter clutch operation
***************************************
Clutch operation checking steps:
8 Install the starter wheel gear to the starter
clutch, and hold the starter clutch.
8 When turning the wheel gear clockwise A
the starter clutch and the wheel gear should
be engaged.
If not the starter clutch is faulty. Replace it.
8 When turning the wheel gear counter clockwise B, the wheel gear should turn freely. If
not, the starter clutch is faulty. Replace it.
***************************************
4-26
C.D.I. MAGNET
ENG
C.D.I. MAGNET
C.D.I. MAGNET
5
8 New
T.
R.
8Nm(0.8kg.m)
T.
R.
43Nm(4.3kg.m)
T.
R.
7Nm(0.7kg.m)
Order
1
2
3
4
5
6
7
8
Job name/Part name
Qty
C.D.I. magneto removal

Rear carrier
Tail cover
Left side cover
Right side cover
Center cover
Lower cowling
Air shroud 3
Fan /O-ring
Magneto rotor
Bind
Couplers (magneto leads)
Stator coil
Wood ruff key
Gasket (Magneto cover)
Remarks

in chapter 3.
1
1/1
1
1
1
1
1
1
4-27
ENG
ENGINE DISASSEMBLY
C.D.I. MAGNETO REMOVAL

1. Remove:
8 Nut 1(rotor)
8 Plain washer
NOTE:
Hold the rotor to loosen the nut by the flywheel

holding tool 2.
2
Flywheel holding tool:
90890-01235
2. Remove:
8 Rotor 1
8 Woodruff key
Use the flywheel magneto puller 2.
Flywheel magneto puller:

90890-01189
8 Stator assembly
8 Gasket
C.D.I. MAGNETO INSTALLATION

1. Install:
8 Gasket 1
2. Apply:
8 Lithium soap base grease
(to oil seal)
3. Pass the C.D.I. magneto lead through the
crankcase hole.
4. Install:
8 Nm(0.8 kg.m)
8 Stator assembly
5. Install:
8 Woodruff key
8 C.D.I. magneto Rotor 1
8 Plain washer
43Nm(4.3 kg.m)
8 Nut
T.
R.
T.
R.
4-28
AUTOLUBE PUMP
ENG
AUTOLUBE PUMP
AUTOLUBE PUMP
5
1
6
4
R.
T.
4Nm(0.4kg.m)
8
7
Order
1
2
3
4
5
6
7
8
Job name/Part name
Qty
Remarks
Refer to C.D.I. magneto section.
Autolube pump removal

C.D.I. magneto
Air shroud 2.
Circlip
Pump drive gear
Pin
Oil hose
Oil delivery hose
Autolube pump cable
Autolube pump assy
1
1
1
1
1
1
1
1
Refer to Autolube pump installation

section
4-29
AUTOLUBE PUMP
ENG
AUTOLUBE PUMP INSTALLATION
cC
After installing autolube pump, it must be
bleeded.
1. Install
8 Pin 1
8 Pump drive gear 2
2
3 New
8 Circlip 3 New
2. Apply:
(to O-ring)
3. Install:
4 Nm(0.4m.kg)
8 Autolube pump 1
T.
R.
4. Apply:
(to autolube pump gear 1,2)
15 cc (0.92 cu in)
4-30
ENG
TRANSMISSION
TRANSMISSION
TRANSMISSION
3
10
8 New
7
New
6
5
T.
R.
18Nm(1.8kg.m)
1
4
T.
R.
12Nm(1.2kg.m)
New
B
Order
Job name/Part name
Qty

Refer to REAR WHEEL/REAR BRAKE
section in chapter 7.
Refer to V-BELT, CLUTCH, SECONDARY/ PRIMARY SHEAVE section
Refer to TRANSMISSION OIL REPLACEMENT section in chapter 3.
Transmission removal
Rear wheel
Secondary sheave
Drain the transmission oil.
1
2
3
4
5
6
7
Remarks
Transmission case cover

Gasket (transmission case cover)
Dowel pin
Primary drive gear
Plain washer
Conical spring washer
Drive gear
1
1
2
1
1
1
1
4-31
ENG
TRANSMISSION
3
10
8 New
7
New
6
5
T.
R.
18Nm(1.8kg.m)
1
4
T.
R.
12Nm(1.2kg.m)
New
B
Order
8
9
10
Job name/Part name
Qty
Circlip
Main axle
Drive axle
Remarks
1
1
1
4-32
CRANKCASE AND REED VALVE
ENG

T.
T.
R.
R.
9Nm(0.9kg.m)
12Nm(1.2kg.m)
7
4
8 New
5
6
B
1
9
10
New
3 New
Order
Job name/Part name
Qty
Remarks
Crankcase and Reed valve removal
Engine removal
Cylinder head, cylinder, piston
Refer to ENGINE REMOVAL section.

Refer to CYLINDER HEAD CYLINDER
AND PISTON section.
Refer to KICK STARTER AND CRANKCASE COVER (LEFT) section.
Refer to V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE section.
Refer to C.D.I. MAGNETO section.
Refer to STARTOR CLUTCH AND
STARTOR MOTOR section.
Refer to AUTOLUBE PUMP section.
Refer to REAR WHEEL AND REAR
BRAKE section in chapter 6.
Refer to TRANSMISSION section.

V-belt, clutch, secondary/primary
sheave
C.D.I . magneto
Starter clutch, starter motor
Autolube pump
Rear wheel
Transmission
4-33
T.
T.
R.
R.
9Nm(0.9kg.m)
ENG
12Nm(1.2kg.m)
7
4
8 New
5
6
B
1
9
10
New
3 New
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Qty
Intake manifold
Reed valve
Valve seat gasket
Stopper
Crankcase 2
Dowel pin
Engine mount spacer
Circlip
Bearing
Oil seal
Remarks
1
1
1
1
1
2
1
1
1
1
4-34
ENG
T.
CRANKCASE(RIGHT) REMOVAL
1. Remove:
8 Oil seal stopper 1
9Nm(0.9 kg.m)
8 Screws (crankcase)
NOTE:
R.
Loosen each screw 1/4 turn, and remove them

after all are loosened.
2. Attach:
8 Crankcase separating tool 1
Crankcase separating tool:
90890-01135
NOTE:
Fully tighten the tool holding bolts, but make
sure the tool body is parallel with the case. If
necessary, one screw may be backed out
slightly to level tool body.
3. Remove
8 Crankcase (right)
As pressure is applied, alternately tap
on the engine mounting bosses.
REED VALVE INSPECTION

1. Measure:
8 Valve stopper height 1
Out of specificationAdjust stopper/Replace valve stopper.
Valve stopper height 1
6.0~6.4 mm
2. Measure:
8 Reed valve clearance 2
Out of specificationReplace reed
valve.
Reed valve clearance 2
Less than 0.2 mm
4-35
ENG
CRANKCASE (RIGHT) INSTALLATION

1. Install:
8 Dowel pins 1
8 Engine mount spacer 2
2. Apply:
8 Yamaha Bond No.1215 3
To the mating surfaces of both case
helves.
3
2
Yamaha bond No.1215:

90890-85505
2
3. Attach:
8 Crankshaft installing tool 1,2,3
Crankshaft installing tool:

90890-012741
90890-012752
90890-01277
4. Tighten:
8 Crankcase holding screws
T.
R.
12 Nm(1.2 kg.m)
NOTE:
Tighten the crankcase holding screws in stage,
using a crisscross pattern.
5. Check:
8 Crankshaft operation
Unsmnoth operation Repair.
6. Install:
New
8 Oil seal (right crank case) 1 New

Apply grease on to oil seal lip.
T.
7. Install:
8 Oil seal stopper plate 1
9 Nm (0.9 kg.m)
R.
4-36
R.
4-37
T.
8. Install:
8 Gasket
8 Reed valve
8 Reed valve 1
ENG
11 Nm(1.1 kg.m)
CRANKSHAFT
ENG
CRANKSHAFT
CRANKSHAFT
2
3
4
1
2
3
E
Order
Job name/Part name
Qty
Crankshaft removal
Right crankcase removal
1
2
3
4
Remarks
Refer to CRANK CASE AND REED
VALVE section.
Crankshaft
Bearing
Oil seal
1
2
2
1
4-38
CRANKSHAFT
CRANKSHAFT REMOVAL
1. Attach:
8 Crankcase separating tool 1
ENG
Crankcase separating tool:

90890-01135
2. Remove:
8 Crankshaft 2
CRANKSHAFT INSPECTION
1. Measure:
8 Runout limit C
8 Connecting rod big end side clearance
D
8 Small end free play limit F
Use V-blocks, dial gauge and thickness
gauge.
F
C
Runout limit C:
0.03 mm
Connecting rod big end side clearance D:
0.2 ~ 0.5 mm
Small end free play F:
0.4 ~ 0.8 mm
2. Inspect:
8 Bearings (crankshaft)
Spin the bearing inner race.
Excessive play/RoughnessReplace.
4-39
CRANKSHAFT
ENG
CRANKSHAFT INSTLATION
1. Attach:
8 Crankshaft Installing Tool
4
3
Crankshaft installing tool:

90890-01274
90890-01275
90890-012771
90890-012882
1
2
2. Install:
8 Crankshaft3
(to the crankcase4)
3. Install:
8 Oil seal 1 New
8 Apply lithium soap base grease onto
the oil seal lip.
Use the guide 2 and seal driver 3 to
install the oil seal
Oil seal driver
90890-01410
Oil seal guide
90890-01409
4-40
CARB
CARBURETOR
CARBURETION
CARBURETOR
3
T.
R.
Order
1
2
3
4
5
6
7
Job name/Part name
Qty
Carburetor removal
Battery box cover
Grip
End cover
Left/Right cover
Center cover
Air cleaner case assembly
Carburetor assembly
Auto choke lead coupler
Fuel hose
Vacuum hose
Oil delivery pipe
Throttle cable
9Nm(0.9kg.m)
Remarks

in CHAPTER 3.
1
1
1
1
1
1
1
5-1
CARBURETOR
CARB
CABURETOR DISASSEMBLY
4
3
r
5
w
6 eq
9
8
Order
1
2
3
4
5
6
7
8
9
0
q
w
e
r
Job name/Part name
Qty
Carburetor disassembly
Throttle valve
Throttle cable
Needle set
Carburetor top cover
Throttle stop screw
Pilot air screw
Auto choke unit assembly
Float chamber/Seal ring
Float pin
Float/Needle valve
Main jet
Pilot jet
Main nozzle
Carburetor body
Remarks
Disassemble the parts in order.
1
1
1
1
1
1
1
1/1
1
1
1
1
1
1
5-2
CARBURETOR
CARB
CABURETOR INSPECTION
Measure:
8 Float height a
Out of specificationInspect needle valve,
float and valve seat.
Float height:
16.5 mm
***************************************
Float height measurement steps:
8 Install the needle valve, float and float pin to
the carburetor body.
8 Hold the carburetor in an upside down position.
8 Measure the distance between the mating
surface of the float chamber (gasket removed) and top of the float using a gauge.
NOTE:
The float arm should be resting on the needle
valve, but not compressing the needle valve.
8 If the float height is not within specification,
inspect the needle valve, float and valve seat.
8 If it is worn, replace it.
*************************************
NOTE:
The float height is properly adjusted at the Yamaha
/MBK factory. Never attempt to adjust it.
CARBURETOR ASSEMBLY
To assemble the carburetor, reverse the disassembly procedures.
Note the following points.
cC
8 Before reassembling, wash all parts in clean
gasoline.
8 Always use a new gasket.
1. Install:
8 Throttle valve 1
8 Jet needle 2
8 Clip 3
8 Spring seat 4
Jet needle clip position:
3/5
5-3
CARBURETOR
CARB
2. Install:
8 Throttle valve 1
NOTE:
1
a
Align the groove of the throttle valve with the

projection a of the carburetor body.
3. Install:
8 Carburetor assembly
NOTE:
Align the projection a with the projections b.
b
FUEL LEVEL ADJUSTMENT
1. Measure:
8 Fuel level a
Out of specificationsAdjust.
Fuel level a:
3.0~4.0 mm(Below the float chamber line
***************************************
Measurement steps:
8 Place the scooter on a level surface.
8 Use a garage jack under the engine to ensure that the carburetor is positioned vertically.
8 Connect the fuel level gauge 1 to the drain
pipe 2.
3
2
Fuel level gauge:

90890-01312
8 Loosen the drain screw 3.
8 Measure the fuel level a with the gauge.
8 If the fuel level is incorrect, adjust the fuel
level:
8 Remove the float chamber, float, valve seat
and the needle valve.
8 Inspect the valve seat and needle valve.
8 If either is worn, replace them both.
5-4
CARBURETOR
CARB
8 If both are fine, adjust float level by bending

the float tang b slightly.
8 Install the carburetor.
8 Recheck the fuel level.
***************************************
AUTO CHOKE INSPECTION

(Ambient temperature lower than 45C)
1. Remove:
8 Carburetor
2. Inspect:
8 Autochoke unit
Connect a suitable pipe 2 to the starter 1,
and blow it with the mouth etc. PossibleGood
condition.
ImpossibleReplace auto choke unit.
3. Inspect:
8 Auto choke unit (with battery)
***************************************
Inspection and adjustment steps:
8 Connect auto choke unit leads to the 12 V
battery for 5 minutes.
Black terminal12 V battery (+) 1
Black terminal12 V battery () 2
8 Connect a suitable pipe 4 to the starter 5,
and blow it with the mouth etc.
PossibleReplace auto choke unit.
ImpossibleGood condition.
***************************************
B B
5-5
CARBURETOR
CARB
FUEL COCK INSPECTION

1. Stop the engine.
2. Remove:
8 Grip
8 End cover
8 Left side cover
8 Battery box cover
in chapter 3.
3. Inspect:
8 Fuel cock
***************************************
Fuel cock inspection steps:
8 Disconnect the fuel hose 1.
8 Place the receptacle under the fuel hose end.
8 If fuel stops flowing out in a few seconds,
the fuel cock is in good condition. If not, clean
or replace the fuel cock.
8 Disconnect the vacuum hose 2 and breathe
in the vacuum hose with the mouth etc. for
vacuum .
8 If fuel flows out of the fuel hose under
vacuum and stops under non-vacuum, the
fuel cock is in good condition.
If not, clean or replace the vacuum hose, fuel
hose and fuel cock.
*************************************
4. Install:
8 Battery box cover
8 Left side cover
8 End cover
8 Grip
5-6
CHAS
FRONT WHEEL AND BRAKE DISC

CHASSIS
2
1
T.
R.
7Nm(0.7kg.m)
3
T.
R.
23Nm(2.3kg.m)
T.
R.
7Nm(0.7kg.m)
LT
8
7
T.
R.
Order
20Nm(2.0kg.m)
Job name/Part name
Qty
Remarks
Front wheel and brake disc removal
w
Securely support the scooter so there is
no danger of it falling over.
1
2
3
4
5
6
7
8
Speedometer cable
Front brake hose holder
Brake caliper
Wheel axle
Front wheel assembly
Gear unit assembly
Collar
Brake disc
1
1
1
1
1
1
1
1
6-1
Refer to FRONT WHEEL INSTALLATION section.
Refer to FRONT WHEEL ASSEMBLY

section.
CHAS
FRONT WHEEL DISASSEMBLY
5
4
New
1
Order
1
2
3
4
5
Job name/Part name
Qty
Front wheel disassembly

Oil seal
Bearing
Collar
Spacer
Bearing
1
1
1
1
1
Remarks
Refer to FRONT WHEEL DISASSEMBLY/ASSEMBLY section.
6-2
CHAS
YP ......
FRONT WHEEL DISASSEMBLY

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

1. Inspect:
8 Front wheel axle
(by rolling it on a flat surface)
BendsReplace.
w
Do not attempt to straighten a bent axle.
Wheel axle bending limit:
0.25 mm
2. Inspect:
8 Front tire
Wear/damageReplace.
Refer to TIRE INSPECTION in CHAPTER 3.
8 Front wheel
Refer to WHEEL INSPECTION in
CHAPTER 3.
3. Measure:
8 Front wheel runout
Over the specified limitsReplace.
Front wheel runout limits:
Radial 1: 1.0 mm
Lateral 2 : 1.0 mm
4. Inspect:
8 Front wheel bearings
Bearings allow free play in the wheel
hub or the wheel does not turn
smoothly Replace.
8 Oil seals
Wear / damageReplace.
6-3
CHAS
4. Inspect:
8 Collar
Grooved wearReplace the collar and
the oil seal as a set.
YP.....
BRAKE DISC INSPECTION

1. Measure:
8 Brake disc deflection1
Maximum deflection:
0.15 mm
2. Measure:
8 Brake disc thicknessa
Brake disc thickness:
4.0 mm
Minimum thickness:
3.5 mm
YP.....
FRONT WHEEL ASSEMBLY

1. Install:
8 Bearing 1
8 Collar 2
8 Spacer 3
8 Bearing 4
8 Oil seal 5
NOTE:
4
3
2
8 Apply the lithium soap base grease on the

bearing and oil seal lip when installing.
8 Use a socket that matches the outside diameter of the race of the bearing.
8 Always use a new oil seal.
8 Install the oil seal with its manufacturers
marks or numbers facing outward.
1
5
New
cC
B
Do not strike the inner race of balls of the bearing. Contact should be made only with the outer
6-4 race.
R.
T.
2. Install:
8 Brake disc 1
CHAS
20 Nm(2.0 m.kg)
NOTE:
Tighten the bolts (brake disc) in stage using a
crisscross pattern.
EB700030
FRONT WHEEL INSTALLATION

Reverse the REMOVAL procedure.
1. Lubricate:
8 Front wheel axle
8 Bearings
8 Oil seal (lips)
8 Drive/driven gear (speedometer)
1
Recommended lubricant:
Lithium soap base grease
2. Install:
8 Speedometer gear unit 1
NOTE:
Make sure that the wheel hub and the speedometer gear unit are installed with the three
projections meshed into the two slots.
3. Install:
8 Front wheel
NOTE:
Make sure that the slot in the speedometer gear
unit fits over the stopper on the front fork outer
tube.
4. Tighten:
8 Front wheel axle 1
8 Axle nut (front wheel axle)
T.
R.
70 Nm(7.0kg.m)
cC
Before tightening the axle nut, stroke the front
fork several times to check for proper fork operation.
w
Make sure that the brake hose is routed prop6-5 erly.
CHAS
YP700040
WHEEL STATIC BALANCE ADJUSTMENT

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

8 Turn the wheel so that the heavy spot is 90
up.
8 Check that the heavy spot is at rest there. If
not, try another weight until the wheel is balanced.
***************************************
6-6
5. Check:
8 Wheel static balance
***************************************
Checking steps:
8 Turn the wheel so that it comes to each point
as shown.
8 Check that the wheel is at rest at each point.
If not, readjust the front wheel static balance.
***************************************
CHAS
6-7
FRONT BRAKE
CHAS
FRONT BRAKE
BRAKE PAD
B
4
2
3
1
T.
R.
23Nm(2.3kg.m)
T.
R.
Order
1
2
3
4
Job name/Part name
Qty
Brake pad removal

Caliper support bolt
Caliper
Brake pad
Pad spring
1
1
2
2
23Nm(2.3kg.m)
Remarks
Refer to BRAKE PAD REPLACEMENT
section .
6-8
FRONT BRAKE
CHAS
cC
Disc brake components rarely require disassembly. DO NOT:
8 Disassembly components unless absolutely
necessary.
8 Use solvents in internal brake component.
8 Use contaminated brake fluid for cleaning.
8 Use only clean fluid.
8 Allow brake fluid to come in contact with the
eyes otherwise eye injury may occur.
8 Allow brake fluid to contact painted surfaces
or plastic parts otherwise damage may occur.
8 Disconnect any hydraulic connection otherwise the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly.
BRAKE PAD REPLACEMENT
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
2
1. Loosen:
8 Retaining bolt 1
2. Remove:
8 Brake caliper 2
8 Holder (brake hose) 3
3. Remove:
8 Retaining bolt
8 Pads 1
8 Pad spring 2
NOTE:
3
1
2
1
8 Replace the pad spring if the pad replacement

is required.
8 Replace the pads as a set if either is found to
be worn to the wear limit.
Wear limit a:
0.8 mm (0.03 in)
6-9
FRONT BRAKE
2
CHAS
4. Install:
8 Pad springs
8 Brake pads (new)
***************************************
Installation steps:
8 Connect a suitable hose 1 tightly to the caliper bleed screw 2. Then, place the other end
of this hose into an open container.
8 Loosen the caliper bleed screw and push the
piston 3 into the caliper by your finger.
8 Tighten the capliper bleed screw.
T.
R.
6 Nm (0.6 kg.m)
T.
8 Install the pad spring (new) and brake pad

(new) 4
23 Nm (2.3 kg.m)
8 Tighten retaining bolt 5
8 Install brake hose holder 6
7 Nm (0.7 kg.m)
8 Install caliper 7
23 Nm (2.3 kg.m)
R.
T.
R.
T.
R.
***************************************
7
6
5
5. Inspect:
8 Brake fluid level
Refer to the BRAKE FLUID INSPECTION section in the CHAPTER 3.
1 LOWER level line

6-10
FRONT BRAKE
CHAS
6. Check:
8 Brake lever operation
A softy or spongy feeling Bleedbrake
system.
Refer to AIR BLEEDING section in
the CHAPTER 3.
6-11
FRONT BRAKE
CHAS
MASTER CYLINDER
T.
R.
9Nm(0.9kg.m)
7
4 New
T.
R.
25Nm(2.5kg.m)
Order
Job name/Part name
Qty
Master cylinder removal

Drain the brake fluid
1
2
3
4
5
6
7
Remarks
Refer to BRAKE FLUID REPLACEMENT section in CHAPTER 3.
Brake lever/compression spring

Brake switch
Union bolt
Copper washer
Brake hose
Master cylinder bracket
Master cylinder
1/1
1
1
2
1
1
1
Refer to MASTER CYLINDER INSTALLATION section.
6-12
FRONT BRAKE
CHAS
MASTER CYLINDER DISASSEMBLY
2 New
Order
1
2
3
4
Job name/Part name
Qty
Remarks
Master cylinder disassembly

Master cylinder boot
Circlip
Master cylinder kit
Spring
1
1
1
1
Refer to MASTER CYLINDER ASSEMBLY section.

assembly.
6-13
FRONT BRAKE
CHAS
YP702040
MASTER CYLINDER INSPECTION

1. Inspect:
8 Master cylinder kit 1
Wear/scratchesReplace the master
cylinder assembly.
8 Master cylinder boot
Cracks/damageReplace.
2. Inspect:
8 Master cylinder 1
8 Scratches/wear/damageReplace the
master cylinder assembly.
1
3. Inspect:
8 Diaphragm 1
Wear/damageReplace.
YP.....
MASTER CYLINDER ASSEMBLY
w
8 All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
Recommended brake fluid:
DOT #4
8 Replace the piston seals and dust seals whenever a master cylinder is disassembled.
1. Install:
8 Cylinder cup 1
8 Master cylinder piston 2
Install cylinder cup 1 by using cylinder
cup installer 3.
Cylinder cup installer set:
90890-01996
6-14
FRONT BRAKE
CHAS
2. Install:
8 Spring 1
Install the spring with its smaller diameter to the master cylinder piston.
8 Master cylinder kit 2
3. Install:
8 Circlip 1 New
Install the circlip securely into the master cylinder groove.
8 Master cylinder boot 2
New
YP.....
MASTER CYLINDER INSTALLATION

1. Install:
8 Master cylinder 1
8 Master cylinder bracket 2
T.
9 Nm (0.9 kg.m)
R.
cC
8 Install the master cylinder bracket 2 with the

UP mark a facing upward.
8 Align the end of the holder with the punch
mark b on the handle bar.
b
6-15
FRONT BRAKE
CHAS
2. Air bleed:
8 Brake system
Refer to AIR BLEEDING section in
CHAPTER 3.
w
8 Use only designated quality brake fluid:
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake perforrmance.
8 Refill with the same type of brake fluid:
Mixing fluids may result in a harmful chemical reaction and lead to poor perforrmance.
8 Be careful that water does not enter the significantly lower the boiling point of the fluid
may result in vapor lock.
3. Inspect:
8 Brake operation
6-16
CHAS
FRONT BRAKE
CALIPER
3
5
T.
R.
25Nm(2.5kg.m)
1
2 New
T.
R.
T.
R.
Order
Job name/Part name
Qty
Caliper removal
Drain the brake fluid
1
2
3
4
5
23Nm(2.3kg.m)
23Nm(2.3kg.m)
Remarks
Refer to BRAKE FLUID REPLACEMENT section in CHAPTER 3.
Union bolt
Copper washer
Brake hose
Caliper support bolt
Caliper assembly
1
2
1
1
1
Refer to CALIPER INSTALLATION section.
6-17
CHAS
FRONT BRAKE
CALIPER DISASSEMBLY
1
B
T.
R.
6Nm(0.6kg.m)
7
3
New
2
5
6
4
Order
1
2
3
4
5
6
7
Job name/Part name
Qty
Caliper disassembly
Caliper bracket
Brake pad
Pad spring
Caliper piston
Dust seal
Piston seal
Bleed screw
Remarks
1
2
2
1
1
1
1
Refer to BRAKE CALIPER DISASSEMBLY/ASSEMBLY section.

assembly.
6-18
FRONT BRAKE
CHAS
YP702020
BRAKE CALIPER DISASSEMBLY

NOTE:
Before disassembling either brake caliper, drain
the brake fluid from the brake hose, master
cylinder, brake caliper and reservoir tank.
1. Remove:
8 Brake caliper piston
***************************************
Removal steps:
8 Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.
w
8 Never try to pry out the caliper piston.
8 Cover the caliper piston with a rag. Be careful not to get injured when the piston is expelled from the master cylinder.
cC
Carefully remove the caliper piston to prevent
damage.
***************************************
2. Remove:
8 Dust seal 1
8 Piston seal 2
When removing, push the seals by your
finger.
cC
8 Do not use a sharp instrument. Remove seals
by your finger.
8 Do not re-use removed parts.
YP...
CALIPER INSPECTION
1. Inspect:
8 Caliper cylinder 1
8 Caliper piston 2
Scratches, wearReplace caliper assembly.
6-19
FRONT BRAKE
CHAS
EB702050
BRAKE CALIPER ASSEMBLY
w
8 All internal brake components should be
cleaned and lubricated with new brake fluid
only before installation.
Recommended brake fluid:
DOT #4
8 Replace the caliper piston seals whenever a
brake caliper is disassembled.
New
1. Install:
8 Piston seal 1 New
8 Dust seal 2 New
2. Install:
8 Caliper piston 1
Apply brake fluid to the outer surface
and install.
cC
8 Do not force.
8 Use care to prevent damage on caliper piston.
YP.....
2
3
CALIPER INSTALLATION
1. Install:
8 Caliper 1
23Nm(2.3m.kg)
8 Caliper support bolt
8 Brake hose 2
8 Copper washer 3 New
8 Union bolt 4
25Nm(2.5 m.kg)
T.
R.
T.
R.
cC
When installing the brake hose to the caliper,
lightly touch the brake hose with the stopper
a on the caliper.
6-20
REAR WHEEL AND REAR BRAKE
CHAS

REAR WHEEL
New
1
T.
R.
120Nm(12kg.m)
T.
R.
26Nm(2.6kg.m)
T.
R.
Order
1
2
3
4
Job name/Part name
Qty
Rear wheel and rear brake removal

Muffler assembly/Gasket
Nut/Plain washer
Rear wheel assembly
Plain washer
12Nm(1.2kg.m)
Remarks
1/1
1
1
1
installation.
6-21
CHAS
REAR BRAKE
T.
R.
8Nm(0.8kg.m)
6
7
1
4
New
Order
1
2
3
4
5
6
7
8
Job name/Part name
Qty
Adjuster
Brake cable
Pin
Return spring
Brake shoe
Camshaft lever
Wear indicator
Brake camshaft
Remarks
1
1
1
1
1
1
1
1
6-22
CHAS
EB701020
REAR WHEEL INSPECTION

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

1. Inspect:
8 Brake lining surface
Glazed areasPolish.
Use coarse sand paper.
NOTE:
After polishing, wipe the polished particles with
a cloth.
2. Measure:
8 Brake lining thickness a
Brake lining thickness a :
Standard:
4 mm
Limit:
2 mm
Measuring points M
NOTE:
Replace the brake shoes as a set if either is worn
to the limit.
3. Measure:
8 Brake drum inside diameter a
Out of specificationReplace the wheel.
Brake drum inside diameter:
Standard:
130 mm
Limit:
131 mm
6-23
CHAS
4. Inspect:
8 Brake drum inner surface
8 Oil/scratchesRepair.
8 Oil
Use a rag soaked in lacquer thinner or
solvent.
8 Scratches
Use an emery cloth (lightly and evenly
polishing)
5. Inspect:
8 Cam shaft face.
WearReplace.
w
When inspecting the brake lining, do not spill
oil or grease on the brake lining.
YP.....
REAR BRAKE INSTALLATION

1. Install:
8 Camshaft 1
8 Indicator plate 2
***************************************
Installation steps:
8 Set the camshaft with its punched mark a
facing the direction as shown.
8 Align the projection b on the indicator plate
with the camshaft notch and install.
8 Check the proper position of the brake shoe.
***************************************
1
a
2. Install:
8 Camshaft lever 1
NOTE:
Set the camshaft with its punched mark a facing the direction on the cam shaft lever b.
a
b
1
6-24
HANDLEBAR
CHAS
HANDLEBAR
HANDLEBAR
12
T.
R.
23Nm(2.3kg.m)
7
T.
R.
43Nm(4.3kg.m)
11
12
6
B
4
B
2
1
8
5
10
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Qty
Handlebar removal
Left/Right bake mirror
Front protector bar
Upper cover
Front/Rear handlebar cover
Left/Right flasher
Brake master cylinder
Front brake switch
Handlebar switch (Right)
Throttle cable
Rear brake cable
Rear brake switch
Handlebar switch (Left)
Bind
Wire harness strap
Remarks
Refer to COVERS AND PANEL IN
CHAPTER 3.
1
1
1
1
1
1
1
1
1
6-25
HANDLEBAR
CHAS
12
T.
R.
23Nm(2.3kg.m)
7
T.
R.
43Nm(4.3kg.m)
11
12
6
B
4
B
2
1
8
5
10
Order
10
11
12
Job name/Part name
Qty
Brake hose
Handlebar comp.
Left/Right grip
Remarks
1
1
1/1
6-26
HANDLEBAR
CHAS
HANDLEBAR INSTALLATION
1. Clean:
8 Steering shaft a
w
Proper cables and leads routing is essential to
issue safe scooter operation.
R.
b
M
T.
2. Install:
8 Handlebar 1
8 Bolt 2
8 Nut
NOTE:
43Nm(4.3 kg.m)
Match the bolt 2 on to the steering column

dent a.
a
cC
There must be a space b after tighting bolt 2.
3. Install:
8 Band
NOTE:
Clamp the wire harness.
4. Apply:
8 Lithium soap base grease (to throttle
cable end and handlebar right end).
5. Install:
8 Handlebar switch (right) 1
NOTE:
1
a
Insert the projection a into the slot b on the

handlebar comp.
b
6-27
HANDLEBAR
CHAS
6. Install:
8 Handlebar switch (left) 1
NOTE:
1
a
Insert the projection a into the slot b on the

handlebar comp.
b
7. Install:
8 Master cylinder
NOTE:
Match the slot with the punched mark b on
the handlebar comp.
6-28
STEERING
CHAS
STEERING
STEERING
1
2
3
6
7
4
B
T.
R.
45Nm(4.5kg.m)
9
9
9
8
5
T.
R.
Order
45Nm(4.5kg.m)
Job name/Part name
Qty
Remove the parts in order

Refer to HANDLEBAR section.
Refer to FRONT WHEEL AND BRAKE
DISC section
Steering removal
Handlebar
Front wheel
1
2
3
4
5
6
7
8
9
Ring nut 1/ Special washer

Ring nut 2/ Rubber washer
Ring nut 3
Under bracket
Front fork (Left/Right)
Bearing cover
Ball race
Ball (Upper/Lower)
Ball race
Remarks
1/1
1/1 Refer to STEERING REMOVAL/INSTAL1
LATION section.
1
1/1
1
1
22/19
3
6-29
STEERING
CHAS
STEERING REMOVAL
w
8 Securely support the scooter so that there is
no danger of it falling over.
8 Stand the scooter on a level surface.
1. Removal:
8 Ring nut 1 1
8 Special washer 2
8 Ring nut 2 3
8 Rubber washer 4
8 Ring nut 3 5
8 Bearing cover 6
8 Ball race 7
8 Ball 8
8 Front fork assembly 9
NOTE:
9
2
3
4
5
6
8 Remove the ring nuts by steering nut wrench.

Steering nut wrench 0
90890-01268
8 Hold the lower bracket by hand, then remove

by using the steering nut wrench 0.
8 Do not loss the balls (Upper: 22 pcs, Lower:
19 pcs).
2. Remove
8 Front fork assembly
Refer to FRONT FORK section.
3. Remove
8 Ball race
***************************************
Ball race replacement steps:
8 Remove the ball races on the head pipe using long rod 1 and the harmmer as shown.
8 Remove the ball races on the under bracket
using the floor chisel 2 and the harmmer as
shown.
***************************************
6-30
STEERING
CHAS
STEERING INSPECTION
1. Wash the bearing races with a solvent.
2. Inspect:
8 Ball race
8 Ball
NOTE:
Always replace bearings and races as set.
3. Inspect:
8 Under bracket 1
Crack/Bend/DamageReplace.
1
w
Do not attempt to straighten a bent under
bracket as this may dangerously weaken the
under bracket.
STEERING INSTALLATION
1. Install:
8 Ball 1
NOTE:
Upper.......22 pcs
Lower...... 19 pcs
1
2. Lubricate
8 Ball
8 Ball race
Wheel bearing grease
6-31
CHAS
STEERING
3. Install:
8 Front fork assembly 1
8 Ball race (Upper) 2
8 Bearing cover 3
8 Ring nut 3 4
8 Rubber washer 5
8 Ring nut 2 6
8 Special washer 7
8 Ring nut 1 8
NOTE:
1
7
6
5
4
3
2
Securely support the steering shaft so that

there is no danger of it falling down.
4. Tighten:
8 Ring nuts
***************************************
Tighten steps:
8 Tighten the ring nut 3 2 using the ring nut
28 Nm (2.8 kg.m)
wrench 1
1
3
T.
R.
Ring nut wrench:

90890-01403
NOTE:
Set the torque wrench 3 to ring nut wrench 1
so that they form right angle.
7
6
5
Do not over-tightening.
8 Loosen the ring nut 3 2 1/4 turn.

8 Check the front fork by turning it lock to lock.
If there is any binding, remove the front fork
assembly and inspect the steering ball bearings and ball races.
8 Install rubber washer 4 and ring nut 2 5,
then turn the ring nut 2 until it contacts with
rubber washer.
6-32
STEERING
CHAS
cC
Slots on the ring nut 2 and ring nut 3 should be
align. If not, turn the ring nut 2 towards tighten
direction until slots alignment.
8 Install special washer 6
NOTE:
Insert the projections of the special washer into
the slots.
8 Install ring nut 1 7 and tighten.
T.
66Nm(6.6 kg.m)
R.
***************************************
6-33
FRONT FORK
CHAS
FRONT FORK
FRONT FORK
3
R.
R.
T.
T.
40Nm(4.0kg.m)
45Nm(4.5kg.m)
1
4
Order
1
2
3
4
5
Job name/Part name
Qty
Remarks
Refer to Steering section.
Front fork removal

Steering
Under fender
Speedometer cable holder
Cap bolt
Pinch bolt
Front fork
1
1
2
2
2
Refer to FRONT FORK REMOVAL/INSTALLATION section.

6-34
FRONT FORK
CHAS
FRONT FORK DISASSEMBLY
New
6
7
New 8
New 9
New
1
3
T.
R.
23Nm(2.3kg.m)
LT
Order
Job name/Part name
Front fork disassembly

Fork spring
2
3
4
5
6
7
8
9
0
Band/Front fork boot

Bolt/Copper washer
Inner tube
Damper rod
Rebound spring
Oil lock piece
Oil seal clip
Oil seal
Outer tube
Qty
Remarks

Refer to FRONT FORK REMOVAL/INSTALLATION section.
1
1/1
1
1/1
1
1/1
1
1
1
Refer to FRONT FORK DISASSEMBLY/

ASSEMBLY section.

assembly.
6-35
FRONT FORK
CHAS
YP.....
FRONT FORK REMOVAL
w
8 Securely support the scooter so there is no
danger of it falling over.
8 Stand the scooter on a level surface.
8 Stand the scooter on its centerstand.
1. Remove:
8 Under fender 1
2. Remove:
8 Cap bolt 1
8 Pinch bolt 2
w
Fork spring will jump out after removing cap
bolt.
2
3
3. Remove:
8 Front fork (Left/Right) 3
YP703020
FRONT FORK DISASSEMBLY

1. Remove:
8 Bolt (damper rod) 1
Loosen the bolt (damper rod) 2 while
holding the damper rod with T-handle
3 and 8 mm hexagon bolt.
T-handle
90890-01326
6-36
FRONT FORK
1
CHAS
2. Remove:
8 Inner tube 1
8 Oil lock pice 2
8 Damper rod 3
8 Rebound spring 4
3
4
2
3. Remove:
8 Oil seal 1 New
cC
Never reuse the oil seal.
New
2 Rag
YP703030
FRONT FORK INSPECTION

1. Inspect:
8 Inner tube bending
Inner tube bending limit:
0.2 mm
Scratches/bends/damageReplace.
w
Do not attempt to straighten a bent inner tube
as this may dangerously weaken the tube.
YP.....
FRONT FORK ASSEMBLY

Reverse the DISASSEMBLY procedure.
1. Install:
8 Damper rod 1
8 Rebound spring 2
8 Oil lock piece 3
8 Inner tube 4
1
2
3
6-37
FRONT FORK
CHAS
2. Install:
8 Inner tube 1
Into outer tube 2.
3. Install:
8 Plain washer 1 New
New
R.
LT
T.
4. Tighten:
NOTE:
23Nm(2.3 m.kg)
Tighten the damper rod bolt 1 while holding

the damper rod with a T-handle 2 and a 8 mm
hexagon bolt 3.
2
3
1
T-handle
90890-01326
5. Install:
8 Oil seal 1 New
8 Retaining clip
Use the fork seal driver weight 2 and
the attachment 3.
NOTE:
New
8 Before installing the oil seal 1, apply lithium

soap base grease onto the oil seal lips.
8 Adjust the retaining clip so that it fits into the
outer tube groove.
cC
Make sure that the oil seal numbered side faces
upward.
6-38
Fork seal driver weight:

90890-01367
Attachment:
90890-01400
FRONT FORK
CHAS
6. Inspect:
8 Inner tube operation
Unsmooth operationDisassembly and
recheck.
7. Fill:
8 Fork oil 1
Oil quantity:
88 cc
Recommended oil:
Fork oil 10 W or equivalent
8. After filling up, slowly pump the fork up
and down to distribute the fork oil.
9. Install:
8 Front fork spring 1
NOTE:
M
a
8 Install the fork spring with its smaller pitcha

upward .
8 Before installing the cap bolt, apply grease
to the O-ring.
8 Temporarily tighten the cap bolt.
EB703050
FRONT FORK INSTALLATION

Reverse the REMOVAL procedure.
1. Install:
8 Front fork 1
NOTE:
3
1
Apply grease onto cap bolt O-ring before installing cap bolt.
R.
T.
R.
6-39
T.
2. Tighten:
8 Cap bolts 2
8 Pinch bolts 3
45Nm(4.5 kg.m)
40Nm(4.0 kg.m)
ELECTRICAL COMPONENTS
ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1Main switch
2Resister
3Audio pilot
4Flasher relay
5Oil level gauge
6C.D.I. UNIT
7Fuel level gauge
8Starter relay
9Fuse
0Battery
qIgnition coil
wRectifier/Regulator
eHorn
6
5
7
4
8
1
0
e
7-1
ELEC
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
1
LOCK
OPEN
OFF
CHECK
ON
B R
R B
Gy Br
Br Gy
B/W
B/W
Br
Gy
Or
Or
Or
Y/R
Y/R
YR
LW
LW
RW
GY
Y/R
B/R
Y/R
Y/R
L/G
W/R
B/R
W/R
Or
L/Y
GY
L/Y
LW
YB
G/R L/R
8
'
:
OFF
START
Y/B
Br
Br
L/R
G/R
L Y/R
L/G L/W
L/R G/R
Y/R L
YR
LG
LW
YB
L/W L/G
Br
Br/W
Dg B
Ch
Y
G
Br
Y
G
GY
G/Y
G/Y
G/Y
LR
Dg
x c v
Ch
t
G/Y L
G Y
Y G
L/R B
B L/R
Ch
Dg
Dg
Dg
Dg
7-2
Ch
Ch
Dg
Ch
Dg
Dg
Ch
Ch
p
Ch
L
Gy
Br/W
L
Gy
G Ch
Ch G
Ch G/R
Br/W
B Dg
Y
Br Dg
G/R Ch
P
4
N
6
Gy
Br
h
&
%
Br
Br
Gy
f
OFF
PUSH
Dg Br
Br/W
Dg
Br
G/R
Br
Br
Gy
Br//W
Gy
W B
R Y/R
L G/Y
-
CIRCUIT DIAGRAM
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
y
u
i
o
p
a
s
d
f
g
h
j
k
l
;
z
x
c
v
b
n
m
,
.
/
Main switch
Main fuse
Battery
Starter relay
Starter motor
Rectifier regulator
Auto choke
C.D.I. magneto
C.D.I. unit
Ignition
Spark plug
Resister
Rear brake switch
Front brake switch
Tail/Brake light
Rear flasher light(right)
Rear flasher light(left)
Audio pilot
Front flasher light(right)
Front flasher light(left)
ELEC
Head light
Flasher relay
Horn
Handlebar switch (left)
Horn switch
Dimmer switch
Turn switch
Fuel sender
Meter
Fuel gauge
Oil indicator light
Meter light
High beam indicator light
Oil level gauge
Handlebar switch (right)
Starter switch
Light switch
Sidestand switch
Auxiliary light
COLOR CODE
Gray
L/R
Blue/ Red
Yellow
R/B
Red/Black
White
R/Y
Red/Yellow
Black/Red
R/W Red/white
Black
Gy
Br
Brown
Ch
Chocolate
Dg
Dark Green
Green
Br/W Brown/White
Blue
G/R
Green/Red
W/G White/Green
Or
Orange
G/Y
Green/Yellow
G/W Green/White
Sb
Sky blue
L/B
Blue/Black
W/R White/Red
Pink
L/Y
Blue/Yellow
L/G
Red
L/W Blue/White
B/R
7-3
Y/R
Yellow/White
Blue/Green
CHECKING SWITCHES
ELEC
YP-N
CHECKING SWITCHES
CHECKING STEPS
Using pocket tester, check switches for continuity between their terminals to determine
whether they are correctly connected.
Replace the switch component if any of the
combinations does not produce the correct
reading.
Pocket tester:
90890-03112
NOTE:
8 Turn the switch to the ON, OFF positions
several times.
8 Adjust the pocket tester to correct 0 position before checking switches.
8 Set the pocket tester selector to 1.
SWITCH CONNECTION AS SHOWN IN THIS
MANUAL
This manual contains connection charts, like
the one shown on the left, showing the terminal connections of switches (e.g. the main
switch, handlebar switch, brake switch, lighting switch etc.)
Br R
OFF
ON
Br
The column on the extreme left indicates the

different switch positions, the top line indicates
the colors of the leads connected to the terminals on the switch.
?? indicates terminals between which
there is continuity, i.e. a closed circuit, in the
given switch position.
In this chart:
Br and R have continuity with the switch in
the ON position.
7-4
CHECKING SWITCHES
ELEC
SWITCH POSITION AND TERMINAL CONNECTION

Before checking a switch refer to the checking switches as shown in the left page and
check for the correct terminal connections
(closed circuit) according to the color combinations shown in the chart.
Poor connection, faultRepair or replace.
Main switch
Gy Br R B B/W
B
Gy
LOCK
OPEN
OFF
*
ON
R
Br
Rear brake switch
Front brake switch
Horn switch
P
Release
Push in
G/R Ch
P Br/W
B Dg
Dimmer switch
G G/R Y
&
%
Y
G
Start switch
L
Y/R
L/G L/W
G/R L/R
Turn switch
Ch Br/W Dg
L/W L/G
Release
Push in
Light switch
Y/R Y/B L/R L G/R
8
'
:
Fuse
7-5
ELEC
IGNITION SYSTEM
CIRCUIT DIAGRAM
1
B R
R B
Gy Br
Br Gy
B/W
B/W
Br
Gy
LOCK
OPEN
OFF
CHECK
ON
Or
Or
W B
R Y/R
W
Y/R
LW
GY
Y/R
B/R
Y/R
Y/R
L/Y
LW
RW
B/R
Or
L/G
4
R
W/R
W/R
Y/R
YR
GY
L/Y
LW
YB
n
,
L/R G/R
G/R L/R
8
'
:
OFF
START
Y/B
Br
Br
L/R
L Y/R
L/G L/W
G/R
Y/R L
YR
LG
LW
YB
L/W L/G
Br
Ch G/R
Br/W
Br/W
B Dg
Dg B
Ch
Y
G
Br
Y
G
GY
G/Y
G/Y
G/Y
x c v
LR
t
G/Y L
G Y
Y G
L/R B
B L/R
Dg
Dg
Ch
Ch
Dg
Dg
Main switch
C.D.I. magneto
C.D.I. unit
Ignition coil
Spark plug
7-6
Ch
Dg
Ch
Dg
Dg
Ch
Ch
Ch
1
8
9
0
q
Ch
Dg
L
Gy
L
Gy
G Ch
Br/W
Gy
Br
Br Dg
Ch G
G/R Ch
P
4
N
6
Dg Br
h
&
%
Br
Br
Gy
f
OFF
PUSH
Br/W
Dg
Br
G/R
Br
Br
Gy
Br//W
Gy
0
Or
L G/Y
-
IGNITION SYSTEM
ELEC
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE
(NO SPARK OR INTERMITTENT SPARK)
NOTE:
8 Remove the following parts before troubleshooting.
1) Battery box cover
4) Tail cover
2) Center cowling
5) Side cover (right)
3) Rear carrier
8 Use the following special tools in this troubleshooting.
Ignition checker:
90890-06754
1.
8
8
8
Pocket tester: Pocket tester:

90890-03112
Spark plug
Check the spark plug condition.
Check the spark plug type.
Check the spark plug gap.
Refer to the SPARK PLUG INSPECTION
section in the CHAPTER 3.
Standard spark plug:

BPR7HS (NGK)
Spark plug gap:
0.9~1.0 mm
INCORRECT
CORRECT
Spark plug is faulty, replace it or repair plug

gap.
2. Ignition spark gap
8 Disconnect the spark plug cap from spark
plug.
8 Connect the ignition checker 1 as shown.
2 Spark plug cap
3 Spark gap
8 Check the ignition spark gap.
8 Start engine, and increase spark gap until
misfire occurs.
Minimum spark gap:
6.0 mm (0.24 in)
MEETS SPECIFICATION
OUT OF SPECIFICATION OR NO
SPARK
Ignition system is good.
7-7
IGNITION SYSTEM
ELEC
3. Spark plug cap resistance

8 Remove the spark plug cap.
8 Connect the pocket tester ( 1k) to the
spark plug cap.
8 Check the spark plug cap for specificated
resistance.
1k
Spark plug cap resistance:

5k at 20C (68F)
OUT OF SPECIFICATION
MEETS
SPECIFICATION
4. Ignition coil resistance
8 Disconnect the ignition coil leads from the
ignition coil.
8 Connect the pocket tester ( 1) to the
ignition coil.
Replace spark plug cap.
Ignition coil:
Tester (+) leadTerminal 1
Tester () leadCoil base 2
8 Check the primary coil for specification
resistance.
Primary coil resistance:
0.32~0.48 at 20C (68F)
8 Connect the pocket tester ( 1 k) to the
ignition coil.
Tester (+) leadSpark plug lead 1
Tester (-) leadCoil base 2
8 Check the secondary coil for specificated
resistance.
Secondary coil resistance:
5.68 ~ 8.52 k at 20C (68F)
(Spark plug lead - Coil base)
BOTH MEET
SPECIFICATIONS
Ignition coil is faulty, replace it.
*
7-8
IGNITION SYSTEM
ELEC
*
5. Pickup coil resistance
8 Disconnect the pickup coil coupler from
the wireharness.
pickup coil terminal.
CDI
Magneto
W
Y/R
B
B/R
W/R
Tester (+) leadWhite/Red lead 1

Tester (-) leadBlack 2
8 Check the pickup coil for specificated resistance.
Pickup coil resistance:

400~ 600 at 20C (68F)
(White/Red-Black)
Pickup coil is faulty, replace it.
MEET
SPECIFICATION
1
6. Source resistance
8 Disconnect the source coil coupler from
the wireharness.
source coil terminal.
B/R
CDI
Magneto
W/R
W
Y/R
B
2
Tester (+) leadBlack/Red lead 1

Tester () leadBlack 2
8 Check the source coil for specificated resistance.
Source coil resistance:

640 ~ 960 at 20C (68F)
(Black/Red - Black )
Source coil is faulty, replace it.
MEET
SPECIFICATION
POOR CONFECTION
7. Wiring connection
Check the entire ignition system for connections.
Refer to the WIRING DIAGRAM section.
Correct.
CORRECT
Replace CDI unit.
7-9
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
CIRCUIT DIAGRAM
1
LOCK
OPEN
OFF
CHECK
ON
B R
R B
Gy Br
Br Gy
Br
Gy
B/W
B/W
Or
Or
W B
R Y/R
W
Y/R
LW
GY
Y/R
B/R
Y/R
Y/R
L/Y
LW
RW
B/R
Or
L/G
4
R
W/R
W/R
Y/R
YR
GY
L/Y
LW
YB
n
,
L/R G/R
G/R L/R
8
'
:
OFF
START
Y/B
Br
Br
L/R
L Y/R
L/G L/W
G/R
Y/R L
YR
LG
LW
YB
L/W L/G
Br
Ch G/R
Br/W
Br/W
B Dg
Dg B
Ch
Y
G
Br
Y
G
GY
G/Y
G/Y
G/Y
x c v
LR
t
G/Y L
G Y
Y G
L/R B
B L/R
Dg
Dg
Ch
Ch
Dg
Dg
Main fuse
Battery
Rectifier Regulator
CDI magnet
7-10
Ch
Dg
Ch
Dg
Dg
Ch
Ch
Ch
2
3
6
8
Ch
Dg
L
Gy
L
Gy
G Ch
Br/W
Gy
Br
Br Dg
Ch G
G/R Ch
P
4
N
6
Dg Br
h
&
%
Br
Br
Gy
f
OFF
PUSH
Br/W
Dg
Br
G/R
Br
Br
Gy
Br//W
Gy
0
Or
L G/Y
-
CHARGING SYSTEM
ELEC
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED.
NOTE:
1) Front protector bar
4) Tail cover
2) Upper cover
5) Right side cover
3) Rear carrier
8 Use the following special tool (s) in this trobleshooting.
Inductive tachometer:
90890-03113
Pocket tester:
90890-03112
1. Fuse (main)
8 Remove the fuse.
fuse.
8 Check the fuse for continuity.
NO CONTINUITY
Fuse is faulty, replace it.

CONTINUITY
2. Battery
8 Check the battery condition
Refer to the BATTERY INSPECTION section in the CHAPTER 3.
INCORRECT
Open circuit voltage:

12.8V or more at 20C (68F)
8 Clean battery terminals.

8 Recharge or replace battery.
CORRECT
7-11
CHARGING SYSTEM
ELEC
*
3. Charging voltage
8 Connect the inductive tachometer to the
spark plug lead.
8 Connect the pocket tester (DC20V) to the
battery.
Tester (+) leadBattery (+) terminal
Tester (-) leadBattery () terminal
8 Start the engine and accelerate to about
5,000 r/min.
8 Check charging voltage.
Charging voltage:
13 ~ 14 V at 4,000 r/min
NOTE:
MEETS SPECIFICATION
Use a full charged battery.

OUT OF
SPECIFICATION
Charging circuit is good.
4. Charging coil and lighting coil resistance
8 Disconnect the charging coil coupler from
the wireharness.
8 Connect the pocket tester 1 to the
charging coils.
8 Measure the charging coil and lighting coil
resistance.
1
2
B/R
CDI
Magneto
W/R
3
Charging coil resistance:
Tester (+) leadWhite lead 1
Tester () leadBLACK 3
Lighting coil resistance:
Tester (+) leadYellow/Red 2
Tester () leadBLACK 3
Charging coil resistance:

0.5~0.7 at 20C (68F)
0.4~0.6 at 20C (68F)
Charging coil is faulty, replace it.
MEET
SPECIFICATION
*
7-12
W
Y/R
B
CHARGING SYSTEM
*
Check the entire ignition system for connections.
POOR CONNECTION
OK
Correct.
Replace rectifier regulator.
7-13
ELEC
ELEC
ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM
1
LOCK
OPEN
OFF
CHECK
ON
B R
R B
Gy Br
Br Gy
Br
Gy
B/W
B/W
Or
Or
W B
R Y/R
W
Y/R
LW
GY
Y/R
B/R
Y/R
Y/R
L/Y
LW
RW
B/R
Or
L/G
4
R
W/R
W/R
Y/R
YR
GY
L/Y
LW
YB
n
,
L/R G/R
G/R L/R
8
'
:
OFF
START
Y/B
Br
Br
L/R
L Y/R
L/G L/W
G/R
Y/R L
YR
LG
LW
YB
L/W L/G
Br
Ch G/R
Br/W
Br/W
B Dg
Dg B
Ch
Y
G
Br
Y
G
GY
G/Y
G/Y
G/Y
x c v
LR
t
G/Y L
G Y
Y G
L/R B
B L/R
Dg
Dg
Ch
Dg
Dg
e
r
m
.
Main switch
Main fuse
Battery
Starter relay
Starter motor
CDI unit
Ch
Front brake switch

Rear brake switch
Starter switch
Sidestand switch
7-14
Ch
Dg
Ch
Dg
Dg
Ch
Ch
Ch
1
2
3
4
5
9
Ch
Dg
L
Gy
L
Gy
G Ch
Br/W
Gy
Br
Br Dg
Ch G
G/R Ch
P
4
N
6
Dg Br
h
&
%
Br
Br
Gy
f
OFF
PUSH
Br/W
Dg
Br
G/R
Br
Br
Gy
Br//W
Gy
0
Or
L G/Y
-
ELEC
TROUBLESHOOTING
STARTER MOTOR DOES NOT OPERATE.
NOTE:
1)Battery box cover
4)Side covers (left and right)
2)Rear carrier
5)Trunk
3)Tail cover
6)Handlebar cover (front)
8 Use the following special tool in this troubleshooting.
Pocket tester:
90890-03112
1. Fuse
8 Remove the fuse.
8 Connect the pocket tester ( 1 ) to the
fuse.
8 Check the fuse for continuity.
NO CONTINUITY
Fuse is faulty, replace it.
CONTINUITY
2. Battery
8 Check the battery condition.
Refer to the BATTERY INSPECTION section in the CHAPTER 3.
INCORRECT
Open circuit voltage:

12.8 V or more at 20C (68F)
CORRECT
3. Starter motor
8 Connect the battery1positive terminal
and starter motor cable 2 using a jumper
lead 3 * .
w
8 A wire for the jumper lead must have the
equivalent capacity as that of the battery lead
or more, otherwise it may cause the jumper
lead to be burned.
8 This check is likely to produce sparks, so be
sure that no flammable gas or fluid is in the
vicinity.
DOES NOT MOVE
8 Check the starter motor for operation.

MOVES
Starter motor is faulty, repair or replace it.

7-15
ELEC
*
4. Starter relay
8 Disconnect the relay unit coupler from the
wire harness.
8 Connect the pocket tester( 1)and
battery(12V) to the relay unit coupler terminals.
L/W
G/Y
Battery(+)lead
Blue/White terminal 1
Battery()lead
Green/Yellow terminal 2
8 Check the starter relay for continuity.

NO CONTINUITY
Tester (+) lead 3 terminal

Tester (-) lead 4 terminal
CONTINUITY
Replace the starter relay.
NO CONTINUITY
5. Main switch
Refer to CHECKING SWITCHS section.
CONTINUITY
Main switch is faulty, replace it.
NO CONTINUITY
6. START switch
Refer to CHECKING SWITCHS section.
CORRECT
START switch is faulty, replace handlebar

switch (right).
7-16
*
7. Sidestand switch
8 Disconnect the sidestand switch coupler
from the wire harness.
8 Check the switch component for the continuity between Blue/Yellow 1 and Black
2.
1
L/Y
POOR CONNECTION
2
Correct.
CORRECT
8. Brake switches (front and rear)
8 Disconnect the brake switch leads from the
wire harness.
8 Connect the pocket tester ( 1 )to the
brake switch leads.
G/Y
Br
8 Check the brake switch for continuity

Switch
Position
Good
condition
Brake is
applied
Brake is
not applied
Bad condition
BAD CONDITION
:Continuity
:No continuity
Replace brake switch(es).
GOOD
CONDITION
7-17
ELEC
*
8 Check the entire electrical starting system
for connections.
Refer to WIRING DIAGRAM section.
POOR CONNECTION
GOOD
CONDITION
Correct.
Replace CDI unit.
7-18
ELEC
ELEC
STARTER MOTOR
2
4
T.
R.
13Nm(1.3kg.m)
3
1
Order
Job name/Part name
Qty
Starter motor removal

Rear carrier
Tail cover
Battery box cover
Left/Right side cover
Center cowling
Muffler
Rear wheel
Air shroud 3
1
2
Remarks
Refer to COVER PANEL section in

CHAPTER 3.
Refer to REAR WHEEL AND REAR

BRAKE section in CHAPTER 6.
Refer to ENGINE REMOVAL section
chapter 4.
2
1
Starter motor coupler

Starter motor
7-19
ELEC
STARTER MOTOR DISASSEMBLY
2
4
T.
R.
13Nm(1.3kg.m)
3
1
Order
1
2
3
4
5
Job name/Part name
Qty
Remarks
Disassembly the parts in order.
Starter motor disassembly

O-ring
Rear bracket
Armature assy
Ring
Brush holder set
1
1
1
1
1
Refer to Starter motor assembly

assembly.
7-20
ELEC
YP803034

1. Inspect:
8 Commutator
DirtClean it with #600 grit sandpaper.
2. Measure:
8 Commutator diameter a
Commutator wear limit:

16.6 mm
Out of specificationReplace the starter
motor
3. Measure:
8 Mica undercut a
Mica undercut:
1.35 mm
Out of specificationScrape the mica to
the proper value (a hacksaw blade can
be ground to fit).
NOTE:
The mica insulation of the commutator must
be undercut to ensure proper operation of commutator.
4. Inspect:
8 Armature coil resistances (installation/
continuity)
DefectsReplace the starter motor.
If commutator is dirty, clean it with sandpaper.
Good
condition
Bad condition
O: Continuity
x: No continuity
Bad conditionReplace.
7-21
ELEC
5. Measure:
8 Brush length a
Brush length wear limit
1.0 mm
6. Measure:
8 Brush spring force
Fatigue/out of specificationReplace as
a set.
7-22
ELEC
LIGHTING SYSTEM
LIGHTING SYSTEM
CIRCUIT DIAGRAM
1
LOCK
OPEN
OFF
CHECK
ON
B R
R B
Gy Br
Br Gy
Br
Gy
B/W
B/W
Or
Or
W B
R Y/R
W
Y/R
LW
GY
Y/R
B/R
Y/R
Y/R
L/Y
LW
RW
B/R
Or
L/G
4
R
W/R
W/R
Y/R
YR
GY
L/Y
LW
YB
n
,
L/R G/R
G/R L/R
8
'
:
OFF
START
Y/B
Br
Br
L/R
L Y/R
L/G L/W
G/R
Y/R L
YR
LG
LW
YB
L/W L/G
Br
Ch G/R
Br/W
Br/W
B Dg
Dg B
Ch
Y
G
Br
Y
G
GY
G/Y
G/Y
G/Y
x c v
LR
t
G/Y L
G Y
Y G
L/R B
B L/R
Dg
Dg
Ch
Ch
Dg
Dg
C.D.I. magneto
c High beam indicator light
Tail light
, Light switch
Head light
/ Auxiliary light
Light dimmer switch
Meter light
7-23
Ch
Dg
Ch
Dg
Dg
Ch
Ch
Ch
8
t
a
h
x
Ch
Dg
L
Gy
L
Gy
G Ch
Br/W
Gy
Br
Br Dg
Ch G
G/R Ch
P
4
N
6
Dg Br
h
&
%
Br
Br
Gy
f
OFF
PUSH
Br/W
Dg
Br
G/R
Br
Br
Gy
Br//W
Gy
0
Or
L G/Y
-
LIGHTING SYSTEM
ELEC
YP805010
TROUBLESHOOTING
IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT
AND/OR METER LIGHT FAIL TO COME ON.
Procedure
Check:
1. Lights switch
2. Dimmer switch
3. Wiring connection (entire lighting system)
NOTE:
1) Front handlebar cover
2) Rear carrier
3) Right side cover
8 Use the special tools specified in the troubleshooting section.
Pocket tester:
90890-03112
NO CONTINUITY
YP .....
1. Lights switch
Refer to CHECKING SWITCHES section.
CONTINUITY
Replace the right handlebar switch.
NO CONTINUITY
YP .....
2. Dimmer switch
Replace the left handlebar switch.

3. Lighting coil resistance
8 Disconnect the lighting coil coupler from
the wireharness.
8 Connect the pocket tester x 1 to the
lighting coils.
8 Measure the lighting coil resistances.
1
B/R
CDI
Magneto
W/R
Tester (+) leadYellow/Red lead 1

Tester () leadBlack 2

0.4 ~ 0.6 at 20C (68F)
MEET
SPECIFICATION
Lighting coil is faulty, replace it.

7-24
W
Y/R
B
LIGHTING SYSTEM
ELEC
*
YP.....
8 Check the connections of the entire lighting system.
Refer to WIRING DIAGRAM.
POOR CONNECTIONS
OK
Correct.
Check the condition of each of the lighting

systems circuits.
Refer to LIGHTING SYSTEM CHECK
YP805020
LIGHTING SYSTEM CHECK

1. If the headlight and the high beam indicator light fail to come on.
1. Bulb and bulb socket
NO CONTINUITY
CONTINUITY
2. Voltage
headlight and high beam indicator light
couplers.
Replace the bulb and/or bulb socket.
A When the dimmer switch is on low beam.

B When dimmer switch is on high beam.
G Y
L/R B
Headlight:
Tester (+) leadGreen 1 or Yellow 2 lead
Tester negative () leadBlack 3 lead
High beam indicator light:
Tester I+) leadYellow 4 lead
Tester () leadBlack 5 lead
Y
L
Gy
B
7-25
LIGHTING SYSTEM
ELEC
*
8 Turn the main switch to on.
8 Turn the light switch to on position.
8 Turn the dimmer switch to low beam or
high beam.
8 Check for voltage (12V) on the lead at bulb
socket connectors.
The wiring circuit from the main switch to

bulb socket connector is faulty. Repair.
MEETS
SPECIFICATION
This circuit is not faulty.
YP805021
2. If the meter light fails to come on.

NO CONTINUITY

CONTINUITY
2. Voltage
bulb socket coupler.
Tester (+) lead
Blue terminal 1
Tester (-) lead
Black terminal 2
1
L
Gy
B
2
8 Turn the lights switch to on.
8 Check the voltage (12V) of the leads on
the bulb socket connector.
MEETS
SPECIFICATION
The wiring circuit from main switch to bulb

socket is faulty. Repair.
7-26
LIGHTING SYSTEM
ELEC
3. Auxilialy light does not come on.

8 Check the bulb and bulb socket for continuity
NO CONTINUITY
CONTINUITY
Bulb and/or bulb socket are faulty, replace.
2. Voltage
bulb socket connector.
Tester (+) lead Blue / Red 1 lead.
Tester (-) lead Black 2 lead.
Y G
B L/R
2

8 Turn the lights switch to PO or ON.
8 Check the voltage (12V) on the Blue lead
at the bulb socket connector.
MEETS
SPECIFICATION
(12V)
Wiring circuit from main switch to bulb

socket connector is faulty. Repair.
7-27
LIGHTING SYSTEM
ELEC
YP805022
4. The taillight fails to come on.

NO CONTINUITY
CONTINUITY
2. Voltage
Tester (+) lead
Blue terminal 1
Tester (-) lead
Black terminal 2
1
L G/Y
- B
2
8 Turn the lights switch to on
8 Check the voltage (12V) on the bulb socket
connector.
MEETS
SPECIFICATION
The wiring circuit from main switch to bulb

connector is faulty. Repair.
7-28
ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM
1
LOCK
OPEN
OFF
CHECK
ON
B R
R B
Gy Br
Br Gy
Br
Gy
B/W
B/W
Or
Or
W B
R Y/R
W
Y/R
LW
GY
Y/R
B/R
Y/R
Y/R
L/Y
LW
RW
B/R
Or
L/G
4
R
W/R
W/R
Y/R
YR
GY
L/Y
LW
YB
n
,
L/R G/R
G/R L/R
8
'
:
OFF
START
Y/B
Br
Br
L/R
L Y/R
L/G L/W
G/R
Y/R L
YR
LG
LW
YB
L/W L/G
Br
Br/W
Ch G/R
Br/W
Br/W
B Dg
Dg B
Ch
Y
G
Br
Y
G
GY
G/Y
G/Y
G/Y
x c v
LR
Ch
Dg
L
Gy
L
Gy
G Ch
Gy
Br
Br Dg
Ch G
G/R Ch
P
4
N
6
Dg Br
h
&
%
Br
Br
Gy
f
OFF
PUSH
Br/W
Dg
Br
G/R
Br
Br
Gy
Br//W
Gy
t
G/Y L
G Y
Y G
L/R B
B L/R
L G/Y
-
p
Ch
Dg
Dg
Ch
Ch
Dg
Dg
1
2
3
e
r
t
y
Main switch
Main fuse
Battery
Rear brake switch
Front brake switch
Brake light
Rear flasher light(right)
Dg
Ch
u
i
o
p
s
d
f
Rear flasher light(left)

Audio pilot
Front flasher light(right)
Front flasher light(left)
Flasher relay
Horn
Handlebar switch (Left)
7-29
g
j
k
;
z
v
b
Ch
Dg
Dg
Ch
Ch
0
Or
Horn switch
Turn switch
Fuel sender
Fuel meter
Oil indicator light
Oil level gauge
SIGNAL SYSTEM
ELEC
YP806010
TROUBLESHOOTING
IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT
FAIL TO COME ON. IF THE HORN FAILS TO SOUND.
Procedure
Check:
1. Fuse (Main)
2. Battery
3.Main switch
4.Wiring connection (entire signal system)
NOTE:
1) Battery box cover
5) Tail cover
2) Front protector bar
6) Side covers(Left/Right)
3) Upper cover
7) Center cover
4) Rear carrier
8 Use the special tools in the troubleshooting section .
Pocket tester:
90890-03112
NO CONTINUITY
YP.....
1. Fuse
CONTINUITY
Replace the fuse.
YP.....
2. Battery
8 Check the battery condition.
Refer to BATTERY INSPECTION section
in CHAPTER 3.
IN CORRECT
CORRECT

YP.....
3. Main switch
NO CONTINUITY
CONTINUITY
Replace the main switch.
7-30
SIGNAL SYSTEM
*
YP......
4. Wireharness
8 Check the connections of the entire signal system.
Refer to CIRCUIT SYSTEM WIRING DIAGRAM section.
POOR CONNECTION
Correct.
CONTINUITY
Check condition of each of the signal
systems circuits.
Refer to SIGNAL SYSTEM CHECK section.
7-31
ELEC
SIGNAL SYSTEM
ELEC
YP806020
SIGNAL SYSTEM CHECK

1. If the horn fails to sound.
NO CONTINUITY
1. HORN switch

CONTINUITY
Br
2. Voltage
horn lead.
Tester (+) leadBrown terminal 1.
Tester (-) leadFrame ground
8 Check for voltage (12V) on the Brown
lead at the horn terminal.
The wiring circuit from the main switch to the

horn is faulty. Repair.
MEETS
SPECIFICATION
Br
3. Horn
horn at the Pink terminal.
Tester (+) leadPink 1 terminal.
8 Check for voltage on the Pink lead at
the horn terminal.
NO CONTINUITY
CONTINUITY
Adjust or replace horn.
Replace the horn.
7-32
SIGNAL SYSTEM
ELEC
YP806022
2. If the brake light fails to come on:

NO CONTINUITY
CONTINUITY

NO CONTINUITY
2. Brake switch (Front/Rear)

CONTINUITY
Replace brake switch.
3. Voltage
Tester (+) leadGGreen/Yellow terminal 1
Tester (-) leadGBlack terminal 2
1
L G/Y
- B
2
8 The brake lever is pulled in.
8 Check for voltage (12V) of the Yellow
lead on the bulb socket connector.
MEETS
SPECIFICATION
8 Wiring circuit from the main switch to the
bulb socket connector is faulty. Repair.
Refer to SIGNAL SYSTEM WIRING DIAGRAM .
7-33
SIGNAL SYSTEM
ELEC
YP806023
3. If the flasher light and/or turn indicator

light fails to blink.
NO CONTINUITY

CONTINUITY
NO CONTINUITY
2. Turn switch
CONTINUITY
FLASHER
3. Voltage
flasher relay coupler.
RELAY
Br/W
Br
Tester (+) leadBrown terminal 1.


8 Check for voltage (12V) of the Brown
lead at the flasher relay terminal.
The wiring circuit from main switch to flasher

relay connector is faulty. Repair.
MEETS
SPECIFICATION
FLASHER
RELAY
4. Voltage
flasher relay coupler.
Br/W
Br
Tester (+) leadBrown/White terminal 1.

8 Check for voltage (12V) on the Brown/
White lead at the flasher relay terminal.
MEETS
SPECIFICATION
The flasher relay is faulty. Replace.
*
7-34
ELEC
SIGNAL SYSTEM
*
5. Voltage
Ch
At flasher light (left)

Tester (+) leadChocolate lead 1
Tester (-) leadBlack terminal 3
Dg
Ch B
Dg B
Ch B
At flasher light (right)

Tester (+) leadDark green lead 2
Dg B

8 Turn the turn switch to left or right.
8 Check for voltage (12V) on the Chocolate lead and Dark green at the flasher
light terminal.
8 Wiring circuit from the turn switch to bulb
socket connector is fault. Repair.
Refer to CIRCUIT DIAGRAM.
MEETS
SPECIFICATION
4. OIL indicator light does not come on.
NO CONTINUITY

8 Check the bulb and bulb socket for continuity.
Replace bulb and/or bulb socket.
CONTINUITY
2. Oil level switch
8 Remove the oil level switch from the oil
tank.
8 Connect the Pocket Tester ( x 1) to the
oil level switch.
Br Gy
Tester (+) LeadBrown 1

Tester () LeadGray 2
8 Check the oil level gauge for continuity.

Good
Bad condition
condition
?
?
A Upright position
B Upside down
?
?
position
Switch position
BAD CONDITION
: No continuity
?: Continuity
Replace oil level switch.

GOOD CONDITION
7-35
SIGNAL SYSTEM
ELEC
3. Voltage
8 Connect the Pocket Tester (DC20V) to the
Tester (+) LeadGray lead 1
Tester (-) LeadFrame ground 2
B Gy L
8 Turn the main switch to *

8 Check for voltage (12V) on the Gray lead
at bulb socket connector.
MEETS
SPECIFICATION
(12V)
This circuit is good.

8 Check the entire signal system for connections.
YP806027
5. If the fuel gauge fails to operate.

1. Fuel sender
8 Remove the fuel sender from the fuel tank.
8 Disconnect the fuel sender coupler from
the wireharness.
Connect the pocket tester ( 10) to the
fuel sender coupler lead.
Tester (+) leadGreen terminal 1

Tester () leadBlack terminal 2
8 Check the fuel sender for specificated resistance.
Float position
UP 3
DOWN 4
Specificated
resistance
4~10
90~100
BOTH MEET
SPECIFICATION
Replace the fuel sender.
7-36
SIGNAL SYSTEM
ELEC
2. Voltage
fuel gauge coupler.
Tester (+) leadBrown terminal 1

8 Turn the main switch to ON.

8 Check for voltage (12V) of the Brown
lead on the fuel sender lead.
Gy B
Br
G
Dg
Ch
MEETS
SPECIFICATION
Check the connection of the entire signal system .
Refer to CHECKING OF CONNECTIONS.
Refer to CIRCUIT DIAGRAM.
3. Fuel gauge
8 Connect the fuel sender to wireharness.
8 Move the float to UP 1 or DOWN 2.
NOTE:
Before reading the meter, stay put the float
for more than three minutes respectively at
UP or DOWN.
8 Turn the main switch to ON.

8 Check the fuel gauge needle moves F
or E.
Float position
DOES NOT MOVE
Needle moves
Float UP 1
Float DOWN2
Replace the fuel gauge.
MOVES
7-37
ELEC
AUTO CHOKE SYSTEM
AUTO CHOKE SYSTEM

CIRCUIT DIAGRAM
1
B R
R B
Gy Br
Br Gy
B/W
B/W
Br
Gy
LOCK
OPEN
OFF
CHECK
ON
Or
Or
W B
R Y/R
W
Y/R
LW
GY
Y/R
B/R
Y/R
Y/R
L/Y
LW
RW
B/R
Or
L/G
4
R
W/R
W/R
Y/R
YR
GY
L/Y
LW
YB
n
,
L/R G/R
G/R L/R
8
'
:
OFF
START
Y/B
Br
Br
L/R
L Y/R
L/G L/W
G/R
Y/R L
YR
LG
LW
YB
L/W L/G
Br
Ch G/R
Br/W
Br/W
B Dg
Dg B
Ch
Y
G
Br
Y
G
GY
G/Y
G/Y
G/Y
x c v
LR
Ch
Dg
L
Gy
L
Gy
G Ch
Br/W
Gy
Br
Br Dg
Ch G
G/R Ch
P
4
N
6
Dg Br
h
&
%
Br
Br
Gy
f
OFF
PUSH
Br/W
Dg
Br
G/R
Br
Br
Gy
Br//W
Gy
t
G/Y L
G Y
Y G
L/R B
B L/R
p
Ch
Dg
Dg
Ch
Ch
Dg
Dg
Dg
Ch
7 Auto choke
8 C.D.I. magneto
7-38
Ch
Dg
Dg
Ch
Ch
0
Or
L G/Y
-
AUTO CHOKE SYSTEM

YP.....
TROUBLESHOOTING
IF THE AUTO CHOKE FAILS TO OPERATE.
Procedure
Check:
2. Auto choke unit resistance
3. Wiring connection (entire auto choke system)
NOTE:
1. Battery box cover
2. Rear carrier
3. Tail cover
4. Right side cover
8 Use the special tools specified in the troubleshooting section.
Pocket tester:
90890-03112

8 Disconnect the CDI magneto couple from
wire harness.
8 Connect the pocket tester ( x1) to the
lighting coil coupler
Tester (+) LeadYellow/Red 1 terminal
Tester (-) LeadFrame earth
CDI
Magneto
W
Y/R
B
2 C.D.I. magneto
8 Check the lighting coil for specificated resistance
Lighting coil resistance

0.4~0.6 20C (68F)
Replace the lighting coil
MEETS
SPECIFICATION
*
7-39
ELEC
AUTO CHOKE SYSTEM
ELEC
*
YP...
2. Auto choke unit resistance

8 Disconnect the auto choke unit coupler
from the wireharness.
8 Connect the pocket tester (x1) to the auto
choke unit coupler lead.
B B
Tester (+) leadBlack terminal 1

Auto choke unit resistance:

16~24(20C)
MEETS
SPECIFICATION
Replace the auto choke unit.
8 Check the connection of the entire auto
choke system.
Refer to CIRCUIT DIAGRAM section.
POOR CONNECTION
Correct.
7-40
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.

PROBABLE CAUSE
FUEL SYSTEM
Fuel tank
8 Empty
8 Clogged fuel filter
8 Deteriorated fuel or fuel containing water or
foreign material
8 Clogged fuel tank cap
Fuel cock
8 Clogged fuel hose

8 Clogged fuel cock
8 Faulty fuel cock operation
8 Broken or disconnected fuel cock
Carburetor
8 Deteriorated fuel, fuel containing water or

foreign material
8 Clogged pilot jet
8 Clogged pilot air passage
8 Sucked-in air
8 Deformed float
8 Groove-worn needle valve
8 Improperly sealed valve seat
8 Improperly adjusted fuel level
8 Improperly set pilot jet
8 Clogged starter jet
8 Improperly adjusted pilot air screw
Auto choke
8 Starter plunger malfunction

8 Wax malfunction
8 Faulty thermister
Air cleaner
8 Clogged air filter
8-1

IGNITION SYSTEM
TRBL
SHTG
PROBABLE CAUSE
Spark plug
8 Improper plug gap

8 Worn electrodes
8 Wire between terminals broken
8 Improper heat range
8 Faulty spark plug cap
Ignition coil
8 Broken or shorted primary/secondary coil

8 Faulty spark plug lead
8 Broken body
CD I unit system
8 Faulty CD I unit
8 Faulty source coil
8 Faulty pick-up coil
Switches and wiring
8 Faulty main switch

8 Broken or shorted wiring
8 Faulty sidestand switch
COMPRESSION SYSTEM
PROBABLE CAUSE
Cylinder and cylinder head
8 Loose spark plug

8 Loose cylinder head or cylinder
8 Broken cylinder head gasket
8 Broken cylinder gasket
8 Worn, damaged or seized cylinder
Piston and piston rings
8 Improperly installed piston ring

8 Worn, fatigued or broken piston ring
8 Seized piston ring
8 Seized or damaged piston
Crankcase and crankshaft
8 Improperly seated crankcase

8 Improperly sealed crankcase (Damaged oil
seal)
8 Seized crankshaft
Reed valve
8 Deformed reed valve stopper

8 Improperly seated read valve
8 Loose intake manifold
8 Broken gasket
8 Broken reed valve
8-2
POOR IDLE SPEED PERFORMANCE

POOR MIDIUM AND HIGH SPEED PERFORMANCE
TRBL
SHTG

PROBABLE CAUSE
Carburetor
8 Improperly returned starter plunger

8 Clogged or loose pilot jet
8 Clogged pilot air jet
8 Improperly adjusted idle speed
(Throttle stop screw)
8 Improper throttle cable play
8 Flooded carburetor
Auto choke
8 Starter plunger malfunction

8 Wax malfunction
8 Faulty thermister
Air cleaner
8 Clogged air cleaner
Ignition system
8 Faulty spark plug

8 Faulty spark plug read
8 Faulty C.D.I. unit
8 Faulty ignition coil
POOR MIDIUM AND HIGH SPEED

PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
Carburetor
PROBABLE CAUSE
8 Refer to starting failure/Hard starting item
(Fuel system, Ignition system, compression
system)
8 Clogged or loose main nozzle
8 Clogged or loose main jet
8 Improperly set clip position of jet needle
8 Improperly adjust fuel level
8 Sucked-in air
Air cleaner
Muffler
8 Clogged
8-3
POOR MIDIUM AND HIGH SPEED PERFORMANCE
TRBL
SHTG
FULTY AUTOMATIC(V-BELT TYPE)

PROBABLE CAUSE
SCOOTER DOES NOT MOVE WHILE ENGINE

IS OPERATING
V-belt
8 Worn, damaged or slipped V-belt
Cam, slider
8 Worn, damaged
Compression spring
8 Damaged
Transmission
8 Damaged
CLUTCH OUT FAILURE

Clutch weight spring
8 Damaged
Clutch shoe
8 Pealed lining
Primary sheave
8 Seized primary sliding sheave and collar
POOR STANDING START(LOW CLIMBING

ABILITY)
PROBABLE CAUSE
V-belt
8 Worn or slipped V-belt
Primary sheave
8 Improper operation
8 Damaged
Compression spring
8 Damaged
Secondary sheave
8 Worn guide pin
Clutch shoe
8 Plealed lining
POOR ACCELERATION(POOR HIGH SPEED)
PROBABLE CAUSE
V-belt
8 Worn
8 Greasy
Weight
8 Worn
8 Worn
Primary/ Secondary seave
8-4
OVER HEAT / POOR SPEED
TRBL
SHTG
OVER HEAT
OVER HEAT
PROBABLE CAUSE
Ignition system
8 Improper plug gap

8 Improper spark plug heat range
Fuel system
8 Improper carburetor setting

Compression system
8 Carbon accumulation of cylinder head
Muffler, Exhaust pipe
8 Clogged
Oil pimp
Brake
8 Faulty oil pump

8 Faulty oil quality
8 Drag
Cooling system
8 Fan damaged
POOR SPEED
POOR SPEED
PROBABLE CAUSE
Ignition system
8 Faulty spark plug

8 Improper spark plug heat range
Fuel system
8 Clogged fuel tank cap

8 Clogged carburetor
Compression system
8 Worm cylinder
8 Worm, fatigued or broken piston ring
8 Broken cylinder head gasket
8 Broken cylinder gasket
8 Carbon accumulation of cylinder head
Muffler, Exhaust pipe
8 Clogged
Clutch
8 Refer to FAULTY AUTOMATIC
Brake
8 Drag
8-5
IMPROPER KICKING
TRBL
SHTG
IMPROPER KICKING
SLIPPING
PROBABLE CAUSE
Kick axle assembly
8 Low tension of kick clip

8 Worn kick axle
8 Worn or damaged kick gear
8 Damaged kick clip
8 Kick clip coming off
8 Damaged kick clip stopper
Transmission oil
8 Improper quality (Low viscosity)

8 Deterioration
HARD KICKING
PROBABLE CAUSE
Kick axle assembly
8 High tension of kick clip

8 Seized kick gear
Cylinder, piston and piston ring
8 Damaged or seized cylinder

8 Damaged or seized piston
8 Damaged or seized piston ring
Crankcase and crankshaft
8 Improperly seated crankcase

8 Improperly seated crankshaft
8 Damaged or seized crankshaft
8 Damaged or seized crankshaft bearing
KICK CRANK NOT RETURNING
PROBABLE CAUSE
Kick axle assembly
8 Damaged kick return spring

8 Kick return spring coming off
8 Kick clip coming off
8 Damaged kick return spring stopper
8-6
FAULTY BRAKE
TRBL
SHTG
FAULTY BRAKE
PROBABLE CAUSE
POOR BRAKING EFFECT

Drum brake
8 Worn brake shoe

8 Worn or rusty brake drum
8 Improperly adjusted brake free play
8 Improper brake cam lever position
8 Improper brake shoe position
8 Fatigue/Damaged return spring
8 Oily or greasy brake shoe
8 Oily or greasy brake drum
8 Broken brake cable
Disc brake
(Front)
8 Worn brake pad

8 Worn brake disc
8 Air in brake fluid
8 Leaking brake fluid
8 Faulty master cylinder kit
8 Faulty caliper seal kit
8 Loose union bolt
8 Broken brake hose
8 Oily or greasy brake pad
8 Oily or greasy brake disc
PROBABLE CAUSE
MALFUNCTION
8 Bent, deformed or damaged inner tube

8 Bent or deformed outer tube
8 Damaged fork spring
8 Worn or damaged slide metal
8 Improper oil viscosity
8 Improper oil level
8-7
INSTABLE HANDLING
TRBL
SHTG
INSTABLE HANDLING
PROBABLE CAUSE
INSTABLE HANDLING
Handlebar
8 Improperly installed or bent
Steering
8 Improperly installed steering column

(Improperly tightened ringnut)
8 Bent steering column
8 Damaged ball bearing or bearing race
Front forks
8 Broken spring
8 Bonded front forks
Tires
8 Uneven tire pressures on both sides

8 Incorrect tire pressure
8 Unevenly worn tires
Wheels
8 Damaged bearing
8 Bent or loose wheel axle
8 Excessive wheel run-out
Frame
8 Twisted
8 Damaged head pipe
8 Improperly installed bearing race
Engine bracket
8 Bent or damaged
Rear shock absorber
8 Fatigued spring
8 Oil leakage
8-8
FAULTY SIGNAL AND LIGHTING SYSTEM
TRBL
SHTG
FAULTY SIGNAL AND LIGHTING

SYSTEM
PROBABLE CAUSE
HEADLIGHT DARK
8 Improper bulb
8 Too many electric accessories
8 Hard charging (Broken charging coil)
8 Incorrect connection
8 Improperly grounded
8 Poor contacts (main or light switch)
8 Bulb life expires
PROBABLE CAUSE
BULB BURNT OUT
8 Improper bulb
8 Faulty main and/or light switch
8 Bulb life expires
PROBABLE CAUSE
FLASHER DOES NOT BLINK
8 Discharged battery
8 Faulty flasher switch
8 Faulty flasher relay
8 Broken wireharness
8 Loosely connected coupler
8 Bulb burnt out
8 Faulty fuse
PROBABLE CAUSE
FLASHER KEEPS ON

8 Insufficient battery capacity (nearly discharged)
8 Bulb burnt out
8-9
FAULTY SIGNAL AND LIGHTING SYSTEM

FLASHER BLINKS SLOWER
TRBL
SHTG
PROBABLE CAUSE
8 Insufficient battery capacity
(nearly discharged)
8 Improper bulb
8 Faulty main and/or flasher switch
FLASHER BLINKS QUICKER
PROBABLE CAUSE
8 Improper bulb
HORN DOES NOT SOUND
PROBABLE CAUSE
8 Faulty battery
8 Faulty fuse
8 Faulty main and/or horn switch
8 Improperly adjusted horn
8 Faulty horn
8 Broken wireharness
8-10
WIRING DIAGRAM
1
B R
R B
Gy Br
Br Gy
B/W
B/W
Br
Gy
LOCK
OPEN
OFF
CHECK
ON
Or
Or
W B
R Y/R
Or
Y/R
Y/R
YR
LW
RW
GY
Y/R
B/R
Or
Y/R
Y/R
L/G
LW
W/R
B/R
W/R
L/Y
GY
L/Y
LW
YB
n
,
L/R G/R
G/R L/R
8
'
:
OFF
START
Y/B
Br
Br
L/R
G/R
L Y/R
L/G L/W
Y/R L
YR
LG
LW
YB
L/W L/G
B Dg
Ch
Y
G
Br
Y
G
GY
G/Y
G/Y
G/Y
LR
Dg
x c v
t
G/Y L
G Y
Y G
L/R B
B L/R
Ch
Dg
Dg
Ch
Dg
Dg
Dg
Ch
Ch
Dg
Ch
Black
Brown
3 Battery
4 Starter relay
Ch
Dg
Chocolate
Dark Green
5 Starter motor
6 Rectifier regulator
G
L
Green
Blue
7 Auto choke
8 C.D.I. magneto
Or
Sb
Orange
Sky blue
9 C.D.I. unit
0 Ignition
P
R
Pink
Red
q Spark plug
w Resister
Gy
Y
Gray
Yellow
e Rear brake switch

r Front brake switch
W
B/R
White
Black/Red
t Tail/Brake light
y Rear flasher light(right)
Br/w
G/R
Brown/White
Green/Red
u Rear flasher light(left)

i Audio pilot
G/Y
L/B
Green/Yellow
Blue/Black
o Front flasher light(right)

p Front flasher light(left)
L/Y
L/W
Blue/Yellow
Blue/White
a Head light
s Flasher relay
L/R
R/B
Blue/ Red
Red/Black
d Horn
f Handlebar switch (left)
R/Y
R/W
Red/Yellow
Red/white
g Horn switch
h Dimmer switch
Y/R
W/G
Yellow/White
White/Green
j Turn switch
k Fuel sender
G/W
W/R
Green/White
White/Red
l Meter
; Fuel gauge
L/G
Blue/Green
L G/Y
-
z Oil indicator light

x Meter light
c High beam indicator light
v Turn indicator light
Dg
Ch
p
Ch
B
Br
Dg B
Ch
Br/W
L
Gy
Ch G/R
Br/W
L
Gy
G Ch
4
N
6
Gy
Br
Br Dg
Ch G
G/R Ch
Dg Br
Br/W
&
%
OFF
PUSH
Br
Br
Gy
Dg
Br
Br/W
Br
G/R
Br
Br
Gy
Br//W
Gy
1 Main switch
2 Main fuse
b Oil level gauge

n Handlebar switch (right)
m Starter switch
, Light switch
. Sidestand switch
/ Auxiary light

B Ws 100 Service

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YW100

HOW TO USE THIS MANUAL

PERIODIC INSPECTION AND

Illustrated symbols 1 to 9 are designed as

The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOUR

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

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

ENGINE SERIAL NUMBER

Initial serial number:

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER PINS

BEARINGS AND OIL SEALS

3. Connect and disconnect the connector two

If there is no continuity, clean the terminals.

HOW TO USE THE CONVERSION TABLE

HOW TO USE THE CONVERSION TABLE

Tool name / Usage

Clutch spring compressor

Crankshaft Installer pot 1

This tool is used for removing the rotor.

Crankcase Separating tool

Oil seal guide

Ring nut wrench

This tool is used to measure the clearance

Tool name / Usage

Oil seal guide

Oil seal installer

Yamaha bond No. 1215

This sealant (bond) is used for crankcase

Front fork seal driver

These tools are used when installing the

Air cooled 2 strcke, gasoline torque induction

Oil Type or Grade:

For YAMAHA brand:

Wet type element

Regular unleaded gasoline

Dry, Centrifugal automatic

Steel tube underbone

200kpa(2.0 kg/cm2, 2.0 bar)

Coil spring/oil damper

Bulb wattage x quantity:

*Lines indicate straightedge measurement

1.2 2.05 mm/keystone

Automatic centrifugal clutch:

Front disc brake:

Rear drum brake:

Frame and engine bracket

Spark plug cap:

Constant mesh type

Oil level gauge:

GENERAL TORQUE SPECIFICATIONS

A: Distance across flats

LUBRICATION POINTS AND LUBRICATION TYPE

LUBRICATION POINTS AND LUBRICATION TYPE

Oil Seal Lip (All)

Small End Bearing

Big End Bearing

Starter Idle Bearing

Primary Drive Gear Bearing

Kick Axle Bearing

Drive Axle Bearing

Main Axle Bearing

Piston, Piston Ring Piston Pin and Cylinder