Yamaha YW100 Service Manual

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. (See”Illustrated symbols”)
1st title 1: This is the title of the chapter with its symbol on the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accom-
panied 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.
2 1 4 3
6
7
8
INDEX
GENERAL INFORMATION
1
SPECIFICATIONS
2
PERIODIC INSPECTION AND
ADJUSTMENT 3
ENGINE OVERHAUL
4
CARBURETION
5
CHASSIS
6
– +
ELECTRICAL
7
TROUBLESHOOTING
8
1 2 EB003000
ILLUSTRATED SYMBOLS
GEN
INFO SPEC Illustrated symbols 1 to 9 are designed as
thumb tabs to indicate the chapter’s number
3 4 and content.
1 General information
INSP
ADJ ENG 2 Specifications
3 Periodic inspection and adjustment
5 6 4 Engine
5 Cooling system
6 Carburetion
COOL CARB 7 Chassis
8 Electrical
7 8 9 Troubleshooting
– +
CHAS ELEC
9 0 Illustrated symbols 0 to u are used to iden-
TRBL tify the specifications appearing in the text.
0 Possible to maintain with engine mounted
SHTG q Filling fluid
q w w Lubricant
e Special tool
r Tightening
t Wear limit, clearance
y Engine speed
e r
u Ω, V, A
T.
R.
t y u
Illustrated symbols i to d in the exploded dia-

grams indicate the types of lubricants and lu-
brication points.
i o p i Apply engine oil
o Apply gear oil
E G M p Apply molybdenum disulfide oil
a Apply wheel bearing grease
a s d s Apply lightweight lithium-soap base grease
M
d Apply molybdenum disulfide grease
B LS
Illustrated symbols f to g in the exploded

f g diagrams indicate the where to apply locking
agent f and when to install new parts g .
LT New 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. Modifica-
tions 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.
Q The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOUR

SAFETY IS INVOLVED!
w 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 dam-

age 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
GEN
SCOOTER INDENTIFICATION INFO
GENERAL INFORMATION
1
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
GEN
SCOOTER INDENTIFICATION INFO
ENGINE SERIAL NUMBER
1 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
IMPORTANT INFORMATION INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES
1. Remove all dirt, mud, dust and foreign ma-
terial before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the “SPECIAL TOOLS” section.
4. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts
that have been “mated” through normal
wear. Mated parts must always be reused
or replaced as an assembly.
5. During machine disassembly, clean all
parts and place them in trays in the order
of disassembly. This will speed up assem-
bly and allow for the correct installation
of all parts.
300-008 6. Keep all parts away from any source of
fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication
jobs. Other brands may be similar in func-
tion and appearance, but inferior in qual-
ity.
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
EB101030
LOCK WASHERS/PLATES AND COTTER PINS

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

Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating
of lightweight lithium base grease to the seal
lips. Oil bearings liberally when installing, if
appropriate.
1 Oil seal
cC
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing surfaces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassem-
bly. 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 op-
posite the thrust 3 it receives. See sec-
tional view.
4 Shaft
1-4
GEN
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 con-
nector.
6. Connect:
8 Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
8 If there is no continuity, clean the termi-
nals.
8 Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
8 For a field remedy, use a contact revitalizer
available on the market.
8 Use the tester on the connector as shown.
1-5
GEN
HOW TO USE THE CONVERSION TABLE INFO
EB201000
HOW TO USE THE CONVERSION TABLE

All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC MULTIPLIER IMP
** mm × 0.03937 = ** in
2 mm × 0.03937 = 0.083 in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
m.kg 7.233 ft.lb
Torque m.kg 86.794 in.lb
cm.kg 0.0723 ft.lb
cm.kg 0.8679 in.lb
Weight kg 2.205 lb
g 0.03527 oz
km/h 0.6214 mph
km 0.6214 mi
Distance m 3.281 ft
m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc(cm3) 0.03527 oz (IMP liq.)
Volume/ cc(cm3) 0.06102 cu.in
Capacity lit(liter) 0.8799 qt(IMP liq.)
lit(liter) 0.2199 gal(IMP liq.)
kg/mm 55.997 lb/in
Miscellaneous kg/cm2 14.2234 psi(lb/in2)
Centigrade 9/5(°C)+32 Fahrenheit (°F)
1-6
GEN
SPECIAL TOOLS 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 inappropri-
ate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name / Usage Illustration

90890-01235 Rotor holding tool
This tool is used to remove the flywheel

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

exhaust and steering ringnut.
90890-01337 Clutch spring compressor
These tools are used for removing the nut

with holding the compression spring.
90890 -01274 Crankshaft Installer pot 1
-01275 Crankshaft Installer bolt 2
-01277 Adapter 3 ,Spacer 4
-01288 These tools are used to install the crank-
shaft.
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
GEN
SPECIAL TOOLS INFO
Tool No. Tool name / Usage Illustration
90890-03112 Pocket tester
These instruments are invaluable for check-

ing 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 crank-

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

case 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 Front fork seal driver 1 2
-01400 2 Weight 1
Adapter 2
These tools are used when installing the

fork seal.
1-8
GENERAL SPECIFICATION SPEC
SPECIFICATION
GENERAL SPECIFICATION
Model YW100E1/2/3/4/5/6/7/8
Model code: 4VPB/F/G/H/J/K/L/M
Dimensions:
Overall length 1,890mm
Overall width 660mm
Overall height 1,115mm
Seat height 765mm
Wheelbase 1,270mm
Minimum ground clearance 119mm
Minimum turning radius 1,800mm
Basic weight:
With oil and full fuel tank 96kg
Engine:
Engine type Air cooled 2 strcke, gasoline torque induction
Cylinder arrangement Forward- inclined single cylinder
Displacement 101cm3
Bore × stroke 52.0 × 47.6 mm
Compression ratio 6.6:1
Starting system Electric and kick starter
Lubrication system: Separate lubrication
Oil Type or Grade:
Engine Oil 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
Transmission Oil SAE 85W/140
Oil Capacity:
Oil Tank (Engine Oil) 1.4L
Transmission Oil:
Periodic Oil Change 0.11L
Total Amount 0.13L
Air Filter: Wet type element
Fuel:
Type Regular unleaded gasoline
Tank Capacity 5.7L
Carburetor:
Type / Manufacturer VM16SS/MIKUNI
2-1
Model YW100E1/2/3/4/5/6/7/8
Spark Plug:
Type/Manufacturer BPR7HS/NGK
Gap 0.9 ~ 1.0 mm
Clutch Type Dry, Centrifugal automatic
Transmission:
Primary Reduction System Herical gear
Primary Reduction Ratio 47/15 (3.133)
Secondary Reduction System Spur gear
Secondary Reduction Ratio 43/13 (3.308)
Transmission Type V-belt
Operation Automatic
Chassis:
Frame type Steel tube underbone
Caster angle 26˚
Trail 86mm
Tire:
Type Tubeless
Size front 120/90-10
rear 130/90-10
Manufacturer front CHENG SHIN
rear CHENG SHIN
Type front 56J
rear 59J
Maximum load* 160 kg
Cold tire Pressure:
Up to 90 kg
Front 200kpa(2.0 kg/cm2, 2.0 bar)
Rear 200kpa(2.0 kg/cm2, 2.0 bar)
90 kg load~Maximum load*
Front 200kpa(2.0 kg/cm2, 2.0 bar)
Rear 200kpa(2.0 kg/cm2, 2.0 bar)
Brake:
Front brake type Single disc brake
operation Right hand operation
Rear brake type Drum brake
operation Left hand operation
Suspension:
Front suspension Telescopic fork
Rear suspension Unit swing
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel:
Front wheel travel 70 mm
Rear wheel travel 55 mm
Electrical:
Ignition system C.D.I
Generator system Flywheel Magneto
Battery type YTX5L-BS
Battery capacity 12V 4AH
2-2
Model YW100E1/2/3/4/5/6/7/8
Headlight type: Bulb S1
Bulb wattage x quantity:
Headlight 25W/25W×2
Tail/brake light 5W/21W×1
Flasher light 10W×4
Auxiliary light 5W×2
Licence plate light 5W×1
Meter light 3.4W×1/1.7W×1
High beam indicator light 1.7W×1
Oil indicator light 1.7W×1
Turn indicator light 1.7W×1
2-3
MAINTENANCE SPECIFICATION SPEC
MAINTENANCE SPECIFICATION
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ... 0.05 mm
*Lines indicate straightedge measurement

Cylinder:
Bore size 52.002~52.012 52.10 mm
Taper limit ... 0.05 mm
Out of round limit ... 0.03 mm
Piston:
Piston to cylinder 0.044~0.045 mm 0.10 mm
clearance ...
Piston size “D” 51.958~51.967 mm ...
Measuring point “H” 10 mm ...
Oversize 1st H 52.52 mm ...
2nd D 52.50 mm ...
Piston pin bore 14.004~14.015 mm 14.045 mm
inside diameter
Piston pin outside diameter 13.996~14.000 mm 13.975 mm
Piston Ring:
Sectional Sketch (B × T)/Type
Top Ring 1.2 × 2.05 mm/keystone
2nd Ring 1.2 × 2.05 mm/keystone
End Gap (Installed):
Top Ring 0.15~0.35 mm 0.10 mm
2nd Ring 0.15~0.35 mm 0.10 mm
Side Clearance ( Installed):
Top Ring 0.03~0.05 mm 0.60 mm
2nd Ring 0.03~0.05 mm 0.60 mm
Crankshaft:
Crank Width “A” 37.90~37.95 mm ...

Run Out Limit “C” 0.03 mm ...
Connecting Rod Big End Side
Clearance “D” 0.2~0.5 mm 1.0 mm
Small End Free Play “F” 0.4~0.8 mm ...
2-4
Item Standard Limit
Automatic centrifugal clutch:
Clutch shoe thickness 4.0 mm 2.5 mm
Clutch housing inside diameter 112 mm 122.5 mm
Clutch shoe spring free length 26.2 mm ...
Clutch - in revolution 2,800~3,400 r/min ...
Clutch - stall revolution 4,500~5,500 r/min ...
V-belt:
V-belt width 17.7 mm 16.0 mm
Transmission:
Main Axle Runout Limit 0.08 mm
Drive Axle Runout Limit 0.08 mm
Kick Starter:
Type Ratchet type
Kick Clip Tension 150~250 g
Carburetor:
I.D. Mark 4VP-30 (4VPL/M:4VP-40)
Main Jet (M .J .) #75
Main nozzle (NJ) E-3
Jet Needle-clip Position (J.N.) 4DM7-3
Main Air Jet ( M .A .J .) ø0.7
Cutaway (C.A.) 3.5
Pilot Jet (P.J.) #32.5
Pilot Air Screw (A.S .) 1and1/4±1/4
Valve Seat Size (V.S.) ø1.5
Starter Jet (G .S.) #30
Float Height 16.5 mm
Fuel level height 3.0~4.0 mm
Engine Idling Speed 1,750~1,850 r/min
Reed Valve:
Valve Stopper Height 6.0~6.4 mm
Reed Valve Clearance Less than 0.2 mm
2-5
TIGHTENING TORQUES
ENGINE
Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m•kg
Spark plug — M 14 1 20 2.0

Cylinder head and cylinder Nut M7 4 14 1.4
Cylinder Stud bolt M7 4 17 1.7
Air shroud 3 Screw M6 3 7 0.7
Air shroud 1×3 Screw 6.0 1 2 0.2
Fan Screw M6 3 7 0.7
Autolube pump Screw M5 2 4 0.4
Reed valve Bolt M6 4 11 1.1
Air filter Screw M6 1 9 0.9
Carburetor cap Screw M4 2 2 0.2
Exhaust pipe Screw M6 2 9 0.9
Muffler Bolt M8 2 26 2.6
Exhaust protector Bolt M6 3 9 0.9
LT
Cap and pipe Bolt M6 3 11 1.1
LT
Exhaust cover Bolt M6 5 13 1.3
LT
Crankcase 1×2 Bolt M6 6 12 1.2
Crankcase cover 2 Bolt M6 6 12 1.2
Crankcase cover 1 Bolt M6 12 12 1.2
Air duct Screw M6 2 7 0.7
Crankcase holder Screw M6 2 7 0.7
Drain bolt Bolt M8 1 18 1.8
Oil plug Plug M 14 1 3 0.3
Idle gear plate Screw M6 2 8 0.8
Kick crank Bolt M6 1 9 0.9
Starter motor Bolt M6 2 13 1.3
Clutch housing Nut M 10 1 40 4.0
Primary sheeve Nut M 12 1 45 4.5
Magnet base Screw M6 2 8 0.8
Magnet rotor Nut M 12 1 43 4.3
2-6
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Ball bearing ...
No /size of steel balls: Upper 22 pcs ...
Lower 19 pcs ...
Front suspension:
Front fork travel 70 mm ...
Fork free length 350.8 mm 212.1 mm
Fork length (Installed) 212.1 mm ...
Spring rate (K1) 15.68 Nm/mm(1.6 kg/mm) ...
(K2) 23.5 Nm/mm(2.43 kg/mm) ...
Oil capacity 88 c.c ...
Oil grade Fork oil 10W or equivalent
Inner tube vend limit ... 0.2 mm
Rear suspension:
Shock absorber stroke 55 mm ...
Shock absorber free length (Installed) 281.8 mm ...
Spring free length (Installed) 159.8 mm ...
Spring rate (K1) 71.15 N/mm(7.26 kg/mm) ...
Front wheel: ...
Type Cast wheel ...
Rim size MT3.50×10 ...
Rim material Aluminum ...
Rim runout limit radial ... 1 mm
lateral ... 1 mm
Rear wheel:
Type Cast wheel ...
Rim size MT3.50×10 ...
Rim material Aluminum ...
Rim runout limit radial ... 1 mm
lateral ... 1 mm
Front disc brake:
Type Single ...
Disc outside diameter × thickness 180×4.0 180×3.5 mm
Pad thickness 6 mm 0.8 mm
Master cylinder inside diameter 11 mm ...
Caliper cylinder outside diameter 34.93 mm ...
Brake fluid type DOT #4 ...
Rear drum brake:
Type Leading, trailing ...
Drum inside diameter 130 mm 131 mm
Shoe thickness 4 mm 2 mm
Brake lever:
Brake lever free play (front at lever side) 2~5 mm ...
Brake lever free play (rear) 10~20 mm ...
Throttle cable free play 3~5 mm ...
2-7
TIGHTENING TORQUES
CHASSIS
Tightening
Thread torque
Part to be tightened Remarks
size
Nm m•kg
Frame and engine bracket M 12 84 8.4

Engine bracket, compression rod and engine M 10 45 4.5
Protect bar M6 10 1.0
Rear grip M6 13 1.3
Sidestand M 10 55 5.5
Rear shock absorber and frame M 10 30 3.0
Rear shock absorber and engine M8 16 1.6
Steering ring nut M 25 22 2.2 See
Handle holder and steering shaft M 10 43 4.3 ”page6-29”
Brake hose and master cylinder M8 20 2.0
Fuel tank M6 10 1.0
Fuel cock M6 7 0.7
Fuel sender M5 4 0.4
Box M6 4 0.7
Seat lock assembly M6 7 0.7
Plastic parts & cover M5 2 0.2
Footrest board M6 7 0.7
Front wheel axle and nut M 10 70 7.0
Rear wheel axle and nut M 14 120 12.0
Rear brake cam lever M6 10 1.0
Front brake caliper and front fork M8 23 2.3
LT
Brake disc and hub M10 20 2.0
Brake hose and front fork(lower)-bolt M6 5 0.5
Brake hose and front fork(lower)-nut M6 11 1.1
Brake hose and front fork(upper)-bolt M6 7 0.7
Brake caliper and bleed screw M5 6 0.6
2-8
ELECTRICAL
Item Standard limit
Ignition timing:
Ignition timing (B.T.D.C.) 14˚ at 5,000 r/min ...
Advanced type Electrical type ...
C.D.I.:
Pickup coil resistance/color 400~600Ω at 20˚C/ ...
(Black-White/Red) ...
Source coil resistance/color 640~960 Ω ...
(Black/ Red ,Black) ...
C.D.I. unit model/manufacturer 4VP/TIIC ...
Ignition coil:
Model/manufacturer 4VP/TIIC ...
Minimum spark gap 6 mm ...
Primary winding resistance 0.32~0.48 Ω at 20˚C ...
Secondary winding resistance 5.68~8.52kΩ at 20˚C ...
Spark plug cap:
Type Resin type ...
Resistance 5 kΩ ...
Charging System/Type: Flywheel magneto ...
C.D.I. Magneto:
Model/Manufacturer 4VP/TIIC ...
Nominal output 12V 85W/5,000 rpm
Charging current 0.6A at 3,000r/min ...
1.2A at 8,000r/min ...
Charging voltage 13~14V at 4,000 rpm ...
Charging Coil Resistance (Color) 0.48~0.72 Ω (White-Black) ...
Lighting Coil Resistance (Color) 0.4~0.6 Ω (Yellow/Red- Black) ...
Lighting Voltage 12~15V (3,000~8,000 rpm) ...
Rectifier: ...
Model/Manufacturer 3GF/Taichung ...
Capacity 8A ...
Withstand voltage 18V ...
Battery:
Specific gravity 1.320 ...
Electric starter system:
Type Constant mesh type ...
Starter motor:
Model/manufacturer/ID number 4VP/TIIC ...
Operation voltage 12V ...
Output 0.2 kw ...
Armature coil resistance 0.03~0.04 Ω at 20˚C ...
Brush overall length 7 mm 3.5 mm
Brash quantity 2 pcs ...
Spring force 400~600g 400g
Commutator diameter 17.6 mm 16.6 mm
Mica undercut (depth) 1.35 mm ...
Starter relay:
Model/manufacturer 3 KW/Shulin ...
Amperage rating 100A ...
Coil winding resistance 3.87~4.73 Ω at 20˚C ...
2-9
Item Standard limit
Horn:
Model/manufacturer 4VP/Asian ...
Maximum amperage 1.5A ...
Flasher relay:
Type Capacitor ...
Flasher frequency 60~120 Cycle/min ...
Fuel gage:
Model/manufacturer 4VP/San Chu ...
Sender unit resistance - full 4~10 Ω ...
- empty 90~100 Ω ...
Oil level gauge:
Model/manufacturer 4VP/Lun Ping ...
Circuit breaker:
Type Fuse ...
MAIN 7Ax1pc. ...
2-10
GENERAL TORQUE SPECIFICATIONS SPEC
GENERAL TORQUE General torque
A B
specifications
SPECIFICATIONS (Nut) (Bolt)
Nm m.kg
This chart specifies torque for standard fasten-
10 mm 6 mm 6 0.6
ers with standard I.S.O. pitch threads. Torque
specifications for special components or as- 12 mm 8 mm 15 1.5
semblies are included in the applicable sections 14 mm 10 mm 30 3.0
of this book. To avoid warpage, tighten multi- 17 mm 12 mm 55 5.5
fastener assemblies in a crisscross fashion, in 19 mm 14 mm 85 8.5
progressive stages, until full torque is reached. 22 mm 16 mm 130 13.0
Unless otherwise specified, torque specifica-
tions call for clean, dry threads. Components
should be at room temperature.
A B
A: Distance across flats

B: Outside thread diameter
2-11
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 E
Big End Bearing E
Starter Idle Bearing G
Primary Drive Gear Bearing G
Kick Axle Bearing G
Drive Axle Bearing G
Main Axle Bearing G
Starter Clutch M
Piston, Piston Ring Piston Pin and Cylinder E
Oil Pump Drive and Driven Gear LS
Sliding Surface (Secondary Sheave) BEL-LAY Assembly Lube®

Oil Seal and O-ring (Secondary Sheave) BEL-LAY Assembly Lube®
Cam Groove (Secondary Sheave) BEL-LAY Assembly Lube®
Crankcase Matching Surface Yamaha Bond No. 1215
CHASSIS
Lubrication Points Lubricant Type
Steering Shaft Bearing B
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 SPEC
CABLE ROUTING r C.D.I. unit E Pass the seat cable through
1 Horn t Throttle cable 1 the inside of frame.
2 Rectifier regulator y Wire harness F Align the clip with the white
3 Main switch A Pass the speedometer cable brand.
4 Resistor through the right hole of front G Clamp the wire harness
5 Headlight leads fender, then through the H Insert the seat cable through
6 Speedometer cable guide. the frame tube.
7 Ignition coil B Pass the wire harness I Clamp wireharness, autolube
8 Throttle cable through the inside of ignition pump cable, rear brake cable
9 Battery negative(-) coil. throttle cable 2.
0 Autolube pump cable C Secure the ground lead and J Position the cylinder between
q Fuel sender lead the ignition coil base to the the supporter and main
w Seat lock cable ignition coil stay. switch.
e Oil tank hose D Pass the wire harness
through the inside of oil tank.
2-13
CABLE ROUTING SPEC
1 Brake cable A Pass the brake hose through the holder.
2 Speedometer cable B Insert the fuel overflowhose bottom.
3 Fuel tank overflow hose C Pass the fuel overflowhose through the rear
4 Brake cable holder fender hole.
5 Air induct pipe D Pass the fuel overflowhose through the
6 Brake hose holder.
7 Brake hose holder E Hold the fuel overflowhose with a clamp.
8 License bracket F Pass the brake cable through the holder.
9 Flasher relay G Pass the brake cable through the hook.
0 Resistance
q Fuel tank breather hose
B 3
6 1 q
2
C
0
7
8
A G 5
F
4
2-14
CABLE ROUTING SPEC
1 Brake hose A Pass the brake hose through the holder.
2 Front fender
3 Front fork assembly
4 Nut
5 Plate washer
6 Brake hose holder
7 Flange bolt
8 Bolt
9 Brake hose holder
0 Flange bolt
1
7
3 5
2
1
1
5
4
3 A
0
6
8
3
7
5
6
5
4
2-15
CABLE ROUTING SPEC
1 Ignition coil r Battery(–)lead F Clamp autochoke leads and
2 Spark plug lead t Battery(+)lead autolube hose on to carburetor
3 Starter relay leads A Pass battery leads through throttle cable.
4 Auto choke leads the slot of footrestboard. G Pass the battery leads over frame
5 Starter relay B Cover them after securing member.
6 Bind starter relay leads. H Put fuse box on to footrest board
7 C.D.I. unit C Pass the seat lock cable holder.
8 Autolube hose through the hole of bracket. I Pass throttle cable2, wireharness,
9 Seat lock cable D Pass the fuel tank breath autolube pump cable, brake cable
0 Bracket hose over seat lock cable. through the outside of battery
q Fuel tank breather hose E Clamp carburetor vacuum box.
w Bind 2 hose, fuel hose and fuel
e Cooling pipe cock vacuum hose.
B 4
6 7 8
5 9
1 A 2
0
3
C
D
q
I e
H t rG
F wE
2-16
CABLE ROUTING SPEC
1 Flasher relay A Pass brake cable through the slot of bracket.
2 Speedometer B Avoid clamping front flasher leads when in-
3 Brake cable stalling handlebar covers.
4 Handlebar switch(left) C Pass throttle cable1 through between
5 Front flasher leads handlebar and wireharness.
6 Speedometer cable D Hang the wireharness bind on to the bracket.
7 Wire harness
8 Brake hose
9 Handlebar switch(right)
0 Throttle cable1
2-17
INTRODUCTION/ INSP
PERIODICMAINTENANCE/LUBLICATION INTERVALS ADJ
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
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 pre-
pared for sale. All service technicians should be familiar with this entire chapter.
YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

BREAK-IN EVERY
6,000 km 12,000 km
NO. ITEM ROUTINE TYPE INITIAL or or
6 months 12months
(1,000
(whichever (whichever
km) comes first) comes first)
• Check fuel hoses and vacuum

1 * Fuel line hose for cracks or damage. – ? ?
• Replace if necessary.
• Check condition.
Refer to SPARK
2 * Spark plug • Clean, regap or replace if neces- PLUG INSPECTION ? ? ?
sary.
3 * Air filter • Clean or replace if necessary. Same as engine oil ? ?
• Check operation, fluide level and
Brake fluid DOT 4
4 Front brake vehicle for fluid leakage. ? ? ?
• Correct accordingly.
• Replace brake pads if necessary.
• Check operation.
5 * Rear brake • Adjust brake lever free play and – ? ? ?
replace brake shoes if necessary.
• Check balance, runout and for
6 * Wheels damage. – ? ?
• Rebalance or replace if necessary.
• Check tread depth and for dam-
age.
7 * Tires • Replace if necesssary. – ? ?
• Check air pressure.
• Correct if necessary.
• Check Bearing for looseness or
8 * Wheel bearings 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).
• Make sure that all nuts, bolts and
10 * Chassis fasteners screws are properly tightened. – ? ?
• Tighten if necessary.
3-1
INSP
PERIODICINSPECTION AND ADJUSTMENTS ADJ
BREAK-IN EVERY
INITIAL 6,000 km 12,000 km
NO. ITEM ROUTINE TYPE or or
(1,000 6 months 12months
km) (whichever (whichever
comes first) comes first)
Sidestand/ • Check operation.

11 * Same as engine oil
? ?
centerstand • Replace if necessary.
12 * Sidestand switch • Check operation. – ? ? ?
• Check operation and for oil leak-
13 * Front fork age. – ? ?
• Correct accordingly.
• Check operation and shock ab-
14 * Rear shock absorber for oil leakage. – ? ?
sorber assembly • Replace shock absorber assembly
if necessary.
• Check engine idling speed and
15 * Carburetor starter operation. – ? ? ?
• Adjust if necessary.
• Check operation.
16 * Autolube pump • Correct if necessary. – ? ? ?
• Bleed if necessary.
• Check oil level and vehicle for oil
leakage.
17 * Final gear oil • Change oil at initial 1,000 km and SAE 85W 140 ? ? ?
thereafter every 24,000 km or 24
months.
18 * V-belt • Check for wear and damage. – ? ? ?
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
COVER AND PANEL ADJ
COVER AND PANEL
SIDECOVER AND SEAT
2 4
13Nm(1.3 kg.m)
T.
R.
7
Order Job name/Part name Q’ty Remarks

Sidecover and seat removal Remove the parts in order.
1. Battery box cover 1 NOTE:
Insert the (-) screwdriver into the slot of
battery cover and pickup then remove.
2. Seat 1
3. Seat hange 1
4. Rear carrier 1
5. Left side cover 1
6. Right side cover 1
7. Center cover 1
Reverse the removal procedure for instal-
lation.
3-3
INSP
COVER AND PANEL ADJ
LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD
6 7
10Nm(1.0kg.m)
T.
R.
4
7Nm(0.7kg.m)
T.
8
R.
5
2
3
9
Order Job name/ part name Q’ty Remarks

Lower cowling, upper cover, leg Remove the parts in order.
shield 1,2 and footrest board re-
moval
1. Lower cowling 1
2. Protector bar 1
3. Upper cover 1
4. Bolt 4
5. Leg shield 1 1
6. Main switch cover/ leg shield 2 1/1
7. Battery 1
8. Footrest board 1
9. Flap 2
lation.
3-4
INSP
COVER AND PANEL ADJ
HANDLEBAR COVER(FRONT AND REAR)
3
1
Order Job name / Part name Q’ty Remarks

Handlebar cover(Front and Rear) re- Remove the part in order.
moval.
1. Mirrors 2
2. Front handlebar cover 1
3. Rear handlebar cover 1
4. Flasher light(Left/Right) 1/1
lation.
3-5
INSP
ENGINE IDLE SPEED ADJUSTMENT ADJ
ENGINE
IDLE SPEED ADJUSTMENT
1. Remove
8 Battery box cover
1 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 posi-
tion.
Pilot air screw turns out:

1and1/4±1/4
3. Start the engine and let it warm up.

1 w
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 specification→Adjust.
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.
1
***************************************
3-6
INSP
THROTTLE CABLE FREE ADJUSTMENT ADJ
THROTTLE CABLE FREE ADJUSTMENT
1. Check:
8 Throttle cable free play a
Free play:
3 ~ 5 mm
◗
a ***************************************
M
Throttle cable free play adjustment steps;
NOTE:
Before adjusting the throttle cable free play, the
engine idle speed should be adjusted.
First step:
1 8 Remove the adjuster cover 1
1
2 8 Loosen the locknut 2 on the throttle cable.
3 8 Turn the adjuster 3 in or out until the speci-
fied free play is obtained.
Turning in→Free play is increased.

Turning out→Free 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:
3 2 8 Remove the left/right side covers and center
1
cover.
8 Remove the adjuster cover 1
8 Loosen the lockout 2
8 Turn the adjuster 3 in or out until the speci-
fied 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/ INSP
AUTOLUBE PUMP CABLE ADJUSTMENT ADJ
AUTOLUBE PUMP AIR BLEEDING
1 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.
1 8 Keep the oil running out until air bubbles dis-
appear.
8 When air bubbles are expelled completely,
tighten the bleed screw.
NOTE:
Check the bleed screw gasket. If damaged, re-
place with a new one.
*************************************
3. Air bleeding:
8 Pump distributor and/or delivery hose
*************************************
Air bleeding steps:
8 Start the engine.
❖ 1
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
a Out of specification→Adjust autolube
pump Cable.
NOTE:
The mark “I”a on the swing plate should be
b aligned with the mark “I”b on the autolube
pump body.
3-8
INSP
SPARK PLUG INSPECTION ADJ
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 align-
3 2 1 ment 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
Incorrect→Replace.
Standard spark plug:

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

0.9~1.0 mm
6. Tighten:
8 Spark plug 20 Nm (2.0 m.kg)
T.
R.
7. Install:
8 Battery box cover.
3-9
INSP
ENGINE OIL LEVEL INSPECTION ADJ
ENGINE OIL LEVEL INSPECTION
1 1. Inspect:
8 Engine oil level Oil level low→Add suf-
60 80 ficient oil by the following inspection
40 100
20
km/h
120
steps.
140
10
000010
1 “OIL” indicator light
Engine oil level visual inspection steps:
Turn main switch to ”*”

position.
“OIL” indicator light does “OIL” indicator light

not comes on. comes on.
Turn main switch to

“ON” position.
“OIL” indicator light does “OIL” indicator light

not come on. comes on.
Inspect faulty electrical Engine oil level and elec- Supply engine oil.
circuit, light bulbs etc. trical circuit are OK.
“OIL” indicator light comes on.
Recommended oil:
1 For Yamaha:
Yamalube 2 or 2-stroke engine oil
(JASO FC grade or ISO EG-C, EG-
D 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
TRANSMISSION OIL REPLACEMENT ADJ
TRANSMISSION OIL REPLACEMENT
1. Warm up the engine for several minutes,
3 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
1
NOTE:
Drain the transmission oil completely.
While draining, slightly tilt the scooter to
4 the right and to the left.
New
4. Inspect:
8 Gasket (drain bolt) 4 New
8 O-ring (oil filler plug) 3
Damage→Replace.
2
5. Install:
8 Drain bolt 18 Nm (1.8 m.kg)
T.
R.
6. Fill:
8 Transmission case
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
INSP
AIR FILTER ELEMENT CLEANING ADJ
AIR FILTER ELEMENT CLEANING
1. Remove:
8 Battery box cover
2. Remove:
8 Caburetor jont clamp 1
3. Remove:
3 8 Screw 1
8 Screw(for clamp) 2
8 Air filter 3
1
4. Remove:
8 Air filter case 1
8 Air filter element
cC
Never operate the engine with the air filter el-
ement removed. This will allow unfiltered air
1 to enter, causing rapid wear and possible en-
gine damage. Additionally, operation without
the cleaner element will affect carburetor jet-
ting 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
Damage→Replace.
6. Clean:
8 Air filter element
*************************************
Air filter element cleaning steps:
1
8 Wash the element gently, but thoroughly in
solvent.
3-12
INSP
AIR FILTER ELEMENT CLEANING 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 ele-

ment 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
INSP
V-BELT INSPECTION 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
1 8 V-belt 1
Cracks/Wear/Damage→Replace.
Oil or grease adhere to the
V-belt→Check the primary and second-
ary sheaves.
Refer to “ENGINE OVERHAUL - INSPEC-
TION AND REPAIR” section in the CHAP-
TER 4.
3. Measure:
8 V-belt width a
Out of specification→Replace.
a
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.
4. Install:
8 Crankcase cover(left) 12Nm(1.2kg.m)
T.
R.
8 Air cleaner joint clamp
3-14
FRONT BRAKE LEVER FREE PLAY CHECK/REAR BRAKE INSP
LEVER FREE PLAY CHECK/BRAKE PAD INSPECTION 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 sys-
tem. This air must be removed by bleeding the
brake system before the motorcycle is oper-
ated. Air in the system will cause greatly di-
minished 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:
a 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 cor-
rect free play is obtained.
***************************************
1
1 BRAKE PAD INSPECTION

1. Activate the brake lever.
2. Inspect:
8 Brake pad
Wear indicator 1 nearly contacting
brake disc→Replace brake pads as a set.
Refer to the “BRAKE PAD REPLACE-
MENT” section in the CHAPTER 6.
3 2
2 Brake disc
3 Brake pads
3-15
BRAKE SHOE INSPECTION/ INSP
BRAKE FLUID LEVEL INSPECTION ADJ
BRAKE SHOE INSPECTION
1. Activate the brake lever.
2. Inspect:
8 Wear indicator 1
Indicator at wear limit line 2→Replace
brake shoes.
1
BRAKE FLUID LEVEL INSPECTION

NOTE:
Position the scooter straight up when inspect-
ing the fluid level.
1 1. Inspect:
8 Fluid level is under “LOWER” level line
1→Fill to proper level.
Recommended fluid:
DOT#4
cC
The fluid may corrode painted surfaces or plas-
tic parts. Always clean up spilled fluid immedi-
ately.
w
8Use only the designated quality fluid. Other-
wise ,the rubberseals may deteriorate caus-
ing leakage and poor brake performance.
8Refill with the same type of fluid. Mixing flu-
ids may result in a harmful chemical reaction
leading to poor brake performance.
8Be careful that water does not enter the mas-
ter cylinder when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.
3-16
INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 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.
1 d. Place the other end of the tube into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in posi-
tion.
g. Loosen the bleed screw and allow the le-
ver 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 bleed-
ing the brake system.
*************************************
3-17
INSP
STEERING ADJUSTMENT ADJ
5 STEERING ADJUSTMENT
4 1. Check:
3
8 Steering assembly bearings
2
Gap the bottom of the forks and gently
1
rock the fork assembly back and forth.
Loosen→Adjust.
***************************************
Adjustment steps:
8 Remove upper cover, lower cowling, leg
shield 1,2. refer to “COVER AND PANEL” sec-
tion.
8 Remove all ringnuts using ringnut wrench.
Ring nut wrench:

90890-01403
8 Tighten the ring nut 3 1 using nut wrench.

28 Nm(2.8 kg.m)
T.
R.
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 un-
til the slots alignment.
8 Install special washer 4

NOTE:
Insert the projections of special washer into the
slots of ring nut 3, 2
8 Install ring nut 1 5 66Nm(6.6 kg.m)

T.
R.
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.
***************************************
3-18
INSP
TIRE INSPECTION ADJ
FRONT TIRE INSPECTION
Manufacturec Size Type w
CHENG SHIN 120/90-10 56J 8 Do not attempt to use tubeless tires on a
wheel designed for tube type tires only.
FRONT
Tire failure and personal injury may result
Manufacturec Size Type from sudden deflation.
CHENG SHIN 130/90-10 59J
Wheel Tire
Tube type Tube type only
Tubeless type Tube type or
tubeless type
8 Be sure to install the correct tube when us-
ing tube type tires.
1. Measure:
8 Air pressure
Maximum load* 160 kg

Cold tire pressure Front Rear
Up to 90 kg 200 kpa(2.00 kg/cm 2,
90 kg load~ Maximum 2.00 bar)
load
* Load is the total weight of cargo, rider, pas-

senger and accessories.
2. Inspect:
8 Tire surfaces
Wear/Damage→Replace.
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 INSP
REAR SHOCK ABSORBER INSPECTION/SEAT LOCK CABLEADJUSTMENT ADJ
WHEEL INSPECTION
1. Inspect:
8 wheels
Damage/Bends→Replace.
w
Never attempt even small repairs to the wheel.
FRONT FORK INSPECTION

1 1. Inspect:
8 Front fork1
Bends/Damage→Replace inner tube
comp, fork ass’y.
Grease leakage→Replace inner tube
comp. fork ass’y.
Unsmooth operation→Replace fork
ass’y.
REAR SHOCK ABSORBER INSPECTION

1. Inspection:
8 Rear shock absorber1
Oil leaks/Damage→Replace.
2. Check
8 Tightening torque
Upper(nut) 30Nm (3.0 m.kg)

Lower (bolt) 16 Nm(1.6 m.kg)
T.
1
R.
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
1 lock cable.
8 Tighten the lock nut.
2 ***************************************
3. Install:
8 Upper cover
8 Protector bar
3-20
INSP
BATTERY INSPECTION ADJ
ELECTRICAL
BATTERY INSPECTION
NOTE:
Since the MF battery is of a sealed-type con-
struction, it is impossible to measure the spe-
cific 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, volt-
age 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 pro-
ceed in the normal way, thus making it im-
possible for the battery to operate regularly.
8 The charging time, charging current and
charging voltage for the MF battery is differ-
ent than general type batteries.
The MF battery should be charged as in-
structed 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 speci-
fied. The specific gravity of the MF battery
electrolyte is 1.32 at 20°C (68°F). (The spe-
cific gravity of the general type battery elec-
trolyte is 1.28. ) If the electrolyte whose spe-
cific gravity is less than 1.32, the sulfuric acid
will decrease and thus low battery perfor-
mance will result.
Should any electrolyte, whose specific grav-
ity 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:
Remove the (–) lead first.
3-21
INSP
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 fol-
low with milk of magnesia, beaten egg, or
vegetable oil. Get immediate medical atten-
tion .
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.
Volt meter 3. Check:

12.8V
8 Battery condition
***************************************
Battery condition checking steps:
8 Connect a digital volt meter to the battery ter-
minals.
Tester (+) lead Battery (+) terminal.

Tester (-) lead Battery (–) terminal.
(v) Relationship between open-circuit

13.0 voltage and charging time 20°C(68°C) NOTE:
Open-circuit voltage
12.5 The state of a discharged MF battery can be

12.0 checked by measuring open circuit voltage (the
11.5 voltage measured with the positive terminals
being disconnected).
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
INSP
14 Ambient Open circuit voltage Charging time
Open-circuit voltage(v)
13 temperature
20°C 12.8 v or more No charging is necessary.
12
11 8 Check the battery condition using figures.

EXAMPLE:
10
Open circuit voltage = 12.0v
100 75 50 30 25 20 0
Charging time = 6.5 hours
Condition of charge in battery(%) Condition of charge in battery = 20 ~ 30%
***************************************
2. Charging method of MF battery
cC
8 If it is impossible to set the standard charg-
ing current, be careful not to overcharge.
8 When charging the battery, be sure to re-
move it from the motorcycle. (If charging has
to be done with the battery mounted on the
motorcycle for some reason, be sure to dis-
connect the wire at the negative terminal.)
8 Never remove the sealing plug from the MF
Ambient temperature
Charging
20°C
battery.
Open-circuit voltage(v)
18
17
8 Use special care so that charging clips are in
16
a full contact with the terminal and that they
15
14
are not shorted. (A corroded clip of the
13
12
charger may cause the battery to generate
11 heat at the contact area. A weak clip spring
10
0 10 20 30 40
Time(Minutes)
may cause sparks.)
Check the open-circuit 8 Before removing the clips from the battery
voltage
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 volt-
age is stabilized 30 minutes after charging
has been completed.
Therefore, to check the condition of the bat-
tery, measure the open-circuit voltage 30
minutes after has been completed.
3-23
INSP
Charging method using a variable-current (voltage) type charger
Charger AMP
NOTE:
meter Measure the open-circuit volt- Voltage should be measured
age prier to charging. 30 minutes after the machine
is stopped.
NOTE:
Connect a charger and AMP Set the changing voltage at
meter to the battery and start 16-17 V. (If the setting is lower,
charging Will be insufficient.
charging. If too high, the battery Will be
over-charged.)
Make sure the current is higher

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

adjust dial, set the charging volt-
age at 20 - 25 V.
Adjust the voltage so that current YES Monitor the amperage for 3-5
is at standard charging level. minutes to check if the standard
charging current is reached.
NO
Set the timer according to the

If current does
charging time suitable for the
not exceed stan-
open-circuit voltage. Refer to
dard charging
“Battery condition checking
current after 5
steps”.
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 bat-
tery 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
INSP
Charging method using a constant-voltage type charger
NOTE:
Measure the open-circuit volt- Voltage should be measured 30 min-
Charger utes after the machine is stopped.
age prier to charging.
AMP meter
Volt meter
Connect a charger and AMP

meter to the battery, and start
charging.
YES Make sure the current is higher NO

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

This type of battery charger Can
battery’s charging voltage is 15
not charge the MF battery. A
volts.
variable voltage charger is rec-
ommended.
NOTE:
Set the charging time at 20 hours
(maximum).
Check the open-circuit voltage after hav-

ing left the battery for 30 minutes
after charging.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is neces-
sary.
Under 12 V --- Replace the battery.
Charging method using a constant current type charger

This type if battery charger Can not charge the MF battery.
3-25
INSP
FUSE INSPECTION ADJ
4. Inspect:
8 Battery terminal
Dirty terminal→Clean with wire brush.
Poor connection→Correct.
NOTE:
After cleaning terminals, apply lightly to the
terminals.
5. Install
8 Battery
8 Battery box cover
FUSE INSPECTION
1 1. Remove:
8 Battery box cover
2. Remove:
8 Fuse 1
3. Inspect:
8 Fuse 1
defective→Replace
***************************************
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 elec-
trical device.
8 If fuse blows immediately again, check cir-
cuit in question.
***************************************
w
Do not use fuses of higher amperage rating
than recommended. Extensive electrical sys-
tem damage and fire could result from substi-
tution of a fuse of improper amperage.
Description Amperage Quantity

Main 7A 1
4. Install:
8 Fuse
3-26 8 Battery box cover
HEADLIGHT BEAM ADJUSTMENT INSP
/HEADLIGHT BULB REPLACEMENT ADJ
HEAD LIGHT BEAM ADJUSTMENT
1. Adjust:
8 Head light (vertically)
1 Turn the adjusting screw in or out to
adjust headlight beam.
HEADLIGHT BULB REPLACEMENT

1. Remove:
8 Protector bar
8 Upper cover
2. Remove:
1 8 Headlight leads coupler 1
1 3. Remove:
8 Bulb holder 1
Turn the bulb holder counterclockwise
to remove it.
4. Remove:
1
8 Bulb(defective)1
Push bulb in and turn it counterclock-
wise 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 INSP
FRONT FLASHER BULB REPLACEMENT 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
ADJUSTMENT”section
TURN SIGNAL AND TAILLIGHT BULB RE-

PLACEMENT
1. Remove:
2 8 Lense 1
8 Bulb 2
1 2. Replace:
8 Bulb 2
3. Install:
8 Lense 1
3-28
TAILLIGHT BULB / REAR FLASHER BULB REPLACEMENT INSP
FRONT FLASHER BULB REPLACEMENT ADJ
cC
Do not over-tighten the screws as the lense
may break.
2 1
LICENSE LIGHT BULB REPLACEMENT

1. Remove:
8 Lense 1
2 8 Bulb 2
1 2. Replace:
8 Bulb (defective) 2
3. Install:
8 Lense 1
3-29
ENGINE REMOVAL ENG
EB400000
ENGINE OVERHAUL
ENGINE REMOVAL
WIREHARNESS AND CABLES
120Nm(12.0kg.m)
T.
R.
9
14 45Nm(4.5kg.m)
T.
R.
1 13 10
11 12
8
3
2
4
6 5
7
15

Wireharness and cables removal Remove the parts in order.
Rear carrier
Tail cover Refer to “COVER AND PANEL” section
Left side panel in CHAPTER 3.
Right side panel
Battery box cover
Center cowling
Air filter case
Carburetor Refer to “CARBURETOR” section in
CHAPTER 6.
1 Air shroud 3 1
2 Rear fender screw 1
3 Autolube delivery hose 1
4 Autolube pump cable 1
4-1
ENGINE REMOVAL ENG
120Nm(12.0kg.m)
T.
R.
9
14 45Nm(4.5kg.m)
T.
R.
1 13 10
11 12
8
3
2
4
6 5
7
15

5 Spark plug cap 1
6 Battery (-) lead 1
7 C.D.I magneto leads coupler 1
8 Starter motor leads coupler 1
9 Rear wheel nut 1
NOTE:
Loosen the rear wheel nut.
10 Rear brake adjuster 1

11 Rear brake cable 1
12 Pin 1
13 Bolt 1
14 Engine mount bolt 1
15 Engine 1
Reverse the removal procesure for in-
stallation.
4-2
CYLINDER HEAD, CYLINDER AND PISTON ENG
CYLINDER HEAD, CYLINDER AND PISTON
CYLINDER HEAD, CYLINDER AND PISTON
26Nm(2.6kg.m)
T.
R.
10 New 1
5
New
4
3
6 New
12Nm(1.2kg.m)
T.
R.
14Nm(1.4kg.m)
T.
R.
2 7
8
9
E

Cylinder head, Cylinder and piston Remove the parts in the order.
removal
Engine Refer to the “ENGINE REMOVAL” sec-
1 Muffler/Gasket 1/1 tion
2 Air shroud (cylinder head) 1
3 Spark plug 1
4 Cylinder head/Cylinder head gasket 1/1
5 Cylinder 1
6 Piston pin clip 2
7 Piston pin/ Bearing 1/1
8 Piston 1
9 Piston ring set 1
10 Cylinder gasket 1
Reverse the removal procedure for in-
stallation.
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 acci-
dentally 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.
2. Inspect:
1 8 Cylinder head warpage
2 Out of specification→Re-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 remov-
ing 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
1 Wear/Scratches→Rebore or replace.
3. Eliminate:
1
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/Damage→Replace.
6. Measure:
8 Piston-to cylinder clearance
*************************************
D1 Piston to cylinder clearance measurement
D2 steps: First step:
8 Measure the cylinder bore “C” with a cylin-
der bore gauge.
NOTE:
D3
D4 Measure the cylinder bore “C” in parallel to and
at right angles to the crankshaft. Then, find the
average of the measurements.
D5
D6
4-5
Standard Wear limit
Cylinder bore 52.002~52.012mm 52.10 mm

“C”
– 0.05 mm
Taper “T”
Out of round – 0.03 mm

“R”
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 cyl-

inder, 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 51.958~51.967 mm
Oversize 1 52.25 mm
Oversize 2 52.50 mm
8 If out of specification, replace piston and pis-

ton 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 cyl-
inder, and replace piston and piston rings as
a set.
Piston-to cylinder clearance:

0.044~0.045mm
Limit : 0.1 mm
4-6
PISTON RINGS INSPECTION
1. Measure:
8 Side clearance
Out of specification→Replace piston
and/or rings.
Use a feeler gauge 1
Standard Limit
Top ring 0.03 ~ 0.05 mm 0.60 mm

2nd ring 0.03 ~ 0.05 mm 0.60 mm
2. Install:
8 Piston ring
Into the cylinder
Push the ring with the piston crown.
3. Measure:
8 End gap
Out of specification→Replace rings as
a a set.
Use a feeler gauge 1.
Standard Limit
Top ring 0.15 ~ 0.35 mm 0.10 mm

2nd ring 0.15 ~ 0.35 mm 0.10 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/Groove→Replace,
then inspect lubrication system.
4-7
2. Measure:
8 Outside diameter a (piston pin)
Out side diameter (piston pin):

13.996~14.000 mm
3. Measure:
→a← 8 Piston pin-to-piston clearance
Out of specification→Replace 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/Damage→Replace.
PISTON PIN AND PISTON INSTALLATION

E 1. Apply:
8 Engine oil
(to the crankshaft bearing, connecting
rod big end bearing, small end bearing,
piston pin, piston ring grooves and pis-
ton skirt areas.)
E
1 2. Install:
8 Reed valve gasket
8 Reed valve
8 Carburetor joint 1 11Nm(1.1 m.kg)
T.
R.
4-8
3. Install:
8 Small end bearing
8 Piston 1
8 Piston pin 2
8 Piston pin clip 3 New
NOTE:
New
a 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 mate-
rial 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:
1 8 Cylinder 1
NOTE:
Install the cylinder with one hand while com-
pressing the piston rings with the other hand.
New
4-9
INSPECTION AND REPAIR ENG
4. Install:
1 8 Cylinder head gasket (new gasket)
5. Install:
8 Cylinder head 1 14Nm(1.4m.kg
T.
R.
8 Spark plug 2 20Nm(2.0m.kg
T.
R.
8 Air shroud
2 NOTE:
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
12Nm(1.2kg.m)
T.
R.
1 90Nm(0.9kg.m)
T.
R.
90Nm(0.9kg.m) 3
T.
R.

Kick starter and crankcase cover (left) Remove the parts in order.
removal
1 Air cleaner assembly mounting screw 1
2 Screw(Bind) 1
3 Kick starter 1
4 Crankcase (left) 1
5 Gasket 1
6 Pin 2
stallation.
4-11
V-BELT, CLUTCH AND
KICK STARTER
4
5
1
B
New

Kick starter removal Remove the parts in order.
1 Kickstarter pinion gear 1
2 Kickstarter pinion gear clip 1
3 Circlip/Plain washer 1/1
4 Kickstarter segment gear 1
5 Return spring 1
6 Collar 1

stallation.
4-12
KICK STARTER ENG
2 KICK STARTER INSTALLATION
1 1. Install:
8 Return spring 1
8 Kick starter segment gear 2
8 Collar 3
5 8 Plain washer 4
8 Circlip 5
3
4
***************************************
6 Installation steps:
a. Install return spring 6 and segment gear
7 as shown.
b. Install clip 5.
c. Hook the spring onto the crankcase pro-
7 jection 8.
6 d. Install the kick starter pinion gear 9 and
the kick starter.
***************************************
4-13
V-BELT, CLUTCH AND
3
2
7 6
1
5
4
40Nm(4.0kg.m)
T.
R.
9
45Nm(4.5kg.m)
8
T.
R.
10

V-belt, clutch and secondary/primary Remove the parts in order.
sheave removal
Lower cowling Refer to “COVER AND PANEL” section
Air shroud 3 in chapter 3.
Crankcase (left) Refer to “ENGINE REMOVAL” section.

1 Clutch housing 1 Refer to “SECONDARY SHEAVE AND V-
2 Secondary sheave assembly 1 BELT REMOVAL ” section.
3 V-belt 1
4 Conical washer/One-way clutch 1/1 Refer to “PRIMARY SHEAVE REMOVAL
5 Crow washer 1 ASSEMBLY” section.
6 Primary fixed sheave 1
7 Collar/Washer 1/1
8 Primary sliding sheave 1
9 Cam/ Slider 1/3
10 Weight 6
stallation
4-14
V-BELT, CLUTCH AND
SECONDARY SHEAVE
SECONDARY SHEAVE
3 New
6
5
4
1
9
7
2
50Nm(5.0kg.m)
T.
R.
8
0
LS
LS

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

assembly.
4-15
V-BELT, CLUTCH AND
PRIMARY SHEAVE REMOVAL
1. Remove:
8 Fan
2. Remove:
8 Nut 1 (primary sheave)
NOTE:
When loosening the nut (primary sheave), hold
2 the C.D.I. magneto using flywheel holding tool
1 2.
Flywheel holding tool:

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

1
1. Remove:
8 Nut 1 (secondary sheave)
2
NOTE:
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
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 parts→Sand with coarse sand-
paper.
NOTE:
After using the sand paper, clean of the pol-
ished particles with cloth.
4-17
V-BELT, CLUTCH AND
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
Crack→Replace.
NOTE:
a 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
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 slid-
ing sheave2, and check for free move-
ment.
Stick or excessive play→Replace the
sheave or collar.
3. Measure:
8 Out side diameter 1 (weight)
Out side diameter (weight)

15.0 mm
<Limit 14.5 mm>
4-19
V-BELT, CLUTCH AND
SECONDARY SHEAVE
1. Inspect:
8 Secondary fixed sheave 1
8 Secondary sliding sheave 2
Scratch/Crack/Damage→Replace as a
set.
8 Oil seal 3
Damage→Replace
2. Inspect:
8 Torque cam grove 1
8 Guide pin 2
Wear/Damage→Replace as a set.
8 O-rings 3
Damage→Replace.
3. Measure:
8 Clutch spring free length
Clutch spring free length:

81 mm
<Limit>:
73 mm
4. Inspect:
8 Clutch housing inner surface
Oil/Scratches→Remove.
Use a rag soaked in lacquer
Oil
thinner or solvent.
a Use an emery cloth (lightly
Scratches
and evenly polishing).
5. Measure:
8 Clutch housing inside diameter a
Clutch housing inside diameter:

a
112.0 mm
<Wear limit>:
112.5 mm
4-20
V-BELT, CLUTCH AND
SECONDARY SHEAVE INSTALLATION
When assembling the secondary sheave, re-
E
verse the disassembly procedure. Note the fol-
lowing points.
1. Apply:
E 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 operation→Repair.
6. Install:
8 Clutch securing nut 1
Use clutch spring holder 2
Clutch spring holder:

90890-01337
7. Tighten:
8 Clutch securing nut 1 50 Nm(5.0 m.kg)
T.
R.
Use Flywheel holding tool 2
Fly holding tool

90890-01235
4-21
V-BELT, CLUTCH AND
8. Install:
1 8 Secondary sheave assembly
8 Clutch housing 1
2 8 V-belt 2
NOTE:
The V-belt must be installed with the arrow
frontward.
9. Tighten:
1
8 Nut 1 (secondary sheave) 40 Nm(4.0 m.kg)
T.
R.
Use sheaveholder 2
2
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 smooth→Repair.
4. Install:
8 Primary sheave assembly 1
8 Collar 2
1
5. Install:
8 V-belt
2
4-22
V-BELT, CLUTCH AND
6. Install:
8 Shim 1
8 Washer 3
8 One-way clutch 4
8 Nut 6
7. Tighten:
8 Nut 1 (primary sheave)
45 Nm(4.5 kg.m)
T.
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:
1 8 V-belt 1
Tense the V-belt by turning the primary
sheave several times.
9. Install:
8 Fan 7 Nm (0.7 kg.m)
T.
R.
4-23
STARTER CLUTCH AND STARTER MOTOR ENG
STARTER CLUTCH AND STARTER MOTOR
STARTER CLUTCH AND STARTER MOTOR
10
New
13Nm(1.3kg.m)
T.
R.
4
3
2
1
8
8Nm(0.8kg.m)
T.
R.
B
M
7
5

Starter clutch and starter motor re- Remove the parts in order.
moval
Left/Right side cover Refer to “COVERS AND PANEL” section
Center cover in chapter 3.
Lower cowling
Air shroud 3 Refer to “C.D.I. MAGNETO ” section
Cooling fan
Rear wheel Refer to “REAR WHEEL” section in chap-
ter 6.
Crankcase cover (left) Refer to “KICKER STARTER ” section.
Primary sheave Refer to “V-BELT, PRIMARY SHEAVE ”

section.
1 Plate 2
2 Plain washer 1
3 Idle gear 1
4 Plain washer 2
5 Starter clutch 1
4-24
STARTER CLUTCH AND STARTER MOTOR ENG
10
New
13Nm(1.3kg.m)
T.
R.
4
3
2
1
8
8Nm(0.8kg.m)
T.
R.
B
M
7
5

6 Plain washer 2
7 Starter wheel gear 1
8 Collar 1
9 Starter motor 1
10 Starter motor coupler 2
Reverse the removal procedure for
instalation
4-25
INSPECTION AND REPAIR ENG
STARTER CLUTCH AND GEARS
1. Inspect:
8 Starter clutch
Push the dowel pin to arrow direction.
Unsmooth operation→Replace starter
clutch assembly.
2. Inspect:
2 1 8 Starter wheel gear teeth 1
8 Idle gear teeth 2
Burrs/Chips/Roughness/Wear→Replace.
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 clock-
wise 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
4 7
8 New
8Nm(0.8kg.m)
T.
R.
43Nm(4.3kg.m)
T.
R.
7Nm(0.7kg.m)
T.
R.

C.D.I. magneto removal Remove the parts in order.
Rear carrier
Tail cover
Left side cover Refer to “COVER AND PANEL” section
Right side cover in chapter 3.
Center cover
Lower cowling
1 Air shroud 3 1
2 Fan /O-ring 1/1
3 Magneto rotor 1
4 Bind 1
5 Couplers (magneto leads) 1
6 Stator coil 1
7 Wood ruff key 1
8 Gasket (Magneto cover) 1
stallation.
4-27
ENGINE DISASSEMBLY ENG
C.D.I. MAGNETO REMOVAL
1
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:
1
8 Rotor 1
8 Woodruff key
Use the flywheel magneto puller 2.
Flywheel magneto puller:

2 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)
B 3. Pass the C.D.I. magneto lead through the
1 crankcase hole.
4. Install:
8 Stator assembly 8 Nm(0.8 kg.m)
T.
R.
1 5. Install:
8 Woodruff key
8 C.D.I. magneto Rotor 1
8 Plain washer
8 Nut 43Nm(4.3 kg.m)
T.
R.
4-28
AUTOLUBE PUMP ENG
AUTOLUBE PUMP
AUTOLUBE PUMP
4
4Nm(0.4kg.m)
3
T.
R.

Autolube pump removal Remove the parts in order.
C.D.I. magneto Refer to “C.D.I. magneto” section.
1 Air shroud 2. 1
2 Circlip 1
3 Pump drive gear 1
4 Pin 1
5 Oil hose 1
6 Oil delivery hose 1
7 Autolube pump cable 1
8 Autolube pump ass’y 1 Refer to “Autolube pump installation”
section

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

Transmission removal Remove the parts in order.
Rear wheel Refer to “REAR WHEEL/REAR BRAKE ”
section in chapter 7.
Secondary sheave Refer to “V-BELT, CLUTCH, SECOND-
ARY/ PRIMARY SHEAVE” section
Drain the transmission oil. Refer to “TRANSMISSION OIL RE-
PLACEMENT ” section in chapter 3.
1 Transmission case cover 1
2 Gasket (transmission case cover) 1
3 Dowel pin 2
4 Primary drive gear 1
5 Plain washer 1
7 Drive gear 1
4-31
TRANSMISSION ENG
10
8 New
7
New 6
5
2
18Nm(1.8kg.m) 1
T.
R.
4
12Nm(1.2kg.m)
T.
R.
New
B

8 Circlip 1
9 Main axle 1
10 Drive axle 1
stallation.
4-32
CRANKCASE AND REED VALVE ENG
CRANKCASE AND REED VALVE
CRANKCASE AND REED VALVE
9Nm(0.9kg.m) 12Nm(1.2kg.m)
T.
T.
R.
R.
7
4
8 New
5 6
1 B
9
10
New
3 New

Crankcase and Reed valve removal Remove the parts in order.
Engine removal Refer to “ENGINE REMOVAL” section.

Cylinder head, cylinder, piston Refer to “CYLINDER HEAD CYLINDER
AND PISTON” section.
Crankcase cover (left) Refer to “KICK STARTER AND CRANK-
CASE COVER (LEFT) ” section.
V-belt, clutch, secondary/primary Refer to “V-BELT, CLUTCH AND SEC-
sheave ONDARY/PRIMARY SHEAVE ” section.
C.D.I . magneto Refer to “C.D.I. MAGNETO” section.
Starter clutch, starter motor Refer to “STARTOR CLUTCH AND
STARTOR MOTOR” section.
Autolube pump Refer to “AUTOLUBE PUMP” section.
Rear wheel Refer to “REAR WHEEL AND REAR
BRAKE” section in chapter 6.
Transmission Refer to “TRANSMISSION” section.
4-33
CRANKCASE AND REED VALVE ENG
9Nm(0.9kg.m) 12Nm(1.2kg.m)
T.
T.
R.
R.
4
8 New
5 6
1 B
9
10
New
3 New

1 Intake manifold 1
2 Reed valve 1
3 Valve seat gasket 1
4 Stopper 1
5 Crankcase 2 1
6 Dowel pin 2
7 Engine mount spacer 1
8 Circlip 1
9 Bearing 1
10 Oil seal 1
stallation.
4-34

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YW100 4VP-ME1

HOW TO USE THIS MANUAL

Illustrated symbols i to d in the exploded dia-

Illustrated symbols f to g in the exploded

Q The Safety Alert Symbol means ATTENTION] BECOME ALERT! YOUR

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

cC A CAUTION indicates special precautions that must be taken to avoid dam-

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

SCOOTER IDENTIFICATION ............................................................................................................. 1-1

GENERAL SPECIFICATIONS ............................................................................................................. 2-1

NTRODUCTION ................................................................................................................................. 3-1

ENGINE OVERHAUL ......................................................................................................................... 4-1

CARBURETION .................................................................................................................................. 5-1

FRONT WHEEL AND BRAKE DISC ................................................................................................... 6-1

ELECTRICAL COMPONENTS ........................................................................................................... 7-1

STARTING FAILURE/HARD STARTING ........................................................................................... 8-1

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

7. Check for continuity with a tester.

HOW TO USE THE CONVERSION TABLE

Tool No. Tool name / Usage Illustration

This tool is used to remove the flywheel

This tool is used to loosen and tighten the

These tools are used for removing the nut

This tool is used for removing the rotor.

This tool is used to remove the crankshaft

This tool is used for protecting the oil seal

This tool is used to loosen and tighten the

This tool is used for holding the secondary

This tool is used to measure the clearance

These instruments are invaluable for check-

This tool is needed for detecting engine

This tool is used to install the left side crank-

This tool is used to install the left side crank-

This instrument is necessary for checking

This sealant (bond) is used for crankcase

This tool is used to loosen and tighten the

These tools are used when installing the

*Lines indicate straightedge measurement

Crank Width “A” 37.90~37.95 mm ...

Spark plug — M 14 1 20 2.0

Frame and engine bracket M 12 84 8.4

A: Distance across flats

Small End Bearing E

Big End Bearing E

Starter Idle Bearing G

Primary Drive Gear Bearing G

Kick Axle Bearing G

Drive Axle Bearing G

Main Axle Bearing G

Piston, Piston Ring Piston Pin and Cylinder E

Oil Pump Drive and Driven Gear LS

Sliding Surface (Secondary Sheave) BEL-LAY Assembly Lube®

Throttle Grip Inner Surface LS

Brake Cables End LS

Brake Cam Shaft and Pin LS

Speedometer Drive and Driven Gear LS

PERIODIC INSPECTIONS AND ADJUSTMENTS

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

• Check fuel hoses and vacuum

Sidestand/ • Check operation.