Instruction/ maintenance manual of the product YP250 Yamaha
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EB000000 YP250 SERVICE MANUAL 1996 by Y amaha Motor Co., Ltd. 1st Edition, January 1996 All rights reserved. Any reprinting or unauthorized use without the written permission of Y amaha Motor Co.
NOTE: CAUTION: EB001000 NOTICE This manual was produced by the Y amaha Motor Company primarily for use by Y amaha dealers and their qualified mechanics.
1 2 4 3 5 6 7 6 8 YP002000 HOW T O USE THIS MANUAL MANUAL ORGANIZA TION 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.
1 3 5 7 9 11 13 15 18 2 4 8 10 12 14 16 6 21 24 25 17 19 20 22 23 EB003000 ILLUSTRA TED SYMBOLS Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter ’s number and content.
GENERAL INFORMA TION SPECIFICA TIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 COOL 5 CARB 6 C.
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CHAPTER 1 GENERAL INFORMA TION SCOOTER IDENTIFICA TION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICA TION NUMBER (for E) 1-1 . . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER 1-1 . . . . . . . .
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1-1 SCOOTER IDENTIFICA TION GEN INFO NOTE: NOTE: YP100000 GENERAL INFORMA TION SCOOTER IDENTIFICA TION YP100010 VEHICLE IDENTIFICA TION NUMBER (for E) The vehicle identification number 1 is stamped into the right side of the frame.
1-2 FEA TURES GEN INFO Engine stop switch Main switch Oil indicator light Fuse Battery Meter Reset button I gnitor unit C.P .U Oil indicator light Reset button NOTE: FEA TURES OIL INDICA TOR LIGHT .
1-3 FEA TURES GEN INFO Main switch Fuse Battery Thermo switch Auto-choke Igniter unit C.P .U Ignition Main switch Engine stop switch Brake switch Fuse Starter relay Relay Ignitor unit Battery Starter .
1-4 IMPORT ANT INFORMA TION GEN INFO EB101000 IMPORT ANT INFORMA TION PREP ARA TION FOR REMOV AL PROCE- DURES 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.
1-5 IMPORT ANT INFORMA TION GEN INFO OR CAUTION: EB101030 LOCK W ASHERS / PLA TES AND COTTER PINS 1. Replace all lock washers / plates and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification.
1-6 IMPORT ANT INFORMA TION GEN INFO NOTE: NOTE: EB801000 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector . 1. Disconnect: S Connector 2. Dry each terminal with an air blower . 3. Connect and disconnect the connector two or three.
1-7 HOW T O USE THE CONVERSION T ABLE GEN INFO EB201000 HOW TO USE THE CONVERSION T ABLE 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 MUL TIPLIER IMP **mm 0.
1-8 SPECIAL TOOLS GEN INFO EB102000 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.
1-9 SPECIAL TOOLS GEN INFO T ool No. T ool name / Usage Illustration 90890-01362 Flywheel puller This tool is used for removing the rotor . 90890-01367 -01368 Fork seal driver weight Fork seal driver attachment (ø33) This tool is used when installing the fork seal.
1-10 SPECIAL TOOLS GEN INFO T ool No. T ool name / Usage Illustration 90890-03141 T iming light This tool is needed for detecting ignition timing. 90890-04101 V alve lapper This tool is used for removing and installing the lifter and for lapping the valve.
CHAPTER 2. SPECIFICA TIONS GENERAL SPECIFICA TIONS 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICA TIONS 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4 . . . . . . . . . . . .
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2-1 GENERAL SPECIFICA TIONS SPEC SPECIFICA TIONS GENERAL SPECIFICA TIONS Model YP250 Model code: 4UC 1 (except for CH, A) 4UD1 (for CH, A) Dimensions: Overall length Overall width Overall height Seat .
2-2 GENERAL SPECIFICA TIONS SPEC Model YP250 Carburetor: T ype / quantity Manufacturer Y28V -1A / 1 TEIKEI Spark plug: T ype Manufacturer Spark plug gap DR8EA NGK 0.
2-3 GENERAL SPECIFICA TIONS SPEC Model YP250 Brake: Front brake type operation Rear brake type operation Single disc brake Right hand operation Drum brake Left hand operation Suspension: Front suspens.
2-4 MAINTENANCE SPECIFICA TIONS SPEC Face Width Seat Width Margin Thickness MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Cylinder head: W arp limit SSS 0.
2-5 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Stem-to-guide clearance IN EX Stem runout limit V alve seat width IN EX 0.010 X 0.037 mm 0.025 X 0.
2-6 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Automatic centrifugal clutch: Clutch shoe thickness Clutch housing inside diameter Clutch shoe spring free length Weight outside diameter Clutch – in revolution Clutch – stall revolution 3.0 mm 135 mm 28.
2-7 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Radiator: T ype Width / height / thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Cooling fin with electric fan 140 / 238 / 24 mm 1 10 X 140 kPa (1.1 X 1.4 kg / cm 2 , 1.
2-8 MAINTENANCE SPECIFICA TIONS SPEC TIGHTENING TORQUES ENGINE Part to be tightened Part name Thread size Q’ty T ightening torque Remarks g size y Nm m S kg Oil check bolt Exhaust pipe stud bolt Spa.
2-9 MAINTENANCE SPECIFICA TIONS SPEC Part to be tightened Part name Thread size Q’ty T ightening torque Remarks g size y Nm m S kg Cover (oil pump) T iming check plug One way clutch Clutch housing G.
2-10 MAINTENANCE SPECIFICA TIONS SPEC CHASSIS Item Standard Limit Steering system: Steering bearing type Ball bearing SSS Front suspension: Front fork travel Fork spring free length Spring rate (K1) Stroke (K1) Oil capacity Oil level Oil grade Inner tube vend limit 100 mm 265.
2-1 1 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Rear drum brake: T ype Drum inside diameter Shoe thickness Leading, trailing 160 mm 4 mm SSS 161 mm 2 mm Brake lever: Brake lever free play (.
2-12 MAINTENANCE SPECIFICA TIONS SPEC TIGHTENING TORQUES CHASSIS Part to be tightened Thread size Tightening torque Remarks Nm m S kg Frame and engine bracket Engine bracket, compression rod and engin.
2-13 MAINTENANCE SPECIFICA TIONS SPEC NOTE: 1. First, tighten the ring nut (lower) approximately 38 Nm (3.8 m S kg) by using the torque wrench, then loosen the ring nut 1 / 4 turn. 2. Second, tighten the ring nut (lower) approximately 22 Nm (2.2 m S kg) by using the torque wrench, then finger tighten the ring nut (center).
2-14 MAINTENANCE SPECIFICA TIONS SPEC ELECTRICAL Item Standard limit Ignition timing: Ignition timing (B.T .D.C.) Advanced timing (B.T .D.C.) Advanced type 10 _ at 1,500 r / min 32 _ at 5,000 r / min Electrical type SSS SSS SSS T .C.I.: Pickup coil resistance / color T .
2-15 MAINTENANCE SPECIFICA TIONS SPEC Item Standard limit Starter relay: Model / manufacturer Amperage rating Coil winding resistance 4FL / JIDECO 100 A 4.
2-16 GENERAL T ORQUE SPECIFICA TIONS SPEC GENERAL TORQUE SPECIFICA TIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. T orque specifications for special components or as- semblies are included in the applicable sections of this book.
2-17 LUBRICA TION POINT AND GRADE OF LUBRICANT SPEC LUBRICA TION POINT AND GRADE OF LUBRICANT ENGINE Lubrication Point Symbol Oil seal lips O-ring (Except V -belt drive unit) Cylinder head tightening .
2-18 LUBRICA TION POINT AND GRADE OF LUBRICANT SPEC CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left / right) Swingarm oil seal lips (left / right) Steering head pipe bearing (upper / .
2-19 CABLE ROUTING SPEC 1 Rectifier regulator 2 Fuel sender 3 Fuse (fan) 4 Roll over valve 5 Ignition coil 6 Seat lock cable 7 Handlebar switch 3 lead (right) 8 Front brake switch lead 9 Brake hose 10.
2-20 E Pass the overflow hose from the reservoir tank through the clamp inside the frame. F Clamp the mainharness, battery (+) lead and (–) lead to clamp of the frame. G Clamp the fuel sender lead to the pipe. H The mainharness connecting to the taillight assembly to the frame.
2-21 CABLE ROUTING SPEC 1 Seat lock 2 Air filter case 3 Breather hose 4 Fuel hose 5 V acuum hose 6 Sidestand switch lead 7 Thermo switch lead 8 Fan motor lead , 9 Breather hose 10 Overflow hose (fuel tank) 11 Relay 12 Auto choke lead 13 A.
2-22 CABLE ROUTING SPEC 1 Front flasher light (right) 2 Front flasher light (left) 3 Handlebar switch (right) lead 4 Front brake switch lead 5 Seat lock cable 6 Throttle cable 7 Brake hose 8 Handlebar.
2-23 CABLE ROUTING SPEC G Pass the brake hose through the hose holder and clamp. H Clamp the headlight lead and horn lead from mainharness to the stay 1.
2-24 CABLE ROUTING SPEC 1 Fuel overflow hose (filler neck) 2 Throttle cable 1 (nut white) 3 Throttle cable 2 (nut black) 4 Air vent hose (carburetor) 5 Coolant drain hose (carburetor) 6 Fuel drain hose (carburetor) 7 Fuel overflow hose (fuel tank) A Pass the brake cable 2 though the holder and clamp to the crankcase.
2-25 CABLE ROUTING SPEC 1 Steering head pipe 2 Brake cable 2 3 Mainharness 4 Downtube 5 Throttle cable 6 Radiator 7 Stay 1 A Pass the brake cable 2 though the clamp on the handlebar holder . B Band the brake cable 2 to the steering head pipe, noting the band direction.
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CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE / LUBRICA TION INTER V ALS 3-1 . . . . . . . . . . . COVER AND P ANEL 3-3 .
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3-1 INTRODUCTION / PERIODIC MAINTENANCE / LUBRICA TION INTERV ALS INSP ADJ EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments.
3-2 PERIODIC MAINTENANCE / LUBRICA TION INTER V ALS INSP ADJ NOTE: BREAK-IN EVERY NO. ITEM ROUTINE TYPE 1,000 km 6,000 km or 6 months 12,000 km or 12 month 15 Centerstand and sidestand pivot Check operation and lubricate. Same as engine oil 16 * Sidestand switch Check and clean or replace if necessary .
3-3 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Side panel and seat removal Rear panel Side panel (left) Side panel (right) Rivet Front panel Clip Damper assembly Seat 1 1 1 2 1 2 1 1 Remove the parts in order . Install the damper assembly to the body with its rod side backward and labels up- ward.
3-4 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 T ail cover and fuel tank removal Grab bar Seat lock bracket Screw T ail cover Fuel tank cap Fuel overflow hose Cover Fuel tank cover Coupler (fuel sender lead) Fuel overflow hose Fuel hose 1 1 2 1 1 1 1 1 1 1 1 Remove the parts in order .
3-5 COVER AND P ANEL INSP ADJ Order Job name / Part name Q’ty Remarks 12 13 14 V acuum hose Bracket Fuel tank 1 1 1 Reverse the removal procedure for installation.
3-6 Order Job name / Part name Q’ ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 Footrest board and lower cover removal Mat (footrest board) (left / right) Cover 2 Battery negative (-) lead Battery positi.
3-7 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Cowling removal Upper cover Wind screen Inner panel Cowling body Coupler (headlight lead) Coupler (front flasher light lead (left)) Coupler (front flasher light lead (right)) 1 1 1 1 1 1 Remove the parts in order .
3-8 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Handle cover , meter assembly and legshield removal Handle cover Coupler (meter lead) Meter cable Meter assembly Main switch cover Cover Legshield 1 1 1 2 1 2 1 Remove the parts in order . Disconnect the couplers.
3-9 V AL VE CLEARANCE ADJUSTMENT INSP ADJ NOTE: ***************************************************** ***************************************************** YP303004 ENGINE V AL VE CLEARANCE ADJUSTMENT V alve clearance adjustment should be made with the engine cool, at room temperature.
3-10 V AL VE CLEARANCE ADJUSTMENT / IDLING SPEED ADJUSTMENT INSP ADJ ***************************************************** ***************************************************** 14 Nm (1.4 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) 18 Nm (1.8 m S kg) 7 Nm (0.
3-1 1 IDLING SPEED ADJUSTMENT / THROTTLE CABLE ADJUSTMENT INSP ADJ ***************************************************** ***************************************************** NOTE: ************************************* NOTE: 3. Check: Engine idling speed Out of specification Adjust.
3-12 THROTTLE CABLE ADJUSTMENT / SP ARK PLUG INSPECTION INSP ADJ ***************************************************** CAUTION: Loosen the locknut 1 on the throttle cable. T urn the adjuster 2 in or out until specified free play is obtained. T urning in Free play is increased.
3-13 SP ARK PLUG INSPECTION / IGNITION TIMING CHECK INSP ADJ 18 Nm (1.8 m S kg) NOTE: NOTE: ***************************************************** ***************************************************** Spark plug gap: 0.6 0.7 mm 6. Install: D Spark plug Before installing a spark plug, clean the gasket surface and plug surface.
3-14 IGNITION TIMING CHECK / COMPRESSION PRESSURE MEASUREMENT INSP ADJ NOTE: NOTE: CAUTION: Ignition timing is not adjustable. 3. Install: T iming check plug YP303060 COMPRESSION PRESSURE MEASUREMENT Insufficient compression pressure will result in performance loss.
3-15 COMPRESSION PRESSURE MEASUREMENT / ENGINE OIL REPLACEMENT INSP ADJ ***************************************************** ***************************************************** 18 Nm (1.
3-16 ENGINE OIL LEVEL INSPECTION / ENGINE OIL REPLACEMENT INSP ADJ CAUTION: NOTE: 32 Nm (3.2 m S kg) NOTE: RECOMMENDED ENGINE OIL Refer to the chart for selection of the oils suited to the atomosperic temperature. API ST ANDARD: API SE or higher grade D Do not put in any chemical sdditives or use oils with a grade of CD a or higher .
3-17 ENGINE OIL REPLACEMENT / ENGINE OIL PRESSURE INSPECTION INSP ADJ ************************************* ***************************************************** NOTE: ***************************************************** 5. Fill: Crankcase Oil quantity: 1.
3-18 ENGINE OIL PRESSURE INSPECTION / TRANSMISSION OIL REPLACEMENT INSP ADJ 10 Nm (1.0 m S kg) CAUTION: ***************************************************** NOTE: NOTE: 22 Nm (2.2 m S kg) CAUTION: D Start the engine after solving the problem(s), and recheck the oil pressure.
3-19 TRANSMISSION OIL REPLACEMENT / EXHAUST SYSTEM INSPECTION / AIR FIL TER CLEANING INSP ADJ 20 Nm (2.0 m S kg) 53 Nm (5.3 m S kg) 20 Nm (2.0 m S kg) CAUTION: 7. Install: D Oil filler cap 1 D O-ring 2 8. Start the engine for several minutes to warm it up and check for the oil leakage.
3-20 AIR FIL TER CLEANING / CRANKCASE FIL TER CLEANING INSP ADJ NOTE: CAUTION: 7 Nm (0.7 m S kg) NOTE: 3. Inspect: D Air filter element Damaged Replace. 4. Clean: D Air filter element 1 Use solvent to clean the element After cleaning, remove the remaining solvent by squeezing the element.
3-21 CRANKCASE FIL TER CLEANING / COOLANT LEVEL INSPECTION INSP ADJ CAUTION: 7 Nm (0.7 m S kg) NOTE: CAUTION: NOTE: This element is a dry type. Be careful not to stain with grease or water . 3. Clean: D Crankcase filter element 1 Blow out the dust in the element from the outer surface using compressed air .
3-22 COOLANT REPLACEMENT INSP ADJ NOTE: YP303180 COOLANT REPLACEMENT 1. Remove: Side panels Fuel tank Refer to the “COVERS AND P ANEL” section.
3-23 COOLANT REPLACEMENT INSP ADJ 10 Nm (1.0 m S kg) ***************************************************** 5. Install: D Gasket 1 D Drain bolt 2 6. Loosen: D Screw 1 (carburetor bleed) 7. Connect: D Hose (reservoir tank) 8. Fill: D Radiator (to specified level 1 ) Fill the coolant slowly , until the coolant comes out from the carburetor drain pipe.
3-24 COOLANT REPLACEMENT INSP ADJ ***************************************************** CAUTION: NOTE: If coolant splashes in your eyes: thoroughly wash your eyes with water and consult a doctor . If coolant splashes on your clothes: quickly wash it away with water and then with soap and water .
3-25 COOLING SYSTEM INSPECTION INSP ADJ YP303190 COOLING SYSTEM INSPECTION 1. Inspect: Radiator 1 Filler hose (radiator) 2 Outlet hose (radiator) 3 Pipe Outlet hose (radiator) 4 Cracks / Damage Replace. Refer to “COOLING SYSTEM” section in chapter 5.
3-26 FRONT BRAKE ADJUSTMENT INSP ADJ ***** ********************************************** ***************************************************** CAUTION: EB304002 CHASSIS FRONT BRAKE ADJUSTMENT 1. Check: Brake lever free play a Out of specification Adjust.
3-27 BRAKE FLUID LEVEL INSPECTION INSP ADJ NOTE: NOTE: CAUTION: YP304020 BRAKE FLUID LEVEL INSPECTION 1. Stand the scooter on a level surface. Make sure the scooter is upright when inspect- ing the brake fluid level. 2. Stand the scooter on its centerstand.
3-28 BRAKE P AD INSPECTION / AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP ADJ ***************************************************** YP304030 BRAKE P AD INSPECTION 1. Operate the brake lever . 2. Inspect: Brake pad (front) Wear indicators 1 almost touch the brake disc Replace the brake pads as a set.
3-29 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) / REAR BRAKE ADJUSTMENT INSP ADJ NOTE: 6 Nm (0.6 m S kg) NOTE: ***************************************************** ****************************************.
3-30 REAR BRAKE ADJUSTMENT / BRAKE SHOE INSPECTION / STEERING HEAD INSPECTION INSP ADJ CAUTION: ***************************************************** NOTE: T ighten the locknut (s). Rear wheel side: T urn the adjuster 3 in or out until the speci- fied free play is obtained.
3-31 STEERING HEAD INSPECTION INSP ADJ ***************************************************** 38 Nm (3.8 m S kg) NOTE: 22 Nm (2.2 m S kg) 5. Remove: D Handlebar lower holder D Woodruf f key Refer to “STEERING” section in chapter 7.
3-32 STEERING HEAD INSPECTION / FRONT FORK INSPECTION INSP ADJ NOTE: 75 Nm (7.5 m S kg) ***************************************************** D Install the lock washer 1 .
3-33 SWINGARM INSPECTION / REAR SHOCK ABSORBER INSPECTION / REAR SHOCK ABSORBER ADJUSTMENT INSP ADJ 40 Nm (4.0 m S kg) 16 Nm (1.6 m S kg) NOTE: YP***** SWINGARM INSPECTION Securely support the scooter so there is no danger of it falling over . 1. Place the scooter on the level place.
3-34 REAR SHOCK ABSORBER ADJUSTMENT / TIRE INSPECTION INSP ADJ ***************************************************** b a CAUTION: ***************************************************** Adjustment steps: T urn the adjuster ring in or out. T urning toward Spring preload is increased.
3-35 TIRE INSPECTION INSP ADJ Basic weight: With oil and full fuel tank 158 kg Maximum load* 197 kg Cold tire pressure Front Rear Up to 90 kg load* 175 kPa (1.75 kg / cm 2 , 1.75 bar) 200 kPa (2.0 kg / cm 2 , 2.0 bar) 90 kg maximum. load* 200 kPa (2.
3-36 TIRE INSPECTION / WHEEL INSPECTION INSP ADJ NOTE: FRONT : Manufacture Size T ype IRC 1 10 / 90-12 64J MB61 CHENG SHIN 1 10 / 90-12 64J C922 REAR: Manufacture Size T ype IRC 130 / 70-12 62L MB61 CHENG SHIN 130 / 70-12 62L C940 After mounting a tire, ride conservatively for a while to give the tire time to seat itself properly in the rim.
3-37 BA TTER Y INSPECTION INSP ADJ NOTE: CAUTION: YP305000 ELECTRICAL BA TTERY INSPECTION Since the MF battery is a sealed type battery , it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery .
3-38 V olt meter Relationship between open-circuit voltage and charging time at 20 _ C (68 _ F) *This varies depending on the temperature, the state of charge in battery plates and the electrolyte level.
3-39 BA TTER Y INSPECTION INSP ADJ Open-circuit voltage (V) Condition of charge in battery (%) Ambient temperature 20 _ C (68 _ F) Open-circuit voltage (V) Charging Ambient temperature 20 _ C (68 _ F).
3-40 Measure the open-circuit voltage prior to charging. Connect a charger and AMP meter to the battery , and start charging. Make sure the current is higher than the standard charging current written on the battery . By turning the charging voltage adjust dial, set the charging voltage at 20 25 V .
3-41 Measure the open-circuit voltage prior to charging. Connect a charger and AMP meter to the battery , and start charging. NOTE: V oltage should be measured 30 min- utes after the machine is stopped. Make sure the current is higher than the standard charging current written on the battery .
3-42 BA TTER Y INSPECTION / FUSE INSPECTION INSP ADJ NOTE: CAUTION: CAUTION: ***************************************************** ***************************************************** NOTE: 6. Inspect: Battery terminals Dirty terminal Clean with wire brush.
3-43 FUSE INSPECTION / HEADLIGHT BEAM ADJUSTMENT INSP ADJ ***************************************************** ***************************************************** 3. Replace: Blown fuse Replacement steps: T urn off the main switch. Install a new fuse with the proper current rat- ing.
INSP ADJ.
CHAPTER 4. ENGINE ENGINE OVERHAUL 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIREHARNESS AND CABLE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOSES, AIR FIL TER CASE, ENGINE MOUNTING BOL T AND ENGINE 4-3 .
OIL PUMP 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP INSPECTION 4-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION 4-44 . . . . . . . . . .
4-1 ENGINE REMOV AL ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Wireharness and cables removal Side panel Footrest board Fuel tank Drain the coolant. Carburetor Spark plug cap Thermo unit lead Startor coil / Pick up coil lead Starting motor lead Earth lead Adjuster Brake cable 1 1 1/1 1 1 1 1 Remove the parts in order .
4-2 ENGINE REMOV AL ENG Order Job name / Part name Q’ty Remarks 8 9 10 11 Pin Compression spring Cable holder Cable holder 1 1 1 1 Reverse the removal procedure for installation.
4-3 ENGINE REMOV AL ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Hoses, air filter , engine mounting bolt and engine removal V acuum hose Crankcase breather hose Inlet hose (wate.
4-4 ENGINE REMOV AL ENG NOTE: 64 Nm (6.4 m kg) 32 Nm (3.2 m kg) YP****** ENGINE REMOUNTING When remounting the engine, reverse the re- moval procedure in job instruction chart.
4-5 CYLINDER HEAD ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Cylinder head removal Drain the coolant. Side panel Footrest board Fuel tank Carburetor Thermo unit lead Plug cap Cran.
4-6 Order Job name / Part name Q’ty Remarks 10 11 12 13 14 15 16 17 18 19 20 21 Crankcase filter cover / seal / element Plug / O-ring Cam sprocket cover / O-ring V alve cover (intake side) / O-ring .
4-7 CYLINDER HEAD ENG NOTE: NOTE: NOTE: NOTE: YP401030 CYLINDER HEAD REMOV AL 1. Align: S “I” mark a on the rotor (with stationary pointer b on the crank case cover) T urn the primary sheave counterclockwise with a wrench and align the “I” mark c with the cylin- der head match mark d when the piston is at TDC on the compression stroke.
4-8 CYLINDER HEAD ENG ***************************************************** ***************************************************** NOTE: NOTE: 22 Nm (2.2 m S kg) 10 Nm (1.0 m S kg) 2. Inspect: S Cylinder head Scratches / damage Replace. 3. Measure: S Cylinder head warpage Out of specification Resurface.
4-9 CYLINDER HEAD ENG ***************************************************** ***************************************************** NOTE: CAUTION: 3. Install: S Cam sprocket 1 S T iming chain 2 Installing steps: D T urn the primary sheave counterclockwise until the TDC mark a matches the stationary pointer b .
4-10 CYLINDER HEAD ENG ***************************************************** ***************************************************** 10 Nm (1.0 m S kg) 8 Nm (0.8 m S kg) 60 Nm (6.0 m S kg) 5. Install: S T iming chain tensioner Installation steps: D Remove the tensioner cap bolt 1 and springs 2 .
4-1 1 CAMSHAFT AND ROCKER ARMS ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Camshaft and rocker arms removal Cylinder head Lock washer Plate Rocker arm shaft (intake) Rocker arm shaft (exhaust) Rocker arm Camshaft Locknut Adjuster O-ring 1 1 1 1 2 1 2 2 1 Remove the parts in order .
4-12 CAMSHAFT AND ROCKER ARMS ENG NOTE: YP****** ROCKER ARM AND ROCKER ARM SHAFT REMOV AL 1. Remove: Rocker arm shaft (intake) Rocker arm shaft (exhaust) Attach a rocker arm shaft puller bolt 1 and weight 2 to the rocker arm shaft and slide out the shaft.
4-13 CAMSHAFT AND ROCKER ARMS ENG ***************************************************** ***************************************************** YP402060 ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 1. Inspect: S Cam lobe contact surface 1 S Adjuster surface 2 Wear / Pitting / Scratches / Blue discolor- ation Replace.
4-14 CAMSHAFT AND ROCKER ARMS ENG 8 Nm (0.8 m kg) NOTE: NOTE: NOTE: CAUTION: 2. Install: Plate 1 Look washer 2 Bolt 3 Bend the lock washer tabs along the bolt 3 flats. 3. Apply: Molybdenum disulfide oil (onto the rocker arm and rocker arm shaft) Molybdenum disulfide oil 4.
4-15 V AL VES AND V AL VE SPRINGS ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 V alves and valve springs removal Cylinder head Rocker arm, rocker arm shaft V alve cotters Spring retainer V alve spring (inner) V alve spring (outer) V alve (intake) V alve (exhaust) V alve guide Spring seat 4 2 2 2 1 1 2 2 Remove the parts in order .
4-16 V AL VES AND V AL VE SPRINGS ENG NOTE: CAUTION: YP401 150 V AL VES AND V AL VE SPRINGS REMOV AL 1. Remove: V alve cotters 1 Attach a valve spring compressor and attach- ment 2 between the valve spring retainer and cylinder head to remove the valve cotters.
4-17 V AL VES AND V AL VE SPRINGS ENG YP402030 4. Measure: S Spring tilt Out of specification Replace. Spring tilt limit: 1.7 mm (2.5 _ ) 5. Inspect: S Spring contact face Wear / Pitting / Scratches Replace. 6. Measure: S V alve guide inside diameter Out of specification Replace.
4-18 V AL VES AND V AL VE SPRINGS ENG ***************************************************** ***************************************************** NOTE: ***************************************************** CAUTION: 3. Measure: S V alve seat width a Out of specification Reface the valve seat.
4-19 V AL VES AND V AL VE SPRINGS ENG NOTE: NOTE: ***************************************************** NOTE: D T urn the valve until the valve face and valve seat are evenly polished, then clean off all compound. For best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hand.
4-20 V AL VES AND V AL VE SPRINGS ENG NOTE: CAUTION: 4. Install: V alve cotters 1 Install the valve cotters while compressing the valve spring with a valve spring compressor and attachment 2 . V alve spring compressor: 90890-04019 Attachment: 90890-04108 5.
4-21 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 Cylinder and piston removal Cylinder head Joint O-ring T iming chain guide (exhaust side) Cylinder Dowel pin Cylinder gasket Piston pin circlip Piston pin Piston Piston ring (top) Piston ring (2nd) Side rail / Spacer 1 2 1 1 2 1 2 1 1 1 1 2/1 Remove the parts in order .
4-22 CYLINDER AND PIST ON ENG NOTE: NOTE: NOTE: YP****** PISTON AND PIST ON RINGS REMOV AL 1. Remove: S Piston pin circlip 1 S Piston pin 2 S Piston 3 Before removing the piston pin circlip, cover the crankcase opening with a clean towel or rag to prevent the circlip from falling into the crank- case cavity .
4-23 CYLINDER AND PIST ON ENG YP****** PISTON AND PIST ON PIN INSPECTION 1. Measure: Piston skirt diameter Out of specification Replace. a 5.0 mm from the piston bottom edge Piston skirt diameter: 68.965 68.980 mm Oversize (2) 69.5 mm Oversize (4) 70.
4-24 CYLINDER AND PIST ON ENG NOTE: NOTE: NOTE: YP4021 1 1 PISTON RINGS INSPECTION 1. Measure: Side clearance Out of specification Replace the piston and the piston rings as a set. Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance.
4-25 CYLINDER AND PIST ON ENG NOTE: NOTE: EB404184 PISTON RINGS, PIST ON AND CYLINDER INST ALLA TION 1. Install: S T op ring 1 S 2nd ring 2 S Side rails (oil ring) 3 S Expander spacer (oil ring) 4 D Make sure to install the piston rings so that the manufactuer ’s marks or numbers are lo- cated on the upper side of the rings.
4-26 CYLINDER AND PIST ON ENG NOTE: NOTE: 4. Position: S Piston rings Offset the piston ring end gaps as shown. a T op ring end b Oil ring end (lower) c Oil ring end (upper) d 2nd ring end 5. Lubricate: S Piston outer surface S Piston ring S Cylinder inner surface Engine oil 6.
4-27 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Crankcase filter cover and crankcase cover (left)removal Side panel Crankcase filter cover Crankcase filter cover seal Crankcase filter element Crankcase cover protector Crankcase cover (left) Crankcase cover gasket 1 1 1 1 1 1 Remove the parts in order .
4-28 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 V -belt, clutch and secondary / primary sheave removal Nut / Plain washer Prima.
4-29 Order Job name / Part name Q’ty Remarks 10 11 12 13 14 Cam Weight Slider Spacer Oil seal 1 8 4 4 1 Refer to “PRIMARY SHEA VE ASSEMBL Y” section. Reverse the removal procedure for installation. 60 Nm (6.0 m kg) 60 Nm (6.0 m kg) 3 Nm (0.
4-30 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Secondary sheave disassembly Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave 1 1 3 1 1 4 1 2 2 1 Disassemble the parts in order .
4-31 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG NOTE: NOTE: CAUTION: NOTE: YP****** PRIMAR Y SHEA VE REMOV AL 1. Remove: Nut 1 (primary sheave) Plate washer Primary fixed sheave 2 Loosen the nut (primary fixed sheave) while holding the primary fixed sheave with the rotor holder 3 .
4-32 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG NOTE: NOTE: CAUTION: NOTE: 3. Remove: S Clutch assembly 1 S V -belt 2 Remove the V -belt from the primary sheave side with clutch assembly .
4-33 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG YP****** V -BEL T INSPECTION 1. Inspect: V -belt 1 Cracks / Wear / Scaling / Chipping Re- place. Oil / Grease Check primary sheave and secondary sheave. 2. Measure: V -belt width 2 Out of specification Replace V -belt width: 22.
4-34 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG NOTE: NOTE: 3 Nm (0.3 m S kg) NOTE: YP****** PRIMAR Y SHEA VE ASSEMBL Y 1. Clean: S Primary sliding sheave face 1 S Primary fixed sheave face 2 S Collar 3 S Weight 4 S Primary sliding sheave cam face 5 Remove any excess grease.
4-35 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG NOTE: CAUTION: NOTE: CAUTION: 3. Install: Guide pin 1 4. Apply: BEL-RA Y assembly lube (to the guide pin sliding groove 1 , and and oil seal 2 ) 5.
4-36 V -BEL T , CLUTCH AND SECONDAR Y / PRIMAR Y SHEA VE ENG 90 Nm (9.0 m kg) NOTE: NOTE: NOTE: 7. Install: Nut 1 (clutch carrier) T ighten the nut (clutch carrier), using the lock- nut wrench 3 while holding the clutch carrier with the rotor holder 2 .
4-37 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Magneto cover and startor coil removal Drain the engine oil. Side panels Couplers (A.C. magneto lead) Exhaust pipe Exhaust pipe gasket Magneto cover Gasket (magneto cover) Dowel pins Startor coil Pick up coil 2 1 1 2 1 2 1 1 Remove the parts in order .
4-38 A.C. MAGNETO AND ST ARTER CLUTCH ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 A.C. magneto and starter clutch removal Rotor Shaft (idle gear) Idler gear Starter one way clutch assembly Woodruf f key Starter wheel gear 1 1 1 1 1 1 Remove the parts in order .
4-39 A.C. MAGNETO AND ST ARTER CLUTCH ENG NOTE: NOTE: CAUTION: YP401081 A.C. MAGNETO ROT OR REMOV AL 1. Remove: S Nut 1 (rotor) S Plain washer 2 D Loosen the nut (rotor) 1 while holding the ro- tor with a sheave holder 3 . D Do not allow the sheave holder to touch the projection on the rotor .
4-40 A.C. MAGNETO AND ST ARTER CLUTCH ENG ***************************************************** ***************************************************** NOTE: NOTE: YP402163 ST ARTER DRIVE GEAR INSPECTION 1. Inspect: S Starter idle gear teeth S Starter drive gear teeth S Starter wheel gear teeth Burrs / chips / roughness / wear Re- place.
4-41 A.C. MAGNETO AND ST ARTER CLUTCH ENG 80 Nm (8.0 m kg) NOTE: 3. T ighten: Nut (rotor) 1 T ighten the nut (rotor) 1 while holding the mag- neto rotor 2 with a sheave holder 3 .
4-42 OIL PUMP ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Oil pump removal A.C. magneto Cover Pump driven gear Dowel pin Oil pump assembly Gasket Impeller shaft gear Dowel pin Shaft 1 1 1 1 1 1 1 1 Remove the parts in order . Refer to the “A.
4-43 OIL PUMP ENG EB402140 OIL PUMP INSPECTION 1. Inspect: Drive gear (oil pump) Driven gear (oil pump) 1 Pump housing Pump housing cover Wear / cracks / damage Replace 2.
4-44 TRANSMISSION ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 T ransmission removal Rear wheel Crankcase cover (left) Drain the transmission oil. T ransmission case cover Gasket (transmission case cover) Dowel pin Primary drive gear Plain washer Plain washer 1st wheel gear 1 1 2 1 1 1 1 Remove the parts in order .
4-45 Order Job name / Part name Q’ty Remarks 8 9 10 11 Drive axle Main axle Primary driven gear Plain washer 1 1 1 1 Reverse the removal procedure for installation.
4-46 CRANKCASE AND CRANKSHAFT ENG Order Job name / Part name Q’ty Remarks 1 2 Crankcase and crankshaft removal Engine removal Cylinder head Cylinder , piston V -belt, clutch, secondary / primary sheave A.C. magneto, starter clutch Oil pump W ater pump Rear wheel Bolt O-ring 1 1 Remove the parts in the order .
4-47 Order Job name / Part name Q’ty Remarks 3 4 5 6 7 8 9 T iming chain guide (intake) Crankcase (right) Dowel pin Crankshaft assembly T iming chain Crankcase (left) Oil seal 1 1 2 1 1 1 1 Refer to “CRANKSHAFT INST ALLA TION” section. Refer to “CRANKSHAFT REMOV AL / INST ALLA TION” section.
4-48 CRANKCASE AND CRANKSHAFT ENG NOTE: NOTE: YP****** CRANKSHAFT REMOV AL 1. Remove: Crankshaft assembly T iming chain 1 Before removing the crankshaft assembly , remove the timing chain from the crank shaft sprocket. If the timing chain hooks to the crankshaft sprocket, the crankshaft cannot be removed.
4-49 CRANKCASE AND CRANKSHAFT ENG NOTE: NOTE: 4. Inspect: Crankshaft sprocket 1 Wear / Damage Replace crankshaft. Bearing 2 Wear / Crack / Damage Replace crank- shaft. Pump drive gear 3 Wear / Damage Replace crankshaft. 5. Inspect: Crankshaft journal Clogged Blow out the journal with com- pressed air .
ENG.
CHAPTER 5. COOLING SYSTEM RADIA TOR 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5-1 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Radiator removal Drain the coolant. Fuel tank Footrest board, under cover Cowling body , leg shield Fan motor leads Thermo switch leads Filler hose (radiator) Outlet hose (radiator) Inlet hose (radiator) Radiator 1 2 1 1 1 1 Remove the parts in order .
5-2 RADIA T OR COOL CAUTION: ***************************************************** ***************************************************** YP500030 INSPECTION 1. Inspect: D Radiator 1 Obstruction Blow out with com- pressed air through the rear of the radia- tor .
5-3 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 W ater pump removal Drain the coolant. Impeller shaft gear Dowel pin / plain washer Shaft Inlet hose (water pump) Holder Housing cover Housing cover gasket W ater pump housing 1 1/1 1 1 1 1 1 1 Remove the parts in order .
5-4 Order Job name / Part name Q’ty Remarks 9 10 11 Impeller shaft O-ring O-ring 1 1 1 Refer to “W A TER PUMP INST ALLA TION” section. Reverse the removal procedure for installation.
5-5 W A TER PUMP COOL NOTE: ***************************************************** ***************************************************** YP****** D It is not necessary to disassemble the water pump, unless there is no abnormality such as excessive change in coolant temperature and / or level, discoloration of coolant, or milky transmission oil.
5-6 W A TER PUMP COOL NOTE: ***************************************************** ***************************************************** NOTE: 10 Nm (1.0 m S kg) 2. Install: D Mechanical seal 1 Apply coolant to the outside of the me- chanical seal before installing.
5-7 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Thermostat removal Drain the coolant Side panel Fuel tank Clip Outlet hose (carburetor) Hose clamp Outlet hose (thermostat) Thermostatic cover Thermostatic valve 1 1 1 1 1 1 Remove the parts in order .
5-8 3mm 95 _ C 82”1.5 _ C THERMOST A T COOL ***************************************************** ***************************************************** NOTE: EB502010 INSPECTION 1. Inspect: D Thermostatic valve V alve does not open at 80.5 83.5 _ C Replace.
CHAPTER 6. CARBURETION CARBURETION 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR DISASSEMBL Y 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBL Y 6-4 . . . . . . . . .
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6-1 Do not bend the air filter joint clamp when installing the carburetor . Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Carburetor removal Side panel Fuel tank Drain the coolant Auto choke.
6-2 Refer to “CARBURETOR ASSEMBL Y” section. Refer to “CARBURETOR ASSEMBL Y” section. Order Job name / Part name Q’ty Remarks Carburetor disassembly Auto choke unit Throttle stop screw set P.
6-3 Order Job name / Part name Q’ty Remarks Float Needle valve Main jet Pilot jet Main nozzle 1 1 1 1 1 Refer to “CARBURETOR ASSEMBL Y” section. Reverse the disassembly procedure for assembly .
6-4 CARBURET OR CARB CAUTION: ***************************************************** NOTE: YP600041 ASSEMBL Y Reverse the “DISASSEMBL Y” procedure. Note the following points. D Before assembling, wash all parts in clean petroleum based solvent. D Always use a new gasket.
6-5 CARBURET OR CARB ***************************************************** NOTE: ***************************************************** Float height (F .H.): 27 mm Out of specification Replace. 5. Install: D Diaphragm 1 Align the tab a on the diaphragm with the slot b on the carburetor body .
6-6 CARBURET OR CARB ***************************************************** ***************************************************** ***************************************************** D Put a garage jack under the engine to ensure that the carburetors are positioned vertically .
6-7 CARBURET OR CARB ***************************************************** ***************************************************** YP****** FUEL PUMP INSPECTION 1. Remove: D Side panels Refer to “COVER AND P ANEL” section in CHAPTER 3. 2. Inspect: D Fuel pump Inspection steps: D Place the receptacle under the fuel pipe end.
CARB.
CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISC 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL AND BRAKE DISC 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL DISASSEMBL Y 7-2 . . . . . . . . . . . . . . .
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7-1 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Front wheel and brake disc removal Speedometer cable Axle nut Wheel axle Front wheel assembly Gear unit assembly Collar Brake disc 1 1 1 1 1 1 1 Remove the parts in order . Securely support the scooter so there is no danger of it falling over .
7-2 1 2 3 4 Order Job name / Part name Q’ty Remarks Front wheel disassembly Oil seal Bearing Spacer Bearing 1 1 1 1 Remove the parts in order . Reverse the removal procedure for installation. Refer to “FRONT WHEEL DISASSEMBL Y / ASSEMBL Y” section.
7-3 FRONT WHEEL AND BRAKE DISC CHAS CAUTION: YP****** FRONT WHEEL DISASSEMBL Y 1. Remove: Bearing 1 Spacer Remove the bearing using a general bear- ing puller 2 . Handle the wheel with care not to damage the brake disc. If the brake disc is damaged, replace.
7-4 FRONT WHEEL AND BRAKE DISC CHAS NOTE: CAUTION: 5. Inspect: S Collar Grooved wear Replace the collar and the oil seal as a set. YP****** BRAKE DISC INSPECTION 1. Measure: S Brake disc deflection Maximum deflection: 0.15 mm Out of specification Replace.
7-5 FRONT WHEEL AND BRAKE DISC CHAS 23 Nm (2.3 m kg) NOTE: NOTE: NOTE: CAUTION: 2. Install: Brake disc 1 T ighten the bolts (brake disc) in stage using a crisscross pattern. EB700030 FRONT WHEEL INST ALLA TION Reverse the “REMOV AL” procedure.
7-6 FRONT WHEEL AND BRAKE DISC CHAS NOTE: ***************************************************** ***************************************************** **************************************************.
7-7 FRONT WHEEL AND BRAKE DISC CHAS ***************************************************** ***************************************************** 5. Check: S Wheel static balance Checking steps: D T urn the wheel so that it comes to each point as shown.
7-8 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Rear wheel and rear brake removal Swingarm Adjuster Brake cable Compression spring Pin Rear wheel assembly Brake lining T ension spring Plate washer Camshaft lever Indicator plate Camshaft 1 1 1 1 1 2 2 1 1 1 1 Remove the part in order .
7-9 REAR WHEEL AND REAR BRAKE CHAS Order Job name / Part name Q’ty Remarks 12 13 Camshaft shim Camshaft seal 1 1 Reverse the removal procedure for installation.
7-10 REAR WHEEL AND REAR BRAKE CHAS NOTE: NOTE: EB701020 REAR WHEEL INSPECTION 1. Inspect: Rear wheel axle Rear wheel Rear wheel bearings Oil seals Refer to “FRONT WHEEL”. 2. Measure: Rear wheel runout Refer to “FRONT WHEEL”.
7-1 1 REAR WHEEL AND REAR BRAKE CHAS ***************************************************** ***************************************************** 4. Inspect: S Brake drum inner surface S Oil / scratches Repair . S Oil Use a rag soaked in lacquer thinner or sol- vent.
7-12 FRONT BRAKE CHAS Order Job name / Part name Q’ty Remarks 1 2 3 Brake pad removal Caliper support bolt Brake pad Pad support 1 2 1 Remove the parts in order . Refer to “BRAKE P AD REPLACEMENT” section. Reverse the removal procedure for installation.
7-13 FRONT BRAKE CHAS NOTE: NOTE: CAUTION: 23 Nm (2.3 m S kg) YP702010 BRAKE P AD REPLACEMENT It is not necessary to disassemble the brake cal- iper and brake hose to replace the brake pads. 1. Remove: S Bolt (caliper support bolt) 1 Move the direction brake caliper to the ar- row mark.
7-14 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Master cylinder removal Drain the brake fluid Rear view mirror (right) Brake lever / compression spring Brake switch Union bolt Plain washer Brake hose Master cylinder bracket Master cylinder 1 1/1 1 1 2 1 1 1 Remove the parts in order .
7-15 Order Job name / Part name Q’ty Remarks 1 2 3 4 Master cylinder disassembly Master cylinder boot Circlip Master cylinder assembly Spring 1 1 1 1 Remove the parts in order . Refer to “MASTER CYLINDER ASSEMBL Y” section. Reverse the disassembly procedure for assembly .
7-16 FRONT BRAKE CHAS YP702040 MASTER CYLINDER INSPECTION 1. Inspect: S Master cylinder 1 Wear / scratches Replace the master cylinder assembly . S Master cylinder cup 2 S Cracks / damage Replace. 2. Inspect: S Master cylinder S Scratches / wear / damage Replace the master cylinder assembly .
7-17 FRONT BRAKE CHAS 10 Nm (1.0 m kg) CAUTION: 26 Nm (2.6 m kg) CAUTION: 2. Install: Spring 1 Install the spring with its smaller diameter to the master cylinder piston. Master cylinder kit 2 3. Install: Circlip 1 Install the circlip securely into the master cylinder groove.
7-18 FRONT BRAKE CHAS 3. Air bleed: S Brake system Refer to “AIR BLEEDING” section in CHAPTER 3. D Use only designated quality brake fluid: Otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance.
7-19 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Caliper removal Drain the brake fluid Brake hose holder Union bolt Plain washer Brake hose Caliper support bolt Caliper assembly 1 1 2 1 1 1 Remove the parts in order . Refer to “BRAKE FLUID REPLACE- MENT” section in CHAPTER 3.
7-20 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Caliper disassembly Brake pad Pad support Caliper piston Dust seal Piston seal Bleed screw / Cap 2 1 2 2 2 1/1 Remove the parts in order . Refer to “BRAKE CALIPER DIS- ASSEMBL Y / ASSEMBL Y” section.
7-21 FRONT BRAKE CHAS NOTE: ***************************************************** ***************************************************** CAUTION: CAUTION: YP702020 BRAKE CALIPER DISASSEMBL Y Before disassembling either brake caliper , drain the brake fluid from the brake hose, mas- ter cylinder , brake caliper and reservoir tank.
7-22 FRONT BRAKE CHAS CAUTION: 23 Nm (2.3 m S kg) 26 Nm (2.6 m S kg) CAUTION: EB702050 BRAKE CALIPER ASSEMBL Y D All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid: DOT #4 D Replace the caliper piston seals whenev- er a brake caliper is disassembled.
7-23 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Front fork removal Front wheel Caliper assembly Front fender Inner fender Bolt (under bracket upper) Cap bolt / O-ring Bolt (under bracket lower) Front fork (left / right) 1 1 1 2 2/2 2 1/1 Remove the parts in order .
7-24 FRONT FORK CHAS Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Front fork disassembly Cap bolt O-ring Fork spring Dust seal Retaining clip Oil seal Bolt (Damper rod) / Gasket Inner tube Oil lock piece Damper rod Rebound spring 1 1 1 1 1 1 1/1 1 1 1 1 Remove the parts in order .
7-25 FRONT FORK CHAS NOTE: NOTE: YP****** FRONT FORK REMOV AL D Securely support the scooter so there is no danger of it falling over . D Stand the scooter on a level surface. D Stand the scooter on its centerstand. 1. Loosen: S Bolt (lower bracket upper) 1 Loosen only the upper bolt.
7-26 FRONT FORK CHAS CAUTION: 2. Remove: Inner tube Oil lock pice 3. Remove: Oil seal 1 Never reuse the oil seal. 2 Rag YP703030 FRONT FORK INSPECTION 1. Inspect: Inner tube bending Inner tube bending limit: 0.2 mm Scratches / bends / damage Replace.
7-27 FRONT FORK CHAS 23 Nm (2.3 m S kg) NOTE: NOTE: CAUTION: 2. Install: S Inner tube 1 Into outer tube 2 . 3. Install: S Plain washer 1 S Bolt (damper rod) 2 4. T ighten: S Bolt (damper rod) 1 T ighten damper rod bolt 1 while holding the damper rod with a T -handle 2 and a damper rod holder 3 .
7-28 FRONT FORK CHAS NOTE: NOTE: 7. Inspect: S Inner tube operation Unsmooth operation Disassembly and recheck. 8. Fill: S Fork oil Oil quantity: 0.142 L Recommended oil: Fork oil 15 WT or equivalent 9. After filling up, slowly pump the fork up and down to distribute the fork oil.
7-29 FRONT FORK CHAS NOTE: 45 Nm (4.5 m kg) 23 Nm (2.3 m kg) EB703050 FRONT FORK INST ALLA TION Reverse the “REMOV AL“ procedure. Note the following points.
7-30 HANDLEBAR CHAS Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Handlebar removal Handlebar upper cover Rear view mirror (right) Rear view mirror (left) Master cylinder bracket Mast.
7-31 HANDLEBAR CHAS Order Job name / Part name Q’ty Remarks 11 12 13 14 15 Handlebar switch (left) Grip end (left) Grip Upper handlebar holder Handlebar 1 1 1 2 1 Refer to “HANDLEBAR INST ALLA TION” section. Refer to “HANDLEBAR REMOV AL” section.
7-32 HANDLEBAR CHAS ***************************************************** ***************************************************** NOTE: 23 Nm (2.3 m S kg) NOTE: NOTE: YP****** HANDLEBAR REMOV AL 1. Remove: S Grip (Left) Removal steps: D Remove the grip end (left).
7-33 HANDLEBAR CHAS NOTE: NOTE: NOTE: ***************************************************** ***************************************************** 4. Install: S Handlebar switch (left) 1 Align the handlebar switch mating surface with the punched mark a on the handlebar .
7-34 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Steering removal Handlebar upper cover Front fork Handlebar Nut Handlebar lower holder Woodruf f key Ring nut (upper) Lock washer Ring nut (center) Rubber washer Ring nut (lower) Ball race cover Ball race 1 Lower bracket 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in order .
7-35 STEERING CHAS Order Job name / Part name Q’ty Remarks 12 13 14 15 Ball bearing Ball bearing Ball race 1 Ball race 2 22 19 1 1 Refer to “STEERING INST ALLA TION” section. Reverse the removal procedure for installation. 139 Nm (13.9 m kg) 75 Nm (7.
7-36 STEERING CHAS NOTE: NOTE: YP704010 STEERING REMOV AL D Securely support the scooter so that there is no danger of it falling over . D Stand the scooter on a level surface. 1. Remove: S Handlebar lower holder 1 S Woodruf f key 2 Remove the handlebar lower holder by loosen- ing the ring nut (upper) 3 gradually .
7-37 STEERING CHAS ***************************************************** ***************************************************** NOTE: CAUTION: 139 Nm (13.9 m S kg) NOTE: Bearing race replacement steps: D Remove the bearing races on the head pipe using long rod 1 and the hammer as shown.
7-38 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Rear shock absorber and swingarm removal Side panels Box Nut Muffler assembly Axle nut Rear shock absorber Swingarm Collar Oil seal Bearing 1 2 1 1 1 1 1 1 1 Remove the parts in order . Refer to “COVER AND P ANEL” section in CHAPTER 3.
CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCHES 8-4 . . . . . .
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8-1 ELECTRICAL COMPONENTS ELEC 1 Main switch 2 Ignition coil 3 Spark plug cap 4 Fuel sender 5 Rectifier / Regulator 6 Starting circuit cut-off relay 7 Wireharness 8 Thermo unit 9 Ignitor unit 10 Sides.
8-2 CIRCUIT DIAGRAM ELEC CIRCUIT DIAGRAM.
8-3 CIRCUIT DIAGRAM ELEC 1 A.C. magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Thermo switch (auto choke) 9 Auto choke 10 Ignitor unit 11 Ignition .
8-4 CHECKING SWITCHES ELEC NOTE: YP-N CHECKING SWITCHES CHECKING STEPS Using pocket tester , check switches for continu- ity between their terminals to determine wheth- er they are correctly connected. Repalce the switch component if any of the combinations does not produce the correct reading.
8-5 Before checking a switch refer to the checking switches as shown in the left page and check for the correct terminal connections (closed circuit) according to the color combinations shown in the chart. Poor connection, fault Repair or replace.
8-6 IGNITION SYSTEM ELEC 3 Main switch 4 Battery 5 Main fuse 10 Ignitor unit 11 Ignition coil 12 Spark plug 13 Pickup coil 14 Sidestand switch 18 Engine stop switch EB802000 IGNITION SYSTEM CIRCUIT DI.
8-7 IGNITION SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section in CHAPTER 8. Replace the fuse. NO CONTINUITY CONTINUITY YP****** 2. Battery Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3.
8-8 IGNITION SYSTEM ELEC YP****** 4. Ignition spark gap S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker as shown. Spark plug S T urn the main switch to “ON”. S Check the ignition spark gap . S Check the spark by pushing the starter switch, and increase the spark gap until a misfire occurs.
8-9 IGNITION SYSTEM ELEC YP****** 6. Ignition coil resistance S Disconnect the ignition coil connector from the wireharness. S Connect the pocket tester ( Ω 1) to the ignition coil. S Check if the primary coil has the specified re- sistance. S Connect the pocket tester ( Ω 1 k) to the ignition coil.
8-10 IGNITION SYSTEM ELEC YP****** 7. Pickup coil resistance S Disconnect the pickup coil coupler from the wireharness. S Connect the pocket tester ( Ω 100) to the pickup coil coupler . : Pickup coil resistance: 168 X 252 Ω (20 _ C) YP****** 8. Main switch Refer to “CHECKING SWITCHES” section in the CHAPTER 8.
8-1 1 CHARGING SYSTEM ELEC 1 A.C. magneto 2 Rectifier regulator 4 Battery 5 Main fuse YP804000 CHARGING SYSTEM CIRCUIT DIAGRAM.
8-12 CHARGING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Replace the fuse. NO CONTINUITY CONTINUITY YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals.
8-13 YP****** 3. Charging voltage S Connect the engine tachometer to the spark plug lead . S Connect the pocket tester (DC20 V) to the battery . S Measure the battery terminal voltage. S Start the engine and accelerate to about 5,000 r / min. S Check the terminal voltage.
8-14 CHARGING SYSTEM ELEC YP****** 4. Starter coil resistance S Remove the A.C. magneto coupler from wireharness. S Connect the pocket tester ( Ω 1) to the sta- tor coil.
8-15 ELECTRIC ST ARTING SYSTEM ELEC 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 14 Sidestand switch 15 Starting circuit cut-off relay 17 Starter switch 18 Engine stop switch 23.
8-16 ELECTRICAL ST ARTING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section in CHAPTER 8. Replace the fuse. NO CONTINUITY CONTINUITY YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3.
8-17 ELECTRICAL ST ARTING SYSTEM ELEC YP****** 3. Starter motor S Connect the battery positive terminal and starter motor cable using a jumper lead. S Check the starter motor operation. CONTINUITY Repair or replace the starter motor . DOES NOT MOVE : : YP****** 4.
8-18 : YP****** 6. Main switch Refer to “CHECKING SWITCHES” section. NO CONTINUITY Replace the main switch. CONTINUITY YP****** 7. Engine stop switch Refer to “CHECKING SWITCHES” section. NO CONTINUITY Replace the right handlebar switch. CONTINUITY YP****** 8.
8-19 ELECTRICAL ST ARTING SYSTEM ELEC Order Job name / Part name Q’ty Remarks 1 Starter motor removal Air cleaner case Starter motor 1 Remove the parts in order . Refer to “ENGINE REMOV AL AND INST ALLA TION” section in CHAPTER 4. Reverse the removal procedure for instal- lation.
8-20 ELECTRICAL ST ARTING SYSTEM ELEC NOTE: Good condition Bad condition A B f f f f YP803034 Inspection and repair 1. Inspect: S Commutator Dirt Clean it with #600 grit sandpaper . 2. Measure: S Commutator diameter a Commutator wear limit: 27 mm Out of specification Replace the starter motor 3.
8-21 ELECTRICAL ST ARTING SYSTEM ELEC NOTE: 5 Nm (0.5 m kg) NOTE: Brush spring force: 570 X 920 g 7. Inspect: Bearing Oil seal Wear / damage Repalce.
8-22 3 Main switch 4 Battery 5 Main fuse 16 Lights switch 29 Dimmer switch 30 Pass switch 32 T ail / Brake light 33 Licence light 36 Head light 39 Auxiliary light 40 Meter lights LIGHTING SYSTEM ELEC .
8-23 LIGHTING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Repalce the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals.
8-24 YP****** 5. Dimmer switch / Pass switch Refer to “CHECKING SWITCHES” section. Replace the left handlebar switch. NO CONTINUITY : YP****** 6. Wiring connection S Check the connections of the entire lighting system. Refer to “WIRING DIAGRAM”.
8-25 LIGHTING SYSTEM ELEC YP805021 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and / or bulb socket. NO CONTINUITY : 2. V oltage S Connect the pocket tester (DC20 V) to the bulb socket coupler . T ester (+) lead Blue terminal T ester (–) lead Black terminal S T urn the main switch to on.
8-26 LIGHTING SYSTEM ELEC 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and / or bulb socket. NO CONTINUITY 2. V oltage S Connect the pocket tester (DC20 V) to the bulb socket connector . T ester (+) lead Blue terminal T ester (–) lead Black terminal S T urn the main switch to on.
8-27 LIGHTING SYSTEM ELEC 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and / or bulb socket. NO CONTINUITY 2. V oltage S Connect the pocket tester (DC20 V) to the bulb socket connector . T ester (+) lead Blue terminal T ester (–) lead Black terminal S T urn the main switch to on.
8-28 SIGNAL SYSTEM ELEC 3 Main switch 4 Battery 5 Main fuse 23 Rear brake switch 24 Front brake switch 25 Flasher relay 26 Horn 27 T urn switch 28 Horn switch 33 T ail / Brake light 34 Rear flasher li.
8-29 SIGNAL SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Replace the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals.
8-30 SIGNAL SYSTEM ELEC YP****** 4. Wireharness S Check the connections of the entire signal system. Refer to “CIRCUIT SYSTEM WIRING DIA- GRAM” section. Correct. POOR CONNECTION : Check condition of each of the signal sys- tem’s circuits. Refer to “SIGNAL SYSTEM CHECK” section.
8-31 SIGNAL SYSTEM ELEC 1. HORN switch Refer to “CHECKING SWITCHES” section. CONTINUITY Replace the left handlebar switch. NO CONTINUITY 2. V oltage S Connect the pocket tester (DC20 V) to the horn lead. T ester (+) lead Brown terminal . T ester (–) lead Frame ground 1 MEETS SPECIFICA TION S T urn the main switch to on.
8-32 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. Replace the bulb and / or bulb socket. NO CONTINUITY 3. V oltage S Connect the pocket tester (DC20 V) to the bulb socket connector . T ester (+) lead Blue terminal T ester (–) lead Black terminal S T urn the main switch to on.
8-33 1. Bulb and bulb socket Refer to “CHECKING SWITCHES” section. MEETS SPECIFICA TION Replace the bulb and / or bulb socket. NO CONTINUITY 3. V oltage S Connect the pocket tester (DC20 V) to the flasher relay coupler . T ester (+) lead Brown terminal .
8-34 6. Wiring connection S Wiring circuit from the turn switch to bulb socket connector is fault. Repair . Refer to “CIRCUIT DIAGRAM”. 5. V oltage S Connect the pocket tester (DC20 V) to the bulb socket connector . At flasher light (left) T ester (+) lead Chocolate lead T ester (–) lead Black terminal S T urn the main switch to on.
8-35 SIGNAL SYSTEM ELEC Float position Specificated resistance UP 4 X 10 Ω 90 X 100 Ω DOWN 1. Fuel sender S Remove the fuel sender from the fuel tank. S Disconnect the fuel sender coupler from the wireharness. Connect the pocket tester ( Ω 10) to the fuel sender coupler lead.
8-36 Float “UP” “F” “E” Float “DOWN” 3. Fuel gauge S Connect the fuel sender to wireharness. S Move the float to “UP” or “DOWN” . 1 S T urn the main switch to “ON”. S Check the fuel gauge needle moves “F” or “E”. Replace the fuel gauge.
8-37 3 Main switch 4 Battery 5 Main fuse 20 Fuse (fan) 21 Thermo switch 22 Fan motor 46 Thermo meter 50 Thermo unit COOLING SYSTEM ELEC YP80700 COOLING SYSTEM CIRCUIT DIAGRAM.
8-38 COOLING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Replace the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals.
8-39 COOLING SYSTEM ELEC 4. Fan motor (inspection 1) Disconnect the fan motor couplers. Cconnect the battery as shown. Battery (+) lead Blue terminal Battery (–) lead Black terminal 1 MOVES Check the fan motor operation. Replace fan motor .
8-40 COOLING SYSTEM ELEC S Handle the thermo switch with special care. Never subject it to strong shocks or allow it to be dropped. Should it be dropped, it must be replaced. S Do not touch the thermo switch to the bottom of the heated vessel. 7. Wiring connection S Check the connection of the entire cooling system.
8-41 COOLING SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Replace the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals.
8-42 D Handle the thermo unit with special care. Never subject it to strong shocks or al- low it to be dropped. Should it be dropped, it must be replaced. D Do not touch the thermo unit to the bot- tom of the heated vessel. 80 _ C 47.5 X 56.8 Ω 26.2 X 29.
8-43 YP****** 6. Wiring connection S Check the connections of the entire cooling system. Refer to “CIRCUIT DIAGRAM” section. Correct. POOR CONNECTION : Replace the temperature gauge.
8-44 3 Main switch 4 Battery 5 Main fuse 8 Thermo switch (auto choke) 9 Auto choke 10 Ignitor unit 18 Engine stop switch AUT O CHOKE SYSTEM ELEC YP****** AUT O CHOKE SYSTEM CIRCUIT DIAGRAM.
8-45 AUT O CHOKE SYSTEM ELEC NOTE: YP****** 1. Fuse Refer to “CHECKING SWITCHES” section. Repalce the fuse. NO CONTINUITY CONTINUITY : YP****** 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” section in CHAPTER 3. S Clean battery terminals.
8-46 AUT O CHOKE SYSTEM ELEC S Disconnect the thermo switch from the ra- diator . S Connect the pocket tester ( Ω 1) to the thermo switch . S Immerse the thermo switch in the coolant . S Check the thermo switch for continuity . Note temperatures while heating the water with the temperature gauge .
8-47 YP****** 6. Auto choke unit resistance S Disconnect the auto choke unit coupler from the wireharness. S Connect the pocket tester ( Ω 1) to the auto choke unit coupler lead. : Auto choke unit resistance: 16 X 24 Ω (20 _ C) T ester (+) lead Black terminal T ester (–) lead Black terminal 1 2 Replace the auto choke unit.
ELEC.
CHAPTER 9. TROUBLESHOOTING ST ARTING F AILURE / HARD ST ARTING 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION SYSTEM 9-1 . .
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9-1 ST ARTING F AILURE / HARD ST ARTING TRBL SHTG NOTE: EB90000 TROUBLESHOOTING The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however , as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.
9-2 POOR IDLE SPEED PERFORMANCE TRBL SHTG IGNITION SYSTEM Battery Improperly charged battery Faulty battery Fuse Burnt out, improper connection Spark plug Improper plug gap Worn el.
9-3 POOR MEDIUM AND HIGH SPEED PERFORMANCE TRBL SHTG EB902000 POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to “ST ARTING F AILURE / HARD ST AR TING” section.
9-4 F AUL TY CLUTCH TRBL SHTG YP****** F AUL TY CLUTCH WHEN ENGINE IS RUN, SCOOTER DOES NOT RUN V belt Worn / bent / slipping Cam, slider Worn / damaged Compression spring Damage Gears .
9-5 OVERHEA TING OR OVER COOLING TRBL SHTG YP905000 OVERHEA TING OR OVER COOLING OVERHEA TING Ignition system Improper spark plug gap Improper spark plug heat range Faulty ignitor unit Fue.
9-6 F AUL TY BRAKE / FRONT FORK MALFUNCTION TRBL SHTG YP906000 F AUL TY BRAKE POOR BRAKING EFFECT Front brake Worn brake pad Worn brake disc Air in brake fluid Leaking brake fluid .
9-7 INST ABLE HANDLING / ST ARTER MOTOR DOES NOT OPERA TE TRBL SHTG YP908000 INST ABLE HANDLING INST ABLE HANDLING Handlebars Loose handlebar tightening bolt Steering Loose or overtightening s.
9-8 F AUL TY SIGNAL AND LIGHTING SYSTEM TRBL SHTG YP909000 F AUL TY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DARK Improper bulb T oo many electric accesories Hard charging Faulty rectifier.
1. A.C. magneto 2. Rectifier / regulator 3. Main switch 4. Main fuse 5. Battery 6. Starter relay 7 Starter motor 8 Thermo switch (auto choke) 9. Auto choke 10. Ignitor unit 1 1. Ignition coil 12. Spark plug 13. Pickup coil 14. Sidestand switch 15. Starting circuit cut-off relay 16.
An important point after buying a device Yamaha YP250 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Yamaha YP250 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Yamaha YP250 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Yamaha YP250 you will learn all the available features of the product, as well as information on its operation. The information that you get Yamaha YP250 will certainly help you make a decision on the purchase.
If you already are a holder of Yamaha YP250, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Yamaha YP250.
However, one of the most important roles played by the user manual is to help in solving problems with Yamaha YP250. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Yamaha YP250 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
