ELEC - Yamaha Majesty Fan Site
Contents
1. 67 D magneto CIRCUIT DIAGRAM ELEC 62 Thermo switch Fan 2 Pickup coil 83 Fan motor 3 Rectifier regulator Brake light switch 4 Main switch 65 Flasher relay 5 Backup fuse 86 Horn 6 Battery 62 Turn switch 7 Main fuse 68 Horn switch Starter relay 69 Dimmer switch 9 Star2. Box light 9 Head light fuse 89 Fan fuse 69 Signal fuse 62 Thermo switch Fan 63 Fan motor I 62 Brake light switch 65 Flasher relay i E 86 Horn L pee H 9 5 9 I 4 6 Turn switch bru dip 1 2 dicar j m 88 Horn switch N oF i BY i i E qt 69 Dimmer switch L Pass switch se y NN E Loos Nul Lud 49 1 uem OO OR Ge EE paya COLORCODE l 1 1 L OO 1 j WB i Biss Black usn Brown White e GEE se B L 8 Br Brown G R Green Red S RCM i7 RE ENIM THRONE SURE D RITE Ch Chocolate G Y Green Yellow 588 a Dg Dark green L B Blue Black d L 4 l Green Li uses Blue Green Al m 1 PEE Blue LiB issus Blue Red 69 5 1 69 4 d
3. 4 Main switch Horn switch 6 Battery Tail Brake light 7 Main fuse Rear flasher lights 6 Signal fuse Front flasher lights 62 Brak light switch Turn indicator lights 65 Flasher relay 63 Fuel gauge Horn Fuel sender Turn switch 80 SIGNAL SYSTEM YP806010 TROUBLESHOOTING IF THE FLASHER LIGHT BRAKE LIGHT AND OR INDICATOR LIGHT FAIL TO COME ON IF THE HORN FAILS TO SOUND Procedure Check 1 Fuse Main signal 2 Battery NOTE a_a Remove the following parts before trouble shooting 1 Cowling body 2 Side panels Use the special tools in the troubleshooting section 3 Main switch 4 Wiring connection entire signal system 7 Z Pocket tester 2 90890 03112 visis NO CONTINUITY Refer to CHECKING SWITCHES section CONTINUITY Replace the fuse INCORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION section Clean battery terminals in CHAPTER 3 Recharge or replace battery CORRECT 3 Main switch Refer to CHECKING SWITCHES section CONTINUI
4. 4 Main switch 6 Battery 7 Main fuse Starter relay 9 Starter motor 12 Starting circuit cut off relay Sidestand switch 63 Starter switch 4 Engine stop switch 69 Ignition fuse 87 Signal fuse 62 Brake light switch Alarm 72 LIGHTING SYSTEM EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM R N OFF on TOO W T ceu Ba 9 1
5. TRBIRAN TG Y i es Main switch Battery 7 Main fuse Ignitor unit 49 Fuel pump 69 Fuel pump relay 62 Engine stop switch 69 Ignition fuse 89 FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor
6. 19 1 Box light 2 Rectifire regulator 3 Air induction system air filter 4 Wireharness 5 Battery negative lead 6 Battery positive lead 7 Seat lock cable assembly Battery 9 Rodiator reservoir tank Ignition coil 12 Air induction system 42 Engine ground B 45 46 00 O CABLE ROUTING SPEC ve Engine bracket Rear brake hose A C magneto lead Starter motor lead Fasten the wireharness to the frame with a plastic locking tie Route the brake hose assembly through the clamp of engine bracket Fix the seat lock to the box 20 D E F G Fasten the wireharness to the frame with a plastic locking tie Clamp the rear brake hose Clamp the wireharness to the frame with a plastic locking tie Fasten the seat lock cable and wireharness with a band and band of the end on inside of the frame 1107 130mm M 20 30mm Fasten the wireharness to the frame with a band and the band of end inside of the frame Clamp the radiator reservoir hose Fa
7. CAUTION gt Hard water or salt water is harmful to en gine parts Use only distilled water if soft water is not available gt H you use tap water make sure it is soft wa ter gt Do not use water containing impurities or oil care that no coolant splashes onto painted surfaces If it does wash them straightaway with water not mix different types of ethylene gly col antifreeze containing corrosion inhibi tors for aluminum engines 9 Tighten gt Screw carburetor bleed Fill the coolant slowly to the specified level 10 Install Radiator cap 11 Start the engine and let it warm up for sever al minutes 12 Stop the engine and inspect the level Refer to COOLANT LEVEL INSPECTION section NOTE Wait a few minutes until the coolant settles be fore inspecting the coolant level 13 Install gt Side cover mole Refer to COVER AND PANEL section INSP HEADLIGHT BEAM ADJUSTMENT ADJ ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1 Adjust Headlight beam vertical Turn the adjuster 1 in or out Turning in Headlight beam moves lower Turning out Headlight beam moves higher 2 Adjust Headlight beam horizontal Turn the adjuster 1 in or out Left headlight Turning in Headlight beam moves left Turning out Headlight beam moves right Right head light Turning in Headlight beam moves right
8. 2 Pickup coil 4 Main switch 6 Battery 7 Main fuse Ignitor unit 45 Ignition coil Spark plug Sidestand switch 62 Engine stop switch Alarm 71 ELECTRIC STARTING EB80300 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM RR w jew e us o
9. 73 TROUBLESHOOTING 74 SIGNAL SYSTEM 80 CIRCUIT DIAGRAM eter pe un rrr nte eh nn sd 80 TROUBLESHOOTING 81 SIGNAL SYSTEM CHECK 83 FUEL PUMP SYSTEM 89 DIAGRAM EE cR Dam qachu popi u 89 FUEL PUMP CIRCUIT OPERATION 90 TROUBLESHOOTING 91 CHECKING THE FUEL PUMP 93 WIRING DIAGRAM SCOOTER IDENTIFICATION REN do 100000 GENERAL INFORMATION SCOOTER IDENTIFICATION YP100010 VEHICLE IDENTIFICATION NUMBER for E The vehicle identification number 1 is stamped into the right side of the frame NOTE _ __ _ _ _ _ The vehicle identification number is used to identify your scooter and may be used to regis ter your scooter with the licensing authority in your country YP100020 FRAME SERIAL NUMBER except for E The frame serial number 1 is stamped into the right side of the frame EB100030 ENGINE SERIAL NUMBER The engine serial number is stamped into the crankcase NOTE Designs and specifications are subject to change without notice MODEL LABEL The model label is affixed under the seat This information will be needed to order spare parts EB102000 SPECIA
10. filter element filter cover seal gt Crankcase filter cover TM 7 Nm 0 7 m kg INSP AIR INDUCTION SYSTEM INSPECTION ADJ AIR INDUCTION SYSTEM INSPECTION 1 Remove gt Side cover mole gt Passenger seat Standing handle gt Side cover 2 Refer to COVER AND PANEL section 2 Inspect Hose 3 D Air filter case 2 Hose 2 3 induction system assembly 4 gt hose 5 3Pipe 1 gt 1 7 Cracks damage Replace 3 Install gt Side cover 2 gt Standing handle gt Passenger seat gt Side cover mole 36 INSP COOLANT REPLACEMENT ADJ 37 YP303180 COOLANT REPLACEMENT 1 Remove gt Side cover mole Refer to the COVERS AND PANEL section 2 Remove 1 reservoir tank Drain the reservoir tank of its coolant 3 Remove Drain bolt 1 Rivet Cover 3 Radiator cap Open the front trunk remove the cover slow ly loosen to remove the radiator cap and drain the coolant WARNING Do not remove the radiator cap when the en gine and radiator are hot Scalding hot fluid and steam may be blown out under pres sure which could cause serious injury When the engine has cooled open the radia tor cap as follows Place a thick rag or a towel over the radiator cap Slowly rotate the cap counterclockwise toward the detent This allows any residual pressure to escape When the hissing sound has
11. 46 e V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE Shell BT grease No 3 90890 69927 Job name Part name Remarks V belt clutch and secondary Remove the parts in order primary sheave removal Nut Plain washer Primary fixed sheave Bracket Nut Spacer O ring Clutch housing Clutch assembly V belt Primary sliding sheave Collar Primary sheave cap Refer to PRIMARY SHEAVE REMOVAL section Refer to SECONDARY SHEAVE AND V BELT REMOVAL section Refer to SECONDARY SHEAVE INSTALLATION section lala lll Refer to PRIMARY SHEAVE ASSEMBLY section 47 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE s Shell BT grease No 3 90890 69927 60 Nm 6 0 m kg Job name Part name Remarks Cam Weight Slider Spacer Cil seal Refer to PRIMARY SHEAVE ASSEMBLY section Reverse the removal procedure for installation 48 s TRANSMISSION TRANSMISSION Job name Part name Remarks Transmission removal Remove the parts in order Rear wheel Refer to REAR WHEEL REAR BRAKE section Crankcase cover left Refer to V BELT CLUTCH SECONDARY PRIMARY SHEAVE section Drain the transmission oil Refer to TRANSMISSION OIL REPLACEMENT section Transmission case cover Gasket transmission
12. Replace the bulb and or bulb socket Tester lead Blue Red terminal 1 Tester lead Black terminal 2 OUT OF SPECIFICATION Turn the main switch to on m wiring circuit from main switch bulb e Turn the lights switch to on or pilot position USE etait e Check the voltage 12 V on the bulb socket p connector MEETS SPECIFICATION This circuit is not faulty 79 SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM tie lun o
13. Turning out Headlight beam moves left 40 e ENGINE REMOVAL ENGINE OVERHAUL EB400000 ENGINE REMOVAL WIREHARNESS CABLE REAR BRAKE Sx s 5 Job name Part name Remarks Wireharness cables and rear brake Remove the parts in order removal Side cover Main box Refer to COVER AND PANEL section Footrest board Drain the coolant Refer to COOLANT REPLACEMENT section Carburetor Refer to CARBURETOR section Spark plug cap Thermo unit lead Startor coil Pick up coil lead Starting motor lead Earth lead 41 s ENGINE REMOVAL 1000000 NI TD 4 Job name Part j Remarks Caliper assembly Brake hose 1 Air induction system hose Reverse the removal procedure for installation 42 ENGINE REMOVAL HOSES AIR FILTER CASE ENGINE MOUNTING BOLT AND ENGINE 67 Job name Part Remarks s Hoses air filter case engine mounting bolt and engine removal Crankcase breather hose Inlet hose water pump Outlet hose cylinder head Air filler case assembly Bolt Self locknut Plane washer Bolt Bolt Plane washer Rod assembly Engine Remove the parts in order Rear shock absorber lower section 1 1 1 2 1 installation 43 Refer to ENGINE REMOUNTING Reverse the removal procedure for CYLINDER HEAD Job name Part
14. R L e alle 9 9 4 switch Pass switch 5 Backup Fuse 42 License plate light 6 Battery Tail Brake light 7 Main fuse Head light Lo 62 Lights switch 47 Head light HI Seat switch Auxiliary light Box light High beam indicator light 9 Head light fuse 6 Meter lights 69 Dimmer switch 73 LIGHTING SYSTEM ELEC YP805010 TROUBLESHOOTING IF THE HEADLIGHT HIGH BEAM INDICATOR LIGHT TAILLIGHT BOX LIGHT LICENSE PLATE LIGHT AND OR METER LIGHT FAIL TO COME ON Procedure Check D h h 1 Fuse Main Backup sn ss 2 Battery 3 Main switch 7 Wiring connection entire lighting system 4 Lights switch NOTE Remove the following parts before trouble shooting 1 Rider seat 2 Passenger seat 3 Box 4 Legshield 5 Cowling body Use the special tools specified in the trouble shooting section Z Pocket tester 90890 03112 1 Fuse CONTINUITY
15. Refer to CHECKING SWITCHES section CONTINUITY INCORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION section Clean battery terminals in CHAPTER 3 Recharge or replace battery RRECT J NO CONTINUITY 3 Main switch Refer to CHECKING SWITCHES section Replace the main switch CONTINUITY NO CONTINUITY Replace the right handlebar switch 4 Lights switch Refer to CHECKING SWITCHES section CONTINUITY 74 LIGHTING System ELEC TN y NO CONTINUITY 5 Dimmer switch Pass switch Refer to CHECKING SWITCHES section Replace the left handlebar switch D NO CONTINUITY 6 Seat switch Refer to CHECKING SWITCHES section Replace the handlebar switch C ypa 7 Wiring connection Check the connections of the entire lighting system Refer to WIRING DIAGRAM POOR CONNECTIONS Correct Check the condition of each of the lighting system s circuits Refer to LIGHTING SYSTEM CHECK YP805020 LIGHTING SYSTEM CHECK 1 If the headlight and the high beam indicator light fail to come on 2 Voltage Connect the pocket tester DC20 V to the headlight and high beam indicator light cou plers When the dimmer switch is on low beam When dimmer switch is on high beam or the Pass switch is pushed Headlight Tester lead Green or Yellow 2 lead
16. CYLINDER HEAD Remarks O1 G Cylinder head removal Drain the coolant Side cover Main box Footrest board Carburetor Thermo unit lead Plug cap Hose Outlet hose cylinder head Vacuum hose Breather hose crankcase Carburetor joint Joint O ring 44 N pP Remove the parts in the order Refer to the COVER AND PANELS section Refer to CARBURETOR section ye CR Job name Part name s CYLINDER HEAD Br 4 Remarks Crankcase filter cover Pipe 1 Gasket Plug O ring Cam sprocket cover O ring Valve cover intake side O ring Valve cover exhaust side O ring Timing chain tensioner assembly Timing chain tensioner gasket Breather plate Cam sprocket Timing chain Cylinder head Cylinder head gasket Dowel pin 45 Refer to CYLINDER HEAD REMOVAL AND INSTALLATION section Reverse the removal procedure for installation V BELT CLUTCH AND 7 SECONDARY PRIMARY SHEAVE oD V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE CRANKCASE FILTER COVER AND CRANKCASE COVER LEFT dus Job name Part name Remarks Crankcase filter cover and crankcase Remove the parts in order cover left removal Side cover panel Refer COVER AND PANEL section Crankcase filter cover Crankcase cover protector Crankcase cover left Crankcase cover gasket Reverse the removal procedure for installation
17. Orange Blue Yellow 2 a o dos masapas ELE abaan L W Blue White ae LS H AS 106 R Red R G Red Green m Ph Yellow R Y Red Yellow B F dus W carson white R W Red White i SE MIA EE ununi boues cx dup BARS uaa Black Red YR tss Yellow Red m P NEAR ANE B W Black White Yellow Blue Br L Brown Blue W G White Green
18. ww oH s Lou 6 Battery 46 Head light LO uo un x e 7 Main fuse Head light HI Starter relay 8 Auxiliary light t 4 9 Starter motor 9 Trun signal indicator light _ 9A m Diode 60 High beam indicator light 2 4 Starting circuit cut off 6 Meter light if M 2 Thermo switch Auto choke 62 Oil indicator light E pese postes ux PLE P 43 Auto choke 63 Fuel gauge Rd ril OE ru gt Es n mer tly i Ignitor unit 64 Thermometer dr Wn oh e nekat N 45 Ignition coil 65 Clock L IE cea M xi pe gt ale LI d i 46 Spark pulg 66 Speedometer e IL EE i m RUE 5 b Gin ss 4 Throttle position sensor 62 Meter assembly r i Speed sensor 68 Fuel sender Fuel pump e Thermo unit Fuel pump relay Alarm gt Sidestand switch 67 Grip warmer switch OPTION ea Light switch 62 Grip warmer OPTION e3 Start switch 63 Ground Engine stop switch 65 Right handlebar switch 26 Ignition fuse Seat switch
19. Clutch stall revolution V belt V belt width Carburetor Type I D mark Ventuly outside diameter Main jet Main air jet Jet needle Throttle valve size Pilot air jet Needle jet Pilot outlet Pilot jet Bypass Pilot screw Valve seat size Starter jet 1 Starter jet 2 Float height Engine idle speed Intake vacuum Oil temperature Cooling water temperature Fuel pump Type Model manufacturer Standard DID SC gt A 0404A SDH 104 Automatic 3 3 mm 135 mm 28 1 mm 20 mm 2 250 2 850 r min 3 700 4 700 r min Y28V 1E 1 5GM 10 028 128 00 9 5D9B 3 5 11 85 90 8 43 0 7 3 2 27 5 mm 1 300 1 500 r min 29 3 36 0kPa 220 270 mmHg 65 75 80 C 2 0 mm 135 5 mm TH 19 5 mm Xx Electrical 2GV MITSUBISHI MAINTENANCE SPECIFICATIONS SPEC ve Standar m Radiator Type Cooling fin with electric fan Width height thickness 140 238 24 mm Radiator cap opening pressure 110 140 kPa 1 1 1 4 kg cm 1 1 1 4 bar Radiator capacity 1 4L Reservoir tank capacity 0 4 L MAINTENANCE SPECIFICATIONS ve TIGHTENING TORQUES ENGINE Thread Tightening Part to be tightened Part name ite Q ty torque Remarks 7 0 7 Oil check bolt Exhaust pipe stud bolt Air induction system pipe stud bolt Spark plug Cam sprocket cover Cylinder head and cylinder Cylinder head
20. Route the starter relay lead to ward inside Route the battery negative lead toward inside 23 Route thermo unit lead through the shortest distance and dont roll another lead but loose the thermounit lead Route the black seat lock cable outer through right side of frame Fasten the A C magneto lead starter motor lead and engine ground lead to the clamp on the engine bracket Route the crankcase breather hose into the hole of air filter case CABLE ROUTING SPEC ve 24 1 Front right turn signal light 2 Relay 3 Front left turn signal light 4 Front brake hose assembly 5 Horn lead Hi 6 Horn Hi 7 Throttle cable Speed sensor lead 9 Front brake hose Horn Lo 47 Stay 2 Seat lock cable 43 Leg sealed Seat lock cable assembly 5 Inner fender CABLE ROUTING 46 Panel 42 Auxiliary light lead A B Dont loosen the break hose when fix the break hose Route the speed sensor lead through the brake hose holder Fix the front brake hose on the front brake hose holder Align the white mark H of head light assem
21. Tester negative lead Black 3 lead High beam indicator light Tester lead Yellow 4 lead Tester lead Black 5 lead LIGHTING SYSTEM ELEC Turn the main switch to on Turn the light switch to on position Turn the dimmer switch to low beam or high beam Pass switch to push in Check for voltage 12 V on the lead at bulb socket connectors OUT OF SPECIFICATION The wiring circuit from the main switch to bulb socket connector is faulty Repair MEETS SPECIFICATION YP805021 2 If the meter light fails to come on This circuit is not faulty NO CONTINUITY 1 Bulb and bulb socket Refer to CHECKING SWITCHES section Replace the bulb and or bulb socket CONTINUITY 2 Voltage Connect the pocket tester DC20 V to the bulb socket coupler Tester lead Blue terminal 1 Tester lead Black terminal 2 Turn the main switch to on Turn the lights switch to on or pilot position Check the voltage 12 V of the leads on the OUT OF SPECIFICATION bulb socket connector MEETS The wiring circuit from main switch to bulb SPECIFICATION socket is faulty Repair This circuit is not faulty 76 LIGHTING system ELEC NO CONTINUITY YP805022 3 The taillight fails to come on 1 Bulb and bulb socket Refer to CHECKING SWITCHES section CONTINUITY 2 Voltage e
22. cover the crankcase opening with a clean towel or rag to preventthe circlip from falling into the crankcase cavity 2 Remove Top ring 2nd ring Oil ring When removing the piston ring open the end gap of the ring by fingers and push up the other side of the ring CYLINDER INSPECTION 1 Measure Cylinder bore Out of specification Rebore or re place NOTE M Measure the cylinder bore with a cylinder bore gauge Measure the cylinder bore in parallel to and at right angles to the crankshaft Then find the average of the measure ments Cylinder bore 69 000 69 005 mm Limit 69 1 mm Defferance limit between A B C 0 03 mm 2 Measure Warpage Out of specification Replace Cylinder warpage limit 0 03 mm EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter s number and content 1 General information 2 Specifications 8 Periodic inspection and adjustment 4 Engine 5 Cooling system 6 Carburetion 7 Chassis Electrical 9 Troubleshooting Illustrated symbols 9 to 7 are used to identify the specifications appearing in the text Possible to maintain with engine mounted 1 Filling fluid 12 Lubricant 3 Special tool 44 Tightening 45 Wear limit clearance Engine speed 2 9 V A Illustrated symbols 8 to 3 in the exploded dia grams indicate th
23. CRANKSHAFT INSTALLATION 1 Install Crankshaft 1 gt Crankcase Install the crankshaft assembly with the crankshaft installer pot 3 crankshaft install er bolt adapter spacer 6 NOTE Hold the connecting rod at top dead center TDC with one hand while turning the nut ofthe crankshaft installing tool with the other Turn the crankshaft installing tool until the crankshaft assembly bottoms against the bear ing Do not tap on the crankshaft 52 CRANKCASE AND CRANKSHAFT 53 Crankshaft installer pot 3 90890 01274 Crankshaft installer bolt 4 90890 01275 Adapter 5 90890 01478 Spacer 6 90890 01016 2 Clean all the gascket mating surface and crankcase surface thoroughly 3 Apply Isealant onto the left crankcase mating surface Yamaha bond No 1215 4 Install Aiming chain D NOTE Install the timing chain not to be seen through the crankshaft hole 8 on the crankcase left 2 5 Install 3Crankcase 2 1 Install the crankshaft assembly with the crank shaft installer pot D crankshaft installer bolt 3 adapter 4 spacer 5 Crankshaft installer pot 2 90890 01274 Crankshaft installer bolt 3 90890 01275 Adapter 4 90890 01280 Spacer 5 90890 01288 YP500000 RADIATOR Job name Part name RADIATOR COOL COOLING SYST
24. DENSO Flasher frequency 75 95 cycle min Fuel gage Model manufacturer 5GM NIPPON SEIKI Sender unit resistance full 4 100 empty 90 100 Q Starting circuit cut off relay Model manufacturer ACA12115 1 MATSUSHITA Coil winding resistance 72 88 Q Electric fan motor Model manufacturer 5GM MITSUBA Thermo switch electric fan Ka ae 5GH NIHON THERMOSTAT Thermo switch auto choke Model manufacturer 5GM NIHON THERMOSTAT Thermo unit Model manufacturer 46X NIPPON SEIKI Circuit breaker Type Fuse MAIN 30 A x 1 pc HEAD LIGHT 15 A x 1 pc SIGNALING SYSTEM 15 A x 1 pc IGNITION 7 5A x 1 pc RADIATOR 4 A x 1 pc BACK UP 10 A x 1 pc Reserve 30 A x 1 pc Reserve 15 A x 1 pc Reserve 10 A x 1 pc Reserve 7 5 x 1 pc TAE TAE FFK K TE TE TAE TEE TE TE TAE K FFK 14 LUBRICATION POINTS AND GRADE OF LUBRICANT ve LUBRICATION POINTS AND GRADE OF LUBRICANT ENGINE Lubrication Point Oil seal lips sq O ring Except V belt drive unit aq Cylinder head tightening nut mounting surface Crankshaft pin outside Connecting rod big end thrust surface Rotary filter inner surface i Drive gear inner surface Cam chain outside sprocket inner surface Piston pin Piston outside and ring groove aq aq Camshaft cam profile Valve stem end IN EX Rocker shaft Valve rocker arm inner surface Shaft Shaft Oil pump assembly Ga
25. Engine oil level Refer to ENGINE OIL LEVEL INSPEC TION section 7 Reset gt ngine oil indicator circuit VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Resetting steps Hurn the main switch to on Push and hold in the reset button for 2 to 5 se conds Release the reset button 1 and the oil indica tor light will go off NOTE If the oil is changed before the oil indicator light comes on i e before the 3 000 km oil change interval is reached be sure to reset the oil indi cator light after changing the oil so that it will come on at the correct time to indicate the next 3 000 km oil replacement To reset the oil indicator light before it comes on Release the reset button and the oil indicator light will come on for 1 4 seconds 35 INSP CRANKCASE FILTER CLEANING CRANKCASE FILTER CLEANING 1 Remove gt rankcase filter cover 1 zICrankcase filter cover seal zICrankcase filter element NOTE When installing the element in its case besure its sealing surface matches the sealing surface of the case so there is no air leak 2 Inspect zICrankcase filter element Damaged Replace CAUTION This element is a dry type Be careful not to stain with grease or water 3 Clean Crankcase filter element 1 Blow out the dust in the element from the out er surface using compressed air 4 Install
26. R have continuity with the switch in the ON position IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM
27. 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 A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING 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 scoot er CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the scooter NOTE A NOTE provides key information to make procedures easier or clearer YP002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects See Illustrated symbols 1st title This is the title of the chapter with its symbol on the upper right corner of each page 2nd 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 This title indicates a sub section that is followed by step by step procedures accompa nied by corresponding illustrations EXPLODED DIAGRAMS To heps identify parts and clarify procedure steps there are exploded diagrams at start of each remov al and disassembly section 1 An easy to see exploded diagram 4 is provided for disas
28. kg cm2 2 25 bar Load is the total weight of cargo rider passenger and accessories GENERAL SPECIFICATIONS SPEC Front brake type operation Rear brake type operation Suspension Front suspension Rear suspension Shock absorber Front shock absorber Rear shock absorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery capacity Headlight type Bulb wattage quantity Headlight High Headlight Low Auxiliary light Tail brake light Flasher light Front Flasher light Rear Meter light High beam indicator light Oil indicator light Turn indicator light License light YP250 Single disc brake Right hand operation Single disc brake Left hand operation Telescopic fork Unit swing Coil spring Oil damper Coil spring Oil damper T C I Digital A C magneto GT7B 4 12 V 6 5 AH Quartz bulb Halogen 12 V 60 W 55 W 1 12V 55 W 1 12V5W 1 12V5W 21W 2 12V214W 2 12V16W 2 12V1 7W 3 12V 1 7W 1 12V 1 7W 1 12V3 4W 2 12V5W 1 MAINTENANCE SPECIFICATIONS ve MAINTENANCE SPECIFICATIONS ENGINE EGET head Warp limit Cam chain Cam chain type No of links Cam chain adjustment method Automatic centrifugal clutch Clutch shoe thickness Clutch housing inside diameter Clutch shoe spring free length Weight outside diameter Clutch in revolution
29. stopped press down on the cap while turning counterclockwise and remove it NOTE a_a Remove the radiator cap after removing the drain bolt Place the scooter upright on a level surface when draining the coolant completely 4 Clean Radiator Fill soft water into the filler neck support 1 reservoir tank INSP COOLANT REPLACEMENT ASQ 38 5 Install Gasket D Drain bolt 10 Nm 1 0 6 Loosen Screw carburetor bleed 7 Connect gt Hose reservoir tank 8 Fill Radiator to specified level Fill the coolant slowly until the coolant comes out from the carburetor drain pipe Reservoir tank to maximum level Recommended coolant High quality ethylene glycol anti freeze containing corrosion inhibitors for aluminium engine Coolant and water 3 soft water Mixed ratio 50 50 Total amount 1 4L Reservoir tank capacity 0 4 L VVVVVVVVVVVVVVVVVVVVVVVVVVVVY Handling notes for coolant Coolant is potentially harmful and should be handled with special care INSP COOLANT REPLACEMENT CI 39 A WARNING gt H coolant splashes in your eyes thoroughly wash your eyes with water and consult a doctor gt H coolant splashes on your clothes quickly wash it away with water and then with soap and water gt H coolant is swallowed quickly make the person who has swal lowed it vomit and then take him to a doc tor
30. unit includes the control unit for the fuel pump Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay Fuel pump 90 FUEL PUMP SYSTEM ELEC EB808020 TROUBLESHOOTING The fuel pump fails to operate Procedure Check Rel fuel 1 Fuse Main and Ignition gt r WS pu s 2 Battery 7 Wiring connection 3 Main switch engine fuel pump system 4 Engine stop switch NOTE Remove the following parts before trouble shooting 1 Rider seat 2 Passenger seat 3 Box 4 Legshield Use the special tools specified in the trouble shooting section Z Pocket tester 90890 03112 CONTINUITY Refer to CHECKING SWITCHES CONTINUITY section Replace the fuse INCORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION section Clean battery terminals in CHAPTER 3 Recharge or replace battery y P NO CONTINUITY Replace the main switch NO CONTINUITY Replace the right handlebar switch 3 Main switch Refer to CHECKING SWITCHES section CONTINUITY 4 Engine stop switch Refer to CHECKING SWITCHES section CONTINUITY 91 FUEL PUMP SYSTEM ELEC 5 Relay unit fuel pump relay Disconnect the relay unit from the coupler Connect the pocket tester O 1 and bat tery 12 V to the relay unit te
31. 10101 O1 O1 See NOTE Il ll ak IS I O IS ao font rear Fuel sender Filter Roll over valve Box Box Bracket Standing handle Sheet lock assembly Plastic parts amp cover Cowling stay Cowling body Footrest board Headlight assembly Tail light assembly Front wheel axle and nut Rear wheel axle and nut Front brake caliper and front fork Brake disc and hub Brake hose and caliper Brake caliper and bleed screw Rear brake caliper and swingarm Speed sensor and sensor housing Windscreen QO KO ty ll O i N Q 0 io ao 11 MAINTENANCE SPECIFICATIONS ve NOTE 1 2 3 First tighten the ring nut lower approximately 38 Nm 3 8 m gt kg by using the torque wrench then loosen the ring nut 1 4 turn Second tighten the ring nut lower approximately 22 Nm 2 2 m gt kg by using the torque wrench then finger tighten the ring nut center Align the slots both ring nut and install the lock washer Final hold the ring nuts lower and center and tighten the ring nut upper 75 Nm 7 5 m gt kg using the torque wrench 12 MAINTENANCE SPECIFICATIONS ELECTRICAL Ignition timing Ignition timing B T D C Advanced timing B T D C Advanced type TG Pic
32. ARBURETOR CARB Job name Part name Remarks Float Needle valve Refer to CARBURETOR ASSEMBLY Main jet section Pilot jet Main nozzle Throttle position sensor Reverse the disassembly procedure for assembly 57 58 CARBURETOR CARB E THROTTLE POSITION SENSOR ADJUST MENT NOTE lt _ __E Before adjusting the throttle position sensor the engine idling speed should be properly ad justed When installing the throttle position sensor adjust its angle according to the RPM which is displayed on the tachometer Refer to the ad justment procedure below 1 Turn the main switch to ON 2 Loosen gt Throttle position sensor screws 1 3 Inspect hrottle position sensor input voltage tester lead blue tester lead black 2 Throttle position sensor in put voltage 5V Out of specification Check the wireharness between battery and igniter or igniter and throttle position sensor hrottle position sensor output voltage tester 4 lead yellow 3 tester lead black Throttle position sensor output voltage 0 73 0 63 V Out of specification Adjust or replace NOTE When checkthe throttle position sensor mustbe connect the throttle sensor coupler to the wire harness 4 Tighten hrottle position sensor screws FRONTWHEEL CHAS CHASSIS FRONT WHEEL SPEED SENSOR AND SENSOR ROTOR Job name
33. CE LUBRICATION INTERVALS 26 COVER AND 28 SIDE COVER SIDE COVER MOLE PASSENGER SEAT 28 RIDER SEAT AND MAINBOX 29 SIDE COVER MOLE AND FOOTREST BOARD 31 COWLING HANDLE COVER METER ASSEMBLY 32 LEGSHIELD AND FUEL TANK 33 ENGINE 34 ENGINE OIL REPLACEMENT 34 CRANKCASE FILTER CLEANING 35 AIR INDUCTION SYSTEM INSPECTION 36 COOLANT REPLACEMENT 37 ELECTRICAL usnu 40 HEADLIGHT BEAM ADJUSTMENT 40 ENGIVE OVERHAUL ENGINE 41 WIREHARNESS CABLE AND REAR BRAKE 41 HOSES AIR FILTER CASE ENGINE MOUNTING BOLT AND ENGINE cst 43 CYLINDER HEAD 44 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE 46 CRANKCASE FILTER COVER AND CRANKCASE COVER MEME 46 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE 47 TRANSMISSION 49 AIR INDUCTION SYSTEM 51 CRANKCASE AND CRANKSHAFT 52 CRANKCASE REMOVAL 52 CRANK
34. Connect the pocket tester DC20 V to the bulb socket connector Replace the bulb and or bulb socket Tester 4 lead Blue terminal 1 Tester lead Black terminal 2 OUT OF SPECIFICATION UR Mn xd om bas The wiring circuit from main switch to bulb e Turn the lights switch to on or pilot position coniecior is faute e Check the voltage 12 V on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty 77 LIGHTING system ELEC NO CONTINUITY YP805022 3 The license plate light fails to come on 1 Bulb and bulb socket Refer to CHECKING SWITCHES section CONTINUITY 2 Voltage e Connect the pocket tester DC20 V to the bulb socket connector Replace the bulb and or bulb socket Tester 4 lead Blue terminal 1 Tester lead Black terminal 2 OUT OF SPECIFICATION e Turn the main switch to on EE bas The wiring circuit from main switch to bulb e Turn the lights switch to on or pilot position conmacior is faute e Check the voltage 12 V on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty 78 LIGHTING system ELEC NO CONTINUITY YP805023 4 If the auxiliary light fails to come on 1 Bulb and bulb socket Refer to CHECKING SWITCHES section CONTINUITY 2 Voltage e Connect the pocket tester DC20 V to the bulb socket connector
35. EM Remarks 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 54 Remove the parts in order Refer to COOLANT REPLACEMENT section Refer to COVER AND PANEL section Reverse the removal procedure for installation EB600000 CARBURETOR Job name Part name Q ty CARBURETOR CARB CARBURETOR Remarks Carburetor removal Side panel Main box Drain the coolant Auto choke lead coupler Throttle position sensor lead Inlet Outlet hose carburetor Fuel hose Throttle cable Air filter joint Nut Carburetor assembly 55 Remove the parts in order Refer to COVER AND PANEL section Refer to COOLANT REPLACEMENT section CAUTION Do not bend the air filter joint clamp when installing the carburetor Reverse the removal procedure for installation CARBURETOR CARB CARBURETOR DISASSEMBLY Job name Part name Remarks Carburetor disassembly Disassemble the parts in order Auto choke unit Throttle stop screw set Pilot screw set Cover Diaphragm spring Piston valve Jet needle assembly Coasting enricher Accererating pump Refer to CARBURETOR ASSEMBLY section Float chamber Float pin Refer to CARBURETOR ASSEMBLY section OO 56 C
36. ER METER ASSEMBLY a Je RAF NW Job name Part name Remarks Cowling handle cover meter Remove the parts in order assembly removal Upper cover Wind screen Inner panel Meter assembly Coupler Meter lead Cowling body Handle cover Coupler headlight lead Coupler front flasher light lead left Coupler front flasher light lead right NOTE Disconnect the couplers O1 NOTE Disconnect the couplers Reverse the removal procedure for installation 32 LEGSHIELD AND FUEL TANK Job name Part name COVER AND PANEL Remarks O1 G Legshield and fuel tank removal Legshield Inner fender Front under braket Fuel tank braket Fuel hose Coupler fuel sensor lead Fuel tank Rivet Cover 33 Gk Remove the parts in order NOTE Disconnect the couplers Revers the removal procedure for installation INSP ENGINE OIL REPLACEMENT 34 ENGINE ENGINE OIL REPLACEMENT 1 Startthe engine and let it warm up for several minutes 2 Turn off the engine and place an oil pan un der the engine 3 Remove Drain plug D gt Gasket Drain the crankcase of its oil 4 Install Gasket Drain plug D 20 Nm 2 0 m o 5 Fill gt rankcase Oil quantity 1 4L 6 Check gt
37. L TOOLS REN 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 name Usage Illustration Crankcase separating tool 90890 01135 This tool is used to remove the crankshaft Installer pot Crankshaft installer pot bolt adapter spacer 90890 01274 Bolt 2 Qe _ 90890 01280 0147 90890 01478 Spacer CS 90890 01016 90890 01288 These tools are used to install the crankshaft GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model code 5GM2 5GM3 Dimensions Overall length 2 140 mm Overall width 780 mm Overall height 1 350 mm Seat height 730 mm Wheelbase 1 535 mm Minimum ground clearance 120 mm Minimum turning radius 2 700 mm Basic weight With oil and full fuel tank Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 0 2491 249 cm Bore stroke 69 0 66 8 mm Compression ratio 10 1 Compression pressure STD 1 400 kPa 14 kg cm2 14 bar at 500 r min Starting system Electric starter Lubrication system Wet sump Oil type or grade Engine oil Temp 20 10 0 10 20 w API STANDERD a SE h
38. NS ve CHASSIS Standard Front suspension Front fork travel 100 mm Fork spring free length 268 mm Spring rate K1 4 82 N mm 0 49 kg mm Spring rate K2 8 84 N mm 0 9 kg mm Stroke K1 0 40mm Stroke K2 40 100mm Oil capacity 0 142 L 142 cm3 Oil level 80 mm Oil grade Fork oil 15 WT or equivalent Inner tube vend limit TAE Rear suspension Shock absorber stroke 106 mm Spring free length 262 mm Spring rate 7 57 N mm 0 77 kg mm 14 N mm 1 43 kg mm 26 39 N mm 2 69 kg mm 40 70mm 70 106 mm 1 2 Stroke K1 0 40mm K2 K3 Rear disk brake Type Single Disc outside diameter thickness 230 5 mm Pad thickness 5 3 mm Master cylinder inside diameter 11 mm Caliper cylinder outside diameter 22 2 2 Brake fluid type DOT 4 Brake lever Brake lever free play front at lever side Brake lever free play rear Throttle cable free play xt 3 3 10 MAINTENANCE SPECIFICATIONS ve TIGHTENING TORQUES CHASSIS Tightening Part to be tightened Thread size Remarks Frame and engine bracket Engine bracket compression rod and engine Compression rod and frame Sidestand bolt and frame Sidestand bolt and nut Rear footrest bracket Swingarm Rear shock absorber and frame Rear shock absorber and engine Steering ring nut Handle holder and steering shaft Handle upper holder and lower holder Brake hose and master cylinder Fuel tank O10
39. OCK ABSORBER AND SWINGARM section Plate O ring Collar Rear wheel Reverse the removal procedure for installation 64 REAR SHOCK ABSORBER AND SWiNGARM CHAS REAR SHOCK ABSORBER AND SWINGARM Job name Part name Remarks Rear shock absorber and swingarm Remove the parts in order removal Side panels Refer to COVER AND PANEL section NOTE Nut Loosen Muffler assembly N NOTE Axle nut Remove with the rear brake applied Rear shock absorber Rear caliper assembly Swingarm Collar Oil seal Bearing Oil seal O1 CO pJ eo Reverse the removal procedure for installation 65 ELECTRICAL COMPONENTS ELEC EB800000 ELECTRICAL ELECTRICAL COMPONENTS D Main switch 9 Fuel pump 2 Ignition coil Sidestand switch 8 Spark plug cap Gp Flasher relay 4 Fuel sender 42 Battery 5 Rectifier Regulator 43 Starter relay 6 Wireharness Starting circuit cut off relay 7 Thermo unit 45 Horn Ignitor unit Fuel pump relay m 5 66 lt tc a 5 O CIRCUIT DIAGRAM
40. Part name Remarks Speed sensor and sensor rotor Remove the parts in order removal Cowling body Refer to COVER AND PANEL section Speed sensor Brake caliper Axle nut Wheel axle Front wheel Sensor housing Collar Front wheel sensor lead connector O O1 G N lll Disconnect the connecter Reverse the removal procedure for installation 59 60 FRONTWHEEL CHAS SPEED SENSOR AND THESENSOR ROTOR CAUTION gt Speed sensor cannot be disassembled Never disassemble it If failed replace with a new one SPEED SENSOR REMOVAL 1 Remove Clamp D NOTE Clamp can be easily removed by moving the clamp tip of brake hose and speed sensor leads up and down 2 Remove 3ealiper 1 Speed sensor 2 CAUTION Care should be taken not to allow the sen sor electrode to contact the metal parts when removing the speed sensor from the wheel hub remove the wheel do not operate the brake lever SPEED SENSOR AND SENSOR ROTOR IN SPECTION 1 Check Speed sensor 1 Cracks bending and distortion Replace Iron powder and dust Clean 19 61 FRONT WHEEL 2 Measure gt Speed sensor resistance Connect the pocket tester Q x 1 to the ter minal of speed sensor connector Tester s positive lead Terminal 1 Tester s negative lead Terminal D Regulated resistance 1 19 to 2 21 kQ at 20 C Out of spe
41. SHAFT REMOVAL 52 CRANKSHAFT INSTALLATION 52 COOLING SYSTEM RADIATOR 54 CARBURETOR 55 CARBURETOR DISASSEMBLY 56 THROTTLE POSITION SENSOR ADJUSTMENT 58 CHASSIS FRONT WHEEL 59 SPEED SENSOR AND SENSOR ROTOR 59 SPEED SENSOR AND THE SENSOR ROTOR 60 SPEED SENSOR REMOVAL 60 SPEED SENSOR AND SENSOR ROTOR INSPECTION 60 SPEED SENSOR ASSEMBLY 61 REAR WHEEL 64 REAR SHOCK ABSORBER AND SWINGARM 65 ELECTRICAL ELECTRICAL COMPONENTS 66 CIRCUIT DIAGRAM 67 CHECKING SWITCHES 69 SWITCH POSITION AND TERMINAL CONNECTION 69 CHECKING STEPS 70 SWITCH CONNECTION AS SHOWN IN THIS MANUAL 70 IGNITION SYSTEM 71 CIRCUIT 71 ELECTRIC STARTING SYSTEM 72 CIRCUIT DIAGRAM aa aane aaa nnn 72 LIGHTING SYSTEM 73 CIRCUIT DIAGRAM
42. TY gt NO CONTINUITY Replace the main switch 81 SIGNAL SYSTEM 4 Wireharness POOR CONNECTION D Check the connections of the entire signal sysiem Refer to CIRCUIT SYSTEM WIRING DIA GRAM section Correct Check condition of each of the signal sys tem s circuits Referto SIGNAL SYSTEM CHECK section 82 YP806020 SIGNAL System ELEC SIGNAL SYSTEM CHECK 1 If the horn fails to sound NO CONTINUITY 1 HORN switch Replace the left handlebar switch Refer to CHECKING SWITCHES section CONTINUITY e Connect the pocket tester DC20 V to the horn lead p q Tester lead Brown terminal 1 Tester lead Frame ground e Turn the main switch to on at the horn terminal MEETS SPECIFICATION e Connect the pocket tester DC20 V to the horn at the Pink terminal Tester lead Pink 1 terminal Tester lead Frame ground Turn the main switch to on e Check for voltage on the Pink lead to frame ground CONTINUITY Adjust or replace horn NO CONTINUITY Replace the horn 83 SIGNAL SYSTEM NO CONTINUITY YP806022 2 If the brake light fails to come on 1 Bulb and bulb socket Refer to CHECKING SWITCHES section Replace the bulb and or bulb socket CONTINUITY NO CONTINUITY Replace brake switc
43. YAMAHA gt 290 SUPPLEMENTARY SERVICE MANUAL FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YP250 For complete service information procedures it is necessary to use this Supplementary Ser vice Manual together with the following manual YP250 SERVICE MANUAL 4UC AE1 YP250 K 98 SUPPLEMENTARY SERVICE MANUAL 4UC AE2 YP250D 98 SUPPLEMENTARY SERVICE MANUAL 5DF AE1 YP250 2000 SUPPLEMENTARY SERVICE MANUAL 1999 by Yamaha Motor Co Ltd 1999 by MBK Industrie First Edition November 1999 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited EB001000 NOTICE This manual was produced by the Yamaha Motor 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 manu al so it is assumed that anyone who uses this book to perform maintenance and repairs on Yama ha 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 Company Ltd is continually striving to improve all its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha MBK dealers and will appear
44. and cylinder Cam chain side Valve cover Rotor Valve adjuster locknut Cam shaft bearing stopper Cam sprocket Cam chain tensioner Body Plug Guide stopper 2 Water pump housing cover Hose joint Thermostatic valve cover Filler neck supporting Oil pump Oil pump cover Oil strainer cover Carburetor joint Carburetor joint and carburetor Air filter assembly Air filter cover Exhaust pipe assembly Muffler Muffler and exhaust pipe Protector Exhaust pipe Protector Muffler end cap Air induction system pipe Air induction system assembly Air induction system air filter assembly Crankcase left and right Drain bolt Engine oil Drain bolt Transmission oil Oil filler Transmission case cover Crankcase cover left Crankcase filter cover Crankcase cover protector Crankcase cover protector Magnet cover N N N N N N QO O BN N O A S o O S O O N O iS RS G OO O O IN IN G N N N G N MAINTENANCE SPECIFICATIONS SPEC Thread Tightening Part to be tightened Part name An Q ty torque Remarks Cover oil pump Timing check plug One way clutch Clutch housing Grease stopper Primary sheave Primary fixed sheave Clutch carrier assembly Stator Pick up coil Starter motor Thermo switch Thermo unit N G N MAINTENANCE SPECIFICATIO
45. ated p resistance OUT OF SPECIFICATION Replace the fuel sender DOWN BOTH MEET SPECIFICATION 2 Voltage Connect the pocket tester DC20 V to the fuel gauge coupler Tester lead Brown terminal 1 Tester lead Frame ground OUT OF SPECIFICATION Turn the main switch to ON Check for voltage 12 V ofthe Brown lead on the fuel sender lead Check the connection of the entire signal MEETS system SPECIFICATION Refer to CHECKING OF CONNECTIONS Refer to CIRCUIT DIAGRAM 87 SIGNAL SYSTEM 3 Fuel gauge Connect the fuel sender to wireharness NOTE Move the float to UP or DOWN Before reading the meter stay put the float for more than three minutes respectively at UP or DOWN Turn the main switch to ON Check the fuel gauge needle moves F or DOES NOT MOVE E Float position Needle moves Float UP 1 F Float DOWN E This circuit is not faulty Replace the fuel gauge 88 FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM
46. binations shown in the chart Poor connection fault Repair or replace B tO immer switch L G 2 B Oj O Pass switch r Sidestand Switch 69 CHECKING SWITCHES ELEC 70 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 Replace the switch component if any of the combinations does not produce the correct reading 90890 03112 NOTE Hurn the switch to the ON OFF positions several times Adjust the pocket tester to correct 0 position before checking switches gt Set the pocket tester selector to x 1 Q SWITCH CONNECTION AS SHOWN IN THIS MANUAL This manual contains connection charts like the one shown on the left showing the terminal connections of switches e g the main switch handlebar switch brake switch lighting switch etc The column on the extreme left indicates the dif ferent switch positions the top line indicates the colors of the leads connected to the terminals on the switch O QO indicates terminals between which there is continuity i e a closed circuit in the giv en switch position In this chart Br and
47. bly with the white tape of coupler lead Install in stay 1 To the headlight assembly Clamp near the caupler side root of auxiliary light lead 25 SPEC INTRODUCTION INSP 4o PERIODIC MAINTENANCE LUBRICATION INTERVALS ADJ Q 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 opera tion and a longer service life The need for costly overhaul work will be greatly reduced This informa tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter YP301000 PERIODIC MAINTENANCE LUBRICATION INTERVALS ITEM CHECKS AND MAINTENANCE JOB Initial EXER ANNUAL 1 000 km 10 000 km 20 000 km CHECK gt kCheck fuel hoses and vacuum hose for cracks or damage j kReplace if necessary Y condition gt if necessary y gt kCheck condition kCheck valve clearance 7 V belt case air filter gt kClean or replace if necessary Check operation fluid level and vehicle for fluid leakage Front brake kCorrect accordingly Replace brake pads if necessary Check operation fluid level and vehicle for fluid leakage Rear brake Correc
48. case cover Dowel pin Primary drive gear Plain washer Plain washer 1st wheel gear 49 Job name Part name s TRANSMISSION Remarks Conical spring washer Drive axle Main axle Conical spring washer Primary driven gear Plain washer Reverse the removal procedure for installation 50 s AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM SUING ER I Job name Part name Remarks Air induction system removal Remove the parts in the order Clip Hose 2 Clip Vacuum hose Clip Hose 1 Air induction system assembly Reverse the removal procedure for installation 51 SN CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT CRANKCASE REMOVAL 1 Remove 3Crankcase 2 1 NOTE Remove the crankshaft assembly with the crankcase separating tool Make sure that the crankcase separating tool is centered over the crankshaft assembly Crankshaft separating tool 90890 01135 CRANKSHAFT REMOVAL 1 Remove Aiming chain D NOTE Before removing the crankshaft assembly re move the timing chain from the crankshaft sprocket tf the timing chain hooks to the crankshaft sprocket the crankshaft cannot be removed erankshaft 1 N Remove the crankshaft assembly with the 9 crankcase separating tool 2 J CAUTION Do not tap on the crankshaft Crankshaft separating tool 90890 01135
49. cification Replace 3 Check gt Sensor rotor D Cracks and damage Replace the wheel assembly NOTE Sensor rotor of YP250 is inserted under pres sure by the special process and cannot be re placed as a single unit To replace the sensor ro tor replace it as a wheel assembly SPEED SENSOR ASSEMBLY Proceed in the reverse order of disassembling paying attention to the following items 1 Apply gt titium soap base grease CD Wheel axle FRONTWHEEL CHAS 2 Install gt Sensor housing 3 Install zIFront wheel gt Wheel axle Axle nut 70 Nm 7 0 mo NOTE Align the slot of sensor housing with the projec tion part of front fork then assemble them CAUTION Install after checking if foreign materials are mixed in the wheel hub If foreign materials are mixed it causes to damage the sensor rotor and speed sensor 4 Install Speed sensor CO Ax 23 Nm 2 3 mxo Brake caliper 50 Nm 5 0 m o Clamp 3 NOTE ___ When installing the speed sensor check if the speed sensor lead is twisted or foreign matters attached to the electrode CAUTION To route the speed sensor lead refer to the CABLE ROUTING 62 FRONT WHEEL CHAS 5 Install Speed sensor lead 1 e v a sQ ER Q A a N oy VERE VA 63 REAR WHEEL CHAS REAR WHEEL Job name Part name Remarks Rear wheel and brake disc removal Swingarm Refer to REAR SH
50. e coolant L jn jg __ Check oil level and vehicle for oil leakage j IL qo g 5 24 26 INSP PERIODIC MAINTENANCE LUBRICATION INTERVALS ADJ Q EVERY Initial ANNUAL ITEM CHECKS AND MAINTENANCE JOB Front Rear brake gt kCheck operation switch gt kAdjust or replace if necessary parts and gt kLubricate if necessary Electrical compo Check all lights signals and switches function Correct if necessary nents gt kAdjust headlight beam if necessary Since these items require special tools data and technical skills they should be serviced by a Yamaha dealer T NOTE see The annual checks must be performed once a year unless a 10 000 km or 20 000 km maintenance was performed in the same year air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake system When disassembling the master cylinder or caliper always replace the brake fluid Check the brake fluid level regularly and fill as required Replace the oil seals on the inner parts of the master cylinder and caliper every two years gt the brake hoses every four years or if cracked or damaged 27 INSP COVER AND PANEL DS COVER AND PANEL SIDE COVER SIDE COVER MOLE PASSENGER SEAT Job name Part name Remarks Side cover Side cover panel and Remove the parts in order passenger seat removal Passenger seat Standin
51. e types of lubricants and lu brication points Apply engine oil Apply gear oil 60 Apply molybdenum disulfide oil 21 Apply wheel bearing grease 2 Apply lightweight lithium soap base grease 63 Apply molybdenum disulfide grease Illustrated symbols 22 to 65 in the exploded dia grams indicate the where to apply locking agent 63 and when to install new parts 69 62 Apply locking agent LOCTITE 65 Use new one CONTENTS GENERAL INFORMATION SCOOTER IDENTIFICATION 1 VEHICLE IDENTIFICATION NUMBER for E 1 FRAME SERIAL NUMBER except for E 1 ENGINE SERIAL NUMBER 2 e cha tr n 1 MODEL LABEL 55568 iae u REPRE 1 SPECIAL TOOLS REY xr SITS ROR A awaqa 2 SPECIFICATIONS GENERAL SPECIFICATIONS 3 MAINTENANCE SPECIFICATIONS 6 It me 6 TIGHTNING TORQUES 8 CHASSIS c PD 10 TIG TNING TORQUES usas yl da iy au unu ee bees 11 ELECTRICAL ROGO RR ENE 13 LUBRICATION POINTS AND GRADE OF LUBRICANT 15 ENGINE p uyay p akawa aa aba a akwa Essays 15 GHASSIS 32092 4088 amu p a 16 CABLE ROUTING 17 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION nrbem Ret e Reo de 26 PERIODIC MAINTENAN
52. ead 17 gt 00 Route the brake hose assembly through the guide on the handle bar Fasten the front brake hose brake hose assembly throttle cable to the frame with a plastic band Fasten the brake hose assembly throttle cable to the frame with a band and the end of band is backward Clamp the brake hose assembly Fasten the seat lock cable throttle cable and wireharness to the frame with a band and the end of band is downward Clamp the switch assembly lead with a band and cut the end of band It s downward Fasten the throttle cable with a band and more than 10 mm between throttle cable and box Don t scrub each other when fix the throttle cables CABLE ROUTING SPEC ve Throttle cable pull side White nut Throttle cable push side Black and white nut Clamp the fuel hose Route the carburetor coolant drain hose carburetor fuel drain hose through the clamp Route the carburetor drain hose through the centerstand spring hook Clamp the sidestand switch lead Touch the protection tube on
53. ead on the frame with the plastic clamp Route the parking cable andrear brake hose through the guide Clamp the A C magneto gt lt SSS 22 1 filter case 2 Seat lock 3 Tensioner 4 Crankcase breather hose 5 Fuel sender 6 Throttle cable 7 Seat lock cable assembly Panel 9 Footrest board Radiator resorvoir tank breather hose 47 Vacuum hose 42 Throttle position sensor lead 43 Seat lock CABLE ROUTING SPEC ve 49 Auto choke lead 5 Brake hose assembly 8 A C magneto lead 47 Starter motor lead 48 Engine ground lead Wireharness A B Don t turn the idle adjust screw when fix the hose Route the gray seat lock outer cable through the left side of frame Setthe fuel tank sender lead and sub lead D Fasten the wireharness on the frome with a band and the end of band match the tank rail pipe angle Fix the seat lock cable along the guide of panel Fasten the wireharness on the frame with a plastic clamp Fasten the starter motor lead on the fuel tank brocket with a plas tic locking tie
54. g handle Side cover mole 3 Cap 1 Cap 2 Side cover 1 Side cover 2 Reverse the removal procedure for installation 28 RIDER SEAT AND MAIN BOX Job name Part name INSP COVER AND PANEL ADJ RITIN Remarks Rider seat and main box removal Fuel tank cap Cover Rider seat Side cover 3 Clip Damper assembly Coupler Seat switch lead Pin Bottom plate 29 Remove the parts in order NOTE Install the damper assembly to the body with its rod side backward and labels up ward NOTE Disconnect the couplers INSP COVER AND PANEL DS RIDER SEAT AND MAIN BOX e 16 mg Job name Part j Remarks Bracket NOTE Coupler Main box light read Disconnect the couplers Seat lock Main box Reverse the removal procedure for installation 30 INSP COVER AND PANEL DS SIDE COVER MOLE AND FOOTREST BOARD Job name Part name Remarks Side panel and footrest board removal Remove the parts in order Mat footrest board left right Cover footrest board left right Cover 2 Battery negative lead Battery positive lead Battery Flasher relay Fuse box Starter relay Side cover mole 1 Side cover mole 2 Footrest board O1 O S Gl Reverse the removal procedure for installation 31 INSP COVER AND PANEL DS COWLING HANDLE COV
55. ge 4 Voltage Tester lead Brown White terminal 1 Tester lead Frame ground Turn the main switch to on Check for voltage 12 V on the Brown White lead at the flasher relay terminal MEETS SPECIFICATION OUT OF SPECIFICATION The flasher relay is faulty Replace 85 SIGNAL SYSTEM 5 Voltage Connect the pocket tester DC20 V to the bulb socket connector At flasher light left Tester lead Chocolate lead 1 Tester lead Black terminal 3 At flasher light right Tester lead Dark green lead 2 Tester lead Black terminal 3 Turn the main switch to on Turn the turn switch to left or right Check for voltage 12 V on the Chocolate OUT OF SPECIFICATION lead and Dark green at the flasher light ter 6 Wiring connection minal Wiring circuit from the turn switch to bulb socket connector is fault Repair MEETS SPECIFICATION Refer to CIRCUIT DIAGRAM This circuit is not faulty 86 SIGNAL SYSTEM YP806027 4 If the fuel gauge fails to operate 1 Fuel sender Remove the fuel sender from the fuel tank Disconnect the fuel sender coupler from the wireharness Connect the pocket tester 0 10 to the fuel sender coupler lead Tester lead Green terminal 1 Tester lead Black terminal 2 Check the fuel sender for specificated resis tance Float position Specltic
56. h 2 Brake switch Front Rear Refer to CHECKING SWITCHES section CONTINUITY 3 Voltage e Connect the pocket tester DC20 V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 OUT OF SPECIFICATION Turn the main switch to on The brake lever is pulled in e Check for voltage 12 V of the Yellow lead on the bulb socket connector 4 Wiring connection MEETS Wiring circuit from the main switch to the SPECIFICATION bulb socket connector is faulty Repair This circuit is not faulty de u NG Dih 84 SIGNAL SYSTEM ELEC 3 If the flasher light and or turn indicator light fails to blink NO CONTINUITY 1 Bulb and bulb socket Refer to CHECKING SWITCHES section Replace the bulb and or bulb socket CONTINUITY NO CONTINUITY 2 Turn switch Replace the left handlebar switch Refer to CHECKING SWITCHES section CONTINUITY Connect the pocket tester DC20 V to the flasher relay coupler Tester lead Brown terminal 1 Tester lead Frame ground Turn the main switch to on Check for voltage 12 V of the Brown OUT OF SPECIFICATION CD lead at the flasher relay terminal The wiring circuit from main switch to flasher relay connector is faulty Repair MEETS SPECIFICATION Connect the pocket tester DC20 V to the flasher relay coupler 3 Volta
57. igher grade 10W 30 200 40 200 Periodic oil change Total amount Transmission oil Total amount Radiator capacity Total amount including all routes Air filter Carburetor side Wet type element Crankcase side Dry type element Fuel Type Regular unleaded gasoline Fuel tank capacity 12L GENERAL SPECIFICATIONS ve Carburetor Type quantity Manufacturer Spark plug Type Manufacturer Spark plug gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Single speed automatic Chassis Frame type Caster angle Trail Tire Type Size front rear Manufacturer front rear Type front rear Tire pressure cold tire Maximum load except motorcycle Loading condition A front rear Loading condition B front rear High speed riding front rear YP250 Y28V 1E 1 TEIKEI Dry centrifugal automatic Helical gear 40 15 2 666 Helical gear 38 15 2 533 Single speed automatic V belt type Centrifugal automatic type 2 44 0 83 1 Steel tube underbone 28 103 Tubeless 110 90 12 64L 130 70 12 62L IRC MICHELN IRC MICHELN MB67 BOPPER MB67 BOPPER 187 kg 0 90 kg 175 kPa 1 75 kg cm2 1 75 bar 200 kPa 2 0 kg cm2 2 0 bar 90 205 kg 200 kPa 2 0 kg cm2 2 0 bar 225 kPa 2 25 kg cm2 2 25 bar 200 kPa 2 0 kg cm2 2 0 bar 225 kPa 2 25
58. kup coil resistance color T C I unit model manufacturer Ignition coil Model manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Spark plug cap Type Resistance Charging system Type Model manufacturer Normal output Stator coil resistance color Rectifire regulator Model manufacturer No load regulated voltage Capacity Withstand voltage Electric starter system Type Starter motor Model manufacturer ID number Operation voltage Output Armature coil resistance Brush overall length Brash quantity Spring force Commutator diameter Mica undercut depth Standard 10 at 1 400 r min 32 at 5 000 r min Electrical type 189 231 Q at 20 C Yellow Blue J4T117 MITSUBISHI F6T507 MITSUBISHI 6 mm 3 6 4 8 Q at 20 G 10 7 14 5 at 20 C Resin type 10 A C magneto F4T370 MITSUBISHI 14 V 19 5 A at 5 000 r min 0 37 0 45 Q at 20 C White White SH640A 12 SHINDENGEN 14 1 14 9 V 18A 200 V Constant mesh type SM 13 MITSUBA SM 13454 12V 0 65 kW 0 0017 0 0027 Q at 20 G 10 mm 2 pcs 8 82 N 899 g 28 mm 0 7 mm 13 MAINTENANCE SPECIFICATIONS ne Standard Starter relay Model manufacturer MS5F 421 JIDECO Amperage rating 180A Coil winding resistance 4 2 4 6 Q at 20 C Horn Model manufacturer YF 12 NIKKO Maximum amperage 3A Flasher hazard relay Type Full transistor type Model manufacturer FE246BH
59. rminals as shown Battery positive terminal red white 1 Battery negative terminal blue red 2 Tester positive probe red white 3 Tester negative probe blue black 4 Turn the main switch to on Check the starter relay for continuity CONTINUITY 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness r D Connect the pockettester Q 1 to the fuel B pump coupler fuel pump side as shown BAE Tester positive probe black blue 1 Tester negative probe black 2 Measure the fuel pump resistance D Fuel pump resistance 11 130 at 20 C OUT OF SPECIFICATION Replace the fuel pump POOR CONNECTION CORRECT 7 Wiring connection Check the entire fuel pump system s wiring Refer to CIRCUIT DIAGRAM Correct Replace the ignition unit 92 FUEL PUMP SYSTEM 93 EB808410 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire Be extremely careful and note the following points e Stop the engine before refuelling Do not smoke and keep away from open flames sparks or any other source of fire elf you do accidentally spill gasoline wipe it up immediately with dry rags elf gasoline touches the engine when it is hot a fire may occur Therefore make sure
60. sembly 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 CYLINDER AND PISTON CYLINDER AND PISTON Job name Part name Remarks Cylinder and piston removal Cylinder head Joint O ring Timing chain guide exhaust side Cylinder Dowel pin Cylinder gasket Piston pin circlip Piston pin Piston Piston ring top Piston ring 2nd Side rail Spacer Remove the parts in order 1 Refer to PISTON RINGS PISTON AND CYLINDER INSTALLATION section Refer to PISTON AND PISTON RINGS REMOVAL section Refer to PISTON RINGS PISTON AND CYLINDER INSTALLATION section Reverse the removal procedure for installation Refer to CYLINDER HEAD section CYLINDER AND Piston ENG PISTON AND PISTON RINGS REMOVAL 1 Remove Piston pin circlip D Piston pin Piston 3 NOTE Before removing the piston pin circlip
61. sket Oil pump assembly Holder Idle gear 1 thrust surfaces Shaft 1 Idle gear 2 thrust surfaces Idle gear 2 inner surface Main axle thrust surfaces Crankcase mating surfaces Yamaha bond No 1215 Crankcase breather plug Stator grommet Yamaha bond No 1215 GJ GJ G iC iC a a q 15 LUBRICATION POINT AND GRADE OF LUBRICANT SPEC ve CHASSIS Lubrication Point Front wheel oil seal lips left right Swingarm oil seal lips left right Steering head pipe bearing upper lower Steering head pipe dust seal lips upper lower Tube guide throttle grip inner surface Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft 16 CABLE ROUTING Speed sensor 2 Front brake hose 3 Throttle cable 4 Relay 5 Brake hose assembly 6 Thermo switch lead 7 Fan motor lead 8 Switch assembly 9 Carburetor fuel drain hose Carburetor coolant drain hose 47 Carburetor air ventilation hose 42 Coolant pipe 43 Sidestand switch Ignitor unit CABLE ROUTING SPEC ve 5 Frame Seat lock cable 42 Footrest board 48 Handlebar Handlebar under cover 69 Handlebar upper cover Right handlebar switch lead 2 Front brake switch lead 3 Left handlebar switch lead 4 Rear brake switch l
62. sten the wireharness to the stay with a band and the end of band on rearside Fasten the speed sensor lead to the stay Route the front speed sensor lead and front brake hose through the clamp on the frame front side speed sensor lead rear side front brake hose CABLE ROUTING SPEC oo Clamp the speed sensor lead to the front brake hose Position the clamp locatio of the speed sen sor to front of the upper clamp and another clamps to outside Through the speed sensor lead between front brake caliper and bolt Route the speed sensor lead through the guide When pull the speed sensor lead Don t loose 21 Q Clamp the speed sensor lead and that caliper tightning bolt and clamp in parallel with front fork Fix the starter relay to the foot rest board Clamp the radiator reservoir hose and starter motor lead to the frame with a plastic clamp Fix the fuse box to the footrest board Fasten the rodiator reservoir hose and starter motor lead on the frame with a plastic clamp 110 130mm M 20 30mm CABLE ROUTING SPEC d V Fix the turn signal relay on the footboard W Fasten the starter motor lead and engine ground l
63. t accordingly Replace brake pads if necessary gt kCheck for cracks or damage Wess gt kCheck balance runout and for damage N Rebalance or replace if necessary tread depth and for damage KReplace if necessary Check air pressure KCorrect if necessary Tires gt kCheck bearing for looseness or damage kReplace if necessary bearing play and steering for roughness gt kCorrect accordingly Steering bearings gt kLubricate with lithium soap base grease Wheel bearings gt kMake sure that all nuts bolts and screws are properly tightened Chassis fasteners Tighten if necessary Sidestand centers gt kCheck operation tand Lubricate and repair if necessary i gt kCheck operation Sidestand switch gt kReplace if necessary gt kCheck operation and for oil leakage gt kCorrect accordingly Rear shock absorb gt kCheck operation and shock absorbers for oil leakage er assemblies gt kReplace shock absorber assembly if necessary engine idling speed and starter operation gt kAdjust if necessary y Check oil level and vehicle for oil leakage Correct if necessary Replace every 3 000 km KChange Warm engine before draining i M Engine oil strainer KClean or replace if necessar san even 9 p y 6 000 Check coolant level and vehicle for coolant leakage Cooling system Correct if necessary v v s Chang
64. ter motor Pass switch Diode Left handlebar switch G Starting circuit cut off relay 42 Thermo switch Auto choke 42 License plate light Tail brake light 43 Auto choke 44 Rear flasher light Ignitor unit Front flasher light 45 Ignition coil 49 Head light LO Spark pulg Head light HI 07 Throttle position sensor 8 Speed sensor Auxiliary light 49 Trun signal indicator light Fuel pump 69 High beam indicator light 69 Fuel pump relay 69 Meter light Sidestand switch 62 Oil indicator light 62 Light switch 63 Fuel gauge 63 Start switch Thermometer 62 Engine stop switch 65 Clock 65 Right handlebar switch 66 Speedometer 69 Ignition fuse 6 Meter assembly Seat switch Fuel sender Box light Thermo unit 69 Head light fuse Alarm Fan fuse Grip warmer switch OPUTION 87 Signal fuse 62 Grip warmer OPUTION Ground NOTE gt Starter switch is closed while the button switch is pushed gt Sidestand switch is closed while the side stand is upped gt switch is closed while the brake is applied COLOR CODE Chocolate Black White Red Green Brown White Red White v wm 28 L L 68 CHECKING SWITCHES ELEC CHECKING SWITCHES SWITCH POSITION AND TERMINAL CONNECTION Before checking a switch refer to the checking switches as shownin the left page and check for the correct terminal connections closed circuit according to the color com
65. that the engine is completely cool before performing the following test 1 Check Fuel pump operation VVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Fill the fuel tank b Put the end of the fuel hose into an open con tainer c Turn the fuel cock to ON or RES d Connect the battery 12 V to the fuel pump coupler as shown Battery positive lead black blue Battery negative lead black 2 e Iffuelflows outofthe fuel hose the fuel pump is OK If fuel does not flow replace the fuel pump YP250 2000 WIRING DIAGRAM D A C magneto Left handlebar switch pee 2 Pickup coil 42 License plate light ma Nia iD EP qs gt Rectifier regulator Tail brake light s umo dium Main switch Rear flasher light u sua Hannes 5 Backup fuse 45 Front flasher light ww
66. the fuel pump P Fasten the wire harness to the frame with a band and the end of band inside Roll the tape because of fix the protection tube to the fuel pum lead Clamp the fuel pump lead and sidestand switch lead Fasten the throttle cable and the end of band backward Lubricate the silicone grease befor fasten the cable and hoses 18 U V W gt lt N More than 10 mm Route the seat lock cable through the footrest board Route the left handlebar switch lead through front side of the handlebar under cover Route the right handlebar switch lead through the clamp Route the front brake hose through the right hole of handle bar under cover Route the brake hose assembly through the left hole of the han dlebar under cover CABLE ROUTING SPEC Fasten the left handlebar switch lead and rear brake switch lead to the handlebar with a plastic locking tie cut the end of locking tie at 5 mm or less Don t catch the seat lock cable between footrest board and box
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