ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS
Item Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Engine idle speed Vacuum pressure at engine idle speed Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Engine oil Lubrication system Recommended oil

-20 -50

Standard Forced Air cooled 4-stroke, SOHC 0.125L(125.0 cm3) Forward inclined single cylinder 51.5 60.0 mm 9.80.4 :1 1600~1700 r/min 30.0 kpa(238.6 mmHg) 950 kPa(9.5kg/cm2) / 300 r/min Regular unleaded gasoline
4.5L (0.98lmp gal, 1.18 USgal) Wet sump SAE20W40SE Yamaha 4-cycle oil EFERO X, Z, BX
SAE 10W-30 SAE 10W-40 SAE 20W-40 SAE 20W-50
Quantity Periodic oil change With oil filter replacement Total amount Final gear oil Recommended oil Periodic oil change Total amount
1.0L(0.92 lmp qt, 1.09 US qt) 1.2L(1.10 lmp qt, 1.31 US qt) 1.2L(1.10 lmp qt, 1.31 US qt)
SAE85W140S Ehypoid gear oil 0.13L(0.12 lmp qt, 0.14 US qt) 0.15L(0.14 lmp qt, 0.16 US qt)

ENGINE SPECIFICATIONS

Item Oil filter Oil filter type Oil pump Oil pump type Inner rotor to outer rotor tip clearance Outer rotor to pump housing clearance Oil pump housing to inner rotor and outer rotor clearance Starting system type Spark plug Model (manufacturer) quantity Spark plug gap Cylinder head Volume Max. warpage Standard Wire mesh Trochoid 0.15 mm 0.013-0.036 mm 0.06-0.10 mm Electric and kick starter CR7E (NGK) 1 0.7~0.8mm 12.3~12.7cm
Limit 0.23mm 0.106mm 0.17mm 0.03 mm
Item Camshaft Drive system Intake camshaft lobe dimensions Standard Chain drive (left)

Limit

Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions
26.153~26.253 mm 21.015~21.115 mm 5.203mm

26.053 mm 20.915 mm

Measurement A Measurement B Measurement C Max. camshaft runout
26.153~26.253 mm 21.056~21.156 mm 5.203 mm
26.053 mm 20.956 mm 0.03 mm
Item Timing chain Model/number of links Tensioning system Valve, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions
Standard Morse 92RH2005 / 88 Automatic
0.08~0.12 mm 0.13~0.17 mm

Head Diameter

Face Width

Limit 2.0mm 120.3mm 19.5mm 0.02 mm 0.02 mm
Item Throttle bodys Model (manufacturer) quantity Intake vacuum pressure Throttle cable free play (at the flange of the throttle grip) ID mark Standard 5YR (SAFETY CONTROL CABLE) 2 30.0kpa (238.6mmHg) 3~5mm 5YR1

Limit

CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS
Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0~90 kg 90~197 kg Min. tire tread depth Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0~90 kg 90~197 kg Min. tire tread depth Standard Steel tube underbone mm Cast wheel 10 MT2.15 Aluminum 59mm Cast wheel 10 MT2.15 Aluminum 54mm Tubeless 3.50-10 51J C-922L (CHENG SHIN)
Limit 1.0 mm 1.0 mm 1.0 mm 1.0 mm 0.8mm 0.8mm
150kpa (1.5 kg/cm, 22 psi) 150kpa (1.5 kg/cm, 22 psi) Tubeless 3.50-10 51J C-6007 (CHENG SHIN) 200kpa (2.0 kg/cm, 29 psi) 225kpa (2.25 kg/cm, 32 psi)

CHASSIS SPECIFICATIONS

Item Front disc brake Brake type Operation Brake lever free play (at lever end) Recommended fluid Brake disc Diameter x thickness Min. thickness Max. deflection Brake pad lining thickness-inner Brake pad lining thickness-outer Master cylinder inside diameter Caliper cylinder inside diameter Standard Single disc brake Right-hand operation 3~5mm DOT 4 180.0 4.0 mm 6.0 mm 6.0 mm 11mm 34.93mm
Limit 180.0 3.5 mm 3.5mm 0.10 mm 0.8mm 0.8mm
Item Rear drum brake Brake type Operation Brake lever free play (at lever end) Brake drum inside diameter Lining thickness Front suspension Suspension type Front fork type Front fork travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Spring rate (K2) Spring stroke (K2) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Inner tube outer diameter Inner tube bending limit Steering system Steering bearing type Lock to lock angle (left) Lock to lock angle (Right) Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard Drum brake Left-hand operation 10~20mm 110 mm 4.0mm Telescopic Coil spring/oil damper 80 mm 257.5 mm 245.5mm 12.7N/mm (1.27 kg/mm) 0~50mm 19.6N/mm (1.96kg/mm) 50~80mm No Fork oil G10 or equivalent 126 2.5cc 33 mm Angular bearing 47.5 47.5 Swingarm Coil spring/oil damper 65mm 208mm 198mm 43N/mm (4.3kg/mm) 0~65mm No

Rear brake Brake hose Wheels Tires Wheel bearings Steering bearings Chassis fasteners Sidestand, centerstand
Sidestand switch Front fork
Shock absorber assembly Check operation and shock absorber for oil leakage. Engine oil Every 1,900 mi (3,000 km)

* * * *

Engine oil filter element Engine oil strainer Final transmission oil V-belt Front and rear brake switches Moving parts and cables
Check operation and free play. Throttle grip housing and Adjust the throttle cable free play if necessary. cable Lubricate the throttle grip housing and cable. Lights, signals and switches Check operation. Adjust headlight beam.

EAU17620

NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Hydraulic brake system 9 When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. 9 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. 9 Replace the brake hoses every four years or if cracked or damaged.

CHK COVER AND PANEL ADJ

COVER AND PANEL

SEAT AND SIDE COVERS

23Nm(2.3mkg, 16.6 ftlb)

Order 13

Job/Part Removing the seat and side covers Seat Rear carrier Side cover( left ) Side cover( right ) Hook( left ) Hook( right ) Cover Front cover Fuel tank cap Rear cover Tail / brake light License plate Trunk
Remarks Remove the parts in the order listed.
FOOTREST BOARD AND FOOTREST BOARD SIDE COVER MOLE
Job/Part Removing the footrest board and footrest board side cover mole Side covers( left and right ) Mat Battery cover Battery negative(-) lead Battery positive(+) lead Battery Footrest board side cover mole( left ) Footrest board side cover mole( right ) Footrest board
Remarks Remove the parts in the order listed. Refer to SEAT AND SIDE COVERS
First, disconnect the negative battery lead, and then the positive battery lead. For installation, reverse the removal procedure.

k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to CHECKING THE BRAKE FLUID LEVEL.
After bleeding the hydraulic brake system, check the brake operation. ***************************************************** 3. Install: reservoir cap 1.6 Nm (0.16 m kg, 1.2 ft lb)
CHK CHECKING AND ADJUSTING THE STEERING HEAD ADJ

EAS00148

CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the scooter on a level surface.
Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Check: 8 steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness Adjust the steering head. 3. Remove: 8 head light cover 8 front turn signal light bracket 8 leg shield 1 Refer to COVER AND PANEL.
4. Adjust: 8 steering head ***************************************************** a. Remove the upper ring nut 1, the lock washer 2, the center ring nut 3 and the rubber washer 4. b. Loosen the lower ring nut 5 and then tighten it to specification with the steering nut wrench 6. NOTE: Set the torque wrench at a right angle to the steering nut wrench.
Steering nut wrench 90890-01403 YU-33975 Lower ring nut (initial tightening torque) 28 Nm (2.8 m kg, 20.3 ft lb)
c. Loosen the lower ring nut completely and then tighten it to specification with a steering nut wrench.
Do not overtighten the lower ring nut.
Lower ring nut (final tightening torque) 9 Nm (0.9 m kg, 6.5 ft lb)

8 a 7 b

d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to STEERING HEAD in chapter 4. e. Install the rubber washer. f. Install the center ring nut. g. Finger tighten the center ring nut 7, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the center ring nut until their slots are aligned. h. Install the lock washer 8. NOTE: Make sure the lock washer tabs a sit correctly in the ring nut slots b. i. Hold the lower and center ring nuts with a ring nut wrench and tighten the upper steering nut with a ring nut wrench. Ring nut wrench 90890-01268 YU-01268 Upper ring nut 75 Nm (7.5 m kg, 54.2 ft lb)
***************************************************** 5. Install: 8 leg shield front turn signal light bracket 8 head light cover Refer to COVER AND PANEL.
CHK CHECKING THE FRONT FORK ADJ

EAS00151

CHECKING THE FRONT FORK 1. Stand the scooter on a level surface.
Securely support the scooter so that there is no danger of it falling over. 2. Check: 8 inner tube Damage/scratches Replace. 8 oil seal Oil leakage Replace. 3. Hold the scooter upright and apply the front brake.
4. Check: 8 front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement Repair. Refer to FRONT FORK in chapter 4.

CHK CHECKING THE TIRES ADJ

EAS00163

CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 8tire pressure Out of specification Regulate.
8 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. 8 The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. 8 Operation of an overloaded scooter could cause tire damage, an accident or an injury. 8 NEVER OVERLOAD THE SCOOTER.
Basic weight (with oil and a full fuel tank) Maximum load* Cold tire pressure Up to 90 kg load* 90 kg ~ maximum load*

97 kg (214 lb)

253 kg (558 lb)
150 kPa (1.kPa (2.00 kgf/cm2, 22 psi) kgf/cm2, 29 psi) 150 kPa (1.kPa (2.25 kgf/cm2, 22 psi) kgf/cm2, 32 psi)
* Total weight of rider, passenger, cargo and accessories
It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately.
2. 1 Check: 8tire surfaces Damage/wear Replace the tire.
Minimum tire tread depth 0.8 mm (0.03 in) 1 Tire tread depth 2 Sidewall 3 Wear indicator
8 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. 8 When using tube tires, be sure to install the correct tube. 8 Always replace a new tube tire and a new tube as a set. 8 To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. 8 Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. A Tire B Wheel
Tube wheel Tubeless wheel Tube tire only Tube or tubeless tire
8 After extensive tests, the tires listed below have been approved by Yamaha Motor Taiwan Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this scooter. Front tire
Manufacturer Model CHENG SHIN C-922L Size 3.50-10 51J

Rear tire

Manufacturer Model CHENG SHIN C- 6007

Size 3.50-10 51J

New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.
NOTE: For tires with a direction of rotation mark 1: 8 Install the tire with the mark pointing in the direction of wheel rotation. 8 Align the mark 2 with the valve installation point.
CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES

EAS00168

CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: 8 wheel Damage/out-of-round Replace.

FRONT WHEEL AND BRAKE DISC

EAS00513

70Nm(7.0mkg, 50.6 ftlb)

20Nm(2.0mkg, 14.5 ftlb)

Job/Part Removing the front wheel and brake disc
Remarks Remove the parts in the order listed. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.
Speedometer cable Front brake caliper assembly Wheel axle nut Wheel axle Front wheel Speedometer gear unit assembly
Refer toREMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL

Spacer Front brake disc

EAS00518

FRONT WHEEL

Order 3 4
Job/Part Disassembling the front wheel Oil seal Bearing Collar Bearing

Qty 1 1

Refer toREMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL For assembly, reverse the disassembly procedure.

EAS00520

REMOVING THE FRONT WHEEL 1. Stand the scooter on a level surface.
Securely support the scooter so that there is no danger of it falling over. NOTE: Place the scooter on a suitable stand so that the front wheel is elevated. 2. Remove: 8 speedometer cable 8 brake hose holder Refer to REMOVING THE FRONT WHEEL AND BRAKE DISC.
3. Remove: 8 brake caliperfront wheel axle 8 front wheel 8 speedometer gear unit assembly NOTE: Do not apply the brake lever when removing the brake caliper. 4. Elevate: 8 front wheel NOTE: Place the scooter on a suitable stand so that the front wheel is elevated.

EAS00525

CHECKING THE FRONT WHEEL 1. Check: 8 wheel axle Roll the wheel axle on a flat surface. Bends Replace.
Do not attempt to straighten a bent wheel axle. 2. Check: 8 tire 8 front wheel Damage/wear Replace. Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3.
3. Measure: 8 radial wheel runout lateral wheel runout 2 Over the specified limits

Replace.

Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm(0.04 in)
4. Check: 8 wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings. 8 oil seals Damage/wear Replace. 5. Replace: 8 wheel bearings New 8 oil seal New *****************************************************

a. b. 2

Clean the outside of the front wheel hub. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. 1
c. Remove the wheel bearings 3 with a general bearing puller. d. Install the new wheel bearings and oil seals in the reverse order of disassembly. *****************************************************

EAS00528

CHECKING THE BRAKE DISC 1. Check: 8 brake disc Damage/galling Replace. 2. Measure: 8 brake disc deflection a Out of specification Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.10 mm (0.04 in)

3. Install: 8 valve 1 8valve spring seat 2 8valve stem seal 3 New 8valve spring 4 8valve spring retainer valve cotter 6 (into the cylinder head) NOTE: Install the valve spring with the larger pitch a facing up. b Smaller pitch
4. Install: 8valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3.
5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer.
Hitting the valve tip with excessive force could damage the valve.

EAS00261*

CHECKING THE CYLINDER AND PISTON 1. Check: 8 piston wall 8 cylinder wall Vertical scratches Replace the cylinder, and the piston and piston rings as a set. 2. Measure: 8 piston-to-cylinder clearance ***************************************************** a. Please carry out the following inspections: 8 cylinder Measure the piston pin in both of its horizontal axis direction a and its right angle direction b at six positions of A, B, C, etc. with a cylinder gauge. Abrasion = Max. value - min. value as measured at those six positions When abrasion is beyond limit Replace it Standard value of cylinder inner diameter 52.40~52.41mm (2.063~2.064 in) Service limit of cylinder inner diameter 52.5mm (2.067 in) b. If out of specification, replace the cylinder, and the piston and piston rings as a set. c. Measure piston skirt diameter P with the micrometer. a 3.5 mm(0.138 in) from the bottom edge of the piston
Piston size P 51.470 ~ 51.510 mm(2.026~ 2.028 in)
d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula.
Piston-to-cylinder clearance = Cylinder bore C - Piston skirt diameter P
Piston-to-cylinder clearance 0.01 ~ 0.03 mm(0.0004~0.0012 in) <Limit>: 0.15 mm(0.006 in) f. If out of specification, replace the cylinder, and the piston and piston rings as a set. ***************************************************** 5-30

EAS00263

CHECKING THE PISTON RINGS 1. Measure: 8 piston ring side clearance Out of specification Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.
Piston ring side clearance Top ring 0.02 ~ 0.08 mm(0.0008~0.0031 in) <Limit>: 0.13mm(0.0051 in) 2nd ring 0.02 ~ 0.06 mm(0.0008~0.0024 in) <Limit>:0.12 mm(0.0047 in)
2. Install: 8 piston ring (into the cylinder)
NOTE: Level the piston ring into the cylinder with the piston crown. a 20 mm (0.79 in) 3. Measure: 8 piston ring end gap Out of specification ton ring.

5. Offset: 8 piston ring end gaps a b c d A Top ring Lower oil ring rail Upper oil ring rail 2nd ring Exhaust side
6. Install: 8 cylinder 1 NOTE: 8 While compressing the piston rings with one hand, install the cylinder with the other hand. 8 Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.

BELT DRIVE

EAS00316

CRANKCASE COVER

7Nm(0.7m kg, 5.1 ft lb) 23Nm(2.3m kg, 16.6 ft lb)

Order 9

Job/Part Removing the belt drive Kickstarter Crankcase cover - 3 V-belt case air filter element holder V-belt case filter element Crankcase cover - 1 Dowel pin O-ring Dowel pin O-ring

EAS00338

KICKSTARTER

9Nm(0.9m kg, 6.5 ft lb)

Job/Part Removing the kickstarter Crankcase cover Plate (V-belt guide) Gasket Kick pinion gear Kick pinion gear clip Circlip / Plate washer Kick shaft assembly Torsion spring Solid bush
Remarks Remove the parts in the order listed. Refer to CRANKCASE COVER.
Refer to INSTALLING THE KICKSTARTER.

EAS00340

INSTALLING THE KICKSTARTER 1. Install: 8 solid bush kickstarter shaft kickstarter spring 3
2. Hook: 8 kickstarter spring
NOTE: Hook the spring enda on the kickstarter shaft b as shown, and hook the other end c on the projectiond.
3. Install: 8 plain washercirclip2 New
4. Install: 8 kick pinion gearkick pinion gear clip 2 NOTE: Install the clip at the position shown.
5. Install: 8 gasket1 New 8 plate2
V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE
60Nm(6.0m kg, 43.4 ft lb)
55Nm(5.5m kg, 39.8 ft lb)
Job/Part Removing the V-belt, clutch, primary and secondary sheave Primary sheave nut / Plate washer Oneway clutch Primary fixed sheave Secondary sheave nut Clutch housing Secondary sheave assembly V-belt Washer / Collar Primary sliding sheave Cam / Weight Slider Oil seal Gasket

1/1 1/1/2 1

Refer to REMOVING AND INSTALLING THE SECONDARY SHEAVE
Refer to REMOVING AND INSTALLING THE PRIMARY SHEAVE
DISASSEMBLING THE SECONDARY SHEAVE
90Nm(9.0m kg, 65.1 ft lb)
Job/Part Disassembling the secondary sheave Clutch carrier nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave
Remarks Disassemble the parts in the order listed.

EAS00317

REMOVING THE PRIMARY SHEAVE 1. Remove: 8 primary sheave nut plate washer 8 primary fixed sheave 2 NOTE: While holding the primary fixed sheave with the rotor holding tool 3, loosen the primary fixed sheave nut.

3. Check: 8 oil pump operation Rough movement Repeat steps (1) and (2) or replace the defective part(s).

EAS00376

INSTALLING THE OIL PUMP 1. Install: 8 gasket 1 New 8 oil pump assemblyoil pump bolt 7 Nm (0.7 m kg, 5.1 ft lb)
After tightening the bolts, make sure the oil pump turns smoothly.

TRANSMISSION

EAS00419
12Nm(1.2m kg, 8.7 ft lb) B
Job/Part Removing the transmission, shift drum assembly, and shift forks Transmission oil Rear wheel Crankcase cover Belt drive Secondary sheave Crankcase cover- 2 Crankcase cover gasket- 2 Dowel pin Primary drive gear shaft Plate washer Main axle Drive axle
Remarks Remove the parts in the order listed. Drain. Refer to REAR WHEEL AND REAR BRAKE in chapter 4. Refer to BELT DRIVE. Refer to V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE.

EAS00425

CHECKING THE TRANSMISSION 1. Measure: 8 main axle runout (with a centering device and dial gauge ) Out of specification Replace the main axle. Main axle runout limit 0.02 mm (0.0008 in) 2. Measure: 8 primary drive gear shaft runout (with a centering device and dial gauge ) Out of specification Replace the drive axle. Primary drive gear shaft runout limit 0.02 mm (0.0008 in)
3. Measure: 8 drive axle runout (with a centering device and dial gauge ) Out of specification Replace the drive axle. Drive axle runout limit 0.02 mm (0.0008 in)
4. Check: 8 transmission gears Blue discoloration/pitting/wear Replace the defective gear(s). 8 transmission gear dogs Cracks/damage/rounded edges Replace the defective gear(s). 5. Check: 8 transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect Reassemble the transmission axle assemblies. 6. Check: 8 transmission gear movement Rough movement Replace the defective part(s).

CRANKCASE AND CRANKSHAFT

EAS00381

8Nm(0.8m kg, 5.8 ft lb)

32Nm(3.2m kg, 23.1 ft lb)
Job/Part Removing the crankshaft assembly Engine Cylinder head Cylinder piston V-belt, clutch, primary / Secondary sheave Starter clutch C.D.I. magneto Oil pump Rear wheel Bolt Collar Plate washer Spring Centerstand Engine bracket Oil elemet cover O-ring Oil elemet Crankcase (right )
Remarks Remove the parts in the order listed. Refer to ENGINE Refer to CYLINDER HEAD Refer to CYLINDER PISTON Refer to V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE. Refer to STARTER CLUTCH AND STARTER MOTOR Refer to C.D.I. MAGNETO Refer to OIL PUMP Refer to REAR WHEEL

CHECKING SWITCH CONTINUITY

EAS00730

Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.
Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester 90890-03132 (YU-03112-C) NOTE: 8 Before checking for continuity, set the pocket tester to 0 and to the 1 range. 8 When checking for continuity, switch back and forth between the switch positions a few times. The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration. NOTE: - indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position). The example illustration on the left shows that: There is continuity between red and brown when the switch is set to ON.

Br R OFF ON

CHECKING THE SWITCHES

EAS00731

Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to CHECKING SWITCH CONTINUITY. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.
Main switch Br R B B/W LOCK OFF ON R B Br

Rear barake light switch

Front barake light switch

Dimmer switch

Br G/Y
Y L G HI LO Horn switch P B OFF PUSH Turn signal light switch Br/ Ch Dg W L N R Dg L Ch B OFF START Engine stop switch B/ B/ L/ Br WWW Sidestand switch L/Y OFF RUN Start switch L/ L/ WW B/W B/W L/W Br

L Ch P Br/W B Dg

B Main fuse
CHECKING THE BULBS AND BULB SOCKETS

EAS00733

Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. No continuity Repair or replace the bulb, bulb socket or both.

4. Stator coil resistance 8 Remove the C.D.I magneto couplers from wireharness. 8Connect the pocket tester ( 1) to the stator coils as shown. Positive tester probe green/ white 1 Negative tester probe black/red 2

B/R G/W W/R W/L

G/W B/R W/L W/R
8Measure the stator coil resistances. Stator coil resistance 688 ~ 1032 at 20C 8Is the stator coil OK? YES NO Replace the stator coil assembly.

EAS00780

LIGHTING SYSTEM

2 f h j l z

C.D.I. magneto Speedometer light Dimmer switch High beam indicator light Fuel lever meter light Headlight

EAS00781 EAS00739

TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, fuel level meter light or meter light. Check: 1. main fuse 2. battery 3. main switch 4. dimmer switch 5. wiring connections (of the entire lighting system) NOTE: 8Before troubleshooting, remove the following part(s): 1. Head light cover 2. Front turn signal light bracket 3. Leg shield 1 4. Rear varrier 5. Side cover (right ) 6. Cover 7. Battery cover 8Troubleshoot with the following special tool(s).
2. Battery 8Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20C 8Is the battery OK? ` YES NO 8Clean the battery terminals. 8Recharge or replace the battery.
3. Main switch 8Check the main switch for continuity. Refer to CHECKING THE SWITCHES. 8Is the main switch OK? YES NO Replace the main switch.

EAS00784

1. Main fuse 8Check the fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. 8Is the fuse OK? YES NO Replace the fuse.
4. Dimmer switch 8Check the dimmer switch for continuity. Refer to CHECKING THE SWITCHES. 8Is the dimmer switch OK? YES NO The dimmer switch is faulty. Replace the left handlebar switch.

EAS00787 EAS00788

5. Wiring 8 Check the entire lighting systems wiring. Refer to CIRCUIT DIAGRAM. 8 Is the lighting systems wiring properly connected and without defects? YES Check the condition of each of the lighting systems circuits. Refer to CIRCUIT DIAGRAM. NO Properly connect or repair the lighting systems wiring.
CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb and socket 8 Check the headlight bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Are the headlight bulb and socket OK? YES NO Replace the headlight bulb, socket or both.

EAS00799

3. The turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal light and turn signal indicator light bulbs and sockets 8 Check the turn signal light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Check the turn signal indicator light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS 8 Are the turn signal light bulb and socket OK? YES NO Replace the turn signal light and/or turn signal indicator light bulb, socket or both. 2. Turn signal switch 8Check the turn signal switch for continuity. Refer to CHECKING THE SWITCHES. 8Is the turn signal switch OK? YES NO Replace the left handlebar switch.
3. Voltage 8Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe brown 1 Negative tester probe ground

B Br/W Br 1

8Set the main switch to ON. 8Measure the voltage (DC 12 V) on brown 1 at the turn signal relay coupler (wire harness side). 8Is the voltage within specification? YES NO The wiring circuit from the main switch to the turn signal relay coupler is faultyand must be repaired. Refer to CIRCUIT DIAGRAM.
4. Voltage 8Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe brown/white 1 Negative tester probe ground
5. Voltage 8Connect the pocket tester (DC 20 V) to the turn signal light connector or meter assembly coupler (wire harness side) as shown. Turn signal light Turn signal indicator light Left turn signal light Positive tester probe chocolate 1 Negative tester probe ground Right turn signal light Positive tester probe dark green 2 Negative tester probe ground
8Set the main switch to ON. 8Set the turn signal switch to 4 or 6. 8Measure the voltage (DC 12 V) on brown/ white 1 at the turn signal relay coupler (wire harness side). 8Is the voltage within specification? YES NO The turn signal relay is faulty and must be replaced.

Ch B Ch B 1

Dg B Dg B 2
8Set the main switch to ON. 8Set the turn signal switch to 4 or 6. 8Measure the voltage (DC 12 V) of the chocolate 1 or dark green 2 at the turn signal light connector (wire harness side). 8Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.

EAS00804

4. The fuel level meter fails to operate. 1. Fuel sender 8 Remove the fuel sender from the fuel tank. 8 Connect the pocket tester ( 1) to the fuel sender coupler (wire harness side) as shown. Positive tester probe green 1 Negative tester probe black 2
2. Voltage 8 Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. Positive tester probe brown 1 Negative tester probe black 2

1 L B Br G Br G L B

(F) G B
8 Measure the fuel sender resistances. Fuel sender resistance (up position F)( 1) 4~10 at 20C Fuel sender resistance (down position E)( 10) 90~100 at 20C 8Is the fuel sender OK? YES NO Replace the fuel sender.
8 Set the main switch to ON. 8 Measure the voltage (DC 12 V) of brown 1 on the meter light coupler (wire harness side). 8 Is the voltage within specification? YES NO Check the wiring connections of the entire signaling system. Refer to CIRCUIT DIAGRAM.
3. Fuel level meter 8 Set the main switch to ON. 8 Move the float up 1 or down 2.
8 Check that the fuel level meter needle moves to F or E. NOTE: Before reading the fuel level meter, leave the float in one position (either up or down) for at least three minutes. 8 Does the fuel level meter needle move appropriately? YES NO

This circuit is OK.

Replace the fuel level meter.
Wiring 8 Check the entire signaling systems wiring

EAS00820

BR BR GW Or R W WR WR

GW BR WL WR

R B Br

E/G STOP OFF RUN

BW BW LW Br BW BW Br LW
CARBURETOR HEATING SYSTEM
CRABURETOR HEATING SYSTEM
Main switch Battery Main fuse Battery (+) lead Battery (-) lead Wire lead Thermo switch Carburetor heater

HORN SW

EAS00821 EAS00739
TROUBLESHOOTING The carburetor heating system fails to operate. Check: 1. Main fuse 2. Battery 3. Main switch 4. Thermo switch 5. Carburetor heater 6. Wiring connections (of the entire carburetor heating system) NOTE: 8 Before troubleshooting, remove the following part(s): 1. Head light cover 2. Front turn signal light bracket 3. Leg shield 1 4. Cover 5. Battery cover 6. Footrest board side cover mole(right) 8 Troubleshoot with the following special tool(s).
1. Main fuse 8Check the fuse for continuity. Refer to CHECKING THE FUSES in chapter 3. 8Is the fuse OK? YES NO Replace the fuse.

EAS00823

4. Thermo switch 8 Remove the thermo switch from the thermo switch plate wire harness. 8 Connect the pocket tester to the ( 1) to the thermo switch 1 as shown. NOTE: Make sure that the thermo switch terminals do not get wet. 8 Immerse the thermo switch in a container filled with coolant 2. 8 Place a thermometer3 in the coolant. 8 Slowly heat the coolant, then let it cool down to the specified temperature. 8 Check the thermo switch for continuity at the temperature indicated below. Test step C o o l a n t temperature ~C 2 More thanC 3* ~ 113 C 4* Less thanC Steps 1 & 2: Heating phase Steps 3 & 4: Cooling phase Continuity YES NO NO YES

Engine Valve inspection and adjustment procedure for Yamaha Vino 125 IN PROCESS/PRELIMINARY By tony_gatto@yahoo.com RevA 10/29/2007
Note: The following procedures are intended as a guide for owners wishing to perform basic maintenance on their Vino 125. This document is neither sanctioned by Yamaha Motor Corporation, nor recommended as a replacement for official Yamaha owner and service manuals. Ive written it to help owners who would ordinarily perform their own periodic maintenance, or those that may wish to do so. In any circumstance where these procedures conflict with those in official Yamaha documents you are at your own risk. Please use common sense, ask questions when necessary, and if unsure of what youre doing then by all means take the scooter to a Yamaha dealer or qualified mechanic. Save me the time needed to write the rest of the legal liability exclusions by using good judgment and taking personal responsibility for what you do. If there is anything in these procedures that you feel may cause damage or harm to either the machine or an individual please contact me at the email address above. Any suggestions for improvement are welcome.
Overview and cautions regarding Engine Valve adjustment Up front Id like to say that I only recommend this Vino 125 maintenance for owners with reasonable mechanical experience. An incorrectly adjusted valve might not be obvious at first. By the time you notice a symptom there might be expensive engine damage. I cant stress strongly enough that if you feel intimidated by this procedure then take the scooter to a qualified mechanic. Another option is to play it safe and just inspect the valves without attempting an adjustment. If you choose to adjust the valves dont run the engine any further if it displays an unusual symptom immediately after. The valve inspection and adjustment procedure in the Yamaha service manual is written for experienced mechanics. But several helpful details are omitted and some areas are confusing, which makes the job more difficult than it should be. One example is the first step which lists items to remove. If youre following the service manual its unnecessary to remove thecover, rear carrier, side covers and hook to perform the valve adjustment. Removing those items adds a lot of effort with little if any access improvement to do the job. The following photos and text hopefully clarify some confusion for experienced mechanics and should keep the less experienced out of trouble. This procedure is meant to stand on its own with the service manual used only as a general reference. As a rule Vino 125 engines are very reliable and have developed a reputation for showing minimal wear after extended use. It's typical for the engine to not require any valve adjustments even after many miles. This assumes regular oil change intervals, but is especially the case after switching to synthetic oil. My wrecked 2004 Vino accumulated 13K+ miles without needing a valve adjustment, and so far my replacement 2007 model has ~ 5K miles with the same result. So its possible the factory recommended inspections at 2K mile intervals are too conservative. But that said theres no guarantee a particular Vino 125 will behave like mine so its important to check the valves on a regular basis. Required Tools & materials (see photos) 3/8 drive socket handle 3/8 drive socket handle extension 3 or longer 3/8 drive socket 19 mm (3/4 will work) Medium point Philips Screwdriver 8 mm combination (box/open end) wrench Feeler (Thickness) gauges covering the range from 0.003 to 0.008 (0.08 mm to 0.20 mm) in 0.001 steps. The photo shows 2 of the gauges out the 0.004 and 0.006 which are the nominal settings for the intake and exhaust valves 24 mm open or box end wrench (15/16 will work) 3.5 mm mini nut driver Small flashlight Shop rag or cloth to capture oil from the exhaust valve cap

Feeler Gauges - 0.004 & 0.006 shown 24 mm wrench
3/8 socket handle, extension, & 19 mm socket wrench
Medium (#2) Philips screwdriver

3.5 mm nut driver

8 mm wrench
Initial Preparation Perform these procedures in a well lit and ventilated area. Always read the warnings on Yamaha documents, oil containers, tool manuals, etc. Its assumed youll have cleaning towels, latex gloves and other consumables on hand to use when appropriate. Valve inspection and adjustment must be done on a cold engine or one thats cooled down to reach the ambient temperature. Its OK to check/adjust valves on an engine thats slightly warm to the touch, but not excessively so. During my Arizona summers its not unusual for external temperatures to be well over 110 F, so an engine wont get any colder than that regardless. If the engine doesnt cool below 120 F because of your climate Id find a temperature-controlled environment to do the valve adjustment. Access the engine valves Accessing the engine for a valve adjustment is the same as for an oil change you remove the rubber floor mat and the engine front panel. Anyone adjusting the valves should already have experience with these items from changing the engine oil. Otherwise see my oil change procedure. Place a rag underneath the exhaust valve cover since it will drip oil when removed. Take off the oil filler cap (covers the intake valve), spark plug boot, and the exhaust valve cap (using the 24 mm wrench) -see photos.

Remove oil filler cap

Remove exhaust valve cover use rag to catch oil

Spark plug boot removed

Threaded adjuster and locknut

Valve and spring

Rocker arm
View of intake valve and rocker arm with square ended threaded adjuster and lock nut

View of exhaust valve

Positioning the engine crankshaft to close the valves for inspection - overview On the Vino 125 the engine valves are opened and closed by rocker arms at specific times during engine rotation. Its important to maintain a precise gap between the rocker arm and valve stem to accommodate the expansion of the materials used for these and other engine parts. If the gap is too small the valve wont close completely. Engine performance will suffer, but more importantly, superheated exhaust gases will blow past the valve seat and burn the valve. If the gap is too wide engine performance is also affected, and the clatter from the excess clearance will eventually damage the valve stems and rocker arms. The gap or clearance between the valves and rocker arms is checked when the valves are closed. On the Vino 125s 4-stroke engine both the intake and exhaust valve are closed when the piston is at top dead center (TDC) at the end of the compression stroke. At this point in the engine rotation the piston is at the top of its linear motion inside the cylinder and positioned closest to the valves and spark plug. (Its roughly at this time that the ignition fires to begin the power producing stroke in the engine). With the valves closed there should be a specific gap between the valve stems and rocker arms. On the Vino 125 the nominal settings are 0.004 for the intake valve (the one under the oil filler cap), and 0.006 for the exhaust valve. The inspection process for this has two aspects: Rotating the engine to TDC on the compression stroke to close both valves Using a thickness gauge to ensure the gap between valve stem and rocker arm is correct An important detail is that the engine reaches TDC twice during a combustion cycle, and this spans two rotations of the engine crankshaft. On most modern engines the intake and exhaust valves are only closed simultaneously during one of those TDC events the end of the compression stroke. The other TDC event is at the end of the exhaust stroke/beginning of the intake stroke. Modern engines usually have both the intake and exhaust valve opened at this point to improve engine performance at high rpm. To guarantee proper engine positioning Ive chosen to use the TDC marks on the crankshaft flywheel and go through a specific rotational sequence. I realize that seasoned mechanics know other quicker methods. One of the more popular is to remove the spark plug and gauge when the piston is at TDC by inserting a stick or other object that gets pushed by the piston. For the inexperienced I think this is asking for trouble, so Im only going to describe the more lengthy method here. An advantage to this approach on the Vino is the spark plug doesnt need to be removed. Rotate the engine crankshaft to close the valves for inspection Attach the 3/8 drive socket handle with the 3 extension and 19 mm socket to the nut that holds the cooling fan to the engine crankshaft (see photo). Rotate the handle continuously clockwise and look

at the intake and exhaust valves. As the engine rotates the valves will rise (closing) and fall (opening) during various portions of the rotation. A valve is completely closed when it stops rising while the engine is still rotating. There will be periods of the rotation when both valves are completely closed, and this is the position we need to check the clearances.
Spark plug access hole and air injection pipe

Spark plug access hole

Air Injection pipe Rotate the engine using the cooling fan retaining nut
While rotating the engine shine a flashlight beam into the access hole for the spark plug (see photos). Carefully position yourself to look deep inside the cooling shroud past the spark plug. The air injection pipe partially blocks the view so move the flashlight and yourself at Engine is at TDC when the T different angles. Theres flywheel marking is next to edge of aluminum casting only a narrow range of angles where youll be able to see properly. What youre looking for is the flywheel that rotates with the engine Air injection there will be several pipe (blurred) alignment marks and letters inscribed on the surface. Keep rotating the engine Edge of aluminum casting until you see the letters and marks sweep past the rectangular aluminumcasting feature (shown towards the right of the arrow in the photo). There View of flywheel marking past the spark plug deep inside the cooling shroud are two letters marked on the flywheel. The T indicates TDC, while F indicates Fire or when the ignition spark actually occurs. (Its normal for these two timing events to be separated on an engine). Youll notice 3 lines scribed near the letters. The one next to the T is the TDC mark. The lines either side of the F mark are for the ignition firing points that change with engine RPM - they arent used for setting the valves.
After identifying the TDC mark on the flywheel the next step is to rotate the engine to get both intake and exhaust valves closed. Slowly turn the engine until the intake valve closes ignore the exhaust valve for now. Continue rotating the engine and watch for the flywheels T (TDC) mark to appear just before the intake valve begins to open again this is the start of the intake stroke. Continue slowly rotating the engine. As the engine continues to rotate the intake valve will close continue looking at the flywheel. The next time you see the T (TDC) mark align with the rectangular aluminum-casting feature stop the rotation the engine will be at TDC for the compression stroke and both intake and exhaust valves will be closed. Confirm this by looking at both valves while going through this process. Do it several times until youre certain you have the right instance of TDC. Check the intake and exhaust valve clearances With both valves closed there should a small amount of play between the square ended threaded adjuster on the rocker arm and the valve stem. Wiggle the adjuster up and down on both valves to get a feeling for the amount. This is the gap were going to inspect with the feeler gauges. As youre likely figured out the working room is extremely tight which makes this process more difficult than typical for larger engines. Also, standard feeler gauges (like the one in the photo) arent ideal for checking the Vino 125s valve clearances. Its best to either get a specialized set or adapt a standard one by bending a dogleg into it permanently. I use my gauges on other vehicles and have enough experience to work with them as is. Starting with the intake valve carefully bend the 0.003 feeler gauge and slide it between the valve stem and the threaded adjuster (see photo). With the gauge shown youll have to give it a pretty sharp curvature in order to clear the engine crankcase, but it should slide in without having to apply a lot of force. Try to keep the gauge flat where it enters the gap. I strongly advise permanently bending an L shape dogleg on your gauges so that you dont have to apply curvature and tension while checking clearances. Repeat the process with the 0.004 and 0.005 gauges. If all three slide in then try a 0.006 gauge. The correct intake valve gap ranges between 0.003 to 0.005. If the Sliding a feeler gauge between valve and adjuster to check valve 0.003 gauge doesnt slide in then the clearance is too tight. If a 0.006 gauge or thicker slides in then the clearance is too loose. In either case youll need to adjust the valve. Repeat the inspection with the exhaust valve except make sure the gap falls between 0.005 and 0.007. Youll have to adjust the valve if you cant slide in a 0.005 gauge, or if its wide enough to allow a 0.008 or larger one to fit.

Adjusting the valve clearance Preferred adjustment approach: If the valve gap falls outside the specifications youll have to loosen and rotate the square headed threaded adjuster to change the clearance. Loosen the locknut with the 8 mm combination wrench. Using the 3.5 mm mini nut driver rotate the square headed adjuster screw counter-clockwise to loosen the valve clearance, or clockwise to tighten it (see photo). Note: the adjustment is very sensitive you dont need much rotation to cause a large change in gap. Try small rotational increments like turn or less for an initial adjustment. Carefully tighten the locknut (5.1 ftlbs) after the adjustment and check the gap as previously described. Repeat until the valve gap is within specification. Alternate adjustment approach: If the valve is very far from the specification a way to quickly get an initial setting is to insert a feeler gauge with the required clearance between the valve and adjuster as shown in the photo. Loosen the valve completely and carefully rotate the adjuster screw until it just seats on the feeler gauge, then tighten the locknut. Note: Using this method its important to not overadjust the screw because it will compress the valve spring and force the valve off the sealing surface on the engine. When you remove the feeler gauge the valve spring will push the valve back and the clearance will be too tight. If you have to substantially force the feeler gauge to remove it then youve gone too far ;). This approach can save some adjustment time but youll still have to check the clearance as described earlier to make sure its correct.
3.5 mm mini nut driver Feeler gauge (for alternate adjustment approach only)
Loosening and adjusting the valve clearance adjustment
When youre satisfied the clearances are correct replace the exhaust valve cover, oil filter cap, spark plug boot, etc. Properly tighten everything youve removed (I couldnt find a spec for the exhaust valve cover so I recommend about 15 ft-lbs). Start the scooter - if you have difficulty starting it or hear any unusual noises dont operate it until youve resolved the issue. If the engine starts and idles properly then take the Vino on the road and operate it for a while. The biggest concern is having over-tightened the valves. This usually displays a symptom after the engine is fully heat soaked from operation with a load. If you experience a loss in power or unusual engine behavior on the road after adjusting the valves dont operate the scooter any further. Take the Vino to a dealer or qualified mechanic and have them check your valve settings.