Yamaha Mio Service Manual

Full download: http://manualplace.com/download/yamaha-mio-service-manual/

MIO

SERVICE MANUAL

5TL-F8197-E0

This is the cut pages sample. Download all 305 page(s) at: ManualPlace.com
EAS00000

AL115
SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
First edition, July 2003
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of motorcycle. Repair and maintenance work attempted by anyone without this knowledge is likely
to render the motorcycle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
_

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
EASF0001

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is a chapter with its symbol on the upper right of each page.
2nd title 2: This title appears on the upper of each page on the left of the chapter symbol. (For
the chapter “Periodic checks and adjustments” the 3rd title appears.)
3rd title 3: This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of triangle “▲” with each proce-
dure preceded by alphabetical letters.
IMPORTANT FEATURES
• Data and a special too are framed in a box preceded by a relevant symbol 5.
• An encircled numeral 6 indicates a part name, and an encircled alphabetical letter or an align-
ment mark 7, the others being indicated by an alphabetical letter in a box 8.
• A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9.
EXPLODED DIAGRAMS
Each chapter provide exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly prodedures.
 EASF0002
1 2 SYMBOLS
GEN The following symbols are not relevant to
INFO SPEC every vehicle.
Symbols 1 to 8 indicate the subject of each
3 4 chapter.
1 General information
CHK ENG 2 Specifications
ADJ 3 Periodic checks and adjustments
4 Engine
5 6 5 Carburetor
6 Chassis
7 Electrical system
CARB CHAS 8 Troubleshooting

7 8

– + TRBL
ELEC SHTG
9 0 Symbols 9 to F indicate the following.
9 Serviceable with engine mounted
0 Filling fluid
A Lubricant
B Special tool
A B C Tightening torque
D Wear limit, clearance
E Engine speed
F Electrical data

C D
T.
R.

E F

G H I Symbols G to L in the exploded diagrams

indicate the types of lubricants and lubrication
points.
E G M G Engine oil
H Gear oil
J K L I Molybdenum-disulfide oil
J Wheel-bearing grease
B LS M K Lithium-soap-based grease
L Molybdenum-disulfide grease

M N Symbols M to N in the exploded diagrams

indicate the following.
M Apply locking agent (LOCTITE®)
LT
New N Replace the part
EASF0003

TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
CHK
ADJUSTMENTS ADJ 3
ENGINE ENG
4
CARBURETOR CARB
5
CHASSIS CHAS
6
– +

ELECTRICAL SYSTEM ELEC

7
TROUBLESHOOTING TRBL
SHTG 8
 GEN
INFO
CHAPTER 1
GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION..................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1

IMPORTANT INFORMATION ......................................................................... 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-3
BEARINGS AND OIL SEALS .................................................................... 1-3
CIRCLIPS ..................................................................................................1-3

CHECKING THE CONNECTIONS ..................................................................1-4

SPECIAL TOOLS ............................................................................................ 1-5

GEN
INFO
 GEN
MOTORCYCLE IDENTIFICATION INFO
EAS00014

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the frame.

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into
the crankcase.
NOTE:
Designs and specifications are subject to
change without notice.

1-1
 GEN
IMPORTANT INFORMATION INFO
EAS00020

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.

EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.

EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.

1-2
 GEN
IMPORTANT INFORMATION INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.

EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appro-
priate.
1 Oil seal
CAUTION:
_

Do not spin the bearing with compressed

air because this will damage the bearing
surfaces.

1 Bearing

EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft

1-3
 GEN
CHECKING THE CONNECTIONS INFO
EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.

3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
_

If the pin 1 on the terminal is flattened, bend it

up.

4. Connect:
• lead
• coupler
• connector
NOTE:
_

Make sure all connections are tight.

5. Check:
• continuity
(with the pocket tester)

Pocket tester
90890-03112

NOTE:
_

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.

1-4
 GEN
SPECIAL TOOLS INFO
EAS00027

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Usage Illustration
Weight
Weight Slide hammer bolt
90890-01084
Slide hammer bolt
90890-01085 These tools are used when removing or
installing the rocker arm shafts.
Fork seal driver weight

90890-01184

This tool is used to installing the oil seal.

Fork seal driver attachment

90890-01186

This tool is used to installing the oil seal.

Flywheel puller

90890-01189
This tool is used for removing the A.C.
magneto rotor.
Rotor holding tool

90890-01235
This tool is used to hold the A.C. mag-
neto rotor when removing or installing
the A.C. magneto rotor nut.
Valve spring compressor
Compressor Valve spring compressor attachment
90890-01253
Attachment
90890-01243 These tools are used when removing or
installing the valve and the valve spring.
Ring nut wrench

90890-01268
This tool is used to loosen and tighten
the steering ring nut.

1-5
 GEN
SPECIAL TOOLS INFO
Tool No. Tool name/Usage Illustration
Tappet adjusting tool

90890-01311
This tool is necessary for adjusting
valve clearance.
Fuel level gauge

90890-01312
This gauge is used to measure the fuel
level in the float chamber.
T-handle

90890-01326
This tool is used for holding the damper
rod holder when removing or installing
the damper rod holder.
Clutch spring holder

90890-01337
This tool is used to disassembly and
assembly the secondary sheave.
Oil seal guide

90890-01384

This tool is used to install oil seals.

Steering nut wrench

90890-01403
This tool is used to loosen and tighten
the steering ring nut.
Socket wrench

90890-01493
This tool is used to loosen and tighten
the clutch carrier locknut of the second-
ary sheave.
Sheave holder

90890-01701
This tool is used for holding the primary
sheave and secondary sheave.

1-6
 GEN
SPECIAL TOOLS INFO
Tool No. Tool name/Usage Illustration
Compression gauge

90890-03081
These tools are used to measure the
engine compression.
Pocket tester

90890-03112
These instruments are invaluable for
checking the electrical system.
Engine tachometer

90890-03113
This tool is needed for detecting engine
rpm.
Valve guide remover (ø5)

90890-04097
This tool is needed to remove and
install the valve guide.
Valve guide installer (ø5)

90890-04098
This tool is needed to install the valve
guide.
Valve guide reamer (ø5)

90890-04099
This tool is needed to rebore the new
valve guide.
Valve lapper

90890-04101

This tool is used for lapping the valve.

Ignition checker

90890-06754
This instrument is necessary for check-
ing the ignition system components.

1-7
 GEN
SPECIAL TOOLS INFO
Tool No. Tool name/Usage Illustration
Yamaha bond No. 1215

90890-85505
This sealant (bond) is used for crank-
case mating surface, etc.

1-8
 SPEC
CHAPTER 2
SPECIFICATIONS

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

ENGINE SPECIFICATIONS ............................................................................2-2

CHASSIS SPECIFICATIONS ..........................................................................2-9

ELECTRICAL SPECIFICATIONS .................................................................2-12

CONVERSION TABLE .................................................................................. 2-15

GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-15

TIGHTENING TORQUES .............................................................................. 2-16

ENGINE TIGHTENING TORQUES......................................................... 2-16
CHASSIS TIGHTENING TORQUES.......................................................2-18

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-20

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ................ 2-20
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES .............. 2-21

CABLE ROUTING ......................................................................................... 2-22

Yamaha Mio Service Manual
Full download: http://manualplace.com/download/yamaha-mio-service-manual/

SPEC

This is the cut pages sample. Download all 305 page(s) at: ManualPlace.com