Yamaha Mio Manuals

Manuals and User Guides for Yamaha Mio. We have 2 Yamaha Mio manuals available for free PDF download: Service Manual

Yamaha Mio Service Manual

Yamaha Mio Service Manual (305 pages)

manual service book

Brand: Yamaha | Category: Scooter | Size: 17.65 MB

Table of Contents

Table of Contents

7
- General Information
  6
- Specifications
  6
- Periodic Checks and Adjustments
  6
  - Table of Contents
    7
- General Information
  11
- Motorcycle Identification
  11
- Vehicle Identification Number
  11
- Engine Serial Number
  11
- Important Information
  12
- Preparation for Removal and Disassembly
  12
- Replacement Parts
  12
- Gaskets, Oil Seals and O-Rings
  12
- Lock Washers/Plates and Cotter Pins
  13
- Bearings and Oil Seals
  13
- Circlips
  13
- Checking the Connections
  14
- Special Tools
  15
Gen Info

19
- General Specifications
  21
- Specifications
  21
- Engine Specifications
  22
- Chassis Specifications
  29
- Electrical Specifications
  32
- Conversion Table
  35
- General Tightening Torque Specifications
  35
- Engine Tightening Torques
  36
- Tightening Torques
  36
- Chassis Tightening Torques
  38
- Engine Lubrication Points and Lubricant Types
  40
- Lubrication Points and Lubricant Types
  40
- Chassis Lubrication Points and Lubricant Types
  41
- Cable Routing
  42
Chapter 3 Periodic Checks and Adjustments

53
- Introduction
  55
- Periodic Checks and Adjustments
  55
- Periodic Maintenance and Lubrication Chart
  55
- Covers
  57
- Installing the Seat and Side Covers
  57
- Removing the Seat and Side Covers
  57
- Removing the Front Cowling and Leg Shield
  58
- Installing the Front Cowling and Leg Shield
  60
- Installing the Headlight Assembly
  61
- Removing the Headlight Assembly
  61
- Adjusting the Valve Clearance
  62
- Engine
  62
- Adjusting the Engine Idling Speed
  64
- Adjusting the Throttle Cable Free Play
  66
- Checking the Spark Plug
  67
- Measuring the Compression Pressure
  68
- Checking the Engine Oil Level
  70
- Changing the Engine Oil
  71
- Changing the Transmission Oil
  72
- Cleaning the Air Filter Element
  73
- Checking the V-Belt
  74
- Cleaning the V-Belt Case Air Filter Element
  75
- Checking the Carburetor Joint and Intake Manifold
  76
- Checking the Fuel and Vacuum Hoses
  77
- Checking the Breather Hoses
  78
- Checking the Exhaust System
  78
- Adjusting the Rear Brake
  79
- Chassis
  79
- Checking the Brake Fluid Level
  79
- Checking the Front Brake Pads
  80
- Checking the Front Brake Hose
  81
- Checking the Rear Brake Shoes
  81
- Bleeding the Hydraulic Brake System
  82
- Checking and Adjusting the Steering Head
  83
- Checking the Front Fork
  85
- Checking the Tires
  85
- Checking and Tightening the Spokes
  88
- Checking the Wheels
  88
- Checking and Lubricating the Cables
  89
- Lubricating the Levers
  89
- Lubricating the Sidestand
  89
- Lubricating the Centerstand
  90
- Checking and Charging the Battery
  91
- Chk Adj
  91
- Electrical System
  91
- Checking the Fuse
  95
- Replacing the Headlight Bulb
  96
- Adjusting the Headlight Beam
  97
Chapter 4 Engine

99
- Eng
  99
- Carburetor
  103
- Covers
  103
- Engine Oil
  103
- Removing the Engine
  103
- Cable and Hose
  104
- Muffler
  104
- Engine Assembly
  105
- Rear Shock Absorber Assembly Bolt
  105
- Cable and Hose
  106
- Engine Assembly
  106
- Installing the Engine
  106
- Rear Shock Absorber Assembly Bolt
  106
- Muffler
  107
- Carburetor
  108
- Covers
  108
- Engine Oil
  108
- Cylinder Head
  109
- Removing the Cylinder Head
  110
- Checking the Cylinder Head
  113
- Checking the Timing Chain Guide
  114
- Checking the Timing Chain Tensioner
  114
- Installing the Cylinder Head
  114
- Camshaft
  119
- Removing the Rocker Arms and Camshaft
  120
- Checking the Camshafts
  121
- Checking the Rocker Arms and Rocker Arm Shafts
  122
- Checking the Camshaft Sprocket
  123
- Checking the Tappet Covers and Camshaft Sprocket Cover
  123
- Installing the Camshafts and Rocker Arms
  123
- Valves and Valve Springs
  125
- Removing the Valves
  126
- Checking the Valves and Valve Guides
  127
- Checking the Valve Seats
  129
- Checking the Valve Springs
  131
- Installing the Valves
  132
- Cylinder and Piston
  134
- Removing the Cylinder and Piston
  135
- Checking the Piston Rings
  137
- Checking the Piston Pin
  138
- Installing the Piston and Cylinder
  139
- Kickstarter
  141
- Disassembling the Kickstarter Shaft
  142
- Removing the Kickstarter
  142
- Checking the Kickstarter
  143
- Assembling the Kickstarter
  144
- Installing the Kickstarter
  144
- Belt Drive
  146
- V-Belt, Primary and Secondary Sheave
  146
- Removing the Secondary Sheave and V-Belt
  148
- Removing the Primary Sheave
  149
- Disassembling the Secondary Sheave
  150
- Checking the Clutch Housing
  151
- Checking the Secondary Sheave
  152
- Checking the V-Belt
  152
- Assembling the Primary Sheave
  153
- Assembling the Secondary Sheave
  155
- Installing the Belt Drive
  157
- Starter Clutch
  159
- Removing the Starter Clutch
  160
- Installing the Starter Clutch
  161
- A.C. Magneto
  163
- Removing the A.C. Magneto
  164
- Installing the A.C. Magneto
  165
- Oil Pump
  166
- Removing the Oil Pump
  167
- Checking the Oil Pump
  168
- Assembling the Oil Pump
  169
- Checking the Oil Strainer
  169
- Transmission
  171
- Checking the Transmission
  173
- Installing the Transmission
  173
- Crankshaft
  175
- Disassembling the Crankcase
  176
- Removing the Crankshaft Assembly
  177
- Checking the Crankshaft and Connecting Rod
  178
- Checking the Timing Chain and Timing Chain Guide
  178
- Checking the Bearings and Oil Seals
  179
- Checking the Crankcase
  179
- Assembling the Crankcase
  180
- Installing the Crankshaft
  180
Carb

183
- Carburetor
  185
- Removing the Carburetor
  186
- Checking the Carburetor
  188
- Assembling the Carburetor
  191
- Measuring and Adjusting the Fuel Level
  192
- Checking the Fuel Cock Operation
  193
- Installing the Carburetor
  193
- Fuel Tank
  195
- Removing the Fuel Tank
  195
- Installing the Fuel Tank
  196
- Air Filter Case
  197
- Installing the Air Filter Case
  197
- Removing the Air Filter Case
  197
Chas

199
- Front Wheel and Brake Disc
  201
- Removing the Front Wheel
  202
- Checking the Front Wheel
  203
- Checking the Brake Disc
  205
- Checking the Speedometer Gear Unit
  206
- Installing the Front Wheel
  207
- Rear Wheel and Brake
  209
- Removing the Rear Wheel and Rear Brake
  210
- Checking the Rear Wheel
  211
- Checking the Brake
  212
- Installing the Rear Wheel and Rear Brake
  213
- Front Brake
  215
- Front Brake Caliper
  215
- Replacing the Front Brake Pads
  216
- Disassembling the Front Brake Caliper
  218
- Checking the Front Brake Caliper
  219
- Front Brake Master Cylinder
  223
- Disassembling the Front Brake Master Cylinder
  224
- Checking the Front Brake Master Cylinder
  226
- Assembling and Installing the Front Brake Master Cylinder
  227
- Front Fork
  231
- Removing the Front Fork Legs
  232
- Disassembling the Front Fork Legs
  233
- Checking the Front Fork Legs
  234
- Assembling the Front Fork Legs
  235
- Installing the Front Fork Legs
  238
- Handlebar
  239
- Removing the Handlebar
  240
- Checking the Handlebar
  242
- Installing the Handlebar
  242
- Steering Head
  245
- Removing the Lower Bracket
  246
- Checking the Steering Head
  247
- Installing the Steering Head
  248
Elec

253
- Electrical Components
  255
- Electrical System
  255
- Checking Switch Continuity
  257
- Checking the Switches
  259
- Checking the Bulbs and Bulb Sockets
  261
- Types of Bulbs
  261
- Checking the Condition of the Bulb Sockets
  263
- Checking the Condition of the Bulbs
  263
- Circuit Diagram
  264
- Ignition System
  264
- Troubleshooting
  265
- Circuit Diagram
  269
- Electric Starting System
  269
- Starting Circuit Cut-Off System Operation
  270
- Troubleshooting
  271
- Starter Motor
  274
- Disassembling the Starter Motor
  275
- Removing the Starter Motor
  275
- Checking the Starter Motor
  276
- Assembling the Starter Motor
  278
- Installing the Starter Motor
  279
- Charging System
  280
- Circuit Diagram
  280
- Troubleshooting
  281
- Circuit Diagram
  283
- Lighting System
  283
- Troubleshooting
  284
- Checking the Lighting System
  286
- Circuit Diagram
  288
- Signaling System
  288
- Troubleshooting
  289
- Checking the Signaling System
  290
- Trbl Shtg
  297
- Electrical System
  299
- Troubleshooting
  299
- Compression System
  300
- Intake and Exhaust System
  301

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Yamaha Mio Service Manual

Yamaha Mio Service Manual (74 pages)

Brand: Yamaha | Category: Scooter | Size: 36.81 MB

Table of Contents

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