Yamaha Mio User manual

5TL-F8197-E0

MIO

SERVICE MANUAL

EAS00000

AL115

SERVICE MANUAL

First edition, July 2003

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!

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.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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 4is 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 6indicates 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.

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SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1to 8indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Carburetor

6Chassis

7Electrical system

8Troubleshooting

Symbols 9to Findicate the following.

9Serviceable with engine mounted

0Filling fluid

ALubricant

BSpecial tool

CTightening torque

DWear limit, clearance

EEngine speed

FElectrical data

Symbols Gto Lin the exploded diagrams

indicate the types of lubricants and lubrication

points.

GEngine oil

HGear oil

IMolybdenum-disulfide oil

JWheel-bearing grease

KLithium-soap-based grease

LMolybdenum-disulfide grease

Symbols Mto Nin the exploded diagrams

indicate the following.

MApply locking agent (LOCTITE®)

NReplace the part

GHI

JKL

GEN

INFO

SPEC

CHK

ADJ ENG

CARB CHAS

–+

ELEC TRBL

SHTG

EGM

BLS M

New

EASF0003

TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

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

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