Yamaha XN125 2000 Manuale utente

XN125 2000

XN150

5MF1-AE2

SERVICE MANUAL

EASM0000

XN125 / XN150

SERVICE MANUAL

2nd edition, April 2001

Any reproduction or unauthorized

use without the written

permission of MBK Industrie

is expressly prohibited.

EAS00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOMEALERT! YOUR SAFETY

IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the scooter operator, a bystander or a person checking or repairing the scooter.

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

to the scooter.

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

NOTE:

WARNING

CAUTION:

EASM0001

NOTICE

This manual was produced by the MBK Industrie primarily for use by Yamaha and MBK dealers 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 and MBK

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

MBK Industrie is continually striving to improve all of its models. Modifications and significant chan-

ges in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers and

will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

TECHNICAL DOCUMENTATION

MBK INDUSTRIE

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

햲The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter. Refer to "SYMBOLS".

햳Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s)

appears.

햴Sub-section titles appear in smaller print than the section title.

햵To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

햶Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates

a disassembly step.

햷Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS".

햸A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

햹Jobs requiring more information (such as special tools and technical data) are described

sequentially.

ENG ENG

EASM0025

CYLINDER AND PISTON

Removing the cylinder and piston Remove the parts in the order listed.

Cylinder head Refer to “CYLINDER HEAD” section.

1 Cylinder bolt 2

2 Timing chain guide (exhaust side) 1

3 Cylinder 1

4 Dowel pin 2

5 Cylinder gasket 1

6 Piston pin clip 2

7 Piston pin 1

8 Piston 1

9 Piston ring (top) 1

10 Piston ring (2nd) 1

11 Oil ring 1For installation, reverse the removal

procedure.

EAS00253

REMOVING THE CYLINDER AND PISTON

1. Remove:

• piston pin clip 햲

• piston pin 햳

• piston 햴

CAUTION:

Do not use a hammer to drive the piston pin

out.

NOTE:

• Before removing the piston pin clip, cover the

crankcase opening with a clean rag to prevent

thepistonpinclipfrom falling intothe crankcase.

• Before removing the piston pin, deburr the

piston pin clip’s groove and the piston’s pin

bore area. If both areas are deburred and the

piston pin is still difficult to remove, remove it

with the piston pin puller.

Piston pin puller

90890-01304

2. Remove:

• top ring

• 2nd ring

• oil ring

NOTE:

When removing a piston ring, open the end gap

with your fingers and lift the other side of the ring

over the piston crown.

EAS00255

CHECKING THE CYLINDER AND PISTON

1. Check:

• piston wall

• cylinder wall

Vertical scratches →Rebore or replace the

cylinder, and replace the piston and piston

rings as a set.

4 - 23 4 - 24

CYLINDER AND PISTON CYLINDER AND PISTON

Order Job/Part Q’ty Remarks

햲

햳

햴

FWD

910 11

T.R

12 Nm (1.2 m•kg)

햲

햹

햳햴햵

햶

햷

햸

COOL

GEN

INFO

ENG

SPEC

햲햳

햵햴

햶햷

햸햹

햺햻

햽햾

햿헀

헁헂

헅

쎻

헄헆

쎻

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 햲to 햺indicate the subject of each

chapter.

햲General information

햳Specifications

햴Periodic checks and adjustments

햵Engine

햶Cooling system

햷Carburetor

햸Chassis

햹Electrical system

햺Troubleshooting

Symbols 햻to 헃indicate the following.

햻Serviceable with engine mounted

햽Filling fluid

햾Lubricant

햿Special tool

헀Tightening torque

헁Wear limit, clearance

헂Engine speed

헃Electrical data

Symbols 헄to 쎻

in the exploded diagrams indicate

the types of lubricants and lubrication points.

헄Engine oil

헅Gear oil

헆Molybdenum disulfide oil

쎻

Wheel bearing grease

쎻

Lithium soap base grease

쎻

Molybdenum disulfide grease

Symbols 쎻

to 쎻

in the exploded diagrams

indicate the following.

쎻

Apply locking agent (LOCTITE®)

쎻

Use a new one

T.R

TRBL

SHTG

ELEC

CHAS

CARB

CHK

ADJ

헃

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETOR

CHASSIS

ELECTRICAL SYSTEM

TROUBLESHOOTING

TRBL

SHTG

GEN

INFO

SPEC

CHK

ADJ

ENG

CARB

ELEC

CHAS

COOL

EAS00010

TABLE OF CONTENTS

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

SCOOTER IDENTIFICATION ........................................................................1-1

VEHICLE IDENTIFICATION NUMBER ....................................................1-1

MODEL LABEL ........................................................................................1-1

FEATURES ................................................................................................... 1-2

OIL INDICATOR LIGHT ...........................................................................1-2

ODOMETER/TRIPMETER READING MODE ......................................... 1-2

BATTERY VOLTAGE/FUEL GAUGE ......................................................1-2

THE CLOCK .............................................................................................1-3

AUTO-CHOKE SYSTEM ......................................................................... 1-3

IMPORTANT INFORMATION ...................................................................... 1-4

PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ 1-4

REPLACEMENT PARTS ........................................................................ 1-4

GASKETS, OIL SEALS AND O-RINGS .................................................. 1-4

LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-5

BEARINGS AND OIL SEALS .................................................................. 1-5

CIRCLIPS ................................................................................................ 1-5

CHECKING THE CONNECTIONS ............................................................... 1-6

SPECIAL TOOLS .......................................................................................... 1-7

GEN

INFO

GEN

INFO

SCOOTER IDENTIFICATION

EAS00015

GENERAL INFORMATION

SCOOTER IDENTIFICATION

EASM0002

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 햲is stamped

into the frame.

EASM0003

MODEL LABEL

The model label 햲is affixed under the seat.

This information will be needed to order spare

parts.

1-1

ZAUM0071

햲

ZAUM0072

햲

GEN

INFO

1-2

FEATURES

EASM0004

FEATURES

OIL INDICATOR LIGHT

• FUNCTION

Pulses (travel distance signals) from the speedometer are counted and cause the oil indicator light

to come on at 500 km for the first time and thereafter every 3,000 km. In this way, the light indicates

the time for oil change.

• RESETTING PROCEDURE

To reset the oil change indicator light

1) Press the “TRIP” button while turning the key to “ON”.

2) Release the button and the oil change indicator light will go off.

NOTE:

To reset the oil change indicator light before the periodic oil change interval has been reached, follow

the above procedure.

ODOMETER/TRIPMETER READING MODE

The odometer and tripmeter can be set to count in either miles or kilometers according to the following

procedure.

1) Turn the key to “ON”.

2) Press the “TRIP” button until the current mode appears in the dispaly:

“CONT” (continental) for kilometer mode and “EnGL” (English) for the mile mode.

3) Press the “TRIP” button to switch mode.

4) Press the “TRIP” button for two seconds to confirm the setting.

NOTE:

• The odometer/tripmeter reading mode can be changed any number of times while the odometer

reading is below 10, but it cannot changed anymore after the reading has reached 10.

• Switching betweenthe mile andthekilometer mode doesnot change orconvertthe current odometer/

tripmeter reading.

BATTERY VOLTAGE/FUEL GAUGE

When the key is turned to “OFF”, the voltage/fuel gauge indicates the battery voltage.

NOTE:

If the battery voltage drops to 10V, refer to “CHECKING THE BATTERY” section in chapter 3.

When the key is turned to “ON”, the voltage/fuel gauge indicates the amount of fuel in the fuel tank

after indicating the battery voltage for two seconds.

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