2004 – 2010 YAMAHA VINO 125 YJ125 Scooter Service Manual + Owner’s Manual Ultimate Set – PDF DOWNLOAD

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2004 – 2010 YAMAHA VINO 125 YJ125 Scooter Service Manual + Owner’s Manual Ultimate Set

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LANGUAGE:ENGLISH
PAGES:377
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2004 – 2010 YAMAHA VINO 125 YJ125 SCOOTER SERVICE MANUAL + OWNER’S MANUAL ULTIMATE SET – PDF DOWNLOAD:

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2004 – 2010 YAMAHA VINO 125 YJ125 Scooter Service Manual + Owner’s Manual Ultimate Set

FOREWORD:

This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha 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 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. Yamaha Motor Taiwan 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 dealers and will appear in future editions of this manual where applicable.

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.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”.
2 Each 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.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

TABLE OF CONTENTS:

2004 – 2010 YAMAHA VINO 125 YJ125 Scooter Service Manual + Owner’s Manual Ultimate Set

SCOOTER IDENTIFICATION 1-1
VEHICLE IDENTIFICATION NUMBER 1-1
MODEL LABEL 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
GENERAL SPECIFICATIONS 2-1
ENGINE SPECIFICATIONS 2-2
CHASSIS SPECIFICATIONS 2-11
ELECTRICAL SPECIFICATIONS 2-14
CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS
2-18
TIGHTENING TORQUES 2-19
ENGINE TIGHTENING TORQUES 2-19
CHASSIS TIGHTENING TORQUES 2-21
LUBRICATION POINTS AND LUBRICANT TYPES 2-22
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2-22
CHASSIS LUBRICATION POINTS AND LUBRICATION TYPES 2-24
OIL FLOW DIAGRAMS 2-25
CABLE ROUTING 2-27
INTRODUCTION 3-1
PERIODIC MAINTENANCE AND MINOR REPAIR 3-2
Periodic maintenance chart for the emission control system 3-2
General maintenance and lubrication chart 3-3
COVER AND PANEL 3-4
SEAT AND SIDE COVERS 3-4
FOOTREST BOARD AND FOOTREST BOARD SIDE COVER
MOLE 3-5
LEG SHIELD 1 , 2 3-6
ENGINE 3-7
ADJUSTING THE VALVE CLEARANCE 3-7
ADJUSTING THE ENGINE IDLING SPEED 3-10
CHECKING THE EXHAUST GAS AT IDLE 3-11
ADJUSTING THE THROTTLE CABLE FREE PLAY 3-13
CHECKING THE SPARK PLUG 3-15
CHECKING THE IGNITION TIMING 3-16
MEASURING THE COMPRESSION PRESSURE 3-17
CHECKING THE ENGINE OIL LEVEL 3-20
CLEANING THE ENGINE OIL FILTER ELEMENT AND ENGINE OIL
STRAINER 3-21
CHANGING THE TRANSMISSION OIL 3-24
MEASURING THE ENGINE OIL PRESSURE 3-25
CLEANING THE AIR FILTER ELEMENT 3-26
CLEANING THE V-BELT CASE AIR FILTER ELEMENT 3-26
CHECKING THE CARBURETOR JOINT AND INTAKE
MANIFOLD 3-28
CHECKING THE FUEL AND VACUUM HOSES 3-29
CHECKING THE CRANKCASE BREATHER HOSE 3-29
CHECKING THE EXHAUST SYSTEM 3-30
CHASSIS 3-31
ADJUSTING THE FRONT BRAKE 3-31
ADJUSTING THE REAR BRAKE 3-31
CHECKING THE BRAKE FLUID LEVEL 3-32
CHECKING THE FRONT BRAKE PADS 3-33
CHECKING THE REAR BRAKE SHOES 3-33
CHECKING THE FRONT BRAKE HOSE 3-33
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISC 4-1
FRONT WHEEL 4-2
REMOVING THE FRONT WHEEL 4-3
CHECKING THE FRONT WHEEL 4-4
CHECKING THE BRAKE DISC 4-5
ASSEMBLING THE FRONT WHEEL 4-7
INSTALLING THE FRONT WHEEL 4-8
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-9
REAR WHEEL AND REAR BRAKE 4-11
CHECKING THE REAR WHEEL 4-12
CHECKING THE BRAKE 4-13
ASSEMBLING THE BRAKE SHOE PLATE 4-14
ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14
FRONT BRAKE 4-15
FRONT BRAKE PADS 4-15
REPLACING THE FRONT BRAKE PADS 4-16
FRONT BRAKE MASTER CYLINDER 4-19
DISASSEMBING THE FRONT BRAKE MASTER CYLINDER 4-20
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4-21
CHECKING THE FRONT BRAKE MASTER CYLINDER 4-21
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER 4-23
FRONT BRAKE CALIPER 4-26
DISASSEMBING THE FRONT BRAKE CALIPER 4-27
DISASSEMBLING THE FRONT BRAKE CALIPER 4-28
CHECKING THE FRONT BRAKE CALIPER 4-29
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPER 4-30
FRONT FORK 4-33
DISASSEMBING THE FRONT FORK LEGS 4-34
REMOVING THE FRONT FORK LEGS 4-35
DISASSEMBLING THE FRONT FORK LEGS 4-36
CHECKING THE FRONT FORK LEGS 4-38
ASSEMBLING THE FRONT FORK LEGS 4-39
INSTALLING THE FRONT FORK LEGS 4-42
CHAS
4-56
HANDLEBAR 4-43
REMOVING THE HANDLEBAR 4-44
CHECKING THE HANDLEBAR 4-44
INSTALLING THE HANDLEBAR 4-45
STEERING HEAD 4-47
LOWER FENDER COVER AND HANDLEBAR LOWER
HOLDER 4-47
LOWER BRACKET 4-48
REMOVING THE LOWER BRACKET 4-50
CHECKING THE STEERING HEAD 4-51
INSTALLING THE STEERING HEAD 4-52
REAR SHOCK ABSORBER 4-53
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-53
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-53
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-54
ENGINE 5-1
LEADS, HOSES AND REAR BRAKE 5-1
INSTALLING THE ENGINE 5-3
MAINFOLD, AIR FILTER AND MUFFLER ASSEMBLY 5-4
CYLINDER HEAD 5-5
CYLINDER HEAD 5-5
REMOVING THE CYLINDER HEAD 5-7
CHECKING THE CYLINDER HEAD 5-9
INSTALLING THE CYLINDER HEAD 5-10
THE ROCKER ARMS AND CAMSHAFT 5-13
THE ROCKER ARMS AND CAMSHAFT 5-13
REMOVING THE ROCKER ARMS AND CAMSHAFT 5-14
CHECKING THE ROCKER ARMS AND ROCKER ARM
SHAFTS 5-15
CHECKING THE CAMSHAFT 5-16
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND
TIMING CHAIN GUIDES 5-17
CHECKING THE TIMING CHAIN TENSIONER 5-17
INSTALLING THE CAMSHAFT AND ROCKER ARMS 5-18
VALVES AND VALVE SPRINGS 5-19
VALVES AND VALVE SPRINGS 5-19
REMOVING THE VALVES 5-20
CHECKING THE VALVES AND VALVE GUIDES 5-21
CHECKING THE VALVE SEATS 5-23
CHECKING THE VALVE SPRINGS 5-25
INSTALLING THE VALVES 5-26
CYLINDER AND PISTON 5-28
CYLINDER AND PISTON 5-28
REMOVING THE CYLINDER AND PISTON 5-29
CHECKING THE CYLINDER AND PISTON 5-30
CHECKING THE PISTON RINGS 5-31
CHECKING THE PISTON PIN 5-32
CHECKING THE TIMING CHAIN GUIDE 5-33
INSTALLING THE PISTON AND CYLINDER 5-33
ENG
5-66
BELT DRIVE 5-35
CRANKCASE COVER 5-35
KICKSTARTER 5-36
INSTALLING THE KICKSTARTER 5-37
V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE 5-38
DISASSEMBLING THE SECONDARY SHEAVE 5-39
REMOVING THE PRIMARY SHEAVE 5-40
REMOVING THE SECONDARY SHEAVE AND V-BELT 5-40
DISASSEMBLING THE SECONDARY SHEAVE 5-41
CHECKING THE CLUTCH SHOE 5-41
CHECKING THE V-BELT 5-42
CHECKING THE PRIMARY SHEAVE 5-42
CHECKING THE PRIMARY SHEAVE WEIGHTS 5-42
CHECKING THE SLIDER 5-43
CHECKING THE SECONDARY SHEAVE 5-43
ASSEMBLING THE PRIMARY SHEAVE 5-43
ASSEMBLING THE SECONDARY SHEAVE 5-45
INSTALLING THE BELT DRIVE 5-46
STARTER CLUTCH AND STARTER MOTOR 5-48
STARTER CLUTCH AND STARTER MOTOR 5-48
CHECKING THE STARTER WHEEL GEAR 5-49
CDI MAGNETO 5-50
CDI MAGNETO 5-50
REMOVING THE CDI MAGNETO 5-51
INSTALLING THE CDI MAGNETO 5-52
OIL PUMP 5-53
OIL PUMP 5-53
CHECKING THE OIL PUMP 5-54
INSTALLING THE OIL PUMP 5-55
TRANSMISSION 5-56
TRANSMISSION 5-56
CHECKING THE TRANSMISSION 5-57
CRANKCASE AND CRANKSHAFT 5-58
CRANKCASE AND CRANKSHAFT 5-58
DISASSEMBLING THE CRANKCASE 5-60
REMOVING THE CRANKSHAFT ASSEMBLY 5-61
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 5-61
CHECKING THE CRANKSHAFT AND CONNECTING ROD 5-62
INSTALLING THE CRANKSHAFT 5-63
ASSEMBLING THE CRANKCASE 5-64
CARBURETOR 6-1
CHECKING THE CARBURETOR 6-3
ASSEMBLING THE CARBURETOR 6-5
INSTALLING THE CARBURETOR 6-6
MEASURING AND ADJUSTING THE FUEL LEVEL 6-7
CHECKING THE FUEL COCK 6-8
CHECKING THE AUTOCHOKE UNIT 6-8
AIR INDUCTION SYSTEM 6-10
CHECKING THE AIR INDUCTION SYSTEM 6-11
ELECTRICAL COMPONENTS 7-1
WIRING DIAGRAM 7-2
CHECKING SWITCH CONTINUITY 7-4
CHECKING THE SWITCHES 7-5
CHECKING THE BULBS AND BULB SOCKETS 7-6
TYPES OF BULBS 7-6
CHECKING THE CONDITION OF THE BULBS 7-7
CHECKING THE CONDITION OF THE BULB SOCKETS 7-8
IGNITION SYSTEM 7-9
CIRCUIT DIAGRAM 7-9
TROUBLESHOOTING 7-10
ELECTRIC STARTING SYSTEM 7-14
CIRCUIT DIAGRAM 7-14
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 7-15
TROUBLESHOOTING 7-16
STARTER MOTOR 7-20
CHECKING THE STARTER MOTOR 7-21
ASSEMBLING THE STARTER MOTOR 7-23
CHARGING SYSTEM 7-24
CIRCUIT DIAGRAM 7-24
TROUBLESHOOTING 7-25
LIGHTING SYSTEM 7-27
CIRCUIT DIAGRAM 7-27
TROUBLESHOOTING 7-28
CHECKING THE LIGHTING SYSTEM 7-29
SIGNALING SYSTEM 7-33
CIRCUIT DIAGRAM 7-33
TROUBLESHOOTING 7-34
CHECKING THE SIGNALING SYSTEM 7-35
CRABURETOR HEATING SYSTEM 7-41
CIRCUIT DIAGRAM 7-41
TROUBLESHOOTING 7-42
AUTO CHOKE SYSTEM 7-45
CIRCUIT DIAGRAM 7-45
TROUBLESHOOTING 7-46
STARTING FAILURES 8-1
ENGINE 8-1
FUEL SYSTEM 8-1
ELECTRICAL SYSTEMS 8-1
STARTING FAILURES/INCORRECT ENGINE IDLING SPEED 8-2
INCORRECT ENGINE IDLING SPEED 8-2
ENGINE 8-2
FUEL SYSTEM 8-2
ELECTRICAL SYSTEMS 8-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY
CLUTCH 8-3
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 8-3
ENGINE 8-3
FUEL SYSTEM 8-3
FAULTY CLUTCH 8-3
ENGINE OPERATES BUT SCOOTER WILL NOT MOVE 8-3
CLUTCH SLIPS 8-3
POOR STARTING PERFORMANCE 8-3
OVERHEATING/POOR BRAKING PERFORMANCE/FAULTY FRONT
FORK LEGS 8-4
POOR SPEED PERFORMANCE 8-4
OVERHEATING 8-4
ENGINE 8-4
FUEL SYSTEM 8-4
CHASSIS 8-4
ELECTRICAL SYSTEMS 8-4
POOR BRAKING PERFORMANCE 8-4
FAULTY FRONT FORK LEGS 8-4
LEAKING OIL 8-4
MALFUNCTION 8-4

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.