Yamaha Mio AL115 Service Manual PDF – DOWNLOAD

Description

Yamaha Mio AL115 Service Manual Complete Repair & Maintenance Guide  – PDF DOWNLOAD

DESCRIPTION

The Yamaha Mio AL115 Service Manual (5TL-F8197-E0) is the official factory repair guide used by Yamaha dealers and certified mechanics. This 298-page manual provides in-depth technical procedures, precise specifications, troubleshooting charts, exploded diagrams, and complete service instructions for the Yamaha Mio 113.7cc scooter.
Based on the original 2003 first edition by Yamaha Motor Co., Ltd.

📘 Manual Coverage

1. General Information

(From Chapter 1)

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• Vehicle Identification Number (VIN) location

• Engine serial number

• Safety precautions & service warnings

• Proper disassembly and inspection methods

• Replacement parts, gasket rules, O-ring servicing

• Bearings, circlips, washer and fastener guidelines

• Complete special tools list with diagrams

2. Specifications

(Chapter 2 – GEN, ENGINE, CHASSIS, ELECTRICAL)

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General Specs:

• Model: AL115

• Dimensions, weight, wheelbase, ground clearance

• Fuel tank capacity: 3.7 L

• Max load: 168 kg

Engine Specs:

• 4-stroke SOHC 113.7 cc engine

• Compression ratio: 8.8:1

• Idle speed: 1400–1600 rpm

• Oil capacity: 0.8 L (change), 0.9 L (total)

• Carburetor: KEIHIN NCV24

Chassis Specs:

• Steel underbone frame

• Front brake: Single disc

• Rear brake: Drum

• Tire sizes: Front 70/90-14, Rear 80/90-14

• Steering, suspension, wheel runout limits

Electrical Specs:

• 12V system

• CDI ignition

• Magneto output: 14V / 100W @ 5000 rpm

• Bulbs, charging, coils, relays, fuse ratings

3. Periodic Checks & Adjustments

(Chapter 3)

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• Full maintenance chart

• Valve clearance adjustment

• Idle speed adjustment

• Throttle free-play

• Spark plug check

• Compression pressure test

• Engine oil & transmission oil change

• V-belt and air filter service

• Fuel & vacuum hose inspection

• Exhaust system check

• Brake system adjustments & bleeding procedures

4. Engine Overhaul Procedures

• Complete disassembly and assembly steps

• Cylinder head, piston, rings, valves, camshaft data

• Timing chain and rocker arm service

• Crankshaft inspection

• Clutch, secondary sheave, transmission service

• Torque tables for all engine fasteners

5. Carburetor Service

• NCV24 disassembly

• Jetting specifications

• Fuel level gauge usage

• Throttle cable free play

• Air/fuel adjustments

6. Chassis Service

• Suspension setups

• Front & rear brake repair

• Wheel inspection and runout limits

• Steering head adjustment

• Frame component tightening torques

7. Electrical System

• Full wiring schematics

• CDI, ignition coil, stator tests

• Starter system diagnostics

• Battery, relays, fuses

• Horn, lighting, charging system diagrams

8. Troubleshooting

• Engine no-start

• Poor acceleration

• Idling problems

• Electrical malfunctions

• Fuel/air system issues

• Brake performance problems

🧩 FILE DETAILS