Yamaha MBK YQ100 Service Manual

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Summary of Contents

Page 1 - 5ME1-AE1

YQ1005ME1-AE1'00SERVICEMANUAL

Page 2

GENINFO1-2IMPORTANT INFORMATIONEAS00020IMPORTANT INFORMATIONPREPARATION FOR REMOVAL ANDDISASSEMBLY1.Before removal and disassembly, remove alldirt, mu

Page 3 - CAUTION:

ENG4-20V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE4. Attach :• Clutch spring holder Clutch spring holder :90890-013375. Remove :• Clutch securing nut

Page 4 - HOW TO USE THIS MANUAL

ENG4-212. Measure :• Clutch shoe thickness aOut of specification→Replace.Clutch shoe thickness :4 mm< Wear limit> :2.5 mmV-BELT INSPECTION1. Ins

Page 5 - EAS00009

ENG4-22V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVEPRIMARY SHEAVE INSPECTION1. Inspect :• Primary sliding sheave • Primary fixed sheave Wear/Cracks/Sc

Page 6 - EAS00011

ENG4-23SECONDARY SHEAVE INSPECTION1. Inspect :• Secondary fixed sheave • Secondary sliding sheave Scratch/Crack/Damage→Replace as a set.• Oil seal 

Page 7

ENG4-24V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVESECONDARY SHEAVE INSTALLATIONWhen assembling the secondary sheave, re-verse the disassembly procedure

Page 8 - GENERAL INFORMATION

ENG4-25V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE9. Tighten :• Nut (secondary sheave)Use sheave holder Sheave holder :90890-01701PRIMARY SHEAVE INST

Page 9

ENG4-26V-BELT, CLUTCH ANDSECONDARY/PRIMARY SHEAVE6. Install :• Shim • Primary fixed sheave • Crow washer • One-way clutch • Conical spring washer

Page 10 - IMPORTANT INFORMATION

ENG4-27Order1234Q’ty1111STARTER CLUTCH AND STARTER MOTORSTARTER CLUTCH AND STARTER MOTORRemarksRemove the parts in order.Refer to “COVERS” in chapter

Page 11

ENG4-28Order5678910Job name/Part nameStarter clutchPlain washerStarter wheel gearCollarStarter motorStarter motor connectorQ’ty121121RemarksReverse th

Page 12 - CHECKING THE CONNECTIONS

ENG4-29STARTER CLUTCH AND GEARS1. Inspect :• Starter clutchPush the dowel pin to arrow direction.Unsmooth operation→Replace starter clutchassembly.2.

Page 13

GENINFO1-3IMPORTANT INFORMATIONCAUTION:EAS00023LOCK WASHERS / PLATES AND COTTERPINS1.After removal, replace all lock washers / plates and cott

Page 14 - EAS00027

ENG4-30Order12345678Q’ty11/1112111C.D.I. MAGNETOC.D.I. MAGNETORemarksRemove the parts in order.Refer to “BATTERY COVER ANDLOWER COVER” section in chap

Page 15

ENG4-31C.D.I. MAGNETO REMOVAL1. Remove :• Nut  (rotor)• Plain washerNOTE:Hold the rotor to loosen the nut by the flywheelholding tool .Flywheel hold

Page 16

ENG4-32Order12345678Q’ty11111111AUTOLUBE PUMPAUTOLUBE PUMPRemarksRemove the parts in order.Refer to “C.D.I. MAGNETO” section.Refer to “AUTOLUBE PUMP I

Page 17 - SPECIFICATIONS

ENG4-33AUTOLUBE PUMPAUTOLUBE PUMP INSTALLATIONAfter installing autolube pump, it must bebleeded.1. Install :• Pin • Pump drive gear • Circlip 2. Ap

Page 18

ENG4-34Order1234567Q’ty1121111TRANSMISSIONTRANSMISSIONRemarksRemove the parts in order.Refer to “REAR WHEEL AND REARBRAKE ” section in chapter 6.Refer

Page 19 - GENERAL SPECIFICATIONS

ENG4-35TRANSMISSIONTRANSMISSION18Nm(1.8kg.m)T R..12Nm(1.2kg.m)T R..12345678910TRANSMISSIONBOrder8910Job name/Part nameCirclipMain axleDrive axleQ’ty11

Page 20

ENG4-36EAS00423CHECKING THE TRANSMISSION1.Measure:•main axle runout (with a centering device and dial gauge)Out of specification → Replace the main a

Page 21 - MAINTENANCE SPECIFICATIONS

ENG4-379Nm(0.9kg.m)T R..12Nm(1.2kg.m)T R..34126578109Order Q’tyCRANKCASE AND REED VALVECRANKCASE AND REED VALVECRANKCASE AND REED VALVERemarksRemove t

Page 22

ENG4-389Nm(0.9kg.m)T R..12Nm(1.2kg.m)T R..34126578109CRANKCASE AND REED VALVECRANKCASE AND REED VALVECRANKCASE AND REED VALVEBOrder12345678910Job name

Page 23

ENG4-392. Attach :• Crankcase separating tool Crankcase separating tool :90890-01135NOTE:Fully tighten the tool holding bolts, but makesure the tool

Page 24 - TIGHTENING TORQUES

GENINFO1-4CHECKING THE CONNECTIONS+-+-EAS00026CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1.Disc

Page 25

ENG4-40CRANKCASE (RIGHT) INSTALLATION1. Install :• Dowel pins • Engine mount spacer 2. Apply :• Yamaha Bond No.1215 To the mating surfaces of both

Page 26

ENG4-41CRANKCASE AND REED VALVE8. Install :• Gasket• Reed valve  11 Nm(1.1 kg.m)T R..

Page 27

ENG4-42Order1234Q’ty1221CRANKSHAFTRemarksRemove the parts in order.Refer to “CRANKCASE AND REEDVALVE” section.Reverse the removal procedure for insta

Page 28

ENG4-43CRANKSHAFTCRANKSHAFT REMOVAL1. Attach :• Crankcase separating tool Crankcase separating tool :90890-011352. Remove :• Crankshaft CRANKSHAFT I

Page 29

ENG4-44CRANKSHAFT INSTALLATION1. Attach :• Crankshaft Installing ToolCrankshaft installing tool:90890-0127490890-0127590890-0127790890-012882. Insta

Page 30

5CARB

Page 31 - GENERAL TIGHTENING TORQUE

CARBCHAPTER 5.CARBURETORCARBURETOR...5-1CARBURETOR ...

Page 32 - EAS00031

CARB5-1CARBURETOROrderJob/Part Q'tyRemoving the carburetorAir filter box1 Fuel hose 12 Vacuum hose 13 Oil delivery hose 14 Choke cable 15 Air fil

Page 33 - EAS00032

CARB5-2CARBURETORCarburetor disassemblyQ Carburetor top 1W Gasket 1E Throttle valve spring 1R Needle set 1T Throttle valve 1Y Starter retaining plate

Page 34 - EAS00035

CARB5-3w Float chamber 1e Float chamber gasket 1r Float pin 1t Float / Needle valve 1/1y Main jet 1u Main nozzle 1i Pilot jet 1o Carburetor body 1Orde

Page 35

GENINFO1-5HOW TO USE THE CONVERSION TABLEHOW TO USE THE CONVERSION TABLEAll specification data in this manual are listed in SI and METRIC UNITS.Use th

Page 36

CARB5-4CARBURETOREAS00485CHECKING THE CARBURETOR1.Check :•carburetor body 햲•float chamber•jet housing•fuel passagesDurt/Obstruction → CleanCracks/dama

Page 37

CARB5-5322018햲햳햳햴햴햵CARBURETOR6.Check :•Throttle valve free movementUnsmooth/Stickiness → Replace.Insert the throttle valve 햲 into the carburetorbody 햳

Page 38

CARB5-6CARBURETOR2.Install :•throttle valve 햲•starter plungerNOTE:Align the groove 햳 of the throttle valve with theprojection 햴 of the carburetor.3.In

Page 39

CARB5-7352001햲322031햲FUEL COCKFUEL COCKINSPECTING THE FUEL COCK1.Stop the engine.2.Remove:• Side coversRefer to "COVERS" in Chapter 3.3.Insp

Page 40

CARB5-8Removing the reed valveCarburetor1 Carburetor joint 12 Reed valve assembly 1OrderJob/Part Q'tyRemarksREED VALVEREED VALVEFor installation

Page 41

CARB5-9REED VALVEYP600051CHECKING THE REED VALVE1.Inspect :• Caburetor jointDamage/Cracks → Replace.• Reed valveFatigue/Cracks → Replace.*************

Page 42

6CHAS

Page 43 - CHAPTER 3

CHASCHAPTER 6.CHASSISFRONT WHEEL AND BRAKE DISC...6-1FRONT WHEEL AND BARKE DISC ...

Page 44 - Every 12,000 km

CHASFRONT FORK...6-30REMOVING THE FRONT FORK LEGS ...

Page 45 - Every 20,000 km

CHAS6-1FRONT WHEEL AND BRAKE DISCOrderRemoving the front wheel and brakediscI Disconnect:1 Speedometer cable 1II Remove:2 Front brake caliper 13 Wheel

Page 46

GENINFO1-6SPECIAL TOOLSCrankshaft installer pot Crankshaft installer bolt Adapter Spacer These tools are used to install the crank-shaft.Flywh

Page 47

CHAS6-2FRONT WHEEL AND BRAKE DISCOrderDisassembling the front wheelI Remove:1 Oil seal 12 Bearing 23 Collar 1Remove the parts in the order listed.Refe

Page 48

CHAS6-3FRONT WHEEL AND BRAKE DISCEAS00520REMOVING THE FRONT WHEEL1.Stand the motorcycle on a level surface.Securely support the motorcycle so that t

Page 49

CHAS6-4FRONT WHEEL AND BRAKE DISCa.Clean the outside of the front wheel hub.b.Remove the oil seal  with a flat-headscrewdriver.NOTE:To prevent damagi

Page 50 - 3 Nm (0,3m.kg)

CHAS6-5FRONT WHEEL AND BRAKE DISC4.Check:• Wheel bearingsFront wheel turns roughly or is loose → Replacethe wheel bearings.• Oil sealsDamage/wear → Re

Page 51

CHAS6-6FRONT WHEEL AND BRAKE DISCEAS00528CHECKING THE BRAKE DISC1.Check:• Brake discDamage/galling → Replace.2.Measure:• Brake disc deflectionOut of s

Page 52 - 4 Nm (0,4 m.kg)

CHAS6-7FRONT WHEEL AND BRAKE DISCBrake disc bolt23 Nm (2.3 m • kg)d.Measure the brake disc deflection.e.If out of specification, repeat the adjustment

Page 53

CHAS6-8EAS00542*INSTALLING THE FRONT WHEEL1.Lubricate:• Wheel axle• Wheel bearings• Oil seal lips• Speedometer drive gear• Speedometer driven gearReco

Page 54 - 322025(b)

CHAS6-9EAS00548ADJUSTING THE FRONT WHEEL STATICBALANCENOTE:• After replacing the tire, wheel or both, the frontwheel static balance should be adjusted

Page 55 - EAS00058

CHAS6-103.Adjust:• Front wheel static balancea.Install a balancing weight  onto the rimexactly opposite the heavy spot “X”.NOTE:Start with the lighte

Page 56 - CHECKING THE SPARK PLUG

CHAS6-11REAR WHEEL AND BRAKEEAS00555REAR WHEEL AND BRAKEOrderRemoving the rear wheel andthe rear brakeLower coverExhaust pipeI Remove:1 Rear axle nut

Page 57

GENINFO1-7SPECIAL TOOLSTool N° Tool name/usage IllustrationRing nut wrench Steering nut wrench These tools are used to loosen and tightenthe steerin

Page 58 - CHECKING THE ENGINE OIL LEVEL

CHAS6-12REAR WHEEL AND BRAKEOrderQ'tyJob/PartRemarks8 Pin 19 Camshaft lever 110 Wear indicator 111 Brake camshaft 1For installation, reverse the

Page 59 - AUTOLUBE PUMP AIR BLEEDING

CHAS6-13346007@REAR WHEEL AND BRAKEEAS00565CHECKING THE REAR WHEEL1.Check:• Wheel axle• Rear wheelRefer to "FRONT WHEEL".2.Check:• Tire• R

Page 60 - AUTOLUBE PUMP AIR BLEEDING/

CHAS6-14346008aREAR WHEEL AND BRAKEINSTALLING THE REAR BRAKEReverse the removal procedure.Note the following points.1.Install:• Brake camshaft NOTE:A

Page 61

CHAS6-15INSTALLING THE REAR WHEELReverse the removal procedure.Note the following points.1.Clean:• Rear wheel axle2.Install:• Rear wheel• Plain washer

Page 62 - ADJUSTING THE REAR BRAKE

CHAS6-16FRONT BRAKEEAS00576FRONT BRAKEFRONT BRAKE PADSOrderRemoving the front brake padsI Remove:1 Plastic cap 12 Retaining clip 13 Retaining pin 14 P

Page 63 - EAS00116

CHAS6-17FRONT BRAKERecommanded brake component replacementschedule:Brake pads If necessaryBrake hose Every two yearsBrake fluidEvery two years or when

Page 64 - CHECKING THE BRAKE SHOES/

CHAS6-18@BRAKE PADS REPLACEMENTNOTE:It is not necessary to disassemble the brakecaliper and brake hose to replace the brakepads.1.Remove:• Brake padsN

Page 65 - WARNING

CHAS6-19OrderRemoving the front brake mastercylinderDrain the brake fluidHandlebar coversI Remove:1 Brake switch 12 Brake lever 13 Union bolt 14 Coppe

Page 66

CHAS6-20FRONT BRAKEEAS00585OrderDisassembling the master cylinderI Remove:Q Master cylinder cap 1W Diaphragm 1II Remove:E Dust boot 1R Actuator 1T Act

Page 67 - CHECKING THE FRONT FORK

CHAS6-21EAS00588DISASSEMBLING THE FRONT BRAKEMASTER CYLINDERNOTE:• Before disassembling the front brake mastercylinder, drain the brake fluid from the

Page 69

CHAS6-22FRONT BRAKEEAS00596ASSEMBLING AND INSTALLING THEFRONT BRAKE MASTER CYLINDER• Before installation, all internal brakecomponents should be clean

Page 70 - CHECKING THE WHEELS/

CHAS6-23FRONT BRAKE4.Fill:• brake master cylinder reservoir(with the specified amount of the recommendedbrake fluid)Recommended brake fluidDOT #3 or D

Page 71 - LUBRICATING THE CENTERSTAND/

CHAS6-24FRONT BRAKEOrderRemoving the front brake caliperDrain the brake fluidI Remove:1 Union bolt 12 Copper washer 13 Brake hose 14 Copper washer 1II

Page 72 - ELECTRICAL SYSTEM

CHAS6-25FRONT BRAKEEAS00614OrderRemove the parts in the order listed.Refer to "REMOVING THE FRONTBRAKE PADS".Refer to "DISASSEMBLING TH

Page 73

CHAS6-26FRONT BRAKEEAS00620DISASSEMBLING THE FRONT BRAKECALIPERNOTE:Before disassembling the brake caliper, drainthe brake fluid from the entire brake

Page 74

CHAS6-27FRONT BRAKEEAS00631CHECKING THE FRONT BRAKE CALIPERRecommanded brake component replacementschedule:Brake pads If necessaryBrake hose Every two

Page 75 - CHECKING THE FUSE

CHAS6-28FRONT BRAKEEAS00635INSTALLING THE FRONT BRAKE CALIPERBefore installation, all internal brakecomponents should be cleaned andlubricated with cl

Page 76 - REPLACING THE HEADLIGHT BULB

CHAS6-294.Fill:• brake master cylinder reservoir(with the specified amount of the recommendedbrake fluid)Recommended brake fluidDOT #3 or DOT #4• Use

Page 77 - ADJUSTING THE HEADLIGHT BEAM

CHAS6-30EAS00646FRONT FORKFRONT FORKOrderRemove the parts in the order listed.Refer to "FRONT WHEEL AND BRAKEDISC".Refer to "REMOVING T

Page 78

CHAS6-31FRONT FORKOrderRemove the parts in the order listed.Refer to "ASSEMBLING THE FRONTFORK LEGS".For installation, reverse the removal p

Page 79 - OVERHAULING THE ENGINE

SPECCHAPTER 2.SPECIFICATIONSGENERAL SPECIFICATIONS ...2-1MAINTENANCE SPECIFICATIONS

Page 80

CHAS6-32FRONT FORKWARNING REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1.Stand the scooter on a level sur

Page 81 - OVERHAULING THE ENGINE

CHAS6-33FRONT FORK4.Remove:• damper rod assembly boltNOTE:While holding the damper rod assembly with thedamper rod holder  and T-handle , loosenthe

Page 82

CHAS6-34FRONT FORK3.Check:• damper rod Damage/wear → Replace.Obstruction → Blow out all of the oil passageswith compressed air.• oil flow stopper Da

Page 83

CHAS6-35FRONT FORKDamper rod holder90890-01294T-handle90890-013264.Install:• oil seal (with the fork seal driver weight  and forkseal driver attach

Page 84 - EAS00192

CHAS6-36FRONT FORKNOTE:• While filling the front fork leg, keep it upright.• After filling, slowly pump the front fork leg upand down to distribute th

Page 85

CHAS6-37HANDLEBARHANDLEBAROrderRemove the parts in the order listed.Refer to "COVERS" in Chapter 3.Refer to "MASTER CYLINDER".Refe

Page 86 - EAS00222

CHAS6-38HANDLEBAROrderRefer to "INSTALLING THE HANDLE-BAR".For installation, reverse the removal pro-cedure.Q'tyJob/PartRemarks6 Handle

Page 87

CHAS6-39EAS00666REMOVING THE HANDLEBAR1.Stand the scooter on a level surface.Securely support the scooter so that there isno danger of it falling over

Page 88

CHAS6-40EAS00673INSTALLING THE HANDLEBAR1.Stand the scooter on a level surface.Securely support the scooter so that there isno danger of it falling ov

Page 89 - 52.10 mm

CHAS6-41HANDLEBAR7.Install:• right handlebar switchMake sure the throttle grip operates smoothly.NOTE:Align the projection on the right handlebar swit

Page 90

SPEC2-1GENERAL SPECIFICATIONSSPECIFICATIONSGENERAL SPECIFICATIONSDimensions:Overall length 1,762 mmOverall width 690 mmOverall height 1,151 mmSeat hei

Page 91

CHAS6-42STEERING HEADEAS00675STEERING HEADOrderRemove the parts in the order listed.Securely support the scooter so thatthere is no danger of it falli

Page 92

CHAS6-43OrderRefer to "REMOVING THE LOWERBRACKET".For installation, reverse the removal proce-dure.Q'tyJob/PartRemarksSTEERING HEAD7 Ba

Page 93

CHAS6-44STEERING HEADWARNING EAS00680REMOVING THE LOWER BRACKET1.Stand the scooter on a level surface.Securely support the scooter so that there isno

Page 94

CHAS6-45STEERING HEADEAS00684INSTALLING THE STEERING HEAD1.Lubricate:• upper bearing• lower bearing• bearing racesRecommended lubricantLithium soap ba

Page 95

CHAS6-46REAR SHOCK ABSORBER ASSEMBLYOrderRemove the parts in the order listed.Refer to "COVERS" in chapter 3.For installation, reverse the r

Page 96

CHAS6-47EAS00695CHECKING THE REAR SHOCK ABSORBERASSEMBLY1. Check:• rear shock absorber rodBends/damage → Replace the rear shockabsorber assembly.• re

Page 97

7ELEC

Page 98 - SECONDARY SHEAVE

ELECCHAPTER 7.ELECTRICALCIRCUIT DIAGRAM ...7-1ELECTRICAL COMPONENTS

Page 99

ELEC7-1ELECTRICALCIRCUIT DIAGRAMCIRCUIT DIAGRAM--MLOCKOFFCHECKON(RED)(RED)BrBrBrLRGyGyGyGYBBGyBBLRGYBRRBrRBW BW BWGyBrRBBWBWOrOrBBOrBBBRBRGWGWWRWRWL

Page 100 - SECONDARY/PRIMARY SHEAVE

ELEC7-2COLOR CODEQ CDI magnetoW CDI unitE Ignition coilR Spark plugT Main switchY FuseU BatteryI Rectifier/regulatorO Starter relayP Starter motor{ Ri

Page 101

SPEC2-2GENERAL SPECIFICATIONSSpark plug:Type BR8HSManufacturer NGKGap 0.5 ~ 0.7 mmClutch type: Dry, centrifugal automaticTransmission:Primary reductio

Page 102

ELEC7-3ELECTRICAL COMPONENTSELECTRICAL COMPONENTSQ Wire harnessW Fuel senderE Starter relayR Ignition coilT CDI unitY Oil senderU BatteryI Resistance햲

Page 103

ELEC7-4햲햳햴햵Q Main switchW Flasher relayE HornR Rectifier/RegulatorELECTRICAL COMPONENTS

Page 104

ELEC7-5"∞""Ω x 1""0"SWITCH INSPECTIONSWITCH INSPECTIONUse a pocket tester to check the terminals forcontinuity. If the c

Page 105

ELEC7-6SWITCH CONTINUITY INSPECTIONBefore checking a switch refer to the checkingswitches as shown in the page 7-5 and checkfor the correct terminal c

Page 106

ELEC7-7--MLOCKOFFCHECKON(RED)(RED)BrBrBrLRGyGyGyGYBBGyBBLRGYBRRBrRBW BW BWGyBrRBBWBWOrOrBBOrBBBRBRGWGWWRWRWLWLWWYRYRWYRWYRYRRWBYRRBRRLWBGYLWGYLWGYR

Page 107

ELEC7-8IGNITION AND STARTING SYSTEMTROUBLESHOOTINGTHE STARTING SYSTEM DOES NOTWORK (NO SPARK OR IRREGULARSPARKS)Procedure:Check:1. Fuse (main)2. Batte

Page 108

ELEC7-9IGNITION AND STARTING SYSTEM4.Spark check• Remove the spark plug cap.• Connect the ignition checker 햲햳 Ground a Spark plug gap• Turn the main s

Page 109 - INSPECTION AND REPAIR

ELEC7-10IGNITION AND STARTER SYSTEM6.Ignition coil resistance• Disconnect the ignition coil leads.• Connect the pocket tester (Ωx1) to the igni-tion c

Page 110 - C.D.I. MAGNETO

ELEC7-11IGNITION AND STARTING SYSTEM9.Main switchRefer to "SWITCH INSPECTION" section.10.Connections• Check all connections in the ignition

Page 111 - ENGINE DISASSEMBLY

ELEC7-12IGNITION AND STARTING SYSTEMTROUBLESHOOTINGSTARTER MOTOR DOES NOT WORKProcedureCheck:1. Fuse (main)2. Battery3. Starter motor4. Starter relayN

Page 112 - AUTOLUBE PUMP

YQ100SERVICE MANUAL© 2000 by MBK INDUSTRIE1st Edition, February 2000All rights reserved. Anyreprinting or unauthorized usewithout the writtenpermissio

Page 113

SPEC2-3Wheel travel:Front 80 mmRear 72 mmElectrical:Ignition system CDICharging system Flywheel magnetoBattery type/model YT4L-BSBattery capacity 12V

Page 114 - TRANSMISSION

ELEC7-13IGNITION AND STARTER SYSTEMWORKSReplace the starter relay.4.Starter relay• Disconnect Blue/White lead from the wireharness.• Connect the (-) t

Page 115

ELEC7-14STARTER MOTOROrderJob name/Part nameQ'tyRemarksStarter motor removalStater motor disassembly햲 O-ring 1햳 Front bracket 1햴 Rubber seal 1햵 B

Page 116 - EAS00423

ELEC7-15STARTER MOTORINSPECTION1.Check:• CommutatorDirty → Clean it with #600 grit sandpaper.2.Measure:• Commutator diameter @Out of specification → R

Page 117 - CRANKCASE AND REED VALVE

ELEC7-16STARTER MOTOR6.Measure:• Brush spring forceFatigue/Out of specification → Replace as aset.Brush spring force:563 ~ 844 g5.Measure:• Brush leng

Page 118

ELEC7-17--MLOCKOFFCHECKON(RED)(RED)BrBrBrLRGyGyGyGYBBGyBBLRGYBRRBrRBW BW BWGyBrRBBWBWOrOrBBOrBBBRBRGWGWWRWRWLWLWWYRYRWYRWYRYRRWBYRRBRRLWBGYLWGYLWGYR

Page 119

ELEC7-18CHARGING SYSTEMTROUBLESHOOTINGTHE BATTERY IS NOT CHARGEDProcedureCheck:1. Fuse (main)2. Battery3. Charging voltage4. Charging coil resistance5

Page 120

ELEC7-19CHARGING SYSTEM3. Charging voltage• Connect the engine tachometer to the sparkplug lead.• Connect the pocket tester (DC20V) to thebattery term

Page 121

ELEC7-20CHARGING SYSTEM4. Charging coil resistance• Disconnect the CDI magneto coupler fromthe wire harness.• Connect the pocket tester (Ω x 1) to the

Page 122 - CRANKSHAFT

ELEC7-21--MLOCKOFFCHECKON(RED)(RED)BrBrBrLRGyGyGyGYBBGyBBLRGYBRRBrRBW BW BWGyBrRBBWBWOrOrBBOrBBBRBRGWGWWRWRWLWLWWYRYRWYRWYRYRRWBYRRBRRLWBGYLWGYLWGYR

Page 123

ELEC7-22LIGHTING SYSTEMTROUBLESHOOTINGTHE HEADLIGHT, HEADLIGHTINDICATOR, POSITION LIGHT, METERLIGHT, LICENSE LIGHT AND/ORTAILLIGHT DO NOT WORKProcedur

Page 124

SPEC2-4Cylinder head:Warp limit *** 0.02 mm* Lines indicate straight edgemeasurements.Cylinder:Bore size 52.002 ~ 52.012 mm ***Taper *** 0.05 mmPiston

Page 125

ELEC7-23YP8020181."LIGHTS" switchRefer to "SWITCH INSPECTION" section.NO CONTINUITYLIGHTING SYSTEM2.Lighting coil resistance• Dis

Page 126 - CARBURETOR

ELEC7-24LIGHTING SYSTEMThere is a defect in the wire harness betweenthe main switch and the bulb socket connector→ Repair.MEETSSPECIFICATIONOUT OF SPE

Page 127 - EAS00480

ELEC7-25LIGHTING SYSTEM2.Voltage• Connect the pocket tester (AC 20 V) to thefront position light connectors.Pocket tester (+) lead → → → → → Blue/Red

Page 128 - EAS000483

ELEC7-26LIGHTING SYSTEM4.The taillight does not work.1.Bulb and socket.Refer to " SWITCH INSPECTION " section.2.Voltage• Connect the pocket

Page 129

ELEC7-272.Voltage• Connect the pocket tester (AC 20 V) to thelicense light coupler.Pocket tester (+) lead →→→→→ Blue/Red 햲Pocket tester (-) lead →→→→→

Page 130

ELEC7-28SIGNAL SYSTEM--MLOCKOFFCHECKON(RED)(RED)BrBrBrLRGyGyGyGYBBGyBBLRGYBRRBrRBW BW BWGyBrRBBWBWOrOrBBOrBBBRBRGWGWWRWRWLWLWWYRYRWYRWYRYRRWBYRRBRRL

Page 131 - EAS00487

ELEC7-29SIGNAL SYSTEMTROUBLESHOOTINGFLASHER LIGHTS, TAIL/BRAKE LIGHT,"OIL" WARNING LIGHT DO NOT WORK.HORN DOES NOT SOUND, FUEL METERDOES NOT

Page 132 - EAS00492

ELEC7-30SIGNAL SYSTEM4.Connections• Check all connections in the signal system.Refer to "WIRE DIAGRAM".CONTINUITYCheck the condition of eac

Page 133 - FUEL COCK

ELEC7-31SIGNAL SYSTEMSIGNAL SYSTEM CHECK1. Horn does not sound.1."HORN" switchRefer to "SWITCH INSPECTION".CONTINUITY2.Voltage• Co

Page 134 - REED VALVE

ELEC7-32SIGNAL SYSTEM2. The brake light does not work.1.Bulb and socket.Refer to "SWITCH INSPECTION".CONTINUITY2.Brake switchRefer to "

Page 135 - YP600051

SPEC2-5MAINTENANCE SPECIFICATIONSCrankshaft:Crank width “A” 37.90 ~ 37.95 mm ***Runout limit “C” *** 0.03 mmConnecting rod length 79.9 ~ 80.1 mmSide c

Page 136

ELEC7-33SIGNAL SYSTEM3.Flashers and flasher indicator do not work.1.Bulb and socketRefer to "SWITCH INSPECTION".CONTINUITY2.Flasher switchRe

Page 137 - CHAPTER 6

ELEC7-34SIGNAL SYSTEM5.Voltage• Connect the pocket tester (DC 20 V) to theflasher coupler.Left flasher bulbPocket tester (+) lead →→→→→ Chocolate 햲Poc

Page 138

ELEC7-35SIGNAL SYSTEM3. Voltage• Connect the pocket tester (DC20V) to thebulb socket connectorPocket tester (+) lead →→→→→ Grey 햲Pocket tester (-) lea

Page 140 - EAS00518

TRBLSHTGCHAPTER 8.TROUBLESHOOTINGSTARTING FAILURE/ HARD STARTING ...8-1FUEL SYSTEM ...

Page 141 - EAS00523

TRBLSHTG8-1STARTING FAILURE/HARD STARTINGTROUBLESHOOTINGNOTE:The following troubleshooting does not cover all the possible causes of trouble. It shoul

Page 142 - EAS00525

TRBLSHTG8-2STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCECOMPRESSION SYSTEMCylinder and cylinder head Crankcase and crankshaft• Loose spar

Page 143

TRBLSHTG8-3POOR MEDIUM AND HIGH SPEED PERFORMANCE/FAULTY AUTOMATICPOOR MEDIUM AND HIGH SPEED PERFORMANCEFUEL SYSTEMFuel tank Carburetor• Clogged fuel

Page 144 - EAS00528

TRBLSHTG8-4FAULTY AUTOMATIC/OVER HEATINGOVER HEATINGOVER HEATINGIgnition system Engine oil• Improper spark plug gap • Improper engine oil quality (hig

Page 145 - 23 Nm (2,3 m.kg)

TRBLSHTG8-5IMPROPER KICKING/FAULTY BRAKEIMPROPER KICKINGSLIPPINGKick axle assembly Transmission oil• Low tension of kick clip • Improper quality (low

Page 146

SPEC2-6MAINTENANCE SPECIFICATIONSModel Standard LimitReed valve:Valve stopper height 6.0 ~ 6.4 mm ***Reed Valve Clearance Less than 0.2 mm ***Lubricat

Page 147 - EAS00548

TRBLSHTG8-6FRONT FORK OIL LEAKAGE AND FRONT FORKMALFUNCTION/INSTABLE HANDLINGINSTABLE HANDLINGINSTABLE HANDLINGHandlebar Wheels• Improperly installed

Page 148

TRBLSHTG8-7FAULTY SIGNAL AND LIGHTING SYSTEMFlasher winks slower Horn is inoperative• Faulty flasher relay • Faulty battery• Insufficient battery capa

Page 149 - EAS00555

YQ100 WIRING DIAGRAMQ C.D.I. magnetoW C.D.I. unitE Ignition coilR Spark plugT Main switchY FuseU BatteryI Rectifier / regulatorO Starter relayP Starte

Page 150

SPEC2-7TIGHTENING TORQUESENGINETighteningPart to be tightened Part Thread Q'ty torque Remarksname sizeNm m.kgSpark plug - M14 1 20 2.0Head cylind

Page 151 - EAS00569

SPEC2-8MAINTENANCE SPECIFICATIONSSteering system:Steering bearing type Ball bearing ***Size of steel balls x qty:Upper ø4.75 mm x 15 ***Lower ø4.75 m

Page 152

SPEC2-9MAINTENANCE SPECIFICATIONSModel Standard LimitFront disk brake:Type Single disc ***Diameter and thickness 190.0 x 3.5 mm ***Pad thickness 4.5 m

Page 153

SPEC2-10MAINTENANCE SPECIFICATIONSTIGHTENING TORQUESCHASSISTighteningPart to be tightened Thread torque Remarkssize Nm m.kgFrame with engine bracket M

Page 154 - EAS00576

SPEC2-11MAINTENANCE SPECIFICATIONSTighteningPart to be tightened Thread torque Remarkssize Nm m.kgScrews tapping in plastic Ø5 3.2 0.32Screws tapping

Page 155 - EAS00579

SPEC2-12MAINTENANCE SPECIFICATIONSELECTRICALVoltage: 12 V ***Ignition system:Ignition timing(B.T.D.C.) 14° at 5000 r/min ***Ignition timing type Const

Page 156

CAUTION:WARNING NOTICEThis manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealersand their qualified mechanics. It is not

Page 157 - EAS00584

SPEC2-13Model Standard LimitBattery :Specific gravity 1.280 ***Starter motor:Model / Type MORYAMAOutput 0.14 kW ***Armature coil resistance 0.06 ~ 0.0

Page 158 - 1.2 Nm (0.12 m.kg)

SPEC2-14GENERAL TORQUE SPECIFICATIONSBAA B General torque(Nut) (Bolt) specificationsNm m.kg10 mm 6 mm 60 0.612 mm 8 mm 15 1.514 mm 10 mm 30 3.017 mm 1

Page 159 - EAS00590

SPEC2-15LUBRICATION POINTS AND LUBRICANT TYPESLubrication point Lubricant typeOil seal lipsO-ringCrankshaft bearingsNeedle bearings (connecting rod)Ma

Page 160 - EAS00596

SPEC2-16LUBRICATION POINT AND GRADE OF LUBRICANTLubrication point Lubricant typeFront wheel oil seal (right/left)Rear wheel oil sealSteering bearing a

Page 161

SPEC2-17CABLE ROUTING햲 Taillight햳 Rear left flasher light햴 Seat lock assy'햵 Band switch햶 Clip햷 Starter relay햸 Fuse햹 Battery assy'햺 Ignition

Page 162 - EAS00612

SPEC2-18CABLE ROUTINGA Untight the seat lock plate to give to the seat lock cable more free play. Tight the seat lock cable at 1 1/2turn.B Fix on the

Page 163 - EAS00614

SPEC2-19CABLE ROUTINGQ Fuel senderW C.D.I. unitE Band switchR Oil level senderT Wire cylinder assy'Y Rectifier / RegulatorU Band switch cordonI M

Page 164

SPEC2-20CABLE ROUTINGA Fix the wire harness, starter motor wire and the flywheel wire all together.B Fix the wire harness.C Pass the wire harness betw

Page 165 - EAS00631

SPEC2-21CABLE ROUTING햲 Resistor assy'햳 Horn햴 Band switch햵 Frame햶 Front brake hose햷 Speedometer cable햸 Gear unit assy'햹 Front mudguard햺 Front

Page 166 - EAS00635

SPEC2-22CABLE ROUTING햲 Right hand grip햳 Master cylinder햴 Speedometer assy'햵 Left hand grip햶 Rear brake lever햷 Rear brake cable햲햳햵햶햵햶햷햸햹햺햻햽햾햾햲햳 햴햴

Page 167

ENGENGCDI MAGNETOCDI magneto, Rotor, Startor removalSeat coverSide coversFootrest board1 Fan cover 12 Fan 13 Nut 14 Washer 15 Magneto rotor 16 Woodruf

Page 168 - FRONT FORK

SPEC2-23CABLE ROUTINGA Fix the wire harness on the frame bracket.B Group all connection in this area.C Pass the starter cable through the hole.D Tight

Page 169

SPEC2-24햲 Speedometer cable햳 Wire harness햴 Front brake hose햵 Rear brake cable햶 Front handlebar cover햷 Speedometer cover햸 Speedometer햹 Rear handlebar c

Page 171 - EAS00656

CHKADJCHAPTER 3.PERIODIC CHECKS AND ADJUSTMENTSPERIODIC MAINTENANCE AND LUBRICATION... 3-1COVERS ...

Page 172 - EAS00659

INSPREG3-1PERIODIC MAINTENANCE AND LUBRICATIONPERIODIC CHECKS AND ADJUSTMENTSEAS00036PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes

Page 173

INSPREG3-2PERIODIC CHECKS AND ADJUSTMENTSNOTE:• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.• Brake f

Page 174

INSPREG3-3COVERSSEAT AND SIDE COVERSOrder Job/Part Q’ty Remarks125 344T.R2 Nm (0,2 m.kg) T.R3 Nm (0,3 m.kg) T.R8 Nm (0,8 m.kg) T.R8 Nm (0,8 m.kg

Page 175 - 60 Nm (6,0 m.kg)

INSPREG3-4COVERSBOX, LOWER SIDE COVERS AND MUDGUARD453312 T.R2,5 Nm (0,25 m.kg) T.R6 Nm (0,6 m.kg) T.R3 Nm (0,3 m.kg) T.R8 Nm (0,8 m.kg) Removing

Page 176

INSPREG3-5COVERSOrderRemoving the frame reinforcement,fuel tank and rear under cover.Rear side coversSeatRemove the parts in the order listed.Refer to

Page 177 - HANDLEBAR

INSPREG3-6COVERSOrderRemoving the front coversI Disconnect:Headlight lead 1II Remove:1 Front cover and headlight 12 Front fender 13 Front inner panel

Page 178 - EAS00673

INSPADJELECGENINFOENGCARBCHASSPECQWRETYUIOP{}qweryoptuiT.RTRBLSHTG[]BLSMEAS00009SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols

Page 179

INSPREG3-7OrderRemoving the handlebar coversI Untighten:Handlebar under cover 햲II Disconnect:Speedometer lead 1Wires and leadsIII Remove:1 Handlebar c

Page 180 - EAS00675

INSPREG3-8OrderRemoving the battery cover andlower cover.SeatBox and side coversFront coversI Remove:1 Battery cover 12 Lower cover 1Remove the parts

Page 181

INSPREG3-9COVERSOrderRemoving the inner panel andfootrest board.I Remove:1 Inner panel 12 Footrest board 1Remove the parts in the order listed.NOTE:To

Page 182

INSPREG3-10COVERSNOTE:Correct routing of cables and wires is essential for a safe operation of this scooter. Refer to the section“CABLE ROUTING” in Ch

Page 183

INSPREG3-11ADJUSTING THE ENGINE IDLING SPEEDEAS00054ENGINEADJUSTING THE ENGINE IDLING SPEEDFor safety reasons, place the scooter on thecenterstand bef

Page 184 - REAR SHOCK ABSORBER ASSEMBLY

INSPREG3-12ADJUSTING THE THROTTLE CABLE FREE PLAY@EAS00058ADJUSTING THE THROTTLE CABLE FREEPLAYNOTE:Prior to adjusting the throttle cable free play, t

Page 185 - EAS00695

INSPREG3-13햳햲Handlebar sidea.Loosen the locknut.b.Turn the adjusting nut in direction left or rughtuntil the specified throttle cable free play isobta

Page 186

INSPREG3-14햲CHECKING THE SPARK PLUG5.Clean:•spark plug(with a spark plug cleaner or wire brush)6.Measure:•spark plug gap 햲(with a wire gauge or feeler

Page 187 - ELECTRICAL

INSPREG3-15CHECKING THE ENGINE OIL LEVELEAS00070CHECKING THE ENGINE OIL LEVEL1.Inspect:•oil levelOil level low → Add oil to proper level asfollows.햲 &

Page 188

INSPREG3-16CHANGING THE TRANSMISSION OIL/AUTOLUBE PUMP AIR BLEEDINGCHANGING THE TRANSMISSION OIL1.Remove:•drain plug 햲•oil filler plug 햳Drain the tran

Page 189 - CIRCUIT DIAGRAM

EAS00011TABLE OF CONTENTSGENERAL INFORMATIONSPECIFICATIONSPERIODIC CHECKS ANDADJUSTMENTSENGINECARBURETORCHASSISELECTRICAL SYSTEMTROUBLESHOOTING1234567

Page 190 - ELECTRICAL COMPONENTS

INSPREG3-17AUTOLUBE PUMP AIR BLEEDING/CLEANING THE AIR FILTER ELEMENTEAS00089CLEANING THE AIR FILTER ELEMENT1.Remove:•air cleaner case cover 햲Never op

Page 191

INSPREG3-18CLEANING THE AIR FILTER ELEMENT/CHECKING THE EXHAUST PIPE SYSTEMb. Squeeze excess solvent out of the elementand let dry.Do not twist the el

Page 192 - SWITCH INSPECTION

INSPREG3-19ADJUSTING THE FRONT BRAKE/ADJUSTING THE REAR BRAKEEAS00108CHASSISADJUSTING THE FRONT BRAKE1.Check:•brake lever free play @Out of specificat

Page 193

INSPREG3-20CHECKING THE BRAKE FLUID LEVELEAS00116CHECKING THE BRAKE FLUID LEVEL1.Stand the scooter on a level surface.NOTE:• Place the scooter on a su

Page 194 - A Starter switch

INSPREG3-21346002(a)햲햲햳CHECKING THE FRONT BRAKE PADS/CHECKING THE BRAKE SHOES/BLEEDING THE HYDRAULIC BRAKE SYSTEM햲EAS00126CHECKING THE BRAKE SHOES1.Op

Page 195 - IGNITION AND STARTING SYSTEM

INSPREG3-22BLEEDING THE HYDRAULIC BRAKE SYSTEM /CHECKING AND ADJUSTING THE STEERING HEADWARNING i. Repeat steps (e) to (h) until all air bubbleshave b

Page 196 - Ω (20°C)

INSPREG3-23Steering nut wrench90890-01403Lower ring nut (initial tighteningtorque)38 Nm (3.8 m•kg)c.Loosen the lower ring nut 햶 of 1/4 turn andthen ti

Page 197 - Ω at 20°C

INSPREG3-245.Install:•front coverRefer to "FRONT COVER"•HandlebarRefer to "HANDLEBAR" in chapter 6.Handlebar holder bolt60 Nm (6.0

Page 198

INSPREG3-25EAS00165CHECKING THE TIRESThe following procedure applies to both of thetires.1.Measure:•tire pressureOut of specification → Regulate.The t

Page 199

INSPREG3-26Minimum tire tread depth0.8 mm햲 Tire tread depth햳 Side wall햴 Wear indicatorDo not use a tubeless tire on a wheel designedonly for tube tire

Page 201 - STARTER MOTOR

INSPREG3-27CHECKING THE WHEELS/CHECKING AND LUBRICATING THE CABLESEAS00168CHECKING THE WHEELSThe following procedure applies to both of thewheels.1.Ch

Page 202

INSPREG3-28LUBRICATING THE CENTERSTAND/LUBRICATING THE REAR SUSPENSIONEAS00173LUBRICATING THE CENTERSTANDLubricate the pivoting point and metal-to-met

Page 203

INSPREG3-29CHECKING THE BATTERYEAS00177ELECTRICAL SYSTEMCHECKING THE BATTERYBatteries generate explosive hydrogen gasand contain electrolyte which is

Page 204 - CHARGING SYSTEM

INSPREG3-304.Check:•electrolyte levelThe electrolyte level should be between theminimum level mark 햳 and the maximumlevel mark 햲.Below the minimum lev

Page 205

INSPREG3-31• Make sure the battery charger lead clipsare in full contact with the battery terminaland that they are not shorted. A corrodedbattery cha

Page 206

INSPREG3-32CHECKING THE BATTERY/CHECKING THE FUSEEAS00181CHECKING THE FUSEThe following procedure applies to all of thefuses.To avoid a short circuit,

Page 207

INSPREG3-333.Replace:• blown fuse 햲a.Set the main switch to “OFF”.b.Install a new fuse of the correct amperage.c.Set on the switches to verify if the

Page 208 - LIGHTING SYSTEM

INSPREG3-34REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAMCAUTION:4.Install:•headlight bulb Secure the new headlight bulb with theheadlight

Page 210

ENGCHAPTER 4.OVERHAULING THE ENGINEENGINE ...4-

Page 211

GENINFOCHAPTER 1.GENERAL INFORMATIONSCOOTER IDENTIFICATION... 1-1VEHICULE IDENTIF

Page 212

ENGCRANKCASE AND REED VALVE ...4-37CRANKCASE (RIGHT) REMOVAL ...

Page 213 - 21W / 5W

ENG4-1OVERHAULING THE ENGINEEAS00188OVERHAULING THE ENGINEENGINELEADS AND HOSESOrder Job/Part Q’ty RemarksRemoving the leads and hoses Remove the part

Page 214

ENG4-2OVERHAULING THE ENGINEOrder Job/Part Q’ty Remarks7 Starter motor lead coupler 1III Untighten :8 Rear wheel nut 1 Note:Loosen the rear wheel nu

Page 215 - SIGNAL SYSTEM

ENG4-3OVERHAULING THE ENGINEEXHAUST PIPEOrder Job/Part Q’ty RemarksRemoving the exhaust pipe Remove the parts in the order listed.Lower cover Refer to

Page 216

ENG4-4OVERHAULING THE ENGINEOrder Job/Part Q’ty RemarksRemoving the engine Remove the parts in the order listed.Leads and hoses NOTE:Exhaust pipe Plac

Page 217

ENG4-5Order Job/Part Q’ty RemarksI. Install: Engine mounting bolt  1 Rear shock absorber bolt (lower)  1 NOTE:Do not fully tighten the bolts.II. Tig

Page 218

ENG4-6CYLINDER HEADEAS00222CYLINDER HEAD, CYLINDER AND PISTONOrder Job/Part Q’ty RemarksRemoving the cylinder head Remove the parts in the order liste

Page 219

ENG4-7PISTON PIN AND PISTON REMOVAL1. Remove:• Piston pin clip NOTE:Before removing the piston pin clip, cover thecrankcase with a clean rag so you w

Page 220

ENG4-8CYLINDER AND PISTON INSPECTION1. Eliminate :• Carbon depositsUse a rounded scraper .2. Inspect :• Cylinder wallWear/Scratches→Rebore or replace

Page 221

ENG4-9• If out of specification, rebore or replacecylinder, and replace piston and piston ringsas a set.2nd step:• Measure the piston skirt diameter “

Page 222

GENINFO1-1112GENERAL INFORMATIONEAS00015GENERAL INFORMATIONSCOOTER IDENTIFICATIONEAS00017VEHICLE IDENTIFICATION NUMBERThe vehicle identification numb

Page 223

ENG4-10 a Measuring Point 20 mmPISTON RINGS INSPECTION1. Measure:• Side clearanceOut of specification→Replace piston and/or rings.Use a feeler gauge 

Page 224 - TROUBLESHOOTING

ENG4-112. Measure :• Outside diameter @ (piston pin)Out of specification→Replace.Outside diameter (piston pin) :13.996~14.000 mm3. Measure:• Piston pi

Page 225

ENG4-123. Install :• Small end bearing• Piston • Piston pin • Piston pin clip NOTE:• The arrow a on the piston to the exhaust side.• Before insta

Page 226 - POOR IDLE SPEED PERFORMANCE

ENG4-134. Install :• Cylinder head gasket (new gasket)5. Install :• Cylinder head  14Nm(1.4m.kg)• Spark plug  20Nm(2.

Page 227 - FAULTY AUTOMATIC

ENG4-14RemarksRemove the parts in order.Reverse the removal procedure for installation.Order123456Q’ty111112Job name/Part nameCrankcase cover (left) r

Page 228 - OVER HEATING

ENG4-15OrderQ’ty111/1111KICK STARTERJob name/Part nameKick starter removalKickstarter pinion gearKickstarter pinion gear clipCirclip/Plain washe

Page 229 - IMPROPER KICKING

ENG4-16KICK STARTER INSTALLATION1. Install :• Return spring • Kick shaft • Collar • Plain washer • Circlip **************************************

Page 230

ENG4-17Order12345678910Q’ty1111/1111/111/36V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVERemarksRemove the parts in order.Refer to “BATTERY COVER ANDLOWE

Page 231

ENG4-18SECONDARY SHEAVESECONDARY SHEAVE50Nm(5.0kg.m)T R..OrderQ’ty1131121221RemarksDisassemble the parts in order.Refer to “SECON

Page 232 - YQ100 WIRING DIAGRAM

ENG4-19PRIMARY SHEAVE REMOVAL1. Remove :• Fan2. Remove :• Nut  (primary sheave)NOTE:When loosening the nut (primary sheave), holdthe C.D.I. magneto u

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