Yamaha Mio User manual

5TL-F8197-E0
MIO
SERVICE MANUAL

EAS00000
AL115
SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
First edition, July 2003
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

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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.
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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:

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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
12
34
56
78
90
AB
CD
EF
GHI
JKL
MN
GEN
INFO
SPEC
CHK
ADJ ENG
CARB CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
New

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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