Yamaha VINO 125, YJ125S Manual

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Yamaha VINO 125, YJ125S Manual

GENERAL INFORMATION

SCOOTER IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped into the steering head pipe.
VEHICLE IDENTIFICATION NUMBER

MODEL LABEL
The model label is affixed to the seat. This information will be needed to order spare parts.

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

  1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.
  2. Use only the proper tools and cleaning equipment. Refer to the "SPECIAL TOOLS".
  3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been "mated" through normal wear. Mated parts must always be reused or replaced as an assembly.
  4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.
  5. Keep all parts away from any source of fire.

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

GASKETS, OIL SEALS AND O-RINGS

  1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.
  2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.

LOCK WASHERS/PLATES AND COTTER PINS

After removal, replace all lock washers/plates and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manufacturer's marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.


Oil seal


Do not spin the bearing with compressed air because this will damage the bearing surfaces.


Bearing

CIRCLIPS

Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip , make sure the sharp-edged corner is positioned opposite the thrust that the circlip receives.
IMPORTANT INFORMATION - CIRCLIPS
Shaft

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc.

  1. Disconnect:
    • lead
    • coupler
    • connector
  2. Check:
    • lead
    • coupler
    • connector
      Moisture → Dry with an air blower.
      Rust/stains → Connect and disconnect several times.
      CHECKING THE CONNECTIONS - Step 1
  3. Check:
    • all connections
      Loose connection → Connect properly.
      warning NOTE:
      If the pin on the terminal is flattened, bend it up.
      CHECKING THE CONNECTIONS - Step 2
  4. Connect:
    • lead
    • coupler
    • connector
      CHECKING THE CONNECTIONS - Step 3
  5. Check:
    • continuity (with the pocket tester)
      Pocket tester
      90890-03132 (YU-03112-C)


      CHECKING THE CONNECTIONS - Step 4

warning NOTE:

  • If there is no continuity, clean the terminals. When checking the wire harness, perform steps (1) to (3).
  • As a quick remedy, use a contact revitalizer available at most part stores.

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.

Tool NO. Tool name / Function Illustration

90890-01083(M6)
YU-01083-1

90890-01085(M8)
YU-01083-2

90890-01084
YU-01083-3

Rocker arm shaft puller bolt
Weight
These tools are used when removing or installing the rocker arm shafts.
90890-01235
YU-01235
Rotor holding tool
This tool is used to remove the flywheel magneto.
90890-01268
YU-01268
Ringnut wrench
This tool is used to loosen and tighten the exhaust and steering ring nut.
90890-01311
YM-08035-A
Valve adjusting tool
This tool is necessary for adjusting valve clearance.
90890-01312
YM-01312-A
Fuel level gauge
This gauge is used to measure the fuel level in the float chamber.
90890-01326
YM-01326
90890-01294
YM-01300-1
T-handle
Damper rod holder
These tool are used for holding the Damper rod holder when removing or installing the damper rod holder.
90890-01337
YM-33285
YM-33285-6
Clutch spring holder
These tool are used for removing the nut with holding the compression spring.
90890-01348
YM-01348
Lock nut wrench
This tool is used when removing or installing the secondary sheave nut.
90890-01189
YM-01189
Flywheel puller
This tool is used for removing the A.C. magneto rotor.
90890-01367
YM-A9409-7
90890-01400 YM-A9409-3
Fork seal driver weight
Fork seal driver attachment(Ø30mm)
This tool is used when installing the fork seal.
90890-01384
YM-33299
Oil seal guide
This tool is used for protecting the oil seal lip when installing the secondary sliding sheave.
90890-01403
YU-33975
Ring nut wrench
This tool is used to loosen and tighten the steering ring nut.
90890-01701
YS-01880-A
Sheave holder
This tool is used for holding the secondary sheave.
90890-03079
YM-34483
Thickness gauge
This tool is used to measure the valve cleanance.
90890-03081
YU-33223
Compression gauge
These tool are used to measure the engine compression.
90890-03132
YU-03112-C
Pocket tester
This instrument is invaluable for checking the electrical system.
90890-03113
YU-08036-C
Engine tachometer
This tool is needed for detecting engine rpm.
90890-03141
YU-03141
Timing light
This tool is needed for detecting ignition timing.
90890-04019
YM-04019
90890-04108
YM-04108
Valve spring compressor Attachment(Ø19mm)
These tools are used when removing or installing the valve and the valve spring.
90890-06754
YM-34487
Ignition checker
This instrument is necessary for checking the ignition system components.
90890-85505
ACC-11001-05-01
Yamaha bond NO.1215
This sealant (bond) is used for crankcase mating surface, etc.
80890-04116
YM-04116
Valve guide remover (4.5 mm)
This tool is used to remove or install the valve guides.
90890-04117
YM-04117
Valve guide installer (4.5 mm)
This tool is used to install the valve guides.
90890-04099
YM-04099
Valve guide reamer (5.0 mm)
This tool is used to rebore the new valve guides.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit
Model code 5YR1 (for USA) ...
5YR2 (for CAN) ...
Dimensions
Overall length 1755 mm (69.1 in) ...
Overall width 699 mm (27.5 in) ...
Overall height 1063 mm (41.8 in) ...
Seat height 759 mm (29.8 in) ...
Wheelbase 1230 mm (48.4 in) ...
Ground clearance 95 mm (3.8 in) ...
Minimum turning radius 1800mm (72 in) ...
Weight
Wet (without oil and a full fuel tank) 109 kg (240 lb) ...
Dry (without oil and fuel) 104kg (229 lb) ...
Maximun load (total of cargo, rider, passenger, and accessories) 253kg (558 lb) ...

ENGINE SPECIFICATIONS

Item Standard Limit
Engine
Engine type Forced Air cooled 4-stroke, SOHC ...
Displacement 0.125L(125.0 cm3) ...
Cylinder arrangement Forward inclined single cylinder ...
Bore × stroke 51.5 × 60.0 mm ...
Compression ratio 9.8±0.4:1 ...
Engine idle speed 1600~1700 r/min ...
Vacuum pressure at engine idle speed 30.0 kpa (238.6 mmHg) ...
Standard compression pressure (at sea level) 950 kPa(9.5kg/cm2) / 300 r/mi ...
Fuel
Recommended fuel Regular unleaded gasoline ......
Fuel tank capacity
Total (including reserve)
4.5L (0.98lmp gal, 1.18 USgal) ...
Engine oil
Lubrication system Wet sump ...
Recommended oil
SAE20W40SE
Yamaha 4-cycle oil
EFERO X, Z, BX
...
Quantity

Periodic oil change

With oil filter replacement

Total amount

1.0L(0.92 lmp qt, 1.09 US qt)

1.2L(1.10 lmp qt, 1.31 US qt)

1.2L(1.10 lmp qt, 1.31 US qt)

...

...

...

Final gear oil

Recommended oil

Periodic oil change

Total amount

SAE85W140S Ehypoid gear oil

0.13L(0.12 lmp qt, 0.14 US qt)

0.15L(0.14 lmp qt, 0.16 US qt)

...

...

...

Oil filter
Oil filter type Wire mesh ...
Oil pump
Oil pump type Trochoid ...
Inner rotor to outer rotor tip clearance 0.15 mm 0.23mm
Outer rotor to pump housing clearance 0.013-0.036 mm 0.106mm
Oil pump housing to inner rotor and outer rotor clearance 0.06-0.10 mm 0.17mm
Starting system type Electric and kick starter ...
Spark plug
Model (manufacturer) × quantity CR7E (NGK) × 1 ...
Spark plug gap 0.7~0.8mm ...
Cylinder head
Volume 12.3~12.7cm³ ...
Max. warpage
... 0.03 mm
Camshaft
Drive system Chain drive (left) ...
Intake camshaft lobe dimensions

Measurement A

Measurement B

Measurement C

26.153~26.253 mm

21.015~21.115 mm

5.203mm

26.053 mm

20.915 mm

...

Exhaust camshaft lobe dimensions

Measurement A

Measurement B

Measurement C

26.153~26.253 mm

21.056~21.156 mm

5.203 mm

26.053 mm

20.956 mm

...

Max. camshaft runout
... 0.03 mm
Timing chain

Model/number of links

Tensioning system

Morse 92RH2005 / 88

Automatic

...

...

Valve, valve seats, valve guides
Valve clearance (cold)

Intake

Exhaust

0.08~0.12 mm

0.13~0.17 mm

...

...

Valve dimensions
Valve head diameter A

Intake

Exhaust

23.9~24.1 mm

20.9~21.1 mm

...

...

Valve face width B

Intake

Exhaust

1.69~2.40 mm

1.69~2.40 mm

...

...

Valve seat width C

Intake

Exhaust

0.9~1.1 mm

0.9~1.1 mm

1.6mm

1.6mm

Valve margin thickness D

Intake

Exhaust

0.85~1.15 mm

0.85~1.15 mm

...

...

Valve stem diameter

Intake

Exhaust

4.475~4.490 mm

4.460~4.475 mm

4.445 mm

4.430 mm

Valve guide inside diameter

Intake

Exhaust

4.500~4.512 mm

4.500~4.512 mm

4.550 mm

4.550 mm

Valve stem to valve guide clearance

Intake

Exhaust

0.010~0.037 mm

0.025~0.057 mm

0.080 mm

0.100 mm

Valve stem runout
... 0.010 mm
Valve seat width

Intake

Exhaust

0.9~1.1 mm

0.9~1.1 mm

1.6mm

1.6mm

Valve springs
Free length

Intake

Exhaust

37.30 mm

37.30 mm

35.40 mm

35.40 mm

Installed length (valve closed)

Intake

Exhaust

25.77mm

25.77mm

...

...

Compressed spring force (installed)

Intake

Exhaust

147±11N (15.0 ± 1.1 kgf/mm)

147±11N (15.0 ± 1.1 kgf/mm)

...

...

Spring tilt

Intake

Exhaust

...

...

2.5°/1.6 mm

2.5°/1.6 mm

Winding direction (top view)

Intake

Exhaust

Clockwise

Clockwise

...

...

Valve seat reformed Yes ...
Cylinder
Cylinder arrangement Forward inclined single cylinder ...
Bore × stroke 51.5 × 60mm ...
Compression ratio 9.8 ± 0.4:1 ...
Bore 51.49~51.53 mm ...
Max. taper ... 0.05 mm
Max. out-of-round ... 0.05 mm
Piston
Piston-to-cylinder clearance 0.010~0.030 mm 0.150mm
Diameter D
51.470~51.510 mm ...
Height H 3.5 mm ...
Piston pin bore (in the piston)
Diameter 13.002~13.013 mm 13.043 mm
Offset 0.35~0.65mm ...
Offset direction Intake side ...
Piston pin
Outside diameter 12.996~13.000 mm 12.976 mm
Piston rings
Top ring B
Ring type Barrel ...
Dimensions (B × T) 1.0 × 2.1mm ...
End gap (installed) 0.10~0.20 mm 0.45mm
Ring side clearance 0.02~0.08 mm 0.13 mm
2nd ring B
Ring type Plain ...
Dimensions (B × T) 1.0 × 2.1mm ...
End gap (installed) 0.20~0.30 mm 0.65mm
Ring side clearance 0.02~0.06 mm 0.12mm
Oil ring B
Dimensions (B × T) 2.0 × 2.2 mm ...
End gap (installed) 0.2~0.7 mm ...
Ring side clearance 0.06~0.15 mm ...
Rocker arm/rocker arm shaft
Rocker arm inside diameter 10~10.015mm ...
Rocker arm shaft outside diameter 9.981~9.991 mm ...
Arm-to-shaft clearance 0.009~0.034 mm ...
Connecting rod
Connecting rod length 97.95~98.05 mm ...
Small end inside diameter 13.015~13.028mm ...
Crankshaft
Width A 45.15~45.20 mm ...
Max. runout C ... 0.03mm
Big end side clearance D 0.10~0.40 mm 1.00mm
Big end radial clearance E 0~0.010mm ...
Clutch

Clutch type

Clutch shoe thickness

Clutch shoe spring free length

Clutch housing inside diameter

Compression spring free length

Weight outside diameter

Clutch-in revolution

Clutch-stall revolution

Automatic centrifugal

3.4 ± 0.1 mm

28.0 ± 0.4 mm

120 ± 0.1 mm

113.6 mm

20 ± 0.1 mm

3200±300 r/min

5500±500 r/min

...

2.0mm

...

120.3mm

...

...

...

...

V-belt
V-belt width 21.6 mm 19.5mm
Transmission

Transmission type

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Max. main axle runout

Max. drive axle runout

V-belt automatic

Helical gear

40/15 (2.667)

Spur gear

38/13 (2.923)

...

...

...

...

...

...

...

0.02 mm

0.02 mm

Carburetor

Model (manufacturer) × quantity

ID mark

Venturi tube bore

Main jet

Main air jet

Jet needle

Needle jet

Pilot air jet 1

Pilot outlet

Pilot jet

Bypass 1

Bypass 2

Bypass 3

Valve seat size

Starter jet 1

Starter jet 2

Throttle valve size

Fuel level ( using fuel level gauge )

Engine idle speed

CO% (air induction system ON)

CO% (air induction system OFF)

Oil temperature (°C)

BS26 (MIKUNI) × 1

5YR 00

Ø22.3

#97.5

0.5

4D×16-1

0-4M

160

0.81

22.5

Ø0.8

Ø1.0

Ø1.1

2.0

40

0.8

115

6.5~7.5mm

1600~1700 r/min

0.2~1.4 %

4.0~5.0 %

70~80°C

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

Throttle bodys

Model (manufacturer) × quantity

Intake vacuum pressure

Throttle cable free play (at the flange of the throttle grip)

ID mark

5YR (SAFETY CONTROL CABLE) × 2

30.0kpa (238.6mmHg)

3~5mm

5YR1

...

...

...

...

CHASSIS SPECIFICATIONS

CHASSIS SPECIFICATIONS - Part 1
CHASSIS SPECIFICATIONS - Part 2
CHASSIS SPECIFICATIONS - Part 3

ELECTRICAL SPECIFICATIONS

Item Standard Limit
System voltage 12V ...
Ignition system

Ignition system type

Ignition timing (B.T.D.C.)

Advancer type

Pickup coil resistance /color

C.D.I. unit model (manufacturer)

C.D.I.

5 °/1650 r/min (IDL)

Digital

304~456 Ω / WR-WL

5YR00(T-MORIC)

...

...

...

...

...

Ignition coil

Model (manufacturer)

Minimum ignition spark gap

Primary coil resistance

Secondary coil resistance

2JN (T-MORIC)

6mm

0.184~0.276 Ω at 20°C

6.32~9.48 kΩ at 20°C

...

...

...

...

Spark plug cap

Material

Resistance

Resin

8~12 kΩ

...

...

Charging system

System type

Model (manufacturer)

Nominal output

Lighting coil resistance /color

Lighting coil resistance /color

C.D.I. magneto

5NW 01 (T-MORIC)

14V 120W / 5000 r/min

0.28~0.42 Ω/B-YR

0.32~0.48 Ω/B-W

...

...

...

...

...

Voltage regulator

Regulator type

Model (manufacturer)

No load regulated voltage (DC)

Semiconductor, short circult

SH671-12 (XIN DIAN YUAN)

14~15 V

...

...

...

Rectifier

Model (manufacturer)

Rectifier capacity(DC)

Withstand voltage

SH671-12 (XIN DIAN YUAN)

8A

200V

...

...

...

Battery

Battery type (manufacturer)

Battery voltage capacity

Specific gravity

Ten hour rate amperage

GTX7A-BS (GS)

12V 6AH

1.330

6 AH

...

...

...

...

Headlight type Krypton bulb ...
Indicator light (voltage/wattage×quantity)

Turn signal indicator light

High beam indicator light

12 V 1.7 W × 1

14 V 3W × 1

...

...

Bulbs (voltage/wattage × quantity)

Headlight

Tail/brake light

Front turn signal light

Rear turn signal light

Speedometer light

Fuel lever meter light

12 V 60 W/55 W × 1

12 V 8W/27 W × 1

12 V 10 W × 2

12 V 10 W × 2

14 V 3 W ×1

14 V 3 W ×1

...

...

...

...

...

...

Electric starting system

System type

Starter motor

Constant mesh ...

Model (manufacturer)

Suction voltage

Power output

4TE1 (T-MORIC)

12V

0.3 kW

...

...

...

Brushes

Overall length

Quantity

Spring force

Commutator diameter

Commutator resistance

Mica undercut (depth)

10.0 mm

2

5.52~8.28 N

22 mm

0.0306~0.0374 Ω at 20°C

1.5 mm

3.5mm

...

...

21mm

...

...

Starter relay

Model (manufacturer)

Amperage

Coil resistance

Suction voltage

3UH1 (SHI LIN)

100 A

3.6-4.4 Ω

Below DC8V

...

...

...

...

Horn

Horn type

Model (manufacturer)

Max. amperage

Performance

Coil resistance

Plane

AH-368 (ASIA TRAFFIC)

1.5 A

95~105db/2m

4.05~4.55 Ω

...

...

...

...

...

Turn signal relay

Relay type

Model (manufacturer)

Self-cancelling device built-in

Turn signal blinking frequency

Wattage

Semi transistor

5CA9 (TA YOUNG)

NO

75~95 cycles/min

10 W × 2 + 1.7 W+ AP

...

...

...

...

...

Fuel sender

Model (manufacturer)

Sender unit resistance-full

Sender unit resistance-empty

5YR1 (CHAO LONG)

4-10 Ω

90-100 Ω

...

...

...

Starting circuit cut-off relay

Model (manufacturer)

Coil resistance

09-N (SHI LIN)

54~66 Ω

...

...

Thermostat switch
Model (manufacturer) 1AJ (NATIONAL) ...
Carburetor heater

Manufacturer

Coil resistance

MIKUNI

30 Ω 20°C

...

...

Fuel lever meter
Type( manufacturer ) Moving magneto (CHAO LONG) ...
Fuse (amperage × quantity)

Main fuse

Reserve fuse

10A×1

10A×1

...

...

CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS

CONVERTION TABLE

All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMPERIAL
** mm 0.03937 ** in
2 mm 0.03937 0.08 in

CONVERSION TABLE

METRIC TO IMPERIAL
Tightening torque Metric unit Multiplier Imperial unit

m·kg

m·kg c

m·kg

cm·kg

7.233

86.794

0.0723

0.8679

ft·lb

in·lb

ft·lb

in·lb

Weight

kg

g

2.205

0.03527

lb

oz

Speed km/hr 0.6214 mph
Distance

km

m

m

cm

mm

0.6214

3.281

1.094

0.3937

0.03937

mi

ft

yd

in

in

Volume/Capacity

cc (cm3)

cc (cm3)

lt (liter)

lt (liter)

0.03527

0.06102

0.8799

0.2199

oz (IMP liq.)

cu-in

qt (IMP liq.)

gal (IMP liq.)

Misc.

kg/mm

kg/cm2

Centigrade (°C)

55.997

14.2234

9/5+32

lb/in

psi (lb/in2)

Fahrenheit (°F)

GENERAL TIGHTENING TORQUE SPECIFICATIONS

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.

  1. Width across flats
  2. Thread diameter
A (nut) B (bolt) General tightening torques
Nm m•kg ft•lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94

ENGINE TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES - Part 1
ENGINE TIGHTENING TORQUES - Part 2

Cylinder head tightening sequence

CHASSIS TIGHTENING TORQUES

CHASSIS TIGHTENING TORQUES

warning NOTE:

  1. First, tighten the ring nut (lower) approximately 28 Nm (2.8m•kg, 20.3ft•lb) by using the torque-wrench, then loosen the ring nut 1/4 turn.
  2. Second, tighten the ring nut (lower) approximately 9 Nm (0.9m•kg, 6.5ft•lb) by using the torque-wrench.
  3. Installing the rubber washer.
  4. Then finger tighten the center ring nut and touch rubber washer. Align the slots both ring nut and install the lock washer.
  5. Final, hold the ring nuts (lower and center) and tighten the ring nut (upper) 75Nm (7.5 m•kg, 54.2ft•lb) by using the torque wrench.

  1. Lower ring nut
  2. Rubber washer
  3. Center ring nut
  4. Lock washer
  5. Upper ring nut

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE LUBRICATION - Part 1
ENGINE LUBRICATION - Part 2

CHASSIS LUBRICATION POINTS AND LUBRICATION TYPES

Lubrication Point Lubricant
Front wheel oil seal lips
Frame head pipe bearing (upper and lower)
Frame head pipe dust seal lips ( lower)
Tube guide (throttle grip) inner surface
Brake lever and lever holder bolt sliding surface
Sidestand and frame sliding surface
Centerstand sliding surface and mounting bolt
Rear footrest (pin) outside surface
Rear shock absorber backward, bush inner surface and spacer sliding surface
Seat lock cable and cylinder inner surface
Engine bracket and engine mound bolt sliding surface

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