1999-2003 Yamaha Beewee YW100 Service & Repair Manual

YW100 4VP-ME1

EB000000 YW100E SERVICE MANUAL ©1999 by Yamaha Motor TAIWAN Co., Ltd. 1st Edition, March 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd. is expressly prohibited.

YP002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See”Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol on the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accom- panied by corresponding illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs. 2. Numbers 5 are given in the order of jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6. The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart. 4 5 6 7 8 1 2 3

INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING 1 2 3 4 5 6 7 8 – +

EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 0 to u are used to identify the specifications appearing in the text. 0 Possible to maintain with engine mounted q Filling fluid w Lubricant e Special tool r Tightening t Wear limit, clearance y Engine speed u Ω, V, A Illustrated symbols i to d in the exploded diagrams indicate the types of lubricants and lubrication points. i Apply engine oil o Apply gear oil p Apply molybdenum disulfide oil a Apply wheel bearing grease s Apply lightweight lithium-soap base grease d Apply molybdenum disulfide grease Illustrated symbols f to g in the exploded diagrams indicate the where to apply locking agent f and when to install new parts g . f Apply locking agent (LOCTITE ® ) g Use new one GEN INFO SPEC INSP ADJ ENG COOL CARB CHAS – + ELEC TRBL SHTG B LS M LT New E G M 1 2 3 4 5 6 7 8 9 0 T R . . q w e r t y u i o p a s d f g

EB001000 NOTICE This manual was produced by the Yamaha Motor Taiwan Company primarily for use by Yamaha/ MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha/MBK scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Repairs attempted by anyone without this knowledge are likely to render the scooter unsafe and unfit for use. Yamaha Motor Taiwan Company, Ltd. is continually striving to improve all its models. Modifica- tions and significant changes in specifications or procedures will be forwarded to all authorized Yamaha/MBK dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations. 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 scooter operator, a bystander or a person inspecting or repairing the scooter. A CAUTION indicates special precautions that must be taken to avoid dam- age to the scooter. A NOTE provides key information to make procedures easier or clearer. w Q NOTE: cC

CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ............................................................................................................. 1-1 FRAME SERIAL NUMBER ............................................................................................................. 1-1 ENGINE SERIAL NUMBER ............................................................................................................ 1-2 IMPORTANT INFORMATION ............................................................................................................ 1-3 PREPARATION FOR REMOVAL PROCEDURES ........................................................................... 1-3 REPLACEMENT PARTS ................................................................................................................. 1-3 GASKETS, OIL SEALS, AND O-RINGS ........................................................................................ 1-3 LOCK WASHERS/PLATES AND COTTER PINS ........................................................................... 1-3 BEARINGS AND OIL SEALS ......................................................................................................... 1-4 CIRCLIPS ........................................................................................................................................ 1-4 CHECKING OF CONNECTIONS ........................................................................................................ 1-5 HOW TO USE THE CONVERSION TABLE ....................................................................................... 1-6 SPECIAL TOOLS ................................................................................................................................ 1-7

CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ............................................................................................................. 2-1 MAINTENANCE SPECIFICATIONS ................................................................................................... 2-4 ENGINE .......................................................................................................................................... 2-4 CHASSIS ........................................................................................................................................ 2-7 ELECTRICAL ................................................................................................................................... 2-9 GENERAL TORQUE SPECIFICATIONS ........................................................................................... 2-11 LUBRICATION POINTS AND LUBRICANT TYPE ........................................................................... 2-12 ENGINE ........................................................................................................................................ 2-12 CHASSIS ...................................................................................................................................... 2-12 CABLE ROUTING ............................................................................................................................. 2-13

CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENTS NTRODUCTION ................................................................................................................................. 3-1 PERIODIC MAINTENANCE/ LUBRICATION INTERVALS ............................................................... 3-1 SIDECOVER AND SEAT ................................................................................................................ 3-3 JOB INSTRUCTION CHART .......................................................................................................... 3-3 LOWER COWLING ,UPPER COVER, LEG SHIELD1,2 AND FOOTREST BOARD ....................... 3-4 HANDLEBAR COVER(FRONT AND REAR) ................................................................................... 3-5 ENGINE .............................................................................................................................................. 3-6 IDLING SPEED ADJUSTMENT ..................................................................................................... 3-6 THROTTLE CABLE FREE ADJUSTMENT ..................................................................................... 3-7 AUTOLUBE PUMP AIR BLEEDING ............................................................................................... 3-8 AUTOLUBE PUMP CABLE ADJUSTMENT .................................................................................. 3-8 SPARK PLUG INSPECTION ........................................................................................................... 3-9 ENGINE OIL LEVEL INSPECTION ............................................................................................... 3-10 TRANSMISSION OIL REPLACEMENT ........................................................................................ 3-11 AIR FILTER ELEMENT CLEANING .............................................................................................. 3-12 V-BELT INSPECTION ................................................................................................................... 3-14 CHASSIS .......................................................................................................................................... 3-15 FRONT BRAKE LEVER FREE PLAY CHECK ................................................................................ 3-15 REAR BRAKE LEVER FREE PLAY CHECK ................................................................................... 3-15 BRAKE PAD INSPECTION ........................................................................................................... 3-15 BRAKE SHOE INSPECTION ........................................................................................................ 3-16 BRAKE FLUID LEVEL INSPECTION ............................................................................................ 3-16 AIR BLEEDING(HYDRAULIC BRAKE SYSTEM) ......................................................................... 3-17 STEERING ADJUSTMENT .......................................................................................................... 3-18 TIRE INSPECTION ........................................................................................................................ 3-19 WHEEL INSPECTION ................................................................................................................... 3-20 FRONT FORK INSPECTION ......................................................................................................... 3-20 REAR SHOCK ABSORBER INSPECTION .................................................................................... 3-20 SEAT LOCK CABLE ADJUSTMENT ........................................................................................... 3-20 ELECTRICAL ..................................................................................................................................... 3-21 BATTERY INSPECTION ............................................................................................................... 3-21 FUSE INSPECTION ...................................................................................................................... 3-26 HEADLIGHT BEAM ADJUSTMENT ............................................................................................ 3-27 HEADLIGHT BULB REPLACEMENT ............................................................................................ 3-27 TAILLIGHT BULB/REAR FLASHER BULB REPLACEMENT ....................................................... 3-28 TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT ........................................................... 3-28 LICENCE LIGHT BULB REPLACEMENT ...................................................................................... 3-29

CHAPTER 4. ENGINE ENGINE OVERHAUL ......................................................................................................................... 4-1 WIREHARNESS AND CABLES ...................................................................................................... 4-1 CYLINDER HEAD, CYLINDER AND PISTON .................................................................................... 4-3 CYLINDER HEAD CYLINDER AND PISTON ................................................................................. 4-3 PISTON PIN AND PISTON REMOVAL .......................................................................................... 4-4 CYLINDER HEAD INSPECTION ..................................................................................................... 4-4 CYLINDER AND PISTON INSPECTION ........................................................................................ 4-5 PISTON RINGS INSPECTION ........................................................................................................ 4-7 PISTON PIN AND PISTON PIN BEARING .................................................................................... 4-7 PISTON PIN AND PISTON INSTALLATION ................................................................................. 4-8 CYLINDER AND CYLINDER HEAD ................................................................................................ 4-9 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHAVE ............................................................. 4-11 KICK STARTER AND CRANKCASE COVER(LEFT) ..................................................................... 4-11 KICK STARTER ............................................................................................................................. 4-12 KICK STARTER INSTALLATION ................................................................................................. 4-13 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................ 4-14 SECONDARY SHEAVE ................................................................................................................ 4-15 PRIMARY SHEAVE REMOVAL .................................................................................................... 4-16 SECONDARY SHEAVE REMOVAL .............................................................................................. 4-16 CLUTCH INSPECTION ................................................................................................................. 4-17 V-BELT INSPECTION ................................................................................................................... 4-18 PRIMARY SHEAVE INSPECTION ................................................................................................ 4-19 SECONDARY SHEAVE ................................................................................................................ 4-20 SECONDARY SHEAVE INSTALLATION ..................................................................................... 4-21 PRIMARY SHEAVE ...................................................................................................................... 4-22 STARTER CLUTCH AND STARTER MOTOR ................................................................................. 4-24 STARTER CLUTCH AND STARTER MOTOR .............................................................................. 4-24 STARTER CLUTCH AND GEARS ................................................................................................ 4-26 C.D.I. MAGNETO ............................................................................................................................. 4-27 C.D.I. MAGNETO ......................................................................................................................... 4-27 C.D.I. MAGNETO REMOVAL ....................................................................................................... 4-28 C.D.I. MAGNETO INSTALLATION .............................................................................................. 4-28 AUTOLUBE PUMP ........................................................................................................................... 4-29 AUTOLUBE PUMP ....................................................................................................................... 4-29 AUTOLUBE PUMP INSTALLATION ........................................................................................... 4-30 TRANSMISSION .............................................................................................................................. 4-31 TRANSMISSION .......................................................................................................................... 4-31 CRANKCASE AND REED VALUE ................................................................................................... 4-33 CRANKCASE AND REED VALUE ................................................................................................ 4-33 CRANKCASE(RIGHT)REMOVAL ................................................................................................. 4-35 REED VALVE INSPECTION ......................................................................................................... 4-35 CRANKCASE(RIGHT)INSTALLATION ........................................................................................ 4-36 CRANKSHAFT .................................................................................................................................. 4-38 CRANKSHAFT .............................................................................................................................. 4-38 CRANKSHAFT REMOVAL ........................................................................................................... 4-39 CRANKSHAFT INSPECTION ....................................................................................................... 4-39 CRANKSHAFT INSTLLATION ..................................................................................................... 4-40

1999-2003 Yamaha Beewee YW100 Service & Repair Manual

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