XQ125 XQ150 2001 5HT1-AE2 SERVICE MANUAL
EASM0000 XQ125 / XQ150 SERVICE MANUAL © 2001 by MBK Industrie 2nd edition, April 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.
EASM0001 NOTICE This manual was produced by the MBK Industrie primarily for use by Yamaha and MBK dealers 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 and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 햲 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to "SYMBOLS". 햳 Each chapter is divided into sections.
햲 EAS00008 햳 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 햲 to 햺 indicate the subject of each chapter. 햲 General information 햳 Specifications 햴 Periodic checks and adjustments 햵 Engine 햶 Cooling system 햷 Carburetor 햸 Chassis 햹 Electrical system 햺 Troubleshooting SPEC 햴 햵 CHK ADJ ENG 햶 햷 COOL CARB 햸 햹 ELEC CHAS 햺 Symbols 햻 to 헃 indicate the following.
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE OVERHAUL ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 SPECIFICATIONS COOLING SYSTEM CARBURETOR CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING
GEN INFO 1
GEN INFO CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................... 1-1 MODEL LABEL ........................................................................................ 1-1 FEATURES ................................................................................................... 1-2 OIL INDICATOR LIGHT ...............................................
SCOOTER IDENTIFICATION GEN INFO EAS00015 GENERAL INFORMATION 햲 SCOOTER IDENTIFICATION EASM0002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 햲 is stamped into the frame. ZAUM0113 EASM0003 MODEL LABEL The model label 햲 is affixed under the seat. This information will be needed to order spare parts.
FEATURES GEN INFO EASM0004 FEATURES OIL INDICATOR LIGHT • FUNCTION Pulses (travel distance signals) from the speedometer are counted and cause the oil indicator light to come on at 500 km for the first time and thereafter every 3,000 km. In this way, the light indicates the time for oil change. • RESETTING PROCEDURE To reset the oil change indicator light 1) Press the “TRIP” button while turning the key to “ON”. 2) Release the button and the oil change indicator light will go off.
FEATURES GEN INFO THE CLOCK • Setting the clock To set the clock: 1) Make sure that the key is turned to “OFF”. 2) Press the “TRIP” button for two seconds and the hour display will flash. 3) Press the “TRIP” button to set the hours. 4) Press the “TRIP” button for two seconds, and the first minute digit will flash. 5) Press the “TRIP” button to set the first minute digit. 6) Press the “TRIP” button for two more seconds, and the second minute digit will flash.
IMPORTANT INFORMATION GEN INFO EAS00020 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.
IMPORTANT INFORMATION GEN INFO EAS00023 LOCK WASHERS / PLATES AND COTTER PINS 1.After removal, replace all lock washers / plates 햲 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. 햲 EAS00024 BEARINGS AND OIL SEALS 1.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 base grease.
CHECKING THE CONNECTIONS GEN INFO EAS00026 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. 3.Check: • all connections Loose connection → Connect properly. 햲 NOTE: If the pin 햲 on the terminal is flattened, bend it up. 4.
SPECIAL TOOLS GEN INFO EAS00027 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.
SPECIAL TOOLS Tool No. 90890-01367 90890-01368 Tool name/usage Fork seal driver weight Frok seal driver attachment These tools are used when installing the fork seal. 90890-01701 Sheave holder This tool is used to hold the secondary sheave when removing or installing the nut. 90890-03111 Valve adjusting tool This tool is necessary for adjusting valve clearance. 90890-03112 Pocket Tester This instrument is invaluable for checking the electrical system.
SPECIAL TOOLS Tool No. 90890-04117 Tool name/usage Valve guide installer This tool is needed to install the valve guide spring. 90890-04118 Valve guide reamer This tool is used to rebore the valve guide. 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. 90890-85505 Yamaha bond No. 1215 This sealant (bond) is used for crankcase mating surface, etc. 90890-03081 Compression gauge This gauge is used to measure the engine compression.
SPEC 2
SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ...................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................. 2-4 ENGINE ................................................................................................... 2-4 CHASSIS ................................................................................................. 2-8 ELECTRICAL ..........................................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item XQ125 [XQ150] Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 1.920 mm 750 mm 1.180 mm 824 mm 1.400 mm 118 mm 2.
GENERAL SPECIFICATIONS Item SPEC XQ125 [XQ150] Carburetor Type/quantity Manufacturer TK 5DS/1 [TK 5KD/1] TEIKEI Spark plug Type Manufacturer Spark plug gap CR8E NGK 0.5~0.7 mm Clutch type Dry, centrifugal automatic Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Helical gear 40/15 (2.666) Spur gear 44/12 (3.
GENERAL SPECIFICATIONS Item SPEC XQ125 [XQ150] Brake Front brake type Front brake operation Rear brake type Rear brake operation Single disc brake Right hand operation Single disc brake Left hand operation Suspension Front suspension Rear suspension Telescopic fork Unit swing Shock absorber Front fork type Rear shock absorber assembly type Coil spring/oil damper Coil spring/oil damper Wheel travel Front wheel travel Rear wheel travel 103 mm 95 mm Electrical Ignition system type Charging system ty
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS * [XQ 150] ENGINE Item Standard Limit Cylinder head Warp limit ••• Cylinder Bore size Out of round limit 53.700~53.705 mm [59.500~59.505 mm]* ••• ••• 0.05 mm Camshaft Drive system Cam dimensions Intake “A” “B” “C” Exhaust “A” “B” “C” Camshaft runout limit 0.03 mm Chain drive (left) C A B 30.811 ~ 30.911 mm 25.145 ~ 25.245 mm 5.666 m 30.811 ~ 30.911 mm 25.152 ~ 25.252 mm 5.659 m ••• Cam chain Cam chain type/No.
MAINTENANCE SPECIFICATIONS SPEC * [XQ 150] Item Valve spring Free length Set length (valve closed) Compressed pressure Tilt limit Standard IN/EX IN/EX IN/EX IN/EX Piston Piston to cylinder clearence Piston size “D” D Measuring point “H” Piston pin bore inside diameter Piston pin outside diameter Piston rings Top ring: Type End gap (installed) Side clearance (installed) 2 nd ring: Type End gap (installed) Side clearence (installed) Oil ring: End gap (installed) H Limit 41.94 mm 37.5 mm 45.1 ~ 50.
MAINTENANCE SPECIFICATIONS SPEC * [XQ 150] Item Carburetor Type I.D mark Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N) Pilot air jet (P.A.J.1) Needle jet (N.J) Pilot jet (P.J) Pilot screw (P.S) Valve seat size (V.S) Starter jet 1 (G.S.1) Float height (F.L) Engine idle speed Standard TK 5DS [TK 5KD]* ••• #116 [#114] ø1.0 [ø1.4] 4E31 (3/5) [4E32 (3/5)]* ø1.30 2.590 #38 [#36] 2 1/4 ~ 2 3/4 [2 ~ 4]* ø2.00 #45 5 ~ 6 mm 1.600 ~ 1.
MAINTENANCE SPECIFICATIONS Item SPEC Size Crankshaft oil seal (left) Crankshaft oil seal (right) Crankshaft oil seal (right) Camshaft bearing (left) Camshaft bearing (right) Starter clutch bearing Primary drive gear bearing (left) Primary drive gear bearing (right) Primary drive gear oil seal Main axle bearing (left) Main axle bearing (right) Drive axle bearing (left) Drive axle bearing (right) Drive axle oil seal 22 x 32 x 7 19 x 30 x 8 (Reinforced) 19 x 30 x 8 (Double lips) 20 x 42 x 12 15 x 32 x 9 17
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Steering system Steering bearing type Front suspension Front fork travel Spring rate Stroke (K1) (K2) (K1) (K2) Oil capacity Oil grade Inner tube outer diameter Optional spring Rear suspension Shock absorber travel Fitting length Spring rate (K1) (K2) (K3) Stroke (K1) (K2) (K3) Spring preload adjusting position Minimum Standard Maximum Limit Ball bearing ••• 103 mm 6.1 N/mm 7.
MAINTENANCE SPECIFICATIONS Item Front disc brake Type Disc outside diameter x thickness Min. thickness Max deflection Pad thickness Master cylinder inside diameter Caliper cylinder outside diameter Brake fluid type Standard SPEC Limit Single disc brake 245 x 4.7 mm ••• ••• 4 mm 13 mm 28 mm DOT #3 or DOT #4 ••• ••• 4.2 mm 0.15 mm 0.8 mm ••• ••• ••• Rear brake Type Disc outside diameter x thickness Min.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Ignition timing Ignition timing (B.T.D.C) Advanced timing (B.T.D.C) Advancer type 10° at 1.700 rpm 26° at 4.500 rpm Digital ••• ••• ••• Ignition system Pickup coil resistance Source coil resistance 248 ~ 372 Ω at 20°C 720 ~ 1080 Ω at 20°C ••• ••• Ignition coil Manufacturer Minimum spark gap Primary coil resistance Secondary coil resistance MORIYAMA 0.5 mm 0.32 ~ 0.48 Ω at 20°C 5.7 ~ 8.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit Horn Model/manufacturer Maximum amperage YF-12 / NIKKO 3A ••• ••• Turn signal relay Model/Manufacturer Turn signal blinking frequency 800 TRANSVAL / 01.2320.01 GUILERA 65 ~ 95 cycles/min. / 70 ~ 90 cycles/min. ••• ••• Fuel gauge Model/manufacturer Sender unit resistance - full - empty 25.33.07 / MAXIMA 4 ~ 10 Ω 90 ~ 100 Ω ••• ••• ••• Circuit breaker Main Radiator fan fuse 20 A x 1 pcs 7.
CONVERSION TABLE SPEC AS00028 CONVERSION 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 IMPERERIAL ** mm x 0.03937 = ** in 2 mm x 0.03937 = 0.08 in CONVERSION TABLE METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Torque m•kg m•kg cm•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/h 0.
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00029 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.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE Item Oil check bolt Spark plug Cylinder, water drain bolt Cylinder head and cylinder Cylinder head and cylinder Cylinder and crankcase Camshaft bearing stopper Camchain guide Valve adjuster nut Camshaft pinion bolt Camshaft tensionner Rocker shaft securing plate Thermostatic valve cover Water pump housing cover Water pump housing Water pump housing Thermostatic valve cover Oil pump Engine drain plug Inlet manifold on cylinder head Air filter cover V-belt
TIGHTENING TORQUES Item Fastener Thermo unit Coolant drain bolt on cylinder Starter motor Rotor Bolt Bolt Nut Stator Bolt 2-15 Thread size Pt 1/8 M6 M6 M12 M16 M16 M6 Q'ty 1 1 2 1 1 1 3 SPEC Tightening torque Nm 75 8 65 70 225 225 70 m•kg 7.5 0.8 6.5 7.0 22.5 22.5 7.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES CHASSIS Item Frame with engine bracket Engine bracket 2 with 3 E/G bracket with E/G (with main stand) Exhaust pipe stud bolt on cylinder Muffler on rear arm Rear arm on crankcase Muffler protector Seat rail with frame Rear cushion with frame Rear cushion with engine Steering shaft Handle with steering shaft Master cylinder with handle Seat lock Box with seat rail Fuel cock with tank Handle seat with frame Box with fuel tank Screw tapping in plastic Screw tapping
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips O-ring (Except V-belt drive unit) Cylinder head tightening nut mounting surface Crankshaft pin outside Connecting rod big end thrust surface Rotary filter inner surface Drive gear inner surface Cam chain outside sprocket inner surface Piston pin Piston outside and ring groove Camshaft cam profile Valve stem (IN, EX) Valve stem end (IN, EX) Rocker shaft Valve rocker a
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left/right) Steering head pipe bearing (upper/lower) Tube guide (throttle grip) inner surface Brake cable (brake lever) Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft 2-18
COOLING SYSTEM DIAGRAMS SPEC EAS00033 COOLING SYSTEM DIAGRAMS Radiator cap Coolant tank cap Coolant hose (cylinder head outlet) Frame Coolant tank Coolant tank breather hose Clip Drain bolt Thermo switch cover Clip Hose Coolant hose (pump inlet) Clamp A Keep the smaller diameter for fixing on the frame (ø 22). B Keep the larger diameter for fixing the hose (ø 24).
COOLING SYSTEM DIAGRAMS SPEC EAS00033(bis) COOLING SYSTEM DIAGRAMS Radiator cap Coolant tank Coolant upper level mark Coolant lower level mark Coolant tank breather hose Battery box Drain bolt (on water pump) Under cover Thermo switch (on radiator) Radiator Grommet Coolant hose (pump inlet) A Pass the hose under the seat rail fixation. B Pass the hose under the frame down tube. C Pass the hose through the under cover.
LUBRICATION DIAGRAMS SPEC EAS00034 LUBRICATION DIAGRAMS 1 Lubrication of the cylinder head Cylinder head Cylinder Crankcase 2 Lubrication of the crankshaft Crankshaft 1 2 2-21
