YAMAHA YQ100 Service Manual

YQ100

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5ME1-AE1

SERVICE MANUAL

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YQ100

SERVICE MANUAL

1st Edition, February 2000

reprinting or unauthorized use

without the written

permission of MBK INDUSTRIE

is expressly prohibited.

NOTICE

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This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe.

MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and MBK dealers and will, where applicable, appear in future editions of this manual.

DOCUMENTATION TECHNIQUE

MBK INDUSTRIE

PARTICULARY IMPORTANT INFORMATION

This material is distinguished by the following notation :

WARNING

CAUTION:

NOTE:

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 damage to the scooter.

A NOTE provides key information to make procedures easier or clearer.

EAS00007

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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.

 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".

 Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears.

 Sub-section titles appear in smaller print than the section title.

 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates

a disassembly step.

 Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS".

 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

 Jobs requiring more information (such as special tools and technical data) are described

sequentially.







CDI MAGNETO

CDI MAGNETO, ROTOR, STATOR

T.R

37 Nm (3.7 m.kg)

T.R

6.5 Nm (0.65 m.kg)

Order

1 Fan cover 1 2 Fan 1 3 Nut 1 4 Washer 1 5 Magneto rotor 1 6 Woodruff key 1 7 Stator assembly 1 8 Gasket 1 9 Oil seal 1

Job name/Part name

CDI magneto, Rotor, Startor removal

Seat cover Side covers Footrest board

CDI MAGNETO

ENG







T.R

8.5 Nm (0.85 m.kg)

Q'ty

Remove the parts in the order below

For installation, reverse the removal procedure

4 - 27 4 - 28

Remarks

Refer to

"COVERS" in Cha

Refer to

"CDI MAGNETO REMOVAL" .

section

pter 3.



CDI MAGNETO

REMOVAL

NOTE:

It is not necessary to remove the engine for removing the CDI magneto

1.Remove:

• Nut  (rotor)

• Plate washer

NOTE:

Hold the rotor using  flywheel holder  to loosen the nut

Flywheel holder:

90890-01235

2.Remove:

• Rotor

• Woodruff key Use the flywheel puller.

Flywheel puller:

90890-01189

• Stator assembly

• Gasket

INSTALLATION

1.Install:

• Gasket

2.Apply

• Lithium soap base grease (to oil seal )

3.Pass the CDI magneto lead through the crankcase

ENG



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GEN

INFO

SPEC

EAS00009

SYMBOLS

The following symbols are not relevant to every vehicle.

INSP

ADJ

CARB

ELEC

{

ENG

CHAS

TRBL SHTG

}

Symbols Q to I indicate the subject of each chapter.

Q General information W Specifications E Periodic checks and adjustments R Engine T Carburetor Y Chassis U Electrical system I Troubleshooting

Symbols O to r indicate the following.

O Serviceable with engine mounted P Filling fluid { Lubricant } Special tool q Tightening torque w Wear limit, clearance e Engine speed r Electrical data

[

T.R

]

Symbols t to p in the exploded diagrams indicate the types of lubricants and lubrication points.

t Engine oil y Gear oil u Molybdenum disulfide oil i Wheel bearing grease o Lithium soap base grease p Molybdenum disulfide grease

Symbols [ to ] in the exploded diagrams indicate the following.

[ Apply locking agent (LOCTITE®) ] Replace the part

EAS00011

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TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

ENGINE

CARBURETOR

GEN

INFO

SPEC

INSP

ADJ

ENG

CARB

CHASSIS

ELECTRICAL SYSTEM

TROUBLESHOOTING

CHAS

ELEC

TRBL

SHTG

7 8

GEN

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INFO

GEN

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INFO

CHAPTER 1.

GENERAL INFORMATION

SCOOTER IDENTIFICATION........................................................................ 1-1

VEHICULE IDENTIFICATION NUMBER .................................................1-1

ENGINE NUMBER ...................................................................................1-1

IMPORTANT INFORMATION ...................................................................... 1-3

PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ 1-3

REPLACEMENT PARTS .........................................................................1-3

GASKETS, OIL SEALS, AND O-RINGS ................................................. 1-3

LOCK WASHERS/PLATES AND COTTER PINS.................................... 1-4

BEARINGS AND OIL SEALS................................................................... 1-4

CIRCLIPS................................................................................................. 1-4

CHECKING THE CONNECTIONS ................................................................1-5

HOW TO USE THE CONVERSION TABLE..................................................1-6

SPECIAL TOOLS ..........................................................................................1-7

GEN

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

GENERAL INFORMATION

EAS00015

GENERAL INFORMATION

SCOOTER IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number  is stamped on the bottom of the frame as shown.

NOTE:

The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your state.

INFO



ENGINE NUMBER

The engine serial number  is stamped on the crankcase as shown.

NOTE:

Designs and specifications are subject to change without notice.

112

1-1

GEN

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IMPORTANT INFORMATION

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.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.

INFO

EAS00021

REPLACEMENT PARTS

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

EAS00022

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.

1-2

GEN

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

IMPORTANT INFORMATION

EAS00023

LOCK WASHERS / PLATES AND COTTER PINS

1.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.

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. Oil bearings liberally when installing, if appropriate.

 Bearing

INFO











CAUTION:

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

 Oil seal

EAS00025

CIRCLIPS

1.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.

 Shaft

1-3

GEN

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

CHECKING THE CONNECTIONS

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.

INFO



NOTE:

If the pin  on the terminal is flattened, bend it up.

4.Connect:

•lead

•coupler

•connector

NOTE:

Make sure all connections are tight.

5.Check:

•continuity (with the pocket tester)

Pocket tester

90890-03112

NOTE:

If there is no continuity, clean the terminals.

NOTE:

When checking the wire harness, perform steps 1 to 3.

NOTE:

As a quick remedy, use a contact revitalizer available at most part stores.

1-4

GEN

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HOW TO USE THE 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 7.233 ft.lb

m·kg 86.794 in.lb cm·kg 0.0723 ft.lb cm·kg 0.8679 in.lb

Weight kg 2.205 lb

g 0.03527 oz Speed km/h 0.6214 mph Distance km 0.6214 mi

m 3.281 ft m 1.094 yd

cm 0.3937 in

mm 0.03937 in

Volume/ cc (cm Capacity cc (cm

lit (litre) 0.8799 qt(IMP liq.)

lit (litre) 0.2199 gal(IMP liq.) Miscella- kg/mm 55.997 lb/in neous kg/cm

Centrigrade 9/5(°C)+32 Fahrenheit(°F)

) 0.03527 oz(IMP liq.)

) 0.061102 cu.in

14.2234 psi(lb/in2)

INFO

1-5

GEN

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SPECIAL TOOLS

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 N° Tool name/usage Illustration

90890-01135

90890-01189

90890-01235

Crankcase separating tool

This tool is used to separate the crankcase and remove the crankshaft.

Flywheel puller

This tool is used to remove the flywheel magneto.

Rotor holding tool

INFO

90890-01274 90890-01275 90890-01277 90890-01288

90890-01384

90890-01348

90890-01701

This tool is used to remove the flywheel magneto.

Crankshaft installer pot  Crankshaft installer bolt  Adapter  Spacer  These tools are used to install the crankshaft.

Oil seal guide

This tool is used to protect the oil seal lip when installing the secondary sheave.

Locknut wrench

This tool is used when removing or installing the secondary sheave nut.

Sheave holder

This tool is used to hold the secondary sheave when removing or installing the nut.









90890-03079

Thickness gauge

This tool is used to measure the clearance.

1-6

GEN

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SPECIAL TOOLS

Tool N° Tool name/usage Illustration

90890-01337

90890-01409 90890-01410

90890-01268 90890-01403

Clutch spring holder.

This tool is used for compressing the spring of the secondary sheave when removing the nut.

Oil seal guide  Oil seal installer .

This tool is used to install the left side crankcase oil seal.

Ring nut wrench  Steering nut wrench 

These tools are used to loosen and tighten the steering ring nuts.



INFO



90890-01367 90890-01400

90890-03112

90890-03113

90890-06754

90890-01294  90890-01326 

Fork seal driver weight . Fork seal driver attachment (ø30) 

These tools are used when installing the fork seals.

Pocket Tester

This instrument is invaluable for checking the electrical system.

Engine tachometer.

This tool is needed for detecting the engine rpm.

Ignition checker.

This instrument is necessary for checking the ignition system components.

Damper rod holder. T-handle.

This tools are used when removing the front fork legs.





1-7

SPEC

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SPEC

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CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS ...................................................................... 2-1

MAINTENANCE SPECIFICATIONS ............................................................. 2-4

ENGINE ...................................................................................................2-4

TIGHTENING TORQUES (ENGINE) .......................................................2-7

CHASSIS .................................................................................................2-9

TIGHTENING TORQUES (CHASSIS) ...................................................2-11

ELECTRICAL .........................................................................................2-13

GENERAL TORQUE SPECIFICATIONS ................................................... 2-15

LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-16

ENGINE .................................................................................................2-16

CHASSIS ...............................................................................................2-17

CABLE ROUTING .......................................................................................2-18

GENERAL SPECIFICATIONS

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SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YQ100

Dimensions:

Overall length 1,762 mm Overall width 690 mm Overall height 1,151 mm Seat height 812 mm Wheelbase 1,272 mm Minimum ground clearance 157 mm Minimum turning radius 1,800 mm

Basic weight:

With oil and full fuel tank 95 kg

Engine:

Type Cylinder arrangement Forward- inclined single cylinder Displacement 101 cm Bore x stroke 52.0 x 47.6 mm Compression ratio 12:1 ± 0.5

Starting system Electrical and Kick starter Lubrication system: Separate lubrification Oil type or grade:

Engine oil: Yamalube 2 or 2 stroke engine oil (JASO FC

Transmission oil SAE 85W140 type SE Oil capacity:

Engine oil: 1.3 L

Transmission oil:

Periodic oil change 0.11 L

Total amount 0.13 L Air filter: Wet type element Fuel:

Type Regular unleaded gasoline with a research

Tank capacity: 7.0 L Carburetor:

Type/quantity TK ø 16

Manufacturer TEIKEI

Air-cooled-2 stroke, gasoline torque induction.

grade or ISO EG-C, ISO EG-D grade).

octane number of 91 or higher.

2-1

GENERAL SPECIFICATIONS

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SPEC

Model YQ100

Spark plug:

Type BR8HS Manufacturer NGK

Gap 0.5 ~ 0.7 mm Clutch type: Dry, centrifugal automatic Transmission:

Primary reduction system Helical gear

Primary reduction ratio 47 / 15 (3.133)

Secondary reduction system Spur gear

Secondary reduction ratio 43 / 13 (3.308)

Transmission V-belt

Operation Automatic Chassis:

Frame type Steel tube backbone

Caster angle 27°

Trail 89.4 mm Tires:

Type Tubeless

Size Front 130 / 60 -13

Rear 140 / 60 -13 Manufacturer (Type) MICHELIN(BOPPER) / PIRELLI (SL 36) Wear limit (Front/Rear) 0.8 mm

Tires pressure (Cold tire):

Front (single riding) 150 kPa (1.50 Kg/cm Rear (single riding) 150 kPa (1.50 Kg/cm Front (dual riding) 150 kPa (1.50 Kg/cm Rear (dual riding) 150 kPa (1.50 Kg/cm

, 1.50 bar)

Brakes: Front brake type Disk brake Operation Right hand operation Rear brake type Drum brake Operation Left hand operation

Suspension:

Front Telescopic fork Rear Unit swing

Shock absorber:

Front Coil spring/ Oil damper Rear Coil spring/ Oil damper

2-2

GENERAL SPECIFICATIONS

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Model YQ100

Wheel travel:

Front 80 mm Rear 72 mm

Electrical:

Ignition system CDI Charging system Flywheel magneto Battery type/model YT4L-BS Battery capacity 12V 3AH

Headlight type: Bulb Bulb wattage x quantity:

Headlight 12V 35W/35W x 1 Position light 12V 5W x 1 License light 12V 5W x 1 Taillight / brake light 12V 5W /21W x 1 Flasher light Front 12V 10W x 2

Rear 12V 10W x 2

Meter light 12V 1.2W x 2

Warning lights wattage/quantity:

"OIL" 12V 1.2W x 1 "TURN" 12V 1.2W x 1 "HIGH BEAM" 12V 1.2W x 1

SPEC

2-3

MAINTENANCE SPECIFICATIONS

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SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Model Standard Limit

Cylinder head:

Warp limit *** 0.02 mm

* Lines indicate straight edge

measurements.

Cylinder:

Bore size 52.002 ~ 52.012 mm *** Taper *** 0.05 mm

Piston:

Piston clearance 0.044 ~ 0.045 0.10 mm

Piston size 51.958 ~ 51.967 mm ***

Measuring point* 10 mm ***

Oversize: 1

52.52 mm ***

52.50 mm ***

Piston rings:

Sectional sketch (BxT)/Type:

Top ring 1.2 x 2.05 mm/keystone *** 2nd ring 1.2 x 2.05 mm/keystone ***

End gap (Installed): Top ring 0.15 ~ 0.35 mm *** 2nd ring 0.15 ~ 0.35 mm *** Side clearance (Installed): Top ring 0.03 ~ 0.05 mm *** 2nd ring 0.03 ~ 0.05 mm ***

Piston pin:

Outside diameter 13.996 ~ 14.000 mm 13.975 mm Piston pin to piston clearance 14.004 ~ 14.015 mm 14.045 mm

2-4

MAINTENANCE SPECIFICATIONS

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SPEC

Model Standard Limit

Crankshaft:

Crank width “A” 37.90 ~ 37.95 mm *** Runout limit “C” *** 0.03 mm Connecting rod length 79.9 ~ 80.1 mm Side clearance “D Small End Free Play 0.4 ~0.8 mm ***

Automatic centrifugal clutch:

Clutch shoe thickness 4.0 mm 2.5 mm Clutch shoe spring free length 26.2 mm *** Clutch housing inside diameter 112 mm 112.5 mm Clutch-in revolution 2800 ~ 3400 r/min *** Clutch-stall revolution 4500 ~ 5500 r/min ***

V-belt:

Width 17.7 mm 16.0 mm

Transmission:

Main axle runout limit *** 0.08 mm Drive axle runout limit *** 0.08 mm

Kick starter:

Type Ratchet type *** Kick clip tension force 0.15 ~ 0.25 kg ***

Carburetor: TEIKEI

I.D. mark TK ø16 *** Main jet (M.J.) # 76 *** Main air jet (M.A.J.) *** *** Jet needle (J.N.) # 3SOF-3/5 *** Needle jet (N.J.) ø2.090 *** Cutaway (C.A.) 3.0 *** Pilot jet (P.J.) # 44 *** Bypass 1 (B.P.1) ø 0.80 Air screw (A.S.) 1 5/8 *** Valve seat size (V.S.) ø 1.80 *** Starter jet (G.S.1) 43 *** Engine idle speed 2000 ± 200 r/min ***

”

0.2 ~ 0.5 mm ***

2-5

MAINTENANCE SPECIFICATIONS

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SPEC

Model Standard Limit

Reed valve:

Valve stopper height 6.0 ~ 6.4 mm *** Reed Valve Clearance Less than 0.2 mm ***

Lubrication System

Autolub Pump Plunger diameter 2.5 mm *** Autolub pump stroke/ Manufacturer PLB-D39 / Dell'orto Minimum output at 3000rpm 4.5 cc/h *** Maximum output at 3000rpm 16 cc/h ***

2-6

MAINTENANCE SPECIFICATIONS

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TIGHTENING TORQUES

ENGINE

Tightening

Part to be tightened Part Thread Q'ty torque Remarks

name size

Nm m.kg Spark plug - M14 1 20 2.0 Head cylinder Nut M7 4 14 1.4 Cylinder stud bolt M7 4 17 1.7 Air shroud (3) Screw M6 3 7 0.7 Fan Screw M6 3 7 0.7 Air shroud (1x3) Screw M6 1 2 0.2 Oil pump assembly Screw M5 2 4 0.4 Reed valve Bolt M6 4 11 1.1 Air filter Screw M6 1 8.5 0.85 Air duct Screw M6 2 6.5 0.65 Exaust pipe/engine Screw M8 2 29 2.9 Exhaust pipe / Cylinder Bolt M6 2 8.5 0.85 Muffler protector Bolt M6 3 9 0.9 Cap and pipe Bolt M6 3 11 1.1 Exhaust Cover Bolt M6 3 13 1.3 Crankcase 1x2 Bolt M6 6 12 1.2 Holder Bolt M6 1 7 0.7 Crankcase cover (right cover) Bolt M6 6 12 1.2 Crankcase cover (left cover) Bolt M6 12 12 1.2 Drain bolt Bolt M8 1 18 1.8 Plug oil Plug oil M14 1 3 0.3 Idle gear plate Screw M6 2 8 0.8 Self starting motor Bolt M6 2 13 1.3 Cluth housing Nut M10 2 40 4.0 Base magneto Screw M6 2 8 0.8 C.D.I. rotor Nut M10 1 43 4.3 Primary sheave Nut M12 1 45 4.5 Kick crank Bolt M6 1 13 1.3

SPEC

2-7

MAINTENANCE SPECIFICATIONS

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SPEC

CHASSIS

Model Standard Limit

Steering system:

Steering bearing type Ball bearing *** Size of steel balls x qty: Upper ø4.75 mm x 15 *** Lower ø4.75 mm x 15 *** Lock to lock angle Left 45° *** Right 45° ***

Front suspension:

Front fork travel 80 mm *** Optional spring No Spring rate (K1) 5.7 N/mm *** Stroke (K1) 0 ~ 80 mm ***

Rear suspension:

Shock absorber travel 60 mm *** Spring free length 234 mm *** Spring fitting length 199.5 mm *** Spring rate (K1) 28 N/mm ***

(K2) 35 N/mm ***

Stroke (K1) 0 ~ 92 mm ***

(K2) 92 ~ 115 mm ***

Optional spring No

Wheels:

Front wheel type Cast wheel Rear wheel type Cast wheel Front wheel size/Material MT 3.00 x13 / Aluminium Rear wheel size/Material MT 3.50 x 13 / Aluminium

Rim runout limit:

Front Radial *** 1 mm

Lateral *** 1 mm

Rear Radial *** 1 mm

Lateral *** 1 mm

2-8

MAINTENANCE SPECIFICATIONS

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SPEC

Model Standard Limit

Front disk brake:

Type Single disc *** Diameter and thickness 190.0 x 3.5 mm *** Pad thickness 4.5 mm 2 mm Master cylinder inside diameter 11 mm *** Caliper cylinder inside diameter 30 mm *** Brake fluid type DOT #3 or DOT#4 ***

Rear drum brake:

Type Leading, trailing *** Drum inside diameter 130 mm 130.5 mm Lining thickness 4 mm 2 mm Spring free length 54 mm ***

Brake lever freeplay:

Front brake lever free play 10 ~ 20 mm *** Rear brake lever free play 10 ~ 20 mm ***

2-9

MAINTENANCE SPECIFICATIONS

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TIGHTENING TORQUES

CHASSIS

Tightening

Part to be tightened Thread torque Remarks

size Nm m.kg

Frame with engine bracket M10 42 4.2 Engine bracket with engine M10 50 5.0 Reinforcement tail M8 12.5 1.25 Rear schock absorber with frame (top) M10 31.5 3.15 Rear schock absorber with engine (bottom) M8 17.5 1.75 Handle with steering shaft M10 60 6.0 Steering nut (securing nut) Upper 75 7.5

Center - Lower 38 3.8 1st tightening

22 2.2 2nd tightening Fuel tank M6 6.5 0.65 Seat lock assy' M6 9.5 0.95 Box M6 8 0.8 Cover tail / Reinforcement tail M6 6 0.6 Fuel tank / Fuel cock - 2.5 0.25 Handle seat / Reinforcement tail M6 3.5 0.35 Front disk brake M10 23 2.3 Front caliper M10 23 2.3 Lever camshaft M6 13.5 1.35 Front wheel shaft M10 35 3.5 Rear wheel shaft M14 125 12.5 Wheel / Hub M10 47 4.7 Guard flap M6 8 0.8 Oil tank M6 5 0.5 Leg shield / Frame M6 4 0.4 Footrest board / Frame M6 4 0.4 Fuel tank M6 6.5 0.65

SPEC

2-10

MAINTENANCE SPECIFICATIONS

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Tightening

Part to be tightened Thread torque Remarks

size Nm m.kg

Screws tapping in plastic Ø5 3.2 0.32 Screws tapping in clip Ø5 2.2 0.22

SPEC

2-11

MAINTENANCE SPECIFICATIONS

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SPEC

ELECTRICAL

Model Standard Limit

Voltage: 12 V *** Ignition system:

Ignition timing(B.T.D.C.) 14° at 5000 r/min *** Ignition timing type Constant ***

CDI:

Model/Manufacturer 4VP / YAMAHA Pickup coil resistance (color) 400 ~ 600 Ω at 20°C (WR/WL) ***

(White/Red-Black)

Source coil resistance (color) 640 ~ 960 Ω at 20°C (BR/GW) ***

(Black/Red-Black)

Ignition coil:

Model/Manufacturer 2JN / MORYAMA *** Minimum spark length *** *** Primary coil resistance 0.32 ~ 0.48 Ω at 20°C *** Secondary coil resistance 5.68 ~ 8.52 kΩ at 20°C ***

Spark plug cap:

Type Resin Resistance 5 kΩ at 20°C ***

Charging system / Type Flywheel magneto CDI Magneto:

Model / Manufacturer 4VP / YAMAHA *** Charging coil resistance (color) 0.48 ~ 0,72 Ω at 20°C ***

(White-Black)

Lighting coil resistance (color) 0.40 ~ 0,60 Ω at 20°C ***

(Yellow/Red-Black)

Voltage Regulator / Rectifier:

Type Semi-conductor,

Short-circuit type Model/Manufacturer DUCATI No load regulated voltage 13 ~ 14 V *** Capacity 8A *** Withstand voltage 600v ***

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MAINTENANCE SPECIFICATIONS

Cortesia de / Courtesy of: www.batmotos.com

SPEC

Model Standard Limit

Battery :

Specific gravity 1.280 ***

Starter motor:

Model / Type MORYAMA Output 0.14 kW *** Armature coil resistance 0.06 ~ 0.08 Ω at 20°C *** Brush length 3.9 mm 0.9 mm Brush spring pressure 563 ~ 844 g *** Commutator diameter 15.8 mm 14.8 mm Mica undercut (depth) 1.15 mm ***

Starter relay:

Model/Manufacturer G8MS / OMRON Amperage rating 20 A *** Coil resistance 54 ~ 66 Ω at 20°C ***

Horn:

Type/Quantity Plane type/1pc. Model/Manufacturer GF-12 / NIKKO or TR9 / TRANSVAL Maximum amperage 2.5 A ***

Flasher relay:

Type Condenser type Self cancelling device No Flasher frequency 80 ~ 160 cycles/min *** Wattage 10W x 2 ***

Circuit breaker:

Type Fuse Amperage for individual circuit x Quantity 7.5 A x 1 ***

Fuel sender unit: Model/Manufacturer MONT. EL. Resistance (Full) 1.5 ~ 7.5 Ω at 20°C ***

(Empty) 90 ~ 100 Ω at 20°C ***

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+ 202 hidden pages

YAMAHA YQ100 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL INFORMATION

SPECIFICATIONS