1XN125 XN150 TEOS 2000.pdf

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XN125 2000

5MF1-AE2

XN150

SERVICE MANUAL

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EASM0000

XN125 / XN150

SERVICE MANUAL

© 2000 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.

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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. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

MBK Industrie is continually striving to improve all of its models. Modifications and significant chan-

ges in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers and

will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

TECHNICAL DOCUMENTATION

MBK INDUSTRIE

EAS00005

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 scooter operator, a bystander or a person checking or repairing the scooter.

WARNING

A CAUTION indicates special precautions that must be taken to avoid damage

to the scooter.

CAUTION:

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

NOTE:

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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.

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.

ENG

ENG

CYLINDER AND PISTON

CYLINDER AND PISTON

EASM0025

CYLINDER AND PISTON

EAS00253

REMOVING THE CYLINDER AND PISTON

1. Remove:

• piston pin clip

• piston pin

CAUTION:

Do not use a hammer to drive the piston pin

out.

NOTE:

• Before removing the piston pin clip, cover the

crankcase opening with a clean rag to prevent

the piston pin clip from falling into the crankcase.

• Before removing the piston pin, deburr the

piston pin clip’s groove and the piston’s pin

bore area. If both areas are deburred and the

piston pin is still difficult to remove, remove it

with the piston pin puller.

Piston pin puller

90890-01304

2. Remove:

• top ring

• 2nd ring

• oil ring

NOTE:

When removing a piston ring, open the end gap

with your fingers and lift the other side of the ring

over the piston crown.

• piston

6

4

5

3

7

8

9 10 11

1

12 Nm (1.2 m•kg)

2

F W D

Order

Job/Part

Q’ty

Remarks

Removing the cylinder and piston

Remove the parts in the order listed.

Cylinder head

Refer to “CYLINDER HEAD” section.

1

Cylinder bolt

2

2

Timing chain guide (exhaust side)

1

3

Cylinder

1

4

Dowel pin

2

5

Cylinder gasket

1

EAS00255

CHECKING THE CYLINDER AND PISTON

1. Check:

• piston wall

• cylinder wall

Vertical scratches → Rebore or replace the

cylinder, and replace the piston and piston

rings as a set.

6

Piston pin clip

2

7

Piston pin

1

8

Piston

1

9

Piston ring (top)

1

10

Piston ring (2nd)

1

11

Oil ring

1

For installation, reverse the removal

procedure.

4 - 23

4 - 24

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EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols

GEN

INFO

SPEC

to

indicate the subject of each

chapter.

General information

CHK

ADJ

ENG

Specifications

Periodic checks and adjustments

Engine

Cooling system

Carburetor

COOL

CARB

Chassis

Electrical system

Troubleshooting

ELEC

CHAS

Symbols

to

indicate the following.

Serviceable with engine mounted

TRBL

SHTG

Filling fluid

Lubricant

Special tool

Tightening torque

Wear limit, clearance

Engine speed

Electrical data

Symbols

23 in the exploded diagrams indicate

the types of lubricants and lubrication points.

to

Engine oil

Gear oil

Molybdenum disulfide oil

22

23

21

21 Wheel bearing grease

22 Lithium soap base grease

23 Molybdenum disulfide grease

Symbols

25 in the exploded diagrams

indicate the following.

24 to

24

25

24 Apply locking agent (LOCTITE®)

25 Use a new one

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