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Yamaha Scorpio - User Manual

Yamaha Scorpio
300 pages
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SCORPIO
( SX-4 )
SERVICE MANUAL
a Winanda Fairyanto's collection
nanda@jogjalandrover.org
fairyanto@gmail.com
yamaha_scorpio@yahoogroups.com
5BP-F8197-B0

Table of Contents

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Summary

BAB 1. INFORMASI UMUM

IDENTIFIKASI SEPEDA MOTOR

Details for identifying the motorcycle's frame and engine numbers.

INFORMASI PENTING

Important information regarding disassembly procedures, replacement parts, and components.

SPECIAL TOOLS

List of specialized tools required for tune-up and assembly procedures.

BAB 2. SPESIFIKASI

SPESIFIKASI UMUM

General specifications including dimensions, weight, engine, chassis, and fuel system details.

SPESIFIKASI PERAWATAN

Maintenance specifications for engine components like cylinder head, camshaft, valves, and piston.

TORSI PENGENCANGAN;TIGHTENING TORQUE

Torque specifications for various fasteners and components, essential for correct assembly.

RANGKA;CHASSIS

Chassis specifications covering steering, suspension, wheels, brakes, and drive chain.

KELISTRIKAN; ELECTRICAL

Electrical system specifications including voltage, ignition, starting, charging, lighting, and signaling systems.

JALUR KABEL

Diagrams illustrating the routing of various cables and wires throughout the motorcycle.

BAB 3. PARAWATAN BERKALA DAN PENYETELAN

MESIN

Maintenance and adjustment procedures for engine components like valve clearance and idle speed.

CHASSIS

Maintenance and adjustment for chassis components including front and rear brakes, tires, and steering head.

ELECTRICAL

Inspection and maintenance of electrical systems such as battery, fuses, and lighting components.

CHAPTER 4. ENGINE OVERHAUL

ENGINE REMOVAL

Step-by-step procedure for removing the engine from the motorcycle.

CYLINDER HEAD

Detailed instructions for removing, inspecting, and installing the cylinder head assembly.

CAMSHAFT AND ROCKER ARMS

Procedures for removing, inspecting, and installing the camshaft and rocker arm components.

CYLINDER AND PISTON

Steps for removing, inspecting, and installing the cylinder, piston, and piston rings.

CRANKCASE AND CRANKSHAFT

Procedures for separating crankcases, inspecting crankshaft, and assembling crankcase.

TRANSMISSION

Steps for removing, inspecting, and installing the transmission gears and related components.

CHAPTER 5. CARBURETION

CARBURETOR REMOVAL

Instructions on how to safely remove the carburetor from the motorcycle.

CARBURETOR DISASSEMBLY

Step-by-step guide for disassembling the carburetor into its individual components.

CARBURETOR INSPECTION

Procedures for inspecting carburetor body, passages, float, jets, and other parts for wear or damage.

CARBURETOR ASSEMBLY

Instructions on how to correctly reassemble the carburetor after inspection or cleaning.

FUEL LEVEL ADJUSTMENT

Procedure for measuring and adjusting the fuel level in the carburetor float bowl.

CHAPTER 6. CHASSIS

FRONT WHEEL AND BRAKE DISC

Procedures for removing, disassembling, inspecting, and installing the front wheel and brake disc assembly.

REAR WHEEL AND REAR BRAKE

Steps for removing, inspecting, and assembling the rear wheel and brake components.

FRONT BRAKE

Detailed procedures for servicing the front brake caliper and master cylinder.

FRONT FORK

Instructions for removing, disassembling, inspecting, and assembling the front fork legs.

STEERING HEAD AND HANDLEBAR

Procedures for removing, inspecting, and installing the handlebar and steering head components.

REAR SHOCK ABSORBER AND SWINGARM

Steps for removing, inspecting, and installing the rear shock absorber and swingarm assembly.

CHAPTER 7. ELECTRICAL

SWITCHES

Procedures for checking switch continuity, condition, and connections.

CHECKING OF BULBS

Guide to checking bulb types, conditions, and continuity.

IGNITION SYSTEM

Troubleshooting procedures for ignition system faults like no spark.

ELECTRIC STARTING SYSTEM

Troubleshooting for the electric starting system when the starter motor does not operate.

CHARGING SYSTEM

Troubleshooting steps when the battery is not charging.

LIGHTING SYSTEM

Troubleshooting for lighting system issues like headlights or taillights not working.

SIGNALING SYSTEM

Troubleshooting for signaling system faults, including horn, lights, and fuel meter.

CHAPTER 8. TROUBLESHOOTING

ELECTRICAL SYSTEM

Common electrical system problems and their potential causes, with visual guides.

COMPRESSION SYSTEM

Visual guide to common compression system issues like insufficient tightening torque or wear.

INTAKE AND EXHAUST SYSTEM

Troubleshooting common issues related to the intake and exhaust systems, including air cleaner and fuel tank.

SX-4 WIRING DIAGRAM

Summary

BAB 1. INFORMASI UMUM

IDENTIFIKASI SEPEDA MOTOR

Details for identifying the motorcycle's frame and engine numbers.

INFORMASI PENTING

Important information regarding disassembly procedures, replacement parts, and components.

SPECIAL TOOLS

List of specialized tools required for tune-up and assembly procedures.

BAB 2. SPESIFIKASI

SPESIFIKASI UMUM

General specifications including dimensions, weight, engine, chassis, and fuel system details.

SPESIFIKASI PERAWATAN

Maintenance specifications for engine components like cylinder head, camshaft, valves, and piston.

TORSI PENGENCANGAN;TIGHTENING TORQUE

Torque specifications for various fasteners and components, essential for correct assembly.

RANGKA;CHASSIS

Chassis specifications covering steering, suspension, wheels, brakes, and drive chain.

KELISTRIKAN; ELECTRICAL

Electrical system specifications including voltage, ignition, starting, charging, lighting, and signaling systems.

JALUR KABEL

Diagrams illustrating the routing of various cables and wires throughout the motorcycle.

BAB 3. PARAWATAN BERKALA DAN PENYETELAN

MESIN

Maintenance and adjustment procedures for engine components like valve clearance and idle speed.

CHASSIS

Maintenance and adjustment for chassis components including front and rear brakes, tires, and steering head.

ELECTRICAL

Inspection and maintenance of electrical systems such as battery, fuses, and lighting components.

CHAPTER 4. ENGINE OVERHAUL

ENGINE REMOVAL

Step-by-step procedure for removing the engine from the motorcycle.

CYLINDER HEAD

Detailed instructions for removing, inspecting, and installing the cylinder head assembly.

CAMSHAFT AND ROCKER ARMS

Procedures for removing, inspecting, and installing the camshaft and rocker arm components.

CYLINDER AND PISTON

Steps for removing, inspecting, and installing the cylinder, piston, and piston rings.

CRANKCASE AND CRANKSHAFT

Procedures for separating crankcases, inspecting crankshaft, and assembling crankcase.

TRANSMISSION

Steps for removing, inspecting, and installing the transmission gears and related components.

CHAPTER 5. CARBURETION

CARBURETOR REMOVAL

Instructions on how to safely remove the carburetor from the motorcycle.

CARBURETOR DISASSEMBLY

Step-by-step guide for disassembling the carburetor into its individual components.

CARBURETOR INSPECTION

Procedures for inspecting carburetor body, passages, float, jets, and other parts for wear or damage.

CARBURETOR ASSEMBLY

Instructions on how to correctly reassemble the carburetor after inspection or cleaning.

FUEL LEVEL ADJUSTMENT

Procedure for measuring and adjusting the fuel level in the carburetor float bowl.

CHAPTER 6. CHASSIS

FRONT WHEEL AND BRAKE DISC

Procedures for removing, disassembling, inspecting, and installing the front wheel and brake disc assembly.

REAR WHEEL AND REAR BRAKE

Steps for removing, inspecting, and assembling the rear wheel and brake components.

FRONT BRAKE

Detailed procedures for servicing the front brake caliper and master cylinder.

FRONT FORK

Instructions for removing, disassembling, inspecting, and assembling the front fork legs.

STEERING HEAD AND HANDLEBAR

Procedures for removing, inspecting, and installing the handlebar and steering head components.

REAR SHOCK ABSORBER AND SWINGARM

Steps for removing, inspecting, and installing the rear shock absorber and swingarm assembly.

CHAPTER 7. ELECTRICAL

SWITCHES

Procedures for checking switch continuity, condition, and connections.

CHECKING OF BULBS

Guide to checking bulb types, conditions, and continuity.

IGNITION SYSTEM

Troubleshooting procedures for ignition system faults like no spark.

ELECTRIC STARTING SYSTEM

Troubleshooting for the electric starting system when the starter motor does not operate.

CHARGING SYSTEM

Troubleshooting steps when the battery is not charging.

LIGHTING SYSTEM

Troubleshooting for lighting system issues like headlights or taillights not working.

SIGNALING SYSTEM

Troubleshooting for signaling system faults, including horn, lights, and fuel meter.

CHAPTER 8. TROUBLESHOOTING

ELECTRICAL SYSTEM

Common electrical system problems and their potential causes, with visual guides.

COMPRESSION SYSTEM

Visual guide to common compression system issues like insufficient tightening torque or wear.

INTAKE AND EXHAUST SYSTEM

Troubleshooting common issues related to the intake and exhaust systems, including air cleaner and fuel tank.

SX-4 WIRING DIAGRAM

Yamaha Scorpio Specifications

General IconGeneral
Compression Ratio9.5 : 1
Lubrication SystemWet Sump
Frame TypeDiamond
Front SuspensionTelescopic Fork
Fuel Tank Capacity13 Liters
Ground Clearance165 mm
Engine Type4-stroke, SOHC, 2 valves
Fuel SystemCarburetor
Ignition SystemCDI
Transmission5-speed
Starting SystemElectric and kick start
Clutch TypeWet, multi-plate
Rear SuspensionSwingarm
Front BrakeDisc
Rear BrakeDrum

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