MIO

SERVICE MANUAL

5TL-F8197-E0
 KICKSTARTER ENG
EASF0033

KICKSTARTER

1 V-belt case air filter cover 7 V-belt case cover protector 2 D Washer
2 V-belt case air filter dust seal 8 V-belt case cover protector 1 E Kickstarter pinion gear
3 V-belt case air filter element 9 Dowel pin F Kickstarter pinion gear clip
4 V-belt case air filter element 0 V-belt case cover G Spacer
guide A Kickstarter crank H Kickstarter spring
5 V-belt case air duct B Oil seal I Kickstarter shaft
6 V-belt case air filter joint C Circlip J Kickstarter shaft plate

4 - 39
 KICKSTARTER ENG
REMOVING THE KICKSTARTER
1. Remove:
• footboard
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
• V-belt case air filter element
Refer to “CLEANING THE V-BELT CASE
AIR FILTER ELEMENT” in chapter 3.

2. Loosen:
• V-belt case air filter joint screw 1
3. Remove:
• V-belt case air duct 2

1
2

2 4. Disconnect:
1 • crankcase breather hose 1
4 5. Remove:
• V-belt case air filter element guide 2
• V-belt case cover protector 1 3
• V-belt case cover protector 2 4

6. Remove:
• kickstarter crank bolt 1
• kickstarter crank 2
• fuel overflow hose holder 3
• V-belt case cover 4
• dowel pins
3 4
2
1

DISASSEMBLING THE KICKSTARTER

SHAFT
1. Remove:
• kickstarter shaft plate 1

4 - 40
 KICKSTARTER ENG
2. Remove:
1 • kickstarter pinion gear 1
2 • kickstarter pinion gear clip 2
NOTE:
Turn the kickstarter crank attached to the kick-
starter shaft in the direction of the arrow a and
a
remove the kickstarter pinion gear and kick-
starter pinion gear clip together.

3. Remove:
1 • oil seal 1
• circlip 2
2
• washer 3
3

4. Remove:
2 • kickstarter shaft 1
• kickstarter spring 2
• spacer

EAS00339
CHECKING THE KICKSTARTER
1. Check:
• kickstarter shaft
• kickstarter pinion gear
Damage/wear → Replace.
2. Check:
• kickstarter spring
Damage/wear → Replace.
3. Measure:
• kickstarter pinion gear clip friction force
(with the spring gauge)
Out of specification → Replace the kick-
starter pinion gear clip.

Kickstarter pinion gear clip fric-

tion force
1.0 ~ 3.5 N
(0.10 ~ 0.36 kgf, 0.22 ~ 0.79 lb)

4 - 41
 KICKSTARTER ENG
EAS00340
ASSEMBLING THE KICKSTARTER
1. Install:
• spacer
1 • kickstarter spring
2
• kickstarter shaft
• washer
• circlip New
• oil seal New
NOTE:
_

• Hook the straight end of the kickstarter

spring onto the notch 1 in the kickstarter
shaft and hook the hooked end of the kick-
starter spring onto the projection 2 as
shown.
• Install the circlip securely into the groove on
the kickstarter shaft.

2. Install:
• kickstarter pinion gear clip
• kickstarter pinion gear
• kickstarter shaft plate
• kickstarter shaft plate screws
9 Nm (0.9 m · kg, 6.5 ft · lb)
T.
R.

INSTALLING THE KICKSTARTER

For installation, reverse the removal proce-
dure.
1. Install:
• dowel pins
• V-belt case cover
• fuel overflow hose holder
• V-belt case cover bolts
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.

2. Install:
• kickstarter crack 1
• kickstarter crack bolt
b 12 Nm (1.2 m · kg, 8.7 ft · lb)
T.
R.

NOTE:
1
_

To install the kickstarter crank, align the notch

a
a in the kickstarter crank with the projection
b on the V-belt case cover.

4 - 42
 KICKSTARTER ENG
3. Install:
• V-belt case cover protector 2
• V-belt case cover protector 2 bolts
10 Nm (1.0 m · kg, 7.2 ft · lb)

T.
R.
• V-belt case cover protector 1
• V-belt case cover protector 1 screws
7 Nm (0.7 m · kg, 5.1 ft · lb)

T.
R.
• V-belt case cover protector 1 bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)

T.
R.
• V-belt case air filter element guide
4. Install:
• V-belt case air duct
• V-belt case air duct bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)

T.
R.

4 - 43
 BELT DRIVE ENG
EASF0030

BELT DRIVE
V-BELT, PRIMARY AND SECONDARY SHEAVE
1 O-ring 8 Secondary sliding sheave
2 Clutch housing 9 Secondary fixed sheave
3 Clutch carrier 0 Guide pin
4 Spring A V-belt
5 Spring seat B Conical spring washer
6 Oil seal C Kickstarter one-way clutch
7 O-ring D Claw washer * Shell Dolium Grease R®

4 - 44
 BELT DRIVE ENG
E Primary fixed sheave
F Washer
G Spacer
H Oil seal
I Primary sliding sheave
J Primary sheave weight
K Slider
L Plastic slider guide
M Gasket

* Shell Dolium Grease R®

4 - 45
 BELT DRIVE ENG
EAS00318
REMOVING THE SECONDARY SHEAVE
AND V-BELT
1. Remove:
• footboard
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
2. Remove:
• V-belt case cover
Refer to “KICKSTARTER”.
3. Remove:
• O-ring 1
3
• secondary sheave nut 2
2 4 • clutch housing 3
1 NOTE:
_

While holding the clutch housing with the

sheave holder 4, loosen the secondary
sheave nut.

Sheave holder
90890-01701

4. Loosen:
• clutch carrier nut
CAUTION:
_

Do not remove the clutch carrier nut at this

stage.

NOTE:
_

While holding the clutch carrier with the rotor

holding tool 1, loosen the clutch carrier nut
one full turn with the socket wrench 2.

Rotor holding tool

90890-01235
Socket wrench
90890-01493

4 - 46
 BELT DRIVE ENG
5. Remove:
2 • secondary sheave 1
• V-belt 2
NOTE:
_

Pull the secondary sliding sheave out as

shown, remove the V-belt along with the sec-
ondary sheave 1, and then remove the V-belt
1 2 from the primary sheave.

6. Remove:
1 • gasket 1

EASF0031
REMOVING THE PRIMARY SHEAVE
1. Remove:
• primary sheave nut 1
• conical spring washer
• kickstarter one-way clutch
• claw washer
1
• primary fixed sheave 2
2
3 • washer
• primary sliding sheave
NOTE:
_

While holding the primary fixed sheave with

the sheave holder 3, loosen the primary
sheave nut.

Sheave holder
90890-01701

4 - 47
 BELT DRIVE ENG
2. Remove:
3 3 1
2 • plastic slider guides 1
• slider 2
• primary sheave weights 3
• spacer 4
• oil seals

1 1
4
3

EAS00319
DISASSEMBLING THE SECONDARY
SHEAVE
1. Remove:
1 • clutch carrier nut 1
NOTE:
_

Install the clutch spring holder 2 onto the sec-

2 ondary sheave as shown. Then, compress the
spring, and remove the clutch carrier nut.

Clutch spring holder

90890-01337

2. Remove:
1 • spring seat
3. Remove:
• guide pins 1
• secondary sliding sheave
• secondary fixed sheave

4 - 48
 BELT DRIVE ENG
EAS00290
CHECKING THE CLUTCH HOUSING
1. Check:
• clutch housing
Damage/wear → Replace.
2. Measure:
a • clutch housing inside diameter a
Out of specification → Replace the clutch
housing.

Clutch housing inside diameter

112 mm (4.41 in)
<Limit>: 112.5 mm (4.43 in)

EAS00291
CHECKING THE CLUTCH SHOES
a
The following procedure applies to all of the
clutch shoes.
1. Check:
• clutch shoe
Damage/wear → Replace the clutch shoes
and springs as a set.
Glazed areas → Sand with course sandpa-
per.
NOTE:
_

After sanding the glazed areas, clean the

clutch with a cloth.

2. Measure:
• clutch shoe thickness a
Out of specification → Replace the clutch
shoes and springs as a set.

Clutch shoe thickness

3.0 mm (0.12 in)
<Limit>: 1.0 mm (0.04 in)

4 - 49
 BELT DRIVE ENG
EAS00320
CHECKING THE V-BELT
1 1. Check:
• V-belt 1
Cracks/damage/wear → Replace.
Grease/oil → Clean the primary and sec-
a ondary sheave.
2. Measure:
• V-belt width a
Out of specification → Replace.

V-belt width
18.2 mm (0.72 in)
<Limit>: 17.2 mm (0.68 in)

EAS00321
CHECKING THE PRIMARY SHEAVE
WEIGHTS
The following procedure applies to all of the
primary sheave weights.
1. Check:
• primary sheave weight
Cracks/damage/wear → Replace.

2. Measure:
• primary sheave weight outside diameter a
Out of specification → Replace.

Primary sheave weight outside

diameter
15 mm (0.59 in)
<Limit>: 14.5 mm (0.57 in)
a

EAS00322
CHECKING THE SECONDARY SHEAVE
1. Check:
• secondary fixed sheave
• secondary sliding sheave
Cracks/damage/wear → Replace the sec-
ondary fixed and sliding sheaves as a set.

4 - 50
 BELT DRIVE ENG
2. Check:
• torque cam groove 1
2 Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
• guide pin 2
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
1

4. Check:
• spring free length
Out of specification → Replace the spring.

Spring free length

74.3 mm (2.93 in)
<Limit>: 70.6 mm (2.78 in)

EAS00323
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
• primary fixed sheave
• primary sliding sheave
• spacer
• primary sheave weights

2. Install:
• oil seal New
3. Lubricate:
• primary sliding sheave
• spacer

Recommended lubricant
Shell Dolium Grease R®

NOTE:
Fill the notch of the primary sliding sheave with
grease. Apply grease to the inner surface of
the primary sliding sheave as shown.

CAUTION:
Do not get any grease on the surfaces of
the sheaves. If any grease gets on the
sheaves, be sure to wipe it off with alcohol,
etc.

4 - 51
 BELT DRIVE ENG
4. Install:
1 1 3
4 • primary sheave weights 1
• spacer 2
• plastic slider guides 3
• slider 4

3 3
2
1

5. Install:
• primary sliding sheave 1
NOTE:
1 When installing the primary sliding sheave,
hold the slider to prevent the primary sheave
weights from falling out of the primary sliding
sheave.

6. Install:
• washer 1
• primary fixed sheave 2
4 5 • claw washer 3
• kickstarter one-way clutch 4
1
• conical spring washer 5
3 • primary sheave nut 6
2 4 5
50 Nm (5.0 m · kg, 36 ft · lb)
6
T.
R.

NOTE:
_

• Install the conical spring washer 5 as shown

in the illustration.
• While holding the primary fixed sheave with
the sheave holder, tighten the primary
sheave nut.

Sheave holder
90890-01701

4 - 52
 BELT DRIVE ENG
EAS00324
ASSEMBLING THE SECONDARY SHEAVE
1
1. Lubricate:
• secondary fixed sheave’s inner surface 1
2
• secondary sliding sheave’s inner surface 2
• oil seals
• bearings
(with the recommended lubricant)

Recommended lubricant
Shell Dolium Grease R®

CAUTION:
Do not get any grease on the surfaces of
the sheaves. If any grease gets on the
sheaves, be sure to wipe it off with alcohol,
etc.

2. Install:
3 • oil seals New
• secondary sliding sheave 1
• secondary fixed sheave 2
NOTE:
1 _

2 Install the secondary sliding sheave onto the

secondary fixed sheave 2 with the oil seal
guide 3.

Oil seal guide

90890-01384

3. Lubricate:
• secondary sliding sheave’s inner surface
(with the recommended lubricant)

Recommended lubricant
Shell Dolium Grease R®

NOTE:
Apply 3 cc of Shell Dolium Grease R® to the
inner surface of the secondary fixed sheave.

4 - 53
 BELT DRIVE ENG
4. Install:
1 • guide pin 1

5. Lubricate:
• guide pin groove 1
• O-rings 2 New
(with the recommended lubricant)
2
New Recommended lubricant
Shell Dolium Grease R®

1
NOTE:
_

Apply 1 cc of Shell Dolium Grease R® to the

guide pin groove.

6. Install:
a
• spring seat 1
CAUTION:
Do not get any grease on the surfaces a
and b of the sheaves. If any grease gets on
the sheaves, be sure to wipe it off with
alcohol, etc.
1
b

4 - 54
 BELT DRIVE ENG
7. Install:
2
3 1 • spring
• clutch carrier 1
NOTE:
3 _

• Attach the clutch spring holder 2 onto the

secondary sheave as shown. Then, com-
press the spring, and tighten the clutch car-
1 rier nut 3.
• Install the clutch carrier nut with the beveled
side of the nut facing the clutch carrier.

Clutch spring holder

90890-01337

EAS00325
INSTALLING THE BELT DRIVE
2 a
For installation, reverse the removal proce-
1 New dure.
1. Install:
• gasket 1 New
• V-belt 2
• secondary sheave 3
3
CAUTION:
_

Do not allow grease to contact the V-belt,

secondary sheave assembly.

NOTE:
_

• The V-belt must be installed, with the arrows

a facing forward.
• Install the V-belt on the primary sheave, then
install the secondary sheave 3 along with
the V-belt 2.
• When installing the secondary sheave, do
not get grease from the inner surface of the
secondary sheave on the primary drive gear.

4 - 55
 BELT DRIVE ENG
2. Install:
• clutch carrier nut
55 Nm (5.5 m · kg, 40 ft · lb)

T.
R.
NOTE:
_

While holding the clutch carrier with the rotor

holding tool 1, tighten the clutch carrier nut
with the socket wrench 2.

Rotor holding tool

90890-01235
Socket wrench
90890-01493

3. Position:
• V-belt 1
1
2 NOTE:
3
_

Position the V-belt in the primary sheave 2

(when the sheave is at its widest position) and
in the secondary sheave 3 (when the sheave
is at its narrowest position), and make sure the
V-belt is tight.

4. Install:
• clutch housing 1
1
• secondary sheave nut 2
3 40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.

2 • O-ring
NOTE:
_

Tighten the secondary sheave nut with the

sheave holder 3.

Sheave holder
90890-01701

4 - 56
 STARTER CLUTCH ENG
EAS00341

STARTER CLUTCH

1 Idle gear plate

2 Idle gear
3 Idle gear shaft
4 Starter clutch assembly
5 Starter wheel gear holder
6 Starter wheel gear
7 Bearing

4 - 57
 STARTER CLUTCH ENG
EAS00344
REMOVING THE STARTER CLUTCH
1. Remove:
• footboard
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
2. Remove:
• V-belt case cover
Refer to “KICKSTARTER”.
• primary sliding sheave
Refer to “BELT DRIVE”.
1 3. Remove:
• idle gear plate 1
• washer
2 • idle gear 2
• washer
3 • starter clutch assembly 3

4. Remove:
• starter wheel gear holder 1
• starter wheel gear 2
2
• bearing 3
3
1

EAS00348
CHECKING THE STARTER CLUTCH
1. Check:
• idle gear
• starter wheel gear
• starter clutch assembly
Burrs/chips/roughness/wear → Replace the
defective part(s).

2. Check:
• starter wheel gear contacting surface
Damage/pitting/wear → Replace the starter
wheel gear.

4 - 58
 STARTER CLUTCH ENG
3. Check:
È É • starter clutch operation
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2 a. Install the starter wheel gear 1 onto the
starter clutch 2 and hold the starter clutch.
b. When turning the starter wheel gear clock-
wise È, the starter clutch and the starter
wheel gear should engage, otherwise the
starter clutch is faulty and must be
replaced.
c. When turning the starter wheel gear coun-
terclockwise É, it should turn freely, other-
wise the starter clutch is faulty and must be
replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:
• bearing
NOTE:
Apply a thin coat of grease to the needle bear-
ing.

Recommended lubricant
Lithium-soap-based grease

2. Install:
• starter wheel gear 1
• starter clutch assembly 2
NOTE:
_

• Pour a few drops of molybdenum disulfide oil

on the areas of the starter clutch shown.
M • When installing the starter clutch assembly,
turn the starter wheel gear in the direction of
the arrow shown.

Recommended lubricant
Molybdenum disulfide oil

4 - 59
 STARTER CLUTCH ENG
3. Install:
• starter wheel gear holder 1
• starter wheel gear holder bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)

T.
R.
NOTE:
Install the starter wheel gear holder in the
direction shown so that the section a of the
holder contacts the left crankcase.

4. Install:
• idle gear plate
• idle gear plate bolts
10 Nm (1.0 m · kg, 7.2 ft · lb)

T.
R.

4 - 60