Which OE parts, seals and consumables should be prepared for a 10,000 km or 20,000 km major service on Yamaha 155cc scooters?
Complete workshop parts preparation list with intervals, tightening torques, and standard consumable sizes.
At 10,000 km: replace spark plug (CPR8EA-9), air filter element, CVT case filter foam, and gear oil drain crush washer. At 20,000 km: replace the CVT V-belt, variator rollers (6 pcs), cam sliders (3 pcs), fuel pump O-ring, and inspect valve clearance (Intake 0.10–0.14 mm / Exhaust 0.18–0.22 mm).
Technical Specification & Interchange Matrix
| Service Item | Interval | Spec / OE Code | Workshop Torque / Note |
|---|---|---|---|
| Spark Plug | Every 8,000 – 10,000 km | NGK CPR8EA-9 (Gap 0.8–0.9 mm) | 13 N·m (M10×1.0 thread) |
| Air Filter Element | Every 10,000 km (5,000 km dusty) | 2DP-E4451-00 / B65-E4451-00 | Viscous paper type — do NOT blow with compressed air |
| CVT V-Belt & Rollers | Every 20,000 – 25,000 km | 2DP-E7641-00 / B65-E7641-00 + 20×12 Rollers | Primary nut 49 N·m, Clutch bell nut 45 N·m |
| Valve Clearance & Cover Gasket | Every 12,000 – 20,000 km | IN: 0.10–0.14 mm / EX: 0.18–0.22 mm | Always measure cold (< 35°C); replace rubber gasket if flattened |
Step-by-Step Verification & Diagnostic Procedure
- 1Prepare single-use gaskets and O-rings before opening covers
Keep gear oil copper washers, water pump O-rings, and side cover grommets (90480-16805-00) on hand so the scooter doesn't wait on a $1 seal.
- 2Degrease the CVT torque driver pins at 20,000 km
Wipe old hardened grease from the 3 guide pins and grooves of the secondary sliding sheave, then repack with high-temp polyurea CVT grease.
Referenced OE Part Numbers & Dossier Links
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