Yamaha Riva 180 Repair & maintenance information

Discussion in 'Battle Scooters' started by Kevinforesthill, Oct 15, 2018.

  1. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Looking to post some useful information I've collected to help other Riva owners keep their scooters going

    Attached Files:

    #1
  2. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
  3. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Roller weights & testing

    Stock roller weights are 6 grams / Size = 17mm x 12mm (8 rollers total)



    A place I found in the US that has the DR Pulley sliders in 17x12 and weight options from 4g to 15g

    https://www.partsforscooters.com/169-254_Dr_Pulley_Roller_Weights

    -------------------------------------------------------
    Roller/Slider Experiment log:

    (Testing done on the same point to point in my area, your test results will be different, this is only a performance comparison test)

    under 5g overall - bad performance & very low max speed

    roller weights 4.5g/5.5g mix (red moly/wheel bearing grease) - Very quick acceleration, small lull @40mph, max speed 60mph @ ?k rpm, uphill max speed 55 mph

    Dr. Pulley Slider weights 6g all around (dry) - Acceleration is pretty close to the 5.5g combo [feels slower but reaches 50 mph faster], smooth acceleration/no lull, Max Speed 65mph (70 mph downhill), uphill max speed 50mph (felt like belt slipping).


    (I did not like using Lithium grease or graphite, both went dry quick and didn't perform well)
    ---------------------------------------------------------------------------------------------------

    Tools required for roller/slider change (same for belt change):


    Phillips screwdriver (JIS 2) - side fairing, air box cover & variator cover
    10mm Socket - floor board
    12mm socket - foot peg
    5mm allen head (aka 5mm hex key) - clutch/variator cover
    Flat head screw drive - Variator tab
    30mm Socket (I strongly suggest using an impact gun) - variator nut
    Pulley Wrench
    Brake cleaner - to clean variator belt surface

    approximate time start to finish = 1 hour

    variator nut is 30mm - torque 36 ft lbs (50 Nm / 5.0 m . kg )


    **PRO TIP: The sliders should be installed with the "Dr Pulley" lettering on top


    ---------------------------------------------------------------------------------------------------
    Testing/Problems:

    (7/17/19) 1st attempt at the DR pulley sliders and something went wrong. Revs fine while on center stand. Will not go uphill at all, no power, feels like clutch is stuck engaged, Boggs down on ground. Will go downhill fine (and up hill at speed), got up to 55 downhill (not max speed), smooth acceleration and no lull - either installed sliders incorrectly (which is what I am thinking) or broke a clutch spring while installing belt.

    (8/14/19) Finally got around to fixing the Riva. It appears that 2 of the sliders fell out of place while installing (?) and I had installed the sliders wrong. Amazed it drove as well as it did with it messed up like it was

    (11/18/19) Been running the Dr Pulley 6gr sliders for a couple months now and I really like them. No problems or complaints. Purchased 5g sliders today and plan on trying a 5g/6g combo to see how it performs
    Edit Delete Report
    ----------------------------------------------------------------------------------------------------------
    #3
  4. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Colored hose routing diagram


    Colored Carb Hose routing with Hose Sizes.jpg Carb hose routing #2.JPG Scooter Carb Picture.png
    #4
  5. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Colorized wiring diagram (Diagram colors match actual wire colors)

    Pages from Electrical diagram colored overall.jpg
    #5
  6. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    BCV Valve Bypass Diagram

    I did this to check my BCV control valve (the impossible to get to valve under the cover on the right front of the motor). Its pretty simple, just cut the two hoses and connect a shut off valve onto both ends (carb & intake side, not BCV side). The valve will need to be either shut or very slightly open depending on the outside temperature on start up and fully open after a few seconds of running. If the BCV has gone bad the scooter will be hard to start and will not have very good acceleration. I just put straight plastic nipples to reconnect the hoses after the
    test. This is the best way I have found to check the BCV valve. [See diagram below]

    Attached Files:

    #6
  7. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Carburetor settings, adjustments and trouble shooting sheet


    OEM Carb is Mikuni BS28 (28mm)

    Document1.jpg
    #7
  8. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Tire selection and tire changing help sheet.

    ---------------------------------------------------
    It looks like the factory suggested are Bridestone ML3 3.5-10 tires were rated 51J (430lbs & 63 mph max).

    I suggest a 59 or higher load index rating & K or higher speed index rating suggested (59K = 536 lbs loaded / 70 mph rated)


    Tires.jpg
    Tire Speed Index Chart.jpg Tire Load index Chart.jpg
    #8
  9. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Compatible Spark plugs:

    DENSO Iridium Racing Plug IU01-27

    NGK Iridium Plug DR7EIX 5686

    NGK (4929) DPR8EA-9
    #9
  10. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Mirrors:

    Mirrors are 8mm (right side is reverse thread - which is common on Yamaha's).



    -----------------------------------------------------------------------------------------------------------
    10mm to 8mm (reverse thread) adapters:

    (US Market) https://www.ebay.com/p/2206682275

    Euro Market) https://www.fastbikebits.com/product/1376/reverse-thread-mirror-adaptor


    Misc 8mm Mirrors (with reverse thread):

    https://www.amazon.com/Yamaha-unive...P9WJSN28T3B&psc=1&refRID=JHXD4MP7ZP9WJSN28T3B

    https://www.amazon.com/gp/product/B...mini_detail?ie=UTF8&psc=1&smid=A3SYOHO0TS2HRW
    (This one comes with adapters, and is what I have installed on mine)
    #10
  11. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    #11
  12. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    DIY spark plug wires (Riva 180 spark plug wires are 7mm, stranded core)


    OEM Spark plug wire part number is 25G-82341-00-00 (none available that I can find)

    -----------------------------------------------------------------------------------------------------------

    I replaced my spark plug wire with a random spark plug wire I had laying in my garage that was the same diameter . It was a high temp silicone filled solid core that came off my 95' Subaru Impreza (nothing at all like the OEM Yamaha spark plug wire except for the diameter). I just cut to length and screwed in the ends (both plug end and coil end caps screw on)....and it works great. I've been running it with this spark plug wire for a couple months now and with problems at all.

    7-24-19 changed the spark plug wire again with a random spark plug wire due to the wire being too short and interfering with the front cover (cut boots off old wire, screwed in Riva coil boot & screwed in Riva plug boot) . I have rode it like this 4 months now and still going strong
    #12
  13. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Shocks


    Rear Shock Part number: 32H-22210-00-00

    Front Shock Part Number: 25G-23350-00-00
    #13
  14. minimac

    minimac Been here awhile

    Joined:
    Jun 8, 2015
    Oddometer:
    890
    Location:
    Central NY & Central Fl
    Thanks for taking the time to post what you've found. I've been considering one but couldn't find much information on this(and the 200)model.
    #14
    Kevinforesthill likes this.
  15. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
  16. fullmetalscooter

    fullmetalscooter Let me take this duck off

    Joined:
    Apr 28, 2009
    Oddometer:
    4,673
    Location:
    BC
    cool , I thought once the rollers on riva 180 and 200 were toast the scooter DOA since no one make the oem one anymore . I ve read that used rollers go for 20 bucks a pop but there also was someone with the skill whom made up a few batches of new one. I guessing if you ve got a lathe , time and knowledge it's doable .
    #16
    Kevinforesthill likes this.
  17. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Yamaha XC180 service manual Shortcuts

    Chapter 1 - General information (page 7)

    Chapter 2 - Periodic Inspections and Adjustments (Page 39)

    Chapter 3 - Engine Overhaul (Page 73)

    Chapter 4 - Carburation (Page 187)

    Chapter 5 - Chassis (Page 205)

    Chapter 6 - Electrical (Page 251)

    Chapter 7 - Appendices (Page 325)

    --------------------------------------------------------------------------------
    Shortcuts:

    Periodic Maintenance chart page 42
    Engine oil & oil filter Page 47-48
    Tire Pressure Page 59

    Specific Tightening torques Page 334
    General torque setting (English) Page 339
    General XC180 specifications page 338
    General specifications Page 327
    Ignition timing specification Page 337
    General bolt/thread sizes Page 336
    General chassis specifications Page 335
    General carburetor settings & jet sizes Page 333


    Variator troubleshoot Page 151
    Carburetor/Auto-choke Troubleshoot Page 190
    Battery/Charging Troubleshoot Page 283
    Electrical diagram (uncolored) Page 255


    Variator removal Page 153
    Carburetor removal page 194

    --------------------------------------------------------------------------------------------------
    Check motorscooterguide for information on owners manuals, sales brochures and Service manuals (cheapest I have found :wink:)

    → → → http://www.motorscooterguide.net/Downloads/Downloads.html ←←←
    #17
  18. minimac

    minimac Been here awhile

    Joined:
    Jun 8, 2015
    Oddometer:
    890
    Location:
    Central NY & Central Fl
    Around here, Rivas go cheap because no one knows how to fix them or get parts. There are only a few things that can go wrong and they are a strong running scooter.
    #18
  19. Kevinforesthill

    Kevinforesthill Been here awhile

    Joined:
    Oct 15, 2018
    Oddometer:
    175
    Location:
    Foresthill, CA
    Petcock

    OEM petcock has a 46mm bolt space and has a vacuum operated shut off.

    The best way to fix this that I have found (other than filling the vacuum side with epoxy and installing an external shutoff valve) is to buy an adapter plate, which gives you the ability to run a common 3/8" NPT petcock. All of the 46mm petcocks I could find were for vintage motorcycles and got up in price pretty quickly. $35 for the adapter plate, or you could very easily make your own adapter plate.

    Adapters:

    http://www.pingelonline.com/fuel-valve-adapters/a1802c.asp

    https://oldbikebarn.com/products/universal-petcock-adapter-plate-46mm

    https://www.z1enterprises.com/pingel-petcock-adapter-plate-46mm-3-8-npt.html


    Petcocks:

    https://www.mikesxs.net/yamaha-xs65...MI_KbQwPuR5QIVzR-tBh09FgrZEAQYBCABEgJ_OfD_BwE



    Generic Vacuum Petcock examples (double check hose size, I didn't):

    https://www.amazon.com/MMG-Valve-Vacuum-Petcock-Scooter/dp/B00D7N8HRK

    https://www.amazon.com/dp/B079QTSCZ...9Y2xpY2tSZWRpcmVjdCZkb05vdExvZ0NsaWNrPXRydWU=
    #19
  20. Wentwest

    Wentwest How's that work?

    Joined:
    Feb 19, 2007
    Oddometer:
    2,985
    Location:
    Northern California
    This is great information. Those of us who nurse old, abused scooters to life need to share this kind of data. You should also get in touch with Jack Stanley at www.jacksscootershop.com, he's been my go to for this kind of stuff and for parts, too.
    #20