Yamaha BWS CW50L User manual

1999 - 2002
MOTORCYCLE
SERVICE MANUAL
Model : CW50L, CW50M, CW50N, CW50P
4RW281972K00 *4RW281972K00*
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NOTICE
This manual was written by the MBK INDUSTRIE primarily foruse by YAMAHA dealers and their
qualified mechanics. It is not possibleto put an entire mechanic's education into one manual, so it is
assumed that persons using this book to performmaintenance and repairs on YAMAHA scooters
have a basic understanding ofthemechanical concepts and procedures inherent in scooter repair
technology. Without such knowledge, attempted repairs or service to this model may render it unfit to
useand/or unsafe.
MBK INDUSTRIE is continually striving to improve all models manufactured.Modifications and sig-
nificant changes in specifications or procedures will beforwarded to allAuthorized YAMAHAdealers
and will, where applicable, appear in future editions ofthis manual.
DOCUMENTATION TECHNIQUE
MBK INDUSTRIE
PARTICULARLY IMPORTANT INFORMATION
This material is distinguished by the following notation:
/_ The safetyAlert Symbol meansATTENTION! BECOMEALERT! YOUR
SAFETY IS INVOLVED!
r.IIY/-'1:I_11_[¢]1 Failure to follow WARNINGinstructions could result in severe injury or
death to the scooter operator, a bystander, ora person inspecting or
repairing thescooter.
CAUT}ONi:A CAUTION indicates special precautions that mustbe takento avoid
damage to the scooter.
NOTE: ANOTE provides key information to make procedures easier or clearer.
CW50
SERVICE MANUAL
©1997 by MBK INDUSTRIE
3st Edition, April 1997
All rights reserved. Any
reprinting or unauthorized use
without the written
)ermission of MBK INDUSTRIE
is expressly prohibited.
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HOW TO USE THIS MANUAL ® ® ILLUSTRATEDSYMBOLS
CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See <<illustratedsymbols). Illustrated symbols _to _are designed as
1st title (_) This is a chapter with its symbol on theupper right of each page. (_ L_ thumb tabs to indicate thechapter'snumber and
2nd tiUe Q ThistiUeappears on the upperof each page on theleft of the chaptersymbol. (For I=-I I _ content.
thechapter (<Periodicinspectionand adjustment)) the 3rd title appears.)I_
3rd title _) This is afinal title. _General information
z(t_Specifications
MANUAL FORMAT _ _ _ Periodic inspectionandadjustment
tionhas been compiledto provide themechanic with aneasy toread, handy reference that contains@Carburetion
comprehensive explanations of all disassembly, repair, assembly, and inspections._ Chassis
Aset of particularly importantprocedure (_)isplaced between a line of asterisks"*"witheach step _ ® _ Electrical
IMPORTANT FEATUREsPrecededby" """II :1 _)Troubleshooting
• Data and a special tools are framedinabox preceded by a relevant symbol®. _ _ Illustrated symbols _ to_are used toidentify
• An encircled numeral ® indicatesa part name,and anencircled alphabetical letter datafor an _
alignments mark Q, the others beingindicated by an alphabetical letterin a box_), the specifications appearing in the text.
•Acondition of a faulty component will precede an arrow symbol and the course of action required
thesymbol(_). ' _ Fillingfluid
@ i @ _ Lubricant
EXPLODED DIAGRAM <_ i_ @ Special tool
Eachchapter provides exploded diagrams are before each disassembly section for ease in identify-@Tightening
ing correct disassembly and assembly procedures. @Wear limit, clearance
@Engine speed
OVA
' _. :_-_.,_.._,';__..... :;"--L'..'._,_ _ _ _ Illustrated symbols _ to @ inthe exploded dia-
"",_ gramindicategrade of lubricantand location of
lubrication point.
_-.- _';"............. !_ .... _ _ _I @ I _ , _ Apply engineoil
__,_.,@ Apply gearoil
--i--|--_ _)Apply molybdenum disulfide oil
:,T_...:.:....C.__,_I_:;-_,..,_tF-.-"'_ _:_'_...... _1___ _ Apply wheel bearing grease
__--:5:,Apply lightweight lithium-soapbase
®_---- _--_1'¢_ ":_""';_"-I J _ _ @ grease
r/,_, j_| [E,;2_;c_E_-- _ _ @ Apply molybdenum disulfide grease
-_-_, :_"':'_-_ _ _ @Applylockingagent(THREADLOCK®)
@
Use new one
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INDEX
SPECIFICATIONS
PERIODIC INSPECTION I _I
AND ADJUSTMENT I'"sP
ENGINEOVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
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CHAPTER 1.
GENERAL INFORMATION
SCOOTER IDENTIFICATION ....................................................................... A-8
VEHICLE IDENTIFICATION NUMBER ................................................... A-8
ENGINE SERIAL NUMBER .................................................................... A-8
IMPORTANT INFORMATION ...................................................................... A-8
ALLREPLACEMENT PARTS ................................................................ A-8
GASKETS, OIL SEALS, AND O-RINGS................................................. A-8
LOCK WASHERS/PLATES AND CO'I-I'ER PINS .................................. A-8
BEARINGS AND OILSEALS.................................................................. A-8
CIRCLIPS ................................................................................................ A-9
SPECIAL TOOLS.......................................................................................... A-9
FOR TUNE UP ........................................................................................ A-9
FOR ENGINE SERVICE ......................................................................... A-9
FOR CHASSIS SERVICE ..................................................................... A-10
FOR ELECTRICALCOMPONENTS ..................................................... A-10
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SCOOTER IDENTIFICATION INFO A-8 IMPORTANT INFORMATION INFO
INFORMATION ALL REPLACEMENT PARTS
1. Use only genuine parts for all replacements.
SCOOTER IDENTIFICATION Useoil and/or grease recommended by MBK/
VEHICLE IDENTIFICATION NUMBER _'-.._ _ _O YAMAHAforassemblyandadjustment.Other
The vehicleidentification numbere isstamped _._ __ _ brandsmay besimilarin functionand appear-
_ _ _ into the frame, ance, but inferior in quality.
NOTE:
Thevehicle identification number is used to
identifyyourscooterand maybeusedto register__(_ GASKETS, OIL SEALS, AND O-RINGS
your scooter with the licensing authority in your 1.All gaskets,seals and O-rings should be re-
state, placed when an engine is overhauled. All
gaskets surfaces, oil seal lips and O-rings
IInitial serial number: I must be cleaned.
2.Properly oil allmating parts and bearing dur-
VG54RWN0*WA101301 ing reassembly. Apply grease to theoil seal
lips.
The engine serial number@is stamped into the PINS
_crankcase. _1.All lock washers/plates (_ and cotter pins
must be replaced whenthey are removed.
NOTE: _ Locktab(s) should bebent along the boltor nut
The first three digits of these numbers are for _MHr,IH'flat(s) after the bolt or nut has been properly
model identifications; the remaining digits are tightened.
the unit production number.
IInitial serial number:
O_ BEARINGS AND OIL SEALS
4UY-200101 1.Install the bearing(s) (_ and oil seal(s) ®with
their manufacturer's marks or numbers facing
NOTE: outward. (In other words, the stamped letters
Designs andspecifications aresubjectto changemust be on the side exposed to view.) When
without notice, installing oil seal(s), apply a light coating of
lightweight lithium base grease to the seal
lip(s). Oil the bearings liberally when installing.
CAUTION:_
Donotusecompressedairtospinthe
__bearings dry. This causes damage to the
bearing surfaces.
1-1 1 -2
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IMPORTANT INFORMATION/SPECIAL TOOLS INFO _A" 9 J SPECIAL TOOLS INFO
CIRCLIPS Flywheel magneto puller
care,u,, e-080-019
[_ fore reassembly. Always replace piston pin
c_) clips once they have been removed. Replace
bent circlips. Wheninstallingacirclip _) makeFOR ENGINE SERVICE
surethat the sharp edge _is positioned
oppositeto thethrust L_ it receives. See the
sectional view.
Shaft
Crankcase separating tool Flywheel holding tool
SPECIAL TOOLS 90890-01135 90890_0t_'_ f{_
The properspecial tools arenecessary for com- _ _ (_
plete and accurate tune-up and assembly. Us-
ing the correct special tool will help prevent
damage caused by the use of improper tools or
improvised techniques.
Inductive tachometer ] Crankshaft installing tool set Clutch servingnutwrenc_
90890-03113 1 90890-01274 _);_'#--'_ 90890-01348
__ 90890-01275 _)
90890-01277 (_) ._
FOR TUNE UP 90890-01411 (_ \_';_:i"
Ignition checker Sheave holder Clutch spring holderri a f_ c-_
g0890_0_4_ go8go.01_01 00890_01010®g°890°1_®___'_-__<"_>_-
Oil Seal Guide
90890-01409 (D
Oil Seal Driver _/
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SPECIAL TOOLS I 'NFO _1_1IA _ol I
- I.FO_1
Ring nut wrench
90890-01268 _,_ _
90890-01403 _)
FOR CHASSIS SERVICE
Damper rod holder T-Handle
90890o01294 90890-01326
Oil seal guide Oil sealguide adapter
90890-01184 90890-01186
Pocket Tester
FORCOMPONENTELECTRICAL 90890-03112 _
1-5
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