Yamaha VINO YJ50RAP User manual

2001 - 2005
MOTORCYCLE
SERVICE MANUAL
Model : YJ50RAP, YJ50RAR, YJ50RAS,
YJ50RAT, YJ50RN, YJ50RP, YJ50RR,
YJ50RS, YJ50RT
5PP281972000 *5PP281972000*
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EAS00000
YJ50RN
SERVICE MANUAL
©2000 by Yamaha Motor Co., Ltd.
First edition, December, 2000
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
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EAS00002 NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
@
Designs and specifications are subject to change without notice.
EAS00005
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the scooter operator, a bystander or a person checking or repairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid damage
to the scooter.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:
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EAS00007 HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter. Refer to “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
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EAS00009
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 8indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Carburetor(s)
7Electrical system
8Troubleshooting
Symbols 9to Findicate the following.
9Serviceable with engine mounted
0Filling fluid
ALubricant
BSpecial tool
CTightening torque
DWear limit, clearance
EEngine speed
FElectrical data
Symbols Gto Lin the exploded diagrams
indicate the types of lubricants and lubrication
points.
GEngine oil
HGear oil
IMolybdenum disulfide oil
JWheel bearing grease
KLithium soap base grease
LMolybdenum disulfide grease
Symbols Mto Nin the exploded diagrams
indicate the following.
MApply locking agent (LOCTITE®)
NReplace the part
12
34
56
78
90
AB
CD
EF
GHI
JKL
MN
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
CARB
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BLS M
LT New
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EAS00011 TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
CHASSIS CHAS 4
ENGINE ENG 5
CARBURETION CARB 6
ELECTRICAL SYSTEM ELEC 7
TROUBLESHOOTING TRBL
SHTG 8
–+
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GEN
INFO
1
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GEN
INFO
CHAPTER 1
GENERAL INFORMATION
SCOOTER IDENTIFICATION..........................................................................1-1
VEHICLE IDENTIFICATION NUMBER.....................................................1-1
MODEL CODE ..........................................................................................1-1
IMPORTANT INFORMATION .........................................................................1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS....................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS.....................................1-2
BEARINGS AND OIL SEALS....................................................................1-3
CIRCLIPS..................................................................................................1-3
CHECKING THE CONNECTIONS............................................................1-4
SPECIAL TOOLS............................................................................................1-5
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GEN
INFO
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1 - 1
GEN
INFO
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is
stamped into the frame.
1
EAS00018
MODEL CODE
The model code label 1is affixed to the loca-
tion shown in the figure. Record the informa-
tion on this label in the space provided. This
information will be needed to order spare
parts.
SCOOTER IDENTIFICATION
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GEN
INFO
IMPORTANT INFORMATION
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
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GEN
INFO
IMPORTANT INFORMATION
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium soap base grease.
Oil bearings liberally when installing, if appro-
priate.
1Oil seal
CAUTION:
@
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2is positioned opposite
the thrust 3that the circlip receives.
4Shaft
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GEN
INFO
IMPORTANT INFORMATION
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture →Dry with an air blower.
Rust/stains →Connect and disconnect sev-
eral times.
3. Check:
• all connections
Loose connection →Connect properly.
NOTE:
@
If the pin 1on the terminal is flattened, bend it
up.
4. Connect:
• lead
• coupler
• connector
NOTE:
@
Make sure all connections are tight.
5. Check:
•continuity
(with the pocket tester)
NOTE:
@
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
Pocket tester
YU-03112
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1 - 5
GEN
INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
YM-01409
Oil seal guide
This tool is used to install oil seals.
YM-01411
Crankshaft installer spacer
This tool is used to install the crank-
shaft.
YM-34487
Dynamic spark tester
This tool is used to check the ignition
system components.
YS-28891
Clutch spring holder
This tool is used to disassembly and
assembly the secondary pulley.
YU-01135
Crankcase separating tool
This tool is used to remove the crank-
shaft and to separate the crankcase.
YU-01235
Rotor holding tool
This tool is used to hold the generator
rotor when removing or installing the
generator rotor bolt.
YU-01444
Steering nut wrench (45 mm)
This tool is used to loosen and tighten
the lower steering stem nut.
SPECIAL TOOLS
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GEN
INFO
YU-01701
Sheave holder
This tool is used to hold the clutch hous-
ing when removing or installing the
clutch housing nut.
YU-03112
Pocket tester
This tool is used to check the electrical
system.
YU-33223
Compression gauge
This tool is used to measure engine
compression.
YU-33975
Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nut.
YU-8036-A
Inductive tachometer
This tool is used to check engine speed.
Crankshaftinstallertool
set
YU-90050
Crankshaft installer pot
YU-90058
Crankshaft installer bolt
YU-90060
Crankshaft installer tool set
Crankshaft installer pot
Crankshaft installer bolt
These tools are used to install the
crankshaft.
YU-90062
Crankshaft installer adaptor (M10)
This tool is used to install the crank-
shaft.
YU-90105
Flywheel puller set
This tool is used to remove the genera-
tor rotor.
Tool No. Tool name/Function Illustration
SPECIAL TOOLS
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1 - 7
GEN
INFO
ACC-1100-15-01
Quick Gasket®
This sealant is used to seal to mating
surfaces (e.g., crankcase mating sur-
faces).
Tool No. Tool name/Function Illustration
SPECIAL TOOLS
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SPEC
2
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