Yamaha YW50P User manual

2002 - 2005
MOTORCYCLE
SERVICE MANUAL
Model : YW50P, YW50R, YW50S, YW50T
5PNF81972000 *5PNF81972000*
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EBO00000
YW50BP
SERVICE MANUAL
©2001 by Yamaha Motor Taiwan Co,.Ltd.
First edition, November 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Taiwan Co,.Ltd.
is expressly prohibited.
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EB001000
NOTICE
This manual was produced bythe Yamaha Motor Company, Ltd. primarily for use byYamaha 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.
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
ZL
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
~'~,WARNING
Failure to folIowWARNING instructions could result in severe injury or death
to the scooter operator, a bystander or a person checking or repairing the
scooter.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the scooter.
NOTE: A NOTE provides key information to make procedures easier or clearer.
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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.
(~ The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter. Refer to "SYMBOLS".
(~ Each 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-sec-
tion title(s) appears.
(~ Sub-section titles appear in smaller print than the section title.
(~ To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
(~ Numbers are given in the order of the jobs in the exploded diagram. A circled number indi-
cates a disassembly step.
(~ Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS".
(~) A job instruction chart accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
(~ Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
®
®
Cvlinder head. Cylinder and piston
removal
Engine
1 Muffler/Gasket
2 Air ~hroud (cylTnder head)
3 SparkIJlug
4 Cylinder head/Cylinder head gasket
Cylinder
6 Piston pin clip
7 Piston pin/Bearing
8 Piston
9 Piston ring set
10 CyITnder gasket
Q'ty Rurllark~
Remove the pa~s Enthe order
Refer to the "ENGINEREMOVAL" sec-
tion
1/1
1
1
1/1
1
2
1
1
1
Reverse the removal procedure for in
stallatien.
CYLINDEB HEAD" CYF~:N::R: P~~
1. Remove:
• san nc
NoTE PI t pT IIp~)
Begore removing tha piston pin celt,, cover the
' crankcase witha clean rag so you will not acci
Z. Ro,,,ovo:
• Piston pTn 1~
• Piston®
• Piston pin bearing ~
GA~ON~
Donot use a hammer to drive the piston pin
out_
CYUNDER HEAD INSPECTION
~. Elhxlin~te:
• Carbon deposits
Use a rounded ~crapper @
• Cylinder head war~3age
Out ofspecification >Re8ur'0ce.
Warpage measurement and re surfacement
• Attach a =traight edge ~ and a thickness
gauge (~ on the cylinder head.
• Measure the warpage limit.
I
• If the warpage is out of specification, reface
the cylinder head.
NOTE:
Rotate the head severaT tTres to avoid remov-
ing too much moteriol from one side.
4-4 ..................................... --
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Q ®
®
®
GEN
INFO
INSP
CARB
ELEC ~=]
®
®
@
@
-n~
SPEC
®
ENG ~)~
®
CHAS (~®
®
TRBL w.~
SHTG •
@
©
@
@
® i i 1
® ® @
@ @
EAS00009
SYMBOLS
The following symbols are not relevant to ev-
ery vehicle.
Symbols (~to (~ are designed as thumb tabs
to indicate the chapter's number and content.
(~ General information
(~ Specifications
(~ Periodic inspection and adjustment
Engine
(~) Carburetor(s)
(~ Chassis
(~ Electrical system
(~ Troubleshooting
Symbols (~ to (~)
®
@
@
@
@
@
@
@
indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols @to @ in the exploded diagrams in-
dicate the types of lubricants and lubrication
points.
(~ Engine oil
@ Gear oil
(~) Molybdenum disulfide oil
(~ Wheel bearing grease
(~ Lithium soap base grease
(~) Molybdenum disulfide grease
Symbols@ to @ in the exploded diagrams
indicate the following.
(~ Apply locking agent (LOCTITE ®)
(~ Replace the part
I~lew
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INDEX
GENERAL INFORMATION
SPECIFICATIONS
1
g,=.
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE OVERHAUL
CARBURETION
CHASSIS
~o
ELECTRICAL
TROUBLESHOOTING
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CHAPTER 1.
GENERAL INFORMATION
SCOOTER INDENTIFICATION ........................................................................................................... 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 OF CONNECTIONS ........................................................................................................ 1-4
HOW TO USE THE CONVERSION TABLE ....................................................................................... 1-5
CONVERSION TABLE .................................................................................................................... 1-5
SPECIAL TOOLS ................................................................................................................................ 1-6
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CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATION ............................................................................................................... 2-1
MAINTENANCE SPECIFICATION ..................................................................................................... 2-4
ENGINE .......................................................................................................................................... 2-4
TIGHTENING TORQUES ............................................................................................................... 2-6
ENGINE .......................................................................................................................................... 2-6
MAINTENANCE SPECIFICATION ..................................................................................................... 2-7
CHASSIS ........................................................................................................................................ 2-7
TIGHTENING TORQUES ............................................................................................................... 2-8
CHASSIS ........................................................................................................................................ 2-8
MAINTENANCE SPECIFICATION ..................................................................................................... 2-9
ELECTRICAL ................................................................................................................................... 2-9
GENERAL TORQUE SPECIFICATIONS ........................................................................................... 2-1 1
LUBRICATION POINTS AND LUBRICATION TYPE ....................................................................... 2-12
ENGINE ........................................................................................................................................ 2-12
CHASSIS ...................................................................................................................................... 2-13
CABLE ROUTING ............................................................................................................................. 2-14
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CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION ................................................................................................................................ 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ................................................................ 3-1
COVER AND PANEL ..........................................................................................................................3-3
SIDECOVER AND SEAT ................................................................................................................3-3
LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD ..................... 3-4
HANDLEBAR COVER(FRONT AND REAR) ...................................................................................3-5
ENGINE ..............................................................................................................................................3-6
IDLE SPEED ADJUSTMENT ..........................................................................................................3-6
THROTTLE CABLE FREE ADJUSTMENT .....................................................................................3-7
AUTOLUBE PUMP AIR BLEEDING ............................................................................................... 3-8
SPARK PLUG INSPECTION ........................................................................................................... 3-9
ENGINE OIL LEVEL INSPECTION ...............................................................................................3-10
TRANSMISSION OIL REPLACEMENT ........................................................................................3-11
AIR FILTER ELEMENT CLEANING ..............................................................................................3-12
V-BELT INSPECTION ...................................................................................................................3-14
CHASSIS ..........................................................................................................................................3-15
FRONT BRAKE LEVER FREE PLAY CHECK ................................................................................ 3-15
REAR BRAKE LEVER FREE PLAY CHECK ................................................................................... 3-15
BRAKE PAD INSPECTION ...........................................................................................................3-15
BRAKE SHOE INSPECTION ........................................................................................................3-16
BRAKE FLUID LEVEL INSPECTION ............................................................................................3-16
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ........................................................................ 3-17
STEERING ADJUSTMENT ..........................................................................................................3-18
TIRE INSPECTION ........................................................................................................................3-19
WHEEL INSPECTION ...................................................................................................................3-22
FRONT FORK INSPECTION .........................................................................................................3-22
REAR SHOCK ABSORBER INSPECTION ....................................................................................3-22
SEAT LOCK CABLE ADJUSTMENT ...........................................................................................3-22
CABLE CHECKING AND LUBRICATING ..................................................................................... 3-23
LEVERS LUBRICATING ...............................................................................................................3-23
CENTERSTAND LUBRICATING ..................................................................................................3-23
ELECTRICAL .....................................................................................................................................3-24
BATTERY INSPECTION ...............................................................................................................3-24
FUSE INSPECTION ......................................................................................................................3-29
HEADLIGHT BEAM ADJUSTMENT ............................................................................................3-30
HEADLIGHT BULB REPLACEMENT ............................................................................................3-30
TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT ........................................................... 3-31
TAILLIGHT BULB REPLACEMENT .............................................................................................. 3-32
LICENSE LIGHT BULB REPLACEMENT ...................................................................................... 3-32
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