Yamaha JOGR JOGRR CS50 User manual

2002
SERVICE MANUAL
CS50/Z 5RW1-AE1

CS50/Z
SERVICE MANUAL
© 2002 by Yamaha Motor España, S.A.
1st Edition, September 2002
Any reprinting or use of this material
without the prior authorisation of
Yamaha Motor España, S.A.
is expressly prohibited.
Printed in Spain.
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NOTICE
This manual was produced by the Yamaha Motor España, S.A., primarily for use by Yamaha/MBK
dealers 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/MBK vehicles should have a basic understanding of the 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 España, S.A., is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha/MBK
dealers and will appear in future editions of this manual where applicabe.
NOTE:
Designs and specifications are subject to change without notice.
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IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLDED!
Failure to follow WARNING instructions could result in severe injury
or death to the scooter operator, a bystander, or a person inspec-
ting 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 cle-
arer.
tt
ssWARNING
CAUTION:
NOTE :

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HOW TO USE THIS MANUAL
FORMAT OF THIS MANUAL
This manual consists of chapters for the main subject categories (See “Illustrated Symbols”).
First heading : This is a chapter with a symbol at the top right-hand side of each page.
Second heading : This title appears at the top of each page to the left of the chapter symbol.
(For the “Inspection and periodic adjustments”, chapter the third heading
appears.)
Third heading : This is a final heading.
MANUAL FORMAT
All the procedures in this manual are organized sequentially, step by step. The information has been
compiled to make reading easy for the mechanic and to provide useful reference material which
contains ample explanations of all disassembly, repair, assembly and inspection procedures. A par-
ticularly important procedure is placed between a lines of asterisks “**” with each procedure pre-
ceded by “•”.
IMPORTANT CHARACTERISTICS
• Data and special tools are put in a box preceded by a corresponding symbol .
• A number within a circle indicates the number of a part, and a alphabetical letter within a cir-
cle indicates data or an alignment mark , everything else is indicated by a letter within a box .
• The conditions of defective components will precede an arrow symbol and the course of action
to be followd will follow the symbol .
DETAILED DIAGRAM
Each chapter provides detailed diagrams before each disassembly section, for the easy identifica-
tion of disassembly/assembly procedures.

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ILLUSTRATED SYMBOLS
(See illustration)
The symbols from to are designed as
thumb indices, to indicate the chapter num-
ber and index.
General information
Specifications
Periodic checks and adjustments
General motor revision
Cooling system
Carburetor
Chassis
Electrical system
Troubleshooting
The illustrated symbols from 10 to 16 are
used to identify the specifications that appear
in the text.
10 Refill liquid
11 Lubricant
12 Special tool
13 Torque
14 Wear, play limit
15 Motor speed
16 Ω, V, A
The illustrated symbols from 17 to 24 of the
detailed diagrams indicate the grade of lubri-
cant and the site of the lubrication point.
17 Apply motor oil
18 Apply gear oil
19 Apply molybdenum disulphide oil
20 Apply wheel bearing grease
21 Apply lightweight lithium soap base
grease
22 Apply molybdenum disulphide grease
23 Apply blocking agent (LOCTITE®)
24 Use a new one
CHK
ADJ
COOL
CHAS
TRBL
SHTG
SPEC
ENG
CARB
ELEC
GEN
INFO
New





11
13
15
17
20
23




10
12
14
16
24
19
22
18
21

SPEC 2
SPECIFICATIONS
CHK
ADJ 3
PERIODIC CHECKS AND
ADJUSTMENTS
ENG 4
ENGINE
COOL 5
COOLING SYSTEM
CARB 6
CARBURETOR
CHAS 7
CHASSIS
ELEC 8
ELECTRICAL SYSTEM
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TABLE OF CONTENTS
TRBL
SHTG 9
TROUBLESHOOTING
GENERAL INFORMATION GEN
INFO 1

GEN
INFO 1

GEN
INFO
CHAPTER 1
GENERAL INFORMATION
SCOOTER IDENTIFICATION……………………………………………………1-1
FRAME SERIAL NUMBER ……………………………………………………1-1
ENGINE SERIAL NUMBER……………………………………………………1-1
IMPORTANT INFORMATION …………………………………………………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 …………………………………………………1-2
CIRCLIPS ………………………………………………………………………1-3
SPECIAL TOOLS …………………………………………………………………1-4

GEN
INFO
IDENTIFICATION OF SCOOTER
1-1
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GENERAL INFORMATION
SCOOTER IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number is stamped on the
chassis.
ENGINE SERIAL NUMBER
The serial number of the engine is stamped
on the raised portion of the rear left section of
the transmission box.
NOTE:
The first three digits of these numbers are for
identifying the model; the remaining digits
constitute the production number of the unit.
NOTE:
Designs and specifications are subject to
change without notice.


GEN
INFO
IMPORTANT INFORMATION
1-2
IMPORTANT INFORMATION
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REPLACEMENT PARTS
1. Use only genuine Yamaha/MBK parts for all
replacements. Use the oil and/or grease
recommended by Yamaha/MBK for
assembly and adjustment.
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GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
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LOCK WASHERS/PLATES AND COTTER
PINS
1. Replace all lock washers/plates and cot-
ter pins after removal. Bend lock tabs along
the bolt or nut flats after the bolt or nut has
been tightened to specification.
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BEARINGS AND OIL SEALS
1. Install the bearings and oil stops with
their manufacturer brands or numbers
facing outwards. (In other words, the stam-
ped letters should be on the side exposed
to view.) When installing oil seals, apply a
light coating of lightweight lithium base gre-
ase to the seal lips. Put oil on the bearings
when installing.
CAUTION:
Do not use compressed air to spin the bea-
rings dry. This will damage the bearing surfa-
ce.