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.
EAS00001

EAS00002
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.
EAS00005
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 :

EAS00007
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.

EAS00008
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
EAS00010
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
EAS00015
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
EAS00021
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.
EAS00022
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.
EAS00023
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.
EAS00024
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.

GEN
INFO
IMPORTANT INFORMATION
1-3
EAS00025
CIRCLIPS
1. Check all circlips carefully before reas-
sembly. Always replace piston pin clips
after one use. Replace distorted circlips.
When installing a circlip , make sure that
the sharp-edged corner is positioned
opposite the thrust it receives. See sec-
tional view.
Shaft.

GEN
INFO
SPECIAL TOOLS
1-4
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropria-
te tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name / Usage Illustration
90890-01235 Rotor holding tool
This tool is used to remove the flywheel
magneto.
90890-01337 Clutch spring bracket
This tool is used to remove the clutch nut
while holding the compression spring.
90890-01274 Container of the crankshaft installer a
-01275 Bolt of the crankshaft installer b
-01277 Adapter c, Spacer d
-01288 These tools are used to install the
crankshaft.
90890-01362 Flywheel puller
. For removing the flywheel.
90890-01135 Crankcase separation tool
This tool is used to remove the
crankshaft or separate the crankcase.
90890-01384 Oil seal guide
Protects the edge of the oil seal during
the installation of the secondary sliding
pulley wheel.
90890-01403 Ring nut wrench
This tool is used to loosen and tighten
the steering ring nut.
90890-01701 Pulley bracket
This tools is used to disassemble and
assemble the secondary pulley.
90890-03079 Thickenss gauge
This tool is used to measure the clearance.

GEN
INFO
SPECIAL TOOLS
1-5
Tool No. Tool name / Usage Illustration
90890-03112 Pocket tester
This instrument is very important
for checking the electrical system.
90890-03113 Engine tachometer
This tool is necessary for detecting
the engine rpm.
90890-01409 Oil seals guide
This tool is used to install the left oil
guide of the crankcase.
90890-01410 Oil seals installer
This tool is used to install the left oil
seal of the crankcase.
90890-06754 Ignition checker
This instrument is necessary
to check the components of the
ignition system.
90890-85505 Yamaha bond No. 1215
This bond (sealant) is used for crankcase
mating surface, etc.
90890-01348 Locknut wrench
This tool is used to loosen and tighten
the secondary sheave nut.
90890-01367 Front oil seals inserter
-01400 Counterweight a
Adapter b
These tools are used in the installation
of seals.
90890-01326 T-handle
90890-01294 Damper rod holder
These tool are used for holding the damper rod
holder when removing or installing the damper
rod holder.

SPEC 2

SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS …………………………………………………2-1
MAINTENANCE SPECIFICATIONS ……………………………………………2-3
ENGINE …………………………………………………………………………2-3
CHASSIS ………………………………………………………………………2-5
ELECTRICAL SYSTEM ………………………………………………………2-6
CONVERSION TABLE……………………………………………………………2-7
GENERAL TIGHTENING TORQUE SPECIFICATIONS ……………………2-7
TIGHTENING TORQUES ………………………………………………………2-8
ENGINE TIGHTENING TORQUES …………………………………………2-8
CHASSIS TIGHTENING TORQUES …………………………………………2-9
COOLING SYSTEM (CS50Z only) ……………………………………………2-10
CABLE ROUTING ………………………………………………………………2-11

SPEC
GENERAL SPECIFICATIONS
2-1
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model CS50 CS50Z
Dimensions:
Overall lenght 1.740 mm
Overall widht 675 mm
Overall height 1.065 mm
Seat height 770 mm / 776 mm
Wheelbase 1.210 mm
Minimum ground clearance 132 mm
Basic weight (With oil and full fuel tank): 80,5 kg 83,7 kg
Engine:
Engine type Plate valve, gasoline, 2-strokes
air-cooled Liquid cooled
Cylinder arrangement Forward-inclined single cylinder
Displacement 49,3 cc
Bore x stroke 40,0 x 39,2 mm
Compression ratio 10,2 : 1 11,4 : 1
Starting system Electric and kickstarter
Lubrication system: Yamaha autolube
Oil type or grade:
Engine oil 2-strokes motor oil (JASO grade FC)
Transmission oil SE type 10W30 SAE motor oil
Oil capacity:
Oil tank (motor oil) 1,4 L
Transmission fluid
Periodic fluid change 0,10 L
Total amount 0,11 L
Cooling system capacity:
(Total amount) – 0,910 L
Air filter: Wet type element
Fuel:
Type Unleaded gasoline
Fuel tank capacity 5,5 L
Carburetor:
Type/quantity PHVA12ZS/1, PY12/1 PHVA12ZS/1
Manufacturer DELL’ORTO, GURTNER DELL’ORTO
Spark plug:
Type/Manufacturer BR8HS/N.G.K.
Spark plug gap 0,6 ~ 0,7 mm
Clutch type: Dry, centrifugal automatic
Transmission:
Primary reduction system Helical gear
Primary reduction ratio 52/13 (4.000)
Secondary reduction system Straight gearing
Secondary reduction ratio 42/13 (3.230) 43/13 (3.310)
Transmission type Single speed automatic
(V-belt type)
Operation Centrifugal automatic type

SPEC
GENERAL SPECIFICATIONS
2-2
Model CS50 CS50Z
Chassis:
Frame type Steel tube underbone
Front axle incline angle 25°
Steering angle base 80 mm
Tire:
Size/Type (Front) 110/70-12 / 47 L
Size/Type (Rear) 120/70-12 / 51 L, 130/70-12 / 56 L
Tire pressure (cold tire):
Front 175 KPa (1,75 kg/cm2)
Rear 200 KPa (2,00 kg/cm2)
Maximum Load:
Front 175 KPa (1,75 Kg/cm2)
Rear 225 KPa (2,25 Kg/cm2)
Brake:
Type of front brake Disk brake
Activation Right hand operation
Type of rear brake Drum brake
Activation Left hand operation
Suspension:
Front suspension Telescopic fork
Rear suspension Unit swing
Shock absorber:
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Oil damper
Wheel travel:
Front wheel travel 70 mm
Rear wheel travel 60 mm
Electrical:
Ignition system DC-CDI
Generator system Magnetic flywheel
Battery type or model Maintenance free
Battery capacity 12V 4AH
Type of headlamp: Bulb
Bulb wattage/quantity:
Headlight 12V, 35W / 35Wx1
Tail/brake light 12V, 5W / 21Wx1
Turn signal light 12V, 10Wx2 (rear) / 12V, 16Wx2 (front)
Auxiliary light 12V, 5W x 2
License plate light 12V, 5W x 1
Meter lighting 12V, 1,2W x 2
Indicator light voltage/quantity:
Oil level warning light LED
Turn signal indicator light 12V, 2W x 2
High beam indicator light 12V, 2W x 1
Coolant temperature warning light – LED

SPEC
MAINTENANCE SPECIFICATIONS
2-3
MAINTENANCE SPECIFICATIONS
ENGINE
Model CS50 CS50Z
Cylinder head:
Warp limit 0,02 mm
* The lines indicate measurement
with straight edge
Cylinder:
Bore size 39,993 ~ 40,012 mm
<Limit> <40,1 mm>
Taper limit 0,05 mm
Out of round limit 0,01 mm
Piston:
Piston size 39,952 - 39,972 mm 39,957 - 39,997 mm
Measuring point 5 mm
Piston clearance 0,034 - 0,047 mm 0,029 - 0,042 mm
On measurement
1st 40,25 mm
Piston rings:
Cut-away section (BXT)/TYPE
Top ring 1.5 x 1.8 mm/Keystone
2nd ring 1.5 x 1.8 mm/Keystone
End gap (installed)
Top ring 0,15 ~ 0,35 mm
2nd ring 0,15 ~ 0,35 mm
<Limit> <0,6 mm>
Sice clearance
Top ring 0,03 ~ 0,05 mm
2nd ring 0,03 ~ 0,05 mm
Crankshaft:
Crank width “A” 37,90 ~ 37,95 mm
Runout limit “C” 0,03 mm
Large end of rod side clearance “D” 0,2 ~ 0,5 mm
Small end of rod clerance “F” 0,4 ~ 0,8 mm

SPEC
MAINTENANCE SPECIFICATIONS
2-4
Model CS50 CS50Z
Automatic centrifugal clutch:
Clutch shoe thickness 2,0 mm
<Limit> <1,0 mm>
Clutch shoe spring free length 29,9 mm
Clutch - in revolution 3.350 - 3.850 r/min. 3.950 - 4.450 r/min.
Clutch - stall revolution 5.200 - 6.000 r/min. 6.900 - 7.700 r/min.
V-belt:
V-belt width 16,5 mm
<Limit> <15,7 mm>
Transmission:
Main axle eccentricity limit 0,08 mm
Drive axle eccentricity limit 0,08 mm
Pedal starting:
Type Ratchet
Strength of pedal spring 150 ~ 250 g
Air filter oil grade: For foam air filter or air-cooled 2-stroke
motor oil
Carburetor:
Type / Manufacturer / Amount PHVA12ZS/1 PY12/1 PHVA12ZS/1
DELL’ORTO GURTNER DELL’ORTO
Main jet / Model (M.J.) #65 #62 #65
Jet needle (J.N.) A20-3/5 B10A-2/3 A35-4/5
Main air jet (M.A.J.) ø 2.5 ø 2.0 ø 2.5
Pilot jet (P.J.) #36 #38 #36
Pilot screw (P.A.S.) 2 - 21/413/4- 2 13/4±1/8
Valve seat size 1.2 1.4 1.2
Engine idling speed 1650 ~ 1950 r/min
Starter jet #50 #42 #50

SPEC
MAINTENANCE SPECIFICATIONS
2-5
CHASSIS
Model CS50 CS50Z
Steering system:
Steering bearing type Upper Ball bearing
Lower Ball bearing
Front suspension:
Front fork travel 70 mm
Fork spring free length 224 mm
Spring rate (K1) 1,33 Kgf/mm
(K2) 2,0 Kgf/mm
Oil capacity 45 cc ± 1
Oil grade Fork oil: 10W or equivalent
Rear suspension:
Shock absorber stroke 60 mm
Spring free length 220 mm
Spring rate (K1) 4,58 Kgf/mm
(K2) 6,12 Kgf/mm
Wheels:
Type of front wheel Alloy rim
Type of rear wheel Alloy rim
Size/material of front tyre 2,75 x 12 / aluminium
Size/material of rear tyre 3,00 x 12 / aluminium
Rim runout limit
Radial 1,0 mm
Lateral 1,0 mm
Front disc brake:
Type Single
Disc outside diameter x thickness ø 190 x 3,5 mm
Pad thickness 4,5 mm
<Limit> <0,5 mm>
Interior diameter of pump 11 mm
Calliper interior diameter 30 mm
Brake fluid type DOT #4
Rear drum brake:
Type Single cam
Drum inside diameter ø 110 mm
<Limit> <ø 110,5 mm>
Shoe thickness 4 mm
<Limit> <2 mm>
Brake levers:
Free play of the front brake lever
(right)/measurement 2 ~ 5 mm / At the end of the lever
Free play of the rear brake lever
(left)/measurement 5 ~ 10 mm / At the end of the lever