Yamaha VINO XC50V User manual

XC50V
SERVICE MANUAL
LIT-11616-19-49 3D1-F8197-10

EAS00000
XC50V 2005
SERVICE MANUAL
©2005 by Yamaha Motor Taiwan Co., Ltd.
First edition, July 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Taiwan Co., Ltd.
is expressly prohibited.
LIT-11616-19-49

EAS00002
NOTICE
This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha
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
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 Taiwan 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
dealers 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!
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 inspecting or repairing the
scooter.
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the scooter.
A NOTE provides key information to make procedures easier or clearer.
NOTE:
w
cC
Q

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 se-
quentially.
5-27
ENG
RemarksOrder Job/Part Q’ty
1
2
3
4
5
6
7
8
9
10
EAS00251
CYLINDER AND PISTON
Removing the cylinder and piston
Cylinder head
Timing chain guide(exhaust side)
Cylinder
Case cap
Reed valve assembly
Dowel pin
Cylinder gasket
Piston pin clip
Piston pin
Piston
Piston ring set
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “ INSTALLING THE PISTON
AND CYLINDER”.
Refer to “ REMOVING THE CYLINDER
AND PISTON”.
Refer to “ INSTALLING THE PISTON
AND CYLINDER”.
For installation, reverse the removal pro-
cedure.
1
1
1
1
2
1
2
1
1
1
CYLINDER AND PISTON
10Nm (1.0 m•kg, 7.2 ft•lb)
5
6
1
3
4
2
5
7
8
7
4
10
44
9
ENG
5-28
EAS00253
REMOVING THE CYLINDER AND PISTON
1. Remove:
8piston pin clip 1
8piston pin 2
8piston 3
cC
Do not use a hammer to drive the piston pin
out.
NOTE:
8Before removing the piston pin clip, cover
the crankcase opening with a clean rag to
prevent the piston pin clip from falling into
the crankcase.
8Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area. If both areas are deburred and
the piston pin is still difficult to remove, re-
move it with the piston pin puller set4.
Piston pin puller set
90890-01304(YU-01304)
CYLINDER AND PISTON
2. Remove:
8top ring
82nd ring
8oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the
ring over the piston crown.
1
2
3
2
4
3
8
4
5
7
1
3
26

GEN
INFO
SPEC
CHK
ADJ
ENG
TRBL
SHTG
CARB
CHAS
-+
ELEC
4
M
BLS
New
M
G
COOL
12
34
56
78
90
qw
er
iop
asd
fg
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Carburetor(s)
8Electrical system
9Troubleshooting
Symbols 0to uindicate the following.
0Serviceable with engine mounted
qFilling fluid
wLubricant
eSpecial tool
rTightening torque
tWear limit, clearance
yEngine speed
uElectrical data
Symbols ito din the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
iEngine oil
oGear oil
pMolybdenum-disulfide oil
aWheel-bearing grease
sLithium-soap- based grease
dMolybdenum-disulfide grease
Symbols fto gin the exploded diagrams indi-
cate the following.
fApply locking agent (LOCTITE®)
gReplace the part
T
R
.
.
t y u
LT

EAS00010
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING
CARBURETOR
ELECTRICAL SYSTEM
TROUBLESHOOTING
-+
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
CARB
ELEC
TRBL
SHTG
COOL
1
2
3
4
5
6
5
7
8
9

1-9
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
SCOOTER IDENTIFICATION ................................................................... 1-1
VEHICLE IDENTIFICATION NUMBER ............................................. 1-1
MODEL LABEL .................................................................................. 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 ............................. 1-3
BEARINGS AND OIL SEALS ............................................................ 1-3
CIRCLIPS ........................................................................................... 1-3
Notes 3 on equipment preparation.................................................... 1-4
CHECKING THE CONNECTIONS ........................................................... 1-5
SPECIAL TOOLS ...................................................................................... 1-6

1-1
GEN
INFO
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is stamped
into the steering head pipe.
EAS00018
MODEL LABEL
The model label 1is affixed to the trunk. This
information will be needed to order spare parts.
SCOOTER IDENTIFICATION
1
1

1-2
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISAS-
SEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “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 replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands may
be similar in function and appearance, but infe-
rior 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.
IMPORTANT INFORMATION

1-3
GEN
INFO
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.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
1Oil seal
cC
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. Al-
ways replace piston pin clips after one use.When
installing a circlip 1, make sure the sharp-edged
corner 2is positioned opposite the thrust 3
that the circlip receives.
4Shaft
IMPORTANT INFORMATION

1-4
GEN
INFO
JAS00021
Notes 3 on equipment preparation
Push Rivet (Push type)
Assembly status of the Push Rivet (Push type)
Dissembling
1. Press Center Pin 1inward to release the
Lock.
2. Remove the Push Rivet main body 2.
Assembling
1. Restore the Center Pin, replace the Push
Rivet main body.
2. Push in the Center Pin until leveling off with
the surface position of the Push Rivet main
body.
12
IMPORTANT INFORMATION

1-5
GEN
INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
8lead
8coupler
8connector
2. Check:
8lead
8coupler
8connector
Moisture JDry with an air blower.
Rust/stains JConnect and disconnect
several times.
3. Check:
8all connections
Loose connection JConnect properly.
NOTE:
If the pin 1on the terminal is flattened, bend it
up.
4. Connect:
8lead
8coupler
8connector
NOTE:
Make sure all connections are tight.
5. Check:
8continuity
(with the pocket tester)
Pocket tester
90890-03132 (YU-03112-C)
NOTE:
8If there is no continuity, clean the terminals.
8When checking the wire harness, perform
steps (1) to (3).
8As a quick remedy, use a contact revitalizer
available at most part stores.
CHECKING THE CONNECTIONS

1-6
GEN
INFO
41
46
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
SPECIAL TOOLS
90890-01085
YU-01083-2
90890-01084
YU-01083-3
90890-01235
YU-01235
90890-01268
YU-01268
90890-01304
YU-01304
90890-01312
YM-01312-A
90890-01337
YM-33285
YM-33285-6
90890-01348
YM-01348
90890-01325
YU-24460-01
90890-01352
YU-33984
Slide hammer bolt (8mm) 1
Weight 2
These tools are needed to remove the cam-
shaft.
Rotor holding tool
This tool is used to remove the flywheel
magneto.
Ring nut wrench
This tool is used to loosen and tighten the
exhaust and steering ring nut.
Piston pin puller set
This tool is used to remove the piston pin.
Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
Clutch spring holder
These tool are used for removing the nut with
holding the compression spring.
Lock nut wrench
This tool is used when removing or install-
ing the secondary sheave nut.
Radiator cap tester1
Radiator cap tester adapter2
This tester and its adapter are needed for
checking the cooling system.
1
2
12

1-7
GEN
INFO
Tool NO. Tool name / Function Illustration
SPECIAL TOOLS
90890-01367
YM-A9409-7
90890-01400
YM-A9409-3
90890-01384
YM-33299
90890-01403
YU-A9472
90890-01701
YS-01880-A
90890-03079
YM-34483
90890-03081
YU-33223
90890-03132
YU-03112-C
90890-03113
YU-08036-C
90890-03141
YU-03141
Fork seal driver weight1
Fork seal driver attachment(Ø30mm)2
This tool is used when installing the fork
seal.
Oil seal guide
This tool is used for protecting the oil seal
lip when installing the secondary sliding
sheave.
Steering nut wrench
This tool is used to loosen and tighten the
steering ring nut.
Sheave holder
This tool is used for holding the secondary
sheave.
Thickness gauge
This tool is used to measure the valve
cleanance.
Compression gauge
These tool are used to measure the engine
compression.
Pocket tester
This instrument is invaluable for checking
the electrical system.
Engine tachometer
This tool is needed for detecting engine rpm.
Timing light
This tool is needed for detecting ignition tim-
ing.
12

1-8
GEN
INFO
Tool NO. Tool name / Function Illustration
SPECIAL TOOLS
90890-04109
YM-04109
90890-04148
YM-04148
90890-04111
YM-04111
90890-04112
YM-04112
90890-04113
YM-04113
90890-06754
YM-34487
90890-85505
ACC-11001-05-01
Valve spring compressor
Compressor adapter(Ø16.5mm)
These tools are used when removing or in-
stalling the valve and the valve spring.
Valve guide remover (4.0 mm)
This tool is used to remove or install the
valve guides.
Valve guide installer (4.0 mm)
This tool is used to install the valve guides.
Valve guide remover (4.0 mm)
This tool is used to rebore the new valve
guides.
Ignition checker
This instrument is necessary for checking
the ignition system components.
Yamaha bond NO.1215
This sealant (bond) is used on crankcase
mating surfaces, etc.

2-34
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ................................................................. 2-1
ENGINE SPECIFICATIONS ..................................................................... 2-2
CHASSIS SPECIFICATIONS ................................................................. 2-10
ELECTRICAL SPECIFICATIONS .......................................................... 2-12
CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICA-
TIONS ................................................................................................. 2-15
TIGHTENING TORQUES........................................................................ 2-16
ENGINE............................................................................................ 2-16
CHASSIS.......................................................................................... 2-18
LUBRICATION POINTS AND LUBRICANT TYPES............................. 2-19
ENGINE............................................................................................ 2-19
CHASSIS.......................................................................................... 2-21
COOLING SYSTEM DIAGRAMS........................................................... 2-22
OIL FLOW DIAGRAMS .......................................................................... 2-26
CABLE ROUTING .................................................................................. 2-28

2-1
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
GENERAL SPECIFICATIONS
Model code 3D11 (for USA) …
3D12 (for CAN) …
Dimensions
Overall length 1665 mm( 65.6in ) …
Overall width 630 mm( 24.8in ) …
Overall height 1005 mm( 39.6in ) …
Seat height 715 mm( 28.2in ) …
Wheelbase 1160 mm( 45.7in ) …
Ground clearance 85 mm( 3.4in ) …
Minimum turning radius 1800mm( 70.9in ) …
Weight
Wet (without oil and a full fuel tank) 81 kg( 179lb ) …
Dry (without oil and fuel) 76kg( 168lb ) …
Maximun load (total of cargo, rider, 158kg( 348lb ) …
passenger, and accessories)

2-2
SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
ENGINE SPECIFICATIONS
-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 20W-50
Engine
Engine type Liquid-cooled, 4-stroke, SOHC …
Displacement 0.049L(49cm3)…
Cylinder arrangement Forward inclined single cylinder …
Bore × stroke 38.0 × 43.5 mm …
Compression ratio 12:1 …
Engine idle speed 2000~2400 r/min …
Vacuum pressure at engine idle speed(AI OFF) 34.7 kpa ( 260 mmHg ) …
Standard compression pressure (at sea level) 1450 kPa (14.5kgf/cm2 )…
at 700 r/min
Fuel
Recommended fuel Unleaded gasoline …
Fuel tank capacity
Total (including reserve) 4.5L ( 0.98 Imp gal, …
1.18 US gal )
Engine oil
Lubrication system Wet sump …
Recommended oil
SAE10W40 …
Yamaha 4-cycle oil
EFERO X,Z,BX
Quantity
Periodic oil change 0.73~0.83 L (0.67~0.76 Imp qt, …
0.80~0.90 US qt)
Total amount 0.8~0.9L (0.74~0.83 Imp qt, …
0.87~0.98 US qt)
Final gear oil
Recommended oil SAE10W30 hypoid gear oil …
Periodic oil change 0.09~0.11L (0.08~0.10 Imp qt, …
0.10~0.12 US qt)
Total amount 0.11~0.13L (0.10~0.12 Imp qt, …
0.12~0.14 US qt)

2-3
SPEC
Item Standard Limit
ENGINE SPECIFICATIONS
Oil filter
Oil filter type Wire mesh …
Oil pump
Oil pump type Trochoid …
Inner rotor to outer rotor tip clearance 0.15 mm or less 0.23mm
Outer rotor to pump housing clearance 0.13-0.18 mm 0.25mm
Oil pump housing to inner rotor and outer 0.07-0.12 mm 0.19mm
rotor clearance
Cooling system
Radiator capacity 0.26L …
Radiator cap opening pressure 93.3~122.7 kpa …
(0.95~1.25kgf/cm2,
13.53~17.79 psi)
Valve relief pressure 1.1kpa (0.01kgf/cm2, 0.16 psi) …
Radiator core
Width 133.3mm …
Height 87mm …
Depth 16mm …
Coolant reservoir
Capacity 0.26L …
<From low to full lever> 0.15L …
Water pump
Water pump type Single suction centrifugal pump …
Max. impeller shaft tilt … 0.15mm
Starting system type Electric and kick starter …
Spark plug
Model (manufacturer) × quantity CR7E (NGK) × 1 …
Spark plug gap 0.7~0.8mm …
Cylinder head
Volume 3.1~3.5cm³ …
Max. warpage … 0.03 mm

2-4
SPEC
Item Standard Limit
C
A
B
C
A
B
ENGINE SPECIFICATIONS
Camshaft
Drive system Chain drive (left) …
Intake camshaft lobe dimensions
Measurement A 30.158~30.258 mm 30.058 mm
Measurement B 25.082~25.182 mm 24.982 mm
Measurement C 5.2077mm …
Exhaust camshaft lobe dimensions
Measurement A 30.158~30.258 mm 30.058 mm
Measurement B 25.020~25.120 mm 24.920 mm
Measurement C 5.2077mm …
Max. camshaft runout … 0.03 mm