Yamaha Vino YJ50RN User manual

YJ50RN
SERVICE MANUAL
LIT-11616-14-50 5LY-28197-E0

EAS00001
YJ50RN
SERVICE MANUAL
©2000 by Yamaha Motor Corporation, U.S.A.
First edition, December, 2000
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A. is expressly
prohibited.
Printed in U.S.A.
P/N LIT-11616-14-50

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:

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.

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
4Engine
5Carburetor(s)
6Chassis
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 ENG
CARB CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BLS M
LT New

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
–+

MEMO

CONTENTS
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
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS.........................................................................2-1
ENGINE SPECIFICATIONS ...........................................................................2-2
CHASSIS SPECIFICATIONS..........................................................................2-6
ELECTRICAL SPECIFICATIONS ...................................................................2-9
CONVERSION TABLE..................................................................................2-11
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-11
TIGHTENING TORQUES ..............................................................................2-12
ENGINE TIGHTENING TORQUES.........................................................2-12
CHASSIS TIGHTENING TORQUES.......................................................2-13
LUBRICATION POINTS AND LUBRICANT TYPES.....................................2-14
ENGINE...................................................................................................2-14
CHASSIS ................................................................................................2-15
CABLE ROUTING .........................................................................................2-16

CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION..............................................................................................3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ....................3-1
SIDE COVERS AND FOOTREST BOARD.....................................................3-3
FRONT PANEL AND LEG SHIELD ................................................................3-5
ADJUSTING THE ENGINE IDLING SPEED .............................................3-7
ADJUSTING THE THROTTLE CABLE FREE PLAY.................................3-8
BLEEDING THE AUTOLUBE PUMP.........................................................3-9
CHECKING THE SPARK PLUG..............................................................3-10
MEASURING THE COMPRESSION PRESSURE..................................3-11
CHECKING THE ENGINE OIL LEVEL....................................................3-13
REPLACING THE TRANSMISSION OIL.................................................3-14
CLEANING THE AIR FILTER ELEMENT................................................3-16
CHECKING THE CARBURETOR JOINT................................................3-17
CHECKING THE FUEL AND VACUUM HOSES.....................................3-17
CHECKING THE CRANKCASE BREATHER HOSE...............................3-18
CHECKING THE EXHAUST SYSTEM....................................................3-18
CHASSIS .......................................................................................................3-19
ADJUSTING THE FRONT BRAKE..........................................................3-19
ADJUSTING THE REAR BRAKE............................................................3-19
CHECKING THE BRAKE SHOES...........................................................3-20
CHECKING AND ADJUSTING THE STEERING HEAD .........................3-20
CHECKING THE FRONT SHOCK ABSORBER .....................................3-22
CHECKING THE TIRES..........................................................................3-22
CHECKING THE WHEELS .....................................................................3-25
CHECKING AND LUBRICATING THE CABLES.....................................3-26
LUBRICATING THE LEVERS .................................................................3-26
LUBRICATING THE CENTERSTAND ....................................................3-26
ELECTRICAL SYSTEM.................................................................................3-27
CHECKING AND CHARGING THE BATTERY.......................................3-27
CHECKING THE FUSE...........................................................................3-34
REPLACING THE HEADLIGHT BULB....................................................3-35
ADJUSTING THE HEADLIGHT BEAM ...................................................3-36
GEN
INFO
1
SPEC
2
CHK
ADJ
3
CHAS
4
ENG
5
CARB
6
ELEC
7
TRBL
SHTG
8
–+

CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE ........................................................................4-1
CHECKING THE FRONT WHEEL ............................................................4-5
CHECKING THE SPEEDOMETER GEAR UNIT.......................................4-6
CHECKING THE BRAKE ..........................................................................4-7
ASSEMBLING THE BRAKE SHOE PLATE ..............................................4-8
INSTALLING THE FRONT WHEEL ..........................................................4-8
REAR WHEEL AND BRAKE.........................................................................4-10
CHECKING THE REAR WHEEL.............................................................4-12
CHECKING THE BRAKE ........................................................................4-12
INSTALLING THE BRAKE SHOE PLATE...............................................4-13
INSTALLING THE BRAKE SHOES.........................................................4-14
INSTALLING THE REAR WHEEL...........................................................4-14
FRONT SHOCK ABSORBER ASSEMBLIES...............................................4-15
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES..............4-16
INSTALLING THE RELAY ARM..............................................................4-16
HANDLEBAR.................................................................................................4-17
REMOVING THE HANDLEBAR..............................................................4-19
CHECKING THE HANDLEBAR...............................................................4-19
INSTALLING THE HANDLEBAR.............................................................4-20
STEERING HEAD..........................................................................................4-22
REMOVING THE FORK..........................................................................4-24
CHECKING THE STEERING HEAD .......................................................4-24
INSTALLING THE STEERING HEAD .....................................................4-25
REAR SHOCK ABSORBER ASSEMBLY.....................................................4-26
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY...................4-27
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY....................4-27
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY..................4-27