1997-2006 Yamaha Aerox 50 YQ50 Service Repair Manual

SERVICE MANUAL YQ50

CAUTION: WARNING NOTICE This manual was written by the MBK INDUSTRIE primarily for use by YAMAHA and MBK dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on YAMAHA and MBK scooters have a basic understanding of the mechanical concepts and procedures inherent in scooter repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. MBK INDUSTRIE is continually striving to improve all models manufactured. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized YAMAHA and MBK dealers and will, where applicable, appear in future editions of this manual. DOCUMENTATION TECHNIQUE MBK INDUSTRIE PARTICULARY IMPORTANT INFORMATION This material is distinguished by the following notation : 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 damage to the scooter. A NOTE provides key information to make procedures easier or clearer. NOTE:

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See «illustrated symbols). 1st title 1 This is a chapter with its symbol on the upper right of each page. 2nd title 2 This title appears on the upper of each page on the left of the chapter symbol. (For the chapter «Periodic inspection and adjustment» the 3rd title appears.) 3rd title 3 This is a final title. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particulary important procedure 4 is placed between a line of asterisks " * " with each step preceded by " • ". IMPORTANT FEATURES • Data and a special tools are framed in a box preceded by a relevant symbol 5. • An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data for an alignement mark 7, the others being indicated by an alphabetical letter in a box 8. • A condition of a faulty component will precede an arrow symbol and the course of action required the symbol 9. EXPLODED DIAGRAM Each chapter provides exploded diagrams are before each disassembly section for ease in identifying correct disassembly and assembly procedures.

ILLUSTRATED SYMBOLS (REFER TO THE ILLUSTRATION) Illustrated symbols Q to W are designed as thumb tabs to indicate the chapter’s number and content. Q General information W Specifications E Periodic inspection and adjustment R Engine T Carburetion Y Chassis U Electrical I Troubleshooting Illustrated symbols O to e are used to identify the specifications appearing in the text. O Filling fluid P Lubricant { Special tool } Tightening q Wear limit, clearance w Engine speed e Ω, V, A Illustrated symbols r to [ in the exploded diagram indicate grade of lubricant and location of lubrication point. r Apply engine oil t Apply gear oil y Apply molybdenum disulfide oil u Apply wheel bearing grease i Apply lightweight lithium-soap base grease o Apply molybdenum disulfide grease p Apply locking agent (THREADLOCK ®) [ Use new one INSP ADJ TRBL SHTG GEN INFO ENG CHAS CARB ELEC SPEC T.R Q W R E T Y U I O P { } q w e r u p [ t y i o

1 2 3 4 6 7 8 9 INDEX SPECIFICATIONS ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT SPEC ENG CARB CHAS ELEC TRBL SHTG GEN INFO INSP ADJ 5 COOLING SYSTEM ENG

1 GEN INFO

GEN INFO CHAPTER 1. GENERAL INFORMATION SCOOTER IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................... 1-1 ENGINE SERIAL NUMBER ..................................................................... 1-1 IMPORTANT INFORMATION ....................................................................... 1-2 ALL 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 1-1 GENERAL INFORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number Q is stamped into the frame. NOTE: The vehicle identification number is used to identify your scooter and may be used to register your scooter with the licensing authority in your state. ENGINE SERIAL NUMBER The engine serial number Q is stamped into the crankcase. NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. NOTE: Designs and specifications are subject to change without notice. SCOOTER IDENTIFICATION  

GEN INFO 1-2 IMPORTANT INFORMATION IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1.Use only genuine parts for all replacements. Use oil and/or grease recommended by MBK/ YAMAHA for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality. GASKETS, OIL SEALS, AND O-RINGS 1.All gaskets, seals and O-rings should be replaced when an engine is overhauled. All gaskets surfaces, oil seal lips and O-rings must be cleaned. 2.Properly oil all mating parts and bearing during reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS 1.All lock washers/plates Q and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. BEARINGS AND OIL SEALS 1.Install the bearing(s) Q and oil seal(s) W with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. CAUTION :

GEN INFO 1-3 IMPORTANT INFORMATION CIRCLIPS 1.All circlips should be inspected carefully before reassembly. Always replace piston pin clips once they have been removed. Replace bent circlips. When installing a circlip Q make sure that the sharp edge W is positioned opposite to the thrust E it receives. See the sectional view. R Shaft

1997-2006 Yamaha Aerox 50 YQ50 Service Repair Manual

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