2002-2007 Yamaha Jog 50 Scooter Service & Repair 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 W ARNING instr uctions could r esult in sever e injur y 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. t s WARNING 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 particularly important procedure  is placed between a lines of asterisks “**” with each procedure preceded 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 circle 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 identification of disassembly/assembly procedures.

EAS00008 ILLUSTRATED SYMBOLS (See illustration) The symbols from  to  are designed as thumb indices, to indicate the chapter number 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 lubricant 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 cotter 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 stamped letters should be on the side exposed to view.) When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Put oil on the bearings when installing. CAUTION: Do not use compressed air to spin the bearings dry. This will damage the bearing surfa- ce.

2002-2007 Yamaha Jog 50 Scooter Service & Repair Manual

You're Reading a Preview

Recently Viewed