2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 Yamaha Zuma YW50 50cc Scooter models Service Manual

YW50AP 5PJ-F8197-10 LIT-11616-15-39

EB000000 YW50AP SERVICE MANUAL ©2001 by Yamaha Motor Corporation U.S.A. First edition, November 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. P/N LIT-11616-15-39

EB001000 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. 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 dam- age to the scooter. A NOTE provides key information to make procedures easier or clearer. w Q NOTE: cC

4 5 6 7 8 1 2 3 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. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each 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. 3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”. 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequen- tially.

EAS00009 SYMBOLS The following symbols are not relevant to ev- ery vehicle. Symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Carburetor(s) 6 Chassis 7 Electrical system 8 Troubleshooting Symbols 9 to y indicate the following. 9 Serviceable with engine mounted 0 Filling fluid q Lubricant w Special tool e Tightening torque r Wear limit, clearance t Engine speed y Electrical data Symbols u to s in the exploded diagrams indicate the types of lubricants and lubrication points. u Engine oil i Gear oil o Molybdenum disulfide oil p Wheel bearing grease a Lithium soap base grease s Molybdenum disulfide grease Symbols d to f in the exploded diagrams indicate the following. d Apply locking agent (LOCTITE ® ) f Replace the part GEN INFO SPEC INSP ADJ ENG CARB CHAS – + ELEC TRBL SHTG B LS M LT New E G M 1 2 3 4 5 6 7 8 9 0 T R . . q w e r t y u i o p a s d f

INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING 1 2 3 4 5 6 7 8 – +

CHAPTER 1. GENERAL INFORMATION SCOOTER INDENTIFICATION ........................................................................................................... 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 OF CONNECTIONS ........................................................................................................ 1-4 HOW TO USE THE CONVERSION TABLE ....................................................................................... 1-5 CONVERSION TABLE .................................................................................................................... 1-5 SPECIAL TOOLS ................................................................................................................................ 1-6

CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATION ............................................................................................................... 2-1 MAINTENANCE SPECIFICATION ..................................................................................................... 2-4 ENGINE .......................................................................................................................................... 2-4 TIGHTENING TORQUES ............................................................................................................... 2-6 ENGINE .......................................................................................................................................... 2-6 MAINTENANCE SPECIFICATION ..................................................................................................... 2-7 CHASSIS ........................................................................................................................................ 2-7 TIGHTENING TORQUES ............................................................................................................... 2-8 CHASSIS ........................................................................................................................................ 2-8 MAINTENANCE SPECIFICATION ..................................................................................................... 2-9 ELECTRICAL ................................................................................................................................... 2-9 GENERAL TORQUE SPECIFICATIONS ........................................................................................... 2-11 LUBRICATION POINTS AND LUBRICATION TYPE ....................................................................... 2-12 ENGINE ........................................................................................................................................ 2-12 CHASSIS ...................................................................................................................................... 2-13 CABLE ROUTING ............................................................................................................................. 2-14

CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENTS INTRODUCTION ................................................................................................................................ 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ................................................................ 3-1 COVER AND PANEL .......................................................................................................................... 3-3 SIDECOVER AND SEAT ................................................................................................................ 3-3 LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD ..................... 3-4 HANDLEBAR COVER(FRONT AND REAR) ................................................................................... 3-5 ENGINE .............................................................................................................................................. 3-6 IDLE SPEED ADJUSTMENT .......................................................................................................... 3-6 THROTTLE CABLE FREE ADJUSTMENT ..................................................................................... 3-7 AUTOLUBE PUMP AIR BLEEDING ............................................................................................... 3-8 SPARK PLUG INSPECTION ........................................................................................................... 3-9 ENGINE OIL LEVEL INSPECTION ............................................................................................... 3-10 TRANSMISSION OIL REPLACEMENT ........................................................................................ 3-11 AIR FILTER ELEMENT CLEANING .............................................................................................. 3-12 V-BELT INSPECTION ................................................................................................................... 3-14 CHASSIS .......................................................................................................................................... 3-15 FRONT BRAKE LEVER FREE PLAY CHECK ................................................................................ 3-15 REAR BRAKE LEVER FREE PLAY CHECK ................................................................................... 3-15 BRAKE PAD INSPECTION ........................................................................................................... 3-15 BRAKE SHOE INSPECTION ........................................................................................................ 3-16 BRAKE FLUID LEVEL INSPECTION ............................................................................................ 3-16 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ........................................................................ 3-17 STEERING ADJUSTMENT .......................................................................................................... 3-18 TIRE INSPECTION ........................................................................................................................ 3-19 WHEEL INSPECTION ................................................................................................................... 3-22 FRONT FORK INSPECTION ......................................................................................................... 3-22 REAR SHOCK ABSORBER INSPECTION .................................................................................... 3-22 SEAT LOCK CABLE ADJUSTMENT ........................................................................................... 3-22 CABLE CHECKING AND LUBRICATING ..................................................................................... 3-23 LEVERS LUBRICATING ............................................................................................................... 3-23 CENTERSTAND LUBRICATING .................................................................................................. 3-23 ELECTRICAL ..................................................................................................................................... 3-24 BATTERY INSPECTION ............................................................................................................... 3-24 FUSE INSPECTION ...................................................................................................................... 3-29 HEADLIGHT BEAM ADJUSTMENT ............................................................................................ 3-30 HEADLIGHT BULB REPLACEMENT ............................................................................................ 3-30 TURN SIGNAL AND TAILLIGHT BULB REPLACEMENT ........................................................... 3-31 TAILLIGHT BULB REPLACEMENT .............................................................................................. 3-32 LICENSE LIGHT BULB REPLACEMENT ...................................................................................... 3-32

CHAPTER 4. ENGINE ENGINE OVERHAUL ......................................................................................................................... 4-1 WIREHARNESS AND CABLES ...................................................................................................... 4-1 CYLINDER HEAD, CYLINDER AND PISTON .................................................................................... 4-3 CYLINDER HEAD, CYLINDER AND PISTON ................................................................................ 4-3 PISTON PIN AND PISTON REMOVAL .......................................................................................... 4-4 CYLINDER HEAD INSPECTION ..................................................................................................... 4-4 CYLINDER AND PISTON INSPECTION ........................................................................................ 4-5 PISTON RINGS INSPECTION ........................................................................................................ 4-7 PISTON PIN AND PISTON PIN BEARING .................................................................................... 4-7 PISTON PIN AND PISTON INSTALLATION ................................................................................. 4-8 CYLINDER AND CYLINDER HEAD ................................................................................................ 4-9 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................... 4-11 KICK STARTER AND CRANKCASE COVER(LEFT) ..................................................................... 4-11 KICK STARTER ............................................................................................................................. 4-12 KICK STARTER INSTALLATION ................................................................................................. 4-13 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE ........................................................ 4-14 SECONDARY SHEAVE ................................................................................................................ 4-15 PRIMARY SHEAVE REMOVAL .................................................................................................... 4-16 SECONDARY SHEAVE REMOVAL .............................................................................................. 4-16 CLUTCH INSPECTION ................................................................................................................. 4-17 V-BELT INSPECTION ................................................................................................................... 4-18 PRIMARY SHEAVE INSPECTION ................................................................................................ 4-19 SECONDARY SHEAVE ................................................................................................................ 4-20 SECONDARY SHEAVE INSTALLATION ..................................................................................... 4-21 PRIMARY SHEAVE ...................................................................................................................... 4-22 STARTER CLUTCH AND STARTER MOTOR ................................................................................. 4-24 STARTER CLUTCH AND STARTER MOTOR .............................................................................. 4-24 STARTER CLUTCH AND GEARS INSPECTION ......................................................................... 4-26 C.D.I. MAGNET ................................................................................................................................ 4-27 C.D.I. MAGNETO ......................................................................................................................... 4-27 C.D.I. MAGNETO REMOVAL ....................................................................................................... 4-28 C.D.I. MAGNETO INSTALLATION .............................................................................................. 4-28 AUTOLUBE PUMP ........................................................................................................................... 4-29 AUTOLUBE PUMP ....................................................................................................................... 4-29 AUTOLUBE PUMP INSTALLATION ........................................................................................... 4-30 TRANSMISSION .............................................................................................................................. 4-31 TRANSMISSION .......................................................................................................................... 4-31 CRANKCASE AND REED VALVE .................................................................................................... 4-33 CRANKCASE AND REED VALVE ................................................................................................ 4-33 CRANKCASE(RIGHT) REMOVAL ................................................................................................ 4-35 CHECKING THE CRANKCASE .................................................................................................... 4-35 CHECKING THE BEARINGS AND OIL SEALS ............................................................................ 4-35 REED VALVE INSPECTION ......................................................................................................... 4-36 CRANKCASE (RIGHT) INSTALLATION ...................................................................................... 4-36 CRANKSHAFT .................................................................................................................................. 4-38 CRANKSHAFT .............................................................................................................................. 4-38 CRANKSHAFT REMOVAL ........................................................................................................... 4-39 CRANKSHAFT INSPECTION ....................................................................................................... 4-39 CRANKSHAFT INSTALLATION ................................................................................................... 4-40

2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 Yamaha Zuma YW50 50cc Scooter models Service Manual

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