Yamaha 2008 YW50X Bedienungsanleitung

2008

MOTORCYCLE

SERVICE MANUAL

Model : YW50X_

5PNF81972100 *5PNF81972100*

EAS00000

YW50X 2007

SUPPLEMENTARY SERVICE MANUAL

First edition, June 2007

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Taiwan Co., Ltd.

is expressly prohibited.

Printed in CANADA

FORWORD

This supplementary service manual has been prepared to introduce new service and data forYW50BP

2001. For complete service manual procedures it is necessary to use this supplementary service

manual together with the following manual.

YW50BP 2001 SERVICE MANUAL : 5PN1-ME1

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!

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.

NOTE:

4-3

ENG

CYLINDER HEAD, CYLINDER AND PISTON

Job name/Part name

Cylinder head, Cylinder and piston

removal

Engine

Muffler/Gasket

Air shroud 2

Spark plug

Cylinder head/Cylinder head gasket

Cylinder

Piston pin clip

Piston pin/ Bearing

Piston

Piston ring set

Cylinder gasket

Remarks

Remove the parts in the order.

Refer to the “ENGINE REMOVAL” sec-

tion

Reverse the removal procedure for in-

stallation.

Order

Q’ty

1/1

10 1

26Nm(2.6 m.kg, 18.2 ft.lb)

14Nm(1.4 m.kg, 10 ft.lb)

9Nm(0.9 m.kg,6.5 ft.lb)

New

CYLINDER HEAD, CYLINDER AND PISTON

4-4

ENG

PISTON PIN AND PISTON REMOVAL

1. Remove:

8Piston pin clip 1

NOTE:

Before removing the piston pin clip, cover the

crankcase with a clean rag so you will not acci-

dentally drop the clip into the crankcase.

2. Remove:

8Piston pin 1

8Piston 2

8Piston pin bearing 3

Do not use a hammer to drive the piston pin

out.

CYLINDER HEAD INSPECTION

1. Eliminate:

8Carbon deposits

Use a rounded scrapper 1.

2. Inspect:

8Cylinder head warpage

Out of specification∅Re-surface.

*************************************

Warpage measurement and re-surfacement

steps:

8Attach a straight edge 1and a thickness

gauge 2on the cylinder head.

8Measure the warpage limit.

Warpage limit:

0.03 mm(0.0012 in)

8If the warpage is out of specification, reface

the cylinder head.

NOTE:

Rotate the head severai tires to avoid remov-

ing too much material from one side.

*************************************

CYLINDER HEAD, CYLINDER, PISTON

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 se-

quentially.

GEN

INFO

SPEC

CHK

ADJ

ENG

TRBL

SHTG

CHAS

ELEC

New

COOL

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

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 gin the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

iEngine oil

oGear oil

pMolybdenum-disulfide oil

aBrake fluid

sWheel-bearing grease

dLithium-soap- based grease

fMolybdenum-disulfide grease

gSilicone grease

Symbols hto jin the exploded diagrams indi-

cate the following.

hApply locking agent (LOCTITE®)

jReplace the part

t y u

CARB

opa

dfg

EAS00010

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

CARBURETOR

GEN

INFO

SPEC

CHK

ADJ

CARB

1-8

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

CHECKING THE CONNECTIONS ........................................................... 1-4

SPECIAL TOOLS ...................................................................................... 1-5

1-1

GEN

INFO

SCOOTER IDENTIFICATION

EAS00015

GENERAL INFORMATION

SCOOTER IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1is stamped

into the frame.

EAS00018

MODEL LABEL

The model label 1is affixed to the seat. This

information will be needed to order spare parts.

1-2

GEN

INFO

IMPORTANT INFORMATION

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.

1-3

GEN

INFO

IMPORTANT INFORMATION

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

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

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