Yamaha BWS CW50L Bedienungsanleitung

1999 - 2002

MOTORCYCLE

SERVICE MANUAL

Model : CW50L, CW50M, CW50N, CW50P

4RW281972K00 *4RW281972K00*

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NOTICE

This manual was written by the MBK INDUSTRIE primarily foruse by YAMAHA dealers and their

qualified mechanics. It is not possibleto put an entire mechanic's education into one manual, so it is

assumed that persons using this book to performmaintenance and repairs on YAMAHA scooters

have a basic understanding ofthemechanical concepts and procedures inherent in scooter repair

technology. Without such knowledge, attempted repairs or service to this model may render it unfit to

useand/or unsafe.

MBK INDUSTRIE is continually striving to improve all models manufactured.Modifications and sig-

nificant changes in specifications or procedures will beforwarded to allAuthorized YAMAHAdealers

and will, where applicable, appear in future editions ofthis manual.

DOCUMENTATION TECHNIQUE

MBK INDUSTRIE

PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation:

/_ The safetyAlert Symbol meansATTENTION! BECOMEALERT! YOUR

SAFETY IS INVOLVED!

r.IIY/-'1:I_11_[¢]1 Failure to follow WARNINGinstructions could result in severe injury or

death to the scooter operator, a bystander, ora person inspecting or

repairing thescooter.

CAUT}ONi:A CAUTION indicates special precautions that mustbe takento avoid

damage to the scooter.

NOTE: ANOTE provides key information to make procedures easier or clearer.

CW50

SERVICE MANUAL

3st Edition, April 1997

reprinting or unauthorized use

without the written

)ermission of MBK INDUSTRIE

is expressly prohibited.

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HOW TO USE THIS MANUAL ® ® ILLUSTRATEDSYMBOLS

CONSTRUCTION OF THIS MANUAL

This manual consists of chapters for the main categories of subjects. (See <<illustratedsymbols). Illustrated symbols _to _are designed as

1st title (_) This is a chapter with its symbol on theupper right of each page. (_ L_ thumb tabs to indicate thechapter'snumber and

2nd tiUe Q ThistiUeappears on the upperof each page on theleft of the chaptersymbol. (For I=-I I _ content.

thechapter (<Periodicinspectionand adjustment)) the 3rd title appears.)I_

3rd title _) This is afinal title. _General information

z(t_Specifications

MANUAL FORMAT _ _ _ Periodic inspectionandadjustment

tionhas been compiledto provide themechanic with aneasy toread, handy reference that contains@Carburetion

comprehensive explanations of all disassembly, repair, assembly, and inspections._ Chassis

Aset of particularly importantprocedure (_)isplaced between a line of asterisks"*"witheach step _ ® _ Electrical

IMPORTANT FEATUREsPrecededby" """II :1 _)Troubleshooting

• Data and a special tools are framedinabox preceded by a relevant symbol®. _ _ Illustrated symbols _ to_are used toidentify

• An encircled numeral ® indicatesa part name,and anencircled alphabetical letter datafor an _

alignments mark Q, the others beingindicated by an alphabetical letterin a box_), the specifications appearing in the text.

•Acondition of a faulty component will precede an arrow symbol and the course of action required

thesymbol(_). ' _ Fillingfluid

@ i @ _ Lubricant

EXPLODED DIAGRAM <_ i_ @ Special tool

Eachchapter provides exploded diagrams are before each disassembly section for ease in identify-@Tightening

ing correct disassembly and assembly procedures. @Wear limit, clearance

@Engine speed

OVA

' _. :_-_.,_.._,';__..... :;"--L'..'._,_ _ _ _ Illustrated symbols _ to @ inthe exploded dia-

"",_ gramindicategrade of lubricantand location of

lubrication point.

_-.- _';"............. !_ .... _ _ _I @ I _ , _ Apply engineoil

__,_.,@ Apply gearoil

--i--|--_ _)Apply molybdenum disulfide oil

:,T_...:.:....C.__,_I_:;-_,..,_tF-.-"'_ _:_'_...... _1___ _ Apply wheel bearing grease

__--:5:,Apply lightweight lithium-soapbase

®_---- _--_1'¢_ ":_""';_"-I J _ _ @ grease

r/,_, j_| [E,;2_;c_E_-- _ _ @ Apply molybdenum disulfide grease

-_-_, :_"':'_-_ _ _ @Applylockingagent(THREADLOCK®)

Use

new

one

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A-4 I

INDEX

SPECIFICATIONS

PERIODIC INSPECTION I _I

AND ADJUSTMENT I'"sP

ENGINEOVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

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CHAPTER 1.

GENERAL INFORMATION

SCOOTER IDENTIFICATION ....................................................................... A-8

VEHICLE IDENTIFICATION NUMBER ................................................... A-8

ENGINE SERIAL NUMBER .................................................................... A-8

IMPORTANT INFORMATION ...................................................................... A-8

ALLREPLACEMENT PARTS ................................................................ A-8

GASKETS, OIL SEALS, AND O-RINGS................................................. A-8

LOCK WASHERS/PLATES AND CO'I-I'ER PINS .................................. A-8

BEARINGS AND OILSEALS.................................................................. A-8

CIRCLIPS ................................................................................................ A-9

SPECIAL TOOLS.......................................................................................... A-9

FOR TUNE UP ........................................................................................ A-9

FOR ENGINE SERVICE ......................................................................... A-9

FOR CHASSIS SERVICE ..................................................................... A-10

FOR ELECTRICALCOMPONENTS ..................................................... A-10

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SCOOTER IDENTIFICATION INFO A-8 IMPORTANT INFORMATION INFO

INFORMATION ALL REPLACEMENT PARTS

1. Use only genuine parts for all replacements.

SCOOTER IDENTIFICATION Useoil and/or grease recommended by MBK/

VEHICLE IDENTIFICATION NUMBER _'-.._ _ _O YAMAHAforassemblyandadjustment.Other

The vehicleidentification numbere isstamped _._ __ _ brandsmay besimilarin functionand appear-

_ _ _ into the frame, ance, but inferior in quality.

NOTE:

Thevehicle identification number is used to

identifyyourscooterand maybeusedto register__(_ GASKETS, OIL SEALS, AND O-RINGS

your scooter with the licensing authority in your 1.All gaskets,seals and O-rings should be re-

state, placed when an engine is overhauled. All

gaskets surfaces, oil seal lips and O-rings

IInitial serial number: I must be cleaned.

2.Properly oil allmating parts and bearing dur-

VG54RWN0*WA101301 ing reassembly. Apply grease to theoil seal

lips.

The engine serial number@is stamped into the PINS

_crankcase. _1.All lock washers/plates (_ and cotter pins

must be replaced whenthey are removed.

NOTE: _ Locktab(s) should bebent along the boltor nut

The first three digits of these numbers are for _MHr,IH'flat(s) after the bolt or nut has been properly

model identifications; the remaining digits are tightened.

the unit production number.

IInitial serial number:

O_ BEARINGS AND OIL SEALS

4UY-200101 1.Install the bearing(s) (_ and oil seal(s) ®with

their manufacturer's marks or numbers facing

NOTE: outward. (In other words, the stamped letters

Designs andspecifications aresubjectto changemust be on the side exposed to view.) When

without notice, installing oil seal(s), apply a light coating of

lightweight lithium base grease to the seal

lip(s). Oil the bearings liberally when installing.

CAUTION:_

Donotusecompressedairtospinthe

__bearings dry. This causes damage to the

bearing surfaces.

1-1 1 -2

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IMPORTANT INFORMATION/SPECIAL TOOLS INFO _A" 9 J SPECIAL TOOLS INFO

CIRCLIPS Flywheel magneto puller

care,u,, e-080-019

[_ fore reassembly. Always replace piston pin

c_) clips once they have been removed. Replace

bent circlips. Wheninstallingacirclip _) makeFOR ENGINE SERVICE

surethat the sharp edge _is positioned

oppositeto thethrust L_ it receives. See the

sectional view.

Shaft

Crankcase separating tool Flywheel holding tool

SPECIAL TOOLS 90890-01135 90890_0t_'_ f{_

The properspecial tools arenecessary for com- _ _ (_

plete and accurate tune-up and assembly. Us-

ing the correct special tool will help prevent

damage caused by the use of improper tools or

improvised techniques.

Inductive tachometer ] Crankshaft installing tool set Clutch servingnutwrenc_

90890-03113 1 90890-01274 _);_'#--'_ 90890-01348

__ 90890-01275 _)

90890-01277 (_) ._

FOR TUNE UP 90890-01411 (_ \_';_:i"

Ignition checker Sheave holder Clutch spring holderri a f_ c-_

g0890_0_4_ go8go.01_01 00890_01010®g°890°1_®___'_-__<"_>_-

Oil Seal Guide

90890-01409 (D

Oil Seal Driver _/

1-3 1-4

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SPECIAL TOOLS I 'NFO _1_1IA _ol I

- I.FO_1

Ring nut wrench

90890-01268 _,_ _

90890-01403 _)

FOR CHASSIS SERVICE

Damper rod holder T-Handle

90890o01294 90890-01326

Oil seal guide Oil sealguide adapter

90890-01184 90890-01186

Pocket Tester

FORCOMPONENTELECTRICAL 90890-03112 _

1-5

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