Yamaha AEROX YQ50 Bedienungsanleitung

SERVICE

MANUAL

YQ50 5BS-AE2

'97

YQ50

SERVICE MANUAL

2st Edition, November 1997

reprinting or unauthorized use

without the written

permission of MBK INDUSTRIE

is expressly prohibited.

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 1This is a chapter with its symbol on the upper right of each page.

2nd title 2This 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 3This is a final title.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-

tion 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 4is 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 6indicates 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 Qto Ware designed as

thumb tabs to indicate the chapter’s number and

content.

QGeneral information

WSpecifications

EPeriodic inspection and adjustment

REngine

TCarburetion

YChassis

UElectrical

ITroubleshooting

Illustrated symbols Oto eare used to identify

the specifications appearing in the text.

OFilling fluid

PLubricant

{Special tool

}Tightening

qWear limit, clearance

wEngine speed

eΩ, V, A

Illustrated symbols rto [in the exploded

diagram indicate grade of lubricant and location

of lubrication point.

rApply engine oil

tApply gear oil

yApply molybdenum disulfide oil

uApply wheel bearing grease

iApply lightweight lithium-soap base

grease

oApply molybdenum disulfide grease

pApply locking agent (THREADLOCK ®)

[Use new one

INSP

ADJ

TRBL

SHTG

GEN

INFO

ENG

CHAS

CARB

ELEC

SPEC

T.R

{}

INDEX

SPECIFICATIONS

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GENERALINFORMATION

PERIODIC INSPECTION

AND ADJUSTMENT

SPEC

ENG

CARB

CHAS

ELEC

TRBL

SHTG

GEN

INFO

INSP

ADJ

COOLING SYSTEM ENG

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 Qis 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 Qis 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:

Designsand specificationsaresubject tochange

without notice.

SCOOTER IDENTIFICATION

햲

GEN

INFO

1-2

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.Properlyoilall mating partsand bearingduring

reassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTER

PINS

1.All lock washers/plates Qand 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) Qand oil seal(s) Wwith

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 bearingsliberally when installing.

Do not use compressed air to spin the

bearings dry. This causes damage to the

bearing surfaces.

CAUTION :

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