Yamaha JOGR JOGRR CS50 Bedienungsanleitung

2002

SERVICE MANUAL

CS50/Z

5RW1-AE1

CS50/Z

SERVICE MANUAL

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.

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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 WARNING instructions could result in severe injury

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.

ssWARNING

CAUTION:

NOTE :

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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 par-

ticularly important procedure is placed between a lines of asterisks “**” with each procedure pre-

ceded 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 cir-

cle 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 identifica-

tion of disassembly/assembly procedures.

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ILLUSTRATED SYMBOLS

(See illustration)

The symbols from to are designed as

thumb indices, to indicate the chapter num-

ber 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 lubri-

cant 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

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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

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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

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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.

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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 cot-

ter pins after removal. Bend lock tabs along

the bolt or nut flats after the bolt or nut has

been tightened to specification.

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BEARINGS AND OIL SEALS

1. Install the bearings and oil stops with

their manufacturer brands or numbers

facing outwards. (In other words, the stam-

ped letters should be on the side exposed

to view.) When installing oil seals, apply a

light coating of lightweight lithium base gre-

ase to the seal lips. Put oil on the bearings

when installing.

CAUTION:

Do not use compressed air to spin the bea-

rings dry. This will damage the bearing surfa-

ce.

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