Yamaha YW50AP Service 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.

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Yamaha YW50AP Scooter Service Manual
index
general information specifications periodic inspection and adjustment engine overhaul carburetion chassi
electrical troubleshooting
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
chapter 5 carburetion
carburetion… 5-1 carburetor… 5-1 caburetor disassembly… 5-2 caburetor inspection… 5-3 carburetor assembly… 5-5 fuel level adjustment… 5-6 auto choke inspection… 5-7 fuel cock inspection… 5-8
chapter 6 chassis
front wheel and brake disc… 6-1 front wheel and brake disc… 6-1 front wheel disassembly… 6-2 front wheel disassembly… 6-3 front wheel inspection… 6-3 brake disc inspection… 6-4 front wheel assembly… 6-4 front wheel installation… 6-5 wheel static balance adjustment… 6-6 front brake… 6-8 brake pad… 6-8 brake pad replacement… 6-9 master cylinder… 6-12 master cylinder disassembly… 6-13 master cylinder inspection… 6-14 master cylinder assembly… 6-14 master cylinder installation… 6-15 caliper… 6-17 caliper disassembly… 6-18 brake caliper disassembly… 6-19 caliper inspection… 6-19 brake caliper assembly… 6-20 brake caliper installation… 6-20 rear wheel and rear brake… 6-21 rear wheel… 6-21 rear brake… 6-22 rear wheel inspection… 6-23 rear brake inspection… 6-23 rear brake installation… 6-24 handlebar… 6-25 handlebar… 6-25 handlebar installation… 6-27 steering… 6-29 steering… 6-29 steering removal… 6-30 steering inspction… 6-31 steering installation… 6-31 front fork… 6-34 front fork… 6-34 front fork disassembly… 6-35 front fork removal… 6-36 front fork disassembly… 6-36 front fork inspection… 6-37 front fork assembly… 6-37 front fork installation… 6-39
chapter 7 electrical
electrical components… 7-1 electrical components… 7-1 circuit diagram… 7-2 checking switches… 7-4 checking steps… 7-4 switch connection as shown in this manual… 7-4 switch position and terminal connection… 7-5 checking the blubs and bulb sockets… 7-5 checking the bulbs and bulb sockets… 7-6 types of bulbs… 7-6 checking the condition of the bulbs… 7-7 checking the condition of the bulb sockets… 7-8 ignition system… 7-9 circuit diagram… 7-9 troubleshooting… 7-10 charging system… 7-14 circuit diagram… 7-14 troubleshooting… 7-15 electric starting system… 7-18 circuit diagram… 7-18 troubleshooting… 7-19 starter motor… 7-22 starter motor disassembly… 7-23 inspection and repair… 7-24 lighting system… 7-26 circuit diagram… 7-26 troubleshooting… 7-27 lighting system check… 7-29 signal system… 7-33 circuit diagram… 7-33 troubleshooting… 7-34 signal system check… 7-36 auto choke system… 7-42 circuit diagram… 7-42 troubleshooting… 7-43
chapter 8 troubleshooting
starting failure/hard starting… 8-1 fuel system… 8-1 ignition system… 8-2 compression system… 8-2 poor idle speed performance… 8-3 poor idle speed performance… 8-3 poor midium and high speed performance… 8-3 poor midium and high speed performance… 8-3 fulty automatic(v-belt type)… 8-4 scooter does not move while engine is operating… 8-4 clutch out failure… 8-4 poor standing start(low climbing ability)… 8-4 poor acceleration(poor high speed)… 8-4 over heat… 8-5 overheat… 8-5 poor speed… 8-5 poor speed… 8-5 improper kicking… 8-6 slipping… 8-6 hard kicking… 8-6 kick crank not returning… 8-6 faulty brake… 8-7 poor braking effect… 8-7 malfunction… 8-7 instable handling… 8-8 instable handling… 8-8 faulty signal and lighting system… 8-9 headlight dark… 8-9 bulb burnt out… 8-9 flasher does not blink… 8-9 flasher keeps on… 8-9 flasher blinks slower… 8-10 flasher blinks quicker… 8-10 horn does not sound… 8-10

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