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CS50/Z
SERVICE MANUAL
© 2002 by Y
amaha Motor España, S.A.
1st Edition, September 2002
Any reprinting or use of this material
without the prior authorisation of
Y
amaha Motor España, S.A.
is expressly pr
ohibited.
Printed in Spain.
EAS00001
1
3
Table of Contents
Main Page
Gen Info Chapter 1 General Information
8
Service Manual
1
Table of Contents
8
Chapter 1 General Information
9
Scooter Identification
9
Frame Serial Number
9
Engine Serial Number
9
Important Information
10
Replacement Parts
10
Gaskets, Oil Seals and O-Rings
10
Lock Washers/Plates and Cotter Pins
10
Bearings and Oil Seals
10
Circlips
11
Special Tools
12
Spec Chapter 2 Specifications
15
Chapter 2 Specifications
16
General Specifications
16
Maintenance Specifications
18
Engine
18
Chassis
20
Electrical System
21
Conversion Table
22
General Tightening Torque Specifications
22
Tightening Torques
23
Engine Tightening Torques
23
Chassis Tightening Torques
24
COOLING SYSTEM (CS50Z Only)
25
Cable Routing
26
Chk Adj Chapter 3 Periodic Checks and Adjustments
30
Periodic Checks and
30
Chapter 3 Periodic Checks and Adjustments
31
Introduction/Periodic Maintenance/Lubrication Intervals
31
Engine
31
Rear Bodywork and Mudguard
32
Removal
32
Installation
33
Front Cowling and Footrest
34
Removal
34
Installation
35
Handlebar Covers
36
Removal
36
Installation
37
Engine
38
Adjusting the Engine Idling Speed
38
Adjusting the Throttle Cable Free Play
39
Checking the Spark Plug
40
Checking the Engine Oil Level
41
Changing the Transmission Oil
42
Autolube Pump Air Bleeding
42
Cleaning the Air Filter Element
43
CHECKING the COOLANT LEVEL (CS50Z Only)
44
CHANGING the COOLANT (CS50Z Only)
45
Chassis
48
Adjustment the Front Brake Lever
48
Adjustment the Rear Brake Lever
48
Checking the Front Brake Pads
48
Checking the Rear Brake Shoes
49
Checking the Brake Fluid Level
49
Bleeding the Hydraulic Brake System
50
Checking and Adjusting the Steering Head
51
Checking the Tires
53
Checking the Wheels
53
Checking the Front Fork
53
Rear Shock Absorber Inspection
54
Electrical System
55
Checking and Charging the Battery
55
Checking the Fuse
60
Replacing the Headlight Bulb
61
Adjusting the Headlight Beam
61
Eng Chapter 4 Engine
63
Cables, Leads and Hoses
64
Chapter 4
64
COOLING SYSTEM (CS50Z Only)
64
Cover Removal
64
Engine Removal
64
Engine Removal
65
Engine Disassembly
66
Removing the Rear Wheel
66
Removing the Cylinder Head and Cylinder
66
Removing the Piston Pin and Piston
66
Removing the Kickstarter System
67
Removing the Primary Sheave
68
Disassembling the Secondary Sheave
69
Removing the Starter System
70
Transmission
70
DC-CDI Magneto
71
Autolube Oil Pump
72
Removing the Centerstand
72
Disassembling the Crankcase and Crankshaft
72
Carburetor
72
Inspection and Repair
74
Checking the Cylinder Head
74
Checking the Cylinder and Piston
75
Checking the Piston Rings
77
Checking the Piston Pin and Piston Pin Bearing
78
Checking the Kickstarter
79
Transmission
79
Autolube Oil Pump
80
Checking the Crankshaft
80
Checking the Bearings
81
Checking the Primary Sheave
81
Checking the Secondary Sheave
82
Checking the V-Belt
83
Starter Clutch and Gears
84
Engine Assembly and Adjustment
85
Crankshaft and Crankcase
85
Installing the Crankshaf
86
Autolube Oil Pump and DC-CDI Magneto
87
Installing the Autolube Oil Pump
88
Installing the DC-CDI Magneto
88
Transmission
90
Installing the Transmission
91
Starter System
92
Installing the Starter System
93
Primary and Secondary Sheave
94
Kickstarter
95
Assembling the Secondary Sheave
96
Assembling the Primary Sheave
97
Installing the Kickstarter
99
Piston, Cylinder and Cylinder Head (Cs50)
100
Piston, Cylinder and Cylinder Head (Cs50Z)
101
Piston and Piston Pin
102
Cylinder and Cylinder Head
102
Engine Remounting
104
Cool Chapter 5 Cooling System (Cs50Z Only)
108
CHAPTER 5 COOLING SYSTEM (CS50Z Only)
109
Radiator and Water Pump
109
Removing the Radiator
110
Removing the Water Pump
110
Checking the Radiator
111
Checking the Water Pump
111
Installing the Water Pump
112
Installing the Radiator
113
Thermostat
113
Removing the Thermostat
113
Checking the Thermostat
114
Installing the Thermostat
114
Carb Chapter 6 Carburetor
117
Chapter 6 Carburetor
118
Disassembling the Carburetor
119
Removing the Carburetor
119
Checking the Carburetor
120
Assembling the Carburetor
122
Checking the Autochoke Unit
123
Fuel Cock
124
Checking the Fuel Cock
124
Installing the Carburetor
124
Reed Valve
125
Removing the Reed Valve
125
Checking the Reed Valve
125
Installing the Reed Valve
126
Chas Chapter 7 Chassis
128
Chassis
128
Front Wheel
129
Chapter 7
130
Removing the Front Wheel
130
Checking the Front Wheel
131
Checking He Speed Sensor Unit
132
Checking the Brake Disc
132
Installing the Front Wheel
134
Front Brake
135
Replacing the Front Brake Pads
136
Removing the Brake Hose
138
Checking the Brake Hose
138
Installing the Brake Hose
139
Rear Wheel
141
Removing the Rear Wheel
142
Checking the Rear Wheel
142
Assembling the Brake Shoes
143
Installing the Rear Wheel
144
Front Fork
145
Removing the Front Fork Legs
146
Disassembling the Front Fork Legs
146
Checking the Front Fork Legs
147
Assembling the Front Fork Legs
148
Installing the Front Fork Legs
150
Handlebar and Steering
151
Removing the Handlebar
152
Removing the Lower Bracket
153
Checking the Steering Head
154
Checking the Handlebar
155
Installing the Steering Head
155
Installing the Handlebar
156
Elec Chapter 8 Electrical System
159
Chapter 8 Electrical System
160
Electrical Components
160
Checking Switch Continuity
162
Checking the Switches
163
Checking the Bulbs and Bulb Sockets
164
Checking the Condition of the Bulbs
164
Checking the Condition of the Bulb Sockets
165
Ignition System
167
Circuit Diagram
167
Troubleshooting
168
Electric Starting System
171
Circuit Diagram
171
Starting Circuit Cut-Off System Operation
172
Troubleshooting
173
Starter Motor
175
Removing the Starter Motor
176
Checking the Starter Motor
176
Assembling the Starter Motor
177
Charging System
178
Circuit Diagram
178
Troubleshooting
179
Lighting System
181
Circuit Diagram
181
Troubleshooting
182
Checking the Lighting System
183
Signaling System
186
Circuit Diagram
186
Troubleshooting
187
Checking the Signaling System
188
Trbl Shtg Chapter 9 Troubleshooting
196
Chapter 9 Troubleshooting
197
Starting Failure/ Hard Starting Engine
197
Fuel System
197
Electrical System
198
Incorrect Engine Idling Speed
198
Engine
198
Fuel System
198
Faulty Clutch
199
Engine Operates but Scooter will Not Move
199
Clutch Slips
199
Poor Starting Performance
199
Poor Speed Performance
199
Poor Medium-And-High-Speed Performance
199
Engine
199
Fuel System
199
OVERCOOLING (CS50Z Only)
200
Overheating
200
Engine
200
Cooling System
200
Fuel System
200
Chassis
200
Electrical System
200
Poor Braking Performance
200
Faulty Front Fork Legs
201
Leaking Oil
201
Malfunction
201
Unstable Handling
201
Faulty Lighting or Signaling System
202
Headlight Does Not Come on
202
Headlight Bulb Burnt out
202
Tail/Brake Light Does Not Come on
202
Tail/Brake Light Bulb Burnt out
202
Turn Signal Does Not Come on
202
Turn Signal Blinks Slowly
202
Turn Signal Remains Lit
202
Turn Signal Blinks Quickly
202
Horn Does Not Sound
202
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