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YN50
SERVICE MANUAL
© 2002 Y
amaha Motor España, S.A.
First Edition, September 2002
All rights reserved.
The reprinting or use of this material without
the written authorisation of Y
amaha Motor
España, S.A is forbidden.
Printed in Spain.
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
Identification of the Scooter
9
Serial Number of the Frame
9
Engine Serial Number
9
Important Information
10
Change of All Parts
10
Oil Seals and O-Rings
10
Sealing Washers/Plate and Keys
10
Bearing and Oil Seals
10
Circlips
11
Special Tools
11
For Servicing the Engine
11
For Servicing the Chassis
13
For Electrical Components
14
Spec Chapter 2 Specifications
17
Chapter 2
18
General Specifications
18
Maintenance Specifications
20
Engine
20
Chassis
22
Electrical System
23
Cable Routing
24
Insp Adj Chapter 3 Periodic Inspection and Adjustments
28
Chapter 3
30
Rear Bodywork and Footrest
30
Removal
30
Installation
31
Installation
32
Removal
32
Handlebar Covers
33
Removal
33
Installation
33
Engine
34
Adjustment of Engine Idling
34
Spark Plug Inspection
36
Inspection of Engine Oil Level
37
Change of Transmission Oil
38
Cleaning Air Filter
38
Chassis
40
Adjustment of Free Play of Front Brake Lever
40
Adjustment of Free Play of Rear Brake Lever
40
Inspection of Brake Pads
40
Inspection of Brake Shoes
41
Inspection of Brake Fluid Level
41
Air Bleeding (Hydraulic Brake System)
42
Steering Adjustment
42
Inspection of Tyres
43
Wheel Inspection
44
Inspection of Rear Fork
44
Rear Shock Absorber Inspection
44
Electrical System
45
Inspection of Fuses
47
Adjustment of Headlamp Beam
48
Replacement of Headlamp Bulb
48
Eng Chapter 4 General Overhaul of Engine
51
Chapter 4 General Overhaul of Engine
52
Engine Removal
52
Carburettor
52
Silencer Assembly
52
Removal of Engine
52
Disassembly the Engine
55
Rear Wheel
55
Cylinder Head and Cylinders
55
Piston Pins and Piston
55
Primary Pulley Wheel
57
Secondary Pulley Wheel
57
Starter System
58
Transmission
59
Magnetic Flywheel
59
Autolubrication Pump
60
Crankcase and Crankshaft
60
Inspection and Repair
62
Cylinder Head
62
Cylinder and Piston
62
Piston Rings
64
Piston Pin and Piston Pin Bearing
65
Kick Starter
66
Transmission
67
Autolubrication Pump
67
Crankshaft
67
Primary Pulley Wheel
68
Secondary Pulley Wheel
69
Trapezoidal Belt
70
Assembly and Adjustment of Engine
72
Crankshaft and Crankcase
73
Autolubrication Pump
74
Flywheel Magnet
75
Transmission
76
Starter Motor
79
Secondary Pulley Wheel
80
Primary Pulley Wheel
80
Starter Pedal
81
Piston and Piston Pin
87
Cylinder and Head
87
Engine Assembly
89
Carb Chapter 5 Carburetor
92
Chapter 5 Carburetor
93
Disassembling the Carburetor
94
Removing the Carburetor
94
Checking the Carburetor
95
Assembling the Carburetor
97
Checking the Autochoke Unit
98
Fuel Cock
99
Checking the Fuel Cock
99
Installing the Carburetor
99
Reed Valve
100
Removing the Reed Valve
100
Checking the Reed Valve
100
Installing the Reed Valve
101
Chas Chapter 6 Chassis
103
Chassis
103
Front Wheel
104
Chapter 6
105
Inspection
105
Installation
106
Front Brake
107
Rear Brake
113
Inspection
113
Installation
115
Disassembly
117
Inspection
118
Assembly
119
Installation
121
Handlebar and Steering
122
Removal
123
Inspection
124
Installation
125
Elec Chapter 7 Electrical System
130
Chapter 7 Electrical System
131
Electrical Components
131
Ignition and Starter System
134
Troubleshooting
135
Charging System
140
Circuit Diagram
140
Charging System Circuit Diagram
140
Lighting System
143
Circuit Diagram
143
Checking of Lighting System
145
Signalling System
147
Circuit Diagram
147
Checking of Signalling System
149
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