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YW50AP
Yamaha YW50AP User Manual
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6-13
CHAS
Order
1
2
3
4
Q’ty
1
1
1
1
MASTER CYLINDER DISASSEMBLY
FRONT BRAKE
Remarks
Remove the parts in order.
Refer
to
“MASTER
CYLINDER
ASSEM-
BLY” section.
Reverse the disassembly
procedure for
assembly.
Job name/Part name
Master cylinder disassembly
Master cylinder boot
Circlip
Master cylinder kit
Spring
2
1
4
3
New
131
133
Table of Contents
Default Chapter
5
General Information
5
Table of Contents
7
Chapter 1
15
General Information
15
Scooter Indentification
15
Vehicle Identification Number
15
Model Code
15
Important Information
16
Preparation for Removal and Disassembly
16
Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
17
Circlips
17
Checking of Connections
18
How to Use the Conversion Table
19
Conversion Table
19
Special Tools
20
General Specification
22
Maintenance Specification
25
Chapter 2
25
Engine
25
Tightening Torques
27
Engine
27
Maintenance Specification
28
Chassis
28
Tightening Torques
29
Chassis
29
Electrical
30
Maintenance Specification
30
General Torque Specifications
32
Lubrication Points and Lubrication Type
33
Engine
33
Chassis
34
Cable Routing
35
Chapter 3
40
Periodic Inspection and Adjustments
40
Introduction
40
Periodic Maintenance/Lubrication Intervals
40
Cover and Panel
42
Sidecover and Seat
42
Lower Cowling, Upper Cover, Leg Shield 1, 2 and Footrest Board
43
Handlebar Cover(Front and Rear)
44
Engine
45
Idle Speed Adjustment
45
Throttle Cable Free Adjustment
46
Autolube Pump Air Bleeding
47
Spark Plug Inspection
48
Engine Oil Level Inspection
49
Transmission Oil Replacement
50
Air Filter Element Cleaning
51
V-Belt Inspection
53
Chassis
54
Front Brake Lever Free Play Check
54
Rear Brake Lever Free Play Check
54
Brake Pad Inspection
54
Brake Shoe Inspection
55
Brake Fluid Level Inspection
55
Air Bleeding (Hydraulic Brake System)
56
Steering Adjustment
57
Tire Inspection
58
Wheel Inspection
61
Front Fork Inspection
61
Rear Shock Absorber Inspection
61
Seat Lock Cable Adjustment
61
Cable Checking and Lubricating
62
Levers Lubricating
62
Centerstand Lubricating
62
Electrical
63
Battery Inspection
63
Fuse Inspection
68
Headlight Beam Adjustment
69
Headlight Bulb Replacement
69
Taillight Bulb Replacement
71
License Light Bulb Replacement
71
Engine Overhaul
72
Chapter 4
72
Wireharness and Cables
72
Engine Removal
73
Cylinder Head, Cylinder and Piston
74
Piston Pin and Piston Removal
75
Cylinder Head Inspection
75
Cylinder and Piston Inspection
76
Piston Rings Inspection
78
Piston Pin and Piston Pin Bearing
78
Piston Pin and Piston Installation
79
Cylinder and Cylinder Head
80
V-Belt, Clutch and Secondary/Primary Sheave
82
Kick Starter and Crankcase Cover(Left)
82
Kick Starter
83
Kick Starter Installation
84
V-Belt, Clutch and Secondary/Primary Sheave
85
Secondary Sheave
86
Primary Sheave Removal
87
Secondary Sheave Removal
87
Clutch Inspection
88
V-Belt Inspection
89
Primary Sheave Inspection
90
Secondary Sheave
91
Secondary Sheave Installation
92
Primary Sheave
93
Starter Clutch and Starter Motor
95
Starter Clutch and Gears Inspection
97
Magnet
98
C.D.I. Magneto
98
C.D.I. Magneto Removal
99
Magneto Installation
99
Autolube Pump
100
Autolube Pump Installation
101
Transmission
102
Crankcase and Reed Valve
104
Crankcase(Right) Removal
106
Checking the Crankcase
106
Checking the Bearings and Oil Seals
106
Reed Valve Inspection
107
Crankcase (Right) Installation
107
Crankshaft
109
Crankshaft Removal
110
Crankshaft Inspection
110
Crankshaft Installation
111
Carburetion
112
Chapter 5
112
Carburetor
112
Caburetor Disassembly
113
Caburetor Inspection
114
Carburetor Assembly
116
Fuel Level Adjustment
117
Auto Choke Inspection
118
Fuel Cock Inspection
119
Front Wheel and Brake Disc
120
Chassis
120
Chapter 6
121
Front Wheel Disassembly
121
Front Wheel Inspection
122
Front Wheel Disassembly
122
Brake Disc Inspection
123
Front Wheel Assembly
123
Front Wheel Installation
124
Wheel Static Balance Adjustment
125
Front Brake
127
Brake Pad
127
Brake Pad Replacement
128
Master Cylinder
131
Master Cylinder Disassembly
132
Master Cylinder Inspection
133
Master Cylinder Assembly
133
Master Cylinder Installation
134
Caliper
136
Caliper Disassembly
137
Brake Caliper Disassembly
138
Caliper Inspection
138
Brake Caliper Assembly
139
Brake Caliper Installation
139
Rear Wheel and Rear Brake
140
Rear Wheel
140
Rear Brake
141
Rear Wheel Inspection
142
Rear Brake Inspection
142
Rear Brake Installation
143
Handlebar
144
Handlebar Installation
146
Steering
148
Steering Removal
149
Steering Inspction
150
Steering Installation
150
Front Fork
153
Front Fork Disassembly
154
Front Fork Removal
155
Front Fork Disassembly
155
Front Fork Inspection
156
Front Fork Assembly
156
Front Fork Installation
158
Chapter 7 Electrical
159
Electrical Components
159
Circuit Diagram
160
Checking Switches
162
Checking Steps
162
Switch Connection as Shown in this Manual
162
Switch Position and Terminal Connection
163
Checking the Bulbs and Bulb Sockets
164
Types of Bulbs
164
Checking the Condition of the Bulbs
165
Checking the Condition of the Bulb Sockets
166
Ignition System
167
Circuit Diagram
167
Troubleshooting
168
Charging System
172
Circuit Diagram
172
Troubleshooting
173
Electric Starting System
176
Circuit Diagram
176
Troubleshooting
177
Starter Motor
180
Starter Motor Disassembly
181
Inspection and Repair
182
Lighting System
184
Circuit Diagram
184
Troubleshooting
185
Lighting System Check
187
Signal System
191
Circuit Diagram
191
Troubleshooting
192
Signal System Check
194
Auto Choke System
200
Circuit Diagram
200
Troubleshooting
203
Starting Failure/Hard Starting
203
Chapter 8
203
Fuel System
203
Ignition System
204
Compression System
204
Poor Idle Speed Performance
205
Poor Midium and High Speed Performance
205
Fulty Automatic(V-Belt Type)
206
Scooter Does Not Move While Engine Is Operating
206
Clutch out Failure
206
Poor Standing Start(Low Climbing Ability)
206
Poor Acceleration(Poor High Speed)
206
Overheat
207
Poor Speed
207
Improper Kicking
208
Slipping
208
Hard Kicking
208
Kick Crank Not Returning
208
Faulty Brake
209
Poor Braking Effect
209
Malfunction
209
Instable Handling
210
Faulty Signal and Lighting System
211
Headlight Dark
211
Bulb Burnt out
211
Flasher Does Not Blink
211
Flasher Keeps on
211
Flasher Blinks Slower
212
Flasher Blinks Quicker
212
Horn Does Not Sound
212
Wiring Diagram
213
4
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Questions and Answers:
D
Daniel Rodriguez
Jul 29, 2025
What to do if my Yamaha YW50AP Scooter has no spark?
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Yamaha YW50AP Specifications
General
Brand
Yamaha
Model
YW50AP
Category
Scooter
Language
English
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