Yamaha 2002 CS50 Manuals

Manuals and User Guides for Yamaha 2002 CS50. We have 1 Yamaha 2002 CS50 manual available for free PDF download: Service Manual

Yamaha 2002 CS50 Service Manual

Yamaha 2002 CS50 Service Manual (204 pages)

MBK

Brand: Yamaha | Category: Scooter | Size: 20.03 MB

Table of Contents

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
- Chassis
  48
- Electrical System
  55
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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