Yamaha XF50W Manuals

Yamaha XF50W Manuals

Manuals and User Guides for Yamaha XF50W. We have 1 Yamaha XF50W manual available for free PDF download: Service Manual

Yamaha XF50W Service Manual

Yamaha XF50W Service Manual (338 pages)

Yamaha XF50W Scooter Service manual

Brand: Yamaha | Category: Scooter | Size: 7.24 MB

Table of Contents

Info \

7
- Service Manual
  1
- Info
  3
  - Table of Contents
    7
- Chapter 1 Vehicle Identification Number
  8
- Model Label
  8
- Scooter Identification
  8
- Features
  9
  - Outline of the Fi System
    9
  - Fi System
    10
- Important Information
  11
  - Preparation for Removal and Disassembly
    11
  - Replacement Parts
    11
  - Gaskets, Oil Seals and O-Rings
    11
  - Lock Washers/Plates and Cotter Pins
    12
  - Bearings and Oil Seals
    12
  - Circlips
    12
  - Equipment Preparation
    13
- Checking the Connections
  14
- Special Tools
  15
Spec 0 *

19
- Chapter 2
  20
- General Specifications
  20
- Engine Specifications
  21
- Chassis Specifications
  31
- Electrical Specifications
  34
  - Torque Specifications
    37
- Tightening Torques
  38
  - Engine
    38
  - Chassis
    40
- Lubrication Points and Lubricant Types
  42
  - Engine
    42
  - Chassis
    44
- Cooling System Diagrams
  45
- Cable Routing
  48
Table of Contents

54
- CHAPTER 3 Periodic Checks and Adjustments
  56
- Introduction
  56
- Periodic Maintenance and Minor Repair
  57
  - Periodic Maintenance Chart for the Emission Control System
    57
  - General Maintenance and Lubrication Chart
    58
- Cover and Panel
  60
  - Side Covers and Tail/Brake Light
    60
  - Single Seat and Trunk
    62
  - Leg Shield1,2
    63
  - Footrest Board and Inner Fender
    64
- Engine
  65
- Chassis
  95
  - Adjusting the Front Brake
    95
  - Adjusting the Rear Brake
    95
  - Checking the Front and Rear Brake Shoes
    96
  - Checking and Adjusting the Steering Head
    98
  - Checking the Front Fork
    99
  - Checking the Tires
    100
  - Electrical System
    105
  - Checking the Fuse
    112
  - Replacing the Headlight Bulb
    113
  - Adjusting the Headlight Beam
    114
Table of Contents

115
- Chapter 4
  117
- Front Wheel
  117
- Front Wheel and Brake
  117
- Front Brake Shoe Plate
  119
- Disassembling the Brake Shoe Plate
  120
- Removing the Front Wheel
  120
- Checking the Front Wheel
  121
- Checking the Speedometer Gear Unit
  122
- Checking the Brake
  123
- Assembling the Brake Shoe Plate
  124
- Assembling the Front Wheel
  125
- Installing the Front Wheel
  126
- Adjusting the Front Wheel Static Balance
  127
- Rear Wheel and Brake
  129
  - Removing the Rear Wheel
    130
  - Checking the Rear Wheel
    130
  - Checking the Rear Wheel Drive Hub
    131
  - Checking the Brake
    131
  - Assembling the Brake Shoe Plate
    132
  - Installing the Rear Wheel
    134
  - Adjusting the Rear Wheel Static Balance
    134
- Front Fork
  135
  - Removing the Front Fork Legs
    137
  - Disassembling the Front Fork Legs
    137
  - Checking the Front Fork Legs
    139
  - Assembling the Front Fork Legs
    140
  - Installing the Front Fork Legs
    142
- Handlebar
  143
  - Removing the Handlebar
    145
  - Checking the Handlebar
    145
  - Installing the Handlebar
    146
- Steering Head
  148
  - Handlebar Bracket and Headlight Stay Bracket
    148
  - Lower Bracket
    149
  - Removing the Lower Bracket
    150
  - Checking the Steering Head
    151
  - Installing the Steering Head
    152
Table of Contents

156
- Chapter 5
  158
- Engine Removal
  158
- Leads, Hoses and Muffler
  158
- Engine
  160
- Installing the Engine
  161
- Cylinder Head
  162
  - Removing the Cylinder Head
    164
  - Checking the Cylinder Head
    166
  - Installing the Cylinder Head
    167
- The Rocker Arms and Camshaft
  170
- Valves and Valve Springs
  177
  - Removing the Valves
    179
  - Checking the Valves and Valve Guides
    181
  - Checking the Valve Seats
    183
  - Checking the Valve Springs
    185
  - Installing the Valves
    186
- Cylinder and Piston
  188
  - Removing the Cylinder and Piston
    189
  - Checking the Cylinder and Piston
    190
  - Checking the Piston Rings
    192
  - Checking the Piston Pin
    193
  - Checking the Timing Chain Guide
    194
  - Installing the Piston and Cylinder
    194
- Belt Drive
  196
  - V-Belt Case Cover
    196
  - Kickstarter
    197
  - Installing the Kickstarter
    198
  - V-Belt and Primary/Secondary Sheave
    199
  - Secondary Sheave
    200
  - Removing the Primary Sheave
    201
  - Removing the Secondary Sheave and V-Belt
    201
  - Disassembling the Secondary Sheave
    202
  - Checking the Clutch Shoes
    202
  - Checking the V-Belt
    203
  - Checking the Primary Sheave
    203
  - Checking the Primary Sheave Weights
    204
  - Checking the Slider
    204
  - Checking the Secondary Sheave
    204
  - Assembling the Primary Sheave
    205
  - Assembling the Secondary Sheave
    206
  - Installing the Secondary Sheave, V-Belt and Primary Sheave
    207
- Starter Clutch and Ac Magneto
  210
  - Stator Coil Assembly
    210
  - Starter Clutch
    212
  - Removing the Ac Magneto
    213
  - Removing the Starter Clutch
    214
  - Checking the Starter Clutch
    215
  - Installing the Starter Clutch
    216
  - Installing the Ac Magneto
    216
- Oil Pump
  218
  - Checking the Oil Pump
    219
  - Assembling the Oil Pump
    220
  - Installing the Oil Pump
    220
- Transmission
  221
  - Checking the Transmission
    222
- Crankshaft
  223
  - Crankshaft Assembly
    223
  - Disassembling the Crankcase
    225
  - Removing the Crankshaft Assembly
    226
  - Checking the Crankshaft and Connecting Rod
    226
  - Checking the Crankcase
    227
  - Checking the Timing Chain and Timing Chain Guide(Intake Side)
    228
  - Checking the Bearings and Oil Seals
    228
  - Checking the Circlips and Washers
    228
  - Installing the Crankshaft
    229
  - Assembling the Crankcase
    229
Cool J C

231
- Radiator
  232
  - Cooling System
    232
- Chapter 6 Checking the Radiator
  233
- Installing the Radiator
  234
- Thermostat
  235
  - Checking the Thermostat
    236
  - Installing the Thermostat
    237
- Water Pump
  238
  - Disassembling the Water Pump
    240
  - Checking the Water Pump
    240
  - Assembling the Water Pump
    241
  - Installing the Water Pump
    242
  - Chas
    242
Fuel Injection System Fi

243
- Cool
  244
- Fuel Injection System
  244
- Chapter 7
  245
- Wiring Diagram
  245
  - Ecu's Self-Diagnostic Function
    247
- Elec
  247
  - Checking for a Defective Engine Trouble Warning Light Bulb
    248
    
    Self-Diagnostic Fanction Table
    248
    
    Fuel Injection System
    249
    
    Troubleshooting Chart
    250
    
    Diagnostic Mode
    251
    
    Fuel Injection System Fi
    253
    
    Troubleshooting Details
    255
  - Throttle Body and Fuel Injector
    269
    
    Throttle Body
    269
    
    Fuel Injector and Fuel Hose
    270
    
    Fuel Tank
    271
    
    Removing the Fuel Hose
    272
    
    Removing the Fuel Pump
    272
    
    Checking the Throttle Body
    273
    
    Installing the Fuel Pump
    274
    
    Installing the Fuel Hose
    274
    
    Checking the Fuel Pump and Pressure Regulator Op- Eration
    275
    
    Checking the Throttle Position Sensor
    275
  - Air Induction System
    278
    
    Air Injection
    278
    
    Air Cut-Off Valve
    278
    
    Air Induction System Diagrams
    279
    
    Air Cut-Off Valve and Air Filter Case
    280
    
    Checking the Air Induction System
    281
Table of Contents

282
- Chapter 8 Electrical Components
  283
- Wiring Diagram
  285
- Checking Switch Continuity
  286
- Checking the Switches
  287
- Checking the Bulbs and Bulb Sockets
  288
- Ignition System
  291
  - Circuit Diagram
    291
  - Troubleshooting
    292
- Electric Starting System
  296
  - Circuit Diagram
    296
  - Starting Circuit Cut-Off System Operation
    297
  - Troubleshooting
    298
  - Starter Motor
    302
  - Checking the Starter Motor
    303
  - Assembling the Starter Motor
    305
- Charging System
  306
  - Circuit Diagram
    306
  - Troubleshooting
    307
- Lighting System
  309
  - Circuit Diagram
    309
  - Troubleshooting
    310
  - Checking the Lighting System
    312
- Signaling System
  316
  - Circuit Diagram
    316
  - Troubleshooting
    317
  - Checking the Signaling System
    318
- Cooling System
  324
  - Troubleshooting
    325
  - Checking the Cooling System
    327
Trbl Q Shtgl •

329
- Chapter 9
  331
- Electrical Systems
  331
- Engine
  331
- Fuel System
  331
- Starting Failure/Hard Starting
  331
- Electrical Systems
  332
- Engine
  332
- Fuel System
  332
- Speed
  332
- Faulty Clutch
  333
  - Engine Operates but Scooter will Not Move
    333
  - Clutch Slips
    333
  - Poor Starting Performance
    333
  - Poor Speed Performance
    334
- Poor Medium-And-High-Speed Performance/Faulty Clutch
  333
  - Engine
    333
  - Fuel System
    333
- Overheating
  334
  - Engine
    334
  - Cooling System
    334
  - Fuel System
    334
  - Chassis
    334
  - Electrical Systems
    334
- Faulty Front Fork Legs
  335
  - Leaking Oil
    335
  - Malfunction
    335
- Poor Braking Performance/Faulty Front Fork Legs/Un- Stable Handling
  335
- Unstable Handling
  335
- Faulty Lighting or Signaling System
  336
  - Headlight Does Not Come on
    336
  - Headlight Bulb Burnt out
    336
  - Tail/Brake Light Does Not Come on
    336
  - Tail/Brake Light Bulb Burnt out
    336

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