Yamaha YW50AP Manuals

Manuals and User Guides for Yamaha YW50AP. We have 2 Yamaha YW50AP manuals available for free PDF download: Service Manual

Yamaha YW50AP Service Manual (214 pages)

Brand: Yamaha | Category: Scooter | Size: 8.3 MB

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
- 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
- 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
- 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
- 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

Yamaha YW50AP Service Manual (215 pages)

Brand: Yamaha | Category: Scooter | Size: 8.3 MB

Important Manual Information: Four Symbols
3
How to Use this Manual
4
Symbols
5
Index
6
Table of Contents
7
General Information
15
Scooter Identification
15
Preparation for Removal and Disassembly
16
Replacement Parts
16
Gaskets, Oil Seats and O-Rings
16
Important Information
16
Bearings and Oil Seals
17
Circlips
17
Checking of Connections
18
How to Use the Conversion Table
19
Special Tools Table
20
General Specification
22
Maintenance Specification
25
General Torque Specifications
32
Lubrication Points and Lubrication Type
33
Cable Routing
35
Periodic Maintenance/Lubrication Intervals
40
Periodic Inspection and Adjustments
41
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 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 Ispection
55
Air Bleeding (Hydraulic Brake System)
56
Air Bleeding Steps
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 Battery Inspection
63
Battery Charging Method
63
Battery: First Aid in Case of Bodily Contact
64
Condition of Charge in Battery Table
65
Charging Method of MF Battery
65
Battery Charging Method Using a Variable-Current Type Charger
66
Battery Charging Method Using a Constant-Voltage Type Charger
67
Fuse Inspection
68
Head Light Beam Adjustment
69
Headlight Bulb Replacement
69
Turn Signal Bulb Replacement
70
Taillight Bulb Replacement
71
License Light Bulb Replacement
71
Engine Overhaul
72
Engine Wireharness and Cables Removal
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 to Cylinder Clearance Measurement Steps
76
Piston Rings Inspection
78
Piston Pin and Piston Pin Bearing
78
Piston Pin and Piston Installation
79
Cylinder and Cylinder Head
80
Kick Starter and Crankcase Cover
82
V-Belt, Clutch and Secondary/Primary Sheave
82
Kick Starter
83
Kick Starter Installation
84
V-Belt, Clutch and Secondary/Primary Sheave Removal
85
Secondary Sheave Disassembly
86
Primary Sheave Removal
87
Clutch Inspection
88
V-Belt Inspection and Replacement
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
CDI Magneto
98
CDI Magneto Removal
99
CDI Magneto Installation
99
Autolube Pump
100
Autolube Pump Installation
101
Transmission
102
Crankcase and Reed Valve Removal
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
To Avoid Scratching the Crankshaft
111
Carburetor
112
Carburetor Disassembly
113
Carburetor Inspection
114
Float Height Measurement Steps
115
Carburetor Assembly
116
Fuel Level Adjustment
117
Auto Choke Inspection
118
Fuel Cock Inspection
119
Front Wheel and Brake Disc
120
Front Wheel Disassembly
121
Front Wheel Inspection
122
Brake Disc Inspection
123
Front Wheel Assembly
123
Front Wheel Installation
124
Wheel Static Balance Adjustment
125
Front Brake: 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
140
Rear Brake
141
Rear Wheel Inspection
142
Rear Brake Inspection
142
Rear Brake Installation
143
Handlebar
144
Steering
148
Steering Removal
149
Steering Inspection
150
Steering Installation
150
Front Fork
153
Front Fork Disassembly
154
Front Fork Removal
155
Disassembly of the Front Fork
155
Inspection of the Front Fork
156
Front Fork Installation
158
Electrical Components: List and Diagram
159
Circuit Diagram
160
Color Code
161
Checking Switches
162
Switch Connection as Shown in this Manual
162
Swutch 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: Circuit Diagram
167
Ignition System: Troubleshooting
168
Charging System: Circuit Diagram
172
Charging System: Troubleshooting
173
Electric Starting System: Circuit Diagram
176
Electric Starting System: Troubleshooting
177
Starter Motor
180
Starter Motor Disassembly
181
Electric Starting System: Inspection and Repair
182
Lighting System: Circuit Diagram
184
Lighting System: Troubleshooting
185
Signal System: Circuit Diagram
191
Signal System: Troubleshooting
192
Signal System Check
194
Auto Choke System: Circuit Diagram
200
Auto Choke System: Troubleshooting
201
Troubleshooting
203
Poor Idle Speed Performance
205
Pooer Medium and High Speed Performance
205
Faulty Automatic (V-Belt Type)
206
Overheat
207
Poor Speed
207
Improper Kicking
208
Faulty Brake
209
Unstable Handling
210
Faulty Signal and Lighting System
211
Wiring Diagram
213

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Yamaha YW50AP Service Manual (214 pages)

Table of Contents

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7 Electrical

Chapter 8

Yamaha YW50AP Service Manual (215 pages)

Table of Contents

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