Yamaha XF50W Service Manual
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Yamaha XF50W Service Manual

Yamaha XF50W Service Manual

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©YAMAHA
XF50W
SERVICE MANUAL
LIT-11616-20-58
3B3-F8197-10

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  • Page 1 ©YAMAHA XF50W SERVICE MANUAL LIT-11616-20-58 3B3-F8197-10...
  • Page 2 EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO 0 » SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM ELECTRICAL SYSTEM ELEC TROUBLESHOOTING SHTG...

  • Page 3: Table Of Contents

    j y * INFO \<^® CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER MODEL LABEL FEATURES OUTLINE OF THE FI SYSTEM FI SYSTEM IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS EQUIPMENT PREPARATION...

  • Page 4: Scooter Identification

    SCOOTER IDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL LABEL The model label 1 is affixed to the frame trunk. This information will be needed to order spare parts.

  • Page 5: Features

    FEATURES EAS00896 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 6: Fi System

    FEATURES EAS00897 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kg/cm , 35.6 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 7: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS "^N Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but infe- rior in quality.

  • Page 8: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the...

  • Page 9: Equipment Preparation

    IMPORTANT INFORMATION INFO EAS00021 EQUIPMENT PREPARATION Push Rivet (Push type) Assembly status of the push rivet(push type). Dissembling 1. Press center p i n 1 inward to release the lock. <D 2. Remove the push rivet main body2. Assembling 1. Restore the center pin, replace the push rivet main body.

  • Page 10: Checking The Connections

    CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8lead 8coupler 8connector 2. Check: • lead • coupler • connector Moisture -» Dry with an air blower. Rust/stains -» Connect and disconnect several times.

  • Page 11: Special Tools

    SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 12 SPECIAL TOOLS Tool NO. Tool name / Function Illustration 90890-01384 Oil seal guide YM-33299 This tool is used for protecting the oil seal lip when installing the secondary sliding sheave. 90890-01403 Steering nut wrench YU-A9472 This tool is used to loosen and tighten the steering ring nut.
  • Page 13 SPECIAL TOOLS Tool NO. Tool name / Function Illustration 90890-03141 Timing light YU-03141 This tool is used to check the ignition tim- ing. 90890-03182 FI diagnostic tool YU-03182 Execute CO adjustment, confirm fault Code, self diagnosis tool 90890-04101 Valve lapper This tool is needed to remove and install the valve lifters.
  • Page 14 Pressure gauge YU-03153 This tool is used to measure fuel pressure. Fuel pressure adapter 90890-03181 This tool is used to measure fuel pressure. Yamaha bond NO.1215 90890-85505 ® Sealant (Quick Gasket ACC-11001-05-01 This sealamt (bond) is used on crankcase mating surfaces(e.g., crankcase mating sur- faces).
  • Page 15 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS CHASSIS SPECIFICATIONS 2-12 ELECTRICAL SPECIFICATIONS 2-15 CONVERTION TABLE / GENERAL TIGHTENING TORQUE SPECIFICA- TIONS 2-18 TIGHTENING TORQUES 2-19 ENGINE 2-19 CHASSIS 2-21 LUBRICATION POINTS AND LUBRICANT TYPES 2-23 ENGINE 2-23 CHASSIS 2-25 COOLING SYSTEM DIAGRAMS 2-26 CABLE ROUTING...
  • Page 16 SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 3B32(USA) … 3B33(CAN) … Dimensions Overall length 1905mm(75.00in) … Overall width 685mm(26.97in) … … Overall height 1045mm(41.14in) … Seat height 735mm(28.94in) Wheelbase 1280mm(50.39in) … Minimum ground clearance 115mm(4.53in) … …...
  • Page 17 SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Standard Limit Item Engine Engine type Liquid-cooled, 4-stroke, SOHC … Displacement 0.049L(49cm³, 2.99cu-in) … Cylinder arrangement Forward inclined single cylinder … 38.0×43.5mm(1.496×1.713in) … Bore×stroke Compression ratio 12:1 … Engine idle speed 2000~2200r/min … Vacuum pressure at engine idle speed 34.7kPa(260mmHg,10.24inHg) …...
  • Page 18 SPEC ENGINE SPECIFICATIONS Standard Limit Item Oil pump Oil pump type Trochoid … Inner rotor to outer rotor tip clearance 0.15mm(0.006in) or less 0.23mm (0.009in) Outer rotor to pump housing clearance 0.13~0.18mm(0.005~0.007in) 0.25mm (0.010in) Oil pump housing to inner rotor and 0.07~0.12mm(0.003~0.005in) 0.19mm outer rotor clearance...
  • Page 19 SPEC ENGINE SPECIFICATIONS Standard Limit Item Camshaft Drive system Chain drive(left) … Intake camshaft lobe dimensions Measurement A 30.158~30.258mm 30.058mm (1.1873~1.1913in) (1.1834in) Measurement B 25.082~25.182mm 24.982mm (0.9875~0.9914in) (0.9835in) Exhaust camshaft lobe dimensions •^ • Measurement A 30.158~30.258mm 30.058mm (1.1873~1.1913in) (1.1834in) Measurement B 25.020~25.120mm 24.920mm...
  • Page 20 SPEC ENGINE SPECIFICATIONS Standard Limit Item Timing chain Model/number of links Morse 92RH2005/82 … Tensioning system Automatic … Valve, valve seats, valve guides Valve clearance(cold) Intake 0.10~0.16mm … (0.0039~0.0063in) Exhaust 0.18~0.24mm … (0.0071~0.0094in) Valve dimensions \ . \ . C Head Diameter Face Width Seat Width...
  • Page 21 SPEC ENGINE SPECIFICATIONS Standard Limit Item Valve stem to valve guide clearance Intake 0.010~0.037mm 0.080mm (0.0004~0.0015in) (0.0031in) Exhaust 0.025~0.052mm 0.100mm (0.0010~0.0020in) (0.0039in) 0.010mm Valve stem runout … (0.0004in) / / / / / / / / / / / / / / / / / / / / / Valve seat width Intake 0.9~1.1mm...
  • Page 22 SPEC ENGINE SPECIFICATIONS Standard Limit Item Valve springs Free length Intake 39.35mm(1.5492in) 37.38mm (1.4717in) Exhaust 41.57mm(1.6366in) 39.49mm (1.5547in) Installed length(valve closed) Intake 28.0mm(1.1024in) … Exhaust 30.0mm(1.1811in) … Compressed spring force(installed) Intake 91.1~104.9N … (9.3~10.7kg, 20.48~23.58lb) Exhaust 107.9~124.1N … (11.0~12.7kg, 24.26~27.90lb) Spring tilt —...
  • Page 23 SPEC ENGINE SPECIFICATIONS Standard Limit Item Piston Piston-to-cylinder clearance 0.010~0.035mm 0.150mm (0.0004~0.0014in) (0.0059in) Diameter D 37.975~37.990mm … (1.4951~1.4957in) "X. -D— Height H 5.0mm(0.1969in) … Piston pin bore(in the piston) Diameter 10.002~10.013mm 10.043mm (0.3938~0.3942in) (0.3954in) 0.35~0.65mm … Offset (0.0138~0.0256in) Intake side Offset direction …...
  • Page 24 SPEC ENGINE SPECIFICATIONS Standard Limit Item Oil ring Dimensions(B×T) 1.5×1.6mm … (0.0591×0.0630in) End gap(installed) 0.2~0.7mm … (0.0079~0.0276in) Ring side clearance 0.03~0.15mm … (0.0012~0.0059in)
  • Page 25 SPEC ENGINE SPECIFICATIONS Standard Limit Item Rocker arm/rocker arm shaft 10.000~10.015mm 10.030mm Rocker arm inside diameter (0.3937~0.3943in) (0.3949in) 9.981~9.991mm 9.950mm Rocker arm shaft outside diameter (0.3930~0.3933in) (0.3917in) 0.009~0.034mm … Arm-to-shaft clearance (0.0004~0.0013in) Connecting rod Connecting rod length 79.95~80.05mm … (3.1476~3.1516in) Small end inside diameter 10.015~10.028mm …...
  • Page 26 SPEC ENGINE SPECIFICATIONS Standard Limit Item Clutch Clutch type Automatic centrifugal … Clutch shoe thickness 3.7mm(0.146in) 2.0mm (0.079in) Clutch shoe spring free length 30.1mm(1.185in) … Clutch housing inside diameter 107mm(4.213in) 107.5mm (4.232in) Compression spring free length 76.4mm(3.008in) … Weight outside diameter 15.0mm(0.591in) 14.5mm (0.571in)
  • Page 27 SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Standard Item Limit Frame Frame type Steel tube backbone … Caster angle … 26° Trail … 84mm(3.31in) Front wheel Wheel type Cast wheel … Size … J10×MT3.00 Material Aluminum … Wheel travel 58mm(2.28in) … Wheel runout Maximum radial wheel runout …...
  • Page 28 SPEC CHASSIS SPECIFICATIONS Standard Limit Item Rear tire Tire type Tubeless … Size 120/90-10 57J … Model(manufacturer) C-6022(CHENG SHIN) … Tire pressure(cold) 0~175kg(0~386lb) 175kPa(1.75kgf/cm², 25psi) … Minimum tire tread depth … 0.8mm (0.03in) Front brake Brake type Drum brake … Operation Right-hand operation …...
  • Page 29 SPEC CHASSIS SPECIFICATIONS Standard Limit Item Steering system Steering bearing type Angular bearing … Lock-to-lock angle(left) … 46° Lock-to-lock angle(right) … 46° Rear suspension Suspension type Unit swing … Rear shock absorber assembly type Coil spring … Rear shock absorber assembly travel 45mm(1.77in) …...
  • Page 30 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Standard Limit Item System voltage … Ignition system Ignition system type Transistorized coil ignition … Ignition timing 5° BTDC at 2000~2200r/min … Advancer type Digita … Crankshaft position sensor resistance/color 248~372 at 20°C(68°F)/ … white/red-white/blue Ignition coil Model(manufacturer) 3B3 00(T-MORIC)
  • Page 31 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Bulbs(voltage/wattage×quantity) Headlight 12V 35/35W×1 … Tail/brake light 12V 5/21W×1 … 12V 10W×2 … Front turn signal light 12V 10W×2 … Rear turn signal light License plate light 12V 5W×1 … Speedometer light 12V 1.7W×1 …...
  • Page 32 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Fuse(amperage×quantity) Main fuse 15A×1 … Fuel gauge Model(manufacturer) 3B3(AISAN) … Sender unit resistance-full 4~10Q … Sender unit resistance-empty 90~100£2 … Starting circuit cut-off relay Model(manufacturer) 4HC1(MATSU SHITA) … Coil resistance 72~88 … Diode … Radiator fan Model(manufacturer) 5ST1(LUNTAI)
  • Page 33 CONVERTION TABLE / GENERAL TIGHTENING SPEC TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
  • Page 34 SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE Tightening Thread Thread ’ ’ Part to be tightened Part to be tightened Part name Part name torque Remarks Remarks size size m»kg ft»lb Exhaust pipe stud bolt Oil check bolt Cylinder head cover Bolt Cylinder head and cylinder —4\\4jl...
  • Page 35 SPEC TIGHTENING TORQUES Tightening Thread Thread ’ ’ Part to be tightened Part to be tightened Part name Part name torque Remarks Remarks size size m»kg ft»lb Drain bolt(engine oil) 2.3 16.6 Centerstand spring Hook Starter clutch 9.0 65.1 Left-hand thread Kickstarter Bolt Primary fixed sheave...
  • Page 36 SPEC 0*" TIGHTENING TORQUES CHASSIS Tightening Thread Thread Part to be tightened Part to be tightened torque Remarks Remarks size size m»kg ft»lb Frame and engine bracket3 33.1 Engine bracket3 and engine 42.0 Handlebar bracket and steering shaft 43.4 Rear shock absorber and frame 21.7 Rear shock absorber and engine 11.6...
  • Page 37 SPEC TIGHTENING TORQUES NOTE : 1. First,tighten the upper bearing inner race approximately 7Nm(0.7m»kg, 5.1ft»lb) by using the torque wrench and check turn steering shaft smoothly. 2. Second,hold the upper bearing inner race and tighten the ring nut 30Nm(3.0m»kg, 21.7ft»lb) by using the torque wrench.
  • Page 38 SPEC 0 * LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant ^^TLS^P^L Oil seal lips O-rings(except V-belt drive unit) ^ ^ L S ^ ^ A O-ring(fuel injector assembly) ~~^\4Jl Cylinder head tightening nut mounting surface ~~^%4Jl Cylinder head stud bolt thread ~ ^ l 4...
  • Page 39 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Lubricant Drive axle taper rollor bearing —HI^GJ ^HICGJ Transmission bearings ® Secondary fixed sheave inner surface BEL-RAY asembly lube ® Secondary sliding sheave torque cam ditch BEL-RAY asembly lube Crankcase mating surfaces Sealant 2-24...
  • Page 40 SPEC 0*" LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Lubricant ^^LSp^L Front wheel oil seal lips ^^LSp^L Steering bearing and bearing races(upper and lower) Frame head pipe dust seal lips(lower) ^ ^ T L S ^ ^ ^ L Tube guide(throttle grip) inner surface ^ L S ^ ^ A ^^LSpn...
  • Page 41 SPEC COOLING SYSTEM DIAGRAMS EAS00033 Insert until contacting with the latch of ra- COOLING SYSTEM DIAGRAMS diator tank. Raidator cap Install white paint marck of pipe 3 toward Coolant reservoir hose the direction of radiator cover. Radiator inlet hose Install clip for the turning knob to face for- Air bleed bolt ward.
  • Page 42 SPEC COOLING SYSTEM DIAGRAMS Radiator Install clip for the turning knob to face down- Radiator inlet hose ward. Radiator outlet hose Thermostat Water pump outlet hose 2-27...
  • Page 43 SPEC COOLING SYSTEM DIAGRAMS Thermostat assembly inlet breather hose Install the paint mark of hose facing up. Breather hose Install clip for the turning knob to face down- Water pump outlet hose ward. Radiator outlet hose Make sure that hose is inserted to the bot- Water pump tom.
  • Page 44 SPEC CABLE ROUTING EAS00035 Battery positive lead hole of down tube 1 . CABLE ROUTING Wire lead cover Fix connector cover on the Assemble cramp on the T- head light stay. Hose3 stud at the right of back Install the protruding part of stay.
  • Page 45 SPEC CABLE ROUTING Speedometer After wiring the cover, Install the horn of coupler Rectifier/Regulator cover the coupler. accotding to the direction Turn signal relay Enter tail/brake light. shown in the drawing, and Throttle cable Ass’y After fixing the rear brake make sure that it is not Holder cable, fix crank case 1 .
  • Page 46 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...

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