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Yamaha YW50AP Service Manual

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Service manual (214 pages)

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YW50AP

LIT-11616-15-39

5PJ-F8197-10

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Table of Contents

Troubleshooting

Summary of Contents for Yamaha YW50AP

Page 1 YW50AP LIT-11616-15-39 5PJ-F8197-10...
Page 5 –...
Page 6 –...
Page 12 CHAPTER 6 CHASSIS FRONT WHEEL AND BRAKE DISC ....................6-1 FRONT WHEEL AND BRAKE DISC ....................6-1 FRONT WHEEL DISASSEMBLY ....................6-2 FRONT WHEEL DISASSEMBLY ....................6-3 FRONT WHEEL INSPECTION ......................6-3 BRAKE DISC INSPECTION ......................6-4 FRONT WHEEL ASSEMBLY ......................6-4 FRONT WHEEL INSTALLATION ....................
Page 15: General Information
SCOOTER INDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL CODE The model code label 1 is affixed to the loca- tion shown in the figure. Record the informa- tion on this label in the space provided.
Page 16: Important Information
IMPORTANT INFORMATION INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISAS- SEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS...
Page 17 IMPORTANT INFORMATION INFO BEARINGS AND OIL SEALS Do not spin the bearing with compressed air because this will damage the bearing surfaces. CIRCLIPS...
Page 18 IMPORTANT INFORMATION INFO CHECKING OF CONNECTIONS NOTE: NOTE:...
Page 19 HOW TO USE THE CONVERSION TABLE INFO HOW TO USE THE CONVERSION TABLE CONVERSION TABLE...
Page 20 SPECIAL TOOLS INFO SPECIAL TOOLS...
Page 21 SPECIAL TOOLS INFO...
Page 22 SPEC GENERAL SPECIFICATION SPECIFICATION GENERAL SPECIFICATION...
Page 23 SPEC GENERAL SPECIFICATION...
Page 24 SPEC GENERAL SPECIFICATION...
Page 25 SPEC MAINTENANCE SPECIFICATION MAINTENANCE SPECIFICATION ENGINE...
Page 26 SPEC MAINTENANCE SPECIFICATION...
Page 27 SPEC MAINTENANCE SPECIFICATION TIGHTENING TORQUES ENGINE...
Page 28 SPEC MAINTENANCE SPECIFICATION CHASSIS...
Page 29 SPEC MAINTENANCE SPECIFICATION TIGHTENING TORQUES CHASSIS...
Page 30 SPEC MAINTENANCE SPECIFICATION ELECTRICAL...
Page 31 SPEC MAINTENANCE SPECIFICATION...
Page 32 SPEC GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS...
Page 33 SPEC LUBRICATION POINTS AND LUBRICATION TYPE LUBRICATION POINTS AND LUBRICATION TYPE ENGINE...
Page 34 SPEC LUBRICATION POINTS AND LUBRICATION TYPE CHASSIS...
Page 35: Cable Routing
SPEC CABLE ROUTING t Wire harness CABLE ROUTING brand. A Pass the speedometer cable G Clamp the wire harness. 1 Horn H Insert the seat cable through through the right hole of front 2 Rectifier regulator fender, then through the the frame tube.
Page 36 SPEC CABLE ROUTING 1 Brake cable A Pass the brake hose through the holder. 2 Speedometer cable B Insert the fuel overflowhose bottom. 3 Fuel tank overflow hose C Pass the fuel overflowhose through the rear 4 Brake cable holder fender hole.
Page 37 SPEC CABLE ROUTING...
Page 38 SPEC CABLE ROUTING...
Page 39 SPEC CABLE ROUTING...
Page 40 INTRODUCTION/ INSP PERIODICMAINTENANCE/LUBLICATION INTERVALS PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION PERIODIC MAINTENANCE/LUBRICATION INTERVALS...
Page 41 INSP PERIODICINSPECTION AND ADJUSTMENTS NOTE: NOTE:...
Page 43 INSP COVER AND PANEL LOWER COWLING, UPPER COVER, LEG SHIELD 1, 2 AND FOOTREST BOARD...
Page 50 INSP TRANSMISSION OIL REPLACEMENT TRANSMISSION OIL REPLACEMENT NOTE: Always use the same type of oil; mixing oils may result in a harmful chemical re- action and lead to poor performance. Do not allow foreign material to enters the transmission case. NOTE:...
Page 64 Volt meter 12.8V Relationship between open-circuit voltage and charging time 20 C(68 C) 13.0 12.5 12.0 11.5 Charging time(hours) •This varies depending on the temperature, the state of charge in battery plates and the electrolyte level.
Page 65 Ambient temperature 20 C 30 25 20 Condition of charge in battery(%) Ambient temperature Charging 20 C Time(Minutes) Check the open-circuit voltage...
Page 66 Charger meter...
Page 67 Charger AMP meter Volt meter...
Page 117 CARB CARBURETOR NOTE: FUEL LEVEL ADJUSTMENT Measurement steps:...
Page 142 w¤...
Page 148 CHAS STEERING STEERING STEERING...
Page 158 ◗...
Page 159 –...
Page 160 – LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH...
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Page 166 –...
Page 167 – LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH...
Page 168 –...
Page 169 –...
Page 170 – Magneto Magneto...
Page 171 –...
Page 172: Charging System Circuit Diagram
– LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH...
Page 173: Charging System Troubleshooting
–...
Page 174 – Magneto...
Page 175 –...
Page 176 – LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH...
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Page 184 – LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH...
Page 185 –...
Page 186 – Magneto...
Page 187 –...
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Page 191 – LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH...
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Page 200 – LOCK OPEN CHECK START Br/W Br/W Br/W & PUSH...
Page 201 – Magneto...
Page 202 –...
Page 203: Troubleshooting
TRBL STARTING FAILURE/HARD STARTING SHTG TROUBLESHOOTING NOTE: STARTING FAILURE/HARD STARTING FUEL SYSTEM PROBABLE CAUSE...
Page 204 TRBL STARTING FAILURE/HARD STARTING SHTG IGNITION SYSTEM PROBABLE CAUSE COMPRESSION SYSTEM PROBABLE CAUSE...
Page 205 POOR IDLE SPEED PERFORMANCE TRBL POOR MIDIUM AND HIGH SPEED PERFORMANCE SHTG POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE PROBABLE CAUSE POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFOR- PROBABLE CAUSE MANCE...
Page 206 TRBL POOR MIDIUM AND HIGH SPEED PERFORMANCE SHTG FAULTY AUTOMATIC(V-BELT TYPE) PROBABLE CAUSE SCOOTER DOES NOT MOVE WHILE ENGINE IS OPERATING CLUTCH OUT FAILURE POOR STANDING START(LOW CLIMBING ABILITY) PROBABLE CAUSE POOR ACCELERATION(POOR HIGH SPEED) PROBABLE CAUSE...
Page 207 TRBL OVER HEAT / POOR SPEED SHTG OVERHEAT OVER HEAT PROBABLE CAUSE POOR SPEED POOR SPEED PROBABLE CAUSE...
Page 208 TRBL IMPROPER KICKING SHTG IMPROPER KICKING SLIPPING PROBABLE CAUSE HARD KICKING PROBABLE CAUSE KICK CRANK NOT RETURNING PROBABLE CAUSE...
Page 209 TRBL FAULTY BRAKE SHTG FAULTY BRAKE PROBABLE CAUSE POOR BRAKING EFFECT PROBABLE CAUSE MALFUNCTION...
Page 210 TRBL INSTABLE HANDLING SHTG UNSTABLE HANDLING PROBABLE CAUSE INSTABLE HANDLING...
Page 211 TRBL FAULTY SIGNAL AND LIGHTING SYSTEM SHTG FAULTY SIGNAL AND LIGHTING SYSTEM PROBABLE CAUSE PROBABLE CAUSE PROBABLE CAUSE PROBABLE CAUSE...
Page 212 TRBL FAULTY SIGNAL AND LIGHTING SYSTEM SHTG PROBABLE CAUSE PROBABLE CAUSE PROBABLE CAUSE...
Page 213: Wiring Diagram
1 Main switch Black WIRING DIAGRAM 2 Main fuse Brown 3 Battery Chocolate 4 Starter relay Dark Green 5 Starter motor Green 6 Rectifier regulator Blue LOCK OPEN 7 Auto choke Orange CHECK 8 C.D.I. magneto Sky blue 9 C.D.I. unit Pink 0 Ignition q Spark plug...
Page 214 YAMAHA MOTOR TAIWAN CO., LTD...