Yamaha VINO YJ50RAP User manual

2001 - 2005

MOTORCYCLE

SERVICE MANUAL

Model : YJ50RAP, YJ50RAR, YJ50RAS,

YJ50RAT, YJ50RN, YJ50RP, YJ50RR,

YJ50RS, YJ50RT

5PP281972000 *5PP281972000*

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EAS00000

YJ50RN

SERVICE MANUAL

First edition, December, 2000

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

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EAS00002 NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in

one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the scooter operator, a bystander or a person checking or repairing the scooter.

A CAUTION indicates special precautions that must be taken to avoid damage

to the scooter.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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EAS00007 HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter. Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)

appears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

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EAS00009

SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1to 8indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Carburetor(s)

7Electrical system

8Troubleshooting

Symbols 9to Findicate the following.

9Serviceable with engine mounted

0Filling fluid

ALubricant

BSpecial tool

CTightening torque

DWear limit, clearance

EEngine speed

FElectrical data

Symbols Gto Lin the exploded diagrams

indicate the types of lubricants and lubrication

points.

GEngine oil

HGear oil

IMolybdenum disulfide oil

JWheel bearing grease

KLithium soap base grease

LMolybdenum disulfide grease

Symbols Mto Nin the exploded diagrams

indicate the following.

MApply locking agent (LOCTITE®)

NReplace the part

GHI

JKL

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

CARB

–+

ELEC TRBL

SHTG

EGM

BLS M

LT New

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EAS00011 TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

ADJ 3

CHASSIS CHAS 4

ENGINE ENG 5

CARBURETION CARB 6

ELECTRICAL SYSTEM ELEC 7

TROUBLESHOOTING TRBL

SHTG 8

–+

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GEN

INFO

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GEN

INFO

CHAPTER 1

GENERAL INFORMATION

SCOOTER IDENTIFICATION..........................................................................1-1

VEHICLE IDENTIFICATION NUMBER.....................................................1-1

MODEL CODE ..........................................................................................1-1

IMPORTANT INFORMATION .........................................................................1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-2

REPLACEMENT PARTS...........................................................................1-2

GASKETS, OIL SEALS AND O-RINGS....................................................1-2

LOCK WASHERS/PLATES AND COTTER PINS.....................................1-2

BEARINGS AND OIL SEALS....................................................................1-3

CIRCLIPS..................................................................................................1-3

CHECKING THE CONNECTIONS............................................................1-4

SPECIAL TOOLS............................................................................................1-5

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