Yamaha YB50 User manual
2002
SERVICE MANUAL
YN50
5RN-AE1
YN50
SERVICE MANUAL
© 2002 Yamaha Motor España, S.A.
First Edition, September 2002
All rights reserved.
The reprinting or use of this material without
the written authorisation of Yamaha Motor
España, S.A is forbidden.
Printed in Spain.
WARNING
This Manual was written by Yamaha Motor España, S.A. principally for the use of Yamaha/MBK
agents and qualified mechanics. As it is not possible to give full mechanical instructions in a manual,
it is presumed that the persons using the book to carry out the maintenance and repair of
Yamaha/MBK motorcycles have a basic knowledge of the concepts and procedures inherent in the
technology of motorcycle repair. Without such knowledge any attempt to repair or service this
model may cause problems in its use and/or safety.
Yamaha Motor España, S.A., is continually trying to improve all models which it manufactures.
Authorised Yamaha/MBK agents will be notified of all significant modifications and changes in the
specifications or procedures and these will appear where applicable in future editions of this
manual.
PARTICULARLY IMPORTANT INFORMATION
This material used the following notation.
sA danger symbol means ATTENTION, BE CAREFUL, YOUR
SAFETY IS IN DANGER!
WARNING Non-compliance with a WANING may cause the serious injury or
death of the driver, a bystander or the person inspecting of
repairing the mortorcycle.
ATTENTION: ATTENTION indicates the special precautions which should be
taken in order to avoid damage to the motorcycle.
NOTE: NOTE provides key information to make the procedures easier
and clearer.
HOW TO USE THIS MANUAL
FORMAT OF THIS MANUAL
This manual is composed of chapters on the main subject categories (See “Illustrated Symbols”).
First heading : This is a chapter with a symbol at the top right-hand side of each page.
Second heading : This title appears at the top of each page to the left of the chapter symbol.
(For the “Inspection and periodic adjustments” chapter the third heading appears)
Third heading : This is a final heading.
MANUAL FORMAT
All procedures in this manual are organised sequentially, step by step. The information has been
compiled to make reading easy for the mechanic and to provide useful reference material which
contains ample explanations of all disassembly, repair, assembly and inspection procedures. A
particularly important procedure is placed between a lines of asterisks “**” with each procedu-
re preceded by “•”.
IMPORTANT CHARACTERISTICS
• Data and special tools are put in a box preceded by a corresponding symbol .
• A number within a circle indicates the number of a part, and an alphabetical letter within a
circle indicates data or an alignment mark , everything else is indicated by a letter within a
box .
• The conditions of defective components will precede an arrow symbol and the course of action
to be followed will follow the symbol .
DETAILED DIAGRAM
Each chapter provides detailed diagrams before each disassembly section, for the easy identifica-
tion of disassembly/assembly procedures.
ILLUSTRATED SYMBOLS
(See illustration)
Illustrated symbols to are designed as
tabs to be followed with the thumb to indicate
the chapter number and the index.
General information
Specifications
Periodic inspection and adjustment
General overhaul of the engine
Carburation
Chassis
Electrical system
roubleshooting
Illustrated symbols to
15 will be used to
identify the specifications which appear in the
text.
Refill with fluid
10 Lubricant
11 Special tool
12 ightening
13 Wear limit, clearance
14 Engine speed
15 ΩV, A
Illustrated symbols
16 to 23 of detailed dia-
grams, indicate the degree of lubricant and
the location of the lubrication point.
16 Apply engine oil
17 Apply gear oil
18 Apply molybdenum disulphide oil
19 Apply grease to wheel bearings
20 Apply grease with lightweight lithium soap
base
21 Apply molybdenum disulphide grease
22 Apply bonding agent (LOC I E®)
23 Use a new part.
INSP/
ADJ
CHAS
TRBL/
SHTG
SPEC
ENG
CARB
GEN
INFO
NEW
11
13
15
16
19
22
10
12
14
23
18
21
17
20
ELEC
SPEC 2
SPECIFICATIONS
INSP
ADJ 3
PERIODIC INSPECTION
AND ADJUSTMENTS
ENG 4
GENERAL OVERHAUL OF
ENGINE
CARB 5
CARBURATION
CHAS 6
CHASSIS
ELEC 7
ELECTRICAL SYSTEM
INDEX
TRBL
SHTG 8
TROUBLESHOOTING
GENERAL INFORMATION GEN/
INFO 1
GEN/
INFO 1
GEN/
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION OF THE SCOOTER…………………………………………1-1
SERIAL NUMBER OF THE FRAME …………………………………………1-1
ENGINE SERIAL NUMBER……………………………………………………1-1
IMPORTANT INFORMATION …………………………………………………1-2
CHANGE OF ALL PARTS ……………………………………………………1-2
OIL SEALS AND O-RINGS……………………………………………………1-2
SEALING WASHERS/PLATE AND KEYS……………………………………1-2
BEARING AND OIL SEALS …………………………………………………1-2
CIRCLIPS ………………………………………………………………………1-3
SPECIAL TOOLS …………………………………………………………………1-3
FOR SERVICING THE ENGINE ………………………………………………1-3
FOR SERVICING THE CHASSIS ……………………………………………1-5
FOR ELECTRICAL COMPONENTS …………………………………………1-6
GEN/
INFO
IDENTIFICATION OF THE SCOOTER
1-1
GENERAL INFORMATION
SCOOTER IDENTIFICATION
FRAME SERIAL NUMBER
The serial number of the frame is stamped
on the steering head pipe.
Frame VTL5AD according standard EU0
Frame VTLSA15 according standard EU1
Frame VTLSA19 according Mofa Version
ENGINE SERIAL NUMBER
The engine serial number is stamped on
the upper part of the rear left-hand section of
the gear box.
NOTE:
The first three digits of these numbers identify
the model, the remaining digits are the manu-
facturing number of the unit.
NOTE:
The designs and specification are subject to
change without prior notice.
GEN/
INFO
IMPORTANT INFORMATION
1-2
IMPORTANT INFORMATION
CHANGE OF ALL PARTS
1. We recommend that original Yamaha parts
are used as spare parts. Use the oil and/or
grease recommended by Yamaha for
assembly and adjustment.
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets and o-rings should be replaced
when the engine is overhauled and repaired.
All gasket surfaces, the lips of seals and o-
rings should be cleaned.
2. Lubricate with grease all corresponding
parts and bearings during assembly. Apply
grease on the lips of seals.
SEALING WASHER/PLATES AND KEYS
1. All washers/plates and keys should be
replaced when they are removed. The loc-
king tabs should be folded along the flat
parts of the bolts or nuts after correctly tigh-
tening them.
BEARINGS AND OIL SEALS
1. Install the bearings and oil seals with
their manufacturer’s marks or numbers
facing outwards (i.e. the printed letters
should on the side exposed to view). When
the oil seals are installed, apply a thin layer
of light lithium-based grease on the edges
of the seal. Put oil on the bearings when
they are installed.
ATTENTION:
Do not turn the bearings in compressed air
to dry them. This will damage the surface
of the bearings.
This manual suits for next models
1
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