Yamaha YB50 User manual

2002

SERVICE MANUAL

YN50

5RN-AE1

YN50

SERVICE MANUAL

First Edition, September 2002

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.

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