User Manuals: Yamaha 2003 YJ50RAP Motorcycle Repair

Manuals and User Guides for Yamaha 2003 YJ50RAP Motorcycle Repair. We have 1 Yamaha 2003 YJ50RAP Motorcycle Repair manual available for free PDF download: Service Manual

Yamaha 2003 YJ50RAP Service Manual

Yamaha 2003 YJ50RAP Service Manual (228 pages)

Brand: Yamaha | Category: Motorcycle | Size: 4.14 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  5
- Chassis
  6
- Electrical System
  6
- Engine
  6
- General Information
  6
- Periodic Checks and Adjustments
  6
- Specifications
  6
- Troubleshooting
  6
  - Table of Contents
    7
  - Gen Info
    9
- Chapter 1 General Information
  12
- Scooter Identification
  12
  - Vehicle Identification Number
    12
  - Model Code
    12
- Important Information
  13
  - Preparation for Removal and Disassembly
    13
  - Replacement Parts
    13
  - Gaskets, Oil Seals and O-Rings
    13
  - Lock Washers/Plates and Cotter Pins
    13
  - Bearings and Oil Seals
    14
  - Circlips
    14
  - Checking the Connections
    15
- Special Tools
  16
- Spec
  20
2 Spec

21
- Chapter 2 Specifications
  23
- General Specifications
  23
- Engine Specifications
  24
- Chassis Specifications
  28
- Electrical Specifications
  31
- Conversion Table
  33
- General Tightening Torque Specifications
  33
- Tightening Torques
  34
  - Engine Tightening Torques
    34
  - Chassis Tightening Torques
    35
- Lubrication Points and Lubricant Types
  36
  - Engine
    36
  - Chassis
    37
- Cable Routing
  38
- Chk Adj
  45
Chapter 3 Periodic Checks and Adjustments

46
- Introduction
  48
- Periodic Maintenance and Lubrication Intervals
  48
- Side Covers and Footrest Board
  50
- Front Panel and Leg Shield
  52
- Chassis
  66
- Electrical System
  74
- Chas
  86
4 Chas

87
- Front Wheel and Brake
  89
- Chapter 4
  93
- Checking the Front Wheel
  93
- Checking the Speedometer Gear Unit
  94
- Checking the Brake
  95
- Assembling the Brake Shoe Plate
  96
- Installing the Front Wheel
  96
- Rear Wheel and Brake
  98
  - Checking the Rear Wheel
    100
  - Checking the Brake
    100
  - Installing the Brake Shoe Plate
    101
  - Installing the Brake Shoes
    102
  - Installing the Rear Wheel
    102
- Front Shock Absorber Assemblies
  103
  - Checking the Front Shock Absorber Assemblies
    104
  - Installing the Relay Arm
    104
- Handlebar
  105
  - Removing the Handlebar
    107
  - Checking the Handlebar
    107
  - Installing the Handlebar
    108
- Steering Head
  110
  - Removing the Fork
    112
  - Checking the Steering Head
    112
  - Installing the Steering Head
    113
- Rear Shock Absorber Assembly
  114
- Eng
  117
Chapter 5 Engine

118
- Engine Removal
  120
  - Installing the Engine
    122
- Cylinder Head, Cylinder and Piston
  123
  - Removing the Cylinder and Piston
    125
  - Checking the Cylinder Head
    125
  - Checking the Cylinder and Piston
    126
  - Checking the Piston Rings
    127
  - Checking the Piston Pin
    128
  - Installing the Piston and Cylinder
    130
- Kickstarter
  132
  - Sheaves Cover
    132
  - Checking the Kickstarter
    134
  - Installing the Kickstarter
    134
- Belt Drive
  135
  - Removing the Secondary Pulley and V-Belt
    138
  - Removing the Primary Sheave
    139
  - Disassembling the Secondary Pulley
    139
  - Checking the Clutch Shoes
    139
  - Checking the Secondary Pulley
    140
  - Checking the V-Belt
    141
  - Checking the Primary Pulley Weights
    141
  - Assembling the Secondary Pulley
    142
  - Installing the Primary Pulley
    143
  - Installing the Belt Drive
    144
- Starter Clutch and Starter Motor
  146
  - Checking the Starter Clutch
    147
  - Installing the Starter Clutch
    147
- Transmission
  149
  - Checking the Transmission
    151
- Generator and Autolube Pump
  152
  - Stator Coil Assembly
    152
  - Autolube Pump
    153
  - Removing the Generator
    154
  - Checking the Autolube Pump
    154
  - Installing the Autolube Pump
    154
  - Installing the Generator
    155
- Crankcase
  158
  - Disassembling the Crankcase
    158
  - Checking the Crankcase
    158
  - Checking the Bearings and Oil Seals
    159
  - Checking the Reed Valve
    159
  - Assembling the Crankcase
    160
- Crankshaft
  161
  - Removing the Crankshaft Assembly
    162
  - Checking the Crankshaft
    162
  - Installing the Crankshaft
    163
- Carb
  164
6 Carb

165
- Carburetion
  165
- Carburetor
  167
- Chapter 6
  170
- Checking the Carburetor
  170
- Assembling the Carburetor
  171
- Installing the Carburetor
  172
- Checking the Autochoke Assembly
  173
- Measuring and Adjusting the Float Height
  173
- Checking the Fuel Cock Operation
  174
- Elec
  175
7 Elec

176
- Chapter 7
  178
- Electrical Components
  178
- Switches
  179
  - Checking Switch Continuity
    179
- Checking the Switches
  180
- Checking the Bulbs and Bulb Sockets
  182
- Ignition System
  185
  - Circuit Diagram
    185
  - Troubleshooting
    186
- Electric Starting System
  190
  - Circuit Diagram
    190
  - Troubleshooting
    191
- Starter Motor
  194
  - Checking the Starter Motor
    196
  - Assembling the Starter Motor
    197
- Charging System
  198
  - Circuit Diagram
    198
  - Troubleshooting
    199
- Lighting System
  201
  - Circuit Diagram
    201
  - Troubleshooting
    202
  - Checking the Lighting System
    203
- Signaling System
  206
  - Circuit Diagram
    206
  - Troubleshooting
    208
  - Checking the Signaling System
    209
- Auto Choke System
  216
  - Circuit Diagram
    216
- Trbl Shtg
  220
Trbl Shtg

221
- Troubleshooting
  221
- Chapter 8
  223
- Electrical Systems
  223
- Engine
  223
- Fuel System
  223
- Starting Failure/Hard Starting
  223
- Faulty Clutch
  224
  - Engine Operates but Scooter will Not Move
    224
  - Clutch Slips
    224
  - Poor Starting Performance
    224
  - Poor Acceleration Performance
    224
- Incorrect Engine Idling Speed
  224
  - Engine
    224
  - Fuel System
    224
  - Electrical Systems
    224
- Poor Medium-And-High-Speed Performance
  224
- Overheating
  225
  - Engine
    225
  - Fuel System
    225
  - Chassis
    225
  - Electrical Systems
    225
- Poor Braking Performance
  225
- Unstable Handling
  225
- Faulty Lighting or Signaling System
  226
  - Headlight Does Not Light
    226
  - Headlight Bulb Burnt out
    226
  - Tail/Brake Light Does Not Light
    226
  - Tail/Brake Light Bulb Burnt out
    226
  - Turn Signal Does Not Light
    226
  - Turn Signal Blinks Slowly
    226
  - Turn Signal Remains Lit
    226
  - Turn Signal Blinks Quickly
    226
  - Horn Does Not Sound
    226

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