Yamaha 2008 YW50X Service Manual
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Yamaha 2008 YW50X Service Manual

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2008
MOTORCYCLE
SERVICE MANUAL
Model : YW50X_
5PNF81972100
*5PNF81972100*

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Summary of Contents for Yamaha 2008 YW50X

  • Page 1 2008 MOTORCYCLE SERVICE MANUAL Model : YW50X_ 5PNF81972100 *5PNF81972100*...
  • Page 2 YW50BP 2001 SERVICE MANUAL : 5PN1-ME1 EAS00000 YW50X 2007 SUPPLEMENTARY SERVICE MANUAL ©2007 by Yamaha Motor Taiwan Co., Ltd. First edition, June 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Taiwan Co., Ltd.

  • Page 3: Important Manual Information

    EAS00002 NOTICE This manual was produced by the Yamaha Motor Taiwan Company, Ltd. primarily for use by Yamaha dealers 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.

  • Page 4: How To Use This Manual

    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. 1 The manual is divided into chapters.
  • Page 5 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Carburetor 8 Electrical system...

  • Page 6: Table Of Contents

    EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CARBURETOR CARB...
  • Page 7 INFO CHAPTER 1 GENERAL INFORMATION SCOOTER IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL LABEL .................. 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 ......

  • Page 8: General Information

    SCOOTER IDENTIFICATION INFO EAS00015 GENERAL INFORMATION SCOOTER IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL LABEL The model label 1 is affixed to the seat. This information will be needed to order spare parts.

  • Page 9: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but infe- rior in quality.

  • Page 10: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the...

  • Page 11: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 8 lead 8 coupler 8 connector 2. Check: 8 lead 8 coupler 8 connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times.

  • Page 12: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 13 90890-06754 Ignition checker YM-34487 This tool is used to check the ignition sys- tem components. 90890-85505 Yamaha bond NO.1215 ACC-11001-05-01 Sealant (Quick Gasket ®) This sealant (bond) is used on crankcase mating surfaces (e.g., crankcase mating surfaces). 90890-01348...
  • Page 14 SPECIAL TOOLS INFO Tool NO. Tool name / Function Illustration 90890-01312 Fuel level gauge YM-01312-A This gauge is used to measure the fuel le- ver in the float chamber.
  • Page 15 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS ..............2-2 CHASSIS SPECIFICATIONS ..............2-6 ELECTRICAL SPECIFICATIONS ............2-9 CONVERTION TABLE ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS ....... 2-12 TIGHTENING TORQUES................ 2-13 ENGINE .................... 2-13 CHASSIS ..................2-14 LUBRICATION POINTS AND LUBRICANT TYPES ......2-16 ENGINE ....................

  • Page 16: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Standard Limit Item Model Code 5PJ5 (USA) … 5PN6 (CAN) … Dimensions Overall length 1890mm (74.41in) … Overall width 705mm (27.76in) … Overall height 1110mm (43.70in) … Seat height 765mm (30.12in) … Wheelbase 1275mm (50.20in) …...

  • Page 17: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Standard Limit Item Engine Engine type Air-cooled 2-stroke reed valve … Displacement 0.049L (49cm³, 2.99cu-in) … Cylinder arrangement Forward inclined single cylinder … Bore × stroke 40.0 × 39.2mm (1.57 × 1.54in) … Compression ratio 7.01:1 …...

  • Page 18: Spec

    SPEC ENGINE SPECIFICATIONS Standard Limit Item Cylinder Bore 40.000 ~ 40.014mm … (1.5748 ~ 1.5754in) Maximum taper … 0.05mm (0.0020in) Maximum out-of-round … 0.05mm (0.0020in) Piston Piston-to-cylinder clearance 0.035 ~ 0.040mm 0.10mm (0.0014 ~ 0.0016in) (0.0039in) Diameter D 39.960 ~ 39.979mm …...
  • Page 19 SPEC ENGINE SPECIFICATIONS Standard Limit Item Crankshaft Width “A” 37.90 ~ 37.95mm … (1.4921 ~ 1.4941in) Maximum runout “C” … 0.03mm (0.0012in) Big end side clearance “D” 0.20 ~ 0.50mm 1.00mm (0.0079 ~ 0.0197in) (0.0394in) Big end radial clearance 0.004 ~ 0.017mm …...

  • Page 20: Carburetor

    SPEC ENGINE SPECIFICATIONS Standard Limit Item Carburetor ID mark 5PJ5 00 … Main jet (M.J.) # 80 … Needle jet (N.J.) 2.085 … Jet needle-clip position (J.N.) 3N24-1/1 … Main air jet (M.A.J.) … Cutaway (C.A.) … Pilot jet (P.J.) # 44 …...

  • Page 21: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Standard Limit Item Frame Frame type Steel tube underbone … Caster angle 26.5° … Trail 93mm (3.66in) … Front wheel Wheel type Cast wheel … Size J10 × MT3.50 … Material Aluminum … Wheel travel 61mm (2.40in) …...
  • Page 22 SPEC CHASSIS SPECIFICATIONS Standard Limit Item Rear tire Tire type Tubeless … Size 130/90-10 59J … Model (manufacturer) C-924 (CHENG SHIN) … Tire pressure (cold) Up to 90kg (198lb) load 200kPa (2.00kgf/cm², 29psi) … 90kg (198lb) load ~ Maximum load* 200kPa (2.00kgf/cm², 29psi) …...
  • Page 23 SPEC CHASSIS SPECIFICATIONS Standard Limit Item Front suspension Suspension type Telescopic fork … Front fork type Coil spring/oil damper … Front fork travel 70mm (2.76in) … Spring Free length 217.1mm (8.55in) 212.8mm (8.38in) Installed length 212.1mm (8.35in) … Spring rate (K1) 15.69N/mm …...

  • Page 24: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Standard Limit Item System voltage … Ignition system Ignition system type C.D.I. … Ignition timing 14° BTDC at 5000r/min … Advancer type Fixed … Pick coil resistance/color 400 ~ 600Ωat 20°C (68°F)/ … black - white/red C.D.I.
  • Page 25 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Headlight type Halogen bulb … Indicator light (voltage/wattage × quantity) Turn signal indicator light 12V 1.7W × 1 … High beam indicator light 12V 1.7W × 1 … Oil level indicator light 12V 1.7W × 1 …...
  • Page 26 SPEC ELECTRICAL SPECIFICATIONS Standard Limit Item Fuse (amperage × quantity) Main fuse 7A × 1 … Fuel sender Model (manufacturer) 4VP (TATUNG) … Sender unit resistance - full 4 ~ 10Ω … Sender unit resistance - empty 90 ~ 100Ω …...

  • Page 27: General Tightening Torque Specifications

    CONVERTION TABLE / GENERAL TIGHTENING SPEC TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.

  • Page 28: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE Tightening Thread Part to be tightened Part name ’ torque Remarks size Nm m•kg ft•lb Spark plug — M 14 Cylinder head and cylinder Cylinder Stud bolt Air shroud 1 Screw Air shroud 1× 2 Screw Screw Autolube pump...

  • Page 29: Chassis

    SPEC TIGHTENING TORQUES CHASSIS Tightening Thread Part to be tightened torque Remarks size m•kg ft•lb Frame and engine bracket M 12 Engine bracket, compression rod and engine M 10 Rear carrier Rear shock absorber and frame M 10 Rear shock absorber and engine Steering ring nut M 25 See “NOTE”...
  • Page 30 SPEC TIGHTENING TORQUES NOTE : 1. First, tighten the ring nut(lower) approximately 38Nm(3.8m•kg, 27.5ft•lb) by using the torque wrench, then loosen the ring nut 1/4 turn. 2. Second, tighten the ring nut(lower) approximately 12Nm(1.2m•kg, 8.7ft•lb) by using the torque wrench. 3.

  • Page 31: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant Oil seal lips O-rings Bearings Piston surface Piston pin Cylinder Transmission case (bearing) Autolube pump Starter wheel gear Idle gear plate Secondary drive gear Kickstarter pinion gear Drive axle Pump drive gear...

  • Page 32: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Lubricant Oil seal lips O-rings Bearings Speedometer drive gear Front brake lever pivot shaft Rear brake lever pivot shaft Front brake camshaft Front brake cable Throttle cable Tube guide (throttle grip) inner surface Upper steering stem ring nut Upper bearing outer race Lower bearing outer race...

  • Page 33: Cable Routing

    SPEC CABLE ROUTING t Wire harness F Align the clip with the white EAS00035 CABLE ROUTING A Pass the speedometer cable brand. G Clamp the wire harness. through the right hole of front 1 Horn H Insert the seat cable through fender, then through the 2 Rectifier regulator guide.
  • Page 34 SPEC CABLE ROUTING 1 Brake cable A Pass the brake hose through 2 Speedometer cable the holder. 3 Fuel tank overflow hose B Insert the fuel overflowhose 4 Brake cable holder bottom. 5 Brake hose C Pass the fuel overflowhose 6 Brake hose holder through the rear fender hole.
  • Page 35 SPEC CABLE ROUTING 1 Brake hose A Tighting torque:3.5 ~ 5.5Nm. 2 Front fender B Assemble the brake hose 3 Front fork assembly holder 3 hang hook must cer- 4 Nut tainty hook the brake hose 5 Plate washer holder. 6 Brake hose holder 1 C Tighting torque:8.5 ~ 14Nm.
  • Page 36 SPEC CABLE ROUTING 1 Ignition coil e Battery - lead F Clamp autochoke leads and 2 Spark plug lead r Battery + lead autolube hose on to carbu- 3 Starter relay leads A Pass battery leads through retor throttle cable. 4 Auto choke leads G Pass the batter y leads the slot of footrestboard.
  • Page 37 SPEC CABLE ROUTING 1 Grip assembly C Route the front turn signal F Route the speedometer 2 Handlebar switch(right) light lead through the slot of cable through between the 3 Front brake light switch handlebar bracket and frame and the brake hose to 4 Speedometer through the backward of rear right side.

  • Page 38: Chk Adj

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..................3-1 PERIODIC MAINTENANCE AND MINOR REPAIR ........ 3-1 Periodic maintenance chart for the emission control system ... 3-1 General maintenance and lubrication chart........3-2 COVER AND PANEL ................3-4 SEAT AND SIDE COVERS..............3-4 LOWER COWLING, UPPER COVER AND LEG SHIELD 1 ....

  • Page 39: Introduction

    EAS00037 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17570 Periodic maintenance chart for the emission control system * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. INITIAL ODOMETER READING 1,000 km...

  • Page 40: General Maintenance And Lubrication Chart

    • Check operation. switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 19000 km (12000 mi) or 36 months, repeat the maintenance intervals starting from 7000 km...
  • Page 41 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17620 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake system ● • When disassembling the master cylinder or caliper cylinder, always replace the brake fluid.

  • Page 42: Cover And Panel

    COVER AND PANEL EAS00038 COVER AND PANEL SEAT AND SIDE COVERS 13Nm (1.3 m•kg, 9.4 ft•lb) Order Job/Part Q’ty Remarks Removing the seat and side covers Remove the parts in the order listed. Battery box cover NOTE: Seat Insert the (-) screwdriver into the slot of Seat hanger battery box cover and pickup then re- Rear carrier...

  • Page 43: Lower Cowling, Upper Cover And Leg Shield 1

    COVER AND PANEL LOWER COWLING, UPPER COVER AND LEG SHIELD 1 Order Job/Part Q’ty Remarks Removing the lower cowling, upper Remove the parts in the order listed. cover, and leg shield 1 Lower cowling Head light lead coupler(low) Disconnect. Head light lead coupler(high) Disconnect.

  • Page 44: Leg Shield 2 And Footrest Board

    COVER AND PANEL LEG SHIELD 2 AND FOOTREST BOARD 7Nm (0.7 m•kg, 5.1 ft•lb) Order Job/Part Q’ty Remarks Removing the leg shield 2 and foot- Remove the parts in the order listed. rest board Leg shield 1 Refer to “LOWER COWLING, UPPER COVER AND LEG SHIELD 1”.

  • Page 45: Handlebar Cover(Front And Rear)

    COVER AND PANEL HANDLEBAR COVER(FRONT AND REAR) Order Job/Part Q’ty Remarks Removing the handlebar cover(front Remove the parts in the order listed. and rear) Handlebar cover(front) Speedometer cable Disconnect. Handlebar cover(rear) For installation, reverse the removal pro- cedure.

  • Page 46: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes.
  • Page 47 ADJUSTING THE ENGINE IDLING SPEED 5. Adjust: 8engine idling speed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. Direction a Engine idling speed is increased. Direction b Engine idling speed is decreased.

  • Page 48: Carb

    CARB CHAPTER 4 CARBURETOR AIR INDUCTION SYSTEM ............... 4-1 AIR FILTER CASE ASSEMBLY ............4-1 CHECKING THE AIR INDUCTION SYSTEM ........4-3...

  • Page 49: Air Induction System

    CARB AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM AIR FILTER CASE ASSEMBLY Order Job/Part Q’ty Remarks Removing the air filter case assem- Remove the parts in the order listed. Hose(to air filter) Disconnect. Disconnect. Pipe(to exhaust pipe) Air filter case assembly For installation, reverse the removal pro- cedure.
  • Page 50 CARB AIR INDUCTION SYSTEM Order Job/Part Q’ty Remarks Remove the parts in the order listed. Disassembling the air filter case as- sembly Damper Air filter case cap Reed valve Reed valve stopper Reed valve seat Reed valve assembly Element Plate O-ring Air filter case body For assembly, reverse the disassembly...
  • Page 51 CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: 8 hoses Loose connection Connect properly. Cracks/damage Replace. 8 pipes Cracks/damage Replace. 2. Check: 8 reed valve 1 8 reed valve stopper 8 reed valve seat Cracks/damage Replace the reed valve assembly.
  • Page 52 1 Main switch YW50X WIRING DIAGRAM 2 Main fuse 3 Battery 4 Starter relay 5 Starter motor 6 Rectifier/regulator 7 Auto choke 8 C.D.I. magneto 9 C.D.I. Unit 0 Ignition coil LOCK q Spark plug OPEN w Front brake light switch CHECK e Rear brake light switch r Tail/brake light...

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