Yamaha Jog Cs50 Service Manual

Full download: http://manualplace.com/download/yamaha-jog-cs50-service-manual/

2002
CS50/Z 5RW1-AE1

SERVICE MANUAL
This is the cut pages sample. Download all 204 page(s) at: ManualPlace.com
EAS00001

CS50/Z
SERVICE MANUAL
© 2002 by Yamaha Motor España, S.A.
1st Edition, September 2002
Any reprinting or use of this material
without the prior authorisation of
Yamaha Motor España, S.A.
is expressly prohibited.
Printed in Spain.
EAS00002

NOTICE
This manual was produced by the Yamaha Motor España, S.A., primarily for use by Yamaha/MBK
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/MBK vehicles should have a basic understanding of the 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 España, S.A., is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha/MBK
dealers and will appear in future editions of this manual where applicabe.

NOTE:
Designs and specifications are subject to change without notice.

EAS00005

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

t The Safety Alert Symbol means ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLDED!

s WARNING Failure to follow WARNING instructions could result in severe injury

or death to the scooter operator, a bystander, or a person inspec-
ting or repairing the scooter.

CAUTION: A CAUTION indicates special precautions that must be taken to

avoid damage to the scooter.

NOTE : A NOTE provides key information to make procedures easier or cle-

arer.
EAS00007

HOW TO USE THIS MANUAL

FORMAT OF THIS MANUAL
This manual consists of chapters for 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 the procedures in this manual are organized 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 par-
ticularly important procedure  is placed between a lines of asterisks “**” with each procedure pre-
ceded 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 a alphabetical letter within a cir-
cle 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 followd will follow the symbol
.

DETAILED DIAGRAM
Each chapter provides detailed diagrams before each disassembly section, for the easy identifica-
tion of disassembly/assembly procedures.
 EAS00008
 
ILLUSTRATED SYMBOLS
GEN SPEC (See illustration)
INFO The symbols from  to
are designed as
thumb indices, to indicate the chapter num-
  ber and index.
CHK
ENG  General information
ADJ  Specifications
 Periodic checks and adjustments
 
 General motor revision
 Cooling system
COOL CARB  Carburetor
 Chassis
 Electrical system

Troubleshooting
CHAS ELEC


10 The illustrated symbols from  10 to  16 are
used to identify the specifications that appear
TRBL in the text.
SHTG

11 
12

10 Refill liquid

11 Lubricant

12 Special tool

13 Torque

14 Wear, play limit

13 
14 
15 Motor speed

16 Ω, V, A


15 
16 The illustrated symbols from  17 to 24 of the
detailed diagrams indicate the grade of lubri-
cant and the site of the lubrication point.


17 
18 
19

17 Apply motor oil

18 Apply gear oil

19 Apply molybdenum disulphide oil

20 Apply wheel bearing grease

21 Apply lightweight lithium soap base

20 
21 
22 grease

22 Apply molybdenum disulphide grease

23 Apply blocking agent (LOCTITE®)

24 Use a new one


23 
24

New
EAS00010

TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG
4
COOLING SYSTEM COOL
5
CARBURETOR CARB
6
CHASSIS CHAS
7
ELECTRICAL SYSTEM ELEC
8
TROUBLESHOOTING TRBL
SHTG 9
GEN
INFO 1
 GEN
INFO
CHAPTER 1
GENERAL INFORMATION

SCOOTER IDENTIFICATION……………………………………………………1-1
FRAME SERIAL NUMBER ……………………………………………………1-1
ENGINE SERIAL NUMBER……………………………………………………1-1

IMPORTANT INFORMATION …………………………………………………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 …………………………………………………1-2
CIRCLIPS ………………………………………………………………………1-3

SPECIAL TOOLS …………………………………………………………………1-4

 GEN
IDENTIFICATION OF SCOOTER INFO
EAS00015

GENERAL INFORMATION

SCOOTER IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number  is stamped on the
chassis.

ENGINE SERIAL NUMBER

The serial number of the engine  is stamped
on the raised portion of the rear left section of
the transmission box.

NOTE:
The first three digits of these numbers are for
identifying the model; the remaining digits
constitute the production number of the unit.

NOTE:
Designs and specifications are subject to
change without notice.

1-1
 GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
EAS00021

REPLACEMENT PARTS
1. Use only genuine Yamaha/MBK parts for all
replacements. Use the oil and/or grease
recommended by Yamaha/MBK for
assembly and adjustment.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.

EAS00023

LOCK WASHERS/PLATES AND COTTER

PINS
1. Replace all lock washers/plates  and cot-
ter pins after removal. Bend lock tabs along
the bolt or nut flats after the bolt or nut has
been tightened to specification.

EAS00024

BEARINGS AND OIL SEALS

1. Install the bearings  and oil stops  with
their manufacturer brands or numbers
facing outwards. (In other words, the stam-
ped letters should be on the side exposed
to view.) When installing oil seals, apply a
light coating of lightweight lithium base gre-
ase to the seal lips. Put oil on the bearings
when installing.

CAUTION:
Do not use compressed air to spin the bea-
rings dry. This will damage the bearing surfa-
ce.

1-2
 GEN
IMPORTANT INFORMATION INFO
EAS00025

CIRCLIPS
1. Check all circlips carefully before reas-
sembly. Always replace piston pin clips
after one use. Replace distorted circlips.
When installing a circlip , make sure that
the sharp-edged corner  is positioned
opposite the thrust  it receives. See sec-
tional view.
 Shaft.

1-3
 GEN
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; this will help prevent damage caused by the use of inappropria-
te tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name / Usage Illustration

90890-01235 Rotor holding tool

This tool is used to remove the flywheel

magneto.
90890-01337 Clutch spring bracket

This tool is used to remove the clutch nut

while holding the compression spring.
90890-01274 Container of the crankshaft installer a
-01275 Bolt of the crankshaft installer b
-01277 Adapter c, Spacer d
-01288 These tools are used to install the
crankshaft.
90890-01362 Flywheel puller

. For removing the flywheel.

90890-01135 Crankcase separation tool

This tool is used to remove the

crankshaft or separate the crankcase.
90890-01384 Oil seal guide

Protects the edge of the oil seal during

the installation of the secondary sliding
pulley wheel.
90890-01403 Ring nut wrench

This tool is used to loosen and tighten

the steering ring nut.
90890-01701 Pulley bracket

This tools is used to disassemble and

assemble the secondary pulley.
90890-03079 Thickenss gauge

This tool is used to measure the clearance.

1-4
 GEN
SPECIAL TOOLS INFO

Tool No. Tool name / Usage Illustration

90890-03112 Pocket tester

This instrument is very important

for checking the electrical system.
90890-03113 Engine tachometer

This tool is necessary for detecting

the engine rpm.
90890-01409 Oil seals guide

This tool is used to install the left oil

guide of the crankcase.
90890-01410 Oil seals installer

This tool is used to install the left oil

seal of the crankcase.
90890-06754 Ignition checker

This instrument is necessary

to check the components of the
ignition system.
90890-85505 Yamaha bond No. 1215

This bond (sealant) is used for crankcase

mating surface, etc.
90890-01348 Locknut wrench

This tool is used to loosen and tighten

the secondary sheave nut.
90890-01367  Front oil seals inserter
-01400  Counterweight a
Adapter b
These tools are used in the installation
of seals.
90890-01326 T-handle
90890-01294 Damper rod holder

These tool are used for holding the damper rod

holder when removing or installing the damper
rod holder.

1-5
SPEC
2
 SPEC
CHAPTER 2
SPECIFICATIONS

GENERAL SPECIFICATIONS …………………………………………………2-1

MAINTENANCE SPECIFICATIONS ……………………………………………2-3

ENGINE …………………………………………………………………………2-3
CHASSIS ………………………………………………………………………2-5
ELECTRICAL SYSTEM ………………………………………………………2-6

CONVERSION TABLE……………………………………………………………2-7

GENERAL TIGHTENING TORQUE SPECIFICATIONS ……………………2-7

TIGHTENING TORQUES ………………………………………………………2-8

ENGINE TIGHTENING TORQUES …………………………………………2-8
CHASSIS TIGHTENING TORQUES …………………………………………2-9

COOLING SYSTEM (CS50Z only) ……………………………………………2-10

CABLE ROUTING ………………………………………………………………2-11

 GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS

Model CS50 CS50Z

Dimensions:
Overall lenght 1.740 mm
Overall widht 675 mm
Overall height 1.065 mm
Seat height 770 mm / 776 mm
Wheelbase 1.210 mm
Minimum ground clearance 132 mm
Basic weight (With oil and full fuel tank): 80,5 kg 83,7 kg
Engine:
Engine type Plate valve, gasoline, 2-strokes
air-cooled Liquid cooled
Cylinder arrangement Forward-inclined single cylinder
Displacement 49,3 cc
Bore x stroke 40,0 x 39,2 mm
Compression ratio 10,2 : 1 11,4 : 1
Starting system Electric and kickstarter
Lubrication system: Yamaha autolube
Oil type or grade:
Engine oil 2-strokes motor oil (JASO grade FC)
Transmission oil SE type 10W30 SAE motor oil
Oil capacity:
Oil tank (motor oil) 1,4 L
Transmission fluid
Periodic fluid change 0,10 L
Total amount 0,11 L
Cooling system capacity:
(Total amount) – 0,910 L
Air filter: Wet type element
Fuel:
Type Unleaded gasoline
Fuel tank capacity 5,5 L
Carburetor:
Type/quantity PHVA12ZS/1, PY12/1 PHVA12ZS/1
Manufacturer DELL’ORTO, GURTNER DELL’ORTO
Spark plug:
Type/Manufacturer BR8HS/N.G.K.
Spark plug gap 0,6 ~ 0,7 mm
Clutch type: Dry, centrifugal automatic
Transmission:
Primary reduction system Helical gear
Primary reduction ratio 52/13 (4.000)
Secondary reduction system Straight gearing
Secondary reduction ratio 42/13 (3.230) 43/13 (3.310)
Transmission type Single speed automatic
(V-belt type)
Operation Centrifugal automatic type

2-1
 GENERAL SPECIFICATIONS SPEC

Model CS50 CS50Z

Chassis:
Frame type Steel tube underbone
Front axle incline angle 25°
Steering angle base 80 mm
Tire:
Size/Type (Front) 110/70-12 / 47 L
Size/Type (Rear) 120/70-12 / 51 L, 130/70-12 / 56 L
Tire pressure (cold tire):
Front 175 KPa (1,75 kg/cm2)
Rear 200 KPa (2,00 kg/cm2)
Maximum Load:
Front 175 KPa (1,75 Kg/cm2)
Rear 225 KPa (2,25 Kg/cm2)
Brake:
Type of front brake Disk brake
Activation Right hand operation
Type of rear brake Drum brake
Activation Left hand operation
Suspension:
Front suspension Telescopic fork
Rear suspension Unit swing
Shock absorber:
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Oil damper
Wheel travel:
Front wheel travel 70 mm
Rear wheel travel 60 mm
Electrical:
Ignition system DC-CDI
Generator system Magnetic flywheel
Battery type or model Maintenance free
Battery capacity 12V 4AH
Type of headlamp: Bulb
Bulb wattage/quantity:
Headlight 12V, 35W / 35Wx1
Tail/brake light 12V, 5W / 21Wx1
Turn signal light 12V, 10Wx2 (rear) / 12V, 16Wx2 (front)
Auxiliary light 12V, 5W x 2
License plate light 12V, 5W x 1
Meter lighting 12V, 1,2W x 2
Indicator light voltage/quantity:
Oil level warning light LED
Turn signal indicator light 12V, 2W x 2
High beam indicator light 12V, 2W x 1
Coolant temperature warning light – LED

2-2
 MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE

Model CS50 CS50Z

Cylinder head:
Warp limit 0,02 mm
* The lines indicate measurement
with straight edge

Cylinder:
Bore size 39,993 ~ 40,012 mm
<Limit> <40,1 mm>
Taper limit 0,05 mm
Out of round limit 0,01 mm
Piston:
Piston size 39,952 - 39,972 mm 39,957 - 39,997 mm
Measuring point 5 mm

Piston clearance 0,034 - 0,047 mm 0,029 - 0,042 mm

On measurement
1st 40,25 mm
Piston rings:
Cut-away section (BXT)/TYPE
Top ring 1.5 x 1.8 mm/Keystone
2nd ring 1.5 x 1.8 mm/Keystone

End gap (installed)

Top ring 0,15 ~ 0,35 mm
2nd ring 0,15 ~ 0,35 mm
<Limit> <0,6 mm>
Sice clearance
Top ring 0,03 ~ 0,05 mm
2nd ring 0,03 ~ 0,05 mm
Crankshaft:

Crank width “A” 37,90 ~ 37,95 mm

Runout limit “C” 0,03 mm
Large end of rod side clearance “D” 0,2 ~ 0,5 mm
Small end of rod clerance “F” 0,4 ~ 0,8 mm

2-3
 MAINTENANCE SPECIFICATIONS SPEC

Model CS50 CS50Z

Automatic centrifugal clutch:
Clutch shoe thickness 2,0 mm
<Limit> <1,0 mm>
Clutch shoe spring free length 29,9 mm
Clutch - in revolution 3.350 - 3.850 r/min. 3.950 - 4.450 r/min.
Clutch - stall revolution 5.200 - 6.000 r/min. 6.900 - 7.700 r/min.

V-belt:
V-belt width 16,5 mm
<Limit> <15,7 mm>

Transmission:
Main axle eccentricity limit 0,08 mm
Drive axle eccentricity limit 0,08 mm

Pedal starting:
Type Ratchet
Strength of pedal spring 150 ~ 250 g

Air filter oil grade: For foam air filter or air-cooled 2-stroke
motor oil

Carburetor:
Type / Manufacturer / Amount PHVA12ZS/1 PY12/1 PHVA12ZS/1
DELL’ORTO GURTNER DELL’ORTO
Main jet / Model (M.J.) #65 #62 #65
Jet needle (J.N.) A20-3/5 B10A-2/3 A35-4/5
Main air jet (M.A.J.) ø 2.5 ø 2.0 ø 2.5
Pilot jet (P.J.) #36 #38 #36
Pilot screw (P.A.S.) 2 - 21/4 13/4 - 2 13/4 ± 1/8
Valve seat size 1.2 1.4 1.2
Engine idling speed 1650 ~ 1950 r/min
Starter jet #50 #42 #50

2-4
Yamaha Jog Cs50 Service Manual
Full download: http://manualplace.com/download/yamaha-jog-cs50-service-manual/

MAINTENANCE SPECIFICATIONS SPEC

CHASSIS

Model CS50 CS50Z

Steering system:
Steering bearing type Upper Ball bearing
Lower Ball bearing
Front suspension:
Front fork travel 70 mm
Fork spring free length 224 mm

Spring rate (K1) 1,33 Kgf/mm

(K2) 2,0 Kgf/mm

Oil capacity 45 cc ± 1
Oil grade Fork oil: 10W or equivalent
Rear suspension:
Shock absorber stroke 60 mm
Spring free length 220 mm
Spring rate (K1) 4,58 Kgf/mm
(K2) 6,12 Kgf/mm
Wheels:
Type of front wheel Alloy rim
Type of rear wheel Alloy rim
Size/material of front tyre 2,75 x 12 / aluminium
Size/material of rear tyre 3,00 x 12 / aluminium
Rim runout limit
Radial 1,0 mm
Lateral 1,0 mm
Front disc brake:
Type Single
Disc outside diameter x thickness ø 190 x 3,5 mm
Pad thickness 4,5 mm
<Limit> <0,5 mm>
Interior diameter of pump 11 mm
Calliper interior diameter 30 mm
Brake fluid type DOT #4
Rear drum brake:
Type Single cam
Drum inside diameter ø 110 mm
<Limit> <ø 110,5 mm>
Shoe thickness 4 mm
<Limit> <2 mm>
Brake levers:
Free play of the front brake lever
(right)/measurement 2 ~ 5 mm / At the end of the lever
Free play of the rear brake lever
(left)/measurement 5 ~ 10 mm / At the end of the lever

2-5

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