![Yamaha YW50AP (2001) [72/214] Chapter 4 engine overhaul](/img/pdf.png)
Yamaha YW50AP (2001) [72/214] Chapter 4 engine overhaul
![Yamaha YW50AP (2001) [72/214] Chapter 4 engine overhaul](/views2/1121445/page72/bg48.png)
4-1
ENG
EB400000
ENGINE OVERHAUL
ENGINE REMOVAL
WIREHARNESS AND CABLES
ENGINE REMOVAL
Remarks
Remove the parts in order.
Refer to “COVER AND PANEL” section
in CHAPTER 3.
Refer to “CARBURETOR” section in
CHAPTER 6.
Job name/Part name
Wireharness and cables removal
Rear carrier
Tail cover
Left side panel
Right side panel
Battery box cover
Center cowling
Air filter case
Carburetor
Air shroud 1
Autolube delivery hose
Order
1
2
Q’ty
1
1
45Nm(4.5 m.kg, 31ft.lb)
T
R
.
.
12
1
8
4
3
5
13
2
6
10
9
11
7
120Nm(12.0 m.kg, 87 ft.lb)
T
R
.
.
Содержание
- Yw50ap 1
- Important manual information 3
- Notice 3
- How to use this manual 4
- Elec trbl shtg 5
- Insp adj 5
- Chapter 1 general information 7
- Table of contents 7
- Chapter 2 specifications 8
- Chapter 3 periodic inspection and adjustments 9
- Chapter 4 engine 10
- Chapter 5 carburetion 11
- Chapter 6 chassis 12
- Chapter 7 electrical 13
- Chapter 8 troubleshooting 14
- Chapter 1 general information 15
- Gen info 15
- General information 15
- Scooter identification 15
- Scooter indentification 15
- Gen info 16
- Important information 16
- Gen info 17
- Important information 17
- Checking of connections 18
- Checking the connections 18
- Gen info 18
- Important information 18
- All specification data in this manual are listed in si and metric units use this table to convert metric unit data to imperial unit data ex metric multiplier imp mm 0 3937 in 2 mm 0 3937 0 83 in 19
- Conversion table 19
- Gen info 19
- How to use the conversion table 19
- Gen info 20
- Special tools 20
- 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 inappropri ate tools or improvised techniques when placing an order refer to the list provided below to avoid any mistakes 20
- Gen info 21
- Special tools 21
- Chapter 2 specifications 22
- General specification 22
- General specifications 22
- Specification 22
- General specification 23
- General specification 24
- Engine 25
- Maintenance specification 25
- Maintenance specifications 25
- Maintenance specification 26
- Maintenance specification 27
- Chassis 28
- Maintenance specification 28
- Maintenance specification 29
- Electrical 30
- Maintenance specification 30
- Maintenance specification 31
- General torque specifications 32
- Lubrication points and lubricant type 33
- Lubrication points and lubrication type 33
- Lubrication points and lubrication type 34
- Cable routing 35
- Cable routing 36
- Cable routing 37
- 7 6 5 4 3 2 1 a b 38
- Cable routing 38
- 9 6 5 d 39
- Cable routing 39
- Chapter 3 periodic inspections and adjustments 40
- Insp adj 40
- Introduction 40
- Introduction periodicmaintenance lublication intervals 40
- Periodic inspections and adjustments 40
- Periodic maintenance lubrication intervals 40
- This chapter includes all information necessary to perform recommended inspections and adjust ments these preventive maintenance procedures if followed will ensure more reliable vehicle operation and a longer service life the need for costly overhaul work will be greatly reduced this information applies to vehicles already in service as well as to new vehicles that are being pre pared for sale all service technicians should be familiar with this entire chapter 40
- From 6 000 mi 9 000 km or 18 months repeat the maintenance intervals starting 2 000 mi 3 000 mi or 6 months 41
- Insp adj 41
- Items marked with an asterisk require special tools data and technical skills for servicing take the scooter to a yamaha dealer 41
- Periodicinspection and adjustments 41
- The air filter needs more frequent service if you are riding in unusually wet or dusty areas brake fluid replacement 1 replace the brake fluid after disassembling the master cylinder or caliper cylinder check the brake fluid level and add fluid as required 2 replace the master cylinder and caliper cylinder oil seals every two years 3 replace the brake hoses every four years or if cracked or damaged 41
- Cover and panel 42
- Insp adj 42
- Cover and panel 43
- Insp adj 43
- Cover and panel 44
- Insp adj 44
- Engine 45
- Engine idle speed adjustment 45
- Insp adj 45
- Insp adj 46
- Throttle cable free adjustment 46
- Autolube pump air bleeding 47
- Insp adj 47
- Insp adj 48
- Spark plug inspection 48
- Engine oil level inspection 49
- Insp adj 49
- Insp adj 50
- Transmission oil replacement 50
- Air filter element cleaning 51
- Insp adj 51
- Air filter element cleaning 52
- Insp adj 52
- Insp adj 53
- V belt inspection 53
- Chassis 54
- Front brake lever free play check rear brake lever free play check brake pad inspection 54
- Insp adj 54
- Brake shoe inspection brake fluid level inspection 55
- Insp adj 55
- Air bleeding hydraulic brake system 56
- Insp adj 56
- Insp adj 57
- Steering adjustment 57
- Insp adj 58
- Tire inspection 58
- Checking the tires 59
- Insp adj 59
- Checking the tires checking the wheels 60
- Insp adj 60
- Insp adj 61
- Rear shock absorber inspection seat lock cableadjustment 61
- Wheel inspection front fork inspection 61
- Cable checking and lubricating levers lubricating 62
- Centerstand lubricating 62
- Insp adj 62
- Battery inspection 63
- Electrical 63
- Insp adj 63
- Battery inspection 64
- Insp adj 64
- Battery inspection 65
- Insp adj 65
- Battery inspection 66
- Insp adj 66
- Battery inspection 67
- Insp adj 67
- Fuse inspection 68
- Insp adj 68
- Headlight beam adjustment headlight bulb replacement 69
- Insp adj 69
- Headlight bulb turn signal bulb replacement 70
- Insp adj 70
- Insp adj 71
- Taillight bulb licence light bulb replacement 71
- Chapter 4 engine overhaul 72
- Engine overhaul 72
- Engine removal 72
- Engine removal 73
- Cylinder head cylinder and piston 74
- Cylinder head cylinder piston 75
- Cylinder and piston inspection 76
- Cylinder head cylinder and piston 77
- Cylinder head cylinder and piston 78
- Cylinder head cylinder and piston 79
- Cylinder head cylinder and piston 80
- Cylinder head cylinder and piston 81
- V belt clutch and secondary primary sheave 82
- V belt clutch and secondary primary sheave 83
- V belt clutch and secondary primary sheave 84
- V belt clutch and secondary primary sheave 85
- V belt clutch and secondary primary sheave 86
- V belt clutch and secondary primary sheave 87
- V belt clutch and secondary primary sheave 88
- V belt clutch and secondary primary sheave 89
- V belt clutch and secondary primary sheave 90
- V belt clutch and secondary primary sheave 91
- V belt clutch and secondary primary sheave 92
- V belt clutch and secondary primary sheave 93
- V belt clutch and secondary primary sheave 94
- Starter clutch and starter motor 95
- Starter clutch and starter motor 96
- Starter clutch and starter motor 97
- C d i magneto 98
- C d i magneto 99
- Autolube pump 100
- Autolube pump 101
- Transmission 102
- Transmission 103
- Crankcase and reed valve 104
- Crankcase and reed valve 105
- Crankcase and reed valve 106
- Crankcase and reed valve 107
- Crankcase and reed valve 108
- Crankshaft 109
- Crankshaft 110
- Crankshaft 111
- Carburetion 112
- Carburetor 112
- Carburetor 113
- Carburetor 114
- Carburetor 115
- Carburetor 116
- Carburetor 117
- Carburetor 118
- Carburetor 119
- Chapter 6 chassis 120
- Chassis front wheel and brake disc 120
- Front wheel and brake disc 120
- Front wheel and brake disc 121
- Front wheel and brake disc 122
- Front wheel and brake disc 123
- Front wheel and brake disc 124
- Front wheel and brake disc 125
- Front wheel and brake disc 126
- Front brake 127
- Front brake 128
- Front brake 129
- Front brake 130
- Front brake 131
- Master cylinder 131
- Front brake 132
- Master cylinder disassembly 132
- Front brake 133
- Front brake 134
- Front brake 135
- Caliper 136
- Front brake 136
- Caliper disassembly 137
- Front brake 137
- Front brake 138
- Front brake 139
- Rear wheel and rear brake 140
- Rear wheel and rear brake 141
- Rear wheel and rear brake 142
- Rear wheel and rear brake 143
- Handlebar 144
- Handlebar 145
- Handlebar 146
- Handlebar 147
- Steering 148
- Steering 149
- Steering 150
- Steering 151
- Steering 152
- Front fork 153
- Front fork 154
- Front fork 155
- Front fork 156
- Front fork 157
- Front fork 158
- Chapter 7 electrical 159
- Electrical 159
- Electrical components 159
- Circuit diagram 160
- Circuit diagram 161
- Checking switches 162
- Before checking a switch refer to the check ing switches as shown in the left page and check for the correct terminal connections closed circuit according to the color combi nations shown in the chart poor connection fault repair or replace 163
- Checking switches 163
- Dimmer switch 163
- Engine stop switch 163
- Front brake switch 163
- Horn switch 163
- Main switch 163
- Rear brake switch 163
- Start switch 163
- Switch position and terminal connection 163
- Turn switch 163
- Checking the bulbs and bulb sockets 164
- Checking the bulbs and bulb sockets 165
- Checking the bulbs and bulb sockets 166
- Circuit diagram 167
- Ignition system 167
- Main switch 8 c d i magneto 9 c d i unit 0 ignition coil q spark plug m engine stop switch 167
- Ignition system 168
- Ignition system 169
- Ignition system 170
- Ignition system 171
- Charging system 172
- Circuit diagram 172
- Main fuse 3 battery 6 rectifier regulator 8 cdi magnet 172
- Charging system 173
- Charging system 174
- Charging system 175
- Circuit diagram 176
- E front brake switch m engine stop switch starter switch 176
- Electric starting system 176
- Main switch 2 main fuse 3 battery 4 starter relay 5 starter motor w rear brake switch 176
- Electric starting system 177
- Electric starting system 178
- Electric starting system 179
- Electric starting system 180
- Electric starting system 181
- Electric starting system 182
- Electric starting system 183
- Circuit diagram 184
- Lighting system 184
- Main switch 2 fuse 3 battery 8 c d i magneto r tail light u licence light 184
- P head light for high beam a head light for low beam j light dimmer switch x meter light c high beam indicator light 184
- Lighting system 185
- Lighting system 187
- Lighting system 188
- Lighting system 189
- Lighting system 190
- Circuit diagram 191
- J turn switch k fuel sender fuel meter z oil indicator light v turn indicator light b oil level gauge 191
- Main switch 2 main fuse 3 battery w rear brake switch e front brake switch r brake light t rear flasher light right 191
- Signal system 191
- Y rear flasher light left i front flasher light right o front flasher light left s flasher relay d horn f handlebar switch left g horn switch 191
- Signal system 192
- Signal system 193
- Signal system 194
- Signal system 195
- Signal system 196
- Signal system 197
- Signal system 198
- Signal system 199
- Auto choke 8 c d i magneto 200
- Auto choke system 200
- Circuit diagram 200
- Auto choke system 201
- Auto choke system 202
- Chapter 8 troubleshooting 203
- Starting faillure hard starting 203
- Starting failure hard starting 203
- Trbl shtg 203
- Troubleshooting 203
- Starting failure hard starting 204
- Trbl shtg 204
- Poor idle speed performance 205
- Poor idle speed performance poor midium and high speed performance 205
- Poor m e dium and high speed performance 205
- Poor medium and high speed performance 205
- Trbl shtg 205
- F a ulty automatic v belt type 206
- Faulty automatic v belt type 206
- Poor midium and high speed performance 206
- Trbl shtg 206
- Over heat poor speed 207
- Overheat 207
- Poor speed 207
- Trbl shtg 207
- Improper kicking 208
- Trbl shtg 208
- Faulty brake 209
- Trbl shtg 209
- Instable handling 210
- Trbl shtg 210
- U nstable handling 210
- Unstable hancling 210
- Faulty signal and lighting system 211
- Trbl shtg 211
- Faulty signal and lighting system 212
- Trbl shtg 212
- B br ch dg g l or sb p r gy y w b r br w g r g y l b l y l w l r r b r y r w y r w g g w w r l g 213
- Black brown chocolate dark green green blue orange sky blue pink red gray yellow white black red brown white green red green yellow blue black blue yellow blue white blue red red black red yellow red white yellow white white green green white white red blue green 213
- Main switch 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 q spark plug w front brake switch e rear brake switch r tail brake light t front flasher light right y front flasher light left u head light i flasher relay o horn p handlebar switch left a horn switch s dimmer switch d turn switch f fuel sender g meter h fuel gauge j oil indicator light k meter light l high beam indicator light turn indicator light z oil level gauge x handlebar switch right c starter switch v engine stop switch 213
- Wiring diagram 213
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