Yamaha_Jog_Service_Manual.pdf

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CS50/Z 5RW1-AE1
SERVICE MANUAL
2002
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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.
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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.
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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.
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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 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-
IMPORTANT CHARACTERISTICS
• Data and special tools are put in a box preceded by a corresponding symbol
.
indicates the number of a part, and a alphabetical letter within a cir-
cle indicates data or an alignment mark
.
• The conditions of defective components will precede an arrow symbol and the course of action
to be followd will follow the symbol
, everything else is indicated by a letter within a box
.
DETAILED DIAGRAM
Each chapter provides detailed diagrams before each disassembly section, for the easy identifica-
tion of disassembly/assembly procedures.
: This is a chapter with a symbol at the top right-hand side of each page.
Second heading
ceded by “•”.
• A number within a circle
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GEN
INFO
SPEC
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ILLUSTRATED SYMBOLS
(See illustration)
The symbols from
to
CHK
ADJ
ENG
General information
Specifications
Periodic checks and adjustments
General motor revision
Cooling system
COOL
CARB
Carburetor
Chassis
Electrical system
Troubleshooting
CHAS
ELEC
10
16 are
used to identify the specifications that appear
in the text.
10 to
TRBL
SHTG
11
12
10 Refill liquid
12 Special tool
13 Torque
14 Wear, play limit
15 Motor speed
13
14
16
, V, A
15
16
24 of the
detailed diagrams indicate the grade of lubri-
cant and the site of the lubrication point.
17 to
17
18
19
17 Apply motor oil
19 Apply molybdenum disulphide oil
20 Apply wheel bearing grease
21 Apply lightweight lithium soap base
grease
20
21
22
22 Apply molybdenum disulphide grease
23 Apply blocking agent (LOCTITE®)
24 Use a new one
23
24
New
are designed as
thumb indices, to indicate the chapter num-
ber and index.
The illustrated symbols from
11 Lubricant
The illustrated symbols from
18 Apply gear oil
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