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YFM50S Service Manual

YFM50S

SERVICE MANUAL

LIT-11616-17-13

5YF-28197-10

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EBS00001

YFM50S

SERVICE MANUAL

©2003 by Yamaha Motor Corporation, U.S.A.

First Edition, April 2003

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-17-13

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NOTICE

This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on

Yamaha machine has a basic understanding of the mechanical ideas and the procedures of

machine repair. Repairs attempted by anyone without this knowledge are likely to render the

machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

NOTE:

_

Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATION

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death

to the machine operator, a bystander or a person checking or repairing the

machine.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

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HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “symbols”)

1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.

3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6 . The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition

to the exploded diagram and the job instruction chart.

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1

2

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SYMBOLS

The following symbols are not relevant to

every machine.

Symbols 1 to 9 indicate the subject of each

chapter.

1

GEN

INFO

SPEC

3

4

CHK

ADJ

General information

ENG

2

Specifications

3

Periodic checks and adjustments

4

Engine

5

6

5

Carburetor

6

Drive train

CARB

DRIV

7

Chassis

8

Electrical

9

Troubleshooting

7

8

CHAS

ELEC

–

+

9

0

Symbols 0 to G indicate the following.

0

Serviceable with engine mounted

TRBL

SHTG

A

Filling fluid

B

Lubricant

C

Special tool

D

Torque

A

B

E

Wear limit, clearance

F

Engine speed

G

Electrical data (

Ω

, V, A)

C

D

E

F

G

H

I

J

Symbols H to M in the exploded diagrams

indicate the types of lubricants and lubrication

points.

H

E

G

M

Apply engine oil

I

Apply gear oil

K

L

M

J

Apply molybdenum disulfide oil

Apply wheel bearing grease

K

B

LS

M

L

Apply lithium-soap-based grease

M

Apply molybdenum disulfide grease

N

O

Symbols N to O in the exploded diagrams

indicate where to apply a locking agent N and

when to install a new part O .

N

LT

New

Apply the locking agent (LOCTITE ® )

O

Replace

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