Yamaha BWS 2003 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6

EAU01008

Troubleshooting

Although  Yamaha  scooters  receive  a
thorough  inspection  before  shipment
from  the  factory,  trouble  may  occur
during  operation. Any  problem  in  the
fuel, compression, or ignition systems,
for  example,  can  cause  poor  starting
and loss of power.
The  following  troubleshooting  chart
represents a quick and easy procedure
for  checking  these  vital  systems
yourself. However, should your scoo-
ter  require  any  repair,  take  it  to  a
Yamaha  dealer,  whose  skilled
technicians have the necessary tools,
experience, and know-how to service
the scooter properly.
Use only genuine Yamaha replacement
parts.  Imitation  parts  may  look  like
Yamaha  parts,  but  they  are  often
inferior, have a shorter service life and
can lead to expensive repair bills.

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Summary of Contents for BWS 2003

Page 1: ...OWNER S MANUAL 1B0 F8199 E0 CW50RS ...

Page 2: ......

Page 3: ...this manual thoroughly so as to enjoy all advantages of your CW50RS The owner s manual does not only instruct you in how to operate inspect and maintain your scooter but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your scooter in the best possible condition If you have any further questions do not hesitate to co...

Page 4: ...recautions that must be taken to avoid damage to the scooter NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current produ...

Page 5: ...EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER IMPORTANT MANUAL INFORMATION ...

Page 6: ...W50RS OWNER S MANUAL 2003 by MBK INDUSTRIE 1st Edition January 2003 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited Printed in France ...

Page 7: ... 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 SCOOTER CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION EAU00009 TABLE OF CONTENTS 2 3 4 5 6 7 8 9 ...

Page 8: ......

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 1 EAU00021 EW000015 GIVE SAFETY THE RIGHT OF WAY 1 ...

Page 10: ...influence of even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the scooter rider as seat belts are for car drivers and passengers Always wear a complete scooter suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots scooter gloves and a properly fitting helmet Optimum protective wear however sh...

Page 11: ...etcar rails iron plates on road construction sites and manhole covers become extremely slippery when wet Slow down and cross them with caution Keep the scooter upright otherwise it could slide out from under you The brake lining could get wet when you wash the scooter After washing the scooter check the brakes before riding Always wear a helmet gloves trousers tapered around the cuff and ankle so ...

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Page 13: ...EAU01161 DESCRIPTION Left view 2 1 Right view 2 2 2 ...

Page 14: ... 5 2 Speedometer unit Page 3 3 3 Left handlebar switches Page 3 4 4 Luggage hook Page 3 10 5 Air filter element Page 6 7 6 Seat lock Page 3 8 7 Final transmission oil filler cap Page 6 6 8 Rear brake adjusting nut Page 6 11 9 Kickstarter Page 3 8 10 Front brake pads Page 6 12 ...

Page 15: ... tank cap page 3 5 13 Fuel tank cap page 3 5 14 Storage compartment page 3 8 15 Main switch steering lock page 3 1 16 Throttle grip page 6 15 17 Right handlebar switches page 3 4 18 Front brake lever page 3 4 19 Battery fuse page 6 17 6 19 20 Securing bracket page 3 11 21 Centerstand page 6 15 ...

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Page 17: ...3 3 Handlebar switches 3 4 Front brake lever 3 4 Rear brake lever 3 5 Fuel and 2 stroke engine oil tank caps 3 5 Fuel 3 6 2 stroke engine oil 3 7 Catalytic converter 3 7 Starter choke lever 3 7 Kickstarter 3 8 Seat 3 8 Storage compartment 3 8 Adjusting the shock absorber assembly 3 9 Carrier 3 10 Luggage hook 3 10 Securing bracket 3 11 3 ...

Page 18: ...lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the po sition release it and then turn it to 3 Remove the key To unlock the steering Insert the key and turn it to EW000016 Never turn the key to or while the scooter is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the scooter is s...

Page 19: ...ou know that the engine oil level is sufficient EAUM0077 Oil level warning light This warning light comes on when the key is in the position or when the oil level in the 2 stroke engine oil tank is low during operation If the warning light comes on during operation stop immediately and fill the oil tank with 2 stroke engine oil of either JASO grade FC or ISO grades EG C or EG D The warning light s...

Page 20: ...speedometer shows riding speed The odometer shows the total distance traveled EAU00113 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank The needle moves towards E Empty as the fuel level decreases When the needle reaches E refuel as soon as possi ble NOTE Do not allow the fuel tank to empty itself completely 3 3 1 ZAUM0178 1 2 1 2 ZAUM0177 UK ONLY ...

Page 21: ... cancel the turn si gnal lights push the switch in after it has returned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU03888 Dimmer switch Set this switch to for the high beam and to for the low beam EAUM0063 Start switch Push this switch while applying the front or rear brake to crank the engine with the starter EC000005 See page 5 1 for starting instruc tions...

Page 22: ...ap are located under the seat See page 3 8 for seat opening and closing procedures Fuel tank cap To remove the fuel tank cap turn it counterclockwise and then pull it off To install the fuel tank cap turn it clockwise 2 stroke engine oil tank cap To remove the 2 stroke engine oil tank cap pull it off To install the 2 stroke engine oil tank cap push it into the oil tank opening EW000025 Make sure t...

Page 23: ...ane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs EWA00008 Since gasoline is flammable the following precautions must be observed Stop the engine before refueling Never attempt to refuel the scooter while smoking or near an open flame Take special care n...

Page 24: ... near possible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long 1 Starter choke lever EAU03839 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke 3 7 EAUM0078 2...

Page 25: ...nd then turn it as shown 2 Fold the seat up To close the seat 1 Fold the seat down and then push it down to lock it in place 2 Remove the key NOTE Make sure that the seat is properly secured before riding 3 8 EAUM0061 Storage compartment There is a storage compartment under the seat See page 3 8 for seat opening and closing procedures EWA00005 Do not exceed the load limit of 3 kg for the storage c...

Page 26: ...ile the scooter is being washed wrap any arti cles stored in the compartment in a plastic bag Do not keep anything valuable or breakable in the storage compartment To store a helmet in the storage compartment place the helmet with the front facing backward NOTE Some helmets cannot be stored in the storage compartment because of their size or shape Do not leave your scooter unattended with the seat...

Page 27: ...ing ring with the position indicator on the shock absorber Minimum soft Setting b middle a Maximum hard Standard b a 1 2 ZAUM0488 1 Spring preload adjusting ring 2 Position indicator 1 ZAUM0489 1 Rear carrier EAU00320 Carrier EW000032 Do not exceed the load limit of 3 kg for the carrier Do not exceed the maximum load of 182 kg for the vehicle 1 Luggage hook EAUT0020 Luggage hook EWT00002 Do not ex...

Page 28: ...ing bracket To prevent theft the securing bracket can be used to chain the scooter to a stationary object such as a lamppost or a fence To secure the scooter with a chain or cable lock place the scooter on the centerstand pass the chain or cable through the securing bracket and around the stationary object and then lock the chain or cable lock 1 Securing bracket 1 ZAUM0490 ...

Page 29: ...EAU01114 PRE OPERATION CHECKS Pre operation check list 4 1 4 ...

Page 30: ... line for leakage Check oil level in oil tank Two stroke engine oil If necessary add recommended oil to specified level 3 7 Check vehicle for oil leakage Final transmission oil Check oil level and vehicle for oil leakage 6 6 Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Front brake Check fluid level in reservoir 3 4 6 11 If necessary add recommended brake fluid to spe...

Page 31: ...er 4 2 Check for damage Wheels and Tires Check tire condition and tread depth 6 9 6 11 Check air pressure Correct if necessary Brake levers Make sure that operation is smooth 3 4 3 5 Lubricate lever pivoting points if necessary Centerstand Make sure that operation is smooth 6 15 Lubricate pivot if necessary Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten i...

Page 32: ......

Page 33: ...ON AND IMPORTANT RIDING POINTS Starting the engine 5 1 Starting a warm engine 5 2 Starting off 5 2 Acceleration and deceleration 5 3 Braking 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 5 ...

Page 34: ...to then when the oil level warning light comes on turn it to EC000045 If the oil level warning light does not come on have a Yamaha dealer check the electrical circuit 2 Turn the starter choke on and completely close the throttle See page 3 7 for starter choke operation 3 Start the engine by pushing the start switch or by pushing the kickstarter lever down while applying the front or rear brake NO...

Page 35: ...ally to the throttle with the starter choke turned off 5 2 EC000046 See page 5 4 for engine break in ins tructions prior to operating the vehicle for the first time EAU04473 Starting off NOTE Before starting off allow the engine to warm up 1 While pulling the rear brake lever with your left hand and holding the carrier with your right hand push the scooter off the centerstand 2 Sit astride the sea...

Page 36: ...th front and rear brakes simultaneously while gradually increasing the pressure EW000057 Avoid braking hard or suddenly especially when leaning over to one side otherwise the scooter may skid or overturn Railroad crossings streetcar rails iron plates on road cons truction sites and manhole covers become extremely slippery when wet Therefore slow down when approaching such areas and cross them with...

Page 37: ...sive load on it for the first 1 000 km The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition that might result in engine overheating must be avoided EAUT0003 0 150 km Avoid operation above 1 3 throttle Stop the engine and let it cool for 5 to 10 minutes after every hour of operation Vary ...

Page 38: ...itch EW000058 Since the engine and exhaust system can become very hot park in a place where pedestrians or children are not likely to touch them Do not park on a slope or on soft ground otherwise the scooter may overturn EC000062 Never park in an area where there are fire hazards such as grass or other flammable materials 5 5 ...

Page 39: ...d rear brake shoes 6 12 Checking the brake fluid level 6 13 Changing the brake fluid 6 14 Checking and lubricating the cables 6 14 6 Checking and lubricating the throttle grip and cable 6 15 Lubricating the front and rear brake levers 6 15 Checking and lubricating the centerstand 6 15 Checking the front fork 6 16 Checking the steering 6 16 Checking the wheel bearings 6 17 Battery 6 17 Replacing th...

Page 40: ...AU03453 Safety is an obligation of the owner Periodic inspection adjustment and lubrication will keep your vehicle in the safest and most efficient condition pos sible The most important points of scooter inspection adjustment and lubrication are explained on the following pages EW000060 If you are not familiar with scooter maintenance work have a Yamaha dealer do it for you EW000063 Modifications...

Page 41: ...acks or damage 2 Spark plug Replace 3 Air filter element Clean Replace 4 Battery Check electrolyte level and specific gravity Make sure that the breather hose is properly routed Check operation fluid level and vehicle for fluid leakage 5 Front brake See NOTE on page 6 4 Replace brake pads Whenever worn to the limit 6 Rear brake Check operation and adjust brake lever freeplay Replace brake shoes Wh...

Page 42: ...is fasteners Make sure that all nuts bolts and screws are properly tightened 13 Centerstand Check operation Lubricate 14 Front fork Check operation and for oil leakage 15 Rear shock absorber Check operation and shock absorber for oil leakage assembly 16 Carburetor Adjust engine idling speed 17 Autolube pump Check operation Bleed if necessary 18 Final transmission oil Check vehicle for oil leakage ...

Page 43: ...ing and cable 23 Lights signals and Check operation switches Adjust headlight beam NO Item Check or maintenance job ODOMETER READING x 1 000 km 1 ANNUAL CHECK 6 12 18 24 EAU03541 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years change the brake flu...

Page 44: ...ne could be defective Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the scooter If the spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Specified spark plug BR8HS NGK Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specificatio...

Page 45: ... Place the scooter on the centerstand 3 Place an oil pan under the final transmission case to collect the used oil 4 Remove the oil filler cap and drain bolt to drain the oil from the final transmission case 5 Install the final transmission oil drain bolt and then tighten it to the specified torque Tightening torque Final transmission oil drain bolt 17 Nm 1 7 m kgf 6 Add the specified amount of th...

Page 46: ...ir filter case cover by removing the screws 2 Pull the air filter element out clean it with solvent and then squeeze the remaining solvent out EW000075 Use only a dedicated parts cleaning solvent To avoid the risk of fire or explosion do not use gasoline or solvents with a low flash point EC000089 To avoid damaging the foam material handle it gently and carefully and do not twist or wring it 3 App...

Page 47: ...ting the throttle cable free play The throttle cable free play should measure 1 5 3 0 mm at the throttle grip Periodically check the throttle cable free play and if necessary have a Yamaha dealer adjust it 4 Insert the element into the air filter case EC000082 Make sure that the air filter element is properly seated in the air filter case The engine should never be operated without the air filter ...

Page 48: ...characteristicsof your scooter you should keep the following precautions in mind NEVER OVERLOAD THE SCOO TER Operation of an overloaded scootermayresultintiredamage loss of control or severe injury Make sure that the total weight of rider cargo and accessories does not exceed the specified maximum load for the vehicle Donotcarryalonglooselypacked items which can shift during a ride Securely pack t...

Page 49: ... can lead to loss of control The replacement of all wheel and brake related parts including the tires should be left to a Yamaha dealer who has the necessary professional knowledge and experience Minimum tire tread depth front and rear 1 6 mm NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations 1 2 ZAUM0054 1 Tread depth 2 Side wall Tire info...

Page 50: ...tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteristics EAU00697 Adjusting the front brake lever free play The brake lever free play should measure 10 20 mm as shown Periodically check the brake lever free play and if necessary have a Yamaha dealer adjust it EW000100 An incorrect brake lever free play ind...

Page 51: ...a Yamaha dealer make this adjustment EAU00720 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EAU01436 Front brake pads Check each front brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is l...

Page 52: ... brake system possibly causing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary Alow brake fluid level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sur...

Page 53: ...oes not move smoothly have aYamaha dea ler check or replace it Recommended lubricant Engine oil EW000112 Damage to the outer sheath may interfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions 6 14 Be careful that water does not enter the master cylinder when refilling Water will significantly lower the bo...

Page 54: ...d rear brake levers must be lubricated at the intervals specified in the periodic main tenance and lubrication chart Recommended lubricant Lithium soap based grease all purpose grease EAU04123 Checking and lubricating the centerstand The operation of the centerstand should be checked before each ride and the pivots and metal to metal contact sur faces should be lubricated if necessary EWA00055 If ...

Page 55: ... in an upright po sition 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly EC000098 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or repair it ZAUM0493 EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the...

Page 56: ...he intervals specified in the periodic maintenance and lubrication chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 1 3 2 ZAUM0495 1 Fuse 2 Panel A 3 Battery 6 17 EAUM0049 Battery A poorly maintained battery will corrode and discharge quickly The electrolyte level battery lead connections and breather hose routing should b...

Page 57: ...contains sulfuric acid which causes severe burns Avoid any contact with skin eyes or clothing and always shield your eyes when workingnearbatteries Incaseof contact administer the following FIRST AID EXTERNAL Flushwithplentyof water INTERNAL Drink large quantities of water or milk and immediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries prod...

Page 58: ...y before installation 4 After installation make sure that the battery leads are properly connected to the battery terminals and that the breather hose is properly routed in good condition and not obstructed EAU00809 Replacing the fuse The fuse holder is located beside the battery compartment behind panel A If the fuse is blown replace it as follows 1 Turn the key to and turn off all electrical cir...

Page 59: ...t bulb and do not touch the bulb until it has cooled down 5 Place a new headlight bulb into position and then secure it with the bulb holder 1 Screw x2 1 Headlight bulb holder 1 ZAUM0325 6 20 6 Connect the headlight coupler and install the front cover EC000105 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bu...

Page 60: ...en turn it clockwise until it stops 4 Install the lens by installing the screws EC000108 Do not overtighten the screws otherwise the lens may break 1 Bulb 1 Screw EAU03497 Replacing a front turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counterclockwise 3 Insert a new bulb into the socket push it in and t...

Page 61: ...of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself However should your scoo ter require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the scooter properly Use only genuine Yamaha replacement parts Imitation parts may look like Yamaha parts but they...

Page 62: ...mpression Check the ignition Have a MBK dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a MBK dealer check the vehicle The engine does not start Have a MBK dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine tu...

Page 63: ...EAU03434 SCOOTER CARE AND STORAGE Care 7 1 Storage 7 4 7 ...

Page 64: ...extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00011 Avoid using strong acidic wheel cleaners especially on spoked wheels Ifsuchproductsareused on hard to remove dirt do not leave the cleaner on the affected area any longer t...

Page 65: ... dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on the roads durin...

Page 66: ...ge caused by stones etc 6 Wax all painted surfaces 7 Let the scooter dry completely before storing or covering it EWA00002 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent Before operating the scooter test its braking performance and ...

Page 67: ...form the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several tim...

Page 68: ...8 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery see page 6 19 NOTE Make any necessary repairs before storing the scooter 7 5 ...

Page 69: ...EAU01038 SPECIFICATIONS Specifications 8 1 Conversion table 8 4 8 ...

Page 70: ...Type 2 strokes engine oil Classification Jaso FC or 4ISO EG C EG D Capacity 1 3 L Final transmission oil Type SAE 10W30 type SE Quantity 0 11L Air filter type Wet type element Fuel Recommended fuel Regular unleaded gasoline RON 91 mini Fuel tank capacity 6 5 L Carburetor Type quantity TK ø12 Manufacturer TEIKEI Spark plug Type Manufacturer BR8HS NGK Spark plug gap 0 5 0 7 mm Clutch type Dry centri...

Page 71: ... Rear 170 kpa 1 70 kg cm2 1 7 bar Total weight of rider passenger cargo and accessories Minimum tire tread depth 1 6 mm Wheels Front Type Cast wheel Aluminium Size 10 X MT 3 00 Rear Type Cast wheel aluminium Size 10 X MT 3 50 Brakes Front Type Single disc brake Operation Right hand operation Type brake fluid DOT 4 or DOT 3 Rear Type Drum brake Operation Left hand operation Suspension Front suspens...

Page 72: ...age capacity 12 V 4 Ah Headlight type Bulb Bulbs voltage wattage x quantity Headlight 12V 35W 35Wx1 Tail brake light 12V 5W 21Wx1 Turn signal light Front 12V 10Wx2 Rear 12V 10Wx2 Meter lights 12V 1 2Wx2 High beam indicator light 12V 1 2Wx1 Turn signal indicator light 12V 1 2Wx1 Oil level warning light 12V 1 2Wx1 Fuses Main fuse 7A ...

Page 73: ...SPECIFICATIONS 8 EAU04513 Conversion table 8 4 ...

Page 74: ......

Page 75: ...9 EAU01039 CONSUMER INFORMATION Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 ...

Page 76: ...1 ZAUM0070 1 ZAUM0327 1 Key identification number 1 Vehicle identification number EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in t...

Page 77: ...1278 Model label The model label is affixed to the bottom of the seat See page 3 8 for seat opening procedures Record the infor mation on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 9 2 ...

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Page 80: ... E PRINTED IN FRANCE 2003 01 YAMAHA MOTOR CO LTD ...

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