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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

WARNING

EWA10790

Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.

4. Place a new bulb into position, and

then secure it with the bulb holder.

5. Install the cowling.
6. Have a Yamaha dealer adjust the

headlight beam if necessary.

EAU24131

Replacing the tail/brake light
bulb

1. Remove the tail/brake light lens by

removing the screws.

2. Remove the defective bulb by

pushing it in and turning it counter-
clockwise.

3. Insert a new bulb into the socket,

push it in, and then turn it clock-
wise until it stops.

4. Install the lens by installing the

screws.

CAUTION:

ECA10680

Do not overtighten the screws, oth-
erwise the lens may break.

1. Push in and turn counterclockwise.

2. Remove the bulb.

3. Headlight bulb

ZAUM0572

1. Screw

ZAUM0573

1. Remove tail/brake light lens.
2. Tail/brake light bulb

ZAUM0574

Содержание BWS CW50L

Страница 1: ...OWNER S MANUAL 2B6 F8199 E0 CW50 CW50L CW50N ...

Страница 2: ......

Страница 3: ...this manual thoroughly so as to enjoy all advantages of your CW50 CW50L CW50N The own er 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 fur ther questions do not he...

Страница 4: ... be minor discrepancies between your scooter and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to th...

Страница 5: ...AUM1010 CW50 CW50L CW50N OWNER S MANUAL 2004 by MBK INDUSTRIE 1st edition February 2004 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited Printed in France ...

Страница 6: ...4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing the cowling and panels 6 5 Checking the spark plug 6 6 Final transmission oil 6 7 Cleaning the air filter element 6 8 Adjusting the carburetor 6 9 Adjusting the throttle cable free play 6 9 Tires 6 10 Cast wheels 6 12 Adjusting the front brake lever free play 6 12 Adjusting the rear b...

Страница 7: ...TABLE OF CONTENTS SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 ...

Страница 8: ...he scooter Making yourself con spicuous appears to be very effec tive in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for scooter accidents to occur Ride where other motorists can see you Avoid riding in another motorist s blind spot Many ac...

Страница 9: ...shoes trousers gloves etc is ef fective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protec tive clothing that covers your legs ankles and feet Passen...

Страница 10: ...reduce ground clearance or cornering clearance limit sus pension travel steering travel or control operation or obscure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be k...

Страница 11: ... line inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes EAU10370 Further safe riding points Be sure to signal clearly when making turns Braking can be extremely difficult on a wet road Avoid hard braking because the scooter ...

Страница 12: ...RMATION 1 5 1 Always wear a helmet gloves trousers tapered around the cuff and ankle so they do not flap and a bright colored jacket Do not carry too much luggage on the scooter An overloaded scoot er is unstable ...

Страница 13: ...page 3 3 3 Left handlebar switches page 3 5 4 Kickstarter page 3 8 5 Air filter element page 6 8 6 Final transmission oil filler cap page 6 7 7 Final transmission oil drain bolt page 6 7 8 Centerstand page 6 16 9 Battery Fuse page 6 18 6 20 10 Shock absorber assembly spring preload adjusting ring CW50L model only page 3 10 ...

Страница 14: ...4 5 6 CW50N 1 Grab bar page 5 2 2 Oil tank cap page 3 6 3 Fuel tank cap page 3 6 4 Throttle grip page 6 9 5 Right handlebar switch page 3 5 6 Front brake lever page 3 5 7 Luggage hook page 3 10 8 Anti theft device housing page 3 9 9 Securing bracket page 3 8 ...

Страница 15: ...oved EAU10670 CHECK The 2 stroke engine oil level warning light should come on See page 3 2 EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the posi tion and then turn it to while still pushing it 3 Remove the key To unlock the steering Push the key in and then ...

Страница 16: ... 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 Ya malube 2 or equivalent 2 stroke engine oil of either JASO grade FC or ISO grades EG C or EG D The warning light should go off after the 2 stroke en gine oil tank has been refilled NOTE If the warning light does not come on when the key is in t...

Страница 17: ...the fuel level drops below approximately 0 6 L 0 17 US gal 0 14 Imp gal When this occurs refuel as soon as possible NOTE Do not allow the fuel tank to empty itself completely The electrical circuit of the warning light can be checked as follows Turn the key to If the warning light does not come on have a Yamaha dealer check the electrical circuit EAU11620 Speedometer unit CW50 CW50L UK only ZAUM05...

Страница 18: ...ance traveled The fuel meter indi cates the amount of fuel in the fuel tank see page 3 2 for an explanation of the fuel level warning light EAU12110 Fuel gauge CW50 CW50L 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 approximately 1 2 L 0 32 US gal 0 26 Imp gal of fuel remain in the fuel tank If t...

Страница 19: ...tch in after it has re turned to the center position EAU12500 Horn switch Press this switch to sound the horn EAUM1130 Start switch Push this switch while applying the front or rear brake to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU12900 Front brake lever The front brake lever is located on the right handlebar grip T...

Страница 20: ...e seat See page 3 9 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 clock wise 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 WARNING EWA10140 Make sure that the fuel and 2 stroke engine oil tank caps are pro...

Страница 21: ... plug life and reduce maintenance costs EAU13440 Catalytic converter This vehicle is equipped with a catalytic converter in the muffler WARNING EWA10860 The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded...

Страница 22: ...revent 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 WARNING EWAT1020 Be sure to remove the chain or cable before riding ot...

Страница 23: ... the key from the main switch if the scooter will be left un attended NOTE Make sure that the seat is properly se cured before riding EAUM1580 Anti theft device housing The anti theft device housing located under the seat is designed to store a joint type anti theft device with a maxi mum length of 1 meter See page 3 9 for seat opening and closing proce dures NOTE Some anti theft devices cannot fi...

Страница 24: ...m beyond the maximum or minimum settings Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b NOTE Align the appropriate notch in the ad justing ring with the position indicator on the shock absorber 1 Lugg...

Страница 25: ... be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always hav...

Страница 26: ...e could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre ope...

Страница 27: ...if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 13 6 14 Rear brake Check operation Check lever free play Adjust if necessary 6 13 Throttle grip Make sure that operation is smooth Check cable free play If necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing 6 9 6 15 Wheel...

Страница 28: ...ake sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Battery Check fluid level Fill with distilled water if necessary 6 18 ITEM CHECKS PAGE ...

Страница 29: ...e page 5 4 for engine break in in structions prior to operating the ve hicle for the first time 1 Turn the key to and when the oil level warning light comes on turn it to CAUTION ECA10240 If the oil level warning light does not come on have a Yamaha dealer check the electrical circuit 2 Close the throttle completely 3 While applying the front or rear brake start the engine by pushing the start swi...

Страница 30: ... hand push the scooter off the centerstand 2 Sit astride the seat and then ad just the rear view mirrors 3 Switch the turn signal on 4 Check for oncoming traffic and then slowly turn the throttle grip on the right in order to take off 5 Switch the turn signal off EAU16780 Acceleration and deceleration The speed can be adjusted by opening and closing the throttle To increase the speed turn the thro...

Страница 31: ... slip pery when wet Therefore slow down when approaching such areas and cross them with cau tion Keep in mind that braking on a wet road is much more difficult Ride slowly down a hill as brak ing downhill can be very diffi cult EAU16820 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the following tips to reduce fuel consumption Avoid high engine s...

Страница 32: ... one set throttle position 150 500 km 90 300 mi Avoid prolonged operation above 1 2 throttle Rev the engine freely through the gears but do not use full throttle at any time 500 1000 km 300 600 mi Avoid prolonged operation above 3 4 throttle CAUTION ECA10370 After 1000 km 600 mi of operation the transmission oil must be changed 1000 km 600 mi and beyond Avoid prolonged full throttle operation Vary...

Страница 33: ...djustment and lubri cation will keep your vehicle in the safest and most efficient condition pos sible The most important points of scooter inspection adjustment and lu brication are explained on the following pages WARNING EWA10320 If you are not familiar with mainte nance work have a Yamaha dealer do it for you ...

Страница 34: ...OR MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 6 12 18 24 1 Fuel line Check fuel and vacuum hoses for cracks 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 5 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn t...

Страница 35: ...ws are properly tightened 13 Centerstand Check operation Lubricate 14 Front fork Check operation and for oil leakage 15 Shock absorber assem bly Check operation and shock absorber for oil leakage 16 Carburetor Check starter choke operation Adjust engine idling speed 17 Autolube pump Check operation Bleed if necessary 18 Final transmission oil Check vehicle for oil leakage Change 19 V belt Replace ...

Страница 36: ...luid level Every two years change the brake fluid Replace the brake hoses every four years and if cracked or damaged 22 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 23 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1000...

Страница 37: ... To install the cowling Place the cowling in the original posi tion and then install the screws EAU19272 Panel A To remove the panel Remove the screw and then pull out ward on the areas shown To install the panel Place the panel in the original position and then install the screw EAU19210 Panel B To remove the panel NOTE Prior to remove the panel B remove the panel A Remove the screws and then tak...

Страница 38: ...e defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If the spark plug shows signs of elec trode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark plug g...

Страница 39: ...l 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 6 Add the specified amount of the recommended final transmission oil and then install and tighten the oil filler cap WARNING EWA11310 Make sure that no foreign mate rial enters the final transmission case Make sur...

Страница 40: ...se 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 CAUTION ECA10510 To avoid damaging the foam materi al handle it gently and carefully and do not twist or wring it 3 Apply oil of the recommended type to the entire surface of the ele ment and then squeeze the ex cess oil out NOTE The air filter element should be ...

Страница 41: ...arburetor is an important part of the engine and requires very sophisti cated adjustment Therefore all carbu retor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe rience EAU21380 Adjusting the throttle cable free play The throttle cable free play should mea sure 1 5 3 0 mm 0 06 0 12 in at the throttle grip Periodically check the throttle cable f...

Страница 42: ...tics of your vehicle you should keep the following precautions in mind NEVER OVERLOAD THE VEHI CLE Operation of an overload ed vehicle may result in tire damage loss of control or se vere injury Make sure that the total weight of rider cargo and accessories does not exceed the specified maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack...

Страница 43: ... worn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience 1 Tire tread depth 2 Tire sidewall Minimum tire tread depth front and rear 1 6 mm 0 06 ...

Страница 44: ...or it to develop its optimal characteris tics EAU22100 Adjusting the front brake lever free play The brake lever free play should mea sure 10 0 20 0 mm 0 39 0 79 in as shown Periodically check the brake le ver free play and if necessary have a Yamaha dealer adjust it WARNING EWA10640 An incorrect brake lever free play in dicates a hazardous condition in the brake system Do not operate the scooter ...

Страница 45: ... the lining thickness If a brake pad is damaged or if the lining thickness is less than 2 mm 0 08 in have a Yamaha dealer replace the brake pads as a set EAU22540 Rear brake shoes The rear brake is provided with a wear indicator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying...

Страница 46: ... turning the handlebars Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the...

Страница 47: ...ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23110 Checking and lubricating the thr...

Страница 48: ...271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the ve...

Страница 49: ...n of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be...

Страница 50: ...ould be checked before each ride and at the in tervals specified in the periodic mainte nance and lubrication chart To check the electrolyte level 1 Place the scooter on a level sur face and hold it in an upright posi tion NOTE Make sure that the scooter is posi tioned straight up when checking the electrolyte level 2 Remove panel B See page 6 5 3 Check the electrolyte level in the battery NOTE Th...

Страница 51: ...N ECA10610 Use only distilled water as tap water contains minerals that are harmful to the battery 5 Check and if necessary tighten the battery lead connections and correct the breather hose routing To store the battery 1 If the scooter will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two...

Страница 52: ...age to the electrical system and possibly a fire 3 Turn the key to and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAUM1410 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Place the scooter on the center stand 2 Remove cowling A See page 6 5 3 Unhook the headl...

Страница 53: ... EAU24131 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break 1 Push ...

Страница 54: ...orough inspection before shipment from the factory trouble may occur dur ing 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 your self However should your scooter re quire any repair take it to a Yamaha dealer whose skill...

Страница 55: ...ession There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Open the throt...

Страница 56: ...remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical produc...

Страница 57: ...s to prevent corrosion After cleaning 1 Dry the scooter with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal in...

Страница 58: ...n the Care section of this chapter 2 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 3 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 4 Perform the following steps to pro tect the cylinder piston rings etc from co...

Страница 59: ...er so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 7 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 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 war...

Страница 60: ...Quantity 1 1 L 1 25 US qt 1 04 Imp qt Final transmission oil Type SAE10W30 type SE motor oil Quantity 0 11 L 0 12 US qt 0 10 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 5 3 L 1 40 US gal 1 17 Imp gal Fuel reserve amount CW50 1 2 L 0 32 US gal 0 26 Imp gal CW50L 1 2 L 0 32 US gal 0 26 Imp gal CW50N 0 6 L 0 17 US gal 0 14 I...

Страница 61: ...W50 10 x MT 3 00 CW50L 12 x MT 3 50 CW50N 10 x MT 3 00 Rear wheel Wheel type Cast wheel Rim size CW50 10 x MT 4 00 CW50L 12 x MT 3 50 CW50N 10 x MT 4 00 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 3 or 4 Rear brake Type Drum brake Operation Left hand operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel t...

Страница 62: ... V 1 2 W x 3 CW50N LED High beam indicator light CW50 12 V 2 0 W x 1 CW50L 12 V 2 0 W x 1 CW50N LED Oil level warning light CW50 12 V 2 0 W x 1 CW50L 12 V 2 0 W x 1 CW50N LED Turn signal indicator light CW50 12 V 2 0 W x 2 CW50L 12 V 2 0 W x 2 CW50N LED Fuel level warning light CW50N LED Fuse Fuse 7 5 A ...

Страница 63: ...ON NUMBER MODEL LABEL INFORMATION EAU26381 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 EAU26410 Vehicle identification number The vehicle identification number is stamped into the frame NOTE The vehicle identification number is used to identify your vehicle and may be u...

Страница 64: ...del label The model label is affixed to the bottom of the seat See page 3 9 Record the information on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha dealer 1 Model label 1 ZAUM0576 ...

Страница 65: ...numbers 9 1 Indicator and warning lights 3 2 K Key identification number 9 1 Kickstarter 3 8 L Luggage hook 3 10 M Main switch steering lock 3 1 Model label 9 2 O Oil level warning light 3 2 P Parking 5 4 Part locations 2 1 Periodic maintenance and lubrication chart 6 2 Pre operation check list 4 2 R Rear brake lever free play adjusting 6 12 S Safe riding points 1 4 Safety information 1 1 Seat 3 9...

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Страница 68: ... E PRINTED IN FRANCE 2004 02 YAMAHA MOTOR CO LTD ...

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